A (nut) B (bolt)

General characteristics of the tightening torques Nm m kg lbfoot

mm mm mm mm mm mm

85 130

0.6 1.5 3.0 5.5 8.5 13.0

4.61 94
A: Distance between sides B: Outer thread diameter
Unit mm cm kg N Nm mkg Pa N/mm L cm3 R/min
Denomination Milimeter Centimeter Kilogram Newton Newton meter Kilogram-meter Pascal Newton per milimeter Litre Cbic centimeter Revolutions per minute
Definition 10-3 10-2 meters meters
Dimension Length Length Weight Force Tightening torque Tightening torque Pressure Spring rating Volumen or capacity Engine revolution speed
103 grams 1 kg x m/sec2 Nxm m x kg N/m2 Nmm
LUBRICATION POINTS AND TYPE OF LUBRICANT
Lubrication point (name of the part) Oil seal lips (all) O rings (all) Bearing seals Crankshaft bearings (left and central) Needle bearings (con rod) Primary shaft bearings Secondary shaft bearings Thrust cam bearing Crankshaft journals Rings, pins and pistons Drive shaft (water pump) Shaft (mixing pump) Clutch casing Thrust rod Thrust lever shaft Sliding gear (transmission) Free gear (transmission) Guide bar (transmission forks) Connection ball (shift pedal) Rotation points (shift pedal) Crankcase matching surfaces Yamaha n 4 adhesive

E E G E E

Type of lubricant
LUBRICATION POINTS AND TYPE OF LUBRICANT CHASSIS
Lubrication point (name of the part) Ball bearings (steering column) Lips of the oil seals (front and rear wheels) Rotation points (brake pedal) Rotation points (side stand) Right end of handlebar End of the throttle cable (throttle twist grip) Rotation axle (clutch lever) Rotation axle (brake handle) Anchorages (rear shock) Swingarm Bearing (swingarm) Front wheel axle Rear wheel axle Bush (front wheel) Speedometer gear unit

CABLE ROUTING

DC-CDI Regulator-rectifier Battery Starter relay Fuse box Horn Flasher relay Neutral relay
Thread the horn cable through the support A Thread the installation through the clamps B Thread the left-hand switch cable through C The mark for installing the system must D
coincide with the frame clamp the frame clamps or bridles on the frame of the air filter casing
Speedometer connector Connector for headlight and front indicator lights Connector for the speedometer sensor Ground cable Electrical installation Tank overflow pipe Carburettor overflow pipe Engine breather pipe
Clamp the generator cable to the frame A Clamp the neutral switch cable to the B Thread the stand and neutral cables C Thread the following cables through the D
frame clamp: Rear brake switch Stand switch Neutral switch Starter motor Thread the cables described in point D E plus the engine breather pipe through the frame clamp through the frame clamps frame

SIDE COVERS SIDE COVERS

DISMANTLING 1. Take off: The seat NOTE:
To open the seat lock, insert the key into this and turn clockwise
2. Dismantle: The grip strap
3. Remove: Screws that secure each side cover and take these out
4. Release: The seat locking cable ASSEMBLY Follow the same procedure as in DISMANTLING but inversely. Observe the following points: 1. Install: The side covers (left and right-hand side), and tighten the screws. The seat locking cable 2. Install: The seat NOTE: Insert the projection of the seat into the recess made in the chassis for this purpose and press the seat downwards.
ADJUSTING THE IDLING SPEED
ADJUSTING THE IDLING SPEED 1. Tighten The air screw Tighten the screw until it gently abuts the end of its travel 2. Loosen: The air screw Partly unscrew this from its slightly abutting position Turns the screw should be loosened: 2 1/8 turns
3. Start the engine up and let this warm up. 4. Connect: The engine tachometer to the spark plug cable Engine tachometer: 90890-03113
5. Check: The engine idling speed Out of specification Adjust Engine idling speed: TZR~ 2000 r/min
ADJUSTING THE AUTOLUBE PUMP CABLE
ADJUSTING THE AUTOLUBE PUMP CABLE NOTE: Before adjusting the automatic mixture pump cable, you must first adjust the free play of the throttle cable. 1. Remove: Cowlings See the section on FAIRING, DISMANTLING The oil pump cover 2. Adjust: The throttle cable 3. Check: The free play while keeping the throttle in the idle position. This is not adjusted Adjust the pump cable 4. Adjust: The pump cable Stages in the Adjustment: Loosen the locknut Tighten or loosen the tensor until getting the minimum play in operation Tighten the locknut
5. Check: Adjust the cable of the lubrication pump
ADJUST THE FREE PLAY OF THE THROTTLE CABLE
6. Adjust: The engine idling speed.
ADJUSTING THE FREE PLAY OF THE THROTTLE CABLE 1. Check: The free play (a) of the throttle cable Out of specification Adjust Free play of throttle cable: 2 ~ 5 mm
2. Adjust: Throttle cable free play Adjustment steps: Loosen the locknut Loosen or tighten the tensor until you get the right free play Tighten Loosen
Increases the free play Reduces the free play

