Yamaha YBR125ED User Manual

2005

YBR125ED

3D9-F8197-E0

SERVICE MANUAL

EAS00000

YBR125ED 2005

SERVICE MANUAL

©2005 by Yamaha Motor Co., Ltd.

First edition, January 2005

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal­ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal­ers and will appear in future editions of this manual where applicable.

NOTE:

_

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death
the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.

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

to

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.

1

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.

2

Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section
title(s) appears.

3

Sub-section titles appear in smaller print than the section title.

4

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.

5

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.

6

Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.

7

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.

8

Jobs requiring more information (such as special tools and technical data) are described sequen­tially.

12

GEN

SPEC

INFO

34

CHK

CHAS

ADJ

56

ENG

78

CARB

EAS00009

SYMBOLS

The following symbols are not relevant to
every vehicle. Symbols 1 to 8 indicate the
subject of each chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Chassis

4

Engine

5

Carburetor

6

Electrical system

7

Troubleshooting

8

–+

TRBL

ELEC

SHTG

90

AB

CD

T

.

R

.

EF

GHI

LS

G

M

M

E

JKL

B

Symbols 9 to F indicate the following.

Serviceable with engine mounted

9

Filling fluid

0

Lubricant

A

Special tool

B

Tightening torque

C

Wear limit, clearance

D

Engine speed

E

Electrical data

F

Symbols G to L in the exploded diagrams
indicate the types of lubricants and lubrication
points.

Engine oil

G

Gear oil

H

Molybdenum-disulfide oil

I

Wheel-bearing grease

J

Lithium-soap-based grease

K

Molybdenum-disulfide grease

L

MN

LT

New

Symbols M to N in the exploded diagrams
indicate the following.

®

Apply locking agent (LOCTITE

M

Replace the part

N

)

EAS00011

– +

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

CHASSIS

ENGINE

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

1

2

3

4

5

CARBURETOR

ELECTRICAL SYSTEM

TROUBLESHOOTING

CARB

ELEC

TRBL

SHTG

6

7

8

CHAPTER 1

GENERAL INFORMATION

GEN

INFO

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER .....................................................1-1

MODEL LABEL..........................................................................................1-1

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 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 THE CONNECTIONS

SPECIAL TOOLS

............................................................................................1-5

............................................................................1-1

.........................................................................1-2

..................................................................1-4

1

1

VEHICLE IDENTIFICATION

EAS00014

GENERAL INFORMATION

VEHICLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is
stamped into the right side of the steering head
pipe.

EAS00018

MODEL LABEL

The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.

GEN

INFO

1 - 1

IMPORTANT INFORMATION

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND
DISASSEMBLY

1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.

3. When disassembling, 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 replaced as an
assembly.

4. During disassembly, clean all of the parts
and place them in trays in the order of dis­assembly. This will speed up assembly and
allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

GEN

INFO

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all
replacements. Use oil and grease recom­mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur­faces, oil seal lips and O-rings must be
cleaned.

2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.

1 - 2

IMPORTANT INFORMATION

EAS00023

LOCK WASHERS/PLATES AND COTTER
PINS

After removal, replace all lock washers/plates

1

and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu­facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro­priate.

Oil seal

1

GEN

INFO

CAUTION:

_

Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.

Bearing

1

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.

Shaft

4

1 - 3

CHECKING THE CONNECTIONS

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.

1. Disconnect:

• lead

• coupler

• connector

2. Check:

• lead

• coupler

• connector

Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev­eral times.

3. Check:

• all connections
Loose connection → Connect properly.

NOTE:

_

If the pin 1 on the terminal is flattened, bend it
up.

GEN

INFO

4. Connect:

• lead

• coupler

• connector

NOTE:

_

Make sure all connections are tight.

5. Check:

• continuity
(with the pocket tester)

Pocket tester

90890-03112, YU-03112-C

NOTE:

_

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer
available at most part stores.

1 - 4

GEN

SPECIAL TOOLS

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri­ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.

NOTE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool No. Tool name/Function Illustration

INFO

Slide hammer bolt

90890-01083

YU-01083-1

Weight

90890-01084

YU-01083-3

90890-01135

YU-01135-B

90890-04019

YM-04019

Pot

90890-01274

YU-90058
YU-90059

Bolt

90890-01275

YU-90060

Slide hammer bolt
Weight

These tools are used to remove or install
the rocker arm shafts.

Crankcase separating tool

This tool is used to remove the crank­shaft.

Valve spring compressor

This tool is used to remove or install the
valve assemblies.

Crankshaft installer pot
Crankshaft installer bolt

These tools are used to install the crank­shaft.

Adapter

90890-01278

YU-90063

Spacer

90890-04081

YM-91044

90890-01304

YU-01304

Adapter (M12)
Spacer (crankshaft installer)

These tools are used to install the crank­shaft.

Piston pin puller set

This tool is used to remove the piston pin.

1 - 5

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Tappet adjusting tool

90890-01311

YM-08035-A

This tool is used to adjust the valve clear­ance.

Fuel level gauge

90890-01312

YM-01312-A

This gauge is used to measure the fuel
level in the float chamber.

T-handle

90890-01326

YM-01326

This tool is used to hold the 14 mm hexa­gon nut/socket wrench when removing or
installing the damper rod.

INFO

90890-01362

YU-33270-B

Weight

90890-01367

YM-A9409-7
YM-A5142-4

Attachment

90890-01400

90890-01403

YU-33975

90890-01701

YS-01880-A

Flywheel puller

This tool is used to remove the generator
rotor.

Fork seal driver weight
Fork seal driver attachment (ø30)

These tools are used to install the oil
seal, dust seal, and the outer tube bush­ing of the front fork legs.

Steering nut wrench

This tool is used to loosen or tighten the
steering ring nuts.

Sheave holder

This tool is used to hold the A.C. magneto
rotor when loosening or tightening the
A.C. magneto rotor nut.

90890-03079

YM-34483

Thickness gauge

This tool is used to measure the valve
clearance.

1 - 6

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Compression gauge

90890-03081

YU-33223

These tools are used to measure the
engine compression.

Pocket tester

90890-03112

YU-03112-C

This tool is used to check the electrical
system.

Timing light

90890-03141

YU-03141

This tool is used to check the ignition tim­ing.

INFO

90890-03158

90890-04086

YM-91042

90890-04097

YM-04097

90890-04098

YM-04098

Carburetor angle driver

This tool is used to turn the air screw
when adjusting the engine idling speed.

Universal clutch holder

This tool is needed to hold the clutch
boss when removing or installing the
boss nut.

Valve guide remover (ø5)

This tool is needed to remove and install
the valve guides.

Valve guide installer (ø5)

This tool is needed to install the valve
guides.

90890-04099

YM-04099

Valve guide reamer (ø5)

This tool is needed to rebore the new
valve guides.

1 - 7

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Valve lapper

90890-04101

This tool is used for lapping the valves.

Ignition checker

90890-06754

YM-34487

This tool is used to check the ignition sys­tem components.

Yamaha bond No. 1215

90890-85505

This bond is used to seal two mating sur­faces (e.g., crankcase mating surfaces).

INFO

1 - 8

CHAPTER 2

SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES.........................................................2-17

CHASSIS TIGHTENING TORQUES.......................................................2-19

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE...................................................................................................2-21

CHASSIS.................................................................................................2-22

..................................................................................2-16

........................................................................2-1

............................................................................2-2

........................................................................2-10

.................................................................2-14

...............................2-16

..............................................................................2-17

....................................2-21

LUBRICATION DIAGRAMS

CABLE ROUTING

.........................................................................................2-25

..........................................................................2-23

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YBR125

SPEC

Model code
Dimensions

Overall length 1,980 mm (78.0 in)
Overall width 745 mm (29.3 in)
Overall height 1,080 mm (42.5 in)
Seat height 780 mm (30.7 in)
Wheelbase 1,290 mm (50.8 in)
Minimum ground clearance 175 mm (6.89 in)
Minimum turning radius 1,750 mm (68.9 in)

Weight

Wet (with oil and full fuel tank) 120.0 kg (265 lb)
Maximum load (total of cargo, rider, passen-

ger, and accessories)

3D91

200.0 kg (441 lb)

2 - 1

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type Air-cooled 4-stroke, SOHC ----

3

Displacement 123.7 cm
Cylinder arrangement Forward-inclined single cylinder ---­Bore × stroke 54.0 × 54.0 mm (2.13 × 2.13 in) ---­Compression ratio 10.0 : 1 ---­Standard compression pressure

(at sea level)
Starting system Electric starter and kickstarter ----

Fuel

Recommended fuel Regular unleaded gasoline only ---­Fuel tank capacity 12.0 L (2.64 Imp gal, 3.17 US gal) ---­Fuel reserve amount 3.0 L (0.66 Imp gal, 0.79 US gal) ----

Engine oil

Type SAE10W30, SAE10W40, SAE15W40,

Recommended engine oil grade API service SE, SF, SG type or higher ---­Lubrication system Wet sump ---­Engine oil quantity

Total amount 1.20 L (1.06 Imp qt, 1.27 US qt) ---­Periodic oil change 1.00 L (0.88 Imp qt, 1.06 US qt) ----

Oil filter type Wire mesh ----

Oil pump

Oil pump type Trochoid ---­Inner-rotor-to-outer-rotor-tip-clear­ance
Outer-rotor-to-oil-pump-housing

clearance
Oil pump-housing-to-inner-rotor-and-

outer-rotor clearance

Spark plug

Model/manufacturer CR6HSA/NGK ---­Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) ----

Cylinder head

Volume 15.20 ~ 15.60 cm
Maximum warpage ---- 0.05 mm

1,200 kPa (12.0 kgf/cm

SAE20W40 or SAE20W50

0.07 mm (0.0028 in) 0.15 mm

0.13 ~ 0.19 mm (0.0051 ~ 0.0075 in) 0.26 mm

0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 0.17 mm

(7.55 cu.in) ----

2

, 170.7 psi) ----

(0.0059 in)

(0.010 in)

(0.0067 in)

3

(0.93 ~ 0.95 cu.in) ----

(0.0020 in)

----

2 - 2

ENGINE SPECIFICATIONS

Item Standard Limit

Camshaft

Drive system Chain drive (left) ---­Intake camshaft lobe dimensions

A

B

Measurement A 25.881 ~ 25.981 mm (1.0189 ~ 1.0229 in) 25.851 mm

Measurement B 21.194 ~ 21.294 mm (0.8344 ~ 0.8383 in) 21.164 mm

Exhaust camshaft lobe dimensions

SPEC

(1.0178 in)

(0.8332 in)

A

B

Measurement A 25.841 ~ 25.941 mm (1.0174 ~ 1.0213 in) 25.811 mm

(1.0162 in)

Measurement B 20.997 ~ 21.097 mm (0.8267 ~ 0.8306 in) 20.967 mm

(0.8255 in)

Maximum camshaft runout ---- 0.03 mm

(0.0012 in)

Timing chain

Model/number of links 92RH2005-90M/90 ---­Tensioning system Automatic ----

Rocker arm/rocker arm shaft

Rocker arm inside diameter 10.000 ~ 10.015 mm (0.3937 ~ 0.3943 in) 10.030 mm

(0.3949 in)

Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) 9.950 mm

(0.3917 in)

Rocker-arm-to-rocker-arm-shaft
clearance

0.009 ~ 0.034 mm (0.0003 ~ 0.0013 in) 0.080 mm
(0.003 in)

2 - 3

ENGINE SPECIFICATIONS

Item Standard Limit

Valves, valve seats, valve guides

Valve clearance (cold)

Intake 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ---­Exhaust 0.10 ~ 0.14 mm (0.0039 ~ 0.0055 in) ----

Valve dimensions

SPEC

B

A

Head Diameter Face Width Seat Width Margin Thickness

Valve head diameter A

Intake 25.90 ~ 26.10 mm (1.0197 ~ 1.0276 in) ---­Exhaust 21.90 ~ 22.10 mm (0.8622 ~ 0.8701 in) ----

Valve face width B

Intake 1.100 ~ 3.000 mm (0.0433 ~ 0.1181 in) ---­Exhaust 1.700 ~ 2.800 mm (0.0669 ~ 0.1102 in) ----

