SERVICE GUIDE

FOREWORD

This SERVICE GUIDE has been prepared for use by Company Authorised
Dealerships and their Service Personnel to attend servicing of .
It is not possible to include Service education into one SERVICE GUIDE.
It is assumed that persons using this book to perform maintenance and
repairs on Yamaha Motorcycle have a basic understanding of mechanical
concepts and procedures inherent to motorcycle repair technology.
Without such knowledge, attempt repair or service of this model may
render it unfit for use and unsafe.

Yamaha Motor India Private Limited continually strives to improve

all its models. Modifications and significant changes in specifications or
procedures will be informed to all Company Authorised Dealership thru
‘Service Action’ and will wherever considered necessary, appear in future
edition of this SERVICE GUIDE.

Service Department
Yamaha Motor India Private Limited
 INDEX

Page No.

1. Salient features..................................................................................... 1
2. Specifications – General / Maintenance ................................................ 2
3. Operation (Fundamental) – 4 Stroke Engine........................................ 9
4. Pre Delivery Inspection (PDI) ............................................................... 10
5. Installation ............................................................................................ 13
6. Preventive Maintenance Schedule ........................................................ 14
7. Special Service Tools / Instruments / Materials ..................................... 15
8. Exploded View – Engine ....................................................................... 21
9. Useful tips for Engine Overhauling ........................................................ 22
10. Engine Bearings ................................................................................... 26
11. Valve Clearance Adjustment / Balancer .............................................. 27
12. Clutch Mechanism Adjustments............................................................ 28
13. Transmission ........................................................................................ 30
14. Carburettor ........................................................................................... 31
15. Lubrication ............................................................................................ 34
16. Electrical Wiring .................................................................................... 38
17. Electrical System – Checking ............................................................... 41
18. Battery Maintenance ............................................................................ 43
19. Tightening Torques – Engine / Frame .................................................... 44
20. Trouble Shooting ................................................................................... 47
 1. SALIENT FEATURES
q SAFE & SECURE RIDING q AMAZING COMFORT
• LONGER WHEEL BASE • COMFORTABLE SITTING POSTURE FOR
• WIDER TYRES RIDER AS WELL PILLION RIDER
• SHOCK PROOF & STURDY SUSPENSION • WIDE & FLAT FOOT BOARD FOR
• KILL SWITCH TO CUT OFF ENGINE FATIGUELESS HIGHWAY RIDING
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q OPTIMISED ENGINE
• IMPROVED INTAKE & EXHAUST SYSTEM q MACHO, ROBUST & STYLISH
• IMPROVED BALANCER TO DAMPEN AESTHETICS
ENGINE VIBRATIONS • IT ATTRACTS EVERYONE ACROSS THE
• SMOOTH CRUISING ON ALL TYPE OF ROAD & GIVES FEELING OF KING WHILE
TERRAIN RIDING
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 GENERAL SPECIFICATION
DESCRIPTION SPECIFICATION

MODEL CODE 5 US

DIMENSIONS
OVERALL LENGTH 2085 MM
OVERALL WIDTH 790 MM
OVERALL HEIGHT 1125 MM
SEAT HEIGHT 720 MM
WHEELBASE 1375 MM
MINIMUM GROUND CLEARANCE 140 MM
MINIMUM TURNING RADIUS 2200 MM

DRY WEIGHT 116 KG.

ENGINE
ENGINE TYPE AIR COOLED, 4 STROKE, SOHC
CYLINDER ARRANGEMENT FORWARD INCLINED, SINGLE CYLINDER
POWER 11 BHP @ 8000 RPM
TORQUE 1.06 Kgf-m @ 6500 RPM
DISPLACEMENT 123.7 CC
BORE X STROKE 54 x 54 MM
COMPRESSION RATIO 10 : 1
STARTING SYSTEM KICK STARTER
LUBRICATION SYSTEM WET SUMP

ENGINE OIL
TYPE / GRADE YAMALUBE ENGINE OIL (EXCEEDING SG GRADE)
PERIODIC OIL CHANGE QUANTITY 1000 ± 20 ML.
FRESH REFILL QUANTITY 1200 ± 20 ML.