Loosen the locknut

BLEEDING THE AUTOLUBE PUMP
The automatic mixing pump and its hoses must be bled in the following cases: When taking a new motorcycle out of its packaging. Whenever the oil tank is completely emptied Whenever any part of the engine oil supply system is disconnected. 1. Remove: The oil pump cover
2. Bleed the air: From the pump casing and/or the oil hose Bleeding air steps: Loosen the bleeding screw Start the engine up Let the oil out until the air bubbles disappear After the air bubbles have been completely removed, tighten the bleeding screw Stop the engine NOTE: Check the O ring of the bleeding screw and if any damage can be seen, change it for a new one

REMOVING THE ENGINE

PETROL TANK 1. Remove: Seat Grip strap Side covers (left / right)
2. Remove the fuel tank cap
3. Remove the bolts of the fuel tank and and of its cover.
4. Lift up the cover of the fuel tank as shown in the drawing and remove the tray and the fuel overflow pipe from its original position. NOTE: Do not remove the lower part of the overflow pipe from its original position
5. Locate the fuel tap in the closed position (OFF) and take the lever out of this. 6. Provisionally lift up the fuel tank and its cover, disconnect the fuel pipe and remove the tank and the cover.
AIR FILTER 1. Remove: Securing screw

2. Take out: Clip

3. Disconnect: Rubber pipe

4. Remove Filter casing

EXHAUST PIPE 1. Remove: Springs Clamp of the AIS system
2. Remove: Exhaust pipe screws and Exhaust pipe
COOLANT PIPES 1. Remove: Fairing Drainage screw 2. Drain: Coolant liquid 3. Disconnect: Coolant pipe (inlet) Coolant pipe (outlet)
SPARK PLUG AND THERMOCONTACT CABLE 1. Disconnect Spark plug cable Thermocontact cable 2. Loosen: Spark plug
CDI CABLE 1. Disconnect: CDI cable
NEUTRAL SWITCH CABLE 1. Disconnect: Neutral switch cable
OIL PUMP 1. Remove: Cover of the oil pump
2. Remove: Cable of the oil pump 3. Disconnect: Oil inlet tube to the pump NOTE:
Plug the oil inlet pipe to the pump so the oil from the tank does not get out.
CARBURETTOR 1. Loosen: Carburettor securing screw
2. Remove: Upper carburettor cover Throttle cable Tube for supplying the oil pump Coolant pipes Starter cover Starter cable
3. Remove: Carburetor Carburetor joint Plate casing NOTE: Cover the carburetor with a clean cloth to prevent dirt from getting into this.
SHIFT CAM, DRIVE CHAIN AND CLUTCH CABLE 1. Remove: Shift cam Pinion cover
2. Loosen: Rear axle nut Chain tensor Drive chain 3. Remove: Drive chain
REMOVING THE ENGINE / DISMANTLING THE ENGINE
4. Disconnect: Clutch cable First disconnect the cable of the crankcase side and then the end at the handlebar lever
REMOVING THE ENGINE 1. Remove: Front engine mounting screw Rear lower engine mounting screw Rear upper engine mounting screw Engine assembly
OIL PUMP 1. Remove: Oil pump cover Oil pump assembly
WATER PUMP COVER 1. Remove: Water pump cover Water pump cover gasket
RIGHT CRANKCASE COVER, OIL PUMP SHAFT AND WATER PUMP SHAFT 1. Remove: Right-hand oil pump cover

DISMANTLING THE ENGINE

2. Remove Clip Washer Water pump driven gear Pin Washer Water pump shaft Clip Oil pump driven gear Pin Washer k 10 Oil pump shaft k 11 Washer k 12 Clip k 13 Washer k) 14 Intermediate gear k 15 Washer k) 16 3. Remove: Locators Gasket
CLUTCH AND PRIMARY TRACTION GEARING 1. Remove: Securing screws for the clutch springs Clutch springs Pressure plate Push rod n 1 Friction discs Clutch discs 2. Remove: Push rod ball Push rod N 2 Shaft set of the clutch push lever

