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T 1240539450 - 14578370 Yamaha RX G Service Manual
T 1240539450 - 14578370 Yamaha RX G Service Manual
YAMAH
...j,'
..i. -'.' .,;. -..
This lvlanual is prepared by EscortsYamaha Motor Ltd. primarily
for use by Company Authorised Dealership and their qualified
mechanics. lt is nol possible to put an entire Mechanic's education in to
one lvlanual, so it is assumed that persons using this book to pedorm
maintenance and repairs on Yamaha motorcycles have a basic
understanding of the mechanical concepts and procedures inherent in
the motorcycle repair technology. Without such knowledge, attempted
repairs or service of this model may render it unfit for use and/or unsafe.
Escorts Yamaha N,4otor Ltd. is continually striving to improve all
models manufactured. Modifications and significant changes in
specifications or procedures will be forwarded to all Company
Authorised Dealerships; and will wherever applicable, appear in future
editions of this Manual.
Service Department
EscortsYamaha Motor Ltd.
LEGENDS
WARNING
to
It lndlcates SPecial Procedures that musi be lollowed to avold damage
the Moiorcyc e
€ IMPORTANT
It provides KeY Inlormation related with procedures and opera_
tions which must be clearlY understood.
MANUAL FORMAT
A of the procedures in th s manual are organised in a sequentlal, step by slep ror
mat. Tl]e Inforrratlon has Deen compiled to provlde the mechanic with an easy to
read'
harldy reierence that contajns comprehensive explanation of all disassernbly, repa r' as
sembly and inspection operallons ln this revised format, the condilion ol lau ty compo-
nent will precede and the course of action required will tollow the symbol e g
Bear ngs
Plttlng,/damage then FeP ace
EXPLODED DIAGRAM
Each chapter provi.les exploded diagrams before each disassmbly sectlon lor ease
in dentifying correct disassembly and assembly procedures
lllustralians in ih/s l4lorkshop l',tlanual may not necessartly match with the physical
appearance af the l"lolaict'cle
t
E.
INDEX
GENERAL
INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE
CARBURETTOR
CHASSIS
ELECTRICALS
TROUBLE SHOOTING
SERVICE INFORMATION
-
]
GENERAL APPLY
GEN
INFORMATION
INFO GREASE
PERIODIC
rff lR INSPECTION &
ADJUSTI\,,1ENT
APPLY
ENGINE A orL
ENG
n
CARBURETTOR
TIGHTENING
CHASSIS
CHAS
SERVICE LIMIT,
ff
E'E^I EL: ELECTRICALS
CLEARANCE
l-
TRSH TROUBLE
SHOOTING
SERVICE
SERV
INFO
Cr INFORN/ATION
\
r!
CHAPTER 1
GENERAL INFOBMATION
I,'OTORCYCLE IDENTIFICATION
- NUMBER
_ : SS S SERIAL
1-1
-r
tr sERVtcE TOOLS...............
=ctAL
fi,i: &5l
CHASSIS SERIAL NU|\,4BER
. The Frame Serial No it is sramped
n to the righi side ol the Steering
Head Pipe.
ENGINE SERIAL NO
I . The Engine Serial Number il rs
stamped In to the Left Side of the
Engine. (Engine Serial No does not
contain Year and lvlonth of productir'rJ
XXXXXX
YEAR OF MONTH MODEL UNIT PRODUCTION
::CDUCTION CODE cooE NUMBER
I ::i-cl cn 2 Digits standing for last t\/o digits of year
F9.96 -1996,97-1997..
One alphabet standing for Month
Eg. A - January, B - February........
L - December
SeIial Number: RXG 1 L5-000001
ctRcLlPs
1. All Circlips should be inspected care-
fully before reassembly. Always replace
Piston Pin Clips after one use. Replace
distorted Circlips. When installing a
Circlip O make sure that the sharp'
edged corner is positioned opposite of
the thrust it receives. See the sectional
view Shaft.
GTTMPoRTANT I
@
I would cause it to iump ott groove and
damage related components. L
Io,
ll"
The Special Service Tools are required for complete and accurate tune-up and as-
sembly. Using the correct Special Service Tool will help prevent damage caused by the
use of improper tools or improvised techniques.
MAGNETO HOLDEF
I
2 ESt\,1202 To remove the Flotor of Magneto Assy
IllAGNETO PULLER
3 ESM205 To hold the Driving Sprocket
--_
Ir_.-
CRANKSHAFT/CRAN KCASE
SEPABATINGTOOL
#p
l3 ESM 266 To install the Crankshaft.
CRANKSHAFT INSTALLING
TOOL
CHAPTER 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS
'J S SIS
.2-17
.2-18
2-21
! _::-RtcAL
2-22
I
J
INSP.
ADJ.
INITIAL
-:qs REMARKS
.
Rep ace (Warm Engine Before
D'a ning).
5'
a
t:
I
Remove cafbon (Cyl/Cyl. head/
P ston Assy llluij er elc )
il
il
'Check e echolyte leve and add
d slrled water every 1s days N
iclreck
specil c srav ty (++) and
breather pipe ior propef roll ng. a
Check,adlust bearn
a
1
INSP.
ADJ.
:
INSP.
ADJ,
t SPARK PLUG
_ r ir\
<
f----
i.. lla!6qP
\ l
\:_ll?
REAR BRAKE
' 2-6
Jr rr
INSP
ADJ.
SPARK PLUG
PLI.
:' over tighten or cross thread the Spark Plug as the Threads of Atuminium
_:?r Head may be damaged.
I: -:: 3llolv any Foreign Panicles to enter the Engine through Spark plug Hole
.e P ug is removed. Please ensure that the l-lole is covered
co with a cloth.
se the recommended ed type
tvpe of Spark Plud lest it wor
Soark Plug would alfect the Engine
PlLrg nd cates how the Engine has been operat ng. From the co our and
Spark P ug the Engine and the riding cond tions of the Motorcycle can be
n the tollowing lable.
2--t
AIR CLEANER ELEMENT
HAIRY
SURFACE
INSP.
ADJ.
.a
Check for Unitorm Application of
2T Oil all over lhe entire surface
(both sides) of the Etement Air
CleanerAfterthe excess 2TOit has
beeh Squeezed out.
. When install ng the Element Air Cleaner in its Cap Assy, be sure its sealng surface matches perfecl
y
with the sealing surface oi the Case Air Filier to prevenl anv A r Leakaoe.
IMPOFTANT
. Dirty Element Air Cleaner causes excessive fuel consumption, wear of piston Rings
and loss ot oower.
. Clean Element Air Cleaner every 1000 KMs.
. The Element Air Cleaner should be cleaned and lubrlcated more frequenfly (every
1O0O
kms or earlier), it Motorcycle is operated in very dusty (e.g. unpaved, dust laden roads)
or wet conditions.
TRANSMISSION OIL
CHECKING
'1. Check Oil Levelwith Motorcycle on Cen-
tral Stand. lvlotorcycle Rear Wheel lifted
ofl ground and Front Wheel touching the
ground.
2. Transmission Oil Level should always be
belween maximum & minimum levels on
Plug Oil Level.O Screwed on Cover Assy.
2 on R.H. Side.
3. Top up if required.
REPLACEMENT
1. Warm up the Engine with Motorcycle on
Central Stand.
2. Keep Oil Pan below the Engine.
3. Rernove Drain Bolt @ along with the cas-
ket @ and drain out Oi, completely..
