YAMAHA AGZDDF 3GX-AEt SERVIGE MANUAL‘AG200F SERVICE MANUAL (©1997 by Yamaha Motor Go, Ltd. ‘st Edition, January 1997 Ailrights reserved. Any reprinting or Unauthorized uso without the suritten permission of Yamaha Motor Co, Ltd |e expressly prohibited, TelNOTICE ‘This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It ig not possible to include all the knowiedge of « ‘mechanic in one manual, 0 it ie assumed that anyone who uses this book to perform ‘maintenance and repairs on Yamaha motorcycle has a basic understanding of the ‘mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone Without this knowladge ara Ikely to render the motorcycle unsafe and unfit for use. Yamahs Motor Company, Ltd. is continually striving to improve all ts models. Modifications And significant changes in specifications or procedures will be forwarded to all authorized ‘Yamaha dealers and will appear in future editions ofthis manual where applicable, Note: Dosigns and epotifications are aubject to change without notice, IMPORTANT INFORMATION Particularly important information is distinguished inthis manual by the following notations. & ‘The Sefety Alrt Symbol means ATTENTION! BECOME ALERT! YOUR SAFETYIS INVOLVED! PNGNIN lure to follow WARNING instructions could result in severe injury or oath tc the motoreyele operator, @ bystandar or a parson inepocting oF fepaiting the motoreycle. A CAUTION indicates special precautions that must be taken to avoid (CAUTION: ‘damageto the motorcycle. Nove: ANOTE provides key information to make procedures easior or clearer,HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. ‘See “Ilustrated symbols") (D: This isthe title of the chapter with its symbol on the upper right corner of each page. 2nd title @: This title indicate the section of the chaptor and only appears on the first page of ‘each section. itis located in the upper left corner of the page. td title @: This tito indicates panied by corresponding usta stu EXPLODED DIAGRAMS ‘Ta help identity parts and clarity procedure stops, removal and disassembly section. 1. An e08y-to-s00 exploded diagram @ is provided for disassembly and assembly jobs. 2. Numbers @ are given ia the order of jobs in the exploded diagram. A number that is ‘nclosed by a cree Indicates a disassembly stop. 3. An explanation of jobs and notes is presented in an eesy-o-read way by the use of symbol ‘marks ©, The meanings ofthe symbol marks are given on the next page. 4. Ajob instuetion chart @ eccompanies tho exploded diagram, providing the order of jobs, ames of parts, note in obs, et. '5, For jobs requiting more information, the step-by-step form: dali tothe exploded diagram and the job instruction chart. hore are exploded diagrams at stat of each supploments @ are given inILLUSTRATED SYMBOLS Iustratod symbols © to @ are designed as thumb tabs to indicate the chapter's num ber and content. @ General information 1 Spociiatons {@ Period inepection and adjustment @ Engine {8 Curburaton @ Choeels Ectial ‘Troubleshooting Illustrated symbols @ to @ are used to identity the specifications appearing in the @Posibo to maintain with engine mounted {Fting ute {Lubreant spacial toot Ilystrated symbols (D to @Din the exploded diagrams indicate the types of lubricants and lubrication points {Apply engine oil Apply gear of {8 Apply molybdenum dislfi {Apply wheel bearing ge {BADD ighsweight thium soap base grease DAppIY melyodenum disulfide grease Ilustrated symbols 09 to G9 in the exploded diagrams indicate the where to apply lock- Jing agent) and when to install new parts 3 Apoly locking agent (LOCTITES) Use new oneINDEX GENERAL INFORMATION ata) INFO. SPECIFICATIONS al PERIODIC INSPECTION AND | _@& ADJUSTMENT Ns ENGINE OVERHAUL _* CARBURATION ae & CHASSIS cme CHAS ELECTRICAL ac be ELEC 2 TROUBLESHOOTING — SHTG =ICHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION. FRAME SERIAL NUMBER. MODEL LABEL. IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES REPLACEMENT PARTS ‘GASKETS, OIL SEALS AND O-FINGS. LOCK WASHERS/PLATES AND COTTER FINS. BEARINGS AND OIL SEALS incurs. ~ ‘CHECKING OF CONNECTIONS. HOW TO USE THE CONVERSION TABLE SPECIAL TOOLS CHAPTER 2. ‘SPECIFICATIONS GENERAL SPECIFICATIONS. MAINTENANCE SPECIFICATIONS. ENGINE chassis ELECTRICAL GENERAL TORUE SPECIFICATIONS. LUBRICATION POINT AND GRADE OF LUBRICANT. ENGINE chassis. LUBRICATION DIAGRAM ‘CABLE ROUTING, CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS lwTRoDUCTION PERIODIC MAINTENANCE/LUBRICATION INTERVALS. SIDE COVER, SEAT AND FUEL. TANK. ENGINE VALVE CLEARANCE ADJUSTMENT. IDLING SPEED ADJUSTMENT. THROTTLE CABLE ADJUSTMENT SPARK PLUG INSPECTION. IGNITION TIMINS CHECK. COMPRESSION °RESSURE MEASUREMENT ENGINE OIL LEVEL INSPECTION ENGINE OIL REPLACEMENT. a4 a4 M1 a2 42 12 12 13 13 a3 18 16 24 2 2 210 249 248 26 216 27 28 2.20(CLUTCH ADJUSTMENT. AIR FILTER CLEANING EXHAUST SYSTEM INSPECTION. chassis : FRONT BRAKE ADJUSTMENT. REAR BRAKE ADJUSTMENT. ‘BRAKE SHOE INSPECTION, ‘RAKE LIGHT SWITCH ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT. STEERING HEAD INSPECTION. 2 FRONT FORK INSPECTION. REAR SHOCK A3SORBER ADJUSTMENT TIRE INSPECTICN. ‘SPOKE INSPECTION AND TIGHTENING. WHEEL INSPECTION. ELECTRICAL BATTERY INSPECTION... FUSE INSPECTION ws HEADLIGHT BEAM ADJUSTMENT. CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL... [EXHAUST PIPE, STARTING MOTOR AND WIRE READ. ‘CARBURETOR, CLUTCH CABLE AND DRIVE CHAIN. ENGINE. non (CYLINDER HEAD. . ‘CAM SPROCKET COVER. (CYLINDER HEAD CYLINDER HEAO REMOVAL CYLINDER HEAO INSPECTION... TIMING CHAIN TENSIONER ADJUSTMENT. CYLINDER HEAD INSTALLATION. ‘CAM SHAFT AND ROCKER ARMS. ROCKER ARM AND ROCKER ARM SHAFT REMOVAL ‘CAMSHAFT INSPECTION ROCKER ARMS AND ROCKER ARIMI SHAFTS INSPECTION CAMSHAFT AND ROCKER ARM INSTALLATION \VALVES AND VALVE SPRINGS... VALVES AND VALVE SPRINGS REMOVAL. VALVES AND VALVE GUIDES INSPECTION. VALVE SEATS INSPECTION. VALVES AND VALVE SPRINGS INSTALLATION (CYLINDER AND PISTON... PISTON AND PISTON RINGS REMOVAL. CYLINDER AND AISTON INSPECTION. PISTON RING INSPECTION. PISTON PIN INSPECTION 313 314 246 316 3.416 3.418 3.418 3.18 3.18 221 32 322 323 35 3.25 (376 331PISTON RINGS, PISTON AND CYLINDER INSTALLATION, cuuren. 