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1. 4 40 EE 4 42 CRANKCASE COVER RIGHT REMOVAL 4 43 GEUTOH REMOVAL EE 4 44 CGEUTCHINS PECETON gr 4 45 CEUTCEHINSTABE RT OIN enam 4 47 KICK STARTER AND SHIFT SHAFT 4 50 KICK SHAFT AND SHIFT SHAFT REMOVAL 4 51 KICK STARTER UNE HENG 4 51 SHIFT INSPECTION ET 4 52 KICK SHAFT ASSENBLINOO dtes e usto 4 53 SHIFT SHAFT AND KICK STARTER INSTALLATION 4 53 OIL PUNIP senen Ng Ban 4 54 Ol PUMP REMOVAL en aa MR BN 4 55 OIL PUMPINSFECTION Mr 4 55 OIL PUMP INSTALLATION im iterata nk ang nga trn Rr reru nana 4 56 CRANKCASE AND CRANKSHAFT 4 57 CRANKCASE SEPARATING 4 58 CRANKSHAFT INSPECTION aa aa ig a ga nnne 4 59 BEARINGS AND OIL SEALS INSPECTION 4 60 TIMING CHAIN TIMING CHAIN DRIVE SPROCKET AND TIMING CHAIN GUIDES INSPECTION 4 60 CRANKSHAFT INSTALLATION 4 61 CRANKCASE ASSEMBUING WEE 4 61 TRANSMISSION ne 4 63 TRANSMISSION REMOVAL 4 64 SHIFT FORK SHIFT CAM INSPECTION 4 64 TRANSMISSION INSPECTION 4 65 TRANSMISSION INSTALLATION 4
2. 7 19 CHARGING SYSTEM etcetera uan st 7 25 CIRCUIT DIAGRAM ducts umen 7 25 TROUBLESHOOTING EEN 7 26 LIGHTING SYSTEM 1 122 22 0 4 1 1 40 ttn 7 28 CIRCUIT DIAGRAM QU UA 7 28 EE 7 29 LIGHTING SYSTEM CHECK EE 7 31 SIGNALING SYSTEM 7 34 CIRCUIT DIAGRAM EE 7 34 TROUBLESHOOTING EEN 7 36 SIGNALE SY EM em apaa raa aa ag Ban ia 7 38 ELECTRICAL COMPONENTS ELEC ELECTRICAL ELECTRICAL COMPONENTS 1 Fuel sender 2 Starting circuit cut off relay 3 Rectifier regulator 4 Rear brake switch 5 Starter relay 6 Battery Main switch ELECTRICAL COMPONENTS ELEC CD Ignition coil 2 Flasher relay 3 CDI unit 4 Neutral switch 5 Horn ES SWITCHES ELEC SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester If the continuity reading is incorrect check the wiring connections and if necessary replace the switch Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end of the cou pler taking care not to loosen or damage the leads Pocket tester 90890 03112 NOTE e Before checking for continuity set the pocket tester to 0 and to the Q x 1 range e When checking for continuity switch back and forth between the switch positions a few times The terminal connect
3. Throttle cable free play is decreased e Tighten the locknut 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 Loosen the locknut 1 Turn the adjusting nut in or out until the specified throttle cable free play is obtained Throttle cable free play is urn in increased Throttle cable free play is decreased e Tighten the locknut 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 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk SPARK PLUG INSPECTION INSP COMPRESSION PRESSURE MEASUREMENT ADJ SPARK PLUG INSPECTION 1 Check e Spark plug type Incorrect Replace Standard spark plug D8EA NGK X24ES U DENSO 2 1 e Electrode 1 Wear damage Replace e Insulator 2 Abnormal color Replace Normal color is a medium to light tan color 3 Clean e Spark plug with spark plug cleaner or wire brush 4 Measure e Spark plug gap 8 with a wire gauge Out of specification Adjust gap Spark plug gap 0 6 0 7 mm COMPRESSION PRESSURE MEASUREMENT NOTE co ll Insufficient compression pressure will result in performance loss 1 Start the engine and let it
4. 5 2 Install e Copper washers D e Brake hose 2 e Union bolt A WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to the CABLE ROUTING section NOTE e While holding the brake hose tighten the union bolt as shown e Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill e Brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 3 or 4 WARNING e Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance e 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 e When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock and plastic parts Therefore always clean up any spilt brake fluid immediately 23 FRONT BRAKE 5 65 4 Bleed e Brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 5 Check e Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper
5. 12310502 12311304 28 FRONT FORK CHAS df NOTE e When assembling the front fork leg be sure to replace the following parts Oil seal dust seal e Before assembling the front fork leg make sure that all of the components are clean 1 Install e Damper rod 1 e Oil lock piece 2 Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate e Inner tube s outer surface Recommended lubricant Fork oil 10 W or equivalent 3 Tighten e Damper rod bolt NOTE While holding the damper rod with the damper rod holder and T handle tighten the damper rod bolt 1 Vz Damper rod holder 19 mm 90890 04084 T handle 90890 01326 4 Install e Oil seal 1 with the fork seal driver weight and adapter Fork seal driver weight 2 90890 01367 Fork seal driver attachment 033 OF 90890 01368 12311310 12310403 12311504 29 FRONT FORK CHAS df Make sure that the numbered side of the oil seal faces up NOTE e Before installing the oil seal apply lithium soap base grease onto its lips e Apply fork oil onto the outer surface of the inner tube e Before installing the oil seal cover the top of the front fork leg with a plastic bag to pro tect the oil seal during installation 5 Install e Oil seal clip NOTE
6. CONTINUITY 2 Voltage Headlight e Connect the pocket tester DC 20 V to the headlight and high beam indicator light leads Headlight Tester lead Yellow or Green 1 lead Tester lead Black 3 lead High beam indicator light Tester lead gt Yellow 4 lead Tester lead Black terminal When dimmer switch is LO position B When dimmer switch is HI position e otart the engine e Turn the lights switch to ON e Turn the dimmer switch to LO or HI posi tion e Check for voltage 12 V on the Green OUT OF SPECIFICATION and Yellow lead at bulb socket connector MEETS SPECIFI 1 CATION 12 V Wiring circuit from main switch to bulb socket This circuit is This circuit is good connector is faulty repair 2 Meter light does not come on LIGHTING SYSTEM ELEC e Check the bulb and bulb socket for continu NO CONTINUITY ity Refer to the CHECKING OF BULBS sec tion qi e ciis 2 Voltage e Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Q terminal Tester lead gt Black 2 terminal L OUT OF SPECIFICATION e Start the engine 1 e Turn the lights switch to ON or PO e Check for voltage 12 V on the Blue lead Wiring circuit from main switch to bulb socket at the bulb socket connector connector is faulty repair MEETS SPECIFI
7. Ukur panjang rantai 15 mata pada bagian dalam dan sisi luar dari pin dan ju mlahkan panjang keduanya e Panjang Odiantara titik tengah pin panjang bagian dalam panjang bagian luar b 2 Ukur 15 mata dari rantai e Diluar spesifikasi ganti rantai penggerak gear sprocket depan dan belakang satu set 0 Q 6 2 9 40 2 3 6 DOOD 6 0 9 40 00 2 9 6 Panjang 15 mata rantai maximum 191 5 mm 7 54 in TIA eP ada saat mengukur 15 mata rantai tekan rantai kedalam untuk menghindari gaya tarik eLakukan pengukuran pada dua tempat yang berbeda 2 Periksa e Rantai penggerak Drive chain kaku bersihkan dan lumasi 13 SHOCK ABSORBER BELAKANG DAN LENGAN AYUN CHAS 3 Pembersihan e Rantai penggerak Drive chain a Bersihkan rantai dengan kain pembersih b Rendam rantai dalam minyak tanah dan ber sihkan kotoran dari rantai c Setelah bersih keringkan rantai dari minyak tanah dengan sempurna AAAAAAAAAAAAAAAAAAAAAAAA PERHATIAN Rantai sepeda motor ini menggunakan O ring dari karet 1 yang terpasang diantara kedua plat Jangan menggunakan udara ber tekanan bensin dan larutan pembersih a l bensin dan jangan membersihkan rantai dengan sikat Tekanan udara yang tinggi dan kandungan air akan merusak kan rantai pada bagian dalam dan cairan pembersih akan merusak O ring
8. 4 Natural indicator light does not come on e Check the bulb and bulb socket for continu ity Refer to the CHECKING OF BULBS sec Bulb and or bulb socket are faulty replace tion CONTINUITY INCORRECT ee I e Check the neutral switch for continuity Refer to the CHECKING THE SWITCHES section Neutral switch is faulty replace it CORRECT e Connect the pocket tester DC 20 V to the bulb socket connector 3 Voltage Tester lead Brown 1 terminal Tester lead gt Frame ground OUT OF SPECIFICATION e Turn the main switch to ON e Check for voltage 12 V on the Brown Wiring circuit from main switch to bulb socket lead at bulb socket connector connector is faulty repair MEETS SPECIFI CATION 12 V This circuit is good SIGNALING SYSTEM ELEC 5 Fuel meter does not operate 1 Fuel sender e Remove the fuel sender 1 from the fuel tank e Connect the pocket tester to the fuel sender coupler Tester lead Green 2 terminal Tester lead gt Black 3 terminal e Check the fuel sender for the specified resistance Bi Fuel sender resistance Up 2 OUT OF SPECIFICATION Q x 1 4 10 O at 20 C Fuel sender resistance Down 5 2x10 BOTH MEET SPECIFICATION 2 Voltage e Connect the pocket tester DC 20 V to the fuel meter coupler Tester lead Brown 1 terminal Tester lead gt Blac
9. CONTINUITY 6 Main switch e Check the main switch for continuity 3 Refer to the CHECKING THE SWITCHES section Replace main switch CORRECT INCORRECT 7 Engine stop switch e Check the engine stop switch for continuity Refer to the CHECKING THE SWITCHES section Replace handlebar switch right CORRECT ELECTRIC STARTING SYSTEM ELEC INCORRECT e Check the neutral switch for continuity Refer to the CHECKING THE SWITCHES section Replace neutral switch CORRECT 9 Clutch switch INCORRECT e Check the clutch switch for continuity Refer to the CHECKING THE SWITCHES section Replace clutch switch CORRECT INCORRECT e Check the start switch for continuity Refer to the CHECKING THE SWITCHES section Replace handlebar switch right CORRECT 8 Neutral switch 10 Start switch 11 Wiring connection POOR CONNECTION e Check the entire ignition system for conti nections Refer to the WIRING DIAGRAM section ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR 1 Brush 2 Armature 3 O ring 4 O ring BRUSH LENGTH LIMIT COMMUTATOR WEAR LIMIT MICA UNDER CUT 1 5mm ELECTRIC STARTING SYSTEM ELEC Removal 1 Remove e Carburetor Refer to the CARBURETOR section in CHAPTER 5 2 Remove e Clutch cable Refer to the WIRE CABLE AND TUBE section in CHAPTER 4 3 Disconnect e Sta
10. 2 0 44 6 16 FRONT BRAKE CALIPER INSPECTION _ 6 17 FRONT BRAKE CALIPER INSTALLATION 6 17 MASTER CYLINDER REMOVAL 2 1 0 1 1 NG 6 20 MASTER CYLINDER INSPECTION eer 6 20 MASTER CYLINDER INSTALLATION ern 6 21 FRONT FORK 2 E 6 24 FRONT FORK REMOVAL Dosen E Sana 6 25 FRONT FORK DISASSBMBIEY ute duce 6 25 FRONTIPORKINSPEG THON tote tte maa saat 6 27 ASSENIBIY sem 6 27 FRONT FORK INSTALLATION 6 30 STEERING HEAD AND HANDLEBAR 6 32 HANDLEBAR saa agati eria aa AN 6 32 Eil Tee E RE 6 33 HANDEEBAR EE 6 34 STEERING HEAD REMOVAL eee tes 6 35 STEERING HEAD AND HANDLEBAR INSPECTION 6 36 STEERING HEAD INS TALIA TION tea coats an Sa uan 6 37 HANDLEBAR INSTALLATION 6 39 REAR SHOCK ABSORBER AND SWINGARM 6 41 REAR SHOCK ABSORBER AND SWINGARM REMOVAL 6 42 REAR SHOCK ABSORBER INSPECTION 6 43 SWINGARM INSPECTION Eege Ee 6 43 RELAY ABM
11. YAMAHA SCORPIO SX 4 MANUAL Winanda Fairyanto s collection nanda jogjalandrover org fairyanto gmail com yamaha scorpio yahoogroups com 5BP F8197 B0 SERVICE MANUAL SCORPIO 2006 oleh Yamaha Motor Co Ltd Edisi kedua Agustus 2006 dialih bahasakan oleh Technical Publication Yamaha Indonesia Motor Manufacturing di cetak di Indonesia PENDAHULUAN Service Manual ini dibuat oleh Yamaha Motor Company Ltd dan dialin bahasakan oleh Technical Publication Yamaha Indonesia diharapkan dapat dipakai oleh Teknisi Bengkel dan Dealer Yamaha Kami menyadari bahwa tidak mungkin menjelaskan seluruh pelajaran teknik perbaikan sepeda motor dalam satu buku saja sehingga kami meyarankan kepada para mekanik harus terlebih dahulu menguasai dasar dasar perbaikan sepeda motor Yamaha dengan mengikuti training training reguler yang diadakan oleh Yamaha Tanpa pengetahuan ini usaha perbaikan akan kurang sempurna Yamaha Motor Indonesia akan terus menerus berusaha meningkatkan mutu produksinya untuk itu jika ada perubahan yang mendasar dalam spesifikasi dan prosedur pengerjaan kami akan sampaikan ke seluruh jaringan Yamaha melalui buletin Servioce Information TECHNICAL PUBLICATION GROUP 1 SERVICE INFORMATION DIV YAMAHA MOTOR LTD INFORMASI PENTING YANG ADA DIDALAM BUKU PETUNJUK INI Informasi penting secara khusus ditandai dengan tanda tanda sebagai berikut AN Simbol ini mengharuskan
12. 4 67 ENGINE REMOVAL ENG ENGINE OVERHAUL ENGINE REMOVAL NOTE V It is not necessary to remove the engine in order to remove the following components e Cylinder head e Cylinder e Piston e Clutch e Kickstarter shaft and shift shaft e Oil pump e Generator 1 Remove e Seat e Fuel tank Refer to the SEAT FUEL TANK section in CHAPTER 3 WARNING Securely support the motorcycle so there is no danger of it falling over ENGINE OIL 1 Remove e Drain plug Refer to the ENGINE OIL REPLACEMENT section in CHAPTER 3 EXHAUST PIPE ASSEMBLY 1 Remove e Bolts right footrest bracket e Right footrest bracket 1 ENGINE REMOVAL ENG 2 Loosen e Bolt exhaust pipe joint 4 3 Remove e Nuts exhaust pipe 4 e Exhaust pipe assembly 5 Remove e Bolts muffler e Nut muffler e Muffler LEFT FOOTREST BRACKET 1 Remove e Bolt shift pedal e Bolts left footrest bracket 7 Y e Left footrest bracket 2 di 7 po NOTE When removing shift pedal shift the transmis sion into 1st gear DRIVE CHAIN 1 Remove e Drive chain case ENGINE REMOVAL ENG 2 Remove e Lock washer 1 e Drive sprocket 2 3 Loosen e Hear wheel axle nut e Locknuts e Drive chain adjuster nuts 4 CARBURETOR 1 Remove e Carburetor Refer to the CARBURETOR section in CHAPTER 5 WIRE CABLE AND TUBE 1 Remove e Spark p
13. Measuring point H Piston ring Top ring Type Dimensions B x T End gap installed Side clearance installed 2nd ring Type Dimensions B x T End gap installed Side clearance Oil ring Dimensions B x T End gap installed ON IB ES MAINTENANCE SPECIFICATIONS SPEC v SX 4 lt 2 591 6 mm lt 2 591 6 mm Counterclockwise Counterclockwise Clockwise Clockwise 0 020 0 025 mm 0 05 mm 69 977 69 996 mm 4 mm Barrel 1 2x 2 8 mm 0 15 0 30 mm 0 03 0 07 mm Taper 1 2 x 2 8 mm 0 15 0 30 mm 0 02 0 06 mm 2 5 x 2 8mm 0 3 0 9 mm MAINTENANCE SPECIFICATIONS SPEC v SKA Crankshaft zi E rn A Crank width A Runout limit B Big end side clearance C Clutch Friction plate Thickness Quantity Wear limit Clutch plate Thickness Quantity Warp limit Free length Quantity Minimum length Push rod bending limit Transmission Main axle deflection limit Drive axle deflection limit Shifter Shifter type Guide bar bending limit Carburetor mark Main jet Main air jet Jet needle Needle jet Pilot jet Pilot air jet Clutch spring Pilot screw Pilot outlet Bypass Valve seat size Starter jet 69 25 69 30 mm lt 0 03 mm gt 0 35 0 85 mm 2 9 3 1mm 6 pcs lt 2 8 mm gt 1 5 1 mm 5 pcs 0 2 mm 34 9 mm 4 pc 33 2 mm 0 5 mm 0 08 mm 0 08 mm Cam drum and guide
14. TIRE INSPECTION section in CHAPTER 3 e Front wheel Refer to the WHEEL INSPECTION section in CHAPTER 3 3 Check e Spokes Bends damage Replace Loose spokes gt Retighten Turn the wheel and tap the spokes with a screwdriver NOTE A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Tighten e Loose spokes e Nipple NOTE _ Check the front wheel runout after tightening the spokes A FRONT WHEEL AND BRAKE DISC CHAS 5 12010101 12210203 5 Measure e Front wheel runout Over the specified limits Replace Front wheel runout limits Radial 2 0 mm Lateral 2 0 mm 6 Inspect e Front wheel bearings Bearings allow free play in the wheel hub or the wheel does not turn smoothly Replace e Oil seals Wear damage Replace 7 1 e Collar Grooved wear Replace the collar and the oil seal as a Set BRAKE DISC INSPECTION 1 Inspect e Brake disc Galling damage Replace 2 Measure e Brake disc deflection Out of specification Inspect the wheel runout lf wheel runout is within the limits replace the brake disc Brake disc maximum deflection 0 15 mm Measuring point 2 mm e Brake disc thickness Out of specification Replace Brake disc minimum thickness 3 5 mm FRONT WHEEL AND BRAKE DISC CHAS df FRONT WHEEL ASSEMBLY 1 Install e Bearing 1 e Spacer e Bearing v e Oil seal T
15. h h5 Adjust the oil seal clip so that it fits into the outer tube s groove 6 Install e Dust seal 1 with the fork seal driver weight Fork seal driver weight 90890 01367 Front fork seal driver attachment 033 90890 01368 7 Fill e Front fork leg with the specified amount of the recommend fork oil Quantity each front fork leg 252 cm Yamaha fork and shock oil 10 W or equivalent 12311403 30 FRONT FORK CHAS df Front fork leg oil level 8 from the top of the inner tube with the inner tube fully compressed and without the fork spring 95 mm NOTE e While filling the front fork leg keep it upright e After filling slowly pump the front fork leg up and down to distribute the fork oil e Be sure to stroke the inner tube slowly because the for oil may spurt out 8 Install e Spring e Spring seat 2 e opacer 3 e Cap bolt 4 NOTE e Install the spring with the smaller pitch facing up e Before installing the cap bolt apply grease onto the O ring e Temporarily tighten the cap bolt EAS00662 FRONT FORK INSTALLATION The following procedure applies to both of the front fork legs 1 Install e Front fork leg Temporarily tighten the handle crown pinch bolt and lower bracket pinch bolt NOTE aaa Make sure that the inner fork tube is flush with the top of the handlebar holder FRONT FORK CHAS 2 Tighten e Lower bracke
16. 4 Inspect e Brake drum inner surface Oil scratches Remove Use a rag soaked in lacquer thinner or solvent Use an emery cloth lightly and evenly polishing 5 Measure e Brake drum inside diameter Out of specification Replace Wear imt Asi mm REAR WHEEL AND REAR BRAKE 5 4 12270504 6 Inspect e Brake shoe plate 1 Cracks damage Replace e Brake camshaft e Camshaft hole 3 Scratches excessive wear Replace T KKKKKK BRAKE SHOE PLATE ASSEMBLY 1 Install e Brake camshaft e Brake shoe wear indicator 2 e e oce e KK KK e e KK e ke ke e e e ke e e ke e e e e ke e e ke e Ae kk Installation steps Set the camshaft with its punched mark facing the direction as shown e Align the projection on the indicator with the camshaft notch and install e Check the proper position of the brake shoe kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk 2 Install e Brake camshaft lever 1 Install the camshaft lever with its slit and the indicator at right angle as shown T kkkkkk REAR WHEEL ASSEMBLY 1 Install e Bearing 1 e Spacer 2 Refer to the FRONT WHEEL AND BRAKE DISC section REAR WHEEL AND REAR BRAKE 5 4 1701032 REAR WHEEL INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install e Brake shoe plate assembly e Rear wheel assembly NOTE LLL Make sure that the slot in the rear whe
17. 90890 01274 Crankshaft installer bolt 3 90890 01275 Adaptor M10 90890 01383 spacer 5 90890 01288 CRANKCASE ASSEMBLING 1 Apply e Sealant To the mating surface of both case halves 1 Yamaha bond No 1215 90890 85505 2 Install e Dowel pins 2 3 Fit the right crankcase onto the left case Tap lightly on the case with a soft hammer Before installing and torquing the crank case holding bolts be sure to check whether the transmission is functioning properly by manually rotating the shift cam either way 4 CRANKCASE AND CRANKSHAFT ENG 4 Tighten e Crankcase bolts NOTE e Tighten the crankcase bolts in stages and in a Crisscross pattern e Install a copper washer on bolts 1 M6 x 70 mm bolts D 3 M6 x 60 mm bolts 2 5 M6 x 55 mm bolts M6 x 45 mm bolts 9 2 ES Bolt left crankcase AN 10 Nm 1 0 m kg 5 Install e Neutral switch 3 6 Install e Push lever clutch e Timing chain drive sprocket 1 e Timing chain guide intake side 2 e Timing chain 3 TRANSMISSION CD Main axle 1st pinion gear 2 3rd 4th pinion gear 3 5th pinion gear 4 2nd pinion gear 5 Drive axle 6 1st wheel gear 3rd wheel gear TRANSMISSION ENG 4th wheel gear 9 5th wheel gear 2nd wheel gear Drive sprocket 2 Shift drum assembly 3 Shift fork L Shift fork 5 Shift fork 4 TRANSMISSION ENG
18. e Neutral switch lead 3 ENGINE INSTALLATION ENG 2 Install e Tachometer cable e Breather hose 3 Install e Clutch cable 4 Install e Ignition coil e Spark plug lead cap 4 CARBURETOR 1 Install e Carburetor Hefer to the CARBURETOR section in CHAPTER 5 DRIVE CHAIN 1 Install e Drive chain e Drive sprocket e Lock washer Nut drive chain Ve 2 Install e Drive chain case LEFT FOOTREST BRACKET 1 Install e Left footrest bracket Bolt shift arm 10 Nm 1 0 m kg Bolt footrest bracket 30 Nm 3 0 m kg ENGINE INSTALLATION ENG EXHAUST ASSEMBLY 1 Install e Muffler e Nut muffler e Bolts muffler 2 Install e Exhaust pipe 3 Tighten e Bolt exhaust pipe joint 4 Tighten e Nuts e Bolts 4 Nuts exhaust pipe 18 Nm 1 8 kg Bolt exhaust pipe joint 20 Nm 2 0 Bolts muffler 30 Nm 3 0 m kg 5 Install e Hight footrest bracket e Bolts right footrest bracket FUEL TANK AND SEAT 1 Install e Fuel tank e Seat Refer to the SEAT FUEL TANK REMOVAL AND INSTALLATION section in CHAPTER 3 2 Fill e Engine oil Into crankcase Refer to the ENGINE OIL REPLACEMENT section in CHAPTER 3 ENGINE INSTALLATION ENG 3 Adjust e Throttle cable free play e Clutch lever free play Refer to the THROTTLE CABLE ADJUST MENT CLUTCH ADJUSTMENT section in CHAPTER 3 4 Throttle cable free play 3 5mm C
19. e Tighten the locknut kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk TIRE INSPECTION INSP STEERING HEAD INSPECTION ADJ amp 12070102 12070203 23 TIRE INSPECTION 1 Measure e lire inflation pressure Out of specification Adjust Basic weight with oil and full fuel tank Maximum load 180 kg Cold tire pressure 200 kPa 200 kPa Up to 100 kg load 2 0 kg cm 100 kg maximum 200 kPa 225 kPa Load 2 0 kg cm 2 25 kg cm Load is the total weight of the cargo rider pas senger and accessories 2 Inspect e lire surfaces Wear Damage Replace Minimum tire tread depth front and rear 0 8 mm CD Tread depth 2 Side wall 3 Wear indicator 3 After a tire repair or replacement be sure to tighten the valve stem locknut 1 to specifi cation STEERING HEAD INSPECTION 1 Stand the motorcycle on a level surface NOTE Stand the motorcycle on its centerstand 2 Elevate the front wheel by placing a suitable stand under the engine INSP STEERING HEAD INSPECTION ADJ d 4 9 d d M A 24 3 Check e Handlebar assembly Grasp the handlebar and gently rock the steering Looseness Adjust the handlebar e Steering assembly bearings Grasp the bottom of the lower front fork tubes and gently rock the fork assembly Looseness Adjust the steering head 4 Adjust e
20. Install new fuse of proper amperage Amperage 10 A 4 Replace e Blown fuse 5525 Lr 7 SDA 0877 Ho kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Blown fuse replacement steps e Turn off ignition and the circuit e Install a new fuse of proper amperage e Turn on switches to verify operation of elec trical device If fuse blows immediately again check circuit in question kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk WARNING Do not use fuse of higher amperage rating than recommended Extensive electrical system damage and fire could result from substitution of a fuse of improper amper age 5 Install e Fuse HEADLIGHT BEAM ADJUSTMENT INSP HEADLIGHT BULB REPLACEMENT ADJ amp HEADLIGHT BEAM ADJUSTMENT 1 Remove e Holding screw 1 e Headlight unit 2 2 Adjust e Headlight beam vertical kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Headlight beam adjustment steps Loosen the bolt headlight body e Position the headlight body up or down to adjust the headlight beam 3 Install e Headlight unit HEADLIGHT BULB REPLACEMENT 1 Remove e Holding screw 1 e Headlight unit 2 2 Remove e Cover 1 e Bulb defective NOTE Turn the bulb holder 2 counterclockwise to remove the bulb WARNING Keep flammable products and your hands away from the bulb while it is on it will be hot Do not touch the bulb u