4. lnstall Drain Bolt @ with its casket €).
Drain Bolt
2.0 Kq.m. 't4 Ft. Lb
RECOMMENOED
.20W40 Oil of Superior grade
quality.
QUANTITY :
. For Overhaul : 700cc t 20 cc
. For exchange : 650cc a 20 cc
during Service
1T'PORTANT
AUTOLUBE PUMP
CABLE ADJUSTMENT
1. Check to see if the Pump Guide Pin (Dis
aligned with the mark on Plate Adjusting
@with the Throttle in closed position hav-
ing no play-
2-12
AIR BLEEDING
1 . REMOVE:
. Pump Bleed Screw @ and keep oil run-
ning out until all the air bubbles disap-
pear
2. INSTALL:
. Gasket
. Hteeo Sctew (,
THROTTLE
o
4. Turn Throttle Stop Screw oul until specr-
fied ldle Speed is attalned. {
{
Engine ldle speed
1700 ! 100 R.PM.
(Uptill Bunning in Period ie. First 1000 Kms.)
1500 r
100 R.PM.
(After Running in Period ,:.e. After First '1000
Kms.)
I
E@
CLUTCH
CABLE ADJUSTIV]ENT
1. LOOSEN: Locknut O
2. ADJUST;
. Cable Ffee Play @ 2-3 mm by turning
Cable Adjusler @ in or oul.
3. TIGHTEN :Locknut O
:alr4OVEl 2. POSITION
. :avef Crankcase-1 G) (On left hand side) The Push Lever (t by the Cable Adjuslere)
a.rd ad.usr Lpve'riegl.t ai lo75 nm.
a
w
, :EVOVE: Generator Cover Assy. O 5. LOOSEN ;Locknut €) on Cover
CrankCase -1
6. SCRFW lN : Adjuster €) until tighl and
back t out by 1/4 turn.
llPoRrANr 7. TIGHTEN :Locknut @ L
€ li f
F
-:eiore Adiusting the Clutch Lever free play, the clutch Mechanism should be adiusted.
@
BRAKES
FRONT
'1
. LOOSEN :Locknut O
FBEE PLAY O
5-8 mm (lndian Markets)
2.5-3.5 mm (Other Markels)
REAR
1 . ADJUST:
. Free Play 6r of Rear Brake Pedal @ to
20-30 mm by turning the Adjuster O :
near the right hand side of the Rear
Wheel in orout (To increase ihe play turn
Anticlockwlse and to decrease the play
turn clockwise.)
d
2, INSPECT
. Position of Wear Indicator @
lf Indicator reaches the wear limit line then
replace Brake Shoes.
WHEELS
1, INSPECT
. WHEEL
lf Crack/ Bend/ Warpage then replace
2, INSPECT
. Spoke
Tap each Spoke with an iron rod lor
sound or feel the looseness ot the
Spokes by hand. lf any Spoke makes a
dullllat sound, Inspect it lor looseness
3. TIGHTEN
. Spoke Nipple
. True the Wheel if necessary.
2-17
INSP.
ADJ.
EIEE
TYRES
1 , INSPECT:
Tyre wear
Wear Limit: 1 mm -{
if
rm
Wear indicatof O ,N
G
Replacement limit @ : '1 MM
2, CHECK: .W
. Air pressure with tyre nozzle in down
position as in figure.
FRONT REAR :r
2.50-18 2.75-18
Tyre Specification
4PR 4PR
NYLON NYLON
Single Rider 22PSl 28 PSI
L,"-: Double Rider 22 PSI 32 PSI
Qbu^*^r^uz
TYRE CONDITION
OVER INFLATED O
Risky/Poor Boad Holding.
PROPERLY INFLATED O
Good and safe riding.
UNDER INFLATED €)
Higher Tyfe Wear & Low Fuel Economy
IMPORTANT ,q
rdl
.Tyre pressure should be checked and corrected under cold conditions (Tyre tem-
4fi!
perature equals ambient lemperature)
. Always check tyre condition before riding lllotorcycle. li badly worn oll then replace
.{n
Tyre immediately . ,"ifl
.In case nail/glass/sharp item is embedded in Tyre. please ensure same is removed
ri
before vulcanising /puncture repair.
7-F
f
@ .
DRIVE CHAIN
SLACK INSPECTION
. Park Molorcycle on Level Ground on
Central Stand.
. Remove Rubber Cap O from lnsoec-
tion Window @ on Chain Case .
. Rotate Rear Wheel @ several revolu-
tions in Forward direction and checkTo-
tal Slack upward & downward several
times to find "Maximum Slack Point" @.
:-te Chain Slack 20-30 mm SLACK ADJUSTMENT
. Park Motorcycle on Central Stand and
loosen Rear Brak€ CableAdiusteron RH
sne
. Remove Cotter Pin @ of Rear Wheel
Axl6 Nut with Dlier on LH side.
. Loosen RearWheelAxle Nut @ usino
Ring Spanner No 22 and Main Sprocket
Shaft Nut. @ using Ring Spanner No
27 on LH side.
. Loosen Chain Puller Lock nuts @ on
each side (LH and RH side).
. To tighten Chain, turn Chain Puller Ad-
I'l. Side
- justers @ clockwiseand to loosen Chain,
turn Adjusters anticlockwise and push
RearWheel Forward
:' _, . Ensure that the matching ofthe notch
on the adiusler with the alignment
.- :- . n----a
5- u marks on Rearonthe ReatSwing Fork
ia same on LH and RH side.
. Atter adjustment , be sure to tighten
Lock Nuts, Sprocket Shaft Nut. Wheel
Axle Nut and adjust the Rear Brake.
. Insert a new Cotter Pin into the Rear
WheelAxle and bend the end ofthe pin.
IIPORTANT
&"Fr adjusting the Drive Chain Slack, Rear Brake pedal Free play should always be
-e4{ed and adjusted, il required.
rc.r'ect alignment adversely affects the lile of Tyres, Wheel Bearings, Sprockets and
:r,e Chain.
, :-s-€ configuration ot Drive Chain to be same when assembled.
' flrts' e .efitting Chain Lock on Drive Chain, please ensure its Closed End is alwavs in
'|!E -rr.eclion of Chain Rotation.
2-19
DRIVE CHAIN CLEANING AND LUBRICATION
,.-7.' ,-:pw,,'^ _
Bemove the Drive Chain trom the Motor- Clean the chain with wire brush.
cyoe. Again dip the drive chain thoroughiy r-
Dip the Drive Chain in Kerosene for aboul crear Kerosene
20 minutes to loosen the dirtfrom internal
surfaces as shown in figure.
Fj.::
v1a?: ^,:
r{
6. Hang the Drive Chain vertcally and dry it 6. Dip the Drive Chain in 20W40 Oil Batf
by using compressed alr. to restore the rnterna ubrication
2-20
STEERING
CHECK\NG
1 . RAISE
. Front Wheel otf the ground.
2, CHECK
. Steering Head Bearing for looseness
Gently fock Front Fork Assembly back-
ward and forward. lf loose then adjust.
ADJUSTMENT
1 . REMOVE
. Cover Crown O by opening 2 Nos.
Screws.
2. LOOSEN:
. Steering Fitting Bolt @
. Ftonl ForK Htncn tJotls lJl
3, ADJUST
. Steenng Heao Ri.rg Nut @ by usrng
Special Service Tool ESI\l-221.@
Tighten the Nut until Steering Head is
tight without binding. lf heavy binding
then replace Race Bearings.
