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Ybr 125 - Gldiator
Ybr 125 - Gldiator
(Gladiator)
SERVICE
MANUAL
5YY-F8197-E0
5YY-F8197-E6
GLADIATOR
SERVICE MANUAL
YAMAHA MOTOR INDIA SALES PVT. LIMITED
All rights reserved.
Any reprinting or unauthorised use without
the written permission of
YAMAHA MOTOR INDIA SALES PVT. LIMITED
is expressly prohibited.
R-1
FOREWORD
This Service Manual has been prepared for use by the Yamaha Motor India
Sales Private Limited. Authorised Dealerships and their service personnel to
attend to servicing of Gladiator Motorcycles. It is not possible to include entire
service education into this Manual. It is assumed that persons using this book
to perform maintenance and repairs on Gladiator 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.
Service Department
Yamaha Motor India Sales Private Ltd.
L-2
4 ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
2 ENGINE ASSEMBLY
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence
• Expander Spacer (Oil Ring) ¿ 3
5 • Side Rails (Oil Ring) À
• 2nd Ring Á
• Top Ring Â
NOTE :
• Make sure to install the Piston Rings so that
the RN marks are located on the upper side
of the 2nd Ring.
• Lubricate the Piston and Piston Rings with
Engine Oil.
7
2. Install :
• Piston ¿
• Piston Pin À using piston pin tool
6
À
¿ Piston Pin replacer tool
YSST - 607
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number
and content.
1. General GEN
Information INFO
2. Specifications SPEC
3. Periodic inspection
INSP 4. Engine ENG
and adjustment
ADJ
TRBL
7. Electrical ELEC 8. Troubleshooting
SHTG
Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.
15.Resistance,
Voltage, Current
Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and
lubrication points.
16. Apply engine oil 17. Apply gear oil 18. Apply molybdenum
disulfide oil
Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking
agent and when to install new parts
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION
AND ADJUSTMENTS INSP
ADJ 3
ENGINE ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLE SHOOTING TRBL
SHTG 8
R-5
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER .........................................................1-1
ENGINE SERIAL NUMBER .......................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY ...................................... 1-2
ALL REPLACEMENT PARTS ....................................................1-3
GASKETS, OIL SEALS, AND O-RINGS ....................................1-3
LOCK WASHERS/PLATES AND COTTER PINS ...................... 1-3
BEARINGS AND OIL SEALS .....................................................1-3
CIRCLIPS ...................................................................................1-3
SPECIAL TOOLS
SPECIAL SERVICE TOOLS ...................................................... 1-4
SERVICE INSTRUMENTS .........................................................1-7
SPECIAL SERVICE MATERIALS .............................................. 1-8
L-6
GEN
MOTORCYCLE IDENTIFICATION INFO
MOTORCYCLE IDENTIFICATION
FRAME NUMBER
XX X 5YY8 - XXXXXX
MODEL SERIAL
NOTE :
CODE NUMBER
Designs and sepecifications are subject to
change without notice.
Starting Serial Number : 000001
1-1
R-7
GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY
1. Remove all dirt, mud, dust and foreign ma-
terial before disassembly.
1-2
L-8
GEN
IMPORTANT INFORMATION INFO
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use Yamalube Oil and
Grease recommended 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 the Engine is overhauled.
2. All surfaces where Gasket, Oil Seal lips and
O-rings contact must be cleaned and
Lubricated.
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
CAUTION:
WARNING
Do not use compressed air to spin the
Bearings dry. This causes damage to the
Bearing surfaces.
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 À is
positioned opposite to the thrust Á it
receives. See the sectional view of shaft Â.
WARNING
If the Circlip is fitted the wrong way it would
cause it to jump off its groove and damage
related components.
1-3
R-9
GEN
YAMAHA SPECIAL SERVICE TOOLS INFO
YAMAHA SPECIAL SERVICE TOOLS
The appropriate Yamaha Special Service Tools are necessary for proper maintenance of the Motorcycle.
Using the correct Yamaha Special Service Tool will help to prevent damage caused by the use of
improper tools or improvised techniques. The following is the detailed list of all Yamaha Special Service
Tools with their application.
Refer to the list provided to avoid errors when placing an order for Yamaha Special service tools.
This tool is used to remove the Magneto This tool is used to replace Piston Pin.
This tool is needed to support the Piston This tool is used to hold the Clutch Hub when
while installing Cylinder. removing or installing Clutch Main Shaft Nut.
1-4
L-10
GEN
YAMAHA SPECIAL SERVICE TOOLS INFO
This tool is used to remove the Crank Shaft This tool is used for scraping the sealent
from the Crank Case. from Crankcase surface.
10. Crank Shaft Installing Tool with spacer 15. Feeler Gauge
(a) YSST - 266 ç è YSST - 615
(b) YSST - 267
These tools are used for installation of This tool is used to check Valve
Crank Shaft. Clearance.
11. Driving Sprocket Holder 16. T.F.F. Oil Seal Removing Tool.
YSST- 605 YSST - 270
13. Steering Nut Socket 18. T.F.F. Oil Seal Installation Tool
YSST - 621 YSST-275
This tool is used to loosen or tighten the This tool is used when installing the TFF
Steering Ring Nut. Oil Seal.
1-5
R-11
GEN
SPECIAL SERVICE TOOLS INFO
To loosen & tighten the front fork top plug. This tool is used to remove the Bearing
6202 of the Axle Drive
This tool is used to loosen or tighten the This tool is used to remove/install the Center
Speedometer Gear Nut. Plug from Crank case Cover#1 (L.H.)
This fixture is used to hold the Engine for To Tighten / Loosen the Spoke.
its disassembly and assembly.
This tool is used to install Oil Seal in This tool is used to remove the Bearing
Crank Case Cover#2. 6203 of the Axle Drive
1-6
L-12
GEN
SERVICE INSTRUMENTS INFO
SERVICE INSTRUMENTS
The following Service Instruments are necessary for complete and accurate tune up of Motorcycle
1. Tachometer 6. Micrometer
YSST - 613 (0-25 mm) & (50-75 mm)
This instrument is used for This instrument is used for measuring ‘CO’
checking ignition timing concentration in exhaust of motorcycle
8.Hydrometer
3. Compression Gauge
This instrument is
used for checking the This instrument is used for checking the
electrical system. Tyre Pressure
This instrument is used for measuring length, This instrument is used for checking intake
width & thickness of components vaccum.
1-7
R-13
GEN
SERVICE INSTRUMENTS INFO
This instrument is used for measuring the This tool is used to tighten the Nuts/Bolts
oil temperature of Engine at a specified torque.
This adhesive is used on mating surfaces This adhesive is used for Torx
while assembling Crankcase#1 and #2. Screw tightening.
1-8
L-14
GEN
INFO
CHAPTER 2
SPECIFICATIONS
SPEC
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Model : GLADIATOR
Model Code : 5YY8/5YYB/5YYC/5YYD
Engine model code: 5YY8
DIMENSIONS:
Overall length 2065 mm
Overall width 730 mm
Overall height 1100 mm
Seat height 795 mm
Wheelbase 1300 mm
Minimum ground clearance 180 mm
Minimum turning radius 2100 mm
2-1
R-3
SPEC
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Clutch type : Wet, Multiple disc
Transmission :
Primary reduction system Helical gear
Primary reduction ratio 68/20 (3.4 : 1)
Secondary reduction system Chain drive
Secondary reduction ratio 45/14 (3.214 : 1)
Transmission type Constant mesh 4-speed
Operation Left foot operation
Gear ratio 1st 33/11 (3.00 : 1)
2nd 32/18 (1.778 : 1)
3rd 25/19 (1.316 : 1)
4th 23/22 (1.045 : 1)
Primary Drive Grading 21/24 (0.875 : 1)
DRIVEN GEAR ASSY. Matching of Grades
GRADE Gear Primary Primary Driven
Drive Gear Assy.
GRADE Z A
A B
B C
C D
GEAR PRIMARY DRIVE
D E
Chassis :
Frame type Diamond
Caster angle 26.0º
Trail 90.0 mm
Tyre :
Type With tube
Size Front 2.75 - 18, 42 P
Rear 3.00 - 18, 6 PR, 52 P
Manufacturer Front LOCAL MADE
Rear LOCAL MADE
Type Front ZEBRA - Y PLUS
Rear ZEBRA - Y PLUS
Tyre pressure (cold tyre) :
Loading condition A* 0 ~ 90 kg (0 ~ 198 lbs)
Front 25 PSI (1.75 kgf/cm²)
Rear 33 PSI (2.25 kgf/cm²)
Loading condition B* 90 ~ 162 kg (198~408 lbs)
Front 25 PSI (1.75 kgf/cm²)
Rear 36 PSI (2.5 kgf/cm²)
*Load is total weight of cargo, rider, passenger and accessories.
2-2
L-4
SPEC
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Brake :
Front brake Type Disc Brake (Dia 240 mm)
Operation Right hand operation
Rear brake Type Drum brake (Dia 130 mm)
Operation Right foot operation
Suspension :
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorbser :
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel :
Front wheel travel 120 mm
Rear wheel travel 90 mm
Electrical :
Ignition system CDI (Digital)
Generator system Flywheel magneto
Battery type LOCAL MADE
Battery capacity 12V - 5 AH
Headlight type : Bulb type
Headlight bulb type S-1 Type Bulb
Bulb (voltage - wattage x quantity) :
Headlight 12V - 35W/35W x 1
Tail/Brake light 12V - 5W/21W x 1
Flasher light 12V - 10W x 4
Meter light 12V - 3.4W x 3
“NEUTRAL” indicator light 12V - 3.4W x 1
“HIGH BEAM” indicator light 12V - 3.4W x 1
“TURN” indicator light 12V - 1.7 x 2
2-3
R-5
SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
DESCRIPTION SPECIFICATION
Cylinder :
Bore size 54.000 ~ 54.020 mm
(in five grades)
Piston :
Piston to Cylinder Clearance 0.020 ~ 0.027 mm
<Limit> <0.15mm>
Piston size “D” 53.977 ~ 53.996 mm
Cylinder Piston Grading (in five grades)
Matching of Grades
2-4
L-6
SPEC
MAINTENANCE SPECIFICATIONS
2-5
R-7
SPEC
MAINTENANCE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Stem outside diameter IN 4.975 ~ 4.990 mm
EX 4.960 ~ 4.975 mm
<Limit> IN <4.950 mm>
EX <4.935 mm>
Guide inside diameter IN 5.000 ~ 5.012 mm
EX 5.000 ~ 5.012 mm
<Limit> IN <5.042 mm>
EX <5.042 mm>
Stem to guide clearance IN 0.010 ~0.037 mm
EX 0.025 ~ 0.052 mm
<Limit> IN <0.08 mm>
EX <0.010 mm>
Stem runout limit
2-6
L-8
SPEC
MAINTENANCE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Clutch :
Friction plate thickness 2.90 ~ 3.10 mm
Quantity 5 pcs.
<Friction plate wear limit> <2.80 mm>
Clutch Plate thickness 1.6 ± 0.15 mm
Quantity 4 pcs.
<Wrap limit> 0.05 mm
Clutch Spring free length 32 mm
Quantity 4 pcs.
Minimum length 31.0 mm
Clutch release method Inner push, cam push
<Push rod bendinglimit> <0.5 mm>
Carburetor :
I. D. Mark 5YY1
Main Jet (M.J.) #127.5
Main Air Jet size (M.A.J.) 85
Jet needle (J.N.) 4DG9-2
Needle jet (N.J.) E-3M (906)
Pilot Air Jet (PAJ-1) 1.4
Pilot outlet (P.O.) 0.8
Pilot jet (P. J.) # 15
Valve seat size (V.S.) 1.8
Starter jet (G.S.1) 35
(G.S.2) 0.6
Fuel Level 6.5 ± 0.5 above the joint line of MCB
(Main Body Chamber) and F.C.B. (Float
Chamber Body)
Float Height 29 mm ± 0.5 Below the Venturi Axis
Engine idle speed 1,300 ~1,500 r/min.
Intake vaccum
New Vehicle 26.0 ~ 31.4 kPa
Market Run Vehicle 31.3 ~ 36.7 kPa
Lubrication system :
Oil filter type Wire mesh type
Oil filter type Trochoid type
Tip Clearance “A” or “B” 0.15 mm
<Limit> <0.2 mm>
Side clearance 0.06 ~ 0.10 mm
<Limit> <0.15 mm>
Housing and rotor clearance 0.06 ~ 0.10 mm
<Limit> <0.15 mm>
2-7
R-9
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUE (ENGINE)
2-8
L-10
SPEC
MAINTENANCE SPECIFICATIONS
Tightening sequence
Cylinder Head
à Ä
À
Á
¿ Â
t È
Crankcase ¿
à Ä
 Æ
Á
À
Right - hand Left - hand
2-9
R-11
SPEC
MAINTENANCE SPECIFICATIONS
CHASSIS
DESCRIPTION SPECIFICATION
Steering system :
Steering Bearing type Retainer Ball Cage
No./size of steel balls (upper) 19 pcs. / 1/4 in
(lower) 16 pcs. / 1/4 in
Front suspension :
Front Fork travel 120 mm
Fork Spring free length 316.9 mm
<Limit> 310.6 mm
Spring rate (K1) 3.7 N/mm
(K2) 5.4 N/mm
Stroke (K1) 0 ~ 70 mm
(K2) 70 ~ 120 mm
Oil grade Special YAMAHA oil. 10W or Equivalent
Rear suspension :
Shock Absorber travel 90 mm
Spring free length 241.9
Fitting length 229.9 mm
Spring rate (K1) 15.08 N/mm
(K2) 22.64 N/mm
Stroke (K1) 0 ~ 38.3 mm
(K2) 38.3 ~ 90 mm
Swingarm :
<Free play limit> End <1.0 mm>
Side <1.0 mm>
Front wheel :
Type Spoke wheel/Cast Wheel
Rim size 1.6 x 18”
Rim material Steel
<Rim run out limit> Radial <1.0 mm>
Lateral <0.5 mm>
Rear wheel :
Type Spoke wheel/Cast Wheel
Rim size 1.6 x 18”
Rim material Steel
<Rim rounout limit> Radial <1.0 mm>
Lateral <0.5 mm>
Drive chain :
Type/manufacturer 428H/TI Diamond (India)
Number of links 120
Chain slack 20 ~ 30 mm
2-10
L-12
SPEC
MAINTENANCE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Free Plays :
Brake Lever free play (At lever end) 25 ~ 30 mm
Brake Pedal free play 20 ~ 30 mm
Clutch Lever free play (at lever end) 10 ~ 15 mm
Throttle Grip free play 3 ~ 5mm
2-11
R-13
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUE (CHASSIS)
*1. Note :
First tighten the Ring Nut approximately 33 Nm (3.3 m.kg 25 ft.lb) by using the torque
wrench then loosen the Ring Nut 1/4 turn.
2. Retighten the Ring Nut to specifications (23 nM (2.3 m.kg. 17 ft.lb)
2-12
L-14
SPEC
MAINTENANCE SPECIFICATIONS
ELECTRICAL
DESCRIPTION SPECIFICATION
Voltage : 12V
Ignition system :
Ignition timing (B.T. D. C) 7º ± 2º BTDC at 1400 rpm.
Advancer Type Electrical type
CDI : Digitally Controlled
Magneto model/manufacturer 5YY/Local Made
Sensor Coil (Color) 240 Ω ± 20%
CDI Unit Model/manufacturer 5YY/ Local made
IgnitionCoil :
Model/Manufacturer 5YY/Wings Automobiles Pvt. Ltd.
Primary Coil Resistance 0.20 Ω ± 15%
Secondary Coil Resistance 3.0 KΩ ± 20%
Spark Plug Cap :
Type Resin Type
Resistance 5 kΩ at 20 ºC (68ºF)
Charging System :
Type Flywheel Magneto
Flywheel Magneto :
Model/Manufacturer 5YY/Local Made
Charging Voltage 13 ~ 14V @ 5000 RPM
Charging Coil Resistance 0.75 Ω ± 20% (68ºF)
Lighting :
Lighting Voltage 14 V ± 0.5 @ 5000 RPM
2-13
R-15
SPEC
MAINTENANCE SPECIFICATIONS
Circuit Breaker :
Type Fuse
Amperage for individual circuit X quantity :
Main 10A X 1pc.
Reserve 10A X 1pc.
Fuel Gauge:
Made/Manufacturers Pricol / Local Made
Sender unit resistance (Full) 10 ± 0-6 Ω
Sender Unit resistance (Empty) 90± 10-0 Ω
2-14
L-16
SPEC
GENERAL TORQUE SPECIFICATION
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque speci-
fication for special components or assemblies are included in applicable section of this book. To
avoid warpage, tighten multi-fastener assemblied in a criss-cross fashion, in progressive stages,
until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry
threads. Components should be at room temperature.
General Torque
A B specifications
(Nut) (Bolt) Nm m•kg ft•lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
A : Distance across flats
B : Outside thread diameter
2-15
R-17
SPEC
LUBRICATION POINTS AND LUBRICANT TYPE
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE
Crank Pin
Piston Pin
Push Rod
Axle Drive
2-16
L-18
SPEC
LUBRICATION POINTS AND LUBRICANT TYPE
CHASSIS
2-17
R-19
SPEC
ENGINE LUBRICATION ROUTE
Engine Lubrication route
CAUTION:
WARNING
DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START
2-18
L-20
SPEC
ENGINE LUBRICATION ROUTE
CAUTION:
WARNING
FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL
2-19
R-21
SPEC
ENGINE BEARINGS
ENGINE BEARINGS
(6203)
2-20
L-22
SPEC
CABLE ROUTING
CABLE ROUTING É Flasher light lead (left) B Pass the Throttle Cable Å,
¿ Handlebar switch (left) Ê Flasher Light and the Brake Hose Ä and
À Clutch cable Ë Flasher Light lead (right) the Front Brake switch lead
Á Starter Wire Ì Master Cylinder Æ through the Cable Guide of
 Speedometer Í Kill Switch the right side.
à Fuel Meter A Pass the Clutch Cable À, C Clamp Wireharness È and
Ä Brake Hose Starter wire Á and front fork.
Å Throttle cable Handle-bar Switch Lead D Pass the Wireharness È and
Æ Brake switch lead through the cable guide of Clutch Cable À.
Ç Speedometer cable the left side.
È Wireharness
 Ã
A
B
À Å
Ä
¿ Ì
Í
Á Æ
Ã
Â
Ì
Å Ê
Ê É
Á
Ë À
C
È
À D
2-21
R-23
SPEC
CABLE ROUTING
¿ Headlight assembly Î Starter Relay D Connect the battery
À Handlebar switch lead Ï H.T. Coil negative (-) lead and
Á Speedometer cable Ð Air Induction system positive (+) lead with the
 Cable guide Ñ Relay Assembly wireharness.
à Clutch cable Ò Battery (+ve) lead E Pass the battery breather
Ä Horn Ó Battery (-ve) lead hose Ì through the hole
Å Fuse A Pass the wireharness through of the lower left side of
Æ CDI unit the cable guide. the Battery Box
Ç Clamp Battery B Pass the speedometer cable F Pass the magneto lead to
È Stop/tail light Á and front brake cable Î the outside of the flange of
É Flasher light lead (LH) through the Cable Guide. the chain cover.
Ê Flasher light C Align the white marking of
Ë Battery Wireharness with the frame
Ì Battery breather hose clamp
Í Starter Motor Lead Wire
À
Ã
Ï
¿
Æ
Ð
C
É
Ó Î Ñ
È
Å
Ä
Á
Ê
A Ò
Ë D
Á Â Ì
E F
Í
2-22
L-24
SPEC
CABLE ROUTING
¿ Throttle cable È A.I.S. Unit A Pass the high tension cord À through the
À High tension cord É Starter wire cable guide and starter wire.