21. Pocket tester 90890 03112 Alat ini digunakan untuk memeriksa rangkaian kelistrikan Engine tachometer 90890 03113 Alat ini digunakan untuk menyetel putaran langsam mesin Valve spring compressor 90890 04019 Alat ini digunakan untuk memasang dan melepas rangkaian klep SPECIAL TOOLS SMD Nomor Tool Gambar ilustrasi Universal clutch holder 90890 04086 Alat ini digunakan untuk menahan clutch boss pada saat memasang dan melepas baut clutch boss nut Ignition checker 90890 06754 Alat ini digunakan untuk memeriksa komponen sistim pengapian BAB 2 SPESIFIKASI SPESIFIKASI UMUM aa 2 1 SPESIFIKASI PERAWATAN 2 4 ME an aa an Nan 2 4 Ra Ee e 2 12 KELISTRIKAN m 2 15 SPESIFIKASI TORS UMUM 2 17 UNIT SATUAN cn 2 17 PELUMASAN DAN PELUMAS YANG DIPAKAI 2 18 ME IN seeen 2 18 PUAN GRAIG TENS EE 2 19 JALUR KABEL SPESIFIKASI UMUM SPESIFIKASI SPESIFIKASI UMUM Kode model Dimensi Panjang Lebar Tinggi Tinggi tempat duduk Jarak sumbu roda Jarak ketanah 5BP1 2 020 mm 770 mm 1 090 770 mm 1 2295 165 Berat Dengan Oli dan bahan bakar terisi penuh 131 kg Kemampuan berbelok 2 100 mm Mesin Tipe Mesin
22. REAR SHOCK ABSORBER AND SWINGARM 5 5 KAKAK REAR WHEEL CLUTCH HUB INSPECTION 1 Inspect e Rear wheel clutch hub Wear damage cracks Replace T kkkkkk DRIVEN SPROCKET ASSEMBLY 1 Install e Driven sprocket 1 e Lock washers 2 e Bolts NOTE Tighten the bolts in a crisscross pattern 2 Bend e Lock washer tab 1 along a flat side of the end REAR SHOCK ABSORBER AND SWINGARM INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate e Bearings e Collars e Dust covers e Pivot shaft e Bushes Recommended lubricant Lithium soap base grease REAR SHOCK ABSORBER AND SWINGARM 5 45 2 Install e Bush 1 e Bearings 2 e Chain guide 3 e Collar chain guide e Bolt chain guide e Dust covers to the swingarm 3 Install e Collar 1 e Bushes 2 e Oil seals 3 to the relay arm 4 Install e Collars e Bushes e Oil seals 3 to the connecting arm 5 Install e Connecting arm 1 e Bolt connecting arm relay arm 2 e Washer 3 e Nut connecting arm relay arm 4 59 Nm 5 9 m kg NOTE e Apply the lithium soap base grease on the bolt e Install the nut on the right side of the chassis REAR SHOCK ABSORBER AND SWINGARM CHAS 5 6 Install e Connecting arm 1 e Bolt connecting arm swingarm 2 e Washer 3 e Nut connecting arm swingarm 4 59 Nm 5 9 kg NOTE
23. Tempat duduk ePergunakan alat spesial tool ini untuk perbaikan Pocket tester 90890 03112 1 Tahanan Lighting coil eLepaskan coupler CDI magneto dari kabel bodi ePasangkan pocket tester Ox1 pada stator coil Kabel Tester 4 terminal kuning 1 Kabel Tester terminal hitam 2 eukur tahanan lighting coil DILUAR SPESIFIKASI Tahanan Lighting coil 0 24 0 36 O pada 20 C 68 F Kuning Hitam SESUAI SPESIFIKASI 2 saklar lampu TIDAK BAGUS eP eriksa sistim penyambungan saklar lampu lihat bagian PEMERIKSAAN SAKLAR SWITCH saklar lampu rusak gt ganti atau perbaiki saklar lampu kanan 16 SISTIM PENERANGAN ELEC 3 Saklar Dimmer TIDAK BAGUS ePeriksa sistim penyambungan saklar dimmer lihat bagian PEMERIKSAAN SAKLAR SWITCH S aklar Dimmer rusak perbaiki atau ganti saklar kemudi sebelah kiri 4 S aklar Pass TIDAK BAGUS ePeriksa sistim penyambungan saklar P ass lihat bagian PEMERIKSAAN SAKLAR SWITCH ng Saklar Pass rusak gt perbaiki atau ganti saklar kemudi sebelah kiri SAMBUNGAN BERMASALAH ePeriksa sistim penyambungan kabel pada sistim penerangan SPT Periksa kondisi kabel kabel pada sistim penerangan lihat bagian PEMERIKSAAN SISTIM PENERANGAN 17 SISTIM PENERANGAN ELEC PEMERIKSAAN SISTIM PENERANGAN 1 lampu depan dan lampu indikator lampu jauh tidak menyala 1 Bohlam dan socket bohlam TIDAK ADA H
24. Tester lead Yellow 1 terminal Tester lead Black 2 terminal e Measure the lighting coil resistance OUT OF SPECIFICATION li Lighting coil resistance 1 0 24 0 36 Q at 20 C Replace stator assembly MEETS SPECIFICATION 2 Lights switch INCORRECT e Check the lights switch for continuity Refer to the CHECKING THE SWITCHES section Lights switch is faulty replace handlebar CORRECT switch right LIGHTING SYSTEM ELEC INCORRECT e Check the dimmer switch for continuity 1 Refer to the CHECKING THE SWITCHES section Dimmer switch is faulty replace handlebar switch left CORRECT 4 Pass switch INCORRECT e Check the pass switch for continuity 1 Refer to the CHECKING THE SWITCHES section Pass switch is faulty replace handlebar switch left CORRECT 3 Dimmer switch 5 Wiring connection POOR CONNECTION e Check the entire lighting system for con nections Refer to the WIRING DIAGRAM section CORRECT Check condition of each circuit for lighting system Refer to the LIGHTING SYSTEM CHECK section LIGHTING SYSTEM ELEC LIGHTING SYSTEM CHECK 1 Headlight and high beam indicator light do not come on 1 Bulb and bulb socket NO CONTINUITY e Check the bulb and bulb socket for continu ity Refer to the CHECKING OF BULBS sec nori Bulb and or bulb socket are faulty replace
25. d 2 nd ring end 11221202 CYLINDER AND PISTON ENG 5 Lubricate e Piston outer surface e Piston ring e Cylinder inner surface 6 Install e Cylinder D _ Install the cylinder with one hand while com pressing the piston rings with the other hand e Pass the timing chain and timing chain guide exhaust side through the timing chain cav ity 7 Install e Oil delivery pipe GENERATOR due CD Drive sprocket cover 2 Cover 3 O ring 4 Crankcase cover left 5 Gasket 6 Dowel pin Stator assembly GENERATOR ENG Pickup coil Generator rotor Starter clutch W Starter clutch gear 42 Bearing 3 Starter clutch idle gear 2 Starter clutch idle gear 1 4 60 Nm 6 0 kg ege ENG Yup CRANKCASE COVER LEFT REMOVAL NOTE Prior to remove the crankcase cover left remove the shift pedal and drain the engine oil g 1 Remove e Fuel tank Refer to the FUEL TANK section in CHAP TER 3 2 Remove e Left footrest bracket Refer to the LEFT FOOTREST BRACKET section 3 Remove Drive sprocket cover 1 e Cover 2 4 Remove e Starter idle gear 1 1 e Bearing 2 e Shaft 3 5 Remove e Neutral switch leads 1 e Crankcase cover left NOTE V V V V Working in a crisscross loosen the bolts 1 4 turn each Remove them after all are loos ened M6 x 40 mm bolts D M6 x 30 mm bolts 7 9 6 R
26. e cover exhaust side 2 3 Remove e Timing mark accessing screw with O ring 1 e Camshaft end cover with O ring 2 4 Measure e Valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 05 0 10 mm Exhaust valve 0 10 0 15 mm Measurement steps Rotate the crankshaft counterclockwise to align the slit on the rotor with the slit on the crankcase cover when the piston is Top Dead Center TDC VALVE CLEARANCE ADJUSTMENT INSP IDLING SPEED ADJUSTMENT ADJ Qi eMeasure the valve clearance by using a feeler gauge Out of specification Adjust clearance kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 5 Adjust e Valve clearance kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Loosen the locknut 1 Turn the adjuster in or out with the tappet adjusting tool until specified clearance is obtained Valve clearance is Turning in decreased Turni Valve clearance is urning out increased Tappet adjusting tool 2 90890 01311 e Hold the adjuster to prevent it from moving and tighten the locknut e Measure the vale clearance elf the clearance is incorrect repeat above steps until specified clearance is obtained 6 Install e O ring e cover intake side 18 Nm 1 8 m kg IDLING SPEED ADJUSTMENT 1 Start the engine and let it warm up for sev
27. e Union bolt 2 e Copper washers e Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove e Master cylinder holder e Brake master cylinder EAS00592 MASTER CYLINDER INSPECTION The following procedure applies to the both of the brake master cylinders 1 Check e Brake master cylinder 1 Damage scratches wear Replace e Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check e Brake master cylinder kit 1 Damage scratches wear Replace 21 FRONT BRAKE CHAS df 3 Check e Brake fluid reservoir 1 Cracks damage Replace e Reservoir diaphragm 2 Cracks damage Replace 4 Check e Brake hose 1 Cracks damage wear Replace EAS00598 MASTER CYLINDER INSTALLATION WARNING e Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid e Never use solvents on internal brake components Recommended brake fluid DOT or 4 1 Install e Brake master cylinder e Master cylinder holder e Brake lever compression spring NOTE e Install the master cylinder bracket with the UP mark facing up e Adjust the brake master cylinder to the proper angle as shown e First tighten the upper bolt then the lower bolt 22 FRONT BRAKE
28. gt Orange 1 terminal Tester lead Ignition coil base Secondary coil Q x 1k Tester lead Spark plug lead 3 Tester lead Ignition coil base e Measure the primary and secondary coil resistances Primary coil resistance 0 32 0 48 at 20 C Secondary coil resistance B 5 68 8 52 kQ at 20 C BOTH MEETS SPECIFICATIONS 5 Main switch e Check the main switch for continuity Refer to the CHECKING THE SWITCHES section Replace main switch INCORRECT 6 Engine stop switch e Check the engine stop switch for continuity 1 Refer to the CHECKING THE SWITCHES section Replace handlebar switch right CORRECT IGNITION SYSTEM ELEC 7 Source coil resistance e Disconnect the CDI magneto coupler from the wire harness e Connect the pocket tester Q x 100 to the source coll Tester lead Brown 1 terminal Tester lead Green C terminal OUT OF SPECIFICATION e Measure the source coil resistance Jill Source coil resistance MEETS SPECIFICATION 8 Pickup coil resistance e Disconnect the CDI magneto coupler from the wire harness e Connect the pocket tester Q x 100 to the pickup coil Tester lead Red 1 terminal Tester lead White terminal OUT OF SPECIFICATION 3 CDI magneto e Measure the pickup coil resistance Pickup coil resistance ri 248 372 0 at 20 C
29. the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS 4 NEUTRAL WHEN THE CLUTCH LEVER IS PULLED IN D Battery 2 Starter relay 3 Starter motor 4 Main switch 5 Starting circuit cut off relay relay assembly 6 Clutch switch Neutral switch Start switch 9 Engine stop switch ELECTRIC STARTING SYSTEM ELEC TROUBLESHOOTING Procedure Check 1 Fuse 6 Main switch 2 Battery 7 Engine stop switch 3 Starter motor 8 Neutral switch 4 Starter relay 9 Clutch switch 5 Starting circuit cut off relay relay assembly 10 Start switch 11 Wiring connection electric starting system NOTE e Remove the following parts before troubleshooting 1 Side cover right 2 Headlight unit 3 Seat 4 Fuel tank e Use the following special tool in this troubleshooting e Connect the pocket tester Q x 1 to the OREO e Check the fuse for continuity Replace fuse e Check the battery condition INCORRECT e Check the batiery fluid level battery termi nals and specific gravity e Refill battery fluid e Clean battery terminals e Recharge or replace battery ELECTRIC STARTING SYSTEM ELEC 3 Starter motor e Connect the battery positive terminal WARNING and starter motor cable 2 using the jumper e wire for the jumper lead must have the lead x equivalent capacity as that of the battery lead or
30. 0 10 0 15 mm 7 Install e Tappet cover e Camshaft sprocket cover Tappet cover 18 Nm 1 8 kg Camshaft sprocket cover 10 Nm 1 0 kg 8 Install e Spark plug e Carburetor joint Spark plug 18 Nm 1 8 m kg Carburetor joint 10 Nm 1 0 m kg CAMSHAFT AND ROCKER ARMS ENG CAMSHAFT AND ROCKER ARMS CD Locknut 2 Valve adjuster 3 Rocker arm 2 Rocker arm shaft exhaust 5 Rocker arm shaft intake 6 O ring 7 Bearing Camshaft 9 Plate gt 14 Nm 1 4 m kg 16 4 CAMSHAFT AND ROCKER ARMS ENG N SN 2 SF LL MT E aS X gt 0 ROCKER ARM AND CAMSHAFT REMOVAL NOTE Prior to remove the rocker arm and camshaft remove the cylinder head 1 Loosen e Locknut 1 e Valve adjuster 2 2 Remove e Stopper plate 3 3 Remove e Camshaft 1 e Bearing 2 NOTE Remove the camshaft and collar by using 10 mm bolt 3 4 Attach e Slide hammer set 1 0 Slide hammer bolt 90890 01085 Weight 90890 01084 5 Remove e Rocker arm shaft e Rocker arm intake exhaust CAMSHAFT AND ROCKER ARMS ENG 11151001 11151002 YP402052 CAMSHAFT INSPECTION 1 Inspect e Cam lobes Pitting Scratches Blue discoloration gt Replace 2 Measure e Cam lobes length and Out of specification Replace Cam lobes length Intake 8 36 52 36 62 mm Limi
31. 2 Install e Rocker arm 1 e Rocker arm shaft 2 NOTE Install the rocker arm shaft exhaust com pletely pushed in CAMSHAFT AND ROCKER ARMS ENG 3 Lubricate e Camshaft 1 Camshatt Molybdenum disulfide grease Camshaft bearing Engine oil 4 Install e Plate 1 e Bolts 2 Nm 0 8 kg 4 VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS dus 1 Valve cotter 2 Upper spring seat 3 Lower spring seat 4 Oil seal 5 Inner valve spring 6 Outer valve spring 7 Valve VALVES AND VALVE SPRINGS ENG 11171401 FS 4 VALVE AND VALVE SPRINGS REMOVAL NOTE V V e Prior to remove the valves remove the cylin der head rocker arm and camshaft e Before removing the internal parts Valve valve spring valve seat etc of the cylinder head the valve sealing should be checked 1 Check e Valve sealing Leakage at valve seat Inspect the valve face valve seat and valve seat width Refer to the VALVE SEATS INSPECTION section kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk Valve seat checking steps e Pour a clean solvent 1 into the intake and exhaust ports e Check the valve seating There should be no leakage at the valve seat 2 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk NS VALVES AND VALVE SPRINGS ENG S SS ZS S 1172101 23 4 2 Attach e Valve spring compressor 1 Valve sp
32. 2500 SHINGAI IWATA SHIZUOKA JAPAN DIAGRAM KELISTRIKAN SCORPIO RW Sb L Y 3 Tei 5 fe BH T BLACK BLACK LAY Pali ev ost WARNA KABEL Hitam Black W Coklat Brown CE Hijau Green B W TO Biru Blue B Y Br W xc ES Merah J ambu Pink Ch Merah Red Dg TES Putih White Kuning Yellow nm Hitam Putih Black White Tm Hitam Kuning Black Yellow U Coklat Putih Brown White Coklat tua Chocolate Hijau tua Dark green Hijau Kuning Green Yellow 1 Kunci kontak 2 Rectifier regulator 3 CDI magneto CDI unit 5 Ignition coil 6 Busi Spark plug 7 Tombol starter Engine stop switch 9 Klakson Horn Relay sinyal belok 1 Switch rem depan 2 Switch rem belakang 43 Saklar kemudi kiri Tombol klakson 45 Saklar lampu Saklar Pass 7 Saklar Dimmer Saklar sinyal belok Switch kopling Lampu belakang rem 0 sinyal belok belakang Lampu sinyal belok depan 03 Lampu depan Lampu senja posisi 05 Switch netral Sender bahan bakar 27 Meter Meter bahan bakar Lampu meter Lampu indika
33. CATION 12 V This circuit is good LIGHTING SYSTEM ELEC NO CONTINUITY 3 Taillight does not come on 1 Bulb and bulb socket e Check the bulb and bulb socket for continu ity Refer to the CHECKING THE SWITCHES section Bulb and or bulb socket are faulty replace 2 Voltage e Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Blue Q terminal Tester lead Black 2 terminal OUT OF SPECIFICATION e otart the engine e Turn the lights switch to ON or PO e Check for voltage 12 V on the Blue lead Wiring circuit from main switch to bulb socket at the bulb socket connector connector is faulty repair MEETS SPECIFI CATION 12 V This circuit is good SIGNALING SYSTEM ELEC SIGNALING SYSTEM CIRCUIT DIAGRAM meh SE P CS GO 3 d uu D hl ll ld i Dx mum d a lt EE E HES 9019 m v19 arra 7 34 CD Main switch 9 Horn Flasher relay 4 Front brake switch 2 Rear brake switch Horn switch Turn signal switch 09 Tail black light 2 Rear turn signal light 02 Front turn signal light 05 Neutral switch 69 Fuel sender Fuel gauge 2 Neutral indicator light 82 Turn indicator light 64 Batt
34. Check the bulb and bulb socket for continu ity Refer to the CHECKING OF BULBS sec tion Bulb and or bulb socket are faulty replace CONTINUITY 2 Brake switch e Check the brake switches for continuity AGONTEOT Refer to the CHECKING THE SWITCHES section CORRECT Brake switch is faulty replace it 3 Voltage e Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow 1 terminal Tester lead Black 2 terminal OUT OF SPECIFICATION e the main switch to ON e The brake level is pulled in or brake pedal is stopped down e Check for voltage 12 V on the Yellow Wiring circuit from main switch to bulb socket lead at the bulb socket connector connector is faulty repair MEETS SPECIFI CATION 12 V This circuit is good ity Refer to the CHECKING OF BULBS sec tion CONTINUITY 2 Turn signal switch e Check the turn signal switch for continuity Refer to the CHECKING THE SWITCHES section CORRECT 3 Voltage e Connect the pocket tester DC 20 V to the flasher relay Tester lead Brown 1 terminal Tester lead gt Frame ground e Turn the main switch to ON e Check for voltage 12 V on the Brown lead at the flasher relay terminal MEETS SPECIFI CATION 12 V SIGNALING SYsTEM ELEC 3 Flasher light and or turn indicator light do not blin
35. Dimmer switch Turn signal switch Clutch switch 29 Tail brake light 2 Rear flasher light 62 Front flasher light 3 Headlight 4 Auxiliary light Neutral switch 69 Fuel sender 07 Meter Fuel gauge 09 Meter light High beam indicatior light 8 Neutral indicator light 82 Turn indicator light 83 Starter motor 64 Battery amg G5 Fuse Starter relay 67 Starting circuit cut off relay RIS Pi ell TI EI 1 GREEN GREEN 6 hoe a Ma aa d tcr 4 Br W Brown White RW Red White Sky blue Chocolate YIR Yellow Red Dark green ETA Greer Green Yellow Black White L W Blue White Black Yellow Blue Yellow YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YAMAHA Scorpio new SUPPLEMENTARY SERVICE MANUAL 5BP F8197 B1 PENDAHULUAN Buku Service Manual tambahan ini dibuat untuk melengkapi Service Manual Scorpio yang sudah ada Untuk mendapatkan petunjuk cara cara perbaikan Sepeda Motor Scorpio dengan sempurna sebaiknya buku ini dipadu dengan Buku Service Manual dibawah ini SERVICE MANUAL SCORPIO 5BP F8197 BO 500000 SERVICE MANUAL TAMBAHAN SCORPIO 2006 oleh Yamaha Motor Co Ltd Cetakan pertama Maret 2006 dilarang memperbanyak tanpa seijin PT
36. Steering head 5 Remove e Handlebar e Pinch bolt e Steering stem nut e Handle crown 6 Adjust e Steering head kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps e Remove the lock washer 1 the upper ring nut and the rubber washer 3 Loosen the lower ring nut 2 and then tighten it to specification with a ring nut wrench NOTE W Set the torque wrench at a right angle to the ring nut wrench Steering nut wrench 90890 01403 Lower ring nut initial tightening torque 48 Nm 4 8 kg Loosen the lower ring nut completely then tighten it to specification WARNING Do not overtighten the lower ring nut Lower ring nut final tightening torque 18 Nm 1 8 kg STEERING HEAD INSPECTION INSP REAR SHOCK ABSORBER INSPECTION ADJ a E r i o eCheck 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 inspect the upper and lower bearings Refer to the STEERING HEAD AND HAN DLEBAR in section CHAPTER 6 e Install the rubber washer 3 e Install the upper ring nut 2 eFinger 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 e Install the lock washer 1 NOTE Make
37. Windings are broken TROUBLESHOOTING SHTG lt COMPRESSION SYSTEM INSUFFICIENT TIGHTNING TORQUE INSUFFICIENT TIGHTNING TORQUE WEAR SCRATCH gue SS b Lt 9 27 Ve quu NS 4 oo NOS d ech CEN 77 WEAR CARBON DEPOSITS Lu x CC mM 2 lt Lu gt WEAR SCRATCH DAMEGE SCH TROUBLESHOOTING GHTG lt AIR CLEANER ELEMENT FUEL TANK CAP e Dirty or clogged e Clogged AN ES INTAKE AND EXHAUST SYSTEM xh 2 AN SENI SILENCER EKHAUST PIPE Clogged Cracked or broken ae Carbon deposits PILOT SCREW Improperty adjusted idling and starting STARTER Improperty adjusted starting THROTTLE STOP SCREW Improperty adjusted idling and starting PILOT JET Be JET NEEDLE Clogged low speed Improperty adjusted Lys medium speed MAIN JET 2 Incorrect size Clogged high speed FLOAT Incorrect fuel level adjustment FLOAT CHAMBER e Puncture Accumulated dust and or water 5 4 WIRING DIAGRAM CD Main switch LOCK 2 Rectifier regulator pore TIO T CDI magnet ON uni 5 Ignition coil 6 Spark plug Start switch Engine stop switch 9 Horn Flasher relay 17 Front brake switch 2 Rear brake switch 3 Handlebar switch left Horn switch 5 Lights switch Pass switch 7
38. anda BERHATI HATI MENYANGKUT KESELAMATAN ANDA ng Memberikan petunjuk khusus yang harus diikuti untuk menghindari kecelakaan bagi pengendara dan orang lain yang sedang memperbaiki sepeda motor Perlu perhatian khusus yang harus diikuti untuk menghindari kerusakan pada sepeda motor CATATAN Memberikan keterangan tambahan untuk mempermudah pengerjaan TEKNIK MEMBACA CEPAT BUKU PETUNJUK SUSUNAN BUKU PETUNJUK Buku ini terdiri dari beberapa BAB utama yang didalamnya terdapat beberapa judul lihat simbol Judul pertama 1 BAB yang disertai simbol terletak disudut kanan atas pada setiap halaman Judul kedua 0 Judul ini adalah judul bagian BAB yang terletak hanya pada halaman pertama dari tiap tiap bagian judul ini terletak disudut kiri atas halaman Judul ketiga 3 Judul ini adalah judul yang lebih spesifik FORMAT BUKU Semua prosedur dalam buku ini dikemas dalam rangkaian tahap demi tahap sehingga petunjuk petunjuk yang ada secara lengkap dapat diterima dengan mudah oleh para mekanik Petunjuk yang ada meliputi berbagai hal antara lain tentang cara membongkar memperbaiki dan pemeriksaan jika ada prosedur yang penting dan perlu perhatian khusus kami beri garis dengan tiap tiap prosedur kami beri tanda 9 INFORMASI PENTING e Data spesifikasi dan special tool diinformasikan dalam frame dengan gambar alat 5 e Angka didalam lingkaran 6 menunjukkan nama komponen dan penjelasan yang meleng
39. batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc e DO NOT SMOKE when charging or han dling batteries e KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 1 Remove e Side cover right Refer to the SIDE COVER section e battery band 1 2 Disconnect e battery leads from the battery terminals First disconnect the negative lead 2 then the positive lead 3 3 Remove e battery UPPER LEVEL LOWER LEVEL INSP BATTERY INSPECTION 4 Inspect e Electrolyte level Electrolyte level should be between the upper D and lower level marks Electro lyte level is too low Add electrolyte to proper level Refill with distilled water only Tap water contains minerals which are harmful to a battery 5 Inspect e Breather hose Obstruction Remove Damage Replace When inspecting the battery make sure that the breather hose is routed correctly If the breather hose is positioned in such a way as to allow battery electrolyte or gas to come into contact with the frame this could damage the motorcycle and ruin its finish 6 Check e Specific gravity Less than 1 280 Recharge the battery Charging Current 0 7 amps 10 hr Specific Gravity 1 280 at 20 C kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replace the battery if Battery voltage will not rise to
40. contoh tindakan lebih lanjut jika diluar spesifikasi dengan simbol panah gt 9 DIAGRAM Semua BAB dilengkapi dengan gambaran sebelum dibongkar hal ini untuk mempermudah prosedur yang benar cara memasang dan membongkar 2 INSPECTION AND REPAIR FENG Mp FRONT FORK lemas Ko een INSPECTION 6 1 Inspect inner fork tube 1 Crankcase separating tool Outer fork tube 2 YU 01135 Scratches Bends Damage Replace 3 Do not attempt to straighten a bent inner for ube as this may dangerously weaken la 9 INSPECTION AND REPAIR CYLINDER HEAD 1 Eliminate tSt Carbon deposit Use a rounded scraper NOTE e Take care to avoide damaging the spark plug threads Do not use arp instrum 3 Avoid scratching the aluminum 2 Measure Fork spring free length 5 Cylinder head warpage Out of specification 4 Replace Qut of specification Resurface Fork spring free length 418 5 16 5 in Minimum free length 410 mm 16 1 in Warpage measurement and urface ment step 4 install 9 Attach a straight edge D and a thickne oL Drive chain 4 ss gauge 2 on the cylinder head mE RE Joint drive chain Measure the warpage Chip drive chain 8 If the warpage is out of specification AES surface the cylinder head 3 em Place a 40
