Ybr 110

2011
SERVICE MANUAL
YBR 110A
5TS-F8197-E2
YBR 110A (5TSG) 2011
SERVICE MANUAL
©2011 by India Yamaha Motor Pvt. Ltd.
First edition, May 2011
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
IMPORTANT
This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
India Yamaha Motor Pvt. Ltd., is continually striving to improve all of its models. Modifications and signif-
icant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE
damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL
MANUAL ORGANISATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the Title of the Chapter with its symbol on the upper right corner of each page.
2nd title 2 : This title indicates the Section of the chapter and only appears on the first page
of each section. It is located in the centre of the page.
3rd title 3 : This title indicates a Subsection that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are Exploded Diagrams at start of
each Removal and Disassembly section.
1. An easy-to-see Exploded Diagram “4” is provided for Disassembly and Assembly jobs.
2. Numbers “5” are given in the order of jobs in the exploded diagram. A number that is en-
closed by a circle indicates a part.
3. An explanation of jobs and notes are presented in an easy-to-read way by the use of Symbol
Marks “6”. The meaning of the Symbol Marks are given on the next page.
4. For jobs requiring more information, the step-by-step format supplements “7” are given in
addition to the exploded diagram.
1
4 ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
2 ENGINE ASSEMBLY
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence 3
• Expander Spacer (Oil Ring) “1”
5 • Side Rails (Oil Ring) “2”
• 2nd Ring “3”
• Top Ring “4”
4 TIP :
• Make sure to install the Piston Rings so that
3 the GTP TOP1/GTP-TOP 2 marks are
located on the upper side of the 2nd Ring/
2 Top Ring
1 • Lubricate the Piston and Piston Rings with
2 Engine Oil.
7
2. Install :
• Piston “1”
6 • Piston Pin “2” using piston pin tool
3
Piston Pin replacer tool
a YSST - 207
• Piston Pin Circlip “3” New

1 2
3
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number
and content.
1. General GEN 2. Specifications SPEC

Information INFO
3. Periodic inspection
INSP 4. Engine
and adjustment ENG
ADJ
5. Carburetion CARB 6. Chassis CHAS
TRBL
7. Electrical ELEC 8. Troubleshooting
SHTG
Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.
9. Filling fluid 10.Lubricant 11.Special Tool
12.Torque 13.Wear Limit, 14.Engine speed

Clearance
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
19. Apply wheel 20.Apply lightweight 21. Apply molyb-

bearing grease lithium-soap denum disulfide
base grease grease
Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking
agent and when to install new parts
22. Apply locking

23. Use New One
agent (LOCKTITE*)
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION
INSP
AND ADJUSTMENTS ADJ 3
ENGINE ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLE SHOOTING TRBL
SHTG 8
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .............................................................................1-1
ENGINE SERIAL NUMBER...............................................................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND 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 ..............................................................................................................1-4

GEN
MOTORCYCLE IDENTIFICATION INFO
VEHICLE IDENTIFICATION NUMBER

(FRAME NO.)
The vehicle identification number “1” is stamped
into the frame.
TIP
The vehicle identification number issued to
identify your motorcycle and may be used to
register your motorcycle with the licensing
authority in your area.
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.
1-1
GEN
IMPORTANT INFORMATION INFO
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use proper Tools and Cleaning Equipment.

Refer to “SPECIAL SERVICE TOOLS” on
page no. 1-4.
3. When disassembling the Motorcycle, keep

mated parts together. This includes gears,
Cylinder, Piston and other mated parts that
have been “mated” through normal wear.
Mated parts must be reused as an assem-
bly or replaced.
4. During the Motorcycle disassembly, clean

all parts and place them in trays in the or-
der of disassembly. This will speed up as-
sembly time and help assure that all parts
are correctly reinstalled.
5. Keep Motorcycle and its parts away from

any source of fire.
1-2
GEN
IMPORTANT INFORMATION INFO
ALL REPLACEMENT PARTS

1. Use only genuine Y amaha parts for all
replacements. Use Y amalube Oil and
Grease recommended by Y amaha for
assembly and adjustment. Other brands
may be similar in function and appearance,
but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
1. Oil 2. During reassembly, properly oil all mating
2. Lip parts and bearings and lubricate the oil
3. Spring
4. Grease seallips with grease.
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1 BEARINGS AND OIL SEALS

1. Install the bearing (s) “1” and Oil Seal (s)
“2” with their manufacturer’s marks or
numbers facing outward. (In other words,
the stamped letters must be on the side
exposed to view.) When installing Oil Seal
1 (s), lubricate a light coating of lightweight
lithium base grease to the seal lip(s). Oil the
Bearings liberally when installing.
NOTICE
WARNING
Do not spin the bearing with compressed air
2
because this will damage 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 “1”, make
sure that the sharp-edged corner “2” is
positioned opposite to the thrust “3” it
1 receives. See the sectional view of shaft “4”.
3
2 WARNING
If the Circlip is fitted the wrong way it would
4 cause it to jump off its groove and damage
related components.
1-3
GEN
SPECIAL SERVICE TOOLS INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques.
Reference
Tool name/Tool No. Illustration
Pages
Piston Pin Replacer 4-6, 5-57

YSST - 207
This tool is used to replace Piston Pin.

T-handle 6-21
YSST-213
This tool is used to hold the TFF plunger for

loosening and tightening of Hex Socket
Head Bolt.
Clutch hub holder 4-7, 5-51

YSST-233
This tool is used to hold the Clutch Hub while

removing or installing Clutch Main Shaft Nut.
Spanner - Speedometer Gear Nut. 6-4, 6-6

YSST - 237
This tool is used to loosen or tighten the

Speedometer Gear Nut.
Crankshaft removing tool 4-12

YSST-265
This tool is used to remove the Crank Shaft

from the Crank Case.
Crank Shaft Installing Tool with Spacer

(a) (b) 4-37
(a) YSST-266
(b) YSST-267
These tools are used for installation of

Crank Shaft.
T.F.F. Oil Seal Remover
YSST - 270 6-21
This tool is used to remove T.F.F. oil seal.
1-4
GEN
Reference
Pages
TFF Oil Seal Installation Tool 6-24

YSST-275
This tool is used to install the TFF Oil Seal.
Valve spring compressor 4-14, 4-34

YSST-603
This tool is used when removing or installing

the valve, valve spring and cotter .
Piston Base
YSST - 604 4-58
This tool is used to support the Piston
Driving Sprocket Holder

YSST- 605 4-45
This tool is used to hold the Driving Sprocket
Valve Clearance Adjusting Tool. 3-7

YSST - 606
This tool is used to adjust valve clearance
Rocker Arm Shaft Puller

4-13
YSST - 608A
This tool is used to remove Rocker Arm Shaft.
Screw Driver (small).

YSST - 609 4-21
This tool is used to adjust throttle screw/retract

timing chain tensioner
1-5
GEN
Reference
Pages
Torx Bit (T - 30) 4-11, 4-47

YSST - 611

Cam Shifter Segment Screw.
Scraper
YSST-612 4-42
This tool is used for scraping the sealent

from Crankcase surface.
Feeler gauge 3-6, 3-7

YSST-615
This tool is used to check valve clearance
Steering nut socket 3-24, 6-29

YSST-621

steering ring nut.
Oil seal installing tool 4-51

YSST-622 f17.8
This tool is used to install oil seal in crank f9.8

case cover (RH).
Bearing Puller 6-2

YSST - 623
This tool is used to remove the Bearing

6201 of the axle main/6004 of the wheel
clutch hub bearing.
1-6
GEN
Reference
Pages
Bearing puller 6203 4-38

YSST-624 A
This tool is used to remove the bearing

6203 of the axle main/axle drive.
Center Plug Spanner 3-6, 3-11

YSST-625
This tool is used to remove/install the timing

mask accessing screw/crankshaft end
accessing screw from magneto cover.
Race Bearing Installing Tool 6-30

YSST-626
To install race bearings.
Magneto puller with spacer 4-10

YSST-628
This tool is used to remove the magneto
Magneto holder 4-6, 4-10

YSST-801
This tool is used to hold the magneto
Fixing tool bearing steering lower

6-30
YSST-870
This tool is used to install under bracket

bearing steering lower.
Mutimeter 3-33, 7-4,
INS-003 7-7, 7-15,
7-20, 7-24,
7-27, 7-33
This instrument is used to check the

electrical system.
1-7
GEN
Reference
Pages
Ignition checker
INS-007
This tool is used to check efficiency of

ignition at spark plug
Timing light 3-11

INS-008
This tool is used to check the ignition timing
Compression gauge 3-13

INS-009
This tool is used to measure engine

compression.
Vaccum Gauge
INS-010
This tool is used to check intake

vaccum.
Tachometer 3-8, 3-11

INS-011
This Instrument is used to check the

Engine RPM
Hydrometer 3-31
INS-012
This tool is used to check specific gravity of

Battery Electrolyte
Shocker Fixture & Shocker Plate 6-32
INS-014
This tool is used to change the damper
1-8
GEN
Reference
Pages
YAMAHA Bond 4-42

TG-1215
YAMAHA BOND
TG-1215
This adhesive is used on mating surfaces
while assembling Crankcase#1 and #2.
LOCTITE
Three Bond 1322
THREE
This adhesive is used fortightening of BOND
Torx Screw .
1-9
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS........................................................................................................ 2-1
MAINTENANCE SPECIFICATIONS (ENGINE) ............................................................................. 2-2
MAINTENANCE SPECIFICATIONS (CHASSIS) ........................................................................... 2-9
MAINTENANCE SPECIFICATIONS (ELECTRICAL) ................................................................. 2-11
TIGHTENING TORQUES
GENERAL TIGHTENING TORQUE SPECIFICATIONS .............................................................. 2-13
ENGINE TIGHTENING TORQUES .............................................................................................. 2-14
CHASSIS TIGHTENING TORQUES ............................................................................................ 2-17
LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE ........................................................................................................................................ 2-18
CHASSIS .......................................................................................................................................2-19
ENGINE LUBRICATION ROUTE

ENGINE LUBRICATION ROUTE ................................................................................................. 2-20
ENGINE BEARINGS .................................................................................................................... 2-22
CABLE ROUTING ........................................................................................................................ 2-23

SPEC
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model 5TSG
Dimensions
Overall length 2040 mm
Overall width 745 mm
Overall height 1120 mm
Seat height 780 mm
Wheelbase 1285 mm
Ground clearance 185 mm
Minimum turning radius 2075 mm
Weight
Curb weight 125 kg
Maximum load 170 kg
2-1
SPEC
ENGINE SPECIFICATIONS
Maintenance Specification (Engine)

Engine
Engine type Air cooled 4-stroke, SOHC
Displacement 106 cm3
Cylinder arrangement Single cylinder
Bore × stroke 49.0 x 56.0 mm
Compression ratio 9.00 : 1
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Unleaded gasoline only
Fuel tank capacity 14.5 L
Fuel reserve amount 2.2 L
Engine oil
Type SAE 20W-40 or 10W-30
Recommended engine oil grade API service SE type or higher, JASO standard MA
Lubrication system Wet sump
Engine oil quantity
Quantity (disassembled) 1.20 L
Periodic oil change 1.00 L
Oil filter type Centrifugal
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.150 mm
Limit 0.20 mm
Outer-rotor-to-oil-pump-housing clearance 0.06-0.10 mm
Limit 0.15 mm
Oil-pump-housing-to-inner-and-outer-rotor clearance0.06-0.10 mm
Limit 0.15 mm
Spark plug (s)

Manufacturer/model CHAMPION POWER/P-RA7HC
Spark plug gap 0.8-0.9 mm
Cylinder head
Combustion chamber volume 10.20-10.60 cm3
Warpage limit 0.03 mm
2-2
SPEC
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 25.356-25.456 mm
Limit 25.326 mm
Intake B 20.989-21.089 mm
Limit 20.959 mm
Exhaust A 25.361-25.461 mm
Limit 25.331 mm
Exhaust B 21.001-21.101 mm
Limit 20.971 mm
Timing chain
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 10.000-10.015 mm
Limit 10.030 mm
Rocker arm shaft outside diameter 9.981-9.991 mm
Limit 9.950 mm
Valve, valve seat, valve guide

Intake 0.08-0.12 mm
Exhaust 0.10-0.14 mm
Valve dimensions
Valve head diameter (intake) 22.90-23.10 mm
Valve head diameter (exhaust) 19.90-20.10 mm
2-3
SPEC
Valve face width (intake) 1.400-3.000 mm

Valve face width (exhaust) 1.600-2.900 mm
Valve seat width (intake) 0.90-1.10 mm

Valve seat width (exhaust) 0.90-1.10 mm
Valve margin thickness (intake) 0.75-1.05 mm

Valve margin thickness (exhaust) 1.15-1.45 mm
Valve stem diameter (intake) 4.975-4.990 mm

Limit 4.450 mm
Valve stem diameter (exhaust) 4.460-4.475 mm
Limit 4.435 mm
Valve guide inside diameter (intake) 5.000-5.012 mm
Limit 5.042 mm
Valve guide inside diameter (exhaust) 5.000-5.012 mm
Limit 5.042 mm
Valve-stem-to-valve-guide clearance (intake) 0.010-0.037 mm
Limit 0.080 mm
Valve-stem-to-valve-guide clearance (exhaust) 0.025-0.052 mm
Limit 0.100 mm
Valve stem runout 0.010 mm
2-4
SPEC
Valve spring
Free length (intake) 47.20 mm
Limit 44.80 mm
Free length (exhaust) 47.20 mm
Limit 44.80 mm
Installed length (intake) 25.60 mm
Installed length (exhaust) 25.60 mm
Spring rate K1 (intake) 7.96 N/mm (0.81 kgf/mm)
Spring rate K2 (intake) 9.33 N/mm (0.95 kgf/mm)
Spring rate K1 (exhaust) 7.96 N/mm (0.81 kgf/mm)
Spring rate K2 (exhaust) 9.33 N/mm (0.95 kgf/mm)
Installed compression spring force (intake) 160.00-184.00 N (16.32-18.76 kgf)
Installed compression spring force (exhaust) 160.00-184.00 N (16.32-18.76 kgf)
Spring tilt (intake) 1.7 mm
Spring tilt (exhaust) 1.7 mm
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 49.000-49.020 mm
Piston
Piston-to-cylinder clearance 0.035-0.042 mm
Diameter D 48.962-48.981 mm
Offset 0.50 mm
Offset direction Intake side
H
D
Piston pin bore inside diameter 13.002-13.013 mm

Limit 13.043 mm
Piston pin outside diameter 12.996-13.000 mm
Limit 12.976 mm
2-5
SPEC
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.00 x 1.95 mm
End gap (installed) 0.10-0.25 mm
Limit 0.35 mm
Ring side clearance 0.030-0.065 mm
Limit 0.115 mm
B
T
2nd ring
Ring type Taper
Limit 0.50 mm
Ring side clearance 0.020-0.055 mm
Limit 0.115 mm
B
T
Oil ring
B
T
2-6
SPEC
Crankshaft
Width A 46.95-47.00 mm
Runout limit C 0.030 mm
Big end side clearance D 0.150-0.450 mm
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Friction plate thickness 2.92-3.08 mm
Wear limit 2.80 mm
Plate quantity 5 pcs
Clutch plate thickness 1.45-1.75 mm
Plate quantity 4 pcs
Warpage limit 0.20 mm
Clutch spring free length 32.00 mm
Limit 30.00 mm
Spring quantity 4 pcs
Push rod bending limit 0.50 mm
Transmission
Transmission type Constant mesh 4-speed
Primary reduction ratio 3.722 (67/18)
Final drive Chain
Secondary reduction ratio 3.214 (45/14)
Operation Left foot operation
Gear ratio
1st 3.000 (33/11)
2nd 1.688 (27/16)
3rd 1.200 (24/20)
4th 0.875 (21/24)
2-7
SPEC
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork thickness 4.76-4.89 mm
Kickstarter
Kickstarter type Ratchet
Kick clip friction force P 5.88-13.72 N (0.60-1.40 kgf)
Air filter
Air filter element Dry element
Carburetor
Type × quantity PTE18
ID mark 5TS3 10
Main jet #85
Main air jet #150
Jet needle NGEA
Pilot outlet 0
Pilot jet #38 x #38
Air screw turns out 5/8/2001
Valve seat size 1.6
Idling condition
Engine idling speed 1300-1500 r/min
CO% (air induction system OFF) 2.0-5.5 %
Intake vacuum 29.3-34.7 kPa (220-260 mmHg)
Oil temperature 75.0-85.0 degree C
2-8
SPEC
CHASSIS SPECIFICATIONS
Maintenance Specification (Chassis)

Chassis
Frame type Double cradle
Caster angle 26.40 degree
Trail 91 mm
Front wheel
Wheel type Cast wheel
Rim size 18x1.60
Rim material Aluminum
Wheel travel 120.0 mm
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 0.5 mm
Rear wheel
Wheel type Cast wheel
Rim size 18x1.60
Rim material Aluminum
Wheel travel 105.0 mm
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 0.5 mm
Front tyre
Size 2.75-18 4PR
Manufacturer/model LOCAL MADE/RIB TYPE
Wear limit (front) 1.0 mm
Rear tyre
Size 3.00-18 6PR
Manufacturer/model LOCAL MADE/RIB LUG TYPE
Wear limit (rear) 1.0 mm
Tire air pressure (measured on cold tires)

Loading condition 0-75 kg
Front 175 kPa (1.75 kgf/cm2)
Rear 225 kPa (2.25 kgf/cm2)
Loading condition 75 kg - maximum load
Front 175 kPa (1.75 kgf/cm2)
Rear 250 kPa (2.50 kgf/cm2)
Front brake
Type Drum brake
Operation Right hand operation
Front brake lever free play 10.0-15.0 mm
Front drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 130.0 mm
Limit 131.0 mm
Lining thickness 4.0 mm
Limit 2.0 mm
Shoe spring free length 52.0 mm
2-9
SPEC
CHASSIS SPECIFICATIONS
Rear brake
Type Drum brake
Operation Right foot operation
Brake pedal position 12.5 mm
Brake pedal free play 20.0-30.0 mm
Rear drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 130.0 mm
Limit 131.0 mm
Lining thickness 4.0 mm
Limit 2.0 mm
Shoe spring free length 52.0 mm
Steering
Steering bearing type Ball bearing
Center to lock angle (left) 43.0 degree
Center to lock angle (right) 43.0 degree
No./size of steel balls
(Upper) 19 pcs/0.187 in
(Lower) 16 pcs/0.250 in
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 120.0 mm
Fork spring free length 345.5 mm
Limit 339.0 mm
Spring rate K1 3.70 N/mm (0.38 kgf/mm)
Spring stroke K1 0.0-70.0 mm
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Rear suspension
Type Swingarm
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 90.0 mm
Spring free length 244.1 mm
Limit 239.2 mm
Spring installed length 227.1 mm
Optional spring available No
Swingarm
Swingarm end free play limit (radial) 1.0 mm
Swingarm end free play limit (axial) 1.0 mm
Drive chain
Type/manufacturer 420/LOCAL MADE
Number of links 118
Drive chain slack 35.0-45.0 mm
2-10
SPEC
ELECTRICAL SPECIFICATIONS
Maintenance Specification (Electrical)

System Voltage
System voltage 12 V
Ignition system
Ignition system DC CDI
Advancer type Electrical
Ignition timing (B.T.D.C.) 7.0 degree/1400 r/min
DC. CDI
Pickup coil resistance 104-156 ohm (L/Y-G)
Ignition coil
Minimum ignition spark gap 6.0 mm
Primary coil resistance 0.15-0.21 ohm
Secondary coil resistance 3.36-5.04 k.ohm
Spark plug cap
Material Resin
Resistance 5.0 k.ohm
AC magneto
Charging coil resistance 0.72-1.08 ohm (W-B)
Lighting coil resistance 0.32-0.48 ohm (Y-B)
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.0-15.0 V
Regulated voltage (AC) 12.8-13.6 V
Rectifier capacity 8.0 A
Battery
Model AB5L-B,12MX5L-B,MLX-5LE
Voltage, capacity 12 V, 5.0 Ah
Specific gravity 1.28
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 35.0 W/35.0 W x 1
Tail/brake light 12 V, 5.0 W/21.0 W x 1
Front turn signal light 12 V, 10.0 W x 2
Rear turn signal light 12 V, 10.0 W x 2
Meter lighting 12 V, 3.4 W x 3
2-11
SPEC
ELECTRICAL SPECIFICATIONS
Indicator light
Neutral indicator light 12 V, 3.4 W x 1
Turn signal indicator light 12 V, 1.7 W x 2
High beam indicator light 12 V, 3.4 W x 1
Electric starting system

System type Constant mesh
Starter motor
Power output 0.40 kW
Starter relay
Amperage 100.0 A
Coil resistance 3.51-4.29 ohm
Horn
Horn type Plane
Quantity 1
Maximum amperage 1.5 A
Turn signal relay

Relay type Full transistor
Built-in, self-canceling device No
Turn signal blinking frequency 70-100 cycles/min
Fuel sender unit

Sender unit resistance (full) 4.0-10.0 ohm
Sender unit resistance (empty) 90.0-100.0 ohm
Starting circuit cut-off relay

Coil resistance 90.0-110.0 ohm
Fuses
Main fuse 10.0 A
Spare fuse 10.0 A
2-12
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for
standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special
components or assemblies are provided for each
chapter of this manual. To avoid warpage, tighten
multi-fastener assemblies in a crisscross pattern
and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications require
clean, dry threads. Components should be at
room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-13
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES

Part to be tightened Parts Thread Q’ty Tightening torque Remark
Name Size Nm M.kg ft.lb
Cylinder Head Bolt M8 4 22 2.2 16 E
Cylinder head. (chain side) Bolt M6 2 10 1.0 7.2 E
Spark Plug - M12 1 17.5 1.75 13

Cylinder Head Side Cover Bolt M6 2 10 1.0 7.2
Valve Cover - M45 2 17.5 1.75 13
Magneto Rotor Nut M12 1 70 7.0 50
Stopper Guide 2 Bolt M6 1 10 1.0 7.2
Adjust Screw Nut M5 2 7.5 0.75 5
Sprocket (Timing Chain) Bolt M8 1 20 2.0 14
Plate To Head Cylinder Bolt M6 1 10 1.0 7.2
Plug (Tensioner Assembly) Bolt M6 1 7.5 0.75 5
Tensioner Assembly Bolt M6 2 10 1.0 7.2
Oil Pump Assembly Screw M6 2 7 0.7 5.1
Drain Plug Plug M12 1 20 2.0 14
Intake Manifold Bolt M6 2 10 1.0 7.2
Carburetor Joint (Manifold) Bolt M6 2 10 1.0 7.2
Air filter Case Bolt M6 2 7 0.7 5.1
Muffler Assy. (Cylinder Head) Bolt M6 2 10 1.0 7.2
Muffler Assembly Bolt M8 1 15 1.5 11
AIS Assembly Bolt M6 1 7 0.7 5.1
Pipe 2 Bolt M6 2 10 1.0 7.2
Crankcase 1 and 2 Bolt M6 2 10 1.0 7.2
Bolt M6 6 10 1.0 7.2
Bolt M6 2 10 1.0 7.2
Crankcase Cover 1 Bolt M6 1 10 1.0 7.2
Bolt M6 2 10 1.0 7.2
Bolt M6 4 10 1.0 7.2
Cover Chain Case 1 Screw M6 2 7 0.7 5.1
Crankcase Cover 2 Bolt M6 7 10 1.0 7.2
Bolt M6 2 10 1.0 7.2
Plate Screw M6 1 7 0.7 5.1
Timing Mark Cap Screw To be tighten closely to the seating surface
Crank Center Cap Screw To be tighten closely to the seating surface
Kick Crank Assembly Nut M12 1 50 5.0 36
Plate Idle Gear Screw M6 2 7 0.7 5.1
Starting Motor Assembly Bolt M6 2 10 1.0 7.2
Starter, clutch out. assembly. Bolt M8 3 30 3.0 2.2
Primary Drive Gear Nut M12 1 70 7.0 51
Pressure Plate 2 Bolt M5 4 6 0.6 4.3
Clutch Boss Nut M12 1 60 6.0 43
Push Rod Nut M6 1 8 0.8 5.8
Plate, Cover Screw M6 2 7 0.7 5.1
Drive Sprocket Bolt M6 1 10 1.0 7.2
2-14
SPEC
TIGHTENING TORQUES
Part to be tightened Parts Thread Q’ty Tightening torque Remark

Name Size Nm M.kg ft.lb
Shift Pedal Bolt M6 1 10 1.0 7.2
Segment Screw M6 1 12 1.2 9
Stopper lever Bolt M6 1 10 1.0 7.2
Sensor Assembly Screw M6 2 10 1.0 7.2
Neutral Switch Assembly - M10 1 17 1.7 13
Neutral Switch Assembly Screw M4 1 1.3 0.13 1
Stator Screw M6 3 10 1.0 7.2
2-15
SPEC
TIGHTENING TORQUES
Cylinder head tightening sequence:
4 1
2 3
5 6
Magneto cover tightening sequence:
7
1,6
5 8
4
9
3,11
2,10
Clutch cover tightening sequence:
2
7
4 5
6
3
9
1 8
2-16
SPEC
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES

PART TO BE TIGHTENED THREAD TIGHTENING TORQUE REMARKS
SIZE Nm m.kg ft.lb
Front Engine Stay and Mount M 8 X 1.25 38 3.8 27.5
Front Engine Stay and Frame M 8 X 1.25 38 3.8 27.5
Rear Engine Mount and Frame M 8 X 1.25 38 3.8 27.5
Upper Engine Stay and Mount M 8 X 1.25 38 3.8 27.5
Upper Engine Stay and Frame M 8 X 1.25 38 3.8 27.5
Front Lower Engine Mount and Frame M 8 X 1.25 38 3.8 27.5
Rear Lower Engine Mount and Frame M 8 x 1.25 38 3.8 27.5
Handle Crown and Inner Tube M 10 X 1.25 45 4.5 33 E
Handle Crown and Steering Shaft M 10 X 1.25 35 3.5 25 E
Under Bracket and Inner Tube M 10 X 1.25 28 2.8 20