7 ‘CRANKCASE CCVER (iGhT).. cure. : CLUTCH REMOVAL. — CLUTCH INSPECTION. PUSH ROD INSPECTION. CLUTCH INSTALLATION. Kick STARTER. - KICK STARTER INSPECTION . KICK STARTER INSTALLATION. ‘on pum. PRIMARY DRIVE GEAR REMOVAL... OIL UMP INSPECTION OIL DELIVERY PASSAGE INSPECTION (CRANK CASE COVER (right. (OL PUMP INSTALLATION vos PRIMARY DRIVE GEAR INSTALLATION... BALANCER GEAR. nn = BALANCER DRIVEN GEAR REMOVAL BALANCER DRIV: GEAR INSPECTION. BALANCER DRIVE GEAR ASSEMBLY, . BALANCER GEAR INSTALLATION sw SHIFT SHAFT AND SEGMENT. — SHIFT SHAFT REMOVAL... : ‘SHIFT SHAFT INSPECTION. vo SEGMENT INSTALLATION, SIFT SHAFT INSTALLATION (CDI MAGNETO AND STARTER CLUTCH. ‘CRANKCASE COVER (LEFT) PICKUP COIL AND STATOR COIL. (CDI MAGNETO AND STARTER CLUTCH... (CDI MAGNETO REMOVAL. STARTER CLUTCH INSPECTION... STARTER CLUTCH INSTALLATION . (COI MAGNETO INSTALLATION, = ‘CRANK CASE AND CRANKSHAFT CCRANKCASE..... . (CRANKSHAFT AND BALANCER WEIGHT : (CRANKCASE SEPARATION... PLUNGER SEAL REMOVAL. ‘CRANKSHAFT INSPECTION : PLUNGER SEAL INSTALLATION. BALANCER WEIGHT INSTALLATION, CCRANKCASE INSTALLATION. ‘TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL SHIFT FORK ANO SHIFT CAM INSPECTION... TRANSMISSION, SHIFT CAM AND SHIFT FORK INSTALLATION. 420 434 434 438 435 “7 437 437 38 438 439 40 440 4-40 a1 a2 ad 8 45 446 44s, a7 48 49 49 450 450 452 452 454 455, 455, 450 457 ar 457 458 400 60 61CHAPTER 5. CARBURETION ‘CARBURETOR. . 51 (CARBURETOR ASSEMBLY. 54 FUEL LEVEL ADJUSTMENT. 55 CHAPTER 6. CHASSIS [FRONT WHEEL AND FRONT BRAKE. eA [FRONT WHEEL DISASSEMBLY. oa [BRAKE SHOE PLATE DISASSEMBLY. 0. 4 FRONT WHEEL NSPECTION wee ‘SPEEDOMETER GEAR INSPECTION 65 FRONT BRAKE INSPECTION. 66 FRONT SHOE PLATE ASSEMBLY 87 FRONT WHEEL ASSEMBLY. 8 FRONT WHEEL INSTALLATION 68 WHEEL STATIC AALANCE ADJUSTMENT... vnn8-10 REAR WHEEL, REAR BRAKE AND ORIVE CHAIN. 512 REAR WHEEL AND REAR BRAKE 612 DDRIVE CHAIN, DRIVE SPROCKET AND OAIVEN SPROCKET, 5.16 REAR WHEEL DSASSEMBLY 19 REAR WHEEL INSPECTION . 6.19 REAR BRAKE INSPECTION. 5.19 DRIVE CHAIN INSPECTION : 620 CLUTCH HUB INSPECTION... 621 BRAKE SHOE PLATE ASSEMBLY. 621 REAR WHEEL ASSEMBLY — 621 DRIVEN SPROCKET ASSEMBLY " 6-22 DRIVEN SPROCKET AND DRIVE CHAIN INSTALLATION snscnns6-22 REAR WHEEL INSTALLATION yun 623 FRONT FORK 824 FRONT FORK REMOVAL 626 FRONT FOAK DISASSEMBLY. 6.26 FRONT FORK INSPECTION wo 627 FRONT FORK ASSEMBLY. ase FRONT FORK INSTALLATION. 630 HANDLEBAR... 631 HANDLEBAR REVIOVAL. 533 HANDLEBAR INSPECTION 633 HANDLEBAR INSTALLATION. 6x3 STEERING. 635 UNDER BRACKET. 688 STEERING REMOVAL. 837 STEERING INSPECTION. 637 STEERING INSTALLATION 638 REAR SHOCK ABSORBER AND SWINGARM. 630‘SWINGARM INSPECTION. ‘SWINGARM SIDE CLEARANCE ADJUSTMENT REAR SHOCK AaSORBER HANDLING NOTES. NOTES ON DISPOSAL, CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS, ‘SWITCH INSPECTION. : INSPECTION STEPS SWITCH CONNECTION AS SHOWN IN THIS MANUAL. SWITCH CONTINUITY INSPECTION. IonmTion system, ‘uRCUIT DIAGRAM, TROUBLESHOOTING. ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM son STARTING CIRCUIT OPERATION ‘TROUBLESHOOTING. STARTER MOTOR. a CHARGING SYSTEM. . CIRCUIT DIAGRAM TROUBLESHOOTING. = ucHtine system, ‘CIRCUIT DIAGRAN. TROUBLESHOOTING. UGHTING SYSTEM CHECK ss scssnsnn AUXILIARY OC OUTPUT SYSTEM CHECK. SIGNAL SYSTEM. ‘iRCUIT DIAGRAM ‘TROUBLESHOO™ING SIGNAL SYSTEN CHECK. CHAPTER 8. TROUBLE SHOOTING STARTING FAILUREIHARD STARING. POOR IDLE SPEED FERFORMANCE: POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR SPEED PERFORMANCE. ‘CLUTCH SLIPPING/DRAGGING. FAULTY GEAR SHIFTING ‘OVER HEATING OR OVER-COOLING. FAULTY BRAKE. [FRONT FORK MALFUNCTION INSTABLE HANDLING. ‘STARTER MOTOR D2ES NOT OPERATE. FAULTY SIGNAL AND LIGHTING SYSTEM eat eat 6.42 2 22 23 23 ea 25 25 86 a7 88speciat Toots [Gey [dm ‘SPECIAL TOOLS Tho following special tals ste necessary for complote and accurate tune-up and assembly. Use nly the appropriate special tools: this will help prevent damage caused by the us Inappropriate tools or improvised techniques. When placing an ordar,rforto tho list provided below to avoid any mistakes. Tool No: Toolname/ Usage Trostration ‘90880-01052 | Woter goa’ bush ool Sa SS steer ncin sents; tha meter ar bush. ‘90890.07080 | Rotor puller ‘082 | Attachment “Thee tool are used when removing the ‘90890-01089 | Focker arm shat puller bot ‘1g | Weight ‘Tse tole are used whan removing oF & instaling the rocker atm shots ‘90890-07268 | fingnut wrench “This tool ls used to looten and tighten the ahust and searing ring Sanaa | vate adtne to! IT fol W GSS to edeeg VON a Saorance, ‘90590-01812 | Fuotevel gauge “This gauge is usod to measure the fuel ow inth floatchamber sesso | Thandie 04084 | Damper rod holder (19 mm) a “Teed irate Usb wo leoece eel dahon a e the front fark dumper rod holding bot. "90800-01267 | Fork seal vor woight SR | FSR Senco 190800.01403 | Ring nutwrench | is toot use o loosen an totem tho | SecingrinmaGEI SPECIAL TOOLS REY os Tool Ne. ‘Tool name / Usage Tusiation 30490-07701 ‘Sheave holder “This tool ie used for holding the magneto ‘90800-09079 “Thickness gauge “This tole used to mensure the valve ‘90890-09081 ‘4082 compression 90090 09112 90990091 “This tools mace for dotting engine pm “This tao! eco install the valve guides properly. samosas | Tringuo ~ KY ‘thc Set gi sasaes | Yaresetepeenen! ' ga | Yayo Le eae tere erates Taseges tendon © eg an 2 Aeetieeyneenncnnngoen | at ane | Vieeem ‘itclinmedo bor thevato ul a soan0cib8 | vam gudenoarmmGEN sPEciaL TooLs | MED | SHO in Tootname Usage Tsvaton Be. 04088 | Gasol eat Tie tools used for holding tha Chath Bose 3000004301 | Va laper Thi ol oud fr ramoving and taling thoi ono tapping tee. 2060008248 | Torque wranch ” od or emoving and inataling thoveomertbot so180.96764 | gnton cheer jR Se This insert is acesny for cesking the ‘onion yom componente. S00. 