2010/2011

MANUAL OF
MAINTENANCE

SZ16
SZ16X
SZ16R

54B-F8197-S0
 SZ16 / SZ16X 2010
SZ16R 2011
MAINTENANCE MANUAL © 2010 by INDIA
YAMAHA MOTOR PVT. LTD.
First edition, August 2010 All rights
reserved. Any reproduction or unauthorized use

without the written permission of Yamaha LTD.

it is expressly prohibited.
EAS20071

IMPORTANT
This Manual was produced by INDIA YAMAHA MOTOR PVT. LTD. primarily to be used by dealerships and their qualified
mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone using this
book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of the mechanics and
techniques for repairing these types of vehicles. Repair and maintenance work performed by someone without this
knowledge may leave the vehicle in an unsafe condition and unsuitable for use.

INDIA YAMAHA MOTOR PVT. continually strives to improve all of its models. Modifications and significant changes to
specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of
this manual when
apply.
TIP_________________________________________________________________________________________
Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT INFORMATION ABOUT THE MANUAL

Particularly important information is distinguished in this manual by the following
conventions.
This is the safety alert symbol. Used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided,

WARNING
could result in death or serious injury.

ATTENTION denotes special precautions that must be taken to avoid damage to

ATTENTION
the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EAS20091

HOW TO USE THIS MANUAL

This manual is designed as a practical, easy-to-read reference book for the mechanic. Complete explanations of all
installation, disassembly, removal, assembly, repair, and verification procedures are explained with individual steps in
sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title "1" is displayed at
the top of each page.
• The titles of subsection "2" appear in smaller type than the title of the section.
• To help identify parts and clarify procedural steps, there are "3" exploded diagrams at the beginning of each
disassembly section.
• The Numbers "4" are given in the order of the tasks on the itemized diagram. A number indicates a clearing step.

• Symbols "5" indicate parts to be lubricated or to be replaced. See "SYMBOLS".

• A table of work instructions "6" accompanies the broken down diagram, showing the order of the tasks, names of the
parts, notes on the tasks, and so on.
• The "7" jobs that require more information (such as special tools and technical data) are described sequentially.

3
7

5
4

2
6
SYMBOLS
The following symbols are used in this manual for ease of understanding.
TIP __________________________________________________________________________________
The following symbols are not relevant for all vehicles.

SYMBOL DEFINITION SYMBOL DEFINITION

Repairable with the engine mounted Gear oil

G

Liquid to fill Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool B Bearing grease

Torque LS Lithium soap-based grease

Wear limit, tolerance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply the blocking agent

LT
(LOCTITE®).

Motor oil New Replace the part with a new

AND one.
 TABLE OF CONTENTS
EAS20110

GENERAL INFORMATION

SPECIFICATIONS

CHECKS AND ADJUSTMENTS

NEWSPAPERS

CHASSIS

MOTOR

FUEL SYSTEM

ELECTRIC SYSTEM

PROBLEM RESOLUTION
 GENERAL INFORMATION

ID................................................. .................................................. .............1-1

VEHICLE IDENTIFICATION NUMBER............................................. .......... 1-1 ENGINE SERIAL SERIAL
NUMBER .............................. ............................ 1-1

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

PREPARATION FOR DISASSEMBLY AND DISASSEMBLY ........................................... 1 -2 SPARE
PARTS ............................................... ....................... ........................... ....... 1-2 GASKETS, SEALINGS AND
O-RINGS ................................. ............................... 1-2 LOCK WASHERS / LOCK NUTS AND
PINS ......... .......... 1-2 BEARINGS AND OIL SEALS ................................ .................................... 1-3 LOCK
RINGS ........ .................................................. ....................................... 1-3

REVIEW OF CONNECTIONS .............................................. .......................................1-4

SPECIAL TOOLS................................................ .........................................1-5

EAS20130

ID
EAS20140

VEHICLE IDENTIFICATION NUMBER

Vehicle identification number "1" is stamped on the
main steering tube.

EAS20160

ENGINE SERIAL NUMBER

The engine serial number "1" is stamped on the left side
of the crankcase.
TIP _________________________________________
Designs and specifications are subject to change
without notice.

1
EAS20180

IMPORTANT INFORMATION
EAS20190

PREPARATION FOR DISASSEMBLY AND

DISASSEMBLY
1. Before disassembling and disassembling,
remove all dirt, mud, dust, and foreign
materials.

EAS20210

GASKETS, SEALINGS AND O-RINGS

1. When assembling the motor, replace all the
gaskets, oil seals and O-rings. All gasket surfaces,
seal edges and oil gaskets and O-rings must be
cleaned.

2. During assembly, put the specified oil on all parts

and bearings, and carefully lubricate the edges
2. Use only proper cleaning tools and equipment.
of the oil seals with grease.
See "SPECIAL TOOLS" on page 1-5.

3. When disassembling, keep the parts that go together

or are the same together. This includes gears,
cylinders, pistons, and other parts that work
"clustered" from normal use. Grouped parts should
always be reused or replaced together.

1. Oil
2. Edge
3. Spring
4. Fat

EAS20220

SAFETY WASHERS
/ LOCK NUTS AND PINS / KEYS
4. During disassembly, clean all parts and place on trays After disassembly, replace all washers / locknuts and
in order of disassembly. This will speed up assembly pins. After the bolt or nut has been tightened to the
and allow proper installation of all parts. specified torque, bend the side edges against the side
of the bolt or nut.

5. Keep all parts away from any source of fire.

EAS20200

SPARE PARTS
Use only genuine Yamaha parts for all shifting. Use the
oil and grease recommended by Yamaha for all
maintenance services.
lubrication. Other brands may be similar in function
and appearance, but of inferior quality.
EAS20230

BEARINGS AND OIL SEALS

Install bearings "1" and oil seals "2" so that the
manufacturer's mark or numbers are visible. When
installing the oil seals, lubricate the edges of the oil
seals with a thin layer of lithium soap-based grease.
Apply oil to the bearings, if needed.

ECA13300

ATTENTION
Do not rotate the bearing with compressed air
as this will damage the bearing surface.

EAS20240

SEAL RINGS
Before assembling, carefully check all seal rings and
replace any that are damaged or bent. Always replace
the piston seal rings after one use. When installing a
lock ring “1”, make sure the sharp corners “2” are
positioned opposite “3” to the thrust the ring receives.
EAS20250

VERIFICATION OF CONNECTIONS Multimeter

Check the cables, couplings and connectors for stains,
oxidation, moisture, etc.
1. Disconnect: TIP __________________________________________
• Cable • If there is no continuity, clean the terminals.
• Coupling • When checking the wire harness, perform
• Connector steps (1) through (3).
2. Check: • As a quick fix, use a contact cleaner, available at
• Cable most auto parts stores.
• Coupling
• Connector
Moisture → Blow dry. Rust / stains → Connect
and disconnect several times.

3. Check:
• All connections
Loose connection → Connect properly.
TIP
If pin "1" of the terminal is crushed, bend it up.

4. Connect:
• Cable
• Coupling
• Connector
TIP ________________________________________
Make sure all connections are tight.

5. Check:
• Continuity
(with the multimeter)
 SPECIAL TOOLS

EAS20260

SPECIAL TOOLS
The following special tools are required for precise setups and adjustments. Use only the appropriate special tools; This
will help you avoid damage caused by the use of improvised tools or improvised techniques. Special tools, part number,
or both may vary depending on the country. When placing an order, refer to the list provided below

to avoid any mistake.

Pages of
Tool Name / No. Illustration
Tool reference

Multimeter 1-4, 5-38, 6-8,

7-45, 7-46,
7-47, 7-49,
7-50, 7-51,
This tool is used to check the electrical 7-52, 7-53,
system. 7-54
Thickness Gauge (Caliper) 3-3, 3-4
YSST-815

This tool is used to adjust the play

of the valves in an engine.

Tappet Screw Holder YSST-706 3-4

This tool is used to adjust valve lash.

YSST-806A hub adjustment 3-4

wrench

This tool is used to adjust valve lash.

YSST-625 Center Plug 3-7

Wrench

This tool is used to remove / install the crankshaft /

timing mark screw end access screw and

access the generator cover.

Stroboscopic lamp 3-7

This tool is used to check the ignition

timing (timing).

Compression gauge 3-8

This tool is used to measure engine

compression.
 SPECIAL TOOLS

Pages of
Tool Name / No. Illustration
reference
Tool
Steering nut wrench YSST-721 3-17, 4-43

This tool is used to tighten and loosen the steering

ring nut.

Retainer Installation Tool 90890-01052 4-19, 4-20

This tool is used to install the retainer

T key 4-34, 4-36

YSST-813
This tool is used to hold the 14mm socket
wrench / hex nut to the
disassemble or install the bar of
cushioning.
TFF Oil Packing Installation Tool 4-36, 4-37

YSST-875
These tools are used to install the oil seal and
dust seal for the front fork legs.

Gasket and Bushing Installer Accessory 4-36

front fork (ø33)
90890-01368
This tool is used to install the oil gasket and outer
tube bushing on the front fork.

Gasket and Bushing Installer Accessory 4-37

front fork (ø41)
90890-01381
This tool is used to install the oil gasket and outer
tube bushing on the front fork.

YSST-603 Valve Spring Compressor 5-18, 5-22

This tool is used to remove and install the valve

and valve spring.

YSST-803A Valve Spring Compressor Accessory 5-18, 5-22

This tool is used to remove and install the valve

and valve spring.

1-6
 SPECIAL TOOLS

Pages of
Tool Name / No. Illustration
reference
Tool
YSST-601B Universal Generator Holder 5-33, 5-34

This tool is used to hold the rotor of the

generator.

Magneto Extractor 5-33

YSST-628

This tool is used to remove the rotor from the

generator with the help of the generator holder.

Yamaha bond No.1215 5-35, 5-65

TG-1215

This adhesive is used to seal two mating

surfaces (eg crankcase elements).

Clutch holder 5-43, 5-45

YSST-733

This tool is used to hold the clutch hub while

removing or installing the clutch hub nut.

YSST-265 Crankshaft Removal Tool 5-67

This tool is used to remove the crankshaft

from the crankcase.

Crankshaft Installation Tool with Spacer 5-67

YSST-266
YSST-267
These tools are used to install the crankshaft.

Pressure / Vacuum Pump Calibrator 6-14

Assembly

This instrument is used to vacuum the air

induction system for your Spark Tester
7-52

This tool is used to check the ignition

timing (timing).

1-7
 SPECIFICATIONS
GENERAL SPECIFICATIONS................................................ .............................2-1

ENGINE SPECIFICATIONS ............................................... ..............................2-2

CHASSIS SPECIFICATIONS ............................................... ..............................2-9

2
ELECTRIC SPECIFICATIONS................................................ .......................2-12

TORQUE ............................................... .................................................. ......2-15

GENERAL TIGHTENING TORQUE SPECIFICATIONS .............................. 2-15 ENGINE TIGHTENING
TORQUE ...... .................................................. ................... 2-16 CHASSIS TIGHTENING
TORQUES ....................... ............................................... 2-20

LUBRICATION POINTS AND TYPES OF LUBRICANTS .......................................2-22

MOTOR................................................. .................................................. ............... 2-22
CHASSIS ............................... .................................................. ................................. 2-24

LUBRICATION SYSTEM TABLES AND DIAGRAMS ....................................2-25

LUBRICATION CHART WITH ENGINE OIL ......................................... 2- 25 LUBRICATION
DIAGRAMS .............................................. ............................ 2-27

CABLE GUIDANCE .............................................. ............................................2-29

EAS20280

GENERAL SPECIFICATIONS

Model
Model
SZ16 54B2
SZ16X 54B1
SZ16R 54B3

Dimensions
Overall length 2050 mm (80.7 in.) 730 mm
Overall width (28.7 in.) SZ16 1040 mm
Overall height (40.9 in.) SZ16X 1100 mm
(43.3 in.) 802 mm (31.6 in.)
Seat height
Distance between axis 1320 mm (52.0 in) 165
Ground clearance mm (6.50 in) 2340 mm
Minimum turning radius (92.1 in)

Weight
With gasoline and oil 132 kg (291 lb)
Maximum load 186 kg (410 lb)
EAS20290

ENGINE SPECIFICATIONS

Motor
Type of motor Air-cooled, four-stroke, SOHC

Displacement 153 cm³

Cylinder arrangement Single cylinder
Bore x stroke 58.0 x 57.9 mm (2.28 x 2.28 in)
Compression ratio 9.50: 1
Standard compression pressure (at sea level) Minimum- 1200 kPa (12.0 kgf / cm², 170.7 psi) 1040-1340
maximum kPa (10.4-13.4 kgf / cm², 147.89 -
190.59 psi)
Start System SZ16 Kick
SZ16X Electric ignition

Fuel
Recommended fuel Regular unleaded gasoline only
Tank capacity 13.8 (3.65 US gal, 3.04 Imp.gal)
Fuel Reserve 1.9 L (0.50 US gal, 0.42 Imp.gal)

Motor oil
Recommended brand YAMALUBE
Lubrication system Wet sump
Guy SAE 20W40 or SAE 20W50
Recommended oil API service type, SE, SF, SG or higher, JASO
standard MA
Oil quantity
Total quantity 1.20 L (1.27 US qt, 1.06 Imp.qt)
Periodic oil change with filter 1.10 L (1.16 US qt, 0.97 Imp.qt)
Periodic oil change without oil filter 1.00 L (1.06 US qt, 0.88 Imp.qt)

