1987 Yamaha Ysr 50t Service Manual

OYAMAHA
YSR50T
SERVICE MANUAL
©1987 by Yamaha Motor Corporation, U.S.A.
1st Edition, March 1987
AII rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/No. LIT-11616-06-05
NOTICE
This manual was written by the Yamaha Motor Company primarily far use by Yamaha dealers and
their qualified mechanics. lt is not possible to put an entire mechanic's education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor
cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle
repair technology. Without such knowledge, attempted repairs ar service to this model may render
it unfit to use and/ ar unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications ar procedures will be forwarded to all Authorized
Yamaha dealers and will, where applicable, appear in future editions of this manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.
NOTE: A NOTE provides key information to make procedures easier ar clearer.
IÍÍÍIÍÍ;; A CAUTION indicates special procedures that must be followed to avoid damage
to the motorcycle.
WARNING: A WARNING indicates special procedures that must be fallowed to avoid injury to
a motorcycle operator ar person inspecting ar repairing the motorcycle.
MANUAL FORMAT
AII of the procedures in this manual are órganized in a sequential, step-by-step farmat. The infarma
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
• Bearings
Pitting/ Damage-+ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams befare each disassembly section far ease in identifying cor
rect disassembly and assembly procedures.
G) ® ILLUSTRATED SYMBOLS
l1i��1�1 lsPEcl
(Refer to the illustration)
pf 1 lllustrated symbols (D to @ are designed as
@ @ thumb tabs to indicate the chapter's number and
content.
l�g�lnl ENG G) General information

�
@W ® Specifications
@ Periodic inspection and adjustment
@ Engine
¡cooLl
@
�I !cARBI
@
fl
@ Cooling system
@ Carburetion
(l) Chassis
@ Electrical
® Troubleshooting
(l) @
!cHAS1� IELEcla
01 l
® ®
lllustrated symbols to ® ®are used to identify
II�i�I ?
the specifications appearing in the text.
• 1
@ Filling fluid
(U)Lubricant
� Special tool
©
@ Tightening
(U) ©
®) Wear limit, clearance
® Engine speed
@ íl, V, A
� �
l�I
@ ®l
�
® ®
[g] ®
�
® lllustrated symbols@ to@ in the exploded dia
@
l
m
l
e
gram indicate grade of lubricant and location of
lubrication point.
@ Apply engine oil
® Apply gear oil
® @ @ ® Apply molybdenum disulfide oil
® Apply wheel bearing grease
@ Apply lightweight lithium-soap base grease
�E:-- �E:-- �E:-- @ Apply molybdenum disulfide grease
@ Apply locking agent ( LOCTITE® )
@
INDEX
GENERAL INFORMATION
�
GEN
INFO
SPECIFICATIONS
SPEC
PERIODIC INSPECTION Fil

AND ADJUSTMENT INSP
ADJ
ENGINE OVERHAUL
CARBURETION
CARB
•
CHASSIS �-- cl:Y0
�
CHAS�
......______________.L--_�
ELECTRICAL
TROUBLESHOOTING =
t-=TRB-L ,_-,
► ◄
SHTG ..,!..
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ...................................1-1

VEHICLE IDENTIFICATION NUMBER ..............................1-1
ENGINE SERIAL NUMBER .......................................1-1
IMPORTANT INFORMATION ......................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ..............1-2
ALL REPLACEMENT PARTS .....................................1-3
GASKETS, OIL SEALS, AND O-RINGS ...........................1-3
LOCK WASHERS/PLATE AND COTTER PINS ....................1-3
BEARINGS AND OIL SEALS.....................................1-3
CIRCLIPS .......................................................1-4
SPECIAL TOOLS ..................................................1-4

FOR TUNE UP ..................................................1-4
FOR ENGINE SERVICE ..........................................1-5
FOR CHASSIS SERVICE.........................................1-6
FOR ELECTRICAL COMPONENTS ................................1-7
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................2-1
MAINTENANCE SPECIFICATIONS .................................2-4

ENGINE ........................................................2-4
CHASSIS .......................................................2-8
ELECTA ICAL ...................................................2-11
GENERAL TORQUE SPECIFICATIONS ............................2-14
DEFINITION OF UNITS ...........................................2-14
t:l\lulNt ....................................................... 2-15

CHASSIS ......................................................2-15
CABLE ROUTING ................................................2-16

CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ...................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............ 3-1 �
COWLINGS REMOVAL ANO INSTALLATION ......................3-3 GEN

COWLINGS .....................................................3-3 INFO
SIDE COVER ................................................... 3-4
ENGINE ...........................................................3-4
IDLE SPEED ADJUSTMENT .....................................3-4
THROTTLE CABLE FREE PLAY ADJUSTMENT....................3-5 SPEC
..,
AUTOLUBE PUMP CABLE ADJUSTMENT ........................3-5
AUTOLUBE PUMP STROKE ADJUSTMENT .......................3-6
AUTOLUBE PUMP AIR BLEEDING ................................3-8
SPARK PLUG INSPECTION ......................................3-9
IGNITION TIMING CHECK ...........................•..........3-10 INSP
ENGINE OIL LEVEL CHECK .....................................3-10
TRANSMISSION OIL LEVEL INSPECTION........................ 3-11
ADJ
TRANSMISSION OIL REPLACEMENT ............................3-12
CLUTCH ADJUSTMENT ........................................3-13
AIR FILTER CLEANING.........................................
· 3-14
CARBURETOR JOINT INSPECTOIN..............................3-16
FUEL UNE INSPECTION........................................3-17 ENG
Y.E.1.S. HOSE INSPECTION ....................................3-17
EXHAUST SY STEM INSPECTION ...............................3-17
CHASSIS ........................................................3-17
FRONT BRAKE ADJUSTMENT..................................3-17
REAR BRAKE ADJUSTMENT ...................................3-18 CARB
BRAKE FLUID INSPECTION ....................................3-18
BRAKE PAD INSPECTION ......................................3-19
BRAKE SHOE INSPECTION .....................................3-19
BRAKE LIGHT SWITCH ADJUSTMENT..........................3-19
BRAKE HOSE INSPECTION .....................................3-19
ORIVE CHAIN SLACK ADJUSTMENT ...........................3-20
ORIVE CHAIN LUBRICATION ...................................3-21
STEERING HEAD ADJUSTMENT ................................3-21
TIRE INSPECTION .............................................3-23
WHEEL INSPECTION ...........................................3-24
CABLE INSPECTION ANO LUBRICATION ........................ 3-24
LEVER ANO PEDAL LUBRICATION .............................3-25
SIDESTAND LUBRICATION .....................................3-25
TRBL
SHTG
ELECTRICAL .....................................................3-26
BATTERY INSPECTION .........................................3-26
FUSE INSPECTION .............................................3-28
HEAOLIGHT BEAM AOJUSTMENT ..............................3-29
HEAOLIGHT REPLACEMENT ....................................3-29
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ................................................4-1

TRANSMISSION OIL ............................................4-1
COWLING ANO SIOE COVER ....................................4-1
FUEL TANK ....................................................4-1
MUFFLER ......................................................4-2
CARBURETOR ..................................................4-2
AUTOLUBE PUMP CABLE ANO HOSE ...........................4-2
LEAOS .........................................................4-3
CLUTCH CABLE ................................................4-3
ORIVE CHAIN ..................................................4-3
ENGINE REMOVAL ..............................................4-4
ENGINE OISASSEMBLY ...........................................4-5

CYLINOER HEAO, CYLINOER ANO PISTON ...................... 4-5
CLUTCH ANO PRIMARY ORIVE GEAR ...........................4-6
KICK AXLE .....................................................4-8
SHIFT SHAFT ..................................................4-9
COI MAGNETO .................................................4-9
CRANKCASE ..................................................4-10
TRANSMISSION, SHIFTER ANO CRANKSHAFT ................. .4-11
INSPECTION ANO REPAIR .......................................4-13

CYLINOER HEAO ..............................................4-13
CYLINOER ANO PISTON .......................................4-13
PISTON RINGS ................................................4-15
PISTON PIN ANO BEARING ....................................4-16
r, IITrLJ ,1-17
SHIFT SHAFT .................................................4-19

TRANSMISSION ANO SHIFTER .................................4-20
CRANKSHAFT .................................................4-21
CRANKCASE ..................................................4-22
AUTOLUBE PUMP .............................................4-22
ENGINE ASSEMBLY ANO AOJUSTMENT ........................4-24

CRANKSHAFT, SHIFTER ANO TRANSMISSION ..................4-24
CRANKCASE ..................................................4-25
COI MAGNETO ................................................4-30
SHIFT SHAFT .................................................4-32
'
KICK AXLE ....................................................4-32
"'
CLUTCH ANO PRIMARY ORIVE GEAR ..........................4-34
CYLINOER HEAO, CYLINOER ANO PISTON .....................4-37
REMOUNTING ENGINE .........................................4-40
CHAPTER 5.
CARBURETION
.--G�E_N_
CARBURETOR ....................................................5-1 INFO
REMOVAL ......................................................5-2
OISASSEMBLY .................................................5-2
INSPECTION ....................................................5-4
ASSEMBLY .....................................................5-5
INSTALLATION .................................................5-6 SPEC
ADJUSTMENT ..................................................5-7
REED VALVE .....................................................5-8

REMOVAL ......................................................5-8
INSPECTION ....................................................5-8 INSP
INSTALLATION .................................................5-9
ADJ
CHAPTER 6.
CHASSIS
FRONT WHEEL....................................................6-1
ENG
REMOVAL ......................................................6-2
INSPECTION ....................................................6-2
INSTALLATION .................................................6-4
REAR WHEEL .................................... - ................6-5

REMOVAL ......................................................6-6
CARB
INSPECTION ....................................................6-6
INSTALLATION .................................................6-8
FRONT BRAKE ...................................................6-10

BRAKE PAO REPLACEMENT ...................................6-11
CALIPER DISASSEMBLY .......................................6-13
MASTER CYLINDER OISASSEMBLY ............................6-14
INSPECTION ANO REPAIR ..................................... 6-15
ASSEMBLY .................................................... 6-16
AIR BLEEDING ................................................6-19
ELEC
FRONT FORK ....................................................6-20
REMOVAL .....................................................6-21
•
OISASSEMBLY ................................................6-21
INSPECTION ................................................... 6-23
ASSEMBL Y ....................................................6-23 TRBL
INSTALLATION ................................................6-26
SHTG
STEERING HEAD ANO HANDLEBAR .............................6-27
REMOVAL .....................................................6-28
INSPECTION ...................................................6-29
INSTALLATION ................................................ 6-30
REAR SHOCK ABSORBER ANO SWINGARM ....................6-33

REMOVAL .....................................................6-34
DISASSEMBLY ................................................6-35
INSPECTION ...................................................6-35
ASSEMBLY ....................................................6-36
INSTALLATION ................................................6-36
ORIVE CHAIN ANO SPROCKETS.................................6-38

REMOVAL .....................................................6-38
INSPECTION ................................................... 6-38
INSTALLATION ................................................6-39
CHAPTER 7.
ELECTRICAL
YSRS0T CIRCUIT DIAGRAM.......................................7-1

COLOR CODE ..................................................7-2
ELECTRICAL COMPONENTS ......................................7-3
IGNITION ANO STARTING SYSTEM............................... 7-4

IGNITION CONTROL CIRCUIT OPERATION .......................7-6
TROUBLESHOOTING ............................................7-7
CHARGING SYSTEM .............................................7-16

TROUBLESHOOTING ...........................................7-18
LIGHTING SYSTEM...............................................7-22
TROUBLESHOOTING (1) ........................................7-24
SIGNAL SYSTEM .................................................7-30

TROUBLESHOOTING ...........................................7-32
DISPLAY SYSTEM................................................7-42
DISPLAY SYSTEM TEST AND CHECK ...........................7-50
CHAPTER 8.
TROU BLESHOOTI NG
STARTING FAILURE/HARD STARTING ............................8-1

FUEL SYSTEM .................................................8-1
ELECTRICAL SYSTEM...........................................8-2
COMPRESSION SYSTEM ........................................8-3
POOR IDLE SPEED PERFORMANCE ...............................8-3
POOR IDLE SPEED PERFORMANCE ..............................8-3
"
POOR MEDIUM ANO HIGH SPEED PERFORMANCE ..............8-4
FUEL SYSTEM .................................................8-4
ELECTRICAL SYSTEM...........................................8-4
COMPRESSION SYSTEM ........................................8-5
GEN
FAULTY GEAR SHIFTING ......................................... 8-6
HARD SHIFTING ............. , ..................................8-6
INFO
CHANGE PEDAL DOES NOT MOVE ..............................8-6
JUMP-OUT GEAR ...............................................8-6
CLUTCH SLIPPING/DRAGGING ...................................8-7

SPEC
..,
CLUTCH SLIPPING .............................................. 8-7
CLUTCH DRAGGING ............................................8-7
IMPROPER KICKING ..............................................8-8

SLIPPING ......................................................8-8
HARD KICKING .................................................8-8 INSP
KICK CRANK NOT RETURNING .................................8-8 ADJ
FAULTY BRAKE ...................................................8-9
POOR BRAKING EFFECT ........................................8-9
FRONT FORK OIL LEAKAGE ANO FRONT FORK MALFUNCTION....8-9

OIL LEAKAGE ..................................................8-9
ENG
MALFUNCTION .................................................8-9
INSTABLE HANDLING ...........................................8-10

INSTABLE HANDLING .........................................8-10
FAULTY SIGNAL ANO LIGHTING SYSTEM .......................8-11

HEADLIGHT DARK .............................................8-11
---
BULB BURNT OUT ............................................8-11
FLASHER DOES NOT LIGHT ...................................8-11 cl::r0
FLASHER KEEPS ON ..........................................8-11
FLASHER WINKS SLOWER ....................................8-12
FLASHER WINKS QUICKER ....................................8-12
CHAS
HORN IS INOPERATIVE ........................................8-12
OVERHEATING ...................................................8-13
OVERHEATING ................................................8-13
YSR50T WIRING DIAGRAM
TRBL
SHTG
GEN
MOTORCYCLE IDENTIFICATION INFO
GENERAL
INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD
is stamped
into the steering head pipe.
Starting Serial Number:

YSR50T ...... JYA2RROO*HA000101
NOTE: �=------------
The vehicle identification number is used to iden
tify your motorcycle and may be used to register
your motorcycle with the licensing authority in
your state.
ENGINE SERIAL NUMBER

The engine serial number CD
is stamped into the
left side of the engine.
Sta1rti11g Serial Numbe1r:

YSR50T .................. 2RR-000101
NOTE:--�-��--�-��-
0The first three digits of these numbers are far
model identifications; the remaining digits are
the unit production number.
'- Designs and specifications are subject to change
without notice.
1-1
IMPORTANT INFORMATION
I �� l'"I
PREPARATION FOR REMOVAL ANO
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removing and disassembling.
2. Use proper tools and cleaning equipment.

Refer to "SPECIAL TOOL."
3. When disassembling the motorcycle, keep

mated parts together. This includes gears,
cylinders, pistons, and other mated parts that
have been "mated" through normal wear.
Mated parts must be reused as an assembly,
or replaced.
4. During the motorcycle disassembly, clean all

parts and place them in trays in the order of
disassembly. This will speed up assernbly time
and help assure that all parts are correctly rein
stalled.
5. Keep away frorn fire.
1-2
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuina parts
for all replacements. Use oil and/ or grease
recommended by Yamaha for assembly and
adjustment.
GASKETS, OIL SEALS, AND O-RINGS

1. AII gaskets, seals and 0-rings should be
replaced when an engine is overhauled. AII
gasket surfaces, oil seal lips and 0-rings must
be cleaned.
2. Properly oil all mating parts and bearings dur

ing reassembly. Apply grease to the oil seal
lips.
LOCK WASHERS/PLATES AND COTTER

PINS
1. AII lock washers/ Plates G) and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
300-000
BEARINGS AND OIL SEALS

1. lnstall the bearing(s) and oil seal(s) with their
manufacturer's marks or numbers facing out
ward. (In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
light-weight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
300-003 G) Oil seal
Do not use compressed air to spin the bear

ings dry. This causes damage to the bearing
surfaces.
G) Bearing
300-002
1-3
___________s_PE_c_1A_ LT
_ _o_oL_ _s_
CIRCLIPS
l <MI
1�� 1
1. Ali circlips should be inspected carefully be
fore reassembly. Always replace piston pin
clips after one use. Replace distorted circlips.
When installing a circlip G), make sure that
the sharp edged comer (Í) is positioned op
posite to the thrust @ it receives. See the
sectional view.
300-001
@ Shaft
SPECIALTOOLS
The proper special tools are necessary for com
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvised
techniques.
FOR TUNE UP
1. lnductive Yiming Light
P/N. YM-33277
This tool is necessary for adjusting ignition timing.
2. Fuel Level Gauge

P/N. YM-01312
This gauge is used to measure the fuel level in

the float chamber.
1-4
___________sP_e_c_1A_L_T_o_o_L __
s 1��
3. Inductiva Tachometer
l 1�1
P/N. YU-08036
This too! is needed for detecting engine rpm.
FOR ENGINE SERVICE

1. Universal Clutch Holder
P/N. YM-91042
This too! is used to hold the clutch when loosen

ing or tightening the clutch boss locknut.
2. Universal Rotor Holder

P/N. YU-01235
This tool is used when loosening or tightening the

flywheel magneto securing bolt.
3. Flywheel Puller
P/N. YM-01189
This tool is used for removing the flywheel.
4. Piston Pin Puller

P/N. YU-01304
This too! is used to remove the pistan pin.

1-5
___________ _s P_E_C_IA_L_T_o_o_L _s _1=1�1
5. Crankcase Separating Tool
P/N. YU-01135
This tool is used to split the crankcases as well

as remove the crankshaft from either case.
,,- ----- -----7 6. Crankshaft lnstalling Tool .............G)

// 1
1 P/N. YU-90050
Adapter ............................(ll
1
1
P/N. YM-90063
These tools are used to install the crankshaft.
FOR CHASSIS SERVICE

1. Front Fork Seal Driver (Weight) .......G)
P/N. YM-33963
Adapter ............................(ll
P/N. YM-33281
This tool is used when installing the fork seal.
2. Ring Nut Wrench

P/N. YU-33975
This tool is used to loosen and tighten the steer

ing ring nut.
1-6
SPECIAL TOOLS 1 ��i 1 �1
FOR ELECTRICAL COMPONENTS
1. Coil Tester
P/N. YU-33261
This tester is necessary for checking the ignition

system components.
2. Pocket Tester
P/N. YU-03112
This tester is invaluable for checking the electri

cal system.
1-7
1-8
GENERAL SPECIFICATIONS I SPEC I Pf 1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YSR50T
Model Code Number: 2RR
Vehicle ldentification Number: JYA2RROO* HA000101
Engine Starting Number 2RR-000101
Dimensions:
Overall Length 1,630 mm (64.2 in)
Overall Width 635 mm (25.0 in)
Overall Height 930 mm (36.6 in)
Seat Height 660 mm (26.0 in)
Wheelbase 1,055 mm (41.5 in)
Minimum Ground Clearance 120 mm (4.7 in)
Basic Weight:
With Oil and Full Fuel Tank 91 kg (201 lb)
Minimum Turning Radius: 2,400 mm (94.5 in)
Engine:
Engine Type Air cooled 2-stroke
lnduction System Reed valve
Cylinder Arrangement Forward inclined single cylinder
Displacement 49.3 cm3
Bore x Stroke 40.0 x 39.2 mm (1.57 x 1.54 in)
Compression Ratio 7.4 : 1
Starting System Kick starter
Lubrication System:
Type Separate lubrication (Yamaha Autolube)
Engine Oil Type Yamalube "2" or air cooled 2 stroke engine oil with
"BIA certified for service TC-W"
Transmission Oil Type Yamalube "4", SAE 10W30 type SE motor oil or
"GL" gear oil
Oil Capacity:
Engine Oil (Oil Tank) 0.73 L (0.64 lmp qt, 0.77 US qt)
Transmission Oil:
Periodic Oil Change 0.60 L (0.53 lmp qt, 0.63 US qt)
Total Amount 0.65 L (0.57 lmp qt, 0.69 US qt)
Air Filter
Type Wet type element
2-1
GENERAL SPECIFICATIONS I SPEC 1 �f 1
Model YSR50T
Fuel:
Type Regular gasoline
Fuel Tank Capacit,
Full Amount 8.0 L (1.76 lmp gal, 2.11 US gal)
Reserve Amount 1.5 L (0.33 lmp gal, 0.39 US gal)
Carburetor:
Type/ Quantity VM16SH/1 pe.
Manufacturer MIKUNI
Spark Plug:
Type/Ouantity B7HS or B8HS
Manufacturer NGK
Plug Gap 0.5-0.6 mm (0.020-0.024 in)
Clutch:
Type Wet, multiple disc
Transmission:
Type Constant mesh 5-speed
Primary Reduction System Helical gear
Primary Reduction Ratio 68/19 (3.579)
Secondary Reduction System Chain drive
Secondary Reduction Ratio 44/12 (3.667)
Operation Left foot operation
Gear Ratio
1st 39/12 (3.250)
2nd 34/17 (2.000)
3rd 30/21 (1.429)
4th 27/24 (1.125)
5th 25/26 (0.962)
Chassis:
Frame Type Double cradle
Caster Angle 25.3 °
Trail 64 mm (2.52 in)
Tire:
Type Tubeless
Size
Front 3.50-12 2PR
Rear 4.00-12 2PR
Tire Pressure (Cold Tire):
Basic Weight:
With Oil and Full Fuel Tank 91 kg (201 lb)
Maximum Load* 68 kg (150 lb)
Cold Tire Pressure: FRONT REAR
Zero-Maximum Load* 130 kPa 150 kPa
(1.3 kg/cm2, 18 psi) (1.5 kg/cm2 , 21 psi)
* Load is total weight of cargo, rider, and accessories.
2-2
GENERAL SPECIFICATIONS I
1 'P'i 1
SPEC
Model YSR50T
Brake:
Front Brake Type Single disc brake
Front Brake Operation Right hand operation
Rear Brake Type Drum brake
Rear Brake Operation Right foot operation
Suspension:
Front Suspension Type Telescopic fork
Rear Suspension Type Swingarm (Monocross suspension)
Shock Absorber:
Front Shock Absorber Coil spring/Oil damper
Rear Shock Absorber Coil spring/Oil damper
Wheel Travel:
Front Wheel Travel 90 mm (3.5 in)
Rear Wheel Travel 75 mm (3.0 in)
Electrical:
lgnition System COI Magneto
Generator System Flywheel magneto
Battery:
Type 6N4-2A-2
Capacity 6V4AH
Headlight:
Type Sealed beem
Bulb Wattage (Quantity):
Headlight 6V 25W/25W (1 pe.)
Tail/Brake Light 6V 25W/5.3W (2 pes.)
Flasher Light 6V 17W (4 pes.)
Licence Light 6V 5.3W (1 pe.)
Meter Light 6V 3W (2 pes.)
"NEUTRAL" lndicator Light 6V 3W (1 pe.)
"HIGH BEAM" lndicator Light 6V 3W (1 pe.)
"TURN" lndicator Light 6V 3W (1 pe.)
"OIL" Warning lndicator Light 3W or so (1 pe.)
(Light Emitting Diode)
2-3
MAINTENANCE SPECIFICATIONS I SPEC [ >1571
MAINTENANCE SPECIFICATIONS
ENGINE
Model YSR50T
Cylinder Head:
Warpage Limit 0.02 mm (0.001 in)
* Unes indicate straightedge measurement.
'
Cylinder:
Bore Size 40.00~40.02 mm (1.575~1.576 in)
Taper Limit 0.05 mm (0.002 in)
Out of Round Limit 0.01 mm (0.0004 in)
Piston:
Piston Size "D" 39.96~39.98 mm (1.573~1.574 in)
Measuring Point "a" 5 mm (0.20 in)
Piston Off-Set 0.2 mm (0.008 in)

Piston-to-Cylinder Clearance 0.030~0.035 mm (0.0012~0.0014 in)
< Limit> < 0.1 mm (0.004 in)>
Oversize 1st 40.25 mm (1.58 in)
Oversize 2nd 40.50 mm (1.59 in)
Piston Ring:
Sectional Sketch Top Ring Keystone type
B = 1.2 mm (0.047 in)
cJ]s T = 1.6 mm (0.063 in)
1-r--l
2nd Ring Plain type
DJs
�T_j
B = 1.2 mm (0.047 in)
T = 1.6 mm (0.063 in)
End Gap 0nstalled) Top Ring 0.15~0.35 mm (0.006~0.014 in)

