NOTICE | written by the Yamaha Motor Company primarily for use by Yamaha dealers and th | Ics. It Is not possible to put an entire mechanic's education Into one manual, so it | persons using this book to perform mainter d repairs on Yamaha motorcycles have | ile understanding of the mech inherent in motorcycle repalr | nology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsat corte Ltd, Is continuall: rove all models manufactured. Modifications and significant in specifications or procedures will be forwarded to all authorized dealers and will, where appear In future editions of this manual ESCORTSLTD.MSD | SERVICE DEPARTMENT | AUTION indicates special procedures that must be followed to avoid damage to the motorcycle. ING: AANING indicates special procedures that must b N 1ust be followed t ir I Gh Be erates robedure tat wed to avoid injury to a motorcycle operator oF UAL FORMAT ee procedures in this manual are organized in a sequential, step-by-step format. The information | mpFeneneioe eaptenpievide the mechanic with an easy to read, handy reference that contains Pte eanae explanations cf al disasaem bly, repair, assembly. and inspection operations. In this i. ition of a faulty compo! acon required wil folow ne Sst, eilfy eomponshit will precede sh arrow symbol and the course earings y itting/Damage -» Replace. ich chapter provides explod | disassembly and assomby pracac nae® Be1ore each disassembly section for ease in identifying correctILLUSTRATED SYMBOLS (Refer to the illustration) lllustrdtedsymbols@)to)are designed as thumb tabs to indicate the chapters number and content @) General information @) Periodic inspection and adjustment @)Engine @ Carburetion @)Chassis @)Electrical @ Appendices Illustrated symbols()tofZ)are used to identity the specifications appearing in the text. ) Filling fluid Lubricant 10) Tightening (11) Wear limit, clearance Engine speed DLA lMustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point Apply locking agent (LOCTITE; or equivalent) §8 Apply engine oil Apply gear oil 7 Apply molybdenum disulfide oil 8 Apply wheel bearing grease ‘Apply lightweight lithium soap base grease Apply molybdenum disullide greaseIF Sa GENERAL INFORMATION GEN PERIODIC INSPECTIONS | ¢ AND ADJUSTMENTS INSP ADJ _*& ENGINE OVERHAUL nc KY ¥ CARBURETION | © cars Ey CHASSIS as ICHAS| ELECTRICAL | = evecl a AN | APPENDICESCHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION. a FRAME SERIAL NUMBER, 4 ENGINE SERIAL NUMBER IMPORTANT INFORMATION 1-2 ALL REPLACEMENT PARTS. 1-2 GASKETS, OIL SEALS, AND O-RINGS. 4-2 LOCK WASHERS/PLATES AND COTTER PINS 1-2. BEARINGS AND OIL SEALS___ CIRGLIPS 4-3 SPECIAL TOOLS. 1-3 FOR ENGINE SERVICE ans a) FOR CHASSIS SERVICE 1-5 ORRIN EC poms Soe 0 FOR ELECTRICAL COMPONENTS. 4-6GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number(1)is stamped into the right side of the steering head pipe. ENGINE SERIAL NUMBER The engine serial number(s stamped into the left side of the engine Nove) 8 Se The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: RXx1o0____ 1.000101 OIE Designs and specifications are subject to change without notice,IMPORTANT INFORMATION IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1, We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease racommended by Escorts