Cy MBX WORKSHOP MANUAL 4LS-F8197-EOFOREWORD This workshop Manual has been prepared for use by the Escorts Yamaha Authorised Dealerships and their service personnel to attend to servicing of YBX Motorcycles. It is not possible to include entire service education in to this Manual. It is assumed that persons using this book to perform maintenance and repairs on YBX Motorcycles have a basic understanding of mechanical concepts and procedures inherent to Motorcycle repair technology. Without such knowledge, attempted repairs or service of this model may render it unfit for use and/or unsafe. Escorts Yamaha Motor Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be informed to all Escorts Yamaha Authorised Dealerships thru Service Actions and will wherever considered necessary, appear in future edition of this Workshop Manual. Service Department Escorts Yamaha Motor Ltd.HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title @: This is the title of the chapter with its symbol on the upper right corner of each page. 2nd title @: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title @: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at start of each removal and disassembly section. 1. An easy-to-see exploded diagram @ is provided for disassembly and assembly jobs. 2. Numbers @) are given in the order of jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks ©. The meanings of the symbol marks are given on the next page. 4, A job instruction chart @ accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements @® are given in addition to the exploded diagram and the job instruction chart.INDEX GENERAL INFORMATION a SPECIFICATIONS = SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP ENGINE ‘oe CARBURETION & cad KS |_chassis oh CHAS ELECTRICAL cA TROUBLE SHOOTINGan vu m a INSP | ABs ENG |p ® © TRBL sural ? ® ® _— @ ® ILLUSTRATED SYMBOLS Illustrated symbols @ to @ are designed as thumb tabs to indicate the chapter's number and content. @ General information @ Specifications @ Periodic inspection and adjustment @ Engine ® Cooling system © Carburetion @ Chassis @ Electrical @ Troubleshooting Illustrated symbols @ to @ are used to identify the specifications appearing in the text @ Filling fluid @ Lubricant @ Special tool @ Torque @ Wear limit, clearance @ Engine speed @2,V,A Ullustrated symbols @ to @ in the exploded diagrams indicate the types of lubricants and lubrication points. @ Apply engine oil @ Apply gear oil ® Apply molybdenum disuifide oil @ Apply wheel bearing grease @ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease Mlustrated symbols @ to @ in the exploded diagrams indicate the where to apply lock- ing agent @ and when to install new parts @. @ Apply locking agent (LOCTITE*) @ Use new oneCONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER. ENGINE SERIAL NUMBER .. IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBL ALL REPLACEMENT PARTS . GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PIN BEARINGS AND OIL SEALS... CIRCLIPS... SPECIAL TOOL! CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATION: MAINTENANCE SPECIFICATIONS. ENGINE CHASSIS. ELECTRICAL... GENERAL TORQUE SPECIFICATIONS LUBRICATION POINTS AND LUBRICANT TYPI ENGINE CHASSIS. LUBRICATION DIAGRAM CABLE ROUTING .. CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION..... PERIODIC MAINTENANCE/LUBRICATION INTERVALS. SEAT, SIDE COVERS AND FUEL TANK. REMOVAL INSTALLATION INSTALLATIONENGINE. VALVE CLEARANCE ADJUSTMENT. IDLING CO. MEASUREMENT AND ADJUSTMENT. THROTTLE CABLE ADJUSTMENT. SPARK PLUG INSPECTIO! IGNITION TIMING CHECK COMPRESSION PRESSURE MEASUREMEN ENGINE OIL LEVEL INSPECTION ENGINE OIL REPLACEMENT... EXHAUST SYSTEM INSPECTION AIR FILTER CLEANING CLUTCH ADJUSTMENT CHASSIS. FRONT BRAKE ADJUSTMENT. REAR BRAKE ADJUSTMENT .. BRAKE SHOE INSPECTION .. BRAKE LIGHT SWITCH ADJUSTMENT. DRIVE CHAIN SLACK ADJUSTMENT STEERING HEAD INSPECTION... FRONT FORK INSPECTION .. REAR SHOCK ABSORBER ADJUSTMENT. TIRE INSPECTION . SPOKE INSPECTION AND TIGHTEN WHEEL INSPECTION...... ELECTRICAL .... BATTERY INSPECTION... FUSE INSPECTION... HEADLIGHT BEAM ADJUSTMENT.. HEADLIGHT BULB REPLACEMEN CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL... SEAT, SIDE COVERS AND FUEL TANK REMOVAI ENGINE OIL... BATTERY. CARBURETOR .. CLUTCH CABLE DRIVE CHAIN.... EXHAUST MUFFLER.. SHIFT PEDAL.... LEADS ENGINE REMOVAL.. ENGINE DISASSEMBLY... CYLINDER HEAD, CYLINDER AND PISTON C.D. MAGNETO CLUTCH...OIL PUM! KICK STARTER. SHIFT SHAFT. CRANKCASE.. BALANCER, TRANSMISSION AND SHIFTER .. CRANKSHAFT ROCKER ARMS, CAMSHAFT AND VALVES.. INSPECTION AND REPAIR CYLINDER HEAD. VALVE SEATS VALVE SPRINGS AND VALVES CAMSHAFT INSPECTION... ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION TIMING CHAIN, SPROCKETS AND CHAIN GUIDES.. TIMING CHAIN TENSIONER CYLINDER AND PISTONS PISTON RING INSPECTION. PISTON PIN INSPECTION... CRANKSHAFT... BALANCER WEIGHT INSPECTION . PRIMARY DRIVE GEAR INSPECTION CLUTCH INSPECTION.. PUSH ROD INSPECTION SHIFT FORK SHIFT CAM INSPECTION... KICK STARTER INSPECTION OIL PUMP INSPECTION.... OIL DELIVERY PASSAGE INSPECTION (CRANK CASE COVER (right))...... CRANKCASE so. 7 BEARINGS AND OIL SEALS.. CIRCLIPS AND WASHERS.. oa ENGINE ASSEMBLY AND ADJUSTMENT... VALVES, ROCKER ARM AND CAMSHAFT VALVES AND VALVE SPRINGS INSTALLATION. CAMSHAFT AND ROCKER ARM INSTALLATION. CRANKSHAFT AND BALANCER SHAFT TRANSMISSION... SHIFTER .. See = TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION .... CRANKCASE. CRANKCASE (RIGHT)... SHIFT SHAFT AND KICK STARTER.. SEGMENT AND SHIFT SHAFT.. KICK STARTER INSTALLATION CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP... OIL PUMP INSTALLATION.. PRIMARY DRIVE GEAR INSTALLATION CLUTCH INSTALLATION CDI MAGNETO...C.D.I. MAGNETO INSTALLATION ... CYLINDER AND PISTON CYLINDER HEAD .. CAM SPROCKET AND TIMING CHAIN PISTON RING, PISTON AND CYLINDER INSTALLATIOI CYLINDER HEAD INSTALLATION .. ENGINE MOUNTING... CHAPTER 5. CARBURETION CARBURETOR . REMOVAL .. DISASSEMBLY INSPECTION . ASSEMBLY INSTALLATION FUEL LEVEL ADJUSTMENT. CHAPTER 6. CHASSIS FRONT WHEEL AND FRONT BRAKE 6-1 FRONT WHEEL FRONT BRAKE.. REMOVAL ... FRONT WHEEL INSPECTION BRAKE SHOE PLATE DISASSEMBLY. SPEEDOMETER GEAR INSPECTION FRONT BRAKE INSPECTION..... BRAKE SHOE PLATE ASSEMBLY. FRONT WHEEL INSTALLATION... REAR WHEEL AND REAR BRAKE.. REAR WHEEL... REAR BRAKE REMOVAL ... REAR WHEEL INSPECTION .. REAR BRAKE INSPECTION. REAR WHEEL INSTALLATION.. DRIVE CHAIN AND SPROCKETS . REMOVAL . DRIVE CHAIN INSPECTION .. CLUTCH HUB INSPECTION... DRIVEN SPROCKET ASSEMBLY DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION FRONT FORK... FRONT FORK REMOVAL..FRONT FORK DISASSEMBLY. FRONT FORK INSPECTION .. FRONT FORK ASSEMBLY. FRONT FORK INSTALLATION .. ‘STEERING HEAD AND HANDLEBAR. REMOVAL... HANDLEBAR REMOVAL HANDLEBAR INSPECTION STEERING INSPECTION STEERING INSTALLATION HANDLEBAR INSTALLATION... REAR SHOCK ABSORBER AND SWINGARM REMOVAI INSPECTION . CHAPTER 7. ELECTRICAL CIRCUIT DIAGRAM .... ELECTRICAL COMPONENTS .. CHECKING OF CONNECTIONS. IGNITION SYSTEM .... CIRCUIT DIAGRAM TROUBLESHOOTING.. CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING .. LIGHTING SYSTEM... CIRCUIT DIAGRAM TROUBLESHOOTING.. LIGHTING SYSTEM CHECK. SIGNAL SYSTEM... CIRCUIT DIAGRAM TROUBLESHOOTING.. SIGNAL SYSTEM CHECK . CHAPTER 8. TROUBLE SHOOTING TROUBLE SHOOTING ELECTRICAL SYSTEM COMPRESSION SYSTEM .. INTAKE AND EXHAUST SYSTEM..MOTORCYCLE IDENTIFICATION | Rey [HS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number @ is stamped into the steering head pipe. ENGINE SERIAL NUMBER The engine serial number @ is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.IMPORTANT INFORMATION | GEN | Gt IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISAS- ‘SEMBLY 1. Remove all dirt, mud, dust, and foreign material before removing and disassem- bling. 