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EB000000
SR125
SERVICE MANUAL
1996 by Yamaha Motor Co., Ltd.
1st Edition, September 1996
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-
torcycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
Yamaha Motor Company, Ltd., is continually striving to improve all its models. Modifications and signif-
icant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future aditions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or

death to the motorcycle operator, a bystander or a person inspecting or
repairing the motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid

damage to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

YP002000
HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
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 upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied 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 enclosed by a
circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to
the exploded diagram and the job instruction chart.
2 1 4 3

EB003000
1 2 ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are designed as
GEN
SPEC thumb tabs to indicate the chapters number
INFO and content.
3 4 1 General information
2 Specifications
INSP
ADJ ENG 3 Periodic inspection and adjustment
4 Engine
5 6 5 Carburation
6 Chassis
CARB CHAS 7 Electrical
8 Troubleshooting
7 8
TRBL
ELEC
SHTG
Illustrated symbols 9 to 16 are used to identify
9 10 the specifications appearing in the text.
9 Possible to maintain with engine mounted
10 Filling fluid
11 Lubricant
11 12 12 Special tool
13 Tightening
14 Wear limit, clearance
15 Engine speed
13 14 16 , V, A
15 16
Illustrated symbols 17 to 22 in the exploded dia-
grams indicate the types of lubricants and lu-
brication points.
17 Apply engine oil
17 18 19 18 Apply gear oil
19 Apply molybodenum disulfide oil
20 Apply wheel bearing grease
21 Apply lightweight lithium-soap baes grease
20 21 22 22 Apply molybdenum disulfide grease
Illustrated symbols 23 to 24 in the exploded dia-

grams indicate the where to apply locking agent
23 and when to install new parts 24 .
23 Apply locking agent (LOCTITE)

23 24
24 Use new one

INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
ADJUSTMENT INSP
ADJ 3
ENGINE OVERHAUL ENG
4
CARBURATION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLESHOOTING TRBL
SHTG 8

CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . . 1-2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1-3
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

GEN
MOTORCYCLE IDENTIFICATION INFO
YP100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
SR100020
FRAME SERIAL NUMBER

The frame serial number 1 is stamped into the
right side of the frame.
EB100030
ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
MODEL LABEL
The model label 1 is affixed under the seat.
This information will be needed to order spare
parts.
1-1

GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the SPECIAL TOOLS section.
4. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been mated through normal wear.
Mated parts must always be reused or re-
placed as an assembly.
5. During machine disassembly, clean all parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
6. Keep all parts away from any source of fire.
NB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-2

GEN
IMPORTANT INFORMATION INFO
EB101030
LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates and cotter
pins after removal. Bend lock tabs along the
OR
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the
manufacturers marks or numbers are visible.
When installing oil seals, apply a light coating of
lightweight lithium base grease to the seal lips.
Oil bearings liberally when installing, if ap-
propriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassemb-
ly. Always replace piston pin clips after one
use. Replace distorted circlips. When instal-
ling a circlp 1 , make sure that the sharp-
edged corner 2 is positioned opposite the
thrust 3 it receives. See sectional view.
4 Shaft
1-3

GEN
CHECKING OF CONNECTIONS INFO
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two

or three.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
Connector
NOTE:
The two connectors click together.
7. Check for continuity with a tester.

NOTE:
If there is no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed above
when checking the wireharness.
For a field remedy, use a contact revitalizer
available on the market.
Use the tester on the connector as shown.
1-4

GEN
HOW TO USE THE CONVERSION TABLE INFO
EB201000
HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in Sl and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMP
** mm 0.03937 = ** in
2 mm 0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
m:kg 7.233 ft:lb
m:kg 86.794 in:lb
Torque
cm:kg 0.0723 ft:lb
cm:kg 0.8679 in:lb
kg 2.205 lb
Weight
g 0.03527 oz
km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume/ cc (cm3) 0.06102 cu:in
Capacity lit (liter) 0.8799 qt (IMP liq.)
lit (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Miscellaneous kg/cm2 14.2234 psi (lb/in2)
Centigrade 9/5 (_C) + 32 Fahrenheit (_F)
1-5

GEN
SPECIAL TOOLS INFO
EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration

90890-01080 Rotor puller
90890-04052 Attachment
This tool is used when removing or installing

the meter gear bush.
90890-01083 Rocker arm shaft puller bolt
90890-01084 Weight
These tools are used when removing or

installing the rocker arm shafts.
90890-01268 Ringnut wrench
This tool is used to loosen and tighten the

exhaust and steering ringnut.
90890-01311 Valve adjusting tool
This tool is necessary for adjusting valve

clearance.
90890-01312 Fuel level gauge
This gauge is used to measure the fuel level

in the float chamber.
90890-01367 Fork seal driver weight
90890-01400 Fork seal driver attachment (30 mm)
This tool is used when installing the fork seal.

90890-01403 Ring nut wrench
This tool is used to loosen and tighten the

steering ring nut.
90890-01701 Sheave holder
This tool is used for holding the secondary

sheave.
90890-01996 Cylinder cup installer set
This tool is used for installing the cylinder

cup to the master cylinder piston.
1-6

GEN
SPECIAL TOOLS INFO
90890-03079 Thickness gauge
This tool is used to measure the valve

clearance.
90890-03081 Compression gauge
90890-04082 Adaptor
These tools are used to measure the engine

compression.
90890-03112 Pocket tester
These instruments are invaluable for

checking the electrical system.
90890-03113 Engine tachometer
This tool is needed for detecting engine rpm.

90890-03141 Timing light
This tool is necessary for checking ignition

timing.
90890-04019 Valve spring compressor
90890-04108 Attachment
These tools are used when removing or

installing the valve and the valve spring.
90890-04064 Valve guide remover 6 mm
This tool is used to remove the valve guide.

90890-04065 Valve guide reamer 6 mm
This tool is used to rebore the valve guide.

90890-04066 Valve guide installer 6 mm
This tool is needed to install the valve guides

properly.
90890-04086 Clutch holding tool
This tool is used for holding the Clutch Boss.
1-7

GEN
SPECIAL TOOLS INFO
90890-04101 Valve lapper
This tool is used for removing and installing

the lifter and for lapping the valve.
90890-06754 Ignition checker
This instrument is necessary for checking the

ignition system components.
90890-85505 Yamaha bond No.1215
This sealant (bond) is used for crankcase

mating surface, etc.
1-8

CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . 2-16

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model SR125
Model code: 3MW6
Dimensions:
Overall length 1,915 mm
Overall width 775 mm
Overall height 1,080 mm
Seat height 745 mm
Wheelbase 1,280 mm
Minimum ground clearance 155 mm
Minimum turning radius 2,100 mm
Basic weight:
With oil and full fuel tank 113 kg
Engine:
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.124 L (124 cm3)
Bore stroke 57.0 48.8 mm
Compression ratio 10.0 : 1
Compression pressure (STD) 1,200 kPa (12.0 kg/cm2, 12.0 bar) at 1,000 r/min
Starting system Electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil API SE or higher grade
Periodic oil change 1.0 L

With oil filter replacement 1.1 L
Total amount 1.3 L
Air filter: Wet type element
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 10.0 L
Fuel reserve capacity 1.6 L
2-1

Model SR125
Carburetor:
Type/quantity Y24P/1
Manufacturer TEIKEI
Spark plug:
Type DR8EA
Manufacturer NGK
Spark plug gap 0.6 X 0.7 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 73/22 (3.318)
Secondary reduction system Chain drive
Secondary reduction ratio 49/14 (3.500)
Transmission type Constant mesh 5 speed
Operation Left foot operation
Gear ratio 1st 36/16 (2.250)
2nd 31/21 (1.476)
3rd 27/24 (1.125)
4th 25/27 (0.926)
5th 23/29 (0.793)
Chassis:
Frame type Diamond
Caster angle 26.75
Trail 90 mm
Tire:
Type Tube type
Size front 3.00-17 45P
rear 3.50-16 52P
Manufacture front INOUE
rear INOUE
Type front 8F
rear 8RA
Tire pressure (cold tire):
Maximum load-except motorcycle 164 kg
Loading condition A * 0 X 90 kg
front 175 kPa (1.75 kg/cm2, 1.75 bar)
rear 200 kPa (2.0 kg/cm2, 2.0 bar)
Loading condition B * 90 X 205 kg
front 175 kPa (1.75 kg/cm2, 1.75 bar)
rear 225 kPa (2.25 kg/cm2, 2.25 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2

Model SR125
Brake:
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel:
Front wheel travel 120 mm
Rear wheel travel 78 mm
Electrical:
Ignition system C.D.I.
Generator system C.D.I. magneto
Battery type 12N 7-3B
Battery capacity 12 V 7 AH
Headlight type: Bulb type
Bulb wattage quantity:
Headlight 12 V 36 W/36 W 1
Auxiliary light 12 V 4 W 1
Tail/brake light 12 V 5 W/21 W 1
Flasher light 12 V 21 W 4
Meter light 12 V 3.4 W 1
High beam indicator 12 V 3.4 W 1
Neutral indicator 12 V 3.4 W 1
TURN indicator 12 V 3.4 W 2
2-3

MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit

Cylinder head:
Warp limit SSS 0.03 mm
Cylinder:
Bore size 57.00 X 57.02 mm 57.1 mm
Taper limit SSS 0.05 mm
Out of round limit SSS 0.01 mm
Camshaft:
Cam dimensions
Intake A 36.537 X 36.637 mm 36.45 mm
B 30.131 X 30.231 mm 30.05 mm
C 6.59 mm SSS
Exhaust A 36.577 X 36.677 mm 36.49 mm
B 30.214 X 30.314 mm 30.13 mm
C 6.63 mm SSS
Camshaft runout limit SSS 0.03 mm
Cam chain:
Cam chain type/No. of links DID 25SH/104 ENDLESS SSS
Cam chain adjustment Manual SSS
Rocker arm/rocker armshaft:
Rocker arm inside diameter 12.000 X 12.018 mm 12.036 mm
Rocker shaft outside diameter 11.985 X 11.991 mm 11.950 mm
Rocker arm-to-rocker armshaft
clearance 0.009 X 0.033 mm SSS
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.05 X 0.09 mm SSS
EX 0.11 X 0.15 mm SSS
Valve dimensions
Head Dia. Face Width Seat Width Margin Thickness

A head diameter IN 28.9 X 29.1 mm SSS
EX 23.9 X 24.1 mm SSS
B face width IN 2.4 X 2.8 mm SSS
EX 2.4 X 2.8 mm SSS
C seat width IN 0.9 X 1.1 mm SSS
EX 0.9 X 1.1 mm SSS
D margin thickness IN 0.8 X 1.2 mm SSS
EX 0.8 X 1.2 mm SSS
Stem outside diameter IN 5.975 X 5.990 mm 5.955 mm
EX 5.960 X 5.975 mm 5.940 mm
2-4

Item Standard Limit

Guide inside diameter IN 6.000 X 6.012 mm 6.042 mm
EX 6.000 X 6.012 mm 6.042 mm
Stem-to-guide clearance IN 0.010 X 0.037 mm 0.08 mm
EX 0.025 X 0.052 mm 0.10 mm
Stem runout limit SSS 0.03 mm
Valve seat width IN 0.9 X 1.1 mm 1.6 mm
EX 0.9 X 1.1 mm 1.6 mm
Valve spring:
Free length (inner) IN/EX 35.5 mm 33.5 mm
(outer) IN/EX 37.2 mm 35.2 mm
Set length (valve closed)
(inner) IN/EX 22.5 mm SSS
(outer) IN/EX 24.0 mm SSS
Compressed pressure
(inner) IN/EX 26.7 X 30.7 kg SSS
(outer) IN/EX 52.4 X 40.2 kg SSS
Tilt limit (inner) IN/EX SSS 2.5_/1.5 mm
Tilt limit (outer) IN/EX SSS 2.5_/1.5 mm
Direction of winding (inner) IN/EX Clockwise SSS
Direction of winding (outer) IN/EX Counterclockwise SSS
Piston:
Piston to cylinder 0.025 X 0.045 mm SSS
clearance
Piston size D 56.960 X 56.975 mm SSS
Piston over size (1st) 57.25 mm SSS
Piston over size (2nd) 57.50 mm SSS
Measuring point H 7.0 mm SSS
Piston off-set 0.5 mm SSS
Piston off-set direction IN side SSS
Piston pin bore 15.002 X 15.013 mm 15.045 mm
inside diameter
Piston pin outside diameter 14.978 X 14.992 mm 14.975 mm
Piston rings:
Top ring:
Type Plane SSS
Dimensions (B T) 2.3 2.5 mm SSS
End gap (installed) 0.15 X 0.35 mm 0.60 mm
Side clearance (installed) 0.03 X 0.07 mm 0.15 mm
2nd ring:
Type Plane SSS
End gap (installed) 0.15 X 0.35 mm 0.60 mm
Side clearance 0.02 X 0.06 mm 0.15 mm
Oil ring:
End gap (installed) 0.3 X 0.9 mm SSS
2-5

Item Standard Limit

Crankshaft:
Crank width A 55.95 X 56.00 mm SSS

Runout limit C SSS 0.03 mm
Big end side clearance D 0.35 X 0.65 mm 1.0 mm
Big end radial clearance 0.010 X 0.025 mm SSS
Small end free play F 0.8 X 1.0 mm SSS
Clutch:
Friction plate thickness 2.9 X 3.1 mm 2.7 mm
Quantity 4 pcs. SSS
Clutch plate thickness 1.6 mm 0.05 mm
Quantity 3 pcs. SSS
Clutch spring free length 34.9 mm 32.9 mm
Quantity 4 pcs. SSS
Push rod bending limit SSS 0.2 mm
Transmission:
Main axle runout limit SSS 0.08 mm
Drive axle runout limit SSS 0.08 mm
Carburetor:
Type Y24P
I.D. mark 4WP-10 SSS
Main jet (M.J) #102 SSS
Main air jet (M.A.J) 1.3 SSS
Jet needle (J.N) 4C9A-3/5 SSS
Needle jet (N.J) 2.600 SSS
Cut away (C.A) 2.25 SSS
Pilot outlet (P.O) 0.8 SSS
Pilot jet (P.J) #38 SSS
Bypass 1 (B.P.1) 1.0 SSS
Pilot screw (P.S) 2 SSS
Valve seat size (V.S) 2.0 SSS
Starter jet 1 (G.S.1) #60 SSS
Starter jet 2 (G.S.2) #64 SSS
Float height (F.H) 28.5 mm SSS
Engine idle speed 1,250 X 1,350 r/min SSS
Intake vacuum 180 X 200 mmHg SSS
CO 4.5 X 5.5%
Oil temperature 60 X 70_C SSS
Oil pump;
Type Trochoid type SSS
Tip clearance 0.03 X 0.09 mm 0.14 mm
Side clearance 0.10 X 0.15 mm 0.35 mm
Bypass valve setting pressure 80 X 120 kPa SSS
(0.8 X 1.2 kg/cm2, 0.8 X 1.2 bar)
2-6

TIGHTENING TORQUES
ENGINE
Tightening
g g
Thread
Th d torque
Part to be tightened
g Part name Qty
y Remarks
size
Nm mSkg
Cylinder head blind plug Screw M6 2 7 0.7
Cylinder head and cylinder Bolt M8 4 22 2.2
Cylinder head Bolt M8 2 20 2.0
(Timing chain side)
Cam sprocket cover Screw M6 2 7 0.7
Valve cover Bolt M6 5 10 1.0
Plate Bolt M6 2 8 0.8
Spark plug M12 1 18 1.8
Cylinder Bolt M6 2 10 1.0
Buffer boss Nut M14 1 50 5.0
C.D.I. magneto Bolt M10 1 50 5.0
Valve adjuster locknut Nut M6 2 14 1.4
Cam sprocket Bolt M10 1 60 6.0
Timing chain tensioner
(Body) Nut M14 1 30 3.0
(Cap) Nut M14 1 5 0.5
Timing chain guide (intake) Bolt M6 2 8 0.8
Oil pump Screw M6 1 7 0.7
Oil pump and crankcase Screw M6 3 7 0.7
Drain plug Bolt M35 1 43 4.3
Oil filter cover Screw M6 2 7 0.7
Drain bolt (oil filter) Bolt M6 1 10 1.0
Carburetor joint and carburetor Screw M6 2 12 1.2
Carburetor joint and cylinder Screw M5 1 2 0.2
Carburetor joint and air filter Screw M5 1 4 0.4
Air filter case Screw M5 2 4 0.4
Air filter case and frame Screw M6 2 7 0.7
Muffler and frame Bolt M8 2 20 2.0
Exhaust pipe and cylinder Bolt M6 2 12 1.2
Crankcase (left and right) Screw M6 13 7 0.7
Crankcase cover (left) Screw M6 9 7 0.7
Crankcase cover (left) Screw M4 1 2 0.2
Crankcase cover (right) Screw M6 9 7 0.7
Drive sprocket cover Screw M6 2 7 0.7
Starter clutch Bolt M8 3 30 3.0 Stake
Kick crank Bolt M32 1
Primary drive gear Nut M14 1 50 5.0
Clutch spring Screw M5 4 6 0.6
Clutch boss Nut M14 1 70 7.0
Push lever axle Screw M8 1 12 1.2
Push lever adjuster Nut M6 1 8 0.8
2-7

Tightening
Thread torque
g Part name Qty
y Remarks
size
Nm mSkg
Drive sprocket Bolt M6 2 10 1.0
Shift cam (Segment) Screw M6 1 12 1.2
Shift pedal Bolt M6 1 8 0.8
Pick up coil Screw M6 4 7 0.7
Neutral switch Screw M10 1 20 2.0
Stator coil Screw M4 6 3 0.3
Starter motor Screw M6 1 7 0.7
2-8

Item Standard Limit
Tightening sequence
Cylinder head
Crankcase
2-9

CHASSIS
Item Standard Limit

Steering system:
Steering bearing type Ball bearing SSS
No./size of steel balls (upper) 22 pcs. 0.1875 in SSS
(lower) 19 pcs. 0.251 in SSS
Front suspension:
Front fork travel 120 mm SSS
Fork spring free length 326.1 mm 321 mm
Fitting length 311.1 mm SSS
Spring rate (K1) 3.6 N /mm (0.36 kg/mm) SSS
(K2) 5.1 N/mm (0.51 kg/mm) SSS
Stroke (K1) 0 X 85 mm SSS
(K2) 85 X 120 mm SSS
Oil capacity 0.177 L (177 cm3) SSS
Oil level 135 mm SSS
Oil grade Fork oil 15 WT or equivalent SSS
Inner tube vend limit SSS 0.2 mm
Rear suspension:
Shock absorber stroke 65 mm SSS
Spring free length 178.5 mm 173 mm
Fitting length 198 mm SSS
Spring rate (K1) 18.3 N/mm (1.83 kg/mm) SSS
(K2) 21.6 N/mm (2.16 kg/mm) SSS
Stroke (K1) 0 X 30 mm SSS
(K2) 30 X 65 mm SSS
Front wheel:
Type Spoke wheel SSS
Rim size 17 1.60 SSS
Rim material Steel SSS
Rim runout limit radial SSS 2 mm
lateral SSS 2 mm
Rear wheel:
Type Spoke wheel SSS
Rim size 16 1.85 SSS
Rim material Steel SSS
Rim runout limit radial SSS 2 mm
lateral SSS 2 mm
Drive chain:
Type/manufacturer 428HG/DAIDO SSS
No. of links 120 SSS
Chain free play 25 X 35 mm SSS
2-10

Item Standard Limit

Front brake:
Type Single disc SSS
Disc outside diameter 267 mm SSS
Disc thickness 4 mm 3.5 mm
Pad thickness (inner) 6.2 mm 0.8 mm
(outer) 6.2 mm 0.8 mm
Master cylinder inside diameter 12.7 mm SSS
Caliper cylinder 1 inside diameter 30.16 mm SSS
Caliper cylinder 2 inside diameter 25.4 mm SSS
Brake fluid type DOT#4 or DOT#3 SSS
Rear brake:
Type Leading, trailing SSS
Drum inside diameter 110 mm 111 mm
Shoe thickness 4 mm 2 mm
Shoe spring free length 50.5 mm SSS
Brake lever:
Brake lever free play (at lever end) 2 X 5 mm SSS
Brake pedal:
Brake pedal free play 20 X 30 mm SSS
Brake pedal position 0 mm SSS
Clutch lever:
Clutch lever free play (at lever end) 10 X 15 mm SSS
Throttle cable free play 3 X 5 mm SSS
2-11