Oil filter
Oil Filter Type Paper

Oil pump
Oil pump type Trochoid
Inner rotor clearance to outer rotor tip Limit Less than 0.150 mm (0.0059 in)
0.23 mm (0.0091 in)
Outer Rotor Clearance to Oil Pump Housing 0.13–0.19 mm (0.0051–0.0075 in)
Limit 0.26 mm (0.0102 in)
Rotor oil pump housing clearance
internal and external 0.05–0.11mm (0.0020–0.0043 in)
Limit 0.18 mm (0.0071 in)

Plugs)
Manufacturer / model NGK / CPR8EA-9
Electrode gap 0.8–0.9 mm (0.031-0.035 in)

Butt
Volume 13.40–14.00 cm³ (0.82–0.85 cu. In.)
 Maximum deformation 0.03 mm (0.0012 in)

Camshaft
Traction system Chain drive (left)
Camshaft Lobe Dimensions
Admission A 30.877-30.977 mm (1.2156-1.2196 in)
Limit 30.847 mm (1.2144 in)
Admission B 25.052–25.152 mm (0.9863–0.9902 in)
Limit 25.022 mm (0.9851 in)
Escape A 30.878–30978 mm (1.2157–1.2196 in)
Limit 30.848 mm (1.2145 in)
Exhaust B 25.030–25.130 mm (0.9854–0.9894 in)
Limit 25,000 mm (0.9843 in)

TO

Camshaft deflection limit 0.030 mm (0.0012 in)

Distribution chain
Tensioning System Automatic

Rocker / rocker
Stick Inner Diameter Limit 9.985–10,000 mm (0.3931–0.3937 in)
10,030 mm (0.3949 in)
Rocker shaft outer diameter Limit 9.966–9.976 mm (0.3924–0.3928 in)
9.950 mm (0.3917 in)
Distance from rocker arm to rocker arm 0.009–0.034 mm (0.004–0.0013 in)
shaft Limit 0.080 mm (0.0031 in)

Valves, valve seats, valve guide

Valve clearance (cold) Intake
0.08–0.12 mm (0.0032–0.0047 in)
Escape 0.12–0.16 mm (0.0047–0.0063 in)
Valve dimensions
Valve head diameter (intake) 27.90–28.10 mm (1.0984–1.1063 in)
 Valve head diameter (exhaust) 23.40–23.60 mm (0.9213-0.9291 in)

TO
Valve face width (intake) 1.538–2.138 mm (0.0606–0.0842 in)
Valve face width (exhaust) 1.538–2.138 mm (0.0606–0.0842 in)

Valve seat width (intake) Valve seat width 0.90–1.10 mm (0.0354–0.0433 in)
(exhaust) 0.90–1.10 mm (0.0354–0.0433 in)

Valve margin thickness (intake) Valve margin 0.50–0.90 mm (0.0197–0.0354 in)

thickness (exhaust) 0.50–0.90 mm (0.0197–0.0354 in)

Valve stem diameter (intake) Limit 4.975–4.990 mm (0.1959–0.1965 in)

4,950 mm (0.1949 in)
Valve stem diameter (exhaust) Limit 4.960–4.975 mm (0.1953–0.1959 in)
4.935 mm (0.1943 in)
Valve Guide Inner Diameter (Intake) Limit 5,000–5.012 mm (0.1969–0.1973 in)
5.050 mm (0.1988 in)
Valve Guide Inner Diameter (Exhaust) Limit 5,000–5.012 mm (0.1969–0.1973 in)
5.050 mm (0.1988 in)
Tolerance between valve stem and guide (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Tolerance between valve stem and guide (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem deflection 0.010 mm (0.0004 in)

Valve Spring
Free length (intake) 39.10 mm (1.54 in)
Limit 37.10 mm (1.46 in)
Free length (exhaust) 39.10 mm (1.54 in)
Limit 37.10 mm (1.46 in)
Installed length (intake) 34.50 mm (1.36 in)
Installed length (exhaust) 34.50 mm (1.36 in)
 Spring constant of spring K1 (intake) 37.05 N / mm (3.78 kgf / mm, 211.56 lb / in)
Constant of elasticity of spring K2 (intake) Constant of 48.22 N / mm (4.92 kgf / mm, 275.34 lb / in)
elasticity of spring K2 (intake) 37.05 N / mm (3.78 kgf / mm, 211.56 lb / in)
Spring constant of elasticity K2 (exhaust) 48.22 N / mm (4.92 kgf / mm, 275.34 lb / in)
Installed spring compression force (intake) 147.90–196.10 N (15.08–20.00 kgf, 33.25–
- 44.08 lbf)
Installed spring compression force (exhaust) 147.90–196.10 N (15.08–20.00 kgf, 33.25–
44.08 lbf)
Spring pitch (intake) spring pitch 2.5 ° / 1.7 mm (2.5 ° / 0.07 in)
(exhaust) 2.5 ° / 1.7 mm (2.5 ° / 0.07 in)

Threading Direction (intake) Clockwise

Threading Direction (exhaust) Clockwise

Cylinder
Diameter 58,000–58,010 mm (2.2835–2.2839 in)
Taper limit 0.05 mm (0.0020 in)
Oval limit 0.05 mm (0.0020 in)

Piston
Clearance between piston and cylinder 0.015–0.040 mm (0.0006–0.0016 in)
Limit 0.15 mm (0.0059 in)
Diameter D 57.970–57.985 mm (2.2823–2.2829 in)
Height H 5.0 mm (0.20 in)

H
D

Deviation 0.25 mm (0.0098 in)

Direction of deviation Intake side
Pin Outside Diameter Limit 15.002–15.013 mm (0.5906–0.5911 in)
15.043 mm (0.5922 in)
Piston pin outer diameter Limit 14.995–15,000 mm (0.5904–0.5906 in)
14.975 mm (0.5896 in)
Clearance between pin and pin ID 0.002–0.018 mm (0.00008–0.00071 in)
Limit 0.068 mm (0.00268 in)

Piston ring
Top ring
Ring Type Crammed
 Dimensions (B × C) 0.80 × 2.30 mm (0.03 × 0.09 in)

B
T

Distance between ends (assembled) 0.10–0.25 mm (0.0039–0.0098 in)

Limit 0.40 mm (0.0157 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.100 mm (0.0039 in)
Second ring
Ring type Conical
Dimensions (B × T) 0.80 × 2.40 mm (0.03 × 0.09 in)

Distance between ends (assembled) 0.10–0.25 mm (0.0039–0.0098 in)

Limit 0.40 mm (0.0157 in)
Ring side clearance Limit 0.020–0.055 mm (0.0008–0.0022 in)
0.100 mm (0.0039 in)
Grease Ring
Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in)

Distance between ends (assembled) 0.20–0.70 mm (0.0079–0.0276 in)

Crankshaft
Width A 47.95–48.00 mm (1.888–1.890 in)
Wear limit C 0.030 mm (0.0012 in)
Crankpin side clearance D 0.110–0.410 mm (0.0043–0.0161 in)

C C

TO

Balancer
Balancer transmission method Pinion

Clutch
Clutch Type, Multiple discs, oil bathed Inner thrust,
Clutch release method Clutch lever play cam driven
10.0–15.0 mm (0.39–0.59 in)
Friction disc thickness 1 Wear 2.90–3.10 mm (0.114–0.122 in)
limit 2.80 mm (0.1102 in)
 Disc quantity 2 pcs
Friction disc thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1102 in) 2
Disc quantity pcs
Friction disc thickness Number of 1.85–2.15 mm (0.073–0.085 in) 3
discs pcs
Maximum deformation 0.20 mm (0.0079 in)
Free length of clutch springs Limit 41.60 mm (1.64 in)
40.60 mm (1.60 in) 4
Number of springs pcs
Maximum push rod deflection 0.500 mm (0.0197 in)

Transmission
Transmission type 5-speed constant gear 75/22 (3.409)
Primary reduction ratio Final drive
Chain
Secondary reduction ratio 42/14 (3,000)
Operation Left foot operation
List of changes
1st 38/14 (2,714)
2nd 34/19 (1,789)
3rd 29/22 (1,318)
4th 23/22 (1,045)
5th 22/24 (0.917)
Main shaft wear limit 0.05mm (0.0020 in)
Drive shaft wear limit 0.05mm (0.0020 in)

Mechanism of Change
Shift mechanism type Shift drum and guide bar
Shift fork guide bar deflection limit 0.030 mm (0.0012 in) Rotor thickness 4.76–4.89 mm (0.1874–0.1925 in)

Kick Start (SZ16)

Kick start type Ratchet

Air filter
Air filter element Dry Element

Carburetor
Identification Mark 54B1 00
Type x quantity BS26 × 1
Main jet Main air jet Jet needle # 120
0.9
4ELG13
Jet needle O-3M
Pilot departure 0.8
Pilot Jet Pilot Screw Exits Valve Seat # 17.5
Size Starter Jet 1 Starter Jet 2 2–1 / 4
Throttle Valve Size Float Height 1.8
# 22.5
0.8
110
*. * mm (*. ** in)
 Fuel level A (using a level gauge)
6.5mm (0.29 in)

Throttle position sensor

Output voltage (idle) 0.63–0.73 V
Resistance 3.0–7.0 kΩ

Idle condition
Engine idle speed 1300–1500 r / min
CO% 2.0–6.0%
Admission gap 31.3–36.7 kPa (235–276 mmHg, 9.3–10.9 inHg)
Oil temperature 75.0–85.0 ° C (167.00–185.00 ° F)
Throttle cable play 3.0–7.0 mm (0.12–0.28 in)
EAS20300

CHASSIS SPECIFICATIONS

Chassis
Frame Type Diamond
Angle 26.00 °
Career 99.0 mm (3.90 in)

Front wheel
Wheel Type Casting Wheel
Rim size 17 × 1.60
Rim material Aluminum
Wheel stroke 135.0 mm (5.3 in)
Wheel radial deviation limit Wheel lateral 1.0 mm (0.04 in)
deviation limit 0.5 mm (0.02 in)

Rear wheel
Wheel Type Casting Wheel
Rim size 17 × 2.15
Rim material Aluminum
Wheel stroke 120.0 mm (4.72 in)
Wheel radial runout limit 1.0 mm (0.04 in)
Wheel lateral deviation limit 0.5 mm (0.02 in)

Front rim
Guy With tire
Size 2.75 / -17–17 41P 4PR
Manufacturer / model TVS / ATT525
Wear limit (front) 1.0 mm (0.04 in)

Back tire
Guy With tire
Size 100 / 90–17 55P
Manufacturer / model TVS / ATT750
Wear limit (rear) 1.0 mm (0.04 in)

Tire air pressure (measured on cold tires):

Lead 200 kPa (2.00 kgf / cm²28 psi)
Rear 225 kPa (2.25 kgf / cm²33 psi)

Front brake
Guy Drum brake
Operation Right hand operation
Throttle handle play 10.0–15.0 mm (0.39–0.59 in)

Front drum brake (SZ16 / SZ16X)

Drum brake type SZ16 / SZ16X Advance, travel SZ16 /
Brake drum inner diameter SZ16X 150.0 mm (5.91 in) SZ16 /
Limit SZ16X 151.0 mm (5.94 in) SZ16 /
Coating thickness Limit SZ16X 4.0 mm (0.16 in) SZ16 / SZ16X
2.0 mm (0.08 in)
Shoe Spring Free Length (Brake Camshaft Side)
SZ16 / SZ16X 63.0 mm (2.48 in)
Shoe Spring Free Length 2 (Pivot Pin Side)
SZ16 / SZ16X 57.0 mm (2.24 in)
 Front disc brake (SZ16R) Disc outer
diameter x thickness Brake disc 245.0 × 4.0 mm (9.65 × 0.16 in)
thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Shoe coating thickness (internal) Limit 4.55 mm (0.1791 in)
0.6 mm (0.02 in)
Shoe coating thickness (external) Limit 4.55 mm (0.1791 in)
0.6 mm (0.02 in)
Master cylinder inner diameter 12.0 mm (0.47 in)
Brake caliper cylinder bore 28.00 mm × 2 (1.10 in × 2)
Recommended liquid DOT 3 - 4

Back brake
Guy Disc pheno
Operation Right foot operation
Brake pedal position 25.0 mm (0.98 in)
Brake pedal play Rear drum 20.0–30.0mm (0.79–1.18 in)
brake
Brake drum type Advance, tour
Brake Drum Inner Diameter Limit 130.0 mm (5.12 in)
131.0 mm (5.16 in)
Coating thickness 4.0 mm (0.16 in)
Limit 2.0 mm (0.08 in)
Shoe Spring Free Length (Brake Camshaft Side)
52.0 mm (2.05 in)
Shoe Spring Free Length 2 (Side of
pivot pin) 48.0 mm (1.89 in)

Address
Steering bearing type Angle to stop Ball bearing
(left) 42.0 °
Angle to stop (right) 42.0 °
No./size of steel spheres
(Higher) 19 pcs
(Lower) 16 pcs

Front suspension
Guy Telescopic fork
Shock / Spring Type Front Fork Travel Oil Damper / Coil Spring
135.0 mm (5.31 in)
Front fork length Limit 460.6 mm (18.13 in)
451.4 mm (17.77 in)
Installed Length 455.6 mm (17.94 in)
Spring tension K1 Spring 4.65 N / mm (0.47 kgf / mm, 26.55 lb / in)
stroke K1 0.0–135.0 mm (0.00–5.31 in)
Inner tube outer diameter Spring 33.0 mm (1.30 in)
Optional available No
Recommended oil 10W fork oil or equivalent
Quantity 203.0 cm³ (6.86 US oz, 7.16 Imp.oz)
Level 128.0 mm (5.04 in)