2. Use proper tools and cleaning equip- ment, Refer to "SPECIAL TOOL". 3, When disassembling the motorcycle, keep mated parts together. This includes gears, cylinder, piston and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4. During the motorcycle disassembly, clean all parts and place them in trays the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. 12IMPORTANT INFORMATION 13 ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and/or grease rec- ommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality, GASKETS, OIL SEALS, AND O-RINGS 1, All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips and O- rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1, All lock washers/plates @ and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) © and oil seal(s) @ with their manufacturer's marks or num- bers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil ‘seal(s), lubricate a light coating of light- weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bear- ings dry. This causes damage to the bearing surfaces.SPECIAL TOOLS | GEN SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assem- bly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the spe- cial tool differ by country, so two types are provided. 1. Magneto Holder ESM - 601 This tool is used to hold the magneto when removing or installing the magneto securing nut 2. Magneto Puller ESM - 602 This tool is used to remove the magneto oS CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip @, make sure that the sharp-edged, corner @ is positioned opposite to the thrust @ it receives. See the sectional view. @Shatt Refer to the list provided to avoid errors when placing an order. 3. Valve Spring Compressor ESM - 603 e@ This tool is used to to remove and install valve spring assemblies. 4. Piston Base ESM - 604 This tool is needed to support the piston while installing cylinder.5. Valve Clearance Adjusting Tool. ESM - 606 This tool is used to adjust valve clear- ance. 6. Piston Pin Replacer ESM -607 This tool is used to replace piston pin. 7. Rocker Arm Shaft Puller ESM - 608 This tool is used to remove rocker arm shaft. 8. Diutch Hub Holder ESM - 233 This tool is used to hold the clutch hub when installing or removing clutch main shaftnut, speciAL Toots | GEN |g 9. Crank Shaft Separating Tool. ESM - 265 This tool is needed to separate the crank shaft from the crank case. 10. Crank Shaft Installing Tool (with spacer) (a) ESM - 266 (b) ESM - 267 These tools are used for installation of crank shaft. 11. Driving Spocket Holder T-10 This tool is used to hold driving sprocket when removing or installing driving sprocket Nut. 12. Screw Driver (small). ESM - 609 To adjust Carburettor pilot screw13. Torx Bit (T - 30) ESM - 611 This tool is used to loosen or tighten the cam shifter segment screw. 14. Scraper ESM - 612 This tool is used for scrapping the sealent from crankcase surface. 15. Tachometer ESM -613 This tool is used to loosen or tighten the cam shifter segment screw. 16.Feeler Gauge ESM - 615 This tool is used to check valve clear- ance of inlet and exhaust valves. speciat Toois | GEN |G 17. Streeing Nut Socket ESM - 621 ©} This tool is used to loosen or tighten the steering ring nut. 18. Front Fork Top Plug Spanner ESM.- 214 This tool is used to loosen or tighten the TFF Top plug. 19. T -Handle ESM - 213, a This tool is used to loosen or tighten the cam shifter segment screw. 20. T.FF. Oil Seal Removing Tool. ESM - 270 This tool is used to remove T.F-F. oil seal. 16SPECIAL TOOL | GEN |G@ 22. Spanner - Speedometer Gear Nut, ESM - 237 21, T.FF. Oil Seal Installation Tool ESM-275 | U This tool is used when installing the T.FF. oil seal. This tool is used to loosen or tighten the meter gear bush. WGENERAL sPeciFications |SPEC SPECIFICATIONS GENERAL SPECIFICATIONS MODEL YBX 125 Model Code = ast Engine model code : 4s DIMENSIONS: Overall length 2020 mm Overall width 740 mm Overall height 1050 mm Seat height 780 mm Wheelbase 1250 mm Minimum ground clearance 145. mm Minimum turning radius 1910 mm Dry weight 100 kg Basic weight 108 kg With oil and full fuel tank ENGINE = Engine type Air-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 128.7 cm? Borexstroke 54x54 mm Compression ratio 10:1 Compression pressure (STD) 1,200 kPa (12 kg/om, 171 psi) Starting system Kick starter Lubrication system Wet sump Max power T7 BRp/B500 RPM Torque 1,06 kgrn/6500 RPM. Oiltype or grade: Engine oil YAMALUBE 20W-50 or equivalent Oil capacity: Engine oil Periodic oil replacement 1.0L Total amount 12L Aic filter Wet type element FUEL: Type Unleaded fuel recommended Fuel tank capacity 1aL Fuel reserve amount 1.4L 2GENERAL SPECIFICATIONS | SPEC] U™* Model YBX125 Carburetor: Type/quantity vM20ss/1 Manufacturer LOCAL MADE (UCAL) Spark plug: Type/manufacturer CR7HSAINGK U22FSR-U/DENSO Spark plug gap 0.7 mm Clutch type: Wet, multiple-dise Transmission: Primary reduction system Helical gear Matching of Grades Primary reduction ratio 68/19 (3.579) Helical Clutch Secondary reduction system Chain drive gear Drum Secondary reduction ratio 44/14 (3.145) 5 A Transmission type Constant mesh 4-speed Operation Left foot operation ree Gear ratio 1st 33/12 (2.750) Oe 2nd 27/16 (1.688) E——>d 3rd 24/20 (1.200) FOE 4th 21/23 (0.913) Chassis: Frame type Diamond Caster angle 26.4° Trail 83mm Tire: Type With tube Size Front | 2.50-18 4PR Rear 2.75-18 PR Manufacturer Front | LOCAL MADE Rear LOCAL MADE Type Front | RIB TYPE Rear RIB LUG TYPE Tire pressure (cold tire): Loading condition A* 0-90 kg (0~198 Ibs) Front | 24PSI (1.70 kgf/em?) Rear 28 PSI (2.00 kaffem’) Loading condition B* 90~162 kg (198-408 Ibs) Front | 24 PS1(1.70 kgf/cm?) Rear 32 PSI (2.30 kgf/om?) Brake: Front brake Type Drum brake Operation | Right hand operation Rear brake Type Drum brake Operation _| Right foot operation *Load is total weight of cargo, rider, passenger and accessories. 22L SPECIFICATIONS | SPEC GENERAI — Mode! YBX125 Suspension: Front suspension Telescopic fork Rear suspension ‘Swingarm Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Oil damper Whee! travel: Front wheel travel 110 mm Rear wheel travel 70mm Electrical: Ignition system col Generator system Flywheel magneto Battery type LOCAL MADE Battery capacity 12V2.5AH Headlight type: Bulb type Headlight bulb type Krypton bulb Bulb voltage, wattage x quantity: Headlight 12V 35W/35W x 1 Tail/Brake light 12V SW/OWx1 Flasher lights 12V 10W x4 Meter light 12 1.7Wx2 Indicator light: “NEUTRAL” indicator light 12V3.4Wx1 “HIGH BEAM” indicator light 12V3.4Wx1 “TURN" indicator light 12V 3.4Wx2 23MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE SPEC Model YBX125 Cylinder head: <0.03 mm (0.0012 in)> ' x | *Lines indicate straightedge measurement. UB KK] Cylinder: Bore size 54.000~54.018 mm. Camshaft: Drive method Chain dri Cam dimensions Intake "A" 25.881~25.981 mm Limits | <25.851 mm> "BY 21.195~21.295 mm | <21.165 mm> “cr 4.931 mm Exhaust "~ 25.841~25.941 mm | <25.811 mm> "8" 21.05-21.15 mm. | <21.02 mm> "ct 0.03 mm Camshaft runout limit Rocker arm/rocker arm shaft: Bearing inside diameter 10.000~10.015 mm | <10.03 mm> 9.981-9.991 mm | <9.95 mm> ‘Cam chain: Cam chain type/No. of tinks BUSH CAIN/88 Cam chain adjustment method Automatic 24MAINTENANCE SPECIFICATIONS |SPEC) U"* | Model | YBx125 ] Valve, valve seat, valve gi | Valve clearance (cold) IN 0.08 ~ 0.12mm EX 0.10~0.14mm Valve dimensions: we LI oe | | “Dp” Head Dia. Face Width Seat Width Margin Thickness “A" head diameter IN 33.934.1 mm EX 28.4~28.6 mm "B" face width IN 2.26 mm Ex 2.26 mm "C" seat width IN 0.9~1.1 mm EX 0.9~1.1 mm "D" margin thickness IN 0.8-1.2 mm Ex 0.8~1.2 mm Stem outside diameter IN 5.975~5.990 mm Ex 5.960~5.975 mm IN <5.95 mm> Ex <5.935 mm> Guide inside diameter IN 6.000~6.012 mm Ex 6.000~6.012 mm IN, <6.042 mm> Ex <6.042 mm> ‘Stem to guide clearance IN 0.010~0.037 mm Ex 0.025~0.052 mm IN <0.08 mm> EX <0.10 mm> Stem runout limit. 