TIGHTENING TORQUES
CHASSIS
Tightening
g Thread size torque Remarks
Nm mSkg
Handle crown and front fork M10 45 4.5
Handle crown and steering shaft M10 40 4.0
Handlebar holder (under and upper) M8 20 2.0
Steering ring nut M25 7 0.7 Refer to NOTE
Master cylinder and cap (front brake) M4 2 0.2
Handlebar under holder and nut M10 40 4.0
Master cylinder (front brake) M6 9 0.9
Brake hose union bolt (front brake) M10 30 3.0
Front flasher and stay M12 4 0.4
Steering shaft and front fork M10 30 3.0
Engine and front engine stay M8 33 3.3
Front engine stay and frame M8 33 3.3
Engine and top engine stay M8 33 3.3
Top engine stay and frame M8 33 3.3
Engine and engine bracket (frame) M8 33 3.3
Swingarm pivot shaft M12 45 4.5
Rear shock absorber and frame M10 40 4.0
Rear shock absorber and swingarm M10 30 3.0
Swingarm and tension bar M8 20 2.0
Tension bar and rear brake shoe plate M8 20 2.0
Grab bar and frame M8 16 1.6
Fuel tank an fuel cock M6 7 0.7
Rear flasher and stay M12 4 0.4
Sidestand (bolt) M8 19 1.9
Sidestand (nut) M8 16 1.6
Rear footrest (left) M10 45 1.5
Front wheel axle M14 59 5.9
Rear wheel axle and nut M14 65 6.5
Brake caliper and front fork M10 40 4.0
Brake disc and front wheel M8 23 2.3
Driven sprocket and clutch hub M10 40 4.0
Brake caliper bleed screw M7 6 0.6
Meter gear and meter cable M12 3 0.3
Brake cam lever M6 9 0.9
Front wheel axle pinch bolt M8 20 2.0
NOTE:
1. When tighten the ring nut, should be steady the ball bearings and the steering shaft moving smooth-
ly.
2. First, tighten the ring nut approximately 38 Nm (3.8 mSkg) by using the torque wrench, then loosen
the ring nut one turn and retighten the ring nut to specification.
2-12

ELECTRICAL
Item Standard Limit

Ignition timing:
Ignition timing (B.T.D.C.) 9_ at 1,300 r/min SSS
Advanced timing 29_ at 5,500 r/min SSS
Advanced type Electrical type SSS
C.D.I.:
Pickup coil resistance/color 656 X 984 at 20_C/ SSS
Red White
Source coil resistance/color 624 X 936 at 20_C/ SSS
Brown Green
C.D.I. unit model/manufacturer 4WP/YAMAHA SSS
Ignition coil:
Model/ manufacturer 2JN/YAMAHA SSS
Minimum spark gap 6 mm SSS
Primary winding resistance 0.32 X 0.48 at 20_C SSS
Secondary winding resistance 5.68 X 8.52 k at 20_C SSS
Spark plug cap:
Type Resin type SSS
Resistance 10 k SSS
Charging system:
Type C.D.I. magneto SSS
Model/manufacturer 4WP/YAMAHA SSS
Standard output 14 V 9 A/5,000 r/min SSS
Stator coil resistance/color 0.48 X 0.72 at 20_C/ SSS
White White SSS
Rectifier/regulator:
Model/manufacturer SH553D/SHINDENGEN SSS
Type (regulator) Semi conductor-short circuit type SSS
No load regulated voltage 14.5 V SSS
Capacity (rectifier) 25 A SSS
Withstand voltage 200 V SSS
Battery:
Specific gravity 1.280 SSS
Electric starter system:
Type Constant mesh type
Starter motor:
Model/ manufacturer SM-14/MITUBA SSS
Output 0.6 kW SSS
Armature coil resistance 0.0207 X 0.0253 at 20_C SSS
Brush overall length 10 mm 3.5 mm
Brash spring pressure 5.30 X 6.47 N SSS
Commutator diameter 28 mm 27 mm
Mica undercut (depth) 0.7 mm SSS
2-13

Item Standard Limit

Starter relay:
Model/manufacturer MS5D-191/JIDECO SSS
Amperage rating 100 A SSS
Coil winding resistance 3.9 X 4.7 at 20_C SSS
Horn:
Model/manufacturer YF-12/NIKKO SSS
Maximum amperage 2.5 A SSS
Flasher relay:
Type Condenser type SSS
Model/manufacturer FR2204/MITUBA SSS
Flasher frequency 85 cycle/min SSS
Circuit breaker:
Type Fuse SSS
Main 20 A 1 pcs. SSS
Reserve 20 A 1 pcs. SSS
2-14

GENERAL TORQUE SPECIFICATIONS SPEC
GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque General torque
specifications for special components or as- A B specifications
semblies are included in the applicable sections (Nut) (Bolt)
of this book. To avoid warpage, tighten multi- Nm mSkg
fastener assemblies in a crisscross fashion, in 10 mm 6 mm 6 0.6
progressive stages, until full torque is reached. 12 mm 8 mm 15 1.5
Unless otherwise specified, torque specifica-
tions call for clean, dry threads. Components 14 mm 10 mm 30 3.0
should be at room temperature. 17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
A: Distance across flats

B: Outside thread diameter
2-15

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
LUBRICATION POINT AND GRADE OF LUBRICANT

ENGINE
Lubrication Point Symbol

Oil seal lips (all)
Bearing retainer (all)
Bolt (cylinder head)
Crank pin
Connecting rod (big end)
Piston pin
Piston/piston ring
Buffer boss
Valve stem/valve guide (IN, EX)
Valve stem end (IN, EX)
Rocker arm shaft
Cam and bearing (camshaft)
Rocker arm inner surface
Crankcase mating surfaces Yamaha bond No.1215
O-ring (all)
Starter idle gear thrust surfaces
Starter clutch (outer/roller)
Starter wheel gear inner surface
Push rod
Primary driven gear inner surface
Push lever axle
Transmission gear inner surface
Shift fork/guide bar
2-16

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
CHASSIS
Lubrication Point Symbol

Steering head pipe bearing (upper/lower)
Front wheel oil seal lips (left/right)
Rear wheel oil seal lips (left/right)
Rear wheel hub
Rear brake shoe plate, camshaft and pivoting pin
Pivoting points (brake pedal shaft and frame)
Sidestand sliding surface/mounting bolt
Pivoting point (centerstand)
Tube guide (throttle grip) inner surface
Brake lever bolt/master cylinder sliding surface
Clutch lever bolt/cable sliding surface
Steering lock sliding surface
Gear unit (speedometer)
Chain guard inner surface/swigarm insert surface
2-17

LUBRICATION DIAGRAM SPEC
LUBRICATION DIAGRAM
1 Rocker arm (IN)
2 Rocker shaft
3 Rocker arm (EX)
4 Camshaft
5 Oil pump
6 Push lever
2-18

LUBRICATION DIAGRAM SPEC
1 Oil pump
2 Oil filter
3 Crankshaft
4 Main axle
5 Drive axle
6 Oil strainer
2-19

CABLE ROUTING SPEC
CABLE ROUTING
1 Front brake switch lead 12 Clutch switch coupler A Clamp the handlebar switch
2 Brake hose 13 Handlebar switch lead (left) lead, (left and right), front brake
3 Handlebar switch lead (right) 14 Front flasher lead (left) switch lead, clutch switch lead to
4 Throttle cable 15 Horn lead the handlebar.
5 Clutch cable 16 Flasher relay B Do not contact the horn and wire-
6 Clutch switch lead 17 Handlebar switch lead (right) harness.
7 Handlebar switch lead (left) 18 Front brake switch lead
8 Speedometer cable 19 Front flasher (right)
9 Clamp 20 Meter lead
10 Main switch coupler 21 Front flasher lead (right)
11 Front flasher (left) 22 Wireharness
2-20

CABLE ROUTING SPEC
1 Clamp A Align the clamp to the white tape
2 Wireharness on the wireharness
3 High tension cord B Pass the clutch cable through
4 Collar the outside of the throttle cable.
5 Ignition coil C Pass the brake hose and throttle
6 Ground lead cable through the slit of the
7 Ignition coil lead headlight body. And pass them
8 Brake hose the right inside of the front fork.
9 Clutch cable D Pass the brake hose to the holder.
10 Rear brake switch E Clamp the clutch cable to the
11 Starting circuit cut-off relay down tube of the frame.
12 Battery breather hose
2-21

CABLE ROUTING SPEC
1 Neutral switch lead 14 Rectifier/ Regulator A Clamp the speedometer cable to
2 Pickup coil lead 15 Thermostatic switch the steering bracket and pass
3 C.D.I. unit 16 Throttle cable the cable to the cable holder.
4 Rear flasher lead (right) 17 Clutch cable B Pass the brake hose through the
5 Rear flasher lead (left) 18 Wireharness brake hose holder.
6 Tail / Brake light lead 19 Speedometer cable
7 C.D.I. magneto lead 20 Cable holder
8 Thermostatic switch lead 21 Brake hose holder
9 Clamp 22 Cable holder
10 Sidestand switch lead 23 Brake hose
11 Starter relay lead 24 Starter motor lead
12 Fuse 25 Sidestand switch
13 Starter relay 26 Rectifier/ Regulator lead
2-22

CABLE ROUTING SPEC
1 Air filter case
2 Battery
3 Swingarm
4 Battery breather pipe
5 Lid
6 Air filter case drain pipe
A Pass the air filter case drain pipe
inside the swingarm.
2-23

SPEC

CHAPTER 3.
PERIODIC INSPECTIONS
AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1
SIDE COVER, SEAT AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . 3-9
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
TIMING CHINE TENSIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . . 3-13
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 3-20
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 3-25
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
SPOKE INSPECTION AND TIGHTENING . . . . . . . . . . . . . . . . . . . . . 3-28
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

INTRODUCTION/ INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-
tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-
tion 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.
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EVERY
BRAKE-IN 6,000 km 12,000 km
NO. ITEM ROUTINE
1,000 KM or or
6 months 12 months
1 * Valve(s) Check valve clearance. Adjust if necessary.
2 * Cam chain Check chain tension. Adjust if necessary.
Check condition.
3 Spark plug
Clean or replace if necessary.
4 Air filter Clean. Replace if necessary.
Check idle speed / starter operation.
5 * Carburetor
Adjust if necessary.
Check fuel hose for cracks or damage.
6 * Fuel line
Replace if necessary.
7 Engine oil Replace (Warm engine before draining.)
8 * Engine oil filter Replace
Check operation / fluid leakage. / see NOTE.
9 * Front brake
Correct if necessary.
10 Rear brake Check operation. Adjust if necessary.
11 Clutch Check operation. Adjust if necessary.
Check rear arm assembly for looseness.
12 * Rear arm pivot Correct if necessary. Moderately repack
every 24,000 km or 24 months.***
Check balance / damage / runout / spoke tightness.
13 * Wheels
Replace if necessary.
Check bearing assembly for looseness / damage.
14 * Wheel bearings
Replace if damaged.
Check bearing assembly for looseness.
15 * Steering Correct if necessary.

bearing Moderately repack every 24,000 km or
24 months.**
Check operation / oil leakage.
16 * Front forks
Repair if necessary.
Rear shock Check operation / oil leakage.
17 *
absorber Repair if necessary.
*: It is recommended that these items be serviced by a Yamaha dealer.

**: Medium weight wheel bearing grease. (bearing type)
***: Lithium soap base grease. (bush type)
3-1

INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
EVERY
BRAKE-IN 6,000 km 12,000 km
NO. ITEM ROUTINE
1,000 KM or or
6 months 12 months
Check chain slack / alignment. Adjust if necessary.
18 Drive chain EVERY 500 km
Clean and lube.
Check all chassis fittings and fasteners.
19 * Chassis fasteners
Check operation.
20 * Sidestand
Repair if necessary.
Check specific gravity.
21 * Battery Check breather pipe for proper operation.
*: It is recommended that these items be serviced by a Yamaha dealer.

**: Medium weight wheel bearing grease. (bearing type)
***: Lithium soap base grease. (bush type)
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and fill the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-2

INSP
SIDE COVER, SEAT AND FUEL TANK ADJ
SIDE COVER, SEAT AND FUEL TANK
Order Job name/Part name Qty Remarks

Side cover, seat and fuel tank Remove the parts in order.
removal
1 Side cover (left) 1
2 Side cover (right) 1
3 Seat 1 NOTE:
4 Fuel pipe 1 Disconnect the fuel pipe, set the fuel cock
lever OFF position.
5 Fuel tank 1
Reverse the removal procedure for instal-
lation.
3-3

INSP
VALVE CLEARANCE ADJUSTMENT ADJ
SR03004
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured or
adjusted, the piston must be at Top Dead Cen-
ter (T.D.C.) on the compression stroke.
1. Remove:
S Seat
S Side cover (left and right)
S Fuel tank
Refer to SIDE COVER, SEAT AND FUEL
TANK section.
2. Remove:
S Spark plug cap 1
S Spark plug
S Valve cover (intake side) 2
S Valve cover (exhaust side) 3
3. Remove:
S Timing check plug (with O-ring) 1
S Center plug (with O-ring) 2
4. Measure:
S Valve clearance
Out of specification Adjust.
Valve clearance (cold):

Intake valve 0.05 0.09 mm
Exhaust valve 0.11 0.15 mm
***************************************
Measurement steps:
S Rotate the crankshaft counterclockwise to
align the slit a on the rotor with the station-
ary pointer b on the crankcase cover (left)
when the piston is Top Dead Center (TDC).
S Measure the valve clearance by using a feel-
er gauge.
Out of specification Adjust clearance.
***************************************
3-4

VALVE CLEARANCE ADJUSTMENT/ INSP
IDLING SPEED ADJUSTMENT ADJ
5. Adjust:
Valve clearance
***************************************
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 3 in or out with the valve ad-
justing tool 2 until specified clearance is ob-
tained.
Turning in Valve clearance is decreased.

Turning out Valve clearance is increased.
Valve adjusting tool:

90890-01311
Hold the adjuster to prevent it from moving and

tighten the locknut.
14 Nm (1.4 mkg)
Measure the valve clearance.

If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
A B ***************************************
6. Install:
Valve cover (intake side) 1
10 Nm (1.0 mkg)
O-ring 2 New
Valve cover (exhaust side) 3
10 Nm (1.0 mkg)
O-ring 4 New
A Intake side
B Exhaust side
7. Install:
Spark plug 18 Nm (1.8 mkg)
Timing check window screw 1

(with O-ring)
Center plug 2
(with O-ring)
YP303022
IDLING SPEED ADJUSTMENT

1. Start the engine and let it warm up for several
minutes.
2. Attach:
Inductive tachometer to the spark plug lead.
Inductive tachometer:
90890-03113
3-5

IDLING SPEED ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ
3. Check:
Engine idling speed
Engine idling speed:

1,250 1,350 r/min
4. Adjust:
Engine idle speed
***************************************
Adjustment steps:
Turn the pilot screw 1 until it is lightly seated.
Turn the pilot screw out by the specified num-
ber of turns.
Pilot screw:
2 turns out
Turn the throttle stop screw 2 in or out until the

specified idling speed is obtained.
Turning in Idling speed is increased.

Turning out Idling speed is decreased.
***************************************
5. Adjust:
Throttle cable free play
Refer to THROTTLE CABLE ADJUST-
MENT section.
YP303032
THROTTLE CABLE ADJUSTMENT

NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.
1. Check:
Throttle cable free play a
Free play (throttle cable):

3 5 mm at throttle grip flange
2. Adjust:
***************************************
Adjustment steps:
NOTE:
Never accelerate the throttle when stopping the
engine.
3-6

THROTTLE CABLE ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
Loosen the locknut 1 on the throttle cable.
Turn the adjuster 2 in or out until specified
free play is obtained.
Turning in Free play is increased.

Turning out Free play is decreased.
Tighten the locknut.
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.
***************************************
EB303040
SPARK PLUG INSPECTION

1. Remove:
Spark plug cap
Spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinder.
1. Check:
Spark plug type
Incorrect Replace.
Standard spark plug:

DR8EA (NGK)
2. Inspect:
Electrode 1
Wear/damage Replace.
Insulator 2
Abnormal color Replace.
Normal color is a medium-to-light tan color.
3. Clean:
Spark plug
(with spark plug cleaner or wire brush)
4. Measure:
Spark plug gap a
(with a wire gauge)
Out of specification Adjust gap.
Spark plug gap:

0.6 0.7 mm
3-7

SPARK PLUG INSPECTION/ INSP
IGNITION TIMING CHECK ADJ
5. Install:
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
YP303052
IGNITION TIMING CHECK

NOTE:
Prior to checking the ignition timing, check all
electrical connections related to the ignition
system. Make sure all connections are tight and
free of corrosion and that all ground connec-
tions are tight.
1. Remove:
Timing check plug
2. Attach:
Timing light 1
Engine tachometer 2
(to the spark plug lead)
Timing light:
90890-03141
Engine tachometer:
90890-03113
3. Check:
Ignition timing
***************************************
Checking steps:
Start the engine and let it warm up for several
minutes. Let the engine run at the specified
speed.
Engine idling speed:

1,250 1,350 r/min
Visually check the stationary pointer a to

verify it is within the required firing range b in-
dicated on the flywheel.
Incorrect firing range Check the ignition
system.
***************************************
NOTE:
Ignition timing is not adjustable.
3. Install:
Timing check plug
3-8

INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
SR303060
COMPRESSION PRESSURE MEASUREMENT

NOTE:
Insufficient compression pressure will result in
performance loss.
1. Check:
Valve clearance
Refer to VALVE CLEARANCE ADJUST-
MENT section.
minutes.
3. Turn off the engine.
4. Remove:
Spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it from
falling into the cylinder.
5. Attach:
Compression gauge 1
Compression gauge:
90890-03081
Adaptor:
90890-04082
6. Measure:
Compression pressure
If it exceeds the maximum pressure allowed
Inspect the cylinder head, valve surfaces
and piston crown for carbon deposits.
If it is below the minimum pressure Squirt
a few drops of oil into the affected cylinder
and measure again.
Follow the table below.
Compression
p pressure
p
(With oil applied into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Possible defective ring(s),
Same as
valves, cylinder head gas-
without oil
ket or piston Repair.
3-9

COMPRESSION PRESSURE MEASUREMENT/ INSP
ENGINE OIL LEVEL INSPECTION ADJ
Compression pressure (at sea lev-
el):
Standard:
1,200 kPa (12.0 Kg/cm2, 12 bar)
Minimum:
1,100 kPa (11.0 Kg/cm2, 11 bar)
***************************************
Measurement steps:
Crank the engine with the throttle wideopen
until the reading on the compression gauge
stabilizes.
WARNING
Before cranking the engine, ground all
spark plug leads to prevent sparking.
7. Install:
YP303070
ENGINE OIL LEVEL INSPECTION

1. Stand the motorcycle on a level surface.
NOTE:
Make sure the motorcycle is upright when in-
specting the oil level.
2. Start the engine and let it warm up for a few

minutes.
3. Turn off the engine.
4. Inspect:
Engine oil level
Oil level should be between maximum 1
and minimum 2 marks.
Oil level is below the minimum mark
Add oil up to the proper level.
RECOMMENDED ENGINE OIL

Refer to the chart for selection of the oils suited
to the atomosperic temperature.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classifica-
tion:
API STANDARD:
API SE or higher grade
3-10

ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
CAUTION:
Do not put in any chemicals additives or
use oils with a grade of CD a or higher.
Be sure not to use oils labeled ENERGY
CONSERVING II b or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
Be sure no foreign material enters the
crankcase.
5. Start the engine and let it warm up for a few

minutes.
6. Turn off the engine and inspect the oil level
once again.
NOTE:
Wait a few minutes until the oil settles before in-
specting the oil level.
SR303082
ENGINE OIL REPLACEMENT

minutes.
2. Turn off the engine and place a container un-
der the engine.
3. Remove:
Oil filler plug 1
Drain plug 2
Drain the crankcase of its oil.
4. Loosen:
Bolt 1 (oil filter cover-lower)
5. Drain the crankcase of its oil.
If the oil filter is to be replaced during this pro-
cedure, remove the following parts and rein-
stall them afterwards.
***************************************
Replacement steps:
Remove the oil filter cover 1 and oil filter ele-
ment 2 .
Check the O-ring 3 . If it is cracked or dam-
aged, replace it.
Install the oil filter element and oil filter cover.
Screw:
7 Nm (0.7 mkg)
Bolt:
10 Nm (1.0 mkg)
***************************************
3-11

INSP
ENGINE OIL REPLACEMENT ADJ
6. Install:
S Drain plug 43 Nm (4.3 mSkg)
NOTE:
Inspect the O-ring. If it is damaged, replace it
with a new one.
CAUTION:
Before reinstalling the drain plug, do not for-
get to fit the O-ring, compression spring and
oil strainer. Be sure you fit each item in the
correct position and order.
7. Fill:
S Crankcase
Oil quantity:
With oil filter change
1.1 L
Without oil filter change
1.0 L
Refer to ENGINE OIL LEVEL INSPECTION

section.
8. Inspect:
S Oil flow
***************************************
Inspection steps:
S Slightly loosen the oil check bolt 1 .
S Start the engine and keep it idling until the oil
begins to seep from the oil check bolt.
If no oil comes out after one minute, turn the
engine off so it will not seize.
S Check oil passages and oil pump for damage
or leakage.
S Start the engine after solving the problem(s),
and recheck the oil pressure.
S Tighten the oil check bolt to specification.
Oil check bolt:

7 Nm (0.7 mSkg)
***************************************
3-12

TIMING CHAINE TENSIONER ADJUSTMENT/ INSP
CLUTCH ADJUSTMENT ADJ
SR*******
TIMING CHAINE TENSIONER ADJUSTMENT

1. Remove:
S Cap 1
2. Check:
S Rod
Check the rod end 1 is flush with the adjust-
er end 2 .
Not flush Adjust.
3. Adjust:
S Timing chine tension
***************************************
Adjustment steps:
S Loosen the locknut 1 .
S Turn the adjuster 2 in or out until the rod end
3 is flush with the adjuster end.
S Tighten the locknut 1 .
Locknut:
30 Nm (3.0 mSkg)
***************************************
4. Install:
S Cap 5 Nm (0.5 mSkg)
EB303093
CLUTCH ADJUSTMENT
1. Check:
S Clutch cable free play a
Free play (clutch lever):

10 15 mm at clutch lever end
3-13

CLUTCH ADJUSTMENT/ INSP
AIR FILTER CLEANING ADJ
2. Adjust:
S Clutch cable free play
***************************************
Adjustment steps:
Crankcase side
S Make sure that the adjuster 1 and locknut 2
are fully tightened.
S Turn the adjuster 1 in or out until the specified
Turning in Free play is decreased.

