s1d

,

YAMAH

...j,'..i. -'.' .,;. -..

This lvlanual is prepared by EscortsYamaha Motor Ltd. primarilyfor use by Company Authorised Dealership and their qualifiedmechanics. lt is nol possible to put an entire Mechanic's education in toone lvlanual, so it is assumed that persons using this book to pedormmaintenance and repairs on Yamaha motorcycles have a basicunderstanding of the mechanical concepts and procedures inherent inthe motorcycle repair technology. Without such knowledge, attemptedrepairs or service of this model may render it unfit for use and/or unsafe.

Escorts Yamaha N,4otor Ltd. is continually striving to improve allmodels manufactured. Modifications and significant changes inspecifications or procedures will be forwarded to all CompanyAuthorised Dealerships; and will wherever applicable, appear in futureeditions of this Manual.

Service DepartmentEscortsYamaha Motor Ltd.

LEGENDS

It lndlcates SPecialthe Moiorcyc e

Procedures that musi be lollowed to avold damage to

MANUAL FORMATA of the procedures in th s manual are organised in a sequentlal, step by slep ror

mat. Tl]e Inforrratlon has Deen compiled to provlde the mechanic with an easy to read'

harldy reierence that contajns comprehensive explanation of all disassernbly, repa r' as

sembly and inspection operallons ln this revised format, the condilion ol lau ty compo-

nent will precede and the course of action required will tollow the symbol e g

Bear ngsPlttlng,/damage then FeP ace

EXPLODED DIAGRAMEach chapter provi.les exploded diagrams before each disassmbly sectlon lor ease

in dentifying correct disassembly and assembly procedures

lllustralians in ih/s l4lorkshop l',tlanual may not necessartly match with the physical

appearance af the l"lolaict'cle

WARNING

IT INDICATES SPECIAL PROCEDURESTHAT MUST BE FOLLOWED

TO AVOID INJURYTOTHE MOTORCYCLE RIDER OR PERSON IN-

SPECTING OR REPAIRING THIS MOTORCYCLE.

IMPORTANT€It provides KeY Inlormationtions which must be clearlY

related with procedures and opera_

understood.

tE.

i

INDEX

GENERALINFORMATION

PERIODIC INSPECTIONSAND ADJUSTMENTS

ENGINE

CARBURETTOR

CHASSIS

ELECTRICALS

TROUBLE SHOOTING

SERVICE INFORMATION

- ]

GENINFO

GENERALINFORMATION

APPLYGREASE

rff lRPERIODICINSPECTION &ADJUSTI\,,1ENT

ENGINE

APPLYorL

CARBURETTOR

CHASSIS

ELECTRICALS

TIGHTENING

CHAS

E'E^I EL:l-

TRSH

SERVICE LIMIT,CLEARANCE

TROUBLESHOOTING

SERVICEINFORN/ATION

ENGA

n

ff

Cr\

SERVINFO

CHAPTER 1

GENERAL INFOBMATION

I,'OTORCYCLE IDENTIFICATION

- _ : SS S SERIAL NUMBER 1-1

=',: \E SERIAL NUM8ER,,,,,.,.. 1-1

tI,I POFTANT INFORMATION

-__ -:-L4UEtVtE:t\ I TAt-it -

-_ - :- :' ) d \JtL -trALJ.....

_ -_,/1>-trnD

i:-* \\, q \LJ \rtL Jtr4LJ................

t-J= _ _ )s

-r tr

=ctAL sERVtcE TOOLS...............

r!

I

fi,i: &5l

CHASSIS SERIAL NU|\,4BER. The Frame Serial No it is

n to the righi side ol theHead Pipe.

srampedSteering

ENGINE SERIAL NO. The Engine Serial Number il rs

stamped In to the Left Side of theEngine. (Engine Serial No does notcontain Year and lvlonth of productir'rJ

AI,IIPER WITH ANY OF THESE NUMBEBS. IT MAY LEAD TO LEGAL

XXXXXX

YEAR OF::CDUCTION

I ::i-cl cn

MONTHCODE

MODELcooE

2 Digits standing for last t\/o digits of yearF9.96 -1996,97-1997..One alphabet standing for MonthEg. A - January, B - February........L - DecemberRXG

UNIT PRODUCTIONNUMBER

1 L5-000001SeIial Number:

:: r, , : c g ts denote year ot prod uction Code, Next dig it represents Month'-: ci",ed by Model Code and the remaining six dig-its a;e the Unit pro_:-',,mber.

GEN 'Iiffi; EElALL REPLACEMENT PARTS'1. We recommend to use ESCORTS

YAMAHA genuine parls for all replace-ments, to ensure safe long and troubletree performance of Motorcycle. Use oil

orgrease recommended by ESCORTSYAMAHA IVIOTOR LTD. for assemblyand adjustmenl.

GASKETS OIL SEALS AND 'O' RINGS'1. All Gaskets and Oil Seals should be

replaced when an Engine ls over-hauled. All Gasket Surfaces, Oil Sealslip and'O Rings must be cleaned.

2. Properly oil all Mating Parts and Bearings during reassembly. Apply grease

to the Oil Seal Lips.

LOCK WASHERS/COTTER PINS

1. All Lock Washers/Cotter Pins must be

replaced when they are removed. LockTabs should be benl along the Bolt orNut flat(s) a{ter the Bolt or Nut has beenproperly tightened.

BEARINGS AND OIL SEALS

1. Installthe Bearing(s) O and Oil Seal(s)with their manufacturefs mark or num-bers facing Upward. (ln other words,the stamped letters must be on the side

exposed to view). When installing OilSeals, apply a light coating of lightlithium base grease (e.9. Servo Greasel\,4.P or equivalent) to the Seal Lips. Oilthe Bearings liberally when insta ling.

IMPORTANT

Oo nol use compressed air io spin the bearings dry.This causes damage lo the

Bearinq Surfaces.

GENINFO &6

ctRcLlPs1. All Circlips should be inspected care-

fully before reassembly. Always replacePiston Pin Clips after one use. Replacedistorted Circlips. When installing aCirclip O make sure that the sharp'edged corner is positioned opposite ofthe thrust it receives. See the sectionalview Shaft.

GTTMPoRTANT I@I would cause it to iump ott groove and

damage related components. L

Io,

ll"

The Special Service Tools are required for complete and accurate tune-up and as-sembly. Using the correct Special Service Tool will help prevent damage caused by theuse of improper tools or improvised techniques.

S NO. TOOL NO FIGURE DESCRIPTION

1 ES tvt201

MAGNETO HOLDEF

To hold the Rotor of Magneto Assy.

2 ESt\,1202

IllAGNETO PULLER

To remove the Flotor of Magneto Assy

3 ESM205

DRIVING SPFOCKET HOLDER

To hold the Driving Sprocket

ES M 507

PISTON PIN REPLACEB

To remove the Piston Pin from th€Piston

5 ES l\i151 0

PISTON BING COlllPBESSOF

To compress Piston Blngs for instalfng the Cyl nder.

6 EStvt213 i.....4

FBONT FORK INNEF TUAE NUTHOLDE F

Tc Hold the TFF plunger

I

I

' --_

Ir_.-

\s\q.\sq\-s.q \tre'se.s- \ qqsqR\e\\q\14 ESM 265

CRANKSHAFT/CRAN KCASESEPABATINGTOOL

To separate RH & LH Crankoasesand to pull out Crankshaft.

l3 ESM 266 #pCRANKSHAFT INSTALLINGTOOL

To install the Crankshaft.

ESM27O

TFF OIL SEAL REMOVALTOOL

To remove ll-F ull Dea

17 ESM275

TFF OIL SEAL INSTALLINGTOOL

To install lFl- utl Sea

I

J

I

CHAPTER 2

PERIODIC INSPECTIONS AND

ADJUSTMENTS

.,:-:s oN |\4A|NTENANCE. ............. 2-1

::: 3DlC MAINTENANCE SCHEDULE ..................... 2-3

: .- : , :TITIVE MAINTENANCE/LUBRICATION............ 2-5

:'. : ":.- - uG ..........2-7

'J S SIS

.2-17

.2-18

2-21

! _::-RtcAL

2-22

1. Thoroughly clean the Frarfe and Engineot dirt and dust, in order to prevent it fromentering the lnside ol the Engine.

tr2. Keep ofi the F re lfom the maintenance

area.

3. When the Special Service Tools are re-quired, use them judiciously to preventany damage to the Motorcyc e parts.

When working on the Motorcycte it rs amusl to use the recommended lypes oftools and instruments. (e.g. Avoid usfrgan open-end wrench as much as possible,n place of a box or socket wrench. )

4. Always use a new casket (pack ng),O Bing, Cotter Pin, Circtip, Lock Wastrer,etc. lo, repa rs. Always use GenuineEscorts Yamaha pans, recommendedgrade of Oils and Grease of superiorquality.

5. During Serv ce,lake Spec a Caresornalyou dont get njured or burnt from rneEnglne, Exhaust Pipe or Siencer.

INSP.ADJ.

6. BATTERY

. Take care so that the Battery Fluid dc€s

IlD\ b)\\ Dl\D\l !\\\s\,s\N) $ .\Molorc'yc\e.

7. NOTES ON DISASSEMBLY AND REAS

SEI\,4BLY

. Place allDisassembled Parts neatly aalseparately in groups so that lhey T?not be confused or lost. (especia 'Washers and Spacors)

. Whenever Screws of dilferent lengths a-.taken out from various assemblies ide-tify them separately.

. Wash the Engine andTransmrssion Pa=in kerosene and blow them drywith co--presseo arr.

.Install the Parls after checking tF:smooth movement.

. Oil the contact surfaces ol the Mov'n:Parts.

' Tighten the Parts to lhe specified torou:by using the Torque Wrench.

c?

Always keep your environment clean.

E

.

ti

ln

5'

ta

t:I

ilil

N

-:qs REMARKSINITIAL

Check Clean or replace.

Rep ace (Warm Engine Before

D'a ning).

Check/adjust idle speed, Starlerlever (choke) operal on and c ean

a a

Check ensure bleeding to avo d ai

a

a

Check lor any damage or crack.

Replace, il necessary

Check al Eng fe nuts and bo ts 1o

Remove cafbon (Cyl/Cyl. head/P ston Assy llluij er elc )

'Check e echolyte leve and addd slrled water every 1s days

iclreck specil c srav ty (++) and

breather pipe ior propef roll ng. a

Check operai on Rep ace, if

Check,adlust bearn a

. PEBIODIC MAINTENANCE SCHEDULE

1

INSP.ADJ.

. PERIODIC MAINTENANCE SCHEDULE

*lt ls recommended lhat lhese175!3ml Servo 1e eschocab or

1.240 at 20'c

nerns be s€rv c€d DY

oi special Escorts ollCOI\I!PANY AUTHOBISEDor sPecialYamaha oil++

DEALERSHIPS + L3:battery spec I c gra _

Check and adiust lension/lubricatDrive chain*C1ean, Lubficale and alrgn

Check fof damage/Bim run oul &

Check tor damage wear'

looseness/lighlness RePlacewneet aearings"

ck tor tyre P€ssure.

Check lor oosenesslighlnessiteering eearins*

C'hech lor oPeralron and orl

Check ior Iooseness.All Nuls & Bolts

Check and lop uP Engine(2T) oilOilTank

Check Reaf Swing Fork AssY lor

looseness {ReP ace sllenl b ock

bushes aiter 24000 Kms or

CLean Feplace rf necessarY

ffir" "-bo* ,""o.mendations are only for general guidance'

.Actuar period of service rarserv oeryl9.:. ill.:l:^Yt"-* ::iY?:lXl3t:*t"*;;ffi !",";;;';;;i"ontJ"t'corirpnrY aurHoRrsED DEALERSHTPS'

:

INSP.ADJ,

THROTTLE

t

::ECTRICALS

AUTOLUBE PUMP FRONT BRAKE

NIINIMUMPt MP STFOKE 0.204.25 mm

SPARK PLUG

_ r ir\f---- <

\ i.. lla!6qP l

\:_ll?

