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YAMAH
...j,'
..i. -'.' .,;. -..
This lvlanual is prepared by EscortsYamaha Motor Ltd. primarily
for use by Company Authorised Dealership and their qualified
mechanics. lt is nol possible to put an entire Mechanic's education in to
one lvlanual, so it is assumed that persons using this book to pedorm
maintenance and repairs on Yamaha motorcycles have a basic
understanding of the mechanical concepts and procedures inherent in
the motorcycle repair technology. Without such knowledge, attempted
repairs or service of this model may render it unfit for use and/or unsafe.
Escorts Yamaha N,4otor Ltd. is continually striving to improve all
models manufactured. Modifications and significant changes in
specifications or procedures will be forwarded to all Company
Authorised Dealerships; and will wherever applicable, appear in future
editions of this Manual.

Service Department
EscortsYamaha Motor Ltd.
LEGENDS

WARNING

IT INDICATES SPECIAL PROCEDURESTHAT MUST BE FOLLOWED


TO AVOID INJURYTOTHE MOTORCYCLE RIDER OR PERSON IN-
SPECTING OR REPAIRING THIS MOTORCYCLE.

to
It lndlcates SPecial Procedures that musi be lollowed to avold damage
the Moiorcyc e

€ IMPORTANT
It provides KeY Inlormation related with procedures and opera_
tions which must be clearlY understood.

MANUAL FORMAT
A of the procedures in th s manual are organised in a sequentlal, step by slep ror
mat. Tl]e Inforrratlon has Deen compiled to provlde the mechanic with an easy to
read'
harldy reierence that contajns comprehensive explanation of all disassernbly, repa r' as
sembly and inspection operallons ln this revised format, the condilion ol lau ty compo-
nent will precede and the course of action required will tollow the symbol e g
Bear ngs
Plttlng,/damage then FeP ace

EXPLODED DIAGRAM
Each chapter provi.les exploded diagrams before each disassmbly sectlon lor ease
in dentifying correct disassembly and assembly procedures

lllustralians in ih/s l4lorkshop l',tlanual may not necessartly match with the physical
appearance af the l"lolaict'cle
t
E.

INDEX

GENERAL
INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS

ENGINE

CARBURETTOR

CHASSIS

ELECTRICALS

TROUBLE SHOOTING

SERVICE INFORMATION
-
]
GENERAL APPLY
GEN
INFORMATION
INFO GREASE

PERIODIC
rff lR INSPECTION &
ADJUSTI\,,1ENT

APPLY
ENGINE A orL
ENG
n
CARBURETTOR

TIGHTENING

CHASSIS
CHAS

SERVICE LIMIT,

ff
E'E^I EL: ELECTRICALS
CLEARANCE
l-

TRSH TROUBLE
SHOOTING

SERVICE
SERV
INFO
Cr INFORN/ATION
\
r!

CHAPTER 1

GENERAL INFOBMATION

I,'OTORCYCLE IDENTIFICATION

- NUMBER
_ : SS S SERIAL
1-1

=',: \E SERIAL NUM8ER,,,,,.,.. 1-1

t I,I POFTANT INFORMATION

-__ -:-L4UEtVtE:t\ I TAt-it -

-_ - :- :' ) d \JtL -trALJ.....


_ -_,/1>-trnD
i:-* \\, q \LJ \rtL Jtr4LJ................
=__ )s t-J

-r
tr sERVtcE TOOLS...............
=ctAL
fi,i: &5l
CHASSIS SERIAL NU|\,4BER
. The Frame Serial No it is sramped
n to the righi side ol the Steering
Head Pipe.

ENGINE SERIAL NO
I . The Engine Serial Number il rs
stamped In to the Left Side of the
Engine. (Engine Serial No does not
contain Year and lvlonth of productir'rJ

AI,IIPER WITH ANY OF THESE NUMBEBS. IT MAY


LEAD TO LEGAL

XXXXXX
YEAR OF MONTH MODEL UNIT PRODUCTION
::CDUCTION CODE cooE NUMBER
I ::i-cl cn 2 Digits standing for last t\/o digits of year
F9.96 -1996,97-1997..
One alphabet standing for Month
Eg. A - January, B - February........
L - December
SeIial Number: RXG 1 L5-000001

:: r, , : c g ts denote year ot prod uction Code, Next dig it represents


Month
'-: ci",ed by Model Code and the remaining six dig-its a;e the
Unit pro_
:-',,mber.
GEN 'I
iffi;
EEl
ALL REPLACEMENT PARTS
'1. We recommend to use ESCORTS
YAMAHA genuine parls for all replace-
ments, to ensure safe long and trouble
tree performance of Motorcycle. Use oil
orgrease recommended by ESCORTS
YAMAHA IVIOTOR LTD. for assembly
and adjustmenl.

GASKETS OIL SEALS AND 'O' RINGS


'1. All Gaskets and Oil Seals should be
replaced when an Engine ls over-
hauled. All Gasket Surfaces, Oil Seals
lip and'O Rings must be cleaned.
2. Properly oil all Mating Parts and Bear
ings during reassembly. Apply grease
to the Oil Seal Lips.

LOCK WASHERS/COTTER PINS


1. All Lock Washers/Cotter Pins must be
replaced when they are removed. Lock
Tabs should be benl along the Bolt or
Nut flat(s) a{ter the Bolt or Nut has been
properly tightened.

BEARINGS AND OIL SEALS


1. Installthe Bearing(s) O and Oil Seal(s)
with their manufacturefs mark or num-
bers facing Upward. (ln other words,
the stamped letters must be on the side
exposed to view). When installing Oil
Seals, apply a light coating of light
lithium base grease (e.9. Servo Grease
l\,4.P or equivalent) to the Seal Lips. Oil
the Bearings liberally when insta ling.
IMPORTANT
Oo nol use compressed air io spin the bearings dry.This causes damage lo the
Bearinq Surfaces.
&6
GEN
INFO

ctRcLlPs
1. All Circlips should be inspected care-
fully before reassembly. Always replace
Piston Pin Clips after one use. Replace
distorted Circlips. When installing a
Circlip O make sure that the sharp'
edged corner is positioned opposite of
the thrust it receives. See the sectional
view Shaft.

GTTMPoRTANT I
@
I would cause it to iump ott groove and
damage related components. L
Io,
ll"

The Special Service Tools are required for complete and accurate tune-up and as-
sembly. Using the correct Special Service Tool will help prevent damage caused by the
use of improper tools or improvised techniques.

S NO. TOOL NO FIGURE DESCRIPTION


1 ES tvt201 To hold the Rotor of Magneto Assy.

MAGNETO HOLDEF
I
2 ESt\,1202 To remove the Flotor of Magneto Assy

IllAGNETO PULLER
3 ESM205 To hold the Driving Sprocket

DRIVING SPFOCKET HOLDER


ES M 507 To remove the Piston Pin from th€
Piston
I
PISTON PIN REPLACEB
5 ES l\i151 0 To compress Piston Blngs for instalf
ng the Cyl nder.

PISTON BING COlllPBESSOF


6 EStvt213 i Tc Hold the TFF plunger
.....4

FBONT FORK INNEF TUAE NUT


HOLDE F

--_
Ir_.-

\s\q.\sq\-s.q \tre'se.s- \ qqsqR\e\\q\


14 ESM 265 To separate RH & LH Crankoases
and to pull out Crankshaft.

CRANKSHAFT/CRAN KCASE
SEPABATINGTOOL

#p
l3 ESM 266 To install the Crankshaft.

CRANKSHAFT INSTALLING
TOOL

ESM27O To remove ll-F ull Dea

TFF OIL SEAL REMOVALTOOL

17 ESM275 To install lFl- utl Sea

TFF OIL SEAL INSTALLINGTOOL


I

CHAPTER 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS

.,:-:s oN |\4A|NTENANCE. ............. 2-1


::: 3DlC MAINTENANCE SCHEDULE ..................... 2-3
: .- : , :TITIVE MAINTENANCE/LUBRICATION............ 2-5
:'. :
.-": - uG ..........2-7

'J S SIS

.2-17
.2-18

2-21
! _::-RtcAL
2-22
I

J
INSP.
ADJ.

1. Thoroughly clean the Frarfe and Engine


ot dirt and dust, in order to prevent it from
entering the lnside ol the Engine.

2. Keep ofi the F re lfom the maintenance


area.
tr

3. When the Special Service Tools are re-


quired, use them judiciously to prevent
any damage to the Motorcyc e parts.
When working on the Motorcycte it rs a
musl to use the recommended lypes of
tools and instruments. (e.g. Avoid usfrg
an open-end wrench as much as possible,
n place of a box or socket wrench. )

4. Always use a new casket (pack ng),


O Bing, Cotter Pin, Circtip, Lock Wastrer,
etc. lo, repa rs. Always use Genuine
Escorts Yamaha pans, recommended
grade of Oils and Grease of superior
quality.

5. During Serv ce,lake Spec a Caresornal


you dont get njured or burnt from rne
Englne, Exhaust Pipe or Siencer.
6. BATTERY
. Take care so that the Battery Fluid dc€s
IlD\ b)\\ Dl\D\l !\\\s\,s\N) $ .\
Molorc'yc\e.

7. NOTES ON DISASSEMBLY AND REAS


SEI\,4BLY
. Place allDisassembled Parts neatly aal
separately in groups so that lhey T?
not be confused or lost. (especia '
c? Washers and Spacors)
. Whenever Screws of dilferent lengths a-.
taken out from various assemblies ide-
tify them separately.
. Wash the Engine andTransmrssion Pa=
in kerosene and blow them drywith co--
presseo arr.
.Install the Parls after checking tF:
smooth movement.
. Oil the contact surfaces ol the Mov'n:
Parts.
' Tighten the Parts to lhe specified torou:
by using the Torque Wrench.

Always keep your environment clean.


E

. PEBIODIC MAINTENANCE SCHEDULE

INITIAL
-:qs REMARKS

Check Clean or replace.

.
Rep ace (Warm Engine Before
D'a ning).

Check/adjust idle speed, Starler


a a ti
lever (choke) operal on and c ean

Check ensure bleeding to avo d ai ln

5'
a

Check lor any damage or crack.


Replace, il necessary
ta
Check al Eng fe nuts and bo ts 1o

t:
I
Remove cafbon (Cyl/Cyl. head/
P ston Assy llluij er elc )

il
il
'Check e echolyte leve and add
d slrled water every 1s days N

iclreck
specil c srav ty (++) and
breather pipe ior propef roll ng. a

Check operai on Rep ace, if

Check,adlust bearn
a

1
INSP.
ADJ.

. PERIODIC MAINTENANCE SCHEDULE

Drive chain* Check and adiust lension/lubricat


C1ean, Lubficale and alrgn
Check fof damage/Bim run oul &

wneet aearings" Check tor damage wear'


looseness/lighlness RePlace

ck tor tyre P€ssure.

iteering eearins* Check lor oosenesslighlness

C'hech lor oPeralron and orl

All Nuls & Bolts Check ior Iooseness.

OilTank Check and lop uP Engine(2T) oil

Check Reaf Swing Fork AssY lor


looseness {ReP ace sllenl b ock
bushes aiter 24000 Kms or

CLean Feplace rf necessarY

*lt COI\I!PANY AUTHOBISED DEALERSHIPS + L3:


ls recommended lhat lhese nerns be s€rv c€d DY or sPecialYamaha oil++ battery spec I c gra
_
175!3ml Servo 1e eschocab or oi special Escorts oll
1.240 at 20'c

ffir" "-bo*,""o.mendations are only for general guidance'


.Actuar period of service rarserv oeryl9.:. ill.:l:^Yt"-* ::iY?:lXl3t:*t"*
;;ffi !",";;;';;;i"ontJ"t'corirpnrY aurHoRrsED DEALERSHTPS'

:
INSP.
ADJ,

THROTTLE AUTOLUBE PUMP FRONT BRAKE

NIINIMUMPt MP STFOKE 0.204.25 mm

t SPARK PLUG

_ r ir\
<
f----
i.. lla!6qP
\ l

\:_ll?
REAR BRAKE

::ECTRICALS TRANSMISSION OIL SILENCER

TYPE 2OW4O MULIIGRADE OIL EAN EVERY3OOOKII/I.


It

' 2-6

Jr rr
INSP
ADJ.

SPARK PLUG
PLI.

::_ airv d ft from around the Spark Plug base.