41. e Disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Loosen e Retaining bolts 2 Remove e Brake caliper bolts e Brake caliper 3 Remove e Retaining bolts 1 e Brake pads 2 NOTE e Install new brake pad springs when the brake pads have to be replaced e Replace the brake pads as a set if either is found to be worn to the wear limit 4 Measure e Brake pad wear limit Out of specification Replace the brake pads as a set Brake pad wear limit 0 8 mm FRONT BRAKE CHAS df 5 Install e Brake pads e Brake pads springs kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk Installation steps eConnect a suitable hose Q tightly to the brake caliper bleed screw Put the other end of this hose into an open container Loosen the brake caliper bleed screw and using a finger push the caliper pistons into the brake caliper Tighten the brake caliper bleed screw N Brake caliper bleed screw 25 6 Nm 0 6 kg einstall new brake pad springs and a new brake pads e Install the brake caliper 3 and retaining bolts 4 brake caliper bolts Retaining bolt 27 Nm 2 7m kg Brake caliper bolt 30 Nm 3 0 m kg KAKAK K
42. e Main axle runout with a centering device and dial gauge Out of specification Replace the main axle Main axle runout limit 0 08 mm 2 Measure e Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle Drive axle runout limit 0 08 mm 11650402 11650401 TRANSMISSION ENG 3 Check e Transmission gears Blue discoloration pitting wear Replace the defective gear s 4 e Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check e Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies NOTE M When reassembling the main axle press the and pinion gear 1 onto it as shown 5 Check e Transmission gear movement Rough movement Replace the defective part s 6 Check e Circlips Damage bends looseness Replace TRANSMISSION ENG TRANSMISSION INSTALLATION 1 Install e Transmission gears assembly 1 e Shift drum assembly 2 255 e Shift fork L 3 Xon e Shift fork 4 0 e d NAN e D WA e Shift fork Into the crankcase right AA e Guide bar O NOTE Facing the mark on shift fork down ward 2 Check e Shifter operation Unsmooth operation Repair NOTE e Oil each gear and bear
43. e Timing chain guide intake side e Timing chain drive sprocket 3 e Push lever clutch 2 Remove e Neutral switch 1 e Crankcase bolts NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them M6 x 70 mm bolts 5 4 M6 x 60 mm bolts 5 6 M6 x 55 mm bolts 7 9 M6 x 45 mm bolts 49 43 3 Remove e Circlip 1 e Crankcase right NOTE Align the shift drum 2 projections with the slots on the right crankcase before removing right crankcase ammer to tap on the case half tap only on reinforced portions of case The slot for separating the crankcase is provided Using the screwdriver separate the case with even force applied to both side Do not damage the crankcase mating surface CRANKCASE AND CRANKSHAFT 11631001 299 4 Remove e Crankshaft Use a crankcase separating tool 5 Crankcase separating tool 90890 01135 T KKKKKK CRANKSHAFT INSPECTION 1 Measure e Crankshaft runout 1 Out of specification Replace crankshaft and or bearing NOTE LLL Measure the crankshaft runout with the crank shaft assembly turning slowly Runout limit 0 03 mm 2 Measure e Big end side clearance 2 Out of specification Replace big end bear ing crank pin and or connecting rod Big end side clearance 0 35 0 85 mm 3 Measure e Crank wi
44. eral minutes 2 Attach e Engine tachometer to the spark plug lead Engine tachometer 90890 03113 IDLING SPEED ADJUSTMENT INSP THROTTLE CABLE ADJUSTMENT ADJ amp 3 Check e Engine idling speed Out of specification Adjust Engine idling speed 1 350 1 450 r min 4 Adjust e Engine idle speed kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Turn the pilot screw until it is lightly seated Turn the pilot screw out by the specified number of turns Pilot screw 3 turns out e Turn the throttle stop screw 2 in or out until the specified idling speed is obtained Idling speed is increased Idling speed is decreased 5 Adjust e Throttle cable free play Refer to the THROTTLE CABLE ADJUST MENT section THROTTLE CABLE ADJUSTMENT NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted 1 Check e Throttle cable free play 8 Out of specification Adjust Free play throttle cable 3 5 mm at throttle grip flange INSP THROTTLE CABLE ADJUSTMENT 2 Adjust e Throttle cable free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Carburetor side Loosen the locknut e Turn the adjusting nut in or out until the specified throttle cable free play is obtained Throttle cable free play is urn in increased SC
45. klakson Kabel Tester gt kabel coklat 1 Tester Masa ground DILUAR SPESIFIKASI eP utar kunci kontak pada posisi ON Rangkaian kabel dari kunci kontakl ke ter ePeriksa voltase 12 V kabel Coklat minal horn rusak perbaiki pada terminal klakson SESUAI SPESIFIKASI 12V SISTIM SINYAL ELEC 3 Klakson Horn eLepaskan kabel warna Pink dari terminal klakson horn ePasang kabel penghubung terminal dan hubungkan ke masa ground ePutar kunci kontak pada posisi ON KLAKSON BERBUNYI Klakson dalam kondisi baik KLAKSON TIDAK BERBUNYI 4 Voltase ePasangkan pocket tester DC 20 V pada terminal klakson Kabel Tester kabel Pink 1 Kabel Tester C Masa ground DILUAR SPESIFIKASI d eP utar kunci kontak pada posisi ON Klakson dalam kondisi rusak ganti perbaiki ePeriksa voltase 12 V pada terminal kabel Pink merah jambu SESUAI SPESIFIKASI 12V Setel atau Ganti Horn 26 SISTIM SINYAL ELEC 1 Bohlam dan socket bohlam TIDAK TERHUBUNG PUTUS 2 lampu rem tidak menyala ePeriksa kondisi Bohlam dan Socket bohlam lihat bagian PEMERIKSAAN BOHLAM Bohlam dan Socket putus ganti il ADA HUBUNGAN 2 Saklar Switch rem TIDAK BAGUS ePeriksa kondisi switch rem lihat bagian PEMERIKSAAN SAKLAR Switch rem rusak ganti 3 Voltase ePasangkan pocket tester DC 20 V pada socket boh
46. level Refer to the BRAKE FLUID LEVEL INSPECTION section in CHAPTER 3 6 Check e Brake lever operation Soft of spongy feeling Bleed the brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 FRONT FORK CHAS df FRONT FORK CD Cap bolt 7 Damper rod 2 O ring Oil lock piece 3 Spacer 9 Inner tube 4 Spring seat Dust seal 5 Fork spring Oil seal clip 6 Rebound spring 42 Oil seal 3 Outer tube 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT FORK CHAS df 500649 FRONT FORK REMOVAL The following procedure applies to both of the front fork legs 1 Stand the motorcycle on a level surface WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Remove e Front wheel Refer to the FRONT WHEEL AND BRAKE DISC section 3 Remove e Bolts front fender e Collars 2 e Front fender 3 4 Loosen e Cap bolt 1 e Handle crown pinch bolt 2 e Lower bracket pinch bolt 3 WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 5 Remove e Front fork leg FRONT FORK DISASSEMBLY The following procedure applies to both of the front fork legs 1 Remove e Cap bolt e O ring e Spacer e opring seat e Fork spring FRONT FORK CHAS df 2 Drain e Fork oil 3 Remove e Dust seal 1 e Oil seal clip with a flat head screwdriver 4 R
47. limit 0 8 mm Tire pressure cold tire Basic weight With oil and full fuel tank 131 kg Maximum load 180 kg Cold tire pressure FRONT REAR Rider 2 00 kg cm 2 00 kg cm With passenger 2 00 kg cm 2 25 kg cm Load is the total weight of cargo rider pas senger and accessories Brake Front Single disc brake Operation Right hand operation Rear Drum brake Operation Right foot operation Suspension Front Suspension Telescopic fork Rear suspension Swing arm GENERAL SPECIFICATIONS SPEC ge Model SX 4 Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system CDI Generator system A C magneto generator Battery type or model GM7B 4B Battery capacity 12 V 7 AH Bulb wattage x quantity Headlight 12 V 35 W 36 5 W x 1 Auxiliary light 12 V 3 4 W x 1 Tail brake light 12V 5 W 21 Wx 1 Flasher light 12V 10W x4 Meter light 12V 1 7W x2 Indicator light NEUTRAL 12 3 4 W x 1 HIGH BEAM 12 3 4 W x 1 TURN 12V 3 4AW x2 MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model SX 4 Cylinder head Warp limit 3 0 03 mm Lines indicate straight edge measurement Cylinder Bore size measuring point X 70 000 70 018 mm 40 mm Wear limit 0 01 mm Camshaft Drive method Chain drive right Camshaft outside dia 24 96 24 98 mm C
48. lubang pembua ngan Pada saat deceleration kondisi handel gas tiba tiba tertutup terjadi hisapan negative presure IC sehingga Air Cut Off Valve tertutup untuk mencegah tekanan balik atau after burning Untuk itu jika kecepatan tinggi dan tekanan ber kurang Air Cut Off Valve otomatis tertutup untuk menghindari tekanan balik dan hilangnya tenaga Dari saringan udara air filter ke cylinder head ke manifold pemasukan 10 AIR INDUCTION SYSTEM CARB ge 1 Pipa Air induction system 2 Gasket 3 Selang Air induction system unit air cut off valve ke cylinder head 4 Selang vacuum Air induction system 5 Unit Air cut off valve 6 Selang Air induction system unti air cut off valve ke rumah saringan udara 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 11 KEMUDI DAN TANGKAI KEMUDI CHAS RANGKA CHASSIS KEMUDI DAN TANGKAI KEMUDI TANGKAI KEMUDI 1 Holder tangkai kemudi 6 Mur ring bawah 2 Baut cap 7 Penutup ball race 3 Washer pengunci Bearing 4 Mur ring atas 9 Bearing 5 Washer karet Bearing race 1 Bracket bawah 110 Nm 11 0 m kg 81 1 ft Ib 19 Nm 1 9 m kg 14 ft lb 23 Nm 2 3 m kg 17 ft lb tst 48 Nm 4 8 m kg 35 4 ft lb 2nd 18Nm 1 8 m kg 13 3 ft lb 7 Nm 0 7 m kg 5 2 ft lb SHOCK ABSORBER BELAKANG DAN LENGAN AYUN CHAS SHOCK ABSORBER BELAKANG DAN LENGAN AYUN 500710 MEMERIKSA RANTAI PENGGERAK 1 Ukur
49. m kg REAR WHEEL AND REAR BRAKE CHAS d REAR WHEEL REMOVAL 1 Remove e Adjuster 1 e Brake rod 0 gt e Tension bar 3 UN NOTE Depress the brake pedal to remove the brake ON iN EN rod S X 2 Loosen e Rear wheel axle nut 1 e Locknuts e Drive chain adjuster nuts 3 Hemove e Rear wheel axle nut 1 e Hear wheel axle 2 e Washers e Spacer 3 e Rear wheel 4 4 Remove e Brake shoe plate T kkkkkk REAR WHEEL DISASSEMBLY 1 Remove e Bearings 1 e Spacer Refer to the FRONT WHEEL AND BRAKE DISC section 12010202 T701020 REAR WHEEL INSPECTION 1 Inspect e Rear wheel axle e Hear wheel e Rear wheel bearings e Oil seals Refer to the FRONT WHEEL AND BRAKE DISC section 2 Check e Spokes Refer to the FRONT WHEEL AND BRAKE DISC section 3 Measure e Rear wheel runout Refer to the FRONT WHEEL AND BRAKE DISC section REAR WHEEL AND REAR BRAKE 5 4 12040202 12270604 4 Inspect e Rear wheel clutch hub damper Wear damage Replace REAR BRAKE INSPECTION 1 Inspect e Brake shoes Glazed parts Sand with coarse sandpa per NOTE After using the sandpaper clean of the pol ished particles with a cloth 2 Measure e Brake shoe thickness Out of specification Replace Brake shoe thickness limit 1 0 mm D Measure point 3 Inspect e Brake shoe spring Wear damage Replace
50. resistance 5 68 8 52 kQ at 20 C Spark plug cap resistance 10 kQ CDI magneto Model manufacturer Nominal output Lighting coil resistance Charging coil resistance Rectifier regulator F5BP YAMAHA 14 V 100 W at 5 000 r min 0 24 0 36 O at 20 C Yellow Red Black 0 32 0 48 Q at 20 C White Black Model manufacturer SH656 12 SHINDENGEN No load regulated voltage DC 14 1 14 9V Capacity 8A Battery Capacity 12 V 7AH Specific gravity 1 280 Electric starter system Type Constant mesh type Starter motor Model manufacturer 5BP YAMAHA Output 0 4 kW Brush Overall length 10 mm lt Limit gt lt 3 5 mm Spring pressure 560 840g Commutator Outside diameter 22mm lt Wear limit gt 21 mm Mica undercut 1 5 mm MAINTENANCE SPECIFICATIONS SPEC v Item 5 4 Horn Type quantity Plain type x 2 Model manufacturer 5BP IMASEN Maximum amperage 1 5A Flasher relay Type Condenser type Model manufacturer 3RS DENSO Self cancelling device No Flasher frequency 75 95 cycle min Wattage 10Wx2 43 4W Starting circuit cut off relay Model manufacturer ACA12115 3 MATSUSHITA Diode Yes Circuit breaker Type Amperage for individual circuit x quantity Main Reserve GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ISPEC GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten General torque ers with standard 1 5 pitch threads SR Beil Torque specifications for special component
51. rotor 1 and the outer rotor 2 e Side clearance between the outer rotor and the pump housing 3 Out of specification Replace the oil pump assembly e Housing and rotor clearance between the pump housing 3 and the rotors 1 Out of specification Replace the oil pump assembly Tip clearance 0 15 mm Limit 0 20 mm Side clearance 0 04 0 09 mm Limit 0 15 mm Housing and rotor clearance C 0 03 0 09 mm Limit 0 15 mm 2 A ENG o OIL PUMP 2 Inspect e Oil stainer Cracks damage Replace Contamination Clean the flushing oil PSN 255255 RON 5950552 11720101 OIL PUMP INSTALLATION 1 Install e Gasket 1 e Oil pump assembly 2 e Oil pump gear 3 e Circlip 4 e Oil strainer Bolt oil pump 6 Nm 0 6 m kg CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT Crankcase left 2 Crankcase right 3 Dowel pin 4 Crank shaft assembly 6 Bearing 6 Timing chain drive sprocket Timing chain Timing chain guide intake side 9 Drain bolt Gasket d gt 10 Nm 1 0 m kg lt lt END 7 2 4 YAA CRANKCASE AND CRANKSHAFT ENG CRANKCASE SEPARATING NOTE Prior to separate the crankcase remove the engine and remove the cylinder head cylinder generator clutch kick axle shift shaft and oll pump 1 Remove e Timing chain 1
52. sure that the lock washer tabs 3 sit cor rectly in the ring nut slots kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 7 nstall e Handle crown e Steering stem nut x 110 Nm 11 0 e Pinch bolt REAR SHOCK ABSORBER INSPECTION 1 Remove e Seat e Side cover right Refer to the SIDE COVER section e Fuel tank Hefer to the FUEL TANK section 2 Check e Hear shock absorber mount Looseness Tighten Bolt upper Nut lower x 59 Nm 5 9 kg Refer to the REAR SHOCK ABSORBER AND SWINGARM section in CHAPTER 6 TIGHTENING CABLE INSPECTION ADJ WHEEL INSPECTION 1 Inspect e Wheels Damage Bends Replace NOTE V Always balance the wheel when a tire or wheel has been changed or replaced WHEEL INSPECTION SPOKE INSPECTION AND INSP WARNING e Never attempt even small repairs to the wheel e Ride conservatively after installing a tire to allow it to seat itself properly on the rim SPOKE INSPECTION AND TIGHTENING 1 Inspect e Spokes 1 Bend Damage Replace Loose spoke gt Retighten 2 Tighten e Spokes BN Nipple 12010801 24 0 6 kg CABLE INSPECTION WARNING Damage cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace such cable as soon as possible 1 Inspect e Cable sheath e Cables throttle clutch and starter Damage Replace 2 IN
53. warm up for sev eral minutes 2 Turn off the engine 3 Remove e Spark plug 4 Attach e Compression gauge 1 K5 Compression gauge 90890 03081 9 She Z WE EAT e Tak COMPRESSION PRESSURE MEASUREMENT INSP de ENGINE OIL LEVEL INSPECTION ADJ Qi 5 Measure e Compression pressure If it exceeds the maximum pressure allowed Inspect the cylinder head valve surfaces and piston crown for carbon deposits If it is below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again Follow the table below Compression pressure With oil applied into cylinder Reading Diagnosis Higher than without oil Worn or damaged pistons Possible defective ring s valves cylinder head gas ket or piston Repair Same as Without oil Compression pressure at sea level Standard 1 200 kPa 12 0 Kg cm 12 0 bar Minimum 1 050 kPa 10 5 Kg cm 10 5 bar kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps Crank the engine with the throttle wide open until the reading on the compression gauge stabilizes WARNING Before cranking the engine ground all spark plug leads to prevent sparking kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ENGINE OIL LEVEL INSPECTION 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand 2 Start the engine warm it up for
54. washer e Nut clutch boss NOTE Install the primary drive gear and clutch boss nut while holding the clutch boss with a clutch holding tool 3 Universal clutch holder 90890 04086 3 Bend e Lock washer tab 1 primary drive gear and clutch boss along a flat side of the end ENG 4 Install e Friction plate 1 3 pcs e Clutch plate 3 pcs e Cushion spring 3 e Friction plate 2 e Clutch plate 5 2 pcs e Friction plate 1 2 pcs e Push rod 2 e Ball e Push rod 1 9 e Push plate N OT E Install the clutch plates and friction plates alter nately on the clutch boss starting with a fric tion plate and ending with a friction plate 5 Install e Pressure plate 1 e Compression springs e Bolts compression springs 6 Nm 0 6 kg NOTE Tighten the bolts in a crisscross pattern 6 Adjust 557 e Clutch mechanism free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 2 0 nga Clutch mechanism free play adjustment steps e Loosen the locknut 1 e Push the push lever toward the front of the engine with your finger to align the push lever tab with the alignment mark on the crankcase e With the push lever in this position turn the screw 2 either in or out until the push lever mark 3 and crankcase match mark are aligned e Tighten the locknut Locknut E KAKAK KK e e oce e AK KK e e KK
55. with lithium soap based grease every 24 000 km d Drive chain Check bearing play and steering for roughness g play g for roug NEM Lubricate with lithium soap based grease every 12 000 km Make sure that all nuts bolts and screws Chassis fasteners properly tightened Sidestand center Check operation Lubricate Check operation and for oil leakage operation and for oil Check operation and for oil leakage ST NN absorber e operation and shock absorber for oil at assembly Rear suspension Check operation Check operation relay arm and con necting arm pivoting Lubricate with lithium soap base grease every 24 000 km points e Check chain slack Every 500 km and after washing the motorcycle or riding in the rain e Make sure that the rear wheel is properly aligned e Clean and lubricate INSP 4o PERIODIC MAINTENANCE LUBRICATION ADJ ODOMETER READING x 1 000 Check starter choke operation Carburetor Adjust engine idling m ment 23 Engine oil strainer Clean Front and rear brake Check operation switches cables Lights signals and Check operation switches Adjust headlight beam Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE e he air filter needs more frequent service if
56. 0 600 grit wet sandpaper S 5 M Make sure that the clip 1 is installed in zh the surface plate and resurface the head correct direction Otherw chain wili be sep d using figure eight sanding pattern NOTE Rotate the head several times to avoid ra moving too much material from one side Chain tube Yamaha chain lube or equivalent SIMBOL Simbol disamping ini tidak selalu berhubungan dengan setiap sepeda motor Simbol 1 hingga 8 menggambarkan isi setiap BAB 1 Informasi umum 2 Spesifikasi 3 Perawatan berkala dan penyetelan 4 Mesin 5 Karburator 6 Rangka Chassis 7 Sistim kelistrikan Mengatasi masalah Troubleshooting Simbol hingga 46 menjelaskan sebagai berikut 9 Perbaikan dengan mesin terpasang Menambah cairan 1 Pelumasan 2 Alat spesial special tool 3 Torsi pengencangan Batas keausan kelonggaran 45 Putaran mesin Data kelistrikan Simbol 7hingga pada gambar diagram menun jukkan tipe pelumas dan bagian yang perlu dilu masi 7 Oli mesin Oli gear Oli Molybdenum disulfide Gemuk bearing roda wheel bearing grease Gemuk Lithium soap based Gemuk Molybdenum disulfide Simbol Q3hingga pada gambar diagram menun jukkan perintah sebagai berikut 03 Berikan cairan pengunci LOCTITE Ganti dengan spare part baru DAFTAR ISI SPESIFIKASI SPESIFIKASI UMUM anakan aa a aa aa a a 1 SPES
57. 4 Bearing Collar 6 Dust cover 2 Connecting arm 6 Bush 3 Bush Drive chain guide Oil seal 5 Collar 59 Nm 5 9 m kg REAR SHOCK ABSORBER AND SWINGARM 5 LIH i CS Y SS 6 42 EAS00703 REAR SHOCK ABSORBER AND SWINGARM REMOVAL 1 Stand the motorcycle on a level surface WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Remove e Air filter case Refer to the CARBURETOR section in CHAPTER 5 3 Hemove e Bolt rear shock absorber 1 NOTE LLL When removing the rear shock absorber lower bolt hold the swingarm so that it does not drop down 4 Remove e Bolt rear shock absorber 1 e Hear shock absorber 5 Check e Swingarm side play e Swingarm vertical movement kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk a Check the tightening torque of the pivot shaft nut DN Pivot shaft nut 24 59 Nm 5 9 m kg b Check the swingarm side play A by moving the swingarm from side to side c lf the swingarm side play is large check the Spacers bearings washers and dust cov ers d Check the swingarm vertical movement by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust covers kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk REAR SHOCK ABSORBER AND SWINGARM CHAS df 12010701 43 500
58. 696 REAR SHOCK ABSORBER INSPECTION 1 Inspect e Rear shock absorber rod Bends damage Replace the rear shock absorber assembly e Hear shock absorber Gas leaks oil leaks replace the rear shock absorber assembly e opring Damage wear Replace the rear shock absorber assembly e Bushings Damage wear Replace e Dust seals Damage wear Replace e Bolts Bends damage wear Replace EAS00707 SWINGARM INSPECTION 1 Inspect e Swingarm Bends cracks damage Replace 2 Inspect e Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING Do not attempt to straighten a bent pivot shaft 3 Wash e Pivot shaft e Dust covers e Collars e Washers e Bearings e Bushes Recommended cleaning solvent REAR SHOCK ABSORBER AND SWINGARM 5 45 12510204 12510203 44 4 Inspect e Dust covers 1 e Bush 2 Damage wear Replace e Bearings Damage pitting Replace EC574210 RELAY ARM INSPECTION 1 Inspect e Bushs 1 e Collar 2 Free play exists unsmooth revolution rust Replace bush and collar as a set 2 1 e Oil seals 3 Damage Replace EC574310 CONNECTING ARM INSPECTION 1 Inspect e Bushs 1 e Collars 2 Free play exists unsmooth revolution rust gt Replace bush and collar as a set 2 Inspect e Oil seals 3 Damage Replace 1701020 DRIVE CHAIN INSPECTION 1 Inspect e Dri
59. AINSPEGJTIOD pter tip stmt bd aute cr 6 44 CONNECTING ARM INSPECTION 6 44 DRIVE GHAIN INSPEGOTION EE 6 44 REAR WHEEL CLUTCH HUB INSPECTION 6 46 DRIVEN SPROGKET ASSEMBLY E 6 46 REAR SHOCK ABSORBER AND SWINGARM INSTALLATION 6 46 FRONT WHEEL AND BRAKE DISC CHAS df CHASSIS FRONT WHEEL AND BRAKE DISC Front wheel axle 2 Collar 3 Oil seal 4 Bearing 5 Spacer 6 Meter clutch Speedometer gear unit Brake disc 23 Nm 2 3 m kg 58 Nm 5 8 kg FRONT WHEEL AND BRAKE DISC CHAS df FRONT WHEEL REMOVAL WARNING Securely support the motorcycle so there is no danger of it falling over 1 Place the motorcycle on level place 2 Remove e Speedometer cable 1 e Front wheel axle nut 2 ANA 5 Z Y Koo EX ls 4 EA y NIS EV 3 Remove e Front wheel axle 1 e Collar 2 e opeedometer gear unit 3 e Front wheel 4 T kkkkkk FRONT WHEEL DISASSEMBLY 1 Remove e Bearings 1 e Spacer 2 Remove the bearings using a general bear ing puller 3 2 lt x 12010202 2 FRONT WHEEL AND BRAKE DISC CHAS df 12010701 1700021 FRONT WHEEL INSPECTION 1 Inspect e Front wheel axle by rolling it on a flat surface Bends Replace WARNING Do not attempt to straighten a bent axle Wheel axle bending limit 0 25 mm 2 Inspect e Front tire Wear damage Replace Refer to the
60. I SPESIFIKASI 12V rangkaian dalam kondisi baik 19 SISTIM PENERANGAN ELEC 1 Bohlam dan socket bohlam TIDAK TERSAMBUNG ePeriksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAAN SAKLAR Bohlam dan socket bohlam rusak perbaiki 3 lampu belakang tidak menyala il ADA HUBUNGAN 2 Voltase ePasangkan pocket tester DC 20 V pada kabel socket bohlam Kabel Tester terminal biru 1 Kabel Tester terminal hitam 2 TIDAK SESUAI eHidupkan mesin 1 SS poset or id Rangkaian kabel dari kunci kontak ke ePeriksa voltase 12 V pada kabel biru socket bohlam rusak perbaiki yang terdapat pada socket SESUAI SPESIFIKASI 12V Rangkaian kabel dalam kodisi baik 20 SISTIM SINYAL ELEC 7 SISTIM SINYAL DIAGRAM KELISTRIKAN 2 O m g c GO 1 Kunci kontak 9 Klakson Horn Relay sinyal belok 1 Switch rem depan 2 Switch rem belakang Tombol klakson Saklar sinyal belok Lampu belakang rem 2 Lampu sinyal belok belakang 2 Lampu sinyal belok depan 5 Switch Netral Sender bahan bakar Meter bahan bakar 5 Lampu Indikator netral 9 Lampu indikator belok Battery 85 Sekring SIGNALING SYSTEM ELE 22 SISTIM SINYAL ELEC MENGATASI MASALAH TROUBLESHOOTING e LAMPU SINYAL BEL LAMPU REM ATAU INDIKATOR LAMPU TIDAK MENYALA e KLAKSON TIDAK BERFUNGSI e METER BAHAN BAKAR TIDAK BE
