ILLUSTRATED SYMBOLS (Refer to the illustration) Mustrated symbols @ to @ are designed as ‘thumb tabs to indicate the chapter's number and content g eee information © Troubleshooting Ilstrated symbols ( to (® are used to identify the specifications appearing in the text. Filing fiid Lubreant Special tool Tightening ‘Wear limit, clearance Engine speed 2,V, A Illustrated symbols (D to @ in the exploded dia- ‘gram indicate grade of lubricant and location of lubrication point. ‘Apply engine oil ‘Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium-soap base grease ‘Apply molybdenum disulfide grease ‘Apply locking agent (LOCTITES)INDEX GENERAL INFORMATION 3 SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ADJ ENGINE OVERHAUL aoe COOLING SYSTEM aa CARBURETION a i CHASSIS le ELECTRICAL a ? | TROUBLESHOOTINGCONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VICHCLE IDENTIFICATION NUMBER : ENGINE SERIAL NUMBER . 2 . IMPORTANT INFORMATION . am PREPARATION FOR REMOVAL AND DISASSEMBLY ... ‘ALL REPLACEMENT PARTS GASKETS, OIL SEALS, AND O-RINGS .... saves LOCK WASHERS/PLATES AND COTTER PINS ........ BEARINGS AND OIL SEALS ..... CIRCLIPS ‘SPECIAL TOOLS za FOR TUNE UP ......... FOR ENGINE SERVICE FOR CHASSIS SERVICE . FOR ELECTRICAL COMPONENTS. CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS .........-...---2.00000-5 eneeesZel MAINTENANCE SPECIFICATIONS ......... ENGINE . CHASSIS........ : ELECTRICAL... GENERAL TORQUE SPECIFICATIONS... DEFINITION OF UNITS .... sig EAE LUBRICATION POINTS AND LUBRICANT TYPE. COOLANT FLOW CHART ...........- sie ese encod vecameninceine Oe CABLE ROUTING... zCHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION... 34 PERIODIC MAINTENANCE/LUBRICATION ......... ed ENGINE wee : cS IDLE SPEED ADJUSTMENT “ 33 THROTTLE CABLE FREE PLAY ADJUSTMENT 34 AUTOLUBE PUMP CABLE ADJUSTMENT . AUTOLUBE PUMP STROKE ADJUSTMENT AUTOLUBE PUMP AIR BLEEDING SPARK PLUG INSPECTION . IGNITION TIMING CHECK ENGINE OIL LEVEL INSPECTION, ‘TRANSMISSION OIL LEVEL INSPECTION . ‘TRANSMISSION OIL REPLACEMENT CLUTCH ADJUSTMENT . AIR FILTER CLEANING .......... CARBURETOR JOINT INSPECTION FUEL LINE INSPECTION 4 EXHAUST SYSTEM INSPECTION . COOLANT LEVEL INSPECTION ...... COOLANT REPLACEMENT COOLING SYSTEM INSPECTION .. CHASSIS : - FRONT BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT. . BRAKE SHOE INSPECTION . BRAKE LIGHT SWITCH ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN LUBRICATION... STEERING HEAD ADJUSTMENT TIRE INSPECTION WHEEL INSPECTION SPOKES INSPECTION AND TIGHTENING. CABLE INSPECTION AND LUBRICATION. LEVER AND PEDAL LUBRICATION ........ SIDESTAND LUBRICATION ELECTRICAL snot BATTERY INSPECTION . . FUSE INSPECTION HEADLIGHT BEAM ADJUSTMENT HEADLIGHT REPLACEMENT ....CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL COOLANT . TRANSMISSION OIL . FUEL TANK . EXHAUST PIPE . CARBURETOR AUTOLUBE PUMP CABLE AND HOSE « CLUTCH CABLE ........22.5 TACHOMETER CABLE....... LEADS AND HOSES ..... BATTERY LEAD DRIVE CHAIN.........- ENGINE REMOVAL ENGINE DISASSEMBLY ........ CYLINDER HEAD, CYLINDER AND PISTON CLUTCH AND PRIMARY DRIVE GEAR CLUTCH PUSH LEVER......... “ KICK AXLE AND KICK IDLE GEAR... SHIFT SHAFT .... a C.D.1. MAGNETO. z CRANKCASE ..........- SHIFTER AND TRANSMISSION - CRANKSHAFT ..... INSPECTION AND REPAIR ... CYLINDER HEAD....... CYLINDER AND PISTON PISTON RINGS : PISTON PIN AND BEARING. ... CLUTCH ..... . PRIMARY DRIVE... TRANSMISSION AND SHIFTER ... KICK STARTER ..........--. SHIFT SHAFT AUTOLUBE PUMP . CRANKSHAFT . BEARINGS AND OIL SEALS . CRANKCASE .......ENGINE ASSEMBLY AND ADJUSTMENT ....... CRANKSHAFT TRANSMISSION . CRANKCASE C.D.I. MAGNETO SHIFT SHAFT KICK AXLE AND KICK IDLE GEAR CLUTCH PUSH LEVER CLUTCH AND PRIMARY DRIVE GEAR ...... CYLINDER HEAD, CYLINDER AND PISTON ... REMOUNTING ENGINE .. . CHAPTER 5. COOLING SYSTEM WATER PUMP . REMOVAL... INSPECTION INSTALLATION THERMOSTATIC VALVE AND RADIATOR. . REMOVAL... INSPECTION... INSTALLATION scsi costae voeaoseeneniess sm CHAPTER 6. CARBURETION CARBURETOR REMOVAL... DISASSEMBLY INSPECTION.......... ASSEMBLY. INSTALLATION .. ADJUSTMENT . REED VALVE......... wwe REMOVAL... cs scscsecseseoes . 6-10 ICHAS| INSPECTION ...... 6-10 INSTALLATION 6-11 CHAPTER 7. CHASSIS FRONT WHEEL REMOVAL DISASSEMBLY ..... INSPECTION......2..... INSTALLATION ...... .REAR WHEEL REMOVAL... INSPECTION . INSTALLATION ..... FRONT FORK ..... REMOVAL... DISASSEMBLY . INSPECTION ASSEMBLY ..... INSTALLATION . STEERING HEAD AND HANDLEBAR... REMOVAL.........- INSPECTION........ INSTALLATION REAR SHOCK ABSORBER AND SWINGARM HANDLING NOTES NOTES ON DISPOSAL REMOVAL.......... . ‘ INSPECTION ceveseeeees INSTALLATION DRIVE CHAIN AND SPROCKETS REMOVAL........ INSPECTION ....... INSTALLATION . CHAPTER 8. ELECTRICAL DT5OU CIRCUIT DIAGRAM . COLOR CODE.. ELECTRICAL COMPONENTS......... IGNITION AND STARTING SYSTEM ...... rs CIRCUIT DIAGRAM .. ceccsseeeees IGNITION CONTROL CIRCUIT OPERATION .. ‘TROUBLESHOOTING .. CHARGING SYSTEM .......... CIRCUIT DIAGRAM .........- ‘TROUBLESHOOTING 819 LIGHTING SYSTEM............ CIRCUIT DIAGRAM .... TROUBLESHOOTING .SIGNAL SYSTEM. CIRCUIT DIAGRAM TROUBLESHOOTING ..... . SIGNAL SYSTEM TEST AND CHECK COOLING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING .... METER ASSEMBLY REMOVAL .. segeegens INSTALLATION ........2000cecreeeeeee CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING FUEL SYSTEM... .-..0ecceceeeees ELECTRICAL SYSTEM COMPRESSION SYSTEM . POOR IDLE SPEED PERFORMANCE ... POOR IDLE SPEED PERFORMANCE. .. POOR MEDIUM AND HIGH SPEED PERFORMANCE. FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM FAULTY GEAR SHIFTING ............2...- HARD SHIFTING .............. ast CHANGE PEDAL DOES NOT MOVE JUMP-OUT GEAR... 2. ee ecco CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING CLUTCH DRAGGING . IMPROPER KICKING . SLIPPING HARD KICKING .. : KICK CRANK NOT RETURNING .. FAULTY BRAKE POOR BRAKING EFFECT... FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION... . OIL LEAKAGE. . MALFUNCTION a vu m fy D. ch ENG | o ag ®|pemc8 oO Al ELEC $ | pon Ll] a elINSTABLE HANDLING ........ INSTABLE HANDLING FAULTY SIGNAL AND LIGHTING SYSTEM ............2.00.0066...9:11 HEADLIGHT DARK . seveseee secre OA BULB BURNT OUT..............- 911 FLASHER DOES NOT LIGHT .. o11 FLASHER KEEPS ON ...... 941 FLASHER WINKS SLOWER 912 FLASHER WINKS QUICKER............ ceceeseeeessA2 HORN IS INOPERATIVE. = S12 OVERHEATING OR OVER-COOLING ...........0020000:eeceee es 918 OVERHEATING .......-...-+ ceveteeeeteensereee DIB. OVER-COOLING........ . 