Á Ignition Coil Ê Carburettor Breather B Pass the throttle cable ¿ and starter wire
 Band - C.D.I. Pipe. É through cable guide.
à Brake Hose front Ë Caliper C Pass the clutch cable Æ through cable
Ä Speedometer Ì Disc guide.
Å Brake switch lead D Pass breather hose through upper right side
Æ Clutch cable hole of frame bracket engine.
Ç Rr Brake Switch E Clamp the hose front brake with front
mudguard.
Ä
Ã
Å
B
 É
È ¿
Á
Æ
C
Ã
Ç
Ê ¿
D
Ë
À
Ì
2-23
R-25
SPEC
CABLE ROUTING
¿ C.D.I. Unit
À Rectifier regulator
Á Flasher relay
 Flasher light lead
A Clamp the Wire Harness lead.
B Pass the Wire Harness between Frame and Rear Fender
À
Å
Ã
Æ
2-24
L-26
SPEC
R-1
CHAPTER 3
INTRODUCTION/ INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable Motorcycle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to Motorcycles already in service as well as to new Motorcycles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
SERVICES
S. NO. ITEM OPERATION FREE PAID EVERY
2000
I II III IV V VI km
12 REAR ARM PIVOT Check Rear Arm assembly for looseness. Tighten
with specified torque if necessary Repack grease Every 10,000 km
13 WHEELS Check runout, Spoke tightness (if applicable),
damage; Correct it if necessary.
3-1
R-3
INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
SERVICES
S. NO. ITEM OPERATION FREE PAID EVERY
2000
I II III IV V VI km
It is recommended that above be authorised YAMAHA MOTOR INDIA SALES PRIVATE LIMITED
dealer *Service more frequently when the vehicle is driven in dusty areas.
3-2
L-4
INSP
SIDE COVERS, SEAT AND FUEL TANK ADJ
SIDE COVERS, SEAT AND FUEL TANK
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Open the Lock ¿ using Main Switch Key.
• Pull the Lug À / Lug Á towards you to remove
Á it from the Fuel Tank.
• Slide the Side Cover towards the front side of
À the Motorcycle for removing the Lug  from
the Chassis.
ææææææææææææææææææææææææææææææææææ
Â
Â
À
3-3
R-5
INSP
SIDE COVERS, SEAT AND FUEL TANK ADJ
REMOVAL SEAT
1. Remove
• Side Cover LH and RH
À ¿ • Bolts 2 Nos - Bolts ¿ and À from LH/RH
¿ÀÁÂÃÄÅÆÇÈÉÊËÌÍÎÏÐÑ
side
• Seatçèéêë
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Open bolts ¿ and À inside the side covers.
• Lift the front of the Seat and slide it forward.
À WARNING
• Gasoline is highly flammable.
• Avoid spilling of fuel on the hot Engine.
NOTE :
• Position the Fuel Cock Á to the ‘OFF’,
disconnect the Fuel Hose.
 • Place a rag under the Fuel Line to absorb any
spilt fuel.
Â
¿
2. Remove
À • Bolt (Fuel Tank) ¿
Á
• Plate À
• Damper Rubber Á
• Fuel Tank Â
3-4
L-6
INSP
SIDE COVERS, SEAT AND FUEL TANK ADJ
INSTALLATION
¿
Reverse the REMOVAL procedure.
Â
Note the following points.
Á 1. Install
À
• Fuel Tank ¿
• Damper Rubber À
• Plate Á
• Bolt Â
• Fuel Hose
NOTE :
• Keep the projection on plate Á downward.
2. Install
• Scoop Bracket
• Bolts - 2 Nos.
3. Install
• Seat
ç
• Bolts ¿ and À
è NOTE :
• Insert the projection ç on the rear of the seat
into the receptacles è on the Chassis, then
push down front of the seat and tighten the
bolts. À
Bolt (Seat)
3.8 Nm (0.38 mkg, 3.0 ft.lb)
¿
4. Install
• Side Cover (LH) ¿ and lock with Key
5. Install
À • Side Cover (RH) À
Á
6. Tighten
• Screw Á
3-5
R-7
INSP
VALVE CLEARANCE CHECKING AND ADJUSTMENT ADJ
ENGINE
NOTE :
Valve clearance checking and adjustment
should be made with the Engine in cold condi-
tion, at room temperature.
When the Valve clearance is to be measured or
adjusted, the Piston must be at Top Dead Cen-
ter (T.D.C.) on the compression stroke and
marking on Cam Sprocket should be aligned
with the marking on Cylinder Head.
1. Remove :
• Side Covers
• Seat
• Fuel Tank
Á Refer to “SIDE COVERS, SEAT AND FUEL
TANK” section Page no 3-3
Â
2. Remove :
À • Spark Plug
• Bolts (Cylinder Head Side Cover) ¿ 2 Nos
¿
• Cylinder Head Side Cover À
• Valve Cover - Intake Á/ Exhaust side Â
3. Remove :
¿ • Timing Check Plug (with O-ring) ¿
• Center Plug (with O-ring) À
À
4. Measure :
• Valve clearance (Intake and Exhaust) ¿
using Feeler Gauge
Out of specification Ÿ Adjust.
Feeler Gauge :
¿ YSST - 615
3-6
L-8
INSP
VALVE CLEARANCE CHECKING AND ADJUSTMENT ADJ
è ææææææææææææææææææææææææææææææææææ
Checking steps :
Measurement steps :
• Rotate the Crankshaft anticlockwise to align
ç the slit ç third mark on the rotor with the sta-
tionary pointer è on the Crankcase Cover LH
when the Piston is at Top Dead Center (T.D.C.)
and in compression stroke.
• Measure the Valve clearance by using a feeler
gauge.
Feeler Gauge
YSST 615
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Loosen the Locknut ¿
• Turn the Adjuster À in or out with the Valve
adjusting tool Á until specified clearance is
obtained.
Locknut :
8 Nm (0.8 m • kg, 5.8 ft • lb)
6. Install
¿ • Timing Check Plug (with O-ring ) ¿
• Center Plug (with O-ring) À
À
3-7
R-9
INSP
IDLING CO. MEASUREMENT AND ADJUSTMENT ADJ
7. Install
¿
• Valve Covers (with O-ring) ¿
¿ • Spark Plug
• Cylinder Head Side Cover À
3. Check :
• Engine idling speed (standard)
Out of specification Ÿ Adjust.
Turn the Throttle Stop Screw ¿ in or out
until specified idling speed is obtained.
Turning IN Increasing in rpm
Turning OUT Decrease in rpm
4. Insert :
À • Sampling probe ¿ (CO. tester ) to the
¿ exhaust pipe À
3-8
L-10
NOTE :
For adjusting the Engine idling speed use the
throttle stop screw À. Do not adjust Engine Idle
RPM by using the Pilot Screw.
•
After adjusting, ‘CO’ concentration as
specified, remove the ‘CO’ tester, make
sure that the Engine idling speed has not
changed.
ææææææææææææææææææææææææææææææææææ
1. Check :
ç • Throttle cable free play ç
Out of specification Ÿ Adjust.
Free play : 3 ~ 5 mm
At Throttle Grip flange
2. Adjust :
• Throttle Cable free play
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
NOTE :
Never accelerate the Throttle when stopping the
Engine.
3-9
R-11
WARNING
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.
2. Check :
• Spark Plug Type / Number
Incorrect Replace
3-10
L-12
Spark Plug :
12.5 Nm (1.25 mkg, 9 ftlb)
NOTE :
• Before installing a Spark Plug, clean the Gas-
ket surface and Plug surface.
• If 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 turn to À using
Box Spanner
1. Remove :
• Plug Straight Screw ¿
2. Attach :
• Timing light À
À Timing light
SKC (S14-121) or any standard
brand
Engine tachometer
YSST - 613
3-11
R-13
INSP
IGNITION TIMING CHECKING PROCEDURE ADJ
3. Check :
• Ignition timing
*********************************************
Checking steps :
• Start the Engine and let it warm up for sev-
eral minutes or run the Motorcycle for approx.
4 kms.
• Maintain the Engine idling speed
4. Check
• Auto advance mechanism
ææææææææææææææææææææææææææææææææææ
Checking steps
• Increase the Engine speed from 1400 r/min to
2250 r/min
• Check the stationery pointer ç should be
within the ignition timing range è marked on
the Rotor Assembly
• Further increase the Engine speed from 2250
r/min onwards.
• Observe that Rotor ignition timing mark moves
in clockwise direction gradually and later not
visible.
A :Auto Advance reverse circuit not working • If above phenomenon is not observed it con-
B :Auto Advance not working firms that the CDI unit is defective (Auto Ad-
C :Delay Auto Advance vance mechanism not working)
D :STD Auto Advance working ææææææææææææææææææææææææææææææææææ
5. Install :
• Plug straight screw (with O-ring)
3-12
L-14
INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
COMPRESSION PRESSURE MEASUREMENT
¿ NOTE :
Insufficient compression pressure will result in
performance loss.
1. Check :
• Valve clearance
Out of specification Ÿ Adjust.
Refer to “VALVE CLEARANCE
ADJUSTMENT” section. Page no 3-6
2. Start the Engine and let it warm up for sev-
eral minutes.
3. Turn off the engine.
4. Remove :
• Spark Plug
5. Attach:
• Compression gauge ¿
Compression Gauge :
6. Measure :
• Compression pressure
If it exceeds the maximum pressure allowed
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.
COMPRESSION PRESSURE Follow the table
(With oil applied into cylinder)
Reading Diag- Compression pressure :
nosis Worn or damaged (at sea level)
Higher than without oil piston Standard : 1200 kPa (12 Kg/cm²)
Possible defective Minimum : 1040 kPa (10.4 Kg/cm²)
Same as without oil ring(s),Valves,Cylinder ææææææææææææææææææææææææææææææææææ
head Gasket or Pis- Measurement steps:
ton Ÿ Repair. • Crank the Engine with the Throttle wide open
until the reading on the compression gauge
stabilizes.
WARNING
Before cranking the engine, ground Spark
Plug leads to prevent sparking
ææææææææææææææææææææææææææææææææææ
7. Install :
• Spark plug
3-13
R-15
3-14
L-16
Bolt :
À
10 Nm, 1.0 m.kg, 7.2 ft. lb.)
2. Inspect :
• Bolt À (Muffler)
Loose/Damage Ÿ Tighten /replace.
Bolt :
15 Nm (1.5 m.kg, 7.2 ft. lb)
3. Inspect :
Á • Screw Á (Muffler Protector) - 6 Nos.
Á Loose/ damage Ÿ Tighten/replace
4. Inspect
• Muffler Catcon
Blockage/damage Ÿ Clean/Replace
¿ 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.
3-15
R-17
INSP
AIR FILTER CLEANING ADJ
1. Remove:
• Side Cover (R.H.)
¿ • Air Filter Case Cap ¿ - Unscrew 4 Nos.
Screws
• Spring Wire À
• Air Filter Element Á
• Element guide Â
CAUTION:
WARNING
Never operate the Engine without the Air
Filter element installed. Unfiltered air will
cause rapid wear of Engine parts and may
damage the Engine. Operating the Engine
À without the Air Filter Element will also affect
the Carburetor tuning, leading to poor
Engine performance and possible
overheating.
2. Inspect:
• Air Filter Element Á
Damaged Ÿ Replace.
3. Clean:
• Air Filter Element Á
Use kerosene to clean the Element.
NOTE :
After cleaning, remove the remaining kerosene
by squeezing rhe element.
CAUTION:
WARNING
Do not twist the Air Filter Element when
squeezing it.
4. Apply the recommended oil to the entyre
surface of the Air Filter Element uniformly
and squeeze out the excess oil.
Recommended oil :
YAMALUBE (20W40) or equivalent
WARNING
Never use low flash point solvents such as
gasoline to clean the Air Filter Element. Such
solvents may cause a fire or an explosion
5. Assemble
• Air Filter Element on Element Guide
6. Install :
• Air Filter Element Assy.
• Spring Wire
• Air Filter Case Cap
• Side Cover (R.H.)
3-16
L-18
INSP
CLUTCH CABLE ADJUSTMENT ADJ
CLUTCH CABLE ADJUSTMENT
1. Check :
• Clutch Cable free play ç
Out of specification Ÿ Adjust,
Free play (clutch lever) :
ç 10 ~ 15 mm at lever end
2. Adjust:
• Clutch Cable free play
ææææææææææææææææææææææææææææææææææ
Adjustment steps:
Lever side
À • Loosen the Locknut ¿
è • Turn the Adjuster À in or out until the speci-
fied free play is obtained.
Turning in ç Ÿ Free play is increased.
ç
Turning out è Ÿ Free play is decreased.
¿
• Tighten the locknut ¿
NOTE :
If not possible to achieve the specified free play
at the Clutch Lever end then adjust it by using
Adjuster below the Carburettor.
3-17
R-19
CAUTION:
WARNING
Make sure that there is no Brake drag after
adjusting the Front Brake Lever free play.
NOTE :
è If not possible to achieve the specified free play
in Brake Lever then adjust it with Adjuster on
ç
the Wheel end of the Front Brake Cable.
Wheel side
Á • Turn the Adjuster Á in or out until the speci-
fied free play is obtained.
3-18
L-20
1. Check :
• Brake light operation timing
Incorrect Adjust.
2. Adjust:
• Brake light operating timing.
ææææææææææææææææææææææææææææææææææ
¿ Adjustment steps:
• Hold the main body ¿ of the switch with your
hand so that it does not rotate, and turn the
adjuster À in or out until the proper operation
À timing is obtained.
ææææææææææææææææææææææææææææææææææ
3-19
R-21
INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
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 tight-
ç est point.
• Check and if necessary adjust the Drive
Chain slack with the Rear Wheel in this “tight-
est” position.
CAUTION:
WARNING
Too little chain slack will overload the engine
and other vital parts; keep the slack within
the specified limits.
• Excessive Chain slack will cause abnormal
noise and will affect the life of chain, sprock-
ets and low fuel efficiency.
WARNING
• Securely support the Motorcycle so that
Â
there is no danger of it falling over.
À • Stand the Motorcycle on its centerstand.
Á
¿
1. Stand the Motorcycle on its center stand.
2. Check :
• Drive chain slack ç
Out of specification Ÿ Adjust.
3-20
L-22
INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Loosen both the Locknuts Â.
 • Turn the Adjuster Á in or out until the speci-
ç fied Drive Chain slack is obtained.
Turning in ç Ÿ Drive Chain slack is
è decreased.
à Á
Turning out è Ÿ Drive Chain slack is
increased.
NOTE :
• Turn each Chain Adjuster exactly the same
amount to maintain correct Axle alignment. To
check the alignment there are marks on Chain
Adjuster Ã. Ensure that left hand and right
hand chain alignment marks are equally
matched. Use them when adjusting the slack
for proper alignment.
• Before tightening the Axle Nut Ä and Driven
Sprocket Locknut to specifications, make sure
that there is no clearance at the Adjuster (or
the Swing Arm end) on both sides by pushing
the Wheel forward.
6. Install :
• Cotter pin Å New
Into the Axle Nut and bend the end of the
Cotter Pin.
New
CAUTION:
WARNING
Å Do not loosen the Axle Nut after tightening
the torque. If the axle nut grooves is not
aligned with the Cotter Pin hole, align the
groove with the hole by tightening up the
Axle Nut.
WARNING
Always use a new cotter pin.
7. Adjust :
• Brake Pedal free play
Refer to “BRAKE FREE PLAY“ section.
page no 3-18
3-21
R-23
INSP
STEERING HEAD INSPECTION ADJ
STEERING HEAD INSPECTION
WARNING
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 Center Stand.
INSP
STEERING HEAD INSPECTION ADJ
NOTE :
Set the Torque Wrench to the Ring Nut Wrench
so that they form a right angle.
WARNING
Avoid over torquing.
• Check the Steering Stem by Turning it Lock to
Lock. If there is any binding, remove the Steer-
ing Stem Assembly and inspect the Steering
Bearings.
Refer to “STEERING HEAD AND HANDLE-
BAR” section in Chapter 6 Page no 6-29
• Install the Damper Rubber Á and Ring Nut À
(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.
6. Install :
• Handle crown ¿
• Handle Crown bolt À
• Handlebar Á
• Handlebar upper holder  - 2 Nos
Ä • Bolts (handlebar upper holders) Ã-4 Nos.
• Bands Ä - 2 Nos.
Á Â
Ä
à Bolts (handle crown and inner tube)
À ¿
23 Nm (2.3 m.kg, 17 ft.lb)
Bolt (handle crown and Steering
Shaft )
35 Nm (3.5 m. kg, 25 ft.lb)
3-23
R-25
INSP
FRONT FORK INSPECTION ADJ
FRONT FORK INSPECTION
WARNING
Securely support the motocycle so that there
is no danger of it falling over.
WARNING
• Always adjust each Rear Shock Absorber
preload to the same setting. Uneven ad-
justment 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 ç
or è using a plain rod.
ç è
3-24
L-26
INSP
REAR SHOCK ABSORBER ADJUSTMENT ADJ
ææææææææææææææææææææææææææææææææææ
Adjustment steps:
• Turn the Adjuster Ring in or out.
ç è
Turning toward ç Ÿ Spring preload is
Decreased.
Turning toward è Ÿ Spring preload is
Increased.
Adjustment numbers:
Standard 4
Minimum 1
Maximum 5
CAUTION:
WARNING
• Never turn the Adjuster beyond the maxi-
mum or minimum setting.
• Always adjust each Shock Absorber to the
same setting.
ææææææææææææææææææææææææææææææææææ
TYRE INSPECTION
1. Measure :
• Tyre inflation pressure
Out of specification Ÿ Adjust.
WARNING
• Tyre inflation pressure should only be
checked and adjusted when the Tyre tem-
perature equals the ambient air tempera-
ture. Tyre inflation pressure and suspen-
sion must be adjusted according to the
cargo, rider, pasenger and accessories
(fairing, saddlebags, etc. if approved for
this model), and according to whether the
Motorcycle will be operated at high speed
or not.
NEVER OVERLOAD THE MOTORCYCLE.
• Operation of an overloaded Motorcycle
could cause tyre damage, accident or injury.
3-25
R-27
INSP
TYRE INSPECTION ADJ
2. Inspect :
• Tyre surfaces
Wear/damage Ÿ Replace
WARNING
After mounting a Tyre, ride conservatively
for a while to give the Tyre time to seat it-
self properly in the Rim, Failure to do so
could lead to an accident with possible in-
jury to the rider or damage to the Motor-
cycle.
Locknut:
1.5 Nm (0.15 m.kg, 1.1 ft.lb)
3-26
L-28
INSP
SPOKE INSPECTION AND TIGHTENEING ADJ
SPOKES INSPECTION AND
TIGHTENING
¿ 1. Inspect :
• Spokes ¿
Bending/damage Ÿ Replace.
Loose spoke Ÿ Retighten
2. Tighten :
• Spokes
Nipple Tighting Tool
YSST - 629
NOTE :
Be sure to tighten the Spokes before and after
break-in.
WHEEL INSPECTION
1. Inspect :
• Wheels
Damage/Bends Ÿ Replace.
NOTE :
Always balance the wheel when a tyre or wheel
has been changed or replaced.
WARNING
Never attempt to make any repairs to the
wheel rim.
3-27
R-29
INSP
FRONT BRAKE FLUID LEVEL ADJ
I
FRONT BRAKE FLUID LEVEL
INSPECTION
1. Place the motorcycle on a level place.
NOTE :
• Position the motorcycle straight up when
inspecting the brake fluid level.
• When inspecting the front brake fluid level
make sure the master cylinder top is
horizontal by turning the handlebars.
