Yamaha FZ-16 Service Manual
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Yamaha FZ-16 Service Manual

Yamaha FZ-16 Service Manual

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SERVICE MANUAL
FZ-16
21C-F8197-EO

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Summary of Contents for Yamaha FZ-16

  • Page 1 SERVICE MANUAL FZ-16 21C-F8197-EO...
  • Page 2 FZ-16 SERVICE MANUAL All rights reserved. Any reproduction or unauthorized use without the written consent of YAMAHA MOTOR INDIA PVT. LTD. is strictly prohibited.
  • Page 3 The repairs and maintenance performed by a person who lacks such knowledge that the vehicle will probably not be secure and fit for use. Yamaha Motor India Pvt Ltd. is continually striving to improve all its models. All Yamaha authorized dealers will be informed of any amendments and changes substantial occur in specifications or procedures, and these are included in future editions of this manual, when necessary.

  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL This manual is intended as a practical tool, easy to read, a book of reference for the mechanic. Includes explanations of all installation, removal, disassembly, assembly, repair, and testing procedures are set out in individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections.
  • Page 5 1. Serviceable with engine mounted SYMBOLS 2. Liquid fill The following symbols are used in this manual 3. Lubricant to facilitate understanding. 4. Special Tool NOTE: 5. Torque The following symbols are not relevant to 6. Wear limit, tolerance each vehicle. 7.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS INSPECTIONS NEWSPAPERS AND ADJUSTMENTS CHASSIS ENGINE CARB ELECTRICAL TROUBLESHOOTING...

  • Page 7: General Information

    GENERAL INFORMATION IDENTIFICATION OF MOTORCYCLE ..........1-1 ..VEHICLE IDENTIFICATION NUMBER .......... 1-1 ENGINE SERIAL NUMBER ..........1-1 ....LCD METER ................... 1-2 INFORMATION IMPORTANT ..........1-3 ...... PREPARATION FOR REMOVAL AND DISASSEMBLY ..1-3 REPLACEMENT PARTS ..........1-3 ....PACKING, OIL SEALS RINGS I .........

  • Page 8: Vehicle Identification Number

    IDENTIFICATION IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (CHASSIS NUMBER) The vehicle identification number "1" is affixed to the chassis. ENGINE SERIAL NUMBER The engine serial number "1" is stamped in the crankcase. NOTE: Designs and specifications are subject to change without notice.

  • Page 9: Multifunction Display

    FEATURES MULTIFUNCTION DISPLAY SELECT 1. Multi-function display 2. "SELECT" button (select) The Multi-function display is equipped with the following: • A speedometer (which shows the speed offset) • An odometer (which shows the total distance traveled) • An odometer (indicating the distance traveled since it was in last reset) •...

  • Page 10: Replacement Parts

    5. Keep all parts away from any fire source. REPLACEMENT PARTS Use only genuine Yamaha parts in all changes. Use oil and grease recommended by Yamaha, for all lubrication services. Other brands may be similar in function and appearance, but...

  • Page 11: Bearings And Oil Seals

    IMPORTANT INFORMATION BEARINGS AND OIL SEALS Assemble the bearings and oil seals so that the mark of the manufacturer or the numbers are visible. When installing oil seals "1", lubricate the edges of oil seals with a thin layer of grease lithium soap base. In the bearings, apply oil, if requested.
  • Page 12 INSPECTION OF CONNECTIONS INSPECTION OF CONNECTIONS NOTE: Check the cables, couplers and connectors • If there is no continuity, clean the terminals stains, oxidation, humidity, etc.. • When checking the wire harness, perform steps (1) to (3). Disconnect: • As a quick fix, use a spray cleaner •Cable contacts, is available in most •Coupler...

  • Page 13: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Special tools shown below, are required for assembly and adjustment precise. Use only the appropriate special tools, which will help to prevent damage by the use of inappropriate tools or improvised techniques. Tool name / Illustration Tool No.
  • Page 14 SPECIAL TOOLS Tool name / Illustration Tool No. Tool to install the crankshaft spacer. (A) YSST-266 (B) YSST-267 These tools are use to install the crankshaft. Tool to remove the crankshaft. YSST-265 This tool is used to remove the crankshaft from Crankcase Fixer clutch hub YSST-733...
  • Page 15 SPECIAL TOOLS Tool name / Illustration Tool No. Adapter valve spring compressor YSST-803 A This tool is used to remove and install valve and the valve spring using YSST 603. Set pump pressure gauges vacuum / pressure This instrument is used to test and verify the vacuum the air induction system.
  • Page 16 Tool No. Multimeter ThEste instrument is used to check the circuits or electrical components. Yamaha Adhesive No. 1215 This adhesive is used in the contact surfaces, while assembling the covers # 1 and # 2 engine. Loctite Three Bond 1322 This adhesive is used to provide greater resistance to Torx screws for adjustment.

  • Page 17: Table Of Contents

    SPECIFICATIONS GENERAL ..........2-1 ..ENGINE SPECIFICATIONS ..........2-2 ..CHASSIS SPECIFICATIONS ..........2-9 ..ELECTRICAL ..........2-12 ..TORQUE ..........2-14 ....... ON GENERAL TORQUE ..2-14 ENGINE TORQUE ..........2-16 ..CHASSIS TORQUE ..........2-19 ..LUBRICATION POINTS AND LUBRICANT TYPES ....2-21 TABLES AND DIAGRAMS LUBRICATION SYSTEM ...

  • Page 18: General

    GENERAL GENERAL MODEL Model 21C1 Dimensions Total length 1973mm Overall width 770mm 1045mm Overall height 790mm Seat Height 1334mm Wheelbase 160mm Ground clearance 2340mm Minimum turning radius Weight With gasoline and oil 135.0kg Peak load 195.0kg...
  • Page 19 SPECIFICATIONS ENGINE SPECIFICATIONS ENGINE Engine Engine Type 4 stroke, air cooled SOHC Displacement 153.0cm 3 Arrangement of cylinder A cylinder leaning forward Bore x stroke 58.0 x 57.9mm Compression ratio 9.50:1 Compression pressure (at sea level) 1200kPa Starting System Electric Start, Kick starter (As the country) Fuel Recommended fuel...
  • Page 20 SPECIFICATIONS ENGINE Spark plug (s) Manufacturer / Model NGK / CPR8EA-9 Distance between electrodes 0.8-0.9mm Head Volume 13.40-14.00cm ³ Maximum deformation 0.03mm Camshaft Drive System Chain drive (Left) Dimensions of camshaft lobes Admission to 31,342 - 2mm 31.44 Limit 31.342mm Admission B 25,166 - 25.26 6mm Limit...
  • Page 21 SPECIFICATIONS ENGINE Supply Chain Model Silent chain Tensioning System Automatic Rocker / Rocker Inner diameter of the beam 9985-10.000mm Limit 10.030mm 9966-9.976mm Outer diameter of the beam 9.950mm Limit Valves, valve seats, valve guides Valve clearance (cold) Admission 0.08-0.12mm Exhaust 0.12-0.16mm Valve dimensions Diameter of the valve head...
  • Page 22 SPECIFICATIONS ENGINE Limit 0.080mm Clearance between the valve stem and guide (Escape) 0.025-0.052mm Limit 0.100mm 0.010mm Limit deformation of the valve stem Valve spring Free length (Admission) 39.40mm Limit 37.40mm Free length (Escape) 39.40mm 37.40mm Limit 34.50mm Installed length (Admission) 34.50mm Installed length (Escape) 35.08N/mm...
  • Page 23 SPECIFICATIONS ENGINE 0.25 mm Deviation Direction of deviation Admission Side Diameter hole for the piston pin 15002-15013 mm Limit 15043 mm Outside diameter of piston pin 14995-15000 mm Limit 14975 mm Piston rings Top ring Ring type Barrel Dimensions (B × T) 0.80 x 2.30 mm Distance between ends (installed) 0.10 to 0.25 mm...
  • Page 24 SPECIFICATIONS ENGINE Small end bore 14090-15028 mm Large end bore 36000-36009 mm Crankshaft Width A 47.95-48.00 mm Maximum deformation C 0030 mm Side clearance of large side D 0110-0140 mm Balancer Method of synchronizing the balanced Gear Clutch Type of clutch Oil-bathed multi-disc Clutch release method Inner force, driven by cam...
  • Page 25 SPECIFICATIONS ENGINE Mechanism of change Type shifting mechanism Drive mechanism and guide bar Thickness of the shift fork 4.76-4.89 mm Decompression device Type of device Auto-decompressor Air filter Air filter element Dry element Carburetor Type X Number BS26X1 Identifying mark 21C1110 Leading supplier # 112.5...

  • Page 26: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Frame type Diamond Angle 25.00 ° Advance 101.2 mm Front Wheel Wheel Type Wheel type Rim size 17 M/CXMT2.50 Material of rim Aluminum Wheel stroke 130.0 mm Radial deviation limit of the wheel 1.0 mm Limit lateral deflection of the wheel 0.5 mm Rear Wheel...
  • Page 27 CHASSIS SPECIFICATIONS Front brake disc Thickness and outer diameter of the disc 267.0 x 4.0 mm Thickness limit of the brake disk 3.5 mm Deviation limit of the brake disk 0.10 mm Coating thickness of brake pads (inside) 4.5 mm Limit 0.8 mm Coating thickness of brake pads (exterior)
  • Page 28 CHASSIS SPECIFICATIONS Free length of spring 187.0 mm Installed length 178.0 mm K1 spring tension 120.0 N / mm K1 Race Spring 0.0-20.0 mm Tilt Free play at the end of the rocker (Limit axial) 2.4 mm Drive chain Type / manufacturer R428HBSX/LGB Number of links Clearance of the drive chain...

  • Page 29: Electrical

    ELECTRICAL ELECTRICAL Voltage System voltage Ignition system Ignition system DC, CDI Type of feed Digital Ignition Timing (B.T.D.C.) 7.0 ° / 1400r/min Coil resistance pulse 192-288 at 20 ° C Ù Ignition coil Primary coil resistance 0.32 to 0.48 at 20 ° C Ù...

  • Page 30: Turn Signal Relay

    ELECTRICAL Electrical ignition system Type of system Constant gear Starter Output power 0.25 kW Start relay Amperage 100 A Coil resistance 3.51-4.29 Ù Horn Horn type Flat Amount 1 pc Maximum amperage 1.5 A Turn signal relay Relay type Transistor relay Integrated self-cancellation device Sign of the flicker frequency 70-100 cycles / min...

