1995 YAMAHA TZ125G1(G) service manual – PDF DOWNLOAD

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1995 YAMAHA TZ125G1(G) service manual – PDF DOWNLOAD

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1995 YAMAHA TZ125G1(G) service manual – PDF DOWNLOAD

Size: 35.0 MB
Pages : 243
Format: PDF
Language: English
Brand: Yamaha

TABLE OF CONTENTS:

1995 YAMAHA TZ125G1(G) service manual – PDF DOWNLOAD

DESCRIPTION 1·1
MACHINE IDENTIFICATION 1 ·2
VEHICLE IDENTIFICATION NUMBER
(For USA, CON, AUS NZ and El 1·2
FRAME SERIAL NUMBER (Except
for USA, CON, AUS, NZ and E) 1-2
ENGINE SERIAL NUMBER 1-2
IMPORTANT INFORMATION 1·3
PREPARATION FOR REMOVAL
AND DISASSEMBLY 1 3
ALL REPLACEMENT PARTS 1 4
GASKETS, OIL SEALS AND
0 -RINGS 1·4
LOCK WASHERS PLATES AND
COTTER PINS 1·4
BEARINGS AND Oil SEALS 1, 4
CIRCLIPS 1 ·5
SPECIAL TOOLS 1 S
FOR TUNE UP 1·5
FOR ENGINE SERVICE 1·5
FOR CHASSIS SERVICE 1 7
FOR ELECTRICAL SERVICE 1·8
CONTROL FUNCTIONS 1·9
“ENGINE STOP” BUTTON 1-9
CLUTCH LEVER 1-9
SHIFT PEDAL 1-9
THROTTLE GRIP 1 9
FRONT BRAKE LEVER 1,9
REAR BRAKE PEDAL 1-10
FUEL COCK 1· 10
STARTER KNOB (CHOKE) 1· 10
WATER TEMPERATURE GAUGE 1·10
VALVE JOINT 1·10
MIXING COVER 1-11
CARBURETOR COVER 1-11
LOWER COWL 1·11
CATCH TANK 1·11
FLAP 1·12
DETACHABLE MAINSTAND 1 12
DETACHABLE SIDESTAND 1·12
FIRE RETARDANT MATERIAL 1-12
FUEL AND ENGINE MIXING OIL 1·13
INFORMATION BEFORE
PRE-OPERATION 1·14
PRE-OPERATION CHECK 1-14
PRE-OPERATION CHECK LIST 1· 16
STARTING AND BREAK-IN 1-17
STARTING A COLD ENGINE 1-17
WARMING UP 1-17
STARTING A WARM ENGINE 1·18
BREAK·IN PROCEDURES 1·18
TORQUE-CHECK POINTS 1-20
CLEANING AND STORAGE 1 21
CLEANING 1·21
STORAGE 1·22
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS 2·1
GENERAL SPECIFICATIONS 2-t
MAINTENANCE SPECIFICATIONS 2·3
Engine 2·3
Cha- ssis 2-6
Electrical 2~10
GENERAL TORQUE
SPECIFICATIONS 2·11
DEFINITION OF UNITS 2·11
CABLE ROUTING DIAGRAM 2·12
SETTING PARTS 2·16
CARBURETOR 2·16
CYLINDER GASKET 2· 16
TRANSMISSION 2·17
DRIVE, DRIVEN SPROCKET
AND DRIVE CHAIN 2· 17
CHAPTER 3
REGULAR INSPECTION
AND ADJUSTMENTS
MAINTENANCE INTERVALS 3·1
LOCKING WIRE INSTALLATION
GUIDE 3-4
FUEL AND ENGINE MIXING OIL 1-13
II N FORM A TI,0 1N BEFORE
IPRE~OPERATION , 1-14
PRE-OPERATION CHECK 1-14
PRE-OPERATION CHECK LISl’ 1-16
STARTING AND BREAK-IN 1-17
STARTING A COLD ENGINE 1-17
WARMING UP 1-17
STAATllNG A WARM ENGINE 1-18
!BREAK-IN PROCEDlllAES 1-18
T10RQU E-CH ECk POi f’4TS, 1-20
CILEANING AND ST10RAGE , 1-21
CLEANING 1 ~21
STORAGE 1-22
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS 2-t
GENERAL SPECIFICATIONS 2 1
MAINTENANCE SPECIFICATIONS 2·3
Engine 2 3
Cha:ss;is 2-6
Electrical 2· 1 0
GIEN ERAL TORQUE
SP ECI FI CATIONS 2-11
DIEF1NITl10N OF UNITS 2-11
CABLE ROUTING D,IAGRAM _ 2-12
SETT1IN1G !PARTS 2-16
CARSURETOR 2-16
CYLINDER GASKET 2-16
TRANSMISSION 2-17
DRIVE, DRIVEN SPROCKET
AND DRIVE CHAIN 2-17
CIHAIPTER 3
REGULAR IIN1SPECTION
AND ADJUSTMENTS