2. Inspect:
¿ • Brake fluid level
• Fluid level is under “LOWER”level line ¿
Ÿ Fill up.
CAUTION:
WARNING
WARNING
• Use only the designated quality brake fluid:
otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor
performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
3-28
L-30
INSP
AIR BLEEDING ADJ
1. Bleed
• Brake system
ææææææææææææææææææææææææææææææææææ
Air bleeding steps :
a. Add proper brake fluid to the reservoir.
À b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect the clear plastic tube ¿ tightly to
the caliper bleed screw À.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
À
h. Tighten the bleed screw when the lever limit
has been reached; then release the lever.
Bleed screw:
6 Nm (0.6 m.kg., 4.0 ft.lb)
3-29
R-31
INSP
CABLE INSPECTION AND LUBRICATION ADJ
CABLE INSPECTION AND
LUBRICATION
WARNING
Damaged cable sheth may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace such
cable as soon as possible.
1. Inspect:
¿ • Cable sheath ¿
Damage Ÿ Replace.
2. Check:
• Cable operation
Unsmooth operation Ÿ Lubricate.
Recommended lubricant:
Yamaha Chain and Cable Lube
or motor oil SAE 20W40
¿
NOTE:
Hold cable end high and apply several drops of
lubricant to cable.
LEVER LUBRICATION
Lubricate the lever ¿ at their pivoting points.
Recommended lubricant:
Yamaha Chain and Cable Lube
or motor oil SAE 20W40
3-30
L-32
INSP
BATTERY INSPECTION ADJ
BATTERY INSPECTION
1. Remove:
• Side Cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 Fazer
Manual.
2. Inspect:
• Electrolyte level
Electrolyte level should be between the
upper ¿ and lower À level marks.
Electrolyte level is too low Ÿ Add
distilled Water to proper level.
WARNING
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
3. Inspect:
• Battery terminals
Dirt Ÿ Clean with a wire brush.
Poor connection Ÿ Correct
NOTE :
¿
After cleaning the terminals, apply a light coat
À
of grease to the terminals.
4. Inspect:
Á • Breather hose Á
Obstruction Ÿ Remove
Damage Ÿ 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
damage the motorcycle and ruin its finish.
5. Connect:
• Breather hose Á
Make sure tha the hose is properly
attached and routed.
6. Check:
• Specific gravity
Less than 1.280 g/dm3 Ÿ Recharge the
battery.
Charging Current : 0.50 amp.
Specific Gravity: 1.280 g/dm3 to 20o C
3-31
R-33
INSP
BATTERY INSPECTION ADJ
ææææææææææææææææææææææææææææææææææ
Replace the battery if:
• Battery voltage will not rise to a specific
value or bubbles fail to rise during
charging.
• 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.
ææææææææææææææææææææææææææææææææææ
CAUTION:
Always charge a new battery before using
it to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic. always follow these preventive
measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
• Wear protective eye wear when handling
or working 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
followed with milk of magnesia, beaten
egg or vegitable oil. Get immediate
medical attention.
• 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.
3-32
L-34
INSP
BATTERY CHARGING / FUSE INSPECTION ADJ
7. Install:
• Battery
8. Connect:
• Battery leads
CAUTION:
Connect the positive lead ¿ first and then
¿
À connect the negative lead À.
9. Connect:
• Breather hose
Be sure the hose is propely attached and
routed.
Refer to “CABLE ROUTING” Chapter 2
Page 2-8.
10. Install:
• Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 Fazer
Service Manual.
FUSE INSPECTION
CAUTION:
Always turn off the main switch when
checking or replacing the fuse. Otherwise,
a short circuit may occur
1. Remove:
• Side Cover (LH)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 Fazer
Service Manual.
• Fuse Holder ¿
2. Inspect:
• Fuse
¿ ææææææææææææææææææææææææææææææææææ
Inspection steps :
• Connect the Multimeter to the fuse and
check it for continuity.
NOTE :
Set the Multimeter selector to “Ω x 1” position
Multimeter.
3-33
R-35
INSP
FUSE INSPECTION ADJ
3. Replace:
• Blown fuse
ææææææææææææææææææææææææææææææææææ
Replacement steps:
• Turn off the main switch.
• Install a new fuse with the proper current
rating.
• Turn on switches to verify operation of related
electrical devices.
• If the fuse blows again immediately, check the
electrical circuit.
WARNING
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 extensive damage to the electrical
system, malfunction of lighting and ignition
systems and could possibly cause a fire.
4. Install:
• Fuse holder
• Side cover (LH)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 “Fazer”
Service Manual.
3-34
L-36
NOTE :
In standard setting projection provided on
Cowling strip Á should align with projection Â
provided on stay.
WARNING
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:
WARNING
Avoid touching glass part of bulb. Also keep
it away from oil otherwise, transparency of
glass, bulb life and brightness will be ad-
versely affected. If oil gets on bulb, clean it
with a cloth moistened thoroughly with al-
cohol or lacquer thinner.
3-35
R-1
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL
SIDE COVERS, SEAT AND FUEL TANK REMOVAL ................4-1
ENGINE OIL DRAIN ...................................................................4-1
BATTERY ....................................................................................4-1
CARBURETOR ...........................................................................4-1
CLUTCH CABLE ........................................................................4-1
DRIVE CHAIN .............................................................................4-2
EXHAUST MUFFLER .................................................................4-2
FOOTREST ASSEMBLY ............................................................4-2
SHIFT PEDAL .............................................................................4-3
BATTERY BOX REMOVAL ........................................................4-3
LEADS ........................................................................................4-3
ENGINE REMOVAL ....................................................................4-3
MOUNTING ON ENGINE STAND .............................................. 4-3
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND PISTON ...........................4-4
CLUTCH .....................................................................................4-7
OIL PUMP ...................................................................................4-8
KICK STARTER .......................................................................... 4-9
SHIFT SHAFT .............................................................................4-9
C.D.I. MAGNETO .......................................................................4-10
GUIDE STOPPER AND TIMIMG CHAIN ...................................4-10
CRANKCASE .............................................................................4-11
TRANSMISSION AND SHIFTER ...............................................4-12
CRANKSHAFT ...........................................................................4-12
CYLINDER HEAD ROCKER ARMS, CAMSHAFT & VALVES .. 4-13
INSPECTION AND REPAIRS
CYLINDER HEAD .......................................................................4-15
VALVE SEATS ............................................................................4-16
VALVE SPRINGS AND VALVES ................................................4-18
CAMSHAFT ................................................................................4-19
ROCKER ARMS AND ROCKER ARM SHAFTS .......................4-20
TIMING CHAIN, SPROCKETS AND CHAIN GUIDES...............4-21
TIMING CHAIN TENSIONER .....................................................4-21
CYLINDER AND PISTONS ........................................................4-22
PISTON RINGS .......................................................................... 4-23
PISTON PIN................................................................................4-24
CRANKSHAFT ...........................................................................4-25
PRIMARY DRIVE GEAR ............................................................4-26
CLUTCH .....................................................................................4-26
PUSH ROD .................................................................................4-27
SHIFT FORK SHIFT CAM .......................................................... 4-28
KICK STARTER .......................................................................... 4-29
OIL PUMP ...................................................................................4-30
OIL DELIVERY PASSAGE(CC COVER RH) .............................4-31
CRANKCASE .............................................................................4-31
L-2
ENG
MAINTENANCE SPECIFICATIONS
BEARINGS AND OIL SEALS ......................................................4-31
CIRCLIPS AND WASHERS .......................................................4-31
ENGINE ASSEMBLY AND ADJUSTMENT ................................4-32
CRANKSHAFT ...........................................................................4-35
TRANSMISSION ........................................................................4-37
SHIFTER.....................................................................................4-38
CRANKCASE .............................................................................4-40
CDI MAGNETO...........................................................................4-42
SHIFT SHAFT AND KICK STARTER .........................................4-44
CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP ................4-47
CYLINDER AND PISTON ...........................................................4-52
CYLINDER HEAD .......................................................................4-53
CAM SPROCKET AND TIMING CHAIN ....................................4-54
ENGINE MOUNTING .................................................................4-60
R-3
ENG
ENGINE REMOVAL
ENGINE REMOVAL
¿ À CARBURETOR
1. Loosen
• Air cleaner case mounting bolts ¿ - 4 Nos.
• Hose Clamp assy À
2. Remove
• Throttle Cable Á
à • Carburetor Mounting Clamp Â
Á • Air vent hose
• Carburetor Ã
 Refer to the “CARBURETOR” section in Chap-
ter 5, Page no 5-2
NOTE :
À
Cover the Carburetor with a clean cloth to pre-
vent dirt or foreign material from entering the
Carburetor.
4-1
L-4
ENG
ENGINE REMOVAL
À CLUTCH CABLE
1. Remove :
• Clutch cable
ææææææææææææææææææææææææææææææææææ
Removal steps :
• Loosen the locknut ¿ of the Clutch Lever.
¿ • Turn in the Adjuster À to enough to free the
inner Clutch Cable
• Unhook the Cable End from Push Lever Á on
the Crankcase L.H.
ææææææææææææææææææææææææææææææææææ
3
DRIVE CHAIN
1. Remove :
• Crankcase Cover#1 (L.H.) ¿
• Drive Chain Case upper À and lower Á
2. Slack off the Drive Chain
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” section in Chapter 3, Page no 3-20
¿ 3. Remove :
Á À
• Bolt ¿ (Holder Sprocket)
• Holder Sprocket À
• Sprocket Drive Á
Á Remove with the Drive Chain
¿ EXHAUST MUFFLER
1. Remove :
À • Bolt (exhaust pipe)
• Bolt (muffler)
Refer to “EXHAUST SYSTEM” section in
Chapter 3, Page no 3-15
2. Remove :
• Exhaust muffler
FOOTREST ASSEMBLY
1. Remove:
• Bolt (footrest) ¿ - 2 Nos. (LH & RH)
• Bolt Axle - Lower rear mounting À
À • Footrest Assembly
À
¿
4-2
R-5
ENG
ENGINE REMOVAL
SHIFT PEDAL
1. Remove
• Bolt (Shift Pedal) ¿
• Shift Pedal À
BATTERY BOX
¿
1. Remove
¿ • Bolt (Battery Box) ¿ 3 nos
À • Battery Box À
LEADS
1. Disconnect:
• Stator Coil Lead Coupler ¿
• Sensor Coil Lead Coupler À
À 2. Remove :
• Spark Plug Cap
¿
ENGINE REMOVAL
1. Remove :
Ç • Engine Mount Bolt (front centre) ¿
• Bolt (Engine Mount stay front upper) À
Æ • Bolt (Engine Mount stay front lower) Á
• Engine Mount Bolt front lower Â
È • Engine Mount stay Ã
Å • Engine Mount Bolt (bottom rear) Ä
• Engine Mount Bolt (upper rear) Å
• Engine mount stay upper Æ
• Bolt AIS Mounting on stay Ç - 2 Nos.
À
• Engine Mount Stay È
Á
3. Remove :
¿ • Engine Assembly
Â
Ä
à 4. Mount
• Engine on Engine Stand
4-3
L-6
ENG
ENGINE DISASSEMBLY
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND
PISTON
NOTE:
With Engine mounted on Motorcycle, the Cyl-
inder Head, Camshaft and Cylinder can be
maintained by removing the following parts.
• Side Covers • Spark Plug Lead
• Seat • Engine Mount Stay
• Chain Tensioner (upper)
À (Retract ) • Timing Check Plug
Á • Exhaust Pipe • Center Plug
• Carburetor • AIS Clamps
¿ ¿
CAUTION:
WARNING
Before Engine disassembly clean the outer
body of Engine properly
1. Remove :
• Spark Plug
¿ • Bolts (Intake Manifold) ¿ 2 nos
• Intake Manifold À
À • Valve Cover with ‘O’ ring Á
2. Remove
• Timing Check Plug (with ‘O’ ring) ¿
• Centre Plug (with ‘o’ ring) À
3. Align :
• Piston to TDC position
NOTE:
è Turn the Crankshaft anticlockwise with a
ç
Socket Spanner 17 mm
ææææææææææææææææææææææææææææææææææ
TDC alignment steps:
• Turn the Crankshaft anticlockwise until the slit
(cut mark on magneto) ç matches the station-
ary pointer è
ê • Align the “I” mark é on the Cam Sprocket with
the stationary pointer ê on the Cylinder Head,
é the Piston is at the Top Dead Center (TDC)
of compression stroke.
NOTE :
To confrim that the Piston is at TDC of com-
pression stroke, check Rocker Arms for free
movement.
4-4
R-7
ENG
ENGINE DISASSEMBLY
5. Remove :
• Tensioner Cap Bolt ¿
• Retract completely the Tensioner Rod by
¿
Screw in (clockwise) direction.
Á • Bolts (timing chain tensioner ) À 2 Nos
• Timing Chain Tensioner Assembly Á
À • Gasket
À 6. Remove :
¿ • Bolt (cam sprocket) ¿
• Plate washer (cam sprocket) À
• Cam sprocket Á
Á
NOTE :
Hold the Nut Rotor with socket spanner for
opening Cam Sprocket Bolt. Fasten a safety
wire  to the Timing Chain to prevent it from
falling in the Crankcase.
Á Ä
7. Remove :
• Bolts (Cylinder Head) as per sequence.
à (6 nos)
Â
• Cylinder Head
NOTE :
¿ À
• Loosen the Bolts 1/4 turn each and remove
then after all are loosened.
• Reomve the Bolts starting with the lowest
Á number one.
¿ 8. Remove :
À • Guide Stopper #1 ¿
 • Dowel Pins À
• Gasket (Cylinder Head) Á
• Cylinder Â
4-5
L-8
ENG
MAINTENANCE SPECIFICATIONS
9. Remove :
À • Dowel Pins ¿ - 2 Nos
• Gasket (Cylinder) À
10. Remove :
Á
• Piston Pin Circlip ¿ 2 nos
• Piston Pin À , using Piston Pin Replacer
À
• Piston Á
¿ NOTE :
Before removing the Piston Pin Circlip, cover
the Crankcase with a clean cloth to prevent the
Circlip from falling into the Crankcase cavity.
C. D. I. MAGNETO
NOTE :
The CDI Magneto can be removed while the
Engine is mounted on the Motorcycle by remov-
ing the following parts :
• Shift Pedal
• Cover Chain Case (L. H.)
1. Remove :
¿ • Bolts (Crankcase Cover-1 L.H.) ¿ - 7 nos
• Crankcase Cover-1 (L.H.)
• Neutral Light wire from Neutral Switch
NOTE :
Loosen the Bolts in criss cross pattern.
¿ 2. Attach
• Magneto holder - ¿
Magneto Holder :
YSST - 627
4-6
R-9
ENG
ENGINE DISASSEMBLY
CLUTCH
À NOTE :
Á The Clutch Assembly can be removed while the
Engine is mounted on the Motorcycle by remov-
ing the following parts and draining the Engine
oil:
• Kick Starter.
Á
¿
1. Remove :
• Nut kick Crank assy ¿.
• Kick Crank Assy À.
• Bolts Crankcase Cover-2 (R.H.) Á - 9 nos
• Crankcase Cover (RH)
NOTE :
¿ • Hold Kick Crank Assy. at extreme down posi-
tion for opening the Nut Kick Crank Assy.
• Loosen the Bolts of Crankcase Cover #2 (RH)
À in a crisscross pattern.
2. Remove :
• Gasket ¿
• Dowel pins À - 2 Nos
3. Remove:
• Pressure Plate Bolts ¿ - 4 Nos
• Clutch Springs À - 4 Nos
• Pressure Plate Á with Push rod 1
• Friction Plates à - 4 Nos
• Clutch Plates  - 3 Nos
NOTE :
Loosen the Pressure Plate Bolts in a crisscross
pattern.
4. Remove :
• Ball Ä
5. Loosen :
• Straighten the Lock Washer tab.
• Nut (clutch boss) ¿
¿ NOTE :
Loosen the Clutch Boss Nut ¿ while holding the
À Clutch Boss À with the Clutch Holder.
4-7
L-10
ENG
ENGINE DISASSEMBLY
6. Remove :
Á Â Ã
• Clutch Boss Nut ¿
¿ À • Lock Washer À
• Clutch Boss Á
• Thrust Washer Â
• Clutch Housing Ã
7. Loosen :
• Nut ¿ (Primary Drive Gear)
¿
NOTE :
• Open the Nut (Primary Drive Gear) by holding
the Magneto with Magneto Holder.
Magneto Holder
YSST - 627 A
À 8. Remove
• Nut
¿ • Plate Washer
• Primary Drive Gear ¿
• Key À
• Rotary Filter Á
Á
OIL PUMP
NOTE :
The oil pump can be removed while the engine
is mounted by removing the following parts
• Clutch
• Primary drive gear
• Rotary filter
¿ 1. Remove :
• Gear pump drive ¿
À • Screw (oil pump-2 nos) À
Á • Oil pump assembly Á
• Gasket (oil pump)
• Oil strainer Â
4-8
R-11
ENG
ENGINE DISASSEMBLY
KICK STARTER
NOTE :
The kick starter can be removed while the en-
gine is mounted by removing the following part.
• Kick Crank Assy
• Crankcase Cover 2 (RH)
• Clutch Drum Assy
Á
Á
1. Remove :
¿
¿ • Circlip ¿
• Plate washer À
À
À • Gear Kick idle Á
• Plate washer
• Circlip
2. Remove :
¿ • Torsion spring ¿
• Kick axle assembly À
À
SHIFT SHAFT
NOTE :
The Shift Shaft can be removed while the Engine
 is mounted by removing the following parts.
Á
• Shift Pedal • Kick Crank Assy.
¿ • Crankcase Cover#2(RH) • Clutch
À
1. Remove :
• Shift Shaft ¿
• Torsion Spring À
Â
• Bolt (stopper lever) Á
• Stopper Lever Â
4-9
L-12
ENG
ENGINE
CDI MAGNETO REMOVAL
1. Remove :
• Screw - 2 Nos. ¿
¿
• Chain cover (Half) À
À
NOTE :
The CDI magneto can be removed while the
engine is mounted by removing the shift pedal.
Magneto Holder :
YSST - 601 - B
2. Remove
Á
• Crank case cover #1
• Neutral switch lead ¿
• Gasket À
• Dowel Á
À • Nut (magneto) Â
Ã
 • Plain washer Ã
¿
3. Remove
• C.D.I. Magneto ¿
• Wood-ruff key
¿ CAUTION:
WARNING
• Cover the crankshaft end with the spacer.
Magneto Puller :
YSST - 628
NOTE :
• Remove the magneto using the flywheel
À puller À with spacer Á.
Á • Center the flywheel puller over the magneto.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the magneto is the same every-
where. If necessary, one holding bolt may
be turned out slightly to adjust the flywheel
puller’s position.
Ã
4. Remove :
 • Starter idler gear ¿
À
• Washer À
5. Remove
• Screw - 2 Nos. Á
• Plate Â
¿ Á
• Starter idler gear Ã
4-10
R-13
ENG
ENGINE DISASSEMBLY
À
Á
5. Remove :
• Torx Screw ¿ (Segment) using Torx Bit.
Torx Bit :
YSST - 611
¿
WARNING
Never use Phillips screw driver
¿ CRANKCASE
1. Remove :
• Bolts (Crankcase RH-2 nos) ¿
¿ 2. Remove :
• Bolts (Crankcase LH-8 nos)
Â
Á
NOTE :
• Loosen the Bolts in a crisscross pattern.
Ä • Loosen each Bolts 1/4 turn at a time and re-
Ã
move them after all are loose.
Å Æ
À
1. Remove :
• Right crankcase half
NOTE :
Open the Engine stand mounting Nuts 2 nos .