  • Page 31: Torque

    TORQUE TORQUE GENERAL OF TORQUE This table specifies the pairs of tightening threaded fasteners I.S.O. standard normalized. Torque specifications Tightening of the components or assemblies Special mentioned in each chapter this manual. To prevent distortion, cross-clamping assemblies with several fastening points, in progressive stages, until the specified torque.
  • Page 32 TORQUE MOTOR TORQUE MOTOR Size Item Amount Torque Observations thread 22 Nm (2.2 m kg, 16ft lb) Head screws (inside) 10 Nm (1.0 m kg, 7ft lb) Head screws (side chain) 13 Nm (1.3 m.kg, 9ft.Ib) Plug 10 Nm (1.0 m.kg, 7ft.Ib) Screw head cover (Conduit) 15 Nm (1.5 m.kg, 11ft.Ib) Cylinder head bolts (exhaust)
  • Page 33 TORQUE MOTOR Size Item Amount Torque Observations thread 10 Nm (1.0 m.kg, 7ft.Ib) Screw the housing 1 and 2 50 Nm (5.0 m.kg, 36ft.Ib) Nut kickstarter 12 Nm (1.2 m.kg, 9ft.Ib) Lead screw gear Screw clutch motor 14 (1.4 Nm m.kg, 10ft.Ib) start 60 (6.0 Nm m.kg, 43ft.Ib) Main gear nut...
  • Page 34 TORQUE MOTOR Sequence cylinder head tightening Tightening sequence of the magneto cover 2.10 Tightening sequence of the clutch cover 2.14 3.15 2-17...
  • Page 35 TORQUE MOTOR Crankcase tightening sequence 2.12 3.13 A. Carter left B. Right side crankcase 2-18...
  • Page 36 TORQUE TORQUE Size Item Amount Torque Observations thread 16 Nm (1.6 m kg, 12ft lb) Screw of the steering column 110 Nm (11.0 kg m, 80ft lb) Nut of the steering column 33 Nm (3.3 m.kg, 24ft.Ib) Lower ring nut (MI) 22 Nm (2.2 m.kg, 16ft.Ib) Upper ring nut (Final) 6 Nm (0.6 m.kg, 4ft.Ib)
  • Page 37 TORQUE Size Item Amount Torque Observations thread Spindle nut of the front wheel 60 Nm (6.0 m.kg, 43ft.Ib) Nut rear wheel axle 90 Nm (9.0 m.kg, 65ft.Ib) Screw crown and hub clutch 43 Nm (4.3 m.kg, 31ft.Ib) Tension bar and shoe holder plate 20 Nm (2.0 m.kg, 14ft.Ib) Camshaft and brake lever 10 Nm (1.0 m.kg, 7ft.Ib)

  • Page 38: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES Point Lubrication Lubricant Edge of the oil seals Bearings O-rings Head screws and washers Thrust surface of the large end of the rod Piston, piston rings and the inner surface of the cylinder Inner surface of the balancer sprocket Camshaft lobes Decompression cam...
  • Page 39 LUBRICATION POINTS AND LUBRICANT TYPES Point Lubrication Lubricant Yamaha Adhesive Crankshaft Position Sensor / washer assembly Lead No. 1215 (Three stator Bond No.1215R) Yamaha Adhesive No. 1215 (Three Contact surface of carcasses Bond No.1215R) Yamaha Adhesive No. 1215 (Three Bond No.1215R)
  • Page 40 LUBRICATION POINTS AND LUBRICANT TYPES Point Lubrication Lubricant Seal edges of the front wheel (left and right) Outer surface of the front wheel axle Speed sensor unit Seal edges of the rear wheel hub Contact surface of the rear wheel hub Outer surface of the rear wheel axle Rear wheel axle and the threads of the nut Pivot point axis of the brake pedal...

  • Page 41: Tables And Diagrams Lubrication System

    LUBRICATION POINTS AND LUBRICANT TYPES TABLES AND DIAGRAMS LUBRICATION SYSTEM TABLE OF ENGINE OIL LUBRICATION Oil strainer Oil pump Oil filter element Crankshaft Camshaft Main shaft Driven shaft 2-24...
  • Page 42 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION CHARTS Push the clutch lever Main shaft Drive shaft Crankshaft Oil filter Oil pump Oil strainer Toward the head 2-25...
  • Page 43 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION CHARTS Camshaft Crankshaft Main shaft Driven shaft 2-26...
  • Page 44 GUIDING CABLES June 9 5 2-27...
  • Page 45 GUIDING CABLES Front brake hose Throttle cable Cable front brake switch Cable right handlebar switch Switch wire left handlebar Clutch switch wire Clutch cable Starter cable Main switch lead Meter cable Lead right front turn signal Cable left front turn signal Streetlight cable Auxiliary Light Cable Go through the right guide bracket lamp RHS...
  • Page 46 GUIDING CABLES February 12 13 14 11 2-29...
  • Page 47 GUIDING CABLES Clutch cable Overflow pipe Throttle cable Starter cable Carburetor vent hose AC magneto lead Negative lead Breather hose from the battery Carburetor drain hose Fuel line Speaker Cable Connector cover Harness Cable sensor unit Switch wires left handlebar Cables right handlebar switch AIS hose Cable clutch and starter cable through the guide...
  • Page 48 GUIDING CABLES February 3 2-31...
  • Page 49 GUIDING CABLES Left handlebar switches Clutch switch wire Clutch cable Cable left handlebar switch Booster Cable Main switch lead Handlebar switch lead right Brake Hose Cable front brake switch Throttle cable Handlebar switches right Cable left rear turn signal Turn Signal Relay Cable from the backlight unit Lead right rear turn signal Cover the seat lock...
  • Page 50 GUIDING CABLES January 25 24 27 A 18 19 B 10 C 21 26 22 E 2-33...
  • Page 51 GUIDING CABLES 1. Throttle cable G. Pass the breather hose and battery 2. Cable sensor unit the drain hose from the carburetor to 3. Brake Hose through the exterior of the motor 4. Speaker Cable H. Pass the breather hose and battery 5.
  • Page 52 PERIODIC MAINTENANCE AND ADJUSTMENTS PERIODIC MAINTENANCE ..........3-1 ......PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ... 3-1 ADJUSTING THE VALVE CLEARANCE ........3-3 ENGINE IDLE ADJUSTMENT ..........3-3 .... MEASUREMENT AND ADJUSTMENT CO ..........3-5 ..... ADJUSTING THE THROTTLE CABLE SLACK ....3-6 SPARK PLUG INSPECTION ..........
  • Page 53 TROUBLESHOOTING ELECTRICAL ..................3-22 CHECKING AND CHARGING THE BATTERY ..........3-22 ..FUSE INSPECTION ..........3-22 ...... BULB REPLACEMENT FAROLA ........... 3 - 22 SETTING THE BEAM BULB FAROLA ......... 3-23 BULB REPLACEMENT OF AUXILIARY ..........3-23 BULB REPLACEMENT TAILLIGHT / BRAKE LIGHT ..3-23 LIGHT BULB REPLACEMENT INDICATOR ......
  • Page 54 All maintenance must be performed according to the periodic maintenance schedule (which mentioned below) to maintain the best performance of the vehicle. The items marked with an asterisk must be performed by a Yamaha dealer as they require special tools, information and technical expertise.
  • Page 55 PERIODIC MAINTENANCE READING ODOMETER INSPECTION OR OPERATION OF ELEMENT (X 1000 km) MAINTENANCE 13691215 •Check the clearance of the bearings and if the Bearings steering for roughness Address •Lubricating grease based on lithium soap. Every 12000 Km •Check that all nuts, bolts and Fasteners screws are properly tightened.
  • Page 56 ENGINE ENGINE a. Rotate the crankshaft in the opposite direction of the b. When the piston is at TDC ADJUSTING THE CLEARANCE .(PMS) of the compression stroke, align the VALVES "A" in the magnet with the fixed point "b" of the cover The following procedure applies to all the magnet.
  • Page 57 ENGINE 8. Assembly: Packing the cylinder head cover Cylinder head cover See the "HEAD" on page 5-5 9. Assembly: Hose air induction system See "INDUCTION SYSTEM AIR "on page 6-9 10. Assemble c. Turn the adjustment screw "3" in direction "a" or "b" Fuel tank to obtain the specified valve clearance.
  • Page 58 ENGINE 3. Check: Engine idle If out of specification? Set. Refer to "ADJUSTING THE IDLE ENGINE "on page 3-4. 4. Insert: Probe "2" meter CO (Calibrated) for the exhaust pipe "3", using the appropriate adapter "4" Direction "a" Increases engine idle Direction "b"...
  • Page 59 ENGINE CAUTION c. Tighten the lock nut. Do not alter the settings of the carburetor, if the engine performance is good. If necessary, adjustments should be recorded existing (No. of turns) screw mixture. To verify the configuration of the screw demezcladelcarburador, sigael CO adjustment procedure "...
  • Page 60 ENGINE CHECKING THE SPARK NOTE: Before installing the spark plug, clean the surface 1. Disconnect: the spark plug and gasket. Spark plug cap 8. Connect: 2. Remove: The spark plug cap Plug ON INSPECTION TIME CAUTION NOTE: Before removing the spark plug, clean air Before checking the ignition timing, compressed dirt that may have accumulate in the gap of the spark plug to prevent...
  • Page 61 ENGINE CAUTION a. Start the engine and let it warm up for Before removing the spark plug, clean air few minutes and then leave the engine compressed dirt that may have up in the specified idle accumulate in the spark plug gap for prevent it from falling into the cylinder Engine idle 1300-1500 r / min...
  • Page 62 ENGINE Compression pressure (with oil applied Type inside the cylinder) SAE 20W50 (Engine Oil LecturaDiagnóstico YAMALUBE-4 times) Greater than without oil piston rings are Worn or damaged CAUTION Repair Do not let foreign materials enter Piston, valves, packing possibly the cylinder head in the crankcase.
  • Page 63 ENGINE verification of oil. If it is not engine oil Assemble the new oil filter element after one minute, turn off the engine to and cover of the oil filter element. no damage occurs. Cover screw element c. Check the engine oil passages, the Oil filter oil filter element and the pump 10 Nm (1.0 m ·...
  • Page 64 ENGINE Tighten the lock nut. Slide the rubber cover into position original. NOTE: If the specified free play of clutch cable, can not be obtained on the side of the handlebar, use the adjusting nut on the motor side. Motor side Loosen the locknut "1"...
  • Page 65 ENGINE CAUTION: Never run the engine without the element of air filter installed. The unfiltered air cause rapid wear of engine parts and may damage it. NOTE: Make sure the air filter element is installed correctly in the filter housing of air.
  • Page 66 ENGINE CHECK THE FILTER WRENCH FUEL Check: •Fuel pipe "1" ReempláceloGrietas / damaged •Fuel filter "1" Tainted / Damaged Replace the fuel wash. Turn fuel valve to "OFF" Remove the filter cup wrench fuel "3". Drain the fuel. Check the filter of the fuel cock. Clean if dirty ReempláceloDañado Install the filter bowl of the fuel cock.
  • Page 67 CHASSIS CHECKING THE BRAKE FLUID LEVEL CHASSIS Place the vehicle on a flat surface. ADJUSTING THE REAR BRAKE DRUM NOTE: Drive your vehicle to the center support Check: Make sure the vehicle is vertical Free pedal brake "a" Set out of specification Check: Brake fluid level.
  • Page 68 CHASSIS CHECKING THE BRAKE FRONT The procedure applies to all brake pads. Operate the front brake. Check: Front brake pads Tread wear indicators "1" almost touch the Replace brake disc game brake pads. See "FRONT BRAKE" on page 4-20 ADJUSTING THE LIGHT SWITCH REAR BRAKE NOTE: The rear brake switch is actuated by...
  • Page 69 CHASSIS Loosen the bleed screw. Remove: Cover the brake master cylinder "1" NOTE: When you release the bleed screw, the pressure will be released and cause the contact of the lever brake with the throttle. Tighten the bleed screw and then release the brake lever Repeat steps "e"...

