Yamaha rx 100 manual de taller

manual de rx 100

1. NOTICE

| was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their
Tmechanles, It fs not possible to pul an entire mechanic's education Into one manual, so itis |
med that persons using this book lo perform maintenance and repairs on Yamaha motorcycles have |
ban understanding ofthe mechanical concepts and procedures inherent in motoreycle realy

‘nit to

airs or service 10 this model may render

la Lie. is continually striving to Improve ail modi
es In specifications or procedures will be torwarc
eable, appear in future editions of this manual.

red. Modilications and significant
‘authorized dealers and wil, where

ESCORTS LTD. MSD.
SERVICE DEPARTMENT

HOW TO USE THIS MANUAL |

son inspecting or repairing the motorcycle. ee Re
à
(VAL FORMAT
of the procedures in this manual are organized in a sequential, step-by-step format. The information
O e vac |

ings
ting/Damage —+ Replace,

XPLODED DIAGRAM

mc useage tuo,

|
À |
|

à before onch disassembly section for ease in identlying correct

2. a |

ILLUSTRATED SYMBOLS.
(Refer to the illustration)

Iustrated symbols lo are designed as thumb
tabs to indicate the chapters number and
content

@ General information

poro inspection and adjustment

À Engine

© Caruraton
Chassis
a

Electrical
ppendices

lea] [ND Inuarataoymbois@to@are use toidantiy te

specifications appearing in the text

E
=

@ Filing fie
E @ Lubricant

U | arca
Cy

(2 Engine mec

lilustrated symbols (3) to & in the exploded
[E

of lubrication paint,
® 62 Apply lacking agent (LOCTITE: or equivalent)

à ‘pp engine ol
‘Apply gear of
©

9 Apply molyodenum disulfide oil
9 Apply whee! bearing grease

| N App lightweight lithium soap base grease
fo) à ‘Apply molybéenum disulide grease.

3. INDEX
GENERAL INFORMATION en
FEI
PERIODIC INSPECTIONS a
AND ADJUSTMENTS NSF
J
ENGINE OVERHAUL +»
ENG E
CARBURETION | $
cars
CHASSIS $e |
CS 5 |
ELECTRICAL E
APPENDICES [AN
APPX 7

4. CHAPTER 1
GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER.

IMPORTANT INFORMATION.
‘ALL REPLACEMENT PARTS, 1
GASKETS, OIL SEALS, AND O-RINGS, 1
LOCK WASHERS/PLATES AND COTTER PINS 1
BEARINGS AND OIL SEALS TT
ano] ci 1

SPECIAL TOOLS.
FOR ENGINE SERVICE
FOR CHASSIS SERVICE
FOR TUNE-UP,

FOR ELECTRICAL COMPONENTS.

5. GENERAL
INFORMATION

MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER

The frame serial numbor(Dis stamped into the
right side of the steering head pipe

ENGINE SERIAL NUMBER,
‘The engine serial number(1¥s stamped into the
Left side of the engine,

The first three digits of these numbers are for
model identitications; the remaining digits are the
unit production number

Starting Serial Number:
RX100.

13-000101

more: RO ES
Designs and pecto ave sujet change
what es

6. IMPORTANT INFORMATION

YAMAHA LIT

IMPORTANT INFORMATION

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts
cements. Use oll and/or grease

by Escorts for assembly and

GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, sal, and O-rings should be
replaced when an engine is overhauled. All
‘gasket surfaces, oil seal lips, and O-rings must
Bo cleaned,

2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil seal
Nips.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock wasners/plates(Dand cotter pins must
be replaced when tney are removed. Lock
tab(s) should bo bont along the bolt or nut
flats) after the bolt or nut has been properly
tightened.

BEARINGS AND OIL SEALS

Install the bearings(s\Dand oil sets) Dat
their manufacturer's marks or numbers facing
utward. (In other words, the stamped letters
‘must bo on the side exposed to view.) When
installing ol seal), apply aight costing af
light-weight ithium base grease (09. Sowa
Grease MP.) tothe seal lis}, Ol the bearings:
Nberally when Intalin.

CAUTION:

Bo nol uve compressed alr to spin the bearinge
dy. Fa causes damage fo the orang ar

7. SPECIAL TOOLS

CIRCLIPS
1. All circllos should be ins

alter one use. Replace

instaling a circo
ged comer ie pas

thrust @itre
@snatt

SPECIAL TOOLS
‘The proper special tools a

Using the corre

Improvised techniques.

FOR ENGINE SERVICE
1. Flywheel Holding Tool
ESM-100000201

2. Flywheel Pullor
ESM-10000202

8. Crankcase Soperating Tool
'ESM-100000265

8. See the sectional view.

complete and accurate tune-up and assembly
ial tool wil help prevent
‘damage caused by the use of improper tools or

8. SPECIAL TOOLS

4. Cluteh Holding Too!
ESM-100000233 >

O

5. Crank installing Toot
ESM-100000266

1 Pot
2801
3 Adaptor:

6 Driving Sprocket Holder
ESM-100000208

7. Piston Pin Replacer
ESM-100000207

=O

9. 8. Piston Ring Compressor
ESM-10000021

10Punch
ESM-100000233
For Gear Shaft Soa!

(ae

FOR CHASSIS SERVICE
1 Steering Nut Wrench
100000221

ESM-1

2. Front Fork Top Plug Spanner
ESM-100000214

10. 3. T Handle
ESM-100000213

4, Front Fork Inner Tube Adjuster
ESM-100000264

EP |

5. Speedometer Gear Nut Spanner
ESM=100000237

A

FOR ELECTRICAL COMPONENTS.
1. Pocket Tester
ESM-100000270

11. CHAPTER 2
. PERIODIC INSPECTIONS AND
ADJUSTMENTS

NOTES ON MAINTENANCE .

PERIODIC MAINTENANCE/LUBRICATION .

