$mrtrlns ilUlffif;$ttal

NOTICE
This manual was written by the Yamaha Motor Company primarily for 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 motorcycles have a basic understanding of the mechanical concepts and procedures in-
herent to motorcycle repair technology. Without such knowledge, attempted repairs or service
to this model may render it unfit to use and/or unsafe'

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

particularly important information is distinguished in this manual by the following notations:

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

A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle'

A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle
operator or person inspecting or repairing the motorcycle.

OVERSEAS SERVICE
OVERSEAS OPERATIONS
YAMAHA MOTOR CO., LTD,
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 INDEX

GENERAL INFORMATION

PERIODIC INSPECTIONS AND

)/
ADJUSTMENTS

ENGINE OVERHAUL
I

CARBURETION I
I

I
CHASSIS 1

L
ELECTRICAL I

APPENDICES
 CHAPTER 1. GENERAL INFORMATION

MOTORCYCLE |DENT|F|CAT|ON.... .......1-1

Frame serial number ........1-1
Engine serial number

SPECTAL TOOLS ........1-2

For tune-up .. . . .......1-2
For engine service .....1-2
For chassis service ....1-3
For electrical components ...1-4

l
 CHAPTER 1.
GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION NOTE:

The first three digits of these numbers are for
Frame serial number model identification; the remaining digits are
The frame serial number is stamped into the the unit production number.
right side of the steering head pipe.

'l . Frame serial number Engine serial number

Engine serial number

The engine serial number is stamped into the Starting serial number: 36X-000101
right side of the engine on top of the crankcase.

1-1
SPECIAL TOOLS 3. Valve seat cutter
P/N. YM-91043
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Us-
ing the correct special tool will help prevent
damage caused by the use of improper tools
or improvised techniques.

For tune-up
1. lnductive timing light
P/N. 90890-03109
2. lnductive tachometer
P/N. 90890-03113
This tool is needed to resurface the valve seat.
3. Compression gauge
P/N. 90890-03081 4. Valve guide remover
4. Fuel level gauge P/N. 90890-04064
P/N,90890-01312

For engine service

1. Clutch holding tool
P/N. 90890-04086

This must be used to remove the valve guides

5. Valve guide installer

P/N. 90890-04065

This tool is used to hold the clutch when removing or installing

the clutch boss lock nut.

2. Valve guide reamer

P/N. 90890-04066

This tool is needed for proper installation of the valve guides.

This must be used when replacing the valve guide.

1-2
 6. Valve spring compressor 9. Rotor puller
P/N. 90890-04019 P/N. 90890-01080

N
This tool must be used for removing and installing the valve This tool is used for removing the flywheel.
assemblies.
10. Piston pin puller
7. Slide hammer P/N. 90890-01304
P/N. 90890-01083 (o)
90890-010&r (@)

This tool is used when removing the piston pin

These tools are used when removing the rocker arm shaft.
For chassis service
1. T-handle
8. Valve adjusting tool
P/N. 90890-01326
P/N. 90890-01311
Damper rod holder
P/N. 90890-04084

This tool is used when adjusting the valve clearance

These tools are used to loosen and tighten the front fork
cylinder holding bolt.
 2. Fork seal driver 2. Electro tester
P/N. 90890-01367 P/N. 90890-03021
Fork seal driver attachment
P/N. 90890-01369

w@
These tools are used to reassemble the lront fork

3. Ring nut wrench

P/N.90890-01051

This tool is used to loosen and tighten the ring nut.

For electrical components

The uses of these tools are described in Chapter
6.
1. Pocket tester
P/N. 90890-03104

N
WW
1-4
 CHAPTER 2.
PERIODIC INSPECTIONS
AND ADJUSTMENTS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . ........2-1
fntroduction.. .....2-1
Periodic maintenance/lubrication chart .....2-1
ENGINE ..2-2
Valve clearance check .. .2-2
Valveclearanceadjustment.... ......2-2
fdling speed adjustment..... ...2-3
Fuel line check ....2-3
Engineoil level measurement.. ......2-3
Engine oil and oil filter replacement... .....2-3
Clutch adjustment.... ...2-s
Decompression cable adjustment..... ......2-6
Cam chain adjustment.... .....2-G
fgnition timing check ... .2-6
Compression pressure measurement. .......2-7
CHASS|S ......2-7
Air filter cleaning . .2-7
Front brake adjustment .... ....2-8
Rearbrakepedal positionadjustment.... ..2-g
Rear brake adjustment.. .......2-9
Brake lining inspection .. .2-g
Rear swingarm pivot shaft lubrication ......2-9
Wheel bearings check .. .2-10
Steering head adjustment .....2-10
Front fork oil change .. .2-11
Rear shock absorber adjustment . . . .2-12
Drive chain tension check .....2-13
Drive chain tension adjustment..... .2-13
Drive chain lubrication . .2-14
Fuel cock cleaning ......2-14
Fuel cock disassembly... .....2-14
Cable inspection and Iubrication .....2-15
Brake and change pedals/brake and clutch levers lubrication .2-15
Sidestands lubrication... ......2-15
Tires check .2-15

ELECTR|CAL.. ......2-16
Battery inspection ......2-16
Spark plug inspection . . .2-1G
Brake light switch adjustment.. .....2-17
Replacing the headlight bulb ..2-17
Headlight beam adjustment.... .....2-17
Fuse replacement .2-18
 CHAPTER 2.
PERIODIC INSPECTIONS AND ADJUSTMENTS
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
lntroduction
This chapter includes all information necessary
to perform recommend inspection and ajust-
ments. These preventative maintenance pro-
cedures, if followed, will insure more reliable
vehicle operation and a longer service life. The
need for costly overhaul work will. be greatly
reduced. This information applies not only to
vehicles already in service, but also to new
vehicles that are being prepared for sale. Any
service technician performing preparation work
should be familiar with this entire chapter.
Periodic maintenance/lubrication chart
The following charts should be considered
''1'
strictly as a guide to general maintenance and
lubrication intervals. You must take into con-
sideration that weather, terrain, geographical
location, and a variety of individual uses all tend
to alter this time schedule. For example, if the
motorcycle is continually operated in an area
of high humidity, then all parts must be
lubricated much more frequently than shown
on the chart to avoid damage caused by water
to metal parts.

Periodic m aintenance/ | ubrication intervals Unit: km (milesl

EVERY
ITEM BREAK-IN
REMARKS 6,000 (4,000) 12,000 (8,000)
1.000 (600)
or 6 months or 12 months
Valve clearance Check/ Adjust valve clearance. o o o
Spark plug Check/ Clean or replace. LJ a) REPLACE
Air filter Clean. Replace if necessary, o o
Carburetor Check/ Adjust/ idle speed, starter operation. a) LJ o
Fuel line Check fuel hose for cracks or damage. a\ o
Engine oil Replace (Warm engine before draining). o o U
Engine oil strainer Clean. o o (t

Engine oil filter Replace. o t) r]

Brake Check operation. o tl

Clutch Check operation. o o

Decompression
system I
Chec k/ Adjust if necessary. o o
Check rear arm assembly for looseness.
Rear arm pivot CHECK o
Moderately repack.**
Check balance/ damage/ runout/ spoke
Wheels
tig htn ess. o U

Check bearings assembly for looseness/

Wheel bearings a\
damage. Replace if damaged. ^
Check bearings assembly for looseness.
Steering bearings Moderately repack every 24,000 ( 16.000) CH ECK CHECK
or 24 months.*
Front forks Check operation/oil leakage. U. o
Rear shock absorber Check operation/oil leakage. (_) LJ

Drive chain Check tension/ alignment/ clean/ lube. VERY s00 (300)
Fittings/ Fasteners Check all chassis fittings and fastners. U (J o
Check specific gravity. Check breather
Battery
pipe for proper operation. LJ o
*: Medium weight wheel bearing grease. **: Lithium soap base grease.
?-1
ENGINE
Valve clearance check lntake valve {cold):
0.10-0.14 mm (0.0039-0.0055 in)
Exhaust valve (cold):
NOTE:
0.16-0.20 mm (0.0063-0.0079 in)
Valve clearance must be measured when the
engine is cool to the touch.

1. Remove the intake and exhaust valve

covers.
2. Remove the timing window and crank-
shaft end cover.

1. Feeler gauge

5. lf the valve clearance is not specification,

adjust the valve clearance.

Valve clearance adjustment

Adjustment of the valve clearance is ac-
3. Align the "T" mark on the flywheel with complished as follows:
the stationary pointer on the crankcase
NOTE:
cover. The pointer can be viewed through
the timing window in the crankcase cover. Valve clearance should be adjusted when the
piston is at T.D.C. on the compression stroke.
When the "T" mark is aligned with the
stationary pointer, the piston is at Top
1. Loosen the valve adjuster lock nut. Turn
Dead Center (T.D.C.). Valve clearance
the adjuster in or out to obtain the speci-
should be checked when the piston is at
fied clearance. Hold the adjuster to pre-
T,D.C. on the compression stroke. The vent it from moving, and thoroughly
piston is at T.D.C. on compression when
tighten the lock nut.
there is free play in both valve adjuster.
Recheck the clearance after tightening.

THE FLYWHEEL IS MARKED AS FOLLOWS:

lntake valve (cold):
0.10-0.14 mm (0.0039-0.0055 in)
Exhaust valve (cold):

r-trl T.D.C. FOR CYLINDER 0.16-0.20 mm (0.0063-0.0079 in)

r--E-- FIRING RANGE FOR

CYLINDER

4. Use a feeler gauge to determine the

clearance.

Feeler gauge
 2. Reinstall removed parts in reverse order. 2. With the engine stopped, check the oil
level through the level window located at
ldling speed adjustment the lower part of the right side crankcase
1. Start the engine and warm it up for a few cover.
minutes (normally, 1 or 2 minutes) at ap_
proximately 1 ,000 - 2,000 r /min, occa_ NOTE:
sionally raising to 4,000 - b,000 r /min f or Wait a few minutes until the oil level settles
a few seconds. When the engine res_ before checking.
ponds quickly, the warm-up is complete.

NOTE:
Use a tachometer for proper idling speed
setting.

.B
2. Maximum mark
\

;#$ 3. The oil levelshould be between maximum

and minimum marks. lf the level is lower,
ffi '.$+ '-
1. Throttle stop screw
add sufficient oil to raise it to the proper
level.
2. Set the engine idle speed to specified
Engine oil and oil filter replacement
revolutions by turning the throttle stop
screw in to increases the engine speed
NOTE:
and back off the throttle stop screw to
Step 5 and 6 are only required when replacing
decrease the engine speed.
the oil filter element.
Standard idling speed: 1,250+S0 r/min 1. Start the engine, and stop it after a few
minutes of warm-up.
2. Place an receiver under the engine.
Fuel line check 3. Remove the oil filler cap. Then, remove
Check the fuel hosg for cracks or damage, the drain bolt and the oil filter cover secur_
replace if necessaryl ing screw (lower), and drain the oil.

Engine oil level measurement NOTE:

1. Place the motorcycle on a level place and
hold it in an upright position. Warm up
the engine for several minutes.
NOTE:
Be sure the motorcycle is positioned straight
up when checking the oil level; a slight tilt
toward the side can produce false readings.
The oil filter cover is secured by three screws.
The lower one should be removed so that the
filter cavity will drain.
When removing the drain bolt, the O_ring,
compression spring, and oil strainer, will
fall off . Take care not to lose these parts.
 Before reinstalling the drain bolt, do not
forget to fit the O-ring, compression spr-
ing, and oil strainer.

OIL STRAINER
," coMPREssloN

(@@66
SPRTNG
1 Drain bolt 2. O ring
a,A
3 Compression sprinq 4. Oil strainer

DRAIN BOLT

8. Add oil through the oil filter hole. lnstall

the oil filler cap and tighten it.

Oil capacity:
Periodic oil change:
1. Filter cover securing screw (lower) 1.0 L (0.90 lmp qt, 1.06 US qt)
Oil filter replacement:
4. Remove the other oil filter cover securing 1.1 L (0.97 lmp qt, 1.16 US qt)
screws (upper), and remove the oil filter Recommended oil:
cover. SAE 20W40 type SE motor oil
5. Remove the oil filter element, and clean
the filter element with solvent. Replace if
necessary.
6. lnstall the filter element in place.
7. lnstall the oil filter cover and drain bolt.
Torque the bolts to specification.

Drain plug:
43 Nm (4.3 m .kg, 31 ft'lb)
Oil filter cover:
Panhead screw (upper):
7 Nm (0.7 m.kg, 5.1 ft.lb)
Hexagon socket head bolt (lower):
9. Start the engine and allow a few minutes
10 Nm (1.0 m .kg, 7 .2 ft . tb)
of warm-up. While warming up, check for
oil leakage. lf oil leaks, stop the engine
NOTE: immediately, and check for the cause.
1. Check O-rings. lf damaged, replace. 10. Stop the engine, and check the oil pres-
2. Before reinstalling the oil strainer, clean su re.
the strainer with solvent.

2-4
After replacing the engine oil, be sure to
check the oil flow as described below.
1. Slightly loosen the check bolt in the
cylinder head.
2. Start the engine and keep it idling un-
til oil flows out of the check hole. lf
no oil comes out after a lapse of one
minute, turn off the engine immedi-
ately so it will not seize. L Adjuster 2. Lock nut
3. Turn the engine off, and tighten the
bolt to specification. 2. Mechanism adjustment
a. Fully loosen the cable in-line length ad-
Tightening torque: juster lock nut and screw in the adjuster
7 Nm (0.7 m'kg, 5.1 ft'lb) until tight.
b. Turn the handlebar lever adjuster in.
c. Remove the rear brake pedal, footrest
(right), kick crank and decompression
Clutch adjustment
cable.
This model has two clutch cable length ad-
d. Drain the engine oil and remove the
justers. The cable length adjusters are used to
crankcase cover (right).
take up slack from cable stretch and to pro-
e. Loosen the clutch mechanism adjuster
vide sufficient free play for proper clutch opera-
lock nut.
tion under various operating conditions.
f. Push the push lever toward the front of
1. Free play adjustment. the engine with your finger until it stops.
The clutch should be adjusted to suit the With the push lever in this position, turn
rider's preference, but free play at the the adjuster either in or out until the push
lever end should be 7- 10 mm 10.28- lever mark and crankcase match mark are
0.40 in). Loosen either the handlebar lever aligned. Tighten the lcok nut.
adjuster lock nut or the cable in-line length
adjuster lock nut. Next, turn the length
. adjuster either in or out until proper lever
free play is achieved.

Clutch lever free play:

7 -10 mm (0.28-0.40 in)

qWFii

1. Adjuster 2. Lock nut

a. 7 - 1O mm (0.28 - 0.40 in)
 Cam chain adjustment
This model has been equipped the automatic
cam chain tensioner. No adjustment is neces-
sary.

lgnition timing check

lgnition timing is checked with a timing light
by observing the position of the stationary
pointer and the marks stamped on the flywheel.

THE FLYWHEEL IS MARKED AS FOLLOWS:

g. Continue reassembly in the reverse of

removal procedure.
h. Readjust the clutch lever free play AS
required.
r-Fl T.D.C. FOR CYLINDER

Decompression cable adjustment

F--cr-] FIRING RANGE FOR CYLINDER

NOTE:
Decompression cable adjustment must follow
the valve clearance adjustment. 1. Remove the timing window plug.
2. Connect the timing light to the spark plug
1. Remove the timing window and crank-
lead.
shaft end cover.
3. Start the engine, and keep the engine
2. Align the "T" mark on the flywheel with
speed as specified. Use a tachometer to
the stationary pointer on the crankcase
check the engine speed.
cover. This places the piston at T.D.C.,
and decompression cable adjustment
Specified engine speed:
should be checked and adjusted with the
piston at T.D.C. on the compression 1,250+50 r/min
stroke.
4. The stationary pointer (in the timing win-
3. Loosen the lock nut on the decompres-
dow) should be within the firing range
sion cable adjuster. Then, turn the ad-
juster so 2-3 mm (0.08-0.12 in) free shown on the flywheel. lf the pointer is
not within the range or if it is not steady,
play can be provided for the end of the
decompression lever.
check the flywheel and/or pick-up
assembly for tightness and damage (See
,,CHAPTER
FREE PLAY 6. ELECTRICAL").
2-3 mm (0.08-0.12 inl 5. Reinsteill the timing window plug.

2-6
E---
Compression pressure measurement CHASSIS
lnsufficient compression pressure will result in Air filter cleaning
performance loss and may indicate leaking 1. Remove the side cover (left) and filter case
valves or worn or damaged piston rings. cover.
1. Make sure the valve clearance is correct.
2. Warm up the engine for 2-3 minutes;
stop the engine.
3. Remove the spark plug.
4. lnstall a compression gauge.
5. Turn over the engine with the kick crank,
holding the throttle wide open until the
pressure indicated on the gauge does not
increase further. The compression should
be within the specified levels.

2. Remove the wing bolt and element

When cranking the engine, ground the holding plate. Then, pull out the element
spark plug lead to prevent sparking. together with steel net.

Compression pressure (at sea level):

Standard:
883 kPa (9 kg/cm2, 128 psi)
Minimum:
785 kPa (8 kg/cm2, 114 psi)
Maximum:
1,030 kPa (10.5 kg/cm2, 149 psi)

3. Remove the element from the steel net.

Then, clean the element with solvent. lf
the element is damaged, replace it.

l. Compression gauge

6. lf the pressure is too low, squirt a few

drops of oil into the cylinder being
measured. Measure compression again.
lf there is a higher reading than before
(without oil), the piston rings may be worn
or damaged. lf the pressure remains the
same after measuring with the oil, one or
both rings and valves may be the source
of the problem.
 4. After cleaning, remove the remaining sol-
vent by squeezing the element. Then,
apply SAE 10W30 motor oil to the entire
surface, and squeeze out the excess oil. .?;

NOTE:
The element should be wet but not dripping.

5. Reassembly by reversing the removal pro-

cedure. Check whether the element is
seated completely against the case.
2. Lock nut
6. The air filter element should be cleaned
at the specified intervals. 1. Loosen the lock nut.
2. Turn the cable length adjuster in or out
NOTE: until adjustment is suitable.
It should be cleaned more often if the motor- 3. Tighten the lock nut.
cycle is operated in dusty or wet areas. 4. lf proper adjustment can not be obtained
at the handlebar lever holder, make a
brake plate adjustment.

Rear brake pedal position adjustment

The engine should never be run without
the air cleaner element installed; excessive
piston and/or cylinder wear may result.
The brake pedaltop end should be 10 mm (0.4
in) below the top of the footrest.
1 . Loosen the lock nut.

2. Turn the adjuster in or out until adjust-

ment is suitable.
Front brake adjustment 3. Tighten the lock nut.
The front brake should be adjusted to suit
rider's preference within a 10-20 mm
Q.4- 0.8 in) free play at the brake lever end.
Adjustment is accomplised at one of two places After adjusting the pedal position, adjust
either the handlebar lever holder or the front the brake pedal free play.
brake plate.

,i

1. Adjuster 2. Lock nut

2-8
Rear brake adjustment
The rear brake should be to suit rider's prefe-
rence with in a20-30 mm (0.8-1.2 in) free
play at the brake pedal end.
1. To adjust, turn the adjuster on the brake
rod clockwise to reduce play; turn the ad-
juster counterclockwise to increase play.

1. Check the operation of the brake light

Wear limit Wear indicator
after adjusting the rear brake.
2. The rear brake adjustment must be
checked anytime chain is adjusted or
rear wheel is removed and reinstalled.

FREE PLAY
20-30 mm (0.8-1.2 in)

Rear swingarm pivot shaft lubrication

Lubricate the rear swingarm pivot shaft with
lithium soap base grease.
!:

Brake lining inspection

To check, see the wear indicator position while
depressing the brake pedal or pulling the brake
lever. lf the indicator reaches to the wear limit
line, replace the shoes.

2-9
Wheel bearings check
lf a rolling rumble is noticed and increases with
increasing wheel speed (not engine or transmis-
sion speed), the wheel bearings may be worn.
Check the wheel bearings of both the front and
rear wheels.
1. Front wheel
Raise the front end of the motorcycle, and
spin the wheel by hand. Touch the axle
or front fender while spinning the wheel.
lf you feel any excessive vibration, the
bearings are rough and should be
replaced.

Steering head adjustment

1. Raise the front end of the motorcycle so
that there is not weight on the front

D wheel.

Securely support the motorcycle so there

is no danger of it falling over.
2. Grasp the bottom of the forks and gently
rock the fork assembly backward and for-
ward, checking for looseness in the steer-
ing assembly bearings.
2. Rear wheel
Remove the rear wheel, and check the
bearing movement with your finger.
Replace the bearings if they are rough or
worn.

2-10
 3. lf there is looseness in the steering head, 1. Elevate the front wheel by placing a
loosen the steering fitting bolt. suitable stand under the engine.
2. Remove the handlebar and the rubber cap
from the top of each fork.
3. Loosen the pinch bolts and remove the
cap bolts from the inner fork tubes.

1. Steering fittinq bolr

4. Use steering nut wrench to loosen the

steering fitting nut.

r. Pinch
1. bolt
r,tnch bolt 2. Cap bolt

4. Place an open container under each drain

hole, Remove the drain screw from each
outer tube.

1. Steering nut wrench 2.

ffi
Steering fitting nut

5. Tighten the steering fitting nut until the

steering head is tight, but does not bind
when the forks are turned.
6. Retighten the steering fitting nut and
1. Drain screw
steering fitting bolt.
7. Recheck steering adjustment to make 5. When most of the oil has drained, slowly
sure there is no binding when the forks raise and lower the outer tubes to pump
are moved from lock to lock. lf necessary, out the remaining oil.
repeat the adjustment procedure. 6. lnspect drain screw gasket. Replace if
damaged. Reinstall drain screw.
7. Pour specified amount of oil into fork in_
Front fork oil change ner tube.

Front fork oil capacity (each fork):

1. Fork oil leakage can cause loss of
294 cm3 (10.3 lmp oz, 9.9 US oz)
stability and safe handling. Have any
Recommended oil:
problem corrected before operating
SAE 10W30 type SE motor oit
the motorcycle.
2. Securely support the motorcycle so
there is no danger of it falling over.

