Manual Service: 21C-F8197-EO

MANUAL SERVICE

FZ-16

21C-F8197-EO
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FZ-16
SERVICE MANUAL All rights
reserved.
Any reprinting or unauthorized use without the
written permission of YAMAHA MOTOR INDIA
PVT. LTD. is expressly prohibited.

ATTENTION
This manual has been prepared by IYM, primarily for use by dealers and their qualified mechanics.
Unable to gather in a manual all the knowledge of a mechanic. Any person carrying out maintenance
and repairs on Yamaha vehicles should have basic mechanical skills and techniques needed to repair
these vehicles. Repair work and maintenance performed by a person who lacks such knowledge, the
vehicle probably will not be safe or suitable for use. Yamaha Motor India Pvt Ltd. is continually striving to
improve all its models. All authorized Yamaha dealers will be informed of any amendments and
substantial changes occur in specifications or procedures, and these will be included in future editions of
this manual, when necessary.

NOTE:
Designs and specifications subject to change without notice.

IMPORTANT INFORMATION HEREIN
Particularly important information is distinguished in this manual by the following symbols:

Safety alert symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!

WARNING A WARNING indicates a hazardous situation which could result in death or serious

injury to the vehicle operator, a bystander or a person who is inspecting or repairing

the vehicle.

CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.

NOTE: A NOTE provides key information to facilitate or clarify procedures.

Using this Guide
This book is intended as a practical tool, easy to read reference book for the mechanic. Includes
explanations of all installation, removal, disassembly, assembly, repair and check procedures are set out
in individual steps in sequential order.

The manual is divided into chapters and each chapter is divided into sections. The current section title
"1" appears at the top of every page.
Sub-section titles "2" appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are diagrams exploited "3" at the start of each
removal and disassembly section.
The numbers "4" are given in the order of jobs in diagrams exploited. A number indicates a
disassembly step.
Symbols "5" indicates the parts to be lubricated or replaced. See
"SYMBOLS".

A table of work instructions "6" accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc..

Jobs "7" that require more information (such as special tools and technical data) are described in sequential
order.

1

3 ClutchHu bHolder
YSST-733 7

4

5

6
2

SYMBOLS 1. Serviceable with engine mounted
The following symbols are used in this manual to 2. Type of liquid
facilitate understanding. 3. Lubricant
4. Special Tool
NOTE:
5. Torque
The following symbols are not relevant
6. Wear limit, tolerance
each vehicle. 7. Engine speed

8. Electrical
9. Motor oil
1 2 3
10. Gear oil

11. Molybdenum disulfide oil
12. Brake fluid
13. Bearing Grease
14. Grease with lithium soap base
4 5 6 15. Molybdenum disulfide grease
16. Silicone Grease
17. Apply locking agent (LOCTITE ®).

18. Replace the part with a new one.

7 8

9 10

E G

11 12

M BF

13 14

B LS

15 16
M S

17 18
LT New

TABLE OF CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS 2

INSPECTIONS
And adjustments 3

CHASSIS 4

MOTOR 5

CARBURETOR 6

ELECTRICAL7

TROUBLESHOOTING 8

GENERAL INFORMATION

IDENTIFICATION OF MOTORCYCLE .............................................. 1-1 .......
VEHICLE IDENTIFICATION NUMBER .......................................... 1-1
ENGINE SERIAL NUMBER ............................................. .................... 1-1

LCD METER ................................................ ................................... 1-2

IMPORTANT INFORMATION ................................................ ....................... 1-3
PREPARATION FOR REMOVAL AND DISASSEMBLY ......... 1-3
REPLACEMENT PARTS ............................................... ............... 1-3
GASKETS, OIL SEALS RINGS I ................................. 1-3
SAFETY WASHERS / LOCKNUTS
AND PINS ................................................ ................................... 1-3
BEARINGS AND OIL SEALS ........................................... 1 - 4
Sealing rings ............................................... ......................... 1-4

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

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

IDENTIFICACIÓN

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (chassis
number)
The vehicle identification number "1" is stamped
on the chassis.

ENGINE SERIAL NUMBER
The engine serial number "1" is stamped on the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.

1
1-1

CARACTERÍSTICAS

Multi-function display

1 2

SELECT

1. Multi-function
display
2. "Select" button (select)

The Multi-function display is
equipped with the following:
• A speedometer (which shows the speed)
• An odometer (which shows the total distance
traveled)
• An odometer (which shows the distance
traveled since it was last reset in)
• A fuel gauge (which indicates the level of fuel
available in the fuel anque)
NOTE
Be sure to turn the key to "ON" before using
the "SELECT" button.

MODE odometer and tripmeter.
A light pulse (less than one second) in the
"SELECT" button switches the display between
odometer and tripmeter.

Fuel meter
1

1. Fuel meter
The fuel gauge indicates the amount of fuel in the

fuel tank. The sec com ments fuel meter
disappear towards "E" (Empty) as the fuel level
decreases. When the last segment fuel gauge
starts flashing, refuel as soon as possible.
1-2

INFORMACIÓN IMPORTANTE

PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, clean all dirt,
mud, dust and foreign material.

GASKETS, OIL SEALS AND O RINGS

1. When assembling the engine, replace all
gaskets, oil seals and O-rings. All packaging
surfaces, edges of oil seals and O-rings must be
2. Use only the proper tools and equipment cleaned.
clean.
See "SPECIAL TOOL S" on page 1-8. 2. During assembly, place the oil specified in all
parts and bearings, and carefully lubricate the
3. When disassembling, always hold together
edges of oil grease them.
parts of the same whole. This includes gears,
cylinders, pistons and other parts that work
"grouped" for normal use. The parts should
always be grouped reused or replaced
altogether.

Lockwashers, locknuts and PINS

After disassembly, replace all lock washers and pins
"1". After it has set the screw or nut to the specified
4. During disassembly, clean all parts and place torque, double side edges against the side of the
screw or nut.
them in trays in the order of disassembly. This
will speed up the assembly and ensure the
correct assembly of the pieces
5. Keep all parts away from any
fire source.

REPLACEMENT PARTS
Use only genuine Yamaha parts in all changes.
Use oil and grease recommended by Yamaha,
for all
.
services lubrication.
Other brands may
be similar in function and appearance, but
inferior in quality.
1-3

INFORMACIÓN IMPORTANTE

BEARINGS AND OIL SEALS
Assemble the bearings and oil seals so that the
manufacturer's mark or numbers are visible.
When installing oil seals "1", lubricate the edges
of oil seals with a thin layer of grease lithium soap
base. In bearings, apply oil, if requested.

PREACAUCIÓN
Do not turn the bearing with compressed air, and
this will damage the surfaces

Sealing rings
Before assembling, carefully check all sealing
rings and replace that are damaged or twisted.
Always replace the sealing rings of the piston pin,
after one use. When installing a sealing ring "1",
make sure that the sharp corners "2" are placed
on the opposite side "3" to the force received by
the closing ring.
1-4

INSPECCIÓN DE LAS CONEXIONES

CHECKING THE CONNECTIONS NOTE:
Verify on the cables, couplers and connectors stains, • If there is no continuity, clean the terminals
oxidation, moisture, etc. • When checking the wire harness, perform steps
1. Disconnect: (1) through (3).
• As a quick fix, use a spray contact cleaner,
•Cable available at most parts stores.
•Coupler
•Connector
2. Verify
•Cable
•Coupler
•Connector
Moisture Dry airjet
Oxidation / stains Connect and disconnect
several times.

3. Check:
•All connections
Loose connection Connect adequately
NOTE:
If crimp the pin "1" of the terminal, fold
up.

4.Connect:
•Cable
•Coupler
•Connector
NOTE:
Make sure all connections are tight.

5. Check:
•Continuity
(With the multimeter)
1-5

HERRAMIENTAS ESPECIALES

SPECIAL TOOLS

Special tools shown below, are necessary for mounting and precise adjustments. Use only the
appropriate special tools, that will help to prevent damage caused by the use of inappropriate tools or
improvised techniques.

Tool name / nr Tool
Illustration
Tappet screw holder

YSST-706

This tool is used to hold the tappet screw to adjust valve
clearance
Tappet adjustment wrench
YSST-806A

This tool is used to loosen and tighten the nut on the
tappet
Thickness gauges
YSST-815

This tool is used to adjust the valve clearance in an engine
Adjuster rear shock

YSST-821

This tool is used for adjusting the rear shock preload
Magneto Holder
YSST-601B

This tool is used to hold the magnet to remove or install
magneto securing nut and main gear nut
Magneto Puller
YSST-628

This tool is used to remove the magnet with the help of
the magnet holder
1-6


Tool name / nr Tool
Illustration
Tool to install the crankshaft spacer.

(A) (B)
(A) YSST-
266 (b)
YSST-267

These tools are using to install the crankshaft.
Tool for removing the crankshaft. YSST-

265

This tool is used to remove the crankshaft from the
crankcase
Clutch Hub Fixer

YSST-733

This tool is used to lock the clutch hub while installing or
removing the locking nut of the clutch hub.
Lamp flicker

This instrument is used to check the ignition timing.
Manometer

This instrument is used to measure the compression of
the engine
Scraper
YSST-612

This tool is used to scrape the tip seal crankcase mating
surface.
Compressor valve spring

YSST-603

This tool is used to remove and install the valve and valve
spring.
1-7


Tool name / nr Tool

Illustration
Adapter valve spring compressor

A-803 YSST

This tool is used to remove and install the valve and the
valve spring using YSST 603.
Set gauge pump vacuum / pressure

This instrument is used to test and verify the vacuum of air
induction system.
Nut wrench address

YSST-721

This tool is used to loosen and tighten the stem nut.
Key in T-
813 YSST

This tool is used to hold the plunger of the front fork to
loosen or tighten the hex bolt.
Assembly tool oil seal front fork

YSST-875

This tool helps you to install the oil seal of the front fork.
Dynamic spark tester

This instrument is used to verify the efficiency of the spark
from the spark plug.
1-8


Tool name / nr Tool
Illustration
Multimeter

ThEste instrument is used to verify the electrical
circuits or components.
Yamaha Adhesive No. 1215

This adhesive is used on the contact surfaces, while the
housings assembled # 1 and # 2 of the engine.
Loctite
Three Bond 1322

This adhesive is used for added strength Torx screws for
adjustment.
Base for piston

YSST-604

This tool is necessary to support the piston in the cylinder
mounting.
Crankshaft key cap

YSST-625

This tool is used to remove / install the plug left crankcase
cover # 1 (LH).
1-9

SPECIFICATIONS

SPECIFICATION ................................................ 2-1 ........

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

CHASSIS SPECIFICATIONS ............................................... 2-9 ........

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

TORQUE ............................................... ............................... 2-14
SPECIFICATIONS TORQUE ON .... 2-14
ENGINE TORQUE ............................................. 2-16 ......
TORQUE CHASSIS ............................................. 2-19 ......

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

LUBRICATION SYSTEM TABLES AND CHARTS ........... 2-24
ENGINE LUBRICATION TABLE ...................................... 2-24
LUBRICATION DIAGRAMS ............................................... 2-25 .......

Cable routing ............................................... ............................. 2-27

ESPECIFICACIONES GENERALES
GENERAL

MODEL
Model 21C1

Dimensions
Total length 1973mm
Total width 770mm
Height totall 1045mm
Seat Height 790mm
Wheelbase 1334mm Ground
clearance 160mm Minimum
turning radius 2340mm

Weight
With gasoline and oil 135.0kg
Peak load 195.0kg
2-1

ESPECIFICACIONES DE MOTOR

ENGINE SPECIFICATIONS

Engine
Engine Type 4-stroke, air-cooled SOHC
153.0cm
3
Displacem
ent
Cylinder Layout A cylinder leaning forward
Bore x stroke 58.0 x 57.9mm
Compression Ratio 9.50:1
Compression pressure (at sea level) 1200kPa
Starting System Electric start, Kickstarter (According
the
Country)
Fuel
Recommended fuel Regular unleaded regular gasoline
Fuel Tank Capacity 12.0 L
Reserve capacity 1.4 L

Motor oil
Lubrication system Wet sump
Type SAE20W50
Recommended grade of motor oil YAMALUBE (Grade-SG)
Quantity of engine oil
Periodic change 1.00 L

Total change 1.20 L

Oil filter
Type oil filter Paper

Oil pump
Type of oil pump Troco-ide
Internal rotor clearance to the outer rotor Less than 0.15mm
Limit 0.20mm
Clearance external rotor casing to the oil
pump 0.13-0.19mm
Limit 0.15 mm
Clearance of the casing until the oil pump
inner rotor and outer rotor 0.06 0.11 mm
Limit 0.15mm
2-2


Spark plug (s)
Manufacturer / Model NGK / CPR8EA-9
Electrode gap 0.8-0.9mm

Butt
Volume 13.40-14.00cm ³
Maximum deformation 0.03mm

Camshaft
Traction system Transmission chain (left) Dimensions of
camshaft lobes
Admission 31,342 - 31.44 2mm
Limit 31.342mm
Admission B 25,166 - 25.26 6mm
Limit 25.136mm
Escape A 31,110 - 31.210mm
Limit 31.080mm
Escape B 25,096 - 25.19 6mm
Limit 25.066mm

B

A

Strain Limit 0.03 mm camshaft

2-3


Timing Chain
Model Silent Chain
Tensioning System Automatic

Rocker / Rocker
Bore rocker 9985-10.000mm
Limit 10.030mm
Outside diameter of rocker 9966-9.976mm
Limit 9.950mm

Valves, valve seats, valve guides
Valve clearance (cold)
Admission 0.08-0.12mm
Exhaust 0.12-0.16mm
Valve Dimensions
Diameter of valve head 27.90-28.10mm
A (Admission)
Diameter of valve head 23.40-23.60mm
A (escape)

A
Face width valve B (Admission) 1538-2.138mm
Face width valve B (Escape) 1538-2.138mm

B

Width C valve seat (Admission) 0.90-1.10mm
Seat width valve C (Escape) 0.90-1.10mm

C

Margin thickness D Valve (Intake) 0.50-0.90mm
Thickness of the valve margin D (Escape) 0.50-0.90mm

D

Diameter of valve stem (Admission) 4975-4.990mm Limit
4.950mm
Diameter of valve stem (Escape) 4960-4.975mm
Limit 4.935mm Internal
diameter of the valve guide (Admission) 5.000-5.012mm
Limit 5.042mm
Internal diameter of the valve guide (Escape) 5.000-5.012mm
Limit 5.042mm
Tolerance between the valve stem and the guide 0.010-0.037mm
(Admission)
2-4


Limit 0.080mm Tolerance
between the valve stem and the guide (Escape) 0.025-0.052mm Limit
0.100mm
Limit deformation of the valve stem 0.010mm

Valve Spring
Free length (Admission) 39.40mm
Limit 37.40mm
Free length (Escape) 39.40mm
Limit 37.40mm
Installed length (Admission) 34.50mm
Installed length (Escape) 34.50mm
Spring spring constant K1 (Admission) 35.08N/mm Spring spring
constant K2 (Admission) 44.40N/mm
Spring Spring constant K1 (Escape) Spring 35.08 N / mm
Spring constant K2 (Escape) 44.40 N / mm
Force compression spring installed (Admission) 160-184 N
Force compression spring installed (Escape) 160-184 N
Tilting the compression spring (Admission) 2.5 ° / 1.7mm
Tilting the compression spring (Escape) 2.5 ° / 1.7mm

Address threading (Admission) Clockwise
Address threading (Escape) Clockwise

Cylinder
Diameter 58,000-58.010mm
Limit of taper 0.05mm
Limit ovalamiento 0.05mm

Piston
Tolerance between the piston and cylinder 0.020-0.035mm
Limit 0.15mm
Diameter D 53,970-53.985mm
2-5


H
D

Deviation

-
0.25 mm
Direction of deviation Side A-dmission
Diameter hole for the piston pin 15.002 15.013 mm
Limit 15,043 mm
Outer diameter of piston pin 14.995 15.000 mm
Limit 14,975 mm

Piston rings
Top ring
Ring type Barrel
Dimensions (B × T) 0.80 x 2.30 mm

B

T

Distance between ends (installed) 0.10 to 0.25 mm
Limit 0.40 mm
Ring side clearance 0030-0065 mm
Limit 0.100 mm
Second Aro
Ring type Conical

B
T

Limit 0.40 mm
Ring side clearance 0020-0055 mm
Limit 0.100 mm
Aro oil

B

T

2-6


Rod
Small end bore 14090-15028 mm
Large end bore 36000-36009 mm

Crankshaft
Width A 47.95-48.00 mm
Maximum deformation C Side clearance
0.030 mm large side D 0110-0140 mm

Balancer
Method of synchronizing the balanced Gear

Clutch
Clutch type oil-bathed multi-disc clutch release method inside push, driven by cam
clearance clutch lever 10.0-15.0 mm
Thickness of the friction plates 2.90-3.10 mm
wear limit 2.80 mm
Number of discs 4 pcs
Thickness of clutch plates 1.85-2.15mm
Number of discs 3 pcs
Flatness Limit 0.20
Free length of clutch springs 41.60 mm 40.60 mm
Minimum length of springs 4 pcs Quantity
Flexion maxim of the dipstick of push 0.500 mm
Transmission
Transmission Type 5-speed constant mesh
Primary reduction system spur
Primary reduction ratio 75/22 (3409)
Secondary reduction system Chain transmission
Secondary reduction ratio 40/14 (2857)
Operation Operation with left foot
Gear ratios
The 1st 38/14 (2,714)
The 2nd 34/19 (1,789)
The 3rd 29/22 (1,318)
The 4th 23/22 (1,045)
The 5th 21/24 (0875)
2-7

Change mechanism
Type shifting mechanism Rod drive mechanism and guide
Thickness shift fork 4.76-4.89 mm

Decompression device
Type of device Auto-decompressor

Air filter
Air filter element Dry element
Carburetor
Type X Quantity BS26X1
Identification mark 21C1110
Main jet # 112.5
Main jet air 0.9
Needle 4D1Z11
Needle seat P-1M
Output Supplier 0.8
Pilot Supplier # 15
Pilot screw turns 3-1/4
Size of the valve seat 1.5
Power Supplier 1 # 35
Supplier Power 2 0.7
Trigs of the valve of accelerator 1.25
Idle Condition
Engine idling 1300-1500 r /
min Oil temperature 75.0-85.0 ° C
CO% 2.0-6.0
Empty admission Temperature
27.9-33.3 kPa plug base 110.0-130.0 ° C
type oil filter Paper
Throttle cable slack 3.0-5.0 mm
2-8

ESPECIFICACIONES DE CHASIS

CHASSIS SPECIFICATIONS

Chassis
Chassis type Diamond
Angle 25.00 º
Avance 101.2 mm
Front Wheel
Wheel Type Casting wheel
Rim size 17 M/CXMT2.50
Material of rim Aluminum
wheel travel 130.0 mm radial deviation
limit wheel 1.0 mm
lateral deviation limit wheel 0.5 mm

Rear Wheel
Wheel Type Casting wheel
Rim size 17 M/CXMT3.50
Material of rim Aluminum
wheel travel 120.0 mm radial deviation
limit wheel 1.0 mm
lateral deviation limit wheel 0.5 mm
Front wheel
Type Tubeless Size 100/80-17M/C 52P
Manufacturer / Model MRF / ZAPPER-X
Rear tire
Type Tubeless
Size 140/60 R-17 M / C 63P
Manufacturer / Model MRF / ZAPPER-X
RevZ
Air pressure of the tires (Measure cold)
Lead 200 kPa, 28psi
Rear 225 kPa, 33psi

Front brake
Type A disc brake
Operation Operation with the hand right
2-9


Front brake disc
Thickness and outer diameter of the disc 267.0 x 4.0 mm
Limit brake disc thickness 3.5 mm
deviation limit of the brake disc 0.10 mm
thickness covering brake pads (interior) 4.5 mm Limit 0.8 mm
coating thickness of the brake pads (outside) 4.5 mm Limit 0.8 mm bore
master cylinder 12.00 mm
inner diameter cylinder 28.0 mm x 2
Recommended liquid DOT3 or DOT4

Back brake
Drum brake type Drum Brake
Operation Operation on the right foot
Free pedal brake 15-20 mm

Rear Drum
Rear drum type Avance tour
Inner diameter of the brake drum 130.0 mm
Limit 131.0 mm
coating thickness of shoes 4.0 mm brake
(interior)
Limit 2.0 mm
free length spring shoes 52.0 mm
Free length of spring shoes 2 48.0 mm

Address
Bearing type steering Ball-bearing
Angle stop (left) 39.0 °
angle stop (right) 39.0 º

Front fork
Type Telescopic fork
Type damper / spring Oil damper / coil spring
Front fork travel Free Length 130.0 mm fork spring
Necklace length 254.4 mm
Length
221.0mm installed 246.4 mm
spring tension K1 9.0 N / mm spring tension K2
10.50 N / mm spring K1 Race
Spring Career 0-75.0 mm K2
75.0-130.0 mm outer diameter inner tube
41.0 mm
Recommended oil Suspension Oil 10W or
equivalent
Amount 459.0 cm3
Level 87.0 mm

Rear Suspension
Type Rocker (Monocross)
Type damper / spring Oil damper / coil spring
Rear Shock Travel 130.0 mm
assembly
2-10

Spring Free Length 187.0 mm installed length

178.0 mm
spring tension K1 120.0 N / mm spring K1 Race
0.0-20.0 mm

Rocker
Free game at the end of the swingarm
(Limit axial) 2.4 mm

Drive chain
Type / manufacturer R428HBSX/LGB
Number of links 128
Clearance transmission chain 30.0-40.0 mm
Limited in length 15 links 191.5 mm
2-11

ESPECIFICACIONES ELÉCTRICAS

ELECTRICAL

Voltage
System voltage 12V

Ignition system
Ignition system DC, CDI
feed type Digital
Ignition advance (B.T.D.C.) 7.0 ° / 1400r/min
Coil Resistance Pulse 192-288Ù at 20 ° C

Ignition Coil
Primary coil resistance 0.32-0.48Ù at 20 °
C secondary coil resistance 5.68-8.52Ù at 20 °
C

Plug cap
Material Resin
Resistance 5kÙ at 20 ° C

Magneto CA
Standard Output 14.0V 125W @ 5000 rpm
Resistance of the stator winding 0464-0.696Ù at 20 ° C

Regulator / rectifier
Regulator Type Semiconductor-Closed Circuit
Regulated voltage (CD) 13.7-14.7 V
rectifier capacity 20.0 A

Battery
Model AB5L-B
voltage, capacity 12 V, 5.0 Ah
rate amperage 10 hours 5.0A

Lamp bulb
Bulb type Halogen bulb

Voltage, wattage bulb and quantity
Streetlight 12 V, 35 W X 1 W/35.0
Tail / Brake 12 V, 5.0 W X 1 W/21.0
Front directional light 12 V, 10.0 W × 2
Rear directional light 12 V, 10.0 W × 2
Light Meter L.E.D.
Auxiliary light 12 V, 5.0 W × 1

Indicator Light
LED indicator light neutral indicator light LED
directional indicator light beam LED Warning Light
LED engine failure
2-12

ESPECIFICACIONES ELÉCTRICAS

Electric Power System
System Type Constant mesh

Starter
Output power 0.25 kW

Starter relay
Amperage 100 A coil
resistance 3.51-4.29 Ù

Horn
Horn type Flat Amount
Maxim
um Amperage 1 pc 1.5 A

Turn signal relay
Type of relay Transistor relay
Integrated self-cancellation device No
Signal frequency of blinking 70-100 cycles / min
Fuel Gauge
Unit resistance meter 19.0-21.0Ù
Resistance at 20 meter unit 137.0-143.0Ù at 20 °
C

Ignition cut relay
Coil Resistance 90.0-110.0Ù

Fuse
Fuse 15.0 A
2-13

PARES DE APRIETE

TORQUE

GENERAL OF TORQUE

This chart specifies tightening torques for
standard fasteners with thread ISO normalized.
The torque specifications for special
components or assemblies mentioned in each
chapter of this manual. To prevent distortion,
cross-clamping sets with multiple attachment
points, in progressive stages, until the specified
torque. If not otherwise specified for torque.
Threads must be clean and dry. The
components, in turn, should be at room
temperature.

A: Face to face
B: Outer diameter of the thread

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

PARES DE APRIETE DE MOTOR

MOTOR TORQUE

Size
Item the Amount Torque Observations
threa
Head screws (interior) M8 4 22 Nm (2.2 m kg, 16ft Ib) E
Head screws (side chain) M6 2 10 Nm (1.0 m kg, 7ft Ib) E
Plug M10 1 13 Nm (1.3 m.kg, 9ft.Ib)

Cylinder head cover bolts (Conduit) M6 10 10 Nm (1.0 m.kg, 7ft.Ib)
Head screws (EP) M8 2 15 Nm (1.5 m.kg, 11ft.Ib)
Balancer sprocket nut M10 1 45 Nm (4.5 m.kg, 33ft.Ib)
Screw nut M6 2 13 Nm (1.3 m.kg, 9ft.Ib)
Screw decompressor M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Screw small chain guide 2 M6 1 8 Nm (0.8 m.kg, 6ft.Ib)
Screws tensor M6 2 9 Nm (0.9 m.kg, 7ft.Ib)
Cap screws M6 2 9 Nm (0.9 m.kg, 7ft.Ib)
Rocker Screws M5 2 8 Nm (0.8 m.kg, 6ft.Ib)
Screws oil pump M5 2 4 Nm (0.4 m.kg, 3ft.Ib)
Oil Drain Plug M12 1 20 Nm (2.0 m.kg, 14ft.Ib)
Element cover screws M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Element cover screws M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Sprocket cover screws M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Screws manifold M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Screw Air Filter (Chassis) M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Screws through M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
AIS system screws M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
Silencer comp. nut (side butt) M8 2 15 Nm (1.5 m.kg, 11ft.Ib)
Silencer comp. screw (bottom
M8 1 12 Nm (1.2 m.kg, 9ft.Ib)
right)
Silencer comp. screw (bottom
M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
left)
Twang Muffler (Side RR. Higher) M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Screw crankcase 1 and 2 M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Screw crankcase 1 and 2 M6 4 10 Nm (1.0 m.kg, 7ft.Ib)
Crankcase Screw 2 M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Crankcase cover 1 M6 6 10 Nm (1.0 m.kg, 7ft.Ib)
Cover plug housing 1 (Cover timestamp) M14 1 3 Nm (0.3 m.kg, 2ft.Ib)

Cover plug housing 1 (Cover crankshaft) M32 1 3 Nm (0.3 m.kg, 2ft.Ib)

Cover transmission chain M6 7 2 Nm (0.2 m.kg, 1ft.Ib)

Crankcase cover screw M6 11 10 Nm (1.0 m.kg, 7ft.Ib)
2-15


Size
threa
Screw crankcase 1 and 2 M6 1 10 Nm (1.0 m.kg, 7ft.Ib) E
Kickstarter Nut M12 1 50 Nm (5.0 m.kg, 36ft.Ib) E
Screw guide sprocket M6 2 12 Nm (1.2 m.kg, 9ft.Ib)

Screw engine clutch
M6 3 14 (1.4 Nm m.kg, 10ft.Ib)
Boot
Main gear nut M12 1 60 (6.0 Nm m.kg, 43ft.Ib)
The pressure plate screws 1 M6 4 8 Nm (0.8 m.kg, 6ft.Ib)
Screw pushrod 1 M6 1 8 Nm (0.8 m.kg, 6ft.Ib)
Clutch Nut M14 1 70 Nm (7.0 m.kg, 51ft.Ib)
Screw drive sprocket M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Screw the cover plate ta M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Screw cap lever M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Shift cam screw M6 1 12 Nm (1.2 m.kg, 9ft.Ib)
Screw the stator M6 3 10 Nm (1.0 m.kg, 7ft.Ib)
Screws pulse coil M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Nut Magnet M12 1 70 Nm (7.0 m.kg, 51ft.Ib)
Neutral switch M10 1 20 Nm (2.0 m.kg, 14ft.Ib)
Screws starter M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
2-16


Sequence cylinder head tightening

5

Torque Sequence magneto cover

7
1.6 8
5

9
4

3
2.10
Tightening sequence clutch cover

1.9
8 10
11

7 12

6

13
5

4 3.15 2.14
2-17


Crankcase tightening sequence

A B

14
1.6 7
8 15

9
5
2.12

4
10
3.13 11

A. Carter left
B. Right side crankcase
2-18

PARES DE APRIETE

TORQUE
Size
thread
Screw steering column M8 2 16 Nm (1.6 m kg, 12ft Ib) E
Nut of the steering column M22 1 110 Nm (11.0 m kg, 80ft Ib) E
Lower ring nut (Initial) M25 1 33 Nm (3.3 m.kg, 24ft.Ib)

Upper ring nut (Final) M25 1 22 Nm (2.2 m.kg, 16ft.Ib)
Front fender M6 1 6 Nm (0.6 m.kg, 4ft.Ib)
Switch / block
M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
address
Support lamppost M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Support lever M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Screw handlebar switch M5 2 10 Nm (1.0 m.kg, 7ft.Ib)
Screw meter and streetlight M5 3 1 Nm (0.1 m.kg, 1ft.Ib)
License holder bolts M5 2 4 Nm (0.4 m.kg, 3ft.Ib)
Screw lamppost M6 3 7 Nm (0.7 m.kg, 5ft.Ib)
Screw end cap lamp M4 4 2 Nm (0.2 m.kg, 1ft.Ib)
Front engine mount M10 2 55 Nm (5.5 m.kg, 40ft.Ib)
Front Engine Support M8 2 55 Nm (5.5 m.kg, 40ft.Ib)
Screw top engine mount M8 3 30 Nm (3.0 m.kg, 22ft.Ib)
Swingarm pivot nut M12 1 46 Nm (4.6 m.kg, 33ft.Ib)
Rear shock lower nut M12 1 60 Nm (6.0 m.kg, 43ft.Ib)
Rear shock top nut M12 1 40 Nm (4.0 m.kg, 29ft.Ib)
And tilt tension bar M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Screw fuel cock M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Ignition coil screw M6 2 7 Nm (0.7 m.kg, 5ft.Ib)
Screw the cover later M6 1 2 Nm (0.2 m.kg, 1ft.Ib)
Screw Battery Case M6 3 7 Nm (0.7 m.kg, 5ft.Ib)
Screw gauge unit
M5 4 4 Nm (0.4 m.kg, 3ft.Ib)
fuel
Nut regulator, rectifier M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
Seat lock. M6 1 4 Nm (0.4 m.kg, 3ft.Ib)
Screw end cap M6 4 2 Nm (0.2 m.kg, 1ft.Ib)
Screw manigueta M8 4 25 Nm (2.5 m.kg, 18ft.Ib)
Screw taillight M5 2 2 Nm (0.2 m.kg, 1ft.Ib)
Nut reflective back M5 1 2 Nm (0.2 m.kg, 1ft.Ib)
Screw ierta cub tank top
M5 10 2 Nm (0.2 m.kg, 1ft.Ib)
fuel
Tank side cover screw
M5 2 2 Nm (0.2 m.kg, 1ft.Ib)
fuel
Guide air half lead screw air M5 2 2 Nm (0.2 m.kg, 1ft.Ib)
Screw air guide M6 2 2 Nm (0.2 m.kg, 1ft.Ib)
Horn Nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
2-19

PARES DE APRIETE

Size
thread
Nut front wheel axle M14 1 60 Nm (6.0 m.kg, 43ft.Ib) E
E
Nut rear wheel axle M14 1 90 Nm (9.0 m.kg, 65ft.Ib)
Screw crown and hub
clutch M8 6 43 Nm (4.3 m.kg, 31ft.Ib)
Tension bar and brake shoe plate M8 1 20 Nm (2.0 m.kg, 14ft.Ib)
Camshaft and brake lever M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
The clamp screw s M10 2 35 Nm (3.5 m.kg, 25ft.Ib)
Brake Disc Screws M8 6 30 Nm (3.0 m.kg, 22ft.Ib)
Screws master cylinder M6 2 10 Nm (1.0 m.kg, 7ft.Ib)
Brake pedal and footrest M10 1 30 Nm (3.0 m.kg, 22ft.Ib)
Screw footrest is and chassis M8 2 35 Nm (3.5 m.kg, 25ft.Ib)
Nut lateral support M10 1 44 Nm (4.4 m.kg, 32ft.Ib)
Nut central support M10 2 46 Nm (4.6 m.kg, 33ft.Ib)
Shift pedal nut M8 1 2 Nm (2.0 m.kg, 22t.Ib)
Nut holder-side bracket and
chassis M10 1 44 Nm (4.4 m.kg, 32ft.Ib)
Support plate nut nut
footrest M6 2 8 Nm (0.8 m.kg, 6ft.Ib)
Nut attachment arm
changes M6 1 10 Nm (1.0 m.kg, 7ft.Ib)
Nut Rear brake switch M6 1 7 Nm (0.7 m.kg, 5ft.Ib)
2-20

PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE

LUBRICATION POINTS AND LUBRICANT TYPES

Point Lubrication Lubricant
Edge oil seals LS
Bearings E
O-rings LS
Head screws and washers E
Thrust surface of the large end of the rod E
Piston, piston rings and the inner surface of the cylinder E
Inner surface of the balancer sprocket E
Camshaft Lobe M
Decompression cam E
Valve stem seal M
Valve stems (intake and exhaust) M
The valve stem ends (intake and exhaust) M
Rocker Shaft E
Inner surface of the rocker shaft M
Pin decompression lever M
Oil Seal (Clutch cover) E
Gear oil pump E
Rotor oil pump (internal and external) E
Pinion thrust surface free starter clutch E
Freewheel shaft starter clutch E
And internal surface of the pinion thrust surface clutch E
Boot
Starter clutch rollers E
Clutch thrust cam E
Primary pinion inner surface E
Clutch Pushrod (short and long) and pellet E
Contact surface of the nut fixing the clutch hub and E

lockwasher
Transmission gear (wheel and pinion) and necklace M
Changes forks and fork guide bar changes E
Gear drum E
Axis of changes E
2-21