913 DTS0U WIRING DIAGRAMMOTORCYCLE IDENTIFICATION GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER ‘The vehicle identification number (1) is stamped into the steering head pipe. NOTE: The vehicle identification number is used to iden tify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. MOTORCYCLE IDENTIFICATION ia Starting Serial Number: JYA3BKAO#JCOOO101 ENGINE SERIAL NUMBER The engine serial number (1)is stamped into the right side of the engine. NOTE: The first three digits of these numbers are for ‘model identifications; the remaining digits are the unit production number. Starting Serial Number: ‘3BK-000101 NOTE: Designs and specifications are subject to change without notice. WWGEN IMPORTANT INFORMATION | INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removing and disassembling, Use proper tools and cleani Refer to “SPECIAL TOOL.” 19 equipment. |. When disassembling the motorcycle, keep mated parts together. includes gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. ‘Mated parts must be reused as an assembly or replaced. + During the motorcycle disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly rein- stalled, 5. Keep away from fire.IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts forall replace- ments. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals and O-rings should be replaced when an engine is overhauled. All ‘gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings dur- ing reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/Plates () and cotter pins must be replaced when they are removed. Lock tabs) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) and oil seal(s) with their manufacturer's marks or numbers facing out- ward. (in other words, the stamped letters. must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip{s). Oil the bearings liberally when installing, © oitseal CAUTION: Do not use compressed air to spin the bear- ings dry. This causes damage to the bt surfaces. @ Bearing 13SPECIAL TOOLS GEN Oe) CIRCLIPS 1. All citclips should be inspected carefully be- fore reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip (1), make sure that the sharp-edged corner (2) is positioned op- posite to the thrust @) it receives. See the sectional view. @ Shatt SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage ‘caused by the use of improper tools or improvised ‘techniques. FOR TUNE UP 1. Fuel Level Gauge P/N. YM-01312-A, ‘This gauge is used to measure the fuel level the float chamber. 2. Engine Tachometer P/N. YU-08036 This tool is needed for detecting engine rpm. FOR ENGINE SERVICE 1. Universal Clutch Holder P/N. YM-91042 This tool is used to hold the clutch when loosen- ing oF tightening the clutch boss locknut.18 GEN speciaLToois | INFO |O™S| 2. Universal Rotor Holder ® PIN, YU-01235 Rotor Puller @ P/N, YM-OT These tool are used when loosening or tighten- ing the flywheel magneto securing bolt. 3. Crankcase Separating Tool « P/N, YU-01135 This tool is used to remove the crankshaft or separate the crankcase. 4. Crankshaft Installing Tool ® P/N. YU-90050 ROSE 6 var enamine ed) P/N. YU-90063 These tools are used to install the crankshaft. 6. Piston Pin Puller P/N. YU-01304 This tool is used to remove the piston pin. 6. Cooling System Tester P/N. YU-22460-01 This tester is needed for checking the cooling system.16 SPECIAL TOOLS 7. Adapter P/N. YU-33984 This tool is used for checking the radiator cap, FOR CHASSIS SERVICE 1. Ring Nut Wrench P/N, YU-33975 This tool is used to loosen and tighten the steer- ing ring nut. 2.TeHandle ....ceeceserseee ® P/N. YM-01326 Front Fork Cylinder Holder P/N. YM-01300-1 ‘These tools are used to loosen and tighten the front fork cylinder holding bolt. 3. Front Fork Seal Driver (Weight) .......@ P/N. YM-33963 Adapter ..... -® P/N. YM-33281 FOR ELECTRICAL COMPONENTS 1. Dynamic Coil Tester P/N. YM-34487 This tester is necessary for checking the ignition system components.SPECIAL TOOLS aN os 2. Pocket Tester P/N. YU-03112 This tester is invaluable for checking the electri- cal system.GENERAL SPECIFICATIONS _| SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model DTs0U ‘Model Code Number 3BK1 Vehicle Identification Number JYA3BKA0%JCO00101 Engine Serial Number 3BK-000101 Dimensions: Overall Length 1,960 mm (77.2 Overall Width 845 mm (33.3 in) Overall Height 1,100 mm (43.3 in) Seat Height 785 mm (30.9 in) ‘Wheel base 1,235 mm (48.6 in) Minimum Ground Clearance ‘265 mm (10.4 in) Basic Weight: With Oil and Full Fuel Tank 86 kg (189.2 Ib) Minimum Turning Radius: 2,000 mm (78.6 in} Engine: Engine Type Liquid cooled 2-stroke, gasoline Induction System Reed valve Cylinder Arrangement Single cylinder, Forward inclined Displacement 49.3 cm’ Borex Stroke 40.0% 39.2 mm (1.57 x 1.54 in) Compression Ratio 65:1 Starting System Kick starter Lubrication System Separate lubrication (Yamaha Autolube) Engine Oi Type Yamalube “2 or air-cooled 2-stroke engine il with "BIA certified for service TC-W". Capacity 1.3 (1.1 Imp at, 1.4 US at) Transmission Oil: Type Yamalube “4” (10W-30), SAE 10W30 type SE motor oil or “GL” gear oil Capacity: Periodic Oil Change 0.70 L (0.61 Imp gt, 0.74 US at) Total Amount 0.75 L (0.66 Imp qt, 0.79 US at) Coolant Capacity: Including All Routes 0.6 L (0.5 Imp at, 0.6 US at) Air Filter: | Type Wet element Fuel: Type Regular gasoline Fuel Tank Capacity: Full Amount 8.5 L (1.9 Imp gal, 2.2 US gal) Reserve Amount 2.0 L (0.4 Imp gal, 0.5 US gal) 24GENERAL speciFications |SPEC| 9 Carburetor: Type/Quantity VNNESS/1 pe. Manufacturer MIKUNI ‘Spark Plug: Type/Quantity BBES/1 pe. Manufacturer NGK Plug Gap 0.7~0.8 mm (0.028 ~ 0.032 in} Clutch: Type Wet, muttiple disc Transmission Type Constant mesh 6-speed Primary Reduction System Helical gear Primary Reduction Ratio 68/19 (3.579) Secondary Reduction System Chain drive Secondary Reduction Ratio 48/13 (3.692) Operation Left foot operation Gear Ratio: ‘Ist 39/12 (3.250) 2nd 34/16 (2.125) 3rd 31/20 (1.550) 4th 27122. (1.227) sth 26/25 (1.040) 6th 24/26 (0.823) Chassis: Frame Type Semi double cradle Caster Angle 28.33° Trail 98 mm (3.858 in) Tire: Type With tube Size: Front 2.50-19 4PR Rear 3.00-17 4PR Maximum Load* 71 kg (157 Ib) Cold Tire Pressure: Front Rear 0 kg (0 Ib) ~ Maximum Load* 130 kPa 130 kPa (1.3 kg/em?, 18 psi) (1.3 kg/em?, 18 psi) Brake: Front Brake Type Front Brake Operation Rear Brake Type Rear Brake Operation Drum brake Right hand operation Drum brake Right foot operation *Load is total weight of cargo, rider, passenger, and accessories. 