AT115C

SUPPLEMENTARY
SERVICE MANUAL

5MX-F8197-E1
 FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
AT115C. For complete service information procedures it is necessary to use this Supplementary
Service manual together with the following manual.

AT115 SERVICE MANUAL: 5MX-F8197-E0

EAS00000

AT115C
SUPPLEMENTARY
SERVICE MANUAL
©2006 by Yamaha Motor Co., Ltd.
First edition, May, 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002

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

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

NOTE:
Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

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

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

cC A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

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

EASF0007

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is a chapter with its symbol on the upper right of each page.

2nd title 2: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter “Periodic inspection and adjustment” the 3 rd title
appears.)

3rd title 3: This is a final title.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step - by - step format. The informa-
tion has been compiled to provide the mechanic with a easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of triangle “▲” with each proce-
dure preceded by “8”.

IMPORTANT FEATURES
8Data and a special tool are framed in a box preceded by a relevant symbol 5 .
8An encircled numeral 6 indicates a part name, and an encircled alphabetical letter date or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8 .
8A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9 .

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
1 2 SYMBOLS
The following symbols are not relevant to every
GEN SPEC vehicle.
INFO Symbols 1 to 8 indicate the subject of each
3 4 chapter.

1 General information
CHK ENG 2 Specifications
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Carburetor
6 Chassis
7 Electrical system
CARB CHAS 8 Troubleshooting

7 8 Symbols 9 to y indicate the following.

TRBL 9 Serviceable with engine mounted

ELEC SHTG 0 Filling fluid
q Lubricant
9 0 w Special tool
e Tightening torque
r Wear limit, clearance
t Engine speed
y Electrical data
q w
Symbols u to s in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.

e r u Engine oil
i Gear oil
o Molybdenum-disulfide oil
p Wheel-bearing grease
a Lithium-soap-based grease
s Molybdenum-disulfide grease
t y

Symbols d to f in the exploded diagrams indi-

cate the following.

u i o d Apply locking agent (LOCTITE®)

f Replace the part

p a s

d f

LT New
 CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS ……………………………………………… 1
MAINTENANCE SPECIFICATIONS ……………………………………… 2
ENGINE …………………………………………………………………… 2
TIGHTENING TORQUES ……………………………………………… 3
CHASSIS ………………………………………………………………… 4
TIGHTENING TORQUES ……………………………………………… 5
ELECTRICAL……………………………………………………………… 5
LUBRICATION POINTS AND LUBRICANT TYPES ………………… 5
CABLE ROUTING …………………………………………………………… 6

PERIODIC CHECKS AND ADJUSTMENTS

SIDE COVER ………………………………………………………………… 17
REMOVING THE SIDE COVER………………………………………… 17
INSTALLING THE SIDE COVER ……………………………………… 17
LEG SHIELD ………………………………………………………………… 18
REMOVING THE LEG SHIELD ………………………………………… 18
INSTALLING THE LEG SHIELD ……………………………………… 20
ENGINE ……………………………………………………………………… 21
CHECKING THE EXHAUST SYSTEM ………………………………… 21

ENGINE
CYLINDER HEAD …………………………………………………………… 22
CHECKING THE TIMING CHAIN TENSIONER ……………………… 23
INSTALLING THE CYLINDER HEAD ………………………………… 23
KICK STARTER ……………………………………………………………… 27
INSTALLING THE KICK STARTER …………………………………… 28
STARTER CLUTCH ………………………………………………………… 29
REMOVING THE STARTER CLUTCH ………………………………… 30
INSTALLING THE STARTER CLUTCH ……………………………… 30

CARBURETOR
CARBURETOR ……………………………………………………………… 31
CHECKING THE AUTO CHOKE UNIT ……………………………… 32
AIR INDUCTION SYSTEM ………………………………………………… 33
AIR INJECTION ………………………………………………………… 33
AIR CUT-OFF VALVE …………………………………………………… 33

CHASSIS
HANDLEBAR ………………………………………………………………… 35
REMOVING THE HANDLEBAR ……………………………………… 36
REAR SHOCK ABSORBER ASSEMBLY AND
REAR SUSPENSION ARM ………………………………………………… 39
ELECTRICAL
CHECKING THE SWITCHES ……………………………………………… 40
LIGHTING SYSTEM ………………………………………………………… 42
CIRCUIT DIAGRAM …………………………………………………… 42
TROUBLESHOOTING …………………………………………………… 43
CHECKING THE LIGHTING SYSTEM ……………………………… 44
AUTO CHOKE SYSTEM …………………………………………………… 49
CIRCUIT DIAGRAM …………………………………………………… 49
TROUBLESHOOTING ………………………………………………… 50

TROUBLESHOOTING
TROUBLESHOOTING ……………………………………………………… 52
INTAKE AND EXHAUST SYSTEM …………………………………… 52

AT115C WIRING DIAGRAM

 GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model AT115C
Model code 2D51
Dimensions
Overall length 1,935 mm (76.2 in)
Overall width 675 mm (26.6 in)
Overall height 1,090 mm (42.9 in)
Seat height 770 mm (30.3 in)
Wheelbase 1,280 mm (50.4 in)
Minimum ground clearance 134 mm (5.28 in)
Minimum turning radius 1,900 mm (74.8 in)
Weight
Wet (with oil and full fuel tank) 108.0 kg (238 lb)
Engine
Engine type Forced-air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 113.7 cm3 (6.90 cu.in)
Bore × stroke 50.0 × 57.9 mm (1.97 × 2.28 in)
Compression ratio 8.8 : 1
Compression pressure (STD) 1,100 kPa (11 kgf/cm2, 156.5 psi) at 510 r/min
Starting system Kick and electric starter
Lubrication system Wet sump
Engine idling speed 1,400 – 1,600 r/min
Oil type or grade
Engine oil SAE 20W40 or 10W30
API service SG type or higher, JASO standard MA
Periodic oil change amount 0.8 L (0.85 US qt, 0.70 imp. qt)
Total amount 0.9 L (0.95 US qt, 0.79 imp. qt)
Transmission oil
Recommended oil YAMALUBE 4 or SAE10W40 type SE motor oil
Periodic oil change 0.1 L (0.11 US qt, 0.09 Imp. qt)
Total amount 0.12 L (0.13 US qt, 0.11 Imp. qt)
Fuel
Recommended fuel Regular gasoline
Fuel tank capacity 4.8 L (1.06 Imp gal, 1.27 us gal)
Bulbs (voltage/wattage x quantity)
Headlight 12 V 25 W/25 W x 2
Tail/brake light 12 V 5 W/21 W x 1
Front turn signal light 12 V 10 W x 2
Rear turn signal light 12 V 10 W x 2
Meter light 12 V 1.7 W x 2
High beam indicator light 12 V 1.7 W x 1
Turn signal indicator light 12 V 1.7 W x 2
Auxiliary light 12 V 3.4W x 2
–1–
 MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.06 − 0.10 mm (0.0024 − 0.0039 in) ----
EX 0.08 − 0.12 mm (0.0032 − 0.0045 in) ----
Valve dimensions