0.010 mm Valve seat width IN EX IN EXMAINTENANCE SPECIFICATIONS SPEC Model YBX125 Valve spring: Free length IN 32.28 mm EX 33.28 mm IN 31.9mm Ex | 31.9 mm Set length (valve closed) IN 25.6 mm EX 25.6 mm IN 2.5/1.2 mm Ex 2.5°/1.2 mm Compression pressure (installed) IN 104.0~119.7 Nm (10.60~12.21 kgf) EX 104.0~119.7 Nm (10.60~12.21 kgf) Direction of winding (top view) Clockwise to fon to cylinder clearance 0.020~0.025 mm | <0.15 mm> Piston size “D’ 53,977~53.996 mm Matching of Grades Piston] Cylinder Red -A[A-Red Measuring point “H” 45mm Orange -B | B - Orange Piston off-set 0.5 mm Green 6 16 Green oe ‘ Purple -D | D-Purple (on off-set direction Intake side Bue -£ |E-Blue Piston pin bore inside diameter 1.002~15.013 mm Piston pin outside diameter 14.991~15.000 mm Piston rings: Top ring: ‘Type Barrel Dimensions (BxT) cH 1.02.1 mm. End gap (installed) 0.15~0.30 mm 0.4mm Side clearance (installed) 0.03-0.07 mm <0.12 mm>MAINTENANCE SPECIFICATIONS |SPEC | U™* Model YBX125 2nd ring: Type Taper Dimensions (BxT) [Nite 1.0x2.1 mm End gap (installed) aed 0.30-0.45 mm 0.55 mm Side clearance 0.02-0.06 mm 0.12 mm Oil ring: Dimensions (BxT) Er 2.0x2.2 mm End gap (installed) ot 0.2~0.7 mm Crankshaft: Crank width "A" i 46.95~47.00 mm aes o hess <0.03 mm> Gear Gear Big end side clearance a 0.15-0.45 mm 5 a F —— Y G — Zz Balancer: H oA Balancer drive method Gear {_ <> 8 Clutch: Friction plate thickness 2.90-3.10 mm Quantity 5 pes. <2.80 mm> Clutch plate thickness 1,05~1.35 mm Quantity 4 pes. 0.05mm Clutch spring free length 33mm Quantity 4 pes. imum length 31mm Clutch release method Inner push, cam push <0.5 mm> ifter: Shifter type Cam drum and guide bar Kick starter: Kick starter type Kick and mesh type Kick clip friction force 7.8~11.8 Nm (0.8~1.2 kgf)MAINTENANCE SPECIFICATIONS |SPEC Model | YBX125 Carburetor: LD. Mark Main jet Main air jet size Jet needle Needle jet Cut away Pilot outlet Pilot jet Valve seat size Starter jet Fuel level (with special tool) Float height Engine idle speed Intake vacuum 4LS 00 (M.J.) | #92.6 (M.AJ.) | 0.8 (WJ.N.) | 5HI48-3 (N.J.) | N-6 (CA) | 2.5 (P.O) | 1.0 (PJ) | #175 WS.) | 1.3 (G.S.1) | #27.5 (FL) | 6-7 mm. Below the float chamber mating surface (front) 20.8-22.8mm. 1,300~1,500 r/min 29.3~34.7 kPa {220~260 mmHg) Lubrication system: Oil filter type Oil pump type Tip clearance “A” or “B" Side clearance Housing and rotor clearance Wire mesh type Trochoid type 0.15 mm <0.2 mm> 0.06~0.10 mm <0.15 mm> 0.06~0.10 mm. <0.15 mm> 28MAINTENANCE SPECIFICATIONS |SPEC Part to be tightened Parts name | Tfe24 | qryy | Mahtening torque] Remarks, Nm |mekg] ft-lb Cylinder head Bolt M8 4 22 | 2.2 | 17 | Oil check Bolt M6 | 2 | 10 | 1.0] 7.2 | Spark plug - M10 | 1 |12.5/1.25| 9 Cylinder head side cover Bot | me | 2 | 10| 10/72 Valve cover — | mas | 2 }17.8] 1.75] 13 CDI magneto rotor Bolt Me | 1 | 70|7.0| 51 Stopper guide Bolt me | 5 | 10 | 10] 7.2 Adjust screw Nut ms | 2 | 8 |08|58 Sprocket (timing chain) Bott | ms | 1 | 20 | 20 |145 Plate Bolt M6 1 10 | 1.0 | 7.2 Plug (tensioner assembly) Plug Ms | 1 | 8 /08}58 Tensioner assembly Bolt M6 2 10 | 1.0 | 7.2 Oil pump assembly screw | Me | 2 | 7 |07|51 Drain plug Screw mi2z | 1 | 20 | 20 |14.5 Pump cover Screw | Ms | 1 | 4 | 04] 36 Intake manifold Bolt me | 2 | 10 | 10] 72 Caburetor joint (manifold) Screw | ma | 1 | 2 |o2/15 Caburetor joint (air filter) Screw | M4 | 1 | 2 |02|15 Air filter case Bolt me | 2] 7 |o7\51 Muffler (cylinder head) Bolt Me | 1 | 7 | 07} 51 Muffler assembly Bolt M8 1 15 | 1.5] 11 Case 1 and 2 Bolt M6 2 10 | 1.0 | 7.2 Bolt M6 6 10 | 1.0 | 7.2 Bolt Me | 2 | 10} 10] 72 Crankcase cover 1 Bolt me | 5 | 10 |10)72 Bolt me | 2 | 10 |10|72 Bolt me | 6 | 7 |o7\51 Crankcase cover 2 Bolt me | 7 | 10 | 10|7.2 Bolt M6 2 10 | 1.0 | 7.2 Plate Screw M6 1 7 107/51 Timing mark check plug Screw M14 1 7 107/51 Center plug Screw | m32| 1 | 7 | 07] 5.1 Kick crank assembly Nut M12 1 50 | 5.0 | 36 Primary drive gear Nut miz | 1 | 70} 7.0] 51 Pressure plate Bolt ms | 4 | 6 |o6|43 Clutch boss Nut wiz | 1 | 60 | 60 {43,5 | Use lock Push rod Nut M6 1 8 | 0.8 | 5.8 | washer Plate Nut M6 2 0.7 | 5.1 Drive sprocket Nut M6 1 10 | 1.0 | 7.2 Shift pedal Bolt M6 1 10 | 1.0 | 7.2 29MAINTENANCE SPECIFICATIONS |SPEC) U™* Part to be tightened Parts name Thread] ayy Tohtering torque] Remarks size Nm |mekg] ft-lb Segment Screw | M6 | 1 | 12| 1.2] 9 | Torbot Stopper lever Bolt Me | 1 | 10/10] 7.2 Pulser assembly Bolt M6 2 10 | 1.0 | 7.2 Neutral switch assembly _ M10 1 4/04) 3 Stator Bolt M6 3 10 | 1.0 | 7.2MAINTENANCE SPECIFICATIONS |SPEC| U™* Tightening sequence: Cylinder head Crankcase Right-hand ee © auMAINTENANCE SPECIFICATIONS |SPEC CHASSIS Model Steering system: Steering bearing type No./size of steel balls (upper) YBX125 | Ball and race bearing 22 pes. 0.1875 in (ower) 19 pes. 0.25 in Front suspension: Front fork travel 110 mm Fork spring free length 296.5 mm <291.5mm > Spring rate (Ky) 3.8 Nimm (k2) 5.2 Nimm Stroke (K1) 0-28 mm (K2) 28-110 mm Optional spring No Oil grade Fork oil 10W or equivalent Rear suspension: Shock absorber travel 70 mm Spring free length 214mm Fitting length 209 mm Spring rate (K1) | 167 Nimm (k2) 25 Nimm Stroke (K1) 0-40 mm (K2) 40-70 mm Optional spring No Enclosed gas pressure (STD) 213 psi (15 kg/om?, 1,500 kPa) ‘Swingarm: End <1.0 mm> Side <1.0 mm> Front wheel: Type Spoke wheel Rim size 16x18 Rim material Steel Radial | <0.5 mm> Lateral | <0.8mm> Rear wheel: Type Spoke wheel Rim size 1.60x18 Rim material Aluminum Radial | <0.5 mm> Lateral__| <0.8mm> Drive chain: Type/manufacturer Number of links Chain slack 428V2/Local MADE 112 20~30 mm 212MAINTENANCE SPECIFICATIONS SPEC Model YBX125 Front drum brake: Type Brake drum inside diameter Lining thickness Shoe spring free length Leading, trailing 130 mm <131> 4.0 mm <2 mm> 36.5 mm Front drum brake: Type Brake drum inside diameter Leading, trailing 130 mm. <131 mm> Lining thickness 4.0mm | <2 mm> Shoe spring free length | 36.5 mm Brake Tever & brake pedal: Brake lever free play (at lever end) 10~15mm Brake pedal position (N) 15mm °) 20~30 mm Clutch lever free play (at lever end) 10~15 mm Throttle grip free play 7mm 2.13MAINTENANCE SPECIFICATIONS SPEC Tightening torque Tightening torque Part to be tightened Thread size Remarks. Nm | mekg | ftelb Front engine stay and mount M 8x1.25 | 38 | 38 | 275 Front engine stay and frame miox1.25 | 55 | 55 | 39 Rear engine mount and frame M 8x1.25 | 38 | 38 | 275 Upper engine stay and mount M 8x1.25 | 38 | 38 | 275 Upper engine stay and frame M 8x1.25 | 38 | 38 | 275 Handle crown and inner tube M 8x1.25 | 23 | 23 | 17 Handle crown and steering shaft m1ox1.25 | 35 | 3.5 | 25 Under bracket and inner tube Mi0x1.25 | 28 | 28 | 20 Steering shaft and ring nut M25x1.25 | 15.5 | 1.55 | 11.2 |Refer to NOTE| Handle crown and handle M ext.25 | 23 | 23 | 17 Screen and cowling body m 5x08 | 38 | 0.38 | 03 Front fender Mexto0 | 7 | 07 | 51 Front flasher and headlight stay Mioxt.0 | 7 | 07 | 51 Speedometer cable and speedometer mi2x1.0 | 25 | 0.25) 2 Headlight and cowling body ms5x08 | 38 | 038 | 3 Handle crown and main switch Mexio | 13 | 13] 94 Handle holder cover M 4x07 | 15 | 0.15 | 1.1 Front wheel axle nut Mioxt.25 | 45.5 | 4.55 | 33 Rear wheel axle nut miax15 | 91 | 9.1 | 66 Wheel sprocket and clutch hub M 8x1.25 | 26 | 26 | 19 Tension bar M 81.25 | 19 | 1.9 | 14 Sprocket axle nut m2ox1.0 | 91 | 9.1 | 66 Camshaft lever M 6x10 | 98 | 0.98 | 7.1 Fuel cock Mexto | 7 | 07 | 51 Fuel sender M 6x10 | 38 | 0.38] 3 Ignition coil M 6x10 | 38 | 038) 3 Tail cover M 5x08 | 38 | 0.38} 3 Rear cover M 5x08 | 38 | 0.38 | 3 Battery box Mex10 | 38 | 0.38) 3 Rear fender Mexio | 38 | 0.38! 