for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS. 1. All lock washers/plates(I)and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1, Install the bearings(s)(@and oil seal(s)(@with their manufacturer's marks or numbers facing ‘outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease (eg. Servo Grease M.P.) to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed alr to spi pin the bearings dry. Thle causes damage to the bearing surlaces.CIRCLIPS 1. All circlips should be inspected carefully before Feassembly. Always replace piston pin clips after one use. Replace distorted circlips. When Installing a circlip@) make sure that the sharp- edged comer (2)is positioned opposite to the thrust @)it receives. See the sectional view, @ Shaft SPECIAL TOOLS ‘The proper special tools are nacessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. FOR ENGINE SERVICE 1. Flywheel Holding Too! SM-100000201 2. Flywheel Puller &SM-10000202 3. Crankcase Separating Tool ESM-100000265a: 4, Clutch Holding Toot ESM-100000233 Q 5. Grank Installing Tool ESM-100000266 Ne Ao: 3 Adapter 6. Driving Sprocket Holder ESM-100000205, —() 7. Piston Pin Replacer ESM-100000207 <=ae a SPECIAL TOOLS 8, Piston Ring Compressor ESM-100000210 oO 9. Punch ESM-100000222 For Crank-Shaft Seal c- 40Punch ESM-100000233 For Gear Shaft Seal (ae FOR CHASSIS SERVICE 1. Steering Nut Wrench SM-100000221 2, Front Fork Top Plug Spanner ESM-1000002143. T Handle ESM-100000213 4, Front Fork Inner Tube Adjuster ESM-100000264 aaa 5. Speedometer Gear Nut Spanner | ESM-100000237 A FOR ELECTRICAL COMPONENTS 1. Pocket Tester ESM-100000270CHAPTER 2 . PERIODIC INSPECTIONS AND ADJUSTMENTS NOTES ON MAINTENANCE | PERIODIC MAINTENANCE/LUBRICATION ENGINE ..... SPARK PLUG | AIR CLEANER ELEM TRANSMISSION OIL, AUTOLUBE PUMP CARBURETTOR CLUTCH , CHASSIS: BRAKE . SEBS 53: DRIVE CHAIN . STEERING HEAD ELECTRICAL . BATTERY ...SSR SSeS eee INS NOTES ON MAINTENANCE ae NOTES ON MAINTENANCE 1. Thoroughly clean the frame and engine of dirt and dust in order to prevent them from enter ing the inside of the engine, 2. Keep off fire, 3, When the special tools are required, be sure to use them so that damage to the motorcycle parts ean be avoided. Always use the right tools and instruments for ~ the right purposes. (Avoid using an open-end wrench as much as possible, in place of a box: or socket wrench.) 4, Always use a new gasket (packing), O-rin cotter pin, circlip, lock washer, etc. for repal Also use genuine Yamaha parts, oll and grease, or those recommended by Escorts.Avoid using other brands. 5. During service, take special care so that you don't get injured or burnt from the engine, exhaust pipe or muffler.‘4, Loosen: © Locknut ’ 5. Screw in adjuster @) until tight and back it out 1/4 turn. 6. Tighten: * Locknut ® CHASSIS BRAKE Front 4, Loosen * Locknut @) 2, Adjust: © Free play by adjuster (2) 8. Tighten * Locknut (4) 5~8 mm Rear 4, Adjust * Free play @) ~ a by turning the adjuster @) (Ref. Page 2-11) @ 20~30 mm AMAHA |® Adjuster TYRE 1. Inspect: © Tyre wear | Wear Limit 1mm J) Wear indicator @) Replacement limit 1 mm 2. Check: © Air pressure MAXIMUM 162 Kg. LOAD* Front Rear Single Rider | 7.5 kg 2.0 kg /em?, (22 psi) | /em?, (28 psi) Double Rider! 