Turning out Free play is increased.
NOTE:
If the amount of free play is still incorrect, adjust
the clutch cable free play with the other adjuster
(on the clutch lever holder).
Lever side
Turning in Free play is increased.

Turning out Free play is decreased.
***************************************
SR303123
AIR FILTER CLEANING

1. Remove:
S Side cover (right)
S Air filter element holder
S Air filter element 1
S Plate 2
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the filter element will also affect the
carburetor tuning, leading to poor engine
performance and possible overheating.
3-14

AIR FILTER CLEANING/ INSP
EXHAUST SYSTEM INSPECTION ADJ
2. Inspect:
Damage Replace.
3. Clean:
S Air filter element
Use solvent to clean the element.
NOTE:
After cleaning, remove the remaining solvent by
squeezing the element.
CAUTION:
Do not twist the filter element when squeez-
ing it.
WARNING
Never use low flash point solvents such as
gasoline to clean the air filter element. Such
solvents may cause a fire or an explosion.
4. Apply the recommended oil to the entire sur-

face of the filter and squeeze out the excess
oil. The element should be wet but not drip-
ping.
Recommended oil:
Engine oil
5. Install:
S Plate 1
S Air filter element holder
S Side cover (right)
T******
EXHAUST SYSTEM INSPECTION

1. Inspect:
S Exhaust pipe 1
S Muffler 2
Crack/Damage Replace.
S Gasket 3
Exhaust gas leaks Replace.
3-15

INSP
EXHAUST SYSTEM INSPECTION ADJ
2. Check:
S Tightening torque
Bolt 1 :
12 Nm (1.2 mSkg)
Nut 2 :
20 Nm (2.0 mSkg)
3-16

FRONT BRAKE ADJUST MENT/ INSP
REAR BRAKE ADJUSTMENT ADJ
EB304002
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever free play a
Free play (Brake lever):

2 5 mm at brake lever end
2. Adjust:
Brake lever free play
***************************************
Adjustment steps:
Turn the adjuster 2 in or out until the specified

Tighten the locknut.
CAUTION:
Make sure that there is no brake drag after
adjusting the front brake lever free play.
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. This air must be removed by bleed-
ing the brake system before the motorcycle
is operated. Air in the brake system will con-
siderably reduce braking performance and
could result in loss of control and possibly
an accident. Inspect and bleed the brake
system if necessary.
***************************************
NB304012
REAR BRAKE ADJUSTMENT

1. Check:
Brake pedal height a
Brake pedal height:

0 mm
below the top of the footrest
3-17

INSP
REAR BRAKE ADJUSTMENT ADJ
2. Adjust:
S Brake pedal height
***************************************
Adjustment steps:
pedal height is obtained.
Turning in Pedal height is decreased.

Turning out Pedal height is increased.
S Tighten the locknut.
***************************************
3. Check:
S Brake pedal free play a
Out of specification Adjust
Free play (Brake pedal):

20 30 mm at brake lever end
4. Adjust:
S Brake pedal free play
***************************************
Adjustment steps:

CAUTION:
Make sure that there is no brake drag after
adjusting the brake pedal height and the
free play.
***************************************
5. Adjust:
S Brake light switch
Refer to BRAKE LIGHT SWITCH ADJUST-
MENT.
3-18

INSP
BRAKE FLUID LEVEL INSPECTION ADJ
EB304020
BRAKE FLUID LEVEL INSPECTION

NOTE:
S Make sure the motorcycle is upright when in-
specting the brake fluid level.
S Stand the motorcycle on its centerstand if it
has one. If not, place a suitable stand under
the motorcycle.
2. Inspect:
S Brake fluid level
Brae fluid level is below the LOWER level
line a Fill to proper level.
Recommended brake fluid:

DOT #4 or DOT #3
NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir is horizontal.
CAUTION:
Brake fluid may corrode painted surfaces or
plastic parts. Always clean up any spilt fluid
immediately.
WARNING
S Use only the designated brake fluid. Other
fluids may deteriorate the rubber seals,
causing leakage and poor brake perfor-
mance.
S Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake perfor-
mance.
S Be careful that water does not enter the
brake fluid reservoir during refilling. Water
will significantly lower the boiling point of
the fluid and may cause vapour lock.
3-19

BRAKE PAD INSPECTION/BRAKE SHOE INSPECTION/ INSP
BRAKE LIGHT SWITCH ADJUSTMENT ADJ
EB304030
BRAKE PAD INSPECTION

1. Operate the brake lever.
2. Inspect:
Brake pad (front)
Wear indicators 1 almost touch the brake
disc Replace the brake pads as a set.
Refer to FRONT BRAKE in CHAPTER 6.
EB304040
BRAKE SHOE INSPECTION

1. Operate the brake pedal.
2. Inspect:
Brake shoes
Wear indicator 1 reaches the wear limit line
2 Replace the brake shoes as a set.
Refer to REAR WHEEL in CHAPTER 6.
EB304050
BRAKE LIGHT SWITCH ADJUSTMENT

NOTE:
The brake light switch is operated by move-
ment of the brake pedal.
Adjustment is correct when the brake light
comes on just before the braking effect actual-
ly starts.
1. Check:
Brake light operation timing
Incorrect Adjust.
2. Adjust:
Brake light operating timing
***************************************
Adjustment steps:
Hold the main body 1 of the switch with your
hand so that it does not rotate, and turn the ad-
juster 2 in or out until the proper operation
timing is obtained.
Turning in Brake light comes on fast.

Turning out Brake light comes on slows.
***************************************
3-20

INSP
AIR BLEEDING ADJ
EB304070
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
WARNING
Bleed the brake system whenever:
S The system is disassembled.
S A brake hose is loosened or removed.
S The brake fluid level is very low.
S Brake operation is faulty.
Loss of braking performance may occur if
the brake system is not properly bled.
1. Bleed:
S Brake system
***************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 .
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all air bubbles
have disappeared from the brake fluid.
NOTE:
When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir before applying the brake
lever. Ignoring this precaution could allow air to
enter the brake system, considerably lengthen-
ing the bleeding procedure.
3-21

AIR BLEEDING/ INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 mSkg)
NOTE:
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the brake system have disappeared.
k. Fill the brake fluid reservoir to the proper lev-

el.
Refer to BRAKE FLUID LEVEL INSPEC-
TION.
WARNING
Check brake operation after bleeding the
brake system.
***************************************
SR304093
DRIVE CHAIN SLACK ADJUSTMENT

NOTE:
Before checking and adjusting, rotate the rear
wheel several revolutions and check the slack
at several points to find the tightest point. Check
and if necessary adjust the drive chain slack
with the rear wheel in this tightest position.
CAUTION:
Too little chain slack will overload the en-
gine and other vital parts; keep the slack
within the specified limits.
WARNING
S Securely support the motorcycle so that
there is no danger of it falling over.
S Stand the motorcycle on its centerstand.
3-22

INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
1. Check:
S Drive chain slack
Out of specification ! Adjust.
Drive chain slack:

25 35 mm
a Check window
b Adjustable limit
c Usable limit
d Usable range
A B 2. Adjust:
S Drive chain slack
A Standard
B Useful limit
***************************************
Adjustment steps:
S Loosen the axle nut 1 .
S Turn the chain adjusters 2 clockwise or coun-
terclockwise until the specified drive chain
slack is obtained.
Clockwise ! Chain slack is decreased.

Counter-
! Chain slack is increased.
clockwise
NOTE:
Turn each chain adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks e on each chain adjuster.
Use them when adjusting the slack for proper
alignment.)
S Before tightening the axle nut to specification,

make sure that there is no clearance at the ad-
juster (or the swingarm end) on both sides by
pushing the wheel forward.
Rear wheel axle:

65 Nm (6.5 mSkg)
***************************************
CAUTION:
Do not adjust the drive chain slack above
the usable range b of check window a .
3-23

INSP
STEERING HEAD INSPECTION ADJ
SR304130
STEERING HEAD INSPECTION

WARNING
Securely support the motorcycle so that

NOTE:
Stand the motorcycle on its centerstand.
2. Elevate the front wheel by placing a suitable

stand under the engine.
3. Check:
Steering assembly bearings
Grasp the bottom of the lower front fork tubes
and gently rock the fork assembly.
Looseness Adjust the steering head.
4. Adjust:
Steering head
***************************************
Adjustment steps:
Tighten the ring nut 1 using the ring nut
wrench 2 .
Loosen the ring nut completely, then tighten it.
NOTE:
When tighten the ring nut, should be steady the
ball bearings and steering shaft moving
smoothly.
Ring nut wrench:

90890-01403
Steering ring nut:

1st step:
38 Nm (3.8 mkg)
2nd step:
7 Nm (0.7 mkg)
Check the steering head for looseness or bind-

ing by turning it all the way in both directions.
***************************************
3-24

FRONT FORK INSPECTION/ INSP
REAR SHOCK ABSORBER ADJUSTMENT ADJ
EB304140
FRONT FORK INSPECTION

WARNING

2. Check:
S Inner tube
Scratches/damage Replace.
S Oil seal
Excessive oil leakage Replace.
Hold the motorcycle upright and apply the
front brake.
3. Check:
S Operation
Push down hard on the handlebars several
times.
Unsmooth operation Repair.
Refer to FRONT FORK in CHAPTER 6.
YP304160
REAR SHOCK ABSORBER ADJUSTMENT

WARNING
S Always adjust each rear shock absorber
preload to the same setting. Uneven ad-
justment can cause poor handling and loss
of stability.
S Securely support the scooter so there is no
danger of it falling over.
1. Adjust:
S Spring preload
Turn the adjuster ring 1 to direction a or b .
***************************************
Adjustment steps:
S Turn the adjuster ring in or out.
Turning toward a Spring preload is

increased.
Turning toward b Spring preload is
decreased.
3-25

REAR SHOCK ABSORBER ADJUSTMENT/ INSP
TIRE INSPECTION ADJ
Adjustment numbers:
Standard 1
Minimum 1
Maximum 5
CAUTION:
S Never turn the adjuster beyond the maxi-
mum or minimum setting.
S Always adjust each shock absorber to the
same setting.
***************************************
EB304171
TIRE INSPECTION
1. Measure:
S Tire inflation pressure
WARNING
S Tire inflation pressure should only be
checked and adjusted when the tire tem-
perature equals the ambient air tempera-
ture. Tire inflation pressure and suspen-
sion must be adjusted according to the
total weight of the cargo, rider, passenger
and accessories (fairing, saddlebags, etc.
if approved for this model), and according
to whether the motorcycle will be operated
at high speed or not.
NEVER OVERLOAD THE MOTORCYCLE.
S Operation of an overloaded motorcycle
could cause tire damage, accident or inju-
ry.
Basic weight:
With oil and 113 kg
full fuel tank
Maximum load* 164 kg
Cold tire pres-
Front Rear
sure
175 kPa 200 kPa
Up to 90 kg
(1.75 kg/cm2, (2.0 kg/cm2,
load*
1.75 bar) 2.0 bar)
175 kPa 25 kPa
90 kg
(1.75 kg/cm2, (2.25 kg/cm2,
maximum. load*
1.75 bar) 2.25 bar)
* Load is the total weight of the cargo, rider, pas-
senger and accessories.
3-26

INSP
TIRE INSPECTION ADJ
2. Inspect:
Tire surfaces
Minimum tire tread depth
(front and rear): 1.6 mm
1 Tread depth
2 Side wall
3 Wear indicator
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread begins to show signs of
wear, replace the tire immediately.
Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement tube.
Do not use tubeless tires on a wheel de-
signed for tube type tires only. Tire failure
and personal injury may result from sud-
den deflation.
Tube type wheel Tube type tire only
Tube type
yp or
T beless type wheel
Tubeless
tubeless tire.
Be sure to install the correct tube when us-
ing tube type tires.
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. No guarantee concern-
ing handling characteristics can be given if
a tire combination other than one ap-
proved by Yamaha is used on this motor-
cycle. The front and rear tires should al-
ways be by the same manufacturer and of
the same design.
WARNING
After mounting a tire, ride conservatively for
a while to give the tire time to seat itself
properly in the rim. Failure to do so could
lead to an accident with possible injury to
the rider or damage to the motorcycle.
2. After a tire repair or replacement, be sure to

tighten the valve stem locknut 1 to specifi-
cation.
Locknut:
1.5 Nm (0.15 mkg)
3-27

SPOKE INSPECTION AND TIGHTENING/ INSP
WHEEL INSPECTION ADJ
EB304190
SPOKE INSPECTION AND TIGHTENING

1. Inspect:
S Spokes 1
Bending/damage Replace.
Loose spoke Retighten.
2. Tighten:
S Spokes
NOTE:
Be sure to tighten the spokes before and after
break-in.
Nipple:
2 Nm (0.2 mSkg)
EB304180
WHEEL INSPECTION
1. Inspect:
S Wheels
Damage/Bends Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
Never attempt to make any repairs to the
wheel.
3-28

INSP
BATTERY INSPECTION ADJ
EB305001
ELECTRICAL
BATTERY INSPECTION
1. Remove:
S Side covers (left and right)
TANK section.
2. Inspect:
S Electrolyte level
Electrolyte level should be between the up-
per 1 and lower 2 level marks.
Electrolyte level is too low Add electrolyte
to proper level.
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
3. Inspect:
S Battery terminals
Dirt Clean with a wire brush.
Poor connection Correct.
NOTE:
After cleaning the terminals, apply a light coat of
grease to the terminals.
4. Inspect:
S Breather hose
Obstruction Remove.
Damage Replace.
CAUTION:
When inspecting the battery, make sure that
the breather hose is routed correctly. If the
breather hose is positioned in such a way as
to allow battery electrolyte or gas to come
into contact with the frame, this could dam-
age the motorcycle and ruin its finish.
5. Connect:
S Breather hose 1
Make sure that the hose is properly attached
and routed.
6. Check:
S Specific gravity
Less than 1.280 Recharge the battery.
Charging Current:
0.7 amps/10 hrs
Specific Gravity:
1.280 at 20_C
3-29

INSP
BATTERY INSPECTION ADJ
***************************************
Replace the battery if:
S Battery voltage will not rise to a specific value
or bubbles fail to rise during charging.
S Sulphation of one or more cells occurs, (as in-
dicated by the plates turning white, or material
accumulating in the bottom of the cell).
S Specific gravity readings after a long, slow
charge indicate that one cell is charged lower
than the rest.
S Warpage or buckling of plates or insulators is
evident.
***************************************
CAUTION:
Always charge a new battery before using it
to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
S Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
S Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
S SKIN Flush with water.
S EYES Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
S Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical
attention.
S Batteries generate explosive hydrogen
gas.
S Always follow these preventive measures:
S Charge batteries in a well ventilated area.
S Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
S DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
3-30

INSP
BATTERY INSPECTION/FUSE INSPECTION ADJ
7. Install:
Battery
8. Connect:
Battery leads
CAUTION:
Connect the positive lead 1 first and then
connect the negative lead 2 .
9. Connect:
Breather hose
Be sure the hose is properly attached and
routed.
Refer to CABLE ROUTING section.
10. Install:
Side covers (left and right)
TANK section.
T305010
FUSE INSPECTION
CAUTION:
Always turn off the main switch when
checking or replacing the fuse. Otherwise, a
short circuit may occur.
1. Remove:
Side covers (left and right)
TANK section.
Fuse holder 1
2. Inspect:
Fuse
***************************************
Inspection steps:
Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the tester selector to 1 position.
Pocket tester:
90890-03112
If the tester is indicated at . Replace the

fuse.
***************************************
3-31

FUSE INSPECTION/ INSP
HEADLIGHT BEAM ADJUSTMENT ADJ
3. Replace:
S Blown fuse
***************************************
Replacement steps:
S Turn off the main switch.
S Install a new fuse with the proper current rat-
ing.
S Turn on switches to verify operation of related
electrical devices.
S If the fuse blows again immediately, check the
electrical circuit.
WARNING
Never use a fuse with a rating other than that
specified. Never use other materials in place
of a fuse. An improper fuse may cause ex-
tensive damage to the electrical system,
malfunction of lighting and ignition systems
and could possibly cause a fire.
***************************************
4. Install:
S Fuse holder
S Side cover (left and right)
TANK section.
EB305022
HEADLIGHT BEAM ADJUSTMENT

1. Adjust:
S Headlight beam (vertical)
Loosen the bolt 1 and adjust the headlight
unit.
3-32

CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
EXHAUST PIPE, STARTING MOTOR AND WIRE READ . . . . . . . . . 4-1
CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN . . . . . . . . . . 4-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
CYLILNDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

CAM SPROCKET COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
CAM SHAFT AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

ROCKER ARM AND ROCKER ARM SHAFT REMOVAL . . . . . . . . . 4-11
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION . . . . 4-12
CAMSHAFT AND ROCKER ARM INSTALLATION . . . . . . . . . . . . . . 4-12
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

VALVES AND VALVE SPRINGS REMOVAL . . . . . . . . . . . . . . . . . . . . 4-15
VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
VALVE SEATS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
VALVES AND VALVE SPRINGS INSTALLATION . . . . . . . . . . . . . . . . 4-18
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

PISTON AND PISTON RINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . 4-21
CYLINDER AND PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 4-21
PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
PISTON PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
PISTON RINGS, PISTON AND CYLINDER INSTALLATION . . . . . . 4-24
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
CRANKCASE COVER (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

PRIMARY DRIVE GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
OIL DELIVERY PASSAGE INSPECTION
(CRANK CASE COVER (right)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
PRIMARY DRIVE GEAER INSTALLATION . . . . . . . . . . . . . . . . . . . . . 4-36

BALANCER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
BALANCER DRIVEN GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 4-38
DRIVE GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
BALANCER DRIVE GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 4-38
BALANCER GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
SHIFT SHAFT AND SEGMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

SHIFT SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
SHIFT SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
SEGMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
SIFT SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
CDI MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-44

CRANKCASE COVER (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
PICKUP COIL AND STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CDI MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . 4-46
CDI MAGNETO REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
STARTER CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
STARTER CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
CDI MAGNETO INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
CRANK CASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
CRANKSHAFT AND BALANCER WEIGHT . . . . . . . . . . . . . . . . . . . . . 4-52
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
PLUNGER SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
PLUNGER SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
BALANCER WEIGHT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
CRANKCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
TRANSMISSION, SHIFT CAM AND SHIFT FORK . . . . . . . . . . . . . . . . . 4-56

DRIVE AXLE AND MAIN AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL . . . . 4-58
SHIFT FORK SHIFT CAM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 4-58
TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION 4-59

ENGINE REMOVAL ENG
EB400000
ENGINE OVERHAUL
ENGINE RE MOVAL
EXHAUST PIPE, STARTING MOTOR AND WIRE READ
12 Nm (1.2 mkg)
20 Nm (2.0 mkg)

Exhaust pipe, starting motor and Remove the parts in order.
wire read removal
Side cover, seat and fuel tank Refer to SIDE COVER, SEAT AND
FUEL TANK section in CHAPTER 3.
1 Rear foot rest (right) 1
2 Exhaust pipe Assy 1
3 Exhaust pipe gasket 1
4 Ground lead 1
5 Starting motor read 1
6 CDI magneto read 1
7 Plug cap 1
Reverse the removal procedure for
installation.
4-1

ENGINE REMOVAL ENG
CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN
65 Nm (6.5 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
8 Nm (0.8 mkg)

Carburetor, clutch cable and drive Remove the parts in order.
chain removal
Carburetor Refer to CARBURETOR section in
CHAPTER 5.
1 Clutch cable 1
2 Crankcase breather hose 1
3 Shift pedal 1
4 Drive sprocket cover 1
5 Rear wheel axle nut 1 NOTE:
Loosen the axle nut and slacken the
drive chain.
6 Sprocket holder 1
7 Drive sprocket/drive chain 1/1 Reverse the removal procedure for
installation.
4-2

ENGINE REMOVAL ENG
ENGINE
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)
33 Nm (3.3 mkg)

Engine removal Remove the parts in order.
Securely support the motorcycle so
1 Engine stay (top) there is no danger of it falling over.
2 Front engine stay 1
3 Engine mount bolt (rear upper) 1
4 Engine mount bolt (rear under) 1
5 Engine 1
1
installation.
4-3

CYLINDER HEAD ENG
CYLINDER HEAD
CAM SPROCKET COVER
18 Nm (1.8 mkg) 10 Nm (1.0 mkg)
2 Nm (0.2 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)

Cam sprocket cover removal Remove the parts in order.
Side cover, seat and fuel tank
Refer to SIDE COVER SEAT AND
FUEL TANK REMOVAL section in
Exhaust pipe assembly CHAPTER 3.
Refer to ENGINE REMOVAL section in
Carburetor assembly CHAPTER 4.
Refer to CARBURETOR section in
Engine stay (top) CHAPTER 5.
Refer to ENGINE REMOVAL section in
CHAPTER 4.
1 Spark plug 1
2 Cam sprocket cover/O-ring 1/1
3 Valve cover (intake side)/O-ring 1/1
4 Valve cover (exhaust side)/O-ring 1/1
5 Carburetor joint/O-ring 1/1
6 Timing mark cap/O-ring 1/1
7 Center cap/O-ring 1/1
installation.
4-4