ENGINE .........
SPARK PLUG . 2111"
AIR CLEANER ELEMENT
TRANSMISSION OIL.
AUTOLUBE PUMP.
CARBURETTOR
CLUTCH …

CHASSIS
BRAKE |
TYRE, 5
DRIVE CHAIN |:
STEERING HEAD

ELECTRICAL .
BATTERY

12. ca E Q ins
NOTES ON MAINTENANCE i

NOTES ON MAINTENANCE

1. Thoroughly clean the frame and engine of dirt
‘and dust in order to pravent them from enter
ing the inside of the engine.

of ire.

3. When the spécial tools are required, be sure to

‘use thom so that damage to the moloreyela
parts can be avoided.
‘Always use the right 10018 and instruments tor
the right purposes. (Avoid using an open-end,
wrench as much as possible, in place of a box:
or socket wrench)

4. Always use a new gasket (packing), O-ring,
cotter pin, oreip, ‘te. for repairs.
‘Also use genul parts, oll and grease,
br those recommended by Escorts Avoid using
ther brands.

5. During servico, take special care so that you
don't get injured or burnt from the engine,
‘exhaust pipe or muffier.

13. onsen: ©
© Locknut

Screw In adjuster @) until tight and back it
ut 174 turn,

Tighten:

+ Locknut D

CHASSIS
BRAKE
Front

2. Adjuse
Free play by aduster @)
3. Tighten
O)
5e mm

Roar
1 Adjust
Free play © =
by tuning The aaluster @) (Ret. Pago 211)

14. O Adjuster
TYRE

1. Inspect
+ Tyre wear

er

@ Wear indicator
(8 Replacement limit 1 mm.

2. Check
= Air pressure

MAXIMUM 162 Kg.
LOAD"

Front Rear

Single Rider | 1.5 ka 20 kg)
em, (22 ps) | Jem’, (28 pal)

Doukimider} 159 | 216
em ta | emt 18

* Load is the total weight of cargo, rider, passenger
and accessories

Q Too nian Rey Poor Reed hong
Good — Good & sale ici
Too tow — Causes higher re wear
{uel economy low.
DRIVE CHAIN
Slack Check

1. Remove

15. DRIVE CHAIN/STEERING HEAD

Slack Adjustment

(O Adiusing boit

NOTE:
Be sure that both right and left chain pullers are
in the corresponding positions

STEERING HEAD
Checking
1. Raise front wheel off the ground,
2. Check:

+ Steering head bear
Gently rock fork a
forware

Looseness + Adjust.

tor looseness
imbly backward and

Adjustment:
1. Looser
«Steering titing boit ©,
Front fork pinen bolts (E)
2. Adjust:
+ Steering head ring nut ©
Tighten nut until steering head ie tight
without binding,
Heavy bincing =? Replace bearings,

3. Tighten:
2 Swing thing son
2 Front fore pinen batt
(OY Steering Fitting Bolt (D:
3: mg, (22 Tb)

Front Fork Finch Bot D:
2.0 m.kg, (14 Mb)

16. LAA FE RO EY

BATTERY

ELECTRICAL

BATTERY
Pld Level
1. check
* Fluid level @ 3
Fuld sel Shou be netten Upper)
and tower ove ie
Ute only diles

for roiling

Battery Charging.
1. Check:
© Battery fluid gravity

‘SPECIFIC GRAVITY

CLIMATE — [INITIAL AT 20° Cf ULLY CHARGED

| À (AT 20°C)
= TROPICAL 1240 1240125
(ABOVE 30*C)|
COLD
TEMPERATE 1.280 126041

(BELOW 20°C)|

2. ll gravity Is below specified, recharge Battery.

‘Charging Hours: 10 hours

17. NOTES ON MAINTENANCE

6 Battery
‘Tako care so that the battery fluid does not spit
on your clothes body or the motorcycle

7. Notes on disassembly and reassembly

a. Place al removed parts neatly and separatoly
in groups so that they will not be contused or
fost,

b. Wash the engine and transmission part in a
détergent oll and blow them out dry with
compressed air.

©. While checking the smooth movement of parts,
install them,

4. Oil the contact surtaces of the moving parts.

8. Tightening torque.
‘Tighten the parts to specitication by using the
torque wrench,

18. EE E Ey Tf

PERIODIC MAINTENANCE/LUBRICATION

Lt

PERIODIC MAINTENANCE/LUBRICATION

= u Unit: Km

TR REMARKS [BREAKIN | THEREAFTER eveny |
1000 3000. [600 Ta

E > or 3 montnalr 6 month or témoins

[Spark Plug [hock Clean or roplace 3 0

Ale er [Cioan, Repiace 1 necessary} —9 a za

Gurbursiior —|Chees/Adjusvcio speed. starter operon] 0" y BE
©

Ful ina [Check fuel nose for erack or damage.

Tranamislon oll |Repiac Warm engine bara anna) | RERACE

Aulolubs pump | Check/Adjust Air bieeding™

Brake" [Gheck“operation 0
Citer [Check operation = a
Fear arm pivot” |Check rear arm assembly for igoseness | 6
place Silent lock bushes 24.000 or
24 monına. x |
LITE (Check balancerdamage/urouvspore y
Nonne
Weel Bearings” | Chock be: sony Tor Toowaneee7
damage, Iteamages, È
Siearing bearing” | Check bearings assombiy for lseness. | 0 REPACK
(GREASE
1 | Fronron oporation oi leakage FF CHECK CHECK | REALAGE
| ie
Fear shock | Gheck opero val eg y
absorber
Drive Chain | Gloanfbe/aion® D
Check tension very 1000 kms /lign”
Fitings/Fasteners Check all ehassia/engine/Cyi/Gyi Head | © a
ET = Check speciic gravity +4
= Check bresthor pige lor proper
‘operation, o o
— Tock sloctroiyte lvol/add sta
water ovory 18 days
Deearbonising® | Ramove carbon 1rom (Gyi/Gyl Haze °
Piston Assy/Mutlir) q Es +
[onion Timing” | chock
Fuel Strainer | Clean E 2 y
Fuel Tank/Fual | Clean,
al
res. Check Coms

{His recommanciod that these lima be serviced by Yamaha center.
‚Medium weight yoo! bearing grease.