Valve seat width C

Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) ---­Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) ----

Valve margin thickness D

Intake 0.40 ~ 0.80 mm (0.0157 ~ 0.0315 in) ---­Exhaust 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) ----

Valve stem diameter

Intake 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in) 4.945 mm

Exhaust 4.960 ~ 4.975 mm (0.1953 ~ 0.1959 in) 4.930 mm

Valve guide inside diameter

Intake 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm

Exhaust 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.050 mm

Valve-stem-to-valve-guide clearance

Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm

Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm

C

(0.1945 in)

(0.1941 in)

(0.1988 in)

(0.1988 in)

(0.0032 in)

(0.0039 in)

D

2 - 4

ENGINE SPECIFICATIONS

Item Standard Limit

Valve stem runout ---- 0.010 mm

Valve seat width (cylinder head side)

Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm

Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm

Valve springs

Free length

Intake 47.06 mm (1.85 in) 44.71 mm

Exhaust 47.06 mm (1.85 in) 44.71 mm

Installed length (valve closed)

Intake 25.6 mm (1.01 in) ---­Exhaust 25.6 mm (1.01 in) ----

Spring rate

Intake (K1) 8.01 N/mm (0.82 kg/mm, 45.74 ft · lb) ---­Exhaust (K1) 8.01 N/mm (0.82 kg/mm, 45.74 ft · lb) ---­Intake (K2) 9.33 N/mm (0.95 kg/mm, 53.27 ft · lb) ---­Exhaust (K2) 9.33 N/mm (0.95 kg/mm, 53.27 ft · lb) ----

Compressed spring force (installed)

Intake 160.0 ~ 184.0 N

(16.32 ~ 18.76 kg, 35.97 ~ 41.36 lb)

Exhaust 160.0 ~ 184.0 N

(16.32 ~ 18.76 kg, 35.97 ~ 41.36 lb)

Spring tilt

SPEC

(0.0004 in)

(0.06 in)

(0.06 in)

(1.76 in)

(1.76 in)

----

----

Intake ---- 2.5°/2.1 mm

(2.5°/0.08 in)

Exhaust ---- 2.5°/2.1 mm

(2.5°/0.08 in)

Winding direction (top view)

Intake Clockwise ---­Exhaust Clockwise ----

2 - 5

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder

Bore 54.024 ~ 54.056 mm (2.1269 ~ 2.1282 in) 54.156 mm

Measuring point 40 mm (1.57 in) ----

Piston

Piston-to-cylinder clearance 0.019 ~ 0.035 mm (0.0007 ~ 0.0014 in) 0.15 mm

Diameter D 53.997 ~ 54.029 mm (2.1259 ~ 2.1271 in) ----

H

D

SPEC

(2.1321 in)

(0.0059 in)

Height H 4.8 mm (0.19 in) ---­Piston pin bore (in the piston)

Diameter 15.002 ~ 15.013 mm (0.5906 ~ 0.5911 in) 15.043 mm

(0.5922 in)

Offset 0.50 mm (0.0197 in) ---­Offset direction Intake side ----

Piston pin

Outside diameter 14.991 ~ 15.000 mm (0.5902 ~ 0.5906 in) 14.971 mm

(0.5894 in)

Piston-pin-to-piston-pin-bore clear­ance

Piston rings

Top ring

T

Ring type Barrel ---­Dimensions (B × T) 1.00 × 2.10 mm (0.039 × 0.082 in) ---­End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.55 mm

Ring side clearance 0.035 ~ 0.070 mm (0.0014 ~ 0.0028 in) 0.120 mm

0.002 ~ 0.022 mm (0.0001 ~ 0.0009 in) 0.072 mm
(0.0028 in)

B

(0.022 in)

(0.0047 in)

2 - 6

ENGINE SPECIFICATIONS

Item Standard Limit

2nd ring

B

T

Ring type Taper ---­Dimensions (B × T) 1.00 × 2.10 mm (0.039 × 0.082 in) ---­End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.80 mm

Ring side clearance 0.020 ~ 0.060 mm (0.0008 ~ 0.0024 in) 0.120 mm

Oil ring

B

T

Dimensions (B × T) 2.00 × 2.25 mm (0.079 × 0.089 in) ---­End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ----

Crankshaft

SPEC

(0.031 in)

(0.0047 in)

C

Width A 46.95 ~ 47.00 mm (1.848 ~ 1.850 in) ---­Maximum runout C ---- 0.030 mm

Big end side clearance D 0.150 ~ 0.450 mm (0.0059 ~ 0.0177 in) ---­Big end radial clearance E 0.010 ~ 0.021 mm (0.0004 ~ 0.0008 in) ----

Balancer

Balancer drive method Gear ----

Clutch

Clutch type Wet, multiple-disc ---­Clutch release method Inner push, cam push ---­Clutch cable free play
(at the pivot bolt of the clutch lever)
Friction plate thickness 3.00 mm (0.118 in) 2.80 mm

Plate quantity 4 pcs ---­Clutch plate thickness 1.60 mm (0.06 in) ---­Plate quantity 3 pcs ---­Maximum warpage ---- 0.20 mm

C

E

D

A

(0.0012 in)

10 ~ 15 mm (0.39 ~ 0.59 in) ----

(0.110 in)

(0.0079 in)

2 - 7

ENGINE SPECIFICATIONS

Item Standard Limit

Clutch spring

Free length 29.30 mm (1.15 in) 27.84 mm

Spring quantity 4 pcs ----

Long clutch push rod bending ---- 0.500 mm

Transmission

Transmission type Constant mesh 5-speed ---­Primary reduction system Helical gear ---­Primary reduction ratio 68/20 (3.400) ---­Secondary reduction system Chain drive ---­Secondary reduction ratio 45/14 (3.214) ---­Operation Left foot operation ---­Gear ratio

1st 37/14 (2.643) ---­2nd 32/18 (1.778) ---­3rd 25/19 (1.316) ---­4th 23/22 (1.045) ---­5th 21/24 (0.875)

Main axle runout limit ---- 0.03 mm

Drive axle runout limit ---- 0.03 mm

Shifting mechanism

Shift mechanism type Shift drum and guide bar ---­Shift fork thickness 4.76 ~ 4.89 mm (0.1874 ~ 0.1925 in) ----

Kickstarter

Kickstarter type Kick and mesh ---­Kickstarter pinion gear clip friction

force

Air filter

Air filter element Dry element ----

8 ~ 12 N
(0.82 ~ 1.22 kgf, 1.80 ~ 2.70 lb)

SPEC

(1.10 in)

(0.0197 in)

(0.0012 in)

(0.0012 in)

----

2 - 8

ENGINE SPECIFICATIONS

Item Standard Limit

Carburetor

Type/quantity VM22SH/1 ---­Manufacturer MIKUNI ---­ID mark 3D91 00 ---­Main jet #97.5 ---­Main air jet ø0.9 ----
Jet needle 5EJ7-2 ---­Needle jet N-7M ---­Pilot air jet 1 #60
Pilot air jet 2 ø1.3
Pilot outlet ø1.0 ----
Pilot jet #15 ---­Pilot screw turns out 1-1/2 ---­Valve seat size ø1.8 ----
Starter jet 1 #25 ---­Starter jet 2 ø0.5
Throttle cable free play
(at the flange of the throttle grip)
Fuel level

(below the float chamber mating sur­face)

Idling condition

Engine idling speed

Air induction system ON 1,400 ~ 1,500 r/min ----

Air induction system OFF 1,350 ~ 1,450 r/min ---­CO% (air induction system OFF) 3.0 ~ 4.0% ---­Intake vacuum 26.8 ~ 32.2 kPa

Oil temperature 75 ~ 85 °C (167 ~ 185 °F) ----

3 ~ 7 mm (0.12 ~ 0.28 in) ----

6.0 ~ 7.0 mm (0.24 ~ 0.28 in) ----

(201.5 ~ 242.1 mmHg, 7.93 ~ 9.53 inHg)

SPEC

----

2 - 9

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Frame

Frame type Diamond ---­Caster angle 26.33° ----
Trail 90.0 mm (3.54 in) ----

Front wheel

Wheel type Cast wheel ---­Rim

Size J18 × 1.60 ----

Material Aluminum ---­Wheel travel 110.0 mm (4.33 in) ---­Wheel runout

Maximum radial wheel runout ---- 1.0 mm

(0.04 in)

Maximum lateral wheel runout ---- 0.5 mm

(0.02 in)

Rear wheel

Wheel type Cast wheel ---­Rim

Size J18 × 1.85 ----

Material Aluminum ---­Wheel travel 105.0 mm (4.13 in) ---­Wheel runout

Maximum radial wheel runout ---- 1.0 mm

(0.04 in)

Maximum lateral wheel runout ---- 0.5 mm

(0.02 in)

Front tire

Tire type With tube ---­Size 2.75-18 42P ---­Manufacturer/model CHENG SHIN/SAKURA S-901

PIRELLI/CITY DEMON

Tire pressure (cold tire)

0 ~ 90 kg (0 ~ 198 lb) 175 kPa (1.75 kgf/cm

90 kg ~ Maximum load

(198 lb ~ Maximum load)
Minimum tire tread depth ---- 1.6 mm

175 kPa (1.75 kgf/cm

2

, 25 psi) ----

2

, 25 psi) ----

(0.06 in)

----

----

2 - 10

CHASSIS SPECIFICATIONS

Item Standard Limit

Rear tire

Tire type With tube ---­Size 90/90-18 57P ---­Manufacturer/model CHENG SHIN/SAKURA S-180

PIRELLI/CITY DEMON

Tire pressure (cold tire)

0 ~ 90 kg (0 ~ 198 lb) 200 kPa (2.00 kgf/cm

90 kg ~ Maximum load

(198 lb ~ Maximum load)
Minimum tire tread depth ---- 1.6 mm

Front brake

Brake type Single-disc brake ---­Operation Right-hand operation ---­Front disc brake

Diameter × thickness 245.0 × 4.0 mm (9.65 × 0.16 in) ----

Minimum thickness ---- 3.5 mm

Maximum deflection ---- 0.15 mm

Brake pad lining thickness-inner 6.0 mm (0.24 in) 0.8 mm

Brake pad lining thickness-outer 6.0 mm (0.24 in) 0.8 mm

Master cylinder inside diameter 12.70 mm (0.50 in) ---­Caliper cylinder inside diameter 35.03 mm (1.3791 in) ---­Recommended fluid DOT 3 or 4 ----

Rear brake

Brake type Drum brake ---­Operation Right-foot operation ---­Brake pedal position 13.5 mm (0.53 in) ---­Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----

Rear brake drum

Drum brake type Leading, trailing ---­Drum inside diameter 130.0 mm (5.12 in) 131.0 mm

Lining thickness 4.0 mm (0.16 in) 2.0 mm

Shoe spring free length 50.5 mm (1.99 in) ----

280 kPa (2.80 kgf/cm

2

, 29 psi) ----

2

, 41 psi) ----

SPEC

----

----

(0.06 in)

(0.14 in)

(0.0059 in)

(0.03 in)

(0.03 in)

(5.16 in)

(0.08 in)

2 - 11

CHASSIS SPECIFICATIONS

Item Standard Limit

Steering

Steering bearing type Ball and race bearing ---­Lock-to-lock angle (left) 47° ----
Lock-to-lock angle (right) 47° ----
No./size of steel balls

Upper 16 pcs 0.250 in ----

Lower 16 pcs 0.250 in ----

Front suspension

Suspension type Telescopic fork ---­Front fork type Coil spring/oil damper ---­Front fork travel 120.0 mm (4.72 in) ---­Spring

Free length 337.0 mm (13.27 in) 330.3 mm

Installed length 318.9 mm (12.56 in) ----

Spring rate (K1) 7.37 N/mm (0.75 kgf/mm, 42.08 lb/in) ----

Spring rate (K2) 10.78 N/mm (1.1 kgf/mm, 61.55 lb/in) ----

Spring stroke (K1) 0 ~ 75 mm (0 ~ 2.95 in) ----

Spring stroke (K2) 75 ~ 120 mm (2.95 ~ 4.72 in) ---­Optional spring available No ---­Fork oil

