Enticer

COVER1 01.8.
1 3:58 PM Page 1
CRUISING SPORTS
SERVICE MANUAL
YBA125
5AP-F8197-E0
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page II
YBA125
SERVICE MANUAL
©2001 by Yamaha Motor Co.Ltd.
First edition, July 2001
All rights reserved. Any reprodction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page A
FOREWORD
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha motorcycle has a basic understanding of the mechanical ideas and the procedures of
motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the
motorcycle unsafe and unfit for use.
NOTE:
Designs and specifications are subject to change without notice.
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page B
HOW TO USE THIS MANUAL

HOW TO SEARCH ON PAGE
1. This manual has been divided 8 chapter
into GENERAL INFORMATION, SERVICE
DATE, PERIODIC CHECKS AND ADJUST-
MENT, OVERHAULING THE ENGINE,
CARBURETION, CHASSIS, ELECTRICAL
and TROUBLESHOOTING.
2. This manual intended as a handy, easy-to-
read reference book for the mechanic.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at start of each removal
and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for disassembly and assembly jobs.
2. Numbers 2 are given in the order of jobs in the exploded diagram. A number that is enclosed by a
circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 3.
The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 5 are given in addition to
the exploded diagram and the job instruction chart.
3 2 1
CLUTCH ENG CLUTCH ENG

REMOVING THE CLUTCH
3 1. Remove:
4 9Nut 1 (clutch boss)
CLUTCH
9Lock washer 2
2 9Clutch boss 3
60 Nm (6.0 m•kg) NOTE:
1

Straighten the lock washer tab 2 and loosen
6 Nm (0.6 m•kg)
the clutch boss nut 1 while holding the clutch
4 boss with a clutch holding tool 4.
8 Nm (0.8 m•kg)
Clutch holding tool:

11 3
90890-04086

13
12 7 CHECKING THE CLUTCH
1. Measure:


2
9Friction plate thickness
Out of specification → Replace the friction
1
6
plates as a set.
Measure at four places. 
5 Thickness (friction plate):
2.90 ~ 3.10 mm

10
<Limit:> 2.8 mm
5

15 2. Measure:
9Clutch plate warpage

14 Out of specification → Replace the clutch
E
3 8
70 Nm (7.0 m•kg)
plates as a set.

9 Use a surface plate and a feeler gauge 1.
1
Warp limit (clutch plate):

1.0 mm
3. Measure:

Order Job name/Part name Q’ty Remarks
9Clutch spring free length a
Removing the clutch removal Remove the parts in order. Out of specification → Replace the clutch
1
2
Clutch spring
Pressure plate
4
1
springs as a set.


3 Ball 1 Refer to “INSTALLING THE CLUTCH” Free length (clutch spring):
4 Lock washer 1 section. 33.0 mm
a
5 Friction plates 5 <Limit:> 31.0 mm
6 Clutch plates 4
INSTALLING THE CLUTCH
7 Clutch boss 1 Refer to “REMOVING THE CLUTCH” section.
4 1 1. Install:
8 Thrust plate 1
9Push lever axle 1
9 Primary driven gear 1
9Torsion spring 2
10 Plate washer/Spring washer 1/1 Refer to “INSTALLING THE CLUTCH”
11 Nut/Washer 1/1 section.
12 Push rod #1 1 2
13 Push plate 1
14 Nut/Washer 1/1
15 Primary drive gear/Straight key 1/1
For installation, reverse the removal
procedure.
4-24 4-26
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page C
SYMBOL MARKS
Particularly important information is distinguished in this manual by the following notations.
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
w Failure to follow WARNING instructions could result in severe injury or death
to the motorcycle operator, a bystander or a person inspecting or repairing
the motorcycle.
dC A CAUTION indicates special precautions that must be taken to avoid dam-
age to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
1 2 ILLUSTRATED SYMBOLS
GEN 1 General information
INFO SPEC 2 Specifications
3 Periodic checks and adjustments
3 4 4 Engine
CHK 5 Cooling system
ADJ ENG 6 Carburation
7 Chassis
8 Electrical
5 6 9 Troubleshooting
COOL CARB
7 8
CHAS ELEC
9 0 0 Maintenance on the chassis
TRBL q Special tool
w Filling fluid
SHTG e Lubricant
r Ω, V, A
q w
t Wear limit, clearance
y Engine speed
u Tightening
e r
t y u
i o p i Apply engine oil

o Apply gear oil
p Apply molybdenum disulfide oil
a Apply wheel bearing grease
s Apply lightweight lithium-soap base grease
a s d d Apply molybdenum disulfide grease
f Apply locking agent (LOCTITE®)
g Use new one
f g
LT New
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page D
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page E
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS
SPEC 2
PERIODIC CHECKS AND
ADJUSTMENT CHK
ADJ 3
OVERHAULING THE ENGINE
ENG 4
CARBURATION
CARB 5
CHASSIS
CHAS 6
ELECTRICAL
ELEC 7
TROUBLESHOOTING TRBL
SHTG 8
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page F
CHAPTER 1.
GENERAL INFORMATION
DRAWINGS OF THE APPEARANCE...............................................................1-1
FRAME SERIAL NUMBER, PRODUCT VEHICLE SERIAL NUMBER ...........1-1
ENGINE SERIAL NUMBER ..............................................................................1-1
IMPORTANT INFORMATION (1) ......................................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ........................................1-4
BEARING AND OIL SEALS .........................................................................1-4
CIRCLIPS.....................................................................................................1-4
CHECKING OF CONNECTIONS.................................................................1-5
HOW TO USE THE CONVERSION TABLE......................................................1-6
SPECIAL TOOLS ..............................................................................................1-7
FOR CHECKING AND ADJUSTMENT........................................................1-7
FOR ENGINE SERVICE ..............................................................................1-8
FOR CARBURETOR ...................................................................................1-10
FOR CHASSIS.............................................................................................1-10
FOR ELECTRICAL ......................................................................................1-11
FOR CHEMICAL ..........................................................................................1-12
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ..........................................................................2-1
MAINTENANCE SPECIFICATIONS .................................................................2-4
ENGINE .......................................................................................................2-4
CHASSIS .....................................................................................................2-7
ELECTRICAL ...............................................................................................2-9
TIGHTENING TORQUES ..................................................................................2-11
ENGINE .......................................................................................................2-11
CHASSIS .....................................................................................................2-13
GENERAL TORQUE SPECIFICATIONS ..........................................................2-14
LUBRICATION POINT AND GRADE OF LUBRICANT....................................2-15
ENGINE .......................................................................................................2-15
CHASSIS .....................................................................................................2-16
LUBRICATION DIAGRAM ................................................................................2-17
CABLE ROUTING .............................................................................................2-19
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page G
CHAPTER 3.
PERIODIC CHECKS
AND ADJUSTMENTS
INTRODUCTION ...............................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ...............................3-1
SIDE COVER, SEAT AND FUEL TANK ...........................................................3-3
ENGINE .............................................................................................................3-4
ADJUSTING THE VALVE CLEARANCE .....................................................3-4
ADJUSTING THE IDLING SPEED ..............................................................3-5
ADJUSTING THE THROTTLE CABLE........................................................3-6
CHECKING THE SPARK PLUG ..................................................................3-7
MEASURING THE COMPRESSION PRESSURE ......................................3-8
CHECKING THE ENGINE OIL LEVEL ........................................................3-9
CHANGING THE ENGINE OIL ....................................................................3-9
ADJUSTING THE CLUTCH .........................................................................3-11
CLEANING THE AIR FILTER ......................................................................3-12
CHASSIS ...........................................................................................................3-13
ADJUSTING THE FRONT BRAKE ..............................................................3-13
CHECKING THE BRAKE PAD.....................................................................3-13
CHECKING THE BRAKE FLUID LEVEL .....................................................3-14
AIR BLEEDING ............................................................................................3-14
REPLACING THE BRAKE FLUID................................................................3-15
CHECKING THE REAR BRAKE..................................................................3-16
BRAKE PEDAL HEIGHT..............................................................................3-16
CHECKING THE BRAKE SHOE..................................................................3-17
ADJUSTING THE BRAKE LIGHT SWITCH.................................................3-17
ADJUSTING THE DRIVE CHAIN SLACK....................................................3-17
CHECKING THE TIRE INFLATION PRESSURE ........................................3-18
CHECKING THE TIRE.................................................................................3-19
CHECKING THE STEERING HEAD............................................................3-19
CHECKING THE SWINGARM.....................................................................3-20
ADJUSTING THE REAR SHOCK ABSORBER...........................................3-20
ELECTRICAL ....................................................................................................3-21
CHECKING THE BATTERY.........................................................................3-21
CHARGING THE BATTERY ........................................................................3-22
CHECKING THE SIGNAL AND LIGHTS .....................................................3-22
ADJUSTING THE HEADLIGHT BEAM........................................................3-22
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page H
CHAPTER 4.
ENGINE .............................................................................................................4-1
CRANKCASE COVER, SHIFT PEDAL AND DRIVE CHAIN .......................4-1
EXHAUST PIPE, BRAKE PEDAL AND SIDE COVER ................................4-2
EARTH LEAD AND ENGINE .......................................................................4-3
CYLINDER HEAD .............................................................................................4-4
CYLINDER HEAD COVER ..........................................................................4-4
CYLINDER HEAD ........................................................................................4-5
REMOVING THE CYLINDER HEAD ...........................................................4-6
CHECKING THE CYLINDER HEAD............................................................4-7
INSTALLING THE CYLINDER HEAD ..........................................................4-7
CAMSHAFT AND ROCKER ARMS..................................................................4-10
REMOVING THE ROCKER ARM AND ROCKER ARM SHAFT .................4-11
CHECKING THE CAMSHAFT .....................................................................4-11
INSTALLING THE ROCKER ARM...............................................................4-12
VALVES AND VALVE SPRINGS.......................................................................4-13
REMOVING THE VALVES AND VALVE SPRINGS .....................................4-14
CHECKING THE VALVES AND VALVE GUIDES ........................................4-14
CHECKING THE VALVE SEATS .................................................................4-15
VALVE LAPPING .........................................................................................4-17
INSTALLING THE VALVES AND VALVE SPRINGS ....................................4-17
CYLINDER AND PISTON .................................................................................4-18
REMOVING THE PISTON AND PISTON RINGS........................................4-19
CHECKING THE CYLINDER.......................................................................4-19
CHECKING THE PISTON AND PISTON PIN..............................................4-20
CHECKING THE PISTON RING..................................................................4-21
INSTALLING THE PISTON RINGS, PISTON AND CYLINDER ..................4-22
CLUTCH ............................................................................................................4-23
CRANKCASE COVER (RIGHT) ..................................................................4-23
CLUTCH.......................................................................................................4-24
PUSH LEVER AXLE ....................................................................................4-25
REMOVING THE CLUTCH..........................................................................4-26
CHECKING THE CLUTCH ..........................................................................4-26
INSTALLING THE CLUTCH.........................................................................4-26
KICK STARTER ................................................................................................4-29
OIL PUMP..........................................................................................................4-31
INSTALLING THE ROTARY FILTER ...........................................................4-33
INSTALLING THE PRIMARY DRIVE GEAR................................................4-33
CHECKING THE OIL PUMP........................................................................4-33
SHIFT SHAFT....................................................................................................4-35
CHECKING THE SHIFT SHAFT..................................................................4-36
INSTALLING THE SIFT SHAFT...................................................................4-36
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page I
C.D.I. MAGNETO AND STARTER CLUTCH ....................................................4-37

CRANKCASE COVER (LEFT).....................................................................4-37
PICKUP COIL AND STATOR COIL .............................................................4-38
C.D.I. MAGNETO AND STARTER CLUTCH ...............................................4-39
REMOVING THE C.D.I. MAGNETO ............................................................4-40
INSTALLING THE C.D.I. MAGNETO ...........................................................4-40
CRANK CASE ...................................................................................................4-41
SEPARATING THE CRANKCASE ...............................................................4-42
INSTALLING THE CRANKCASE.................................................................4-42
TRANSMISSION, SHIFT CAM AND SHIFT FORK ..........................................4-44
DRIVE AXLE ................................................................................................4-45
MAIN AXLE ..................................................................................................4-46
REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK.........4-47
CHECKING THE SHIFT FORK AND SHIFT CAM.......................................4-47
INSTALLING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK .......4-48
CRANKSHAFT AND BALANCER WEIGHT.....................................................4-49
REMOVING THE CRANK SHAFT AND BALANCER WEIGHT...................4-50
CHECKING THE CRANK SHAFT................................................................4-50
INSTALLING THE CRANK SHAFT AND BALANCER WEIGHT .................4-51
CHAPTER 5.
CARBURETION
CARBURETOR .................................................................................................5-1
CHECKING THE FLOAT HEIGHT ...............................................................5-3
ADJUSTING THE FUEL LEVEL ..................................................................5-3
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page J
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC ................................................................6-1
DISASSEMBLING THE FRONT WHEEL ....................................................6-3
CHECKING THE FRONT WHEEL...............................................................6-3
CHECKING THE BRAKE DISC ...................................................................6-4
ASSEMBLING FRONT WHEEL...................................................................6-4
INSTALLING THE BRAKE DISC .................................................................6-4
INSTALLING THE FRONT WHEEL .............................................................6-5
ADJUSTING THE WHEEL STATIC BALANCE............................................6-5
FRONT BRAKE.................................................................................................6-7
BRAKE PAD.................................................................................................6-7
MASTER CYLINDER ...................................................................................6-8
DISASSEMBLING THE MASTER CYLINDER ............................................6-9
CHECKING THE MASTER CYLINDER.......................................................6-10
ASSEMBLING THE MASTER CYLINDER ..................................................6-10
INSTALLING THE MASTER CYLINDER .....................................................6-11
CALIPER......................................................................................................6-12
DISASSEMBLING THE CALIPER ...............................................................6-13
DISASSEMBLING THE BRAKE CALIPER ..................................................6-14
CHECKING THE CALIPER..........................................................................6-14
INSTALLING THE CALIPER........................................................................6-15
REAR WHEEL, REAR BRAKE, DRIVE SPROCKET AND DRIVE CHAIN......6-16
REAR WHEEL AND REAR BRAKE.............................................................6-16
DRIVE SPROCKET .....................................................................................6-17
BRAKE SHOE PLATE..................................................................................6-18
DRIVE CHAIN ..............................................................................................6-19
REMOVING THE DRIVE CHAIN .................................................................6-20
CHECKING THE DRIVE CHAIN..................................................................6-20
CLEANING THE DRIVE CHAIN ..................................................................6-20
CHECKING THE CLUTCH HUB..................................................................6-21
INSTALLING THE CLUTCH HUB ................................................................6-21
INSTALLING THE DRIVE CHAIN ................................................................6-21
CHECKING THE REAR WHEEL .................................................................6-22
CHECKING THE REAR BRAKE..................................................................6-22
ASSEMBLING THE BRAKE SHOE PLATE .................................................6-23
FRONT FORK ...................................................................................................6-24
DISASSEMBLING THE FRONT FORK .......................................................6-26
CHECKING THE FRONT FORK..................................................................6-26
ASSEMBLING THE FRONT FORK .............................................................6-27
INSTALLING THE FRONT FORK................................................................6-29
HANDLEBAR ....................................................................................................6-30
INSTALLING THE HANDLEBAR .................................................................6-31
STEERING.........................................................................................................6-32
HEADLIGHT AND METER ..........................................................................6-32
UNDER BRACKET ......................................................................................6-33
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page K
REMOVING THE STEERING ......................................................................6-35

INSTALLING THE STEERING.....................................................................6-35
REAR SHOCK ABSORBER AND SWINGARM ...............................................6-36
CHECKING THE SWINGARM.....................................................................6-37
CHECKING THE REAR SHOCK ABSORBER ............................................6-37
1
CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS .........................................................................7-1
WIRING DIAGRAM ...........................................................................................7-2
SWITCH.............................................................................................................7-4
CHECKING THE SWITCHES ......................................................................7-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL ...........................7-4
IGNITION SYSTEM ...........................................................................................7-6
CIRCUIT DIAGRAM.....................................................................................7-6
TROUBLESHOOTING .................................................................................7-7
CHARGING SYSTEM........................................................................................7-11
CIRCUIT DIAGRAM.....................................................................................7-11
ELECTRIC STARTING SYSTEM ......................................................................7-14
CIRCUIT DIAGRAM.....................................................................................7-14
STARTER MOTOR ......................................................................................7-18
CHECKING THE STARTER MOTOR ..........................................................7-19
LIGHTING SYSTEM ..........................................................................................7-20
CIRCUIT DIAGRAM.....................................................................................7-20
CHECKING THE LIGHTING SYSTEM ........................................................7-22
SIGNAL SYSTEM..............................................................................................7-25
CIRCUIT DIAGRAM.....................................................................................7-25
CHECKING THE SIGNAL SYSTEM ............................................................7-27
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page L
CHAPTER 8.
TROUBLE SHOOTING
STARTING FAILURE/HARD STARTING..........................................................8-1
POOR IDLE PERFORMANCE ..........................................................................8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE....................................8-3
POOR SPEED PERFORMANCE ......................................................................8-3
CLUTCH SLIPPING, DRAGGING.....................................................................8-4
FAULTY GEAR SHIFTING ................................................................................8-4
OVER HEATING................................................................................................8-5
FAULTY BRAKE ...............................................................................................8-5
FRONT FORK MALFUNCTION ........................................................................8-6
STARTER MOTOR DOES NOT OPERATE ......................................................8-6
INSTABILE HANDLING ....................................................................................8-7
FAULTY SIGNAL AND LIGHTING SYSTEM....................................................8-8
WIRING DIAGRAM
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 1
DRAWINGS OF THE APPEARANCE/

FRAME SERIAL NUMBER, PRODUCT VEHICLE SERIAL NUMBER/ GEN
ENGINE SERIAL NUMBER INFO
GENERAL INFORMATION
DRAWINGS OF THE APPEARANCE:
SIDE VIEW
TOP VIEW
FRONT VIEW REAR VIEW
FRAME SERIAL NUMBER, ENGINE SERIAL NUMBER:

PRODUCT VEHICLE SERIAL NUMBER:
2
1
1 Frame serial number 3 Engine serial number

2 Product vehicle serial number
1-1
5AP-E0 0-1-1/1 01.7.27 8:26 AM Page 2
GEN
IMPORTANT INFORMATION (1) INFO
IMPORTANT INFORMATION (1)
1. Vehicle washing and simple treatment
Remove all dirt, mud and dust carefully off
the chassis and engine to avoid their inclu-
sion during operation.
1 1
2. Smoke and fire are strictly forbidden
Smoke and fire are strictly forbidden at
maintenance locations.
3. Proper and right tools

Special tools must be used in operations
where it is necessary to use them in order
to avoid damages on the parts. Select prop-
er and right tools and instruments and
adopt appropriate operation methods (avoid
using adjustable spanners wherever possi-
ble, use ring spanners, socket spanners,
etc.).
4. Wearable and consumable parts

Gaskets (washers), O-rings, flat pins, spring
rings and lock washers should all be
replaced by new parts.”
5. Genuine parts
Parts, oil and greases that are used must
be the genuine Yamaha products or the rec-
ommended ones. Do not use others.
1-2
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 3
GEN
6. Wound, burns and scald
Avoid injuries in maintenance. In maintain-
ing the engine, exhaust pipes and muffler,
avoid burning accidents and be careful for
your operations.
1 7. Important information during disassem-

bling and assembling operations
1) During disassembly, check, measure and
record necessary parts as reference for
assembly.
2) Make arrangements in the sequence of
positions to avoid disorder or loss of parts.
3) Disassembled parts from the engine and
gear shift system should be washed in
gasoline before they are dried in air.
4) Proceed with assembly while confirming the
data taken after modification and before dis-
assembly.
5) Avoid inclusion of dirt and foreign materials
Fill in the MF battery electrolyte. during assembly.
1) Prepare MF batteries
Place the MF battery vertically on a horizontal place and remove its
sealing tape.
6) Confirm after completion of assembly in the
cC sequence of positions and then go on with
Do not remove the sealing tape when electrolyte is not fill in.
2) Prepare electrolyte
the next step of assembly.
Use special MF battery electrolyte in the same packet. Take the
electrolyte container out of the plastic bag and remove the cover to 7) Paste sliding parts with grease.
use it as sealing cap for the battery.
cC
8) Observe stipulated tightening torque.
Do not remove or break the sealing film at the filling hole.
9) Keep close contact between each other
3) Fill in the electrolyte
Lift the electrolyte container upside down vertically, to align the six when the operation is made between two
filling holes of the container to the six filling holes of the battery.
Forcefully press the electrolyte container to break the sealing film of
the filling hole of the container so that the electrolyte can be fill into
persons.
the battery.
8. How to use sealed batteries
cC
Do not place the electrolyte container in a slant way, otherwise, the
electrolyte may stop flowing.
Charging method
4) Confirm filling status 9 It is a sealed battery. Even in the charging operation, do not pull
Check to see if there is any air bubble in the pipes of the container
and then keep it in this condition for more than 20 minutes. off the sealing cap. Never replenish it with water.
cC 9 Charge it in line with the following current and time at 12V.
If there is no bubble, slap the container bottom slightly 2 or 3 times
so that normal filling can start. It is unnecessary to pull out the
container.
Standard: 0.7A x 5 hour, or 3A x 1 hour for rapid charging.
5) Remove the electrolyte container
When all the electrolyte is filled, slap the container bottom several Attention for battery use
times again to let all the remaining fluid go and then remove the
container slowly. It is a 12V sealed battery with no need of electrolyte level
Do not pull off the sealing cap during charging in any case (separate
exhaust orifice is available). inspection or water replenishment.
6) Seal the battery
Pay special attention to the followings:
Align the six plugs of the sealing cap to the six filling holes of the
battery and press the plate strongly. Make sure that the sealing cap 9 Use digital voltmeter to measure the voltage in the charged
is flush with the top surface of the battery.
condition (nominal voltage should be over 12.8V).
cC
After the sealing cap is completely inserted, never open the sealing
9 The battery cannot be used on motorcycles that are not suit-
cap.
able for sealed type batteries.
Batteries may give out flammable gases. Smoke and fires are
strictly forbidden during operations to avoid fires and explosion.
Battery electrolyte are corrosive. Be careful not to splash on
clothes, skin or eyes during operation.
On-site emergent treatment.
In case of splashing onto clothes, skin or eyes, wash them with
large amount of water immediately and take medical treatment
from the doctor with no delay.
1-3
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 4
GEN
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut has been properly tightened.
1
300-000
BEARINGS AND OIL SEALS

1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer's marks or numbers
1 facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil seal(s),
lubricate a light coating of light-weight lithi-
um base grease to the seal lip(s). Oil the
300-002
bearings liberally when installing.
2
cC
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.
300-003
CIRCLIPS
1
1. All circlips should be inspected carefully
3 before reassembly. Always replace piston
2 pin clips after one use. Replace distorted
circlips. When installing a circlip 1, make
4 sure that the sharp-edged corner 2 is posi-
tioned opposite to the thrust 3 it receives.
See the sectional view.
300-001
4 Shaft
1-4
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 5
GEN
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
9Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two

q
or three.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
9Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.

NOTE:
9If there is no continuity, clean the terminals.
9Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
9For a field remedy, use a contact revitalizer
available on the market.
9Use the tester on the connector as shown.
1-5
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 6
GEN
HOW TO USE THE CONVERSION TABLE INFO
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMP
** mm × 0.03937 = ** in
2 mm × 0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
m•kg 7.233 ft•lb
m•kg 86.794 in•lb
Torque
cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb
kg 2.205 lb
Weight
g 0.03527 oz
km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume/ cc (cm3) 0.06102 cu•in
Capacity lit (liter) 0.8799 qt (IMP liq.)
lit (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Miscellaneous kg/cm2 14.2234 psi (lb/in2)
Centigrade 9/5(°C)+32 Fahrenheit (°F)
1-6
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 7
GEN
SPECIAL TOOLS INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
FOR CHECKING AND

ADJUSTMENT
1. Measure the valve clearance.
Thickness gauge 90890-03709
2. Adjust the valve clearance.

Valve adjusting tool 90890-01311
3. Measure the compression pressure.

q
Compression gauge 90890-03081 1
Adaptor 90890-04082 2
w q w
4. Detect the engine idling speed.

q
Engine tachometer 90890-03113 1
1-7
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 8
GEN
SPECIAL TOOLS INFO
5. Measure the voltage of the MF type battery.
Battery tester for motorcycle 90890-03112
6. Charge the MF type battery.