4, TIGHTEN
. Steering Fitting Bolt @
. Fronl Fork Pinch Boll @
5. ASSEN,lBLE
. uover urown tll
Steering Fining Bolt
3.1 Kgm(22Ft.Lb)
BATTERY
o '1. CHECK
.
Fluid level
:
2-22
INSP
ADJ.
IMPORTANT
. Maintain Electrolyte at Upper Level.
. Do not add Electrolyte when recharging the Battery
.Top up only with Distilled Water.
.The Ballery should be firmly mounted.
. The Breather pipe ol the Battery and its mounting should not have any lolds o
blockages and should be done as per the given illustration.
. Whenever Battery is not in the Circuit (i.e..emoved for Charging etc.) the Headligh
switch must be shifted to "ON" position, otherwise Neutral Light Bulb wilt Fuse an
BR unit will get damaged.
. Check for the Fuse in the Fuse box.
'Check for the proper coupler connections of RR unit.
2-23
CHAPTER 3
ENGINE
ENGINE DISASSEMBLY
CYLINDER HEAD AND CYLINDER 3-1
PtsToN .............. J-t
CRANKCASE COVERS J-l
GENERATOR ASSY ................ 3-2
DRTVE SPROCKET........................ 3-2
cLUTCH ............ 3-3
(ICK STARTER .. 3-4
SHIFT SHAFT 3-4
CRANKCASE 3-5
TRANSMISSION AND SHIFTER... 3-5
CRANK SHAFT 3-6
CBANK SHAFT
TRANSM ISS ION J- t.t
BEARING & OIL SEAL ....... 3-14
(contd....)
ENGINE ASSEMBLY AND ADJUSTMENTS
CRANK SHAFT ..'".. 3-15
TRANSMISSION AND SHIFTER... ..... 3-16
CRANKCASE ASSEMBLY ... . . 3-18
GENERATOR ASSY ................. ......... 3-19
sHtFT SHAFT ... 3-20
KICK STARTER. ...... 3-21
C1UTCH... ...... ...... 3-23
PR VARY DRIVE GEAR .............. 3-25
DRTV|NG SPROCKET....... ....... .... 3-2s
CRANKCASE COVERS ... ... .......... 3-25
PIsToN. ........... ..... 3-26 .:4.
.-.-'. .....3-27 t
cYLINDER
ENGINE MOUNTING .................... --.-' 3-28
cotvPoNENTS GRADING ......... 3-29
CYLINDER HEAD AND CYLINDEF
1 . REI\/OVE
. Spark Plug O
. Cylinder Head Nuts @ (4 Nos.)
. Cylinder Head O
. Cylinder Nuts @ (4 Nos.)
. Cylinder O
PISTON
1. REI\,4OVE
. Piston Pin Clips O (2 Nos.)
1 , REMOVE
. Piston Pin @ using Special Service Tool
O
ESI\,4 507 @ (Piston Pin Replacer)
. Needle Boller Bearing @
.
O
Piston @
. Piston Rings and Expander @)
CRANKCASE COVERS
1 . REMOVE
. Cfankcase Cover R H G)
By Opening 9 Nos. Screws.
GENERATOR ASSEMBLY
,1
. ATTACH
. Special Service Tool ESI\,4-201 €) Fc-
2@ holding the Rotor Assembly.
2, REN4OVE
36
:
3. ATTACH :
5. REMOVE :
DBIVE SPROCKET
1 . FEMOVE
Drlve Sprocket Nuto by using socket N:
26, and Holding the Sprocket by Spe-
cial Service Tool ESI\,I 205 @
Lock Washef @
Drive Sprocket @
I
I
2, REI\4OVE
. Shift Cam Blind Plug @
. Gasket @
CLUTCH
,I
, REMOVE
. Clutch Spring Bolts O 4Nos.
. Clutch Springs @ 4 Nos.
. Pressure Plate @
. Friction Plate @ 6 Nos.
. Clutch Plate G) 5 Nos.
. Push Rod @
2, ATTACH
. Speclal Service Toot ESM-233 @ For
holding the Driven cear Assembly @
REMOVE
.Driver Gear Assembly s by ooen ng
Nut @
. Washer Conical Spring @
. Plale Thrust-1 (]
. Spacer O
. Washer Plate (,
ATTACH
. Botor Assembly on L. H. JoJ, ral of Cranl
Sl^att and holo loySpecta. Serv.ceToo
ESM 201
5. RE]\,1OVE
. Pr mary Drive cear Nut @
. Washer 6r
. Prin'rary Drlve Gear @
t.9 .
.
Straight Key @
Spacer t!
. O ISea Retainer @
KICK STARTEB
1 , REMOVE
. Circlip O
. Washer @
. Kick ldle Gear @
. Washer @
. Circlip €)
2, UNHOOK
. Kick Return Spring @
3. REIVIOVE
. Kick Starter Assembly @
SHIFT SHAFT
1 . REITIOVE
. Crankcase Tightening Screws (13 Nos )
LH side.
2, ATTACH
. Special Service Tool ESM-265 O for sepa-
rating the Crankcase (On right hand side)
by tighiening Securing Bolis
(a
t 3. DISASSEMBLE
. Crankcase RH
the lever ot
O & LH @ bY rotating
the Special Service Tool
ESM-265 Clockwise and gently tapprng
the Hear end of the RH Crankoase with
Mallel.
REI\,4OVE
. Shift Carn Assembly
REIVIOVE
. Axle lMain Assembly €)
. Axle Drive Assembly @
CRANK SHAFT
1 . ATTACH
. Special Service Tool ESM-265 G) for
separating CrankShaft €) from
Crankoase LH O , by tightening Secur'
ing Bolts @
2 REI\,IOVE
. Crankshalt Assembly by rotating the
lever €) Clockwise
While removing Crankshaft lrom LH Crankcase hold it trom the RH side to prevent it
trom falling down.
CYLINDER HEAD
1. REMOVE
. Carbon deposit, Use rounded scrapef.
2, I\,4EASURE
. Cylinder Head warpage using straight
edge O, Feeler cauge @
lf out of speciflcation, resurlace or replace.
CYLINDER
1. REMOVE
. Carbon deposit from the Exhaust Port.
Use rounded scraper.
2. INSPECT
. Cylinder Wall for Wear/ Scralches
Rebore or Replace
3. MEASURE
. Bore using Cylinder cauge 10 mm from
TDC at Poinls shown.
I out of speclfication, rebore the Cylin-
0et,
PISTON
1. INSPECT :
3. IVEASURE
. Piston outside diameter wlth .
Micrometer.
lf out of specillcation , replace
Oversize 2
4. PISTON CLEARANCE
. li oui of specif cation, replace p ston anc
or rebore Cylinder.
IMPORTANT
Measurement should be madeal a point
10 mm above the bottom edge ol the Piston Clearance = Minimum Cylinder
Piston skirt & perpendicular to the axis Bore - Piston Diameter
of the Piston Pin. 0.034 - 0.039
PISTON RING
'1
. MEASURE :
. Side Clearance @
Use a Feeler Gauge @
lf
out of specification th€n replace
Piston and / or Piston Rings.
2. N,IEASURE
.Endgap:O
Use Feeler Gauge @
Out of specification, Replace Piston
Rjngs as a set.