  • Page 70: Specifications

    CHASSIS Rotate the rear wheel to find the point with NOTE: greater tension in the chain. To maintain proper alignment of the wheel, Check: adjust both sides equally. Clearance of the transmission chain "a" Out of specification Adjust. Secure the axle nut to the torque wheel specified.

  • Page 71: Inspections

    CHASSIS Tighten the lower ring nut "4" key of the nut on the steering column "5". NOTE: Set the torque wrench at a right angle for the nut wrench the steering column. Spray the lubricant inside the chain between inner and outer plates, rollers and bearings.
  • Page 72 CHASSIS Assembly: Upper yoke WARNING Refer to "STEERING COLUMN" The pressure should be checked and corrected on page 4-43 when the temperature of the rim is equal VERIFICATION OF THE FORK at room temperature. FRONT The pressure should be in accordance with 1.

  • Page 73: Engine

    Wheels. sudden deflation. Damage / deformacionesReemplazar. After extensive testing, the tires listed below have been approved by Yamaha for this model. WARNING Front and rear wheels should be Never attempt any repairs always the same manufacturer and same wheels.
  • Page 74 CHASSIS LUBRICATING THE BRAKE LEVER Adjuster rear shock YSST-821 Lubricate the pivot points and moving parts metal-metal of the lever. Recommended lubricant Silicone grease PEDAL LUBRICATION Lubricate the pivot points and moving parts metal-metal of the lever. Recommended lubricant Based grease lithium soap LUBRICATION SIDESTAND Lubricate the pivot points and moving parts metal-metal of the lever.
  • Page 75 ELECTRICAL SYSTEM ELECTRICAL 4. Remove: • Lamp "1" lamp holder "2" CHECKING AND CHARGING THE BATTERY See "Components ELECTRIC "on page 7-34 FUSE INSPECTION See "Components ELECTRIC "on page 7-34 CHANGE THE BULB FAROLA The following procedure applies to the light bulb dipped and main beam.

  • Page 76: Electrical System

    ELECTRICAL SYSTEM Assembly: AUXILIARY LIGHT REPLACEMENT •Lamp bulb The following procedure applies to the bulb Secure the lamp bulb again low beam and high beam. the lamp bulb holder Remove: CAUTION: •Side covers (See change Avoid touching the glass bulb of the bulb of the lamp) on page 3-22 Cembran to keep it free of oil, it •The connections of the signal indicating...
  • Page 77 ELECTRICAL SYSTEM TO REPLACE THE REAR LIGHT 3. Remove: • Coupler taillight "1" • Screws "2" from inside the mudguard CHANGE INDICATOR LIGHT BULB DRAWING Remove: •Screw "1" from the indicator light •Lens "2" of light Push the bulb "3" and gently turn counterclockwise.
  • Page 78 CHASSIS GENERAL CHASSIS ASSEMBLY OF THE AIR FILTER HOUSING FRONT WHEEL REMOVING THE FRONT WHEEL DISASSEMBLY OF THE FRONT WHEEL CHECKING THE FRONT WHEEL FRONT WHEEL ASSEMBLY TERA FRONT WHEEL ASSEMBLY (DISCO) REAR WHEEL 4-12 REMOVING THE REAR WHEEL 4-14 CHECKING THE REAR WHEEL 4-14 CHECKING THE REAR WHEEL HUB...
  • Page 79 CHASSIS STEERING COLUMN 4-43 REMOVING THE LOWER BRACKET 4-45 VERIFICATION OF THE STEERING COLUMN 4-45 COLUMN MOUNT DIRECTION N 4-45 REAR SHOCK 4-47 REMOVING THE REAR SHOCK 4-48 CHECKING THE REAR SHOCK 4-48 REAR SHOCK MOUNTING 4-48 SWING 4-49 REMOVING THE ROCKER 4-51 VERIFICATION OF OVERHEAD 4-51...
  • Page 80 GENERAL CHASSIS GENERAL CHASSIS 2 Nm (0.2 m kg, 1ft 25 Nm (2.5 m kg, 18 ft 2 Nm (0.2 m kg, 1ft 2 Nm (0.2 m kg, 1ft 7 Nm (0.7 m kg, 5ft 2 Nm (0.2 m kg, 1ft 2 Nm (0.2 m kg, 1ft 2 Nm (0.2 m...
  • Page 81 GENERAL CHASSIS Removing the fuel tank 2 Nm (0.2 m kg, 1ft 4 Nm (0.4 m kg, 3ft 4 Nm (0.4 m kg, 3ft Order Procedure / Parts to remove Amount Observations Refer to "GENERAL CHASSIS" Side Cover 1 & 2, Seat on page 4-1 Fuel Tank Cap Fuel Tank Cap...
  • Page 82 GENERAL CHASSIS Removing the lamp and the meter 2 Nm (0.2 m kg, 1ft 2 Nm (0.2 m kg, 1ft 2 Nm (0.2 m kg, 1ft 2 Nm (0.2 m kg, 1ft 7 Nm (0.7 m kg, 5ft Order Procedure / Parts to remove Amount Observations Side covers...
  • Page 83 GENERAL CHASSIS Removing the air filter full 2 Nm (0.2 m kg, 1ft 23 Nm (2.3 m kg, 17 ft 7 Nm (0.7 m kg, 5ft Order Procedure / Parts to remove Amount Observations Refer to "GENERAL Seat, side cover 1 & 2 CHASSIS "on page 4-1 Filter Box Cover Filter housing cover...

  • Page 84: General Chassis

    GENERAL CHASSIS INSTALLING THE AIR FILTER HOUSING 1. Install: Bracket air filter binding NOTE; Align the projection "a" in the filter housing air slot "b" in the union of air filter.
  • Page 85 FRONT WHEEL FRONT WHEEL Removing the front wheel and brake disc 30 Nm (3.0 m kg, 22 ft 7 Nm (0.7 m kg, 5ft 60 Nm (6.0 m kg, 43 ft Order Procedure / Parts to remove Amount Observations Sensor cable clamp speed Spindle nut of the front wheel Front wheel axle Front Wheel...
  • Page 86 FRONT WHEEL Disassembly of the front wheel Order Procedure / Parts to remove Amount Observations Oil Seal Bearing Spacer Bearing For assembly, reverse the procedure disassembly.
  • Page 87 FRONT WHEEL REMOVING THE FRONT WHEEL Place the vehicle on a flat surface. WARNING Support the vehicle safely to avoid there is a risk of falling. Survey: • Front wheel NOTE: Place the vehicle on a suitable support, so that the front wheel is lifted. Remove: VERIFICATION FRONT WHEEL...
  • Page 88 FRONT WHEEL FRONT WHEEL ASSEMBLY (DISCO) Ensemble: l Brake delantero.Disco Screw the front brake disc 30 Nm (3.0 m · kg, 22 ft · lb) LOCTITE ® NOTE: 4. Check: Tighten the brake disc in stages Wheel bearings and in a crisscross pattern. The front wheel rotates irregularly shaped or this loose Replace bearings...
  • Page 89 FRONT WHEEL Assembly: velocidadUnidad sensor NOTE: Make sure the speed sensor and the wheel hub are installed with the two interlocking projections into the two slots respectively. Assembly: delanteraRueda NOTE: Make sure the slot "a" enters the tube foreign and fits over the top "b" in the unit Speed sensor.
  • Page 90 FRONT WHEEL 4-11...