3 Pivot axle nut M12x1.25 | 59 | 59 | 43 Rear shock absorber Mioxt.25 | 40 | 40 | 29 Tension bar and rear arm M 8x1.25 | 19 | 19 | 14 Side stand M 8x1.25 | 25 | 25 | 18 Footrest and frame M 8x1.25 | 16 | 1.6 | 12 NOTE: 1. First, tighten the ring nut approximately 45.5 Nm (4.55 mrkg, 32.3 ft-lb) by using the torque wrench, then loosen the ring nut one turn. 2. Retighten the ring nut to specification. 244MAINTENANCE SPECIFICATIONS ELECTRICAL Model YBX125 Voltage: Ww Ignition system: 7° at 1,500 r/min Advancer type Electrical type CDI: Magneto model/manufacturer F4LS/LOCAL MADE Pickup coil resistance (color) Source coil resistance (color) CDI unit model/manufacturer 248-3720. at 20°C (68°F) (Red—White) 688~-10320 at 20°C (68°F) (Brown—Green) 4LS/LOCAL MODE Ignition coil: Model/manufacturer Primary coil resistance Secondary coil resistance 4LS/LOCAL MODE 0.9~1.19 at 20°C (68°F) 5.3~7.9kQ. at 20°C (68°F) Spark plug cap: Type Resistance Resin type 5kQ at 20°C (68°F) Charging system: Type Flywheel magneto: Model/manufacturer Charging voltage Charging coil resistance (color) Flywheel magneto FALS/LOCAL MODE 14~15V/5000 RPM 0.320.480 at 20°C (68°F) (White—Black) Lighting voltage (min) (max) Lighting coil resistance (color) 12V/3,000 r/min 15V/8,000 r/min 0.28~-0.420 at 20°C (68°F) (Yellow—Black) Rectifier/regulator: Type Semi conductor - Short circuit type Model/manufacturer 36L/LOCAL MADE No load regulated voltage 13-14 Capacity 8A Withstand voltage 400 V Battery: Specific gravity 1.240 2.15MAINTENANCE SPECIFICATIONS | SPEC Model YBX125 Horn: Type Plane type Quantity 1 pe. Model/manufacturer 36L/LOCAL MADE Maximum amperage 2.5A Flasher relay: Type ‘Semi transistor type Model/manufacturer ALS/LOCAL MADE Self cancelling device No Flasher frequency 60~120 cycles/min Wattage 10Wx2 Fuel gauge: Model/manufacturer 4LS/LOCAL MADE Sender unit resistance -full 4~102 at 20°C (68°F) -empty 90~1002 at 20°C (68°F) Circuit breaker: Type Fuse Amperage for individual circuitxquantity: MAIN 10Ax1 po. Reserve 1OAx1 pe. 2416GENERAL TORQUE SPECIFICATIONS SPEC y= GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fas- teners with standard |.S.0. pitch threads Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a criss- cross fashion, in progressive stages, until full torque is reached. Unless otherwise spe fied, torque specifications call for clean, dry threads. Components should be at room tem- perature. Distance across flats jutside thread diameter General torque specifications (Nut) | (Bolt) "Nim | mkg | ftlb tomm| 6mm| 6 | 06 | 43 tamm| 8mm| 15 | 15 | 11 14mm | 1omm| 30 | 30 | 22 [17mm | 12mm 55 | 55 | 40 19mm | i4mm| 85 | 85 | 61 22mm | 16mm | 130 | 13.0 | 94 217LUBRICATION POINTS AND LUBRICANT TYPE SPEC| U™ LUBRICATION POINTS AND LUBRICANT TYPE ENGINE Lubrication points (part name) Lubricant type Oil seal lips (all) : Bearing retainer (all) L © Bolt (cylinder head) L ‘a O-ring (cylinder head side cover and valve cover) Crank pin -—a =a Connecting rod (big end) Piston and piston ring l © Piston pin Valve stem and valve guide Oil seal (valve stem end) Rocker arm shaft and rocker arm Cam and bearing (camshaft) Push rod Primary driven gear and main axle Push lever axle Rotary filter and oil pump Sliding gear (transmission) Kick axle shaft Drive axle Shift fork and guide bar Shift cam and bearing (shift cam) ddddidddsiddddidid Crankease mating surfaces Crankcase cover 1 and grommet Yamaha bond No. 1215 Yamaha bond No. 1215 |LUBRICATION POINTS AND LUBRICANT TYPE | SPEC Lubrication points (part name) Lubricant type CHASSIS. Gear unit (gear meter and drive Oil seal lips (all) Pivot shaft (swingarm) Pivoting points (brake pedal shaft and frame) Ball and ball race (steering head) Tube guide (right grip) Pivoting points (brake lever and clutch lever) Pivoting point (brake shoe plate) Cable end (front brake and clutch) Pivoting points (sidestand, mainstand and rear footrest) SOH0GLOS 008 Brake camshaft (cam and shaft) 2419LUBRICATION DIAGRAM |SPEC LUBRICATION DIAGRAM ROCKER ARM GNCET) PUSH LEVER ont ‘CRANK CASE CAUTION: DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE Oll. LEAKAGE WILL START. 2:20LUBRICATION DIAGRAM | SPEC CAMSHAFT i CYLINDER HEAD CYLINDER COVER LH, CENTRIFUGAL aS FILTER CRANK ‘SHAFT MAINAXLE, CRANK CASE RLH, RANK CASE LL Luton DRIVE AXLE COVER RM. IMPORTANT : FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE Ol 221CABLE ROUTING SPEC| U™* CABLE ROUTING @ Handlebar switch (left) @® clutch cable @ Starter cable @ Handlebar switch lead @® Speedometer © Brake cable @ Throttle cable @ Brake switch lead @ Speedometer cable @ Wireharness @ Clamp @ Flasher light lead (left) @ Horn @ Flasher light lead (right) @ Flasher relay Pass the clutch cable, the starter cable and the handle- bar switch lead through the cable guide of the left side. Pass the throttle cable, the brake cable and the front brake switch lead through the cable guide of the right side. Clamp the handlebar switch, the brake switch, meter and the main switch harness together on the left side of front fork. {D)Pass the meter cable and the brake cable through the cable guide, E)Pass the clutch cable into the cable guide. 222CABLE ROUTING |SPEC @ Starter cable [Pass the high tension cord @ Throttle cable through the cable guide to the @ High tension cord inside of throttle cable and the @ Ignition cable clutch cable. © Band Tighten the ground lead and © Brake cable ignition coil together @ Speedometer [Pass the throttle cable to the © Brake switch lead outside of the headlight stay. @ Flasher relay {By Cut the end of the clamp at 10 @ Clutch cable mm from the clamped por- @ Horn lead tions. @ Breather hoseCABLE ROUTING @ Headlight assembly @ Handlebar switch lead @ Speedometer cable @ Cable guide © Clutch cable @ Starter cable Air vent hose @ Fuel sender @ Fuel sender lead @ Fuse © CDi unit @ Clamp @ Stop/tail tight @ Flasher light lead (right) @ Flasher light @ Battery @ Battery breather hose @ Neutral switch lead ® Over flow hose @ Crankcase breather hose @ Brake cable [i)Pass the clutch cable and the ireharness through the cable guide. Bi Insert the air vent hose to the hole of the frame. (Align the white marking of wireharness with the frame clamp. [i Tighten the battery negative (-) lead and the ground lead of the wireharness together. Pass the battery breather hose through the hole of the left side of the engine bracket. Pass the battery breather hose 1 the crankcase breather hose and the carburetor overflow pipe to the inside of the hose guide. Pass the battery breather hose , the crankcase breather hose ‘and the carburetor overflow pipe to the left side of crankcase. Pass the magneto lead to the outside of the flange of the chain cover. 2-24CABLE ROUTING |SPEC @ Clamp Clamp the battery positive (+) @ Fuel sender lead lead to the battery box. @ Rectifier regulator Pass both rear flasher light @ Flasher light lead leads under the tail ight boss. @ Stopttail light lead © Wireharness @ Battery 2:25INTRODUCTION/ | INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS | ADJ INTRODUCTION PERIODIC INSPECTIONS AND ADJUSTMENTS This chapter includes all information necessary-to-perform recommended inspections and ad- justments. These preventive maintenance procedures, if followed, will ensure more reliable ve- hicle operation and a longer service life. The need for costly overhaul work be greatly re- duced, This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE/LUBRICATION INTERVALS PREVENTIVE MAINTENANCE SCHEDULE ‘Dunins Pe SERVICE ro ‘OcoURS FIRST senvices I Replace oil maT | soe | ww | oo —|0ayson| sonson | moaarson| PEP INO. ITEM OPERATION 99.700 | 2si.27m | gsosoa | “* 1 | VALVES Check vaive clearance, adjust ifnecessary. | O | O | O | O ‘Check condition, gap: o foto lo 2 |SPARKPLUG | Clean and reset if necessary. EVERY 10,000km___| Check idle speed, starter operation. i 5 3 |CARBURETOR | Tune if necessary. | ca | cae |e 4 |FAIRFILTER | Clean, inspect & lubricate. (replace ifnecessary] O | O | O | O 5 [ruELUNE Check fuel hose and vacuum hose cracks or damage. |G | oO Replace if necessary. 