Steering Shaft and Ring Nut* M 25 X 1.25 22 2.2 17
Handle Crown and Handle M 8 X 1.25 23 2.3 17
Front Fender M 6 X 1.0 10 1.0 7
Front Flasher and Headlight stay M 12 X 1.25 7 0.7 5.1
Speedometer Cable and Speedometer M 12 X 1.0 2.5 0.25 2
Stay Cowling & Under Bracket M 6 X 1.0 10 1.0 7
Handle Crown and Main Switch M 6 X 1.0 13 1.3 9.4
Stay Head Light and Emblem M 5 X 0.8 3.8 0.38 3
Front Wheel Axle Nut M 10 X 1.25 45.5 4.55 33
Rear Wheel Axle Nut M 14 X 1.5 91 9.1 66
Wheel Sprocket and Clutch Hub M 8 X 1.25 40 4.0 29
Tensioner Bar M 8 X 1.25 19 1.9 14
Sprocket Axle Nut M 20 X 1.0 91 9.1 66
Camshaft Lever M 6 X 1.0 9.8 0.98 7.1
Fuel Cock M 6 X 1.0 7 0.7 5.1
Ignition Coil M 6 X 1.0 3.8 0.38 3
Battery Box M 6 X 1.0 3.8 0.38 3
Rear Fender M 6 X 1.0 3.8 0.38 3
Pivot Axle Nut M 12 X 1.25 59 5.9 43
Rear Shock Absorber M 10 X 1.25 40 4.0 29
Tension Bar and Rear Arm M 8 X 1.25 19 1.9 14
Side Stand M 8 X 1.25 28 2.8 20
Footrest and Frame M 8 X 1.25 33 3.3 23
Footrest Mounting Lower M 8 x 1.25 16 1.6 12
Horn Nut M6 7 0.7 5
Taillight assembly M5 2 0.2 1
TIP :
1. First tighten the Ring Nut approximately 45.5 Nm (4.55 m.kg 32.3 ft.lb) by using the torque
wrench then loosen the Ring Nut one turn.
2. Retighten the Ring Nut to specifications
2-17
SPEC
TIGHTENING TORQUES
LUBRICATION POINTS AND LUBRICANT TYPE

ENGINE
Lubrication points (part name) Lubricant type
Oil Seal lips (all) LS
Bearing Retainer (all) E
Bolt (Cylinder Head) LS
O-ring (Cylinder Head Side Cover and Valve Cover) E
Crank Pin E
Connecting Rod (big end) E
Piston Pin E
Valve Stem and Valve Guide E
Oil Seal (Valve Stem End) E
Rocker Arm Shaft and Rocker Arm E
Cam and Bearing (Camshaft) E
Push Rod E
Primary Driven Gear and Main Axle E
Push Lever Axle E
Rotary Filter and Oil Pump E
Sliding Gear (Transmission) E
Kick Axle Shaft E
Axle Drive E
Shift Fork and Guide Bar E
Shift Cam and Bearing (shift cam) E
Camshaft lobes E
Crankcase Mating Surfaces Yamaha bond No. 1215
Crankcase Cover 1 and Grommet Yamaha bond No. 1215
2-18
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
LUBRICATION POINTS AND LUBRICANT TYPE

CHASSIS
Lubrication points (part name) Lubricant type
Gear Unit (Gear Meter and Drive) LS
Oil Seal Lips (all) LS
Pivot Shaft (Swingarm) LS
Pivoting Points (Brake Pedal Shaft and Frame) LS
Ball and Ball Race (Steering Head) LS
Tube Guide (Right Grip) LS
Pivoting points (Brake Lever and Clutch Lever) LS
Pivoting Point (Brake Shoe Plate) LS
Cable End (Front Brake and Clutch) LS
Pivoting Points (Sidestand Mainstand and Rear Footrest) LS
Brake Camshaft (Cam and Shaft) LS
Rear Wheel Axle Outer Surface LS
Rear Wheel Axle and Nut Threads LS
Front Wheel Axle Outer Surface LS
Steering Head Dust Seal LS

®)
Yamaha bond No.
Crankcase mating surface 1215 (Three Bond
No.1215 ®)
Yamaha bond No.
Timing chain tensioner bolts 1215 (Three Bond
No.1215 ®)
2-19
SPEC
Engine Lubrication route
NOTICE
WARNING
Do not damage crank case surfaces, otherwise oil leakage will start
2-20
SPEC
Engine Lubrication route
CAM SHAFT
CYLINDER HEAD
CYLINDER
COVER L.H.
SPACER
ROTARY FILTER
CRANK SHAFT
AXLE MAIN
CRANK
CASE R.H.
CRANK CASE L.H.

CLUTCH
AXLE DRIVE
COVER L.H.
2-21
SPEC
Engine Bearings
CAM SHAFT
BALL BEARING
BALL BEARING
SPACER
BALL BEARING
CRANK SHAFT
AXLE MAIN
BALL
BEARING
BALL
BEARING CLUTCH
AXLE DRIVE
BALL BEARING
BALL BEARING
2-22
SPEC
CABLE ROUTING
B
A 2
1
3
D
9
E
8 F
4
7
G
6
2-23
SPEC
CABLE ROUTING
1. Carburettor hose air bent A. Put on end wire at first next, put on outer
2. High tension cord wire. Never make inner wire bend
3. Throttle wire B. Pass throttle wire and starter wire
4. Clutch wire C. Tighten both earth lead wires of wire
5. Earth lead wire harness & ignition coil and ignition coil Brkt.
6. Clip together
7. RR. Stop SW. D. Starter wire:
8. RR. Stop SW. lead wire Pass upside of throttle wire.
9. Crank case breather pipe E. Pass throttle wire & starter wire
F. Pass clutch wire
G. Plug cap shall be installed such that
direction of high tension cord will be kept
backside
H. RR. Stop SW. to be tightened such that
direction of wire brake SW. will be kept
towards main pipe of frame.
2-24
SPEC
CABLE ROUTING
9 8
O
A
B C
1 4
2 3
5
E
N
L 7 F
K
G
H
6 I
10
13
11 16
14
18
17
12 19
G 15
2-25
SPEC
CABLE ROUTING
1. FR. Stop SW. lead wire A. Boot should be covered certainly after nut
2. Meter was adjusted.
3. Main SW. B. Pass starter wire through wire guide of Brkt.,
4. Clutch SW. lead wire : 5TS-H350E-1 0.
5. Flasher light C. Guide wire in stay:
6. Wire harness Route the wires - “most inner side starter
7. Horn wire then clutch wire and then clutch SW.
8. Bracket lead wire and then SW., handle 4 lead wire”.
9. Cover connector D. SW., handle 4 lead wire and clutch SW. lead
10. Meter lead wire wire pass behind of speedometer cable.
11. Starter wire E. Clamp:
12. Main S/W lead wire Put the connectors inside "cover connector"
13. Starter wire and next clamp cover connector & wire of
14. SW. handle 4 lead wire Brkt. : 5TS-H350E-10. After proper
15. Throttle wire clamping, cut extra length and turn the edge
16. Wire harness upside
17. Clutch wire F. Clamp :
18. Brake wire Clamp wire harness and clutch wire after
19. Clamp proper clamping, cut extra length and turn
the edge outside.
G. Pass speedometer cable through wire
guide.
H. Put brake wire in the front of wire harness &
clutch wire
I. Pass wire harness & clutch wire through
clamp. Wire harness must pass more left
side of vehicle than clutch wire at clamp.
J. Clamp:
Brake wire and clutch wire at the part of
under Brkt. After proper clamping, cut extra
length and turn the edge to right side of
vehicle.
K. Brake wire:
Put more left side of vehicle than Brkt. to
install cowling in stay, head light.
L. Starter wire:
Pass behind of SW., handle 4 lead wire,
clutch SW. lead wire & brake wire.
M. To headlight
N. Flasher light (L) lead wire shall be passed
fwd. side of "cover connector" and joined
inside "cover connector".
O. Guide wire in stay:
Route the wires -"inner side throttle wire and
outer side brake wire and front side stop
SW. lead wire".
2-26
SPEC
CABLE ROUTING
2
1
3
A
B
4C
5
6
8
7
D
2-27
SPEC
CABLE ROUTING
1. SW. Handle 1 lead wire A. Pass throttle wire FR. Stop SW. lead wire,
2. FR. Stop SW. brake wire & SW. handle 1 lead wire .
3. SW., Handle 1 B. Band:
4. FR. Stop SW. lead wire Clamp FR. Stop SW. lead wire and SW.,
5. Clutch SW. handle 1 lead wire at upper bend
6. Starter wire C. Band:
7. SW., handle 4 Clamp SW., handle 4 lead wire and clutch
8. SW., handle 4 lead wire SW. lead wire at upper bend
D. Pass clutch wire, starter wire, SW., handle 4
lead wire 8, clutch SW. lead wire
2-28
SPEC
CABLE ROUTING
B
A
C
2
3
7
5
F
6
H
E
2-29
SPEC
CABLE ROUTING
1. Tail light A. Put the connector of wires between clamps

2. Clamp B. Clamp:
3. Clamp Clamp tail light lead wire & flasher lead wire
4. Clamp (L.R.)
5. Clamp C. Clamp:
6. Rectifier regulator Clamp wire harness & flasher lead wire(L)
7. Carburettor hose air bent for about wire harness. Clamp the naked
part
D. Pass wire harness between frame and RR.
fender wire harness shall not ride on the
frame
E. Tighten earth lead wire and rectifier
regulator together
F. Wire harness to be setted such that direction
of flasher relay lead wire shall be kept
rightside
G. Clamp:
Carburettor hose air bent should not
collapse and break by clamping
H. At inspection, put out the plus terminal under
the side cover and connect it with the
outside battery
2-30
Y Z 24
19 34
X 20 25
23
AA 26
W 22 27
18 33
21 28
A 3
1 C F 29
16 32
2 B D 30
G
17 E
H 4 I J 31
K
5
K
6
2-31
M
N
O
13
CABLE ROUTING
39
8 40 38 35
12 37
Q 41
42
14 R
SPEC
V U 11
15 10 S 43 36
44
9 T
SPEC
CABLE ROUTING
1. Ignition coil F. Sender lead wire pass from front side

2. Sender G. Flasher relay:
3. Magneto lead wire Install flasher relay to frame after
4. Relay assy. connecting coupler
5. Battery plus lead wire H. Fit white marking of wire harness to frame
6. Starter relay clamp
7. Flasher light I. Make starter motor lead wire bend
8. Earth lead wire J. Push starter relay lead wire inside after
9. Starter motor lead wire connection
10. Carburettor overflow pipe K. Pass starter relay lead wire & plus lead wire
11. Clip through guide of battery box
12. Hose L. Pass through hole
13. Clip M. Clamp:
14. Brake wire After proper clamping cut extra length and
15. Speedometer cable turn the edge inside
16. Wire harness N. Fuse:
17. RR. fendor Fuse box shall be installed such that
18. Frame direction of battery connector side will be
19. Band kept downside
20. Battery minus lead wire O. Battery breather pipe:
21. Relay lead wire Pass inside battery fix white marking to rib
22. RR. Stop SW. lead wire of btry. box
23. Magneto lead wire P. When battery box is installed, pass starter
24. Relay assy. motor lead wire through wire guide of
25. Btry. Assy. backside of battery box. Confirm it by hole
26. Battery minus lead wire of battery box.
27. Band battery Q. Pass carburettor overflow pipe 8, battery
28. Relay lead wire breather pipe & starter motor lead wire
29. Magneto lead wire through left side between frame and crank
30. Starter motor lead wire case
31. Battery breather pipe R. Insert magneto lead wire to guide of cover,
32. Earth lead wire chain case
33. Carburettor overflow pipe S. Pass neutral lead wire through the ditch of
34. RR. Stop SW. lead wire cover crank case
35. CDI lead wire T. Pass carburettor overflow pipe & battery
36. Band breather pipe between footrest and frame
37. Wire harness U. Holder wire:
38. Ignition coil lead wire Pass brake wire and speedometer cable.
39. Starter motor lead wire V. Adjust length of boot to 45mm with bolt for
40. Wire harness adjustment of lever on handle side.
41. Rec/Reg lead wire W. Wire harness shall be installed such that
42. Band direction of branch of earth lead wire will be
43. Magneto lead wire kept towards upside
44. Sender lead wire X. Holder wire:
Pass wire harness & ignition coil lead wire.
A. CDI unit: Don't bend the holder wire when the wire is
Both sides of holder shall be in contact the installed
step of Brkt. Y. Pass ignition coil lead wire upside wire
B. CDI lead wire: harness ignition coil lead wire and bead
Don't stretch lead wire tight never touch each other
C. Wire harness shall be installed such that Z. RR. Stop SW. lead wire and bead never
direction of branch of Rec/Reg lead wire will touch each other
be kept downwards AA. Clamp magneto to lead wire first
D. Band:
Clamp sender lead wire, Rec/Reg lead wire
& magneto lead wire
E. Pass magneto lead wire, RR. stop SW. lead
wire & sender lead wire inside Rec/Reg lead
wire
2-32
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENTS
PERIODIC MAINTENANCE / LUBRICATION INTERVALS ...........................................................3-1
SIDE COVER, SEAT AND FUEL TANK

REMOVAL....................................................................................................................................... 3-3
INSTALLATION .............................................................................................................................. 3-5
ENGINE
VALVE CLEARANCE CHECKING ADJUSTMENT......................................................................... 3-6
IDLING CO MEASUREMENT AND ADJUSTMENT ........................................................................3-8
THROTTLE CABLE ADJUSTMENT ............................................................................................... 3-9
SPARK PLUG INSPECTION ....................................................................................................... 3-10
IGNITION TIMING CHECK ............................................................................................................3-11
COMPRESSION PRESSURE MEASUREMENT.......................................................................... 3-13
ENGINE OIL LEVEL INSPECTION .............................................................................................. 3-14
CHANGING THE ENGINE OIL ......................................................................................................3-15
EXHAUST SYSTEM INSPECTION................................................................................................3-15
AIR FILTER CLEANING.................................................................................................................3-16
CLUTCH CABLE ADJUSTMENT...................................................................................................3-18
CHASSIS
FRONT BRAKE ADJUSTMENT.....................................................................................................3-19
REAR BRAKE ADJUSTMENT .......................................................................................................3-20
BRAKE SHOE INSPECTION .........................................................................................................3-20
ADJUSTING THE REAR BRAKE LIGHT SWITCH........................................................................3-21
DRIVE CHAIN SLACK ADJUSTMENT ..........................................................................................3-21
CHECKING AND ADJUSTING THE STEERING HEAD................................................................3-24
CHECKING THE FRONT FORK....................................................................................................3-26
ADJUSTING THE SHOCK ABSORBER ASSEMBLIES ................................................................3-26
CHECKING THE TIRE ...................................................................................................................3-27
CHECKING THE WHEELS ............................................................................................................3-29
ELECTRICAL
CHECKING AND CHARGING THE BATTERY..............................................................................3-30
FUSE INSPECTION.......................................................................................................................3-33
HEADLIGHT BEAM ADJUSTMENT ..............................................................................................3-34
HEADLIGHT BULB REPLACEMENT ............................................................................................3-34
INTRODUCTION/ INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
TIP :
• From 12500 km (7800 mi), repeat the maintenance intervals starting from 2500 km (1550 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 500 km 2500 km 4500 km 6500 km 8500 km 10500km
(310 mi) (1550 mi) (2800 mi) (4040 mi) (5280 mi) (6520 mi)
1 * Fuel line • Check fuel hoses for cracks or damage.

2 * Fuel cock filter • Check condition and clean if necessary.
3 Spark plug • Check condition.
• Clean and regap.
• Replace.
4 * Valves • Check valve clearance. Adjust if necessary.
5 * Carburetor • Check starter (choke) operation.
• Adjust engine idling speed.
6 * Air induction system • Check the air cut-off valve, reed valve, and hose
for damage.
• Replace any damaged parts if necessary.
General maintenance and lubrication chart

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 500 km 2500 km 4500 km 6500 km 8500 km 10500 km
(310 mi) (1550 mi) (2800 mi) (4040 mi) (5280 mi) (6520 mi)
1 Air filter element • Clean.
• Replace. Every 12000 km (7500 mi)
2 * Battery • Check the battery output voltage.
• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly
routed.
3 Clutch • Check operation.
• Adjust.
4 * Front brake • Check operation and adjust brake lever free play.
• Replace brake shoes. Whenever worn to the limit
5 * Rear brake • Check operation and adjust brake pedal free play.
• Replace brake shoes. Whenever worn to the limit
6 * Wheels • Check runout and for damage.
7 * Tires • Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
8 * Wheel bearings • Check bearing for looseness or damage. Replace
if necessary.
• Lubricate with lithium-soap-based grease. Every 10000 km (6000 mi)
9 * Swingarm • Check operation and for excessive play.
10 Drive chain • Check chain slack, alignment and condition. Every 2000 km (1200 mi) after the initial 500 km (300 mi)
• Adjust and thoroughly lubricate chain with and after washing the motorcycle, riding in the rain or
YAMALUBE engine oil. riding in wet areas
3-1
INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 500 km 2500 km 4500 km 6500 km 8500 km 10500 km
(310 mi) (1550 mi) (2800 mi) (4040 mi) (5280 mi) (6520 mi)
11 * Steering bearings • Check bearing play and steering for roughness.
12 * Chassis fasteners • Make sure that all nuts, bolts and screws are
properly tightened.
13 Brake lever pivot shaft • Lubricate with silicone grease.
14 Brake pedal pivot shaft • Lubricate with lithium-soap-based grease.
15 Clutch lever pivot shaft • Lubricate with lithium-soap-based grease.
16 Shift pedal pivot shaft • Lubricate with lithium-soap-based grease.
17 Sidestand, centerstand • Check operation.
• Lubricate with lithium-soap-based grease.
18 * Front fork • Check operation and for oil leakage. Repair if
necessary.
• Replace oil. Every 10000 km (6000 mi)
19 * Shock absorber assembly • Check operation and shock absorber for oil
leakage.
20 Engine oil
• Change. (See page 3-15.)
• Check vehicle for oil leakage.

21 * Engine oil strainer • Clean.
22 * Front and rear brake
• Check operation.
switches
23 Moving parts and cables • Lubricate.
24 * Throttle grip • Check operation.
• Check throttle grip free play and adjust if
neccesary.
• Lubricate cable end and grip housing.
25 * Lights, signals and • Check operation.
switches • t t .
TIP :
• The air filter needs more frequent service if you riding in unusally wet or dusty areas.
3-2
INSP
SIDE COVERS, SEAT AND FUEL TANK ADJ
2 REMOVAL SIDE COVER (LH)

3 1. Remove
• Side Cover (LH)
ssssssssssssssssssssssss
Removal steps :
1
• Insert the key into the lock “1”, and then turn
it clockwise.
• Pull the Lug “2” towards you to remove it
from the Fuel Tank.
• Slide the Side Cover towards the front end
of the Motorcycle for removing the Lug “3”
from the Chassis.
2 3
3 2
REMOVAL SIDE COVER (RH)
1. Remove
• Side Cover (RH)
YBR
Removal steps :
1 • Remove the Screw “1” (bolt type).
• Pull the lug “2” outwards you to remove
it from the Fuel Tank.
• Slide the Side Cover forward to remove the
lug “3”.
3
3-3
INSP
3 REMOVAL SEAT
2 1 1. Remove
• Side Cover LH and RH “1”
• Bolts “2” Nos “2” from each side
• Seat “3”
REMOVAL FUEL TANK

1
Removal steps :
• Open seat bolts inside the side covers “1”.
• Lift the front of the Seat and slide it forward.
TIP:
• Position the Fuel Cock “2” to the ‘OFF’,
then disconnect the Fuel Hose.
• Place a cotton avoid the spilling of fuel in the
2
motorcycle
OFF
1. Disconnect
• Fuel Hose
• sender unit connector.
WARNING
• Gasoline is highly flammable.
• Avoid spilling of fuel on the hot Engine.
4
2. Remove
2 1 • Bolt (Fuel Tank) “1”
• Plate “2”
• Damper Rubber “3”
4. Remove
• Fuel Tank “4”
3-4
INSP
INSTALLATION
1
Reverse the REMOVAL procedure.
3 4 Note the following points.
Connect the fuel sender unit connections.
1. Install
• Fuel Tank “1”
• Damper Rubber “2”
• Plate “3”
• Bolt “4”
2. Connect
2
• Fuel Hose
Bolt (fuel tank)

16 Nm (1.6 mkg; 11 ft.lb)
a
TIP
• Keep the projection on plate “3” downward.
2
3. Install
b • Seat
• Bolts “1” and “2”
1 TIP
• Insert the projection “a” on the rear of the
seat into the seat holder “b” on the Chassis,
then push down front of the seat and tighten
1 the bolts.
Bolt (Seat)
7 Nm (0.7 mkg, 5.1 ft.lb)
4. Install
• Side Cover (LH) “1”.
• Insert the key, turn it counter clockwise,
and turn and then remove it
2 5. Install
• Side Cover (RH) “2”
• Secure the rear of the side cover, and
then push the front of the side cover in.
• Install the screw “3”
6. Tighten
• Screw “3” (bolt)
3 Screw (Side Cover)

3.8 Nm (0.38 mkg, 3.0 ft.lb)
3-5
INSP
VALVE CLEARANCE CHECKING AND ADJUSTMENT ADJ
ENGINE
VALVE CLEARANCE CHECKING AND
ADJUSTMENT
TIP
Valve clearance checking and adjustment
should be made with the Engine in cold
condition, at room temperature. When the
Valve clearance is to be measured or
adjusted, the Piston must be at Top Dead
Center (T.D.C.) on the compression stroke
and marking on Cam Sprocket should be
aligned with the marking on Cylinder Head.
1. Remove :
• Side Covers
• Seat
• Fuel Tank
Refer to “SIDE COVERS, SEAT AND FUEL
TANK” on Page no 3-3
3 2. Remove :
• Spark Plug
• Bolts (Cylinder Head Side Cover) “1” 2 nos
1 • Cylinder Head Side Cover “2”
4 • Valve Cover (intake side) “3”
• Valve Cover (exhaust side) “4”
2
3. Remove :
• Timing mark accessing screw “1” (with O-ring)
• Crank shaft end accessing scew “2”
3 (with O-ring).
• (With using Centre Plug Spanner “3”.
1
Centre Plug Spanner :
2 YSST - 625
4. Measure :
• Valve clearance (Intake and Exhaust) “1”
using Feeler Gauge “2”
Out of specification Ô Adjust.
Feeler Gauge :
2 YSST - 615
1 Valve clearance (cold)

Intake : 0.08 ~ 0.12 mm
Exhaust: 0.10 ~ 0.14 mm
3-6
INSP
VALVE CLEARANCE CHECKING AND ADJUSTMENT ADJ
Checking steps :
Measurement steps :
• Rotate the Crankshaft anticlockwise to align
a
the slit “a” third mark on the rotor with the
stationary pointer “b” on the Crankcase
b 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 “1”.
Out of specification Ô Adjust clearance.
1 Feeler Gauge
YSST 615
5. Adjust :
• Valve clearance
Adjustment steps :
• Loosen the Locknut “1”.
• Insert a filler guage “2” between the end of
the adjusting screw and valve tip.
• Turn the Adjuster “3” in or out with the Valve
adjusting tool “4” until specified valve
clearance is obtained.
Valve adjusting tool :

1 2 YSST - 606
4 Turning in Ô Valve clearance is decreased.

3
Turning out Ô Valve clearance is increased.
• Hold the Adjuster to prevent it from moving

and tighten the Locknut to specification.
Locknut :
8 Nm (0.8 m • kg, 5.8 ft • lb)
• Measure the Valve clearance again.

• If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
1
2 6. Install
• Timing mark accessing screw “1”
• Crank shaft and accessing screw
(with O-ring) “2”
3-7
INSP
IDLING CO. MEASUREMENT AND ADJUSTMENT ADJ
7. Install
1 • Valve Covers (with O-ring) “1”
• Spark Plug
• Cylinder Head Side Cover “2”
Valve cover (intake and exhaust) :

17.5 Nm (1.75 m kg, 13 ft-lb)
2 Bolts (cylinder head side cover) :
10 Nm (1.0 m kg, 7.2 ft-lb)
8. Install
• Fuel Tank
• Seat
• Side Covers
Refer to the “FUEL TANK, SEAT AND SIDE
COVERS” on Page no 3-3
1
IDLING CO. MEASUREMENT AND
ADJUSTMENT
Ÿ Prior to adjusting the engine idling speed, the

air filter element should be clean, spark pug
gap properly adjust and the engine should
have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:
ŸDigital tachometer “1” (onto the spark plug
lead)
2. Check :
1 ŸEngine idling speed
ŸTurn the throttle stop screw “1” in or out
IN until the specified engine idle speed is
OUT
obtained.
Turning In : Ô Increase in RPM
Turning Out : Ô Decrease in RPM
1 TIP :
Ÿ Before checking engine idle RPM always
check throttle cable free movement and free
play.
4. Insert :
• Sampling probe “1” (CO. tester ) to the exha-
ust pipe “2”
2
3-8
IDLING ‘CO’ MEASUREMENT AND ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ
CO.concentration :
2.0 - 5.5% with AIS Closed
IN
5. Adjust :
OUT
1 • ‘CO’ concentration
Adjustment steps :
• Turn the pilot screw “1” in or out until the
specified ‘CO’ concentration is obtained.
Turning in Ô ‘CO’ concentratin Increases

Turning out Ô ‘CO’ concentration decreases
TIP
For adjusting the Engine idling speed use the
2 throttle stop screw “2” . Do not adjust Engine
idle RPM by using the Air screw “1”
• After adjusting, ‘CO’ concentration as specified,

remove the ‘CO’ tester, make sure that the
Engine idling speed has not changed.
THROTTLE CABLE ADJUSTMENT

TIP
Prior to adjusting the Throttle Cable free play,
the Engine idling speed should be adjusted.
1. Check :
• Throttle cable free play a
Throttle cable free play (at the

a inner edge of the throttle grip)
3.0 - 5.0 mm
2. Adjust :
• Throttle Cable free play
Adjustment steps :
TIP
Never accelerate the Throttle when stopping
the Engine.
3-9
THROTTLE CABLE ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
TIP
_
The engine idling speed must be correctly

adjusted before checking and adjusting the
throttle grip free play.
_
1.Slide the rubber cover “1” back at the throttle cable.