B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 22.9 − 23.1 mm (0.9016 − 0.9094 in) ----
EX 19.9 − 20.1 mm (0.7835 − 0.7913 in) ----
“B” face width IN 1.20 − 2.50 mm (0.0472 − 0.0984 in) ----
EX 1.6 − 2.9 mm (0.0630 − 0.1142 in) ----
“C” seat width IN 0.9 − 1.1 mm (0.0354 − 0.0433 in) 1.6 mm
(0.0630 in)
EX 0.9 − 1.1 mm (0.0354 − 0.0433 in) 1.6 mm
(0.0630 in)
“D” margin thickness IN 0.7 mm (0.0276 in) ----
EX 1.0 mm (0.0394 in) ----
Valve stem outside diameter IN 4.970 − 4.985 mm (0.1957 − 0.1963 in) 4.930 mm
(0.1941 in)
EX 4.955 − 4.970 mm (0.1951 − 0.1957 in) 4.920 mm
(0.1937 in)
Valve guide inside diameter IN 5.000 − 5.012 mm (0.1969 − 0.1973 in) 5.050 mm
(0.1988 in)
EX 5.000 − 5.012 mm (0.1969 − 0.1912 in) 5.050 mm
(0.1988 in)
Valve-stem-to-guide clearance IN 0.015 − 0.042 mm (0.0006 − 0.0017 in) 0.08 mm
(0.0032 in)
EX 0.030 − 0.057 mm (0.0012 − 0.0022 in) 0.110 mm
(0.0043 in)
Valve stem runout limit ---- 0.01 mm
(0.0004 in)

Kick starter
Kick starter type Ratchet type ----
Kick clip friction force 1.00 − 3.50 N ----
(0.10 − 0.36 kgf, 0.22 − 0.79 lb) ----

–2–
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Carburetor
Type BS25 x 1 ----
I.D. mark 2D51 00 ----
Main jet (M.J.) #98.8 ----
Main air jet (M.A.J.) Ø0.8 ----
Jet needle (J.N.) 4CEY1-2 ----
Needle jet (N.J.) E-5M (906) ----
Pilot air jet 1 #170 ----
Pilot air jet 2 #170 ----
Pilot outlet (P.O.) Ø0.8 ----
Pilot jet (P.J) #20 ----
Bypass 1 0.7 ----
Bypass 2 0.7 ----
Bypass 3 0.7 ----
Bypass 4 0.7 ----
Pilot screw turns out 1–13/16 ----
Valve seat size Ø1.8 ----
Starter jet 1 #32.5 ----
Starter jet 2 Ø0.65 ----
Throttle valve size #115 ----
Fuel level (using fuel level gauge) 7.8 – 8.0 mm (0.28 – 0.31 in) ----
Engine idling speed 1400 – 1600 r/min ----

TIGHTENING TORQUES
ENGINE
Tightening
Thread
Part to be tightened Part name Q’ty torque Remarks
size
Nm m·kg ft·lb
Camshaft sprocket cover breather Bolt M6 1 10 1.0 7.2
plate
Engine cooling fan Bolt M6 3 9 0.9 6.5
Exhaust pipe nut Nut M8 2 20 2.0 14
Muffler and rear suspension arm Bolt M10 3 53 5.3 38
Muffler clamp bolt Bolt M8 1 12 1.2 8.7
Air cut-off valve assembly Bolt M6 2 6 0.6 4.3
Air induction system pipe Bolt M6 1 8 0.8 5.8
Air induction system pipe clamp
Screw — 1 40 4 2.9
screw
V-belt check plug Plug M32 1 7 0.7 5.1
V-belt case cover protector plate Bolt M6 4 9 0.9 6.5 LT

Kickstarter crank Bolt M6 1 12 1.2 8.7

Primary pulley nut Nut M12 1 50 5.0 36
Clutch carrier nut Nut M28 1 55 5.5 40
Thermo switch — M16 1 23 2.3 17

–3–
 MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
Steering system
Steering bearing type Angular bearing ----
Lock to lock angle left 47.0° ----
Lock to lock angle right 47.0° ----
Front suspension
Front fork travel 90 mm (3.54 in) ----
Fork spring free length 297.7 mm (11.72 in) 291.8 mm
(11.5 in)
Installed length 287.7 mm (11.33 in) ----
Spring rate (K1) 7.8 N/m (44.54 lb/in) (0.8 kgf/mm) ----
(K2) 15.6 N/m (89.08 lb/in) (1.59 kgf/mm) ----
Stroke (K1) 0 – 60 mm (0 – 2.36 in) ----
(K2) 60 – 90 mm (2.36 – 3.54 in) ----
Optional spring available No ----
Oil capacity 63.0 mm3 (2.13 US oz) (2.22 Imp. oz) ----
Oil level 106 mm (4.17 in) ----
Recommended oil Fork oil 10 W or equivalent ----
Inner tube outer diameter 26 mm (1.02 in) ----
Inner tube vend limit ---- 0.2 mm
(0.008 in)
Rear suspension
Shock absorber stroke 62.0 mm (2.44 in) ----
Spring free length 263.5 mm (10.37 in) 258.2 mm
(10.2 in)
Installed length 209 mm (8.23 in) ----
Spring rate (K1) 16 N/m (91.36 lb/in) (1.63 kgf/mm) ----
(K2) 48 N/m (274.08 lb/in) (4.89 kgf/mm) ----
Stroke (K1) 0 – 35 mm (0 – 1.38 in) ----
(K2) 35 – 62 mm (1.38 – 2.44 in) ----
Optional spring available No ----

–4–
 MAINTENANCE SPECIFICATIONS/LUBRICATION
POINTS AND LUBRICANT TYPES SPEC

Item Standard Limit

Front wheel
Type Cast wheel
Rim size 16 × 1.40 ----
Rim material Aluminum ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)
Rear wheel
Type Cast wheel
Rim size 16 × 1.60 ----
Rim material Aluminum ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)

TIGHTENING TORQUES
CHASSIS

Tightening torque
Part to be tightened Thread size Remarks
Nm m·kg ft·lb
Engine mounting rubber damper and engine M8 17 1.7 12
bracket
Center cover M6 7 0.7 5.1
Battery box M6 4 0.4 2.9
Grab bar M6 10 1.0 7.2
Handlebar nut M10 53 5.3 39

ELECTRICAL
Item Standard Limit
DC.C.D.I.
Pickup coil resistance 248 – 372 Ω at 20°C, W/L – W/R ----
C.D.I. unit model/manufacturer 5TL/YIMM ----

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE
Lubrication point Lubricant
Camshaft O-ring

–5–
 CABLE ROUTING SPEC
CABLE ROUTING
1 Right handlebar switch lead å Pass the left handlebar switch ∂ Fasten the rear brake cable,
2 Left handlebar switch lead lead behind the handlebar and speedometer cable, and throt-
3 Rear brake light switch lead over the rear brake cable, and tle cable with a plastic locking
4 Rear brake cable then connect it in front of the tie, making sure that the paint
5 Speedometer cable meter assembly. marks on the rear brake cable
6 Wire harness ∫ Connect the brake light switch and throttle cable are aligned
7 Front brake hose coupler in front of the rear with the guide weld.
8 Throttle cable brake cable.
9 Front brake light switch lead ç Pass the right handlebar switch
0 Plug lead behind the handlebar, and
then connect it in front of the
meter assembly.