REAR BRAKE

TRANSMISSION OIL SILENCER

EAN EVERY3OOOKII/I.TYPE 2OW4O MULIIGRADE OIL

It

' 2-6

Jr rr

: : edges and the side electrodes should not be efoded. D scard the Spark P ug I there:-.::ent wear. & if the insulator s cracked/ chipped.

SPARK PLI.

::_ airv d ft from around the Spark Plug base.:: -.ect the Spark P ug Cap. Remove the Spark Plug with the Box Spanner No 21 .

: r nspect the Spark Piug Electrodes for wear. The Centre E ectrode shouci have

'= :Jre thai ihe Spark P ug Gap ill is

- : 7 mm. Measure the gap us ng a: -. pe Feeler Gauge. lf adjustment is::: ,:,r,,, do it by bending ony the sde

-: - Lo,c u,,y.

: : : - e that the PlLrg Washer is in Good

' '_: P lrg Washer attached, screw - jn: :,..{ P ug by hand to prevent cross::r --i \t' th the Box Spanner. tighten: :- ilrn after tl're Plug seats fully.

Spark Plug : BPRBHS

Spark Plug is new, tighlen tlhe Box Spanner to cornpress (14.0 Fr. Lb)

:' over tighten or cross thread the Spark Plug as the Threads of Atuminium_:?r Head may be damaged.I: -:: 3llolv any Foreign Panicles to enter the Engine through Spark plug Hole

.e P ug is removed. Please ensure that the l-lole is cose the recommended tvpe of Soark Plud lest it wor

is covered with a cloth.ed type of Spark Plug lest it would alfect the Engine

PlLrg nd cates how the EngineSpark P ug the Engine and then the tollowing lable.

has been operat ng. From the co our andriding cond tions of the Motorcycle can be

. ] T ON COLOUR AND APPEARANCE INDICATION

nsLr lor tip grey sh yellow to ight brown

Du b ack velvely carbon depos ts.

S. ning black wet carbon deposits

ifsulator burni while wth peafyieposits ol efoded Electrodes.

. Clogged Air Flter.. \s\ !.\\\\s\a \\s\

. E\ec\\ode Gap \\\o\ e

" Co d'P ug used.! nsuff c enl H.T. vo tage. Pro onged ld ng ol Enq ne.

'O i-F!e M xture rich.

' Worn-out Cyhnder/Piston Rrngs

INSPADJ.

PLUG

2--t

Recommended(NGK JAPAN)

. Every Thing s in order.

Fuel'ArMxturelean.mproper Seating oi PlLrg.Hol'P ug used.

AIR CLEANER ELEMENT

A) Opening ot Air Cleaner Assembly'1. Remove Cover Side-2 @ (on right hand

side) by opening 1 No Screw.

2. Unsc.e\'r, cap Assembly Air Cleaner @ byopening 3 Nos Screws,

B) Inspectionblv

of Air Cleaner Assem-

l. Inspect for any existing Air Leakage intothe Case Air Filter. (lt is observed thatthere is dust accumulation at the leakage

Point.)lf there exists any air leakage

Check for :

A) Warpage oI Case Air Filter or Cap As-sembly Air Cleaner{Fig A)

B) Proper seating and condition ol SealCase Air Filter. (Fig B)

ll damaged or cut replace it with a newone.

C) Grooves ol Case Air Filter and Edge ofCap Assembly Air Cleaner for damagedmaiing surlace. (Fig C)

D) Condition ol Element Air Cleaner. lfdamaged or cut then Replace it with anew one. (Fig D)

2.

INSP.ADJ.

C) Cleaning of Element Air CleanerL Centll pullout Flcmenl Air ( leaner O &om

Cap Assembly AirCleaner. @.

2. . Clean Element Air Cleanet in clearPetrol (without any oiltrace), thoroughly,in a clean kay.

. Repeat the procedure tillall the dusydirthas been washed off.

3. Squeeze out the excess petrol by press-ing the Element Air Cleaner in the fist .

D) Oiling of Element Cleaner1. . Take 2T Oil in a Clean Tray.

. Dip the Element Air Cleaner in 2T Oilforunitorm Soaking. (Keep the ltairy surtaceDown).

HAIRYSURFACE

INSP.ADJ.

1/ ,,n'2. Squeeze out excess 2T Oii by pressing

The Elemenl Air Cleaner in the Fisl asshown in Fig 1.

.aCheck for Unitorm Application of

2T Oil all over lhe entire surface(both sides) of the Etement AirCleanerAfterthe excess 2TOit hasbeeh Squeezed out.

. Do not wring Elenrent Air Cleaner as shown in Flg 2.

. No such strong force should be apptied to the Element Air Cleaner, while squeezing, Whichmay caLrse tear ng or damage to the Element Air Cleaner.

Screws Tightening Sequence

E) Installation of Air Cleaner Assem-bly

1. Assemb e the Air Cleaner assembly n reverse sequenc-A.Check for :

The blockages in the Air Passage ofthe BodyAir Ceaner Clean it with a ctean cioth.The screws of the Cap Assy Air Fi[ersholld be tightened as per the shown se-quence, in two steps. (All the three screwsto be tightened genfly first and then fu ytightened in the same sequence.)

. When install ng the Element Air Cleaner in its Cap Assy, be sure its sealng surface matches perfecl ywith the sealing surface oi the Case Air Filier to prevenl anv A r Leakaoe.

IMPOFTANT

. Dirty Element Air Cleaner causes excessive fuel consumption, wear of piston Ringsand loss ot oower.

. Clean Element Air Cleaner every 1000 KMs.

. The Element Air Cleaner should be cleaned and lubrlcated more frequenfly (every 1O0Okms or earlier), it Motorcycle is operated in very dusty (e.g. unpaved, dust laden roads)or wet conditions.

TRANSMISSION OIL

CHECKING'1. Check Oil Levelwith Motorcycle on Cen-

tral Stand. lvlotorcycle Rear Wheel liftedofl ground and Front Wheel touching theground.

2. Transmission Oil Level should always bebelween maximum & minimum levels onPlug Oil Level.O Screwed on Cover Assy.2 on R.H. Side.

3. Top up if required.

REPLACEMENT1. Warm up the Engine with Motorcycle on

Central Stand.

2. Keep Oil Pan below the Engine.

3. Rernove Drain Bolt @ along with the cas-ket @ and drain out Oi, completely..

4. lnstall Drain Bolt @ with its casket €).

Drain Bolt2.0 Kq.m.

5. Fill Transrn ission Oil.

6. Check oil level with the help of Plug OilLevel O

RECOMMENOED.20W40 Oil of Superior grade

quality.

QUANTITY :

. For Overhaul : 700cc t 20 cc

. For exchange : 650cc a 20 ccduring Service

't4 Ft. Lb

" r/;ats usc only recommended grade/quantity of Transmission Oil.

1T'PORTANT

-h -'ci add any chemical additives into the Gear Box as cear Box oil also lubricatestfE C'lch. and additives can cause the Clutch to sliD_

t.r

AUTOLUBE PUMP

CABLE ADJUSTMENT1. Check to see if the Pump Guide Pin (Dis

aligned with the mark on Plate Adjusting@with the Throttle in closed position hav-ing no play-

2. lI Pump Guide Pin is not aligned, align bylurning Adiuster @ in or out, looseningLocknut @ and then retightening.

MINIMUM PUMP STROKE AA'USTMENT1. Throttle Grip full closed position.

2. Remove Spark Plug

3. Slowly move the Kick Crank downwardsby hand, holding the Kick Crank at theposition where the clearance betweenadiust Pulley and Plale adjustrng is maxi-mum.

4. Measurc lvlinimum Pump Stroke (t withFeeler Gauge.

5. lf clearance is not cor.ect adjust by theShims @. Adding Shims will increase thestroke and vice versa.

Minimum Pump Stroke 0.20 - 0.25 mm

When insening theThickness caugebetween the Plate Adiusting and theAdjusting Pulley, be carelul that neitherthe Plate nor lhe Pulley is moved.

2-12

AIR BLEEDING

1 . REMOVE:. Pump Bleed Screw @ and keep oil run-

ning out until all the air bubbles disap-pear

2. INSTALL:. Gasket. Hteeo Sctew (,

3. Start the Engine, disconnect the OutletPipe ol the Oil Pump from the Carburel-tor. Pullthe Oil Pump Cable (O allthe wayoui to sel pump stroke to a maximum lorIew minutes, to ensurethat allairbubblesare removed and smooth oilflow is takingplace. Beconnect the Outlet Pipe back tothe Carburettor

THROTTLE

THROTTLE GRIP FREE PLAY

1 . LOOSEN:. Locknut G)

2. ADJUST:. Cable free play 1-2 mm by turning

Cable Adjuster @ in or out.

3. TIGHTEN:. Locknut (D

THROTTLE CABLE FREE PLAY

1 , LOOSEN:. Locknut @

2. ADJUST:. Cable free play @ 5-8 mm.Turn cable

adjuster @ in or out.

3. TIGHTEN:. Locknut O

CARBURETTOR

IDLE SPEED'1 . Start the Engine and warm for 5 minuies

2. Turn Pilot Air Screw @ ln unti lghtilseated-

3. Back out by specified number ot tufns wit.screw drlver

Pilot Ait ScrewTurn Out1 Y2 ! o.sTurns

4. Turn Throttle Stop Screw oul until specr-

fied ldle Speed is attalned.

STARTER LEVER FREE PLAY

1. LOOSEN:. Locknut @)

ADJUST:. Cable lree play @ 3-5 mm by turn ng

Cable Adjuster O in or out.

TIGHTEN:. Locknul €)

2.

3.

Starter Lever Cable Free Play : 3-5 l\4M

Engine ldle speed1700 ! 100 R.PM.(Uptill Bunning in Period ie. First 1000 Kms.)

1500 r 100 R.PM.(After Running in Period ,:.e. After First '1000

Kms.)

-d

o

{{

I

E@CLUTCH

SLUTCH MECHANISM ADJUSTMENT

CABLE ADJUSTIV]ENT1. LOOSEN: Locknut O

2. ADJUST;. Cable Ffee Play @ 2-3 mm by turning

Cable Adjusler @ in or oul.

3. TIGHTEN :Locknut O

2. POSITIONThe Push Lever (t by the Cable Adjuslere)

a.rd ad.usr Lpve'riegl.t ai lo75 nm.

3. INSTALL :Cover Crankcase -1 G)

:alr4OVEl

. :avef Crankcase-1 G) (On left hand side)

, :EVOVE: Generator Cover Assy. O 5. LOOSEN ;Locknut €) on CoverCrankCase -1

€ llPoRrANr li

6. SCRFW lN : Adjuster €) until tighl andback t out by 1/4 turn.

7. TIGHTEN :Locknut @ L

fF

aw

-:eiore Adiusting the Clutch Lever free play, the clutch Mechanism should be adiusted.

@BRAKES

FRONT'1 . LOOSEN :Locknut O

2. ADJUST : Free Play @ by Adjuster @

3. TIGHTEN:Locknut O

FBEE PLAY O5-8 mm (lndian Markets)2.5-3.5 mm (Other Markels)

. The Front Brake play can be Adjusledeilner oa tl_e Adjuster e) on Brake -evelor by the Adjuster @ loodted on FronlWheel Plate Brake Shoe.

REAR

1 . ADJUST:. Free Play 6r of Rear Brake Pedal @ to

20-30 mm by turning the Adjuster Onear the right hand side of the RearWheel in orout (To increase ihe play turnAnticlockwlse and to decrease the playturn clockwise.)

. Brakes ensure personal safety andshould always be maintained forproper adjustmeni.

. Always check Brake Lighl operationafter Front and Rear brakes adjust-ment is done.

. Proper Lever Free Play is essentialtoavoid excessive brake Drag-

, r;t

:

d

t!I:

WHEELS

BRAKE LINING WEAR INSPECTION1. Depress the Brake Pedal @

2, INSPECT. Position of Wear Indicator @lf Indicator reaches the wear limit line thenreplace Brake Shoes.