1.5k9 23 kg Jom?, (22 psi) | /em*, (32 psi) * Load is the total weight of cargo, rider, passenger, and accessories. Too high — Risky — Poor Read holding Good — Good & safe riding Too low — Causes higher tyre wear fuel economy low. DRIVE CHAIN Slack Check 1, Remove: «Rubber cap 2. Gheck: ive chain slack@IVE CHAIN/STEERING HEAD Slack Adjustment 1, Remove: * Cotter pin @ 2, Loosen: @ Axle nut * Sprocket shaft nut @) 3. Adjust; # Slack @) Adjusting bolt NOTE:. Be sure that both right and left chain pullers are in the corresponding positions, STEERING HEAD ‘Checking 1. Raise front wheel off the ground, 2. Check: * Steering head bearing for looseness Gently rock fork assembly backward and forward Looseness - Adjust. Adjuster . Loosen: © Steering fitting bolt @) '* Front fork pinch bolts (2) Adjust: * Steering head ring nut Tighten nut until steering head is tight without binding. Heavy binding Replace bearings, 3. Tighten: * Steering fitting bolt @) * Front fork pinch bolt (2) Steering Fitting Bolt (1): 3.1 mkg, (22 fib) Front Fork Pinch Bolt @): 2.0 m.kg, (14 fl.lb)BATTERY ELECTRICAL BATTERY Fluld Level 1. Check: # Fluid level @) Fluid level should be between upper(@) and lower level tine (@) Use only distilled water for refilling. Battery Charging 1. Check: © Battery fluid gravity SPECIFIC GRAVITY | CLIMATE INITIAL AT 20°C} TROPICAL 1240 (ABOVE 30°C) COLD/ TEMPERATE 1.260 {BELOW 30°C) 2. If gravity is below specified, recharge battery. ‘Charging CurrentNOTES ON MAINTENANCE 6. Battery Take care so that the battery fluid does not spilt ‘on your clothes body or the motorcycle, T. Notes on disassembly and reassembly 4, Place all removed parts neatly and separately ip groups so that they will not be confused or lost. b, Wash the engine and transmission parts in a detergent oil and blow them out dry with compressed air. ¢. While checking the smoath movement of parts, install them, d. Oll the contact surfaces of the moving parts. 8. Tightening torque. Tighten the parts to specification by using the ‘torque wrench.Ee Ei PERIOD! [eEMAnKs. —? BREAK-IN | THEREAFTER EVERY. (000 EO [te B.000 12000 O13 monthslor 6 months| or 12 monthe [Gheck/Clean or replace [6 0 oe (Clean, Replace if necessary 0 oO [Check/Adjust/idle speed, starter operation| 0 0 Check fuel hose for cracks or damage oO 0 eplace (Warm engine before draining) | REPLACE | CHECK | AEPLAGE Check/Adjust'/Air bleeding" ° 0 al Chack/operation 0 0 Cheek operation 0 oO o ‘Check rear arm assembly for looseness. 0 0 feplace Silent block bushes 24,000 or 24 months. Check balance/damage/runout/spoke 0 0 tightness ‘Check bearings assembly for loosenessy 0 ‘| REPAGK™ damage. Replace if damaged GREASE ‘Check bearings assembly for looseness. 0 REPACK™ GREASE CHECK ‘CHEGK | REPLACE ‘OIL 0 Check operation/ell leakage Clean/iube/align® Check tension every 1000 kms /align’ ‘Cheek all hassis/engine/Cyl/Cyl. Head = Check specific gravity *¥ — Check breather pipe for proper ‘operation. — Check electrolyte level/add distilled water every 15 days. Remove carbon trom (Cyl./Cyl. Heads Piston Assy/Muffler)y) ES CE EH SR AR GRA GEE PRE FO |] PERIODIC MAINTENANCE/LUBRICATION | | INSP | (Qe BP7HS 0,7~0.8 mm FeeeA FW PP PERIODIC MAINTE -uppen.