Yamaha Adhesive
Crankshaft Position Sensor / washer assembly stator lead
No. 1215 (Three
Bond No.1215R)
Yamaha Adhesive
Contact surface of carcasses No. 1215 (Three
Bond No.1215R)
Yamaha Adhesive
Screws chain tensioner distribution No. 1215 (Three
Bond No.1215R)
2-22


Seal edges of the front wheel (left and right) LS
Outer surface of the front wheel shaft LS
LS
Speed Sensor Unit
LS
Seal edges of the rear wheel hub
LS
Contact surface of the rear wheel hub
LS
Outer surface of the rear wheel axle
S
Rear wheel axle and the threads of the nut
S
Pivot point of the brake pedal shaft
Inner surface of the slide pin holder clamp LS
brake
Inner surface of the guide of the throttle grip and cable LS
accelerator
S
Extreme clutch cable and clutch lever
LS
Outer surface of the pivot brake lever
Bearings of the steering column and the edges of the cover LS
upper bearing
LS
Dust of the steering column
LS
Threads of nuts and bolts (relay arm and calls)
LS
Threads of nuts and bolts (Biela and relay arm)
LS
Threads of nuts and bolts (rear shock and relay arm)
LS
Threads of nuts and bolts (relay and rocker arm)
LS
Threads of nuts and bolts (Biela and tilt)
LS
Edges of oil seals (relay and rocker arm)
LS
Hubs (relay and rocker arm)
LS
Pivot axis of the nut and threads
LS
Outer surface of the pivot axis
LS
Outer surface of the swingarm bushing
LS
Edges dusty swingarm
LS
Pivot point lateral support and movement point metal to metal
LS
Footrest pivot point
LS
Pivot Point Passenger footrest
LS
Pedal pivot point changes
I Tornill and motor mounting nuts E
2-23


LUBRICATION SYSTEM TABLES AND CHARTS

TABLE OF ENGINE OIL LUBRICATION

5

3

4

2

6
1

7

1. Oil Strainer
2. Oil pump
3. Oil Filter Element
4. Crankshaft
5. Camshaft
6. Main shaft
7. Driven shaft
2-24


LUBRICATION DIAGRAMS

1

2
A

3

4

5

6

7
1. Clutch thrust lever
2. Main shaft
3. Drive shaft
4. Crankshaft
5. Oil filter
6. Oil pump
7. Oil Strainer
A. Towards the head
2-25


LUBRICATION DIAGRAMS

1

2

3

4

1. Camshaft
2. Crankshaft
3. Main shaft
4. Driven shaft
2-26

GUIADO DE CABLES

3 1 A 10
4
965

3 7
C
G
8
6
F 11
5
2 12
2 RR C 8
1 7
A 4
5
4 13 D
6

2 14 11
3 9

B 9 D
1
R-R

12
B
H
1
I
2-27

GUIADO DE CABLES

1. Front brake hose
2. Throttle Cable
3. Cable front brake switch
4. Cable right handlebar switch
5. Cable left handlebar switch
6. Clutch switch lead
7. Clutch Cable
8. Cable boot
9. Main switch lead
10. Meter Cable
11. Cable the right front turn signal
12. Cable left front directional light
13. Cable lamppost
14. Cable Auxiliary Light
A. Go through the right guide bracket lamp RHS B. Go
through the right guide bracket lamp RHS C. Go through the left guide bracket lamp LHS D.
Go through the left guide bracket lamp LHS E. Hold the bracket clamp lamp
F. Run the cable from the right front directional guidance through
G. Pass the cable through the left front directional guide
H. Pass the wire harness, cables handlebar switch, the cable from the sensor unit through the
lamp guide bracket
I. The cable sensor unit through the guide bracket lamppost
2-28

GUIADO DE CABLES

17
3 17 17
13 2
5

4 13
E-E B-B D-D C-C

1A
3 2 4 B
C

5
F
E
DC

14 S
S
J E
D
C
15
L
16

M
N
I
D
6
GH M 7

11 8

F2
E

10
9

Februa

13 14 11
ry 12
13

14
16
15 16
6
L 12 N
2 15 S-S 6 M-M
J
2-29

GUIADO DE CABLES

1. Clutch Cable
2. Overflow pipe
3. Throttle Cable
4. Cable boot
5. Carburetor vent hose
6. Magneto Cable CA
7. Negative cable
8. Breather hose battery
9. Carburetor drain hose
10. Fuel Hose
11. Speaker wire
12. Connector Cover
13. Harness
14. Cable sensor unit
15. Cables left handlebar switch
16. Cables right handlebar switch
17. AIS hose
A. Clutch cables and starter cable through the guide
B. Overflow pipe through the left edge of the fuel tank
C. Throttle cable and starter cable through the guide
D. Attach the AC magneto lead frame bracket
E. Pass the breather hose from the battery and the carburetor drain hose through the holes
in the hose joint
F. Pass the overflow pipe through the guide
G. Pass the wire harness, cable sensor unit, cables handlebar switch through the guide
H. Pass the speaker wire, after spending the overflow tube through the guide
I. Pass the wire harness, cable sensor unit, cables handlebar switch through the guide
J. Inserting the projection of the connector housing through the hole in the chassis
K. After connecting the cable, all cables are covered by the connector cover. The bare wires
do not protrude from the connector housing.
2-30

GUIADO DE CABLES

6 9
10
8

5 11

February 3
4
1

7

10
3

20

A

19 13

18

17

16
15
22
21
12

14
15 A-A
2-31

GUIADO DE CABLES

1. Left Handlebar switches
2. Clutch switch lead
3. Clutch cable
4. Cable left handlebar switch
5. Cable Boot
6. Main switch lead
7. Cable right handlebar switch
8. Brake Hose
9. Cable front brake switch
10. Accelerator cable
11. Handlebar switches right
12. Cable left rear directional light
13. Turn Signal Relay
14. Cable tail light unit
15. Cable right rear directional light
16. Cover the seat lock
17. Cable lock seat
18. Relay circuit starter cut
19. CDI Unit
20. Carburetor vent hose
21. Rear fender
22. Rear fender cover
A. Insert the breather hose into the hole carburetor air filter
B. Fix cables handlebar switch and clutch with handlebar clamp
C. Fix cables handlebar switches and front brake lever clamping
D. Route the taillight wires through the hole of the rear fender
E. Set the power line and vent hose with 1 bracket
F. Attach the clutch cable and hose vacuum detection with 1 bracket
2-32

GUIADO DE CABLES

25 31

16
17
29 28
5
16
30
10
H-H K-K U-U TT

30
251 31
24 27 23
A18 19 B10 C 21
26 22 E 5
U
T

T

K
16 6
K
P O
8
MN 7
15 H
F
9
G
29 I
H
14
L J 10
13 K Dec. 11
2-33

GUIADO DE CABLES

1. Accelerator cable G. Pass the breather hose from the battery and
2. Cable sensor unit the carburetor drain hose through the engine
3. Brake Hose exterior
4. Speaker wire H. Pass the breather hose from the battery and
5. Cable high the carburetor drain hose through the inside
6. Plug cap of here
7. Starter Cable I. Attach the positive lead and the fuse holder to
8. Cable starter relay the battery belt
9. Fuse holder J. Pass the wire harness through the hook on
10. Negative cable the battery box
11. Carburetor drain hose K. Attach the controller cable, rectifier, wire
12. Breather hose battery harness and cable brake switch chassis
13. Starter relay clamp
14. Brake switch L. Pass the wire harness through the rear of
15. Battery the battery box
16. Harness M. Pass the wire harness through the slot on the
17. Cable regulator, rectifier air filter cover
18. Air filter cover N. Adjust the white label wiring harness with the
19. Regulator rectifier clamp on the right side of the battery box
20. Carburetor breather hose O. Attach the negative cable and fuse. The
21. Positive cable positive cable to the battery belt
22. Magneto Cable CA
23. Ignition Coil
24. Cable ignition coil
25. Clutch Cable
26. Cable throttle position sensor
27. Fuel Meter Cable
28. Battery box
29. Brake switch lead
30. Detecting vacuum hose
31. Hose AIS
A. Pass the wire harness through the air filter
guide
B. Pass the wire harness, the negative cable
through the rear hook of the battery box
C. Adjust the white mark wire harness with a
clamp
D. Tighten the clamp on the rear engine mount
chassis 1
E. Opposite the clamp white painted detection
vacuum hose 1
F. Route the starter relay and the starter through the clamp on the
battery box
2-34

PERIODIC MAINTENANCE AND ADJUSTMENT

PERIODIC MAINTENANCE ................................................ 3-1 ..........................
Periodic maintenance and lubrication intervals ... 3-1
ADJUSTMENT valve clearance ........................................ 3-3

ENGINE IDLE ADJUSTMENT ............................................. 3-3 ............
CO measurement and adjustment ............................................. ..................... 3-5
ADJUSTING THE THROTTLE CABLE SLACK ................... 3-6
SPARK PLUG INSPECTION .............................................. 3-7 ..........................
ON INSPECTION TIME ......................................... 3-7
MEASURING THE COMPRESSION PRESSURE ....................................... 3-8
OIL LEVEL INSPECTION ............................................. 3-9 ..........
ENGINE OIL CHANGE ............................................. ............... 3-9
FREE PLAY ADJUSTMENT CABLE CLUTCH .................. 3-10
CLEANING THE AIR FILTER ELEMENT .................................. 3-11
CHECK THE BOARD AND CARBURETOR
CONNECTING THE AIR FILTER BOX ................................. 3-12
CHECK THE BREATHER TUBE HEAD ............................... 3-12
CHECK THE EXHAUST SYSTEM ............................................. 3-12 ......
Check the filter of the fuel tap ...................... 3-13
REAR BRAKE ADJUSTMENT .............................................. 3-14 ..............

CHECKING THE BRAKE FLUID LEVEL ................................ 3-14
CHECKING THE FRONT BRAKE PADS ................ 3-15
CHECKING THE FRONT BRAKE HOSE ................. 3-15
CHECKING THE REAR BRAKE PADS ....................... 3-15
SWITCH ADJUSTMENT REAR BRAKE LIGHT ....... 3-15
BLEEDING THE HYDRAULIC BRAKE .................................. 3-15
CLEARANCE ADJUSTING THE DRIVE CHAIN ............ 3-16
DRIVE CHAIN LUBRICATION ................................... 3-17
CHECKING AND ADJUSTING THE STEERING ................. 3-18
FRONT FORK INSPECTION .................................... 3-19
TIRE INSPECTION .............................................. ............... 3-19
CHECKING THE WHEELS .............................................. 3-20 .................
INSPECTION AND LUBRICATION. CABLES ................................ 3-20
LUBRICATION CLUTCH LEVER ............................... 3-20
LUBE BRAKE LEVER ....................................... 3-21
LUBRICATION PEDALS .............................................. 3-21 ............
LUBRICATION SIDESTAND ............................................. 3 -21
LUBRICATING THE REAR SUSPENSION ................................... 3-21
Rear shock absorber adjustment ........................................... 3.21

TROUBLESHOOTING

ELECTRICAL ................................................ ...................................... 3-22
INSPECTION AND CHARGING ............................................ 3-22 ......
Fuse inspection ............................................... ...................... 3-22
BULB REPLACEMENT FAROLA ........................................... 3 - 22
SETTING THE BEAM BULB FAROLA ................................. 3-23
AUXILIARY BULB REPLACEMENT .............................................. 3-23
BULB REPLACEMENT TAILLIGHT / BRAKE LIGHT ....... 3-23
LIGHT BULB REPLACEMENT INDICATOR .............................. 3-24

MANTENIMIENTO PERIÓDICO

PERIODIC MAINTENANCE

Table of lubrication and routine maintenance
NOTE:
All maintenance must be performed according to routine maintenance program (discussed below) to maintain the best performance of the
vehicle.
The items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data
and technical skills.

READING
OR MAINTENANCE INSPECTION ODOMETER (x 1000
NOT. ELEMENT
km)
1 3 6 9 12 15
Line • Check fuel lines are 䌮䌮䌮䌮䌮
1 *
fuel cracked or damaged.
• Check the condition
2 Plug • Clean and adjust the tolerance
• Change Every 12000 km
• Review tolerance 䌮䌮䌮䌮䌮
3 * Valves
• Set
• Clean 䌮䌮䌮䌮䌮
4 * Air filter
• Change Every 12000 km
• Check the output voltage 䌮䌮䌮䌮䌮
5 * Battery
• Check the electrolyte / specific gravity
• Check operation.
6 Clutch • Adjust. 䌮䌮䌮䌮䌮䌮
• Lubricate lever
• Check operation, fluid level and 䌮䌮䌮䌮䌮䌮
Front leakage.
7 *
brake Always to the limit
• Replace brake pads
wear
• Check operation of the brake shoes
brake
䌮䌮䌮䌮䌮䌮
8 Back brake
Always to the limit
• Change the brake shoes
wear
Hose • Check for cracked or damaged. 䌮䌮䌮䌮䌮
9 *
brake • Change Every 4 years
10 * Wheels • Check runout or dañada.s 䌮䌮䌮䌮䌮
• Check tread depth and if
damaged.

11 * Tires • Replace if necessary. 䌮䌮䌮䌮䌮
• Check air pressure.
• Correct if necessary.
Bearings • Check bearing for looseness or 䌮䌮䌮䌮䌮
12 *
wheel damaged.
• Check operation and clearance is 䌮䌮䌮䌮䌮䌮
13 * Rocker excessive.
• Lubricating grease based on lithium soap. Every 12000 km
• Check chain slack, alignment and condition
Every 500 km and after
Drive chain chain.
14 washing the motorcycle or
• Adjust and lubricate chain with a chain
riding in the rain
lubricant
3-1

MANTENIMIENTO PERIÓDICO

READING
OR MAINTENANCE INSPECTION ODOMETER (x 1000
NOT. ELEMENT
km)
1 3 6 9 12 15
Bearing
• Check bearing for play and if the 䌮䌮䌮䌮䌮䌮
15 * steering for roughness
direction
• Lubricating grease based on Every 12000 km
Fasteners • Check that all nuts, bolts and 䌮䌮䌮䌮䌮
16 *
frame screws are properly tightened.

Side support
17 / Central
• Check operation. 䌮䌮䌮䌮䌮
• Lubricate
Fork
• Check operation and for oil 䌮䌮䌮䌮䌮
18 * lead
leakage.
Set

amortiguadore • Check operation and 䌮䌮䌮䌮䌮
19 *
s shock absorber for oil
leakage.
Motor oil • Change. 䌮䌮䌮䌮䌮䌮
20 *
• Check oil level and leaks.
Oil filter • Change. 䌮 Every 10000 km
21 motor (odometer)

Switches
Front and
• Check operation
22 rear brake 䌮䌮䌮䌮䌮䌮
Pieces
25 * phones • Lubricate. 䌮䌮䌮䌮䌮䌮
and

Grip housing
throttle and
• Check operation and free play.
• Adjust the free play of the

26 * cable throttle cable if necessary. 䌮䌮䌮䌮䌮䌮
• Lubricate the throttle grip housing
and
Air • Check the air cut-off valve, the

Induction reed valve and pipe damage. 䌮䌮䌮䌮䌮
27 *
System • Replace damaged parts if
necessary.
Lights,
signals • Check operation. 䌮䌮䌮䌮䌮䌮
28 *
and switches • Adjust the light of the street lamp
(if needed).

NOTE: Theair filter needs
morefrequentserviceifyoudriveonexcessivelywetordustyareas.
Hydraulic brake service.
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the master cylinder, the brake caliper and brake fluid
change.
Replace the brake hoses every four years or when you notice cracks or damage.
3-2

MOTOR

MOTOR
a. Rotate the crankshaft in the opposite direction of the
b. When the piston is at top dead center (TDC) of the
ADJUSTING THE VALVE CLEARANCE compression stroke, align the "a" in the magnet with
The following procedure applies to all valves. the fixed point "b" of the magneto cover.

NOTE:
Adjusting the valve clearance should be done
with the engine cold at room temperature. b
When you measure or adjust the valve
clearance, the piston must be at top dead
center (TDC) in the race

1.

Remov
e: Seat
to
Refer to "GENERAL CHASSIS" on page 4-1
Fuel tank c. Verify that the camshaft lobes are positioned as
Refer to "GENERAL CHASSIS" on page 4-2 shown in the illustration.
2. Disconnect
Hose air induction system Refer to "AIR
INDUCTION SYSTEM" on page 6-9
3. Remove:
Head cover
Gasket head cover
See "HEAD" on page 5-5
4. Remove:
Screw access time to the mark "1" to access the end screw
of the crankshaft "2"

NOTE:
In this position, both valves must be some clearance

d. Measure the valve clearance with a feeler gauge
1 "1".
OOS Adu
j st

2

5. Measure:
Valve clearance
OOS Adjust

Valve clearance
(Cold)
Admission
0.08 to 0.12 mm
1
Exhaust 6. Fit:
0.12 to 0.16 mm Valve clearance

a. Loosen the locknut "1".
b. Insert thickness gauge "2" between the end of the
adjustment screw and the valve tip.
3-3

MOTOR
8. Assembly:
2
Barrette
Gasket head cover New
1 Head cover
See "HEAD" on page 5-5

9. Assembly:
Hose air induction system

Refer to "AIR INDUCTION SYSTEM" on page 6-9

10. Assemble
c. Turn the adjustment screw "3" in direction "a" or "b" Fuel tank
to obtain the specified valve clearance.
Side cover
Seat
to Refer to "GENERAL CHASSIS" on page 4-2
b 3 ENGINE IDLE ADJUSTMENT
3 NOTE:

Before adjusting the engine idling, must clean the air
filter element, and motor

1. Start the engine and warm it up for a few minutes.
2. Install: Digital
Tachometer
(In the spark plug wire)
Direction "a"
Increases valve clearance.
Direction "b"
Reduces valve clearance

Tappet screw holder
YSST-706
Wrench adjustment screw
YSST-806A

Hold the adjusting screw to prevent it from
moving and tighten the nut to specification.

Locknut
13 Nm (1.3 m · kg, 9 lb · ft)
3. Check:
Engine idling
d. Recheck the valve clearance. OOS Adjust.
e. If the valve clearance is out of specification,
repeat the adjustment until the specified Engine idling
clearance. 1300-1500 r / min

4. Fit:
7. Assembly: Engine idling
Access to the screw end of the crankshaft (with the O-ring New)
Screw access to the time stamp (together with the O-ring New)
a. Turn the throttle stop screw "1" in direction "a" or
"b" until the specified idling speed is obtained.
3-4

MOTOR

3. Check:
Engine idling
If out of specification? Adjust. See "ENGINE
IDLE ADJUSTMENT" on page 3-4.

4. Insert:
Probe "2" meter CO
1 (Calibrated) by the exhaust pipe "3", using
b to
the appropriate adapter "4"

Direction "a"
Engine idling increases
Direction "b"
Engine idling speed is decreased

8. Remove:
Digital Tachometer
Density 'CO':
2.0 - 6.0%

Out of specification? Adjust.
5. Fit:
Adjust the density of CO through the mixture
screw

Turn the mixture tronillo "5" inward or outward
until the value specified in the density of "CO"

Turn out
The density of the "CO" increases
9. Fit: Turn inward
The density of the "CO" is decreased
Freeplay throttle cable See "free play adjusting

THROTTLE CABLE" on page 3-6
Reset idle as specified

Freeplay 3.0-5.0 mm
throttle cable

5

CO measurement and adjustment

1. Start the engine and leave calendar for the
equivalent of walking 4 kms.
2. Install:
Tachometer in the spark plug wire
3-5

MOTOR

CAUTION c. Tighten the locknut.

Do not alter carburetor adjustments, if engine
performance is good. 1
If necessary, you must register the existing settings
(# of turns) mixture screw.
To check the configuration of the screw
carburetor mixing, follow the to
CO adjustment procedure " b

Ensure proper blanking plug fixation

6. Fit:
5
The engine idle stop screw
accelerator "1"

NOTE:
Engine idling R.P.M.
If not obtain the specified free play throttle cable
1300 to 1500 RPM
on the side of the carburetor, use the adjusting
nut on the side of the handlebar.
FREE PLAY ADJUSTMENT THROTTLE
Keep upright handlebars.
CABLE
NOTE:
Before adjusting the free play of the throttle
cable, adjust the engine idle Handlebar side
a. Slide back the rubber cover "1" b. Loosen the
1. Verify locknut "2"
Clearance "a" throttle cable c. Turn the adjusting nut "3" in direction "a" or "b"
until you obtain the specified free play in the
OOS Adjustment throttle cable

Direction "a"
The free play is increased throttle cable
Direction "b"
The free play is decreased throttle cable

Throttle cable slack
3.0-5.0 mm

2. Adjustment b 3
Throttle cable slack
1
to
2
Carburetor Side d. Tighten the nut
a. Loosen the locknut "1" Throttle Cable e. Slide the rubber to its original position
b. Turn the adjusting nut "2" in direction "a" or
"b" until you obtain the specified free play in WARNING
the throttle cable
After adjusting the free play of the throttle cable,
start the engine and turn the handlebars to the right
Direction "a"
or left to make sure this does not lead to changes in
The free play is increased throttle cable engine idle.
Direction "b"
The free play is decreased throttle cable
3-6

MOTOR

CHECKING THE SPARK

NOTE:

1. Disconnect: Spark Before installing the spark plug, clean the spark
plug plug and gasket.

8. Connect:
2.
The spark plug cap
Remov

e:
ON INSPECTION TIME
Spark
NOTE:
CAUTION Before checking the ignition timing, check the

Before removing the spark plug, clean with connection of all wires around the ignition
compressed air dirt that may have accumulated in system. Cone.xiones sure all are tight and free of

the spark plug hole to prevent it from falling into the 1.
cylinder Remove:

Screw access timestamp is "1"

3. Check:
Type plug (NGK / CPR8EA-9)
Incorrect Switch.
4. Check:
Electrode "1"
Damage / wear? Replace the spark plug.
Insulation "2"
5. Clean:
Spark
(With a spark plug cleaner or wire brush)
6. 1

Measure:

Clearance of spark plug electrodes "a"
(With a feeler gauge) Crankshaft key cap
OOS Adjust. YSST-625

2. Connect:
Strobe "1" Digital Tachometer plug
Distance between the
electrodes of the spark plug wire

0.8-0.9 mm

Lamp flicker

7. Install:
Spark 1

Plug 3. Check:
13 Nm (1.3 m · kg, 9.4 Ignition Time
3-7

MOTOR

CAUTION
a. Start the engine and warm it up for a few
minutes and then leave the engine running at Before removing the spark plug, clean with
specified idle compressed air dirt that may have accumulated
in the spark plug hole to prevent it from falling
Engine idling into the cylinder
1300-1500 r / min
5. Install: Gauge
b. Verify that the stationary pointer "a" in the "1"
magneto cover is within the firing interval "b" of
the rotor magnet.
Incorrect firing interval Verify the Manometer
Ignition system

1
to

b

4. Remove:
Digital Tachometer
Lamp flicker 6. Measure:
Compression pressure
5. Assembly: Out of specification? See steps
Screw access to the time stamp (C) and
(Along with the O-ring New) (d).

MEASURING THE
COMPRESSION PRESSURE Compression pressure
1200 kPa (at sea level)
NOTE:
Insufficient compression pressure will result in
performance loss.
a. Set the main switch in position
1. Measure: "ON"
Valve clearance b. With the throttle open, operate the starter until
OOS Adjust. the gauge reading stabilizes.
Refer to "ADJUSTING c. If compression is above the maximum
Valve clearance "on specification, check carbon deposits on the
- page 3-3 cylinder head, the valve surfaces and piston
2. Start the engine and leave for a few minutes head.
calendar and then off. Carbon deposits Remove.
d. If compression is below the
3. Disconnect: Spark minimum specification, put a spoon of engine oil
plug into the spark plug hole and measure again.
4. See the table below.
Remove
: The
spark
plug

3-8

MOTOR

Compression pressure (with oil applied into
Type
the cylinder) SAE 20W50 (Engine Oil
Reading Diagnosis YAMALUBE-4 times)
Greater than without Piston rings are worn or
damaged ‫וי‬

oil Repair CAUTION

Piston, valves, cylinder Do not allow foreign matter entering the
head gasket possibly crankcase.
Oil-like d e f e c t i v e ‫וי‬
Repair / replace 4. Start the engine, warm it up for several minutes
and then shut.
5. Check the engine oil level again.
7. Remove:
Gauge NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
8. Assemble:
Spark. ENGINE OIL CHANGE
1. Start the engine, warm it up for several minutes
Plug and then shut.
13 Nm (1.3 m · kg, 9.4 ft · lb)
2. Place a container under the oil drain screw
9. Connect: motor.
Spark plug cap. 3. Remove:
Gauge Engine oil level "1". Plug "2".
CHECKING THE ENGINE OIL LEVEL
1. Place the vehicle on a flat surface.
Note:
Place the vehicle on the center stand. Make

sure the vehicle is vertical.
2. Start the engine, warm it up for several minutes
1
and then shut.
3. Check:
Engine oil level.
The engine oil level should be between the
minimum level "a" peak "b"
Below the minimum level mark, add engine oil 2
of the recommended type to the specified 4. Drain:
level. Motor oil

(Completely c r a n k c a s e ) .
Note:
5. If the oil filter element should also be replaced,
Before checking the engine oil level, wait a few proceed as follows.
minutes until the oil has settled.
Do not screw the dipstick "1" when a. Remove the cover from the oil filter element "1"
Check the oil level. and the oil filter element "2".

b. Install new O-Rings "3"
1

1

to
b
2 New 3 1
3-9

MOTOR

c. Assemble the new oil filter element and cover verification oil. If no engine oil comes out after one
the oil filter element. minute, turn the engine so that no damage
occurs.
Cover Screw oil filter element c. Check the engine oil passages, the oil filter element and
10 Nm (1.0 m · kg, 7.2 ft · the oil pump is damaged or leaking. Refer to "OIL
lb) PUMP" on page 5-43.
d. Start the engine after solving the problem (s)
and check the engine oil pressure again.

e. Tighten the check to the specified torque.
7. Ensemble:
Drain Plug Washer Screw oil verification
7 Nm (0.7 m · kg, 5.1 ft · lb)

Drain plug
20 Nm (2.0 m · kg, 14 ft · lb)

8. Filling:
Carter FREE PLAY ADJUSTMENT CABLE CLUTCH
(With the specified amount of oil 1. Check:

recommended) Game

Adjust
clutch cable
Specification free "to"‫וי‬
Out of
Free play the clutch lever
Engine Oil quantity / amount 10.0-15.0 mm
Periodic oil change
1.00 lt
Total quantity of oil

9. Assembly:
Engine oil meter
10.Arranque the engine, warm it up for several
minutes and then shut.
11.Verifique

Engin
2. Adjust
e
Freeplay clutch cable
Engine Oil Leak)
Handlebar side
12.Verificar: a. Pull back the rubber cover "1"
Engine Oil Level b. Loosen the locknut "2"
Refer to "CHECKING AND ENGINE OIL c. Turn the adjustment screw "3" in direction "a"
LEVEL" on page 3-9 or "b" to obtain the specified free play of the
13.Check: clutch cable.
Engine Oil Pressure
Direction "a"
The free play is increased clutch cable
a. Loosen screw oil check "1". Direction "b"
The free play is decreased clutch cable

February 1 3

to
1

b
b. Start the engine and idle until
oil begins to leak from the screw
3-10

MOTOR

d. Tighten the locknut.
e. Slide the rubber cover to its original position.
NOTE:
If the free play specified clutch cable, can not be
obtained on the handlebar side, the adjusting nut
used in the motor side.

Motor side
a. Loosen the locknut "1"
b. Turn the adjustment screw "2" in direction "a" 1
1. Remove:
or "b" to obtain the specified free play of the
Seat
clutch cable.
Direction "a"
The free play is increased clutch cable 2. Remove:
Direction "b" Cover the air filter box "1" air filter
The free play is decreased clutch cable element

NOTE: 1
Keep the right handlebar

2

1 to
b 3. Clean:
Air filter element "1"
Apply dry compressed air from the internal surface
of the outside of the air filter element.

c. Tighten the locknut.

Locknut
9 Nm (0.9 m · kg, 6.5 ft · lb)

1
CLEANING THE AIR FILTER ELEMENT
NOTE: 4. Check:
There inspection hose "1" at the base of the air Air filter element
filter housing. If there is dust and / or water Replace damaged ‫וי‬
accumulated in the hose, clean the air filter 5. Assembly:
element and air filter box. Assembly:
Cover the air filter box (along with gaskets)
3-11

MOTOR

1
CAUTION:
Never run the engine without the air filter
element installed. The unfiltered air will cause
rapid wear of engine parts and may damage it.

NOTE:
Make sure the air filter element is properly
installed on the air filter box.

VERIFY UNON CARBURETOR AND
CONNECTING THE AIR FILTER BOX
1.
Remove: 3. Assembly:
Seat Fuel tank
Fuel tank Seat
Refer to "GENERAL CHASSIS". On page 4-2 Refer to "GENERAL CHASSIS" on page 4-2
2. Check: CHECK THE EXHAUST SYSTEM
Carburetor Union "1" 1. Verify: Silencer
Cover theReplace
damage ‫ וי‬/
air filter box "2" Cracks "1"
Cracks / damage Replace ‫וי‬

Exhaust seal "2"
Exhaust gas leaks ‫וי‬
Replace
1 2. Check:
Torque
Muffler Nuts "3" muffler screw
"4" Muffler Screw "5"

Muffler Nut
15 Nm (lower left) Muffler

Screw

20 Nm (2.0m.kg, 15ft.lb)

Screw the muffler (bottom right)
12 Nm (1.2m.kg, 9ft.lb)
3. Assembly: 2
Fuel tank
Side cover 2
Seat
Refer to "GENERAL CHASSIS"
On page 4-2 3
VERIFY THE BREATHER TUBE
HEAD 4
1. Remove: 5
Seat 3
Side cover (left) 4 1
2. Check:
Breather Replace
damage ‫ וי‬/
tube of the butt "1" Cracks
Loose connections Connect ‫ וי‬correctly.
3-12

MOTOR

Check the filter of the fuel cock

1. Check:
•Fuel pipe "1"
Cracks / damage Replace ‫וי‬

3 1

•Fuel filter "1"
Contaminated / Damaged Replace ‫ וי‬the
Fuel wash.

2

a. Turn fuel valve to "OFF"
b. Remove the cup filter fuel valve "3".
c. Drain fuel.
d. Check the filter of the fuel tap.
If dirty ‫ וי‬Clean
Impaired Replace ‫וי‬
e. Install the filter bowl of the fuel tap.
3-13

CHASIS

CHASSIS CHECKING THE BRAKE FLUID LEVEL
ADJUSTING THE REAR BRAKE DRUM NOTE:

1. Check: Place the vehicle on the center support
Adjust
Free pedal brake
Specification ‫וי‬
"to" Out of
Make sure the vehicle is vertical
2. Check:
Free game Brake fluid level.
15.0-20.0 mm Below the minimum level mark, add fluid
recommended brake to proper level

Recommended fluid:
DOT 3 or DOT 4

Max.

Min

1

2. Adjust
Free pedal brake

a. Turn the adjusting nut "1" in direction "a" or "b"
until the specified free play of the brake pedal. WARNING
Use only recommended brake fluid, other brake fluids
Direction "a" may cause damage to the rubber seals, causing leakage
The free play is increased brake pedal and loss of braking efficiency. Refill with the same type
Direction "b" of brake fluid that is already in the system, the fluid
The free play is decreased brake pedal mixture can cause a harmful chemical reaction that
would cause a malfunction of the brakes
When refilling, be careful not to get water in the master
cylinder. The water significantly decreases the boiling point
of the fluid and may cause vapor lock.

CAUTION

to Brake fluid may damage painted surfaces or
plastic. Immediately clean
1 b any spilled brake fluid

CAUTION
After adjusting the free play of the brake pedal,
make sure the brake does not drag.
NOTE:
To ensure a correct reading of brake fluid level,
3. Adjust verify that the master cylinder top is horizontal.
Switch the rear brake light
See "SWITCH ADJUSTMENT
THE REAR BRAKE LIGHT ".
On page 3-15
3-14

CHASIS

CHECKING THE FRONT BRAKE PADS
2
The procedure applies to all
brake pads. 1
1. Apply the front brake.
2. Check:
Front brake pads
Wear indicators "1" almost touching the
brake disc Replace ‫ וי‬play
brake pads. See
"FRONT BRAKE" on page 4-20

1
SWITCH ADJUSTMENT REAR BRAKE
LIGHT
NOTE:
The rear brake switch is actuated by movement of the
brake pedal. When the light switch rear brake is
adjusted correctly, when the light is turned on
CHECKING THE BRAKE HOSE immediately before the braking effect.
1. Check: Brake Hose
1. Check:
Cracks / damage / wear Replace ‫וי‬ Operation of the brake light.
Incorrect Adjust ‫וי‬.
2. Fit:
Operation of the brake light

a. Hold the main body "1" switch
U
1 Rear brake and turn the adjusting nut "2"
T
U
T in the sense "a" or "b" until the brake light
comes on at the right time.

