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EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:This is a chapter with its symbol on the upper right of each page. 2nd title 2:This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment”...
SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor 6 Chassis 7 Electrical system CARB CHAS 8 Troubleshooting...
TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
INFO CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 ENGINE SERIAL NUMBER ................1-1 IMPORTANT INFORMATION ................. 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ........1-2 REPLACEMENT PARTS .................. 1-2 GASKETS, OIL SEALS AND O-RINGS ............1-2 LOCK WASHERS/PLATES AND COTTER PINS ..........
VEHICLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION VEHICLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the frame as shown. ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.
5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COT- TER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. 300-000 EAS00024 BEARINGS AND OIL SEALS...
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 9lead 9coupler 9connector 2. Check: 9lead 9coupler 9connector Moisture → Dry with compressed air. Rust/stains → Connect and disconnect several times.
SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
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SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Crankcase installer bolt 90890-01275 This tool is necessary for installing the crankshaft. Adoptor (M12) 90890-01278 This tool is necessary for installing the crankshaft. Tappet adjusting tool 90890-01311 This tool is necessary for adjusting valve clearance.
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SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Thickness gauge 90890-03079 This tool is used to measure the valve clearance. Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 This instrument is necessary for checking the electrical system.
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Valve guide reamer (4.5 mm) 90890-04118 This tool is needed rebore the new valve guide. Ignition checker 90890-06754 This instrument is necessary for check- ing the ignition system components. Yamaha bond No. 1215 90890-85505 This sealant (bond) is used for crankcase mating surface, etc.
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head Max. warpage “*” ---- 0.03 mm (0.0012 in) Cylinder 51.000 − 51.015 mm (2.0079 − 2.0085 in) 51.1 mm Bore (2.03 in) Out of round limit ---- 0.03 mm (0.0012 in) Camshaft Drive Method...
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SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Valve, valve seat, valve guide 0.05 − 0.09 mm (0.0020 − 0.0035 in) Valve clearance (cold) ---- 0.08 − 0.12 mm (0.0032 − 0.0045 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness 22.9 −...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring Free length IN/EX 33.75 mm (1.33 in) 32.05 mm (1.26 in) Installed length (valve closed) IN/EX 24.2 mm (0.95 in) ---- IN/EX 138 − 148 N (31.02 − 33.27 lb, Compressed spring force ---- 14.07 −...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft 42.95 − 43.00 mm (1.691 − 1.693 in) Crank width “A” ---- Max. runout limit “C” ---- 0.03 mm (0.0012 in) 0.11 − 0.41 mm (0.0043 − 0.0161 in) Big end side clearance “D” ---- 0.004 −...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Kickstarter Kickstarter type Ratchet type ---- 5.8 − 14.7 N (1.3 − 3.3 lb)(0.59 − 1.50 kgf) ---- Kick clip friction force Carburetor Type VM17SH ---- I.D. mark 5VT1 00 ---- Main jet (M.J) #105 ---- Main air jet...
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SPEC MAINTENANCE SPECIFICATIONS Model T110LE/T110LSE Lubrication chart OIL RING PISTON CYLINDER HEAD CAMSHAFT CONNECTING ROD BIG END CRANKSHAFT CLUTCH TRANSMISSION OIL PUMP OIL STRAINER OIL PAN...
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system Steering bearing type Ball and race bearing ---- Lock-to-lock angle (left/right) 45° ---- Front suspension Front fork travel 95 mm (3.74 in) ---- Fork spring free length 275.7 mm (10.85 in) 270 mm (10.63 in) Installed length...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear wheel Type Spoke wheel ---- 17 × 1.40 Rim size ---- Rim material Steel ---- Max. radial wheel runout ---- 1.0 mm (0.04 in) Max. lateral wheel runout ---- 0.5 mm (0.02 in) Drive chain Type/manufacturer 428/DAIDO...
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SPEC SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear brake Drum brake type Leading, trailing ---- 20 − 30 mm (0.79 − 1.18 in) Rear brake pedal free play (pedal ---- end) Drum inside diameter 130 mm (5.12 in) 131 mm (5.16 in) Lining thickness 4.0 mm (0.16 in)
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening torque Part to be tightened Thread size Remarks Nm m·kg ft·lb Handlebar bracket and lower bracket Handlebar and handlebar bracket Brake hose and brake master cylinder (T110LSE) Brake hose and brake caliper (T110LSE) Brake master cylinder and holder (T110LSE) Brake lever holder (T110LE)
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SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks Nm m·kg ft·lb Front cowling bracket and crankcase cover (left and right) Main switch and frame Ignition coil and frame Fuel tank and frame Fuel cock and frame Seat and seat bracket NOTE: 1.
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit System voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 10° at 1,500 r/min ---- Advanced type Digital ---- DC-C.D.I 248 − 372 Ω at 20 °(68 °F)/R–W Pickup coil resistance/color ---- C.D.I. unit model/manufacturer 5VT/MORIC ---- Ignition coil...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starting system Type Constant mesh ---- Starter motor Model/manufacturer 3S4/MORIC ---- Operation voltage 12 V ---- Power output 0.35 kW ---- 0.018 − 0.022 Ω at 20 °C(68 °F) Armature coil resistance ---- Brush overall length 7 mm (0.28 in) 3.5 mm...
SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head tightening nut and stud bolt thread Rocker arm inner surfaces Rocker arm shaft Camshaft Valve stem (IN, EX) Valve stem guide (IN, EX) Piston pin Piston outside and ring groove...
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LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Transmission side plate inner surface Transmission pinion gears inner surface Starter motor guard bolt Yamaha bond No.1215 Generator lead grommet Yamaha bond No.1215 Crankcase cover bolt Yamaha bond No.1215 Crankcase mating surface Yamaha bond No.1215...
SPEC CABLE ROUTING CABLE ROUTING ∫ Push in the coupler between the handlebar and 1 Band 2 Choke cable speedometer assembly, after connected. ç Hock the wire harness onto the strap. 3 Headlight assembly ∂ Push in the coupler between the handlebar and 4 Wire harness 5 Brake hose (T110LSE) speedometer assembly, after connected.
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SPEC CABLE ROUTING 1 Wire harness å Pass through the wire harness onto the cable 2 Cable guide guide. 3 Choke cable ∫ Align the clamp with the white tape on the wire 4 Throttle cable harness. 5 Speedometer cable ç...