CYLINDER HEAD ENG
CYLINDER HEAD
22 Nm (2.2 mkg)
20 Nm (2.0 mkg)
5 Nm (0.5 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)

Cylinder head removal Remove the parts in order.
1 Timing chain tensioner cap/O-ring 1/1
2 Timing chain tensioner assembly 1
3 Cam sprocket/Timing chain 1/1 Refer to CYLINDER HEAD REMOVAL/
4 Ignition coil 1 INSTALLATION section.
5 Cylinder head 1
6 Dowel pins 3
Refer to CYLINDER HEAD
7 Gasket 1
INSTALLATION section.
8 Cylinder head gasket 1
installation.
4-5

CYLINDER HEAD ENG
T401030
CYLINDER HEAD REMOVAL

1. Align:
Slit a on the magneto
(with stationary pointer b on the crank case
cover)
NOTE:
Turn the crank shaft counterclockwise with
a wrench and align the I mark c with the
cylinder head match mark d when the piston is
at TDC on the compression stroke.
2. Loosen:
Cam sprocket bolt 1
3. Remove:
Timing chain tensioner assembly 1
4. Remove:
Cam sprocket bolt
Cam sprocket 1
Timing chain 2
NOTE:
Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
4-6

CYLINDER HEAD ENG
5. Remove:
Cylinder head
NOTE:
Loosen the nuts in their proper loosening
sequence.
Start by loosening each nut 1/2 turn until all
are loose.
YP402000
CYLINDER HEAD INSPECTION

1. Eliminate:
Carbon deposits
(from combustion chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
Spark plug threads
Valve seats
2. Inspect:
Cylinder head
Scratches/damage Replace.
3. Measure:
Cylinder head warpage
Out of specification Resurface.
Cylinder head warpage:

Less than 0.03 mm
***************************************
Warpage measurement and resurfacement
steps:
Place a straightedge and a feeler gauge
across the cylinder head.
Measure the warpage.
If the warpage is out of specification, resurface
the cylinder head.
Place a 400 600 grit wet abrasive paper on
the surface plate, and resurface the head us-
ing a figure-eight sanding pattern.
NOTE:
Rotate the cylinder head several times for an
even resurfacement.
***************************************
4-7

CYLINDER HEAD ENG
SR********
CYLINDER HEAD INSTALLATION
1. Install:
Dowel pins 1 New
Gasket 2
Gasket (cylinder head) 3 New
2. Install:
Cylinder head
M8 (1 4) 22 Nm (2.2 mkg)
M8 (5 6 20 Nm (2.2 mkg)
NOTE:
apply engine oil onto the nut threads.
Tighten the bolts starting with the lowest
numbered one.
3. Install:
Calm sprocket
Timing chain
***************************************
Installing steps:
Turn the crank shaft counterclockwise until the
slit 1 matches the stationary pointer 2 .
Align the dowel pin 3 on the camshaft with the
stationary pointer 4 on the cylinder head.
Align the I mark 5 on the cam sprocket with
the stationary pointer 6 on the cylinder head.
Fit the timing chain 7 onto cam sprocket 8
and install the cam sprocket on the camshaft.
NOTE:
When installing the cam sprocket, keep the tim-
ing chain as tight as possible on the exhaust
side.
CAUTION:
Do not turn the crankshaft during installa-
tion of the camshaft. Damage or improper
valve timing will result.
Remove the safety wire from the timing chain.

***************************************
4-8

CYLINDER HEAD ENG
4. Install:
Plate washer
Bolt (timing chain)
Timing chain tensioner assembly
5. Tighten:
Bolt (timing chain) 60 Nm (6.0 mkg)
NOTE:
Install the bolt while holding the magneto
mounting bolt with a wrench.
6. Check:
Magneto rotor slit
Align the stationary pointer with the crank-
case cover (left).
Cam sprocket I mark
Align the stationary pointer with the cylinder
head.
Out of alignment Adjust.
7. Check:
Timing chain tension
Refer to TIMING CHAIN ADJUSTMENT
section in CHAPTER 3.
Valve clearance
Refer to VALVE CLEARANCE ADJUST-
MENT section in CHAPTER 3.
4-9

CAM SHAFT AND ROCKER ARMS ENG
CAM SHAFT AND ROCKER ARMS
14 Nm (1.4 mkg)
14 Nm (1.4 mkg)
8 Nm (0.8 mkg)

Cam shaft and rocker arm removal Remove the parts in order.
Cylinder head Refer to the CYLINDER HEAD section.
1 Lock washer 1 Refer to the CAMSHAFT AND ROCKER
2 Plate 1 ARM INSTALLATION section.
3 Collar 1 Refer to the ROCKER ARM AND
4 Cam shaft 1 ROCKER ARM SHAFT REMOVAL/
5 Rocker arm shaft (intake side) 1 CAMSHAFT AND ROCKER ARM
6 Rocker arm shaft (exhaust side) 1 INSTALLATION section.
7 Rocker arm 2
8 O-ring 1
9 Nut/Adjuster 2/2
installation.
4-10

SR******
ROCKER ARM AND ROCKER ARM SHAFT

REMOVAL
1. Remove:
Camshaft 1
Collar (camshaft) 2
NOTE:
Use 10 mm bolt 3 to remove the camshaft.
2. Remove:
Rocker arm shaft (intake)
Rocker arm shaft (exhaust)
NOTE:
Attach a rocker arm shaft puller bolt 1 and
weight 2 to the rocker arm shaft and slide out
the shaft.
Rocker arm shaft puller bolt:

90890-01083
Weight:
90890-01084
YP402052
CAMSHAFT INSPECTION
1. Inspect:
Cam lobes
Pitting/Scratches/Blue discoloration
Replace.
2. Measure:
Cam lobes length A and B .
Out of specification Replace.
Cam lobes length:

Intake:
A 36.537 36.637 mm
<Limit: 36.45 mm>
B 30.13 30.231 mm
<Limit: 30.05 mm>
Exhaust:
A 36.577 36.677 mm
<Limit: 36.49 mm>
B 30.214 30.314 mm
<Limit: 30.13 mm>
3. Inspect:
Camshaft oil passage
Stuffed Blow out oil passage with com-
pressed the air.
4-11

YP402060
ROCKER ARMS AND ROCKER ARM

SHAFTS INSPECTION
1. Inspect:
Rocker arm shafts
Rocker arms
Wear/Pitting/Scratches/Blue discoloration
Replace.
***************************************
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 Replace.
Inspect the surface condition of the rocker arm
shafts.
Pitting/scratches/blue discoloration Re-
place or check lubrication.
Measure the inside diameter a of the rocker
arm holes.
Inside diameter (rocker arm):

12.000 12.018 mm
<Limit: 12.036 mm>
Measure the outside diameter of the rocker

arm shafts.
Outside diameter (rocker

arm shaft):
11.985 11.991 mm
<Limit: 11.950 mm>
***************************************
SR******
CAMSHAFT AND ROCKER ARM

INSTALLATION
1. Lubricate:
Camshaft
Camshaft:
Molybdenum disulfide oil
Camshaft bearing:
Engine oil
4-12

2. Apply:
(onto the rocker arm and rocker arm shaft)
3. Install:
Rocker arm
Rocker arm shaft 1
NOTE:
Apply engine oil onto the outside of the rocker
arm shaft and apply molybdenum disulfide oil
onto the inside of the rocker arm.
Install the rocker arm shaft (intake), mach the
cut away a and bolt hole b .
CAUTION:
Make sure that the rocker shaft install
direction.
Install the rocker arm shaft into the thread
side for the out.
4. Install:
Camshaft 1
Collar 2
NOTE:
Apply engine oil onto the cam profile face and
journal face.
Install the camshaft, mach the dowel pin a
and cylinder head mark b .
5. Install:
Plate 1
Lock washer 2 New
Bolt 3 8 Nm (0.8 mkg)
NOTE:
After tighten the bolt, bend the end of the rock
washer.
4-13

VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS

Valves and valve springs removal Remove the parts in order.
Cylinder head Refer to CYLINDER HEAD section.
Rocker arm, Camshaft Refer to CAMSHAFT AND ROCKER
ARMS section.
1 Valve cotters 4 Refer to VALVES AND VALVE

SPRINGS REMOVAL/INSTALLATION
section.
2 Spring retainer 2
3 Valve spring (inner) 2
4 Valve spring (outer) 2 Refer to VALVES AND VALVE
5 Valve (intake) 1 SPRINGS INSTALLATION section.
6 Valve (exhaust) 1
7 Valve guide (stem seal) 2
8 Spring seat 2
installation.
4-14

YP401150
VALVES AND VALVE SPRINGS REMOVAL

1. Remove:
Valve cotters 1
NOTE:
Attach a valve spring compressor and attach-
ment 2 between the valve spring retainer and
cylinder head to remove the valve cotters.
CAUTION:
Do not compress so much as to avoid dam-
age to the valve spring.
Valve spring compressor:

90890-01253
Valve spring compressor
attachment:
90890-04108
NB402010
VALVES AND VALVE GUIDES

1. Measure:
Stem-to-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a
valve stem diameter b
Out of specification Replace the valve
guide.
Clearance (stem to guide):

Intake:
0.010 0.037 mm
<Limit: 0.08 mm>
Exhaust:
0.025 0.052 mm
<Limit: 0.10 mm>
2. Replace:
Valve guide
***************************************
Replacement steps:
NOTE:
Heat the cylinder head in an oven to 100C to
ease guide removal and installation and to
maintain correct fit.
Remove the valve guide using a valve guide

remover 1 .
4-15

Install the new valve guide using a valve guide
installer 2 and valve guide remover 1 .
After installing the valve guide, bore the valve
guide using a valve guide reamer 3 to obtain
proper stem-to-guide clearance.
Valve guide remover (6 mm):

90890-04064
Valve guide installer (6 mm):
90890-04065
Valve guide reamer (6 mm):
90890-04066
NOTE:
Reface the valve seat after replacing the valve
guide.
***************************************
3. Eliminate:
Carbon deposits (from the valve face)
4. Inspect:
Valvel face
Pitting/wear Grind the face.
Valve stem end
Mushroom shape or diameter larger than the
body of the stem Replace.
5. Measure:
Margin thickness a
Margin thickness:
Intake
0.8 1.2 mm
Exhaust
0.8 1.2 mm
6. Measure:
Runout (valve stem)
Runout:
Less than 0.03 mm
NOTE:
Always replace the guide when installing a
new valve.
Always replace the oil seal if the valve is re-
moved or replaced.
4-16

EB402020
VALVE SEATS INSPECTION

1. Eliminate:
Carbon deposits
(from the valve face and valve seat)
2. Inspect:
Valve seats
Pitting/wear Reface the valve seat.
3. Measure:
Valve seat width a
Out of specification Reface the valve seat.
Valve seat width:

Intake:
0.9 1.1 mm
<Limit: 1.6 mm>
Exhaust:
0.9 1.1 mm
<Limit: 1.6 mm>
***************************************
Measurement steps:
Apply Mechanics blueing dye (Dykem) 1 to
the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
Measure the valve seat width. Where the valve
seat and valve face made contact, blueing will
have been removed.
If the valve seat is too wide, too narrow, or the
seat is not centered, the valve seat must be re-
placed.
***************************************
EB402020
4. Lap:
Valve face
Valve seat
NOTE:
After replacing the valve seat, valve and valve
guide, the valve seat and valve face should be
lapped.
***************************************
Lapping steps:
Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let compound enter the gap between
the valve stem and the guide.
4-17

Apply molybdenum disulfide oil to the valve
stem.
Turn the valve until the valve face and valve

seat are evenly polished, then clean off all
compound.
Valve lapper:
90890-04101
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.
Apply a fine lapping compound to the valve

face and repeat the above steps.
NOTE:
Make sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
Apply Mechanics blueing dye (Dykem) b to

the valve face.
Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
Measure the valve seat width c again.
***************************************
EB404032
VALVES AND VALVE SPRINGS

INSTALLATION
1. Deburr:
Valve stem end
Use an oil stone to smooth the stem end.
4-18

2. Apply:
(onto the valve stem 3 and oil seal 2 )
3. Install:
Valve spring seat 1
Valve stem seat 2 New
Valve 3
(into the cylinder head)
Valve spring 4
Spring retainer 5
NOTE:
Install the valve spring with the larger pitch a
facing upwards.
b Smaller pitch
4. Install:
Valve cotters 1
NOTE:
Install the valve cotters while compressing the
valve spring with a valve spring compressor and
attachment 2 .
Valve spring compressor:

90890-01253
Valve spring compressor
attachment:
90890-04108
5. Secure the valve cotters onto the valve stem

by tapping lightly with a piece of wood.
CAUTION:
Do not hit so much as to damage the valve.
4-19

CYLINDER AND PISTON ENG
CYLINDER AND PISTON

Cylinder and piston removal Remove the parts in order.
1 Timing chain guide (exhaust side) 1
2 Cylinder/O-ring 1/1
3 O-ring 1 Refer to PISTON RINGS, PISTON AND
4 Dowel pin 2 CYLINDER INSTALLATION section.
5 Cylinder gasket 1
6 Piston pin circlip 2 Refer to PISTON AND PISTON RINGS
7 Piston pin 1 REMOVAL section.
8 Piston 1 Refer to PISTON RINGS, PISTON AND
9 Piston ring set 1 CYLINDER INSTALLATION section.

installation.
4-20

YP******
PISTON AND PISTON RINGS REMOVAL

1. Remove:
Piston pin circlip 1
Piston pin 2
Piston 3
NOTE:
Before removing the piston pin circlip, cover the
crankcase opening with a clean towel or rag to
prevent the circlip from falling into the
crankcase cavity.
2. Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
EB402100
CYLINDER AND PISTON INSPECTION

1. Inspect:
Cylinder and piston walls
Vertical scratches 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 cylinder
bore gauge.
NOTE:
Measure the cylinder bore C in parallel to and
at right angles to the crankshaft. Then, find the
average of the measurements.
4-21

Cylinder bore C 57.00 57.02 mm

Taper limit T 0.05mm
Out of round R 0.01mm
C = Maximum D
T = (Maximum D1 or D2)
(Maximum D5 or D6)
R = (Maximum D1, D3 or D5)
(Minimum D2, D4 or D6)
If out of specification, rebore or replace the cyl-
inder, and replace the piston and piston rings
as a set.
2nd step:
Measure the piston skirt diameter P with a
micrometer.
a 5.5 mm from from the piston bottom edge.
Piston size P
Standard 56.960 56.975 mm
Oversize 1 0.25 mm
Oversize 2 0.50 mm
If out of specification, replace the piston and
the piston rings as a set.
3rd step:
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:
0.025 0.045 mm
If out of specification, rebore or replace the cyl-

inder, and replace the piston and piston rings
as a set.
***************************************
4-22

EB402110
PISTON RING INSPECTION

1. Measure:
Side clearance
Out of specification Replace the piston
and the piston rings as a set.
NOTE:
Eliminate the carbon deposits from the piston
ring grooves and rings before measuring the
side clearance.
Side clearance:
Top ring: <Limit>
0.03 0.07 mm <0.15 mm>
2nd ring: <Limit>
0.02 0.06 mm <0.15 mm>
2. Position:
Piston ring
(into the cylinder)
NOTE:
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
a 5 mm
3. Measure:
End gap
NOTE:
You cannot measure the end gap on the expan-
der spacer of the oil ring. If the oil ring rails show
excessive gap, replace all three rings.
End gap:
Top ring: <Limit>
0.15 0.35 mm <0.60 mm>
2nd ring: <Limit>
0.15 0.35 mm <0.60 mm>
Oil ring:
0.3 0.9 mm
4-23

EB402120
PISTON PIN INSPECTION

1. Inspect:
Piston pin
Blue discoloration/grooves Replace, then
inspect the lubrication system.
2. Measure:
Piston pin-to-piston clearance
***************************************
Measurement steps:
Measure the piston pin outside diameter a .
If out of specification, replace the piston pin.
Outside diameter (piston pin):

14.978 14.992 mm
<Limit> 14.975 mm
Measure the piston inside diameter b .

Calculate the piston pin-to-piston clearance
using the following formula:
Piston pin-to-piston clearance =

Bore size (piston pin) b
Outside diameter (piston pin) a
If out of specification, replace the piston.
Clearance (piston pin-to-piston):

0.010 0.035 mm
***************************************
EB404184
PISTON RINGS, PISTON AND CYLINDER

INSTALLATION
1. Install:
Top ring 1
2nd ring 2
Side rails (oil ring) 3
Expander spacer (oil ring) 4
NOTE:
Make sure to install the piston rings so that the
manufacturers marks or numbers are located
on the upper side of the rings.
Lubricate the pistons and piston rings liberally
with engine oil.
4-24

2. Install:
Piston 1
Piston pin 2
Piston pin clip 3 New
NOTE:
Apply engine oil onto the piston pins.
The mark a on the piston must face the
exhaust side of the cylinder.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
Make sure to install each piston in its respec-
tive cylinder.
3. Install:
Gasket (cylinder) New
Dowel pins
4. Position:
Piston rings
NOTE:
Offset the piston ring end gaps as shown.
a Top ring end

b Oil ring end (lower)
c Oil ring end (upper)
d 2nd ring end
5. Lubricate:
Piston outer surface
Piston ring
Cylinder inner surface
Engine oil
6. Install:
Gasket (cylinder) 1 New
Cylinder 2
NOTE:
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
4-25

CLUTCH ENG
CLUTCH
CRANKCASE COVER (RIGHT)
45 Nm (4.5 mkg)
7 Nm (0.7 mkg)

Crankcase cover (right) removal Remove the parts in order.
Drain the engine oil Refer to ENGINE OIL REPLACEMENT
1 Nut 1
2 Foot rest (right) 1
3 Clutch cable 1
4 Crankcase cover (right) 1
5 Crankcase cover gasket (right) 1
6 Dowel pins 2
installation.
4-26

CLUTCH ENG
CLUTCH
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
12 Nm (1.2 mkg)
6 Nm (0.6 mkg)

Clutch removal Remove the parts in order.
Sprocket cover Refer to ENGINE REMOVAL section.
1 Clutch springs 4
2 Pressure plate 1 Refer to CLUTCH INSTALLATION
3 Friction plates 4 section.
4 Clutch plates 3
5 Nut/Lock washer 1/1 Refer to CLUTCH REMOVAL/
6 Clutch boss 1 INSTALLATION section.
7 Plate washer 1
8 Primary driven gear 1
Refer to CLUTCH INSTALLATION
9 Ball 1
section.
10 Push rod #2 1
11 Push lever screw/Gasket 1/1
4-27

CLUTCH ENG
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
12 Nm (1.2 mkg)
6 Nm (0.6 mkg)

12 Push lever axle 1 Refer to CLUTCH INSTALLATION sec-
13 Torsion spring 1 tion.
14 Circlip 1
15 Oil seal 1
16 Nut/Washer 1/1 Refer to CLUTCH INSTALLATION sec-
17 Push rod #1/O-ring 1/1 tion.
18 Push plate 1
installation.
4-28

CLUTCH ENG
SR401061
CLUTCH REMOVAL
1. Remove:
Nut 1 (clutch boss)
Lock washer 2
Clutch boss 3
Straighten the lock washer tab 2 .
NOTE:
Loosen the clutch boss nut 1 while holding the
clutch boss with a clutch holding tool 4 .
Clutch holding tool:

90890-04086
SR402181
CLUTCH INSPECTION
1. Inspect:
Friction plates
Damage/wear Replace the friction plates
as a set.
2. Measure:
Friction plate thickness
Out of specification Replace the friction
plates as a set.
Measure at four places.
Thickness (friction plate):

2.9 3.1 mm
<Limit: 2.7 mm>
3. Inspect:
Clutch plates
Damage Replace the clutch plates as a
set.
4. Measure:
Clutch plate warpage
Out of specification Replace the clutch
plates as a set.
Use a surface plate and a feeler gauge 1 .
Warp limit (clutch plate):

Less tan 0.05 mm
5. Inspect:
Clutch springs
Damage Replace the clutch springs as a
set.
4-29

CLUTCH ENG
6. Measure:
Free length (clutch spring) a
Out of specification Replace the clutch
springs as a set.
Free length (clutch spring):

34.5 mm
<Lilmit: 32.9 mm>
7. Inspect:
Dogs on the primary driven gear 1
Scoring/wear/damage Deburr or re-
place.
Clutch boss splines 2
Scoring/wear/damage Replace clutch
boss.
NOTE:
Scoring on the clutch housing dogs and the
clutch boss splines will cause erratic operation.
SR********
PUSH ROD INSPECTION

1. Inspect:
Push rod #1 1
Ball 2
Push rod #2 3
Wear/crack/damage Replace.
SR******
CLUTCH INSTALLATION
1. Install:
Push lever axle 1
Gasket 2 New
Screw 3 12 Nm (1.2 mkg)
2. Install:
Primary driven gear 1
Plate washer 2
Clutch boss 3
NOTE:
Tighten the nut (primary drive gear) while hold-
ing the rotor with the sheave holder 3 .
4-30

CLUTCH ENG
3. Install:
Lock washer 1 New
Nut 2 (clutch boss) 70 Nm (7.0 mkg)
NOTE:
Install the clutch boss nut 2 while holding the
clutch boss with a clutch holding tool 3 .
Clutch holding tool:

90890-04086
4. Bend:
Lock washer tab
(along a flat side of the end)
5. Install:
Friction plate 1
Clutch plate 2
NOTE:
Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a fric-
tion plate and ending with a friction plate.
Coat all clutch and friction plates with engine
oil before installation.
6. Install:
Push rod #2
Ball
7. Install:
Push rod #1 1
O-ring 2 New
Push plate 3
Plate washer 4
Nut 5 (push rod #1)
8. Install:
Pressure plate 1
Compression springs 2
Bolts 3 (clutch springs)
6 Nm (0.6 mkg)
NOTE:
Tighten the clutch spring bolts in stage, using a
crisscross pattern.
4-31

CLUTCH ENG
9. Check:
Push lever position
Push the push lever assembly in the arrow
direction and make sure that match marks
are be aligned Adjust.
a Match mark on the push lever assembly
b Match mark on the crankcase
10. Adjust:
Push lever position
***************************************
Adjustment steps:
Turn the adjuster 2 clockwise or counter-
clockwise to match alignment marks.
Hold the adjuster to prevent it from moving and
tighten the locknut to specification.
CAUTION:
Take care not to overtighten the adjuster 2
and to remove the free play between both
push rods.
Tighten the lock nut 1 .