2nd Ring 0.15~0.35 mm (0.006~0.014 in)
Side Clearance Top Ring 0.03~0.05 mm (0.001~0.002 in)
2nd Ring 0.03~0.05 mm (0.001~0.002 in)
2-4
______M_A _ 1 N _ T_EN_ A_N_ c_ E_ s_P_E _c 1_F_1 c _A_T 1_o_N _s_ l I Pf l
SPEC
Model YSR50T
Crankshaft:
Crank Width "A" 37.90~37.95 mm (1.492~1.494 in)
Runout Limit "B" 0.03 mm (0.0012 in)
Big End Side Clearanee "C" 0.2~0.7 mm (0.008~0.028 in)
< Limit> < 1.0 mm (0.04 in)>
Small End Free Play "D" 0.8~1.0 mm (0.032~0.039 in)
< Limit> < 1.5 mm (0.06 in)>
Cluteh:
Frietion Plate:
Thiekness 3.5 mm (0.138 in)
Quantity 2 pes.
Wear Limit 2.7 mm (0.106 in)
Cluteh Plate:
Thiekness 2.0 mm (0.079 in)
Quantity 1 pe.
Warpage Limit 0.05 mm (0.002 in)
Cluteh Spring:
Free Length 28.2 mm (1.11 in)
Quantity 4 pes.
Minimum Free Length 26.2 mm (1.03 in)
Cluteh Release Method lnner push, eam push
< Push Rod Bending Limit> < 0.2 mm (0.008 in)>
Transmission:
Main Axle Runout Limit 0.08 mm (0.003 in)
Orive Axle Runout Limit 0.08 mm (0.003 in)
Shifter:
Type Cam drum and guide bar
Guide Bar Bending Limit 0.025 mm (0.001 in)
Kiek Starter:
Type Kiek and Mesh type
2-5
MAINTENANCE SPECIFICATIONS I SPEC 1 )Vf 1
Model YSR50T
Air Filter:
Oil Grade Foam-Air-Filter oil or Yamalube "2"
Carburetor:
I.D. Mark 2AL 01
Main Jet (M.J.) #120
Air Jet (A.J.) </:>2.5
Jet Needle-Position (J.N.) 3G21-4
Needle Jet (N.J.) E-O
Cutaway (C.A.) 2.0
Pilot Outlet (P.O.) <f:>0.9
Pilot Jet (P.J.) #17.5
Air Screw (A.S.) 1-1/8
Valve Seat Size (V.S.) </:>1.5
Starter Jet (G.S.) #20
Fuel Leve! (F.L.) 0-1 mm (0-0.04 in)
Float Height (F.H.) 21-23 mm (0.83-0.91 in)
ldling Speed 1,300-1,400 r/min
Reed Valve:
Valve Thickness 0.15 mm (0.006 in)
Valve Stopper Height 6.7-7.3 mm (0.26-0.29 in)
Valve Bending Limit 0.3 mm (0.012 in)
Lubrication System:
Autolube Pump
Color Code Green
Minimum Stroke 0.20-0.25 mm (0.008-0.010 in)
Maximum Stroke 1.85-2.05 mm (0.073-0.081 in)
Minimum Output 0.50-0.63 cm3 per 200 strokes
Maximum Output 4.64-5.15 cm3 per 200 strokes
Pulley Adjusting Mark At idle
2-6
TIGHTENING TORQUE
MAINTENANCE SPECIFICATIONS I I Júf l
SPEC
Bolt/Nut Tightening torque

Part to be tightened
size Nm m•kg ft•lb
Spark plug M14x1.25 25 2.5 18
Cylinder head M6 X 1.0 10 1.0 7.2
Autolube pump M5 x0.8 5 0.5 3.6
lntake manifold M6 X 1.0 8 0.8 5.8
Muffler (Front) M6 X 1.0 8 0.8 5.8
Muffler (Rear) M8 X 1.25 18 1.8 13
Crankcase M6 X 1.0 8 0.8 5.8
Crankcase cover M6 X 1.0 10 1.0 7.2
Transmission oil drain bolt M12x1.5 20 2.0 14
Autolube pump cover M6 X 1.0 8 0.8 5.8
Kick crank assembly M6 X 1.0 12 1.2 8.7
Primary drive gear M12x1.0 60 6.0 43
Clutch boss M12x1.0 45 4.5 32
Pressure plate M5 x0.8 6 0.6 4.3
Stopper plate (Bearing) M6 X 1.0 10 1.0 7.2
Stopper plate (Shift cam) M6 X 1.0 8 0.8 5.8
Shift lever adjuster nut M8 X 1.25 25 2.5 18
Change pedal M6 X 1.0 11 1.1 8.0
Stator M5 x0.8 8 0.8 5.8
CDI magneto M12 X 1.25 70 7.0 50
Neutral switch M10x 1.25 4 0.4 2.9
2-7
MAINTENANCE SPECIFICATIONS I SP E C I
f>f 1
CHASSIS
Model YSR50T
Steering System:
Bearing Type Ball Bearing
Bearing Si2e (Quantity)
Upper 3/16 in (22 pes.)
Lower 1/4 in (19 pes.)
Front Suspension:
Front Fork Travel 90 mm (3.54 in)
Fork Spring Free Length ( Left side only) 374.2 mm (14.7 in)
< Limit> <367 mm (14.4 in)>
Spring Rate (Ki) 8.2 N/mm (0.83 kg/mm, 46.6 lb/in)
Stroke (Ki) 0.0~90.0 mm (0.0~3.5 in)
Optional Spring No.
LEFT RIGHT
Oil Capacity 126 cm3 (4.44 lmp 02, 164 cm3 (5.77 lmp 02,
4.26 US 02) 5.54 US 02)
Oil Level 146 mm (5.74 in) 51 mm (2.01 in)
From top of inner tube From top of inner tube
fully compressed without compressed without
spring. spring.
Oil Grade Yamaha fork oil 10WT or +-
equivalent
Rear Suspension:
Shock Absorber Travel 18.0 mm (0.71 in)
Spring Free Length 86 mm (3.4 in)
Fitting Length 82 mm (3.2 in)
Spring Rate (K1) 353 N/mm (36 kg/mm, 2,020 lb/in)
Stroke (K1) O.O~18 mm (0.0~0.71 in)
Optional Spring No.
Swingarm:
Free Play Limit (Swingarm end) 1.0 mm (0.039 in)
Move swingarm end side to side
Front Wheel:
Type Panel wheel
Rim Si2e MT2.50x 12
Rim Material Steel
Rim Runout Limit
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
2-8
______M_ A_1N_ TEN_
_ A_ N_ c_ E _ s_P_Ec_11_
_F cA_ T
_ 1_oN
_ s
_ _ l SPEC j �f l
Model YSR50T
Rear Wheel:
Type Panel wheel
Rim Size MT2.50x 12
Rim Material Steel
Rim Runout Limit
Vertical 2.0 mm (0.08 in)
Lateral 2.0 mm (0.08 in)
Orive Chain:
Type/Manufacturer 420M/DAIDO
Number of Links 99 Links + joint
Chain Free Play 25-30 mm (1.0-1.2 in)
-
Front Disc Brake:
Type Single
Disc Outside Diameter 203 mm (8.00 in)
Disc Thickness 4.0 mm (0.16 in)
Pad Thickness 6.0 mm (0.24 in)
<Wear Limit> <0.5 mm (0.02 in)>
Master Cylinder lnside Diameter 11.0 mm (0.433 in)
Caliper Cylinder lnside Diameter 34.9 mm (1.37 in)
Brake Fluid Type DOT No. 3
Rear Drum Brake:
Type Leading, Trailing
Brake Drum lnside Diameter 110 mm (4.33 in)
< Limit> <111 mm (4.37 in)>
Shoe Spring Free Length 50.5 mm (1.99 in)
Lining Thickness 4 mm {0.16 in)
< Limit> <2 mm (0.08 in)>
Brake Lever and Brake Pedal:
Brake Lever Free Play 2-5 mm (0.08-0.20 in)
Brake Pedal Free Play 20-30 mm (0.8-1.2 in)
Below top of footrest
Clutch Lever and Throttle Grip:
Clutch Lever Free Play 2-3 mm (0.08-0.12 in)
Throttle Cable Free Play 3-7 mm (0.12-0.28 in)
At grip flange
2-9
______M_ AI_ N_T _ E_N_A _N_C_E S
TIGHTENING TOROUE
_ P
_ E_ c_1 _F1_c A _ s_ _ 1
_ N
_ T_ 1o SPEC I p7 1
Tightening torque
Part to be tightened Bolt/Nut size O'ty
Nm m•kg ft•lb
Chassis:
Engine mounting;
Engine stay M ax1.25 2 25 2.5 18
Frame and engine M 8x1.25 3 25 2.5 18
Pivot shaft and nut M10x1.25 1 40 4.0
Rear shock absorber and frame M10x1.25 1 40 4.0 29
Front fork cap bolt (Handlebar) M21 X 1.0 2 55 5.5 40
Under bracket and inner tube M10x1.25 2 30 3.0 22
Steering ring nut M25x1.25 1 6 0.6 4.3
Refer to NOTE
Steering stem bolt M10x1.25 1 40 4.0 29
Wheel hub and wheel rim M ax1.25 4 31 3.1 22
Front brake disc and wheel hub M 8x1.25 4 20 2.0 14
Brake caliper and outer tube M10x1.25 2 35 3.5 25
Front wheel axle and nut M10x1.25 1 40 4.0 29
Brake cam lever and camshaft M 6x1.0 1 10 1.0 7.2
Rear wheel sprocket and wheel hub M 8x1.25 4 36 3.6 25
Tension bar and plate/fran_:ie M 8x1.25 2 19 1.9 13
Rear wheel axle and nut M12x1.25 1 60 6.0 43
Rear view mirror and stay M 8x1.25 2 19 1.9 13
Brake hose union bolt M10x1.25 2 26 2.6 19
Footrest and frame M 8x1.25 4 25 2.5 18
Cowling stay and frame M 8x1.25 2 19 1.9 13
Windscreen and cowling M 5x0.8 8 0.6 0.06 0.43
CDI unit and frame - 2 2 0.2 1.4
Rectifier/Regulator - 1 1 0.1 0.7
Down tube and frame M 8x1.25 6 25 2.5 18
Engine bracket ( Front) and frame M10X 1.25 2 40 4.0 29
Engine bracket (Rear) and frame M10x1.25 1 25 2.5 18
NOTE:------------------------------
1. First, tighten the ring nut approximately 30 Nm (3.0 m•kg, 22 ft•lb) by using the torque wrench,
then loasen the ring nut one turn.
2. Retighten the ring nut to specification.
2-10
MAINTENANCE SPECIFICATIONS I I f>f
SPEC
1
ELECTRICAL
Model YSR50T
Voltage: 6V
lgnition System:
lgnition Timing (B.T.D.C.) 22º at 5,000 r/min
Advancer Type Electrical type
�
u
o
-ce
1-
o r
N
I
Ol
e
.E
e
·.¡:¡
o
...-
'e:Ol
o 1 2 3 4 5 6 7 8 9 10
Engine Speed (x1,000 r/min)
C.D.I.:
Magneto Model/Manufacturer 2RR/YAMAHA
C.D.I. Unit Model/Manufacturer 2GX/YAMAHA
Pickup Coil Resistance (Color) 16-24íl at 20 º C (68 ° F)
(White/Red- Black)
Source Coil Resistance (Color) 264-396íl at 20 º C (68 ° F)
( Black/Red-B\ackl
lgnition Coil:
Model/Manufacturer 2JN/YAMAHA
Minimum Spark Gap 6 mm (0.24 in)
Primary Coil Resistance 0.7-1.1íl at 20 ° C (68 ° F)
Secondary Coil Resistance 5.7-8.5kíl at 20 ° C (68 ° F)
Spark Plug Cap:
Type Resin Type
Plug Cap Resistance 4-6kíl at 20º C (68 ° F)
2-11
______M_A1_
_ NT_ E_NA_ _ N_c_E _sP
_ E_ 1
_ c_F1A N _ _s_ l sPEC
_c_T_1_o
I Pf 1
Model YSR50T
Charging System: Flywheel Magneto

C.D.I. Magneto:
Model/Manufacturer 2RR/YAMAHA
Charging Coil Resistance (Color) 0.24~0.36íl at 20 ºC (68 º F) (White-Black)
Standard Output 7.4~8.2V at 5,000 r/min
10
8 V
-
/
> /
a) 6
.... 4
....
o 1 2 3 4 5 6 7 8 9 10
Engine Speed ( x 1,000 r/min)
Lighting Coil Resistance (Color) 0.16~0.24íl at 20 ºC (68 º F) (Yellow/Red-Black)

Standard Output 6.2~7.2V at 3,000 r/min or more
Voltage Regulator:
Model/Manufacturer SH582-6/SHINDENGEN
Rectifier:
Model/Manufacturer SH582-6/SHINDENGEN
Capacity 8A
Withstand Voltage 120V
Battery:
Specific Gravity 1.280
Horn:
Type Plane Type
Quantity 1 pe.
Model/ Manufacturer GF-12/NIKKO
Maximum Amperage 1.5A
2-12
MAINTENANCE SPECIFICATIONS I SPEC I Pf 1
Model YSR50T
Flasher Relay:
Type Condenser Type
Model/Manufacturer FZ636SD/NIPPON DENSO
Self Cancelling Device No
Flasher Frequency 75-95 cycles/min
Wattage 17Wx2+3W (6V)
Oil Level Switch:
Model/Manufacturer 3J0/STANLEY
Curcuit Breaker:
Type Fuse
Curcuit (Fuse):
"MAIN" 10A (1 pe.)
2-13
G EN E A L T
-____ _ _ _ _R_ _ _ _o_R_a_u_
E _s _P_Ec_ _F, _c, _ A_T _'º_ N_ s_1 1
DEFINITION OF UNITS _
_
SPEC . TI I 1
e;<, o
_
GENERA L T O RQUE
SP ECIFIC A TIONS
This chart specifies torque for standard fasteners
with standard I.S.0. pitch threads. Torque specifi
cations for special components or assemblies are
included in the applicable sections of this book.
A
(Nutl
B
(Bolt)
Nm
General torque
specifications
m•kg ft•lb
1
10 mm 6 mm 6 0.6 4.3
To avoid warpage, tighten multi-fastener assem 12 mm 8 mm 15 1.5 11
blies in a crisscross fashion, in progressive stages, 10 mm 30 3.0 22
14 mm
until full torque is reached. Unless otherwise
17 mm 12 mm 55 5.5 40
specified, torque specifications call for clean, dry
19 mm 14 mm 85 8.5 61
threads. Components should be at room tem
22 mm 16 mm 130 13.0 94
peratura.
A: Distance across flats

B: Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure
mm millimeter 10- 3 meter Length
cm centimeter 10- 2 meter Length
kg kilogram 103 gram Weight
2
N Newton 1 kgxm/sec Force
Nm Newton meter Nxm Torque
m•kg Meter kilogram mxkg Torque
Pa Pascal N/m2 Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter - Volume or capacity
cm3 Cubic centimeter
r/min Rotation per minute - Engine speed
2-14
__
L _U _B _R _IC_A_ T_1_o _N _P o_1 N_T _S_ A_ N _D_L_ U_ B_ R_ I_C A_ _N_T _ T_Y_P_E 1
L U B R IC A T ION P OI NT S A NO L U B R IC A NT T Y P E
_
SPEC I Jlif 1
ENGINE
Lubrication Points ( Part name) Lubricant Type
Oil seal lip �

0-ring __;a�
Small end/ Big end bearing -•0

Bearing -•0
Piston ring -•0
Piston -•0
Cylinder inner surface -•0
Piston pin -•0
Kick axle -•0
Primary driven/drive gear -•(§]
Push rod __;a�
Push lever -(§]

Pinion/Wheel gears -@
Collar (Orive axle) -•@
Guide bar (Shift fork) -e@
Shift shaft -•(§]
Shift carn -Q
CHASSIS
Lubrication Points ( Part name) Lubricant Type

Steering Upper/ Lower balls __;a�
Front/Rear wheel oil seal lip __;a�
Brake cam shaft __;a�
Speedometer gear unit/ oil seal __;a�
Brake pedal pivot -•(§]

Rear shock absorber collar -e
Handlebar (Right) end __;a�
Sidestand pivot -•(9]

Footrest pivot -•Gl
Clutch lever pivot/ cable end -•@
Brake lever pivot -e(§]
Pin (Rear shock absorber) __;a�
Pivot shaft �
2-15
CABLE ROUTING I SP E C I Pf l
CABLE ROUTING
CD Handlebar switch (Right) lead
(2) Main switch lead
@ Clutch cable
@ Handlebar switch (Left) lead
@ Clamp
@ Throttle cable
(J) Front brake hose
2-16
CABLE ROUTING I 1757 I
SPEC
CABLE ROUTING
CD Headlight lead 18] Pass the speedometer cable through the cable
� Spark plug lead holder.
@ Clutch cable
@ Horn lead
@ Sidestand switch lead
@ Band
(J) Cable holder
@ Speedometer cable
® Meter light lead
2-17
__________cA
CABLEROUTING
_ B
_ L_ ER _ _ G_ 1
_ IN
_ _o_uT SPEC 1 �1 1
G) Front brake hose ® Carburetor breather hose !Al Clamp the brake hose.
(2) Clamp ® Carburetor air vent hose [al Pass the battery breather hose through the
® Cable guide @ COI magneto lead hole on the rear tender.
@ Oil hose © Battery breather hose
@ Oil pump cable @ Rear brake switch lead
@ Oil delivery hose @ Band
(J) Fuel tank breather hose @ Tail/brake light lead
® Wireharness
@
\ ®
2-18
CABLE ROUTING I SPEC I júf 1
CABLE ROUTING
G) Clamp @ Wireharness 1A] Pass the oil tank breather hose through the
® Band @ Clutch cable hole on the frame.
@ Throttle cable ® Sidestand switch lead [B] Pass the main switch and brake switch lead in-
@ Front brake hose @ Handlebar switch ( Left) lead side of the oil tank cap
@ Brake switch lead @ Spark plug lead (e Pass the sidestand lead above the Y.E.I.S.
@ Rectifier / Regulator ©) lgnition coil hose.
Q) Main switch lead @ Oil tank breather hose
@ Oil level switch
2-19
CABLE ROUTING I SPEC I jl>f 1
CABLE ROUTING
CD Band 1A] Pass the wireharness, flasher light lead and
� Cable guide battery breather hose through the guide.
@ Rear flasher light (Right) lead [a] Pass the flasher light lead through the guide.
@ Taillight lead
@ Rear flasher light (Left) lead
@ Battery negative ( - ) lead
(J)
Battery positive ( + ) lead
@ Battery
® Flasher relay
@ CDI unit
f' ¡'
\
2-20
INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventiva maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life. The need for costly overhaul work will be greatly reduced. This information ap
plies to vehicles already in service as well as new vehicles that are being preparad for sale. AII service
technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS unit: km (mil
EVERY
BREAK-IN 3,000 6,000
ITEM REMARKS
1,000 (600) (2,000) or (4,000) or
6 months 12 months
Spark plug(s)
Check condition. Clean or replace if
necessary.
o o o
Air filter* Clean. Replace if necessary. o o
Carburetor*
Check idle speed/starter operation.
Adjust if necessary.
o o
Fuel line*
Check fuel hose far cracks or damage.
Replace if necessary.
o o
Check oil level/oil leakage.
Transmission oil*
Correct if necessary.
Replace every 12,000 (8,000) or 24 months
REPLACE o o
(Warm engine befare draining.)
Autolube pump*
Check operation. Correct if necessary.
Air bleedi.ng.
o o
Check operation/fluid leakage/See NOTE.
Brake* Correct if necessary (front). o o
Check operation. Adjust if necessary (rear).
Clutch* Check operation. Adjust if necessary. o o
Wheels*
Check balance/damage/runout.
Repair if necessary.
o o
Wheel bearings*
Check bearings assembly far looseness/
damage. Replace if damaged.
o o
Check bearings assembly far looseness.
Steering bearing*
Moderately repack every 24,000 (16,000)
o o
or 24 months.**
Front farks*
Check operation/oil leakage.
o o
Rear shock
absorber*
Check operation/oil leakage.
o o
Check chain slack/alignment.
Orive chain EVERY 500 (300)
Adjust if necessary. Clean and lube.
Fittings/ Fasteners*
Check all chassis fittings and fasteners.
o o o
Sidestand* Check operation. Repair if necessary. o o o
Sidestand switch*
Check operation.
Clean or replace if necessary.
o o o
Check specific gravity.
Battery* Check breather pipe far proper operation. o o
*· lt is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**· Medium weight wheel bearing grease. (bearing type) 3-1
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS :1 iANDSJP
:1 � 1
a:c• _
NOTE:--------------------------------
Brake system:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2. We recommend that, on the inner parts of the master cylinder and caliper cylinder, replace the
oil seals every two years.
3. We recommend that, replace the brake hoses every four years, or if cracked or damaged.
3-2
INSP
COWUNGS
ADJ
COWUNGS REMOVAl D
�NSTALLAT�ON
COWUNGS
Removai
1. Remove:
o Lower cowling CD
2. Remove:
CD
r
"Flasher lights ( Left and right)
11;¡ �
° Flasher light stays (2)
tJ
�,@J��
3. Remove:
oUpper cowling CD
íllíllstaiia1tio111
Reverse the removal steps.
Note the following points.
1. lnstall:
@ Flasher light ( Right)
@ Flasher light ( Left)
NOTE: ==----========
0 On the left side, install the flasher light having
a chocolate color lead. Next, install the other
flasher light with a dark green color lead on the
right side.
®lnstall the flasher light with the notch in its end
fitting the convex part of the flasher light stay.
® Connect the flasher light lead and the negative
lead to the wire harness. The leads of identical

colors should be connected.
Nut (Flasher light}:

�� 10 Nm (1.IOJ m kg, 7.2 h ib}
0 0
3-3
INSP
SIDE COVER/IDlE SPEED ADJUSTMENT ADJ
SIDE COVER
Removal
1. Remove:
® Front seat G)
®Side cover (2)
lnstallation
Reverse removal step.
ENGINE
IDlE SIPEED ADJUSTMENT
1. Remove:
® Lower cowling
Refer to "COWLINGS" section.

2. Start the engine and warm it up.
3. Attach:
® 1 nductive Tachometer
To the spark plug lead.
lnductive Tachometer:
VU-08036
4. Check:
® Engíne idle speed
Out of specification ➔ Adjust.
Engine ld!e Speed:

1,300~ 1,400 r/min
5. Adjust:
® Engine idle speed
Adjustment steps:
@Turn the throttle stop screw G) in or out un-
til specified idle speed is obtained.
Tum in !die speed becomes higher.

Tum out !die speed becomes lower.
3-4
THROTTLE CABLE FREE PLAY ADJUSTMENT/ INSP
AUTOLUBE PUMP CABLE ADJUSTMENT ADJ
6. lnstall:
lll Lower cowling
THROTTlE CABLE FREE PLAY

ADJUSTMENT
NOTE:-------------
Befare adjusting throttle cable free play, engine
idle speed should be adjusted.
1. Check:
® Throttle cable free play ®
Out of specification � Adjust.
Thrnttle Cable Free Play:

3-7 mm I0.12-0l.28 in)
2. Adjust:
9 Throttle cable free play
Adjustment steps:
0 Loosen the locknut G).
@Turn the adjuster (2) in or out until the cor-

rect free play is obtained.
Tum in Free play is increased.

Turn out Free play is decreased.
@Tighten the locknut.
AUTOLUBE PUMP CABLE ADJUSTMENT

NOTE:---�---------
Before adjusting Autolube pump cable, the throt
tle cable free play should be adjusted.
1. Remove:
® Lower cowling
3-5
AUTOLUBE PUMP CABLE ADJUSTMENT/ INSP
AUTOLUBE PUMP STROKE ADJUSTMENT
ADJ
2. Remove:
oAutolube pump cover CD
3. Check:
oAlignment mark
Checki111g steps:
@ Start the engine.
® Rotate the throttle grip slightly until the slack

is removed from ·ali cables (Until the engine
speed just begins to rise).
°Check to see that Autolube pump plunger pin
CD is aligned with the match mark (2).
lncorrect-+ Adjust Autolube pump cable.
4. Adjust:
@Autolube pump cable
Adjustme111t steps:
® Loasen the locknut @.
eTurn the adjuster@ in or out until the align
ment mark is aligned with the pin.
oTighten the locknut.
5. lnstall:
0 Autolube pump cover
e Lower cowling
AUTOlUIBE PUMP STROKE ADJUSTMENT

1. Remove:
0 Lower cowling
Refer to the "COWUNGS" section.
3-6
AUTOLUBE PUMP STROKE ADJUSTMENT
INSP
ADJ
2. Remove:
oAutolube pump cover G)
3. Start the engine and warm it up.
4. While running the engine at idle, observe the

pump adjusting plate carefully. Stop the en
gine the moment that the adjusting plate G)
moves out to its limit.
5. Measure:
oGap
Out of specification-Adjust.
Measure the gap with the thickness gauge
between the raised boss (Z) on the pump
adjusting pulley and the adjusting plate G).
Mh1ümum Pump Stmkie:

0.20-0.25 mm
NOTE: -�=�==��=====-
When inserting the thickness gauge between the
adjusting plate and the adjusting pulley, be care
ful so that neither the plate nor the pulley is
moved. In other words, do not force the thick
ness gauge into the gap.
6. Adjust:
eAutolube pump mínimum stroke
Adjustment steps:
@Remove the locknut G), spring washer (2)
and adjusting plate ®·
@Adjust the pump stroke by adding or remov-
ing a shim(s) @).
Add shim Pump strnke is increased.

Remove shim Pump strnke is decreased.
3-7
AUTOLUBE PUMP STROKE ADJUSTMENT/ INSP
AUTOLUBE PUMP AIR BLEEDING
ADJ
@lnstall the adjusting plate, spring washer and
locknut.
locknut:
� 7 Nm (0.7 m•kg, 5.1 ft•lb)
• Recheck the minimum pump stroke. lf out of
specification, perform the above steps again.
7. lnstall:
® Autolube pump cover
"Lower cowlíng
AUTOLUBE PUMP AIR BLEEDING

NOTE:----------�-�
The Autolube pump and delivery lines must be
bled on the following occasions:
Setting up a new motorcycle out of the crate.
@
®Whenever the oil tank has run dry.

;,¡Whenever any portian of the engine oil system
is disconnected.
1. Remove:
® Lower cowling
Refer to "COWUNGS" section.