ç Then separate the Crankcase by using the flat
ç
head screw driver in the separating slit ç.
4-11
L-14
ENG
ENGINE DISASSEMBLY
CAUTION:
WARNING
À ¿ • Do not use the flat head screw driver ex-
cept at the separating slot.
• Separate the Crankcase after first check-
ing that the shift cam segments and the
Drive Axle Circlip can be removed.
• Do not damage the Crankcase mating sur-
faces.
2. Remove :
• Dowel pins ¿
• Balancer À
¿ À
3. Remove :
• Neutral switch ¿
¿
• Gasket neutral switch
4-12
R-15
2. Remove :
¿
• Crankshaft ¿ using Crankshaft removal
tool À
NOTE :
Fully tighten the Crankshaft removal tool hold-
ing Bolts, but make sure that the tool body is
parallel with the Crankcase. If necessary, one
holding bolt may be turned out slightly to adjust
the Crankshaft Removal Tool’s position.
3. Attach
¿
• Rocker arm shaft puller ¿
5. Remove :
• Camshaft Assy ¿ with spacer À
NOTE :
Before the Valves, Valve Springs, Valve Stem
Seals, etc. are removed from the Cylinder Head,
the Valve sealing should be checked.
4-13
L-16
ENG
ENGINE DISASSEMBLY
6. Check
• Valve sealing
Leakage at the valve seat Ÿ Inspect the
valve face, valve seat and seat width.
Refer to “INSPECTION AND REPAIR
VALVE SEAT”. on Chapter 4 Page no 4-16
ææææææææææææææææææææææææææææææææææ
Checking Steps :
• Pour clean petrol ¿ into the intake and ex-
haust ports.
• Check the valve sealing. There should be no
leakage at the valve seat À
ææææææææææææææææææææææææææææææææææ
7. Attach
¿
Valve Spring compression Tool ¿
À
Valve Spring Compressor :
YSST - 603
8. Remove :
• Valve Cotters À
NOTE :
Valve Spring compressor tool is to be attached
between the Valve Spring retainer and the Valve
face (Inlet and Exhaust) one at a time.
9. Remove :
• Valve Spring Retainer ¿
• Valve Spring À
• Valve Á
• Valve Stem Seal Â
• Valve Spring Seat Ã
NOTE :
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
4-14
R-17
CYLINDER HEAD
1. Remove :
• Carbon deposits from combustion
chambers using a rounded scraper.
NOTE :
Do not use a sharp instrument to avoid dam-
aging or scratching :
• Spark Plug threads
• Valve seats
2. Inspect :
• Cylinder Head
Scratches/damage Ÿ Replace
3. Measure :
• Cylinder Head warpage
Out of specification Ÿ resurface/ replace.
ææææææææææææææææææææææææææææææææææ
Warpage measurement and resurfacement
steps:
• Place a straightedge ¿ and a feeler gauge À
across the Cylinder Head.
• Measure the warpage.
• If the warpage is out of specification, resur-
face the Cylinder Head/replace if necessary.
• Place a 400 ~ 600 grit wet abrasive paper on
the surface plate, and resurface the Head
using a figure-eight sanding pattern.
NOTE :
Rotate the Cylinder Head several times for an
even resurfacement.
ææææææææææææææææææææææææææææææææææ
4-15
L-18
ENG
INSPECTION AND REPAIR:VALVE SEATS
VALVE SEATS
1. Remove :
• Carbon deposits from the Valve Face and
Valve Seat.
2. Inspect :
• Valve Seats
Pitting/wear Ÿ reface the valve seat.
3. Measure :
• Valve Seat width ç
Out of specification Ÿ Reface the Valve
Seat.
ææææææææææææææææææææææææææææææææææ
Measurement steps :
• Apply Mechanic’s blueing dye (Dykem) è to
the valve face.
• Install the Valve in the Cylinder Head
• Press the Valve through the Valve Guide and
onto the valve seat to make a clear pattern.
• Measure the Valve Seat width. Where the
Valve Seat and Valve Face made contact,
blueing will have been removed.
• If the Valve Seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be refaced.
ææææææææææææææææææææææææææææææææææ
4. Lap :
• Valve face
• Valve seat
NOTE :
After refacing the Valve Seat or replacing the
Valve, the Valve Seat and Valve Face should be
lapped.
4-16
R-19
ENG
INSPECTION AND REPAIRS
ææææææææææææææææææææææææææææææææææ
Lapping steps :
• Apply coarse lapping compound ç to the Valve
Face
CAUTION:
WARNING
Do not let compound enter the gap between the
Valve Stem and the Guide.
• Apply molybdenum disulfide oil to the Valve
Stem.
• Install the Valve into the Cylinder Head.
• Turn the Valve in one Direction using the Valve
lapping tool until the Valve Face and Valve
Seat are evenly polished, then clean off all
compound.
NOTE :
For best lapping results, lightly tap the Valve
seat while rotating the Valve.
NOTE :
Make sure to clean off all compound from the
Valve face and Valve seat after every lapping
operation.
4-17
L-20
2. Measure :
• Spring tilt ç
Out of specification Ÿ Replace
3. Check
• Spring contact face
Wear/pitting/scratches Ÿ Replace
4. Measure :
• Valve guide inside diameter
5. Measure :
Valve stem diameter
4-18
R-21
ENG
ENGINE INSPECTION AND REPAIR
6. Calculate :
Stem Guide Clearance
Stem-to-guide clearance =
Valve guide inside diameter –
Valve stem diameter
Runout Limit :
0.01 mm
CAMSHAFT INSPECTION
1. Inspect :
• Cam lobes
Pitting/scratches/blue discoloration Ÿ
Replace
2. Measure :
ç • Cam lobes dimension ç and è
Out of specification Ÿ Replace.
è
Cam lobes dimension :
Intake :
ç 25.881 ~ 25.981 mm
<limit 25.851 mm>
è 21.195 ~ 21.295 mm
<limit 21.165 mm>
Exhaust :
ç 25.841 ~ 25.941 mm
<limit 25.811 mm>
è 21.05 ~ 21.15 mm
<limit 21.02 mm>
3. Inspect :
• Camshaft oil passage
Chocked Ÿ Blow out oil passage with
compressed air.
4-19
L-22
ENG
ENGINE INSPECTION AND REPAIR
ROCKER ARMS AND ROCKER ARM
SHAFTS INSPECTION
1. Inspect :
• Cam lobe contact surface ¿
• Adjuster surface À
Wear/pitting/scratches/blue discoloration Ÿ
¿ Replace
À ææææææææææææææææææææææææææææææææææ
Inspection steps :
• Inspect the two contact areas on the Rocker
Arms for signs of unusual wear.
• Rocker Arm Shaft hole
• Cam-lobe contact surface
Excessive wear Ÿ Replace
• Inspect the surface condition of the Rocker
Arm Shafts
Pitting/scratches/blue discoloration Ÿ Re-
place and check lubrication route
• Measure the inside diameter ç of the Rocker
Arm holes
Out of specification Ÿ Replace
ææææææææææææææææææææææææææææææææææ
4-20
R-23
ENG
ENGINE INSPECTION AND REPAIR
TIMING CHAIN, SPROCKETS AND
CHAIN GUIDES
1. Inspect :
• Timing Chain
Wear out/Stiffness/damage Ÿ Replace the
Chain and the Sprockets as a set.
2. Inspect :
• Cam Sprocket
Wear/damage Ÿ Replace the Cam
Sprocket and the timing chain as a set.
3. Inspect :
• Guide Stopper #1 ¿
• Guide Stopper # 2 À and Bush
Wear/damage Ÿ Replace
À
4-21
L-24
ENG
ENGINE INSPECTION AND REPAIR
CYLINDER AND PISTONS
1. Inspect :
• Cylinder and Piston walls
Vertical scratches Ÿ Rebore or replace
the Cylinder and the Piston
2. Measure :
• Piston-to-Cylinder clearance
ææææææææææææææææææææææææææææææææææ
Measurement steps :
1st step :
• Measure the Cylinder Bore “C” with a Cylin-
der Bore Gauge.
NOTE :
Measure the Cylinder Bore “C” in parallel to and
at right angles to the Crankshaft. Then, find the
average of the measurements.
Piston-to-Cylinder clearance :
0.020 ~ 0.025 mm
4-22
R-25
ENG
ENGINE INSPECTION AND REPAIR
PISTON RING INSPECTION
1. Measure :
• Side clearance
Out of specification Ÿ Replace the Piston
and the Piston Rings as a set
NOTE :
Remove the carbon deposits from the Piston
Ring Grooves and Rings before measuring the
side clearance.
Side clearance :
Top Ring : <Limit>
0.030 ~ 0.07 mm
2nd Ring : <Limit>
0.020 ~ 0.060 mm
2. Position :
• Piston Ring
5mm
1 (in the Cylinder bore)
NOTE :
Push the Ring with the Piston Crown so that
the Ring will be at right angles to the Cylinder
Bore 5 mm from the bottom side.
3. Measure :
• End gap ¿ using a feeler gauge
Out of specification Ÿ Replace
NOTE :
You cannot measure the end gap on the ex-
pander spacer of the Oil Ring, If the Oil Ring
Rails show excessive gap, replace all three
Rings.
Eng gap :
Top Ring : 0.15 ~ 0.30 mm
<limit> : <0.40 mm>
2nd Ring : 0.30 ~ 0.45 mm
<Limit> : <0.55 mm>
Oil Ring : 0.2 ~ 0.7 mm
4-23
L-26
ENG
ENGINE INSPECTION AND REPAIR
PISTON PIN INSPECTION
1. Inspect :
• Piston Pin
Blue discoloration/grooves Ÿ Replace and
inspect the lubrication system
2. Measure :
• Piston Pin-to-Piston clearance
ææææææææææææææææææææææææææææææææææ
Measurement steps.
• Measure the Piston Pin outside diameter ç
ç using a micrometer. If out of specification, re-
place the Piston Pin.
ææææææææææææææææææææææææææææææææææ
4-24
R-27
ENG
ENGINE INSPECTION AND REPAIR
CRANKSHAFT
1. Measure :
• Crankshaft runout, using a Surface plate
and Dial gauge. Keep the Crankshaft on
V blocks and rotate slowly while
measuring.
Out of spescification Ÿ Replace
Runout : 0.01 mm
<limit> : <0.03 mm>
2. Measure :
• Big end side clearance ç using a Feeler
Gauge
Out of specification Ÿ Replace big end
Bearing , Crank Pin and Connecting Rod
3. Measure :
• Crank width ç
Out of specification Ÿ Replace Crankshaft.
Crank width :
46.95 ~ 47.00 mm
4. Inspect :
À
• Crankshaft Sprocket ¿
¿
Wear/damage Ÿ Replace Crankshaft
• Bearing À
Wear/crack/damage Ÿ Replace
Crankshaft
5. Inspect :
• Crankshaft journal oil passage
Clogged Ÿ Blow the oil passage with
compressed air
4-25
L-28
ENG
ENGINE INSPECTION AND REPAIR
BALANCER WEIGHT INSPECTION
1. Inspect:
• Balancer drive gear teeth ¿
• Balancer driven gear teeth À
Wear/damage Ÿ Replace as a set
2. Inspect:
• Balancer Shaft
• Wear/bend/damageŸ Replace
CLUTCH INSPECTION
1. Inspect :
• Friction Plates
Wear/damage Ÿ Replace the Friction
Plates as a set
2. Measure :
• Friction Plate thickness ç using a Vernier
Calliper at four points.
Out of specification Ÿ Replace the
Friction Plates as a set
4-26
R-29
ENG
ENGINE INSPECTION AND REPAIR
4. Inspect :
• Clutch Springs
Damage Ÿ Replace the Clutch springs as
a set.
5. Measure
• Free length (Clutch Spring) ç
¿ Out of specification Ÿ Replace the Clutch
springs as a set.
6. Inspect :
• Dogs on the Primary Driven Gear ¿
¿ Scoring/wear/damage Ÿ Deburr or
replace
• Clutch Boss Splines À
Scoring/wear/damage Ÿ Replace
À NOTE :
Scoring on the Clutch Housing Dogs and the
Clutch Boss Splines will cause erratic operation
of the clutch.
2. Inspect :
¿ • Push Rod # 2 ¿
Wear/damage/Bend Ÿ Replace
4-27
L-30
ENG
ENGINE INSPECTION AND REPAIR
SHIFT FORK SHIFT CAM INSPECTION
¿ 1. Inspect :
• Shift Fork follower ¿
• Shift Fork Pawl À
À
Scoring/bends/wear/damage Ÿ Replace
2. Inspect :
• Shift Cam grooves ¿
Wear/damage/scratches Ÿ Replace
• Shift Cam Segment À
Wear/damage Ÿ Replace
À
¿
3. Check :
• Shift Fork movement
(on the Guide Bar )
Unsmooth operation Ÿ Replace the Shift
Fork and the Guide Bar
4. Inspect :
à Ä The assembly for proper working
¿ • Shift Fork “C” (center) ¿
• Shift Fork “R” (right) À
Á • Shift Fork “L” (left) Á
Â Ä • Guide bars (small and big) Â
• Shift Cam Ã
Â
• Shift fork cam follower Ä
Roll the Guide Bar on a flat surface
Bent Ÿ Replace
WARNING
Do not attempt to straighten a bent Guide
Bar.
4-28
R-31
ENG
ENGINE INSPECTION AND REPAIR
5. Measure :
• Axle runout (Main and Drive)
Use a centering device and a dial gauge ¿
Out of specifications Ÿ Replace the bent
Axle
Runout : 0.01 mm
<limit> : 0.03 mm
6. Inspect :
• Gear teeth
Blue discoloration/pitting/wear Ÿ Replace
• Mated Dogs
Rounded edges/cracks/missing portions Ÿ
Replace
À 7. Inspect :
• Shift Shaft ¿
¿
Damage/bent/wear Ÿ Replace
• Return spring (shift shaft) À
Á • Return Spring (stopper lever) Á
Wear/damage Ÿ Replace
2. Measure :
• Torsion spring ¿ force Using a Spring
Gauge
Out of specification Ÿ Replace
4-29
L-32
ENG
ENGINE INSPECTION AND REPAIR
OIL PUMP INSPECTION
1. Measure :
• Tip clearance ç
(between the inner rotor ¿ and the outer
rotor À) using feeler gauge.
• Side clearance è
(between the outer rotor À and the Pump
Housing Á) using feeler gauge
Out of specification Ÿ Replace the Oil
Pump Assembly
• Housing and Rotor clearance é
(between the Pump Housing Á and the
Rotors ¿ and À )
Out of specification Ÿ Replace the Oil
• Pump Assembly
Damage Ÿ Replace
Contamination Ÿ Clean with flushing oil.
Tip clearance ç
0.15 mm <Limit:0.20 mm>
Side clearance è:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
Housing and Rotor clearance é:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
2. Inspect :
¿
• Rotary Filter ¿
Cracks/damage/chocked Ÿ Replace
Contamination Ÿ Clean with flushing oil
3. Inspect :
¿ • Oil strainer ¿
Damage Ÿ Replace
Contamination Ÿ Clean with flushing oil.
4-30
R-33
ENG
ENGINE INSPECTION AND REPAIR
DELIVERY PASSAGE INSPECTION
¿
CRANK CASE RH
1. Check :
• Oil delivery passage
Blockage Ÿ Blow the passage with com-
pressed air.
CRANKCASE
1. Thoroughly wash the crankcase L.H. & R.H.
in mild solvent.
2. Thoroughly clean all the Gasket Mating
surfaces and Crankcase Mating surfaces
using solvent.
3. Inspect :
• Crankcase
Cracks/damage Ÿ Replace
• Oil delivery passages
Blockage Ÿ Blow the passages with
compressed air
2. Inspect :
• Oil Seals À
Damage/ wear Ÿ Replace
4-31
L-34
ENG
ENGINE INSPECTION AND REPAIR
1. Inspect:
• Gear teeth ç, è and é
Burrs/chips/roughness/wear Ÿ Replace
2. Check
• Starter clutch operation
é
ç
ææææææææææææææææææææææææææææææææææææ
Checking steps :
À • Install the starter wheel gear ¿ to the
B
starter clutch À, and hold the starter
clutch.
• When turning the starter wheel gear
A clockwise A , the starter clutch and the
wheel gear should be engaged. If not, the
starter clutch is faulty. Replace it.
¿
• When turning the starter wheel gear
counter closckwise B , the starter clutch
gear should turn freely. If not, the starter
clutch is faulty. Replace it.
ææææææææææææææææææææææææææææææææææææ
R-35
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
ENGINE ASSEMBLY AND ADJUSTMENTS
4-32
L-36
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
WARNING
¿ ¿ For Engine Assembly, replace the following
parts with new ones :
• O-Rings
• Gaskets
• Oil Seals
• Copper Washers
• Lock Washers
• Circlips
à 3. Install :
• Valve Spring Seat ¿
À New • Valve Stem Seal À New
• Valve Á in the valve guide(Cylinder Head)
 • Valve Spring Â
• Spring retainer Ã
NOTE :
Install the Valve Spring with the small pitch è
¿ facing downward
ç facing upwards
è facing downward
4. Install :
À
• Valve Cotters ¿
¿ NOTE :
Install the Valve Cotters while compressing the
valve spring with Valve Spring compressor À
4-33
R-37
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
5. Secure the Valve Cotters onto the Valve
Stem by tapping lightly with a mallet
CAUTION:
WARNING
Do not hit so much as to damage the Valve
2. Apply :
• Molybdenum disulfide oil on the rocker
arm and Rocker Arm Shaft
3. Install :
• Rocker Arm as shown in figure
• Rocker Arm Shaft by pushing it in
completely
4. Install :
À ¿
• Plate ¿
• Bolt À
Bolt (Plate) :
7 Nm (0.7 m.kg, 5.1 ft.lb)
4-34
L-38
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CRANKSHAFT
¿ Crank Pin à Crankshaft Bearing
À Crank Shaft Ä Wood-ruff Key
Á Connecting Rod Å Gear Balancer
 Big end Bearing Æ Balancer Assy.
Ç Bearing
4-35
R-39
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CRANKSHAFT
1. Insert :
• CrankShaft in the Crankcase (L.H.)
2. Attach :
• Crankshaft Installing Tool on Crankshaft
3. Install :
• Crankshaft by tightening the Nut ¿
NOTE :
Hold the Connecting Rod at Top End with one
hand while turning the Nut of the Installing Tool
¿ with the other. Operate the Installing Tool until
the Crankshaft is seated against the Bearing.
CAUTION:
WARNING
To avoid scratching the Crankshaft and to
ease the Installation procedure, apply Engine
Oil onto each Bearing and crankcase LH.
¿ 4. Install :
• Balancer shaft ¿
NOTE :
è When installing the balancer shaft, align the
ç punched mark ç on the crankshaft drive gear
with the punched mark è on the balancer gear.
5. Install :
• Neutral Switch ¿
¿
4-36
L-40
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
TRANSMISSION
¿ Drive Sprocket È Bearing
À Oil Seal É Bearing
Á Bearing Ê 4th Pinion Gear
 4th Wheel Gear Ë 3rd Pinion Gear
à Drive Axle Ì 2nd Pinion Gear
à 2nd Wheel gear Í Main axle
Å 3rd Wheel Gear Î Plate
Æ Clutch Dog Ï Bearing
4-37
R-41
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
SHIFTER
¿ Shift Fork Guide Bar (long) Ä Shift Fork Guide Bar (short)
À Shift Fork # R Å Shift fork # C
Á Shift Fork # L Æ Torx Screw
 Shift Cam Ç Pin Shaft Cam
à Segment
4-38
L-42
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
TRANSMISSION, SHIFT CAM AND
SHIFT FORK INSTALLATION
1. Measure :
• Axle Main Assembled length ç
3. Install :
The following parts in Crankcase LH in
following sequence.