|t OWERS. VAY W)ENGINE SPARK PLUG 4, Clean: * Spark plug 2. Adjust: Piug gap) Ay® AIR CLEANER ELEMENT 1. Remove: © Right side cover * Air cleaner case cover (7) © Air cleaner element (2) 2. Clean: ® Air cleaner element Wash the ¢lement in solvent. Squeeze excess solvent out of the element and dry. CAUTION: DO NOT SQUEEZE BY TWISTING 8. Apply: * A small quantity of 2-stroke engine oll Squeeze excess oil 4. Install: ® Air cleaner element | TRANSMISSION OIL Checking 1. Check: * Oil level Maintain transmission oil level always bel” ween MAX and MIN lines. Recommended Oll: Servo Super 30 or EquivalentReplacement 1. Start the engine and tet it wars 2. Remove: eee * Drain bolt (1) Drain oil after warmi 3. Install: “er a * Drain bolt @ i e 3. Fill '* Transmission oil yy 0.65 L 4, Check * Oil level AUTOLUBE PUMP Cable Adjustment 1. Check to see if pump guide pin is aligned with mark on adjusting pulley 2. If not aligned, align by turning adjuster @ in or out. - | @)LocknutMinimum pump stroke adjustment 1. Flotate engine so that adjust plate moves out to limit 2. Measure: * Minimum pump stroke | | Minimum Pump Stroke: | 25 mm | 3. If clearance is not correct, adjust by the shim ® Aaidng of shim wil increase the stroke and vice versa. Air Bleeding 1. Remove: © Pump bleed screw @) Keep oil running out unt! air bubbles disappear 2. Install: * Bleed screw (1) 8. Start the engine and pull the pump wire@) all the way for some minutes, CARBURETTOR Throttle Grip Free Play 1. Loosen: * Locknut @ 2 Adjust: * Cable free play @) 1-2 mm Turn cable adjuster) in or Sut. 3. Tighten: * LocknutCARBURETTOR/CLUTCH Throttle Cable Free Play Loosen: + Loosen @) . Adjust: * Cable free play (2) 5~8 mm Turn cable adjuster (8) in or out Tighten; * Locknut @ Idle Speed 1. Turn pilot air screw @) in until lightly seated. 2. Back out by specified numbers of turns. X] Pilot Air Screw Turn Out: 1-1/481/2 @rsnise ve 3. Start the engine and let it warm up. 4, Tur the throttle stop screw (1) in or out un- til idle speed is at specified rpm. Cy Engine Idle Speed: 1,200 + 50 rpm CLUTCH Gable Adjustment Loosen: © Locknut @) Adjust: © Cable free play 2) 2~3 mm Turn eable adjuster @) in or out. Tighten: * Locknut @) Mechanism Adjustment 1. Remove: @ Left crankease cover 2. Position the push lever 8 by the cable adjuster 8. Install: "Left crankcase cover @) @ 75mmCHAPTER 3 ENGINE OVERHAUL ENGINE DISASSEMBLY . CYLINDER HEAD AND CYLINDER... PISTON ... FLYWHEEL M CUUTCH “ieess Replace. ee ‘Small End Free Play: 4.5~2.0 mm TRANSMISSION Shit Shaft 1. Inspect ® Shift shat @. © Springs(@) Wear/Bend — Replace.(ion i T INSPECTION AND REPAIR oe a ae | ‘Shift Fork 1. Inspect: © Shift forks @) (on the gear and shift cam contact surface) © Shift fork guide bars (2) Wear/Chating/Bends/Damage —> Replace, 2, Check: © Shift fork movement (on shift cam) Unsmooth operation = Replace fork and/or guide bar. Shift Cam 1. Inspect: * Shift cam grooves @) Wear/Damage/Scratches - Replace. © Shift cam pins Wear/Damage - Replace. Main Axle and Drive Axle 4, Measure: + Axle runout Use centering device and Dial Gauge @) ‘Out of specification > Replace. Runout Limi 1mm Gears 1. Inspect: © Gears Damage/Wear ~> Replace. 2, Check: © Gear movement Unsmooth operation = Replace. 3. Inspect: ¢ Matching dogs Cracks/Wear/Damage — Replace.INSPECTION AND REPAIR BEARING AND OIL SEALS | 1, Gheck: | * All bearings (with finger) Rough spot/Play - Replace. 