2
Direction "a"
Brake light comes on before. Direction
"b"
Brake light comes on after.

2. Verify
Caliper brake hose

Loose connections Tighten ‫ וי‬screw clamp
3. Hold the vehicle and apply the front brake
several times.
Brake fluid leak ‫וי‬Replace

Refer damaged hose
"FRONT BRAKE" on page 4-16

CHECKING THE REAR BRAKE BANDS BLEEDING THE HYDRAULIC
1. Apply the front brake. BRAKE SYSTEM

2. Check: WARNING
Wear indicators "1" of the brake bands
Reaches the wear limit mark "2" ‫וי‬ Make bleed hydraulic brake system whenever:
Replace the brake bands play. Refer to The system is dismantled. A brake hose is
"FRONT BRAKE" on page 4-26 removed, disconnected or replaced.
The brake fluid level is too low. Braking is
inappropriate.
3-15

CHASIS

1. Remove: g. Loosen the bleed screw.
Cover the brake master cylinder "1" NOTE:

When you release the bleed screw, the pressure
will be released and cause contact with the brake
lever the throttle.

1
h. Tighten the bleed screw and then release the
brake lever
i. Repeat steps "e" to "h" until all air bubbles
have disappeared brake fluid in the plastic
hose.
j. Tighten the drain plug to the specified torque.

Bleed screw:
NOTE: 6 Nm (0.6 m · kg, 4.3 ft · lb)
Be careful not to spill brake fluid and do not let the master cylinder
reservoir overflow. k. Fill the brake fluid reservoir to the proper level
When you bleed the brake hydraulic system, with the recommended brake fluid.
make sure there is always enough brake fluid Refer to "CHECKING THE BRAKE FLUID
before toggling. If this precaution is ignored, may LEVEL" on page 3-14
occur in the air inlet hydraulic brake system,
greatly increasing the purge procedure time. WARNING
If bleeding is difficult, it may be necessary to let
After making the bleed hydraulic brake system,
the brake fluid settle for a few hours. Repeat
when small air bubbles are gone. check the brake operation.

2. Bleed: 3. Assembly:
Hydraulic Brake System Cover the brake master cylinder
a. Fill the brake fluid reservoir to the proper level CLEARANCE ADJUSTING THE DRIVE CHAIN

with the recommended brake fluid. NOTE:
b. Assemble reservoir diaphragm brake master The slack of the drive chain must be verified at
cylinder. the point of greatest stress.

c. Securely attach clear plastic hose "1" in the
bleed screw 2. CAUTION

A string stretched excessively load the engine
and other vital parts and a loose chain can go out
2 and damage the swingarm or cause an accident.
Therefore, maintaining the tension of the
transmission chain within specification limits.

1 1. Place the vehicle on a flat surface

WARNING

d. Place the other end of the hose into a Securely support the vehicle so there is no risk of
container. falling.

e. Slowly actuate the brake lever several times. NOTE:
f. Pull the lever fully without releasing brake
Place the vehicle on the main stand, so that the
rear wheel is elevated.
3-16

CHASIS

2. Rotate the rear wheel to find the point of NOTE:
greater tension in the drive chain.
To maintain proper alignment of the wheel,
3. Check: adjusting both sides equally.
Clearance transmission chain "a"
OOS Adjust ‫וי‬. e. Secure the axle nut with the torque wheel
specified.

Axle nut wheel:
90 Nm (9.0 m · kg, 65 ft · lb)

5. Fit:
Free pedal brake
Refer to "ADJUSTING THE REAR BRAKE"
on page 3-14
Clearance transmission
chain: 6. Align the rear axle
30-40 mm

NOTE: a. To maintain proper alignment of the shaft.
Measure clearance transmission chain between Reference lines "1" in the swingarm must
the coupling pin and the rear wheel axle. correspond with the same outer diameter of
the washer "2" on both sides.
4. Fit:
Clearance of the transmission chain.

1

a. Loosen the nut on the brake rod "1" 2

b. Loosen screw "2" wheel shaft

b. After adjusting, tighten each nut adjustment.
2 Then tighten the axle nut to the specified

torque.
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not properly
maintained, wear quickly. Therefore,
maintenance to be done, particularly when the
1 vehicle is used in dusty areas.
c. Turn the adjusting nuts "3" to adjust the slack
We recommend using a chain cleaner and a lubricant
chain tension specified.
suitable for O-ring chains.
Steering
The chain is tensioned
Address b
The chain is loosened

Recommended lubricant
Lubricant for chains with O-
ring

1. ite all deposits of dust, dirt, mud,
or oil. during wash and air dry.
to
2. Spray the chain with a degreaser
chain to remove fat deposition
b for 5 minutes.

3. Clean the chain with a clean cloth and wait
3-17

CHASIS

b. Tighten the lower ring nut "4" wrench nut
steering column "5".
NOTE:
Set the torque wrench at a right angle to the nut
wrench the steering column.

5

4Spray the lubricant within the chain between
the inner and outer plates, rollers and
bearings. 4

5After waiting for lubrication
15 minutes.
6Excess lubricant should be wiped with a clean Nut wrench address: YSST-721
cloth before driving.

CHECKING AND ADJUSTING THE Lower ring nut (initial tightening torque d)
STEERING 33 Nm (3.3 m · kg, 24 ft · lb)
c. Loosen the lower ring nut "4" completely, then
WARNING tighten to specification with nut wrench the
Securely support the vehicle so there is no steering column.
risk of falling. WARNING

NOTE: Do not overtighten the lower ring nut.
Place the vehicle on the center support so that
the front wheel is elevated. Lower ring nut (final torque)

22 Nm (2.2 m · kg, 16 ft · lb)
2. Check:
Steering column. d. Check that the steering is not loose or hard when turning the
Hold the front fork legs and gently move the fork fully in both directions. If it feels hard, remove the
fork. bottom bracket and check the upper and lower bearings.
Dura / loose ‫וי‬Adjust column Refer to "STEERING"
direction. on page 4-43.
3. Remove: e. Assemble the rubber washer "3".
Upper fork f. Assemble the upper ring nut "2".
Refer to "STEERING HEAD" on page 4- g. Finger tighten the upper ring nut "2" and align
43
the slots of both ring nuts. If necessary, hold
4. Fit: the lower ring nut and tighten the upper ring
•
S e
t e n
i
r gc o u
lm n nut until the grooves are aligned.

a. Remove the lock washer "1" upper ring nut NOTE:
"2" and the rubber washer "3". Make sure that the latch is properly seated in the
grooves of the ring nuts "b"
3-18

CHASIS

5. Assemble:
upper fork WARNING
Refer to "STEERING"
on page 4-43 The pressure should be checked and
corrected when the tire temperature is equal to
CHECKING THE FRONT FORK
room temperature.
1. Place the vehicle on a flat surface. The pressure should be in accordance with the

WARNING total weight (including cargo, rider, passenger
and accessories) and conduction velocity of
Securely support the vehicle so there is no
the vehicle.
risk of falling.
Drive vehicle overload can damage tires, loss
2. Verify: inner tubes of control or a major accident.
Damage / scratches ‫וי‬Replace. NEVER OVERLOAD THE VEHICLE.
Oil Seals
Oil Leaks ‫וי‬Replace.
3. Keep the vehicle in vertical position and pull Air pressure of the tires
the front brake (measured on cold tires): Front:
200 kPa (28 psi) (2.0 kgf / cm ²)
4. Check:
Rear:
Operation of the front fork. Pump the handle
225 kPa (33 psi) (2.25 kgf / cm ²)
repeatedly check if the front fork gently
cushions.
Irregular Movement ‫וי‬Repair.
Refer to "FRONT FORK" WARNING
on page 4-35 It's dangerous to drive with a worn tire. When

the tread reaches the wear limit, replace the tire
immediately.

2. Check:
Tire surface
Damage / wear Replace ‫ וי‬㻚 rim
TIRE INSPECTION
The following procedure applies to both wheels.
1. Check:
•Tire pressure.

1. Depth of the tread
OOS ‫וי‬Adjust. 2. Sideband
3. Wear indicator
3-19

CHASIS

WARNING CHECKING THE WHEELS
The following procedure applies to both wheels.
Do not use a tubeless tire wheel tires
designed only for camera, avoid failures and 1. Check:
personal injury due to sudden deflation. Wheels.
After extensive tests, the tires listed below Damage / deformations ‫וי‬Replace.
have been approved by Yamaha for this
WARNING
model. The front and rear tires should always
be the same manufacturer and the same Never attempt to make any repairs on the
design. There is no guarantee on handling wheels.

characteristics that can be given if combined
tires have not been approved by Yamaha for NOTE:
this vehicle. After a tire or wheel has been changed, it must
balance the wheel.

INSPECTION AND LUBRICATION OF
Front wheel CABLES

Size
The following procedure applies to internal and
100/80-17M/C 52P
external cables
Manufacturer / Model:
MFR / ZAPPER-X
WARNING
The exterior of the damaged cable can cause
Rear tire corrosion in the cable and interfere with their
Size movement. Replace damaged exterior and
140/60-R17M/C 63P interior wiring as soon as possible.

Manufacturer / Model:
MFR / ZAPPER RevZ 1. Check:
Exterior cable. Victim
‫וי‬replace.
2. Check:
WARNING
Operation of the cable. Irregular
New tires have a relatively low grip tread lightly Movement Lubricate ‫וי‬.
until they are worn. So you should be driving
about 100 km at normal speed before speeding. Recommended lubricant

Engine oil or a suitable cable
NOTE:
lubricant.
For rims with rotation mark "1": Assemble tire

marked pointing NOTE:
the sense of rotation of the wheel.
Hold the cable end upright and pour a few drops of
Align the mark "2" with the mounting of the lubricant into the cable sheath or use a suitable
valve. lubricating device

LUBRICATION CLUTCH LEVER
Lubricate the pivot point and the metal-metal
moving parts of the lever.

Soap-based grease Lithium
3-20

CHASIS

LUBRICATING THE BRAKE LEVER
Adjuster rear shock
Lubricate the pivot point and the metal-metal YSST-821

Silicone Grease

LUBRICATION PEDALS


LUBRICATION SIDESTAND Lubricate the pivot
point and the metal-metal moving parts of the
lever.


LUBRICATING THE REAR SUSPENSION

Recommended lubricant CAUTION
Soap-based grease Lithium Never go beyond the maximum or minimum

adjustment positions
ADJUSTING THE REAR SHOCK
1. Fit:
The following procedure applies to the • spring preload
adjustment of the rear cushion.
a. Turn the adjustment ring "1" in direction "a" or
"b"
WARNING b. Align the desired position on the adjustment
•Securely support the vehicle so there is no risk ring with the abutment "2".
of falling.

The spring preload is
Steering increased (suspension is
harder)

The spring preload is
Address b decreased (suspension

softer)

b Adjustment positions
to Minimum (soft): 1
Standard: 4
Maximum (hard): 7

3-21

SISTEMA ELECTRICO

ELECTRICAL 4. Remove:

• Lamp "1" lamp holder "2"
INSPECTION AND CHARGING See
"ELECTRICAL COMPONENTS" on page 7-
34 1

Fuse inspection
See "ELECTRICAL COMPONENTS" on
page 7-34

BULB CHANGE THE LANTERN The
following procedure applies to the low beam
bulb and high beam.

1. Remove:
•Side cover "1"
2

1 5. Remove:
•Lamp bulb cover "1"
•Lamp bulb holder "2"

2. Disconnect:
•Connecting the turn indicator signal "1"
from the end. 2
1

1
6. Lamp bulb holder "2"
•Streetlight bulb "1"

1

3. Remove:
• Screw the lamppost "1" from the end.
• Screw adjusting light "2".

1
WARNING

Since the lamp bulb may be
2 extremely hot, keep products
flammable and hands away from the bulb until it
has cooled.
3-22

SISTEMA ELECTRICO

4. Assembly: CHANGE OF LIGHT AUXILIARY
•Lamp bulb
The following procedure applies to the low beam
Secure the new lamp bulb holder with
bulb and high beam.
bulb lamp
CAUTION: 1. Remove:
Avoid touching the glass part of the bulb to keep •Side Covers (see Changing the bulb of the
it free Cembran oil, otherwise the transparency lamp) on page 3-22
of glass, the bulb life and brightness will be •The connections of the indicator signal
adversely affected. If the lamp bulb is dirty, wipe turn (see Changing the bulb of the lamp)
it with a cloth moistened with alcohol or lacquer on page 3-22
thinner. 2. Remove:
• auxiliary Bulb "1 as shown in
5. Assembly:
illustration ".
•Lamp bulb holder
6. Assembly:
•Cover lamp bulb

BEAM ADJUSTMENT OF FAROLA The
following procedure applies to adjust the light 1

beam of the streetlight.
Loosen the screw and move the lamppost

lamppost as follows to adjust the beam of the
lamp

Steering
The beam of light from the lamp low BULB REPLACEMENT REAR / BRAKE CYLINDER

Address b 1. Remove:
The beam of light from the lamp rises •Screw "1"
•Lens "2"

1

2t
o

2. Push the bulb "1" and gently rotate
counterclockwise.

1
3-23

SISTEMA ELECTRICO

TO REPLACE THE REAR LIGHT
3. Remove:
• Coupler taillight "1"
•Screws "2" from inside the fender

2

2

1

CHANGING THE LIGHT BULB turn indicator
1. Remove:
•Screw "1" from the indicator light
•Lens "2" of light
2. Push the bulb "3" and gently rotate
counterclockwise.

3

2 1
3-24

CHASIS

GENERAL CHASSIS 4-1
ASSEMBLY OF THE AIR FILTER BOX 4-5

FRONT WHEEL 4-6
REMOVING THE FRONT WHEEL 4-8
FRONT WHEEL DISASSEMBLY 4-8
CHECKING THE FRONT WHEEL 4-9
FRONT WHEEL ASSEMBLY TERA 4-8
FRONT WHEEL ASSEMBLY (DISC) 4-9

REAR WHEEL 4-12
REAR WHEEL REMOVAL 4-14
CHECKING THE REAR WHEEL 4-14
CHECKING THE REAR WHEEL HUB 4-14
CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4-14
REAR WHEEL ASSEMBLY 4-15
REAR WHEEL ASSEMBLY (DRUM) 4-15

FRONT BRAKE 4-16
INTRODUCTION 4-19
CHECKING THE FRONT BRAKE DISC 4-19
REPLACING THE FRONT BRAKE PADS 4-20
REMOVING THE FRONT BRAKE CALIPER 4-21
REMOVAL OF THE FRONT BRAKE CALIPER 4-21
CHECKING THE FRONT BRAKE CALIPER 4-21
ASSEMBLY FRONT BRAKE CALIPER 4-22
MOUNTING FRONT CALIPER 4-22
REMOVING THE FRONT BRAKE MASTER CYLINDER 4-23
CHECKING THE FRONT BRAKE MASTER CYLINDER 4-23
ASSEMBLY FRONT BRAKE MASTER CYLINDER 4-23
INSTALLING THE FRONT BRAKE MASTER CYLINDER 4-23

REAR BRAKE 4-26
CHECKING THE REAR BRAKE BANDS 4-27
HOLDER ASSY REAR BRAKE BANDS 4-27
Limit check WEAR BRAKE DRUM 4-28

HANDLEBAR 4-30
HANDLE REMOVAL 4-32
HANDLEBAR VERIFICATION 4-32
HANDLEBAR MOUNTED JE 4-32

FRONT FORK 4-35
Strip the FRONT FORK 4-38
REMOVAL OF FRONT FORK BARS 4-38
CHECKING THE FRONT FORK BARS 4-39
BARS ASSY FRONT FORK 4-39
ASSEMBLING THE FRONT FORK BARS 4-42

CHASIS

STEERING COLUMN 4-43
LOWER BRACKET REMOVAL 4-45
VERIFICATION OF THE STEERING 4-45
COLUMN MOUNT DIRECTION N 4-45

REAR SHOCK 4-47
REMOVING THE REAR SHOCK 4-48
CHECKING THE REAR SHOCK 4-48
Rear shock mounting 4-48

TILTING 4-49
SWINGARM REMOVAL 4-51
CHECKING THE ROCKER 4-51
TILT MOUNT 4-51

DRIVE CHAIN 4-53
CHECKING THE DRIVE CHAIN 4-54
FITTING THE DRIVE CHAIN 4-55

GENERAL DEL CHASIS

GENERAL CHASSIS

2 Nm (0.2 m lkg, 1ft lIb) 1

25 Nm (2.5 m lkg, 18 ft lIb)

4
2

2 Nm (0.2 m lkg, 1ft lIb)

5
6

9

3

7


Order Procedure / Parts to remove Amount Observations
1 Seat 1
2 Side cover 1 & 2 1/1
3 Side cover 3 & 4 1/1
4 Tail cover 1
5 Manigueta 1
6 Mud Protector 1
7 Air intake Support 1
8 Air intake 1
9 Footrest Protector 1
For assembly, reverse the disassembly
procedure.
4-1

GENERAL DEL CHASIS

Removing the fuel tank

2 1

3

2

4


5

Side cover 1 & 2, Seat
on page 4-1
1 Fuel Tank Cap 1

2 Fuel Tank Cap 2
3 Side Covers Fuel Tank LH & RH 1
NOTE:
Disconnect the fuel lines and fuel drain pipe
before
4 Upper Deck Fuel Tank 1 combustib.le removing tank.

5 Fuel tank 1 For assembly, reverse the disassembly
procedure
4-2

GENERAL DEL CHASIS

Removing the lamp and the meter



6

3 5 2 Nm (0.2 m lkg, 1ft lIb)
4

7

1 2

1

1 Side covers 2
2 Full Farola 1
3 License Plate 1 Disconnect
4 Support license plate 1
5 Connection Meter 1
6 Meter 1
7 Support lamppost 1
procedure.
4-3

GENERAL DEL CHASIS

Removing the air filter
full 1


2

4 3

23 Nm (2.3 m lkg, 17 ft lIb)

5

8
6 7 7 Nm (0.7 m lkg, 5ft lIb)
Refer to "GENERAL CHASSIS" on

Seat, side cover 1 & 2
page 4-1
1 Filter box cover 1
2 Filter housing cover 1
3 Stamps air filter 2
4 Air filter 1
5 Resonator 1
6 Hose Clamp air filter 1
7 Air Cleaner Hose 1
8 Air Filter Housing 1
procedure.
4-4

GENERAL DEL CHASIS

INSTALLING THE AIR FILTER BOX
1. Install:
C
•a
lm p un o
in a t
r
l
ir
f
e
NOTE;
Align the projection "a" on the air filter box with
slot "b" at the junction of the air filter.

to

b
4-5

RUEDA DELANTERA

FRONT WHEEL

Removing the front wheel and the brake disc

30 Nm (3.0 m lkg, 22 ft lIb) LS
3

LT
(5 1


6

2
7

LS

60 Nm (6.0 m lkg, 43 ft lIb)

6

4

1 Cable clamp speed sensor 1
2 Nut front wheel axle 1
3 Front wheel axle 1
4 Front Wheel 1
5 Speed sensor 1
6 Spacer 1
7 Brake disc 1

procedure.
4-6

RUEDA DELANTERA

Disassembly of the front wheel

4 3

LS

2
New 1

1 Oil Seal 1
2 Tread 1
3 Spacer 1
4 Tread 1

procedure.
4-7

RUEDA DELANTERA

REMOVING THE FRONT WHEEL

WARNING
Securely support the vehicle so there is no risk of
falling.

2. Survey:
•Front Wheel
NOTE:
Place the vehicle on a suitable stand so that the

front wheel is lifted.

3. Remove:
•Front Wheel VERIFICATION FRONT WHEEL
•Speed Sensor Unit 1. Check:
•Spacer W
• h e e a
l x e
l
Roll the wheel axle on a flat surface.
NOTE:
Warping Replace ‫וי‬.
Do not depress the brake lever when removing
the front wheel. WARNING

Do not attempt to straighten a wheel axle.
FRONT WHEEL DISASSEMBLY
1. Remove:
•Oil Seal
•Wheel Bearings

a. Clean the outside of the front wheel
hub.
b. Remove the oil seal "1" with a

flathead screwdriver.
NOTE:
To avoid damaging the wheel, placing a cloth "2" 2. Check:
between the screwdriver and the wheel surface. •m
R i
F
• o
r n W
t h e e l
Damage / wear Replace ‫וי‬.
Refer to "CHECKING THE TIRES" on
page 3-19
Refer to "CHECKING THE WHEELS" on
page 3-20

3. Measure:
w
• h e e a
r
l d a
il
d e va
ioin
t "1"
• h
W e e w
l n
id a g e "
2"

Off limits specified Replace ‫וי‬.

c. Remove the wheel bearings with a bearing
Radial deviation limit wheel
puller. 1.0 mm
Limit lateral deviation of the wheel
0.5 mm
4-8

RUEDA DELANTERA

FRONT WHEEL ASSEMBLY (DISC)

1. Assemble: l
D
• s
ic
ofront brake.

Screws front brake disc
30 Nm (3.0 m · kg, 22 ft ·
lb) LOCTITE ®

NOTE:
Tighten the brake disc bolts in stages and in a
4. Check:
•W h e e B
l e a r
n
ig s crisscross pattern.

The front wheel rotates this irregular or loose
Replace ‫ וי‬the bearings
wheel.
O
• l
i e
S a l

2. Check:
•s
D ic o Front brake

Refer to "CHECKING THE FRONT BRAKE DISC"
on page 4-19
3. Lubricate:
FRONT WHEEL ASSEMBLY W
• h e e H
l u b
1. Assembly: E
• d g e s o l
ie
s a l
W
• h e
eB
l e a n
i
rgs
New E
• d g e s s p e e dse n so r
•
O l
i e
S aNew
l
a. Assemble the bearings and new oil seal in the

reverse order of disassembly. 4. Assembly:
CAUTION W
• h
eel
lead

Do not touch the inside track "1" or areas "2" of

wheel bearings. Contact must be made just NOTE:
outside the track "3". Assemble the wheel rim and marked "1", pointing
in the direction of wheel rotation.
NOTE:
Use a wrench "4" to match the outside diameter
of the bearing and oil seal.

4-9

RUEDA DELANTERA

5. Assembly:
U
• n
t
i
speed sensor

NOTE:
Make sure the speed sensor and the hub of the
wheel is installed with the two projections
meshed into the two slots respectively.

6. Assembly:
W
• h
eel
lead
NOTE:
Make sure the slot "a" enters the outer tube and
fits over the top "b" in the unit
speed sensor.

b

to

7. Tighten:
S
•ha
t
f
wheel

Wheel Hub
60 Nm (6.0 m · kg, 43 ft · lb)

WARNING
Make sure the brake hose is guided properly.

CAUTION
Before tightening the wheel axle nut, push down
hard on the handlebar several times and check
if the front fork rebounds smoothly.
4-10

RUEDA DELANTERA
4-11

RUEDA TRASERA

Removal of the rear wheel and the brake band carrier

90 Nm (9.0 m kg, 65 ft lb) LS July 6

10

New

11

3 4 1
13

5 2 12
10

14

8

9

LS

1 Adjusting nut brake rod 1
2 Brake rod 1
3 Spring 1
4 Pin 1
5 ROD 1
6 Nut 1
7 Washer 1
8 Rear wheel axle 1
9 Washer 1
10 Chain tensioner 2
11 Spacer 1
12 Spacer 1
13 Rear Wheel 1
14 Porta bands 1

procedure.
4-12

RUEDA TRASERA

Disassembly of the rear wheel

1 Rear wheel sprocket 1
2 Necklace 1
3 Oil Seal 1
4 Tread 1
5 RWD Cube 1
6 Shock rear drive hub 4
7 Tread 2
8 Spacer 1
9 Oil Seal 1

procedure.
4-13

RUEDA TRASERA

REMOVING THE REAR WHEEL (DRUM)
1. Place the vehicle on a flat surface. 3. Measure:
Radial deflection of the wheel
WARNING Windage wheel
Securely support the vehicle so there is no risk Refer to "CHECKING THE FRONT WHEEL"
of falling. on page 4-8

NOTE: CHECKING THE REAR WHEEL
Place the vehicle on a suitable stand so that the 1. Check:
front wheel is lifted. Cube rear wheel traction

2. Remove: Cracks / damage Replace ‫וי‬.
Adjusting nut brake rod "1" brake rod "2" Dampers hub of the rear wheel drive
Spring "3" Damage / wear Replace ‫וי‬.

Pin "4" CHECKING AND REPLACING THE GEAR
NOTE: REAR WHEEL
Press down on the brake pedal to remove the 1. Check:
pin from the brake rod. Sprocket of the rear wheel
More than 1/4 of tooth wear ‫וי‬Replace
the whole transmission chain, sprocket, and the
sprocket of the rear wheel.
Teeth bent ‫וי‬Replace the entire
transmission chain, sprocket, and larueda rear wheel
sprocket.

3. Remove: Rear
Wheel

NOTE: b. Correct
Push the rear wheel forward and remove the
1. Transmission roller chain
drive chain from the rear wheel sprocket.
2. Sprocket of the rear wheel

VERIFICATION REAR WHEEL 2. Replace:
1. Check: Sprocket of the rear wheel
Wheel Hub
a. Remove the counter-nuts of the sprocket
Rear Wheel of the rear wheel.
Wheel bearings b. Clean the bucket wheel drive
back with a clean, especially clean surfaces
Oil Seals that are in contact with the sprocket of the
Refer to "CHECKING THE FRONT WHEEL" rear wheel.
on page 4-8 c. Assemble a new sprocket on the rear
2. Check: wheel.
Tire
Rear Wheel Nuts sprocket of the rear wheel
43 Nm (4.3 m · kg, 31 ft · lb)
Refer to "CHECKING THE TIRES" on page 3-19
and "CHECKING THE TIRES" on page 3-20
4-14

RUEDA TRASERA

NOTE: 5. Tighten:
Assemble the sprocket on the rear wheel with Nut wheel axle
the maker's mark out.
Nut wheel axle
Tighten the self-locking nuts in stages and in a 90 Nm (8.0 m · kg, 58 ft · lb)

crisscross pattern
6. Fit:
Free pedal brake
Refer to "ADJUSTING THE DRUM BRAKE"
on page 3-14

Free pedal brake
15.0-20.0 mm

REAR WHEEL ASSEMBLY (DRUM)
1. Lubricate:
Oil Seal edges


2. Assembly:
Rear sprocket.
Refer to "CHECKING AND REPLACING THE GEAR
REAR WHEEL" on page 4-14
3. Lubricate:
Wheel Hub
Wheel Bearings


4. Fit:
Clearance transmission chain
Refer to "ADJUSTING THE CLEARANCE DRIVE
CHAIN" on page
3-16

chain
30-40 mm
4-15

FRENO DELANTERO

FRONT BRAKE
Disassembly of the front brake pads

1 Fastener brake hose 1
2 Screw the front brake caliper 2
3 Front Caliper 1
4 Clip of brake pads 2
5 Brake Pad Pin 1
6 Front brake pads 2
7 Spring brake 1

procedure.
4-16

FRENO DELANTERO

Removing the front brake master cylinder

10 Nm (1.0 m kg, 7ft Ib)

1

2

7 Nm (0.7 m kg, 5ft Ib) 10

3 4

S
11

9 7
5 6
7
8
New
26 Nm (2.6 m kg, 19 ft lb)
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-15
1 Right rear view mirror 1
2 Tank cover brake master cylinder 1

3
Bra Tank diaphragm brake master cylinder 1
4 Reservoir diaphragm brake master cylinder 1
5 Brake Light Switch 1
6 Combination screw brake hose 1
7 Copper washer 2
8 Front brake hose 1
9 Brake Lever 1
10 Clamp the front brake master cylinder 1
11 Front brake master cylinder 1
procedure.
4-17

FRENO DELANTERO

Disassemble the front brake master cylinder

2

4

1
5

3
7

6

1 Smock 1
2 Pushrod 1
3 Spring 1
4 Pin lock 1
5 Complete piston 1
6 Spring 1
7 Cylinder Body 1
procedure.
4-18

FRENO DELANTERO

INTRODUCTION a. Place the vehicle on a suitable stand so that the
front wheel is lifted.
WARNING
b. Before measuring the deformation of the front
The disc brake components rarely require brake disc, rotating the handlebar to the left or
disassembly. Therefore, always follow these right to ensure that the front wheel is fixed.
precautions: c. Remove the brake caliper.
Never disassemble brake components unless d. Keep the comparator at right angles relative to
absolutely necessary. If any connection is the brake disk surface.
disconnected in the brake hydraulic, must e. Measuring the deformation of the disc 5 mm
disassemble the entire brake system, drain, below the edge of the brake disc.
clean, fill and purge properly assembled after
Never use solvents on internal brake 4.
components Measure:
Use only brake fluid to clean or new cleaning Brake disc thickness
brake components. Measure the brake disc thickness at
Brake fluid may damage painted surfaces and different locations.
plastic parts. Therefore, always immediately OOS Replace ‫וי‬.
clean spilled brake fluid.
Do not allow brake fluid to come into contact

with the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: Flush with water for 15 minutes and
seek medical attention immediately.

CHECKING THE FRONT BRAKE DISC
1.
Remove:
Front Wheel
Refer to "FRONT WHEEL"
on page 4-6. Limit the brake disc thickness
2. Check: Disc 3.5 mm
Brake
Damaged / scratched Replace ‫וי‬. 5. Adjust
3. Deformation of the brake disc
Measure:
Deformation of the brake disc a. Remove brake disc
OOS Correct ‫ וי‬deformation b. Rotating brake disc of a screw hole
Brake disc or replace the brake disc. c. Brake disc assembly

Brake Disc Screws
30 Nm (3.0 m · kg, 22 ft ·
lb) LOCTITE ®

NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.

Limit brake disc deformation of
0.10 mm
4-19

FRENO DELANTERO

NOTE:
Assemble the new brake pads and new brake
pads spring.
a. Securely attach clear plastic hose "1" in the
bleed screw "2". Place the other end of the
hose into a container.

d. Measuring deformation of the brake
disk
e. If out of specification, repeat the adjustment
until the brake disc deflection is within the
specified
f. If the deformation of disc brake disc can not be
brought within specification, replace the brake
disc. b. Loosen the bleed screw and push the piston
6. Assembly: Front brake caliper with your fingers
Wheel
Refer to "FRONT WHEEL" c. Tighten the bleed screw
on page 4-6
Bleed screw
REPLACING THE FRONT BRAKE PADS
6 Nm (0.6 m · kg, 4.3 ft · lb)
NOTE:

When replacing the brake pads, it is not d. Assemble the brake pads and brake springs
necessary to disconnect the brake hose or
disassemble the brake caliper. again.

3. Verify
1.
Brake fluid level
Measure
Desgate limit of the brake pad "to" Out of Below the minimum level mark "a" Add
Specification ‫וי‬Replace ‫ וי‬brake fluid
set of brake pads recommended to the proper level. Refer to
"CHECKING THE BRAKE FLUID LEVEL"
Coating thickness of the brake on page 3-14.

pads (interior)
4.5 mm
Max.
Limit 0.8 mm Min
Coating thickness of the brake

pads (outside)
4.5 mm
Limit 0.8 mm

to 4. •
O p e a
r o
t
in o h
t
f eb a
r
ke e
lve r

Soft or spongy feeling Purge ‫ וי‬the
Brake system.
2. Assemble: Brake Refer to "BLEEDING HYDRAULIC BRAKE
Pads SYSTEM " on page 3-15.
Spring brake
4-20

FRENO DELANTERO

REMOVING THE FRONT BRAKE b. Disassemble dust seals and brake caliper
CALIPER

NOTE:
Before disassembling the brake caliper, drain all CHECKING THE BRAKE CALIPER

the brake fluid from the brake system.

Plan recommended replacement brake
1. Disassembly: components
Combination screw brake hose
Brake pads If required
Copper Washers
Brake Hose Piston seals Every two years

NOTE: Overalls Every two years
Place the end of the brake hose into a container Brake Hose Each four years
and pump out the brake fluid carefully. Every two years and
Brake fluid whenever the brake is
DISASSEMBLY CALIPER disassembled

1. Disassembly: 1. Check:
Piston brake caliper "1" Piston brake caliper "1" Roughness /
Seals Piston Caliper "2" dust seals scratches / wear Replace ‫וי‬
Caliper "3" pistons in the brake caliper.
Cylinders caliper "2"
Scratches / wear Replace ‫ וי‬clamp
Brake

Body caliper "3"
Cracks / damage Replace ‫ וי‬clamp
1 brake.
2
Flights distribution of brake fluid
3 (Body of the brake caliper) Obstructed ‫וי‬
Blow with compressed air.
1
2 WARNING
Whenever the brake caliper is disassembled,
a. Apply compressed air through the opening "a" replace the piston seals and dust
of the union of the brake hose to force out the

pistons from the brake caliper.
3
WARNING
Cover the caliper piston brake with a rag.
Be careful to avoid injury when the 2 2
piston is expelled from the brake caliper.
Never attempt to remove the pistons
pushing the brake caliper.