1 2

0å
ç 9 3
8 4
7 6 5 ∫
B
4
1 8

A-A
6
B

–6–
 CABLE ROUTING SPEC
1 Rear brake cable w Turn signal relay lead
2 Throttle cable e Main switch lead
3 Seat lock cable r Horn lead
4 Cylinder head breather hose t Turn signal relay
5 Air vent hose
6 Fuel overflow hose å Fasten the throttle cable, rear brake cable, and
7 Battery speedometer cable with a plastic locking tie.
8 Speedometer cable ∫ Fasten the cylinder head breather hose with the
9 Front brake hose holders on the carburetor joint.
0 Horn ç Fasten the air vent hose with the holder.
q Headlight unit assembly lead coupler

9
r 8
t
r 0
8
e 9
w D
A q

D
B
B A

C 5
E 4
C 1
2
3
8

1 2 1 2 7 6
B-B C-C

–7–
 CABLE ROUTING SPEC
∂ Face the formed part toward font side of the vehicle
and clamp the naked area.
´ Pass the cylinder head breather hose through the
guide.
ƒ Fasten the cylinder head breather hose with the
holder on the intake manifold.
© Be careful not to bend while installing.

9
r 8
t
r 0
8
e 9
w D
A q

D
B
B A

C 5
E 4
C 1
2
3
8

1 2 1 2 7 6
B-B C-C

–8–
 CABLE ROUTING SPEC
1 Seat lock cable å Use the holder to hold the vacuum hose and fuel
2 Fuel hose hose to frame side as shown.
3 Vacuum hose ∫ Pass the drain hose, vacuum hose, and fuel hose
4 Drain hose through the guide.
5 Rear brake cable ç Make sure that the metal clip does not interfere with
the vacuum hose, when clamping it to the fuel
hose.
∂ Make sure that the metal clip does not interfere with
the fuel hose, when clamping it to the vacuum
hose.

3
3
2 2
2
3
C
A-A B-B
4
3
12

A
B C

F E D
G

F 5 E D
5 G

5
5
5
F-F G-G E-E D-D

–9–
 CABLE ROUTING SPEC
1 Air induction system hose (air cut-off valve assem- q Front brake hose
bly to air filter case) w Starter relay
2 Thermo switch lead e Starter relay lead
3 Negative battery lead r Positive battery lead
4 Starter motor lead t Battery breather hose
5 Ground lead y Battery
6 Seat lock cable u Auto choke unit lead
7 Wire harness i Thermo switch
8 Turn signal relay o Battery band
9 Horn lead p Fuel hose
0 Headlight unit assembly lead coupler

p 4 8 9
7
7
u3
6
G F-F A-A

6 6
4 4

7 7
7 7
A 0
u u B-B
3 H-H 3 E-E
A
q
1 6
2
3 5
4
B
H F E
B

C C
H
I G
E w
F D
D

I
e
y

r 4 r
y
i u2 t r
o 4
1 3
t 7 7
D-D C-C
I-I

–10–
 CABLE ROUTING SPEC
å Pass the wire harness, negative battery lead, and ´ Fasten the main switch lead and wire harness with
starter motor lead through the guide. a plastic clamp.
∫ There should be no slack in the auto choke unit ƒ Fasten the positive battery lead, starter motor lead,
lead. and wire harness with a plastic band.
ç Align the white tape of the wire harness with the © There should be no slack in the thermo switch lead.
holder. ˙ Install the clamp so that its ends are within the 90°
∂ Pass a plastic locking tie through the hole in the range shown in the illustration.
front cover stay, and then fasten the wire harness ˆ Route the positive battery lead in front of the nega-
at the white tape with the tie. tive battery terminal.

p 4 8 9
7
7
u3
6
G F-F A-A

6 6
4 4

7 7
7 7
A 0
u u B-B
3 H-H 3 E-E
A
q
1 6
2
3 5
4
B
H F E
B

C C
H
I G
E w
F D
D

I
e
y

r 4 r
y
i u2 t r
o 4
1 3
t 7 7
D-D C-C
I-I

–11–
 CABLE ROUTING SPEC
∆ Fasten the starter motor lead, wire harness, and ¬ Left side
positive battery lead with a plastic band. The end of µ Right side
the plastic band should be facing rearward so that ˜ Install the plastic locking tie so that its buckle and
it does not contact the side panel (right). end are within the 90° range shown in the illustra-
˚ Do not pinch the negative battery lead, starter tion.
motor lead, and auto choke unit lead between the ø Cut the clamp end maximum 5 mm.
wire harness and frame. π Cut the clamp end less than 5 mm.

p 4 8 9
7
7
u3
6
G F-F A-A

6 6
4 4

7 7
7 7
A 0
u u B-B
3 H-H 3 E-E
A
q
1 6
2
3 5
4
B
H F E
B

C C
H
I G
E w
F D
D

I
e
y

r 4 r
y
i u2 t r
o 4
1 3
t 7 7
D-D C-C
I-I

–12–
 CABLE ROUTING SPEC
1 Fuel sender lead 0 A.C. magneto lead
2 Seat lock cable q Rectifier/regulator
3 Ignition coil w C.D.I. unit
4 Wire harness e Tail/brake light unit assembly lead
5 Spark plug lead r Negative battery lead
6 Thermo switch lead
7 Air induction system hose (air cut-off valve assem- å Place the tail/brake light unit assembly coupler
bly to air filter case) between the frame and C.D.I. unit.
8 Air induction system pipe ∫ Make sure that the rubber cover does not pinch the
9 Starter motor lead seat lock cable and the fuel sender lead.

4
4 0

A-A B-B

1
2 C-C

3
A
4
5
6
C 7

A
B
e w C
B

q D E
0

D E
6 9
6 r
7
7
5 9

D-D E-E

–13–
 CABLE ROUTING SPEC
ç Pass the wire harness through the guide. ∆ When passing the thermo switch lead through the
∂ Install the plastic locking tie side of the bracket weld guide, place it in the corner of the guide as shown
on the frame. in the illustration.
´ Install the plastic locking tie side of the bracket weld ˚ Left side
on the frame. ¬ Right side
ƒ Fasten the wire harness, rectifier lead and thermo
switch lead with a plastic locking tie.
© 10 mm (0.39 in)
˙ 60 mm (2.36 in)
ˆ Fasten the A.C. magneto lead and thermo switch
lead with a plastic clamp.

4
4 0

A-A B-B

1
2 C-C

3
A
4
5
6
C 7

A
B
e w C
B

q D E
0

D E
6 9
6 r
7
7
5 9

D-D E-E

–14–
 CABLE ROUTING SPEC
1 Air vent hose q Throttle cable
2 Wire harness
3 Seat lock cable
4 Starter motor lead
5 Negative battery lead
6 Starter motor
7 Fuel hose
8 Vacuum hose
9 Drain hose
0 Cylinder head breather hose

4 5

0
A-A
1

9
2
8
3
7
A A
4
5

–15–
 CABLE ROUTING SPEC
1 Starter motor lead å Install the plastic clip in the direction shown.
2 Negative battery lead ∫ Fasten the seat lock cable and fuel sender lead
3 A.C. magneto lead with a metal holder.
4 Thermo switch lead
5 Wire harness
6 Seat lock cable
7 Fuel sender
8 Fuel sender lead

1 2 3 4 5

–16–
 CHK
SIDE COVER ADJ
PERIODIC CHECKS AND
ADJUSTMENTS
SIDE COVER
REMOVING THE SIDE COVER
1. Remove:
9 side panel (left and right) 1
2. Open the seat.