5. Apply: 2 stroke engine oil to the crankshaft pin, bearing and oil feed bore. 6. Check: Operation of the crankshaft and shift. This works incorrectly repair 7. Install: Neutral switch
8. Install: Circlip Sprocket Circlip

STARTER MOTOR

Starter motor Screw Magnetic flywheel Screw Nut
STARTER MOTOR 1. Install: Starter motor
2. Install: Coil plate in the crankcase Coil screw: 0.9 m kg
CAUTION Install the coil holder plate so that the marks on the plate and on the crankcase, made during the dismantling process, coincide.
CDI MAGNETO 1. Install: Coil plate 2. Install: Key CDI flywheel Nut
CLUTCH AND PRIMARY DRIVE GEARING
Primary drive gearing Bush O ring Nut Clutch housing Thrust washer Clutch boss Friction disc Clutch disc
k Pressure plate 10 k Spring 11 k Screw with washer 12 k Pusher plate 13 k Conical washer 14 k Conical washer 15 k Nut 16 k Pusher plate 17 k Push rod 1 18
k Tensor 19 k Nut 20 k Ball 21 k Push rod k Push lever shaft 23 k Spring 24 k Flat washer 25 k Seal 26
A: LIMIT OF FREE LENGTH OF CLUTCH SPRING: 30.0 mm B: LIMIT OF FRICTION DISC WEAR : 2.7 mm C: LIMIT OF DISC WARPAGE: 0.05 mm
To tighten the CDI magneto nut use the flywheel holder 90890-01235 and without releasing this also tighten the nuts of the balancer shaft and that of the crankshaft gear
CDI magneto nut: 5.2 m kg Crankshaft gear nut: 6.0 m kg
1. Install: Washer Tachometer gear Washer
2. Install: Key Driven gear of balancer Washer Nut
3. Install: O ring Bush Drive gear Key Primary transmission gear Nut NOTE: The driven and drive gears must have the two marks aligned
4. Install: Conical spring washer Washer Primary drive gear Washer Clutch boss Washer Clutch boss nut
5. Tighten: Clutch boss nut Use the universal clutch holder Clutch holder: 90890 - 04086 To hold the clutch boss Clutch boss nut 7.5 m kg 6. Install: Shaft assembly of the clutch push lever Push rod n Ball of the push rod
7. Install: Clutch discs Friction discs Push rod n 1 Pressure plate Washer Nut Clutch springs Screws for securing the clutch spring NOTE: Install the clutch discs and the friction discs alternately in the clutch boss starting and ending with a friction disc Install the clutch discs so that each of these is 120 offset with the previous one.

2. Assemble: The radiator
3. Tighten: The screws (radiator) Screws (radiator): 0.6 kg m
4. Fill up: The coolant See the section on CHANGING THE COOLANT in CHAPTER 3. 5. Inspect: The cooling system Reduce the pressure (leaks) as required.

Repair

Inspection steps: Connect the cooling system tester to the radiator Cooling system tester: 90890 - 01325 Apply 1.0 kg/cm2 pressure Measure the pressure with the manometer. 6. Install: The seat

CHAPTER 6 CARBURATION

CARBURETOR 6-1 REMOVAL 6-2 DISMANTLING 6-2 INSPECTION6-2 ASSEMBLY 6-3 INSTALLATION 6-3 ADJUSTING THE PETROL LEVEL 6-3 REED VALVE 6-4 REMOVAL 6-4 DISMANTLING 6-4 INSPECTION6-4 ASSEMBLY 6-5 INSTALLATION 6-6

CARBURETOR

CARBURATION
Carburetor Carburetor cover Needle valve Float chamber Main jet Diffuser k Idling jet 10
k 14 k 13 k 15 k 24 k 27 k 26
Spring Casing Choke jet Idling screw Float pin Float
SPECIFICATIONS Main jet (M.J.) Pilot air screw (P.A.S.) Fuel level (F.L.) Idling speed # 1/~14 mm 1850 150
REMOVAL 1. Remove: Carburetor assembly See the section on engine removal
DISMANTLING 1. Remove: Idling stop screw
2. Remove: Float chamber Float pin Float Water valve Gasket Main jet Idling jet Choke jet
INSPECTION 1. Inspect: Carburetor body Dirty clean NOTE: Use a petroleum type solvent for cleaning. Clean all the holes and jets with compressed air. 2. Inspect: Valve seat / float valve Wear / Dirt Change NOTE: Always change the float chamber valve and valve seat as a set.
3. Inspect Jets Wear / Dirt

