Yamaha YFM350 User Manual
YFM350S
3GD-AE7
SUPPLEMENTARY SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the YFM350S. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
YFM350X(J) ’97 SERVICE MANUAL: 3GD-AE5
YFM350X(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 3GD-AE6
YFM350S
SUPPLEMENTARY
SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd.
First edition, January 2004 All rights reserved.
Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all 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.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
WARNING
CAUTION:
NOTE:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person checking or repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
1.An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2.Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page.
4.A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5.For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.
1 2
GEN
INFO 
SPEC
3 |
4 |
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CHK |
ENG |
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ADJ |
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5 6
CARB
CHAS
7 8
ELEC – |
+ |
TRBL |
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SHTG |
9 0
A B
T .
R .
C D
E
F G H
E G M
I J K L
B |
LS |
M |
S |
M N
New
LT
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter.
1 General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetion
6Chassis
7Electrical
8Troubleshooting
Illustrated symbols 9 to E are used to identify the specifications appearing in the text.
9 Filling fluid
0 Lubricant A Special tool
BTorque
CWear limit, clearance
DEngine speed
EΩ, V, A
Illustrated symbols F to L in the exploded diagrams indicate the types of lubricants and lubrication points.
F Apply engine oil G Apply gear oil
H Apply molybdenum disulfide oil I Apply wheel bearing grease
J Apply lightweight lithium soap base grease K Apply molybdenum disulfide grease
L Apply silicon grease
Illustrated symbols M to N in the exploded diagrams indicate where to apply a locking agent M and when to install a new part N.
MApply the locking agent (LOCTITE®)
NReplace
CONTENTS |
|
GENERAL INFORMATION ................................................................................ |
1 |
MACHINE IDENTIFICATION ....................................................................... |
1 |
MODEL LABEL ...................................................................................... |
1 |
SPECIAL TOOLS ......................................................................................... |
2 |
SPECIFICATIONS .............................................................................................. |
3 |
GENERAL SPECIFICATIONS ..................................................................... |
3 |
MAINTENANCE SPECIFICATIONS ............................................................ |
5 |
ENGINE ................................................................................................. |
5 |
CHASSIS ............................................................................................... |
7 |
ELECTRICAL ....................................................................................... |
10 |
CABLE ROUTING ...................................................................................... |
11 |
PERIODIC CHECKS AND ADJUSTMENTS.................................................... |
23 |
INTRODUCTION ........................................................................................ |
23 |
PERIODIC MAINTENANCE/LUBRICATION.............................................. |
23 |
SEAT, FENDERS AND FUEL TANK.......................................................... |
25 |
SEAT, SIDE COVERS, AND FRONT PANEL ..................................... |
25 |
FOOT PROTECTORS, ENGINE SKID PLATE, |
|
AND FRONT BUMPER....................................................................... |
26 |
HEADLIGHTS AND FRONT FENDER ................................................ |
27 |
REAR FENDER ................................................................................... |
28 |
FUEL TANK ......................................................................................... |
30 |
CHASSIS.................................................................................................... |
32 |
CHECKING THE FRONT BRAKE PADS............................................. |
32 |
ADJUSTING THE PARKING BRAKE .................................................. |
32 |
ADJUSTING THE REAR SHOCK ABSORBER................................... |
33 |
ELECTRICAL SYSTEM.............................................................................. |
35 |
CHECKING AND CHARGING THE BATTERY ................................... |
35 |
ADJUSTING THE HEADLIGHT BEAMS ............................................. |
40 |
REPLACING A HEADLIGHT BULB ..................................................... |
41 |
ENGINE ............................................................................................................ |
42 |
ENGINE REMOVAL ................................................................................... |
42 |
INSTALLING THE ENGINE ................................................................. |
42 |
CLUTCH ..................................................................................................... |
43 |
INSTALLING THE RIGHT CRANKCASE COVER............................... |
43 |
CARBURETOR................................................................................................. |
44 |
CARBURETOR .......................................................................................... |
44 |
CHASSIS .......................................................................................................... |
47 |
REAR WHEELS AND REAR AXLE HUB ................................................... |
47 |
REMOVING THE REAR AXLE ............................................................ |
49 |
INSTALLING THE REAR AXLE........................................................... |
50 |
FRONT ARMS AND FRONT SHOCK ABSORBER ................................... |
51 |
REAR BRAKE ............................................................................................ |
53 |
ASSEMBLING THE REAR BRAKE CALIPER ..................................... |
53 |
REAR SHOCK ABSORBER AND SWINGARM ......................................... |
54 |
HANDLING THE REAR SHOCK ABSORBER |
|
AND GAS CYLINDER......................................................................... |
56 |
DISPOSING OF THE REAR SHOCK ABSORBER |
|
AND GAS CYLINDER......................................................................... |
56 |
ELECTRICAL ................................................................................................... |
57 |
ELECTRICAL COMPONENTS................................................................... |
57 |
YFM350S WIRING DIAGRAM |
|
GEN
MACHINE IDENTIFICATION INFO
GENERAL INFORMATION
MACHINE IDENTIFICATION
MODEL LABEL
The model label 1 is affixed to the frame. This information will be needed to order spare parts.