2. Remove:
©Autolube pump cover G)
3. Air bleed:
®Pump case and/or oil pipe
A.ir bleeding steps:

Remove the bleed screw G).
@
® Keep the oil running out until air bubbles dis
appear.
•When air bubbles are expelled completely,
tighten the bleed screw.
NOTE:------------
Check the bleed screw gasket (2), and if
damaged, replace with a new one.
3-8
AUTOLUBE PUMP AIR BLEEDING/ INSP
SPARK PLUG INSPECTION ADJ
4. Air bleed:
®Pump distributor and/or delivery hose
Air bleeding steps:

0Start the engine.
ciPull the pump cable G) all the way out to set
the pump stroke to a maximum.
NOTE:-=---=�---=�
lt is difficult to bleed the distributor complete
ly with the pump stroke at a mínimum, and
therefore the pump stroke should be set to a
maximum.
Qll Keep the engine running at about 2,000 r/min

for two minutes or so, and both distributor
and delivery pipe can be completely bled.
5. lnstall:
®Autolube pump cover
®
Lower cowling
SPARK PlUG INSPIECTION

1. Remove:
® Lower cowling
Refer to the "COWUNGS" section.
2. Remove:
0 Spark plug
3. lnspect:
@Spark plug type
lncorrect ➔ Replace.
Standard Spark Plug:

B7HS or B8HS/N.G.K.
3-9
SPARK PLUG INSPECTION/
IGNITION TIMING CHECK/ENGINE Oll LEVEL CHEC
4. lnspect:
c.Electrode G)
Wear / Damage- Replace.
0 1nsulator (2)
Abnormal color -+ Replace

Normal color is a medium-to-light tan color.
G) 5. Clean the spark plug with a spark plug clean
er or wire brush.
377-000 6. Measure:
®Plug gap ®
Use a Wire Gauge or Feeler Gauge.
Out of specification- Regap.
S¡parlk iP'h.ig Gap:

0.!5-0.6 mm í0.020-0.024 in}
7. Tighten:
0 Spark plug(s)
Befare installing a spark plug, clean the

gasket and plug surfaces.
NOTE: �=--�=-==-====
Finger-tighten the spark plug(s) before ing
to specification.
Spaak
25 Nm {2.5 m•
8. lnstall:
® Lower covvling
!GNIT!ON TIMiNG CHECK

Adjustment free.
IENGINIE O!l llEVEl CHECK

1. Check:
@Qi! level
Oíl leve! low --+ Add sufficient oíl.
Recom Oi!:
Yamalube "2" or Air Cooled 2
Strnke Engine Oii with "BIA
Certifiedl for Sernice TC-W"
Oil Tank Capacity:
0.73 l imp qt, 0.17 US qt)
3-10
ENGINE Oll LEVEL CHECK/ INSP
TRANSM ISSION O1 l LEVEL INSPECTION
ADJ
Oll lEVEl AND "Oll" WARNING INDICATOR LIGHT CHECKING METHOD
Main switch "ON"
Gears in "NEUTRAL"
"Oll" warning indicator "Oll" warning indicator

light does not come on light comes on
Shift into gear
"Oll" warning indicator "Oil" warning indicator

liglht goes off. light stays on
!nspect electricai cir
cuit. Refer to
Engine oi! leve! and elec ppiy engine oii
"CHAPTER 7-SiG
NAl SYSTIEM" trical circuit are OK. Go
section. ahead with riding.
G) "OIL" warning indicator light
Always use the same type of engine oil; mix

ing oils may result in a harmful chemical
reaction and lead to poor performance.
TRANSMISSION Oil LEVEL INSPIECTION

1. Place the motorcycle on a ievel surface and
warm up the engine for severa! minutes.
2. Stop the engine and remove the oil filler cap.
3-11
TRANSMISSION OIL LEVEL INSPECTION/ INSP
TRANSMISSION OIL REPLACEMENT ADJ
3. Rest the oil dip stick G) on the threads of the
hale.
NOTE:�--------�---
®Waít a few minutes until level settles befare in
specting.
@Qil dip stick is included in owner's too! kit.
e Position motorcycle straight up when inspect
ing oil leve!, a slight tilt to the side can produce

false readings.
4. lnspect:
@Qil level
Oil level should be between maximum (2)
and minimum ® marks.
Oil level low Add oil to proper leve!.
->
Recommended Oil:
Yamalube "4", SAE 10W30 Type
SE Motor Oil or "Gl" Gear Oil
NOTE:---��-�-�---�
Recommended engine oil classification; API Serv
ice "SE", "SF" type or equivalent (e.g. "SF-SE",
"SF-SE-CC", "SF-SE-SD" etc.).
TRANSMISSION Oll REPLACEMENT

1. Warm up the engine far several minutes and
stop the engine.
2. Place an oil pan under the engine.
3. Remove:
*Üil filler cap
® Drain plug G)
Drain the engine oil.
4. lnspect:
@Gasket G) (Drain plug)
@Q-ring (2) (Oil filler cap)
Damage-> Replace.
3-12
TRANSMISSION OIL REPLACEMENT/ INSP
CLUTCH ADJUSTMENT ADJ
5. lnstall:
@Drain plug
' Drain Plug:

�� 20 Nm (2.0 m•kg, 14 ft•lbl
6. Fill:
®Crankcase
Recommended Oii:
Yamalube "4", SAE 10W30 Type
SE Motor Oil or "Gl" Gear Oil.
Oil Capacity (Periodic Oil Change):
0.60 L {0.53 lmp qt, 0.63 US qt)
NOTE:--------===-�
Recommended engine oil classification; API Serv
ice "SE", "SF" type or equivalent (e.g. "SF-SE",
"SF-SE-CC", "SF-SE-SD" etc.).
® Do not allow foreign material to enter the

crankcase.
® Do not add any chemical additives. Tnms
mission oil also iubricates the clutch ami ad

ditives could cause clutch siippage.
7. lnstall:
@Qil filler cap
8. lnspect:
@Qil leaks
®Üil leve!
CLUTCH ADJUSTMENT
Free Play Adjustment
1. Check:
®Clutch cable free play ®
Out of specification- Adjust.
Al
AI
Free Play:
Iv 2-3 mm I0.08-0.12 in)
2. Adjust:
®Clutch cable free play
Adjustment steps:
® Loosen the locknuts G).
eTum the adjusters (í) in or out until the

specified free play is obtained.
Tum in Free play is increased.

Tum out Free play is decreased.
3-13 0 Tighten the locknuts.
INSP
CLUTCH ADJUSTMENT/AIR FILTER CLEANING ADJ
NOTE: �-----=�-==�=
The above procedure provides for maximum
cable free play to allow for proper clutch actu
ating mechanism adjustment.
Mechanism Adjustment
1. Loasen:
® Cable length adjuster locknut
2. Tighten:
® Cable length adjuster ( Until tight)
3. Remove:
® Lower cowling
® Flywheel magneto cover CD
4. Adjust:
° Clutch push lever free play
Adjustment ste¡ps:
® Loosen the locknut (D.
®Tum the adjuster (2) until it is lightly seated.
9 Turn out the adjuster 1 /4 tum.
0 Tighten the locknut while holding the ad
juster.
5. lnstall:
® Flywheel magneto cover
® Lower cowling
6. Adjust:
® Clutch cable free play
Refer to "Free play adjustment" section.
AIR FilTER ClEANiNG

1. Remove:
® Front seat
®Side cover
Refer to "SIDE COVER" section.
3-14
INSP
AIR FILTER CLEANING
ADJ
2. Turn the fuel cock to "OFF" and disconnect
the fue! hose.
3. Remove:
® Fuel tank G)
4. Remove:
® Air filter cover G)
5. Remove:
0 Air filter element CD
0 Element guide (2)
Never operai:e the engine with the airr fi!terr

element removed. This wm aliow unfüterndl
airr to enter, cam,ing rnpid wearr and possi
ble engine damage. Additeonaily,
without the füter e!emer ri: wm affact carbu
rretor tuning with subsequent pom perfor
mance and possible engine overheating.
6. Clean:
® Air filter element
Cleaning steps:
®Wash the element gently, but thoroughly in
solvent.
Never use low flash point solvents sud1 as

gasoline to clean the element. Such sol
vent may lead to a fire or explosion.
3-15
AIR FilTER CLEANING/ INSP
CARBURETOR JOINT INSPECTION ADJ
0 Squeeze the excess solvent out of the element
and let dry.
Do not twist the element when equeezing

the element.
7. lnspect:
® Air filter element
®Seal CD
Damage-+ Replace.
8. Apply:
® Foam-air-filter oil or Yamalube 2-cycle oil
Onto the element.

9. Squeeze out the excess oil.
NOTE: --------------
The element should be wet but not dripping.
10. lnstall:
111 Air filter element
0 Element guide
® Air filter case cover
When instaliing the air filter element in its

case, be sure its seaiing surface matches the
sealing surface of the case so there is no air
leak.
11. lnstall:
eFuel tank
9 Front seat
®Side cover
CARBURETOR JOINT INSPECTION

1. Remove:
e Lower cowling
2. lnspect:
• Carburetor joint CD
Cracks/ Damage-+ Replace.
3. lnstall:
@Lower cowl
3-16
FUEL UNE INSPECTION/Y.E.I.S. HOSE INSPECTION/ INSP
EXHAUST SYSTEM INSPECTION/FRONT BRAKE ADJUSTMENT
ADJ
¡¡,,.,.;;;....=__,==',,_=_
FUEL UNE INSPECTION

1. Remove:
® Lower cowling
Refer to "COWLINGS" section

2. lnspect:
e Fuel hose G)
Cracks/ Damage-Replace.
3. lnstall:
®lower cowl
Y.E.LS. HOSE INSPECTION

1. Remove:
"'Lower cowling
Refer to "COWUNGS" section..
2. lnspect:
®Y.E.I.S. hose G)
3. lnstall:
® Lower cowling
EXHAUST SYSTEM INSPECTION

1. Remove:
® Lower cowling
Refer to "COWUNGS" section.

2. lnspect:
® Exhaust pipe
®Gaskets
Exhaust gas leakage-Replace or tighten the
ring nut (Exhaust pipe).
Ring Nut (Exhaust Pipe):

6 Nm (0.6 m•kg, 4.2 ft•lbl
Bolt (Exhaust Pipe):
18 Nm 11.8 m•kg, 13 ft•lb)
3. lnstall:
® Lower cowling
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
®
e Brake lever free play
Out of specification-lnspect the brake
system.
Refer to "CHAPTER 7- FRONT BRAKE"
section.
Free Play:
3-17 2~5 mm (0.08~0.20 in)
REAR BRAKE ADJ STMENT/ INSP
BRAKE FUJU) INSPECTION
ADJ
RIEAR BRAKE ADJUSTMENT
1. Check:
® Brake pedal free play ®
Out of specification-Adjust.
Brnke IPedai Free Play:

20~30 mm !0.8~ 1.2 inl
Adjiustment steps:
® Turn the adjuster G) in or out until the speci-
fied free play is obtained.
T1.1m in Free play is decreasecl.

Tmn 01.1t Free play is increasedl.
BRAKiE Fll!ílD iNSPECTKJJN

1 . Make sure the master cylinder top is horizontal
turning the handlebars.
2. lnspect:
0 Brake fluid leve!
Fluid leve/ is under "LOWER" !evel line

G)---->Replenish.
Brnke fluid! may emde ¡painted sudaces or

piasii:iic pBl!'ts. Aiways dean up spiiied fü.1itdl
immediateiy.
0 Use oniy the designated iq¡iuaiity brnke fluid:

o1i:herrwise, the mbber seais may deteri
mate, causing ieakage amd poor brnke ¡per
formance.
o Refü! with the same type of brake fluid;
mixing fluids may result in a harmful c:hem
ic:a! reaction and lead to poor performance.
oBe carefo! that water does not enter the
master cylinder when refüling. Water wm
significant!y iower the boiling point of the
fluid arnd may result in vapor iock.
BRAKE PAD INSPIECTION/BRAKE SHOE INSPECTION/BRAKE INSP
LIGHT SWITCH AOJUSTMENT/BRAKE HOSE iNSPECTION
ADJ
BRAKE PAD INSPECTiON
1. Actívate the brake lever.
2. lnspect:
0 Brake pad G)
Wear indicator (2) almost contacts brake

disc®- Replace brake pad as a set.
Refer to "BRAKE PAD REPLACEIViENT"
section in the CHAPTER 6 far replacement.
346-024
BRAKIE SHOE !NSPIECTION

1. Actívate the brake pedal.
2. lnspect:
®Wear indicator G)
lndicator at wear limit line (2)-Replace
brake shoes.
BRAKIE UGHT SWITCH ADJUSTMENT

NOTE: ===�=========
The brake light switch is operated by movement
of the brake pedal.
Proper adjustment is achieved when the brake
light comes on just befare the brake begins to take
effect.
1. Hold the switch body G) with your hand so

that it does not rotate and tum the adjusting
nut (2).
BRAKE HOSE U\ISPlECTiON

1. lnspect:
® Brake hose G)
Crack/ Damage/ Fluid leakage--, Replace.
3-19
INSP
ORIVE CHAIN SLACK ADJUSTMENT ADJ
ORIVE CHAIN SlACK ADJUSTMENT
NOTE: --------------
Befare checking and/or adjusting, rotate the rear
wheel through several revolutions and check slack
at several points to find the tightest point. Check
and/or adjust the chain slack with the rear wheel
in this "tightest" position.
1. Check:
® Orive chain slack ®
Out of specification-----+Adjust.
Orive Chain Slack:

25~30 mm (1.0~1.2 in)
2. Adjust:
® Orive chain slack
Adjustment steps:
Too small chain slack wm overload the en

gine am:I other vital parts; keep the slack
within tlhe specified !imits.
"'Remove the cotter pin (D.

® Loasen the nut (Rear wheel axle) (2).
®Turn the adjusters ®
in or out until specific
slack is obtained
Tum out the adjusters and

lncrease slack push the rear wheel
forward.
Decrease slack Tum in the adjusters.
NOTE:------------
Turn each adjuster exactly the same amount
to maintain correct axle alignment. (There are
marks @ on each side of swingarm and on
each chain puller; use them to check for proper
alignment.)
3-20
ORIVE CHAIN SLACK ADJUSTMENT/DRIVE CHAIN INSP
LUBRICATION/STEERING HEAD ADJUSTMENT
ADJ
eTighten the nut (Rear wheel axle)
Nut (Rear Wheel Axle):

�
""'� 60 Nm (6.0 m•kg, 44 ft•lb)
9 1nsert a new cotter pin.
-NlNt�IR00100�:
ti �s z; =-� �:: -,;c,,r
Always use a new cotter pin.
®Bend the end of cotter pin as shown.

®Adjust the free play in the brake pedal.
ORIVE CHA!N lUBRICATION

The chain consists of many parts which work
against each other. lf the chain is not maintained
properly, it will wear out rapidly, therefore, form
the habit of periodically servicing the chain. This
service is especially necessary when riding in
dusty conditions.
1. Use any brand of spray type chain lubricant.
First, remove all dirt and mud from the chain
with a brush or cloth, then spray a lubricant
between both rows of side plates and on all
center rollers.
2. To clean the chain, remove the chain from the
machine, dip it in solvent, and clean out as
much dirt as possible. Take the chain out of
the solvent and dry it. lmmediately lubricate
the chain to prevent rust.
STEERING HEAD ADJUSTMENT
Securely support the motorcycle so therre is

no danger of it falling over.
1. Remove:
® Lower cowling
2. Elevate the front wheel by placing a suitable
stand under the engine.
3-21
INSP
STEEFUNG HEAD ADJUSTMENT
ADJ
3, Check:
0 Steering assembly bearings
Grasp the bottom of the forks and gently

rock the fork assembly back and forth,
Looseness-,, Adjust steering head,
4, Adjust:
0 Steering head
Adjustment steps:
0
Loosen the cap bolts G),
o loasen the steering stem bolt (V,
0 Tighten the ring nut using the Ring Nut
j
¡ Wrench CT),
Ring Nli.flt Wrench:

YU-33975
, NOTE: =======-=�=�=
1
Set the torque wrench to the ring nut wrench
1 so that they fom, a right angle.
iFfü1g Nli.flt liriiítiai Tightening):

30 Nm {3,0 m kg, 22 h lb)
0 0
i 0 Loosen the ring nut one tum,

© Retighten the ring nut using the Ring Nut
Wrench,
Avoid over-tigMening,
Ring Nut (Fina! Tighteningl:

6 Nm !0,15 m•kg, 4,3 fi:•lb)
@Tighten the steering stem bolt and cap bolt,
Steel'ing Stem Bo!t:

40 Nm {4,0 m•kg, 28 ft lb) 0
Cap Bo!t:
30 Nm {3.0 m•kg, 22 fíi: lb) 0
5, lnstall:
0 Lower cowling
3-22
TIRE INSPECTION
INSP
ADJ
TIRE INSPECTION
WARNING:
Do not attempt to use tubeless tires on a

wheel designad for tube type tires only. Tire
failure and personal injury may result from
sudden deflation.
Wheel Tire
Tube type Tube type only
Tubeless Tube type or tubeless
Be sure to install the correct tube when us

ing tube type tires.
1. Measure:
•Tire pressure
Out of specification--t Adjust.
WARNING:
Tire inflation pressure should be checked and

adjusted when the temperatura of the tire
equals the ambient air temperatura. Tire in
flation pressure must be adjusted according
to total weight of cargo, rider, passenger,
and accessories (fairing, saddlebags, etc. if
approved for this model), and vehicle speed.
Basic weight:
With oil and full 91 kg (201 lb)
fuel tank
Maximum load* 68 kg (150 lb)
Cold tire pressure Front Rear
Zero - Maximum 130 kPa 150 kPa

(1.3 kg/cm2 , (1.5 kg/cm2 ,
load*
18 psi) 21 psi)
*Load is the total weight of cargo, rider, and
accessories.
2. lnspect:
•Tire surfaces
Wear / Damage--t Replace.
Minimum Tire Tread Depth:

(Front and Rear)
1.0 mm (0.04 in)
CD Tread depth
(í)Side wall
@ Wear indicator
3-23
WHEEL INSPECTION/CABLE INSPECTION AND
LUBRICATION
WHEEL INSPECTION
1
_
�gs .1 �
....-- _1
1. lnspect:
•Wheels
Damage/ Bends---+ Replace.
NOTE:-------------
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING:
Nevar attempt even small repairs to the
wheel.
2. Tighten:
•Valve stem locknut
NWARNING:
1.5 Nm 10.15 m,kg, 1.1 lt-lbl
1
Ride conservatively after installing a tire to

allow it to seat itself properly on the rim.
CABLE INSPECTION ANO LUBRICATION

WARNING:
Damaged 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. lnspect:
• Cable sheath
Damage---+ Replace.
3-24
CABLE INSPECTION AND LUBRICATION/LEVER AND
PEDAL LUBRICATION/SIDESTAND LUBRICATION
2. Check:
l
_
i::!g� 1. �
�- _1
• Cable operation
Unsmooth operation- Lubricate.
Recommended Lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 Motor Oil
NOTE:-------------
Hold cable end high and apply severa! drops of
lubricant to cable.
LEVER AND PEDAL LUBRICATION

Lubricate pivoting parts of each lever and pedal.
SIDESTAND LUBRICATION
Lubricate the sidestand at pivot points.
3-25
BATTERY INSPECTION
INSP
ADJ
ELECTRICAL
BATTERY INSPECTiON
1. Remove:
°Front seat
0 Side cover
Refer to "SIDE COVER" section

2. lnspect:
Fluid leve! should be between upper (D and
lower � level marks.
incorrect_.,. Refill.
Refill with disfüled water oniy; tap water

contains minarais harmfol to a battery.
3. lnspect:
0 Battery terminal
Dirty terminal----, Clean with wire brush.
-------=----�
Poor connection ----, Correct.
NOTE:
After cleaning the terminals, apply grease lightly
to the terminals.
4. Connect:
® Breather hose (D
Be sure the hose is properly attached and

routed.
el) Pass the breather hose into the clamp.
5. lnspect:
® Breather hose
Obstruction----, Remove.
Damage----, Replace.
When inspecting the battery, be sme the

breather hose is routed correctly. lf the
breather hose touches the frame or exits in
such a way as to cause battery electrnlyte
or gas to exit onto the frame, stmcturnl and
cosmetic damage to the motorcycle can
occur.
----l> 6. Check:
® Specific gravity
Less than 1.280----, Recharge battery.
Charging Cmirent:
0.4 amps/10 hrs (6V)
Specific Gravity:
1.280 at 20° C (68 ° F)
3-26
BATTERY INSPECTION 1 �g� n 1 1
Replace the battery if:

• Battery voltage will not rise to a specific value
or bubbles fail to rise even after many hours
of charging.
•Sulfation of one or more cells occurs, as in
dicated by the plates turning white, or an ac
cumulation of material exists in the bottom
of the cell.
•Specific gravity readings after a long, slow
charge indicate one cell to be lower than the
rest.
•Warpage or buckling of plates or insulators
is evident.
Always charge a new battery before using

it to ensure maximum performance.
WARNING:
Battery electrolyte is dangerous; it contains

sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive measures:
•Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
367-009
injury.
•Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
•SKIN-Flush with water.
•EYES-Flush with water for 15 minutes and
get immediate medica! attention.
Antidote (INTERNAL):
• Drink large quantities of water of milk. Fol
low with milk of magnesia, beaten egg, or
vegetable oil. Get immediate medical at
tention.
Batteries also generate explosive hydrogen
gas, therefore you should always follow
these preventive measures:
•Charge batteries in a well-ventilated area.
•Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
3-27
INSP
BATTERY INSPECTION/FUSE INSPECTION
ADJ
®DO NOT SMOKE When charging or han
dling batteries.
KEEP BATIERIES AND ElECTROlYTE OUT
OF REACH OF CHILDREN.
FUSE INSPECTION
1. Remove:
G>Front seat
®Side cover
Refer to "SIDE COVER" section
2. Remove:
®Fuse G)
3. lnspect:
G>Fuse
lnspeiction steps:
@Connect the Pocket Tester to the fuse and
check it for continuity.
NOTE:
Set the tester selector to "íl x 1" position.
fb
Pocket Tester:
YU-03112
® lf the tester is indicated at oo. The fuse is
blown, replace it.
4. Replace:
0 Blown fuse
Blown fose replacement steps:

0Turn off ignition and the circuit.
®lnstall a new fuse of proper amperage.
fuse: 10A
@Turn on switches to verify operation of elec-

trical device.
® lf fuse blows immediately again, check circuit
in question.
3-28
FUSE INSPECTION/HEADUGHT BEAM ADJUSTMENT/ INSP
HEADUGHT REPLACEMENT
ADJ
' '
WA:ROOIOOG:
,x.¡
" , ;,
Do rmt use foses of higher amperage rnting

than recommended. Extensive electrical sys
tem damage and fire could result fmm sub
stñtution of a fose of improper amperage.
HEADLIGHT BEAM ADJUSTMENT

1. Adjust:
0 Headlight beam (Vertical)
To raise the Tum the adjustell' G)

beam clockwise.
To !ower Tum the adjuster G)
the beam countercloc kwise.
2. Adjust
® Headlight beam (Horizontal)
To irigM ti-le ®
Tum ti-le adjuster
beam ccn.mterclockwise.
To left the Tum the adjuster ®
beam clockwise.
HEADUGHT REPLACEMENT
1. Remove:
0 Lower cowling
° Flasher lights ( Left and right)

° Flasher light stay
2. Remove:
0 Headlight CD
3. lnstall:
0 Headlight (New)
4. lnstall:
° Flasher light stay
® Flasher lights ( Left and ríght)
® Lower cowling
5. Adjust:
0 Headlight beam
Refer to "HEADUGHT BEAM ADJUST

MENT" section.
3-29
INSP
ADJ
ENGINE REMOVAl ENG
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: ---------��-==
® lt is not necessary to remove the engine in ord-
er to remove the following components:
®Cylinder head
@Cylinder
® Pistan and pistan ring
@Clutch
0 Primary drive gear
®Kick axle
@Shift shaft
@CDI magneto
@Autolube pump
TRANSMISSION Óll
1. Drain:
®Transmission oil
Refer to "CHAPTER 3- TRANSMISSION
OIL REPLACEMENT".
COWUNG AND SiDE COVER
1. Remove:
® Lower cowling
Refer to "CHAPTER 3-COWLINGS''

section.
® Front seat
0 Side cover
Refer to "CHAPTER 3-SIDE COVER"

section.
FUEL TANK
1. Turn the fuel cock to "OFF" position and dis
connect the fue! hose G).
2. Remove:
® Fuel tank
4-1
ENGINE REMOVAl ENG
MUFFLER
1. Remove:
®Ring nut CD
2. Remove:
vMuffler CD
CARBURETOR
1. Remove:
ª Carburetor assembly
Refer to the "CHAPTER 5-CARBURE
TOR" section.
AUTOLUBE PUMP CAIBllE AND HOSE

1. Remove:
®Autolube pump cover CD
2. Disconnect:
®Autolube pump cable G)
®Üil hose (2)
NOTE: ------�=-----
Plug the oil hose end with a suitable screw.
4-2
ENGH\IE REMOVAL ENG
lEADS
1. Disconnect:
0 Spark plug lead G)
0 YEIS hose�
2. Disconnect:
©COI magneto leads
0 Neutral switch leads
3. Remove:
0 Bands CD
r
cu. rcH CABLE
1. Remove:
®Change pedal CD
°Crankcase cover (left) �
0 Gasket (Crankcase cover - left)
DfffVIE CHAiN
1. Loasen:
0 Nut (Rear wheel axle) G)
oAdjuster�
2. Push forward the rear wheel to loasen the
drive chain.
3. Remove:
®Circlip CD
0 Orive sprocket�
0 Orive chain @
4-3
ENGI E RE l
ENGiNE IREMOVAL
1. Remove:
e Side stand switch leads CD
0 8ands (2)
0 Down tube ®
2. Place a suitable stand under the engine.