22 _GENERAL SPECIFICATIONS Mode! DTS0U ‘Suspension: Front Suspension Type Rear Suspension Type Telescopic fork ‘Swingarm (Monocross suspension) ‘Shock Absorber: Front Shock Absorber Rear Shock Absorber Coil-air spring/Oil damper Coil and gas spring/Oil damper Wheel Travel: Front Wheel Travel 170 mm (6.7 in) Rear Wheel Travel 150 mm (5.9 in) Electrical: Ignition System col Generator System CDI magneto Battery: Type 6V4B-2A Capacity 6V4AH Headlight: Type Bulb type Bulb Wattage (Quantity): Headlight Tail/Brake Light Flasher Light Meter Light "NEUTRAL" Indicator Light “HIGH BEAM" Indicator Light “OIL” Indicator Light “TURN” Indicator Light 6V 25W/25W (1 pc.) 5.3W/25W (1 pc.) 6V 17W (4 pcs.) 6V 3W 22 pcs.) 6V 3W (1 pe.) 6V 3W (1 pc.) BV 3W (1 po.) 6V 3W (1 pc.) 23MAINTENANCE SPECIFICATIONS _| SPEC MAINTENANCE SPECIFICATIONS ENGINE Model DT50U Cylinder Head: * Warpage Limit 0.03 mm (0.0012 in) “Lines indicate straightedge measurement. = Cylinder: Bore Size 40.00 ~ 40.02 mm (1.575 ~ 1.576 in) Taper Limit | 0.05 mm (0.002 in) Out of Round Limit 0.01 mm (0.0004 in) Piston: Piston Size 39.94~40.00 mm (1.572~1.575 in} Measuring Point “a” Piston Off-Set Piston-to-Cylinder Clearance 5 mm (0.20 in) 0.2 mm (0.079 in} (0.030~0.035 mm (0.0012 ~ 0.0014 in) <0.1 mm (0.004 in)> Sectional Sketch End Gap (Installed) Side Clearance Top Ring Over Size 1st 40.25 mm (1.585 in) Over Size 2nd 40.50 mm (1.595 in) Piston Ring: Keystone type B=1.2 mm (0.047 in} T=1.6 mm (0.063 in) Plain type B=1.2 mm (0.047 in) T=1.6 mm (0.063 in} 0.15~0.30 mm (0.006~0.012 in) 0.15~0.30 mm (0.006~0.012 in) 0.03~0.05 mm (0.001 ~0.002 in) 0.03~0.07 mm (0.001 ~0.003 in) 24MAINTENANCE SPECIFICATIONS Crankshaft: Crank Width Runout Limit "B"” Big End Side Clearance “C’" ‘Small End Free Play ““D'" D. 8 coh al DTS0U 44.90~44.95 mm (1.768~ 1.770 in) 0.03 mm (0.0012 in) 0.20~0.70 mm (0.008 ~0.028 in) <1.0 mm (0.040 in) > 0.8~1.0 mm (0.031 ~0.040 in} Clutch: Friction Plate: Thickness. Quantity ‘Wear Limit Clutch Plate: Thickness Quantity Warpage Limit Clutch Spring: Free Length Quantity Minimum Free Length Clutch Release Method Push Rod Bending Limit 3.5 mm (0.138 in) 3 pes. 3.2 mm (0.126 in} 1.6 mm (0.063 in} 2 pes. 0.05 mm (0.002 in) 31.5 mm (1.240 in) 4 pes. 29.0 mm (1.14 in) Inner push, Cam push 0.15 mm (0.006 in) Transmission: Main Axle Runout Limit Drive Axle Runout Limit 0.02 mm (0.001 in) 0.02 mm (0.001 in) Shifter: Type Guide Bar Bending Limit Cam drum and guide bar 0.03 mm (0.0012 in) Kick Starter: Type Kick & mesh type Air Filter: Oil Grade Foam-Air-Filter oil or SAE 1OW30SE 26MAINTENANCE SPECIFICATIONS [ sPec | Carburetor: 1D. Mark wo Main Jet (Mig) | #100 Air Jet (As. | 62.5 Jet Needle-Position WN) | 411-3 Needle Jet J.) | D8 Cutaway (c.a.)]2.0 Pilot Outiet (P.0.) | 60.9 Pilot Jet #225 Air Screw 1-1/4 turns out Bypass 1 o14 Valve Seat Size (V8. | 61.2 Starter Jet (G.s.) | #30 Fuel Level (F.L.) | 0~1 mm (0~0.04 in) Float Height (F.H.) | 18~20 mm (0.71~0.79 in) Idling Speed 1,250~ 1,350 r/min Reed Valve: Valve Thickness Valve Stopper Height 0.15 mm (0.006 in) 7.0 mm (0.276 in} Valve Bending Limit 0.5 mm (0.02 in) Lubrication System: Autolube Pump: Color Code Brown Minimum Stroke 0.10~0.15 mm (0.004 ~ 0.006 in) Maximum Stroke Minimum Output Maximum Output Pulley Adjusting Mark 1.35~1.70 mm (0.053 ~0.067 in) 0.19~0.28 cm? per 200 strokes 2.59~3.26 cm’ per 200 strokes At idle Cooling System: Radiator Core Width Radiator Core Height Radiator Cap Opening Pressure Reservoir Tank Capacity Water Pump Type 107.6 mm (4.236 in} 180 mm (7.1 in) 16.0 mm (0.63 in) 75~105 kPa (0.75~1.05 kg/cm?, 10~14 psi) 0.38 L (0.33 Imp qt, 0.40 US qt) Single-suction centrifugal pump ‘Thermostatic Valve: Opening Temperature Full Open Temperature/Lift 63~67°C (146~ 153°F) 80°C (176°F)/7 mm (0.28 in) or more 26MAINTENANCE SPECIFICATIONS [sPEC| Tightening Torque: 27 Part to be tightened arty | Thread | Tahtenina trav | Remarks size | Nm |mekg] ftelb ‘Spark plug 1 = 25 | 25 | 18 Cylinder head and cylinder Nut 4 |max125| 32 | 3.2| 23 Stud bolt 4 |m8x1.25| 10 | 1.0 | 7.2 |Apply LOCTITE® C.D.1. magneto Nut 1 |M10x1.25] 50 | 5.0 | 36 Housing cover Bolt, screw a |mexto| 8 |os| 58 Radiator cover Screw 2 |msxos | 5 |05| 36 Joint pipe Screw 2 |mexto | 10 | 10 | 7.2 Oil pump Screw 2 |Msxo8 | 5 | 05/36 Intake manihold Bolt 4 |Mexto| 8 |o8| 58 Exhaust pipe Stud bolt 2 |msx125] 8 |os| 58 Nut 2 |Mex125) 18 | 18) 13 Crankcase Screw 9 |mM6x10] 8 | o8|58 Plate (Crankcase) Screw 1 | M6x1.0] 10 | 1.0 | 7.2 Transmission oil drain bot 1 Jmt2x1.5 | 20 | 20] 14 Neutral switch 1 - 5/05 | 36 Crankcase cover (Right) ‘Screw 5 |mexi0| 5 |05|36 Crankcase cover (Left) Screw a |m6xio | 10 | 1.0 | 7.2 il pump cover Screw 2-|me6xto | 10 | 1.0 | 7.2 Kickcrank boss Bolt 1 [Mtoxt.0 | 12 | 12) 87 Primary drive gear Nut 1 |M12x1.0 65 | 47 Clutch housing Nut 1 [M12x1.0 65 | 47 Pressure plate (Clutch) Bolt 4 |mexio| 6 | 06 | 42 Plate (Bearing) Screw 1 |M6x1.0 | 10 | 1.0 | 7.2 Tachometer cable Screw M 6x10 1.0 | 7.2MAINTENANCE sPEciFicaTIons | SPEC] Tightening Torque: ; Part to be tightened Thread | Tihioning see Remarks size | Nm |mekg] feb ‘Stopper lever (Shift cam) Bott mexto | 14] 14 | 10 Shift pedal Bolt max1.25| 17 | 17 | 12 shit arm Boit mex1.o | 10 | 10 | 72 Clutch cable holder | Bolt |mexio | 13 | 13 | 94 Maer Bolt mexio | 21 | 21 | 15 Cooiant drain bolt mexto | 14 | 14| 10 28MAINTENANCE SPECIFICATIONS [sPeC| CHASSIS Model! DTs0U Steering System: Bearing Type Ball bearing Bearing Size (Quantity): Upper 3/16 in (22 pes.) Lower 1/4 in (19 pes.) Front Suspension: Front Fork Travel Fork Spring Free Length Spring Rate Stroke Optional Spring Oil Capacity Oil Level Oil Grade 170 mm (6.69 in} 351 mm (13.8 in) <346 mm (13.6 in)> 6.1 N/mm (0.61 kg/mm, 34 Ib/in) 0.0~170 mm (0.0~6.70 in} No. 175 cm* (6.12 Imp oz, 5.92 US oz) 129 mm (6.08 in) From top of inner tube fully compressed without spring. Fork oil TOW or equivalent Rear Suspension: Shock Absorber Travel! Spring Free Length Spring Rate Stroke Optional Spring Enclosed Gas Pressure 68 mm (2.68 in) 172 mm (6.77 in) <166 mm (6.54 in) > 55 N/mm (5.5 kg/mm, 308 Ib/in) 0.0~68 mm (0.0~2.68 in) No. 1471.0 kPa (15 kg/cm?, 213 psi) ‘Swingarm: Free Play Limit (Swingarm End) 1.0 mm (0.04 in) Move swingarm end side to side Front Wheel: Type Rim Size Rim Material Rim Runout Limit Vertical Lateral ‘Spoke wheel 1.40x19 Steel 2.0 mm (0.08 in) 2.0 mm (0.08 in) Rear Wheel: Type Rim Size Rim Material Rim Runout Limit Vertical Lateral ‘Spoke wheel 1.6017 Steel 2.0 mm (0.08 in) 2.0 mm (0.08 in) 29MAINTENANCE spEciFications |SPEC| Modet DTS0U Drive Chain: ‘Type/Manufacturer 420M/DAIDO Number of Links 109 Links + Joint Chain Free Play 40~50 mm (1.6~2.0 in) Front Drum Brake: Type Leading trailing Brake Drum Inside Dia. 110 mm (4.33 in) <111 mm (4.37 in)> Lining Thickness 4mm (0.16 in) <2 