2-11
 8. After filling, slowly pump the outer tubes
up and down to distribute the oil.
9. lnspect the "O-ring" on the cap bolt.
Replace the "O-ring", if damaged.

Rear shock absorber adjustment

The spring preload of the rear shock absorber
can be adjusted to suit rider's preference,
1. O-ring weight, and the course conditions.
1. Remove the seat.
10. Reinstall the cap bolts and tighten the
pinch bolts.

Tightening torque:
Cap bolt:
23 Nm (2.3 m.kg, 17 ft . lb)
Pinch bolt:
23 Nm 12.3 m.kg, 17 ft. lb)

11. Reinstall the rubber caps and handlebar.

NOTE: 2. To increase preload, raise the spring seat.

The upper handlebar holder should be install- To decrease preload, lower the spring
ed with the punched mark forward. seat.

Hard STD

ittTi:ffi$+; Adjusting
,S", position 5 4 3 2

First tighten the bolts on the front side of

the handlebar holder, and then tighten the
bolts on the rear side.

Tightening torque:
Handlebar:
20 Nm (2.0 m.kg, 14 ft.lb)

Stiffer
Special nut wrench

NOTE:
When adjusting, use the special nut wrench
which is included in the owner's tool kit.
2-12
 3. Reinstall the seat in the original position.

li$
Chain puller cam Axle nut
Cotter pin Sprocket shaft nut

Drive chain tension check 5. After adjustment, be sure to tighten the

NOTE:
Before adjusting, rotate rear wheel through
several revolutions and check tension several
times to find the tightest point. Adjust chain
tension with rear wheel in this "tight chain"
position.
sprocket shaft nut and axle nut. lf the nut
notch and the cotter pin hole do not
match, tighten the nut slightly to match.
Tightening torque:
Sprocket shaft nut and axle nut:
85 Nm (8.5 m'kg, 61 ft. lb)

6. lnsert a new cotter pin into the rear wheel

To check and/or adjust the chain play, the
motorcycle must stand vertically with its both
wheels on the ground and without rider on it.
The normal vertical deflection is approximate-
ly 30-45 mm (.2- 1.8 in). lf the chain deflec-
tion is not as specified, adjust the chain tension.
axle nut and bend the end of the cotter
pin as shown in the illustration (if the nut
notch and the cotter pin hole do not
match, loosen the nut slightly to match).

Always use a new cotter pin on the axle

nut.

30-45 mm
(.2-1.8 inl

Drive chain tension adjustmdnt COTTER PIN

1. Loosen the rear brake adjuster.
2. Remove the cotter pin of the rear wheel
axle nut with pliers.
3. Loosen the rear wheel axle nut and 7 . ln the final step, adjust the play in the
sprocket shaft nut. brake pedal.
4. Turn chain puller both left and right, un-
til axle is situated in same cam slot
position.

2-13
Excessive chain tension will overload the
engine and other vital parts; keep the ten-
sion within the specified limits.
Drive chain lubricatidn
The chain consists of many parts which work
against each other. If the chain is not maintain-
ed properly, it will wear out rapidly.
Without lubrication the chain could wear out.
Therefore, form the habit of periodically sevic-
ing the chain. This service is especially neces-
sary when driving in dusty conditions.
1 . Use any of the many brands of spray type
chain lubricant. First, remove dirt and
mud from the chain with a brush or cloth
and then spray the lubricant between both
rows of side plates and on all center
rollers.
2. To clean the entire chain, first remove the
chain from the motorcycle, dip it in sol-
vent and clean out as much dirt as possi-
ble. Then take the chain out of the sol-
vent and dry it. After drying, lubricate the
chain to prevent the formation of rust.
Fuel cock cleaning
1. Turn the fuel cock lever to "OFF"; then
remove the filter cup and clean the bot-
tom of the cup with solvent.
2. Remove the filter screen and clean it with
solvent.
3. Check the condition of the filter gasket.
lf it is damaged, replace.
When reassembling, be careful not to
tighten the filter cup too much as this may
crush the filter gasket, resulting in fuel
leakage.
2-14
FUEL IS HIGHLY FLAMMABLE:
o Always turn off the engine when
cleaning.
Take care not to spill any fuel on the
engine or exhaust pipe{s)/muffler(s)
when cleaning.
Never clean the fuel cock while smok-
ing or in the vicinity of an open flame.
Fuel cock disassembly
lf either fuel cock is leaking or is excessively
contaminated, it should be removed from the
fuel tank and inspected.
1. Remove the fuel tank and position it so
that fuel will not spill when the cock is
removed.
2. Remove the cock and inspect the filter
screen. Replace the filter if it is seriously
contaminated.
3. Remove the screws on the front and rear
of the cock; remove the plate, gaskets,
lever.
4. lnspect all components, and replace any
that are damaged. lf the cock gasket sur-
faces are scratched or corroded, the cock
assembly must be replaced. lf there is
abrasive damage to any components, the
fuel tank must be drained and flushed.
5. Reassemble the cock, and install it on the
fuel tank.
 Sidestands lubrication
Lubricate the sidestand at their pivot point.

Recommended lubricant:
SAE 10W30 motor oil
FILTER SCREEN

Tires check
To insure maximum performance, long service,
and safe operation, note the following pre-
cautions:
1. Check tire pressure before riding; adjust
as necessary.
2. Before operation, always check the tire
surfaces for wear and/or damage; look for
cracks, glass, nails, metal fragments,
stones, etc. Correct any such hazard
before riding.
Cable inspection and lubrication 3. Tires and wheels should be balanced
The throttle twist grip assembly should be whenever either one is changed or replac-
greased when the cable is lubricated since the ed. Failure to have a wheel assembly
grip must be removed to get at the end of the balanced can result i11 poor performance,
throttle cable. Two screws clamp the throttle adverse handling characteristics, and
housing to the handlebar. Once these two are shortened tire life.
removed, the end of the cable can be held high 4. After installing a tire, ride conservatively
to pour in several drops of lubricant. With the to allow the tire to seat itself on the rim
throttle grip disassembled, coat the metal sur- properly. Failure to allow proper seating
face of the grip assembly with a suitable all- may cause tire failure resulting in damage
purpose grease to cut down friction. to the motorcycle and injury to the rider.
1. Damage to the outer housing of the 5. After repairing or replacing a tire, check
various cables may cause corrosion. Often to be sure the valve stem lock nut is
free movement will be obstructed. An un- securely fastened. lf not, torque it as
safe condition may result. Replace such specified.
cables as soon as possible.
2. lf the inner cables do not operate Tightening torque:
smoothly, lubricate or replace them. 1.5 Nm (0.15 m .kg, 1.1 ft.lb)

Recommended lubricant: 6. lf a tire tread shows lines crossing the

SAE 10W30 motor oil tread, it means that the tire is worn to its
limit. Replace the tire.

Brake and change pedals/brake and clutch

levers lubrication
Lubricate the pivoting parts of each lever and
pedal.

Recommended lubricant: WEAR INDICATOR

SAE 10W30 motor oil

2-15
ELECTRICAL
Battery inspection
1. The fluid level should be between the up-
per and lower level marks. Use only distill-
ed water if refilling is necessary.
Normal tap water contains minerals which
are harmful to a battery; therefore, refill
only with distilled water.
2. Always make sure the connections are
correct when installing the battery. Make
sure the breather pipe is properly con-
nected, properly routed, and is not
damaged or obstructed.
BREATHER
PIPE
The battery must be charged before using
to insure maximum performance. Failure
to properly charge the battery before first
use, or low electrolyte level will cause
premature failure of the battery.
Charging current: 0.6 amps/lO hrs or un-
til the specific gravity reaches 1.2ffi at20oC
(680F)
2-16
Battery electrolyte as poisonous and
dangerous, causing severe burns, etc. lt
contains sulfuric acid. Avoid contact with
skin, eyes or clothing.
Antidote: EXTERNAL-Flush with water.
INTERNAL-Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician
immediately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention. Batteries
produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate
when charging or using in closed space.
Always shield eyes when working near
batteries. KEEP OUT OF REACH OF
CHILDREN.
Spark plug inspection
1. Check the electrode condition and wear,
insulator color and electrode gap.
2. Use a wire gauge for measuring the plug
gap.
3. lf the electrodes become too worn, re-
place the spark plug.
4. When installing the plug, always clean the
gasket surface. Wipe off any grime that
might be present on the surface of the
spark plug, and torque the spark plug
properly.
Standard spark plug:
DSEA (NGK) or X24ES-U (N.D.)
Spark plug gap:
0.6-0.7 mm (0.024-0.028 in)
Spark plug tightening torque:
18 Nm (1.8 m-kg, 12.5 ft.lb)
Brake light switch adjustment 4. Slip a new bulb into position and secure
The brake light switch is operated by move- it with the bulb holder.
ment of the brake pedal. To adjust, hold the 5. Reinstall the lens unit assembly to the
main body of the switch with your hand so it headlight body. Adjust the headlight
does not rotate and turn the adjusting nut. Pro- beam if necessary.
per adjustment is achieved when the brake light
comes on just before the brake begins to take
Headlight beam adjustment (Vertical
effect.
adjustment)
When necessary, adjust the headlight beam as
follows:
1. Remove the headlight lens unit holding
screw.

Replacing the headlight bulb

1. Remove the headlight lens unit holding
screw to the headlight body.
1. Holding screw

2. Loosen the headlight body mounting

nuts, and reinstall the headlight lens unit
assembly to the headlight body.
NOTE:
Do not tighten the headlight lens unit holding
screw in this stage.

3. Adjust the beam vertically by moving the

headlight body up or down. When the
proper adjustment is determined, remove
1. Holding screw the headlight lens unit and retighten the
2. Disconnect the leads, and remove the lens headlight body mounting nuts. Then,
unit assembly. reinstall the headlight lens unit with
3. Push and turn the bulb holder counter- holding screw.
clockwise. Then, remove the defective
bulb.
Fuse replacement
lf fuse is blown, turn off the ignition switch and
the switch in the circuit in question; install a
new fuse of proper amperage. Turn on the
switches, and see if the electrical device
operates. lf the fuse immediately blows again,
check the circuit in question (Refer to "Chapter
6. ELECTRICAL").

Specified fuse: 10A

Do not use fuses of a higher amperage

rating than those recommended.
Substitution of a fuse of improper rating
can cause extensive electrical system
damage and possible fire.

2-18
 CHAPTER 3.
ENGINE OVERHAUL

REMOVAL ... ........ 3_1

Preparation for removal . ... .,,.. ,.. 3-1
Seat and fuel tank ..,,,.. .. 3_1
Footrest (right) and brake pedal ............3-1
Change pedal, drive sprocket and footrest (left) .... t , . . . . . . . . . . , . . , 3_1
Exhaust pipe... . .... ....... 3_2
Horn.. ............9-2
Carburetor. ........g-2
Wiring and cable... ........3_3
Engine guard ......3_3
Engine mounting bolts ..... 3_3

oVERHAUL ... ... .... 3_4

Cylinder head and cylinder .........3-4
Cylinder head disassembly .... .....3-s
C.D.l. magneto ............ 3_6
Piston . . ... ... ..... 3-7
Crankcase cover (right) .. ...,,.. ... 3-7
Glutch . ... ... .... .. 3-B
Starter . ... .,.,... .3-g
Kick idle gear... ...........3_g
Oil pump .. ... ... ..3-9
Balancer driven and drive gear .,,..3-g
Shifter. ...........3-10
Crankcase (left) . .. ........3-10
Transmission, crankshaft and balancer shaft.., ,,.. 3-10
INSPECTTON AND REpAtR ........ .3_11
Cylinderhead... ..........3-11
Valve.. . ..... .....3_11
Valve guide .......3-12
Valve seat .. ... ...3-13
Valve and valve seat lapping . .....3_I4
Valve spring ......3,14
Rocket arms and rocker arm shafts ...: ...,.......3-1S
Camshaft, cam chain and cam sprockets ...,......3-1e
Cylinder ........ ..3-17
Piston and piston rings ....,......5-17
Piston pin .. ... ...3-19
Crankshaft .......3-19
Oil pump ....:... .........3-20
Primary drive ... ... .......3-20
Clutch . .. _....... .3-21
Transmission .,,..3-22
 .
Starter ..........3-23
Crankcase .... ... .3-23
Bearings and oil seals .... .3-23
REASSEMBLY ....,.3-24
lmportant informations ...........3-24
Crankshaft and balancer gear . ,. . .... ... ..3-25
Transmission .....3-26
Crankcase .. ... ...3-26
Shifter. .. ... ..... .3-28
Balancer driven and drive gear ....3-28
Oil pump ... .. ... .3-29
Kick idle gear... ..........3-29
.
Starter . ..... ... .3-30
clutch. ...........3-32
Crankcase cover (rightl . ... ... ... .3-34
Piston . .. .... ... ..3-35
Cylinder . .... ..... 3-35
Cylinder head.. . . ......... 3-37
G.D.l. magneto .. .........3-42
Chain tensioner. .... .. ....3-42
Remounting engine. ......3-43
 CHAPTER 3.
ENGINE OVERHAUL
REMOVAL 2. Remove the brake rod adjuster, and
NOTE: remove the brake pedal.
It is not necessary to remove the engine in order
Change pedal, drive sprocket and footrest
to remove the cylinder head, cylinder, or ( left)
pistons.
1. Remove the change pedal.

Preparation lor removal

2. Remove the dust cover fitting plate, and
remove the drive sprocket cover.
1. All dirt, mud, dust and foreign material
should be thoroughly removed from the
exterior of the engine before removal and
disassembly. This will help prevent any
harmful foreign material from engine oil_
2. Before the engine removal and disas-
sembly, be sure that you have the proper
tools and cleaning equipment so that you
can perform a clean and efficient job.
3" During disassembly of the engine, clean
and place all of the parts in trays in order
of disassembly. This will speed up
assembly time and help insure correct 3. Remove the drive sprocket securing bolts
reinsta ll-action of all the engine parts. and holding plate. Then, remove the drive
4. Place the motorcycle on its sidestands. sprocket.
Start the engine and allow it to warm up.
Stop the engine and drain the engine oil.

Seat and fuel tank

1. Remove the side covers (left and right).
2. Remove the seat securing bolts, and
remove the seat.
3. Turn the fuel cock to "OFF", and discon-
nect the fuel pipe.
4. Remove the fuel tank securing bolts and
securing plates. Then, remove the fuel
tank. 1. Ho ding plate 2. Drive sprocket

Footrest (right) and brake pedal 4. Remove the footrest (left).

1. Remove the footrest securing bolts, and
remove the footrest (right).
Exhaust pipe
1. Remove the exhaust pipe securing bolts
from the cylinder head.

Carbu retor
1. Remove the carburetor holding clamps to
the air filter case and intake manihold.
2. Remove the muffler protector, and loosen
the exhaust pipe holding bolt. Then,
remove the exhaust pipe.

2. Remove the starter {CHOKE) cable

assembly from the carburetor assembly.
NOTE:
When removing the starter (CHOKE) cable,
starter plunger and spring will fall off. Take care
not to lose these parts.

Horn
1. Remove the horn securing bolt-
1. Starter (CHOKE) cable
2. Disconnect the horn lead, and remove the
horn. 3. Pull the carburetor assembly to the rear.
4. Disconnect the throttle cable from the
throttle lever, and remove the carburetor
assembly to the left.
 Engine guard
1 . Remove the engine guard securing bolts,
and pull out the engine guard.

Throttle cable

Wiring and cable

1. Disconnect the clutch cable at the crank-
case side. Then, remove the crankcase
ventilation hose at the air filter case.
Engine mounting bolts
'1. Remove the engine mounting bolts and
nuts. Remove the brackets.

1. Crankcase ventilation hose

2. Remove the spark plug lead.

3. Disconnect the C.D.l. magneto leads.
Position the disconnect the leads so that
they can be safely removed.

The C.D.l. magneto leads are clamped at

the cross tube of the frame, Do not forget
to remove this clamp before removing the
engine.

2. Remove the engine to the right.

NOTE:
The engine and swingarm are installed using
the same pivot shaft. Therefore, take care so
that the pivot shaft is pulled, not entirely out,
but for enough 1o set the engine free.
 3. Remove the side cover.
OVERHAUL
Cylinder head and cylinder
1 . Remove the decompression cable assem-

bly from the engine.

4. Remove the left crankcase cover.

5. Remove the cam sprocket securing bolt

as shown.
2. Remove the cam chain tensioner assem-
blv. NOTE:
When removing the cam sprocket, it is not
necessary to separate the cam chain.

3-4
 L Front cam chain guide

the cam sprocket.

10. Remove the cylinder securing bolts, and
remove the cylinder.

1. Cam sprocket

7. Remove the six cylinder head secufl ng

bolts (two of which are internal hexagon
bolts). Cylinder head disassembly
1. Straighten the lock washer tabs, and
NOTE: remove the securing bolts, lock washer
Loosen the bolts, starting the highest num- and the camshaft retaining plate in that
order.
bered bolt.

^d"
\ :.ii! ! \:-,/

2. Securing bolt

8. Remove the cylinder head.

9. Remove the front cam chain guide.
 2. Screw in Slide Hammer Holding Screw 5. Remove the valve retainers with a mag-
(special tool) into the threaded hole on the neto or tweezers, and remove the valve
rocker shaft, and pull out the rocker shaft. spring.

L Slide Hammer {special tool) 1. Valve retainers 2. Valve spring

2. Slide Hammer Holding Screw (special tool)
3. Bocker shaft
6. Remove the valves.
3. Screw in a suitable length of 10 mm bolt NOTE:
into the threaded hole on the camshaft, Deburr any deformed valve stem end. Use an
and pull out the camshaft. oil stone to smooth the stem end. This will help
prevent damage to the valve guide during valve
removal.

DEBURR

Camshaft

4. Mount the Valve Spring Compressor (spe-

cial tool) on the head, and depress each
valve spring. C.D.l. magneto
1. Remove the magneto securing bolt as
shown.

1. Valve Sprinq Compressor (special tool)

36
 2. Screw in the Rotor Puller (special tool) in- 2. Push the piston pin from the opposite
to the crankshaft. Remove the magneto side. Then, pull out the piston pin, and
as shown. remove the piston.
NOTE:
Before removing the piston pin, deburr the clip
groove and pin hole area. lf the piston pin
groove is deburred and the piston pin is still dif-
ficult to remove, use Piston Pin Puller (special
tool).

Do not use a ham mer to drive the piston

1. Rotor Puller (special tool) pin out.

3. Remove the rear cam chain guide. Then,

remove the cam chain.
Crankcase cover (right)
'l . Remove the kick crank securing bolt, and
remove the kick crank.
NOTE:
The securing bolt must be completely remov-
ed from the kick crank.

2. Remove the crankcase cover {right).

NOTE:
For this step, sl;ts in the crankcase can be us-
ed as shown.
Rear cam chain quide 2. Cam chain

Piston
1. Remove the piston pin clip from the
piston.
NOTE:
Before removing the pin clip, cover the crank-
case with a clean towel or rag so you will not
accidentally drop the pin clip and material into
the crankcase.

L Prston pin c|p

 Clutch 4. Remove the clutch boss, holding plate
1 . Release the tension evenly on the 6 mm and the primary driven gear.
bolts, and remove the clutch pressure
plate and clutch springs.

5. Remove the setting screw, and unhook

the push lever axle spring from its posi-
2. Remove the friction plates and clutch
tion. Then, pull up the push lever axle.
plates. Then, remove the ball and push
tod #2.

1. Setting screw 2. Push lever axle sprinq

3. Push lever axle
Push rod #2

3. Straighten the lock washer tab. Use the Starter

Clutch Holding Tool (special tool)to hold 1. .Unhook the kick spring from its position.
the clutch boss, and remove the lock nut Then, remove the kick axle assembly by
and lock washer. rotating the shaft cou nterclockwise.

Clutch Holding Tool (special tool) Kick axle assemblV

I
$,, 3R
 2. Remove the decompression shaft assem- Balancer driven and drive gear
blv. 1. Straighten the lock washer tab on the
drive gear.
2. Place a folded rag between the teeth of
the driven and drive gear to lock them as
shown. Then, loosen the drive gear secur-
ing nut.

1 Decompression shaft assembly

Kick idle gear

1. Remove the circlip, special washer, kick
idle gear, plain washer and circlip in that
order. 1, Drive qear securing nut Folded raq

3. Straighten the lock washer tab on the

driven gear.
4. Place a folded rag between the teeth of
the driven and drive gear to lock them as
shown. Then, loosen the driven gear se-
curing nut.

1. Circlip
2. Special washer
3. Kick idle gear

Oil pump
1. Remove the oil pump cover securing
screws, and remove the oil pump assem-
blv.
1. Driven gear securing nut 2,
2. Folded rag

5. Remove the securing nuts, and remove

the driven gear assembly and the drive
gear assembly.

NOTE:
When removing the driveri and drive gear, do
not forget to remove the keys (driven gear and
drive gear).

3-9
Shifter
1 . Remove the shift shaft assembly.

2. Separate the left crankcase from the right

1. Shift shatt assembly
crankcase.

2. Remove the segment securing screw, and NOTE:

remove the segment. For this step, slit in the crankcase can be used
as shown.

Segment

Crankcase (left) Transmission, crankshaft and balancer

1. Loosen the left crankcase securing bolts, shaft
starting the highest numbered bolt. After 1 . Remove the transmission shaft, shift forks
all bolt are loosened, remove them. and shift cam. Tap lightly on the transmis-
sion drive shaft with a soft hammer to
remove.

NOTE:
When removing the these parts, pay attention
to the following points.
1. Note the position of each part.
2. Pay attention to the location and direc-
tion of shift forks.

3-10
 Valve
1. Check the valve face and the stem end
for wear. lf the valve face and/or the stem
end are pitted or worn, regrind the valve
with a valve refacer. Replace the valve if
any dimension exceeds the specifications
in the illustration.