Recommended oil Fork oil 10W or equivalent ----

Quantity (each front fork leg) 0.154 L (0.136 Imp qt, 0.163 US qt) ----

Level (from the top of the inner

tube, with the inner tube fully com-

pressed, and without the fork

spring)

Inner tube outer diameter 30 mm (1.18 in) ----

Inner tube bend limit ---- 0.2 mm

Rear suspension

Suspension type Swingarm ---­Spring/shock absorber type Coil spring/oil damper ---­Rear shock absorber assembly travel 90.0 mm (3.54 in) ---­Spring

Free length 226.5 mm (8.92 in) 222.0 mm

Installed length 219.5 mm (8.64 in) ----

Spring rate (K1) 13.30 N/mm (1.36 kgf/mm, 75.94 lb/in) ----

Spring rate (K2) 16.20 N/mm (1.65 kgf/mm, 92.50 lb/in) ----

Spring rate (K3) 24.30 N/mm (2.48 kgf/mm, 138.75 lb/in) ----

Spring stroke (K1) 0 ~ 7 mm (0 ~ 0.28 in) ----

Spring stroke (K2) 7 ~ 47 mm (0.28 ~ 1.85 in) ----

Spring stroke (K3) 47 ~ 90 mm (1.85 ~ 3.54 in) ---­Optional spring available No ----

166 mm (6.54 in) ----

SPEC

(13.00 in)

(0.008 in)

(8.74 in)

2 - 12

CHASSIS SPECIFICATIONS

Item Standard Limit

Swingarm

Free play limit (at the end of the swin­garm)-radial

Free play limit (at the end of the swin­garm)-axial

Drive chain

Type/manufacturer DID428V2/DAIDO ---­Link quantity 118 ---­Drive chain slack 20 ~ 30 mm (0.79 ~ 1.18 in) ---­15-Link length limit ---- 191.5 mm

---- 1.0 mm

---- 1.0 mm

SPEC

(0.04 in)

(0.04 in)

(7.54 in)

2 - 13

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage
Ignition system

Ignition system type DC. C.D.I. ---­Ignition timing (B.T.D.C.) 7.0° at 1,400 r/min ---­Advanced type Digital ----

DC.C.D.I.

Pickup coil resistance/color 248 ~ 372 Ω at 20 °C (68 °F)/white–red ----
C.D.I. unit model/manufacturer 3D9-00/SHY ----

Ignition coil

Model/manufacturer 5VL/SHY ---­Minimum ignition spark gap 6.0 mm (0.24 in) ---­Primary coil resistance 0.32 ~ 0.48 Ω at 20 °C (68 °F) ---­Secondary coil resistance 5.68 ~ 8.52 kΩ at 20 °C (68 °F) ----

Spark plug cap

Material Resin ---­Resistance 4.0 ~ 6.0 kΩ at 20 °C (68 °F) ----

Charging system

Type A.C. magneto ---­Model/manufacturer 3D9/SHY ---­Standard output 14 V 115 W at 5,000 r/min ---­Charging coil resistance/color 0.64 ~ 0.96 Ω at 20 °C (68 °F)/white–white ----

Rectifier/regulator

Regulator type Semi conductor-short circuit ---­Model/manufacturer SANXIN ---­No load regulated voltage (DC) 13.7 ~ 14.7 V ---­Rectifier capacity 8.0 A ---­Withstand voltage 200 V ----

Battery

Model/manufacturer CB5L-B/TIANJIN TONG YEE INDUS-

Battery voltage/capacity 12 V/5.0 Ah ---­Specific gravity 1.280 ----

Headlight

Bulb type Krypton bulb ----

Bulbs (voltage/wattage × quantity)

Headlight 12 V 35 W/35 W × 1 ---­Auxiliary light 12 V 5 W × 1 ---­Tail/brake light 12 V 5 W/21 W × 1 ---­Front turn signal light 12 V 10 W × 2 ---­Rear turn signal light 12 V 10 W × 2 ---­Meter lighting 12 V 1.7 W × 4 ----

12 V ----

TRIAL

----

2 - 14

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Indicator lights
(voltage/wattage × quantity)

Neutral indicator light 14 V 3 W × 1 ---­Turn signal indicator light 14 V 3 W × 2 ---­High beam indicator light 14 V 3 W × 1 ----

Electric starting system

System type Constant mesh ----

Starter motor

Model/manufacturer 3D9/SHY ---­Power output 0.4 kW ---­Armature resistance 0.017 ~ 0.021 Ω ----
Brushes

Overall length 10.0 mm (0.39 in) 3.5 mm

Spring force 5.52 ~ 8.28 N

(563 ~ 844 gf, 19.87 ~ 29.80 oz)

Commutator diameter 22.0 mm (0.87 in) 21.0 mm

Mica undercut 1.5 mm (0.06 in) ----

Starter relay

Model/manufacturer SANXIN ---­Amperage 150 A ---­Coil resistance 3.6 ~ 4.4 Ω ----

Horn

Horn type Plane ---­Model/manufacturer × quantity YF-12/NIKKO × 1 ---­Maximum amperage 3.0 A ---­Coil resistance 1.15 ~ 1.25 Ω ----
Performance 105 ~ 120 dB/2 m ----

Turn signal relay

Relay type Condenser ---­Self-cancelling device built-in No ---­Turn signal blinking frequency 75 ~ 95 cycles/min. ---­Wattage 10 W × 2 + 1.7 W ----

Fuel gauge

Model/manufacturer LOCAL MADE ---­Sender unit resistance- full 4 ~ 10 Ω at 20 °C (68 °F) ---­Sender unit resistance- empty 90 ~ 100 Ω at 20 °C (68 °F) ----

Fuses (amperage

Fuse 15 A ---­Spare fuse 15 A ----

quantity)

×

SPEC

(0.14 in)

(0.83 in)

----

2 - 15

CONVERSION TABLE/

GENERAL TIGHTENING TORQUE SPECIFICATIONS

SPEC

EAS00028

CONVERSION TABLE

All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL

** mm

2 mm

CONVERSION TABLE

Tighten­ing torque

Weight

Speed km/hr 0.6214 mph

Distance

Volume/
Capacity

Misc.

×

0.03937 = ** in

×

0.03937 = 0.08 in

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m·kg
m·kg
cm·kg
cm·kg

kg
g

km
m
m
cm
mm

3

cc (cm

)

3

cc (cm

)
lt (liter)
lt (liter)

kg/mm

2

kg/cm
Centigrade

(°C)

7.233

86.794

0.0723

0.8679

2.205

0.03527

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199

55.997

14.2234
9/5+32

ft·lb
in·lb
ft·lb
in·lb

lb
oz

mi
ft
yd
in
in

oz (IMP lip.)
cu.in
qt (IMP liq.)
gal (IMP liq.)

lb/in
psi (lb/in
Fahrenheit (°F)

2

)

EAS00030

GENERAL TIGHTENING TORQUE
SPECIFICATIONS

This chart specifies tightening torques for stan­dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe­cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com­ponents should be at room temperature.

A: Distance between flats
B: Outside thread diameter

General tightening

A

(nut)

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

B

(bolt)

torques

Nm m · kg ft · lb

2 - 16

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Part to be tightened Part name

Thread

size

Q’ty

Tightening torque

Remarks

Nm m · kg ft · lb

Cylinder head Bolt M8 4 22 2.2 16

Bolt M6 2 10 1.0 7.2
Oil gallery bolt Bolt M6 1 7 0.7 5.1
Spark plug — M10 1 13 1.3 9.4 Sealant
Camshaft sprocket cover Bolt M6 2 10 1.0 7.2
Tappet cover (intake and exhaust
side)

— M45 2 18 1.8 13

A.C. magneto rotor Nut M12 1 70 7.0 50
Timing chain guide (intake side) Bolt M6 1 10 1.0 7.2
Valve adjusting screw locknut (intake

and exhaust side)

Nut M5 2 8 0.8 5.8

Camshaft sprocket Bolt M8 1 20 2.0 14
Camshaft retainer Bolt M6 1 10 1.0 7.2
Timing chain tensioner cap Bolt M6 1 8 0.8 5.8
Timing chain tensioner Bolt M6 2 10 1.0 7.2
Oil pump assembly Screw M6 2 7 0.7 5.1
Oil pump housing cover Screw M5 2 5 0.5 3.6
Engine oil drain bolt Bolt M12 1 20 2.0 14
Intake manifold (cylinder head side) Bolt M6 2 10 1.0 7.2
Intake manifold (carburetor side) Bolt M6 2 10 1.0 7.2
Carburetor joint clamp Screw M4 1 2 0.2 1.4
Air filter case Bolt M6 2 7 0.7 5.1
Exhaust pipe and cylinder head Bolt M6 2 10 1.0 7.2
Muffler and passenger footrest

bracket

Bolt M8 1 22 2.2 16

Exhaust pipe protector Screw M6 2 8 0.8 5.8
Muffler protector Screw M6 4 8 0.8 5.8
Air cut-off valve assembly Screw M6 2 7 0.7 5.1
Air induction system pipe and cylinder
head

Bolt M6 2 10 1.0 7.2

Crankcase Bolt M6 10 10 1.0 7.2 Sealant
A.C. magneto rotor cover Bolt M6 7 10 1.0 7.2
Clutch cover Bolt M6 9 10 1.0 7.2
Stator coil lead holder Screw M6 1 7 0.7 5.1
Timing mark accessing screw — M14 1 7 0.7 5.1
Crankshaft end accessing screw — M32 1 7 0.7 5.1
Kickstarter lever Nut M12 1 50 5.0 36
Starter clutch idle gear holder Screw M6 2 7 0.7 5.1
Starter motor Bolt M6 2 10 1.0 7.2
Starter clutch Bolt M8 3 30 3.0 22 Stake
Primary drive gear Nut M12 1 70 7.0 50

E

E

LT

LT

LT

LT

2 - 17

TIGHTENING TORQUES

SPEC

Part to be tightened Part name

Thread

size

Q’ty

Tightening torque

Nm m · kg ft · lb

Clutch pressure plate Screw M5 4 6 0.6 4.3
Clutch boss Nut M12 1 60 6.0 43
Short clutch push rod locknut Nut M6 1 8 0.8 5.8
Bearing retainer Bolt M6 2 7 0.7 5.1
Shift pedal Bolt M8 1 10 1.0 7.2
Shift drum segment Screw M6 1 12 1.2 8.7
Stopper lever Bolt M6 1 10 1.0 7.2
Pickup coil Bolt M6 2 10 1.0 7.2
Neutral switch — M10 1 4 0.4 2.9
Stator coil Bolt M6 3 10 1.0 7.2

Remarks

LT

LT

LT

LT

LT

2 - 18

CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Part to be tightened Thread size

Remarks

Nm m · kg ft · lb

Engine mounting:

Front mounting bolt M8 38 3.8 27
Lower engine bracket and frame M10 55 5.5 40
Rear mounting bolt M8 38 3.8 27
Upper mounting bolt M8 38 3.8 27
Left upper engine bracket and frame M8 38 3.8 27
Right upper engine bracket and frame M8 38 3.8 27

Brake caliper bracket bolt M10 35 3.5 25

Tightening torque

Brake disc and front wheel M8 23 2.3 17

LT

Front wheel axle and front wheel axle nut M14 59 5.9 43
Brake hose holder and front brake hose guide M6 7 0.7 5.1
Brake caliper and brake caliper bracket M8 23 2.3 17
Brake hose union bolt (to front brake caliper) M10 25 2.5 18
Brake caliper holding bolt M8 23 2.3 17

LT

Bleed screw M6 6 0.6 4.3
Rear wheel axle and rear wheel axle nut M14 91 9.1 66
Brake torque rod and brake shoe plate M8 19 1.9 13
Chain puller locknut M8 16 1.6 11
Rear wheel sprocket and rear wheel drive hub M8 40 4.0 29
Rear brake camshaft lever and rear brake cam­shaft
Brake master cylinder and brake master cylinder

holder

M6 10 1.0 7.2

M6 10 1.0 7.2

Brake hose union bolt (to brake master cylinder) M10 26 2.6 19
Front brake master cylinder and brake lever M6 10 1.0 7.2
Front fender and front fork M6 10 1.0 7.2
Upper bracket pinch bolt M8 23 2.3 17
Lower bracket pinch bolt M10 30 3.0 22
Front fork cap bolt M25 23 2.3 17
Damper rod bolt M10 23 2.3 17