1, INSPECT

. WHEELlf Crack/ Bend/ Warpage then replace

2, INSPECT. Spoke

Tap each Spoke with an iron rod lorsound or feel the looseness ot theSpokes by hand. lf any Spoke makes adullllat sound, Inspect it lor looseness

3. TIGHTEN. Spoke Nipple. True the Wheel if necessary.

Always balance the wheel when a tyreor wheel has been changed or replaced

2-17

INSP.ADJ. EIEE

TYRES

Wear Limit: 1 mm

Wear indicatof OReplacement limit @ : '1 MM

2, CHECK:. Air pressure with tyre nozzle in down

1 , INSPECT:Tyre wear

TYRE CONDITION

OVER INFLATED ORisky/Poor Boad Holding.

PROPERLY INFLATED OGood and safe riding.

UNDER INFLATED €)Higher Tyfe Wear & Low Fuel Economy

An mproperly inflaled Tyre may lead toloss of Motoreycle Road Contact caus-ing accident /injufy to Rider.

.Tyre pressure should be checked and corrected under cold conditions (Tyre tem-perature equals ambient lemperature)

. Always check tyre condition before riding lllotorcycle. li badly worn oll then replaceTyre immediately .

.In case nail/glass/sharp item is embedded in Tyre. please ensure same is removedbefore vulcanising /puncture repair.

L,"-:Qbu^*^r^uz

position as in figure.

FRONT REAR

Tyre Specification2.50-18

4PRNYLON

2.75-18

4PRNYLON

Single Rider 22PSl 28 PSI

Double Rider 22 PSI 32 PSI

IMPORTANT

-{ifrm,NG

.W

:r

,qrdl

4fi!

.{n,"ifl

ri

7-Ff

.@DRIVE CHAIN

- I'l. Side

SLACK INSPECTION. Park Molorcycle on Level Ground on

Central Stand.. Remove Rubber Cap O from lnsoec-

tion Window @ on Chain Case .

. Rotate Rear Wheel @ several revolu-tions in Forward direction and checkTo-tal Slack upward & downward severaltimes to find "Maximum Slack Point" @.

SLACK ADJUSTMENT. Park Motorcycle on Central Stand and

loosen Rear Brak€ CableAdiusteron RHsne

. Remove Cotter Pin @ of Rear WheelAxl6 Nut with Dlier on LH side.

. Loosen RearWheelAxle Nut @ usinoRing Spanner No 22 and Main SprocketShaft Nut. @ using Ring Spanner No27 on LH side.

. Loosen Chain Puller Lock nuts @ oneach side (LH and RH side).

. To tighten Chain, turn Chain Puller Ad-justers @ clockwiseand to loosen Chain,turn Adjusters anticlockwise and pushRearWheel Forward

. Ensure that the matching ofthe notchon the adiusler with the alignmentmarks on Rearonthe ReatSwing Forkia same on LH and RH side.

. Atter adjustment , be sure to tightenLock Nuts, Sprocket Shaft Nut. WheelAxle Nut and adjust the Rear Brake.

. Insert a new Cotter Pin into the RearWheelAxle and bend the end ofthe pin.

:' _,

. n----a.- :- 5- u

IIPORTANT

&"Fr adjusting the Drive Chain Slack, Rear Brake pedal Free play should always be-e4{ed and adjusted, il required.rc.r'ect alignment adversely affects the lile of Tyres, Wheel Bearings, Sprockets and:r,e Chain.

, :-s-€ configuration ot Drive Chain to be same when assembled.' flrts' e .efitting Chain Lock on Drive Chain, please ensure its Closed End is alwavs in

'|!E -rr.eclion of Chain Rotation.

:-te Chain Slack 20-30 mm

2-19

DRIVE CHAIN CLEANING AND LUBRICATION

Bemove the Drive Chain trom the Motor-cyoe.Dip the Drive Chain in Kerosene for aboul20 minutes to loosen the dirtfrom internalsurfaces as shown in figure.

Clean the chain with wire brush.

Again dip the drive chain thoroughiy r-crear Kerosene

6. Hang the Drive Chain vertcally and dry itby using compressed alr.

6. Dip the Drive Chain in 20W40 Oil Batfto restore the rnterna ubrication

7. Hang the chain in such a manner that theexcessive oil drips off in to the oll bath

8. Inspecl the Drive Chain lor wear if da.raged of worn out, the Drive Chain alongwith Both the Sprockets should be re-placed as a set.

,.-7.' ,-:pw,,'^ _

Fj.::v1a?: ^,:

r{

I

2-20

STEERING

CHECK\NG

1 . RAISE. Front Wheel otf the ground.

2, CHECK. Steering Head Bearing for looseness

Gently fock Front Fork Assembly back-ward and forward. lf loose then adjust.

ADJUSTMENT

1 . REMOVE. Cover Crown O by opening 2 Nos.

Screws.

2. LOOSEN:. Steering Fitting Bolt @. Ftonl ForK Htncn tJotls lJl

3, ADJUST. Steenng Heao Ri.rg Nut @ by usrng

Special Service Tool ESI\l-221.@Tighten the Nut until Steering Head istight without binding. lf heavy bindingthen replace Race Bearings.

4, TIGHTEN. Steering Fitting Bolt @. Fronl Fork Pinch Boll @

5. ASSEN,lBLE. uover urown tll

Steering Fining Bolt3.1 Kgm(22Ft.Lb)

o3f-

BATTERY

BATTERY FLUID CHECK'1. CHECK :

. Fluid levelFluid Level Should be between up..and lower level line.

. For tightness o{ Termlnals.

. Specific Gravity of the Battery F . c :using Hydrometer.It should be 1 .230 i 0.005 (1.225-- .: ::

2. Use only disiilled water for topping.

BATTERY CHARGING (NEW BAITERY

1, ELECTROLYTE PREPARATION. Mi\ one part of SulphJric Acid ro.- :

parts of disrilled water to get tl'e de) ::Electrolyle .e. In 100 ml sulphLflc r :

add 250m1 of water.. Checkfo.tf'e Specif c Graviryof lhe r'

polyle I shoLld be 1.230 r 0.005 , --:1.235)

. The Soecrfrc Cravrly shoLd al!{a/. :

Checked us'ng a proper hycirori,(size 5.00mm)

2.

3.

4.

5

6

Fill Electrolyte of specil ed gravity L: :"Upper Level" Mark in each Cellol the E:',|ety.

Leave the Battery idle for 30 to 60 - -

utes aiter lilling the Electfo yte for sc..ing the Plales in the Electrolyte.

In case the Elecirolyte Level fa ls be : rthe "Upper Level" during the above sc: 'ing period then lop it up again.

Charge the batlery as per following

Charging Current = 0.25 Ampres.

Charging Duration =15 Hours

Us ng a good Battery Charger

Slop chargrng the battery when spe, :grav ty of the e ectro yte in each ce :ta ns a value of 1.240 ndicat ng ',Charged Conditjon.

IMPORTANT

Incase the battery is more than 3monihs old (fromthe month ol manu-facture), duration of initial chargingto be extended till lull charqe condi-

il

lll

1

I

'ilI

;:

2-22

INSPADJ.

IMPORTANT

. Maintain Electrolyte at Upper Level.

. Do not add Electrolyte when recharging the Battery

.Top up only with Distilled Water.

.The Ballery should be firmly mounted.

. The Breather pipe ol the Battery and its mounting should not have any lolds oblockages and should be done as per the given illustration.

. Whenever Battery is not in the Circuit (i.e..emoved for Charging etc.) the Headlighswitch must be shifted to "ON" position, otherwise Neutral Light Bulb wilt Fuse anBR unit will get damaged.

. Check for the Fuse in the Fuse box.'Check for the proper coupler connections of RR unit.

2-23

CHAPTER 3

ENGINE

ENGINE DISASSEMBLYCYLINDER HEAD AND CYLINDER

PtsToN ..............

CRANKCASE COVERS

GENERATOR ASSY ................

DRTVE SPROCKET........................cLUTCH ............

(ICK STARTER ..

SHIFT SHAFT

CRANKCASETRANSMISSION AND SHIFTER...CRANK SHAFT

INSPECTION AND REPAIR

CYLINDER HEAD ,,, ,,.,,,,, ..

CYLINDER

PtsroN..............PTSTON RING

PISTON PIN AND SIVALL END BEARING,,,

c1UTCH.............KICK STARTER,,

CBANK SHAFT

TRANSM ISS ION

BEARING & OIL SEAL .......

3-1

J-t

J-l

3-23-2

3-3

3-43-43-5

3-5

3-6

3-73-7

3-8

3-9

3-9

3-10

3-1 1

J- t.t

3-14

(contd....)

ENGINE ASSEMBLY AND ADJUSTMENTS

CRANK SHAFT ..'".. 3-15

TRANSMISSION AND SHIFTER... ..... 3-16

CRANKCASE ASSEMBLY ... . . 3-18

GENERATOR ASSY ................. ......... 3-19

sHtFT SHAFT ... 3-20

KICK STARTER. ...... 3-21

C1UTCH... ...... ...... 3-23

PR VARY DRIVE GEAR .............. 3-25

DRTV|NG SPROCKET....... ....... .... 3-2s

CRANKCASE COVERS ... ... .......... 3-25

PIsToN. ........... ..... 3-26

cYLINDER .-.-'. .....3-27

ENGINE MOUNTING .................... --.-' 3-28

cotvPoNENTS GRADING ......... 3-29

.:4.

t

CYLINDER HEAD AND CYLINDEF

PISTON

CRANKCASE COVERS

1 . REI\/OVE. Spark Plug O. Cylinder Head Nuts @ (4 Nos.). Cylinder Head O. Cylinder Nuts @ (4 Nos.). Cylinder O

1. REI\,4OVE

. Piston Pin Clips O (2 Nos.)

1 , REMOVE. Piston Pin @ using Special Service Tool

ESI\,4 507 @ (Piston Pin Replacer). Needle Boller Bearing @. Piston @. Piston Rings and Expander @)

1 . REMOVE. Cfankcase Cover R H G)

By Opening 9 Nos. Screws.

OO

2@364@

GENERATOR ASSEMBLY,1

. ATTACH. Special Service Tool ESI\,4-201 €) Fc-

holding the Rotor Assembly.

2, REN4OVE :

. Botor Holding Nut @ by using So -:-No 19.

. Spring Washer @

. Washer @

ATTACH :

. Special Seruice Tool ESlvl-202 @ (Ror:Assembly Pullerwith Left hand thfeadsholding Rotor Assembly by Specia S:'vice Tool ESM 201 @

REMOVE:. Rotor Assembly. @. Woodruft Key @

3.

4.

5. REMOVE :

. Stator Holding Screws @ (2 Nos)Neutral Switch Lead Wire @

. Stator Assembly @

DBIVE SPROCKET

1 . FEMOVE

Drlve Sprocket Nuto by using socket N:26, and Holding the Sprocket by Spe-

cial Service Tool ESI\,I 205 @

Lock Washef @Drive Sprocket @

II

CLUTCH

2, REI\4OVE. Shift Cam Blind Plug @. Gasket @

,I , REMOVE. Clutch Spring Bolts O 4Nos.. Clutch Springs @ 4 Nos.. Pressure Plate @. Friction Plate @ 6 Nos.. Clutch Plate G) 5 Nos.. Push Rod @

2, ATTACH. Speclal Service Toot ESM-233 @ For

holding the Driven cear Assembly @

REMOVE. Driver Gear Assembly s by ooen ng

Nut @. Washer Conical Spring @. Plale Thrust-1 (]. Spacer O. Washer Plate (,ATTACH

5.

. Botor Assembly on L. H. JoJ, ral of CranlSl^att and holo loySpecta. Serv.ceTooESM 201

RE]\,1OVE

. Pr mary Drive cear Nut @

. Washer 6r

. Prin'rary Drlve Gear @

. Straight Key @

. Spacer t!

. O ISea Retainer @

t.9

KICK STARTEB

1 , REMOVE. Circlip O. Washer @. Kick ldle Gear @. Washer @. Circlip €)

2, UNHOOK. Kick Return Spring @

3. REIVIOVE

. Kick Starter Assembly @

SHIFT SHAFT

1. REIVIOVE (On LH Side). Circlip O' Washer (9

REMOVE (On RH Side). lensron bpnnq !t. Shlit Shaft Assemb y (9. treaflng Helalnel Flale L9

. Stopper Lever Assembly (O by us.lSocket No 12.