1
2. Check:
Support the brake caliper
Cracks / damage Replace ‫וי‬.

to
4-21

FRENO DELANTERO

ASSEMBLY FRONT BRAKE CALIPER 3. Assembly:
WARNING Spring brake pads
Before installation, all internal brake Brake pads
components should be cleaned and lubricated Caliper
with a liquid cleaner or brake again. Fastener brake hose
Never use solvents on internal brake
components, as it will cause the piston seals Assembly:
and dust seals to swell and deform. Spring brake pads
Whenever you remove the brake caliper, Brake pads
REPLACE ace piston seals and dust from the Caliper
brake caliper. Fastener brake hose

See "REPLACING THE FRONT BRAKE"
Recommended liquid
on page 4-20
DOT 3 or DOT 4
4. Fill:
ASSEMBLY FRONT BRAKE CALIPER Deposit brake master cylinder (with the
1. Assemble: Caliper specified amount and recommended brake
(Temporarily) fluid)

Copper Washers News Recommended liquid
Brake Hose DOT 3 or DOT 4

Combination screw brake hose 26 WARNING
Nm (2.6 m · kg, 19 ft · lb)
Use only the recommended brake fluid, other brake
fluids may cause damage to the rubber seals,
2. Disassembly: causing leakage and loss of braking efficiency.
Caliper "1" Refill with the same type of brake fluid that is already in
the system, the fluid mixture can cause a harmful
chemical reaction that would cause a malfunction of the
brakes. When refilling, be careful not to get water in the
master cylinder. The water significantly decreases the

boiling point of the fluid and may cause vapor lock.

CAUTION

Brake fluid may damage painted surfaces or
1 plastic. Immediately clean up any spilled brake
fluid.

5. Purge:
Brake system
See "bleeding the hydraulic brake system" on
page 3-15.
6. Check:
Brake fluid level
Below the minimum level mark
"A" Add ‫ וי‬Recommended brake fluid
to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-14
4-22

FRENO DELANTERO

Max. CHECKING THE FRONT BRAKE MASTER

Min CYLINDER
1. Check:
Brake Master Cylinder "1" Damage /
scratches / wear Replace‫וי‬.
Flights distribution brake fluid "2" (Body brake
caliper)
Obstructed ‫ וי‬Blow with compressed air.

1
7. 7. Check:
Operation of the brake lever
Brake system
See "PURGING SYSTEM 2
HYDRAULIC BRAKE "on page 3-15.

REMOVAL OF FRONT BRAKE MASTER

CYLINDER
2. Check:
NOTE: Kit brake master cylinder
Before disassembling the front brake master Damage / scratches / wear Replace‫וי‬.
cylinder, drain the brake fluid 3. Check:
entire brake system Deposit brake master cylinder
Damage / scratches / wear Replace‫וי‬.

1. Disconnect:
Brake light switch front "1" Diaphragm brake master cylinder
Damage / wear Replace‫וי‬.
NOTE:
Press the catch to remove the brake light switch Cracks / damage / wear Replace‫וי‬.
front brake master cylinder.

ASSEMBLY FRONT BRAKE MASTER
CYLINDER

WARNING
Prior to assembly, all internal brake
components must be cleaned and lubricated
with a cleanser or new brake fluid. Never use
solvents on internal brake components.

Recommended liquid
2. DOT 3 or DOT 4
Remove:
Copper Washers INSTALLING THE FRONT BRAKE MASTER
Brake Hose CYLINDER

NOTE: 1. Assembly:
Brake Master Cylinder "1"
To collect the remaining brake fluid, place a Clamp the brake master cylinder "2"
container under the master cylinder and the end
of the brake hose. Screw clamp brake master
cylinder
10 Nm (1.0 m · kg, 7 ft · lb)
4-23

FRENO DELANTERO

3. Fill:
Deposit brake master cylinder (with the
2 and recommended specified amount of brake
fluid)

Recommended fluid:
DOT 3 or DOT 4

WARNING
Nte solame Use the recommended brake
fluid, other brake fluids may cause
1 damage to the rubber seals, causing
leakage and loss of efficiency elfrenado.
Refill with the same type of brake fluid that is
2. Ensemble:
already in the system, the mixture
Copper washers "1" News
brake hose "2"
Fluid can cause a chemical reaction
Screw joint brake hose "3"
harmful that would cause a malfunction of the
brakes
Combination screw brake hose 26 Nm When refilling, be careful not to get water in the
(2.6 m · kg, 19 ft · lb) master cylinder.

The water significantly decreases the boiling
point of the fluid and may cause vapor lock.

WARNING
Proper guidance is essential for the safe CAUTION
operation of the vehicle Brake fluid may damage painted surfaces or
plastic. Immediately clean up any spilled brake
NOTE: fluid.

Hose assembly to the front brake master
4. Purge:
cylinder at the angle shown in Figure
Brake System
While holding the brake hose, Tighten the union
See "PURGING hydraulic brake system" on
of the brake hose as shown.
page 3-15.
Turn the handlebar to the left and right to make
sure that the brake hose does not touch other 5. Check:
parts (eg, wire harness, cables, conductors). Brake fluid level
Correct if necessary. Below the minimum level mark "a" ‫וי‬Add
Recommended brake fluid to the proper level. Refer to
"CHECKING THE BRAKE FLUID LEVEL" on page 3-14

Max.
1
Min
3

2

6. Check:
Operation of the brake lever
Brake system
4-24

FRENO DELANTERO

See "PURGING hydraulic brake system" on page
3-15.
4-25

FRENO TRASERO

REAR BRAKE

Disassembly of the bands 10 Nm (1.0 m kl g, 7ft lIb)
Brake

4
3 LS

2
5

6

S LS

1

New
(6)
43 Nm (4.3 m lkg, 31 ft lIb) LS
Porta full bands Refer to "REAR WHEEL"

on page 4-12
1 Brake bands 2
2 Spring full bands 2
3 Lever brake camshaft 1
4 Wear indicator of the brake bands 1
5 Brake Camshaft 1
6 Plate holder bands 1

procedure.
4-26

FRENO TRASERO

REAR BRAKE to
1. Check:
• Lining Brake Shoe

Crystallized areas ‫ וי‬Repair.
Sand crystallized areas with coarse
sandpaper.
NOTE:

After sanding crystallized surfaces, clean the
brake bands with a cloth.
2. Measure: 4. Check:
•
c
oa t
n
ig h
t c
ik n
es
sba
rk
e •Inner surface of the brake drum
ban d sa
" O
" uo
ts
fpe
cf
c
iao
i
tn Deposits Oil Clean ‫וי‬
Replace ‫וי‬. Remove the oil with a rag soaked in lacquer

thinner or solvent.
Coating Thickness Scratch ‫ וי‬Repair.
4.0 mm (0.16 in) Lightly and evenly polish the scratches with
Limit emery cloth.
2.0 mm (0.08 in) 5. Check:

Brake camshaft

HOLDER ASSY REAR BRAKE BANDS
1. Assembly:
• Tree brake cam "1"
• Indicator Wear of the brake bands "2"
• Lever the brake camshaft "3"

Screw lever brake camshaft
10 Nm (1.0 m.kg, 7.2 ft.lb)

WARNING a. Assemble the brake camshaft so that their
perforation mark "a" remains as shown.
Do not allow oil or grease to come into contact
with the brake bands. 1

NOTE:
to
Replace all the brake bands, if any of them
reaches the limit of wear.
3. Measure:
•
n
It
e n
r a d
la
im ee
to
r h
t
fe b a
r k e
d u
r m o
t
"O
" uo
tf
S p ecf
c
iao
i
tnReplace ‫ וי‬the
wheel.

Inner diameter of the brake
drum 130.0 mm
Limit
131.0 mm
b. Align the projection "b" wear indicator brake
shoe with the slot in the brake camshaft.
4-27

FRENO TRASERO

New 1 S

A A

B B
c. Align the slot "c" in the lever brake camshaft
with the slot in the brake camshaft. New 1

3 A-A

c
B-B

d. Verify that the bands are properly positioned.
Limit check WEAR BRAKE DRUM REAR
WHEEL
2. Assembly: NOTE:
•Spring brake bands "1" New After assembling new brake bands, the inner
•Brake bands diameter of the brake drum can be
NOTE: check this within the wear limit "a"
•Lubricate the pivot with a thin layer of silicone by the wear indicator holder in the brake bands.
grease.

•Do not damage the springs during installation.
•Install the spring brake bands as shown.
to

WARNING
No coating of grease applied to the brake
bands.

1. Check:
•The position at which to install the camshaft
lever brake
the brake camshaft
•Reinstall the camshaft lever brake, if installed in the
position is out of range.
2. Check:
•Free pedal brake
If the free play is out of specification. Refer to
"ADJUSTING THE REAR BRAKE DRUM" on
page 3-14.
4-28

FRENO TRASERO

3. While pressing the brake pedal all the way
down, push the lever brake camshaft
completely in the direction of the arrow and
check that the wear indicator brake bands not
wear indicator reaches the drum brake.
Not enough ‫ וי‬still can be used.
Reach Replace ‫ וי‬the wheel.

4-29

MANILLAR

HANDLEBAR
Removing the handlebar

10 Nm (1.0 m •kg, 7ft • Ib)
1
2 26 Nm (2.6 m •kg, 19 ft • Ib)
7
16 LS
5
3
LS 1

LS
4 10

13

17

8 6

9 12 2
15
14 11

LS

7 Nm (0.7 m •kg, 5ft • Ib)

1 Rearview mirror 2
2 Handlebar Plug 2
3 Right handlebar switch 1
4 Throttle Cable 1
5 Throttle grip 1
6 Switch front brake light 1
7 Clamp the front brake master cylinder 1
8 Front brake master cylinder 1
9 Clutch cable 1
10 Clutch switch coupler 1 Disconnect
11 Cable boot 1
12 Left handlebar switch 1
13 Handlebar grip 1
14 Clutch Lever 1
4-30

MANILLAR

Removing the handlebar

10 Nm (1.0 m •kg, 7ft • Ib)
1
2 26 Nm (2.6 m •kg, 19 ft • Ib)
7
16 LS
5
3
LS 1

LS
4 10

13

17

8 6

9 12 2
15
Nov. 14

LS

7 Nm (0.7 m •kg, 5ft • Ib)

15 Support the clutch lever 1
16 Handlebar clamp upper 2
17 Handlebar 1

procedure.
4-31

MANILLAR

HANDLE REMOVAL HANDLE ASSY
1. Place the vehicle on a flat surface 1. Place the vehicle on a flat surface

WARNING WARNING
Securely support the vehicle so there is no risk Securely support the vehicle so there is no risk
of falling. of falling.

2. 2. Assemble: l
Remove: •Handlebar
•Switch front brake light "1" "1"
NOTE: •Handlebar clamp upper "2"

Press the catch to remove the brake light switch Screw top handlebar clamp
front brake master cylinder. 26 Nm (2.6 m 䞉 kg, 19 ft 䞉lb)

CAUTION
First, tighten the screws on the front of the
handlebar clamp, and then in the back.
Turn the handlebars to the left and right. If no
contact with the fuel tank, adjust the handlebar
position.

NOTE:
Aligning the marks "a" of the handlebar with the
upper surface of the clamp bracket
3.
Remove: handlebar.
•Handlebar grip "1"
2
NOTE:
Blow compressed air between the left handlebar 2
and the handlebar grip, and gradually
push the handle out. 1

to

HANDLEBAR VERIFICATION
1. Check:
•Handlebar
Curves / cracks / damage Replace
‫וי‬.

WARNING
Do not attempt to straighten a bent handlebar as 3. Assembly:
dangerously weakened. •Support the clutch lever "1"
NOTE:
Align the bracket slot the clutch lever to match
the mark "a" on the handlebars.
4-32

MANILLAR

1
to

4. Assembly:
•Switch front brake light "1" 6. Assembly:
NOTE: •Clutch Cable
Align the projection "a" on the left handlebar switch NOTE:
with the hole "b" on the handlebars. Lubricate the clutch cable end with a thin layer of
grease lithium soap base.
to
7. Assembly:
b
1 •brake master cylinder
•Clamp brake master cylinder
See the "BRAKE
FRONT "on page 4-23.
8. Assembly:
• l Throttle grip "1"
•The throttle cable "2"

•The right handlebar switch "3"
5. Assembly: •Handlebar Plug
•Left handlebar "1" NOTE:
•Handlebar cap "1" •Lubricate the throttle cable end and the inside of
the throttle grip with a thin layer of grease
a. Apply a thin layer of rubber adhesive on the left based on lithium soap and then install the
end of the handlebar. handlebar grip.
b. Slide the handlebar handle at the left end •Route the throttle cable through the slot on the right
of the handlebar. handlebar switch, then install the cable.
c. Wipe off any excess rubber adhesive with a clean •Align the projection "a" on the right handlebar
cloth. switch with the hole "b" on the handlebars.
•Must have 1-3 mm of clearance "c" between the
WARNING Do handlebar grip and handlebar end 㻚
not touch the handlebar grip until the rubber adhesive
is completely dry.
NOTE:
There should be less than 3 mm of clearance
"a" between the handlebar handle and the end
Handlebar 㻚
4-33

MANILLAR

3 1
b

2
to

c

9. Fit:
•Cable free play Refer clutch "FREE PLAY
ADJUSTMENT CABLE CLUTCH" on page 3-
10.

Free play the clutch lever
10.0-15.0 mm

10. Fit:
•Cable free play Refer throttle "FREE PLAY
ADJUSTMENT THROTTLE CABLE" on page
3-6.

Set throttle cable free
3.0-5.0 mm
4-34

HORQUILLA DELANTERA

FRONT FORK

Removing the fork legs 25 Nm (2.5 m k•g, 18 ft • Ib)
lead

3 2

25 Nm (2.5 m • k g,18ft • Ib)

1

4

6 Nm (0.6 m •kg 4ft • Ib)
The following procedure applies to both

front fork legs
Front Wheel Refer to "REAR WHEEL" on page 4-6
1 Front fender 1
2 Screw top bracket 1 Loosen
3 Screw bottom bracket 1 Loosen
4 Front fork legs 1
procedure.
4-35

HORQUILLA DELANTERA

Disassemble the front fork legs

New 1
2 12

3

4 6New
7New
13
14 New

5

10 15

11
9

8
The following procedure applies to both

front fork legs
1 Screw cap 1
2 O-ring 1
3 Spacer 1
4 Washer 1
5 Fork spring 1
6 Smock 1
7 Oil Seal Clip 1
8 Screw the damper rod 1
9 Copper washer 1
10 Damper rod 1
11 Oil flow obturator 1
12 Inner tube 1
13 Oil Seal 1
14 Oil Seal Washer 1
4-36

HORQUILLA DELANTERA

Disassemble the front fork legs

New 1
2 12

3

4 6New
7
13 New
14 New

5

10 15

11
9

8

15 Outer tube 1
procedure.
4-37

HORQUILLA DELANTERA

Strip the FRONT FORK
The following procedure applies to both front fork 2. Drain:
legs •Fork Oil
1. Place the vehicle on a flat surface NOTE:

WARNING Press the outer tube several times while leaving
Securely support the vehicle so there is no risk the fork oil

of falling.

2.
Loosen:
•Top bracket screw "1"
•Lower bracket screw "2"
WARNING

Before loosening the screws on the top and
bottom support, hold the front fork legs.

NOTE:
To facilitate removal of the stop screws, first loosen 3. Remove:
the top bracket, then loosen the cap slightly without •Dust "1"
loosening the bottom bracket while the front fork is •Oil Seal Clip "2"
installed in the vehicle. (With a flathead screwdriver)

CAUTION
Do not scratch the inner tube.

1 1

2

4.
Remove:
•Screw the damper rod "1"
•Damper rod

2
3. Remove:
•Front fork legs
REMOVAL OF FRONT FORK BARS
The following procedure applies to both front fork
legs
1. Remove:
•Rubber cover
•Clip "1"
•Front fork cover "2" (with O-ring)
•Fork spring.
4-38

HORQUILLA DELANTERA

NOTE: 3. Check:
While holding the damper rod with the clip of the •Damper rod
damper rod "2" and the T-wrench "3", loosen Damage / wear Replace ‫וי‬.
the damper rod.
Obstructed Blow compressed air ‫ וי‬all
oil passages
•Oil flow stopper
Impaired Replace ‫וי‬.

CAUTION
When disassembling and assembling the front
fork legs, perrmita no foreign materials enter the
front fork.

BARS ASSY FRONT FORK

Key in T legs

YSST-813
WARNING
Make sure the oil levels in both front fork legs
CHECKING THE FRONT FORK BARS are equal
The following procedure applies to both front fork Different oil levels can result in little loss of
legs maneuverability and stability.

1. Check:
•Inner tube
•Outer tube NOTE:
Curves / damage / scratches Replace •During assembly of the front fork legs, be sure to
‫וי‬. replace the following parts:
- Bushing outer tube
WARNING - Oil Seal
- Dust
Do not attempt to straighten a bent inner tube as - Clip
dangerously weakened •Before assembling the front fork legs, make sure
2. Measure: all components are clean.

•Spring free length "a" 1. Assemble:
OOS Replace ‫וי‬. •Damper rod

Spring Free Length
254.4 mm

CAUTION
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2. Lubricate:
•Outer surface of the inner tube
4-39

HORQUILLA DELANTERA

Recommended oil Assembly tool oil seal front fork
Oil suspension YSST-875
10W or equivalent

3. Tighten: CAUTION
•Screw the damper rod "1"
Be sure to assemble the oil seal with the
Screw the damper rod number up.
28 Nm (2.8 m · kg, 20 ft · lb)
NOTE:
NOTE:
•Before installing the oil seal, lubricate the edges
While holding the damper rod with the clip of the with soap base grease lithium.
damper rod "2" and the T-wrench "3", tighten the •Lubricate the inner tube outer surface with oil
damper rod suspension.
•Before installing the oil seal, cover the top of the front
fork leg with a plastic bag to protect the oil seal during
assembly.

4. Assembly:
•Bushing outer tube "1" New
•Washer "2"
(With the Mounting tool seal
Front fork oil)

YSST-875
New

5. Assembly:
6. Assembly:
•Oil Seal "1" New
• Oil Seal Clip "1" New
Assembly tool oil seal front fork "2"
NOTE:
Adjust the oil seal clip to fit into the slot inside the
outer tube.

2

New

New
4-40

HORQUILLA DELANTERA

7. Assembly:
•Dust "1" New
(With the Mounting tool seal
Front fork oil "2")
YSST-875

10.Antes to measure the oil level of the fork, wait ten
minutes until the oil has settled and the air bubbles
have dispersed.

NOTE:

New Be sure to purge the front fork leg of any
residual air.

8. Filling: 11.
Measure:
• Sweep the front fork
(With the specified amount of oil •Oil level of the front fork leg "a" (from the top of
recommended) the inner tube with the inner tube fully
compressed and without fork spring)
OOS Correct ‫וי‬.

Level
Recommended oil 87.0 mm
Suspension Oil 10W or equivalent
Quantity 459 cm3

CAUTION
• B e s u re t
o u s e t
h e
re c o m m e n d e d
o l
i s u s p e n s o
in .
O h
t e r o s
l
i m a y
h a v e a n a d v e rs e
e e
f c t o n t
h e
p e ro
f rm a n c e o fh
t e

r
fo n o
f
t rk .
12. Assembly:
• W h e n
d s
ia s s e m b n
i
l ga n d
a s s e m b n
i
lg h
t e r
f
o n t
o
f r
k
e
lg s ,p e rm t
in
a o o
fr e g
in
m a e
t r
a
is le n e
t r
h
t e r
f
o n o
f
t r
k .
•Spring fork "1"
9. After filling the front fork leg, slowly pull the NOTE:
inner tube "1" from top to bottom (at least ten Install the spring with the lower end up "to" down
times) to distribute oil suspension.
NOTE:

Ensure slowly drive the inner tube because the oil
can flow suspension. to
1
4-41

HORQUILLA DELANTERA

13. Assembly: WARNING
•O-ring New Make sure the brake hose, cable
(The screw cap of the front fork) clutch, and the cables are guided
correctly.
•Screwthe top of the front fork
•Clip New

BLACK:
•Before installing the screw top of the front fork,
lubricate the O-ring with grease.
•Before installing the screw cap of the fork
2f
ront, lubricate the O-ring with grease.

BARS ASSY FRONT FORK

legs

1. Assembly:
•Delanter fork legs Temporarily tighten the
screws on the top and bottom brackets

2. Tighten: 1
•Top bracket screw "1"

Screw top bracket
25 Nm (2.5 m · kg, 18 ft · lb)

•Lower bracket screw "2"

Screw bottom bracket
25 Nm (2.5 m · kg, 18 ft · lb)

NOTE:
•To give the correct torque to cap screws, first
tighten the bottom bracket, then tighten the
screw cap before tightening the screw on the
top bracket.
4-42

COLUMNA DE LA DIRECCIÓN

STEERING
Disassembly of the steering column 110 Nm (11.0m •kg, 80 ft •lb)

1

22 Nm (2.2 m •kg, 16 ft •lb)

2

13
LS 11
3
14 4
New 15 5
6
8
12 9
10
7

7 Nm (0.7 m •kg, 5ft •lb)

22 Nm (2.2 m •kg, 16 ft •lb)
1st 33 Nm (3.3 m •kg, 24 ft •lb)

2nd 22 Nm (2.2 m •kg, 16 ft •lb)
Refer to section "GENERAL CHASSIS"

Full Farola
on page 4-1
Front fork legs Refer to "FRONT FORK"
on page 4-40
1 Screw steering column 1
2 Upper Bracket 1
3 Lockwasher 1
4 Upper ring nut 1
5 Grommet 1
6 Lower ring nut 1
7 Bottom Bracket 1
8 Bearing cover 1
9 Upper bearing inner race 1
10 Upper bearing 1
11 Lower bearing 1
12 Upper bearing outer race 1
4-43


Disassembly of the steering column 22 Nm (2.2 m •kg, 16 ft • lb)

1

22 Nm (2.2 m •kg, 16 ft • lb)

2

13
LS 11
3
14 4
New 15 5
6
8
12 9
10
7

7 Nm (0.7 m •kg, 5ft •lb)

22 Nm (2.2 m •kg, 16 ft •lb)
1st 33 Nm (3.3 m •kg, 24 ft •lb)

2nd 22 Nm (2.2 m •kg, 16 ft •lb)

13 Lower bearing outer race 1
14 Lower bearing inner race 1
15 Smock 1
procedure.
4-44


BOTTOM BRACKET REMOVAL b. Remove the bottom bracket bearing with a
chisel "2" and the hammer.
1. Place the vehicle on a flat surface
c. Install bearing races and a new coat.
WARNING CAUTION
Securely support the vehicle so there is no risk If the bearing races are not installed properly,
of falling.
it could damage the tube steering column.
2. Disassembly:
NOTE:
•Upper ring nut
•Grommet •Always replace bearings and bearing races as a
set.
•Lower ring nut "1"
•Lower bracket "2" •Each time the column is removed
1dirección, replace the dust.
NOTE:

Disassemble the lower ring nut with the wrench to
the stem nut "2".

Nut wrench address
YSST-721

WARNING
Secure the bottom bracket securely so
there is no risk of falling.

2

1

4. Check:
CHECKING THE STEERING
•Upper Bracket
1. Wash: •Bottom Bracket
•Bearings
•Bearing races (Along with the steering stem) Curves /
cracks / damage Replace ‫וי‬.
Recommended cleaning
solvent
Kerosene

ASSEMBLY OF THE STEERING
2. Check:
1. Lubricate:
•Bearings •Upper bearing
•Bearing races
•Lower bearing
Damage / pitting ‫ וי‬Reem.
•Bearing races
place
3. Replace:
•Bearings Recommended lubricant
•Bearing races Soap-based grease Lithium

a. Remove the bearing races tube steering 2. Assemble:
column with a long rod "1" and the hammer. •Lower ring nut
•rubber washer
4-45


•Upper ring nut
•Lockwasher
Refer to "CHECKING AND ADJUSTING THE
STEERING HEAD" on page 3-18
3. Assemble:
•Upper Bracket
•Nut of the steering column

4. Assemble:
•Front fork bars Refer to "FRONT
FORK" on page 4-35

NOTE:
Temporarily tighten the mounting bolts top and bottom.
5. Tighten:
•Nut of the steering column

Nut of the steering column
110 Nm (11.0 m · kg, 80 ft · lb)
4-46

AMORTIGUADOR TRASERO

REAR SHOCK

Removing the rear shock

60 Nm (6.0 m •kg, 43 ft •lb)

1
2
6

1

3

4
5

3
40 Nm (4.0 m •kg, 29 ft •lb)
Seat, side covers 1 & 2, mud guard Refer to "GENERAL CHASSIS"

on page 4-1
1 Nut / bolt rear upper shock 1/1
2 Washer 1
3 Nut / rear lower shock bolt 1/1
4 Washer 1
5 Spacer 1
6 Rear Shock 1
procedure.
4-47

AMORTIGUADOR TRASERO

REMOVING THE REAR SHOCK

WARNING
Securely support the vehicle so there is no risk
of falling.

NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.

CHECKING THE REAR SHOCK
1. Check:
•Rear shock absorber rod. Deformation /
damage Replace ‫ וי‬the
rear shock.
•Rear shock.
Oil Leaks Replace ‫ וי‬the
rear shock.
•Spring
Damage / wear Replace ‫ וי‬the
rear shock.
•Hubs
rear shock.
•Screws
Curves / damage / wear Replace ‫וי‬.

Rear shock mounting

1. Assembly:
•Rear Shock

2. Tighten:
•Rear shock absorber upper nut

Rear shock absorber upper nut
40 Nm (4.0 m · kg, 29 ft · lb)

•Rear shock lower nut

Rear shock lower nut
60 Nm (6.0 m · kg, 43 ft · lb)

3. Fit:
•Rear shock. (Refer to "ADJUSTING THE
REAR SHOCK" on page 3-21)
4-48

BASCULANTE

TILTING
Removing the rocker

60 Nm (6.0 m •kg, 43 ft •lb)

10 Nm (1.0 m •kg, 7 ft •lb)

1

3

5

2
4

10 Nm (1.0 m •kg, 7 ft •lb)

30 Nm (3.0 m •kg, 22 ft •lb)
Rear Wheel
Rear Shock Refer to "REAR SHOCK" on page 5-1
Rear fender Refer to "REAR WHEEL" on page 4-12
1 Pivot axle nut 1

2 Pivot shaft 1
3 Support the right footrest 1
4 Left footrest support 1
5 Seal stores 1
6 Rocker 1
7 Oil Seal 2
8 Dust Cover 2
9 Bushing 2
10 Tread 2
procedure.
4-49

BASCULANTE

Removing the rocker

60 Nm (6.0 m •kg, 43 ft •lb)

10 Nm (1.0 m •kg, 7 ft •lb)

1

3

5

2
4

10 Nm (1.0 m •kg, 7 ft •lb)

30 Nm (3.0 m •kg, 22 ft •lb)

11 Tread 2

procedure.
4-50

BASCULANTE

SWINGARM REMOVAL WARNING
Do not attempt to straighten the pivot axis.
WARNING
of falling.

NOTE:
of falling.

2. Measure:
•Swingarm side play.

a. Measuring the torque of the pivot shaft nut. 3. Wash:
•Pivot shaft
Pivot axle nut •Overalls
60 Nm (6.0 m · kg, 43 ft · lb) •Spacers
•Bearings
b. Measure the swingarm side play "to"
moving the swingarm from side to side. Recommended cleaning
solvent
c. If you look at the swingarm side play, check Kerosene
the spacers, bearings, and overall.
4. Check:
•Overalls
•Spacers
•Oil Seals
•Bearings
Damage / pitting Replace ‫וי‬

SWINGARM ASSY
1. Lubricate:
•Bearings
•Spacers
•Overalls
•Pivot shaft

CHECKING THE ROCKER Soap-based grease Lithium
1. Check:
•Rocker 2. Assemble:
Curves / damage / wear Replace ‫וי‬. •Bearings "1"
2. Check:
•Pivot shaft Mounting depth "a"
Rotating the pivot axis on a flat surface. 0.5-1.5 mm
Curves Replace‫וי‬.
4-51

BASCULANTE

to 121st

A B

2. Rocker
A. Left
B. Right side

to

4. Assembly:
•Rear Shock
•ROD
•Rear Wheel
See section "SHOCK
BACK "on page 4-47 and" REAR WHEEL
"on page 4-12.
5. Fit:
•Clearance of the transmission chain, see
section "CLEARANCE DRIVE CHAIN" on
page
3-16.

chain:
30-40 mm
4-52

CADENA DE TRANSMISIÓN

DRIVE CHAIN
Removing the drive chain

4

1
3
2
10 Nm (1.0 m •kg, 7 ft •lb)

10 Nm (1.0 m •kg, 7 ft •lb)
Rear Wheel Refer to "REAR WHEEL"

on page 4-12
Support the right footrest, left footrest support Refer to "SWINGARM" on page 4-49
Rear fender
1 Chain cover 1
2 Retention of the drive sprocket 1
3 Gear 1
4 Transmission chain 1

procedure.
4-53


CHECKING THE DRIVE CHAIN
1. Measure:
•15 links of the drive chain
OOS Replace ‫ וי‬the
chain.

Link length limit of 15
191.5 mm

a. Measure the length "a" between the inner
faces of the roller and the length "b" between 3. Clean:
the outer faces of the rollers 15 in a section of •Drive chain
the chain links of the transmission as shown a. Clean the drive chain with a clean cloth.
in the illustration. b. Sprinkle with chemical cleaner chain drive
chain and thoroughly clean.

Chain cleaner recommended for
chains with O-ring

4. Check:
• Roller transmission chain "1" Damage /
b. Calculate the length "c" of section 15 links in wear Replace ‫ וי‬chain
the chain of transmission using the following transmission.
formula "c" = (length "a" between the inner • Side plates of the chain of transmission "2"
faces of the rollers + length "b" between the Damage / wear Replace ‫ וי‬chain
outer faces of the rollers) / 2 transmission.
NOTE: Cracks Replace ‫ וי‬transmission chain.
•When measuring the segment of 15 links in the
chain of transmission, ensure that the drive
chain is taut.
•Perform the measurement in two or three
different points each time

5. Lubricate:
•Drive chain

Recommended lubricant chain
lubricant suitable for O-ring
chains

2. Check:
•Drive chain Wipe excess lubricant.
Stiffness Clean ‫ וי‬and lubricate or
replace.
4-54


6. Check:
•Gear
Refer to "REAR WHEEL" on
page 4-12

ASSEMBLY DRIVE CHAIN
1. Lubricate:
•Drive chain

Recommended lubricant chain
lubricant suitable for O-ring
chains

2. Assemble:
•Drive chain
•Drive sprocket
•Retention of the drive sprocket

Screw retention of the drive sprocket
10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Assemble:
•Rocker
Refer to "SWINGARM" on
page 4-49
•Rear Wheel
Refer to "REAR WHEEL" on
page 4-12

4. Fit:
•Chain slack transmission See "CLEARANCE
DRIVE CHAIN" on page
3-16

chain
30-40 mm

CAUTION
A string stretched excessively load the engine
and other vital parts and a loose chain can go out
and damage the swingarm or cause an accident.
Therefore, maintaining the tension of the
transmission chain within specification limits.
4-55

MOTOR

ENGINE REMOVAL 5-1
ENGINE MOUNTING 5-4
CHANGES Arm Mount 5-4

HEAD 5-5
REMOVING THE HEAD 5-7
HEAD INSPECTION 5-7
GEAR INSPECTION AND DISTRIBUTION
GUIDE TO THE TIMING CHAIN 5-8
INSPECTION OF TENSION DISTRIBUTION CHAIN 5-8
INSPECTION SYSTEM DECOMPRESSION 5-9
CYLINDER ASSEMBLY 5-9

CAMSHAFT 5-12
REMOVING THE ROCKER ARMS AND CAMSHAFT 5-13
CAMSHAFT INSPECTION 5-13
INSPECTION AND ROCKER ROCKER SHAFT 5-13
ROCKER ASSEMBLY AND THE CAMSHAFT 5-14

VALVES AND VALVE SPRINGS 5-15
REMOVING THE VALVES 5-16
CHECKING THE VALVES AND VALVE IAS GU 5-16
CHECKING THE VALVE SEATS 5-17
CHECKING THE VALVE SPRINGS 5-18
VALVE ASSEMBLY 5-19

CYLINDER AND PISTON 5-21
Piston Removal 5-22
INSPECTION PISTON CYLINDER & D 5-22
CHECKING THE PISTON RINGS 5-23
Piston pin INSPECTION 5-24
ASSEMBLY PISTON AND CYLINDER 5-24

STARTING AND MAGNETO GEAR 5-26
MAGNETO REMOVAL 5-28
ARR GEAR REMOVAL ANQUE 5-28
STARTING GEAR INSPECTION 5-28
STARTING GEAR ASSEMBLY 5-29
MAGNETO ASSEMBLY 5-29

ELECTRIC START 5-31
ELECTRIC STARTER REMOVAL 5-33
VERIFICATION OF ELECTRIC START 5-33
STARTER ASSEMBLY 5-34

CLUTCH 5-35
CLUTCH REMOVAL 5-38
INSPECTION OF RECORDS OF FRICTION 5-38
CHECKING THE CLUTCH PLATES 5-38
CHECKING THE CLUTCH SPRINGS 5-39
INSPECTION Caddy 5-39
INSPECTION OF PRESSURE PLATE 5-39
CHECKING THE CLUTCH PUSH LEVER
SHORT AND PUSH ROD 5-39
PRIMARY DRIVE GEAR INSPECTION 5-39
PRIMARY DRIVEN GEAR INSPECTION 5-40
CLUTCH INSPECTION 5-40

OIL PUMP 5-43
CHECKING THE OIL PUMP 5-45
MOUNT OIL PUMP 5-45
MOUNT OIL PUMP 5-46

SHIFT SHAFT 5-47
SHIFT SHAFT INSPECTION 5-48
INSPECTION OF POSITION LEVER 5-48
SHIFT SHAFT ASSEMBLY 5-48

BALANCER SPROCKET 5-49
PRIMARY DRIVE GEAR REMOVAL AND
PRIMARY DRIVE GEAR INSPECTION AND
GEARS OF BALANCE ADOR 5-51
ASSEMBLY BALANCER DRIVEN GEAR 5-51
PRIMARY DRIVE GEAR REMOVAL AND

CASES 5-53
SEPARATION OF CASES 5-56
INSPECTION OF CASES 5-56
INSPECTION AND SUPPLY CHAIN
GUIDE TO THE TIMING CHAIN 5-56
INSPECTION OIL STRAINER 5-56
INSPECTION OF BEARINGS AND OIL SEALS 5-56
RETAINER BEARING INSPECTION 5-57
ASSEMBLY OF CASES 5-57

CRANKSHAFT 5-58
Remove Crankshaft 5-59
CRANKSHAFT INSPECTION 5-59
CRANKSHAFT ASSEMBLY 5-59

TRANSMISSION 5-61
CHECKING THE SHIFT FORKS 5-64
CHANGE DRUM INSPECTION 5-64
Transmission Inspection 5-64
MOUNT push rods 5-65
MAIN SHAFT ASSEMBLY AND DRIVE SHAFT 5-65
FITTING THE DRUM FORKS AND CHANGES 5-65

DESMONTAJE DEL MOTOR

ENGINE REMOVAL

Muffler Removal

1

2

12 Nm (1.2 m •kg, 9 ft •Ib)

4
3
15 Nm (1.5 m •kg, 11 ft •Ib)

20 Nm (2.0 m •kg, 14 ft •Ib)

1 Air Duct 2
2 Air Guide 1
3 Silencer 1
4 Exhaust gasket 1
procedure.
5-1


Disconnect cables and connectors
3
4
8 2

1

6

10
5

7 9
10 Nm (1.0 m •kg, 7 ft •Ib) 10 Nm (1.0 m •kg, 7 ft •Ib)


CAUTION
First, disconnect the battery negative
cable and then the positive cable from the
battery.