LT

Handlebar holder and upper bracket M8 23 2.3 17
Steering stem nut M22 110 11.0 80
Lower ring nut M25 ———See NOTE.
Headlight assembly and headlight bracket M10 9 0.9 6.5
Front turn signal light assembly and lower bracket M6 13 1.3 9.4
Wire harness/clutch cable guide and upper
bracket

M6 7 0.7 5.1

Meter assembly and upper bracket M6 7 0.7 5.1
Front turn signal light and headlight bracket M12 7 0.7 5.1
Drive sprocket cover M6 7 0.7 5.1
Drive sprocket M6 10 1.0 7.2

2 - 19

TIGHTENING TORQUES

SPEC

Part to be tightened Thread size

Passenger footrest bracket (left and right), center­stand and frame

Brake torque rod and swingarm M8 19 1.9 13
Pivot shaft and pivot shaft nut M12 59 5.9 43
Rear shock absorber assembly and swingarm M10 32 3.2 23
Rear shock absorber assembly and frame M10 40 4.0 29
Fuel tank and frame M8 16 1.6 11
Fuel tank and fuel cock M6 7 0.7 5.1
Fuel sender and fuel tank M5 4 0.4 2.9
Carrier and frame M8 30 3.0 22
Seat and frame M6 7 0.7 5.1
Battery box and frame M6 7 0.7 5.1
Rear fender and frame M6 7 0.7 5.1
Tail/brake light assembly and frame M6 7 0.7 5.1
Rear turn signal light and frame M12 7 0.7 5.1
Rider footrest and frame M8 23 2.3 17
Rectifier/regulator M6 4 0.4 2.9
Ignition coil and frame M6 4 0.4 2.9

M8 26 2.6 19

Tightening torque

Nm m · kg ft · lb

Remarks

NOTE:

1. First tighten the lower ring nut 33 Nm (3.3 m · kg, 24 ft · lb) with a torque wrench, then loosen the
ring nut 1/4 turn.

2. Retighten the lower ring nut to 22 Nm (2.2 m · kg, 16 ft · lb) with a torque wrench.

2 - 20

LUBRICATION POINTS AND LUBRICANT TYPES

EAS00031

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication Point Symbol

SPEC

Oil seal lips

O-rings

Bearings

Cylinder head tightening bolts and washers

Crankshaft pin

Connecting rod big end thrust surface

Piston pin

Piston and ring groove

Cylinder inner surface

Balancer weight surface

Camshaft lobes

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Rocker arm shaft

Rocker arm inner surface

Kickstarter shaft

Kickstarter idle gear

Starter clutch idle gear inner surface

Starter clutch gear (inner and outer)

Starter clutch assembly

Push lever

Primary driven gear

Short clutch push rod

Long clutch push rod ends and ball

Transmission gears (wheel and pinion)

Main and drive axle

Shift forks and shift fork guide bars

Shift drum

Crankcase mating surface

A.C. magneto lead grommet (A.C. magneto cover)

LS

LS

E

E

E

E

E

E

E

E

M

E

E

E

E

E

E

E

E

E

E

E

E

E

M

M

E

E

Yamaha bond

No.1215

Yamaha bond

No.1215

2 - 21

EAS00032

CHASSIS

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

SPEC

Front wheel oil seal lip

Speedometer gear unit inner surface

Rear wheel oil seal lip and O-ring

YAMAHA GREASE

LS

LS

F 150G

Rear wheel drive hub oil seal lip YAMAHA GREASE

F 150G

Rear brake camshaft

Brake pedal inner surface

Brake shoe pivot pin

Brake caliper bolt

Throttle grip tube guide inner surface and throttle cable end

Clutch cable end at the clutch lever

Brake lever pivot bolt outer surface

Clutch lever pivot bolt outer surface

Steering head bearing inner race

Steering head bearing outer race

Steering head upper bearing

Steering head lower bearing

Swingarm pivot shaft

Swingarm bushing outer surface

Dust cover oil seal lips

Centerstand pivot shaft

Passenger footrest pivoting point

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

2 - 22

EAS00034

LUBRICATION DIAGRAMS

Rocker arm

1

Rocker arm shaft

2

Camshaft

3

Crankshaft

4

Oil pump

5

Oil strainer

6

LUBRICATION DIAGRAMS

SPEC

2 - 23

1 Camshaft
2 Rotary filter
3 Crankshaft
4 Main axle
5 Drive axle

LUBRICATION DIAGRAMS

SPEC

2 - 24

EAS00035

CABLE ROUTING

Front brake light switch lead

1

Front brake hose

2

Meter assembly lead

3

Left handlebar switch lead

4

Speedometer cable

5

Clutch cable

6

Front turn signal light lead (left)

7

Headlight assembly lead

8

Wire harness

9

CABLE ROUTING

Front turn signal light lead (right)

0

Main switch lead

A

Throttle cable

B

Clutch switch lead

C

Right handlebar switch lead

D

Horn lead

E

Horn

F

To headlight assembly

È

SPEC

B
A

1

0

2

È

ÊÉ

9

1A4

2

43

8

5

7

6

Ë

B

2

Ì

D

1

Í

Î

4

6

C

Ì

B

Ð

Ë

6

5

Ï

9

E

F

2 - 25

CABLE ROUTING

SPEC

É Make sure that the headlight assembly lead is

routed through the protective covering.

Ê Connect the main switch lead, right handlebar

switch lead, left handlebar switch lead, meter
assembly lead, clutch switch lead, front brake
light switch lead, front turn signal light lead
(right), and front turn signal light lead (left), and
then cover the leads with the protective cover­ing, and attach the protective covering.

Ë Pass the clutch cable, left handlebar switch lead,

and clutch switch lead through the guide.

1

2

43

È

5

B
A

6

Ì Pass the throttle cable, front brake hose, front

brake light switch lead, and right handlebar
switch lead through the guide.

Í Fasten the right handlebar switch lead and front

brake light switch lead with the plastic band.

Î Fasten the left handlebar switch lead and clutch

switch lead with the plastic band.

Ï Pass the speedometer cable through the guide.
Ð Fasten the wire harness with the plastic locking

tie to the bracket. Cut off the excess end of the
plastic locking tie.

B

2

Ì

D

1

0

7

8

ÊÉ

9

Ë

1A4

2

Ì

B

Í

Î

4

6

C

Ë

6

5

Ï

Ð

9

E

F

2 - 26

CABLE ROUTING

SPEC

1 Clutch cable
2 C.D.I. unit
3 Fuel hose
4 Rectifier/regulator
5 Fuel sender
6 Fuel sender lead
7 Air vent hose
8 Fuse
9 Turn signal relay
0 Headlight relay
A Positive battery lead

Ó

B Starter relay
C Starter motor lead
D Battery breather hose
E Negative battery lead
F Carburetor overflow hose
G Ignition coil
H Horn
I Wire harness
J Speedometer

D

F

C

C

Ô

3

E

A

Ê

C-C

7

Õ

1

B

2

3

È

4

5

É

6

Ê

7

8

Ë

9

C

B

C

J

Ò

A

Ñ

G

HI

0

A

B

C

Ð

F

E

Ï

Î

D

Ì

Í

2 - 27

CABLE ROUTING

SPEC

È Fasten the wire harness at the white tape with

the holder.

É Fasten the fuel sender lead with the holder.
Ê Fasten the fuel hose and air vent hose with the

holder.

Ë Insert the ends of the air vent hoses into the hole

in the battery box.

Ì Route the battery breather hose to the inside of

the battery.

F

C

Ó

E

A

1

Í Route the starter motor lead to the inside of the

battery.

Î Fasten the A.C. magneto lead and rear brake

light switch lead with the holder.

Ï Pass the A.C. magneto lead through the guide

on the drive sprocket cover.

Ð Pass the starter motor lead through the guide.
Ñ Pass the wire harness through the guide.

D

C

Ô

3

Ê

7

C-C

Õ

B

2

3

È

4

5

É

6

Ê

7

8

Ë

9

C

B

C

J

Ò

A

Ñ

G

HI

0

A

B

C

Ð

F

E

Ï

Î

D

Ì

Í

2 - 28

Ò Pass the speedometer cable through the guide.
Ó Route the starter motor lead in the groove in the

lower engine bracket.

Ô Pass the carburetor overflow hose through the

guide.

Õ Route the carburetor overflow hose in front of

the battery breather hose, negative battery lead,
and starter motor lead.

F

CABLE ROUTING

D

C

SPEC

Ó

2

3

Ô

C

Õ

È

4

5

3

Ê

C-C

É

6

Ê

C

7

7

8

Ë

9

C

E

A

1

B

J

Ò

B

A

Ñ

G

Ð

F

E

Ï

Î

Í

D

C

Ì

HI

0

A

B

2 - 29

CABLE ROUTING

SPEC

1 Air vent hose
2 Air induction system hose (air filter to air cut-off

valve assembly)

3 Carburetor heater lead
4 Air cut-off valve assembly
5 C.D.I. unit
6 Spark plug lead
7 Ignition coil
8 Throttle cable
9 Wire harness
0 Front brake hose

A Clutch cable
B Horn
C Air induction system pipe
D Air induction system hose (air cut-off valve

assembly to cylinder head)

E Crankcase breather hose
F Rear brake light switch lead
G Carburetor overflow hose
H Battery breather hose
I Negative battery lead
J Rear brake light switch

È

J

12

I

3

H

É

Ê

Ë

G

4

Ô

Ì

F

Í

E

5

6

7

8

Î

D

Ó

C

Ò

9

Ï

Ð

0

A

B

Ñ

Ï

2 - 30

CABLE ROUTING

SPEC

È Face the ends of the hose clamp forward.
É Face the ends of the hose clamp downward.
Ê Install the air induction system hose (air filter to

air cut-off valve assembly) with its white paint
mark facing to the right.

Ë Face the ends of the hose clamp to the right.
Ì Install the air induction system hose (air cut-off

valve assembly to cylinder head) with its white
paint mark facing to the right.

Í Install the air induction system vacuum hose

with its white paint mark facing to the right.

Î Pass the throttle cable through the guide.
Ï Fasten the front brake hose with the holder.
Ð Fasten the wire harness with the plastic locking

tie to the guide. Cut off the excess end of the
plastic locking tie.

Ñ Pass the clutch cable through the guide.
Ò Install the ignition coil ground lead terminal and

the ignition coil using the same screw.

Ó Face the ends of the hose clamp forward.
Ô Pass the carburetor overflow hose and battery

breather hose between the engine and the frame.

È

J

12

I

3

H

É

Ê

Ë

G

4

Ô

Ì

F

Í

E

5

6

7

8

Î

D

Ó

C

Ò

9

Ï

Ð

0

A

B

Ñ

Ï

2 - 31

CABLE ROUTING

SPEC

1 C.D.I. unit
2 Air cut-off valve assembly
3 Rectifier/regulator
4 Carburetor heater lead
5 Thermo switch
6 Rear turn signal light lead (right)
7 Thermo switch lead
8 Tail/brake light lead
9 Rear turn signal light lead (left)
0 Wire harness
A Air vent hose

Õ

Ø

Ù

È Fasten the plastic locking tie next to the rectifier/

regulator bracket.

É Fasten the carburetor heater lead with the plas-

tic locking tie. Face the buckle of the plastic lock­ing tie inward. Cut off the excess end of the
plastic locking tie.

Ê Connect the rear turn signal light lead connec-

tors under the thermo switch lead and tail/brake
light lead.

1

2

3

È

A-A

Ú

×

Ô

Í

Ö

Ò

Ñ

Ð

Ï

Õ

0

9

A

Î

É

Û

4

Þ

Ý

Ü

B

ß

Ó

À

7

8

9

C-C

DD

Ë

B

A

C

5

Ê

Á

C

Ì

8

A

2 - 32

7

6

D-D

CABLE ROUTING

SPEC

Ë Make sure that there is no slack in the rear turn

signal light lead between the hole in the rear
fender and the plastic locking tie.