  • Page 91: Rear Wheel

    REAR WHEEL Removing the rear wheel and brake bands holder 90 Nm (9.0 m kg, 65 ft lb) . TR. Order Procedure / Parts to remove Amount Observations Adjusting nut brake rod Brake rod Spring Tension bar Washer Rear wheel axle Washer Chain tensioner Spacer...
  • Page 92 REAR WHEEL Disassembly of the rear wheel Order Procedure / Parts to remove Amount Observations Rear wheel sprocket Necklace Oil Seal Bearing Rear-wheel hub Shock rear drive hub Bearing Spacer Oil Seal For assembly, reverse the procedure disassembly. 4-13...
  • Page 93 REAR WHEEL REMOVING THE REAR WHEEL (DRUM) 3. Measure: Place the vehicle on a flat surface. Radial deviation of the wheel Lateral deviation of the wheel Refer to "CHECKING WARNING FRONT WHEEL "on page 4-8 Support the vehicle with safety to there is no risk of falling.
  • Page 94 REAR WHEEL NOTE: Tighten: Nut wheel axle Sprocket assembly of the rear wheel manufacturer's brand out. Nut wheel axle 90 Nm (8.0 m · kg, 58 ft · lb) Tighten self-locking nuts in stages and in a crisscross pattern Fit: Free pedal brake Refer to "Brake Adjustment DRUM "on page 3-14...
  • Page 95 FRONT BRAKE FRONT BRAKE Disassembly of the front brake pads Order Procedure / Parts to remove Amount Observations Bra brake hose Screw the front brake caliper Front brake callipers Brake Pad Clip Pin pads Front brake pads Spring brake pads For assembly, reverse the procedure disassembly.
  • Page 96 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg 7ft Ib) 7 Nm (0.7 m kg 5ft Ib) 26 Nm (2.6 m kg, 19 ft lb) . R. Order Procedure / Parts to remove Amount Observations Drain.
  • Page 97 FRONT BRAKE Disassemble the front brake master cylinder Order Procedure / Parts to remove Amount Observations Smock Pushrod Spring Pin lock Full Piston Spring Cylinder body For assembly, reverse the procedure disassembly. 4-18...
  • Page 98 FRONT BRAKE INTRODUCTION Place the vehicle on a suitable support, so that the front wheel is lifted. WARNING Before measuring the deformation of the disc The disc brake components seldom front brake, turn the handlebars to the left require disassembly. Therefore, always or right to ensure that the wheel follow these precautions: front is fixed.
  • Page 99 FRONT BRAKE NOTE: Assemble the new brake pads and spring new brake pads. Securely attach a plastic hose transparent "1" bleed screw "2". Place the other end of the hose a container. Measuring deformation of the brake disk If out of specification, repeat the setting until the deformation of the disc brake is within the specified If the deformation of the disc brake disk...
  • Page 100 FRONT BRAKE REMOVING THE BRAKE CALIPER Disassemble the seals and dust covers FRONT the brake caliper NOTE: Before disassembling the brake caliper, drain all the brake fluid brake system. CHECKING THE BRAKE CALIPER Replacement recommended plan Disassembly: brake components Screw connection brake hose Copper washers Brake Hose Brake pads...
  • Page 101 FRONT BRAKE ASSEMBLY OF THE BRAKE CALIPER Assembly: FRONT Spring brake pads WARNING Brake pads Caliper Before assembly, all components Bra brake hose internal brake should be lubricated and cleaned with a liquid cleaner or Assembly: new brake. Spring brake pads Never use solvents on the components Brake pads internal brake, as it will make the seals...
  • Page 102 FRONT BRAKE CHECK THE MASTER CYLINDER Max. FRONT BRAKE Check: Brake master cylinder "1" Damage / scratches / wear Replace. Liquid distribution passages brake "2" (Body of the brake caliper) Blow with compressed air clogged. 7. Check: Operation of the brake lever Soft or spongy feeling Bleed Brake system See "PURGING THE SYSTEM...
  • Page 103 FRONT BRAKE Fill: Deposit brake master cylinder (with the specified amount and recommended brake fluid) Liquid preferred DOT 3 or DOT 4 WARNING Use solame efore the brake fluid recommended, some brake fluid may cause damage to rubber seals, causing leaks and loss of efficiency elfrenado.
  • Page 104 FRONT BRAKE See "PURGING SYSTEM HYDRAULIC BRAKE "on page 3-15. 4-25...
  • Page 105 REAR BRAKE REAR BRAKE Disassembly of the bands 10 Nm (1.0 m kg, 7ft Brake 43 Nm (4.3 m kg, 31 ft Order Procedure / Parts to remove Amount Observations Porta full bands Refer to "REAR WHEEL" on page 4-12 Brake bands Spring full bands Lever brake camshaft...
  • Page 106 REAR BRAKE REAR BRAKE Check: • Covering the brake shoe Repair crystallized areas. Sand the crystallized areas with sandpaper thick. NOTE: After sanding the surface crystallized clean brake bands with a cloth. Check: Measure: • inside surface of the brake drum Coating thickness of the bands Clean oil tanks brake "to"...
  • Page 107 REAR BRAKE Align the slot "c" in the handle of the tree brake cam with the slot in the tree brake cam. d. Verify that the bands are correctly positioned. TESTING THE LIMITS OF WEAR DRUM BRAKE WHEEL REAR NOTE: Assembly: After joining new brake bands, •...
  • Page 108 REAR BRAKE While pressing the brake pedal to down to the end, push the lever brake camshaft completely the direction of the arrow and check the wear indicator strips does not reach the brake wear indicator of the brake drum. Not enough can still be used.
  • Page 109 HANDLE HANDLE Removing the handle 10 Nm (1.0 m kg 7ft • • 26 Nm (2.6 m kg, 19 ft • • 14 11 7 Nm (0.7 m kg, 5ft • • Order Procedure / Parts to remove Amount Observations Rearview mirror Plug the handlebar Right handlebar switch...
  • Page 110 HANDLE Removing the handle 10 Nm (1.0 m kg 7ft • • 26 Nm (2.6 m kg, 19 ft • • January 7 Nm (0.7 m kg, 5ft • • Order Procedure / Parts to remove Amount Observations Support of the clutch Handlebar top clamp Handlebar For assembly, reverse the procedure...
  • Page 111 HANDLE REMOVING THE HANDLEBAR HANDLEBAR ASSEMBLY I placed the vehicle on a flat surface I placed the vehicle on a flat surface WARNING WARNING Support the vehicle safely to avoid Support the vehicle with safety to there is a risk of falling. there is no risk of falling.
  • Page 112 HANDLE Assembly: • Brake light switch front "1" Assembly: • NOTE: Clutch cable Align the projection "a" in the handlebar switch NOTE: left with the hole "b" on the handlebars. Lubricate the clutch cable end with a thin layer of grease lithium soap base. Assembly: •...
  • Page 113 HANDLE Fit: • Free play of clutch cable "SETTING THE GAME CLUTCH CABLE FREE "on page 3-10. Free play of the lever clutch 10.0-15.0 mm Fit: • Set throttle cable free "SETTING THE GAME THROTTLE CABLE FREE "in page 3-6. Cable free play accelerator 3.0-5.0 mm...
  • Page 114 FRONT FORK FRONT FORK Removing the fork legs 25 Nm (2.5 m kg, 18 ft • • lead 25 Nm (2.5 m kg, 18 ft • • 6 Nm (0.6 m kg, 4ft • • Order Procedure / Parts to remove Amount Observations The following procedure applies to...
  • Page 115 FRONT FORK Disassembly of the front fork legs 7New Order Procedure / Parts to remove Amount Observations The following procedure applies to both front fork legs Screw cap O-ring Spacer Washer The fork spring Smock Oil Seal Clip Screw the damper rod Copper washer Damper rod Oil flow obturator...
  • Page 116 FRONT FORK Disassembly of the front fork legs Order Procedure / Parts to remove Amount Observations Outer tube For assembly, reverse the procedure disassembly. 4-37...

  • Page 117: Front Fork

    FRONT FORK REMOVING THE BARS FRONT FORK Drain: The following procedure applies to both • Fork oil Front fork bars NOTE: I placed the vehicle on a flat surface Operate the outer tube several times while leaving the fork oil WARNING Support the vehicle with safety to there is no risk of falling.
  • Page 118 FRONT FORK NOTE: Check: • While holding the damper rod with Damper rod the holder of the damper rod "2" and Damage / wear Replace. T key in "3", loosen the screw rod Blow with compressed air blocked all shock. oil passage •...
  • Page 119 FRONT FORK Recommended Oil Seal assembly tool Oil suspension of the front fork oil 10W or equivalent YSST-875 Press: • Screw rod of the damper "1" CAUTION Be sure to join the oil seal Screw rod with the number upwards. buffer 28 Nm (2.8 m ·...
  • Page 120 FRONT FORK Assembly: • Dust "1" (With the Seal assembly tool of Front fork oil "2") Seal assembly tool of the front fork oil YSST-875 10.Antes measure the level of fork oil, wait ten minutes until the oil has settled and the air bubbles has dispersed. NOTE: Be sure to purge the fork leg front of any residual air.
  • Page 121 FRONT FORK WARNING Assembly: • O-ring Make sure the brake hose, cable clutch, and the cables are guided (In the screw cap of the front fork) • Screw the top of the front fork correctly. • Clip BLACK: • Before installing the screw cap of the fork front, lubricate the O-ring grease.
  • Page 122 STEERING STEERING Disassembly of the steering column 110 Nm (11.0m kg, 80 ft • • 22 Nm (2.2 m kg, 16 ft • • 7 Nm (0.7 m kg, 5ft • • 22 Nm (2.2 m kg, 16 ft • •...
  • Page 123 STEERING Disassembly of the steering column 22 Nm (2.2 m kg 16 ft • • 22 Nm (2.2 m kg 16 ft • • 7 Nm (0.7 m kg, 5ft • • 22 Nm (2.2 m kg, 16 ft • •...
  • Page 124 STEERING DISASSEMBLY OF LOWER BRACKET Remove the lower bearing support chisel "2" and the hammer. I placed the vehicle on a flat surface Install the bearing races and a new overall. WARNING Support the vehicle with safety to CAUTION there is no risk of falling. If the bearing races are not installed correctly, it could damage the Disassembly:...
  • Page 125 STEERING • Upper ring nut • Lockwasher Refer to "CHECKING AND ADJUSTING THE STEERING COLUMN " on page 3-18 Assemble: • Upper Bracket • Nut of the steering column Assemble: • Front fork bars See section "FORK FRONT "on page 4-35 NOTE: Temporarily tighten the mounting bolts top and bottom.
  • Page 126 REAR SHOCK REAR SHOCK Removing the rear shock 60 Nm (6.0 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Procedure / Parts to remove Amount Observations Seat, side covers 1 & 2, mud guard Refer to "GENERAL CHASSIS"...
  • Page 127 REAR SHOCK REMOVING THE SHOCK REAR I placed the vehicle on a flat surface WARNING Support the vehicle with safety to there is no risk of falling. NOTE: Place the vehicle on a suitable support so that the rear wheel is elevated. VERIFICATION OF SHOCK REAR Check:...
  • Page 128 SWING SWING Removing the rocker 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7 ft • • 10 Nm (1.0 m kg, 7 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 129 SWING Removing the rocker 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7 ft • • 10 Nm (1.0 m kg, 7 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Procedure / Parts to remove Amount...
  • Page 130 SWING REMOVING THE ROCKER WARNING I placed the vehicle on a flat surface Do not attempt to straighten the axis of the pivot. WARNING Support the vehicle with safety to there is no risk of falling. NOTE: Support the vehicle safely to avoid there is a risk of falling.
  • Page 131 SWING 2. Tilt A. Left B. Right side Assembly: • Rear Shock • Tension bar • Rear Wheel Refer to "SHOCK BACK "on page 4-47 and" WHEEL BACK "on page 4-12. 5. Fit: • backlash of the drive chain See section "CLEARANCE CHAIN "on page 3-16.
  • Page 132 CHAIN CHAIN Removing the transmission chain 10 Nm (1.0 m kg, 7 ft • • 10 Nm (1.0 m kg, 7 ft • • Order Procedure / Parts to remove Amount Observations Rear Wheel Refer to "REAR WHEEL" on page 4-12 See "TILT"...
  • Page 133 CHAIN CHAIN CHECK TRANSMISSION Measure: • 15 links the drive chain Replace out of specification chain. Length limit of 15 links 191.5 mm Measure the length "a" between the inner faces Clean: of the rollers and the length "b" between faces •...
  • Page 134 CHAIN Check: • Gear Refer to "REAR WHEEL" in page 4-12 ASSEMBLY OF THE CHAIN Lubricate: • Drive chain Recommended lubricant Proper chain lubricant for chains with O-ring Assemble: • Drive chain • Drive sprocket • Retaining the drive sprocket Screw retention of the wheel sprocket 10 Nm (1.0 m ·...
  • Page 135 ENGINE REASSEMBLY MOTOR ASSEMBLY CHANGES ARM ASSEMBLY HEAD REMOVING THE HEAD INSPECTION OF THE HEAD INSPECTION OF DISTRIBUTION AND PINION GUIDE TO THE SUPPLY CHAIN INSPECTION OF TENSION DISTRIBUTION CHAIN DECOMPRESSION SYSTEM INSPECTION HEAD ASSEMBLY CAMSHAFT 5-12 REMOVING THE ROCKER ARMS AND CAMSHAFT 5-13 CAMSHAFT INSPECTION 5-13...
  • Page 136 CLUTCH 5-35 REMOVING THE CLUTCH 5-38 INSPECTION OF RECORDS OF FRICTION 5-38 CHECKING THE CLUTCH PLATES 5-38 CHECKING THE CLUTCH SPRINGS 5-39 INSPECTION Cutterbar 5-39 CHECKING THE PRESSURE PLATE 5-39 CHECKING THE CLUTCH LEVER PUSH SHORT AND PUSH ROD PRIMARY DRIVE GEAR INSPECTION 5-39 PRIMARY DRIVEN GEAR INSPECTION 5-39...
  • Page 137 CRANKSHAFT 5-58 REMOVING THE CRANKSHAFT 5-59 CRANKSHAFT INSPECTION 5-59 CRANKSHAFT ASSEMBLY 5-59 TRANSMISSION 5-61 CHECKING THE SHIFT FORKS 5-64 CHECKING THE SHIFT DRUM 5-64 INSPECTION OF TRANSMISSION 5-64 FITTING THE PUSH RODS 5-65 MAIN SHAFT ASSEMBLY AND DRIVE AXLE 5-65 ASSEMBLY OF FORKS AND CHANGE DRUM 5-65...
  • Page 138 REASSEMBLY REASSEMBLY Removing the silencer 12 Nm (1.2 m kg, 9 ft • • 15 Nm (1.5 m kg, 11 ft • • 20 Nm (2.0 m kg, 14 ft • • Order Procedure / Parts to remove Amount Observations Air Duct Air guide Silencer...
  • Page 139 REASSEMBLY Disconnect cables and connectors 10 Nm (1.0 m kg, 7 ft • • 10 Nm (1.0 m kg, 7 ft • • Order Procedure / Parts to remove Amount Observations CAUTION First, disconnect the negative battery cable and then positive battery.