AIR FILTER WASHABLE, DUAL FOAM,WET TYPE ( OIL SOAKED )

FUEL CAPACITY
FUEL TANK CAPACITY 13.0 LITERS
FUEL RESERVE QUANTITY 2.43 LITERS

CARBURETTOR
TYPE VM 20 SS
MANUFACTURER UCAL
 GENERAL SPECIFICATION
DESCRIPTION SPECIFICATION

SPARK PLUG
NUMBER CR7HSA - R
MANUFACTURER NGK
SPARK PLUG GAP 0.6 ~ 0.7 MM

CLUTCH TYPE WET, MULTIPLE - DISC.

NO. OF PLATE FRICTION 5 Nos.
NO. OF PLATE CLUTCH 4 Nos.

TRANSMISSION
PRIMARY REDUCTION SYSTEM HELICAL GEAR
PRIMARY REDUCTION RATIO 19/68 (1 : 3.579)
SECONDARY REDUCTION SYSTEM CHAIN DRIVE
SECONDARY REDUCTION RATIO 15/47 (1 : 3.133)
TRANSMISSION TYPE CONSTANT MESH 4-SPEED
GEAR RATIO
No. of teeth Ratio
Main Axle Drive Axle
1st 12 33 2.75
2nd 16 27 1.68
3rd 20 24 1.20
4th 23 21 0.91

PRIMARY DRIVE GRADING

Matching of Grades
PRIMARY DRIVEN GEAR ASSY.
GRADE
Gear Primary PrimaryDriven
Drive Gear Assy.

B A
GRADE
C B
D C
E D
GEAR PRIMARY DRIVE F E

LUBRICATION
OIL FILTER WIRE MESH TYPE & ROTARY TYPE
OIL PUMP TROCHOID TYPE

TYRE
SIZE (INCHES)
– FRONT 2.75 X 18" - 42 P [ZAPPER - FS]. 4PR
– REAR 120 / 80 - 16" - 60P [ZAPPER - Y]. 6PR
 GENERAL SPECIFICATION
DESCRIPTION SPECIFICATION

TYRE PRESSURE
LOADING CONDITION SINGLE RIDING DOUBLE RIDING
– FRONT 24 PSI 24 PSI
– REAR 28 PSI 32 PSI

SUSPENSION
FRONT SUSPENSION TELESCOPIC FORK
REAR SUSPENSION SWING ARM

SHOCK ABSORBER
FRONT SHOCK ABSORBER COIL SPRING / OIL DAMPER
REAR SHOCK ABSORBER COIL SPRING / OIL DAMPER (Adjustable-5 positions)

WHEEL TRAVEL
FRONT WHEEL TRAVEL 130 MM
REAR WHEEL TRAVEL 70 MM

ELECTRICAL
IGNITION SYSTEM C.D.I.
GENERATOR SYSTEM FLYWHEEL MAGNETO
BATTERY CAPACITY 12V - 2.5 AH

BULB (VOLTAGE - WATTAGE X QUANTITY)

HEADLIGHT 12 V - 35W / 35 W X 1
TAIL / BRAKE LIGHT 12 V - 5 W / 21 W X 1
INDICATOR LIGHT 12 V - 10 W X 4
METER LIGHT 12 V - 1.7 W X 1
NEUTRAL LIGHT 12 V - 1.7 W X 1
HIGH BEAM INDICATOR 12 V - 1.7 W X 1
TURN INDICATOR 14 V - 3 W X 1
PARK LIGHT 12 V - 4 W X 1
HORN 12 V - 2.5 Amp
BALANCER
BALANCER DRIVE METHOD GEAR
BALANCER GEAR GRADING Matching of Grades
Balancer Driven Gear Balancer Drive Gear
D X
E Y
F Z
G A
H B
 MAINTENANCE SPECIFICATIONS
ENGINE

ITEM STANDARD LIMIT

E1 CYLINDER
Bore 54.000 ~ 54.024 mm Can be bored upto
(in five grades) 2nd over size

E2 CAM CHAIN
No. of Links 88
Adjustment method Automatic

E3 VALVES (INLET & EXHAUST)

Valve Clearance
(Cold Condition)
• INLET 0.08 ~ 0.12 mm
• EXHAUST 0.10 ~ 0.14 mm
Valve Spring Free Length
• INLET 39.62 mm 38.17 mm
• EXHAUST 39.62 mm 38.17 mm

E4 PISTON
Piston Size (STD) D 53.977 ~ 54.000 mm (in five grades)
Piston Size measuring point H H = 5.0 mm
Grades (STD) Matching of Grades