3. Remove:
@Bolt (Engine-Rear) CD
® Engine assembly
4-4
ENGINE DISASSE EN
ENGINE DISASSEMBlY
CYUNDER HEAD, CYUNDIER AND
PISTON
NOTE: ��===-----��-
With the engine mounted, the cylinder head,
cylinder and pistan can be maintained by remov
ing the following parts.
0 Lower cowling
0 Muffler
1. Remove:
0 Spark plug G)
o Cylinder head (2)
2. Remove:
®Gasket (Cylinder head) G)
oCylinder (2)
0 Gasket ( Cylinder)
0 1ntake manifoid @
0 Oil delivery hose @
oReed valve
0 Gasket (Reed valve)
3. Remove:
® Pistan pin clip G)
NOTE:=�===-=�===�-
Befare removing pistan pin circlip, cover crank
case with a clean rag to prevent circlip from fall
ing into crankcase cavity.
4-5
ENGINE DISASSEMBLV E G
4. Remove:
9 Piston pin
o Pistan
0 Small end bearing
NOTIE: -�=-�=========
Befare removing the pistan pin, deburr the clip
grooved and pin hole area. lf the pistan pin groove
is deburred and pistan pin is still difficult to re
move, use Pistan Pin Puller.
IPiston Piro Pulier:

YU-01304
Do not use a hammer to drive the pistoro pin

ICH..111:.
ClUTCH AND IPIR:!MARY DRIVIE GIEAR

NOTIE: =======--�---=
With the engine maunted, the clutch and primary
drive gear can be maintained by removing the fol
lowing parts.
0 lower cowl
8 Autolube pump cable and hoses
1. Remove:
6)Kick crank CD
eCrankcase cover (Right) (2)
2. Remove:
®Bolts (Pressure plate) CD
o Springs (Pressure platel
4-6
ENGiNE DISASSEMBlY ENG
3. Remove:
® Pressure plate G)
° Friction plates 0
oCushion spring @
o Clutch plate @)
® Clutch damper @
0Push rod # 1 @
' 0Ball (JJ
\--®
0Push rod #2 @
·----{!)
\---@
4
4. Remove:
0Nut (Clutch boss) G)
oConical spring washer
° Clutch boss 0
oThrust washer
Use the Universal Clutch Holder @ to hold
the clutch boss.
Univernal Clutch Hokler:

YM-91042
5. Remove:
eNut (Primary drive gear) G)
° Conical spring washer
NOTE: �=�==---�----�
Place a folded rag0 between the teeth of the
primary drive gear and driven gear.
4-7
ENG!NE DISASSEMBLY E G
6. Remove:
"'Clutch housing G)
@Spacer (2)
0 Thrust washer ®
® Primary drive gear @
o Straight key @
@Collar@
KICK AXlE
NOTE: �=============
With the engine mounted, the kick axle and kick
idle gear can be maintained by removing the fol
lowing parts.
® Lower cowling
®Autolube pump cable and hoses
Crankcase cover ( Right)
G)
@Clutch
1. Unhook the spring G).
2. Remove:
"'Kick axle assembly (2)
3. Remove:
°Circlips G)
6 Washer (2)
® Kick idle gear ®
4-8
ENGílN!E DISASSEMBL 'V ENG
SHIFT SHAFT
NOTE: ==�-==
With the engine rnounted, t.he shift shaft can be
ma¡nt&ined by removing the followir.g parts.
"Lower cowling
� Autolube p;.,1mp cable and hoses
®Crankcase cover (Right)
°Clutch
1. Remove:
(l)Circlip G)
t) Shift lever (Í)
2. Remove:
oCirclip (Changa pedal side) G)
eiWasher
0 Shift shaft (2)
CDu iViAGi\lETO
NOlri=: --�-------
With the engine mounted, the COI magneto can
be maintained by removing the following parts.
0
Lower cowiing
1. Remove:
sNut (Rotor) G)
Use the Universal Rotor Holder � to hold
the CDI magneto.
Universal Rotoir Holder:

-=-.1!.=�v_u_-0_1_23=5�_________ j
4-S
ENGINE ISASSEMB
2. Remove:
o RotorCD
0 Woodruff key
Use the Fiywheel Puller W to remove the

rotor.
Fiywhee! Pu!ler:
P/N YM-01189
3. Remove:
0 StatorCD
o Neutral switch lead W
CRANl<CASE
1. Remove:
0 Shifter holder CD
0 Bearing holder W
2. Remove:
0 Bolt (Shift cam stopper) CD
0 Gasket W
oSpring @
0 Shift cam stopper @
3. Remove:
�--=�--�---=--
0 Screws (Crankcase)
NOTE:
Working in a crisscross pattern, loasen ali screws
1 / 4 turn each. Remove them after ali are
loosened.
4-10
ENGINE DISASSEMBLY ENG
4. Attach:
°Crankcase Separating Tool G)
Cn,1nkcase Separating Too!:

P/N YU-01135
5. Remove:
E:JCrankcase (Right) (2)
NOTE: -============�
° Fully tighten the tool holding bolts, but make
sure the tool body is parallel vvith the case. lf
necessary, one screw may be backed out slightly
to level tool body.
0 /l.s pressure is applied, altemately tap on the
front engine mounting boss, transmission shafts,

and shift cam.
CAUT!ON:
Use soft hammew t(()J tap mi the case ha!f. Tap
only (()Jll1 lf·einforc:ed portions of caise. Do not
tap on gasket mating surface. Wmk simNiy
and carefully. Make stme the case haives
separate evenly. ir «:me erwl "hangs up," take
prnssv:rn oH the p1.1sh scrrew, rna!ign, ,,md
sítart oveL if the cases do not separnte,
!Check ·�m a remaining case sc¡¡ew or fitting.
D(O) not force,
TRANSM!SSiON, SHiFTER AND

CRANl<SHAFT
1. Remove:
eGuide bar (Shift fork) G)
oShift fork #2 (2)
@Shift fork #3 @
®Shift cam @
®Main axle@
o Drive axle ®
oShift fork it-1 (JJ
Remove the transmission assembly upward.
4-11
ENGINE DISASSEMBLY ENG
2. Remove:
® Crankshaft CD
Use the Crankcase Separating Tool 0-

Crankcase Separating Tooi:
YU-01135
4-12
_ _ P_ EC
__________INS _ _T_ ION _ _D_R_E P_ A_ _IR_ I ENG
_ _ AN
INS P ECTION AND RE P A IR
1,� 1
CYLINDER HEAD
1. Eliminate:
• Carbon deposits
Use a rounded scraper.
NOTE: --------------
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
325-001
scratching the aluminum.
2. Measure:
• Cylinder r 1ead warpage
Out of specification-+ Resurface.
Warpage Limit:
0.02 mm (0.001 in)
301-009
Warpage measurement and resurface
ment steps:
•Attach a straight edge G) and a thickness
gauge (l) on the cylinder head.
• Measure the warpage.
• lf the warpage is out of specification, resur
face the cylinder head.
•Place a 400 ~ 600 grit wet sandpaper on the
surface plate, and resurface the head using
a figure-eight sanding pattern.
NOTE:------------
Rotate the head severa! times to avoid remov
ing too much material from one side.
CYLINDER ANO PISTON

1. Eliminate:
• Carbon deposits
From the pistan crown and ring grooves.
2. Eliminate:
• Score marks and lacquer deposits
From the sides of pistan.
Use a 600 ~ 800 grit wet sandpaper.
NOTE: --------------
Sand in a crisscross pattern. Do not sand exces
sively.
3. lnspect:
307-002 •Pistan wall
4-13 Wear/ Scratches/ Damage-+ Replace.
INSPECTION AND REPAIR I ENG 1 ,.. ,
4. Remove:
•Carbon deposits
Use a rounded scraper.
325-003
5. Measure:
•Piston-to-cylinder clearance
Piston-to-cylinder clearance measurement

steps:
First Step:
•Measure the cylinder bore "C" with a Cylinder
Bore Gauge.
NOTE:
Measure the cylinder bore "C" in parallel to and
at right angles to the crankshaft. Then, find the
average of the measurements.
Standard Wear Limit

�
Cylinder Bore 40.00-40.02 mm 40.1 mm
''C'' (1.575-1.576 in) (1.579 in)
Taper "T" 0.05 mm
(0.0019 in)
Out of Round 0.01 mm
''R'' (0.0004 in)
C=Maximum D
T=(Maximum D1, or D2)-
(Maximum Ds or D6)
R = (Maximum D1, D3 or Ds)-
(Minimum D2 D4 or D6)
•lf out of specification, rebore or replace

cylinder, and replace piston and piston rings
as a set.
Second Step:
•Measure the piston skirt diameter "P" with
a micrometer.
® 5 mm (0.20 in) from the pistan bottom
edge.
307-000
4-14
_D_R_E _ P_A _IR_
_________I_N _S_PE_C_T_ I_O_N_ A_ N I 1,�1
ENG
1� Standard
Piston size P
39.96~39.98 mm
(1.573~1.574 in)
Oversize 1 40.25 mm (1.58 in)
Oversize 2 40.50 mm (1.59 in)
• lf out of specification, replace pisten and
pisten rings as a set.
Third Step:
•Calculate the piston-to-cylinder clearance with
following formula:
Piston-to-cylinder Clearance =
Cylinder Bore "C" -
Piston Skirt Diameter "P"
• lf out of specification, rebore or replace

cylinder, and replace pisten and pisten rings
as a set.
Piston-to-cylinder Clearance:
� 0.030~0.035 mm
(0.0012 ~ 0.0014 in)
Limit: 0.1 mm (0.004 in)
PISTON RINGS
1. Measure:
•Side clearance
Out of specification---+ Replace pisten and/ or
rings.
Use a Feeler Gauge (D.
Top
0.03~0.05 mm
307-005
Side (0.001~0.002 in)
Clearance 0.03~0.05 mm
2nd (0.001~0.002 in)
4-15
INSPECTION ANO REPAIR I 1,.. 1
ENG
2. lnstall:
•Piston ring
lnto the cylinder.
Push the ring with the piston crown.
3. Measure:
l- J
'
'
•End gap
Out of specification-. Replace rings as a set.
Use a Feeler Gauge.
-- ,,
307-027
0.15-0.35 mm
Top
(0.006-0.014 in)
End Gap
0.15-0.35 mm
2nd
(0.006-0.014 in)
Oversize Piston Ring

Oversize 1 25
Oversize 2 50
PISTON PIN ANO BEARING

1. Lubricate:
•Piston pin (Lightly)
2. lnstall:
• Small end bearing
•Piston pin
lnto the small end of connecting rod.
3. Check:
•Free play
There should be no noticeable free play.
Free play exists-> lnspect the connecting rod
for wear/Replace the pin and/or connect
ing rod as required.
4. lnstall:
307-014 •Piston pin
lnto the piston pin hole.
4-16
INSPECTION AND REPAIR
5. Check:
I 1,.. 1
ENG
• Free play (when the pistan pin is in place in

the pistan)
There should be no noticeable free play.
Free play exists-➔ Replace pistan pin and/ar
pistan.
6. lnspect:
• Pistan pin and bearing
307-016
Signs of heat discolaration-➔ Replace.
CLUTCH
1. lnspect:
• Friction plate
Damage/Wear-➔ Replace friction plate as a
set.
2. Measure:
• Friction plate thickness
Out of specificatian-➔ Replace frictian plate
311-000 as a set.
Measure at all four points.
1� Wear Limít: 2.7 mm (0.106 ínl
3. lnspect:
• Clutch pi ate
Damage-➔ Replace clutch plate as a set.
4. Measure:
• Clutch plate warpage
Out of specificatian-➔ Replace clutch plate
as a set.
Use a surface plate and Feeler Gauge G).
311-002
� Warp Limít: 0.05 mm (0.001 inl
5. lnspect:
• Clutch damper
Wear/ Damage-➔ Replace.
4-17
_________,_N_SP_ E_C_T_IO_ N_A _ _ND_R_EP_A_ I_R_ I
6. Measure:
ENG 1,.1
•Clutch spring free length G)
Out of specification -+ Replace spring as a
set.
Clutch Spring Minimum Length:

26.2 mm (1.03 in)
302-005
7. lnspect:
• Dogs on the clutch housing
Cracks/Wear/ Damage -+ Deburr or replace.
•Clutch housing bearing
Scoring /Wear/ Damage -+ Replace clutch
housing.
NOTE:-------------
Scoring on the clutch housing dogs will cause
erratic operation.
8. lnspect:
•Clutch boss splines
Scoring /Wear/ Damage -+ Replace clutch
� � boss.
- NOTE:-------------
I l¡.,11'
-
1
¡ Scoring on the clutch boss splines will cause er
-
1
� 1� I ratic operation.
�
- \
�
9. Check:
•Circumferential play
Free play exists -+ Replace.
10. Measure:
e Push rod runout
Out of specification -+ Replace.
Bending Limit:
0.2 mm (0.008 in)
8 '7-í-
311-003
4-18
U\ISPECTION AND REPA!R ENG
PfUMAIPfY IORIVIE
1. lnspect:
o Primary drive gear teeth CD
ei Primary driven gear teeth (V
Wear/ Damage -> Replace both gears.
Excessive noises during operation -> Replace
both gears.
KICK
1. lnspect:
o Kick gear teeth CD
® Kick idle gear teeth �
Damage/wear- Replace both gears.
2. Measure:
o Kick clip tension
Out of specification- Replace.
Use a spring balance G).
:::::::::::::::::::
Kick Clip Tension:
( U 8-1.3 kg 11.76-2.81 ilb)
317-003
SHIFT SHAFT
1. lnspect:
©Shift shaft G)
Damage/ Bends/Wear- Replace.
@Shift lever (2)
Wear/ Damage- Replace.
4-19
SPECT!ON IR E
TRANSMiSSION AND SHiFTER
1. lnspect:
oShift fork cam follower G)
0 Shift fork pawl (2)
Scoring/ Bends/Wear-+ Replace.
2. lnspect:
c,Shift cam groove
eShift cam segment
Wear/ Damage-> Replace.
3. Check:
0 Shift fork movement
Unsmooth operation -+ Rep!ace sllift fork

and/or guide bar.
4. inspect:
oGuide bar
Roll the guide bar on a flat surface.
Bends-+ Replace.
Do not attempit to straighten a bent guide

bar.
5. Measure:
®Axle runout
Use centering device and dial gauge.
Out of specification -+ Replace bent axle.
Runout limit:
0.08 mm í0.003 in)
4-20
INSPECTION ANO REPAIR
6. lnspect:
•Gear teeth
Blue discoloration/ Pitting/Wear -+ Replace.
•Mated dogs
Rounded edges/Cracks/Missing portions -+
Replace.
7. Check:
• Proper gear engagement (Each gear)
(to its counterpart)
lncorrect -+ Reassemble.
•Gear movement
Roughness -+ Replace.
8. lnspect:
•Circlips
Damage/ Looseness/ Bends -+ Replace.
-G) CRANKSHAFT
1. Measure:
•Runout
Use a centering device and Dial Gauge.
I�AJ�
Out of specification -+ Replace or repair.
Runout Limit:
v 0.03 mm (0.0012 in)
_
308-001
2. Measure:
•Small end free play G)
Use a Dial Gauge.
Out of specification -+ Replace the defective
parts.
Small End Free Play:

0.8-1.0 mm (0.032-0.039 in)
<Limit>:
<1.5 mm (0.060 in)>
3. Measure:
• Big end side clearance (2)
Use a Feeler Gauge.
Out of specification-+ Replace the defective
parts.
Big End Side Clearance:

0.2-0.7 mm (0.008-0.028 in)
<Limit>
<1.0 mm (0.04 in)>
4-21
INSPECTION ANO REPAIR ENG
4. lnspect:
•Crankshaft bearing
Pitting/ Damage--. Replace.
NOTE: --------------
Lubricate the bearings immediately after examin-
ing them to prevent rust.
5. lnspect:
•Oil seals
Wear/ Damage--. Replace.
CRANKCASE
1. Thoroughly wash the case halves in mild
solvent.
2. Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3. lnspect:
•Crankcase
Cracks/ Damage--. Replace.
•Oil delivery passages
Clog --. Blow out with compressed air.
AUTOLUBE PUMP
Wear or an interna! malfunction may cause pump
output to vary from the factory setting. This sit
uation is, however, extremely rare. lf improper
output is suspected, inspect the following:
1. lnspect:
• Delivery line
Obstructions --. Blow out.
•Pump body seal/Crankcase cover seal
Wear/ Damage--. Replace.
•Check ball/Spring
Miss/ lmproper --. Repair.
2. lnspect:
•Allowing air
Air exists-->Air bleed.
4-22
INSPECTION AND REPAff� ENG
3. Check:
® Pump output
Out of specification----. Adjust.
Minimum Outpurlt/200 Stmke:

0.50-0.63 cm 3
Maximum Output/200 Stmke:
4.64-5.15 cm 3
4. lnspect:
0 0il hose
@ Oil delivery hose
Crack/ Darnage/ Clog �> Replace.
4-23
ENGINE ASSEMBLY AND ADJUSTMENT ENG
ENGINE ASSEMBLY D
A USTMENT
CRANKSHAIFT, SHIIFTEIR AND
TRANSM!SSION
1. Attach:
®Crankshaft lnstalling Tool CD
@Adapter (2)
Crnnkshaft h11stalli111g Too!:

YU-90050
Adapter:
YIU-90063
2 lnstall:
®Crankshaft
To Crankcase (Left)
Hokl the connecting¡ red at top dead center

with orne hand whiie t11..11rning the n11..11t oi the
!nstamng Too! with the other. Operarte the
!nstalfü1g Tooí llintül the cnainkshah bot!:oms
against the beau-ing¡.
3. lnstall:
@Shift fork # 1 CD
oShih fork #2 (2)
0 Shift fork #3 @
®Guide bar (Shift fork) @

®Shift cam ®
® Main axle assembly @
® Orive axle assembly (J)
4. Check:
®Shifter operation
0 Transmission operation
Unsmooth operation --+ Repair.
4-24
ENGINE ASSEMB AND USTME G
CRANKCASE
1. Apply:
0 Yamabond No.4
To the mating surfaces of both crankcase

halves.
l?I Yamabond illo.4:
2. lnstall:
ACC-11001-30-00
0 0-rings
0 Dowel pins CD
Onto the crankcase ( Lower)
3. Fit the right crankcase onto the left case. Tap

iightly on the case with a soft hammer.
Before instaifü1g and torquing the crnnkcase

holding scnews, be surn to check whetherr
the tra1nsmission is foru:::tioning prnpedy
marmaiiy rntating the shifl: cam either '\Jway.
4. Tighten:
0 Screw (Crankcase)
Tighten the crankcase tightening screws in

stages, using a crisscross pattern.
Scn:iw:s, !Crnnkca::;e):
8 Nm I0.8 m•kg, 5.8 tt•ifo}
4-25
ENGi E ASSEMBLY AN ADJUSTMENT ENG
5. Remove:
@Bond
Forced out on-the cylinder mating surface.
6. Apply:
@2-stroke oil
To the crank pin, bearing and oil delivery
hole.
7. Check:
@Crankshaft and transmission operation
Unsmooth operation --+ Repair.
8. install:
@Shift cam stopper G)
0 Spring (2)
@Gasket (New) @
oBolt (Shift cam stopper) @
9. lnstall:
@Shifter holder G)
0 Bearing holder (2)
Screws !Beatring Holder):

8 Nm IO.S m •kg, !5.8 ft ibl
0
ILOCT!TIE®
Scrnw ISlhifter
8 Nm IO.S m k91, !5.8 H lb)
0 0
lOCTITIE®
4-26
ENGINE ASSEMBLY EN
CRANKSHAFT, PiSTON AND IPiSTON R!NG
CD Crankshaft assembly @ Piston ® Bearing
(2) Crank ( Left) ® Pistan ring set @ Oil seal ( Left)
@ Crank (Right) @ Pistan pin @ Oil seal (Right)
@ Connecting rod (U) Piston pin clip
@ Big end bearing @) Small end bearing
@ Crank pin @ Woodruff key
(J) Bearing @ Collar
A IP'!STON TO CYUNDIER CLIEARANCE: B END GAP UNSTAlllEDl:

0.1)30-0.035 mm (ll0012-0.0I014 inl TOP R!NG
<UMiT> l[U5-0.35 mrn !l)).Ol6-[Hi14 in)
<(ll.1 mm (C).004 in)> 2nd R!NG
0.15-0.35 mm (i(l.016-0.014 in)
C SIDE ClEARANCIE:
TOP R!NG
0.030-0.035 mm (l().IJ01-l[U]02 in)
2nd R!NG
0.030-[UJl35 mm (l(Jl.001-0.1)02 in)
\1
E USE NEW ONIE
l
E
, l:
l
[l
4-27
TRANSMISS!ON
G) Main axle assembly ® Orive axle
� Main axle Q]) 1 st wheel gear
@ 4th pinion gear @ 4th wheel gear
@ Circlip @ 3rd wheel gear
@ 3rd pinion gear @ 2nd wheel gear
® 2nd pinion gear ® 5th wheel gear
(jJ 5th pinion gear ® Oil seal
® Bearing holder @ Orive sprocket
® Bearing @ Circlip
B USE NIEW ONIE

4
11
13
1 B / �SE NEW ONE j

10
,
rl ' 'e¡,- · '
' '
1 '. - '
1
1
B USE NIEW ONIE
B USE NEW ONE
4-28
SHIIFTER
CD Guide bar (Shift fork) @ Shift cam assembly
e?) Shift fork #2 ® Shift cam plate
@ Shift fork #3 @ Shift cam stopper
@ Pin (U) Spring
@ Circlip @ Bolt
@ Shift fork #1 @ Circlip
(!) Cotter pin @ Segment
A USIE NEW ONE
1
G
4-29
CDi MAGNETO
1. lnstall:
®Stator G)
® Neutral switch lead (2)
Bolts (Statorl:
8 Nm {0.8 m•kg, 5.8 ft ib) 0
2. lnstall:
®Woodruff key G)
® Rotor (2)
NOTE:�-�----------
When installing the rotor, make sure the woodruff
key is properly seated in the keyway of the
crankshaft.
Clean the tapered portian of the crankshaft end
with a cloth.
3. Tighten:
0 Nut G) (Rotor)
Use the Universal Rotor Holder (2) to hold

the rotor.
Universal Roti:n Holder:

YU-01235
Nut {Rotor):
50 Nm (5.0 m kg, 36 ft•lb)
0
4-30
ENGINE ASSEMBLY AND ADJUSTMENT
CDi MAGNETO
CD Rotor
� Stator ass�m bl y
� Charge coi!
_
@� L"1g hting coi!
@ Pickup COI·1
4-31
ENGINE ASSEMBLV AND ADJUSTMENT ENG
SHIFT SHAFT
1. lnstall:
@Shift shaft
eiCirclip (New) G)
2. lnstall:
® Shift lever el)
NOTE:=-----=-===-�
Be sure the shift lever el) correctly engages the
shift cam and shift shaft.
KICK AXlE
1. lnstall:
0 l<ick axle assembly CD
NOTE: ---========--
º Make sure that the kick stopper is stopped at
the projection o-f the crankcase.
0 1\/lake sure that the kick el ip is engaged with the
crankcase hole.
2. Hook the kick spring el).
3. lnstall:
°Circlips G)
® Kick idle gear el)
@Washers@
4-32
ENG '\11 1
ENGINE ASSEMBlY ANO ADJUSTIV'IENT
--------------��-------� 6=...�-�-==a=!
SHIFT SHAFT AND KICK AXLE

G) Shift shaft ® Change pedal
(2) Circlip ® Kick crank
@ Shift lever @ Return spring
@ Rotor (jJ) Collar
@ Return spring @ Kick axle
@ Pin @ Kick idle gear
(J) Oil seal
l
G
ft lbl
0
"-=-�-�-�=-=
10 ��
�8
Q ,f/4lil 11 -
10 Nm !H.I m kg, 7.2 ft
0
��
l
�
u. �
1
�--�
2 ,�
�'
1
4-33
ENGINE ASSEMBLY AN ENG
CUJTCH ANO PRIMARY DR!VIE GEAR
1. lnstall:
0CollarCD
0 Strnight key (Í)
@ Primary drive gear ®

o Thrust washer @
°Collar@
°Clutch housing @
° Conical spring washer (j)
0 Nut@
NOTE: =-===========
® Be sure to install the conical spring washer (JJ
as shown.
0 Apply the transmission oil onto the collars.
2. Tighten:
oNut (Primary drive gear)
NOTE: ======-�=====�
Place a folded rag CDbetween the teeth of the
primary drive gear and driven gear.
3. lnstall:
0 Thrust washer CD
° Clutch boss (V
@ Conical spring washer ®
0 Nut (Clutch boss) @
NOTE: -�===�=-----�
Be sure to install the canica! spring washer 1'.:ID
as shown.
4. Tighten:
0Nut (Clutch boss) CD
Use the Universal Clutch Holder (Í) to hold
clutch boss.
Univernal Clutch Holder:

YM-91042
5. Insta!!:
®Clutch damper G)
° Friction pi ate (l)
® Clutch plate ®
°Cushion spring @
®
\�
0 Push rod #2
eBall@
o Push rod # 1 (jJ
'---@
r-<v
0 Pressure plate @
NOTE:==-=-�----=--
lnstall the clutch damper and friction plate alter
nately on the clutch boss, starting with a clutch
damper, and install the clutch plate between first
friction plate and second clutch damper.
6. lnstall:
0Springs (Pressure plate)
G)Bolts (Pressure plate G)
NOTE:===-========-
Tighten the bolts in stages, using a crisscross
pattern.
7. lnstall:
® Dowel pins G)
0 Gasket (Crankcase cover-New) (2)
®Crankcase cover ®
@ Kick crank @
NOTE: -�=-=�==--===-
Tighten the screws in stages, using a crisscross
pattern.
Screws (Crnnkcase Cover-Rügh11:):

10 Nm 11.0 m•kg, 7.2 ft•lb)
!Boit (Kick Crnnk):
20 Nm (2.0 m•kg, 14 ft•ib)
4-35
ENGINE ASSEMBLY AND ADJ STMENT E
ClUTCH ANO PRIMARY ORIVE GEAR
G) Straight key ® Clutch boss
(2) Primary drive gear (U) Clutch damper
@ Conical spring washer @ Friction plate
@ Push rod #2 @ Clutch plate
@ Ball @) Cushion spring
® Thrust washer @ Conical spring washer
(J) Collar ® Push rod # 1
@ O-ring @ Pressure plate
® Clutch housing
ClUTCH SPRiNG FREE:

A lENGTH UMIT:
26.2 mm IU)3 in)
FRiCTION IPlATE WEAR UMIT:
B
2.7 mm (0.106 in)
ClUTCH PlATE WARP UMIT:
C
0.0!5 mm !0.002 in)
60 Nm 16.0 m•kg, 43 ft•ib)
4-36
CYUNDER HEAD, CYUNDER AND P!STON
1. Apply:
@Engine oíl
To the small end bearing and big end
bearing.
2. lnstall:
0 Small end bearing
e Pistan
@Piston pin
NOTE: ==-----�-=-�--
The arrow CD on the pistan must point to the
front of the engine.
3. lnstall:
0 Pistan pin clip CD
NOTE: =�==��=�-�=�==
Befare installing the pistan pin clip, cover the
crankcase with a clean towel or rag so you will
not accidentally drop the pin clip and material into
the crankcase.
4. lnstall:
0 Gaskets (Cylinder-New)
4-37
5. lnstall:
e Cylinder G)
NOTE:�=====-==----
lnstall the cylinder with one hand while compress
ing the pistan rings with the other hand.
Befoire instamng the cylinder, make surn

ring's ends are propewly fitted arna.md the
ring iocating pins in tlhe grnoves.
6. lnstall:
eGasket (Cylinder head-New) G)
° Cylinder head �
oReed valve
®Gasket
®lntake manifold
®Üil delivery hose
NOTE:��---===-====
Tighten the nuts in stages, using a crisscross
pattern.
', Nuts (Cylinder Head):