Battery charger
FOR ENGINE SERVICE

1. Remove and install the rocker arm shaft.
Rocker arm shaft puller bolt
90890-01083 1
Weight 90890-01084 2
q
w q
2. Remove and install the valve and the valve

spring.
Valve spring compressor 90890-04019 1
Attachment 90890-04108 2
3. Remove and install the valve lifter and for

the lapping the valve
Valve rapper 90890-04101
1-8
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 9
GEN
SPECIAL TOOLS INFO
4. Hold the magneto rotor nut.
Sheave holder 90890-01701
5. Remove the magneto rotor

Rotor puller 90980-01362
w
6. Separate the crankcase.

Crankcase separating tool 90890-01135
7. Hold the clutch boss nut.

Clutch holding tool 90890-04086
8. Crankcase install
Crankshaft installer pot 90890-01274 1
Crankshaft installer bolt 90890-01275 2
r Adopter 90890-01278 (M12) 3
Spacer 90890-04081
(for crankshaft installer) 4
q
q w e r
w
e
1-9
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 10
GEN
SPECIAL TOOLS INFO
FOR CARBURETOR
1. Measure the fuel height
Fuel level gauge 90890-01312
FOR CHASSIS
1. Loosen and tighten the steering ring nut.
Exhaust ring nut wrench 90980-01268
2. Install the fork seal.

Fork seal driver weight 90890-01367 1
Fork seal driver attachment 90890-01400 2
q w
w
3. Loosen and tighten the ring nut wrench.

Ring nut wrench 90890-01403
1-10
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 11
GEN
SPECIAL TOOLS INFO
4. Loosen and tighten the damper rod bolt.
T-handle 90890-01326 1
w Damper rod holder 90890-01294 2
q
q w
5. Chain cutter
FOR ELECTRICAL
1. Check the spark plug gap.
Ignition checker 90980-06754
2. Measure and check the electrical system.

Pocket tester 90890-03112
1-11
5AP-E0 0-1-1/1 01.7.26 10:28 AM Page 12
GEN
SPECIAL TOOLS INFO
FOR CHEMICAL
1. The.crankcase left and right for sealing
Yamaha bond No. 1215 90980-85505
1-12
5AP-E0 2 01.7.26 10:35 AM Page 1
GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model name: YBA 125
Model code: 5AP1
Dimensions:
Overall length 2,080 mm
Overall width 790 mm
2 Overall height
Seat height
Wheelbase
1,110 mm
710 mm
1,370 mm
2
Minimum ground clearance 155 mm
Minimum turning radius 2,200 mm
Basic weight:
With oil and full fuel tank 125 kg
Engine:
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.124 L (123.7 cm3)
Bore × stroke 54 × 54 mm
Compression ratio 10.0 : 1
Compression pressure (STD) 1,200 kPa (12.0 kgf/cm2) at 1,400 r/min
Starting system Electric starter and Kick starter
Lubrication system: Wet sump
2-1
5AP-E0 2 01.7.26 8:26 PM Page 2
Item Standard specification

Air filter: Wet type element
Clutch: Wet multiple - disc
Engine oil:
Periodic oil change 1.0 L (1,000cm3)
Total amount 1.2 L (1,200cm3)
Recommended engine oil SAE10W30 type SE motor oil or
SAE20W40 type SE motor oil
Transmission:
2 Primary reduction ratio
Secondary reduction ratio
68/19 (3.579)
47/15 (3.133)
2
Transmission type Constant mesh 5 speed
Gear ratio 1st 37/14 (2.643)
2nd 32/18 (1.778)
3rd 25/19 (1.316)
4th 23/22 (1.045)
5th 21/24 (0.875)
Chassis:
Frame type Diamond
Caster angle 29°
Trail 108 mm
Fuel:
Type Regular gasoline
Fuel tank capacity 13 L
Fuel reserve capacity 1.8 L
Tire:
Type Tube type
Size front 2.75-18 42P
rear 120/80-16 60P
Wear limit front 0.8 mm
rear 0.8 mm
Tire pressure:
Rider front 175 kPa (1.75 kgf/cm2)
rear 200 kPa (2.0 kgf/cm2)
With passenger front 200 kPa (2.0 kgf/cm2)
rear 225 kPa (2.25 kgf/cm2)
2-2
5AP-E0 2 01.7.26 10:35 AM Page 3
Item Standard specification

Brake:
Front brake type Single disc brake
Rear brake type Drum brake
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorber:
Front shock absorber Coil spring/Oil damper
2 Rear shock absorber

Wheel base:
Coil spring/Oil damper
1,370mm
Ignition system: C.D.I.
Spark plug:
Type CR7HSA/U22FSR-U
Manufacturer NGK/DENSO
Spark plug gap 0.6 ~ 0.7 mm
Headlight type: Bulb type
Bulb wattage × quantity:
Headlight 12V 35 W/35 W × 1
Auxiliary light 12V 4 W × 1
Tail/brake light 12V 5 W/21 W × 1
Turn signal light 12V 10 W × 4
Meter light (fuel meter) 12V 1.7 W × 1
(speedometer) 12V 1.7 W × 1
Indicator bulb wattage × quantity:
High beam indicator 12V 1.7 W × 1
Neutral indicator 12V 1.7 W × 1
Turn signal indicator 14V 3 W × 1
2-3
5AP-E0 2 01.7.26 10:35 AM Page 4
MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ••• 0.03 mm
Cylinder:
Bore size 54.024~54.056 mm •••
Out of round limit ••• 0.01 mm
Camshaft:
Cam dimensions
Intake “A” 25.881~25.981 mm 25.851 mm
“B” 21.195~21.295 mm 21.165 mm
Exhaust “A” 25.841~25.941 mm 25.811 mm
“B” 21.05~21.15 mm 21.02 mm
Camshaft runout limit ••• 0.03 mm
Cam chain:
Model/No. of links BUSH CHAIN/88 •••
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.08~0.12 mm •••
EX 0.10~0.14 mm •••
Stem outside diameter IN 4.475~4.490 mm 4.45 mm
EX 4.460~4.475 mm 4.435 mm
Guide inside diameter IN 5.000~5.012 mm 5.042 mm
EX 5.000~5.012 mm 5.042 mm
Stem-to-guide clearance IN 0.010~0.037 mm 0.08 mm
EX 0.025~0.052 mm 0.10 mm
Stem runout limit ••• 0.01 mm
Valve seat width IN 0.9~1.1 mm 1.6 mm
EX 0.9~1.1 mm 1.6 mm
Valve seat replace Replaceable •••
Rocker arm/rocker arm shaft:
Bearing inside diameter 10.000~10.015 mm 10.03 mm
Rocker shaft outside diameter 9.981~9.991 mm 9.95 mm
2-4
5AP-E0 2 01.7.26 10:35 AM Page 5
Item Standard Limit

Valve spring:
Free length 33.28 mm 31.9 mm
Tilt limit ••• 2.5°/1.2 mm
Piston:
Piston to cylinder clearance 0.020~0.034 mm 0.15 mm
Piston size “D” 53.998~54.029 mm •••
Piston off-set (2nd) 0.5 mm •••
Measuring point “H” 5.0 mm •••
Piston pin bore inside diameter 15.002~15.013 mm 15.043 mm
Piston pin outside diameter 14.991~15.000 mm 14.971 mm
Piston rings:
Top ring:
Type Barrel •••
End gap (installed) 0.15~0.30 mm 0.4 mm
Side clearance (installed) 0.03~0.07 mm 0.12 mm
2nd ring:
Type Taper •••
End gap (installed) 0.30~0.45 mm 0.55 mm
Side clearance 0.02~0.06 mm 0.12 mm
Oil ring:
End gap (installed) 0.2~0.7 mm •••
Crankshaft:
Crank width “A” 46.95~47.00 mm •••

Runout limit “C” ••• 0.03 mm
Big end side clearance “D” 0.15~0.45 mm 0.8 mm
2-5
5AP-E0 2 01.7.26 10:35 AM Page 6
Item Standard Limit

Clutch:
Friction plate thickness 2.9~3.1 mm 2.8 mm
Quantity 5 pcs. •••
Clutch plate thickness 1.05~1.35 mm •••
Warp limit ••• 0.05 mm
Max wrapage ••• 1 mm
Clutch spring free length 33 mm 31 mm
Push rod bending limit ••• 0.5 mm
Carburetor:
I.D. mark 5AP1-00 •••
Main jet (M.J) #92.5 •••
Main air jet (M.A.J) 0.8 •••
Jet needle (J.N) 5FV1-2 •••
Needle jet (N.J) N-6 •••
Pilot outlet (P.O) 0.75 •••
Pilot jet (P.J) #15 •••
Pilot screw (P.S) 1~3 •••
Valve seat size (V.S) 1.8 •••
Starter jet 1 (G.S.1) #30 •••
Float height (F.H) 21.8 mm •••
Engine idle speed 1,300~1,500 r/min •••
Intake vacuum 26.7 kPa(200 mmHg) •••
Oil pump:
Type Trochoid type •••
Tip clearance 0.15 mm (maximum) 0.2 mm
Side clearance 0.06~0.10 mm 0.15 mm
Housing and rotor clearance 0.06~0.10 mm 0.15 mm
2-6
5AP-E0 2 01.7.26 10:35 AM Page 7

CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Ball and race bearing •••
Size/No. of steel balls (upper) 0.25 in/19 pcs •••
(lower) 0.25 in/19 pcs •••
Front suspension:
Front fork travel 130 mm •••
Fork spring free length 426 mm 417.5 mm
Oil capacity 0.157 L (157 cm3) •••
Oil level 178 mm •••
Oil grade Fork oil 10 WT or equivalent •••
Inner tube out side diameter 30mm •••
Inner tube bend limit ••• 0.2 mm
Rear suspension:
Shock absorber stroke 70 mm •••
Spring rate (K1) 19.6 N/mm (2 kgf/mm) •••
(K2) 62.5 N/mm (6.37 kgf/mm) •••
Stroke (K1) 0 ~ 40 mm •••
(K2) 40 ~ 70 mm •••
Front wheel:
Rim size 18 × 1.60 •••
Rim runout limit radial ••• 1 mm
lateral ••• 0.5 mm
Wheel axle bend limit ••• 0.25 mm
Rear wheel:
Rim size 16 × 2.50 •••
Rim runout limit radial ••• 1 mm
lateral ••• 0.5 mm
Wheel axle bend limit ••• 0.25 mm
Drive chain:
Type/manufacturer 428HG(I)/DAIDO •••
No. of links 130 •••
Chain free play 30~45 mm •••
10 link length ••• 121 mm
2-7
5AP-E0 2 01.7.26 10:35 AM Page 8

Item Standard Limit
Front brake:
Disc outside diameter x thickness 267 x 4 mm 3.5 mm
Brake disc runout limit ••• 0.15 mm
Pad thickness (inner) 6.5 mm 0.8 mm
(outer) 6.5 mm 0.8 mm
Brake fluid type DOT 4 or DOT 3 •••
Rear brake:
Drum inside diameter 130 mm 131 mm
Lining thickness 4 mm 2 mm
Brake lever:
Brake lever free play (at lever end) 2~5 mm •••
Brake pedal:
Brake pedal position 77 mm •••
Brake pedal free play 20~30 mm •••
Clutch lever:
Clutch lever free play (at lever end) 10~15 mm •••
Throttle cable free play 3~5 mm •••
2-8
5AP-E0 2 01.7.26 10:35 AM Page 9

ELECTRICAL
Item Standard limit
Ignition timing:
Ignition timing (B.T.D.C.) 7° at 1,400 r/min •••
Advanced type Electrical type •••
C.D.I.: (C.D.I magneto)
Model F5AP
Pickup coil resistance/color 248~372 Ω at 20°C/Red — White •••
Source coil resistance/color 720~1,080 Ω at 20°C/Brown — Green •••
Stator coil resistance/color 0.44~0.66 Ω at 20°C/White — White •••
C.D.I. unit model 5AP •••
Ignition coil:
Model 4FP •••
Minimum spark gap 6 mm •••
Primary coil resistance 0.32~0.48 Ω at 20°C •••
Secondary coil resistance 5.68~8.52 kΩ at 20°C •••
A.C. Magneto:
Model 5AP •••
Standard output 14 V 100 W (5,000 r/min) •••
Rectifier/regulator:
Model SH620B-12 •••
No load regulated voltage 13~14 V •••
Starter motor:
Model 5AP •••
Output 0.4 kW •••
Brush overall length 10 mm 3.5 mm
Brash spring pressure 5.52~8.28 N (563~844 gf) 230 gf
Commutator diameter 22 mm 21 mm
Mica undercut (depth) 1.5 mm •••
2-9
5AP-E0 2 01.7.26 10:35 AM Page 10
Item Standard limit

Starter relay:
Model MS5D-191 •••
Amperage 100 A •••
Coil resistance 3.87~4.73 Ω at 20°C •••
Hauling voltage 8V or more •••
Horn:
Model YML-12 •••
Maximum amperage 4A •••
Coil resistance 0.44~0.48 Ω •••
Flasher relay:
Type Condenser •••
Model FZ222SD •••
Flasher frequency 75~95 cycle/min •••
Starting circuit cut - off relay:
Model G8MS-1A41T-Y30 •••
Coil resistance 90~110 Ω •••
Circuit breaker:
Type Fuse •••
Main 10 A × 1 pcs. •••
Reserve 10 A × 1 pcs. •••
2-10
5AP-E0 2 01.7.26 10:35 AM Page 11
TIGHTENING TORQUE SPEC

TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Q’ty Remarks
size
Nm m•kg
Cylinder head M8x1.25 4 22 2.2
Cylinder head M6x1.0 2 10 1.0
Spark plug M10x1.0 1 12.5 1.25
Cylinder head cover M6x1.0 4 10 1.0
Valve cover M45x1.5 2 18 1.8
C.D.I. magneto rotor M12x1.25 1 70 7.0
Valve adjusting screw and nut M5x0.5 2 7.5 0.75
Guide stopper 2 M6x1.0 1 10 1.0 LT
Cam sprocket M8x1.25 1 20 2.0

Cam sprocket plate M6x1.0 1 10 1.0 LT
Timing chain tensioner cap bolt M6x1.0 1 7.5 0.75

Timing chain tensioner ass’y M6x1.0 2 10 1.0
Oil pump ass’y M6x1.0 2 7 0.7
Drain bolt M12x1.5 1 20 2.0
Oil pump cover M5x0.8 1 4 0.4
Cylinder head and carburetor joint M6x1.0 2 10 1.0
Carburetor joint and carburetor M4x0.7 1 2 0.2
Carburetor and air filter M4x0.7 1 2 0.2
Air filter case M6x1.0 2 7 0.7
Exhaust pipe M6x1.0 2 10 1.0
Muffler ass’y M8x1.25 2 22 2.2
Crankcase left and right M6x1.0 10 10 1.0
Crankcase cover left (Flange bolt) M6x1.0 7 10 1.0
Crankcase cover left (Screw) M6x1.0 3 7 0.7
Crankcase cover right M6x1.0 9 10 1.0
Plate M6x1.0 1 7 0.7
Timing check plug M14x1.5 1 7 0.7
Center plug M32x1.5 1 7 0.7
2-11
5AP-E0 2 01.7.26 10:35 AM Page 12
Tightening
Thread torque
Part to be tightened Q’ty Remarks
size
Nm m•kg
Kick starter M12x1.0 1 50 5.0
Idle gear plate M6x1.0 1 7 0.7
Starting motor ass’y M6x1.0 2 10 1.0
Primary drive gear M12x1.0 1 70 7.0
Pressure plate M5x0.8 4 6 0.6
Clutch boss M12x1.0 1 60 6.0
Push lever axle M6x1.0 1 8 0.8
Cover plate M6x1.0 2 7 0.7 LT
Sprocket M6x1.0 1 10 10
Shift pedal M6x1.0 1 10 1.0
Shift rod M6x1.0 1 7 0.7
Shift rod M6x1.0 1 7 0.7
Segment M6x1.0 1 12 1.2 LT
Stopper lever M6x1.0 1 10 1.0 LT
Pickup coil M6x1.0 2 10 1.0 LT
Neutral switch ass’y M10x1.25 1 4 0.4

Neutral switch lead M4x0.7 1 2 0.2
Stator coil M6x1.0 3 10 1.0
Item Standard Limit

Tightening sequence
Cylinder head
3 5
1
4
2
6
Crankcase
1 6
9
0
5 7
8
4
3 2
2-12
5AP-E0 2 01.7.26 10:35 AM Page 13

TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread size torque Remarks
Nm m•kg
Front engine mount and engine stay 2 M8x1.25 32 3.2
Engine stay 2 and frame M10x1.25 55 5.5
Rear engine mount and frame M8x1.25 32 3.2
Upper engine mount and engine stay 1 M8x1.25 32 3.2
Engine stay 1 and frame M8x1.25 32 3.2
Ignition coil and frame M6x1.0 4 0.4
Main switch and frame M6x1.0 10 1.0
Sidestand M10x1.25 40 4.0
Footrest bracket and frame (right) M8x1.25 32 3.2
Footrest bracket and frame (left) M8x1.25 32 3.2
Lever ass’y and lever M6x1.0 10 1.0
Footrest bracket and engine stay 2 M10x1.25 55 5.5
Handle crown and inner tube M8x1.25 30 3.0
Handle crown and steering shaft M14x1.25 54 5.4
Handle crown and handle under holder M10x1.25 32 3.2
Handle under holder and Upper holder M8x1.25 23 2.3
Under bracket and inner tube M10x1.25 30 3.0
Master cylinder and bracket M6x1.0 7 0.7
Brake hose union bolt M10x1.25 30 3.0
Front master cylinder cap M4x0.7 1.5 0.15
Stay and handle crown M6x1.0 10 1.0
Front flasher and stay M12x1.25 7 0.7
Headlight stay and under bracket M6x1.0 10 1.0
Headlight stay and headlight M6x1.0 7 0.7
Headlight body and unit M5x0.8 2.5 0.25
Meter and meter cable M12x1.0 2.5 0.25
Steering shaft and nut M25x1.0 — — Refer to NOTE
Fuel meter and handle crown M6x1.0 10 10
Brake lever adjust screw locknut M6x0.75 4 0.4
Pivot shaft and frame M12x1.25 59 5.9
Rear shock absorber and frame M10x1.25 40 4.0
Rear shock absorber and swingarm M10x1.25 40 4.0
Tension bar and swingarm M8x1.25 19 1.9
Tension bar and brake shoe plate M8x1.25 19 1.9
Chain case and swingarm M6x1.0 4 0.4
2-13
5AP-E0 2 01.7.26 10:35 AM Page 14
TIGHTENING TORQUE/
GENERAL TORQUE SPECIFICATIONS SPEC
Tightening
Part to be tightened Thread size torque Remarks
Nm m•kg
Fuel cock and fuel tank M6x1.0 7 0.7
Fuel sendor and fuel tank M5x0.8 4 0.4
Fuel tank cap M5x1.0 4 0.4
Rear flasher and rear fender M12x1.25 7 0.7
Side cover 2 and frame M6x1.0 4 0.4
Side cover 3, frame and bracket 3 M6x1.0 4 0.4
Stay 1,2 and stay 3 M8x1.25 23 2.3
Front wheel shaft and nut M14x1.5 91 9.1
Rear wheel shaft and nut M14x1.5 91 9.1
Front caliper and front fork M10x1.25 35 3.5
Brake disk and wheel M8x1.25 23 2.3 LT
Brake hose union bolt M10x1.25 30 3.0

Breed screw and caliper M8x1.25 6 0.6
Driven sprocket and clutch hub M8x1.25 32 3.2
Chain puller lock nut M8x1.25 16 1.6
Camshaft and lever M6x1.0 10 1.0
Meter cable and gear unit M6x1.0 3 0.3
NOTE:
1. When tighten the ring nut, should be steady the ball bearings and the steering shaft moving
smoothly.
2. First, tighten the ring nut approximately 33 Nm (3.3 m•kg) by using the torque wrench, then
loosen the ring nut one turn and retighten the ring nut 22 Nm (2.2 m•kg).
GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasten- General torque
ers with standard I.S.O. pitch threads. Torque A B specifications
(Nut) (Bolt)
specifications for special components or Nm m•kg
assemblies are included in the applicable sec- 10 mm 6 mm 6 0.6
tions of this book. To avoid warpage, tighten 12 mm 8 mm 15 1.5
multi-fastener assemblies in a crisscross fash- 14 mm 10 mm 30 3.0
ion, in progressive stages, until full torque is
17 mm 12 mm 55 5.5
reached. Unless otherwise specified, torque
19 mm 14 mm 85 8.5
specifications call for clean, dry threads.
Components should be at room temperature. 22 mm 16 mm 130 13.0
A B
A: Distance across flats

B: Outside thread diameter
2-14
5AP-E0 2 01.7.26 10:35 AM Page 15
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE
Lubrication Point Symbol
Oil seal lip (all)
Bearing retainer (all)
O-ring (all)
Cylinder head mounting surface
Crank pin
Connecting rod (big end)
Piston pin
Piston and piston ring
Buffer boss
Valve stem, stem seal and valve guide
Valve stem end
Rocker shaft and rocker arm
Camshaft
Idler gear and shaft
Idler gear inner surface
Starter one-way
Push rod
Main axle outer surface
Timing chain case
Kick idle gear inner surface
Kick idle gear outer surface
Kick axle
Push lever oil seal
Push lever outer surface
Starting motor O-ring
Transmission gear
Shift fork guide bar sliding surface
Shift cam groob and axle
Drive axle
Crankcase mating surface Yamaha bond No. 1215
2-15
5AP-E0 2 01.7.26 10:35 AM Page 16
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

CHASSIS
Lubrication Point Symbol

Speedometer gear unit
Front wheel oil seal lip
Rear wheel oil seal lip
Rear brake camshaft and lever pivot
Rear swingarm nipple
Rear swing arm oil seal
Rear swing arm collar
Pivot shaft
Main stand pivoting surface
Steering bearing
Throttle grip inner surface
Clutch cable end
Brake lever/Clutch lever pivoting surface
Bracket support
Rear shock absorber mounting surface (flange)
Rear shock absorber mounting surface (collar)
Shift pedal pipe inner surface
Brake cable end
Brake pedal pivoting surface
2-16
5AP-E0 2 01.7.26 10:35 AM Page 17
LUBRICATION DIAGRAM SPEC

LUBRICATION DIAGRAM
1 Rocker arm (IN)
2 Rocker shaft
3 Rocker arm (EX)
4 Camshaft
5 Crank
6 Oil pump
7 Oil strainer
1
2
3
4
2-17
5AP-E0 2 01.7.26 10:35 AM Page 18
LUBRICATION DIAGRAM SPEC

1 Camshaft
2 Oil filter
3 Crankshaft
4 Main axle
5 Drive axle
2-18
5AP-E0 2 01.7.26 10:35 AM Page 19
CABLE ROUTING SPEC

CABLE ROUTING
1 Wireharness e Starting motor lead B Pass the throttle cable and
2 Starter cable r Vent hose starter cable through the cable
3 Clutch cable t Main switch guide.
4 Clutch switch lead y Horn C Pass the wireharness and lead
5 Handlebar switch (left) u Speedometer into the hole of the headlight
6 Air vent hose i Cover (left) body, then connect in the head-
7 Fuel sender light body.
8 C.D.I. unit A Pass the wireharness into the D Insert the air vent hose into the
9 Rear flasher light lead (left) cable guide. flame.
0 Tail/Brake light lead E Clamp the air vent hose and
q Starter relay main switch lead.
w C.D.I. magneto lead
5
3 4
2
ç ∂
1 7
´ ƒ
6 ©
∫ ˙
8
å ˆ
A
π
09 A
y B
∆
3
0
t
q
r
2
u ø 3 ˚
¬
˜
µ
o
i
œ
® B
A-A
2-19
5AP-E0 2 01.7.26 10:35 AM Page 20
CABLE ROUTING SPEC

F Pass the throttle cable, starter J Pass the tail/brake light lead N Clamp the starting motor lead.
cable and wireharness into the and rear flasher light lead into O Clamp the starting motor lead
cable guide. the slot the mud guard (left and inside the engine stay.
G Connect the fuel hose to the right). P Pass the wireharness into the
fuel cock and carburetor, then K Pass the starting motor lead cable guide.
clip each end. and negative lead into the cable Q Pass through the C.D.I. magne-
H Clamp the fuel sendor lead. guide. to lead into the slot.
I Align the wireharess and wire- L Attach the neutral switch lead R Pass the tail/brake light lead
harness holder with the white into the crankcase slot (seclud- and rear flasher light lead inside
tape. ed part). the mud guard (left and right).
M Through the crankcase breather
hose end in the hose clamp to
the rear side.
5
3 4
2
ç ∂
1 7
´ ƒ
6 ©
∫ ˙
8
å ˆ
A
π
09 A
y B
∆
3
0
t
q
r
2
u ø 3 ˚
¬
˜
µ
o
i
œ
® B
A-A
2-20
5AP-E0 2 01.7.26 10:35 AM Page 21
CABLE ROUTING SPEC

1 Air filter case e Flasher relay E Do not contact the wireharness
2 Drain hose r Rectifier/Regulator and lead in the handle lock cap,
3 Ignition coil t Clutch cable when turn the handlebar right
4 Front brake switch lead side.
5 handlebar switch lead (right) A Clamp the wireharness. F Clamp the brake hose to the
6 Brake hose B Clamp the rear brake switch brake hose holder.
7 Throttle cable lead.
8 Brake hose holder C Pass the hi-tension cord into
9 Cable holder the cable guide.
0 Main switch D Pass the clutch cable into the
q Hi-tension cord cable guide.
w Rear brake switch
4
5
6
7
ç 3 ´
∂
2
8
∫ ƒ
8
å 1
e
r w
2-21
5AP-E0 2 01.7.26 10:35 AM Page 22
CABLE ROUTING SPEC

1 Fuel meter r Starer relay D Clamp the handlebar switch
2 Speedometer lead (left) on the bended part
3 Front flasher light (left) A Clamp the handlebar switch center.
4 Speedometer cable lead (right) on the bended part E Clamp the speedometer cable
5 Front flasher light (right) under. into the cable guide.
6 Stay B Clamp the handlebar switch F Pass the wireharness into the
7 Rear flasher light (right) lead (right) on the bended part hose guide.
8 Rear flasher light lead (right) center. G Pass the wireharness and lead
9 Rear flasher light coupler C Clamp the handlebar switch inside the stay, without
0 Tail/Brake light lead (left) on the bended part speedometer cable.
q Tail/Brake light lead under. H Clamp the wireharness.
w Rectifier/Regulator lead
e Rear flasher light lead (left)
å ∂
∫ 2 ç
1
5 3
© 4
ƒ ´
˙ 9 8
q 0
r e
˙ w
2-22
5AP-E0 3 01.7.26 10:56 AM Page 1
INTRODUCTION/ CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checkings and adjusting.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information applies
to vehicles already in service as well as to new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

AFTER BRAKE-IN EVERY
BRAKE-IN
1,000 km 3,000 km 3,000 km
ITEM ROUTINE
or or or
1 month 3 months 3 months
* Valve(s) Check valve clearance. Adjust if necessary. 1 1 1
Spark plug Check condition.