Marking Piston Cylinder

Marking Marking

A A

H B B
Marking
C C
D D
Piston O/s. Ist
E E
IInd
Piston - Cylinder Clearance 0.020 ~ 0.027 mm 0.15 mm

E5 PISTON RINGS
Ist Ring (Top)
• Type Barrel Faced
• End Gap RN 0.15 ~ 0.30 mm 0.40 mm
• Clearance 0.030 ~ 0.070 mm 0.12 mm
2nd Ring
• Type Taper Faced
• End Gap 0.30 ~ 0.45 mm 0.55 mm
• Side Clearance 0.02 ~ 0.06 mm 0.12 mm
Oil Ring
• End Gap 0.2 ~ 0.7 mm
(For Rail Upper & Rail Lower)
 MAINTENANCE SPECIFICATIONS
ENGINE

ITEM STANDARD LIMIT

E6 CRANK SHAFT C C
Crank width A = 46.95 ~ 47.00 mm
Big End Clearance B = 0.15 ~ 0.45 mm
Runout limit C B = 0.01 mm 0.01 mm

E7 CLUTCH
Friction plate

• Quantity 5 Pcs.
• Thickness 2.9 ~ 3.1 mm 2.8 mm

Clutch Plate

• Quantity 4 Pcs. More Than

• Warp Limit 0.05 mm 0.05 mm

Clutch spring

• Quantity 4 Pcs.
• Free Length 32 mm 30.5 mm

E8 CARBURETTOR
Make UCAL
Size VM20SS
Main Jet # 92.5
“C” Lock Position Middle Groove
Pilot Jet # 17.5
Pilot Screw Setting To achieve recommended idle
‘CO’ value (<1.5%) - v/v
Idle R.P.M. 1300 - 1500
Intake Vacuum 220 ~ 260 mm Hg
Float Height 21.8 ± 1 mm
Fuel Level 6-7 mm (Below the centre joint
of MCB and FCB)
 2. MAINTENANCE SPECIFICATIONS
FRAME

ITEM STANDARD LIMIT

F1 STEERING
Steering Bearing
• Type Retainer Ball Cage
No. of steel Balls
• Upper 16 Pcs. In Cage
• Lower 16 Pcs. In Cage

F2 FRONT SUSPENSION
TFF Spring
• Free Length 426.5 mm 419.5 mm
TFF Oil
• Oil grade “TELE SHOCAB” oil
• Oil Quantity
– Complete Overhauling 157 ± 3 ml
– Periodic Replacement 145 ± 3 ml Change after
every 10000 kms.

F3 SECONDRY DRIVE CHAIN

No. of Links 129
Free play 20 ~ 30 mm (REF. PAGE NO. 12)

F4 BRAKE - FRONT & REAR

Type Leading & Trailing
Brake drum inside dia 130 mm

F5 FREE PLAYS
Brake lever free play (at lever end) 10 ~ 15 mm
Brake pedal free play 20 ~ 30 mm (REF. PAGE NO.12)
Clutch lever free play (at lever end) 10 ~ 15 mm
Throttle grip free play 3 ~ 7 mm

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 2. MAINTENANCE SPECIFICATIONS
ELECTRICALS

ITEM STANDARD

Elt. 1 ELECTRICAL SYSTEM 12V

Elt. 2 IGNITION SYSTEM

Ignition Timing (Auto Advance) 7° ± 1.6° BTDC / 1500 rpm

Elt. 3 RESISTANCE
STARTING SYSTEM
Source Coil 860 Ω ± 20%
Pickup Coil 180 Ω ± 20%
Spark Plug Cap 5kΩ
H.T. COIL
– Primary Winding 1 Ω ± 10%
– Secondary Winding 6.0 k Ω ± 20%

CHARGING SYSTEM
Charging Coil 0.4 Ω ± 20%

LIGHTING SYSTEM
Lighting Coil 0.35 Ω ± 20%

Elt. 4 R R UNIT (with full charged Battery)

Charging Voltage (with Full AC Load) 14 ~ 15V / 5000 rpm
Lighting Voltage (with Full AC Load) 13 - 14V / 5000 rpm