– 1 –
SPECIAL TOOLS
EB102001
SPECIAL TOOLS
GEN 
INFO 
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US and CDN
P/N. 90890-
Tool No. |
Tool name/How to use |
Illustration |
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Steering nut wrench |
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90890-01443 |
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YU-33975 |
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This tool is needed to loosen and tighten |
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the rear shock absorber locknut. |
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Axle nut wrench (46 mm) |
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90890-01498 |
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YM-37134 |
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This tool is needed to loosen or tighten |
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the rear axle nut. |
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– 2 –
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GENERAL SPECIFICATIONS |
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SPEC |
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SPECIFICATIONS |
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GENERAL SPECIFICATIONS |
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Model |
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YFM350S |
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Model code number |
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5YT1 (For USA and Oceania) |
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5YT2 (For CDN) |
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5YT3 (For Europe) |
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Dimensions |
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Overall length |
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1,770 mm (69.7 in) |
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Overall width |
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1,095 mm (43.1 in) |
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Overall height |
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1,080 mm (42.5 in) |
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Seat height |
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820 mm (32.3 in) |
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Wheelbase |
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1,210 mm (47.6 in) |
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Minimum ground clearance |
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115 mm (4.53 in) |
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Basic weight |
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With oil and full fuel tank |
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180.0 kg (397 lb) |
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Minimum turning radius |
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3,100 mm (122 in) |
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Engine |
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Engine type |
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Air-cooled 4-stroke, SOHC |
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Cylinder arrangement |
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Forward-inclined single cylinder |
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Displacement |
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349.0 cm3 (21.30 cu.in) |
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Bore × stroke |
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83.0 × 64.5 mm (3.27 × 2.54 in) |
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Compression ratio |
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9.20 : 1 |
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Compression pressure |
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850 kPa (8.5 kg/cm2, 120.9 psi) at 350 r/min |
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Starting system |
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Electric starter |
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Oil capacity |
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Engine oil |
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Periodic oil change |
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2.50 L (2.20 Imp qt, 2.64 US qt) |
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With oil filter replacement |
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2.60 L (2.29 Imp qt, 2.75 US qt) |
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Total amount |
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3.20 L (2.82 Imp qt, 3.38 US qt) |
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Fuel |
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Type |
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Regular unleaded gasoline only |
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(For CDN and Europe) |
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Unleaded gasoline only (For USA and Oceania) |
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Tank capacity |
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9.0 L (1.98 Imp gal, 2.38 US gal) |
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Reserve amount |
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2.7 L (0.59 Imp gal, 0.71 US gal) |
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Carburetor |
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Type/manufacturer |
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BSR36/MIKUNI |
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– 3 –
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GENERAL SPECIFICATIONS |
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SPEC |
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Model |
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YFM350S |
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Transmission |
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Primary reduction system |
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Spur gear |
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Primary reduction ratio |
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76/24 (3.167) |
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Secondary reduction system |
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Chain drive |
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Secondary reduction ratio |
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38/13 (2.923) |
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Transmission type |
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Constant mesh, 6-speed forward, 1-speed |
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reverse |
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Operation |
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Left foot operation |
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Gear ratio |
1st |
36/16 × 20/27 × 29/18 (2.685) |
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2nd |