Rear suspension
Guy Swingarm
Shock Absorber / Spring Type Helical Spring / Oil Damper
Rear shock absorber assembly travel 100.0 mm (3.94 in)
 Spring Free Length 276.0 mm (10.87 in)
Installed Length 259.0 mm (10.20 in)
Spring tension K1 Spring 16.60 N / mm (1.69 kgf / mm, 94.79 lb / in)
tension K2 Spring stroke 21.00 N / mm (2.14 kgf / mm, 119.91 lb / in)
K1 0.0–42.5 mm (0.00–1.67 in)
Spring stroke K2 Optional 42.5–100.0 mm (1.67–3.94 in) No
spring available

Chain of Transmission
Type / Manufacturer 428H / LGB
Number of links 126
Drive chain slack Limit length at 15 links 40.0–50.0 mm (1.57–1.97 in)
194.3 mm (7.65 in)
EAS20310

ELECTRIC SPECIFICATIONS

Voltage
System voltage 12V

Ignition system
Ignition system DC CDI
Type of advance Digital
Ignition advance (BTDC) 7.0 ° / 1400 r / min

DC. CDI
Crankshaft position sensor resistance 248–372Ω at 20 ° C (68 ° F)
CDI Unit Manufacturer / Model SZ16 / SZ16X 54B-0 / YAMAHA
SZ16R 54B-1 / YAMAHA

Ignition coil
Minimum distance between spark plug electrodes 6.0 mm (0.24 in)
Primary coil resistance Secondary coil 0.32-0.48 Ω at 20 ° C (68 ° F)
resistance 5.68-8.52 kΩ at 20 ° C (68 ° F)

Spark plug cap

Material Resin
Resistance 3.7–6.2 kΩ (3.7–6.2 KΩ) at 20 ° C

Magneto AC
Standard outlet 14.0 V, 135 W at 5000 r / min
Coil Resistance 0.336-0.504 Ω at 20 ° C (68 ° F)

Rectifier / regulator
Regulator Type Semiconductor-Closed Circuit
Regulated voltage (DC) 14.0-15.0 V
Rectifier capacity (DC) 14.0 A

Battery
Model SZ16 AB2.5L-C-4 / MLX- 2.5LC
SZ16X / SZ16R AB5L-B / MLX-5LE
Voltage, capacity SZ16 12V, 2.5 Ah
SZ16X / SZ16R 12 V, 5.0 Ah
Specific gravity SZ16 1,280 at 20 ° C (68 ° F) (MLX-2.5LC) SZ16
1,230 at 27 ° C (80.6 ° F) (AB2.5L-C-4) SZ16X /
SZ16R 1,280 at 20 ° C (68 ° F) (MLX5LE)

SZ16X / SZ16R 1,280 to 27 ° C (80.6 ° F)

(AB5L-B)
Maker AMCO BATTERIES LIMITED
MINDA
10 hour amperage rate SZ16 0.25 A
SZ16X / SZ16R 0.50 A

Streetlight

Bulb type Halogen

Bulb voltage, wattage and quantity
Streetlight 12V, 35W / 35W x 1 12V,
Rear / brake light 5.0W / 21.0W × 1 12V,
Directional front 10.0W x 2
Directional rear 12V, 10.0W x 2
Meter light (dash) 12V, 1.7W × 2

Indicator light
Neutral indicator light 12V, 1.7W x 1
Directional indicator light 12V, 1.7W x 1
High beam indicator light 12V, 1.7W x 1
Engine trouble indicator light 12V, 1.7W × 1

Electric ignition system

Type of system SZ16X / SZ16R Constant Gear

Starting motor
Output power SZ16X / SZ16R 0.28 kW
Coil resistance SZ16X / SZ16R 0.0279–0.0341 Ω
Brushes total length Limit SZ16X / SZ16R 7.0 mm (0.28 in)
SZ16X / SZ16R 3.50 mm (0.14 in)
Brushes spring force SZ16X / SZ16R 3.92–5.88 N (400–600 gf, 14.11–21,
17 oz)
Switch diameter Limit SZ16X / SZ16R 17.6 mm (0.69 in)
SZ16X / SZ16R 16.6 mm (0.65 in)
Mica notch (depth) SZ16X / SZ16R 1.35 mm (0.05 in)

Starter relay
Amperage SZ16X / SZ16R 100.0 A
Coil resistance SZ16X / SZ16R 3.42–4.18 Ω at 20 ° C (68 ° F)

Horn
Horn type Flat (ordinary)
Quantity 1 pc
Maximum amperage 2.5 A
Coil Resistance 1.35–1.75 Ω
Performance 108-114 dB / 2 m

Directional light relay

Relay Type Transistorized
Integrated, self-canceling device Frequency of Do not

flashing 70–100 cycles / min

Wattage 10W × 2 + 3.4W

Fuel Meter (Sender) Unit

Meter unit resistance (full) Meter unit resistance 4.0–10.0 Ω
(empty) 90.0–100.0 Ω

Starter circuit cut-off relay

Coil resistance SZ16X / SZ16R 90.0-110.0 Ω
Fuse
Fuse 15.0 A
Spare fuse 15.0 A
 TIGHTENING TORQUES (TORQUES)

EAS20320

TIGHTENING TORQUE (TORQUES)

EAS20330

GENERAL SPECIFICATIONS OF TIGHTENING

TORQUE
This table specifies the tightening torques for standard
ISO threaded fasteners.
standardized. Torque specifications for special
components or assemblies are mentioned in each
chapter of this manual. To avoid deformation, cross-
tighten the assemblies with several fixing points, in
progressive phases, until the specified torque is reached.
Unless otherwise specified, the tightening torques
require a clean, dry thread. The components, meanwhile,
must be at room temperature.

A. Distance between faces

B. Outside diameter of the thread

Specifications
TO B generals of the pair
(nut) (cap screw) squeeze in

Nm m kg ft lb

10 mm 6 mm 6 0.6 4.3
12 mm 8 mm fifteen 1.5 eleven

14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
 TIGHTENING TORQUES (TORQUES)

EAS20340

ENGINE TIGHTENING TORQUES

Size
Item of the Qty Torque Comments
thread .
Cylinder Head Bolt M8 4 22 Nm (2.2 m kg, 16 ft lb)
M

Cylinder Head Bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb) AND

Spark plug M10 1 13 Nm (1.3 m kg, 9.4 ft lb)

Cylinder head cover bolt M6 5 10 Nm (1.0 m kg, 7.2 ft lb) LT

Camshaft output sprocket cover bolt M6 3 10 Nm (1.0 mkg, 7.2 ftlb) LT

Breather plate screw M5 4 4 Nm (0.4 mkg, 2.9 ftlb) LT

Air duct screw M6 2 8 Nm (0.8 mkg, 5.8 ftlb)

Oil check screw M6 1 7 Nm (0.7 m kg, 5.1 ft lb)

Balancer Driven Gear Nut M10 1 45 Nm (4.5 m kg, 32 ft lb)

Valve adjusting screw locknut M6 2 14 Nm (1.4 mkg, 10 ftlb)

Camshaft gear bolt M8 1 20 Nm (2.0 mkg, 14 ftlb)

Timing chain guide bolt M6 1 8 Nm (0.8 mkg, 5.8 ftlb)

Yamaha bond
Chain tensioner bolt M6 2 11 Nm (1.1 m kg, 8.0 ft lb) 9 No.1215
Timing chain cover bolt M6 2 Nm (0.9 m kg, 6.5 ft lb) LT

Camshaft retainer bolt M5 2 8 Nm (0.8 mkg, 5.8 ftlb) 4

Water pump assembly screw M5 2 Nm (0.4 mkg, 2.9 ftlb)

Engine oil drain bolt M12 1 20 Nm (2.0 mkg, 14 ftlb)

Oil filter cover screw Oil baffle plate M6 3 10 Nm (1.0 m kg, 7.2 ft lb)
screw M6 2 10 Nm (1.0 m kg, 7.2 ft lb) L

Intake manifold bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

Carburetor union clamp bolt M4 1 2 Nm (0.2 mkg, 1.4 ftlb)

Intake Manifold Union Bracket M4 1 2 Nm (0.2 mkg, 1.4 ftlb)

Screw
Air filter housing union clamp screw
M4 1 2 Nm (0.2 m kg, 1.4 ft lb)
Air filter housing assembly screw M6 3 10 Nm (1.0 m kg, 7.2 lb)

Air induction system tube M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

Air shutoff valve assembly screw M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

Exhaust pipe nut Muffler M8 2 15 Nm (1.5 m kg, 11 ft lb)

bolt M8 1 20 Nm (2.0 m kg, 14 ft lb)

Muffler End Cap Screw M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

Muffler Guard Screw M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

Crankcase bolt M6 eleven 10 Nm (1.0 mkg, 7.2 ftlb)

M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

Crankcase bolt I: 55 mm

Clutch cable bracket screw M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

2-16
 TIGHTENING TORQUES (TORQUES)

Size
Item Qty. Torque Comments
of the
thread
Generator cover screw M6 8 10 Nm (1.0 mkg, 7.2 ftlb)

Drive pinion cover M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Clutch cover bolt M6 eleven 10 Nm (1.0 mkg, 7.2 ftlb)

Kick Start Lever Nut (SZ16) M12 1 50 Nm (5.0 mkg, 36 ftlb)

Sprocket Gear Guide Screw M6 2 12 Nm (1.2 mkg, 8.7ftlb)

Weight screw (SZ16) M6 3 14 Nm (1.4 mkg, 14 ftlb)

Choke clutch bolt (SZ16X / SZ16R)

M6 3 14 Nm (1.4 mkg, 14 ftlb) Stake.

Primary Drive Pinion Nut M12 1 60 Nm (6.0 mkg, 43 ftlb)

Pressure disc screw M6 4 8 Nm (8.0 mkg, 5.8 ftlb)

Clutch Push Rod Lock Nut M6 1 8 Nm (8.0 mkg, 5.8 ftlb)

Clutch hub nut M14 1 70 Nm (7.0 mkg, 50 ftlb)

Bearing retainer screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Stopper lever cap M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

Shift drum segment bolt M6 1 12 Nm (1.2 mkg, 8.7 ftlb)

Stator coil screw M6 3 10 Nm (1.0 mkg, 7.2 ftlb)

Crankshaft position sensor bolt M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

Generator rotor nut M12 1 70 Nm (7.0 mkg, 50 ftlb)

Neutral switch M10 1 17 Nm (1.7 mkg, 12 ftlb)

Starter motor bolt (SZ16X /

SZ16R) M6 2 10 Nm (1.0 mkg, 7.2 ftlb)

Negative battery terminal M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

2-17
 TIGHTENING TORQUES (TORQUES)

Cylinder Head Tightening Sequence

1 3
5

4 2

Generator cap tightening sequence:

1.6
7

5 8

4
9

3.11
2.10

Clutch cover tightening sequence:

6
1.7 8

5 9

4
10
2.12
3.13 eleven
 TIGHTENING TORQUES (TORQUES)

Crankshaft tightening sequence:

TO B
14
7
1.6
8 fifteen

5 9
2.12

4
10
3.13 eleven

A. Left crankshaft
B. Right crankshaft
 TIGHTENING TORQUES (TORQUES)

EAS20350

CHASSIS TIGHTENING TORQUES

Size
Item of the Qty. Torque Comments
thread
Top clamp bolt Steering stem bolt M10 2 35 Nm (3.5 m kg, 25 ft lb)
M10 1 35 Nm (3.5 m kg, 25 ft lb)

Lower clamp clamping bolt M10 2 30 Nm (3.0 mkg, 22 ftlb)

Lower ring nut (initial tightening
See TIP.
torque) M25 1 33 Nm (3.3 mkg, 24 ftlb)
Lower ring nut (final torque)
See TIP.
M25 1 22 Nm (2.2 m kg, 16 ft lb)
Handlebar mount screw M8 4 23 Nm (2.3 m kg, 17 ft lb)

Main switch screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Lamp assembly bracket screw M6 2 13 Nm (1.3 mkg, 9.4 ftlb)

Lamp clamp screw M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

Lamppost inner cover screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Brake knob bracket bolt

(SZ16 / SZ16X) M6 1 7 Nm (0.7 mkg, 5.1 ftlb) 7
Clutch Knob Support Bolt M6 1 Nm (0.7 mkg, 5.1 ftlb)

Rear brake pedal bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

Engine mounting nut (front side) M10 2 55 Nm (5.5 mkg, 40 ftlb)

Engine mounting nut (front side) M10 2 55 Nm (5.5 mkg, 40 ftlb)

Engine mounting nut (upper rear side)

M10 1 55 Nm (5.5 mkg, 40 ftlb)

Engine mounting nut (lower rear side)

M10 1 55 Nm (5.5 m kg, 40 ft lb)
Motor mounting nut (upper side) M8 1 30 Nm (3.0 m kg, 22 ft lb)

Engine mount screw (upper side) M8 2 30 Nm (3.0 mkg, 22 ftlb)

Pivot shaft nut M12 1 59 Nm (5.9 mkg, 43 ftlb) LS

Chain guide nut M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

transmission
Shock absorber assembly bolt
rear M10 2 40 Nm (4.0 mkg, 2.9 ftlb)
Rear Shock Assembly Nut
M10 2 16 Nm (1.6 m kg, 11 ft lb)
Brake Torque Bar Nut M8 2 19 Nm (1.9 m kg, 13 ft lb)