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SPEC CABLE ROUTING 1 Wire harness w Starter motor lead 2 Air vent hose e Choke cable 3 Air induction system vacuum hose r Throttle cable 4 Clamp t Main switch lead 5 A.C. magneto lead y Battery breather hose 6 Neutral switch lead u Fuel cock vacuum hose 7 Turn signal relay...
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SPEC CABLE ROUTING å Pass the wire harness, choke cable, and throttle cable through the guide. ∫ Pass the fuel hose and fuel cock vacuum hose through the guide. ç Pass the starter cable, neutral switch lead, and A.C. magneto lead through the guide. ∂...
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SPEC CABLE ROUTING 1 Rectifier/regulator w Main switch 2 Ignition coil e Starter motor cover 3 Air vent hose r Starter motor 4 Cover t Starter motor lead 5 Main switch lead y Footrest 6 Horn u Brake hose holder (T110LSE) 7 Spark plug lead i Cable guide (T110LSE) 8 Turn signal relay...
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SPEC CABLE ROUTING 1 Fuel sender w Battery positive lead 2 Battery breather hose e Wire harness 3 Starter motor lead 4 Rear brake light switch å Insert the battery breather hose into the hose 5 Rear brake light switch lead guide.
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SPEC CABLE ROUTING 1 Wire harness å Clamp the fuel sender lead wire harness. ∫ Align the white tape of the wire harness with the 2 Rectifier/regulator 3 Battery guide on the fuel tank. 4 C.D.I. unit ç To the battery. ∂...
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ......3-1 COVERS ......................... 3-3 REMOVING THE FRONT COWLINGS ............3-3 INSTALLING THE FRONT COWLINGS ............3-3 REMOVING THE REAR COWLINGS ............... 3-4 INSTALLING THE REAR COWLINGS .............. 3-4 REMOVING THE HEADLIGHT ASSEMBLY .............
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LUBRICATING THE SIDESTAND..............3-35 LUBRICATING THE CENTERSTAND .............. 3-35 ELECTRICAL SYSTEM ..................3-36 CHECKING AND CHARGING THE BATTERY ..........3-36 CHECKING THE FUSE ..................3-40 REPLACING THE HEADLIGHT BULBS ............3-41 ADJUSTING THE HEADLIGHT BEAM ............. 3-42...
INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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• Check that the breather hose is working properly. • Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
COVERS EASF0004 COVERS REMOVING THE FRONT COWLINGS 1. Remove: 9main switch cover 1 9center panel 2 NOTE: Remove the main switch cover by turning it in the direction of the arrow shown. 2. Remove: 9front cowlings (left and right) 1 3.
COVERS REMOVING THE REAR COWLINGS 1. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS”. 9side panel 1 2. Remove: 9rear panel 1 NOTE: Remove the rear panel by sliding it in the direc- tion of the arrow shown. 3.
COVERS 3. Install: 9side panel 1 NOTE: Before tightening side panel screw, make sure that projections is securely fitted. 9front cowlings (left and right) Refer to “INSTALLING THE FRONTCOWL- INGS”. REMOVING THE HEADLIGHT ASSEMBLY 1. Remove: 9headlight assembly 1 2. Disconnect: 9turn signal light coupler 1 9headlight connectors 2 INSTALLING THE HEADLIGHT ASSEMBLY...
ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 9Valve clearance adjustment should be made on a cold engine, at room temperature. 9When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
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ADJUSTING THE VALVE CLEARANCE 4. Measure: 9valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.05–0.09 mm (0.0020–0.0035 in) Exhaust valve 0.08–0.12 mm (0.0032–0.0045 in) MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the “I”...
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ADJUSTING THE VALVE CLEARANCE 9Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut 7 Nm (0.7 m·kg, 5.0 ft·lb) d. Measure the valve clearance again. e. If the valve clearance is still out of specifica- tion,repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained.
ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS”.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 6. Adjust: 9throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.28 in) 7.
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG 3. Adjust: 9throttle cable free play MMMMMMMMMMMMMMMMMMMMMMMM a. Pull back the adjusting nut cover. b. Loosen the locknut 1 c. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.
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CHECKING THE SPARK PLUG 4. Check: 9spark plug type Incorrect → Change. Spark plug type (manufacturer) C6HSA (NGK) 5. Check: 9electrode 1 Damage/wear → Replace the spark plug. 9insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6.
MEASURING THE COMPRESSION PRESSURE EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 9valve clearance Out of specification → Adjust Refer to “ADJUSTING THE VALVE CLEAR- ANCE”. 2. Start the engine, warm it up for several min- utes, and then turn it off.
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MEASURING THE COMPRESSION PRESSURE MMMMMMMMMMMMMMMMMMMMMMMM a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. To prevent sparking, ground the spark plug lead before cranking the engine. c.
CHECKING THE ENGINE OIL LEVEL EAS00070 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3.
CHANGING THE ENGINE OIL EAS00075 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 9oil level plug 1 9engine oil drain plug 2 (with gasket) 4.
CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH RELEASE SYSTEM 5. Install: 9air filter element 9air filter case cover Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHECKING THE FUEL AND VACUUM HOSES EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS”. 2. Check: 9carburetor joint 1 9intake manifold 2 Cracks/damage →...
ADJUSTING THE FRONT BRAKE(T110LE)/ ADJUSTING THE REAR BRAKE EAS00109 CHASSIS EAS00113 ADJUSTING THE FRONT BRAKE (T110LE) 1. Check: 9brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 10–20 mm (0.39–0.79 in) 2.
ADJUSTING THE REAR BRAKE/ CHECKING THE FRONT BRAKE PADS (T110LSE) 2. Adjust: 9brake pedal free play MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the adjuster 1 in direction a or b until the specified brake pedal free play is obtained. Brake pedal free play is Direction a a increased.
CHECKING THE REAR BRAKE SHOES (T110LSE)/ CHECKING THE FRONT AND REAR BRAKE SHOES (T110LE)/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00126 CHECKING THE REAR BRAKE SHOES (T110LSE) 1. Operate the brake. 2. Check: 9wear indicator 1 Reaches the wear limit line 2 → Replace the brake shoes as a set.