8808 bond No. 216 2 (bond) Is used for crankoase mating src,mororcycte ipennirication | GEN [deo] LI GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER, ‘Tho framo sorial number @ is stamped into o the right side ofthe frame MODEL LABEL ‘The modo! label @ ie affixed under the fue! tank. This information will be needed to ‘order spare parts,IMPORTANT INFORMATION | EO | O™® IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dit, mud, dust and foraign, bi. 2, Use proper tools and cleaning eauip. 3, Refer tothe "SPECIAL TOOLS" section, 4 When disassembling the machine, always keep mated parts together. This includes gears, eylinders, pistons and other parts that have boon “mated” through normal wear, Mated parts must always be roused or replaced as an assembly. 5, During machine disassembly, clean all pars and place them in trays inthe order of disassembly. This will speed up assombly and allow for the correct Inetallation of al pars. 8. Koop all parts away from eny source of REPLACEMENT PARTS. 1. Use only genuine Yamaha parts for ll replacements. Use oil and grease fecommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. (GASKETS, OlL SEALS AND O-RINGS. 4. Replace all gaskots, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings mu be claaned 2. Properly oil all mating parte and bearings during reassembly. Apply ‘rease10 the ol eal ip. 12N ImpoRTANT INFORMATION [GE | SHS LOCK WASHERS PLATES AND COTTER PINS 1. Replace al lock washersiplates and cottr pins after removal. Bond lock tabs along the bolt or nut fats after the bolt or aut has boon tghtoned to specification BEARINGS AND OIL. SEALS Install bearings and oll seals so that the manufacturer's marks ar numbers are visible. When Installing oll seals, apply a light coating of lightweight lithium base grease 12 tho seal lips. Oil bearings liberally when Installing, f appropriate @ oleae feauTiol Do not use compressed alt to spin the bearings dry. This will damage the bearing surfaces. Beating ‘rcurs 1. Check all circl reassembly, Always replace piston clips efter one use. Replace distor ircips. When insaling a cirelip@), make sure that tho sharp-edged corner @ ie positioned opposite the thrust @ it receives, See = carefully before @ shatcHeckine oF connections | EO | © CHECKING OF CONNECTIONS Dealing with stalne, rt, moltre, ee. on the connector ON | J ". Disconnect ‘Connctor 2. ry each rnin! witha sr blower. 3. Connect and disconnect the connector to or three, 4, Pull the lead to chack that it will not come of, 5. Ifthe torminal comes off, bond up the pin @ and reinsert the terminal into the connector 1. Connect Connector Note: ‘Tho two connectors “click” together 1. Check for continuity with a tester. NoTE: sit hore is no continuity, loan the trminals *Be sure to perform the stops 1 t0 7 listed ‘above whan checking the wireharness. or a fold romadt, use a contact revializer available on the market. *Use the taster on the connector as shown.HOW TO USE THE CONVERSION TABLE Sele) HOW TO USE THE CONVERSION TABLE All specification dats in thiemanual ne listod in Sand METRIC UNITS, Use this table to convert METRIC unit data to IMPERIAL unit data, ee METRIC = MULTIPLES IMP mm x 003837 in 2mm x 003897 = 008i ‘CONVERSION TABLE TETHC TOM Tow uepter a Tas eb kg 704 in Foraue emaa | 00723 ftp feng [oaera ins fe 2208 1 eiah A sear on emia zie mpi km ez m oistance er S261 e tana A Vooe va en 3097 i in see tn ecco | o0asar (oz MPa) Hvotunes fetem | o0st02 en fraen | agree Me ig) indie [02109 el MP ig) iim [55957 ‘i riscancous fase | 442206 alta entgrade | accies2 Fatonbet 6)SPEC GENERAL SPECIFICATIONS ‘SPECIFICATIONS GENERAL SPECIFICATIONS "Medel AG200F Model code: 3GXA, Dimensions: Overall length 2,160 mn ‘Overall wicth ‘930 mm Overall height 1,185 mm Seat height ‘Wheelbase Minimum ground clearance Minimum turning rade ‘aslo weigh ‘With it and ful uel tank rar kg Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio. ‘Compression presi ‘Starting system Lubrication system: (s7) Air-cooled 4-stroke, SOHC Forwaréinclined single eyinder 0.196 L (196 om") 67.055. mm 95:1 900 kPa (9.0 kgfom 9.0 bar) at 1,000 rimin Electric starter Wet sump Oil type oF grade: Engine oil Periodic oll change With ot iter coplacement Total amount 10, aa aa Wet type element Fuel reserve capacity Ale ter Fuck: Type. lod gas Ful tank eapacityGENERAL SPECIFICATIONS | SPEC Model AG2OOF Carburetor: “Typeiquantity aszan Manufacturer MIKUMI Bpark plug: Type Dae Ax24ES. Manufacturer NGKIDENSO Spark plug gap 08-0.7 mm hutch type: ‘Wet, mutipi disc “Transmission Primary reduction system Primary reduction ratio ‘Secondary reduction systom Secondary reduction ratio Transmission type Spur gear "720 (3.700) Chain ative 54/14 (3.887) Constant mesh 5 speed Operation Left foot operation Gearratio 1st 35/11 (3.181) 26 31715 (2.066) 3rd 30,21 (1.428) ath 25,26 (0.961) sth 22131 (0.708) Chassis: Frame type Diamond Caster angle 29" Trail 87 mm Tee Type ‘Tube type Size front 80/100-21 51M roar 400-18 59M Manufacturer front INOUE rear INOUE Type front ves reat FARM SPECIAL -Z2 Tire pressure (ool tre Maximum load-except motorcycle Loading condition A* front mekg o-112kg 120 kPa (1.2 kglem, 1.2 bar) 150 kPa (1.5 kom, 1.5 bar) ‘Load isthe total weight of estgo, rider, passenger, and eccessoriesSPEC GENERAL SPECIFICATIONS Model _ ‘AG200F Brake: Front brake type rum brake operation Fight hand operation Rear brake type Drum brake operation Right foot operation Suspension: Front suspension Rear suspension Telescopic fork Swingarm (monacrose) ‘Shock absorber: Front shock absorber Fear shock absorber Coil spring/Oil damper Coil spring/Gas-Oit damper Wheel travel: Front whee! travel 200mm Rear wheel travel 165 mm Elootical Ignition system col Generator systom COI magneto Battory type Gees Battery capacity 1v6AH Headlight type: Bulb ype Bulb wattage x quantity Headlight 12 45 WHS Wc Tailorake light aavswaiWxt Flasher light rv OW x4 ‘Meter light ravi Wx1 Neutral indicator revi WtMAINTENANCE SPECIFICATIONS |SPEC| U=* MAINTENANCE