2.

t

t

CRANKCASE

TRANSMISSION AND SHIFTER

2, ATTACH. Special Service Tool ESM-265 O for sepa-

rating the Crankcase (On right hand side)

by tighiening Securing Bolis (a

3. DISASSEMBLE

1 . REITIOVE. Crankcase Tightening Screws (13 Nos )

LH side.

. Crankcase RH O & LH @ bY rotating

the lever ot the Special Service Tool

ESM-265 Clockwise and gently tapprng

the Hear end of the RH Crankoase with

Mallel.

I INSTALL. Engine Stand Mounting Nuts with Spacer

on LH Crankcase

HEMOVE. Bar Shift Fork Guide -1 O. Bar Shift Fork Guide -2 O. Fork Shift -2 @. Fork Shift '3 @. Fork Shilt "1 @

tBefore application ol the Special sevice Tool ESM 265 for separatinCrankcase, ensure that lhe mounlinnuts of the Engine Stand are removed

. Make sure the tool body is parallel wiihe Crankcase.

I'

REI\,4OVE. Shift Carn Assembly

REIVIOVE. Axle lMain Assembly €). Axle Drive Assembly @

CRANK SHAFT

1 . ATTACH. Special Service Tool ESM-265 G) for

separating CrankShaft €) fromCrankoase LH O , by tightening Secur'ing Bolts @

2 REI\,IOVE. Crankshalt Assembly by rotating the

lever €) Clockwise

While removing Crankshaft lrom LH Crankcase hold it trom the RH side to prevent ittrom falling down.

CYLINDER HEAD

CYLINDER

. Carbon deposit, Use rounded scrapef.

2, I\,4EASURE. Cylinder Head warpage using straight

edge O, Feeler cauge @lf out of speciflcation, resurlace or replace.

1 . REMOVE

INSPECT. Cylinder Wall for Wear/ Scralches

Rebore or Replace

MEASURE

1. REMOVE. Carbon deposit from the Exhaust Port.

Use rounded scraper.

2.

3.. Bore using Cylinder cauge 10 mm from

TDC at Poinls shown.I out of speclfication, rebore the Cylin-0et,

PISTON

1. INSPECT :

. Wear Scratches/Damages or reolac.

2. REI,4OVE :

. Carbon deposit lrom the Piston crownUse Rounded Scfaper.

Do not use a sharp ihstrument and avoiddamage or scratching.

Aller correcting, clean the Piston with a

clean cloth.

3. IVEASURE. Piston outside diameter wlth .

Micrometer.

16

4. PISTON CLEARANCE. li oui of specif cation, replace p ston anc

or rebore Cylinder.

Piston Clearance = Minimum CylinderBore - Piston Diameter

lf out of specillcation , replace

57.967 - 57.982

57.985

Standard

<Limit>

Oversize 1

Oversize 2

IMPORTANT

Measurement should be madeal a point10 mm above the bottom edge ol thePiston skirt & perpendicular to the axisof the Piston Pin. 0.034 - 0.039

PISTON RING

PISTON PIN AND SMALL END BEARING

'1 . MEASURE :

. Side Clearance @Use a Feeler Gauge @lf out of specification th€n replacePiston and / or Piston Rings.

2. N,IEASURE.Endgap:O

Use Feeler Gauge @Out of specification, Replace PistonRjngs as a set.

End Gap

0nsralled)

Standard Limit

0.25 to 0.45mm

0.6 mm

1, INSTALL. Pislon Pin O and Bearing after Lubrica-

tion (into small end of Connecting Rod@)

3. CHECK i

. Free Playlf free play is excessive, Inspect Con-necting Rod Small End and Piston PinlorWear.

4. INSTALL. Piston Pin O (in to Piston)

5, CHECK :

. Free Playll lree play out of specification, replacePiston Pin and/or Piston.

Side Clearance : 0.03 to 0.05 mm

3-9

CLUTCH

DRIVEN GEAB ASSEMBLY

1. INSPECT. Dogs on Housing O

lf CracksMea/Damage then Deburreplace

. Circumferential Play €), lf Playspecif icatlon then replace.

. Gear Teeth @ of Driven Gear Assernc .

CLUTCH BOSS'1, INSPECT :

. clutch Boss Splines @Scor ng Wear/Dar.age ther DebL 'Replace.

FRICTION PLATE'1. INSPECT :

. Friction Platesll Damages/Wear, Replace as a set

2, I\iIEASURE

Friction Plate thicknessN4easLre al dll lhe fo rr poinls as.ho

CLUTCH PLATE

1 , MEASURE. Waroage of ClJrch Plate 5. Use :

IaCe tslale L9, anO ieeleT bauqe Ili oul of specification then Replace

Wear limit : 2.7 mm

Warp limit : 0.05 mm

IMPORTANT

Plates Solines will cause erratic operation-

Minimum Lengih CLUTCH SPRING

1. MEASURE. Free length

lf less than the length specified, Replacethe Clutch Springs as a set.

STANDARD LENGTH SERVICE LIMIT

34.5 mm 33 rnm

KICK STARTEB

1 . INSPECT :

. Splines of Kick Shaft Assembly O

. KtcK uear teeln t4r

. Kick ldle GearTeeih @Teeth wofn out/darnaged then replacethe concerned Gear.

2. CHECK :

. Kick Geaf movement smoothly overspllnes.

3, I\,1EASURE. Kick Clip Friclion Force

Out of specification then Replace KickClip.

G CAUTION

-' clron Fotce u.u

--3 K ck gear should be firmly held in the V se whie measuring the Kick Clip Friction

3-1 1

CRANKSHAFT

Runout limit0.02 mm

1, MEASURE. Runout

Use Dial gauge.lf out ol specification then Replace.

2. [/]EASURE. Crank Width

lf Out of specification then Replace

3.IVIEASUBE. Big End Side Clearance

Use Feeler Gaugelf out oJ specification then Beplace

4, I\4EASURE. Small End Ffee PLay

ll out of specilication then Replace

Small end free play :

0.03 to 0.18 mm

Crankshaft & Connecting Rod to be re-placed as a set il the above paramelersindicate the need.

Reoair ofeither CrankShaft or Connect-ing Rod is not recommended as itwould affect the Engine performance.

CrankWidth :55.90 to 55.95 mm

g end side Clearance0.2 to 0.7mm

IMPORTANT

3-12

TRANSMISSION

]

-- k=r

SHIFT SHAFT

1. INSPECT I

. Shift Shaft O

. bpnnqs La

. Stopper Lever Assembly Olf Weaf/Bend, Replace

SHIFT FORK'1. INSPECT

. Shift Forks at(On the Gear and Shift Carn contactsunace)

. Shift Fork cuide Bars @Wear /Chaling/Bends/Damage thenReplace Fork and/or cuide Bar.

SI{IFT CAM'1. INSPECT

. Shifl Cam Grooves O

. Shifl Cam P ns @Wear/Damage/Scratches then Re-place

MAIN AXLE AND DRIVE AXLE

1 ]\,4EASURE:. Axle Runout

! se Cente'irg Devir.e and Dial GaugeI out of specificat on then replace.

Runout limit : 0.1 mm

3-13

GEABS'1, INSPECT

. Gearslf DamageMear then RePlace

2, CHECK. Gear Movement

It operalion ls not smootl' then Bep ace

the concerned Gear'

3. INSPECT. Matching Dogs.

lf Cracks, Wear, Damage observed ihenreplace.

BEARING AND OIL SEALS

1. CHECK

ll Rough Spots/Play then RePlace

2. INSPECT. All Oil Seal Lips

li DamageMear then BePlace

***

Always replace Crankshaft Oil Seals

whenever the Engine is opened.

CRANKSHAFT ASSEMBLY

CRANKSHAFTWOODRUFF KEYNEEDLE ROLLERBEARING

1. ATTACH :

. Special Service Tool ESNI 266 O (To

lhe left side of the Crankcase)for install-ing the Crankshaft. @

2. TIGHTEN:. Nut ofthe Special Service Tool ESM 266

i .Hold the Conreciing Bod ar TopDead Center.

Gf,MP{r\ Belore assemb\ing the Engine , uash \Ithe Crankshaft in mild solvent (perrol/

Ikerosene) |

f

^*4*'u@k'*w-.a 16v4

SPROCKET DRIVE (15 T)AXLE DRIVEGtrAtr tqT \A/1.]trtrI

CLUTCH DOGGEAR 3RD WHEEL (26 T)GEAR 4TH WHEEL (23 T)GEAR 1ST WHEEL (35 T)2ND PtNtON GEAR (r 5 T)3RD PTNTON GEAR (19 T)4TH PTNTON GEAR (23 T)AXLE I\,1AIN

PLATE COVER

FORK SHIFT -1FORK SHIFT - 3BAR SHIFT FORK GUIDE - 2PLUG BLINDGASKET PLUG BLINDSHIFT CAI\,IPINSPLATE SIDESTOPPER LEVERBAR SHIFT FORK GUIDE -1

FORK SHIFT " 2

13.

17.18.'1 9.20.21.22.23

TBANSMISSION AND SHIFTER

3-16

1. INSTALL:

Axle Drive Assembly @Axle Main Assembly @Shiti Cam Assembly @Fork Shift"l @Fork Shilt-3Bar Shift Fork Guide-2 @Fork Shi1r2Bar Shift Fork Guide-'1

2. CHECK:. Rolate Cam Shift and Check l\4ovement

of Fork and Sliding ol Attached cearslf Incorrect operation then Reassemble.

CRANKCASE ASSEMBLY

DKgm (11 Ft. Lb)

2.0 Kgm (14 Ft. Lb)

1.

2.3.4.5.6.

OIL SEALBEARING 6304BEARING (NRB)OIL SEALCRANKCASE LHCRANKCASE RH

BEARING 6204BEARING 6205DRAIN PLUGOIL SEAL RETAINEFIOIL SEALBEARING 6303 Z

1 . APPLY:. Yamaha 3 t\,4 Bond €) (to both The

Crankcase mating surlaces.)

2. INSTALL:

3, INSTALL. R ght Hand Crankcase €) (Tap as sho$'.

wth Ma let)

. Dowel Knock Pins @

I

4, TIGHTEN:. CrankcaseTightening Screws.(1 3 Nos.)

Tighten the Screws in the shown se-quence and in two steps (1) Semitighten(2) Full itighten.

FLYWHEEL MAGNETO

1 INSTALL. Stator Assembly O

2 CONNECT. Neutral Switch Lead Wire @

3 1NSTALL. Woodrulf Key. Rolor Assembly @. Lock Washer

TIGHTEN. \ul E using socket No 19 with To'que

W.erch holding Botor assembly w.thSpecial Service Tool ESN,I 201 6)

E\,ra:f11r9lNESR\NN

0.7 Kgm (s.1 Ft. Lb)

crankcase (Left hand and Right Hand) should always be replaced as a set.

SHIFT SHAFT

o

1.0 Ksm (7'0 Ft Lb) I

PIN CLEVISSPLIT PINROD SHIFTWASHER PLATE

CIRCLIPWASHER PLATEPEDAL SHIFTCOVER SHIFT PEDAL

ARM SHIFT

10. clRcLlP,11. WASHER PLATE

12, OIL SEAL'I3. SHIFT SHAFT14. SPRINGTORSON15, SPRING TENSION

16. scREW17, NUT'18, WASHER LOCK

1, INSTALL:. Stopper Lever Assembly O. Plate Cover (a

. Shift Shaft Assembly @

2, INSTALL:. Washer @. circlip @

1.4 Kgm (10 Ft. Lb)

2, ADJUST:. Shift Lever position (by Adjuster Screw

@ and Locknut @). Gap @ to be equal on both the sides.

While adiusting the transmissionshould be engaged in the 2nd Gear.