mm {0.08 in)> Shoe Spring Free Length 34.5 mm (1.36 in) Rear Drum Brake: Type Leading trailing Brake Drum Inside Diameter 110 mm (4.33 in) <111 mm (4.37 in) > Lining Thickness 4 mm (0.16 in) <2 mm (0.08 in) > Shoe Spring Free Length 34.5 mm (1.36 in) Brake Lever and Brake Pedal: Brake Lever Free Play 10~20 mm (0.4~0.8 in) At end of brake lever Brake Pedal P 10 mm (0.4 in) Below top of footrest Brake Pedal Free Play 20~30 mm (0.8~1.2 in) Clutch Lever and Throttle Grip: Clutch Lever Free Play 2~3 mm (0.08~0.12 in) At the lever pivot Throttle Cable Free Play 2~5 mm (0.08~0.20 in} 210MAINTENANCE SPECIFICATIONS Tightening Torque: Tightening torque Part to be tightened Thread size Remarks Nm | mekg | ft-lb Front wheel axle and nut mi2x1.25 | 45 | 45 | 32 Rear wheel axle and nut mi2x1.25 | 60 | 60 | 43 Rear wheel sprocket m8x1.25 | 20 | 20 | 14 Engine mounting: Front maxt25 | 2 | 22 | 16 Rear M10x1.25 | 53 | 53 | 38 Pivot shaft mi2x1.25 | 53 | 53 | 38 Handle crown and inner tube M8x1.25 | 23 | 23 | 17 Handle crown and steering shaft m1ox1.25 | 40 | 4.0 | 29 Handlebar holder mexto0 | 14 | 14 | 10 Ring nut (Steering shaft) m25x1.0 | 8 | 08 | 5.28 | Refer to “NOTE”, Under bracket and inner tube mi0x1.25 | 33 | 33 | 24 Tension bar and rear arm msx125 | 18 | 18 | 13 Tension bar and brake shoe plate Max125 | 18 | 18 | 13 NOTE: 1. First, tighten the ring nut approximately 38 Nm (3.8 m+kg, 27 ftelb) by using the torque wrench, then loosen the ring nut one tun. 2. Retighten the ring nut to specification. anMAINTENANCE SPECIFICATIONS ELECTRICAL Model DTS0U ev Ignition System: Ignition Timing (B.T.D.C.) 27° at 3,000 r/min Advancer Type Electrical type 3 5 ze a é ze / z 1 5 oll g 12° 2 2 7 t ° 2 4 6 8 70 Engine Speed (1,000 r/min} C.D. Magneto Model/Manufacturer €.D.1. Unit Model/Manufacturer Pickup Coil Resistance (Color) Source Coil Resistance (Color) F3BK/YAMAHA ‘3BK/YAMAHA 140~2100 at 20°C (68°F) (White/Red—Black) 196~ 2940 at 20°C (68°F) (Black/Red—Black) Ignition Coil: Model/Manufacturer Minimum Spark Gap Primary Coil Resistance Secondary Coil Resistance C24 YAMAHA 6 mm (0.24 in) 1.3~1.99 at 20°C (68°F) 5.9~7.3k0 at 20°C (68°F) ‘Spark Plug Cap: Type Plug Cap Resistance Resin Type 4~GkQ at 20°C (68°F) 242MAINTENANCE SPECIFICATIONS Model DTS0U Charging System: Flywheel magneto A.C. Magneto Generator: Model/ Manufacturer F3BK/YAMAHA Charge Coil Resistance (Color) 0.26 ~0.349 at 20°C (68°F) (White—Black) Standard Output 6V 1.04 at 3,000 r/min 2 g i : / é 1 é | 0 4 6 @ 10 Engine Speed (x 1,000 r/min) Voltage Regulator: Type ‘Semi conductor — Short circuit type Rectifier: Model/Manutacturer ‘SH582A—06/SHINDENGEN Capacity 8A Withstand Voltage 240v Battery: Specific Gravity 1.280 Horn: Type Plane type Quantity 1 pe. Model/Manufacturer MF6/NIKKO Maximum Amperage 1.58 243MAINTENANCE SPECIFICATIONS Model DT50U Flasher Relay: Type Condenser type Model/Manufacturer FZ636SD/NIPPON DENSO Self Cancelling Device Flasher Frequency No 70~ 100 cycles/min Wattage 17Wx2+3W Ignition Control Uni Model/Manufacturer 4Y3/YAMAHA Oil Level Switch: ‘Model/Manufacturer 3M7/STANLEY Thermo Unit: ‘Model/Manufacturer 14K/NIPPON SEIKI Curcuit Breaker: Type Fuse Curcuit (Fuse): “MAIN” 104 (1 pe.) 214GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS GENERAL TORQUE ni General torque SPECIFICATIONS wii | ceo; eters This chart specifies torque for standard fasteners ona = Sa EE with standard 1.S.0. pitch threads. Torque o | 4 specifications for special components or a Semi} 6 _| “rs | At assemblies are included in the applicable sections ae a a of this book. To avoid warpage, tighten multi- Tmm | 12mm [ss | 85 | 40 fastener assemblies in a crisscross fashion, in pro- 19mm ‘4mm a | 85 | 61 sressive stages, until full torque is reached. Unless Zmm_ | vemm_ | 130 | 130 | 94 otherwise specified, torque specifications call for clean, dry threads. Components should be at : room temperature. ‘A: Distance cross flats B: Outside thread diameter DEFINITION OF UNITS Unit] ad Definition mm ter 10% meter om, [centimeter 10"* meter kg Kilogram 10° gram N Newton kg x m/sec Nm Newton mneter Nxm m-kg Meter kilogram mekg Pa Pascal Nim? Némm Newton per milimeter N/mm Spring rate t Liter _ Volume cm’, Cubic centimeter ‘or Capacity Rotation per minuteLUBRICATION POINTS AND LUBRICANT TYPE | SPEC LUBRICATION POINTS AND LUBRICANT TYPE ENGINE iz Lubrication Points (Part name) Lubricant Type Oil seal lips (All) [ O-rings (All) | Bearing retainer Crankshaft bearings Needle bearings (Connecting rod) Main axle bearings Drive axle bearings Push lever bearing Crank pins: Piston rings, piston pins and pistons Impeller shaft (Water pump) ‘Warm shaft (Autolube pump) | Kick idle gear Kick axle Primary driven gear (Clutch housing) Push rod Push lever axle Sliding gear (Transmission) Free movement gear (Transmission) Guide bar (Shift forks) BIRR IA TAIRA ARABS Crankcase mating surfaces 216 ‘Yamaha bond No. 4°LUBRICATION POINTS AND LUBRICANT TYPE | SPEC CHASSIS Lubrication Points (Part name) Lubricant Type PF Oil seal lip (Wheels) Bearing (Wheels) ‘Speedometer drive gear shaft and axle Brake cable end ‘Whoeel axles Brake cam shaft and brake shoe pivot Rear arm pivot, bush and pivot shaft Pin (Rear shock absorber} Ball bearing and ball race Throttle grip inner surface Sidestand pivot Change pedal boss BIAIATRIAvAvAT RAIACOOLANT FLOW cHaRT |SPEC| © COOLANT FLOW CHART (Carburetor warmer Outlet hose 1 Coolant is cooled (Less than 65°C (149°F)). *2 Coolant is hot (65°C (149°F) or more} 218CABLE ROUTING [spec] #9 | CABLE ROUTINGCABLE ROUTING [spec] 9 | CABLE ROUTING Clamp 1B] Pass the oil hose out of ol delivery hose Thermo switch lead IB] After connecting the leads, locate the couplers Throttle cable ineide the rubber boot. Front brake cable Pass the battery breather hose between the Wireharness swingarm and engine Oit hose Battery bresther hose Rear brake switch Cable holder 220caste RouTING |SPEC| SF CABLE ROUTING Rear flasher light lead Sidestand switch lead Wireharness Band Clamp Taillight leadcase routine |SPEC| PY CABLE ROUTING Flasher relay i Pass the clutch cable and reservoir hose Wireharness (Radiator) Ignition control unit C.D.I. unit ‘Clamp ‘Sidestand switch lead Guide Breather hose (Coolant reservoir tank) Reservoir hose (Radiator) Clutch cable 222INTRODUCTION/PERIODIC MAINTENANCE/ [INSP LUBRICATION ADs PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. ‘These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information ap- plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE/LUBRICATION Unit: km (eiles) RY. bREAK Noe 1,000 | 3 x rm REMARKS. {600) {12,0001 or| 14,0000 o 6 months [12 mor Spark plugis) | Check condition. Glean or replace Hf necessary, 3 o oO Ait filter ‘lean. Replace Hf necessary. ° ° 7 ‘Check idle peed (synchronization) /starter operation| Gaborwoe Adjust i necessary. 