2. Inspect’ * All oll seal lips Damage/Wear + Replace. [oj eee IG NS ENE Always replace crankshaft oil seals.ENGINE ASSEMBLY AND ADJUSTMENT CRANK PIN ENGINE ASSEMBLY AND ADJUSTMENT NOTE: ————— Before assembling the engine, thoroughly wash the parts in mild solvent, CRANKSHAFT 4 WOODRUFF KEY O|L SEAL aes pb 4, Attach: + Crankshaft Installing Too! Esm-100000266 (1) (to the left side crankcase) 2, Tighten: * Nut of the installing tool Hold the connecting rod at top dead center.2 POP EE YG il ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISSION AND SHIFTER RIVE AXLE BEARING GIL SEAL COLLAR DRIVE SPROCKET (57) 4.4 m-kg (10 ftsIb) @e aN ) 1ST WHEEL GEAR: Oy A =~ (gon) & GUIDE BAR 4TH WHEEL cean——! EC, i) "Ge (231) : : 3RD WHEEL GEAR Or ©) (ar) WP Oo Ke CLUTCH’ Coy, STOPPER LEVER CO 2ND WHEEL 3 zs GEAR (307) @ D PINION GEAR—— = ast) oy 2.0 mekg (14 ft-lb) LO ese 2ND PINION GEAR GUIDE BAR 7 % : BORIC! BLIND PLUG 1. Install: * Transmission assembly 2, Check: ‘© Transmission operation Incorrect operation -» Reassambly. a14 .SZ Teme] hy & * Yamaha Bond No.4 (to both crankcase mating surfaces.) install ‘© Dowel knock pins @) . Install: * Right crankcase half (Tap with plastic hammer) Tighten: * Crankcase tightening screws Tighten the screws in showing sequence and in two steps.‘SHIFT LEVER, TENSION SPRING SHIFT SHAFT ASSY wn A> LockNur, 1. Install * Stopper lever assembly (@) Lesem * Shift shaft assembly @) * Washer @ * Circlip @ Adjust: * Shift lever position (by adjuster screw (1) and locknut @2)) 8. Gap @) To be equal on both sides.m_| ENGINE ASSEMBLY AND ADJUSTMENT 2.5 moka. 18 ft-lb) of | ag BALL io | Ona are <> KICK STARTER SPACER RETURN SPRING KICK GEAR ae OIL SEAL WASHER Instat * Kick starter assembly Position the kick clip (7) in groove (®) of the crankcase as shown. n 2 Hook: # Return spring @ Install: © Circlip © Washer ® Kick idle gear @ © Washer (2 = Circlip @) a a aCLUTCH CLUTCH SPRING PRESSURE PLATE |e, PUSH ROD SPACER PUusH ROD. e - seach STRAIGHT KEY 1, Install! * Thrust washer @) * Spacer + Glutch housing ‘© Thrust washer 2. Install: ® Clutch boss : wong © Nut @) CLUTCH PLATE WARP LIMIT: 0.05 er THRUST WASHER 0 BALL cLuTcH no nen JOlL SEAL ADJUSTER. l< y)] Clutch Boss: OY 4.3 mskg, (31 ft-lb)maa ENGINE ASSEMBLY AND ADJUSTMENT Clutch plates + Ball(3) * Push rod @) CAUTION: The clutch fA] :tst (B] :2nd [CG] : 3rd. [D) : ath 4, Install: ‘* Pressure plate @) * Springs * Bolts (3) © Clutch Spring Nut: 0.6 m.kg. (4.9 ftlb) PRIMARY DRIVE GEAR 4, Install: * Spacer (1 * Primary drive gear(2) * Straight Ker * Washer (4). * Nut 6) Primary Drive Gear: 5.5 m.kg (40 fttb) FLYWHEEL MAGNETO 1. Install * Stater assembly @) ssl a CL ‘Stator: 0.7 in.kg, (5-1 ft.tb) 2, Connect: * Neutral switch led wire) 3. Install * Woodruff key @) © Flywheel Flywheel Magneto: T.0m.kg. (50 ft.lb)ENGINE DISASSEMBLY CLUTCH 1. Remove: Crankcase cover (Right) luteh spring bolts © Cluteh springs © Pressure plate 1 © Friction plates * Clutch piate@) 2 Remove: | 7 + Primary drive gear nut @ Use folded 2g) + Washer Primary drive gear@) Straight key © Spacer 3. Attach: © Clutch Holding Tool ESM-100000233 (1) Remove: * Clutch assembly ‘© Oil seal retainer @ KICK STARTER 1. Unhook: © Kick return spring@) 2, Remove: © Kick starter assembly (2) 3, Remove: ® Girclip * Washer! © Kick idle gear * Washer 2) * CirclipPISTON 2.5 m-k9.