(a) 2. Loosen the locknut “2”
3. To increase the throttle grip free play, turn the
throttle grip free play adjusting nut “3” in
2 3 direction “a”. To decrease the throttle grip
(b) 1 free play, turn the adjusting nut in direction
“b”.
4. Tighten the locknut.
5. Slide the rubber cover back to its
original position.
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.
1 SPARK PLUG INSPECTION

1. Disconnect :
• Spark Plug Cap “1”
2. Remove :
• Spark Plug
Before removing the spark plug, blow away

any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
3. Check :
• Spark Plug Type and Number
Incorrect Ô Replace
Manufacture / model
Champion Power P-RA7HC
4. Check:
• Electrode “1”
Damage/wear Ô Replace the spark plug.
• Insulator “2”
a Abnormal color Ô Replace the spark plug.
2 Normal color is medium-to-light tan.
5. Clean:
1
• Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge) Out of
specification Ô Regap.
Spark Plug Gap:
0.8 ~ 0.9 mm
3-10
SPARK PLUG INSPECTION/ INSP
IGNITION TIMING CHECKING PROCEDURE ADJ
6. Install :
• Spark Plug
Spark Plug :
17.5 Nm (1.75 mkg, 12.6 ftlb)
TIP
• Before installing a Spark Plug, clean the
spark plug and gasket surface.
2 1 • If a Torque Wrench is not available, a good
estimate of the correct tightening torque is to
finger tighten “1” the Spark Plug and then
tighten it another 1/4 to 1/2 turn to “2” using
Box Spanner.
IGNITION TIMING CHECKING PROCEDURE

TIP
Ÿ Prior to checking the ignition timing, check
the wiring connections of the entire ignition
system. Make sure all connections are tight
and free of corrosion.
1. Remove:
• Timing mark accessing screw “1” with
center plug spanner “2”.
1 Center Plug Spanner
YSST - 625
2
2. Connect :
• Timing light “3”.
• Digital Tachometer “4”.
Timing Light
INS - 008
Tachometer
INS - 011
1
3
3-11
INSP
IGNITION TIMING CHECKING PROCEDURE ADJ
3. Check :
• Ignition timing
Checking steps :
a. Start the engine, warm it up for several
minutes, and then let it run at the specified
engine idling speed.
Engine idling speed :

1,300 ~ 1,500 r/min
Ÿ Confirm that the stationary

pointer on LH Crankcase Cover “a”
falls within the ignition timing range “b”
marked on Rotor Assembly.
a TIP
Ÿ The Ignition timing is not adjustable.
b 4. Check
• Auto advance mechanism
Checking steps
• Increase the Engine speed from 1400 r/min to
2000 r/min
• Check the stationery pointer “a” should be within
the ignition timing range “b” marked on the Rotor
Assembly
• Further increase the Engine speed from 2000
7°
r/min onwards.
• Observe that Rotor ignition timing mark moves in
clockwise direction gradually and laternot
visible.
1 2 3 4 • If above phenomenon is not observed it confirms
A: Auto Advance reverse ignition circuit not that the CDI unit is defective (Auto Advance
working mechanism not working)
B: Auto Advance not working
C: Delay Auto Advance
D :STD Auto Advance working 4. Remove:
ŸDigital tachometer
ŸTiming light
5. Install:
• Timing mark accessing screw (with O-ring)
3-12
INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
COMPRESSION PRESSURE MEASUREMENT

TIP
Insufficient compression pressure will result
a loss of performance.
1. Check :
• Valve clearance
Refer to “VALVE CLEARANCE ADJUSTMENT”
On page no 3-6.
2. Start the Engine and let it warm up for several
minutes and then turn it off.
3. Turn off the engine.
4. Disconnect :
1 • Spark Plug Cap “1”
5. Remove :
• Spark Plug
Before removing the spark plug, use com-

pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from
falling into the cylinder.
6. Attach:
• Compression gauge “2”
1
Compression Gauge :
INS - 009
7. Measure:
• Compression pressure Out of
specification Ô Refer to steps (c) and (d).
2 Compression pressure :
(at sea level)
Standard: 1200 kPa (12 Kg/cm²)
Minimum : 1040 kPa (10.4 Kg/cm²)
a.Set the main switch to “ON”.

b.With the throttle wide open, crank the
engine until the reading on the
Refer to the following table.
compression gauge stabilizes.
Compression pressure (With oil applied into c. If the compression pressure is above the
cylinder) maximum specification, check the cylinder
head, valve surfaces and piston crown for
Reading Diagnosis
carbon deposits.
Higher than without oil Piston ring(s) wear or Carbon deposits Ô Eliminate.
damage Ô Replace. d.If the compression pressure is below the
Same as without oil Piston, valves, cylinder minimum specification, pour a teaspoonful
head gasket or piston of engine oil into the spark plug bore and
possibly defective Ô measure again.
Replace.
8. Remove :
• Compressor guage
3-13
ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
9. Install :
• Spark Plug
• Spark Plug Gap
Spark Plug :
17.5 Nm (1.75 mkg, 12.6 ftlb)
10.Install :
• Fuel tank
• Seat
• Side covers
Refer to “SIDE COVERS, SEAT AND FUEL
ENGINE OIL LEVEL INSPECTION
1 1. Stand the vehicle on a level surface.
TIP :
Ÿ Place the vehicle on the center stand.
Ÿ Make sure the vehicle is upright.
2. Start the engine, warm it up for several

minutes, and then turn it off.
3. Check:
ŸEngine oil level.
The engine oil level should be between
the minimum level mark “a” and maximum
level mark “b”.
Below the minimum level mark Ô Add the
recommended engine oil to the proper level.
TIP :
Ÿ Before checking the engine oil level, wait a
few minutes until the oil has settled.
b Ÿ Do not screw the dipstick “1” in when
checking the oil level.
a
Recommended brand
YAMALUBE
Type
SAE 20W40 or SAE 10W30
Recommended engine oil grade
API service SE type or
higher, JASO standard MA
Do not allow foreign materials to enter the

crankcase.

5. Check the engine oil level again
Below the minimum level mark Ô Add the
recommended engine oil to the proper level.
TIP :
Ÿ Before checking the engine oil level, wait a
few minutes until the oil has settled.
3-14
ENGINE OIL REPLACEMENT/ INSP
EXHAUST SYSTEM INSPECTION ADJ
CHANGING THE ENGINE OIL

2. Place a oil pan “1” under the engine oil drain
bolt.
3. Remove:
ŸEngine oil filler cap “1”
2 ŸEngine oil drain bolt “2”
(along with the gasket)
1 4. Drain:
ŸEngine oil (completely from the
crankcase)
5. Install:
ŸEngine oil drain bolt
(along with the gasket NEW )
Engine oil drain bolt

20 Nm (2.0 m-kg, 14 ft-lb)
6. Fill:
ŸCrankcase
(with the specified amount of the
recommended engine oil)
Recommended engine oil grade:
API service SE type or higher,
JASO standard MA
Engine oil quantity
Total amount
1.20 L (1.27 US qt, 1.06 Imp.qt
Periodic oil change
1.00 L (1.06 US qt, 0.88 Imp.qt)
7. Check:
ŸEngine oil level
Refer to “ENGINE OIL LEVEL
INSPECTION” on Page no 3-14
8. Install:
ŸDipstick and tighten
EXHAUST SYSTEM INSPECTION
1 1. Inspect :
• Bolt “1” (Exhaust Pipe)
Loose/ Damage Ô Tighten / replace.
• Gasket (Exhaust Pipe)
Exhaust gas leaks Ô Tighten / replace.
Bolt :
10 Nm (1.0 m.kg, 7.2 ft. lb.)
3-15
INSP
AIR FILTER CLEANING ADJ
2. Inspect :
2 • Bolt “2” (Muffler)
Loose/Damage Ô Tighten /replace.
Bolt :
15 Nm (1.5 m.kg, 7.2 ft. lb)
3. Inspect :
• Screw “3” (Muffler Protector)
Loose/ damage Ô Tighten/replace
Bolt :
8 Nm (0.8 m.kg, 5.8 ft. lb)
AIR FILTER CLEANING
TIP :
Ÿ On the bottom of the Air Filter Case, there
is a Check. Hose “1”. If dust and/or water
collects in this hose, clean the Air Filter
Element and Air Filter Case.
1
1. Remove:
2 • Side Cover (RH)
• Air Filter Case Cover screws “1”
• Air Filter Case cover “2”
• Unlock holder Wire “3”

4 • Removed the air filter element “4” from the
case
2 NOTICE
1
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 without the
3 air filter element will also affect throttle body
turning, leading to poor engine performance
and possible overheating.
3-16
INSP
AIR FILTER CLEANING ADJ
2. Inspect:
• Air Filter Element “1”
1 Damaged Ô Replace.
3. Lightly tap the air filter element to remove
most of the dust and dirt, and then blow the
remaining dirt out with compressed air as
shown. If the air filter element is damaged,
replace it.
TIP :
Ÿ Blow air from inner side, as shown.
Ensure the air is dry and hot water particle

comes with air.
TIP :
Ÿ Ensure no distoration / proper positioning of
felt Seal "1" , if damaged Ô Replace
1
1 4. Insert the air filter element “1” into the air

filter case.
5. Hook the holder wire “2” over the air filter
2 element.
1
Make sure that the air filter element is

2
properly seated in the air filter case. The
engine should never be operated without the
air filter element installed, otherwise the
piston(s) and/or cylinder(s) may become
excessively worn.
3 6. Install the air filter case cover “3” by

installing the screws “4”.
Air Filter Assy. screw

7 Nm (0.8 m.kg, 5.1 ft. lb)
4
7. Install:
ŸSide Cover (R.H.)
3-17
INSP
CLUTCH CABLE ADJUSTMENT ADJ
CLUTCH CABLE ADJUSTMENT

1. Check :
• Clutch Cable free play “a”.
Free play (clutch lever) :

10 ~ 15 mm at lever end
1 2. Adjust:
3 • Clutch Cable free play
2 (a)
a
a4
(b)
b
Adjustment steps:
Lever side
1. Slide the rubber cover back “1” at the clutch
lever.
2. Loosen the locknut “2”
3. To increase the clutch lever free play, turn the
clutch lever free play adjusting bolt “3” in
direction (a). To decrease the clutch lever free
play, turn the adjusting bolt in direction (b).
TIP :
Ÿ If not possible to achieve the specified free
play at the Clutch Lever end then adjust it by
using Adjuster at the crankcase.
At the Crankcase
IN 3 • Remove Side Covers
• Loosen the Locknut “3”
• Turn the adjuster “4” inward or outward to
increase and decrease the Clutch leaver
OUT free play.
• Tighten the locknut “1”
4 end as before.
• Adjust the Clutch Cable free play at Lever
end as before.
4. Tighten the locknut and then slide the rubber
“1” cover to its original position.
3-18
FRONT BRAKE ADJUSTMENT/ INSP
REAR BRAKE ADJUSTMENT ADJ
FRONT BRAKE ADJUSTMENT

1 1. Check :
• Brake Lever free play “a”
(b) 3 2 4
a Out of specification Ô Adjust.
Free play (Brake Lever):
(a) 10 ~ 15 mm at Brake Lever end
2. Adjust :
• Brake Lever free play
Adjustment steps :
Lever Side
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting bolt “3” in direction “a” or
“b” until the specified brake lever free play is
obtained.
Direction “a”
Brake lever free play is increased
Direction “b”
Brake lever free play is decreased
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
TIP :
Ÿ If the specified brake lever free play cannot
be obtained on the handlebar side of the
brake cable, use the adjusting nut on the
wheel side.
Wheel Side
a. Turn the adjusting nut “1” in direction “a” or
“b” until the specified brake lever free play is
obtained.
Direction “a”
Brake lever free play is increased.
a Direction “b”
1 Brake lever free play is decreased.
b
After adjusting the brake lever free play,
make sure there is no brake drag.
3-19
FRONT BRAKE ADJUSTMENT/ INSP
REAR BRAKE ADJUSTMENT ADJ
REAR BRAKE ADJUSTMENT

1. Check :
• Brake Pedal free play "1"
Brake pedal free Play :

3
1000 cm
20 ~ 30 mm
1 Out of specification Ô Adjust
Adjustment steps:
2. Adjust :
• Brake Pedal free play
a. Turn the brake rod adjusting nut “1” in direction
“a” or “b” until the specified brake pedal free
play is obtained.
Direction “a”
Brake pedal free play is increased.
Direction “b”
Brake pedal free play is decreased.
a
After adjusting the brake pedal free play,
b make sure there is no brake drag.
1
3. Adjust :
• Rear brake light switch
Refer to "ADJUSTING THE REAR BRAKE
LIGHT SWITCH "on page 3-20.
1 2
BRAKE SHOE INSPECTION
1. Operate the brake lever or pedal.
2. Inspect :
• Brake shoes
Wear indicator “1” reaches the wear limit line “2”
Ô Replace the brake shoes as a set.
Refer to “FRONT WHEEL” and “REAR WHEEL”
on page no 6-1 and 6-9.
1
2
3-20
REAR BRAKE ADJUSTMENT/ INSP
BRAKE SHOE INSPECTION ADJ
ADJUSTING THE REAR BRAKE LIGHT

SWITCH
TIP :
Ÿ The rear brake light switch is operated by
movement of the brake pedal. The rear brake
light switch is properly adjusted when the
brake light comes on just before the braking
effect starts
1 1. Check:
ŸRear brake light operation timing Incorrect
Ô Adjust
a b
2. Adjust:
ŸRear brake light operation timing.
2
a. Hold the main body “1” of the rear brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
rear brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
ADJUSTING THE DRIVE CHAIN SLACK

TIP :
Ÿ The drive chain slack must be checked at the
tightest point on the chain
A drive chain that is too tight will overload the

engine and other vital parts, and one that is
too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
1. Stand the vehicle on a level surface.
Securely support the vehicle so that there is

no danger of it falling over.
TIP :
Ÿ Place the vehicle on the center stand so
1 that the rear wheel is elevated
2. Spin the rear wheel several times and find

the tightest position of drive chain
3. Check:
ŸDrive chain slack “a” Out of specification
Ô Adjust.
Drive chain slack

35-45 mm (1.57-1.97 in)
3-21
INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
5
6 4. Adjust:
3
5 ŸDrive chain slack
b ssssssssssssssssssssssss
6
7
a a. Loosen the brake rod adjusting nut “1”.
1 2
4 b. Remove the cotter pin “2”.
4 c. Loosen the brake torque rod nut “3”.
d. Remove the cotter pin “4”.
e. Loosen the wheel axle nut “5”.
f. Loosen both chain puller locknuts “6”.
g. Turn both chain puller adjusting nuts “7” in
direction “a” or “b” until the specified drive
3 chain slack is obtained.
Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
2
TIP :
Ÿ To maintain the proper wheel alignment,
1
adjust both sides “1” evenly.
h. Tighten both chain puller locknuts to specifi-

cation
Cain puller locknut
7 Nm, 0.7 m.kg, 5.1 ft. lb.)
i. Tighten the wheel axle nut to specification
Wheel axle nut

90 Nm (9.0 m-kg, 65 ft-lb)
j. Install the cotter pin “1” into the axle nut “2”
2 and then bend its end as shown.
1 k. Tighten the brake torque rod nut to
specification.
Brake torque rod nut

19 Nm (1.9 m-kg, 13 ft-lb)
l. Install the cotter pin into the brake torque rod

bolt
Always use a new cotter pin.
5. Adjust:
ŸBrake pedal free play Refer to
“ADJUSTING THE REAR DRUM BRAKE”
on page 3-16.
3-22
INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas. Use only
kerosene to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with
yamalube engine oil.
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
3-23
INSP
STEERING HEAD INSPECTION ADJ
CHECKING AND ADJUSTING THE

STEERING HEAD

no danger of it falling over
TIP :
Ÿ Place the vehicle on a suitable stand so
that the front wheel is elevated.
3. Check:
ŸSteering head Grasp the bottom of the
front fork legs and gently rock the front
fork.
Blinding/looseness Ô Adjust the steering
head.
4. Remove :
• Bands “1”
1 • Bolts (Handlebar Upper holders) “2”
• Handlebar upper holders “3”
2 • Handlebar lower holders “4”
1 5
6 • Handlebar “5”
3
4 • Handle crown bolt “6”
3 • Handle crown “7”
4 7
5. Adjust :
• Steering head
Adjustment steps:
1 • Remove Spacer “1”
1 • Remove the lock washer “2”
2 • Remove the Ring Nut “3” (upper) and Damper
3 “4”, then loosen the Ring Nut “5” (lower)
4 using the Ring Nut wrench.
5 • Tighten the ring nut (lower) at initial tight-
ening torque
Ring nut socket :
YSST 621
Ring nut-lower (initial tightening ):

45.5 Nm (4.55m.kg, 32.3 ft.lb)
c. Loosen the lower ring nut completely and

then tighten it to specification with a steering
nut wrench.
TIP
Set the Torque Wrench to the Ring Nut Wrench
so that they form a right angle.
Ring nut-lower (final tightening) :

22 Nm (2.2 m.kg, 17 ft. lb)
3-24
INSP
STEERING HEAD INSPECTION ADJ
WARNING
Do not overtighten the lower ring nut.
d. Check the steering head for looseness or

1 binding by turning the front fork all the way in
1 both directions. If any binding is felt, remove
2 the lower bracket and check the upper and
3 lower bearings.
4 Refer to “STEERING HEAD” on page 3-24.
5 e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the upper ring
nut until their slots are aligned.
h. Install the lock washer “2”.
TIP
Make sure the lock washer tab is placed in
the slots.
6. Install :
• Handle crown “1” with Spacer
• Handle Crown bolt “2”
7
• Handlebar Lower Holder “3”
• Handlebar “4”
6
7 4 • Handlebar upper holder “5”
2 5
3 • Bolts (handlebar upper holders) “6”
5 • Bands “7”
3 1
Bolts (handle crown and inner tube)
45 Nm (4.5 m.kg, 33 ft.lb)
Bolt (handle crown and steering shaft)
35 Nm (3.5 m. kg, 25 ft.lb)
Bolts (handlebar upper holder)

23 Nm (2.3 m. kg, 17 ft. lb)
3-25
INSP
FRONT FORK INSPECTION ADJ
CHECKING THE FRONT FORK

1
2 Securely support the vehicle so that there is
2. Check:
ŸInner tube “1”
Damage/scratches Ô Replace.
ŸOil seal “2”
Oil leakage Ô Replace.
3. Hold the vehicle upright and apply the front
brake
4. Check:
ŸFront fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement Ô Repair.
Refer to "FRONT FORK" on page 6-19.
ADJUSTING THE SHOCK ABSORBER
ASSEMBLIES
WARNING
Always adjust both shock absorber
assemblies equally, otherwise poor handling
and loss of stability may result.
a b
Each shock absorber assembly is equipped
with a spring preload adjusting ring.
To avoid damaging the mechanism, do not

1 attempt to turn beyond the maximum or
minimum settings.
Adjust the spring preload as follows. To increase

the spring preload and thereby harden the
suspension, turn the adjusting ring on each
shock absorber assembly in direction (a). To de
crease the spring preload and thereby soften the
suspension, turn the adjusting ring on each
shock absorber as sembly in direction (b). Align
the appropriate notch in the adjusting ring with
the position indicatoron the shock absorber.
1. Shock absorber assembly spring preload

adjusting ring
Spring preload setting:

Minimum (soft):
1
Standard:
3
Maximum (hard):
5
3-26
INSP
REAR SHOCK ABSORBER ADJUSTMENT ADJ
CHECKING THE TIRES

The following procedure applies to both of the
tires.
3. Check:
ŸTire pressure
Out of specification Ô Regulate.
WARNING
1. The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
2. The tire pressure must be adjusted accord-
ing to the total weight (including cargo, rider,
passenger and accessories) and the
anticipated riding speed.
3. Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE

Basic weight :
With oil and full fuel tank 125 kg
Cold tyre pressure Front Rear
Up to 90 kg load* 25 psi 33 psi

90 kg ~ maximum
load* 25 psi 36 psi
*Load is the total weight of the cargo,
rider, passenger and accessories.
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately
2. Check:
ŸTire surfaces
Damage/wear Ô Replace the tire.
Wear limit (front)

1.0 mm (0.03 in)
Wear limit (rear)
1.0 mm (0.03 in)
WARNING
1. Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire failure
and personal injury from sudden deflation.
2. When using a tube tire, be sure to install the
correct tube.
3. Always replace a new tube tire and a new
tube as a set.
3-27
INSP
TYRE INSPECTION ADJ
4. To avoid pinching the tube, make sure the

wheel rim band and tube are centered in the
wheel groove.
5. Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do so,
use great care and replace the tube as soon
as possible with a good quality replacement.
Tube wheel Tube tire only

Tubeless wheel Tubeless tire
WARNING
After extensive tests, the tires listed below
have been approved by India Yamaha Motor
PVT. LTD. for this model. The front and rear
tires should always be by the same manufac
turer and of the same design. No guarantee
concerning handling characteristics can be
given if a tire combination other than one ap
proved by Yamaha is used on this vehicle.
Front Tire
Size
2.75-18 4PR
Manufacturer/model
TVS/ATT450
Rear Tire
Size
3.00-18 6PR
Manufacturer/model
TVS/ATT550
WARNING
1. New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
2. After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem nut
"1" to specification.
TIP :
For tires with a direction of rotation mark “1”.
Ÿ Install the tire with the mark pointing in the
direction of wheel rotation.
Ÿ Align the mark" 2" with the valve installation
point.
3-28
INSP
SPOKE INSPECTION AND TIGHTENEING ADJ
CHECKING THE WHEELS

wheels
3. Check:
ŸWheel
Damage/out-of-round Ô Replace.
WARNING
Never attempt to make any repairs to the
wheel
TIP :
Ÿ After a tire or wheel has been changed or
replaced, always balance the wheel
3-29
INSP
BATTERY INSPECTION ADJ
CHECKING AND CHARGING THE BATTERY

WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes—Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
2 1. Remove:
ŸRight side cover.
Refer to “GENERAL CHASSIS” on page
6-1.
2. Disconnect:
1 ŸBattery leads “1” and “2”
(from the battery terminals)
First, disconnect the negative battery lead

"1", then the positive battery lead "2".
3. Remove:
ŸBattery
4. Check:
ŸElectrolyte level
The electrolyte level should be between
the minimum level mark “a” and the
maximum level mark “b”.
Below the minimum level mark Ô Add dis-
tilled water to the proper level.
Add only distilled water. Tap water contains

minerals which are harmful to the battery.
3-30
INSP
BATTERY INSPECTION ADJ
5. Check:
1 ŸSpecific gravity with hydrometer “1”
Less than 1.280 Ô Recharge the battery
Specific gravity
1.280 at 20 C (68° F)
Model
AB5L-B, 12MX5L-B, MLX-5LE
Voltage Capacity
12v, 5.0 Ah.
5. Charge:
ŸBattery
Battery charging amperage and time
0.50 amps/10 hrs
WARNING
Do not quick charge a battery.
• Loosen the battery sealing caps.

• Make sure the battery breather hose and
battery vent are free of obstructions.
• To ensure maximum performance, always
charge a new battery before using it.
• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative lead from the
battery terminal.)
• To reduce the chance of sparks, do not plug
in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
3-31
INSP
BATTERY INSTALLATION ADJ
TIP :
Replace the battery whenever:
Ÿ battery voltage does not rise to
specification or bubbles fail to rise during
charging,
Ÿ sulphation of one or more battery cells
occurs (as indicated by the battery plates
turning white or material accumulating in
the bottom of the battery cell),
Ÿ specific gravity readings after a long, slow
charge indicate that one battery cells
charge is lower than the rest.
Ÿ warpage or buckling of the battery plates or
insulators is evident.
7. Check:
ŸBattery breather hose and battery vent
Obstruction Ô Clean.
Damage Ô Replace.
8. Install:
ŸBattery
9. Connect:
ŸBattery breather hose “1”
When checking the battery, make sure the

battery breather hose is properly installed
and routed correctly. If the battery breather
hose is positioned so as to allow electrolyte
or hydrogen gas from the battery to contact
the frame, the vehicle and its fin.
ŸAlways charge a new battery completely
before installing it to ensure maximum
performance.
1
10. Check:
ŸBattery terminals
Dirt Ô Clean with a wire brush. Loose
connection Ô Connect properly
11.Connect:
ŸBattery leads
2 (to the battery terminals)
ŸBe sure the hose is properly attached and
routed. Refer to “CABLE ROUTING” on
Page no. 2-23.
First, connect the positive battery lead “1”,

then the negative battery lead “2”.
12. Lubricate:
ŸBattery terminals
Recommended lubricant
Dielectric grease
13. Install:
ŸRight side cover
Refer to “GENERAL CHASSIS” on page
6-1.
3-32
INSP
FUSE INSPECTION ADJ
FUSE INSPECTION
NOTICE
Always turn off the Main Switch when
checking or replacing the Fuse. Otherwise, a
short circuit may occur.
1. Remove:
1 • Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” on Page no 3-3
• Fuse holder “1”
2. Inspect :
• Fuse
Inspection steps :
• Connect the Multimeter to the fuse and
check it for continuity.
TIP
Set the multimeter selector to “Ohm x
resistance ” position.
WARNING
Multimeter
Never use a Fuse with a rating other than that
INS - 003
specified. Never use other materials in place
of a Fuse. An improper Fuse may cause
extensive damage to the electrical system,
• If the Multimeter is indicates non continuity
malfunction of lighting and ignition and could
Ô Replace the fuse.
possibly cause a fire.
3. Replace :
• Blown Fuse
Replacement steps:
• Turn off the Main Switch.
• Remove the blown fuse and then install a
new fuse of the specified as per range.
• Turn the key to “ON” and turn on the
electrical circuits to check if the device
operate.
• If the fuse blows again immediately, check
the electrical circuit.
Specified Fuse :
10.0 A
4. Install :
• Fuse holder
• Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” on Page no 3-3
3-33
HEADLIGHT BEAM ADJUSTMENT/ INSP
HEADLIGHT BULB REPLACEMENT ADJ
3 HEADLIGHT BEAM ADJUSTMENT