Elt. 5 BATTERY
Capacity 12V - 2.5 AH
Specific Gravity 1.230 ± 0.005

Elt. 6 HORN
Type DC - 12V
Ampere (Maximum) 2.5 A

Elt. 7 FUSE
Ampere 10 A

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 3. OPERATION (FUNDAMENTAL)
4 STROKE CYCLE (One Power Stroke in Two Full Crank Rotations)
INTAKE
● INTAKE VALVE – OPEN
IN EX
● EXHAUST VALVE – CLOSED

● PISTON MOVEMENT – TDC TO BDC

● CRANK ROTATION – HALF

● ABOVE PISTON – SUCTION TAKES

CROWN PLACE

AIR FUEL MIXTURE 1

COMPRESSION
● INTAKE VALVE – CLOSED

IN EX ● EXHAUST VALVE – CLOSED

● PISTON MOVEMENT – BDC TO TDC

● CRANK ROTATION – ONE (FROM STARTING)

● ABOVE PISTON – COMPRESSION

CROWN TAKES PLACE

COMBUSTION
● INTAKE VALVE – CLOSED

IN EX ● EXHAUST VALVE – CLOSED

● PISTON MOVEMENT – TDC TO BDC

● CRANK ROTATION – ONE AND HALF

(FROM STARTING)

● ABOVE PISTON – POWER DEVELOPS

CROWN
3

EXHAUST
● INTAKE VALVE – CLOSED

IN EX ● EXHAUST VALVE – OPEN

● PISTON MOVEMENT – BDC TO TDC

● CRANK ROTATION – TWO (FROM STARTING)

● ABOVE PISTON – EXHAUST

CROWN TAKES PLACE
4
BURNT GASES

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 4. PRE DELIVERY INSPECTION (PDI)
ITEM TO CHECK & RECTIFY (if necessary) SPECIFICATION

1. VEHICLE • For missing item(s), Scratches on

painted / Plated part(s) and other
external damage

2. GENERAL
(i) Brakes Front • Free play at lever end 10 ~ 15 mm
Rear • Free play at Rear brake pedal 20 ~ 30 mm
(ii) Clutch • Free play at lever end 10 ~ 15 mm
(iii) Throttle • Free play at grip 3 ~ 7 mm
(iv) Steering • Steering Head for looseness
• Steering for free movement
(v) Suspension Front fork • Free Stroking
• Oil leakage
Rear Shock • Free stroking
Absorber • Adjuster ring position should be
same in both shock absorbers
(vi) Wheel Tyre • Tyre Pressure Single Double
Riding Riding
Front 24 PSI 24 PSI
Rear 28 PSI 32 PSI

Rim • Rim runout Radial 0.5 mm

(vii) Secondary Drive chain
Lateral 0.8 mm
• Check for alignment Ensure notch on adjuster
is on the same mark on
Left and right side
• Check for free play 20 ~ 30 mm

(viii) Locks • Steering Lock • Steering lock operation

• Fuel tank Lock • Fuel tank lock operation
• LH Side Cover Lock • L.H. Side cover Lock Operation

3. IMPORTANT FASTENERS TORQUES SPECIFIED TORQUE

Nm kgm LBFT

• Cam Sprocket Bolt 20 2.0 14.5

• Cylinder Head bolts 22 2.2 17.0
• Cylinder Head Allen Bolt (Chain Side) 10 1.0 7.2
• Engine Mounting bolts 32 3.2 23.0
• Silencer Mounting Front 7 0.7 5.1
Rear 15 1.5 11.0
• Front Wheel Axle Nut 91 9.1 66.0
• Rear Wheel Axle Nut 91 9.1 66.0
• Front fork (Crown Handle and Inner tube) 23 2.3 17.0
• Handle bar Mounting bolt 22 23 2.3 17.0
• Rear Shock absorber Mounting Bolt 40 4.0 29.0

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 4. PRE DELIVERY INSPECTION (PDI)
S.No. ITEM TO CHECK / RECTIFY SPECIFICATION

4. BATTERY • Electrolyte level (REF. PAGE NO. 43)

• Charge Battery as Recommended
• Electrolyte Specific gravity 1.230 ± 0.005
• Proper Routing of breather pipe
• Fuse for continuity

5. ENGINE
(i) Engine oil • Oil level (For detail Refer Owner’s Manual)
• Check for any leakage
(ii) Spark plug • Recommended Spark plug No. CR7HSA-R - NGK