Negative battery cable / battery Refer to "CHECKING AND CHARGING THE
positive cable BATTERY" on page 7-34
Drain.
Motor oil See "ENGINE OIL REPLACEMENT" on
page 3-9

Refer to "FUEL TANK" on page 4-
2

1 Fuel tank 1 Disconnect

2 Spark plug 1 Disconnect

3 Starter Cable 1 Disconnect

4 Throttle Cable 1 Disconnect

5 TPS 1 Disconnect

6 Connector stator coils / crankshaft sensor 1/1 Disconnect
connector
7 Neutral switch connector 1 Disconnect

8 Clutch Cable 1 Disconnect

9 Negative battery cable 1 Disconnect

10 Arm changes 1 Disconnect
procedure
5-2


Engine removal
30 Nm (3.4 m •kg, 22 ft •Ib)

3
4

2
5

1 3

55 Nm (5.5 m •kg, 40 ft •Ib)

2

55 Nm (5.5 m •kg, 40 ft •Ib)
Silencer Refer to "ENGINE REMOVAL" on page 5-

1
Fuel tank Refer to "GENERAL CHASSIS" on
page 4-2
1 Screw / nut assembly of the motor 4/4
(Front Side)
(Bottom side rear)
(Rear upper side)
(Upper side)
5 Engine 1
procedure.
5-3


ENGINE MOUNTING
ARM ASSEMBLY OF CHANGES
1. Urge: 1. Install:
• Motor "1" • changes Arm "1"
•Motor mounting screw (upper side) "2"
•Motor mounting nut (rear upper side) "3"

Screw changes arm
•Motor mounting screw (rear lower side) "4"
10 Nm (1.0 m · kg, 7.2 ft · lb)
•Motor mounting nut (front side) "5"

NOTE:
1
Do not fully tighten the screws and nuts.

3

4

1

2

5

2. Tighten:
•Motor mounting nut (upper side)

Motor mounting nut
(Rear upper side)
30 Nm (3.0 m · kg, 22 ft · lb)

•Motor mounting nut (Underside rear)

Motor mounting nut
(Bottom side rear)
55 Nm (5.5 m · kg, 40 ft · lb)

• Nut mounting the engine (front side)

Motor mounting nut
(Front Side)
55 Nm (5.5 m · kg, 40 ft · lb)
5-4

CULATA

HEAD
Removing the cylinder head 22 Nm (1.0 m •kg, 16 ft •Ib)

13 Nm (1.3 m •kg, 9 ft •Ib) 10 Nm (1.0 m •kg, 7 ft •Ib) 8 Nm (0.8 m •kg, 6 ft •Ib)

5 9 Nm (0.9 m •kg, 7 ft •Ib)

E 8
E

6 8 Nm (0.8 m •kg, 6 ft •Ib)
1 New 9

20 Nm (2.0 m •kg, 14 ft •Ib)
New 10 LS
LS
7 New 11
2
M

E

12 14

13
4

15
14 10 Nm (1.7 m •kg, 7 ft •Ib)
3
7 Nm (7.0 m •kg, 5 ft •Ib)
Seat, side cover 1 side cover 2 Refer to "GENERAL CHASSIS"

on page 4-1
Fuel tank
Throttle cable, starter cable, clutch cable Disconnect
Refer to "REMOVAL
MOTOR "on page 5-2
Carburetor / Manifold Refer to "CARBURETOR" on page 6-1
Silencer Refer to "ENGINE REMOVAL" on page 5-

1
1 Spark plug 1 Disconnect
2 Plug 1
3 Access screw crank end 1
5-5

CULATA
Removing the cylinder head 22 Nm (2.2 m •kg, 16 ft •Ib)

10 Nm (1.0 m •kg, 7ft •Ib) 8 Nm (0.8 m •kg, 6 ft •Ib)

5 9 Nm (0.9 m •kg, 7 ft •Ib)

E 8
E 8 Nm (0.8 m •kg, 6 ft •Ib)
6
1 New 9

20 Nm (2.0 m •kg, 14 ft •Ib)
New 10 LS
LS
7 New 11
2
M

E

12 14

13
4

15
14 10 Nm (1.7 m •kg, 7 ft •Ib)
3
7 Nm (0.7 m •kg, 5 ft •Ib)

5 Head cover 1
6 Gasket head cover 1
7 Dowel pin 1
8 Tensor distribution chain 1
9 Tensioner Gasket chain 1
10 Camshaft sprocket 1
11 Decompression cam 1
12 Butt 1
13 Cylinder head gasket 1
14 Dowel pin 2
15 Guide the distribution chain (exhaust side) 1

procedure.
*Yamaha Adhesive No. 1215 (Three Bond No. 1215)
5-6

CULATA

REMOVING THE HEAD
1. Align:
• The brand "I" in the magneto rotor "a"1
(With the stationary mark "b" on the cover
Magneto)
2
a. Turn the crankshaft counterclockwise.
b. When the piston is in neutral

higher (PMS) on the compression stroke,
3. Remove:
align the "I" of the timing sprocket "c" with the
•Camshaft sprocket.
stationary mark "d" on the plate holding the

camshaft. NOTE:

To prevent the chain from falling into the
crankcase, with a cable hold.
b

4. Remove:
•Butt.
NOTE:

to •Loosen the screws in the correct sequence, as

shown.
•Loosen each bolt 1/2 turn each time. When all
bolts are completely loose, remove them.

d
4 2
6 2

c
3 1
5

d

HEAD INSPECTION
c 1. Delete:
•Carbon deposits from the chamber
combustion (with a rounded scraper).
NOTE:
Do not use sharp instrument to avoid damage or
scratches in:
•Spark plug thread
•Valve seats.

2. Loosen:
• Screw the timing sprocket "1".
NOTE:
While holding the magneto nut with a wrench "2",
loosen the screw on the camshaft sprocket.
5-7

CULATA

2. Check:
•Butt. a. ¼ tooth
Damage / scratches → Replace. b. Correct
•Water jacket of the cylinder head 1. Contact roller chain
Mineral deposits oxide / ‫ וי‬Delete. 2. Camshaft sprocket
3. Measure:
•Deformation of the cylinder head. 2. Check:
OOS → Grind the butt. •Guide chain
(Side Exhaust)

Strain Limit INSPECTION OF TENSION DISTRIBUTION
0.03 mm CHAIN

1. Check:
a. Put a rule "1" and a feeler gauge •Tensor of the distribution chain. Cracks / damage /
"2" along the cylinder movement
head. unequal Replace ‫וי‬.

a. Lightly press the tensioner rod chain inside
the box tensioner timing chain by hand.
NOTE:
While pressing the tensioner rod chain, turn to the
right with a
screwdriver "1" until it stops
b. Measure the deformation.

c. If the limit is exceeded, the butt rectified as
follows.
d. Place a wet sandpaper 400-600 on 1
the rectifying plate and the cylinder head
surface with a pattern of sanding a figure
eight.

NOTE:

To ensure a level surface, turn the head several
times. b. Remove the screwdriver and slowly release
the tensioner rod chain.
INSPECTION CAMSHAFT SPROCKET AND c. Make sure the tensioner rod chain leaves the
CHAIN GUIDE DISTRIBUTION box of ten so r na ca dist ri bu if n ci ng probl

em as. If there is sudden movement
1. Check:
procedures, replace the tensioner chain.
•Camshaft sprocket
Over one quarter of wear "a" in the tooth
‫וי‬Replace the camshaft sprocket, timing chain
and crankshaft as a
whole.
5-8

CULATA

INSPECTION SYSTEM
DECOMPRESSION B 2

1. Check:
• Decompression System
a. Check the decompression system with camshaft
sprocket and the decompression cam installed
on the camshaft.
b. Check that the decompression lever "1" moves
smoothly.
c. Without operate the decompression lever, check
that the decompression cam "2" projects from CYLINDER ASSEMBLY

the camshaft (exhaust cam) as shown in
1. Assembly:
illustration "A".
•Butt.
d. Move the decompression lever "1" as shown in
NOTE:
the direction of the arrow and check that the
decompression cam does not project from the Timing chain pass through the cavity of the
camshaft (exhaust cam) as shown in illustration distribution chain.
"B". 2. Tighten:
•Head bolts "1".
1
Head bolts
22 Nm (2.2 m · kg, 16 ft · lb)

•Head bolts "2".

Head bolts
10 Nm (1.0 m · kg, 7.2 ft · lb).

NOTE:
A •Lubricate the threads of the cylinder head bolts
with engine oil.
•Tighten the cylinder head bolts in the specified
2
sequence as shown and tighten
two steps.

2

5

1

2

3. Assembly:
•Camshaft sprocket.

a. Rotate the crankshaft counterclockwise.
b. Align the mark "I" in the magneto rotor "a" with
the stationary mark "b" on the magneto cover
5-9

CULATA

c. Align the "I" of the timing sprocket "c" with the c. tighten the tensioner timing chain "3" to the
stationary mark "d" on the plate holding the specified torque.
camshaft.
Screws chain tensioner distribution
d. Install the timing chain on the sprocket 9 Nm (0.9 m · kg, 7 ft · lb)
Camshaft and then install the camshaft
sprocket on the camshaft.

b

1

to

2

3
d

1

c

d. Remove the screwdriver, make sure the rod
NOTE: chain tensioner return distribution.

When installing the camshaft sprocket, make

sure to keep the chain on the exhaust side as
stressed as possible.
5. Turn:
•Crankshaft
(Several times clockwise)
CAUTION 6. Check:
Do not turn the crankshaft when installing the •"I" mark "a"
camshaft to avoid damage or malfunction of the Align the "I" of the magnet with the brand
valves. stationary "b" in the magneto cover.

e. While holding the camshaft, temporarily
tighten the screw shaft sprocket camshaft. •"I" mark "c"
Align the "I" of the camshaft sprocket with the
f. Remove the cable from the distribution chain.
stationary mark "d" in the butt.
4. Install:
•Tensioner Gasket chain New Out of alignment Correct ‫וי‬
•Tensor distribution chain See previous assembly steps.
a. While pressing gently rod
chain tensioner distribution with b
hand, turn it clockwise with a thin screwdriver
"1".
b. With tensor rod distribution chain completely
rotated in the box
tensor of the distribution chain (With
to
the screwdriver still installed), install
tensor packaging and distribution chain "2" in
the body of the cylinder.
5-10

CULATA

d

c

7. Tighten:
•Screw camshaft sprocket

Screw camshaft sprocket
20 Nm (2.0 m · kg, 14 ft · lb)

PRCAUCIÓN
Be sure to tighten the screw on the camshaft
sprocket with the specified torque to avoid the
possibility that the screw loosening and
damaging the motor.

8.
Measure:
•Valve clearance
OOS Adjust ‫וי‬.
Refer to "ADJUSTING THE VALVE
CLEARANCE" on page 3-3.
5-11

ÁRBOL DE LEVAS

CAMSHAFT
Removing the rocker arms and camshaft 22 Nm (2.2 m •kg, 16 ft •Ib)

10 Nm (1.0 m •kg, 7 ft •Ib)

7 6 1
13 Nm (1.3 m •kg, 9 ft •Ib)
3
2 2
1
M

M

5

E

4
E

M
Butt See "HEAD" on page 5-5

1 Locknut 2
2 Adjusting Screw 2
3 Retainer camshaft bearing 1
4 Camshaft 1
5 Rocker 2
6 Intake rocker 1
7 Exhaust Rocker 1

procedure.
5-12

ÁRBOL DE LEVAS

REMOVING THE ROCKER ARMS AND Dimensions of the camshaft
CAMSHAFT lobes
1. Loosen:
•Locknut "1" Admission
31342-31442 mm
•Adjustment screw valve clearance "2" Limit
•Rocker "3" 31,342 mm
2
Admission B
1 25166-25266 mm
Limit
25,136 mm
3
Escape A
31110-31210 mm
Limit
31,080 mm

2. Remove: Escape B
•Camshaft "1" 25096-25196 mm
Limit
NOTE:
25,066 mm
8-mm screw "2" on the threaded end of the camshaft and then
remove the camshaft.

b

1

2

to

CAMSHAFT INSPECTION
1. Check:
•Camshaft Lobe
Blue discoloration / pitting /
scratches Replace‫ וי‬the camshaft.

2. Measure:
•Dimension of the lobes Camshaft
"A" and "b"
OOS Replace ‫ וי‬the 3. Check:
camshaft. •Oil passage camshaft
Blocked Blow ‫ וי‬compressed air
㻚

CHECKING THE ROCKER ROCKER AND
AXLES
The following procedure applies to all the rockers
and rockers.
1. Check:
•Rocker
5-13

INSPECCIÓN DEL ÁRBOL DE LEVAS

2. Check:
•Rocker Shaft Clearance between the rocker
Blue discoloration / pitting excessive wear / arm and rocker aje
scratches Replace ‫ וי‬to verify 0009-0034 mm
Limit
lubrication system. 0.08 mm
3. Measure:
•Bore rocker "A"
OOS Replace ‫וי‬. ASSEMBLY CAMSHAFT AND ROCKER
1. Lubricate:
Bore rocker •Rocker
9985-10000 mm •Rocker shafts
Limit
10,030 mm Recommended lubricant
Inner surface of the rocker
molybdenum disulfide oil to the
rocker shaft
Motor oil

2. Lubricate:
•Camshaft

Camshaft
Oil molybdenum disulfide camshaft
bearings Motor Oil

4. Measure: 3. Install:
•Outside diameter of rocker "A" •Intake and exhaust rocker arms
OOS Replace ‫וי‬. •Rocker Shaft

Outside diameter of rocker
9966-9976 mm
Limit
9950 mm

5. Calculate:
•Clearance between the rocker arm and rocker
NOTE:
Calculated by subtracting the outside diameter
clearance rocker shaft bore
rocker.
OOS Replace ‫ וי‬defective parts.
5-14

VÁLVULAS Y RESORTES DE VÁLVULAS

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

1
1
2
3
2
3 6New
New 6

7
7 M
M

M
M
4
5

Rocker / Camshaft Refer to "CAMSHAFT" on page 5-12
1 Pin Valve 4
2 Upper spring seat of the valve 2
3 Valve spring 2
4 Inlet valve 1
5 Exhaust valve 1
6 Seal valve stem 2
7 Lower spring seat valve 2
8 Valve guide 2

procedure.
5-15


REMOVING THE VALVES
NOTE:
The following procedure applies to all valves and Identify the position of each part very carefully
related components. so that it can be reinstalled in its original place.

NOTE:
Before removing the internal parts of the head
(eg, valves, valve springs, valve seats), make
sure the valves seal well.
1. Check:
•Sealing of valves
Leaking valve seat Verify ‫וי‬

the face of the valve, valve seats, and the
width of the valve seat.
INSPECTION valves and valve guides
Refer to "CHECKING THE VALVE SEATS" on
page The following procedure applies to all valves and
5-17. valve guides.
a. Pour a clean solvent "a" in the input and output 1.
ports Measure:
b. Check valve seal •Clearance between the valve stem and
valve guide
NOTE:
OOS Replace ‫ וי‬the butt
There is no leakage in the valve seat "1".
•Clearance between the valve stem and valve
guide = Inner diameter of the valve guide "a" -
diameter of the valve stem "b"

Clearance between the valve
stem and the valve guide
(Admission)
0010-0037 mm
2. Remove: Limit
0080 mm
•Pines valve "1".
Clearance between the valve
NOTE: stem and the valve guide
Remove the valve pin compressing the valve (Escape)
spring with the spring compressor and the valve
spring compressor adapter valve "2" 0025-0052 mm
Limit
Compressor valve spring 0.100 mm
YSST-603
A-803 YSST

2

1
3. Remove:
•Upper spring seat of the valve "1"

•Valve spring "2"
•Valve "3"
•Seal valve stem "4" Clearance valve and valve guide = a-b
•Lower spring seat valve "5"
5-16


2. Delete:

CHECKING THE VALVE SEATS
•Carbon deposits
(From the valve face and valve seat) The following procedure applies to all valves
3. Check: and valve seats.
•Valve face 1. Delete:
Pitting / wear Rectify ‫ וי‬face •Carbon deposits
valve. (From the valve face and valve seat)
•End of the valve stem 2. Check:
Mushroom
stem to the or a larger
valve diameter
Replace ‫וי‬. than the valve •Valve Seat
4. Measure: Pitting / wear Replace ‫ וי‬the butt.
•Thickness D of the valve margin "a" 3. Measure:
OOS Replace ‫ וי‬valve. •Width of the valve seat C "to" Out of
specification Replace ‫ וי‬the
Thickness of the valve margin butt.

D (Admission) Width of the valve seat
From 0.50 to 0.90 mm C(Admission)
Thickness of the valve margin 0.90-1.10 mm
D (Escape) Width of the valve seat
From 0.50 to 0.90 mm) C(Escape)
0.90-1.10 mm)

5. Measure:
•Deformation of the valve stem
valve. a.Instale valve in the cylinder head.
NOTE:
•When installing a new valve, always replace
the valve guide.
•If the valve is removed or replaced, always
replace the stem seal
the valve.

Limit deformation of the
valve stem
0,010 mm

b. Pressing the valve through the valve guide and
the valve seat to make a clear print.
c. Measure the width of the valve seat. NOTE:
When the valve seat and the face of the
valve have been in contact with each other, the
blue dye has been removed.
5-17


4. Grind:
•Valve face
•Valve Seat
NOTE:
After replacing the head or replace the valve
and the valve guide, should be lapped the valve
seat and valve face

a. Apply lapping compound secondary

"A" to the valve face. e. Apply a fine lapping compound to the valve

CAUTION face and repeat the above steps.
f. After every lapping procedure, be sure to clean
Do not let enter the lapping compound between
the valve stem and valve guide. all of the mixture to
lapping the face of the valve and valve seat.

b. Apply molybdenum disulfide oil to the valve g. Install the valve in the cylinder head.
stem. h. Pressing the valve through the end of the
valve guide and the valve seat to make a
clear print.
i. Measure the width of the valve seat "c" again.
If the width of the valve seat out of
specification, and correct it again lapping the
valve seat.

c. Install the valve in the cylinder
head
d. Turn the valve until the valve face and valve
guide seats are uniformly bright, clean after all
the lapping compound.

NOTE:
For best lapping results, lightly tap the valve seat
while CHECKING THE VALVE SPRINGS The following
turn the valve back and forth between his procedure applies to all valve springs.
hands. 1.
Measure:
•Free length of valve spring "to" Out of
Specification Replace ‫ וי‬the
valve spring.
5-18


Tilting the compression
Free length (Admission) spring (Admission)
39.40 mm 2.5 ° / 1.7 mm
Limit Tilting the compression
37.40 mm spring (Escape)
Free length (Escape) 2.5 ° / 1.7 mm

39.40 mm
Limit
37.40 mm

VALVE ASSEMBLY
The following procedure applies to all
valves and related components.
2. 1. Remove burrs:
Measure:
•Compression force of the spring installed in •End of the valve stem
valve "" (With an oil stone)
valve spring.

Force compression spring installed
(Admission)
160-184
Force compression spring installed
(Escape)
160-184
Installed length (Admission)
34.50 mm
Installed length (Escape)
34.50 mm 2. Lubricate:
•Valve stem "1"
•Seal valve stem "2" New
(With the recommended lubricant)

With the recommended lubricant
Molybdenum disulfide oil

New

b. Installed length

3. Measure:
•Tilt the valve spring "to" Out of
Specification Replace ‫ וי‬the
valve spring.
3. Install:
•Lower spring seat valve "1"
5-19


•Seal valve stem "2" New
•Valve "3"
•Valve spring "4" 1
•Upper spring seat valve "5" (in the butt)

NOTE:
•Ensure that each valve is installed in its original
position
•Install the valve with the long end "a"
upwards.

5. To ensure the valve pin in the valve stem,
lightly tap the valve tip with a soft-faced
hammer.

CAUTION
Hitting the valve tip with excessive force could
damage the valve.
b. Short end

4. Install:
•Pines valve "1"
NOTE:
Install the valve pin compressing the valve
spring with the spring compressor and the valve
spring compressor adapter valve "2"

Compressor valve spring
YSST-603
A-803 YSST
5-20

CILINDRO Y PISTÓN

CYLINDER AND PISTON
Removing the cylinder and piston

7
E
8
9 6

5 E

New 4 4New

1
E

E

2New

3

3

1 Cylinder 1
2 Cylinder Gasket 1
3 Dowel pin 2
4 Piston pin 2
5 Piston pin 1
6 Piston 1
7 Top Ring 1
8 Second ring 1
9 Ring oil 1
procedure.
5-21

CILINDRO Y PISTÓN

REMOVAL cylinder and piston

1.
Remove:
•Piston pin "1"
•Piston pin "2"
•Piston "3"

CAUTION
Do not use a hammer to remove the piston pin

NOTE:
•Before removing the piston pin, cover the
crankcase opening with a clean rag to prevent

the piston pin from falling into the crankcase. INSPECTION cylinder and piston
1. Check:
•Before removing the piston pin, pin clean burrs •Piston wall
from piston pin and the groove of the piston
•Cylinder wall
area.
Vertical scratches Replace ‫ וי‬cylinder,
the piston and piston rings, as a whole.
2. Measure:
•Piston-cylinder clearance

a. Measure cylinder bore "C" with the cylinder
with the cylinder diameter meter.
2 1

3

2. Remove: NOTE:
•Top Ring Measure cylinder bore "C" verifying
•Second ring measurements from side to side and front to back
•Ring oil measurements of the cylinder. Then, find the
average of the measurements.

Diameter
NOTE:
58000-58010 mm
When removing a piston ring, open the end inal
fingers and lift the other side of the ring
on the piston head.
5-22

CILINDRO Y PISTÓN

"C" = maximum of D1-D2 CHECKING THE PISTON RINGS
"T" = maximum of D1 or D2 - Up to D5 or D6 1. Measure:
•Ring Side Clearance
"R" = maximum of D1, D3 or D5 - Minimum of OOS Replace‫ וי‬piston
and piston rings, as a whole. NOTE:
D2,
D4 or D6 Before measuring the lateral clearance of the
ring,
remove carbon deposits from the slots
b. If out of specification, replace the cylinder, piston and rings.
piston and piston rings as a set.
c. Measure the diameter of the piston skirt "D"

Piston Rings
"a" with the micrometer. Top Ring
Ring Side Clearance
0030-0065 mm
Limit
0.100 mm
Second ring
Ring Side Clearance
0020-0055 mm
Limit
0.100 mm

b. 5.0 mm (0.20 in) from the lower edge of the
piston

Piston
Diameter D
53970-53985 mm

d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the clearance with the cylinder-
piston
following formula. 2. Install:
•Piston Ring
•Piston-cylinder clearance = Cylinder bore "C" (Inside the cylinder)
- piston skirt diameter "D"
NOTE:

Piston-cylinder clearance Level the piston ring in the cylinder with the
0020-0035 piston head.
Limit
0.15 mm

f. If out of specification, replace the cylinder,
piston and piston rings as a set.

a. 40mm
5-23

CILINDRO Y PISTÓN

3. 3. Measure:
Measure: •Inner diameter of the piston pin hole "a"
•Distance between centers of rings Out of specification Replace piston ‫וי‬
OOS Replace‫ וי‬the
piston rings. Bore piston pin hole
NOTE: 15002-15013
The opening of the oil ring spacer can not be Limit
measured. In case the oil ring opening is 15,043 mm
excessive, replace the three segments as a
whole.

Piston Rings
Top Ring
Distance between tips of ring
(Installed)
0.10 to 0.25 mm
Limit
0.40 mm
Second ring
Distance between tips of ring
(Installed)
0.10 to 0.25 mm
Limit 4. Calculate:
0.40 mm •Piston pin clearance - inner diameter of piston
Ring oil pin
Distance between tips of ring OOS ‫וי‬Replace
(Installed) piston pin and the piston as a whole.
0.20 to 0.70 mm

•Piston pin clearance - inner diameter of piston
pin bore = piston pin hole "b" - Outer diameter
INSPECTION PISTON PIN of piston pin "a"
1. Check:
•Piston pin
Blue discoloration / grooves Replace ‫וי‬ Install piston and cylinder
piston pin and then check the lubrication 1. Install:
system •Top ring "1"
2. •Second ring "2"
Measure: •Oil ring expansion "3"
•Outer diameter
specification of piston
Replace ‫ וי‬pin "a" Out of •Oil lower guide ring "4"
piston pin •Oil Ring top guide "5"
NOTE:
Outer diameter of piston pin Be sure to install the piston rings so that the
14995-15000 mm manufacturer's marks or numbers
Limit
are up.
14,975 mm
5-24

CILINDRO Y PISTÓN

and to
120 °

b
120 ° 120 °

90 º
d 45 ° c
A 45 º

2. Install: a. Top Ring
•Piston "1" b. Oil ring expander
•Piston pin "2" c. Upper guide ring oil
•Piston pin "3" New d. Oil lower guide ring
e. Second ring
NOTE:
A. Side exhaust
•Apply engine oil to piston pin.
•Make sure the arrow mark "a" piston points towards 5. Install:
the exhaust side of the cylinder. •Dowel pin
•Before installing the piston pin pin, cover the •Head gasket New
crankcase opening with a clean •Cylinder "1"
to prevent the pin from falling into the crankcase.
NOTE:
•While compressing the piston rings with one
1 hand, install the cylinder with the other hand.
Pass the chain and guide the chain (intake side)
• through the cavity of the distribution chain.
to 2

3New 1

3. Lubricate:
•Piston
•Piston Rings
•Cylinder

Engine Oil

4. Scroll:
•Tips piston rings
5-25

MAGNETO Y EMBRAGUE DEL ARRANQUE

MAGNETO AND STARTER CLUTCH

Removing the magneto and starter clutch

1

2
10 Nm (1.0 m kg, 7ft Ib)
l l

LT
9
10 Nm (1.0 m kg, 7ft Ib)
l l
12 8
7New

10
14 3 LS
17 8
19 16 15
E New
E
13 4
E 6
New 18 New
5
E
14 Nm (1.4 m kg, 10 ft Ib)
l l

New LS

20
E
11
10 Nm (1.0 m kg, 7ft Ib)
l l
70 Nm (7.0 m kg, 51 ft lb)
l l
Drain
page 3-9
Cover transmission chain See "chain of transmission" on page
4-53
1 Connector stator coil 1 Disconnect
2 Connector crankshaft position sensor 1 Disconnect
3 Cable connector neutral switch 1 Disconnect
4 Screw access to the time stamp 1
6 Magneto cover 1
7 Package magneto cover 1
8 Dowel pin 2
9 Crankshaft Position Sensor 1
10 Stator coil 1
11 Magneto Rotor 1
5-26


Removing the magneto and starter clutch
1

2
10 Nm (1.0 m kg, 7ft Ib)
l l

LT
9
10 Nm (1.0 m kg, 7ft Ib)
l l
12 8
7New

10
14 3 LS
17 8
19 16 15
E New
New
E
13 4
E 6
New 18 New 5
E
14 Nm (1.4 m kg, 10 ft Ib)
l l
New LS

20
E
11
10 Nm (1.0 m kg, 7ft Ib)
l l
70 Nm (7.0 m kg, 51 ft lb)
l l

12 Woodruff key 1
13 Starter Clutch Sprocket 1
14 Tread 1
15 Washer 1
16 Shaft freewheel clutch starter 1
17 Washer 1
18 Pin lock 1
19 Freewheel clutch starter 1
20 Starter Clutch 1

procedure.
5-27


MAGNETO REMOVAL
1. Remove:
•Magneto rotor nut 2
•Washer
NOTE:
•While holding the magneto rotor using the rotor
magnet holder "1", loosen the rotor magnet.
1

STARTER CLUTCH REMOVAL
1. Remove:
•Starter clutch bolts "1"
1
NOTE:
•While holding the rotor magnet with magnet
holder, remove the starter clutch bolts "1"

1

Magnet holder
YSST-601B

2. Remove:
•Rotor magnet "1"
(With the magneto puller "2")
STARTER CLUTCH INSPECTION
•Woodruff key
1. Check:
CAUTION •The starter clutch rollers "1"
To protect the end of the crank, placing a suitably •Clutch Covers Spring Starter "2"
•Clutch springs engine
sized wrench between the extractor and the
Boot "3"
crankshaft magnet. Damage / wear Replace ‫ וי‬the clutch
boot.
NOTE:
Make sure the exhaust is centered on magneto
magneto rotor.

Magneto Puller
YSST-628
5-28


1 2 NOTE:
3
•While holding the rotor magnet,
tighten the starter clutch "1".
1
•Mark end "A" of each screw
starter clutch.
2

3
3 1
2 1

2. Check:
•Freewheel starter clutch
•Starter Clutch Sprocket
Burrs / chips / roughness Replace ‫וי‬
defective parts.
3. Check:
•Contact surfaces Starter Clutch Damage /
pitting / wear ‫וי‬
Replace the starter clutch gear.
4. Check:
•Starter Clutch Operation to
a. Install the starter clutch gear "1"
the starter clutch and hold the rotor to
magneto rotor.
b. When turning the starter clutch pinion
clockwise "A", the starter clutch and the starter
clutch gear should
mesh, otherwise the starter clutch to
is defective and must be replaced.
c. When turning the starter clutch pinion
counterclockwise "B", should turn freely,
otherwise the starter clutch is faulty and must
be replaced. MOUNTING MAGNETO
1. Install:
• Woodruff key magnet
A 1 • rotor Rotor Washer
• Magneto rotor nut
•
B
NOTE:
•Clean the tapered portion of the crankshaft and

magneto rotor shaft.
•When installing the magneto rotor, make sure
the woodruff key is properly
seated in the groove of the crankshaft.

STARTER CLUTCH ASSEMBLY 2. Tighten:

1. Install: •Magneto rotor nut "1"
•Starter Clutch
Magneto rotor nut
•Starter clutch bolts "1" New 70 Nm (7.0 m · kg, 50 ft · lb)

Starter clutch bolts
14 Nm (1.4 m · kg, 10 ft · lb)
5-29


NOTE:

•While holding the magneto rotor "2", tighten the 7
1.6 8
magneto rotor nut "1".
5

1 9
4

3
2.10

2

3. Apply:
•Sealant
(In the crankshaft position sensor / the
buttonhole for mounting the stator wire)

Yamaha Adhesive No. 1215
TG-1215

LS

4. Install:
•Magneto cover

Screw magneto cover
10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
Tighten the magneto cover in the proper tightening
sequence as shown.
5-30

ARRANQUE ELÉCTRICO

ELECTRIC START

Removing the starter motor

2 Nm (0.2 m •kg, 1ft • Ib)

10 Nm (1.0 m •kg, 7ft • Ib)

(2)

2

1

1 Starter 1
2 Starter Cable 1 Disconnect

procedure.
5-31

ARRANQUE ELÉCTRICO

Disassemble the starter

11

2 9

10

3
1
4 5
6
7
8

1 Starter 1
2 Cover Package 1
3 Set of carbon brushes 1
4 Support carbon brushes 1
5 Oil Seal 1
6 Pin lock 1
7 Stop washer 1
8 Washer 1
9 Tread 1
10 Front cover starter 1
11 Starter 1
procedure.
5-32

ARRANQUE ELÉCTRICO

STARTER REMOVAL NOTE:
1. To ensure proper operation of the switch must
Remove: be lowered mica.
•Starter "1"
•Motor front cover
start / brush holder assembly "2"

NOTE:
Before disassembling the starter, make alignment
marks "a" in the starter cover and front cover
starter / brush holder assembly.