SPECIFICATIONS: ENGINE tom Standard vindor head: Wap limit ~ 0.03 mm Cylinder Bore size (1d | o8.97-67.02 mm Measuring point* 40mm ‘Camshatt: | | ‘cam dimensions intake "A" top| 3654-36.64 mm 36.48 mm vo 30,18-30.25 mm 301mm scr * | 659mm. 7 Exhaust “A 36.58-36.68 mm 36.49 mm "8 30.27-30:37 mm 30.2 mm = 6.63 mm ea {Camshatt runout limit 0.03 mm (Cam chain: ‘Cam chain type/No. of links Do 256H/104 ENDLESS ea Cam chain adjustment Automatic Rocker armyrocker armshaft Rocker arm inside diameter 12.000-12.018 mm 12.096 mm Rocker shaft outside diameter | 11.981=11.991 mm 11.950 mm Rocker aem-to-rocker armshaft clearance Valve, valve seat, valve guice: Valve clearance (cold) In ]o.10-0.14 mm G ex. |0.16-0.20mm Na el Heed De Face Wisin Seat wath “A” head diameter IN | 339-2341 mm Ex | 284-28.6mm "8" faco wieth In |2.26mm Ex. |2.26mm "C" seat wieth IN [09-11 mm ex |ogt1mm "D* margin thickness Ww | og-1.2mm x [o8-12mm Stom outside diameter IN| 5.975-5.990 mm ex_|5.960-5.975 mm + Margin Thickness 1.6mm 1.6mm 5.955 mm 5.940 mm 2MAINTENANCE SPECIFICATIONS |SPEC) U= Tom Standard mie Guide inside diameter IN| 6.000-80%2 mm 082mm ®x | 6000-6012 mm 6.082 mm ‘Stem-to-guide clearancs IN| 0.010-0.037 mm (0.08 mm x | «.026-0.052 mm 0.10 mm Stom runout iit - 0.03 mm Valve seat width tw | 09-1. mm 16mm &x_|o911 mm 1.6 mm Voive spring Free length (inner), inex 35:5 mm l335 mm ‘outer inex | 37.2 mm 35.2 mm Sot length (valve closed) {inner tne] 30.5 mm “ (outer ‘nvex | 32.0 mm 7 Compressed pri (inner inex | 6.4-10.2 kg (outer INIEX | 16.6-2044 kg Titlimit inner) INFEX | + 2571.5 mm Ttlimit (outer Iyex | [2577.6 mm rection of winding (inner) INEX outer) INEX CCounterclockwise Clockwise Piston: Piston to eylindor clearance Piston size “D* ‘Measuring point “H” Piston oversize (1st) Piston oversize (2nd) Piston pin bore inside diamater Piston pin outside diamet Piston pinto piston cleararco 0.025-0.085 mm 66.935-65.985 mm 7.8mm 87.25 mm {61.50 mm 16.002-16.013 mm 15.991-16.000 mm 0,002-0.022 mm Piston tings: Top ring Type Barrel os Dimensions (8 @r«rEvvO——MAINTENANCE SPECIFICATIONS |SPEC| U=™ ELECTRICAL item ‘Standard Timi Ignition timing Ignition timing (8.7.0.C.) 9° 9 1,300 ein Advanced timing 29 at 6,00 ein eS Advanced type Electrical type ” cr ‘CDI magneto model/manufacturer | FSGX/VAMAHA o Pickup coll esistance/color 856-984 0 at 20°C) a Fed — White ‘Source coil 1 resistancefeolor | 700-900. at 20°C/ oo Brown — Green Source coll 2resistancefenlor | 472-708.0 at 20°C} Yellow — Gro CDI unit modelimanufacturer__| 3GXVAMAHA = Ignition cot Modol/manufacturer 2INYAMAHA z Minimum spark gap mm es Primary winding resistance 0.27-0:53 0 at 20°C a Secondary winding resistance __| 5.76-8.52 ko at 207 : ‘Spark plug cap: Type Resin type Resistance 10ka Charging system: Type (cD! magneto . Modolimanutscturer FaGXVAMAHA . ‘Standard output 14V 12.45,000 min “ Stator coil resistancelcolor 0.48-0.72 0 at 20°C) . White— White . Rectifierregulator: ‘Modelimanufacturor ‘SH569A.12/SHINDENGEN : Type (rogulaton Semiconductor shart cireuttype | o No load regulated voltage 141-149 V Capacity (rectifier) 25a Withstand voltage 240V o Batery: ‘Specific gravity 1.320 = locri starter system: Type Constant mesh type Starter motor Modelimanutacturer SGX/VAMAHA, Output ow x Armature coil resistance 0.0171-0,0207 2 at 20°C e Brush overall length 10mm 35mm Brash spring pressure 5.49-6.24 N (560-8404) F 2aMAINTENANCE SPECIFICATIONS |SPEC) U=* item Standerd Tint ‘Commutator diameter 22mm 2imm Mica undercut (depth) 15mm a Starter relay ‘Modelimanufacturer ar UJIDECO. Amperage rating 108 Coil winding resistance 39-47 0 at 20°C Hor: ‘Modelimanufacturor GE-T2INIKKO. ‘Maximum amperage 15a o Flasher relay: Tyre Modolmanufacturer Flasher frequency Full transistor type FEZI8BHIDENSO 86 cyalejmin Starting circu cutoff relay Mdol/manufacturer Coil winding resistance ‘ACA12115./MATSUSHITA Circuit breaker: Type Fuse - Main 20Ax 1 pes. es Reserve 20Ax 1 pes. Auxiliary BC terminal TOA 1 pes. Reserve. 10x 1 pes.GENERAL TORQUE SPECIFICATIONS SPEC) = GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard 1.5.0. pitch threads. Torque specifications for apecial components or assomblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a erisseress fashion, in progressive stages, until full torque is reached, Unloss otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. L@/7 ‘A: Distance actors fat B: Outside vvend diam A 5 spocteatons ww | eo ena Timm | émm | 6 08 [2mm | —amm | 15 18 emm | 0mm | 90 30 Timm | 12mm | 65 | ss) Tamm | 1émm | as a5 22mm | 16mm | 190 | 1907) LUBRICATION POINT AND GRADE OF LuBRICANT |SPEC) U=* LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubication Point ‘Symbol [oil seal ips al Bearing retainer (all) Bolt (eylindor hoad rank pin Connecting rod (big end) Piston pin Piston/pston ring Buffer boss: Valve stervivalve guide (IN EX) ‘Valve stem end (IN, EX) Rocker arm shaft {Gam and bearing camshat) Focker aim inner surface odd dda dla diaid § Crankcase mating surfaces Yornaha bond No. 1215 ‘O-rings (al ‘Kick gear inside Kick dle gear inside Kick erank boss Sta ‘Star ‘Starter wheel gear inner surface Push rod Primary driven gear inner surface Push laver axle Transmission gear inner surface Shift forkiguide barshift shatishift cam a 4/ddddldldaididsLUBRICATION POINT AND GRADE OF LUBRICANT @ a m 8 CHASSIS Letieation Point 3 z ‘Steering head pipe bearing (upperiiower) Front who il sea ips (etight) Rear whee! il sea ips (efiright) Fear wheal hub Frontier brake, camshi si ing surfacofmounting bolt id pivoting pin Stand “Tube guide throttle grip] inner surface Clutch lever boleollarieabe sliding surface Gear i (speedometer) ‘Swingarm pivot shaft and bush Roar shock absorber bush lswing arm side) Swingarm grease nipple BE s)g 0 0d 2g )0 8)LUBRICATION DIAGRAM ‘SPEC u=|- LUBRICATION DIAGRAM ® FoeLUBRICATION DIAGRAM |SPEC| O=* pump | uttercaste RouTING |SPEC om CABLE ROUTING @ Roar carrier @ Front laser lead Clamp. {@ Clutch switch coupior @ Front broke suite load Rear flasher