Clean or replace if necessary.
1 1 1 3
Air filter Clean. Replace if necessary. 1 1 1
Check idle speed/starter operation.
* Carburetor 1 1 1
Adjust if necessary.
Check fuel hose for cracks or damage.
* Fuel line 1 1
Replace if necessary.
* Fuel filter Clean. Replace if necessary. 1 1
* Engine oil Replace (Warm engine before draining.) 1 1 1
* Front brake Check operation/fluid leakage. /see NOTE.

Correct if necessary.
* Rear brake Check operation. Adjust if necessary. 1 1
* Clutch Check operation. Adjust if necessary. 1 1
Check rear arm assembly
* Swingarm pivot for looseness. 1 1 1
Correct if necessary.***
Wheels Check balance/damage/runout/spoke tightness.

* Replace if necessary. 1 1
Check bearing assembly for looseness/damage.

* Wheel bearings
Replace if damaged. 1 1
Check bearing assembly for looseness.

Steering Correct if necessary.
* bearing Moderately repack every 12,000 (8,000) km or 1 1 1
12 months. **
Check operation/oil leakage.
* Front forks 1 1
Repair if necessary.
Rear shock Check operation/oil leakage.
* absorber Repair if necessary. 1 1
*: It is recommended that these items be serviced by a Yamaha dealer.

**: Medium weight wheel bearing grease. (bearing type)
***: Lithium soap base grease.
3-1
5AP-E0 3 01.7.26 10:56 AM Page 2
CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
AFTER BRAKE-IN EVERY
BRAKE-IN
1,000 km 3,000 km 3,000 km
ITEM ROUTINE
or or or
1 month 3 months 3 months
Check chain slack/alignment. Adjust if necessary.

* Drive chain EVERY 500 km
Clean and lube.
Check all chassis fittings and fasteners.
* Nut/Bolt fasteners* Correct if necessary. 1 1 1
Check operation.
* Main stand Repair if necessary. 1 1 1
*: It is recommended that these items be serviced by a Yamaha dealer.

**: Medium weight wheel bearing grease. (bearing type)
***: Lithium soap base grease.
NOTE:
Brake fluid replacement:
3 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally
check the brake fluid level and fill the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-2
5AP-E0 3 01.7.26 10:56 AM Page 3
CHK
SIDE COVER, SEAT AND FUEL TANK ADJ
SIDE COVER, SEAT AND FUEL TANK
3 7
6
5
2

Removing the side cover, seat and Remove the parts in order.
fuel tank
1 Side cover (left) 1
2 Side cover (right) 1
3 Seat 1
4 Fuel pipe 1 NOTE:
Disconnect the fuel pipe, set the fuel cock
lever “OFF” position.
5 Fuel sender coupler 1 NOTE:

Disconnect the fuel sender coupler.
6 Fuel tank 1
7 Rear fender plate (left) 1
8 Rear fender plate (right) 1
9 Tail cover 1
Reverse the removal procedure for
installation.
3-3
5AP-E0 3 01.7.26 10:56 AM Page 4
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
ENGINE
ADJUSTING THE VALVE CLEARANCE
cC
Adjusting the valve clearance should be
made with the engine cool, at room tempera-
ture.
1. Remove:
9Side cover (left and right)
9Seat
9Fuel tank
Refer to “SIDE COVER, SEAT AND FUEL
TANK” section .
9Cylinder head side cover left and right
Refer to “ENGINE OVERHAUL” section in
the chapter 4.
2. Remove:
1
9Spark plug cap
9Spark plug
9Valve cover (intake side) 1
2 9Valve cover (exhaust side) 2
3. Remove:
9Timing check plug 1
9Center plug 2
1
2
4. Rotate the crankshaft counterclockwise to

align the slit a on the rotor with the station-
ary pointer b on the crankcase cover (left)
b when the piston is Top Dead Center
(T.D.C.).
3-4
5AP-E0 3 01.7.26 10:56 AM Page 5
ADJUSTING THE VALVE CLEARANCE/ CHK

ADJUSTING THE IDLING SPEED ADJ
5. Check:
9Valve clearance
Out of specification → Adjust.
Valve clearance (cold):

Intake valve 0.08 ~ 0.012 mm
Exhaust valve 0.10 ~ 0.14 mm
6. Adjust:
9Valve clearance
1
************************************************
Adjusting steps:
2 8 Loosen the locknut 1.
8 Insert the thickness gauge 2.
8 Turn the adjuster 3 in or out with the valve
adjusting tool 4.
Valve adjusting tool:

90890-01311
3 4
8 Adjust until specified clearance is obtained.
8 Hold the adjuster to prevent it from moving
and tighten the locknut.
7.5 Nm (0.75 m•kg)
8 Measure the valve clearance.

8 If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
************************************************
ADJUSTING THE IDLING SPEED
1
1. Start the engine and let it warm up for sev-
eral minutes.
2. Attach:
9Inductive tachometer 1 to the spark plug
lead.
Inductive tachometer:
90890-03113
3. Check:
9Engine idling speed
Engine idling speed:

1,300 ~ 1,500 r/min
4. Adjust:
9Engine idle speed
3-5
5AP-E0 3 01.7.26 10:56 AM Page 6
ADJUSTING THE IDLING SPEED/ CHK

ADJUSTING THE THROTTLE CABLE ADJ
************************************************
Adjusting steps:
8 Turn the pilot screw 1 until it is lightly seated.
cC
Do not lock it too tight.
8 Turn the pilot screw out by the specified num-

1 ber of turns.
Pilot screw:
2 turns out
8 Start the engine.

8 Turn the throttle stop screw 2 in or out until
the specified idling speed is obtained.
Turning in → Idling speed is increased.
2
Turning out → Idling speed is decreased.
************************************************
ADJUSTING THE THROTTLE CABLE
1. Check:
9Throttle cable free play a
Out of specification → Adjust the pilot
screw (also adjust idle speed screw)
Free play (throttle cable):
a
3~5 mm at throttle grip flange
2. Adjust:
9Throttle cable free play
************************************************
Adjusting steps:
Step 1 (Handlebar side)
8 Loosen the locknut 1 on the throttle cable.
8 Turn the adjuster 2 in or out until specified
2 1 free play is obtained.
Turning in → Free play is decreased.

Turning out → Free play is increased.
8 Tighten the locknut.

NOTE
If the free play can be adjusted hear, adjust it at
the carburetor side.
3-6
5AP-E0 3 01.7.26 10:56 AM Page 7
ADJUSTING THE THROTTLE CABLE/ CHK

CHECKING THE SPARK PLUG ADJ
3 Step 2 (Carburetor side)
4 8 Loosen the locknut 3 on the throttle cable.
8 Turn the adjuster 4 in or out until specified
free play is obtained.
Turning in → Free play is increased.

Turning out → Free play is decreased.
8 Tighten the locknut 3.

w
After adjusting, turn the handlebar to the
right and to the left to ensure that this does
not cause the engine idling speed to change.
************************************************
CHECKING THE SPARK PLUG

1. Check:
2 9Spark plug
Wear/damage → Replace.
a Abnormal color → Replace.
1 Clean with spark plug cleaner or wire
brush.
2. Check:
9Electrode 1
9Insulator 2
9Spark plug gap 3
Out of specification → Adjust gap.
Spark plug gap:

0.6 ~ 0.7 mm
Standard spark plug:

CR7HSA (NGK) / U22FSR-U (DENSO)
3-7
5AP-E0 3 01.7.26 10:56 AM Page 8
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
MEASURING THE COMPRESSION PRESSURE
2 1. Start the engine and let it warm up for sev-
1 eral minutes.
2. Remove:
9Spark plug
3. Attach:
9Compression gauge 1
9Adopter 2
To the spark plug hole.
Compression gauge:
90890-03081
Adopter:
90890-01082
4. Measure:
9Compression pressure
************************************************
Measuring steps:
8 Turn the throttle to full close position.
8 Crank the engine. (use starting motor or
kick starter)
8 Read the compression gauge.
Compression pressure
Standard:
1,200 kPa (12.0 kgf/cm2)
at 1,400 r/min
************************************************
8 If it exceeds the maximum pressure

allowed
Check the cylinder head, valve surfaces and pis-

ton crown for carbon deposits.
If it is below the minimum pressure → Squirt a

few drops of oil into the affected cylinder and
measure again.
Compression pressure
(With oil applied into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Possible defective ring(s),
Same as
valves, cylinder head gasket
without oil
or piston → Repair.
3-8
5AP-E0 3 01.7.26 9:26 PM Page 9
CHECKING THE ENGINE OIL LEVEL/ CHK

CHANGING THE ENGINE OIL ADJ
CHECKING THE ENGINE OIL LEVEL
NOTE:
Make sure the motorcycle is upright when
checking the oil level.
a
1 1. Check:
9Engine oil level
Start the engine several minites, and
straiten the motorcycle and check the oil
level into the level window 1 between
maximum and minimum range a,after
stop the engine several minites.
RECOMMENDED ENGINE OIL
SAE10W-30 Oil quantity:

Periodic oil change:
SAE10W-40
1.0 L (1,000 cm3)
SAE20W-40 Total amount:
1.2 L (1,200 cm3)
SAE20W-50
-20 -10 0 10 20 30 40 ( C)
Recommended oil:
Refer to the chart for selection of the oils
suited to the atmospheric temperature.
CHANGING THE ENGINE OIL

NOTE:
Wait a few minutes until the oil settles before
checking the oil level.
1. Start the engine and let it warm up for sev-

eral minutes.
2. Remove:
9Drain bolt 1
NOTE:
The drain bolt should be removed so that the
1 drain hole will drain.
3-9
5AP-E0 3 01.7.26 10:56 AM Page 10
CHK
CHANGING THE ENGINE OIL ADJ
3. Remove:
9Drain bolt 1
9Gasket 2
4. Remove:
9Oil filler plug 1
9O-ring
5. Drain the crankcase of its oil.
1
6. Install:
9Gasket
9Drain bolt 20 Nm (2.0 m•kg)
7. Fill the crankcase of its oil at specification

level.
8. Install:
9O-ring
9Oil filler plug
9. Start the engine and let it warm up for a few

minutes, then check the engine oil level.
3-10
5AP-E0 3 01.7.26 10:56 AM Page 11
CHK
ADJUSTING THE CLUTCH ADJ
ADJUSTING THE CLUTCH
1. Check:
9Clutch lever free play a
Free play (clutch lever):
10 ~ 15 mm
at clutch lever end
a
2. Adjust:
9Clutch lever free play
************************************************
1 2 Adjusting steps:
1st step (engine side)
8 Loosen the locknut 1.
8 Turn the adjuster 2 in or out until the speci-
fied free play is obtained.

8 Tighten the locknut .
NOTE:
If the amount of free play is still incorrect, adjust
the clutch cable free play with the other adjuster
(on the clutch lever holder).
2nd step (lever side)

2
Turning in → Free play is increased.
. Turning out → Free play is decreased.

1
************************************************
3-11
5AP-E0 3 01.7.26 10:56 AM Page 12
CHK
CLEANING THE AIR FILTER ADJ
CLEANING THE AIR FILTER
1 1. Remove:
9Side cover (right)
9Air filter case cover
9Air filter element 1
2. Check:
9Air filter element 1
1 Damage → Replace.
3. Clean:
9Air filter element
Use solvent to clean the element.
NOTE:
After cleaning, remove the remaining solvent by
squeezing the element.
cC
Do not twist the filter element when squeez-
ing it.
w
Never use low flash point solvents such as
gasoline to clean the air filter element. Such
solvents may cause a fire or an explosion.
4. Apply the engine oil to the entire surface of

the filter and squeeze out the excess oil.
The element should be wet but not dripping.
3-12
5AP-E0 3 01.7.26 10:56 AM Page 13
ADJUSTING THE FRONT BRAKE/ CHK

CHECKING THE BRAKE PAD ADJ
CHASSIS
ADJUSTING THE FRONT BRAKE
w
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. This air must be removed by bleed-
ing the brake system before the motorcycle
is operated. Air in the brake system will con-
siderably reduce braking performance and
could result in loss of control and possibly
an accident. Check and bleed the brake sys-
tem if necessary.
1. Check
9Check the brake hose is contact with other
parts, when vibration during the left and
right turning or during engine operating.
Incorrect → Correct.
2. Check:
a 9Brake lever free play a
Free play (Brake lever):

2 2 ~ 5 mm
at brake lever end
1
2. Adjust:
9Brake lever free play
************************************************
Adjusting steps:
************************************************
CHECKING THE BRAKE PAD
1. Check:
9Brake pad (front)
Wear indicators 1 almost touch the brake
disc 2 → Replace the brake pads as a
1 set.
3-13
5AP-E0 3 01.7.26 10:56 AM Page 14
CHECKING THE BRAKE FLUID LEVEL/ CHK

AIR BLEEDING ADJ
CHECKING THE BRAKE FLUID LEVEL
2
1. Check:
9Brake fluid level
Brake fluid level is below the “LOWER”
1 level line 1 → Fill to proper level.
Recommended brake fluid:

DOT 4 or DOT 3
NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir cap 2 is horizontal.
w
8Use only the designated brake fluid. Other
fluids may deteriorate the rubber seals,
causing leakage and poor brake perfor-
mance.
8Refill with the same type of fluid. Mixing flu-
ids may result in a harmful chemical reac-
tion leading to poor brake performance.
AIR BLEEDING
w
Bleed the brake system whenever:
8The system is disassembled.
8A brake hose is loosened or removed.
8The brake fluid level is very low.
8Brake operation is faulty.
Loss of braking performance may occur if
1 the brake system is not properly bled.
2
************************************************
Air bleeding steps:
1. Remove the reservoir tank cap.
2. Remove the diaphragm.
3. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 and place the other
end of the hose into a container.
4. Slowly apply the brake lever several times.
Pull the lever in. Hold the lever in position.
Loosen the bleed screw and allow the lever
to travel towards its limit.
NOTE:
Tighten the bleed screw when the lever has
been reached, then release the lever.
3-14
5AP-E0 3 01.7.26 10:56 AM Page 15
AIR BLEEDING/ CHK

REPLACING THE BRAKE FLUID ADJ
5. Repeat the steps (4) until the air bubbles
have been removed from the system.
NOTE:
Add proper brake fluid to the master cylinder
while the air breeding.
w
Hold the brake lever and check if there is
brake fluid leakage.
NOTE
Clean the brake fluids split on the brake disc,
tires and wheel hub.
6. Install the diaphragm.

7. Install the reservoir tank cap.
************************************************
REPLACING THE BRAKE FLUID

1
2 ************************************************
Replacing steps:
1. Stand the level place and remove the reser-
voir tank cap.
3. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 and place the other
end of the hose into a container.
cC
Clean the brake fluid split on the brake disc,
tires and wheel hub.
3. Tighten the bleed screw.

6 Nm (0.6 m•kg)
4. Remove the diaphragm 3.

5. Add the brake fluid proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” section.
3
6. Air bleeding:
Refer to “AIR BLEEDING” section.
************************************************
3-15
5AP-E0 3 01.7.26 10:56 AM Page 16
CHK
CHECKING THE REAR BRAKE/BRAKE PEDAL HEIGHT ADJ
CHECKING THE REAR BRAKE
1. Check:
9Brake pedal free play a
a Out of specification → Adjust.
Free play (Brake pedal):
20 ~ 30 mm
at brake pedal end
2. Adjust:
9Brake pedal free play
************************************************
Adjusting steps:

1
************************************************
BRAKE PEDAL HEIGHT

1. Check:
9Brake pedal height a
a Brake pedal height:
77 mm
below the top of the footrest
2. Adjust:
9Brake pedal height
************************************************
Adjusting steps:
2 8 Loosen the locknut 1.
fied pedal height is obtained.
Turning in → Pedal height is decreased.

1 Turning out → Pedal height is increased.

************************************************
3-16
5AP-E0 3 01.7.26 10:56 AM Page 17
CHECKING THE BRAKE SHOE/

ADJUSTING THE BRAKE LIGHT SWITCH/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
CHECKING THE BRAKE SHOE
1 1. Operate the brake pedal.
2. Check:
2 9Brake shoes
Wear indicator 1 reaches the wear limit
line 2 → Replace the brake shoes as a
set.
w
Replace the tension spring as a set when
replace the brake shoes.
ADJUSTING THE BRAKE LIGHT SWITCH

1
1. Check:
9Brake light operating timing
Brake light comes on, when push down
the brake pedal 20-30mm.
2 Incorrect → Adjust.
1 Rear brake light switch

2 Adjuster
ADJUSTING THE DRIVE CHAIN SLACK

1. Check:
9Drive chain slack a
Drive chain slack:
30 ~ 45 mm
a
2. Adjust:
9Drive chain slack
5 ************************************************
Adjusting steps:
8 Loosen the adjuster 1
3 8 Loosen the axle nut 2
2
4 8 Loosen the lock nut 3
8 Turn the chain adjusters 4 clockwise or
counterclockwise until the specified drive
1 chain slack is obtained.
Clockwise → Chain slack is decreased.

Counter-
→ Chain slack is increased.
clockwise
NOTE:
There are marks 5 on each chain adjuster. Use
them when adjusting the slack for proper align-
ment.
3-17
5AP-E0 3 01.7.26 10:56 AM Page 18
ADJUSTING THE DRIVE CHAIN SLACK/ CHK

CHECKING THE TIRE INFLATION PRESSURE ADJ
8 Tighten the axle nut.
NOTE
Press the drive chain with the finger then tighten
the nut into the rear wheel until it is fixed.
Rear wheel axle nut:

91 Nm (9.1 m•kg)
8 Tighten the lock nut.

8 Adjust the brake pedal free play.
************************************************
CHECKING THE TIRE INFLATION PRESSURE

1. Measure:
9Tire inflation pressure
Check the tire pressure, when the room
temperature.
Basic weight:
With oil and 125 kg
full fuel tank
Maximum load* 125 kg
Cold tire pressure Front Rear

175 kPa 200 kPa
Up to 90 kg load*
(1.75 kgf/cm2) (2.0 kgf/cm2)
90kg~ 175 kPa 225 kPa
maximum. load* (1.75 kgf/cm2) (2.25 kgf/cm2)
*Load is the total weight of the cargo, rider, pas-

senger and accessories.
Front tire size 2.75 - 18 42P
Rear tire size 120/80 - 16 60P
3-18
5AP-E0 3 01.7.26 10:56 AM Page 19
CHECKING THE TIRE/ CHK

CHECKING THE STEERING HEAD ADJ
CHECKING THE TIRE
1. Check:
9Tire surfaces
1 Wear indicator
1
Minimum tire tread depth
(front and rear):
0.8 mm
CHECKING THE STEERING HEAD

1. Check:
9Steering assembly bearings
Grasp the bottom of the lower front fork
tubes and gently rock the fork assembly.
Looseness → Adjust the steering head.
2. Adjust:
9Steering head
************************************************
Adjusting steps:
8 Remove the handle bar
Refer to “HANDLEBAR” section in the chapter
6.
8 Remove the handle crown
8 Remove the upper ring nut
Refer to “STEERING” section in the chapter
6.
Tighten the ring nut 1 using the ring nut

wrench 2.
Steering ring nut:
2
1st step:
1 33 Nm (3.3 m•kg)
Ring nut wrench:

90890-01403
8 Loosen the ring nut 1/4, then tighten it.