Á
 • Shift Fork “L” (left) ¿
à (face the “L” side for the Clutch side.)
À • Shift Fork “R” (right) À
(face the “R” side for the Clutch side)
• Shift Fork “C” (center) Á
¿
(face the “C” side for the Clutch side)
• Shift Fork Guide Bar #1 Â (Short)
• Shift Fork Guide Bar #2 Ã (Long)
NOTE :
Install the Shift Forks with the embossed mark
facing upward.
4. Check :
• Shift Cam operation
Improper operation Ÿ Reassemble/Repair
NOTE :
Check the transmission and Shift Forks for
smooth operation by turning the Shift cam with
your hand.
4-39
R-43
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
Tightening Sequence ¿
Ç
Â
È
Á
Ä
Ã
Æ
Å
À
CRANKCASE
¿ Crankcase #1 (LH)
À Dowel Pins
Á Crankcase Breather Hose
 Crankcase #2 (RH)
à Holder Clutch Cable
4-40
L-44
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CRANKCASE LH
1. Apply :
• Sealant on the Crankcase Mating surfaces
Sealant
Yamaha bond No. 1215:
2. Install :
• Dowel Pins ¿
NOTE :
ç Do not allow any sealant to come in contact with
the Oil Galleries ç and è as shown in the fig-
ure.
3. Install:
• Crankcase RH with the Crankcasse LH.
Tap lightly on the Case with mallet.
è
NOTE :
Tighten the Engine Mounting Nuts-2 nos for
Ç
holding the Engine on the engine stand.
È
4. Tighten :
• Bolts 2 nos Crankcase RH
• Bolts 8 nos Crankcase LH as per
sequence
Bolts (Crankcase) :
10 Nm (1.0 m.kg, 7.2 ft.lb)
¿
5. Apply :
 • 4-Stroke Engine Oil on the Crank Pin,
Á
Bearings and Oil Delivery Hole
Ä
6. Check :
• Crankshaft and transmission operation for
à smooth rotation/ shifting by hand
Æ
Å Unsmooth operation Ÿ Reassemble/Repair
À
4-41
R-45
ENG
CDI MAGNETO
¿ Starter idle gear 1 Ä Stator assembly
À Plate Å Gasket
Á Washer Æ Dowel pin
 Starter wheel gear 2 Ç Crankcase cover
à CDI Magneto rotor
Á
Â
Ã
¿
À
Ä
Ç
4-42
L-46
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
À
2. Apply
• 4-stroke engine oil.
(onto journal and starter drives)
¿
3. Install
• Washer ¿
• Starter idle gear À
4. Install:
• Wood-ruff key
• Magneto rotor Á
NOTE :
Temporarily install the rotor aligning the key way
of the rotor with the wood-ruff key. Turn the
starter wheel gear clockwise and install the
rotor to the start wheel gear.
5. Tighten :
• Nut (rotor) ¿
À Á
Á Nut (rotor):
70 Nm ( 7.0 m. kg., 51 ft.lb)
NOTE :
• Tighten the nut (rotor) ¿ while holding the ro-
tor À with the magneto holder Á.
Magneto Holder :
YSST 601 - B
4-43
R-47
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
SPROCKET DRIVE
1. Install
• Sprocket Drive ¿
Á • Drive Sprocket Washer À
À 2. Tighten
• Bolt Á (Drive Sprocket) using the
¿ sprocket Holder.
3. Install:
• Dowl pin ¿
• Gasket À
• Crankcase cover (LH)
• Bolts - Seven Nos.
4-44
L-48
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
SHIFT SHAFT AND KICK STARTER
¿ Shift Shaft Å Circlip
À Torsion Spring Æ Washer
Á Stopper Lever Ç Kick Idle Gear
 Return Spring È Kick Shaft Assy.
à Segment É Cover Crankcase # 2
Ä Kick Starter Assembly
4-45
R-49
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
SEGMENT AND SHIFT SHAFT
¿ 1. Install
À
• Dowel Pins ¿ on the Cam Shifter À
2. Install :
• Segment ¿ using Torx Bit Tool
¿ NOTE :
Fit the Dowel Pins on the Cam Shifter to the lo-
cating hole on the Cam Shifter and install the
Segment ¿
3. Install :
¿
Á • Stopper Lever ¿
• Spring À
4. Tighten
À • Bolt stopper lever Á
NOTE :
Hook the Spring ends on the Stopper Lever ¿
and the Crankcase Pin
Mesh the Stopper Lever ¿ with the Cam Shifter
Stopper.
5. Install :
• Shift Shaft Assembly Â
Â
NOTE :
Apply Oil to the Stopper Pin and hook the Spring
ends on the Stopper pin Ã
4-46
L-50
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
KICK STARTER INSTALLATION
1. Install :
¿ À Á Â Ã Ä Å
• Kick axle ¿
• Ratchet gear with return spring À
• Shim Á
• Ratchet gear Â
• Shim Ã
• Torsion spring Ä
• Spacer Å
2. Install :
ç
• Kick Axle Assembly ¿
• Kick Gear Clip À
• Torsion Spring Á
À NOTE :
Turn the Torsion Spring clockwise and hook into
¿ the proper hole ç in the Crankcase.
Á
2. Install :
Following parts on the Axle Drive Ä
• Circlip ¿
• Washer À
• Kick Idle gear Á
• Washer Â
• Circlip Ã
NOTE :
Install Circlips radius side towards the compo-
nent refer Chapter 1, Page no 1-3
4-47
R-51
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP
¿ Clutch Spring Æ Thrust Washer Í Key
À Pressure Plate Ç Primary Driven Gear Î Oil Pump Drive Gear
Á Push Plate È Ball Ï Oil Pump Driven Gear
 Push Rod #1 É Push Rod # 2 Ð Oil Pump
à Friction Plate Ê Push lever Axle Ñ Gasket
Ä Clutch Plate Ë Primary Drive Gear
Å Clutch Boss Ì Rotary Filter
4-48
L-52
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
OIL PUMP INSTALLATION
1. Lubricate :
¿ • Oil delivery passage (Crankcase RH)
• Oil Pump Assembly ¿
Recommended Lubricant:
4- Stroke Engine Oil
2. Install :
• Drive gear (Oil Pump) ¿
¿ • Gasket
• Oil Pump Assy À
À 3. Tighten
• Screw (2 nos) Á
Á
4. Install
• Rotary Filter
NOTE :
ç è
Align the Rotary Filter Dog ç with groove of the
Crankshaft è and make sure to keep ‘TOP’
marking facing upside.
NOTE :
Hold the Rotor with Magneto Holder then tighten
the Primary Drive Gear Nut.
Magneto Holder
YSST - 627
4-49
R-53
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CLUTCH INSTALLATION
1. Install :
• Oil Seal ¿ New
• Circlip New
¿ • Push Lever Axle À
New NOTE :
Install longer side ç of the Spring on Push Le-
À
ver and smaller side è on the Crankcase Notch.
2. Install :
• Primary Driven Gear ¿
à ¿ • Thrust Washer À
• Clutch Boss Á
• Lock Washer  New
Â
À • Clutch Boss Nut Ã
Á
3. Tighten :
• Nut Clutch Boss ¿ while holding the Clutch
¿ Boss with Clutch Hub Holder À
À Clutch Hub Holder
YSST - 233
4. Bend :
• Lock Washer tab
(along a flat side of the end)
5. Install :
• Friction Plate ¿ 5 Nos
• Clutch Plate À 4 nos
NOTE :
• Install the Clutch Plates and Friction Plates al-
ternately on the Clutch Boss, starting with a
Friction Plate and ending with a Friction Plate.
• Lubricate all Clutch and Friction Plates with
Engine Oil before installation
• Be sure to install a Clutch Plate with “Projec-
tion Mark” offset approximately 90 º from pre-
vious plates projection continue this procedure
in clockwise direction until all Clutch Plates
are installed
4-50
L-54
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
6. Install :
• Ball
7. Install :
• Push Rod # 1 ¿
¿ À • Push Plate À
 Á • Plate Washer Á
• Nut  (Push Rod # 1)
8. Install :
¿
• Pressure Plate ¿
• Compression Springs À
Á • Bolts Á (Clutch Spring)
è
9. Check :
• Push Lever position
• Push the Push Lever Assembly in the
arrow direction and make sure that the
mach mark are aligned adjust;
ALIGNED NON ALIGNED ç Match mark on the Push Lever Assembly
è Match mark on the Crankcase
10. Adjust :
• Push Lever position
ææææææææææææææææææææææææææææææææææ
Adjustment steps :
• Loosen the Lock Nut ¿
•Turn the Adjuster À clockwise or anticlockwise
to match alignment marks.
4-51
R-55
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
• Hold the Adjuster to prevent it from moving and
tighten the Locknut to specification
À CAUTION:
WARNING
¿ Take care not to overtighten the Adjuster À and
remove the freeplay between both Push Rods.
11. Install
• Strainer
NOTE :
Always keep its wider side, outside of Crankcase
12. Install :
• Dowel Pins
• Gasket (Crankcase #2) New
• Crankcase Cover #2 (RH)
¿ Ä
à Bolts (Crankcase Cover):
Å 10 Nm (1.0 m.kg, 7.2 ft.lb)
Â
NOTE :
Tighten the Bolts in decreasing numerical order
Æ (see number on the illustration)
Á 13. Install :
À Ç
• Kick Crank ¿
• Nut Kick Crank À
¿
Nut (Kick Arm):
50 Nm (5.0 m.kg, 36 ft. lb)
14. Install :
• Dowel Pins
• Gasket (Crankcase Cover #1) New
À • Crankcase Cover #1(L.H.)
NOTE:
Tighten the Bolts in decreasing numerical order.
à ¿ Ä
4-52
L-56
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CYLINDER AND PISTON
¿ Cylinder à Piston Pin Circlips
À Gasket Cylinder Ä Piston
Á Dowel Pins Å Pin Piston
 Piston Rings Æ O’ Ring
4-53
R-57
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CYLINDER HEAD
¿ Bolt Flange Å Cylinder Head
À Washer Æ Dowel Pin
Á Bolt Ç Gasket Cylinder Head
 Valve Cover (intake) È O-Ring
à O-Ring É Cover Cylinder Head Side # 3
Ä Valve Cover (exhaust) Ê Spark Plug
4-54
L-58
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
CAM SPROCKET AND TIMING CHAIN
4-55
R-59
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence
• Expander Spacer (Oil Ring) ¿
• Side Rails (Oil Ring) À
• 2nd Ring Á
• Top Ring Â
NOTE :
• Make sure to install the Piston Rings so that
the RN mark is located on the upper side of
the 2nd Ring.
• Lubricate the Piston and Piston Rings with En-
gine Oil.
2. Install :
• Piston ¿
• Piston Pin À using Piston Pin Replacer
Tool
NOTE :
• Apply Engine Oil on the Piston Pin
• The “Ÿ”mark ç on the Piston must be kept
towards the exhaust side of the Cylinder
À
ç • Before installing the Piston Pin Circlip, Cover
the Crankcase opening with a clean cloth.
¿
3. Install :
• Dowel Pins ¿ - 2 Nos.
• Gasket (Cylinder) À New
4-56
L-60
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
4. Install :
• Piston Rings ¿
NOTE :
Offset the Piston Rings end gaps as shown.
5. Lubricate :
• Piston outer surface
• Piston Rings
• Cylinder Inner Surface
6. Install :
¿ • Cylinder ¿
NOTE :
À • Install the Cylinder with one hand while com-
pressing the Piston Rings with the other hand
• Pass the Timing Chain and Guide stopper # 2
through the Timing Chain Cavity.
• Press the Piston down to rest on Piston
Base À YSST - 604
Piston Base
YSST - 604
4-57
R-61
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
2. Install :
¿ Â
• Cylinder Head
• Bolt with Washer (Cylinder Head)
NOTE :
• Apply Engine Oil onto the Bolt thread
• Tighten the Bolts starting with the lowest num-
bered one.
ê 3. Install :
é ¿
• Cam Sprocket À
À • Timing Chain ¿
ææææææææææææææææææææææææææææææææææ
Installing steps :
• Turn the Crank Shaft anticlockwise until the
slit ç (3rd Mark) matches the stationary
pointer è
• Align the “I” mark é on the Cam Sprocket with
the stationary pointer ê on the Cylinder Head.
• Fit the Timing Chain ¿ on Cam Sprocket À
and install the Cam Sprocket on the Camshaft.
è
ç NOTE :
When installing the Cam Sprocket , keep instal-
lation of the Camshaft. Damage or improper
Valve timing will result.
CAUTION:
WARNING
Do not turn the Crankshaft during installa-
tion of the Camshaft. Improper Valve Tim-
ing will result.
NOTE :
Remove the safety wire from the Timing Chain
before installation of Sprocket Cam.
ææææææææææææææææææææææææææææææææææ
4-58
L-62
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
¿ 4. Install :
• Plate Washer
5. Tighten
• Bolt Sprocket ¿
ç
7. Install :
• Gasket (Timing Chain Tensioner)
• Timing Chain Tensioner
ææææææææææææææææææææææææææææææææææ
Installation steps :
¿ • Remove the Tensioner Cap Bolt
• While Pressing the Tensioner Rod lightly with
fingers, use a Flat Head Screwdriver ¿ and
retract the Tensioner Rod up fully clockwise
• With the Rod fully retracted, install the Gasket
Á and the Chain Tensioner  and tighten the
Bolt à with Copper Washer to the specified
torque
• Release the Chain Tensioner Rod by Screw-
driver, Then install the Gasket À and the Cap
Á
 Bolt ¿ to the specified torque.
4-59
R-63
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
8. Check :
• Valve clearance specifications
Out of specification Ÿ Adjust.
Refer to the “VALVE CLEARANCE ADJUST-
MENT” section in Chapter 3, Page no 3-8
9. Lubricate :
• 4 Stroke Engine Oil
Recommended Lubricant :
Engine Oil - YAMALUBE
10.Install :
À • Valve Covers (with O-Ring) ¿
• Cylinder Head Side Cover (with O-Ring) À
¿
• Bolts Á
Valve Cover :
Á 17.5 Nm (1.75 m.kg, 13 ft.lb)
Bolts (Cylinder Head Side Cover)
10 Nm (1.0 m.kg, 7.2 ft.lb)
11. Install :
• Timing Check Plug (with O-Ring) ¿
¿
• Center Plug (with O-Ring) À
À
12. Install
• O-Ring (intake manifold)
À • Intake Manifold ¿
13. Tighten
• Bolts (intake manifold) À 2 Nos.
4-60
L-64
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
14. Install :
• Spark Plug
Spark Plug :
12.5 Nm (1.25 m.kg, 12.6 ft. lb)
15. Install :
¿ • Plug Drain ¿
Plug Drain :
20 Nm (2.0 m.kg, 2.0 ft.lb)
ENGINE MOUNTING
When remounting the Engine, reverse the re-
moval procedure. Note the following points :
1. Install :
• Engine Assembly (from the Left side of
the Motorcycle)
2. Install
• Footrest Assy
3. Install :
• Engine Mount Bolt (front centre) ¿
• Bolt (Engine Mount stay front upper) À
• Bolt (Engine Mount stay front lower) Á
• Engine Mount Bolt front lower Â
• Engine Mount stay Ã
• Engine Mount Bolt (bottom rear) Ä
• Engine Mount Bolt (upper rear) Å
• Engine mount stay upper Æ
• Bolt AIS Mounting on stay Ç - 2 Nos.
• Engine Mount Stay È
4. Tighten :
• Bolts Foot Rest Assembly
4-61
R-65
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
Engine Mount Bolt (Rear) : Bolt (Engine Mount stay front lower)
38 Nm (3.8 m.Kg.27.5 ft. lb) 55 Nm (5.5 m.kg., 40 ft.lb)
Bolt (Engine mount Stay) : Engine Mount Bolt (Front lower)
38 Nm (3.8 m..kg, 27. 5 ft.lt) 38 Nm (3.8 m.kg., 27.5 ft.lb)
Engine mount bolt (upper) Engine Mount bolt (from upper))
38 Nm (3.8 m..kg, 27. 5 ft.lt) 38 Nm (3.8 m.kg., 27.5 ft.lb)
Bolt (Engine Mount Stay front upper)
55 Nm (5.5 m.kg., 40 ft.lb)
5. Install :
• Gasket
À • Exhaust pipe ¿
Á
• Bolts Exhaust Pipe À - 2 nos
• Bolt (Muffler) Á
À
Bolt (Shift Pedal):
10 Nm (1.0m. kg, 7.2 ft. lb)
¿ 8. Install :
• Stay Clutch Cable
9. Install
• Clutch cable
• Adjust Clutch Cable free play at Lever end
Refer “CLUTCH ADJUSTMENT” in Chapter 3,
Page no 3-17
10. Adjust
Drive Chain Slackness
Refer to “DRIVE CHAIN SLACK
ADJUSTMENT” section in Chapter 3, Page
no 3-20
4-62
L-66
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
11. Install:
• Carburetor
Refer to “CARBURETOR “ section in
Chapter 5 page no 5-7
12. Tighten:
• Air Filter Case Screws
13. Install
• Battery Box
• Battery
• Battery Flap
¿
À
Bolts (Battery Box)
3.8 Nm (0.38 mkg), 3 ft lb
14. Connect
• Battery Leads
• Sensor Coil Lead Coupler ¿
CAUTION:
WARNING
¿
Connect the positive lead ¿ First and then the
negative lead À
15. Install
Spark Plug Cap
16. Fill
• Crankcase
Refer to “ENGINE OIL REPLACEMENT”
section in Chapter 3, Page no 3-14
17. Adjust :
• Idle Speed
Refer to “IDLING CO. MEASUREMENT
AND ADJUSTMENT” in Chapter 3, Page
no 3-8
18. Adjust :
• Throttle cable Free play
Refer to “THROTTLE CABLE
ADJUSTMENT” in Chapter 3, Page no 3-9
4-63
CHAPTER 5
CARBURETION
CARBURETOR VIEW ................................................................5-1
REMOVAL ...................................................................................5-2
DISASSEMBLY ...........................................................................5-3
INSPECTION .............................................................................. 5-4
ASSEMBLY .................................................................................5-6
INSTALLATION ...........................................................................5-7
TUNING .......................................................................................5-8
FUEL LEVEL ADJUSTMENT ...................................................... 5-9
THROTTLE POSITION SENSOR (TPS) ...................................... 5-10
AIR INDUCTION SYSTEM ...........................................................5-12
L-2
CARB
CARBURETOR
CARBURETOR
1 SCREW (TOP COVER) 17 PLUNGER 32 FLOAT PIN FIXING SCREW
2 TOP COVER 18 AIR VENT HOSE 33 FCB O-RING
3 PISTON VALVE SPRING 19 THROTTLE POSITION SENSOR 34 FLOAT CHAMBER BODY
4 HOLDER (JET NEEDLE) (TPS) KIT ASSY
5 JET NEEDLE RETAINER SPRING 20 PILOT SCREW 35 DRAIN SCREW
6 RING 21 SPRING 36 FCB - FIXING SCREW
7 JET NEEDLE E-RING 22 O-RING 37 CLIP FOR DRAIN HOSE
8 JET NEEDLE RING 23 WASHER 38 DRAIN HOSE
9 WASHER 24 PILOT JET ASSY. 39 NEEDLE SET KIT
10 JET NEEDLE 25 HOLDER 40 STARTER SET KIT
11 PISTON VALVE ASSY 26 IDLE ADJUSTER SPRING
12 DIAPHRAGM (PISTON VALVE) 27 IDLE ADJUSTER SCREW
13 CAP PLUNGER 28 MAIN JET
14 GUIDE HOLDER 29 NEEDLE VALVE ASSY. KIT
15 O-RING 30 FLOAT ASSEMBLY
16 PLUNGER SPRING 31 FLOAT PIN
2
13
14 41
15
3
16
17
23
22
21
20
4
5
19 6
7
39 8
26
9
18
25
24 27 10
28 29
31 11
30
33 32
35 12
34
36
37
38
5-1
R-3
CARB
CARBURETOR
R E M O VA L
1 . Remove :
• Side Covers (LH /RH)
Refer to the “SIDE COVER, SEAT AND
FUEL TANK” section in Chapter 3, Page
No.- 3-3
2. Close
• Fuel
3. Drain :
• Fuel from Float Chamber
NOTE :
Place a rag under the over flow hose to absorb
the spilt fuel.