INTAKE/EXHATJST VALVE

2. Remove the crankshaft and balancer shaft

from the crankcase.
MINIMUM THICKNESS
ISERVICE LIMIT) 1.0 mm (0.04 in) --tF
INSPECTION AND REPAIR
Cylinder head
1. Using a rounded scraper, remove carbon
deposits from combustion chamber. Take
care to avoid damaging spark plug threads
and valve seats. Do not use a sharp in-
strument. Avoid scratching the aluminum. MINIMUM LENGTH
{SERVICE LIMIT)
2. Check the cylinder head warpage with a 4 mm {0.16 in)
straight edge as shown.
The warpage should not exceed the
specified limit, it necessary resurface- lf 2. Valve stem wear must be measured and
the warpage exceeds allowable limit, the then combined with valve guide measure-
cylinder head should be replaced with a ments to guide clearance. This clearance
new one. must be w;thin tolerances. lf it exceeds
the maximum limit, then replace either or
Cylinder head warpage: both valve and guide, as necessary.
Less than 0.03 mm (0.0012 in)
Allowable limit: 0.25 mm (0.010 in) Valve Stem Clearance Maximum

lntake
0.010 - 0.037 mm 0.10 mm
(0 .
- 0.001 5 in )
0004 (0.004 in )

0.025 - 0.052 mm 0.12 mm

Exhaust
(0.0010 - 0.0020 in ) (0.005 in)

3-1 1
 1 . Measure valve guide inside diameter with
a small bore gauge.lf it exceeds the limit,
replace with an oversize valve guide.

Guide diameter (1.D.):

Limit: 6.10 mm (0.240 in)

2. To ease guide removal and reinstallation,

3. lnspect the end of the valve stem. lf the
end appears to be "mushroomed" or has
a larger diameter than the rest of the stem,
the valve, valve guide, and oil seal should
be replaced.
4. Turn valve on "V" blocks and measure
the amount of stem runout with a dial
gauge. lf it exceeds the maximum limit,
replace the valve.
and to maintain the correct interference
fit,heat the head to 100oC l212oFl. rJse
an oven to avoid any possibility of head
warpage due to uneven heating.
3. Use the Valve Guide Remover {special
tool) and Valve Guide lnstaller (special
tool) to drive out the old guide and drive
in the new guide.
NOTE:
When a valve guide is replaced, the O-ring
shouid also be replaced.
REMOVER

Maximum valve stem ru nout:

0.03 mm (0.0012 in)

VALVE INSTALLER

Valve guide
lf oil leaks into the cylinder through a valve due
to a worn valve guide, or if a valve is replaced,
the valve guide should also be replaced.

NOTE:
The valve oil seal should be replaced whenever
a valve is removed or replaced.
 4. After installing the valve guide, use the
6 mm reamer (special tool) to obtain the
proper valve guide to valve stem clear-
a nce,
2.
5. After installing the valve guide in the
cylinder head, the valve seat must be
recut. The valve should be lapped to the
new seat.
Valve seat
1. The valve seat is subiect to severe wear.
Whenever the valve is replaced or the
valve face is re-surfaced (see CAUTION),
the valve seat should be re-surfaced at a
45o angle. lf a new valve guide has been
installed the valve seat must be recut to
guarantee complete sealing between the
valve face and seat.
lf cutting section "A" of the valve seat,
Seat width
use 30o cutter. lf cutting section "8", use
the 45o cutter. lf cutting section "C", use
600 cutter.
.i"'"1.{'i'].
'64tfi.ffi6et4
lf the valve seat is obviously pitted or
worn, it should be cleaned with a valve
seat cutter. Use the 45o cutter, and when
twisting the cutter, keep an even down-
ward pressure to prevent chatter marks.
3.
3-13
Measure valve seat width. Apply
mechanic's bluing dye (such as Dykem)
to the valve face and valve seat, apply a
very small amount of fine grinding com-
pound around the surface of the valve
face insert the valve into position, and spin
the valve quickly back and forth. Lift the
valve, clean off all grinding compound,
and check valve seat width. The valve
seat and valve face will have removed blu-
ing wherever they contacted each other.
Measure the seat width with vernier
calipers. lt should measure approximate-
ly 0.9- 1.1 mm {0.035-0.043 in). Also,
the seat should be uniform in contact
area. lf valve seat width varies, or if pits
still exist, further cutting will be necessary.
Remove just enough material to achieve
a satisfactory seat.
Standard Width Wear Limit
0.9-1.1 mm 2.0 mm
{0.035 - 0.043 in) (0.080 in)
SEAT WIDTH
lf the valve seat is uniform around the
perimeter of the valve face, but is too wide
or not centered on the valve face, it must
be altered. Use either the 30o, 45o or 600
cutters to correct the improper seat loca-
tion in the manner described below:

T CUTTER
a. lf the valve face shows that the valve seat
is centered on the valve face, but too
wide, then lightly use both the 30o and
the 600 cutters to reduce the seat width
to 0.9- 1.1 mm (0.035'0.043 in).
b. lf the seat shows to be in the middle of
the valve face, but too narrow, use the
45o cutter u ntil the width equals 0.9 - 1 .1
mm (0.035 - 0.043 in).
c. lf the seat is too narrow and right up near
the valve margin, then first use the 30o
cutter and then the 45o cutter to get the
correct seat width.
d. lf the seat is too narrow and down near
the bottom edge of the valve face, then
first use the 600 cutter and then the 450
cutter.
Valve and valve seat lapping
The valve/valve seat assembly should be lap-
ped if neither the seat nor the valve face are
severely worn.
1. Apply a small amount of coarse lapping
compound to valve face. lnsert the valve
into the head. Rotate the valve until the
valve and valve seat are evenly polished.
Clean off the coarse compound, then
follow the same procedure with fine
compound.
Continue lapping until the valve face
shows a complete and smooth surface all
the way around. Clean off the compound
material. Apply bluing dye to the valve
face and seat and rotate the valve face for
full seat contact which is indicated by a
grey surface all around the valve face
where the bluing has been rubbed away.
2. After all work has been on the valve and
valve seat, and all head parts have been
assembled, check for proper valve/valve
seat sealing by pouring solvent into each
of the intake ports, then the exhaust
ports. There should be no leakage past
the seat. lf fluid leaks, disassemble and
continue to lap with fine lapping com-
pound. Clean all parts thoroughly,
reassemble and check again with solvent.
Repeat this procedure as often as neces-
sary to obtain a satisfactory seal.
Valve spring
This engine uses two springs of different sizes
to prevent valve float or surging. The valve
spring specifications show the basic value
c ha ra cteristics.
 1. Even though the spring is constructed of
durable spring steel, it gradually loses
LARGER PITCH
some of it's tension. This is evidenced by o // o,
a gradual shortening of free length. Use // \l
a vernier caliper to measure spring free // o,,,
length. lf the free length of any spring has
decreased more than 2 mm (0.080 in) from
/o ,)
MALLER
its specification replace it. OO -,'?
\.w

Rocker arms and rocker arm shafts

1 . The rocker arm usually wears at two loca-

tions: at the rocker shaft hole and at the

2. Another symptom of a fatigued spring is
insufficient spring pressure when com-
pressed. This can be checked using a
valve spring compression rate gauge. Test
each spring individually. Place it in the
gauge and compress the spring first to the
specified compressed length with the
valve closed (all spring specifications can
be found in the previous section, valve
spring), then to the length with the valve
open. Note the poundage indicated on the
scale at each setting. Use this procedure
with the outer springs, then the inner
springs.
NOTE:
All valve springs must be installed with larger
pitch upward as shown.
Valve Spring Specifications
OUTER
35.5 mm
Free length
(1 .398 in ) (1.465 in)
lnstalled length 30.5 mm
(valve closed) (1.201 in)
cam-lobe-contact surface. Check these
areas for signs of unusual wear.
2. Measure the rocker arm inside diameter-
lf it exceeds specification, replace the
rocker arm.
Maximum inside diameter:
12.018 mm (0.4731 in)
3. Measure the outside diameter of the
rocker arm shaft. lf it is less than the
specified value, replace the rocker arm.
Minimum outside diameter:
1 1 .981 mm i'0.4-117 inl
4. Calculate the clearance by subtracting the
rocker-arm-shaft outside diameter from
the rocker-arm inside diameter. lf this
clearance is greater than 0.1 mm (0.0039
in), replace either or both parts.
The rocker arm shaft has been hardened;
it should not wear excessively. lf a groove
INNER
can be felt in the bearing surface or if the
372mm shaft shows a blue discoloration, the shaft
should be replaced and the lubrication
32.0 mm system checked.
(1 .260 in I

lnstalled pressure
8.4 -10.2 kg 16.6 - 20.4 ks
(18.5 - 22_5 tb) (36.0 - 45.0 rb)
Allowable tilt
2.50 2.5"
lrom vertical

3-15
 rup%
0il
2. Camshaft bushing
Camshaft, cam chain and cam sprockets a. Before checking the camshaft bushing, it
1. Camshaft should be cleaned and dried.
a. The cam lobe metal surface may have a b. Check the bushing inner surface for pits,
blue discoloration due to excessive fric- rust spots, or chatter marks.
tion. The metal surface could also start
to flake off or become pitted.
b. lf any of the above wear conditions are
readily visible, the camshaft should be
replaced.

@
c. Even though the cam lobe surface ap-
pears to be in satisfactory condition, the
lobes should be measured with a microm-
eter. Cam lobe wear can occur without
scarring the surface. lf this wear exceeds
a pre-determined amount, valve timing
and lift are affected. Replace the camshaft
if wear exceeds the limits- c. lf any of these conditions exist, the
bushing should be replaced.
Wear limit lntake Exhaust J. Cam chain
Except in cases of oil starvation, the cam
36.54 mm 36.58 mm
(1.439 in) (1 .440 in) chain wears very little. lf the cam chain
has stretched excessively and it is difficult
30.15 mm 30.27 mm
B
(1.187 in) (1
to keep the proper cam chain tension, the
.192 in )
chain shou ld be replaced.
4. Cam sprockets
Check cam sprockets for obvious wear.

16; €) -
<>6):
6<>
 5. Cam chain dampers and tensioner
Check the cam chain dampers for ex-
cessive wear. Any that shows excessive
wear should be replaced. Worn dampers
may indicate an improperly adjusted or
wornout cam chain.

\Wff- Piston and piston rings

1 . Piston
a. Measure the outside diameter
piston at the piston skirt.
Measurement should be made at a point
7.5 mm (0.295 in) above the bottom edge
of the piston. Place the micrometer at
of the

right angles to the piston pin.

Cylinder Size
1. lnspect the cyiinder walls for scratches.
Overslze 1

lf vertical scratches are evident, the

Oversize 2 67.50 mm (2.657 in)
cylinder wall should be rebored or the
cylinder should be replaced. Oversize 3
2. Measure cylinder wall wear as shown. lf Oversize 4 68.00 mm (2.677 in)
wear is excessive, compression pressure
will decrease. Rebore the cylinder wall and
replace the piston and piston rings.
Cylinder wear should be measured at
three depths with a cylinder bore gauge.
(See illustration. )
lf the cylinder wall is worn more than the
wear limit, it should be rebored.

Standard Wear Limit

67.00 mm 67.10 mm
Cylinder bore
{2.638 in) 12.642in)

Cylindertaper 0.05 mm
{0.002 in)
b. Determine piston clearance as follows:
Minimum bore measurement
0.01 mm
Cylinder out-ot-round
{0.0004 in) - Maximum piston measurement
: Piston clearance

3-17
 EXAMPLE: Size Color
67.00 mm (2.6378 in) Oversize 1

- 66.96 mm (2.6362 in)

: 0.04 mm (0.0016 in) Oversize 2 Blue

Piston clearance Oversize 3

Oversize 4 Yellow
Piston clearance:
Standard: 0.025 - 0.045 mm c. lnsert a ring into the cylinder, and push
(0.0010-0.0018 in) it approximately 20 mm (0.8 in) into the
Service limit: 0.1 mm (0.0039 in) cylinder. Push the ring with the piston
crown so the ring will be at a right angle
c. Piston ring/ring groove fit must have cor- to the cylinder bore.
rect clearance. lf the piston and ring have Measure the ring end gap with a feeler
already been used, the ring must be gauge. lf the end gap exceeds tolerance,
removed and the ring groove cleaned of replace the whole set of rings.
carbon. The ring should be then reinstall-
ed. Use a feeler gauge to measure the gap NOTE:
between the ring and the land. The end gap on the expander spacer of t$e oil
0.03 - 0.07 mm control ring is unmeasurable. lf the oil control
Top
(0.0012 - 0.0028 in ) ring rails show excessive gap, all three com-
Side clearance ponents should be replaced.
0.02 - 0.06 mm
2nd
(0.0008 - 0.0024 in )

Standard Limit

0.15 - 0.35 mm 1.0mm

Top/2nd ring (0.0059 - 0 .01 38 in (0.039 in
) )

Oil control 0.3 - 0.9 mm l.5mm

(Rails) (0.012 - 0.035 inl {0.059 in }

Piston pin
1 . Apply a light film of oil to pin. lnstall in
connecting rod small end. Check for play.
There should be no noticeable vertical
2. Piston ring play. lf play exists, check connecting rod
a. The oversize top and middle ring sizes are small end for wear. Replace pin and con-
stamped on top of the ring. necting rod as required.

Oversize 1

Oversize 2 0.50 mm (0.0197 in)

Oversize 3 (
Oversize 4 1.00mm (0.0394in) )
b. The expander spacer of the bottom ring
(oil control ring) is color-coded to iden-
tify sizes.
The color mark is painted on the expander
spacer.
2. The piston pin should have no noticeable
Move the connecting rod to one side and in-
free play in piston. lf the piston pin is sert a feeler gauge. Big end axial play should
loose, replace the pin and/or the piston. be within 0.35-0.65 mm (0.014-0.026 in).

lf excessive axial play is present,0.7 mm

(0.028 in) or more, disassemble the
crankshaft and replace any worn parts.

Check crankshaft assembly runout. (Misalign

ment of crankshaft parts. )

Crankshaft
1. Crankshaft
a. Support the crankshaft at both ends on
V-blocks.
b. Check the crankshaft components should Dial gauge readings should be within 0.03
mm (0.0012 in).
be follows:

Check connecting-rod axial play at small end

(to determine the amount of wear or crank
pin and bearing at big end).
Correct any misalignment by tapping the
flywheel with a brass hammer and by using a
wedge.

Small end play should not exceed 2 mm Crankshaft specifications

(0.08 in).
56 d o5mm
Crank Width "A"
.2.211 Eoozinl

Runout Limit "B" 0.03 mm (0.0012 in)

Big End Side 0.35 - 0.65 mm

Clearance "D" {0.0'14 - 0.026 in)
lf small end play exceeds 2 mm (0.08 in)
disassemble crankshaft, check connecting Small End Free 0.8 '1.0 mm
-
rod. crank pin and big end bearing. Play " C" (0.03 - 0.04in)
Replace defective parts. Play after
reassembly should be within 0.8 - 1.0 mm
(0.03 0.04 in)
-

Check the connecting rod side clearance at

big end.
 2. Crankshaft bearing
a. Before checking the crankshaft bearing,
it should be cleaned and dried.
b. Check the bearing for pits, rust spots, or
chatter marks where the balls have
dragged.

NOTE: KCASE
Lubricate the bearing immediately after exam-
ing them to prevent rust,

Oil pump
1 . Check the rotor width on the pump. lf out
of specification, replace the pump.

Rotor width: 6 mm (0.236 in)

2. Check the tip clearance and side

clearance. lf out of specification, replace
the pump.

Tip clearance:
c. lf any of these conditions exist, the bear-
0.15 mm 10.0059 in)
ing should be replaced.
Side clearance:
3. Crankshaftreassembly
0.03 - 0.09 mm (0.0012-0.0035 in)
When reassembling the crankshaft, pay
attention to the following points.
a. Make sure the oil passages of the crank OUTEB ROTOR
INNER ROTOR
and crank pin are lined up during assem-
blv.

TIP CLEARANCE

otL
PASSAGE

SIDE CLEARANCE

Primary drive
The drive gear is mounted on the crankshaft;
the driven gear is mounted on the transmission,
b. Oil from the oil pump flows to the crank- and is integrated with the clutch assembly.
shaft passage by the pin. 1 . Check the drive gear and the driven gear

for obvious signs of wear or damage from

NOTE: foreign material within the primary case.
Check the movement of the pin and the stretch 2. lf the primary drive is excessively noisy
force. during operation, replace both the drive
and the driven gears.

9,-tn
Clutch NOTE:
1. Clutch housing For optimum performance, if any friction or
a. Check the dogs on the clutch housing. clutch plate requires replacement, it is advisable
Look for cracks and signs of galling on to replace the entire set.
edges. lf damage is moderate, deburr. lf
severe, replace the clutch housing.
Standard Wear limit
NOTE:
Galling on the friction plate dogs of the clutch Friction plate 3.0 mm 2.8 mm
thickness {0.12 in ) (0.11 in)
housing will cause erratic clutch operation.
Clutch plate 0.05 mm
b. Check the clutch housing bearing for warp limit (0.0020 in)
damage. lf damaged replace bearing.

2. Clutch boss
a. Check splines on clutch boss for galling.
lf damage is slight to moderate, deburr;
if it is severe, replace clutch boss.
NOTE:
Galling on clutch plate splines will cause erratic
operation.

4. Clutch push rod

a. Support the push rod at both ends on V-
blocks.
b. Roll the push rod, and check for bends.

3. Friction and clutch plates

Check clutch steel plates and friction
plates for heat damage. Measure f riction
plate thickness at 3 or 4 points. Check
each clutch plate for signs of heat damage
and warpage. Place on surface plate (plate
glass is acceptable) and use feeler gauge
as illustrated. lf warpage exceeds toler-
ance, replace.
 c. lf the push rod is bent, replace the push
rod.
5. Clutch springs
Measure the clutch spring free length us-
ing the vernier caliper.
Replace the springs as a set, if any is less
than minimum free length.
Clutch spring minimum length:
22.4 mm (0.88 in)
Transmission
1. lnspect each shift fork for signs of gall-
ing on gear contact surfaces. Check for
bending. Make sure each fork slides freely
on its guide bar.
y')-,,
2. Roll the guide bar across a surfa__qe
lf the bar is bent,replace.
3. Check the shift cam grooves for signs of
wear or damage. lf any profile has ex-
cessive wear and/or damage, replace
cam.
4. Check the cam followers on each shift
fork for wear. Check the ends that ride
in the grooves in the shift cam. lf they are
worn or damaged, replace the shift forks.
5. Check shifi cam dowel pins and side plate
for looseness, damage or wear. Replace
as required.
b. Check the shift cam stopper plate and
circlip and stopper for wear. Replace as
required.
7. Check the transmission shafts using a
centering device and dial gauge. lf any
shaft is bent beyond specified limit, rep-
lace shaft.
Maximum run-out: 0.08 mm (0.0031 in)
place. 8. Carefully inspect each gear. Look for signs
of obvious heat damage (blue discolora-
tion). Check the gear teeth for signs of
pitting, galling or other extreme wear.
Replace as required.
9. Check to see that each gear moves free-
ly on its shaft.
10. Check to see that all washers and clips are
properly installed and undamaged. Rep-
lace bent or loose clips and bent washers.
11. Check to see that each gear properly
engages its counterpart on the shaft.
Check the mating dogs for rounded
edges, cracks, or missing portions. Rep-
lace as required.
Starter
1. Check the surface of the kick gear and
idler gear for pitting or other damage. lf
the damage is severe, replace the gear(s).
2. Check the tension of the return spring. lf
it is damaged or fatigued, replace the
spring.
3. Check the tension of the kick gear spring
clip with a spring gauge. lf either clip is
not within specification, replace it.
Kick clip friction force "P":
Minimum: 0.65 kg (1.43 lb)
Maximum: 1.05 kg (2.32 lb)
4. Check the kick axle for damage, replace
it, if it is damaged.
Crankcase
1 .
Thoroughly wash the case halves in mild
solvent-
2. Clean all gasket mating surfaces and
crankcase mating surfaces thoroughly.
J- Visually inspect case halves for any cracks
or other damage.
4. Check all f ittings not previously removed
for signs of loosening or damage.
5. lf
bearings have been removed, check
their seats for signs of damage (such as
the bearing spinning in the seat, etc.)
ti- Check oil delivery passages for signs of
blockage.
7. lf bearings have not been removed, oil
them thoroughly, immediately after
washing and drying. Rotate the bearing,
checking for roughness which indicates
damaged races or balls.
8. Check needle bearing{s) in transmission
for damage. Replace as required.
w^i
( )'-r--=11'o1
T \,)Jr----\l
Bearings and oil seals
'1. lnspectioh
a. After cleaning and lubricating the bear-
ings, rotate the inner race with a finger.
lf rough spots are noticed, replace the
bearing.
b. Check the oil seal lips for damage and
wear. Replace as required.
2. Removal
a. Pry oil seal(s) out of place with a screw-
driver.
Replace all oil seals when overhauling the
engine.
NOTE:
Place a piece of wood under the screwdriver
to prevent damage to the case.
b. Drive out the bearing(s) with the ap-
propriate special tool.
NOTE:
Bearing(s) are most easily removed or install-
ed if the cases are first heated to approximately
95o - 125oC Q05" -257"Fl.. Bring the case up
to proper temperature slowly. Use an oven-

REASSEMBLY
I mportant informations
1. Gasket and seal
All gaskets and seals should be replaced
when an engine is overhauled. All gasket
surfaces and oil seal lips must be cleaned.
2. Properly oil all mating engine and trans-
mission parts and bearings during
reassembly.
3. Circlip
All circlips should be inspected carefully
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips.
When installing a circlip, make sure that
the sharp edged corner is positioned op-
posit to the thrust it receives. See the sec-
tional view below.
LOCK WASHER
OR LOCK PLATE
5. Bearings and oil seals
lnstall the bearing(s) and oil seal(s) with
their manufacturer's marks or numbers
facing outward. ln other words, the
stamped letters must be on the side ex-
posed to view. When installing the oil
seal(s), apply a light coating of lightweight
lithium base grease to the seal lip(s)"
When installing the bearing(s), liberally oil
the bearing(s).

BEARING

EDGED CORNER

4. Lock washer/plate and cotter pin

All lock washers/plates and cotter pins
must be replaced when they are remov-
ed. Lock washer/plate tab(s) should be
bent over along the bolt or nut flat(s) after
tightening the bolt or nut properly (see
illustration ).