Fuel valve screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Fuel tank clamp bolt M6 2 10 Nm (1.0 m kg, 7.2 ft lb)

Fuel tank screw M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

Fuel tank cap screw M5 2 4 Nm (0.4 mkg, 2.9 ftlb)

Fuel gauge screw M5 4 4 Nm (0.4 m kg, 2. 9 ft lb)

Battery box screw M6 3 7 Nm (0.7 mkg, 5.1 ftlb)

Regulator / Rectifier Screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Seat Lock Bracket Screw M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

 TIGHTENING TORQUE (TORQUES)

Size
Item of the Qty. Torque Comments
thread
Grab bar screw Air guide bracket M8 4 25 Nm (2.5 m kg, 18 ft lb)
screw M8 2 16 Nm (1.6 m kg, 11 ft lb)

Horn screw M6 1 7 Nm (0.7 m kg, 5.1 ft lb)

Front wheel axle nut M12 1 60 Nm (6.0 m kg, 43 ft lb) LS

Rear wheel axle nut M14 1 90 Nm (9.0 mkg, 65 ftlb)

Rear wheel sprocket nut M8 6 43 Nm (4.3 mkg, 31 ftlb)

Rear brake camshaft lever bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

Drive chain puler lock nut M6 2 7 Nm (0.7 mkg, 5.1 ftlb)

Drive chain cover bolt M6 4 7 Nm (0.7 mkg, 5.1 ftlb)

Front brake knob nut (SZ16) M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

Clutch knuckle nut M6 1 7 Nm (0.7 mkg, 5.1 ftlb)

Front Brake Camshaft Knob Lower Bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)
(SZ16 / SZ16X)
Front brake disc bolt (SZ16R) M8 5 23 Nm (2.3 mkg, 17 ftlb)

Front brake caliper bolt (SZ16R) M10 2 35 Nm (3.5 mkg, 25 ftlb)

Front brake hose bracket lower bolt M6 1 7 Nm (0.7 mkg, 5.1 ftlb)
(SZ16R)
Front brake caliper bleed screw M10 1 14 Nm (1.4 mkg, 10 ftlb)
(SZ16R)
Brake hose union bolt (master cylinder M10 1 24 Nm (2.4 mkg, 17 ftlb)
side) (SZ16R)

Brake hose union bolt (caliper side) M10 1 24 Nm (2.4 mkg, 17 ftlb)
(SZ16R)
Front brake master cylinder mounting M6 2 10 Nm (1.0 mkg, 7.2 ftlb)
bolt (SZ16R)
Pilot footrest screw M8 2 34 Nm (3.4 mkg, 24 ftlb)
Side leg nut M10 1 44 Nm (4.4 mkg, 32 ftlb)

Shift arm bolt M6 1 10 Nm (1.0 mkg, 7.2 ftlb)

Front fork cover screw Shock M25 2 22 Nm (2.2 m kg, 16 ft lb)

absorber bar screw M8 2 20 Nm (2.0 m kg, 14 ft lb)

Magazine screw M8 4 16 Nm (1.6 mkg, 11 ftlb)

TIP ____________________________________________________________________________________________
1. • First, tighten the bottom ring nut to approximately 33 Nm (3.3 m kg, 40 p · lb) with a torque wrench, then loosen
the bottom ring nut completely.
2. • Retighten the lower ring nut to 22 Nm (2.2 m kg, 16 p · lb) with a torque wrench.
EAS20360

TYPES OF LUBRICANT
EAS20370

MOTOR
Lubrication point Lubricant

Oil Gasket Edge

O-rings, O-rings Bearings

Cylinder Head Bolts (M8)

Cylinder Head Bolts (M6)

Timing chain output sprocket

Piston Pin Bigger End Thrust Surface

Piston, Piston Rings, and Inner Surface of Cylinders Inner Surface of

Balancer Driven Gear Camshaft Lobes

Decompression cam

Valve stem (intake and exhaust)

Valve stem ends (intake and exhaust) Valve stem packing

Rocker Axle

Rocker Internal Surfaces

Decompression lever pin Oil pump driven gear Oil pump

rotors (internal and external)

Kick Starter Gear and Ratchet Gear (SZ16) Kick Starter Shaft (SZ16)

Kick Start Gear Inner Surface (SZ16)

Starter Clutch Gear Inner Surface and Thrust Surface (SZ16X / SZ16R)

Starter Clutch Rollers (SZ16X / SZ16R)

Starter clutch idle pinion shaft (SZ16X / SZ16R)

Inner surface of starter clutch idle gear and thrust surface (SZ16X / SZ16R)

Clutch Knob

Friction discs and clutch discs

Inner surface of primary drive gear

Clutch push rod (short and long) and ball

Clutch hub nut and lockwasher contact surface

Transmission gears (Wheel and Pinion) and collar

 Lubrication point Lubricant

Shift fork guide bar and shift forks Shift pedal shaft AND

AND

Yamaha bond
Crankshaft Position Sensor / Stator Assembly Plug
No.1215

Yamaha bond
Generator Cover Screws
No.1215
Yamaha bond
Crankcase mating surface
No.1215
Yamaha bond
Chain tensioning bolts
No.1215

2-23
EAS20380

CHASSIS
Lubrication point Lubricant

Front wheel oil seal edge

Inner surface of speedometer driven gear

Front brake shoe plate pivot pin (SZ16 / SZ16X) Front brake camshaft (SZ16 /

SZ16X)

Inner surface of speedometer gear unit (SZ16R)

Rear wheel oil gasket edge

Rear wheel drive ground splice surface Pin rear brake shoe plate shaft

Rear brake camshaft

Swingarm bearing outer surface Swingarm dust cover

edges

Swingarm Oil Packing Edges

Swingarm axle outer surface

Steering column bearings

Steering column bearing cover edge

Brake pedal pivot point

Brake rod shaft pin

Brake pedal pivot point

Side leg pivot point and metal-to-metal moving parts

Pivoting axis of the central leg

Throttle cable end and inner surface of throttle grip tube guide

Clutch Cable End at Clutch Knob

Clutch lever pivot point and metal-to-metal moving point

Front brake cable end at brake lever (SZ16 / SZ16X)

Front brake lever pivot point and metal-to-metal moving point (SZ16 / SZ16X)

Front brake lever pivot point and metal-to-metal moving point (SZ16R)
 LUBRICATION SYSTEM DIAGRAMS AND TABLE

EAS20390

LUBRICATION SYSTEM DIAGRAMS AND TABLE

EAS20400

ENGINE OIL LUBRICATION CHART

5 7 8 3 9 10

6 2

1
 LUBRICATION SYSTEM DIAGRAMS AND TABLE

1. Oil container
2. Oil strainer filter
3. Oil Pump
4. Oil filter
5. Cylinder head

6. Camshaft
7. Piston cooler
8. Crankshaft
9. Drive shaft
10. Main Shaft
 LUBRICATION SYSTEM DIAGRAMS AND TABLE

EAS20410

LUBRICATION DIAGRAMS

2 3

7
 LUBRICATION SYSTEM DIAGRAMS AND TABLE

1. Clutch Knob
2. Main Axis
3. Transmission shaft
4. Crankshaft
5. Oil filter
6. Water pump assembly
7. Oil filter (strainer)
8. Camshaft
1. Starter cable
2. Clutch switch (SZ16X / SZ16R)
3. Clutch cable
4. Left handlebar switch contact
5. Throttle cable
6. Rear brake light switch
7. Starter switch
8. Front brake light switch contact
9. Start switch contact (SZ16X / SZ16R)
10. Left handlebar switch
11. Throttle cable housing
12. Main switch
13. Meter assembly
14. Clutch switch contact (SZ16X / SZ16R)
15. Left front turn signal
16. Main switch contact
17. Speedometer Cable
18. Wire harness
19. Lamp contact
20. Front brake cable (SZ16 / SZ16X)
21. Right front directional contact
22. Meter assembly
A. Pass the throttle cable through the guide.
B. Secure the front brake light switch contact and
the starter switch contact (SZ16 / SZ16X) to the
handlebar with the plastic band.

C. Secure the clutch switch contact (SZ16X / SZ16R)

and the left handlebar switch contact to the
handlebar with the plastic band.

D. SZ16
E. Attach the plastic bands to the vertical portions of
the handlebar as shown in the illustration.

F. Route the speedometer cable to the front of the

coupling cover.
G. Pass the front brake cable (SZ16 / SZ16X)
and the speedometer cable through the
guide.
A. Pass the wire harness through the guide.
I. Pass the lamp contact through the center
opening on the right side of the coupling
cover.
J. Route the front brake cable (SZ16 / SZ16X) to the
rear of the coupling cover.
1. Rectifier / regulator
2. Battery breather hose (SZ16X / SZ16R)
3. Positive battery terminal
4. Starter circuit cut-off relay
5. Directional light relay
6. Fuel gauge lead wire
7. Air shut-off valve
8. Spark plug contact
9. Throttle cable
10. Spark plug cap
11. Clutch cable (SZ16 / SZ16X)
12. Starter relay (SZ16X / SZ16R)
13. Carburetor vent hose
14. Rear brake light switch contact
15. Starter motor contact (SZ16X / SZ16R)
16. Negative battery terminal (SZ16X / SZ16R)
17. Rear brake light switch
18. Air induction system hose (air shutoff valve to
air induction system tube)

19. Air induction system vacuum hose

20. Cylinder head breather hose
21. Choke cable
22. Clamp
23. Negative battery terminal
24. Battery breather hose
25. Rubber battery cap
26. Fuse holder
27. Air induction system hose (air filter housing to
air shutoff valve)

A. Pass the throttle cable between the edge of the

grommet and the frame.
B. Route the starter motor contact (SZ16X / SZ16R)
and carburetor breather hose to the outside of
the clutch cable.

C. Bring the rear brake light switch contact and

battery negative contact (SZ16X / SZ16R) to the
outer part of the starter motor contact (SZ16X /
SZ16R).
D. Pass the rear brake light switch contact
through the hole in the rear fender.

E. Pass the battery breather hose through the

hole in the battery box.
F. Pass the negative battery contact (SZ16X / SZ16R)
and the rear brake light switch contact through the guide.
G. Route the throttle cable to the outside of the
air induction system vacuum hose.

H. Route the choke wire to the inside of the

induction system vacuum hose hence

I. Pass the clutch cable, starter cable, and throttle

cable through the guide.

J. SZ16
K. Pass the carburetor bleed hose out of the clutch
cable.
L. Secure clutch cable and carburetor focus hose
with bracket.
M. View of the cable routing inside the battery box.
1. Lamp assembly
2. Clutch cable
3. Starter cable
4. Fuel hose
5. Throttle position sensor contact
6. Air duct hose
7. Carburetor exhaust hose
8. Battery breather hose
9. Plug
10. Neutral switch contact
11. Starter motor contact (SZ16X / SZ16R)
12. Horn
13. Starter motor contact (SZ16X / SZ16R)
14. Speedometer Cable
15. Wire harness
16. Starter motor (SZ16X / SZ16R)
17. Horn contact
18. Rear turn signal contact.
19. Chair lock cable
A. Pass the clutch cable and starter cable between
the edge of the grommet and the frame.
B. Pass the AC generator contact between the
cylinder head breather hose and the induction air
system hose (air filter housing to air shutoff
valves), then back to the back of the breather
hose.
C. Secure clutch cable and carburetor breather
hose with bracket.
D. Pass the speedometer cable and front brake
cable (SZ16X / SZ16R) through the guide.

E. Pass the wire harness through the guide.

F. Align the tape on the wire harness with the guide.
G. Install the L-shaped horn connectors so that the
contacts are guided inward.

H. Make sure the rear turn signal contacts do not

protrude above the rear fender blades. If necessary,
pull the rear turn signal end of each contact rearward
to remove any play in the contact so that it does not
protrude over the edges of the rear fender.
 TO

C
7

AND

TO

TO
1. Right rear turn signal contact.
2. Brake / tail light switch
3. Brake / tail light assembly
4. Left rear turn signal contact.
5. Chair lock cable
6. CDI unit
7. Air duct hose
A. Install the ignition coil connector so that the
contact faces out.
B. Secure the wire harness with the plastic band,
making sure the band contacts the rear end of
the clamp on the frame. Align the white tape on
the wire harness with the plastic band.

C. Lead the wire harness to the left of the air filter

housing groove.
D. Pass the rear right turn signal contact, the rear
left turn signal contact, and the brake / tail light
contact between the splines on the rear fender.

E. Route the seat lock wire to the right of the groove

on the rear fender.
For SZ16R

2 3 4

TO
TO
TO

4 3

1 B
B
AA
1. Throttle cable
2. Front brake hose
3. Front brake light switch contact
4. Right handlebar switch contact
A. Route the front brake hose into the throttle
cable.
2-39
 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE................................................ .............................................3-1

PERIODIC MAINTENANCE TABLE FOR THE EMISSIONS CONTROL
SYSTEM ....................................... .................................................. ........................... 3-1
GENERAL MAINTENANCE AND GREASING TABLE ............................................ .... 3-1

MOTOR................................................. .................................................. ................................3-3

VALVE CLEARANCE ADJUSTMENT ............................................ ....................... 3-3 ADJUSTING THE ENGINE IDLE SPEED ................. .................................. 3-4 CHECKING AND ADJUSTING THE

EXHAUST GAS ...... .................................................. ....... 3-5 THROTTLE CABLE PLAY ADJUSTMENT ................................. .............. 3-6 CHECKING THE SPARK

PLUG ............................. .................................................. ................. 3-7 CHECKING THE IGNITION TIMING ......................... ......................................... 3-7 COMPRESSION PRESSURE

MEASUREMENT ......... ................................ .3-8 OIL LEVEL CHECK MOTOR................................................ ............ 3-9 CHANGING THE ENGINE OIL .............................. .................................................