6 [FUEL FILTER | Check or fre flow of petrol, cleanliness of bow olololo Replace if necessary. Replace with recommended oi ever 7 [ENGINE Ol _| (Warm engine before draining) OTS |S | seo ENGINE OIL, Wash with petrol. | 8 [ructer scréen | “9s? Wh Powe! : {21° ° |BRAKE-FRONT& | Check operation. Adjust if necessary. olololo REAR Grease the brake cam. yo [BRAKE SHOES- | Check for wear. olo lo FRONT& REAR _ | Replace if necessary. ‘Check alignment marks on push lever and oo ue crankcase LH; Adjust if necessary. Eas ‘Check rear arm assembly for looseness. CEonno 12 |REAR ARM PIVOT | Tighten with specified torque if necessary _ Repack grease_| EVERY 10,000 km Paar ‘Check runout, spoke tightness, damagi o]lo]o]o Correct it, if necessary. - ‘Check bearing assembly for looseness; olololo 14 |WHEEL BEARING | Correct, if necessary. 2 Repack grease EVERY 10,000 km ‘Check bearing assembly for looseness, damage; o]o]o 15 | STEERING BEARING| Correct if necessary. | | Repack grease _ oo FRONT FORKS | Check operation/oilleakege, Repair if necessary. ofoltotlfo EVERY 10,000 km.PERIODIC MAINTENANCE/LUBRICATION INTERVALS IN: Ads | oaveontawncreven | ‘mee PREVENTIVE MAINTENANCE SCHEDULE occu st sees wast] sono | mm] ce __ sonrson) onon | roars No. Tem OPERATION sore | amare | waosmo | 2M 17 [REAR SHOCK | Check operation/oil leakage. Paleo ABSORBER _| Replace if necessary. : Check chain slack; aliment. Adjust if necessary. 18 |ORIVE CHAIN | Clean and lubricate. ee NUTS, BOLTS AND| Check all chassis fitings and fasteners for necessary ainCnINS 79 | EASTENERS ighten as per spet 2 20 oem Check operation and lubricate if necessary. ° ° ° ° Check electrolyte level and top it up if necessary. 21 [BATTERY Check specific gravity and charge if required. EVERY MONTH Check breather pipe for blockage and routing. CONTROL CABLES -THROTTLE | Check operation, free play, cable damage. ? | "clutcH Readjust or replace as required. Ss en oa | “FRONT BRAKE Itis recommended that above be authorised ESCORTS YAMAHA dealer. *Service more frequently when the vehicle is driven in dusty areas.SEAT, SIDE COVERS 33 ISP AND FUEL TANK | ADJ SEAT, SIDE COVERS AND FUEL TANK REMOVAL 1, Remove: *Seat Use main switch key. 2. Remove: +*Side cover (left) © Noe: — When removing the side cover @ (left), pull the upper receptacle of the side cover upward to remove from the frame. Then pull the front, and rear portion of the side cover outward to remove the projection @ from the grommet. Then pull the side cover outward to remove the portion @ from the lobe. 3. Remove: +Side cover (right) ® NOTE: ——___________ When removing the side cover @ (right), pull the upper receptacle of the side cover upward to remove from the frame. Then pull the front and rear portion of the side cover outward to remove the projection @ from the grommet. Then pull the side cover outward to remove the portion @ from the lobe.INSP SEAT, SIDE COVERS AND FUEL TANK | ADJ 4. sconnect: *Fuel sender lead © Disconnect the coupler from the wire- harness. 5. Disconnect: +Fuel hose NOTE: Position the fuel cock @ to the “OFF”, dis- connect the fuel hose. Place a rag under the fuel line to absorb any spilt fuel. WARNING Gasol highly flammable. Avoid spilling fuel on the hot engine. 6. Remove: +Bolt (fuel tank) © *Plate@ *Dumper rubber @ Fuel tank @ INSTALLATION Reverse the REMOVAL procedure. Note the following points. 1. Install: +Fuel tank Bolt Bolt (fuel tank): 20 NM (2.0 mak 34SEAT, SIDE COVERS AND FUEL INSP TANK/COWLING | ADJ 2. Install: Seat NOTE: Insert the projections on the front of the seat into the receptacles on the frame, then push down the seat end, 3. Install: *Side covers (left and right) COWLING REMOVAL 1. Remove: “Bolts (cowling) *Cowling @ NOTE: When removing the cowling @, remove the bolts then the receptacle @ from the grom- mets. 35 INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Install: +Cowling *Bolts Ng Bolt (cowling): 1.2. Nm (0.12 mkg, 0.9 ft-lb)INSP VALVE CLEARANCE ADJUSTMENT | ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: — Valve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression stroke. Remove: «Seat +Side covers *Fuel tank Refer to “SEAT, SIDE COVERS AND FUEL TANK” section . Remove: *Spark plug Bolts (cylinder head side cover) © *Cylinder head side cover @ *Valve cover (intake side) @) +Valve cover (exhaust side) © 2 Remove: *Timing check plug (with O-ring) © *Center plug (with O-ring) @ = Measure: *Valve clearance Out of specification > Adjust. | vaive clearance (cold): Intake: 0.08 ~ 0.12 mm Exhaust: 0.10 ~ 0.14 mm 36INSP VALVE CLEARANCE ADJUSTMENT | ADJ Peet cn Measurement steps: © Rotate the crankshaft counterclockwise to align the slit @ on the rotor with the station- ary pointer ® on the crankcase cover 1 when the piston is Top Dead Center (TDC). and marking on cam sprocket aligns with marking on cylinder Head, © Measure the valve clearance by using a feeler gauge. Out of specification > Adjust clearance. 5. Adjust: +Valve clearance Adjustment steps: © Loosen the locknut ©. © Turn the adjuster @ in or out with the valve ® 2 adjusting tool @ until specified clearance is = obtained. \ SA) ing inValve clearance is ing out *Valve clearance Valve adjusting tool: ESM-606 © Hold the adjuster to prevent it from moving and tighten the locknut Locknut: 8 Nm (0.8 m-kg, 5.8 ftlb) © Measure the valve clearance. © If the clearance is incorrect, repeat above steps until specified clearance is obtained. SH 6. Install: *Timing check plug (with O-ring) D *Center plug (with O-ring) @ 37INSP Q IDLING CO. MEASUREMENT AND ADJUSTMENT | ADJ 7. Install *Valve cover (with O-ring) @ *Spark plug *Cylinder head side cover Valve cover (intake and exhaust): 17.5 Nm (1.75 mekg, 13 ftelb) Bolts (cylinder head side cover): 10 Nm (1.0 m-kg, 7.2 ft-lb) 8. Install: *Fuel tank *Side covers *Seat Refer to the "SEAT, SIDE COVERS AND FUEL TANK" section. IDLING CO. MEASUREMENT AND ADJUST- MENT 1. Start the engine and let it warm up for several minutes. 2. Attach: +Inductive tachometer to the spark plug lead, tachometer: ESM-613 3. Check : +Engine idling speed (standard) Out of specification > Adjust. Turn the throttle stop screw @ in or out ul d idling speed is obtained. a 1,300 ~ 1,500 r/min 4, Insert: +Sampling probe (CO. tester) © to the exhaust pipe @ CO. concentr: % Out of specification + Adjust. 38IDLING CO. MEASUREMENT AND ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT | ADJ INSP 5. Adjust : *CO. concentration Adjustment steps: © Turn the pilot screw @ in or out until speci- fied CO. concentration. ‘Adjustable range: Lightly seated ~ 6-turns out Nore; — Turn the throttle stop screw @ while adjusting the engine idling speed. Because changeable the engine idling speed by only turning the pilot screw @. © After adjusting, check the CO. concentra- tion specification and remove the CO. tester, make sure that the engine idling speed does not change. THROTTLE CABLE ADJUSTMENT Note: —— Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: “Throttle cable free play @ Out of specification > Adjust. Free play: 3-7 mm At throttle grip flange 39 2. Adjust: *Throttle cable free play Adjustment steps: NOTE: Never accelerate the throttle when stopping the engine.THROTTLE CABLE ADJUSTMENT/ [INSP SPARK PLUG INSPECTION | ADJ © Loosen the locknut @ on the throttle cable. ‘® Turn the adjuster @ in or out until specified free play is obtained. Turning in @ ~Free play is sed. ee play is decreased. Turning out © © Tighten the locknut. NOTE: If the free play is incorrect yet, adjust it with the adjuster @ under the throttle grip side. @ Lock nut AWARNING After adjusting, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. ‘SPARK PLUG INSPECTION 1, Remove: *Spark plug cap *Spark plug CAUTION: Before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinder. 