33/20 × 20/27 × 29/18 (1.969) |
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3rd |
29/23 × 20/27 × 29/18 (1.504) |
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4th |
27/26 × 20/27 × 29/18 (1.239) |
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5th |
25/28 × 20/27 × 29/18 (1.066) |
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6th |
23/29 × 20/27 × 29/18 (0.946) |
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Reverse |
33/16 × 33/10 (6.806) |
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Chassis |
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Frame type |
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Steel tube frame |
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Caster angle |
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6° |
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Trail |
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26.0 mm (1.02 in) |
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Toe-in (unloaded) |
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20 ~ 30 mm (0.79 ~ 1.18 in) |
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Tires |
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Type |
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Tubeless |
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Size |
front |
AT21 × 7-10 |
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rear |
AT20 × 10-9 |
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Manufacturer |
front |
DUNLOP |
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rear |
DUNLOP |
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Type |
front |
KT851B |
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rear |
KT877A |
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Brakes |
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Front brake |
type |
Dual disc brake |
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operation |
Right hand operation |
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Rear brake |
type |
Single disc brake |
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operation |
Right foot operation |
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Electrical |
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Ignition system |
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DC C.D.I. |
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Generator system |
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A.C. magneto |
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Battery voltage/capacity |
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12 V/8.6 Ah |
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Battery type |
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YTZ10S |
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Bulb wattage × quantity |
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Headlight |
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12 V 30 W/30 W × 2 |
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Tail/brake light |
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12 V 5 W/21 W × 1 |
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Neutral indicator light |
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12 V 1.7 W × 1 |
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Reverse indicator light |
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12 V 1.7 W × 1 |
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– 4 –
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model |
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YFM350S |
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Rocker arm/rocker arm shaft |
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Rocker arm inside diameter |
|
11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) |
Rocker arm shaft outside diameter |
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11.961 ~ 11.971 mm (0.4709 ~ 0.4713 in) |
Rocker-arm-to-rocker-arm-shaft clearance |
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) |
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Carburetor |
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I.D. mark |
|
5YT1 00 |
Main jet |
(M.J) |
#142.5 |
Main air jet |
(M.A.J) |
#35 |
Jet needle |
(J.N) |
5JFC39-2 |
Needle jet |
(N.J) |
P-0M |
Pilot jet |
(P.J) |
#22.5 |
Pilot air jet |
(P.A.J.1) |
#65 |
|
(P.A.J.2) |
#165 |
Pilot outlet |
(P.O) |
1 |
Bypass 1 |
(B.P.1) |
0.8 |
Bypass 2 |
(B.P.2) |
0.8 |
Bypass 3 |
(B.P.3) |
0.8 |
Pilot screw turns out |
(P.S) |
2-1/4 (For CDN, Europe, and Oceania) |
Valve seat |
(V.S) |
2.5 |
Starter jet |
(G.S) |
#70 |
Throttle valve size |
(Th.V) |
#105 |
Fuel level |
(F.L) |
4 ~ 5 mm (0.16 ~ 0.20 in) |
|
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Above the float chamber mating surface |
Float height |
|
13.0 mm (0.51 in) |
Engine idling speed |
|
1,450 ~ 1,550 r/min |
Intake vacuum |
|
33.3 kPa (250 mmHg, 9.83 inHg) |
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– 5 –
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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Tightening torques |
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Part to be tightened |
Part name |
Thread |
Q’ty |
Tightening torque |
Remarks |
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size |
Nm |
m · kg |
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ft · lb |
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Carburetor joint |
Bolt |
M8 |
2 |
20 |
2.0 |
14 |
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Carburetor clamp (cylinder head side) |
Screw |
M4 |
1 |
3 |
0.3 |
2.2 |
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Carburetor clamp (air filter case side) |
Screw |
M4 |
1 |
3 |
0.3 |
2.2 |
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Air filter case |
Screw |
M4 |
1 |
3 |
0.3 |
2.2 |
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Muffler and exhaust pipe |
Bolt |
M8 |
1 |
16 |
1.6 |
11 |
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Muffler |
Bolt |
M8 |
2 |
34 |
3.4 |
24 |
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Clutch cable holder |
Bolt |
M8 |
1 |
16 |
1.6 |
11 |
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Right crankcase cover |
Bolt |
M6 |
15 |
10 |
1.0 |
7.2 |
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Left crankcase cover |
Bolt |
M6 |
9 |
11 |
1.1 |
8.0 |
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Crankshaft end cover |
Bolt |
M6 |
4 |
7 |
0.7 |
5.1 |
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Bearing retainer (balancer shaft) |
Screw |
M6 |
2 |
7 |
0.7 |
5.1 |
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Bearing retainer (main axle) |
Screw |
M6 |
2 |
7 |
0.7 |
5.1 |
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Bearing retainer (left crankcase) |
Screw |
M5 |
2 |
7 |
0.7 |
5.1 |
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Drive sprocket |
Nut |
M20 |
1 |
90 |
9.0 |
65 |
Use a lock |
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washer. |
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Stopper lever |
Bolt |
M6 |
1 |
10 |
1.0 |
7.2 |