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT BRAKE HOSE (T110LSE) 3. Adjust: 9rear brake light operation timing MMMMMMMMMMMMMMMMMMMMMMMM a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.
BLEEDING THE HYDRAULIC BRAKE SYSTEM (T110LSE) EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM (T110LSE) Bleed the hydraulic brake system when- ever: 9 9 the system is disassembled. 9 9 a brake hose is loosened, disconnected or replaced. 9 9 the brake fluid level is very low. 9 9 brake operation is faulty.
BLEEDING THE HYDRAULIC BRAKE SYSTEM(T110LSE)/ ADJUSTING THE DRIVE CHAIN SLACK NOTE: Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i.
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ADJUSTING THE DRIVE CHAIN SLACK 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.
LUBRICATING THE DRIVE CHAIN/ CHECKING THE BRAKE FLUID LEVEL (T110LSE) EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas.
CHECKING THE BRAKE FLUID LEVEL(T110LSE)/ CHECKING AND ADJUSTING THE STEERING HEAD 9 9 When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Brake fluid may damage painted surfaces and plastic parts.
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CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: 9steering head MMMMMMMMMMMMMMMMMMMMMMMM a. Pull back the rubber cover 1. b. Loosen the upper ring nut 2 c. Loosen the lower ring nut 3 and then tight- en it to specification with a steering nut wrench 4.
CHECKING THE FRONT FORK EAS00149 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Check: 9inner tube Damage/scratches → Replace. 9oil seal Oil leakage →...
CHECKING THE TIRES EASF0015 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 9tire pressure Out of specification → Regulate. 9 9 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
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Ltd. for this model. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. 3-33...
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES 9 9 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. 9 9 After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut 1 1 to specification.
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVER AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. Damaged outer cable may cause the cable to corrode and interfere with its movement.
CHECKING AND CHARGING THE BATTERY EAS00176 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 9 9 Wear protective eye gear when handling or working near batteries.
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CHECKING AND CHARGING THE BATTERY 2. Disconnect: 9battery leads (from the battery terminals) First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: 9battery 4. Check: 9electrolyte level The electrolyte level should be between the minimum level mark a and the maximum level mark b.
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CHECKING AND CHARGING THE BATTERY 9 9 Loosen the battery sealing caps. 9 9 Make sure the battery breather hose and battery vent are free of obstructions. 9 9 To ensure maximum performance, always charge a new battery before using it. 9 9 Do not use a high-rate battery charger.
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CHECKING AND CHARGING THE BATTERY 9warpage or buckling of the battery plates or insulators is evident. 7. Check: 9battery breather hose and battery vent Obstruction → Clean. Damage → Replace. 8. Install: 9battery 9. Connect: 9battery breather hose 1 9 9 When checking the battery, make sure the battery breather hose is properly installed and routed correctly.
CHECKING THE FUSE EASF0017 CHECKING THE FUSE To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Open the seat, and then open the battery cover. 2. Remove: 9fuse holder 1 3.
REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to the headlight bulb. 1. Remove: 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”. 2. Remove: 9headlight bulb holder 1 3. Remove: 9headlight bulb 1 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
ADJUSTING THE HEADLIGHT BEAM EAS00186 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 9headlight beam (vertically) MMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the bolt 1. b. Slide the bottom of the headlight unit for- ward a or backward b. Slide forward Headlight beam is raised. Slide backward Headlight beam is lowered.
CHAPTER 4 ENGINE REMOVING THE ENGINE ..................4-1 ENGINE OIL ...................... 4-1 CARBURETOR ....................4-1 MUFFLER AND EXHAUST PIPE ..............4-1 FOOTREST AND ENGINE GUARD ..............4-2 BRAKE PEDAL ....................4-2 SHIFT PEDAL....................4-3 FRONT COWLING BRACKET ................4-3 WIRE, CABLE AND HOSE ................4-3 ENGINE ASSEMBLY ..................
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CYLINDER AND PISTON ..................4-31 REMOVING THE CYLINDER AND PISTON ............ 4-32 CHECKING THE CYLINDER AND PISTON ............. 4-33 CHECKING THE PISTON RINGS ..............4-34 CHECKING THE PISTON PIN ................4-35 INSTALLING THE PISTON AND CYLINDER ........... 4-36 GENERATOR AND STARTER CLUTCH ............... 4-38 REMOVING THE GENERATOR ...............
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SHIFT SHAFT ......................4-62 REMOVING THE SHIFT SHAFT ..............4-63 CHECKING THE SHIFT SHAFT ............... 4-65 CHECKING THE STOPPER LEVER ..............4-65 CHECKING THE SHIFT GUIDE ............... 4-65 CHECKING THE OIL SEAL ................4-65 INSTALLING THE SHIFT SHAFT ..............4-66 CRANKCASE AND CRANKSHAFT ..............
REMOVING THE ENGINE EASF0018 ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine in order to remove the following components. • Cylinder head • Cylinder • Piston • Clutch • Kickstarter • Shift shaft • Oil pump •...
INSTALLING THE ENGINE EASF0019 INSTALLING THE ENGINE ENGINE ASSEMBLY Securely support the vehicle so there is no danger of it falling over when installing engine. 1. Install: 9engine assembly 9rear lower mounting bolt 9front mounting bolt 9rear upper mounting bolt 9washer 9rear lower mounting nut 34 Nm (3.4 m·kg, 25 ft•lb)
INSTALLING THE ENGINE CARBURETOR 1. Install: 9carburetor assembly Refer to “CARBURETOR” in chapter 5. 2. Adjust: 9throttle cable free play 9rear brake light operation timing Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” and “ADJUSTING THE REAR BRAKE LIGHT SWITCH” in chapter 3.
CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9carburetor assembly Refer to “CARBURETOR” in chapter 5. 9exhaust pipe Refer to “REMOVING THE ENGINE”. 2. Remove: 9air induction system pipe bolts 9air induction system pipe 1 9air induction system pipe gasket...
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CYLINDER HEAD 6. Align: • “I” mark a on the generator rotor (with the stationary pointer b on the crank- case) MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the “I” mark c on the camshaft sprocket with the stationary point- er d on the cylinder head.
CYLINDER HEAD 10. Remove: 9cylinder head bolts 9cylinder head nuts 9cylinder head " NOTE: 9Loosen the nuts in the proper sequence as shown. 9Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. 11.