«Uso 178 2 See Servo Teleshocas oll of Ms Indian Ol.
Battery Specie gravity = 1240/20"

YAMAHA LL

23

21. SPARK PLUG/AIR CLEANER ELEMENT TRANSMISSION O1L

ENGINE
SPARK PLUG
1. Clean:

© Spark plug
2. Adjust

+ Plug gap)

Plug Gap:
07-08 mm

AIR CLEANER ELEMENT

Squeeze excess solvent out of the element
and dry.

CAUTION:
DO NOT SQUEEZE BY TWISTING

3. Apply
‘+ À small quantity of 2-stroke engine oil
‘Squeeze excess Oil
4, Install:
+ Air cleaner element

TRANSMISSION OIL

22. Stat the engine and et it warm up
© Drain boit (D)
Drain oll alter warm
3. Install ER
+ Drain boit @

El Drain Bolt:
2.0 mag. (14 4.10)

8 Fil
+ Transmission oil

es

4. Check
+ Oil level

AUTOLUBE PUMP

Cable Adjustment

1. Check to see if pump guide pin () is aligned
vil mark on adjusting pulley (2)

2. if not aligned, align by turing adjuster @ in
ï

@ Locknut

23. | BY E a a a E E
AUTOLUBE PUMP/CARBURETTOR |
;

Minimum pump stroke adjustment |
1 otae engine so that aus pate mous out |

2. Measure:
+ Minimum pump stroke

A Minimum Pump Brake
020-028 mm

8, If clearance Is not correct, adjust by the shim

‘Adding of shim will increase the stroke
and vies versa.

Alr Bleeding
1. Remove:

2) Pump bleed screw @)
Keep oil running out until air bubbies
disappear.

2 Install
Blood sorew @) |

3. Star the engine and pull the pump wire)
all the way for some minutos

‘CARBURETTOR
Throttle Grip Free Play
+. Loosen

* Locknut ©
2 Adjust

+ Cable tros play @ 1-2 mm
Turn cable adjuster @) nor dut
Tighten
= Locknut D

24. CARBURETTOR/CLUTCH El

Throttie Cable Free Play
1 Loosen: _
Loosen ©
Adjust
+ Cable froo play (2) 58 mm
Turn cable adjuster (5) in or out
Tighten: à
+ Locknut (D)

2

Speed

4. Turn pto ar screw (D) in until lightly seated.
2. Back out by specific numbers of turns
VAT or Ar Serew Turn Out F
1-1/421/2 ¥
Orwasın
3. Start the engine and lt it warm up
4 Tum the thot stop serew (Dn or out une

tilidle speed is at spocilled rpm

cy

Engine Idle Speed:
1,200 + 50 rpm

CLUTCH
Cable Adjustment
* Loosen: u

* Locknut
2 Adjust

+ Cabio oo play (2) 225 mm

Tür cable adjuster @ in or out.

3. Tighten

2 Lociout O,

Mechanism Adjustment
1. Remove:
«Loft crankcase cover
2. Position the push le
adjuster
3. insta
«rl crankcase cover @)

Bev ne aio

25. ENGINE OVERHAUL

ENGINE DISASSEMBLY
CYLINDER HEAD AND CYLINDER
PISTON .

FLYWHEEL MAGNETO
CLUTCH...
KICK STARTER ...

SHIFT SHAFT „u...
GRANKOASE
TRANSMISSION AND SHIFTER
CRANKSHAFT...

INSPECTION AND REPAIR .
‘CYLINDER HEAD
CYLINDER
PISTON
PISTON RING
PISTON PIN AND SMALL END BEARING
CLUTCH
KICK STARTER
CRANKSHAFT.
TRANSMISSION
BEARINGS AND OIL SEALS

ENGINE ASSEMBLY AND ADJUSTMENT ..
(CRANKSHAFT 6
TRANSMISSION AND SHIFTER.
CRANKGASE ASSEMBLY :
SHIFT SHAFT . a
KICK STARTER . re
CLUTCH .. Ra
PRIMARY DRIVE GEAR
FLYWHEEL MAGNETO .
PISTON ..
CYLINDER |
GYLINDER HEAD ..
ENGINE MOUNTING

26. + Cylinder

PISTON
4. Remove:
+ Piston pin clip @)

NOTE

Before removing the piston pin cli, cover the
Srankesso with à clean rag (0)

FLYWHEEL MAGNETO

+. Remove:
+ Crankcaco cover (Left)

‘ach:

+ Flywheel Holding Tool ESM-100000201()

Be

FFhraneel holding nut ©
Ecco
nar

Auach:
Flywhee! Puller ESM-100000202 @)
(Lett-Hand-Threads)

Remove:
= Fiyaneel O)
2 Woodrutf Key

Stator retaing serews O,
2 Real out ane wi ©)
+ Stator assembly @)

27. 3. Repair:
+ Crankenatt
Using copper hammer @)

4, Measure:
+ Eigen side clearance

ae fooler gauge (1)
‘Out of specification — Repair or replace.

Big End Side Clearance:
02-07 mm

5. Measure:
«Small end free play
Out of specification > Replace.

B ‘Small End Free Pl

TRANSMISSION
Shit Sha
12 Inspect
shift hat D
+ Springs!
Wear/aend — Replace.

28. INSPECTION AND REPAIR

Shit Fork.

=P and shift cam contact surface)
& + Sion quite bar
‘Cheling/Benda/Bamage > Roplece,

+ Shift fork movement
(on shift cam)
Unsmooth operation > Replace fork and/or
guide bar

on ~2 Shit Cam
OS 1. mpect
VENÍ cam grooves E)
Kear/Damage/Seratènes =» Replace.
«+ Sn cam pins
By ins
Wear/oamage > Roplace

E y

Main Axle and Drive Axle
1. Maasure
* ue runout
Use contoring device and Dial Gauge @
Dut ot apectteation => Replace

Runout Limit
04 mm

Gears
1. Inspect
«Gears
Damage Wear -> Replace
2. Check:
+ Gear movement
Unsmooth operation > Replace.