Steering ring nut:
2nd step:
22 Nm (2.2 m•kg)
8 Tighten the upper ring nut
8 Install the handle crown
8 Install the handlebar
3-19
5AP-E0 3 01.7.26 10:56 AM Page 20
CHECKING THE SWINGARM/ CHK

ADJUSTING THE REAR SHOCK ABSORBER ADJ
CHECKING THE SWINGARM
1. Check:
9Operation
Move the rear shock absorber several
times, front and rear or left and right.
Unsmooth operation → Repair.
ADJUSTING THE REAR SHOCK ABSORBER

w
8Always adjust each rear shock absorber
preload to the same setting. Uneven adjust-
ment can cause poor handling and loss of
1 stability.
8Securely support the motorcycle so there is
no danger of it falling over.
a
b
1. Adjust:
9Spring preload
Turn the adjuster ring 1 to direction a or
b.
************************************************
Adjusting steps:
8 Turn the adjuster ring in or out.
Turning toward a →Spring preload is

increased.
Turning toward b →Spring preload is
decreased.
Adjustment numbers:
Standard 2
Minimum 1
Maximum 5
cC
8Never turn the adjuster beyond the maxi-
mum or minimum setting.
8Always adjust each shock absorber to the
same setting.
************************************************
3-20
5AP-E0 3 01.7.26 10:56 AM Page 21
CHK
CHECKING THE BATTERY ADJ
ELECTRICAL
CHECKING THE BATTERY
Charging method
9 It is a sealed battery. Even in the charging operation, do not pull
off the sealing cap. Never replenish it with water.
9 Charge it in line with the following current and time at 12V.
Standard: 0.7A x 5 hour, or 3A x 1 hour for rapid charging.
Attention for battery use

It is a 12V sealed battery with no need of electrolyte level
inspection or water replenishment.
Pay special attention to the followings:
9 Use digital voltmeter to measure the voltage in the charged
condition (nominal voltage should be over 12.8V).
9 The battery cannot be used on motorcycles that are not suit-
able for sealed type batteries.
Batteries may give out flammable gases. Smoke and fires are
strictly forbidden during operations to avoid fires and explosion.
Battery electrolyte are corrosive. Be careful not to splash on
clothes, skin or eyes during operation.
On-site emergent treatment.
In case of splashing onto clothes, skin or eyes, wash them with
large amount of water immediately and take medical treatment
from the doctor with no delay.
2
BATTERY INSTALLATION NOTE
3 9Install the battery to the battery box.
1
9When install the battery band 1 , take
care battery (+) lead.
BATTERY REMOVAL NOTE

cC
Disconnect the negative lead 2 first and
then disconnect the positive lead 3.
BATTERY CONDITION
1. Check:
9Battery condition
Connect a digital volt meter 1 to the bat-
tery terminals.
Yellow or red range → Recharigng the bat-
tery.
No charge is necessary:
Green range
1 Charge is necessary:
Yellow or red range
cC
Refer the digital circuit tester, when using
the tester.
3-21
5AP-E0 3 01.7.26 10:56 AM Page 22
CHARGING THE BATTERY/

CHECKING THE SIGNAL AND LIGHTS/ CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
CHARGING THE BATTERY
1 w
8Keep batteries away from fire, sparks or
open flames (e.g., welding equipment, light-
ed cigarettes, etc.)
8This is a sealed type battery. Never remove
the sealing caps. If the sealing caps have
been removed, the balance will not be main-
tained and battery performance will deterio-
rate.
8Charging time, charging current and charg-
ing voltage for the MF battery are different
from those of batteries of general type.
8The MF battery should be charged as
explained in “CHARGING METHOD”. If the
battery is overcharged, the electrolyte level
will drop considerably. Therefore, take spe-
cial care when charging the battery.
8The battery charger 1 for MF type use only.
NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit voltage
(i.e. the voltage when the positive terminal is dis-
connected).
Standard charging:
0.7 A x 5 h
Rapid charging:
3Ax1h
Open circuit voltage:
.
12.8 V or more
CHECKING THE SIGNAL AND LIGHTS

1. Check:
9Wireharness
Wear/Damage → Repair.
9Connector and clamp
Loosen → Reconnect.
1 9Headlight and Tail/Brake lamp operation
9Flasher lamp operation at 60-120cycle
Incorrect → Correct.
ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
9Headlight beam (horizontal)
Loosen the screw 1 and adjust the head-
light unit.
3-22
5AP-E0 4-1 01.7.26 11:02 AM Page 1
ENGINE ENG
ENGINE
CRANKCASE COVER, SHIFT PEDAL AND DRIVE CHAIN
40 Nm (4.0 m•kg)
6 2
5
7 3
8
10 Nm (1.0 m•kg)
32 Nm (3.2 m•kg)
4
Removing the crankcase cover, shift Remove the parts in order.
pedal and drive chain
Drain the engine oil Refer to “CHANGING THE ENGINE OIL”
section in CHAPTER 3.
Seat, fuel tank, side cover left and right Refer to “SIDE COVER, SEAT AND
FUEL TANK” section in CHAPTER 3.
Carburetor Refer to “CARBURETOR” section in
CHAPTER 5.
1 Battery negative lead 1
2 Drive sprocket cover 1
3 Shift pedal 1 NOTE:
Install the pedal thread, should be same
height.
4 Drive sprocket holder 1
NOTE:
5 Drive sprocket/Drive chain 1/1
Install the sprocket “YAMAHA” mark out-
side.
6 C.D.I. magneto read 1
7 Cylinder head side cover left 1
8 Sidestand ass’y mount bolt 2 For installation, reverse the removal
procedure.
4-1
5AP-E0 4-1 01.7.26 11:02 AM Page 2
ENGINE ENG
EXHAUST PIPE, BRAKE PEDAL AND SIDE COVER
9
8 7
6
1 3
4 2
55 Nm (5.5 m•kg)
22 Nm (2.2 m•kg) 32 Nm (3.2 m•kg)
10 Nm (1.0 m•kg)

Removing the exhaust pipe, Remove the parts in order.
brake pedal and side cover
1 Side cover 3 1
2 Exhaust pipe/Gasket 1/1
3 Footrest ass’y 1 NOTE:
4 Rear brake rod 1 Remove the rear brake rod, then remove
the footrest ass’y.
5 Cylinder head side cover (right) 1
6 Starting motor/Starting motor lead 1/1
7 Spark plug cap 1
8 Breather hose 1
9 Clutch cable 1 For installation, reverse the removal
procedure.
4-2
5AP-E0 4-1 01.7.26 11:02 AM Page 3
ENGINE ENG
EARTH LEAD AND ENGINE
2 32 Nm (3.2 m•kg)
32 Nm (3.2 m•kg)
32 Nm (3.2 m•kg)
32 Nm (3.2 m•kg)
55 Nm (5.5 m•kg) 10 Nm (1.0 m•kg)

3 4

Removing the earth lead and engine Remove the parts in order.
Support the lower part of the engine with
jacking up before operation.
1 Earth lead 1
2 Engine stay 1 1
3 Engine stay 2 1
4 Engine 1
procedure.
4-3
5AP-E0 4-1 01.7.26 11:02 AM Page 4
CYLINDER HEAD ENG
CYLINDER HEAD
CYLINDER HEAD COVER
12.5 Nm (1.25 m•kg) 18 Nm (1.8 m•kg)
LS
2
1
LS
10 Nm (1.0 m•kg)
LS
LS
LS
4

Removing the cylinder head cover Remove the parts in order.
Side cover, seat and fuel tank Refer to “SIDE COVER, SEAT AND
FUEL TANK” section in CHAPTER 3.
Exhaust pipe ass’y Refer to “REMOVING THE ENGINE”

section.
Carburetor ass’y Refer to “CARBURETOR” section in

CHAPTER 5.
Engine stay 1 Refer to “REMOVING THE ENGINE” sec-

tion.
1 Spark plug 1
2 Cam sprocket cover/O-ring 1/1
3 Valve cover/O-ring 2/2
4 Straight plug screw/O-ring 2/2
procedure.
4-4
5AP-E0 4-1 01.7.26 9:27 PM Page 5
CYLINDER HEAD ENG
CYLINDER HEAD
22 Nm (2.2 m•kg)
5 10 Nm (1.0 m•kg)
E
10 Nm (1.0 m•kg) 7.5 Nm (0.75 m•kg)
7
1
8
6 4 2
E
3
7
20 Nm (2.0 m•kg)

Removing the cylinder head Remove the parts in order.
1 Cap bolt/O-ring 1/1
Refer to “INSTALLING THE CYLINDER
2 Timing chain tensioner ass’y 1
HEAD” section.
3 Gasket 1
4 Cam sprocket/Timing chain 1/1 Refer to “REMOVING/INSTALLING THE
CYLINDER HEAD” section.
5 Cylinder head side cover holder 1
6 Cylinder head 1 Refer to “REMOVING/INSTALLING THE
CYLINDER HEAD” section.
7 Dowel pin 2 Refer to “INSTALLING THE CYLINDER
8 Cylinder head gasket 1 HEAD” section.
procedure.
4-5
5AP-E0 4-1 01.7.26 11:02 AM Page 6
CYLINDER HEAD ENG

REMOVING THE CYLINDER HEAD
1. Align:
9Slit 1 on the magneto
2 (with stationary pointer 2 on the crank
case cover)
NOTE:
1
Turn the crank shaft counterclockwise with a
wrench and align the “I” mark a with the
cylinder head match mark b when the piston
is at T.D.C. on the compression stroke.
b
2. Loosen:
9Cam sprocket bolt 1
3. Remove:
3 9Cap bolt 1
9Bolt 2
9Timing chain tensioner ass’y 3
1
4. Remove:
1
2 9Cam sprocket bolt 1
a 9Cam sprocket 2
NOTE:
Fasten a safety wire a to the timing chain to
prevent it from falling into the crankcase.
4-6
5AP-E0 4-1 01.7.26 11:02 AM Page 7
CYLINDER HEAD ENG

5. Remove:
9Cylinder head
6 4
2 NOTE:
9Loosen the nuts in their proper loosening
sequence.
9Start by loosening each nut 1/2 turn until all are
3
5 1 loose.
CHECKING THE CYLINDER HEAD

1. Eliminate:
9Carbon deposits
(from combustion chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
9Spark plug threads
9Valve seats
2. Check:
9Cylinder head
Scratches/damage → Replace.
3. Measure:
9Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:

Less than 0.03 mm
INSTALLING THE CYLINDER HEAD
1. Install:
2 9Dowel pins 1
9Gasket (cylinder head) 2
1
2. Install:
9Cylinder head
3 5 M8 (1~4) 22 Nm (2.2 m•kg)
1 M6 (5~6) 10 Nm (1.0 m•kg)
NOTE:
9Apply engine oil onto the nut threads.
4 9Tighten the bolts starting with the lowest num-
2 6 bered one.
4-7
5AP-E0 4-1 01.7.26 11:02 AM Page 8
CYLINDER HEAD ENG

3. Turn the crankshaft counterclockwise until
the slit 1 matches the stationary pointer 2
on the crankcase. (top dead center)
2
4. Install:
3 9Camshaft
1 9Plate 1
NOTE:
Align the slot 2 on the camshaft with the sta-
2 tionary pointer 3 on the cylinder head.
5. Install:
b 2
9Cam sprocket 1
9Timing chain 2
a NOTE:
1 9Align the “I” mark a on the cam sprocket with
the stationary pointer b on the cylinder head.
9When installing the cam sprocket, keep the tim-
ing chain as tight as possible on the exhaust
side.
6. Use a flat head screwdriver 1 until if it

stops and wind the tensioner rod up fully
clockwise.
NOTE:
1
While pressing the tensioner rod lightly with fin-
gers.
7. Install:
1 5 9Gasket 1
4
9Timing chain tensioner 2
9Bolt 3 10 Nm (1.0 m•kg)
3 9Washer 4
2 9Cap bolt 5 7.5 Nm (0.75 m•kg)
4-8
5AP-E0 4-1 01.7.26 11:03 AM Page 9
CYLINDER HEAD ENG

8. Install:
9Cam sprocket bolt
20 Nm (2.0 m•kg)
NOTE:
Install the bolt while holding the magneto
mounting bolt with a wrench.
9. Check:
9Cam sprocket “I” mark
Unmatch → Reinstall the cam sprocket.
10. Check:
9Valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” section in CHAPTER 3.
11. Fill:
9Camshaft
engine oil (50cm3) to the camshaft.
NOTE:
Fill the engine oil, when remove the cylinder
head.
4-9
5AP-E0 4-1 01.7.26 11:03 AM Page 10
CAMSHAFT AND ROCKER ARMS ENG
CAMSHAFT AND ROCKER ARMS
7.5 Nm (0.75 m•kg)

7
3
E
4
M
7 5
10 Nm (1.0 m•kg)
6
E

Removing the camshaft and Remove the parts in order.
rocker arm
Cylinder head Refer to the “CYLINDER HEAD” section.
1 Plate 1
2 Rocker arm shaft (intake side) 1
3 Rocker arm (intake side) 1
4 Rocker arm shaft (exhaust side) 1
5 Rocker arm (exhaust side) 1
6 Cam shaft ass‘y 1
7 Nut/Adjuster 2/2
procedure.
4-10
5AP-E0 4-1 01.7.26 11:03 AM Page 11

REMOVING THE ROCKER ARM AND
2 ROCKER ARM SHAFT
1 1. Remove:
9Camshaft 1
9Collar (camshaft) 2
NOTE:
Use 10 mm bolt 3 to remove the camshaft.
3
2. Remove:
9Rocker arm shaft
2
1 NOTE:
Attach a rocker arm shaft puller bolt 1 and
weight 2 to the rocker arm shaft and slide out
the shaft.
Rocker arm shaft puller bolt:

90890-01083
Weight:
90890-01084
CHECKING THE CAMSHAFT

1. Check:
9Cam lobes
Pitting/scratches/blue discoloration→
Replace.
2. Measure:
9Cam lobes length A and B .
Out of specification → Replace.
Cam lobes length:
Intake:
A 25.881~25.981 mm
<Limit:> 25.851 mm
B 21.195~21.295 mm
<Limit:> 21.165 mm
A B Exhaust:
A 25.841~25.941 mm
<Limit:> 25.811 mm
B 21.050~21.150 mm
<Limit:> 21.02 mm
3. Check:
9Rocker arms
Out of specification→Replace.
Inside diameter (rocker arm):
10.000~10.015 mm
<Limit:> 10.030 mm
4-11
5AP-E0 4-1 01.7.26 11:03 AM Page 12

4. Check:
9Rocker arm shafts
Outside diameter
(rocker arm shaft):
9.981~9.991 mm
<Limit:> 9.950 mm
INSTALLING THE ROCKER ARM

1. Install:
b
9Rocker arm
9Rocker arm shaft 1
1
NOTE:
a Install the rocker arm shaft (intake), mach the
cut away a and bolt hole b .
cC
9Make sure that the rocker shaft install direc-
tion.
9Install the rocker arm shaft into the thread
side for the out.
4-12
5AP-E0 4-1 01.7.26 11:03 AM Page 13
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS
3
2 7
1
3 6
7 M
5
E

Removing the valves and Remove the parts in order.
valve springs
Cylinder head Refer to “CYLINDER HEAD” section.
Rocker arm, Camshaft Refer to “CAMSHAFT AND ROCKER ARMS”
section.
1 Valve cotters 4 Refer to “REMOVING/INSTALLING THE
VALVES AND VALVE SPRINGS” section.
2 Spring retainer 2
3 Valve spring 2
Refer to “INSTALLING THE VALVES AND
4 Valve (intake) 1 VALVE SPRINGS” section.
5 Valve (exhaust) 1
6 Spring seat 2
7 Valve guide (stem seal) 2 For installation, reverse the removal
procedure.
4-13
5AP-E0 4-1 01.7.26 11:03 AM Page 14

REMOVING THE VALVES AND VALVE SPRINGS
2
1. Remove:
9Valve cotters 1
NOTE:
Attach a valve spring compressor and attach-
ment 2 between the valve spring retainer and
cylinder head to remove the valve cotters.
1
cC
Do not compress so much as to avoid dam-
age to the valve spring.
Valve spring compressor:

90890-04019
Valve spring compressor attachment:
90890-04108
CHECKING THE VALVES AND VALVE GUIDES

1. Measure:
9Valve stem diameter
Out of specification → Replace the valve
guide.
Clearance:
Intake:
4.475 ~ 4.990 mm
<Limit:> 4.45 mm
Exhaust:
4.460 ~ 4.475 mm
<Limit:> 4.435 mm
2. Measure:
9Runout (valve stem)
Runout:
Less than 0.01 mm
NOTE:
Take 1/2 of measured value of the indicator as
the bending value.
3. Measure:
9Valve spring free length a
Valve spring free length:
a 32.28 mm <Limit:> 31.9 mm
4-14
5AP-E0 4-1 01.7.26 11:03 AM Page 15

4. Measure:
a
9Spring tilt a
Spring tilt limit:
1.2 mm (2.5°)
5. Measure:
9Spring contact face
Wear/pitting/scratches → Replace
6. Measure:
9Valve guide inside diameter
Valve guide inside diameter:
Intake:
5.000~5.012 mm
<Limit:> 5.042 mm
Exhaust:
5.000~5.012 mm
<Limit:> 5.042 mm
7. Measure:
Stem-to-guide clearance =
Valve guide inside diameter -
Valve stem diameter
Stem-to-guide clearance limit:

Intake:
<Limit:> 0.08 mm
Exhaust:
<Limit:> 0.10 mm
Out of specification → Replace the valve
guide.
CHECKING THE VALVE SEATS
1. Eliminate:
9Carbon deposits
(from the valve face and valve seat)
2. Coat the valve surface with a fine lapping
compound.
3. Insert the valve into the valve guide and
press it into the valve seat.
NOTE:
Do not rotate the valve is pressed, when check-
ing.
4-15
5AP-E0 4-1 01.7.26 11:03 AM Page 16

4. Measure:
9Valve face width a
Check if the contact part in the range of
specified values.
Out of specification → Reface the valve
seat.
a Valve face width:
0.9~1.1 mm
<Limit:> 1.6 mm
5. Measure:
a 9Valve seat width a
Check if the contact part in the range of
specified values.
Out of specification → Reface the valve
seat.
Valve seat width:
0.9~1.1 mm
<Limit:> 1.6 mm
6. Measure:
9Valve contact position
9Valve contact width
Apply Mechanic’s blueing dye (Dykem) to
the valve face.
Out of specification → Replace
0.3mm
0.9~1.1mm
4-16
5AP-E0 4-1 01.7.26 11:03 AM Page 17

VALVE LAPPING
1. Apply a coarse lapping compound to the
valve face and valve stem.
M
Valve lapper:
90890-04101
2. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all
compound. Apply a fine lapping compound
to the valve face and repeat the above
steps.
3. Apply Mechanic’s blueing dye (Dykem) to
the valve face. Press the valve through the
valve guide and onto the valve seat to make
a clear pattern. Measure the valve seat
width again.
cC
Do not let compound enter the gap between
the valve stem and the guide.
NOTE:
Make sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
INSTALLING THE VALVES AND VALVE SPRINGS

1. Install:
9Valve cotters 1
NOTE:
2
Install the valve cotters while compressing the
valve spring with a valve spring compressor and
attachment 2.
Valve spring compressor:

90890-04019
1 Valve spring compressor attach-
ment:
90890-04108
cC
Do not compress so much as to avoid dam-
age to the valve spring.
2. Secure the valve cotters onto the valve

stem by tapping lightly with a piece of wood.
4-17
5AP-E0 4-1 01.7.26 11:03 AM Page 18
CYLINDER AND PISTON ENG
CYLINDER AND PISTON
4
E
LS
3
1 2
8 5
E 6

Removing the cylinder and piston Remove the parts in order.
1 Timing chain guide 1
2 Cylinder/O-ring 1/1
3 Dowel pin 2 Refer to “INSTALLING THE PISTON
4 Cylinder gasket 1 RINGS, PISTON AND CYLINDER” section.
5 Piston pin circlip 2 Refer to “REMOVING THE PISTON AND
6 Piston pin 1 PISTON RINGS” section.
7 Piston 1 Refer to “INSTALLING THE PISTON
8 Piston ring set 1 RINGS, PISTON AND CYLINDER” section.
procedure.
4-18
5AP-E0 4-1 01.7.26 11:03 AM Page 19

REMOVING THE PISTON AND PISTON RINGS
1. Remove:
9Piston pin circlip 1
2 9Piston pin 2
9Piston 3
3 cC
1 Before removing the piston pin circlip, cover the
crankcase opening with a clean towel or rag to
prevent the circlip from falling into the crankcase
cavity.
2. Remove:
9Piston ring
NOTE:
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
CHECKING THE CYLINDER

1. Check:
A.B a 9Cylinder
Measure the cylinder bore “A and B” with a
B
A cylinder bore gauge.
NOTE:
Measure the cylinder bore “A and B” in parallel
to and at right angles to the crankshaft. Then,
find the average of the measurements.
a 5mm form the top of the cylinder

Cylinder bore:
54.024 ~ 54.056 mm
If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.
2. Measure:
9Cylinder warpage
Check the wrappage in the six directions of
the cylinder mating surface.
Cylinder warpage:
Less than 0.01 mm
4-19
5AP-E0 4-1 01.7.26 11:03 AM Page 20

CHECKING THE PISTON AND PISTON PIN
1. Check:
a 9Piston diameter
Measure the piston skirt diameter with a
micrometer.
a 5 mm from from the piston bottom edge.
Piston skirt diameter:

53.998 ~ 54.029 mm
2. Check:
9Piston clearance
Piston-to-cylinder clearance:
0.020 ~ 0.034 mm
Piston-to-cylinder clearance =
Cylinder bore –
Piston skirt diameter
NOTE:
9 In case of piston clearance below the specifi-
cation, proceed with the honing process to
increase it in the specification.
9 In case of piston clearance above the specifi-
cation, proceed with the honing process to
decrease it in the specification.
3. Check:
9Piston pin inside diameter
Piston pin inside diameter:
15.002 ~ 15.013 mm
<Limit:> 15.043 mm
4. Check:
9Piston pin outside diameter
Piston pin outside diameter:
14.991 ~ 15.000 mm
<Limit:> 14.971 mm
4-20
5AP-E0 4-1 01.7.26 11:03 AM Page 21

5. Check:
9Piston pin smooth operation
Blue discoloration/grooves → Replace,
then check the lubrication system.
CHECKING THE PISTON RING

1. Measure:
1 9End gap
Out of specification → Replace the piston
and the piston rings as a set.
NOTE:
Push the ring 1 into 5 mm with the piston crown
so that the ring will be at a right angle to the
cylinder bore.
End gap:
Top ring: <Limit>
0.15 ~ 0.30 mm <0.4 mm>
2nd ring: <Limit>
0.30 ~ 0.45 mm < 0.55 mm>
Oil ring:
0.2 ~ 0.7 mm
2. Measure:
9Side clearance
Out of specification → Replace the piston
and the piston rings as a set.
Side clearance:
Top ring: <Limit>
0.03 ~ 0.07 mm <0.12 mm>
2nd ring: <Limit>
0.02 ~ 0.06 mm < 0.12 mm>
NOTE:
When measuring, make measurement at several
locations instead of one.
4-21
5AP-E0 4-1 01.7.26 9:28 PM Page 22

INSTALLING THE PISTON RINGS, PISTON
AND CYLINDER
NOTE:
9 Make sure to install the piston rings so that the
manufacturer’s marks or numbers are located
on the upper side of the rings.
9 Lubricate the pistons and piston rings liberally
with engine oil.
1
2 1. Install:
9Top ring 1
4 92nd ring 2
9Expander spacer (oil ring) 3
3
9Side rails (oil ring) 4
4
2. Apply engine oil onto the piston pins.