(18 ftlby END GAP; 0.18-0.35 mm PISTON CLEARANCE: 0,030 ~0,032 mm PISTON PIN PISTON PIN CLIP 3.5 m-k9.125 fe-lb) (ALWAYS USE A NEW ONE! 1. Install * Piston rings @) ‘¢ Small end bearing @) # Fiston pin@ * Piston pin clips (New)@) * Piston 6) NOTE: + Make sure ring ends(1) are properly fitted around ring locating pins in piston grooves. © The arrow (@) on piston deme must face ex haust side.Sr eT a ie ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER 1. Install * Gasket (New) * Cylinder Cylinds CYLINDER HEAD 4. Install * Head gasket @) * Gylinder head) + Nuts @) Cylinder Head: 2.5 m.kg, (18 {t1b) ENGINE MOUNTING Engine Mount Bolts: 3.0 m.kg, (22 ftulb) 6.0 makg, (43 ftlb)‘SHIFT SHAFT 1. Remove: * Girclip (on left side) 2. Remove: © Shift shaft assembly @) + Stopper lever assembly) ‘CRANKCASE 1. Remove: © Grankease tightening screws 2. Attach: © Crankcase separating too ESM-100000265@) (fo the right side crankcase) NOTE: A ee eS Make sure the tool body is parallel with the case. ‘Make sure the too Se ee 3. Tighten: © Securing bolt 2) TRANSMISSION AND SHIFTER 4, Remove: Shift cam blind plug @). * Gasket @)ENGINE DISASSEMBLY 2, Remove: © Transmission assembly CRANKSHAFT 4. Attach: ie © Grankcase separating tool ESM-100000265(1) NOTE:, Make sure the tool body is parallel with the case. 2. Tighten: Securing bolt @) | 3. Remove: | © Crankshaft Assy. |a a a ae a Gl a ON BS 4 9 INSPECTION AND REPAIR Vv INSPECTION AND REPAIR ‘CYLINDER HEAD 1. Remove: * Carbon deposit Use rounded scraper. NOTE, 2 oO Sis SP Do not use a sharp instrument and avoid damag- ing or scratching. 2. Measure: * Cylinder head warpage ‘Out of specitication - Resurface or replace é S | Less than 0.03 mm (D Straight edge @) Thickness gauge CYLINDER 1, Remove: * Carbon deposit Use rounded seraper. NOTE Do not use a sharp instrument and avoid damage: or scratching, 2. Inspect * Cylinder wall Wear/Scratches -» Rebore or replace. 3. Measure * Gylinder bore “©” Use Cylinder Bore Gauge. Out of specification -» Rebore @ 0 | ‘Standard | Wear Limit a T | 50.00 50.02 Cylinder Bore G: ae 60.1 mm 0.05 mm Cylinder Taper T: s © = Cylinder bore T = (Maximum C)-(Ninimum C)INSPECTION AND REPAIR PISTON 1, Inspect * Piston wall Wear/Scratches/Damages — Repair or re- place. 2. Remove: | © Carbon deposit | Use rounded scraper. NOTE:. © Do not use a sharp instrument and avoid damag- ing or scratching. * After correcting, clean the piston with a clean cloth, 3. Measure: ® Piston outside diameter “P” Out of specification -> Replace: Size A [Standard 49.966 — 49.986 mm 49:90 mm Oversize 1 50.25 mm Oversize 2 50.50 mm [Oversize 3 50.75 mm Oversize 4 51.00 mm NOTE:;_ a © Measurement should be made at a point 10mm above the bottom edge of the piston skirt. 1) 10 mm Piston pin 90° 4, # Piston clearance ~ Out of specification + Rebore cylinder or replace piston. Piston Clearance = Minimum Cylinder Bore ‘C’ — Piston di 0.030~0.038 mmMaximum cylinder bore P = Piston outside diameter PISTON RING 1. Measure: Side clearance @) Use a fealer gauge @) Out of specification > Replace piston and/or rings. Side Clearance: 0.02 — 0.06 mm 2, Measure: * End gap: (I) Use feeler gauge @) ‘Out of specification + Replace rings as a set. 3. Check 4. Install: ‘* Piston pin @) {into piston) 5, Check: * 12) i" Free Play -» Replace piston pin and/or piston. Standard Limit End Gap: |} — (installed) | 0.15~0.35 mm | 0.6 mm Ps a ed PISTON PIN AND SMALL END BEARING 1. Lubrieate: '* Piston pin (1) and bearing 2, Install: Piston pin and bearing (into small end of connecting rod @) ) Free play Free play > Inspect connecting rod for wear. Wear 9 Inspect connecting rad and piston pin.IN AND REPAIR CLUTCH Cluteh Hout 1. Inspect: ® Dogs on housing (7) Cracks/Wear/Damage — Deburr of replace. 