CYLINDER HEAD 3. Measure: 9cylinder head warpage Out of specification → Resurface the cylin- der head. Maximum cylinder head warpage 0.03 mm (0.0012 in) MMMMMMMMMMMMMMMMMMMMMMMM a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c.
CYLINDER HEAD EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: 9timing chain tensioner Cracks/damage → Replace. MMMMMMMMMMMMMMMMMMMMMMMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. b.
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CYLINDER HEAD 3. Tighten: 9cylinder head nuts 22 Nm (2.2 m·kg, 16 ft•lb) 9cylinder head bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) " NOTE: 9Lubricate the cylinder head nuts and bolts with engine oil. 9Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
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CYLINDER HEAD 5. Install: 9timing chain tensioner MMMMMMMMMMMMMMMMMMMMMMMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise.
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CYLINDER HEAD 8. Check: 9“I” mark a Align the “I” mark on the generator rotor with the stationary pointer b on the crank- case. 9“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head.
CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1. Loosen: 9locknuts 1 9adjusting screws 2 2. Remove: 9camshaft retainer 1 3. Remove: 9camshaft 1 NOTE: Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft.
CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 9camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9camshaft lobe dimensions a and b → specification Replace camshaft. Camshaft lobe dimension limit Intake a a 25.745 mm (1.0136 in) b b 21.015 mm (0.8274 in) Exhaust a a 25.749 mm (1.0137 in) b b 20.924 mm (0.8238 in)
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CAMSHAFT 2. Check: 9rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: 9rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 10.000 – 10.015 mm (0.3937 – 0.3943 in) <Limit>: 10.030 mm (0.3949 in) 4.
CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: 9camshaft sprocket Worn more than 1/4 tooth a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain 2 Camshaft sprocket EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1.
VALVES AND VALVE SPRINGS EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylinder head, camshaft and rocker arms. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.
VALVES AND VALVE SPRINGS 2. Remove: 9valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 3. Remove: 9upper spring seat 1 9valve spring 2 9valve stem seal 3 9lower spring seat 4 9valve 5 NOTE:...
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VALVES AND VALVE SPRINGS 2. Replace: 9valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C in an oven. MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the valve guide with the valve guide remover 1.
VALVES AND VALVE SPRINGS 6. Measure: 9valve stem runout Out of specification → Replace the valve. NOTE: 9When installing a new valve, always replace the valve guide. 9If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout limit 0.01 mm (0.0004 in) EAS00240...
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VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. LLLLLLLLLLLLLLLLLLLLLLLL 4. Lap: 9valve face 9valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.
VALVES AND VALVE SPRINGS j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. LLLLLLLLLLLLLLLLLLLLLLLL EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
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VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 9valve stem end (with an oil stone) 2. Lubricate: 9valve stem 1 9valve stem seal 2 (with the recommended lubricant) Recommended lubricant Engine oil 3.
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VALVES AND VALVE SPRINGS 4. Install: 9valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.
CYLINDER AND PISTON EASF0028 REMOVING THE CYLINDER AND PISTON NOTE: Prior to removing the cylinder and piston, remove the cylinder head. 1. Remove: 9cylinder 1 2. Remove: 9dowel pins 1 9gasket 2 3. Remove: 9piston pin clip 1 9piston pin 2 9piston 3 Do not use a hammer to drive the piston pin out.
CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 9piston wall 9cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 9piston-to-cylinder clearance MMMMMMMMMMMMMMMMMMMMMMMM a. Measure cylinder bore “C” with the cylinder bore gauge.
CYLINDER AND PISTON Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.020 – 0.025 mm (0.0008 – 0.0010 in) <Limit>: 0.15 mm (0.0059 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
CYLINDER AND PISTON 3. Measure: 9piston ring end gap Out of specification → Replace the piston ring. NOTE: The end gap of the oil ring expander cannot be measured. If the end gaps of the oil ring rails are excessive, replace all three piston rings. Piston ring end gap Top ring 0.10 –...
CYLINDER AND PISTON 4. Calculate: 9piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b b – Piston pin outside diameter a a Piston-pin-to-piston-pin-bore clearance 0.002 – 0.017 mm (0.0001 –...
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CYLINDER AND PISTON 3. Install: 9gasket 1 9dowel pins 2 4. Lubricate: 9piston 9piston rings 9cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 9piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring å...
GENERATOR AND STARTER CLUTCH EAS00346 REMOVING THE GENERATOR 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9front cowling (left) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9shift pedal 9drive sprocket cover Refer to “REMOVING THE DRIVE CHAIN...
GENERATOR AND STARTER CLUTCH EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: 9starter clutch 1 14 Nm (1.4 m•kg, 10.1 NOTE: 9While holding the generator rotor 2 with the sheave holder, tighten the starter clutch bolt. 9Do not allow the sheave holder to touch the projection on the generator rotor.
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GENERATOR AND STARTER CLUTCH 3. Apply: 9sealant (on to the generator lead grommet) Yamaha bond No. 1215 90890-85505 4. Install: 9gasket 9crankcase cover 10 Nm (1.0 m•kg, 7.2 ft•lb) 4-43...
KICKSTARTER REMOVING THE KICKSTARTER 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”.
CLUTCH EAS00277 REMOVING THE CLUTCH 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”.
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CLUTCH 6. Straighten the lock washer tab. 7. Loosen: 9clutch boss nut 1 NOTE: While holding the clutch boss 2 with the uni- versal clutch holder 3, loosen the clutch boss nut. Universal clutch holder 90890-04086 8. Remove: 9clutch boss nut 1 9lock washer 2 9clutch boss 3 9washer 4...
CLUTCH EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: 9clutch spring Damage → Replace the clutch springs as a set. 2. Measure: 9clutch spring free length a Out of specification → Replace the clutch springs as a set.
CLUTCH CHECKING THE CLUTCH RELEASE SHIFT ARM 1. Check: 9clutch release shift arm 1 Damage/wear → Replace. 9clutch release adjusting screw 2 Damage/wear → Replace. EAS00293 INSTALLING THE CLUTCH 1. Install: 9washer 9cage 1 9cage springs 2 9rollers 3 9clutch shoe housing boss 4 2.