NOTE:
Cotter pins should be replaced after one use.
Crankshaft and balancer gear
Crankshaft and balancer gear

50 Nm (5.0 m.ks, 35 tt.lbl

rl
s
--j.
l---

1. Balancer driven gear 12. Special washer

2. Bearing {with groove)
3. Key 13. Balancer drive gear
4. Balancer weight 14. Compression spring
5. Eearing 15. Dowel pin
6- Primary drive gear 16. Buffer boss
7. Key 17. Special washer
8. Pump drive gear (without groovel
9. Clevis pin 18. Bearing (86306)
10. Dowel pin 19. Crankshaft assembly
11. Compression spring

3-25
After all bearings and oil seals have been in- NOTE:
stalled in both crankcase halves, install the Oil each gear and bearing thoroughly.
crankshaft and balancer shaft as follows:
1. Place the right crankcase underside.
2. Fit the crankshaft onto the right case half
by tapping the crank pin area with a soft
hammer while turning the crankshaft.
Work slowly and carefully, a'nd make sure
the crankshaft it set evenly.

NOTE:
Pay attention to the parallelism between the
crankweb and the crankcase surface.

3. lnstall the balancer shaft onto the right 1.

3.
Crankshaft
Shitt cam
2.
4.
Balancer shatt
Guide bar
case half .
5. Apply Yamaha Bond #4 sealant or equiv-
alent to the crankcase mating surface.
Transmission
1. lnstall the drive axle and main axle onto
the right case. Tap lightly on the axle with
a soft hammer while turning the axle.
2. lnstall the shift cam onto the right case.
3. lnstall the shift forks and guide bar.
NOTE:
Each shift fork is identified by a number cast
on its side. All the numbers should face the left
side.
1. Yamaha Bond #4 sealant

Crankcase
1. Fit the left crankcase onto the right case.
Tap lightly on the case with a soft
hammer-

'Clrufielfl:
Before installing and torquing the
crankcase bolts, be sure to check whether
the transmission is functioning properly by
manually rotating the shift cam either
way.

2. Tighten the left crankcase securing bolts,

starting the highest numbered bolt- Tor-
4. Check to see that all parts move freely
que the bolt to specification.
prior to installing the left case half. Check
for correct transmission operation; make
certain that all shims are in place.

3-?6
Transmission

10 Nm (1.0 m kg, 7.2 fi.lbl

o

@
1. Bearing 14. Oil seal
2. Circlip 15. Drive sprocket
3. Plain washer 16. Bearing (86204)
4. lst wheel gear 17. Main axle
5. 4th wheel gear 18. 4th pinion gear
6. Circlip 19. Special washer
7. Special washer 20. Circlip
8. 3rd wheel gear 21. 3rd plnion gear
9. 5th wheel gear 22. 5th pinion gear
10. Drive axle assembly 23. 2nd pinion gear
11. 2nd wheel gear 24. Bearing (86202)
12. Plain washer 25. Oil seal
13. Eearing (8630443)
NOTE:
After installing the crankcase, apply a liberal
coating of 4-stroke engine oil to the crank pin
and bearings.

Tightening torque:
7 Nm (0.7 m ' kg. 5.1 ft . lb)

Segment pin 2. Shi{t cam hole

2. lnstall the shift shaft assembly with the

stopper lever and shift lever are properly
position as shown.

1. Stopper lever 2. Shift lever

Balancer driven and drive gear

1. lnsert the special washer (without
groove), key, balancer drive gear, special
washer (with groove), pump drive gear,
Shifter , primary drive gear, new lock washer and

1. lnstall the segment, and secure it with the lock nut in that order into the crankshaft.
securing screw. Apply a thread locking
compound such as "LOCTITE" to the
screw threads. Torque the screw to spe-
cification.

NOTE:
Be sure that the segment pin engages the shift
cam hole.

Tightening torque:
12 Nm (1.2 m . kg, 8.7 ft.lb) 1. Special washer (without groove) 5. Pump drive gear
2. l<eY 6. Primary drive gear
3. Balancer drive gear t.
4. Special washer {with groove) 8. Lock nut
 2. lnstall the balancer driven gear, key, new
lock washer and lock nut in that order in-
to the balancer shaft.

NOTE:
Note that there is the pu nch mark on the drive
gear and the punch mark on the driven gear
which must be aligned to install the driven gear.

1. 2. Drive gear securing nut

3 Folded rag (For driven gear) 4. Folded rag (For drive oear)

4. Bend the lock washer tab along the each

nut flats.

Oil pump
1. Fit the oil pump assembly onto the case.
' Then, torque the securing screw to the
1. Balancer driven gear 2. Key specification.
3. 4. Lock nut
N OTE:
Note that there are the oil passage holes on the
oil pump assembly and the oil passage holes
on the case which must be aligned to install
the oil pump assembly.

Tightening torque:
7 Nm (0.7 m.k9,5.1 ft.lb)

l, Punch mark

3. Place a folded rag between the teeth of

the drive and driven gear to lock them as
shown. Then, torque the driven gear
securing nut and drive gear securing nut
to specification.

Tightening torque:
50 Nm (5.0 m . kg, 36 ft . lb)

Kick idle gea r

1. lnstall the circlip, plain washer, kick idle
gear, special washer and circlip in that
order into the drive axle.

3-29
1. Circlip 2. Plain washer 3. Kick idle gear
4- washer 5. Circlip
Spec;al

Starter
1. lnstall the decompression shaft assembly

3. Hook the kick spring to its position.

NOTE:
After installing the kick axle assembly, be sure
to check whether it operates smoothly or not.
1. Decompression shaft assembly

2. lnstall the kick axle assembly by rotating

clockwise in proper position.
Starter

@
1, Decompression cable lever 13. Spacer
2. iorsion spring 14. Torsion spring
3. Plain washer 15. Spring cover
4. Oil seal 16. Kick gear
5. Plain washer 17. Clip
6. Circlip 18. Kick axle assembly
7. Decompression shaft 19. Circlip
8. Kick crank assembly 20. Specjal washer
L Oil seal 21. Kick idle gear
10. washer 22. Plain washer
11. Plain washer 23. Circlip
12. Circlip

3-31
Clutch
1. lnsert the push lever axle, and hook the
push lever axle spring to its position.
Then, torque the setting screw to the
specification.
Tightening torque:
12 Nm {1.2 m . ks, 8.7 ft.lb)
3. lnstall a new lock washer and lock nut,
and tighten the nut to the specification.
Use the Clutch Holding Tool (special tool)
to hold the clutch boss.
Tightening torque:
50 Nm (5.0 m . ks, 36 ft ' lb)

1. Clutch Hold;ng Tool {special tool)

Setting screw
4. Bend the lock washer tabs along the nut
flats.
5. lnstall the push rod #2 and ball into the
main axle hole.

1. Push lever axle spring

2. lnstall the primary driven gear, holding

plate and the clutch boss onto the main
axle. Push rod #2

6. lnstall the friction plates and clutch plates

alternately on the clutch boss, starting
with a friction plate and ending with a fric-
tion plate.
::::..::::::::::
wE+;
When installing the friction plates and
clutch plates, be careful to install the
cushion spring in proper position as
shown.
Holding plate
Clutch

8 Nm (0.8 m.kg, 5.8 {t,lb}

50 Nm 15.0 m .kq, 36 ft . lbl

12 Nm {1.2 m.ks. 8.7 ft . lbl

1. Compression spring 11. Holding plate

2. Clutch pressure plate 12. Primary drive gear
3. Push plate 13. Ball
4. O-ring 14. Push rod #2
5. Push rod #1 15. Push lever assembly
6. Friction plate 16. Torsion spring
7. Cushion spring 17. Circlip
8. Chrtch plate 18. Oil seal
L Friction plate 19. Bush
10. Clutch boss 20. Setting screw

3-33
 CUSHION SPRING

1. Push 2. Crankcase mark 3. Push lever mark

d. Torque the lock nut to the specification.

Tightening torque:
8 Nm (0.8 m.ks, 5.8 ft'lb)
7. lnstall the clutch pressure plate onto the
clutch boss- Crankcase cover (rig ht)
d. lnstall the clutch springs and screws. Tor- 1. Fit the right crankcase cover onto the right
que the screw to specification. case. Tap lightly on the cover with a soft
hammer.
Tightening torque: 2. Tighten the right crankcase cover secur-
6 Nm (0.6 m . kg, 4.3 ft ' lb) ing bolts. Torque the bolt to specification.

9. Clutch mechanism adjustment Tightening torque:

Adjustment of the clutch free play is ac- 7 Nm {0.7 m. kg, 5.1 ft.lb)
complised as follows:
a. Loosen the lock nut on the pressure plate.
b. Push the push lever to toward the front
of ne engine with your finger until it
stops. With the push lever in this position,
turn the adjuster either in or out until the
push lever mark and crankcase match
mark are aligned.

3. lnstall the kick crank. Tighten the kick

crank securing bolt to specification.

Tightening torque:
20 Nm (2.0 m . kg, '14 ft . lb)

Lock nut
Piston 2. lnstall a new cylinder base gasket and
1. Fit the piston onto the connect;ng rod, dowel pins. lnstall the new O-rings to the
and push in the piston pin into the piston. cra nkcase and cylinder bottom.
Then, install the piston pin clip.

NOTE:
1 . The arrow on the piston must point to the
front of the engine.
2. Before installing the piston 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.
3. Always use a new piston pin clip.

Dowel pin

1. Arrow 2. piston pin clip

Piston

1. O-ring
Cylinder
1. lnstall the cam chain to the cam chain 3. Offset the piston ring end gaps as shown.
drive gear, and install the rear cam chain
guide. Torque the cam chain guide secur- NOTE:
ing bolt to specification. 1. Be sure to check the manufacture's marks
or numbers stamped on the rings are on
Tightening torque: the top side of the rings.
8 Nm {0.8 m'kg, 5.8 ft lb) 2. Before installing the cylinder, apply a
liberal coating of 4-stroke engine oil to the
piston rings, piston skirt areas and piston
pin.

'eAUY.*{$}"
Make sure the ends of the oil ring expand-
ers are not overlapped.

Cam chain 2. Rear cam chain gu,de

Cylinder and piston

PISTON CLEARANCE:

{0.0010- 0.0018 inl

10 Nm {1.0 m .kc, 7.2 ft.tb)

,g
/P
(o./
6)
@

1. Cylinder 6. Piston ring set

2. Oring 7. Piston
3. Cylinder gasket 8. Piston pin clip
4. Dowel pin 9. Piston pin
5. O-ring

3-?6
 Cylinder head
RING {LOWER}
1 " Valve reassembly
Reassembly of the valves are accomplis-
ed as follows:

OIL RING {U

4- lnstall the cylinder with one hand while

compressing the piston rings with the
other hand.

NOTE:
Tie the cam chain with a piece of machanic's
wire, and feed it through the chain opening.

a. Lubricate the valve stem and oil seal with

a high-quality molybdenum disulfied
motor oil.
b. lnsert the valve in the cylinder head, and
install the oil seal.

NOTE:
Carefully fit the oil seal over the valve stem,
and push it into position on top of the valve
guide.
5. lnstall the cylinder securing bolts, and tor-
'que the bolt to specification. c" lnstall the spring seat and both valve
springs.
Tightening torque:
ft' NOTE:
10 Nm 11.0 m 'ks, 7.2 lb)
All valve springs must be installed with larger
pitch upward as shown.
6. lnstall the front cam chain guide onto the
crankcase.

LARGER PITCH
o
\1 --"'
o SMALLEB PITCH
)."
\1
/
1. Front cam chain guide

3-37
Valve/camshaft/rocker arm shaft

1. lntake rocker arm 11. Exhaust rocker arm shaft

2. lntake rocker arm shaft 12. O-rinq
3. Valve retaine.s 13. Exhaust valve
4. Valve spring retainer 14. Camshaft
5. Valve stem seal 15. Dowel pin
6. Valve spring (inner) 16. Collar
7. Valve spring (outer) 17. Decompression cam
8. Valve spring seat 18. Torsion spring
9. lntake valve 19- Plain washer
10. Exhaust rocker arm 20. Oil seal

3-38
 d. lnstall the collar on the spring. NOTE:
1. lntake rocker arm shaft
NOTE: This is not fitted with an O-ring. When in-
Be sure it is properly seated on the valve serting the shaft, be careful not to touch
springs. the cylinder head securing bolt.
e. Mount the Vaive Spring Compressor
2. Exhaust rocker arm shaft
This is f itted with an O-ring. When inser-
(special tool) on the head, and depress
ting the shaft, be careful not to damage
each valve spring.
the O-ring.

1. Vaive Sprinq Cornpressor (special tool)

1. lntake rocker arm shaft 2. Exhaust rocker arm sha{t
f. lnstall the valve retainers with the
tweezers. c. lnstall the camshaft retaining plate in pro-
per position.
NOTE:
Be sure the retainers properly engage the valve
stem.

Retaining plate

d. lnstall a new lock washer, and tighten the

securing bolt to the specification.
1. Valve retainers

g. Remove the Valve Spring Compressor Tightening torque:

(special tool) from the head. 8 Nm (0.8 m . ks, 5.8 ft . lb)
2. Camshaft reassembly
Reassembly of the camshaft is accomplis-
e. Bend the lock washer tabs along the nut
flats.
ed as follows:
a. Fit the rocker arms onto the head, and in-
stall the camshaft assembly.
b. lnsert the rocker arm shafts into the head.

3-39
 n):
t-_
l-
/:
2. Securing bolt a\q
>-.'//'^\
\ a / //,,--\'
5_ lnstall a new cylinder head gasket and
dowel pins. lnstall a new O-ring to the
cylinder.

6. Rotate the crankshaft cou nterclockwise

direction until the crankcase pointer and
a dot on the cam chain drive sprocket are
aligned. At same time, rotate the cam
sprocket cou nterclockwise direction un-
til the cylinder head pointer and the slit
on the cam sprocket are aligned, and in-
stall the cam chain.
NOTE:
Cam sprocket rotation can be facilitated by use

O ring
of the cam sprocket securing bolt.
1. Dowel pin

4. lnstall the cylinder head onto the cylinder.

Pull the cam chain through the cylinder
head as it is installed.

NOTE:
Tie the cam chain so that it does not fall into
the crankcase.

5. Tighten the cylinder head securing bolts,

starting the highest numbered bolt. Tor-
Crankcase pointer
que the bolt to specification.

Tightening torque:
Flange bolt:
22 Nm \2.2 m . ks, 16 ft. lb)
B olt:

20 Nm (2.0 m ' ks, 14 ft' lb)

?_4O 1. Cyinder head pointer

Cylinder head

?2 Nm 12.2 m .kg, 16 tt lb)

20 Nm (2.0 m.kg, 14 tt.lbl

SPARK PLUG:

(-,
H
la
g
a
1. Cylinder head cover {intake) 7. Cylinder head side cover
2. O-ring 8. Dowel pin
3. Circlip 9. O-ring
4. Valve guide 10- Cylinder head gasket
5. Camshalt retaining plate 11. Decompression cable
6. Lock washer 12. Cvlinder head cover {exhaust}

3-41
C.D.l. magneto 5. lnstall the side cover onto the cylinder
1. lnstall the C.D.l. magneto onto the head.
crankshaft.

NOTE: Chain tensioner

Before installing the C"D.l. magneto, install the 1 . Remove the chain tensioner cap from the
key onto the crankshaft. chain tensioner assembly.

2. lnstall the magneto securing bolt, and tor-

que the bolt to specification.
i2)
Tightening torque: !
50 Nm (5.0 m . kg, 36 ft . lb) Q

i... *,8

1. Chain tensioner cap 2. Chain tensioner assembly

2- lnsert a small screwdriver into the ten-

sioner body slit. While pressing the ten-
sioner rod, rotate the screwdriver coun-
terclockwise until the it stops turning.

3. lnstall the cam sprocket securing bolt as

shown. Torque the bolt to specification.

Tightening torque:
60 Nm (6.0 m'kg, lB ft.lb)
a+ ,'"'

\
:iiL!
1. Screwdriver 2. Press

3. While still pressing the tensioner rod,

remove the screwdriver. lnsert a tensioner
plate into the tensioner body slit.

NOTE:
4. lnstall the left crankcase cover, and tor- Cut a tensioner plate out of a steel sheet 1 mm
que the bolt to specification. {0.04 in) thick, to the dimensions shown below.

Tightening torque:
7 Nm (0.7 m . kg, 5.1 ft . lb)

3-42
 6. lnstall the decompression cable assembly
STEEL PLATE to the engine.

NOTE:
Hook the decompression shaft spring to its
position.

20 mm 10.80 inl

4. lnstall the cam chain tensioner body on-

to the cylinder. Torque the bolt to speci-
fication -

NOTE:
Always use a new gasket.

Tightening torque:
10 Nm (1 .0 m ' ks, 7.2 ft ' lb)

5. Remove the tensioner plate from the cam

chain tensioner, and install the tensioner
cap. Torque the cap to specification.
Tightening torque:
7 Nm (0.7 m kg, 5.1 ft . lb)
Remounting engine
1. Refer to "REMOVAL" section. Reverse
the applicable removal steps.
NOTE:
Apply thread-locking compound such as LOC-
TITE to the sprocket cover securing bolts.

2. lnstall and tighten the engine mounting

bolts as illustrated-

1. Tensioner cap
3-43
Remounting engine

3} Nm (3.3 m. kg, 24 ft. lbl :Xl Nm (3.3 m . kg, 24 lt . lbl

3l Nm (3.3 m .kg.
24 tt. tbl

i(l Nm 13.3 m . kc. 24 ft. lbl

1. Engine stay (top)

2. Engine stay (lront)
3. Enqine quard
4. Rubber damper
 Tightening torque:
4. Add oil to the engine.
Engine and engine stay {front):
NOTE:
33 Nm (3.3 m ' kg, 24 ft' lb)
The oil quantities are for an overhauled engine.
Frame and engine stay (front):
33 Nm (3.3 m . kg, 24 ft . lb)
Engine and engine stay (top):
Recommended oil:
33 Nm (3.3 m' kg, 24 ft' lb)
SAE 20W40 type SE motor oil
Frame and engine stay (top):
Oil quantity:
33 Nm (3.3 m ' ks, 24 ft ' lb)
1.3 L (1.14 lmp qt, 1.37 US qt)
Engine and frame (rear under):
33 Nm (3.3 m ' kg, 24 ft' lb)
Pivot shaft and nut:
5. Start the engine, and check the oil pres-
sure and oil leakage.
80 Nm (8.0 m' ks, 58 ft' lb)

3. lnstall and tighten the drain bolt before fill-

ing the engine oil.

N OTE:
1. Check O-ring. lf damaged, replace.
2. Before reinstalling the oil strainer, clean
the strainer with solvent.

Before reinstalling the drain bolt, do not

forget to fit the O-ring, compression spring
and oil strainer.

Tightening torque:
4i| Nm (4.3 m ' kg, 31 ft ' lb)

*%
olL
STRAINER
coMPREssloN
-'- _sPRtNG
^-,.'

BOLT

3-45
 CHAPTER 4. CARBURETION

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

Section view... ..,,.....4-2
Specif ications .. ... .... . .4-3
Disassembly . .. ..., ,... .4-3
lnspection ,.,...4-4
Reassembly .....4-s
Fuel level adjustment. .....,.....4-s
AIR CLEANER AND CRANKCASE VENTILATION SYSTEM........,4-6
 CHAPTER 4, CARBURETION
CARBURETOR

.g
"/b
o-=_
---==
C
g
---@
\J-f--.------ 6

"--=€-d
9aF

'At @-
o-----l
,______.----g

e
@gt
I
e
ffj-'

'1. Piston valve

2. Spring clip
3. Jet needle
4. Main nozzle
5. Pilot air jet
6. Pilot screw
7. Starter plunger

@ 8. Throttle stop screw

L
10.
Needle valve assembly
Main jet
11. Pilot jet
12. Float
13. Drain screw
Section view

_-z'-e,/4_
. ---R..fr

-:l
l___-)
_L
I '----:.
-_-:
--l -:
\-- ---)4

I Piston valve
2. Spring clip
3. Jet
to',
needle
4. Main air jet
5. Main jet
6. Needle jet
7. Pjlot jet
8. Ihrottle valve
q@ti*ru,"
9. By-pass hole
10. Pilot outlet
11. Pilot screw
12. Pilot air jet fr.u.'

4-2
Specifications

Main jet l#120

Jet needle I JZ 2.5/5
Needle jet 1393 P2
Pilot jet #35
Starter jet #30
Fuellevel 14.5- 1 mm (0.18+0.04 in)
Float height l30t 1mm (1.18i0.04in)
Pilotscrew lPreset
Engine idle speed | 1,250 + 50 r'min

:gA'{,rr{o.H1
The pilot screw setting is adjusted for
maximum performance at the factory with
the use of specialized equipment, Do not
attempt to change these settings. lf all
other engine systems are functioning cor-
rectly, and changes will decrease perfor-
mance.
3. Remove the pilot air jet.

Disassembly
1. Remove the starter plunger from the car-
buretor body.

1. Pilot air jet

4. Remove the float chamber cover holding

screws, and remove the cover. The main
1. Starter plunger
and pilot jets are located in the float bowl.
Remove the jets if necessary.
2. Remove the vacuum chamber cover, and
remove the spring and diaphragm
(vacuum piston ).

NOTE:
Note that there is the tab on the rubber
diaphragm. There is the matching recess in the
carburetor body for the diaphragm tab.
 2. Examine the condition of the floats. lf the
float are damaged, they should be re-
placed.
) lnspect the float needle valve and seat for
wear or contamination. Replace these
components as a set_

1. [\/ain Jet 2. Pilot jet 3. Blind plug @

5. Pull out the float pivor pin. Remove the
float assembly. Be careful not to lose the
/*{*"}ryhb
float valve under the float arm.

4. lnspect the vacuum piston and rubber

diaphragm. lf the piston is scratched or
the diaphragm is torn, the assembly must
be replaced.

6. Remove the f loat valve seat secu ring

screw, and remove the float valve seat.
/#
*-- , *,-.

z^/t
?
c#,
i4r
I 3. Set spring
2. Needle jet 4. Need e jet cover

R lnspect the starter plunger for damage.

lf damaged, replace.

L Float valve seat

lnspection
1. Examine the carburetor body and fuel
passages. lf contaminated, wash the car-
buretor in a petroleum-based solvent.
Do not use caustic carburetor cleaning
solutions. BIow out all passages and jets
with compressed air.