lod ight) Front ark breather hose @ Brako cable 8 Clamp. Handi load (igh Q) Rear laher lee (tt) Handle oad lo) G@ Wireharess Rectieegulator ‘lute eablo {Front broke owtch coupler (Cable gu ‘Main sith coup Speedometer ‘Aunliary OC terminal coupor © Nin ow 1 Motor teas {@ Battry pastive load {Front flesher lead et)CABLE ROUTING ‘SPEC i Clamp the handlebar ewichcaste ROUTING |SPEC| O= TE] Band the wiehrnoss, CO! uit) Tea and starting motor tho top onthe wire hameseto the seat pier tube. (C) (Bena puter cll ead, charge nl leaded, dd start.) starter eabla in front teats cable and teh ing motor ood. ‘cluteh cable into the cable Psa the CO! unit lea, trot cal ead togethor front and fear beloreinset the covercaBLe ROUTING |SPEC) UO O ssnaiir Si mrad ave tea vot pipe I the (auxiliary OC terminal) Breather hose: ot clamp. @ Wwataan agent ed Savoy posted Ovrom hone ane {@ Ronrbate sen Baty $9 fear rte So ea fate regnive tod Yee or mo he gna cord se gud ro lento co tm Tgnton the ground tad round fad together with he ont bot {@ ignion coll primary lead (G)Aajust the cable poston, do @ Hon hot allow the tater cabo to © Airvont pipe ontet the olinm INTRODUCTION) [INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSF Qa PERIODIC INSPECTIONS AND ADJUSTMENTS. INTRODUCTION ‘This chapter includes all information necessary to perform racommended inspections and ‘adjustments. These preventive maintonance procodures, i followed, will ensure more cllable Vehicle operation and a longer sarvie life, The need for costly overhaul work willbe greatly reduced. This information applies to vehicles already in service 9s well as to new vehiclas that tare being prepared forsale, Al sevice tochnicians shouldbe feriliar with this enti chapter PERIODIC MAINTENANCE/LUBRICATION INTERVALS TRY Iwo) ew Por peace com [22008 eon 2 mont [avo | Grove dawen Aahtteasenay | [0 | © seerkotoa | coon ropa cee. cuca Ee E fy airiior | an Role nec oe Je] [earburerr | Shack ide spectre: operation ofol]o tine | Str oo min [Emin of | pie Warm ng before renin) o [oo ff [emi araner [can ° 3 i [Encino tor Coan ° o| fF facie Chek eran haha necany ooo. f= fom Chk erin Atif esse o [0 + Tres am nor | Gem ager ron cxx | o | 0 , Check flnldarapenotapoke anes “ Raplace't necessary. e [elo a heck toring sen forlosenendorage fo restvoings | Sean en ° | ° heck tsig asa for oso jJ.|seeing Gomes ct cece beating ‘Moderayrepock every 24,000 km or nec ston! rrncions | Shek pron ata. o | o iiSeae*_[wsaes o fe tisrcommonod tat tet tons sree by # Yamaha dale. Light weight ihion ap bso geese,INSP. PERIODIC MAINTENANGE/LUBRICATION INTERVALS ['ADy | GR LT fosnaae | Sac aeomnr ass cena [a [eenna _ [Smecreion ojo je ‘= Rierecommanded that these ems be serena by 0 Varah dealer. ‘+: Light welght ium soap taco grease. NOTE: The ar fiter neds more frequent service if you ding in unusually wet or dusty areas.IN SIDE COVER, SEAT AND FUEL TANK eT Qa SIDE COVER, SEAT AND FUEL TANK ‘Order “ob namalPar name. Romarke Side cover, seat and wel tank removal ‘Soat Ful bose Fu tank the fuel cock Revors he moval rocodia forINSP VALVE CLEARANCE ADJUSTMENT [ADJ ENGINE VALVE CLEARANCE ADJUSTMENT Nore Valve clearance adjustment should be ma with the angine coal, a room temperature When the valve clearence is to be measured fr adjusted, the piston must be at Top Dead Center (T.D.C, on the comprassion stroke 1. Remove: *Seat Fuel tank TANK" section 2, Remove: Spark plug cap @ Spark plug ‘Valve cover tints Valve cover (oxhau: 3, Remove: 4. Measure: Valve clearance ‘Side cover (lett and sight sido) @ side) @ (ut of specification + Adjust Rofer to “SIDE COVER, SEAT AND FUEL ‘Timing check plug (with Oxing) ‘Cantor plug (with Oxing) @ 3% Valve clearance (cola: Intake valve 0.10 ~ 0.14 mm Exhaust valve 0.16 ~ 0.20 mm Measurement stops: tionary 9 *@ on (roc), fester gauge. Outot specification » Agjust ci ‘© Rotate the crankshatt counterclockwise to align the slit @ on the rotor with the sta- 12 crankcase cover Uiet) when the piston is Top Dead Center ‘Measure the valve clearance by using @VALVE CLEARANCE ADJUSTMENT/ [INSP SURARANes ADAUSTTENTL NEP] QR 5 Adjust ‘Valve clearance Adjustment stops: # Loosen the locknut . © Tum the adjuster @ in or out with the valve adjusting tool @ until specified coar ance is obtained. Turning in d “Turning out Valve clearance is increased. ve clearance ie daore Valve adjusting took 90890-01311, | Hold the adjuster to prevent it from mov: Ing an tighton the locknut ure the valve #1 the ol is incorroct, repeat above stop unl specified clearance is obtained 6. Instat ‘Valve cover tintake side) © o a ve cover (exhaust side) [Lion roma) +01ing ® [Bletake sida Exhaust ide 7 Insal "Spark iming check window screw @) (with Oxing) Center plug @ with O-ring) IDLING SPEED ADJUSTMENT 1. Start the engine and lot it warm up for several minute 2, Attach ‘Engine tachometer to tho sparkplug oad. Engine tachometer ‘90880-03113,IDLING SPEED ADJUSTMENT/ [INSP THROTTLE CABLE ADJUSTMENT [ADs | GR 3. Cheok Engine ling speed ‘Out of specification + Adjust. Engine iaing speed 1,300 ~ 1400 min Adu ‘Engine idle speed Adjustment stops: ‘Turn the pilot screw (unt itis lightly seated, ‘2 Turn the pilot serew out by the specified umber of turns Pilot sero 2tums out ‘Tun the throtte stop serew @ in or out nti the specified ling speed is obt “Turning in ling speed is increased “Turning out ding speed is decreased 5. Adjust ‘Throttle cable tre ploy Rofer to “THROTTLE CABLE ADJUST. IMENT section ‘THROTTLE CABLE ADJUSTMENT NoTE: Prior to adjusting the throtte cab © ‘tho engine ialing speed should be 1. Checks ‘Throttle cable tre play @ ‘Out of specification > Adjust. Free play thro cable) 3-5 mm at throttle gp flange 2. Adjust: ‘Throtle cable ree play tree play, djusted Adjustment steps! Nove; Never accelerate the throttle when stopping the engine.THROTTLE CABLE ADJUSTMENT INSP SPARK PLUG INSPECTION [Ay | GR {# Loosen the locknut @ on the thot cable Tum the adjuster @ in or out until specified {roe pay is obtained “Turing in Free play is nereased: “Turing out=Froe play is decreased. After adjusting, turn the handlebar to the right and to the loft to onsure that this doe ot cause the engine fling speed to change. ‘SPARK PLUG INSPECTION 1. Remove: *Spark plug cap Spark plug CAUTION: —______ Before removing the spark plug, use com- pressed air to blow away any dirt accumulat- {ed inthe spark plug walls to pravent it from falling into the eylinda. 