�� 10 Nm (1.0 m kg, 7.2 ft lb)
0 0
7. lnstall:
®Spark plug
Spark Plug:
25 Nm 12.5 m kg, 18 ft•ib)
0
4-38
CYUNDER AND CYLINDER HEAD
CD Cylinder head
� Gasket (Cylinder head)
Q) Spark plug
@ Cylinder
@ Gasket (Cylinder)
CYUNDER HEAID WARPAGIE UMff:

A
(U)2 mm ((U)Cl1 in)
CYUNDER BORE S!ZIE:
8
40.00-40.02 mm (1.575-1.576 in)
10 Nm (1.0 m•kg, 7.2 ft•lb
4-39
ENGINE ASSEMBLY AND ADJUSTMENT
REMOUNTING IENGINE
I ENG 1 \i11I
Reverse the engine removal procedure.
1. lnstall:
0 Engine assembly
0 Bolt (Rear - Upper) CD
2. lnstall:
0 Down tube CD
® Bolts (Down tube) �
3. Tighten:
@Nuts
0 Bolts
!Bolts (Dow1111 Tube - Fm111t):

25 Nm (2.5 m kg, 18 ft•!b)
0
18o!ts IDown Tube - Reaid:

25 Nm (2.5 m kg, 18 ft•ibl
0
Nut {E111gine - Frnntl:

40 Nm (4.0 m•kg, 29 ft ib)
0
Nut {Engim� - Read:

25 Nm 12.5 m •kg, 18 ft ibl
0
4. lnstall:
® Orive chain CD
® Orive sprocket �
®Circlip (New} ®
NOTE:�-========�--
Befare installing the drive sprocket, loosen the
rear wheel axle and push forward the rear wheel.
Use a new circiip.
4-40
ENGI E ASSEMBLY AND ADJUSTMENT
5. lnstall:
I ENG 1 \i1ll!il
®Gasket (Crankcase cover - New)
0 Crankcase cover CD
°Change pedal (%)
NOTE: ==---=--------
Tighten the screws in stages, using a crisscross
pattern.
6. Adjust:
@Autolube pump cable:
Refer to "CHAPTER 3-AUTOLUBE PUMP
CABLE" section.
7. lnsta!I:
®Muffler
Ring Nut ( uffleirl:

6 Nm !0.6 m• 4.2 ft•
IBloh IM
8. Adjust:
0 Orive cha in slack ®
Orive Chain Siaclc
2!5-30 mm !U:l-·1.2
Refer to "CHAPTER 3-DRIVE CHAIN

SLACK ADJUSTMENT" section.
9. Adjust:
@Throttle cable free play ®
, Thrntde Cable Free Play:
3-7 mm ((l.12-0.28 in)
Refer to "CHAPTER 3-THROTTLE CABLE

ADJUSTMENT" section.
10. Adjust:
0 Brake pedal free play ®
Brake Pedal Free Play:
20-30 mm (0.8-1.2 in)
Refer to "CHAPTER 3-REAR BRAKE AD

JUSTMENT" section.
4-41
ENGINE ASSEMBLY ANO ADJUSTMENT ENG
11. Adjust:
"'Clutch cable free play
Ciutch Cable free Play:

2-3 mm I0.08-0.12 in)
Refer to "CHAPTER 3-CLUTCH ADJUST

MENT" section.
12. Fill:
0 Transmission oíl
� Total Amoa.mt:
0
V 0.165 l (0.57 imp qt, 0.169 US qt)
Refer to "CHAPTER 3- TRANSMISSION

OIL REPLACEMENT" section.
13. Air bleed:

0 Autolube pump
Refer to "CHAPTER 3-AUTOLUBE PUMP

AIR BLEEDING" section.
4-42
CARBURETOR CARB
CARBURET�ON
CARBURETOR SPIECifiCATIONS
G) Spring (Throttle valve) @ Main nozzle Main jet #120
� Jet needle assembly ® Main jet Piiot jet #11.!5
® Throttle valve @ Valve seat assembly Jet needle 3G21-4
@ Throttle stop screw @ Float Need!e jet E-O
@ Pilot screw © Pin ( Float) Thrnttle valve cut-away 2.0
® Starter plunger @ Float chamber Pilot scwew 1-1 /8
(j) Pilot jet @ Drain screw Valve seat size 1.5
Stawter jet #20
Fioat heig¡M 21-23 mm
(0.83-0.91 in)
fue! leve!@ 0-1 mm
(IO-(U)4 in)
r---------------------7
1 1
1 1
1
-=--==--=>- 1
1 1
��-b.L-J.('-�
1
1
1
1 1
1 1
1 1
1
1
1 :
r'---'-----"-�
1 "¡----------,-«-==--+-+--+ 1
1 @1
l=::r-------e--.....¡-.-----1
1 1
1 1
1 1
1 1
:,
1-e�TS�<V
1
1
1--�===- 1
1
1
1
1 1
L______________________ J
�� 10
9
11
✓
"'
o
1 íl
�
5-1
CARB RETOR CAR
REMOVAl
NOTE: ===--====----==
The following parts can be cleaned and inspect
ed without carburetor disassembly.
®Starter plunger
® Pi!ot screw
1. Remove:
0 Lower cowiing
Refer to "CHA,PTER 3� NGS"

section.
2. Turn the fuel cock to "OFF" position and dis
connect the fuel hose G).
3. Loosen:
® Screws (Carbu retor joint)
L:,, Remove:
° Carburetor assembly G)
DISASSEMBLV
1. Remove:
@Throttle valve assembly G)
oSpring (Throttle valve) 0
2. Remove:
@Starter plunger CD
®Throttle stop screw 0
o Pilot screw Q)
5-2
3. Remove:
o Float chamber
4. Remove:
0 Pin ( Float)
o Float
5. Remove:
oPilot G)
Gf\1ain jet �
oj\/Jain nozzle CT)
0 Needle valve @
0 Valve seat @
5-3
CARBURETOR CARB
!NSPECTION
1. lnspect:
0 Carbu retor body
® Fuel passage
Contamination-. Clean as indicated.
Carburetor cleaning steps:

0 Wash carburetor in petroleum based solvent.
322-021 ( Do not use any caustic carburetor cleaning

solution).
® Blow out ali passages and jets with com
pressed air.
2. lnspect:
°Float G)
Damage-. Replace.
0 Gasket
®Ü-ring
Damage-. Replace.
3. lnspect:
0 Needle va!ve G)
@Valve seat (2)

®Gasket ®
Damage/Wear/Contamination -. Replace.
NOTE:
3
Always replace the needle valve and valve seat
as a set.
4. lnspect:
0 Throttle valve
Wear/ Damage-> Replace.
5-4
CARBURETOR CARB
5. Check:
11 Free movement
Stick---+ Replace.
lnsert the throttle valve into the carburetor
body, and check for free movement.
6. lnspect:
0 Jet needle G)
Bends/Wear ---+ Replace.

® Clip position
Standard Clip Position:

No. 4 Grnove
7. lnspect:
® Starter plunger G)
Wear/ Damage ---+ Replace.

®Throttle stop screw (2)
® Pilot screw @
Wear/ Damage ---+ Replace.
ASSIEMBlY
Reverse the disassemby procedure.
CA\l!TlQN:
Before reassembiing, wash all parts in clean
gasoiine.
1. IVleasure:
e Float height @
Out of specification ---+ Adjust.
Float Height @:
21-23 mm (0.83-0.91 in)
5-5
ETOR
Fioat heigM measurnment and adjumtmentt

steps:
oHold the carburetor in an upside down po
sition.
® Measure the distance between the mating sur
face of the float chamber and top of the float

using a gauge.
The float arm should be resting on the needle

valve, but not compressing the needle valve.
o lf the float height is not within specification,

inspect the valve seat and needle valve.
0 1f either is worn, replace them both.
1 ,., lf both are fine, adjust the float height by

· bending the float tang G) on the float.
e Recheck the float height.
!NSTAllATmN
Reverse the removal procedures.
. nstall:
oThrottle valve assembly G)
To carburetor body.
NOTE:--==-=�-===-
the groove ®
of the throttle valve with the
projection @ of the carburetor body.
2. Adjust:
oldle speed
Refer to the "CHAPTER 3-IDLE SPEED
USTMENT" section.
Engine id!e Speed:

1 ,JOO - 1 ,400 r /mi n
5-6
CARB RETOR
3. Adjust:
oThrottle cable free play
Refer to the "CHAPTER 3-THROTTLE CA
BLE FREE PLAY ADJUSTMENT" section.
Throtde Cable Frne Play: l1

3-7 mm (0.12-0.28 in) 1
ADJUSTMENT
\i::uel leve! Adjustment
NOTE: --=�=-��---
Befare adjusting the fuel level, the float height
should be adjusted.
1. Place the motorcycle on a leve! place.

2. Use a garage jack under the engine to ensure
that the carburetor is positioned vertically.
3. Attach the Fuel Level Gauge G) to the f!oat
chamber nozzle.
--~¡
_j
1
4. Loosen the drain screvv (2), and warm up the
engine far severa! minutes.
5. Measure:
o Fuel leve! ®
Out of specification-e Adjust.
®
IFuel Leve! ®:
Zero-1 mm (Zero-0.04
IBelow the Carburntor Body IEdlge
6. Adjust:
2
°Fuel level
Adjustment ste¡os:
®Remove the carburetor.
0 lnspect the valve seat and needle valve.
0 lf either ís wom, replace them both.
@ lf both are fine, adjust the float height by
bending the float tang CD on the float.

® Recheck the fuel level.
5-7
REED VALVE CARB
REED VALVE
REMOVAL
1. Remove:
® Carburetor assembly
Refer to "CARBURETOR-REMOVAL"
section.
2. Remove:
°Carburetor joint CD
ciY.E.I.S. hose (2)
®Üil hose@
oReed valve
INSPECTiON
1. Measure:
0 Valve stopper height CD
Out of specification ➔ Replace.
Valve Stopper Height:

6.7-7.3 mm Wl.26-0.29
322-032
2. Measure:
®Reed valve bending (2)
Out of specification ➔ Repiace.
Reedl Vaive Bendling limit:

0.3 mm (I0.012 in)
Replacememt steps:
0 Remove the screws (Reed valve)
®lnstall the reed valves (New)

NOTIE:
lnstall the reed valves as shown.
0 Tighten the screws (Reed valve).

· ·cA.ú"r10N:
Tighten each scirew gradua!ly to avoid
warping.
322 030
Screw (Reed Va!ve):

�� 1 Nm (0.1 m•kg, 0.7 ft•ib)
® Recheck reed valve bending.
5-8
___________R_ E_E _D_V _A_LV_E_ ICARBI • 1
INSTALLATION
Reverse the removal procedure.
Note following points.
1. Tighten:
-Carburetor joint
Bolt (Carburetor Joint):

8 Nm (0.8 m•kg, 5.8 ft•lb)
5-9
________ ,CARBI.,
5-10
FRO EEL
C ASSIS -
FRONT WHEEl BASIC WEIGHT:
G) Front wheel WITH OIL ANO 91 kg (201 lb)
(2) Hub FULL FUEL TANI<
@ Front wheel axle MAXIMUM LOAD* 68 kg (150 lb)
@ Cotter pin COLO TIRE
@ Collar FRONT REAR
PRESSURE:
@ Oil sea!
(J) Bearing 130 kPa 150 kPa
ZERO- MAXIMUM
(1.3 kg/cm 2 , (1.5kg/cm 2 ,
@ Speedometer gear unit LOAD*
18 psi) 2·1 psi)
*Load is the total weight of cargo, rider, and

accessories.
TIRE SIZE:
A 3.50-12 2PR
R!M SIZE:
D USE NEW ONE B
MT 2.50x 12
IRIM RUNOUT UMff:
VERTICAL:
C 2.0 mm W.013 inl
lATIERAl:
2.0 mm W.08
140 Nm (4.0 m•kg, 29 ft ibl 1 0
6-1
FRONT wHEEL jcHAsj
ci-::r0 I
REMOVAL
Support the motmcycle secmely so there is

no dlanger of it faiiing over.
1. Remove:
0 Lower cowling
Refer to "CHAPTER 3-COWL!NGS"

section.
2. Remove:
0Cotter pin
3. Loasen:
G>Nut (Front wheel axle) CD
4. Elevate the front wheel by placing a suitable
5. Disconnect:
@Speedometer cable �
6. Remove:
° Front wheel
0 Speedometer gear unit
@Collar
° Front wheel axle
iNSPECTmN
1. Eliminate any corrosion from parts.
2. lnspect:
® Front axle
Roll the axle on a flat surface.

Bends-+ Replace.
340-008
Do not attempt to strnñgh'i:en a lbent ande.
3. lnspect:
0 Wheel
Cracks/ Bends/Warpage -+ Replace.
6-2
FRONT WHEEL CHAS ct::r0
4. Measure:
@Wheel runout
Out of specification-Check the wheel and
bearing play.
Rim R1.1nout Umit:

Radial G): 2.0J mm (0.08 in)
lateral @: 2.0 mm W.08 in)
340-000
5. Check:
0 Wheel bearings
Bearings allow play in the wheel hub or

wheel turns roughly- Replace.
Wheel beari111g replacement steps:

®Clean the out side of the wheel hub.
® Remove the bearing using a general bearing
puller
® lnstall the new bearing.
NOTE: ============
Use a socket CD that matches the outside di
ameter of the race of the bearing.
Do not stirike the inner mee of baiis of the

beadng. Contact sho1.1ld be made only
wñth the outer mee.
eAfter mounting a tire, ride conservatively

to ailow ¡prnper tire to rrim seating. Failure
to do so may cause an accident resulting
in motoi'lcycle damage and possible opera
tor injury.
0 After a tire repair m rnplacement, be surn
to torque tighten the valve stem lockrmt G)

to specification.
Valve-stem loc!rnut:
1.5 Nm I0.15 m kg, 1.1 ft•lbl
0
341-009
6-3
FRONT wHEEL icHAsl r/fi:Y@]
INSTALLATION
Reverse the removal procedure. Note the follow
ing points.
1. Apply:
0 Lithium base grease
Lightly grease to the oil seal and gear unit.
2. lnstall:
0 Speedometer gear unit
@Collar
NOTE: -==========�=
Make sure the projections inside the gear unit are
meshed with the flats in the wheel hub.
3. lnstall:
° Front wheel assembly
NOTE: --�=�---==�=�=
Be sure the boss on the outer fork tube correctly
engages with the locating slot on the gear unit
assembly.
4. Tighten:
eNut (Front wheel axle)
Nut ílFrnnt Wheel A,del:

40 Nm {4.Cl m 0
5. lnstall:
'"'Cotter pin (l\lew)
Aiways use a new cottt:er pin.
6. Bend the end of cotter pin.
6-4
R EEl
REAR EEL
G) Rear wheel ® Brake shoes
� Hub ® Bearing
@ Brake shoe plate (j]) Collar
@ Tension bar © Bearing
@ Brake cam lever @ Driven sprocket
@ Orive chain puller @) Orive chain
(JJ Cotter pin @) Joint
@ Brake cam shaft ® Rear wheel axle
TIRE SIZIE: BRAKE SHOE UNING THICKNIESS UM!T:

A D
4.00-12-2PR 2 mm (0.08 in)
1B WHEEl SiZIE: lE IBRAKE DRUM INS!DIE IDiAMETIER UMiT:
MT 2.!50 X 12 111 mm (4.37 in)
WHIEIEl RUNOUT UMiT: f SHOE SPRING FREE lENGTH UMff:
C VERTICAL: 2.0 mm (0.08 in) 50.5 mm 12.99 onl
LATERAL: 2.IQI mm (i).08 in)
H USE !\JIEW ONIE
(31 Nm (3.1 m kg, 22 ft•lb) 1

0
136 Nm (3.6 m•kg, 25 ft•lbl 1

11
6-5
REMOVAL
Support the motorcyde securely so there ns

no dariger of it falling over.
1. Remove:
wCotter pin (Tension bar)
e;,Nut (Tension bar) G)
®Adjuster (Rear brake) (2)
"'Pin@
®Spring @
® Cotter pin (Rear axle)
2. Loasen:
@Nut (Rear wheel axle)
®Nuts (Chain puller) @
3. Elevate the rear wheel by placing a suitable
4. Push the wheel forward and remove the drive
chain.
5. Remove:
0 Nut (Rear wheel axle) G)
® Rear wheel axle (2)
0 Rear wheel
°Collars
0 Brake shoe plate
6. Remove:
0 Brake cam lever G)
@Wear indicator (2)

® Brake shoes
® Springs ( Brake shoe)
e Brake cam shaft ®
INSPECTION
1. lnspect:
® Rear wheel axle
Refer to "FRONT WHEEL-INSPECTION"

section.
2. lnspect:
@Wheel
section.
6-6
REAR WHEEL
3. Measure:
@Wheel runout
section.
4. Check:
oWheel bearings
Refer to "FROI\JT WHEEL-INSPIECTION"
section.
6. inspect:
@ Brake lining surface
Blazed arnas-> Remove.

Use a coarse sand paper.
NOTE:
After using the sand paper, clean of the polished
particles with cloth.
346-021
7. �/leasure:
CD 0 Brake lining thickness
Out of specification �' Replace.

CD Measuring points
. "�-' -íElrn1lzie
- lirdng l"hnc:krt!Bss:
·- - --- "- --- •----
di, mrm HlUl5\ in)

Wear Umit:
346-006 2 [11,H'ífl W.08 in)
NOTE:
Replace the brake shoes as a set if either is found
to be worn to the wear limit.
8. lnspect:
0 Brake drum inner surface
Oil/Scratches-Remove.
Use a rng soaked in iacquer

Oil
thinner or solvent.
Use an emery cloth
Scrntches
(lightly and evenly ¡polishingl.
. -
6-7
REA EEl
9. Measure:
0 Brake drum inside diameter
Out of specification- Replace.
Brake Drnm Wearr Umiil::

111 mm 14.37
INSTAllAT!ON
ing points.
í. lnstall:
0 Brake cam shaft CD
0 Wear indicator
(2)
NOTE: ==--=====-====
@Apply the lithium soap base grease onto the
brake cam shaft.
0 Align the slot ®
on the brake cam shaft with
the projection @ on the wear indicator.
2. lnstall:
e Brake cam lever CD
NOTE:
lnstall the brake cam lever as shown.
Bolt (Brnke Cam lever):

1 �� 10 Nm i1.0 m kg, 7.2 h lb)
0 0
3. Apply:
0 Lithium soap base grease
Onto the brake cam lever CD and pivot shaft

(2).
6-8
REAR WHEEl CHAS <ff:Y°0
4. lnstall:
@ Brake shoes CD
0 Springs (Brake shoe) ií:)

CAUT!QN:
When k1stalling the spr:ng and brake shoe,
take carn not to damage the spring and not
to apply grnas'8 to the brnke shoes.
5. Apply:
0 Lithium base grease
Lightly grease to the oil seal lips.
6. Adjust:
0 Drive chain slack
Refer to "CHAPTER 3-- DRiVE CHAlr\l AD

JUSTMENT" section.
7. Tighten:
0 Nut (Rear wheel axle)
0 Nut (Torsion bar)
Nut (Rear Wheel Axle):

60 Nm í6.0 m kg1, i!J.3 ft lb)
0 0
Nut (Torsion bai·l:

19 Nm (1.9 m kg, '13 fit ibi
0 0
8. lnstall:
®Cotter pin
9. Bend the ends of cotter pins.
10. Adjust:
0 Rear brake pedal pree piay

JUSTMENT" section.
Rea1r Brrake Pedal frne Play:

20-30 mm IOU:.!-1.2 in)
6-9
rnoN1r s11AKE icHAsl c!f::y-0 I
FRONT BRAKE
G) Caliper ® Brake hose

� Bleed screw ® Union bolt
@ Pad spring dJ) Copper washer
@ Brake pads @ Master cylinder kit
@ Dust seal @ Master cylinder cap
@ Pistan seal @) Diaphragm
@ Brake disc @ Brake hose holder
IBRAKE FLUID TYPE:

A
DOT #3
BRAKIE PAD WIEAR UMiT:
1B
1 1 5 mm (Ol.02 in)
C
C BRAKIE D!S WIEAR UMiT: 11() Nm (1.0 md<g, 7.2 ft
3.5 mm (Cl.14 in)
� 35 Nm 13.!'ii md<g, 25 ft 1bl 1

0
26 Nm (2.6 m•kg,
19 ft ibl .
0 1,i
"' 11
11
10
6-10
icHAsl
�1
FRONT sRAKE
Disc brnke components rarely require dñsas

sembly. Do not disassembie components un
iess absoiutely necessary. lf any hydrauiic
connection in the system is opened, the en
tire system should be disassembled, drained,
cleaned andl ther11 properly füled amd bled
upon reassemb!y. Do not use solvents on
brnke intemai compommts.
Soivents wm cause seals to swell and distort.
Use only clean brake fluid for cieaning. Use
carie with brake fluid. Brake fluid is in]mious
to eyes aru:I wm damage painted surfaces
and plastic parts.
IBRAKE PAD RIEPLACEMIEN'T

NO'TIE:
lt is not necessary to disassemble the brake caliper
and brake hose to replace the brake pads.
1. Remove:
lll Bolt (Caliper body)
2. Remove:
0 Brake pads G)
® Pad springs �
® Pad Wear Umit @:

0.5 mm (0.02 in)
NOTE:--�=---------
Replace the pads as a set if either is found to be
worn to the wear limit.
346-022
3. Connect a suitable hose G) tightly to the

caliper bleed screw. Then, place other end of
this hose into an open container.
6-11
4. Loasen the caliper bleed screw and push the
pistons into the caliper by your finger.
5. Tighten:
°Caliper bleed screw
Caiiper Bleed Screw:

5 Nm (0.5 m•kg, 3.6 ft•lb)
6. lnstall:
0 Pad springs CD
0 Brake pads (New) �
NOTE: ==-�=-=-======
lnstall the pad spring with it longer tangs facing
towards the disc rotation direction.
7. lnstall:
0 Bolts (Caliper body)
® Caliper cover
Boits (Caiipeir body):

20 Nm {2.0 m •kg, 14 ft•ib)
8. lnspect:
0 Brake fluid level
Refer to "BRAKE FLUID INSPECTION" sec

tion in CHAPTER 3.
G) "LOWER" level line
9. Check:
0 Brake lever operation
A softy or spongy filling ...... Bleed brake

system.
Refer to "AIR BLEEDING" section in CHAP
TER 6.
6-12
CAUIPER D!SASSEMBiLY
NOTE:��-��-�----�
Before disassemblying the brake caliper, drain the
brake system of the brake fluid.
1. Remove:
®Brake pads
Refer to "BRAKE PAD REPLACEMENT"
section.
2. Remove:
0 Union bolt (Brake hose) G)
° Copper washers�
® Caliper body
°Caliper bracket @
3. Remove:
®Caliper pistan G)
@Clip�
@Pistan seal @
0 Dust seal @)
Removal steps:
®Using a rag @, lock the right side pistan.
® Blaw compressed air into the hose joint open-
ing to force out the caliper pistan from the

caliper body.
(; Remove the clip.
When removing the clip, take carn no to

damage the dust seal.
® Remove the dust seal and pistan seal.
6-13
FROll!T BRAKE icHAs] � 1
MASTER CYUNDIER DISASSEMBlY
NOTE: ===�======-===
Befare disassemblying the frnnt master cylinders,
drain the brake system of the brake fluid.
1. Remove:
8 Brake switch CD
® Brake lever (2)
0S pring
2. Remove:
@LJnion bolt (Brake hose) CD
Copper washers (2)
@ Brake hose @
0
3. Remove:
® Master cylinder cap CD
®Diaphragm
"'Master cylinder (2)
0 Master cylinder bracket @
4. Remove:
® Master cylinder bootCD
@Circlip (2)
®Master cylinder kit @
6-14
FR011.1T BRAKE icHAsl Á 1
iNSPIECTION AND REPAIR
1. lnspect:
o Caliper pistan CD
Rust/Wear ---+ Replace.
® Caliper cylinder body �
Wear/ Scratches---+ Replace.