• Spark plug gap 0.6 ~ 0.7 mm

(iii) Valve Clearance • Inlet 0.08 ~ 0.12 mm
(Cold Condition) • Exhaust 0.10 ~ 0.14 mm
(iv) Carburettor • Idle R.P.M. (After Warm Up) 1300 ~ 1500 r.p.m.
• Check for no overflow

6. ROAD TEST OF VEHICLE

General • Kick operation - For free movement
• Starting
• Gear Shifting operation
• Clutch operation
• Application of brakes (Front & Rear)
• Speedometer/odometer functioning

7. ELECTRICALS
(i) Switch Main • Starting & Lighting
(ii) Switch Handle • Proper Working of Horn, Indicators, Tail Light,
Park light, Speedometer &Head Light
(Hi-Beam/Low Beam)
(iii) Bulbs • Proper Functioning
(iv) Brake Light • Proper Functioning
(v) Kill Switch • Proper Functioning

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 4. PRE-DELIVERY INSPECTION (PDI)
Battery Throttle Clutch Front Brake Light, Indicator, Horn Ignition Switch/Handle Lock
A
A
A
UPPER
LOWER
A B

A For Electrolyte level

B For Specific Gravity 1.230 ± 0.005 A Free play at grip 3~7mm A Free Play at lever end 10~15mm A Free Play at lever end 10~15 mm For Proper Operation For Proper Operation

Rear Suspension Steering

B A

zz
For Free Movement (A) For Looseness
Same Notch Position Both Side (B) For Free Movement of Handle

Drive Chain Carburettor

A Chain Play 20-30 mm

Idle RPM 1300 ~ 1500

Chain Alignment Front Suspension

L.H./R.H. Side

Tyre Pressure Spokes Valve Clearance (cold) Engine Oil Rear Brake Spark Plug
A

Stop
Screw
A

Inlet - 0.08 ~ 0.12 mm Engine Oil : Total - 1.2 Litre

For Looseness Exhaust - 0.10 ~ 0.14 mm Periodic - 1 Litre A Free Play at brake padel 20 ~ 30 mm CR7HSA-R - NGK, Gap 0.6 ~0.7mm

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 5. INSTALLATION

EXPLANATION TO THE CUSTOMERS AT THE TIME OF DELIVERY OF THE MOTORCYCLE

1. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.)

2. • Fuel Cock Lever operation and its reserve position.

• Fuel Tank Capacity including Reserve.

3. Operation of Starter Lever.

4. Operation of Kick Lever.

5. Operation of Throttle.

6. Operation of Switch Handle, kill switch and its functions.

7. Use of clutch with disadvantage of riding on half clutch.

8. Operation / Use of trip meter.

9. Gear shifting pattern.

10. Use of Front and Rear Brakes with emphasis on simultaneous use of Front and Rear Brakes.

11. Tyre inflation pressure; Front – 24 PSI; Rear – 28 PSI (SOLO), 32 PSI (DOUBLE)

12. Correct type of spark plug and spark plug gap.

• Spark Plug No. CR7HSA-R - NGK

• Spark Plug Gap – 0.6 ~ 0.7 mm

13. Engine oil level checking and explaining the importance of replacing the engine oil Yamalube (SG Grade)
after every 2000 Kms. (Refer owner’s Manual)

14. Removal & Installation of side cover LH / RH.

15. Location of Storage of Tool Kit / Registration papers / First Aid Kit, compartments and their use.

16. Battery maintenance – Checking of electrolyte level (To add only distilled water if required).

17. Maintenance of air filter.

18. Correct Secondary Drive Chain play (20 ~ 30 mm)

19. TFF oil to be changed after every 10,000 Kms.

20. Always adjust both the right and left shock absorber to the same position.

21. Vehicle Running-in-Instructions. (Avoid overloading)

22. Information on ‘CO’ Emission and safety Norms. ( Refer Owner’s Manual )

23. Importance and schedule of Free Services/Paid Services.

24. Warranty Terms and conditions.

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 SERVICES
6. PREVENTIVE MAINTENANCE SCHEDULE VII-VIII IX-X XI-XV EVERY
I-VI
FREE PAID BONUS PAID 2000km
S.No. ITEM OPERATION FREE
1- VALVES Check valve clearances, adjust if necessary. • • • • •
2- SPARKPLUG Check condition, gap;
Clean and reset if necessary.
• • • •
REPLACE EVERY 10,000 kms
•
3- CARBURETOR Check idle speed, Choke lever operation.
• • • • •
4-
5-
AIR FILTER
FUEL LINE
* Clean, inspect & lubricate. (replace if necessary)
Check fuel hose, for cracks or damage.
• • • • •
6- FUEL FILTER
Replace if necessary.
Check for free flow of petrol, cleanliness of filter bowl.
• • • • •
replace if necessary. • • • • •
7- ENGINE OIL Replace with recommended oil -Yamalube SG Grade