3. Remove:
9 rear panel 1
1 NOTE:
Remove the rear panel by sliding it in the direc-
tion of the arrow shown.

4. Remove:
1
9 grab bar 1
2
9 side cover (left and right) 2
NOTE:
Remove the side cover by sliding it in the direc-
tion of the arrow shown.

INSTALLING THE SIDE COVER

2
1 1. Install:
9 side cover (left and right) 1
9 grab bar 2
9 grab bar bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
9 When installing the side cover, slightly pull
a b
section a of the center cover away from the
machine to fit the projection on the side
cover into the slot in the center cover. Before
tightening the side cover screws, make sure
that all hooks are securely fitted.
9 After installing the side cover, make sure that
the section b of the cover is under the rear
fender.

–17–
 CHK
SIDE COVER/LEG SHIELD ADJ
2. Install:
9 rear panel 1
1
NOTE:
When installing the rear panel, be sure to align
the projections a on the panel with the slots in
å a b the left and right side covers and align the pro-
å
jection b on the panel with the slot in the tail/
brake light unit assembly.

3. Install:
9 side panel (left and right) 1

LEG SHIELD
REMOVING THE LEG SHIELD
2
3 1. Remove:
9 side cover (left and right)
Refer to “SIDE COVER”.
2. Remove:
9 footboard mat (left and right) 1
1 9 footboard (left and right) 2
NOTE:
Remove the battery breather hose 3 that pass-
es through the hole in the right footboard.

–18–
 CHK
LEG SHIELD ADJ
3. Remove:
9 front cover 1
9 front panel 2
9 bottom cover
NOTE:
9 When removing the front cover, pull it away
from the leg shield starting at the top.
9 Disconnect the headlight unit assembly cou-
pler 3.

4. Remove:
9 seat 1
1

5. Remove:
1 9 center cover 1

–19–
 CHK
LEG SHIELD ADJ
6. Remove:
9 hook 1
9 main switch cover 2
9 leg shield 3

INSTALLING THE LEG SHIELD

1. Install:
9 leg shield
9 main switch cover
9 hook
9 center cover
2. Install:
9 seat
9 seat nuts 7 Nm (0.7 m•kg, 5.1 ft•lb)

3. Install:
9 bottom cover
9 front panel
9 front cover 1
NOTE:
9 Connect the headlight unit assembly coupler
2.
9 When installing the front cover, insert the
tabs on the leg shield into the slots in the
cover starting at the bottom.

4. Install:
9 footboard (left and right) 1
9 footboard mat (left and right) 2
1 NOTE:
3
Pass the battery breather hose 3 through the
hole in the right footboard.

5. Install:
2 9 side cover (left and right)
Refer to “SIDE COVER”.

–20–
 CHK
CHECKING THE EXHAUST SYSTEM ADJ
ENGINE
EAS00100

CHECKING THE EXHAUST SYSTEM

1. Remove:
9 footboard (right)
Refer to “LEG SHIELD”.

2. Check
9 exhaust pipe 1
9 muffler 2
Cracks/damage → Replace.
5 Exhaust gas leaks → Replace the gasket.
3. Check:
5 9 tightening torque

Exhaust pipe nut 3

20 Nm (2.0 m·kg, 14 ft·lb)
Muffler clamp bolt 4
4 2 12 Nm (1.2 m·kg, 8.7 ft·lb)
1 Muffler bolt 5
53 Nm (5.3 m·kg, 38 ft·lb)

4. Install:
3 9 footboard (right)
Refer to “LEG SHIELD”.

–21–
 CYLINDER HEAD ENG

EASF0221
ENGINE
CYLINDER HEAD

1 Cylinder head 8 Plate t O-ring

2 Spark plug 9 Timing chain guide (exhaust side) y Intake manifold
3 O-ring 0 O-ring u Air shroud
4 Tappet cover q Camshaft sprocket cover i Rubber cover
5 Thermo switch w Dowel pin o Air duct
6 Thermo switch bracket e Gasket p Timing chain tensioner
7 Camshaft sprocket r Gasket a Gasket

9 Nm (0.9 m•kg, 6.5 ft•lb)

o

T.
R.
10 Nm (1.0 m•kg, 7.2 ft•lb)
T.
R.

u a
New

y i

LS t
New
13 Nm (1.3 m•kg, 9.4 ft•lb)
T.

r
R.

18 Nm (1.8 m•kg, 13 ft•lb)

T.
R.

4
3 1w New
u
2 e

5 6
w 30 Nm (3.0 m•kg, 22 ft•lb)
T.
R.

3 7
8

E 4 9
10 Nm (1.0 m•kg, 7.2 ft•lb)
T.
R.

22 Nm (2.2 m•kg, 16 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb)

T.
R.
T.
R.

LS 0
23 Nm (2.3 m•kg, 17 ft•lb) q
T.
R.

12 Nm (1.2 m•kg, 8.7 ft•lb)

T.
R.

–22–
 CYLINDER HEAD ENG
EAS00210

CHECKING THE TIMING CHAIN

1 TENSIONER
1. Check:
9timing chain tensioner
Cracks/damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. Remove the screwdriver 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
9cap bolt
9one-way cam
9timing chain tensioner rod
Damage/wear → Replace the timing chain
tensioner.

EAS00231

2
INSTALLING THE CYLINDER HEAD
1. Install:
9timing chain guide (exhaust side) 1
New 3 9dowel pins 2
9gasket 3
2. Install:
1 9cylinder head 1
9thermo switch bracket 2
3. Tighten:
9cylinder head nuts
22 Nm (2.2 m•kg, 16 ft•lb)
9cylinder head bolts
1 5
3 10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
9 Lubricate the cylinder head nuts with engine
4
2 6 oil.
2
1 9 Tighten the cylinder head nuts and bolts in
the proper tightening sequence as shown
and torque them in two stages.
–23–
 CYLINDER HEAD ENG
4. Tighten:
1 9thermo switch 1
23 Nm (2.3 m•kg, 17 ft•lb)
5. Connect:
9thermo switch coupler

6. Install:
1 9camshaft sprocket 1
9timing chain 2
d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
c b. Align the “I” mark a on the generator rotor
with the stationary pointer b on the crank-
2 case.
c. Align the “I” mark c on the camshaft sprock-
et with the stationary pointer d on the cylin-
der head.
b d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
9When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
a the exhaust side.
9Align the projection e on the camshaft sprock-
et with the slot in the camshaft.

e
cC
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

e. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

–24–
 CYLINDER HEAD ENG
7. Install:
9timing chain tensioner
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.

1 b. Install the gasket and the timing chain ten-

2 sioner 2 onto the cylinder.

w
Always use a new gasket.