®Pistan seal @
0 Dust seal @
Damage---+Replace.
2. Measure:
o Brake pad thickness ®
Out of specification->Replace. \
PIBldl We/Blr limit:

0.5 mm I0.02 in)
®
NOTE: �============-
Replace the pads as a set if either is found to be
345-022
wom to the wear limit.
3. lnspect:
® Brake hose CD
Cracks/Damage---+ Replace.
4. inspect:
@Master cylinder body CD
Scratches/Wear ---+ Replace.
NOTE: -========-�===
Clean ali passages with new brake fluid.
"'Diaphragm �
2 GÍ Damage---+ Replace.
5. lnspect:
® Master cylinder kit CD
Scratches/Wear ---+Replace.
6-15
FRONT BRAKE CHAS <ff:50
6. lnspect:
® Brake disc
Out of specification-Replace.
Maximum Deflection:
0.15 mm (0.006 in)
Minimum Disc Thiclmess:
3.5 mm (6.14 ird
ASSEMBLY
0 Al! intemai pai"l:s shoukl be c!eain11edl in rnew

brnke fü.llid
0 inil:emal pali'ts slholl.lid be h..11bricated wiil:h
lbrnke fluid whren in�r!taliedL
D
¡;
!Brnke IF!uid:
DOT #3
@ R,eplace the pisil:on seails

is ifü,assembi®d.
1. nstall:
o Pistan seal CD
o Caliper pistan (2)
9 Dust seal (ID
°Clip@
NOTE: =====�-=�==�==
Apply the lithium soap base grnase onta the
pistan seal, caliper pistan and dust seal.
lnstali the clip onto the slot ® on the calipew

body correctly.
2. lnstall:
°Caliper
Boh {Caliper brnckert:):

35 Nm 13.!5 m kg, 25 ft•lb)
0
6-16
FRONT BRAKE CHASclv@
3. lnstall:
ei Pad springsCD
@ Brake pads (2)
Refer to "BRAKE PAD REPLACEMENT"

section.
4. lnstall:
@Caliper CD
NOTE: ----=-====--==
Apply the grease onto the caliper shaft.
®Take care not to aiiow the lnake pads to be

smeared by grease.
®Wipe off any urmecessarry grease that
comes out of piace.
5. lnstall:
®Bolt (Caliper body)
IBoh (Caliper body):

20 Nm (2.0 m•kg¡, 14 ft•
6. lnstall:
0 Master cylinder kit CD
°Circlip (2)
® Dust boot (ID
1 7. lnstall:
@ Master cylinder
® Master cylinder bracket
NOTE: ====--=--=-===
lnstall the master cylinder bracket with the "UP"

mark facing upward.
\Bolt (Master Cyiinder Brncketl:

10 Nm (1.0 m•kg, 7.2 ft•lbl
6-17
8. lnstall:
@ Brake hose CD
® Copper washers (Z)
'"Union bolts ®
Union Bolts:
26 Nm (2.6 m•kg, 19 ft•llb)
Pwper hose rrn.1tüng is essential to insme safe

motorcyde opernítion. Re-fer to "CAIBLIE
ROUTING".
9. lnstall:
0 Brake lever
®Spring
10. Fill:
o Brake fluid
11. Bleed:
oAir
From brake system.
Refer to "AIR BLEEDING" section.
12. lnstall:
®Diaphramm
"'Master cylinder cap
6-18
AiR BlEEDiNG
B!eed the brnke system if:

0 The system has beern disassembled.
0 A brnke hose has been ioosened or
removed.
@The brnke fluid is very !ow.
@The brnke operntiorn is faulty.
A dangernus !oss of braking¡ ¡perfoirmamce
may occu1r if d1e brnke system is not ¡pmperly
bled.
Air bleedirng steps:

a. Add proper brake fluid to the reservoir.
b. lnstall diaphragm.
Be careful not to spill any fluid or allow the
reservoir to overflow.
c. Connect the clear plastic tube (4.5 mm
(3/ 16 in) inside dia.) to the caliper
bleed screw G).
d. Place the other end of the tube into a con-
tainer.
e. Slowly apply the brake lever severa! times.
f. Pull the lever in. Hold the lever in position.
g. Loasen 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.
i. Repeat steps (e) to (h) until ali of the air
bubbles have been removed from the
system.
6-19
FRONT FOR
G) Cap bolt (J) Plain washer
(Í) 0-ring @ Oil seal
@ Spring seat ® Slide metal
@ Dust seal @ lnner tube
@ Fork spring (U) Outer tube
@ Circlip
LEFT RIGHT
A FORK O!l 126 cm3 (4.44 im¡p qt, 164 cm3 (5.11 imp qt,
CAPACITY: 4.26 us qt) 5.54 us qt)
B FORK Oll 146 mm (5.14 in) 51 mm (2.01 in)
lEVIEl: FROM TOP OF THE INNER FORK TUBE
FUllY COMPRESSED (W!THOUT SPRiNG)
C FORK Oll GRADE:
YAMAHA FORK O!l 10WT OR EQUIVAlENT
FORK SPRING (llEIFT SIDIE ONLY)

D MINIMUM FREIE llENGTH:
367 mm 114.4 in)
30 Nm (3.0 m•kg, 22 ftdb) 1
B--.::;;;:s;�� 9�
/�
//
//
�
11
1 E I USE NEW ONE 1

9
I
L___�
6-20
-=-=�==�==��=F�R=o_N_T_F=o=R_K icHAsl r#:'r0 I
REMOVAL
Su¡pport the motoli'cycie secmeiy so there is

no dlaingeli' of it faim111g over.
1. Remove:
@ Front wheel
Refer to "FRONT WHEEL-REMOVAL"
section.
2. Remove:
C)Front tender G)
3. Remove:
e Cap bolts G)
o Hand!ebars (l)
4. Loasen:
@Pinch bolt (Lower) G)
5. Remove:
° Front fork (2)
Support the fork before loosening the pinch

bolt.
DISASSIEM!BlY
1. Remove:
@Spring seat G) (Left side only)
°Fork spring (l) (Left side only)
6-21
FRONT FORK CHAS c#:Y0
2. Drain:
® Fork oil
3. Remove:
0 Dust seal CD
®Circlip (2)
0 Plain washer @
4. Remove:
®lnner tube
Removal steps:
® H old the fork leg horizontally.
"'Pull out the inner fork tube from the outer

tube by forcefully, but carefully, withdrawing
the inner fork tube.
NOTE: ============�
Avoid bottoming the inner tube in the outer
tube during the above procedure, as the inner
tube will be damaged.
5. Remove:
CD
0 0il seal
®Slide metal (2)
Always replace the oil seal when disassem

bling the front fork.
6-22
FRONT R
!NSPECT!ON
1. lnspect:
0 1nner fork tube G)
0Quter fmk tube

Scratches/
Do not sr�tern
·fork tlLibe as th!§ ffli6JV
the tll)ibe.
2. lnspect:
oDust seal
®Ü-ring (Cap
Scrntches/ Dama.ge-> Repiace.
2. Measure:
side only)
342-018
3. lnspect:
Slide metai G)
Scratches/VVear/ F1epiace.
ASSEMBLV
Reverse the disassembly
NOTE:-�=�==
Be sure al! cornponents are clean befare as
sembly.
6-23
FRONT FORK
1. lnstall:
@Slide metal G)
°Clip (2)
To inner tube.
2. lnstall:
clnner tube CD
To outer tube.
3. lnstall:
®Üil seal (New) CD
NOTE: =�==��--�-=--=
0 Apply the lithium soap base grease onto the oil
seal lip befare installing the oil seal.
0 Be sure oil seal numbered side face upward.
342-016
®Take c:arn not to damage the oii seai iip.
®Always iUISe a new oii sea!.
4. Press the oil seal into the inner tube with Fork
Seal Driver ® and Weight (2).
Fork: Sea! Driver:

YM-33281
Weight:
YM-33963
5. lnstall:
0 Plain washer CD
® Circlip (2)
0 Dust seal®
6-24
6. Fil!:
e; Front fork
fmk Oi! Capacity:

left:
126 cm3 (4.44 imp qt,
4.26 us qt)
Right:
164 cm3 (5.77 imp qii:,
5.54 us qt)
Grade:
Yamaha FoH"k Oil 10WT CH
Equiva!erri:
NOTIE: �===�==-
After filling the front fork with fork oil, slowly
pump the front fork up and down to distribute oiL
7. Measure:
c:,Qil leve!®
Out of specification-> t\dd or reduce oiL
Oii leve!:
® teft: 146 mm (5.74 in)i
Right: 51 rnm (2.01 in)
From the top of the ünneH· fork
ii:ube fully comprassed without
spring.
NOTE:=--====
Place the front fork on upright position.
8. lnstall:
o Fork spring G) ( left side only)
@Spring seat � (Left side only)
-- NOTE: �-=�===-===-�-
�-
lnstall the fork spring so that tapered side face
upward.
��
�
6-25
FRONT FORK CHAS �0
iNSTALlATION
1. lnstall:
Front fork
G)
2. lnstall:
®Handlebar
@Cap bolt G)
NOTIE: =�=-=-�=-====-
Apply the lithium soap base grease onto the
O-ring.
Boht (Haindiebaid:
10 Nm 11.0 m kg, 7.2 f-ii: ib)
0 0
Cap Bolt:
55 Nm l!5i.5 m 0 kg¡, 40 h ibl
0
6-26
STEERING HEAD AND HANDLEBAR CHAS c#::T@
STEER! G HEAD AND HANDLEBAR

G) Bearing raee (Lower-Bottom) ® Handle erown
(l) Ball (1 /4 in-19 pes.) ® Steering stembolt
@ Bearing raee (Lower- Top) (Ü) Handlebar (Right)
@ Bearing raee (Upper-Bottom) © Handlebar (Left)
@ Ball (3/16 in-22 pes.) @ Cap
® Bearing raee (Upper- Top) @) Throttle housing
(J) Bearing raee eover @ Throttle grip
@ Ring nut
(? i)_/ i 10 film 11.0 m•kg, 7.2 lt•lb) 1
. /\
;�)'
1� �-�
�-. -- g
1st: Tighten the ring nut

30 Nm 13.0 m kg, 22 ft•lbl
0
2nd: loosen it one turn.

3rd: Retighten it
IS Nm !0.6 m kg, 4.3 ft•lb)
0
6-27
sTEEmNG EAD AND HANDLEBAR icHAs[ � 1
REMOVAL
Sec11..m=.1!y support the motorcyde so thern is

no danger of it fal!ing over.
1. Remove:
® Lower cowling
® Upper cowling
Refer to "CHAPTER 3-COWLINGS"
section.
2. Remove:
o Front wheel
Refer to "FRONT WHEEl-REMOVAL"
section.
3. Disconnect:
® Clutch cable G)
4. Remove:
G Front brake master cylinder (Z)
BThrottle grip @
0 Handlebar switch ( Left) @
c:!Cap bolts @
Handlebars @
(l)
5. Remove:
® Front forks
Refer to "FRONT FORK-REMOVAL"
section.
6. Remove:
e Steering stem bolt G)
@Washer (Z)
® Handle crown @
6-28
STEERING HEAD AND HANDLEBAR CHAS @Í:;50
7. Remove:
®Ring nut CD
® Ball race cover �
Use the Ring Nut Wreneh ®·
Ring Nut Wre111ch:

YU-33975
8. Remove:
®Ball race (Upper-Top) CD
cUpper balls (3/16 in-22 pes.) �
®lower balls (1/4 in-19 pes.)®
eLJnder braeket @
!NSPECT!ON
1. Wash the ball bearings and bearing races with
a solvent.
2. lnspeet:
"Ball bearings
G Bearing raees
Pitting/ Damage-> Replace.
NOTE: ======-======
Always replaee bearings and races as a set.
Beawi111g mee repiacemer ri: siteps:

® Remove the bearing races on the head pipe
using long rodCD and the hammer as shown.

® Remove the bearing race on the under braeket
using the floor chisel � and the hammer as

shown.
354 005
®lnstall the new dust seal and raees.
354-007
6-29
EAD AND HANDLEBAR CHAS@f:r0
3. lnspect:
Handlebars
@
Bends/ Cracks/ Damage ---> Replace.
Do not attempt to straighten a bent handle

bar as this may dangernusly weaken the han
dlebar.
INSTAllAT!ON
ing points.
1. Apply:
® lithium soap base grease
To bearing races.
2. lnstall:
0 Upper balls �
To bearing race (Upper-Bottom).

o Lower balls G)
To bearing race (Lower-Bottom).
Arrange the bearings around race, and ap
ply more grease.
!Ball Q11.rnnítity/Size
Up¡pew 22 pes./ 3/14 in
lower 191 pes./ 1/4 i11
3. lnstal.1:
0 Under bracket @
CAUTU)N;
Hok! the 11.mdler brncket until it is secuu-1:H:I.
4. Tighten:
®Ring nut
Ring nut tightening steps:

®Tighten the ring nut using the Ring Nut
Wrench G).
Ring Nut Wrench:

VU-33975
6-30
STEEfUNG HEAD AND HAN LEBAR
NOTE: -��====�==�==
Set the torque wrench to the ring nut wrench
so that they form a angle.
Rnng Nut 0lílitial Ti,g¡htell1iing):

30 Nm 13.0 m kg, 22 fi!: ibl
0 0
the ring nut one tum.

ten the ring nut using the Nut
Ring Nut !Final Tightening):

6 Nm
5. lnstall:
o Handle crown
NOTE:�=======�===�
Temporary tighten the steering fitting bolt G).
6. lnstall:
© Front forks
Refer to "FRONT FORK-INSTALLATION"

section.
7. Tighten:
0 Steering stem bolt
Siteerong Stem Bolt:

40 Nm 14.0 m kg, 29 ft•lb)
0
6-31
STEERING HEAD ANO HANDLEBAR icHAs[ c!f::::r0 J
8. lnstall:
® Handlebars
®Cap bolts
NOTE: �=========�---
Befare installing the right-hand handlebar onto
the handle crown, apply a light coat of lithium
soap base grease onto the handlebar end and in
stall the throttle grip to the handlebar.
IBoit !Handllebarl:
10 Nm 11.0 m kg, 12. ft !b)
0 0
Cap Boit:
55 Nm 15.5 m kg, 40 ft lbl:
0 0
9. lnstall:
® Front brake master cylinder
NOTIE: ==============
e lnstall the
master cylinder bracket with the "UP"
mark facing upward.
®Tighten first the upper bolt, then the lower bolt.
Boits (Master Cyfü1der Braicket):

10 Nm (1.0 m kg, 7.2 ft•llb)
0
10. lnstall:
® Clutch cable
NOTE: =--===----=--
Apply a light coat of lithium soap base grease onto
the clutch cable end.
11. lnstall:
e Front wheel
Refer to "FRONT WHEEL-REMOVAL"
section.
Nut (Frnnt Wheel Axle):

40 Nm (4.0 m•kg, 29 ft•lbl
12. Adjust:
® Clutch Cable Free Play
Free Play:
2~3 mm (0.08~0.12 in)
6-32
REAR SHOCK ABSORBER AND SWINGARM CHAS <ff::T0
REAR SHOCK ABSORBER AND SWINGARM
CD Rear shock absorber
(2) Bush
@ Cotter pin
@ Swingarm
® Push
® Spacer
(J) Chain support
@ Chain cover
SWINGARM SIDIE PLAY:

2.0 mm (0.08 in)
40 Nm {4.0 m•kg, 29 ft•ibl
40 Nm (4.0 m•kg, 29 ft•lbl
6-33
REMOVAl
Serc1.meiy suppicu·t the motoirrcyde so ithere is

no dBlngrer of iíi: faifü1g oveL
Rear Shock Absmbfü

1. Remove:
@ Lower cowling
Refer to "CHAPTER 3-COWLINGS"

section.
2. Place a jack under the engine and elevate the

motorcycle.
3. Remove:
o
CD
0 Plain washer
0 Pin (Rear shock absorber-
4. Remove:
0 Bolt (Rear shock absorber-Upper) CD
o Rear shock absorber (Z)
0Bush
Swingarrm
Seic1.mely suppo1"'íc thie motmcycie so therrie is

no d¡:mger of it falling over.
1. Remove:
0Rear wheel
Refer to "REAR WHEEL-REMOVAL"
section.
6-34
REAR SHOC ABSORBER
2. Remove:
0 cover G)
Remove:
o CD
"
0 Plain washer
0 Pin (Rear shock absorber-
4. Remove:
o Pivot shaft G)
oSwingarm �
D IBlY
1. Remove:
oChain guide G)
oTension bar �
iNSPIECTílON
1. Wash the bushes and swingarm in a
solvent.
2. lnspect:
0 Rear shock absorber
Oil leaks/ Damage -> Repiace.
6-35
REAR sHocK ABSORBER AND sw1NGARM !cHAsl r/f:Y0 I
3. lnspect:
®Swingarm
Bends/ Cracks/ Damage-Replace.
4. lnspect:
illBushes
Wear/ Damage-Replace.
5. lnspect:
®Chain guide
Excess wear/ Damage-Replace.
ASSEMBlV
1. lnstall:
@Chain guide (D
5 Tension bar el)
Nut (Tension Sal'):

19 Nm (1.9 m•kg, 13 ft•lb)
INSTAllATION
Swingarm
Reverse removal procedure.
1. lnstall:
*Swingarm
NOTE: -------------
Apply the lithium soap base grease onto the pivot
shaft.
Nut (Pivot Shaft):

40 Nm (4.0 m•kg, 29 ft•lb)
2. lnstall:
ill Pin (Rear shock absorber- Lower)
®Cotter pin

6-36
-��R_EA�R _S_H_O _C_K_A_B_ S_ O_ R�B_ E_R_A_ N_D_S_W_I_N _G_
A _R_M�
icHAs[ rffc50 [
3. Insta!!:
@Rear wheel
Refer to "REAR WHEEL-INSTALLATION"
section.
Nut (Rear Wheel A:xie):

60 Nm (6.0 m•kg, 43 ft•lbl
Nut (Tension Bar):
19 Nm (1.9 molqJ, 13 ft•!bl
4. Adjust:
® Brake pedal free play
® Drive chain slack

JUSTMENT and DRIVE CHAIN ADJUST
MENT" section.
Orive Chain S!ack:

25-30 mm (1.0-1.2 in)
Brnke Pedal Free Play:
20-30 mm I0.8-1.2 in)
Rear Shock Absoirbell'

1. lnstall:
® Rear shock absorber
� Bolt IRear Shock Absoirberr-

__
%"""" Upperl:
40 Nm (4.0 m•kg, 29 ft ib) 0
NOTE:�==--=-==-==-
Apply the lithium soap base grease onto the pin,
bolt and oil seal lip.
6-37
omve cHA1N ANo sPRocKns jcHAsj � 1
ORIVE CHAIN AND SPROCKETS
REMOVAl
1. Remove:
oChange pedal G)
(l)Crankcase cover (Left) �
2. Remove:
oClip (Orive chain) G)
@Joint (Orive chain) �
0 Drive chain @
ílNSPIECTiON
1. Check:
0 Orive chain stretch
Pull � the chain away from the driven

sprocket.
Distance chain/sprocket higher than 1 /2
tooth G)-+ Replace drive chain.
2. Clean:
® Orive chain
Place it in solvent, and brush off as much

dirt as possíble. Then remove the chain from
the solvent and dry the chain.
3. Check:
® Orive chain stiffness
Clean and oil the chain and hold as illus

trated.
Stiff-+ Replace drive chain.
343-007
6-38
4. lnspect:
® Orive and driven sprockets
Wear / Damage- Replace.
G) 1 /4 tooth
(Z) Correct
(J) Roller
@ Slip off
Dwiven sprnckeil: rnpiacemenil: steps:

"'Straighten the lock washer tabs and remove
the driven sprocket.
0 lnstall a new driven sprocket and lock
washers.
A!ways use new lock washern.
,)7
l��l
Nuil: {Driven Sprncket):
35 Nm (3.5 m kg, 25 h•ib)
0
0 Bend the lock washer tabs along the nut flats.
iNSTAllATION
Reverse the removal steps.
1. lnstall:
oRear wheel
Refer to "CHAPTER 3-REAR WHEEL IN
STALLATION" section.
Nut {Rear Wheei):

160 Nm 16.0 m•kg, 43 ft•lbl
Nut (Tenskm Bar):
19 Nm 11.9 m•kg, 13 ft•lb)
2. lnstall:
® Orive sprocket
®Circlip
l!Jse a new dn::lip.
6-39
ORIVE CHAIN AND SPROCKETS CHAS c#Ye
-- -- -- - -
�
/
I
--- ""
"\
3. lnstall:
0 Drive chain
eJoint (Orive chain)

,,,,-
....._
(
\
I
! '
\
\
o \ eClip (Drive chain)
\ / NOTE: =��====�--=-�=
During reassernbly, the master link clip must be
!T7f----=_,,,_.:;:..- / installed with the rounded end facing the direc
tion of travel.
343·004
CD Turning direction
4. Lubricate:
0 Orive cha in
C!hiain lube:
Vamaha Chain lMbíe orr
IEquivalent
5. lnstall:
° Crankcase cover
e Change pedal
Scnew (Crnnkcase Cover);

8 Nm (0.8 m kg, 5.8 f'fcoibl
0
Boit IChange Pedal):

10 Nm (1.0 m•kg, 1.'2 ft•ib)
NOTIE: -=======--===
Align the punch mark ® with slit @.
6-40
I
YSR50T CIRCUIT DIAGRAM ELEC 1
§ 1
ELECTRICAL
YSR50T CIRCUIT DIAGRAM
r
@--
o� (J)
8/W
W/R @
8/R-- 8/R
r __
....._
8
-------8/W-----'
-
Br
-
i--------R-----.....,.
Y�A� @
@
8
Y/R 8
-
Br 8
....L.
/ Y
r
Sb
® L
8
........._
@I -
8
-
Br
Br---�1------e----.,.....--+-4------------e
1@61
Br Br Br
®6
T1 1 L
_J
b
D
�
Sb
®I
8 8
....L. ....L.
7-1
________v_s_R _s_oT_c _1R_c_u_ 1T_o_1A_G_R_A_M_ j ELEC I B 1
CD Spark plug ® Flasher relay

(2) lgnition coil @ "TURN" switch
@ COI magneto @ "TURN" indicator light
@ COI unit @) Flasher light (Left)
@ Rectifier/Regulator ®) Flasher light (Right)
@ "ENGINE STOP" switch @ Horn
(j) Main switch @ "HORN" switch
@ Fuse @ "OIL" warning indicator light
® Battery ® Oil level switch
@ "LIGHTS" (Oimmer) switch ® "NEUTRAL" indicator light
(U) "HIGH BEAM" indicator light ® Neutral switch
@) Headlight @ Front brake switch
@ Meter light ® Rear brake switch
® Sidestand switch @ Tail/Brake light
@ lgnition control unit
COLOR CODE
B Black p Pink
R Red Sb Sky blue
Br Brown B/R Black/Red
o Orange B/W Black/White
w White W/R White/Red
L Blue Br/W Brown/White
G Green G/Y Green/Yellow
y Vellow Y/R Yellow/Red
Og Dark green L/Y Blue/Yellow
Ch Chocolate
7-2
________E_LE
_ C _TR_ I
_ A_
C_ L _ CO_M P
_ _O_N_E_NT_S_ 1 ELEC I a 1
ELECTRICAL COMPONENTS BATTERY:

G) Wireharness @ Sidestand switch CAPACITY 6V 4AH
(Z) Main switch ® Neutral switch
@ lgnition control unit ® lgnition coil
SPECIFIC GRAVITY 1.280
@ Oil level switch (U) COI unit IGNITION COIL:
@ Rectifier/Regulator @ Flasher relay PRIMARY COIL
@ Horn @ Battery 0.7-1.1íl at 20º C (68 °F)
Q) Rear brake switch (B) Fuse
SECONDARY COIL
5.7-8.5kíl at 20°C (68 °F)
7-3
!GNITION AND STARTílNG SYSTE ElEC §
�GNiTiON AND STARTi G SYSTE
Below circuit diagram shows ignition and starting svstem.
/ Y
@j
r
8
..L.
7-4
IGNITION AND STARTING SVSTEM I 1
ELEC § 1
NOTE:-------------
For the color codes, see page 7-2.
CD Spark plug
(2) lgnition coil
@ COI magneto
@ COI unit
@ "ENGINE STOP" switch
(J) Main switch
Q4) Sidestand switch
@ lgnition control unit
® Neutral switch
7-5
_____
IGNITION
_
1GN1T 1 oN A No s T A RT 1N G svs TEM
_ _ _ _ _ OPERATION
CONTROL CIRCUIT _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
I 1 53
ELEC
1
The ignition control circuit on this model consists

Transmission Sidestand Spark
of the ignition control unit, neutral switch, neu (Neutral switch) (Sidestand switch) plug
tral indicator light, and the sidestand switch. lf Neutral Up
the engine stop switch and the main switch are � (close) (close)
Spark
both on, the ignition spark can produce only if: Neutral Down
1. The transmission is in neutral (the neutral � (close) (open) Spark
switch is on).
IN gear Up
2. The sidestand is up (the sidestand switch is � (open) (close) Spark
on).
IN gear Down No
� (open) (open) spark
e
@
y
(J)
�
- - - - -
-
CD
@
(J)
,i Bypass current flows into the thyristor which is

thus turned on, thereby grounding the current of
_ the source coil. In this way, no sparks will be
produced.
CD lgnition control unit @ COI unit
Q Bypass current
� Sidestand switch @ lgnition coil
® Neutral switch (J) Spark plug
@ Thyristor • Current of source coil
@ COI magneto
7-6
_____ I_G _N _IT _IO_ N_A _N_D_S_ T_A_R_T _I N_ G_ s_v_s T_E_M_
_
I
ELEC I a 1
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT

SPARK).
Procedure (1)
Check;
1. Spark plug 7. lgnition coil resistance
2. lgnition spark gap 8. Pick-up coil resistance
3. lgnition circuit 9. Source coil resistance
4. Main switch 10. Wiring connection
5. Spark plug cap resistance (Entire ignition system)
6. "ENGINE STOP" switch
NOTE:--------------------------------
• Remove the following parts befare troubleshooting.
1) Lower cowling
2) Upper cowling
3) Seat
4) Side cover
5) Fuel tank
•Use the following special tool(s) in this troubleshooting.
Pocket Tester:
YU-03112
1. Spark plug
•Check the spark plug condition.
•Check the spark plug type.
•Check the spark plug gap.
Refer to the "SPARK PLUG INSPECTION"
section in the CHAPTER 3.
INCORRECT
Standard Spark Plug:
B7HS (N.G.K.), B8HS (N.G.K.)
Spark Plug Gap:

0.5~0.6 mm (0.20~0.24 in) 1 Repair or replace spark plug.
CORRECT
*
7-7
_____ I_G_N _IT_IO_N A
_
_ _ N_DS
_ T_A_R_ T_IN_ G_ s_v_s T_ E_M_ I ELEC I a 1
*
2. lgnition spark gap
•Connect the Coil Tester G) as shown.
� Spark plug cap
@ Spark plug
MEETS SPECIFICATION
G) l lgnition system is good.
•Start the engine, and increase the spark gap

until misfire occurs.
Minimum Spark Gap:

6 mm (0.24 in)
OUT OF SPECIFICATION
OR NO SPARK
3. lgnition circuit
• Disconnect the ignition control unit lead G)
(Brown).
•Start the engine.
ENGINE STARTS (SPARK)
Starting circuit is faulty, go to "Procedure (2)".
ENGINE DOES
NOT START
7-8
______
I_G _N_IT IO_ N_A _N_D_S_ T_A_R_T _ IN_ G_ s_v_s T_E_M
_ _
I ELEC I a 1
*
4. Main switch
•Disconnect the main switch coupler ( Red,
Brown and Black) and lead (Black/White)
from the wireharness.
• Connect the Pocket Tester (íl x 1) to the main
switch.
Tester ( +) Lead-+Black/White G) Lead

Tester ( - ) Lead-+Black @ Lead.
BAO CONDITION
•Turn the main switch to "ON" and "OFF".
•Check the main switch for continuity.
Switch Good
Bad condition
1 Main switch is faulty, replace it.
position condition
OFF o X X o
ON X o X o
O: Continuity x: Nocontinuity
GOOD CONDITION
5. Spark plug cap resistance