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CLUTCH 4. Tighten: 9clutch boss nut 1 70 Nm (7.0 m•kg, 50 ft•lb) NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3, tighten the clutch boss nut. Universal clutch holder 90890-04086 5. Bend the lock washer tab along a flat side of the nut.
OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1. Install: 9gasket 9oil pump assembly 1 7 Nm (0.7 m•kg, 5.0 ft•lb) NOTE: Install the gasket with section a in the position as shown in the illustration. After tightening the bolts, make sure the oil pump turns smoothly.
SHIFT SHAFT EASF0037 SHIFT SHAFT 1 Shift lever assembly 8 Shift guide spring t Stopper lever spring 2 Shift drum segment 9 Shift fork guide bar y Stopper lever assembly 3 Washer 0 Shift pedal 4 Thrust bearing q Shift shaft 5 Guide w Shift lever 6 Pawl holder...
SHIFT SHAFT REMOVING THE SHIFT SHAFT 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9clutch Refer to “CLUTCH”. 9oil pump driven gear Refer to “OIL PUMP”. 3. Remove: 9shift fork guide bar 1 9washer 2 9shift guide spring 4.
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SHIFT SHAFT 6. Remove: 9shift shaft assembly 1 9shift shaft spring stopper 2 9shift lever assembly 3 7. Remove: 9circlip 1 9washer 2 9shift shaft spring 3 9shift lever 4 9shift shaft 5 8. Remove: 9stopper lever assembly 1 9stopper lever spring 2 9.
SHIFT SHAFT EAS00331 INSTALLING THE SHIFT SHAFT 1. Install: 9shift drum segment 1 12 Nm (1.2 m•kg, 8.6 ft•lb) NOTE: Apply locking agent (LOCTITE ® ) to the threads of shift drum segment screw. 2. Install: 9stopper lever 1 9stopper lever spring 2 NOTE: 9Hook the ends 3 of the stopper lever spring onto the stopper lever and the crankcase boss.
CRANKCASE AND CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 9engine Refer to “REMOVING THE ENGINE”. 2. Remove: 9starter motor lead 9starter motor Refer to “STARTER MOTOR” in chapter 7. 3. Remove: 9cylinder head Refer to “CYLINDER HEAD”. 9cylinder 9piston Refer to “CYLINDER AND PISTON”. 9clutch Refer to “CLUTCH”.
CRANKCASE AND CRANKSHAFT 6. Remove: 9crankcase bolts 9starter motor lead holders 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 7.
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CRANKCASE AND CRANKSHAFT 2. Measure: 9big end side clearance Out of specification → Replace the crank- shaft. Big end side clearance 0.11 – 0.41 mm (0.0043 – 0.0161 in) 3. Measure: 9crankshaft width Out of specification → Replace the crank- shaft.
CRANKCASE AND CRANKSHAFT EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: 9crankcase Cracks/damage → Replace. 9oil delivery passages Obstructions → Blow out with compressed air.
90890-01278 EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: 9 9 sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery 1. 2. Install: 9dowel pins 2 3.
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4. Install: 9starter motor lead holders 9crankcase bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Apply sealant to the threads of crankcase bolt Yamaha bond No. 1215 90890-85505 5. Apply: 9engine oil (onto the crankshaft bearings and oil deliv- ery holes) 6.
TRANSMISSION EASF0042 REMOVING THE TRANSMISSION NOTE: Prior to removing the transmission, separate the crankcase. 1. Remove: 9shift fork guide bar 1 9shift fork guide bar spring 9shift fork “R” 2 9shift fork “L” 3 9shift drum 4 NOTE: Note the position of each part. Pay particular attention to location and direction of shift forks.
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TRANSMISSION 2. Remove: 9circlips 1 9washers 2 9collars 3 91st wheel gear 4 94th wheel gear 5 93rd wheel gear 6 9side plate 7 9side plate spring 8 9drive axle/2nd wheel gear 9 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to both of the shift forks.
TRANSMISSION 4. Check: 9transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. NOTE: 19.3~19.5 mm When reassembling the drive axle, press the 2nd wheel gear 1 onto the drive axle 2 as shown.
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TRANSMISSION 2. Check: 9transmission 9shift drum 9shift forks Rough movement → Repair. NOTE: 9Oil each gear, shaft, and bearing thoroughly. 9Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. 4-79...
CARB CHAPTER 5 CARBURETOR CARBURETOR ...................... 5-1 REMOVING THE CARBURETOR ..............5-2 DISASSEMBLING THE CARBURETOR ............5-3 CHECKING THE CARBURETOR ..............5-5 ASSEMBLING THE CARBURETOR ..............5-7 INSTALLING THE CARBURETOR ..............5-7 MEASURING AND ADJUSTING THE FUEL LEVEL......... 5-8 CHECKING THE FUEL COCK OPERATION............. 5-9 AIR INDUCTION SYSTEM..................
CARB CARBURETOR EASF0043 CARBURETOR CARBURETOR 1 Starter plunger assem- 6 Jet needle set e Needle jet o Float pivot pin 7 Throttle valve r Main jet p Float chamber 2 Coasting enricher 8 Throttle stop screw set t Pilot jet a Fuel drain screw 9 Pilot air screw set y Needle valve...
CARB CARBURETOR REMOVING THE CARBURETOR Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 1. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 2. Loosen: 9fuel drain screw 1 3. Drain: 9fuel (from float chamber) 4.
CARB CARBURETOR 11. Check: 9hose joints Cracks/damage → Replace. 12. Check: 9air vent hose 9fuel hoses Cracks/damage/wear → Replace. Obstructions → Clean. Blow out the hoses with compressed air. EAS00487 ASSEMBLING THE CARBURETOR 9 9 Before assembling the carburetor, wash all of the parts in a petroleum-based sol-vent.
CARB CARBURETOR 5. Adjust: 9throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.28 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1.
CARB CARBURETOR 2. Adjust: 9fuel level MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the carburetor. b. Check the needle valve. c. If worn, replace the needle valve. d. If fine, adjust the float level by the needle valve is slightly bending the float tang 1. e.
CARB AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
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CARB AIR INDUCTION SYSTEM 1 Air cut-off valve assembly 2 Air induction system hose (air cut-off valve assembly to cylinder head) 3 Air induction system vacuum hose 4 Air induction system hose (air cut-off valve assembly to air filter) 5 Air filter 5-11...