Timing chain tensioner bolt

9 Nm (0.9 m·kg, 6.5 ft•lb)

c. Turn the timing chain tensioner rod counter-

clockwise with a thin screwdriver 1, make
sure it releases, and then install the cap.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8. Tighten:
9camshaft sprocket bolt
30 Nm (3.0 m•kg, 22 ft•lb)
cC
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibili-
ty of the bolt coming loose and damaging the
engine.

9. Turn:
9crankshaft
(several turns clockwise)

–25–
 CYLINDER HEAD ENG
10. Check:
9“I” mark a
b
Align the “I” mark on the generator rotor
with the stationary pointer b on the crank-
case.
9“I” mark c
Align the “I” mark on the camshaft sprocket
with the stationary pointer d on the cylinder
a head.
Out of alignment → Correct.
Refer to the installation steps above.

11. Measure:
9valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
(Manual No.: 5MX-F8197-E0)
12. Install:
9intake manifold
9intake manifold bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
13. Install:
9tappet cover (exhaust side)
9tappet cover (intake side)
18 Nm (1.8 m•kg, 13 ft•lb)
9camshaft sprocket cover
9camshaft sprocket cover bolts
12 Nm (1.2 m•kg, 8.7 ft•lb)
14. Install:
9spark plug 13 Nm (1.3 m•kg, 9.4 ft•lb)

–26–
 KICK STARTER ENG
EASF0338

KICK STARTER
1 V-belt case cover protector 1 8 V-belt case air filter cover t Washer
2 Dowel pin 9 Kickstarter pinion gear
3 V-belt case cover 0 Kickstarter pinion gear clip
4 V-belt case cover protector 2 q Spacer
5 Kickstarter crank w Kickstarter spring
6 Oil seal e Kickstarter shaft
7 Circlip r Kickstarter shaft plate

9 Nm (0.9 m•kg,6.5 ft•lb)

23 Nm (2.3 m•kg,17 ft•lb)

LS

r
10 Nm (1.0 m•kg,7.2 ft•lb)
q 2
t
e 3
4
w
0
9
LS

M 7
6 New
LS 5

11 Nm (1.1 m•kg,8.1 ft•lb)

10 Nm (1.0 m•kg,7.2 ft•lb)

–27–
 KICK STARTER ENG
INSTALLING THE KICKSTARTER
1. Install:
9 dowel pins
9 V-belt case cover
9 V-belt case cover bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)

cC
Inject the grease (0.5-1.0 cm3) into the inner
race of the ball bearing inside of the V-belt
case cover before install it.

9 V-belt case cover protector 2

9 V-belt case cover protector 2 bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
9 kickstarter crank
9 kickstarter crank bolt
11 Nm (1.1 m•kg, 8.1 ft•lb)
2. Install:
9 V-belt case air filter cover
9 V-belt case air filter cover bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
9 V-belt case cover protector 1
9 V-belt case cover protector 1 bolts
23 Nm (2.3 m•kg, 17 ft•lb)

–28–
 STARTER CLUTCH ENG
EASF0341

STARTER CLUTCH
1 Idle gear plate
2 Idle gear
3 Starter clutch assembly
4 Circlip
5 Starter wheel gear
6 Bearing

10 Nm (1.0 m•kg, 7.2 ft•lb)

T.
R.
LS
2
1

5
4

3
LT

10 Nm (1.0 m•kg, 7.2 ft•lb)

T.

–29–
 STARTER CLUTCH ENG
REMOVING THE STARTER CLUTCH
1. Remove:
9primary sliding sheave
Refer to “BELT DRIVE”.
(Manual No.: 5MX-F8197-E0)

1 2. Remove:
9idle gear plate 1
9washer
9idle gear 2
2
9washer
3 9starter clutch assembly 3

3. Remove:
9circlip 1
2 9starter wheel gear 2
1

EAS00355

INSTALLING THE STARTER CLUTCH

2
1. Install:
9starter wheel gear 1
9circlip
1 9starter clutch assembly 2
NOTE:
Install the starter wheel gear 1 while turning
the starter clutch assembly 2 counterclock-
wise.

Recommended lubricant
Shell Dolium grease R

2. Install:
9idle gear plate
9idle gear plate bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)

–30–
 CARBURETOR CARB
EASF0480

CARBURETOR
CARBURETOR
1 Vacuum chamber cover 9 Auto choke unit G Main jet
2 Piston valve spring 0 Throttle stop screw set H Needle valve
3 Jet needle set A Coasting enricher spring I Float
4 Piston valve B Coasting enricher J Float pivot pin
5 Air vent hose C Pilot jet K Gasket
6 Pilot screw set D Cap L Fuel drain screw
7 Auto choke unit housing E Main nozzle M Float chamber
8 Gasket F Needle jet N Fuel overflow hose

1
5

4 0

6
9

7
8
New C
E
H F
D
K New G
I
B
A
L J

M
N

–31–
 CARBURETOR CARB
CHECKING THE AUTO CHOKE UNIT
NOTE:
When checking the auto choke unit, the ambi-
ent temperature must be lower than 45°C.

1. Remove:
• carburetor:
Refer to “CARBURETOR” in chapter 5.
(Manual No.: 5MX-F8197-E0)

2. Check:
• auto choke unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a 3.3 mm hose 1 to the starter air
passage 2 and blow into the hose.
2 NOTE:
When the starter plunger is open, air should
1 come out of the other side of the starter air
passage.

Air can be blown through the hose →

Perform step (3).
Air cannot be blown through the hose →
Replace the auto choke unit.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• auto choke unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the auto choke unit leads to a
12.0 V battery for five minutes.
2
1
Positive battery lead 1 → black
Negative battery lead 2 → black

b. Connect a 3.3 mm hose 3 to the starter air

B 4 passage 4 and blow into the hose.
B

3 Air can be blown through the hose →

Replace the auto choke unit.
Air cannot be blown through the hose →
Auto choke is OK.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• carburetor
Refer to “CARBURETOR” in chapter 5.
(Manual No.: 5MX-F8197-E0)

–32–
 CARBURETOR CARB
EAS00507

AIR INDUCTION SYSTEM

AIR INJECTION
The air induction system burns unburned
exhaust gases by injecting fresh air (second-
ary air) into the exhaust port, reducing the
emission of hydrocarbons.
When there is negative pressure at the
exhaust port, the reed valve opens, allowing
secondary air to flow into the exhaust port. The
required temperature for burning the unburned
exhaust gases is approximately 600 to 700 °C
(1,112 to 1,292 °F).

EAS00508
AIR CUT-OFF VALVE
The air cut-off valve is operated by the intake
1 gas pressure through the piston valve dia-
phragm. Normally, the air cut-off valve is open
Ê
to allow fresh air to flow into the exhaust port.
È During sudden deceleration (the butterfly valve
suddenly closes), negative pressure is gener-
ated and the air cut-off valve is closed in order
to prevent after-burning.
Additionally, at high engine speeds and when
the pressure decreases, the air cut-off valve
É automatically closes to guard against a loss of
performance due to self-EGR (Exhaust Gas
Recirculation).
1 During normal operation, the air cut-off valve is
open.
2 During sudden deceleration (the butterfly valve
2 3 suddenly closes), the air cut-off valve closes.
3 At high engine speeds and when the pressure
decreases, the air cut-off valve is open.
È From the air filter case
É To the cylinder head
Ê To the intake manifold

–33–
 CARBURETOR CARB
1 Cover
2 Air induction system hose (air cut-off valve assembly to air filter case)
3 Air induction system vacuum hose
4 Air induction system hose (air cut-off valve assembly to air induction system pipe)
5 Air induction system pipe
6 Gasket
7 Air cut-off valve assembly
8 Air induction system bracket

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.