  • Page 140: Removing The Motor

    REASSEMBLY Removing the motor 30 Nm (3.4 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Procedure / Parts to remove Amount Observations Silencer Refer to "REMOVAL MOTOR "on page 5-1 Refer to "GENERAL...
  • Page 141 REASSEMBLY MOTOR ASSEMBLY ARM ASSEMBLY OF CHANGES 1. Install: 1. Urge: • Arm changes "1" • Motor "1" • Motor mounting screw (upper side) "2" • Motor mounting nut (top rear side) "3" • Screw the arm of the changes Motor mounting screw (rear bottom side) "4"...

  • Page 142: Carb

    HEAD HEAD Removing the head 22 Nm (1.0 m kg, 16 ft • • 10 Nm (1.0 m kg, 7 ft 13 Nm (1.3 m kg, 9 ft • • 8 Nm (0.8 m kg, 6 ft • • • •...
  • Page 143 Dowel pin Tensor of the distribution chain Tensor packaging supply chain Camshaft sprocket Decompression cam Head Head gasket Dowel pin Guide the distribution chain (side exhaust) For assembly, reverse the procedure disassembly. * Adhesive Yamaha No. 1215 (Three Bond No. 1215)
  • Page 144 HEAD REMOVING THE HEAD 1. Align: • The mark "I" in the rotor magnet "a" (With the stationary mark "b" on the cover Magneto) Rotate the crankshaft counterclockwise. When the piston is in the neutral upper (PMS) in the compression stroke, Remove: align the "I"...
  • Page 145 HEAD Check: • Stock. ¼ tooth Damage / Scratches →Replace. Correct • Water jacket of the cylinder head Contact roller chain Mineral deposits oxide / Remove. Camshaft sprocket Measure: • Deformation of the cylinder head. Check: Out of specification →Rectify the butt. •...
  • Page 146 HEAD INSPECTION SYSTEM DECOMPRESSION 1. Check: • Decompression System a. Check the decompression system with camshaft sprocket and the cam decompression installed on the camshaft. b. Verify that the decompression lever "1" moves smoothly. c. Without operating the decompression lever, verify that the decompression cam "2"...
  • Page 147 HEAD Align the "I" of the timing sprocket tighten the chain tensioner "C" with the stationary mark "d" on the plate distribution "3" to the specified torque. Retention of the camshaft. Screw the chain tensioner Install the timing chain on the pinion distribution camshaft and then install the pinion 9 Nm (0.9 m ·...
  • Page 148 HEAD Press: • Screw camshaft sprocket Screw camshaft sprocket 20 Nm (2.0 m · kg, 14 ft · lb) PRCAUCIÓN Be sure to tighten the screw on the pinion camshaft to the specified torque avoid the possibility that the screw is loosened and damaging the motor.
  • Page 149 CAMSHAFT CAMSHAFT Removing the rocker arms and camshaft 22 Nm (2.2 m kg, 16 ft • • 7 Nm (0.7 m kg, 5 ft • • 10 Nm (1.0 m kg, 7 ft • • 13 Nm (1.3 m kg, 9 ft •...
  • Page 150 CAMSHAFT REMOVING THE ROCKER AND Dimensions of the lobes of CAMSHAFT camshaft 1. Loosen: • Locknut "1" Admission to • Screw adjustment valve clearance "2" 31342-31442 mm • Rocker "3" Limit 31,342 mm Admission B 25166-25266 mm Limit 25,136 mm Escape A 31110-31210 mm Limit...

  • Page 151: Camshaft Inspection

    CAMSHAFT INSPECTION 2. Check: Clearance between the rocker and the aje • Shaft Rocker Rocker Blue discoloration / wear excessive 0009-0034 mm bite / scratch Replace to verify Limit the lubrication system. 0.08 mm 3. Measure: • Internal diameter of the beam "A"...
  • Page 152 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Removing the valves and valve springs 6New Order Procedure / Parts to remove Amount Observations Head See the "HEAD" on page 5-5 Rocker / Camshaft Refer to "CAMSHAFT" in page 5-12 Valve Pin Upper spring seat valve Valve spring Intake valve...
  • Page 153 VALVES AND VALVE SPRINGS REMOVING THE VALVES NOTE: The following procedure applies to all Identify the position of each part with much valves and related components. care that can be reinstalled in their original place. NOTE: Before removing the internal parts of the head (For example, valves, valve springs, valve seats), make sure the valve seal well.
  • Page 154 VALVES AND VALVE SPRINGS 2. Delete: INSPECTION OF THE SEATS OF THE • Carbon deposits VALVES (From the valve face and valve seat) The following procedure applies to all 3. Check: valves and valve seats. • Side valve 1. Delete: Pitting / wear face Grind •...
  • Page 155 VALVES AND VALVE SPRINGS Rectify: • Valve face • Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide must be lapped the valve seat and the face of the valve Apply lapping compound secondary "A"...
  • Page 156 VALVES AND VALVE SPRINGS Tilt Spring Free length (Admission) compression (Admission) 39.40 mm 2.5 ° / 1.7 mm Limit Tilt Spring 37.40 mm compression (Escape) Free length (Escape) 2.5 ° / 1.7 mm 39.40 mm Limit 37.40 mm VALVE ASSEMBLY The following procedure applies to all valves and related components.
  • Page 157 VALVES AND VALVE SPRINGS • Stem seal valve "2" • Valve "3" • Valve spring "4" • Upper spring seat valve "5" (In stock) NOTE: • Ensure that each valve is installed in its original position • Install the valve with the long end "a" upwards.
  • Page 158 CYLINDER AND PISTON CYLINDER AND PISTON Removal of the cylinder and piston 4New 2New Order Procedure / Parts to remove Amount Observations Head See the "HEAD" on page 5-5 Cylinder Cylinder gasket Dowel pin Piston pin Piston pin Piston Top Ring Second ring Oil ring For assembly, reverse the procedure...

  • Page 159: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Remove: • Piston pin "1" • Piston pin "2" • Piston "3" CAUTION Do not use a hammer to remove the bolt from piston NOTE: • Before removing the piston pin, cover the crankcase opening with a clean cloth INSPECTION OF CYLINDER AND PISTON prevent the piston pin from falling into the...
  • Page 160 CYLINDER AND PISTON "C" = maximum of D1-D2 CHECKING THE PISTON RINGS Measure: "T" = maximum of D1 or D2 - D5 or D6 maximum • Ring side clearance Out of specification Replace the piston "R" = maximum of D1, D3 or D5 - minimum of D2, and piston rings, as a whole.
  • Page 161 CYLINDER AND PISTON Measure: Measure: • • Distance between centers of rings Inner diameter of the pin Out of specification Replace Piston "a" piston rings. Out of specification Replace the piston NOTE: The opening of the oil ring spacer Inner diameter of can not be measured.
  • Page 162 CYLINDER AND PISTON 120 ° 120 ° 120 ° 90 ° cd 45 º 45 º Install: Top Ring • Piston "1" Oil ring expander • Piston pin "2" Oil ring upper guide • Lower guide ring oil Piston pins "3" Second ring Exhaust side NOTE:...
  • Page 163 MAGNETO AND STARTER CLUTCH MAGNETO AND STARTER CLUTCH Removing the magneto and starter clutch 10 Nm (1.0 m kg 7ft Ib) 10 Nm (1.0 m kg 7ft Ib) 7New 14 Nm (1.4 m kg, 10 ft lb) 10 Nm (1.0 m kg 7ft Ib) 70 Nm (7.0 m kg, 51 ft lb)
  • Page 164 MAGNETO AND STARTER CLUTCH Removing the magneto and starter clutch 10 Nm (1.0 m kg 7ft Ib) 10 Nm (1.0 m kg 7ft Ib) 7New NewNuevo 14 Nm (1.4 m kg, 10 ft lb) 10 Nm (1.0 m kg 7ft Ib) 70 Nm (7.0 m kg, 51 ft lb) Order...
  • Page 165 MAGNETO AND STARTER CLUTCH MAGNET REMOVAL Remove: • Magneto rotor nut • Washer NOTE: • While holding the rotor magnet using the rotor magnet holder "1", loosen the magneto rotor nut. REMOVING THE STARTER CLUTCH Remove: • Starter clutch bolts "1" NOTE: •...
  • Page 166 MAGNETO AND STARTER CLUTCH NOTE: • While holding the rotor magnet, tighten the starter clutch "1". • Mark the end "A" of each screw starter clutch. Check: • Freewheel clutch start • Starter clutch sprocket Burrs / chips / roughness Replace defective parts.
  • Page 167 Apply: • Sealant (In the crankshaft position sensor / in eyelet for mounting the stator wire) Yamaha Adhesive No. 1215 TG-1215 4. Install: • Cover the magnet Magneto cover screw 10 Nm (1.0 m · kg, 7.2 ft · lb)
  • Page 168 ELECTRIC START ELECTRIC START Removing the starter motor 2 Nm (0.2 m kg, 1ft • • 10 Nm (1.0 m kg 7ft • • Order Procedure / Parts to remove Amount Observations Starter Starter Cable Disconnect For assembly, reverse the procedure disassembly.
  • Page 169 ELECTRIC START Disassemble the starter Order Procedure / Parts to remove Amount Observations Starter Cover Gasket Set of carbon brushes Support for carbon brushes Oil Seal Pin lock Stop washer Washer Bearing Front cover of the starter Starter For assembly, reverse the procedure disassembly.