WARNING
Petrol is highly flammable. Avoid spilling
fuel on the hot Engine.
4. Disconnect :
À
• Air Vent Hose ¿
• Fuel Hose À
• Over Flow Hose Á
 ¿
5. Remove :
• Starter wire Nut - Â
Á
6. Remove
• Throttle Cable - ¿
¿
7. Unscrew
• Clamp Front/Rear
• Remove carburettor from Engine.
5-2
L-4
CARB
DISASSEMBLY
DISASSEMBLY
NOTE:
The following parts can be cleaned and
inspected without Carburetor Disassembly.
• Throttle Cable
• Starter Plunger Assembly
• Fuel Hose, Air vent Hose, over flow Hose
• Before disassembly of Carburetor clean the
outer surface of Carburettor and Check the
Starter cable operator.
Á 1. Open :
• Screw (Pan Head) 2-Nos- ¿
¿ 2. Remove :
• Cover À
Â
À • Spring Á
• Diaphragm with Piston Valve Â
3. Open :
¿ • Screw (Float chamber) -3 Nos- ¿
Á
À
4. Remove :
• Float Chamber Body À
• Seal Float Chamber Á
5. Remove :
• Screw- ¿
• Float Pin- À
• Float - Á
Á
À
¿
5-3
R-5
CARB
DISASSEMBLY/INSPECTION
6. Remove :
 • Needle Valve- ¿
Á
7. Open :
• Main jet- À # 127.5
¿ • Main Nozzle- Á
À • Pilot Jet- Â
8. Remove :
• Pilot screw Assy.¿ (With spring, washer
¿
and O’Ring)
9. Unscrew :
• Throttle Stop Screw with Spring À
À
NOTE:
Don’t Remove/Unscrew the T.P.S. (Throttle
Position Sensor) during normal screw
INSPECTION
Carburetor Body
1. Inspect :
• Cracks/damage Ÿ Replace
• Fuel Passages Blockage Ÿ Clean with
petrol and Compressed air.
• Contamination in jet housings Ÿ Clean
Carburetor Float Chamber Body
1. Inspect
• Cracks/damage Ÿ Replace
• Fuel Starter Passage Blockage Ÿ Clean
with petrol and compressed air
• Contamination in Starter jet Ÿ Clean
ææææææææææææææææææææææææææææææææææ
Cleaning Steps :
ó Wash the Carburetor in petroleum based sol-
vent. (Do not use any caustic cleaning solu-
tion )
ó Blow all passages and Jets with compressed
air.
ææææææææææææææææææææææææææææææææææ
5-4
L-6
CARB
INSPECTION
Float
1. Inspect :
• Damage/Leakage Ÿ Replace
Piston Valve
1. Check :
• Free movement
Insert the Piston Valve with Diaphragm in
Carburetor body, and check for free
movement
Hinderance Ÿ Clean/Replace
Throttle Valve
1. Check :
• Free movement with throttle lever Ÿ Clean
and Lubricate.
Hinderance Ÿ Clean/Replace
Starter Assembly
1. Inspect :
• Starter plunger movement
• Starter spring
• Starter wire
5-5
R-7
CARB
ASSEMBLY
ASSEMBLY
Reverse the disassembly procedure.
1. Wash
• All the parts in clean petroleum based
solvent
• Always use new ‘o’ Rings
2. Install :
• Pilot screw assembly ¿
3. Install :
• Main Nozzle ¿
Á • Main Jet À
¿ • Pilot Jet Á
4. Install :
 • Needle valve assembly Â
À • Float Ã
• Float Pin Ä
5.Tighten :
• Screw float Pin Å
Å Ä
6. Install
¿ Á • Seal Float chamber ¿ New
• Float chamber À
À
• Screw - 3 Nos. Á
7. Install
• Throttle stop screw assembly ¿
5-6
L-8
CARB
INSTALLATION
8. Install
¿ • Piston Valve Assy. with Diaphragn ¿
NOTE :
Hold the piston Valve Assy. with diaphragm
open condition and Aligns the diaphragn match
mark with carburetor mark,, Then put the pan
head with spring on Top of diaphragn press the
spring to same holding position of piston Valve
and tighten the screw pan head. After Tighting
the screw, Release the piston Valve Assy.
INSTALLATION
Reverse the “REMOVAL” procedure
2. Install :
Throttle cable assembly ¿ on carburettor.
4. Connect :
à • Over Flow Hose Á
• Air Vent Hose Â
• Fuel Hose Ã
À Â
5-7
R-9
CARB
CARBURETOR TUNING
8. Adjust :
• Idling speed by Throttle Stop Screw ¿
CARB
CARBURETOR TUNING
CAUTION:
WARNING
Do not disturb settings of the Carburetor if
the Engine performance is O.K.
• If required, must record the existing set-
ting (No. of turns) of the Pilot Screw.
• To counter check the setting of the Pilot
Screw, follow the ‘CO’ adjustement proce-
dure.
• Ensure proper clamping of the blind plug
6. Adjust :
• Idling speed by Throttle Stop Screw ¿
ææææææææææææææææææææææææææææææææææ
¿ FUEL LEVEL ADJUSTMENT
1. Measure :
• Fuel Level ç
• Out of specification Ÿ Adjust
Fuel level :
6.5 ± 0.5 mm Above the Joint of
Main Chamber Body and Float
Chamber Body
ææææææææææææææææææææææææææææææææææ
Measurement and adjustment steps :
• Place the motorcycle on a level surface on cen-
tre stand
• Connect the Fuel Level Gauge ¿ to the Drain
Pipe À
5-9
R-11
CARB
CARBURETOR TUNING
• Otherwise adjust Float level by bending the
Float Tang  on the Float slightly up or down
 as required.
• Install the Carburetor
• Recheck the fuel level
• Adjust Float height through Float Tang Â
By Bending Down Ÿ Float Height increase
By Lifting Up Ÿ Float Height Decrease
Multimeter YTPS
Specification
At Idling 3.5 ~ 6.5 K Ohms
À
• Check TPS resistance at full throttle
¿
position without starting engine
Multimeter YTPS
Specification
By slowly 0 ~ 5 K Ohms
À
¿ opening
the throttle
5-10
L-12
CARB
CARBURETOR TUNING
Multimeter YTPS
Input Voltage
5 V ± 0.05 V
Multimeter YTPS
Output Voltage
0.7 V ± 0.05 V
5-11
R-13
CARB
CARBURETOR TUNING
AIR INDUCTION SYSTEM
AIR INJECTION
Ã
Ä
Á
1. Check
• hose Â
Loose connection Ÿ
Connect Properly
Crack/Damage Ÿ Replace
• Pipes Ã
Â Ä Crack/damage Ÿ Replace
• Clamps Ä
for proper clamping
5-12
L-14
CARB
R-1
CHAS
CHAPTER 5
CARBURETION
CHAS
FRONT WHEEL AND FRONT BRAKES
FRONT WHEEL
¿ Wheel axle Æ Gear Unit (Speedometer)
À Collar Ç Axle Nut
Á Oil Seal È Split Pin
 Bearing
à Spacer Collar
Ä Front Wheel
Å Bearing
Á
Â
Ã
Å
Æ
Ç
È
Ä
6-1
R-3
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
FRONT WHEEL
¿ Wheel Axle Ç Bearing
À Collar È Clutch Meter
Á Dust Cover É Retainer Clutch Meter
 Oil Seal Ê Oil Seal
à Bearing Ë Gear Unit (Speedometer)
Ä Brake Disc Ì Axle Nut
Å Bolt Brake Disc Í Nut
Æ Spacer Î Split Pin
À
Á
Â
à Ä
Ì
Í
Î
Æ
Ç
È
É
Ê
Ë
6-2
L-4
CHAS
FRONT WHEEL AND FRONT BRAKES
REMOVAL
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
¿
4. Remove:
 • Wheel axle Â
• Front Wheel Ã
NOTE:
Do not depress the brake level when the wheel
is off the motorcycle otherwise the brake pads
à will be forced shut.
5. Remove:
• Collar ¿
• Dust Cover À
• Gear Unit (Speedometer) Á
B A
Á
A Right side
B Left Side
À
6-4
R-5
CHAS
FRONT WHEEL AND FRONT BRAKES
INSPECTION
1. Eliminate any corrosion from parts.
2. Inspect:
ò Wheel axle
Roll the axle on a flat surface.
Bends Ÿ Bends
WARNING
Do not attempt to straighten a bent axle.
3. Inspect:
• Tyre
Wear/Damage Ÿ Replace.
• Wheel
Bends/Damage Ÿ Replace.
4. Check:
• Spoke(s)
Bend/Damage Ÿ Replace.
Loose spoke(s) ŸRetighten.
Turn the wheel and tap the spokes with
a screw driver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
lookse spoke will sound flat.
5. Tighten:
• Loose spokes
Nipple :
3 Nm (0.3 m.kg. -2.0 lbft)
NOTE:
Check the wheel runout after tightening spoke.
6. Measure:
• Wheel runout
Out of specification Ÿ check the wheel
and bearing play.
6-5
L-6
CHAS
FRONT WHEEL AND FRONT BRAKES
WARNING
After mounting a tyre, ride conservatively to
allow proper tyre to rim seating. Failure to
do so may cause an accident resulting in
motorcycle damage and possible operator
injury.
After a tyre repair or replacement, be sure to
torque tighten the valve stem locknut ¿ to
specification
7. Check
• Wheel bearings ¿
• Abnormal noise/turn roughly/free play
Ÿ replace.
• Oil seal À
Wear/damage Ÿ replace.
A Free Play
ææææææææææææææææææææææææææææææææææ
6-6
R-7
CHAS
FRONT WHEEL AND FRONT BRAKES
Ä NOTE:
Use a socket Ä that matches the outside
diameter of the race of the bearing and oil seal.
Ã
Á
 CAUTION:
WARNING
Do not strike the centre race Á or balls  of the
bearing. Contact should be made only with the
outer race Ã.
ææææææææææææææææææææææææææææææææææ
ææææææææææææææææææææææææææææææææææ
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the left or
right to ensure that the front wheel is
stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be
low the edge of the brake disc.
ææææææææææææææææææææææææææææææææææ
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a
few different locations.
Out of specificationŸ Replace.
6-7
L-8
CHAS
FRONT WHEEL AND FRONT BRAKES
4. Adjust:
• brake disc deflection
ææææææææææææææææææææææææææææææææææ
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE :
Tighten the brake disc bolts in stages and in a
crisscross pattern.
INSTALLATION
6-8
R-9
CHAS
è 2. Install:
• Gear unit assembly ¿.
¿ WARNING
NOTE:
Make sure the projections on the meter clutch
ç and meshed with the flats in the wheel hub è
3. Install :
• Collar ¿
• Dust Cover À
NOTE :
À
Install the oil seal taking care not to damage or
reverse the lips.
ç 4. Install :
• Front wheel assembly
NOTE :
Be sure the boss on the outer fork tube ç
è
correctly engages with the locating slot on the
gear unit assembly è.
5. Install :
¿ • Wheel axle ¿
• Axle nut À
6. Tighten
• Nut À
7. Install:
• Split Pin Á
À • Speedometer cable Â
À
6-9
L-10
CHAS
CAUTION:
WARNING
 Make sure that the speedometer cable  is
Á
routed properly.
NOTE :
Install the tire and wheel with the mark CD
pointing in the direction of wheel rotation.
6-10
R-11
CHAS
FRONT WHEEL AND FRONT BRAKES
FRONT BRAKE
¿ Master cylinder cap Ç Rubber boot
À Diaphragm È Brake caliper body
Á Master cylinder kit É Bleed Screw
 Master cylinder Ê Pad spring
à Brake hose Ë Brake pads
Ä Holder (brake hose and meter cable) Ì Piston seal
Å Caliper bracket Í Piston
Æ Retaining bolt Î Brake disc
¿
À
Á
Å Æ
Ç É
Ê
Ë
Î Ì
Í
6-11
L-12
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
CAUTION:
WARNING
Disc brake components rarely require
disassembly. DO NOT:
• Disassembly components unless
absolutely necessary.
• Use solvents on internal brake
component.
• Allow brake fluid to come in contact with
the eyes otherwise eye injury may occur.
• Allow brake fluid to contact painted
surfaces or plastic parts otherwise
damage may occur.
• Disconnect any hydraulic connection
otherwise the entire system must be
disassembly, drained, cleaned, and then
properly filled and bled after reassembly.
WARNING
Securely support the motorcycle there is no
danger of falling over.
¿
2. Remove:
¿ • Clip Pins - 2 Nos ¿.
À • Retaining Pin À.
Á 3. Remove:
• Brake Pads Á.
• Pad Spring Â.
À
¿ Â
6-12
R-13
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
NOTE:
WARNING
• Replace the pad spring if the pad replacement
¿ is required.
• Replace the pads as a set if either is found
ç to be worn to the wear limit.
3. Install:
À • Pad Spring ¿
• Brake pads À
4. Install / Lubricate:
• Retaining pin Á
Á • Clip pin - 2 Nos. Â
 ¿
Recommended lubricant :
Lithium soap base grease
ææææææææææææææææææææææææææææææææææ
ç
Installation steps:
è • Connect the clear plastic tube ç tightly to
the caliper bleedscrew è. Then, place the
other end of this hose into an open con-
tainer.
• Loosen the caliper bleed screw and push the
piston into the caliper by your finger.
• Tighten the caliper bleed screw.
ç • Install pad spring and brake pads.
ææææææææææææææææææææææææææææææææææ
Caliper bleed screw :
6 Nm (0.6m.kg, 4 ft.lb)
5. Install:
• Retaining pin
6. Inspect:
• Brake fluid level ç
Refer to the Brake Fluid Inspection
on Chapter 3 Page No.: 3-1
¿ “LOWER” level line.
¿
7. Check:
• Brake lever operation ¿
A softy or spongy feeling Ÿ Bleed
brake system.
Refer to the Air Bleeding section on
Chapte 3Page No.: 3-2
6-13
L-14
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
CALIPER DIASSEMBLY
À NOTE:
Before disassembling the front brake caliper,
drain the brake system of its brake fluid.
¿ WARNING
Á Securely support the motorcycle there is no
Á danger of falling over.
1. Remove:
Á • Bolt ¿
• Copper Washers 2 Nos. À
NOTE:
¿ Place the container under the caliper to catch
À the standing brake fluid.
 2. Disconnet:
• Brake hose Á
3. Remove:
• Clip pin Â
Ä • Retaining pin Ã
• Brake pads Ä
• Pad spring
4. Remove
• Bolts Å
à • Brake Caliper Body.
 5. Remove:
• Piston Æ
• Piston seal Ç
ææææææææææææææææææææææææææææææææææ
Removal steps:
• Blow compressed air into the Bleeding Bolt
Å opening to force out the piston from the
caliper body.
WARNING
• Never try to pull out the piston.
• Cover the piston with a rag. Use care so
Ç that piston does not cause injury as it is
come out from the CaIiper Body.
CAUTION:
WARNING
Æ Remove the piston seal by pushing it in with
finger. Do not use a screwdriver.
ææææææææææææææææææææææææææææææææææ
6-14
R-15
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
MASTER CYLINDER DISASSEMBLY
¿
WARNING
NOTE:
Before disassembling the front brake master
cylinder, drain the brake system of the brake
fluid.
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
À Á
1. Remove:
• Mirror (right) ¿
• Brake lever cover
• Brake switch À
Á 2. Loosen:
• Union bolt Á
¿ 3. Remove:
Á • Master cylinder ¿
• Union bolt À
• Copper washer - 2 Nos. Á
À
NOTE:
WARNING
Place a container under the master cylinder to
catch the standing brake fluid.
¿ 4. Remove
À
Á • Screw ¿
• Cover master cylinder À
• Diaphragm Á
¿ À 5. Remove
• Bolt ¿
• Brake Lever À
• Brake Lever Pin with spring, boot Á
• Circlip Lock Â
Á • Master Cylinder Kit Ã
à Â
6-15
L-16
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
INSPECTION AND REPAIR
¿
WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents will
cause seals to swell and distort.
1. Inspect:
• Caliper cylinder
Wear / scratches Ÿ Replace caliper
Á
À assembly.
• Caliper piston À
Scratches/rust/wearŸReplace
À caliper assembly
• Caliper body Á
Cracks/damage ŸReplace brake
caliper assembly.
• Rubber boots
• Cracks/wear/damageŸReplace
Á • Oil delivery passage (caliper body) Â
Blow out with compressed air.
WARNING
Â
Replace the piston seal and dust boot when-
ever a caliper is disassembled.
2. Inspect :
• Caliper bracket
Cracks / damage ŸReplace brake
caliper assembly
¿
3. Inspect :
• Master cylinder ¿
¿ Wear/ScratchesŸReplace master cylinder
assembly.
• Oil delivery passage (master cylinder
body)
Blow out with compressed air.
6-16
R-17
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
4. Inspect :
Á
• Diaphragm ¿
• Master Cylinder Kit À
¿ • Spring Á
Wear/damage Ÿ Replace
5. Inspect :
• Brake hoses ¿
¿ Cracks/wear/damage ŸReplace
6. Measure :
• Brake pad thickness ç
Out of specification ŸReplace
¿
¿ WARNING
NOTE:
Replace the pads ¿ as a set either if found to
be worn to the wear limit.
7. Inspect :
• Brake disc ¿
¿ Galling/damage ŸReplace
6-17
L-18
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
9. Measure :
• Brake disc deflection
Out of specificationŸInspect wheel runout.
DeflectionŸreplace.
Maximum deflection
0.3 mm
¿ Dial gauge
• Brake disc thickness ç
Out of specification Ÿ replace.
ç Brake Disc thickness ç
5.0 mm
<Wear Limit:3.5 mm>
WARNING
NOTE:
Tighten the bolts (brake disc) in stage using
a crissross pattern.
¿ CALIPER ASSEMBLY
WARNING
• All internal parts should be cleaned in
new brake fluid only.
Brake Fluid :
DOT # 3
• Internal parts should be lubricated with
brake fluid when installed.
• Replace the piston seal and dust boot
whenever a caliper is disassembled.
À
1. Install:
• Piston seal ¿
• Piston À
• Dust boot Á
WARNING
NOTE:
Always use new piston seal.
2. Install:
 • Caliper bracket Â
• Brake caliper body Ã
Á
Ä • Bolt Ä
à • Brake hose
• Union bolt with Copper washer
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
WARNING
• Proper hose routing is essential to insure
safe motorcycle operation.
• Always use new copper washers.
3. Install:
• Pad spring ¿
• Brake pads À
• Retaining pin Á
• Clip Â
4. Fill:
• Brake fluid
¿ Brake Fluid :
DOT # 3
CAUTION:
WARNING
À Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
WARNING
• Use only the designated quality brake
Á Â fluid: otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemcial reaction and lead to poor
performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
5. Air bleed:
• Brake system
Refer to the Air Bleeding section on
Chapter-3, Page No. 3-2
6. Install:
• Brake fluid level
Refer to the Brake Fluid Inspection
section on Chapter 3, Page No. 3-1
6-19
L-20
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
WARNING
• All internal parts should be cleaned in new
brake fluid only.