2. Checks *Spark plug type Incorrct + Replace ‘Standard spark plog ‘DBEA/X24ES-U (NGK/DENSO} 3. Inspect: Electrodo Wearldamage ~+ Replace snguletor @ "Abnormal color ~ Replace, Normal color is a medium-to-light tan color 4, Clean: Spark lug ‘with spark plug cleaner or wire beush) 5. Messure: Spork plug aap @ (ith a wire gauge) Out of specification + Adjust gap. ‘Spark plug gap (06-07 mm GSPARK PLUG INSPECTION/ [INSP IGNITION TIMING CHECK [AD-| QR ett “Sher ea hore afore inang » spark pu, cen he Gar Ket euree and plug eure IGNITION TimiNG CHECK Nore; —________ Prior to checking the ignition timing, check all ‘lctrcal connections rolated to the ignition system. Make sure all connections are tight land free of corrosion and tht al ground con- rections are tight. 1. Remove: ‘Timing check plug 2, Attach: Timing tight © Engine tachometer @ {to tho sparkplug lead) ing ight 90090-03181 Engine tachometer: 90890-03113, 3. Checks slanition ting Checking steps: ‘Start tho engine and lt it warm up for sev {eral minutes. Let the engine run st the spoc- fed spood, Engine "1300 ~ a6 Visually check the stationary pointer @ to ty its within the required firing range © Indicated on the tywoa firing range.» Check the ignition Note nition timing isnot adjustable. Insta ‘Timing ebock pgcompression pressure uensunemenr [RSE] OR ‘COMPRESSION PRESSURE MEASUREMENT NOTE: Inutficiont compression pressure wil result in performance loss. 1. chook ‘Valve clearance ‘ut of specification -» Adjust Refer to “VALVE CLEARANCE ADJUST. MENT section, 2. Start the engine and several minutes. 23, Tutn off the engine 4 Romove: Spark pg ;eAUTION:! Before removing the spark plug, use com: pressed air to blow away any dit accumu: lated in the spark plug well to prevent ft fom falling into the eylinder 5. Attach: Compression gauge @ ‘Compression gauge: © ‘90890-02087 Adaptor: @ 90880-04082 5 Measure Compression pressure If it exceads the maximum pressure allowed -+ Inspect the cylinder h valve surfaces and piston erown for car- bon deposits. IV itis below the minimum prassure > Squirt 8 fow drops ofall nto the affect. ed cylinder and messure again, tabla below, Higher than without oit Same as without ofCOMPRESSION PRESSURE MEASUREMENT/ [INSP ENGINE OIL LEVEL INSPECTION [ADs | QR ‘Compression pressure (at soa oval Standard: ‘900 kPa (2.0 kg/em? , 90 bar) ‘Minimum: 800 kPa (8.0 kg/om?, 6.0 bar Maximum: 1,000 kPa (10.0 kg/em®, 10.0 ban) ‘Measurement steps: ‘Crank the ongine with tho throttle wide: ‘open until the roading on the compression Before cranking tho engine, ground pig leads to pravent sparking ee *Sperk lug ENGINE OIL LEVEL INSPECTION 1. Stand the motoreyele on a level surfac, NoTe: Make sure the motoreyele ie upright when inspecting the ol level 2. Start the engine and lat it warm up for @ few minutes 2. Turn off the engin, 4 Inspect: Engine oll ove! it level should be betweon maximum @ and minimurn @ marks Oil evel i below the minimum mark “Add oll upto the proper love, RECOMMENOED ENGINE Ot Ffor tthe cot for elcton fhe tate the moroapa operate, Teconmended ol ALD] retort th towing cart tor selection of ols which are sulted om to the atmospheric tomperatures| eet Recommended engine oi lasitin-| ee tion - | ‘APL STANDARD: Te ew APL"SE” or highor gradoENGINE OIL LEVEL INSPECTION/ [INSP ENGINE OIL REPLACEMENT | ADJ {cauTION: *Do not put in any tse ols with a grade of CO @ or higher. fe sure not to use oils laboled “ENERGY CONSERVING II" @ or higher. Engine oi also lubricates the clutch and additives could cause clutch slippag 1¢ sure no foreign material enters the crankease. vomicals adaltives oF 5. Start the engine and let it warm up for » {ow minutes. 6. Turn off tho engine and inspect the oil level once again Nore: ita fow minutes until the ol setae before Inspecting the ol lev ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes 2 Tum off the engine and place a container under the engine, 2. Remove Replace, 2. Check ‘Tightening torque Bor ® 10 Nm (1.0 rma) Bott 20 Nem (2.0 kg) Bolt 27 Nr (2.7 ekg)FRONT BRAKE ADJUST MENT/ [INSP REAR BRAKE ADJUSTMENT [ADI | QR CHASSIS FRONT BRAKE ADJUSTMENT 1. Check *Brako lover roe play @ Out of specification + Adjust B Fres play (Brake lever 0~20mm atbrake lover ond 7% Adjust ‘Brake lover roe play Adjustment steps ‘*Turn the adjuster @ in oF out until the specified free play is obtsined, “Turing in-Free play is decreased. 246 Turing out=Free play is increased. ‘Tighten the locknut adjusting the front brake lover 32 play. Wheels ‘Loosen the locknut @. Turn tho adjuster @ in oF out until the specitiod tro ply is obtained. “Troing n-*ree pay is decreased “Turning out-Fre0 play is increased. ‘Tighten the looknit REAR BRAKE ADJUSTMENT 1. Check: ‘Brake podal height @ Out of specification > Adjust Brake pedal height below the top ofthe footrestREAR BRAKE ADJUSTMENT | ADJ INSP. 2. Adjust Brake pedal height Adjustment stops: ‘Loosen the locknut @. Turn the adjuster @ in or out until the specified pedal height is obtained. “Turing in Pedal height la decreased: Turning out=Pedal height I inereased ‘Tighten the focknu 2, Check: *Brake pedal free play ® Out of specification » Adjust. Free play (Brake pedal 20~30mm a ‘at brake lover ond 4 Adj *Brako podal fre play Adjustment steps: ‘Turn the adjuster @ in or out until the specified free play is obtained. “Turning inFreo play fe docrensed “Turing out=Free play is increased. CAUTION: Make sure that there ie no brake dag after Rafer to “BRAKE LIGHT SWITCH ADJUSTMENT”,BRAKE SHOE INSPECTION/ BRAKE LIGHT SWITCH ADJUSTMENT/ [INSP DRIVE CHAIN SLACK ADJUSTMENT | apg | QR [BRAKE SHOE INSPECTION 1. Operate the brake lever or brake pedal 2. Inspoct: *Brako shows ‘Wear indicator @ teaches the wear limit line @ ~ Replace the brake choos as 3 efor to "REAR WHEEL” in CHAPTER BRAKE LIGHT SWITCH ADJUSTMENT wove; ‘The brake light switch i operated by move: ‘ment ofthe brake ped. “Adjustment is corect when the brake light comes on just bofore the braking effect actualy stants, 1. Check 7 ‘Brake light operation timing incorrect» Adjust 2. Adjust @ ‘Brake light operating timing Adjustment stops: ‘Hold the main body @ of the switch with ‘your hand so that it does not rtato, and turn the adjuster @ in oF out until the proper operation timing is obtained, “Turning in *Brake ight comes on fast “Turning out *Brake light comes on slow. DRIVE CHAIN SLACK ADJUSTMENT wore; Bolore checking and adjusting, rotate the ear whael several revolutions and check the slack at several points to find the tightast point. Check and ifnecessary adjust the drive “tightest” poston.INSP. Drive cial stack apJustwent [aby] QR CAUTION: Too tte chan sack will overioad the engine ‘and other vital parts; Koop the slack within the specified limits. PMIEININGS Securely support the motoreyele s0 that ‘there is no danger of i faling over. ‘Hold the motorcycle upright ona level sur- ‘a NOTE: Both wheels should be on the ground and ‘nobody should sit on the motoreyele while this adjustment is boing performed. 1. Remove! scam 2. Check ‘rive chain slack @ Out of specification > Adjust. Drive chain lace 30-45 mm @ check window 8. Remove: scottor pin 4 Adjust ‘Drive chain slack Adjustment steps ‘© Loosen the @ Loosen shaft nut @ 1 Tuin the chain adjusters @ clockwise or counterclockwise until the specified drive chain slacks obtained, Clockwise “Chain sack ie decreased Counter clockwise rake adjust axlo nut @) and the sprocket “Chain slack is increased.INSP’ Q DRIVE CHAIN SLACK ADJUSTMENT | ADJ note: Turn each chain adjuster exactly the same amount to maintain correct a (There aro marks @) on each chain adjuster. Use them when adjusting the slack for proper alignment) ‘¢Bofor tightening the axle nut to spactton, ‘ako sute that there is no elearanco at the aaister (or the swingarm and) on both sides by pushing the whoo! forward Driven sprosket shat 20 im (00mg) Fear wheat axe a0 tinn (0 mk) 5. Insta: ooter pin © ESM Into the axle Hut and bend the end of the cotter pin CAUTION: Do not loosen the axle nut after tightening the torque. Ifthe axle nut groove is not aligned with the cotter pin hol, align the ‘groove with the hole by tightening up the axle nut pedal foe play olor to “BRAKE PEDAL FREE PLAY"INSP ‘STEERING HEAD INSPECTION | ADJ STEERING HEAD INSPECTION PMT Securely support the motoreyele £0 that thore is no danger of i fling aver 1, Stand the motoroyelo ona level surface Nore Stand the motoreyelo on its centerstand if it has one. If not, place a suitable stand under {Grasp the bottom ofthe lower font fork tubes and gonty rock the fork assem by. Loaseness + Adjust the stearing head. 4, Adjust ‘Steering head Aajustment stops: ‘ Loosea the handle crown bolt ®. ‘Tighten the ring nut @ using the ring nut wrench @. (X[38Nm Gomag)] | Loosen the ring aut NOTE: When toosen the ring nut, should be steady the ball bearings and stoering shaft moving ‘smooth, Ting ut wrench: 90890-01403 ‘© Tighten the handle crown bolt. ‘Chock the steering heed for looseness oF binding by turning tall the way in both directions.FRONT FORK INSPECTION [INSP nean soci Roo NSeSTEN FIESET OY FRONT FORK INSPECTION TENN ‘Securely support the motoreyele so that Is no danger of falling ove 1. Stand the motoreyele ona evel surface 2. Check: slnnor tube ‘Scratchesidamege ~ Replace, +01 soa! Excossve oil leakage ~ Replace Hold the motoreycie upright and apply the front brake. 2. Check: Operation ish down hard on the handlebars sev times, Unsmooth operation + Repalt, Refer to “FRONT FORK" in CHAPTER 6 REAR SHOCK, “AWARNIN Securely support the motore thorois no danger of i fling over. IRBER ADJUSTMENT that Spring pretos: Seat 2. Adjust *Spring preload Note: Use the special wrench and extension ber included in the owners toolkit adjust the spring preload. Aijostoent stops: ‘¢Turn the adjuster to direction @ or ©, Turing toward ® * Spring proload is increased, Turning toward @ Spring preload is dacrasedREAR SHOCK ABSORBER ADJUSTMENT/ [INSP. TIRE INSPECTION | ADJ Aajustment numbers Standard nur 5 Minimum number 5 ‘Maximum number 1 (CAUTION: Never turn the adjuster beyond the maximum ‘oF minimum adjustment number 2, Inetal Seat TIRE INSPECTION 1. Measure: ‘Tira inflation prossure ‘Out of specitiestion » Adjust. WENA ‘Tite inflation pressure should only be ‘checked and adjusted when the tire tem- pporature equals the amblent ale tamper {ure Tie inflation pressure and suspension must be adjusted according to the total ‘wight of the eargo, rider and accessories {izing, saddlebags, ete: approved for this ‘modell, and according to whether the ‘motoreycle will be oporated at high speed NEVER OVERLOAD THE MOTORCYCLE. Operation of an overloaded motoreyele could eause tire damage, accident or injury. se walaht With oi and verkg {ul fel tank Moximum ood Tek p Front Rear 20 750 Golde pressure ig [stale * Load fe the total weight of the cargo, Fido, and accossories. anINSP- ine nspection {aps | QR 2 Ingpect: Tire surlacos Woaridamage ~ Replace vam te toad depth win (front and reat D Yewd apa @ suewal (Bima nceator PNA ‘itis dangerous to ride with a worn-out te. When the tre tread begins to show signs ‘of wear, replace the tre immediately, ‘Patching @ punctured tubo fs not recom: ‘mended, If ts absolutely necessary to do 20, use great care and replace the tube as s00n as possible with # good quality placement tube. *Do not use tubeless tires on a wheel do: signed for tube type ties only. Tie falure land petsonal injury may result from sudden, deflation. “Tube type wheal > Tube type te only “Tubeless type wheel ~ Tube type or tubeless tre, Be sure to Install the correct tube