2 4
1. Loosen:
• Head light adjusting bolt “1”
2. Loosen:
• Screw “2” - 2 Nos.
3. Adjust :
• Headlight beam (vertical)
1
b Direction “a”
Headlight beam is lowered
Direction “b”
Headlight beam is raised
a
TIP
In standard setting projection provided on
Cowling Strip “3” should align with projection
“4” provided on stay.
4. Tighten Bolt “1” and screw “2”.
HEADLIGHT BULB REPLACEMENT
1. Remove:
• Cowling
• Headlight Assy.
2. Disconnect :
• Headlight beam leads
• Bulb cover
3. Remove :
• Bulb
TIP
Unhook the Bulb spring.
WARNING
from the Bulb while it is on, it will be hot. Do
not Keep flammable products and your
hands away touch the bulb unit it cools
down.
4. Install:
• Bulb (new)
Secure the new Bulb with the Bulb spring.
5. Install Headlight Assembly & cowling.
NOTICE
Avoid touching glass part of bulb. Also keep it
away from oil otherwise, transparency of glass,
bulb life and brightness will be adversely
affected. If oil gets on bulb, clean it with a cloth
moistened thoroughly with alcohol or lacquer
thinner.
3-34
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL
SIDE COVERS, SEAT AND FUEL TANK REMOVAL .....................................................................4-1
ENGINE OIL.....................................................................................................................................4-1
BATTERY.........................................................................................................................................4-1
CARBURETOR ................................................................................................................................4-1
CLUTCH CABLE ..............................................................................................................................4-2
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
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND PISTON .................................................................................4-4
C.D.I. MAGNETO ............................................................................................................................4-6
CLUTCH...........................................................................................................................................4-7
OIL PUMP .......................................................................................................................................4-8
KICK STARTER ...............................................................................................................................4-9
SHIFT SHAFT ..................................................................................................................................4-9
CDI MAGNETO REMOVAL ...........................................................................................................4-10
CRANKCASE .................................................................................................................................4-11
TRANSMISSION AND SHIFTER ...................................................................................................4-12
CRANKSHAFT ...............................................................................................................................4-12
DISASSEMBLY 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 INSPECTION ......................................................................................................4-23
PISTON PIN INSPECTION ...........................................................................................................4-24
CRANKSHAFT ..............................................................................................................................4-25
PRIMARY DRIVE GEAR INSPECTION ....................................................................................... 4-26
CLUTCH INSPECTION ................................................................................................................ 4-26
PUSH ROD INSPECTION ........................................................................................................... 4-27
SHIFT FORK SHIFT CAM INSPECTION...................................................................................... 4-28
KICK STARTER INSPECTIOIN .................................................................................................... 4-29
OIL PUMP INSPECTION .............................................................................................................. 4-30
DELIVERY PASSAGE INSPECTION (CRANK CASE COVER RH) ............................................ 4-31
CRANKCASE ................................................................................................................................ 4-31
BEARINGS AND OIL SEALS ....................................................................................................... 4-31
CIRCLIPS AND WASHERS .......................................................................................................... 4-31
STARTER IDLE GEAR INSPECTION ...........................................................................................4-32
VALVES, ROCKS ARM AND CAMSHAFT ................................................................................... 4-33
VALVES AND VALVES SPRINGS INSTALLATION ......................................................................4-34
CAMSHAFT AND ROCKS ARM INSTALLATION ........................................................................ 4-35
CRANKSHAFT ...............................................................................................................................4-36
TRANSMISSION ........................................................................................................................... 4-38
SHIFTER ....................................................................................................................................... 4-39
TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION .............................................4-40
CRANKCASE ................................................................................................................................ 4-41
CDI MAGNETO ............................................................................................................................. 4-43
TIMING CHAIN AND GUIDE STOPPER#2 ...................................................................................4-44
CDI MAGNETO INSTALLATION ...................................................................................................4-45
SPROCKET DRIVE........................................................................................................................4-45
SHIFT SHAFT AND KICK STARTER ........................................................................................... 4-46
SEGMENT AND SHIFT SHAFT.....................................................................................................4-47
KICK STARTER INSTALLATION...................................................................................................4-48
CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP .................................................................. 4-49
OIL PUMP INSTALLATION............................................................................................................4-50
PRIMARY DRIVE GEAR INSTALLATION .....................................................................................4-50
CLUTCH INSTALLATION ..............................................................................................................4-51
CYLINDER AND PISTON ............................................................................................................. 4-54
CYLINDER HEAD ......................................................................................................................... 4-55
CAM SPROCKET AND TIMING CHAIN ....................................................................................... 4-56
PISTON RING, PISTON AND CYLINDER INSTALLATION ..........................................................4-57
CYLINDER HEAT INSTALLATION ................................................................................................4-58
ENGINE MOUNTING .................................................................................................................... 4-62
ENG
ENGINE REMOVAL
ENGINE REMOVAL
It is not necessary to remove the Engine
in order to remove the following parts.
• Cylinder Head
• Cylinder
• Piston
• Clutch
• CDI Magneto
SIDE COVERS, SEAT AND FUEL TANK
REMOVAL
1. Remove :
• Side covers (LH and RH)
• Seat
• Fuel tank
Refer to the “SIDE COVERS, SEAT AND FUEL
ENGINE OIL
1. Drain :
• Engine oil
Refer to the “ENGINE OIL REPLACEMENT”
on Page no 3-14
BA TTERY
1. Remove :
• Fuse “1”
• Negative terminal (Black) “2”
• Battery Breather Hose “3”
• Battery “4”
1
NOTICE :
Disconnect the Battery Negative Terminal
3 (Black) first and then disconnet the Positive
2 4 Terminal (Red).
CARBURETOR
1. Loosen
• Air cleaner case mounting bolts “1” & “2”
• Hose Clamp assy “3”
2. Remove
• Throttle Cable “4”
1 4 • Starter Cable “5”
5 • Carburetor Mounting Bolts “6” (2 nos)
• Air vent Hose
7 • AIS Hose Pipe “7”
• Carburetor “8”
2 3 6 Refer to the “CARBURETOR” on Page no 5-1.
8
4-1
ENG
ENGINE REMOVAL
TIP :
1 2 Cover the Carburetor with a clean cloth to
prevent dirt or foreign material from entering the
Carburetor.
CLUTCH CABLE
1. Remove :
• Clutch cable
Removal steps :
• Loosen the locknut “1” of the Clutch Lever.
• Turn in the Adjuster “2” to enough to free the
3
inner Clutch Cable
• Unhook the Cable End from Push Lever “3” on
the Crankcase L.H.
2 DRIVE CHAIN
1. Remove :
• Drive sprocket cover (L.H.) “1”
• Drive Chain Case upper “2” and lower “3”
2. Slack off the Drive Chain
Refer to “DRIVE CHAIN SLACK ADJUST-
MENT” on Page no 3-21.
3 3. Remove :
1 • Bolt “1” (Holder Sprocket)
• Holder Sprocket “2”
• Sprocket Drive “3”
Remove with the Drive Chain
1
EXHAUST MUFFLER
1. Remove :
2 • Bolt (exhaust pipe) - 2 Nos.
3 • Bolt (muffler)
Refer to “EXHAUST SYSTEM”
on Page no 3-15
2. Remove :
• Exhaust muffler
FOOTREST ASSEMBLY
1. Remove:
1 • Bolt (footrest) “1”
• Bolt Axle - Lower rear mounting “2”
2 1 • Footrest Assembly
4-2
ENG
ENGINE REMOVAL
SHIFT PEDAL
1. Remove
• Bolt (Shift Pedal) “1”
• Shift Pedal “2”
BATTERY BOX
1. Remove
• Bolt (Battery Box) “1” 2 nos
• Battery Box “2”
1
LEADS
1. Disconnect:
• Stator Coil Lead Coupler “1”
• Sensor Coil Lead Coupler “2”
2. Remove :
• Spark Plug Cap.
2
1
ENGINE REMOVAL
8 1. Remove :
• Engine Mount Bolt (front upper) “1”
• Bolt (Engine Mount stay front upper) “2”
• Bolt (Engine Mount stay front lower) “3”
• Engine Mount Bolt front upper “4”
1 9 • Engine Mount Bolt (front -lower) “5”
• Engine Mount Bolt (rear) “6”
• Engine Mount Bolt (upper) “7”
4 • Bolts (Engine mount stay upper) “8”
• Engine Mount Stay (upper) “9”
2
• AIS Mtg. (bolt or clamp)
3. Remove :
3 • Engine Assembly
(From the left side of the Motorcycle)
5 6
4. Mount
• Engine on Engine Stand
4-3
ENG
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND

PISTON
TIP :
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)
3 (Retract ) • Timing Check Plug
• Exhaust Pipe • Center Plug
1
• Carburetor • AIS Mounting
2
WARNING
Before Engine disassembly clean the outer
body of Engine properly
1. Remove :
• Spark Plug
1 • Bolts (Intake Manifold) “1” 2 nos
• Intake Manifold “1”
• Valve Cover with ‘O’ ring “1”
2
2. Remove
• Timing mark accessing screw “1”
• Crank shaft end accessing screw
(with ‘o’ ring) “2”
3. Align :
• Piston to TDC position
TIP :
T urn the Crankshaft anticlockwise with a
a Socket Spanner 17 mm
b
TDC alignment steps:
• Turn the Crankshaft anticlockwise until the slit
(cut mark on magneto) “a” matches the station-
ary pointer “b”.
d • Align the “I” mark “c” on the Cam Sprocket with
the stationary pointer “d” on the Cylinder Head,
c the Piston is at the Top Dead Center (TDC)
of compression stroke.
TIP :
To confrim that the Piston is at TDC of com-
pression stroke, check Rocker Arms for free
movement.
4-4
ENG
ENGINE DISASSEMBLY
5. Remove :
• Tensioner Cap Bolt “1”
• Retract completely the Tensioner Rod by
Screw in (clockwise) direction.
2
• Bolts (timing chain tensioner ) “2” 2 Nos
1 • Timing Chain Tensioner Assembly “3”
• Gasket
3
6. Remove :
1 • Bolt (cam sprocket) “1”
4 • Plate washer (cam sprocket) “2”
• Cam sprocket “3”
2
TIP :
3 Hold the Nut Rotor with socket spanner for
opening Cam Sprocket Bolt. Fasten a safety
wire “4” to the Timing Chain to prevent it from
falling in the Crankcase.
5 7. Remove :
2 • Bolts (Cylinder Head) as per sequence.
3
(6 nos)
• Cylinder Head
TIP :
• Loosen the Bolts 1/4 turn each and remove
1 6 then after all are loosened.
• Reomve the Bolts starting with the lowest
4
number one.
4 8. Remove :
• Guide Stopper #1 “1”
3 • Dowel Pins “2”
• Gasket (Cylinder Head) “3”
• Cylinder “4”
4-5
ENG
MAINTENANCE SPECIFICATIONS
2 9. Remove :
• Dowel Pins “1”
• Gasket (Cylinder) “2”
10. Remove :
• Piston Pin Circlip “1” 2 nos
• Piston Pin “2” , using Piston Pin Replacer
2 • Piston “3”
TIP :
3 Before removing the Piston Pin Circlip, cover
1 the Crankcase with a clean cloth to prevent the
Circlip from falling into the Crankcase cavity.
Piston Pin Replacer :

YSST - 207
C. D. I. MAGNETO
TIP :
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 1
1 1. Remove :
• Bolts (Crankcase Cover-1 L.H.) “1” 7 nos
• Crankcase Cover 1 (L.H.)
1 • Neutral Light wire from Neutral Switch
TIP :
1 Loosen the Bolts in criss cross pattern.
1 1
2. Attach
• Magneto holder “1”
Magneto Holder :
YSST - 801
4-6
ENG
ENGINE DISASSEMBLY
7 CLUTCH
2
TIP :
4 The Clutch Assembly can be removed while the
5 Engine is mounted on the Motorcycle by remov-
6 ing the following parts and draining the Engine
oil:
3 • Kick Crank Assy.
9 1 8
1. Remove :
• Nut kick Crank assy.
• Kick Crank Assy.
• Bolts Crankcase Cover-2 (R.H.) “1” 9 nos
2
• Crankcase Cover (RH)
1 TIP :
• Hold Kick Crank Assy. at extreme down posi-
tion for opening the Nut Kick Crank Assy.
• Loosen the Bolts of Crankcase Cover #2 (RH)
2 in a crisscross pattern.
2. Remove :
• Gasket “1”
1 • Dowel pins “2” (2 nos.)
2
3 3. Remove:
• Pressure Plate Bolts “1” (4 nos.)
• Clutch Springs “2” ( 4 nos.)
• Pressure Plate “3” with Push rod 1
• Friction Plates “4” (5 nos.)
• Clutch Plates “5” (4 nos.)
TIP :
Loosen the Pressure Plate Bolts in a crisscross
pattern.
5
4 4. Remove :
• Ball “6”
5. Loosen :
• Straighten the Lock Washer tab.
• Nut (clutch boss) “1”
TIP :
Loosen the Clutch Boss Nut “1” while holding the
1
Clutch Boss “2” with the Clutch Holder.
Clutch Hub Holder

YSST - 233
2
4-7
ENG
ENGINE DISASSEMBLY
6. Remove :
1
2 • Clutch Boss Nut “1”
• Lock Washer “2”
• Clutch Boss “3”
3 • Thrust Washer “4”
4 • Clutch Housing “5”
5 • Spacer “6”
• Washer “7”
6
7
7. Loosen :
• Nut “1” (Primary Drive Gear)
TIP :
• Open the Nut (Primary Drive Gear) by holding
the Magneto with Magneto Holder.
1
Magneto Holder
YSST - 627
8. Remove
• Nut
2 • Plate Washer
1 • Primary Drive Gear “1”
• Key “2”
• Rotary Filter “3”
3
OIL PUMP
NOTE :
The oil pump can be removed while the engine
is mounted by removing the following parts
• Clutch
• Primary drive gear
1 • Rotary filter
3 1. Remove :
3 • Gear pump drive “1”
2 • Screw (oil pump-2 nos) “2”
• Oil pump assembly “3”
• Gasket (oil pump)
• Oil strainer
4-8
ENG
ENGINE DISASSEMBLY
KICK STARTER
TIP :
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
1. Remove :
• Circlip “1”
• Plate washer “2”
1
2 • Gear Kick idle “3”
• Plate washer “4”
3 4 5 • Circlip “5”
2. Remove :
• Torsion spring “1”
1 • Kick axle assembly “2”
Kick Starter disassembly

1. Remove :
• Spacer “1”
1 • Torsion spring “2”
• Shim “3”
2 • Ratchet Gear “4”
3
4 • Shim “5”
5 • Ratchet Gear with Return Spring “6”
6 • Kick Axle “7”
7 SHIFT SHAFT
TIP :
The Shift Shaft can be removed while the Engine
is mounted by removing the following parts.
• Shift Pedal • Kick Crank Assy.
• Crankcase Cover#2(RH) • Cutch
4
3
1 1. Remove :
• Shift Shaft “1”
2 • Torsion Spring “2”
• Bolt (stopper lever) “3”
• Stopper Lever “4”
4-9
ENG
ENGINE DISASSEMBLY
CDI MAGNETO REMOVAL

1. Remove :
1 • Nut (magneto)
• Plain washer
TIP :
2
• Loosen the Nut Magneto while holding the
Magneto “2” with Magneto Holder “1”
Magneto Holder :
YSST - 801
1 2. Attach
• Bush “1”
TIP :
• Place the Bush on the Crankshaft threaded
end before using the Magneto Puller to avoid
thread damage.
3. Remove :
• CDI magneto “1” using magneto puller “2”
• Key wood-ruff
1
Magneto Puller :
YSST - 628
4. Remove
2 • Bolt “1”
3 • Guide Stopper# 2 “2”
• Bush
• Timing chain “3”
5. Remove :
5 • Starter idler gear “1”
• Washer “2”
6. Remove
2 4 • Screw - 2 Nos. “3”
• Plate “4”
• Starter idler gear “5”
1 3
4-10
ENG
ENGINE DISASSEMBLY
7. Remove :
• Torx Screw “1” (Segment) using Torx Bit.
Torx Bit :
YSST - 611
1
WARNING
Never use Phillips screw driver
1 CRANKCASE
1. Remove :
• Bolts (Crankcase RH-2 nos) “1”
1 2. Remove :
4
• Bolts (Crankcase LH-8 nos)
3 TIP :
6 • Loosen the Bolts in a crisscross pattern.
• Loosen each Bolts 1/4 turn at a time and re-
5 8 move them after all are loose.
7 2
1. Remove :
• Right crankcase half
TIP :
Open the Engine stand mounting Nuts 2 nos .
Then separate the Crankcase by using the flat
a head screw driver in the separating slit “a”
a
• 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 is removed.
• Do not damage the Crankcase mating sur-
faces.
1 2. Remove :
1
• Dowel pins “1” 2 Nos.
4-11
ENGINE DISASSEMBLY: ENG
TRANSMISSION AND SHIFTER
TRANSMISSION AND SHIFTER

1. Remove :
4
1 • Shift Fork Guide Bar “1” (short)
• Shift Fork Guide Bar “2” (long)
• Shift Cam “3”
2 • Shift Fork -R “4”
5 • Shift Fork - L “5”
2. Remove :
• Axle Drive assembly “2”
• Axle Main assembly “1”
3 • Push Rod # 2
1 • Washer
• Push Lever Assembly “3”
• Lock
2 • Oil Seal
3. Remove :
• Neutral switch “1”
• Gasket
CRANKSHAFT
1. Attach
2
• Crankshaft Removal Tool “2”
Crankshaft Removal Tool :

YSST - 265
1 2. Remove :
• Crankshaft “1” using Crankshaft removal
tool “2”
TIP :
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.
4-12
ENG
ENGINE DISASSEMBLY
DISASSEMBLY OF CYLINDER HEAD,

2 4 3 ROCKER ARMS, CAMSHAFT AND
VALVES
1. Loosen :
1 • Valve Adjuster Locknuts “1”
• Valve Adjusters “2”
2. Remove :
• Stopper Plate “4” by opening allen bolt “4”
3. Attach
• Rocker arm shaft puller “1”
1
Rocker Arm Shaft Puller
2 YSST - 608A
4. Remove :
• Rocker Arm Shafts by tightening the Puller
nut “2”
• Rocker Arms (intake/exhaust)
5. Remove :
• Camshaft Assy “1” with spacer “2”
1 TIP :
Before the Valves, Valve Springs, Valve Stem
Seals, etc. are removed from the Cylinder Head,
the Valve sealing should be checked.
6. Check
• Valve sealing
Leakage at the valve seat Ô Inspect the
1
valve face, valve seat and seat width.
Refer to “INSPECTION AND REP AIR
VALVE SEAT”. on Page no 4-16.
Checking Steps :
2 • Pour clean petrol “1” into the intake and ex-
haust ports.
• Check the valve sealing. There should be no
leakage at the valve seat “2”
4-13
ENG
ENGINE DISASSEMBLY
7. Attach
1 Valve Spring compression Tool “1”
Valve Spring Compressor :

YSST - 603
8. Remove :
• Valve Cotters “2”
TIP :
2
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 “1”
• Valve Spring “2”
• Valve “3”
1 • Valve Stem Seal “4”
• Valve Spring Seat “5”
2
TIP :
4 Identify the position of each part very carefully
so that it can be reinstalled in its original place.
5
3
4-14
INSPECTION AND REPAIR: ENG
CYLINDER HEAD
CYLINDER HEAD
1. Remove :
• Carbon deposits from combustion
chambers using a rounded scraper.
TIP :
Do not use a sharp instrument to avoid dam-
aging or scratching :
• Spark Plug threads
• Valve seats
2. Inspect :
• Cylinder Head
Scratches/damage Ô Replace
3. Measure :
• Cylinder Head warpage
Out of specification Ô resurface/ replace.
Cylinder Head warpage :

Less than 0.03 mm
Warpage measurement and resurfacement
steps:
• Place a straightedge “1” and a feeler gauge “2”
across the Cylinder Head.
• Measure the warpage.
• If the warpage is out of specification, resur-
1 face the Cylinder Head/replace if necessary.
2 • Place a 400 ~ 600 grit wet abrasive paper on
the surface plate, and resurface the Head
using a figure-eight sanding pattern.
TIP :
Rotate the Cylinder Head several times for an
even resurfacement.
4-15
ENG
INSPECTION AND REPAIR:VALVE SEATS
VALVE SEATS
a 1. Remove :
• Carbon deposits from the Valve Face and
Valve Seat.
2. Inspect :
• Valve Seats
Pitting/wear Ô reface the valve seat.
3. Measure :
• Valve Seat width “a”
Out of specification Ô Reface the Valve
Seat.
Valve seat width :

Intake :
0.90 ~ 1.10 mm
Limit : 1.6 mm
Exhaust :
0.90 ~ 1.10 mm
Limit : 1.6 mm
Measurement steps :
• Apply Mechanic’s blueing dye (Dykem) “b” to
the valve face.
• Install the Valve in the Cylinder Head
b • 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.
4. Lap :
• Valve face
• Valve seat
TIP :
After refacing the Valve Seat or replacing the
Valve, the Valve Seat and Valve Face should be
lapped.
4-16
ENG
INSPECTION AND REPAIRS
Lapping steps :
• Apply coarse lapping compound “a” to the Valve
a Face
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.
TIP :
For best lapping results, lightly tap the Valve
seat while rotating the Valve.
• Apply a fine lapping compound “b” to the Valve

face and repeat the above steps.
TIP :
b Make sure to clean off all compound from the
Valve face and Valve seat after every lapping
operation.
• Apply Mechanic’s blueing dye (Dykem) “b” to

the Valve face.
c • Install the Valve in the Cylinder Head.
• Press the Valve through the Valve Guide and
onto the Valves Seat to make a clear pattern.
• Measure the Valve Seat width “c” again. If the
Valve Seat width is out of specification, lap the
Valve and Valve Seat.
4-17
INSPECTION AND REPAIR : ENG
VALVE SPRINGS AND VALVES
VALVE SPRINGS AND VALVES

1. Measure :
• Valve Spring free length “a”
Out of specification Ô Replace.
Valve spring free length :

47.2 mm
<Limit 44.8 mm>
a
a 2. Measure :
• Spring tilt “a”
Out of specification Ô Replace
Spring Tilt Limit :

1.7 mm
3. Check
• Spring contact face
Wear/pitting/scratches Ô Replace
4. Measure :
• Valve guide inside diameter
Valve guide inside diameter :

Intake :
5.000 ~ 5.012 mm
<Limit : 5.042mm>
Exhaust :
5.000 ~ 5.012 mm
<Limit : 5.042mm>
5. Measure :
Valve stem diameter
4-18
ENG
ENGINE INSPECTION AND REPAIR
6. Calculate :
Stem Guide Clearance
Stem-to-guide clearance =
Valve guide inside diameter –
Valve stem diameter
Stem-to-guide clearance limit :

Intake :
0.010 ~ 0.0370 mm
<limit : 0.080 mm>
Exhaust :
0.025 ~ 0.052 mm
<limit : 0.10 mm>
Out of specification Ô Replace the Cylinder

Head
7. Measure :
• Runout (valve stem)
Runout Limit :
0.01 mm
CAMSHAFT INSPECTION
1. Inspect :
• Cam lobes
Pitting/scratches/blue discoloration Ô
Replace
2. Measure :
• Cam lobes dimension “a”and “b”
Cam lobes dimension :

a b Intake :
“a” 25.356 ~ 25.456 mm
<limit 25.326 mm>
“b” 20.989 ~ 21.089 mm
<limit 20.959 mm>
Exhaust :
“a” 25.361 ~ 25.461 mm
<limit 25.331 mm>
“b” 21.001 ~ 21.101 mm
<limit 20.971 mm>
3. Inspect :
• Camshaft oil passage
Chocked Ô Blow out oil passage with
compressed air.
4-19
ENG
ROCKER ARMS AND ROCKER ARM

SHAFTS INSPECTION
1. Inspect :
1 • Cam lobe contact surface “1”
• Adjuster surface “2”
Wear/pitting/scratches/blue discoloration Ô
Replace
2
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 Ô Replace
• Inspect the surface condition of the Rocker
Arm Shafts
Pitting/scratches/blue discoloration Ô Re-
place and check lubrication route
• Measure the inside diameter “a” of the Rocker
Arm holes
Inside diameter (Rocker Arm) :

a 10.000 ~ 10.015 mm
<Limit>:10.03 mm
• Measure the outside diameter “b” of the Rocker

Arm Shafts.
Outside diameter(Rocker Arm Shaft):

9.981 ~ 9.991 mm
<Limit> : 9.95 mm
4-20
ENG
TIMING CHAIN, SPROCKETS AND

CHAIN GUIDES
1. Inspect :
• Timing Chain
Wear out/Stiffness/damage Ô Replace the
Chain and the Sprockets as a set.
2. Inspect :
3 1
• Cam Sprocket
2 Wear/damage Ô Replace the Cam
Sprocket and the timing chain as a set.
“1” 1/4 tooth gap
“2” Correct Tooth Profile
“3” Roller
4 “4” Sprocket
3. Inspect :
• Guide Stopper #1 “1”
• Guide Stopper # 2 “1” and Bush
Wear/damage Ô Replace
1 2
TIMING CHAIN TENSIONER

1. Check :
• One-way Cam operation
If Unsmooth operation Ô Replace
1 Checking steps :
• While pressing the Tensioner Rod lightly with
fingers, use a flat screwdriver “1” and retract
the Tensioner Rod up fully clockwise.
• When releasing the screwdriver by pressing
lightly with fingers, make sure that the
Tensioner Rod will come out smoothly.
• If not, replace the Tensioner Assembly
4-21
ENG
CYLINDER AND PISTONS

1. Inspect :
• Cylinder and Piston walls
Vertical scratches Ô Rebore or replace
the Cylinder and the Piston
2. Measure :
• Piston-to-Cylinder clearance
Measurement steps :
1st step :
• Measure the Cylinder Bore “C” with a Cylin-
der Bore Gauge.
TIP :
Measure the Cylinder Bore “C” in parallel to and
at right angles to the Crankshaft. Then, find the
average of the measurements.
• If out of specification, rebore or replace the

Cylinder- Piston Kit
2nd step :
Cylinder Bore “C” 49.000 ~ 49.020 mm
• Measure the Piston Skirt diameter “P” with a
Taper limit “T” 0.07 mm Micrometer.
Out of round “R” 0.004 mm “a” 4.5 mm from the Piston bottom edge
“C”=Maximum Diameter D Piston size p

“T” =(Maximum D1 or D2) - (Maximum D5 or D6) 48.962 ~ 48.981 mm
“R”=(Maximum D1, D3 or D5) Ist
Oversize
- (Maximum D2, D4 or D6) II nd
• If out of specification, replace the Piston and

the Piston Rings as a set.
3rd step:
a
• Calculate the Piston-to Cylinder clearance us-
ing the following formula :
Piston-to-Cylinder clearance = Cylinder

Bore “C”– Piston Skirt diameter “P”
Piston-to-Cylinder clearance :
0.035 ~ 0.042 mm
• If out of specification, rebore or replace the

Cylinder, and replace the Piston and Piston
Rings as a set
4-22
ENG
PISTON RING INSPECTION