61. IFIKASI PERHAWATAN aa 2 ME SINI an a Ba AA 2 TORS PENGENCANGAN TIGHTENING TORQUE 2 RANGKA CHASSIS 3 JALUH KABEL Lis e 4 PERAWATAN BERKALA DAN PENYETELAN MESIN Seno aaa aaa a a EN 8 MEMERIKSA SISTIM PEMBUANGAN 8 MEMBONGKAR MESIN KEPALA CYLINDER CYLINDER HEAD 9 KARBURATOR AIR INDUCTION SYSTEM senen 10 AIR INJECTION E 10 AIR CUT OFF VALVE 10 RANGKA CHASSIS KEMUDI STEERING HEAD DAN TANGKAI KEMUDI 12 2 12 SHOCK ABSORBER BELAKANG DAN LENGAN AYUN 13 MEMERIKSA RANTAI 13 KELISTRIKAN ELECTRICAL SISTIM PENERANGAN sensasi aa sa uas 15 RANGKAIAN DIAGRAM on 15 MEMERIKSA SISTIM 18 SISTIM SINY AL sasasi aaa bapae nun Sa aana ga a ajaa a MENE aaa SA aga Da 21 RANGKAIANDIAGRAM 2 2020202 2 21 MEMERIKSA SISTIM SINYAL 25 DIAGRAM KELISTRIKAN SCORPIO SPESIFIKASI UMUM SPEC vs SPESIFIKASI SPESIFIKASI UMUM Berat Dengan Oli dan bensin penuh 136 kg 300 Ib Busi Spark plug Tipe Pabrik pembuat D8EA 9 NGK Keren
62. IN TENSIONER INSPECTION 4 13 CYLINDER HEAD 4 14 CAMSHAFT AND ROCKER ARMS 4 16 ROCKER ARM AND CAMSHAFT REMOVAL _ 4 17 CAMSHAFT INSPEG TION EE 4 18 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 4 18 CAMSHAFT AND ROCKER ARM INSTALLATION 4 19 VALVES AND VALVE SPRINGS 4 21 VALVE AND VALVE SPRINGS REMOVAL 4 22 VALVES AND VALVE SPRINGS INSPECTION 4 24 VALVE SEATS INSPECTION 3 cens 4 25 VALVES AND VALVE SPRINGS INSTALLATION 4 27 CYLINDER AND PISTON sek aan eege 4 29 PISTON REMOVAL bh apo 4 30 GENDER TNSIPBEGTIKO etnia cedes tiber a 4 31 PISTON AND PISTON PIN INSPECTION 4 32 PISTON RINGS INSPECTION iieri irri rte epa e Ree 4 33 PISTON RINGS PISTON AND CYLINDER INSTALLATION 4 34 GENERATOR oreesa 4 36 CRANKCASE COVER LEFT REMOVAL 4 37 GENERATOR ROTOR REMOVAL _ 4 38 STARTER CLUTCH INSPEG FON ber en hee Qu aa 4 39 GENERATOR INSTALLATION 4 39 CRANKCASE COVER LEFT INSTALLATION
63. K KK KK KK ke e e ke ck e KK ke e e ke e e e e ke 6 Inspect e Brake fluid level Refer to the BRAKE FLUID LEVEL INSPECTION section in CHAPTER 3 LOWER level line 7 Check e Brake lever operation Soft or spongy feeling Bleed the brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 16 FRONT BRAKE 5 5 500619 FRONT BRAKE CALIPER REMOVAL NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove e Union bolt 1 e Copper washers 2 e Brake hose NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully 2 Remove e Retaining bolts 1 e Brake caliper 2 3 Remove e Brake caliper pistons 1 e Brake caliper piston seals 2 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper WARNING e Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper e Never try to pry out the brake caliper pis tons b Remove the brake caliper piston seals kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk FRONT BRAKE 5 4 500633 FRONT BRAKE CALIPER INSPECTION Recommended brake component replacement schedule Replace when Brake fluid br
64. KERJA Prosedur Periksa 1 Sekring 2 Battery 3 Kunci kontak 4 Sambungan kabel pada sistim sinyal CATATAN eLepaskan komponen komponen dibawah ini sebelum bekerja 1 Penutup samping kanan 2 Lampu depan 3 Tempat duduk 4 Tangki bensin ePergunakan alat dibawah ini untuk perbaikan 9 Pocket tester 90890 03112 1 Sekring eLepaskan sekring TIDAK TERSAMBUNG ePasangkan pocket tester 1 pada sekring eperiksa kondisi sekring lihat bagian PEMERIKSAAN SEKRING sekring putus ganti sekring BAB 3 TIDAK SESUAI ePeriksa kondisi Battery lihat bagian PEMERIKSAAN BATTERY Isi air Battery botol biru eBersihkan terminal Battery eSetrom Battery atau ganti Battery 23 SISTIM SINYAL ELEC 3 kunci kontak TIDAK BAGUS ePeriksa kondisi penyambungan kunci kontak lihat bagian PEMERIKSAAN SAKLAR Kunci kontak rusak perbaiki atau ganti SAMBUNGAN TIDAK BAGUS ePeriksa sistim penyambungan kabel pada sistim sinyal lihat bagian DIAGRAM KELISTRIKAN Perbaiki Periksa kondisi kabel pada sistim sinyal lihat bagian PEMERIKSAAN SISTIM SINYAL 24 SISTIM SINYAL ELEC PEMERIKSAAN SISTIM SINYAL 1 Horn Klakson tidak berfungsi 1 Tombol klakson Horm TIDAK BAGUS ePeriksa sistim penyambungan tombol lihat bagian PEMERIKSAAN SAKLAR tombol klakson rusak perbaiki atau ganti saklar kemudi 2 Voltase ePasangkan pocket tester DC 20 V pada kabel
65. LISTRIKAN AU 7 0 TRBL TROUBLESHOOTING G CO BAB 1 INFORMASI UMUM IDENTIFIKASI SEPEDA MOTOR 1 1 NOMOR RANGKA sesame ang us 1 1 NOMOR MESIN see ta bantuan 1 1 INFORMASI PENTING oo mna 1 2 PROSEDUR PERSIAPAN MEMBONGKAR 1 2 PART PENGGANTI 7 1 2 GASKETS OIL SEALS DAN O RINGS 1 2 LOCK WASHERS PLATES DAN COTTER PINS 1 3 BEARING SEAL 1 3 Mio qo ARR EIER NT 1 3 MEMERIKSA SAMBUNGAN KABEL 1 4 SPEGIAL TOOLS 1 5 IDENTIFIKASI SEPEDA MOTOR GEN ders YP100000 INFORMASI UMUM IDENTIFIKASI SEPEDA MOTOR YP100020 NOMOR RANGKA CHASIS Nomor rangka 1 tercetak pada rangka di bagian down tube EB100030 NOMOR MESIN Nomor mesin 2 tercetak pada crankcase mesin sebelah kanan bentuk dan spesifikasi sewaktu waktu dapat berubah tanpa pemberitahuan 300 016 EB101000 INFORMASI PENTING PROSEDUR PERSIAPAN MEMBONGKAR 1 Bersihkan dari dan kotoran yang menempel pada sepeda motor Pergunakan peralatan yang tepat dan bersih Lihat bagian SPECIAL TOOLS Komponen yang telah dibongkar tempatkan dalam kondisi terangkai Misalnya rangkaian gears cylinders pistons dan komponen lain yang memerlukan pengepasan kompon
66. MENT a Dang a a a a aga 3 17 BRAKE PAD INSPEG TION sana aia aana a aia aaa 3 17 BRAKE FLUID LEVELAINSGPEGTION iii eie eee sana 3 18 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 3 18 BRAKE ROSE INSPECTION mk 3 19 REAR BRAKE ADJUSTMENT Lee mua bawa 3 20 BRAKE SHOE INSPECTION c 3 21 BRAKE LIGHT SWITCH ADJUSTMENT 3 21 DRIVE CHAIN SLACK ADJUSTMENT 3 22 TREINSPECTION ait atus atout heat feos Ee eto 3 23 STEERING HEAD INSPECTION 3 23 REAR SHOCK ABSORBER INSPECTION 3 25 aa ha 3 26 SPOKE INSPECTION AND TIGHTENING 3 26 CABLE INSPECTION E 3 26 LAB Mec 3 27 ADJ G BEEC TRIGA c ati naa B 3 28 BATTERY INSPECTION im 3 28 FUSE JINSREG TION Leone oa HOP 3 31 HEADLIGHT BEAM ADJUSTMENT _ 3 32 HEADLIGHT BULB REPLACEMENT eee 3 32 INTRODUCTION PERIODIC MAINTENANCE INSP 4 LUBRICATION ADJ amp PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust ments These preventive maintenance procedures if followe
67. N 1 Inspect e otopper lever Roller turns roughly Replace Bends damage Replace 2 Inspect e Stopper lever spring Wear damage Replace 11530602 3 Inspect e ohift shaft assembly e ohift shaft spring Bends wear damage Replace 4 4 KICK STARTER AND SHIFT SHAFT ENG KICK SHAFT ASSEMBLING 1 Install e Kick shaft e Kick segment gear 2 e Ratchet gear 3 NOTE lll Align the punch mark of kick shaft to the kick segment gear SHIFT SHAFT AND KICK STARTER INSTALLATION 1 Install e otopper lever assembly 1 Bolt stopper 10 Nm 1 0 m kg LOCTITE 2 Install e Shift shaft assembly 1 e Kick shaft assembly 2 NOTE Hook the kick spring onto the crankcase stop per 3 Install e Circlip e Washer e Kick pinion gear 3 e Washer 2 e Circlip 5 4 Bend e Lock washer OIL PUMP ENG OIL PUMP due D Oil pump assembly 2 Oil pump gear 9 Circlip 4 Gasket 5 Oil strainer E LA 5 5 5 g 1710404 293 OIL PUMP REMOVAL N OT E Prior to remove the oil pump remove the clutch assembly 4 1 Remove e Oil strainer e Circlip 2 e Oil pump gear 3 e Oil pump assembly 4 e Gasket 5 NOTE Do not remove the screw to avoid disassem bling oil pump 1402140 PUMP INSPECTION 1 Measure e Tip clearance between the inner
68. Replace pickup coil MEETS SPECIFICATION POOR CONNECTION 9 Wiring connection e Check the entire ignitions system for con nections Refer to the WIRING DIAGRAM section CORRECT CDI unit is faulty Replace it 7 12 2 4 T an18 Ge g Mov18 T NG E ELECTRIC STARTING SYSTEM ELEC LLI 42 gt 42 o amp E TEE gt e ceca Oe H gt Oo OS 2o SI lt 99 5 35 gt S ctog25t29ct O 5 z ouozimioo 0066969669 13 ELECTRIC STARTING SYSTEM ELEC STARTING CIRCUIT OPERATION The starting circuit on this model consist of the starter motor starter relay and the relay unit starting circuit cut off relay If the engine stop switch and the main switch are both closed the starter motor can operate only if The transmission is in neutral the neutral switch is closed or if The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter from operating when neither of these conditions has been met In this instance the Starting circuit cut off relay is open so current cannot reach the starter motor When one of both of the above conditions have been met however
69. S Apply the lithium soap base grease on the bolt 7 Install e Swingarm 1 e Pivot shaft 2 e Washer Nut NOTE e Apply the lithium soap base grease on the pivot shaft e Insert the pivot shaft from right side 8 Install e Bolt relay arm frame 1 e Washer 2 e Nut relay arm frame 3 x 59 Nm 5 9 kg NOTE HE Apply the lithium soap base grease on the bolt 9 Install e Bolt rear shock absorber frame 1 NOTE Apply the lithium soap base grease on the bolt 10 Install e Bolt rear shock absorber relay arm 1 e Washer 2 e Nut rear shock absorber relay arm 3 59 Nm 5 9 kg NOTE e Apply the lithium soap base grease on the bolt e Insert the bolt from left side CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS 01 eee anana 7 1 SWITCHES 7 3 CHECKING SWITCH CONTINUITY 7 3 CHECKING THE SWITCHES 7 4 CHECKING OF BULBS 22 12 2212 03 4 2 0220 6 1 0046 000001 7 6 KIND OF C 7 6 CHECKING BULB CONDITION moon 7 6 lire En WE 7 8 CIRCUIT DIAGRAM EE 7 8 7 9 ELECTRIC STARTING SYSTEM ooooooooooooooooooooooWoooooo 7 13 CIRCUIT DIAGRAM see 7 13 STARTING CIRCUIT OPERATION 7 14 TROUBLESHOOTING s eese me Alana ala 7 15 STARTER MOTOR
70. SP LUBRICATION AD LUBRICATION Cables 1 Check e Cable operation Unsmooth operation Lubricate Recommended lubricant Engine oil NOTE Hold cable end high and apply several drops of lubricant to cable 2 Apply the grease to the throttle cable end and cable guide groove at inside of throttle housing D Lithium soap base grease Level pedal 1 Lubricate the pivoting parts of the each lever and pedal Recommended lubricant Engine oil Sidestand centerstand 1 Lubricate the pivoting parts Recommended lubricant Engine oil Rear suspension 1 Lubricate the pivoting parts Recommended lubricant i Lithium soap base grease INSP BATTERY INSPECTION ELECTRICAL BATTERY INSPECTION WARNING Battery electrolyte is dangerous It con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures e Avoid bodily contact with electrolyte as it can cause severe burns and permanent eye injury e Wear protective eye gear when handling or working near batteries e Antidote EXTERNAL e SKIN Flush with water e EYES Flush with water for 15 minutes and get immediate medical attention e Antidote INTERNAL e Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention e Batteries generate explosive hydrogen gas e Always follow these preventive measures e Change
71. Susunan Cylinder Volume cylinder Diameter x Langkah Perbandingan kompresi Tekanan kompresi Sistim starter pendingin udara 4 tak bensin SOHC Tegak single cylinder 223 cm 70 x 58 mm 9 5 1 8 5 kg cm 370 r min Motor starter dan kick starter Sistem pelumasan Pelumasan basah Tipe oli atau grade Oli mesin 0 10 20 30 40 SAE10W 30 SAE20W 40 Kapasitas oli Oli mesin Penggantian berkala Dengan melepas filter oli Kapasitas total SAE 20W40 tipe SE motor oil YAMALUBE jika temperature dibawah 15 C SAE 10W30 tipe SE motor oil jika temperatur diatas 15 C 1 2 Liter 1 3 Liter 1 4 Liter Element tipe kering Bahan bakar Tipe Kapasitas tangki bensin Total Cadangan Reserve Bensin reguler 12 Liter 3 Liter Karburator Tipe pabrik pembuat BS30 MIKUNI SPESIFIKASI UMUM SPEC y Busi Tipe pabrik pembuat D8EA NGK atau X24ES U DENSO Gap 0 6 0 7 mm Basah multiple disc Transmisi Sistim reduksi Primary Spur gear Perbandingan reduksi primary 74 24 3 083 Sistim reduksi secondary penggerak Perbandingan reduksi secondary 44 15 2 933 Tipe Transmission Constant mesh 5 kecepatan Operation Left foot operation Gear ratio 36 14 2 571 32 19 1 684 28 22 1 273 26 25 1 040 23 27 0 852 Chassis Frame type Double cradle Caster angle 25 37 Trail 85 mm Tire Type With tube Size F 80 100 18 M C 47P Size R 100 90 18 M C 56P Wear
72. TRANSMISSION REMOVAL NOTE Prior to remove the transmission separate the crankcase 4 1 Remove ERES SEA 5 PAKAI OT aa e Dowel pin ter T ide bo psa e Shift fork O e Shift fork C e Shift fork L 3 e Shift drum assembly 4 NOTE Note the position of each part Pay particular attention to the location and direction of shift forks 2 Remove e Transmission gear assembly 1 Kult rt ee Et A 9 feo uet SHIFT FORK SHIFT CAM INSPECTION 1 Inspect e Shift fork cam follower 1 e Shift fork pawl 2 ocoring bends wear damage Replace 2 Inspect e Shift drum grooves 1 Wear damage scratches Replace e Shift drum segment 2 Damage wear Replace 11530101 11520401 11650702 11650701 TRANSMISSION ENG 3 Inspect e Shift fork 1 e Shift fork e Shift fork 3 e Shift fork guide bar e ohift drum assembly 5 e Pin 6 Roll the shift fork guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent shift fork guide bar 4 Check e Shift fork movement along the shift fork guide bar Unsmooth operation Replace the shift fork and the shift fork guide bar NOTE 3 When damaged the shift fork and mission gear replace the facing each gear as set EAS00424 TRANSMISSION INSPECTION 1 Measure
73. To determine the condition of a bulb check for continuity at the bulb terminal KINDS OF BULBS The bulbs used in motorcycles can be classi fied by shape of socket and use and are the main types used in head lights O is mainly used for the flasher light and tail 18410603 brake light D and are mainly used for meter lights and other indicator lights O D E AN CHECKING BULB CONDITION ys A 1 Remove the bulb V lt NOTE 2 e Bulbs of the and type uses a bulb holder Remove the bulb holder before 18410604 removing the bulb itself Most of the bulb holders for this type can be removed by turn ing counterclockwise e Most of the bulbs of O and D type can be removed from the bulb sockets by pushing and turning them counterclockwise e Bulbs of the type can just be pulled out Be sure to hold the socket firmly when removing the bulb Never pull the lead Oth erwise the lead may be pulled off the termi nal in the coupler WARNING Headlight bulbs become very hot even after a short time Keep flammable products away from a hot headlight bulb and be careful never to touch it before it had time to cool down CHECKING OF BULBS ELEC 2 Check for continuity at the bulb terminals kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Set the pocket tester selector to Q x 1 Connect the tester leads to the respective bulb terminals T
74. UBUNGAN ePeriksa kondisi bohlam dan penyambu ngan socket Ganti Bohlam Socket Bohlam yang rusak il ADA PENYAMBUNGAN 2 Voltase Lampu depan ePasangkan pocket tester DC 20 V pada lampu depan dan kabel lampu indikator lampu jauh Lampu depan Kabel Tester gt Kabel Kuning 2 atau Hijau 1 Kabel Tester gt Kabel hitam 3 Lampu indikator lampu jauh Kabel Tester 4 Kabel kuning 4 Kabel Tester kabel hitam 5 A J posisi saklar dimmer LO B J posisi saklar dimmer HI eHidupkan mesin egeser saklar lampu pada posisi ON eGeser saklar dimmer pada posisi LO atau posisi HI ePeriksa voltase 12 V pada kabel hijau DILUAR SPESIFIKASI atau kabel kuning pada socket connector hr i 1 s rangkaian kabel dari kunci kontak ke socket rangkaian kabel OK bohlam rusak perbaiki 18 SISTIM PENERANGAN ELEC 1 Bohlam dan socket bohlam TIDAK TERSAMBUNG eperiksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAAN BOHLAM Bohlam Socket bohlam rusak perbaiki ganti 2 Lampu meter tidak meyala 2 Voltase ePasangkan pocket tester DC 20 V pada kabel socket bohlam Kabel Tester terminal biru 1 Kabel Tester terminal hitam 2 TIDAK TERSAMBUNG eHidupkan mesin 1 del Rangkaian kabel dari kunci kontak ke ePeriksa voltase 12 V pada kabel biru ins connector rusak perbaiki pada connector socket SESUA
75. Yamaha Indonesia Motor Manufacturing dialih bahasakan oleh Technical Publication PT Yamaha Indonesia Motor Manufacturing di cetak di Indonesia EAS00002 KATA PENGANTAR Buku ini dibuat oleh Yamaha Motor Company Ltd dan dialih bahasakan oleh Technical Publication Service Division PT Yamaha Indonesia Motor Manufacturing diharapkan bisa dipakai oleh Mekanik Bengkel Resmi Yamaha Kami menyadari bahwa tidak mungkin menjelaskan seluruh pelajaran teknik perbaikan sepeda motor dalam satu buku saja sehingga kami menyarankan kepada para mekanik harus terlebih dahulu menguasai dasar dasar perawatan sepeda motor Yamaha dengan mengikuti training training reguler yang diadakan oleh Yamaha tanpa pengetahuan ini usaha perbaikan akan kurang sempurna Yamaha Motor Indonesia akan terus menerus berusaha meningkatkan mutu produksinya untuk itu jika ada perubahan yang mendasar dalam spesifikasi dan prosedur pengerjaan kami akan sampaikan keseluruh jaringan Yamaha melalui buletin Service Information CATATAN Bentuk dan spesifikasi sewaktu waktu dapat berubah mengikuti perkembangan model EAS00004 INFORMASI PENTING YANG DIDALAM BUKU PETUNJUK INI Informasi penting secara khusus ditandai dengan tanda tanda sebagai berikut AN Simbol ini mengharuskan anda BERHATI HATI MENYANGKUT KESELAMATAN ANDA TN memberikan petunjuk khusus yang harus diikuti untuk menghindari kecelakaan bagi pengendara dan orang lain yang sedang memperbaiki sepe
76. a specific value or bubbles fail to rise during charging Sulphation of one or more cells occurs as indicated by the plates turning white or material accumulating in the bottom of the cell INSP BATTERY INSPECTION e Specific gravity readings after a long slow charge indicate that one cell is charged lower than the rest e Warpage or buckling of plates or insulators is evident kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 7 Connect e Breather hose battery Be sure the hose is properly attached and routed CAUTION When inspecting the battery be sure the breather pipe is routed correctly If the breather pipe touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the motorcycle can occur 8 Inspect e Battery terminals Dirty Clean with a wire brush Poor connection Correct NOTE 2 After cleaning the terminals apply light coat of grease 9 Install e Battery 10 Connect e Battery leads First connect the positive lead 1 then connect the negative lead 2 11 Install e Battery band 3 e Side cover right Refer to the SIDE COVER section INSP FUSE INSPECTION FUSE INSPECTION 1 Remove e Side cover right Refer to the SIDE COVER section 2 Remove e Fuse 1 3 Inspect e Fuse Defective Replace Blown fuse new Inspect circuit NOTE
77. ake for example a 3 termi nal bulb as shown left First check the conti between the terminals 1 and 2 by connecting the tester lead to the terminal 1 and the tester lead to the terminal 2 Then check the continuity between the termi nals 1 and by connecting the tester lead still to the terminal and the tester lead to the terminal 3 If the tester shows oo in either case replace the bulb kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 18410602 3 Check the bulb socket by installing a proven bulb to it As in the checking of bulbs con nect the pocket tester leads to the respective leads of the socket and check for continuity in the same manner as mentioned above _ 121 mi 5 60 o 5 Te 59 e o Ge 59 82 e li vu qS coto gl EN 5 SO pm 298966 T koe gt EI E 9 1 Ox eko voL IGNITION SYSTEM CIRCUIT DIAGRAM IGNITION SYSTEM ELEC TROUBLESHOOTING IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE NO SPARK OR INTERMITTENT SPARK Procedure Check 1 Spark plug 6 Engine stop switch 2 Ignition spark gap 7 Source coil resistance 3 Spark plug cap resistance 8 Pickup coil resistance 4 Ignition coil resistance 9 Wirin
78. akes are disas sembled 1 Check e Brake caliper pistons 1 Rust scratches wear Replace the brake caliper Piston assembly e Brake caliper cylinders 2 Scratches wear Replace the brake cali per e Brake caliper 3 Cracks damage Replace e Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals FRONT BRAKE CALIPER INSTALLATION WARNING e Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid e Never use solvents on internal brake components as they will cause the piston seals to swell and distort e Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 3 or 4 18 FRONT BRAKE 5 1 Install e Brake caliper 1 temporarily e Copper washers 2 e Brake hose 3 e Union bolt A WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to the CABLE ROUTING section brake caliper D make sure that the brake pipe touches the projection on the brake caliper 2 Install e Brake pad springs e Brake pads e Brake caliper e Brake caliper retaining bolt 27 Nm 2 7 m kg e Brake master cylinder reservoir with the specified amount of the rec
79. alve seat to make a clean pattern Measure the valve seat width again kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk EB404032 VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr e Valve stem end Use an oil stone to smooth the stem end 2 Apply e Molybdenum disulfide oil onto the valve stem and seal Molybdenum disulfide oil 3 Install Lower spring seat 1 e Oil seal 2 e Valve 3 into the cylinder head e Inner valve spring 4 e Outer valve spring 5 e Upper spring seat 6 NOTE Install the valve spring with the larger pitch facing upwards D Smaller pitch VALVES AND VALVE SPRINGS ENG 11171802 11171302 28 4 Install e Valve cotters 1 NOTE Install the valve cotters while compressing the valve spring with a valve spring compressor 2 Valve spring compressor 90890 04019 5 Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood Do not hit so much as to damage the valve CYLINDER AND PISTON D Oil delivery pipe 2 Cylinder 3 O ring 4 Gasket 6 O ring 6 Dowel pin 7 Piston Piston rings 9 Piston pin clip Piston pin 7910 Nm 1 0 m kg CYLINDER AND PISTON ENG 20 Nm 2 0 m kg 4 gt 18 Nm 1 8 kg CYLINDER AND PISTON ENG 4 PISTON REMOVAL NOTE V Prior to remove the cylinder remove the cylin der head carburetor joint and exhaust pi
80. am dimensions Intake A 36 52 36 62 mm B 30 201 30 301 mm Exhaust A 36 564 36 664 mm B 30 216 30 316 mm Camshaft runout limit lt 0 03 mm gt Rocker arm and rocker arm shaft Rocker arm inside diameter 14 992 15 000 mm Shaft outside diameter 14 960 14 981 mm Arm to shaft clearance 0 009 0 037 mm Cam chain Cam chain type no of links DID SCR 0404SDH Cam chain adjustment method Automatic Valve valve seat valve guide Valve clearance cold 0 05 0 10 mm 0 10 0 15 mm MAINTENANCE SPECIFICATIONS SPEC ge Model SX 4 Value dimensions NB A head IN 33 9 34 1 mm EX 28 4 28 6 mm B face width IN 2 26 mm EX 2 26 mm C seat width IN 0 9 1 1mm EX 0 9 1 1mm D margin thickness IN 0 8 1 2 0 8 1 2 Stem outside dia IN 5 975 5 990 mm EX 5 960 5 975 mm Guide inside dia IN 6 000 6 012 mm EX 6 000 6 012 mm Stem to guide clearance IN 0 010 0 037 mm 0 025 0 052 mm Stem runout limit 0 03 mm Valve spring Free length Inner 36 17 36 17 Outer 36 63 mm 36 63 mm Set length valve closed Inner 30 5 30 5 Outer 32 mm 32 mm Compressed pressure installed Inner i 7 65 9 35 kg 7 65 9 35 kg Outer 13 1 16 1 kg 13 1 16 1 kg Direction of winding Inner Outer Piston Piston to cylinder clearance lt Limit gt Piston size D