4,4
Reassembly
Fuel level:
To reassemble the carburetor, reverse the
disassembly procedures. Pay close attention to 4.5+ 1 mm (0.18+0.04 in)
the installation of the vacuum piston diaphragm
below from the carburetor mixing
and the location of each jet. chamber body edge.

Fuel level adjustment

NOTE:
Before checking the fuel level, note the
following:
1. Place the motorcycle on a level surface.
2. Adjust the motorcycle position by plac-
ing a suitable stand or a garage jack under
the engine so that the carburetor is posi-
tioned vertically.

1. Connect the Level Gauge (Special tool)

or a vinyl pipe of 6 mm (0.24 in) inside
diameter to the float bowl nozzle on the
carbu retor.
2. Set the gauge as shown, and loosen the
drain screw.
5. lf the fuel level is incorrect. remove the
carburetor assembly from the motorcycle
and check the fuel valve and float
assembly for damage.
6. lf no damage is found in these parts, ad-
iust the float level by slightly bending the
float arm tang. Recheck the fuel level.

1. Level Gauge {special tool) Drain screw

3. Start the engine and stop it after a few

minutes of run. This procedure is neces- 1. Float arm tanq
sary to obtain the correct fuel level.

NOTE:
Make sure the fuel cock is "ON" or "RES"
position.

4. Check the fuel level. lt should be within

the specified range.
AIR CLEANER AND CRANKCASE VEN-
TILATION SYSTEM

f arow-av cas
(= rnesn nrn

Refer to "CHAPTER 2" for the air filter main-

tenance.

4-6
 CHAPTER 5. CHASSIS

FRONT WHEEL ... ........5-1

Removal ........5-2
lnspection ......5-2
Reassembly. ............5-2
Front axle inspection ........ ....5-3
Brake drum inspection ,...... ...5-3
Brake shoe inspection ,.. .. ... ..5-3
Brake camshaft inspection ......5-4
Replacing wheel bearings .......5-4
Spokes inspection ,.,.. .5-4

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

Removal ....,,,5-6
lnspection ... ..,5-6
Reassembly. ............5,6
Rear axle inspection ... ..... ....5-7
Brake drum inspection ..........5-7
Brake shoe inspection ,,. ... ....5-7
Brake camshaft inspection ,.....5-7
Replacing wheel bearings ..,....5-7
Spokes inspection ., .., .5-7

,
TIRE AND TUBES .......5-7
Removal ........5-7
Reassembly. .... . .... ...5-7

DRIVE CHAIN AND SPROCKETS .... ... ..5-8

Removal ....,'i..5-8
Drive sprocket inspection ..... .5-8
Driven sprocket inspection ..... .5-9
Chain inspection . , . . . . ..........5-g
Chain maintenance .. .. . .... ....5-9
Reassembly. . ... .......5-10
FRONT FORK ....5-11
Removal and disassembly..,,.. ,.......5-12
lnspection .... .5-14
Reassembly. . ..........5-14

STEERING HEAD , ..,...5-17

Removal .......5-18
lnspection ,.. ,.5-19
Reassembly. . ........ ..S-19

\_
SWTNGARM . ....5-20
Free play inspection. .,..,..,,,.5-21
Removal ......,5-21
Adjustment ....5-2.
lnspection and lubrication ......5-2.
Reassembly. ...........5-23
REAR SHOCK ABSORBER ..,...5-24
Handling notes .. ......5-25
Notes on disposal .,...,5-25
Removal .......5-25
lnspection ... ..5-26
Reassembly. ,,..,..,...5-26
CABLES AND FITTINGS .,......,5.27
Cable maintenance,.. ..,.,.,,.,5-27
Throttle maintenance ..........5-27
 CHAPTER 5. CHASSIS
FRONT WHEEL

*APPLY LITHIUM,BASE GREASE

19x 1.60
, ve nrrc"qr- T rlrEnal
2mm 2mm

<.
RUNOUT
LIMIT 10.08 in) (0.08 in)

d-.- (l*
)=-
"%.i-l/t)
(K,WJ,
VZS to*
118 kPa (1.2 kg/cml <^ @/
18 psi)
^%t
Wtr l

33 Nm (3.9 m.k9, 28 fr.lb)

1. Collar 7. Bearing {8630lZ)

2. Dust cover 8. Meter drive gear
3. Oil seal 9. Brake shoe
4. Bearing 10. Brake camshaft
5. Spacer 11. Meter gear
6. Flanoe spacer

5-1
Removal
1. Elevate the front wheel by placing a Rim run-out limit:
suitable stand under the engine.
Vertical-2 mm (0.08 in)
Lareral -2 mm (0.08 in)
2. Remove brake cable; loosen all cable ad-
.iusters and remove cable from handlebar
lever holder. Then remove cable from cam
lever at front brake shoe plate. GAUGE

3. Check wheel balance. Rotate the wheel

lightly several times and observe resting
Brake cable 2. Cotter pin 3. Axle nut
position. lf the wheei is not statically
balanced, it will come to reset at the same
3. Remove speedometer cable from front
position each time- lnstall an appropriate
brake shoe plate: first remove clip and
then pull cable out. balance weight at lightest position (at
top).
4. After installing a tire, ride conservatively
to allow the tire to seat itself on the rim
properly. Failure to allow proper seating
may cause tire failure, resulting in damage
SPEEDOMETER to the motorcycle and injury to the rider.
CABLE 6 After repairing or replacing a tire, check
to be sure the valve stem lock nut is
securely fastened. lt not, torque it as
specified.

Tightening torque:
1.5 Nm (0.15 m.kg, 1.1 ft lb)
4. Remove cotter pin from front wheel ax-
le, and remove axle nut.
5. Turn and pull out the front wheel axle; the
wheel assembly can now be removed. Reassembly
When installing the front wheel, reverse the
removal procedure taking the following steps:
lnspection
1 . Make sure the two projections inside the
1. Check for cracks, bends or warpage of the
brake shoe plate assemlby are meshed
wheel. lf a wheel is deformed or crack-
with the two f lats in the wheel hub.
ed, it must be replaced.
2. Check wheel run-out. lf the deflection ex-
ceeds the tolerance below, check the
spoke-tension, rim deformation, and
wheel bearings. Replace the wheel as
required.

5-2
 Brake drum inspection
Oil or scratches on the inner surface or the
brake drum will impair braking performance or
result in abnormal noises.
Remove oil by wiping with a rag soaked in lac-
quer thinner or solvent.
Remove scratches by lightly and evenly polish-
ing with emery cloth.

Brake shoe inspection

2. Check for proper engagement of the boss 1 . Check the brake lining thickness with slide
on the outer fork tube with the locating calipers.
slot on the brake shoe plate.
NOTE:
Replace the brake shoes as a set if either ts
found to be worn to the wear limit.

Brake lining thickness:

4 mm {0.16 in)
Wear limit:
2 mm (0.08 in)

3. Always secure the front wheel axle as MEASURING POINTS

follows:
a. Torque the front axle nut.

Axle nut torque: -,A'-

39 Nm (3.9 m . kg, 28 ft . lb)

b. lnstall a new cotter pin; discard old pin.

2. Check any glazed areas on the brake lin-

Always use a new cotter pin on the axle ing surface. lf any, remove the glazed
n ut. areas from brake lining using coarse sand
paper.
c. Adjust the play in the brake lever.
N OTE:
After using the sand paper, clean off the polish-
Front axle inspection
ed particles with cloth.
Remove any corrosion f rom the axle with fine
emery cloth. Place the axle on a surface plate
and check for bends. lf bent, replace axle. Do
not attempt to straighten a bent axle.

EQ
 Brake camshaft inspection Spokes inspection
Remove the camshaft and grease. lf the cam Loose spokes can be checked by bracing the
face is worn, replace. motorcycle off the ground so that the wheel
can spin freely. Slowly rotate the wheel and
NOTE:
at the same time let the metal shaft of a fairly
Before removing the cam lever, put a match heavy screwdriver bounce off each spoke. lf
mark on the cam lever and camshaft to indicate all the spokes are tightened approximately the
their positions for easy assembly. same, then the sound given off by the screw_
driver hitting the spokes should sound the
same. lf one spoke makes a dull, flat sound,
Replacing wheel bearings then check it for looseness.
lf the bearings allow play in the wheel hub or
if wheel does not turn smoothly, replace the
bearings as follows: Spoke tightening torque:
1. First clean the outside of the wheel hub. 3 Nm {0.3 m .kg, 2.2 Ir.tbl
2. Drive the bearing out by pushing the
spacer aside (the spacer ,,float,, between
the bearings) and tapping around the
perimeter of the bearing inner race using
a soft metal drift pin and hammer. Either
or both bearings can be removed in this
manner.

@@
Eye protection is recommended when us-
ing striking tools.

3. To install the wheel bearing, reverse the

above sequence. Be sure to grease the
bearing before installation. Use a socket
that matches the outside race of the bear_
ing as a tool to drive in the bearing.

Do not strike the center race or balls of the

bearing. Contact should be made only
with the outer race.
REAR WHEEL

*APPLY LITHIUM-BASE GBEASE

O*

-\eJ $,
A..- ," I

lax 1.85

VERTICAL LATERAL
RUNOUT 2mm 2mm
LIMIT (0.08 in) (0.08 in)

30 Nm {3.0 m.ks, 22 ft.lb}

@)
*

85 Nm (8.5 m . kg, 61 tt'lb)

FREE PLAY:
30 -45 mm (1.2-1.8 in)

10. Bearing {862022)

2. Brake tension bar 11. O ring
3. Brake camshaft 12. Dampet
4. Brake shoe plate 13- Clutch hub
5. Brake shoe 14. Plate cover
6. Oil seal 15. Driven sprocket
7. Bearing (862022) 16. Sprocket axle
L Flange spacer 17. Bearing (860042)
L Spacer 18. Oil seal

5-5
Removal 5. Remove the cotter pin from the wheel axle
1. Elevate the rear wheel by placing a suita- and remove the rear wheel axle nut and
ble stand under the engine. sprocket shaft nut.
2. Remove the chain case guard.

Cotter pin Axle nut 3. Sprocket shaft nut

3. Remove the chain case. 6. Remove the chain.

7. The rear wheel assembly, the collar, the
chain puller(s), etc., can be removed from
the motorcycle by pulling out the wheel
axle.

lnspection
Refer to "FRONT WHEEL, lnspection" section.

Reassembly
When installing the rear wheel, reverse the
removal procedure taking the following steps:
'1. When installing the chain, make certain
4. Remove the tension bar and the brake rod
closed end of master link clip is facing
from the brake shoe plate. The tension bar direction of rotation.
can be removed by removing the cotter
pin and nut from the tension bar bolt. The
brake rod can be removed by removing
the adjuster.

lT'L

1. Tension bar 2. Brake rod

5-6
 2. Make sure the rear wheel axle is inserted
on the left-hand side and that the chain
pullers are installed with the number pun-
ched side outward.
3. Make sure the rear wheel axle nut and
sprocket shaft nut are properly torqued.
Tightening torque:
Sprocket shaft nut and axle nut:
85 Nm (8.5 m . kg, 61 ft . lb)
TIRE AND TUBES
Removal
1 . Remove valve cap, valve core, and valve
stem lock nut. Loosen bead spacer(s),
(rim locks).
2. When all air is out of tube, separate tire
bead from rim (both sides) by stepping on
tire with your foot.
3. Use two tire removal irons {with rounded
edges) to work the tire bead over the edge
of the rim, starting 180o opposite the tube

tr@
Always use a new cotter pin.
stem. Take care to avoid pinching the
tube as you do this.
4. After you have worked one side of the tire
completely off the rim, then you can slip
4. Adjust the drive chain tension. the tube out. Be very careful not to
5. Adjust the brake pedal and brake light damage the stem while pushing it back
switch. out of the rim hole.

NOTE:
Rear axle inspection
lf you are changing the tire itself, then finish
Refer to "FRONT WHEEL, Front axle inspec-
the removal by working the second bead off
tion" section.
the rim.
Brake drum inspection
Refer to "FRONTWHEEL, Brakedrum inspec-
tion" section. Reassembly
Reinstalling the tire and tube can be ac-
complished by reversing the disassembly pro-
Brake shoe inspection
cedure. The only difference in procedure would
Refer to "FRONT WHEEL, Brake shoe inspec-
tion".section. be right after the tube has been installed.
Before the tire has been completely slipped on-
Brake camshaft inspection to the rim, momentarily inflate the tube. This
removes any creases that might exist. Release
Refer to "FRONT WHEEL, Brake camshaft in-
spection" section. the air and continue with reassembly. Also,
right after the tire has been completely slipped
Replacing wheel bearings onto the rim, check to make sure that the stem
comes out of the hole in the rim at a right angle
Refer to "RRONT WHEEL, Replacing wheel
bearings" section. to the rim.
Finally, inflate the tire.
Spokes inspection
Refer to "FRONT WHEEL, Spokes inspection" Tire pressure lCold tire pressure)
section.
Normal riding

Front 118 kPa (1.2 kg/cm2, 18 psi)

Rear 147 kPa 11.5 ka/cm2 , 22 psi)

5-7
DRIVE CHAIN AND SPROCKETS NOTE:
Removal When removing the drive sprocket secu ring
1. Remove the chain case guard. bolts, apply the rear brake.

5. Bring the master link clip before the

sprocket wheel, and remov"e the chain
joint clip, joint plate and the chain joint.
Then, separate the chain.

2. Remove the chain case.

Chain joint

6. Remove the rear wheel (Refer to "REAR

WHEEL, Removal" section ).

Drive sprocket inspection

3. Remove the dust cover fitting plate and
remove the change pedal and the drive
sprocket cover.
'1. Check sprocket wear. Replace if wear
decreases tooth width as shown.
2. Replace if tooth wear shows a pattern
such as that in the illustration, or as
precaution and common sense dictate.
3. Tighten the securing bolts.
Drive sprocket securing bolt torque:
10 Nm {1.0 m.kq, 7.2 ft.lb)

1/4 TOOTH

1. plate
I Dust cover fitting plate 2. Dust cover

4. Remove the drive sprocket securing bolts

SPROCKET
and holding plate. Then, remove the drive
sprocket.
 SLIP OFF
BENT TEETH
Driven sprocket inspection
1. Check the sprocket wear using pro-
cedures for the drive sprocket.
2. Check the sprocket to see that it runs true.
lf bent, replace.
3. During reassembly, make sure that
sprocket and sprocket seat are clean.
Tighten the securing nuts in a crisscross
pattern.
Bend the tabs of the lock washers fully
against the securing nut flats.
Driven sprocket securing nut torque:
30 Nm (3.0 m . ks, 22 ft . tb)
CORRECT
INCORRECT
Chain inspection
1 . With the chain installed on the motorcy_
cle, excessive wear may be roughly deter_
mined by attempting to pull the chain
away from the rear sprocket. lf the chain
will lift away more than one-half the
length of the sprocket teeth, remove and
inspect.
lf any portion of the chain shows signs
of damage, or if either sprocket shows
signs of excessive wear, remove and
inspect.
F9
Ooo
oz1\o \
,t'-]- )o
\r,1",
(J O\J
1/2 TOOTH
2. Check the chain for stiffness. Hold as il-
lustrated. lf stiff, soak in solvent solution,
clean with wire brush, dry with high
pressure air. Oil chain thoroughly and at-
tempt to work out links. lf still stiff,
replace, chain.
3. Check the side plate for damage. Check
to see if excessive play exists in pins and
rollers. Check for damaged rollers. Re-
place as required.
Chain maintenance
The chain should be lubricated according to the
recommendations given in the periodic main-
tenance/ lubrication intervals charts, or more
often if possible. (Preferably after every use.)
1 . Wipe off dirt with shop rag. lf accumala-
tion is severe, use wire brush, then rag.
2. Apply lubricant between roller and side
plates on both inside and outside of chain.
Don't skip a portion as this will cause
uneven wear. Apply thoroughly. Wipe off
excess.
Recommended lubricant:
SAE 10W30 motor oil
 J. Periodically, remove the chain. Wipe
and/or brush excess dirt off. Blow off
with high pressure air.
4. Soak chain in solvent, bushing off remain-
ing dirt. Dry with high pressure air.
Lubricate thoroughly to make sure lubri-
cant penetrates. Wipe off excess.
Reinstall.

Reassembly
When installing the chain case, reverse the
removal procedure taking the following steps:
1. When install the chain, make certain the
closed end of the master link clip is fac-
ing direction of rotation.

-11-'-:n---..',
I

2. lnstall the drive sprocket cover securing

screws, and torque the screws to spe-
cification.

NOTE:
Apply the LOCTITE to the securing screws.

Tightening torque:
10 Nm (1.0 m'kg, 7.2 ft.lb)

3. When installing the chain case, make sure

dust cover sealing surface matches
perfectly the sealing surface of the chain
case and drive sprocket cover as shown.
FRONT FORK

tr-
,#/'
tt

FORK OIL CAPACITY (EACH FORKI:

294+4 cmr {10.4+0.14 tmp oz,
9.94+0.14 US ozl

F RECOMMENDED olLr
SAE 1OW3O TYPE SE

I
MOTOR OIL

L__

APPLY LOCTITE
23 Nm (2.3 m kq, 17 ft.lbl

1. Front fork cap 9. Oil lock piece

2. Cap bolt 10. Dust seal
3. O ring 11. Betaining clip
4. Spacer 12. Oil seal
5. Spring seat 13. Outer tube
6. Fork spring 14. Drain screw
15. Cylinder securing boh
8. lnner lube

5-1 1
Removal and disassembly

Securely support the motorcycle so it

won't fall over when the front wheel and
front forks are removed.
1. Remove the front wheel. Refer to
"FRONT WHEEL, Removal" section.
2. Remove the handlebars.
3. Remove the brake cable holder and 1. Pinch bolt

speedometer cable holder.

6. Remove the rubber boot.

7. Remove the cap bolt and spacer.
4. Remove the rubber cap from the top of
the fork.

NOTE:
Before loosen the pinch bolts, loosen the fork
cap bolt.

1.

Place an open container under the fork,

and turn the fork upside down, and drain
the oil.

1. Damper Rod Holder (special tool)

5. Loosen the front fork pinch bolts in the

handle crown and under bracket. Remove
the front forks.
 9. Remove the spring seat and fork spring.

':it a
, /'// #"'t'JiJf}if,WTr, YYff''ffimmem

1.

1. Spring seat 2. Fork spring

I .J. Remove the retaining clip from the outer
fork tube.
10. Remove the cylinder securing bolt from
the bottom of the outer fork tube with
special tools (T-handle and Damper Rod
Holder).

1. Reraining clip

14. Hold the front fork outer tube in a vise

horizontally. Out in the inner fork tube just
before it bottoms out and then pull it back
1. T handle (special tool) quickly. Repeat this step until the inner
2. Da.nper Rod Ho der (special too )

fork tube can be pulled out from the outer

11. Remove the damper rod (cylinder com- fork tube {usual 2 or 3 times). Then,
plete) and rebound spring. remove the oil lock piece.

CAUTION:
Don't bottom out the inner fork tube in the
above step, or the oil lock piece will be
damaged.

1. Damper rod {Cylinder complete)

2. Rebound spring

12. Remove the dust seal with a thin screw

driver. Take care not to scratch the inner
fork tube. Discard the dust seal.
1. Put in slowly 2 PLrll bacl qurckly
5-13
15. Pry out the oil seal from the outer tube.

NOTE:
Be careful not to damage the outer tube
surface.

'l. O-ring

6. Check the damger rod for wear, damage,

or contamination. Blow out all oil pas-
sages with compressed air.lf it is worn
or damaged, replace it.

2. lnner fork tube

lnspection
Clean and inspect all front fork components.
Replace any worn or damaged components
prior to reassembly.
1. Check the inner fork tube and replace if
the tube is badly scratched or bent.

7. Check the oil lock piece. Replace it, if

Do not attempt to straighten a bent inner damaged.
fork tube as this may dangerously weaken
the tube.
Reassembly
Check the outer surface of the fork seal
?
seat in the outer fork tube for damage. NOTE:
Replace the tube if for necessary. ln front fork reassembly, be sure to use follow-
3. Check the outer tube for dents. Replace ing new parts.
the tube if for necessary. . Oil seal
4. Check the lree length of the fork spring. . Dust seal

Fork spring free length: 1. Make sure all components are clean
403.5 mm (15.9 in) before reassembly.
2. lnstall the rebound spring to the damper
5. Check the O-ring of the cap bolt. Replace rod.
any damaged O-ring. 3. Slide the damper rod into the inner fork
tube from its top.
4. Fit the oil lock piece over the damper rod
sticking out of the inner fork tube.

5-14
 FORK SEAL
ATTACHMENT

ETAINING

L Damper rod 2. Oil lock piece

q lnstall the fork spring and spring seal in
5. lnstall the inner tube into the outer tube. that order.
6. Apply thread-locking compound such as 10. Pour the specified amount of recommend-
LOCTITE to the cylinder securing bolt,
ed fork oil into the inner fork tube.
and install it. Torque the bolt to speci-
f ication.
Fork oil capacity (each fork):
294+4 cm3 (10.4+0.14 lmp oz,
Tightening torgue:
9.94 +0.14 US oz)
23 Nm (2.3 m . ks, 17 ft . lb)
Recommended oil:
SAE 10W30 type SE motor oil
7. Apply oil to the oil seal, and install the oil
seal by pressing it in with special tools
(Fork Seal Driver and Fork Seal Driver
1 1 . After filling, slowly pump the forks up and
down to distribute the oil and install the
Attachment). Then, install the retaining
spacer. Then, temporarily install the cap
clip.
bolt.
12- lnstall the rubber boot.
13. Slide the fork into the under bracket and
handle crown in the following way.

NOTE:
FORK SEAL 1. Fit the front fork by pushing it up until its
DRIVER ATTACHMENT top is flush with the handle crown top
end.
Holding the front fork in this position,
OUTER TUB
temporariiy tighten the pinch bolts with
fingers.
2. lnsert the fork boot breather pipe into the
8. lnstall the dust seal by pressing it in with headlight body, and clamp it-
special tools (Fork Seal Driver and Fork
Seal Driver Attachment).