3. Inspect
Matching dogs
(Gracks/Wear/amage — Replace.

29. ENG

INSPECTION AND REPAIR

BEARING AND OIL SEALS

7 1. Check:
+ Al bearings
(with finger)

Rough spot/Play — Replace,

= À SAT ao les

amage/Wear + Replace,
> Damage Wear + Rep!

Always replace orankshaft oil seas,

if
(| Nor ee
( (| =

ee es FE KO FE EN

30. ENG

ENGINE ASSEMBLY AND ADJUSTMENT

ENGINE ASSEMBLY AND
ADJUSTMENT

a ©
{Before assembling tha engine, thoroughly wash
the parts in mild solvent.

CRANKSHAFT

a

WOODRUFF KEY

OL SEAL

1. attach:

+ Crankanat nealing Tool
Esm-roogo0286 (D)

ftp une ttt sce crankcase)

2, Tighten:
2 Rut of the Installing too!
ible tno connecting rod at top dead conter,

31. % 3 n
ENGINE ASSEMBLY AND ADJUSTMENT

‘TRANSMISSION AND SHIFTER

RIVE AXLE

BEARING
IL SEAL
COLLAR

DRIVE
SPROCKEr
on

Ta mek (10 FR)

Ser WHEEL quan \
a
GUIDE BAR ATH WHEEL GEAR És N
an CR
ano WHEEL GEAR
NS Ÿ
a FORK 3 Dos CLUTCH Eee SS
SO ge) >|
STOPPER Leven zu men |
ie O
A @ |
CERAMICA

am
4TH PINION en de >
en CC

ano pion cean— UE
EA 17
ND PINION GEAR
2 en

FORK 2 BUND PLUG

1. insta:
+ Transmission assembly
2. Check
+ Transmission operation
Incorrect operation -= Renssombiy.

32. RE A A a ES a L
ENGINE ASSEMBLY AND ADJUSTMENT

CRANKCASE ASSEMBLY

1. Apply:
+ Yamaha Bond Not
(to both erankease mating surtaces.)

Insta
Bone! knock pins D

instal:
« Right orankcaso half
(Tap with plastic hammer)

Tighton:

« Erankcaso tightening screws
‘Tighten the screws in showing sequence and
in two stops.

El 0.7 mag. (5.1 110)

33. 4. Install ;
+ Stopper lover assembly (D)

[A 14 mag, (10410)

+ Shit snaftassomoy (2)
© Washer @)
+ Grele @
2 Adjust
Shit lover postion
er screw @) and locknut E)

2. Gap @ To be equal on both sides

34. nn ENG
ENGINE ASSEMBLY AND ADJUSTMENT.
KICK STARTER

|

Rep a SPACER RETURN SPRING
dx aran
\\@
| 97
e e
No |
eae | Wop roue ees
onc | Po:
sen vb
ina
idos arar sem
the kick clip (D) in groove (2)

i:
of the crankcase as shown,

3. Hook
+ Return spring @)

shor
À Kick die goer ©
© Washer (3)
+ Calp @

35. Am! ENG
ENGINE ASSEMBLY AND ADJUSTMENT
cuuron
ae durer
A
pures JR
FES
8

"THRUST WASHER —
®

Were

ES
>> _ousen
ADJUSTER

(Pn, EEE

4, Install:
rro washer D

+ Auen reusing ©
= Trust washer)

2 Instat

Clutch Boss!
4.3 m-kg, (31 fes1b)

36. RE DEE RP LE Em
‘ENGINE ASSEMBLY AND ADJUSTMENT

ENG

3. Install:
e Erico

RENTO
AO]

‘CAUTION? = eee

‘The clutch plates must be so installed thet

thelr cutaways do not overlapeach other.

As Bl:ma [ie (5) an
4. Ina

+ Pressure plato D

+ Springs @

DES)

Clutch Spring Nut:
0.6 mg. (43 ftib)

PRIMARY DRIVE GEAR
Y Install
«Spacer @)
+ Primary drive gear @)
aight Key)
+ washer @
“Nu

Primary Drive Gear.
5.5 mg (40 ft1b)
FLYWHEEL MAGNETO

bat
Biter son O

=
(ON "ran ann

2. Connect:
Neutral switch led vire @)

BÉ
Eee
=

Flywheel Magneto:
7.0mkg. (50 fb)

37. ENGINE DISASSEMBLY |

CLUTCH

+. Remov
«+ Crankcaso cover (Right)
+ Gluteh spring bots
Clutch springs: |
+ Pressure plate 1 |
+ Friction plates!

+ Clutch plate @)

2 Romove: s
Seren arv gear out @
Ue tied rad

her

Primery crive gear @)
Straight key

+ Spacer

3. Attach: =
* Clutch Holding Tool ESM-100000233 1)
4. Remove:
= Clutch assembly,
+ Oil seal retainer (2)

KICK STARTER.

* Girelp

38. [ sum:
3 ENGINE ASSEMBLY AND ADJUSTMENT

PISTON

E

mans ur

AE

À piston pin
PISTON pm cur|

[ALWAYS USE A NEW ONE]

Insta
«piston rings (O)

< Small end beanng ©
platon pin)

2 Piston pla lips (NO)
+ Piston &)

sure ring anda) ara propariy fitted
ating pins In piston grooves.
‘on piston domo must face ex

39. ENGINE ASSEMBLY AND ADJUSTMENT it

CYLINDER
1. Install
+ Gasket (New)
+ Oylinder

SY

CYLINDER HEAD.