MAINTEINANCE INiTERVALS 3-1
LOCKING WIRE INSTALLA TilON
1GIU I DE 34
COOLING WATER LEVEL
IN SPECTIO’N 3-5
COOLING WATER REPLACEMENT 3-5
RADIATOR CAP INSPECTION 3-7
RADIATOR CAP OPENING
PRIESSURE INSPECTION _ 3-7
COOLING SYSTEM INS P£CTJON 3-8
CLUTCH CARE 3-8
CLUTCH ADJUSTMENT _ _ 3-8
PILOT AIR SCREW ADJUSTME T 3-9
TH ROTTLE CAB LE AIOJ U STMENT 3-9
YPVS OPEN SIDE CABLE
ADJUSTMENT 3-10
YPVS CLOSE SmE CABLE
ADJUSTMENT _ _ 3-11
YPVS COMPONENTS
R1ITIGHTENING 3-11
TRANSMISSION OIL LEVE
Cil-llECK 3-12
TRANSMISSION OIL
RIEPlACEMiENT 3-13
BRAKE SYSTEM AIR BLEEDING 3-H
FRONT BRAKE ADJUSTMENT 3-15
REAR BRAKE ADJUSTMENT _ 3 15
FRONT BRAKE PAO INSPECTION
ANID REPLACEMENT J-16
REAR BRAKE PAD INSPECTION
AND REPLACEMENT, 3-17
BRAKE FUJI D l~EL INSPECTLON 3-19
SPROOKETS INSPECTION 3· 19
DRIVE CHAIN INSPECTION 3,20
ORl1VE CHAIN SLACK
ADJUSTMENT 3-22
WH~EL ALIGNMENT AD1JUSTMENT J-23
FRONT FOR I< INSPECTION 3-25
FRONT FORIK TOP END
ADJUSTMENT _J, 25
!FRONT FORK SPRING
PRELOA01 ADJUSTMENT 3-27
FRO NT FORK REBOUND DAM PING
FORCE ADJUSTMENT 3-27
FAO NT FORK COMPRESSION
DAMPING FORCE ADJUSTMENT 3-28
REAR SHOCK ABSORBER
INSPECTION -3-29
SEAT I-IEIG~T ADJUSTMENT_ 3-30
REAR SH OCI< AIB SORBER SPRING
PR ELOAD ADJUSTMENT 3-30
REAR SHOCI<‘ ABSORBER REBOUND
DAMPING fORCE ADJUSTMENT 3 31
COOLING WATER LEVEL
INSPECTION 3-5
COOLING WATER REPLACEMENT 3-5
RADIATOR CAP INSPECTION 3 7
RADIATOR CAP OPENING
PRESSURE INSPECTION 3·7
COOLING SYSTEM INSPECTION 3·8
CLUTCH CARE 3·8
CLUTCH ADJUSTMENT 3·8
PILOT AIR SCREW ADJUSTMENT 3·9
THROTTLE CABLE ADJUSTMENT 3·9
YPVS OPEN SIDE CABLE
ADJUSTMENT 3-10
YPVS CLOSE SIDE CABLE
ADJUSTMENT 3· 11
YPVS COMPONENTS
RETIGHTENING 3· 11
TRANSMISSION OIL LEVEL
CHECK 3· 12
TRANSMISSION OIL
REPLACEMENT 3·13
BRAKE SYSTEM AIR BLEEDING 3·14
FRONT BRAKE ADJUSTMENT 3· 15
REAR BRAKE ADJUSTMENT 3·15
FRONT BRAKE PAD INSPECTION
AND REPLACEMENT 3· 16
REAR BRAKE PAD INSPECTION
AND REPLACEMENT 3-17
BRAKE FLUID LEVEL INSPECTION 3· 19
SPROCKETS INSPECTION 3·19
DRIVE CHAIN INSPECTION 3·20
DRIVE CHAIN SLACK
ADJUSTMENT 3·22
WHEEL ALIGNMENT ADJUSTMENT 3·23
FRONT FORK INSPECTION 3·25
FRONT FORK TOP END
ADJUSTMENT 3·25
FRONT FORK SPRING
PRELOAD ADJUSTMENT 3·27
FRONT FORK REBOUND DAMPING
FORCE ADJUSTMENT 3 27
FRONT FORK COMPRESSION
DAMPING FORCE ADJUSTMENT 3·28
REAR SHOCK ABSORBER
INSPECTION -3·29
SEAT HEIGHT ADJUSTMENT 3·30
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT 3 30
REAR SHOCK ABSORBER REBOUND
DAMPING FORCE ADJUSTMENT 3-31
REAR SHOCK ABSORBER
COMPRESSION DAMPING FORCE
ADJUSTMENT 3·32
TIRE PRESSURE CHECK 3·33
TIRE INSPECTION 3·33
WHEEL INSPECTION 3·34
STEERING HEAD INSPECTION
AND ADJUSTMENT 3·34
STEERING DAMPER
ADJUSTMENT 3·36
WIRES CABLES 3·36
MUFFLER INSPECTION 3·36
SILENCER INSPECTION 3·37
COWLING INSTALLATION
INSPECTION 3·37
LUBRICATION 3·38
SPARK PLUG INSPECTION 3·39
IGNITION TIMING CHECK 3-40
CHAPTER 4
ENGINE
COWLING SEAT FUEL TANK
EXHAUST PIPE AND SILENCER 4-1