5-15
i---
 Tightening torque:
20 Nm (2.0 m'kg, 14 ft.lb)

1. Breather pipe 2. Clamp

14. Tighten the fork pinch bolts at the han-

dle crown and under bracket. Then,
tighten the cap bolt.

Tightening torque:
Handle crown:
34 Nm (3.4 m . kg, 24 ft . lb)
Under bracket:
23 Nm {2.3 m'kg, 17 ft lb)
Cap bolt:
23 Nm {2.3 m ' kg, 17 ft ' lb)

'15.lnstall the brake cable holder, speedo-

meter cable holder and the front wheel.
16. lnstall the rubber cap and handlebars.

NOTE:
The upper handlebar holder should be install-
ed with the punched mark forward.

First tighten the bolts on the front side of

the handlebar holder, and then tighten the
bolts on the rear side.

5- 16
STEERING HEAD

Z) Nm {2.0 m.ks, 14 ft lbl

-o
,t 5

xa
*@

*APPLY MEDIUM WEIGHT WHEEL

BEARING GREASE

F
q9
s
a

1. Steering fitting bolt 7. Upper ball race {bottom)

2. Handle crown 8. Lower ball race (top)
3. Steering fitting nut 9. Lower ball (19 pcs.)
4. Ball race cover 10. Lower ball race {bottom)
5. Upper ball race (top) 11. Steerinq seal
6. L.Jpper ball (22 pcs.)

5-17
Removal

@
Securely support the motorcycle so it
won't fall over when the front wheel and
fron forks are removed.
1. Remove the front wheel, front forks, front
fender and handlebars.
2. Remove the meter assemlby, flasher
lights, front carrier and headlight body. Ball race cover 2. Upper ball race (top)
Upper ball bearings
Remove the steering fitting bolt and han-
dle crown.
6. Remove the under bracket while being
very careful not to lose any ball bearings
from the under bracket. Then, remove the
lower ball bearings, lower ball race (bot-
tom) and steering seal.

1. Steering fitting bolt

4. Remove the steering fitting nut with the

steering nut wrench.

NOTE:
1. Lower bali bearings 2. Lower ball race (bottom)
Support the under bracket with one hand so 3 Steering seal
that the ball bearings will not fall down.
7. Remove the lower ball race (top) and up-
per ball race (bottom) from the steering
head using a drift punch and hammer as
shown. Work the race out gradually by
tapping lightly around its complete
diameter.

1, Steering nut wrench

5. While still supporting the under bracket,
remove the ball race cover, upper ball race
(top) and upper ball bearings.

A 1a
lnspection 4. Carefully slide the under bracket into the
. 'l Wash the balls in solvent. steering head.
2. lnspect the balls and races for pitting or 5. Grease the upper ball race (bottom) with
other damage. lf any one is found defec- medium weight wheel bearing grease, and
tive, the entire set (all balls and both races) arrange the upper ball bearings around it.
should be replaced. Then, apply more grease to the ball bear-
ings, and install the upper ball race (top)
Reassembly and the ball race cover.

NOTE: Ball quantity/size:

ln steering head reassembly, be sure to use 19 pcs. /i/4 in diameter
following new parts.
. Lower ball races b. lnstall the steering fitting nut. Tighten it
. Upper ball races to approximately 35-40 Nm (3.5-4.0
m'k9,25-29ft. lb). Do not over tighten
it.
CAlt-TlONi
7. Continue reassembly in the reverse of
Hold the under bracket until it is secured. removal procedure.
8. When reassembly is complete, check the
1. lnstall the lower ball race (top) and the up- steering stem by turning it from lock to
per ball race (bottom) to the steering lock. lf there is any binding or looseness,
head. read.iust the steering stem tightness.

1. Upper

2. lnstall the steering seal, lower ball race

(bottom) to the under bracket.
3. Grease the lower ball race (bottom) with
medium weight wheel bearing grease, and
arrange the lower ball bearings around it.
Then, apply more grease to the ball
bearings.

Ball quantity/size:
22 pcs. /31 16 in diameter

5-19
SWINGARM

*APPLY LITHIUM-BASE GREASE

@.-

SIDE CLEARANCE:
0.3 mm {0.012 in) 80 Nm (8.0 m . kg, 58 tt. lb)

1. Pivot shalt 8. Guard seal

2. Guard seal Bush
3. Shim 10. Distance collar
4. Eush 1 11. Chain guard
5. Distance collar 12. Drive chain guide
6. Eush 1 13. Swingarm mud guard
7. Shim 14 Rubber boot
Free play inspection 3. Remove the drive chain guide.
1. Remove the rear wheel, shock absorber
and the chain case assembly.
Grasp the swingarm and try to move it
from side to side as shown. Check for free
plav.

Free play (at end of swingarm):

1 mm (0.04 in)

4. Turn over the rubber boot at the bottom.

2. lf free play is excessive, remove the

swingarm and replace the bushings. Re-
place the thrust cover or oil seal if
necessary. 5. Remove the cotter pin, plain washer and
holding pin. Then, disconnect the shock
Removal
absorber from the swingarm.
1. Remove the seat, rear wheel and the
chain case assembly.
2. Remove the swingarm mud guard from
the swingarm.

pin
1. Cotter pin 2. Plajn washer 3. Holding pin

6. Remove the swingarm pivot shaft, and

remove the swingarm.
Adjustment

1 . Measure the swingarm right side member 4. lf the side clearance is not within speci-
A as illustration. fication, adjust it by means of shim_ lf only
2. Measure the collar spacer length B as il- one shim is used, install it on the left side.
lustration. lf B is not within specification, Two shims must be installed both sides.
replace the collar spacer.
Side clearance:
Collar spacer length: 0.3 mm (0.012 in)
B: 54.5-54.7 mm (2.1u16-2.153 in)

3. Calculate the side clearance C by using

lnspection and lubrication
the formula given below.
1. Examine the thrust covers and oil seals.
Replace if they are damaged.
C=B-A 2. lnspect the collar spacer and the bushings
for scratches or other damage.
lf the collar spacer and the bushings are
Example:
damaged, they should be replaced.
1) lf the swingarm right side member
A is below. NOTE:
A...... .......S4.0 mm
When pressing the new oil seal and bushings,
2) lf the collar spacer length B is
pay attention to the following.
below.
B ...... .......54.5
1. Oil seal should be exactly located as
mm
shown in the illustration [0.5 mm (0.020
C=B-A
: in) from left sidel.
54.5 - 54.0
2. Grease them liberally with lithium base
= 0.5 mm {0.020 in)
waterproof wheel bearing grease.
Then, install the one shim lshim
thickness: 0.3 mm (0.012 in)].
Reassembly 5. Using a grease gun, lubricate the pivot
When installing the swingarm, reverse the points.
removal procedure taking the following steps:
1. lnstall the swingarm pivot shaft. Torque
the bolt to specification.

Tightening torque:
80 Nm (8.0 m . kg, 58 ft . lb)

2. lnstall the swingarm to the shock

absorber.

lnsert a new cotter pin into the holding pin

and bend the end of the cotter pin.
3. lnstall the drive chain guide.
4. lnstall the swingarm mud guard and rub-
ber boot to the swingarm.

Mud guard Rubber boot Securing boh

5-23
BEAR SHOCK ABSORBER (MONOCROSS SUSPENSION "DE CARBON" SYSTEM}

$o@-
-."
-c6-^ BUSH

{,
25 Nm {2.5 m.ko. 18 ft.lb}
\

@-tt.

a-.--\

,TTAKE CARE THAT THE SHOCK ABSORBER IS

INSTALLED WITH ITS WARNING LABEL UPWARD
FOR A PROPEB DAMPING EFFECT,
Handling notes Rem oval
1. Remove the seat, rear wheel and the

@
This shock absorber con; highly
2.
chain case assembly.
Remove the shock absorber top holding
bolt.
pressurized n itrogen gas.
Read and understand the following infor-
mation before handling the shock ab-
sorber. The manufacturer cannot be held
responsible for property damage or per-
sonal injury that may result from improper
handling.
1. Do not tamper with or attempt to
open the cylinder assembly.
2. Do not subject shock absorber to an
open flame or other high heat source.
This may cause the unit to explode '. Holding bolt

due to excessive gas pressure. 3. Remove the swingarm mud guard from
3. Do not deform or damage the cylinder the swingarm.
in any way. Cylinder damage will
result in poor damping performance.
4. Take care not to scratch the contact
surface of the piston rod with the
cylinder; or oil could leak out.
5. When scrapping the shock absorber,
follow the instructions on disposal.

Notes on disposal
Before disposing the shock absorber, be sure
to extract the nitrogen gas. To do so, drill a
2-3 mm (0.08 - 0.12 in) hole through the tank
at a position 15 mm (0.59 in) from the bottom
end of the tank. At this time, wear eye pro-
tection to prevent eye damage from escaping
gas and/or metal chips.

2-3 mm
n (0.08-0.12 inl 15 mm
DRILL (0.59 in

. vl-
I
o/-'
\_, (o
I O/
-L

5-25
4. Turn over the rubber boot at the bottom. lnspection

1. Check the rod, and if it is bent or damag-

5. Remove the cotter pin, plain washer and
ed, replace the shock absorber.
holding pin. Then, disconnect the shock
2. Check for oil leakage. lf oil leakage is evi-
absorber from the swingarm.
dent, replace the shock absorber.
3. By moving the spring, check to see if it
has proper damping effect. Slight resis-
tance should be felt on the compression
{down) stroke and considerable resistance
should be felt on the return (up) stroke.

Reassembly
When installing the shock absorber, reverse the
removal procedure taking the following steps:
1. Fit the shock absorber to the frame.
Cotter pin 2. Plain washer 3. Holding pin

Take care that the shock absorber is in-

6. Carefully pull out the shock absorber from stalled with its WARNING label upward for
the f rame. a proper damping effect. lf not, damping
performance is lost as air enters piston
chamber-
 2. lnstall the shock absorber to the
swingarm.
lnsert a new cotter pin into the holding pin
and bend the end of the cotter pin.
3. lnstall the shock absorber top holding
bolt. Torque the bolt to specification.
Tightening torque:
25 Nm (2.5 m . kg, 18 ft. lb)
4. lnstall the swingarm mud guard and rub-
ber boot to the swingarm.
CABLES AND FITTINGS
Cable maintenance
NOTE:
See "Maintenance and Lubrication" intervals
charts. Cable maintenance is primarily concern-
ed with preventing deterioration and providing
proper lubrication to allow the cable to move
freely within its housing. Cable removal is
straightforward and uncomplicated. Removal
is not discussed within this section.
Cable routing is very important. For details
of cable routing, see the cable routing
diagrams at the end of this manual. lm-
properly routed or adjusted cables may
make the motorcycle unsafe for operation.
I. Remove the cable.
2. Check for free movement of the cable
within its housing. lf movement
obstructed, check for frayed strands or
kinking of the cable. lf damage is evident,
replace the cable.
3. To lubricated the cable, hold it in a ver
tical position. Apply lubricant to the up-
permost end of the cable. Leave it in the
vertical position until the lubricant appears
at the bottom. Allow any excess to drain,
and reinstall the cable.
NOTE:
Choice of a lubricant depends upon conditions
and preferences. However, a semidrying chain
and cable lubricant will perform adequately
under most conditions.
Th rottle maintenance
1 . Remove the phillips head screws from the
throttle housing assembly and separate
the two halves of housing.
2. Disconnect the cable end from the throt-
tle grip assemlby, and remove the grip
assembly.
3. Wash all parts in a mild solvent, and check
all contact surfaces for burrs or other
damage. (AIso clean and inspect the right-
hand end of the handlebar.)
4. Lubricate all contact surfaces with a light
coat of lithium-soap base grease and
reassemble.
NOTE:
Tighten the housing screws evenly to maintain
an even gap between the two halves.
5. Check for smooth throttle operation and
quick spring return. Make certain that the
housing does not rotate on the handlebar.
is
 CHAPTER 6. ELECTRICAL

AG200L CTRCUTT DTAGRAM ......6_1

CHARGING SYSTEM. .....6-2

Circuit diagram .........6-2
Troubleshooting ...... ..........6-3
Battery .........6-3
Charging output test ............6-4
Charging coil resistance test ,., .........0-4
rGNlTroN SYSTEM ... ....6-5
Circuit diagram .........6-E
Troubleshooting ...... ..........6-6
lgnition spark gap test .... ... ...6-6
Spark plug. .....6-7
Direct current resistance test.... ........6-7
Pick-up coil resistance test.. .. ....... ...6-7
Source coil resistance test ... ....... ....6-8
LTGHTTNG SYSTEM ...... 6_9
Gircuit diagram ........6-9
Troubleshooting ...... .. ... ....6-10
A.C. lighting circuit output test .. .. . . . .6-10
Lighting coil resistance test .. . . ,.......6-11
SIGNAL SYSTEM ........6-12
Circuit diagram ........6-12
Troubleshooting .,.,.. .. . ... ...6-13
Signal system tests and checks . .......6-13
Switches
 CHAPTER 6. ELECTRICAL
AG2OOL CIRCUIT DIAGRAM

FLASHER

"HORN" SWITCH

"NEUTRAL" INDICATOR LIGHT

I
BATTERY
RECTIFIER WITH NEUTRAL
REGULATOR swtrcH
REAR BRAKE SWITCH
swtTcH

,,LIGHTS" (DIMMER)
+ "ffiS'*"
swtTcH
"LIGHTS" SWITCH
lR4crt SW|TCH

c.D.t. MAGNETO
METER LIGHT
:
{*
SPARK

COLOR CODE
Br......,Brown
R .......Red L/B.....Blue/Black
R/Y.....Red/Yellow
Y/B . . .. .Yellow/Black
B.......Black BrlW....Brown/White
Y/G .... .Yellow/Green
Dg....--Dark Green
W/G ....White/Green
Ch......Chocolate Y/R .....Yellow/Red
Sb......SkyBlue W/R ....White/Red
L.......Blue L/R .....B|tre/Red
P.......Pink G/Y.....Green/Yellow
O.......Orange B/R.....Black/Red
G.......Green Gy.-....Gray
R/W ....Red/White B/Y.....Black/Yellow
L/W .... Blue/White

6-1
CHARGING SYSTEM
Circuit diagram

FLASHER
LIGHT (RIGHTI
"TURN"
FLASHER RELAY
"HORN" SWITCH SWITCH

MAIN SWITCH FLASHER LIGHT (LEFTI

,,NEUTRAL" INDICATOR LIGHT

RECTIFIER WITH NEUTRAL

REG ULATOR
SWITCH
REAR BRAKE sWITcH TAIL,/BRAKE

,,LIGHTS" SWITCH "LIGHTS" (DIMMER)

4 'r*; tR-_o/o-a swtTcH

o-G

C.D,I, MAGNETO
METER LIGHT
{*
SPARK PLUG

FUSE

6-2
t.
Troubleshooting
lf the charging system should become tn-
operative, the troubleshooting aids will be
useful.
Check entire charging system for connections (Re-
fer to "WlRlNG DIAGRAM" section).
Check battery for voltage and specific gravity (Refer
to "Battery" section).
Check fuse and fuse connections.
Check charging amperage and charging coil
resistance of C.D.l. magneto (Refer to "Charging
output test" and "Charging coil resistance,,
section).
Rectifier with regulator is faulty, replace it.
Battery
lf the battery shows the following defects, it
should be replaced:
i. The battery voltage will not rise to
specific value or no bubbles rise in any cell
even after many hours of charging.
2. Sulfation of one or more cells is indicated
by the plates turning white or an ac-
cumulation of material in the bottom of
the cell.
3. Specific gravity readings after a long, slow
charge indicate a cell to be lower than any
others.
4. Warpage or buckling of plates or insu-
lators is evident.
Battery electrolyte is poisonous and dan-
gerous, causing severe burns. etc. lt con-
tains sulf uric acid. Avoid contact with the
skin, eyes, or clothing.
Poor connection
Low voltage and low
specific gravity
lf other than specified
Antidote: EXTERNAL - Flush with water.
INTERNAL - Drink large quantities of
water or milk. Follow with milk of magne-
a sia, beaten eggs, or vegetable oil. Call
phsician im mediately.
Eyes: Flush with water for 15 minutes, and
get prompt medical attention. Batteries
produce explosive gases, Keep sparks,
flame, cigarettes, etc. away, Ventilate
when charging or using in an enclosed
space. Always shield your eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
This service life of a battery is usually two to
three years. Lack of care, as described below,
will shorten the life of the battery.
. Negligence in keeping battery topped off
with distilled water.
. Battery left discharged.
o Over-charging with heavy charge.
 Freezing.
Charging amperage:
Filling with tap water or sulfuric acid con-
Day:
taining impurities.
lmproper charging voltage or current on
.0A
1 or more 3,000 r/min
new battery. 3.0A or less 8,000 r/min
Night:
lf the motorcycle is not to be used for a long
1.5A or more 3,000 r/min
3.0A or less 8,000 r/ min
time, remove the battery and have it stored.
The following instructions should be observed:
1. Recharge the battery periodically.
2. Store the battery in a cool, dry place.
3. Recharge the battery before reinstallation-

Battery 6N4B-2A

Electrolyte Specilic g ravity: 1 .260

lnitial charging current 0.4amp for'10 hours
{new battery)

Recharging current '10 hours (or until

l. Battery positive lead 2. Fuse positive lead
specific gravity reaches
1 .260) 5. lf the indicated amperage cannot be
reached, then perform the next test.
Refill fluid Distilled water (to
maximum levelline)
Charging coil resistance test
Refill period Check once per month 1. Remove the side cover (Left).
(or more often, as 2. Disconnect the 4-pin connector from the
required) C.D.l. magneto.
Connect the pocket tester leads as
shown, and set the tester selector to
Charging output test "ohm x 1" position.
4. Check the resistance between terminals,
NOTE: lf resistance is out of specification, coil is
The battery must be fully charged when testing broken. Replace the stator assembly.
the charging output.
Charging coil resistance (White, Black):
1. Disconnect the positive lead from the
0.251O+10% at 20oC (68oF)
battery.
2. Connect the pocket tester leads as
shown, and set the tester selector to "DC
A x 5" position.
3. Start the engine.
4. Accelerate engine to specifications and
check the charging amperage.

CAUTIQT,TI:

Never disconnect the leads from the bat-

tery before stopping the engine.

6-4
IGNITION SYSTEM
Gircuit diagram

"HORN" SWITCH

FTJS E
"NEUTRAL" INDICATOR LIGHT

I
BATTEBY
= RECTIFIER WITH
REGULATOR NEUTRAL
swtTcH
TAIL/BRAKE

MAIN SWITCH

,,LIGHTS" SWITCH
"ENGINE
SWITCH lB--{o-L

IGNITION
co tL
C.D.I. MAGNETO
METER LIGHT
I-*
SPARK PLUG

MAIN SWITCH
Troubleshooting
lf the ignition system should become in-
operative (No spark or intermittent spark), the
troubleshooting aids will be useful.

Check spark gap using Electro tester (Refer to "lg-

nition spark gap test" section).

lf other than specified

Check entire ignition system for connections (Refer Poor connection

,,WIRING
tO DIAGRAM" SCCIiON).

Check spark plug condition (Refer to "Spark plug,, Poor condition

section).

Check resistance of ignition coil {Refer to "Direct lf other than specified

current resistance test" section).

Check pick-up and source coil resistance of C.D.l. lf other than specified
magneto (Refer to "Pick-up coil resistance test..
and "Source coil resistance test" section).

C.D.l. unit is faulity, replace it.

lgnition spark gap test 3. Start the engine, and increase the spark
'1. Disconnect the high tension cord from the gap until misfire occurs (Test at various
spark plug. revolution between 1,000 - 6,500 r/min).
2. Connect the Electro tester as shown.

Do not run the engine in neutral above

6,000 r/min for more than 1 o.2 seconds.

Minimum spark gap:

6 mm (0.24 in)

tl t)
Spark plug PRIMARY WINDING CHECK
The life of a spark plug and its discoloring vary
according to the habits of the rider. At each
periodic inspection, replace burned or fouled
plugs with new ones of the specified type. lt
is actually economical to install new plugs often
since it will tend to keep the engine in good
condition and prevent excessive fuel con- I

I
sumption. IGNITION
1. lnspection cotL
a. lnspect and clean at the specified inter-
vals and replace as required.
b. Clean the electrodes of carbon and adjust
the electrode gap to the specification.
2. lnstallation
Be sure to use the proper reach. type and
electrode gap plug(s) as a replacement to
avoid overheating, fouling or piston SECONDARY WINDING CHECK
damage.

Type: DSEA (NGK)

Electrode gap:
0.6 - 0.7 mm (0.024 - 0.028 in)
Tightening torque:
18 Nm (1.8 m. kg, 12.5 ft. Ib) I
IGNITION
cotL

Direct current resistance test

1. Remove the fuel tank.
l_
2. Disconnect the ignition coil leads fiom the
wire harness and spark plug.
3. Connect the pocket tester as shown, and
set the tester selector to "ohm x 1 " (For
primary winding resistance check) or
Pick-up coil resistance test
"ohm x 100" (For secondary winding coil
resistance check) position.
1. Remove the side cover (Left).
4. Check the resistance between terminals.
2. Disconnect the 2-pin connector from the
C.D.l. magneto.
lf resistance are out of specifications, coil
is broken. Replace the ignition coil.
3. Connect the pocket tester as shown, and
set the tester selector to "ohmx100"
position.
Primary winding resistance: 4. Check the resistance between terminals.
1 .60 + 10olo at 20oC (680F)
lf resistance is out of specification, coil is
Secondary winding resistance: broken. Replace the pick-up coil as-
6.6kO *20olo at 20oC (68oF)
sembly.

Pick-up coil resistance:

265Q +10o/o at 20oC (68oF)
1. White 2. Green

Source coil resistance test

1. Remove the side cover (Left).
2. Disconnect the two leads from the C.D.l.
magneto.
3. Connect the pocket tester as shown, and
set the tester selector to "ohmx100"
position.
4. Check the resistance between terminals.
lf resistance is out of specification, coil is
broken. Replace the stator assembly.