81. ang terdapat pada fender belakang sebelah kanan V d j JALUR KABEL SPEC y Masukkan kabel lampu sinyal kedalam special washer kanan dan kiri N Arahkan ke arah depan O Bungkus kabel seperti pada gambar P Jangan mengikat pada kabel telanjang Q Jangan mengikat pada kabel yang telanjang R J epit kabel positive Battery pada pengikat karet Battery Ke motor starter Ke battery 30 10 WAN A SO AR 1 v LK gt AC Dorm rm sin ECH E SAN AP me D N lt 4 e SC E T SENE ANY p TESS E AS 6 amp SE Pena E SEK LE SU i UU Say MF ot AA TU No 5 25 A 2 Pd db S EN gt LF KN DU S T D D Kabel kopling 2 Selang Air induction 3 Selang Vacuum sensing 4 Selang pernafasan 5 Kabel switch netral 6 Kabel Magneto 7 Selang pernafasan Battery selang over flow karburator 9 Kabel speedometer Kabel bodi 10 kabel Magneto 2 Selang Bend JALUR Clamp selang pernafasan Battery dan selang karburator over flow Tepatkan kabel speedometer kedalam holder Clamp kabel magneto dan kabel switch netral KABEL SPEC v D Clamp kabel switch netral terlebih dahulu dan selanjutnya clamp kabel magne
82. ankshaft counter clockwise with wrench e Align the mark 4 on the flywheel with the slit on the crankcase cover Install the camshaft sprocket with the mark facing outward Force the camshaft counter clockwise to remove the cam chain slack your finger into the cam chain ten sioner hole and push the cam chain damper inward While pushing the cam chain damper be sure the camshaft sprocket I mark 1 aligns with the stationary pointer on the cylinder head at TDC marks are aligned tighten the camshaft sprocket bolt temporary elf marks do not align change meshing position of sprocket and chain kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk 3 Install e Gasket new e Timing chain tensioner NOTE Use the gasket new 4 CYLINDER HEAD kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk Timing chain tension installation steps Turn the stopper clockwise Hold the stopper with the bolt Install the tensioner with a new gasket into the cylinder NG Bolt tensioner cylinder 2 10 Nm 1 0 m kg kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk 4 Tighten e Bolt camshaft sprocket Bolt camshaft sprocket 60 Nm 6 0 m kg 5 Check e Alignment marks If the marks do not align Adjust 6 Adjust e Valve clearance Refer to the VALVE CLEARANCE ADJUST MENT section in CHAPTER 3 Intake valve cold 0 05 0 10 mm Exhaust valve cold
83. ar kunci kontak pada posisi ON ePeriksa voltage 12 V pada kabel Coklat BEE Putih pada terminal relay belok den SESUAI SPESIFIKASI 12V ePasangkan pocket tester DC 20 V pada connector socket bohlam 5 Voltase Geser saklar sinyal kiri Kabel Tester kabel coklat 1 kabel Tester Masa ground Geser saklar sinyal kanan Kabel Tester kabel hijau tua 2 Kabel Tester Masa ground e Putar kunci kontak pada posisi ON DILUAR SPESIFIKASI eGeser saklar sein ke arah L atau R ePeriksa voltase 12 V pada kabel coklat atau kabel hijau tua pada connector sock et bohlam rangkaian kabel dari sinyal belok ke connector belok k iki er Pea 12 rangkaian kelistrikan 29 4 lampu indikator netral tidak menyala 1 Bohlam dan socket bohlam ePeriksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAN BOHLAM il ADA HUBUNGAN 2 5 witch netral ePeriksa sistim kerja switch netral lihat bagian PEMERIKSAAN SAKLAR 3 Voltase ePasangkan pocket tester DC 20 V pada connector socket bohlam Kabel Tester terminal coklat 1 Kabel Tester Masa ground eP utar kunci kontak pada posisi ON ePeriksa voltase 12 V pada kabel coklat yang berada pada connector SESUAI SPESIFIKASI 12V Rangkaian dalam kondisi baik SISTIM SINYAL ELEC TIDAK ADA HUBUNGAN B
84. arging system 3 Charging voltage NOTE e Remove the following parts before troubleshooting 1 Side cover right 2 Seat 3 Fuel tank e Use the following special tools in this troubleshooting Inductive tachometer 90890 03113 e Connect the pocket tester Q x 1 to the NO CONTINUITY fuse e Check the fuse for continuity CORRECT Replace fuse 2 Battery e Check the battery condition INCORRECT e Check the battery fluid level battery termi nals and specific gravity Refer to the BATTERY INSPECTION section in CHAPTER 3 e Refill battery fluid e Clean battery terminals e Recharge or replace battery Jul Specific gravity ri 1 280 at 20 C CORRECT 3 Charging voltage e Connect the Indicative tachometer to the spark plug lead e Connect the pocket tester DC 20 V to the battery Tester lead gt Battery terminal 1 Tester lead gt Battery terminal 2 e Start the engine MEETS SPECIFICATION e Measure the charging voltage l Charging voltage 12 V or more at 3 000 r min 14 5 V or less at 8 000 r min Replace battery OUT OF SPECIFICATION 4 Charging coil resistance e Disconnect the CDI magneto coupler from the wire harness e Connect the pocket tester Q x 1 to the stator coil Battery lead White 1 terminal Battery lead gt Black terminal OUT OF SPECIFICATION e Measure the charging coil resista
85. arm Neutral switch Stator Part name Bolt Bolt Flange bolt Bolt Stud bolt Bolt Bolt Screw Flange bolt Nut Bolt Bolt Bolt Bolt Screw Bolt Union bolt Union bolt Bolt Bolt Bolt Flange bolt Nut Flange bolt Flange bolt Flange bolt Flange bolt Bolt Screw Bolt Nut Nut Screw Nut Screw Nut Bolt Bolt Thread size NNNNNN 4 zb NN 4 Ht WN gt FN bh wech wech sch eck sch sch DR sch sch DA sch 10 1 0 K State ES Use lock washer Use lock washer MAINTENANCE SPECIFICATIONS SPEC y e Tightening Part to be tightened Part name E torque Remarks size 7 0 Pickup coil Starter motor Kick crank Kick racket wheel guide MAINTENANCE SPECIFICATIONS SPEC CHASSIS Steering system Steering bearing type Angular bearing Front Suspension Front fork travel 140 mm Fork spring free length 391 5 mm Spring rate 0 75 kg mm 1 0 kg mm Stroke 0 95 mm 95 140 mm Optional spring No Oil capacity 252 cm Oil level 95 mm From top of fully compressed inner tube without fork spring Cil grade Yamaha fork oil 10W or equivalent Rear suspension Shock absorber travel 32 mm Spring rate 16 01 kg mm Stroke 0 32 Optional spring No Swingarm Swingarm free play limit Swingarm free play limit Front wheel Type Spoke wheel Rim size 1 85 x 1 60 Rim material Steel Rim runout limit Vertical 2 mm Lateral 2 mm Rear whe
86. at it does not rotate and turn the adjuster in or out until the proper opera tion timing is obtained Brake light comes on first Brake light comes on slow kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk INSP DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT WARNING e Securely support the motorcycle so that there is no danger of it falling over Stand the motorcycle on its centerstand 0 1 Check NG ne ea Nas e Drive chain slack Out of specification Adjust Drive chain slack 20 30 NO GP I WW MALAE 2 Adjust e Drive chain slack kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Loosen the each locknuts 1 and chain adjuster nuts Loosen the axle nut 3 e Turn the chain adjustment nuts 2 clockwise or counterclockwise until the specified drive chain slack is obtained Drive chain slack is Turning in decreased Drive chain slack is Turning out increased NOTE e Turn each chain adjuster nuts exactly the same amount to maintain correct axle align ment There are marks a on each chain adjuster nuts Use them when adjusting the slack for proper alignment e Before tightening the axle nut and locknuts to specification make sure that there is no clearance at the adjuster nuts or the swin garm end on both sides by pushing the wheel forward e Tighten the axle nut
87. bar 0 025 mm 5BP1 00 110 120 4EL10 2 O 2 3117 5 65 1 2 3 00 8 00 9 00 8 00 8 02 0 25 0 7 MAINTENANCE SPECIFICATIONS SPEC v Model SX 4 Fuel level 2 4 7 mm below the float chamber line Engine idling speed 1 350 1 450 r min Lubrication system Oil filter type Paper and wire mesh type Oil pump type Trochoid type Tip clearance 0 15 mm Side clearance 0 04 0 09 mm MAINTENANCE SPECIFICATIONS SPEC v Model SX 4 Lubrication chart OIL CLEANER PIN WITH HOLE CYLINDER HEAD DRIVE AXLE MAIN AXLE OIL PUMP CRANKSHAFT CAMSHAFT OIL STRAINER OIL PAN MAINTENANCE SPECIFICATIONS SPEC v Tightening Q ty torque Tightening torque Part to be tightened Camshaft sprocket cover Tappet cover Cylinder head Cylinder head exhaust pipe Cylinder head bearing plate Cylinder head breather plate Oil pressure checking screw Spark plug Rotor CDI magneto Valve adjusting locknut Cam sprocket Chain guide Chain tensioner Oil pump Oil filter cover Oil delivery pipe crankcase cover cylinder Carburetor joint Air filter case lower upper Exhaust pipe joint lower Exhaust pipe Muffler Crankcase Crankcase cover left Crankcase cover right Magneto lead clamp Neutral switch lead clamp Drain bolt Starter clutch Primary drive gear Clutch boss Clutch spring Clutch adjuster locknut Clutch push lever Drive sprocket Shiftcam stopper Shift
88. cation Replace as a set Brush spring pressure 560 840g 7 Inspect e Bearing e Oil seal e O ring Wear damage Replace Assembly Reverse the Removal procedure Note the following points 1 Install e Brush e Brush spring Using a thin screw driver ELECTRIC STARTING SYSTEM 2 Install e Armature 1 3 Install e O ring e Starter motor yoke 2 4 Install e Starter motor assembly NOTE V V Align the groove on the starter motor assembly with the groove on the housing 5 Install e O ring D e Screw WARNING Always use a new O ring 6 Install e O ring 2 WARNING Always use a new O ring NOTE Apply a lightly grease to the O ring 2 ELECTRIC STARTING SYSTEM ELEC Installation 1 Install e Starter motor 1 e Starter motor lead 2 G Bolt starter motor A 10 Nm 1 0 m kg Ji B o 6 Ge e 0019910 CO eq pq ED ang EB CHARGING SYSTEM ELEC 410v 18 B i ER CHARGING SYSTEM CIRCUIT DIAGRAM 2 Rectifier regulator 3 CDI magneto Battery 65 Fuse 7 25 CHARGING SYSTEM ELEC TROUBLESHOOTING Procedure Check 1 Fuse 4 Charging coil resistance 2 Battery 5 Wiring connection ch
89. d will ensure more reliable vehicle operation and a longer service life The need for costly overhaul work will be greatly reduced This information applies to vehicles already in service as well as new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter PERIODIC MAINTENANCE LUBRICATION ODOMETER READING x 1 000 km ITEM CHECK OR MAINTENANCE JOB E CNN EN NN m MSN hl eme o em eme 07 doe ale le 2 fiter Check condition Replace if necessary Check condition Replace if necessary condition Replace if necessary Check condition Spark plug Clean and regap e Replace if necessary Replace if necessary necessary e Check valve clearance Valves Adjust et Air filter element Clean Replace if necessary 0000 Clean Replace if necessary 0000 if necessary e Check electrolyte level and specific gravity Battery Make sure that the breather hose is properly routed Check operation Check operation fluid level and vehicle for fluid Front brake leakage Replace brake pads if necessary Check operation and adjust brake pedal free Rear brake play Replace brake shoes if necessary Wheels Check runout spoke tightness and for damage Tighten spokes if necessary Wheel bearings Check bearing for looseness damage Check operation and for excessive play 2 2 2 2 Lubricate
90. d feeler gauge across the cylinder head Measure the warpage elt the warpage is out of specification resur face the cylinder head Place a 400 600 grit wet abrasive paper on the surface plate and resurface the head using a figure eight sanding pattern NOTE Rotate the cylinder head several times for an even resurfacement kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk IN CYLINDER HEAD ENG oD TIMING CHAIN TENSIONER INSPECTION 1 Check e timing chain tensioner Cracks damage rough movement Replace KAKAK KK KK KAKAK KK a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand NOTE V V V While pressing the timing chain tensioner rod wind it clockwise with stopper 1 until it stops b Remove your finger and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner KK KAKAK KK KK ke e e e ke e e ke e e e e ke e e ke e e e e CYLINDER HEAD ENG CYLINDER HEAD INSTALATION 1 Install e Cylinder 22 Nm 2 2 Bolt 20 Nm 2 0m kg 2 Install e Camshaft sprocket e Timing chain e Washer e Bolt camshaft sprocket kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Camshaft sprocket installing steps rear cylinder e Turn the cr
91. da motor PERHATIAN Perlu perhatian khusus yang harus diikuti untuk menghindari kerusakan pada sepeda motor CATATAN Memberikan keterangan tambahan untuk mempermudah pengerjaan 5 0007 TEKNIK BUKU PETUNJUK SUSNAN BUKU PETUNJUK Buku ini terdiri dari beberapa BAB utama yang didalamnya terdapat beberapa judul lihat simbol udul pertama 1 BAB yang disertai simbol terletak disudut kanan atas pada setiap halaman kedua 2 Judul ini adalah judul bagian BAB yang terletak hanya pada halaman pertama dari tiap tiap bagian judul ini terletak disudut kiri atas halaman Judul ketiga 3 Judul ini adalah judul yang lebih spesifik FORMAT BUKU Semua prosedur dalam buku ini dikemas dalam rangkaian tahap demi tahap sehingga petunjuk petunjuk yang ada secara lengkap dapat diterima dengan mudah oleh para mekanik Petunjuk yang ada meliputi berbagai hal antara lain tentang cara membongkar memperbaiki dan pemeriksaan jika ada prosedur yang penting dan perlu perhatian khusus tambahkan gambar A segi tiga hitam dengan tanda seru didalamnya INFORMASI PENTING eData spesifikasi dan special tool diinformasikan dalam frame dengan gambar alat 5 eAngka didalam lingkaran 69 menunjukkan nama komponen dan penjelasan yang melengkapi gambar 7 ada kalanya kita gunakan huruf didalam segi empat box 8 Untuk menjelaskan tindakan lebih lanjut kita gunakan tanda panah sebagai
92. dth 3 Out of specification Replace crankshaft Crank width 69 25 69 30 mm 4 Inspect e Bearing 1 Wear crack damage Replace crankshaft CRANKCASE AND CRANKSHAFT ENG 12510204 12560103 4 5 Inspect e Crankshaft journal Clogged Blow out the journal with com pressed air EAS00401 BEARINGS AND OIL SEALS INSPECTION 1 Check e Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check e Oil seals Damage wear Replace EAS00207 TIMING CHAIN TIMING CHAIN DRIVE SPROCKET AND TIMING CHAIN GUIDES INSPECTION 1 Check e Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check e Timing chain drive sprocket More than 1 4 tooth 8 wear Replace the camshaft sprocket and the timing chain as a Set 8 1 4 tooth D Correct CD Timing chain roller 2 Timing chain drive sprocket CRANKCASE AND CRANKSHAFT ENG 3 Check e Timing chain guide exhaust side e Timing chain guide intake side Damage wear Replace the defective part s CRANKSHAFT INSTALLATION 1 Install e Crankshaft Into the crankcase right NOTE LLL Hold the connecting rod 1 at top dead center with one hand while turning the nut of the instaling tool with the other Operate the instaling tool unit the crankshaft bottoms against the bearing X Crankshaft installer pot
93. e bearing race on the lower bracket using the floor chisel and the hammer as shown Install the new bearing races kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk Always replace bearings and races as a set 4 Inspect e Handlebar Bends damage Replace STEERING HEAD INSTALLATION Reverse the REMOVAL procedures Note the following points 1 Lubricate e Bearing upper lower e Bearing race Lithium soap base grease STEERING HEAD AND HANDLEBAR CHAS df 2 Install e Bearing lower Onto the bearing race e Lower bracket WARNING Support the lower bracket until it is secured e Bearing upper e Bearing race upper e Bearing race cover e Ring nuts 3 Tighten e Ring nut Refer to the STEERING HEAD INSPEC TION section in CHAPTER 3 4 Install e Holder Pass the brake cable and wire harness through the holder 5 Install e Front fork leg Temporarily tighten the upper and lower bracket pinch bolts 6 Install e Handle crown BN Nut steering stem 25 110 Nm 11 0 kg 7 Install e Front fork Refer to the FRONT FORK section Pinch bolt lower bracket 30 Nm 3 0 m kg Pinch bolt handle crown 23 Nm 2 3 m kg 8 Install e Front wheel Refer to the FRONT WHEEL AND BRAKE DISC section PN Nut front wheel axle A 58 Nm 5 8 m STEERING HEAD AND HANDLEBAR CHAS d HANDLEBAR INSTALLATION 1 Install e
94. e fuel level e Remove the carburetor e Inspect the needle valve e it is worn replace it ef it is fine adjust float level by bending the float tang slightly e Install the carburetor e Recheck the fuel level kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISC 6 1 FHONT WHEELETENIOWVAL saus an 6 2 FRONT WHEEL DISASSEMBLY ite eee te 6 2 FRONT WHEELINSPEGTION sitter one 6 3 BRAKE DISC INSPECTION aee mms Ene 6 4 EHONT MWEBHEEL ASSEMBLY 6 5 FRONT WEEELINSTAEBAPDIODI 6 5 REAR WHEEL AND REAR BRAKE 6 7 REAR WHEEL REMOVAL EE 6 8 HEAR WHEEL DISASSEMBLY 6 8 REAR WHEEL INSPEG 6 8 REAR BRAKE INSPECTION 6 9 BHAKE SHOE PEATE ASSEMBE 6 10 REAR WHEEL ASSEMDBPLY 25565 ana 6 10 REAR WEEELINSTAEBEA TIO ee 6 11 FRONI BRAKE 2 Tee ana 6 12 FRONT BRAKE CALIPER Rose eie dana 6 12 MASTER GYENDER ceed Dies EA 6 13 BRAKE PAD iieri tee 6 14 FRONT BRAKE CALIPER REMOVAL
95. e ke e e e e ke e e ke e e cures ENG 7 Tighten e Screw push lever axle Screw 8 Install e Dowel pins 1 e Gasket 2 9 Install e Crankcase cover right NG Bolts crankcase cover right A 10 Nm 1 0 M6 x 55 mm bolt 1 M6 x 50 mm bolts 2 4 M6 x 35 mm bolt 5 M6 x 25 mm bolts 3 10 Install e Kick crank 1 NOTE Align the lip of kick crank boss with the bolt D as shown 4 49 KICK STARTER AND SHIFT SHAFT KICK STARTER AND SHIFT SHAFT 1 Kick shaft des 2 Kick segment gear 3 Kick pinion gear 4 Kick spring 5 Kick crank 6 Shift shaft assembly Stopper lever 10 Nm 1 0 m kg 4 KICK STARTER AND SHIFT SHAFT ENG D KICK SHAFT AND SHIFT SHAFT REMOVAL NOTE Prior to remove the kick shaft remove the clutch assembly 1 Remove e Clutch housing Refer to the CLUTCH REMOVAL section 2 Remove e Shift pedal Refer to the LEFT FOOTREST BRACKET section 3 Remove e Circlip e Washer e Kick pinion gear 3 e Washer 2 e Circlip 5 4 Remove e Kick shaft assembly 1 e Shift shaft assembly 2 52 5 Remove Stopper lever assembly 1 T KKKKKK KICK STARTER INSPECTION 1 Inspect e Kick segment gear 1 e Ratchet gear teeth 2 Wear damage Replace KICK STARTER AND SHIFT SHAFT ENG 2 Inspect e Kick spring Wear crack Replace 1402200 SHIFT SHAFT INSPECTIO
96. e valve guide and onto the valve seat to make a clear pattern eMeasure the valve seat width Where the valve seat and valve face made contact blueing will have been removed elt the valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced oce e AK ke e e e ke e e ke 402020 4 Lap e Valve face e Valve seat NOTE mmm After replacing the valve seat valve and valve guide the valve seat and valve face should be lapped Lapping steps Apply a coarse lapping compound to the valve face Do n let compound enter the gap between the valve stem and the guide e Apply molybdenum disulfide oil to the valve stem VALVES AND VALVE SPRINGS ENG 11171601 11171701 11171202 11172002 IN OD Install the valve into the cylinder head Turn the valve unit the valve face and valve seat are evenly polished then clean off all compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hand Apply a fine lapping compound to the valve face and repeat the above steps NOTE Make sure to clean off all compound from the valve face and valve seat after every lapping operation Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head e Press the valve through the valve guide and onto the v
97. ee movement Insert the throttle valve into the carburetor body and check for free movement Stick Replace 6 Inspect e Main jet 1 e Needle jet 2 e Pilot jet 3 e Pilot screw e Pilot air jet Bends wear damage Replace Contamination Blow out jets with a com pressed air 7 inspect e otarter plunger assembly 1 CARBURETOR CARB ASSEMBLY To assemble the carburetor reverse the disas sembly procedures Note the following points NOTE e Before reassembling wash all parts in clean gasoline e Always use a new gasket 1 Install e Jet needle set To piston valve assembly NOTE L Be sure to install the jet needle plate so that the projection 8 is located toward the hole in the piston valve 2 Install Pilot screw set 1 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Note the following installation points e Screw in the pilot screw 4 until it is lightly seated e Back out by the specified number of turns Pilot screw turn out 2 1 2 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CARBURETOR CARB Tei 3 Install e Needle jet To carburetor NOTE Be sure to insert the slot 8 onto the projection p 4 Install e Needle valve holder NG Screw float valve holder A 2 Nm 0 2 m kg 5 Install e Float chamber cover 1 N Screw float chamber cover A 5 Nm 0 5 m kg 6 Ins
98. el Type opoke wheel Him size 1 85 x 2 15 Rim material oteel Rim runout limit Vertical 2 mm Lateral 2 mm Drive chain Type manufacturer 428 V DAIDO No of links 118 Drive chain slack 20 30mm MAINTENANCE SPECIFICATIONS SPEC v Item 5 4 Front disc brake Disc brake type Single Disc outside diameter x thickness 267 x4 lt Limit gt lt 3 5 mm gt Brake pad lining thickness 5 3 mm lt Limit gt lt 0 8 mm gt Master cylinder inside diameter 11mm Caliper cylinder inside diameter 26 99 mm 22 22 mm Recommended fluid DOT 3 or 4 Rear drum brake Type Leading and trailing Drum inside diameter 130 mm Limit 131 mm Lining thickness 4 mm Limit lt 1 mm Shoe spring free length 50 5 mm Brake lever and brake pedal Brake lever free play 2 5 Brake pedal free play 20 30 mm Clutch lever Clutch lever free play 10 15mm MAINTENANCE SPECIFICATIONS SPEC v Tightening Thread size torque Remarks Tightening torque Part to be tightened Handle crown and inner tube Handle crown and steering stem Steering stem and ring nut Handle crown and upper holder Master cylinder Engine stay and engine Engine stay and frame Engine mounting rear lower and frame Engine mounting rear upper and frame Engine mounting front and frame Tension bar and swingarm Kick starter and frame Front wheel axle Front brake disc Front brake caliper Brake hose union bolt Brake caliper bleed screw Rear
99. el clutch hub damper fits over the tab on the rear wheel clutch hub assembly 2 Install e Hear wheel e Spacer e Rear wheel axle e Rear wheel axle nut 5 85 Nm 8 5 m kg 3 Install Tension bar d Adjust e Brake pedal free play Brake pedal free play 20 30 mm 5 Adjust e Drive chain slack Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in CHAPTER 3 Drive chain slack 20 30 mm FRONT BRAKE CHAS 56 FRONT BRAKE FRONT BRAKE CALIPER CD Brake caliper 2 Brake pad 3 Brake pad spring 2 Retaining bolt 5 Brake caliper piston 6 Brake caliper piston seal Bleed screw kit Brake caliper bolt 30 Nm 3 0 m kg 27 Nm 2 7 kg 6 Nm 0 6 kg 6 12 FRONT BRAKE CHAS df MASTER CYLINDER CD Brake master cylinder 2 Brake master cylinder kit 3 Reservoir diaphragm 4 Reservoir cap 5 Master cylinder holder 6 Brake hose 7 Union bolt Copper washer 7 Nm 0 7 m kg 26 Nm 2 6 kg 26 Nm 2 6 m kg FRONT BRAKE 5 Disc brake components rarely require dis assembly DO NOT e Disassemble components unless abso lutely necessary e Use solvents on internal brake compo nents e Use spent brake fluid for cleaning use only clean brake fluid e Allow brake fluid to come in contact with the eyes as this may cause eye injury e Splash brake fluid onto painted surfaces or plastic parts as this may cause dam age
100. ement cover bolt 25 10 Nm 1 0 kg Outside Inside 6 Check e Engine oil drain bolt gasket e Oil filter element drain bolt gasket Damage Replace 7 Install e Engine oil drain bolt along with the gasket e Oil filter element drain bolt along with he gasket 10 Nm 1 0 m kg 8 Fill e Crankcase With the specified amount of the recom mended engine oil Quantity Total amount 1 4L Without oil filter element replacement 1 2L With oil filter element replace ment 1 3 L 9 Install e Engine oil filler cap ENGINE OIL REPLACEMENT INSP CLUTCH ADJUSTMENT ADJ 10 Start the engine warm it up for several min utes and then turn it off 11 Check e Engine for engine oil leaks 12 Check e Engine oil level Refer to the ENGINE OIL LEVEL INSPEC TION section 13 Check e Engine oil pressure kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps Slightly loosen the oil gallery bolt 1 e 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 e Check the engine oil passages and the oil pump for damage or leakage Refer to the OIL PUMP section in CHAPTER 4 e Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification Cil ga