8 Nm (0.8 mkg)
***************************************
4-32

OIL PUMP ENG
OIL PUMP
50 Nm (5.0 mkg)
7 Nm (0.7 mkg)

Oil pump removal Remove the parts in order.
Clutch Refer to CLUTCH section.
1 Nut 1
2 Lock washer 1 Refer to PRIMARY DRIVE GEAR
3 Primary drive gear 1 REMOVAL/INSTALLATION section.
4 Oil pump cover 1
5 Oil pump assembly 1 Refer to OIL PUMP REMOVAL/INSTAL-
LATION section
6 Gasket (oil pump cover) 1
installation.
4-33

OIL PUMP ENG
7 Nm (0.7 mkg)

Oil pump disassembly Disassemble the parts in order.
1 Oil pump housing 1
2 Dowel pin 1
3 Oil pump driven gear 1
4 Dowel pins 2
5 Inner rotor 1
6 Outer rotor 1
7 Housing 1
Reverse the disassembly procedure for
assembly.
4-34

OIL PUMP ENG
SR401070
PRIMARY DRIVE GEAR REMOVAL

NOTE:
Straighten the lock washer tab.
1. Remove:
Nut (primary drive gear) 1
Lock washer 2
Primary drive gear 3
NOTE:
Place a folded aluminium plate or copper wash-
er a between the teeth of the balancer drive
gear 4 and balancer driven gear 5 .
T402140
OIL PUMP INSPECTION

1. Measure:
Tip clearance A
(between the inner rotor 1 and the outer ro-
tor 2 )
Side clearance B
(between the outer rotor 2 and the pump
housing 3 )
Out of specification Replace the oil pump
assembly.
Housing and rotor clearance C
(between the pump housing 3 and the ro-
tors 1 , 2 .)
Out of specification Replace the oil pump
assembly.
Tip clearance A :
0.03 0.09 mm
<Limit: 0.14 mm>
Side clearance B :
0.10 0.15 mm
<Limit: 0.35 mm>
Housing and rotor clearance C :
0.03 0.09 mm
<Limit: 0.14 mm>
SR******
OIL DELIVERY PASSAGE INSPECTION (CR-

ANK CASE COVER (right))
1. Check:
Oil delivery passage
Blockage Blow by the compressed air.
4-35

OIL PUMP ENG
SR404010
OIL PUMP INSTALLATION

1. Lubricate:
Oil delivery passage (crankcase right)
Oil pump assembly
Recommended lubricant:
Engine oil
SR404140
PRIMARY DRIVE GEAR INSTALLATION

1. Install:
Primary drive gear 1
Lock washer 2 New
Nut (primary drive gear) 3
50 Nm (5.0 mkg)
NOTE:
Place a folded aluminium plate or copper
washer a between the teeth of the balancer
drive gear 4 and balancer driven gear 5 .
Bend the lock washer tab, after tighten the nut
flats.
4-36

BALANCER GEAR ENG
BALANCER GEAR
50 Nm (5.0 mkg)

Balancer gear removal Remove the parts in order.
Primary drive gear Refer to OIL PUMP section.
1 Nut/Lock washer 1/1 Refer to BALANCER DRIVEN GEAR
2 Balancer driven gear 1 REMOVAL/BALANCER GEAR
3 Woodruff key 1
4 Claw washer 1
5 Balancer drive gear 1
6 Buffer boss 1 Refer to BALANCER DRIVE GEAR
7 Compression spring 6 ASSEMBLY section.
8 Dowel pins 3
9 Woodruff key 1
10 Plate washer 1
installation.
4-37

BALANCER GEAR ENG
SR******
BALANCER DRIVEN GEAR REMOVAL

NOTE:
Straighten the lock washer tab.
1. Remove:
Nut (balancer driven gear) 1
Lock washer 2
Balancer driven gear 3
NOTE:
Place a folded aluminium plate or copper wash-
er a between the teeth of the balancer drive
gear 4 and balancer driven gear 3 .
SR******
DRIVE GEAR INSPECTION

1. Inspect:
Balancer drive gear 1
Buffer boss 2
Compression spring 3
Dowel pins 4
Wear/Pitting/Scratches Replace.
SR******
BALANCER DRIVE GEAR ASSEMBLY

1. Assembly:
Dowel pins 1
NOTE:
Install the dowel pins and compression springs
alternately as shown as.
2. Install:
Buffer boss 1
NOTE:
Align the punched mark a on the buffer boss
with the one on the balancer drive gear.
4-38

BALANCER GEAR ENG
SR******
BALANCER GEAR INSTALLATION

1. Install:
Balancer driven gear 1
NOTE:
Install the balancer driven gear, then mesh the
balancer driven gear match mark a and ba-
lancer drive gear assembly match mark b .
2. Install:
Lock washer 1 New
Nut (balancer drive gear) 2
50 Nm (5.0 mkg)
NOTE:
Place a folded aluminium plate or copper
washer a between the teeth of the balancer
drive gear 3 and balancer driven gear 4 .
Bend the lock washer tab, after tighten the nut
flats.
4-39

SHIFT SHAFT AND SEGMENT ENG
SHIFT SHAFT AND SEGMENT
12 Nm (1.2 mkg)

Shift shaft and segment removal Remove the parts in order.
Shift pedal Refer to ENGINE REMOVAL section.
1 Shift shaft 1
2 Plate washer 1
3 Torsion spring 1
4 Stopper lever 1 Refer to SHIFT SHAFT
5 Plate washer 1 REMOVAL/INSTALLATION section.
6 Circlip 1
7 Torsion spring 1
8 Collar 1
9 Tension spring 1
4-40

12 Nm (1.2 mkg)

10 Screw 1
11 Segment 1 Refer to SEGMENT INSTALLATION
12 Dowel pins (short length) 4 section.
13 Dowel pins (long length) 1
installation.
4-41

SR******
SHIFT SHAFT REMOVAL

1. Remove:
Shift shaft assembly 1
NOTE:
Push the shift lever arm 2 and the stopper lever
3 to the arrow direction and remove them from
the segment.
T402200
SHIFT SHAFT INSPECTION

1. Inspect:
Stopper lever
Roller turns roughly Replace.
Bends/damage Replace.
2. Inspect:
Torsion springs (stopper lever and shift arm)
3. Inspect:
Shift shaft assembly 1
Shift lever 2
Bends/wear/damage Replace.
SR******
SEGMENT INSTALLATION
1. Install:
Segment 1
Dowel pins 2 (short length)
Dowel pin 3 (long length)
NOTE:
Install the dowel pin 2 (long length) into the
hole beside the match mark a position.
4-42

2. Install:
Segment 1
NOTE:
Fit the dowel pin 2 (long length) on the seg-
ment to the locating hole a on the sift cam and
install the segment.
3. Tighten:
Screw 1 12 Nm (1.2 mkg)
SR******
SIFT SHAFT INSTALLATION

1. Install:
Shift shaft assembly
***************************************
Instaling steps:
Set the stopper lever and return spring to the
shift shaft.
Mesh the stopper lever 1 with the shift cam
segment.
Install the shift lever 2 to the shift cam seg-
ment.
After installing the shift shaft, check the shift
cam for smooth operation by turning the shift
shaft with your hand.
***************************************
2. Check:
Shift lever 1 position
Gaps a and b are not equal Replace the
defective parts.
4-43

CDI MAGNETO AND STARTER CLUTCH ENG
CDI MAGNETO AND STARTER CLUTCH

CRANKCASE COVER (LEFT)
7 Nm (0.7 mkg)

Crankcase cover (left) removal Remove the parts in order.
Side cover Refer to SIDE COVER, SEAT AND
FUEL TANK section in CHAPTER 3.
Drive sprocket cover
DCI magneto lead couplers Refer to ENGINE REMOVAL section.
1 Neutral switch lead connector 1
2 Crankcase cover (left) 1
3 Gasket 1
4 Dowel pins 2
installation.
4-44

PICKUP COIL AND STATOR COIL
3 Nm (0.3 mkg)
7 Nm (0.7 mkg)

Pickup coil and stator coil removal Remove the parts in order.
1 Clamp (stator coil) 1
2 Clamp (pickup coil) 1
3 Pickup coil 1
4 Stator coil 1
installation.
4-45

CDI MAGNETO AND STARTER CLUTCH
30 Nm (3.0 mkg)
50 Nm (5.0 mkg)

CDI magneto and starter clutch Remove the parts in order.
removal
1 CDI magneto 1 Refer to CDI MAGNETO
REMOVAL/INSTALLATION section.
2 Idle shaft/collar 1
3 Starter idle gear 1
4 Woodruff key 1
Starter wheel gear 1 Refer to CDI MAGNETO
5
Shim 1 INSTALLATION section.
6
7 Dowel pins (Inner) 3
8 Spring caps 3
Compression springs 3 Refer to STARTER CLUTCH
9
Dowel pins (outer) 3 INSTALLATION seciton.
10
11 Starter clutch 1
Remove the removal procedure tor
installation.
4-46

YP401081
C.D.I. MAGNETO REMOVAL

1. Remove:
Bolt 1 (magneto)
Plain washer 2
NOTE:
Loosen the bolt (magneto) 1 while holding
the rotor with a sheave holder 3 .
Do not allow the sheave holder to touch the
projection on the magneto.
Sheave holder:
90890-01701
2. Remove:
CDI magneto assembly 1
Woodruff key
NOTE:
Remove the magneto using sheave holder 2 ,
rotor puller 3 and rotor puller attachment 4 .
Rotor puller:
90890-01080
Rotor puller attachment:
90890-04052
SR402163
STARTER CLUTCH INSPECTION

1. Check:
Starter clutch operation
Push the dowel pins to the arrow direction.
Unsmooth operation Replace.
***************************************
Checking steps:
Hold the starter clutch.
When turning the starter wheel gear clockwise
a , the starter clutch and the starter wheel
gear should be engaged.
If not, the starter clutch is faulty. Replace it.
When turning the starter wheel gear counter-
clockwise b , it should turn freely.
If not, the starter clutch is faulty. Replace it.
***************************************
2. Inspect:
Dowel pins 1
Spring caps 3
Wear/Damage Replace.
4-47

3. Inspect:
Starter wheel gear
(contacting surface)
Pitting/Wear/Damage Replace.
SR******
STARTER CLUTCH INSTALLATION

1. Install:
Starter clutch assembly 1
30 Nm (3.0 mkg)
2. Unloosen the starter clutch assembly by us-

ing the center punch.
3. Install:
Spring caps 2
Dowel pins 3
YP404131
C.D.I. MAGNETO INSTALLATION

1. Install:
Shim 1
Starter wheel gear 2
Woodruff key 3
2. Install:
C.D.I. magneto assembly 1
NOTE:
Clean the tapered portion of the crankshaft
and the magneto hub.
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft and turning the stater
wheel gear 2 clockwise.
4-48

3. Tighten:
CDI magneto assembly 1
50 Nm (5.0 mkg)
NOTE:
Tighten the bolt while holding the CDI magneto
assembly with the sheave holder 2 .
Sheave holder:
90890-01701
4-49

CRANKCASE AND CRANK SHAFT ENG
CRANK CASE AND CRANKSHAFT

CRANKCASE
8 Nm (0.8 mkg)
7 Nm (0.7 mkg)

Crankcase separation Remove the parts in order.
Engine Refer to ENGINE REMOVAL section.
Cylinder and piston Refer to CYLINDER AND PISTON
section.
Primary drive gear/oil pump Refer to OIL PUMP section.
Balancer weight drive gear Refer to BALANCER DRIVE GEAR
section.
Shift shaft and segment Refer to SHIFT SHAFT AND
SEGMENT section.
CDI magneto/starter clutch Refer to CDI MAGNETO AND
STARTER CLUTCH section.
1 Timing chain guide (intake) 1
4-50

8 Nm (0.8 mkg)
7 Nm (0.7 mkg)

2 Timing chain 1
3 Crankcase 1 Refer to CRANKCASE
SEPARATION/INSTALLATION section.
4 Dowel pins 2
installation.
4-51

CRANKSHAFT AND BALANCER WEIGHT

Crankshaft and balancer weight Remove the parts in order.
removal
1 Balancer weight 1 Refer to BALANCER WEIGHT
2 Crankshaft assembly 1 INSTALLATION seciton.
3 Dowel pin 1
4 Plunger seal 1 Refer to PLUNGER SEAL
5 Compression spring 1 REMOVAL/INSTALLATION section.
6 Bearing (balancer weight) 1
7 Bearing (crankshaft right) 1
installation.
4-52

SR401132
CRANKCASE SEPARATION
1. Remove:
Crankcase screws
NOTE:
The numbers embossed on the crankcase in-
dicate the tightening sequence. Loosen the
screws in decreasing numerical order (see
numbers on the illustration).
Loosen each screw 1/4 turn at a time and re-
move them after all are loose.
2. Remove:
Right crankcase half
NOTE:
Set the left crankcase half under then put in the
flat head screw driver to the separating slit a .
CAUTION:
Do not use the flat head screw driver ex-
cept place as shown.
The left crankcase half should be under.
Separate the crankcase after first checking
that the shift cam segments and the drive
axle circlip can be removed.
Do not damage the crankcase mating sur-
faces.
SR******
PLUNGER SEAL REMOVAL

1. Remove:
Dowel pin 1
Plunger seal 2
NOTE:
Remove the plunger seal and compression
spring, push the plunger seal lightly and remove
the dowel pin.
4-53

T******
CRANKSHAFT INSPECTION
1. Measure:
Crankshaft runout
Out of specification Replace crankshaft
and/or bearing.
NOTE:
Measure the crankshaft runout with the crank-
shaft assembly turning slowly.
Runout limit:
0.03 mm
2. Measure:
Big end side clearance
Out of specification Replace big end bear-
ing, crank pin and/or connecting rod.
Big end side clearance:

0.35 0.65 mm
Limit
0.1 mm
3. Measure:
Crank width
Out of specification Replace crankshaft.
Crank width:
55.95 56.00 mm
4. Inspect:
Timing chain sprocket 1
Wear/Damage Replace crankshaft.
Bearing 2
Wear/Crack/Damage Replace crank-
shaft.
5. Inspect:
Crankshaft journal
Clogged Blow out the journal with com-
pressed air.
4-54

SR******
PLUNGER SEAL INSTALLATION

1. Install:
Plunger seal 2
Dowel pin 3
2. Check the plunger seal smooth operation
pushing the plunger seal by your finger.
T*****
BALANCER WEIGHT INSTALLATION

1. Install:
Crankshaft assembly 1
Balancer weight assembly 2
CAUTION:
Do not use the hammer forcefully during
installation of the crankshaft. Damage the
crankcase oil seal lip and gear teeth.
SR404073
CRANKCASE INSTALLATION
1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.
2. Apply:
Sealant
(onto the crankcase mating surfaces)
Yamaha bond No.1215:

90890-85505
NOTE:
DO NOT ALLOW any sealant to come in con-
tact with the oil gallery a .
3. Tighten:
Crankcase right half
7 Nm (0.7 mkg)
NOTE:
Tighten the screws in decreasing numerical or-
der (see numbers on the illustration).
4-55

TRANSMISSION SIFT CAM AND SHIFT FORK ENG
TRANSMISSION, SHIFT CAM AND SHIFT FORK

Transmission, shift cam and Remove the parts in order.
shift fork removal
Crankcase separating Refer to CRANKCASE AND
CRANKSHAFT section.
1 Shift fork guide bar 2 (short length) 1
2 Shift fork guide bar 1 (long length) 1
Refer to TRANSMISSION, SHIFT CAM
3 Shift cam 1
AND SHIFT FORK INSTALLATION
4 Shift fork 1 C (center) 1
section.
5 Shift fork 2 R (right) 1
6 Shift fork 3 L (left) 1
7 Main axle assembly 1
8 Plate washer 1 Refer to TRANSMISSION, SHIFT CAM
9 Drive axle assembly 1 AND SHIFT FORK REMOVAL/
10 Plate washer 1 INSTALLATION section.
installation.
4-56

DRIVE AXLE AND MAIN AXLE

Drive axle and main axle Disassemble the parts in order.
disassembly
1 Second wheel gear 1
2 First wheel gear 1
3 Fifth wheel gear 1
4 Circlip/washer 1/1
5 Third wheel gear 1
6 Forth wheel gear 1
7 Drive axle 1
8 Second pinion gear 1
9 Forth pinion gear 1
10 Third pinion gear 1
11 Circlip/washer 1/1
12 Fifth pinion gear gear 1
13 Main axle 1
assembly.
4-57

SR******
TRANSMISSION, SHIFT CAM AND SHIFT

FORK REMOVAL
1. Install:
O-Ring 1
To the drive sprocket groove.
2. Remove:
Drive axle assembly 1
Main axle assembly 2
Remove them at same the time.
T402190
SHIFT FORK SHIFT CAM INSPECTION

1. Inspect:
Shift fork cam follower 1
Shift fork pawl 2
Scoring/bends/wear/damage Replace.
2. Inspect:
Shift cam grooves
Wear/damage/scratches Replace.
Shift cam segment
Damage/wear Replace.
3. Inspect:
Shift fork 1 C (center) 1
Shift fork 2 R (right) 2
Shift fork 3 L (left) 3
Guide bar 4
Shift cam 5
Dowel pin 6
Roll the guide bar on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent guide
bar.
4-58

4. Check:
Shift fork movement
(on the guide bar)
Unsmooth operation Replace the shift
fork and the guide bar.
NOTE:
When damaged the shift fork and mission gear,
replace the facing each gear as set.
SR******
TRANSMISSION, SHIFT CAM AND SHIFT

FORK INSTALLATION
1. Measure:
Main axle assembled length a
Assembled length (main axle):

90.9 91.1 mm
2. Install:
O-ring 1
To the drive sprocket folder groove.
3. Install:
Shift fork 3 L (left) 1
(face the L side for the clutch side.)
Shift fork 2 R (right) 2
(face the R side for the clutch side.)
Shift fork 1 C (center) 3
(face the C side for the magneto side.)
Shift fork guide bar 1 4 (long)
Shift fork guide bar 2 5 (short)
NOTE:
Install the shift forks with the embossed mark to
the right and in sequence (R, C, L) beginning
from the right.
4. Check:
Shift cam operation
Unsmooth operation Repair.
NOTE:
Check the transmission and shift forks for
smooth operation by turning the shift cam with
your hand.
4-59

ENG

CHAPTER 5.
CARBURETION
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

CARBURETOR CARB
EB600000
CARBURETION
CARBURETOR

Carburetor removal Remove the parts in order.
Side cover Refer to SIDE COVER, SEAT AND
Seat FUEL TANK section in CHAPTER 3.
Fuel tank
Heater unit lead NOTE:
Disconnect the cable from wireharness.
1 Carburetor joint clamp screw 1 NOTE:

2 Air filter joint clamp screw 1 Loosen.
3 Carburetor assembly 1
4 Carburetor top 1
installation.
5-1

CARBURETOR CARB

Carburetor disassembly Disassemble the parts in order.
1 Throttle cable 1
2 Throttle valve assembly 1
3 Throttle valve spring 1
4 Mixing chamber top/O-ring 1/1
5 Drain screw assembly 1
6 Float chamber 1
7 Gasket (float chamber) 1
8 Float pin/float 1/1
9 Needle valve assembly 1 Refer to CARBURETOR ASSEMBLY
10 Main jet 1 section.
11 Main nozzle/O-ring 1/1
5-2

CARBURETOR CARB

12 Pilot screw assembly 1 Refer to CARBURETOR ASSEMBLY
13 Pilot jet 1 section.
14 Throttle stop screw assembly 1
15 Starter plunger assembly 1
16 Screw/gasket 1/1
17 Heater unit/washer 1/1
assembly.
5-3

CARBURETOR CARB
SR******
CARBURETOR ASSEMBLY
CAUTION:
Do not use a wire for cleaning.
Before assembling, wash all parts in clean
petroleum based solvent.
Always use a new gasket.
1. Install:
Pilot jet 1
Pilot screw assembly 2
Pilot screw (turn out):