1. Install

« Head gasket (D)
ylinder head 2)

+ Nuts@)

Cylinder Head:
25 mg, (18 tb)

ENGINE MOUNTING,

Engine Mount Bolts:
GQ 20 mao, 22 tue)

2) 6.0 mg, (43 U)

5 mg, (25 tb)

40. ASSEMBLY
SHIFT SHAFT

1. Remove:

Fab a
ri Pas

2 Remove
+ Shift shaft assembly @)
+ Stopper lever assembly E)

CRANKCASE

1. Remove:
+ Crankcaso tightening screws

2. Attach:
© Srankcase separating too ESM-100000265 0)
{Go the right side crantcaso)
AoE A
‘Make sure the 1001 body s parallel with the caso,

3 Tight
2 Securing bo @

HS SHIFTER
+ Rom

CE cam bina plug O)

+ Gasket (2)

41. ta] ENG
ENGINE DISASSEMBLY

2, Remove:
2 Transmission assombly

CRANKSHAFT
1. Attach

+ Crankcase separating tool ESM-100000265(
NOTE:
Make sure the 1001 body is parallel with the case.
2. Tighten:

+ Securing bolt 2)
3. Remove

e Crankshaft Assy |

42. INSPECTION AND REPAIR
CYLINDER HEAD.
1. Remove
+ Carbon deposit
Use rounded scraper.
NOTE:

Do not uso a sharp instrument and avoid damage
ing or scratching, Es

2. Measure:
+ Cylindar head warpage
Out of specification =» Resurface or replace

a

Less than 0.03 mm

(1) Straight edge
@ Thickness gauge

CYLINDER
1. Remove
+ Carbon deposit
Use rounded scraper.

NOTE — — — — — = —.
Do not use a sharp Instrument and avoid damage
or scratching,

2 np
2 Eyindar wal
Near Sc ignes -> Rebore or rolac,
3. Measure
e Éninger bare °C"
She Cyinéer Bore Gauge,
Sut of specication > Rebore.

on

Toyingerbore
© 2 (acimum O)-(inimum C)

43. INSPECTION AND REPAIR

PISTON
1. Inspect
= Piston wall
Wonr/Scratches/Damages => Repair or re
place. |
2. Remove:
= Carbon deposit
{Use rounded scraper.

NOTE: Se |

+ Do not use a sharp Instrument and avoid damag
Ing or scratching.

+ Aller corracting, clean the piston with a clean
cloth,

3. Measure:
= Piston outside dlameter 'P"
Out of specification > Replace.

Sire A ]
Standard 49.966 — 49.988 mm)
<Limit> 49.90 mm
(Oversize 1 5025 mm
Oversize 2 50.50 mm

5075 mm

51.00 mm

+ Measurement should be mad
bove the bottom edge of the piston

point 10mm

ski
D 10 mm

Piston pin

©
4. + Piston clearance

" Out of specification -> Rebore cylinder or
replace piston

Piston Clearance = Minimum
Cylinder Bore © — Platon dia P*

.030~0.038 mm

44. INSPECTION AND REPAIR

PISTON RING
1. Measure
+ Side clearance G)
Uso a foeler gauge @

‘Out of specification => Replace piston and/or

rings.
Side Clearance:
0.02 — 008 mm
2. Measure:

End gap. D
Una feclr gauge ©)
Out of speetetion + Replace rings as a set.

Standard] Umit

End Gap: |
(male) | 015-095 mm | 06 mm

PISTON PIN AND SMALL END BEARING
1. Lubricate:
«piston pin D and bearing
2. instal
Bist pin and bearing
{into Small and of connecting rod)
3. Chock?

play
ree play -> Inspect connecting rod for wear
Waar-> inspect connecting rod and piston

pin

4, Insta
« Piston pin (D)
{into piston)
5, check
= Free play

free play > Replace piston pin and/or piston.

45. ENG

INSPECTION AND REPAIR

cuurcH
Gluteh Housing
1 Inspect
"Bogs on housing (E
Cracke Woar/Damäge — Deburr o

+’ Gleunierental play
Play > Ra
NOTE:
DO NOT GLEAN WITH PETROL
(Clutch Bose
1. Inspect
+ Gluten boss spines)
Scoring/Viear/Damage > Deburr or replace
2 AA PAN
Seoring an cluton plato splinos will cause erratic.

een

Fricllon Plate

1. Inspect
+ Friction plates)
Damage/Wear => Replace as a set
2. Measure’
+ Friction plate thickness
‘Measure all at four points.
‚Out of specification => Replace as a set.

Chen Pinte
1. Measure
“Slot plate D warpage
Se suvace sate (2 aná focor auge,
Suk of enscilcaton > Ropa.

Warp Limit:
0.05 mm

46. INSPECTION AND REPAIR

Clutch Spring

1. Measure:
+ Free length
Out of specification > Replace as a sot

| Minimum Length: Fi
mm

KICK STARTER
1. Inspect:
+ Kick gear teeth
* Kick idle gear teath
Wear/Damage -> Replace.
2. Check
© Kick gear movement

3. Moasure:
* Kick clip friction force,
‚Out of specification => Replace kick olip.

Kick Cilp Friction Force:
08-12 kg,

CRANKSHAFT
7 Mau, ©)

+ Runout (@
Use Dial Gauge )
Out af epecitieation -» Repair or replace.
© 78mm

‘lunout Limit:
0.03 mm

2. Measure:
Crank wish

Gut of specification =» Repair or replace.

AE ELLA amos

47. CHAPTER 4

CARBURETION
CARBURETTOR 4
SECTION VIEW... Be Ber
WORKING RANGE OF EACH COMPONENT = #1
GEMOVAL AND DISASSEMBLY S 22
INSPECTION 42
REED VALVE , 43
INSPECTION 43

48. CARBURETTOR

VALVE STOPPER HEIGHT.
rem oz

ae

VALVE STOPPER
REED VALVE

Float REG.
ime

de SECTION VIEW.