,

I

I

I

iKICK STARTER

COVEF KICK LEVERK CK CRANKSPRINGBALLBOSS KICK CRANKSPACER

SPRING TORSIONCOVER SPRINGGEAR KICKGEAR KICK IDLECLIPKICK AXLE ASSEMBLY

3-21

1, INSTALL. Kick Starier Assembly

2. POSITION. The Kick CliP @ in groove @ ot the

crankcase as shown

3. HOOK. Return Spring @

4. INSTALL. Ckclip

. Kick ldle Gear @

. Washer @

. Circlip €)

ENG

N.SN @;\%6

^.%1,1t

P,pg 26

=@

22

BOLT WITH WASHERSPRING COI\,lPRESSIONPLATE PRESUREROD PUSH 1

NUTWASHEF CONICAL SPRING

PLATE FRICTIONPLATE CLUTCHBOSS CLUTCHPLATE THRUST - 1

PBII\,'IARY DRIVEN GEAR

SPACERWASHER PLATE

14. BALL15. ROD PUSH - 2

16. OIL SEAL17. LEVER PUSH

18. SPRING19. OIL SEAL20. SCREW PUSH

21 BOLT SET22. NUT23. NUT24 WASHER SPRING

25, GEAR PRIMARY DRIVE

26. STRAIGHT KEY

27, COLLAR

CLUTCH

3-23

'1, INSTALL. Thrust Washer O. Spacer @. Driven Gear Assy. O. Thrust Washer @. Oil Seal Retainer @. Spacer @. Straight Key @. Primary Drive Gear @

Insiallation ol Dliven Gear Assy. andPrimary Drive Gear should be doneSimultaneously

2. INSTALL. Cluich Boss @. Washer @

'Nut@

3. TIGHTEN

'Driven Gear AssY Nut with Tc':-iW'ench ard no dlng tle Clulcf B' :'w,ll. Specral Se.v'ce Too FSV .: :

(31 Fr. Lb)

The Clutch Plates must be so insta le:their cutways do not overJap each otf:except for the Plates 1 and 5

4, INSTALL. Friction Plates (6 Nos) @. Clutch Plates (5 nos)@.

'Ball@' Push Rod @

I

E\ [.*n'"\\1

Arrow of Pressure Plate should b€

matched with the Dot Mark on clul]-Boss

15

4 (( )12

3-24

5, INSTALL. Pressure Plate @. Springs @

. Bolts @

6. TIGHTEN. Primary Drive Gear Nut along with

washer by using Torque Wrench.

DRIVING SPROCKET

1 , INSTALL. Drive Sprocket O. Lock Washer

TIGHTEN. Drive Sprocket Nut @ with torque wrench

having socket No 26, holding theSprocket by Specral Service Tool ESlvl -

205 @

CRANKCASE COVERS

l INSTALL. Crankcase Cover RH O

5.5 Kgm (40 Ft. Lb)

b"V4*YY'

s'a{4 il

s9 ,'

SPARK PLUGNUTCYLINDEB HEADGASKET CYLINDER HEADBOLT STUDCYLINDERBOLT STUD

NUT1.

2.3.4.5.6.7.

B.

L'1 0.11.12.13.1r1

15.

GASKET CYLINDERRINGSEXPANDEFPISTONBEARING CYLINDRICALPIN PISTONCIRCLIP

ENG

3

1, INSTALL. Piston O. Piston Rings with Expander @

. Needle Roller Bearing

. Piston pin O using Special Service Tool -

ESM 507 @ (Piston Pin FePlacer). Piston Pin clips (new) @

CYLINDEB

INSTALL. casket (new) at. Cylinder @l Using Special Service Tool

ESVI 5'0 3 tPislon qrng Compressorl

TIGHTEN. Cylinder Nuts Gr (4 Nos )

IMPORTANT

Make sure Piston Ring Ends are prop-

erty titted around Piston Ring LocatingPins in Piston Grooves

The arrow on Piston Dome musl face

Exhaust Side.

Belore installing the Piston Pin Clipcover the Crankcase with a Clean Rag

Q*:"re{"i3-27

1, INSTALL. Head Gasket O. cylinder Head iO

2, TIGHTEN. Cylinder Head Nuts Ol 4 nos. with torque

wrench using Socket No 14

" Spark Plug €)

il

{

Ifi

1

tiQ\.1,:lyll".-.'f

ENGINE MOUNTING

1. TIGHTEN. Engine Mountlng Bolts

. Eng ne Mounting Bo ts le

9\ ..0 *n* (* r,. .01

IN STALL. L.H. crankcase Cover i.0,

F ILL

GearBox Oil. L.Fl. cfankcase Cover

...-:'

3-28

GRADE

"r=h@DF VEN GEAR ASSY

DRIVEN GEAR ASSY, & GEARPRII\,4ARY DRIVE GRADING

COLOURcoDE (DOT)

GRADE

PR MARYI

:\]NECT NG ROD (S]\,4ALL END) &::DLE ROLLER BEARING (SIIIALL END) CUT N,4ARK

ON CAGE SIDE

. SPEC FIED ALLOWFD COI\,IBINATION.OLOUR BAND

BODY CYL NDERASSY. (STD )

(STD)

STANDARD PISTON & STANDARDBODY CYLINDER

J:IDE PUNCHED ON BASE FRONT: l: TEXHAUST PORT SIDE)

..: :rnbLnalrnsol gra'lesareappL,.ablelo(standadl; rden ..y.vers'ze (OrS) gody Cy .ders the

, .: il Pslon [.!d be delerm ned by lhe rebored.:.1fi€rnaloflhe B.dy cy rnder l

29

DB]VEN GEAR

GEAR \PR]N4ARY DRIVE

GRADESz A B c D

GBADEe

AB

cD

E

. SPEC FIED ALLOWED CO]VBINAT ON

.{N ROD(sE)

'-\

.--ir'rcrsEr\

COLOUBCODES

WHITE

(D0T)BLUE(D0T)

BED(DoT)

I{1 CUT MABK)B

AIII (2 CUT |\4ARKS)

UI3 CUT MARKS

SMALL END NEEDLE

CRANK SHAFT

P STON (STD)

3CDY CTL lSTD.

COLOUR BANDS

$n RED

D

Er

E'

r.

DS

e!41!GE

GREEN

PURPLE

FRONT

3-

!

CHAPTER 4

CARBURETTOR

CARBURETTOR

cARBURETTOR EXPLODED VtEW .......... ... . ... .......4-1

opERAT|ON OF CARBU RETTOR ................................ 4-2

WORKING RANGE OF EACH COMPONENTS - , .4-3

REMOVAL AND DISASSEMBLY ........4-4

TNSPECTION -.....-...4-5

REED VALVE

TNSPECTTON ..........4-5

19

1F116

&17

CAPGASKETSPRING THBOTTLE VALVENEEDLE SETVALVE THROTTLE - 1

CABBURETTOR BODYAlR SCREW SETfLUNGER STARTER ASSYTHROTTLE SCREW SET

-, \LL\LL \NL\L N\S\.- . .P\N FLOAf

12. FLOAT ASSY13 FLOAT CHAMBER14, GASKET FLOAT CHAIV]BER15. JET PILOT16. NOZZLE IVIAIN

17. JET MAIN18. CLAN4P HOSE] 9 JO NT CARBURETTOR20 REED VALVE

2\ q}\\\.L\\\\\LSE\\

,l

4-l

CARBIG

@f

OPERATION OF CARBURETTOR

LOW SPEED CONTROL SYSTEM

OTO 1/8 ffHROTTLE OPENING)

MrxrNG

-|l llqT ourtE-

{li,ru

t!4-

Throttle Valveopening Angle

OperatingSystem

ldling 0 Piloi Jet

Low speed 0 to 1/8 Piot Jet

Low and [/ed um Speeds1/B to '114

Pilot Jet/Cutav'vay

Nledium and high Speeds114lo 314

Marn Jet

[/ediL]m and high Speeds3/4 to Full

Main Jet

lr tl\-:-r

0- 1/8

LOW SPEED CONTROL SYSTEM

1/8 TO 1/4 (THROTTLE OPENTNG)

_tFUELi_}L8]!8I!EfI

MEDIUM SPEED CONTROL SYSTEM

1/4 TO 3/4 (THROTTLE OPENTNG)

HIGH SPEED CONTROL SYSTEM

3/4 TO FULL (THROTTLE OPENING)

WORKING RANGE OF EACHCOMPONENT

A) MAIN JET

B) NEEDLE JET AND JET NEEDLE

C) THROTTLE VALVE CUTAWAY

D) PILOT AIR SCREW & JET

1_1tTlffiLS71

tl8-?Ai\9r+

ED1 1 1 18424

Throllle va]velplsro.)

MIXING

Thronle vaNe(piston)

ENGINE

NEEDLE JE

JET NEEDLE

NEEDLE JET

MIXING

FULL OPEN

r

DIS AS S E tt'lB LY

1 := "'3,

.. :r.:- S:e 2.ri RH side.

' aa. Assernbll/ A r Cieaner G) by opening

3 \las saretls

2. LOOSEN. Jo ni Arr C eaner Clamps Screw @

. C amp Carburettor Hose Scfew ol Jolnt

Carburettor:r.

3, DISCONNECT:. Fuel Hose @)

. Oil Delivery Hose 64. REN4oVE:

. Carburettor lO

. CarburettorToP @

5. DISCONNECT:. Throttle Cable (O

. Throtile Valve AssY.

6. REMOVE:. Starter PlLlnger Assembly €l. Float Chamber @ by opening four nos

scre\i/s.. Float @ by removing Pin Float (a

. Needle Valve Assembly d,

. lvain Jet by @

. Pilot Jet bY screw driver 6'

7, REMOVE. Reed Valve Assembly @ by opening,:

No bolts (Reed Valve, Joint Carburettof

Gasket)

REMOVAL AND

IMPORTANT

drop in fuel average-

. Never clean the Jets with a wire.

. Alwavs clean the Carburettor lrom outside belore disassembly'

. irpi6p"t ""ning

of Float Height, C-lock on Jet Needle' and Air Screw can ca

OdDpa-

CLEANING ANDINSPECTION

1. CLEAN. Using high pressure air, blow out all pas-

sages anq lers.2, INSPECT:

. Needle Valve Assembly1 Gasket O2 Valve Seat @3 Needle Valve @

Damaged or Worn oul -Replaceasaset

3. INSPECT :

. Throttle Valve

. Jet Needle @Scratch/Bent -

@

Replace

4. MEASURE:. Float Height @ Without Gasket

wilh Needle Valve Assembly in posiiionlf found incorrect then Adjust

5. ADJUST. Float Height

by bending the Tang @

lf Float Height is more than specified,less petrol in Float Chamber.

lf Float Height is lessthan specified, thenmore petrol in Float Chamber.

\\ N /2, ]'@ffi

IMPORTANT

4-5

CARB

REED VALVE

T

, ,: ,: :i::3e'neight oa-: a' :3:. i ;alon -AdjLlst. ?ea. !a re gending goLt oi sPec flcatlon -RePlace

Valve StoPPer Height @ 9i0 3

Fteed Valve Bending Limit O0.2mm

FUEL LEVEL. Place the Motorcycle on level surface. Attach the FLlel Level Gauge Gl to the

Float Chamber Nozzle. Loosen the Drdin Scle',i/ 2 and

"larl I'

Enqine.. Me;sure the Fuer Level J wilh OaJg". lt the fuel level is incorrect adjusl the

Float

FUEL LEVEL:5.7 i 0.5 MM

{MEASURED FROM THETOPTHE FLOAT CHAMBER)

EDGE OF

Note the cut is in the lower corner or

the Reed and the StoPPer Plate'

ThecalburettorisPresetattheFactoryaftermanytests.|fthesettings'aredisturbed

"i-tro"i ftltlng

""V technicat knowledge, poor Engine Perfomance may result.

FRONT WHEEL

12

"@-*^,{n'@

16

n.,,.'A6-

k'*,,7

a.2.-0.'1.

AXLE WHEELCOVER ASSEMBLYOIL SEALBEABINGTYRETU BEBANDBlMSPOKE SETHUB FBONTSPACER ASSEI\IBLY

12, BEARING13. BRAKE SHOE COMLPLETE14. CLUTCH METER15. GEAB DRIVE16 OIL SEAL17. CAM SHAFT1B PLATE BRAKE SHOE19 LEVEF CAM SHAFT 1

20. GEAR METER21 BUSH22 O L SEAL

CHAS

tr...