2 turns out
2. Install:
O-ring New
Main nozzle 1
Main jet 2
3. Install:
Valve seat 1
Needle valve 2
4. Install:
Float 1
Float pin 2
5-4

CARBURETOR CARB
YP600060
FUEL LEVEL ADJUSTMENT

1. Measure:
Fuel level a
Fuel level:
2.5 3.5 mm below the
float chamber line
***************************************
Measurement and adjustment steps:
Place the motorcycle on a level surface.
Put a garage jack under the engine to ensure
that the carburetors are positioned vertically.
Connect the fuel level gauge 1 to the drain
pipe 2 .
Fuel level gauge:

90890-01312
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.
Remove the carburetor.
Inspect the valve seat and needle valve.
If either is worn, replace them both.
If both are fine, adjust float level by bending the
float tang 4 slightly.
Install the carburetor.
Recheck the fuel level.
***************************************
5-5

CARB

CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
FRONT WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 6-6
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
BRAKE CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN . . . . . . . . . . . . . . . . 6-20

REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
REAR WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
REAR BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
DRIVE CHAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
BRAKE SHOE PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
HANDLEBAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
STEERING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . 6-43

SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

FRONT WHEEL AND BRAKE DISC CHAS
EB700000
CHASSIS
FRONT WHEEL AND BRAKE DISC
20 Nm (2.0 mkg)
59 Nm (5.9 mkg)
23 Nm (2.3 mkg)

Front wheel and brake disc removal Remove the parts in order.
WARNING
Securely support the motorcycle so
1 Speedometer cable 1
2 Axle pinch bolt 1
NOTE:
3 Wheel axle 1 Loosen the axle pinch bolt.
4 Front wheel assembly 1
5 Collar 1 Refer to FRONT WHEEL
6 Meter gear unit assembly 1 INSTALLATION section.
7 Brake disc 1 Refer to FRONT WHEEL ASSEMBLY
section.
installation.
6-1


Front wheel disassembly Disassemble the parts in order.
1 Oil seal 1 Refer to FRONT WHEEL ASSEMBLY
section.
2 Bearing 1
3 Spacer 1 Refer to FRONT WHEEL
4 Spacer flange 1 DISASSEMBLY/ASSEMBLY section.
5 Bearing 1
reassembly.
6-2

T******
FRONT WHEEL DISASSEMBLY

1. Remove:
Bearings 1
Spacer
Remove the bearings using a general bear-
ing puller 2 .
CAUTION:
Handle the wheel with care not to damage
the brake disc. If the brake disc is damaged,
replace.
T700021
FRONT WHEEL INSPECTION

1. Inspect:
Front wheel axle
(by rolling it on a flat surface)
Bends Replace.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:

0.25 mm
2. Inspect:
Front tire
Refer to TIRE INSPECTION in CHAPTER
3.
Front wheel
Refer to WHEEL INSPECTION in CHAP-
TER 3.
3. Check:
Spokes
Loose spokes Retighten.
Turn the wheel and tap the spokes with a
screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
4. Tighten:
Loose spokes
Nipple
NOTE:
Check the front wheel runout after tightening
the spokes.
6-3

5. Measure:
Front wheel runout
Over the specified limits Replace.
Front wheel runout limits:

Radial 1 : 2.0 mm
Lateral 2 : 2.0 mm
6. Inspect:
Front wheel bearings
Bearings allow free play in the wheel hub or
the wheel does not turn smoothly
Replace.
Oil seals
7. Inspect:
Collar
Grooved wear Replace the collar and the
oil seal as a set.
YP******
BRAKE DISC INSPECTION

1. Measure:
Brake disc deflection
Maximum deflection:
0.15 mm

2. Measure:
Brake disc thickness
Brake disc thickness:

4.0 mm
Minimum thickness:
3.5 mm

YP******
FRONT WHEEL ASSEMBLY

1. Install:
Bearing 1
Spacer 2
Spacer flange 3
Bearing 4
Oil seal 5
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diame-
ter of the race of the bearing.
Always use a new oil seal.
Install the oil seal with its manufacturers
marks or numbers facing outward.
6-4

CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
2. Install:
Brake disc 1 23 Nm (2.3 mkg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
SR700030
FRONT WHEEL INSTALLATION

Reverse the REMOVAL procedure.
Note the following points.
1. Lubricate:
Front wheel axle
Bearings
Oil seal (lips)
Drive/driven gear (speedometer)
Recommended lubricant:
Lithium soap base grease
2. Install:
Speedometer gear unit 1
NOTE:
Make sure that the wheel hub and the
speedometer gear unit are installed with the two
projections a meshed into the two slots b .
3. Install:
Front wheel
NOTE:
Make sure that the slot a in the speedometer
gear unit fits over the stopper b on the front fork
outer tube.
6-5

4. Tighten:
: Front wheel axle 59 Nm (5.9 m:kg)
: Axle pinch bolt 20 Nm (2.0 m:kg)
CAUTION:
Before tightening the wheel axle, stroke the
front fork several times to check for proper
fork operation.
WARNING
Make sure that the brake hose is routed
properly.
YP700040
WHEEL STATIC BALANCE ADJUSTMENT

NOTE:
: After replacing the fire and/or rim, the wheel
static balance should be adjusted.
: Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
: Balancing weight 1
2. Set:
: Wheel
(on a suitable stand)
3. Find:
: Heavy spot
***************************************
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an X1 mark on the wheels bottom spot.
c. Turn the wheel so that the X1 mark is 90_
up.
d. Release the wheel and wait for it to rest.
Put an X2 mark on the wheels bottom spot.
e. Repeat the above b., c., and d. several times
until all marks come to the same spot.
f. This spot is the wheels heavy spot X.
***************************************
6-6

4. Adjust:
: Wheel static balance
***************************************
Adjusting steps:
: Install a balancing weight 1 on the rim exactly
opposite to the heavy spot X.
NOTE:
Start with the smallest weight.
: Turn the wheel so that the heavy spot is 90_

up.
: Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
***************************************
5. Check:
: Wheel static balance
***************************************
Checking steps:
: Turn the wheel so that it comes to each point
as shown.
: Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
***************************************
6-7

FRONT BRAKE CHAS
FRONT BRAKE
BRAKE PAD
23 Nm (2.3 mkg)

Brake pad removal Remove the parts in order.
1 Bolt (caliper support bolt) 1
Refer to BRAKE PAD REPLACEMENT
2 Brake pads 2
section.
3 Pad support 1
installation.
6-8

FRONT BRAKE CHAS
SR702010
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake cal-
iper and brake hose to replace the brake pads.
1. Remove:
Bolt (caliper support bolt) 1
Move the direction brake caliper 2 to the ar-
row mark.
2. Remove:
Brake pads 1
NOTE:
Install new brake pad springs 2 when the
brake pads have to be replaced.
Replace the brake pads as a set if either is
found to be worn to the wear limit.
3. Push the caliper piston into the brake caliper

by finger.
CAUTION:
When pushing the caliper piston into the
brake caliper, brake fluid level in reservoir
tank is increasing higher.
4. Install:
Brake pad 1
Install the brake pad, and move the brake
caliper to the allow mark direction.
5. Install:
Bolt (caliper support bolt)
23 Nm (2.3 mkg)
6. Inspect:
Brake fluid level
TION section in CHAPTER 3.
7. Check:
Brake lever operation
Soft spongy feeling Bleed the brake sys-
tem.
Refer to AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM) in CHAPTER 3.
6-9

FRONT BRAKE CHAS
MASTER CYLINDER
2 Nm (0.2 mkg)
9 Nm (0.9 mkg)
30 Nm (3.0 mkg)

Master cylinder removal Remove the parts in order.
Drain the brake fluid
1 Rear view mirror (right) 1
2 Brake lever/compression spring 1/1
3 Brake switch 1
4 Union bolt 1
5 Plate washer 2
6 Brake hose 1 Refer to MASTER CYLINDER
7 Bracket (master cylinder) 1 INSTALLATION section.
8 Master cylinder 1
installation.
6-10

FRONT BRAKE CHAS

Master cylinder disassembly Disassemble the parts in order.
1 Rubber boots
2 Circlip 1 Refer to MASTER CYLINDER
3 Master cylinder kit 1 ASSEMBLY section.
4 Spring 1
reassembly.
6-11

FRONT BRAKE CHAS
YP702040
MASTER CYLINDER INSPECTION

1. Inspect:
Master cylinder piston 1
Wear/scratches Replace the master cyl-
inder kit.
Master cylinder cup 2
Cracks/damage Replace.
2. Inspect:
Master cylinder
Scratches/wear/damage Replace the
master cylinder assembly.
3. Inspect:
Diaphragm
YP******
MASTER CYLINDER ASSEMBLY

WARNING
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT #4 or DOT #3
Replace the piston seals and dust seals

whenever a master cylinder is disas-
sembled.
1. Install:
Spring 1
Install the spring with its smaller diameter to
the master cylinder piston.
Master cylinder kit 2
6-12

FRONT BRAKE CHAS
2. Install:
Circlip 1 New
Install the circlip securely into the master cyl-
inder groove.
Rubber boot 2
YP******
MASTER CYLINDER INSTALLATION

1. Install:
Master cylinder 1
Master cylinder bracket 2
9 Nm (0.9 mkg)
CAUTION:
Install the master cylinder bracket 2 with
the UP mark facing upward.
2. Install:
Plain washer 1 New
Brake hose 2
Plain washer 3 New
Union bolt 4 30 Nm (3.0 mkg)
A NOTE:
Install the brake hose as shown.
3. Fill:
Reservoir tank

DOT #4 or DOT #3
CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.
6-13

FRONT BRAKE CHAS
WARNING
Use only designated quality brake fluid:
Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid:mix-
ing fluids may result in a harmful chemical
reaction and lead to poor performance.
Be careful that water does not enter the sig-
nificantly lower the boiling point of the
fluid may result in vapor lock.
4. Air bleed:
Brake system
Refer to AIR BLEEDING section in CHAP-
TER 3.
5. Inspect:
Brake fluid level
Brake fluid level is under the LOWER level
line Fill up.
Refer to BRAKE FLUID INSPECTION
6-14

FRONT BRAKE CHAS
CALIPER
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)

Caliper removal Remove the parts in order.
Drain teh brake fluid
1 Brake hose holder 1
2 Union bolt 1
3 Plain washer 1
4 Brake hose 1 Refer to CALIPER INSTALLATION
5 Caliper support bolt 1 section.
6 Caliper assembly 1
installation
6-15

FRONT BRAKE CHAS
6 Nm (0.6 mkg)

Caliper disassembly Disassemble the parts i order.
Brake pad Refer to BRAKE PAD section.
1 Caliper piston 2
2 Dust seal 2 Refer to BRAKE CALIPER
3 Piston seal 2 DISASSEMBLY/ASSEMBLY section.
4 Bleed screw/Cap 1
reassembly.
6-16

FRONT BRAKE CHAS
SR******
BRAKE CALIPER DISASSEMBLY

NOTE:
Before disassembling either brake caliper,
drain the brake fluid from the brake hose, mas-
ter cylinder, brake caliper and reservoir tank.
1. Remove:
Brake caliper pistons
Caliper piston seals/dust seals
***************************************
Removal steps:
Use a piece of wood 1 to secure the smaller
side caliper pistons.
To force out the bigger side caliper pistons
from the brake caliper body blow compressed
air into the hose joint opening a .
Remove the caliper piston seals and reinstall
the bigger side caliper pistons.
Repeat the previous steps to force out the
smaller side caliper pistons from the brake cal-
iper body.
WARNING
Never try to pry out the caliper piston.
***************************************
YP******
CALIPER INSPECTION
1. Inspect:
Caliper cylinder 1
Caliper piston 2
Scratches, wear Replace caliper assem-
bly.
EB702050
BRAKE CALIPER ASSEMBLY

WARNING
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT #4 or DOT #3
Replace the caliper piston seals whenever

a brake caliper is disassembled.
6-17

FRONT BRAKE CHAS
1. Install:
Piston seals 1 New
Dust seal 2 New
WARNING
Always use new caliper piston seals.
2. Install:
Caliper piston 1
Apply brake fluid to the outer surface and
install.
YP******
CALIPER INSTALLATION
1. Install:
Caliper 1 40 Nm (4.0 mkg)
Caliper support bolt 2

23 Nm (2.3 mkg)
Brake hose 3
Plain washer 4 New
Union bolt 5
30 Nm (3.0 mkg)
CAUTION:
When installing the brake hose to the cali-
per, lightly touch the brake hose with the
stopper a on the caliper.
2. Fill:
Reservoir tank

DOT #4 or DOT #3
CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.
6-18

FRONT BRAKE CHAS
WARNING
Use only the designated quality brake
fluid: other brake fluids may deteriorate the
rubber seals, causing leakage and poor
brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful
chemical reaction and lead to poor brake
performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3. Air bleed:
Brake system
Refer to AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM) in CHAPTER 3.
4. Inspect:
Brake fluid level
Brake fluid level is under the LOWER level
line Fill up.
TION in CHAPTER 3.
6-19

REAR WHEEL, REAR BRAKE AND DRIVE CHAIN CHAS
REAR WHEEL, REAR BRAKE AND DRIVE CHAIN

REAR WHEEL AND REAR BRAKE
40 Nm (4.0 mkg)
65 Nm (6.5 mkg)
20 Nm (2.0 mkg)

Rear wheel and rear brake removal Remove the parts in order.
1 Adjuster 1
2 Brake rod 1
3 Pin 1
4 Compression spring 1
5 Cotter pin 1
6 Tension bar 1
NOTE:
7 Chain case 1 Bend the end after installing.
8 Axle nut 1
9 Chain puller 2
10 Wheel axle 1
11 Collar 1
6-20

REAR WHEEL REAR BRAKE AND DRIVE CHAIN CHAS
40 Nm (4.0 mkg)
65 Nm (6.5 mkg)
20 Nm (2.0 mkg)

12 Rear wheel assembly 1
13 Collar 1
14 Shoe plate 1
15 Nut (driven sprocket) 4
16 Circlip 1 Refer to REAR WHEEL ASSEMBLY
17 Washer 1 section.
18 Driven sprocket 1
installation.
6-21


Rear wheel disassembly Disassemble the parts in order.
1 Bearing 1
2 Collar 1
3 Spacer 1 Refer to REAR WHEEL
4 Oil seal 1 DISASSEMBLY/ASSEMBLY section.
5 Bearing 1
reassembly.
6-22

9 Nm (0.9 mkg)

Brake shoe plate disassembly Disassemble the parts in order.
1 Brake shoe kit 2
2 Tension springs 2
3 Cam lever 1 Refer to BRAKE SHOE PLATE
4 Indicator plate 1 ASSEMBLY section.
5 Camshaft 1
reassembly.
6-23

DRIVE CHAIN
65 Nm (6.5 mkg)
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)
8 Nm (0.8 mkg)

Drive chain removal Remove the parts in order.
Chain case Refer to REAR WHEEL, REAR BRAKE
AND DRIVE CHAIN section.
NOTE:
1 Axle nut 1 Loosen the axle nut and slacken the
drive chain.
2 Shift pedal 1
3 Sprocket cover 1
4 Sprocket holder 1
5 Clip 1
6 Plate 1 Refer to DRIVE CHAIN INSTALLATION
7 Chain joint 1 section.
8 Drive chain 1
9 Drive sprocket 1
installation.
6-24

T******
REAR WHEEL DISASSEMBLY

1. Remove:
Bearings 1
Spacer 2
Collar 3
Refer to FRONT WHEEL.
SR701020
REAR WHEEL INSPECTION

1. Inspect:
Rear wheel axle
Rear wheel
Rear wheel bearings
Oil seals
Refer to FRONT WHEEL.
2. Inspect:
Clutch hub damper
SR701021
REAR BRAKE INSPECTION

1. Inspect:
Brake lining surface
2. Measure:
Brake lining thickness a
Brake lining thickness:

Standard:
4 mm
Limit:
2 mm
WARNING
When inspecting the brake lining, do not
spill oil or grease on the brake lining.
3. Inspect:
Brake drum inner surface
Oil
Scratches
4. Measure:
Brake drum inside diameter a
Brake drum inside diameter:

Standard:
110 mm
Limit:
111 mm
6-25

5. Inspect:
Cam shaft face
T701020
DRIVE CHAIN INSPECTION

1. Inspect:
Drive chain stiffness
Stiffness Clean and lubricate or replace.
2. Inspect:
Drive chain 1
Driven sprocket 2
More than 1/2 tooth a wear Replace the
drive chain.
Use new driven sprocket.
3. Measure:
10 link length a (drive chain)
Out of specification Replace the drive
chain.
10 link length limit:

122 mm
NOTE:
Tighten the drive chain with a finger before
measuring.
10 link length is the distance between the
inside edge of roller 1 and 11 as shown.
10 link length measurement should be done at
two or three different places.
6-26

4. Clean:
Drive chain
Put it in kerosene, and brush off as much dirt
as possible. Then remove the drive chain
from the kerosene and dry it.
Drive chain lubricant:

Engine oil
SR******
BRAKE SHOE PLATE ASSEMBLY

1. Install:
Camshaft 1
Indicator plate 2
***************************************
Installation steps:
Align the projection a on the indicator plate
with the camshaft notch b and install.
Check the proper position of the brake shoe.
***************************************
2. Install:
Cam lever 1 9 Nm (0.9 mkg)
NOTE:
Align the punch mark c on the cam shaft with
the mark made on the cam lever d .
Apply lithium soap base grease onto the brake
cam shaft and pin.
3. Install:
Brake shoes 1
Tension springs 2 New
NOTE:
When installing the springs and brake shoes,
take care not to damage the springs.
Replace the tension spring as a set when re-
place the brake shoes.
WARNING
After installing the rear brake cam shaft, re-
move the excess grease.
6-27

SR******
REAR WHEEL ASSEMBLY

1. Install:
Bearing 1
Spacer 2
Collar 3
Bearing 4
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diame-
ter of the race of the bearing.
Always use a new oil seal.
Install the oil seal with its manufacturers
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
2. Install:
Driven sprocket 1
Washer 2
Circlip 3 New
Nut 4 40 Nm (4.0 mkg)
T*****
DRIVE CHAIN INSTALLATION

1. Install:
Drive chain 1
Chain joint 2
Plate 3
2. Install:
Clip 1 New
CAUTION:
Be sure to install the chain joint clip to the
direction as shown.
6-28

FRONT FORK CHAS
FRONT FORK
48 Nm (4.8 mkg)
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)

Front fork removal Remove the parts in order.
Front wheel Refer to FRONT WHEEL AND BRAKE
DISC section.
1 Brake hose holder 1
2 Caliper 1
3 Front fender 1
4 Cover 1
5 Bolt/washer 1/1
6 Bolt (under bracket) 1 Refer to FRONT FORK INSTALLATION
section.
NOTE:
7 Front fork assembly (left) 1 Loosen the bolt.
8 Front fork assembly (right) 1
installation.
6-29

FRONT FORK CHAS
65 Nm (86.5 mkg)

Front fork disassembly Disassemble the parts in order.
1 Cap bolt/O-ring 1/1
2 Collar/washer 1/1
NOTE:
3 Fork spring 1
4 Dust cover 1 Drain the fork oil.
5 Retaining clip 1
6 Washer (oil seal) 1 Refer to FRONT FORK
7 Inner tube assembly 1 DISASSEMBLY/ASSEMBLY section.
8 Oil seal 1
9 Piston metal 1 Refer to FRONT FORK ASSEMBLY
10 Damper rod 1 section.
11 Outer tube 1
assembly.
6-30

FRONT FORK CHAS
SR******
FRONT FORK DISASSEMBLY

1. Remove:
Cap bolt 1
Collar 2
Washer 3
Fork spring 4
2. Remove:
Dust cover 1
Retaining clip 2
(using a slotted-head screwdriver)
Washer (oil seal) 3
CAUTION:
Take care not to scratch the inner tube.
3. Remove:
Inner tube
***************************************
Removal steps:
Hold the fork leg horizontally.
Securely clamp the outer tube in a vise with
soft jaws.
Separate the inner tube from the outer tube by
pulling forcefully but carefully the inner tube.
CAUTION:
Excessive force will damage the oil seal
and/or the metal. damaged oil seal and met-
al must be replaced.
***************************************
YP703030
FRONT FORK INSPECTION

1. Inspect:
Inner tube bending
Inner tube bending limit:

0.2 mm
Scratches/bends/damage Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
6-31

FRONT FORK CHAS
2. Measure:
Fork spring a
Front fork spring free length:

326.1 mm
<Wear limit>
321 mm
Over the specified limit Replace.
3. Inspect:
Rod assembly 1
CAUTION:
The front fork has a built-in piston rod and
a very sophisticated internal construction
which are particularly sensitive to foreign
material.
When disassembling and assembling the
front fork do not allow any foreign material
to enter the oil.
SR******
FRONT FORK ASSEMBLY

Reverse the DISASSEMBLY procedure.
NOTE:
When assembling the front fork be sure to re-
place the following parts.
* Piston metal
* Slide metal
* Oil seal
* Dust seal
Before assembling the fork, make sure that all
of the components are clean.
1. Install:
Damper rod 1
Inner tube 2
NOTE:
Install the damper rod into the inner tube before
install to the outer tube.
6-32