101. emove e Gasket e Dowel pin 0 Ta CI Oa gt gt O AN Ken 12 GENERATOR ENG GENERATOR ROTOR REMOVAL 1 Remove e Bolt 1 NOTE LLL e Do not touch the projection 8 when install ing the sheave holder e Loosen the nut while holding the generator rotor with sheave holder 2 4 2 Remove e Generator rotor 1 Use a flywheel puller 2 Sheave holder 90890 01701 Flywheel puller 90890 01362 3 Remove e Woodruff key 1 4 Remove e Washer 1 e Starter clutch idle gear 2 2 e Washer 3 e Starter clutch gear 4 e Bearing 5 e Washer 6 GENERATOR ENG EAS00351 STARTER CLUTCH INSPECTION 4 1 Check e Starter clutch idle gear 1 1 np Ss e Starter clutch idle gear 2 2 x j 5 gt e Starter clutch gear 3 Burrs chips roughness wear Replace the defective part s 2 Check e Starter clutch gear s contacting surfaces 8 Damage pitting wear Replace the starter clutch gear 3 Check e otarter clutch operation kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk a Install the starter clutch gear onto the starter clutch and hold the starter clutch b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage If the starter clutch gear and starter clutch do not engage the starter clutch is faulty and must be
102. emove e Damper rob bolt e Copper washer NOTE nmm While holding the damper rod with the damper rod holder D and T handle loosen the damper rod bolt 3 12310502 RL Damper rod holder 19mm 90890 04084 T Handle 90890 01326 5 Remove e Inner tube e Damper rod Pull out the inner tube with damper rod 6 Remove e Oil seal 1 Never se the oil seal 2 Rag 12311311 12311703 12310302 27 FRONT FORK CHAS df EAS00657 FRONT FORK INSPECTION The following procedure applies to both of the front fork legs 1 Check e Inner tube 1 e Outer tube 2 Bends damage scratches Replace WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure e Spring free length 3 Over the specified limit Replace Spring free length limit 384 mm 3 Check e Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air e Oil lock piece 2 Damage Replace When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 4 Check e Cap bolt O ring Damage wear Replace 500659 FRONT FORK ASSEMBLY The following procedure applies to both of the front fork legs WARNING e Make sure that the oil levels in both front fork legs are equal e Uneven oil level can result in poor han dling and a loss of stability
103. en komponen yang bekerja bersamaan harus diganti lengkap satu set Pada saat konsdisi komponen part dilepas bersihkan dari kotoran yang menempel pada komponen untuk mempermudah dan mem percepat pemasangan kembali Jaga semua komponern dari pengaruh panas EB101010 PART PENGGANTI 1 Pergunakan hanya spare part asli Yamaha genuine part pergunakan juga oli dan gemuk yang disarankan Yamaha untuk pelumasan Komponen imitasi terlihat sama dengan yang asli tetapi kualitasnya jauh lebih buruk EB101020 GASKETS SEAL OIL DAN O RINGS jn Ganti semua gaskets seals dan O rings pada saat membongkar mesin bersihkan gasket yang menempel pada permukaan sambungan dengan sempurna Lumasi dengan pelumas pada saat memasang bearing dan lumasi gemuk pada permukaan singgung seal oli EB101030 LOCK WASHERS PLATES DAN COTTER PINS 1 Ganti lock washers plates dan cotter pin setelah dibuka Tekuk lock washer plat di bagian yang rata pada bagian Mur setelah mur dikencang sesuai spesifikasi pengencangan EB101040 BEARING DAN SEAL OIL Pasang bearing dan seal oli dengan posisi marking berada di luar Pada saat memasang seal oli lumasi dengan gemuk light weight lithium pada pada permukaan lidah seal dan pada saat mema sang bearings lumasi dengan oli dan pastikan bearing berputar lancar D Oil seal Jangan menggunakan udara bertekanan untuk membersihkan bearing hal ini akan merusak permukaan beari
104. ery 65 Fuse SIGNALING SYSTEM ELEC 35 SIGNALING SYSTEM ELEC e FLASHER LIGHT BRAKE LIGHT AND OR INDICATOR LIGHT DO NOT COME ON e HORN DOES NOT SOUND TROUBLESHOOTING e FUEL GAUGE DOES NOT OPERATED Procedure Check 1 Fuse 2 Battery 3 Main switch 4 Wiring connection entire signal system NOTE e Remove the following parts before troubleshooting 1 Side cover right 2 Headlight unit 3 Seat 4 Fuel tank e Use the following special tool s in this troubleshooting 7 gt lt gt Pocket tester 90890 03112 e Remove the fuse e Connect the pocket tester Q x 1 to the NO CONTINUITY fuse e Check the fuse for continuity Refer to the FUSE INSPECTION section in CHAPTER 3 Fuse is faulty replace it CONTINUITY 2 Battery INCORRECT e Check the battery condition Refer to the BATTERY INSPECTION section in CHAPTER 3 e Refill battery fluid Jul Specific gravity e Clean battery terminals ri 1 280 at 20 C e Recharge or replace battery CORRECT SIGNALING SYSTEM ELEC INCORRECT e Check the main switch for continuity 1 Refer to the CHECKING THE SWITCHES section Main switch is faulty replace it CORRECT 4 Wiring connection 3 Main switch POOR CONNECTION e Check the entire signal system for connec 2 tions Refer to the WIRING DIAGRAM section o emer s dh CORRECT Check condition of each circuit for
105. etal rusak bocor perbaiki e Joint pipa pembuangan 3 e Gasket 4 Rusak bocor perbaiki 2 Kencangkan e Pipa Muffler dan exhaust Mur pipa pembuangan 5 18 Nm 1 8 m kg 13 1 Baut joint pipa exhaust 20 Nm 2 0 m kg 15 ft Ib Baut muffler 7 30 Nm 3 0 m kg 22 ft Ib SN CYLINDER HEAD ENG MEMBONGKAR MESIN CYLINDER HEAD se D O ring 7 Gasket 9 Timing chain guide 2 Tappet cover Camshaft sprocket sisi exhaust side 3 O ring 9 Gasket Gasket 4 Camshaft sprocket cover Dowel pin 65 Air induction system pipe 5 Plate 4 Cylinder head O ring 6 Cam chain tensioner 2 Busi S park plug 20 Nm 2 0 m kg 15 ft lb 22 Nm 2 2 m kg 16 ft Ib 8 Nm 0 8 m kg 6 0 ft Ib 60 Nm 6 0 m kg 44 3 ft lb AIR INDUCTION SYSTEM CARB ge KARBURATOR AIR INDUCTION SYSTEM AIR INJECTION Air Induction System AIS berfungsi menetra lisir bahan bakar yang tidak terbakar dengan cara menginjeksi udara segar ke lubang pembu angan bertujuan untuk mengurangi kerapatan kadar emisi hydrocarbon J ika tekanan negative timbul pada lubang pembuangan reed valve terbuka sehingga udara segar akan mengalir ke lubang pembuangan Suhu untuk membakar gas buang diperlukan 600 to 700 C AIR CUT OFF VALVE Air cutoff valve bekerja karena tekanan gas pemasukan melalui diaphragma piston valve Dalam kondisi normal Air Cut Valve terbuka sehingga udara mengalir ke
106. g connection ignition system 5 Main switch NOTE e Remove the following parts before troubleshooting 1 Headlight unit 2 Seat 3 Fuel tank e Use the following special tools in this troubleshooting 1 Spark plug e Check the spark plug type condition and gap Refer to the SPARK PLUG INSPECTION section in CHAPTER 3 Standard spark plug D8EA NGK or X24ES U DENSO Spark plug gap CORRECT Repair or replace spark plug IGNITION SYSTEM ELEC 2 lgnition spark gap e Disconnect the spark plug cap from the spark plug e Connect the ignition checker 1 between cylinder head and spark plug cap set the specified spark gap 3 e Turn the main switch to ON then apply clutch lever or shift the transmission into neutral SPARK e Push the start switch or kick the kick crank e Check the ignition spark condition Ignition circuit is good OUT OF SPECIFICATION 3 Spark plug cap resistance e Remove the spark plug cap e Connect the pocket tester Q x 1k to the spark plug cap e Checking the spark plug cap for the speci OUT OF SPECIFICATION Spark plug cap resistance ri 10 at 20 C Replace spark plug cap MEETS SPECIFICATION IGNITION SYSTEM ELEC 4 Ignition coil resistance e Disconnect the ignition coil lead Orange from the wire harness e Connect the pocket tester to the ignition coil Primary coil Q x 1 Tester lead
107. ggangan 0 8 0 9 mm 0 0315 0 0354 in Tekanan angin ban kondisi dingin Berat Dengan oli dan bensin penuh 136 kg 300 Ib Beban maksimum 180 kg 396 Ib Berat total barang bawaan pengendara penumpang dan aksesoris SPESIFIKASI PERAWATAN SPEC SPESIFIKASI PERAWATAN MESIN Wd Med Karburator mark 5BP4 00 Main jet JJ 110 Main air jet A J 120 Jet needle 4EL10 2 Needle jet J O 2M Pilot jet J 17 5 Pilot air jet A J 90 0 9 Setelan Pilot scre S 3 putaran keluar Pilot outlet O 20 8 ck 20 9 20 8 20 8 Valve seat size D 22 0 Starter jet 9 25 0 7 Ketinggian bahan bakar 3 8 5 8 mm 0 15 0 23 in dibawah sambungan rumah pelampung Putaran langsam mesin 1 350 1 450 r min TORSI PENGENCANGAN BAUT TIGHTENING TORQUE Torsi komponen yang dikencangkan nama pei Q ty Keterangan Pipa Air induction system Baut 2 10 1 0 72 Unit Air cut off valve Baut 2 10 10 72 SPESIFIKASI PERAWATAN SPEC vs RANGKA CHASSIS Tromol rem belakang Tipe Leading dan trailing Diameter dalam tromol 130 mm 5 12 in lt Limit gt lt 131 mm 5 16 in gt Ketebalan kampas rem 4 mm 0 16 in lt Limit gt lt 1 mm 0 04 in gt Panjang per kampas rem 52 mm 2 05 in 48 mm 1 89 in JALUR KABEL 1 KabelTachometer 2 Selang rem 3 Holder selang rem 4 Kabel bodi 5 Selang pernafasan 6 Kabel motor starter 7 Kabel negative Battery Kabel positi
108. id any mistakes Gambar ilustrasi Weight Slide hammer bolt 90890 01084 90890 01085 Alat ini digunakan untuk melepas dan memasang as rocker arm Crankcase separating tool 90890 01135 Alat ini digunakan untuk memisahkan crank case Crankshaft installer pot Pot Crankshaft installer bolt 90890 01274 Bolt 90890 01275 Alat ini digunakan untuk memasang poros engkol crankshaft opacer 90890 01288 Adapter M10 90890 01383 Alat ini digunakan untuk memasang poros engkol crankshaft Tappet adjusting tool 90890 0131 1 Alat ini digunakan untuk menyetel kelonggaran klep valve clearance Fuel level gauge 90890 01312 Alat ini digunakan untuk mengukur ke tinggian pelampung kondisi terpasang T handle T handle Damper rod holder 19 mm 90890 01326 Rod holder 90890 04084 Alat ini digunakan untuk mengendorkan dan mengencangkan baut damper rod Gambar ilustrasi Flywheel puller 90890 01362 Alat ini digunakan untuk melepas magnet Fork seal driver weight Fork seal driver attachment 033 Weight 90890 01367 Attachment 90890 01368 Alat ini digunakan untuk memasang seal oli dan seal debu pada fork depan Steering nut wrench 90890 01403 Alat ini digunakan untuk mengencangkan dan mengendorkan baut kemudi steering Sheave holder 90890 01701 Alat ini digunakan untuk menahan magnet secondary sheave Compression gauge 90890 03081 Alat ini digunakan untuk mengukur tekanan kompresi mesin
109. ing thoroughly e Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely CHAPTER 5 CARBURETION CARBURETOR eee 5 1 esta i 5 2 DISASSEMBLY asa 5 3 INSPECTION e I 5 5 ca e 5 7 TON RE 5 9 FUEL LEVEL ADJUSTMENT RE 5 10 CARBURETOR CARB Tei CARBURETION CARBURETOR D Vacuum chamber cover Needle jet Drain hose 2 Piston valve spring Pilot jet 5 Float pivot pin 3 Jet needle set 9 Throttle stop screw set Float 4 Pilot screw set Gasket 7 Drain screw 5 Piston valve Main jet Pilot air jet 6 Starter plunger assembly 2 Needle valve assembly Coasting enricher 3 Needle valve holder 29 Coasting enricher spring CARBURETOR CARB REMOVAL WARNING Gasoline is highly flammable Avoid spilling fuel on the hot engine 1 Remove e Fuel tank Refer to the FUEL TANK section in CHAPTER 3 2 Remove e Battery Refer to the BATTERY INSPECTION sec tion in CHAPTER 3 3 Remove e Drive chain guard 1 4 Remove e Battery case 1 5 Remove e CDI unit 1 e Starter relay 2 e Fuse 3 CARBURETOR CARB 6 e Air filter case 1 7 Drain Loosen the drain screw 1 and drain the gas oline 8 Loosen e Lock nut 2 throttle cable 9 Remove e Throttle cable 3 10 Loosen e Screw 1 carburetor joint 11 Remove e Carb
110. int 3 e gasket 4 Damage Leak Repair or replace 2 Tighten e Muffler and exhaust pipe Nuts exhaust pipe joint 5 18 Nm 1 8 m kg Bolt exhaust pipe joint 6 20 Nm 2 0 m kg Bolts muffler 30 Nm 3 0 m kg FRONT BRAKE ADJUSTMENT INSP BRAKE PAD INSPECTION ADJ Qi CHASSIS FRONT BRAKE ADJUSTMENT 1 Check e Brake lever free play 8 Out of specification Adjust Free play brake lever 2 5 mm at brake lever end 2 Adjust e Brake lever free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Loosen the locknut 1 Turn the adjuster in or out until the speci fied free play is obtained Turnina i brake lever free play is urning in decreased brake lever free play is Turning out increased Tighten the locknut After adjusting the front brake lever free play make sure that there is no brake drag kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk BRAKE PAD INSPECTION 1 Operate the brake lever 2 Inspect e Brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as set Refer to the BRAKE PAD PEPLCEMENT section in CHPTER 6 BRAKE FLUID LEVEL INSPECTION INSP AIR BLEEDING HYDRAULIC BRAKE SYSTEM ADJ BRAKE FLUID LEVEL INSPECTION 1 Stand the motorcycle on a level surface NOTE When inspecting the brake fluid level make sure the moto
111. ions for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions 8 are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration 0 0 indicates a continuity of electricity between switch terminals i e a closed circuit at the respective switch position The example illustration on the left shows that There is continuity between black white and black when the switch is set to OFF or LOCK There is continuity between brown and red when the switch is set to ON CHECKING THE SWITCHES ELEC CHECKING THE SWITCHES 00731 Check each switch for damage or wear proper connections and also for continuity between the ter minals Refer to the CHECKING SWITCH CONTINUITY section Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch Br B LL LL 1 Clutch switch 2 Pass switch 3 Horn switch Dimmer switch 5 Turn switch 6 Main switch Lights switch Front brake switch 9 Engine stop switch Start switch Fuse 2 Rear brake switch 3 Neutral switch CHECKING THE SWITCHES ELEC CHECKING OF BULBS ELEC CHECKING OF BULBS FOR HEADLIGHT TAIL BLAKE LIGHT FLASHER LIGHT METER LIGHT ETC
112. k 1 Bulb and bulb socket e Check the bulb and bulb socket for continu NO CONTINUITY Bulb and or bulb socket are faulty replace INCORRECT Turn signal switch is faulty replace handle bar switch left OUT OF SPECIFICATION Wiring circuit from main switch to flasher relay connector is faulty repair 7 41 SIGNALING SYSTEM ELEC 4 Voltage e Connect the pocket tester DC 20 V to the flasher relay Tester lead Brown White 1 terminal Tester lead gt Frame ground OUT OF SPECIFICATION e Turn the main switch to ON 1 e Check for voltage 12 V on the Brown White lead at the flasher relay terminal Flasher relay is faulty replace it MEETS SPECIFI CATION 12 V 5 Voltage e Connect the pocket tester DC 20 V to the bulb socket connector At flasher light left Tester lead gt Chocolate 1 lead Tester lead Frame ground At flasher light right Tester lead gt Dark green 2 lead Tester lead gt Frame ground e Turn the main switch to ON OUT OF SPECIFICATION e Turn the turn signal switch to L or R e Check for voltage 12 V on the Chocolate lead or Dark green lead at the bulb socket E Wiring circuit from turn signal switch to bulb MEETS SPECIFI socket connector is faulty repair iL CATION 12 V This circuit is good SIGNALING SYSTEM ELEC NO CONTINUITY 1 Bulb and bulb socket
113. k 2 terminal e Turn the main switch to ON OUT OF SPECIFICATION e Check for voltage 12 V on the Brown lead at the fuel meter coupler MEETS SPECIFI Check the entire signal system for connec SIGNALING SYSTEM ELEC NOTE Before reading the meter stay put the float for more than three minutes respectively at UP or DOWN DOES NOT MOVE e the main switch to ON 1 e Check the fuel meter needle moves FULL or EMPTY Replace fuel meter MOVES e Check the entire signal system for connec 4 Wiring connection tion Refer to the WIRING DIAGRAM section SHTG CHAPTER 8 TROUBLESHOOTING TROUBLESHOOTING 8 1 ELECTRICAL SY STEM 8 1 COMPRESSION SYSTEM 8 2 INTAKE AND EXHAUST SYSTEM TRBL sara 2 TROUBLESHOOTING GHTG lt TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM CHECK ALL WIRES CONNECTIONS IGNITION COIL see page 7 11 MAIN SWITCH see page 7 4 Primary or secondary windings ET are broken or faulty Main switch is shorted High tension lead is faulty Plug cap is faulty e C D I unit is broken Many carbon deposits Electrodes are wet Improper gap Broken SLANTEN MOTON Page CHARGING COIL see page 7 27 Starter motor is broken or faulty PICKUP COIL see page 7 12 e Starter relay is broken Starter switch is broken e
114. kapi gambar 2 ada kalanya kita gunakan huruf didalam segi empat box 8 e Untuk penjelasan tentang tindakan lebih lanjut kita gunakan tanda panah sebagai contoh tindakan lebih lanjut jika diluar spesifikasi dengan simbol panah gt 9 DIAGRAM Semua BAB dilengkapi dengan gambaran sebelum dibongkar hal ini untuk mempermudah prosedur yang benar cara memasang dan membongkar 2 INSPECTION AND REPAIR FRONT FORK CHAS 75 y Scratches Bends Damage Replace WARNING WARNING Do not attempt to straighten a bent inner fork tube as this may dangerously weaken He 8 9143001 INSPECTION AND REPAIR CYLINDER HEAD 1 Eliminate Dust sea Carbon deposit Use a rounded scraper NOTE Take to avoide damaging the spark plug threads D ot use sh instrument 7 Avoid scratching the aluminum 2 Measure E Fork spring free length a 5 Cylinder head warpage da Out of specification Replace f fi 3 CG Out of specification gt Resurface Fork spring freu length Warpage limit 418 5 mm 16 5 0 02 mm 0 001 in Minimum free length 410 mm 16 1 in Warpage me ment and t ment step 4 Install Attach a straight edge 1 and a thickne Drive chain 4 ss gauge 2 on the cylinder head Joint drive chain Measure the warpage 2 7 Clip drive chain If the warpage is out of specification y WARNUNG surface the cylinder head A WARNUNG Place a 400 600 grit we
115. lam Kabel Tester terminal kabel kuning 1 Kabel Tester terminal kabel hitam 2 DILUAR SPESIFIKASI P utar kunci kontak pada posisi ON Rangkaian kabel dari kunci kontak ke socket eTarik tuas rem atau injak pedal rem bohlam rusak perbaiki hingga posisi berhenti di bawah ePeriksa voltase 12 V pada kabel kuning pada socket bohlam SESUAI SPESIFIKASI 12V Rangkaian kelistrikan dalam kondisi OK 27 SISTIM SINYAL ELEC 1 Bohlam dan socket bohlam TIDAK TERHUBUNG ePeriksa kondisi bohlam dan socket bohlam lihat bagian PEMERIKSAAN BOHLAM Bohlam dan socket bohlam rusak ganti 3 lampu sein dan indikator lampu sein tdak berkedip TIDAK BAGUS ePeriksa sistim penyambungan pada saklar lihat bagian PEMERIKSAAN SAKLAR Saklar sein beloki rusak perbaiki atau ganti saklar kemudi kiri 3 Voltase ePasangkan pocket tester DC 20 V pada relay sinyal belok Kabel Tester terminal kabel coklat 1 Kabel Tester C Masa ground eP utar kunci kontak pada posisi ON ePeriksa voltase 12 V pada kabel coklat DILUAR SPESIFIKASI pada terminal relay SESUAI SSPESIFIKASI 12V Rangkaian kabel dari kunci kontak ke relay E rusak perbaiki 28 SISTIM SINYAL ELEC 4 ePasangkan pocket tester 20 V sinyal relay belok Kabel Tester terminal Coklat Putih 1 Kabel Tester masa ground DILUAR SPESIFIKASI e Put
116. lders 7 Remove e Handlebar STEERING HEAD REMOVAL WARNING Securely support the motorcycle so there is no danger of its falling over 1 Place the motorcycle on the centerstand and place a suitable stand under the engine to elevate the front wheel 2 Remove e Handlebar e Headlight unit 1 3 Remove e Leads 1 e Headlight body e Speedometer cable 3 e Tachometer cable 4 e opeedometer assembly 5 e Holder 6 STEERING HEAD AND HANDLEBAR CHAS 456 4 Remove e Front wheel e Front fork Refer to the FRONT WHEEL AND FRONT FORK REMOVAL section NOTE It is not necessary to remove the cap bolts when removing front fork 5 Remove e Handle crown 1 e Upper ring nut 2 e Rubber washer e Lower ring nut 3 Use the steering nut wrench to remove the upper ring nut and lower ring nut RL Steering nut wrench 90890 01403 e Lower bracket WARNING Support the lower bracket so that it may not fall down STEERING HEAD AND HANDLEBAR INSPECTION 1 Wash the bearing race and ball with solvent 2 Inspect e Lower bracket 1 e Bearings 2 e Bearing races 3 e Inner surface 4 handle crown Scratches damage Replace STEERING HEAD AND HANDLEBAR CHAS 5 12460504 37 3 Remove e Ball race cover 1 e Bearing race 2 e Bearing 3 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk Bearing race replacement steps Remove th
117. llery bolt NES 5 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CLUTCH ADJUSTMENT 1 Check e Clutch cable free play Out of specification Adjust Clutch cable free play at the end of the clutch lever 10 15 mm CLUTCH ADJUSTMENT INSP AIR FILTER CLEANING ADJ 2 Adjust e Clutch cable free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Handlebar side Loosen the locknut 1 Turn the adjusting bolt in or out until the specified clutch cable free play is obtained Clutch cable free play is increased E Clutch cable free play is decreased e Tighten the locknut 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 Loosen the locknuts 1 Turn the adjusting bolt in or out until the specified clutch cable free play is obtained Clutch cable free play is increased Clutch cable free play is decreased Tighten the locknuts AIR FILTER CLEANING 1 Check Air filter check hoses 1 NOTE mw On the bottom of the air filter case is a check hoses 1 If dust or water or both collects in this hoses clean the air filter element and air filter case 2 Remove e oide cover left Refer to the SIDE COVER section INSP AIR FILTER CLEANING 3 Remove e Air filte
118. lug lead cap 1 e Ignition coil 2 Straighten e Stopper 3 Hemove e Clutch cable 1 4 Remove e Breather hose 1 e Tachometer cable 2 ENGINE REMOVAL ENG 5 Remove e Neutral switch lead e Generator lead coupler e Generator leads 3 4 STARTER MOTOR 1 Remove e Starter motor Refer to the ELECTRIC STARTING SYS TEM in CHAPTER 7 ENGINE 1 Remove e Engine mounting bracket 1 ESI T 2 Remove ff Ss e Rear upper mounting bolt 1 gt e Front mounting bolt 2 Ol N e Rear lower mounting boli ENGINE INSTALLATION ENG ENGINE INSTALLATION ENGINE ASSEMBLY WARNING Securely support the motorcycle so there is no danger of it falling over when install ing engine 1 Install e Engine assembly e Rear lower mounting bolt e Rear upper mounting bolt Rear lower mounting bolt 79 Nm 7 9 kg Rear upper mounting bolt 58 Nm 5 8 kg 2 Install e Front mounting bolt Front mounting bolt 2 58 Nm 5 8 kg 3 Install e Engine mounting bracket e Bolt engine mounting bracket frame e Bolt engine mounting bracket engine Bolt engine mounting bracket frame 30 Nm 3 0 m kg Bolt engine mounting bracket engine 58 Nm 5 8 kg STARTER MOTOR 1 Install e Starter motor Refer to the ELECTRIC STARTING SYS TEM in CHAPTER 7 WIRE AND CABLES 1 Install e Generator leads 1 e Generator lead coupler 2
119. luid When bleeding the brake system make sure that there is always enough brake fluid in the brake fluid reservoir before applying the brake lever Ignoring this precaution could allow air to enter the brake system lengthening the bleeding procedure considerably j Tighten the bleed screw Bleed screw P NOTE LLL If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the brake system have disappeared k Fill the brake fluid reservoir to the proper level Refer to the BRAKE FLUID LEVEL INSPECTION section WARNING After bleeding the brake system check the brake operation kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk BRAKE HOSE INSPECTION 1 Inspect e Brake hose Cracks wear damage Replace 2 Check e Brake hose clamp s Loose Tighten 3 Hold the motorcycle upright and apply the front brake 4 Check e Brake hose Activate the brake lever several times Brake fluid leakage Replace the faulty hose Refer to the FRONT BRAKE section in CHAPTER 6 INSP REAR BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT 1 Check e Brake pedal position distance from the top of the rider footrest to the top of the brake pedal Out of specification Adjust Brake pedal position below the top of the rider footrest 30 mm 2 Adjust e Brake pedal positio