1. Measure :
• Side clearance
Out of specification Ô Replace the Piston
and the Piston Rings as a set
TIP :
Remove the carbon deposits from the Piston
Ring Grooves and Rings before measuring the
side clearance.
Side clearance :
Top Ring :
0.030 ~ 0.065 mm
<Limit> : <0.115 mm>
2nd Ring :
0.020 ~ 0.055 mm
<Limit> : <0.115 mm>
2. Position :
• Piston Ring
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 “1” using a feeler gauge
TIP :
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 : 0.10 ~ 0.25 mm
<limit> : <0.35mm>
2nd Ring : 0.25 ~ 0.40 mm
<Limit> : <0.50 mm>
Oil Ring : 0.20 ~ 0.70 mm
4-23
ENG
PISTON PIN INSPECTION

1. Inspect :
• Piston Pin
Blue discoloration/grooves Ô Replace and
inspect the lubrication system
2. Measure :
• Piston Pin-to-Piston clearance
Measurement steps.
• Measure the Piston Pin outside diameter “a”
using a micrometer. If out of specification, re-
place the Piston Pin.
Outside diameter (Piston Pin):

12.996 ~ 13.000 mm
<Limit:> : 12.976 mm
• Measure the Piston Pin hole inside diameter

“b” using a Internal Micrometer
• Calculate the Piston Pin -to-Piston clearance
using the following formula :
Piston Pin-to-Piston clearance =

Bore size (Piston Pin) “b” – Outside diam-
eter (Piston Pin) “a”
b
• Out of specification Ô replace the Piston
Clearance ( Piston Pin to Piston ) :

0.006 ~ 0.013 mm
4-24
ENG
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 Ô Replace
Runout :
<limit> : <0.03 mm>
2. Measure :
a
• Big end side clearance “a” using a Feeler
Gauge
Out of specification Ô Replace big end
Bearing , Crank Pin and Connecting Rod
Big end side clearance :

0.15 ~ 0.45 mm
3. Measure :
• Crank width “a”
Out of specification Ô Replace Crankshaft.
Crank width :
46.95 ~ 47.00 mm
4. Inspect :
• Crankshaft Sprocket “1”
2
Wear/damage Ô Replace Crankshaft
• Bearing “2”
1
Wear/crack/damage Ô Replace
Crankshaft
5. Inspect :
• Crankshaft journal oil passage
Clogged Ô Blow the oil passage with
compressed air
4-25
ENG
PRIMARY DRIVE GEAR INSPECTION

2 1. Inspect :
• Primary Drive Gear teeth “1”
• Primary Driven Gear teeth “2”
1
Wear/damage Ô Replace both Gears as
a set.
TIP :
Refer the general specification for grading.
Excessive noise during operation Ô Replace

both Gears as a set.
CLUTCH INSPECTION
1. Inspect :
• Friction Plates
Wear/damage Ô Replace the Friction
Plates as a set
2. Measure :
• Friction Plate thickness “a” using a Vernier
Calliper at four points.
Out of specification Ô Replace the
Friction Plates as a set
a Thickness (Friction Plate) :

2.92 - 2.92-3.08 mm
<Limit> : <2.80 mm>
3. Inspect :
• Clutch Plates for damage
• Clutch Plate Warpage Using a Surface
Plate and a Feeler Gauge “1”
Out of specification Ô Replace the Clutch
Plates as a set
Warp limit (Clutch Plate ):

Less than 0.20 mm
4. Inspect :
1 • Clutch Springs
Damage Ô Replace the Clutch springs as
a set.
5. Measure
• Free length (Clutch Spring) “a”
Out of specification Ô Replace the Clutch
springs as a set.
Free length (Clutch Spring) :

a 32 mm
<Limit> : 30.0 mm
4-26
ENG
6. Inspect :
• Dogs on the Primary Driven Gear “1”
Scoring/wear/damage Ô Deburr or
replace
• Clutch Boss Splines “2”
1 Scoring/wear/damage Ô Replace
TIP :
2 Scoring on the Clutch Housing Dogs and the
Clutch Boss Splines will cause erratic operation
of the clutch.
PUSH ROD INSPECTION

1. Inspect :
• Ball “1”
2 • Push Rod #1 “2”
1 Wear/damage/Bend Ô Replace
2. Inspect :
• Push Rod # 2 “1”
1
Wear/damage/Bend Ô Replace
4-27
ENG
SHIFT FORK SHIFT CAM INSPECTION

1. Inspect :
• Shift Fork follower “1”
1 • Shift Fork Pawl “2”
Scoring/bends/wear/damage Ô Replace
2. Inspect :
• Shift Cam grooves “1”
Wear/damage/scratches Ô Replace
• Shift Cam Segment “2”
2
1
3. Check :
• Shift Fork movement
(on the Guide Bar )
Unsmooth operation Ô Replace the Shift
Fork and the Guide Bar
4. Inspect :
2 4 5
The assembly for proper working
1
5 • Shift Fork “R” (right) “2”
• Shift Fork “L” (left) “3”
• Guide bars (small and big) “4”
• Shift Cam “5”
3
• Shift fork cam follower “6”
3
Roll the Guide Bar on a flat surface
Bent Ô Replace
WARNING
Do not attempt to straighten a bent Guide
Bar.
4-28
ENG
5. Inspect :
• Gear teeth
Blue discoloration/pitting/wear Ô Replace
• Mated Dogs
Rounded edges/cracks/missing portions Ô
Replace
6. Inspect :
• Shift Shaft “1”
1
Damage/bent/wear Ô Replace
• Return spring (shift shaft) “2”
• Return Spring (stopper lever) “3”
3 2
2 1 KICK STARTER INSPECTION

1. Inspect :
• Gear teeth (kick Gear) “1”
• Gear teeth (Idle Gear) “2”
2. Measure :
• Torsion spring “1” force Using a Spring
Gauge
1 Out of specification Ô Replace
Kick Clip friction force :

5.88 ~ 13.72 kg
4-29
ENG
OIL PUMP INSPECTION

b
1. Measure :
1 • Tip clearance “a”
(between the inner rotor “1” and the outer
rotor “2”) using feeler gauge.
a • Out of specification Ô Replace the Oil
2
Pump Assembly
• Side clearance “b”
(between the outer rotor “2” and the Pump
3 Housing “3”) using feeler gauge
• Housing and Rotor clearance “c”
c
(between the Pump Housing “3” and the
Rotors “1” and “2” )
Out of specification Ô Replace the Oil
Damage Ô Replace
Contamination Ô Clean with flushing oil.
Tip clearance “a”:

0.15 mm <Limit:0.20 mm>
Side clearance “b”:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
Housing and Rotor clearance “c”:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
2. Inspect :
• Rotary Filter “1”
1
Cracks/damage/chocked Ô Replace
Contamination Ô Clean with flushing oil
3. Inspect :
• Oil strainer “1”
Damage Ô Replace
1
Contamination Ô Clean with flushing oil.
4-30
ENG
DELIVERY PASSAGE INSPECTION
1 CRANK CASE RH
1. Check :
• Oil delivery passage
Blockage Ô 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 Ô Replace
• Oil delivery passages
Blockage Ô Blow the passages with
compressed air
BEARINGS AND OIL SEALS

1. Inspect :
• Bearings “1”
Clean with solvent and lubricate with
multigrade oil, then rotate the bearing
using finger
2 Roughness/noise Ô Replace
1
2. Inspect :
• Oil Seals “2”
Damage/ wear Ô Replace
CIRCLIPS AND WASHERS

1
1. Inspect :
• Circlips “1”
• Washers
Damage/looseness/bends Ô Replace
4-31
ENG
a STARTER IDLE GEAR INSPECTION
1. Inspect:
• Gear teeth “a”, “b” and “c”
Burrs/chips/roughness/wear Ô Replace
b
2. Check
c • Starter clutch operation
Checking steps :
2 • Install the starter wheel gear “1” to the
b
starter clutch “2”, 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.
1 • 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.
4-32
ENG
VALVES, ROCKER ARM AND CAMSHAFT

1. Valve Cotters 8. Lock Nut
2. Valve Spring Retainer 9. Adjuster
3. Valve Springs 10. Valve Rocker Arm
4. Valve Stem Seal 11. Rocker Arm Shaft
5. Valve Spring seat 12. Camshaft
6. Valve (intake) 13. Plate
7. Valve (exhaust)
1
2
9 3
8
11 4
5
11
10
10 13
9 8 6
1 2 3 4 5
12
7
4-33
ENG
WARNING
1
For Engine Assembly, replace the following
parts with new ones :
1 • O-Rings
• Gaskets
• Oil Seals
• Copper Washers
• Lock Washers
• Circlips
VALVES AND VALVE SPRINGS

INSTALLATION
1. Deburr :
• Valve Stem end “1” Using an Oil Stone for
smoothing.
2. Apply :
• Molybdenum disulfide oil on the Valve
Stem and Oil Seal
NEW 2
Molybdenum Disulfide Oil
5 3. Install :
• Valve Spring Seat “1”
• Valve Stem Seal “2” New
4 • Valve “3” in the valve guide(Cylinder Head)
• Valve Spring “4”
• Spring retainer “5”
TIP :
Install the Valve Spring with the small pitch “b”
1 facing downward
“a” facing upwards
“b” facing downward
a
3
b
4. Install :
2
• Valve Cotters “1”
TIP :
Install the Valve Cotters while compressing the
valve spring with Valve Spring compressor “2”
Valve Spring Compressor :

1 YSST - 603
4-34
ENG
5. Secure the Valve Cotters onto the Valve

Stem by tapping lightly with a mallet
Do not hit so much as to damage the Valve
CAMSHAFT AND ROCKER ARM

1 INSTALLATION
1. Lubricate :
• Camshaft “1”
Camshaft and Camshaft bearing :

Multrigrade engine oil.
2. Apply :
• Molybdenum disulfide oil on the rocker
arm and Rocker Arm Shaft
Molybdenum disulfide oil
3. Install :
• Rocker Arm
• Rocker Arm Shaft “1” by pushing it in
1
completely
4. Install :
2
1 • Plate “1”
• Bolt “2”
Bolt (Plate) :
7 Nm (0.7 m.kg, 5.1 ft.lb)
4-35
ENG
CRANKSHAFT
1. CRANKSHAFT ASSY 6. PISTON RING SET (STD)
2. BEARING PISTON RING SET (0.50MM O/S)
BEARING PISTON RING SET (1.00MM O/S)
3. PISTON (STD) 7. KEY, WOODRUFF
PISTON (0.50MM O/S) WASHER, PLATE
PISTON (1.00MM O/S) 8. NUT, FLANGE
4. PIN, PISTON
5. CIRCLIP
5
4
5
8
9
4-36
ENG
CRANKSHAFT
1. Insert :
• CrankShaft in the Crankcase (L.H.)
2. Attach :
• Crankshaft Installing Tool on Crankshaft
Crankshaft Installing Tool “1”

YSST - 266
Spacer “2”
YSST - 267
3. Install :
3 • Crankshaft by tightening the Nut “3”
TIP :
Hold the Connecting Rod at Top End with one
1 hand while turning the Nut of the Installing Tool
with the other. Operate the Installing Tool until
2
the Crankshaft is seated against the Bearing.
To avoid scratching the Crankshaft and to

ease the Installation procedure, apply Engine
Oil onto each Bearing and crankcase LH.
4. Install :
• Neutral Switch “1”
4-37
ENG
TRANSMISSION 12. DRIVE AXLE ASSY

1. AXLE, MAIN (11T) 13. GEAR, 2ND WHEEL
2. GEAR, 3RD PINION 14. WASHER
3. WASHER 15. CIRCLIP
4. CIRCLIP 16. GEAR, 3RD WHEEL
5. GEAR, 2ND PINION 17. GEAR, 1ST WHEEL
6. GEAR, 4TH PINION (24T) 18. WASHER, PLATE
7. WASHER PLATE 19. COLLAR 1
8. BEARING 20. BEARING
BEARING BEARING
9. BEARING 21. OIL SEAL
BEARING
22. BEARING
10. PLATE COVER BEARING
11. SCREW, PAN HEAD 23. SPROCKET, DRIVE (14T)
24. HOLDER, SPROCKET
25. BOLT, FLANGE
9
10
11
1
2
3
22 4
18 5
19 6
17 7
8
18
12 16
15
14
13
20
21
23
24 25
4-38
ENG
SHIFTER
1. Shift Fork Guide(long) “1” 5. Shift Fork Guide Bar (2 short)
2. Shift Fork # R 6. Shift fork # L
3. Shift Cam 7. Torx Screw
4. Segment 8. Pin Shaft Cam
4-39
ENG
TRANSMISSION, SHIFT CAM AND

SHIFT FORK INSTALLATION
1. Install :
• Push rod # 2 “1” in the Axle Main.
2. Install :
3 2 The following parts in Crankcase LH in
4 following sequence.
1 • Shift Fork “L” (left) “1”
(face the “L” side for the Clutch side.)
• Shift Fork “R” (center) “2”
(face the “R” side for the Clutch side)
• Shift Fork Guide Bar #1 “3” (Short)
• Shift Fork Guide Bar #2 “4” (Long)
TIP :
Install the Shift Forks with the embossed mark
facing upward.
3. Check :
• Shift Cam operation
Improper operation Ô Reassemble/Repair
TIP :
Check the transmission and Shift Forks for
smooth operation by turning the Shift cam with
your hand.
4-40
ENG
Tightening Sequence
1 9
6
10
7
5
4
8
3 2
CRANKCASE
1. Crankcase #1 (LH)
2. Dowel Pins
3. Crankcase Breather Hose
4. Crankcase #2 (RH)
5. Holder Clutch Cable
4-41
ENG
CRANKCASE LH
1. Apply :
• Sealant on the Crankcase Mating surfaces
Sealant
Yamaha bond No. 1215:
1 TG-125
1
2. Install :
• Dowel Pins “1”
TIP :
a
Do not allow any sealant to come in contact with
the Oil Galleries “a” and “b” as shown in the fig-
ure.
3. Install:
• Crankcase RH with the Crankcasse LH.
b Tap lightly on the Case with mallet.
TIP :
Tighten the Engine Mounting Nuts-2 nos for
1 holding the Engine on the engine stand.
6
4. Tighten :
7 • Bolts 2 nos Crankcase RH
• Bolts 8 nos Crankcase LH as per
5
sequence
Bolts (Crankcase) :
4
10 Nm (1.0 m.kg, 7.2 ft.lb)
8
3 2
5. Apply :
9 • 4-Stroke Engine Oil on the Crank Pin,
10 Bearings and Oil Delivery Hole
6. Check :
• Crankshaft and transmission operation for
smooth rotation/ shifting by hand
Unsmooth operation Ô Reassemble/Repair
4-42
ENG
CDI MAGNETO
1. Timing Chain 5. Stator Assy.
2. Guide Stopper # 1 and # 2 6. Gasket
3. CDI Rotor Assy 7. Dowel Pin
4. Wood-Ruff Key 8. Cover Crankcase #1
4 2
7
8
5
6
7
4-43
ENG
TIMING CHAIN AND GUIDE STOPPER#2

2 1. Install
1 • Timing Chain “1”
2. Install
• Guide stopper#2 “2” with spacer
• Tighten the bolt “3”
3
ROTOR AND STARTER IDLE GEAR

INSTALLATION
1. Install
• Starter idle gear “1”.
• Plate “2”.
• Screw - 2 Nos. “3”.
2. Apply
• 4-stroke engine oil.
(onto journal and starter drives)
1 3. Install
• Washer “1”
• Starter idle gear “2”
4. Install:
• Wood-ruff key
• Magneto rotor “3”
TIP :
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
2 3 rotor to the start wheel gear.
5. Tighten :
• Nut (rotor) “1”.
Nut (rotor):
70 Nm ( 7.0 m. kg., 51 ft.lb)
3 TIP :
• Tighten the nut (rotor) “1” while holding the ro-
tor “2” with the magneto holder “3”.
Magneto Holder :
YSST 601 - B
4-44
ENG
C.D.I. MAGNETO INSTALLATION

1. Install :
1 • Woodruff Key “1”
2. Install :
• C.D.I. Magneto “2”
• Washer
• Nut
TIP :
When installing the Magneto Rotor, make sure
that the Woodruff Key is properly seated in the
Keyway of the Crankshaft.
3. Tighten :
• Nut (CDI Magneto) using the Magneto
2 Holder “2”
Nut (CDI Magneto):

70 Nm (7.0 m.kg, 51 ft.lb)
SPROCKET DRIVE
1. Install
2
• Sprocket Drive “1”
• Drive Sprocket Washer “2”
2. Tighten
• Bolt “3” (Drive Sprocket) using the
sprocket Holder.
1
Drive sprocket Holder
YSST-605
Bolt Sprocket Drive

10 Nm (1.0 m.kg, 7.2 ft.lb)
4-45
ENG
SHIFT SHAFT AND KICK STARTER

1. Shift Shaft 7. Circlip
2. Torsion Spring 8. Washer
3. Stopper Lever 9. Kick Idle Gear
4. Return Spring 10. Kick Shaft Assy.
5. Segment 11. Cover Crankcase # 2
6. Kick Starter Assembly
10 7
8
9
8
11 7
NEW
4 3
3 2
4-46
ENG
SEGMENT AND SHIFT SHAFT

1. Install
2 1 • Dowel Pins “1” on the Cam Shifter “2”
2. Install :
• Segment “1” using Torx Bit Tool
Torx Bit Tool

YSST - 611
1 TIP :
Fit the Dowel Pins on the Cam Shifter to the lo-
a cating hole “a” on the Cam Shifter and install the
Segment “1”
3. Install :
1 • Stopper Lever “1”
• Spring “2”
3 4. Tighten
• Bolt stopper lever “3”
2 Bolt (Stopper Lever) :

10 Nm (1.0 m.kg, 7.2 ft.lb)
TIP :
Hook the Spring ends on the Stopper Lever “1”
and the Crankcase Pin
Mesh the Stopper Lever “1” with the Cam Shifter
Stopper.
5 5. Install :
• Shift Shaft Assembly “4”
TIP :
Apply Oil to the Stopper Pin and hook the Spring
ends on the Stopper pin “5”
4
4-47
ENG
KICK STARTER INSTALLATION

1. Install :
1 • Kick Axle Assembly “1”
• Kick Gear Clip “2”
• Torsion Spring “3”
3 TIP :
2
T urn the Torsion Spring clockwise and hook into
a the proper hole “a” in the Crankcase.
2. Install :
5
4 Following parts on the Axle Drive “6”
• Circlip “1”
3 • Washer “2”
2 • Kick Idle gear “3”
1
6 • Washer “4”
• Circlip “5”
TIP :
Install Circlips radius side towards the compo-
nent refer on Page no 1-3
4-48
ENG
CLUTCH, PRIMARY DRIVE GEAR AND OIL PUMP
1. Clutch Spring 8. Thrust Washer 15. Key
2. Pressure Plate 9. Primary Driven Gear 16. Oil Pump Drive Gear
3. Push Plate 10. Ball 17. Oil Pump Driven Gear
4. Push Rod #1 11. Push Rod # 2 18. Oil Pump
5. Friction Plate 12. Push lever Axle 19. Gasket
6. Clutch Plate 13. Primary Drive Gear
7. Clutch Boss 14. Rotary Filter
1
2
3 5
6
4
7 8
13
9 10 12
NEW 11
16
15
14
17
18 19
4-49
ENG
OIL PUMP INSTALLATION

1. Lubricate :
• Oil delivery passage (Crankcase RH)
• Oil Pump Assembly “1”
Recommended Lubricant:
1 Yamalube Engine Oil
1 2. Install :
3 • Drive gear (Oil Pump) “1”
• Gasket
2
• Oil Pump Assy “3”
2
3. Tighten
• Screw (2 nos) “2”
a 4. Install
• Rotary Filter
TIP :
Align the Rotary Filter Dog “a” with groove of the
Crankshaft “b” and make sure to keep ‘TOP’
b marking facing upside.
PRIMARY DRIVE GEAR INSTALLATION

1. Install :
• Primary Drive Gear “1”
• Key
• Washer “2”
2 2. Tighten :
• Nut “3”
1 3
Nut (Primary Drive Gear)
70 Nm (7.0 m.kg, 51 ft.lb)
TIP :
Hold the Rotor with Magneto Holder then tighten
the Primary Drive Gear Nut.
Magneto Holder
YSST - 627
4-50
ENG
CLUTCH INSTALLATION
2 1. Install :
b • Oil Seal “1” New

• Circlip New
• Push Lever Axle “2”
1 TIP:
Install longer side “a” of the Spring on Push Le-
ver and smaller side “b” on the Crankcase Notch.
2. Install :
1
5
• Primary Driven Gear “1”
4
NEW • Thrust Washer “2”
• Clutch Boss “3”
2
3 • Lock Washer “4” New
• Clutch Boss Nut “5”
3. Tighten :
1 • Nut Clutch Boss “1” while holding the
Clutch Boss with Clutch Hub Holder “2”
Clutch Hub Holder

YSST - 233
2
Nut (Clutch Boss ):
60 Nm (6.0 m. kg, 43.5 ft. lb)
4. Bend :
• Lock Washer tab
(along a flat side of the end)
2 5. Install :
• Friction Plate “1” 5 Nos
• Clutch Plate “2” 4 Nos
TIP :
1 • 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° from pre-
vious plates projection continue this procedure
in clockwise direction until all Clutch Plates
are installed
4-51
ENG
6. Install :
• Ball
7. Install :
3 • Push Rod # 1 “1”
• Push Plate “2”
4 • Plate Washer “3”
1 • Nut “4” (Push Rod # 1)
2
8. Install :
3 2
1 • Pressure Plate “1”
• Compression Springs “2”
• Bolts “3” (Clutch Spring)
Bolts (Clutch Spring) :

a 6 Nm (0.6 m.kg, 4.3 ft. lb)
b
TIP :
Match arrow mark “a” on the Pressure Plate with
the Punch mark on Clutch Boss “b” while in-
stalling the Pressure Plate.
b Tighten the Clutch Spring Bolts in stage, using
a a crisscross pattern.
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 “a” Match mark on the Push Lever Assembly
“b” Match mark on the Crankcase
10. Adjust :
• Push Lever position
Adjustment steps :
• Loosen the Lock Nut “1”
• Turn the Adjuster “2” clockwise or anticlockwise
to match alignment marks.
4-52
ENG
• Hold the Adjuster to prevent it from moving and

tighten the Locknut to specification
1
Take care not to overtighten the Adjuster “2” and

remove the freeplay between both Push Rods.
2
• Tighten the Locknut “1”
11. Install
• Strainer
TIP :
Always keep its wider side, outside of Crankcase
12. Install :
• Dowel Pins
• Gasket (Crankcase #2) New
• Crankcase Cover #2 (RH)
1 6 Bolts (Crankcase Cover):

5 10 Nm (1.0 m.kg, 7.2 ft.lb)
7
4 TIP :
8 Ÿ Tighten the bolts in ascending order (see
number on the illustration).
3 2 9
13. Install :
• Kick Crank “1”
• Nut Kick Crank “2”
Nut (Kick Arm):

1 50 Nm (5.0 m.kg, 36 ft. lb)
14. Install :
2 • Dowel Pins
• Gasket (Crankcase Cover #1) New
• Crankcase Cover #1(L.H.)
1 6
5
4 Bolts (Crankcase Cover):

2 10 Nm ( 1.0 m.kg, 7.2 ft.lb)
7
3
4-53
ENG
CYLINDER AND PISTON
1. Cylinder 5. Piston Pin Circlips
2. Gasket Cylinder 6. Piston
3. Dowel Pins 7. Pin Piston
4. Piston Rings
3
5 6
4-54
ENG
CYLINDER HEAD
1. Bolt Flange 7. Cylinder Head
2. Washer 8. Dowel Pin
3. Bolt 9. Gasket Cylinder Head
4. Valve Cover (intake) 10. O-Ring
5. O-Ring 11. Cover Cylinder Head Side # 3
6. Valve Cover (exhaust) 12. Spark Plug
2
4
12
5
3
5
6
8
9
10
11
4-55
ENG
CAM SPROCKET AND TIMING CHAIN
1. Gasket 4. Cam Sprocket

2. Timing Chain Tensioner Assembly 5. Timing Chain
3. Guide Stopper # 2 6. Guide Stopper # 1
3
1
4-56
ENG
PISTON RING, PISTON AND CYLINDER

INSTALLATION
1. Install in following sequence
• Expander Spacer (Oil Ring) “1”
• Side Rails (Oil Ring) “2”
• 2nd Ring “3”
• Top Ring “4”
TIP :
• Make sure to install the Piston Rings so that
4
the “GTP TOP1” / “GTP-TOP 2” marks are lo-
3 cated on the upper side of the 2nd Ring/Top Ring
• Lubricate the Piston and Piston Rings with En-
2 gine Oil.
1 2. Install :
2 • Piston “1”
• Piston Pin “2” using Piston Pin Replacer
Tool
Piston Pin replacer tool

YSST - 207
• Piston Pin Circlip “3” New
TIP :
• Apply Engine Oil on the Piston Pin
3 • The Ô mark “a” on the Piston must be kept
a towards the exhaust side of the Cylinder
• Before installing the Piston Pin Circlip, Cover
the Crankcase opening with a clean cloth.
1 2
3
3. Install :
2 • Dowel Pins “1” 2 nos.
• Gasket (Cylinder) “2” New
4-57
ENG
4. Install :
1 a • Piston Rings “1”
TIP :
d Offset the Piston Rings end gaps as shown.
a. Top Ring End

b. Oil Ring end (lower)
c c. Oil Ring End (upper)
d. 2nd Ring End
b 5. Lubricate :
• Piston outer surface
• Piston Rings
• Cylinder Inner Surface
6. Install :
• Cylinder “1”
1
TIP :
2 • 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 “2” YSST - 604
Piston Base
YSST - 604
CYLINDER HEAD INSTALLATION

1
1. Install
• Dowel Pins “1” New
2
• Gasket ( Cylinder Head) “2” New
• Guide Stopper#1 “3”
1
4-58
ENG
2. Install :
• Cylinder Head
5 • Bolt with Washer (Cylinder Head)
4
2
Bolts (Cylinder Head ):
M8 (1-4) :
6
22 Nm (2.2 m.kg, 17 ft.lb)
3 1
M6(5-6) :
10 Nm (1.0 m.kg., 7.2 ft. lb)
TIP :
• Apply Engine Oil onto the Bolt thread
• Tighten the Bolts starting with the lowest num-
bered one.
d 1 3. Install :
• Cam Sprocket “2”
• Timing Chain “1”
c ssssssssssssssssssssssss
2 Installing steps :
• Turn the Crank Shaft anticlockwise until the
slit “a” (3rd Mark) matches the stationary
pointer “b”
• Align the “I” mark “c” on the Cam Sprocket with
the stationary pointer “d” on the Cylinder Head.
• Fit the Timing Chain “1” on Cam Sprocket “2”
and install the Cam Sprocket on the Camshaft.
b
TIP :
When installing the Cam Sprocket , keep instal-
b a lation of the Camshaft. Damage or improper Valve
timing will result.
Do not turn the Crankshaft during installa-

tion of the Camshaft. Improper Valve Tim-
ing will result.
TIP :
Remove the safety wire from the Timing Chain
before installation of Sprocket Cam.
4-59
ENG
4. Install :
1 • Plate Washer
5. Tighten
• Bolt Sprocket “1”
Bolt (Timing Chain Sprocket) :