  • Page 170: Electric Start

    ELECTRIC START NOTE: DISASSEMBLY STARTER To ensure correct operation of the Remove: • switch should be cut mica. Starter "1" • Engine front cover Start / brush holder assembly "2" NOTE: Before disassembling the starter, make alignment marks "a" in the starter cover and front cover Starter / brush holder assembly.
  • Page 171 ELECTRIC START Check: • Sprocket teeth Damage / wear Replace the sprocket. Check: • Bearing • Oil Seal Damage / wear Replace the cover starter frontal / group brush holder STARTER ASSEMBLY Install: • Front cover of the starter / brush support assembly "1"...
  • Page 172 CLUTCH CLUTCH Removing the clutch cover kg 7ft 9 Nm (0.9 m • • 10 Nm (1.0 m kg 7ft 10 Nm (1.0 m kg 7ft • • • • Order Procedure / Parts to remove Amount Observations Drain Motor oil See "OIL CHANGE MOTOR "on page 3-9 Disconnect...
  • Page 173 CLUTCH Removing the clutch 70 Nm (7.0 m kg, 51 ft lb) 8 Nm (0.8 m kg 6ft Ib) Order Procedure / Parts to remove Amount Observations Locknut Clutch spring Pressure Plate Short rod Clutch thrust Holder of the clutch pushrod Ball Friction disc 1 Clutch disc...
  • Page 174 CLUTCH Removing the push lever 3New 4New Order Procedure / Parts to remove Amount Observations Clutch Refer to "CLUTCH" on page 5-35 Push the clutch lever Spring clutch push lever Pin lock Oil Seal Bearing For assembly, reverse the procedure disassembly.
  • Page 175 CLUTCH REMOVING THE CLUTCH Straighten the lock washer. Loosen: • The nut of the clutch disc carrier "1" NOTE: While holding the clutch disc carrier "2" with the clutch fastener "3", loosen the Clutch cutterbar nut. Clutch retainer YSST-733 Friction disc 1 B.
  • Page 176 CLUTCH Thickness of clutch discs 1.85-2.15 mm Limit deformation 0.20 mm Check: • Bearing Damage / wear Replace the bearing and the clutch. INSPECTION OF caddy CLUTCH INSPECTION OF SPRINGS CLUTCH Check: The following procedure applies to all • Lace Clutch cutterbar of clutch springs.
  • Page 177 CLUTCH Check: NOTE: • Primary drive gear Make sure the corners with sharp edges Damage / wear Replace gear thrust washer "a" is placed opposite primary drive and clutch the clutch disc carrier. as a whole. Excessive noise during operation Replace the primary drive gear and the clutch as a whole.
  • Page 178 CLUTCH Bend the tab washer Fit: along a flat side of the nut. • Free play of the clutch mechanism Lubricate: • Friction discs • Clutch discs Verify that the projection "a" in the lever (With the recommended lubricant) Clutch "1" is aligned with the mark "b" shown in Figure crankcase pushing the push lever clutch Recommended lubricant...
  • Page 179 CLUTCH 10. Install: • Oil Seal "1" • Oil Seal "2" 11. Install: • Clutch cover Clutch cover screw 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the the cover screws clutch in proper tightening sequence as shown.
  • Page 180 OIL PUMP OIL PUMP Removing the oil pump 4 Nm (0.4 m kg, 3ft • • 4 Nm (0.4 m kg, 3ft • • 10 Nm (1.0 m kg 7ft • • 10 Nm (1.0 m kg 7ft • • Order Procedure / Parts to remove Amount...
  • Page 181 OIL PUMP Disassembly of the oil pump Order Procedure / Parts to remove Amount Observations Housing cover of the oil pump Primary driven gear oil pump Internal rotor of the oil pump External rotor oil pump Pump housing oil For assembly, reverse the procedure disassembly.
  • Page 182 OIL PUMP CHECKING THE OIL PUMP Clearance between the inner rotor and the external rotor Check: • Less than 0.15 mm Primary drive gear pump Limit 0.20 mm • Primary driven gear pump Clearance between the outer rotor and the housing of the oil pump •...
  • Page 183 OIL PUMP Check: • Operating the oil pump See "INSPECTION OIL PUMP "on page 5-45. ASSEMBLING THE OIL PUMP Install: • Oil pump Screw oil bulges 4 Nm (0.4 m · kg, 2.4 ft · lb) CAUTION After tightening the screws, make sure that the oil pump rotates smoothly.
  • Page 184 AXIS OF CHANGES AXIS OF CHANGES Removing the shift shaft and lever stop 9 Nm (0.9 m kg 7ft • • Order Procedure / Parts to remove Amount Observations Clutch Refer to "CLUTCH" on page 5-35 Shift arm Axis changes Pin lock Shift shaft spring Lever cap...
  • Page 185 AXIS OF CHANGES SHAFT INSPECTION OF CHANGES Check: • Axis changes Curves / damage / wear Replace. • Changes shaft spring Damage / wear Replace. TOP LEVER INSPECTION Check: • Lever cap Curves / damage Replace. Replace harsh roller rotates the top of the lever.
  • Page 186 PINION BALANCER PINION BALANCER Removing the sprocket and balancer primary drive gear 60 Nm (6.0 m kg, 43 ft • • 7New 45 Nm (4.5 m kg, 33 ft • • Order Procedure / Parts to remove Amount Observations Clutch Refer to "CLUTCH"...
  • Page 187 PINION BALANCER Removing the sprocket and balancer primary drive gear 60 Nm (6.0 m kg, 43 ft • • 45 Nm (4.5 m kg, 33 ft lb) • • 7New Order Procedure / Parts to remove Amount Observations Spacer For assembly, reverse the procedure disassembly.
  • Page 188 PINION BALANCER PINION BALANCER DRIVEN GEAR ASSEMBLY PRIMARY BALANCER Assembly: Loosen: • Pin pin "1" • Primary drive gear nut "1" • Spring "2" NOTE: (With the glass top) Place a sheet of leather or a leather "A" between the primary drive gear NOTE: balancer "2"...
  • Page 189 PINION BALANCER Bend the tab washer along a flat side of the nut. Press: • Nut primary driven gear balancer "1" • Primary drive gear "2" Driven gear nut primary balancer 45 Nm (4.5 m · kg, 33 ft · lb) Primary drive gear 60 Nm (6.0 m ·...
  • Page 190 CARTER CARTER Separation of the crankcase 10 Nm (1.0 m • kg, 7 ft • Ib) 10 Nm (1.0 m • kg, 7 ft • Ib) 10 Nm (1.0 m • kg, 7 ft • Ib) Order Procedure / Parts to remove Amount Observations Engine...
  • Page 191 CARTER Separation of the crankcase 10 Nm (1.0 m • kg, 7 ft • Ib) 10 Nm (1.0 m • kg, 7 ft • Ib) 10 Nm (1.0 m • kg, 7 ft • Ib) 10 Nm (1.0 m • kg, 7 ft • Ib) Order Procedure / Parts to remove Amount...
  • Page 192 CARTER Dismantling of bearings and oil seals 7 Nm (0.7 m kg, 5 ft • • Order Procedure / Parts to remove Amount Observations Crankshaft / Balancer Refer to "CRANKSHAFT" on page 5-58 Transmission Refer to "TRANSMISSION" on page 5-61 Oil Seal Bearing retainer Bearing...
  • Page 193 CARTER CRANKCASE SEPARATION CAUTION Remove: Tapping on a side of the crankcase • Crankcase screws with a soft-faced hammer. Hit only in the reinforced portions of the NOTE: sump, not on the contact surfaces Loosen each bolt 1/4 turn back to the stage crankcase.
  • Page 194 Thoroughly clean all surfaces contact seal and the crankcase. Apply: • Sealant (On the contact surfaces of the housing) Yamaha Adhesive No. 1215 2.12 3.13 NOTE: Do not allow product to come in contact with the oil passage. Casing left...
  • Page 195 CRANKSHAFT CRANKSHAFT Removing the crankshaft and the balancer Order Procedure / Parts to remove Amount Observations Refer to "CRANKCASE" on page Sump 5-53 Balancer Crankshaft For assembly, reverse the procedure disassembly. 5-58...
  • Page 196 CRANKSHAFT REMOVING THE CRANKSHAFT Remove: • Crankshaft "1" NOTE: • Remove the crankshaft with the tool to remove the crankshaft "2". • Make sure the tool to remove the crankshaft is centered on the crankshaft. CAUTION Measure: • Connecting rod side clearance •...
  • Page 197 CRANKSHAFT CAUTION To avoid scratching the crankshaft and to facilitate procedure, assembly, lubricate the edges of oil seals with soap-based grease Lithium and each bearing with engine oil. NOTE: Keep the rod in the top dead (PMS) with one hand while turning the nut crankshaft mounting screw with the other.
  • Page 198 TRANSMISSION TRANSMISSION Removing the transmission, the drum changes and changes the hairpin Order Procedure / Parts to remove Amount Observations Refer to "CRANKCASE" on page Sump 5-53 Guide bar claw changes Spring Shift drum Right-shift fork Shift fork-Center Left-shift fork Drive shaft Main shaft Long pushrod clutch...
  • Page 199 TRANSMISSION Disassemble the main axis Order Procedure / Parts to remove Amount Observations Second pinion Fifth-pinion Third-pinion Pin lock Toothed washer Fourth pinion Main shaft / pinion first For assembly, reverse the procedure disassembly. 5-62...
  • Page 200 TRANSMISSION Disassembly of the coupling pin Order Procedure / Parts to remove Amount Observations Pin lock Washer Second Gear Fifth Gear Washer First gear Necklace Washer Fourth gear Pin lock Washer Third Gear Drive shaft For assembly, reverse the procedure disassembly.
  • Page 201 TRANSMISSION INSPECTION OF FORKS INSPECTION OF CHANGE DRUM CHANGES Check: Surcos changes in the drum The following procedure applies to all Damage / scratches / wear Replace changes forks. drum changes. Check: Segment of the drum change "1" Cam pin of the yoke of change "1" Damage / wear Replace the drum Clips shift fork "2"...
  • Page 202 TRANSMISSION MAIN SHAFT ASSY, SPINDLE TRACTION Install: Adjust dial "1" Pin lock "2" NOTE: Be sure to install the lock pin so its sharp edge "to" be back to the lock washer and gear. Make sure the ends of the lock pin Check: "B"...
  • Page 203 TRANSMISSION NOTE: The markings on the shift forks should be facing the right side of engine and be in the following sequence: "R", "C", "L". Check: Transmission Rough motion repair NOTE: Apply engine oil to each gear and bearing. Before assembling the engine crankcase, make sure the transmission is in neutral and that the gears rotate freely.
  • Page 204 FUEL SYSTEM CARB CARBURETOR REMOVAL CARBURETOR DISASSEMBLY CARB INSPECTION CARBURETOR ASSY CARBURETOR ASSEMBLY MEASURING AND ADJUSTING THE FUEL BLE INSPECTION OF THE FUEL WRENCH AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYSTEM 6-10 INSPECTION SYSTEM AIR INDUCTION 6-11...
  • Page 205 CARB CARB Removing the carburetor Order Procedure / Parts to remove Amount Observations Seat, side covers 1 & 2, hose Refer to "GENERAL Fuel CHASSIS "on page 4-1 Overflow fuel hose Disconnect Fuel line Screw clamp connection carburetor Loosen Screw clamp Throttle cable Starter cable TPS connector...
  • Page 206 CARB Disassemble the carburetor Order Procedure / Parts to remove Amount Observations Disassemble the carburetor Remove the parts in the order listed Diaphragm cover Diaphragm spring Needle valve Piston valve Diaphragm Ring Drain screw Float chamber O-ring Support sprayer Leading supplier O-ring Main nozzle...
  • Page 207 CARB Disassemble the carburetor Order Procedure / Parts to remove Amount Observations Float pin Float Set needle Throttle stop screw Washer Spring Jet pilot O-ring Washer Spring O-ring Filter mesh Cover plunger Support guide...
  • Page 208 CARB Disassemble the carburetor Order Procedure / Parts to remove Amount Observations O-ring Spring plunger Plunger Spring washer Throttle stop Stop washer Spring O-ring Pin lock Washer Washer For assembly, reverse the procedure disassembly.
  • Page 209 CARB CARBURETOR DISASSEMBLY 4.Verificar: • Check: Body of the float chamber "1" •Carburetor body "1" Dirt - Clean. •Float chamber "2" •Accommodation supplier "3" Cracks / damage-Replace. 5.Verificar: • Rubber gasket of the chamber float "1" Cracks / damage / wear - Replace. NOTE: Check: Always replace the gasket with a new one.
  • Page 210 CARB 8. Check: • Mesh Filter "1" Damaged / obstructed ---- Replace 9. Check: •Leading supplier "1" / accommodation supplier "2" / O-ring "3" / main nozzle "4" Damage / obstruction - Replace CARBURETOR ASSY CAUTION: 10. Check: • jet pilot "1" •Before assembling the carburetor, wash all parts with a solvent-derived Damage / obstruction - Replace...
  • Page 211 CARB 2.Install: Install: • mixture screw "1" • Float "1" • Mesh Filter "2" • Float Pin "2" • Screw "3" • Gasket float chamber "4" • Float chamber "5" 5.Instalar: • Diaphragm Valve "1" CAUTION 3.Instalar: • Needle valve "1" Do not overtighten any screws, this can damage gaskets and O-rings.
  • Page 212 CARB 6. Install: • Spring Iris "1" • Cover the diaphragm "2", tighten the screws 2.Ajustar: • Fuel level CARBURETOR ASSEMBLY a. Removing the carburetor. 1.Connect all wires and cables. b. Check valve seat of the needle Refer to "REMOVAL and needle valve.