Standard Limit
End Gap
0.25 to 0.45 0.6 mm
0nsralled)
mm
1, INSTALL
. Pislon Pin O and Bearing after Lubrica-
tion (into small end of Connecting Rod
@)
3. CHECK i
. Free Play
lf
free play is excessive, Inspect Con-
necting Rod Small End and Piston Pin
lorWear.
4. INSTALL
. Piston Pin O (in to Piston)
5, CHECK :
. Free Play
ll lree play out of specification, replace
Piston Pin and/or Piston.
3-9
CLUTCH
CLUTCH BOSS
'1, INSPECT :
. clutch Boss Splines @
Scor ng Wear/Dar.age ther DebL '
Replace.
FRICTION PLATE
'1. INSPECT :
. Friction Plates
ll Damages/Wear, Replace as a set
2, I\iIEASURE
Friction Plate thickness
N4easLre al dll lhe fo rr poinls as.ho
Wear limit : 2.7 mm
IMPORTANT
Plates Solines will cause erratic operation-
Minimum Lengih CLUTCH SPRING
1. MEASURE
. Free length
lf less than the length specified, Replace
the Clutch Springs as a set.
34.5 mm 33 rnm
KICK STARTEB
1 . INSPECT :
2. CHECK :
3, I\,1EASURE
. Kick Clip Friclion Force
Out of specification then Replace Kick
Clip.
G CAUTION
--3 K ck gear should be firmly held in the V se whie measuring the Kick Clip Friction
3-1 1
CRANKSHAFT
1, MEASURE
Runout limit . Runout
0.02 mm
Use Dial gauge.
lf out ol specification then Replace.
2. [/]EASURE
. Crank Width
lf Out of specification then Replace
4, I\4EASURE
. Small End Ffee PLay
ll out of specilication then Replace
3-12
TRANSMISSION
SHIFT SHAFT
1. INSPECT I
. Shift Shaft O
. bpnnqs La
. Stopper Lever Assembly O
lf Weaf/Bend, Replace
SHIFT FORK
'1. INSPECT
. Shift Forks at
(On the Gear and Shift Carn contact
sunace)
. Shift Fork cuide Bars @
Wear /Chaling/Bends/Damage then
Replace Fork and/or cuide Bar.
SI{IFT CAM
'1. INSPECT
. Shifl Cam Grooves O
. Shifl Cam P ns @
Wear/Damage/Scratches then Re-
place
] 1 ]\,4EASURE:
. Axle Runout
! se Cente'irg Devir.e and Dial Gauge
-- k=r I out of specificat on then replace.
3-13
GEABS
'1, INSPECT
. Gears
lf DamageMear then RePlace
2, CHECK
. Gear Movement
It operalion ls not smootl' then Bep ace
the concerned Gear'
3. INSPECT
. Matching Dogs.
lf Cracks, Wear, Damage observed ihen
replace.
***
1. CHECK
2. INSPECT
. All Oil Seal Lips
li DamageMear then BePlace
CRANKSHAFT
WOODRUFF KEY
NEEDLE ROLLER
BEARING
1. ATTACH :
. Special Service Tool ESNI 266 O (To
lhe left side of the Crankcase)for install-
ing the Crankshaft. @
2. TIGHTEN:
. Nut ofthe Special Service Tool ESM 266
i .Hold the Conreciing Bod ar Top
Dead Center.
Gf,MP{r
\Belore assemb\ing the Engine , uash \
Crankshaft in mild solvent (perrol/
Ithe
kerosene) I
|
f
^*4
*'u@k'
*w
-.a
v4
16
3-16
1. INSTALL:
Axle Drive Assembly @
Axle Main Assembly @
Shiti Cam Assembly @
Fork Shift"l @
Fork Shilt-3
Bar Shift Fork Guide-2 @
Fork Shi1r2
Bar Shift Fork Guide-'1
2. CHECK:
. Rolate Cam Shift and Check l\4ovement
of Fork and Sliding ol Attached cears
lf Incorrect operation then Reassemble.
CRANKCASE ASSEMBLY
D
Kgm (11 Ft. Lb)
1 . APPLY:
. Yamaha 3 t\,4 Bond €) (to both The 3, INSTALL
Crankcase mating surlaces.) . R ght Hand Crankcase €) (Tap as sho$'.
2. INSTALL: wth Ma let)
. Dowel Knock Pins @
4, TIGHTEN:
. CrankcaseTightening Screws.(1 3 Nos.)
Tighten the Screws in the shown se-
quence and in two steps (1) Semitighten
(2) Full itighten.
FLYWHEEL MAGNETO
1 INSTALL
. Stator Assembly O
2 CONNECT
. Neutral Switch Lead Wire @
3 1NSTALL
. Woodrulf Key
. Rolor Assembly @
. Lock Washer
TIGHTEN
. \ul E using socket No 19 with To'que
W.erch holding Botor assembly w.th
Special Service Tool ESN,I 201 6)
NESR\NN
E\,ra:f11r9l
crankcase (Left hand and Right Hand) should always be replaced as a set.
SHIFT SHAFT
PIN CLEVIS
10. clRcLlP
,11. WASHER PLATE
SPLIT PIN 12, OIL SEAL
ROD SHIFT 'I3. SHIFT SHAFT
WASHER PLATE 14. SPRINGTORSON
CIRCLIP
WASHER PLATE
15, SPRING TENSION
PEDAL SHIFT
16. scREW
17, NUT
COVER SHIFT PEDAL '18, WASHER LOCK
ARM SHIFT
2, INSTALL:
1, INSTALL:
. Stopper Lever Assembly O . Washer @
. Plate Cover (a . circlip @
. Shift Shaft Assembly @ 1.4 Kgm (10 Ft. Lb)
2, ADJUST:
. Shift Lever position (by Adjuster Screw
@ and Locknut @)
. Gap @ to be equal on both the sides.
While adiusting the transmission
should be engaged in the 2nd Gear.
KICK STARTER
i
3-21
1, INSTALL
. Kick Starier Assembly
2. POSITION
. The Kick CliP @ in groove @ ot the
crankcase as shown
3. HOOK
. Return Spring @
4. INSTALL
. Ckclip
CLUTCH
N.
SN
\%6@;
^.%1,
1t
P,pg 26
=@
22
14. BALL
BOLT WITH WASHER 15. ROD PUSH - 2
SPRING COI\,lPRESSION 16. OIL SEAL
PLATE PRESURE 17. LEVER PUSH
ROD PUSH 1 18. SPRING
NUT 19. OIL SEAL
WASHEF CONICAL SPRING 20. SCREW PUSH
PLATE FRICTION 21 BOLT SET
PLATE CLUTCH 22. NUT
BOSS CLUTCH 23. NUT
PLATE THRUST - 1 24 WASHER SPRING
PBII\,'IARY DRIVEN GEAR 25, GEAR PRIMARY DRIVE
SPACER 26. STRAIGHT KEY
WASHER PLATE 27, COLLAR
3-23
'1, INSTALL
. Thrust Washer O
. Spacer @
. Driven Gear Assy. O
. Thrust Washer @
. Oil Seal Retainer @
. Spacer @
. Straight Key @
. Primary Drive Gear @
2. INSTALL
. Cluich Boss @
. Washer @
I
'Nut@
3. TIGHTEN
'Driven Gear AssY Nut with Tc':-i
W'ench ard no dlng tle Clulcf B' :'
w,ll. Specral Se.v'ce Too FSV.: :
E\
\\1
[.*n'" (31 Fr. Lb)
4, INSTALL
15 . Friction Plates (6 Nos) @
. Clutch Plates (5 nos)@.