Source coil resistance:

4159 +10o/o at 20oC (68oF)

t\#l-t

6-8
LIGHTING SYSTEM
Circuit diagram

FLASHER
LIGHT (RIGHT)
.,-nsxen n:Lnv if"!||"
"HORN" SWITCH

FUSE MAIN SWITCH FLASHER LIGHT { LEFT) -

"NEUTRAL" INDICATOR LIGHT

RECTIFIEB WITH --@-sr*r-o-e-

NFTITFAI +
REGULATOR swtTcH
REAR BRAKE SWITCH T'AIL/BRAKE

MAIN SWITCH

,,LIGHTS" SWITCH ,,LIGHTS" (DIMMER)

"ENGINE STOP'' tR--{o-L SWITCH
swtrcH - /6i\ HEADLIGHT
-o---9'-\-rr'rn
ecr'g
"^tf
_r__v ou_s_
_.1-
METER LIGHT =
C.D.I. UNIT
{*
SPARK PLUG

RECTIFIER WITH
LATOR

MAGNETO

6-9
Troubleshooting
lf the lighting system should become in-
operative, the troubleshooting aids will be
useful.

Check bulb conditions of headlight, meter light and Poor condition

raillisht- Replace bulb(s)

Check entire lighting system for connection (Refer Poor connection

tO ,,WIRING DIAGRAM" SECIION}.

Check voltage of A.C. lighting circuit (Refer to

"A.C. lighting circuit output test" section).

lf other than specified

Check lighting coil resistance of C.D.l. magneto lf other than specified

(Refer to "Lighting coil resistance test" seciion).

Rectifier with regulator is faulty, replace it.

A.C. lighting circuit output test

1. Remove the headlight lens unit.
2. Disconnect the headl;ght lens unit lead
from the wire harness.
3. Connect the pocket tester as shown, and
set the tester selector to "AC 2OV"
position.
4. Start the engine.
5. Accelerate the engine to specifications
and check the output voltage.
23 4 5 6 7 A
Engine speed ( x 1Or r/min)

Do not run the engine in neutral above

6,000 r/min for more than 1 or 2 seconds.

Lighting voltage:
6.5V or more at 2,500 r/min
8.0V or less at 8,000 r/min

6-10
6. lf the indicated voltage cannot be reach-
ed, then perform the next test.

Lighting coil resista nce test

1. Remove the side cover lLeft).
2. Disconnect the 4-pin connector from the
C.D.l. magneto.
5. Connect the pocket tester leads as
shown, and set the tester selector to
"ohm x 1" position.
4. Check the resistance between terminals.
lf resistance is out of specification, coil is
broken. Replace the stator assembly.

Lighting coil resistance:

0.165Q+10% at 20oC (680 F )

- --lEr.l
O- r=,

(.1)-l+ l-ll

611
SIGNAL SYSTEM
Circuit diagram

FLAS H ER
LIGHT (RIGHT)
,,HORN swtTcH

MAIN SWITCH FLASHER LIGHT {LEFT}

"NEUTRAL" INDICATOR LIGHT
BATTERY

I RECTIFIER WITH
REGULATOR
BRAKE SWITCH
NEUTRAL
SWITCH
TAIL/BRAKE

MAIN SWITCH

,,LIGHTS" SWITCH
"ENGINE STOP" \tF-_o/o-L
swtTcH

IGNITION
co rL MAGNETO

{*
SPARK PLUG

MAIN
,,NEtJTRAL" IND TOR LIGHT swtrcH
,,HORN" SWITCH
,,TURN" SWITCH
FLASHEB LI

FLASHEB LIGHT

NEUTRAL
SWITCH BRAKE LIGHT

BATTERY

REAR ARAKE SWITCH

6-12
Troubleshooting
lf the signal system should become inoperative,
the troublesooting aids will be useful.

Poor condition
Check bulb conditions of flasher Iights,
"NEUTRAL" indicator light and brake light.

Low voltage and low

Check battery for voltage and specific gravity {Refer
specific gravity
to "Battery" section).

Poor connection
Check entire signal system for connections (Refer
tO
,,WIRING DIAGRAM" SECIiON).

Check fuse and fuse connections.

Check condition of each circuit for signal system Poor condition

(Refer to "Signal system tests and checks" and Replace poor condition
"Switches" section). electrical component(s)

Signal system tests and checks

NOTE:
The battery provides power for operation of the
horn, flasher lights, indicator light and brake
light. lf none of the above operates, always
check the battery voltage before proceeding
further. Low battery voitage indicates either a
faulty battery, low battery electrolyte, or a
defective charging system. See "CHARG-
ING SYSTEM" foT checks of the battery and
charging system. Also, check the fuse condi-
tion. Replace the fuse if necessary.
1. Horn does not work
Check for voltage (6V) on "Br" lead at horn No voltage Wiring circuit from fuse to
terminal. horn terminal is faulty,
repair

"P" No voltage
Check for voltage (6V) on Iead at "HORN"
Horn is faulty, replace
swilch connector.

No continuity
Check for continuity of "HORN" switch.

Continuity

Adjust horn, replace it damage.

2. Brake light does not work

Check for voltage (6V) on "Br" Wiring circuit from fuse to

lead at rear brake
switch connector. brake switch connector is
faulty, repair

Rear brake switch is faulty

Check for voltage {6V) on "G/Y" lead at rear brake
switch connector while applying brake. or maladjustment, replace or
adjust

Brake light bulb socket is faulty, replace it.

3. Flasher lights (Left and/or right) do not

work
Check for voltage (6V) on "Br" lead at flasher relay
Wiring circuit from fuse to
terminal. flasher relay terminal is
faulty, repair

Check for voltage {6V) on "BrlW" Iead at flasher

Flasher relay is faulty, replace
relay terminal.

"BrlW" "TURN" Wiring circuit from flasher

Check for voltage (6V) on lead at
relay to "TURN" switch is
switch connector. faulty, repair

Check for voltage (6V) on "Ch" and/or "Dg" lead

at "TURN " switch connector.

Flasher light bulb socket is faulty, replace it

6-14
 4. Neutral indicator light does not work
Wiring circuit from fuse to
Check for voltage (6V) on "Br" lead at indicator indicator light connector is
light connector. faulty, repair

Check for voltage (6V) on "Sb" lead at neutral

switch connector.

Check for continuity of neutral switch.

Switches 5. "TURN" switch

Switches may be checked for continuity with
a pocket tester on the "ohm x 1" position. Switch Lead color
1 . Main switch position Dg Br/W ch

Switch Lead color R ---o

position B B/W R Br N

OFF o_ -o L o_ -----o
ON o- ----o
6. "HORN" switch
2. "ENGINE STOP" switch Lead color
Switch
Lead color position P B
Switch
position B/W B OFF

RI.JN ON -o
OFF o

3. "LIGHTS" switch

Switch Lead color

position Y L

HI o_ o
LO o- ---o

4. "LIGHTS" (Dimmer) switch

Switch Lead color

position Y/R L

OFF

ON o o

A-16
 CHAPTER 7. APPENDICES

SPEC|F|CATTONS..... .....7_1
r. GENERAL SPEC|F|CAT|ONS..... ........7-1
II.MAINTENANCE SPECIFICATIONS. ......7-3
A. ENGINE .. ..7-3
.
B. CHASSIS ......... ..7-10
c. ELECTR|CAL....... ...... .. .7-13
GENERAL TOROUE SPECIFICATIONS .... .,....,.7-15
DEFtNtTtON OF UNTTS ....... ....7-15

EXPLODED DIAGRAMS ....,... ,.7-16

VALVE/CAMSHAFT/ROCKER ARM SHAFT ...,.....7-16
CYLTNDER HEAD . . ....... .. ....7-17
CYL|NDER/P|STON ..... ..........7-18
CRANKSHAFT/BALANCER GEAR.. ......7-19
TRANSMTSSTON .......7_m
CLUTCH .......7-21
STARTER .......7-2.
CARBURETOR ...........7-23
FRONT WHEEL ........ ..7-24
REAR WHEEL ...........7-Ui
FRONT FORK ..........7-26
STEER|NG HEAO . . .... ..7-27
SW|NGARM . . . . . . . . . . . .7_28
REAR SHOCK ABSORBER ......7_29
ELECTRTCAL. . . . . . . . . . , . .7-30

LUBRICATION DIAGRAMS ,...,..7-31

CABLE ROUTING..,. ,..,7.33

AG2OOL WIRING DIAGRAM ......7-36

 CHAPTER 7. APPENDICES
SPECIFICATIONS
I. GENERAL SPECIFICATIONS
1 Model Code Number 36X

2. Frame Starting Number 36X-000101

3. Engine Starting Number 36X-000101

4. Dimensions:
a Overall Length 2.135 mm (&1.05 in)
b Overall Width 930 mm (36.6 in)
c Overall Height 1,110mm {43.7 in)
d Seat Height 820 mm (32.3 in)
Wheelbase 1,345mm (53.0 in)
f. Minimum Ground Clearance 245mm ( 9.7 in)
5. Weight:
a. With Oil and Full Fuel Tank 121 ks (267lb)

6. Minimum Turning Radius 1,985 mm (78.2 in)

7. Engine:
Engine Type Air-cooled, 4-stroke, gasoline, SOHC
b Cylinder Arrangement Forward-incline, Single cylinder
c Displacement '196 cm3 (11.96 cu.in )
d Bore x Stroke 67.0 x 55.7 mm (2.638 x 2.193 in)
Compression Ratio 9-5 : 1
t. Compression Pressure 785 -
1,030 kPa (8.0 10.5 kg/cm,,
-
1 14 - 149 psi)
s Starting System Kick starter
d. Lubrication System Pressure lubricated, Wet sump

9. Engine Oil Type Grade SAE 20W40 type SE motor oil

10. Engine Oil Capacity:

a Periodic Oil Change 1.0 L (0.90 lmp qt, 1 .06 US qt)
b Oil Filter Replacement 1.1 L (0.97 lmpqt, 1.16 US qt)
c Total Amount 1.3 L (1- 14lmp qt, 1.37 US qt)
11 Air Filter Wet type element
't2. Fuel:
a Type Regular gasoline
b Tank Capacity 10.0 L (2.20 lmp qt, 2.64 US gal)
Reserve Amount 2.0 L (0.114 lmp gal. 0.53 US gal)
13. Carburetor:
a. Type 8526 X 1
b. Manufacturer MIKUN I

14. Spark Plug:

a. Tvpe D8EA or X24ES-U
b. Manufacturer NGK or N.D.
c. Gap 0.6 - 0.7 mm (0.024 - 0.028 in)
15. Clutch Type: Wet, multiple-disc
'16. Transmission:
a. Primary Reduction System Spar gear
b. Primary Reduction Batio 74/20 13.700t
7-1
 c Secondary Reduction System Chain drive
d Secondary Reduction Ratio v/14i.3357)
e Transmission Type Constant mesh, S-speed drum shifter
t. Operation Left foot operation
s Gear Ratio 1st 35/ 11 (3.181)
2nd 31/15 (2.066)
3rd 30/21 11 .4281
4th 25/26 t0.961t
5th 22/31 l0.70€l
Chassis:
a Frame Type Tubular steel diamond
b Caster Angle 27025',
Trail 100 mm (3.94 in)

18. Tire:
Tire Type \Mth tube
b Tire Size (F) 3.00-19-4PR
c Tire Size (R) 4.10-l&4PR
d lvlanufacturer INOUE

19. Tire Pressure: (Cold pressure)

a. Front 118 kPa {1.2 kg/cm'?, l8psi)
b. Rear 147 kPa (1.5 kg/cm', 22 psi)
20. Brake:
a Front Brake Type Drum brake
b Operation Right hand
c Rear Brake Type Drum brake
d Operation Bight foot
21. Suspension:
a, Front Suspension Telescopic fork
b. Rear Suspension Swingarm {Monocross suspension)
22. Shock Absorber:
a. Front Shock Absorber Oil damper, coil spring
b. Rear Shock Absorber Oil damper, gas and coil spring

x. Wheel Travel:
a. Front Wheel Travel 200mm (7.9 in)
b. Rear Wheel Travel 165mm (6.5 in)
24. Electrical:
a lgnition System C.D.l. ignition
b Generator System Flywheel magneto
c Battery Type or Model 6N4B-2A
d Battery Capacity 6V 4AH

25. Headlight Type Bulb Type

zo. Bulb Wattage x Pcs.
Headlight 25W/25Wx1
b Turn light 8Wx4
c Tail/ Brake light 5.3W17Wx 1

d Meter light 3Wx1

27. lndicator Light Wattage x Pcs:
a. NEUTRAL 3WX 1

7-2
II, MAINTENANCE SPECIFICATIONS
A. ENGINE
1. Cylinder Head:
a, Volume 23.3 - 23.9 cm3 (1.42 - 1.46cu.in)
b. Warp Limit (0.03 mm {0.0012 in)>
* Lines indicate straightedge measurement.

2. Cylinder:
a. Material Aluminium alloy with pressed-in sleeve
b. Bore Size 66.97 - 67.02 mm (2.637 - 2.639 in)
c. Taper Limit (0.05 mm {0.0020 in)>
d. Out-of-round Limit (0.01 mm (0.0004 in)>

3. Camshaft:
a. Drive lvlethod Chain drive (Left)
+8.021mm (0.994 *&@in)
b. Cam Cap lnside Diameter 25
Camshaft Outside Diameter 25 -8'8ffmm (0.984 8:min)
d. Shaft-to-cap Clearance 0.020 - 0.061 mm (0.0008 - 0.0024 in )

Cam Dimensions
lntake 36.54 - 36.64 mm {1.439 - 1.4213 in)
"B" 30.15 - 30.25mm (1.187 - 1.191 in)
"c" 6.59 mm (0.259 in)
Exhaust 36.58 36.68 mm (1 .440 - 1.444 in)
-
"8" 30.27 - 30.37 mm (1 .192 - 1.196 in)
"c" 6.63 mm {0.261 in)

f. Valve Timing
T, D. C.
..---'l----r
lN. Open B.T.D.C.260
Close A.8.C.D.600
EX. Open 8.8.D.C.70.
Close A.T.D.C.240
Overlap a=50o

s Camshaft Runout Limit 0.03 mm (0.0012 in)

h Cam Chain Type/ Number of Links DtD25SH / 104
i. Cam Chain Adjustment Method Automatic
4. Rocker Arm, Rocker Arm Shaft:
n8 o18mm *8@7
a Bearing lnside Diameter 12 10.4724 inl
b Shaft Outside Diameter 12 :88?3mm (0.4724 :8mtin)
c Arm to Shaft Clearance 0.009 - 0.037 mm (0.0004 - 0.0016 in)

5. Valve, Valve Seat, Valve Guide:

Valve Clearance (Cold) lN, 0.10 - 0.14mm (0.0039 - 0.0055 in)
EX. 0.16 - 0.20 mm (0.0063 - 0.0079 in )
 Face Width Seat Width Margin Thickness

"A" Head Dia. tN. 34.0 + 0.1 mm (1.339 t 0.004in)

EX. 28.5 + 0.1 mm (1.122 + 0.004 in)
"8" Face Width tN. 2.26 mm t0.089 in)
EX. 2.26 mm (0.089 in)
"C" Seat Limit Width tN. 110.1mm (0.039 -r 0.004 in)
EX, 1a0.1mm {0.039 + 0.004 in)
"D" Margin Thickness Limit tN. 1 .0 t 0.2 mm (0.039 -r 0.008 in )

EX. 1 .0 r 0.2 mm (0.039 -r 0.008 in )

c Stem Outside Diameter IN. 6 83lgmm {0.2362lSmin)

EX. 6:88ffmm {0.2362 :8'88l8in )

d Guide lnside Diameter tN. 6

+oo12mm (0.2362 *3@5in)
*gorzrnrn *3@sin)
EX, 6 {0.2362
e Stem-to-guide Clerance
tN. 0.010 0.037 mm (0.0004 - 0.0015 in)
-
EX 0.025 - 0.052 mm (0.0010-0.0020 in)
f. Stem Runout Limit (0.03 mm (0.0012 in)>

g Valve Seat Width Standard 0.9 - 1.1 mm (0.035 - 0.0213 in)

<Limit> (2.0 mm (0.080 in)>

6. Valve Spring:
a Free Length
lnner Spring lN. 35.5 mm (1.398 in )

EX. 35.5 mm (1.398 in)

Outer Spring lN. 37.2 mm (1.465 in)
EX. 37.2 mm (1.465 in)
b Spring rate
lnner Spring lN. K, : 2.429 kglmm {136|b/in}
EX. K, : 2.429 kglmm (136|b/in)
Outer Spring lN. K, : 4.726 kg/mm (2651b/in)
EX. K, : 4.726 kg/mm {2651b/in)
c Compression Length (Valve Closed)
Inner Spring lN. 30.5 mm ('1.201 in)
EX. 30.5 mm {1.201 in)
Outer Spring lN. 32.0 mm (1.260 in)
. EX. 32.0 mm {1.260 in)
d Compression Force (Valve Closed)
lnner Spring lN. 8.4 - 10.2 kg {18.s - 22.5|b)
EX. 8.4 - 10.2 ks (18.5 - 22.5|b)
Outer Spring lN. '16.6
- 20.4 ks (36.6 - 45.01b)
EX. 16.6 - 20.4 ks (36.6 - 45.0|b)

7-4
 Tilt Limit
lnner Spring 2.5o/ 1.5 mm (0.059 in)
Outer Spring 2.50/ 1.6 mm (0.063 in)

T, Direction of Winding (Top view) lntake Exha ust

7. Piston:
a Piston Size/ Measuring Point (A) 67.0 mm (2.638 in )/7.5 mm {0.295 in}
{From bottom line of piston skirt)

I
(A)
-f-
b Clearance between Piston I Cylinder 0.025 - 0.045 mm {0.0010 - 0.0018 in )

Limit (0.1 mm (0.0039 in)>

c Oversize 1st
2nd 67.50 mm (2.657 in)
3rd
4th 68.00 mm 12.677 inl
d Piston Pin Hole Off-Set 0.5 mm (0.02 in) lnside

Piston Ring:
a Sectional Sketch
r-r- Top Ring B 1.2 8:8jmm (0.0472 :88fllin)

%1"
--
T 2.7 I 0.1 mm (0.106 + 0.004 in)

r-r
%f"
f-r---t
2nd Ring B
T
1.2 83:mm (0.0472
2.7 a 0.1 mm (0.106 + 0.004 in)
8 8811in )

N-tl
tK<<{
Oil Ring B
T
2.5 mm (0.098 in)
t
2.8 0.15 mm (0.1 10 + 0.0059 in )

b End Gap (lnstalled) Top Ring 0.15 - 0.35 mm (0.0059 - 0.0138 in)
Limit (1.0 mm (0.039 in)>
2nd Ring 0.15 - 0.35 mm (0.0059-0.0138in)
(1.0 mm (0.039 in)>
Oil Ring 0.3 - 0.9 mm (0.012 - 0.035 in)
(1.5 mm (0.059 in)>
c Side Clearance Top Fing 0.03 - 0.07 mm {0.0012 - 0.0028 in)
Lim it (0.15 mm (0.059 in)>
2nd Ring 0.02 - 0.06 mm (0.0008 - 0.0024 in)
(0.15mm (0.059 in)>
d Plating or Coating Top Ring Chrome plated, Ferox coating
2nd Ring Parkerrizing
Oil Ring Chrome plated, Parkerrizin g
 q Crankshaft:
a. Crank Width "A" A = 56,3obmm 12.2't1 -8 azinl
b. Runout Limit "B" <0.03 mm (0.0012 in)>
c. Big End Side Clearance "D" 0.35 - 0.65 mm (0.014 - 0.026 in)
d. Small End F,ee Play " C" 0.8 - 'l .0 mm (0.03 - 0.04 in)

10. Ballancer:
a. Ballancer Drive Method Gear

11. Clutch:
a Friction Plate Thickness/ Quantity 3.0 t 0.1 mm {0.12-r0.004in)i 5
b Wear Limit (2.8 mm (0.11 in)>
c Clutch Plate Thickness/ Ouantity 1.6 i 0.1 mm (0.063-r 0.004in)/4
d Warp Limit (0.05mm {0.002 in))
Clutch Spring Free Length/ Ouantity 37 .3 mm 11 .47 inl /4
f. Minimum Length 22.4 mm (0.88 in)
s Primary Reduction Gear Backlash 0.009 - 0.073 mm (0.0004 - 0.0030 in)
Tolerance
h Clutch Release Method lnner push, Cam push
12. Transmission:
a. Main Axle Run-out Limit (0.08 mm (0.0031 in))
Shifter:
a. Shifter Type Cam drum and guide bar
b. Shift Fork Thickness/ Limit 4.89 mm (0.187
4.76 - - 0.193 in )/
(4.70mm (0.185 in))
14. Kick Starter:
a. Kick Starter Type Kick 6 Mesh type
b. Kick Clip Friction Force "P"
P Minimum 0.65 ks (1 .€ lb)
Maximum 1 .05 kg (2.321b)

15. Decompression Device

a. Type Kick synchronous
b. Cable Free Play 2-3mm (0.08 - 0.12 in )

16. Air Filter:

a. Air Filter Oil Grade SAE 10W30 type SE motor oil
17. Carburetor:
Type/ Manufacturer/ Quantity 8526/ MtKUNT/ 1

b l.D. Mark 36X 00

c MainJet {M.J.) #120
d Main AirJet (l/l.A.J. ) o1.6
e Jet Needle {J.N.} JZ2.5t5
f. Needle Jet {N.J. ) 393 P2
s Throttle Valve (Th.V.) #120
7-6
 h. PilotJet (P.J.) #35
i. jet
Pilot Air {P.A.J.) #125
i. Pilot Outlet Size (P.O.) a0.8
k. StarterJet {G.S.) #30
t. Fuel Level (F. L. ) 4.5+1 mm (0.18+0.04 in)
m. Float Height (F. H. ) 30t 1mm (1.18-+ 0.04 in)
n. Engine ldling Speed 1,250 t 50 r/min
o. Vacuum Pressure at ldling Speed 180 - 200 mmHg (7.08 - 7.87 inHs)

18. Lubrication System:

a Oil Filter Type Wre mesh
b Oil Pump Type Trochoid pump
Tip Clearance 0.15mm (0.0059 in )
d Side Clearance 0.03 0.09 mm (0.0012 - 0.0035 in)
-
e Bypath Valve Setting Pressure 98 t 20 kPa
(1 .0 t
0.2 kg/cm'z, 14.2r2.8psil
f. Lubrication Diagram Refer to page 7-31
'19. Crankcase Tightening Sequence