Ì Less than 10 mm (0.39 in)
Í Make sure that the rear turn signal light lead

connectors are positioned in the area shown in
the illustration.

Î Fasten the thermo switch lead, rear turn signal

light lead (right), rear turn signal light lead (left),
and tail/brake light lead with the holders.

Ù

Õ

Ø

Ï Fasten the wire harness, thermo switch lead, and

tail/brake light lead with the holder, making sure
that the holder does not contact the rear fender.

Ð Make sure that the thermo switch lead coupler is

positioned in the area shown in the illustration.

Ñ Connect the thermo switch lead coupler, making

sure that the coupler is on top of the wire har­ness and to the inside of the frame.

Ò Fasten the wire harness with the holder, making

sure that the holder does not contact the rear
fender.

1

2

3

È

A-A

Ú

×

Ô

Í

Ö

Ò

Ñ

Ð

Ï

Õ

0

9

A

Î

É

Û

4

Þ

Ý

Ü

B

ß

Ó

À

7

8

9

C-C

DD

Ë

B

A

C

5

Ê

Á

C

Ì

8

A

2 - 33

7

6

D-D

CABLE ROUTING

SPEC

Ó Be sure to route the wire harness to the inside of

the frame in the area shown in the illustration.

Ô Make sure that there is no slack in the wire har-

ness in the area shown in the illustration.

Õ Fasten the wire harness with the holder.
Ö Pass the air vent hoses through the hole in the

battery box, making sure not to pinch or crush
the hoses.

× Any slack in the wire harness should be in the

area shown in the illustration.

Ù

Õ

Ø

Ø Fasten the wire harness with the plastic locking

tie. Cut off the excess end of the plastic locking
tie.

Ù Fasten the wire harness with the plastic band.
Ú Install the thermo switch on the bottom side of its

bracket.

Û Connect the tail/brake light leads to the tail/

brake light terminals according to the lead colors
shown next to the terminals in the illustration.

Ü Yellow
Ý Blue

1

2

3

È

A-A

Ú

×

Ô

Í

Ö

Ò

Ñ

Ð

Ï

Õ

0

9

A

Î

É

Û

4

Þ

Ý

Ü

B

ß

Ó

À

7

8

9

C-C

DD

Ë

B

A

C

5

Ê

Á

C

Ì

8

A

2 - 34

7

6

D-D

Þ Black
ß Cut off the excess end of the plastic locking tie to

2 mm or less, and then face the end of the tie
inward and upward in the range shown in the
illustration.

À Be sure to fasten the rear turn signal light lead

(left) on its protective sleeve with the plastic
locking tie.

Á The wire harness should not protrude past the

lines shown in the illustration.

Ù

Õ

Ø

CABLE ROUTING

1

2

3

È

SPEC

Ú

A-A

×

Ô

Í

Ö

Ò

Ñ

Ð

Ï

Õ

0

9

A

Î

É

Û

4

Ó

DD

B

A

Ë

C

C

Ê

5

9

Þ

À

Ý

Ü

B

ß

7

8

C-C

Á

Ì

8

A

2 - 35

7

6

D-D

CHK

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

ADJ

INTRODUCTION

PERIODIC MAINTENANCE AND LUBRICATION CHART

SIDE COVERS, SEAT AND FUEL TANK

BATTERY AND BATTERY BOX

ENGINE

...........................................................................................................3-7

ADJUSTING THE VALVE CLEARANCE ..................................................3-7

CHECKING AND ADJUSTING THE EXHAUST GAS...............................3-9

ADJUSTING THE ENGINE IDLING SPEED ...........................................3-11

ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-12

CHECKING THE SPARK PLUG .............................................................3-14

CHECKING THE IGNITION TIMING.......................................................3-15

MEASURING THE COMPRESSION PRESSURE.................................. 3-16

CHECKING THE ENGINE OIL LEVEL.................................................... 3-17

CHANGING THE ENGINE OIL ...............................................................3-19

ADJUSTING THE CLUTCH CABLE FREE PLAY...................................3-20

CLEANING THE AIR FILTER ELEMENTS .............................................3-21

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD...... 3-23

CHECKING THE FUEL HOSE AND FUEL COCK FILTER ....................3-24

CHECKING THE CRANKCASE BREATHER HOSE ..............................3-24

CHECKING THE EXHAUST SYSTEM.................................................... 3-25

..............................................................................................3-1

............................3-1

.......................................................3-3

.....................................................................3-5

CHASSIS

ADJUSTING THE REAR BRAKE............................................................3-26

CHECKING THE BRAKE FLUID LEVEL.................................................3-26

CHECKING THE FRONT BRAKE PADS ................................................3-27

CHECKING THE REAR BRAKE SHOES................................................ 3-28

ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-28

CHECKING THE FRONT BRAKE HOSE................................................ 3-29

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-30

ADJUSTING THE DRIVE CHAIN SLACK ...............................................3-31

LUBRICATING THE DRIVE CHAIN ........................................................3-33

CHECKING AND ADJUSTING THE STEERING HEAD .........................3-34

CHECKING THE FRONT FORK .............................................................3-35

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES ..............3-36

CHECKING THE TIRES..........................................................................3-37

CHECKING THE WHEELS .....................................................................3-40

CHECKING AND LUBRICATING THE CABLES ....................................3-40

LUBRICATING THE LEVERS AND PEDALS ......................................... 3-41

LUBRICATING THE CENTERSTAND .................................................... 3-41

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

CHK

ADJ

ELECTRICAL SYSTEM.................................................................................3-42

CHECKING AND CHARGING THE BATTERY.......................................3-42

CHECKING THE FUSE...........................................................................3-46

REPLACING THE HEADLIGHT BULB....................................................3-47

ADJUSTING THE HEADLIGHT BEAM ................................................... 3-48

INTRODUCTION/

PERIODIC MAINTENANCE AND LUBRICATION CHART

EAS00036

CHK

ADJ

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.

PERIODIC MAINTENANCE AND LUBRICATION CHART

NOTE:

• The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.

• From 30000 km, repeat the maintenance intervals starting from 6000 km.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special

tools, data and technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

Fuel line

1*

(See page 3-24.)

Fuel cock filter

2*

(See page 3-24.)

Spark plug

3

(See page 3-14.)

Valves

4*

(See page 3-7.)

Air filter element

5

(See page 3-21.)

Battery

6*

(See page 3-42.)

Clutch

7

(See page 3-20.)

Front brake

8*

(See pages 3-26,
3-27.)

Rear brake

9*

(See pages 3-26,
3-28.)

Brake hose

10 *

(See page 3-29.)

Wheels

11 *

(See pages 4-3,
4-12.)

Tires

12 *

(See page 3-37.)

Wheel bearings

13 *

(See page 4-3.)

• Check fuel hoses for cracks or damage.

• Check condition.

• Check condition.

• Clean and regap.

• Replace.

• Check valve clearance.

• Adjust.

• Clean.

• Replace.

• Check electrolyte level and specific gravity.

• Make sure that the breather hose is properly

routed.

• Check operation.

• Adjust.

• Check operation, fluid level and vehicle for fluid

leakage.

• Replace brake pads.

• Check operation and adjust brake pedal free

play.

• Replace brake shoes.

• Check for cracks or damage.

• Replace.

• Check runout and for damage.

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check bearing for looseness or damage.

ODOMETER READING (× 1000 km)

1 6 12 18 24

√√√√ √

√√

√√

√√

√√√√

√√

√√

√√√√ √

√√√√√

√√√√√ √

Whenever worn to the limit

√√√√√ √

Whenever worn to the limit

√√√√ √

Every 4 years

√√√√

√√√√ √

√√√√

ANNUAL

CHECK

3 - 1

PERIODIC MAINTENANCE AND LUBRICATION CHART

CHK

ADJ

NO. ITEM CHECK OR MAINTENANCE JOB

Swingarm

14 *

(See page 4-67.)

Drive chain

15

(See pages 3-31,
4-61.)

Steering bearings

16 *

(See page 3-34.)

Chassis fasteners

17 *

(See page 2-19.)

Centerstand

18

(See page 3-41.)

Front fork

19 *

(See page 3-35.)

Shock absorber

20 *

assemblies
(See page 4-68.)

Carburetor

21 *

(See page 3-11.)

Engine oil

22

(See pages 3-17,
3-19.)

Front and rear

23 *

brake switches
(See page 7-3.)

Moving parts and
cables

24

(See pages 3-40,
3-41.)

Throttle grip hous-

25 *

ing and cable
(See page 3-12.)

Air induction sys-

26 *

tem
(See page 6-12.)

Lights, signals and
switches

27 *

(See pages 3-48,
7-3.)

• Check operation and for excessive play.

• Lubricate with lithium-soap-based grease.

• Check chain slack, alignment and condition.

• Adjust and lubricate chain with a special O-ring

chain lubricant thoroughly.

• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease.

• Make sure that all nuts, bolts and screws are

properly tightened.

• Check operation.

• Lubricate.

• Check operation and for oil leakage.

• Check operation and shock absorbers for oil leak-

age.

• Check starter (choke) operation.

• Adjust engine idling speed.

• Change.

• Check oil level and vehicle for oil leakage.

• Check operation.

• Lubricate.

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

• Check the air cut-off valve, reed valve, and hose

for damage.

• Replace any damaged parts if necessary.

• Check operation.

• Adjust headlight beam.

ODOMETER READING (× 1000 km)

1 6 12 18 24

√√√√

Every 24000 km

Every 1000 km and after washing the vehicle or

riding in the rain

√√√√√

Every 24000 km

√√√√ √

√√√√ √

√√√√

√√√√

√√√√√ √

√√√√√ √

√√√√√ √

√√√√ √

√√√√ √

√√√√ √

√√√√√ √

ANNUAL

CHECK

NOTE:

●

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

●

Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.

• Every two years replace the internal components of the brake master cylinder and caliper, and

change the brake fluid.

• Replace the brake hoses every four years and if cracked or damaged.

3 - 2

SIDE COVERS, SEAT AND FUEL TANK

EAS00042

SIDE COVERS, SEAT AND FUEL TANK

CHK

ADJ

10

14

T

16 Nm (1.6 m

.

R

.

•

kg, 11 ft

•

Ib)

T

30 Nm (3.0 m

.

R

.

3

•

kg, 22 ft

•

Ib)

4

13

12

7

11

8

6

9

2

5

Order Job/Part Q’ty Remarks

Removing the side covers, seat and

Remove the parts in the order listed.

fuel tank

1 Left side cover 1
2 Right side cover 1
3 Seat 1
4 Carrier 1
5 Rear cowling assembly 1
6 Left rear side cover 1
7 Right rear side cover 1
8 Rear panel 1

9 Left air duct 1
10 Right air duct 1
11 Air duct stay 1

1

3 - 3

SIDE COVERS, SEAT AND FUEL TANK

CHK

ADJ

10

14

T

16 Nm (1.6 m

.

R

.

•

kg, 11 ft

•

Ib)

T

30 Nm (3.0 m

.

R

.

3

•

kg, 22 ft

•

Ib)

4

13

12

7

11

8

6

9

2

5

Order Job/Part Q’ty Remarks

12 Fuel hose (fuel cock side) 1

NOTE:

Before disconnecting the fuel hose, turn
the fuel cock to “OFF”.

13 Fuel sender coupler 1 Disconnect.
14 Fuel tank 1

For installation, reverse the removal pro­cedure.