8- ENGINE OIL
(Warm engine before draining)
Wash with petrol.
• • • • •
9-
FILTER SCREEN
BRAKE-FRONT & Check operation./Adjust if necessary.
• • • • •
10-
REAR
BRAKESHOES
Grease the brake cam.
Check for wear, replace if necessary.
• • • • •
11-
FRONT & REAR
CLUTCH Check alignment marks on Push lever and
• • • • •
12- REAR ARM PIVOT
Crankcase L.H. Adjust if necessary.
Check rear Arm assembly for looseness.
• • • • •
13- WHEELS
Tighten with specified Torque if necessary
Check runout, spoke tightness, damage
• • • • •
Correct it, if necessary. • • • • •
14- WHEEL BEARING Check Bearing assembly for looseness, damage;
Replace if necessary. Repack grease
• • •
EVERY 10,000 KMS
• •
15- STEERING BEARING Check Bearing assembly for looseness;
Correct if necessary. Repack grease
• • •
EVERY 10,000 KMS
• •
16- FRONT FORKS Check operation/oil leakage. Repair if necessary.
• • • • •
Replace Oil EVERY 10,000 KMS
17- REARSHOCK Check operation/oil leakage.
ABSORBER Replace if necessary • • • • •
18- DRIVE CHAIN Check Chain slack, alignment. Adjust if necessary.
Clean periodically. • • • • •
19- NUTS, BOLTS AND Check all Chassis fittings and fasteners for looseness.
FASTENERS Tighten as per specification. • • • • •
20- CENTERSTAND Check operation and lubricate if necessary.
AND SIDE STAND • • • • •
21- BATTERY Check electolyte level and top it up if necessary.
Check specific gravity and lubricate if necessary. EVERY MONTH
Check breather pipe for blockage and routing.
22- CONTROLCABLES Check operation, free play, cable damage
– THROTTLE Readjust or replace as required.
– CLUTCH • • • • •
– FRONT BRAKE

IT IS RECOMMENDEDTHATTHE ABOVE BE SERVICED BY AUTHORIZEDYMI DEALER.

★ SERVICE MORE FREQUENTLYWHENTHEVEHICLE IS DRIVEN IN DUSTY AREAS.

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 7. SPECIAL SERVICE TOOLS
S. NAME / TOOL No. ILLUSTRATION USAGE
No.

1. Magneto Holder
YSST - 601-A

2. Magneto Puller
YSST - 602
A – Spacer

3. Valve Spring Compressor

YSST - 603

4. Piston Base
YSST - 604

5. Valve Clearance Adjusting Tool

YSST - 606

6. Piston Pin Replacer

YSST - 607

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 7. SPECIAL SERVICE TOOLS
S. NAME / TOOL No. ILLUSTRATION USAGE
No.
OLD NEW
7. Rocker Arm Shaft Puller YSST - 608 YSST - 608A
YSST - 608
YSST - 608A

8. Clutch Hub Holder

YSST - 233

9. Crank-Shaft Removal Tool

YSST - 265

10. Crank Shaft Installing Tool

(with - spacer)
(a) YSST - 266
(b) YSST - 267

11. Driving Sprocket Holder

YSST - 605

12. Screw Driver (Small)

YSST - 609
To adjust carburettor
Pilot Screw

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 7. SPECIAL SERVICE TOOLS
S. NAME / TOOL No. ILLUSTRATION USAGE
No.

13. Torx Bit (T-30)

YSST - 611

For Scrapping the Sealent

14. Scraper
YSST - 612
from crankcase surface

15. Feeler Gauge

YSST - 615

16. Ring Nut Socket To loosen or tighten the

YSST - 621 steering ring nut

17. Engine Stand

A,B,C,D - Engine Mountings for chasis

B,C - Engine Mountings for Engine Stand

18. Front Fork Inner Tube Cylinder

Holder
To Hold the TFF Cylinder
YSST - 213

19. Rear Shock Absorber Adjuster To Adjust Spring preload of

YSST - 221 Both Rear Shock Absorbers

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 7. SPECIAL SERVICE TOOLS/MATERIALS
S. NAME / TOOL No. ILLUSTRATION USAGE
No.