Change / Clean

4. Inspect: Plunger Wear/damage Replace 5. Check: Free movement Difficulty Change Insert the plunger into the carburetor body.
6. Inspect Float Damaged O ring Damaged

Change Change

ASSEMBLY 1. Install: Follow the dismantling procedure inversely INSTALLATION 1. Install: Carburetor assembly Apply the removal procedure inversely ADJUSTING THE FUEL LEVEL 1. Measure: Float height Outside specifications Service Float height (FH) : 13 -14 mm

CARBURETOR / REED VALVE

Adjustment steps: Take out the carburetor Inspect the valve seat and the float chamber valve. If either of the two parts is worn, change both. Check the petrol level again

REED VALVE

REMOVAL 1. Remove: Reed valve assembly See the engine removal section DISMANTLING 1. Remove: Reed valve stop Reed valve
INSPECTION 1. Inspect: Rubber gasket Deteriorated Change Reed valve Ageing / cracks Change Inspection steps: Visually inspect the reed valve NOTE A proper reed valve should install in aligned or almost aligned with the neoprene base. In the event of any doubt about sealing apply suction to the part in the carburetor mounting Any leaks must be moderate

FRONT BRAKE

Disc brake Screw Complete brake caliper Complete pistons Brake pads
Drain screw Pin Through screw Seal k Screw 10

A: CHANGE AS AN ASSEMBLY

B; WEAR LIMIT OF THE BRAKE PADS: 0.5 mm
C: WEAR LIMIT BRAKE DISC: 3.5 mm
The components of the disk brake rarely need to be dismantled. Do not do so unless this is absolutely necessary. If any of the hydraulic coupling components of the system is disconnected the whole system must be dismantled to drain this, clean it and then fill it and bleed it properly. Do not use solvents to clean the components. Solvents make seals swell and deform. Only use clean brake liquid for cleaning. Take care with brake liquid, as this is harmful for the eyes and damages painted surfaces and plastic parts.
CHANGING THE BRAKE PADS NOTE: To change the brake pads the line does not need to be taken off.
1. Dismantle: The screws (brake caliper) The retaining screw The retaining pin The pads
2. Measure: The thickness (a) of the pads: If this does not match the value specified replace NOTE: Replace the pads as a set, if you find that any of them is worn beyond the limit.

Wear limit: 0.5 mm

3. Firmly connect a suitable tube 1 to the caliper bleeding screw. Then insert the other end of the tube into an open recipient. 4. Unscrew the bleed screw of the caliper and press the piston with your finger to make it go into this.
5. Tighten: The caliper bleeding screw Caliper bleeding screw: 0.5 m kg
6. Assembly: The brake pads (new) The retaining screw The retaining pin
7. Install: The screws (brake caliper) Screws (brake caliper): 3.5 kg m
8. Inspect: The level of the brake liquid See the section on INSPECTING THE BRAKE LIQUID in CHAPTER 3.
9. Check: The operation of the brake lever. If this is soft or spongy bleed the brake system. See the section on BLEEDING THE AIR in CHAPTER 3.
DISMANTLING THE CALIPER 1. Remove: The coupling screw The copper washers NOTE: Place the open end of the line in a recipient and carefully pump to remove the old liquid.
2. Dismantle: The screws (brake caliper) The brake pads See the section on CHANGING THE BRAKE PADS

3. Dismantle: Pistons

Dismantling steps: Use a cloth to block the piston on the right-hand side. Blow compressed air in through the coupling hole of the line to force the piston on the left-hand side out of the caliper. Insert the piston a few mm and lock it with a cloth to prevent it from getting out. Repeat the previous steps with the piston for the right-hand side, to force it out of the caliper. s WARNING Never attempt to take the piston out of the caliper by levering this with a tool. Cover the piston with a cloth Take care to avoid injuries by the piston being ejected out of the cylinder.