• Remove the spark plug cap.
•Connect the pocket Tester (íl x 1 k) to the
spark plug cap.
7-9
1 GN1T1o N ANo sTART1N G s vsTEM
______ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
•Check the spark plug cap for specificated OUT OF SPECIFICATION
I 1 53 1
ELEC
ra
resistance.
Spark Plug Cap Resistance: Spark plug cap is faulty, replace it.
4-6kíl at 20 º C (68 º F)
MEETS
SPECIFICATION
6. "ENGINE STOP" switch

•Disconnect the "ENGINE STOP" switch leads
(Black/White and Black) from the wire
harness.
m
•Connect the Pocket Tester x 1) to the "EN
GINE STOP" switch.
Tester ( +) Lead---+ Black/Whie G) Lead

Tester (-) Lead---+Black@ Lead
•Turn the "ENGINE STOP" switch to"OFF"

and "RUN".
•Check the "ENGINE STOP" switch for con
tinuity.
BAD CONDITION
Switch Good
Bad condition
position condition
RUN X o X o
OFF o X X o "ENGINE STOP" switch is faulty, replace it.
O: Continuity x : Nocontinuity
GOOD CONDITION
7. lgnition coil resistance

•Disconnect the ignition coil lead (Orange)
m
•Connect the Pocket Tester x 1) to the ig
nition coil.
7-10
IGNITION AND STARTIÑG SYSTEM I ELEC 1 53 1
Tester ( + l Lead--+Orange G) Lead
Tester (- l Lead--+ lgnition Coil Base
•Check the primary coil far specificated

resistance.
Primary Coil Resistance:

0.7~1.1íl at 20 º C (68º Fl
(Orange-Coil Base)
•Connect the Pocket Tester (íl x 1 k) the igni

tion coil.
Tester ( + l Lead--+Spark Plug Lead G)

Tester (- l Lead--+lgnition Coil Base
•Check the secondary coil far specificated
resistance.
Secondary Coil Resistance:

5.7 ~ 8.5kíl at 20 ° C (68º Fl l lgnition coil is faulty, replace it.
(Spark Plug Lead-Coil Base)
BOTH MEET
SPECIFICATIONS
8. Pickup coil resistance

• Disconnect the COI magneto lead (White/
Red) and coupler (Sky blue, White, Black and
Yellow/Red) from the wireharness.
•Connect the Pocket Tester (íl x 10) to the
pickup coil leads.
7-11
_
____ I _GN
_
_ IT
_ _IO_NA
_ _N_D_ S_TA
_ R
_ T
_ _IN_ G_ S Y_
_ STE
_ M
_
_
1 ELEC I a 1
Tester ( +) Lead--+White/Red G) Lead

Tester ( - ) Lead--+Black @ Lead
•Chec!< the pickup coil for specificated OUT OF SPECIFICATION

resistance.
Pickup Coil Resistance:

16 ~ 24íl at 20° C (68º Fl 1 Pickup coil is faulty, replace it.
(White/Red-Black)
MEETS SPECIFICATION
9. Source coil resistance

• Disconnect the COI magneto lead ( Black/
Red) and coupler (Sky blue, White, Black and
Yellow/Red) from the wireharness.
source coil leads.
Tester ( +) Lead--+Black/Red G) Lead

Tester (-) Lead--+Black @ Lead
- �,+.....-
•Check the source coil for specificated
resistance.
ra Source Coil Resistance:

264 ~ 396íl at 20º C (68 º Fl
(Black/Red-Black)
1 Source coil is faulty, replace it.
MEETS SPECIFICATION
* 7-12
I
*
IGNITION ANO STARTING SYSTEM ELEC I a 1
10. Wiring connection POOR CONNECTION

Check the entire ignition system far connec
tions. Refer to the "WIRING DIAGRAM"
section.
1 Correct.
CORRECT
CDI unit is faulty, replace it.
Procedure (2)
Check;
1. Sidestand switch
2. Neutral switch
3. Wiring connection
( Entire starting system)
1. Sidestand switch
•Disconnect the sidestand switch coupler
(Blue/Yellow and Black) from the wire
harness.
•Connect the Pocket Tester (íl x 1) to the side
stand switch.
Tester ( +) ·Lead--+Blue/Yellow G) Lead

Tester (-) Lead--+Black@ Lead
7-13
______,_ G_ N_IT_I_O_N _A _ N_D_S_TA_R_ T_IN_ G
• Move the sidestand to up position and down
_ _ s_v_s _T _EM_ I Ia1
ELEC
position.
•Check the sidestand switch for continuity.
BAD CONDITION
Sidestand Good
Bad condition
position condition
Up o X X o
Down X o X o Sidestand switch is faulty, replace it.
GOOD CONDITION
2. Neutral switch
•Disconnect the CDI magneto coupler (Sky
blue, White, Black and Yellow/Red) from the
wireharness.
•Connect the Pocket Tester (íl x 1) to the neu
tral switch leads.
Tester ( +) Lead---+Sky blue G) Lead

Tester (-) Lead---+Black Lead. ®
•Shift the transmission in neutral and gear.

•Check the neutral switch for continuity.
BAD CONDITION
ransmission Good
Bad condition
position condition
Neutral o X X o
Gear X o X o Neutral switch is faulty, replace it.
GOOD CONDITION
7-14
¡ ELEC I
IGNITION ANO STARTING SYSTEM s 1
POOR CONNECTION
Check the entire starting system for connec
section. 1 Correct.
CORRECT
lgnition control unit is faulty, replace it.
7-15
CHA-RGING SYSTEM
Below circuit diagram shows charging system.
7-16
I
CHARGING SYSTEM ELEC I
é3 1
NOTE:-------------
@ CDI magneto
@ Rectifier/Regulator
@ Fuse
® Battery
7-17
I
CHARGING SYSTEM E L EC I s 1
TROUBLESHOOTING
1 THE BATTERY IS NOT CHARGED.
Check;
Procedure
1. Fuse 4. Charging coil resistance

2. Battery 5. Wiring connection
3. Charging voltage (Charging system)
NOTE:------------------------------
•Remove the following parts befare troubleshooting.
1) Side cover
�---... - _· ...l '

e o eter
__.I 111
_ -�--�-i�_ _!_ª_ _h_ _m_ _ _ _: ___
_ _n�
c c P ck t T s
o e e ter
YU-03112
:
1. Fuse
•Connect the Pocket Tester ("ílx 1") to the
fuse.
•Check the fuse for continuity.
NOCONTINUITY
1 Replace fuse.
.. 1
CONTINUTY
INCORRECT
2. Battery
11"
•Check the battery condition. Refer to "CHAP-

TER 3. BATTERY INSPECTION".
•Refill battery fluid.
•Clean battery terminals;
• Recharge or replace battery.
Specific Gravity:
1.280 at 20 º C (68 º F)
CORRECT
*
"- "'
7-18
*
3. Charging voltage
®Connect the Engine Tachometer to the spark
plug lead.
@Connect the Pocket Tester (DC20V) to the
battery.
Tester ( +) lead-Battery ( +) Terminal

Tester ( - l lead-Batten¡ ( - ) Terminal
@Start the engine and accelerate to about 5.000 MEETS SPECIFICATION

r/min.
®Check charging voltage.
□
�
Charging Vo!tage:
7.4-8.2V at 5,000 rr/min
Charging system is good.
4. Charging coil resistance

a Disconnect the CDI magneto coupler (Sky
wireharness.
eConnect the Pocket Tester (ílx 1) to the
charging coil leads.
Tester ( + l lead-White G) lead

Testeu- 1-) leadl-Biack � lead
7-19
@ Check the charging coil far specificated OUT OF SPECIFICATION
resistance.
ra Charging Coil Resistarn::e:

0.24-0.360 at 20°C (68ºFl
(White-Blackl
1 Charging coil is faulty, replace it.
MEETS SPECIFICAT!ON
POOR CONNECTION
iring connection
Check the entire charging system far connec
tions. Refer to the "WIRING DIAGRAM" orrect.
section.
CORRECT
Rectifier/Regulator is fautly, replace it.
7-20
CHARGING SYSTEM
¡ EL EC ls 1
-�MEMO-�
7-21
UG G SYSTE E
NOTE: =======-=-====
Far the color codes, see page 7-2.
@ COI magneto
@ Rectifier/Regulator
(j) Main switch
® Fuse
® Battery
® "LIGHTS" (Dimmer) switch
@ Headlight
®) Tail/Brake light
7-23
TROUBlESHOOTING (1}
HEADUGHT DOES NOT COME ON.
Prnc:edlu re
Check;
1. Headlight
2. "LIGHTS" (Dimmer) switch
3. Lighting circuit output
4. Lighting coil resistance
NOTE:-===================�==========-
@Remove the following parts befare troubleshooting.
1) Seat
2) Side cover
Cl>LJse the following special tool(s) in this troubleshooting.
Pocket Testerr: im:h.11ctive Tachomieri:er:

YU-03112 YU-03036
1. Headlight
@Connect the Pocket Tester (ílx 1k) to the
headlight.
Tester 1 +) lead->Terminal (j)

Tesíter {-) lead-Terminai @
Tester ( +} lead-Terminai ®
Tester ( - ) le.ad-Terminal @
CONTINUITY DOES NOT

EXIST ON ONE CIRCUIT.
@Check the headlight for continuity.

1 Headlight is faulty, replace it.
]
CONTINUITY EXISTS
ON BOTH CIRCUITS.
*
7-24
LIGHTING SYSTEM IELEcla
---------------------------- 1
*
•Disconnect the handlebar switch couplers
[(Chocolate, Green, Dark green and Yellow)
(Black, Pink, Yellow/Red and Brown/White)l
"LIGHTS" (Dimmer) switch leads.
When turning "LIGHTS" (Dimmer) switch

to "HI".
Tester ( +) Lead---+Yellow/Red G) Lead
Tester ( - ) Lead---+ Yellow Lead ®
When turning "LIGHTS" (Dimmer) switch
to "LO".
Tester ( +) Lead---+Yellow/Red G) Lead
Tester ( - ) Lead---+Green @ Lead
•Turn the "LIGHTS" (Dimmer) switch to the

"HI" and "LO".
•Check the "LIGHTS" (Dimmer) switch for
continuity.
BAD CONDITION
Switch Good
Bad condition
position condition
HI o X o X "LIGHTS" (Dimmer) switch is faulty, replace
LO o o X X handlebar switch.
GOOD CONDITION

•Turn the "LIGHTS" (Dimmer) switch to
"LO".
•Connect the Pocket Tester (AC V-20) to the
headlight Jeads.
Tester ( +) Lead---+Green G) Lead

Tester ( - ) Lead---+ Black Lead® 7-25
___________L_I _G _H_TI_N_ G_ s_v_s _ T_EM_ 1 ELEC I a 1
1AC V-201
•Connect the lnductive Tachometer to the

spark plug lead.
•Start the engine and check the output
voltage.
• ·• éiijf,lm:'
MEETS SPECIFICATION
Do not run the engine in neutral above 1-------------.
6,000 r/min for more than 1 or 2 seconds.
1 Lighting system is good.

Standard Output:
6.2- 7.2V at 3,000 r/min or more
OUT OF
SPECIFICATION

• Disconnect the CDI magneto coupler (Sky
wireharness.
•Connect the Pocket Tester (íl x 1) to the light
ing coil leads.
Tester ( +) Lead-+Yellow/Red G) Lead

Tester (-) Lead-+Black @ Lead
•Check the lighting coil for specificated

resistance.
7-26
___________LI _G _H_TI_N_ G_ s_v_s _ T_E_M_ I ELEC I a 1
Lighting Coil Resistance: OUT OF SPECIFICATION

0.16 ~ 0.24íl at 20 ° C (68° F)
(Yellow / Red - B lack)
MEETS SPECIFICATION
1 ghting_ coil is _fault , replace it
.__u_ _ _ _ _ _ _ _ _ v
_ _ _ _ _ _ _ _ _ ________.
Check the entire lighting system for connec POOR CONNECTION
section.
CORRECT 1 Correct.
Rectifier/Regulator is faulty, replace it.
TROUBLESHOOTING (2)
1 TAILLIGHT DOES NOT COME ON.
Procedure
1. Fuse
2. Battery
3. Tail/Brake light bulb
4. Main switch
NOTE:--------------------------------
•Remove the following parts befo re troubleshooting.
1) Seat
2) Side cover
Pocket Tester:
YU-03112
1. Fuse
NOCONTINUITY
•Remove the fuse.
•Connect the Pocket Tester (íl x 1) to the fuse.
Fuse if faulty , replace it.
CONTINUITY
*
7-27
___________L_I _G _H_T I_N_ G_ s_v_s _T _EM_
I ELEC I a 1
*
2. Battery
•Check the battery condition. Refer to the INCORRECT
"BATTERY INSPECTION" section in the
CHAPTER 3.
Specific Gravity:
1.280 at 20º C (68 ° F)
•Clean battery terminals.
•Recharge or replace battery.
CORRECT
3. Tail/Brake light bulb

•Remove the tail/brake light bulb.
•Connect the Pocket Tester mx 1k) to the
tail/brake light bulb.
Tester ( +) Lead-+Terminal G)
Tester (-) Lead-+Terminal @
Tester ( +) Lead-+Termi�al @
Tester ( - ) Lead-+Terminal @
íl X 1k
-@+o+------
CONTINUITY DOES NOT

íl X 1k
EXIST ON ONE CIRCUIT.
•Check the tail/brake light bulb for continuity.

Tail/Brake light bulb is faulty, replace it.
CONTINUITY EXISTS
ON BOTH CIRCUITS.
4. Main switch
•Disconnect the main switch coupler (Red,
Brown and Black) from the wireharness.
•Connect the Pocket Tester m x 1) to the main
switch leads.
7-28
I _s_v_sT_E_M_ I ELEC I
___________L_IG_H_T_N_G a 1
Tester ( +) Lead-+Red G) Lead

Tester (-) Lead-+Brown @ Lead

•Check the main switch for continuity.
BAO CONDITION
Switch Good
Bad condition
position condition
ON o X X o
OFF X o X o 1 Main switch is faulty, replace it.
GOOD CONDITION
Check the entire lighting system for connec
INCORRECT
section.
CORRECT 1 Correct.
Tail/Brake light bulb socket is faulty, replace

tail/brake light assembly.
7-29
SI SYSTEM
Below circuit diagram shows signa! system.
®f
B B B 18 B
...J.... ....1..., � -l... -
...J.....
-= @) -:::" --:=- ® -=-
7-30
____________s _lG_N_A_L_ s_v_s_T_EM_ I
NOTE:-------------
ELEC Ia1
For the color code, see page 7-2.
(J) Main switch @ Flasher light (Right)

@ Fuse @ Horn
® Battery @ "HORN" switch
® Flasher relay @ Front brake switch
@ "TURN" switch ® Rear brake switch
@ Flasher light ( Left) @ Tail/Brake light
7-31
___________
s _1G_N_A_L_s_v_s_T_EM_
_
I
ELEC I e 1
TROUBLESHOOTING
FLASHER LIGHT, BRAKE LIGHT AND/OR HORN DO NOT OPERATE.
Procedure
Check;
1) Fuse
2) Battery
3) Main switch
4) Wiring connection
NOTE:--------------------------------
• Remove the fallowing parts befare troubieshooting.
1) Seat
2) Side cover
•Use the fallowing special tool(s) in this troubleshooting.
lP1 Pocket Tester:

YU-03112
1. Fuse
•Remove the fuse. NOCONTINUITY
•Check the fuse far continuity.
CONTINUITY Fuse is faulty, replace it.
2. Battery
•Check the battery condition. Refer to the
"BATTERY INSPECTION" section in the
CHAPTER 3. INCORRECT
Specific Gravity:
1.280 at 20 ° C (68 ° F)
•Clean battery terminaIs.
CORRECT • Recharge or replace battery.
3. Main switch
• Disconnect the main switch coupler (Red,
•Connect the Pocket Tester (íl x 1) to the main
switch leads.
7-32
v_s_T_E_M_ 1 ELEC 1 1
___________S_I_G_NA_L_s
§

•Check the main switch far continuity.
BAO CONOITION
Switch Good
Bad condition
position condition
ON o X X o
GOOO CONOITION
INCORRECT
Check the entire signal system far connections.
Refer to the "WIRING OIAGRAM" section.
1 Correct.
CORRECT
Go to the "SIGNAL SYSTEM TEST ANO

CHECK" section.
7-33
___________ s_,_G_NA_L _sv_ s_T_E_M_ I ELEC I a 1
SIGNAL SYSTEM TEST ANO CHECK
1. Horn does not sound, when pushing "HORN" switch.
1. "HORN" switch check

[(Brown/White, Yellow/Red, Black and Pink)
(Yellow, Green, Dark green and Chocolate)]
"HORN" switch.
Tester ( +) Lead--+ Pink CD

Lead
Tester (-) Lead--+Black @ Lead
•Check the "HORN" switch far continity.

BAD CONDITION
Switch Good
Bad condition
position condition
"HORN" switch
is pushed.
o X X o
"HORN" switch
is not pushed
X o X o "HORN" switch is faulty, replace handlebar
switch.
GOOD
CONDITION
2. Voltage check
•Connect the Pocket Tester (DC20V) to the
horn at the brown terminal.
Tester ( + l Lead--+ Brown CD

Lead
Tester (-) Lead--+Frame Ground
7-34
s _1 _N_A_L_ s_v_s_T_E_M_ I
____________ G
ELEC Ia1
•Checkfor voltage (6V) on the "Brown" lead

at the horn terminal. Wiring circuit from main switch to horn termi
nal is faulty, repair.
MEETS
SPECIFICATION (6V)
3. Horn check
•Disconnect the "Pink" lead at the horn
terminal.
•Connect a jumper lead G) to the horn termi
nal and ground the jumper lead.
HORN IS SOUNDED
1 Horn is good.
HORN IS NOT
SOUNDED
4. Voltage check

horn at the Pink terminal.
Tester (+) Lead---+Pink G) Lead

Tester ( - ) Lead---+Frame Ground
7-35
___________
s_1G_N_A_L_sv_s_T_E_M_ I ELEC [� 1
•Check for voltage (6V) on the "Pink" lead at OUT OF SPECIFICATION

the horn terminal.
MEETS SPECIFICATION
(6V)
1 Horn is faulty, replace it.
Adjust or replace horn.
2. Brake light does not come on when applying rear or front brake.
1. Bulb check
•Remove the tail/brake light bulb.
•Connect the Pocket Tester (íl x 1 k) to the
bulb.
Tester ( +) Lead-Terminal G)
Tester ( - ) Lead-Terminal @
Tester ( +) Lead-Terminal @
CONTINUITY DOES NOT

EXIST ON ONE CIRCUIT
íl X 1k
Tail/Brake light bulb is faulty, replace it.

•Check the bulb for continuity.
CONTINUITY EXISTS
ON 80TH CIRCUITS
2. Front brake switch check

•Disconnect the front brake switch coupler
(Brown and Green/Yellow) from the wire
harness.
•Connect the Pocket Tester (íl x 1) to the brake
switch leads.
Tester ( +) Lead- Brown G) Lead

Tester (-) Lead-Green/Yellow @
Lead
7-36
E _I
1 _N_A_L_ s_v_s_T_M ELEC I B 1
____________s _G
•Check the brake switch for continuity.

BAD CONDITION
Switch Good
Bad condition
position condition
Front brake
is applied. o X X o
Front brake
is not applied
X o X o Front brake switch is faulty, replace it.
GOOD
CONDITION
3. Voltage check
front brake switch.
Tester ( +) Lead-Brown G) Lead

Tester ( - ) Lead-Frame Ground
•Check for voltage (6V) on the "Brown" lead

at the brake switch coupler. Wiring circuit from main switch to brake switch
connector is faulty, repair.
MEETS
SPECIFICATION (6V)
7-37
_
____________s 1G_N_A_L_
s_v_s_T_EM_ 1 ELEC I B1
*
4. Rear brake switch check
•Disconnect the rear brake switch leads

(Brown and Yellow) from the wireharness.
•Connect the Pocket Tester (íl x 1) to the brake
switch lead.
•Check the brake switch for continuity.

BAD CONDITION
Switch Good
Bad condition
position condition
Rear brake
is applied. o X X o
Rear brake
is not applied
X o X o Rear brake switch is faulty, replace it.
GOOD
CONDITION
5. Voltage check
rear brake switch.
Tester ( +) Lead-+Brown G) Lead

Tester ( - ) Lead-+Frame Ground
7-38
_N_A_L_s_v_s_TE_M_
____________s_1G
I ELEC I a 1
•Check far voltage (6V) on the "Brown" lead OUT OF SPECIFICATION

at the brake switch connecter.
MEETS
Wiring circuit from main switch to brake switch
SPECIFICATION (6V)
connector is faulty, repair.
Tail/Brake light bulb socket is faulty, replace
tail/brake light assembly.
3. Flasher lights do not blink.
1. Bulb check
• Remove the flasher light bulb.

•Connect the Pocket Testar (ílx 1k) to the
bulb.
Tester ( +) Lead-+Terminal CD
Tester (-) Lead-+Terminal ®
NOCONTINUITY
•Check the bulb far continuity. 1 Bulb is faulty, replace it.
CONTINUITY
2. Bulb socket check
•lnstall the bulb to the socket.

•Disconnect the flasher light leads [ ( Chocolate
and Black) or (Dark green and Black)l
•Connect the Pocket Testar (íl x 1k) to the
flasher light leads.
When checking right flasher light:

Tester ( +) Lead-+Dark Green LeadCD
Tester ( - ) Lead-+Black @ Lead
When checking left flasher light:

Tester ( +) Lead-+Chocolate CD
Lead
Tester ( - ) Lead-+Black @ Lead
7-39
SIGNAL SYSTEM I ELEC 1
§ 1
NOCONTINUITY
Bulb socket is faulty, replace flasher light as

•Check the bulb socket for continuity. sembly.
CONTINUITY
3. "TURN" switch check

[(Chocolate, Dark green, Yellow and Green)
(Black, Pink, Yellow/Red and Brown/White)J
"TURN" switch leads.
When turning "TURN" switch to "R":

Tester ( +) Lead-+ Brown/White G)
Lead
Tester (-) Lead-+ Dark green @ Lead
When turning "TURN" switch to "L":

Tester ( +) Lead-+ Brown/White G)
Lead
Tester (-) Lead-+Chocolate @ Lead
•Turn the "TURN" switch to the "R" and "L".

•Check the "TURN" switch for continuity.
BAD CONDITION
Switch Good
Bad condition
position condition
R o X o X
L o o X X
"TURN" switch is faulty, replace handlebar
switch.
GOOD
* CONDITION
7-40
SIGNAL SYSTEM IELEclal
-------------------
*
4. Voltage check

flasher relay.
Tester ( +) Lead--►Brown G) Lead

Tester (-) Lead--►Frame Ground

Wiring circuit from main switch to flasher re
at the flasher relay terminal. lay connector is faulty, repair.
MEET
SPECIFICATION (6V)
Flasher relay is faulty, replace it.
7-41
DílSP SYSTE
,.
B
....L.
Br
®'
18/ IR Sb
r
Sb�
®
®I
1B B
....L. ..J..._
7-42
___________D_I_SP_L_A_v _ s_ v_s
NOTE:-------------
_T_E_M_ I Ia
ELEC 1
@ COI magneto @ lgnition control unit

@ Rectifier / Regulator ® Flasher relay
(j) Main switch @ "TURN" switch
@ Fuse @ "TURN" indicator light
® Battery @ "OIL" warning indicator light
@ "LIGHTS" (Dimmer) switch ® Oil level switch
(jJ) "HIGH BEAM" indicator light @ "NEUTRAL" indicator light
@ Meter light ® Neutral switch
8 5 (j)
7-43
___________0_1_s P_L_A_v _ s_ v_s _T_EM_
I
ELEC
I
a 1
TROUBLESHOOTING (1)
METER LIGHT AND/OR "HIGH BEAM" INDICATOR LIGHT DO NOT COME ON.
Procedure
Check;
1) Meter light and "HIGH BEAM" indicator light
2) "LIGHTS" (Dimmer) switch
3) Lighting circuit output
4) Lighting coil resistance
NOTE:-----------------------------
•Remove the fallowing parts befare troubleshooting.
1) Seat
2) Side cover
•Use the fallowing special tool(s) in this troubleshooting.
...___· l_·t:....l__p º-�-�-�-�

3 2
ster
-�_� _ _ _ =________I �I lnductive Tachometer:
YU-08036
1. Meter light and "HIGH BEAM" indicator

light
•Remove the bulb (Meter light or "HIGH

BEAM" indicator light).
•Connect the Pocket Tester (ílx 1k) to the
bulb.
Tester ( +) Lead-+Terminal G)
Tester ( - ) Lead-+Terminal @
NOCONTINUITY
1 Bulb is faulty, replace it.

•Check the bulb far continuity.
CONTINUITY
*
7-44
___________0_1_s P_L_A_v _ s_ v_s _T_E_
M_ I ELEC I a1
*

[(Chocolate, Green, Dark green and Yellow)
(Black, Pink, Yellow/Red and Brown/White)]
•Connect the Pocket Tester m x 1) to the
"LIGHTS" (Dimmer) switch leads.
When turning "LIGHTS"(Dimmer) switch

to "HI":
Testar( +) Lead-Yellow/Red G) Lead
Testar(-) Lead-Yellow @ Lead
When turning "LIGHTS"(Dimmer) switch

to "LO":
Testar( +) Lead-Yellow/Red G) Lead
Testar(-) Lead-Green @ Lead
•Turn the "LIGHTS" (Dimmer) switch to the

"HI" and "LO".
•Check the "LIGHTS"' (Dimmer) switch for
continuity. BAD CONDITION
Switch Good
Bad condition
position condition
HI o X o X
LO o o X X "LIGHTS" (Dimmer) switch is faulty, replace
O: Continuity x : Nocontinuity handlebar switch.
GOOD CONDITION
•Turn the "LIGHTS" (Dimmer) switch to

"LO".
•Connect the Pocket Tester (AC V-20) to the
headlight leads.
Testar( +) Lead-Green G) Lead

7-45
Testar(-) Lead-Black @ Lead
___________0_1_s _PL_A_v_ s_ v_s_T_E_M_
I 1 53 1
ELEC
1
AC V-20
1
•Connect the lnductive Tachometer to the

spark plug lead.
•Start the engine and check the output
voltage.
MEETS SPECIFICATION
Do not run the engine in neutral above ...... ::::::::::::::::::::

6,000 r/min for more than 1 or 2 seconds.
1 Bulb socket is faulty, replace it.