20 Nm (2. 0 m.kg, 14.5 ft. lb)
TIP :
Install the Bolt while holding the Magneto
Mounting nut with a Wrench.
6. Check :
d • Magneto Rotor Slit “a” Third mark in
b
Anticlockwise direction.
c Align with stationary pointer “b” in the
Crankcase Cover #1 (LH)
a • Cam Sprocket “I” mark “c”
Align with stationary pointer “d” on the
Cylinder head
Out of alignment Ô Adjust
7. Install :
• Gasket (Timing Chain Tensioner)
• Timing Chain Tensioner
1 Installation steps :
• Remove the Tensioner Cap Bolt
• While Pressing the Tensioner Rod lightly with
fingers, use a Flat Head Screwdriver “1” and
retract the Tensioner Rod up fully clockwise
• With the Rod fully retracted, install the Gas-
ket “4” and the Chain Tensioner “5” and tighten
the Bolt “6” with Copper Washer to the speci-
fied torque
• Release the Chain Tensioner Rod by Screw-
driver, Then install the Gasket “2” and the Cap
3 Bolt “3” to the specified torque.
4 2
Bolts (Timing Chain Tensioner):
6 10 Nm (1.0 m.kg, 7.2 ft.lb)
Cap Bolt (Timing Chain Tensioner):
5 1 8 Nm (0.8 m.kg, 5.8 ft.lb)
4-60
ENG
8. Check :
• Valve clearance specifications
Refer to the “VALVE CLEARANCE ADJUST -
9. Lubricate :
• Yamalube
Recommended Lubricant :
Engine Oil - YAMALUBE
10.Install :
1 • Valve Covers (with O-Ring) “1”
• Cylinder Head Side Cover (with O-Ring) “2”
• Bolts “3”
2 Valve Cover :
17.5 Nm (1.75 m.kg, 13 ft.lb)
3
Bolts (Cylinder Head Side Cover)
10 Nm (1.0 m.kg, 7.2 ft.lb)
11. Install :
• Timing mark accessing screw
1 (with O-Ring) “1”
• Crankcase end accessing plug
2 (with O-Ring) “2”
12. Install
2 • O-Ring (intake manifold)
• Intake Manifold “1”
13. Tighten
1 • Bolts (intake manifold) “1” - 2 Nos.
Bolts (intake Manifold) :

10 Nm (1.0 m.kg, 7.2 ft. lb)
4-61
ENG
14. Install :
• Spark Plug
Spark Plug :
17.5 Nm (1.75 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)
8 2. Install
9 • Footrest Assy
3. Install :
• Engine Mount Bolt (Rear) “1” Lower
• Engine Mount stay upper “2”
4
• Engine Mount bolt (Front upper) “9”
2 • Mounting Bolt
7 (Engine mount stay upper) “3”
3 • Mounting Bolt (upper) “4”
• Engine Mount Stay front “5”
5
• Bolt (Engine Mount Stay Front upper) “6”
6
• Bolt (Engine Mount stay Front lower) “7”
• Engine Mount Bolt (Front lower) “8”
• Engine Mount Bolt (Front upper) “9”
4. Tighten :
• Bolts Foot Rest Assembly
Bolts (foot rest) :

17.5 Nm (1.6 m.kg, 7.2 ft lb)
4-62
ENG
Engine Mount Bolt (Rear) : Bolt (Engine Mount stay front lower)
38 Nm (3.8 m.Kg.27.5 ft. lb) 38 Nm (3.8 m.kg., 27.5 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)
38 Nm (3.8 m.kg., 27.5 ft.lb)
2 3 5. Install :
• Gasket
• Exhaust pipe “1”
• Bolts Exhaust Pipe “2” - 2 nos
• Bolt (Muffler) “3”
Bolts (Exhaust Pipe) :

10 Nm (1.0m. kg, 7.2 ft. lb)
1 Bolt (Muffler) :
15 Nm (1.5 m.kg, 11 ft lb)
6. Install :
• Shift Pedal “1”
7. Tighten :
• Bolt Shift Pedal “2”
1
Bolt (Shift Pedal):
2
10 Nm (1.0m. kg, 7.2 ft. lb)
8. Install :
1 • Stay Clutch Cable “1”.
Bolt (cable stay) :

7 Nm (0.7 m.kg, 5.1 ft. lb)
9. Install
• Clutch cable
• Adjust Clutch Cable free play at Lever end
Refer “CLUTCH ADJUSTMENT”
on Page no 3-18.
10. Adjust
Drive Chain Slackness
Refer to “DRIVE CHAIN SLACK
ADJUSTMENT” on Page no 3-21.
4-63
ENG
11. Install:
• Carburetor
Refer to “CARBURETOR” on page no 5-7
12. Tighten:
1 • Air Filter Case Screws “1”
Bolts (Air Filter Case ):

7 Nm (0.7 m.kg, 5.1 ft.lb)
13. Install
• Battery Box
• Battery
• Battery Flap
Bolts (Battery Box)

3.8 Nm (0.38 mkg), 3 ft lb
14. Connect
• Battery Leads
• Sensor Coil Lead Coupler
Connect the positive lead “1” First and then the

2 negative lead “2”
1
15. Install
Spark Plug Cap
16. Fill
• Oil in Crank Case
Refer to “ENGINE OIL REPLACEMENT”
on Page no 3-15.
17. Adjust :
• Idle Speed
Refer to “IDLING CO. MEASUREMENT
AND ADJUSTMENT” on Page no 3-8
18. Adjust :
• Throttle cable Free play
Refer to “THROTTLE CABLE
4-64
CHAPTER 5
CARBURETION
CARBURETOR VIEW ......................................................................................................................5-1

REMOVAL........................................................................................................................................5-2
DISASSEMBLY ................................................................................................................................5-3
INSPECTION ...................................................................................................................................5-4
ASSEMBLY ......................................................................................................................................5-6
INSTALLATION................................................................................................................................5-7
CARBURETOR TUNING .................................................................................................................5-8
FUEL LEVEL ADJUSTMENT...........................................................................................................5-9
AIR INJECTION .............................................................................................................................5-10
CHECKING THE AIR INDUCTION SYSTEM ................................................................................5-10
CARB
CARBURETOR
CARBURETOR
1. Throttle cable 12. Throttle valve
2. Jet needle assembly 13. Holder, needel jet
3. Spring throttle valve 14. Air screw assembly
4. Plug drain 15. Jet pilot
5. Float chamber body 16. Starter assy.
6. O-ring 17. Throttle stop screw
7. Main chamber body 18. Pipe drain
8. Float pin 19. Cable adjust screw set
9. Float 20. Seal (f.c.b.)
10 needle valve assembly 21. Gasket
11. Jet main 22. Needle Jet
19
7
6
21
17
16
14
3
22 15
10
13
11
2
2 9
8
20
1212
18 4
5-1
CARB
CARBURETOR
REMOVAL
1. Remove :
• Side Covers (LH & RH)
Refer to the “SIDE COVER, SEAT AND
FUEL TANK” on, Page no. 3-3
2. Drain :
• Fuel (Float Chamber)
TIP :
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 2 3. Disconnect :
• Air Vent Hose
• Fuel Hose “2”
• Over Flow Hose “3”
4. Loosen :
• Screw Clamp (Air Filter Hose) “4”
3 • Bolts (Air Filter Case ) (2 nos)
5. Remove
1 • Bolts (Intake Manifold) “1” (2 nos)
• Joint “2” with ‘O’ ring
6. Remove :
2
• Carburetor Assembly with ‘O’ ring
7. Remove
• Throttle Cable “1”
Remove with Carburetor Chamber Top
1 and Throttle Valve
5-2
CARB
DISASSEMBLY
DISASSEMBL Y
TIP
The following parts can be cleaned and
inspected without Carburetor Disassembly.
• Throttle Valve Assembly
• Before disassembly of Carburetor clean the
outer surface of Carburtor and Check the
Starter Lever Opeartion.
1
1. Open
• Screws (Float chamber) “1” 2 Nos
2
2. Remove :
• Float Chamber “2”
3
• Seal Float Chamber “3”
1
1 3. Remove :
• Float Pin “1”
• Float “2”
2
4. Remove :
• Needle Valve “1”
5. Remove :
1
4 • Jet Main “1”
• Holder, needel jet “2”
• Needle Jet “3”
2 • Jet pilot “4”
3
5-3
CARB
DISASSEMBLY / INSPECTION
6. Remove :
• Air Screw Assembly “1” (Spring, Washer
and ‘O’ ring)
7. Remove :
1 2 • Cap plunger “1”
• Starter Lever Assembly “2”
8. Remove
4 • Throttle Stop Screw Set “4” with spring.
INSPECTION
Carburetor Body
1. Inspect :
• Cracks/damage Ô Replace
• Fuel Passages Blockage Ô Clean with
petrol and Compressed air.
• Contamination in jet housings Ô Clean
Carburetor Float Chamber Body
1. Inspect
• Cracks/damage Ô Replace
• Fuel Starter Passage Blockage Ô Clean
with petrol and compressed air
• Contamination Ô Clean
Cleaning Steps :
• Wash the Carburetor in petroleum based sol-
vent. (Do not use any caustic cleaning solu-
tion )
• Blow all passages and Jets with compressed
air.
5-4
CARB
INSPECTION
Float
1. Inspect :
• Damage Ô Replace
Needle Valve and Valve Seat

1 1. Inspect
• Needle Valve “1”
Damage/wear /blockage Ô Clean/Replace
as a set
Jets and Screws

1. Inspect :
3 • Holder, needle jet “1”
5 4 • Jet main “2”
• Air screw “3”
6
• Jet pilot “4”
1 • Throttle Stop Screw “5”
2 • Needle Jet “6” (Main Nozle)
• Bends/wear/damage Replace
Blockage Ô Blow the Jets with
compressed air
Throttle Valve
6 1. Check :
• Free movement
Insert the Throttle Valve in the Carburetor
body, and check for free movement
Hinderance Ô Clean/Replace
5-5
CARB
ASSEMBLY
ASSLEMBLY
Reverse the disassembly procedure.
1 1. Wash
• All the parts in clean petroleum based
solvent
• Always use new ‘o’ rings
2. Install :
• Air screw assembly “1”.
• Install Starter Assy.
1 3. Install :
4
• Jet main “1”
• Holder, needle jet “2”
2 • Needle Jet “3” (Main Nozzle)
3 • Jet pilot “4”
4. Install :
3 • Needle Valve “1”
1 5. Install :
• Float “2”
• Float Pin “3”
2
6. Measure
• Float Height “a”
Float Height : 10.7 ± 1 mm
3
7. Install
• Seal Float Chamber “1” New
• Float Chamber “2”
• Screw “3” (2 nos)
1 3
2
5-6
CARB
INSTALLATION
1 8. Install
• Throttle Stop Screw set “1”
INSTALLATION
Reverse the “REMOVAL” procedure
1. Install :
• Spring, Throttle Valve with the Throttle
1 Cable
2. Install :
• Throttle Valve Assembly
With Carburetor Chamber Top
TIP
2 Align the slot “1” on the Throttle Valve with the
projection on “2” the Carburetor Body.
3. Install :
• Carburetor Assembly and Joint “a” with
a
O-ring “3” together on the intake manifold.
4. Tighten
• Bolts (Intake manifold 2 nos ) “1”
3 5. Install
•Air Filter hose on the Carburetor
6. Tighten :
• Clamp Screw “2”
• Bolts (Air Filter Case - 2 nos)
7. Connect :
2
1 • Over Flow Hose “3”
• Fuel Hose
• Air vent hose
3 4
5-7
CARB
CARBURETOR TUNING
8. Adjust :
• Idling speed by Throttle Stop Screw “1”
1 Engine Idling Speed :

1300 - 1500 R.P.M.
9. Adjust :
Refer to “THROTTLE CABLE
Carburetor Tuning
‘CO MEASUREMENT AND ADJUSTMENT”
1. Start the Engine and let it worm up by
running approximately 4 kms.
2. Attach :
• Tachometer to the Spark Plug lead
3. Check :
• Engine idling speed
If out of sepecification Ô adjust
Engine Idling Speed :

1300 - 1500 R.P.M.
Adjustment Steps
T urn the Throttle Stop Screw “1” in or out until
2 specified idling speed is obtained.
Turning in Ô RPM Increases

Turning Out Ô RPM Decreases
4 4. Insert :
3 • Sampling probe “2” of ‘CO’ tester
(calibrated) to the exhaust pipe “3” using
suitable adapter “4”
‘CO’ density :
2.0 ± 0.5% with AIS Closed
If out of specification Ô adjust
5. Adjust :
• ‘CO’ density through air screw
Adjustment Steps
Turn the Air Screw “5” in or out until the speci-
5 fied ’CO’ density is achieved.
Turning In Ô ‘CO’ density Increases
Turning Out Ô ‘CO’ density Decreases
• Reset idling speed as per specifications

5-8
CARB
CARBURETOR TUNING
NOTICE :
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 Air Screw.
• To counter check the setting of the Air Screw,
follow the ‘CO’ adjustement procedure.
6. Adjust :
• Idling speed by Throttle Stop Screw 1
1
Engine Idling R.P.M.
1300 to 1500 RPM
FUEL LEVEL ADJUSTMENT

1. Measure :
• Fuel Level “a”
Fuel level :
3.0 PL/minus 0.5 mm below the
a Joint of Main Chamber Body
and Float Chamber Body
1
2 Measurement and adjustment steps :

• Place the motorcycle on a level surface on cen-
tre stand
• Connect the Fuel Level Gauge “1” to the Drain
3 Pipe “2”
Fuel Level Gauge

a
• Loosen the Drain Screw“3”
• Hold the Gauge vertically next to the Float
Chamber Line
• Measure the Fuel level “a” with the Gauge
• If the fuel level is incorrect, adjust the fuel level,
using the following steps
• Remove the Carburetor
• Inspect the Valve Seat and Needle Valve
• If worn, replace necessary components.
5-9
CARB
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned

exhaust gases by injecting fresh air(secondary
air) into the exhaust port, reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust

port, the reed valve opens, allowing secondary
2 air to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600° to 700° C.
1. Air Filter Case “1”

1
2. AIS Unit “2”
3 3. Exhaust Port “1”
CHECKING THE AIR INDUCTION

1 SYSTEM
2
1. Check
2
• Hose “1”
3
Loose connection Ô Connect Properly
Crack/Damage Ô Replace
• Pipes “2”
Crack/damage Ô Replace
• Clamps “3”
3 1
for proper clamping
5-10
CHAPTER 6
CHASSIS
FRONT WHEEL AND FRONT BRAKE .......................................................................................... 6-1

FRONT WHEEL ............................................................................................................................. 6-1
FRONT BRAKE SHOES DISASSEMBLING .................................................................................. 6-2
REMOVAL ...................................................................................................................................... 6-3
FRONT WHEEL INSPECTION ...................................................................................................... 6-3
BRAKE SHOE PLATE DISASSEMBLY .......................................................................................... 6-4
SPEEDOMETER GEAR INSPECTION .......................................................................................... 6-4
CHECKING THE FRONT BRAKE SHOES .................................................................................... 6-5
BRAKE SHOE PLATE ASSEMBLY ................................................................................................ 6-6
FRONT WHEEL INSTALLATION ................................................................................................... 6-7
REAR WHEEL ............................................................................................................................... 6-9
REAR BRAKE .............................................................................................................................. 6-10
REMOVAL .................................................................................................................................... 6-11
REAR WHEEL INSPECTION ....................................................................................................... 6-12
REAR BRAKE INSPECTION ........................................................................................................ 6-12
REAR WHEEL INSTALLATION ................................................................................................... 6-13
DRIVE CHAIN AND SPROCKETS .............................................................................................. 6-14
REMOVAL .................................................................................................................................... 6-15
DRIVE CHAIN INSPECTION ........................................................................................................ 6-16
CLUTCH HUB INSPECTION ....................................................................................................... 6-17
DRIVEN SPROCKET ASSEMBLY ............................................................................................... 6-17
DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION ........................................................ 6-17
FRONT FORK .............................................................................................................................. 6-19
FRONT FORK REMOVAL ............................................................................................................ 6-20
FRONT FORK DISASSEMBLY..................................................................................................... 6-21
FRONT FORK INSPECTION ........................................................................................................ 6-22
FRONT FORK ASSEMBLY........................................................................................................... 6-23
FRONT FORK INSTALLATION .................................................................................................... 6-25
INSTALLING THE FRONT FORK LEGS .......................................................................................6-26
STEERING HEAD AND HANDLEBAR ........................................................................................ 6-27
REMOVAL .................................................................................................................................... 6-28
HANDLEBAR REMOVAL ............................................................................................................. 6-29
HANDLEBAR INSPECTION ......................................................................................................... 6-29
STEERING INSPECTION ............................................................................................................ 6-30
STEERING INSTALLATION ......................................................................................................... 6-30
HANDLEBAR INSTALLATION ..................................................................................................... 6-31
REAR SHOCK ABSORBER AND SWING ARM VIEW ................................................................ 6-32
REMOVAL .................................................................................................................................... 6-33
INSPECTION ................................................................................................................................ 6-34
CHAS
FRONT WHEEL AND FRONT BRAKES
FRONT WHEEL
Remove the front wheel :
1. Front brake adjusting nut
2. Pin
3. Spring
4. Brake cable
5. Stopper ring
6. Speedometer cable
7. Front wheel axle nut
8. Front wheel axle
9. Front wheel 10 Collar
11. Front brake shoe plate assembly
12. Dust cover
6-1
CHAS
FRONT BRAKE SHOES DIASSEMBLING
1. Brake shoe spring 10. Washer

2. Brake shoe spring 11. Ring stop
3. Brake shoe 12. Oil seal
4. Brake camshaft lever 13. Retainer (Bush)
5. Brake shoe wear indicator 14. Washer plate
6. Brake camshaft 15. Speedometter driven gear
7. Oil seal 16. Brake shoe plate
8. Circlip
9. Speedometer drive gear
8
12
13
10
1 14
3 15
10
9 7
2
5
6
16
6-2
CHAS
REMOVAL
WARNING
To avoid injury, securely support the vehicle
so there is no danger of it falling over.
1. Place the motorcycle on the center stand.

2. Disconnect the brake cable at the wheel hub
1 by loosening the brake lever free play
adjusting nut “1”, then removing the cable
from the brake camshaft lever and brake
shoe plate.
3. Disconnect the speedometer cable “2” by

removing the locking clip “3”.
2
4. Remove the cotter pin “4”.
5 5. Remove the axle nut and washer.

6. Pull the wheel axle out, and then remove the
4 wheel.
7. Remove:
Ÿ Front Wheel Axle “1”
Ÿ Brake Shoe Plate Assembly “2”
Ÿ Dust Seal/Collar “3”
ŸFront Wheel “4”
FRONT WHEEL INSPECTION

1. Inspect
• Front Wheel Axle
(by rolling it on a flat surface)
Bends Ô Replace
WARNING
Do not attempt to straighten a bent wheel axle
2. Inspect :
• Front Tyre
Refer to “TYRE INSPECTION” on Page
no 3-27.
• Front Wheel
Refer to “WHEEL INSPECTION” on
Page no 3-29.
6-3
CHAS
5. Measure :
• Front Wheel runout using a height gauge
b Over the specified limits Ô Replace
a
Front Wheel runout limits :
Radial “a” : 1.0 mm
Lateral “b” : 0.5 mm
6. Inspect :
• Front Wheel Bearings
Bearings allow free play in the Wheel Hub
or the Wheel does not turn smoothly Ô
Replace the wheel bearings
• Oil Seals
7. Inspect :
• Collar
Grooved Wear Ô Replace the Collar and
the Oil Seal as a set
BRAKE SHOE PLATE DIASSEMBLY

1. Remove :
• Bush “1”
• Meter Gear “2”
Remove the bush using a special
Tool “3”
2
1 3 Speedometer Gear Nut
removing tool
YSST - 237
SPEEDOMETER GEAR INSPECTION

1. Inspect :
• Meter Drive Gear “1”
• Meter Gear “2”
1 2
6-4
CHAS
CHECKING THE FRONT BRAKE SHOES

1. Check:
ŸBrake shoe lining Glazed areas Ô Repair.
Sand the glazed areas with course
sandpaper
TIP :
Ÿ After sanding the glazed areas, clean the
brake shoe with a cloth
2. Measure:
ŸBrake shoe lining thickness “a”.
Lining thickness
4.0 mm (0.16 in) Limit
Limit
2.0 mm (0.08 in)
WARNING
Do not allow oil or grease on the brake shoes.
TIP :
Ÿ Replace the brake shoes as a set, if either
is worn to the wear limit.
3. Measure:
ŸBrake drum inside diameter “a”.
Out of specification Ô Replace the wheel.
Brake drum inside diameter

130.0 mm (5.16 in)
Limit
131.0 mm (5.16 in)
4. Check:
ŸBrake drum inner surface.
Oil deposits Ô Clean.
ŸRemove the oil with a rag soaked in
lacquer thinner or solvent.
Scratches Ô Repair.
Lightly and evenly polish the scratches
with an emery cloth.
1
5. Check:
ŸBrake camshaft.
Damage/wear Ô Replace.
6-5
CHAS
BRAKE SHOE PLATE ASSEMBLY

a 1. Install :
2 b • Camshaft “1”
• Indicator Plate “2”
1 Installation steps :
• Align the projection “a” on the Indicator
Plate “2” with the Camshaft notch “b”
2. Install :
2 • Cam Lever “1”
• Bolt and nut Cam Lever “2”
1 Cam Lever Nut :

10 Nm (1.0m.kg, 7.2 ft.lb)
3. Install:
ŸBrake shoe spring (pivot pin side) “1”
ŸBrake shoe spring (brake camshaft side)
“2”.
TIP :
ŸLubricate the pivot pin with a thin coat of
wheel bearing grease.
ŸDo not damage the springs during
installation.
ŸInstall the brake shoe springs as shown.
WARNING
Do not apply grease to the brake shoe linings
3. Install:
ŸSpeedometer driven gear “1”
ŸRetainer “2”
(with the meter gear bush tool “3”)
Speedometer gear nut

removing tool
YSST-237
6-6
CHAS
5. Install :
a b • Brake Shoe Plate Assembly “1”
TIP :
Make sure that the Wheel Hub and the Speed-
ometer Gear Unit are installed with the two pro-
jections “a” meshed into the two solts “b”
1 6. Install :
• Hub Dust Cover
• Collar
FRONT WHEEL INSTALLATION

Note the following points
1. Lubricate :
• Axle Front Wheel
• Bearings
• Oil Seal (lips)
• Drive/Driven Gear (Speedometer)
Recommended lubricant :
2 Lithium Soap base grease
1. Install the brake shoe plate into the wheel

hub.
2. Lift the wheel up between the fork legs.
TIP :
Ÿ Make sure that the slot “1” in the brake
1 shoe plate fits over the retainer “2” on the
fork leg.
1 3. Insert the wheel axle from the right side.

4. Install the washer and axle nut, and then
tighten the axle nut to the specified torque.
1 5. Install the cotter pin “2” and bend it to lock.
WARNING
Always us a new Cotter Pin
6-7
CHAS
6. Connect the brake cable “1” at the brake

camshaft lever “2” on the wheel hub, and
then install the brake cable free play
adjusting nut “3”.
7. Install the speedometer cable and secure it

2 with the clip.
1 WARNING
3 Make sure that the Brake Cable and Meter
Cable is routed properly.
8. Adjust the brake lever free play “1”.