4 (( )12 'Ball@
' Push Rod @
3-24
5, INSTALL
. Pressure Plate @
. Springs @
. Bolts @
6. TIGHTEN
. Primary Drive Gear Nut along with
washer by using Torque Wrench.
DRIVING SPROCKET
5.5 Kgm (40 Ft. Lb)
1 , INSTALL
. Drive Sprocket O
. Lock Washer
TIGHTEN
. Drive Sprocket Nut @ with torque wrench
having socket No 26, holding the
Sprocket by Specral Service Tool ESlvl -
205 @
CRANKCASE COVERS
l INSTALL
. Crankcase Cover RH O
b"
V4*
YY'
s' a{4 il
s9 ,'
B. NUT
1. SPARK PLUG
2. NUT
L GASKET CYLINDER
'1
0. RINGS
3. CYLINDEB HEAD
11. EXPANDEF
4. GASKET CYLINDER HEAD
12. PISTON
5. BOLT STUD
13. BEARING CYLINDRICAL
6. CYLINDER
1r1 PIN PISTON
7. BOLT STUD
15. CIRCLIP
ENG
1, INSTALL
. Piston O
. Piston Rings with Expander @
. Needle Roller Bearing
. Piston pin O using Special Service Tool -
IMPORTANT
Make sure Piston Ring Ends are prop-
erty titted around Piston Ring Locating
Pins in Piston Grooves
The arrow on Piston Dome musl face
Exhaust Side.
Belore installing the Piston Pin Clip
cover the Crankcase with a Clean Rag
CYLINDEB
INSTALL
. casket (new) at
. Cylinder @l Using Special Service Tool
qrng Compressorl
ESVI 5'0 3 tPislon
TIGHTEN
. Cylinder Nuts Gr (4 Nos )
Q*:"re{"i
3-27
1, INSTALL
. Head Gasket O il
. cylinder Head iO
{
I
fi
2, TIGHTEN
t
. Cylinder Head Nuts Ol 4 nos. with torque
wrench using Socket No 14
" Spark Plug €)
Q\.1,:lyll".-.'f i
ENGINE MOUNTING
...-:' 1. TIGHTEN
. Engine Mountlng Bolts
. Eng ne Mounting Bo ts le
IN STALL
. L.H. crankcase Cover i.0,
F ILL
GearBox Oil
.L.Fl. cfankcase Cover
3-28
DRIVEN GEAR ASSY, & GEAR
PRII\,4ARY DRIVE GRADING
DF VEN GEAR ASSY
GRADE
DB]VEN GEAR
GRADES
"r=h
@ GEAR \
PR]N4ARY DRIVE
G A
z A B c D
B B
GRADE
A
D
c
PR MARYI E
D
e E
:\]NECT NG ROD (S]\,4ALL END) & . SPEC FIED ALLOWED CO]VBINAT ON
::DLE ROLLER BEARING (SIIIALL END) CUT N,4ARK
COLOUR ON CAGE SIDE
.{N ROD(sE) COLOUB coDE (DOT)
CODES
'-\
WHITE BLUE BED
.--ir'rcrsEr\ (D0T) (D0T) (DoT) SMALL END NEEDLE
I
B {1 CUT MABK)
AII
I (2 CUT |\4ARKS)
UI CRANK SHAFT
3 CUT MARKS
l
, .: il Pslon [.!d be delerm ned by lhe rebored
.:.1fi€rnaloflhe B.dy cy rnder D PURPLE
S
3- 29
!
CHAPTER 4
CARBURETTOR
CARBURETTOR
DISASSEMBLY
REMOVAL AND ........4-4
TNSPECTION -.....-...4-5
REED VALVE
TNSPECTTON ..........4-5
,l
19
1
F
116
&17
4-l
IG
CARB
@
f
OPERATION OF CARBURETTOR
Throttle Valve Operating
opening Angle System
ldling 0 Piloi Jet
lr tl
\-:-r0- 1/8
MrxrNG llqT ourtE- {
-|l li,ru
t!
4-
LOW SPEED CONTROL SYSTEM
Throllle va]velplsro.) 1/8 TO 1/4 (THROTTLE OPENTNG)
MIXING
_t
FUELi_}L8]!8I!EfI
NEEDLE JE
JET NEEDLE
NEEDLE JET
MIXING
8-? 1_1
tl
5. DISCONNECT:
. Throttle Cable (O
. Throtile Valve AssY.
6. REMOVE:
. Starter PlLlnger Assembly €l
. Float Chamber @ by opening four nos
scre\i/s.
. Float @ by removing Pin Float (a
. Needle Valve Assembly d,
. lvain Jet by @
. Pilot Jet bY screw driver 6'
7, REMOVE
. Reed Valve Assembly @ by opening,:
No bolts (Reed Valve, Joint Carburettof
Gasket)
IMPORTANT
. Never clean the Jets with a wire.
. Alwavs clean the Carburettor lrom outside belore disassembly'
. irpi6p"t of Float Height, C-lock on Jet Needle' and Air Screw can ca
drop in fuel""ning
average-
CLEANING ANDINSPECTION
1. CLEAN
. Using high pressure air, blow out all pas-
OdDp
sages anq lers.
2, INSPECT:
. Needle Valve Assembly
a- 1 Gasket O
2 Valve Seat @
3 Needle Valve @
Damaged or Worn oul -Replaceasaset
3. INSPECT :
. Throttle Valve @
. Jet Needle @
Scratch/Bent - Replace
4. MEASURE:
. Float Height @ Without Gasket
wilh Needle Valve Assembly in posiiion
lf found incorrect then Adjust
\\'@/2,
N ]
5. ADJUST
.
ffi Float Height
by bending the Tang @
IMPORTANT
4-5
T
CARB
REED VALVE
, ,: ,: :i::3e'neight o
a-: a' :3:. i ;alon -AdjLlst
. ?ea. !a re gending g
oLt oi sPec flcatlon -RePlace
FUEL LEVEL
. Place the Motorcycle on level surface
. Attach the FLlel Level Gauge Gl to the
Float Chamber Nozzle
. Loosen the Drdin Scle',i/ 2 and "larl I'
Enqine.
. Me;sure the Fuer Level J wilh OaJg"
. lt the fuel level is incorrect adjusl the
Float
ThecalburettorisPresetattheFactoryaftermanytests.|fthesettings'aredisturbed
Perfomance may result.
ftltlng technicat knowledge, poor Engine
"i-tro"i ""V
FRONT WHEEL
12
"@-*^ n.,,.'
A6-
,{n'@
16
7
k'*,,
CHAS
3. DISCONNECT:
. The brake cable @ by pressing Lever
Camshafll L4l
4. DISCONNECT:
. Removing the Ring Stop @ Disconnect
the Speedometer Cable a6l
{fi
Y'
Front Axle Nut 4.3 Kg. m
(31 FtrLb.\
5. REMO\E:
. Colter Pin ill
. Axle Nut €) by using rlng spanne".
. Axle Shaft O
. Front Whee @
CHAS
REAR WHEEL
'a
13
&..r{*t
t t1,
fzs L"qJ
I
;* *;'@"" -** -4
zs- @o
::t,'',
I
:
, : r' 1 : - or -r screvlirg Nulwing 3
t i: ': :':r: hoo !