2 2 © ‘Check fuel hose (and vacuum pipe) for cracks Maid ‘or damage. Replace if necessary. B ig Check oil level/ol leakage. Correct if necessary. Transmission oi" | Replace every 12,000 (8,000) or 24, months REPLACE] © ° (Warm engine before draining.) + | Check operation. Correct if necessary | nine) Sse opel Brake Check operation. Adjust it necessary. o | 6 Clutch Check operation. Adjust if necessary. o [0 " Check balance/damage/tunout/spoke tightness é mae | eke [Le Wheel bearings* | Check bearings assembly for looseness/damage o 6 Replace if damaged. ‘Check bearings assembly for looseness, «| Comect if necessary. Steering bearing" / Moderately repack every 24,000 (16,000) ° @ or 24 months." Front forks Check operation/oil leakage. Repair Ff necessary. o ° esr shod Check operation/oll leakage. Repair if necessary ° ° Check coolant leakage. Repair necessary. Cooling system | Replace coolant every 24,000 (16,000) or ° ° 24 months. Drive chain Check chien sek skoraventsAddust necessary, EVERY 500 (300) «| Check all chassis ftings and fasteners. Fittngs/Fasteners* | Check al fe ° ° ‘Sideststand” ‘Check operation. Repair if necessary. oa Ee) oO ‘Sidestand switch* | Check operation. Clean or replace if necessary. ° ° o Check specific gravity Battery" Check breather pipe for proper operation. ° ° Correct if necessary. ‘2 Itis recommended that these items be serviced by a Yamaha dealer. “+: Medium weight wheel bearing grease, 34PERIODIC MAINTENANCE/LUBRICATION NOTE: Brake fluid replacement: 11. When disassembling the master cylinder or caliper cylinder replace the brake fluid. Normaly check ‘the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged. 32IDLE SPEED ADJUSTMENT [ADJ INSP \ ENGINE IDLE SPEED ADJUSTMENT 1. Tighten: Pilot air screw @ Tum the pilot air screw in until lightly seated. 2. Loosen: Pilot air sorow Back it out from its lightly seated position. Pilot Air Screw Turns Out: and 1/4 3. Start the engine and let it warm up. 4. Attach: Engine tachometer To the spark plug lead. Engine Tachometer: ‘YU-08036 5. Check: ‘Engine idle speed Out of specification Adjust. Zs] Enaine tate Speod: 1,250~ 1,350 r/min 6. Adjust: ‘Engine idle speed Adjustment steps: Turn the throttle stop screw @ in or out un- til specified idle speed is obtained. 33 Turn in| Idle speed becomes higher. Turn out_| Idle speed becomes lower.AUTOLUBE PUMP CABLE ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. THROTTLE CABLE FREE PLAY ADJUSTMENT/ INSP ADJ 1. Checl “Throttle cable free play @) Out of specification—- Adjust. Throttle Cable Free Play: 2~5 mm (0.08~0.20 in) 2. Adjust: Throttle cable free play Adjustment steps: Loosen the locknut ‘Turn the adjuster @) in or out until the cor- rect free play is obtained. Turn in__| Free play is increased. Turn out_| Free play is decreased. ‘Tighten the locknut. AUTOLUBE PUMP CABLE ADJUSTMENT NOTE: Before adjusting Autolube pump cable, throttle cable free play should be adjusted. 7. Remove: ‘*Autolube pump cover @ 2. Rotate the throttle grip slightly until all siack. ig removed from all cables. Hold this position. 3. Check: ‘Alignment mark @) position Mark @) should be aligned with pin @. Not aligned Adjust Autolube pump cable. 34AUTOLUBE PUMP STROKE ADJUSTMENT 4, Adjust: ‘*Autolube pump cable Adjustment steps: Loosen the locknut @. Turn the adjuster @ in or out until the align- ment mark is aligned with the pin. ‘Tighten the locknut. 6. Install: ‘*Autolube pump cover (Autolube Pump Cot 5.Nm (0.5 6 ftelb) AUTOLUBE PUMP STROKE ADJUSTMENT 1. Remove: ‘Autolube pump cover 2. Start the engine and let it warm up. 3. While running the engine at idle, observe the ump adjusting plate carefully. Stop the en- ‘gine moment that the adjusting plate moves out to its limit. °Gap @ Out of specification—- Adjust. Measure the gap with the thickness gauge @ between the raised boss @ on the pump adjusting pulley and the adjusting plate @. Minimum Pump Stroi 15 mm (0.004~0.006 in)AUTOLUBE PUMP AIR BLEEDING NOTE: ‘When inserting the thickness gauge between the adjusting plate and the adjusting pulley, be care- ful so that neither the plate nor the pulley is moved. In other words, do not force the thick- ness gauge into the gap. 5. Adjust: ‘*Autolube pump minimum stroke Adjustment steps: ‘Remove the locknut (1), spring washer (2) and adjusting plate @). ‘Adjust the pump stroke by adding or remov- ing a shim @. ‘Add shim Pump stroke is increased. Pump stroke is decreased. ‘*Install the adjusting plate, spring washer and locknut. Ny] Locknut: Ax} 7. Nm (0.7 mekg, 5.1 ft-lb) Recheck the minimum pump stroke. If out of specification, perform the above steps again. 6. Install: ‘*Autolube pump cover ‘Screw (Autolube Pump Coveri: 5 Nm (0.5 m-kg, 3.6 ft-lb) AUTOLUBE PUMP AIR BLEEDING NOTE: ‘The Autolube pump and delivery lines must be bled on the following occasions: ‘*Setting up a new motorcycle out of the crate. ‘*Whenever the oil tank has run dry. ‘Whenever any portion of the engine oil system disconnected.INSP AUTOLUBE PUMP ADJUSTMENT [Any 37 1. Remove: *Autolube pump cover 2. Air bleed: ‘*Pump case and/or oil pipe Air bleeding steps: ‘*Romove the bleed screw ‘Keep the oil running out until air bubbles dis- ‘ppear. ‘*When air bubbles are expelled completely, tighten the bleed screw. NOTE: Check the bleed screw gasket, and if damaged, replace with a new one. 3. Air bleed: ‘*Pump distributor and/or delivery pipe Air bleeding steps: ‘Remove the clip (). ‘*Start the engine ‘Pull the pump cable @) all the way out to set the pump stroke to a maximum, NOTE: Itis difficult to bleed the distributor complete- ly with the pump stroke at @ minimum, and therefore the pump stroke should be set to @ maximum. ‘*Keep the engine running at about 2,000 r/min for two minutes or so, and both distributor and delivery pipe can be completely bled. 4, Install: “ci ‘*Autolube pump cover Screw (Autolube Pump Cover): 5 Nm (0.5 m-kg, 3.6 ft-lb)[INSP | gery SPARK PLUG INSPECTION ADJ ‘SPARK PLUG INSPECTION 1. Remove: Spark plug 2. Inspect: ‘Spark plug type Incorrect Replace. Standard Spark Plug: BSES (N.G.K.) 3. Inspect: “Electrode D Wear/Damage~ Replace. ‘Insulator @ ‘Abnormal color-*Replace. Normal color is a medium-to-light tan color. 4, Clean the spark plug with a spark plug clean- er or wire brush. 