1

3 - 4

BATTERY AND BATTERY BOX

BATTERY AND BATTERY BOX

CHK

ADJ

13

11

8

12

10

3

9

2

4

14

14

6

5

1

15

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

Order Job/Part Q’ty Remarks

Removing the battery and battery

Remove the parts in the order listed.

box

Left side cover Refer to “SIDE COVERS, SEAT AND

FUEL TANK”.
1 Battery band 1
2 Negative battery lead 1 Disconnect.
3 Negative lead connector 1 Disconnect.
4 Positive battery lead 1
5 Battery breather hose 1 Disconnect.
6 Battery 1
7 Starter motor lead 1 Disconnect.
8 Starter relay coupler 1 Disconnect.
9 Starter relay 1

10 Turn signal relay coupler 1 Disconnect.
11 Turn signal relay 1

7

3 - 5

BATTERY AND BATTERY BOX

8

11

CHK

ADJ

13

12

10

3

9

2

4

14

14

6

5

1

15

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

Order Job/Part Q’ty Remarks

12 Headlight relay coupler 1 Disconnect.
13 Headlight relay 1
14 Air vent hose 2
15 Battery box 1

For installation, reverse the removal pro-

cedure.

7

3 - 6

ADJUSTING THE VALVE CLEARANCE

EAS00049

ENGINE

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.

NOTE:

_

• Valve clearance adjustment should be made
on a cold engine, at room temperature.

• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.

1. Disconnect:

• spark plug cap

2. Remove:

• spark plug

CHK

ADJ

3. Remove:

• intake tappet cover

• exhaust tappet cover

• camshaft sprocket cover

4. Remove:

• timing mark accessing screw

• crankshaft end accessing screw

5. Measure:

• valve clearance
Out of specification → Adjust.

Valve clearance (cold)

Intake valve

0.08 ~ 0.12 mm
(0.0031 ~ 0.0047 in)

Exhaust valve

0.10 ~ 0.14 mm
(0.0039 ~ 0.0055 in)

1

2

3

1

2

3 - 7

ADJUSTING THE VALVE CLEARANCE

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-

sion stroke, align the “I” mark a on the A.C.
magneto rotor with the stationary b on the
A.C. magneto rotor cover.

c. Align the “I” mark c on the camshaft

sprocket with the stationary pointer d on
the cylinder head.

d. Measure the valve clearance with a thick-

ness gauge 1.

Thickness gauge

90890-03079, YM-34483

Out of specification → Adjust.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

CHK

ADJ

6. Adjust:

• valve clearance

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the

end of the adjusting screw and the valve tip.

c. Turn the adjusting screw 3 in direction a

or b until the specified valve clearance is
obtained.

Direction

Direction b

a

Tappet adjusting tool

90890-01311, YM-08035-A

Valve clearance is
increased.

Valve clearance is
decreased.

3 - 8

ADJUSTING THE VALVE CLEARANCE/

CHECKING AND ADJUSTING THE EXHAUST GAS

• Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica­tion.

Locknut

8 Nm (0.8 m · kg, 5.8 ft · lb)

T

.

R

.

d. Measure the valve clearance again.
e. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust­ment steps until the specified clearance is
obtained.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

7. Install:

• timing mark accessing screw

• crankshaft end accessing screw

8. Install:

• O-rings

• camshaft sprocket cover

• intake tappet cover

• exhaust tappet cover

9. Install:

• spark plug

10.Connect:

• spark plug cap

New

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

18 Nm (1.8 m · kg, 13 ft · lb)

.

R

.

T

18 Nm (1.8 m · kg, 13 ft · lb)

.

R

.

T

13 Nm (1.3 m · kg, 9.4 ft · lb)

.

R

.

CHK

ADJ

1

EAS00868

CHECKING AND ADJUSTING THE
EXHAUST GAS

1. Stand the vehicle on a level surface.

NOTE:

_

• Place the vehicle on a suitable stand.

• Make sure the vehicle is upright.

• Measure the exhaust gas at idle when the air

induction system is not operating.

2. Install:

• temperature probe tester 1
(onto the engine oil drain bolt)

3 - 9

CHECKING AND ADJUSTING THE EXHAUST GAS

3. Disconnect:

• air induction system hose
(air cut-off valve to cylinder head) 1

4. Stop air induction system operation.

CHK

ADJ

1

NOTE:

Crimp the hose 1 running from the reed valve
to the air cut-off valve to prevent the air cut-off
valve from operating.
Make sure not to damage the hose while
crimping it.

5. Start the engine and warm it up until the
specified oil temperature is reached.

Oil temperature

75 ~ 85 °C (167 ~ 185 °F)

6. Measure:

• engine idling speed
(air induction system OFF)
Out of specification → Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.

Engine idling speed

1,350 ~ 1,450 r/min

3 - 10

7. Install:

• CO tester 1

• sampling probe 2

NOTE:

• Be sure to set the heat-resistant rubber tube
so that exhaust gas does not leak out.

• Before using the CO tester, be sure to read
the user’s manual.

CHECKING AND ADJUSTING THE EXHAUST GAS/

ADJUSTING THE ENGINE IDLING SPEED

8. Measure:

• CO density

Out of specification → Adjust.
Within specification → Check the air induc­tion system.
Refer to “AIR INDUCTION SYSTEM” in
chapter 6.

CO density (when the air induc­tion system is not operating)

3.0 ~ 5.0%

CHK

ADJ

1

9. Adjust:

• pilot screw 1

Pilot screw

1-1/2 turns out

If the CO density cannot be adjusted with the
pilot screw, overhaul the carburetor and check
the air filter.

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

NOTE:

_

Prior to adjusting the engine idling speed, the
air filter element should be clean, and the
engine should have adequate compression.

1. Start the engine and let it warm up for sev-

eral minutes.

2. Check:

• engine idling speed
(air induction system ON)
Out of specification → Adjust.

3 - 11

Engine idling speed

1,400 ~ 1,500 r/min

ADJUSTING THE ENGINE IDLING SPEED/

ADJUSTING THE THROTTLE CABLE FREE PLAY

3. Adjust:

• engine idling speed

CHK

ADJ

3

2

b

b

a

a

1

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the pilot screw 1 in or out until it is

lightly seated with the carburetor angle
driver 2.

Carburetor angle driver

90890-03158

b. Turn the pilot screw out the specified num-

ber of turns.

Pilot screw setting

1-1/2 turns out

c. Turn the throttle stop screw 3 in direction

a or b until the specified engine idling
speed is obtained.

Direction

Direction b

a

Engine idling speed is
increased.

Engine idling speed is
decreased.

a

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

4. Adjust:

• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.

Throttle cable free play (at the
flange of the throttle grip)

3 ~ 7 mm (0.12 ~ 0.28 in)

EAS00058

ADJUSTING THE THROTTLE CABLE FREE
PLAY

NOTE:

_

Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted.

1. Check:

• throttle cable free play a
Out of specification → Adjust.

3 - 12

Throttle cable free play (at the
flange of the throttle grip)

3 ~ 7 mm (0.12 ~ 0.28 in)

ADJUSTING THE THROTTLE CABLE FREE PLAY

2. Adjust:

1

3

bab

2

• throttle cable free play

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

Carburetor side

a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or

b until the specified throttle cable free play
is obtained.

CHK

ADJ

a

(a)

b

1

3

2

Direction

Direction

a

b

Throttle cable free play
is increased.

Throttle cable free play
is decreased.

d. Tighten the locknut.
e. Slide the rubber cover to its original posi-

tion.

NOTE:

_

If the specified throttle cable free play cannot
be obtained on the carburetor side of the
cable, use the adjusting nut on the handlebar
side.

Handlebar side

a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or

b until the specified throttle cable free play
is obtained.

3 - 13

Direction

a

Direction b

Throttle cable free play
is increased.

Throttle cable free play
is decreased.

d. Tighten the locknut.
e. Slide the rubber cover to its original posi-

tion.

WARNING

_

After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

CHECKING THE SPARK PLUG

EAS00060

CHECKING THE SPARK PLUG

1. Disconnect:

• spark plug cap

2. Remove:

• spark plug

CAUTION:

_

Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from fall­ing into the cylinder.

3. Check:

• spark plug type
Incorrect → Change.

Spark plug type (manufacturer)

CR6HSA (NGK)

CHK

ADJ

4. Check:

• electrode 1
Damage/wear → Replace the spark plug.

• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.

5. Clean:

• spark plug
(with a spark plug cleaner or wire brush)

6. Measure:

• spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.

Spark plug gap

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

7. Install:

• spark plug

NOTE:

_

T

13 Nm (1.3 m · kg, 9.4 ft · lb)

.

R

.

Before installing the spark plug, clean the
spark plug and gasket surface.

3 - 14

8. Connect:

• spark plug cap

CHECKING THE IGNITION TIMING

EAS00064

CHECKING THE IGNITION TIMING

NOTE:

_

Prior to checking the ignition timing, check the
wiring connections of the entire ignition sys­tem. Make sure all connections are tight and
free of corrosion.

1. Remove:

• timing mark accessing screw

2. Connect:

• timing light 1
(onto the spark plug lead)

Timing light

90890-03141, YU-03141

CHK

ADJ

3. Check:

• ignition timing

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Start the engine, warm it up for several min-

utes, and then let it run at the specified
engine idling speed.

Engine idling speed

1,400 ~ 1,500 r/min

b. Check that the stationary pointer a is within

the firing range b on the A.C. magneto
rotor.
Incorrect firing range → Check the ignition
system.

NOTE:

_

The ignition timing is not adjustable.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

4. Disconnect:

• timing light

5. Install:

• timing mark accessing screw

3 - 15

MEASURING THE COMPRESSION PRESSURE

EAS00067

MEASURING THE COMPRESSION
PRESSURE

NOTE:

_

Insufficient compression pressure will result in
a loss of performance.

1. Measure:

• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.

2. Start the engine, warm it up for several min­utes, and then turn it off.

3. Disconnect:

• spark plug cap

4. Remove:

• spark plug

CHK

ADJ

CAUTION:

_

Before removing the spark plug, use com­pressed air to blow away any dirt accumu­lated in the spark plug well to prevent it
from falling into the cylinder.

5. Install:

• compression gauge

1

Compression gauge

90890-03081, YU-33223

6. Measure:

• compression pressure
Out of specification → Refer to steps (c)
and (d).

Compression pressure (at sea
level)

Minimum

1,044 kPa

2

(10.4 kg/cm

, 148.5 psi)

Standard

1,200 kPa

2

(12.0 kg/cm

, 170.7 psi)

Maximum

1,344 kPa

2

(13.4 kg/cm

, 191.2 psi)

3 - 16

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Set the main switch to “ON”.
b. With the throttle wide open, crank the

engine until the reading on the compression
gauge stabilizes.

WARNING

_

To prevent sparking, ground the spark plug
lead before cranking the engine.

c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits → Eliminate.

d. If the compression pressure is below the

minimum specification, pour a teaspoonful
engine of oil into the spark plug bore and
measure again.
Refer to the following table.

CHK

ADJ

Compression pressure

(with oil applied into the cylinder)

Reading Diagnosis

Higher than with­out oil

Piston ring(s), pis­ton wear or dam­age → Repair.

Valves, cylinder
Same as without
oil

head gasket or pis-

ton possibly defec-

tive → Repair.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

7. Install:

• spark plug

T

13 Nm (1.3 m · kg, 9.4 ft · lb)

.

R

.

8. Connect:

• spark plug cap

EAS00069

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.

3 - 17

NOTE:

_

• Place the vehicle on a suitable stand.

• Make sure the vehicle is upright.

2. Start the engine, warm it up for several min­utes, and then turn it off.

-20 -10 0

SAE 10W-30

10

CHECKING THE ENGINE OIL LEVEL

3. Check:

• engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.

NOTE:

_

• Before checking the engine oil level, wait a
few minutes until the oil has settled.

20 30

40

50 ˚C

• Do not screw the dipstick 1 in when check-
ing the oil level.

CHK

ADJ

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

Recommended oil

Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temper­atures.
API standard

SE or higher grade

CAUTION:

_

• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and
do not use oils labeled “ENERGY CON­SERVING II” d or higher.

• Do not allow foreign materials to enter the
crankcase.

NOTE:

_

Before checking the engine oil level, wait a few
minutes until the oil has settled.

3 - 18

4. Start the engine, warm it up for several min-

utes, and then turn it off.

5. Check the engine oil level again.

NOTE:

_

Before checking the engine oil level, wait a few
minutes until the oil has settled.

CHANGING THE ENGINE OIL

EAS00076

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-

utes, and then turn it off.

2. Place a container under the engine oil drain

bolt.