5 . So' .!
ca.npress on 6
. vlasher P ate O
4, REN,4OVE:
. Split Pin O
. Axle Nut @ using Ring Spanner No 22.
5. REN4OVE|
. Axle Wheel O While pressing the Assist
Grip @ down with force.
. Collar @
. Rear Wheel @ tiiting the Motorcycle to
Lelt Hand Side.
2. FIEMOVE:
I
. sprocket Assy @ by opening Nut Gl us-
I ing Ring Spanner No 27.
. Sprocket Driven @ from Clutch Hub (a
I
by un ocking and opening bolts screws
I
(4Nos.)
INSPECTION
1. INSPECT;
. Axle Wheel (Beaf and Fronl)
Roll the Axle Shaft on a Flat SLrrface
lf Shaft Bent then Replace.
2. INSPECT:
. Wheel (Rear and Front)
lf Tyre Cracked/Rim Heavily Bent then
tr6nl'.o th6.^n.d.han
^rrt
3. MEASURE:
. Wheel Runout
f out of Specification then True the
Wheel or Replace.
Rim Runout Limits
FadialoMax 2.0 mm
Latera\OMax 2.0 mm
4. IN SPECT;
. $Jf,ee\ Bear\ngs
f excess play in the Bearings or Bear-
rng Jarnmed then Rep\aae.
5. MEASURE:
. Brake Shoe thickness
Out ol specification then Beplace.
6, NIEASURE:
. Brake drum inside diameter
Out ol specification, Beplace.
T.INSPECT:
'tl . uflve SprocKel ql
. Driven Sprocket @
F@S ll Wear/BentTeeth ihen Replace both r:
Sprockets and the Chain as a set.
8, MEASURE:
. Drive chain length (10 Links) 'A'
li Out of specification then Replace
9. INSTALL
. The Chain Clip O with rounded end fac-
ing the direction ol travel of Chaln
10.cHECK
. That bolh ihe RH and LH Chain Adjusl
ers are adjusted to the same position to
maintain correct Axle alignment.
. The Chain Slackness should be between
20 to 30 mm with Motorcycle on Centfal
Stand.
KITIMPoRrlNrl
I Please lubricate Chain with Multigrade
| 20w40 oil belore installing.
I
I
I
lnftxl
l"" "tot l
:-
1 , REMOVE:
. Front Wheel as described on page 5-1
. Front Fender bV opening bolts (4 Nos)
2. LOOSEN:
. Front Fork Pinch Bolt Upper O (2 Nos)
. Hemove uap hronl ForK !9
. Bolt Cap @(2 Nos)
Use Specia' Servce Tool ESM.2l4 a
3. REMOVE:
. Emblern 6) by opening screws (2Nos)
LOOSEN:
. Front Fork Pinch Boll Lower @ (2 Nos)
using Ring Spanner No 14
5. REMOVE:
. Front Fofk Assembly L.H. & R.H.a0
DISASSEMBLY
'1. RE]\,4OVE:
pl . Botoap O
' spacer rg
- t " Spring Seat O
8,, !, E
. Spri.g @
f
-
DISASSEMBLY
2 DFAI\
. Fr.ri F:'( O ci Pumping InnerTube@
-^ ns de :h: O!iaf T.rbe tt
3. OPEN:
. Bolt Hexagonal Socket Head @ by us'
ing Allen key No 8
. Use Special ServiceTool G) {ES-\,4 - 213)
1o hold the CYlinder ComPlete
(9
4. REMOVE:
. tnnet tuoe 9
. Cylinder ComPlete @
. Spindle TaPer @
5, REMOVE:
. Dust cover @
. Clip Oilseal @
. Washer ()
. Oil Seal @ using Special Service Tool
@ (ESM 270)
INSPECTION
1. INSPECT:
t." a** tr* l . lnner Tube il-
. Outer Tube
Scratches/Bends/Dan'rage Rep ace
Teourred.
\leasure Length of Fork Spring €l lf Out
oi specificat on Then ReP ace
O Ring of Bolt CaP
Specified 296.5 mm Cvl nder CornPlete for Damages
Nlinimum limit 291.5 C Seal ot Outer Tube lor dan]ages
5-10
t
ASSEMBLY
1. INSTALL:
. Insert Cylinder Complete O (with Spring
@) irom the top end ol the InnerTube @
. Spindle Taper @ on the lower end of the
Cylinder Complete
. Inserttheaboveassemblyintothe outer
tube 6)
. Bolt Hex Socket Head @ Using allen key
No 8 and Special Service Tool @ (ESM
21s)
Cylinder Comp ; 2.3 Kg.m,
(17 Ft.Lb)
2. INSTALL:
. Oil SeaL @ with Special Service Tool -
EStVt 275 €).
3. INSTALL:
13 . Front Fork Spring @
'11
. spring Seat @
Each Fork Leg
' Spacer @
175 r 3cc
. Boit Cap @
. Dust Cap @ SERVO
TELESHOCAB
4. FILL: otL
. Front Fork Oil
5. INSTALL
. Front Fork Assembly LH & RH.
. Tighten the Bolt Cap.
'. Pinch Bolt upper and lower
Cap Front Fork
L-
REMOVAL
1 . REMOVE:
. Front Wheel as per instructions on page
REMOVAL
I REMOVE:
.trrolt Wheel as per rlsl.uctro'rs on page
s-12
3, REMOVE:
. Cover Crown O
. Bolt Crown @ bY using socket No 17
. Crown Head assembly @
. Headlight Stays (LH & RH) @
4. DISCONNECT:
. Brake Cable @ {rom the Brake Lever @)
. clutch cable (0 from the clutch Lever @
5, REMOVE:
lnigil 1t . Fork stem Nut @ using Special Ser-
vice Tool @ ESM 221
13 . Cover Ball Race @
6 '14 . Race Ball 1 @
. Top Balls @ (22 nos )
t5 . Bottom Balls q9 (19 nos )
. Under bracket @
t6
6, FIEMOVE
. Race Ball 2 (Lower @ and Upper @)
Using a long rod.
. Race Ball 1 @ (Lower) Using a cold
chisel.
T
CHA a
INSPECTION
'.EW =
:-:; tarage Then Replace.
INSTALLATION
J \S-ALL
. Fa.e Ba T (bottom) €Jon the under
cra:K:l ano race ball 2 bottorn Oand
upcer ,2 insrde the head tube of the
frarne uslng punch
l.Grease the Balls and Baces
2, INSTALL
. Under Bracket @
. Race ball 1 upper
. Beaflng uover a
. Ring Nut lO
3. TIGHTENi
. Ring Nut @ with Specia Service Too
ESM 221 t-'
(So that a I play is taken up, but the
DracKel can still pivot freely.)
INSTALL:
Handle Crown w th Head ght stays
Crown Bolt
Front Forks LH and RH as per nslruc
tions on page 5-8
CHAS
@q$roo
f\\Cr--
;3 \ ,iu
1. SHAFT PIVOT 5, BRACKET UPPER
2. BUSH 6. COVER OUTER
3. REAR ARM COMPLETE 7. SPRING
SHOCK ABSOFIBE R 8. SEAT SPRING
ASSY REAR 9. DAIVPER ASSY
REMOVAL
REMOVE:
. Chain Case
. Drive Chain
. Dfiven Sprocket
. Chain Case
REMOVE:
. Shock Absorber Mount Bolts@
. Shock Absorbers
REMOVE:
I
CHAS
INSPECTION
t.....:''':'
lhen Beplace
2 '.s;:a-
. S,', -l a'-
'.,'i- :.as!','ng arm Installed gfasp the
sl., .;
ar.n enC to check forfree play- Free
p ay rc: .ed Replace bushes.