16. Dismantle: The clamp of the brake line
17. Dismantle: The upper crown
18. Remove: The ring nut Use the wrench for ring nuts Wrench for annular nuts : 90890 - 01403 WARNING Support the steering axle so that this cannot fall
19. Dismantle: The cover of the bearing races The upper race of the bearing The balls
20. Dismantle: The steering axle The ball bearings
INSPECTION 1. Wash the ball bearings and races with solvents. 2. Inspect: The ball bearings The bearing races Pitting / Damage Replace
NOTE: Always replace the bearings and races as a set
Replacement steps: Dismantle the bearing races from the steering arm with a long rod 1 and a hammer, as shown in the figure. Dismantle the bearing race fitted on the lower support with a chisel 2 and a hammer, as shown in the illustration. Install the new dust cover seal and the new races.
3. Inspect: The handlebars Deformations / Cracks / Damage Replace s WARNING
Do not attempt to straighten the handlebars if these are deformed as this could considerably weaken them
ASSEMBLY Apply the procedure for DISMANTLING inversely. Take into account the following points. 1. Apply : Lithium soap grease to the bearing races
2. Install: The bearings Install the balls on the race and apply more grease N and dimensions of the balls: 19 units above / 1/4 inch 19 units below 1/4 inch
3. Install: The steering axle s WARNING Immobilise the steering axle until this is fixed.
4. Tighten: The ring nut Tightening steps: Tighten the annular nut using the wrench for annular nuts Wrench for annular nuts: 90890 - 01403 NOTE: Couple the torque wrench to the wrench for annular nuts so that these form a right angle. Ring nut (initial tightening): 3.8 kg m Turn the steering 2 or 3 times Loosen the nut half a turn Tighten the annular nut again with the special wrench s WARNING Do not tighten excessively Wrench for annular nuts: 0.7 kg m
5. Install: The upper crown
Screw (steering axle ): 5.4 kg m NOTE: Provisionally tighten nut 2 of the steering axle.
6. Install: The headlight support The clamp of the brake line Screw (headlight support): 1.0 kg. m
7. Install: The fork See the section on FITTING THE FORK Clamp screw (steering axle): 3.0 kg m Clamp screw (upper shank of the handlebar): 2.0 kg m 8. Install: The handlebars Clamp screw (handlebar) 2.0 kg m Screws (handlebar) : 0.9 kg m
9. Install: The support of the clutch lever The twist grip (left-hand) The twist grip counterweight (left-hand) The control unit 4 of the left-hand twist grip
Stages in replacing the left-hand handlebar: Couple the lever support to the handlebar, as shown in the illustration. Align the mark of the handlebar with the support of the clutch lever. Screw (handlebar support): 0.9 kg m Apply a light layer of some special adhesive for rubber to the end of the handlebar, as shown in the illustration. Insert the twist grip into the end of the handlebar as far as it will go.

NOTE: Clean off the excess adhesive with a clean cloth. s WARNING Do not touch the handlebar until the adhesive has dried enough to ensure the twist grip is firmly adhered. Install the counterweight of the handlebar twist grip (left-hand) Counterweight of the handlebar twist grip: 20 Nm (2.0 kg m) Install the switches of the left-hand handlebar
10. Install: The twist grip (right-hand) The throttle cable The switches of the right-hand handlebar NOTE: Before installing the twist grip (right-hand), apply a light layer of lithium soap grease to the end of the handlebar.

s WARNING 1 mm

Leave a space of 1 mm between the twist grip and the counterweight. Otherwise the twist grip could stick.
11. Install: The counterweight of the twist grip (right-hand) Counterweight of the twist grip: 2.0 kg m 12. Install: The front brake pump Screw (brake pump support): 0.8 kg m 13. Install: The front mudguard Screw: (Front mudguard): 0.8 kg m 14. Install: The front wheel See the section on FRONT WHEEL FITTING Wheel axle: 6.5 kg m Screw (brake caliper): 3.5 kg m 15. Install: The clutch cable NOTE: Apply a light layer of lithium soap grease to the end of the clutch cable. 16. Install: The front of the fairing 17. Connect: The headlight connectors 18. Install: The rear view mirrors
19. Adjust: The free play of the clutch cable See the section on ADJUSTING THE CLUTCH in CHAPTER 3 Free play: 10 ~ 15 mm
20. Install: The fairing See the section on FAIRING - FITTING.
REAR SHOCK ABSORBER AND SWINGARM
Swingarm Roller bearing Thrust cover Hub Swinging arm axle Self-locking nut Cover Chain protector

4.0 m kg 6.0 m kg

k 10 k 11 k 12 k 13 k 14 k 15 k 16
Bush Flat washer Bolt with washer Full shock absorber Bolt Bush Flat washer Self-locking nut
k Screw 17 k Washer 18 k Self-locking nut 19
A: SWINGARM / LIMIT OF FREE PLAY: B: LATERAL PLAY: 1.0 mm (0.04 inch)

6.0 m kg

OBSERVATIONS ON HANDLING
This shock absorber contains gaseous nitrogen at high pressure. Before handling it, read and understand the following information. The manufacturer will not accept any liability for damage to property or personal injuries stemming from improper handling. Do not tamper with or attempt to open the cylinder assembly. Do not let the shock absorber get in contact with flames or other sources of intense heat. This could cause an explosion through excessive pressure. Do not deform the cylinder or allow this to deteriorate in any way. Any damage to the cylinder will reduce the efficiency of damping. Take care not to scratch the contact surface of the piston with the cylinder as there could be oil leaks. If you wish to get rid of the shock absorber see the section on OBSERVATIONS ON ELIMINATION