  • Page 213: Air Induction System

    AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM Hose air induction system (air filter). Vacuum hose of the air induction system. Through the air induction system (to the motor) Air filter Air induction system.
  • Page 214 AIR INDUCTION SYSTEM Removing the air induction system Order Procedure / Parts to remove Amount Observations Seat, side cover, side cover 1 & 2 Refer to "GENERAL CHASSIS "on page 4-1 Refer to "GENERAL Fuel tank CHASSIS "on page 4-2 Hose air induction system (air filter).
  • Page 215 AIR INDUCTION SYSTEM INDUCTION SYSTEM INSPECTION Cracks / damage Replace. • Union 3-way Air injection Cracks / damage Replace. 2. Check: • The air induction system burning gases Reed valve • unburned exhaust by injecting Valve stop reed • fresh air (secondary air) at the port of Valve seat sheet exhaust, reducing the emission of hydrocarbons.
  • Page 216 AIR INDUCTION SYSTEM Air shutoff valve is opened Replace the air shutoff valve. Air shutoff valve closed The air shutoff valve is OK NOTE: This test should be performed when the pressure is less than - 50 kPa. 6-12...

  • Page 217: Troubleshooting

    ELECTRICAL IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM OPERATING SYSTEM BOOT CUT TROUBLESHOOTING CHARGING SYSTEM 7-11 CIRCUIT DIAGRAM 7-11 TROUBLESHOOTING 7-13 LIGHTING SYSTEM 7-14 CIRCUIT DIAGRAM 7-14 TROUBLESHOOTING 7-16 SIGNALLING SYSTEM 7-17 CIRCUIT DIAGRAM 7-17 TROUBLESHOOTING 7-19 SELF DIAGNOSIS FUNCTION 7-23 SELF DIAGNOSIS FUNCTION...
  • Page 218 IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM (Black) LBSb RB RW (Black) (Black) BL L BL L LY Y TC VCC SGND SPEED TACHO FUEL + FUEL - ILLMI NEUTRAL RW YWLg - ILLUMI HI BEAM TURN DIAG - Sb Bl - YW L g W S IG SGND DIAG...
  • Page 219 IGNITION SYSTEM 1. Magneto CA 3. Unit Regulator / Rectifier 4. Main fuse 5. Battery 6. Main switch 7. CDI 8. Ignition coil 19. TPS 20. Plug 21. Cable Positive + 22. Negative cable - 30. Engine stop switch...
  • Page 220 IGNITION SYSTEM TROUBLESHOOTING The ignition system is not working (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following parts: Seat Side cover 1 and 2 Fuel tank 1. Check the fuse. NG → See the section Replace the fuse. "CHECKING THE FUSE"...
  • Page 221 IGNITION SYSTEM NG → The engine stop switch is Check the stop switch damaged. Replace the switch motor. right handlebar Refer to the "VERIFICATION SWITCH "on page 7-30. OK ↓ NG → 10.Verificar Wiring system full power. Connect or repair wiring system See section "CHART Ignition CIRCUIT "on page 7-1.

  • Page 222: Electric Starting System

    ELECTRIC STARTING SYSTEM STARTING CIRCUIT CIRCUIT DIAGRAM (Black) RB - LBSb RB RW (Black) (Black) BL L LY Y BL L SGND SPEED TC VCC TACHO FUEL + FUEL - ILLMI NEUTRAL RW YWLg - ILLUMI HI BEAM TURN DIAG - Sb Bl - YW Lg W VCC S IG SGND...
  • Page 223 ELECTRIC STARTING SYSTEM 2. Neutral switch 4. Main fuse 5. Battery 6. Main switch 21. Cable Positive + 22. Negative cable - 23. Starter relay 24. Starter 26. Start switch 27. Starter cut relay 28. Clutch switch 30. Engine stop switch...
  • Page 224 ELECTRIC STARTING SYSTEM SYSTEM OPERATION STARTING CIRCUIT COURT If the engine cutoff switch is set to "" and the ignition key is positioned "ON" (both switches are closed), the starter will operate if one of the following conditions is served: •...
  • Page 225 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN IS CLUTCH LEVER SHOT TO THE HANDLEBARS 1. Battery 2. Fuse 3. Main switch 4. Engine stop switch 5. Starter cut relay 6. Clutch switch 7. Neutral switch 8.
  • Page 226 ELECTRIC STARTING SYSTEM TROUBLESHOOTING The starter will not start. NOTE: • Before troubleshooting, remove the following parts: Seat Side cover 1 and 2 NG → 1. Check the fuse. Refer to the "VERIFICATION Replace the fuse. FUSE "on page 7-34. ↓...
  • Page 227 ELECTRIC STARTING SYSTEM Check the stop switch NG → The engine stop switch is motor. See the section damaged. Replace i n t e r r u p t o r "VERIFICATION right handlebar SWITCHES "on page 7-30. ↓ Check the neutral switch. Refer to the "VERIFICATION NG →...
  • Page 228 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM (Black) LBSb RB RW (Black) (Black) BL L BL L LY Y TC VCC SGND SPEED TACHO FUEL + FU E L - ILLMI NEUTRAL RW YWLg - ILLUMI HI BEAM TURN DIAG - Sb Bl - YW Lg W GIS SGND DIAG...
  • Page 229 CHARGING SYSTEM 1. Magneto CA 3. Regulator / rectifier 4. Main fuse 5. Battery 21. Cable Positive + 22. Negative cable - 7-12...
  • Page 230 CHARGING SYSTEM TROUBLESHOOTING The battery is not charging. NOTE: • Before troubleshooting, remove the following parts: Seat Left side panel / cap. NG → Check the fuse. Refer to the "VERIFICATION Replace the fuse FUSE "on page 7-34 OK ↓ NG →...
  • Page 231 LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM (Black) LBSb RB RW (Black) (Black) BL L LY Y BL L TC VCC SGND SPEED TACHO FUEL + FU E L - ILLMI NEUTRAL RW YWLg - ILLUMI HI BEAM TURN DIAG - Sb Bl - YW Lg W VCC GIS SGND DIAG...
  • Page 232 LIGHTING SYSTEM 4. Main fuse 5. Battery 6. Main switch 13. Meter 15. Streetlight 18. Taillight 21. Cable Positive + 22. Negative cable - Light switch 31 34. Light switch...
  • Page 233 LIGHTING SYSTEM TROUBLESHOOTING Any of the following lights failure: Lamp, light-beam indicator, backlight, auxiliary light or light meter. NOTE: • Before troubleshooting, remove the following parts: 1. Seat 2. Cap 1 and cap 2 3. Streetlight 4. Fuel tank 1. Check each bulb and the condition NG →...
  • Page 234 SIGNALLING SYSTEM SIGNALLING SYSTEM CIRCUIT DIAGRAM (Black) LBSb RB RW (Black) (Black) BL L BL L LY Y TC VCC SGND SPEED TACHO FUEL + FUEL - ILLMI NEUTRAL RW YWLg - ILLUMI HI BEAM TURN DIAG - YW Lg W - Sb Bl GIS SGND DIAG...
  • Page 235 SIGNALLING SYSTEM 2. Neutral switch 4. Main fuse 5. Battery 6. Main switch 7. CDI 9. Horn 10. Relay turn signal 11. Front brake switch 12. Rear brake switch 13. Meter 16. Headlight turn indicator (LH) 17. Headlight turn indicator (RH) 21.
  • Page 236 SIGNALLING SYSTEM TROUBLESHOOTING •Any failure following lights: turn indicator lights, brake light or indicator lights. •The horn does not sound. •The fuel gauge does not work. NOTE: •Before troubleshooting, remove the following parts: 1. Seat 2. Fuel tank 3. Streetlight 4.
  • Page 237 SIGNALLING SYSTEM NG → 3. Check the wiring system signaling. See the section Connect or repair wiring system "CIRCUIT DIAGRAM" on signaling page 7-17. Ok ↓ The system circuit is OK The brake light / rear does not light. NG → 1.
  • Page 238 SIGNALLING SYSTEM 3. Check the light switch NG → The horn switch is faulty. indicator of rotation. Refer to Replace the left switch section "VERIFICATION handlebar SWITCHES "on page 7-30. Ok ↓ 4.Verificar relay indicator light of rotation. See the section NG →...
  • Page 239 SIGNALLING SYSTEM NG → 2.Check wiring system signaling. See the section Connect or repair wiring system "CIRCUIT DIAGRAM" on signaling page 7-17. Ok ↓ Replace the meter. 7-22...
  • Page 240 SELF-DIAGNOSIS FUNCTION SELF-DIAGNOSIS FUNCTION The vehicle is equipped with an auto-diagnosis. If this function detects a bad Operating on the system immediately operates the engine under substitute characteristics and illuminates the warning light engine failure to alert the driver that there has been a system failure.
  • Page 241 SELF-DIAGNOSIS FUNCTION FAULT CODE TABLE Can / Can / Code can not can not Item Symptom fault boot drive Throttle Position Sensor Throttle Position Sensor: (Open or short) open or short circuit detected. Throttle Position Sensor Throttle Position Sensor (Attached) is attached Verification of the light bulb warning of engine failure The warning light engine trouble lights for 3 seconds after the main switch is turned to "ON".
  • Page 242 SELF-DIAGNOSIS FUNCTION TROUBLESHOOTING DETAILS This section describes the steps to the fault code number displayed on the meter. Check and service elements or components that are the likely cause of failure. Symptom Throttle position sensor: open circuit or Fault code No. short circuit detected Item / components and cause Method...
  • Page 243 SELF-DIAGNOSIS FUNCTION Fault code No. The throttle position sensor is attached Component: Throttle Position Sensor Item / components and cause Method Order Verification or maintenance work reinstatement likely Start the Condition sensor assembly motor • Check for loose or pressed. It used arlo in throttle position.
  • Page 244 SELF-DIAGNOSIS FUNCTION Symptom: The signals received from the speed sensor is not normal. Component: vehicle speed sensor Item / components and cause Method Order Verification or maintenance work likely reinstatement Condition sensor assembly Start the • Check for loose or pressed. speed.