1

2 4. Measure:
•Armor resistances (commutator and
insulation)
OOS Replace‫ וי‬the motor
boot.

to a. Measure the resistance of the armor with the
multimeter.
STARTER INSPECTION
1. Check: Multimeter

•Switch
Dirt Cleaning ‫ וי‬with 600 grit
sandpaper.
2. Measure: Armor Coil
•Diameter of the switch "a" Resistance of the switch "1"
OOS Replace‫ וי‬the Ù 0.0315 to 0.0385 at 20 ° C (68 ° F)
starter.

Limit
17.6 mm b. If the resistance is out of specification
Replace‫ וי‬starter.

to

3. Measure:
•Mica recess "a" 5. Measure:
OOS ‫וי‬Undercut the mica to the proper size •Brush length "a"
with a saw blade for metal frosted, until it
motor front cover
clicks into the switch.
start / brush holder assembly

Mica undercut (depth) Brushes length "a"
2.10 mm 7.5 mm
Limit
4.0 mm
5-33

ARRANQUE ELÉCTRICO

6. Check:
•Pinion Teeth
Damage / wear Replace ‫ וי‬pinion.
7. Check:
•Tread
•Oil Seal
Damage / wear Replace ‫ וי‬cover
front starter / brush holder assembly
STARTER ASSY
1. Install:
•Front cover starter /
Brush holder assembly "1"
•Starter Deck "2"

NOTE:
Align the marks "a" in the starter cover and
front cover starter / bracket assembly.

1

2

to
5-34

EMBRAGUE

CLUTCH

Removing the clutch cover

9 Nm (0.9 m •kg, 7ft • Ib)

1

8
New 7

New 2

E

5 4

6 New

LS
3

LS (4) (6)

10 Nm (1.0 m •kg, 7ft • Ib) 10 Nm (1.0 m •kg, 7ft • Ib)
Drain
page 3-9
1 Clutch cable 1 Disconnect
2 Oil Seal 2
3 Oil filter cover 1
4 Oil filter 1
5 Dowel pin 2
6 Clutch cover 1
7 Gasket clutch cover 1

procedure.

EMBRAGUE

Clutch Removal

70 Nm (7.0 m kg, 51 ft lb)

11 New

8 Nm (0.8 m kg, 6ft Ib)

E
3 10 12
6
4
5
1

15
(4) 7
2 8 13
(4) 9
8
7 14
8
7

E

E

1 Locknut 1
2 Clutch Spring 4
3 Pressure Plate 1
4 Short rod Clutch thrust 1
5 Fastener the clutch pushrod 1
6 Ball 1
7 Friction Disc 1 2
8 Clutch disc 3
9 Friction Disc 2 2
10 Nut disc holder 1
11 Lockwasher 1
12 Disc holder 1
13 Thrust Washer 1
14 Clutch 1
15 Conical spring washer 1

procedure.
5-36

EMBRAGUE

Removing the push lever

1

E
2

3New

LS
E

4New

5
Clutch Refer to "CLUTCH" on page 5-35

1 Clutch thrust lever 1
2 Spring clutch push lever 1
3 Pin lock 1
4 Oil Seal 1
5 Tread 1

procedure.
5-37

EMBRAGUE

CLUTCH REMOVAL

1. Straighten the lock washer.
2. Loosen:
•The clutch disc holder nut "1"
NOTE:
While holding the tray clutch "2" with the clutch
holder "3", loosen the nut on the clutch disc
holders.

Clutch Holder
YSST-733

A B
2

1

3 XY

A. Friction Disc 1
INSPECTION OF RECORDS OF FRICTION The B. B. Friction Disc 2
following procedure applies to all friction discs.
1. Check: X= The space between the friction material
•Friction disc coating on the friction disc 1.
Damage / wear Replace ‫ וי‬discs And= The space between the friction material
friction as a whole. coating on the friction disc 2.
2. 2.
NOTE:
Measure:
The space X must be less than the disc space
•Thickness of the friction plates
and one friction and friction disc 2, respectively.
friction disks as an assembly. CHECKING THE CLUTCH DISCS
NOTE: The following procedure applies to all the clutch
Measure the friction plates in four places. plates.
1. Check:
Thickness of the friction plates •Clutch disc
1&2 Damage / wear Replace ‫ וי‬discs
2.90-3.10 mm clutch as a whole.
Wear limit 2. Measure:
2.80 mm
•Deformation of the clutch plates
(With a surface plate and thickness gauge "1")
Out of Specification ‫וי‬
Replace the clutch plates as a set
5-38

EMBRAGUE

Thickness of clutch discs
1.85-2.15 mm
Strain Limit
0.20 mm

2. Check:
•Tread
Damage / wear Replace ‫ וי‬bearing
and the clutch.

CLUTCH INSPECTION caddy
CHECKING THE CLUTCH SPRINGS 1. Check:
The following procedure applies to all clutch •Lace the clutch disc carrier
springs. Damage / pitting / wear Replace ‫וי‬
1. Check: the tray clutch.

•Clutch springs NOTE:
Damage Replace ‫ וי‬Clutch springs
Stings in the caddy lace clutch will cause erratic
a set
operation of the clutch.
2. Measure:
•Free length of clutch springs "to" Out of
Specification ‫וי‬Replace
clutch springs as a whole

Free length of the clutch
springs
41.60 mm
Minimum length
40.60 mm
PRESSURE PLATE INSPECTION

1. Check:
•Pressure Plate
Cracks / damage Replace ‫ וי‬dish
pressure.

PRIMARY DRIVE GEAR INSPECTION

CHECKING THE CLUTCH BELL
1. Check:
•Pressure Plate
1. Check: •Cracks / damage Replace ‫ וי‬dish
•Lace clutch of "1" Damage / pitting / wear pressure.
Deburring ‫וי‬
lace of the clutch or replace the clutch. PRIMARY DRIVE GEAR INSPECTION

NOTE: 1. Remove:
Lace pitting the clutch will cause erratic operation •Primary drive gear
of the clutch. See "BALANCER SPROCKET"
on page 5-49.
5-39

EMBRAGUE

2. Check: NOTE:
•Primary drive gear Make sure the corners with sharp edges of the thrust
Damage / wear Replace ‫ וי‬gear washer "a" is placed opposite the clutch disc
primary drive and clutch as a whole. holders.
Excessive noise during operation ‫וי‬

Replace the primary drive gear and the clutch
as a whole. 1
3. Install:
•Primary Drive Gear See "BALANCER
SPROCKET" on page 5-49.
to
PRIMARY DRIVEN GEAR INSPECTION
1. Check:
•Primary driven gear "1"
Damage / wear Replace ‫ וי‬gear
primary drive and clutch as a whole. Excessive
noise during 3. Install:
operation Replace ‫ וי‬drive gear •Clutch disc carrier "1"
primary and the clutch as a whole. •Lockwasher "2" New
•Nut caddy
NOTE:
•Lubricate the threads of the nut and clutch disc
holder contact surfaces of the lock washer with
engine oil.
1 •Align the notch "a" in the washer with a lower rib
"b" in the tray clutch.

New 2 1

b

CLUTCH ASSEMBLY
1. Install:

•Conical spring washer "1"
to
NOTE:
Install the conical washer, as shown in the
illustration. 4. Tighten:
•Caddy clutch nut "1"

1 Clutch Nut caddy
70 Nm (7.0 m · kg, 50 ft · lb)

NOTE:
While holding the tray clutch "2" with the clutch
holder "3", press the
caddy clutch nut.

Clutch Holder
2. Install: YSST-733
•Clutch Bell
•Thrust washer "1"
5-40

EMBRAGUE

2

1

5. Fold the tab washer along a flat side of the nut.
6. Lubricate: 9. Fit:
•Friction Plates •Free play of the clutch mechanism

•Clutch discs
a. Verify that the projection "a" on the clutch lever "1" is
aligned with the mark "b" shown in the illustration of
Recommended lubricant the crankcase, pushing the clutch lever manually
Engine Oil push in the direction "c" until it stops.
7. Install:
•Seat cushion spring
Clutch "1" to
c
•Clutch damper spring "2"
•Two friction discs b
•Clutch discs 1
•Friction Plates 1
NOTE:
•Install the seat cushion clutch spring and
damper spring clutch as shown in the
illustration. b. If the projection "a" is not aligned with the
mark "b", aligned as follows:
•First, install a friction disk and then switch
between a clutch plate and friction disc. •Loosen the locknut "2".
•With the push lever clutch completely pushed
in the direction "c", turn the push rod clutch
short "3" inward or outward until the
projection "a" is aligned with the mark "b".
•Hold the short rod thrust
12 clutch to keep it from moving and tighten the
locknut to specifications.

Nut (short push rod clutch)
8 Nm (0.8 m · kg, 5.8 ft · lb)

8. Install:
•Pressure Plate
•Clutch springs "1"
•Screws clutch springs "2" 2

Screws clutch springs
8 Nm (0.8 m · kg, 6 ft · lb)

NOTE: 3
Tighten the clutch springs in stages and in a
crisscross pattern.
5-41

EMBRAGUE

10. Install:
•Oil Seal "1"
•Oil Seal "2"

1
to

2

b

11. Install:
•Clutch cover

Clutch cover screw
10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
Tighten the cover screws
clutch in the proper tightening sequence as
shown.

1.9
8 10
11

7 12

6

13

5

4 3.15 2.14

13. Fit:
•Freeplay clutch cable See "FREE PLAY
ADJUSTMENT CABLE CLUTCH" on page 3-
10.
5-42

BOMBA DE ACEITE

OIL PUMP

Removing the oil pump

3

4 Nm (0.4 m •kg, 3ft • Ib)

2
4 Nm (0.4 m •kg, 3ft • Ib)

1

LT
LT

10 Nm (1.0 m •kg, 7ft • Ib)
10 Nm (1.0 m •kg, 7ft • Ib)
Primary drive gear / pinion balancer See "BALANCER SPROCKET" on

page 5-49
1 Oil deflector plate 1
2 Oil pump 1
3 Primary drive gear oil pump 1

procedure.
5-43

BOMBA DE ACEITE

Disassembly of the oil pump

2

6

5

4

3

E

1
E

1 Housing cover oil pump 1
2 Pin 1
3 Primary driven gear oil pump 1
4 Internal rotor of the oil pump 1
5 External rotor of the oil pump 1
6 Pump housing oil 1

procedure.
5-44

BOMBA DE ACEITE

CHECKING THE OIL PUMP
Clearance between the inner
1. Check: rotor and the outer rotor
•Primary drive gear oil pump Less than 0.15 mm
•Primary driven gear oil pump Limit
•Pump housing oil 0.20 mm
Cracks / damage / wear Replace ‫ וי‬the Clearance between the outer rotor
defective parts. and the casing of the oil pump
2. Measure: 0.13 to 0.19
•Clearance between the inner rotor and outer rotor mm
Limit
"a"
0.15 mm
•Clearance between the outer rotor and the Clearance between the casing
casing of the oil pump "b" of the oil pump and the inner
• Clearance between the casing of the oil pump and outer rotors
and the inner and outer rotors "c". 0.06 to 0.11
Out of specification Replace pump ‫וי‬ mm
oil. Limit
0.15 mm

3. Check:
•Pump operation
Rough movement Repeat ‫ וי‬Steps (1)
and
(2) or replace the defective part.

ASSEMBLY OIL PUMP
1. Lubricate:
•Internal rotor of the oil pump
•External rotor of the oil pump

•Primary driven gear oil pump (With the
recommended lubricant)

1. Internal rotor
2. External rotor Engine Oil
3. Housing oil pump
2. Install:
•Internal rotor of the oil pump
•External rotor of the oil pump "1"
•Primary driven gear oil pump
•Pin "2"

NOTE:
When installing the inner rotor, align the pin "2"
on the shaft of the oil pump slot with "a" in the
inner rotor "1."
5-45

BOMBA DE ACEITE

1
2
to

3. Check:
•Operation of the oil pump Refer to
"CHECKING THE OIL PUMP" on page 5-
45.

MOUNT OIL PUMP
1. Install:
•Oil pump

Screw oil bulges
4 Nm (0.4 m · kg, 2.4 ft · lb)

CAUTION
After tightening the screws, make sure the oil
pump rotates smoothly.
5-46

EJE DE CAMBIOS

SHIFT SHAFT

Removing the shift shaft and lever stop

6

LS

New 2

E 3

LT
4
5

1

9 Nm (0.9 m •kg, 7ft • Ib)
Shift arm
1 Axis of changes 1
2 Pin lock 1
3 Shift shaft spring 1
4 Lever cap 1
5 Stopper lever spring 1
6 Oil Seal 1

procedure.
5-47

EJE DE CAMBIOS

SHIFT SHAFT INSPECTION
1. Check:
•Axis of changes
Curves / damage / wear Replace ‫וי‬.
•Changes shaft spring

INSPECTION STOP LEVER
1. Check:
•Lever cap
Curves / damage Replace ‫וי‬.
Roller turns roughly Replace ‫ וי‬the top of
the lever.
•Stopper lever spring

CHANGES Shaft Assembly
1. Install:
•Top of the lever "1"
•Stopper lever spring "2"
NOTE:
•Hook the ends of the spring lever stop at the top
of the lever and the crankcase boss "3".
•Engage the lever stop the drum segment
changes.

3

21

2. Install:
•Axis of changes "1"
NOTE:
Hook the end of the shift shaft spring on the
spring axle stop change "2".

21
5-48

PIÑÓN DEL BALANCEADOR

BALANCER SPROCKET

Removing the balancer sprocket and
primary drive gear

6

5
15
13 10
4 14
3 9

1
12
E 11
60 Nm (6.0 m •kg, 43 ft •Ib)

8

7New
2 45 Nm (4.5 m •kg, 33 ft •Ib)

1 Primary drive gear nut 1
2 Nut balancer drive gear 1
3 Washer 1
4 Primary drive gear 1
5 Primary balancer drive gear 1
6 Cotter straight 1
7 Lockwasher 1
8 Plate 1 of the balancer driven gear 1
9 Balancer driven gear 1
10 Cup stop 1
11 Spring 4
12 Dowel pin 2
13 Cotter straight 1
14 Plate 2 balancer driven gear 1
5-49


Removing the balancer sprocket and
primary drive gear

6

5
15
13 10
4 14
3 9

1
12
E 11
60 Nm (6.0 m •kg, 43 ft •Ib)

8
45 Nm (4.5 m •kg, 33 ft •Ib)
7New


15 Spacer 1

procedure.
5-50


BALANCER SPROCKET ASSEMBLY PRIMARY BALANCER DRIVEN
GEAR
1. Loosen: 1. Assembly:
•Primary drive gear nut "1" •Dowel pin "1"
NOTE: •Springs "2"
Place a sheet of leather or a leather "a" between (With the glass ceiling)
the primary drive gear anceador bal "2" and led
engranaj primary balancer and "3", and then NOTE:
loosen the nut of gear driving primary. Install the pins and springs alternately as shown.

2

3

1 1

to
2
2. Straighten the lock washer. 2. Assembly:
3. Loosen: •Glass ceiling "1"
•The primary driven gear nut balancer "1" •Primary balancer driven gear "2"
NOTE:
NOTE:
Place an aluminum plate "a" between the Align the punch mark "a" in the glass ceiling with
primary balancer drive gear "2" and the primary the punch mark "b" on the balancer driven gear
balancer driven gear "3", and then loosen the nut primary.
on the balancer driven gear primary.

to 1
2

1
b to 2
MOUNT BALANCER GEARS AND GEAR
3 PRIMARY CONDUCTOR
1. Install:

INSPECTION PINION BALANCER GEARS AND •Primary balancer drive gear "1"
•Lockwasher New
GEAR PRIMARY CONDUCTOR
•Primary balancer driven gear "2"
1. Check: •Primary drive gear
•Primary balancer drive gear •Washer "3"
•Nut primary driven gear
•Primary balancer driven gear balancer
•Cup stop •Primary drive gear nut
•Spring
NOTE:
•Dowel pin
Cracks / damage / wear Replace ‫וי‬. •Align the punch mark "a" on the primary drive
gear balancer with the punch mark "b" on the
2. Check: balancer driven gear primary "1".
•Primary drive gear •Make sure the corners with sharp edges of the
See " INSPECTION thrust washer "c" stands next
Primary drive gear "On page 5-39. opposite the primary drive gear.
5-51


b
2 3
1

2

4
to b

3. Fold the tab washer along a flat side of the
nut.
3

c

2. Tighten:
•Nut primary balancer driven gear "1"
•Primary drive gear "2"

Nut primary balancer driven gear
45 Nm (4.5 m · kg, 33 ft · lb)
primary drive gear
60 Nm (6.0 m · kg, 43 ft · lb)

NOTE:
•Place an aluminum plate "a" between the
primary balancer drive gear "3" and the primary
balancer driven gear "4", and then tighten the
nut on the balancer driven gear primary.
•Place an aluminum plate "b" between primary
balancer drive gear "3" and the primary
balancer driven gear "4", and then tighten the
nut on the balancer driven gear primary.

3

4

1
to
5-52

CÁRTER

CARTER
Crankcase separation

10 Nm (1.0 m •kg, 7 ft •Ib)

4 10 Nm (1.0 m •kg, 7 ft •Ib)

5 6

3

1

5
7

2

10 Nm (1.0 m •kg, 7 ft •Ib)
Engine
Refer to "CYLINDER AND PISTON"

Cylinder and piston
on page 5-21
Clutch Bell Refer to "CLUTCH" on page 5-35
Oil pump Refer to "OIL PUMP" on page 5-43
Axis of changes Refer to "SHIFT SHAFT" on page 5-47

Electric Start
See "ELECTRIC START"
on page 5-31
Sprockets balancer See "BALANCER SPROCKET" on
page 5-49
See "MAGNETO AND STARTER CLUTCH" on
Magneto
page 5-26
1 Guide the chain (intake side) 1
2 Chain cover 1
3 Timing Chain 1
4 Housing right 1
5-53

CÁRTER

Crankcase separation

10 Nm (1.0 m •kg, 7 ft •Ib)

4 10 Nm (1.0 m •kg, 7 ft •Ib)

5 6

10 Nm (1.0 m •kg, 7 ft •Ib)

3

1

5
7

2

10 Nm (1.0 m •kg, 7 ft •Ib)

5 Dowel pin 2
6 Left housing 1
7 Nozzle 1
procedure.
5-54

CÁRTER

Dismantling of bearings and oil seals

3 E

7 Nm (0.7 m •kg, 5 ft •Ib)
3 E

2

3
3

3 3
LT

1

3

E

LS

Crankshaft / Balancer See "Crankshaft" on page 5-58
Transmission See "Transmission" on page 5-61

1 Oil Seal 1
2 Bearing retainer 1
3 Tread 7

procedure.
5-55

CÁRTER

CRANKCASE SEPARATION CAUTION
1. Tap on one side of the pan with a soft-faced
Remove: hammer. Tap reinforced only on portions of the
•Crankcase Bolts crankcase, not the contacting surfaces of the
NOTE: crankcase. Work slowly and carefully and make
sure the pan is separated into halves evenly.
Loosen each screw 1/4 turn at a time in stages and
in the correct sequence as shown.
A
2

CASING INSPECTION
1
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Clean all contact surfaces of the seals and
crankcase.

3. Check:
•Sump

B
•Cheap oil distribution
10.15 Obstruction Blow ‫ וי‬with compressed air.
9
8 INSPECTION OF THE TIMING CHAIN AND CHAIN

7 GUIDE DISTRIBUTION
11 4.14
1. Check:
12
• The distribution chain
6
3.13 5 Damage / stiffness Replace ‫ וי‬chain
distribution and the camshaft sprocket
A. Housing right as a whole.
B. Left housing

2. Spin:
•Changes drum segment
NOTE:
Rotate the drum segment changes "1" to the
position shown in the illustration. In this position,
the teeth of the drum segment changes touch with
the crankcase sump during separation.

2. Check:
•Guide chain
(Intake side)
INSPECTION OIL STRAINER
1. Check:
•Oil Strainer
Damage Replace ‫וי‬.
Pollutants Clean ‫ וי‬solvent.
3. Remove: INSPECTION OF BEARINGS AND OIL
• Housing Right SEALS
1. Check:
•Bearings
Clean and lubricate the bearings, then rotate the
inner race with a finger
5-56

CÁRTER

Rough movement Replace ‫וי‬. 3. Install:
•Oil Seals •Housing right
Damage / wear Replace ‫וי‬. NOTE:

BEARING RETAINER ASSEMBLY Rotate the drum segment changes "1" to the
position shown in the illustration. In this position,
1. Install: the teeth of the drum segment changes touch
•Bearing retainer "1" with the casing during assembly of sump.
NOTE:
•Install the bearing retainer "1" marked "OUT"
"to" out. 1
•Apply a locking agent (LOCTITE) to the screw
threads of the retainer
bearing.

Bearing retainer screw
7 Nm (0.7 m · kg, 5.1 ft ·
lb) LOCTITE

4. Install:
to •Crankcase Bolts

Crankcase Bolts
10 Nm (1.0 m · kg, 7.2 ft · lb)
1

NOTE:
Tighten each screw 1/4 turn at a time on stage and in
the correct sequence as shown.
• M6 × 70 mm: "7-9", "11"

CRANKCASE ASSEMBLY • M6 × 55 mm, "14", "15"
1. Clean all contact surfaces of the seals and • M6 × 45 mm: "1-5", "10"

crankcase. A
2. Apply:
•Sealant 1.6 7
(On the crankcase mating surfaces) 8

Yamaha Adhesive No. 5 9

2.12
1215
4 10
NOTE: 3.13 11

Do not allow product to come in contact

with the oil passage. B
14

15

A. Left housing
B. Housing right
5-57

CIGÜEÑAL

CRANKSHAFT

Remove Crankshaft and balancer

2

E

E

LS

1

LS
New

New
Refer to "CRANKCASE" on page

Sump
5-53
1 Balancer 1
2 Crankshaft 1
For assembly, reverse the procedure

disassembly.
5-58

CIGÜEÑAL

Remove Crankshaft
1. Remove:
•Crankshaft "1"
NOTE:
•Remove the crankshaft with the tool to
remove the crankshaft "2".
•Be sure to remove the tool
crankshaft is centered on the crankshaft.

CAUTION 2. Measure:
•To protect the end of the crank, placing a •Side Clearance rod
suitably sized wrench removal tool between the OOS ‫וי‬Replace
crankshaft and the crankshaft. the crankshaft
•Do not hit the crank.
The rod side clearance D
0110-0410 mm

Tool for removing the crankshaft.
3. Measure:
YSST-265
•Crankshaft Width
OOS ‫וי‬Replace
the crankshaft

Crankshaft Width A
47.95-48.00 mm
2

4. Check:
•Crankshaft sprocket
crankshaft.
•Tread

Cracks / damage / wear Replace ‫ וי‬the
1
crankshaft.
5. Check:
CRANKSHAFT INSPECTION •Crankshaft Support
1. Measure: Scratches / wear Replace ‫ וי‬the
•Crankshaft Deformation crankshaft.
OOS Replace ‫ וי‬the •Oil passages crankshaft support
crankshaft bearing or both. Blocked Blow ‫ וי‬compressed air 㻚

NOTE:

Slowly turn the crankshaft. CRANKSHAFT ASSEMBLY
1. Install:
•Crankshaft "1"

Deformation limit C
0,030 mm
5-59

CIGÜEÑAL

1

CAUTION
To avoid scratching the crankshaft and to
facilitate the process, assembly, lubricate the
edges of oil seals with grease lithium soap base
and each bearing with engine oil.

NOTE:
Maintain the rod in the upper dead center (TDC)
with one hand while rotating the nut screw
assembly of the crankshaft with the other. Turn
mounting the crankshaft screw until the bottom of
this against the bearing crankshaft.
5-60

TRANSMISIÓN

TRANSMISSION

Removing the transmission, the shift drum and changes forks

7

1
4
8
2
5 9 E
2 6

2

E

E
3
Refer to "CRANKCASE" on page

Sump
5-53
1 Barra claw guide changes 2
2 Spring 4
3 Shift drum 1
4 Right-shift fork 1
5 Shift fork-Center 1
6 Left-shift fork 1
7 Drive shaft 1
8 Main shaft 1
9 Long pushrod clutch 1

procedure.
5-61

TRANSMISIÓN

Disassembly of the main shaft

M

7
M

6 M
5
4

3

2

1

1 Second Pinion 1
2 Fifth gear 1
3 Sprocket third 1
4 Pin lock 1
5 Toothed washer 1
6 Sprocket quarter 1
7 Main shaft / sprocket first 1

procedure.
5-62

TRANSMISIÓN

Drive Shaft Disassembly
5

6

7
8

9

10
11
12

13

4

3 M

2
1

M

M
1 Pin lock 1
2 Washer 1
3 Second gear 1
4 Fifth Gear 1
5 Washer 1
6 First gear 1
7 Necklace 1
8 Washer 1
9 Fourth gear 1
10 Pin lock 1
11 Washer 1
12 Third gear 1
13 Drive shaft 1
procedure.
5-63

TRANSMISIÓN

CHECKING THE SHIFT FORKS DRUM INSPECTION OF CHANGES
1. Check:
The following procedure applies to all changes Grooves changes in the drum
l
forks. Damage / scratches / wear Replace ‫וי‬

1. Check: the drum changes.
l
Cam pin fork changes "1" Clips shift fork "2" The drum segment changes "1" Damage / wear
l
l
Replace ‫ וי‬the drum
Curves / damage / stretch marks / wear changes.
Replace ‫וי‬
Bearing changes drum "2" Damage / pitting
l
changes fork. Replace ‫ וי‬the drum

changes.

2. Check: Transmission Inspection
l
Bar fork guide changes 1. Measure:
Roll the guide bar shift fork on a flat surface. Shaft Deformation main
l
Curves Replace ‫וי‬. (With a centering device and dial indicator "1")
OOS Replace ‫ וי‬shaft
WARNING
principal.
Do not attempt to straighten a guide bar bent
shift fork.

Shaft limit deformation main
0.03 mm

3. Check:

Movement of the shift fork (Displacement
l

along the guide bar shift fork) 2. Measure:
Rough movement Replace ‫ וי‬Fork Warp Drive Shaft
l
changes and fork guide bar changes as a (With a centering device and dial indicator "1")
whole. OOS Replace ‫ וי‬shaft
traction.

Shaft limit tensile deformation
0.03 mm
5-64

TRANSMISIÓN

MAIN SHAFT ASSEMBLY AND DRIVE SHAFT
1. Install:
Toothed washer "1"
l
Pin lock "2" New

l
NOTE:
Be sure to install the lock pin so that its sharp
l
edge "to" be back to the ring gear and the gear.

3. Check: Make sure the ends of the pin lock
l
Transmission gears
l
"B" is placed in the groove in the shaft groove
Blue discoloration / pitting / wear ‫וי‬ "c".
Replace damaged gears.
Lace transmission gears
l
Cracks / damage / rounded edges ‫וי‬
Replace defective parts. New

2. Install:
Sprocket second "1"
l

NOTE:
Press the second pinion on the main shaft "2", as
4. Check: shown in the illustration.
lGear transmission sprockets. (Each pinion
engages in its respective gear wheel) Mounting depth "a"
Wrong Reassemble ‫ וי‬the axes of 106.85-107.05 mm
the
transmission
5. Check:
Movement of transmission gears
l
Rough movement Replace ‫ וי‬parts

defective.
CHECKING THE CLUTCH PUSH ROD
1. Check:
l
Long push rod clutch
Cracks / damage / wear Replace ‫ וי‬the
long push rod of the clutch. ASSEMBLY SHIFT FORKS DRUM AND
2. Measure: CHANGES

l
Deformation limit of the push rod 1. Install:
Other than those specified Replace ‫וי‬ Left-shift fork "1"
l
long push rod of the clutch Shift fork-Center "2"

l

Bending limit of the push rod Right-shift fork "3"
l
0.500 mm Drum changes "4"

l
Springs
l
Guide bar changes claw "5"

l
Guide bar changes claw "6"

l
5-65

TRANSMISIÓN

NOTE:
The markings on the shift forks should be facing
the right side of the engine and be in the
following sequence: "R", "C", "L".

2. Check:
Transmission
l
Rough movement ‫ וי‬repair

NOTE:
Apply engine oil to each gear and bearing.
l
Before assembling the crankcase, make sure

l
the transmission is in neutral and the gears

turn freely.

5-66

FUEL SYSTEM

CARBURETOR
CARBURETOR REMOVAL 6-1
CARBURETOR DISASSEMBLY 6-2
CARBURETOR INSPECTION 6-4
CARBURETOR ASSY 6-6
CARBURETOR ASSEMBLY 6-7
MEASURING AND ADJUSTING THE FUEL BLE 6-7
INSPECTION FUEL WRENCH 6-8

AIR INDUCTION SYSTEM
AIR INDUCTION SYSTEM 6-9
REMOVAL AIR INDUCTION SYSTEM 6-10
INSPECTION SYSTEM AIR INDUCTION 6-11

CARBURADOR

CARBURETOR
Disassembling the carburetor

Seat, side covers 1 & 2, fuel hose Refer to "GENERAL CHASSIS" on
page 4-1

1 Fuel overflow hose 1 Disconnect

2 Fuel Hose 1

3 Clamp bolt carburetor union 1 Loosen

4 Screw clamp 1

5 Throttle Cable 1

6 Cable boot 1

7 TPS connector 1

8 Carburetor 1

procedure.

6-1

CARBURADOR

Disassemble the carburetor

Disassemble the carburetor Remove the parts in the order listed

1. Diaphragm cover 1
2. Diaphragm spring 1
3. Needle Valve 1
4. Piston valve 1
5. Diaphragm 1
6. Ring 1
7. Drain bolt 1
8. Float chamber 1
9. O-ring 1
10. Support sprayer 1
11. Main jet 1
12. O-ring 1
13. Main Nozzle 1

6-2

CARBURADOR


31

14. Float Pin 1

15. Float 1
16. Set needle 1
17. Throttle stop screw 1
18. Washer 1
19. Spring 1
20. Pilot Supplier 1
21. O-ring 1
22. Washer 1
23. Spring 1
24. O-ring 1
25. Strainer 1
26. Cover plunger 1
27. Support guide 1

6-3

CARBURADOR


7
28. O-ring 1
29. Plunger spring 1
30. Plunger 1
31. Spring washer 1
32. Throttle stop 1
33. Stop washer 1
34. Spring 1
35. TPS 1
36. O-ring 1
37. Pin lock 1
38. Washer 1
39. Washer 1
procedure.

6-4

CARBURADOR

CARBURETOR DISASSEMBLY 4.Verificar:
1. Check: •Camera body float "1" Dirt - Clean.

•Carburetor Body "1"
•Float chamber "2"
•Accommodation supplier "3"
Cracks / damage-Replace.

5.Verificar:
•Rubber gasket float chamber "1"
Cracks / damage / wear - Replace.

NOTE:
Always replace the gasket with a new one.

2. Check:
•Flights fuel
Clogged - Clean.

6.Verificar:
• Float "1"
Damage - Replace.

NOTE:

Wash the carburetor in petroleum-based
solvent.
Do not use any caustic carburetor cleaning.
Blow out all passages and jets with 7.Verificar:
compressed air. •Needle Valve "1"
•Seat needle valve "2"
•O-ring "3"
3.Verificar: Damage / obstruction / wear - Replace
•Diaphragm Valve "1" Cracks / needle valve "1", the seat of the needle valve
damage - Replace "2" O-ring "3" as a whole.

6-5

CARBURADOR

8. Check:
• Filter mesh "1"
1
Damaged / Replace clogged ----

1 2

9. Check:
•Main jet "1" / accommodation supplier
"2" / O-ring "3" / main nozzle "4"
Damage / obstruction - Replace
2 3 4
1

CARBURETOR ASSY

10. Check: CAUTION:

• jet pilot "1" •Before assembling the carburetor, clean all parts
Damage / obstruction - Replace with a petroleum solvent.
• Always use new gaskets.
1
1. Install:
•Throttle screw "1"
11.Check: •Jet pilot "2"
• mixture screw "1" •Main nozzle "3"
Damage / wear - Replace. •O-ring "4"
•Main nozzle "5"
•Main jet "6"
1

12. Check:
• throttle screw "1"
Damage / wear - Replace.
1

1

2

6
13.Verificar:
•YTPS "1" 3
Damage / defective - Replace. 4 5
•Butterfly / Butterfly axis "2" movement
Obstruction / damage / wear - Replace the
carburetor

6-6

CARBURADOR

2.Install: 4. Install:
• mixture screw "1" • Float "1"
• Filter mesh "2" • Float Pin "2"
• Screw "3"
• Packaging of the float chamber "4"
• Float chamber "5"

1
3

2

2

1

5

4

5.Instalar:
• Diaphragm Valve "1"

3.Instalar: CAUTION
• Needle valve "1" Do not overtighten any screws, this can damage

gaskets and O-rings. This can lead to fuel
leakage.