20. TFF Oil Seal Removal Tool

YSST - 270
To remove TFF Oil Seal

21. TFF Oil Seal Installing Tool

YSST - 275
To install TFF Oil Seal

22. Spanner Speedometer

Gear Nut
YSST - 237 To loosen or tighten Speedom-
eter Gear Nut

23. Punch Oil Seal

YSST - 622

To install oil seal in

Crankcase Cover-2

24. Bearing Puller

YSST-623

To remove the bearing main Axle

No. 6201 from crankcase LH.

25. Bearing Puller

YSST-624 To remove the bearing Drive Axle
No. 6202 from crankcase RH.

26. Centre Plug Wrench

YSST - 625 To Open / Tight the centre plug
of crank case cover LH.

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 7. SERVICE INSTRUMENTS
S. NAME / TOOL No. ILLUSTRATION USAGE
No.

1. Tachometer
To check Engine RPM

2. Timing Light

To check Ignition Timing

3. Vernier Caliper
(150 mm)

4. Micrometer
(0-25 mm)
(50-75 mm)

5. Multimeter

To check Resistance, Voltage,

Ampere, Continuity

6. Feeler Gauge

7. Vaccum Gauge

To check Intake Vaccum

8. Tyre Pressure Gauge

To check Tyre Pressure

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 7. SERVICE INSTRUMENTS
S. NAME / TOOL No. ILLUSTRATION USAGE
No.

9. Compression Gauge
To check Compression
Pressure of an Engine

10. Hydrometer
To check Battery
Specific Gravity

11. 'CO' Gas Analyser

12. Torque Wrench

(10 – 50 LBFT) To tighten Nut/Bolts at specified
(20 – 100 LBFT) Torque

SPECIAL SERVICE MATERIALS

S. NAME / TOOL No. ILLUSTRATION USAGE
No.

1. YAMAHA BOND
TG-1215

Sealent for Joining Crankcase LH & RH

(For detail application Ref. Page 21)

2. LOCKTITE
THREE BOND-1322

For Application
(Refer Page - 21)

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 9. USEFUL TIPS FOR ENGINE OVERHAULING
Engine Assembling
Crank Case Note : While Installing forks, keep marking L, C & R)
1. All oil galleries should be cleaned properly upward position.
2. Grease should be applied on the lip of oil seal 6. • Ensure the surface to be oil-free and dry, before
so that it may not get damaged while installing applying sealant on crank case R.H.
the component. • Don’t Apply Sealant (TG-1215) on the area (a)
3. While installing the balancer, make sure that punch & (b) (as shown in fig.) of crank case RH.
mark on the Balancer gear a aligns with
corresponding punch mark b provided on crank
gear.

7. Don’t apply excessive sealant so that it may not

Block any oil gallery.
8. • Tightening Sequence - crank case & cover RH
4. E axle
Insert push rod in axle main before installing the and LH.

➞
main & axle drive in to crank case.
(If missed out, it will require to repeat the complete Starting Point
work again).
5. Assemble gear box according to following order:

➞Second Point
9. While installing rotary filter (a) on crank shaft (b)
make sure to keep ‘Top’ marking on top side. (As
wrong fitment will result insufficient lubrication to
• Axle main (A)
big end bearing of crank shaft.)
• Install plain washer with Axle drive (B) in the
side of drive sprocket.
• Install fork shift ‘L’ (left) on Axle drive.
• Install fork shift ‘R’ (right) on axle drive.
• Install fork shift ‘C’ (centre) on axle main.
• Install shift shaft cam.
• Insert Forks pin of ‘L’, ‘C’, ‘R’ on cam shifter
groove.
• Install bar- shift fork guide (small)  on fork
shift ‘C’.
• Install bar- shift fork guide (big) ‚ on fork shift
‘R’ and ‘L’.