4
2

8
3

30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.

6 New

8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.

–34–
 HANDLEBAR CHAS

EASF0664
CHASSIS
HANDLEBAR
1 Rear view mirror
2 Throttle grip
3 Handlebar
4 Throttle cable
5 Rear brake cable
6 Rear brake lever
7 Handlebar grip

32 Nm (3.2 m•kg, 23 ft•lb)

3 7 Nm (0.7 m•kg, 5.2 ft•lb)

4 7

53 Nm (5.3 m•kg, 39 ft•lb)

–35–
 HANDLEBAR CHAS
EASF0666
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
NOTE:
_

Make sure the vehicle is upright.

2. Remove:
• handlebar cover (front and rear)
• brake master cylinder
Refer to “FRONT BRAKE” in chapter 6.
(Manual No.: 5MX-F8197-E0)
NOTE:
_

It is not necessary to disconnect the brake

hose when the brake fluid has been removed.

3. Remove:
1 • meter assembly 1
4. Disconnect:
• speedometer cable
• meter assembly coupler 2
3 • right handlebar switch coupler 3
• left handlebar switch couplers 4
2 5 • rear brake light switch coupler 5
4

5. Remove:
1 • plastic locking tie 1
• wire harness 2

6. Remove:
• right handlebar switch screws 1
2
• right handlebar switch 2

–36–
 HANDLEBAR CHAS
7. Remove:
• throttle cable 1
• throttle grip 2
2

8. Remove:
2 1 • left handlebar switch screws 1
• left handlebar switch 2

9. Remove:
• rear brake light switch 1

10.Remove:
1 • handlebar grip 1
NOTE:
_

Blow compressed air between the handlebar

and the handlebar grip, and gradually push the
grip off the handlebar.

11.Remove:
1 • rear brake cable 1
• rear brake lever bolt 2
• rear brake lever holder 3

2 3

–37–
 HANDLEBAR CHAS
12.Remove:
• handlebar nut 1
• handlebar bolt 2
3 • handlebar 3

–38–
 REAR SHOCK ABSORBER ASSEMBLY AND
REAR SUSPENSION ARM CHAS
EASF0685

REAR SHOCK ABSORBER ASSEMBLY AND REAR SUSPENSION ARM

1 Rear shock absorber (right)
2 Rear shock absorber (left)
3 Axle nut
4 Collar
5 Oil seal
6 Bearing
7 Collar
8 Air induction system bracket
9 Rear suspension arm

30 Nm (3.0 m•kg, 22 ft•lb)

T.
R.
1
104 Nm (10.4 m•kg, 75 ft•lb)
T.
R.

16 Nm (1.6 m•kg, 11 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb)

T.
R.

T.
R.

8
3
4
5
LS 2

6
7
4

LS

16 Nm (1.6 m•kg, 11 ft•lb)

T.
R.

30 Nm (3.0 m•kg, 22 ft•lb)

T.
R.

–39–
 CHECKING THE SWITCHES ELEC
ELECTRICAL
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY” in chapter 7. (Manual No.: 5MX-F8197-E0)
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.

1 2 3 4 5
Y P
Y/R L — Y L G Ch Br/W Dg L Y/R
OFF OFF HI L
G B
B PUSH PO LO N
B ON R
Dg

(BLACK) Br/W
Ch

6 7
L/W B
OFF
START L/W Br
B G/Y

8
Br R
R
OFF
Br
ON

–40–
 CHECKING THE SWITCHES ELEC

1 Rear brake light switch

2 Horn switch
3 Light switch
4 Dimmer switch
5 Turn signal switch
6 Start switch
7 Front brake light switch
8 Main switch
9 Main fuse

–41–
 R R
1 Main switch
Y/B Y/B 7 2 Battery EAS00780
R Y/B
1 Br B O
3 Main fuse
OFF R R W B W/R W/L Y/B 6 Rectifier/ regulator
ON Br Br R Y

(BLACK) 8 A. C. magneto
Br R
W W W /L W/L O O
a Light switch
R 6 Y Y/R
8 W /R W/R w Y/B
e
Br
s Dimmer switch
W W
B
Y/R Y/R
h Tail/ brake light
B B r
l Auxiliary light
CIRCUIT DIAGRAM

B B

R
W/L W/R W/R W/L
; Headlight
R
LIGHTING SYSTEM

3 B
x High beam indicator light
L/W Br/Y

(BLACK) v Meter light

Br/Y Y/B

R 9
4
R L/W L/W
t
B Y/B
B 0 B B

OFF
q
B
START
B
2
B
5 Br L/W L/W Br

B G/Y B B G/Y
B

B
B Br G/Y

–42–
Br Br

y
i Br/W Br B

Br
u G/Y B

(BLACK) (BLACK)
Br
P Br/W G/Y
z Br Ch Dg Y
o P Y /R Br/W

P Y Y P
p a s d
Y/R L L Y/ R
OFF OFF HI L
Br Y Y Br vv c c x B G G B
PUSH PO LO N
G Ch Ch G b ON R
B Dg Dg B Dg Dg

Br/W Br/W
(BLACK) (BLACK)
Ch Ch

B L Y G Ch Dg
LIGHTING SYSTEM

G B

G Ch Dg L G/Y

j Ch L Y G Dg f
G G

B B L g g h
ELEC

G Y Y G k ; ; k B L L B
n (GREEN)
B L L B Y G/Y

Dg Ch Ch Dg Ch Dg Dg Ch

B
l l

B B
 LIGHTING SYSTEM ELEC
EAS00781 EAS00739

TROUBLESHOOTING 2. Battery
Any of the following fail to light: head light, 9Check the condition of the battery.
high beam indicator light, auxiliary light, refer to “CHECKING AND CHARGING THE
taillight or meter light. BATTERY” in chapter 3 (Manual No.: 5MX-
F8197-E0).
Check:
1. main fuse Minimum open-circuit voltage
2. battery 12.8 V or more at 20°C (68°F)
3. main switch
9Is the battery OK?
4. light switch
5. wiring connections
YES NO
(of the entire lighting system)
NOTE: 9Clean the battery
9Before troubleshooting, remove the following terminals.
part(-s):
9Recharge or
1. rear panel
2. side panel (right) replace the battery.
3. side panel (left)
EAS00783
4. side cover (right)
5. side cover (left) 3. Main switch
6. front cover 9Check the main switch for continuity.
7. handlebar cover Refer to “CHECKING THE SWITCHES”.
9Troubleshoot with the following special tool(s). 9Is the main switch OK?