3. Install:
9Piston 1
3
9Piston pin 2
9Piston pin circlip 3
NOTE:
The “→” mark a on the piston must face the
a 2 exhaust side of the cylinder.
3
1
cC
9Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
120° the piston pin clip from falling into the
120° 120° crankcase.
9Make sure to install each piston in its respec-
tive cylinder.
4. Position:
20mm
9Piston rings
NOTE:
20mm
Offset the piston ring end gaps as shown.
4-22
5AP-E0 4-2 01.7.26 11:09 AM Page 23
CLUTCH ENG
CLUTCH
CRANKCASE COVER (RIGHT)
5
2
50 Nm (5.0 m•kg)
10 Nm (1.0 m•kg)
1

Removing the crankcase cover (right) Remove the parts in order.
Exhaust pipe ass‘y Refer to “EXHAUST PIPE AND BRAKE
Footrest board stay PEDAL AND SIDE COVER” section.
1 Starting motor/Starting motor lead 1/1
2 Kick crank 1
3 Crankcase cover (right) 1
4 Gasket 1
5 Dowel pin 2
6 Clutch cable 1
procedure.
4-23
5AP-E0 4-2 01.7.26 11:09 AM Page 24
CLUTCH ENG
CLUTCH
60 Nm (6.0 m•kg)
6 Nm (0.6 m•kg)
4
8 Nm (0.8 m•kg)
11 3
12 7
13
2
1
6
5
10
15
14
E
8
9 70 Nm (7.0 m•kg)

Removing the clutch assembly Remove the parts in order.
1 Clutch spring 4
2 Pressure plate 1
3 Ball 1 Refer to “INSTALLING THE CLUTCH”
4 Lock washer 1 section.
5 Friction plates 5
6 Clutch plates 4
7 Clutch boss 1 Refer to “REMOVING THE CLUTCH” section.
8 Thrust plate 1
9 Primary driven gear 1
10 Plate washer/Spring washer 1/1 Refer to “INSTALLING THE CLUTCH”
11 Nut/Washer 1/1 section.
12 Push rod #1 1
13 Push plate 1
14 Nut/Washer 1/1
15 Primary drive gear/Straight key 1/1
procedure.
4-24
5AP-E0 4-2 01.7.26 11:09 AM Page 25
CLUTCH ENG
PUSH LEVER AXLE
E
2 3 LS

Removing the push lever axle Remove the parts in order.
Drive sprocket cover Refer to “REMOVING THE ENGINE”
Clutch cable section.
Clutch ass’y
1 Push lever axle 1
2 Torsion spring 1
3 Circlip 1
4 Oil seal 1
procedure.
4-25
5AP-E0 4-2 01.7.26 11:09 AM Page 26
CLUTCH ENG
REMOVING THE CLUTCH
3 1. Remove:
9Lock washer 2
2 9Clutch boss 3
NOTE:
1 Straighten the lock washer tab 2 and loosen
the clutch boss nut 1 while holding the clutch
boss with a clutch holding tool 4.
Clutch holding tool:

90890-04086
CHECKING THE CLUTCH

1. Measure:
9Friction plate thickness
Out of specification → Replace the friction
plates as a set.
Measure at four places.
Thickness (friction plate):
2.90 ~ 3.10 mm
<Limit:> 2.8 mm
2. Measure:
9Clutch plate warpage
Out of specification → Replace the clutch
plates as a set.
Use a surface plate and a feeler gauge 1.
1
Warp limit (clutch plate):
0.05 mm
3. Measure:
9Clutch spring free length a
Out of specification → Replace the clutch
springs as a set.
Free length (clutch spring):

33.0 mm
a
<Limit:> 31.0 mm
INSTALLING THE CLUTCH

1 1. Install:
9Push lever axle 1
9Torsion spring 2
4-26
5AP-E0 4-2 01.7.26 11:09 AM Page 27
CLUTCH ENG
2. Install:
1 9Spring washer 1
9Plate washer 2
NOTE:
Tighten the nut (primary drive gear) while hold-
ing the rotor with the sheave holder.
2
3. Install:
1
9Primary driven gear 1
9Thrust washer 2
9Clutch boss 3
3 2
1 4. Install:
9Lock washer 1
NOTE:
Install the lock washer tab into the clutch boss
slot.
5. Install:
60 Nm (6.0 m•kg)
NOTE:
Install the clutch boss nut while holding the
1 clutch boss with a clutch holding tool 2, then
bend along a flat side of the end.
6. Install:
12 21 9Friction plate 1
9Clutch plate 2
NOTE:
9Coat all clutch and friction plates with engine oil
before installation.
9Install the clutch plates and friction plates alter-
nately on the clutch boss a, starting with a fric-
1 a tion plate and ending with a friction plate with
the locating of 90°.
4 2
3 4-27
5AP-E0 4-2 01.7.26 11:09 AM Page 28
CLUTCH ENG
7. Install:
9Ball
8. Install:
9Push rod #1 1
3
9Push plate 2
9Plate washer 3
4
1 9Nut 4 (push rod #1)
2 8 Nm (0.8 m•kg)
9. Install:
9Pressure plate 1
2 9Clutch springs 2
1
9Bolts 3 (clutch springs)
6 Nm (0.6 m•kg)
3 cC
Tighten the clutch spring bolts in stage, using a
crisscross pattern.
10. Check:
9Push lever position
Push the push lever assembly in the arrow
direction and make sure that match marks
are be aligned → Adjust.
b
a Match mark on the push lever assembly
a b Match mark on the crankcase
11. Adjust:
1 9Push lever position
Loosen the locknut 1 and turn the push
rod 2 clockwise or counterclockwise to
match alignment marks.
12. Tighten:
9Lock nut 8 Nm (0.8 m•kg)
2
4-28
5AP-E0 4-2 01.7.26 11:09 AM Page 29
KICK STARTER ENG
KICK STARTER
6
5
3 4
2
E

Removing the kick starter Remove the parts in order.
Clutch ass’y Refer to “CLUTCH” section.
1 Kick starter ass’y 1
2 Circlip 1
3 Washer 1
4 Kick idle gear 1
5 Washer 1
6 Circlip 1
procedure.
4-29
5AP-E0 4-2 01.7.26 11:09 AM Page 30
KICK STARTER ENG
1
E

Disassembling the kick starter Disassemble the parts in order.
1 Collar 1
2 Torsion spring 1
3 Washer 1
4 Kick gear 1
5 Kick gear clip 1
6 Kick axle 1
For assemble, reverse the disassemble
procedure.
4-30
5AP-E0 4-2 01.7.26 11:09 AM Page 31
OIL PUMP ENG
OIL PUMP
2
1
3
E
4
5
7 Nm (0.7 kg•m)

Removing the oil pump Remove the parts in order.
Clutch Refer to “CLUTCH” section.
1 Rotary filter 1 Align the tab with the crankcase slot.

2 Pump drive gear 1
3 Oil pump ass’y 1 Fill the engine oil to the delivery passage
4 Gasket (oil pump) 1
5 Oil strainer 1
procedure.
4-31
5AP-E0 4-2 01.7.26 11:09 AM Page 32
OIL PUMP ENG
4
6 5
8 7
9
3
0
2

Disassembling the Oil pump Disassemble the parts in order.
1 Circlip/Driven gear 1/1
2 Spring washer 1
3 Circlip/Washer 1/1
4 Cap 1
5 Dowel pin 2
6 Shaft 1
7 Dowel pin 1
8 Oil pump housing 1
9 Inner rotor 1
0 Outer rotor 1
procedure.
4-32
5AP-E0 4-2 01.7.26 11:09 AM Page 33
OIL PUMP ENG

a INSTALLING THE ROTARY FILTER
1. Install:
9Drive gear (oil pump)
9Straight Key
9Rotary filter
b NOTE:
Align the rotary filter dog a with groove of the
crankshaft b.
INSTALLING THE PRIMARY DRIVE GEAR

1. Install:
9Primary drive gear 1
9Primary driven gear 2
2 9Washer 3
a
9Nut (primary drive gear) 4
3
NOTE:
1 4 Place a folded aluminium plate or copper wash-
er a between the teeth of the primary drive
gear and primary driven gear .
B CHECKING THE OIL PUMP

1 1. Measure:
9Tip clearance A
9Side clearance B
9Housing and rotor clearance C
2 1 Inner rotor
2 Outer rotor
A
3 Pump housing
Tip clearance A:
3
0.15 mm <Limit:> 0.20mm
Side clearance B:
C 0.06 ~ 0.10 mm <Limit:> 0.15 mm
Housing and rotor clearance C:
0.06 ~ 0.10 mm <Limit:> 0.15 mm
Out of specification → Replace the oil
pump assembly.
2. Check:
9 Rotary filter
Cracks/damage → Replace.
Contamination → Clean the flushing oil.
4-33
5AP-E0 4-2 01.7.26 11:09 AM Page 34
OIL PUMP ENG

3. Check:
9Oil stainer
Cracks/damage → Replace.
Contamination → Clean the flushing oil.
4-34
5AP-E0 4-2 01.7.26 11:09 AM Page 35
SHIFT SHAFT ENG
SHIFT SHAFT
10 Nm (1.0 m•kg)
3

Removing the shift shaft Remove the parts in order.
Shift pedal Refer to “REMOVING THE ENGINE” section.
1 Shift shaft 1
2 Bolt 1
3 Stopper lever 1
4 Tension spring 1
5 Circlip 1
6 Torsion spring 1
procedure.
4-35
5AP-E0 4-2 01.7.26 11:09 AM Page 36
SHIFT SHAFT ENG

CHECKING THE SHIFT SHAFT
1. Check:
9Stopper lever
Roller turns roughly → Replace.
Bends/damage → Replace.
2. Check:
9Torsion springs (shift arm)
3. Check:
9Shift shaft 1
9Shift lever 2
1 Bends/wear/damage → Replace.
INSTALLING THE SIFT SHAFT

1. Install:
8Sift shaft 1
2. Install:
2
9Stopper lever 2
9Tension spring 3
Mesh the stopper lever with the shift cam
1 segment.
3
3. Check:
1 8Shift lever 1 position
Gaps a and b of the each pins 2 are not
a equal → Replace the defective parts.
4-36
5AP-E0 4-2 01.7.26 11:09 AM Page 37
C.D.I. MAGNETO AND STARTER CLUTCH ENG
C.D.I. MAGNETO AND STARTER CLUTCH

CRANKCASE COVER (LEFT)
4
2
5
5
3
10 Nm (1.0 m•kg)

Removing the crankcase cover (left) Remove the parts in order.
Side cover (left) Refer to “SIDE COVER, SEAT AND FUEL
TANK” section in CHAPTER 3.
1 C.D.I. magneto lead couplers 1
2 Neutral switch lead connector 1
3 Crankcase cover (left) 1
4 Gasket 1
5 Dowel pin 2
procedure.
4-37
5AP-E0 4-2 01.7.26 11:09 AM Page 38
PICKUP COIL AND STATOR COIL
4 Nm (0.4 m•kg)
10 Nm (1.0 m•kg)

Removing the pickup coil and stator coil Remove the parts in order.
1 Pickup coil 1
2 Clamp 1
3 Stator coil 1
procedure.
4-38
5AP-E0 4-2 01.7.26 11:09 AM Page 39
C.D.I. MAGNETO AND STARTER CLUTCH
4 3
1
2
70 Nm (7.0 m•kg)

Removing the C.D.I. magneto and Remove the parts in order.
starter clutch
1 C.D.I. magneto 1 Refer to “REMOVING/INSTALLING THE
C.D.I. MAGNETO” section.
2 Woodruff key 1
3 Starter wheel gear 1
4 Washer 1
5 Idle gear plate 1
6 Starter idle gear 1
procedure.
4-39
5AP-E0 4-2 01.7.26 11:09 AM Page 40

REMOVING THE C.D.I. MAGNETO
1 1. Remove:
9Bolt 1 (magneto)
2 NOTE:
Loosen the bolt (magneto) while holding the
rotor with a sheave holder 2.
Sheave holder:
90890-01701
2. Remove:
1 9C.D.I. magneto 1
2
NOTE:
Remove the magneto using rotor puller 2.
Rotor puller:
90890-01362
INSTALLING THE C.D.I. MAGNETO

1. Install:
9Washer 1
1 2 9Starter wheel gear 2
9Woodruff key 3
3
NOTE:
Make sure the woodruff key install after the
starter wheel gear.
2. Install:
9C.D.I. magneto 1
2 NOTE:
9When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft and the starter wheel
gear 2 rotate to the right.
1 9Clean the tapered portion of the crankshaft
and the magneto hub.
1 3. Tighten:
9C.D.I. magneto 1 70 Nm (7.0 m•kg)
2 NOTE:
Tighten the bolt while holding the C.D.I. magne-
to with the sheave holder 2.
Sheave holder:
90890-01701
4-40
5AP-E0 4-2 01.7.26 11:09 AM Page 41
CRANKCASE ENG
CRANK CASE
12 Nm (1.2 m•kg)
3 1
10 Nm (1.0 m•kg)

Separating the crankcase Remove the parts in order.
Engine Refer to “REMOVING THE ENGINE” section.
Cylinder and piston Refer to “CYLINDER AND PISTON”
section.
Kick starter Refer to “KICK STARTER” section.
Oil pump Refer to “OIL PUMP” section.
Shift shaft and segment Refer to “SHIFT SHAFT” section.
C.D.I. magneto/starter clutch Refer to “C.D.I. MAGNETO AND STARTER
CLUTCH” section.
1 Clutch cable holder 1
2 Timing chain guide/Timing chain 1/1
3 Shift cam segment/Dowel pin 1/2
4 Crankcase (right)/Dowel pin 1/2
procedure.
4-41
5AP-E0 4-2 01.7.26 11:09 AM Page 42
CRANKCASE ENG
SEPARATING THE CRANKCASE
1. Remove:
9Shift cam segment 1
1 9Dowel pin
2. Remove:
9Right crankcase half
NOTE:
9Set the left crankcase half under shown the
screw hole on the crankcase.
9Use the crankcase separation tool 3, installed
the bolt to 1 and 2, If necessary, one screw
4 may be backed out slightly to level body.
Crankcase separating tool:

90890-01135
cC
9Do not use the hammer or other tools to
separate the crankcase.
9The left crankcase half should be under.
INSTALLING THE CRANKCASE

1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.
2. Apply:
9Sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215 :

90890-85505
NOTE:
DO NOT ALLOW any sealant to come in con-
tact with the oil gallery.
3. Install:
9Dowel pins 1
1
1
4-42
5AP-E0 4-2 01.7.26 11:09 AM Page 43
CRANKCASE ENG
9 4. Tighten:
9Crankcase right half
0
NOTE:
Tighten the screws in decreasing numerical
order (see numbers on the illustration).
1 6
5 7
8
4
32
5. Install:
9Dowel pins 1
1 9Shift cam segment 2
3
NOTE:
Fit the dowel pins on the segment to the locat-
ing hole on the shift cam 3 and install the seg-
ment.
3
2
4-43
5AP-E0 4-2 01.7.26 11:09 AM Page 44
TRANSMISSION SIFT CAM AND SHIFT FORK ENG
TRANSMISSION, SHIFT CAM AND SHIFT FORK
2 7
4
5
1 6

Removing the transmission, Remove the parts in order.
shift cam and shift fork
Crankcase separating Refer to “CRANKCASE” section.
1 Shift fork guide bar 2 (short length) 1
2 Shift fork guide bar 1 (long length) 1 Refer to “INSTALLING THE TRANSMISSION,
3 Shift fork 2 “C”(center) 1 SHIFT CAM AND SHIFT FORK” section.
4 Shift fork 3 “R”(right) 1
5 Shift fork 1 “L”(left) 1
6 Shift cam 1
7 Main axle ass’y 1 Refer to “REMOVING/INSTALLING THE
TRANSMISSION, SHIFT CAM AND SHIFT
8 Drive axle ass’y 1 FORK” section.
9 Plate washer 1 For installation, reverse the removal
procedure.
4-44
5AP-E0 4-2 01.7.26 11:09 AM Page 45
DRIVE AXLE
1
2 3
6 7

Disassembling the drive axle Disassemble the parts in order.
1 Circlip 1
2 Washer 1
3 First wheel gear 1
4 Forth wheel gear 1
5 Circlip 1
6 Washer 1
7 Third wheel gear 1
8 Drive axle 1
9 Second wheel gear 1
0 Fifth wheel gear 1
procedure.
4-45
5AP-E0 4-2 01.7.26 11:09 AM Page 46
MAIN AXLE
5
6
4
1 3
2
LS

Disassembling the Main axle Disassemble the parts in order.
1 Push rod 1
2 Fifth pinion gear gear 1
3 Second pinion gear 1
4 Third pinion gear 1
5 Circlip 1
6 Washer 1
7 Forth pinion gear 1
8 Main axle 1
procedure.
4-46
5AP-E0 4-2 01.7.26 11:09 AM Page 47

REMOVING THE TRANSMISSION, SHIFT
CAM AND SHIFT FORK
1. Install:
9O-Ring 1
Before removing the drive axle, install the
O-ring to protect the drive sprocket
groove.
1
2. Remove:
9Shift fork guide bar 1 (short length)
3
9Shift fork guide bar 2 (long length)
1
q
9Shift fork 2 3
9Shift fork 3 4
2 9Shift fork 1 5
6
y 9Shift cam 6
4
5
3. Remove:
9Main axle assembly 1
9Push rod 2
9Drive axle assembly 2
3
9Spring
1 9Push lever 3
CHECKING THE SHIFT FORK AND SHIFT

CAM
1. Check:
2 9Shift fork cam follower 1
9Shift fork pawl 2
Scoring/bends/wear/damage → Replace.
2. Check:
9Shift cam
Wear/damage/scratches → Replace.
4-47
5AP-E0 4-2 01.7.26 11:09 AM Page 48

INSTALLING THE TRANSMISSION, SHIFT
CAM AND SHIFT FORK
a 1. Measure:
9Main axle assembled length a
Assembled length (main axle):

83.25 ~ 83.45 mm
2. Install:
9Push rod 2
Into the main axle.
3. Install:
9O-ring 1
Before install the drive axle, install the O-
1 ring to protect the drive sprocket groove.
5 3 4. Install:
4 9Shift cam
(up to the neutral switch contact surface
2
on the shift cam)
1 9Shift fork 1 “L”(left) 1
(face the “L” side for the clutch side.)
9Shift fork 3 “R”(right)2
(face the “R” side for the clutch side.)
9Shift fork 2 “C”(center)3
(face the “C” side for the clutch side.)
9Shift fork guide bar 1 4 (long)
9Shift fork guide bar 2 5 (short)
5. Check:
9Shift cam operation
Unsmooth operation → Repair.
cC
Check the transmission and shift forks for
smooth operation by turning the shift cam with
your hand.
4-48
5AP-E0 4-2 01.7.26 11:09 AM Page 49
CRANKSHAFT AND BALANCER WEIGHT ENG
CRANKSHAFT AND BALANCER WEIGHT
3
1

Removing the crankshaft and Remove the parts in order.
balancer weight
Crankcase separation Refer to “CRANKCASE” section.
1 Balancer weight 1
2 Crankshaft ass’y 1
3 Bearing 2
procedure.
4-49
5AP-E0 4-2 01.7.26 11:09 AM Page 50

REMOVING THE CRANK SHAFT AND BAL-
1 ANCER WEIGHT
3
1. Remove:
9Balancer weight 1
9Crank shaft 2
Use the crankcase separating tool 3 for
removal.
2 Crankcase separating tool:

90890-01135
w
Never use the hammer to tapping and remov-
ing the crankshaft directly.
CHECKING THE CRANKSHAFT

1. Measure:
9Crankshaft runout
Out of specification→Replace crankshaft
and/or bearing.
Runout limit:
0.03 mm
NOTE:
Measure the crankshaft runout with the crank-
shaft assembly turning slowly.
2. Measure:
9Big end side clearance
Out of specification→Replace big end
bearing, crank pin and/or connecting rod.
Big end side clearance:
0.15 ~ 0.45 mm
Limit
0.8 mm
4-50
5AP-E0 4-2 01.7.26 11:09 AM Page 51

3. Measure:
9Crank width
Out of specification→Replace crankshaft.
Crank width:
46.95 ~ 47.00 mm
4. Check:
9Timing chain sprocket 1
Wear/damage→Replace crankshaft.
2
9Bearing 2
Wear/crack/damage→Replace crankshaft.
1
5. Check:
9Crankshaft journal
Clogged→Blow out the journal with com-
pressed air.
INSTALLING THE CRANK SHAFT AND BAL-

ANCER WEIGHT
1. Install:
2 9Crank shaft 1
3 5 4 Use the crankshaft installing tool (spacer
2, installer pod 3, installer bolt 4, adap-
tor 5 ) to install the crankcase (left).
w
9Hold the connecting rod at top dead center
1
with one hand while turning the nut of the in-
stalling tool with the other.
9Operate the installing tool until the crank-
shaft bottoms against the bearing .
Crank pot spacer 2:

90890-04081
Crank shaft installer pot 3:
90890-01274
Crank shaft installer bolt 4:
90890-01275
Adaptor 5:
90890-01278
4-51
5AP-E0 4-2 01.7.26 11:09 AM Page 52

2. Install:
2
9Balancer shaft 1
b
NOTE:
a
When installing the balancer shaft, align the
1
punched mark a on the crankshaft drive gear
2 with the punched mark b on the balancer
gear.
4-52
5AP-E0 5 01.7.26 11:11 AM Page 1
CARBURETOR CARB
CARBURETION
CARBURETOR
6 4
5
Removing the carburetor Remove the parts in order.
1 Fuel hose 1
2 Carburetor top 1
3 Starter ass’y 1
4 Carburetor joint clamp screw 1
5 Air filter joint clamp screw 1
6 Carburetor ass’y 1
For installtion, reverse the removal
procedure.
5-1
5AP-E0 5 01.7.26 11:11 AM Page 2
CARBURETOR CARB
q e
r
w
!3
!2
!1
o
!0 u
i
5
Disassembling the carburetor Disassemble the parts in order.
1 Throttle cable 1
2 Throttle valve ass’y 1
3 Carburetor top 1
4 Starter ass’y 1
5 Float chamber/Gasket 1/1
6 Float pin/Float 1/1
7 Needle valve ass’y 1
8 Main jet/Main nozzle 1/1
9 Pilot jet 1
0 Pilot screw ass’y 1
q Throttle stop screw 1
w Diaphragm cover 1
e Diaphragm/Spring 1/1
procedure.
5-2
5AP-E0 5 01.7.26 11:11 AM Page 3
CARBURETOR CARB
CHECKING THE FLOAT HEIGHT
1. Measure:
8Float height a
Hold the carburetor in an upside down
a position and measure the distance from
the mating surface of the float chamber
(gasket removed) to the top of the float.
Float height (F.H.):
21.8 mm
2. Adjust:
8Float height
If both are fine, adjust the float height by
bending the float tang 1 on the float.
ADJUSTING THE FUEL LEVEL

1. Attach:
8Fuel level gauge 1
Connect the fuel level gauge to the drain
pipe.
a Fuel level gauge:

90890-01312
1 2. Turn the fuel cock to the “ON” or “RES”

position.
3. Measure:
8Fuel level a
Hold the gauge vertically next to the float
chamber line 2, loosen the drain screw 3
and measure the fuel level a with the
gauge.
Out of specification → Bend the float arm
tong 4 to adjust.
Fuel level:
4 4.5 ~ 5.5 mm below the float
chamber line
5-3
5AP-E0 6 01.7.26 11:14 AM Page 1
FRONT WHEEL AND BRAKE DISC CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
7 91 Nm (9.1 m•kg)
LS
6 Removing the front wheel and brake disc Remove the parts in order.
NOTE:
Place the suitable stand under the frame.
1 Speedometer cable 1
2 Axle nut/Washer 1/1
Refer to “INSTALLING THE FRONT
3 Front wheel axle 1 WHEEL” section.
4 Front wheel ass’y 1
5 Meter gear unit 1
6 Collar/Dust seal 1/1
7 Brake disc 1 Refer to “INSTALLING THE BRAKE DISC
” section.
procedure.
6-1
5AP-E0 6 01.7.26 11:14 AM Page 2
1
Disassembling the front wheel
Oil seal 1
Disassemble the parts in order.
Refer to “ASSEMBLING THE FRONT
6
WHEEL”section.
2 Bearing 1
Refer to “DISASSEMBLING/ASSEMBLING
3 Spacer 1
THE THE FRONT WHEEL” section.
4 Bearing 1
procedure.
6-2
5AP-E0 6 01.7.26 11:14 AM Page 3

DISASSEMBLING THE FRONT WHEEL
2 1. Remove:
9Bearing 1
9Spacer
Remove the bearings using a general
bearing puller 2.
1
cC
Handle the wheel with care not to damage
the brake disc. If the brake disc is damaged,
replace.
b
a CHECKING THE FRONT WHEEL
1. Measure:
9Vertical runout limit a
9Lateral runout limit b
Over the specified limits → Replace.
Front wheel runout limits:
Vertical: 1.0 mm
Lateral: 0.5 mm
2. Check:
9Bearing
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly →
Replace.
3. Check:
9Front wheel axle
Over the specified limits → Replace.
Wheel axle bending limit:

0.25 mm
NOTE:
1/2 of the measured value is the bending value.
6-3
5AP-E0 6 01.7.26 11:14 AM Page 4

CHECKING THE BRAKE DISC
1. Measure:
9Brake disc deflection a
Maximum deflection:
b 0.15 mm
2. Measure:
9Brake disc thickness b
Brake disc thickness:
4.0 mm
<limit:>
3.5 mm
ASSEMBLING FRONT WHEEL

1. Install:
9Bearing 1
9Spacer 2
9Bearing 3
4 3
2 9Oil seal 4
NOTE:
9Install the bearing from brake disc side.
9Install the oil seal with its manufacturer’s marks
or numbers facing outward.
9Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
LS
1
INSTALLING THE BRAKE DISC

1 1. Install:
9Brake disc 1 23 Nm (2.3 m•kg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
6-4
5AP-E0 6 01.7.26 11:14 AM Page 5

b 1 INSTALLING THE FRONT WHEEL
1. Install:
9Meter gear unit 1
NOTE:
Make sure that the wheel hub and the meter
a
gear unit are installed with the two projections
a meshed into the two slots b.
2. Install:
9Front wheel
b 9Front wheel axle
9Speedometer cable
9Axle nut 91 Nm (9.1 m•kg)
a
NOTE:
Make sure that the slot a in the meter gear unit
fits over the stopper b on the front fork outer
tube.
ADJUSTING THE WHEEL STATIC BALANCE

q
NOTE:
9After replacing the tire and/or rim, the wheel
static balance should be adjusted.
9Adjust the front wheel static balance with the
brake disc installed.
X 1. Remove:
9Balancing weight 1
2. Set:
9Wheel
(on a suitable stand)
3. Find:
X1 9Heavy spot
********************************************************
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X1” mark is 90°
up.
d. Release the wheel and wait for it to rest. Put
an “X2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d.several times
until all marks come to the same spot.
X2
f. This spot is the wheel’s heavy spot “X”.
********************************************************
X1
6-5
5AP-E0 6 01.7.26 11:14 AM Page 6