1

1

A

NOTE:
Make sure the raised "A", under the diaphragm,
must be aligned with the slot "B" in the body of
the carburetor.
6-7

CARBURADOR

6. Install:
• Diaphragm Spring "1"
• Cover the Iris "2", tighten the screws

2

4
1

2.Ajustar:

•Fuel Level

CARBURETOR ASSEMBLY

a. Remove the carburetor.
1.Connect all wires and c ables.
Refer to "ENGINE REMOVAL" on page 5- b. Check valve seat of the valve needle and
2. the needle.
c. If either is worn, replace them as a set.
2.Ajustar d. If both are ok, adjust the level of the pin
•Freeplay throttle cable See "FREE PLAY bending float float "1".
ADJUSTMENT THROTTLE CABLE" on
page 3-6 e. Install the carburetor.
f. Measuring the fuel level again. g. Repeat
3.Ajustar: steps a through f until the
•Engine idling fuel level is within specifications.
1300 to 1500 r / min.
See "ENGINE IDLE ADJUSTMENT" on page
3-4

MEASURING AND ADJUSTING THE
FUEL

1.Medir:
• Fuel level "a" 1
Out of specification - adjust

Fuel level (below the contact surface of
the float chamber)
6.0 ~ 7.0 mm INSPECTION FUEL WRENCH
a. Place the vehicle on a flat surface. 1.Check:
b. Place the vehicle on a suitable stand to • Key Fuel
Cracks / damage / wear - replace.
ensure that the vehicle remains upright.
c. Install the fuel level gauge
"1" in the fuel drain hose "2" d. Loosen the fuel
drain "3"
e. Keep the fuel level gauge vertically next to
the float chamber "4"
f. Measuring the fuel level "a".
6-8

SISTEMA DE INDUCCIÓN DE AIRE

AIR INDUCTION SYSTEM

5
1

2 4

3

3
2

5
4
1

1Hose air induction system (air filter).
2Vacuum hose from the air induction system.
3Through the air induction system (to the engine)
4Air Filter
5Air Induction System.
6-9


Removing the air induction system
1

3

4

2

Seat, side cover Side cover 1 & 2 Refer to "GENERAL CHASSIS" on
page 4-1
Fuel tank Refer to "GENERAL CHASSIS" on
page 4-2
1 Hose air induction system (air filter). 1

2 Vacuum hose from the air induction system. 1

3 Duct air induction (Towards the butt) 1

4 Air Induction System. 1
For assembly, reverse the
disassembly procedure.
6-10


INSPECTION SYSTEM AIR INDUCTION Cracks / damage Replace ‫וי‬.
Air injection •3-way junction
The air induction system of burning the unburnt
exhaust gases by injecting fresh air (secondary 2. Check:
air) into the exhaust port of reducing hydrocarbon •Reed valve
emissions. When there is negative pressure in •Top of the valve sheet
the exhaust port, the reed valve opens, allowing •Seat valve sheet
the secondary air into the exhaust port. The Cracks / damage Replace ‫ וי‬valve
temperature required to burn the unburned sheets.
exhaust gas is approximately 3. Check:
600 to 700 ° •Air Switching Valve
C. Cracks / damage Replace ‫וי‬.

4. Check:
Air Switching Valve
The air shutoff valve is operated by the inlet gas
•Operation of the air shutoff valve
pressure across the diaphragm of the valve Not working Replace ‫וי‬.
piston. Normally, the air cut valve opens to allow
fresh air ue in the exhaust port. During a sudden
a. Blow air through the hose end of the air induction
system (3-way junction to air shutoff valve) and
deceleration (the throttle valve is suddenly
check that the air flow from the air shutoff valve
closed), the negative pressure is generated, and
(towards the head).
the air shutoff valve is closed to prevent
afterburning. Furthermore, at high rpm and when
the pressure decreases, the air shutoff valve Air cut valve opens
closes automatically to protect against yield loss Perform step (b).
due to self Exhaust Gas Recirculation (EGR). Air shutoff valve closed
Replace the air shutoff valve.

C

B

b. Install pump pressure / vacuum in the air

cut valve "1" and apply negative pressure
A to the valve.

Manometer
A. From the air filter box
B. Airflow exhaust port
C. Towards the intake manifold
c. Blow air through the hose end of the air
1. Check: induction system (3-way junction to air
•Hoses: shutoff valve) and check that air does not
Loose connections Connect ‫וי‬ flow and exit through the air shutoff valve
correctly. (towards the butt ).
6-11


Air Switching Valve Replace valve opens
air cutting. Air shutoff valve closed
The air cut valve is OK

1

NOTE:
This test should be done when the pressure is less than - 50
kPa.
6-12

ELECTRICAL

IGNITION SYSTEM 7-1
CIRCUIT DIAGRAM 7-1
TROUBLESHOOTING 7-3

ELECTRIC STARTING SYSTEM 7-5
CIRCUIT DIAGRAM 7-5
OPERATION starter cut 7-7
TROUBLESHOOTING 7-9

CHARGING SYSTEM 7-11
CIRCUIT DIAGRAM 7-11
TROUBLESHOOTING 7-13

LIGHT SYSTEM 7-14

SIGNAL SYSTEM 7-17

SELF DIAGNOSIS FUNCTION 7-23
SELF DIAGNOSIS FUNCTION 7-23
WARNING LIGHT ENGINE FAILURE ERROR CODE 7-23
FAULT CODE TABLE 7-24
BULB INSPECTION OF THE ENGINE WARNING LIGHT 7-24
TROUBLESHOOTING METHOD 7-24
SETTLEMENT DETAIL pro blems 7-25

ELECTRICAL COMPONENTS 7-28
CHECKING SWITCHES 7-30
CHECKING THE BULBS AND SOCKETS OF BULBS 7-33
CHECKING THE FUSE 7-34
CHECKING AND CHARGING 7-34
CHECKING THE RELAYS 7-37
VERIFICATION OF RELAY TURN SIGNAL 7-38
CHECKING THE SPARK PLUG CAP 7-39
CHECKING THE IGNITION COIL 7-39
VERIFICATION OF DISTANCE spark 7-40
CHECKING THE CRANKSHAFT POSITION SENSOR 7-40
CHECKING THE STARTER OPERATION 7-40
CHECKING THE STATOR COIL 7-41
CHECKING THE REGULATOR / RECTIFIER 7-41
SPEAKER VERIFICATION 7-42
CHECKING THE FUEL GAUGE 7-42
CHECKING THE THROTTLE POSITION SENSOR 7-43
CHECKING THE SPEED SENSOR 7-43

IGNITION SYSTEM
CIRCUIT DIAGRAM
GB
Sb
LY
G BL

1
W
W
W
W Br
B Br R
W - W (BLACK) R

RB 3 LY Or Or
CRK + IG 8
B

R
B
WW

Sb
Sb
R
Sb
LY G 20
7

Sb
W W BL LY 31 BL
26 START 30
Sb 6 STOP LIGHT L
2 4 START
VCC 19 BL L Y
RUN PO A

15A
ON nd GIS
OFF OFF OFF BL
Br MAIN SGND
nd
R
ON
A
RW Br

OFF
YW
LWWB B L TC
Lg
(BLACK) DIAG
21 LW
VB GND
R
LB
WB
LW
Rw
Br
B

L
RwBr

RW
WBLW
B
5 B - Or BL L
23
LW
RW
LW
L B
(BLACK)
RW YWLg - LY Y

RW

22 27 RB
LB
RW Sb
LB RW LB
(Black)
13 NEUTRAL
RB
B
Br Sb
B
Br
Br
24

Br
ORW BL Br - Br2 YW W Y Dg Lg GB
Ch - Bl Sb TACHO
Br BRB
11 28
9 (BLACK)
- -

7-1
B1 B
P 10 GY GY
+ GND (Black) (Black)
12 - - Br W
SPEED
Br Br YW
ILLMI TC
B
BRW
L
(RED) (RED) VCC
BRW BL
GY
An
SGND
d
Br

OR
BRW

FUEL
An
WB
W
L
d
P
GB
FUEL +
IGNITION SYSTEM
14 -

BL
Dg Br 35 FLASHER
W
BRW P DIMMER 34 HORN 36

L
PASS
BRWWB WB Br
ON HI OFF L Br OR 29 ILLUMI
Ch P Dg Ch OFF LO ON NL W
GB

N
And A
12V21W 35W
/
12V10W
NR
25
WL
BL
ORW
R 18

G G
B B
DIAG Lg
LW
Ch
Dg
An
B
G
B
d
BL
Dg
TURN
Ch

And HI BEAM

Ch
Dg
Ch
Dg

G
Y
L
16 17 32 33
12V5W
LL G
- - And B
12V35W/35W
12V10W
12V10W
12V10W
BB
15

B
B
(BLACK) (BLACK)
B

SISTEMA DE ENCENDIDO

1. Magneto CA
3. Unit Regulator / Rectifier
4. Main fuse
5. Battery
6. Main switch
7. CDI Unit
8. Ignition Coil
19. TPS
20. Plug
21. Cable Positive +
22. Negative cable -
30. Engine stop switch
7-2


TROUBLESHOOTING

The ignition system is not working (no spark or intermittent spark).

NOTE:
•Before troubleshooting, remove the following parts:
1. Seat
2. Side cover 1 and 2
3. Fuel tank

1. Check the fuse. NG
See section Replace the fuse.
"CHECKING THE FUSE" on
page 7-34.
OK t

2. Check the battery.
NG
•Clean the battery terminals 㻚
Refer to the "CHECKING AND •Recharge or replace the battery.
CHARGING THE BATTERY" on
page 7-34.
OK t
NG
3. Check the spark
plug. Re-calibrate, or replace the spark plug.
Refer to "Checking the spark plug"
on page 3-7. NG

OK t

4. Check the spark plug cap.
See section NG Replace the spark plug cap.
"Checking the spark plug cap" on
page 7-39.

OK t
5. Check the ignition coil. NG
See section Replace the ignition coil.

"CHECKING THE IGNITION COIL"
on page 7-39.

OK t

6. Check the crankshaft position sensor.
Refer to the "CHECKING Replace the crankshaft position
CRANKSHAFT POSITION
NG
SENSOR" on page 7-40. sensor.

OK t

7. Check main switch. NG
See section
"MAIN switch check" on page 7-30.
Replace the main switch.
OK t
8. Check the TPS See section
"CHECKING TPS" on page 7-43

OK t
Replace the TPS.
7-3


9. Check the engine stop switch. NG The engine stop switch is faulty.
See the "Verifying SWITCHES" on page Replace the switch
7-30. 㻚 right handlebar

OK t

10.Verificar wiring the entire ignition
system. NG
See section "CIRCUIT DIAGRAM" on
Connect or repair wiring ignition system 㻚
page 7-1.
OK t

Replace the CDI.
7-4

CIRCUIT DIAGRAM
STARTING CIRCUIT
GB
Sb
LY
G BL

1
W
W
W
W Br
B Br R
W - W (BLACK) R

RB 3 LY Or Or
CRK + IG 8
B

R
B
WW

Sb
Sb
R
Sb
LY G 20
7

Sb
W W BL LY BL
26 START 30 LIGHT 31
Sb 6 STOP L
2 4 START PO VCC 19 BL L Y
RUN A

15A
ON OFF
nd GIS
OFF OFF BL
Br MAIN ON SGND
nd
R
A
OFF RW Br
21 LW
LW WB B L
(BLACK)
TC
DIAG
YW
Lg
VB GND
R
LB
WB
LW
Rw
Br
B

L
Br Rw
RW
B
5 WB LW B - Or BL L
23
LW
RW
LW
LB
(BLACK)
RW YWLg - LY Y

RW

22 27 RB
LB
RW Sb
LB RW LB
(Black)
13 NEUTRAL
RB
B
Br Sb
B
Br
Br
ELECTRIC STARTING SYSTEM

24

Br
Ch - Bl Sb TACHO
Br BRB
11 28
9 (BLACK)
- -

7-5
B1 B
P 10 GY GY
12 - - Br W
SPEED
Br Br
YW
ILLMI TC
B
BRW
L
(RED) (RED) VCC
BRW BL
GY
An
SGND
d
Br

OR

BRW

FUEL
An
WB
W
L

P
GB
FUEL +
14 34

-
BL
Dg Br
W
BRW P HORN 35 FLASHER 36

L
PASS DIMMER
BRWWB WB Br
ON HI OFF L Br OR 29 ILLUMI
Ch P Dg Ch

OFF
12V10W
LO ON NL
N
W
GB
And NR WL
And 25
BL
12V21W/35W

ORW
G R 18
G
B B DIAG Lg
LW
BL
Ch
Dg
An
B
G
B
d
TURN
Dg
Ch

And HI BEAM

Ch
Dg
Ch
Dg

G
Y
L
16 17 32 33
12V5W
LL G
- - And B
12V35W/35W
12V10W
12V10W
12V10W
BB
15

B
B
(BLACK) (BLACK)
B

SISTEMA DE ARRANQUE ELÉCTRICO

2. Neutral switch
4. Main fuse
5. Battery
6. Main switch
23. Starter relay
24. Starter
26. Start switch
27. Starter cut relay
28. Clutch switch
7-6


SYSTEM OPERATION START CIRCUIT COURT

If the engine cutoff switch is set to "" and the ignition switch is positioned to "ON" (both switches are
closed), the starter may work if one of the following conditions is served:
•The transmission is in neutral (neutral switch is closed).
•Pull the clutch lever to the handlebar (the clutch switch is closed). Cutting the ignition system prevents the starter
motor when any of the
above conditions are not met. In this case, the starting circuit is open, then the current fails to
reach the starter. When at least one of the above conditions is met, the starting circuit is closed
and you can start the engine by pushing the start switch "".

2
3

1

4

9
5

8

10

7 6

to b
7-7


a. When the transmission is in neutral
b. When the lever is pulled CLUTCH
HANDLEBAR
1. Battery
2. Fuse
3. Main switch
6. Clutch switch
7. Neutral switch
8. Start switch
9. Starter relay
10. Starter
7-8


TROUBLESHOOTING
The starter does not turn.

NOTE:
1. Seat
2. Side cover 1 and 2

See "Checking the Fuse" on page 7-34. Replace the fuse.

OK t

Refer to the "CHECKING AND NG
CHARGING THE BATTERY" on •Clean the battery terminals 㻚
page 7-34. •Recharge or replace the battery.

OK t

3. Check operation of the starter motor. OK
Refer to the "CHECKING STARTER
OPERATION" on page 7-40. The starter is good. Perform electrical
troubleshooting system boot from step 5.
NG t

4. Check the engine starts.
See "Verifying
STARTER "on page 5-33. NG

OK t
Repair or replace the starter.

5. Check the circuit starter cut relay.
See the "Verifying RELAYS" on page 7-
NG
37.
OK t

Replace the starter cut relay.

6. Check the starter relay.
See the "Verifying RELAYS" on page 7-

37. NG

OK t

Replace the starter relay.
7. Check main switch.
See "Verifying
SWITCHES "on page 7-30. NG
OK t

Replace the main switch.
7-9


8. Check the engine stop switch. See the NG The engine stop switch is faulty.
"Verifying SWITCHES" on page 7-30. Replace r i n t e r u p t o r
OK t 㻚 right handlebar

9. Check the neutral switch.
See "Verifying
NG
SWITCHES "on page 7-30.
OK t Replace the neutral switch.

10.Verificar clutch switch.
See "Verifying NG

OK t

NG Replace the clutch switch.
11.Verificar the start switch. See the
"Verifying SWITCHES" on page 7-
30.
OK t NG
The ignition switch is faulty. Replace the
12.Verificar wiring the ignition switch right
system. See section "CIRCUIT Handlebar 㻚

DIAGRAM" on page 7-5.

OK t

The starting system circuit is OK 㻚 Connect or repair wiring system boot 㻚
7-10

CHARGING SYSTEM
CIRCUIT DIAGRAM
GB
Sb
LY
G BL
B Br R
1 W
W
W
W
Br
W - W (BLACK) R

3 LY Or Or
CRK + IG 8
B

R
B
WW

Sb
Sb
R
Sb
LY G 20
7

Sb
W W BL LY BL
Sb 6 STOP L
2 4 START PO
VCC 19 BL L Y
RUN A

15A
ON OFF
nd GIS
OFF OFF BL
Br MAIN ON SGND
nd
R
A
RW Br

OFF
YW
LWWB B L TC
Lg
(BLACK) DIAG
21 LW
VB GND
R
LB
WB
LW
Rw
Br
B

L
RwBr

RW
WBLW
B
5 B - Or BL L
23
LW
RW
LW
L B
(BLACK)
RW YWLg - LY Y

RW

22 27 RB
LB
RW Sb
LB RW LB
(Black)
13 NEUTRAL
RB
B
Br Sb
B
Br
Br
24

Br
Ch - Bl Sb TACHO
Br BRB
11 28
9 (BLACK)
- -

7-11
B1 B
P 10 GY GY
12 - - Br W
SPEED
Br Br YW
ILLMI TC
B
BRW
L
(RED) (RED) VCC
BRW BL
GY
An
SGND
d
Br

OR
BRW

FUEL
An
WB
W
L

P
GB
FUEL +
14

-
BL
Dg Br
W
BRW P DIMMER 34 HORN 35 FLASHER 36

L
PASS
BRWWB WB Br HI
ON OFF L Br OR 29 ILLUMI
Ch P Dg Ch LO

OFF
12V10W
ON NL
N
W
GB
And NR WL
And 25
CHARGING SYSTEM
BL
12V21W/35W

ORW
G R 18
G
B B DIAG Lg
LW
BL
Ch
Dg
An
B
G
B
d
TURN
Dg
Ch

And HI BEAM

Ch
Dg
Ch
Dg

G
Y
L
16 17 32 33
12V5W
LL G
- - And B
12V35W/35W
12V10W
12V10W
12V10W
BB
15

B
B
(BLACK) (BLACK)
B

SISTEMA DE CARGA

1. Magneto CA
3. Regulator / rectifier
4. Main fuse
5. Battery
7-12

SISTEMA DE CARGA

TROUBLESHOOTING
The battery is not charging.
NOTE:
1. Seat
2. Panel on the left side / side cover.

See "Checking the Fuse" on page 7-34 Replace the fuse

OK t

Refer to the "CHECKING AND
NG
CHARGING THE BATTERY" in the •Recharge or replace the battery.
page 7-34.
OK t

3. Check operation of the stator coil. Refer to NG
"Checking the stator coil" on page 7-41.
Change the position of the crankshaft
OK t position sensor / stator.
4. Check the regulator / rectifier. NG
See "Verifying
REGULATOR / RECTIFIER "on page 7-
41.
OK t NG Replace the regulator / rectifier.

5. Check the wiring of the charging system.

page 7-11.
OK t Connect or repair wiring 㻚 charging
The circuit charging system is OK 㻚 system
7-13

CIRCUIT DIAGRAM
LIGHT SYSTEM
GB
Sb
LY
G BL

R2
B Br R
1 W2
W W
W2 Br
W - W2 (BLACK) R

3 LY Or Or
CRK + IG 8
B

R
B
WW

Sb2
Sb

R
Sb
BL G LY 37
7

Sb2
W W2 LY BL
Sb 6 STOP L
2 4 START PO VCC 19 BL L Y
RUN A

15A
ON OFF
nd GIS
OFF OFF BL
Br MAIN ON SGND
nd
A
OFF RW Br
21 LW
LWWB B L
(BLACK)
TC
DIAG
YW
Lg
R2
VB GND
LB
WB
LW
Rw
Br
B

L
RwBr

RW
WBLW
B
5 B - Or BL L
23
LW
RW
LW
L B
(BLACK)
RW YWLg - LY Y

RW

22 27 RB
LB
RW Sb
LB RW LB
(Black)
13 NEUTRAL
RB
B
Br Sb
B
Br
Br
24

Br
Ch - Bl Sb TACHO
Br BRB
11 28
9 (BLACK)
- -

7-14
P 10 GY GY
+
GND
B1
(Black)
B
(Black)
12 - - Br W
SPEED
Br Br
YW
ILLMI TC
B
BRW
L
(RED) (RED) VCC
BRW BL
GY
An
SGND
d
Br

OR
BRW

FUEL
An
WB
W
L
d
P
GB
FUEL +
14

-
BL
Dg Br 34 HORN OFF 35 FLASHER 36

W
BRW P
L
PASS DIMMER
BRWWB WB Br ON
ON HI L Br OR 29 ILLUMI
Ch P Dg Ch

OFF LO NL W
N GB
12V10W
NR WL
And And
25
BL
12V21W/35W

LIGHT SYSTEM
ORW
G R 18
G
B B DIAG Lg
LW
BL
Ch
Dg
An
B
G
B
d
TURN
Dg
Ch

And HI BEAM

Ch
Dg
Ch
Dg

G
Y
L
16 17 32 33
12V5W
LL G
- - And B
12V35W/35W
12V10W
12V10W
12V10W
BB
15

B
B
(BLACK) (BLACK)
B

SISTEMA DE LUCES

4. Main fuse
5. Battery
6. Main switch
13. Meter
15. Streetlight
18. Taillight
31 Light Switch
34. Light switch

SISTEMA DE LUCES

TROUBLESHOOTING
Any of the following lights fails: Street Light, light beam indicator, tail light, auxiliary light or light
meter.
NOTE:
• Before to solve problems, remove the following parts:
1. Seat
2. One side cover and side cover 2
3. Streetlight
4. Fuel tank

1. Check each bulb and the condition of NG
each bulb socket. Refer to the section
"Verifying the bulbs and sockets Replace the bulb (s) and the socket of the
bulbs" on page 7-33. bulb (s).

Okt

2. Check the fuse.
See "Checking the Fuse" on page 7-34. NG
Okt Replace the fuse.

See "Verifying
AND CHARGING THE BATTERY "on NG
page
7-34.
•Recharge or replace the battery.

Okt

See "Verifying Replace the main switch.
Okt
NG
5. Check the light switch. See the "Verifying
SWITCHES" on page 7-30. The light switch is broken. Replace the
Okt switch left
NG Handlebar 㻚
6. Check the switch happened.
See "Verifying
NG The bypass switch is faulty. Replace
Okt
the switch left
7. Check the wiring of the lighting system. Handlebar 㻚
page 7-14.

Okt
Connect or repair wiring system boot 㻚
The system circuit is OK 㻚

7-16

CIRCUIT DIAGRAM
SIGNAL SYSTEM
GB
Sb
LY
BL
B Br R
1 W
W
W
W
Br
W - W (BLAC K) R

3 LY Or Or
CRK + IG 8
B
WW
B

Sb
Sb Sb
LYG 20
7

Sb
W W BL LY BL
26 START 30 31
Sb 6 STOP LIGHT L
2 4 START
VCC 19 BL L Y
RUN PO A

15A
MAIN nd GIS
R OFF OFF OFF BL
Br ON SGND
R
ON
RW An

OFF
L
d
LWWB
YW
B L Br TC
Lg
21 LW
DIAG
(BLACK)
R
LB VB GND
WB
LW
Rw
Br
B

L
RwBr
WBLW

B
5 B - Or BL L
23
LW
RW
LW
L B
(BLACK)
RW YWLg - LY Y

RW

22 27 RB
LB
RW Sb
LB RW LB
(Black)
13 NEUTRAL
RB
Br Sb
B
Br
Br
24
ORW Br B L - Lg YW W
Br
B
Br2 and DG GB Ch - Bl Sb TACHO
Br BRB
11 28
9 (BLACK)
-
-
7-17
B1 B
P 10 GY GY
12 - -

Br2 W
SPEED
Br Br YW
ILLMI TC
B
BRW
L
(RED) (RED) VCC
BRW BL
GY
An
SGND
d
Br

SIGNAL SYSTEM

OR
BRW

FUEL
An
WB
W
L
d
P
GB
FUEL +
14

-
BL
BRW WB BRW P 34 HORN OFF 35 FLASHER 36

L
PASS DIMMER
Br Dg WB Br ON 29
ON HI L Br OR ILLUMI
Ch P Dg Ch

OFF LO NL
N
W
GB
And NR W L
And 25
BL
12V21W/35W

ORW
G R 18
G
B B DIAG Lg
L W
12V10W
BL
Dg
Ch
An
B
G
B
d
TURN
Dg

Ch

And HI BEAM RW

Ch
Dg
Ch
Dg

G
Y
L
16 17 32 33
12V5W
LL G
- - And B
12V35W/35W
12V10W
12V10W
12V10W
B1 B1
15

B
B
(BLACK) (BLACK)
B

SISTEMA DE SEÑALIZACIÓN

2. Neutral switch
4. Main fuse
5. Battery
6. Main switch
7. CDI
9. Horn
10. Relay turn signal
11. Front brake switch
12. Rear brake switch
13. Meter
16. Front turn indicator light (LH)
17. Front light turn indicator (RH)
25. Speed sensor
29. Fuel Gauge
32. Backlight turn indicator (LH)
33. Backlight turn indicator (RH)
35. Horn switch
36. Switch turn signal
7-18


TROUBLESHOOTING
• Any of the following fault lights: turn indicator lights, brake light or indicator lights.
• The horn does not sound.
• The fuel gauge does not work.

NOTE:
• Before troubleshooting, remove the following parts:
1. Seat
2. Fuel tank
3. Streetlight
4. Multi-function display

See "Checking the Fuse" on page 7-34. Replace the fuse.
Okt

Refer to the "CHECKING AND NG
CHARGING THE BATTERY" on page •Clean the battery terminals 㻚
7-34. •Recharge or replace the battery.

Okt

See "Verifying
SWITCH "on page Replace the main switch.
7-30.
Okt

4. Check the wiring circuit signaling system. NG
See under "SIGNAL SYSTEM CHECK"
㻚 Connect or repair the signaling system
Okt wiring.
Check the status of each of the signaling
system circuits. See "Verifying the signaling
system."

Signalling System Verification

Horn does not sound.
NG
1. Check the horn switch. See "Verifying SWITCH" The horn switch is faulty. Replace the
on page switch left
7-30. Handlebar 㻚
Okt

NG
2. Check the horn.
See "Verifying Replace the horn.
HORN "on page 7-42.

Okt
7-19


3. Check the wiring of the signaling system. NG
See section "CIRCUIT DIAGRAM" on Connect or repair wiring 㻚 signaling
page 7-17. system
Okt

The brake light / rear does not light.

NG
1. Check the bulb brake light
/ Back and the Replace the bulb brake light / rear of
socket. the socket or both
Refer to the section "Verifying the bulbs
and sockets bulbs" on page 7-33.
Okt
NG
2. Check the front brake switch. See "Verifying
SWITCH" on page

Replace front brake switch.
7-30.

Okt
3. Check the rear brake switch. See "Verifying NG
SWITCH" on page Replace the rear brake switch.
7-30.

Okt

NG
4. Check the wiring of the signaling system.
page 7-17. system
Okt

The turn indicator light, indicator light turning, both or no flash.
NG
1. Check the indicator light bulb and socket pivot.
Refer to the section "Verifying the bulbs and
sockets bulbs" on page 7-33. Replace the light bulb turn indicator, socket
or both

Okt

NG
2. Check the turn signal bulb and socket.

Refer to the section "Verifying the bulbs Replace the turn signal bulb, socket or
and sockets bulbs" on page 7-33. both
Okt
7-20


3.Verificar switch indicator light turn. NG
See the "Verifying SWITCHES" on The horn switch is faulty. Replace the
switch left
page 7-30.
Handlebar 㻚
Okt
4.Verificar r e l a y s h i f t i n d i c a t o r
light. See "Verifying RELAY NG
TURN INDICATOR LAMP" on
page 7-38. Replace the relay turn indicator light.

Okt

5.Verificar t h e s i g n a l i n g s y s t e m
wiring. See section NG
"CIRCUIT DIAGRAM" on Connect or repair wiring 㻚 signaling
page 7-17.
system
Okt
Replace the meter 㻚

The neutral indicator light does not light.
NG
1.Check the light bulb and
socket neutral. Refer to the
section "Verifying the bulbs Replace light bulb in neutral, the socket or
and sockets bulbs" on page 7- both
33.

Okt
NG
2.Check neutral switch. See
"Verifying SWITCH" on page Replace the neutral switch 㻚
7-30.
Okt

NG
3.Verificar
the signaling
system wiring. See Connect or repair wiring 㻚 signaling
section "CIRCUIT system
DIAGRAM" on page 7-17.
Okt
Replace the meter 㻚 .

The fuel gauge is not working.

1.Check fuel gauge. See "Checking NG
the fuel gauge" on page 7-43. Replace the fuel gauge 㻚 .
Okt
7-21


2.Check the signaling system wiring. NG
page 7-17. system
Okt
Replace the meter 㻚 .
7-22

FUNCIÓN DE AUTO-DIAGNÓSTICO

SELF-DIAGNOSIS FUNCTION
The vehicle is equipped with a self-diagnostic function. If this function detects a malfunction in the
system, immediately operate the engine under substitute characteristics and illuminates the warning light
Engine trouble to alert the driver that a fault has occurred in the system. Once it has detected a
malfunction, an error code will be stored in the memory of CDI.
•If a fault is detected in the system for the self-diagnostic function to alert the driver of the malfunction
detected, warning light illuminated with engine trouble.

•After the engine has stopped, the error code number appears on the warning light engine trouble. It will
be stored in system memory until it is deleted.

1

1. Warning light engine failure.

Identification Code fault warning light engine trouble
10 Digits: Cycles of 1 second on and 1.5 seconds off ON OFF.
1 Digit: Cycles of 0.5 seconds on and 0.5 seconds off ON OFF.

Example: Fault code No. 15

OFF

to
ON c d and and F

c. 1 sec d. 1.5 sec e. 0.5 sec f. 3.0 sec

a. Light on b.
Light off
c. 1
d. 1.5
e. 0.5
f. 3
7-23


FAULT CODE TABLE

Fault
Can / can Can /
Item Symptom not boot can not
Code
drive

Throttle Position Sensor Throttle position sensor:
15 You can You
(Open or short) open or short circuit detected.

can
16 Throttle Position Sensor Throttle position sensor is You can You
(Attached) attached can

Verification bulb warning light engine trouble
The warning light comes on engine failure for 3 seconds after the main switch is turned to "ON". If the
warning light does not come on in these conditions, the communication cable is disconnected or the LED
warning light may be defective.

to b
to b
c d c
c d c

a. Switch to "OFF" b. Switch to d. Warning Light Engine trouble on for 3
"ON" seconds
c. Warning Light Engine trouble off

TROUBLESHOOTING METHOD

Motor operation is not normal and the warning
Fault Code No. No fault code
light comes on engine failure.
1. Check: Check and repair. See "D ata Check and repair
•Fault code number TROUBLESHOOTING" See "Table of the
Monitoring the operation of auto-diagnosis"
a. Check the fault code displayed on the meter. sensors and actuators in the
b. Identify the flaw in the system with the fault diagnostic mode. See
code. ection "T ableof operation of
See "Table of the auto-diagnosis." sensors" and "actuators
c. Identify the likely cause of the failure. operating table"
See "Fault Code Table".

2. Check and repair the probable cause of evil
operation. Turn the ignition switch to "OFF" and return to
"ON", and check for any number of
Fault code is shown.
7-24


TROUBLESHOOTING DETAILS

This section describes the steps to the fault code number displayed on the meter. Check and service
elements or components that are the likely cause of the failure.

Symptom throttle position sensor: open or short circuit detected
Fault Code No. 15

Element / components and Method
Order Check or maintenance job
probable cause reintegration
1 Assembly condition of the throttle Turn the
position sensor. • Check for loose or pressed. main switch
• Check that the sensor is assembled to the ON
in the specified position. position
2 Connections
• Check the coupler terminals that may
• Plug the throttle position sensor
have emerged.
• CDI connector on the harness
• Check the lock status
coupler.
• If there is a malfunction, repair and
connect the coupler seugra form.
3 Open or short circuit in wire harness
• Repair or replace if there is an
open or short circuit.
• Among the connector position sensor
accelerator and the CDI
connector (black / blue, black /
blue) (yellow-yellow)
(Blue-blue)
4 Throttle position sensor defective. • Check for open circuit and replace
the throttle position sensor.
Open circuit Detail
Output Voltage
Ground wire 5V
open circuit
Cable open 0V
circuit output
Power supply
open circuit 0V
5 Throttle position sensor defective.

• Replace the carburetor, If
defective
Refer to "CHECKING THE THROTTLE
POSITION SENSOR" on page 8-72.
CAUTION:
Do not remove the throttle position
sensor carburetor.
7-25


Fault Code No. 16 The throttle position sensor is attached
Component: Throttle Position Sensor

1 Condition sensor assembly Arran car
throttle position. • Check for loose or pressed. the idle
• Check that the sensor is assembled in motory arlo
the specified position. utiliz, then
at high rpm.
2 Throttle Position Sensor • Replace the carburetor, If
defective. defective
Refer to "CHECKING THE THROTTLE
POSITION SENSOR" on page -743.

Symptom: Cable primary ignition coil: Open circuit detected.
Component: Ignition Coil

1 Connections • Check connector terminals and Start the
• Connector Ignition Coil coupler that may have emerged. motor.
(Primary coil side) • Check the connector lock and
• CDI connector on the harness coupler.
• If there is a malfunction, repair, and
connect the coupler securely.
2 Cable Harness for open or short • Repair or replace if there is a circuit
circuit. open or shorted.
• Between coil connector
Ignition and CDI coupler / main wiring
harness and ground.
(Orange-orange)
3 Faulty ignition coil. • Test the continuity of the primary and
secondary coils.
• Replace if defective. Refer to
"IGNITION SYSTEM" on page 7-1.

Symptom: Faulty CDI.
Component: CDI

1 Malfunction of CDI. Turn
Replace the CDI the
NOTE: Do not perform this procedure with the m a i n
main switch to "ON". switch
to
"ON"
7-26


Symptom: The signals received from the speed sensor is not normal.

Component: Vehicle Speed Sensor

1 Condition sensor assembly Start the
• Check for loose or pressed.
speed. engine and
2 Connections • Check that the coupler terminals activate
• Speed sensor coupler may have left. the speed
• Cable Coupler main harness. • Check the lock status of the sensor,
couplers. pony endo
• If there is a malfunction, repair op
and connect the coupler erating the
3 Open wire or short circuit. vehicle.
• Repair or replace if there is an
open or short circuit.
• Enter the speed sensor coupler and
coupler wiring harness.
4 Faulty speed sensor.