FRONT FORK CHAS
2. Install:
Piston metal 1 New
Oil seal 2 New
Use the fork seal driver weight 3 and the at-
tachment 4 .
NOTE:
Before installing the oil seal 2 , apply lithium
soap base grease onto the oil seal lips.
CAUTION:
Make sure that the oil seal numbered side
faces upward.
Fork seal driver weight:

90890-01400
Attachment:
90890-01367
3. Install:
Washer (oil seal) 1
Retaining clip 2 New
Dust seal 3
NOTE:
Adjust the retaining clip so that it fits into the out-
er tube groove.
4. Inspect:
Inner tube operation
Unsmooth operation Disassembly and re-
check.
5. Fill:
Fork oil 1
Oil quantity:
0.177 L
Recommended oil:
Fork oil 15WT or equivalent
6. After filling up, slowly pump the fork up and

down to distribute the fork oil.
6-33

FRONT FORK CHAS
7. Measure:
Oil level a
Oil level:
165 mm
(from the top of the inner tube
fully compressed and without
the fork spring)
NOTE:
Hold the fork in an upright position.
8. Install:
Front fork spring 1
NOTE:
Install the fork spring with its smaller pitch up-
ward.
Before installing the cap bolt, apply grease to
the O-ring.
Temporarily tighten the cap bolt.
9. Install:
Plate washer
Spacer
O-ring New
Cap bolt 65 Nm (6.5 mkg)
EB70307250
FRONT FORK INSTALLATION

1. Install:
Front fork 1
Plate washer 2
Temporary tighten the pinch bolts.
NOTE:
Pull up the inner tube until its end flushes the top
of the under bracket, then temporarily tighten
the bolt (under bracket lower).
2. Tighten:
Cap bolts 3 48 Nm (4.8 mkg)
Pinch bolts (under bracket)

30 Nm (3.0 mkg)
6-34

HANDLEBAR CHAS
HANDLEBAR
9 Nm (0.9 mkg)
20 Nm (2.0 mkg)

Handlebar removal Remove the parts in order.
1 Headlight assembly 1
NOTE:
2 Handlebar switch lead (left and right), 1
front brake switch lead and clutch Disconnect the connector.
switch lead
3 Master cylinder bracket 1
4 Master cylinder 1
5 Housing (throttle grip) 1 Refer to HANDLEBAR INSTALLATION
6 Throttle cable 1 section.
7 Throttle grip assembly 1
8 Handle bar switch (right) 1
9 Clutch switch 1
10 Clutch cable 1
6-35

HANDLEBAR CHAS
9 Nm (0.9 mkg)
20 Nm (2.0 mkg)

11 Handlebar switch (left) 1
12 Grip (left) 1 Refer to HANDLEBAR REMOVAL
section.
13 Lever holder (left) 1
14 Upper holder 2 Refer to HANDLEBAR INSTALLATION
15 Handlebar 1 section.
installation.
6-36

HANDLEBAR CHAS
YP******
HANDLEBAR REMOVAL
1. Remove:
Grip (Left)
***************************************
Removal steps:
Remove the grip end (left).
Blow with compressed air between the hadle-
bar and adhesive side of the grip to remove.
***************************************
YP704020
HANDLEBAR INSPECTION
1. Inspect:
Handlebar
Bends/Cracks/Damage Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
SR******
HANDLEBAR INSTALLATION
1. Install:
Handlebar 1
Upper handlebar holder 2
20 Nm (2.0 mkg)
NOTE:
Apply a light coat of lithium soap base grease
onto the handlebar right end.
The upper handlebar holders should be
installed with the longer side a to the forward,
then tighten the front bolt as shown.
2. Install:
Handlebar switch (right) 1
Grip assembly
Throttle cable
Cover (throttle grip)
NOTE:
Align the projection a on the handlebar switch
with the hole b in the handlebar.
WARNING
Check the throttle grip for smooth opera-
tion.
6-37

HANDLEBAR CHAS
3. Install:
Master cylinder 1
Master cylinder bracket 2
9 Nm (0.9 mkg)
NOTE:
Install the master cylinder bracket with the UP
mark facing upward.
4. Adjust:
Brake operation.
Refer to THROTTLE CABLE ADJUST-
MENT/BRAKE LEVER ADJUSTMENT
6-38

STEERING CHAS
STEERING
UNDER BRACKET
40 Nm (4.0 mkg)
1st step:
38 Nm (3.8 mkg)
2nd step:
7 Nm (0.7 mkg)

Under bracket removal Remove the parts in order.
Front fork Refer to FRONT FORK section.
Handlebar Refer to HANDLEBAR section.
1 Flasher light assembly (left) 1
2 Flasher light assembly (right) 1
3 Cover 1
NOTE:
4 Meter cable/Meter lead 1/1
5 Meter assembly/Handlebar crown 1/1 Disconnect the connector.
6 Horn 1
7 Ring nut 1 Refer to STEERING
REMOVAL/INSTALLATION section.
8 Ball race cover 1
9 Under bracket 1
6-39

STEERING CHAS
40 Nm (4.0 mkg)
1st step:
38 Nm (3.8 mkg)2nd
step:
7 Nm (0.7 mkg)

10 Ball race (upper) 1
11 Ball 22
Refer to STEERING REMOVAL/
12 Ball 19
13 Ball race (center) 1
14 Ball race (lower) 1
installation.
6-40

STEERING CHAS
YP704010
STEERING REMOVAL
WARNING
Stand the motorcycle on a level surface.
1. Remove:
Ring nut 1
Use a exhaust and steering nut wrench 2 .
Exhaust and steering out wrench:

90890-01268
WARNING
Securely support the steering shaft so that
there is no danger of it falling down.
STEERING INSPECTION
1. Wash the bearing and ball races with a sol-
vent.
2. Inspect:
Bearings
Ball races
Pitting/Damage Replace.
***************************************
Bearing race replacement steps:
Remove the ball races on the head pipe using
long rod 1 and the hammer as shown.
Remove the ball race on the under bracket us-
ing the floor chisel 2 and the hammer as
shown.
Install the new dust seat and races.
***************************************
NOTE:
Always replace bearings and races as a set.
Replace the dust seal whenever a steering
head disassembled.
CAUTION:
If the bearing race is not fitted squarely, the
head pipe could be damaged.
6-41

STEERING CHAS
EB704030
STEERING INSTALLATION
1. Lubricate:
Bearings (upper and lower)
Ball races
Recommended lubricant
Lithium-soap base grease
2. Install:
Ring nut 1 7 Nm (0.7 mkg)
Refer to STEERING HEAD INSPECTION

6-42

REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM
40 Nm (4.0 mkg)
45 Nm (4.5 mkg)
20 Nm (2.0 mkg)
30 Nm (3.0 mkg)

Rear shock absorber and swingarm Remove the parts in order.
removal
Rear wheel
Chain case Refer to REAR WHEEL, REAR BRAKE
Drive chain AND DRIVE CHAIN section.
1 Rear shock absorber 2
2 Nut 1
3 Footrest assembly (right) 1
4 Pivot shaft 1
5 Footrest assembly (left) 1
6 Swingarm 1
7 Tension bar 1
8 Cover (swingarm) 1
9 Bush 2
installation.
6-43

REAR SHOCK ABSORBER AND SWINGARM CHAS
T*****
SWINGARM INSPECTION
1. Inspect:
Swingarm side play
Free play exists Check side clearance.
Swingarm up and down movement
Unsmooth movement/bending/rough spots
Grease or replace bearings, solid bushes
and collars.
6-44

CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

INSPECTION STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
SWITCH CONNECTION AS SHOWN IN THIS MANUAL . . . . . . . . . 7-2
SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

ELECTRICAL COMPONENTS ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Horn 8 Neutral relay 15 C.D.I. unit
2 Flasher relay 9 Thermo switch
3 Main switch 10 Sidestand switch
4 Starter relay 11 Rear brake switch
5 Rectifier/ Regulator 12 Neutral switch
6 Battery 13 Spark plug cap
7 Fuse holder assembly 14 Ignition coil
7-1

SWITCH INSPECTION ELEC
YP-N
SWITCH INSPECTION
INSPECTION STEPS
Using pocket tester, check switches for continu-
ity between their terminals to determine wheth-
er they are correctly connected.
Replace the switch component if any of the
combinations does not produce the correct
reading.
Pocket tester:
90890-03112
NOTE:
Turn the switch to the ON, OFF positions
several times.
Adjust the pocket tester to correct 0 position
before checking switches.
Set the pocket tester selector to 1 .
SWITCH CONNECTION AS SHOWN IN THIS

MANUAL
This manual contains connection charts, like
the one shown on the left, showing the terminal
connections of switches (e.g. the main switch,
handlebar switch, brake switch, lighting switch
etc.)
The column on the extreme left indicates the dif-

ferent switch positions, the top line indicates the
colors of the leads connected to the terminals
on the switch.
indicates terminals between which

there is continuity, i.e. a closed circuit, in the giv-
en switch position.
In this chart:
Br and R have continuity with the switch in the
ON position.
7-2

SWITCH INSPECTION ELEC
SWITCH CONTINUITY INSPECTION
Refer to SWITCH INSPECTION and check for continuity between lead terminals.
Poor connection, no continuity Correct or replace.
* The coupler locations are circled.
1 Clutch switch 7 Engine stop switch 13 Thermo switch

2 Turn switch 8 Start switch
3 Dimmer switch 9 Rear brake switch
4 Horn switch 10 Neutral switch
5 Main switch 11 Sidestand switch
6 Front brake switch 12 Fuse
7-3

IGNITION SYSTEM ELEC
EB802000
IGNITION SYSTEM
CIRCUIT DIAGRAM
1 C.D.I. magneto
6 Main switch
10 Engine stop switch
12 C.D.I. unit
13 Ignition coil
14 Spark plug
15 Sidestand switch
7-4

SR802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE.

(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check:
1. Spark plug 6. Source coil resistance
2. Ignition spark gap 7. Main switch
3. Spark plug cap resistance 8. Engine stop switch
4. Ignition coil 9. Sidestand switch
5. Pickup coil resistance 10. Wiring connection
(entire ignition system)
NOTE:
Remove the following parts before trouble- Use the special tools specified in the trouble
shooting. shooting section.
1) Side cover (left and right)
2) Seat Ignition checker:
3) Fuel tank 90890-06754
4) Headlight unit Pocket tester:
90890-03112
YP*****
1. Spark plug Standard spark plug:

DR8EA/NGK
Check the spark plug condition.
Check the spark plug type.
Check the spark plug gap.
Refer to SPARK PLUG INSPECTION sec- OUT OF SPECIFICATION
tion in CHAPTER 3.
Spark plug gap:
0.6 0.7 mm
MEETS Repair or replace the spark plug

SPECIFICATION
7-5

:
YP*****
2. Ignition spark gap

S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker 1 as shown.
2 Spark plug cap
S Turn the main switch to ON.
S Check the ignition spark gap a .
S Check the spark by pushing the starter
switch, and increase the spark gap until a
misfire occurs. MEETS SPECIFICATION
Minimum spark gap:
6 mm
OUT OF SPECIFICA- The ignition system is not faulty.

TION OR NO SPARK
YP*****
3. Spark plug cap resistance Tester (+) lead

Spark plug side 1
S Remove the spark plug cap.
Tester () lead
S Connect the pocket tester ( 1k) to the
High tension cord side 2
spark plug cap.
NOTE:
S When removing the spark plug cap, do not
pull the spark plug cap from high tension
cord.
Remove Turning counterclockwise.
Connect Turning clockwise.
S Check the high tension cord when connect-
ing the spark plug cap.
S When connecting the spark plug cap, cut the
high tension cord about 5 mm.
OUT OF SPECIFICATION
Spark plug cap resistance:

10 k (20_C)
MEETS Replace the spark plug cap.

SPECIFICATION
7-6

:
YP*****
4. Ignition coil resistance Tester (+) lead

Orange Terminal 1
S Disconnect the ignition coil connector from Tester () lead
the wireharness. Ground Terminal 2
S Connect the pocket tester ( 1) to the
ignition coil.
S Check if the primary coil has the specified re-
sistance.
Primary coil resistance:
0.32 X 0.48 (20_C)
Tester (+) lead

Spark plug lead 1
Tester () lead
Orange Terminal 2
S Connect the pocket tester ( 1k) to the

ignition coil.
S Check the secondary has the specified re-
sistance.
Secondary coil resistance:
5.68 X 8.52 k (20_C)
BOTH MEET Replace the ignition coil.

SPECIFICATION
7-7

:
YP******
5. Pickup coil resistance

S Disconnect the pickup coil coupler from the
wireharness.
pickup coil coupler.
Tester (+) lead
White Terminal 1
Tester () lead
Red Terminal 2
S Check the pickup coil has the specified re-

sistance. OUT OF SPECIFICATION
Pickup coil resistance:
659 X 984 (20_C)
Replace the pickup coil.
MEETS
SPECIFICATION
T******
6. Source coil resistance

S Disconnect the source coil coupler from the
wireharness.
charging coil coupler.
Tester (+) lead
Brown Terminal 1
Tester () lead
Green Terminal 2
S Check the source coil has the specified re-

sistance. OUT OF SPECIFICATION
Source coil resistance:
624 X 936 (20_C)
MEETS Replace the source coil.
SPECIFICATION
YP*****
NO CONTINUITY
7. Main switch
Refer to SWITCH INSPECTION section.
CONTINUITY Replace the main switch.
7-8

:
YP*****
NO CONTINUITY
8. Engine stop switch
CONTINUITY Replace the handlebar switch (right).

YP*****
NO CONTINUITY
9. Sidestand switch
CONTINUITY Replace the sidestand switch

YP*****
10.Wiring connection
S Check the connection of the entire ignition POOR CONNECTIONS
system.
Refer to CIRCUIT DIAGRAM.
CORRECT Correct.
Replace the C.D.I. unit.
7-9

ELECTRIC STARTING SYSTEM ELEC
EB80300
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
3 Starter relay
4 Battery
5 Fuse
6 Main switch
11 Start switch
15 Clutch switch
16 Sidestand switch
17 Neutral relay
24 Neutral switch
38 Starter motor
7-10

ELECTRICAL STARTING SYSTEM ELEC
SR******
STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the
starter motor, starter relay, and the neutral relay.
If the engine stop switch and the main switch
are both closed, the starter motor can operate
only if:
The transmission is in neutral (the neutral

relay is closed).
or if
The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the side-
stand is up (the sidestand switch is closed).
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND

THE CLUTCH LEVER IS PULLED
IN
1 Battery
2 Main fuse
3 Main switch
5 Neutral relay
6 Clutch switch
7 Sidestand switch
8 Neutral switch
9 Start switch
10 Starter relay
11 Starter motor
7-11

YP803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE.

Procedure
Check:
1. Fuse 7. Engine stop switch
2. Battery 8. Neutral switch
3. Starter motor 9. Sidestand switch
4. Starter relay 10. Clutch switch
5. Neutral relay 11. Start switch
6. Main switch 12. Wiring connection (entire starting system)
NOTE:
Remove the following parts before trouble- Use the special tools specified in the trouble-
2) Headlight unit Pocket tester:
3) Seat 90890-03112
4) Fuel tank
YP******
NO CONTINUITY
1. Fuse
CONTINUITY Replace the fuse.
YP******
2. Battery
Check the battery condition.
Refer to BATTERY INSPECTION section
in CHAPTER 3. INCORRECT
Specific gravity:
1.280 at 20C
CORRECT Refill the battery fluid.

Clean battery terminals.
Recharge or replace the battery.

7-12

:
YP******
3. Starter motor *
S Connect the battery positive terminal 1 WARNING
and starter motor cable 2 using a jumper S A wire used as a jumper lead must have the
lead 3 *. equivalent capacity as that of the battery
S Check the starter motor operation. lead or more, otherwise it may burn.
S This check is likely to produce sparks, so
be sure that no flammable gas or fluid is in
the vicinity.
DOES NOT MOVE
MOVES Repair or replace the starter motor.

YP******
4. Starter relay
S Disconnect the relay unit coupler from the
wireharness.
S Connect the pocket tester ( 1) and bat-
tery (12 V) to the relay unit coupler terminals.
Battery (+) lead
Blue/White terminal 1
Battery () lead
Red/White terminal 2
S Check the starter relay for continuity. NO CONTINUITY
Tester (+) lead 3 terminal
Tester () lead 4 terminal
Replace the starter relay.
CONTINUITY
7-13

:
YP******
5. Neutral relay
S Remove the relay from the frame.
Battery and the relay connecter.
Tester (+) lead
Terminal 1 1
Tester () lead
Terminal 3 2
Battery (+) lead
Terminal 2 3
Battery () lead NO CONTINUITY
Terminal 4 4
Check the Terminal 1 and 3 for continuity.

Replace the neutral relay.
CONTINUITY
YP******
NO CONTINUITY
6. Main switch
CONTINUITY Replace the main switch
YP******
NO CONTINUITY
7. Engine stop switch
Replace the handlebar switch (right).
CONTINUITY
YP******
8. Neutral switch NO CONTINUITY (at NEUTRAL position)

CONTINUITY
(at NEUTRAL position) Replace the neutral switch.
YP******
9. Sidestand switch NO CONTINUITY

CONTINUITY
Replace the sidestand switch.
7-14

:
YP******
NO CONTINUITY
10.Clutch switch
CONTINUITY Replace the clutch switch.

YP******
NO CONTINUITY
11. Start switch
CONTINUITY Replace the handlebar switch (right).
YP******
12.Wiring connection
S Check the connections of the entire starting POOR CONNECTION
system.
Correct.
7-15

STARTER MOTOR
7 Nm (0.7 mkg)

Starter motor removal Remove the parts in order.
Crankcase cover (right) Refer to CLUTCH REMOVAL section in
CHAPTER 4.
1 Starter motor lead 1
2 Starter motor 1
3 O-ring 1
installation.
Starter motor disassembly Disassemble the parts in order.
1 Front bracket 1
2 Washer set 1
3 Rear bracket 1
Refer to Assembly section.
4 Washer set 1
5 Brush holder/brush 1
6 Armature coil 1
assembly.
7-16

YP803034
Inspection and repair

1. Inspect:
Commutator
Dirt Clean it with #600 grit sandpaper.
2. Measure:
Commutator diameter a
Commutator wear limit:

27 mm
Out of specification Replace the starter

motor
3. Measure:
Mica undercut a
Mica undercut:
0.7 mm
Out of specification Scrape the mica to the

proper value (a hacksaw blade can be
ground to fit).
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of commu-
tator.
4. Inspect:
Armature coil resistances
(installation/continuity)
Defects Replace the starter motor.
If commutator is dirty, clean it with sandpa-
per.
Good
Bad condition
condition
A
B
: Continuity
: No continuity
Bad condition Replace.
5. Measure:
Brush length a
Brush length wear limit:

3.5 mm
7-17

6. Measure:
Brush spring force
Fatigue/out of specification Replace as a
set.
Brush spring force:

540 X 660 g
7. Inspect:
Oil seal
YP******
Assembly
Reverse the Disassembly procedure.
1. Install:
Brush holder 1
NOTE:
Align the lib on the brush holder with the slot a
on the bracket, before assembly.
2. Install:
Washer set 1
Armature coil 2
3. Install:
Ring 1 New
Stator assembly 2
Washer set 3
Front bracket 3 Nm (0.3 mkg)
NOTE:
Apply molybdenum grease lightly on to the
bearings of the starter motor.
Align the match marks on the yoke with the
match marks on the brackets.
7-18

CHARGING SYSTEM ELEC
YP804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
1 C.D.I. magneto
2 Rectifier/ Regulator
4 Battery
5 Fuse
7-19

YP804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED

Procedure
Check:
1. Fuse 4. Stator coil resistance
2. Battery 5. Wiring system (entire charging system)
3. Charging voltage
NOTE:
2) Seat Engine tachometer
3) Fuse 90890-03113
Pocket tester:
90890-03112
YP******
NO CONTINUITY
1. Fuse

YP******
2. Battery
Specific gravity:
1.280 at 20C
CORRECT Refill the battery fluid.
Clean battery terminals.

7-20

:
YP******
3. Charging voltage
S Connect the engine tachometer to the spark
plug lead.
S Connect the pocket tester (DC20V) to the
battery.
Tester (+) lead
Battery (+) terminal 1
Tester () lead
Battery () terminal 2
S Measure the battery terminal voltage. Left side Right side
S Start the engine and accelerate to about
5,000 r/min.
S Check the terminal voltage.
MEETS SPECIFICATION
Charging voltage:
14.5 V at 5,000 r/min
NOTE:
Use a fully charged battery. The charging circuit is not faulty.
Replace the battery.
OUT OF
SPECIFICATION
YP******
4. Stator coil resistance

S Remove the C.D.I. magneto coupler from
wireharness.
S Connect the pocket tester ( 1) to the sta-
tor coil.
Tester (+) lead White terminal
Tester () lead White terminal
S Measure the stator coil resistance.
Stator coil resistance: OUT OF SPECIFICATION
0.48 X 0.72 (20_C)
MEETS
SPECIFICATION
Replace the stator coil.
:
7-21


YP******
5. Wiring connection
POOR CONNECTION
Check the entire charging system for connec-
tions.
Refer to CIRCUIT DIAGRAM section.
CORRECT Correct.
Replace the rectifier/regulator.
7-22

LIGHTING SYSTEM ELEC
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
4 Battery
5 Fuse
6 Main switch
22 High beam indicator light
23 Meter light
26 Tail / Brake light
30 Auxiliary light
34 Lights switch
36 Dimmer switch
39 Headlight
7-23

YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, AUXILIARY LIGHT, HIGH BEAM INDICATOR LIGHT,

TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON.
Procedure
Check:
1. Fuse 4. Lights switch
2. Battery 5. Dimmer switch
3. Main switch 6. Wiring connection (entire lighting system)
NOTE:
1) Seat
2) Fuel tank Pocket tester:
3) Side cover (left and right) 90890-03112
4) Headlight unit
YP******
NO CONTINUITY
1. Fuse

YP******
2. Battery
Specific gravity:
1.280 at 20C
Refill the battery fluid.
CORRECT Clean battery terminals.
YP******
3. Main switch NO CONTINUITY

CONTINUITY
Replace the main switch.