PREPARATION FOR REMOVAL 4-1
RADIATOR 4·3
PREPARATION FOR REMOVAL 4-3
NOTE ON REMOVAL AND
REASSEMBLY 4-4
REMOVAL POINTS 4 4
Radiator 4-4
INSPECTION 4 5
Radiator 4 5
ASSEMBLY AND INSTALLATION 4 5
Radiator 4-5
CARBURETOR AND REED VALVE 4-7
PREPARATION FOR REMOVAL 4 7
NOTE ON REMOVAL AND
REASSEMBLY 4·8
REMOVAL POINTS 4-9
Throttle valve 4-9
Float chamber 4 9
INSPECTION 4·9
Carburetor ~9
PISTON 4-17
PREPARATION FOR REMOVAL 4-17
N01TE ON REMOVAL AND
REASSEMBLY 4-18
R EMOVAl POi NTS 4-18
YPVS cable 4 1 B
Piston and piston rr ng 4-19
Power velve 4-20
INSPECTION 4-20
Cylinder head 4-20
Cylinder 4-21
Piston 4-22
Piston pin and small end beanng 4-22
Piston ring 4-23
Piston clearam;:e- 4 p24
Combination of p iston and
cylinder 4-24
Power valve 4·2-5
Power v-aLve hot9 on c:ylindllr 4-25
ASSEMBLY AND INSTALLATION 4·26
Pow11r v:alve 4-26
Piston rin9 ind pislon 4-2?
Cylinder head and cylinder 4-28
Cl! UTCH 4-31
PRAPAFIATION FOR REMOVAL 4-31
NOTE ON R6MOVA L AND
FI EASSEM 13 LY 4-32
REMOVAL POINTS 4-32
Clutch boss 4 32
I NSPECT110N 4-33
C1utc::h housing am d boss 4-33
Clutch housing 4-33
Clutch 5:pring 4-33
Frlctlon plate 4-33
Cltneh plate 4-34
Push lever axle 4-:34
Pu !ih rod axle 4-34
ASSEMBl Y AND INSTALLATION 4-34
Push levor axle 4-34
c rutch 4-35
PRIMARY DRIVE GEAR !PRIMARY
DRIVEN GEAR AND BALANCER
SHAFT 4 -39
PREPARATION FOR REMOVAL 4-39
NOTE ON REMOVAL A ND
REASSE!MBL Y 4-40
REMOVAL POINTS 4-40
Primary drive gear and balancer
weight gea,r 4-40
BaJancer shaft 4·41
INSPECTION 4-41
Primary drive gea1r and primary
driven 9,{lar A-41
Balancer weight gear and
balancer drive gear 4-41
Crankcase cover (right~ 4-42
Balancer shaft 4-42
ASSEMBL V AND INSTALLATION 4-42
INSPECTION 4-48
Shift shaft 4-48
Stopper lever 4-48
Oil pump 4-49
NOTE ON REMOVAL AND
R EASSE M8 LY 4-54
REMOVAL POINTS 4-5-t
Drive sprocket 4 54
Shift cam 4-55
INSPECTION 4-55
Oi I delivery pip8 4, 55
Gears 4-56
Sih ift fort groov(I 4-56
Bea,i l’\Q 4-56
Shift fork and shift cam 4 ,J57
ASSEMBLY AND INSTALLATION 4-57
Shirt cam 4-57
Drive sprocket 4-61
COi MAGNETO ·· 4-63
PREPARATION FOR REMOVAL 4 53
NOTE ON REMOVAL AND
REASSEMBLY 4 64
REMOVAL POINTS 4-64
Rotor 4-64
INSPECTION 4-64
COi magneto 4-64
Woodruff key 4-65
ASSEMBLY ANO INSTALLATION 4·65
COi magneto 4 ,55
ENGINE REMOVAL 4~
PREPARATION FOR REMOVAL 4~
NOTE ON REMOVAL ANO
REASSEMBLY 4·70
REMOVAL POINTS 4·70
Engine removal 4-70
ASSEMBLY AND INSTALLATION 4 71
Engine installation 4-71
CRANKCASE, CRANKSHAFT
ANO WATER PUMP 4 73
PREPARATION FOR REMOVAL 4·73
NOTE ON REMOVAL AND
REASSEMBLY,, 4-74
REMOVAL POINTS 4 74
Crankcase 4-74
Crankshaft 4-75
Impeller shaft 4 76
Oil seal 4-76
INSPECTION 4 76
Crankcase 4-76
Crankshaft 4-77
Impeller shaft 4-n
Oil seal 4-77
ASSEMBLY AND INSTALLATION 4 78
Oil seafiirnpe11er shaft) 4-78
Impeller shaft 4-78
Oil seal (crank shaft) 4· 79
Crankshaft 4·79
CHAPTER 5
CHASSIS
FRONT WHEEL · · · 5 1
PREPARATION FOR REMOVAL 5· 1
REMOVAL POINTS 5·2