2. Check: Spark plug type Incorrect -* Replace. ‘Standard spark plug: CR7HSA(NGK), U22FSR-U(DENSO) 3. Inspect: *Electrode © Wear/damage ~ Replace. *Insulator @ Abnormal color > Replace. Normal color is a medium-to-light tan color. 310SPARK PLUG INSPECTION/ IGNITION TIMING CHECK INSP. ADJ 4. Clean: *Spark plug (with spark plug cleaner or wire brush) 5. Measure: +Spark plug gap @ (with a wire gauge) Out of specification > Adjust gap. VAS] Spark plug gap: a 0.7mm 6. Install: *Spark plug Ny ‘Spark plug: 12.5 Nm (1.25 mekg, 17 ftelb) NOTE: “Before installing a spark plug, clean the gas- ket surface and plug surface. *lf a torque wrench is not available, a good estimate of the correct tightening torque is to finger tighten @ the spark plug and then tighten it another 1/4 to 1/2 of 1 to @. Always use a new spark plug gasket. IGNITION TIMING CHECK NOTE: Prior to checking the ignition timing, check all electrical connections related to the ignition system. Make sure all connections are tight and free of corrosion and that all ground con- nections are tight. 1. Remove: *Timing check plug 2. Attach: *Timing light © Engine tachometer @ {to the spark plug lead) Timing light Engine tachometer: ESM-613IGNITION TIMING CHECK / | INSP COMPRESSION PRESSURE ADJUSTMENT | ADJ 3-12 3. Check: ignition timing Checking steps: © Start the engine and let it warm up for sev- eral minutes. Let the engine run at the spec- ified speed. ay Engi ling speed: 1,300 ~ 1,500 r/min © Visually check the stationary pointer @ to verify it is within the required firing range @ indicated on the flywheel. Incorrect firing range + Check the ignition system. NOTE: Ignition timing is not adjustable. 3. Install: *Timing check plug (with O-ring) COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure wil in performance loss. result 1. Check *Valve clearance Out of specification > Adjust. Refer to “VALVE CLEARANCE ADJUST- MENT" section. 2. Start the engine and let it warm up for several minutes. 3, Turn off the engine. 4, Remove: *Spark plug CAUTION: Before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug well to prevent it from into the cylinder. 6. Attach: +Compression gauge ® ZX Compression gauge:INSP COMPRESSION PRESSURE ADJUSTMENT | apy Q| 6. Measure: Compression pressure If it exceeds the maximum pressure al- lowed ~ Inspect the cylinder head, valve surfaces and piston crown for carbon deposits. If it is below the minimum pressure > ‘Squirt a few drops of oil into the affected cylinder and measure again. Follow the table below. Compression pressure (With oil applied into cylinder) Reading Diagnosis Higher than i. without oi | "Orn oF damaged pistons Possible defective ring(s), ‘Same as valves, without oil der_head gasket or piston -> Repair. Compression pressure (at sea level): Standar: 1,200 kPa (12 Kg/em”) Minimum: 1,040 kPa (10.4 Kg/cm’) Measurement ste Crank the engine with the throttle wide- ‘open until the reading on the compression gauge stabilizes. AWARNING Before cranking the engine, ground alll spark plug leads to prevent sparking. 8. Install: *Spark plug 9. Install: *Side panels Refer to “SEAT, SIDE COVERS AND FUEL TANK” section. 313ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. Note: — Make sure the motorcycle is upright when in- specting the oil level. 2. Start the engine and let it warm up for a few minutes. 3. Turn off the engine. 4, Remove the dip stick (oil level gauge). Wipe off the dip stick (oil level gauge) by the rag and rest it on the threads of oil filler hole. Then remove the dip stick (oil level gauge) 5. Inspe +Engine oil level Oil level should be between maximum and minimum @ marks. Oil level is below the minimum mark *Add oil up to the proper level. RECOMMENDED ENGINE OIL, yy YAMALUBE (20W50) or equivalent 6. Start the engine and let it warm up for a few minutes. 7. Turn off the engine, Note: — Wait a few minutes until the oil settles before inspecting the oil level. ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Turn off the engine and place an oil pan under the engine. 3. Remove: *Dip stick (oil level gauge) *Drain plug ® *Gasket Drain the crankcase of its oil. 314EXHAUST SYSTEM INSPECTION | ADJ ENGINE OIL REPLACEMENT/ [INSP Cy 4. Install: *Drain plug D (oil level gauge) ill: rankcase Oil quantity: 1.0L 6. Check: +Engine oil level Refer to “ENGINE OIL LEVEL INSPEC- TION” section. EXHAUST SYSTEM INSPECTION 1. Inspect: *Bolt @ (exhaust pipe) Loose/ Damage ~> Tighten/ replace. + Gasket (exhaust pipe} Exhaust gas leaks ~ Tighten/ replace. Bolt: 7.Nm (0.7 m-kg,5.1 ft-lb) 2. Inspect: *Bolt @ (muffler) Loose/ Damage ~ Tighten replace. Bolt: 15 Nm (1.5 m-kg, 7.2 ftlb) AIR FILTER CLEANING NOTE: —— On the bottom of the air filter case, there is a check hose @. If dust and/or water collects in this hose, clean the air filter element and air filter case. 315AIR FI 316 INSP ILTER CLEANING | ADJ 1, Remove: +Side cover (right) +Air filter case cap @ *Air filter element @ (1and2) *Element guide @ CAUTION: | the engine without the air ter element installed. Unfiltered air will cause e parts and may damage the engine. Operating the engine without the filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating. 2. Inspect: Iter element (1 and 2) Damage — Replace. 3. Clean: Air filter element @ Use kerosen to clean the element. NOTE: After cleaning, remove the remaining kerosen by squeezing the element. CAUTION: Do not twist the fitter element when squi ing it. 4, Apply the recommended oil to the entire surface of the filter and squeeze out the excess oil. The element should be wet but not dripping. Recommended oil: YAMALUBE (20W50) or equivalent AWARNING Never use low flash point solvent (kerosen) ‘such as gasoline to clean the air filter ele- ment. Such solvent (kerosen) may cause a fire or an explosion. 5. Install: + Air filter element (1 and 2) *Air filter case cap *Side cover (right) Refer to “ENGINE REMOVAL" section in chapter 4.CLUTCH ADJUSTMENT/ | INSP. FRONT BRAKE ADJUSTMENT | ADJ CLUTCH ADJUSTMENT 1. Check: *Clutch cable free play @ Out of specification — Adjust. (AAG Free play (clutch lever): VAY] 10-15 mmat lever end 2. Adjust: *Clutch cable free play Adjustment steps: Lever side Loosen the locknut @. Turn the adjuster @ in or out until the spec- ified free play is obtained. ‘Turning in @ ~Free play is increased. Turning out © Free play is decreased. ‘Tighten the locknut @. CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: «Brake lever free play @ Out of specification -> Adjust. WA%| Free play (brake lever): (2X) 10 ~ 15 mm at brake lever end 2. Adjust: *Brake lever free play Adjustment steps: Lever side © Loosen the locknut ®. © Turn the adjuster @ in or out until the spec- ified free play is obtained. Make sure that there is no brake drag after adjusting the front brake lever free play.REAR BRAKE ADJUSTMENT/ | INSP BRAKE SHOE INSPECTION | ADJ Wheel side © Loosen the locknut ®. © Turn the adjuster @ in or out until the spec- d free play is obtained. g in @ Free play is decreased. ‘Turning out © ~Free play is increased. © Tighten the locknut. REAR BRAKE ADJUSTMENT 1. Check: Brake pedal free play Out of specification > Adjust. Free play: 20 ~ 30 mm 2. Adjust: Brake pedal free play Adjustment steps: © Turn the adjuster @ in or out until the spec- ified free play is obtained. Turning in @ ~Free play is decreased. adjusting it. 3. Adjust: Brake light switch Refer to “BRAKE LIGHT SWITCH AD- JUSTMENT”. BRAKE SHOE INSPECTION 1. Operate the brake lever or pedal. 