• Replace if defective
Refer to "CHECKING THE SPEED
SENSOR" on page 7 -
43.
7-27


COMPONENTES ELÉCTRICOS

ELECTRICAL COMPONENTS

1 2

3

4

5 10

11

12

6

9

14

13

8

7
7-28



2. Fuel Gauge
4. CDI Unit
5. Main switch
6. Horn
7. Starter relay
8. Neutral switch
10. Battery
11. Regulator / rectifier
12. Fuse
13. Spark plug
14. Ignition Coil
7-29



SWITCH INSPECTION
1234

BBr OFF
R/B ON
B GY
(BLACK) B RBr BR Br YY

(RED)

5

Sb

11 10 9 87 6
12 Br Dg
L/WB Br R / W

PO W / B And G BRP CDHGBr/W W / Br / W An

OFF
PASS B
P Ch
ON Br R / W
An
L/ W/B
d
W
G
B L B
7-30



1. Clutch switch
2. Main switch
5. Neutral switch
7. Horn switch
8. Light switch
9. Light Switch step
11. Start switch
12. Light Switch
7-31



Check continuity of each switch with the multimeter. If the continuity reading is incorrect, check the connections, and
if necessary, replace the switch.
CAUTION:
Never insert the tester probes into the slots of the coupling terminal "a". Always insert probes for the
opposite end of the coupler, being careful not to loosen or damage the cables.

Multimeter

NOTE:
l • Before checking for continuity, set the multimeter in continuity mode.
• When checking the continuity, toggle switch positions several times.

Switches and terminal connections are illustrated in the following example of the main switches.
Positions "a" shown in the left column and the switch lead colors
"B" are shown in the top row.

The continuity (ie, a closed circuit) between the terminals of the switch is given by the position indicated
by ! ". Continuity between red and brown / blue when the switch is "ON".

b

R Br
to ON
OF
F

R
Br
7-32



CHECKING THE BULBS AND SOCKETS WARNING
OF BULBS
Since the streetlight bulbs get very hot, keep
Check each bulb and bulb socket for damage or wear, flammable products and your hands away from
proper connections and continuity between terminals. them until they have cooled.
Damage / wear ‫וי‬Repair or replace
bulb, the bulb socket or both. Bad connection CAUTIONN:
‫וי‬Connect correctly. No continuity ‫וי‬Repair or
replace e •Be sure to hold the socket firmly when removing
bulb, the bulb socket or both. the bulb bulb. Never pull the cord, if it can be
pulled out of the terminal on the coupler.
Types of bulbs •Avoid touching the glass of a lamp bulb and keep
The bulbs used in the vehicle shown in the it free from oil, otherwise the transparency of
illustration on the left. glass, the life of the bulb and the luminous flux
•Bulbs "a" and "b" are used for streetlights and will be adversely affected. If the bulb of the lamp
typically use a socket to be separated before is dirty, clean it thoroughly with a cloth
removing the bulb. Most of these types of moistened with alcohol or lacquer thinner.
bulbs can be remo vidos of their sockets by
turning counterclockwise. 2. Check:
•Bulb (for continuity) (with
•Bulbs "c", is used to turn the indicator light and multimeter)
the taillight / brake lights, and can be removed No continuity Replace‫וי‬.
from the socket by pressing and turning the
bulb counterclockwise. Multimeter

NOTE:
Before checking for continuity, set the
multimeter in continuity mode.

a. Connect the positive probe of the multimeter to
terminal "1" and the negative probe of the
multimeter to terminal "2", and check the
continuity.
b. Connect the positive probe of the multimeter to
terminal "1" and the negative probe of the
multimeter to terminal "3", and check the
continuity.
c. If any of the readings indicate no continuity,
replace the bulb.

Checking the condition of the bulbs The following
procedure applies to all bulbs.
1.
Remove:
•Bulb
7-33



Checking the condition of the bulbs sockets
The following procedure applies to all of the light
bulb sockets. a. Set the main switch to "OFF".
1. Check: b. Install a new fuse of the correct amperage. c.
•Bulb socket (for continuity) (with Setting switches to verify if the
multimeter) electrical circuit is operating.
No continuity Replace‫וי‬. d. If the fuse immediately blows again, check
the electrical circuit.
Multimeter
Classification

Article
Amperage
Amount

NOTE: Fuse 15 A 1
Check the continuity of each socket in the same
manner as described in the section of the bulb, WARNING
however, please note the following. Never use a fuse with a rating other than that
specified. Improvising or using a fuse with the
a. Install a good bulb into the socket. b. wrong amperage can cause serious damage to
Connect the probes of the multimeter to the the electrical system, causing a malfunction in
respective socket wires. the lighting and ignition systems, and may cause
c. Check the continuity of the socket. If any of the
a fire.
readings indicate no continuity, replace the
socket.
4. Install:
•Seat and right cover
CHECKING THE FUSE Refer to "GENERAL CHASSIS"

on page 4-1.
CAUTIONN:
To prevent a short circuit, always place the main CHECKING AND CHARGING
switch to "OFF" when checking or replacing a
fuse. WARNING

1. Remove: Batteries produce explosive hydrogen gas and
•Seat and right side cover contain electrolyte which is toxic and highly
Refer to "GENERAL CHASSIS" corrosive sulfuric acid. Therefore, always follow
on page 4-1. these precautions:

2. Check: • Use p r o t ec t iv e e q ui pm en t f or e ye s
•Fuse when handling or working near batteries.
• Load batteries in a well ventilated area.
a. Connect the meter to the fuse and check for • Keep batteries away from heat, sparks or flames (eg,
continuity. welding equipment, lighted cigarettes).
NOTE: • No smoke while charging or handling batteries.
Set the multimeter to "Ù × 1". • Store batteries and electrolyte OUT OF

REACH OF CHILDREN.
Multimeter • Avoid bodily contact with electrolyte as it can cause
severe burns or permanent eye injury.
b. If the meter indicates "䌲", replace the FIRST AID IF IN BODY:
fuse. EXTERNA

L
3. Replace: •Skin - Wash with water.
•Blown fuse •Eyes - Flush with water for 15 minutes
and get immediate medical attention.
7-34



INTERNA
L Example
• Drink plenty of water or milk followed by milk Open circuit voltage = 12.0 V Charging
of magnesia, beaten egg or vegetable oil. Get time = 5-10 hours Charging the
immediate medical attention. battery = 20-30%

1.
Remove:
•Seat and right side cover
on page 4-1.
2. Disconnect:
•Battery cables
(From the battery terminals)

CAUTION:
First, disconnect the negative battery "1", then
A. Open circuit voltage (V) B.
the positive battery "2".
Charging time (hours)

C. Relationship between the open circuit
voltage and the charging time at 20 ° C (68
2 ° F)
D. These values vary with the temperature, the
1
state of the battery plates and the electrolyte
1 level.

3.
Remove:
• Battery
4. Check:
•Battery voltage
•Electrolyte level in the battery cell
•Charging the battery
A. Open circuit voltage (V)
B. Condition of Battery Charge (%)
a.Connect a multimeter to the battery C. Ambient temperature of 20 ° C (68 ° F)
terminals.
•Positive probe of the multimeter
5. Load:
Terminal ‫ וי‬battery positive
•Multimeter negative probe •Battery
Terminal ‫ וי‬Negative battery (See illustration of the proper method of
loading)

NOTE:
The charge level of the battery can be checked by
measuring the voltage
open circuit (i.e., the voltage when the
positive battery terminal is disconnected). No
need to charge when the open circuit voltage is
less than 12.8 V.

b.Verificar charging the battery, as shown in the
graphs and the following example.
7-35



WARNING
Do not charge a battery quickly.

CAUTION: Charging method with a charger
(voltage) variable
Do not use a battery charger quick charge, a. Measuring the open circuit voltage prior to
and requiring a high amperage in the battery charging.
quickly and can cause overheating and
damage the battery plates. NOTE:
If it is impossible to regulate the charging The voltage should be measured after 30
current to the battery charger, be careful not minutes without using the battery.
to overcharge the battery. b. Connect a charger and an ammeter to the
When charging a battery, be sure to remove
battery and start charging.
it from the vehicle. (If the load mounted on
the vehicle, disconnect the negative battery c. Make sure that the current is higher than the
terminal.) standard charging current in the battery
To reduce the risk of ignition, do not connect the written.
battery charger until the cables battery charger
NOTE:
connected to the battery.
If the load current is less than written charge level in
Before removing wires from the battery
charger, the battery terminals, be sure to turn the battery, the voltage setting of the load
off the battery charger. Make sure the battery 20-24 V and make up the amperage for
charger cables are properly connected to the 3-5 minutes to check the battery.

battery terminal and are not shorted. A charger
with corroded wires can generate heat in the • If the load current standard was reached by
contact area and a weak clip can cause the battery is good.
sparks. • If the load current standard was not met
If the battery becomes hot to the touch, at any by battery replace battery.
time during the charging process, disconnect
the charger from the battery and let the d. Adjust the voltage range so that the normal load
battery cool before reconnecting. A warm level.
battery can explode! e. Set time in accordance with the appropriate
charge time for the voltage to the circuit open.
f. If the load required more than 5 hours, it is
advisable to control the charging current after 5
hours. If there is any change in the amperage,
readjust the voltage to obtain the standard
charging level.
g. Measuring the load voltage of the battery open
circuit, after having been unused for more than
30 minutes.
12.8 V or more --- Charging
complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
A. Open circuit voltage (V) B.
Time (minutes)
C. Load
D. Ambient temperature of 20 ° C (68 ° F) E.
Check the open circuit voltage.
7-36



8. Check:
Charging method with a constant voltage •Batteryterminals
charger Sulfation → Clean with hot water. Loose
connection Connect ‫ וי‬correctly.
a. Measure the open circuit voltage, before 9. Lubricate:
loading. •Batteryterminals
NOTE:
The voltage should be measured after 30 Recommended lubricant
minutes without using the battery. Dielectric grease

b. Connect a charger and an ammeter to the 10.Instalar:
battery and start charging. •Seat and right side cover
c. Make sure that the current is higher than the Refer to "GENERAL CHASSIS" on page 4-1.
standard charging current in the battery
CHECKING THE RELAYS
written.
Check continuity of each switch pocket tester. If the
NOTE: continuity reading is incorrect, replace the relay.
If the load current is less than the written charge
level in the battery charger such Multimeter

Battery may not charge the MF battery. It
recommends a variable voltage charger.

d. Charge the battery until the charging voltage of 1. Disconnect the relay harness cable assembly.
the battery is 15 V. 2. Connect the multimeter (Ù × 1) and battery
NOTE: terminal (12 V) to the relay terminal as shown.
Check the operation of the relay.
Set the charging time at 20 hours (maximum).
OOS Replace ‫וי‬.
e. Measuring the load voltage of the battery
open circuit, after having been unused for
more than 30 minutes.

12.8 V or more --- Charging complete. Starter relay 1 2
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

6. Install: 3 4
•Battery R B
7. Connect: LW R/W
•Battery cables
(To the battery terminals)

CAUTION 1. Positive battery terminal
2. Negative battery terminal
First, connect the positive battery 3. Tester positive probe
"1", and then the negative cable from the battery 4. Tester negative probe
"2".

Result
2 Continuity
(Between "3" and "4")
1
1
7-37



Starter cut relay b. Turn the ignition switch to "ON".
c. Measure the input voltage signal relay
1 of rotation.

Output voltage relay turn signal 12 V

DC
2 3
LB RB 2. Check:

• The output voltage relay turn signal. OOS
RW Replace ‫וי‬.

a. Connect the multimeter to the terminal relay turn
1. Positive battery terminal signal, as shown.
2. Negative battery terminal
3. Tester positive probe Multimeter

4. Tester negative probe

Result • Positive tester probe ‫וי‬
Continuity brown / white "1"
(Between "1" and "3") • Negative tester probe ‫וי‬
land

VERIFICATION OF RELAY TURN SIGNAL
1. Check:
• Input voltage relay turn signal
OOS ‫ וי‬The from circuit

switch to the relay coupler turn signal is faulty 1

and must be repaired. Br / W

Input voltage relay turn signal DC 12 V Br

a. Connect the multimeter to the terminal relay
turn signal, as shown.
b. Turn the main switch to "ON".
Multimeter c. Measuring the output voltage relay turn signal.

• Positive tester probe ‫וי‬
coffee
"1"
• Negative tester probe ‫וי‬
land

Br / W

Br

1
7-38



VERIFICATION plug cap
a. Disconnect connectors of the ignition coil, the
1.Check: terminals of the ignition coil.
• plug cap resistance b. Connect the multimeter (Ù × 1) to the ignition
OOS Replace ‫וי‬. coil, as shown.

Resistance of the plug cap Multimeter
5.0 kU at 20 ° C (68 ° F)

a. Remove the spark plug cap from the spark orange "1"
plug wire. • Negative tester probe ‫וי‬
b. Connect the multimeter (Ù × 1k) to the spark land "2"
plug cap as shown.

Multimeter

c. Measure the secondary coil resistance.

2.Check:
c. Measure the resistance of the spark plug cap. • secondary coil resistance

CHECKING THE IGNITION COIL
1.Check: Secondary coil resistance
• Primary coil resistance KU 5.68-8.52 at 20 ° C (68 ° F)

Primary coil resistance a. Disconnect the spark plug cap from the
Ù 0.32 to 0.48 at 20 ° C (68 ° F) ignition coil.
b. Connect the multimeter (Ù × 1k) to the ignition
coil, as shown.

Multimeter
7-39



• Positive tester probe ‫וי‬ Sensor check crankshaft position
High voltage cable 1 .. Disconnect:
• Negative tester probe ‫וי‬ • Coupling crankshaft position sensor
land (From the wire harness)

2.Check:
• Reliability of crankshaft position sensor
OOS ‫ וי‬The position sensor
1 Crankshaft / stator assembly.

Position sensor resistance
Ù 192-288 crank at 20 ° C (68 ° F)

2
c. Measure the secondary coil resistance.

VERIFICATION OF THE DISTANCE a. Connect the multimeter coupler crankshaft
BETWEEN spark plug electrodes position sensor as shown.
1. Check:
• Distance between the spark plug electrodes Multimeter

OOS Perform ‫ וי‬solution
of power system problems, beginning with
step 5. See "TROUBLESHOOTING" on page • Positive tester probe ‫וי‬
7-3. blue / yellow "1"
Minimum distance between the spark green "2"
plug electrodes from 0.8 to 0.9 mm

NOTE:
If the distance between the spark plug
electrodes is within specifications, the circuit of
the ignition system is operating normally.

a. Disconnect the spark plug cap from the spark
plug. b. Connect the dynamic spark tester "1"
as shown. LYG

Dynamic spark tester 1 2

b. Measure the resistance of crankshaft position
sensor.

CHECKING THE STARTER OPERATION

1.Check:

• Operation of the starter
Do not work ‫ וי‬troubleshooting
Electric starter, starting with step 4. See
1. Dynamic spark tester
2. Spark plug "TROUBLESHOOTING" on page 7-9.
c. Turn the ignition switch to "ON" and the engine
stop switch to position
! ".
d. Measure the distance from spark ignition "a". e.
Start the engine by pushing the switch
boot! '
7-40



a. Connect the positive battery terminal "1" and
the starter cable "2" with a jumper wire "3".
WARNING
• The cable used for the bridge must 2
have at least the same capacity of the cable 1 W
battery, otherwise, the jumper cable may be
burned.
• This check is likely to produce
sparks, therefore, ensure that no gas or b. Measuring the resistance of the stator coil.
flammable liquid around.
CHECKING THE REGULATOR /
RECTIFIER
1.Check:
• Charge Voltage
regulator / rectifier.

Charge Voltage
13.7-14.7 V at 5000 r / min

b. Check the operation of the starter motor. a. Connect the engine tachometer to the spark
plug wire.

b. Connect the multimeter to the coupling of the
CHECKING THE STATOR COIL
regulator / rectifier, as shown.
1.Desconectar:
C Coupling of the stator coil
(From the wire harness) Multimeter
2.Check:
• Resistance of the stator winding
OOS Replace ‫ וי‬the sensor • Positive tester probe ‫וי‬
Crankshaft position / stator assembly. red "1"
Resistance of the stator winding black "2"
Ù 0464-0696 to 20 ° C (68 ° F)

a. Connect the multimeter (Ù × 1) onto the stator

coil, as shown.
B Br R
W 1
Multimeter

white "1" c. Start the engine and run at about 5000 r
• Negative tester probe ‫וי‬ / min.
white "2"
d. Measure the charging voltage.
7-41



CHECKING THE FUEL GAUGE

1. Remove:
SPEAKER VERIFICATION • Fuel Tank
1.Check: 2. Remove:
• Resistance of the horn • Fuel Gauge
OOS Replace ‫וי‬
3. Check:
Coil Resistance • Resistance fuel gauge
Ù 1.95-2.25 at 20 ° C OOS Replace ‫ וי‬the
Fuel meter

a. Disconnect the connectors of the speaker Fuel Gauge
terminals of the horn. Unit resistance meter (full)
b. Connect the multimeter (Ù × 1) to the speaker Ù -21.5 18.5 to 20 ° C (68 ° F)
terminals. Unit resistance meter (empty)

137-143 Ù to 20 ° C (68 ° F)
Multimeter

a. Connect the multimeter (Ù × 100) in the fuel
• Positive tester probe ‫וי‬ gauge coupling, as shown
horn terminal "1"
• Negative tester probe ‫וי‬ Multimeter
horn terminal "2"

1 orange / white "1"
green / black "2"

2

c. Measure the resistance of the speaker. 2 1

2. Check:
• Sound the horn ORW GB

Sound Adjust or replace defective ‫וי‬.

a. Connect a battery (12 V) to the speaker.
b. Turn the adjusting screw in direction "a" or
"B" until the specified tone is obtained.
b. Move the float fuel gauge the level of
minimum and maximum.
c. Measure the fuel gauge resistance.

to b
7-42



CHECKING THE THROTTLE POSITION SENSOR CHECKING THE SPEED SENSOR
1. Check: 1. Check:
• Throttle Position Sensor • Voltage output speed sensor
a. Connect the digital circuit tester to the terminals
of the throttle sensor body, as shown. Reading cycle of the output voltage
• Positive tester probe ‫וי‬ 0 V to 5.0 V to 0 V to 5.0 V
Blue terminal "1
• Negative tester probe ‫וי‬ a. Connect the multimeter to the speed sensor
black / blue terminal "2" coupler (at the end of the cable harness), as
shown.
b. Measure the input voltage of the throttle
position sensor. Multimeter
OOS Replace ‫ וי‬or repair
wire harness.
Connect the multimeter to the terminals of the
throttle sensor body, as shown. • Positive tester probe white
"1"
• Negative tester probe blue /
black "2"

• Positive tester probe ‫וי‬ 1
blue "1" W L
• Negative tester probe ‫וי‬ BL
black / blue terminal "2"
2
LW
Input voltage sensor BL
throttle position
5V
(Azul-negro/azul)

b. Adjust the position of the main switch to "ON".

d. While slowly opening the throttle, check that the c. Raise the front wheel and rotate it slowly. d.
voltage output of the throttle position sensor, Measure the voltage of white and blue / black.
increase. With each full rotation of the front wheel, the cycle
The voltage does not change or changes of voltage readings should be
abruptly
0 V to 5.0 V to 0 V to 5.0 V.
Replace ‫ וי‬the throttle body.
Out of Specification (closed position)
Replace ‫ וי‬carburetor.

Output Voltage Throttle position sensor
(closed) 0.65 to 0.75 V
(Amarillo-negro/azul)

BL L And

2
1 3
7-43


TROUBLESHOOTING

TROUBLESHOOTING 8-1
GENERAL INFORMATION 8-1
Misfires 8-1
INCORRECT ENGINE IDLE 8-1
Poor performance in medium and high speed 8-2
GEAR FAILURE ELBCIAOMDE 8-2
SHIFT PEDAL DOES NOT MOVE 8-2
JUMPING GEARS 8-2
CLUTCH FAILURE 8-2
OVERHEATING 8-2
Supercooling 8-3
PERFORMANCE POBREFREENNEALDO 8-3
FAILURE HORQEULILALNATEDRA 8-3
UNSTABLE HANDLING 8-3
FAILURE OF LIGHTING SYSTEM OR SIGNALLING 8-4
WIRING DIAGRAM 8-5

SOLUCIÓN DE PROBLEMAS

Electrical System
TROUBLESHOOTING 1. Battery

• Battery discharged
GENERAL INFORMATION • Battery failure
NOTE: 2. Fuse
The following troubleshooting guide does not cover • Blown, damaged or incorrect
• improperly installed fuse
all possible causes. It should be useful,
3. Plug
however, as a basic guide to the
• Improper plug cap
troubleshooting. See the procedure in this manual
• heat range spark plug incorrect
for checks, adjustments and parts replacement.
• Faulty spark plug
• Worn or damaged electrode
STARTING FAILURES • worn or damaged insulation
• Spark plug defective
Engin 4. Ignition Coil
e • Body of the ignition coil cracked or fractured
1. Cylinder and • primary and secondary coils fractured or
cylinder head • short circuit
Defective spark plug
• Spark plug loose
• Loose cylinder head or cylinder 5.S Power ystem
• Damage to the head gasket • Faulty CDI
• Damaged cylinder gasket • crankshaft position sensor defective
• Cylinder worn or damaged • Magneto or broken rotor keyway
• Improper valve clearance adjustment 6. The switches and wiring
• Valve not closed • The switches and wiring
• Improper break valve • Defective main switch
• Sync incorrect valve • Engine stop switch defective
• defective valve spring • Broken or shorted wiring
Faulty neutral switch
• seized valve • Starter switch defective
2. Piston and piston rings • Faulty clutch switch
• Improperly installed piston rings • Grounding circuit
• Damage, wear or fatigue piston rings • Loose
• Rings stiff 7. Starting System
• Piston damaged or seized • Starter defective
3. Air filter • Starter relay faulty
• Air filter installed improperly • Relay faulty ignition cutoff
• Air filter element clogged • Faulty starter clutch

4. Crankcase and
crankshaft Improper engine idling
• Crankcase incorrect assembly
• Crankshaft seized
1. Cylinder and cylinder head
Fuel System • Improper valve clearance adjustment
1. Fuel tank • valvetrain components damaged
• Fuel tank empty 2. Air filter
• Clogged fuel filter • Air filter element clogged
• Fuel deteriorated or contaminated
2. Carburetor Fuel System
• Fuel deteriorated or contaminated 1.Carburador
• Fuel dispenser clogged • Union carburetor loose or damaged
• Carburetor out of adjustment • Set the throttle cable free inadequate
• Carburetor flooded
• Air Induction System defective
8.1

Electrical System
JUMPING GEARS
1. Battery
• Battery discharged

Axis of changes
• Defective battery
• Shift Pedal Position incorrect
2. Plug
• The return lever stop improperly
• Distance between the spark plug electrodes
Forks of changes
incorrect
• Worn shift fork
• heat range spark plug incorrect
• Faulty spark plug

Shift drum
• Worn or damaged electrode
• Axial wrong
• worn or damaged insulation
• Spark plug defective • Wear drum grooves changes
3. Ignition Coil
Transmission
• primary and secondary coils broken or
shorted • Wear lace Gear
• Faulty spark plug cable
• Ignition coil cracked or fractured Clutch CLUTCH FAILURE slips
4. Ignition system 1. Clutch
• Faulty CDI • Incorrect assembly clutch
• crankshaft position sensor defective • Improper setting of the cable free play
• Magneto or broken rotor keyway • Clutch spring fatigued or loose
• Wear of the friction plates
Poor performance in medium and high speed
• Wear on the clutch plates
See "start failure" on page 8-1. 2. Motor oil
Mo.tor • Incorrect oil level
1. Air filter • Incorrect oil viscosity (low)
• Air filter element clogged • Impairment of oil

Fuel System Drag Clutch
1. Carburetor 1. Clutch
• Carburetor defective • unequal voltage clutch springs
• Pressure plate deformed
FAILURE GEAR Changing gear is difficult • Clutch plate bending
See "Drag clutch". • Friction disc swelling
• Clutch Pushrod bent
• Disc holder fractured
SHIFT PEDAL DOES NOT MOVE axis
• Primary Gear Bushing burned
2. Motor oil
changes
• Incorrect oil level
• Bent shift shaft
• Incorrect oil viscosity (Alta)

Changes drum and forks • Impairment of oil
• Foreign body in a drum groove changes
• shift fork stuck OVERHEATING Ignition
• Sweep guide bent shift fork
System
Transmission • Distance between the spark plug electrodes
• transmission gear attached incorrect
• Foreign objects between transmission gears • heat range spark plug incorrect
• Incorrect assembly of the transmission • Faulty CDI
8.2


Fuel System • Grease or oil on the brake disc
• Improper carburetor adjustment • Grease or oil on brake pads
• Setting the wrong fuel level • Brake fluid level incorrect
• Blocked air filter element
FRONT FORK FAILURE oil leak
Compression System • Inner tube bent, damaged or corroded
• Many carbon deposition • broken or damaged outer tube
• improperly adjusted valve timing • Oil seal installed incorrectly
• Valve clearance maladjusted • Edges damaged oil seal
• Incorrect oil level (high)
Motor oil • Screw loose cushion rod
• Incorrect oil level • copper washer damper rod damaged
• Incorrect oil quality • O-ring screw cap damaged
• Low oil level Malfunction

• bent or damaged inner tube
Fuel System
• Outer tube bent or damaged
1. Throttle Body
• damaged fork spring
• Damaged or loose throttle union
• damper rod bent or damaged
2. Air filter
• Incorrect oil viscosity
• The air filter element is clogged
• Incorrect oil level

Chassis
1. Brake (s) UNSTABLE HANDLING
• Drag Brake 1. Handlebar
• Folding handlebar or incorrectly installed
Electrical System 2. Components of the steering column
1. Plug • Upper bracket improperly
• Distance between the spark plug electrodes installed
incorrect • Lower bracket improperly
• heat range spark plug incorrect installed
2. Ignition system (Void improperly tightened nut)
• Faulty CDI • Stem bending direction
• Ball or damaged tracks
3. Bar (s) of the front fork
Cooling system
• Oil levels mixed (both front fork legs)
• uneven spring tension (both front fork
overcooling legs)
1. Thermostat • fork spring fractured
• The thermostat is open • bent or damaged inner tube
• Outer tube bent or dañad
4. Rocker
POOR PERFORMANCE BRAKE
• Bearing Wear
1. Disc brake • Bent or damaged swingarm
• Wear of the brake pads
• Brake disc wear
• Air in hydraulic brake system
• Loss of brake fluid
• Failure to set the brake caliper
• Failure to seal the brake caliper
• Coupling screws loose
• Damage to the brake hose
8.3


5. Rear Shock • Light Bulb melt rotation
• Faulty rear shock spring • Bad connection
• Oil Leaks • Damaged or faulty wiring harness
6. Tire (s) • Grounding circuit
• Unequal tire pressures (front and rear) • Battery failure
• Improper tire pressure • Fuse broken, damaged or incorrect
• Uneven tire wear
7. Wheel (s) Light turn signal flashes slowly
• Incorrect wheel balance • turn signal relay defective
• Deformation of the casting wheel • Defective main switch
• Damage to the wheel bearings • turn signal switch defective
• Wheel axle loose or bent • turn signal bulb incorrect
• Excessive deformation of the wheels
8.Chasis Signal light remains illuminated rotation
• Chassis folded • turn signal relay defective
• Tube damaged steering column • Light Bulb melt rotation
• improperly installed bearing race
FAILURE OF LIGHTING SYSTEM OR Light turn signal flashes rapidly
SIGNALLING • turn signal bulb incorrect
• turn signal relay defective
The front light does not light • Light Bulb melt rotation
• Bulb wrong lamppost
• Many electrical accessories Horn does not sound
• Dura loading • Horn maladjusted
• Bad connection • Horn damaged or defective
• Grounding circuit • Defective main switch
• Poor contact (switch or the light) • Horn switch defective
• Bulb melt lamppost • Battery failure
• Fuse broken, damaged or incorrect
Streetlight bulb cast • Damaged or faulty wiring harness
• Bulb wrong lamppost
• Battery failure
• Failure of the regulator / rectifier
• Grounding circuit
• Defective main switch
• Faulty Light Switch
• Due to the length of the lamp bulb
Tail / brake light does not come on
• Bulb taillight / brake incorrect
• Many electrical accessories
• Bad connection
• Bulb taillight / brake light cast

Bulb taillight / brake light cast
• Bulb taillight / brake incorrect
• Battery failure
• Switch the taillight / brake light incorrectly
adjusted
• Due to the length of the light bulb
Tail / brake light
Light no turn signal lights
• turn signal switch defective
• turn signal relay defective
8.4

GB
Sb
LY
BL
B Br R
1 W
W W
W
W - W (BLACK) R
Br

3 LY Or Or
CRK + IG8
B

WW B

Sb
Sb Sb
LYG
7
WW
Sb
BL LY BL
START 30LIGHT
Sb 6 STOP L
24 OFF 31 VCC 19 BL L Y
OFF A
15A
MAIN OFF
nd GIS
26
R ON START RUN PO BL
Br R SGND
ON
L
An

OFF RW
d
LWWB B
YW
Br L TC
Lg
21 LW
DIAG
(BLACK)
R
LB VB GND
WB
LW
Rw
Br
B

L

RwBr
B
5 B - Or BL L
23
LW
RW
LW
WBLW
L B
RW YWLg - LY Y

RW
(BLACK)

22 27 RB LB

LB RW LB RW Sb
(Black)
13 NEUTRAL
RB
BRSB
B
Br
Br
24

Br
ORW Br B L - Lg YW W
B
Br2 and DG GB Ch - Bl Sb TACHO
Br BRB
8.5
911 (BLACK) 28
- -
B1 B
P 10 GY GY
12 - -
Br2 W
BR BR SPEED
YW
ILLMI TC
B
BRW
L
(RED) (RED) VCC
BRW BL
GY
An
SGND
d
Br

WIRING DIAGRAM
OR
BRW
FUEL

An
WB
W

d
L

P
14 GB
FUEL +
-
Dg Br

BL
35 FLASHER
W
BRW P DIMMER 34 HORN 36

L
PASSON
BRW WB WB Br
OFF HI OFF L Br OR 29 ILLUMI
Ch P Dg Ch LO

ON NL
N
W
GB
And NR W L
And 25
BL
12V21W/35W

ORW
GB R 18
G
B DIAG Lg
12V10W
LW
BL
Ch
Dg
An
B
G
B
d
TURN
Dg

Ch

And HI BEAM RW

Ch
Dg
Ch
Dg

G
Y
L
16173233
12V5W
L L G
- And B
12V35W/35W
12V10W
12V10W
12V10W
B1 B1
15

B
B
(BLACK) (BLACK)
B

DIAGRAMA DE CABLEADO

FZ-16 COLOR CODE
1. Magneto CA B Br Black
2. Neutral switch Coffee
3. Regulator / Rectifier ChChocolate
4. Main fuse Dark green Dg
5. Battery G Green
6. Main switch GyGris
7. CDI Unit LgVerde clear
8. Ignition Coil O L Blue
9. Horn Orange
10. Relay turn signal Rosa P
11. Front brake switch Red R
12. Rear brake switch Blue sky Sb
13. Meter W White
14. Light Switch step And Amarillo
15. Streetlight B / L Black / Blue
16. Front turn indicator light (L / H) Br / L Coffee / Blue
17. Front light turn indicator (R / H) Br / W Brown / White
18. Taillight G / R Green / Red
19. TPS G / W / Wh G / Y
21. Cable Positive + Green / Yellow L / B
22. Negative cable - Blue / Black
23. Starter relay L / W Blue / White
24. Starter O / B Orange / Black
25. Speed sensor P / W Pink / White
26. Start switch R / B Red / Black
27. Starter cut relay R / L Red / Blue
28. Clutch switch R / W Red / White
29. Fuel Gauge W / Y White / Yellow
30. Engine stop switch Y / G Yellow / Green
31. Light Switch Y / L Yellow / Blue
32. Backlight turn indicator (L / H) Y / R Yellow / Red
33. Backlight turn indicator (R / H)
34. Light switch
35. Horn switch

8.6

Manual Service: 21C-F8197-EO

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LCD METER ................................................ ................................... 1-2

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The fuel gauge indicates the amount of fuel in the

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Tappet screw holder

Adjuster rear shock

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Tool to install the crankshaft spacer.

Tool for removing the crankshaft. YSST-

Clutch Hub Fixer

Compressor valve spring

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Tool name / nr Tool

Adapter valve spring compressor

Set gauge pump vacuum / pressure

Nut wrench address

Assembly tool oil seal front fork

Dynamic spark tester

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Yamaha Adhesive No. 1215

Base for piston

Crankshaft key cap

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Periodic change 1.00 L

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Spring Free Length 187.0 mm installed length

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Head screws (side chain) M6 2 10 Nm (1.0 m kg, 7ft Ib) E

Plug M10 1 13 Nm (1.3 m.kg, 9ft.Ib)

Cover plug housing 1 (Cover crankshaft) M32 1 3 Nm (0.3 m.kg, 2ft.Ib)

Cover transmission chain M6 7 2 Nm (0.2 m.kg, 1ft.Ib)

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Kickstarter Nut M12 1 50 Nm (5.0 m.kg, 36ft.Ib) E

Screw guide sprocket M6 2 12 Nm (1.2 m.kg, 9ft.Ib)

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Lower ring nut (Initial) M25 1 33 Nm (3.3 m.kg, 24ft.Ib)

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