2, Gheok: * Circumferential play Play —» Replace. NOTE: DO NOT GLEAN WITH PETROL Clutch Boss: 1. Inspect: * Clutch boss splines(2) Scoring/Weat/Damage — Deburr or replace. NOTE: Scoring on clutch plate splines will cause erratic operation. Friction Plate 1. Inspect: © Friction plates@) Damage/Wear > Replace as a set 2, Measure: © Friction plate thickness Measure all at four points, Gut of specification > Replace as a set. X<]_ Wear Limit: 2.7 mm Clutch Plate 1. Measure: © Clutch plate @) warpage Use surface plate (2) and fesler gauge. Out of specification > Replace, | Warp Limit: 8.05 mmGlutch Spring 1. Measure: © Free length Out of specification + Replace as a set, “| ‘Minimum Length: rh 33 mm KICK STARTER 1. Inspect: * Kick gear teeth * Kick idle gear teeth Wear/Damage ~ Replace. 2, Check + Kick gear movement 3. Measure: * Kick clip friction force Out of specification ~ Replace kick olip. [AN&] Kick Clip Friction Fores: (AX) 0e~t.2 ko CRANKSHAFT 1. Measure: # Runout @) Use Dial Gauge (1) Out of specification -> Repair or replace. @ 75mm Runout Limit: 0.03 mm 2, Measure: * Crank width Out of specification —> Repair or replace. Crank Width: §5.90~55.95 mmCHAPTER 4 CARBURETION CARBURETTOR ... SECTION VIEW . : i WORKING RANGE OF EACH COMPONENT 44 44 4-1 REMOVAL AND DISASSEMBLY 4-2 INSPECTION 402 REED VALVE .... + 43 INSPECTION , 2 43CARBURETTOR CARBURETTOR WALWE STOPPER HEIGHT: 9mm (0.36 in) VALVE STOPPER REED VALVE F SECTION VIEW. ere Throttle valve Jat needle Main jet Needle jot @ Pilot jot OB mkg.AS.7 ft-lb) Y iy THROTTLE VALVE (CUTAWAY) 2: p FLOAT HEIGHT: 7 poe | Needle vane 8 g @ L 7) “JET NEEDLE.|-— Spy PILOT AIR LoAT <4) PLATE WORKING RANGE OF EACH COMPONENT 99892 St Ouse v4 v2 a4 Main jet @ Noere jot & Jet needle Throttle valve cutaway Pilot air screw @ jet 6) Closed : ®) Full open screw turns Out Cop STARTER PLUNGER 6‘CARBURETTOR REMOVAL AND. DISASSEMBLY 1. Remove: © Right side cover * Air cleaner case screws (1) , Loosen: * Carburettor joint screw Disconnect * Fuel hose * Oil delivery hose@) ern 4, Remove: * Carburettor * Carburetor top) Disconnect: * Throttle cable(@) 6. Remove: + Startar plunger) © Float! Needle valve @) hoa INSPECTION 1. Using high pressure air, blow out all passages and jets. 2. Inspect: Needle valve Damaged or worn -+ Replace as a set. a t 2) Valve seat () Needle valve @) Check here.CARBURETOR 3. Inspect © Throttle valve @) * Jot needle (2 Scratch/Bent > Replace 2. Measure: * Float height (7) Without Gasket Incorrect —> Adjust Float Height: 24.0 -1.0 mm NOTE: The float should be just resting on, but not depressing, the spring loaded inlet needle. 5, Adjust ‘* Float height : by bending the tang @) REED VALVE INSPECTION rh 1, Measure: © Valve stopper neigh © Out of specification — Adjust. * Reed valve bending @ Out of specification — Replace. Valve Stopper Helght: 8mm Reed Valve Bending Limit: 0.3 mm NOE Note the out in the lower corner of the reed and stopper plate.