2. Inspect: *Brake shoes Wear indicator @ reaches the wear limit line @ + Replace the brake shoes as a set. Refer to “FRONT WHEEL” and “REAR WHEEL" in CHAPTER 6.DRIVE CHAIN SLACK ADJUSTMENT | ADJ Cy BRAKE LIGHT SWITCH ADJUSTMENT NOTE: The brake light switch is operated by move- ment of the brake pedal. Adjustment is correct when the brake light ‘comes on just before the braking effect actu- ally starts. 1. Check: *Brake light operation timing — Incorrect -> Adjust. 2. Adjust: *Brake light opérating timing Adjustment steps: Hold the main body @ of the switch your hand so that it does not rotate, and turn the adjuster @ in or out until the prop- er operation timing is obtained. DRIVE CHAIN SLACK ADJUSTMENT NOTE: ‘Before checking and adjusting, rotate the rear wheel several revolutions and check the slack at several points to find the tightest point. Check and if necessary adjust the drive chain slack with the rear wheel in this “tightest” position. AWARNING “Securely support the motorcycle so that there is no danger of it falling over. *Stand the motorcycle on its centerstand. 319INSP DRIVE CHAIN SLACK ADJUSTMENT | ADJ 1. Stand the motorcycle on its center stand. NOTE: Elevate the rear wheel by placing a’ suitable stand under the engine, if no centerstand is provided. 2. Checl *Drive chain slack @ Out of specification + Adjust. Drive chain slack: 20 ~ 30mm 3. Remove: +Cotter pin @ 4, Loosen: +Axle nut @ * Sprocket axle nut @ 3, Adjust: * Drive chain slack Adjustment steps: © Loosen the both locknuts @. © Turn the adjuster ©) in or out until the spec- ified drive chain slack is obtained. Turning in @ ~Drive chain stack is decreased. Turning out @ ~-Drive chain stack is increased. NOTE: *Turn each chain adjuster exactly the same amount to maintain correct axle alignment. (There are marks © on each chain adjuster. Use them when adjusting the slack for prop- er alignment.) “Before tightening the axle nut and driven sprocket locknut to specification, make sure that there is no clearance at the adjuster (or the swingarm end) on both sides by pushing the wheel forward Nut (driven sprocket axle): 91 Nm (9.1 mekg, 66 ft-lb) Nut (rear wheel axle): 91 Nm (9.1 m-kg, 66 ft-Ib) 3:20DRIVE CHAIN SLACK ADJUSTMENT/ | INSP STEERING HEAD INSPECTION | ADJ 6. Install: Cotter pin@ Into the axle nut and bend the end of the cotter pin. CAUTION: Do not loosen the axle nut after tightening the torque. If the axle nut groove is not aligned with the cotter pin hole, align the groove with the hole by tightening up the axle nut. AWARNING Always use a new cotter pin. 7. Adjust: *Brake pedal freeplay Refer to “BRAKE PEDAL FREE PLAY” section. STEERING HEAD INSPECTION AWARNING Securely support the motorcycle so that there is no danger of it falling over. 1, Stand the motorcycle on a level surface. NOTE: Stand the motorcycle on its centerstand. 2. Elevate the front wheel by placing a suit- able stand under the engine. 3. Check: +Handlebar assembly Grasp the handlebar and gently rock the steering. Looseness ~ Adjust the handlebar. *Steering assembly bearings Grasp the bottom of the lower front fork tubes and gently rock the fork assembly. Looseness > Adjust the steering head. 4. Remove: *Cowling +Handlebar upper cover © 3.21P STEERING HEAD INSPECTION Wi Cy Loosen: «Pinch bolts (handle crown) @ > Loosen: *Bands ® *Bolts (handlebar upper holders) @ +Handlebar upper holders @ +Handlebar ® *+Handle crown bolts ©) Handle crown © 7. Adjust: +Steering head Adjustment steps: © Remove the lock washer @. © Remove the ring nut @ (upper) and dumper rubber @, then loosen the ring nut @ (lower) using the ring nut wrench. ‘Tighten the ring nut (lower) at initial tightening torque Ring nut wrench: ESM 621 Ring nut-lower (initial tightening): 45.5 Nm (4.55 m-kg, 32.3 ft-lb) Loosen the ring nut @ (lower) one turn. © Retighten the ring nut (lower) using the ring ‘nut wrench. NOTE: — Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut-lower (final tightening): 15.5 Nm (1.55 mekg, 11.2 ft-lb) AWARNING Avoid over torque 3-22STEERING HEAD INSPECTION © Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. © Install the damper rubber @ and ring nut @ (upper), then align the slots of both ring nut @ (lower) and tighten the other until they are aligned. Install the lock washer NOTE: Make sure the lock washer tab is placed in the slots. 8. Install: Handle crown Handle crown bolt +Handlebar +Handlebar upper holders *Bolts (handlebar upper holders) *Bands Refer to "STEERING HEAD AND HAN- DLEBAR” section in the chapter 6. NOTE Insert the grommet of the headlight holder into the hole of the handle crown, while in- stalling the handle crown. Na Bolts (handle crown): 35 Nm (3.5 mekg, 25 ft-lb) Bolts (handlebar upper holders): 23 Nm (2.3 mekg, 17 ft-Ib) 9. Tighten: +Pinch bolts (handle crown) © Pinch bolts (handle crown): 23 Nm (2.3 m+kg, 17 ft-lb) 10. Tighten: +Handlebar upper cover *Cowling Refer to the “COWLING INSTALLATION” section 3:23FRONT FORK INSPECTION/ | INSP REAR SHOCK ABSORBER ADJUSTMENT | ADJ FRONT FORK INSPECTION CGN Securely support the motorcycle so that there is no danger of it falling over. 1. Stand the motorcycle on a level surface. 2. Check: *Inner tube Scratches/damage ~ Replace. “/ *Oil seal Excessive oil leakage -> Replace. Hold the motorcycle upright and apply the front brake. 3. Check: + Operation Push down hard on the handlebars sev- eral times. Unsmooth operation > Repair. Refer to “FRONT FORK” in CHAPTER 6. REAR SHOCK ABSORBER ADJUSTMENT PNG Always adjust each rear shock absorber preload to the same setting. Uneven adjust- ment can cause poor handling and loss of stability. Securely support the motorcycle so that there is no danger of it falling over. 1. Adjust: *Spring preload Turn the adjuster ring @ to direction @ or ®. 3:24REAR SHOCK ABSORBER ADJUSTMENT/ | INSP TIREINSPECTION | ADJ \, oe NN Adjustment steps: Turn the adjuster ring in or out. Turning toward @ Spring preload is creased. "Turning toward © ~Spring preload is decreased. Adjustment numbers: ‘Standard 3 CAUTION: Never turn the adjuster beyond the maxi- mum or minimum setting. ‘*Always adjust each shock absorber to the same setting. TIRE INSPECTION 1. Measure: *Tire inflation pressure Out of specification > Adjust. CVI Tire inflation pressure should only be checked and adjusted when the tire temper- ature equals the ambient air temperature. Tire inflation pressure and suspension must be adjusted according to the total weight of the cargo, rider, passenger and accessories. (fairing, saddlebags, etc.if approved for this model), and according to whether the mo- torcycle will be operated at high speed or not. NEVER OVERLOAD THE MOTORCYCLE. Operation of an overloaded motorcycle could cause tire damage, accident or inji 3:25INSP ‘Q]| TIRE INSPECTION | ADJ weight: oil and full fuel tank Maximum load* Cold tire pressure Up to 90 kg load* 90kg~ maximum. load* 32 psi *Load is the total weight of the cargo, rider, passenger and accessories. 