ORRIN RANOEOF
O

o]
al
al

N mac Dile

Pt ae ame de 5 Cd

49. Ben

REMOVAL AND DISASSEMBLY
Y. Remove:

+ Right side cover
+ Air cleaner case screws (i)
Loosen:

# Carburettor joint screw

3. Disconnect |

+ Fuel hose
+ Oil delivery hose (3)

4. Remove
Peewee n
3 Carburetor ton

5. Disconnect
volt cable @)

6. Remove:

+ Starter plunger@®
Ele

INSPECTION
1. Using high
‘and Jets.

blow out all passages

2. Inspect:
Neeate valve
‘Damaged oF worn -+ Replace as a set.

D Gasket
2) vaio sont
‘Noodle valve

Check here

50. CARBURETOR: E]

3. Inspect
Throttle valve @
+ Jot seedie (2
Scratch/Bont -» Replace
2. Mossure:

‘Float height (D) Without Gasket
Incorrect — Agjust

Float gh =
21010 mm |
sao bm fon rong oy Bagot
(oe ORNE

5. Adjust
‘Float height ei.
by bending the lang ()

REED VALVE
INSPECTION
1. Measure
+ Valve stopper height
Out of specification >
+ Reed valve bending @)
Gut of specification = Replace

Reed Valve Bending Limit
03 mm

A
Mbs en he tower comer alo food and

stopper plate

51. CHAPTER 5
CHASSIS

WHEELS, BRAKES, SPROCKETS AND CHAIN
FRONT WHEEL REMOVAL
REAR WHEEL REMOVAL
INSPECTION
INSTALLATION +

FRONT FORK
REMOVAL ......
DISASSEMBLY
INSPECTION ......
REASSEMBLY ..
INSTALLATION

‘STEERING HEAD
REMOVAL.
INSPECTION.
INSTALLATION

REAR SHOCK ABSORBERS AND SWINGARM
REMOVAL >
INSPECTION .
INSTALLATION.

52. ROCKETS AND CHAI

WHEELS, BRAKES, SPROCKETS AND CHAIN

SS
ae ||

/ Onsen

~ ‘sore

D
GA

Se E ‘oe
2 ?

FRONT WHEEL REMOVAL.
1. Place a suitable stand under the engine.
2. Disconnect

= Brake cable D

Disconnect:

= Speedometer cable ©
Remove

53. El STEERING HEAD.

4. Install
Front forks
jandle crown
+ Steering fiting bolt

Fitting Bolt:
4.0 m-kgi29 ft1b)

5. Tighten:
+ Inner tube pinch bolts

¡ÓN Inner Tube Pinch Bolt:
mag, (11 fib)
mix, (22 tb)

54. REAR SHOCK

REAR SHOCK ABSORBER AND SWINGARM

ORBER AND SWINGARM

REMOVAL
1. Remove
= "Rear who!
2 Chain case!
2 Driven Sprocket
à Drive chain
2. Remove
"Shock absorber mount bolts ©)
à Shock absoroers

3. Romove a
Pat sate ut ©
2 Pet anatt ©
À Swingarm

55. de CHAS
REAR SHOCK ABSORBER AND SWINGARM

INSPECTION
1. Inspect

+ Shock absorber
e (Ol leaks/Damage — Roplaco,

2. Inspect
"Swingarm
‘With the swingarm Installed grasp the
‘swingarm and to chook for les play
Free play => Replace bushes,

AT Swingarm Free Play Limit
20 mm

3. Ingpect
= Bush À
Pivot Shatt (2)
ust/Dity > Clean or Replace.
Bent > Replace

INSTALLATION.

Reverse removal stops.
1. Grease the bushes and pivot shaft

swingarm
+ Phot shalt

[OY semis. ro 14

56. is

NL SEAL
BEARING

REAR WHEEL REMOVAL
aoe the motorcycle on its centerstand.

Romove

+ Brake tonsian bar (D)

2 Brake roo)

sera ©

+ Rear whee!

57. + Sprocket shaft nut
+ Sprocket assembly
+ Drive chain

INSPECTION

2

Inspect
Axle shaft
Roll the axle shaft on a Flat Surface,
Bende => Replace

Inspect:
+ Whee!
Cracks/Heavily Bends => Replace
Measure
+ Wheel runout
Out of specification => Retighten or Replace,

ST Rim Runout Limits
Radial (À) — 2.0 mm

Lateral (2) — 2.0 mm

4

Inspect
+ Vineel bearings
Bearings allow play in the whee! hub or
‘whee! furns roughly => Replace.

58. a Erg 5 | WHEELS, BRAKES, SPROCKETS AND CHAIN |

(Out al specication => Replace.

Brake Drum Wear Limit
131 mm.

7. Inspoot:
+ Drive sprocket
+ Driven sprocket
Wear > Replace with the chain as set.

Good
No Good
8. Measure:

+ Drive chain length (10 Links) @)
Out of specitiction => Replace.

SA Drive chain Length (10 Links)
it
rm

INSTALLATION
4. Install

+ Wihecis

Reverse removal steps.

Note the following Installation points:
+ Lighty grease the wheel oll
teath of the speedometer dri

lightweight, lithium bese grease.)

+ Be sure tnat topper Is positioned
correct,

+ Install te chain clip with rounded end facing
the direction of travel

(OD Drive direction

59. FRONT FORK

FRONT FORK

“aster
ES
78

spacer

// [Fee

ans

[SERVO reueshocas OIL
FC por sae

REMOVAL

Remove:
2 Front whos!
2 Front fender

2, Looser

«Front fork pinch boit ()
+ Cap bolt @
Use Top Plug Spanner
(ESM-10000021) @)

Loosen
+ Front tor pinch bolt (Lower)

Front fork

60. FRONT FORK

“aes
S pe

so

EYE

DISASSEMBLY

+ Cap bolt @
+ Spacer.

* Fork oil

à Remon
FE le Soctemosa ro securing bot ©
Use Hand @>es-r00000218)
+ ir tobe
Se IS
Betis

4, Remove:
+ Dust cover
+ Giip oliseal ©
+ it seal @)

INSPECTION

Een sing À
SP fenton = à

ST rar pring Fr
HET mm

61. FRONT FORK

ASSEMBLY
‘instal

ylinder Complete ()
pina (8
inner tube @)
Bolt Hex Socket Ha @)

ET ee cone
pertain

LOCTITE OR EQUIVALENT.