3-9 ADJUSTING THE CLUTCH CABLE PLAY ............................................. .... 3-11 CLEANING THE AIR FILTER ELEMENT .................................... ................ 3-11 CHECKING THE CARBURETOR GASKET

3
AND THE AIR FILTER HOUSING JOINT ............... .................................................. .................................................. ..... 3-12 CHECKING THE CYLINDER HEAD BREATHER

HOSE ................................. ..3-12 EXHAUST SYSTEM CHECK ........................................ ............................... 3-12 FUEL VALVE FILTER CHECK ........ ............. 3-133-11 CLEANING THE AIR FILTER

ELEMENT ........................................ ............ 3-11 CHECKING THE CARBURETOR GASKET AND THE AIR FILTER HOUSING

JOINT ................... .................................................. .................................................. .3-12 CHECKING THE CYLINDER HEAD BREATHER HOSE ................................... 3- 12 EXHAUST SYSTEM

CHECK ............................................ ........................... 3-12 CHECKING THE FUEL VALVE FILTER ............ ......... 3-133-11 CLEANING THE AIR FILTER ELEMENT ........................................ ............ 3-11

CHECKING THE CARBURETOR GASKET AND THE AIR FILTER HOUSING JOINT ................... .................................................. .................................................. .3-12 CHECKING THE CYLINDER HEAD

BREATHER HOSE ................................... 3- 12 EXHAUST SYSTEM CHECK ............................................ ........................... 3-12 CHECKING THE FUEL VALVE FILTER ............ ......... 3-133-12 CHECKING

THE CYLINDER HEAD BREATHER HOSE ................................... 3-12 EXHAUST SYSTEM CHECK ............................................. .......................... 3-12 FUEL VALVE FILTER CHECK ............. ........ 3-133-12

CHECKING THE CYLINDER HEAD BREATHER HOSE ................................... 3-12 EXHAUST SYSTEM CHECK ............................................. .......................... 3-12 FUEL VALVE FILTER CHECK ............. ........

3-13

CHASSIS................................................. .................................................. .............................3-14

ADJUSTING THE FRONT DRUM BRAKE (SZ16R / SZ16X) ........................... 3-14 ADJUSTING THE REAR
DRUM BRAKE ... .................................................. ...... 3-14 CHECKING THE BRAKE FLUID LEVEL
(SZ16R) ............................... ......... 3-15 CHECKING THE FRONT BRAKE PADS (SZ16R) ..................... 3-15
CHECKING THE HOSES FRONT BRAKE (SZ16R) .................. 3-16 CHECKING THE FRONT BRAKE SHOES
(SZ16R / SZ16X) ........... .... 3-16 CHECKING THE REAR BRAKE SHOES .................................... .......... 3-16
REAR BRAKE LIGHT SWITCH ADJUSTMENT ............................ .3-16 BLEEDING THE HYDRAULIC BRAKE
SYSTEM (SZ16R) ..................................... 3-17 ADJUSTING DRIVE CHAIN PLAY .......................................
.3-17 DRIVE CHAIN LUBRICATION ......................................... ............ 3-18 CHECKING AND ADJUSTING
THE HEAD HEAD ............................ ................... 3-18 CHECKING THE FRONT
FORK ....................... ....................................... 3-20 CHECKING THE
TIRES ... .................................................. ................................. 3-20 CHECKING THE
WHEELS .......... .................................................. ............................ 3-21 CHECKING AND LUBRICATING
THE CABLES ............. .............................................. 3-21 LUBRICATION OF THE CLUTCH
HANDLE ............................................. .3-22 CHECKING THE FRONT BRAKE HANDLE (SZ16 /
SZ16X) ............. 3-22 FRONT BRAKE HANDLE LUBRICATION (SZ16R) ........3-22 SHIFT PEDAL
LUBRICATION .......................................... ........................ 3-22 BRAKE PEDAL
LUBRICATION .................. .................................................. ..3-22 SIDE LEG
LUBRICATION ........................................ ............................... 3-22 CENTRAL LEG
LUBRICATION ........... .................................................. .......... 3-22 REAR SUSPENSION
LUBRICATION ................................ ........................ 3-223-22 CENTER LEG
LUBRICATION .......................................... ............................. 3-22 REAR SUSPENSION
LUBRICATION ............. ........................................... 3-223-22 CENTER LEG
LUBRICATION .......................................... ............................. 3-22 REAR SUSPENSION
LUBRICATION ............. ........................................... 3-22
ELECTRIC SYSTEM................................................ .................................................. ......3-23
CHECKING AND CHARGING THE BATTERY ............................................ ............................ 3-23
CHECKING THE FUSE ................ .................................................. ............................ 3-23 CHANGING THE
LAMP BULB ............. .................................................. ... 3-23 LAMP BEAM
ADJUSTMENT ...................................... ....................................... 3-23 REPLACING THE TAILLIGHT BULB /
BRAKE .................................... 3-24 CHANGING THE DIRECTIONAL LIGHT
BULB .. .............................................. 3-24
 PERIODIC MAINTENANCE

EAS20450

PERIODIC MAINTENANCE
EAUE0220

PERIODIC MAINTENANCE TABLE FOR THE EMISSIONS CONTROL SYSTEM

TIP ________________________________________________________________________________________
• Starting at 18,000 km (1,100 mi), repeat maintenance intervals beginning at 3,000 (1,900
mi) km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they are
they require special tools, data and technical skills.

ODOMETER READING

DO NOT. ITEM MAINTENANCE OR REVIEW WORK

1000 km 3000 km 6000 km 9,000 km 12,000 km 15,000 km (5,600
(600 mi) (1900mi) (3700 mi) mi) (7,500 mi) (9,300 mi)

1 * Fuel line • Look for cracks or damage in the fuel hoses. √ √ √ √ √ √

2 * Valve filter • Check operation and clean if necessary √ √ √ √ √ √

fuel

• Check the status.

√ √ √ √ √
3 Spark plug
• Clean and adjust the electrode gap.

• Replace √

• Check the valve clearance.

4 * Valves √ √ √ √ √ √
• Adjustment.

• Check the choke operation.

5 * Carburetor √ √ √ √ √ √
• Adjust the engine idle speed

• Check the air shutoff valve, reed valve, and hose for
damage.
6 * induction system √ √ √ √ √ √
air
• Replace any damaged parts if necessary.

EAUE0880

GENERAL LUBRICATION AND MAINTENANCE CHART

TIP _____________________________________________________________________________________________

• Starting at 18,000 km (1,100 mi), repeat maintenance intervals beginning at 3,000 (1,900
mi) km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they are
they require special tools, data and technical skills.

ODOMETER READING

DO NOT. ITEM MAINTENANCE OR REVIEW WORK

1000 km 3000 km 6000 km 9,000 km 12,000 km 15,000 km (5,600
(600 mi) (1900mi) (3700 mi) mi) (7,500 mi) (9,300 mi)

• Clean. √ √ √ √ √ √
1 Air filter
• Replace Every 12000 km (7500 mi)

• Check the battery output voltage.

• Check electrolyte level and specific gravity
2* Battery √ √ √ √ √ √
• Make sure the breather hose is properly guided.

• Check operation.
3 Clutch √ √ √ √ √ √
• Adjustment.

• Check operation and adjust brake lever play.

√ √ √ √ √ √
4 * Front Brake

• Replace the shoes. Every time they're worn to the limit

• Check operation and adjust brake pedal play.

√ √ √ √ √ √
5 * Rear brake

• Replace the shoes. Every time they're worn to the limit

6 * Wheels • Check for wear and damage. √ √ √√√ √

3-1
 PERIODIC MAINTENANCE

ODOMETER READING

DO NOT. ITEM MAINTENANCE OR REVIEW WORK

1000 km 3000 km 6000 km 9000 km 12000 km 15000 km (600 mi) (1900mi)
(3700 mi) (5600 mi) (7500 mi) (9300 mi)

• Check depth of tilling and for damage.

7 * Tires • Replace if necessary. √ √ √ √ √ √

• Check the pressure.
• Correct if necessary.

• Check the bearings for looseness or damage.

8 * Bearings √ √ √ √ √ √
wheels
• Check the operation and that there is no √ √ √ √ √ √
excessive play.
9 * Swingarm
• Lubricate with a lithium soap-based
Every 12000 km (7500mi)
grease.

• Check chain play, chain

Every 2000 km (1200 mi) after the first 1000
alignment and its condition.
10 Chain of Transmission km (600 mi) and after washing the motorcycle, drive it
• Adjust and lubricate the chain with
in the rain or wet areas.
YAMALUBE.

• Check the steering bearing play for roughness.

√ √ √ √ √ √
eleven * Bearings
address • Lubricate with a lithium soap-based
Every 12000 km (7500mi)
grease.

• Make sure all nuts, screws and bolts are properly

12 * Fixing elements tightened
√ √ √ √ √ √
chassis

Rotation axis of • Lubricate with a silicone grease.

√ √ √ √ √ √
the knuckle of the
Brake

Rotation axis of
• Lubricate with a silicone grease. √ √ √ √ √ √
brake pedal

Rotation axis of • Lubricate with a lithium soap-based

√ √ √ √ √ √
the knuckle of the grease.
clutch

Rotation axis of • Lubricate with a lithium soap-based

√ √ √ √ √ √
gear pedal grease.

• Check operation.
Side leg, leg
13 • Lubricate with a lithium soap-based √ √ √ √ √ √
central
grease.

14 * Front fork • Check the operation and that there is no oil √ √ √ √ √ √

leakage.
• Check the shock absorber operation and that there is
fifteen * Set of √ √ √ √ √ √
damping no oil leakage.

• Change. √ 2000 km (1200 my) after one of the

first 1000 (600 mi) km and every 3000
16 Motor oil
(1800 mi) km thereafter
• Check the oil level and the vehicle for leaks.
Every 3000 km (1800 mi) √

Oil filter element

17 • Replace √ Every 10,000 km (600 mi)

Switches
18 * • Check operation. √ √ √ √ √ √
front brakes and
rear
Cables and Moving Parts
19 • Lubricate. √ √ √ √ √ √

• Check operation.
• Check the throttle play, and adjust if necessary.
twenty * Throttle √ √ √ √ √ √
• Lubricate the grip housing and cable.

twenty-one * Lights, signals and

• Check operation.
√ √ √ √ √ √
switches
• Adjust the beam of the streetlight.

3-2
 MOTOR

EAS20471

MOTOR Valve clearance (cold) Intake

EAS20520

0.08–0.12 mm (0.0032–0.0047 in)

VALVE CLEARANCE ADJUSTMENT
Exhaust
The following procedure applies to all valves.
0.12–0.16 mm (0.0047–0.0063 in)

TIP ▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
• Valve clearance adjustment should be done on to. Rotate the crankshaft counterclockwise
a cold engine, at room temperature. (counterclockwise).
b. Align the “a” mark on the TDC on the generator
• When valve clearance is to be measured or adjusted, rotor with the stationary “b” mark on the
the piston must be at Top Dead Center (TDC) on the generator cover.
compression stroke.

1. Remove: b
• Air guide (SZ16X)
• Internal air guide (SZ16R)
• External air guide (SZ16R)
• Seat
See "OVERALL CHASSIS" on page 4-1.
to
• Gasoline tank
See "GASOLINE TANK" on page 6-1. c. Check that the cam lobes are positioned as shown in
the illustration.
• Air duct
See "CYLINDER HEAD" on page 5-7.
2. Disconnect:
• Spark plug cap
• Air induction system hose (air shutoff valve to air
induction system tube)

Refer to "AIR INDUCTION SYSTEM" on page 6-11.

3. Remove:
• Cylinder head coverage
• Cylinder head cover gasket Safety pin d. Measure the valve clearance with a "1" gauge (feeler
gauge).
See "CYLINDER HEAD" on page 5-7. Out of specification → Adjustment.
4. Remove:
• Access screw to time stamp "1" Thickness Gauge (Caliper)
• Access bolt to the end of the crankshaft "2" YSST-815

5. Measure:
• Clearance of Valves
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Adjustment.
6. Adjustment:
• Clearance of Valves

3-3
 MOTOR

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust F. If valve clearance is still out of specification, repeat all
to. Loosen locknut "1". adjustment steps until valve clearance is obtained
b. Insert a "2" gauge (gauge) between the end of the
adjusting screw and the valve tip. specified.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
Thickness Gauge (Caliper)
• All parts removed
YSST-815
TIP __________________________________________
For installation, reverse the removal procedure.

EAS20610

ADJUSTING THE ENGINE IDLE SPEED

TIP__________________________________________
Before adjusting the engine idle speed, the air filter
must be cleaned, and the engine must have adequate
compression.

c. Turn adjusting screw "3" in direction "a" or "b" until 1. Start the engine and allow it to warm up for several
the specified valve clearance is obtained. minutes.
2. Install:
• Digital Tachometer
Address "to" (at the spark plug contact)
Valve clearance increases. Address "b" 3. Check:
• Engine idle speed
Reduces valve clearance. Out of specification → Adjustment.

Engine idle speed

Tappet Screw Holder 1300–1500 r / min
YSST-706
Bucket adjustment wrench
YSST-806A
4. Adjustment:

• Engine idle speed

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
to. Turn adjusting nut "1" in direction "a" or "b" until the
engine idles.