LEFT SIDE RIGHT SIDE

20. lTightening Torque

Thread Tightening torque

Part to be tightened Part name O'ty Remarks
size Nm m'k9 ft.lb
ENGINE:

Cylinder head Flange bolt M8 4 22 2.2 16 Apply oil

Bolt M8 2 20 2.0 14

Cylinder head cover Panhead screw M6 2 7 o.7 5.1

Bolt M6 5 10 1.0 7.2

Camshaft bearing plate Bolt M6 2 8 0.8 5.8 use lock washer
Spark plug M12 18 1.8 '12.5

Cylinder body Bolt M6 2 10 1.0 7.2

Balancer weight gear Nut M14 50 5.0 36 Use lock washer

Flywheel magneto Bolt M10 50 5.0 36

Valve clearance adjusting nut Nut M6 2 't4 't.4 10

Cam sprocket Bolt _M10 60 6.0 4il

Cam chain tensioner Bolt M6 10 1.0 7.2 Use lock washer

Cam chain tensioner cap Bolt M6 7 0.7 5.1 Use lock washer

Stopper guide Bolt M6, 2 8 0.8 5.8

Oil pump assembly Flathead screw M6 3 7 0.7 5.1

Drain plug Plug M35 43 4.3 31

Oil filter cover Panhead screw M6 2 7 0.7 5.1

Bolt M6 1 10 1.0 7.2

Carburetor ioint Bolt M6 2 12 1.2 8.7
Carburetor Hose clamp M5 1 2 0.2 1.4

Muffler Flange bolt M8 2 27 2.7 19

Exhaust pipe Bolt M6 2 10 1.0 7.2

Exhaust pipe protector Screw M6 2 7 o.7 5.1 Use LOCTITE

Exhaust pipe and muffler Bolt M8 1 20 2.0 14

Outlet pipe Screw M6 1 10 1.0 7.2

Crankcase Panhead screw M6 12 7 0.7 5.1

Crankcase cover Panhead screw M6 21 7 0.7 5.1

7-8
 Thread Tightening torque
Part to be tightened Part name O'ty Remarks
size Nm m'kg ft.lb
Kick crank boss Bolt M8 20 2.0 't4

Decompression shaft Nut M6 8 0.8 5.8 Use lock washer

Kick crank Screw M6 7 0.7 5.1 Use lock washer

Primary drive gear Nut M14 50 5.0 36 Use lock washer

Clutch spring Screw M5 4 6 0.6 4.3

Clutch boss Nut M14 50 5.0 36 Use lock washer
Push lever assembly Screw M8 12 1.2 8.7
Nut M6 1 8 0.8 5.8
Drive sprocket Bolt M6 2 10 1.0 7.2
Change pedal Bolt M6 1 10 1.0 7.2
B. CHASSIS

1. Steering System:
a Steering Bearing Type Ball Bearing
b No./ Size of Steel Balls Upper 22/3/16in
Lower 19/11 4in
c Lock-to-lock Angle 480

2. Front Suspension:
a Front Fork Travel 200 mm (7.87 in)
b Fork Spring Free Length 403.5 mm (15.9 in)
c Collar Length 170 mm (6.69 in)
d Spring Rate/ Stroke K, 5.0 N/mm (0.5 kg/mm, 28.01b/in)/
-
0 145 mm {0 - 5.71 in)
K, 6.5 N/mm (0.65 kg/mm,36.41blin)/
145 - 215 mm (5.71 - 8.46 in)
e Optional Spring No
f. Oil Capacity 294 4 cm3 !
or Oil Level t
(10.4 0.14lmp o2,9.9410.14 Us oz)
'l 17 mm (4.61 in)

{From top of inner tube fully compressed

without spring.)
s Oil Grade SAE 10W30type SE motor oil or equivalent
Rear Suspension:
a Shock Absorber Travel 82 mm (3.23 in )
b Spring Free Length 279 mm (10.98 in )
c Spring Rate/Stroke K, 45.2 N/mm 14.52 kg/ mm, 253.211: /inl /
0 - 56 mm lQ -?.20inl
K, 72.2 N/ nm 17 .22 kg I mm, 404.4 lb I inl /
56 - 106 mm 12.20 - 4.17 in)
d Optional Spring No.
e Enclosed Gas Pressure 150 kPa (15 kgi cm'?, 213 psi)

4. Rear Arm:
a. Swingarm Free Play Limit
1 mm {0.04 in )
- End
- Side 0.3 mm (0.012 in)
Wheel:
a Front Wheel Type Spoke wheel
Rear Wheel Type Spoke wheel
b Front Rim Size/Material 19x1.60/Steel
Rear Rim Size/ Material 18x1.85/Steel
c Rim Runout Limit Vertical (2.0 mm (0.08 in)>
-
- Lateral (2.0 mm {0.08 in))
6. Drive Chain:
a Type/ Man ufacturer DID428DS/ DAIDO
b No. of Links 121 + Joint
c Chain Free Play 30-45mm (1.2- 1.8in)

7-10
7. Drum Brake
a. Type Front Leading and trailing
Rear Leading and trailing
b. Brake Drum lnside Diameter/ Limit
Front 110mm (4.33in1/(111mm (4.37 in ))
Rear 130 mm (5.12in)/(131 mm (5.16in))
Lining Thickness/ Limit Front 4mm (0.16 in)/(2 mm (0.08in))
Rear 4mm (0.16 in)/(2 mm (0.08in))
d. Shoe Spring Free Length Front 54mm (2.13 in)
Rear 36.5 mm (1.lKin)

8. Brake Lever I Brake Pedal:

Brake Lever Free Play 10 - 20 mm (0.4 - 0.8 in)
b. Brake Pedal Free Play 20 - 30 mm (0.8 - 1.2in)
c. Brake Pedal Position 10 mm (0.4 in)
(Vertical height below footrest top.)

9. Clutch Lever Free Play 7 - 10 mm 10.28 - 0.40 in)

7-11
10. lTightening Torque
Tightening torque
Part to be tightened Thread size Remarks
Nm mkg fttb
CHASSIS:

Front wheel axle and nut M10 x 1.25 39 3.9 28

Handle crown and inner tube M10 x 1.25 u 3.4 24
Handle crown and steering shaft M't4x't.25 55 5.5 N
Steering shaft and ring nut M25x 1.0 38 3.8 27
Handle crown and upper handlebar holder lVlS x 1 .25 20 2.0 14

Under bracket and inner tube M8 x1.25 23 2.3 17

Front fork cylinder and inner tube 23 2.3 17

Engine and engine stay {front} M8 x 1.25 JJ 1e 24

Frame and engine stay (front) M8 x1.25 55 24
.>.> .>
Engine and engine stay {top) M8 x1.25 ', 24
Frame and engine stay {top) M8 x 1.25 11 24
Engine and frame (rear under) MB x 1.25 33 aa 24
Pivot shaft and nut M12\ 1 .25 80 8.0 58
Rear wheel axle and nut M14x 1.5 80 8.0 58

Sprocket axle and nut M20x 1.0 80 8.0 58

Camshaft lever and camshaft M6 x 1.0 9 0.9 6.5

Sprocket wheel and clutch hub M8 x1.25 30 3.0 22
Tension bar and brake shoe plate M8 x 1.25 20 2.0 't4

Tension bar and rear arm M8 x 'l .25 20 2.0 14

Footrest (Left) and frame M12\ 1 .25 60 6.0 43

Footrest (Right) and frame M10 x 1.25 45 4.5
Rear shock absorber and frame M10 x 1.25 2.5 18
.>.>
Clutch hub and stud bolt M8 x1.25 24

7-12
C. ELECTRICAL

1 Voltage 6V
2. lgnition System:
a- lgnition Timing ( B.T.D.C. ) 90/ 1,300 r/min
b. Advanced Timing ( B.T. D.C.) 29ol6,000 ri min

q
a
I
.E
E
tr
.9

Engine St )eed ( x 103 r/min)

Advancer Type Electricaltype

3. c. D. t.:
a Magneto- Model/ Manufacturer F36X/ YAMAHA
Pick up Coil Resistance (Color) 265 Q + 1Qo/o at 20oC (68oF) (W
b
- c)
c Source Coil Resistance (Color) 415Q + 10o/o at20oC(68oF) (R
- Br)
d C. D.l. Unit-Model/ Manufacturer 12V-MOi YAMAHA
4. lgnition Coil:
a Model/ Manufacturer C2T4lYAIVIAHA
b Minimum Spark Gap 6 mm {0.24 in) or more at 500 r/min
(17 KV/300 r/min at 6V, 17 KVi
6,500 r/min at 14V)
c Primary Winding Resistance 1.6 Q + 107o at 20oC (680F)
d Secondary Windin g Resistance 6.6 KQ-t- 20olo at 20oC (680F)

5. Charging System
a Tvpe Flywheel magneto
b Model/ Manufacturer F36X/ YAMAHA
c Charging Current Day 1.0A or more 3,000 r/min
3.0A or less 8,000 r/min
Nisht 1.5A or more 3,000 r/min
3,0A or less 8,000 r/min

gt l

Q
1. Lighting voltage
O= 2. Charging current Day
'./ a3) 3. Charging currnt Night
-
34567
Engine Speed { x 10' r/min)

d Charging Coil Resistance (Color) 0.251 Q + 10olo ar 20oC {680F) {W B)

Lighting Voltage more 2,500 r/min
l6.5Vor
8.0V or less 8,000 r/min
|
f. Lighting Coil Resistance (Color) | 0.165 A r
10olo at20oC(680F) (y
- B)
 b. Voltage Regulator:
a Type Semi conductor type
b Model/ Manufacturer SU229Y/ STANLEY
c No Load Regulated Voltage 7.0 -7.7V

7. Rectifier:
a Model/ Manufacturer SU229Y/ STANLEY
b Capacity 4A
Wthstand Voltage 7V
8. Battery:
a. Capacity 6V 4AH
b. Specific Gravity 1 ,260
o Horn:
a Type/ Ouantity Plain type/ 1

b Model/ Man ufacturer M F-6/ NIKKO

c Maximum-Amperage 1.5A

10. Flasher Relay:

a Tvpe Condenser type
b Model/ Man ufacturer FZ6165Di NIPPONSENSO
c Self Cancelling Device No
d Flasher Frequency 85 t 10 cycle/min
e Wattage 8WX2
11. Circuit Breaker:
a- Type Fuse
b. Amperage for lndividual Circuit
Main 10A/ 1

Reserve 1oAi 1

7-14
GENERAL TOROUE SPECIFICATIONS Generaltorque
This chart specifies torque for standard B specifications
fasteners with standard l.S.O. pitch threads. (Nut) (Bolt)
Nm mkg ft lb
Torque specifications for special components
or assemblies are included in the applicable 10 mm 6mm 6 o.6 4.3
sections of this book. To avoid warpage, 12 mm 8mm t5 r.5 11

tighten multi-fastener assemblies in a 14 mm l0 mm 30 J-U

crisscross fashion, in progressive stages, until
mm mm
f ull torque is reached. Unless otherwise
17 12 55 40

specified, torque specifications call for clean, 19 mm 14 mm 85 8.5 61

dry threads. Components should be at room 22mm '16 mm 130 13.0 94

temperature.

Distance across flats

B, Outside thread diameter

DEFINITION OF UNITS

Unit Read Definition Measure

mm millimeter 10-' meter Length
cm centimeter 10-r meter Length
kg kilogram 10r gram Weight
N Newton 1 kg x 67"""' Force
Nm Newton meter N xm Torque
mkg Meter kilogram mxkg Torque
Pa Pascal N/m l Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter Volume
cm' Cubic centimeter or Capacity
r/ min Botation per minute Engine Speed

7
EXPLODED DIAGRAMS
VALVE/CAMSHAFT/ROCKER ARM SHAFT

1. lntake rocker arm 11. Exhaust rocker arm shait

2. lntake rocker arm sha{t 12. O+ing
3. Vaive retainers 13. Exhaust valvo
4. Valve spring retainer 14. Camshaft
5. Valve stem seal 15. Dowel pin
6. Valve spring (inner) 16. Collar
7. Valve spring (outer) 17. Decompression cam
8. Valve spring seat 18. Torsion spring
9. lntake valve 19. Plain washer
'10. Exhaust rocker arm 20. Oil seal

7-16
CYLINDER HEAD

22 Nm 12.2 m .kg, 16 ft . lb)

20 Nm (2.0 m . kc, 14 tt. lb)

o
H
EI
g

1. Cylinder head cover (intake) 7. Cylinder head side cover

2. O-ring 8. Dowel pin
3. Circlip 9. O-ring
4. Valve quide 10. Cylinder head gasket
5. Camshaft retaining plate 1l. Decompression cable
6. Lock washer 12. Cylinder head cover (exhaust)

7-'17
CYLINDEB/PISTON

10 Nm {1.0 m'kc, 7.2 fr.tb}

,g
,/P
@) ./
6f
@

1. Cylinder 6. Piston ring set

2. O'ring 7. Piston
3. Cylinder gasket 8. Piston pin clip
4. Dowel pin 9. Piston pin
5. O-ring

7-1a
CRANKSHAFT/BALANCER GEAR

50 Nm (5.0 m . kc, 36 tt , lbl

.t_ls
Ir
t'-.

1. Balancer driven gear 12. Special washer

2. Bearing (with groovo)
3. Key 13. Balancer drive gear
4. Balancer weight 14. Compression spring
5. Bearing 15. Dowel pin
6. Primary drive gear 16. Eufter boss
7. Key 17. Special washer
8. Pump drive gear (without groove)
9. Clevis pin 18. Bearing (86306)
10. Dowel pin 19. Crankshaft assembly
11. Compression spring

7 10
TRANSM ISSION

10 Nm (1.0 m .kg. 7.2 tt.tbl

@
1- Bearing 14. Oil seal
2. Circlip 15. Drive sprocket
3. Plain washer 16. Bearing {86204}
4. lst wheel gear 17. Main axle
5. 4th wheel gear 18. 4th pinion gear
6. Circlip '19. Special washer
7. Special washer 20. Circlip
8. 3rd wheel gear 21. 3rd pinion gear
9. sth wheel gear
,l0. Drive axle assembly
22. 5th pinion gear
23. 2nd pinion gear
11. 2nd wheel gear 24. Bearing (86202)
12. Plain washer 25. Oil seal
'13. Bearing (8630443)

7-20
CLUTCH

8 Nm {0.8 m . kg. 5.8 ft. lb}

50 Nm (5.0 m. kg, 36 ft . lb)

12 Nm (1.2 m .kq, 8.7 ft. lb)

1. Compression spring 1'1. Holding plate

2. Clutch pressure plate 12. Primary drive gear
3. Push plate 13. Eall
4. O-ring 14. Push rod #2
5. Push rod #1 15. Push lever assembly
6. Friction plate 16. Torsion spring
7. Cushion spring 17. Circlip
8. Clutch plate 18. Oil seal
9. Frictjon plate 19. Bush
10. Clutch boss 20. Settinq screw

7-21
STARTER

\--...-
\\''-\...1
t.

@
1. Decompression cable lever 13. Spacer
2. Torsion spring 14. Tors;on spring
3. Plain washer 15. Spring cover
4. Oil seal 16. Kick gear
5. Pla,n washer 17. Clip
6. Circlip 18. Kick axle assembly
7. Decompression shaft 19. Circlip
8. Kick crank assembly 20. Special washer
9. Oil seal 21. Kick idle gear
10. Washer 22. Plain washer
11. Pla;n washer 23. Ckclip
12. Citclip
CARBURETOR

@-------r
H

re
e -P ffj-"

-o
*/ 1. Piston valve
4, 2.
3. Jet
Spring clip
needle
@ 4. Main nozzle
5. Pilot ajr jet
E 6, Pilot screw
7. Starter plunger

@ 8. Throttle stop
9.
10.
screw
Needle valve assembly
Main jet
11. Pilot jet
12. Float
13. Drain screw

7-t2
FRONT WHEEL

ITAPPLY LITHIUM-BASE GREASE

19x 1.60
VERTICAL LATERAL
RUNOUT 2mm 2mm
LIMIT 10.08 inl (0.08 inl

39 Nm {3,9 m.kg, 28 ft . lbl

1. Collar 7. Bearing (863012)

2. Dust cover 8. Meter drive gear
3. Oil seal 9. Brake shoe
4. Bearing 10. Brake camshaft
5. Spacer 11. Metor gear
6. Flange spacer

7-24
REAR WHEEL

*APPLY LITHIIJ M-BASE GBEASE

€oe

f4rors4PRl
18x 1.85
VERTICAL I LATERAL
RUNOUT 2nm I 2mm
LIMIT {0.08 inl {0.08 in)

30 Nm (3.0 m.kg, 22 ft.lbl

85 Nm (8.5 m.ks, 61 ft.lbl

FREE PLAY:
30-45 mm (1.2-1.8 in)

1. Collar 10. Bearing {862022)

2. Brake tension bar 11. O ring
3. Brake camshaft 12. Dampet
4. Brake shoe plate 13. Clutch hub
5. Brake shoe 14. Plate cover
6. Oil seal 15. Driven sprocket
7. Bearing (862022) 16. Sprocket axle
8. Flange spacer 17. Bearing {860042)
9. Spacer 18. Oil seal

7,25
FRONT FORK

'E#
*=o e
,#

FORK OIL CAPACITY (EACH FORK):

294+4 cm3 (10.4+0.14 lmp oz.
9.94+0.14 US oz)
RECOMMENDED OII-:
SAE 1OW3O TYPE SE
MOTOR OIL

@
APPLY LOCTITE
23 Nm {2.3 m . ks. 17 tt ' lb)

1. Front fork cap 9. Oil lock piece

2. Cap bolt 10. Dust seal
3. O ring 11- Retaining clip
4. Spacer 12. Oil seal
5. Spring seat 13. Outer tube
6. Fork spring 14. Drain screw
7. Fork boot 15. Cylinder securing bolt
8. lnner tube

7-26
STEERING HEAD

20 Nm (2,0 m.kg, 14 ft.lb)

'no
*@
*o
*@

* APPLY MEDIUM WEIGHT WHEEL

BEARING GREASE

1. Steering fitting bolt '1. Upper ball race (bottom)

2. Handle crown 8. Lower ball race {top)
3. Steering fitting nut 9. Lower ball (19 pcs.)
4. Ball race covor 10. Lower ball race (bottom)
5. Upper ball race (top) 11. Steering seal
6. Upper ball (22 pcs.)
SWINGARM

*APPLY LITHIUM-BASE GREASE

b
I

-<d o*

@ SIDE CLEARANCE:
0.3 mm 10.012 in) 80 Nm 18.0 m ' ks, 58 ft' lb)

1. Pivot shaft 8. Guard seal

2. Guard seal 9. Bush
3. Shim 10. Distance collar
4. Bush 1 '11. Chain guard
5. Distance collar 12. Drive chain guide
6. Bush i 13. Swingarm mud guard
7. Shim 14. Rubber boot
REAR SHOCK ABSORBER

$oe-__-t-

{,
25 Nm {2.5 m.ko, 18 fr.lb)
\

@tt-

@..--\

*TAKE CARE THAT THE SHOCK ABSORBER IS

INSTALLED WITH ITS WARNING LABEL UPWABD
FOR A PROPER DAMPING EFFECT.

7-29
ELECTRICAL

w
Y"
$'

t===€,
qJ'/

7. Neutral switch
2. Rectifier with regulator 8. Horn
3. Fuse 9. lgnition coil
4. Battery 10. Flasher relay
5. Rear brake switch 11. C.D.L unit
6. Front brake switch 12. Main switch

7-30
LUBRICATION DIAGRAMS
7-32
)
CABLE ROUTINGS

I
F
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JJ
6
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IE
fuJ 6 o
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to
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o.

l
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ul

4
o E
5
 PASS THROUGH THE

FUSE HOLDER
DECOMPRESSION CABLE

INSERT THE FUSE HOLOER INTO

THE MUD PROJECTION
o\o/

GNITION COIL
PRIMARY LEAD

GROUND LEAD: FASTEN

GROUND LEAD TOGETHER
FRONT SECURING BOLT.

SWITCH LEAD
DO NOT ALLOW THE STARTER CABLE TO
CONTACT THE CYLINDER.

KCASE VENTILATION PIPE

BATTERY BREATHER PIPE
PASS BREATHER PIPE THROUGH
MUD GUARD GROOVE.

7-34
 STARTER RAKE CABLE

CABLE GUI
THROTTLE CABLE
CLUTCH

MAIN SWITCH SPEEDOMETER LEAD

,,ENGINE STOP" SWITCH HANDLEBAR SWITCH
LEAD
FRONT FLASHER LIGHT (RIG HTI

FLASH€R RELA
FLASHER LIGHT
{LEFT) LEAD

PASS ALL LEAD IN FRONT OF CABLES fTHROTTLE CLAMP THE BREATHER PIPE
CABLES, STARTER CABLE AND CLUTCH CAELE),
AND INSERT THEM INTO THE RIGHT HOLE OF
HEADLIGHT BODY. BOOT BREATHER PIPE
INSERT THE BREATHER PIPE INTO THI
HEADLIGHT BODY.

DO NOT ALLOW THE LEAD TO

DO NOT ALLOW THE LEADS TO CONTACT CONTACT THE MUFFLER.
THE EXHAUST PIPE,
CLAMP
BATTERY
LEAD
BBAKE BATTERY REAR FLASHER LIGHT
SWITCH NEGATIVE LEAD {Rl LEAD

TAIL/BRAKE LIGHT
LEAD

FLASHER LIGHT
(LEFT} LEAD
REGULATOR GROUND LEAD {FASTEN GROUND
LEAD TOGETHER BOLT)

CLAMP
 B
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1l
f
:::::::::::::
trI Etr ) 3B.o>.o€oPcc3cc>a
HE ,i:)E-;fiiB;,i)d;
n
H3 a
F

eeIA- /T\*"
JA. s o-86fi;
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LI
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F 6:EE*i!;3i F $ 0
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7-36
 t

. YAMAHA rwoToffi Gs.,[ffm"

:FD li'l J.j\lAN
i']Rlr!
33 4 0.6:1 ll
t(