> Dust cover

® Inner tube,
© Outer tube

3. Fi
+ Front fork

NP] each Fore
175 2300

SERVO TELESHOCAB' OIL

4, Install:
So] 6 Fork spring @

Lo : ION

Beit

re)

8. Mor nta th fon fr,
EN

‘Cap Bott
23 mia, (17 fib)

62. LA] cHas

‘STEERING HEAD

STEERING HEAD.

Hanus BALL (IE. pes
‘CROWN
ama 018 po)

FTGHTEN ONTIC BALL RAGE Te FIKeD
IEERTAINLY ANO STEERING SHAFT
fevowves smooth.

LUNOER BRACKET

REMOVAL
1. Remove:
Front whee!
Front forks
2, Disconnect
Brake cable
Throttle cablo
Gui cable

3. Disconnect
» Electrical load wires
(in tha headlight case)
4, Remove:
adlight

5, Remove.
= Steering fiting bolt
+ Handle crown assembly
© Headlight stays
{together with hoaciight case)

63. STEERING HEAD

6. Remove:
e Forkstom nut @
* Bearing caver (2)
NOTE:

‘Support ha Under bracket noto lose any
bearings

© Under bracket
+ Bearings

INSPECTION

1. Wiseh the bearings in

2 Inspect
Bearings ©
Ping Dara
+ Bearing races
Pittng Damage => Replace,

= Replace.

NOTE:
‘Always replace bearing and race as a el

3. When replacing the bearing, use a long rod
nd cold chisel (2) to remove the race.

INSTALLATION
1. Greese the bearings and races

2. instal:
a Under bracket

3. Tighten:

«Ring nut

[80 all roo play ls taken up. But so the
bracket can sl pivot trey.)

64. CHAPTER 6
ELECTRICAL

GIRGUIT DIAGRAM .
IGNITION SYSTEM
CHARGING SYSTEM
LIGHTING SYSTEM
SIGNAL SYSTEM ....
SWITCH INSPECTION

65. ELEC 161
CIRCUIT DIAGRAM

Additional electrical nccossories may overioad the oxisting electrical system. Severa overloads may
(damage tha wiring harness or creato a dangerous situation du to the loss of electrical power dur ng
‘the operation of the motoroyolo

(YAMAHA

66. Brake light

Front brake switch
Roar brake switen
Light switeh
Dimmer switch
Headlight

Meter dont
Tal ight
Main Switch
late cal
eben
Pulsar coll
Source colt

‘Gharge/lighting coil
CDI: magneto
Body earth
Battery
Fuse
Roctifie/Regulaior
Main switeh

sher lights (lft)
pilot light
lasher lights (right)
Flasher relay
Flasher switch
Horn switch
Horn
Neutral switen
Neutral light

CIRCUIT DIAGRAM

COLOR CODE
ine
Br

De
E

Black
Brown
Chocolate
Dark green
Green

Blue

Pink

Rod

Sky blue
white
Orange
Yellow
Black/Red
Black/White
Brown/White
White/Red
Yollow/Res
Yeliow/Write
Bluerwnite
Blue/Red |
Greon/Yallow

67. FUNCTION
Funetlon No. 1

‘As the rotor turns, current ls produced in the
Source coll and then stored in the ignition

Function No2
“At the same time, the plckup coll sends a pulse.
(signal) 19 activate the thyristor.

Function Not
hon condenser char ve
I produced.

68. E e 6 nn
1GNITI ‘STEM

‘TROUBLESHOOTING CHART
A tos connection must checkin advance.

EI OTE
waa

(Ground the spark plug o the cyindor hand and Check to pickup col resitnce

ee «D x |
oe

TL Sonn Gop Test ETE

ott rin mad me
‘ek tha sur

one A
me
EE

ETA

oRcoutecr

Ent a)

Dane en en cup and HE ne Chack the rence of io primary ard secan
more nr eat weigh

e Jon xf Lo

a] a] a]

69. ELEC

CHARGING SYSTEM

CHARGING SYSTEM

= cren” i

ruse

=

2. Charing Col Reetonce
Discos the genero lads ed cack charg

ee ee

pace char sol

A ur ol specifications, check charging cof wine ou of speci

(dng tranca. And ore than SV, replace
the Rectro/Regulco E

70. LIGHTING SYSTEM

LIGHTING SYSTEM

HIGH BEAM INDICATOR LIGHT.
HA DUR

Ha Swırch

WER]

Ione)

even vH

fran. ë

4. Ugg Voltage Test
Remove a height leads and connect tho taser
lends a shown. Star the engin and chock te

f

Il out ef spectre, stack ing core

stance and ein egw ator,

71. eg ASHER
lt

CN

Flashen
tae

Faces

Barren

frases
Le fit
tot

SWITCH INSPECTION Maln ewiich

FEMALE von CEROS como TERT TEE Te
ale: oF S| OO
[Oo

ono

»2 02
CONTINUE) (CONTINUED)

72. ELEC
SIGNAL SYSTEM

Dimmer switch

73. CHAPTER 7

APPENDICES
SPECIFICATIONS 74
CABLE ROUTINE DIAGRAM Ta
WIRING DIAGRAM E 745
ENGINE TROUBLESHOOTING rar
ELECTRICAL SYSTEM rar
COMPRESSION SYSTEM... : 746
INTAKE AND EXHAUST SYSTEMS 7-19

74. SPECIFICATIONS Me

|
| SPECIFICATION
à GENERAL seciricaTions
= ri
cs a
pr
ae os
Soe Te nd bors ES
ee Bere
en =
ee Be
Bin tees
Ee Se a A
ir mare
nee aa
a eee
u a
en a
‘Clutch Type Wet, multiple-Diso

YAMAHA

75. SPECIFICATIONS

©. ELECTRICAL
Tost CTI
vom w
anti Sram:
grin Ting (87.0.6) 20 à 1.800 8000 min
Are pe. heir

Al

Es

1

E.