CARB AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYS- 1. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9rear cowling (left) Refer to “REMOVING THE REAR COWL- INGS” in chapter 3. 9air filter 1 2.
CHAS CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISC (T110LSE) ........... 6-1 REMOVING THE FRONT WHEEL ..............6-2 CHECKING THE FRONT WHEEL ..............6-3 CHECKING THE BRAKE DISC ................. 6-5 CHECKING THE SPEEDOMETER GEAR UNIT..........6-6 INSTALLING THE FRONT WHEEL ..............6-7 FRONT WHEEL AND DRUM BRAKE (T110LE) ...........
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CHAS HANDLEBAR ......................6-44 REMOVING THE HANDLEBAR ................ 6-45 CHECKING THE HANDLEBAR ................. 6-47 INSTALLING THE HANDLEBAR ..............6-47 STEERING HEAD ....................6-50 REMOVING THE LOWER BRACKET ............... 6-51 CHECKING THE STEERING HEAD ..............6-51 INSTALLING THE STEERING HEAD ..............6-53 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM .......
CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9speedometer cable 1 9axle nut 2 9washer 3 3.
CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EAS00526 CHECKING THE FRONT WHEEL 1. Check: 9wheel axle Roll the wheel axle on a flat surface. → Replace. Bends Do not attempt to straighten a bent wheel axle. 2. Check: 9tire Damage/wear → Replace. Refer to “CHECKING THE TIRES”...
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CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) 5. Check: 9spacers Damage/wear → Replace. 9 9 After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim.
CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) d. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing inner race 4 4 or balls 5 5 . Contact should be made only with the outer race 6 6 .
CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) 3. Measure: 9brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 3.0 mm (0.12 in) 4. Adjust: 9brake disc deflection MMMMMMMMMMMMMMMMMMMMMMMM a.
CHAS FRONT WHEEL AND BRAKE DISC (T110LSE) EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 9wheel axle 9wheel bearings 9oil seal lips 9speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 9brake disc 9front wheel Refer to “CHECKING THE BRAKE DISC”. NOTE: Make sure the projection a on the speedometer gear unit fits between the projections on the...
CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) EASF0045 FRONT WHEEL AND DRUM BRAKE (T110LE) 1 Front wheel axle 0 Brake camshaft 2 Collar q Brake shoe plate 3 Oil seal w Speedometer driven gear 4 Bearing e Brake shoe wear indicator 5 Spacer r Brake camshaft lever 6 Oil seal...
CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9brake cable adjusting nut 9brake cable 9boot 9compression spring...
CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) 2. Remove: 9brake shoes 1 9speedometer clutch 2 9speedometer drive gear 3 9washer 4 3. Remove: 9brake camshaft lever 1 9brake shoe wear indicator 2 9brake camshaft 3 NOTE: When removing the brake camshaft lever, mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft.
CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: 9speedometer clutch Bends/damage/wear → Replace. 2. Check: 9speedometer drive gear 1 9speedometer driven gear 2 Damage/wear → Replace. EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes.
CHAS FRONT WHEEL AND DRUM BRAKE (T110LE) 2. Install: 9speedometer driven gear 1 9bushing (with the special tool 2) Meter gear bush tool 90890-01052 EAS00538 ASSEMBLING THE FRONT WHEEL 1. Install: 9brake shoe plate assembly Align the tab on the speedometer clutch with the slot in the wheel hub.
CHAS REAR WHEEL AND BRAKE EAS00563 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
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CHAS REAR WHEEL AND BRAKE 5. Remove: 9rear wheel axle nut 1 9washer 9rear wheel axle 2 9washer 9collar 6. Remove: 9rear wheel assembly 1 NOTE: Push the rear wheel forward and remove the drive chain from the driven sprocket. 7.
CHAS REAR WHEEL AND BRAKE EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 9brake camshaft 1 9brake shoe wear indicator 2 9brake camshaft lever 7 Nm (0.7 m·kg, 5.0 ft·lb) MMMMMMMMMMMMMMMMMMMMMMMM a. Install the brake camshaft so its punch mark a is positioned as shown.
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CHAS REAR WHEEL AND BRAKE 4. Adjust: 9drive chain slack Drive chain slack 25–35 mm (0.98–1.38 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 5. Tighten: 9wheel axle nut 60 Nm (6.0 m·kg, 43 ft·lb) Do not loosen the wheel axle nut after tight- ening it to the specified torque.
CHAS FRONT BRAKE (T110LSE) EAS00579 Disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: 9 9 Never disassemble brake components unless absolutely necessary. 9 9 If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
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CHAS FRONT BRAKE (T110LSE) 2. Remove: 9clips 9brake pad retaining pin 9brake pads 1 9brake pad spring 3. Measure: 9brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.4 mm (0.06 in) 4.
CHAS FRONT BRAKE (T110LSE) 5. Lubricate: 9brake pad retaining pin Recommended lubricant Lithium-soap-based grease 9Do not allow grease to contact the brake pads. 9Remove any excess grease. 6. Install: 9brake caliper bolts 35 Nm (3.5 m·kg, 25 ft·lb) 7. Check: 9brake fluid level Below the minimum level mark a →...
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CHAS FRONT BRAKE (T110LSE) 1. Remove: 9union bolt 1 9copper washers 2 9brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: 9brake caliper 1 9pin 9brake pad retaining pin 9brake pads 9brake pad spring 3.
CHAS FRONT BRAKE (T110LSE) EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1.
CHAS FRONT BRAKE (T110LSE) EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 9 9 Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. 9 9 Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
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CHAS FRONT BRAKE (T110LSE) 4. Fill: 9brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 3 or 4 9 9 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
CHAS FRONT BRAKE (T110LSE) EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: 9front cowling (right) Refer to “REMOVING THE FRONT COWL- INGS” in chapter 3. 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”...
CHAS FRONT BRAKE (T110LSE) 3. Check: 9brake master cylinder reservoir 1 Cracks/damage → Replace. 9brake master cylinder reservoir diaphragm 2 Damage/wear → Replace. 4. Check: 9brake hose 1 Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 9 9 Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid.
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CHAS FRONT BRAKE (T110LSE) 3. Install: 9copper washers 1 9brake hose 2 9union bolt 26 Nm (2.6 m·kg, 19 ft·lb) Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING”. NOTE: Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).