OBSERVATIONS ON ELIMINATION Elimination steps: Before throwing the shock away the gas under pressure should be released. Do this by making 1 a 2 ~ 3 mm hole in the wall of the cylinder at a point located 15 ~ 20 mm from the end of the gas chamber. s WARNING
Use protective glasses to prevent eye injuries caused by the escaping gas and/or shreds of metal.
DISMANTLING Rear swingarm s WARNING
Stand the motorcycle up firmly so that it does not fall over. 1. Dismantle: The seat The side covers or cowlings (left and right-hand) See the section on SIDE COVERS DISMANTLING in CHAPTER 3. 2. Lift up the rear wheel, installing an appropriate support under the engine.
3. Dismantle: The rear wheel See section on REAR WHEEL - DISMANTLING 4. Dismantle: The footrest support (left and right-hand ) The chain guard
5. Remove: The screw (rear-lower shock absorber )
6. Remove: The screw (rear- upper shock absorber )

Swingarm s WARNING

Stand the motorcycle up firmly so that it does not fall over. 1. Lift up the rear wheel, installing an appropriate support under the engine. 2. Dismantle: The rear shock absorber 3. Dismantle: The rear wheel See the section on REAR WHEEL - DISMANTLING
4. Check: The swingarm (lateral play) Move the swinging arm from one side to another. Out of specification Change the bearings Lateral play (at the end of the swinging arm): 1.0 mm 5. Check: The swingarm (vertical oscillation). Move the swingarm up and down. Difficult to move / sticking / scraping replace the bearings
6. Dismantle: The covers of the swingarm axle The swingarm axle 7. Dismantle: The swingarm
INSPECTION 1. Inspect: The shock absorber Oil leaks / damage replace
2. Inspect: The swingarm Deformations / Cracks / damage replace
3. Inspect: The oil seals Damage Replace The thrust covers Damage Replace The bushes Scratches / Damage Replace The bushes Pitting / Damage Replace
INSTALLING Swingarm Apply the same procedure as for DISMANTLING but inversely. Take into account the following points: 1. Apply: Lithium soap grease to the oil seals, the bushes and the inside of the thrust covers. 2. Install: The swingarm Swingarm axle: 7.4 kg m
Rear shock absorber Apply the same procedure as in DISMANTLING but inversely. Take into account the following points: 1. Apply: Lithium soap grease to the oil seals and bush

5. Adjust: The chain slack See the section on TIGHTENING The TRANSMISSION CHAIN in CHAPTER 3. Drive chain slack: 20 ~ 25 mm
CHAPTER 8 ELECTRICAL SYSTEM
ELECTRICAL DIAGRAM 8-2 ELECTRICAL COMPONENTS 8-4 IGNITION AND STARTING SYSTEM 8-6 ELECTRIC STARTING SYSTEM 8-8 TROUBLESHOOTING 8-9 CHARGING SYSTEM 8-12 TROUBLESHOOTING 8-14 LIGHTING SYSTEM 8-18 LOCATING BREAKDOWNS 8-20 CHECKING AND TESTING THE LIGHTING SYSTEM 8-23 SIGNALING SYSTEM 8-28 TROUBLESHOOTING 8-30 CHECKING AND TESTING THE SIGNALING SYSTEM 8-32 COOLING SYSTEM 8-46 TROUBLESHOOTING 8-48

ELECTRICAL DIAGRAM

Magnetic flywheel Regulator / Rectifier Starting relay Fuse Main switch CDI Diode x 2 Spark plug Handlebar switch (rh) Handlebar switch (lh) Front headlight / flasher (lh) Front headlight (flasher rh) Neutral switch Rear indicator (lh) Rear indicator (rh)
k 10 k 11 k 12 k 13 k 14 k 15
k 16 k 17 k 18 k 19 k 20 k 21 k 22 k 23 k 24 k 25 k 26 k 27 k 28 k 29 k 30
Front brake switch Rear brake switch Tail light Instrument panel Neutral relay Battery Horn Flasher relay Clutch switch Side stand switch Thermocontact Oil level switch Coil Starter motor Speedometer sensor