3. Remove:

• engine oil filler cap 1

• engine oil drain bolt 2

(along with the gasket)

4. Drain:

• engine oil
(completely from the crankcase)

5. Check:

• engine oil drain bolt gasket
Damage → Replace.

6. Install:

• engine oil drain bolt
(along with the gasket)

T

20 Nm (2.0 m · kg, 14 ft · lb)

.

R

.

7. Fill:

• crankcase
(with the specified amount of the recom­mended engine oil)

CHK

ADJ

Quantity

Total amount

1.20 L (1.06 Imp qt, 1.27 US qt)

Periodic oil change

1.00 L (0.88 Imp qt, 1.06 US qt)

8. Install:

• engine oil filler cap

9. Start the engine, warm it up for several min­utes, and then turn it off.

10.Check:

• engine
(for engine oil leaks)

11.Check:

• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

3 - 19

CHANGING THE ENGINE OIL/

ADJUSTING THE CLUTCH CABLE FREE PLAY

12.Check:

• engine oil pressure

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Slightly loosen the oil gallery bolt 1.
b. Start the engine and keep it idling until

engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.

c. Check the engine oil passages and the oil

pump for damage or leakage. Refer to “OIL
PUMP” in chapter 5.

d. Start the engine after solving the problem(s)

and check the engine oil pressure again.

e. Tighten the oil gallery bolt to specification.

Oil gallery bolt

7 Nm (0.7 m · kg, 5.1 ft · lb)

T

.

R

.

CHK

ADJ

a

1

2

3

b

c

b

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

EAS00078

ADJUSTING THE CLUTCH CABLE FREE
PLAY

1. Check:

• clutch cable free play a
Out of specification → Adjust.

Clutch cable free play (at the end
of the clutch lever)

10 ~ 15 mm (0.39 ~ 0.59 in)

2. Adjust:

• clutch cable free play

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

Handlebar side

a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting bolt 3 in direction b or

c until the specified clutch cable free play
is obtained.

3 - 20

Direction

Direction

b

c

Clutch cable free play is
increased.

Clutch cable free play is
decreased.

ADJUSTING THE CLUTCH CABLE FREE PLAY/

CLEANING THE AIR FILTER ELEMENTS

d. Tighten the locknut.
e. Slide the rubber cover to its original posi-

tion.

NOTE:

_

If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable,
use the adjusting nut on the engine side.

Engine side

a. Slide back the rubber cover 1.
b. Loosen the locknut 2.

1

b

c. Turn the adjusting bolt 3 in direction a or

b until the specified clutch cable free play

is obtained.

CHK

ADJ

a

3

2

Direction

Direction

d. Tighten the locknut.
e. Slide the rubber cover to its original posi-

tion.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

EAS00086

CLEANING THE AIR FILTER ELEMENTS

NOTE:

There is a check hose 1 at the bottom of the
air filter case. If dust and/or water collects in
this hose, clean the air filter elements and air
filter case.

a

b

Clutch cable free play is
increased.

Clutch cable free play is
decreased.

1

1. Remove:

• right side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

3 - 21

1

CLEANING THE AIR FILTER ELEMENTS

2. Remove:

• air filter case cover 1

• air filter element 1

• air filter element 2

3. Check:

2

1

• air filter element 1 1

• air filter element 2 2

Damage → Replace.

CHK

ADJ

1

4. Clean:

• air filter element 2 1
Apply compressed air to the outer surface
of the air filter element 2.

5. Clean:

• air filter element 1

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Wash the element gently, but thoroughly in

solvent.

WARNING

Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.

3 - 22

b. Squeeze the excess solvent out of the ele-

ment and let it dry.

CAUTION:

Do not twist or wring out the element. This
could damage the foam material.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

CLEANING THE AIR FILTER ELEMENTS/

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD

6. Install:

• air filter element 2

• air filter element 1

• air filter case cover

CAUTION:

_

Never operate the engine without the air fil­ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheat­ing.

NOTE:

_

When installing the air filter element into the air
filter case cover, make sure their sealing sur­faces are aligned to prevent any air leaks.

CHK

ADJ

3

1

2

7. Install:

• right side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

EAS00094

CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD

1. Remove:

• side cover (left and right)
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

2. Check:

• carburetor joint (intake manifold side) 1

• intake manifold 2

• carburetor joint (air filter case side) 3

Cracks/damage → Replace.
Refer to “CARBURETOR” in chapter 6.

3. Install:

• side cover (left and right)
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

3 - 23

CHECKING THE FUEL HOSE AND FUEL COCK FILTER/

CHECKING THE CRANKCASE BREATHER HOSE

EAS00097

CHECKING THE FUEL HOSE AND FUEL
COCK FILTER

1. Remove:

• left air duct
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

2. Check:

2

1

T

3 Nm (0.3 m · kg, 2.2 ft · lb)

.

R

.

• fuel hose
Cracks/damage → Replace.

• fuel filter
Contaminants/damage → Replace the cock

13

assembly.

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the fuel cock to the “OFF”.
b. Remove the fuel cock filter cup 3.
c. Drain the fuel.
d. Checking the fuel cock filter.
e. Install the fuel cock filter cup.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

2

3. Install:

• left air duct
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

CHK

ADJ

1

3 - 24

EAS00098

CHECKING THE CRANKCASE BREATHER
HOSE

1. Remove:

• right side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

2. Check:

• crankcase breather hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.

CAUTION:

_

Make sure the crankcase breather hose is
routed correctly.

3. Install:

• right side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

CHECKING THE EXHAUST SYSTEM

EAS00099

CHECKING THE EXHAUST SYSTEM

1. Check:

• muffler assembly
Cracks/damage → Replace.

• exhaust pipe gasket
Exhaust gas leaks → Replace.

2. Check:

• tightening torques

1

CHK

ADJ

2

Exhaust pipe bolts

10 Nm (1.0 m · kg, 7.2 ft · lb)

T

.

R

.

Muffler bolt

4

22 Nm (2.2 m · kg, 16 ft · lb)

3

3 - 25

a

ADJUSTING THE REAR BRAKE/

CHECKING THE BRAKE FLUID LEVEL

CHASSIS

EAS00113

ADJUSTING THE REAR BRAKE

1. Check:

• brake pedal free play a
Out of specification → Adjust.

1

a

2. Adjust:

• brake pedal free play

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the brake rod adjusting nut 1 in direc-

tion a or b until the specified brake pedal
free play is obtained.

Brake pedal free play (at the end
of the brake pedal)

20 ~ 30 mm (0.79 ~ 1.18 in)

CHK

ADJ

b

Direction

Direction

CAUTION:

_

a

b

Brake pedal free play is
increased.

Brake pedal free play is
decreased.

After adjusting the brake pedal free play,
make sure there is no brake drag.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

3. Adjust:

• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.

3 - 26

EAS00115

CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.

NOTE:

_

• Place the vehicle on a suitable stand.

• Make sure the vehicle is upright.

a

CHECKING THE BRAKE FLUID LEVEL/

CHECKING THE FRONT BRAKE PADS

2. Check:

• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.

Recommended brake fluid

DOT 3 or 4

WARNING

_

• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.

• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.

• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.

CHK

ADJ

CAUTION:

_

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

NOTE:

_

In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.

EAS00117

CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
brake pads.

1. Operate the brake.

3 - 27

1

CHECKING THE FRONT BRAKE PADS/

CHECKING THE REAR BRAKE SHOES/

ADJUSTING THE REAR BRAKE LIGHT SWITCH

2. Remove:

• check plug 1

3. Check:

• front brake pad

Wear indicators 2 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “REPLACING THE FRONT

2

BRAKE PADS” in chapter 4.

4. Install:

• check plug

CHK

ADJ

2

1

EAS00126

CHECKING THE REAR BRAKE SHOES

1. Operate the brake.

2. Check:

• wear indicator 1

Reaches the wear limit line 2 → Replace
the brake shoes as a set.
Refer to “REAR WHEEL, BRAKE SHOE
PLATE, AND REAR WHEEL SPROCKET”
in chapter 4.

EAS00128

ADJUSTING THE REAR BRAKE LIGHT
SWITCH

NOTE:

_

The rear brake light switch is operated by
movement of the brake pedal. The rear brake
light switch is properly adjusted when the
brake light comes on just before the braking
effect starts.

3 - 28

1. Remove:

• right side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

2. Check:

• rear brake light operation timing
Incorrect → Adjust.

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE FRONT BRAKE HOSE

3. Adjust:

• rear brake light operation timing

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Hold the main body 1 of the rear brake light

switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper
time.

2

1

a

b

CHK

ADJ

Direction

Direction

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

4. Install:

• right side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

EAS00129

CHECKING THE FRONT BRAKE HOSE

1. Check:

• brake hose
Cracks/damage/wear → Replace.

2. Check:

• brake hose clamp
Loose connection → Tighten the clamp bolt.

3. Hold the vehicle upright and apply the front
brake several times.

4. Check:

• brake hose

Brake fluid leakage → Replace the dam­aged hose.
Refer to “FRONT BRAKE” in chapter 4.

a

b

Brake light comes on
sooner.

Brake light comes on
later.

3 - 29

BLEEDING THE HYDRAULIC BRAKE SYSTEM

EAS00133

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

WARNING

_

Bleed the hydraulic brake system when­ever:

• the system is disassembled.

• a brake hose is loosened, disconnected

or replaced.

• the brake fluid level is very low.

• brake operation is faulty.

NOTE:

_

• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir to over­flow.

• When bleeding the hydraulic brake system,

make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably length­ening the bleeding procedure.

• 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 hose have disappeared.

CHK

ADJ

1

2

1. Bleed:

• hydraulic brake system

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.

b. Install the brake master cylinder reservoir

diaphragm.

c. Connect a clear plastic hose 1 tightly to the

bleed screw 2.

d. Place the other end of the hose into a con-

tainer.

e. Slowly apply the brake lever several times.
f. Fully pull the brake lever without releasing

it.

3 - 30

BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE DRIVE CHAIN SLACK

g. Loosen the bleed screw.

NOTE:

_

Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip.

h. Tighten the bleed screw and then release

the brake lever.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the brake
fluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw

6 Nm (0.6 m · kg, 4.3 ft · lb)

T

.

R

.

k. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

CHK

ADJ

WARNING

_

After bleeding the hydraulic brake system,
check the brake operation.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

EAS00140

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:

_

The drive chain slack must be checked at the
tightest point on the chain.

CAUTION:

_

A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci­fied limits.

3 - 31

ADJUSTING THE DRIVE CHAIN SLACK

1. Stand the vehicle on a level surface.

WARNING

_

Securely support the vehicle so that there
is no danger of it falling over.

NOTE:

_

Place the vehicle on a suitable stand so that
the rear wheel is elevated.

2. Spin the rear wheel several times and find
the tightest position of drive chain.

3. Check:

• drive chain slack a

Out of specification → Adjust.

CHK

ADJ

6

5

3

c

a

5

4

2

6

1

(b)

b

a

Drive chain slack

20 ~ 30 mm (0.79 ~ 1.18 in)

T

.

R

.

4. Adjust:

• drive chain slack

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Remove the cotter pin 1.
b. Loosen the brake torque rod nut 2.
c. Loosen the brake rod adjusting nut 3.
d. Loosen the wheel axle nut 4.
e. Loosen both chain puller locknuts 5.
f. Turn both chain puller adjusting bolts 6 in

direction a or b until the specified drive
chain slack is obtained.

Direction

Direction

NOTE:

_

a

b

Drive chain is tightened.

Drive chain is loosened.

To maintain the proper wheel alignment, adjust
both sides c evenly.

3 - 32

g. Tighten both chain puller locknuts to specifi-

cation.

Chain puller locknut

16 Nm (1.6 m · kg, 11 ft · lb)

T

.

R

.

ADJUSTING THE DRIVE CHAIN SLACK/

LUBRICATING THE DRIVE CHAIN

h. Tighten the wheel axle nut to specification.

Wheel axle nut

91 Nm (9.1 m · kg, 66 ft · lb)

T

.

R

.

i. Tighten the brake torque rod nut to specifi-

cation.

Brake torque rod nut

19 Nm (1.9 m · kg, 13 ft · lb)

T

.