Wheel bearing (if necessary) 5·2
INSPECTION · 5·2
Front wheel 5-2
Front wheel axle 5·2
Brake disc 5-3
ASSEMBLY ANO INSTALLATION 5·3
Front wheel 5–3
REAR WHEEL 5·7
PREPARATION FOR REMOVAL 5 7
REMOVAL POIITTS 5-8
Rear wheel 5-8
Wheel bearing (if necessary) 5-8
INSPECTION 5-8
Rear wheel 5-8
Rear wheel axle 5·9
Brake disc 5 9
Clutch hub 5· 10
ASSEMBLY ANO INSTALLATION 5·10
Rear wheel 5-1 O
FRONT BRAKE 5· 15
PREPARATION FOR REMOVAL , 5·15
REMOVAL POINTS 5-17
Caliper , 5-17
Caliper piston 5 17
Piston $ealkit 5-18
Master cylil\der kit 5·18
INSPECTION 5·18
Master cylinder 5· 18
Caliper 5· 19
Brake hose 5-19
ASSEMBLY AND INSTALLATION 5·19
Caliper piston 5-20
Ca!iper S -20
Master cylinder kit 5·21
Master cylinder 5·22
Brake hose 5·23
Brake fluid 5-24
REAR BRAKE , 5·27
PREPARATION FOR REMOVAL 5·27
REMOVAL POINTS, 5·29
CaHper 5·29
Caliper pistoh- 5·29
Piston seal kit 5·29
Master cylinder kit 5-30
INSPECTION 5-30
Master cylinder 5-30
Caliper 5·31
Brake hose 5-31
ASSEMBLY AND INSTALLATION 5·31
Caliper piston 5·31
Caliper 5·32
Master cylinder kit 5-33
Master cylinder 5-34
Brake hose 5–34
Brake fluid , 5 35
FRONT FORK 5 37
PREPARATION FOR REMOVAL ,, ,, 5 37
HANDLING NOTE 5·38
REMOVAL POINTS, 5 39
Cap bolt 5-39
Oil seal 5-39
Damper rod 5-40
INSPECTION 5-40
Damper rod 5 40
Fork spring 5-40
Inner tube 5 4 l
Outer tube 5-41
Cap bolt 5-41
ASSEMBLY AND INSTALLATION 5-42
Front fork assembly 5-42
Installation 5-48
STEERING 5 51
PREPARATION FOR REMOVAL 5 51
REMOVAL POINTS S-52
Ring nut 5-52
INSPECTION 5-52
Bearing S-52
Steering shaft 5-53
Steefing damper 5-53
ASSEMBLY AND INSTALLATION 5 53
Under bracket 5-53
SWINGARM S,59
PREPARATION FOR REMOVAL 5 59
NOTE ON REMOVAL AND
REASSEMBLY 5-60
REMOVAL POINTS 5-60
Swingarm 5-60
INSPECTION 5-61
Swingarm 5-61
Relay arm 5-61
Connecting rod 5-61
Swingarm side clearance 5-62
ASSEMBLY AND INSTALLATION 5-63
Swingarm 5-63
REAR SHOCK ABSORBER 5-65
PREPARATION FOR REMOVAL 5-65
HANDLING NOTE 5-66
NOTES ON DISPOSAL (YAMAHA
DEALERS ONLY) 5-67
REMOVAL POINTS S-67
Rear shock absorber 5–67
Spring {rear shock absorber) 5-68
INSPECTION · 5-68
Rear shock abSorber 5-68
ASSEMBL Y AND INSTALLATION 5-69
Spring (rear shock absorberl 5 69
Rear shock absorber 5_69
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM 6-1
ELECTRICAL COMPONENTS 6-1
WIRING DIAGRAM 6-1
IGNITION SYSTEM 6 2
INSPECTION STEPS 6-2
SPARK GAP TEST 6 3
SPARK PLUG CAP INSPECTION 6-3
COUPLERS ANO LEADS
CONNECTION INSPECTION 6 3
“ENGINE STOP” BUTTON
INSPECTION 6-4
IGNITION COIL INSPECTION 6 4
COi MAGNETO INSPECTION 6-5
COi UNIT INSPECTION 6-5
YPVS SYSTEM 6 6
INSPECTION STEPS 6-6
COUPLERS AND LEADS
CONNECTION INSPECTION 6 7
SERVOMOTOR OPERATION 6 7
SERVOMOTOR INSPECTION 6 7
OUT-PUT VOLTAGE INSPECTION 6-8
SOLENOID VALVE SYSTEM 6 9
INSPECTION STEPS 6-g
COUPLERS ANO LEADS
CONNECTION INSPECTION 6-lo
SOLENOID VALVE OPERATION 6 10
SOLENOID VALVE INSPECTION 6 10
CHAPTER 7
TUNING
coefficient , 7 5