2. Inspect: *Tire surfaces Wear/damage ~> Replace. Minimum tire tread depth (front and rear): 1.6mm. @ Tread depth @ Side wall @ Wear indicator WARNING elt is dangerous to ride with a worn-out ti When the tire tread begins to show signs of wear, replace the tire immediately. *Patching a punctured tube is not recom- mended. If it is absolutely necessary to do 50, use great care and replace the tube as soon as possible with a good quality re- placement tube. *Do not use tubeless tires on a wheel de- signed for tube type tires only. Tire failure and personal injury may result from sudden deflation. Tube ty Tubeless type wh wheel — Tube type tire only Tube type or tubeless tire. “Be sure to install the correct tube when using tube type tires. 3:26TIRE INSPECTION/ SPOKE INSPECTION AND TIGHTENING/ WHEEL INSPECTION INSP ADJ AWARNING After mounting a tir a whi properly the rim. Fi ide conservatively for to give the tire time to seat itself re to do so could lead to an accident with possible injury to the. rider or damage to the motorcycl specification. 2. After a tire repair or replacement, be sure to tighten the valve stem locknut @ to Locknut: a 1.5 Nm (0.15 mekg, 0.2 ft-ll) eeseavo 1. Inspect: *Spokes ® 2. Tighten: Spokes. NOTE: break-in. WHEEL INSPECTION 1. Inspect: +Wheels NOTE: PGI wheel. 3:27 SPOKE INSPECTION AND TIGHTENING Bending/damage ~> Replace. Loose spoke -> Retighten. Be sure to tighten the spokes before and after y 2.Nm (0.2 m Ib) Damage/Bends ~ Replace. Always balance the wheel when a tire or wheel has been changed or replaced. Never attempt to make any repairs to theINSP BATTERY INSPECTION | ADJ ELECTRICAL BATTERY INSPECTION 1, Remove: *Side cover (right) Refer to “SEAT, SIDE COVERS AND FUEL TANK" section. 2. Inspect: *Electrolyte level Electrolyte level should be between the upper @ and lower @ level marks. Eleo- trolyte level is too low > Add electrolyte to proper level. CAUTION: Refill with distilled water only. Tap water contains minerals which are harmful to a bat- tery. 3. Inspect: + Battery terminals Dirt > Clean with a wire brush. Poor connection ~> Correct. NOTE: After cleaning the terminals, apply a light coat of grease to the terminals. 4. Inspect: *Breather hose @ Obstruction -» Remove. Damage ~> Replace. CAUTION: When inspecting the battery, make sure that the breather hose is routed correctly. If the breather hose is positioned in such a way as to allow battery electrolyte or gas to come into contact with the frame, this could dam- age the motorcycle and ruin its finish. 3-28] 5. Connect: «Breather hose Make sure that the hose is properly at- tached and routed. 6. Check: +Specific gravity @ Less than 1.2400-+ Recharge the battery. Charging Current: 0.25 amp. Specific Gravity: 1.240INSP BATTERY INSPECTION | ADJ 3:29 Replace the battery if: © Battery voltage will not rise to a specific value or bubbles fail to rise during charg- ing. © Sulphation of one or more cells occurs, (as indicated by the plates turning white, or material accumulating in the bottom of the cell). © Specific gravity readings after a long, slow charge indicate that one cell is charged lower than the rest. © Warpage or buckling of plates or insulators is evident. FEE HHO HORE RON o a aE ESE EEE Always charge a new battery before using it to ensure maximum performance. AWARNING caustic. Always follow these preventive measures: *Avoid bodily contact with electrolyte as it can cause severe burns and permanent eye injury. Wear protective eye gear when handling or ing near batteries. Antidote (EXTERNAL SKIN — Flush with water. *EYES - Flush with water for 15 minutes and get immediate medical attention. “Antidote (INTERNAL): Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical atten- tion, “Batteries generate explosive hydrogen gas. ‘Always follow these preventive measures: ‘Charge batteries in a well - ventilated area. ‘*Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.) *DO NOT SMOKE when charging or handling batteries. ‘*KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.INSP BATTERY INSPECTION/FUSE INSPECTION | ADJ 3-30 7. Install: Battery 8. Connect: . secee wate Connect the positive lead @ first and then connect the negative lead @ 9. Connect: +Breather hose Be sure the hose is properly attached and routed. Refer to “CABLE ROUTING” section. 10. Install: *Side cover (right) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section. FUSE INSPECTION “CAUTION: Always turn off the main switch when check- ing or replacing the fuse. Otherwise, a short cireuit may occur. 1, Remove: *Side cover (right) Refer to “SEAT, SIDE COVERS AND FUEL TANK" section. Fuse holder ® 2. Inspect: Fuse Inspection steps: Connect the Multimeter to the fuse and check it for continuity. Nore: — Set the Multimeter selector to “x1” position. wine If the Multimeter is indicated at «. Replace the fuse.FUSE INSPECTION/ HEADLIGHT BEAM ADJUSTMENT/ ISP HEADLIGHT BULB REPLACEMENT | ADJ 3. Replace: Blown fuse Replacement steps: © Turn off the main switch. Install a new fuse with the proper current rating. Turn on switches to verify operation of relat- ed electrical devices. if the fuse blows again immediately, check the electrical circuit AWARNING Never use a fuse with a rating other than that specified. Never use other materials in place of a fuse. An improper fuse may cause exten- e damage to the electrical system, mal- function of lighting and ignition systems and could possibly cause a fire. 4, Install: +Fuse holder *Side cover (right) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section. HEADLIGHT BEAM ADJUSTMENT 1. Adjust: Headlight beam (vertical) Loosen the bolt @ and adjust the head- light unit. Push~Headlight HEADLIGHT BULB REPLACEMENT 1. Remove: *Cowling +Headlight assembly Refer to “COWLING" section. 3:31INSP HEADLIGHT BULB REPLACEMENT | apJ S 3:32 2. Disconnect: Headlight beam leads Bulb cover 3. Remove: Bulb NOTE: Unhook the bulb spring. /ARNING Keep flammable products and your hands away from the bulb while it is on, it will be hot. Do not touch the bulb unit it cools down. 4. Install: *Bulb (new) Secure the new bulb with the bulb spring. CAUTION: Avoid touching glass part of bulb. Also keep it away from oil otherwise, transparency of glass, bulb life and illumines flux will be ad- versely affected. If oil gets on bulb, clean it with a cloth moistened thoroughly with alco- hol or lacquer thinner.ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: It is not necessary to remove the engine in order to remove the following parts. “Cylinder head Cylinder “Piston “Clutch *CDI Magneto ‘SEAT, SIDE COVERS AND FUEL TANK REMOVAL 1, Remove: *Seat *Side covers (left and right) Fuel tank Refer to the “SEAT, SIDE COVERS AND FUEL TANK" section in Chapter 3. ENGINE OIL 1. Drai Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in Chapter 3. ensoo10 BATTERY 1. Remove: * Battery breather hose Battery CAUTION: Disconnect the negative lead @ first and then disconnect the positive lead @. otc CARBURETOR 1. Disconnect: *Air vent hose +Starter cable Disconnect from starter lever side. 2. Remove: + Carburetor Refer to the “CARBURETOR” section in Chapter 5. NoTe: ——____ Cover the carburetor with a clean rag prevent dirt or foreign material from entering the car- buretor. 44ENGINE REMOVAL | ENG ~ CLUTCH CABLE 42 1. Remove: *Clutch cable Removal steps: Loosen the locknut @ of the lever side. *Turn the adjuster @ enough to free the clutch cable. ‘© Unhook the cable end from cable holder of the crankcase side. DRIVE CHAIN |. Remove: *Drive chain case (upper and lower) *Crankease cover 2 Slack off the drive chain. Refer to “DRIVE CHAIN SLACK ADJUST- MENT” section in Chapter 3. x 3. Remove: + Bolt (drive sprocket holder) *Drive sprocket holder *Drive sprocket Remove with the drive chain. EXHAUST MUFFLER . Remove: +Foot rest assembly *Bolt (exhaust pipe) +Nut (muffler) Refer to “EXHAUST SYSTEM” section in Chapter3. Remove: +Exhaust muffler x SHIFT PEDAL 1. Remove: *Shift pedal