:: -.ect the Spark P ug Cap. Remove the Spark Plug with the Box Spanner No 21 .
: r nspect the Spark Piug Electrodes for wear. The Centre E ectrode shouci have
: : edges and the side electrodes should not be efoded. D scard the Spark P ug I there
:-.::ent wear. & if the insulator s cracked/ chipped.
'= :Jre thai ihe Spark P ug Gap ill is
- : 7 mm. Measure the gap us ng a
: -. pe Feeler Gauge. lf adjustment is
::: ,:,r,,, do it by bending ony the sde
-: - Lo,c u,,y.
: : : - e that the PlLrg Washer is in Good
' '_: P lrg Washer attached, screw - jn
: :,..{ P ug by hand to prevent cross
::r --i \t' th the Box Spanner. tighten Recommended Spark Plug : BPRBHS
: :- ilrn after tl're Plug seats fully. (NGK JAPAN)
Spark Plug is new, tighlen t
lhe Box Spanner to cornpress (14.0 Fr. Lb)

:' over tighten or cross thread the Spark Plug as the Threads of Atuminium
_:?r Head may be damaged.
I: -:: 3llolv any Foreign Panicles to enter the Engine through Spark plug Hole
.e P ug is removed. Please ensure that the l-lole is covered
co with a cloth.
se the recommended ed type
tvpe of Spark Plud lest it wor
Soark Plug would alfect the Engine

PlLrg nd cates how the Engine has been operat ng. From the co our and
Spark P ug the Engine and the riding cond tions of the Motorcycle can be
n the tollowing lable.

. ] T ON COLOUR AND APPEARANCE INDICATION


nsLr lor tip grey sh yellow to ight brown . Every Thing s in order.
Du b ack velvely carbon depos ts. . Clogged Air Flter.
. \s\ !.\\\\s\a \\s\
. E\ec\\ode Gap \\\o\ e
" Co d'P ug used.
! nsuff c enl H.T. vo tage
. Pro onged ld ng ol Enq ne.

S. ning black wet carbon deposits 'O i-F!e M xture rich.


' Worn-out Cyhnder/Piston Rrngs
ifsulator burni while wth peafy Fuel'ArMxturelean.
ieposits ol efoded Electrodes. mproper Seating oi PlLrg.
Hol'P ug used.

2--t
AIR CLEANER ELEMENT

A) Opening ot Air Cleaner Assembly


'1. Remove Cover Side-2 @ (on right hand
side) by opening 1 No Screw.

2. Unsc.e\'r, cap Assembly Air Cleaner @ by


opening 3 Nos Screws,

B) Inspection of Air Cleaner Assem-


blv
l. Inspect for any existing Air Leakage into
the Case Air Filter. (lt is observed that
there is dust accumulation at the leakage
Point.)
2. lf there exists any air leakage
Check for :
A) Warpage oI Case Air Filter or Cap As-
sembly Air Cleaner{Fig A)
B) Proper seating and condition ol Seal
Case Air Filter. (Fig B)
ll damaged or cut replace it with a new
one.
C) Grooves ol Case Air Filter and Edge of
Cap Assembly Air Cleaner for damaged
maiing surlace. (Fig C)
D) Condition ol Element Air Cleaner. lf
damaged or cut then Replace it with a
new one. (Fig D)
INSP.
ADJ.

C) Cleaning of Element Air Cleaner


L Centll pullout Flcmenl Air ( leaner O &om
Cap Assembly AirCleaner. @.

2. . Clean Element Air Cleanet in clear


Petrol (without any oiltrace), thoroughly,
in a clean kay.
. Repeat the procedure tillall the dusydirt
has been washed off.

3. Squeeze out the excess petrol by press-


ing the Element Air Cleaner in the fist .

D) Oiling of Element Cleaner


1. Take 2T Oil in a Clean Tray.
.
. Dip the Element Air Cleaner in 2T Oilfor
unitorm Soaking. (Keep the ltairy surtace
Down).

HAIRY
SURFACE
INSP.
ADJ.

2. Squeeze out excess 2T Oii by pressing


,,n'
1/ The Elemenl Air Cleaner in the Fisl as
shown in Fig 1.

.a
Check for Unitorm Application of
2T Oil all over lhe entire surface
(both sides) of the Etement Air
CleanerAfterthe excess 2TOit has
beeh Squeezed out.

. Do not wring Elenrent Air Cleaner as shown in Flg 2.


. No such strong force should be apptied to the Element Air Cleaner,
while squeezing, Which
may caLrse tear ng or damage to the Element Air Cleaner.

E) Installation of Air Cleaner Assem-


bly
1. Assemb e the Air Cleaner assembly n re
verse sequenc-A.
Check for :
The blockages in the Air Passage ofthe Body
Air Ceaner Clean it with a ctean cioth.
The screws of the Cap Assy Air Fi[er
sholld be tightened as per the shown se-
quence, in two steps. (All the three screws
Screws Tightening Sequence to be tightened genfly first and then fu y
tightened in the same sequence.)

. When install ng the Element Air Cleaner in its Cap Assy, be sure its sealng surface matches perfecl
y
with the sealing surface oi the Case Air Filier to prevenl anv A r Leakaoe.

IMPOFTANT
. Dirty Element Air Cleaner causes excessive fuel consumption, wear of piston Rings
and loss ot oower.
. Clean Element Air Cleaner every 1000 KMs.
. The Element Air Cleaner should be cleaned and lubrlcated more frequenfly (every
1O0O
kms or earlier), it Motorcycle is operated in very dusty (e.g. unpaved, dust laden roads)
or wet conditions.
TRANSMISSION OIL
CHECKING
'1. Check Oil Levelwith Motorcycle on Cen-
tral Stand. lvlotorcycle Rear Wheel lifted
ofl ground and Front Wheel touching the
ground.
2. Transmission Oil Level should always be
belween maximum & minimum levels on
Plug Oil Level.O Screwed on Cover Assy.
2 on R.H. Side.
3. Top up if required.

REPLACEMENT
1. Warm up the Engine with Motorcycle on
Central Stand.
2. Keep Oil Pan below the Engine.
3. Rernove Drain Bolt @ along with the cas-
ket @ and drain out Oi, completely..
4. lnstall Drain Bolt @ with its casket €).
Drain Bolt
2.0 Kq.m. 't4 Ft. Lb

5. Fill Transrn ission Oil.


6. Check oil level with the help of Plug Oil
Level O

RECOMMENOED
.20W40 Oil of Superior grade
quality.
QUANTITY :
. For Overhaul : 700cc t 20 cc
. For exchange : 650cc a 20 cc
during Service

1T'PORTANT

" r/;ats usc only recommended grade/quantity of Transmission Oil.


-h -'ci add any chemical additives into the Gear Box as cear Box oil also lubricates
tfE C'lch. and additives can cause the Clutch to sliD_
t.r

AUTOLUBE PUMP
CABLE ADJUSTMENT
1. Check to see if the Pump Guide Pin (Dis
aligned with the mark on Plate Adjusting
@with the Throttle in closed position hav-
ing no play-

2. lI Pump Guide Pin is not aligned, align by


lurning Adiuster @ in or out, loosening
Locknut @ and then retightening.

MINIMUM PUMP STROKE AA'USTMENT


1. Throttle Grip full closed position.
2. Remove Spark Plug
3. Slowly move the Kick Crank downwards
by hand, holding the Kick Crank at the
position where the clearance between
adiust Pulley and Plale adjustrng is maxi-
mum.
4. Measurc lvlinimum Pump Stroke (t with
Feeler Gauge.
Minimum Pump Stroke 0.20 - 0.25 mm 5. lf clearance is not cor.ect adjust by the
Shims @. Adding Shims will increase the
stroke and vice versa.

When insening theThickness cauge


between the Plate Adiusting and the
Adjusting Pulley, be carelul that neither
the Plate nor lhe Pulley is moved.

2-12
AIR BLEEDING
1 . REMOVE:
. Pump Bleed Screw @ and keep oil run-
ning out until all the air bubbles disap-
pear
2. INSTALL:
. Gasket
. Hteeo Sctew (,

3. Start the Engine, disconnect the Outlet


Pipe ol the Oil Pump from the Carburel-
tor. Pullthe Oil Pump Cable (O allthe way
oui to sel pump stroke to a maximum lor
Iew minutes, to ensurethat allairbubbles
are removed and smooth oilflow is taking
place. Beconnect the Outlet Pipe back to
the Carburettor

THROTTLE

THROTTLE GRIP FREE PLAY


1. LOOSEN:
. Locknut G)
2. ADJUST:
. Cable free play 1-2 mm by turning
Cable Adjuster @ in or out.
3. TIGHTEN:
. Locknut (D

THROTTLE CABLE FREE PLAY


1, LOOSEN:
. Locknut @
2. ADJUST:
. Cable free play @ 5-8 mm.Turn cable
adjuster @ in or out.
3. TIGHTEN:
. Locknut O
CARBURETTOR
IDLE SPEED
'1
. Start the Engine and warm for 5 minuies
2. Turn Pilot Air Screw @ ln unti lghtil -d
seated-
3. Back out by specified number ot tufns wit.
screw drlver
Pilot Ait ScrewTurn Out
1 Y2 ! o.sTurns

o
4. Turn Throttle Stop Screw oul until specr-
fied ldle Speed is attalned. {
{
Engine ldle speed
1700 ! 100 R.PM.
(Uptill Bunning in Period ie. First 1000 Kms.)
1500 r
100 R.PM.
(After Running in Period ,:.e. After First '1000
Kms.)

STARTER LEVER FREE PLAY


1. LOOSEN:
. Locknut @)
2. ADJUST:
. Cable lree play @ 3-5 mm by turn ng
Cable Adjuster O in or out.
3. TIGHTEN:
. Locknul €)

Starter Lever Cable Free Play : 3-5 l\4M

I
E@
CLUTCH
CABLE ADJUSTIV]ENT
1. LOOSEN: Locknut O
2. ADJUST;
. Cable Ffee Play @ 2-3 mm by turning
Cable Adjusler @ in or oul.
3. TIGHTEN :Locknut O

SLUTCH MECHANISM ADJUSTMENT

:alr4OVEl 2. POSITION
. :avef Crankcase-1 G) (On left hand side) The Push Lever (t by the Cable Adjuslere)
a.rd ad.usr Lpve'riegl.t ai lo75 nm.

3. INSTALL :Cover Crankcase -1 G)

a
w
, :EVOVE: Generator Cover Assy. O 5. LOOSEN ;Locknut €) on Cover
CrankCase -1
6. SCRFW lN : Adjuster €) until tighl and
back t out by 1/4 turn.
llPoRrANr 7. TIGHTEN :Locknut @ L
€ li f
F
-:eiore Adiusting the Clutch Lever free play, the clutch Mechanism should be adiusted.
@
BRAKES
FRONT
'1
. LOOSEN :Locknut O

, r;t 2. ADJUST : Free Play


3. TIGHTEN:Locknut O
@ by Adjuster @

FBEE PLAY O
5-8 mm (lndian Markets)
2.5-3.5 mm (Other Markels)

. The Front Brake play can be Adjusled


eilner oa tl_e Adjuster e) on Brake -evel
or by the Adjuster @ loodted on Fronl
Wheel Plate Brake Shoe.

REAR
1 . ADJUST:
. Free Play 6r of Rear Brake Pedal @ to
20-30 mm by turning the Adjuster O :
near the right hand side of the Rear
Wheel in orout (To increase ihe play turn
Anticlockwlse and to decrease the play
turn clockwise.)
d

. Brakes ensure personal safety and


should always be maintained for
proper adjustmeni.
. Always check Brake Lighl operation
after Front and Rear brakes adjust-
ment is done.
. Proper Lever Free Play is essentialto
avoid excessive brake Drag-
t!
I
:
BRAKE LINING WEAR INSPECTION
1. Depress the Brake Pedal @

2, INSPECT
. Position of Wear Indicator @
lf Indicator reaches the wear limit line then
replace Brake Shoes.