Table of correction coefficients
for carburetor setting 1 6
Other setting pans 7-7
Plug chop 7-8
Setting of cylinder gasket 7–8
Measuring piston protrusion 7-10
Se lection of tnmsmisson gear ratio 7·11
Suspension setting 7 12
Senings 7 -13
Symptom 7-15
Setting record table 7-17DESCRIPTION 1·1
MACHINE IDENTIFICATION 1 ·2
VEHICLE IDENTIFICATION NUMBER
(For USA, CON, AUS NZ and El 1·2
FRAME SERIAL NUMBER (Except
for USA, CON, AUS, NZ and E) 1-2
ENGINE SERIAL NUMBER 1-2
IMPORTANT INFORMATION 1·3
PREPARATION FOR REMOVAL
AND DISASSEMBLY 1 3
ALL REPLACEMENT PARTS 1 4
GASKETS, OIL SEALS AND
0 -RINGS 1·4
LOCK WASHERS PLATES AND
COTTER PINS 1·4
BEARINGS AND Oil SEALS 1, 4
CIRCLIPS 1 ·5
SPECIAL TOOLS 1 S
FOR TUNE UP 1·5
FOR ENGINE SERVICE 1·5
FOR CHASSIS SERVICE 1 7
FOR ELECTRICAL SERVICE 1·8
CONTROL FUNCTIONS 1·9
“ENGINE STOP” BUTTON 1-9
CLUTCH LEVER 1-9
SHIFT PEDAL 1-9
THROTTLE GRIP 1 9
FRONT BRAKE LEVER 1,9
REAR BRAKE PEDAL 1-10
FUEL COCK 1· 10
STARTER KNOB (CHOKE) 1· 10
WATER TEMPERATURE GAUGE 1·10
VALVE JOINT 1·10
MIXING COVER 1-11
CARBURETOR COVER 1-11
LOWER COWL 1·11
CATCH TANK 1·11
FLAP 1·12
DETACHABLE MAINSTAND 1 12
DETACHABLE SIDESTAND 1·12
FIRE RETARDANT MATERIAL 1-12
FUEL AND ENGINE MIXING OIL 1·13
INFORMATION BEFORE
PRE-OPERATION 1·14
PRE-OPERATION CHECK 1-14
PRE-OPERATION CHECK LIST 1· 16
STARTING AND BREAK-IN 1-17
STARTING A COLD ENGINE 1-17
WARMING UP 1-17
STARTING A WARM ENGINE 1·18
BREAK·IN PROCEDURES 1·18
TORQUE-CHECK POINTS 1-20
CLEANING AND STORAGE 1 21
CLEANING 1·21
STORAGE 1·22
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS 2·1
GENERAL SPECIFICATIONS 2-t
MAINTENANCE SPECIFICATIONS 2·3
Engine 2·3
Cha- ssis 2-6
Electrical 2~10
GENERAL TORQUE
SPECIFICATIONS 2·11
DEFINITION OF UNITS 2·11
CABLE ROUTING DIAGRAM 2·12
SETTING PARTS 2·16
CARBURETOR 2·16
CYLINDER GASKET 2· 16
TRANSMISSION 2·17
DRIVE, DRIVEN SPROCKET
AND DRIVE CHAIN 2· 17
CHAPTER 3
REGULAR INSPECTION
AND ADJUSTMENTS
MAINTENANCE INTERVALS 3·1
LOCKING WIRE INSTALLATION
GUIDE 3-4
FUEL AND ENGINE MIXING OIL 1-13
II N FORM A TI,0 1N BEFORE
IPRE~OPERATION , 1-14
PRE-OPERATION CHECK 1-14
PRE-OPERATION CHECK LISl’ 1-16
STARTING AND BREAK-IN 1-17
STARTING A COLD ENGINE 1-17
WARMING UP 1-17
CILEANING AND ST10RAGE , 1-21
CLEANING 1 ~21
STORAGE 1-22
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS 2-t
GENERAL SPECIFICATIONS 2 1
MAINTENANCE SPECIFICATIONS 2·3
Engine 2 3
Cha:ss;is 2-6
Electrical 2· 1 0
GIEN ERAL TORQUE
SP ECI FI CATIONS 2-11
DIEF1NITl10N OF UNITS 2-11
CABLE ROUTING D,IAGRAM _ 2-12
SETT1IN1G !PARTS 2-16
CARSURETOR 2-16
CYLINDER GASKET 2-16
TRANSMISSION 2-17
DRIVE, DRIVEN SPROCKET
AND DRIVE CHAIN 2-17
CIHAIPTER 3
REGULAR IIN1SPECTION
AND ADJUSTMENTS
MAINTEINANCE INiTERVALS 3-1
LOCKING WIRE INSTALLA TilON
1GIU I DE 34
COOLING WATER LEVEL
IN SPECTIO’N 3-5
COOLING WATER REPLACEMENT 3-5
RADIATOR CAP INSPECTION 3-7
RADIATOR CAP OPENING
PRIESSURE INSPECTION _ 3-7
COOLING SYSTEM INS P£CTJON 3-8