1 9. Take the motorcycle off the center stand so
that the front wheel is on the ground.
10. Push down hard on the handlebar several
times to check for proper fork operation.
6-8
CHAS
REAR WHEEL AND REAR BRAKE
REAR WHEEL
1. Adjuster 8. Spacer
2. Pin 9. Rear Wheel Assembly
3. CompressionSpring 10. Brake Shoe Plate Assembly
4. Cotter Pin 11. Damper
5. Tension Bar 12. Bearing
6. Axle Nut 13. Spacer/Collar
7. Chain Puller 14. Bearing
4 7
6
1
2
3
12
10
4
13
14
11 11
5
11 11
8
6-9
CHAS
REAR BRAKE
1. Brake Shoe Kit
2. Cam Lever
3. Indicator Plate
4. Camshaft
3
4
6-10
CHAS
REMOVAL
WARNING
TIP :
Ÿ Place the vehicle on a center stand so that
the rear wheel is elevated
2
1. Remove :
• Chain Cover (upper “1” and lower “2”)
2 2. Remove the cotter pin “1” and nut “2” and

then remove the brake torque rod “3” from
the brake shoe plate.
1
3
3. Remove the brake pedal free play adjusting

3 6 nut “1”, and then disconnect the brake rod
“2” from the brake camshaft lever.
4 4. Loosen the drive chain puller locknut “3” and
the drive chain slack adjusting bolt on both
1 5 ends of the swingarm.
2 5. Remove the axle nut cotter pin “5”.
6. Remove the axle nut “6”, and then pull the
wheel axle “7” out.
7. Push the wheel forward, and then remove
the drive chain from the rear sprocket.
TIP
7 Ÿ The drive chain does not need to be
disassembled in order to remove and install
the wheel.
8. Remove the wheel.
6-11
CHAS
REAR WHEEL INSPECTION

1. Inspect :
• Axle Rear Wheel
• Rear Wheel
1
• Bearings Rear Wheel
• Oil Seals
Refer to “FRONT WHEEL INSPECTION”
Page no 6-3.
• Tire
Damage/Wear Ô Replace
2. Measure :
b
• Redial wheel runout “a”.
a • Lateral wheel runout “b”.
Over the specified limit Ô Replace.
3. Inspect :
1 1 • Clutch Hub Damper “1”.
1 1
REAR BRAKE INSPECTION
1. Check:
ŸBrake shoe lining
Glazed areas Ô Repair.
Sand the glazed areas with coarse
sandpaper.
TIP
Ÿ After sanding the glazed areas, clean the
brake shoe with a cloth.
2. Measure:
ŸBrake shoe lining thickness “a”
Lining thickness
4.0 mm (0.16 in) Limit
Limit
2.0 mm (0.08 in)
WARNING
Do not allow oil or grease on the brake shoes.
TIP
Ÿ Replace the brake shoes as a set, if either
is worn to the wear limit.
6-12
CHAS
3. Measure:
ŸBrake drum inside diameter “a”.
Out of specification Ô Replace the wheel.
Brake drum inside diameter

130.0 mm (5.12 in)
Limit
131.0 mm (5.16 in)
4. Check:
ŸBrake drum inner surface
Oil deposits Ô Clean.
Remove the oil with a rag soaked in
lacquer thinner or solvent.
Scratches Ô Repair.
Lightly and evenly polish the scratches
with an emery cloth.
5. Check:
ŸBrake camshaft
REAR WHEEL INSTALLATION

1 1. Install the wheel by inserting the wheel axle
“1” from the left-hand side.
2. Install the drive chain onto the rear sprocket.
3. Install the axle nut “1”.
4. Install the brake rod “2” onto the brake
camshaft lever and then install the brake
pedal free play adjusting nut “3” onto the
brake rod.
5. Connect the brake torque rod “4” to the
brake shoe plate by installing the bolt and
nut “5”.
6. Adjust the drive chain slack. (See page 6-
1
17.)
7. Tighten the axle nut, and then the brake
torque rod nut to the specified torques.
3 Tightening torques:
6 Axle nut:
2
90 Nm (9.0 m·kgf, 65 ft·lbf)
Brake torque rod nut:
19 Nm (1.9 m·kgf, 13 ft·lbf)
8. Insert a new cotter pin into the axle nut “6”
and the brake torque rod bolt “7”, and then
bend the ends of each cotter pin.
5 WARNING
Make sure that the Brake Cable and Meter
Cable is routed properly.
9. Adjust the brake pedal free play. (Refer to
REAR BRAKE ADJUSTMENT” on Page
7 No.- 3-20.)
WARNING
4
After adjusting the brake pedal free play,
check the operation of the brake light.
6-13
CHAS
DRIVE CHAIN AND SPROCKETS

1. Chain Case 7. Drive Chain
2. Drive Sprocket cover 8. Oil Seal
3. Drive Sprocket 9. Driven Sprocket Assembly
4. Clip Chain Joint 10. Chain Tensioner
5. Link Plate 11. Circlip
6. Chain Joint 12. Bearings
12
11
8
6
4
7 5
10
3
6-14
CHAS
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 :
1
• Chain Case (upper and lower) “1”
• Shift pedal “2”
• Drive sprocket cover “3”
• Drive Sprocket
Refer to “ENGINE REMOVAL” on
Page No 4-1.
2 3 3. Remove
• Rear Wheel
Refer to “REAR WHEEL” on Page no 6-11.
4. Remove :
• Chain Joint Clip “1”
3
• Link Plate “2”
4 • Chain Joint “3”
• Drive Chain “4”
1
2
5. Remove :
1 • Driven Sprocket “1”
(with Sprocket Hub)
• Puller chain assy. “2”
6-15
CHAS
DRIVE CHAIN INSPECTION

1. Inspect :
• Drive Chain
Stiffness Ô Clean and Lubricate or replace
2. Inspect :
1 • Drive Chain “1”
2 • Driven Sprocket “2”
More than 1/4 tooth wear “a” Ô Replace
the Drive Chain and both the Sprockets as
a set.
3. Measure :
• 10 link length “b” (Drive Chain)
1 2 3 4 5 6 7 8 9 10 11
Out of specification Ô Replace the Drive
Chain
10 link length limit :

127 mm
b TIP :
• Tighten the Drive Chain with a fingers before
measuring
• 10 link length is the distance “b” between the
inside edge of Roller “1” and “11” as shown.
• 10 link length measurement should be done
at two or three different places.
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.
Drive Chain Lubricant :

Yamalube Engine Oil
6-16
CHAS
CLUTCH HUB INSPECTION

1. Inspect :
Clutch Hub
Wear/damage/cracks Ô Replace.
DRIVEN SPROCKET ASSEMBLY

1 1. Install
• Driven Sprocket “1” on Clutch Hub
• Lock Washer “2” New
3 • Nut “3”
2
Nut (Driven Sprocket ):
40 Nm (4.0 m.kg, 29 ft.lb)
TIP :
• Tighten the Nuts in a crisscross pattern
1
2. Bend :
Lock Washer Tab “1”
(along a flat side of the end)
DRIVEN SPROCKET AND DRIVE CHAIN

INSTALLATION
1. Install :
• Puller chain assy. “1”.
• Spacer “2” with Driven Sprocket
Assembly “3”
6-17
CHAS
3. Install :
2 • Driven Sprocket alongwith wheel
assembly.
• Drive Chain “1”
1 • Chain Joint “2”
• Plate “3”
(Refer to “REAR WHEEL ASSY.
INSTALLATION” on Page 6-13.)
3
4. Install :
Clip “1” New
WARNING
Be sure to install the Chain Joint Clip to the
direction as shown
1
5. Install :
• Chain Case (upper)
• Chain Case (lower)
• Shift Pedal
Refer to “ENGINE REMOVAL”
on Page no 4-1
6. Adjust :
• Drive Chain Slack
Refer to “DRIVE CHAIN SLACK ADJUST-
A drive chain that is too tight will overload the

engine and other vital parts, and one that is
too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
6-18
CHAS
FRONT FORK
FRONT FORK
1. Front Fender 7. Fork Spring 12. Spindle Taper
2. Cap Bolt 8. Seal Dust 13. Cylinder Comp Front Fork
3. Holder Cable 9. Ring Snap 14. Inner Tube
4. O Ring 10. Bolt 15. Sub Spring
5. Spacer 11. Gasket 16. Oil seal
6. Spring Seat 17. Outer Tube
18. Cap
45 Nm (4.5 m.kg, 33 ft.lb)
45 Nm (4.5 m·kg, 33 ft·lb)
1 18
14
3 4 New
5
6 12
8
9
7 16
New
17
13
11New
15
10
23 Nm (2.3.m·kg, 17 ft·lb)
6-19
CHAS
FRONT FORK
FRONT FORK REMOVAL

WARNING
Securely support the Motorcycle so there is
no danger of it falling over
1. Stand the Motorcycle on a level surface

2. Elevate the Front Wheel by placing a suit-
able stand under the Engine
3. Remove :
• Front Wheel
• Front Fender
Refer to “FRONT WHEEL REMOVAL ”
on Page no 6-3
• Handlebar
Refer to “HANDLEBAR REMOVAL”
on Page no 6-29.
4. Remove
• Upper bracket bolt
1 • Lower bracket pinch bolt
5. Loosen the cap bolt “1”
6-20
CHAS
FRONT FORK
FRONT FORK DISASSEMBLY

front fork legs.
1. Remove:
ŸCap bolt (Front Fork)
2. Drain:
ŸFork oil
TIP :
Ÿ Stroke the inner tube several times while
draining the fork oil.
1
3. Remove:
2 ŸDust seal “1”
ŸOil seal clip “2”
(with a flat-head screwdriver)
Do not scratch the inner tube.
4. Remove:
1 ŸOil seal “1”
(with TFF oil seal remover)
TFF oil seal remover

YSST-270
5. Remove:
ŸDamper rod bolt “1”
ŸCopper washer
TIP :
Ÿ While holding the damper rod with the 11-
mm hexagon nut/socket wrench “2” and T-
handle “3”, loosen the damper rod bolt.
T-handle
YSST-213
6-21
CHAS
FRONT FORK
FRONT FORK INSPECTION

front fork legs.
1. Check:
ŸInner tube
ŸOuter tube
Bends/damage/scratches Ô Replace
WARNING
Do not attempt to straighten a bent inner tube
as this may dangerously weaken it.
2. Measure:
ŸSpring free length “a”
Front Fork Spring free length :

345.5 mm
<Wear limit>
339.0 mm
Over the specified limit Ô Replace
3. Inspect:
ŸCylinder Complete Front Fork “1”
ŸPiston Ring
Wear/cracks/damage Ô Replace
ŸSpring Sub “3”
ŸSpindle Taper “4”
Bends/damage Ô Replace
Contamination Ô Blow out all Oil
passages with Compressed Air
When disassembling and assembling the

front fork leg, do not allow any foreign mate-
rial to enter the front fork.
4. Check:
ŸCap bolt Ô O-ring
6-22
CHAS
FRONT FORK
FRONT FORK ASSEMBLY

front fork legs.
WARNING
Ÿ Make sure the oil levels in both front fork
legs are equal.
Ÿ Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP :
Ÿ When assembling the front fork leg, be sure
to replace the following parts:
- Oil seal
- Capper washer
- Oil seal clip
- Dust seal
- O-ring
Ÿ Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
ŸDamper rod “1”
Rebound spring “2”
Allow the damper rod assembly to slide

slowly down the inner tube “3” until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:
ŸInner tube outer surface.
Recommended oil
Fork oil 10W or equivalent
2 1
3. Install:
ŸInner tube “1”
(into outer tube “2”)
3 ŸSpindle taper “3”
4. Install:
ŸCopper washer “1” NEW
ŸDamper rod bolt “2”
When disassembling and assembling the

front fork do not allow only foreigh material to
enter the oil.
6-23
CHAS
FRONT FORK
5. Tighten:
1 ŸDamper rod bolt “1”
2
Damper rod bolt
20 Nm (2.0 m-kg, 14ftlb)
LOCTITE ®
3
TIP
Ÿ While holding the damper rod with the 11-
mm hexagon nut/socket wrench “2” and T-
handle “3”, tighten the damper rod bolt.
T-handle
YSST-213A
6. Install :
2 • Oil Seal “1” New Using TFF Oil Seal
1 1 Installation Tool
TFF Oil Seal Installation Tool

YSST - 275
TIP :
• Before installing the Oil Seal “1” apply lithium
soap base grease onto the Oil Seal lips.
• Adjust the Ring Snap so that it fits into the
Outer Tube Groove
NOTICE :
WARNING
Make sure that the Oil Seal numbered side
faces upward
1
2 3 7. Install :
• Washer “1”
• Ring Snap “2”
• Dust Seal “3”
8. Inspect :
• Inner Tube operation
Unsmooth operation Ô Disassembly and
recheck
6-24
CHAS
FRONT FORK
9. Fill :
1 • Fork Oil “1”
Oil Quantity (Per One Piece) :

Overhauling - 155 ± 3 ml
Recommended Oil :
10 W or equivalent
10. After filling up, slowly Pump the Fork up

and down to distribute the Fork Oil
11. Install :
• Front Fork Spring “1”
• Seat Upper
• Spacer
• Allen Bolt By using YSST-237
1
TIP :
• Install the Fork Spring with its smaller Pitch
upward.
• Before installing the Cap Bolt, apply grease to
the O-Ring.
FRONT FORK INSTALLATION

Reverse the “REMOVAL PROCEDURE”
Note the following points
1. Install
• Front Fork
• Temporarily tighten Pinch Bolt
(Underbracket) “1”
1 TIP :
Pull up the inner to until its end flushes with the
top of the Handle Crown then temporarily tighten
the bolts (underbracket)
2. Tighten
• Pinch Bolts (underbracket) “1”
• Cap Bolts “2”
Pinch Bolt (Underbracket) :

28Nm (2.8 m.kg, 20 ft.lb)
Bolt (Cap Bolt) :
45Nm (4.5 m.kg, 33 ft.lb)
6-25
CHAS
FRONT FORK
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
Front fork leg “1”
a. Temporarily install the front fork leg so that

the top of the fork leg is positioned between
the upper bracket and the lower bracket.
b. Tighten the pinch bolt “2” and then cap bolt
“3”.
c. Loosen the lower bracket pinch bolt “2”
raise the front fork leg, and then tighten the
upper bracket bolt “4”.
6-26
CHAS
STEERING HEAD AND HANDLEBAR

1. Holder Handle Bar Lower 10. Ball Race Cover
2. Holder Handlebar Upper 11. Under Bracket
3. Handlebar 12. Ball Race (upper)
4. Grip Assembly (right) 13. Ball Cage (upper)
5. Handle Crown 14. Ball Cage (lower)
6. Lock Washer 15. Ball Race (center)
7. Ring Nut (upper) 16. Ball Race (lower)
8. Damper Rubber 17. Bush
9. Ring Nut (lower)
6
7 17
8
9
10
12
13
15
14
16
Tightening Steps
11
• Tighten the ring nut Lower
45.5 Nm (4.55 m.kg, 32.3 ft.lb)
• Loosen One turn
• Retighten The ring nut Lower
22 Nm (2.2 m.kg, 17 ft.lb)
6-27
CHAS
1 2 REMOVAL
1
WARNING
3
Securely support the motorcycle so that
there is no danger of it falling over
Stand the motorcycle on a level surface
4 1. Remove :
• Band “1”
• Brake Cable (front) “2”
• Clutch Cable “3”
1 • Speedometer Cable “4”
2. Remove :
Switch Handle “1”
3. Remove :
• Bolts (4 Nos) “1”
• Handlebar Upper Holder “2”
3 • Handlebar “3”
1 • Throttle Grip
• Lever Holder (Front Brake)
2
4. Remove :
• Front Wheel
Refer to “FRONT WHEEL” on
Page No. 6-3.
• Front Fender
• Front Fork
Refer to “FRONT FORK” on
Page No. 6-20.
5. Remove :
• Fuel Tank
Refer to “SIDE COVERS, SEAT, FUEL
1 6. Remove :
• Headlight Assembly “1”
6-28
CHAS
7. Remove :
1 Lock Washer “1”
Ring Nut (upper) “2”
2 Damper Rubber “3”
8. Remove :
• Ring Nut (lower) “1”
Use a Ring Nut Socket “2”
2
Ring Nut Socket :
YSST - 621
1 WARNING
Securely support the Steering Shaft so that
there is no danger of it falling down
1 9. Remove :
2 • Bearing Cover “1”
3 • Bearing Race “2”
• Balls (upper) “3”
5 4 • Lower Bracket “4”
• Balls (lower) “5”
HANDLEBAR REMOVAL
1. Remove :
• Grip (left)
Removal Steps :
• Blow with compressed air between the Handle-
bar and Adhesive side of the Grip to remove
HANDLEBAR INSPECTION
1. Inspect :
• Handlebar
Bends/Cracks/damage Ô Replace
WARNING
Do not attempt to straighten a bent Handle-
bar as this may dangerously weaken the
Handlebar
6-29
CHAS
STEERING INSPECTION
1. Wash the Bearing and Ball Races with a sol-
vent
2. Inspect :
• Bearing Races “1”
1 • Ball races “2”
Pitting/Damage Ô Replace
Bearing Race replacement steps :
• Remove the Ball Races on the Head Pipe us-
ing Long Rod “1” and the hammer as shown
• Remove the Ball Race on the Under Bracket
using the floor chisel “2” and the hammer as
shown
• Install the new Dust Seal and Races
2 ssssssssssssssssssssssss
TIP :
Always replace Bearing races as a set.
WARNING
If Bearing Race is not fitted squarely, the
Head Pipe could be damaged.
STEERING INSTALLATION
1. Lubricate
ŸUpper bearing
ŸLower bearing
ŸBearing races
TIP :
Ÿ Install bearing steering lower on under
bracket with fixing tool bearing steering
lower "1" as shown in the illustration.
4
3 Fixing tool bearing steering lower
YSST-870
2
1
2. Install
ŸLower ring nut
ŸRubber washer
ŸUpper ring nut
ŸLock washer
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-24.
3. Install
ŸUpper bracket
ŸSteering stem bolt
6-30
CHAS
TIP :
Ÿ Temporarily tighten the steering stem bolt.
2. Install
ŸFront fork legs Refer to "FRONT FORK"
on page 4-47.
TIP :
Ÿ Temporarily tighten the lower bracket pinch
bolts.
3. Tighten
ŸSteering stem bolt
Steering stem bolt

35 Nm (13.5 m-kg, 25 ft-lb)
HANDLEBAR INSTALLATION
a 2
1. Install :
• Holder Handelbar Lower “1”
• Handlebar “1”
• Upper Handlebar Holder “2”
1 Bolt (Handlebar Upper Holder):

7.5 ~ 12 Nm (2.3 m.kg, 17 ft.lb)
TIP :
• 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 :
1 • Front Brake Lever Assembly “1”
• Handlebar Switch (left)
• Grip Assembly
• Throttle Cable
a • Housing (Throttle Grip)
b
TIP :
Align the projection “a” on the Handlebar Switch
with the Hole “b” in the Handlebar.
WARNING
Check the throttle grip for smooth operation
3. Adjust :
• Brake operation
Refer to “THROTTLE CABLE ADJUSTMENT
/ BRAKE LEVER ADJUSTMENT” on
Page no 3-9.
6-31
CHAS
REAR SHOCK ABSORBER AND SWING ARM
REAR SHOCK ABSORBER AND SWINGARM

1. Rear Shock Absorber
2. Axle Nut
3. Swing arm
4. Tension Bar
21
21
21
12 9
20
19
11 15
20
15 19
18 10
18
14
25
24 13 20
19
14 17
16
13 22
2 24
1 25
23
1
17
6 16
7 3
2 24
25
5
4
3 2
8
6-32
CHAS
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 ” on Page no. 3-3
3. Remove :
• Rear Wheel
• Driven Sprocket Assembly
Refer to “DRIVE CHAIN AND
SPROCKETS” on Page no. 6-17.
4. Remove :
• Nut Rear Shocker (upper and lower)
• Rear Shock Absorber (left and right)
1 2
5. Remove :
• Bolt Footrest “1” L.H./R.H.
• Axle Nut (Swing Arm “1”)
• Washer “2”
4 • Axle Shaft “3”
• Swing Arm “4”
3
6-33
CHAS
INSPECTION
1. Measure :
ŸSwingarm side play
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
59Nm(5.9mkg,43ftlb)
b. Measure the swingarm side play “A” by

moving the swingarm from side to side.
c. If the swingarm side play is observed, check
the spacers, bushings, and dust covers.
2. Inspect :
ŸRear shock absorber
Oil leaks/damage Ô Replace the rear
Shock absorber element
3. Check :
ŸSwingarm
Bends/cracks/damage Ô Replace.
a 4. Check :
ŸPivot shaft
Roll the pivot shaft on a flat surface
Bends Ô Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
5. Wash :
ŸPivot shaft
ŸDust covers
ŸSpacers
ŸBushings
Recommended cleaning solvent

Kerosene
6. Check :
Ÿ Dust covers
ŸOil seals
ŸSpacers
ŸBushings Damage/wear Ô Replace.
6-34
CHAPTER 7
ELECTRICAL
WIRING DIAGRAM .........................................................................................................................7-1

LOCATION OF ELECTRICAL COMPONENTS ...............................................................................7-3
CHECKING OF CONNECTIONS.....................................................................................................7-4
IGNITION SYSTEM
CIRCUIT DIAGRAM .........................................................................................................................7-5
TROUBLESHOOTING .....................................................................................................................7-7
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM .......................................................................................................................7-12
STARTING CIRCUIT CUT OFF SYSTEM OPERATION ...............................................................7-14
TROUBLESHOOTING ...................................................................................................................7-15
STARTER MOTOR ........................................................................................................................7-18
CHECKING THE STARTER MOTOR ............................................................................................7-20
ASSEMBLING THE STARTER MOTOR........................................................................................7-21
CHARGING SYSTEM
CIRCUIT DIAGRAM .......................................................................................................................7-22
LIGHTING SYSTEM
CIRCUIT DIAGRAM .......................................................................................................................7-25
SIGNAL SYSTEM
CIRCUIT DIAGRAM .......................................................................................................................7-31
1
13
14
B r LW
LB B 15
2 11
7
LW RW START 12
OFF
ON B RW START
4
LB RW
Br RW
B
LW
10
5
16
3
6
9 19
29 28 17
27 26
7-1
20
21
YR
L
P
18
BrW
30
22
WIRING DIAGRAM
L I G H T 31 DIMMER 32 HORN 33 TURNSIGNAL 34 22

OFF HI OFF NL
ON LO ON N
NR 22
Ch L
Brw P 23
Y
B
Dg YR
CIRCUIT DIAGRAM
24
Dg
Ch
Y
G
B
L Ch 25
P Brw
YR D g
ELEC
12V10W
12V10W
12V10W
12V10W
12V35/35W
35 36 37 38 39 40
ELEC
CIRCUIT DIAGRAM
YBR 5TSG WIRING DIAGRAM COLOR CODE

1. A.C. magneto B Black
2. Neutral switch Br Brown
3. Rectifier/regulator Ch Chocolate
4. Battery Dg Dark green
5. Wire plus lead G Green
6. Wire minus lead L Blue
7. Fuse Sb Sky blue
8. Starter relay O Orange
9. Starter motor P Pink
10. Main switch R Red
11. Right handlebar switch W White
12. Start switch Y Yellow
13. C.D.I. unit B/W Black/White
14. Ignition coil Br/W Brown/White
15. Spark plug L/B Blue/Black
16. Relay assy. L/W Blue/White
17. Clutch switch L/Y Blue/Yellow
18. Fuel sender R/B Red/Black
19. Meter assembly W/B White/Black
20. Neutral indicator light
21. Fuel gauge
22. Meter light
23. Left turn signal indicator light
24. Right turn signal indicator light
25. High beam indicator light
26. Rear brake light switch
27. Front brake light switch
28. Turn signal relay
29. Horn
30. Left handlebar switch
31. Light switch
32. Dimmer switch
33. Horn switch
34. Turn signal switch
35. Headlight
36. Rear left turn signal light
37. Front left turn signal light
38. Front right turn signal light
39. Rear right turn signal light
40. Tail/brake light
7-2
ELEC
ELECTRICAL COMPONENTS
LOCATION OF ELECTRICAL COMPONENTS
1. Main Switch 8. Neutral Switch Assy
2. Flasher Relay Assy 9. Stop Switch Rear
3. Fuel Sender Unit 10. Spark Plug
4. Rectifier / Regulator Assy 11. Spark Plug Cap
5. C.D.I. Unit Assy 12. Ignition Coil Assy
6. Battery 13. Horn
7. Fuse
4
2
1
13
12
11
10
9
7-3
ELEC
CHECKING OF CONNECTIONS
CHECKING THE CONNECTIONS Multimeter

Check the leads, couplers, and connectors INS-003
for stains, rust, moisture, etc.
1. Disconnect:
TIP
• Lead
• Coupler • If there is no continuity, clean the terminals.
• Connector • When checking the wire harness, perform
2. Check: steps (1) to (3).
• Lead • As a quick remedy, use a contact revitalizer
• Coupler available at most part stores.
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
3. Check:
• All connections
Loose connection → Connect properly.
TIP
If the pin “1” on the terminal is flattened,
bend it up.
4. Connect:
• Lead
• Coupler
• Connector
TIP
Make sure all connections are tight.
5. Check:
• Continuity
(with the multimeter)
7-4
1
13
14
B r LW
LB B 15
2 11
7
IGNITION SYSTEM
LW RW START 12
OFF
ON B RW START
4
LB RW
Br RW
B
LW
10
5
16
3
6
9 19
29 28 17
27 26
20
7-5
21
YR
L
P
18
BrW
30
22

OFF HI OFF NL
ON LO ON N
NR 22
Ch L
Brw P 23
Y
B
Dg YR
24
IGNITION SYSTEM
Dg
Ch
Y
G
B
L Ch 25
P Brw
YR D g
ELEC
12V10W
12V10W
12V10W
12V10W
12V35/35W
35 36 37 38 39 40
ELEC
IGNITION SYSTEM
1. A.C. magneto
4. Battery
5. Wire plus lead
6. Wire minus lead
7. Fuse
10. Main switch
13. C.D.I. unit
14. Ignition coil
15. Spark plug
7-6
ELEC
IGNITION SYSTEM
TROUBLE SHOOTING
If the ignition system fails to operate (No spark or intermittent spark)
PROCEDURE TIP :
CHECK Remove the required parts before trouble shooting.
1. Spark Plug 1) Side covers (LH and RH)
2. Spark Plug Cap resistance 2) Seat
3. Ignition coil 3) Fuel Tank
4. Main switch • Use Service Instrument as specified.
5. Sensor coil resistance
Multimeter
6. Charging Coil resistance INS-003
7. Rectifier cum Regulator Unit
8. Wiring connections (entire ignition system) TIP :
9. CDI For Checking Coil resistance, set Multimeter a
10. Fuse step higher than specified range.
11. Battery
7-7
ELEC
IGNITION SYSTEM
PROCEDURE STEPS :
1. SPARK PLUG Standard Spark Plug

• Check the spark plug condition Champion power/P-RARHC
• Check the Spark Plug type
• Check the Spark Plug gap Spark Plug Gap : 0.8 ~ 0.9 mm
• Refer to “SPARK PLUG INSPECTION“
on Page no. 3-10 OUT OF SPECIFICATION
2. SPARK PLUG CAP RESISTANCE Adjust or replace the Spark Plug

• Remove the Spark Plug Cap from the
spark plug lead
• Connect the Multimeter (Ω X1k) to the Spark Multimeter (+) lead Ô Spark Plug side “1”
Plug Cap. Multimeter (-) lead Ô High tension Cord
TIP : side “2”
• When removing the Spark Plug Cap, turn
out the Spark Plug Cap from high tension
Cord.
Remove Ô Turn anticlockwise

Connect Ô Turn clockwise
• When connecting the Spark Plug Cap, cut
the High Tension Cord about 5 mm.
Spark Plug Cap resistance :

Ω (at 20°C)
5 KΩ
OUT OF SPECIFICATION
MEETS
*
SPECIFICATION
Replace the Spark Plug Cap
2. Battery
3. Fuse
• Check the condition of the battery.
• Check the fuse for continuity. Refer to “CHECKING AND CHARGING
Refer to “CHECKING THE FUSE” THE BATTERY” on page no. -30.
on page no. 3-33.
Minimum open-circuit voltage
• Is the fuse OK? 12.8 V or more at 20 °C (68 °F)
YES NO • Is the battery OK?
YES NO
Replace the fuse.
• Refill battery fluid.