Pocket tester YES NO

90890-03112

EAS00738
Replace the main
switch
1. Main fuse
9Check the main fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 4. Light switch
3 (Manual No.: 5MX-F8197-E0).
9Check the light switch for continuity.
9Is the light fuse OK?
Refer to “CHECKING THE SWITCHES”.
9Is the light switch OK?
YES NO

YES NO
Replace the fuse.
Replace the light
switch

–43–
 LIGHTING SYSTEM ELEC
EAS00779 EAS00788

5. Wiring CHECKING THE LIGHTING SYSTEM

1. The headlight and high beam indicator light
9Check the wiring connections of the entire
fail to come on.
charging system.
EAS00784
Refer to “CIRCUIT DIAGRAM”.
9Is the charging system wiring properly con- 1. Dimmer switch
nected and without defects?
9Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
YES NO
9Is the dimmer switch OK?

Check the condition Properly connect or

YES NO
of each of the light- repair the lighting
ing system’s cir- system’s wiring.
The dimmer switch
cuits.
is faulty. Replace
Refer to “CHECK-
the left handlebar
ING THE LIGHT-
switch.
ING SYSTEM”.

2. Headlight bulb and socket

9Check the headlight bulb and socket for con-
tinuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS” (Manual No.: 5MX-F8197-
E0).
9Are the headlight bulb and socket OK?

YES NO

Replace the head-

light bulb, socket or
both.

–44–
 LIGHTING SYSTEM ELEC

3. Voltage 9Set the main switch to “ON”.

9Connect the pocket tester (AC 20 V) to the 9Start the engine.
headlight and high beam indicator light cou- 9Set the dimmer switch to “PO” or “ON”.
pler as shown. 9Set the dimmer switch to “%” or “&”.
åWhen the dimmer switch is set to “%”. 9Measure the voltage (AC 12 V) of green 1
∫When the dimmer switch is set to “&”. (yellow 2) on the headlight coupler (wire har-
Headlight coupler (wire harness side) ness side) and yellow 4 on the meter
assembly coupler (wire harness side).
∫ 9Is the voltage within specification?
AC20V 1 2
YES NO
G Y
å
B L
The wiring circuit from
Dg Ch
3 the main switch to the
headlight coupler or
Headlight meter assembly cou-
Positive tester probe → pler is faulty and must
green 1 or yellow 2 be repaired.
Negative tester probe → black 3
Meter assembly coupler (wire harness side)

Y Br Br Y
Ch G G Ch
Dg B B Dg

High beam indicator light

Positive tester probe → yellow 4
Negative tester probe → black 5

–45–
 LIGHTING SYSTEM ELEC
EAS00776 EAS00789

4. Lighting coil resistance 2. The meter light fails to come on.

9Connect the pocket tester (Ω × 1) to the light- 1. Meter light bulb and socket
ing coil terminals as shown.
9Check the meter light bulb and socket for
Positive tester probe → yellow/red 1 continuity.
Negative tester probe → black 2 Refer to “CHECKING THE BULBS AND
BULB SOCKETS” (Manual No.: 5MX F8197-
E0).
9Are the meter light bulb and socket OK?

YES NO

B Y/R W W/R W/L Replace the meter

light bulb, socket or
2 1 both.
9Measure the lighting coil resistances.
Lighting coil resistance 2. Voltage
0.24–0.36 Ω at 20°C (68°F) (Y/R – B)
9Connect the pocket tester (DC 20 V) to the
9Is the lighting coil OK? meter light coupler (wire harness side) as
shown.
YES NO Positive tester probe → brown 1
Negative tester probe → black 2
This circuit is OK. Replace the stator
coil coil assembly.
1
Y Br Br Y
Ch G G Ch
Dg B B Dg

9Set the main switch to “ON”.

9Start the engine.
9Measure the voltage (DC 12 V) of brown lead
terminal 1 on the meter light coupler (wire
harness side).
9Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit from

the main switch to the
meter assembly cou-
pler is faulty and must
be repaired.

–46–
 LIGHTING SYSTEM ELEC
EAS00790 EAS00776

3. The tail/brake light fails to come on. 3. Lighting coil resistance

1. Tail/brake light bulb, and socket 9Connect the pocket tester (Ω × 1) to the light-
ing coil terminals as shown.
9Check the tail/brake light bulb and socket for
continuity. Positive tester probe → yellow/red 1
Refer to “CHECKING THE BULBS AND Negative tester probe → black 2
BULB SOCKETS” (Manual No.: 5MX-F8197-
E0).
9Are the tail/brake light bulb and socket OK?

YES NO

B Y/R W W/R W/L

Replace the tail/
brake light bulb, 2 1
socket or both.
9Measure the lighting coil resistances.
Lighting coil resistance
2. Voltage
0.24–0.36 Ω at 20°C (68°F) (Y/R – B)
9Connect the pocket tester (AC 20 V) to the
9Is the lighting coil OK?
tail/brake light coupler (wire harness side) as
shown.
YES NO
Positive tester probe → blue 1
Negative tester probe → black 2 Replace the stator
This circuit is OK.
coil coil assembly.
1 2

B L L B
Y G/Y
Ch Dg Dg Ch

9Set the main switch to “ON”.

9Start the engine.
9Measure the voltage (AC 12 V) of blue lead
terminal 1 on the tail/brake light coupler
(wire harness side).
9Is the voltage within specification?

YES NO

The wiring circuit from

the main switch to the
tail/brake light is faulty
and must be repaired.

–47–
 LIGHTING SYSTEM ELEC
EAS00776
4. The auxiliary light fails to come on.
3. Lighting coil resistance
1. Auxiliary light bulb, and socket
9Connect the pocket tester (Ω × 1) to the light-
9Check the auxiliary light light bulb and socket ing coil terminals as shown.
for continuity.
Positive tester probe → yellow/red 1
Refer to “CHECKING THE BULBS AND
Negative tester probe → black 2
BULB SOCKETS” (Manual No.: 5MX-F8197-
E0).
9Are the auxiliary light bulb and socket OK?

YES NO

Replace the auxil- B Y/R W W/R W/L

iary light light bulb,
socket or both. 2 1

9Measure the lighting coil resistances.

2. Voltage
Lighting coil resistance
9Connect the pocket tester (AC 20 V) to the 0.24–0.36 Ω at 20°C (68°F) (Y/R – B)
headlight coupler (wire harness side) as
shown. 9Is the lighting coil OK?
Positive tester probe → blue 1
YES NO
Negative tester probe → black 2
Headlight coupler (wire harness side) This circuit is OK. Replace the stator
coil coil assembly.

AC20V
1
G Y
B L
Dg Ch
2

9Set the main switch to “ON”.

9Start the engine.
9Measure the voltage (AC 12 V) of blue lead
terminal 1 on the headlight coupler (wire
harness side).
9Is the voltage within specification?

YES NO

The wiring circuit from

the main switch to the
auxiliary light is faulty
and must be repaired.