FRONT WHEEL REI,IOVAL

' :-ra: --: ','OIORCYCLE ON ITSa:'.-::3-i'.l2 - a::

='.t -.: -a:{_-: ! and screw n the adjuster: ic :aaa' tfre brake cable on the front\.;ree t are brake shoe.

3. DISCONNECT:. The brake cable @ by pressing Lever

Camshafll L4l

4. DISCONNECT:. Removing the Ring Stop @ Disconnect

the Speedometer Cable a6l

Relit TheWheel in Reverse Sequence.

Axle Nut 4.3 Kg. mLb.\

{fi FrontY' (31 Ftr

5. REMO\E:. Colter Pin ill. Axle Nut €) by using rlng spanne".. Axle Shaft O. Front Whee @

CHAS

REAR WHEEL

'a13

&..r{*tt t1, If L"qJzs ;* -** -4*;'@""

zs- @o

AXLE WHEELPULLER CHAIN 2COLLARLEVER CAM SHAFTPLATE BRAKE SHOECAI\,I SHAFTBRAKE SHOE SETTYRETUBEBANDRll\,1

SPOKE SET

OIL SEALBEAFINGSPACER ASSEIMBLY 2HUBBEARINGDAI\,4PER

CLUTCH HUBBEARINGOIL SEALAXLE SPROCKETCHAINSPROCKET DRIVEPULLEF CHAIN 1

17.

19.24.21

22.23.

25.

T

ii!: ,I.gEL REMOVAL

--: ,,. :-SRCYCLE ON ITS

.-_: " - ::A SUPPORT

., 'anovLng splitpin and

-s rg r ng spanner No

::t,'', :

, : r' 1 : - or -r screvlirg Nulwing 3

t i: ': :':r: hoo !. So' .! ca.npress on 6. vlasher P ate O

I

4, REN,4OVE:

. Split Pin O

. Axle Nut @ using Ring Spanner No 22.

5. REN4OVE|

. Axle Wheel O While pressing the Assist

Grip @ down with force.. Collar @. Rear Wheel @ tiiting the Motorcycle to

Lelt Hand Side.

Cale should be taken that the'AxleWheellshould not Rub the Silencer while it be.J

ing pulled out from ihe Real Wheel.

REFIT THE WHEEL IN BEVERSE SE.OUENCE.

5

lQIe""'^'"]1s.2 Ks. m (66 FtLb.)

CHAS

I

I

I

I

{

SPROCKET DRIVEN &

INSPECTION

CHAIN REMOVAL

1, REN,4OVEi

. Chain Case 1O by open ng screws (4 Nos)

. Dr ve Cha n lock O and Drive Chain O.

2. FIEMOVE:. sprocket Assy @ by opening Nut Gl us-

ing Ring Spanner No 27.. Sprocket Driven @ from Clutch Hub (a

by un ocking and opening bolts screws(4Nos.)

1. INSPECT;. Axle Wheel (Beaf and Fronl)

Roll the Axle Shaft on a Flat SLrrfacelf Shaft Bent then Replace.

INSPECT:2.. Wheel (Rear and Front)

lf Tyre Cracked/Rim Heavily Bent thentr6nl'.o th6.^n.d.han

^rrt

3. MEASURE:. Wheel Runout

f out of Specification then True theWheel or Replace.

4. IN SPECT;. $Jf,ee\ Bear\ngs

f excess play in the Bearings or Bear-rng Jarnmed then Rep\aae.

Rim Runout LimitsFadialoMax 2.0 mmLatera\OMax 2.0 mm

5. MEASURE:. Brake Shoe thickness

Out ol specification then Beplace.

Brake Shoe Wear limit 2MM

6, NIEASURE:. Brake drum inside diameter

Out ol specification, Beplace.

lBrake Drum Diameter Limit '13-1 mm. (max.)

T.INSPECT:. uflve SprocKel ql. Driven Sprocket @

ll Wear/BentTeeth ihen Replace both r:Sprockets and the Chain as a set.

8, MEASURE:. Drive chain length (10 Links) 'A'

li Out of specification then Replace

'tlF@S

Diive Chain Length (10 Links)

Maximum Lim:t:'12'l mm

CHAS

9. INSTALL. The Chain Clip O with rounded end fac-

ing the direction ol travel of Chaln

10.cHECK. That bolh ihe RH and LH Chain Adjusl

ers are adjusted to the same position tomaintain correct Axle alignment.

. The Chain Slackness should be between

20 to 30 mm with Motorcycle on CentfalStand.

KITIMPoRrlNrlI Please lubricate Chain with Multigrade

I

| 20w40 oil belore installing. I

Note the following installation points

- ghtLy grease the wheel oil seal lips and geaf teeth of the speedometer drive and driven

Jears.LJse jghtwe ght, lithium base grease )

3e sure that the tongue stopper is posiUoned cofrect y.

rIltiu-I

lnftxl "totl"" l

:-

E I\,1BLE IM

FRONT FORK ASSEMBLY RH.

UNDER BFACKET COMPLETECAP FRONT FORKBOLT CAPSPACERSPRING SEATSPRING

L10.11.12.'1 3.14.15.

CYLINDEF COI\,4PLETEINNER TUBE COI\,lPLETESPINDLETAPERSEAL DUSTCLIP OIL SEALOIL SEALOUTER TUBE LH

REMOVAL

1 , REMOVE:. Front Wheel as described on page 5-1. Front Fender bV opening bolts (4 Nos)

2. LOOSEN:. Front Fork Pinch Bolt Upper O (2 Nos). Hemove uap hronl ForK !9. Bolt Cap @(2 Nos)

Use Specia' Servce Tool ESM.2l4 a

(Top Plug Spanneo

REMOVE:. Emblern 6) by opening screws (2Nos)

LOOSEN:. Front Fork Pinch Boll Lower @ (2 Nos)

using Ring Spanner No 14

5. REMOVE:. Front Fofk Assembly L.H. & R.H.a0

3.

DISASSEMBLY

pl

- t!,Ef

'1. RE]\,4OVE:

. Botoap O' spacer rg

" Spring Seat O. Spri.g @8,,

DISASSEMBLY

-

2 DFAI\. Fr.ri F:'( O ci Pumping InnerTube@

ns de :h: O!iaf T.rbe tt

OPEN:. Bolt Hexagonal Socket Head @ by us'

ing Allen key No 8. Use Special ServiceTool G) {ES-\,4 - 213)

1o hold the CYlinder ComPlete (9

REMOVE:. tnnet tuoe 9. Cylinder ComPlete @. Spindle TaPer @

3.

4.

5, REMOVE:. Dust cover @. Clip Oilseal @. Washer (). Oil Seal @ using

@ (ESM 270)Special Service Tool

INSPECTION

t." a** tr* l1. INSPECT:

. lnner Tube il-

. Outer TubeScratches/Bends/Dan'rage Rep aceTeourred.\leasure Length of Fork Spring €l lf Out

oi specificat on Then ReP aceO Ring of Bolt CaP

Cvl nder CornPlete for DamagesC Seal ot Outer Tube lor dan]ages

-^

5-10

Specified 296.5 mm

Nlinimum limit 291.5

t

ASSEMBLY

1. INSTALL:. Insert Cylinder Complete O (with Spring

@) irom the top end ol the InnerTube @. Spindle Taper @ on the lower end of the

Cylinder Complete. Inserttheaboveassemblyintothe outer

tube 6). Bolt Hex Socket Head @ Using allen key

No 8 and Special Service Tool @ (ESM21s)

2. INSTALL:

. Oil SeaL @ with Special Service Tool -EStVt 275 €).

. Clip Oil Seal

3. INSTALL:

. Front Fork Spring @

. spring Seat @

' Spacer @. Boit Cap @

. Dust Cap @

4. FILL:. Front Fork Oil

Each Fork Leg175 r 3cc

SERVOTELESHOCABotL

t

il

I

5. INSTALL. Front Fork Assembly LH & RH.. Tighten the Bolt Cap.

' Pinch Bolt upper and lower. Cap Front Fork

t6\ cap Bolr: 2.3 Kg.m, (17 Fr.Lb)\ \ Pinch Bolt:Upper: 1.5 Kg.m, (11 Ft.Lb)

Cylinder Comp ; 2.3 Kg.m,

(17 Ft.Lb)

13

'11

Lower : 3.0 Kg.m, (22 Ft.Lb

COVEB UPPER RIGHTCOVER UPPER LEFTCOVER OUTER RIGHTCOVER OUTER LEFTEMBLEMUNDER BRACKETLOWER RACE BALL 1

BALL 19 NOSLOWER RACE BALL . 2

e11€tz

UPPER RACEBALL - 2BALL (22 NOS)UPPER RACE BALL - 1

COVER BALL RACENUTCROWN HANDLEHOLDER HANDLE UPPERBOLT CROWN

1 . REMOVE:. Front Wheel as per instructions on page

. Front Forks as per instructtons on page

5-6.. Headlight Bezel Assy. O

2 DLSCONNECT:. All Electrical lead wires @

(in the Headlight Case)

gF

ePE0

kis?l-/P

L-

10.11.

14.

17.

REMOVAL

e1413 ^-

g"_5 rz s,9.d:

16

COVER UPPER RIGHTCOVER UPPER LEFTCOVER OUTER RIGHTCOVER OUTER LEFTEMBLEIiIUNDER BRACKETLOWER RACE BALL 1

BALL 19 NOSLOWER HACE BALL . 2

'1 0.1',t.

12.

14.

17.

UPPER RACEBALL . 2BALL (22 NOS)UPPER RACE BALL - 1

COVER BALL RACENUTCROWN HANDLEHOLDER HANDLE UPPERBOLT CROWN

REMOVAL

I REMOVE:. trrolt Wheel as per rlsl.uctro'rs on page

. tr'o1t Forks as per Insl.lrctions or pagc

. Headlight Bezel Assy. O2 DISCONNECT:

. A I E ectrical lead wires @(in the Headlight Case)

s-12

3, REMOVE:. Cover Crown O. Bolt Crown @ bY using socket No 17. Crown Head assembly @. Headlight Stays (LH & RH) @

4. DISCONNECT:. Brake Cable @ {rom the Brake Lever @)

. clutch cable (0 from the clutch Lever @

5, REMOVE:. Fork stem Nut @ using Special Ser-

vice Tool @ ESM 221. Cover Ball Race @. Race Ball 1 @. Top Balls @ (22 nos )

. Bottom Balls q9 (19 nos )

. Under bracket @

6, FIEMOVE. Race Ball 2 (Lower @

Using a long rod.. Race Ball 1 @ (Lower)

chisel.

and Upper @)

Using a cold

lnigil

6

1t

13

'14

t5

t6

T

CHAa

@"@INSPECTION

INSTALLATION

--: ::::: :_: Sals in pekol.

2 \,s:::-. : -:r ::_rage Then Replace.

= :-:; tarage Then Replace.

oqr. ^'.EW

J \S-ALL. Fa.e Ba T (bottom) €Jon the under

cra:K:l ano race ball 2 bottorn Oandupcer ,2 insrde the head tube of thefrarne uslng punch

l.Grease the Balls and Baces

. Under Bracket @

. Race ball 1 upper

. Beaflng uover a

. Ring Nut lO

TIGHTENi. Ring Nut @

ESM 221 t-'(So that a I

DracKel can

INSTALL:

3.

with Specia Service Too

play is taken up, but thestill pivot freely.)

Handle Crown w th Head ght staysCrown BoltFront Forks LH and RH as per nslructions on page 5-8

2, INSTALL

CHAS

el

I

@q$roo

f\\Cr--;3 \ ,iu

1.2.3.