5. Measure: *Plug gap @ Use a Wire Gauge or Feeler Gauge. Out of specification—Regap. “&] Spark Plug Gap: 0.7~0.8 mm (0.028~0.032 in) 6. Tighten: Spark plug Before installing 2 spark plug, clean the gasket and plug surfaces. Spark Plu a] 20 Nm (2.0 mekg, 14 feeb) NOTE: Finger-tighten the spark plug before torquing to specification. IGNITION TIMING CHECK Adjustment free.INSP ENGINE OIL LEVEL INSPECTION ADJ ENGINE OIL LEVEL INSPECTION 1. Check: Oil level Oil level low->Add sufficient oil. Recommended Oil: Yamalube “2” or air cooled 2-stroke engine oil with “BIA certified for service TC-W”. Oil Tank Capaci 1.3L (1.1 Imp qt, 1.4 US qt) OIL WARNING LIGHT CHECKING METHOD (Main switch “ON” Gears in “NEUTRAL” ee ‘Oil warning indicator [Oil warning indicator ‘t does not come on light comes on into gear] —— a! Oil warning indicator light (Oil warning indicator does not come on light comes on z [Supply engine oil Always use the same type of engine oil; mix- ing oils may result in a harmful chemical reaction and lead to poor performance. 39TRANSMISSION OIL LEVEL INSPECTION/ [INSP. TRANSMISSION OIL REPLACEMENT [ADJ TRANSMISSION OIL LEVEL INSPECTION 1. Keep the engine running idle for a minute. 2. Place the motorcycle on a level place and hold it on an upright position. 3. Remove: *0i filer cap D 4, Rest the oil dip stick (D on the thread of the 1 hole. NOTE: Oil dip stick is included in owner's tool kit. 5. Inspect: *0il level Oil level should be between maximum @) and minimum @) marks. Oil level low- Add cil to proper level Recommended Oil: Yamalube “4” (10W-30), SAE 10W30 type SE Motor Oil or “GL” Gear Oil ‘CAUTION: *Do not add any chemical additives. Trans- mission oil also lubricates the clutch and ad- ditives could cause clutch slippage. *Be sure no foreign material enters the crankcase. TRANSMISSION OIL REPLACEMENT 1. Warm up the engine for several minutes. 2. Place an open container under the engine. 340CLUTCH ADJUSTMENT [ADJ | 3. Remove: *0il filer cap *Drain bott @) 4, Drain: *Transmission cit NOTE: Drain the transmission oil with the motorcycle slightly inclined to the right. 5. Inspect: ‘*Gasket (Drain bolt) *0-ring (Oil filler cap) Damage-Replace. 6. Install: *Drain bolt Xy | Drain Bol A 16 Nm (1.6 mekg, 11 ftelb) 7. Fil: Transmission cil Recommended Oil: Yamalube “4” (10-30), SAE 10W30 SE Motor Oil or “GL” Gear 01 Periodic Oil Change: 0.70 L (0.61 Imp qt, 0.74 US qt) CLUTCH ADJUSTMENT Free Play Adjustment 1. Check: Clutch lever free play @ Out of specification-+ Adjust. 4] Free Play: 2~3 mm (0.08~0.12 in) 341INSP | gery CLUTCH ADJUSTMENT west Fa 2. Adjust: *Ciutch lever free play Adjustment steps: ‘Loosen the locknut (D). ‘Turn the adjuster (2) in or out until the speci- fied free play is obtained Turn in__ | Free play is increased. Turn out_| Free play is decreased. Tighten the locknut. NOTE: ‘The above procedure provides for maximum ca- ble free play to allow for proper clutch actuating mechanism adjustment. Mechanism Adjustment 1. Loosen: Cable length adjuster locknuts (Fully) 2. Tighten ‘*Cable length adjusters (Until tight) 3. Drain: *Coolant Refer to “COOLANT REPLACEMENT” section. Transmission oil Refer to “TRANSMISSION OIL REPLACE- MENT” section. 342INSP CLUTCH ADJUSTMENT se] 5, Remove: “Joint pipe D *Radiator hose @) #Kick erank @ *Crankcase cover (Right) @ 6. Loosen: *Locknut @ 7. Push the push lever toward the front of the engine with your finger until it stops. @ Adjuster 8. Adjust: *Free play With the push lever inthis position, turn the adjuster either in or out until the push lever projection @) and crankcase match mark @ are aligned. 9. Tighten: *Locknut Locknut: 8 Nm (0.8 m-kg, 5.8 ft-lb) 10. Install: *Crankcase cover crank *Radiator hose Joint pipe Screw (Crankcase Cover-Left): 10 Nm (1.0 mekg, 7.2 ft-lb) Kick Crank: 12. Nm (1.2 mekg, 8.7 ftelb) 11. Fill: *Cooling system Refer to “COOLANT REPLACEMENT” section *Crankcase Refer to “TRANSMISSION OIL REPLACE- MENT” section. 12, Adjust: ‘*Clutch lever free play 313INSP AIR FILTER CLEANING [apg AIR FILTER CLEANING 1. Remove: ‘*Side cover (Right) Air filter case cover D 2. Remove: ‘Air fiter element D “Guide 2) Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid wear and possi- ble engine damage. Additionally, operation without the filter element will affect carbu- retor tuning with subsequent poor perfor- mance and possible engine overheating. 3. Inspect: ‘Air filter element Damage- Replace. 4. Clean: ‘Air filter element Cleaning steps: Wash the element gently, but thoroughly in i solvent ©. Word i Never use low flash point solvents such as gasoline to clean the element. Such sol- vent may lead to a fire or explosion. ‘Squeeze the excess solvant out of the element the element when squeezing 344CARBURETOR JOINT INSPECTION/ | INSP. FUEL LINE INSPECTION ADJ Te Apply the or Form air filter oil or SAE 10W30 motor oil Q)- ait 4 ‘*Squeeze out the excess oil WY NOTE: x The element should be wet but not dripping. 6. Install: Guide ‘Air filter element CAUTION: Make sure the element edge fits into the cor- responding filter case groove. 6. Install: ‘Air filter case cover Side cover CARBURETOR JOINT INSPECTION 1. Inspect: *Carburetor joints Cracks/Damage~ Replace. FUEL LINE INSPECTION 1. Inspect: *Fuel delivery hose. @D Cracks/Damage~ Replace.EXHAUST SYSTEM INSPECTION/ | INSP. COOLANT LEVEL INSPECTION ADJ EXHAUST SYSTEM INSPECTION 1. Inspect: Exhaust pipes Mufflers Cracks/Damage--Replace. Gaskets © Exhaust gas leaks—>Replace. Replacement steps: ‘*Remove the muffler assembly. ‘install a new muffler assembly. Nut (Exhaust Pipe) @: 18 Nm (1.8 m+kg, 13 ft-lb) Bolt (Exhaust Pipe and Muffler) ®: 21 Nm (2.1 mekg, 15 ftelb) COOLANT LEVEL INSPECTION 1. Warm up the engine for several minutes. NOTE: Waita few minutes until the coolant-level settles before inspecting. 2. Place the motorcycle on 2 level place and hold it on an upright position. 3. Inspect: Coolant level is under low level line @-Aadd soft water (Tap water) NOTE: Position the motorcycle straight up when inspect- ing the coolant level, a slight tilt to the side can produce false readings. Hard water or salt water is harmful to the en- gine parts. You may use boiled water or dis- tilled water, if you can’t get soft water. 346INSP_ COOLANT REPLACEMENT [ADJ 5. Add: Soft water (Tap water) Until the coolant level reaches "FULL" lev- el mark ©. Reservoir Tank Capacity: Total: 0.38 L (0.33 Imp qt, 0.40 US qt) From LOW to FULL Level: 0.20 L (0.18 Imp qt, 0.21 US at) COOLANT REPLACEMENT Gn Do not remove the radiator cap when the en- gine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the ‘engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly ro- tate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turn- ing counterclockwise and remove it. 1. Disconnect: Reservoir tank hose 2. Drain the coolant from reservoir tank. 37COOLANT REPLACEMENT 3. Remove: *Radiator cover D) Radiator cap 4, Remove: *Drain bolt D) Drain the coolant from cooling system. NOTE: Drain the coolant with the motorcycle slightly in- clined to the right '5. Remove: Drain bolt (Cylinder) @ Drain the coolant from cylinder. 