WHEELS
1, INSPECT
. WHEEL
lf Crack/ Bend/ Warpage then replace

2, INSPECT
. Spoke
Tap each Spoke with an iron rod lor
sound or feel the looseness ot the
Spokes by hand. lf any Spoke makes a
dullllat sound, Inspect it lor looseness

3. TIGHTEN
. Spoke Nipple
. True the Wheel if necessary.

Always balance the wheel when a tyre


or wheel has been changed or replaced

2-17
INSP.
ADJ.
EIEE
TYRES
1 , INSPECT:
Tyre wear
Wear Limit: 1 mm -{
if
rm
Wear indicatof O ,N
G
Replacement limit @ : '1 MM

2, CHECK: .W
. Air pressure with tyre nozzle in down
position as in figure.
FRONT REAR :r
2.50-18 2.75-18
Tyre Specification
4PR 4PR
NYLON NYLON
Single Rider 22PSl 28 PSI
L,"-: Double Rider 22 PSI 32 PSI
Qbu^*^r^uz
TYRE CONDITION
OVER INFLATED O
Risky/Poor Boad Holding.

PROPERLY INFLATED O
Good and safe riding.

UNDER INFLATED €)
Higher Tyfe Wear & Low Fuel Economy

An mproperly inflaled Tyre may lead to


loss of Motoreycle Road Contact caus-
ing accident /injufy to Rider.

IMPORTANT ,q
rdl
.Tyre pressure should be checked and corrected under cold conditions (Tyre tem-
4fi!
perature equals ambient lemperature)
. Always check tyre condition before riding lllotorcycle. li badly worn oll then replace
.{n
Tyre immediately . ,"ifl
.In case nail/glass/sharp item is embedded in Tyre. please ensure same is removed
ri
before vulcanising /puncture repair.
7-F
f

@ .

DRIVE CHAIN

SLACK INSPECTION
. Park Molorcycle on Level Ground on
Central Stand.
. Remove Rubber Cap O from lnsoec-
tion Window @ on Chain Case .
. Rotate Rear Wheel @ several revolu-
tions in Forward direction and checkTo-
tal Slack upward & downward several
times to find "Maximum Slack Point" @.
:-te Chain Slack 20-30 mm SLACK ADJUSTMENT
. Park Motorcycle on Central Stand and
loosen Rear Brak€ CableAdiusteron RH
sne
. Remove Cotter Pin @ of Rear Wheel
Axl6 Nut with Dlier on LH side.
. Loosen RearWheelAxle Nut @ usino
Ring Spanner No 22 and Main Sprocket
Shaft Nut. @ using Ring Spanner No
27 on LH side.
. Loosen Chain Puller Lock nuts @ on
each side (LH and RH side).
. To tighten Chain, turn Chain Puller Ad-
I'l. Side
- justers @ clockwiseand to loosen Chain,
turn Adjusters anticlockwise and push
RearWheel Forward
:' _, . Ensure that the matching ofthe notch
on the adiusler with the alignment
.- :- . n----a
5- u marks on Rearonthe ReatSwing Fork
ia same on LH and RH side.
. Atter adjustment , be sure to tighten
Lock Nuts, Sprocket Shaft Nut. Wheel
Axle Nut and adjust the Rear Brake.
. Insert a new Cotter Pin into the Rear
WheelAxle and bend the end ofthe pin.
IIPORTANT
&"Fr adjusting the Drive Chain Slack, Rear Brake pedal Free play should always be
-e4{ed and adjusted, il required.
rc.r'ect alignment adversely affects the lile of Tyres, Wheel Bearings, Sprockets and
:r,e Chain.
, :-s-€ configuration ot Drive Chain to be same when assembled.
' flrts' e .efitting Chain Lock on Drive Chain, please ensure its Closed End is alwavs in
'|!E -rr.eclion of Chain Rotation.

2-19
DRIVE CHAIN CLEANING AND LUBRICATION

,.-7.' ,-:pw,,'^ _

Bemove the Drive Chain trom the Motor- Clean the chain with wire brush.
cyoe. Again dip the drive chain thoroughiy r-
Dip the Drive Chain in Kerosene for aboul crear Kerosene
20 minutes to loosen the dirtfrom internal
surfaces as shown in figure.

Fj.::
v1a?: ^,:

r{

6. Hang the Drive Chain vertcally and dry it 6. Dip the Drive Chain in 20W40 Oil Batf
by using compressed alr. to restore the rnterna ubrication

8. Inspecl the Drive Chain lor wear if da.r


7. Hang the chain in such a manner that the aged of worn out, the Drive Chain along
excessive oil drips off in to the oll bath with Both the Sprockets should be re-
placed as a set.

2-20
STEERING
CHECK\NG
1 . RAISE
. Front Wheel otf the ground.
2, CHECK
. Steering Head Bearing for looseness
Gently fock Front Fork Assembly back-
ward and forward. lf loose then adjust.

ADJUSTMENT
1 . REMOVE
. Cover Crown O by opening 2 Nos.
Screws.

2. LOOSEN:
. Steering Fitting Bolt @
. Ftonl ForK Htncn tJotls lJl

3, ADJUST
. Steenng Heao Ri.rg Nut @ by usrng
Special Service Tool ESI\l-221.@
Tighten the Nut until Steering Head is
tight without binding. lf heavy binding
then replace Race Bearings.

4, TIGHTEN
. Steering Fitting Bolt @
. Fronl Fork Pinch Boll @

5. ASSEN,lBLE
. uover urown tll
Steering Fining Bolt
3.1 Kgm(22Ft.Lb)
BATTERY

BATTERY FLUID CHECK il

o '1. CHECK
.
Fluid level
:

Fluid Level Should be between up..


lll
1

3f- and lower level line.


. For tightness o{ Termlnals.
. Specific Gravity of the Battery F . c :
using Hydrometer.
I
'il
I

It should be 1 .230 i 0.005 (1.225-- .: ::


2. Use only disiilled water for topping. ;
:
BATTERY CHARGING (NEW BAITERY
1, ELECTROLYTE PREPARATION
. Mi\ one part of SulphJric Acid ro.- :
parts of disrilled water to get tl'e de) ::
Electrolyle .e. In 100 ml sulphLflc r :
add 250m1 of water.
. Checkfo.tf'e Specif c Graviryof lhe r'
polyle I shoLld be 1.230 r 0.005 , --:
1.235)
. The Soecrfrc Cravrly shoLd al!{a/. :
Checked us'ng a proper hycirori,
(size 5.00mm)

2. Fill Electrolyte of specil ed gravity L: :


"Upper Level" Mark in each Cellol the E:'
,|ety.

3. Leave the Battery idle for 30 to 60 - -


utes aiter lilling the Electfo yte for sc..
ing the Plales in the Electrolyte.
4. In case the Elecirolyte Level fa ls be : r
the "Upper Level" during the above sc: '
ing period then lop it up again.
5 Charge the batlery as per following
Charging Current = 0.25 Ampres.
Charging Duration =15 Hours
Us ng a good Battery Charger
IMPORTANT 6 Slop chargrng the battery when spe, :
grav ty of the e ectro yte in each ce :
Incase the battery is more than 3
ta ns a value of 1.240 ndicat ng ',
monihs old (fromthe month ol manu-
Charged Conditjon.
facture), duration of initial charging
to be extended till lull charqe condi-

2-22
INSP
ADJ.

IMPORTANT
. Maintain Electrolyte at Upper Level.
. Do not add Electrolyte when recharging the Battery
.Top up only with Distilled Water.
.The Ballery should be firmly mounted.
. The Breather pipe ol the Battery and its mounting should not have any lolds o
blockages and should be done as per the given illustration.
. Whenever Battery is not in the Circuit (i.e..emoved for Charging etc.) the Headligh
switch must be shifted to "ON" position, otherwise Neutral Light Bulb wilt Fuse an
BR unit will get damaged.
. Check for the Fuse in the Fuse box.
'Check for the proper coupler connections of RR unit.

2-23
CHAPTER 3
ENGINE

ENGINE DISASSEMBLY
CYLINDER HEAD AND CYLINDER 3-1
PtsToN .............. J-t
CRANKCASE COVERS J-l
GENERATOR ASSY ................ 3-2
DRTVE SPROCKET........................ 3-2
cLUTCH ............ 3-3
(ICK STARTER .. 3-4
SHIFT SHAFT 3-4
CRANKCASE 3-5
TRANSMISSION AND SHIFTER... 3-5
CRANK SHAFT 3-6

INSPECTION AND REPAIR


CYLINDER HEAD ,,, ,,.,,,,, .. 3-7
CYLINDER 3-7
PtsroN.............. 3-8
PTSTON RING 3-9
PISTON PIN AND SIVALL END BEARING,,, 3-9
c1UTCH............. 3-10
KICK STARTER,, 3-1 1

CBANK SHAFT
TRANSM ISS ION J- t.t
BEARING & OIL SEAL ....... 3-14

(contd....)
ENGINE ASSEMBLY AND ADJUSTMENTS
CRANK SHAFT ..'".. 3-15
TRANSMISSION AND SHIFTER... ..... 3-16
CRANKCASE ASSEMBLY ... . . 3-18
GENERATOR ASSY ................. ......... 3-19
sHtFT SHAFT ... 3-20
KICK STARTER. ...... 3-21
C1UTCH... ...... ...... 3-23
PR VARY DRIVE GEAR .............. 3-25
DRTV|NG SPROCKET....... ....... .... 3-2s
CRANKCASE COVERS ... ... .......... 3-25
PIsToN. ........... ..... 3-26 .:4.

.-.-'. .....3-27 t
cYLINDER
ENGINE MOUNTING .................... --.-' 3-28
cotvPoNENTS GRADING ......... 3-29
CYLINDER HEAD AND CYLINDEF
1 . REI\/OVE
. Spark Plug O
. Cylinder Head Nuts @ (4 Nos.)
. Cylinder Head O
. Cylinder Nuts @ (4 Nos.)
. Cylinder O

PISTON

1. REI\,4OVE
. Piston Pin Clips O (2 Nos.)

1 , REMOVE
. Piston Pin @ using Special Service Tool

O
ESI\,4 507 @ (Piston Pin Replacer)
. Needle Boller Bearing @
.
O
Piston @
. Piston Rings and Expander @)

CRANKCASE COVERS
1 . REMOVE
. Cfankcase Cover R H G)
By Opening 9 Nos. Screws.
GENERATOR ASSEMBLY
,1
. ATTACH
. Special Service Tool ESI\,4-201 €) Fc-
2@ holding the Rotor Assembly.
2, REN4OVE
36
:

. Botor Holding Nut @ by using So -:-


No 19.
4@ . Spring Washer @
. Washer @

3. ATTACH :

. Special Seruice Tool ESlvl-202 @ (Ror:


Assembly Pullerwith Left hand thfeads
holding Rotor Assembly by Specia S:'
vice Tool ESM 201 @
4. REMOVE:
. Rotor Assembly. @
. Woodruft Key @

5. REMOVE :

. Stator Holding Screws @ (2 Nos)


Neutral Switch Lead Wire @
. Stator Assembly @

DBIVE SPROCKET
1 . FEMOVE
Drlve Sprocket Nuto by using socket N:
26, and Holding the Sprocket by Spe-
cial Service Tool ESI\,I 205 @
Lock Washef @
Drive Sprocket @
I
I
2, REI\4OVE
. Shift Cam Blind Plug @
. Gasket @

CLUTCH
,I
, REMOVE
. Clutch Spring Bolts O 4Nos.
. Clutch Springs @ 4 Nos.
. Pressure Plate @
. Friction Plate @ 6 Nos.
. Clutch Plate G) 5 Nos.
. Push Rod @

2, ATTACH
. Speclal Service Toot ESM-233 @ For
holding the Driven cear Assembly @
REMOVE
.Driver Gear Assembly s by ooen ng
Nut @
. Washer Conical Spring @
. Plale Thrust-1 (]
. Spacer O
. Washer Plate (,
ATTACH
. Botor Assembly on L. H. JoJ, ral of Cranl
Sl^att and holo loySpecta. Serv.ceToo
ESM 201
5. RE]\,1OVE
. Pr mary Drive cear Nut @
. Washer 6r
. Prin'rary Drlve Gear @

t.9 .
.
Straight Key @
Spacer t!
. O ISea Retainer @
KICK STARTEB
1 , REMOVE
. Circlip O
. Washer @
. Kick ldle Gear @
. Washer @
. Circlip €)

2, UNHOOK
. Kick Return Spring @
3. REIVIOVE
. Kick Starter Assembly @

SHIFT SHAFT

1. REIVIOVE (On LH Side)


. Circlip O
' Washer (9
2. REMOVE (On RH Side)
. lensron bpnnq !t
. Shlit Shaft Assemb y (9
. treaflng Helalnel Flale L9
. Stopper Lever Assembly (O by us.l
Socket No 12.
t CRANKCASE

1 . REITIOVE
. Crankcase Tightening Screws (13 Nos )
LH side.