SHAFT PIVOT 5, BRACKET UPPER6. COVER OUTER7. SPRING8. SEAT SPRING9. DAIVPER ASSY

BUSHREAR ARM COMPLETESHOCK ABSOFIBE R

ASSY REAR

REMOVAL

REMOVE:

. Chain Case

. Drive Chain

. Dfiven Sprocket

. Chain Case

REMOVE:. Shock Absorber Mount Bolts@. Shock Absorbers

REMOVE:

. Pivot Shalt Nut O

. Pivot Shatt 0

t\

. Sw)ng arm

CHAS

5-16

INSPECTION

t.....:''':'

lhen Beplace

2 '.s;:a-. S,', -l a'-

'.,'i- :.a s!','ng arm Installed gfasp thesl., .; ar.n enC to check forfree play- Freep ay rc: .ed Replace bushes.

Swing arm Free Play Limit: 2.0 mm

)o 3. INSPECT:. P vot Shaft 2

Rusvd rty Clean or Replace.Bent - Replace

INSTALLATION

1 . GREASE THE BUSHES AND PIVOTSHAFT.

2INSTALL:. Swlng arm. P vot Shaft

Kgm (43 Ft. Lb)

Always adjust both the right and left shock absorbers to the same posit on.

ELEU

t2! 5/2tW

ls\*sJl -u

]HTET tIql

r"l-E

-

I

-a

z

EisiE

- M-

6+.o

6

dts

rt"'lrIE

FLASHEFLIOHI LGI]I 12VN4W ]21J-3 4W

12V.1Cr' 12V.3lW

HEAD L]6 -12V.35r3!rr _:-_

: :r'

o

==

4

II

a.s

E9*FzITo(l

e t-l;"s:E?lsa

s;:869s

ft -:HEecFii?

-li .

O6dEt;

I

t

t

<f@o-

IGNITION COIL

SOURCE COIL

PICK UPcotL

FUNCTION

CHARGING. As tt-te fotor turns, cufienl ls produced in

'ie so- ce.oil a1d then storpo il rl^e.g1.t on condenser. (Fig. 1)

TR GGER NG. Att e same time.The pickup coil sends a pulse

s gna I to activate the thyristor (Fig. 2)

SPARKING

' --:. the gnilion condenser discharges:-: :iored current rapidly. This induces a- l- . c tage n the lgnition coil and a stronc::: < s oroduced.(Fig. 3)

,,i----\ 'i

ffitr{!,}

vi il

FIG 2

E)0 T

TROUBLESHOOTING CHART

. All wires Conneclion must be checked in advance.

1 Spark Gap Test

Cylinder. Ground the Spark Plug toHead and Kick the Starter

No Spark or WeakSpark

nder Head

No Spark

. Disconnect the Mainkick the Sta er.

Pick Up Coil

the

+. Check the Pickup Coil Resistance

"^+ *o+

rk Gao Test

. Hold the lgnition Lead 5 mm from the Cyl-

check the Plug Capand Spark Plug

3 rk Gap Test

Switch Coupler and

Check Main Switch Rep ace the CDI Ljnit

Replace the Pick Up Coil

5 | SoLrrce Coil Check

. Check up source coil resistance

o*+ *+Replace the Source Coil

. Check the resistance of the primary andsecondary coil winding.

Replace the lgn tion Coil

6 | lqnition Coil Check

OPRM

o L 6_J:!qqnt--tnlt . t-- -rtl

HY'"6No Spark

I\,/ 5parK "^+

*"+

RECTIFIER/REGULATOR

l..Charging Voltaqe Test. Connect the lester leads

minals as shown.Startcheck voltage.

with battery ter-the engine and

FUSE

2. Charging Coil BesistanceDlsconnect the generator leads an:check charging coil winding resistanc€

iHAFG NG COIL RES STANCE: .q olll,,4s r l0?" (Wlrrle/B ack)

CHARG NG VOLTAGE14.5i05Vai5000FPNj

lf out of speciiications checK Char,o _!

coil windlngs reslstance Ata ' ff :'athan 12V replace the Rectre"Fe!-:'10r

--.--\

CHARGING ; -corL .i ,i

BATTERY

: -: :: soec l cation, reP ace charglng .-

neoo.,cr-, ). J\" I llil e.+" l f'l)lL?'T , Yl

AUXTL|ARY I r*-lLIGI,]T i

,rrrr^- *

| o,0;";*"t

rllGH BEArli NDtCaTOF LtcFT

BECTIFIEFBEGULATOF

LroHlruc coti

LIGHTINGSWITCH

LIGHT

=

l.Lighting Voltage Test

I:To'1e t:e headl;ght reads and conneclIne lester leads as shown St:ri rh. -^^;ard .necF rr^e uoi,uj"" "*" " = - tgrn"

2.Lighting Coil Reststance

ll:n.:'::J ;":t j ";:;,,;1:1". ."

YELLOW

H GH BEAM IND CATOF LIGH' LIGHTINGSWITCH

HEADLIGHT

/:4.r\14*Fr

FIECTIF ERLIGHTING COIL

REGULATOF

,ti

l.Lighting Voltage TestRemove the Headlight leads and connectthe lester leads as shown.Start the engineand check the voltage.

2.Lighting Coil Resistance

L G]]TING VOLTAGE13.5!0 5V AT 5000 BPl",l(Yel ow /Black or Grcen/Back)

L GHTING CO L FES STANCE0.55 OHNIS r r0%Yellow Red/Bla

lf o.rl o' spec:'icatio Ihe.( | rgl^lng coilresislance and Rectif ler/Regu ator.

--I

HLGH BEAM INDICATOF LIGI]T LIGHTINGSWITCH

HEADLIGHT

METEFIL GIIT

L GHTING COIL

L GHTBECTIFIEBREGULATOR

=T---L-

l.Lighting Volage TestRemove the Headlight leads and connectthe lester leads as shown.Start the engineand check the voltage.

2.Lighting Coil Resistance

LIGHTING VOLTAGEl3 5!0.5V AT 5000 RPM(Ye low iB ack or GreedBlack)

LIGHTING CO L RESISTANCE0.55 Ol'llr4s i 10%

li out of specification, check L ghting Coilresistance and Rectif ier/Regulator-

L GHT

MAIN SWITCH

r

swtTct \ i:-tt:

Br

.i

SWITCH INSPECTION

(:rc

(oscoNTlNrlED) {coNTrNUEo)

Briw

sw Tcfl

FLASHEFLGHT(FF)

FLASHEF

FLASIIEF INDL GHT (B)

LGHT (L.F l

LGHT(LFl

FLASI]EF N:L GHT (L)

+BATTERY

I SHIFT

BRAKE LIGHT

MAIN SWITCH

B/W R BroFs G ooNo G.

LIGHT SWITCHL

o -{fPO G o oON o- -o

6-6

I,IMER SWITCH

ASHER SWITCH

qN SWITCH

BRAKE SWITCH

\JS G -o

-..-

DIMMEF SWITCH

G

H' Qt o oro ci o --o

BBAKE SWITCH

\JS O --o

FLASHER SWITCH

B/w D9

o-N

o- -o

HORN SWITCH

i:l --o

G

G_

ciLO o- --o

DIMMER SWITCH BRAKE SWITCH

FLASHER SWITCH

\J>\Js o

Br/w Dg

o-N

-o

HORN SWITCH

7777

Irl o

t

o I delivelr crank veniilarcn hoso

calbu1610r br€atherhose

STARTING TROUBLE

Fuel Coch cjosed

ri'"",'"",',iti :?11 fl:? ll .,,":fiJ'

Air veni hole n FuelTanf Crp "log;;Choked FueICock

Carbureitor llooded

Chocked Fuel Filter

IGNITION

f"1arn Switch OFF,

Spart eiug Otrty or. OriOg;;y s;;H. T. tead toose/broken.

lnsulatton of Spark plug cracked

Elecl ron ic i g ni tion system;f e;;

POOR PICK UPPOSSIBLE CAUSES

A r F[ler choked or drrly

!g1Oer Carluretror aCtustme,,rt

POSSIBLE CAUSES

FUEL SYSTEM

No luelln TankBefrtJfuelrn Tank

Turn Fuet Coctco ,ON, Foitroi

3:Tlr:,i:ilank, Fuer c";" F*il;""d

Clean Fuel Tank Cap

Get Fuet Cock cteaned

T,,rn F,,-i ^-^,-.,;";::::1,:,y.' .pos,uon. oDer rre rhro re

;;;;ff il:j :"^ ifj :rar.airer unscrewns sparkl;1g T:,t :g:'ln:l'" i'; --;;;il'Jil : :['Jl"'u,,,. He'lt upark plug and k,cx start rne i.g,"sGet Fuel Fjller cleaned

Turn key to ON'positio;

cl""n, "t,""t

uno uo;rs rnu $rkEfEE[IZ"pFrt propertyheptace H.TIeJ

Replace Spark pjug.

Check ior ioose conneclions-

\4|rfJier ouIet chokecJClean Ihe t!,lulfter

Clean Air Filler/Beplace

najL,sr tne Carburettor sen-iniiCylinder Head Loose

C utch stippingf'On'"n CV""O", Uo"o t,r" ,o *"a,t,J,o,GAdJUst Cturch se rngirenorQuality ol Fuel cn"1!115g11a111.0^"[osoodquJ. .-,,r1,"1

3rake(s) b ndrngAdjust Brake(s)

?islon Fing worn outReplace pisron Fings as a;

STARTING TROUBLE

POSSIBLE CAUSES REMEDIES

FUEL SYSTEM

No fuel n Tank Retilfuel n Tank

FLre Cock closed Turn Fuel Cock to ON' position

lmproper iue supp y due to sed mentorwater n fuelor alr lock in iuel line.

Clean Fuel fank, Fuel Cock, Fuel Line andCarbureitor.

Air vent hole in Fuel Tank Cap clogged

Choked Fuel Cock

Carbureltor floo.led

C ean FuelTank C_ap

Get Fuel Cock cleaned

Turn Fuel Cock to OFF'position. Open the Throttleand endeavour lo kick slad after unscrewing SparkPlug and plugging the Spark Plug hote with a cleanc oll . Refil Soark P Lg and k'ck start rhe Engine.

Chocked Fuel F lter Gel Fue Fiter c eaned

IGNITION

Ma n Swilch OFF-' Turn key to 'ON' posilion

Spark P ug diriy or brdged by soot or Clean, check and adjust the Spark ptug Electrode cap

H. T. lead loose broken Fit properly/rep ace H.T. lead

Insulation of Spark Plug cracked Replace Spark Plug.

Eleclronrc rgn 1on system delect ve. Check lor loose connect ons

POOR PICK UP

POSSIBLE CAUSES REMEDIES

I\,4uifief out et choked

A r F terchoked or dirly

lmproper carbure or adj!stmenl

Clean the IVluttler

-

-:. _---Lrean A r I Tel/Hep ace

Adj,r.l th" C"rb,""1i", *til"S"Cylnder Head Loose

C utch s rpp rgI sh"l]?4d"'. j""gli"lIp"Il"d t"!*Adjust Clutch se ing.

Inlerior Oua fy ol FLrel Check and replace with specfied good qualty fue.Brake(s\ hind\ng \ NNs\B\ake\s\

Piston R ng v/orn olt Rep ace Piston Fings as a set.

ENGINE GETS OVER HEATED

POSSIBLE CAUSES BE|llEDIES

Fue -Arr L4i^ture ean

Air F lter choked by dirl

Adlusl Carburellor Selt ng

C ean Replrce Arr F Ter

I\,4uil er outlel choked Clean the lMutiler

Carbon depost n lhe Engine Decarbonise lhe Cy inder Head

Spark Plug ol Incorreci Heai Range Repla' e rrt_ Sp. r Dr ro ol Co_e.lHe.L qdnge

POOR BRAKING

POSSIBLE CAUSES REMEDIES

Brake(s) not propery adlusted Adj!st Brake(s) propeny

Lin ng of Brake Shoe worn out Replace Brake Shoes(s)

Brake Drum worn oul or scored Rep ace Brake Drum

Brake no sy Gr nd Brake Shoe surlace propeny

MOTOCYCLE WOBBLING

POSSIBLE CAUSES REIMEDIES

R m Run Oul orwobb e

Loose/Broken Spokels) Trghten tenlace Spol'e(s)

ncoffect F trnenl of Tyre (s) Rel I Tyre propery

Worn oul Whee Bearing(s) Rep ace Wheel Bearingls)

Rear arnr Bush(es) worn oul Replac€ Birsh(es) {Replace Reaf Sw rg Fofk

Tyre Pressure loo low Inflale T!reisi l. Iifcoer press!re

POSSIBLE CAUSES

KNOCKING IN THE FRAME HEAD

R EI\,'I E DIES

REIVEDIES

Ba Races Loose/ptted Ber.... :_: a: I rtes

POSSIBLE CAUSES

Cha n oose

DRIVE CHAIN NOISE

:-E: led s ac[ lm L

BULBS DO NOT GLOW

Rep ace/assemb e Fuse assy.