6. Install: Gasket (New) *Drain bolts Drain Bolt: 14. Nm (1.4 mekg, 10 ftelb) 7. Connect: Reservoir tank hose 8. Fill: ‘Reservoir tank ‘*Cooling system Recommended Coolant: High Quality Ethylene Glycol Anti-freeze Containing Anti-corrosion for Aluminum Engine Inhibitors Coolont and Water (Soft Water) Mixed Ratio: 50% /50% Total Amount: 1.1L (1.3 Imp at, 1.4 US at) Reservoir Tank Capacity: 0.38 L (0.33 Imp qt, 0.40 US qt)‘The coolant is harmful so it should be handled with special care. WARNING: ‘When coolant splashes to your ey Thoroughly wash your eye with water and see your doctor. ‘*When coolant splashes to your clothes. Quickly wash it away with water and then with soap. ‘*When coolant is swallowed. Quickly make him vomit and take him to a doctor. ‘CAUTION: Hard water or salt water is harmful to the ‘engine parts; use bolled or distilled water if you can’t get soft water. *Do not use water containing impurities or oil. “Take care so that coolant does not splash to painted surfaces. If splashes, wash it away with water. Coolant filling steps: ‘Loosen the bleed bolt () 12~15 mm (0.5~ 0.6 in) of thermostat cover. ‘+Fil the coolant into the radiator. ‘*Keep the coolant running out until air bub- bles disappear. Tighten the bleed bolt. Bleed Bolt: 10. Nm (1.0 mekg, 7.2 ftelb) ‘*Fill the coolant into the radiator to specified level @ install the radiator cap. 319COOLING SYSTEM INSPECTION | ADJ ‘Fill the reservoir tank with the coolant until the coolant level reaches "FULL" level mark o. Start the engine and let it warm up. ‘Stop the engine and inspect the cooiant level. NOTE: Wait a few minutes until the coolant level set- tles before inspecting. COOLING SYSTEM INSPECTION 1. Inspect Radiator @ inlet hose @) Outlet hose @) Cracks/Damage—-Replace. Refer to the “COOLING SYSTEM" section in the CHAPTER 5. 3:20FRONT BRAKE ADJUSTMENT/ [INSP | gry REAR BRAKE ADJUSTMENT | ADJ CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: Brake lever free play @ Out of specification Adjust. ZR Fe Par Z 10~20 mm (0.4~—0.8 in) 2. Adjust: ‘Brake lever free play Adjustment steps: ‘*Turn the adjuster @ in or out until the speci fied free play is obtained. [Tum out [Free plays inerensea. | REAR BRAKE ADJUSTMENT Rear Brake Pedal Height adjustment ® 1. Check: ‘Brake pedal free play @ ‘Out of specification Adjust. Brake Pedal Height: 10 mm (0.39 in} Below Top of Footrest. 2. Adjust: Brake pedal height Adjustment steps: ‘Loosen the locknut @). Turn the adjuster (1) in or out until the speci- fied pedal height is obtained. 321BRAKE SHOE INSPECTION [INSP | ger LADJ | Turn in__| Pedal height is increased. Turn out_| Pedal height is decreased. WARNIN! Adjust pedal height, then adjust brake pe- dal free play. ‘Tighten the locknut. Rear Brake Pedal Free Play Adjustment 1, Check: + Brake pedal free play © Out of specification Adjust. Brake Pedal Free Play: 20~30 mm (0.8~1.2 in) 2. Adjust: Rear brake pedal free play Adjustment steps: ‘Turn the adjuster in or out until the speci fied pedal free play Pedal free play is increased. Turn out _| Pedal free play is decreased. WARNING: ‘The rear brake pedal adjustment must be checked anytime chain is adjusted or rear wheel is removed and then reinstalled. *Check the operation of the brake light ter adjusting the rear brake. BRAKE SHOE INSPECTION Front 1. Pull in the brake lever, 2. Inspect: ‘*Wear indicator D Indicator wear limit line @—-Replace Front brake shoes. Refer to “FRONT WHEEL" section in the CHAPTER 7. 322REAR BRAKE LIGHT SWITCH ADJUSTMENT/ [INSP DRIVE CHAIN SLACK ADJUSTMENT [ADJ Rear 1. Depress the brake pedal. 2. Inspect: Wear indicator Indicator wear limit line @)—rReplace the rear brake shoes. Refer to “REAR WHEEL” section in the CHAPTER 7. REAR BRAKE LIGHT SWITCH ADJUSTMENT NOTE: ‘The brake light switch is operated by movement of the brake pedal. Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect. 1. Hold the switch body @) with your hand so. that it does not rotate and turn the adjusting rut @. ‘CAUTION: After adjusting, be sure to check the lighting. DRIVE CHAIN SLACK ADJUSTMENT NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check slack at several points to find the tightest point. Check and/or adjust the chain slack with the rear wheel in this “tightest” position. 1. Place the motorcycle on a level place, and hold it in an upright position. NOTE: ‘The both wheels on the ground without rider on it.[INSP | DRIVE CHAIN SLACK ADJUSTMENT ea 2. Check: Drive chain slack @ Out of specication = Adjust 3. Adjust: Drive chain slack Adjustment steps: “CAUTION: Too small chain slack will overload the en- and other vital parts; keep the slack within the specified limits. ‘Remove the cotter pin @. Loosen the axle nut @. Turn the adjuster @) in or out until the speck fied slack obtained. Turn in| Slack is decreased. Turn out_| Slack is increased, NOTE: Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks on each side of swingarm and on each chain puller; use them to check for proper alignment.) “Tighten the axle nut ©). ‘Axle Nut: 60 Nm (6.0 m-kg, 43 ft-lb) NOTE: While holding the drive chain tense by hand, tighten the axle nut. This maintains the cor- rect chain play. ‘Tighten the adjuster @. Adjuster 5 Nm (0.5 m-kg, 3.6 ft-lb) 3.24INSP. DRIVE CHAIN LUBRICATION INSE Fa ‘install the cotter pin (New) @) and bend the end of it as shown. ‘Adjust the free play in the brake pedal. Refer to the “REAR BRAKE ADJUST- MENT". NOTE: Do not loosen the axle nut after torque tight- ening. If the axle nut groove is not aligned with soe the wheel shaft cotter pin hole, align groove the hole by tightening up on the axle nut. “Always use a new cotter pin on the axle nut. ‘*Check the operation of the brake light af- ter adjusting the rear brake. DRIVE CHAIN LUBRICATION The chain consists of many parts which work against each other. If the chain is not maintained property, it will wear out rapidly, therefore, form, the habit of periodically servicing the chain. This service is especially necessary when riding in dusty conditions. 1. Use any brands of spray type chain lubricant. First, remove all dirt and mud from the chain with a brush or cloth, then spray a lubricant between both rows of side plates and on all center rollers. 