–48–
 R R
Y/B Y/B 7
R Y/B
1 Br B O
OFF R R W B W/R W/L Y/B
ON Br Br R Y
(BLACK)

Br R W W W/L W/L O O
R 6 Y Y/R 8 W/R W/R w Y/B e
Br
W W
CIRCUIT DIAGRAM

B
Y/R Y/R
B B r
B B

R W/L W/R W/R W/L

R
3 L/W Br/Y B
AUTO CHOKE SYSTEM

(BLACK)
Br/Y Y/B
R 9
4
R L/W L/W
t
B Y/B
B 0 B B
OFF q
B
2 START
B
B
5 Br L/W L/W Br
B G/Y B B G/Y
B

B B Br G/Y

–49–
B

Br Br

y
i Br/W Br B

Br
u G/Y B

(BLACK) (BLACK)
Br
P Br/W G/Y
z Br Ch Dg Y
o P Y/R Br/W

P Y Y P p a s d
Y/R L L Y/R
AUTO CHOKE SYSTEM

OFF OFF HI L
Br Y Y Br vv c c x B G G B
PUSH PO LO N
G Ch Ch G b ON R
B Dg Dg B Dg Dg
Br/W Br/W
(BLACK) (BLACK) Ch Ch

B L Y G Ch Dg

2 Battery G B
ELEC

3 Main fuse
7 Thermo switch G Ch Dg L G/Y

w C.D.I. unit j Ch L Y G Dg f
t Auto choke unit G G
B B L g g h
k ; ; k
 AUTO CHOKE SYSTEM ELEC
TROUBLESHOOTING 3. Thermo switch
The auto choke system fails to operate. • Remove the thermo switch from the cylin-
der head.
Check: • Connect the pocket tester (Ω × 1) to the
1. main fuse thermo switch 1 as shown.
2. battery • Immerse the thermo switch in a container
3. thermo unit filled with water 2.
4. auto choke unit NOTE:
_

5. wiring connections Make sure that the thermo switch terminals

(of the entire lighting system) do not get wet.
NOTE:
9Before troubleshooting, remove the following • Place a thermometer 3 in the water.
part(-s): • Slowly heat the water, then let it cool to the
1. air filter case specified temperature as indicated in the
9Troubleshoot with the following special tool(s). table.
• Check the thermo switch for continuity at
the temperatures indicated in the table.
Pocket tester
Test Conti-
90890-03112 Water temperature
step nuity
EAS00738
Less than 65 ± 2 °C
1. Main fuse 1 NO
(149 ± 3.6 °F)
9Check the main fuse for continuity. More than 65 ± 2 °C
2 YES
Refer to “CHECKING THE FUSE” in chapter (149 ± 3.6 °F)
3 (Manual No.: 5MX-F8197-E0).
3 More than 56 °C (132.8 °F) YES
9Is the light fuse OK?
4 Less than 56 °C (132.8 °F) NO
YES NO Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
Replace the fuse.
EAS00739

2. Battery
9Check the condition of the battery.
refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3 (Manual No.: 5MX-
F8197-E0).
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)

9Is the battery OK?

YES NO

9Clean the battery

terminals.
9Recharge or
replace the battery.

–50–
 AUTO CHOKE SYSTEM ELEC

4. Auto choke unit

WARNING
• Handle the thermo switch with special • Remove the auto choke unit from the car-
care. buretor.
• Never subject the thermo switch to • Connect the pocket tester to the auto
strong shocks. If the thermo switch is choke unit coupler as shown.
dropped, replace it. Tester positive probe → black 1
Tester negative probe → black 2
Thermo switch
23 Nm (2.3 m · kg, 17 ft · lb)
T.
R.

È The thermo switch circuit is closed.

É The thermo switch circuit is open.

• Measure the auto choke unit resistance.

Auto choke unit resistance
30 Ω at 20 °C (68 °F)

• Does the thermo switch operate properly • Is the auto choke unit OK?
as described above?
YES NO
YES NO
Replace the auto
Replace the thermo choke unit.
switch.
5. Wiring
• Check the entire auto choke system’s wir-
ing.
• Refer to “CIRCUIT DIAGRAM”.
• Is the auto choke system’s wiring properly
connected and without defects?

YES NO

Replace the C.D.I. Properly connect or

unit. repair the auto choke
system’s wiring.

–51–
 TRBL
TROUBLESHOOTING SHTG
TROUBLESHOOTING
TROUBLESHOOTING
INTAKE AND EXHAUST SYSTEM

FUEL TANK CAP

• Clogged

SILENCER
• Clogged EXHAUST PIPE AIR CLEANER ELEMENT
• Cracked or broken • Dirty or clogged
• Carbon deposits

JET NEEDLE
• Improperly adjusted
(medium speed)

PILOT SCREW
THROTTLE STOP SCREW
• Improperly adjusted
(idling and starting) • Improperly adjusted
(idling and starting)

AUTO CHOKE UNIT

• Faulty

NEEDLE VALVE
• Wear

MAIN JET
• Incorrect size
• Clogged (high speed) PILOT JET
• Clogged (low speed)

FLOAT
• Incorrect fuel level adjustment
• Puncture

FLOAT CHAMBER
• Accumulated dust and/or water

–52–
 YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
AT115C WIRING DIAGRAM
1 Main switch
R R 2 Battery
Y/B Y/B 7 3 Main fuse
R Y/B 4 Starter relay
1
OFF R R W B
Br B
W/R W/L Y/B
O
5 Starter motor
ON Br Br R Y 6 Rectifier/ regulator
(BLACK)
7 Thermo switch
Br R W W W/L W/L O O
8 A. C. magneto
R 6 Y Y/R 8 W/R W/R w Y/B e 9 Right handlebar switch
W W
Br
B
0 Start switch
Y/R Y/R
q Front brake light switch
B B r
B B
w C. D. I. unit
R W/L W/R W/R W/L
e Ignition coil
R r Spark plug
3 L/W Br/Y B
t Auto choke unit
(BLACK)
y Rear brake light switch
Br/Y Y/B
u Turn signal relay
R
4
9
i Horn
t
R
B
L/W L/W
0
B Y/B o Left handlebar switch
OFF q
B B
p Horn switch
2
B
START a Light switch
B
5 Br L/W L/W Br
B s Dimmer switch
B G/Y B B G/Y d Turn signal switch
B

B
f Tail/ brake light unit assembly
B Br G/Y
g Rear turn signal light
B h Tail/ brake light
j Headlight unit assembly
Br Br
k Front turn signal light
y l Auxiliary light
i ; Headlight
Br/W Br B

Br
u G/Y B z Meter assembly
(BLACK) (BLACK) x High beam indicator light
P
Br
Br/W G/Y
c Turn signal indicator light
z Br Ch Dg Y v Meter light
o P Y/R Br/W
b Fuel gauge
P Y Y P p a s d n Fuel sender
Y/R L L Y/R
OFF OFF HI L
Br Y Y Br vv c c x B G G B
PUSH PO LO N
G Ch Ch G b ON R
B Dg Dg B Dg Dg
Br/W Br/W
(BLACK) (BLACK) Ch Ch

B L Y G Ch Dg
G B

G Ch Dg L G/Y
j Ch L Y G Dg f
G G
B B L g g h
G Y Y G k ; ; k B L L B
n (GREEN)
B L L B Y G/Y

B
Dg Ch Ch Dg
l l Ch Dg Dg Ch

B B

COLOR CODE
B...................Black P...................Pink L/W...............Blue/White
Br .................Brown R ..................Red W/L...............White/Blue
Ch ................Chocolate W..................White W/R ..............White/Red
Dg ................Dark green Y...................Yellow Y/B ...............Yellow/Black
G ..................Green Br/W .............Brown/White Y/R ...............Yellow/Red
L ...................Blue Br/Y ..............Brown/Yellow
O ..................Orange G/Y...............Green/Yellow