2a ee ae
Er Sone 1 1/

or : a
Pickup Col Raitance (Cor
“Source Col sistas (Colour

DO 210% at 200 (eu) ae)
220 D à 10w at 20 eh 8)

Mann Cale

Minimum Spark Gap

Primary Winding Reste
Secondary Winding Resistance

srr Sealed ype

12 HV or more at 500 min
2HV of more at 8,000 r/min
Tm

NaC IR 200 (oor)
ER oo am)

(har Systems Type

Fires megreto

76. 'ECIFICATIONS. SES 7 |

Modo

CT

FW. Magnets:
‘Charging Curent Day. (OA or mot at 2800 nin

SOA or oss 000 mn

44 or mors a 250 min

SOA or Joa at 8 00 r/min

(GAL 2 fom at 200 Ber) =)

Non

‘Charging Col Renitanes (Colour)

Taming vorge. SOV ce mare 2800 rnin
104 elsa a 8.600 nn
Ligning Col Resistence (Colour 0

210% m 206 (ur) (YA) |

Lo.
BI VÍ no regul
pa VR no regala

77. Tissot

EXT]
aster meguttcr
NevowsReguatorVolage (mana [15-800
cmo | Las men cay
Capa. ¡Gregor | 408
ami) [aoû
no
Casey, eran
ESTO 102°C.
pau an pe = 1
Maxinon Ampetaze 304

an ate:

Far Fecuoncy
Marge

(eux re

‘Raporage for nava Crcuvosnuiy
ra

sat

78. Tete cae

a eee ose

81. a
ST

82. AS

ENGINE TROUBLESHOOTING

1. ELECTRICAL SYSTEM
[ewer AUC VIE CONNECTIONS

CNAE
Min Sth Sone

Hoy Tension Le fe rau
tg Cap ay

lo

4

[source er]

83. APPX

2. COMPRESSION SYSTEM

à [SUECIA more ToROUE

[surcar novena
[roroue

84. INTAKE AND EXHAUST SYSTEMS

| ao
|

Î

Îl
|
i

|

E

5

7 > m Uf |
ul
ESTATE
ETE] ren] sn
lage ESS

0

Wed Spa d
REED VE
Ben (Swen EEC

ing Ard Starr)

“Oils À

PLOT ver
age (Com Same

AW Er
nasa
EA ; o |
ES TLE Sar sc
2 sa tes
B © ale
lis Fame oat VANE
see es Dan a patea

85. SPECIFICATIONS

= zn
A
ie un,
Beer | ran
eee oe
is ones,
ue o
a ome
=
= Mt 96/11 (9.162)
» mes
a a
E sn
ES oon
a, =
We With tube
En D
atoms
O eee
Es Arie
= Vies
une | MBS
SEE ici
Fe en
ram eme
== en,
Eli er
En mows
mee
eee, en...
See nz
=
a a
ar Shock Abtarber Caine ae
Fa
Be ES
a ES
=.
ner: OD. Mag
Senet” Span Er rad
sr Bar“

86. SPECIFICATIONS:

Woda aE:
Hewat Type" EXI
Bulb wattage Quant
ev.
om EN
E (towne
Park ot DEN
Indicator ight Watage Quant
EUTRAL" ev amet
HH ea EY]
r ea
Meter int eam
B. MAINTENANCE SPECIFICATIONS ENGINE
Moser Ex
Gyinaer Hens =
Grinser
Bore Size So em
ur! Reung Lit 00% mmı

ES :
a EE es
en ae |
= Bam
= Reed
Po EN
Fe
Fr
SL
cr reuse
= =

87. ‘SPECIFICATIONS:
end Goo 015 - 038 mm
noe) 318 = 06mm
sie eurer 508 > ace am
‘atid 9652 ou
seman = seo amm
Run Out Lloc Sam
Srwinmannemse ° |G2-07mm
“Chance 0
Sr Ena Fee Pay und 200m
Tito Pale exe Guy 20mm=s
Gen SpungrenLangtvauntiy | 348 mrad
‘Guten Spung Minime cet om
teh Roue Mela inner Bun. Ser wish
aan Roa ending Lit oi
o E
Em
Shing Ty uae tar
luce bar Bereng Lit ass mn
Gos cp rice occ prio
‘Ein = Mae > ta
Au Fer OÙ Grace (Oe Fe E77

88. Lubieton Sates Saparm aia
Autoude Pump-Gobr Code

Minimum Soke
Maximum stoke
Ply Rating Mar At ilo

0202 mn

Ben /

Cantos Tiantoning Sequence

[eo]

89. SPECIFICATIONS:

Tiohiening Tore

Treas 8

[am Ju

ua

Cransense,

Crarkease dover

Dram pl

CDTI

DIET

Primary ane gr.

nero

Gun es

LES)

eh

eto

vents

Mero.

Change peca

Wen

PRE

Manns

Maas as

MeO.

90. Mode!

OT

“Steering Syste

SlerigBosring Type Gun Bearing
NovSize el Sao! Dl
upper 22 pes (rei,
tower 49 bea (04 0)
Front Surpanson
Front Far Teva! Norm
Fork Spring Fes Length 2365 mm
Cnt ausm
ON Capacity Ms: 00
Où Grace Sano senora où
Rear Suspension
‘Shock Ansorbor Tano! Tom
Silo Arm ron tay Lint
Eng (skew) <2mm
EN mm
ne: m
Peur Whe! Type Spoke Wes!
Front Alm Sata Von Vent
eas Alm Santana 1802 en

YAMAHA L

91. AN apex

YA SPECIFICATIONS

ET

170 tne
200 mn

Lansing ana rin.

‘rans Pedal Fre Payo

peda somm
rans Lever & Brake peda
‘rate Laver Fes Ply/psiion 5— emma ve poo.

Tn |
Pgh blew corea! 09)

22 mnt pet

92. SPECIFICATIONS:

Tiahiening Torque

‘Grown nana tbe

Trrand Si ow
CT

‘Grown ane Soaring shai

PIES

Handle crown-Handi hele

z
+
wats a
Under biter nee n
Biol shat is ur +
er 5
Sean = 2
PS 2 >
a + al
Tr = =
Shock seer ws =
tongs sena Pan 2
Fat upper ens ma Oo TES ra
Fee Snes mora an ra
ES we

[cap Bot Frent ork

Mage