B R O L P Y G W Ch Dg

Black Red Orange Blue Pink Yellow Green White Chocolate Dark green
B/Br Sb Br L/B L/W L/Y B/Y B/W B/R B/L
Black/(brown Sky blue Brown Blue/Black Blue/White Blue/Yellow Black/Yellow Black/White Black/Red Black/Blue
W/R W/B W/G Y/L Y/R G/R G/Y Br/W L/R Y/B
White/Red White/Black White/Green Yellow/Blue Yellow/Red Green/Red Green/Yellow Brown/White Blue/Red Yellow/Black

ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS (1)
CDI Spark plug pipe Neutral switch O ring Thermostat switch Starter motor
k Battery 12 k Regulator/Rectifier 15 k Main switch 17 k Rear brake light switch 20
STARTER COIL PRIMARY COIL RESISTANCE: 0.23 W + 20C SECONDARY COIL RESISTANCE: 7.9 K W
k Electrical installation 21 k Fuse 23 k Diode 24 k Oil level switch 27

k 29 k 31 k 32 k 33

Side stand switch Relay Indicator flasher relay Horn
BATTERY: CAPACITY: 12 V 3AH NO MAINTENANCE
IGNITION AND STARTING SYSTEM

CIRCUIT DIAGRAM

The following circuit diagram shows the ignition and starting system
NOTE: For the colour codes, please see the electrical diagram C.D.I. magneto Starter relay Main switch C.D.I. Spark plug Handlebar switch (RH) k Battery 21 k Coil 28 k Starter motor 29

ELECTRIC START SYSTEM

k 13 k 20 k 21 k 24 k 25 k 29
Starter relay Fuse Main switch Diodes Engine/starter stop switch Neutral switch Neutral relay Battery Clutch switch Side stand switch Starter motor
TROUBLESHOOTING THE STARTER MOTOR DOES NOT WORK NOTE: Use the following tools in this fault location Pocket tester: 90890 -03112 4. Neutral relay Remove the relay

1. Fuse (main) Check the condition of the fuse. See INSPECTING THE FUSE in CHAPTER 3. OK NOT OK
Use the battery to supply terminals Br and Sb. Then check the continuity between GB and BW
OK Change the fuse 2. Battery Check the condition of the battery. See INSPECTING THE BATTERY in CHAPTER 3. OK NOT OK Charge or change the battery 3. Starter motor

NOT OK

Change the neutral relay
5. Starter relay Remove the relay
Use the battery to supply terminals Br and WG. Check the continuity between R and R
OK Connect a bridge Check the operation of the starter motor OK NOT OK Repair or change the starter motor
NOT OK Change the starter relay
6. Main switch Place in the ON position 8. Neutral switch
Separate the connections Check the continuity between R and Br NOT OK Repair the main switch Check the continuity: Light blue ground OK NOT OK Change the neutral switch
7. Engine kill switch Place in RUN position (not pressed)
9. Side stand switch Separate the blue connection Fold up the side stand
Separate connections Check the continuity between BW and B. OK NOT OK Repair the handlebar switch (Right)
Check the continuity between B and B OK NOT OK Repair the side stand switch
10. Clutch switch Separate the yellow connection
Press the clutch Check the continuity between BG and LY OK NOT OK Repair the side stand switch
11. Starter switch Separate the connection Press the switch
Check the continuity between WG and BG OK NOT OK Change the handlebar switch (right hand)
12. Connections of the system Check all the connections of the starting system. See CIRCUIT DIAGRAM OK NOT OK Correct

CHARGING SYSTEM

NOTE: For the colour codes please see the electrical diagram
C.D.I. magneto Regulator / Rectifier Fuse CDI Spark plug k Battery 21 k Coil 28
CHARGING SYSTEM TROUBLESHOOTING
THE BATTERY IS FLAT Procedure (1) Check: 1. The fuse 2. The battery 3. The charging voltage NOTE: Dismantle the following components, before locating the fault. 1) The seat 2) The fuel tank To solve these problems use the following special tools: Pocket tester: 90890-03112
4. The resistance of the stator coil 5. The cable connections (charge system)
Tachometer for engine: 90890 - 03113
1. Fuse Remove the fuse Connect the pocket tester ( x 1) to the fuse. Check if the continuity is correct in the fuse NO CONTINUITY

CONTINUITY OK

Replace the fuse
2. Battery Check the condition of the battery. See the section on INSPECTING THE BATTERY in CHAPTER 3. INCORRECT

CORRECT

Clean the terminals Recharge or replace the battery
3. Charging voltage Connect the engine tachometer to the spark plug cable Connect the pocket tester (DC, 20V) to the battery (+) probe of tester (+) terminal of the battery (-) probe of tester (-) terminal of the battery