  • Page 245: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 7-28...
  • Page 246 ELECTRICAL COMPONENTS 1. Front brake switch 2. Fuel gauge 3. Starter cut relay 4. CDI 5. Main switch 6. Horn 7. Start relay 8. Neutral switch 9. Rear brake switch 10. Battery 11. Regulator / rectifier 12. Fuse 13. Spark plug cap 14.
  • Page 247 ELECTRICAL COMPONENTS SWITCH INSPECTION (BLACK) Br and (RED) Br Dg L / W B Br R / W W/B and G Br Ch/WDG W/Br B / W Y P Ch PASS Br R / W L / W W / B 7-30...
  • Page 248 ELECTRICAL COMPONENTS 1. Clutch switch 2. Main switch 3. Front brake switch 4. Rear brake switch 5. Neutral switch 6. Switch turn signal 7. The horn switch 8. Light switch 9. Light Switch step . Engine stop switch 11. Start switch 12.
  • Page 249 ELECTRICAL COMPONENTS Check continuity of each circuit with the multimeter. If the reading of continuity is not correct, check the connections, and if necessary, replace the switch. CAUTION: Never insert the tester probes into the slots of the coupling terminal "a". Insert the probes provided by the opposite end of the coupler, taking care not loosen or damage the cables.
  • Page 250 ELECTRICAL COMPONENTS VERIFICATION OF BULBS AND WARNING SOCKETS OF BULBS Since the lamp bulbs are heated Check each bulb and bulb socket much, keep flammable products and damage or wear, proper connections hands away from them until they have and continuity between the terminals. cooled.
  • Page 251 ELECTRICAL COMPONENTS Checking the status of sockets of bulbs a. Set the main switch to "OFF". The following procedure applies to all b. Install a new fuse of the correct amperage. sockets for light bulbs. c. Setting the switches to verify if the 1.
  • Page 252 ELECTRICAL COMPONENTS INTERNAL • Drink plenty of water or milk Example followed by milk of magnesia, beaten eggs Open circuit voltage = 12.0 V or vegetable oil. Get medical attention Charging time = 5-10 hours immediately. Charging the battery = 20-30% 1.
  • Page 253 ELECTRICAL COMPONENTS WARNING Do not charge a battery quickly. Charging method with a charger CAUTION: current (voltage) variable Do not use a battery charger charging a. Measuring open circuit voltage before fast, as it forces a high amperage to loading. the battery quickly and can cause overheating and damage to the plates NOTE:...
  • Page 254 ELECTRICAL COMPONENTS Check: • Battery terminals Charging method with a charging voltage Sulfation→Clean with hot water. constant Connect loose connection correctly. Measuring open circuit voltage before Lubricate: upload. • Battery terminals NOTE: The voltage must be measured after 30 minutes Recommended lubricant without using the battery.
  • Page 255 ELECTRICAL COMPONENTS Starter cut relay b. Turn the main switch to "ON". c. Measuring the input voltage signal relay of rotation. Output voltage relay Turn signal 12 V DC 2. Check: LB RB • The output voltage relay turn signal. Replace out of specification.
  • Page 256 ELECTRICAL COMPONENTS CHECKING THE SPARK PLUG HOOD a. Disconnect the coil connectors ignition of the coil terminals 1.Check: lit. • plug cap resistance b. Connect the multimeter (Ù × 1) to the coil Replace out of specification. on, as shown. Plug cap resistance Ku 5.0 at 20 °...
  • Page 257 ELECTRICAL COMPONENTS VERIFICATION OF THE POSITION SENSOR • Tester positive probe CRANKSHAFT High voltage cable • Tester negative probe 1 .. Disconnect: • coupler crankshaft position sensor land (From the wiring harness) 2.Check: • Reliability of crankshaft position sensor Off-specification position sensor Crankshaft / stator assembly.
  • Page 258 ELECTRICAL COMPONENTS a. Connect the positive battery terminal "1" and the starter cable "2" with a jumper cable "3". WARNING • The cable used for the bridge should have at least the same capacity of the cable battery, otherwise, the cable bridge will burn.
  • Page 259 ELECTRICAL COMPONENTS VERIFICATION METER FUEL SPEAKER VERIFICATION 1. Remove: • 1.Check: Fuel tank • Resistance of the horn 2. Remove: • Replace out of specification Fuel gauge Coil resistance 3. Check: Ù 1.95-2.25 at 20 ° C • Fuel gauge resistance Out of specification Replace fuel gauge a.
  • Page 260 ELECTRICAL COMPONENTS VERIFICATION OF POSITION SENSOR CHECKING THE SPEED SENSOR THROTTLE 1. Check: • 1. Check: Output voltage of the speed sensor • Throttle Position Sensor Replace out of specification. Reading cycle of the output voltage a. Connect the digital circuit tester to 0 V to 5.0 V to 0 V to 5.0 V terminals throttle sensor body, as shown.

  • Page 261: General Information

    TROUBLESHOOTING TROUBLESHOOTING GENERAL INFORMATION POWER FAILURE INCORRECT ENGINE IDLE PERFORMANCE POOR MEDIUM AND HIGH SPEED FAILURE OF BIO MARCHASCAM SHIFT PEDAL DOES NOT MOVE SKIP GEARS CLUTCH FAILURE OVERHEATING Supercooling POOR PERFORMANCE ELFRENADO FAILURE OF THE FRONT FORK UNSTABLE HANDLING FAILURE OF SIGNALLING OR LIGHTING SYSTEM WIRING DIAGRAM...
  • Page 262 TROUBLESHOOTING Electrical System TROUBLESHOOTING 1. Battery • Discharged battery • Battery failure GENERAL INFORMATION 2. Fuse • NOTE: Fuse, damaged or incorrect • Fuse improperly installed The following guide for troubleshooting does not 3. Plug cover all possible causes. It should be useful, •...
  • Page 263 TROUBLESHOOTING Electrical System SKIP GEARS 1. Battery • Discharged battery Axis changes • Defective battery • Pedal position error changes 2. Plug • • The top of the lever returns so Electrode gap of spark plug incorrect • incorrect Heat range spark plug incorrect Forks of changes •...
  • Page 264 TROUBLESHOOTING • Fuel System Grease or oil on brake disc • • Improper carburetor adjustment Grease or oil on brake pads • • Setting the wrong fuel level Brake fluid level incorrect • Blocked air filter element FAILURE OF THE FRONT FORK Compression System •...
  • Page 265 TROUBLESHOOTING • 5. Rear Shock Light bulb turning molten • • Faulty rear shock spring Bad connection • • Oil loss Damaged or faulty wiring harness • 6. Tire (s) Grounding the circuit • • Uneven tire pressure (front Battery failure •...

  • Page 266: Wiring Diagram

    WIRING DIAGRAM (Black) RB - LBSb RB RW (Black) (Black) BL L BL L LY Y VCC SGND SPEED TACHO FUEL + FUEL - ILLMI NEUTRAL RWYWLg - ILLUMI HI BEAM TURN DIAG - Sb Bl - YW Lg W SGND DIAG VB GND...
  • Page 267 WIRING DIAGRAM FZ-16 COLOR CODE 1. Magneto CA B Black Neutral switch Coffee Br 3. Regulator / Rectifier ChChocolate 4. Main fuse Dark green Dg 5. Battery G Green 6. Main switch GyGris 7. CDI L Blue 8. Ignition coil LgVerde clear 9.

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