Standard Output:
6.2-7.2V at 3,000 r/min or More
OUT OF
SPECIFICATION

wireharness.
-Connect the Pocket Tester (íl x 1) to the light
ing coil leads.
Tester ( +} Lead-+Yellow/Red G) Lead

Tester (-} Lead-+Black @ Lead
•Check the lighting coil for specificated

resistance.
7-46
DISPLAY SYSTEM I
1 1
ELEC
§
Lighting Coil Resistance:
� 0.16 ~ 0.24íl at 20º C (68 º F}
(Yellow/Red-Black}
1 Lighting coil is faulty, replace it.
MEETS
SPECIFICATION
Check the entire display system for connec POOR CONNECTION

section.
1 Correct.
CORRECT
Rectifier/Regulator is faulty, replace it.
7-47
1 1 1
___________D_I_SP_L_A_Y _ S_ Y_S _T_E_M_ ELEC §
TROUBLESHOOTING (2)
"TURN", "NEUTRAL" INDICATOR LIGHT AND/OR "OIL" WARNING INDICATOR LIGHT

DO NOT COME ON.
Procedure
Check;
1) Fuse
2) Battery
3) Main switch
NOTE:------------------------------
•Remove the following parts befare troubleshooting.
1) Seat
2) Side cover
Pocket Tester:
YU-03112
1. Fuse
•Remove the fuse.

NOCONTINUITY
..
1 Fuse is faulty, replace it.
1
CONTINUITY
"" 'r
2. Battery
•Check the battery condition.

Refer to the "BATTERY INSPECTION" sec- INCORRECT
tion in the CHAPTER 3.
Specific Gravity:
1.280 at 20 º C (68 º F) •Refill battery fluid.
•Clean battery terminals.
CORRECT •Recharge or replace battery.
"""'�
3. Main switch
• Disconnect the main switch coupler (Red,

•Connect the Pocket Tester (íl x 1) to the main
switch leads.
7-48
___________0_1_s P_L_A_v _ s_ v_s _TE_M_ I Ia1
ELEC


•Check the main switch far continuity.
BAO CONDITION
Switch Good
Bad condition
position condition
ON o X X o
GOOD CONDITION
INCORRECT
Check the entire display system far connec
section.
1 Correct.
CORRECT
Go to the "DISPLAY SYSTEM TEST ANO

CHECK" section.
7-49
T EM_
___________0_1_s P_L_A_v _ s_ v_s _ _
DISPLAY SYSTEM TEST AND CHECK
I Ia
ELEC
1
1. "NEUTRAL" indicator light does not come on.
1. Bulb check
•Remove the bulb.

•Connect the Pocket Tester (íl X 1k) to the
bulb.
Tester ( +} Lead-+Terminal CD
Tester (-) Lead-+Terminal @
NOCONTINUITY
•Check the bulb for continuity. 1 Bulb is faulty, replace it.
CONTINUITY
2. Neutral switch check

wireharness.
•Connect the Pocket Tester (íl x 1) to the neu
tral switch leads.
Tester ( +) Lead-+Sky blue Lead CD

7-50
0_1s_P_L_A_v _ s_ v_s _TE_M_
____________
•Shift the transmission in neutral and gear.
I Ia1
ELEC
•Check the neutral switch for continuity.

Trans-
Good BAO CONDITION
mission Bad condition
condition
position
Neutral o X X o
Gear X o X o 1 Neutral switch is faulty, replace it.
GOOD CONDITION
,...... -
3. Voltage check

"NEUTRAL" indicator light lead.
a=+•
Tester (+) Lead-Brown G) Lead
Tester ( - ) Lead-Frame Ground
�#
B/RIX B, B, X B/R
r-
Sb Y B B Y Sb 1/,'i,A
Sb- Dg Ch L L Ch Dg
�1--' -
� 2
_L
1
DC20V
-
._ �®t
(2) Wireharness
•Check for voltage (6V) on the "Brown" lead Wiring circuit from main switch to "NEUTRAL"
at the connector. indicator light connector is faulty, repair.
MEETS
SPECIFICATION (6V)
.............
lgnition control unit is faulty, replace it.
7-51
___________0_1_s P_L_A_v _ s_ v_s _T_
EM_ I
2. "OIL" warning indicator light does not come on.
ELEC Ia1
1. "OIL" warning indicator light (L.E.D.)
check
•Disconnect the meter coupler ( Black/ Red,

Brown, Sky blue, Yellow, Black, Dark green,
Chocolate and Blue) from the wireharness.
•Connect a full charged battery (6V) to the
meter coupler.
Battery ( +) Lead-+Brown G) Lead

Battery (-) Lead-+Black/Red @ Lead
INDICATOR LIGHT DOES

NOT COME ON.
Br 8/R
6V
"OIL" warning indicator light (L.E.D.) is faulty,
replace it.
INDICATOR LIGHT
COMES ON.
2. Oil level switch check ( 1)
•Remove the oif level switch from the oif tank.

•Connect the Pocket Tester (íl x 1) to the oil
level switch lead.
Tester ( +) Lead-+Black/Red G) Lead

Tester ( - ) Lead-+Sky blue @ Lead
NOCONTINUITY
Oil level switch is faulty, replace it.

•Check the oil level switch for continuity.
CONTINUITY
*
7-52
___________0_ 1_s P_L_A_v _ s_ v_s _T_M
E _1 ELEC I a 1
3. Oil level switch check (2)
•Connect the Pocket Tester m x 1) to the oil

level switch.
Tester ( +) Lead-+Black/Red G) Lead

- B
r"--l"'�
)
'
-
Sb
t--·J 1
8/R
�
-@+G
:, -
•Check the oil level switch for continuity.
Switch Good
Bad condition
position condition BAD CONDITION
Upright
position
o X X o
o o
1
Up-side down
1 Oíl level switch is faulty, replace it.
X X
position
GOOD
�....7 CONDITlON
4. Voltage check
"OIL" warning indicator light.

Tester (-) Lead-+Frame Ground
� #�--
B/ R B/RIX Br Br IX B/R
Sb Y B B Y Sb 1 �
D!l Ch L L Ch Dg
Br- :::::::¡ _
r�
_
11 2
-
fü+
�---
----€) \D/Bt-
� Wireharness
7-53
___________D_IS_P_L_A_v _ s_ v_s _T_EM_
•Check far voltage (6V) on the "Brown" lead
I Ia
ELEC 1
at connector.
MEETS
SPECIFICATION (6V) Wiring circuit from main switch to "OIL" warn
ing indicator light connecter is faulty, repair.
Wiring connection is faulty, correct.
3. "TURN" indicator light does not come on.
1. Bulb Check
•Remove the bulb.
•Connect the Pocket Tester (íl x 1k) to the
bulb.
Tester ( +) Lead-Terminal G)
NOCONTINUITY
•Check the bulb far continuity. 1 Bulb is faulty, replace it.
iCONTINUITY
,
2. "TURN" switch check
• Disconnect the handlebar switch couplers

[(Chocolate, Dark green, Yellow and Green)
(Black, Pink, Yellow/Red and Brown/White)]
"TURN" switch leads.

Tester ( +) Lead-Brown/White G)
Lead
Tester (-) Lead-Dark green @ Lead

Tester ( +) Lead-Brown/White G)
Lead
Tester (-) Lead-Chocolate Lead®
7-54
IELEclal
-------------------
DISPLAY SYSTEM
•Turn the "TURN" switch to the "R" and "L".

•Check the "TURN" switch for continuity.
BAD CONDITION
Switch Good
Bad condition
position condition
R o X o X
L o o X X
"TURN" switch is faulty, replace handlebar
switch.
GOOD
CONDITION
3. Voltage check

flasher relay.

Tester (-) Lead-+Frame Ground

Wiring circuit from main switch to flasher re
at the flasher relay terminal.
lay connector is faulty, repair.
MEET
SPECIFICATION (6V)
1 Flasher relay is faulty, replace it.
7-55
--------- 1 ELECI a¡
7-56
-____________ íls
STARTING FAILURE/HARD STARTING �
T R B L
HT G J
?•
TROUBLESHOOTING
NOTE:-----------------------------
The following troubleshooting does not cover all the possible causes of trouble. lt should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING
l•
FUEL SYSTEM PROBABLE CAUSE
Fuel tank ----------- • Empty
Clogged fuel filter
•Clogged air passage (Fuel tank cap)
• Deteriorated fuel or fuel containing water or
foreign material
Fuel cock ---------- • Clogged fuel hose
Carburetor ----------.-- • Deteriorated fuel, fuel containing water or

foreign material
•Clogged pilot jet
• Clogged pilot air passage
•Sucked-in air
• Deformed float
•Groove-worn needle valve
• lmproperly sealed vatve seat
• lmproperly adjusted fuel level
• lmproperly set pilot jet
•Clogged starter jet
•Starter plunger malfunction
•lmproperly adjusted starter cable
Air cleaner ---------- •Clogged aír fílter
8-1 [;J
----------.--l
?•
ls H T G 1
T R BL
STARTING FAILURE/HARD STARTING _
-______________
ELECTRICAL SYSTEM PROBABLE CAUSE
Spark plug •lmproper plug gap
•Worn electrodes
•Wire between terminals broken
•lmproper heat range
----------,-L-
•Faulty spark plug cap
lgnition coil •Broken or shorted primary/secondary
--------.--l
• Faulty spark plug lead
•Broken body
C.D.I. unit system •Faulty C.D.I. unit

•Faulty source coil
•Faulty pick-up coil
•Broken woodruff key
Switches and wiring ------- •Faulty main switch

•Faulty engine stop switch
•Broken or shorted wiring
•Faulty neutral switch
•Faulty sidestand switch
• Faulty lgnition control unit
8-2
sTART1 N. GFA 1LuRE 1 H ARo sT ART1NG1 Pºº R
7•
-__ _ _ PERFO
IDLE ___SPEED - RMA NCE_ ls HTG
TR B L 1
?•
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
COMPRESSION SYSTEM PROBABLE CAUSE
Cylinder and cylinder head Loose spark plug
• Loose cylinder head or cylinder
• Broken cylinder head gasket
• Broken cylinder gasket
7
•Worn, damaged or seized cylinder
Pisten and pisten rings •lmproperly installed pisten ring

•Worn, fatigued or broken pisten ring
•Seized pisten ring
•Seized or damaged pisten
L
Crankcase and crankshaft ------T- •lmproperly seated crankcase
•lmproperly sealed crankcase (Damaged oil seal)
----,---------.--•
•Seized crankshaft
Reed valve Deformed reed valve stopper
l
•lmproperly seated read valve
• Loose intake manifold
• Broken gasket
• Broken reed valve
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE
L Carburetor ----------r- •lmproperly returned starter plunger
•Clogged or loose pilot jet
•Clogged pilot air jet
•lmproperly adjusted idle speed
(Throttle stop screw)
•lmproper throttle cable play
• Flooded carburetor
8-3
POOR MEDIUM ANO HIGH SPEED PERFORMANCE ?•
POOR MEDIUM ANO HIGH SPEED PERFORMANCE
l•
FUEL SYSTEM PROBABLE CAUSE
Fuel tank ----------,..-•Clogged fuel filter
Deteriorated fuel or fuel containing water
or foreign material
•Clogged air passage (Fuel tank cap)
Fuel cock ---------- •Clogged fuel hose
Carburetor----------,..-•Deteriorated fuel, fuel containing water or

foreign material
•Sucked-in air
•Deformed float
•Groove-worn needle valve
•lmproperly sealed valve seat
•lmproperly set clip position of jet needle
• lmproperly adjusted fuel level
• Clogged or loose main jet
• Clogged or loose main nozzle
Air cleaner ----------•Clogged air filter
ELECTRICAL SYSTEM
l
PROBABLE CAUSE
Spark plug-----------.-•lmproper plug gap
•Worn electrodes
•Wire between terminals broken
•lmproper heat range
•Faulty spark plug cap
L•
C.D.I. unit system-------•Faulty C.D.I. unit
Faulty source coil
•Faulty pick-up coil
8-4
7•
?•
-___________ ls HTG I
TR B L
POOR MEDIUM ANO HIGH SPEED PERFORMANCE _
COMPRESSION SYSTEM PROBABLE CAUSE
Cylinder and cylinder head Loose spark plug
• Broken cylinder head gasket
• Broken cylinder gasket
• Loese cylinder head er cylinder
•Wern, damaged ar seized cylinder
L
Pistan and pisten ring •lmpreperly installed pisten ring
•Wern, fatigued ar breken pisten ring
• Seized pistan ring
7
• Seized ar damaged pisten
Crankcase and crankshaft •lmpreperly seated crankcase

• lmpraperly sealed crankcase
(Damaged ail seal)
• Seized crankshaft
Reed valve ---------� •Deformed reed valve stepper

• lmpreperly adjusted reed valve stapper height
• lmpraperly seated reed valve
• Loose intake manifold
• Broken gasket
• Broken reed valve
8-5
FAULTY GEAR SHIFTING
FAULTY GEAR SHIFTING
HARD SHIFTING PROBABLE CAUSE
Clutch ----------�-•lmproperly adjusted clutch cable
•lmproperly adjusted push lever position
•lmproper engagement of push lever and push
rod
•Seized bush at primary driven gear
•Warped clutch plate
•Swollen friction plate
• Broken clutch plate
Transmission oil ---------.-•High oil level

L •lmproper quality (High viscosity)
•Deterioration
CHANGE PEDAL DOES NOT MOVE PROBABLE CAUSE

Shift shaft--------- ......... •lmproperly adjusted shift rod
•Bent shift shaft
Shift cam and shift fork----� -•Groove jammed with impurities

L •Seized shift fork
•Bent shift fork guide bar
Transmission---------.-•Seized transmission gear

L •Jammed impurities
•lncorrectly assembled transmission
JUMP-OUT GEAR PROBABLE CAUSE

Shift shaft--------- ......... •lmproperly adjusted shift lever position
•lmproperly returned stopper lever
Shift fork -----------•Worn shift fork
Shift cam ----------.--•lmproper thrust play

•Worn shift cam groove
Transmission ---------•Worn gear dog
8-6
-______________ CLUTCH SLIPPING/DRAGGING l s
CLUTCH SLIPPING/DRAGGING
_
T RB L
H T G J ?•
_
CLUTCH SLIPPING PROBABLE CAUSE

Clutch-------------T - •lmproperly adjusted clutch cable
-t..oose clutch spring
l -Fatigued clutch spring
•Worn friction plate
•Worn clutch plate
Transmission oil ---------.- • Low oil level

L -lmproper quality ( Low viscosity)
-Oeterioration
CLUTCH DRAGGING PROBABLE CAUSE

Clutch-------------T- •lmproperly adjusted clutch cable
•lmproperly adjusted pull lever position
•lmproper engagement of pull lever and pull rod
• Seized bush at primary driven gear
•Warped clutch plate
• Swollen friction plate
• Broken clutch boss
Transmission oil -------�- -High oil level

L •lmproper quality (High viscosity)
-Oeterioration
8-7
-___...;..._..__________ _
IMPROPER KICKING
IMPROPER KICKING
ls H T G
T RB L
1 ?•
_
SLIPPING PROBABLE CAUSE
Kick axle assembly------�- •Low tension of kick clip
•Worn kick axle
•Worn ar damaged kick idle gear
•Worn or damaged kick gear
•Damaged kick clip
•Kick clip coming off
•Damaged kick clip stopper
Transmission oil----------,- •lmproper quality (Low viscosity)

• Deterioration
HARD KICKING
Kick axle assembly --------rl- PROBABLE CAUSE
•High tension of kick clip
•Seized kick gear
•Seized kick idle gear
Transmission oíl--------- •lmproper quality (High viscosity)

•Deterioration
L
7
Cylinder, pistan and pistan ring •Damaged or seized cylinder
• Damaged or seized pistan
• Damaged or seized pistan ring
Crankcase and crankshaft •lmproperly seated crankcase

•lmproperly seated crankshaft
•Damaged or seized crankshaft
• Damaged or seized crankshaft bearing
KICK CRANK NOT RETURNING

L Kick axle assembly ------�l- PROBABLE CAUSE
•Damaged kick return spring
• Kick return spring coming off
•Kick clip coming off
• Damaged kick return spring stopper
8-8
FAULTv eRAKE/FRoNT FoRK 01L LEAKAGE
ANO FRONT FORK MALFUNCTION lsT.HRTBGL. I ?.
_ . _
_I
FAULTY BRAKE
POOR BRAKING EFFECT PROBABLE CAUSE
Disc brake ------------.-- •Worn brake pad
•Worn brake disc
•Air in brake fluid
• Leaking brake fluid
• Faulty cylinder kit cup
• Faulty caliper kit seal
•Loosen union bolt
• Broken brake hose
•Oily or greasy brake disc
•Oily or greasy brake pad
•lmproper brake fluid leve!
Drum brake----------r- •Worn brake shoe

•Worn or rusty brake drum
•lmproperly adjusted brake cable/pedal free play
•lmproper brake cam lever position
•lmproper brake shoe position
•Fatigued or/damaged return spring
•Oily or greasy brake shoe
•Rusty, oily or greasy brake drum
• Broken brake cable
FRONT FORK OIL LEAKAGE ANO FRONT FORK MALFUNCTION

OIL LEAKAGE PROBABLE CAUSE
.________________...-- • Bent, damaged or rusty inner tube
• Damaged or cracked outer tube
• Damaged oil seal lip
•lmproperly installed oil seal
•lmproper oil leve! (too much)
• Loose damper rod holding bolt
• Broken cap bolt 0-ring
• Loose drain bolt
• Damaged drain bolt gasket
MALFUNCTION PROBABLE CAUSE

-----------------r--- • Bent, deformad or damaged inner tube
• Bent or deformad outer tube
• Damaged fork spring
•Worn or damaged slide metal
• Bent or damaged damper rod
•lmproper oil viscosity
•lmproper oil level
8-9
-______________
INSTABLE HANDLING
INSTABLE .HANDLING
_l s H T G
T RB L
1
l•
INSTABLE HANDLING PROBABLE CAUSE
Handlebars----------- -tmproperly installed or bent
Steering--------------.� •lmproperly installed handle crown

Bent under-bracket
•lmproperly installed steering shaft
l•
(lmproperly tightened ringnut)
•Damaged ball bearing or bearing race
Front forks----------- •Uneven oil levels on both sides

Uneven spring tension
(Uneven damping adjuster position)
•Broken spring
•Twisted front forks
------------l-
Tires------------� •Uneven tire pressures on both sides
•lncorrect tire pressure
•Unevenly worn tires
Wheels -tncorrect wheel balance

•Deformed cast wheel
•Loose bearing
•Bent or loose wheel axle
-Excessive wheel run-out
Frame------------.- •Twisted
•Damaged head pipe
•lmproperly installed bearing race
Swingarm-----------.- •Worn bearing or bush

-Sent or damaged
Rear shock absorber ________,,..... •Fatigued spring

L •lmproperly adjusted spring preload
•Oil leakage
Orive chain---------- •lmproperly adjusted chain slack
Cowl------------....- •Damaged or broken

•lncorrectly installed
8-10
?•
_ HT G 1
ls
T R BL
FAULTY SIGNAL ANO LIGHTING SYSTEM
-________________
FAULTY SIGNAL ANO LIGHTING SYSTEM
HEADLIGHT DARK PROBABLE CAUSE
.._______________-.- •lmproper bulb
•Too many electric accessories
•Hard charging (Broken charging coil and/br
faulty rectifier / regulator)
•lncorrect connection
•lmproperly grounded
• Poor contacts (main or light switch)
•Bulb life expired
BULB BURNT OUT PROBABLE CAUSE

---------------.- •lmproper bulb
•Faulty battery
•Faulty rectifier / regulator
•lmproperly grounded
•Faulty main and/or light switch
•Bulb life expired
FLASHER DOES NOT LIGHT PROBABLE CAUSE

.________________ •lmproperly grounded
• Discharged battery
•Faulty flasher switch
•Faulty flasher relay
•Broken wireharness
• Loosely connected coupler
•Bulb burnt out
FLASHER KEEPS ON
l PROBABLE CAUSE
...l _____________---.--•Faulty flasher relay
•lnsufficient battery capacity
(nearly discharged)
•Bulb burnt out
8-11
?•
-____________ l
T R B L
FAULTY SIGNAL ANO LIGHTING SYSTEM _s HT G 1
FLASHER WINKS SLOWER PROBABLE CAUSE

'-------------- -----,- -Faulty flasher relay
•lnsufficient battery capacity
(nearly discharged)
•lmproper bulb
•Faulty main and/ or flasher switch
FLASHER WINKS QUICKER PROBABLE CAUSE

..__--------------•lmproper bulb
•Faulty flasher relay
HORN IS INOPERATIVE PROBABLE CAUSE

-----------------.-- -Faulty battery
•Faulty main and/or horn switch
•lmproperly adjusted horn
•Faulty horn
• Broken wireharnes
8-12
-____________ _ls HTG J
TR B L
OVERHEATING
OVERHEATING
L•
OVERHEATING PROBABLE CAUSE
lgnition system -------....- •lmproper spark plug gap
l
lmproper spark plug heat range
•Faulty C.D.I. unit
Fuel system ---------- •lmproper carburetor main jet

(lmproper setting)
•lmproperly adjusted fuel height
• Clogged air cleaner element
•Lean mixture (Faulty autolube pump settings)
Compression system --------- • Heavy carbon build-up
L•
Transmission oil--------.- •lncorrect oil level
lmproper oil viscosity
•Inferior oil quality
Brake ------------ • Dragging brake
Clutch ------------.- •Worn friction plate

•Worn clutch plate
8-13
YSR50T WIRING DIAGRAM
m.fi
Neutral
011 level
switch
switch
rde-¡
Fuse
8/R " �
Front flaaher rn.-Dg--(:>[=:J--

o
light (Rlghtl '---.)-¿__
e-C:>C:]----e Battery
Headlight CD�i Rear flasher light (Right)
9--D<J-Dg.JÍ)
e-D<}-e_]'-/
v--D<J-vR)
"OIL" warning L--c:::::J<J- L
indlcator light e--D<}-e
Tail/brake light
"NEUTRAL"
indlcato,·llght
B--D<J--B
"TURl'f' Ch-C}<J-ChJ.(--\
indlcetor light 1...l....)
Rear flasher light (Leftl

"HIGH BEAM"
indlcator light
front flaaher rn.-C�

Ch
light lleltl �
e-{:>[::J---e
COLOR COOE
Horn oc-----P
§1------e,
B ....... Black
Br....... Brown
Ch ......Chocolate
Dg ...... Dark green
G ....... Green
[}J
L .......Blue
O .......Orange
P ....... Pink
Rear brake
R .......Red
switch Sb ......Sky blue
w.......White
Y .......Yellow
Flaahar
Earth B/R ..... Black/Red
Sldfltand
ralay awitch
B/W ....Black/White
Br /W.... Brown/White
G/Y .....Green/Yellow
L/W .... Blue/White
L/Y .....Blue/Yellow
Y/R .....Yellow/Red

1987 Yamaha Ysr 50t Service Manual

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1987 Yamaha Ysr 50t Service Manual

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OYAMAHA

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION

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

l�g�lnl ENG G) General information

PERIODIC INSPECTION Fil

MOTORCYCLE IDENTIFICATION ...................................1-1

IMPORTANT INFORMATION ......................................1-2

SPECIAL TOOLS ..................................................1-4

GENERAL SPECIFICATIONS .......................................2-1

MAINTENANCE SPECIFICATIONS .................................2-4

GENERAL TORQUE SPECIFICATIONS ............................2-14

DEFINITION OF UNITS ...........................................2-14

t:l\lulNt ....................................................... 2-15

CABLE ROUTING ................................................2-16

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............ 3-1 �

COWLINGS REMOVAL ANO INSTALLATION ......................3-3 GEN

ENGINE REMOVAL ................................................4-1

ENGINE OISASSEMBLY ...........................................4-5

INSPECTION ANO REPAIR .......................................4-13

SHIFT SHAFT .................................................4-19

ENGINE ASSEMBLY ANO AOJUSTMENT ........................4-24

REED VALVE .....................................................5-8

REAR WHEEL .................................... - ................6-5

FRONT BRAKE ...................................................6-10

REAR SHOCK ABSORBER ANO SWINGARM ....................6-33

ORIVE CHAIN ANO SPROCKETS.................................6-38

YSRS0T CIRCUIT DIAGRAM.......................................7-1

ELECTRICAL COMPONENTS ......................................7-3

IGNITION ANO STARTING SYSTEM............................... 7-4

CHARGING SYSTEM .............................................7-16

SIGNAL SYSTEM .................................................7-30

STARTING FAILURE/HARD STARTING ............................8-1

CLUTCH SLIPPING/DRAGGING ...................................8-7

IMPROPER KICKING ..............................................8-8

FRONT FORK OIL LEAKAGE ANO FRONT FORK MALFUNCTION....8-9

INSTABLE HANDLING ...........................................8-10

FAULTY SIGNAL ANO LIGHTING SYSTEM .......................8-11

YSR50T WIRING DIAGRAM

Starting Serial Number:

ENGINE SERIAL NUMBER

Sta1rti11g Serial Numbe1r:

2. Use proper tools and cleaning equipment.

3. When disassembling the motorcycle, keep

4. During the motorcycle disassembly, clean all

5. Keep away frorn fire.

GASKETS, OIL SEALS, AND O-RINGS

2. Properly oil all mating parts and bearings dur­

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

Do not use compressed air to spin the bear­

This tool is necessary for adjusting ignition timing.

2. Fuel Level Gauge

This gauge is used to measure the fuel level in

This too! is needed for detecting engine rpm.

FOR ENGINE SERVICE

This too! is used to hold the clutch when loosen­

2. Universal Rotor Holder

This tool is used when loosening or tightening the

This tool is used for removing the flywheel.

2. Properly oil all mating parts and bearings dur

Do not use compressed air to spin the bear

This too! is used to hold the clutch when loosen

This tool is used to loosen and tighten the steer

This tester is invaluable for checking the electri

® Keep the oil running out until air bubbles dis

Always use the same type of engine oil; mix