MATCHES SPECIFICATION

Replace the battery
Start the engine up and rev. up to about 3.000 r/min. Check the charge voltage Charge voltage: 14.0 V at 5000 rpm
DOES NOT MATCH SPECIFICATIONS
4. Resistance of the stator coil. Disconnect the stator coil coupler from the connector. Connect the pocket tester ( x 1 ) to the stator coil. Stator coil: (+) probe of tester Yellow-black terminal (-) probe of tester White terminal
Check to see if the stator coil has the specified resistance. DOES NOT MATCH SPECIFICATION Resistance of the stator coil: 0.4 ~ 0.6 at 20 C Replace the stator coil MATCHES SPECIFICATION
5. Cable connections Check the connections of the charging system See the section on CABLE DIAGRAM BAD CONNECTIONS

Correct these.

Change the rectifier / regulator

LIGHTING SYSTEM

NOTE: For colour codes please see the electrical diagram Fuse Main switch k Front headlight / indicator (LH) 11 k Front headlight / indicator (RH) 12 k Rear indicator (LH) 14 k Rear indicator (RH) 15 k Front brake switch 16 k Rear brake switch 17 k Tail light 18 k Instrument panel 19

k 11 k 12 k 15 k 14

LIGHTING SYSTEM TROUBLESHOOTING
THE HEADLIGHTS, THE SIDE LIGHTS OR THE INSTRUMENT PANEL DO NOT LIGHT UP Procedure Check: 1.The fuse 2.The light switch LIGHTS 3.The cable connections (lighting system) NOTE: Dismantle the following components before locating the fault. 1)The seat 2)The fuel tank 3)The front bulb holders Use the following special tool for solving this fault. Pocket tester: 90890 - 03112
1. Fuse Remove the fuse Connect the pocket tester ( x 1 ) to the fuse. Check to see if the continuity is correct in the fuse NO CONTINUITY

Replace the fuse.

2. Light switch LIGHTS Disconnect the coupling of the light switch LIGHTS from the connector (yellow).
Check (low beam headlights): Place the switch in LOW position (k) Check the continuity between L and G. Check (high beam headlights): Place the switch in HIGH position (j) Check the continuity between L and Y. Check (headlight flash): Hold the headlight flash switch down Check the continuity between L and G.

Fill the battery up with liquid Clean the terminals Recharge or replace the battery
3. Main switch Disconnect the connector of the main switch Connect the pocket tester ( x 1) to the main switch Place the main switch in positions ON and OFF successively. Check if the continuity is correct between the red and brown cables only in the ON position.

IN BAD CONDITION

IN GOOD CONDITION

Replace the main switch.

4. Cable connections Check the connections of the full signalling system See the section on WIRING DIAGRAM CONNECTIONS INCORRECT
See the section on CHECKING AND TESTING THE SIGNALLING SYSTEM
CHECKING AND TESTING THE SIGNALING SYSTEM 1. The indicators do not flash
1. Indicator bulb Remove the indicator bulb Connect the pocket tester ( x 1) to the bulb (+) probe of tester Terminal (-) probe of tester Terminal
Check whether the continuity is correct in the headlight bulb CONTINUITY OK
Replace the indicator bulb.
2. Bulb holder bush of the indicator Place the bulb in the holder Disconnect the indicator wires (chocolate and black) or (dark green and black). Connect the pocket tester ( x 1) to the indicator cables To check the right indicator: (+) probe of tester Dark green cable (-) probe of tester Black cable To check the left-hand indicator: (+) probe of tester Chocolate cable (-) probe of tester Black cable
Check/replace the indicator.
Check if the continuity is correct in the bulb holder bush of the indicator. CONTINUITY OK
3. Turning switch TURN Disconnect the large coupler (yellow) from the lefthand switch on the handlebars Connect the pocket tester ( x 1) to the turning switch TURN With the turn switch in position : (+) probe of tester Brown/white terminal (-) probe of tester Dark green terminal With the turn switch in position : (+) probe of tester Brown/white terminal (-) probe of tester Chocolate terminal Place the TURN switch in positions d and c successively Check if the continuity is correct in the TURN switch. Switch position d (right) c (left) : Continuity In good condition X In bad condition X X X IN BAD CONDITION
X : There is no continuity
Replace the handlebar switch.
4. Voltage Place the main switch in the ON position Connect the pocket tester (DC, 20 V) to the coupler of the indicator relay. (+) probe of tester brown terminal (-) probe of tester to ground
Check the voltage of the indicator relay Voltage of the indicator relay: 12.0 V MATCHES THE SPECIFICATION