7-24

:
YP****** NO CONTINUITY
4. Lights switch
CONTINUITY Replace the handlebar switch (left).
YP******
5. Dimmer switch NO CONTINUITY
CONTINUITY Replace the handlebar switch (left).

YP******
S Check the connections of the entire lighting POOR CONNECTIONS
system.
Refer to WIRING DIAGRAM.
CORRECT Correct.
Check the condition of each of the lighting

systems circuits.
Refer to LIGHTING SYSTEM CHECK
SR805020
LIGHTING SYSTEM CHECK

1. If the headlight and the high beam indicator light fail to come on.
NO CONTINUITY
1. Bulb and bulb socket
CONTINUITY Replace the bulb and/or bulb socket.
2. Voltage
headlight and high beam indicator light cou-
plers.
A When the dimmer switch is on low beam.
B When dimmer switch is on high beam.
Headlight:
Tester (+) lead Green 1 or Yellow 2
lead B
Tester negative () lead Black 3 lead
High beam indicator light:
Tester (+) lead Yellow 4 lead
Tester () lead Black 5 lead
:
7-25

:
S Turn the main switch to on position.
S Turn the lights switch to on position.
S Turn the dimmer switch to low beam or high
beam.
S Check for voltage (12 V) on the lead at bulb
socket connectors.
MEETS The wiring circuit from the main switch to bulb
SPECIFICATION socket connector is faulty. Repair.
This circuit is not faulty.
SR805021
2. If the meter light fails to come on.

NO CONTINUITY
2. Voltage
bulb socket coupler.
Tester (+) lead
Blue terminal 1
Tester () lead
Black terminal 2
S Turn the main switch to on.

S Turn the lights switch to on position.
S Turn the dimmer switch to low beam or high
beam.
S Check the voltage (12 V) of the leads on the
bulb socket connector.
MEETS The wiring circuit from main switch to bulb

SPECIFICATION socket is faulty. Repair.
7-26

YP805022
3. The taillight fails to come on.

NO CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to the
Tester (+) lead
Blue terminal 1
Tester () lead
Black terminal 2
Turn the main switch to on position.
Turn the lights switch to on position.
Turn the dimmer switch to low beam or high
beam. OUT OF SPECIFICATION
Check the voltage (12 V) on the bulb socket
connector.
SPECIFICATION connector is faulty. Repair.
SR******
4. The auxiliary light fails to come on.

NO CONTINUITY
2. Voltage
Tester (+) lead
Blue/Red terminal 1
Tester () lead
Black terminal 2
Turn the main switch to on position.
Turn the lights switch to on position.
Turn the dimmer switch to low beam or high
beam. OUT OF SPECIFICATION
Check the voltage (12 V) on the bulb socket
connector.
SPECIFICATION connector is faulty. Repair.
7-27

SIGNAL SYSTEM ELEC
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
4 Battery 28 Rear brake switch

5 Fuse 29 Front flasher lights
6 Main switch 31 Flasher relay
7 Thermo switch 32 Horn
8 Heater unit 35 Horn switch
19 Neutral indicator light 37 Turn switch
20 Turn indicator light (left)
21 Turn indicator light (right)
24 Neutral switch
25 Rear flasher lights
26 Tail / Brake light
27 Front brake switch
7-28

SIGNAL SYSTEM ELEC
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON.
IF THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse 3. Main switch
2. Battery 4. Wiring connection (entire signal system)
NOTE:
S Remove the following parts before trouble- S Use the special tools in the troubleshooting
shooting. section.
1) Headlight unit
2) Side cover (left and right) Pocket tester:
90890-03112
YP******
NO CONTINUITY
1. Fuse

YP******
2. Battery
S Check the battery condition.
Specific gravity:
1.280 at 20_C
S Refill the battery fluid.
CORRECT S Clean battery terminals.
S Recharge or replace the battery.
YP******
NO CONTINUITY
3. Main switch
CONTINUITY Replace the main switch.
7-29

SIGNAL SYSTEM ELEC
:
YP******
4. Wireharness
S Check the connections of the entire signal
system. POOR CONNECTION
Refer to CIRCUIT SYSTEM WIRING DIA-
GRAM section.
Correct.
CORRECT
Check condition of each of the signal sys-

tems circuits.
Refer to SIGNAL SYSTEM CHECK section.
7-30

SIGNAL SYSTEM ELEC
YP806020
SIGNAL SYSTEM CHECK

1. If the horn fails to sound. NO CONTINUITY
1. Horn switch
Replace the left handlebar switch (left).
CONTINUITY
2. Voltage
horn lead.
Tester (+) lead Brown terminal 1
Tester () lead Frame ground
Turn the main switch to on.
Check for voltage (12V) on the Brown lead OUT OF SPECIFICATION
at the horn terminal.
MEETS The wiring circuit from the main switch to the

SPECIFICATION horn is faulty. Repair.
3. Horn
horn at the Pink terminal.
Tester (+) lead Pink 1 terminal
Check for voltage (12V) on the Pink lead to OUT OF SPECIFICATION
frame ground.
MEETS
SPECIFICATION Replace the horn.
Adjust or replace horn.
7-31

SIGNAL SYSTEM ELEC
YP806022
2. If the brake light fails to come on:

NO CONTINUITY
Replace the bulb and/or bulb socket.
CONTINUITY
NO CONTINUITY
2. Brake switch (Front/Rear)
Replace brake switch.
CONTINUITY
3. Voltage
Tester (+) lead Yellow terminal 1
Tester () lead Black terminal 2

The brake lever (or brake pedal) is pulled in OUT OF SPECIFICATION
(down).
Check for voltage (12V) of the Yellow lead
on the bulb socket connector.
MEETS 4. Wiring connection

SPECIFICATION Wiring circuit from the main switch to the bulb
socket connector is faulty. Repair.
This circuit is not faulty. Refer to SIGNAL SYSTEM WIRING DIA-
GRAM.
7-32

SIGNAL SYSTEM ELEC
YP806023
3. If the flasher light and/or turn indicator light

fails to blink. NO CONTINUITY
Replace the bulb and/or bulb socket.
CONTINUITY
NO CONTINUITY
2. Turn switch
Replace the left handlebar switch (left).
CONTINUITY
3. Voltage
flasher relay coupler.
Tester (+) lead Brown terminal 1
S Check for voltage (12V) of the Brown 1 OUT OF SPECIFICATION
lead at the flasher relay terminal.
The wiring circuit from main switch to flasher

MEETS relay connector is faulty. Repair.
SPECIFICATION
4. Flasher relay
flasher relay coupler.
Tester (+) lead Brown/White terminal 1
S Check for voltage (12V) on the Brown/ OUT OF SPECIFICATION
White lead at the flasher relay terminal.
MEETS
SPECIFICATION The flasher relay is faulty. Replace.
:
7-33

SIGNAL SYSTEM ELEC
:
5. Voltage
At flasher light (left)
Tester (+) lead Chocolate lead 1
At flasher light (right)
Tester (+) lead Dark green lead 2
S Turn the turn switch to left or right.
S Check for voltage (12V) on the Chocolate
lead and Dark green at the flasher light ter- Wiring connection
minal.
Wiring circuit from the turn switch to bulb
MEETS socket connector is fault. Repair.
SPECIFICATION Refer to CIRCUIT DIAGRAM.
SR806027
4. If the neutral indicator lights fails to operate.

NO CONTINUITY
2. Neutral switch NO CONTINUITY

CONTINUITY
Replace the left neutral switch.
:
7-34

SIGNAL SYSTEM ELEC
:
3. Voltage
fuel gauge coupler.
Tester (+) lead
Brown terminal 1
Tester () lead
Sky blue terminal 2
S Turn the main switch to on position.

S Select the gear position in neutral. OUT OF SPECIFICATION
S Check for voltage (12V) of the Sky blue
lead on the neutral switch.
MEETS Check the connection of the entire signal sys-

SPECIFICATION tem.
SR******
5. If the carburetor heater fails to operate.
1. Thermo switch
S Disconnect the thermo switch connector
from the wireharness.
thermo switch lead.
Tester (+) lead Black terminal 1
S Check the Terminal 1 and 3 for continuity.
A COOL DOWN
B HEAT UP
MEETS Replace the thermo switch.
SPECIFICATION
:
7-35

SIGNAL SYSTEM ELEC
:
2. Heater unit resistance

S Remove the heater unit from the carburetor.
heater unit.
Tester (+) lead Terminal 1
Tester () lead Terminal 2
S Check the heater unit for specificated resis-
tance.
Heater unit resistance: OUT OF SPECIFICATION
6 X 10 (20_C)
MEETS
SPECIFICATION Replace the heater unit.
S Check the connections of the entire signal
system.
Refer to WIRING DIAGRAM.
7-36

CHAPTER 8.
TROUBLE SHOOTING
STARTING FAILURE/HARD STARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . 8-3
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
OVER HEATING OR OVER-COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FRONT FORK MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
STARTER MOTOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . 8-7
FAULTY SIGNAL AND LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8-8

TRBL
STARTING FAILURE/HARD STARTING SHTG
EB90000
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
SR90000
STARTING FAILURE/HARD STARTING

FUEL SYSTEM
Fuel tank Carburetor
Empty Deteriorated fuel or fuel containing water or
Clogged fuel tank cap breather hole foreign material
Deteriorated fuel or fuel containing water or Clogged pilot jet
foreign material Clogged air passage
Fuel cock Improperly set pilot screw
Clogged fuel hose Clogged pilot air passage
Clogged fuel cock Improperly sealed valve seat
Improperly adjusted fuel level
Clogged starter jet
Damaged carburetor joint
Improperly tightened carburetor joint clamp
hose
Starter plunger malfunction
Clogged emulsion (heated water) tube
Sucked-in air
Air filter
Clogged air filter element
Improper air filter setting
COMPRESSION SYSTEM
Cylinder and cylinder head Valve system
Loose spark plug Improperly adjusted valve clearance
Loose cylinder head Improperly sealed valve
Broken cylinder head gasket Improperly contacted valve and valve seat
Broken cylinder gasket Improper valve timing
Worn, damaged or seized cylinder Broken valve spring
Piston and piston ring Seized valve
Worn piston
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston
8-1

TRBL
POOR IDLE SPEED PERFORMANCE SHTG
IGNITION SYSTEM
Battery Ignition system
Improperly charged battery Faulty C.D.I. unit
Faulty battery Faulty pick up coil
Fuse Broken magneto woodruff key
Burnt out, improper connection Switch
Spark plug Faulty main switch
Improper plug gap Faulty ENGINE STOP switch
Worn electrodes Faulty front and/or rear brake switch
Wire between terminals broken Faulty sidestand switch
Improper heat range Wiring
Faulty spark plug cap Loose battery terminal
Ignition coil Loose coupler connection
Broken or shorted primary/secondary coil Improperly grounded
Faulty high tension cord Broken wireharness
Broken ignition coil body
SR901000
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Air filter
Improperly returned starter plunger Clogged air filter element
loose or clogged pilot jet Ignition system
Damaged carburetor joint Faulty spark plug
Improperly tightened carburetor joint clamp Faulty high tension cord
hose Faulty C.D.I. unit
Improperly adjusted idle speed Faulty pick up coil
(Pilot screw), (Throttle stop screw) Faulty ignition coil
Improperly adjusted throttle cable Valve system
Flooded carburetor Improperly adjusted valve clearance
8-2

TRBL
POOR MEDIUM AND HIGH SPEED PERFORMANCE SHTG
EB902000
POOR MEDIUM AND HIGH SPEED PERFORMANCE

POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to STARTING FAILURE/HARD STARTING section. (Fuel system, electrical system, compres-
sion system and valve train)
Carburetor Air filter
Improperly adjusted fuel level Clogged air filter element
Clogged main nozzle
Clogged or loose pilot jet
SR******
POOR SPEED PERFORMANCE

POOR SPEED PERFORMANCE
Ignition system Compression system
Dirty spark plug Worn cylinder
Improper heat range Worn or seized piston ring
Faulty C.D.I. unit Cylinder head gasket broken
Faulty pick up coil Cylinder gasket broken
Fuel system Carbon deposit build-up
Clogged fuel tank cap breather hole Improperly adjusted valve clearance
Clogged air cleaner element Improperly contacted valve and valve seat
Clogged jet Faulty valve timing
Improperly adjusted fuel level Clutch
Refer to CLUTCH SLIPPING/DRAGGING
section
Engine oil
Improper oil level (low or over oil level)
Improper quality (Low oil viscosity)
Deterioration
Clogged oil passage
Brakes
Dragging brake
8-3

TRBL
FAULTY CLUTCH/FAULTY GEAR SHIFTING SHTG
EB904000 EB903000
CLUTCH SLIPPING/DRAGGING FAULTY GEAR SHIFTING

CLUTCH SLIPPING HARD SHIFTING
Clutch Refer to CLUTCH DRAGGING.
Improperly adjusted clutch cable SHIFT PEDAL DOES NOT MOVE
Loose clutch spring Shift shaft
Fatigued clutch spring Improperly adjusted shift rod
Worn friction plate/clutch plate Bent shift shaft
Incorrectly assembled clutch Shift cam, shift fork
Engine oil Groove jammed with impurities
Improper oil level Seized shift fork
Improper quality/(low viscosity) Bent shift fork guide bar
Deterioration Transmission
Seized transmission gear
CLUTCH DRAGGING Jammed impurities
Clutch Incorrectly assembled transmission
Warped pressure plate JUMP-OUT GEAR
Unevenly tensioned clutch spring Shift shaft
Bent push rod Improperly adjusted shift lever position
Broken clutch boss Improperly returned stopper lever
Burnt primary driven gear bushing Shift fork
Bent clutch plate Worn shift fork
Swollen friction plate Shift cam
Match marks not aligned Improper thrust play
Engine oil Worn shift cam groove
Improper oil level Transmission
Improper quality/(high viscosity) Worn gear dog
Deterioration
8-4

TRBL
OVER HEATING/FAULTY BRAKE SHTG
SR905000 SR906001
OVER HEATING OR OVER-COOL- FAULTY BRAKE

ING POOR BRAKING EFFECT
OVER HEATING Front brake
Ignition system Worn brake pad
Improper spark plug gap Worn brake disc
Improper spark plug heat range Air in brake fluid
Faulty C.D.I. unit Leaking brake fluid
Fuel system Faulty master cylinder kit
Improper carburetor setting Faulty caliper seal kit
Improper fuel level adjustment Loose union bolt
Clogged air filter element Broken brake hose
Compression system Oily or greasy brake pad
Heavy carbon deposit build-up Oily or greasy brake disc
Improperly adjusted valve timing Rear brake
Improperly adjusted valve clearance Improper brake pedal adjustment
Engine oil Worn brake shoe
Incorrect engine oil level Improper brake shoe contact
Improper engine oil quality (High viscosity) Worn camshaft
Low engine oil quality Worn brake drum
Brakes Mud or water into brake drum inside
Dragging brake Oily or greasy brake lining
Faulty brake cable
Broken or fatigued tension spring
Faulty camshaft, cam lever
8-5

TRBL
FRONT FORK MALFUNCTION/INSTABLE HANDLING SHTG
SR907000 SR908000
FRONT FORK MALFUNCTION INSTABLE HANDLING

OIL LEAKAGE INSTABLE HANDLING
Bent, damaged or rusty inner tube Handlebars
Damaged or cracked outer tube Improperly installed or bent
Damaged oil seal lip Loose handlebar tightening bolt
Loose hexagon bolt Steering
Damaged cap bolt O-ring Improperly installed handlebar crown
Improperly installed oil seal Loose or overtightening steering nut
MALFUNCTION Bent under bracket
Bent inner tube Improperly installed steering shaft
Deformed outer tube (improperly tightened ring nut)
Damaged fork spring Damaged bearing or ball race
Bent cylinder complete Front forks
Improper oil viscosity (High viscosity) Uneven oil levels on both sides
Improper oil level Uneven spring tension
Worn or damaged slide metal Broken front fork spring
Fatigued front fork spring
Twisted front forks
Wheels
Incorrect wheel balance
Loose spooks
Deformed wheel rim
Unevenly worn tires
Incorrect tire pressure
Loose bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Twisted
Improperly installed bearing race
Damaged head pipe bearings
Rear arm
Faulty bearings
Worm or damaged
Faulty bushing
Bent rear arm
Rear shock absorber
Fatigued spring
Improperly adjusted spring preload
Oil leakage
Drive chain
Improperly adjusted chain line
8-6

TRBL
STARTER MOTOR DOES NOT OPERATE SHTG
SR******
STARTER MOTOR DOES NOT OPERATE

STARTER MOTOR DOES NOT OPERATE
Battery
Insufficient battery capacity
Faulty battery
Fuse
Burnt out, improper connection
Switch
Faulty main switch
Faulty starter switch
Faulty clutch switch
Faulty neutral switch
Faulty sidestand switch
Faulty starting circuit cut-off relay
Faulty starter relay
Wireharness
Loose battery terminal
Loosely connected coupler
Improperly grounded
Broken wireharness
Starter motor
Worn brush
Faulty commutator
Broken armature coil
Engine
Faulty starter clutch
Seized engine
8-7

TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
YP909000
FAULTY SIGNAL AND LIGHTING SYSTEM

HEADLIGHT DARK FLASHER BLINKS SLOWER
Improper bulb Faulty flasher relay
Too many electric accessories Insufficient battery capacity
Hard charging (nearly discharged)
Faulty rectifier/regulator Improper bulb
Faulty battery Faulty main and/or turn switch
Improperly connected coupler, connector, FLASHER BLINKS QUICKER
wireharness Improper bulb
Improperly grounded Faulty flasher relay
Faulty main switch or Lights (dimmer) switch HORN DOES NOT SOUND
Bulb life expired Faulty battery
BULB BURNT OUT Faulty fuse
Improper bulb Faulty main and/or horn switch
Faulty battery Improper horn adjustment
Faulty rectifier/regulator Faulty horn (burnt coil, connector)
Improperly grounded Broken wireharness
Improperly mounting light unit
Bulb life expired
FLASHER DOES NOT BLINK
Improperly grounded
Faulty fuse
Faulty turn switch
Faulty flasher relay
Broken wireharness, incorrect coupler con-
nection
Bulb burnt out
FLASHER KEEPS ON
Faulty flasher relay
(nearly discharged)
Bulb burnt out (front or rear)
8-8

SR125 97 WIRING DIAGRAM 1 C.D.I. magneto
2 Rectifier / Regulator
3 Starter relay
4 Battery
5 Fuse
6 Main switch
7 Thermo switch
8 Heater unit
9 Handlebar switches (right)
11 Start switch
12 C.D.I. unit
13 Ignition coil
14 Spark plug
15 Clutch switch
16 Sidestand switch
17 Neutral relay
18 Speedometer
19 Neutral indicator light
20 Turn indicator light (left)
21 Turn indicator light (right)
22 Hi-beam indicator light
23 Meter light
24 Neutral switch
25 Rear flasher lights
26 Tail/ Brake light
27 Front brake switch
28 Rear brake switch
29 Front flasher lights
30 Auxilialy light
31 Flasher relay
32 Horn
33 Handlebar switches (left)
34 Lights switch
35 Horn switch
36 Dimmer switch
37 Turn switch
38 Starting motor
39 Headlight
COLOR CODE
B ..... Black Sb . . . . Sky blue G/Y . . Green / Yellow W / L . . White / Blue
Br . . . . Brown P ..... Pink L/ B . . . Blue/ Black W / R . . White / Red
Ch . . . Chocolate R..... Red L/ R . . . Blue/ Red
Dg . . . Dark green Y ..... Yellow L/ W . . Blue/ White
G .... Green W .... White L/ Y . . . Blue/ Yellow
L ..... Blue Br / L . . Brown/ Blue Y/R . . . Yellow/ Red
O .... Orange Br / W . Brown/ White R/ W . . Red/ White

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IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

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FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

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GASKETS, OIL SEALS AND O-RINGS

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LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

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3. Connect and disconnect the connector two

7. Check for continuity with a tester.

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HOW TO USE THE CONVERSION TABLE

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Tool No. Tool name/Usage Illustration

This tool is used when removing or installing

These tools are used when removing or

This tool is used to loosen and tighten the

This tool is necessary for adjusting valve

This gauge is used to measure the fuel level

This tool is used when installing the fork seal.

This tool is used to loosen and tighten the

This tool is used for holding the secondary

This tool is used for installing the cylinder

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This tool is used to measure the valve

These tools are used to measure the engine

These instruments are invaluable for

This tool is needed for detecting engine rpm.

This tool is necessary for checking ignition

These tools are used when removing or

This tool is used to remove the valve guide.

This tool is used to rebore the valve guide.

This tool is needed to install the valve guides

This tool is used for holding the Clutch Boss.