Address "to"
Increase idle speed. Address "b"

Reduce idle speed.

d. Hold the adjusting screw to prevent it from

moving and tighten the nut according to the
specification.

Lock nut
14 Nm (1.4 mkg, 10 ftlb) to b

and. Measure the Valve Clearance again.

1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-4
 MOTOR

5. Adjustment: 5. Start the engine and warm it up to the specified oil

• Throttle cable play temperature.
See "ADJUSTING THE THROTTLE CABLE
PLAY" on page 3-6. Oil Temperature
75.0–85.0 ° C (167.00–185.00 ° F)

6. Measure:
• Throttle cable play
3.0–7.0 mm (0.12–0.28 in) • Engine idle speed (air induction system
OFF) Out of specification → Adjust.
EAS54B1010

CHECKING AND ADJUSTING THE EXHAUST GAS Refer to "IDLE SPEED ADJUSTMENT" on page 3-4.
1. Place the vehicle on a flat surface.
TIP
Engine idle speed
• Place the vehicle on the center leg. 1300–1500 r / min
• Make sure the vehicle is straight
• Measure the exhaust gas at idle when the air
induction system is not operating. 7. Install:
2. Install: • CO tester "1"
• Temperature tester "1" • Sample probe “2”
(on the engine oil drain screw) 1
2

TIP ___________________________________________
• Be sure to fit a heat resistant rubber tube so that the
3. Disconnect: exhaust gases do not leak.
• Air induction system hose (air shutoff valve to
cylinder head) • Before using the CO tester, be sure to read the user
4. Stop the operation of the air induction system. manual.

8. Measure:
TIP __________________________________________ • CO density
Bend the hose “1” from the reed valve to the air shutoff Out of specification → Adjustment. Within
valve to prevent activation of the shutoff valve. specification → Check air induction system

Make sure not to damage the hose when Refer to "AIR INDUCTION SYSTEM" on page 6-11.
fold.

CO%
2.0–6.0%

9. Adjustment:
• Pilot screw "1"
TIP _____________________________________
If CO density cannot be adjusted with pilot screw, tune
carburetor and check air filter

3-5
 MOTOR

Pilot screw rotates out 2–1 / 4

2 1

to

c. Tighten the locknut.

TIP__________________________________________
1 If the specified throttle cable play is not achieved at the
end of the throttle cable, use the adjusting nut at the
EAS20660

ADJUSTING THE CLUTCH CABLE PLAY end of the handlebar.

TIP _________________________________________ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Before adjusting the throttle cable play, the engine
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
idle speed must be adjusted.
Handlebar side
to. Slide back the rubber cover "1"
1. Check: b. Loosen locknut "2"
• Throttle cable play "a" c. Turn adjusting nut "3" in direction "a" or "b" until the
Out of specification → Adjustment. specified throttle cable play is obtained.

Throttle cable play

3.0-7.0mm Address "to"
Increase the throttle cable play. Address "b"

Reduce throttle cable play.

2. Adjustment:

• Throttle cable play

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
d. Tighten the locknut.
Throttle body side
and. Slide the rubber cap to its original position.
to. Loosen the locknut "1" on the throttle cable. EWA12930

WARNING________________________
b. Turn adjusting nut "2" in direction "a" or "b" until the
After adjusting the throttle cable free play, start the
specified throttle cable play is obtained.
engine and turn the handlebars to the right and left to
check for variations in idle speed.

Address "to"
Increase the throttle cable play. Address "b" ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Reduce throttle cable play.

3-6
 MOTOR

TIP
EAS20690

CHECKING THE SPARK PLUG

1. Remove:
Before installing, clean the spark plug and gasket
• Air duct surface.
See "CYLINDER HEAD" on page 5-7. 9. Connect:
2. Disconnect: • Spark plug cap
• Spark plug cap 10. Install:
3. Remove: • Air duct
• Spark plug
See "CYLINDER HEAD" on page 5-7.
ECA13330

ATTENTION EAS20700

Before removing the spark plug, blow out any CHECKING THE IGNITION TIME
accumulated dirt with compressed air to prevent (ADJUSTMENT)
it from falling into the cylinder. TIP __________________________________________
Before checking the ignition timing, check the
wiring connections for the entire ignition system.
4. Check:
• Spark plug type Make sure all connections are tight and free of
Incorrect → Change. corrosion.

Manufacturer / model: 1. Remove:

NGK / CPR8EA-9 • Access screw to time stamp "1"

Crankshaft Center Plug Wrench

5. Check:
YSST-625
• Electrode "1"
Damage / wear → Replace the spark plug.
• Insulator "2"
Abnormal color → Replace the spark plug. The
normal color is light to medium tan.
6. Clean:
1
• Spark plug

(with a spark plug cleaner or metal grata)

7. Measure:
• Distance between electrodes "a"
(with a caliper or feeler gauge)
Out of specification → Adjust distance
between electrodes.
2. Connect:
Electrode gap • Strobe lamp "1"
0.8–0.9 mm (0.031–0.035 in) • Digital Tachometer

Stroboscopic lamp

8.
Install:
• Spark plug
3. Check:
Spark plug
• Ignition adjustment
13 Nm (1.3 mkg, 9.4 ftlb)

3-7
 MOTOR

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust ECA54B1016

ATTENTION __________________________________
to. Start the engine, let it warm up for a few minutes,
and then let it run at the specified idle speed. Before removing the spark plug, blow out any
accumulated dirt with compressed air to prevent
it from falling into the cylinder.
Engine idle speed 1300–1500
r / min

b. Check that the stationary mark "a" on the alternator 6. Position:

cover is within range "b" of the alternator rotor. • Decompression lever "1"
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
to. Remove the camshaft sprocket cap.
Incorrect ignition interval → Check ignition
b. Turn the decompression lever to the position shown
system.
in the illustration and then
Secure lever to camshaft output sprocket "2" using
wire "3".
to ECA54B1023

ATTENTION __________________________________
Cut the "a" ends of the wire so that it does not
b contact any engine components while the engine is
running.

TIP __________________________________________
Put a clean cloth on the cylinder head opening as
shown in the illustration to prevent dirt or foreign
TIP __________________________________________
materials from entering the engine.
The timing (timing) of the ignition is not adjustable.

c. Install the camshaft sprocket cover.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Remove: Axle shaft output sprocket cover
• Digital Tachometer cams
• Stroboscopic lamp 10 Nm (1.0 mkg, 7.2 ftlb)
5. Install:
• Access screw to the synchronization mark

EAS20710

MEASUREMENT OF COMPRESSION
PRESSURE
TIP
Insufficient compression pressure will decrease
performance.
1. Measure:
• Clearance of Valves ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Adjustment. Refer to
7. Install:
"ADJUSTING THE VALVE CLEARANCE" on page 3-3.
• Compression Gauge "1"

2. Start the engine and allow it to warm up for several Compression gauge
minutes, then turn it off.
3. Remove:
• Air duct
See "CYLINDER HEAD" on page 5-7.
4. Disconnect:
• Spark plug cap
5. Remove:
• Spark plug

3-8
 MOTOR

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
1 to. Remove the camshaft sprocket cap.
b. Remove wire "2" that is securing decompression
lever to camshaft output sprocket "3".

TIP _________________________________________
Put a clean cloth on the cylinder head opening as
shown in the illustration to prevent
dirt or foreign materials get into the motor.

c. Install the camshaft sprocket cover.

8. Measure:
• Compression Pressure Axle shaft output sprocket cover
Out of specification → Refer to steps (c) and (d). cams
10 Nm (1.0 mkg, 7.2 ftlb)

Standard compression pressure (at

sea level)
1200 kPa (12.0 kgf / cm², 170.7
psi)
Min MAX
1040-1340 kPa (10.4-13.4 kgf /
cm², 147.89-190.59 psi)

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
to. Set the main switch to "ON".
b. With the throttle wide open, crank the engine until
the compression gauge reading stabilizes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
11. Install:
c. If compression pressure is higher than specified
• Spark plug
maximum, check for carbon build-up on cylinder
head, valve surfaces, and piston crown.
Spark plug

13 Nm (1.3 mkg, 9.4 ftlb)

Carbon build-up → Remove. 12. Connect:

d. If the compression pressure is below the specified • Spark plug cap
minimum, pour a teaspoon of engine oil onto the 13. Install:
inside diameter of the spark plug and measure the • Air duct
pressure again. See "CYLINDER HEAD" on page 5-7.
Please refer to the table below.
EAS28920

Compression pressure (after introducing

CHECKING THE ENGINE OIL LEVEL
oil into cylinder)
1. Place the vehicle on a flat surface.
Reading Diagnosis TIP _______________________________________
Higher than Piston rings • Place the vehicle on the center leg.
without oil worn or damaged • Make sure the vehicle is straight
→ Repair. 2. Start the engine, warm it up for several minutes, and
Possible defects in the then turn it off.
piston, valves, 3. Check:
Same as without oil
cylinder head or piston • Oil level
gasket → Repair. The engine oil level must be between the minimum
level mark "a", and the maximum level mark "b".
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Remove: Below the minimum mark → Add oil to reach
• Compression gauge the proper oil level.
10. Position:
• Decompression lever "1"

3-9
 MOTOR

TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.

• Do not screw the dipstick "1" when checking the

oil level. 1

b
to

Recommended brand 2
YAMALUBE
Guy
SAE 20W40 or SAE 20W50 4. Drain:
Recommended motor oil type Motor oil
(completely from the crankcase)
API service type SE, SF, SG or 5. If the filter needs to be changed and oil, perform the
higher, JASO standard MA following procedure.
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
ECA54B1022
to. Remove the oil filter cap "1" and the oil filter.
ATTENTION
Do not allow foreign materials to enter the crankcase b. Install a new O-ring “3”.

4. Start the engine, warm it up for several minutes, and

then turn it off.
5. Check the engine oil level again.
TIP
• Before checking the engine oil level, wait a few
minutes until the oil has run out.
settled.

2 New 3 1
EAS20810

CHANGING THE ENGINE OIL c. Install the new filter and filter cap.
1. Start the engine, warm it up for several
minutes, and then turn it off. Oil filter cover screw
2. Place an oil pan under the oil drain screw. 10 Nm (1.0 mkg, 7.2 ftlb)

3. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Duct cover to fill motor oil 6. Install:

"1" • Engine oil drain screw
• Engine oil drain screw “2” (together with
(together with the packaging New )
gasket)

Engine oil drain bolt

20 Nm (2.0 mkg, 14 ftlb)

3-10
 MOTOR

EAS20870

7. Fill in: ADJUSTING THE CLUTCH CABLE PLAY

• The Crankcase

(with the specified amount of the 1. Check:

recommended oil) • Clutch cable play "a"
Out of specification → Adjustment.
Oil quantity
Total quantity Clutch lever play
1.20 L (1.27 US qt, 1.06 Imp.qt) No 10.0–15.0 mm (0.39–0.59 in)
filter element change
1.00 L (1.06 US qt, 0.88 Imp.qt) With
filter element change
1.10 L (1.16 US qt, 0.97 Imp.qt)

8. Install:
• Oil tank cap
9. Start the engine, warm it up for several minutes, and
then turn it off.
10. Review:
• Motor
(looking for leaks)
11. Review: 2. Adjustment:
• Oil level • Clutch cable play
Refer to "CHECKING THE ENGINE OIL
LEVEL" on page 3-9. ▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
12. Review: Handlebar side
• Engine oil pressure to. Slide back the rubber cover "1"
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust b. Loosen locknut "2"
to. Slightly loosen the oil check screw "1". c. Turn adjusting nut "3" in direction "a" or "b" until
the specified play is obtained in the clutch cable.

Address "to"
Increase clutch cable play. Address "b"

Reduces clutch cable play.

1

b. Start the engine and keep it idling until oil starts to

come out of the oil check screw. If no oil comes out
after one minute, stop the engine so that it does not

drowned.
c. Check the engine oil passages, oil filter element, and
oil pump for damage or leaks. See "OIL PUMP" on
page 5-51.
d. Tighten the locknut.
d. Start the engine after troubleshooting and recheck and. Slide the rubber cap to its original position.
the oil pressure. TIP
If clutch cable play cannot be reached on the cable side
and. Tighten the oil check screw to the specified of the handlebar, use the adjusting nut at the end of the
torque. motor.

Oil check screw 7 Nm (0.7 mkg, ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5.1 ftlb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

to

3-11
 MOTOR

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
Motor side
to. Loosen locknut "1". 1
b. Turn adjusting nut "2" in direction "a" or "b" until the
specified throttle cable play is obtained.

Address "to"
Increase clutch cable play. Address "b"

Reduces clutch cable play.

3. Clean:
• Air filter element “1”
Apply compressed air to the outer side of the
air filter element.

2 1
1
to
b

c. Tighten the locknut.

Locknut
9 Nm (0.9 mkg, 6.5 ftlb) 4. Check:
• Air filter element Damaged
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ → Replace.
EAS20921 5. Install:
CLEANING THE AIR FILTER • Air filter element
TIP________________________________________ • Air filter housing cover (together with
gaskets)
There is a "1" check hose at the bottom of the air filter ECA54B1017

housing. If dust and / or water collects on this hose, ATTENTION ____________________________________

clean the air filter element and filter housing. Never operate the engine without the air filter in
place. Unfiltered air causes rapid wear on parts and
can damage the engine.
Running the engine without the air cleaner
element can also affect throttle timing, causing
poor engine performance and possible
1 overheating.

TIP __________________________________________
Make sure that the air filter is properly seated in the
filter housing.