)o 3. INSPECT:
. P vot Shaft 2
Rusvd rty Clean or Replace.
Bent - Replace
INSTALLATION
1. GREASE THE BUSHES AND PIVOT
SHAFT.
2INSTALL:
. Swlng arm
. P vot Shaft
Always adjust both the right and left shock absorbers to the same posit on.
5-16
ELEU
t2! 5/2tW
a.s o
ls
I \*s -u F
=
=
Jl
]HTET
z E9*
t 6 IT
o
Ei ql I (l 4
si - M-
E
r"l -
I
I
-E 6+
.o e t-l;"
s:E?lsa
dts
s;:869s
-a
rt"'lr
IE ft -:HE
ecFii?
z
-li .
O6dEt;
HEAD L]6 -
FLASHEFLIOHI LGI]I 12VN4W ]21J-3 4W 12V.35r3!rr _:-_
12V.1Cr' 12V.3lW : :r'
I
t
SOURCE COIL
IGNITION COIL
,,i----\ 'i
<f
@o- PICK UP
t
cotL
FIG 2
tr{!,}
ffi vi il
E)
0 T
FUNCTION
CHARGING
. As tt-te fotor turns, cufienl ls produced in
'ie so- ce.oil a1d then storpo il rl^e.g1.
t on condenser. (Fig. 1)
TR GGER NG
. Att e same time.The pickup coil sends a pulse
s gna I to activate the thyristor (Fig. 2)
SPARKING
' --:. the gnilion condenser discharges
:-: :iored current rapidly. This induces a
- l- c tage n the lgnition coil and a stronc
.
. Ground the Spark Plug to the Cylinder . Check the Pickup Coil Resistance
Head and Kick the Starter
*o+
No Spark or Weak
Spark + "^+ Replace the Pick Up Coil
. Hold the lgnition Lead 5 mm from the Cyl- . Check up source coil resistance
nder Head
No Spark
o*+ *+
check the Plug Cap
and Spark Plug Replace the Source Coil
HY
Check the resistance of the primary and
kick the Sta er.
I\,/ 5parK "^+
secondary coil winding.
*"+
No Spark
Check Main Switch Rep ace the CDI Ljnit Replace the lgn tion Coil
RECTIFIER/
REGULATOR
--.--\
FUSE
CHARGING ;-
corL .i ,i
BATTERY
_! .-
lf out of speciiications checK Char,o : -: :: soec l cation, reP ace charglng
coil windlngs reslstance Ata ' ff :'a
than 12V replace the Rectre"Fe!-:'
10r
rllGH BEArli NDtCaTOF
LtcFT LIGHTING
SWITCH
neoo.,cr-, ).
\"
e.+" l
I ll J
il f'l)l
L?'TI r*-l,
AUXTL|ARY
Yl
LIGI,]T i
*
,rrrr^-
LIGHT
| o,0;";*"t
BECTIFIEF LroHlruc
BEGULATOF coti
=
YELLOW
,ti
/:4.
r\14*Fr
LIGHTING COIL
FIECTIF ER
REGULATOF
L GHT
METEFI
L GIIT
MAIN SWITCH
L GHTING COIL
BECTIFIEB
L GHT REGULATOR
=T
---L-
Br Briw FLASHEF
LGHT(FF)
FLASHEF
swtTct .i \
tt: i:-
sw Tcfl FLASIIEF IND
L GHT (B)
I SHIFT
+ LGHT (L.F l
LGHT(LFl
BATTERY
FLASI]EF N:
L GHT (L)
BRAKE LIGHT
MAIN SWITCH
B/W R Br
SWITCH INSPECTION
oFs G o
oNo G.
(:rc
LIGHT SWITCH
L
o -{f
PO G o o
(oscoNTlNrlED) {coNTrNUEo) ON o- -o
6-6
I,IMER SWITCH BRAKE SWITCH
\JS G -o
ASHER SWITCH
qN SWITCH
-..-
FLASHER SWITCH
B/w D9
o-
N
o- -o
HORN SWITCH
i
:l --o
DIMMER SWITCH BRAKE SWITCH
G \J>
G_ \Js o
LO ci o- --o
FLASHER SWITCH
Br/w Dg
o-
N
-o
HORN SWITCH
7777
I
rl o
t
hoso
crank veniilarcn
o I delivelr
calbu1610r br€atherhose
STARTING TROUBLE
POSSIBLE CAUSES
FUEL SYSTEM
No luelln Tank
BefrtJfuelrn Tank
Fuel Coch cjosed
Turn Fuet Coctco ,ON,
Foitroi
.,,":fiJ'
ri'"",'"",',iti :?11 fl:? ll 3:Tlr:,i:ilank,
Fuer c";" F*il;""d
Air veni
hole n FuelTanf Crp
Clean Fuel Tank Cap
Choked FueICock "log;;
Get Fuet Cock cteaned
Carbureitor llooded
T,,rn F,,-i
^-^,-.
,;";::::1,:,y.' .pos,uon. oDer rre rhro re
;;;;ff il:j :"^ ifj i';
:rar.airer unscrewns spark
--;;;il'Jil
l;1g T:,t :g:'ln:l'" : :['Jl
Chocked Fuel Filter "'u,,,. He'lt upark plug and k,cx start rne i.g,"s
Get Fuel Fjller cleaned
IGNITION
f"1arn Switch OFF,
Turn key to ON'positio;
Spart eiug Otrty or. OriOg;;y s;; cl""n,
"t,""t
uno uo;rs rnu $rkEfEE[IZ"p
H. T. tead toose/broken.
Frt propertyheptace
H.TIeJ
lnsulatton of Spark plug
cracked
Replace Spark pjug.
Elecl ron ic i g ni tion system;f e;; Check ior ioose conneclions-
POOR PICK UP
POSSIBLE CAUSES
\4|rfJier ouIet chokecJ
Clean Ihe t!,lulfter
Ar F[ler choked or drrly
Clean Air Filler/Beplace
!g1Oer Carluretror aCtustme,,rt najL,sr tne Carburettor
Cylinder Head Loose sen-inii
f'On'"n CV""O", Uo"o
C utch stipping t,r" ,o *"a,t,J,o,G
AdJUst Cturch se rng
irenorQuality ol Fuel
.-,,r1,"1
cn"1!115g11a111.0^"[osoodquJ.
3rake(s) b ndrng
Adjust Brake(s)
?islon Fing worn
out
Replace pisron Fings
as a;
STARTING TROUBLE
POSSIBLE CAUSES REMEDIES
FUEL SYSTEM
Spark P ug diriy or brdged by soot or Clean, check and adjust the Spark ptug Electrode cap
Eleclronrc rgn 1on system delect ve. Check lor loose connect ons
POOR PICK UP
POSSIBLE CAUSES REMEDIES
I\,4uifief out et choked Clean the IVluttler
-:. _---
A r F terchoked or dirly Lrean A r I Tel/Hep ace
lmproper carbure or adj!stmenl Adj,r.l th" C"rb,""1i", *til"S"
-
Cylnder Head Loose
I sh"l]?4d"'. j""gli"lIp"Il"d t"!*
C utch s rpp rg Adjust Clutch se ing.