when us- Ing tube type tires. oAtor extensive tost, the tres listed below have been approved by Yamaha Motor Co. Lilfor this model. No guarantee eoncern- Ing handling characteristics ean be given it 8 tre combination other than one approved bby Yamaha is used on this motoreyte. The ‘ont and rear tres should always be by the same manufacturer and ofthe same design, "AWARNING ‘Ator mounting a tre, ride conservatively for ‘ while to give the tee time to seat itself properly in the rim. Failure to do so could lead to an aceident with possible injury to the der or damage to the motoreyele 2, Alter a tre repair or repacament, be sure to tighten the valve stem tocknut @ to specication. Tek “U5 Ne (0.15 akgSPOKE INSPECTION AND TIGHTENING/ [INSP WHEEL INSPECTION [Aba | QR 9p ‘SPOKE INSPECTION AND TIGHTENING 1. Inspect: *Spokos © < Bondingldamago ~ Roplaco, ee Loose spoke > Retighton. a 2. Tighten Spokes \ NOTE: Be sure to tighten the spokes before an breakin. ‘Nipple 21m (0.2 mks) WHEEL INSPECTION Damage/Bonds-+ Replace. Note: Always balance the wheel when a tire oF ‘whoo! has been changed or replaced. 325INSP artery wvsPection [aps | GR ELECTRICAL BATTERY INSPECTION NOTE: ‘Since the MF battery is sealed type battery, itis not possible to measure the specitic ‘ravity ofthe electrolyte inorder to chack tho Charge state of the battery. Therefore the targe of the battery has to be checked by ‘measuring the voltage atthe battery termi als (CAUTION: ‘CHARGING METHOD ‘This is a sealed type battery. Never remove the sealing caps. Ifthe sealing caps have been removed, tho balance will not be ‘iaintained and battery performance wi deteriorate. “Charging time, charging current and charg ing voltage for the MF battery are ifforent {rom those of batteries of general type. sThe MF battery should be charged as ‘explained In “CHARGING METHOD”. If the battery Is ovarchargod, the elecrolyte level will drop considersbly. Therefore, take spe- lal eare when charging the battery CNN Battory electrolyte ls dangerous: it contains ‘sulfurle acid which ie poisonous and highly ‘custo, ‘Always follow these preventive measures: ‘Avoid bodily contact with electrolyte as it ean cause severo burns or permanent eve Injury ‘Wear protective eye gear when handling oF working neat batteries ‘Aatidote EXTERNAL} SKIN - Flush with water EVES - Flush with water for 15 minutes and get immediate medical attention ‘Antidote (INTERNAL! *Drink large quantitos of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable ol. Get immediate medical atten:INSP, D axrreny mseeoion [NSP] QQ] [P “Battorios generate explosive hydrogen gas. Always follow the following preventive charge batteries in a wel-ventilated are. ‘Keep batterles away from fire, sparks or open flames (2.9, wolding equipment, ight- ed cigarettes, ote) *DO NOT SMOKE when charging or handling hattories KEEP BATTERIES AND ELECTROLYTE OUT (OF REACH OF CHILDREN. 1. Remove: Side cover (eight) ‘Cover (batty caso) Refer to “SIDE COVER, SEAT AND FUEL TANK" section 2. Disconnect! ‘Batory loads (CAUTION: Disconnect the negative lead @ frst and then disconnect the positive lead @). 3. Remove: Battery 4, Check ‘Batory condition Battery condition chesking ‘*Connect a digital volt m to the battery “Testor (oad Battery (a) termi “ester (+ lead “Battery (terminal 327 wove, — ‘The charge state of an MF battery can be checked by measuring the open-circuit volt {age (ie. tho voltaga whon tho postive tami: fal dieconnectod) ‘Open cect vokage | Charging unelal INSP’ artery inspection [apy | QR 328 "© Check the condition af the battory using the charts Example: Open-crcuit voltage = 12.0V Charging time = 65 hours Charge condition of the battery = 20 ~ 20% 5. Charging method for MF betteriog (CAUTION: “if it is impossibie to set the standard charg- Ing current, be careful not to overcharge When charging the battery, be sure to remove it fom the motoreyele. (if eharging has to bo dono with the battery mounted fon the motoreyele, be sure to disconnect ‘the wire atthe negative terminal.) ‘Novor romove the sealing caps of an MF battery ‘Make sure that the charging elips are In full -antact with the terminal and that they are not shorted together. (A corroded clip on the chargor may eause the battery to gener- ‘ate heat in the contact atoa. A weak cl ‘pring may cause sparks) ‘Before removing the clips from the battery ‘terminals, be sure to tun off the chargor's power switch. ‘The open-circuit voltage variation for the IMF battory aftor charging is shown below. ‘As shown in the figura, the open-clreult voltage stabilizes about 30 minutes after charging has been complated ‘Therefore, wait 30 minutes after charging is smploted before measuring the open-cir- cult voltage,BATTERY INSPECTION INSF Qa ‘Charging method using a variable-curent (voltage type charger charger Measure the open-circuit] yore ‘ve mar | votage prior tocharaing:| eg age pease a ~ Ce oI id Seen ‘onnect a charger and] nore AL | amPmoterto the batory,| Save sargraronge ec U and startcherging, et fos ety et ‘Mako sure the current fe yes __| higher than the standard] NO charging current writen on the battery. By turing the charging volage adjust dal, sot the charging voltage at 20-25. [etesee soa —__ ‘Adjust the vole so that a ccacesseeee eres rent is at standard charging 1, TES | rsinutes to chock ifthe stan- | —) love dard charging current reached. No If current doo not exceed stan- deed charging current after 5 minutes, replace tha bey the timer aocordng 1 the Charging time suitable for ‘ho ‘open-circuit voltage. Refer to ‘tho "Battry concition check ing tops" scton Tn cave thet cvrging requires more than 8 hous, ts advisable to chock the charging curent after a lapse of 5 hours If thar is any change In the amperogo, readjust the voltage to obtain tho standard charging "Measur the batry open-circuit voltage after having let the battery ‘unused fr more than 30 minutos. 1288 or moe - Charging is complete. 123V or less Rocharing is require. Under 120V-Repiae the battery