2, ATTACH
. Special Service Tool ESM-265 O for sepa-
rating the Crankcase (On right hand side)
by tighiening Securing Bolis
(a

t 3. DISASSEMBLE
. Crankcase RH
the lever ot
O & LH @ bY rotating
the Special Service Tool
ESM-265 Clockwise and gently tapprng
the Hear end of the RH Crankoase with
Mallel.

tBefore application ol the Special se


vice Tool ESM 265 for separatin
Crankcase, ensure that lhe mounlin
nuts of the Engine Stand are removed
. Make sure the tool body is parallel wi
ihe Crankcase.

TRANSMISSION AND SHIFTER


I INSTALL
. Engine Stand Mounting Nuts with Spacer
on LH Crankcase
HEMOVE
. Bar Shift Fork Guide -1 O
. Bar Shift Fork Guide -2 O
. Fork Shift -2 @
. Fork Shift '3 @
. Fork Shilt "1 @
I'

REI\,4OVE
. Shift Carn Assembly

REIVIOVE
. Axle lMain Assembly €)
. Axle Drive Assembly @

CRANK SHAFT

1 . ATTACH
. Special Service Tool ESM-265 G) for
separating CrankShaft €) from
Crankoase LH O , by tightening Secur'
ing Bolts @
2 REI\,IOVE
. Crankshalt Assembly by rotating the
lever €) Clockwise

While removing Crankshaft lrom LH Crankcase hold it trom the RH side to prevent it
trom falling down.
CYLINDER HEAD

1. REMOVE
. Carbon deposit, Use rounded scrapef.
2, I\,4EASURE
. Cylinder Head warpage using straight
edge O, Feeler cauge @
lf out of speciflcation, resurlace or replace.

CYLINDER
1. REMOVE
. Carbon deposit from the Exhaust Port.
Use rounded scraper.

2. INSPECT
. Cylinder Wall for Wear/ Scralches
Rebore or Replace
3. MEASURE
. Bore using Cylinder cauge 10 mm from
TDC at Poinls shown.
I out of speclfication, rebore the Cylin-
0et,
PISTON

1. INSPECT :

. Wear Scratches/Damages or reolac.


2. REI,4OVE :

. Carbon deposit lrom the Piston crown


Use Rounded Scfaper.

Do not use a sharp ihstrument and avoid


damage or scratching.
Aller correcting, clean the Piston with a
clean cloth.

3. IVEASURE
. Piston outside diameter wlth .
Micrometer.
lf out of specillcation , replace

Standard 57.967 - 57.982


16 <Limit> 57.985
Oversize 1

Oversize 2

4. PISTON CLEARANCE
. li oui of specif cation, replace p ston anc
or rebore Cylinder.

IMPORTANT
Measurement should be madeal a point
10 mm above the bottom edge ol the Piston Clearance = Minimum Cylinder
Piston skirt & perpendicular to the axis Bore - Piston Diameter
of the Piston Pin. 0.034 - 0.039
PISTON RING
'1
. MEASURE :
. Side Clearance @
Use a Feeler Gauge @
lf
out of specification th€n replace
Piston and / or Piston Rings.

Side Clearance : 0.03 to 0.05 mm

2. N,IEASURE
.Endgap:O
Use Feeler Gauge @
Out of specification, Replace Piston
Rjngs as a set.

Standard Limit
End Gap
0.25 to 0.45 0.6 mm
0nsralled)
mm

PISTON PIN AND SMALL END BEARING

1, INSTALL
. Pislon Pin O and Bearing after Lubrica-
tion (into small end of Connecting Rod
@)
3. CHECK i

. Free Play
lf
free play is excessive, Inspect Con-
necting Rod Small End and Piston Pin
lorWear.
4. INSTALL
. Piston Pin O (in to Piston)
5, CHECK :
. Free Play
ll lree play out of specification, replace
Piston Pin and/or Piston.

3-9
CLUTCH

DRIVEN GEAB ASSEMBLY


1. INSPECT
. Dogs on Housing O
lf CracksMea/Damage then Debur
replace
. Circumferential Play €), lf Play
specif icatlon then replace.
. Gear Teeth @ of Driven Gear Assernc .

CLUTCH BOSS
'1, INSPECT :
. clutch Boss Splines @
Scor ng Wear/Dar.age ther DebL '
Replace.

FRICTION PLATE
'1. INSPECT :

. Friction Plates
ll Damages/Wear, Replace as a set
2, I\iIEASURE
Friction Plate thickness
N4easLre al dll lhe fo rr poinls as.ho
Wear limit : 2.7 mm

Warp limit : 0.05 mm CLUTCH PLATE


1 , MEASURE
. Waroage of ClJrch Plate 5. Use :
IaCe tslale L9, anO ieeleT bauqe I
li oul of specification then Replace

IMPORTANT
Plates Solines will cause erratic operation-
Minimum Lengih CLUTCH SPRING
1. MEASURE
. Free length
lf less than the length specified, Replace
the Clutch Springs as a set.

STANDARD LENGTH SERVICE LIMIT

34.5 mm 33 rnm

KICK STARTEB

1 . INSPECT :

. Splines of Kick Shaft Assembly O


. KtcK uear teeln t4r
. Kick ldle GearTeeih @
Teeth wofn out/darnaged then replace
the concerned Gear.

2. CHECK :

. Kick Geaf movement smoothly over


spllnes.

3, I\,1EASURE
. Kick Clip Friclion Force
Out of specification then Replace Kick
Clip.

-' clron Fotce u.u

G CAUTION
--3 K ck gear should be firmly held in the V se whie measuring the Kick Clip Friction

3-1 1
CRANKSHAFT
1, MEASURE
Runout limit . Runout
0.02 mm
Use Dial gauge.
lf out ol specification then Replace.

2. [/]EASURE
. Crank Width
lf Out of specification then Replace

CrankWidth :55.90 to 55.95 mm

g end side Clearance 3.IVIEASUBE


0.2 to 0.7mm . Big End Side Clearance
Use Feeler Gauge
lf out oJ specification then Beplace

4, I\4EASURE
. Small End Ffee PLay
ll out of specilication then Replace

Small end free play :

0.03 to 0.18 mm IMPORTANT

Crankshaft & Connecting Rod to be re-


placed as a set il the above paramelers
indicate the need.
Reoair ofeither CrankShaft or Connect-
ing Rod is not recommended as it
would affect the Engine performance.

3-12
TRANSMISSION

SHIFT SHAFT
1. INSPECT I

. Shift Shaft O
. bpnnqs La
. Stopper Lever Assembly O
lf Weaf/Bend, Replace

SHIFT FORK
'1. INSPECT
. Shift Forks at
(On the Gear and Shift Carn contact
sunace)
. Shift Fork cuide Bars @
Wear /Chaling/Bends/Damage then
Replace Fork and/or cuide Bar.

SI{IFT CAM
'1. INSPECT
. Shifl Cam Grooves O
. Shifl Cam P ns @
Wear/Damage/Scratches then Re-
place

MAIN AXLE AND DRIVE AXLE

] 1 ]\,4EASURE:
. Axle Runout
! se Cente'irg Devir.e and Dial Gauge
-- k=r I out of specificat on then replace.

Runout limit : 0.1 mm

3-13
GEABS
'1, INSPECT
. Gears
lf DamageMear then RePlace
2, CHECK
. Gear Movement
It operalion ls not smootl' then Bep ace
the concerned Gear'

3. INSPECT
. Matching Dogs.
lf Cracks, Wear, Damage observed ihen
replace.
***

BEARING AND OIL SEALS

1. CHECK

ll Rough Spots/Play then RePlace

2. INSPECT
. All Oil Seal Lips
li DamageMear then BePlace

Always replace Crankshaft Oil Seals


whenever the Engine is opened.
CRANKSHAFT ASSEMBLY

CRANKSHAFT
WOODRUFF KEY
NEEDLE ROLLER
BEARING

1. ATTACH :
. Special Service Tool ESNI 266 O (To
lhe left side of the Crankcase)for install-
ing the Crankshaft. @
2. TIGHTEN:
. Nut ofthe Special Service Tool ESM 266
i .Hold the Conreciing Bod ar Top
Dead Center.

Gf,MP{r
\Belore assemb\ing the Engine , uash \
Crankshaft in mild solvent (perrol/
Ithe
kerosene) I

|
f

TBANSMISSION AND SHIFTER

^*4
*'u@k'
*w
-.a
v4
16

SPROCKET DRIVE (15 T) 13. FORK SHIFT -1


AXLE DRIVE FORK SHIFT - 3
GtrAtr tqT \A/1.]trtrI BAR SHIFT FORK GUIDE - 2
CLUTCH DOG PLUG BLIND
GEAR 3RD WHEEL (26 T) 17. GASKET PLUG BLIND
GEAR 4TH WHEEL (23 T) 18. SHIFT CAI\,I
GEAR 1ST WHEEL (35 T)
'1
9. PINS
2ND PtNtON GEAR (r 5 T) 20. PLATE SIDE
3RD PTNTON GEAR (19 T) 21. STOPPER LEVER
4TH PTNTON GEAR (23 T) 22. BAR SHIFT FORK GUIDE -1
AXLE I\,1AIN 23 FORK SHIFT " 2
PLATE COVER

3-16
1. INSTALL:
Axle Drive Assembly @
Axle Main Assembly @
Shiti Cam Assembly @
Fork Shift"l @
Fork Shilt-3
Bar Shift Fork Guide-2 @
Fork Shi1r2
Bar Shift Fork Guide-'1

2. CHECK:
. Rolate Cam Shift and Check l\4ovement
of Fork and Sliding ol Attached cears
lf Incorrect operation then Reassemble.
CRANKCASE ASSEMBLY

D
Kgm (11 Ft. Lb)

2.0 Kgm (14 Ft. Lb)

1. OIL SEAL BEARING 6204


2. BEARING 6304 BEARING 6205
3. BEARING (NRB) DRAIN PLUG
4. OIL SEAL OIL SEAL RETAINEFI
5. CRANKCASE LH OIL SEAL
6. CRANKCASE RH BEARING 6303 Z

1 . APPLY:
. Yamaha 3 t\,4 Bond €) (to both The 3, INSTALL
Crankcase mating surlaces.) . R ght Hand Crankcase €) (Tap as sho$'.
2. INSTALL: wth Ma let)
. Dowel Knock Pins @
4, TIGHTEN:
. CrankcaseTightening Screws.(1 3 Nos.)
Tighten the Screws in the shown se-
quence and in two steps (1) Semitighten
(2) Full itighten.

0.7 Kgm (s.1 Ft. Lb)

FLYWHEEL MAGNETO

1 INSTALL
. Stator Assembly O
2 CONNECT
. Neutral Switch Lead Wire @

3 1NSTALL
. Woodrulf Key
. Rolor Assembly @
. Lock Washer

TIGHTEN
. \ul E using socket No 19 with To'que
W.erch holding Botor assembly w.th
Special Service Tool ESN,I 201 6)

NESR\NN
E\,ra:f11r9l
crankcase (Left hand and Right Hand) should always be replaced as a set.
SHIFT SHAFT

1.0 Ksm (7'0 Ft Lb) I

PIN CLEVIS
10. clRcLlP
,11. WASHER PLATE
SPLIT PIN 12, OIL SEAL
ROD SHIFT 'I3. SHIFT SHAFT
WASHER PLATE 14. SPRINGTORSON
CIRCLIP
WASHER PLATE
15, SPRING TENSION
PEDAL SHIFT
16. scREW
17, NUT
COVER SHIFT PEDAL '18, WASHER LOCK
ARM SHIFT

2, INSTALL:
1, INSTALL:
. Stopper Lever Assembly O . Washer @
. Plate Cover (a . circlip @
. Shift Shaft Assembly @ 1.4 Kgm (10 Ft. Lb)
2, ADJUST:
. Shift Lever position (by Adjuster Screw
@ and Locknut @)
. Gap @ to be equal on both the sides.
While adiusting the transmission
should be engaged in the 2nd Gear.