R

.

j. Install the cotter pin.

WARNING

_

Always use a new cotter pin.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

5. Adjust:

• brake pedal free play
Refer to “ADJUSTING THE REAR BRAKE”.

CHK

ADJ

EAS00142

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained prop­erly, it will wear out quickly. Therefore, the
drive chain should be serviced, especially
when the vehicle is used in dusty areas.
This vehicle has a drive chain with small rub­ber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain sol­vents, and the use of a coarse brush can dam­age these O-rings. Therefore, use only
kerosene to clean the drive chain. Wipe the
drive chain dry and thoroughly lubricate it with
engine oil or chain lubricant that is suitable for
O-ring chains. Do not use any other lubricants
on the drive chain since they may contain sol­vents that could damage the O-rings.

Recommended lubricant

Engine oil or chain lubricant
suitable for O-ring chains

3 - 33

CHECKING AND ADJUSTING THE STEERING HEAD

EAS00146

CHECKING AND ADJUSTING THE
STEERING HEAD

1. Stand the vehicle on a level surface.

WARNING

_

Securely support the vehicle so that there
is no danger of it falling over.

NOTE:

_

Place the vehicle on a suitable stand so that
the front wheel is elevated.

2. Check:

• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.

3. Remove:

• upper bracket
Refer to “STEERING HEAD” in chapter 4.

4. Adjust:

• steering head

CHK

ADJ

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Remove the lock washer 1, the upper ring

nut 2, and the rubber washer 3.

b. Loosen the lower ring nut 4 and then

tighten it to specification with a steering nut
wrench 5.

NOTE:

_

Set the torque wrench at a right angle to the
steering nut wrench.

Steering nut wrench

90890-01403, YU-33975

Lower ring nut (initial tightening
torque)

T

.

R

.

33 Nm (3.3 m · kg, 24 ft · lb)

c. Loosen the lower ring nut 4 1/4 turn, and

then tighten it to specification.

WARNING

_

Do not overtighten the lower ring nut.

3 - 34

CHECKING AND ADJUSTING THE STEERING HEAD/

CHECKING THE FRONT FORK

Lower ring nut (final tightening
torque)

T

.

R

.

22 Nm (2.2 m · kg, 16 ft · lb)

d. Check the steering head for looseness or

binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 4.

e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2, then

align the slots of both ring nuts. If neces­sary, hold the lower ring nut and tighten the
upper ring nut until their slots are aligned.

h. Install the lock washer 1.

NOTE:

_

Make sure the lock washer tabs a sit correctly
in the ring nut slots b.

CHK

ADJ

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

5. Install:

• upper bracket
Refer to “STEERING HEAD” in chapter 4.

EAS00149

CHECKING THE FRONT FORK

1. Stand the vehicle on a level surface.

WARNING

_

Securely support the vehicle so that there
is no danger of it falling over.

2. Check:

• inner tube
Damage/scratches → Replace.

• oil seal
Oil leakage → Replace.

3. Hold the vehicle upright and apply the front
brake.

4. Check:

• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 4.

3 - 35

ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLIES

EAS00160

ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLIES

The following procedure applies to both of the
rear shock absorber assemblies.

WARNING

_

• Securely support the vehicle so that there
is no danger of it falling over.

• Always adjust both rear shock absorber
assemblies evenly. Uneven adjustment
can result in poor handling and loss of
stability.

Spring preload

CAUTION:

_

Never go beyond the maximum or mini­mum adjustment positions.

CHK

ADJ

1. Adjust:

• spring preload

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the adjusting ring 1 in direction a or

b

.

b. Align the desired position on the adjusting

ring with the stopper 2.

Spring preload is

Direction

a

increased (suspension
is harder).

Spring preload is

Direction

b

decreased (suspension
is softer).

Adjusting positions

Minimum (soft): 1
Standard: 2
Maximum (hard): 5

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

3 - 36

CHECKING THE TIRES

EAS00166

CHECKING THE TIRES

The following procedure applies to both of the
tires.

1. Check:

• tire pressure
Out of specification → Regulate.

WARNING

_

• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.

• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.

• Operation of an overloaded vehicle could
cause tire damage, an accident or an
injury.

NEVER OVERLOAD THE VEHICLE.

CHK

ADJ

Basic weight
(with oil and a

120 kg (265 lb)

full fuel tank)

Maximum
load*

Cold tire
pressure

Up to 90 kg
load*

90 kg ~ maxi­mum load*

* Total weight of rider, passenger, cargo and

accessories

WARNING

_

200 kg (441 lb)

Front Rear

175 kPa

2

,

(1.75 kgf/cm

(2.00 kgf/cm2,

25 psi)

175 kPa

(1.75 kgf/cm

2

,

(2.80 kgf/cm2,

25 psi)

200 kPa

29 psi)

280 kPa

41 psi)

It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.

3 - 37

ÈÉ

CHECKING THE TIRES

2. Check:

• tire surfaces

Damage/wear → Replace the tire.

Minimum tire tread depth

1.6 mm (0.06 in)

Tire tread depth

1

Sidewall

2

Wear indicator

3

WARNING

_

• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.

• When using tube tires, be sure to install
the correct tube.

• Always replace a new tube tire and a new
tube as a set.

• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.

• Patching a punctured tube is not recom­mended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement.

Tire

È

Wheel

É

CHK

ADJ

Tube wheel Tube tire only

Tubeless wheel

Tube or tubeless
tire

• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning han­dling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this vehicle.

3 - 38

CHECKING THE TIRES

Front tire

Manufacturer Model Size

CHK

ADJ

CHENG SHIN

PIRELLI

SAKURA

S-901

CITY

DEMON

2.75-18 42P

2.75-18 42P

Rear tire

Manufacturer Model Size

CHENG SHIN

PIRELLI

WARNING

_

SAKURA

S-180

CITY

DEMON

90/90-

18 57P

90/90-

18 57P

• New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed
before any high-speed riding is done.

• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 to specification.

NOTE:

_

For tires with a direction of rotation mark 2:

• Install the tire with the mark pointing in the
direction of wheel rotation.

• Align the mark 3 with the valve installation
point.

Tire air valve stem locknut

2 Nm (0.2 m · kg, 1.4 ft · lb)

T

.

R

.

3 - 39

CHECKING THE WHEELS/

CHECKING AND LUBRICATING THE CABLES

EAS00168

CHECKING THE WHEELS

The following procedure applies to both of the
wheels.

1. Check:

• wheel
Damage/out-of-round → Replace.

WARNING

_

Never attempt to make any repairs to the
wheel.

NOTE:

_

After a tire or wheel has been changed or
replaced, always balance the wheel.

CHK

ADJ

EAS00170

CHECKING AND LUBRICATING THE
CABLES

The following procedure applies to all of the
inner and outer cables.

WARNING

_

Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.

1. Check:

• outer cable
Damage → Replace.

2. Check:

• cable operation
Rough movement → Lubricate.

Recommended lubricant

Engine oil or a suitable cable
lubricant

3 - 40

NOTE:

_

Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.

LUBRICATING THE LEVERS AND PEDALS/

LUBRICATING THE CENTERSTAND

EAS00171

LUBRICATING THE LEVERS AND PEDALS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.

Recommended lubricant

Lithium-soap-based grease

EAS00173

LUBRICATING THE CENTERSTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.

Recommended lubricant

Lithium-soap-based grease

CHK

ADJ

3 - 41

D

A

CHECKING AND CHARGING THE BATTERY

EAS00176

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE
BATTERY

WARNING

_

Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:

• Wear protective eye gear when handling
or working near batteries.

• Charge batteries in a well-ventilated area.

• Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,
lighted cigarettes).

• DO NOT SMOKE when charging or han­dling batteries.

• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.

FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL

• Skin — Wash with water.

• Eyes — Flush with water for 15 minutes

and get immediate medical attention.

INTERNAL

• Drink large quantities of water or milk fol­lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.

A

N

C

G

I

D

E

R

CHK

ADJ

1

UPPER LEVEL

LOWER LEVEL

2

3 - 42

1. Remove:

• left side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

2. Disconnect:

• battery leads
(from the battery terminals)

CAUTION:

_

First, disconnect the negative battery lead

, and then the positive lead 2.

1

CHECKING AND CHARGING THE BATTERY

3. Remove:

• battery band

• battery

4. Check:

• electrolyte level
The electrolyte level should be between the
minimum level mark a and the maximum
level mark b.
Below the minimum level mark → Add dis­tilled water to the proper level.

CAUTION:

_

Add only distilled water. Tap water con­tains minerals which are harmful to the bat­tery.

CHK

ADJ

5. Check:

• specific gravity
Less than 1.280 → Recharge the battery.

Specific gravity

1.280 at 20 °C (68 °F)

6. Charge:

• battery

Battery charging amperage and time

0.5 amps/10 hrs

WARNING

_

Do not quick charge a battery.

CAUTION:

_

• Loosen the battery sealing caps.

• Make sure the battery breather hose and

battery vent are free of obstructions.

• To ensure maximum performance, always
charge a new battery before using it.

3 - 43

CHECKING AND CHARGING THE BATTERY

• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.

• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.

• When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
on the vehicle, disconnect the negative
lead from the battery terminal.)

• To reduce the chance of sparks, do not
plug in the battery charger until the bat­tery charger leads are connected to the
battery.

• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.

• Make sure the battery charger lead clips
are in full contact with the battery termi­nal and that they are not shorted. A cor­roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.

• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!

CHK

ADJ

3 - 44

NOTE:

_

Replace the battery whenever:

• battery voltage does not rise to specification
or bubbles fail to rise during charging,

• sulphation of one or more battery cells
occurs (as indicated by the battery plates
turning white or material accumulating in the
bottom of the battery cell),

• specific gravity readings after a long, slow
charge indicate that one battery cell’s charge
is lower than the rest,

• warpage or buckling of the battery plates or
insulators is evident.

CHECKING AND CHARGING THE BATTERY

7. Check:

• battery breather hose and battery vent

Obstruction → Clean.
Damage → Replace.

8. Connect:

• battery breather hose

9. Install:

• battery

• battery band

CAUTION:

_

• When checking the battery, make sure the
battery breather hose is properly installed
and routed correctly. If the battery
breather hose is positioned so as to allow
electrolyte or hydrogen gas from the bat­tery to contact the frame, the vehicle and
its finish may be damaged.

• Make sure the battery breather hose is
properly routed away from the drive chain
and from below the swingarm. Refer to
“CABLE ROUTING”.

CHK

ADJ

2

UPPER LEVEL

LOWER LEVEL

1

10.Check:

• battery terminals

Dirt → Clean with a wire brush.
Loose connection → Connect properly.

11.Connect:

• battery leads
(to the battery terminals)

CAUTION:

_

First, connect the positive battery lead 1,
and then the negative battery lead 2.

12.Lubricate:

• battery terminals

Recommended lubricant

Dielectric grease

3 - 45

13.Install:

• left side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

CHECKING THE FUSE

EAS00181

CHECKING THE FUSE

CAUTION:

_

To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.

1. Remove:

• left side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

2. Check:

• fuse

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Connect the pocket tester to the fuse and

check the continuity.

NOTE:

_

Set the pocket tester selector to “Ω × 1”.

CHK

ADJ

Pocket tester

90890-03112, YU-03112-C

b. If the pocket tester indicates “∞”, replace

the fuse.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

3. Replace:

• blown fuse

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage

rating.

c. Set on the switches to verify if the electrical

circuit is operational.

3 - 46

CHECKING THE FUSE/

REPLACING THE HEADLIGHT BULB

d. If the fuse immediately blows again, check

the electrical circuit.

CHK

ADJ

Amperage

rating

Fuse 15 A 1

Spare 15 A 1

WARNING

_

Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat­ing may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

4. Install:

• left side cover
Refer to “SIDE COVERS, SEAT AND FUEL
TANK”.

Q’ty

1

1

EAS00182

REPLACING THE HEADLIGHT BULB

1. Remove:

• headlight assembly

2. Disconnect:

• headlight coupler

3. Remove:

• headlight unit 1

4. Remove:

• headlight bulb holder 1

3 - 47