CLUTCH CARE 3-8
CLUTCH ADJUSTMENT _ _ 3-8
PILOT AIR SCREW ADJUSTME T 3-9
TH ROTTLE CAB LE AIOJ U STMENT 3-9
YPVS OPEN SIDE CABLE
ADJUSTMENT 3-10
YPVS CLOSE SmE CABLE
ADJUSTMENT _ _ 3-11
YPVS COMPONENTS
R1ITIGHTENING 3-11
TRANSMISSION OIL LEVE
BRAKE SYSTEM AIR BLEEDING 3-H
FRONT BRAKE ADJUSTMENT 3-15
REAR BRAKE ADJUSTMENT _ 3 15
FRONT BRAKE PAO INSPECTION
ANID REPLACEMENT J-16
REAR BRAKE PAD INSPECTION
AND REPLACEMENT, 3-17
BRAKE FUJI D l~EL INSPECTLON 3-19
SPROOKETS INSPECTION 3· 19
DRIVE CHAIN INSPECTION 3,20
ORl1VE CHAIN SLACK
ADJUSTMENT 3-22
WH~EL ALIGNMENT AD1JUSTMENT J-23
FRONT FOR I< INSPECTION 3-25
FRONT FORIK TOP END
ADJUSTMENT _J, 25
!FRONT FORK SPRING
PRELOA01 ADJUSTMENT 3-27
FRO NT FORK REBOUND DAM PING
FORCE ADJUSTMENT 3-27
FAO NT FORK COMPRESSION
DAMPING FORCE ADJUSTMENT 3-28
REAR SHOCK ABSORBER
INSPECTION -3-29
SEAT I-IEIG~T ADJUSTMENT_ 3-30
REAR SH OCI< AIB SORBER SPRING
PR ELOAD ADJUSTMENT 3-30
REAR SHOCI<‘ ABSORBER REBOUND
DAMPING FORCE ADJUSTMENT 3 31
COOLING WATER LEVEL
INSPECTION 3-5
COOLING WATER REPLACEMENT 3-5
RADIATOR CAP INSPECTION 3 7
RADIATOR CAP OPENING
PRESSURE INSPECTION 3·7
COOLING SYSTEM INSPECTION 3·8
CLUTCH CARE 3·8
CLUTCH ADJUSTMENT 3·8
PILOT AIR SCREW ADJUSTMENT 3·9
THROTTLE CABLE ADJUSTMENT 3·9
YPVS OPEN SIDE CABLE
ADJUSTMENT 3-10
YPVS CLOSE SIDE CABLE
ADJUSTMENT 3· 11
YPVS COMPONENTS
RETIGHTENING 3· 11
TRANSMISSION OIL LEVEL
CHECK 3· 12
TRANSMISSION OIL
REPLACEMENT 3·13
BRAKE SYSTEM AIR BLEEDING 3·14
FRONT BRAKE ADJUSTMENT 3· 15
REAR BRAKE ADJUSTMENT 3·15
FRONT BRAKE PAD INSPECTION
AND REPLACEMENT 3· 16
REAR BRAKE PAD INSPECTION
AND REPLACEMENT 3-17
BRAKE FLUID LEVEL INSPECTION 3· 19
SPROCKETS INSPECTION 3·19
DRIVE CHAIN INSPECTION 3·20
DRIVE CHAIN SLACK
ADJUSTMENT 3·22
WHEEL ALIGNMENT ADJUSTMENT 3·23
FRONT FORK INSPECTION 3·25
FRONT FORK TOP END
ADJUSTMENT 3·25
FRONT FORK SPRING
PRELOAD ADJUSTMENT 3·27
FRONT FORK REBOUND DAMPING
FORCE ADJUSTMENT 3 27
FRONT FORK COMPRESSION
DAMPING FORCE ADJUSTMENT 3·28
REAR SHOCK ABSORBER
INSPECTION -3·29
SEAT HEIGHT ADJUSTMENT 3·30
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT 3 30
REAR SHOCK ABSORBER REBOUND
DAMPING FORCE ADJUSTMENT 3-31
REAR SHOCK ABSORBER
COMPRESSION DAMPING FORCE
ADJUSTMENT 3·32
TIRE PRESSURE CHECK 3·33
TIRE INSPECTION 3·33
WHEEL INSPECTION 3·34
STEERING HEAD INSPECTION
AND ADJUSTMENT 3·34
STEERING DAMPER
ADJUSTMENT 3·36
WIRES CABLES 3·36
MUFFLER INSPECTION 3·36
SILENCER INSPECTION 3·37
COWLING INSTALLATION
INSPECTION 3·37
LUBRICATION 3·38
SPARK PLUG INSPECTION 3·39
IGNITION TIMING CHECK 3-40
CHAPTER 4
ENGINE
COWLING SEAT FUEL TANK
EXHAUST PIPE AND SILENCER 4-1
PREPARATION FOR REMOVAL 4-1
RADIATOR 4·3
PREPARATION FOR REMOVAL 4-3
NOTE ON REMOVAL AND
REASSEMBLY 4-4
REMOVAL POINTS 4 4
Radiator 4-4
INSPECTION 4 5
Radiator 4 5
ASSEMBLY AND INSTALLATION 4 5
Radiator 4-5
CARBURETOR AND REED VALVE 4-7
PREPARATION FOR REMOVAL 4 7
NOTE ON REMOVAL AND