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Reverse shift cam stopper bolt |
Bolt |
M14 |
1 |
18 |
1.8 |
13 |
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Drive select lever assembly |
Bolt |
M8 |
2 |
20 |
2.0 |
14 |
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Drive select lever shift rod and |
Bolt |
M6 |
1 |
16 |
1.6 |
11 |
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reverse shift cam |
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Shift rod (shift pedal) locknut |
Nut |
M6 |
2 |
8 |
0.8 |
5.8 |
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– 6 –
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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CHASSIS |
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Model |
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YFM350S |
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Steering system |
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Lock-to-lock angle |
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Left |
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42.5° |
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Right |
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42.5° |
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Front suspension |
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Shock absorber stroke |
|
90.0 mm (3.54 in) |
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Shock absorber spring free length |
|
232.5 mm (9.15 in) |
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Spring rate |
(K1) |
32.00 N/mm (3.26 kg/mm, 182.72 lb/in) |
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|
(K2) |
45.00 N/mm (4.59 kg/mm, 256.95 lb/in) |
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Spring stroke |
(K1) |
0 ~ 45.0 mm (0 ~ 1.77 in) |
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(K2) |
45.0 ~ 90.0 mm (1.77 ~ 3.54 in) |
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Optional spring |
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No |
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Rear suspension |
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Shock absorber stroke |
|
88.0 mm (3.46 in) |
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Shock absorber spring free length |
|
238.5 mm (9.39 in) |
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Spring rate |
(K1) |
57.00 N/mm (5.81 kg/mm, 325.46 lb/in) |
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Stroke |
|
0 ~ 88.0 mm (0 ~ 3.46 in) |
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Enclosed gas pressure |
(standard) |
1,500 kPa (15.0 kg/cm2, 213.3 psi) |
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(Min) |
1,450 kPa (14.5 kg/cm2, 206.2 psi) |
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(Max) |
1,550 kPa (15.5 kg/cm2, 220.4 psi) |
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Wheel |
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Front wheel type |
|
Panel wheel |
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Rear wheel type |
|
Panel wheel |
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Front rim size/material |
|
10 × 5.5 AT/Aluminum |
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Rear rim size/material |
|
9 × 8.5 AT/Aluminum |
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Rim runout limit |
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Vertical |
|
<2.0 mm (0.08 in)> |
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Lateral |
|
<2.0 mm (0.08 in)> |
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Front disc brake |
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Type |
|
Dual disc brake |
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Disc outside diameter × thickness |
|
161.0 × 3.5 mm (6.34 × 0.14 in) |
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<Limit> |
|
<3.0 mm (0.12 in)> |
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Pad thickness |
|
4.2 mm (0.17 in) |
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<Limit> |
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<1.0 mm (0.04 in)> |
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Rear disc brake |
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Type |
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Single disc brake |
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Disc outside diameter × thickness |
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200.0 × 3.6 mm (7.87 × 0.14 in) |
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<Limit> |
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<3.1 mm (0.12 in)> |
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Pad thickness |
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4.5 mm (0.18 in) |
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<Limit> |
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<1.0 mm (0.04 in)> |
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– 7 –
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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Model |
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YFM350S |
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Brake lever and brake pedal |
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Brake lever free play |
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0 mm (0 in) |
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Brake pedal position |
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50.2 mm (1.98 in) |
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From the top of the frame to the top of the brake |
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pedal |
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Throttle lever free play |
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2 ~ 4 mm (0.08 ~ 0.16 in) |
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Drive chain |
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Type/manufacturer |
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DID520V/DAIDO |
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Number of links |
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97 + 1 links |
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Chain free play |
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25.0 ~ 35.0 mm (0.98 ~ 1.38 in) |
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Tightening torques |
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Part to be tightened |
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Thread size |
Tightening torque |
Remarks |
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Nm |
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m · kg |
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ft · lb |
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Engine and frame |
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M10 |
73 |
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7.3 |
53 |
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Front shock absorber and frame |
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M10 |
48 |