4. Adjust:
q 9Wheel static balance
********************************************************
Adjusting steps:
8 Install a balancing weight 1 on the rim exactly
opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
X
8 Turn the wheel so that the heavy spot is 90°

up.
8 Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
X X anced.
********************************************************
5. Check:
9Wheel static balance
********************************************************
Checking steps:
8 Turn the wheel so that it comes to each point
X as shown.
8 Check that the wheel is at rest at each point. If
not, readjust the front wheel static balance.
********************************************************
X X
6-6
5AP-E0 6 01.7.26 11:14 AM Page 7
FRONT BRAKE CHAS
FRONT BRAKE
BRAKE PAD
3 35Nm (3.5 m•kg)
18 Nm (1.8 m•kg) 2 1 3 Nm (0.3 m•kg)

Removing the brake pad Remove the parts in order.
1 Screw 1
2 Caliper support bolt 1
3 Caliper 1
4 Brake pad 2
5 Pad support 1
procedure.
6-7
5AP-E0 6 01.7.26 11:14 AM Page 8
FRONT BRAKE CHAS
MASTER CYLINDER
7 Nm (0.7 m•kg)
8
2
30 Nm (3.0 m•kg)
LS
6
4

Removing the master cylinder Remove the parts in order.
Drain the brake fluid Refer to “CHENGING THE BRAKE FLUID”
section in chapter 3.
1 Rear view mirror (right) 1
2 Brake lever/compression spring 1/1
3 Brake switch 1
4 Union bolt 1
5 Washer 2 Refer to “INSTALLING THE MASTER
6 Brake hose 1 CYLINDER” section.
7 Master cylinder bracket 1
8 Master cylinder 1
procedure.
6-8
5AP-E0 6 01.7.26 11:14 AM Page 9
FRONT BRAKE CHAS
DISASSEMBLING THE MASTER CYLINDER

Disassembling the master cylinder Disassemble the parts in order.
1 Rubber boots 1
Refer to “ASSEMBLING THE MASTER
2 Circlip 1
CYLINDER” section.
3 Master cylinder kit 1
procedure.
6-9
5AP-E0 6 01.7.26 11:14 AM Page 10
FRONT BRAKE CHAS

2 CHECKING THE MASTER CYLINDER
1. Check:
9Master cylinder piston 1
Wear/scratches → Replace the master
cylinder kit.
9Master cylinder cup 2
1 Cracks/damage → Replace the master
cylinder kit.
2. Check:
9Master cylinder
Scratches/wear/damage → Replace the
master cylinder ass’y.
3. Check:
9Diaphragm
ASSEMBLING THE MASTER CYLINDER

1. Install:
1 9Spring 1
Install the spring with its smaller diameter
2 to the master cylinder piston.
9Master cylinder kit 2
2.Install:
9Circlip 1
1
Install the circlip securely into the master
cylinder groove.
2 9Rubber boot 2
6-10
5AP-E0 6 01.7.27 8:28 AM Page 11
FRONT WHEEL AND FRONT BRAKE CHAS

INSTALLING THE MASTER CYLINDER
1
1. Install:
9Master cylinder 1
9Master cylinder bracket 2
7 Nm (0.7 m•kg)
NOTE:
9Install the master cylinder bracket 2 with the
2 “UP” mark facing upward.
9Align the slit of the master cylinder with the
punched mark a on the handlebar as shown.
2. Install:
3 9Washer 1
9Brake hose 2
4 9Washer 3
9Union bolt 4
1
30 Nm (3.0 m•kg)
NOTE:
Install the brake hose as shown å.
2
å 3. Fill in the brake fluid and air bleed form the

brake system.
Refer to ”AIR BLEEDING” section in
CHAPTER 3.
w
Check the brake fluid leakage from union
bolt, while brake lever operating after
10 °
installed.
4. Check:
9Brake fluid level
Refer to ”CHECKING THE BRAKE FLUID”
6-11
5AP-E0 6 01.7.26 11:14 AM Page 12
FRONT BRAKE CHAS
CALIPER
35 Nm (3.5 m•kg)
1 30 Nm (3.0 m•kg)
4
3
2
6
LS

Removing the caliper Remove the parts in order.
Drain the brake fluid Refer to “CHANGING THE BRAKE FLUID ”
section in chapter 3.
1 Union bolt 1
2 Washer 2
3 Brake hose 1
4 Bolt 2
5 Caliper ass’y 1
6 Caliper bracket 1
procedure.
6-12
5AP-E0 6 01.7.26 11:14 AM Page 13
FRONT BRAKE CHAS
DISASSEMBLING THE CALIPER
4 6 Nm (0.6 m•kg)

Disassembling the Caliper Disassemble the parts in order.
1 Caliper piston 2
2 Dust seal 2 Refer to “DISASSEMBLING/ASSEM-
3 Piston seal 2 BLING THE BRAKE CALIPER” section.
4 Bleed screw 1
procedure.
6-13
5AP-E0 6 01.7.26 11:14 AM Page 14
FRONT BRAKE CHAS

DISASSEMBLING THE BRAKE CALIPER
1. Remove:
9Caliper piston
To force out caliper pistons from the brake
caliper body blow compressed air into the
hose joint opening.
w
9Do not remove rapidly or high pressure air.
9Cover the piston with a rag. Use care so
that piston does not cause injury as it
expelled from the cylinder.
cC
Never try to pry out the caliper piston.
2. Remove:
9Dust seal 1
1 2 9Piston seal 2
Remove the dust seal and piston seal, use
the finger.
cC
9Do not use a screw driver, remove the seal
by pushing it in wit a finger.
9Do not reuse the seal.
CHECKING THE CALIPER

1. Check:
9Caliper cylinder 1
2 9Caliper piston 2
Scratches, wear → Replace caliper ass’y.
1
6-14
5AP-E0 6 01.7.26 11:14 AM Page 15
FRONT WHEEL AND FRONT BRAKE CHAS

INSTALLING THE CALIPER
1. Install:
9Caliper 1 35 Nm (3.5 m•kg)
2. Install:
3 1 9Brake hose 1
9Washer 2
2
9Union bolt 3 30 Nm (3.0 m•kg)
NOTE:
When installing the brake hose to the caliper,
a lightly touch the brake hose with the stopper a
on the caliper.
3. Fill in the brake fluid and air bleed from the

brake system.
Refer to “AIR BLEEDING” section in
CHAPTER 3.
w
Check the brake fluid leakage from union
bolt, while brake lever operating after
installed.
4. Check:
9Brake fluid level
Refer to “CHECKING THE BRAKE FLUID”
6-15
5AP-E0 6 01.7.26 11:14 AM Page 16
REAR WHEEL, REAR BRAKE,

DRIVE SPROCKET AND DRIVE CHAIN CHAS
REAR WHEEL, REAR BRAKE, DRIVE SPROCKET AND DRIVE CHAIN

REAR WHEEL AND REAR BRAKE
19Nm (1.9 m•kg)

8 10 9
1
91 Nm (9.1 m•kg) 4
3
11
2
5
6

Removing the rear wheel and rear brake Remove the parts in order.
NOTE:
Place the suitable stand under the frame.
1 Adjuster 1
2 Brake rod 1
3 Compression spring 1
4 Pin 1
5 Tension bar 1
6 Wheel axle 1
7 Chain adjuster (left and right) 1/1
8 Collar 1
9 Rear wheel ass’y 1
10 Brake shoe plate 1
11 Collar 1
procedure.
6-16
5AP-E0 6 01.7.27 8:29 AM Page 17

DRIVE SPROCKET
1
2
3 5
32 Nm (3.2 m•kg)
3
6 2
4
4 1
8
7
LS

Removing the drive sprocket and Remove the parts in order.
clutch hub
1 Nut/Lock washer 4/2
2 Drive sprocket 1
3 Collar 1
4 O-ring 1
5 Damper 4
6 Clutch hub 1
7 Oil seal 1
8 Bearing 1
procedure.
Disassembing the rear wheel Disassemble the parts in order.

1 Oil seal 1
2 Bearing 1
3 Collar 1
4 Bearing 1 For assemble, reverse the disassemble
procedure.
6-17
5AP-E0 6 01.7.26 11:14 AM Page 18

BRAKE SHOE PLATE
4 10Nm (1.0 m•kg)
1
5

Disassembling the brake shoe plate Disassemble the parts in order.
1 Brake shoe kit 2
2 Tension springs 2
Refer to “ASSEMBLING THE BRAKE
3 Cam shaft lever 1
SHOE PLATE” section.
4 Indicator plate 1
5 Camshaft 1
procedure.
6-18
5AP-E0 6 01.7.26 11:14 AM Page 19

DRIVE CHAIN
10 Nm (1.0 m•kg)
5
4

Removing the drive chain and Remove the parts in order.
drive sprocket NOTE:
Loosen the axle nut and slacken the drive
chain.
1 Cover (left) 1
2 Chain joint/Plate/Clip 1/1/1
3 Drive chain 1
4 Sprocket holder 1
5 Drive sprocket 1
procedure.
6-19
5AP-E0 6 01.7.26 11:14 AM Page 20

REMOVING THE DRIVE CHAIN
1. Remove:
3 9Clip 1
9Plate 2
4 9Chain joint 3
9Drive chain 4
1
2
CHECKING THE DRIVE CHAIN

1. Measure:
9Drive chain 10 link length a
Out of specification → Replace the Driven
sprocket, drive sprocket and drive chain as
a set.
a
10 link length limit:
121 mm
2. Check:
9Drive chain
9Joint plate
Fall off/Wear/Damage → Replace the
Driven sprocket, drive sprocket and drive
chain as a set.
CLEANING THE DRIVE CHAIN

1. Clean the drive chain with clean water or
neutral soap.
Lubricate the chain oil or SAE10W-30 motor
oil onto the drive chain.
cC
Do not use steam cleaning, gasoline and
certain solvent.
6-20
5AP-E0 6 01.7.26 11:14 AM Page 21

CHECKING THE CLUTCH HUB
1. Check:
9Clutch hub
Wear/damage/cracks → Replace.
INSTALLING THE CLUTCH HUB

1 1. Install:
9Drive sprocket 1
9Lock washer 2
2 9Nut 3 32 Nm (3.2 m•kg)
3 NOTE:
Tighten the nuts in a crisscross pattern.
3
2
2. Bend:
1 9Lock washer tab 1
(along a flat side of the end, as shown a
a
or b)
INSTALLING THE DRIVE CHAIN

1. Install:
2 9Drive chain 1
9Chain joint 2
1
9Plate 3
2. Install:
9Clip 1
cC
Be sure to install the chain joint clip to the
direction as shown.
1
6-21
5AP-E0 6 01.7.26 11:14 AM Page 22

CHECKING THE REAR WHEEL
1. Check:
9Wheel runout
9Spokes
9Wheel bearings
9Wheel axle
9Wheel balance
Refer to “FRONT WHEEL”.
2. Check:
9Damper
Clack/wear/damage → Replace.
CHECKING THE REAR BRAKE

a 1. Check:
9Brake liner surface
2. Measure:
9Brake drum inside diameter a
Brake drum inside diameter:
Standard:
130 mm
<Limit:>
131 mm
2. Measure:
9Brake lining thickness a
a
Brake lining thickness :
Standard:
4.0 mm
<Limit:>
2.0 mm
w
When checking the brake lining, do not spill
oil or grease on the brake lining.
6-22
5AP-E0 6 01.7.26 11:14 AM Page 23

ASSEMBLING THE BRAKE SHOE PLATE
1. Apply lithium soap base grease onto the
a
brake cam shaft and pin.
3 b 2. Install:
9Brake shoe plate 1
2 9Camshaft 2
9Indicator plate 3
1 Align the projection a on the indicator
plate with the camshaft notch b and
install.
3. Install:
2
9Cam shaft lever 1
10 Nm (1.0 m•kg)
Align the indicater plate 2 as shown
1
4. Install:
1 1 9Brake shoes 1
9Tension springs 2
NOTE:
9When installing the springs and brake shoes,
take care not to damage the springs.
2
9Replace the tension spring as a set when
replace the brake shoes.
w
After installing the rear brake cam shaft,
remove the excess grease.
6-23
5AP-E0 6 01.7.26 9:31 PM Page 24
FRONT FORK CHAS
FRONT FORK
5 30 Nm (3.0 m•kg)
30 Nm (3.0m•kg) 7 23 Nm (2.3 m•kg)

6
1
9
4 3

Removing the front fork Remove the parts in order.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISC” section.
Caliper Refer to “FRONT BRAKE” section.
1 Cover 1
2 Fender stay 1
3 Reflector (left/right) 1/1
4 Front fender 1
5 Pinch bolt (handle crown) 2 NOTE:
6 Cap bolt 2 Loosen.
7 Pinch bolt (under bracket) 2
8 Front fork ass’y (left) 1 Refer to “INSTALLING THE FRONT FORK”
9 Front fork ass’y (right) 1 section.
procedure.
6-24
5AP-E0 6 01.7.26 11:14 AM Page 25
FRONT FORK CHAS
1
23 Nm (2.3 m•kg)
9
0
q
6
30 Nm (3.0 m•kg)

Disassembling the front fork Disassemble the parts in order.
1 Cap bolt/O-ring 1/1
2 Collar/Washer 1/1
3 Fork spring 1
4 Bolt/Gasket 1/1
5 Inner tube 1
6 Damper rod 1
7 Taper spindle 1
8 Dust seal 1
9 Circlip 1
0 Oil seal 1
q Slide metal 1
w Outer tube procedure.
6-25
5AP-E0 6 01.7.26 11:14 AM Page 26
FRONT FORK CHAS

DISASSEMBLING THE FRONT FORK
1. Remove:
2 9Bolt 1
Loosen the bolt while holding the damper
rod with T-handle 2 and damper rod
holder 3.
3 1
Damper rod holder:
90890-01294
T-handle
90890-01326
2. Remove:
9Dust seal
9Circlip
3. Remove:
9Oil seal 1
1 9Slide metal 2
2
cC
Take care not to scratch the outer tube inner
surface.
CHECKING THE FRONT FORK

1. Check:
9Inner tube bending
Over the specified limit → Replace.
Inner tube bending limit:

0.2 mm
NOTE:
1/2 of the measured value is bending limit.
w
Do not attempt to straiten a bet inner tube as
this may dangerously weaken the tube. (use
of straightened)
6-26
5AP-E0 6 01.7.26 11:14 AM Page 27
FRONT FORK CHAS

2. Measure:
9Fork spring free length a
a Over the specified limit → Replace.
Front fork spring free length:
426 mm
<Wear limit>
417.5 mm
ASSEMBLING THE FRONT FORK

2 1. Install:
9Damper rod 1
9Rebound spring 2
9Taper spindle 3
9Inner tube 4
3 1
4
2. Install:
2 9Inner tube 1
9Outer tube 2
3. Tighten:
9Bolt 1 30 Nm (3.0 m•kg)
Tighten the bolt while holding the damper
2 rod with T-handle 2 and damper rod
holder 3.
1 Damper rod holder:

3 90890-01294
T-handle
90890-01326
1 4. Install:
9Slide metal 1
6-27
5AP-E0 6 01.7.26 11:14 AM Page 28
FRONT FORK CHAS

5. Install:
3 9Oil seal 1
9Circlip
2
9Dust seal
1 1 Use the fork seal driver weight and the
attachment, then install the circlip.
Attachment: 2
90890-01400
Fork seal driver weight: 3
90890-01367
6. Check:
9Inner tube operation
Unsmooth operation→Disassembly and
recheck.
7. Fill the fork oil specification in the :

1 9Fork oil 1
Oil quantity:
0.157 L (157cm3)
Recommended oil:
Fork oil 10W or equivalent
[Example]
9Oil level a
from the top of the inner tube fully com-
pressed and without the fork spring
Oil level (fully compressed):
a
178 mm
NOTE:
Hold the fork in an upright position.
6-28
5AP-E0 6 01.7.26 11:14 AM Page 29
FRONT FORK CHAS

8. Install:
9Fork spring 1
NOTE:
Install the fork spring with its smaller pitch
upward and temporarily tighten the cap bolt.
INSTALLING THE FRONT FORK

1. Install:
9Front fork 1
NOTE:
Pull up the inner tube as shown from top of the
1 0mm
under bracket, then temporarily tighten the
pinch bolt (under bracket lower).
2. Tighten:
9Pinch bolts (under bracket) 1
30 Nm (3.0 m•kg)
9Cap bolts 2
23 Nm (2.3 m•kg)
9Pinch bolts (handle crown) 3
30 Nm (3.0 m•kg)
3
2
6-29
5AP-E0 6 01.7.26 11:14 AM Page 30
HANDLEBAR CHAS
HANDLEBAR
2 23 Nm (2.3 m•kg)
1
LS
4
12
8 1
6 13
7
9
3 5
8
10 11
LS

Removing the handlebar removal Remove the parts in order.
1 Rear view mirror (left/right) 1/1
2 Master cylinder bracket 1
3 Master cylinder ass’y 1
4 Handle bar switch (right) 1
5 Throttle cable 1
6 Grip end 1
7 Grip 1
8 Handle bar switch (left) 1
9 Grip end/Grip 1/1
10 Clutch switch/Clutch cable 1/1
11 Lever holder/Lever/Boots 1/1/1
12 Handlebar upper holder 2
13 Handlebar 1
procedure.
6-30
5AP-E0 6 01.7.26 11:14 AM Page 31
HANDLEBAR CHAS
INSTALLING THE HANDLEBAR
1. Install:
9Handlebar 1
NOTE:
Align the handlebar should be installed with the
1 punched mark.
2. Install:
a 9Handlebar 1
9Upper handlebar holder 2
1
23 Nm (2.3 m•kg)
b NOTE:
2 The upper handlebar holders should be installed
with the longer side a to the forward, then tight-
en the front bolt and rear bolt b as shown.
3. Install:
9Lever holder (left) 1
NOTE:
1 Align the slit of the handlebar switch with the
a
4. Install:
1 a 9Handlebar switch (left) 1
NOTE:
Align the slit of the handlebar switch with the
5. Install:
9Handlebar switch (right) 1
q NOTE:
b Align the projection a on the handlebar with
the handlebar switch and align the slit of the
a handlebar switch with the punched mark b on
the handlebar.
w
Check the throttle grip for smooth operation.
6-31
5AP-E0 6 01.7.26 11:14 AM Page 32
STEERING CHAS
STEERING
HEADLIGHT AND METER
5 6

Removing the headlight and meter Remove the parts in order.
Handlebar Refer to “HANDLEBAR” section.
1 Headlight unit 1
2 Meter coupler/Turn signal light connecter/
Fuel meter coupler -
3 Headlight body 1
4 Harness holder/Brake hose holder 1/1
5 Front flasher light (left and right) 1
6 Speedometer cable 1
7 Speedometer 1
8 Fuel meter 1
procedure.
6-32
5AP-E0 6 01.7.26 11:14 AM Page 33
STEERING CHAS
UNDER BRACKET
54 Nm (5.4 m•kg)
1
2
1st step 33 Nm (3.3 m•kg)
3 2nd step 22 Nm (2.2 m•kg)
4
6
LS
8
9
11
12
10
12
13

Removing the under bracket Remove the parts in order.
Front wheel Refer to “FRONT WHEEL” section.
Front fork Refer to “FRONT FORK” section.
Handlebar Refer to “HANDLEBAR” section.
Headlight and meter
1 Handle clown 1
2 Special washer 1
Refer to “INSTALLING THE STEERING”
3 Ring nut (upper) 1
section.
4 Washer 1
5 Ring nut (lower) 1 Refer to “REMOVING THE STEERING”
section.
6 Ball race cover 1
7 Under bracket 1
8 Ball race 1 1
6-33
5AP-E0 6 01.7.26 11:14 AM Page 34
STEERING CHAS
54 Nm (5.4 m•kg)
1
2
1st step 33 Nm (3.3 m•kg)
3 2nd step 22 Nm (2.2 m•kg)
4
6
LS
8
9
11
12
10
12
13
9 Ball bearing 19
10 Ball bearing 19
11 Ball race 2 1
12 Ball race 3/4 1/1
13 Dust seal 1
procedure.
6-34
5AP-E0 6 01.7.26 11:14 AM Page 35
STEERING CHAS
REMOVING THE STEERING
w
9Securely support the motorcycle so that
1
there is no danger of it falling over.
2 9Stand the motorcycle on a level surface.
1. Remove:
9Ring nut (lower) 1
Use a exhaust and steering nut wrench 2.
3 Exhaust and steering nut wrench:

90890-01268
w
Securely support the steering shaft so that
there is no danger of it falling down.
********************************************************
Bearing race replacement steps:
8 Remove the ball races on the head pipe using
long rod 3 and the hammer as shown.
4
8 Remove the ball race on the under bracket
using the floor chisel 4 and the hammer as
shown.
8 Install the new dust seal and races.
********************************************************
INSTALLING THE STEERING

2 1. Install:
9Ring nut (lower) 1
Refer to ”CHECKING THE STEERING
HEAD” section in CHAPTER 3.
1
********************************************************
Tightening steps:
8 Tighten the ring nut using the ring nut wrench
2. 33 Nm (3.3 m•kg)
Ring nut wrench:

90890-01403
8 Loosen the ring nut completely, then tighten it.
22 Nm (2.2 m•kg)
8 Check the steering head for looseness or
binding by turning it all the way in both direc-
tions.
********************************************************
6-35
5AP-E0 6 01.7.26 11:14 AM Page 36
REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM
40 Nm (4.0 m•kg)
59 Nm (5.9 m•kg)
40 Nm (4.0 m•kg)
1
2
5
6
8
4
7
8
1

Removing the rear shock absorber Remove the parts in order.
and swingarm
Rear wheel Refer to “REAR WHEEL, REAR BRAKE
AND DRIVE CHAIN” section.
1 Cover (left and light) 1/1
2 Rear shock absorber 2
3 Pivot shaft 1
4 Swingarm 1
5 Tension bar 1
6 Chain case 1
7 Chain guard 1
8 Collar 2
Reverse the removal procedure for
installation.
6-36
5AP-E0 6 01.7.26 11:14 AM Page 37
REAR SHOCK ABSORBER AND SWINGARM CHAS

CHECKING THE SWINGARM
1. Check:
9Swingarm looseness
Looseness exists → Tighten the pivot shaft
nut or replace bushes.
9Swingarm up and down movement
Unsmooth movement/bending/rough spots
→ Replace bushes.
CHECKING THE REAR SHOCK ABSORBER

Refer to ”CHECKING THE REAR SHOCK
ABSORBER” section in CHAPTER 3.
6-37
5AP-E0 7 01.7.26 9:38 PM Page 1
ELECTRICAL COMPONENTS ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 Ignition coil 6 Fuse holder assembly q Rear brake switch
2 Spark plug cap 7 Battery w Starter relay
3 Fuel sendor 8 C.D.I. unit e Horn
4 Main switch 9 Rectifier/Regulator
5 Turn signal relay 0 Starter circuit cut-off relay
3
1
4
2
e
5
7
7
0
9
q
8
7-1
5AP-E0 7 01.7.26 9:38 PM Page 2
WIRING DIAGRAM ELEC

WIRING DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L PUL
2 B/R B/R CHA 3 5
G/W G/W CHA
STOP
GNO
B
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R Br
OFF
Br Br
W W ON
6 7
15A
R W
B B u B/Y R/W
(B) R Sb Br
(B)
B B
B Sb
R
R/W
R R R/W B/Y
B/W
q e
R i
L/W L/W
B B/Y
9 r t B B
L/W L/W
B OFF OFF (G) (G)
R/W R/W
ON RUN
B
0 B B
w y L/W Br Y/R L/W

OFF B L/B L/B B
PO L L
ON
(B) (B)
B B
Y/R L/B B
L
Br
Br
Br Br L Br
h Br/W
g Br Br
f
sp
Br Y Y Br Br
Y Y
(B) (B) o Br G
L B
G Br
B L
(B) (B)
Br/W
Y (B) (B)
Y
P B G
L/B j Br/W
Y L
k l ;
Ch Br/W
B P
L/B Dg
Br/W Ch
P B
Dg L/B
OFF
ON
B
Y
B
G
HI
LO
Y G
L
N
R
d
B
L
Y
B
L
Y
B
a
B
(G)
G
B
G
B
(G)
7
B B Y G z Ch Dg
Y Y
B
G Ch Dg Ch Dg Dg
Ch
L Br
Sb m
c v b n
7 x
B L/R
B
B
B B B
! / . ,
L B
Br Dg
Ch Sb
(R)
B L
Dg Br
Sb Ch
(R)
Y B
7-2
5AP-E0 7 01.7.26 9:38 PM Page 3
WIRING DIAGRAM ELEC
COLOR CODE 1 Neutral switch