120. lutch lever free play 10 15 mm 4 Adjust e Drive chain slack Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in CHAPTER 3 Drive chain slack 20 30 mm CYLINDER HEAD D O ring 2 Tappet cover 3 O ring 4 Camshaft sprocket cover 5 Plate 6 Cam chain tensioner 8 Nm 0 8 kg CYLINDER HEAD ENG 7 Gasket Camshaft sprocket 9 Gasket Dowel pin W Cylinder head 2 Spark plug 3 Timing chain guide exhaust side CYLINDER HEAD ENG CYLINDER HEAD REMOVAL NOTE AAA Prior to remove the cylinder head remove the seat fuel tank and air scoop and drain the engine oil 4 1 Remove e Exhaust pipe assembly Refer to the ENGINE REMOVAL section in CHAPTER 3 2 Remove e Carburetor Refer to the CARBURETOR section in CHAPTER 5 3 Remove e Carburetor joint 1 e Spark plug 2 4 Remove e cover 1 e Tachometer cable 2 e Camshaft sprocket cover 3 5 Remove e Timing mark accessing screw with O ring 1 e Camshaft end cover with O ring 6 Align e Camshaft sprocket I mark With the stationary pointer on the cylinder head kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkxkk TDC alignment steps e Turn the crankshaft counter clockwise with wrench e Align the camshaft sprocket I mark with the stationary pointer on the cylinder head When the 1 mark is aligned with the stationary poi
121. more otherwise it may cause the jumper lead to be burned e This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity e Check the starter motor operation INOPERATIVE Repair or replace starter motor 18210801 4 Starter relay e Disconnect the starter relay coupler from A WARNING the wire harness e A wire for the jumper lead must have the e Connect the battery 12 v to the starter equivalent capacity as that of the battery relay terminals using the jumper leads lead or more otherwise it may cause the Battery lead gt Yellow Red 1 terminal jumper lead to be burned Battery lead Black terminal e This check is likely to produce sparks so be sure that no flammable gas or fluid is the vicinity DOES NOT MOVES Replace starter relay ELECTRIC STARTING SYSTEM ELEC 5 Starting circuit cut off relay e Disconnect the relay lead coupler from the wire harness e Connect the pocket tester x 1 and bat tery 12 V to relay Step 1 Battery lead Brown terminal 1 Battery lead gt Sky blue terminal 2 Tester lead Brown terminal 1 Tester lead Red White terminal 4 Step 2 Battery lead Brown terminal 1 Battery lead gt Blue Yellow terminal 5 Tester lead Brown terminal 1 Tester lead Red White terminal 4 NO CONTINUITY e Check the relay for continuity Replace relay
122. n M6 x 40 mm bolts M6 x 30 mm bolts 7 9 NN Bolts crankcase cover left AN 7 Nm 0 7 m kg 4 4 Install e Neutral switch lead 5 Install e Starter clutch idle gear 1 e Cover 1 e Drive sprocket cover 2 6 Install e Left footrest bracket Refer to the LEFT FOOTREST BRACKET section 7 Install e Fuel tank Refer to the FUEL TANK section in CHAP TER 3 CLUTCH CLUTCH Crankcase cover right 7 Push rod 1 Clutch housing 2 Gasket Clutch plate 5 Ball 3 Dowel pin 9 Friction plate 1 Push rod 2 4 Compression spring Cushion spring 7 Push lever assembly 5 Pressure plate 1 Friction plate 2 Primary drive gear 6 Push plate 2 Clutch boss Collar 3 Thrust washer Q9 Straight key 6 Nm 0 6 kg 8 Nm 0 8 m 20s 44 MA 9 2 D Sy gr CL ZA J SNE 4 A 0 Ky H SS 70 Nm 7 0 kg 80 Nm 8 0 m kg ENG 4 CRANKCASE COVER RIGHT REMOVAL NOTE Prior to remove the crankcase cover right drain the engine oil 1 Remove e Oil filter cover e Oil filter e O ring 3 filter cover e O ring 4 2 Remove e Oil delivery pipe 1 3 Remove e Kick starter 1 4 Remove e Crankcase cover right NOTE V e Working in crisscross pattern loosen screw 1 4 turn each Remove them after all are loo
123. n kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Loosen the locknut 1 Turn the adjusting bolt in or out until the specified brake pedal position is obtained Brake pedal is raised Brake pedal is lowered Tighten the locknut to specification Locknut kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Check e Brake pedal free play Out of specification Adjust Free play 20 30 mm REAR BRAKE ADJUSTMENT BRAKE SHOE INSP INSPECTION BRAKE LIGHT SWITCH ADJUSTMENT ADJ 4 Adjust e Brake pedal free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Turn the adjuster in or out until the speci fied free play is obtained Free play is decreased Free play is increased Make sure that the brake does not drag after adjusting it 5 Adjust e Brake light switch Refer to the BRAKE LIGHT SWITCH ADJUSTMENT section BRAKE SHOE INSPECTION 1 Operate the brake pedal 2 Inspect e Brake shoes Wear indicator 1 reaches the wear limit line 2 Replace the brake shoes as a set Refer to the REAR WHEEL AND REAR BRAKE section in CHAPTER 6 BRAKE LIGHT SWITCH ADJUSTMENT 1 Check e Brake light operation timing Incorrect Adjust 2 Adjust e Brake light operation timing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Hold the main body of the switch with your hand so th
124. nce Charging coil resistance Bi 0 32 0 48 at 20 C White Black Replace stator assembly MEETS SPECIFICATION 5 Wiring connection POOR CONNECTION e Check the entire charging system for con 1 nections Refer to the WIRING DIAGRAM section CORRECT Replace rectifier regulator 1 21 FS Y e ENTE E GIS Spee bd 18 8 anna ania LIGHTING SYSTEM ELEC mans Ox 1 rove rovig B bog 5 2 oz else SE 0 oOS lt KANAN Et 505580520 FE 9 59 55 Lo Ont Of Eric 28 LIGHTING SYSTEM ELEC TROUBLESHOOTING HEADLIGHT HIGH BEAM INDICATOR LIGHT TAILLIGHT AND OR METER LIGHT DO NOT COME ON Procedure Check 1 Lighting coil resistance 4 Pass switch 2 Lights switch 5 Wiring connection entire lighting system 3 Dimmer switch NOTE e Remove the following parts before troubleshooting 1 Side cover right 2 Headlight unit 3 Seat e Use the following special tool s in this troubleshooting 1 Lighting coil resistance e Disconnect the CDI magneto coupler from the wire harness e Connect the pocket tester Q x 1 to the stator coil
125. ng Bearing EB101050 CIRCLIPS 1 Periksa dengan seksama circlip sebelum pemasangan Selalu ganti circlip pin piston dengan yang baru Ganti circlip jika telah rusak Pemasangan circlip 1 pastikan sudut yang tajam pada permukaan tekanan 2 berlawa nan dengan gaya tekanan 3 lihat gambar penjelasan disamping 4 As Shaft EB801000 MEMERIKSA SISTIM PENYAMBUNGAN Bersihkan debu dan kotoran yang terdapat pada pada connector 1 Lepaskan e Connector 2 Semprot dengan udara bertekanan 3 Pasang dan cabut connector dua atau tiga kali pemasangan 4 Tarik kabel untuk memeriksa agar kabel tidak tercabut terlepas 5 Jika mudah tercabut bengkokkan pin pengait 1 dan pasangkan kembali ke terminal connector 6 Pasang e Connector CATATAN Kedua connectors harus click bersamaan 7 Periksa sistim penyambungan dengan tester CATATAN Jika tidak ada sambungan bersihkan terminal Lakukan langkah pemeriksaan 1 hingga 7 pada saat memeriksa kabel bodi e Untuk pemeriksaan dapat menggunakan tester yang ada di pasaran e Pergunakan tester seperti pada gambar SPECIAL TOOLS GEN SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropriate special tools this will help prevent damage caused by the use of inappropriate tools or improvised techniques When placing an order refer to the list provided below to avo
126. nter the piston is at Top Dead Center TDC CYLINDER HEAD ENG NOTE TDC on compression stroke check e Both rocker arms must have a valve clearance when the 4 mark on the flywheel is aligned with the slit on the crankcase cover e f not give the crankshaft one counter clock wise turn to meet above condition 4 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk 7 Loosen e Bolt camshaft sprocket 1 NOTE Hold the crankshaft end with a wrench 8 Remove e Cam chain tensioner 1 9 Remove e Camshaft sprocket NOTE Fasten a safety wire to the cam chain 10 Remove e Engine mounting bracket Refer to the ENGINE REMOVAL section 11 Remove e Cylinder head 1 NOTE Loosen the bolts in this stage using a criss cross pattern CYLINDER HEAD ENG 12 Remove e Dowel pins 1 e Gasket cylinder head 2 e Timing chain guide exhaust side 3 4 CYLINDER HEAD INSPECTION 1 Eliminate e Carbon deposits from combustion chambers Use a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching 11110106 e Spark plug threads e Valve seats 2 Inspect e Cylinder head Scratches damage Replace 3 Measure e Cylinder head warpage Out of specification Resurface Cylinder head warpage Less than 0 03 mm kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk Warpage measurement and resurfacement steps ePlace a straightedge an
127. ntil it cools down INSP HEADLIGHT BULB REPLACEMENT ADJ 3 Install e Bulb new Secure the new bulb with the bulb holder Avoid touching glass part of bulb Also keep it free from oil otherwise transpar ency of glass bulb life and illuminous flux will be adversely affected If oil gets on bulb clean it with a cloth moistened thor oughly with alcohol or lacquer thinner 4 Install e Cover e Headlight unit CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL geed 4 1 ENGINE OIL san Len ang aka E ka aa bass ungu Na nu 4 1 EXHAUST PIPE ASSEIIBLY ee o eti aa b a aga aste edat 4 1 LEFI FEOOTRESTBBAGISET as 4 2 DRIVE GRAN aana aa aana aaa a a aab 4 2 EE EEN Ke EE 4 3 WIRE CABLE AND TUBE saasta an sa 4 3 STARTER MOTOR ee 4 4 cj i 4 4 ENGINE INSTALLATION an Ead timus enteros oid nud 4 5 ENGINE ASSEMBLY EE 4 5 SARTE R MOTOR d 4 5 WIRE AND M m 4 5 CARBURETOR 4 6 DRIVE GRAIN ME 4 6 LEFT FOOTREST BRACKET cein n E 4 6 EXAHAUSIKASSEMBEY sena nembak Bm 4 7 FUEL TANI AND SEAT Jute gmana 4 7 CYLINDER HEAD 4 9 CYLINDER HEAD REMOVAL 4 10 CYLINDER HEAD INSPECTION 4 12 TIMING CHA
128. ohlam dan socket bohlam ruisak perbaiki TIDAK SESUAI Switch netral rusak perbaiki DILUAR SPESIFIKASI Rangkaian kabel dari kunci kontak ke socket bohlam rusak perbaiki 30 SISTIM SINYAL ELEC 5 Meter bahan bakar tidak berfungsi 1 Sender bahan bakar e epaskan sender bahan bakar 1 dari tangki bensin ePasangkan pocket tester pada coupler sender bahan bakar Tahanan sender keatas Qx1 D DILUAR SPESIFIKASI 4 10 pada 20 C 68 F Tahanan sender kebawah 5 2 1 SESUAI SPESIFIKASI 2 Voltase ePasangkan pocket tester DC 20 V pada coupler meter bahan bakar Kabel Tester terminal coklat Kabel Tester terminal hitam 2 utar kunci kontak pada posisi ON DILUAR SPESIFIKASI eperiksa voltase 12 V pada kabel coklat pada coupler meter bahan bakar SESUAI SPESIFIKASI periksa sambungan kabel pada sistim 12V sinyal 31 SISTIM SINYAL ELEC 3 meter bahan bakar egerakkan ke UP QY atau DOWN 2 AAA sebelum membaca tahanan pada posisi atas maupun bawah biarkan terlebih dahulu pada posisinya selama 10 detik JARUM TIDAK BERGERAK e Putar kunci kontak pada posisi ON ePeriksa pergerakan jarum ke FULL atau EMPTY ganti meter bahan bakar BERGERAK ePeriksa jalur kabel pada bagian sistim 4 jalur kabel sinyal lihat bagian DIAGRAM KELISTRIKAN 32 YAMAHA YAMAHA MOTOR LTD
129. om mended brake fluid Recommended brake fluid DOT 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 e 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 FRONT BRAKE CHAS df e When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed e Brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 5 Check e Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to the BRAKE FLUID LEVEL INSPECTION section in CHAPTER 3 6 Check e Brake level operation Soft or spongy feeling Bleed the brake system Refer to the AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 20 FRONT BRAKE 5 45 500588 MASTER CYLINDER REMOVAL NOTE Before removing the front brake master cylin der drain the brake fluid from the entire brake system 1 Remove e Brake lever compression spring e Brake switch 1 2 Remove
130. on skirt diameter Out of specification Replace 8 4 0 mm form the piston bottom edge Piston skirt diameter 69 977 69 996 mm Oversize 2 70 50 mm Oversize 4 71 00 mm 2 Calculate e Piston to cylinder clearance Piston to cylinder clearance z Cylinder bore Piston skirt diameter Refer to the CYLINDER section for cylinder bore measurement Out of specification Replace the piston and piston rings as a set Piston to cylinder clearance 0 020 0 025 mm Limit 0 05 mm 3 Measure e Piston pin bore diameter Out of specification Replace Piston pin bore diameter 16 002 16 013 mm Limit 16 043 mm 4 Measure e Piston pin outside diameter Out of specification Replace Piston pin outside diameter 15 996 16 000 mm Limit 15 97 mm 5 Inspect e Piston pin Blue discoloration groove Clean or replace CYLINDER AND PISTON ENG 4 YP402111 PISTON RINGS INSPECTION 1 Measure e Side clearance Out of specification Replace the piston and the piston rings as a set NOTE lt lt lt Eliminate the carbon deposits from the piston ring grooves and piston rings before measur ing the side clearance Side clearance piston ring Top ring 0 03 0 07 mm Limit 0 1 mm 2 nd ring 0 02 0 06 mm Limit 0 1 mm gt IN 11221402 11221401 2 Position e Piston rings into the cylinder NOTE V V Push the ring with
131. opeedometer assembly e Handlebar 1 e Handlebar holders 2 e Bolt cap 9 NOTE Lu Ll e Punch mark 1 should be flush with upper bracket when installing the handlebar e Arrow marks 2 should be pointed toward when installing handlebar holder ENS Bolt handlebar holder 2 19 Nm 1 9 kg 2 Install e Clutch lever 1 e Grip 2 left e Grip end 3 left e Handlebar switch 4 left e Align the handlebar switch projection with the hole on the handlebar e Apply lithium soap base grease to clutch cable end when installing left handlebar switch 3 Install e Brake lever holder 1 e Throttle grip right e Throttle grip end 3 e Handlebar switch 2 right e hrottle cable 5 NOTE LLL e Align the handlebar switch projection with the hole on the handlebar e Apply lithium soap base grease to throttle cable end when installing right handlebar switch STEERING HEAD AND HANDLEBAR CHAS df WARNING It should have 1 3 mm when installing throttle grip end Bolt throttle grip end A 23 Nm 2 3 m kg 4 Adjust e Throttle cable free play Refer to the THROTTLE CABLE FREE PLAY ADJUSTMENT section in CHAPTER 9 Throttle cable free play 3 5mm REAR SHOCK ABSORBER AND SWINGARM 5 45 REAR SHOCK ABSORBER AND SWINGARM Rear shock absorber Relay arm 2 Bush 9 Bush 3 Swingarm Oil seal
132. pe 1 Remove e Oil delivery pipe 1 2 Remove e Cylinder 1 e O ring 2 e Dowel pin 3 e Gasket cylinder e O ring 5 3 Remove e Piston pin clip 1 N OT E naaamaaai Before removing the piston pin clip cover the crankcase with a clean so you will not accidentally drop the clip into the crankcase 4 Remove e Piston pin 1 e Piston 2 NOTE V V V Before removing the piston pin deburr the clip grooved and pin hole area If the piston pin groove is deburred and piston pin is still diffi cult to remove use the piston pin puller pin out CYLINDER AND PISTON ENG 11221501 11210103 11210301 4 5 Remove e Piston rings 1 NO TE ll E L When removing a piston rings open the end gap with your fingers and lift the other side of the ring over the piston crown YP40210 CYLINDER INSPECTION 1 Measure e Cylinder bore Out of specification Rebore or replace NOTE e Measure the cylinder bore with a cylinder bore gauge e Measure the cylinder bore in parallel to and at right angles to the crankshaft Then find the average of the measurements Cylinder bore 70 000 70 018 mm Limit 70 1 mm Difference limit between A B and C 0 03 mm 2 Measure e Warpage Out of specification Replace Cylinder warpage limit 0 01 mm CYLINDER AND PISTON ENG kkkkkk 1 Measure e Pist
133. plate 1 2 2 9 3 1 mm Limit 2 8 mm 3 Inspect e Clutch plates Damage Replace the clutch plates as a Set 4 Measure e Clutch plate warpage Out of specification Replace the clutch plates as a set Use a surface plate and a feeler gauge 61 Warp limit clutch plate Less than 0 2 mm 4 ENG 5 Inspect e Compression springs Damage Replace the compression springs as a set 6 Measure e Free length compression spring 8 Out of specification Replace the clutch springs as a set Free length clutch spring 34 9 mm Limit 33 2 mm 11412901 7 inspect e Push rod 2 Wear crack damage Replace 8 Measure e Push rod 2 Out of specification Replace Bending limit push rod 2 0 5 mm 11412601 9 Inspect e Dogs on the housing Cracks wear damage Deburr or replace 11411301 10 Inspect e Clutch housing bearing 1 Cracks wear damage Replace 11 Inspect e Clutch boss splines ocoring wear damage Replace clutch boss assembly 4 11410301 12 Inspect e Oil filter Cracks damage Replace Contamination Clean the flushing oil T KKKKKK CLUTCH INSTALLATION 1 Install e Straight key e Collar 1 e Primary drive gear 2 e Crow washer 9 e Lock washer e Nut primary drive gear 80 Nm 8 0 kg 2 Install e Clutch housing e Thrust washer e Clutch bass e Lock
134. r case cover 1 e Air filter element 2 4 Clean e Air filter element with solvent WARNING Never use low flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explo sion NOE After cleaning gently sgueeze the air filter ele ment to remove the excess solvent Do not twist the air filter element when sgueezing it 5 Check e Air filter element Damage Replace 6 Apply the recommended oil to the entire sur face of the air filter element and squeeze out the excess oil The air filter element should be wet but not dripping Recommended oil Engine oil AIR FILTER CLEANING CARBURETOR JOINT INSP 46 INSPECTION FUEL LINE INSPECTION ADJ Qi 7 Install e Air filter element e Air filler case cover ever operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performance and possible overheat ing CARBURETOR JOINT INSPECTION 1 Inspect e Carburetor joint 1 Cracks Damage Replace FUEL LINE INSPECTION 1 Inspect e Fuse hose Cracks Damage Replace INSP EXHAUST SYSTEM INSPECTION ADJ EXHAUST SYSTEM INSPECTION 1 Inspect e Exhaust pipe 1 e Muffler Cracks Damage Leak Repair or replace e Exhaust pipe Jo
135. rcycle is upright 2 1 e Brake fluid level Brake fluid level is below the LOWER level line Fill to proper level Recommended brake fluid 6 DOT 3 or 4 NOTE nmm For a correct reading of the brake fluid level make sure the top of the handlebar brake fluid reservoir is horizontal AIR BLEEDING HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system whenever e The system is disassembled e A brake hose is loosened or removed e The brake fluid level is very low e Brake operation is faulty If the brake system is not properly bled a loss of braking performance may occur 1 Bleed e Brake system kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Air bleeding steps a Fill the reservoir with the proper brake fluid b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect a clear plastic hose 1 tightly to the caliper bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever several times Pull the lever in Hold the lever in position g Loosen the bleed screw and allow the lever to travel towards its limit h Tighten the bleed screw when the lever limit has been reached then release the lever AIR BLEEDING HYDRAULIC BRAKE SYSTEM INSP BRAKE HOSE INSPECTION ADJ amp i Repeat steps e to h until all the air bub bles have disappeared from the bake f
136. replaced c When turning the starter clutch gear coun terclockwise B it should turn freely If the starter clutch gear does not turn freely the starter clutch is faulty and must be replaced kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk GENERATOR INSTALLATION 1 Install e Washer 1 e Bearing 2 e otarter clutch gear 3 e Washer 4 e Starter clutch idle gear 2 Washer 6 GENERATOR ENG 2 Install Woodruff key 1 e Generator rotor e Washer 3 e Bolt Use the sheave holder 5 Sheave holder 7 90890 01701 NOTE M e Before installing the generator rotor clean the outside of the crankshaft and inside of D the generator rotor V 2 e When installing the generator rotor make sure the woodruff key is properly seated in N the key way of the crankshatt NOTE Do not allow the special tool to touch the pro jection on the generator rotor Nut rotor lees CRANKCASE COVER LEFT INSTALLATION 1 Install e Stator coil 1 e Pickup coil 2 Bolts starter coil 7 Nm 0 7 m kg Screws pickup coil 7 Nm 0 7 m kg 2 Install e Dowel pin e Gasket WE OO PN 23 ONA Z NG 4 JOO Q ES CN d m DO GENERATOR ENG 3 Install e Crankcase cover left NOTE Tighten the bolts crankcase cover left in a crisscross patter
137. retor over flow hose 7 Fuel tank over flow hose Speedometer cable 9 Wire harness Pick up coil lead 4 Magneto lead CABLE ROUTING SPEC y 2 Fuel tank over flow hose D Clamp the magneto lead and pick up coil lead Install the horn lead long side Clamp the battery breather to the left side of the horn hose Clamp the battery breather hose carburetor over flow hose and fuel tank over flow hose C Pass the speedometer cable through the holder BL 7 8 INSP ADJ BAB 3 PARAWATAN BERKALA DAN PENYETELAN PENDAHULUAN ea ee 3 1 PERAWATAN BERKALA PELUMASAN 3 1 TEMPAT DUDUK JOK sopan na kop kana 3 3 PENUTUP SAMPING SIDE COVER 2 3 3 TANGKI BENSIN e 3 3 MESIN Tc 3 4 MENYETEL KELONGGARAN KEEP 3 4 MENYETEL PUTARAN LANGSAM 3 5 MENYETL GAS 3 6 SPARK PLUG INSPEC HON ee aan ena 3 8 COMPRESSION PRESSURE MEASUREMENT 3 8 ENGINE OIL LE VELINSPEGTION 3 9 ENGINE OIL REPLACEMENT eene 3 10 RER Gr ADJUSTMENT baa ntu 3 12 Mel ae e TE WE 3 13 CARBURETOR 3 15 FUEL LEINEINSPEG HON EE 3 15 EXHAUST SYSTEM INSPECTION yssen asipar 3 16 CHASSIS 3 17 FRONT BRAKE ADJUST
138. ring 30 5 mm at 7 65 9 35 kg Outer valve spring 32 mm at 13 1 16 1 kg YP402030 5 Measure e Valve spring tilt Out of specification Replace Spring tilt limit 2 57 16 mm 4 VALVES AND VALVE SPRINGS ENG 6 Inspect e opring contact face Wear Pitting Scratches Replace 7 Measure e Valve guide inside diameter Out of specification Replace Valve guide inside diameter Intake 6 000 6 012 mm Limit 6 042 mm Exhaust 6 000 6 012 mm Limit 6 042 mm YP402010 8 Measure Stem to guide clearance Valve guide inside diameter 3 Valve stem diameter 11170501 Out of specification Replace the valve guide Stem to guide clearance limit Intake 0 08 mm Exhaust 0 1 mm EB402020 VALVE SEATS INSPECTION 1 Eliminate e Carbon deposits from the valve face and valve seat 2 Inspect e Valve seats Pitting wear Reface the valve seat VALVES AND VALVE SPRINGS ENG 11171701 11171601 11171601 302 024 4 3 Measure e Valve seat width Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm Limit 1 6 mm Exhaust 0 9 1 1 mm Limit 1 6 mm e KK e ke ck e KK ke e e ke ke e e e ke e e e e e e e ke e e e e Ae kk Measurement steps e Apply Mechanic s blueing dye to the valve face e Install the valve into the cylinder head e Press the valve through th
139. ring compressor 90890 04019 3 Remove e Valve cotters 1 e Upper spring seat e Outer valve spring 3 e Inner valve spring e Oil seal e Lower spring seat 6 e Valve 7 NOTE V V V e Identify each part position very carefully so that it can be reinstalled in its original place e Deburr any deformed valve stem end Use an oil stone to smooth the stem end CD Deburr 2 Valve stem 4 Eliminate e Carbon deposit From the combustion chamber Use a rounded scraper NOTE LLL Do not use a sharp instrument and avoid dam aging or scratching e opark plug threads e Valve seat e Cylinder head VALVES AND VALVE SPRINGS ENG 11172102 11172103 11171902 11171904 MM 11171903 4 YP kkkkkk ALVES AND VALVE SPRINGS INSPECTION 1 Measure e Valve stem diameter Out of specification Replace Valve stem diameter Intake 5 975 5 990 mm Limit 5 95 mm Exhaust 5 960 5 975 mm Limit 5 935 mm YP402010 2 Measure e Runout valve stem Out of specification Replace Runout limit 0 03 mm YP402030 3 Measure e Free length valve spring 8 Out of specification Replace Valve spring free length Inner valve spring 36 17 mm Limit 34 47 mm gt Outer valve spring 36 63 mm Limit 34 63 mm gt 4 Measure e Compressed valve spring force 8 Out of specification Replace D Installed length Inner valve sp