6. Install:
• Left side cover
1. Remove:
Refer to "GENERAL CHASSIS" on page 4-
• Left side cover 1.
See "GENERAL CHASSIS" on page
4-1. EAS54B1011

2. Remove: CHECKING THE CARBURETOR GASKET AND AIR FILTER

• Air filter housing bracket "1" HOUSING GASKET
• Air filter element 1. Check:
• Union (gasket) of carburettor “1”

3-12
 MOTOR

• Air filter housing joint “2” Cracks / Damages

→ Replace. Exhaust pipe nut 15 Nm (1.5
mkg, 11 ftlb) Muffler bolt
1
20 Nm (2.0 mkg, 1.4 ftlb)

2
1

2
4 3
EAS21050

CHECKING THE CYLINDER

HEAD BREATHER HOSE
1. Remove:
• Right side cover EAS54B1012

See "OVERALL CHASSIS" on page 4-1. CHECKING THE FUEL VALVE FILTER

2. Check: 1. Remove:
• Cylinder head breather hose "1" Cracks / • Fuel valve tap filter cap “1”
Damages → Replace.
Loose connection → Connect properly. • Fuel valve filter
ECA14920
• O-ring
ATTENTION __________________________________ ▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust

Make sure the cylinder head breather hose is to. Turn the fuel valve to "OFF".
correctly guided. b. Remove the filter cap from the fuel valve

1
1

c. Drain the fuel

3. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Right side cover 2. Clean:
See "GENERAL CHASSIS" on page • Fuel valve filter
4-1.
EAS21080

EXHAUST SYSTEM CHECK

1. Check:
• Silencer "1"
Cracks / Damages → Replace.
• Exhaust pipe gasket "2"
Exhaust gas leaks → Replace.
2. Check: 3. Check:
• Torque • Damaged fuel valve filter →
• Exhaust pipe nuts "3" Replace.
• Muffler screw “4 '”

3-13
 MOTOR

4. Install:
• O-ring New
• Fuel valve filter
• Fuel valve filter cap

• Fuel valve cap 5 Nm (0.5 m · kg,

3.6 ft · lb)

3-14
 CHASSIS

EAS21140
TIP ________________________________________
CHASSIS
If the specified free play of the brake handle on the
EAS54B1068
handlebar is not reached at the end of the brake cable,
FRONT DRUM BRAKE ADJUSTMENT (SZ16 / SZ16X)
use the adjusting nut on the side of the wheel.

1. Check:
• Brake lever play "a" ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Adjustment.
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust

Play in the brake lever. Wheel side

10.0–15.0 mm (0.39–0.59 in) to. Turn adjusting nut "1" in direction "a" or "b" until
the specified brake lever play is obtained.

Address "to"
Increase brake lever play. Address "b"

to Reduce brake play.

1
2. Adjustment:
to
• Brake lever play

▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust b
Handlebar side
to. Slide back the rubber cover "1" ECA54B1004

b. Loosen locknut "2" ATTENTION __________________________________

c. Turn adjusting screw "3" in direction "a" or "b" After adjusting the brake lever play, make sure
until the specified brake lever play is obtained. there is no resistance from the brakes.

Address "to" ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Increase the play of the front brake lever. EAS21220

ADJUSTING THE REAR DRUM BRAKE

Address "b" 1. Check:
Increase the play of the handle of the • Brake pedal play "a"
Brake. Out of specification → Adjustment.

Brake pedal play

20.0–30.0mm (0.79–1.18 in)
1
2
b

to

d. Tighten the locknut.

and. Slide the rubber cap to its original position.
ECA54B1004

ATTENTION
After adjusting the brake lever play, make sure 2. Adjustment:
there is no resistance from the brakes. Brake pedal play

3-14
 CHASSIS

▼ humana ghetto bust bust bust bust bust bust bust bust bust
to. Turn the brake rod adjusting nut "1" in
direction “a” or “b” until obtaining the set of the to
Brake

Address "to"
Increase brake pedal play. Address "b"

Reduce brake pedal play.

EWA13090

WARNING
• Use only designated brake fluid. Other brake
fluids can cause rubber seals to deteriorate,
causing leaks or poor brake performance.

to • Refill with the same type of brake fluid that is

already in the system. Mixing brake fluids can
result in a harmful chemical reaction, leading to
1 b poor brake performance.
ECA54B1018

ATTENTION • When refilling, be careful not to get water into

After adjusting the brake pedal free play, make sure the brake fluid reservoir. Water significantly
there is no resistance from the brake lowers the boiling point of brake fluid and can
brakes. result in vapor lock.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ECA13540

3. Adjustment: ATTENTION
• Rear brake light switch Refer to "ADJUSTING THE
Brake fluid can damage painted surfaces or plastic
REAR BRAKE LIGHT SWITCH" on page 3-16.
parts. Therefore, always wipe up spilled brake fluid
immediately.

TIP
EAS54B1062

CHECKING THE BRAKE FLUID LEVEL.

To ensure a correct reading of the brake fluid level,
(SZ16R) make sure the top of the brake fluid tank is
1. Place the vehicle on a flat surface. horizontal.
TIP
• Place the vehicle on the center leg.
• Make sure the vehicle is straight EAS54B1063

CHECKING THE FRONT BRAKE PADS

2. Check:
• Brake fluid level (SZ16R)
Below the minimum mark "a" → Add The following procedure applies to all brake
recommended brake fluid to the proper pads.
level. 1. Operate the brake.
2. Check:
Recommended liquid • Front brake pads
DOT 3 or 4 The wear indicator “a” has practically disappeared
→ Replace the pad set. Refer to “FRONT BRAKE
(SZ16R)” on page 4-28.

3-15
 CHASSIS

EAS54B1066

REVIEW OF THE REAR BRAKE SHOES.

1. Operate the brake.

2. Check:
• Shoe wear indicator “1” Reaches the wear limit at
mark “a” → Replace the shoes as a whole. Refer to
"REAR BRAKE" in

page 4-38.

to
EAS54B1064

CHECKING THE FRONT BRAKE HOSE 1

(SZ16R)
1. Check:
• Brake hose Cracks / damage / wear →
Replace.
2. Check:
• Brake hose holder EAS21330

Loose connection → Tighten the bracket screw. ADJUSTING THE REAR BRAKE LIGHT SWITCH
3. Hold the vehicle straight and apply the front
brake several times. TIP
4. Check: The rear brake light switch is operated by the movement
• Brake hose
of the brake pedal. The rear brake light switch is set
Liquid leakage → Replace the damaged
correctly when the brake light comes on when the brakes
hose.
take effect or just before.
Refer to “FRONT BRAKE (SZ16R)” on page 4-28.

EAS54B1065
1. Check:
CHECKING THE FRONT BRAKE SHOES • Operation time of the rear brake light Incorrect →
Adjust.
2. Adjustment:
(SZ16 / SZ16X)
1. Operate the brake. • Rear brake light operating time
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
2. Check:
to. Hold the main body “1” of the rear brake light switch so
• Shoe wear indicator “1” Reaches the wear limit at
that it does not move and turn the adjusting nut “2” in
mark “a” → Replace the shoes as a whole. Refer to
direction “a” or “b” until the light comes on at the
"FRONT BRAKE
proper time.

(SZ16 / SZ16X) "on page 4-23.

Address "to"
The brake light comes on earlier.
to
1 Address "b"
The brake light comes on afterwards.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-16
 CHASSIS

EAS54B1067
grip of the throttle grip.
BLEEDING THE HYDRAULIC BRAKE SYSTEM
h. Tighten the bleed screw and then release the
(SZ16R)
EWA13100
brake knob.
i. Repeat steps (e) through (h) until all brake fluid
WARNING____________________________ bubbles have disappeared in the plastic hose.

Bleed the hydraulic brake system whenever:

j. Tighten the bleed screw to specification.

• The system is disassembled.

Bleed screw
• A brake hose becomes loose, disconnected or
14 Nm (1.4 mkg, 10 ftlb)
replaced.
• The brake fluid level is low.
k. Fill the brake fluid reservoir to the proper level with the
• The brake operation is faulty.
recommended brake fluid.
TIP __________________________________________ Refer to "CHECKING THE BRAKE FLUID LEVEL (SZ16R)"
• Be careful not to spill brake fluid or allow the brake on page 3-15.
EWA13110

master cylinder tank to get too full.

WARNING ______________________________

• When bleeding the hydraulic brake system, make After bleeding the hydraulic brake system,
sure that there is always enough brake fluid check the operation of the brakes.
before applying the brakes. Ignoring this ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
precaution could allow air to enter the brake EAS21420

system, considerably lengthening the bleeding ADJUSTING DRIVE CHAIN PLAY

process.
TIP _________________________________________
• If bleeding becomes difficult, it may be necessary to
Drive chain slack should be checked at the tightest
let the brake fluid settle for a few hours. Repeat the
point in the chain.
purge procedure when the bubbles in the hose have
disappeared. ECA13550

ATTENTION ___________________________________
A chain that is too tight will overload the engine and
1. Purge: other vital parts, and one that is too loose can skip
• Hydraulic brake system and damage the swingarm or cause an accident.
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust Therefore, keep the chain play within the specified
to. Fill the brake fluid reservoir to the proper level limits.
with brake fluid
1. Place the vehicle on a flat surface.
recommended. EWA13120

b. Install the master cylinder tank diaphragm. WARNING __________________________

Firmly support the vehicle so there is no danger of
c. Connect a clear plastic hose "1" tightly to the it falling over.
bleed screw "2".
TIP __________________________________________
Position the vehicle on the center leg so that the rear
wheel is elevated.
2
2. Spin the rear wheel several times and find the tightest
position on the chain.
1 3. Check:
• Drive chain play “a” Out of specification →
Adjustment.
d. Place the other end of the hose in a container.
Chain play
and. Slowly apply the brake lever several times. 40.0–50.0 mm (1.57–1.97 in)

F. Pull the brake lever fully without releasing it.

g. Loosen the bleed screw.

TIP
Loosening the bleeder screw will release the pressure
and make the brake knob contact the

3-17
 CHASSIS

Chain puller lock nut 7 Nm (0.7 mkg, 5.1

ftlb)

i. Tighten the wheel axle nut to specification

Wheel axle nut

90 Nm (9.0 mkg, 65 ftlb)

j. Install the cotter pin.

k. Tighten the brake torque rod nut to specification.
4. Adjustment:
• Chain play
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
Brake Torque Bar Nut
to. Loosen the brake rod adjusting nut "1"
19 Nm (1.9 mkg, 13 ftlb)
b. Remove cotter pin “2”.
c. Loosen the brake torque rod nut “3”.
l. Install the cotter pin.
d. Remove cotter pin “4”.
and. Loosen the wheel axle nut “5”. WARNING____________________________
F. Loosen both chain puller locknuts “6”.
Always use a new safety pin.

g. Turn both puller adjusting nuts “7” in direction “a” or “b” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
until play is reached. 5. Adjustment:
specified from the string. • Brake pedal play
See "ADJUSTING THE REAR DRUM BRAKE" on page
Address "to" 3-14.
The chain slack is tightened. EAS21450

Address "b" DRIVE CHAIN LUBRICATION

Chain slack is loose.
The transmission chain consists of many
interacting parts. If the chain is not maintained
67 4 5 properly, it will wear out quickly. Therefore, the
drive chain must be maintained, especially when
to
the vehicle is used in dusty areas.

b Use only kerosene to clean the drive chain. Dry the

c drive chain with a rag and carefully lubricate it with
1 engine oil or chain lubricant that is suitable for chains
2 3 without O-rings.

Recommended lubricant Engine oil or

chain lubricant suitable for chains
c without O-rings

to
EAS21510

CHECK AND ADJUSTMENT OF THE STEERING

b COLUMN
1. Place the vehicle on a flat surface.
6 EWA13120

7 WARNING____________________________
Support the vehicle well so that there is no danger
TIP
of it falling over.
To maintain proper wheel alignment, adjust both
sides "c" evenly. TIP
Place the vehicle on a suitable stand so that the
h. Tighten both chain puller nuts to specification. front wheel is elevated.

3-18
 CHASSIS

2. Check:
• Steering column
Grab the bottom of the front fork legs and
gently rock the fork.

Binding / loose → Adjust the printhead 5

address.

c. Loosen the lower ring nut "4" completely, and

then tighten it to specification with a steering
nut wrench.

EWA13140

3. Remove: WARNING ________________________

• Upper Clamp Do not overtighten the lower ring nut.
Refer to "STEERING HEAD" on page 4-55.

4. Adjustment:
Lower Ring Nut (Final Torque)
• Steering column
▼ humana ghetto bondage bust bust bust bust bust bust bust bust bust
to. Remove washer "1", upper ring nut "2", and 22 Nm (2.2 m kg, 16 ft lb)
rubber washer "3".
d. Check that the steering head is not loose or stuck by
turning the front fork all the way in both directions. If
any jamming is felt, remove the lower clamp and
check the upper and lower bearings. Refer to
"STEERING HEAD" on page 4-55.

and. Install the rubber washer "3".

f Install the upper ring nut "2".
g. Finger tighten the top ring nut, then align the slots on
both ring nuts. If necessary, hold the lower nut and
b. Tighten the lower area nut “4” with a tighten the upper nut until the two slots line up.
wrench for steering nut “5”.