2 C.D.I. magneto
B...................Black 3 C.D.I. unit
Br .................Brown 4 Ignition coil
5 Spark plug
Ch ................Chocolate
6 Rectifier/Regulator
Dg ................Dark green
7 Fuse
G ..................Green
8 Main switch
L ...................Blue
9 Battery
O ..................Orange
0 Ground lead
P...................Pink q Starter relay
R ..................Red w Starter motor
Sb.................Sky blue e Handlebar switch (right)
W..................White r Starter switch
Y...................Yellow t Engine stop switch
B/L................Black/Blue y Light switch
B/R ...............Black/Red u Starter circuit cut-off relay
B/W ..............Black/White i Clutch switch
B/Y ...............Black/Yellow o Fuel meter
Br/W .............Brown/White p Meter light (fuel)
G/W..............Green/White a Fuel sender
L/B................Blue/Black s Rear brake switch
L/R ...............Blue/Red d Tail/Brake light
L/W...............Blue/White f Front brake switch
R/W ..............Red/White g Turn signal relay
W/L...............White/Blue h Horn
W/R ..............White/Red j Handlebar switch (left)
k Horn switch
l Dimmer switch
; Turn signal switch
z Auxiliary light
x Headlight
c Front turn signal light (left)
v Front turn signal light (right)
b Rear turn signal light (left)
n Rear turn signal light (right)
m Meter
, Neutral indicator light
. Meter light
/ Turn signal indicator light
7 ! High beam indicator light
7-3
5AP-E0 7 01.7.26 9:38 PM Page 4
SWITCH ELEC
SWITCH
CHECKING THE SWITCHES
Using pocket tester, check switches for continuity
between their terminals to determine whether
they are correctly connected.
Replace the switch component if any of the com-
binations does not produce the correct reading.
Pocket tester:
90890-03112
NOTE:
9Turn the switch to the “ON”, “OFF” positions
several times.
9Adjust the pocket tester to correct “0” position
before checking switches.
9Set the pocket tester selector to “×1”Ω.
SWITCH CONNECTION AS SHOWN IN THIS

Br R MANUAL
This manual contains connection charts, like the
OFF
ON one shown on the left, showing the terminal con-
nections of switches (e.g. the main switch, han-
dlebar switch, brake switch, lighting switch etc.)
Br R The column on the extreme left indicates the dif-

ferent switch positions, the top line indicates the
colors of the leads connected to the terminals on
the switch.
“2—2” indicates terminals between which there

is continuity, i.e. a closed circuit, in the given
switch position.
In this chart:
“Br and R” have continuity with the switch in the
“ON” position.
7-4
5AP-E0 7 01.7.26 9:38 PM Page 5
CHECKING THE SWITCH ELEC
CHECKING THE SWITCH CONTINUITY

Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals.
Poor connection, no continuity → Correct or replace.
*The coupler locations are circled.
1
5 Y/R L L/B
OFF
B
PO
B
ON
(GREEN)
6 B B/W
2 Ch Br/W Dg OFF
RUN
L
N
R
7 L/W
OFF
3 Y L/B G ON
HI
LO
4 P B
L/W Br
OFF
B L/B
ON
L
Br/W Ch
Y B G P B
Dg L/B
w
B
B
8 9 0 q
R B B B/W
R
OFF
B Br
ON
B B
1 Clutch switch 6 Engine stop switch q Main switch

2 Turn signal switch 7 Starter switch w Front brake switch
3 Dimmer switch 8 Fuse
4 Horn switch 9 Rear brake switch
5 Light switch 0 Neutral switch
7-5
5AP-E0 7 01.7.26 9:38 PM Page 6
IGNITION SYSTEM ELEC

IGNITION SYSTEM
CIRCUIT DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L PUL
2 B/R B/R CHA 3 5
G/W G/W CHA
STOP
GNO
B
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R
OFF
Br Br
W W ON
6 7
15A
B B
R W
(B) R
B B
B
R
R R R/W
B/W
q e
R
L/W L/W
9 r t
L/W L/W
B OFF OFF
R/W R/W
ON RUN
B
0 B
w y L/W Br Y/R L/W

OFF B L/B L/B B
PO L L
ON
(B) (B)
B B
Y/R L/B B
L
Br
Br
Br Br
h Br/W
Br g Br Br
Y
f Br Br
Y
Y Y
s
(B) (B)
(B) (B)
Br/W
Y
Y
2 C.D.I. magneto 8 Main switch

3 C.D.I. unit 9 Battery
4 Ignition coil 0 Ground lead
5 Spark plug e Handlebar switch (right)
7 Fuse t Engine stop switch
7-6
5AP-E0 7 01.7.26 9:38 PM Page 7

TROUBLESHOOTING
THE IGNITION SYSTEM FAILS TO OPERATE.

(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check:
1. Spark plug 6. Source coil resistance
2. Ignition spark gap 7. Main switch
3. Spark plug cap resistance 8. Engine stop switch
4. Ignition coil 9. Neutral switch
5. Pick up coil resistance 10. Wiring connection
(entire ignition system)
NOTE:
8Remove the following parts before trou- 8Usethe special tools specified in the trouble
bleshooting. shooting section.
1) Side cover
Ignition checker
2) Seat
90890-06754
3) Fuel tank
Pocket tester:
4) Headlight unit
90890-03112
1. Spark plug
8Check the spark plug condition.
INCORRECT
Refer to “CHECKING THE SPARK PLUG”
CORRECT Repair or replace the spark plug
7-7
5AP-E0 7 01.7.26 9:38 PM Page 8

*
2. Ignition spark gap

8Disconnect
2
the spark plug cap from the
spark plug.
Spark plug cap → Ignition checker 1
Ignition checker lead → Cylinder head 2
8Turn the main switch to “ON”.
8Check the ignition spark gap 3. 1
8Check the spark by pushing the starter 3
switch, and increase the spark gap until a
misfire occurs. MEETS SPECIFICATION
Minimum spark gap:
6 mm or more
OUT OF
SPECIFICATION The ignition system is not faulty.
OR NO SPARK
3. Spark plug cap resistance NOTE:

9When removing the spark plug cap, do not pull
8Remove the spark plug cap.
the spark plug cap from high tension cord.
8Connect the pocket tester (Ω×1k) to the
Remove → Turning counterclockwise.
spark plug cap.
Connect → Turning clockwise.
Tester (+) lead → Spark plug side 1 9Check the high tension cord when connecting
Tester (_) lead → High tension cord side 2 the spark plug cap.
9When connecting the spark plug cap, cut the
high tension cord about 5 mm.
OUT OF SPECIFICATION
Spark plug cap resistance:
4 ~ 6kΩ (20°C)
MEETS
Replace the spark plug cap.
SPECIFICATION
7-8
5AP-E0 7 01.7.26 9:38 PM Page 9

*
4. Ignition coil resistance (primary coil)
8Disconnect the ignition coil connector from
the wireharness.
8Connect the pocket tester (Ω×1) to the igni- 1
tion coil.
8Check if the primary coil has the specified
resistance.
2
Tester (+) lead → Orange Terminal 1
Tester (_) lead → Ground Terminal 2
Primary coil resistance:
0.32 ~ 0.48Ω (20°C) 1
MEETS
SPECIFICATION 2
Ignition coil resistance (secondary coil)
8Connect the pocket tester (Ω×1k) to the igni-
tion coil.
8Check the secondary has the specified re-
sistance. OUT OF SPECIFICATION
Tester (+) lead → Spark plug lead 1
Tester (_) lead → Orange Terminal 2
Secondary coil resistance:
5.68 ~ 8.52kΩ (20°C) Replace the ignition coil.
BOTH MEET
SPECIFICATION
5. Pickup coil resistance

8Disconnect Br G
the pickup coil coupler from the
R W
wireharness.
8Connect the pocket tester (Ω×100) to the
1 2
pickup coil coupler.
Tester (+) lead → White Terminal 1
Tester (_) lead → Red Terminal 2
8Check the pickup coil has the specified re-
sistance.
Pickup coil resistance:
248 ~ 372Ω (20°C)
MEETS
Replace the pickup coil.
SPECIFICATION
*
7-9
5AP-E0 7 01.7.26 9:38 PM Page 10
6. Source coil resistance 2 1

8Disconnect the source coil coupler from the Br G
wireharness. R W
8Connect the pocket tester (Ω×100) to the
charging coil coupler.
Tester (+) lead → Brown Terminal 1
Tester (_) lead → Green Terminal 2
8Check the source coil has the specified re-
sistance. OUT OF SPECIFICATION
Source coil resistance:
720 ~ 1080Ω (20°C)
MEETS Replace the source coil.
SPECIFICATION
7. Main switch
NO CONTINUITY
Refer to “CHECKING THE SWITCHES” section.
CONTINUITY
Replace the main switch.
8. Engine stop switch

NO CONTINUITY
CONTINUITY
Replace the handlebar switch (right).
9. Neutral switch
NO CONTINUITY
CONTINUITY
Replace the neutral switch.
10. Wiring connection

POOR CONNECTIONS
8Check the connection of the entire ignition
system.
Refer to “CIRCUIT DIAGRAM”.
Correct.
CORRECT
Replace the C.D.I. unit.
7-10
5AP-E0 7 01.7.26 9:38 PM Page 11
CHARGING SYSTEM ELEC

CHARGING SYSTEM
CIRCUIT DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L PUL
2 B/R B/R CHA 3 5
G/W G/W CHA
STOP
GNO
B
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R
OFF
Br Br
W W ON
6 7
15A
B B
R W
(B) R
B B
B
R
R R R/W
q
R
L/W
9
L/W L/W
B R/W R/W
B
0 B
B B
2 C.D.I. magneto
6 Rectifier/Regulator
7 Fuse
9 Battery
0 Ground lead
7-11
5AP-E0 7 01.7.26 9:38 PM Page 12

TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
Procedure
Check:
1. Fuse 4. Stator coil resistance
2. Battery 5. Wiring system (entire charging system)
3. Charging voltage
NOTE:
8Remove the following parts before trou- 8Use the special tools specified in the trou-
bleshooting. bleshooting section.
1) Side cover
Inductive tachometer
2) Seat
90890-03113
3) Fuel tank
Pocket tester:
90890-03112
1. Fuse
NO CONTINUITY
Refer to “CHECKING THE SWITCH CONTINU-
ITY” section.
CONTINUITY Replace the fuse.
2. Battery
8Check the battery condition.
Refer to “CHECKING THE BATTERY” sec- INCORRECT
tion in CHAPTER 3.
CORRECT
8Cleanbattery terminals.
8Recharge or replace the battery.
*
7-12
5AP-E0 7 01.7.26 9:38 PM Page 13

* NOTE:
Use a fully charged battery. (12.8V or more)
3. Charging voltage
8Connect the inductive tachometer to the
spark plug lead.
8Connect the pocket tester (DC20V) to the
battery.
Tester (+) lead → Battery (+) terminal 1

Tester (_) lead → Battery (_) terminal 2
2
8Measure the battery terminal voltage. 1
8Start the engine and accelerate to about
5,000 r/min.
8Check the terminal voltage.
Charging voltage:
Increase 0.2 ~ 2.5V
MEETS
The charging circuit is not faulty.
SPECIFICATION
Replace the battery.
4. Stator coil resistance

8Remove the C.D.I. magneto coupler from
1 2
wireharness.
8Connect the pocket tester (Ω×1) to the stator
W W
coil. W
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 2
3
Tester (+) lead → White terminal 3
Tester (–) lead → White terminal 2
8Measure the stator coil resistance.
Stator coil resistance:

0.44 ~ 0.66Ω (W-W at 20°C)
Replace the stator coil.
MEETS
SPECIFICATION
Check the entire charging system for con- POOR CONNECTION
nections.
Refer to “CIRCUIT DIAGRAM” section.
CORRECT Correct.
Replace the rectifier/regulator.
7-13
5AP-E0 7 01.7.26 9:38 PM Page 14
ELECTRIC STARTING SYSTEM ELEC

ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L PUL
2 B/R B/R CHA 3 5
G/W G/W CHA STOP
GNO
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R Br
OFF
Br Br
W W ON
6 7
15A
R W
B B u B/Y R/W
(B) R Sb Br
(B)
B B
B Sb
R
R/W
R R R/W B/Y
B/W
q e
R i
L/W L/W
B B/Y
9 r t B B
L/W L/W
B OFF OFF (G) (G)
R/W R/W
ON RUN
B
0 B B
w y L/W Br Y/R L/W

OFF B L/B L/B B
PO L L
ON
(B) (B)
B B
Y/R L/B B
L
1 Neutral switch w Starting motor

7 Fuse e Handlebar switch (right)
8 Main switch r Starter switch
9 Battery t Engine stop switch
0 Ground lead u Starter circuit cut-off relay
q Starter relay i Clutch switch
7-14
5AP-E0 7 01.7.26 9:38 PM Page 15
ELECTRICAL STARTING SYSTEM ELEC

TROUBLESHOOTING
THE STARTER MOTOR FAILS TO OPERATE.
Procedure
Check:
1. Fuse 7. Engine stop switch
2. Battery 8. Neutral switch
3. Starter motor 9. Clutch switch
4. Starter relay 10. Starter switch
5. Starter circuit cut-off relay 11. Wiring connection (entire starting system)
6. Main switch
NOTE:
1) Side cover
Pocket tester:
2) Seat
90890-03112
3) Fuel tank
4) Headlight unit
1. Fuse
NO CONTINUITY
ITY” section.
2. Battery
8Check the battery condition. INCORRECT
Refer to “CHECKING THE BATTERY” sec-
tion in CHAPTER 3.
8Clean battery terminals.
CORRECT 8Recharge or replace the battery.
3. Starter motor
8Remove and check the starter motor.
w
8Connect the battery positive terminal This check is likely to produce sparks, so be
and starter motor cable using a jumper lead. sure that no flammable gas or fluid is in the
8Check the starter motor operation. vicinity.
MOVE DOES NOT MOVE
*
Repair or replace the starter motor.
7-15
5AP-E0 7 01.7.26 9:38 PM Page 16
4. Starter relay b
a
8Disconnect the relay unit coupler from the
wireharness.
8Connect the pocket tester (Ω×1) and battery
(12V) to the relay unit coupler terminals. L/W 1
Tester (+) lead → a terminal 1 R/W 2
Tester (_) lead → b terminal 2
Battery (+) lead → Blue/White terminal 1
Battery (_) lead → Red/White terminal 2
NO CONTINUITY
8Check the terminal a and b for continuity.
CONTINUITY Replace the starter relay.
5. Starter circuit cut-off relay

8Disconnect the relay unit coupler from the 1 2
wireharness. 3 4
8Connect the pocket tester (Ω×1) and battery
(12V) to the relay unit coupler terminals.
Tester (+) lead → 4 terminal 1
Tester (_) lead → 2 terminal 2
Battery (+) lead → 4 terminal 1
Battery (_) lead → 3 terminal 2
NO CONTINUITY
8Check the terminal 4 and 2 for continuity.
CONTINUITY Replace the starter circuit cut-off relay.
6. Main switch
NO CONTINUITY
CONTINUITY
Replace the main switch.
7. Engine stop switch

NO CONTINUITY
CONTINUITY
7-16
5AP-E0 7 01.7.26 9:38 PM Page 17

*
8. Neutral switch NO CONTINUITY (at NEUTRAL position)

CONTINUITY
(at NEUTRAL position) Replace the neutral switch.
9. Clutch switch NO CONTINUITY

CONTINUITY Replace the clutch switch.
10. Start switch NO CONTINUITY

CONTINUITY Replace the handlebar switch (right).

8Check the connections of the entire starting POOR CONNECTION
system.
Correct.
7-17
5AP-E0 7 01.7.26 9:38 PM Page 18

STARTER MOTOR
10 Nm (1.0 kg•m)
6
1
2
1
4
2 1

Removing the starter motor Remove the parts in order.
1 Starter motor/O-ring 1/1
2 Starter motor lead 1 For installation, reverse the removal
procedure.
Disassembling the starter motor Disassemble the parts in order.
1 Front bracket/O-ring 1/1
2 Washer 1
3 Rear bracket/O-ring 1/1
4 Armature coil 1
5 Case ass’y 1
6 Brush/Brush spring 2/2
procedure.
7-18
5AP-E0 7 01.7.26 9:38 PM Page 19

CHECKING THE STARTER MOTOR
1. Measure:
8Brush length a
Standard brush length:

10 mm
a <limit:> 3.5 mm
2. Inspect:
8Armature coil resistances
(installation/continuity)
Defects→Replace the starter motor.
If commutator is dirty, clean it with sandpa-
∫ per.
å
Good
Bad condition
condition
A 2 2 × ×
B × 2 × 2
2: Continuity
× : No continuity
Bad condition→Replace.
a 3. Measure:
9Commutator diameter a
Out of specification→Replace the starter
motor
Standard commutator diameter:
22 mm
<limit:> 21 mm
4. Measure:
8Mica undercut a
Mica undercut:
1.5 mm
a
Out of specification→Scrape the mica to
the proper value (a hacksaw blade can be
ground to fit).
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of commu-
tator.
6. Measure:
9Brush spring force
Fatigue/out of specification→Replace as a
set.
Standard brush spring force:

563 ~ 844 gf
<limit:> 230 gf
7-19
5AP-E0 7 01.7.26 9:38 PM Page 20
LIGHTING SYSTEM ELEC

LIGHTING SYSTEM
CIRCUIT DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L PUL
2 B/R B/R CHA 3 5
G/W G/W CHA
STOP
GNO
B
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R Br
OFF
Br Br
W W ON
6 7
15A
R W
B B u B/Y R/W
(B) R Sb Br
(B)
B B
B Sb
R
R/W
R R R/W B/Y
B/W
q e
R i
L/W L/W
B B/Y
9 r t B B
L/W L/W
B OFF OFF (G) (G)
R/W R/W
ON RUN
B
0 B B
w y L/W Br Y/R L/W

B L/B L/B B
OFF
L L
PO
ON (B) (B)
B B
Y/R L/B B
L
Br
Br
Br Br L Br
h Br/W
g Br Br
f
sp
Br Y Y Br Br
Y Y
(B) (B) o Br G
L B
G Br
B L
(B) (B)
Br/W
Y (B) (B)
Y
P B G
L/B j Br/W
Y L
k l ;
OFF HI L
d G
ON LO N
L L a B
G
B
R Y Y
B B (G) (G)
Ch Br/W Br/W Ch
B P P B Y B
L/B Dg Dg L/B B B
B G Y G
B B Y G z Ch Dg
Y Y
B
G Ch Dg Ch Dg Dg
Ch
L Br
Sb m
c v b n
x
B L/R L B B L
B Br Dg Dg Br
Ch Sb Sb Ch
! / . , (R) (R)
B B B B
Y B
7 Fuse y Light switch z Auxiliary light

8 Main switch p Meter light (fuel) x Headlight
9 Battery d Tail/Brake light . Meter light
0 Ground lead j Handlebar switch (left) ! High beam indicator light
e Handlebar switch (right) l Dimmer switch
7-20
5AP-E0 7 01.7.26 9:38 PM Page 21

TROUBLESHOOTING
THE HEADLIGHT, AUXILIARY LIGHT, HIGH BEAM INDICATOR LIGHT,

TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON.
Procedure
Check:
1. Fuse 4. Light switch
2. Battery 5. Dimmer switch
3. Main switch 6. Wiring connection (entire lighting system)
NOTE:
1) Side cover
Pocket tester:
2) Seat
90890-03112
3) Fuel tank
4) Headlight unit
1. Fuse
Refer to “CHECKING THE SWITCH CONTINU- NO CONTINUITY
ITY” section.
CONTINUITY
Replace the fuse.
2. Battery
tion in CHAPTER 3.
CORRECT
8Cleanbattery terminals.
3. Main switch NO CONTINUITY

CONTINUITY Replace the main switch.
4. Light switch
NO CONTINUITY
CONTINUITY
*
7-21
5AP-E0 7 01.7.26 9:38 PM Page 22

*
NO CONTINUITY
5. Dimmer switch
Replace the handlebar switch (left).
CONTINUITY
POOR CONNECTIONS
8Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”.
CORRECT Correct.
Check the condition of each of the lighting

system’s circuits.
Refer to “CHECKING THE LIGHTING SYSTEM”
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator light fail to come on.
NO CONTINUITY
1. Bulb and bulb socket
Check the bulb and bulb socket are continuity.
CONTINUITY Replace the bulb and or bulb socket.
2. Voltage
8Connect
∫
the pocket tester (DC20V) to the
headlight and high beam indicator light cou- 2 3
plers.
Headlight: Y Y
Tester (+) lead → B B
å
Green 1 or Yellow 2 lead G G
1
Tester negative (_) lead →
Black 3 lead
High beam indicator light: 5
Tester (+) lead → Yellow 4 lead
Tester (_) lead → Black 5 lead L B B L
Br Dg Dg Br
A When the dimmer switch is on low beam.
Ch Sb Sb Ch
B When dimmer switch is on high beam.
8Turn the lights switch to “ON” position.
8Turn the dimmer switch to “LO” or “HI” posi-
tion. 4
8Check for voltage (12V) on the lead at bulb
MEETS SPECIFICATION
socket connectors.
OUT OF
SPECIFICATION The wiring circuit from the main switch to bulb
* 7-22
socket connector is faulty. Repair.
5AP-E0 7 01.7.26 9:38 PM Page 23

*
8Check the connections of the entire lighting POOR CONNECTION
system.
Correct.
2. The meter light fails to come on.

NO CONTINUITY
Replace the bulb and or bulb socket.
CONTINUITY
1 2
2. Voltage
8Connect the pocket tester (DC20V) to the L B B L
bulb socket coupler. Br Dg Dg Br
Ch Sb Sb Ch
Tester (+) lead → Blue terminal 1
Tester (_) lead → Black terminal 2
8Check the voltage (12V) of the leads on the OUT OF SPECIFICATION
bulb socket connector.
MEETS
SPECIFICATION
The wiring circuit from main switch to bulb
This circuit is not faulty. socket is faulty. Repair.
7-23
5AP-E0 7 01.7.26 9:38 PM Page 24
3. The taillight fails to come on.

NO CONTINUITY
CONTINUITY
2. Voltage L L
8Connect the pocket tester (DC20V) to the Y Y
bulb socket connector. B B
Tester (+) lead → Blue terminal 1 2
8Turn the main switch to “ON” position.
8Check the voltage (12V) on the bulb socket OUT OF SPECIFICATION
connector.
MEETS
The wiring circuit from main switch to bulb
SPECIFICATION
connector is faulty. Repair.
This circuit is not faulty.
4. The auxiliary light fails to come on.

