Stand the motorcycle on a level surface. The meter light fails to come on. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Bleed screw 6 Nm 0. Never attempt to make any repairs to the wheel.
Measure: 8 brush length a Out of specification Replace the brushes as a set. Install: 8 slider 1 8 primary sliding sheave 2 8 cam 3 5-44. Measure: 8 compression pressure Out of specification Refer to steps c and d. Blow out the jets with compressed air. Measure: 8 valve spring free length a Out of specification Replace the valve spring.
Direction a Throttle cable free play is increased. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 Do not use a hammer to drive the piston pin out. The headlight and the high beam indicator ing. Install: 8 gasket 1 8 oil pump assembly2 8 oil pump bolt 7 Nm 0. While holding the camshaft, temporarily tighten the camshaft sprocket bolts. Measure: 8 brush spring force Out of specification Replace the brush springs as a set. Start the engine, warm it up for several min- utes, and then turn it off.
Remove: 8 spark plug Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. Check: 8 brake lever free play a Brake lever free play at the end of the brake lever 3 ~ 5mm 0. Stand the scooter on a level surface. Brake fluid may damage painted surfaces and plastic parts. Lubricate: 8valve stem 8valve stem seal with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3. Check: 8 piston wall 8 cylinder wall Vertical scratches Replace the cylin- der, and the piston and piston rings as a set. The rack-and-pinion steering unit is mounted behind the engine and has electric power assist.
Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. Lighting coil resistance 8 Disconnect the lighting coil coupler from the wire harness. Measure: 8 main axle runout with a centering device and dial gauge Out of specification Replace the main axle. Check: 8 commutator Dirt Clean with 600-grit sandpaper. Check: 8 fuel passages Obstruction Clean. Therefore, always follow these preventive measures: 8 8 8 8 8 Wear protective eye gear when handling or working near batteries.
Check: 8 wheel axle Roll the wheel axle on a flat surface. Check: 8 hoses Loose connection Connect properly. Do not overtighten the lower ring nut. Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Special tools, part numbers or both may differ depending on the country. Check: 8 lead 8 coupler 8 connector Moisture Dry with an air blower. Use oil and grease recommended by Yamaha for all lubrication jobs.
Check: 8 engine oil level Below the minimum level mark Add the recommended engine oil to the proper level. Brake light switch front and rear 8 Disconnect the starter relay coupler from 8 Check the brake light switch for continu- the coupler. Connect: 8 battery leads to the battery terminals First, connect the positive battery lead 1 1 1 1 1 , and then the negative battery lead 2 2 2 2 2. Stand the scooter on a level surface. Remove: 8 locknut 1 8 stopper plate 2 2. Do not twist the V-belt case air filter element when squeezing it.
Main switch 8 Check the main switch for continuity. Battery 8Check the condition of the battery. Stand the scooter on a level surface. It is this level of detail, along with hundreds of photos and illustrations, that guide you through each service and repair procedure. Measure: 8 piston pin outside diameter a Out of specification Replace the pis- ton pin. Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft.
Disconnect: 8 spark plug cap 3. Turn the front wheel 90° so that the heavy spot is positioned as shown. Brush length wear limit 3. Caliper bracket Brake pad Brake pad plate Brake spring Dust seal. Remove: 8 bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Compression pressure at sea level Minimum 827 kPa 8.
Remove: 8 brake pad bolt 8 brake pad spring 1 8 brake pads 2 8 brake pad plate 3 4. Stand the scooter on a level surface. Check: 8 brake fluid level Below the minimum level mark a the recommended brake fluid to the proper level. Disconnect: 8 brake switch coupler from the brake switch 2. Measure: 8 brake disc thicknessb Measure the brake disc thickness at a few different locations.