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4.8 |
35 |
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Front shock absorber and lower arm |
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M10 |
48 |
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4.8 |
35 |
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Steering knuckle and front wheel hub |
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M14 |
70 |
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7.0 |
50 |
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Steering shaft and frame |
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M10 |
35 |
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3.5 |
25 |
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Tie-rod locknut |
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M10 |
15 |
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1.5 |
11 |
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Disc cover (inner) |
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M6 |
7 |
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0.7 |
5.1 |
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Front brake master cylinder |
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M6 |
7 |
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0.7 |
5.1 |
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Clutch and parking brake lever assembly |
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M5 |
4 |
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0.4 |
2.9 |
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Front brake hose and upper front arm |
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M6 |
7 |
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0.7 |
5.1 |
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Front brake pipe and brake pipe joint |
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M10 |
19 |
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1.9 |
13 |
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Brake pipe joint and frame |
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M6 |
10 |
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1.0 |
7.2 |
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Brake caliper bleed screw |
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M8 |
6 |
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0.6 |
4.3 |
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Rear brake hose union bolt |
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M10 |
28 |
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2.8 |
20 |
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Parking brake adjusting bolt and locknut |
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M8 |
16 |
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1.6 |
11 |
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Rear brake light switch bracket and frame |
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M6 |
7 |
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0.7 |
5.1 |
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Rear brake master cylinder and frame |
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M8 |
23 |
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2.3 |
17 |
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Rear brake fluid reservoir and frame |
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M6 |
7 |
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0.7 |
5.1 |
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Rear brake hose and swingarm |
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M6 |
7 |
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0.7 |
5.1 |
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Rear hub and rear brake caliper |
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M8 |
34 |
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3.4 |
24 |
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Rear axle ring nut |
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M33 |
160 |
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16.0 |
115 |
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LT |
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Rear axle ring nut set bolt |
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M6 |
7 |
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0.7 |
5.1 |
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LT |
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Rear hub and swingarm (lower) |
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M10 |
73 |
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7.3 |
53 |
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Rear shock absorber and frame |
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M12 |
80 |
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8.0 |
58 |
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Relay arm and swingarm |
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M12 |
73 |
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7.3 |
53 |
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Rear shock absorber and relay arm |
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M12 |
73 |
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7.3 |
53 |
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Connecting rod and relay arm |
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M12 |
73 |
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7.3 |
53 |
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Connecting rod and frame |
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M12 |
73 |
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7.3 |
53 |
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Spring preload adjusting locknut (rear shock |
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M44 |
42 |
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4.2 |
30 |
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absorber) |
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– 8 –
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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Part to be tightened |
Thread size |
Tightening torque |
Remarks |
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Nm |
m · kg |
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ft · lb |
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Swingarm guard and swingarm |
M8 |
16 |
1.6 |
11 |
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Driven chain sprocket and boss |
M10 |
55 |
5.5 |
40 |
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Front bumper |
M8 |
12 |
1.2 |
8.7 |
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Rear bumper |
M8 |
34 |
3.4 |
24 |
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Drive chain guard |
M8 |
12 |
1.2 |
8.7 |
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Foot protectors (left and right) and frame |
M8 |
16 |
1.6 |
11 |
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Foot protectors (left and right), rear fender stay |
M8 |
17 |
1.7 |
12 |
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and frame |