KICK STARTER
i

COVEF KICK LEVER SPRING TORSION


K CK CRANK COVER SPRING
SPRING GEAR KICK
BALL GEAR KICK IDLE
BOSS KICK CRANK CLIP
SPACER KICK AXLE ASSEMBLY

3-21
1, INSTALL
. Kick Starier Assembly
2. POSITION
. The Kick CliP @ in groove @ ot the
crankcase as shown

3. HOOK
. Return Spring @

4. INSTALL
. Ckclip

. Kick ldle Gear @


. Washer @
. Circlip €)
ENG

CLUTCH

N.
SN
\%6@;

^.%1,
1t

P,pg 26
=@

22

14. BALL
BOLT WITH WASHER 15. ROD PUSH - 2
SPRING COI\,lPRESSION 16. OIL SEAL
PLATE PRESURE 17. LEVER PUSH
ROD PUSH 1 18. SPRING
NUT 19. OIL SEAL
WASHEF CONICAL SPRING 20. SCREW PUSH
PLATE FRICTION 21 BOLT SET
PLATE CLUTCH 22. NUT
BOSS CLUTCH 23. NUT
PLATE THRUST - 1 24 WASHER SPRING
PBII\,'IARY DRIVEN GEAR 25, GEAR PRIMARY DRIVE
SPACER 26. STRAIGHT KEY
WASHER PLATE 27, COLLAR

3-23
'1, INSTALL
. Thrust Washer O
. Spacer @
. Driven Gear Assy. O
. Thrust Washer @
. Oil Seal Retainer @
. Spacer @
. Straight Key @
. Primary Drive Gear @

Insiallation ol Dliven Gear Assy. and


Primary Drive Gear should be done
Simultaneously

2. INSTALL
. Cluich Boss @
. Washer @
I
'Nut@
3. TIGHTEN
'Driven Gear AssY Nut with Tc':-i
W'ench ard no dlng tle Clulcf B' :'
w,ll. Specral Se.v'ce Too FSV.: :
E\
\\1
[.*n'" (31 Fr. Lb)

The Clutch Plates must be so insta le:


their cutways do not overJap each otf:
except for the Plates 1 and 5

4, INSTALL
15 . Friction Plates (6 Nos) @
. Clutch Plates (5 nos)@.
4 (( )12 'Ball@
' Push Rod @

Arrow of Pressure Plate should b€


matched with the Dot Mark on clul]-
Boss

3-24
5, INSTALL
. Pressure Plate @
. Springs @
. Bolts @

6. TIGHTEN
. Primary Drive Gear Nut along with
washer by using Torque Wrench.

DRIVING SPROCKET
5.5 Kgm (40 Ft. Lb)
1 , INSTALL
. Drive Sprocket O
. Lock Washer
TIGHTEN
. Drive Sprocket Nut @ with torque wrench
having socket No 26, holding the
Sprocket by Specral Service Tool ESlvl -
205 @

CRANKCASE COVERS
l INSTALL
. Crankcase Cover RH O
b"
V4*
YY'

s' a{4 il

s9 ,'
B. NUT
1. SPARK PLUG
2. NUT
L GASKET CYLINDER
'1
0. RINGS
3. CYLINDEB HEAD
11. EXPANDEF
4. GASKET CYLINDER HEAD
12. PISTON
5. BOLT STUD
13. BEARING CYLINDRICAL
6. CYLINDER
1r1 PIN PISTON
7. BOLT STUD
15. CIRCLIP
ENG

1, INSTALL
. Piston O
. Piston Rings with Expander @
. Needle Roller Bearing
. Piston pin O using Special Service Tool -

ESM 507 @ (Piston Pin FePlacer)


. Piston Pin clips (new) @
3

IMPORTANT
Make sure Piston Ring Ends are prop-
erty titted around Piston Ring Locating
Pins in Piston Grooves
The arrow on Piston Dome musl face
Exhaust Side.
Belore installing the Piston Pin Clip
cover the Crankcase with a Clean Rag

CYLINDEB

INSTALL
. casket (new) at
. Cylinder @l Using Special Service Tool
qrng Compressorl
ESVI 5'0 3 tPislon

TIGHTEN
. Cylinder Nuts Gr (4 Nos )

Q*:"re{"i
3-27
1, INSTALL
. Head Gasket O il
. cylinder Head iO
{

I
fi

2, TIGHTEN

t
. Cylinder Head Nuts Ol 4 nos. with torque
wrench using Socket No 14
" Spark Plug €)

Q\.1,:lyll".-.'f i

ENGINE MOUNTING

...-:' 1. TIGHTEN
. Engine Mountlng Bolts

. Eng ne Mounting Bo ts le

*n* (* r,. .01


9\ ..0

IN STALL
. L.H. crankcase Cover i.0,

F ILL
GearBox Oil
.L.Fl. cfankcase Cover

3-28
DRIVEN GEAR ASSY, & GEAR
PRII\,4ARY DRIVE GRADING
DF VEN GEAR ASSY
GRADE
DB]VEN GEAR
GRADES
"r=h
@ GEAR \
PR]N4ARY DRIVE

G A
z A B c D

B B
GRADE
A
D
c
PR MARYI E
D
e E
:\]NECT NG ROD (S]\,4ALL END) & . SPEC FIED ALLOWED CO]VBINAT ON
::DLE ROLLER BEARING (SIIIALL END) CUT N,4ARK
COLOUR ON CAGE SIDE
.{N ROD(sE) COLOUB coDE (DOT)
CODES
'-\
WHITE BLUE BED
.--ir'rcrsEr\ (D0T) (D0T) (DoT) SMALL END NEEDLE

I
B {1 CUT MABK)
AII
I (2 CUT |\4ARKS)
UI CRANK SHAFT

3 CUT MARKS

. SPEC FIED ALLOWFD COI\,IBINATION


STANDARD PISTON & STANDARD
.OLOUR BAND
BODY CYLINDER
BODY CYL NDER
ASSY. (STD ) P STON (STD)
COLOUR BANDS

(STD) 3CDY CTL lSTD.

J:IDE PUNCHED ON BASE FRONT


$n RED

: l: TEXHAUST PORT SIDE) E' e!41!GE


..: :rnbLnalrnsol gra'lesareappL,.ablelo(standad D r. GREEN
l; rden ..y.vers'ze (OrS) gody Cy .ders the
Er

l
, .: il Pslon [.!d be delerm ned by lhe rebored
.:.1fi€rnaloflhe B.dy cy rnder D PURPLE
S

3- 29
!

CHAPTER 4
CARBURETTOR

CARBURETTOR

cARBURETTOR EXPLODED VtEW .......... ... . ... .......4-1

opERAT|ON OF CARBU RETTOR ................................ 4-2


WORKING RANGE OF EACH COMPONENTS - , .4-3

DISASSEMBLY
REMOVAL AND ........4-4

TNSPECTION -.....-...4-5

REED VALVE

TNSPECTTON ..........4-5
,l

19

1
F
116
&17

CAP 12. FLOAT ASSY


GASKET 13 FLOAT CHAMBER
SPRING THBOTTLE VALVE 14, GASKET FLOAT CHAIV]BER
NEEDLE SET 15. JET PILOT
VALVE THROTTLE - 1 16. NOZZLE IVIAIN
CABBURETTOR BODY 17. JET MAIN
AlR SCREW SET 18. CLAN4P HOSE
fLUNGER STARTER ASSY ]9 JO NT CARBURETTOR
THROTTLE SCREW SET 20 REED VALVE
-,
-.
\LL\LL \NL\L N\S\. 2\ q}\\\.L\\\\\LSE\\
.P\N FLOAf

4-l
IG
CARB
@
f

OPERATION OF CARBURETTOR
Throttle Valve Operating
opening Angle System
ldling 0 Piloi Jet

Low speed 0 to 1/8 Piot Jet


Low and [/ed um Speeds Pilot Jet
'114 /Cutav'vay
1/B to
Nledium and high Speeds Marn Jet
114lo 314
[/ediL]m and high Speeds Main Jet
3/4 to Full

LOW SPEED CONTROL SYSTEM


OTO 1/8 ffHROTTLE OPENING)

lr tl
\-:-r0- 1/8
MrxrNG llqT ourtE- {
-|l li,ru

t!
4-
LOW SPEED CONTROL SYSTEM
Throllle va]velplsro.) 1/8 TO 1/4 (THROTTLE OPENTNG)

MIXING

_t
FUELi_}L8]!8I!EfI

MEDIUM SPEED CONTROL SYSTEM


Thronle vaNe(piston)
1/4 TO 3/4 (THROTTLE OPENTNG)
ENGINE

NEEDLE JE

JET NEEDLE

HIGH SPEED CONTROL SYSTEM


3/4 TO FULL (THROTTLE OPENING)

NEEDLE JET

MIXING

8-? 1_1
tl

Ai tTl WORKING RANGE OF EACH


\9r+ ffiL COMPONENT
S71
A) MAIN JET
B) NEEDLE JET AND JET NEEDLE
C) THROTTLE VALVE CUTAWAY
ED1 1 1 1 FULL OPEN D) PILOT AIR SCREW & JET
8424
r

REMOVAL AND DIS AS S E tt'lB LY


1 := .
"'3, S:e 2.ri
. :r.:- RH side.
' aa. Assernbll/ A r Cieaner G) by opening
3 \las saretls
2. LOOSEN
. Jo ni Arr C eaner Clamps Screw @
. C amp Carburettor Hose Scfew ol Jolnt
Carburettor:r.
3, DISCONNECT:
. Fuel Hose @)
. Oil Delivery Hose 6
4. REN4oVE:
. Carburettor lO
. CarburettorToP @

5. DISCONNECT:
. Throttle Cable (O
. Throtile Valve AssY.
6. REMOVE:
. Starter PlLlnger Assembly €l
. Float Chamber @ by opening four nos
scre\i/s.
. Float @ by removing Pin Float (a
. Needle Valve Assembly d,
. lvain Jet by @
. Pilot Jet bY screw driver 6'

7, REMOVE
. Reed Valve Assembly @ by opening,:
No bolts (Reed Valve, Joint Carburettof
Gasket)

IMPORTANT
. Never clean the Jets with a wire.
. Alwavs clean the Carburettor lrom outside belore disassembly'
. irpi6p"t of Float Height, C-lock on Jet Needle' and Air Screw can ca
drop in fuel""ning
average-
CLEANING ANDINSPECTION
1. CLEAN
. Using high pressure air, blow out all pas-

OdDp
sages anq lers.
2, INSPECT:
. Needle Valve Assembly
a- 1 Gasket O
2 Valve Seat @
3 Needle Valve @
Damaged or Worn oul -Replaceasaset

3. INSPECT :

. Throttle Valve @
. Jet Needle @
Scratch/Bent - Replace

4. MEASURE:
. Float Height @ Without Gasket
wilh Needle Valve Assembly in posiiion
lf found incorrect then Adjust

\\'@/2,
N ]
5. ADJUST
.
ffi Float Height
by bending the Tang @

IMPORTANT

lf Float Height is more than specified,


less petrol in Float Chamber.
lf Float Height is lessthan specified, then
more petrol in Float Chamber.

4-5
T

CARB

REED VALVE

, ,: ,: :i::3e'neight o
a-: a' :3:. i ;alon -AdjLlst
. ?ea. !a re gending g
oLt oi sPec flcatlon -RePlace

Valve StoPPer Height @ 9i0 3


Fteed Valve Bending Limit O
0.2mm

Note the cut is in the lower corner or


the Reed and the StoPPer Plate'

FUEL LEVEL
. Place the Motorcycle on level surface
. Attach the FLlel Level Gauge Gl to the
Float Chamber Nozzle
. Loosen the Drdin Scle',i/ 2 and "larl I'
Enqine.
. Me;sure the Fuer Level J wilh OaJg"
. lt the fuel level is incorrect adjusl the
Float

FUEL LEVEL:5.7 i 0.5 MM


{MEASURED FROM THETOP EDGE OF
THE FLOAT CHAMBER)

ThecalburettorisPresetattheFactoryaftermanytests.|fthesettings'aredisturbed
Perfomance may result.
ftltlng technicat knowledge, poor Engine
"i-tro"i ""V
FRONT WHEEL

12

"@-*^ n.,,.'
A6-
,{n'@
16
7
k'*,,

AXLE WHEEL 12, BEARING


COVER ASSEMBLY 13. BRAKE SHOE COMLPLETE
OIL SEAL 14. CLUTCH METER
BEABING 15. GEAB DRIVE
TYRE 16 OIL SEAL
TU BE 17. CAM SHAFT
BAND 1B PLATE BRAKE SHOE
a. BlM 19 LEVEF CAM SHAFT 1
2. SPOKE SET 20. GEAR METER
-0. HUB FBONT 21 BUSH
'1. SPACER ASSEI\IBLY 22 O L SEAL
tr...