2. To clean the chain, remove the chain from the motorcycle, dip it in solvent, and clean out as much dirt as possible. Take the chain out of the solvent and dry it. Immediately lubri- cate the chain to prevent rust. Recommended Lub: SAE 10W30 Type SE Motor Oil 325INSP STEERING HEAD ADJUSTMENT ADJ STEERING HEAD ADJUSTMENT RGN Securely support the motorcycle so there i no danger of it falling over. 1. Elevate the front whee! by placing a suitable stand under the engine. 2. Check: *Steering assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back and forth. Looseness— Adjust steering head. 3. Adjust: ‘Steering head Adjustment steps: ‘Loosen the pinch bolt (Handle crown) (and bolt (Steering shaft) 2). ‘*Remove the seat and fuel tank. ‘sTighten the ring nut @) using the Ring Nut Wrench @, 1g Nut Wrench: Set the torque wrench to the ring nut wrench ‘so that they form a right angle. ‘Loosen the ring nut one turn. ‘*Retighten the ring nut using the Ring Nut Wrench. Avoid over-tightening. Ring Nut (Final Tightening): 8 Nm (0.8 m-kg, 5.8 ft-lb) 3:26TIRE INSPECTION TIRE INSPECTION 1. Measure: ‘Air pressure Out of specification Adjust. Basic weight: ‘With oil and full 86 kg (190 1b) fuel tank ‘Maximum load* 71 kg (157 Ib) Cold tire pressure | Front Rear 130 kPa_| 130 kPa 0 kg (0 tb) ~ 2 2 (1.3 kg/om?.f(1.3 kg/em?, Maximum load’ woe Load is the total weight of cargo, rider, pas- sengs accessories. Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted ac- cording to total weight of cargo, rider, pas- senger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed. 2. Inspect: *Tire surfaces Wear/Damage~-Replace. Z AS Minimum Tire Tread Depth: (Front and Rear) 1.0 mm (0.04 in) Tread depth Side wall Wear indicatorTIGHTENING ans) It is dangerous to ride with a worn-out tire. When a tire tread begins to show lines, replace the tire immediately. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do ‘so, use great care and replace the tube as soon as possible with a good quality replace- ment. WHEEL INSPECTION/SPOKES INSPECTION AND | INSP ADJ WHEEL INSPECTION 1. Inspect: “Wheels Damage/Bends~-Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. SPOKES INSPECTION AND TIGHTENING 1. Inspect: Spokes Bend/Damage-+ Replace. Loose spoke-+Retighten. 2. Tighten: Spokes @ Spoke wrench NOTE: Be sure to retighten these spokes before and af- ter Break-i Nipple: 6 Nm (0.6 m-kg, 4.3 ft-lb) 3:28CABLE INSPECTION AND LusRicaTioN/ | INSP | gay LEVEL AND PEDAL LUBRICATION/SIDESTAND LUBRICATION | ADJ CABLE INSPECTION AND LUBRICATION CCN Damaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result so replace such cable as soon as possible. 1. Inspect: Cable sheath Damage—Replace. 2. Check: *Cable operation Unsmooth operation—+ Lubricate, Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil NOTE: Hold cable end high and apply several drops of lubricant to cable. LEVER AND PEDAL LUBRICATION Lubricate pivoting parts of each lever and pedal. Recommended Lubricant: Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil SIDESTAND LUBRICATION Lubricate the sidestand at pivot points. Recommended Lubricant: Yamaha Chain and Cable Lube or SAE 10W30 Motor OilBATTERY INSPECTION INSP_ ADJ ELECTRICAL BATTERY INSPECTION Refer to the “SIDE COVERS—REMOVAL” section. 2. Inspect: Fluid level should be between upper (1) and lower @) level marks. Incorrect Refi Refill with distilled water only; tap water contains minerals harmful to a battery. 3. Inspect: ‘Battery terminal Dirty terminal—Clean with wire brush. Poor connection-+Correct NOTE: ——____ After cleaning the terminals, apply grease lightly to the terminals. 3:30 4. Connect: ‘Breather hose @ Be sure the hose is properly attached and routed. @ Pass the battery breather hose between the en- ine and swingarm.INSP. BATTERY INSPECTION | ADJ 5. Inspect: Breather hose Obstruction Remove. Damage~Replace. CAUTION: When inspecting the battery, be sure the breather hose is routed correctly. If the breather hose touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the motorcycle can 6. Check: ‘Specific gravity Less than 1.280--Recharge battery. Charging Current: 0.4 amps/10 hrs Specific Gravity: 1.280 at 20°C (68°F) Replace the battery it “Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging. ‘Sulfation of one or more cells occurs, as in- dicated by the plates turning white, or an ac- cumulation of material exists in the bottom of the cell. ‘Specific gravity readings after a long, slow charge indicate one cell to be lower than the rest. ‘*Warpage or buckling of plates or insulators. is evident. Always charge a new battery before using it to ensure maximum performance.INSP BATTERY INSPECTION/FUSE INSPECTION [ anJ WARNING: Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: “Avoid bodity contact with electrolyte as it can cause severe burns or permanent eye injury. ‘*Wear protective eye gear when han: working near batteries. Antidote (EXTERNAL) *SKIN—Flush with water. *EYES—Flush with water for 16 minutes and get immediate medical attention. Antidote (INTERNAL): Drink large quantities of water or milk fol- low with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical at tention. Batteries also generate explosive hydrogen gas, therefore you should always follow these preventive measures: “Charge batteries in a well-ventilated area. ‘Keep batteries away from fire, sparks, or ‘open flames (e.g., welding equipment, lighted cigarettes, etc.) *DO NOT SMOKE When charging or han- dling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. FUSE INSPECTION 1. Remove *Side cover (Right) sFuse © 3:32INSP_ Fa HEADLIGHT BEAM ADJUSTMENT | ADJ 2. Inspect sFuse D Inspection steps: Connect the Pocket Tester to the fuse and check it for continuity. NOTE: Set the tester selector to “0X 1" position, Pocket Tester: YU-03112 ‘if the tester is indicated at oe. The fuse is, blown, replace it. 3. Replace *Blown fuse Fuse: 108. Blown fuse replacement steps: *Tum off ignition and the circuit. ‘Install a new fuse of proper amperage. *Tum on switches to verify operation of elec- trical device, ‘If fuse blows immediately again, check circuit in question. (Zuni Do not use fuse of higher amperage rating than recommended. Extensive electrical sys- tem damage and fire could result from sub- stitution of a fuse of improper amperage. HEADLIGHT BEAM ADJUSTMENT 1. Adjust: ‘Headlight beam (Vertical) ‘To raise the | Turn the adjuster beam Clockwis To lower the | Turn the adjuster @) beam counterclockwise. 2. Adjust *Headlight beam (Horizontal) To right the | Turn the adjuster @) beam counterclockwise. To left the | Turn the adjuster @) beam clockwise, 338