140. rter motor lead 1 4 Remove e Starter motor 2 5 Remove e Bolts starter motor front cover 6 Remove e Starter motor yoke 1 e O ring 7 Remove e Armature 1 Inspection and repair 1 Inspect e Commutator Dirty Clean it with 600 grit sandpaper 2 Measure e Commutator diameter Out of specification Replace starter motor Commutator wear limit 21mm 7 20 ELECTRIC STARTING SYSTEM ELEC 3 Measure e Mica undercut Out of specification Scrape the mica to el proper value use a hacksaw blade can be ground to fit Mica undercut 1 5mm NOTE the mica insulation of the commutator must be undercut to ensure proper operation of com mutator 18210901 4 Inspect e Armature coil continuity insulation Defects s Replace starter motor kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Inspecting steps eConnect the pocket tester for continuity check and insulation check Pocket tester 90890 031 12 Armature coil resistance Continuity check 1 Q x 1 0 Q at 20 C Insulation check 2 Q x 1k More than 1 MQ at 20 C elt the resistance is incorrect replace the starter motor n 5 Measure e Brush length 8 Out of specification Replace oS Brush length limit Jh dE J ELECTRIC STARTING SYSTEM ELEC 6 Measure e Brush spring pressure Fatigue out of specifi
141. s begitu juga ujung sikat akan merusakkan O rings Untuk itu hanya minyak tanah yang diijinkan jangan merendam dalam minyak tanah lebih dari 10 menit hal ini akan merusakkan O ring pada rantai 4 Periksa e O rings 1 12510201 Rusak Ganti rantai penggerak e Roller rantai 2 Rusak Aus Ganti rantai e Plat rantai 3 Retak Aus karat Ganti rantai penggerak 5 Lumasi e Rantai penggerak Pelumas rantai yang dianjurkan Oli mesin atau pelumas rantai 12510201 khusus untuk rantai dengan O ring 6 Periksa e Sprocket penggerak e Sprocket yang digerakkan Aus lebih dari 1 2 gigi 8 Ganti rantai dan sprocket gear satu set Gigi bengkok Ganti rantai dan Sprocket gear satu set b Kondisi normal 1 Riler rantai oe 2 Sprocket gear 14 SISTIM PENERANGAN ELEC KELISTRIKAN SISTIM PENERANGAN DIAGRAM KELISTRIKAN 3 CDI magneto 45 Saklar lampu Switch pass 7 Saklar dimmer Lampu belakang rem 03 Lampu depan Lampu senja posisi Lampu meter Lampu tanda lampu jauh SISTIM PENERANGAN ELEC 7 CARA MENGATASI MASALAH TROUBLESHOOTING LAMPU DEPAN LAMPU INDIKATOR LAMPU JAUH LAMPU BELAKANG LAMPU METER TIDAK MENYALA Prosedur Periksa 1 Tahanan Lighting coil 4 Saklar Pass 2 Saklar lampu 5 Sambungan kabel pada sistim penerangan 3 Saklar dimmer CATATAN eBuka komponen dibawah ini sebelum melakukan perbaikan 1 Penutup samping kanan 2 Lampu depan 3
142. s si Nm m kg assemblies are included the applicable 10 mm 4 3 sections of this book To avoid warpage tighten multifastener assemblies in a crisscross fash 14 mm 10 mm 30 3 0 22 ion in progressive stages until full torque is 6 mm 6 06 43 reached Unless otherwise specified torque specifications call for clean dry threads Com ponents should be at room temperature A Distance across flats B Outside thread diameter DEFINITION OF UNITS Unt Read Definition Measure centimeter 102 meter 752 we Wit _ N Newton gems Newton meter Nxm Torque um Meter kilogram m x kg Torque Pa Pascal N m Pressure N mn Newton per millimeter N mn Spring rate Volume or capacit Cubic centimeter poy Rotation per minute Rotation per minute minute Engine speed LUBRICATION POINTS AND LUBRICANT TYPE SPEC y LUBRICATION POINTS AND LUBRICANT TYPE ENGINE Grankcase mating Yamaha bona Notz _ LUBRICATION POINTS AND LUBRICANT TYPE SPEC y CHASSIS Front wheel oil seal right left Clutch hub oil seal Clutch hub fitting area Lithium soap base grease Lithium soap base grease Rear brake pedal shaft Change pedal Lithium soap base grease Lithium soap base grease Lithium soap base grease Side main stand sliding surface Brake lever bolt sliding surface Hear brake camshaft Brake shoe plate pivot Lithium
143. sened e Be sure not to give damages to the mating surface M6 x 55 mm bolt 1 M6 x 50 mm bolts 2 4 M6 x 35 mm bolt 5 M6 x 25 mm bolts 3 5 Remove e Gasket e Dowel pin ENG CLUTCH REMOVAL 1 Remove e Bolts clutch springs e Clutch springs 4 2 Remove e Pressure plate 1 e Friction plate 1 5 pcs e Friction plate 2 3 1 pcs e Clutch plate 4 5 pcs e Cushion spring 5 e Push plate 6 e Push rod 1 e Ball e Push rod 22 9 3 Straighten e Lock washer tab gt NOTE Slide the right side of crankcase to remove ball and push rod 1 4 Loosen e Nut clutch boss e Nut primary drive gear NOTE Loosen the nut clutch boss while holding the clutch boss with universal clutch holder 1 2 Universal clutch holder 4 90890 04086 11411901 4 ENG 5 Remove e Nut clutch boss e Lock washer 2 e Clutch boss 3 e Thrust washer 4 e Clutch housing 5 6 Remove e Nut primary drive gear e Lock washer 2 e Crow washer 9 e Primary drive gear 4 e Collar 5 e Straight key 1402181 CLUTCH INSPECTION 1 Inspect e Friction plate 1 2 Damage wear Replace the friction plates as a Set 2 Measure e Friction plate thickness Out of specification Replace the friction plates as a Set Measure at four places Thickness friction
144. several min utes and then turn it off ENGINE OIL LEVEL INSPECTION INSP ENGINE OIL REPLACEMENT ADJ 3 Check e Engine oil level The engine oil level should be between the minimum level mark and maximum level mark Below the minimum level mark Add the recommended engine oil to the proper level Recommended oil Refer to the chart for the engine oil grade API standard SE or higher grade 10 20 30 40 enee LE Do not allow foreign materials to enter the SAE20W 40 crankcase NOTE Before checking the engine oil level wait a few minutes until the oil has settled ENGINE OIL REPLACEMENT 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 e Engine oil filler bolt e Engine oil drain bolt 1 along with the gasket e Oil filter element drain bolt along with the gasket 4 Drain e Engine oil completely from the crankcase c FR INSP ENGINE OIL REPLACEMENT ee d 5 If the oil filter element is also to be replaced perform the following procedure kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps Remove the oil filter element cover and oil filter element Check the O rings 3 and replace them if they are cracked or damaged Install the new oil filter element and the oil fil ter element cover NG Oil filter el
145. signal sys tem Refer to the SIGNAL SYSTEM CHECK section SIGNALING SYSTEM ELEC 1 Horn switch INCORRECT e Check the horn switch for continuity Refer to the CHECKING THE Horn switch is faulty replace handlebar switch left SIGNAL SYSTEM CHECK 1 Horn does not sound 2 Voltage e Connect the pocket tester DC 20 V to the horn lead Tester lead Brown 1 lead Tester lead gt Frame ground OUT OF SPECIFICATION e the main switch to ON e Check for voltage 12 V on the Brown Wiring circuit from main switch to horn termi lead at the horn terminal nal is faulty repair MEETS SPECIFI CATION 12 V SIGNALING SYSTEM ELEC e Disconnect the Pink lead at the horn ter minal e Connect a jumper lead 1 to the horn termi nal and ground the jumper lead e the main switch to ON HORN IS SOUNDED HORN IS NOT SOUNDED 4 Voltage e Connect the pocket tester DC 20 V to the horn at the Pink terminal Tester lead Pink lead Tester lead gt Frame ground OUT OF SPECIFICATION e Turn the main switch to ON 1 e Check for voltage 12 V on the Pink lead at the horn terminal Horn is faulty replace it MEETS SPECIFI CATION 12 V Adjust or replace horn SIGNALING SYSTEM ELEC 2 Brake light does not come on 1 Bulb and bulb socket NO CONTINUITY e
146. soap base grease em Litiumsoap base grease em Littiumsoap base grease lt 4 D ri lt 4 CABLE ROUTING D Tachometer cable Fuel sender lead 2 Brake hose 2 Breather hose 3 Brake hose holder 3 Air vent hose Wire harness Throttle cable 5 Air vent hose 5 Clutch cable 6 Starting motor lead Magneto lead 7 Battery negative lead Pick up coil lead Battery positive lead Wire harness 9 Rear brake switch lead Taillight lead CABLE ROUTING SPEC y Clamp the wire harness Pass the cable holder through the tachometer cable Install the horn lead short side to the right side of the horn D Clamp the taillight lead Clamp the wire harness Clamp the wire harness at the white tape portion IE ks un N reh ho b CUL lt A CABLE ROUTING SPEC y To fuel tank Clamp the throttle cable and clutch cable Turn the clamp end to inside of motorcycle 1 Clamp the throttle cable and clutch cable Insert the air vent hose into the frame Clamp the wire harness and turn the clamp end to inside of motorcycle Clamp the magneto lead and pick up coil lead and push the leads into holder Ws ONT s a EA Roya NN NS D Clutch cable 2 Breather hose 3 Fuel tank over flow hose 4 Magneto lead 5 Battery breather hose 6 Carbu
147. t 36 42 mm 30 201 30 301 mm Limit 30 1 mm Exhaust 8 36 564 36 664 mm Limit 36 46 mm 30 216 30 316 mm Limit 30 12 mm 3 Inspect e Camshaft oil passage Stuffed Blow out oil passage with com pressed the air YP402060 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1 Inspect e Cam lobe contact surface 1 e Adjuster surface 2 Wear Pitting Scratches Blue discoloration gt Replace kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk Inspection steps Inspect the two contact areas on the rocker arms for signs of unusual wear Rocker arm shaft hole e Cam lobe contact surface e Excessive wear Replace CAMSHAFT AND ROCKER ARMS ENG 11160302 FS OD the surface condition of the rocker arm shafts e Pitting scratches blue discoloration Replace or check lubrication eMeasure the inside diameter of the rocker arm holes Out of specification Replace Inside diameter rocker arm 14 992 15 000 mm Limit 15 02 mm e Measure the outside diameter of the rocker arm shafts Out of specification Replace Outside diameter rocker arm shaft 14 960 14 981 mm Limit 14 94 mm kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk kkkkkk INSTALLATION 1 Lubricate e Rocker arm shaft e Rocker arm inner surface Rocker arm shaft Engine oil Rocker arm inner surface Molybdenum disulfide grease
148. t pinch bolt 1 e Handle crown pinch bolt 2 e Cap bolt WARNING Make sure that the brake hoses are routed properly 3 Install e Front fender e Collars e Bolts front fender 4 Install e Front wheel Refer to the FRONT WHEEL AND BRAKE DISC section 2 STEERING HEAD AND HANDLEBAR CHAS df STEERING HEAD AND HANDLEBAR HANDLEBAR Grip end 2 Throttle grip 3 Handlebar 2 Throttle cable 5 Clutch cable 23 Nm 2 3 m kg STEERING HEAD Handlebar holder 2 Bolt cap 3 Lock washer 4 Upper ring nut 5 Rubber washer 23 Nm 2 3 m kg STEERING HEAD AND HANDLEBAR CHAS df 6 Lower ring nut Ball race cover Bearing 9 Bearing Bearing race Lower bracket 19 Nm 1 9 m kg 48 Nm 4 8 kg 18 Nm 1 8 m kg E rj STEERING HEAD AND HANDLEBAR CHAS 5 HANDLEBAR REMOVAL 1 Remove e Handlebar switch 1 left 90900 Di ON 2 Remove e Grip end 1 left e Handlebar grip 2 left e Clutch cable 3 e Clutch lever holder 4 NOTE Before removing the clutch lever holder 2 remove the clutch switch leads and clutch cable 3 Remove e Handlebar switch 1 right 4 Remove e Throttle cable 1 d DAK 5 Remove e Grip end 1 right e Throttle grip 2 e Brake lever holder 3 STEERING HEAD AND HANDLEBAR 5 6 Remove e N A e Bolt cap 1 en e Handlebar ho
149. t sandpaper on ake e the surface plate and resurface the head ing figure eight sanding pattern using NOTE Rotate the head several times to avoid re moving too much material from one side 959299009020020900950920989000920999000029 SIMBOL sesuai illustrasi simbol 1 hingga amp merupakan simbol di setiap BAB yang menggambarkan isi dari setiap BAB 1 Informasi Umum 2 Spesifikasi 3 Perawatan berkala dan pelumasan 2 Membongkar mesin 5 Karburator 6 Rangka Chassis Kelistrikan Electrical Cara mengatasi masalah Troubleshooting Ilustrasi simbol 9 hingga 46 menjelaskan sebagai berikut 9 Perbaikan dengan mesin terpasang Pengisian cairan 4 Pelumasan 2 Alat khusus Special tool 43 Pengencangan Bats keausan kelonggaran 5 Putaran mesin Ilustrasi simbol 7 hingga 4 pada gambar menunjukkan tipe pelumas dan bagian yang perlu dilumasi 07 Lumasi dengan oli mesin Lumasi dengan oli gear Lumasi dengan molybdenum disulfide oil GO Lumasi dengan gemuk bearing Lumasi dengan gemuk lightweight lithium soap base 9 Lumasi dengan gemuk molybdenum disulfide 63 Berikan cairan pengunci LOCTITE 4 Ganti dengan yang baru DAFTAR ISI INFORMASI UMUM er SPESIFIKASI PERAWATAN BERKALA DAN PENYETELAN ADI 3 MEMBONGKAR MESIN d CARBURATOR CAR n RANGKA CHASSIS I gt D KE
150. tall e Piston valve assembly 1 e Piston valve spring 2 e Vacuum chamber cover 3 Screw vacuum chamber cover 25 4 Nm 0 4 kg NOTE Match the tab on the rubber diaphragm to the matching recess in the piston valve CARBURETOR CARB Tei INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install e Carburetor NOTE c o Be sure to insert the projection 8 into the slot D of carburetor joint 2 Adjust e Engine idle speed Refer to the IDLING SPEED ADJUST MENT section in CHAPTER 3 Engine idle speed Fy 1 350 1 450 r min 3 Adjust e Throttle cable free play 8 throttle grip Refer to the THROTTLE CABLE ADJUST MENT section in CHAPTER 3 Throttle cable free play 3 5mm 14510605 CARBURETOR CARB Tei FUEL LEVEL ADJUSTMENT 1 Measure e Fuel level 8 Out of specification Adjust Fuel level 2 4 7 mm below the float chamber line kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Fuel level measurement and adjustment steps Place the motorcycle on a level surface e Use centerstand to ensure that the carbure tor is positioned vertically e Connect the fuel level gauge 1 to the drain pipe 2 using a level gauge adapter Fuel level gauge 90890 01312 Loosen the drain screw 3 e Measure the fuel level 8 with the gauge elf the fuel level in incorrect adjust th
151. the piston crown so that the ring will be at a right angle to the cylinder bore 3 Measure End gap Out of specification Replace NOTE V V V You cannot measure the end gap on the expander spacer of the oil ring If the oil ring rails show excessive gap replace all three rings 8 40 0 mm End gap Top ring 0 15 0 30 mm Limit 0 6 mm 2 nd ring 0 15 0 30 mm Limit 0 6 mm Cil ring 0 3 0 9 mm IN CYLINDER AND PISTON ENG 404184 PISTON RINGS PISTON AND CYLINDER INSTALLATION 1 Install e ring 1 e 2nd ring 2 e Oil ring 3 NOTE e Make sure to install the piston rings so that the manufactures marks or numbers are located on the upper side of the rings e Lubricate the pistons and piston rings liber ally with engine oil 11221301 2 Install e Piston 1 e Piston pin 2 e Piston pin clip 3 NOTE e Apply engine oil onto the piston pins The mark on the piston must face the exhaust side of the cylinder e Before installing the piston pin clip cover the crankcase opening with a clean rag to pre vent the piston pin clip from falling into the crankcase e Make sure to install each piston in its respec tive cylinder 3 Install e O ring e Gasket cylinder e Dowel pins 4 Position e Piston rings NOTE Offset the piston ring end gaps as shown Top ring end D Oil ring end lower C Oil ring end upper
152. to Clamp selang pernafasan Battery 1 kabel saklar tangkai kemudi 2 kabel kopling 3 Kabel sinyal belok kiri 4 Kabel speedometer 5 Kabel bodi 6 Kabel Tachometer 7 Kabel sinyal belok kanan Kabel gas 9 Selang rem Kabel saklar rem depan 47 Kabel saklar tangkai kemudi 2 Kabel kunci kontak 9 Kabel meter Nod Z rm 2 591 BE Nd os JALUR KABEL SPEC vs Clamp kabel saklar tangkai kemudi Tepatkan klem kabel kopling ke arah dalam baut pengunci handel crown Masukkan kabel kopling kedalam guide penuntun D Masukkan kabel bodi kedalam guide penuntun Clamp selang rem Masukkan selang rem kabel gas kedalam guide penuntun Tepatkan kabel gas diluar baut pengunci handle crown Clamp kabel saklar tangkai kemudi dan kabel switch rem Q3 9 ES 1 Kabel main switch jangan tertarik dan tepatkan dengan kabel meter Clamp selang rem dan kabel gas Ke head lamp Clamp kabel kopling Clamp kabel bodi kabel lampu sein kabel switch rem depan kabel saklar tangkai kemudi dan kabel kunci kontak di bagian pelindung IN Clamp kabel bodi kabel sinyal belok saklar tangkai kemudi kabel lampu meter pada posisi isolasi putih CHK MEMERIKSA SISTIM PEMBUANGAN PEMERIKSAAN BERKALA DAN PENYETELAN MESIN MEMERIKSA SISTIM PEMBUANGAN 1 Periksa e Pipa Exhaust 1 e Knalpot Muffler 2 R
153. tor lampu jauh 8 Lampu indikator netral 9 Lampu indikator belok 3 Motor Styarter Battery 85 Sekring Starter relay 67 Relay rangkaian cut off L W Biru Putih Blue White Biru Kuning Blue Yellow RW Merah Putih Red White Kuning Merah Yellow Red
154. u NOTE YA e Apply the lithium soap base grease on the bearing and oil seal lip when installing e Use a socket that matches the outside diam eter of the race of the bearing e Always use a new oil seal e Install the oil seal with its manufacturer s marks or numbers facing outward Do not strike the inner race of balls of the bearing Contact should be made only with the outer race FRONT WHEEL INSTALLATION 1 Install e Brake disc NOTE GG e Apply LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages using gt e Tig ges using 22 2 D J crisscross pattern SS NI 2 Install e opeedometer gear unit 1 NOTE Be sure that projections 8 inside the wheel hub mesh with the slots b in the gear unit assembly 12010504 FRONT WHEEL AND BRAKE DISC CHAS df 3 Tighten e Front wheel axle nut 58 Nm 5 8 kg TE 2 Be sure that the projection torque stopper 8 of the gear unit housing is positioned correctly 4 Connect e Speedometer cable REAR WHEEL AND REAR BRAKE CHAS df REAR WHEEL AND REAR BRAKE CD Drive chain puller Oil seal 2 Brake camshaft lever 9 Bearing 3 Brake shoe wear indicator Spacer 4 Spacer 1 Rear wheel clutch hub damper 5 Brake shoe plate 2 Rear wheel clutch hub 6 Brake camshaft 3 Driven sprocket 7 Brake shoe Collar 5 Rear wheel axle 10 Nm 1 0
155. uretor 1 DISASSEMBLY 1 Remove e Vacuum chamber cover 1 2 Remove e Piston valve spring 2 e Piston valve 3 CARBURETOR CARB 3 Remove e Jet needle set 1 4 Remove Pilot screw set 1 5 Remove e Float chamber cover 1 e Gasket 6 Remove e Float pivot pin 1 e Float 2 e Needle valve 3 7 Remove e Needle valve holder ol ADA TN a e d AN KL NESS 14510605 CARBURETOR CARB 8 Remove e Main jet 1 e Washer 2 e Needle jet 3 e Pilot jet 9 Remove e Starter plunger assembly 1 INSPECTION 1 Inspect e Carburetor body e Fuel passage Contamination Clean as indicated kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Carburetor cleaning steps e Wash carburetor in petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all passages and jets with a com pressed air AKA AKA AKK KA KAKAK KAKAK AKK KA 2 1 Float Damage Replace 3 Inspect e Needle valve assembly 1 Damage wear contamination Replace as a set CARBURETOR CARB Tei 4 Inspect e Piston valve Cracks Replace e Rubber diaphragm 2 Tears Replace e Jet needle 3 Bend Replace NOTE If you suspect the piston valve has been dam aged check the component for cracks by pouring gasoline into the valve If it leaks replace with a new piston valve 5 Check e Fr
156. ve Battery 9 Kabel switch rem belakang Kabel sinyal belok belakang sebelah kanan 1 Kabel Fuel sender 5 y Sal z SS W 5 2 5 STA A 2 LINS ll LE SS Di pa 0 JALUR KABEL 2 Selang pernafasan 43 Selang pernafasan Kabel gas Throttle cable 45 Kabel kopling Kabel magnet 7 Kabel switch netral Kabel bodi Kabel sinyal belok belakang sebelah kiri Battery 07 Kabel kuning Kabel biru ES ANY 2 Sr A lt 2 Ye KC Les a Q a Yo d 1 CC m 27 OS aL ey TAA RER 3 Kabel hitam Karet pengikat Battery Klem kabel bodi Masukkan kabel tachometer kedalam guide Tempatkan terminal dibelakang bodi mesin D ikat kabel bodi dengan plastik pengikat Ikat kabel bodi pada bagian isolasi putih Ad D ke tangki bensin Ikat kabel gas dan kabel kopling dan jangan sampai kabel koOling menyentuh selang pernafasan mesin pada saat tangkai kemudi dibelokkan ke kiri arahkan ujung klem menghadap ke atas Ikat kabel gas dan kabel kopling 1 Masukkan selang pernafasan mesin kedalam rangka Ikat kabel bodi dan dan arahkan ujung klem mengha dap kedalam Ikat kabel magnet dan kabel switch netral dan tekan kabel kearah dalam dari holder Masukkan kabel sein kedalam lubang y
157. ve chain stiffness Stiffness Clean and lubricate or replace 2 1 e Drive chain 1 e Driven sprocket More than 1 2 tooth a wear Replace the drive chain Use new driven sprocket REAR SHOCK ABSORBER AND SWINGARM 5 12510206 12510302 12510201 12510201 45 3 Measure e 10 link length 8 drive chain Out of specification Replace the drive chain 10 link length limit 119 5 mm NOTE we e Tighten the drive chain with a finger before measuring e 10 link length is the distance between the inside edge of roller 1 and 9 as shown e 10 link length measurement should be done at two or three different places 4 Clean e Drive chain Put it in kerosene and brush off as much dirt as possible Then remove the drive chain from the kerosene and dry it Drive chain lubricant Engine oil or chain lubricant for O ring chain This motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain sol vents e g benzene or a coarse brush to clean the drive chain Don t soak drive drain in kerosine for more than ten minutes O ring is damage by ker osine 5 Check e O rings D Damage Replace the drive chain e Drive chain rollers 2 Damage wear Replace the drive chain e Drive chain side plates 3 Cracks damage wear Replace the drive chain
158. wheel axle oprocket and wheel hub Tension bar and rear brake shoe plate Brake lever camshaft Fuel sender and fuel tank Footrest and footrest bracket Footrest bracket and brake pedal Footrest bracket and frame Rear footrest bracket and frame Pivot shaft Rear shock absorber upper Rear shock absorber lower Relay arm and frame Relay arm and connecting rod Connecting rod and frame Chain case and swingarm Chain guide and swingarm NOTE 1 First tighten the ring nut approximately 48 Nm 4 8 m kg by using the torque wrench then loosen the ring nut one turn 2 Retighten the ring nut 18 Nm 1 8 m kg M8 x 1 25 M22 x 1 0 M8 x 1 25 M6 x 1 0 M10 x 1 25 M8 x 1 25 M10 x 1 25 M10 x 1 25 M10 x 1 25 M8 x 1 25 M10 x 1 25 M14 x 1 5 M6 x 1 0 M10 x 1 25 M10 x 1 25 M7 x 1 0 M14 x 1 5 M8 x 1 25 M8 x 1 25 M6 x 1 0 M5 x 0 8 M8 x 1 25 M10 x 1 25 M8 x 1 25 M8 x 1 25 M12 x 1 25 M12 x 1 25 M12 x 1 25 M12 x 1 25 M12 x 1 25 M12 x 1 25 M6 x 1 0 M6 x 1 0 1 8 See NOTE MAINTENANCE SPECIFICATIONS ELECTRICAL Voltage 12V Ignition system Ignition timing B T D C 5 at 1 450 r min Advancer type Electrical CDI Pickup coil resistance color 248 372 at 20 C Red White Source coil resistance 688 1 032 Q at 20 C Brown Green CDI unit model manufacturer 5BP YAMAHA Ignition coil Model manufacturer 5BP YAMAHA Primary winding resistance 0 32 0 48 Q at 20 C Secondary winding
159. you are riding in unusually wet or dusty areas e Hydraulic brake systems e After disassembling the brake master cylinder and caliper cylinder always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required e Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two years e Replace the brake hose every four years or if cracked or damaged ITEM CHECK OR MAINTENANCE JOB INSP SEAT SIDE COVER FUEL TANK ADJ SEAT 1 Install e Seat 1 NOTE Insert the projection 8 on the front of the seat into the seat holder as shown SIDE COVER 1 Remove e Seat 2 Remove e Side covers left and right NOTE Remove screws and knob and then pull the side cover off as shown FUEL TANK 1 Remove e Air scoop left and right e Bolt e Washer e Fuel sender coupler e Breather hose e Fuel hose e Fuel tank 1 NE Turn the fuel cock to OFF position before removing fuel hose INSP VALVE CLEARANCE ADJUSTMENT ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE Valve clearance adjustment should be made with the engine cool at room temperature When the valve clearance is to be measured or adjusted the piston must be at Top Dead Center T D C on the compression stroke 1 Remove e Air scoop left and right 2 Remove e Spark plug e Tappet cover intake side

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