CHAS

FRONT WHEEL REI,IOVAL


' :-ra: --: ','OIORCYCLE ON ITS
a:'.-::3-i'.l
2 - a:: ='.
t -.: -a:{_-: ! and screw n the adjuster
: ic :aaa' tfre brake cable on the front
\.;ree t are brake shoe.

3. DISCONNECT:
. The brake cable @ by pressing Lever
Camshafll L4l

4. DISCONNECT:
. Removing the Ring Stop @ Disconnect
the Speedometer Cable a6l

Relit TheWheel in Reverse Sequence.

{fi
Y'
Front Axle Nut 4.3 Kg. m
(31 FtrLb.\

5. REMO\E:
. Colter Pin ill
. Axle Nut €) by using rlng spanne".
. Axle Shaft O
. Front Whee @
CHAS

REAR WHEEL

'a
13

&..r{*t
t t1,
fzs L"qJ
I

;* *;'@"" -** -4
zs- @o

AXLE WHEEL OIL SEAL


PULLER CHAIN 2 BEAFING
COLLAR SPACER ASSEIMBLY 2
LEVER CAM SHAFT HUB
PLATE BRAKE SHOE 17. BEARING
CAI\,I SHAFT DAI\,4PER
BRAKE SHOE SET 19. CLUTCH HUB
TYRE 24. BEARING
TUBE 21 OIL SEAL
BAND 22. AXLE SPROCKET
Rll\,1
23. CHAIN
SPOKE SET SPROCKET DRIVE
25. PULLEF CHAIN 1
T

ii!: ,I.gEL REMOVAL


--: ,,.
:-SRCYCLE ON ITS
.-_: - ::A SUPPORT
"

., 'anovLng splitpin and


-s rg r ng spanner No

::t,'',

I
:
, : r' 1 : - or -r screvlirg Nulwing 3
t i: ': :':r: hoo !
5 . So' .!
ca.npress on 6
. vlasher P ate O

4, REN,4OVE:
. Split Pin O
. Axle Nut @ using Ring Spanner No 22.

5. REN4OVE|
. Axle Wheel O While pressing the Assist
Grip @ down with force.
. Collar @
. Rear Wheel @ tiiting the Motorcycle to
Lelt Hand Side.

Cale should be taken that the'AxleWheell


should not Rub the Silencer while it be.J
ing pulled out from ihe Real Wheel.

REFIT THE WHEEL IN BEVERSE SE.


OUENCE.

lQIe""'^'"]1s.2 Ks. m (66 FtLb.)


CHAS

SPROCKET DRIVEN & CHAIN REMOVAL


1, REN,4OVEi
. Chain Case 1O by open ng screws (4 Nos)
. Dr ve Cha n lock O and Drive Chain O.

2. FIEMOVE:
I
. sprocket Assy @ by opening Nut Gl us-
I ing Ring Spanner No 27.
. Sprocket Driven @ from Clutch Hub (a
I
by un ocking and opening bolts screws
I
(4Nos.)

INSPECTION

1. INSPECT;
. Axle Wheel (Beaf and Fronl)
Roll the Axle Shaft on a Flat SLrrface
lf Shaft Bent then Replace.
2. INSPECT:
. Wheel (Rear and Front)
lf Tyre Cracked/Rim Heavily Bent then
tr6nl'.o th6.^n.d.han
^rrt
3. MEASURE:
. Wheel Runout
f out of Specification then True the
Wheel or Replace.
Rim Runout Limits
FadialoMax 2.0 mm
Latera\OMax 2.0 mm

4. IN SPECT;
. $Jf,ee\ Bear\ngs
f excess play in the Bearings or Bear-
rng Jarnmed then Rep\aae.
5. MEASURE:
. Brake Shoe thickness
Out ol specification then Beplace.

Brake Shoe Wear limit 2MM

6, NIEASURE:
. Brake drum inside diameter
Out ol specification, Beplace.

Drum Diameter Limit '13-1 mm. (max.)


lBrake

T.INSPECT:
'tl . uflve SprocKel ql
. Driven Sprocket @
F@S ll Wear/BentTeeth ihen Replace both r:
Sprockets and the Chain as a set.

8, MEASURE:
. Drive chain length (10 Links) 'A'
li Out of specification then Replace

Diive Chain Length (10 Links)


Maximum Lim:t:'12'l mm
CHAS

9. INSTALL
. The Chain Clip O with rounded end fac-
ing the direction ol travel of Chaln

10.cHECK
. That bolh ihe RH and LH Chain Adjusl
ers are adjusted to the same position to
maintain correct Axle alignment.
. The Chain Slackness should be between
20 to 30 mm with Motorcycle on Centfal
Stand.

KITIMPoRrlNrl
I Please lubricate Chain with Multigrade
| 20w40 oil belore installing.
I
I

Note the following installation points


ghtLy grease the wheel oil seal lips and geaf teeth of the speedometer drive and driven
-
Jears.
LJse jghtwe ght, lithium base grease )
3e sure that the tongue stopper is posiUoned cofrect y.
rI
l
u-
ti

I
lnftxl
l"" "tot l

:-

E I\,1BLE IM L CYLINDEF COI\,4PLETE


FRONT FORK ASSEMBLY RH. 10. INNER TUBE COI\,lPLETE
UNDER BFACKET COMPLETE 11. SPINDLETAPER
CAP FRONT FORK 12. SEAL DUST
BOLT CAP
'1
3. CLIP OIL SEAL
SPACER 14. OIL SEAL
SPRING SEAT 15. OUTER TUBE LH
SPRING
REMOVAL

1 , REMOVE:
. Front Wheel as described on page 5-1
. Front Fender bV opening bolts (4 Nos)
2. LOOSEN:
. Front Fork Pinch Bolt Upper O (2 Nos)
. Hemove uap hronl ForK !9
. Bolt Cap @(2 Nos)
Use Specia' Servce Tool ESM.2l4 a

(Top Plug Spanneo

3. REMOVE:
. Emblern 6) by opening screws (2Nos)
LOOSEN:
. Front Fork Pinch Boll Lower @ (2 Nos)
using Ring Spanner No 14
5. REMOVE:
. Front Fofk Assembly L.H. & R.H.a0

DISASSEMBLY

'1. RE]\,4OVE:
pl . Botoap O
' spacer rg
- t " Spring Seat O
8,, !, E
. Spri.g @

f
-

DISASSEMBLY
2 DFAI\
. Fr.ri F:'( O ci Pumping InnerTube@
-^ ns de :h: O!iaf T.rbe tt

3. OPEN:
. Bolt Hexagonal Socket Head @ by us'
ing Allen key No 8
. Use Special ServiceTool G) {ES-\,4 - 213)
1o hold the CYlinder ComPlete
(9

4. REMOVE:
. tnnet tuoe 9
. Cylinder ComPlete @
. Spindle TaPer @

5, REMOVE:
. Dust cover @
. Clip Oilseal @
. Washer ()
. Oil Seal @ using Special Service Tool
@ (ESM 270)

INSPECTION
1. INSPECT:
t." a** tr* l . lnner Tube il-
. Outer Tube
Scratches/Bends/Dan'rage Rep ace
Teourred.
\leasure Length of Fork Spring €l lf Out
oi specificat on Then ReP ace
O Ring of Bolt CaP
Specified 296.5 mm Cvl nder CornPlete for Damages
Nlinimum limit 291.5 C Seal ot Outer Tube lor dan]ages

5-10
t

ASSEMBLY
1. INSTALL:
. Insert Cylinder Complete O (with Spring
@) irom the top end ol the InnerTube @
. Spindle Taper @ on the lower end of the
Cylinder Complete
. Inserttheaboveassemblyintothe outer
tube 6)
. Bolt Hex Socket Head @ Using allen key
No 8 and Special Service Tool @ (ESM
21s)
Cylinder Comp ; 2.3 Kg.m,
(17 Ft.Lb)

2. INSTALL:
. Oil SeaL @ with Special Service Tool -
EStVt 275 €).

. Clip Oil Seal

3. INSTALL:
13 . Front Fork Spring @
'11
. spring Seat @
Each Fork Leg
' Spacer @
175 r 3cc
. Boit Cap @
. Dust Cap @ SERVO
TELESHOCAB
4. FILL: otL
. Front Fork Oil

5. INSTALL
. Front Fork Assembly LH & RH.
. Tighten the Bolt Cap.
'. Pinch Bolt upper and lower
Cap Front Fork

t t6\ cap Bolr: 2.3 Kg.m, (17 Fr.Lb)


\ \ Pinch Bolt:
il
Upper: 1.5 Kg.m, (11 Ft.Lb)

I Lower : 3.0 Kg.m, (22 Ft.Lb


e11
€tz eP
g
E0
kis?
l-/P
F

L-

COVEB UPPER RIGHT 10. UPPER RACEBALL - 2


COVER UPPER LEFT 11. BALL (22 NOS)
COVER OUTER RIGHT UPPER RACE BALL - 1
COVER OUTER LEFT COVER BALL RACE
EMBLEM 14. NUT
UNDER BRACKET CROWN HANDLE
LOWER RACE BALL 1 HOLDER HANDLE UPPER
BALL 19 NOS 17. BOLT CROWN
LOWER RACE BALL . 2

REMOVAL

1 . REMOVE:
. Front Wheel as per instructions on page

. Front Forks as per instructtons on page


5-6.
. Headlight Bezel Assy. O
2 DLSCONNECT:
.All Electrical lead wires @
(in the Headlight Case)
e14
13 ^-
_5 rz s,9
.d:
g"
16

COVER UPPER RIGHT '1


0. UPPER RACEBALL . 2
COVER UPPER LEFT 1',t. BALL (22 NOS)
COVER OUTER RIGHT 12. UPPER RACE BALL - 1
COVER OUTER LEFT COVER BALL RACE
EMBLEIiI 14. NUT
UNDER BRACKET CROWN HANDLE
LOWER RACE BALL 1 HOLDER HANDLE UPPER
BALL 19 NOS 17. BOLT CROWN
LOWER HACE BALL . 2

REMOVAL

I REMOVE:
.trrolt Wheel as per rlsl.uctro'rs on page

. tr'o1t Forks as per Insl.lrctions or pagc

. Headlight Bezel Assy. O


2 DISCONNECT:
.A I E ectrical lead wires @
(in the Headlight Case)

s-12
3, REMOVE:
. Cover Crown O
. Bolt Crown @ bY using socket No 17
. Crown Head assembly @
. Headlight Stays (LH & RH) @

4. DISCONNECT:
. Brake Cable @ {rom the Brake Lever @)
. clutch cable (0 from the clutch Lever @

5, REMOVE:
lnigil 1t . Fork stem Nut @ using Special Ser-
vice Tool @ ESM 221
13 . Cover Ball Race @
6 '14 . Race Ball 1 @
. Top Balls @ (22 nos )
t5 . Bottom Balls q9 (19 nos )
. Under bracket @
t6

6, FIEMOVE
. Race Ball 2 (Lower @ and Upper @)
Using a long rod.
. Race Ball 1 @ (Lower) Using a cold
chisel.
T
CHA a

INSPECTION

--: ::::: :_:


@"@
Sals in pekol.
2 \,s:::-
oqr. ^ .: -:r ::_rage Then Replace.

'.EW =
:-:; tarage Then Replace.

INSTALLATION
J \S-ALL
. Fa.e Ba T (bottom) €Jon the under
cra:K:l ano race ball 2 bottorn Oand
upcer ,2 insrde the head tube of the
frarne uslng punch
l.Grease the Balls and Baces

2, INSTALL
. Under Bracket @
. Race ball 1 upper
. Beaflng uover a
. Ring Nut lO
3. TIGHTENi
. Ring Nut @ with Specia Service Too
ESM 221 t-'
(So that a I play is taken up, but the
DracKel can still pivot freely.)
INSTALL:
Handle Crown w th Head ght stays
Crown Bolt
Front Forks LH and RH as per nslruc
tions on page 5-8
CHAS

@q$roo

f\\Cr--
;3 \ ,iu
1. SHAFT PIVOT 5, BRACKET UPPER
2. BUSH 6. COVER OUTER
3. REAR ARM COMPLETE 7. SPRING
SHOCK ABSOFIBE R 8. SEAT SPRING
ASSY REAR 9. DAIVPER ASSY

REMOVAL
REMOVE:

. Chain Case
. Drive Chain
. Dfiven Sprocket
. Chain Case
REMOVE:
. Shock Absorber Mount Bolts@
. Shock Absorbers

REMOVE:

el . Pivot Shalt Nut O t\


. Pivot Shatt 0
. Sw)ng arm

I
CHAS

INSPECTION

t.....:''':'

lhen Beplace

2 '.s;:a-
. S,', -l a'-
'.,'i- :.as!','ng arm Installed gfasp the
sl., .;
ar.n enC to check forfree play- Free
p ay rc: .ed Replace bushes.