NO CONTINUITY
CONTINUITY
1
2. Voltage
L/R
bulb socket connector. B
Tester (+) lead → Blue/Red terminal 1
2
8Check the voltage (12V) on the bulb socket OUT OF SPECIFICATION
connector.
MEETS
SPECIFICATION The wiring circuit from main switch to bulb
connector is faulty. Repair.
7-24
5AP-E0 7 01.7.26 9:38 PM Page 25
SIGNAL SYSTEM ELEC

SIGNAL SYSTEM
CIRCUIT DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L PUL
2 B/R B/R CHA 3 5
G/W G/W CHA
STOP
GNO
B
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R Br
OFF
Br Br
W W ON
6 7
15A
R W
B B u B/Y R/W
(B) R Sb Br
(B)
B B
B Sb
R
R/W
R R R/W B/Y
B/W
q e
R i
L/W L/W
B B/Y
9 r t B B
L/W L/W
B OFF OFF (G) (G)
R/W R/W
ON RUN
B
0 B B
w y L/W Br Y/R L/W

OFF B L/B L/B B
PO L L
ON
(B) (B)
B B
Y/R L/B B
L
Br
Br
Br Br L Br
h Br/W
g Br Br
f
Br Y Y Br
Y
Br
Y
sp
(B) (B) o Br G
L B
G Br
B L
(B) (B)
Br/W
Y (B) (B)
Y
P B G
L/B j Br/W
Y L
k l ;
OFF HI L
d G
ON LO N
L L a B
G
B
R Y Y
B B (G) (G)
Ch Br/W Br/W Ch
B P P B Y B
L/B Dg Dg L/B B B
B G Y G
B B Y G z Ch Dg
Y Y
B
G Ch Dg Ch Dg Dg
Ch
L Br
Sb m
c v b n
x
B L/R L B B L
B Br Dg Dg Br
Ch Sb Sb Ch
! / . , (R) (R)
B B B B
Y B
1 Neutral switch f Front brake switch b Rear turn signal light (left)
7 Fuse g Turn signal relay n Rear turn signal light
8 Main switch h Horn (right)
9 Battery j Handlebar switch (right) m Meter
0 Ground lead k Horn switch , Neutral indicator light
o Fuel meter ; Turn signal switch / Turn signal indicator light
a Fuel sender c Front turn signal light (left)
s Rear brake switch v Front turn signal light
d Tail/Brake light (right)
7-25
5AP-E0 7 01.7.26 9:38 PM Page 26
SIGNAL SYSTEM ELEC

TROUBLESHOOTING
THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON.
THE HORN FAILS TO SOUND. FUEL METER DOES NOT OPERATE.
Procedure
Check:
1. Fuse 3. Main switch
2. Battery 4. Wiring connection (entire signal system)
NOTE:
8Remove the following parts before trou- 8Use the special tools in the troubleshooting sec-
bleshooting. tion.
1) Side cover
2) Seat
Pocket tester:
3) Fuel tank
90890-03112
4) Headlight unit
1. Fuse
NO CONTINUITY
ITY” section.
2. Battery
tion in CHAPTER 3.
CORRECT
8Clean battery terminals.
3. Main switch NO CONTINUITY
CONTINUITY Replace the main switch.
4. Wireharness
POOR CONNECTION
8Check the connections of the entire signal
system.
Refer to “CIRCUIT SYSTEM WIRING DIA-
GRAM” section. Correct.
7-26
5AP-E0 7 01.7.26 9:38 PM Page 27
SIGNAL SYSTEM ELEC

CHECKING THE SIGNAL SYSTEM
1. The horn fails to sound. NO CONTINUITY
1. Horn switch
Replace the left handlebar switch (left).
CONTINUITY
2. Voltage
horn lead.
Tester (+) lead → Brown terminal 1
Tester (_) lead → Frame ground
1
Br P
8Turn the main switch to on.

8Check for voltage (12V) on the “Brown” lead The wiring circuit from the main switch to the
at the horn terminal. horn is faulty. Repair.
MEETS
SPECIFICATION
Br P
3. Horn
8Connect the pocket tester (DC20V) to the 1
horn at the “Pink” terminal.
Tester (+) lead → Pink terminal 1

8Check for voltage (12V) on the “Pink” lead to
frame ground.
MEETS
SPECIFICATION
Replace the horn.
Adjust or replace horn.
7-27
5AP-E0 7 01.7.26 9:38 PM Page 28
SIGNAL SYSTEM ELEC

2. The brake light fails to come on.
NO CONTINUITY
CONTINUITY
NO CONTINUITY
2. Brake switch (Front/Rear)
Replace brake switch.
CONTINUITY
3. Voltage
bulb socket connector.
Tester (+) lead → Yellow terminal 1
L L
Y Y
B B

8The brake lever (or brake pedal) is pulled in
(down).
8Check for voltage (12V) of the “Yellow” lead OUT OF SPECIFICATION
on the bulb socket connector.
MEETS
SPECIFICATION
This circuit is not faulty. Wiring circuit from the main switch to the bulb
socket connector is faulty. Repair.
Refer to “SIGNAL SYSTEM WIRING DIA-
GRAM”.
7-28
5AP-E0 7 01.7.26 9:38 PM Page 29
SIGNAL SYSTEM ELEC

3. The turn signal light and or turn signal indica-
tor light fails to blink.
NO CONTINUITY
CONTINUITY
NO CONTINUITY
2. Turn signal switch
Replace the left handlebar switch (left).
CONTINUITY
3. Voltage
turn signal relay coupler.

8Check for voltage (12V) of the “Brown” lead OUT OF SPECIFICATION
at the turn signal relay terminal.
The wiring circuit from main switch to turn sig-

MEETS
nal relay connector is faulty. Repair.
SPECIFICATION
7-29
5AP-E0 7 01.7.26 9:38 PM Page 30
SIGNAL SYSTEM ELEC

*
4. Voltage
turn signal relay coupler.
Tester (+) lead →Brown/White terminal 1
Tester (_) lead →Frame ground

8Turn the turn signal switch to “L” or “R”.
8Check for voltage (12V) on the “Brown/ OUT OF SPECIFICATION
White” lead at the turn signal relay terminal.
MEETS The turn signal relay is faulty. Replace.

SPECIFICATION
5. Voltage
bulb socket connector. B Ch B Dg
At turn signal light (left)

Tester (+) lead → Chocolate lead 1 3 1 3 2
At turn signal (right)
Tester (+) lead → Dark green lead 2
8Turn the turn signal switch to “L” or “R”.
8Check for voltage (12V) on the “Chocolate”
lead and “Dark green” at the turn signal light
terminal.
MEETS 6. Wiring connection

SPECIFICATION
Wiring circuit from the turn signal switch to
This circuit is not faulty. bulb socket connector is fault. Repair.
7-30
5AP-E0 7 01.7.26 9:38 PM Page 31
SIGNAL SYSTEM ELEC

4. The neutral indicator light fails to operate.
NO CONTINUITY
Replace the bulb and/or bulb socket.
CONTINUITY
NO CONTINUITY
2. Neural switch
Replace the neutral switch.
CONTINUITY
3. Voltage
meter coupler.
Tester (_) lead → Sky blue terminal 2

8Select the gear position in neutral. OUT OF SPECIFICATION
8Check for voltage (12V) of the “Sky blue”
lead on the neutral switch.
Check the connection of the entire signal sys-
MEETS
tem.
SPECIFICATION
7-31
5AP-E0 7 01.7.26 9:38 PM Page 32
SIGNAL SYSTEM ELEC

5. The fuel meter fails to operate.
1. Fuel sender
3
8Remove the fuel sender from the fuel tank.
8Disconnect the fuel sender coupler from the
wireharness.
Connect the pocket tester (Ω×10) to the fuel
sender coupler lead.
4 1
Tester (+) lead → Green terminal 1
Tester (_) lead → Black terminal 2 2
8Check the fuel sender for specificated resis- OUT OF SPECIFICATION

tance.
Specificated
Float position
resistance
Replace the fuel sender.
UP 3 4 ~ 10Ω
DOWN 4 90 ~ 100Ω NOTE:
9Measure the resistance, when the float position
BOTH MEET “UP” 3 or “DOWN” 4.
SPECIFICATION 9Measure the resistance, when the float until
stops each position.
2. Voltage
fuel gauge coupler. 1
Br G G Br
2
Tester (+) lead → Brown terminal 1 L B B L
Tester (_) lead → Frame ground 2
8Turn the main switch to “ON”. OUT OF SPECIFICATION
8Check for voltage (12V) of the “Brown” lead
on the fuel sender lead.
MEETS
SPECIFICATION 8Check the connections of the entire signal
system.
* Refer to “WIRING DIAGRAM”.
7-32
5AP-E0 7 01.7.26 9:38 PM Page 33
SIGNAL ELEC
*
3. Fuel meter NOTE:

Before reading the meter, stay put the float for
8Connect the fuel sender to wireharness.
more than three minutes respectively at “UP” or
8Move the float to “UP” 1 or “DOWN” 2.
“DOWN”.

8Check the fuel meter needle moves “F” or
“E”.
Float position Needle moves
Float “UP” 1 “F” DOES NOT MOVE
Float “DOWN” 2 “E”
MOVES
Replace the fuel meter.

7-33
5AP-E0 8 01.7.26 10:44 AM Page 8-1
TRBL
STARTING FAILURE/HARD STARTING SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING

FUEL SYSTEM
Fuel tank 9 Empty

9 Clogged fuel filter
9 Clogged fuel breather hose
9 Deteriorated fuel or containing water or
foreign material
Fuel cock 9 Clogged fuel hose
9 Clogged fuel cock
Carburetor 9 Deteriorated fuel, fuel containing water or
foreign material
9 Clogged pilot jet
9 Clogged air passage
9 Improperly adjusted pilot screw
9 Clogged pilot air passage
9 Damaged carburetor joint
9 Improperly tightened carburetor joint clamp
hose screw
9 Improperly sealed valve seat
9 Improperly adjusted fuel level
9 Clogged starter jet
9 Starter plunger malfunction
9 Flooded carburetor
9 Deformed float
9 Groove-worn needle valve
Air filter 8 Clogged air filter element
8 Improper air filter setting
COMPRESSION SYSTEM
Cylinder and cylinder head 8 Loose spark plug
8 Loose cylinder head
8 Broken cylinder head gasket
8 Broken cylinder gasket
8 Worn, damaged or seized cylinder
Piston and piston ring 8 Worn piston
8 Worn, fatigued or broken piston ring
8 Seized piston ring
8 Valve stem
8 Seized or damaged piston
8 Improperly adjusted valve clearance
8 Improperly sealed valve
8
8 Improperly contacted valve and valve seat
8 Improper valve timing
8 Broken valve spring
8 Seized valve
8-1
5AP-E0 8 01.7.26 10:44 AM Page 8-2
STARTING FAILURE/HARD STARTING/ TRBL

POOR IDLE PERFORMANCE SHTG
IGNITION SYSTEM
Battery 9 Improperly charged battery

9 Faulty battery
Fuse 9 Burn out, improper connection
Spark plug 8 Improper plug gap
8 Worn electrodes
8 Wire between terminals broken
8 Improper heat range
8 Faulty spark plug cap
Ignition coil 8 Broken or shorted primary/secondary coil
8 Faulty high tension cord
8 Broken ignition coil body
C.D.I. unit system 8 Faulty C.D.I. unit
8 Faulty pick up coil
8 Broken magneto woodruff key
Switches 8 Faulty main switch
8 Faulty engine stop switch
8 Faulty clutch switch
8 Faulty neutral switch
Wiring 8 Loose battery terminal
8 Loose coupler connection
8 Improperly grounded
8 Broken wireharness
POOR IDLE PERFORMANCE
POOR IDLE PERFORMANCE
Carburetor 8 Improperly returned starter plunger

8 Loose or clogged pilot jet
8 Damaged carburetor joint
8 Improperly tightened carburetor joint
clamp hose
8 Improperly adjusted idle speed
(throttle stop screw), (pilot screw)
8 Improperly adjusted throttle cable
8 Flooded carburetor
8 Improperly installed air filter element
Ignition system 8 Faulty spark plug
8 Faulty high tension cord
8 Faulty C.D.I. unit
8 Faulty ignition coil
8 Valve system 8 Improperly adjusted valve clearance

8
8-2
5AP-E0 8 01.7.26 10:44 AM Page 8-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE/ TRBL

POOR SPEED PERFORMANCE SHTG
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” section (fuel, electrical, compression,
valve system).
Carburetor 9 Improperly adjusting fuel level
9 Clogging main nozzle
9 Clogged or loose pilot jet
9 Clogged passage
POOR SPEED PERFORMANCE

POOR SPEED PERFORMANCE
Ignition system 8 Dirty spark plug

8 Improper heat range
Fuel system 8 Clogged fuel tank cap breather hole
8 Clogged air cleaner element
8 Clogged jet
8 Improperly adjusted fuel level
Compression system 8 Worn cylinder
8 Worn or seized piston ring
8 Cylinder head gasket broken
8 Cylinder gasket broken
8 Carbon deposit build-up
8 Improperly contacted valve and valve seat
8 Faulty valve timing
Clutch 8 Refer to “CLUTCH SLIPPING/DRAGGING”
section
Engine oil 8 Improper oil level (low or over oil level)
8 Improper quality (low oil viscosity)
8 Deterioration
8 Clogged oil passage
Brake 8 Dragging brake
8-3
5AP-E0 8 01.7.26 10:44 AM Page 8-4
CLUTCH SLIPPING, DRAGGING/ TRBL

FAULTY GEAR SHIFTING SHTG
CLUTCH SLIPPING, DRAGGING
CLUTCH SLIPPING
Clutch 8 Improperly adjusted clutch cable

8 Loose clutch spring
8 Fatigued clutch spring
8 Worn friction plate/clutch plate
8 Incorrectly assembled clutch
Engine oil 9 Improper oil level (low)
9 Improper quality (low viscosity)
CLUTCH DRAGGING
Clutch 8 Warped pressure plate

8 Unevenly tensioned clutch spring
8 Bent push rod
8 Broken clutch boss
8 Burnt primary driven gear bushing
8 Bent clutch plate
8 Swollen friction plate
8 Match marks not aligned
Engine oil 8 Improper oil level (high)
8 Improper quality (high viscosity)
8 Deterioration
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “CLUTCH DRAGGING”.

Shift shaft 8 Improperly adjusted shift rod
8 Warm or damage torsion spring
8 Bent shift shaft
Shift cam, shift fork 8 Groove jammed with impurities
8 Sized shift fork
8 Bent shift fork guide bar
8 Jammed with impurities
Transmission 8 Sized transmission gear
8 Jammed impurities
8 Incorrectly assembled transmission
JUMP-OUT GEAR
Shift shaft 8 Worm torsion spring

Shift fork 8 Worm stopper roller
8 Worm shift fork
Shift cam 8 Improper thrust play
8 Worm shift cam groove
Transmission 8 Worm gear dog
8-4
5AP-E0 8 01.7.26 10:44 AM Page 8-5
TRBL
OVER HEATING/FAULTY BRAKE SHTG
OVER HEATING
OVER HEATING
Ignition system 8 Improper spark plug gap

8 Improper spark plug heat range
Fuel system 8 Improper carburetor setting
8 Improper fuel level adjustment
8 Clogged air filter element
Compression system 8 Heavy carbon deposit build-up
8 Improperly adjusted valve timing
Engine oil 8 Incorrect engine oil level
8 Improper engine oil quality (high viscosity)
8 Low engine oil quality
9 Clogged oil passage
Brake 9 Dragging brake
FAULTY BRAKE
POOR BRAKING EFFECT
Front brake 8 Worn brake pad

8 Worn brake disc
8 Air in brake fluid
8 Leaking brake fluid
8 Faulty master cylinder kit
8 Faulty caliper seal kit
8 Loose union bolt
8 Broken brake hose
8 Oily or greasy brake pad
8 Oily or greasy brake disc
8 Improper brake fluid level
Rear brake 8 Improper brake pedal adjustment
8 Worn brake shoe
8 Improper brake shoe contact
8 Worn camshaft
8 Worn brake drum
8 Mud or water into brake drum inside
8 Oily or greasy brake lining
8 Faulty brake cable
8 Broken or fatigued tension spring
8 Faulty camshaft, cam lever
8-5
5AP-E0 8 01.7.26 10:44 AM Page 8-6
FRONT FORK MALFUNCTION/ TRBL

STARTER MOTOR DOES NOT OPERATE SHTG
FRONT FORK MALFUNCTION
OIL LEAKAGE
8 Bent, damaged or rusty inner tube
8 Damaged or cracked outer tube
8 Loose hexagon bolt
8 Damaged cap bolt O-ring
8 Improperly installed oil seal
8 Improper oil level (high)
MALFUNCTION
8 Bent, damaged or deformed inner tube
8 Deformed outer tube
8 Damaged fork spring
8 Bent cylinder complete
8 Improper oil viscosity (high viscosity)
8 Improper oil level (low)
8 Worn or damaged slide metal
STARTER MOTOR DOES NOT OPERATE

STARTER MOTOR NOT OPERATE
Battery 8 Insufficient battery capacity
8 Faulty battery
Fuse 8 Burnt out, improper connection
Switch 8 Faulty main switch
8 Faulty clutch switch
8 Faulty neutral switch
8 Faulty starter switch
8 Faulty starting circuit cut-off relay
8 Faulty engine stop switch
8 Faulty starter relay
Wireharness 8 Loose battery terminal
8 Loosely connected coupler
Starter motor 8 Worn brush
8 Faulty commutator
8 Broken armature coil
Engine 8 Faulty starter clutch
8 Seized engine
8-6
5AP-E0 8 01.7.26 10:44 AM Page 8-7
TRBL
INSTABILE HANDLING SHTG
INSTABILE HANDLING
INSTABILE HANDLING
Handlebar 9 Improperly installed or bent

9 Loose handlebar tightening bolt
Steering 8 Improperly installed handle crown
8 Bent under bracket
8 Improperly installed steering shaft
(improperly tightened ring nut)
8 Damaged bearing or ball race
8 Loose or over tightening steering nut
Front forks 8 Uneven oil levels on both sides
8 Uneven spring tension
8 Broken front fork spring
8 Fatigued front fork spring
8 Twisted front forks
Wheels 8 Incorrect wheel balance
8 Loose spooks
8 Deformed wheel rim
8 Unevenly worn tires
8 Incorrect tire pressure
8 Loose bearing
8 Bent or loose wheel axle
8 Excessive wheel runout
Frame 8 Twisted
8 Improperly installed bearing race
8 Damaged head pipe bearings
Swingarm 8 Faulty bearings
8 Worm or damaged
8 Faulty bushing
8 Bent rear arm
Rear shock absorbers 8 Fatigued spring
8 Improperly adjusted spring preload
8 Oil leakage
Drive chain 9 Improperly adjusted chain slack
8-7
5AP-E0 8 01.7.26 10:44 AM Page 8-8
TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM
HEADLIGHT DARK
9 Improper bulb (out of specification)
9 Too many electric accessories
9 Hard charging (broken charging coil)
9 Faulty rectifier/regulator
9 Faulty battery
9 Incorrect connection
9 Poor contacts (main or light switch)
9 Bulb life expired
BULB BURNT OUT
9 Faulty battery
9 Faulty rectifier/regulator
9 Bulb life expired
9 Incorrect connection (out of specification)
TURN SIGNAL DOES NOT LIGHT
9 Discharged battery
9 Faulty fuse
9 Faulty turn signal switch
9 Faulty turn signal relay
9 Broken wireharness and or loosely connected
coupler
9 Bulb burnt out
TURN SIGNAL KEEPS ON
9 Insufficient battery capacity
(nearly discharged)
9 Bulb burnt out (front or rear each one)
TURN SIGNAL BLINKS SLOWER
9 Insufficient battery capacity
(nearly discharged)
9 Faulty main and/or turn signal switch
TURN SIGNAL BLINKS QUICKER
HORN DOES NOT SOUND
9 Faulty battery
9 Faulty fuse
9 Faulty main and/or horn switch
9 Improperly adjusted horn
9 Faulty horn
(broken coil or damaged connector)
8-8
WIRING DIAGRAM 01.7.26 9:42 PM Page 1
YBA125 WIRING DIAGRAM
Sb
Or B/R B/W G/W
1 Br G G/W B/R
B W/R W/L
W/L W/R
R W
4
W/R W/R PUL IGN Or
W/L W/L
2 B/R B/R
PUL
CHA 3 5
G/W G/W CHA
STOP
GNO
B
W W W W
W W
B B/W
W W W
B/W
R R
W W W R
8
R R Br
OFF
Br Br
W W
6 7
ON
15A
R W
B B u B/Y R/W
(B) R Sb Br
(B)
B B
B Sb
R
R/W
R R R/W B/Y
B/W
q e
R i
L/W L/W
B B/Y
9 r t B B
L/W L/W
B OFF OFF (G) (G)
R/W R/W
ON RUN
B
0 B B
w y L/W Br Y/R L/W

OFF B L/B L/B B
PO L L
ON
(B) (B)
B B
Y/R L/B B
L
Br
Br
Br Br L Br
h Br/W
g Br Br
f
Br Y Y Br
Y
Br
sp
(B) (B) Y
o Br G
L B
G Br
B L
(B) (B)
Br/W
Y (B) (B)
Y
B G
P
L/B j Br/W
Y L
k l ;
OFF HI L
d
ON LO N
L L a G
B
G
B
R Y Y
B B (G) (G)
Ch Br/W Br/W Ch
B P P B Y B
L/B Dg Dg L/B B B
B G Y G
B B Y G z Ch Dg
Y Y
B
G Ch Dg Ch Dg Dg
Ch
L Br
Sb m
c v b n
x
B L/R L B B L
B Br Dg Dg Br
Ch Sb Sb Ch
! / . , (R) (R)
B B B B
Y B
COLOR CODE 1 Neutral switch h Horn

B............Black 2 C.D.I. magneto j Handlebar switch (left)
Br ..........Brown 3 C.D.I. unit k Horn switch
Ch .........Chocolate 4 Ignition coil l Dimmer switch
Dg .........Dark green 5 Spark plug ; Turn signal switch
G ...........Green 6 Rectifier/Regulator z Auxiliary light
L ............Blue 7 Fuse x Headlight
O ...........Orange 8 Main switch c Front turn signal light
P............Pink 9 Battery (left)
R ...........Red 0 Groumd lead v Front turn signal light
Sb..........Sky blue q Starter relay (right)
W...........White w Starter motor b Rear turn signal light
Y............Yellow e Handlebar switch (left)
B/L.........Black/Blue (right) n Rear turn signal light
B/R ........Black/Red r Starter switch (right)
B/W .......Black/White t Engine stop switch m Meter
B/Y ........Black/Yellow y Light switch , Neutral indicator light
Br/W ......Brown/White u Starter circuit . Meter light
G/W .......Green/White cut-off relay / Turn signal indicator
L/B.........Blue/Black i Clutch switch light
L/R ........Blue/Red o Fuel meter ! High beam indicator
L/W........Blue/White p Meter light (fuel) light
R/W .......Red/White a Fuel sendor
W/L........White/Blue s Rear brake switch
W/R .......White/Red d Tail/Brake light
f Front brake switch
g Turn signal relay
MARKS MEANS OF MARKS

Connecting the ground lead
of the wireharness
Ground
COVER4 01.8.1 3:58 PM Page 1

Enticer

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Enticer

Uploaded by

Copyright:

Available Formats

COVER1 01.8.

HOW TO USE THIS MANUAL

CLUTCH ENG CLUTCH ENG

i o p i Apply engine oil

C.D.I. MAGNETO AND STARTER CLUTCH ....................................................4-37

REMOVING THE STEERING ......................................................................6-35

DRAWINGS OF THE APPEARANCE/

FRONT VIEW REAR VIEW

FRAME SERIAL NUMBER, ENGINE SERIAL NUMBER:

1 Frame serial number 3 Engine serial number

3. Proper and right tools

4. Wearable and consumable parts

1 7. Important information during disassem-

BEARINGS AND OIL SEALS

3. Connect and disconnect the connector two

7. Check for continuity with a tester.

FOR CHECKING AND

2. Adjust the valve clearance.

3. Measure the compression pressure.

4. Detect the engine idling speed.

6. Charge the MF type battery.

FOR ENGINE SERVICE

2. Remove and install the valve and the valve

3. Remove and install the valve lifter and for

5. Remove the magneto rotor

6. Separate the crankcase.

7. Hold the clutch boss nut.

2. Install the fork seal.

3. Loosen and tighten the ring nut wrench.

2. Measure and check the electrical system.

GENERAL SPECIFICATIONS SPEC

GENERAL SPECIFICATIONS SPEC

Item Standard specification

GENERAL SPECIFICATIONS SPEC

Item Standard specification

2 Rear shock absorber

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Crank width “A” 46.95~47.00 mm •••

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS SPEC

Item Standard limit

TIGHTENING TORQUE SPEC

Cam sprocket M8x1.25 1 20 2.0

Timing chain tensioner cap bolt M6x1.0 1 7.5 0.75

TIGHTENING TORQUE SPEC

Stopper lever M6x1.0 1 10 1.0 LT

Pickup coil M6x1.0 2 10 1.0 LT

Neutral switch ass’y M10x1.25 1 4 0.4

Item Standard Limit

TIGHTENING TORQUE SPEC

Brake hose union bolt M10x1.25 30 3.0

GENERAL TORQUE SPECIFICATIONS

A: Distance across flats

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

Lubrication Point Symbol

LUBRICATION DIAGRAM SPEC

LUBRICATION DIAGRAM SPEC