• Clean the battery
terminals.
• Recharge or
replace the battery.
7-8
ELEC
IGNITION SYSTEM
*
Multimeter (+) lead Ô Orange Terminal “1”
3A. IGNITION COIL RESISTANCE (Primary) Multimeter (-) lead Ô Earth “2”
• Disconnect the Ignition Coil Connector

From the Wire harness
• Connect the Multimeter to the Ignition Coil.
• Check the primary Coil resistance
Primary coil resistance :

0.15 -0.21 Ω ( at 20º C)
3B. IGNITION COIL RESISTANCE (Sec- Multimeter (+) lead Ô High Tension lead “1”
ondary) Multimeter (-) lead Ô Orange Terminal “2”
• Connect the Multimeter to the Ignition Coil
• Check the secondary coil resistance
Secondary coil resistance :

3.36 - 5.04 k Ω (at 20° C)
BOTH MEET
SPECIFICATIONS
Ignition Coil OK Replace the Ignition Coil
4. MAIN SWITCH
• Check for Continuity of Switch ON position

NO CONTINUITY
Multimeter (+) R
Multimeter (-) BRL
• Check for ignition “ON” “OFF” position

Replace the Main Switch
CONTINUITY
Main Switch OK
7-9
ELEC
IGNITION SYSTEM
5. SENSOR COIL RESISTANCE Mutimeter (+) lead Ô Blue/Yellow terminal “1”

Multimeter (-) lead Ô White/Red tertminal
• Disconnect the sensor Coil Coupler from
the Wiring Harness
• Connect the Multimeter (Ω X 100) to the
sensor coil coupler
• Check the sensor coil resistance
Sensor coil resistance :

104 - 156 Ω (at 20° C) OUT OF SPECIFICATION
MEETS
SPECIFICATION
Sensor coil is OK Replace the Sensor Coil Assembly
6. CHARGING COIL RESISTANCE Multimeter (+) lead Ô White Terminal “1”

Multimeter (-) lead Ô Black Terminal “2”
• Remove the Charging Coil coupler from the
Wire Harness
• Connect the Multimeter to the charging coil
• Measure the charging coil resistance
Charging coil resistance

0.72 - 1.08 Ω (W-B)
MEETS
SPECIFICATIONS
Charging coil is OK Replace the Charging CoiL
7-10
ELEC
IGNITION SYSTEM
7. RECTIFIER CUM REGULATOR UNIT Multimeter (+) lead Ô Battery (+) terminal “1”
Multimeter (-) lead Ô Battery (-) terminal “2”
• Check the Charging Voltage
Procedure Steps 1
• Connect the Tachometer to Spark plug lead
• Connect the Multimeter ( DC 20V) to Bat- 2
tery Red Wire.
Measure the Battery Voltage : 12V
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
8. WIRING CONNECTIONS
• Check the connection for entire Ignition and

Charging System “REFER TO CIRCUIT
DIAGRAM” on Page no. 7-5.
POOR CONNECTIONS
IF CORRECT
9. CDI Unit Repair/ Replace the Harness
• Check CDI unit “REFER IGNITION

TIMING PROCEDURE on Page no. 3-11
7-11
1
13
14
B r LW
LB B 15
2 11
7
LW RW START 12
OFF
ON B RW START
4
LB RW
Br RW
B
LW
10
5
16
3
6
19
29 28 17
27 26
20
7-12
21
YR
L
P
18
BrW
30
22

OFF HI OFF NL
ON LO ON N
NR 22
Ch L
Brw P 23
Y
B
Dg YR
24
Dg
Ch
Y
G
B
L Ch 25
P Brw
YR D g
ELEC –
12V10W
12V10W
12V10W
12V10W
12V35/35W
35 36 37 38 39 40
+
– +
ELEC
2. Neutral switch
4. Battery
5. Wire plus lead
6. Wire minus lead
7. Fuse
8. Starter relay
9. Starter motor
10. Main switch
12. Start switch
16. Relay assy.
17. Clutch switch
7-13
– +
ELEC
STARTING CIRCUIT CUT-OFF SYSTEM

OPERATION
If the main switch is set to “ON ” (switch is
closed), the starter motor can only operate if at
8 least one of the following conditions is met:
• The transmission is in neutral (the neutral
M switch is closed).
• The clutch lever is pulled to the handlebar
(the clutch switch is closed).
1 Battery
7 2 Fuse
3 Main switch
1 4 Start switch
5 Clutch switch
6 Neutral switch
7 Starter relay
8 Starter motor
2
5 6
7-14
– +
ELEC
TROUBLESHOOTING
2. Battery
The starter motor fails to turn. • Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check:
THE BATTERY” on page no. 3-30.
1. Fuse
2. Battery Minimum open-circuit voltage
3. Starter motor 12.8 V or more at 20°C (68 °F)
4. Starter relay
• Is the battery OK?
5. Main switch
6. Neutral switch YES NO
7. Clutch switch
8. Start switch
• Refill battery fluid.
9. Wiring connections
• Clean the battery
(of the entire starting system)
terminals.
TIP :
_ • Recharge or
• Before troubleshooting, remove the following replace the battery.
part(s):
1. left side cover
2. headlight assembly 3. Starter motor
3. fuel tank
• Connect the positive battery terminal “1”
• Troubleshoot with the following special
and starter motor lead “2” with a jumper
tool(s).
lead “3”.
3
2
Multimeter
INS-003
1. Fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE”
on page on. 3-33. WARNING
• Is the fuse OK? • A wire that is used as a jumper lead
must have at least the same capacity or
YES NO
more as that of the battery lead, other-
wise the jumper lead may burn.
Replace the fuse. • This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
• Does the starter motor turn?
YES NO
Repair or replace the

starter motor.
7-15
– +
ELEC
4. Starter relay
• Remove the starter relay.
• Connect the multimeter ( Ω x 1) and bat-
tery (12 V) to the starter relay terminals as
shown.
Positive battery terminal → Red/white 1
Negative battery terminal → Blue/white 2
Positive tester probe → red “3”
Negative tester probe → black “4”
1
4
• Does the starter relay have continuity

between red and black?
YES NO
Replace the starter

relay.
7-16
– +
ELEC
6. Main switch 9. Start switch

• Check the main switch for continuity. • Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK? • Is the start switch OK?
YES NO YES NO
Replace the main Replace the right

switch. handlebar switch.
7. Neutral switch 10.Wiring

• Check the neutral switch for continuity. • Check the entire starting system’s wiring.
Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”.
• Is the neutral switch OK? • Is the starting system’s wiring properly
connected and without defects?
YES NO
YES NO
Replace the neutral

switch. The starting system Properly connect or
circuit is OK. repair the starting
system’s wiring.
8. Clutch switch
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
YES NO
Replace the clutch

switch.
7-17
– +
ELEC
STARTER MOTOR
STARTER MOTOR
Order Job/Part Q’ty Remarks

Removing the starter motor Remove the parts in the order listed.
1 Starter motor 1
2 Starter motor lead 1 Disconnect.
TIP :
Pull out the starter motor before discon-
necting the starter motor lead.
For installation, reverse the removal pro-

cedure.
7-18
– +
ELEC
STARTER MOTOR
7
2
6
Order Job/Part Q’ty Remarks

Disassembling the starter motor Remove the parts in the order listed.
1 Front bracket 1
2 O-ring 2
3 Rear bracket 1
Refer to “ASSEMBLING THE STARTER
4 Oil seal 1
MOTOR”.
5 Brush set 1
6 Armature assembly 1
7 Starter motor yoke 1
7-19
– +
ELEC
STARTER MOTOR
CHECKING THE STARTER MOTOR

1. Check:
a
• commutator
Dirt Ô Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter “a”
Out of specification Ô Replace the starter
motor.
Commutator wear limit

21.0 mm (0.83 in)
3. Measure:
a • mica undercut a
Out of specification Ô Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.5 mm (0.06 in)
TIP :
_
The mica of the commutator must be undercut

to ensure proper operation of the commutator.
4. Measure:
• armature assembly resistances (commuta-
tor and insulation)
Out of specification Ô Replace the starter
motor.
a. Measure the armature assembly resis-

tances with the multimeter
2
Multimeter
1 INS - 003
Armature coil
Commutator resistance “1”
0.017 ~ 0.021 Ω at 20 °C (68 °F)
Insulation resistance “2”
Above 1 MΩ at 25 ± 5 °C
b. If any resistance is out of specification,

replace the starter motor.
7-20
ELEC – +
STARTER MOTOR
5. Measure:
• brush length “a”
Out of specification Ô Replace the brushes
as a set.
Brush length wear limit

3.5 mm (0.14 in)
6. Measure:
• brush spring force
Out of specification Ô Replace the brush
springs as a set.
Brush spring force

5.52 ~ 8.28 N
(563 ~ 844 gf, 19.87 ~ 29.80 oz)
7. Check:
• gear teeth
Damage/wear Ô Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear Ô Replace the defective
part(s).
ASSEMBLING THE STARTER MOTOR

1. Install:
3 • starter motor yoke “1”
1
• front bracket “2”
2
• rear bracket “3”
a TIP :
_
Align the match marks a on the starter motor

yoke with the match marks b on the front and
b
rear brackets.
b
7-21
1
13
14
B r LW
LB B 15
2 11
7
LW RW START 12
OFF
ON B RW START
CIRCUIT DIAGRAM
LB RW
Br RW
B
LW
10
5
16
3
6
9 19
29 28 17
27 26
20
7-22
21
YR
L
P
18
BrW
30
22

OFF HI OFF NL
ON LO ON N
NR 22
Ch L
Brw P 23
Y
B
Dg YR
24
CHARGING SYSTEM
Dg
Ch
Y
G
B
L Ch 25
P Brw
YR D g
ELEC
12V10W
12V10W
12V10W
12V10W
12V35/35W
35 36 37 38 39 40
ELEC
CHARGING SYSTEM
1. A.C. magneto
3. Rectifier/regulator
4. Battery
5. Wire plus lead
6. Wire minus lead
7. Fuse
7-23
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
Engine Tachometer.
5. Wiring system (entire charging system)
Multimeter
INS-003
1. FUSE
Refer to “FUSE INSPECTION SECTION”
on Page no 3-33. NO CONTINUITY
CONTINUITY
2. BATTERY Replace the Fuse

• Check the Battery condition.
Refer to “BATTERY INSPECTION”
on Page no 3-30.
Specific Gravity : 1.280 at 20°C INCORRECT
CORRECT
3. CHARGING VOLTAGE • Top up with distilled water

• Refer to Rectifier cum Regulator unit • Clean the Battery terminals
inspection method in the Ignition System • Recharge or Replace the Battery
on Page no 7-8
MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
4. CHARGING COIL RESISTANCE. The Charging circuit is OK
• Refer to Charging coil resistance checking
method in the Ignition System OUT OF SPECIFICATION
on Page no 7-7
MEETS
SPECIFICATION Replace the Charging Coil
5. WIRING CONNECTION
• Check entire Charging system for poor POOR CONNECTIONS
connections.
Refer to circuit diagram Page no 7-4
Repair or Replace the Wiring Harness
7-24
1
13
14
B r LW
LB B 15
2 11
7
CIRCUIT DIAGRAM
LIGHTING SYSTEM
LW RW START 12
OFF
ON B RW START
4
LB RW
Br RW
B
LW
10
5
16
3
6
9 19
29 28 17
27 26
20
7-25
21
YR
L
P
18
BrW
30
22

OFF HI OFF NL
ON LO ON N
NR 22
Ch L
Brw P 23
Y
B
Dg YR
24
LIGHTING SYSTEM
Dg
Ch
Y
G
B
L Ch 25
P Brw
YR D g
ELEC
12V10W
12V10W
12V10W
12V10W
12V35/35W
35 36 37 38 39 40
ELEC
LIGHTING SYSTEM
1. A.C. magneto
4. Battery
5. Wire plus lead
6. Wire minus lead
7. Fuse
10. Main switch
22. Meter light
25. High beam indicator light
31. Light switch
32. Dimmer switch
35. Headlight
7-26
ELEC
LIGHTING SYSTEM
TROUBLE SHOOTING
IF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHT
DO NOT WORK
PROCEDURE TIP :
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.
Multimeter
INS-003
7-27
ELEC
LIGHTING SYSTEM
1. LIGHTING COIL RESISTANCE Multimeter (+) lead Ô Y ellow terminal “1”

Multimeter (-) lead Ô Black terminal “2”
• Remove the C.D.I. Magento Coupler from
the wiring Harness
• Connect the Multimeter (Ω X 1) to the Light-
ing Coil
• Measure the Lighting Coil resistance
Lighting Coil resistance

0.32-0.48 Ω (4-B) at 20ºC
MEETS
SPECIFICATIONS
2. LIGHT SWITCH Replace the Lighting Coil
• Disconnect the Handlebar Switch (LH)

Coupler from Wireharness
• Connect the Multimeter (Ω X 1) to Handle-
bar Switch (LH) Terminals
• Check the switch connections for continu-
ity between “Blue” and “Yellow/Red”
NO CONTINUITY
CONTINUITY
Repair or Replace the Handlebar Switch LH

3. DIMMER SWITCH
• Disconnect the Handlebar Switch (LH)

Coupler from wireharness.
• Connect the Multimeter (Ω X 1) to Handle-
bar Switch (LH) Terminals
• Check the Switch connections for continu-
ity between “Yellow and Green”, “Yellow
and Yellow” NO CONTINUITY
CONTINUITY Repair or Replace the Handlebar Switch LH

*
7-28
ELEC
LIGHTING SYSTEM
*
4. LIGHTING VOLTAGE
Multimeter (+) lead Ô Blue terminal “1”
• Connect the Tachometer to Spark Plug Multimeter (-) lead Ô Black terminal “2”
lead.
• Disconnect the Taillight coupler from wire LIGHT
OFF
harness ON
• Connect the Multimeter (AC 20 V) to tail-

light wire
• Start the Engine and accelerate the engine
12V21/5W
up to 3000 RPM and then to 8000 RPM
• Measure the lighting Voltage with (full load
by switching on the Headlight)
Lighting Voltage (min) :

12.8-13.6 V- @5000 RPM
(With Full Load) (max) :
13.6 V @ 500 RPM
MEETS
SPECIFICATION
5. WIRING CONNECTIONS Check the Lighting Coil resistance

• Check entire lighting system for poor Con-
nections refer to “WIRING DIAGRAM”
on Page no. 7-25.
POOR CONNECTIONS
CONTINUITY
• Check the condition of individual Lighting • Repair or Replace wireharness

System Circuits
7-29
ELEC
LIGHTING SYSTEM
*
6. INDIVIDUAL LIGHTING CIRCUITS
A. If the Headlight and Highbeam Indicator
Light do not work
1. BULB AND BULB SOCKET
• Check the Bulb and Bulb socket for conti-

nuity. NO CONTINUITY
CONTINUITY
2. LIGHTING VOLTAGE Replace Bulb and/or Bulb Socket.
• Refer the lighting Voltage section Page no

7-12
B. If the meter light does not work
• Check the Bulb and Bulb Socket for

continuity.
NO CONTINUITY
Continuity
2. LIGHTING VOLTAGE Replace Bulb and/or Bulb socket.

7-12
C. If the Tail Light does not work
• Check the Bulb and Bulb Socket for

NO CONTINUITY
continuity.
CONTINUITY
Replace Bulb and/or Bulb socket.

2. LIGHTING VOLTAGE

7-12
7-30
1
13
14
B r LW
LB B 15
2 11
7
LW RW START 12
CIRCUIT DIAGRAM :
OFF
ON B RW START
4
LB RW
Br RW
B
LW
10
5
16
3
6
9 19
29 28 17
27 26
20
7-31
21
YR
L
P
18
BrW
30
22

OFF HI OFF NL
ON LO ON N
NR 22
Ch L
Brw P 23
Y
B
Dg YR
24
SIGNAL SYSTEM
Dg
Ch
Y
G
B
L Ch 25
P Brw
YR D g
ELEC
12V10W
12V10W
12V10W
12V10W
12V35/35W
35 36 37 38 39 40
ELEC
SIGNAL SYSTEM
1. A.C. magneto
2. Neutral switch
4. Battery
5. Wire plus lead
6. Wire minus lead
7. Fuse
10. Main switch
13. C.D.I. unit
18. Fuel sender
20. Neutral indicator light
21. Fuel gauge
23. Left turn signal indicator light
24. Right turn signal indicator light
26. Rear brake light switch
27. Front brake light switch
28. Turn signal relay
29. Horn
33. Horn switch
34. Turn signal switch
36. Rear left turn signal light
37. Front left turn signal light
38. Front right turn signal light
39. Rear right turn signal light
7-32
ELEC
SIGNAL SYSTEM
TROUBLE SHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND INDICATOR LIGHTS DO NOT WORK
IF THE HORN DOES NOT WORK
PROCEDURE TIP :
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 Multimeter
4. Wiring connections (entire lighting system) 4) Headlight INS-003
5. Check individual lighting circuits
7-33
ELEC
SIGNAL SYSTEM
1. FUSE
Refer to “FUSE INSPECTION SECTION”

on Page 3-33. NO CONTINUITY
CONTINUITY
2. BATTERY Replace fuse
• Check the Battery condition

Refer to “BATTERY INSPECTION SEC-
TION” on Page 3-30. INCORRECT
CORRECT
• Top up the Battery fluid

3. MAIN SWITCH • Clean Battery terminal
• Recharge or replace the Battery
• Disconnect the main switch coupler from
wireharness
• Check the continuity between ”Brown” and
Red” wires NO CONTINUITY
CONTINUITY
4. WIRE HARNESS Repair/Replace the Main Switch
• Check the entire signal system for poor

connections
Refer to “SIGNAL SYSTEM CIRCUIT DIA-
GRAM” on Page 7-31. POOR CONNECTIONS
CORRECT
• Check the condition of each of the signal Repair/Replace the Wireharness

system circuits
7-34
ELEC
SIGNAL SYSTEM
5. INDIVIDUAL SIGNAL SYSTEMS
A. If the Horn does not work.
1. HORN SWITCH
• Disconnect the Handlebar Switch Coupler NO CONTINUITY

from Wireharness.
• Check the continuity between the “Pink” and
“Black” with switch in Pressed Position.
Replace the Switch Handle (LH)
CONTINUITY
Multimeter (+) lead Ô Brown “1” Terminal
2. VOLTAGE Multimeter (-) lead Ô Body earth “2”
• Connect the Multimeter (DC20 V) to the

Horn lead
• Turn the Main Switch to “ON”
• Check the Voltage (12V) between the
“Brown” wire and Body Earth.
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 Ô Horn Terminal “1”
• Connect the multimeter (5 A) to the open
Multimeter (-) lead Ô Body earth “2”
terminal “1” at “Horn”
• Turn the main switch “ON”
• Check current (Amperage) drawn by Horn
by connecting to body earth.
Specified current 1.5 A OUT OF SPECIFICATION / NO SOUND
MEETS
SPECIFICATION
Horn is OK Adjust / Replace the Horn
7-35
ELEC
SIGNAL SYSTEM
B. If the Brake Light does not work.
1. BULB AND BULB SOCKETS
• Check the Bulb and Bulb sockets for con-

tinuity. NO CONTINUITY
CONTINUITY
Replace Bulb and/or Bulb socket.
2. BRAKE SWITCH FRONT / REAR
• Disconnect the Brake switch Coupler from

wire Harness.
• Check the switch front and rear for conti-
nuity between “Brown and Yellow/Green”
for front and “Brown and Green/Yellow” for
Rear NO CONTINUITY
CONTINUITY
Replace the Brake Switch
3. VOLTAGE Multimeter (+) lead Ô Y ellow terminal “1”

Multimeter (-) lead Ô Black terminal “2”
• Connect the Multimeter “DC20V” to bulb
socket connector
• Turn the Main Switch to “ON”
• Apply the Front/Rear Brake
12V-24/5W
• Check The voltage (12V) between the “Yel-

low and Black terminal”
MEETS SPECIFICATIONS
OUT OF
SPECIFICATION
4. WIRING CONNECTION Brake Light circuit is OK
Wiring circuit from Main Switch to the Bulb

Sockets connector is faulty. Repair
Refer to “SIGNAL SYSTEM” wiring diagram
Page no 7-31.
7-36
ELEC
SIGNAL SYSTEM
C. If the flasher light and/or turn

indicator light fails to blink.
• Check the Bulb and Bulb Socket continuity NO CONTINUITY
CONTINUITY
2. TURN SWITCH Replace the Bulb and/or Bulb socket
• Disconnect the Handlebar Switch (left) cou-

pler from Wireharness.
• Check the switch component for the conti-
nuity between “Brown/White and Darkgreen”
and “Brown/White and Chocolate”.
NO CONTINUITY
CONTINUITY
Replace the left Handlebar Switch.
3. VOLTAGE Multimeter (+) lead Ô Brown Terminal “1”

Flasher Relay coupler.
• T urn the Main Switch to ‘ON’ .
• Check or voltage (12V) of the “Brown” “1”
lead at the Flasher Relay terminal and (-)
terminal body earth (Black Wire).
* MEETS
SPECIFICATION The wiring circuit from Main Switch to
Flasher Relay connector is faulty. Repair/
Replace
7-37
ELEC
SIGNAL SYSTEM
4. FLASHER RELAY Multimeter (+) lead Ô Brown/White Terminal “1”

• Connect the Multimeter (DC20V) to the
flasher relay coupler
• Turn Main switch to ‘ON’
• Check for voltage (12V) on “Brown/White”
TURN SIGNAL RELAY

lead at Flasher Relay and (-) terminal body
earth
MEETS The Flasher Relay is faulty. Replace.

SPECIFICATION
5. VOLTAGE At Turn Signal (LH)

• Multimeter (+) lead Ô Chocolate Terminal “1”
• Connect the Multimeter (DC20V) to the • Multimeter (-) lead Ô Body earth “2”
Bulb Socket connector At Turn Signal (RH)
• Turn the Main Switch to ‘ON’ • Multimeter (+) lead Ô Dark Green Terminal “3”
• Turn the Turn Switch to left or right • Multimeter (-) lead Ô Body earth “4”
• Check for voltage (12V) on the “Chocolate”
lead and “Dark green” at the Flasher Light
terminal.
MEETS
SPECIFICATIONS
This circuit is O.K. OUT OF SPECIFICATION
Wiring connection
Wiring circuit from the Turn Switch to Bulb
Socket connector is faulty. Repair/Replace
Refer to “CIRCUIT DIAGRAM” on page
no. 7-1
7-38
ELEC
SIGNAL SYSTEM
D. If the neutral indicator lights fails to

operate.
• Check the bulb and bulb socket for conti-

nuity. NO CONTINUITY
CONTINUITY
Replace the Bulb and/or Bulb Socket

2. NEUTRAL SWITCH
• Disconnect the neutral switch lead.

• Check the continuity between the switch
terminal and ground.
NO CONTINUITY
CONTINUITY
Replace the Neutral switch.
3. VOLTAGE Multimeter (+) lead Ô Sky Blue Terminal “1”

Multimeter (-) lead Ô Body Earth “2”
neutral switch lead
• T urn the main switch to on position.
• Select the gear position in neutral.
• Check for voltage (12 V) on the “Brown” ter-
minal on the “Neutral Bulb” and body earth
(“Sky Blue” wire)
MEETS
SPECIFICATION
Check the connection of the entire signal
system.
Refer to “CIRCUIT DIAGRAM” Page no 7-31.
This circuit is O.K.
7-39
CHAPTER 8
TROUBLE SHOOTING
GENERAL INFORMATION ..............................................................................................................8-1

STARTING FAILURES.....................................................................................................................8-1
INCORRECT ENGINE IDLING SPEED ...........................................................................................8-1
POOR MEDIUM AND HIGH SPEED PERFORMANCE ..................................................................8-2
FAULTY GEAR SHIFTING...............................................................................................................8-2
SHIFT PEDAL DOES NOT MOVE...................................................................................................8-2
JUMPS OUT OF GEAR ...................................................................................................................8-2
FAULTY CLUTCH ............................................................................................................................8-2
OVERHEATING ...............................................................................................................................8-3
POOR BRAKING PERFORMANCE.................................................................................................8-3
FAULTY FRONT FORK LEGS.........................................................................................................8-3
UNSTABLE HANDLING...................................................................................................................8-3
FAULTY LIGHTING OR SIGNALING SYSTEM...............................................................................8-4
TRBL
SHTG
8-1
8-2
8-3
TRBL
TROUBLESHOOTING SHTG
8-4
INDIA YAMAHA MOTOR PVT. LTD.
A-3, Industrial Area, Noida Dadri Road,
Surajpur – 201 306, Distt. – Gautam Budh Nagar, (U.P)
5TS-F8197-E2

Ybr 110

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2011

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

• Piston Pin Circlip “3” New

1. General GEN 2. Specifications SPEC

5. Carburetion CARB 6. Chassis CHAS

9. Filling fluid 10.Lubricant 11.Special Tool

12.Torque 13.Wear Limit, 14.Engine speed

19. Apply wheel 20.Apply lightweight 21. Apply molyb-

22. Apply locking

SPECIAL TOOLS ..............................................................................................................1-4

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

PREPARATION FOR REMOVAL AND

2. Use proper Tools and Cleaning Equipment.

3. When disassembling the Motorcycle, keep

4. During the Motorcycle disassembly, clean

5. Keep Motorcycle and its parts away from

ALL REPLACEMENT PARTS

LOCK WASHERS/PLATES AND COTTER

1 BEARINGS AND OIL SEALS

Piston Pin Replacer 4-6, 5-57

This tool is used to replace Piston Pin.

This tool is used to hold the TFF plunger for

Clutch hub holder 4-7, 5-51

This tool is used to hold the Clutch Hub while

Spanner - Speedometer Gear Nut. 6-4, 6-6

This tool is used to loosen or tighten the

Crankshaft removing tool 4-12

This tool is used to remove the Crank Shaft

Crank Shaft Installing Tool with Spacer

These tools are used for installation of

This tool is used to remove T.F.F. oil seal.

TFF Oil Seal Installation Tool 6-24

This tool is used to install the TFF Oil Seal.

Valve spring compressor 4-14, 4-34

This tool is used when removing or installing

This tool is used to support the Piston

Driving Sprocket Holder

This tool is used to hold the Driving Sprocket

Valve Clearance Adjusting Tool. 3-7

This tool is used to adjust valve clearance

Rocker Arm Shaft Puller

This tool is used to remove Rocker Arm Shaft.

Screw Driver (small).

This tool is used to adjust throttle screw/retract

Torx Bit (T - 30) 4-11, 4-47

This tool is used to loosen or tighten the

This tool is used for scraping the sealent

Feeler gauge 3-6, 3-7

This tool is used to check valve clearance

Steering nut socket 3-24, 6-29

This tool is used to loosen or tighten the

Oil seal installing tool 4-51

This tool is used to install oil seal in crank f9.8

Bearing Puller 6-2

Bulb voltage, wattage × quantity