REASSEMBLY 4·8
REMOVAL POINTS 4-9
Throttle valve 4-9
Float chamber 4 9
INSPECTION 4·9
Carburetor ~9
N&edle valve , 4· 10
Throttle valve 4-10
Float arm height 4 11
Float 4, 11
Reed valve 4-11
CYLINDER HEAD; CVU NDER AND
PISTON 4-17
PREPARATION FOR REMOVAL 4-17
N01TE ON REMOVAL AND
REASSEMBLY 4-18
R EMOVAl POi NTS 4-18
YPVS cable 4 1 B
Piston and piston rr ng 4-19
Power velve 4-20
INSPECTION 4-20
Cylinder head 4-20
Cylinder 4-21
Piston 4-22
Piston pin and small end
Piston ring 4-23
cylinder 4-24
Power valve 4·2-5
Power valve hot9 on c:ylindllr 4-25
ASSEMBLY AND INSTALLATION 4·26
Pow11r v:alve 4-26
Piston rin9
Cylinder head and cylinder 4-28
Cl! UTCH 4-31
PRAPAFIATION FOR REMOVAL 4-31
NOTE ON R6MOVA L AND
FI EASSEM 13 LY 4-32
REMOVAL POINTS 4-32
Clutch boss 4 32
I NSPECT110N 4-33
C1utc::h housing am d boss 4-33
Clutch housing 4-33
Clutch 5:pring 4-33
Frlctlon plate 4-33
Cltneh plate 4-34
Push lever axle 4-:34
Pu !ih rod axle 4-34
ASSEMBl Y AND INSTALLATION 4-34
Push levor axle 4-34
c rutch 4-35
PRIMARY DRIVE GEAR !PRIMARY
DRIVEN GEAR AND BALANCER
SHAFT 4 -39
PREPARATION FOR REMOVAL 4-39
NOTE ON REMOVAL A ND
REASSE!MBL Y 4-40
REMOVAL POINTS 4-40
Primary drive gear and balancer
INSPECTION 4-41
Primary drive gea1r and primary
driven 9,{lar A-41
Balancer weight gear and
balancer drive gear 4-41
Crankcase cover (right~ 4-42
Balancer shaft 4-42
ASSEMBL V AND INSTALLATION 4-42
Balancer 51haft and prfmary
drive g ea, 4-42
Prim arv drive11 gearr 4-45
SHIFT SHAFT AND Oil PUMP’ 4-47
PREPARATION FOR REMOVAL 4-47
NOTE ON REMOVAL ANID
NOTE ON REMOVAL AND
R EASSE M8 LY 4-54
REMOVAL POINTS 4-5-t
Drive sprocket 4 54
Shift cam 4-55
INSPECTION 4-55
Oi I delivery pip8 4, 55
Gears 4-56
Shift fork and shift cam 4 ,J57
ASSEMBLY AND INSTALLATION 4-57
Shirt cam 4-57
Drive sprocket 4-61
COi MAGNETO ·· 4-63
PREPARATION FOR REMOVAL 4 53
NOTE ON REMOVAL AND
REASSEMBLY 4 64
REMOVAL POINTS 4-64
Rotor 4-64
INSPECTION 4-64
COi magneto 4-64
Woodruff key 4-65
ASSEMBLY ANO INSTALLATION 4·65
COi magneto 4 ,55
ENGINE REMOVAL 4~
PREPARATION FOR REMOVAL 4~
NOTE ON REMOVAL ANO
REASSEMBLY 4·70
REMOVAL POINTS 4·70
Engine removal 4-70
ASSEMBLY AND INSTALLATION 4 71
Engine installation 4-71
CRANKCASE, CRANKSHAFT
ANO WATER PUMP 4 73
PREPARATION FOR REMOVAL 4·73
NOTE ON REMOVAL AND
REASSEMBLY,, 4-74
REMOVAL POINTS 4 74
Crankcase 4-74
Crankshaft 4-75
Impeller shaft 4 76
Oil seal 4-76
INSPECTION 4 76
Crankcase 4-76
Crankshaft 4-77
Impeller shaft 4-n
Oil seal 4-77
ASSEMBLY AND INSTALLATION 4 78
Oil seafiirnpe11er shaft) 4-78
Impeller shaft 4-78
Oil seal (crank shaft) 4· 79
Crankshaft 4·79
CHAPTER 5
CHASSIS
FRONT WHEEL · · · 5 1
PREPARATION FOR REMOVAL 5· 1
REMOVAL POINTS 5·2
Wheel bearing (if necessary) 5·2
INSPECTION · 5·2
Front wheel 5-2
Front wheel axle 5·2
Brake disc 5-3
ASSEMBLY ANO INSTALLATION 5·3
Front wheel 5–3
REAR WHEEL 5·7
PREPARATION FOR REMOVAL 5 7
REMOVAL POIITTS 5-8
Rear wheel 5-8