Inlerior Oua fy ol FLrel Check and replace with specfied good qualty fue.
Brake(s\ hind\ng NNs\B\ake\s\
\
Piston R ng v/orn olt Rep ace Piston Fings as a set.
ENGINE GETS OVER HEATED
POSSIBLE CAUSES BE|llEDIES
Spark Plug ol Incorreci Heai Range Repla' e rrt_ Sp. r Dr ro ol Co_e.lHe.L qdnge
POOR BRAKING
POSSIBLE CAUSES REMEDIES
MOTOCYCLE WOBBLING
POSSIALE CAUSES
F!sed Bu bs Rep ace Bu bs
mproper connect ons Make proper connect ons
Indicator S!./ilch defect ve Rep ace Ind cator Switch
Flasher Un t defectrve Feplace Flasher unrt.
rmproper earllr ng Check earthing connections and rectify thenr.
CHASSIS:
Type Double Cradle
Construction Duplex, l\,4ade of Tubular Section
Castor Angle 27.54
Traii 90 mm
TYRE
Size (Front) 2.50x1 8-4PFl-Nylon'Ribbed
Size (Rea0 2 75x18 4PR-Ny on-Universal
TYRE PRESSURE
Front (Solo/Double) 22 PSI
Rear - Solo 2a PSI
- Double 32 PSI
Aq
BRAKE
Fronl Brake Type Drum Brake (130 O), Intemally Expanding
Operation Right Hand Operation
. Rear Brake Type Drum Brake (130 O), Intemally Expanding
Operation Right Foot Operation
SUSPENSION
Front Suspension CerianiType, Telescopic Fork, Oil Damped
Rear Suspension Swing Arm (Adjustable 5 Positions), Coil
Spring, Oil Damped.
WHEEL TRAVEL
Front Wheel Travel 110mm
Rear Wheel Travel 75 mm
ELECTRICAL
lgnition System cDl
Generator System Flywheel Magneto
lgnition Timing 15 a 3 at 1300 R.PM. BTDC
:
'19 r 3 at 6000 R.PM. BTDC
SYSTEM 12 VOLT
Head Light 12V- 35W35W
Tail/Brake Light 12V- 5W/10W
Flasher Light 12V- 10W(x4)
Park Light 12V- 3AW
Neutral lndicator 12V- 3.4W
High beam Indicator '12V- 3.4W
Turn lndicators 12V- 3.4W(x2)
N/leter Light 12V- 3.4W
HO rn
'12V- 1.sAmp
BATTERY
Rating 12V-2.5 AH
Charging Current 0.25 Amp
Charging Time '15 Hrs (Approximate)
Specific Gravity '1.240 (Fully charged)
RESISTANCE SPECIFICATIONS
Pick up Coil resistance 80 o a20% (MFIL)
SoUrce Coil resistance 230 or20% (MFIL)
lgnition Coil resistance
Primary Coil 1.6 o r 10%
.
Secondary Coil 6.6 Ko r 10%
Lighting Coil resistance 0.55 o r20%(MFIL)
Charging coil resistance 0.80 o r 10% (MFIL)
MAINTENANCE SPECIFICATIONS
CYLINDER HEAD
(Warp Limit) <0.03 mm
Lines Indicate Straight Edge l\,4easurenre.:
CYLINDER
Bore Size 58.00 - 58.02 mm in 4 Grades
Taper Limit <0.004 mm
Out of Round Limit <0.004 mm
PISTON
Piston Clearance (C) : 34-39 l\4icrons (0.034 mm - 0.039 mm,
Piston Cylinder
Red
Orange B
Green c
Pu rple D
c=A_B
SIZE (STANDARD) 57.967- 57.982 mm in 4 Grades
srzE iovERSrzE)
First Oversize
Second Oversize
58.25 mm
58.50 mm
I
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PISTON RINGS
SECTIONAL SKETCH
--'-----)' T
I tl
f-r-]
Top Ring Key Stone
B=1.2 mm
f=2.2 mm
2nd Ring Key Stone
B=1.2 mm
T=2.0 mm
END GAP
Top Ring 0.25-0.45 mm
2nd Ring 0.25-0.45 mm
Service Limit 0.60 mm
SIDE CLEARANCE
Top Ring 0.03-0.05 mm
2nd Ring 0.03-0.05 mm
CRANK SHAFT
;a^
,:r l1I l-<
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Main Axle Deflection Limit 0.1 mm
(Run Out)
Drive Axle Deflection Limit 0.1 mm
(Run Out)
SHIFTER
Shifting Type Guide Bar
Guide Bar Bending Limit <0.05 mm
KICK STARTEH
TYPe Kick and Mesh Type
Kick Clip Friction Force P=1.0 Kg.
(lvl in - N4 ax) (0.8-1.2 Ks)
Air Filter Element 2T oilof Superior Grade Qualily
CARBURETTOH
TYPe vM22
lvlanufacturer I\,4IKUNI
lvlain Jet # 165
Jet Needle-Clip Position 3rd Groove From TOP
Pilot Jet # 17.5
Starter jet #20
Pilot Air Screw Setting 1.5a0.5 Turns-(Adj. at max. r.p.m. position)
Float Height 22.50+1 mm (As reference)
Engine ldling Speed 150011m pm (After running in of 1000 kms)
(On warm Engine) '700:'00 'om lupto 'u.-ing in or 1000 k.ns/
LUBRICATION
l\y'inimum Stroke 0.20-0.25 mm
l\,4aximum Stroke 1.95-2 05 mm
Pulley Adjusting Mark
Ai ldle
SE RV
INFO A
Gr
CHASSIS
STEERING SYSTEM
Steering Bearing Type BaLl Bear ng
Number of Balls/Size of Steel Balls
Upper 22 Nos (3/16')
Lower 19 Nos (1/4')
FBONT SUSPENSION
Front Fork travel 110 mm
Spring Free lenght 296.5 mm
Spring l\.4inimum Length 291.5 mm
Oil Capacity (New Fill) 17 5!3cc
Oil Capacity (For Replacement) 158a3cc
Grade Special Yamaha Oil
REAR SUSPENSION
Shock Absorber Travel 70 mm
Rear Swing Fork
Swingarm Free Play Limit
End (Skew) <2.0 mm
Side < 2.0 mm
WHEEL
Front & Rear Wheel Type Spoke Wheel
Front & Rear Rim Size/lvlaterial 1.50x18/Steel
Rim Run Out Limit
Venicai <2.0
Lateral <2.0 mm
DRIVE CHAIN
No. ol Links 110
Chain Slackness 20-30 mm
DRUM BRAKE
Type Internally Expanding, Leading &
Drum lnside Dia 130 mm
Service Limit <131 mm
Lining Thickness 5.0 mm
Service Limit <2.0 mm
BRAKE LEVER & BBAKE PEDAL
Brake Lever Free Play/ 5'B mm ( nd an l\,4arket)
At Lever Point 2.5'3 5 mm (Other N/arket)
Brake Pedal Free Play 20'30.nm
CLUTCH LEVER
Free Play/At Lever Point 2-3 mnl
Free Play At Tappel Rod r. Turn oose (Anti Clock Wise)
B-7
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TIGHTENING TOROUE THREAD QTY Lb"Ft. Kg.M
SIZE
ENGINE
'6
I'