Check electolyle eveland reptenish wilh dislj edwater. Check battery leads ior proper contact . CheckRecl lier/Regulator un t.

Repa r/ Feplace Handte Bar Switch.

Replace bulb(s)

Chech earthinq connecttons and clean lhem.

Checl, and recify connectons.

POSSIBLE CAUSES

No Fuse in lhe c rcu I or defective Flse

Battery D scharged

Handle Bar Sw tch defecUve

Bulb(s) Fused

mproper Earthing

Loose or improper connections

POSSIBLE CAUSES

Battery Discharged

Horn Defective

Horn Sw tch detecltve

INDICATORS NOT WORKING

POSSIALE CAUSES

F!sed Bu bs

mproper connect ons

Indicator S!./ilch defect ve

Flasher Un t defectrve

rmproper earllr ng

HORN DOES NOT BLOW

Check electolyte level and repten sh with d stileowater. Check battery teads for proper contact . CheckRectif ierlRegulalof Unil.

Feplace Horn

Replace Horn Swtch

Rep ace Bu bs

Make proper connect ons

Rep ace Ind cator Switch

Feplace Flasher unrt.

Check earthing connections and rectify thenr.

BRAKE LIGHT NOT WORKING

POSSIBLE CAUSES REMEDIES

rmproper adluslment ol Rear BrakeLight Swtch. _Slicky Front Brak," Llght Sw tch _Fused Bulb.

Adjust the Erake Light Switch

Clean/Replace ihe Switch

R"pb"" B,rb

A\Seat HeightWheel BaseMinimum Ground Clearancel\y'inimum Turning Radius

WEIGHT

Dry

CLUTCH

TypeClutch PlateFriction PlateLining of Friciion Plate

TRANSMISSION

Primary Reduction SystemPrimary Reduction RatioSecondary Reduction SystmSecondary Reduction RatioTransmission TypeOperatjon

GEAR RATIO'I St

2nd3rd41h

CHASSIS:

TypeConstructionCastor AngleTraii

TYRE

Size (Front)Size (Rea0

TYRE PRESSURE

Front (Solo/Double)Rear - Solo

- Double

765 mm1245 mm145 mm2100 mm

103 Kgs

Wet l\.4ultiple Disc5 Nos6 NosRubberised Cork Working in Oil

HELICAL GEAR71/22 \3.227)CHAIN DRIVE37115 (2.460)CONSTANT MESH, 4-SPEEDThrough Foot Operated Lever, Mouni.:on LH Side of Gear Box with NeutraGea. Positron Belween Frrsl Speed -

Second Speed

(35/11)(30/15)(26/19)(23/23)

t

3.182:12.000.11 .368:11 .000r'l

Double CradleDuplex, l\,4ade of Tubular Section27.5490 mm

2.50x1 8-4PFl-Nylon'Ribbed2 75x18 4PR-Ny on-Universal

222a32

PSIPSIPSI

Drum Brake (130 O), Intemally ExpandingRight Hand OperationDrum Brake (130 O), Intemally ExpandingRight Foot Operation

CerianiType, Telescopic Fork, Oil DampedSwing Arm (Adjustable 5 Positions), CoilSpring, Oil Damped.

110mm75 mm

cDlFlywheel Magneto15 a 3 at 1300 R.PM. BTDC'19 r 3 at 6000 R.PM. BTDC

12 VOLT

12V- 35W35W12V- 5W/10W12V- 10W(x4)12V- 3AW12V- 3.4W'12V- 3.4W12V- 3.4W(x2)12V- 3.4W'12V- 1.sAmp

12V-2.5 AH0.25 Amp'15 Hrs (Approximate)'1.240 (Fully charged)

80 o a20% (MFIL)230 or20% (MFIL)

1.6 o r 10%6.6 Ko r 10%0.55 o r20%(MFIL)0.80 o r 10% (MFIL)

BRAKE

Fronl Brake TypeOperation

. Rear Brake TypeOperation

SUSPENSION

Front SuspensionRear Suspension

WHEEL TRAVEL

Front Wheel TravelRear Wheel Travel

ELECTRICAL

lgnition SystemGenerator Systemlgnition Timing

:

SYSTEM

Head LightTail/Brake LightFlasher LightPark LightNeutral lndicatorHigh beam IndicatorTurn lndicatorsN/leter LightHO rn

BATTERY

RatingCharging CurrentCharging TimeSpecific Gravity

RESISTANCE SPECIFICATIONS

Pick up Coil resistanceSoUrce Coil resistancelgnition Coil resistance

Primary Coil

. Secondary CoilLighting Coil resistanceCharging coil resistance

Aq

CYLINDER HEAD

(Warp Limit)

MAINTENANCE SPECIFICATIONS

<0.03 mmLines Indicate Straight Edge l\,4easurenre.:

l

CYLINDERBore SizeTaper LimitOut of Round Limit

PISTON

Piston Clearance (C)

c=A_BSIZE (STANDARD)

srzE iovERSrzE)First OversizeSecond Oversize

58.00 - 58.02 mm in 4 Grades<0.004 mm<0.004 mm

: 34-39 l\4icronsPistonRedOrangeGreenPu rple

(0.034 mm - 0.039 mm,Cylinder

BcD

57.967- 57.982 mm

58.25 mm58.50 mm

in 4 Grades

I

A\PISTON RINGS

SECTIONAL SKETCH

--'-----)' TI tlf-r-]

Top Ring Key StoneB=1.2 mmf=2.2 mmKey StoneB=1.2 mmT=2.0 mm

0.25-0.45 mm0.25-0.45 mm0.60 mm

0.03-0.05 mm0.03-0.05 mm

2nd Ring

END GAP

Top Ring2nd RingService Limit

SIDE CLEARANCE

Top Ring2nd Ring

CRANK SHAFT

Crank Width 'A'Runout Limit 'C'Con. Rod Big End side clearance'DSmall end Free Play Limit'F

55.9+0oshm<0.02 mm0.20-0.70 mm<0.03-0.18 mm

;a^l1,:r I l-<

I

A\CLUTCH

Friction Plate Thickness/Quantit,Service LimitClutch Plate Thickness/QuantityService Limit (Warp)Clutch Spring Free Length/QuantityClutch Spring lvlinimum LengthClutch Release l\,4ethod

Push Rod Bending Limit

TRANSMISSION

Main Axle Deflection Limit(Run Out)Drive Axle Deflection Limit(Run Out)

SHIFTER

Shifting TypeGuide Bar Bending Limit

KICK STARTEH

TYPe

Kick Clip Friction Force(lvl in - N4 ax)Air Filter Element

CARBURETTOH

TYPe

lvlanufacturerlvlain JetJet Needle-Clip PositionPilot JetStarter jetPilot Air Screw SettingFloat HeightEngine ldling Speed(On warm Engine)

LUBRICATION

l\y'inimum Strokel\,4aximum StrokePulley Adjusting MarkAi ldle

3.0mmx6<0.02 mm'1.05-1.35 mm (x 5)<0.05 mm34.5 mm x 4<33.2 mmInner Push, Screw Push<0.15 mm

0.1 mm

0.1 mm

Guide Bar<0.05 mm

Kick and Mesh TypeP=1.0 Kg.(0.8-1.2 Ks)2T oilof Superior Grade Qualily

vM22I\,4IKUNI

# 1653rd Groove From TOP# 17.5#201.5a0.5 Turns-(Adj. at max. r.p.m. position)22.50+1 mm (As reference)150011m pm (After running in of 1000 kms)'700:'00 'om lupto 'u.-ing in or 1000 k.ns/

0.20-0.25 mm1.95-2 05 mm

i

SE RVINFO A Gr

CHASSIS

STEERING SYSTEM

Steering Bearing TypeNumber of Balls/Size of Steel BallsUpperLower

FBONT SUSPENSION

Front Fork travelSpring Free lenghtSpring l\.4inimum LengthOil Capacity (New Fill)Oil Capacity (For Replacement)Grade

REAR SUSPENSION

Shock Absorber TravelRear Swing ForkSwingarm Free Play LimitEnd (Skew)Side

WHEEL

Front & Rear Wheel TypeFront & Rear Rim Size/lvlaterialRim Run Out LimitVenicaiLateral

DRIVE CHAIN

No. ol LinksChain Slackness

DRUM BRAKE

TypeDrum lnside DiaService LimitLining ThicknessService Limit

BRAKE LEVER & BBAKE PEDAL

Brake Lever Free Play/At Lever PointBrake Pedal Free Play

CLUTCH LEVER

Free Play/At Lever PointFree Play At Tappel Rod

BaLl Bear ng

22 Nos (3/16')19 Nos (1/4')

110 mm296.5 mm291.5 mm17 5!3cc158a3ccSpecial Yamaha Oil

70 mm

<2.0 mm< 2.0 mm

Spoke Wheel1.50x18/Steel

<2.0<2.0 mm

11020-30 mm

Internally Expanding, Leading &130 mm<131 mm5.0 mm<2.0 mm

5'B mm ( nd an l\,4arket)

2.5'3 5 mm (Other N/arket)20'30.nm

2-3 mnlr. Turn oose (Anti Clock Wise)

B-7

TIGHTENING TOROUE THREADSIZE

QTY Lb"Ft. Kg.M

ENGINE

Oll Pump lvl5 2 3.60 0.50

Drain Plug t\r12 'I '14.00 2.00

Cylinder Head t\.48 4 18.00 2.50

Cylinde r l\i11 0 4 25.00 3.50

Spark Plug t\,414 1 14.00 2.00

Intake Manifold M6 4 5.70 0.80

Primary Drive Gear M12 1 40.00 5.50

Clulch Boss t\,412 l 31.00 4.30

Clutch Spring tvl5 4 4.30 0.60

Drive Sprocket

Neutral Point

l\.416 1

-l\.414 1

40.00

14.00

5.50

2.OA

Neutral Switch l\,1r 2 2.go 0.40

Cam Stopper l\,11 4 14.00 2.00

Shift Cam StopperLever

Change Shalt Adluster

M6 l

l

10.0

t\,16

t\,18

7.00

22.40

1 4A

1 .00

3.00

Oil Seal Retainer

Flywheel lvlagneto

IV]B

tvl12

1.60

7.04

A\

TIGHTENING TOROUE THREAslzE

OTY Lb.Ft. Kg.M

CHASSIS

Front Axle Shaft t\,110 1 31.00 4.30

Crown Handle-lnner Tube t\,18 2 1 1.00 1.50

Crown Handle-SteeringShaft

l\41 0 1 29.00 4.00

Handle crown-HandleHolder

M8 4 13.00 '1 .90

Under Bracket-lnner Tube tvt10 2 22.00 3.00

Pivot Shaft M12 '1 43.00 6.00

Tension Bar l\,18 2 13.00 1 .90

Sprocket Bear M8 4 18.00 2.60

Camshaft Lever M6 2 6.50 0.90

Flear Axie Shaft l\i]14 1 66.00 9.20

Sprocket Shaft Nut t\,120 '1 66.00 9.20

Shock Absorber l\41 0 2 29.00 4.00

Front Engine Mtg. Bolt t!18 1 22.OO 3.00

RearBolt

Upper Engine Niltg. M10 1 43.00 6.00

Rear Lower Engine Mtg.Bolt

t\41 0 1 43.00 6.00

Foolrest Frame [,48 4 17.00 2.30

Cap Bolt Front Fork l\i]25 2 '1 7.00 2.30

j 'tI

'6

I'

ESGORTS YAMAHA MOTOR LIMITED19/6, Mathura Road,

Faridabad 121 006 (lNDlA)