Wheel bearing (if necessary) 5-8
INSPECTION 5-8
Rear wheel 5-8
Rear wheel axle 5·9
Brake disc 5 9
Clutch hub 5· 10
ASSEMBLY ANO INSTALLATION 5·10
Rear wheel 5-1 O
FRONT BRAKE 5· 15
PREPARATION FOR REMOVAL , 5·15
REMOVAL POINTS 5-17
Caliper , 5-17
Caliper piston 5 17
Piston $ealkit 5-18
Master cylil\der kit 5·18
INSPECTION 5·18
Master cylinder 5· 18
Caliper 5· 19
Brake hose 5-19
ASSEMBLY AND INSTALLATION 5·19
Caliper piston 5-20
Ca!iper S -20
Master cylinder kit 5·21
Master cylinder 5·22
Brake hose 5·23
Brake fluid 5-24
REAR BRAKE , 5·27
PREPARATION FOR REMOVAL 5·27
REMOVAL POINTS, 5·29
CaHper 5·29
Caliper pistoh- 5·29
Piston seal kit 5·29
Master cylinder kit 5-30
INSPECTION 5-30
Master cylinder 5-30
Caliper 5·31
Brake hose 5-31
ASSEMBLY AND INSTALLATION 5·31
Caliper piston 5·31
Caliper 5·32
Master cylinder kit 5-33
Master cylinder 5-34
Brake hose 5–34
Brake fluid , 5 35
FRONT FORK 5 37
PREPARATION FOR REMOVAL ,, ,, 5 37
HANDLING NOTE 5·38
REMOVAL POINTS, 5 39
Cap bolt 5-39
Oil seal 5-39
Damper rod 5-40
INSPECTION 5-40
Damper rod 5 40
Fork spring 5-40
Inner tube 5 4 l
Outer tube 5-41
Cap bolt 5-41
ASSEMBLY AND INSTALLATION 5-42
Front fork assembly 5-42
Installation 5-48
STEERING 5 51
PREPARATION FOR REMOVAL 5 51
REMOVAL POINTS S-52
Ring nut 5-52
INSPECTION 5-52
Bearing S-52
Steering shaft 5-53
Steefing damper 5-53
ASSEMBLY AND INSTALLATION 5 53
Under bracket 5-53
SWINGARM S,59
PREPARATION FOR REMOVAL 5 59
NOTE ON REMOVAL AND
REASSEMBLY 5-60
REMOVAL POINTS 5-60
Swingarm 5-60
INSPECTION 5-61
Swingarm 5-61
Relay arm 5-61
Connecting rod 5-61
Swingarm side clearance 5-62
ASSEMBLY AND INSTALLATION 5-63
Swingarm 5-63
REAR SHOCK ABSORBER 5-65
PREPARATION FOR REMOVAL 5-65
HANDLING NOTE 5-66
NOTES ON DISPOSAL (YAMAHA
DEALERS ONLY) 5-67
REMOVAL POINTS S-67
Rear shock absorber 5–67
Spring {rear shock absorber) 5-68
INSPECTION · 5-68
Rear shock abSorber 5-68
ASSEMBL Y AND INSTALLATION 5-69
Spring (rear shock absorberl 5 69
Rear shock absorber 5_69
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM 6-1
ELECTRICAL COMPONENTS 6-1
WIRING DIAGRAM 6-1
IGNITION SYSTEM 6 2
INSPECTION STEPS 6-2
SPARK GAP TEST 6 3
SPARK PLUG CAP INSPECTION 6-3
COUPLERS ANO LEADS
CONNECTION INSPECTION 6 3
“ENGINE STOP” BUTTON
INSPECTION 6-4
IGNITION COIL INSPECTION 6 4
COi MAGNETO INSPECTION 6-5
COi UNIT INSPECTION 6-5
YPVS SYSTEM 6 6
INSPECTION STEPS 6-6
COUPLERS AND LEADS
CONNECTION INSPECTION 6 7
SERVOMOTOR OPERATION 6 7
SERVOMOTOR INSPECTION 6 7
OUT-PUT VOLTAGE INSPECTION 6-8
SOLENOID VALVE SYSTEM 6 9
INSPECTION STEPS 6-g
COUPLERS ANO LEADS
CONNECTION INSPECTION 6-lo
SOLENOID VALVE OPERATION 6 10
SOLENOID VALVE INSPECTION 6 10
CHAPTER 7
TUNING
Table of correction coefficients
for carburetor setting 1 6
Other setting pans 7-7
Plug chop 7-8
Setting of cylinder gasket 7–8
Measuring piston protrusion 7-10
Symptom 7-15
Setting record table 7-17
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