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Foot protectors (left and right) and footrest |
M8 |
17 |
1.7 |
12 |
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Footrest and frame |
M10 |
73 |
7.3 |
53 |
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Battery holder |
M6 |
10 |
1.0 |
7.2 |
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Front fender and front fender bracket |
M6 |
7 |
0.7 |
5.1 |
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Front fender and frame |
M6 |
7 |
0.7 |
5.1 |
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Front fender bracket (center) and frame |
M6 |
10 |
1.0 |
7.2 |
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Front fender brackets (left and right) and frame |
M6 |
13 |
1.3 |
9.4 |
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Headlight bracket and front fender bracket |
M6 |
7 |
0.7 |
5.1 |
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Rear fender and frame |
M6 |
10 |
1.0 |
7.2 |
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Rear fender and rear bumper |
M6 |
7 |
0.7 |
5.1 |
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Rear fender and rear fender stay |
M6 |
7 |
0.7 |
5.1 |
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Rear fender stay and frame |
M6 |
7 |
0.7 |
5.1 |
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Rear fender stay and frame |
M8 |
16 |
1.6 |
11 |
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Engine skid plate and frame |
M8 |
12 |
1.2 |
8.7 |
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Fuel tank |
M6 |
7 |
0.7 |
5.1 |
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Fuel cock and fuel tank |
M6 |
4 |
0.4 |
2.9 |
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Rectifier/regulator |
M6 |
7 |
0.7 |
5.1 |
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Tail/brake light bracket and rear fender |
M6 |
4 |
0.4 |
2.9 |
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– 9 –
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Model |
YFM350S |
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C.D.I. |
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Magneto model/manufacturer |
F4T466/MITSUBISHI |
Pickup coil resistance |
459 ~ 561 Ω at 20 °C (68 °F) |
(Color) |
(White/Red-White/Green) |
Rotor rotation direction detection coil resis- |
0.083 ~ 0.101 Ω at 20 °C (68 °F) |
tance |
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(Color) |
(Red-White/Blue) |
C.D.I. unit-model/manufacturer |
F8T40374/MITSUBISHI |
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Rectifier/regulator |
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Regulator type |
Semi conductor-short circuit |
Model/manufacturer |
SH640E-11/SHINDENGEN |
No-load regulated voltage |
14.1 ~ 14.9 V |
Rectifier capacity |
14 A |
Withstand voltage |
200 V |
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Starter relay |
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Model/manufacturer |
2768095-A/JIDECO |
Amperage rating |
180 A |
Coil winding resistance |
4.18 ~ 4.62 Ω |
Battery |
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Specific gravity |
1.310 at 20 °C (68 °F) |
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Starter motor |
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Model/manufacturer |
DBQD5/DENSO |
Output |
0.7 kW |
Armature coil resistance |
0.0118 ~ 0.0133 Ω at 20 °C (68 °F) |
Brush overall length |
12 mm (0.47 in) |
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8.5 mm (0.33 in) |
Brush spring pressure |
6.38 ~ 9.32 N (651 ~ 950 gf, 22.96 ~ 33.55 oz) |
Commutator diameter |
28 mm (1.10 in) |
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27 mm (1.06 in) |
Mica undercut |
0.6 mm (0.024 in) |
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– 10 –
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CABLE ROUTING |
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SPEC |
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CABLE ROUTING |
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1 Clutch switch lead |
0 Handlebar switch lead |
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2 Starter cable |
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3 Clutch cable |
È Fasten the front brake light switch lead with two |
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4 Parking brake cable |
plastic bands. |
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5 Front brake hose |
É Fasten the starter cable, clutch switch lead, and |
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6 Front brake light switch lead |
handlebar switch lead with a plastic band. |
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7 Throttle cable |
Ê Fasten the clutch switch lead and handlebar |
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8 Neutral indicator light |
switch lead with a plastic band. |
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9 Reverse indicator light |
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1 |
2 3 4 |
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5 |
6 |
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Ê |
É 9 |
8 |
È |
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0 |
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7 |
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– 11 – |
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CABLE ROUTING |
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SPEC |
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1 Parking brake cable |
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È Pass the clutch switch lead, handlebar switch |
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2 Clutch cable |
lead, neutral/reverse indicator light lead, front |
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3 Starter cable |
brake light switch lead, and starter cable through |
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4 Clutch switch lead |
the guide. |
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5 Handlebar switch lead |
É Fasten the clutch switch lead, handlebar switch |
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6 Neutral/reverse indicator light lead |
lead, neutral/reverse indicator light lead, and |
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7 Rectifier/regulator |
front brake light switch lead securely with a plas- |
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8 Front brake light switch lead |
tic locking tie. |
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9 Front brake hose |
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0 Throttle cable |
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2 3
0
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4 5
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7
– 12 –
CABLE ROUTING SPEC
ÊRoute the clutch switch lead, handlebar switch lead, neutral/reverse indicator light lead, and
front brake light switch lead in front of the guide.
ËPass the throttle cable, clutch cable, and parking brake cable to the right side of the steering shaft.
1
2 3
0
9
8
4 5
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É
Ê
Ë
7
– 13 –
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