• Internal parts should be lubricated with
brake fluid when installed.
Brake fluid :
DOT # 3
1. Install:
• Master cylinder kit ¿
• Circlip À
Á
• Brake lever with spring & Pin, Boot Á
• Master cylinder
¿ À 2. Install:
• Brake switch ¿
• Mirror (right) À
3. Tighten
• Bolt Á
 • Nut
4. Install:
Ã
Á • Copper washers
• Brake hose Â
• Copper washers
• Union bolt Ã
Union bolt:
25 Nm(2.5 m.kg. - 18 lbft)
NOTE:
WARNING
Always use new copper washers.
WARNING
Proper hose routing is essential t insure safe
motorcycle operation. Refer to the Cable
Routing section in the Chapter 2, Page No.
5. Fill:
• Brake fluid
6-20
R-21
CHAS
FRONT WHEEL AND FRONT BRAKES - CAST WHEEL
6. Install:
• Brake system
Refer to the Air Bleeding section in
the Chapter 3 Page No. 3-2.
7. Inspect:
• Brake fluid level ¿
6-21
L-22
CHAS
REAR WHEEL AND REAR BRAKE
REAR WHEEL
¿ Adjuster Æ Spacer
À Pin Ç Rear Wheel Assembly
Á CompressionSpring È Brake Shoe Plate Assembly
 Cotter Pin É Damper
à Tension Bar Ê Bearing
Ä Axle Nut Ë Spacer/Collar
Å Chain Puller Ì Bearing
6-22
R-23
CHAS
REAR WHEEL AND REAR BRAKE
REAR WHEEL
¿ Adjuster Æ Spacer
À Pin Ç Rear Wheel Assembly
Á CompressionSpring È Brake Shoe Plate Assembly
 Cotter Pin É Damper
à Tension Bar Ê Bearing
Ä Axle Nut Ë Spacer/Collar
Å Chain Puller Ì Bearing
6-23
L-24
CHAS
REAR WHEEL AND REAR BRAKE
REAR BRAKE
¿ Brake Shoe Kit
À Cam Lever
Á Indicator Plate
 Camshaft
à Spring
6-24
R-25
CHAS
REAR WHEEL AND REAR BRAKE
¿ REMOVAL
WARNING
Á • Securely support the Motorcycle on centre
stand so that there is no danger of it fall-
ing over
• Stand the Motorcycle on a level surface
À
1. Remove :
• Chain Cover (upper ¿ and lower À)
2. Loosen
• Chain Adjuster Á
3. Remove :
• Nut (Rear Brake) ¿
• Cotter Pin À
• Nut Á with Bolt
 • Tension Rod Â
Ä À • Compression Spring Ã
Ã
• Brake Rod Ä
¿ Á
4. Remove :
 • Cotter Pin ¿
• Nut (Wheel Axle) À
¿ • Wheel Axle Á
• Collar Â
À Á
NOTE :
When removing the Wheel Axle, the Collar will
fall off. Take care not to lose it.
5. Remove :
• Axle Wheel ¿
• Rear Wheel À
• Rear Brake Shoe Plate
Remove the Rear Wheel Hub. with chain
¿ and spacer
6-25
L-26
CHAS
REAR WHEEL AND REAR BRAKE
REAR WHEEL INSPECTION
1. Inspect :
• Axle Rear Wheel
¿
• Rear Wheel
• Bearings Rear Wheel
• Oil Seals
Refer to “FRONT WHEEL INSPECTION”
Page no 6-4
2. Measure :
• Rear Wheel runout
Refer to “FRONT WHEEL INSPECTION ”
Page no 6-4
3. Inspect :
• Clutch Hub Damper
Wear/damage Ÿ Replace
6-26
R-27
CHAS
REAR WHEEL AND REAR BRAKE
REAR WHEEL INSTALLATION
Reverse the “REMOVAL” procedure
1. Install :
• Chain Adjuster in Rear Swinging fork
• Rear Wheel Assembly in Sprocket Hub
with spacer
• Brake Shoe Plate Assembly
• Spacer between Chain Sprocket and
Frame
• Spacer (RH) between brake plate and
frame.
• Axle Rear Wheel
NOTE :
Make sure that the slots in the Rear Wheel Hub
Damper fits over the tabs on the Clutch Hub as-
sembly
2. Adjust :
• Drive Chain Slack
Refer to “DRIVE CHAIN ADJUSTMENT”
section in Chapter 3, Page no 3-20
3. Tighten :
• Nut Rear Wheel Axle
NOTE :
Do not loosen the Axle Nut after torque tighten-
ing. If Axle Nut Groove is not aligned with the
Wheel Axle Cotter Pin Hole, align Groove to hole
by tightening up on the Axle Nut.
¿ 4. Install :
New • Cotter Pin ¿ New
NOTE :
Bend the ends of the Cottor Pin
WARNING
Always use a new Cottor Pin
5. Check :
• Rear Brake Pedal free play
Refer to “REAR BRAKE ADJUSTMENT”
section in Chapter 3, Page no 3-18
6-27
L-28
CHAS
DRIVE CHAIN AND SPROCKETS
DRIVE CHAIN AND SPROCKETS
¿ Chain Case Å Drive Chain
À Crankcase Cover 3 Æ Spacer
Á Drive Sprocket Ç Driven Sprocket Assembly
 Clip Chain Joint È Chain Tensioner Adjuster
à Link Plate É Circlip
Ä Chain Joint Ê Oil Seal
6-28
R-29
CHAS
DRIVE CHAIN AND SPROCKETS
REMOVAL
1. Stand the Motorcycle on a level surface.
WARNING
Securely support the Motorcycle on Centre
stand so that there is no danger of it falling
over.
2. Remove :
• Chain Case (upper and lower) ¿
• Shift pedal À
Á • Crankcase Cover 3 Á
• Drive Sprocket
Refer to “ENGINE REMOVAL” Section in
Chapter 4, Page No 4-1
À
¿
3. Remove
• Rear Wheel
Refer to “REAR WHEEL” Section Page no
6-12
4. Remove :
Á • Chain Joint Clip ¿
 • Link Plate À
À • Chain Joint Á
• Drive Chain Â
¿
5. Remove :
• Rear wheel Assy. removal
Refer to Rear Wheel removal on page 6-12
• Rear wheel Sprocket Assy.
6-29
L-30
CHAS
DRIVE CHAIN AND SPROCKETS
DRIVE CHAIN INSPECTION
1. Inspect :
• Drive Chain stiffness
Stiffness Ÿ Clean and Lubricate or replace
2. Inspect :
• Drive Chain ¿
• Driven Sprocket À
More than 1/2 tooth wear ç Ÿ Replace
the Drive Chain and both the Sprockets as
a set.
3. Measure :
• 10 link length è (Drive Chain)
Out of specification Ÿ Replace the Drive
Chain
4. Clean :
• Drive Chain
Put it in Kerosene and brush off as much
dirt as possible. Then remove the Drive
Chain from the ketosene and dry it.
6-30
R-31
CHAS
DRIVE CHAIN AND SPROCKETS
CLUTCH HUB INSPECTION
1. Inspect :
Clutch Hub
Wear/damage/cracks Ÿ Replace
NOTE :
Tighten the Nuts in a crisscross pattern
2. Bend :
Lock Washer Tab ¿
(along a flat side of the end)
6-31
L-32
CHAS
DRIVE CHAIN AND SPROCKETS
3. Install :
À • Drive Chain ¿
¿ • Chain Joint À
Á • Plate Á
• Chain Joint Clip Â
Â
4. Install :
Clip ¿ New
CAUTION:
WARNING
Be sure to install the Chain Joint Clip to the di-
rection as shown
5. Install :
• Chain Case (upper)
• Chain Case (lower)
• Crank Case Cover - 3
Refer to “ENGINE REMOVAL” section in
Chapter 4 Page no 4-1
6. Adjust :
• Drive Chain Slack
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” section in Chapter 3, Page no 3-20
6-32
R-33
CHAS
FRONT FORK
FRONT FORK
¿ Front Fender Å Fork Spring Ë Spindle Taper
À Cap Bolt with Gromet Æ Seal Dust Ì Cylinder Comp Front Fork
Á Holder Cable Ç Ring Snap Í Inner Tube
 O Ring È Washer Î Sub Spring
à Collar É Bolt Ï Oil seal
Ä Spring Seat Ê Gasket Ð Outer Tube
6-33
L-34
CHAS
FRONT FORK
FRONT FORK REMOVAL
WARNING
¿ Securely support the Motorcycle so there is
no danger of it falling over
3. Remove :
• Front Wheel
• Front Fender
Refer to “FRONT WHEEL REMOVAL”
Section Page no 6-3
• Handlebar
Refer to “HANDLEBAR REMOVAL”
À Section Page no 6-30
4. Remove
• Rubber Cap LH/RH
• Pinch Bolt (Inner Tube) - 2 Nos ¿
• Cap Bolt Under Bracket - 2 Nos À
3. Remove :
Á • Spacer ¿
• Seat Upper À
• Spring Front Fork Á
¿
À
6-34
R-35
CHAS
FRONT FORK
4. Loosen :
• Bolt Allen (Damper Rod) ¿
Loosen the Bolt (Damper Rod) ¿ while
holding the Damper Rod with T-Handle À
T-Handle
¿ YSST - 213
À
5. Remove :
• Bolt (Damper Rod) ¿
• Washer À
• Cylinder com plete Fornt Fork Á
À • Spindle Taper Â
• Spring Sub Ã
¿
6. Remove :
• Ring snap
À • Washer
• Oil Seal ¿ using Oil Seal Remover À
CAUTION:
WARNING
Never reuse the Oil Seal
6-35
L-36
CHAS
FRONT FORK
FRONT FORK INSPECTION
1. Inspect :
• Inner Tube bending
WARNING
Do not attempt to straighten a bent Inner
Tube as this may dangerously weaken the
ç Tube
2. Measure :
• Fork Spring length ç
CAUTION:
WARNING
• When disassembling and assembling the
Front Fork do not allow any foreign mate-
rial to enter the Oil
6-36
R-37
CHAS
FRONT FORK
FRONT FORK ASSEMBLY
Reverse the “DISASSEMBLY” procedure
Note the following points
NOTE :
• When assembling the Front Fork be sure to
replace the following parts
• Oil Seal
• Seal Dust
• Snap Ring
• Before assembling the Fork, make sure that
all the components are clean.
¿
À
1. Install :
• Spring Sub ¿
• Cylinder Complete À
WARNING
Allow the Cylinder Complete to slide slowly
down the Inner Fork Tube until it protrudes
from the bottom, being careful not to dam-
age the Inner Fork Tube
2. Lubricate :
• Inner Tube (outer surface)
Recommended lubricant :
Fork Oil 10 W or equivalent
 3. Install :
• Cylinder Complete ¿
• Spindle Taper À
• Inner Tube Á
À ¿ Á • Outer Tube Â
4. Install :
• Washer ¿ New
• Bolt (Damper Rod) À
¿
New
À
6-37
L-38
CHAS
FRONT FORK
5. Tighten :
• Bolt (Cylinder Complete) ¿ holding the
Cylinder Complete with a T-Handle À
6. Install :
À • Oil Seal ¿ New Using TFF Oil Seal
Installation Tool À
NOTE :
• Before installing the Oil Seal ¿ apply lithium
soap base grease onto the Oil Seal lips.
• Adjust the Ring Snap so that it fits into the
Outer Tube Groove
CAUTION:
WARNING
Make sure that the Oil Seal numbered side
faces upward
7. Install :
¿ • Washer ¿
À Á
• Ring Snap À
• Dust Seal Á
8. Inspect :
• Inner Tube operation
Unsmooth operation Ÿ Disassembly and
recheck
6-38
R-39
CHAS
FRONT FORK
9. Fill :
• Fork Oil ¿
Oil Quantity :
Overhauling - 153 ± 3 ml
Refilling - 139 ± 3 ml
Recommended Oil :
Teleshocab Oil
11. Install :
¿ • Front Fork Spring ¿
• Seat Upper
• Spacer
12. Install :
• Cap Bolt Temporarily to avoid oil drain.
NOTE :
• Install the Fork Spring with its smaller Pitch
upward.
• Before installing the Cap Bolt, apply grease to
the O-Ring.
2. Tighten
• Pinch Bolts (underbracket) ¿
• Cap Bolts À
À
6-39
L-40
CHAS
STEERING HEAD AND HANDLEBAR
STEERING HEAD AND HANDLEBAR
¿ Bolt Steering È Ball Race Cover 1
À Holder Handle bar Upper É Under Bracket
Á Handlebar Ê Ball Race (upper)
 Grip Assembly (right) Ë Ball (upper)
à Handle Crown Ì Ball (lower)
Ä Lock Washer Í Ball Race (center)
Å Ring Nut (upper) Î Ball Race (lower)
Æ Damper Rubber
Ç Ring Nut (lower)
¿
Ã
Tightening Steps
• Tighten the ring nut Lower
33 Nm (3.3 m.kg, 25 ft.lb)
• Loosen One turn
• Retighten The ring nut Lower
23 Nm (2.3 m.kg, 17 ft.lb)
6-40
R-41
CHAS
STEERING HEAD AND HANDLEBAR
REMOVAL
WARNING
À
Á Securely support the motorcycle so that
there is no danger of it falling over
Stand the motorcycle on a level surface
1. Remove :
¿ • Band ¿
• Brake Hose (front) À
• Clutch Cable Á
À • Speedometer Cable
2. Remove :
• Starter wire ¿
• Switch Handle À
3. Remove :
• Bolts (4 Nos) ¿
• Handlebar Upper Holder À
• Handlebar Á
• Throttle Grip
• Lever Holder (Front Brake)
Á À ¿ 4. Remove :
• Front Wheel
Refer to “FRONT WHEEL” Section, Page
No 6-4
• Front Fender
• Front Fork
Refer to “FRONT FORK” Section, Page no
6-21
5. Remove :
• Fuel Tank
Refer to “SIDE COVERS, SEAT, FUEL
TANK” section in Chapter 3, page no 3-3
¿
6. Remove :
• Headlight Assembly ¿
• Bolt Steering
• Bolt Cap (Upper Bracket) - 2 Nos.
• Upper Bracket
6-41
L-42
CHAS
STEERING HEAD AND HANDLEBAR
7. Remove :
Lock Washer ¿
¿ Ring Nut (upper) À
À Damper Rubber Á
8. Remove :
• Ring Nut (lower) ¿
Use a Ring Nut Wrench À
À
Ring Nut Wrench :
YSST - 621
¿ WARNING
Securely support the Steering Shaft so that
there is no danger of it falling down
9. Remove :
• Bearing Cover ¿
• Bearing Race À
• Rack Balls (upper) Á
• Lower Bracket Â
• Rack Balls (lower) Ã
HANDLEBAR REMOVAL
1. Remove :
• Grip (left)
ææææææææææææææææææææææææææææææææææ
Removal Steps :
• Blow with compressed air between the Handle-
bar and Adhesive side of the Grip to remove
ææææææææææææææææææææææææææææææææææ
HANDLEBAR INSPECTION
¿ 1. Inspect :
• Handlebar ¿
Bends/Cracks/damage Ÿ Replace
WARNING
Do not attempt to straighten a bent Handle-
bar as this may dangerously weaken the
Handlebar
6-42
R-43
CHAS
STEERING HEAD AND HANDLEBAR
STEERING INSPECTION
1. Wash the Bearing and Ball Races with a sol-
vent
2
2. Inspect :
1 • Bearing Races ¿
• Ball Cage Bearing À
Pitting/Damage Ÿ Replace
ææææææææææææææææææææææææææææææææææ
Bearing Race replacement steps :
• Remove the Ball Races on the Head Pipe us-
ing Long Rod ¿ and the hammer as shown
• Remove the Ball Race on the Under Bracket
using the floor chisel À and the hammer as
shown
• Install the new Dust Seal and Races
ææææææææææææææææææææææææææææææææææ
NOTE :
Always replace Bearing races as a set.
CAUTION:
WARNING
If Bearing Race is not fitted squarely, the
Head Pipe could be damaged.
STEERING INSTALLATION
Reverse the “REMOVAL”procedure
Note the following points
1. Lubricate
• Balls (upper and lower)
• Ball Races
Recommended lubricant
Lithium - soap base grease
2. Install :
• Ring Nut (lower) ¿
• Damper Rubber À
• Ring Nut (upper) Á
• Lock Washer Â
Refer to “STEERING HEAD
INSPECTION” section in Chapter 3, Page
no 3-22
3. Install :
• Bush
• Meter Assembly with Handle Crown
Ring Nut:
23 Nm (2.3 m.kg, 17 ft.lb)
6-43
L-44
CHAS
STEERING HEAD AND HANDLEBAR
4. Install :
• Front Fork
Refer to “FRONT FORK” Section, Page no
6-27
• Front Fender
• Front Wheel
Refer to “FRONT WHEEL” Section, Page
no 6-8
HANDLEBAR INSTALLATION
1. Install :
• Holder Handelbar Lower ¿
• Handlebar ¿
• Upper Handlebar Holder À
NOTE :
• Apply a light coat of lithium soap base grease
onto the Handlebar right end
• The Upper Handlebar Holders should be in-
stalled with the longer side ç to the forward,
then tighten the Front Bolt as shown
2. Install :
• Front Brake Lever Assembly ¿
• Handlebar Switch (left)
• Grip Assembly
• Throttle Cable
• Housing (Throttle Grip)
¿
NOTE :
Align the projection ç on the Handlebar Switch
with the Hole è in the Handlebar.
WARNING
Check the throttle grip for smooth operation
ç
3. Adjust :
• Throttle Cable free play
• Brake operation
Refer to “THROTTLE CABLE ADJUSTMENT
/ BRAKE LEVER ADJUSTMENT” section in
è
Chapter 3, Page no 3-9 and 3-18
6-44
R-45
CHAS
REAR SHOCK ABSORBER AND SWING ARM
REAR SHOCK ABSORBER AND SWINGARM
¿ Rear Shock Absorber
À Axle Nut
Á Swing arm
 Tension Bar
à Seal Guard
6-45
L-46
CHAS
REAR SHOCK ABSORBER AND SWING ARM
REMOVAL
1. Stand the Motorcycle on a level surface.
WARNING
Securely support the Motorcycle on a level sur-
face
2. Remove :
• Side Covers (left and right)
• Seat
• Cover Chaincase
• Chain Case (upper and lower)
Refer to “SIDE COVERS, SEAT, AND
FUEL TANK ” section in Chapter 3, Page
no 3-3
3. Remove :
• Rear Wheel
• Driven Sprocket Assembly
Refer to “DRIVE CHAIN AND
SPROCKETS” section, Page no 6-16
4. Remove :
• Nut Rear Shocker (upper and lower)
• Rear Shock Absorber (left and right)
5. Remove :
• Nut Footrest L.H./R.H.
• Axle Nut (Swing Arm) ¿
¿ À
• Washer À
• Axle Shaft Á
Â
• Foot Rest LH/RH
• Swing Arm Â
Á
6-46
R-47
CHAS
REAR SHOCK ABSORBER AND SWING ARM
INSPECTION
1. Inspect :
• Swingarm looseness
Looseness exists Ÿ Tighten the Pivot
Shaft nut or replace Bushes
• Swingarm up and down movement
Unsmooth movement/bending/rough spots
Ÿ Replace Bushes
2. Inspect :
• Rear Shock Absorber
Oil leaks/damage Ÿ Replace the Rear
Shock Absorber Element
6-47
L-48
CHAS
R-1
ELEC
CHAPTER 7
ELECTRICAL
7-1
L-2
ELEC
CIRCUIT DIAGRAM
7-2
R-3
ELEC
ELECTRICAL COMPONENTS
LOCATION OF ELECTRICAL COMPONENTS
¿ Main Switch Å Neutral Switch Assy
À Flasher Relay Assy Æ Rectifier / Regulator Assy
Á C.D.I. Unit Assy Ç Ignition Coil Assy
 Battery È Spark Plug Cap
à Fuse É Horn
Ä Stop Switch Rear Ê Throttle Position Sensor (TPS)
7-3
L-4
ELEC
CHECKING OF CONNECTIONS
CHECKING OF CONNECTIONS
Dealing with wire pressed stains, rust,
moisture etc. on the connector.