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CHAS FRONT BRAKE (T110LSE) 5. Bleed: 9brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (T110LSE)” in chapter 3. 6. Check: 9brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL (T110LSE)”...
CHAS FRONT FORK EASF0054 FRONT FORK 1 Front fork cap bolt 0 Front fender 2 Dust seal 3 Oil seal clip 4 Oil seal 5 Fork spring 6 Damper rod 7 Inner tube 8 Outer tube 9 Damper rod bolt 6-35...
CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
CHAS FRONT FORK 7. Remove: 9front fork cap bolt 1 (with a 10-mm hexagonal wrench) 8. Loosen: 9lower bracket pinch bolt 2 Before loosening the lower bracket pinch bolt, support the front fork leg. 9. Remove: 9front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the...
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CHAS FRONT FORK 4. Remove: 9damper rod assembly bolt 9copper washer NOTE: While holding the damper rod assembly with a 10 mm hexagon nut/socket wrench 1 and the Thandle 2, loosen the damper rod assembly bolt 3. T-handle 90890-01326 5. Remove: 9inner tube 9rebound spring 9damper rod...
CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 9inner tube 1 9outer tube 2 Bends/damage/scratches → Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2.
CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 9 9 Make sure the oil levels in both front fork legs are equal. 9 9 Uneven oil levels can result in poor han- dling and a loss of stability.
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CHAS FRONT FORK NOTE: Tighten the damper rod assembly bolt 1 while holding the damper rod with the T-handle 2 and a 10 mm hexagon nut/socket wrench 3. T-handle 90890-01326 4. Install: 9oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3) Fork seal driver weight 90890-01184...
CHAS FRONT FORK 6. Fill: 9front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.059 L (59cm Recommended oil Fork oil 10W or equivalent Front fork leg oil level a a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring)
CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9front cowlings (left and right) Refer to “REMOVING THE FRONT COWL- INGS”...
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CHAS HANDLEBAR 7. Remove: 9right handlebar switch 1 8. Remove: 9throttle cable 1 9throttle grip 2 9. Remove: 9washer 9starter lever 1 9starter cable 2 9spring washer 10. Remove: 9left handlebar switch 1 11. Remove: 9handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
CHAS HANDLEBAR 12. Remove: 9wire harness strap 1 13. Remove: 9handlebar 1 9washers 9bushings 9handlebar bracket 2 EAS00668 CHECKING THE HANDLEBAR 1. Check: 9handlebar 1 Bends/cracks/damage → Replace. Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. EAS00670 INSTALLING THE HANDLEBAR 1.
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CHAS HANDLEBAR 3. Install: 9bushings 9washers 9handlebar 16 Nm (1.6 m·kg, 12 ft·lb) 9wire harness strap Refer to “CABLE ROUTING” in chapter 2. 4. Install: 9handlebar grip MMMMMMMMMMMMMMMMMMMMMMMM a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b.
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CHAS HANDLEBAR 8. Install: 9brake master cylinder (T110LSE) 11 Nm (1.1 m·kg, 7.9 ft·lb) Refer to “FRONT BRAKE (T110LSE)”. 9brake lever holder (T110LE) 7 Nm (0.7 m·kg, 5.0 ft·lb) 9. Install: 9plastic locking ties Refer to “CABLE ROUTING” in chapter 2. 10.
CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9front panel Refer to “REMOVING THE FRONT COWL- INGS”...
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CHAS STEERING HEAD 2. Check: 9bearings 1 9bearing races 2 Damage/pitting → Replace. 3. Replace: 9bearings 9bearing races MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
CHAS STEERING HEAD EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: 9upper bearing 9lower bearing 9bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 9lower ring nut 9upper ring nut Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 3. Install: 9front fork legs Refer to “FRONT FORK”.
REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM EAS00691/EAS00702 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
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REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM 5. Remove: 9rear shock absorber bolt (left and right) 1 9washer 9rear shock absorber nut (left and right) 2 9washers 9rear shock absorber assembly (left and right) 3 6. Measure: 9swingarm side play 9swingarm vertical movement MMMMMMMMMMMMMMMMMMMMMMMM a.
REAR SHOCK ABSORBER ASSEMBLY AND CHAS SWINGARM EAS00707 CHECKING THE SWINGARM 1. Check: 9swingarm Bends/cracks/damage → Replace. 2. Check: 9swingarm pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. Do not attempt to straighten a bent pivot shaft.
CHAS DRIVE CHAIN AND SPROCKETS EAS00706 REMOVING THE DRIVE CHAIN AND SPROCKETS 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
CHAS DRIVE CHAIN AND SPROCKETS 7. Straighten the lock washer tabs. 8. Remove: 9driven sprocket nuts 9driven sprocket bolts 9lock washers 1 9driven sprocket 2 EAS00710 CHECKING THE DRIVE CHAIN 1. Measure: 1 2 3 4 5 6 7 8 9 0 q w e r t 9Measure the length of 15 links on the inner side a and outer side b of the pin and cal- culate the length between pin centers.
CHAS DRIVE CHAIN AND SPROCKETS 4. Check: 9drive chain rollers 1 Damage/wear → Replace the drive chain. 9drive chain side plates 2 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: 9drive chain Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 6.
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CHAS DRIVE CHAIN AND SPROCKETS 3. Install: 9drive sprocket 1 9circlip 2 NOTE: Install the drive sprocket with the flat side a towards the engine. 4. Lubricate: 9drive chain 9master link Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 5.
ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ................7-1 CHECKING SWITCH CONTINUITY ..............7-3 CHECKING THE SWITCHES ................7-5 CHECKING THE BULBS AND BULB SOCKETS ..........7-7 TYPES OF BULBS ................... 7-7 CHECKING THE CONDITION OF THE BULBS ..........7-8 CHECKING THE CONDITION OF THE BULB SOCKETS .......
ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the cou- pler terminal slots 1 1 .
ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
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ELEC CHECKING THE SWITCHES 1 Horn switch 2 Dimmer switch 3 Turn signal switch 4 Neutral switch 5 Rear brake light switch 6 Fuse 7 Start switch 8 Light switch 9 Front brake light switch (T110LSE) 0 Front brake light switch (T110LE) q Main switch...
ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 9bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 9 9 Be sure to hold the socket firmly when removing the bulb.
ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: 9bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...
ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no 9Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse Minimum open-circuit voltage 2.
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ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 9Disconnect the spark plug cap from the 9Remove the spark plug cap from the spark spark plug. plug lead. 9Connect the pocket tester (“Ω × 1k” range) to 9Connect the ignition checker 1 as shown.
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ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance 9Disconnect the ignition coil connector from 9Disconnect the pickup coil coupler from the the ignition coil terminal. wire harness. 9Connect the pocket tester (Ω × 1) to the igni- 9Connect the pocket tester (Ω...
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ELEC IGNITION SYSTEM EAS00754 9. Wiring 9Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM”. 9Is the ignition system wiring properly con- nected and without defects? Properly connect or Replace the C.D.I. repair the ignition unit. system wiring. 7-14...
ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C 3.
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ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00764 4. Starter relay 6. Start switch 9Remove the starter relay from the starter 9Check the start switch for continuity. relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”. 9Connect the pocket tester (Ω × 1) and bat- 9Is the start switch OK? tery (DC 12 V) to the starter relay coupler as shown.
ELEC STARTER MOTOR REMOVING THE STARTER MOTOR 1. Remove: 9footrest assembly 9starter motor guard Refer to “REMOVING THE ENGINE” in chapter 4. 2. Remove: 9starter motor 1 3. Remove: 9starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 1. Remove: 9starter motor front cover bolts (with washers) 9starter motor front cover 1 9gasket 2...
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ELEC STARTER MOTOR 2. Measure: 9commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) 3. Measure: 9mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
ELEC STARTER MOTOR 5. Measure: 9brush length a Out of specification → Replace the brush- es as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 9brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 3.92–5.88 N (400–600 gf) 7.
ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery 9Check the condition of the battery. The battery cannot be charged. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C 3.
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ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Charging coil resistance 9Connect the engine tachometer to the spark 9Disconnect the stator coil coupler from the plug lead. wire harness. 9Connect the pocket tester (Ω × 1) to the 9Connect the pocket tester (DC 20 V) to the battery as shown.
ELEC LIGHTING SYSTEM EAS00781 EAS00776 TROUBLESHOOTING 2. Lighting coil resistance Any of the following fail to light: head- 9Disconnect the stator coil coupler from the light, high beam indicator light, taillight, or wire harness. meter light. 9Connect the pocket tester (Ω × 1) to the lighting coil terminals as shown.
ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM 9Connect the pocket tester (AC 20 V) to the 1. The headlight and the high beam indicator headlight and high beam indicator light con- light fail to come on. nectors as shown. EAS00784 åWhen the dimmer switch is set to “%”.
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ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket 9Check the meter light bulb and socket for 9Check the tail/brake light bulb and socket for continuity.
ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 7-29...
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ELEC SIGNALING SYSTEM 1 Main switch 2 Fuse 3 Battery r Rear brake light switch t Front brake light switch y Turn signal relay u Horn o Horn switch a Turn signal switch s Tail/brake light d Rear turn signal light f Front turn signal light h Neutral switch j Fuel sender...
ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery 9 9 Any of the following fail to light: turn sig- 9Check the condition of the battery. nal light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE 9 9 The horn fails to sound. BATTERY”...
ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 9Disconnect the pink connector at the horn 1. The horn fails to sound. terminal. 1. Horn switch 9Connect a jumper lead 1 to the horn termi- nal and ground the jumper lead. 9Check the horn switch for continuity.
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ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. 9Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light coupler (wire harness side) as shown. 9Check the tail/brake light bulb and socket for Positive tester probe →...
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ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator 9Connect the pocket tester (DC 20 V) to the light or both fail to blink. turn signal relay coupler as shown. 1. Turn signal indicator light bulb and socket Positive tester probe →...
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ELEC SIGNALING SYSTEM 5. Voltage 4. Voltage 9Connect the pocket tester (DC 20 V) to the 9Connect the pocket tester (DC 20 V) to the turn signal light coupler (wire harness side) turn signal relay coupler as shown. as shown. Positive tester probe →...
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ELEC SIGNALING SYSTEM EAS00801 9Set the main switch to “ON”. 4. The gear position indicator lights fail to 9Set the turn signal switch to “4” or “6”. come on. 9Measure the voltage (DC 12 V) of the chocolate 1 or dark green lead terminal 2 1.
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ELEC SIGNALING SYSTEM EAS00804 3. Voltage 5. The fuel level gauge fails to operate. 9Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) as shown. 9Remove the fuel sender from the fuel tank. 9Connect the pocket tester to the fuel sender Neutral indicator light Positive tester probe →...
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ELEC SIGNALING SYSTEM 3. Fuel level gauge 2. Voltage 9Connect the pocket tester (DC 20 V) to the 9Set the main switch to “ON”. 9Move the float up 1 or down 2. meter assembly coupler (wire harness side) 9Check that the fuel level gauge needle as shown.
TRBL SHTG CHAPTER 8 TROUBLESHOOTING TROUBLESHOOTING ................... 8-1 ELECTRICAL SYSTEM ..................8-1 COMPRESSION SYSTEM ................8-2 INTAKE AND EXHAUST SYSTEM ..............8-3...
TRBL TROUBLESHOOTING SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM *CHECK ALL WIRES CONNECTIONS IGNITION COIL (see page 7-13) 8 Primary or secondary windings are broken or faulty MAIN SWITCH (see page 7-5) 8 Spark plug wire is faulty 8 Main switch is shorted 8 Spark plug cap is faulty SPARK PLUG C.D.I.
TRBL TROUBLESHOOTING SHTG INTAKE AND EXHAUST SYSTEM FUEL COCK 8 Clogged FUEL TANK CAP DRY TYPE 8 Clogged AIR FILTER ELEMENT FUEL HOSE 8 Dirty or clogged 8 Clogged, damaged or kinked SILENCER EXHAUST PIPE 8 Clogged 8 Cracked or broken 8 Carbon deposits...
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T110LE/T110LSE WIRING DIAGRAM 1 Main switch 2 Fuse 3 Battery 4 Starter relay 5 Starter motor 6 Right handlebar switch 7 Start switch 8 Light switch 9 Rectifier/ regulator Br R 0 A. C. magneto q C. D. I. unit w Ignition coil e Spark plug r Rear brake light switch...