Swing arm Free Play Limit: 2.0 mm

)o 3. INSPECT:
. P vot Shaft 2
Rusvd rty Clean or Replace.
Bent - Replace

INSTALLATION
1. GREASE THE BUSHES AND PIVOT
SHAFT.
2INSTALL:
. Swlng arm
. P vot Shaft

Kgm (43 Ft. Lb)

Always adjust both the right and left shock absorbers to the same posit on.

5-16
ELEU

t2! 5/2tW

a.s o

ls
I \*s -u F
=
=
Jl
]HTET
z E9*
t 6 IT
o
Ei ql I (l 4
si - M-
E
r"l -
I
I
-E 6+
.o e t-l;"
s:E?lsa
dts

s;:869s
-a
rt"'lr
IE ft -:HE
ecFii?
z

-li .
O6dEt;

HEAD L]6 -
FLASHEFLIOHI LGI]I 12VN4W ]21J-3 4W 12V.35r3!rr _:-_
12V.1Cr' 12V.3lW : :r'
I
t

SOURCE COIL
IGNITION COIL
,,i----\ 'i

<f
@o- PICK UP
t
cotL

FIG 2
tr{!,}

ffi vi il

E)
0 T
FUNCTION
CHARGING
. As tt-te fotor turns, cufienl ls produced in
'ie so- ce.oil a1d then storpo il rl^e.g1.
t on condenser. (Fig. 1)
TR GGER NG
. Att e same time.The pickup coil sends a pulse
s gna I to activate the thyristor (Fig. 2)

SPARKING
' --:. the gnilion condenser discharges
:-: :iored current rapidly. This induces a
- l- c tage n the lgnition coil and a stronc
.

::: < s oroduced.(Fig. 3)


TROUBLESHOOTING CHART
. All wires Conneclion must be checked in advance.
1 Spark Gap Test Pick Up Coil

. Ground the Spark Plug to the Cylinder . Check the Pickup Coil Resistance
Head and Kick the Starter
*o+
No Spark or Weak
Spark + "^+ Replace the Pick Up Coil

rk Gao Test 5 | SoLrrce Coil Check

. Hold the lgnition Lead 5 mm from the Cyl- . Check up source coil resistance
nder Head

No Spark
o*+ *+
check the Plug Cap
and Spark Plug Replace the Source Coil

3 rk Gap Test 6 | lqnition Coil Check


OPRM

. Disconnect the Main Switch Coupler and


.
'"6 o L 6_J:!qqn
t--tnl
t . t-- -rtl

HY
Check the resistance of the primary and
kick the Sta er.
I\,/ 5parK "^+
secondary coil winding.
*"+
No Spark

Check Main Switch Rep ace the CDI Ljnit Replace the lgn tion Coil
RECTIFIER/
REGULATOR

--.--\

FUSE
CHARGING ;-
corL .i ,i

BATTERY

2. Charging Coil Besistance


l..Charging Voltaqe Test
. Connect the lester leads with battery ter- Dlsconnect the generator leads an:
check charging coil winding resistanc€
minals as shown.Start the engine and
check voltage.

CHARG NG VOLTAGE iHAFG NG COIL RES STANCE


14.5i05Vai5000FPNj : .q olll,,4s r l0?" (Wlrrle/B ack)

_! .-
lf out of speciiications checK Char,o : -: :: soec l cation, reP ace charglng
coil windlngs reslstance Ata ' ff :'a
than 12V replace the Rectre"Fe!-:'
10r
rllGH BEArli NDtCaTOF
LtcFT LIGHTING
SWITCH
neoo.,cr-, ).
\"
e.+" l
I ll J

il f'l)l
L?'TI r*-l,
AUXTL|ARY
Yl
LIGI,]T i
*
,rrrr^-
LIGHT
| o,0;";*"t

BECTIFIEF LroHlruc
BEGULATOF coti
=

l.Lighting Voltage Test


t:e headl;ght reads and connecl 2.Lighting Coil Reststance
I:To'1e
Ine lester leads as shown St:ri rh.
-^^;
ard .necF rr^e uoi,uj"" "*" " = - tgrn"

YELLOW

ll:n.:'::J ;":t j ";:;,,;1:1". ."


H GH BEAM IND CATOF LIGH' LIGHTING
SWITCH
HEADLIGHT

,ti

/:4.
r\14*Fr

LIGHTING COIL
FIECTIF ER
REGULATOF

l.Lighting Voltage Test 2.Lighting Coil Resistance


Remove the Headlight leads and connect
the lester leads as shown.Start the engine
and check the voltage.

L G]]TING VOLTAGE L GHTING CO L FES STANCE


13.5!0 5V AT 5000 BPl",l r
0.55 OHNIS r0%
(Yel ow /Black or Grcen/Back) Yellow Red/Bla

lf o.rl o' spec:'icatio Ihe.( | rgl^lng coil


resislance and Rectif ler/Regu ator.
--I

HLGH BEAM INDICATOF LIGI]T LIGHTING


SWITCH
HEADLIGHT

L GHT

METEFI
L GIIT

MAIN SWITCH

L GHTING COIL
BECTIFIEB
L GHT REGULATOR

=T
---L-

l.Lighting Volage Test 2.Lighting Coil Resistance


Remove the Headlight leads and connect
the lester leads as shown.Start the engine
and check the voltage.

LIGHTING VOLTAGE LIGHTING CO L RESISTANCE


l3 5!0.5V AT 5000 RPM 0.55 Ol'llr4s i 10%
(Ye low iB ack or GreedBlack)

li out of specification, check L ghting Coil


resistance and Rectif ier/Regulator-
r

Br Briw FLASHEF
LGHT(FF)

FLASHEF

swtTct .i \
tt: i:-
sw Tcfl FLASIIEF IND
L GHT (B)

I SHIFT
+ LGHT (L.F l

LGHT(LFl
BATTERY
FLASI]EF N:
L GHT (L)

BRAKE LIGHT

MAIN SWITCH
B/W R Br
SWITCH INSPECTION
oFs G o
oNo G.

(:rc

LIGHT SWITCH
L
o -{f
PO G o o
(oscoNTlNrlED) {coNTrNUEo) ON o- -o

6-6
I,IMER SWITCH BRAKE SWITCH

\JS G -o

ASHER SWITCH

qN SWITCH
-..-

DIMMEF SWITCH BBAKE SWITCH


G

H' Qt o o \JS O --o


ro ci o --o

FLASHER SWITCH
B/w D9
o-
N

o- -o

HORN SWITCH

i
:l --o
DIMMER SWITCH BRAKE SWITCH
G \J>
G_ \Js o
LO ci o- --o

FLASHER SWITCH
Br/w Dg

o-
N

-o

HORN SWITCH
7777

I
rl o
t
hoso
crank veniilarcn
o I delivelr

calbu1610r br€atherhose
STARTING TROUBLE
POSSIBLE CAUSES

FUEL SYSTEM

No luelln Tank
BefrtJfuelrn Tank
Fuel Coch cjosed
Turn Fuet Coctco ,ON,
Foitroi
.,,":fiJ'
ri'"",'"",',iti :?11 fl:? ll 3:Tlr:,i:ilank,
Fuer c";" F*il;""d
Air veni
hole n FuelTanf Crp
Clean Fuel Tank Cap
Choked FueICock "log;;
Get Fuet Cock cteaned
Carbureitor llooded
T,,rn F,,-i
^-^,-.
,;";::::1,:,y.' .pos,uon. oDer rre rhro re
;;;;ff il:j :"^ ifj i';
:rar.airer unscrewns spark
--;;;il'Jil
l;1g T:,t :g:'ln:l'" : :['Jl
Chocked Fuel Filter "'u,,,. He'lt upark plug and k,cx start rne i.g,"s
Get Fuel Fjller cleaned
IGNITION
f"1arn Switch OFF,
Turn key to ON'positio;
Spart eiug Otrty or. OriOg;;y s;; cl""n,
"t,""t
uno uo;rs rnu $rkEfEE[IZ"p
H. T. tead toose/broken.
Frt propertyheptace
H.TIeJ
lnsulatton of Spark plug
cracked
Replace Spark pjug.
Elecl ron ic i g ni tion system;f e;; Check ior ioose conneclions-

POOR PICK UP
POSSIBLE CAUSES
\4|rfJier ouIet chokecJ
Clean Ihe t!,lulfter
Ar F[ler choked or drrly
Clean Air Filler/Beplace
!g1Oer Carluretror aCtustme,,rt najL,sr tne Carburettor
Cylinder Head Loose sen-inii
f'On'"n CV""O", Uo"o
C utch stipping t,r" ,o *"a,t,J,o,G
AdJUst Cturch se rng
irenorQuality ol Fuel
.-,,r1,"1
cn"1!115g11a111.0^"[osoodquJ.
3rake(s) b ndrng
Adjust Brake(s)
?islon Fing worn
out
Replace pisron Fings
as a;
STARTING TROUBLE
POSSIBLE CAUSES REMEDIES

FUEL SYSTEM

No fuel n Tank Retilfuel n Tank

FLre Cock closed Turn Fuel Cock to ON' position


lmproper iue supp y due to sed ment Clean Fuel fank, Fuel Cock, Fuel Line and
orwater n fuelor alr lock in iuel line. Carbureitor.
Air vent hole in Fuel Tank Cap clogged C ean FuelTank C_ap

Choked Fuel Cock Get Fuel Cock cleaned


Carbureltor floo.led Turn Fuel Cock to OFF'position. Open the Throttle
and endeavour lo kick slad after unscrewing Spark
Plug and plugging the Spark Plug hote with a clean
c oll . Refil Soark P Lg and k'ck start rhe Engine.

Chocked Fuel F lter Gel Fue Fiter c eaned


IGNITION
Ma n Swilch OFF-' Turn key to 'ON' posilion

Spark P ug diriy or brdged by soot or Clean, check and adjust the Spark ptug Electrode cap

H. T. lead loose broken Fit properly/rep ace H.T. lead

Insulation of Spark Plug cracked Replace Spark Plug.

Eleclronrc rgn 1on system delect ve. Check lor loose connect ons

POOR PICK UP
POSSIBLE CAUSES REMEDIES
I\,4uifief out et choked Clean the IVluttler
-:. _---
A r F terchoked or dirly Lrean A r I Tel/Hep ace
lmproper carbure or adj!stmenl Adj,r.l th" C"rb,""1i", *til"S"
-
Cylnder Head Loose
I sh"l]?4d"'. j""gli"lIp"Il"d t"!*
C utch s rpp rg Adjust Clutch se ing.
Inlerior Oua fy ol FLrel Check and replace with specfied good qualty fue.
Brake(s\ hind\ng NNs\B\ake\s\
\
Piston R ng v/orn olt Rep ace Piston Fings as a set.
ENGINE GETS OVER HEATED
POSSIBLE CAUSES BE|llEDIES

Fue -Arr L4i^ture ean Adlusl Carburellor Selt ng

Air F lter choked by dirl C ean Replrce Arr F Ter

I\,4uil er outlel choked Clean the lMutiler

Carbon depost n lhe Engine Decarbonise lhe Cy inder Head

Spark Plug ol Incorreci Heai Range Repla' e rrt_ Sp. r Dr ro ol Co_e.lHe.L qdnge

POOR BRAKING
POSSIBLE CAUSES REMEDIES

Brake(s) not propery adlusted Adj!st Brake(s) propeny

Lin ng of Brake Shoe worn out Replace Brake Shoes(s)

Brake Drum worn oul or scored Rep ace Brake Drum

Brake no sy Gr nd Brake Shoe surlace propeny

MOTOCYCLE WOBBLING

POSSIBLE CAUSES REIMEDIES

R m Run Oul orwobb e


Loose/Broken Spokels) Trghten tenlace Spol'e(s)

ncoffect F trnenl of Tyre (s) Rel I Tyre propery

Worn oul Whee Bearing(s) Rep ace Wheel Bearingls)

Rear arnr Bush(es) worn oul Replac€ Birsh(es)


{
Replace Reaf Sw rg Fofk
Tyre Pressure loo low Inflale T!reisi l. Iifcoer press!re

KNOCKING IN THE FRAME HEAD

POSSIBLE CAUSES R EI\,'I E DIES

Ba Races Loose/ptted Ber.... :_: a: I rtes

DRIVE CHAIN NOISE

POSSIBLE CAUSES REIVEDIES

Cha n oose :-E: led s ac[ lm L


BULBS DO NOT GLOW
POSSIBLE CAUSES

No Fuse in lhe c rcu I or defective Flse Rep ace/assemb e Fuse assy.