1. Disconnect
• Connector ¿
2. Dry each terminal with an air blower
3. Connect and disconnect the Connector two
or three times.
4. Pull the lead to check that it will not come
off.
7-4
R-5
ELEC
CHECKING OF SWITCHES
CHECKING OF SWITCHES
CHECKING STEPS
Use a pocket tester to check the terminals
for continuity. If the continuity is faulty at
any point, replace the switch.
NOTE:
• Turn the switch key to the “ON” and “OFF”
several times.
• Set the pocket tester selector to the
“Ohm x 1
• Set the pocket tester to “0” before starting
the test.
In this chart:
“Br” and “R” are continuous with the “ON”
switch position.
7-5
L-6
ELEC
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUTOFF SYSTEM
OPERATION
à Ä
¿ Battery
Æ À Fuse(main)
Á Main Switch
 Kill Switch
à Neutral Light Switch
Ä Clutch Switch
 ŠStarter Switch
Å Æ Relay-1
Ç Starter Relay
È Starter Motor
Ç È
Conition-1
Vehicle in Neutral Gear
The main switch Á and kill switch  is
set to “ON” position then Press the
starter switch Å to operate the starter
motor È.
Á Condition-2
À Vehicle in Gear
¿
The main switch Á and kill switch  set
“ON” position and press the clutch lever
to operate the clutch switch Ä then
press the starter switch Å simultaniously
to operate the starter motor È.
COLOUR CODE
R Red
B/L Brown/Blue
Br Brown
LB Blue/Black
RW Red/White
LW Blue/White
Sb Sky Blue
RB Red/Blue
7-6
R-7
ELEC
IGNITION SYSTEM / CHARGING SYSTEM
CIRCUIT DIAGRAM Å Ignition coil and Spark plug
¿ Magneto Æ Fuse
À Rectifier / Regulator Ç Starter Relay Assy.
Á Battery È Relay-A
 Main switch É Clutch Switch
à “Engine Stop” switch Ê Neutral Switch
Ä C.D.I. unit Ë Starter Motor
Ì Starter Switch
IGNITION SYSTEM, CHARGING SYSTEM AND TACHOMETER CIRCUIT
Ë
Ç
Æ Á
¿ À
7-7
L-8
ELEC
IGNTION SYSTEM / CHARGING SYSTEM
Procedure
Check: 7. Sensor coil resistance
1. Fuse 8. Charging coil resistance
2. Battery 9. Rectivier cum Regulator Unit
3. Spark plug 10. Wiring connection
4. Spark plug cap resistance (entire ignition system)
5. Ignition coil resistance 11. CDI Unit
6. Main switch 12. Tachometer
13. Engine stop switch
NOTE:
• Remove the following parts before troubleshooting:
1) Side covers (LH/RH)
2) Saddle
3) Fuel Tank
• Use the special tools specified in this troubleshooting
Multemeter
1. FUSE
• Remove the fuse. NON CONTINUITY
Ω x1) to the
• Connect the pocket tester (Ω
fuse.
• Check the fuse for continuity.
Refer to the Fuse inspection section in
Chapter 3 Page No. 3-6.
Fuse is faulty, replace it.
CONTINUITY
2.BATTERY
• Check the battery condition.
INCORRECT
Voltage:12.8V
Specifc gravity: 1.280 g/dm³
Electrolyte level
CORRECT
• Clean battery terminals.
• Recharge or replace battery.
• Refil with distilled water.
7-8
R-9
ELEC
IGNTION SYSTEM / CHARGING SYSTEM
CORRECT
MEETS
SPECIFICATION
7-9
L-10
¿
Primary coil resistance :
À
0.22 Ω ± 15 %
5B. IGNITION COIL RESISTANCE (Second- Multimeter (+) lead Ÿ High Tension lead ¿
ary) Multimeter (-) lead Ÿ Green Terminal À
• Connect the Multimeter to the Ignition Coil
• Check the secondary coil resistance
À
OUT OF SPECIFICATION
BOTH MEET
SPECIFICATIONS
Ignition Coil OK Replace the Ignition Coil
6. MAIN SWITCH
Main Switch OK
7-10
R-11
MEETS
SPECIFICATION
OUT OF SPECIFICATION
MEETS
SPECIFICATIONS
7-11
L-12
ELEC
IGNITION SYSTEM / CHARGING SYSTEM
9. RECTIFIER CUM REGULATOR UNIT Multimeter (+) lead Ÿ Battery (+) terminal ¿
Multimeter (-) lead Ÿ Battery (-) terminal À
• Check the Charging Voltage
À
Procedure Steps ¿
• Connect the Tachometer to Spark plug lead
• Connect the Multimeter ( DC 20V) to Bat-
tery Red Wire.
Measure the Battery Voltage : 12.8 V
If less than specifications, charge the
Battery
• Start the engine and accelearte the Engine
up to 5000 RPM .
• Check the Charging voltage :
Charging voltage :
14 ~ 15 V at 5000RPM MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
Rectifier cum Regulator unit is faulty. Charging Circuit and Rectifier cum Regula-
• Replace RR unit tor are OK
IF CORRECT
7-12
R-13
ELEC
IGNITION SYSTEM / CHARGING SYSTEM
YES NO
Replace the Right
Handlebar Switch
TROUBLE SHOOTING
Check:
• Check the fuse for continuity.
1. Main fuse
Refer to Fuse inspection section in
2. Battery
Chapter-3 Page No. 3-6.
3. Starter motor
4. Relay -A
5. Starter relay
6. Main switch
7. Engine Stop switch
8. Starter Switch YES NO
9. Wiring connections
Replace the fuse
(Entire starting system)
NOTE:
2. BATTERY
• Before troubleshooting, remove the
• Check the condition of the battery.
following part(s):
Refer to Checking and charging the battery
1. Side panel (LH/RH)
in chapter 3 Page No. 3-4.
2. Saddle
3. Fuel Tank Minimum open-circuit voltae :
• Troubleshoot with the following special 12.8V or more at 20o C
tools(s) • Is the battery OK?
Multemeter :
YES NO
• Clean the battery
terminals.
• Recharge or replace
the battery.
7-13
L-14
ELEC
CHARGING SYSTEM
TROUBLE SHOOTING
IF THE BATTERY IS NOT CHARGED
PROCEDURE Note :
CHECK Remove the following parts before trouble shoot-
1. Fuse ing.
2. Battery 1) Side covers (LH )
3. Charging voltage • Use Service Instruments as specified.
4. Charging coil resistance
5. Wiring system (entire charging system) Engine Tachometer.
Digital Multimeter
1. FUSE
Refer to “FUSE INSPECTION SECTION” in
Chapter 3, Page no 3-30 NO CONTINUITY
CONTINUITY
CORRECT
OUT OF
SPECIFICATION
4. CHARGING COIL RESISTANCE. The Charging circuit is OK
• Refer to Charging coil resistance checking
method in the Ignition System section in OUT OF SPECIFICATION
this Chapter, Page no 7-7
MEETS
SPECIFICATION Replace the Charging Coil
5. WIRING CONNECTION
• Check entire Charging system for poor con- POOR CONNECTIONS
nections.
Refer to circuit diagram Section Page no 7-4
7-14
R-15
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM : AC
TROUBLE SHOOTING
IF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHT
DO NOT WORK
PROCEDURE Note :
CHECK Remove the following parts before trouble
1. Lighting Coil resistance shooting.
2. Light Switch 1) Side covers (LH and RH)
3. Dimmer Switch 2) Seat
4. Lighting Voltage 3) Headlight Assembly
5. Wiring connections (entire lighting system) 4) Battery
6. Check individual lighting circuits 5) Battery Box
Engine Tachometer.
Digital Multimeter
7-15
L-16
ELEC
LIGHTING SYSTEM
MEETS
SPECIFICATIONS
NO CONTINUITY
CONTINUITY
7-16
R-17
ELEC
LIGHTING SYSTEM
æ
4. LIGHTING VOLTAGE
Multimeter (+) lead Ÿ Blue terminal ¿
• Connect the Tachometer to Spark Plug Multimeter (-) lead Ÿ Black terminal À
lead.
• Disconnect the Taillight coupler from wire
harness
• Connect the Multimeter (AC 20 V) to tail-
light wire ¿
• Start the Engine and accelerate the engine
up to 5000 RPM
• Measure the lighting Voltage with (full load
by switching on the Headlight) À
Lighting Voltage :
(With Full Load) :
14V ±0.5 at 5000 RPM
OUT OF SPECIFICATION
MEETS
SPECIFICATION
CONTINUITY
7-17
L-18
ELEC
LIGHTING SYSTEM
æ
6. INDIVIDUAL LIGHTING CIRCUITS
A. If the Headlight and Highbeam Indicator
Light do not work
CONTINUITY
Continuity
CONTINUITY
7-18
R-19
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM : DC
Fuel Meter
TROUBLE SHOOTING
PROCEDURE Note :
CHECK Remove the following parts before trouble shooting.
1. Fuse 1) Side covers (LH/RH)
2. Battery 2) Seat
3. Main Switch 3) Fuel Tank
Digital Multimeter
4. Wiring connections (entire lighting system) 4) Headlight
5. Check individual lighting circuits
7-19
L-20
ELEC
SIGNAL SYSTEM
1. FUSE
CONTINUITY
CORRECT
CONTINUITY
CORRECT
7-20
R-21
ELEC
SIGNAL SYSTEM
5. INDIVIDUAL SIGNAL SYSTEMS
A. If the Horn does not work.
1. HORN SWITCH
OUT OF SPECIFICATION
MEETS
SPECIFICATION
3. HORN The wiring circuit from the Main Switch to the
Horn is faulty. Repair/Replace wireharness.
• Disconnect the “Pink” terminal from the
horn.
Multimeter (+) lead Ÿ Horn Terminal ¿
• Connect the multimeter (5 A) to the open
Multimeter (-) lead Ÿ Body earth À
terminal ¿ at “Horn”
• Turn the main switch “ON”
• Check current (Amperage) drawn by Horn
by connecting to body earth.
MEETS
SPECIFICATION
Horn is OK Adjust / Replace the Horn
7-21
L-22
ELEC
SIGNAL SYSTEM
B. If the Brake Light does not work.
1. BULB AND BULB SOCKETS
CONTINUITY
CONTINUITY
Replace the Brake Switch
MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
7-22
R-23
ELEC
SIGNAL SYSTEM
CONTINUITY
CONTINUITY
Replace the left Handlebar Switch.
OUT OF SPECIFICATION
æ MEETS
SPECIFICATION The wiring circuit from Main Switch to
Flasher Relay connector is faulty. Repair/
Replace
7-23
L-24
ELEC
SIGNAL SYSTEM
OUT OF SPECIFICATION
MEETS
SPECIFICATIONS
Wiring connection
Wiring circuit from the Turn Switch to Bulb
Socket connector is faulty. Repair/Replace
Refer to “CIRCUIT DIAGRAM”.
7-24
R-25
ELEC
SIGNAL SYSTEM
CONTINUITY
CONTINUITY
Replace the Neutral switch.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Check the connection of the entire signal
system.
Refer to “CIRCUIT DIAGRAM” Page no 7-14.
This circuit is O.K.
7-25
L-26
ELEC
IGNITION SYSTEM / CHARGING SYSTEM
RW RB
WARNING
LB SB
• A wire that is used as a jumper lead must
have atleast the same capacity or more as
that of the battery lead, otherwise the
jumper lead may burn. • Does the Relay-A have continuity between
• This check is likely to produce sparks, blue/black and red/white
therefore, make sure nothing flammable
is in the vicinity.
• Does the starter motor turn?
YES NO
5. STARTER RELAY
• Disconnect the starter relay coupler from
the harness.
• Connect the Multimeter (Ω Ω x 1) and battery
(12 V) to the starter relay coupler as
shown.
Positive Battery Terminal Ÿ blue/white ¿
Negative Battery Terminal Ÿ red/white À
7-26
R-27
ELEC
IGNITION SYSTEM / CHARGING SYSTEM
8. START SWITCH
YES NO
YES NO
YES NO
YES NO
The starting system Properly connect or
Replace the Main circuit is OK. repair/replace the
Switch. Wiring Harness.
YES NO
Replace the Right
Handlebar Switch
7-27
L-28
6 1
7
8
9
4
10 12
11
13
7-28
R-29
REMOVAL
1. Remove
• Starter Motor lead ¿
À Á 2. Remove
• Bolts À
¿ • Starter Motor Á
DISASSEMBLY
Á Â Ã 1. Put identifying marks on the
brackets for reassembly.
2. Remove:
¿ À • Bolts - 2 Nos. ¿
• Front bracket À
Ä Å • Shim Á
• Washer Â
3. Remove:
• Armature Ã
• Yoke Ä
• Rear bracket Å
¿
4. Remove:
• Screw - 2 Nos ¿
• Brush spring set À
2. Measure:
• Commutator diameter ç
Out of specification Ÿ Replace
¿
starter motor
7-29
L-30
Mica Undercut
0.7 mm
4. Inspect:
• Armature coil (insulation/continuity)
Defects Ÿ Replace starte motor.
ææææææææææææææææææææææææææææææææææ
Inspecting steps :
• Connect the Multimeter for continuity
check ¿ and insulation check À.
• Measure the armature resistances.
• If the resistance is incorect, replace the
starter motor.
ææææææææææææææææææææææææææææææææææ
NOTE:
The brush dust in the armature should be
throughly cleaned before this test.
7-30
R-31
NOTE:
When replacing the brush, take care as
one side soldered.
7. Measure:
• Brush spring force
Fatigue/Out of specification Ÿ
Replace as a set.
8. Inspect:
¿ • Bearing ¿
• Oil Seal À
• Bush Á
Damage ŸReplace the bracket.
À • O-Ring Â
 Á Wear/damageŸReplace
ASSEMBLY
Reverse the “REMOVAL”procedure.
¿ 1. Install:
• Brush springs ¿
• Brush set À
À
7-31
L-32
NOTE:
When installing the brush, pass the brush
lead outside of the projection on the brush
¿ spring holder. During installing the brush,
install the brush lead terminal to the
projection on the side of brush spring
holder.
NOTE:
When installing the armature, press the
brush with thin screwdriver, etc. to avoid
damage to the brush and install.
3. Install:
• O-ring
CAUTION:
Always use O-rings.
4. Install:
¿
• Yoke ¿
NOTE:
Align the match mark on the yoke with the
match mark on the rear bracket.
7-32
R-33
NOTE:
• Align the projection of the washer with
the slot of the front bracket and install.
• Align the match mark ç on to yoke with
the match mark è on the front bracket.
Bolt :
5 Nm (0.5 m.kg. --- lbft)
INSTALLATION
1. Install:
• Starter motor - ¿
ç
è NOTE:
Apply a lightly grease to the O-ring.
2. Install:
• Starter motor bolts À
¿ • Starter motor lead Á
À
7-33
L-34
ELEC
7-34
CHAPTER 8
TROUBLE SHOOTING
TRBL
STARTING FAILURE / HARD STARTING SHTG
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection,
adjustment and replacement of parts.
Air Filter
• Clogged Air Filter element
• Improper Air Filter fitment
8-1
8-2
R-3
TRBL
POOR IDLE SPEED PERFORMANCE SHTG
IGNITION SYSTEM Ignition system
• Faulty C.D.I Unit
Spark Plug • Faulty Sensor Coil
• Improper Plug gap • Broken Magneto Woodruff Key
• Worn Electrodes
• Wire between Terminals broken Switch
• Improper heat range • Faulty Main Switch
• Faulty Spark Plug Cap
Wiring
Ignition Coil • Loose Coupler connection
• Broken or shorted Primary /Secondary Coil • Improperly grounded
• Faulty High Tension Cord • Broken Wireharness
• Broken Ignition Coil body R. R. Unit
• Faulty R. R. Unit
8-3
L-4
TRBL
POOR SPEED PERFORMANCE SHTG
Engine Oil
Brakes
• Dragging brake
CLUTCH SLIPPING/DRAGGING
Clutch Clutch
• Improperly adjusted clutch cable • Warped pressure plate
• Loose clutch spring • Unevenly tensioned clutch spring
• Fatigued clutch spring • Bent push rod
• Worn friction plate/clutch plate • Broken clutch boss
• Incorrectly assembled clutch • Burnt primary driven gear bushing
• Bent clutch plate
Engine oil • Swollen friction plate
• Improper oil level
• Improper quality (low viscosity) Engine oil
• Deterioration • Improper oil level
• Improper quality/(high viscosity)
• Deterioration
8-4
R-5
TRBL
FAULTY GEAR SHIFTING / OVERHEATING SHTG
Transmission
• Seized Transmission Gear
• Clogged impurities
• Incorrectly assembled transmission
OVER HEATING
Ignition system Compression System
• Improper Spark Plug gap • Heavy carbon deposit built-up
• Improper Spark Plug heat range • Improperly adjusted Valve timing
• Faulty C.D.I. unit • Improperly adjusted Valve clearance
Brakes
• Dragging brake
FAULTY BRAKE
8-5
8-4
L-6
UNSTABLE HANDLING
Handlebars Wheels
• Improperly installed or bent • Incorrect Wheel balance
• Loose Handlebar Tightening Bolt • Loose Spokes
Steering • Deformed Wheel Rim
• Improperly installed Handlebar Crown • Unevenly worn Tyres
• Loose or overtightened Steering Nut • Incorrect Tyre pressure
• Loose or overtightened Steering Nut • Loose Bearing
• Bent Under Bracket • Bent or loose Wheel Axle
• Improperly installed Steering Shaft (improp- • Excessive Wheel Runout
erly tightened Ring Nut) Frame
• Damaged Bearing or Ball Race • Twisted
Front forks • Improperly installed Bearing Race
• Uneven oil levels on both sides • Faulty Bushing
• Uneven spring tension • Bent Rear Arm
• Broken Front Fork Spring Rear arm
• Fatigued Front Fork Spring • Worn or damaged Bush
• Twisted Front Forks • Bent rear arm
Rear shock absorber
• Fatigued spring
• Improperly adjusted Spring preload
• Oil leakage
Drive chain
• Improperly adjusted Chain line
8-5
8-6
R-7
TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
FLASHER KEEPS ON
• Faulty Flasher Relay
• Insufficient Battery capacity (nearly dis-
charged)
• Bulb burnt out (front or rear)
8-7
8-6
L-8
TRBL
STARTING FAILURE / HARD STARTING SHTG
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection,
adjustment and replacement of parts.
BRAKE
• Glazed Pads.
8-8
R-9
TRBL
POOR IDLE SPEED PERFORMANCE SHTG
STARTER MOTOR
• Motor defective
8-9
NOTES
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
NOTES
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
NOTES
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
NOTES
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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NOTES
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○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
YAMAHA MOTOR INDIA SALES PVT. LIMITED
A-3, Industrial Area, Noida Dadri Road, Surapur 201 306 (UP) India
5YY-F8197-E0
PRINTED IN INDIA
GLADIATOR
1Y16(WM-01)298-03-07-E
MARCH
YBR125 DX (Gladiator) SERVICE MANUAL 2007
E
IN
SP