Steering nut wrench YSST-721 h. Install lock washer "1"

TIP __________________________________________
Make sure the edges of the lock washers “a” are
Lower Ring Nut (Initial Torque)
properly seated in
the ring nut slots "b"
33 Nm (3.3 m kg, 24 ft lb)

TIP
Set the torque wrench at a right angle to the
wrench on the steering nut.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Install:
• Upper Clamp
Refer to “HEAD HEAD on page

3-19
 CHASSIS

EAS21530
• Tire pressure should be adjusted according to total
CHECKING THE FRONT FORK
weight (including cargo, rider, passengers, and
1. Place the vehicle on a flat surface.
EWA13120
accessories) and anticipated driving speed.
WARNING____________________________
Firmly support the vehicle so there is no danger of it • Operating an overloaded vehicle could cause
falling over. tire damage, accident or injury.

2. Check: NEVER OVERLOAD THE VEHICLE.

• Inner tube
Damaged / Scratched → Replace.
• Oil packing Tire air pressure (measured on
Oil leak → Change. cold tires):
3. Hold the vehicle straight and apply the front Forwards
brake. 200 kPa (2.00 kgf / cm², 28 psi)
4. Check: Rear
• Front Fork Operation Push the Handlebar down 225 kPa (2.25 kgf / cm², 33 psi)
hard several times and check if the front fork (Total weight of rider, passenger, cargo and
rebounds smoothly. accessories)

Rough movement → Repair. Refer to “FRONT

EWA13190

WARNING_____________________________
FORK” on page 4-47.
It is dangerous to drive with a worn tire. When the
tire tread reaches the wear limit, change the tire
immediately.

2. Check:
• Tire surfaces Damage / wear → Change
the tire.

EAS21660

TIRE CHECK
The following procedure applies to both tires.

1. Check:
• Tire pressure
Out of specification → Regulate.
1. Depth of rim tread
2. Side of the rim
3. Wear indicator

Wear limit (front)

1.0 mm
Wear limit (rear)
1.0 mm

EWA14080

WARNING___________________________
• Do not use a tireless or tubeless wheel on a wheel
EWA54B1006 designed only for tires with tires to avoid tire
WARNING__________________________ failure and personal injury.
• The tire pressure should only be checked and
regulated when the tire temperature is equal to • When using a rim with tires, be sure to install the
the ambient temperature. correct tire.

3-20
 CHASSIS

• Always replace a new rim and a new tire as a

set.
• To avoid pinching the tire, make sure the wheel
rim band and tire are centered in the wheel
groove.

• It is not recommended to use patches on a flat tire.

If it is absolutely necessary to do so, be very careful
and replace the tire as soon as possible with a good
quality replacement.

TIP ___________________________________________
Tire wheel Rim with tire
For tires with a "1" direction of rotation mark:
only
Wheel without tire Rim with or without
tire • Install the rim with the mark pointing in the
direction of wheel rotation.
EWA14090

WARNING___________________________ • Align the mark "2" with the valve installation point.
After extensive testing, the tires listed below have
been approved by Yamaha Motor Co. Ltd. for this
model. The front and rear tires must always be of the
same brand and of the same design. No guarantee can
be given regarding handling characteristics if a
combination of tires other than those approved by
Yamaha is used for this vehicle.

Front rim
Size EAS21670

2.75–17 41P 4PR CHECKING THE WHEELS

Manufacturer / model The following procedure applies to both wheels.
TVS / ATT525
1. Check:
• Wheel
Back tire
Damaged / runout → Replace.
Size
100 / 90–17 55P EWA13260

Manufacturer / model WARNING_____________________________

TVS / ATT750 Never attempt to repair the wheels

EWA54B1007
TIP __________________________________________
WARNING______________________________
After changing or replacing a tire or wheel, always
• New tires have relatively low grip on the road surface
balance the wheels.
until they show slight wear. Therefore, approximately
100 km should be traveled at normal speed before EAS21690

driving at high speeds. INSPECTION AND LUBRICATION OF CABLES

The following procedure applies to all internal and
external cables.
• After the tire has been repaired or changed, be sure
EWA13270

WARNING_____________________________
to tighten the tire air valve stem nut "1" to the
A damaged cable on the outside can cause the
specification. cable to corrode and interfere with its
movement. Replace damaged covers and cables
as soon as possible.

3-21
 CHASSIS

1. Check: EAS21720

LUBRICATING THE SIDE LEG

• Cable sheath
Lubricate the metal-to-metal contact moving parts of
Damaged → Replace.
the side leg.
2. Check:
• Cable operation Rough movement
Recommended lubricant
→ Lubricate.
Lithium soap-based grease
Recommended lubricant
Lithium soap-based grease
EAS21730

LUBRICATING THE SIDE LEG

Lubricate moving parts with metal contact
TIP _ against metal of the center leg.
Hold up the end of the cable and pour a few drops of oil
into the sheath or use a lubrication device. Recommended lubricant
Lithium soap-based grease

EAS21740
EAS54B1013

CLUTCH HANDLE LUBRICATION REAR SUSPENSION LUBRICATION

Lubricate the metal-to-metal contact moving parts of
Lubricate the metal-to-metal contact moving parts of the rear suspension.
the handle.
Recommended lubricant
Recommended lubricant Lithium soap-based grease
Lithium soap-based grease

EAS54B1014

BRAKE HANDLE LUBRICATION (SZ16 / SZ16X)

Lubricate the metal-to-metal contact moving parts of

the handle.

Recommended lubricant
Lithium soap-based grease

EAS54B1015

BRAKE HANDLE LUBRICATION (SZ16R)

Lubricate the metal-to-metal contact moving parts of

the handle.

Recommended lubricant
Silicone grease

EAS54B1016

SHIFT PEDAL LUBRICATION

Lubricate the metal-to-metal contact moving parts of
the pedal.

Recommended lubricant
Lithium soap-based grease

EAS54B1017

BRAKE PEDAL LUBRICATION

Lubricate moving parts with metal contact
against metal of the handle.

Recommended lubricant
Lithium soap-based grease

3-22
 ELECTRIC SYSTEM

EAS21750 EWA13320

ELECTRIC SYSTEM WARNING __________________________

Since the streetlight bulb gets extremely hot, keep
flammable products and your hands away from the
EAS21760

CHECKING AND CHARGING THE BATTERY

bulb until it has cooled down.
Refer to "ELECTRICAL COMPONENTS" on page 7-41.

5. Install:
EAS21770

CHECKING THE FUSE • Streetlight bulb New

Refer to "ELECTRICAL COMPONENTS" on page 7-41. Secure the new streetlight bulb with the bulb
holder.
ECA13690

EAS21780 ATTENTION _________________________________

CHANGING THE LAMP BULB Avoid touching the glass part of the headlight bulb
1. Remove: to keep it free of oil, otherwise the transparency of
• Lamp assembly "1" the glass, the brightness of the bulb and the life of
See "GENERAL CHASSIS" on page the lamp will be adversely affected. If the headlight
4-1. bulb becomes dirty, clean it thoroughly with a cloth
dampened with alcohol or thinner.

1
6. Install:
• Bulb coverage
7. Connect:
• Lamp connection
8. Install:
• Lamp assembly

EAS21800

2. Disconnect: LAMP BEAM ADJUSTMENT

• Lamp connection "2" 1. Loosen:
3. Remove: • Lamppost adjustment screw “1”
• Bulb cover "3" 2. Adjustment:
• Streetlight beam (vertically)
2 Move the lamp assembly "2" in the direction
3 "A" or "b".

Address "to"
The beam of the lighthouse
rises. Address "b"
The headlight beam is lowered.

4. Remove: b
• Lamp bulb "4"
2
1
4

to

3. Tighten:
• Lamppost adjusting screw

3-23
 ELECTRIC SYSTEM

2. Press the bulb "2" and rotate it clockwise.

• Lamppost adjusting screw 7 Nm
(0.7 m · kg, 5.1 ft · lb)

EAS54B1018

REPLACING THE TAILLIGHT / BRAKE BULB

1. Remove:
• Seat
See "OVERALL CHASSIS" on page 4-1.
1
2. Remove:
• Brake / tail light bracket “1”
2

3. Insert a new bulb into the socket, push it in, and

then turn it clockwise until it stops.

4. Install:
• Directional light lens

3. Press the bulb "2" and rotate it clockwise.

2
1

4. Insert a new bulb into the holder, push it in, and

then turn it clockwise until it stops.

5. Install:
• Brake / tail light bracket
6. Install:
• Seat
See "GENERAL CHASSIS" on page
4-1.

EAS54B1019

CHANGING THE DIRECTIONAL LIGHT

BULB
1. Remove:
• Directional light lens "1"

3-24
 ELECTRIC SYSTEM

3-25
n

CHASSIS

CHASSIS SPECIFICATIONS ............................................... ..............................4-1

INSTALLING THE SIDE COVERS ............................................. .......... 4-3 AIR FILTER
INSTALLATION., .............................. .................................. 4-6

FRONT WHEEL (SZ16 / SZ16X) ........................................... ................................4-7

REMOVE THE FRONT WHEEL .............................................. .......................... 4-9 REMOVING THE
FRONT WHEEL ................ ............................................ 4-9 REVIEW OF THE FRONT
WHEEL................................................ ............... 4-9 FRONT WHEEL
ASSEMBLY ........................... ............................. 4-9
INSTALLING THE FRONT WHEEL (DRUM) ................................... 4-10

FRONT WHEEL (SZR16) ............................................. ....................................4-12

REMOVE THE FRONT WHEEL .............................................. ........................ 4-14 FRONT WHEEL
DISASSEMBLY .................. ................................. 4-14 CHECKING THE FRONT
WHEEL ......... .................................................. ..4-14 SPEEDOMETER GEAR UNIT CHECK ... ...........
4-15 FRONT WHEEL ASSEMBLY ................. .................................... 4-15 FRONT WHEEL STATIC
BALANCE ADJUSTMENT ... ................ 4-15 INSTALLING THE FRONT WHEEL

4
(DISC) ....................... ................ 4-16

REAR WHEEL ................................................ .................................................. ...4-18

REMOVE THE REAR WHEEL (DRUM) ........................................... ..... 4-21 CHECKING THE REAR
WHEEL ..................................... ............................ 4-21 CHECKING THE REAR WHEEL
HUB ............ .................................. 4-21 CHECKING AND CHANGING THE OUTPUT SPROCKET
OF THE REAR WHEEL .. ..... 4-21 REAR WHEEL (DRUM) INSTALLATION .................................. .....
4-22

FRONT BRAKE (SZ16 / SZ16X) ........................................... ..............................4-23

BRAKE SHOE PLATE DISASSEMBLY .......................... 4-25 CHECKING THE FRONT BRAKE
SHOE ..... ................................ 4-25 FRONT BRAKE SHOE PLATE ASSEMBLY ..... ...... 4-25 FRONT
BRAKE DRUM WEAR LIMIT
CHECK ............................... .................................................. ....................... 4-26

FRONT BRAKE (SZR16) ............................................. .....................................4-28

INTRODUCTION................................................. .................................................4 -32 CHECKING
THE FRONT BRAKE DISC .......................................... .4-32 CHANGING THE FRONT BRAKE
SHOES ...................................... 4 -33 REMOVING THE FRONT BRAKE CALIPER ..............................
4-34 CHECKING THE FRONT BRAKE CALIPER. ................................ 4-34 FRONT BRAKE CALIPER
ASSEMBLY ........ ......................... 4-34 FRONT BRAKE CALIPER INSTALLATION ............... ............
4-35 REMOVING THE FRONT BRAKE MASTER CYLINDER ................ 4-36 CHECKING THE FRONT
BRAKE MASTER CYLINDER .. ................. 4-36 FRONT BRAKE MASTER CYLINDER
ASSEMBLY ...................4-36 INSTALLING THE FRONT BRAKE MASTER CYLINDER ............ 4-36
BACK BRAKE................................................ ...........................................4-38
REAR BRAKE SHOE CHECK ................................. 4-39 SHOE PLATE ASSEMBLY BRAKE
DRUM ................................. 4-39 REAR BRAKE DRUM WEAR LIMIT
CHECK ... .................................................. ............ ...................................... .4-40

HANDLEBAR................................................. .................................................. .............4-42

DISASSEMBLY OF THE HANDLEBAR ............................................... .............................. 4-44
CHECKING THE HANDLEBAR .............. .................................................. ............. 4-44 HANDLEBAR
INSTALLATION ............................... ........................................... 4-44

FRONT FORK ................................................ ....................................4-47

REMOVING THE FRONT FORK RODS ..................... 4-50 FRONT FORK
DISASSEMBLY ................ ............................... 4-50 CHECKING THE FRONT FORK BARS ........ ....
4-51 FRONT FORK ROD ASSEMBLY .................... 4-51 FRONT FORK ROD
INSTALLATION .... ........... 4-53

HEAD OF MANAGEMENT ............................................... ........................................4-55

DISASSEMBLY OF THE LOWER BRACKET .......... .................................... .4-59 REVIEW OF THE
STEERING COLUMN ........................................ .... 4-59 STEERING COLUMN
INSTALLATION ..................................... ...... 4-59

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM…… .. ……… .4-61

REMOVING THE REAR SHOCK ABSORBERS AND SWINGARM ............. 4-62 CHECKING THE
REAR SHOCK ABSORBER ASSEMBLY .............. 4-62 CHECKING THE
SWINGARM .. .................................................. ...................... 4-62 SWINGARM
INSTALLATION ...................... .............................................. 4-62 INSTALLATION OF THE REAR
SHOCK ABSORBER ASSEMBLY ......... 4-63

DRIVE CHAIN ............................................... .....................................4-64

CHAIN CHAIN CHECK ............................................ .... 4-65 DRIVE CHAIN
INSTALLATION ..................................... .... 4-66