Battery D scharged Check electolyle eveland reptenish wilh dislj ed
water. Check battery leads ior proper contact . Check
Recl lier/Regulator un t.
Handle Bar Sw tch defecUve Repa r/ Feplace Handte Bar Switch.
Bulb(s) Fused Replace bulb(s)
mproper Earthing Chech earthinq connecttons and clean lhem.
Loose or improper connections Checl, and recify connectons.

HORN DOES NOT BLOW


POSSIBLE CAUSES
Battery Discharged Check electolyte level and repten sh with d stileo
water. Check battery teads for proper contact . Check
Rectif ierlRegulalof Unil.
Horn Defective Feplace Horn
Horn Sw tch detecltve Replace Horn Swtch

INDICATORS NOT WORKING

POSSIALE CAUSES
F!sed Bu bs Rep ace Bu bs
mproper connect ons Make proper connect ons
Indicator S!./ilch defect ve Rep ace Ind cator Switch
Flasher Un t defectrve Feplace Flasher unrt.
rmproper earllr ng Check earthing connections and rectify thenr.

BRAKE LIGHT NOT WORKING


POSSIBLE CAUSES REMEDIES
rmproper adluslment ol Rear Brake Adjust the Erake Light Switch
Light Swtch.
_
Slicky Front Brak," Llght Sw tch Clean/Replace ihe Switch
_
Fused Bulb. R"pb"" B,rb
A\
Seat Height 765 mm
Wheel Base 1245 mm
Minimum Ground Clearance 145 mm
l\y'inimum Turning Radius 2100 mm
WEIGHT
Dry 103 Kgs
CLUTCH
Type Wet l\.4ultiple Disc
Clutch Plate 5 Nos
Friction Plate 6 Nos
Lining of Friciion Plate Rubberised Cork Working in Oil
TRANSMISSION
Primary Reduction System HELICAL GEAR
t
Primary Reduction Ratio 71/22 \3.227)
Secondary Reduction Systm CHAIN DRIVE
Secondary Reduction Ratio 37115 (2.460)
Transmission Type CONSTANT MESH, 4-SPEED
Operatjon Through Foot Operated Lever, Mouni.:
on LH Side of Gear Box with Neutra
Gea. Positron Belween Frrsl Speed -
Second Speed
GEAR RATIO
'I
St (35/11) 3.182:1
2nd (30/15) 2.000.1
3rd (26/19) 1 .368:1
41h (23/23) 1 .000r'l

CHASSIS:
Type Double Cradle
Construction Duplex, l\,4ade of Tubular Section
Castor Angle 27.54
Traii 90 mm
TYRE
Size (Front) 2.50x1 8-4PFl-Nylon'Ribbed
Size (Rea0 2 75x18 4PR-Ny on-Universal

TYRE PRESSURE
Front (Solo/Double) 22 PSI
Rear - Solo 2a PSI
- Double 32 PSI
Aq
BRAKE
Fronl Brake Type Drum Brake (130 O), Intemally Expanding
Operation Right Hand Operation
. Rear Brake Type Drum Brake (130 O), Intemally Expanding
Operation Right Foot Operation
SUSPENSION
Front Suspension CerianiType, Telescopic Fork, Oil Damped
Rear Suspension Swing Arm (Adjustable 5 Positions), Coil
Spring, Oil Damped.
WHEEL TRAVEL
Front Wheel Travel 110mm
Rear Wheel Travel 75 mm
ELECTRICAL
lgnition System cDl
Generator System Flywheel Magneto
lgnition Timing 15 a 3 at 1300 R.PM. BTDC
:
'19 r 3 at 6000 R.PM. BTDC

SYSTEM 12 VOLT
Head Light 12V- 35W35W
Tail/Brake Light 12V- 5W/10W
Flasher Light 12V- 10W(x4)
Park Light 12V- 3AW
Neutral lndicator 12V- 3.4W
High beam Indicator '12V- 3.4W
Turn lndicators 12V- 3.4W(x2)
N/leter Light 12V- 3.4W
HO rn
'12V- 1.sAmp

BATTERY
Rating 12V-2.5 AH
Charging Current 0.25 Amp
Charging Time '15 Hrs (Approximate)
Specific Gravity '1.240 (Fully charged)

RESISTANCE SPECIFICATIONS
Pick up Coil resistance 80 o a20% (MFIL)
SoUrce Coil resistance 230 or20% (MFIL)
lgnition Coil resistance
Primary Coil 1.6 o r 10%
.
Secondary Coil 6.6 Ko r 10%
Lighting Coil resistance 0.55 o r20%(MFIL)
Charging coil resistance 0.80 o r 10% (MFIL)
MAINTENANCE SPECIFICATIONS
CYLINDER HEAD
(Warp Limit) <0.03 mm
Lines Indicate Straight Edge l\,4easurenre.:

CYLINDER
Bore Size 58.00 - 58.02 mm in 4 Grades
Taper Limit <0.004 mm
Out of Round Limit <0.004 mm

PISTON
Piston Clearance (C) : 34-39 l\4icrons (0.034 mm - 0.039 mm,
Piston Cylinder
Red
Orange B
Green c
Pu rple D

c=A_B
SIZE (STANDARD) 57.967- 57.982 mm in 4 Grades

srzE iovERSrzE)
First Oversize
Second Oversize
58.25 mm
58.50 mm
I
A\
PISTON RINGS
SECTIONAL SKETCH

--'-----)' T
I tl
f-r-]
Top Ring Key Stone
B=1.2 mm
f=2.2 mm
2nd Ring Key Stone
B=1.2 mm
T=2.0 mm
END GAP
Top Ring 0.25-0.45 mm
2nd Ring 0.25-0.45 mm
Service Limit 0.60 mm
SIDE CLEARANCE
Top Ring 0.03-0.05 mm
2nd Ring 0.03-0.05 mm

CRANK SHAFT

;a^
,:r l1I l-<
I

Crank Width 'A' 55.9+0oshm


Runout Limit 'C' <0.02 mm
Con. Rod Big End side clearance'D 0.20-0.70 mm
Small end Free Play Limit'F <0.03-0.18 mm
A\
CLUTCH
Friction Plate Thickness/Quantit, 3.0mmx6
Service Limit <0.02 mm
Clutch Plate Thickness/Quantity '1.05-1.35 mm (x 5)
Service Limit (Warp) <0.05 mm
Clutch Spring Free Length/Quantity 34.5 mm x 4
Clutch Spring lvlinimum Length <33.2 mm
Clutch Release l\,4ethod Inner Push, Screw Push
Push Rod Bending Limit <0.15 mm
TRANSMISSION

i
Main Axle Deflection Limit 0.1 mm
(Run Out)
Drive Axle Deflection Limit 0.1 mm
(Run Out)
SHIFTER
Shifting Type Guide Bar
Guide Bar Bending Limit <0.05 mm
KICK STARTEH
TYPe Kick and Mesh Type
Kick Clip Friction Force P=1.0 Kg.
(lvl in - N4 ax) (0.8-1.2 Ks)
Air Filter Element 2T oilof Superior Grade Qualily
CARBURETTOH
TYPe vM22
lvlanufacturer I\,4IKUNI
lvlain Jet # 165
Jet Needle-Clip Position 3rd Groove From TOP
Pilot Jet # 17.5
Starter jet #20
Pilot Air Screw Setting 1.5a0.5 Turns-(Adj. at max. r.p.m. position)
Float Height 22.50+1 mm (As reference)
Engine ldling Speed 150011m pm (After running in of 1000 kms)
(On warm Engine) '700:'00 'om lupto 'u.-ing in or 1000 k.ns/
LUBRICATION
l\y'inimum Stroke 0.20-0.25 mm
l\,4aximum Stroke 1.95-2 05 mm
Pulley Adjusting Mark
Ai ldle
SE RV
INFO A
Gr
CHASSIS
STEERING SYSTEM
Steering Bearing Type BaLl Bear ng
Number of Balls/Size of Steel Balls
Upper 22 Nos (3/16')
Lower 19 Nos (1/4')
FBONT SUSPENSION
Front Fork travel 110 mm
Spring Free lenght 296.5 mm
Spring l\.4inimum Length 291.5 mm
Oil Capacity (New Fill) 17 5!3cc
Oil Capacity (For Replacement) 158a3cc
Grade Special Yamaha Oil
REAR SUSPENSION
Shock Absorber Travel 70 mm
Rear Swing Fork
Swingarm Free Play Limit
End (Skew) <2.0 mm
Side < 2.0 mm
WHEEL
Front & Rear Wheel Type Spoke Wheel
Front & Rear Rim Size/lvlaterial 1.50x18/Steel
Rim Run Out Limit
Venicai <2.0
Lateral <2.0 mm
DRIVE CHAIN
No. ol Links 110
Chain Slackness 20-30 mm
DRUM BRAKE
Type Internally Expanding, Leading &
Drum lnside Dia 130 mm
Service Limit <131 mm
Lining Thickness 5.0 mm
Service Limit <2.0 mm
BRAKE LEVER & BBAKE PEDAL
Brake Lever Free Play/ 5'B mm ( nd an l\,4arket)
At Lever Point 2.5'3 5 mm (Other N/arket)
Brake Pedal Free Play 20'30.nm
CLUTCH LEVER
Free Play/At Lever Point 2-3 mnl
Free Play At Tappel Rod r. Turn oose (Anti Clock Wise)

B-7
A\
TIGHTENING TOROUE THREAD QTY Lb"Ft. Kg.M
SIZE

ENGINE

Oll Pump lvl5 2 3.60 0.50

Drain Plug t\r12 'I '14.00 2.00

Cylinder Head t\.48 4 18.00 2.50

Cylinde r l\i11 0 4 25.00 3.50

Spark Plug t\,414 1 14.00 2.00

Intake Manifold M6 4 5.70 0.80

Primary Drive Gear M12 1 40.00 5.50

Clulch Boss t\,412 l 31.00 4.30

Clutch Spring tvl5 4 4.30 0.60

Drive Sprocket l\.416 1 40.00 5.50


-
Neutral Point l\.414 1 14.00 2.OA

Neutral Switch l\,1r 2 2.go 0.40

Cam Stopper l\,11 4 14.00 2.00

Shift Cam Stopper M6 l 10.0 1 4A


Lever

t\,16 l 7.00 1 .00

Change Shalt Adluster t\,18 22.40 3.00

Oil Seal Retainer IV]B 1.60

Flywheel lvlagneto tvl12 7.04


TIGHTENING TOROUE THREA OTY Lb.Ft. Kg.M
slzE
CHASSIS

Front Axle Shaft t\,110 1 31.00 4.30

Crown Handle-lnner Tube t\,18 2 1 1.00 1.50

Crown Handle-Steering l\41 0 1 29.00 4.00


Shaft

Handle crown-Handle M8 4 13.00 '1


.90
Holder

Under Bracket-lnner Tube tvt10 2 22.00 3.00

Pivot Shaft M12 '1


43.00 6.00
Tension Bar l\,18 2 13.00 1 .90
Sprocket Bear M8 4 18.00 2.60
Camshaft Lever M6 2 6.50 0.90
Flear Axie Shaft l\i]14 1 66.00 9.20
Sprocket Shaft Nut t\,120 '1
66.00 9.20
Shock Absorber l\41 0 2 29.00 4.00
Front Engine Mtg. Bolt t!18 1 22.OO 3.00
Rear Upper Engine Niltg. M10 1 43.00 6.00
Bolt

Rear Lower Engine Mtg. t\41 0 1 43.00 6.00


Bolt

Foolrest Frame [,48 4 17.00 2.30


Cap Bolt Front Fork l\i]25 2 '1
7.00 2.30
j 't
I

'6

I'

ESGORTS YAMAHA MOTOR LIMITED


19/6, Mathura Road,
Faridabad 121 006 (lNDlA)

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