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 9. USEFUL TIPS FOR ENGINE OVERHAULING
10. While Installing strainer oil make sure to keep its 13. Piston Rings & Piston
‘Wider Side’ out side. (A) Piston Rings should be installed in manner
sequence given below
(i) Oil ring (Spacer, Rail lower, Rail upper)
(ii) 2nd Compression ring
(iii) Ist (TOP) compression ring
(B) RN marking on 2nd ring should be kept upward.

RN

Clutch
11. Align arrow mark a on pressure plate with
corresponding punch mark b on clutch hub.

14. Butting ends of Piston rings should be kept in a

12. Before installing clutch cover, align the pointer (a)
provided on push lever with casting mark (b) on
crank case LH. by turning the adjusting screw (c),
In or Out provided on pressure plate.
(REFER PAGE NO. 28)
manner W.R.T arrows marking on piston top.
(a) Butting end – 1st (TOP) Ring
(b) Butting end – 2nd Ring
(c) Butting end – Oil ring – Rail upper
(d) Butting end – Oil ring – Rail lower
While Installing piston, ensure arrow on piston
top should be towards exhaust side.

Arrow on Piston Top to 20

mm
mm
keep on Exhaust Side 20

a Top ring end

b 2nd Ring end
c Oil Ring end
(Upper Rail)
d Oil Ring end
1200
(Lower Rail)

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 9. USEFUL TIPS FOR ENGINE OVERHAULING
Cylinder Head 18. Tightening Sequence – Cylinder Head
15. Install valve spring with larger pitch side facing
towards spring retainer (Topside) (White painted)

Spring retainer
Valve Spring

Larger Pitch

Small Pitch
19. While installing cam chain and cam sprocket, make
sure that marking a on cylinder head aligns with
corresponding mark b on sprocket, when piston
is at TDC and chain is in stretched position and
check valve clearance in same position in cold
condition.
16. After installing valve assy. check with mallet for
proper fitment of valve cotters. a
b

17. While installing rocker pin make sure that its 20. Ensure Recommended torquing of Bolt-cam
threaded area is towards installing side (Out side).
c sprocket (Ref. above illustration) - [20 Nm]

21. First install chain tensioner ➀ by taking its spring

loaded stem inside. Release spring loaded stem
by unscrewing it then install plug.

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 9. USEFUL TIPS FOR ENGINE OVERHAULING
Engine Disassembling
1. Before removing the cylinder head ensure that
both the valves are at fully closed position by
bringing piston to TDC position i.e. when marking
on cylinder Head a alligns with corresponding
marking b on cam sprocket.
4. Do not Interchange (Mix-up) inlet and Exhaust
rocker Arms. While removing rocker arms make
marking to identify Inlet & Exhaust Rocker Arms.
5. While removing valve springs, make marking for
Inlet and Exhaust Valves.
6. Remove Torx screw of cam shifter segment using
Torx bit (YSST-611) before separating crank
case RH & LH.

(Never use Philips Screw Driver to open Torx

Screw).

2. Retract spring loaded stem of chain tensioner .

7. Before separating crank case, make sure to open

screws 2 nos. from R.H. side after opening screw
8 nos. from L.H. side.

LH. Side

3. • Loosen the cylinder head bolts in their proper

loosening sequence.
• Start by loosening each bolts by 1/2 turn until all
are loose.

RH. Side

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 10. ENGINE – BALL BEARINGS
CAM SHAFT

BALL BEARING (6002-Z)

BALL BEARING (6003)

SPACER

ROTOR
BALL BEARING (6205)

GEAR PRIMARY DRIVE

(Z-19)

CRANK SHAFT AXLE MAIN

AXLE DRIVE
BALL BEARING (6205)

CLUTCH

BALL BEARING (6201)

SPROCKET, DRIVE
(Z-15) BALL BEARING (6203)

BALL BEARING (6204)

BALL BEARING (6202) GEAR KICK IDLE

26
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 11. VALVE CLEARANCE
MEASUREMENT
LH Cover
Measurement steps :
b • Engine must be in cold condition

a • Rotate the crankshaft anti-clockwise to align TDC marking

a on the magneto with the stationary pointer b on the
Magneto crankcase cover (left), when the piston is at Top Dead
Center (TDC) and in compression stroke. When marking
of cylinder Head c align with comesponding marking
d on cam sproket
c • Measure the valve clearance by using a feeler gauge.
d
• If out of specification – Adjust

VALVE CLEARANCE (cold condition)

• INTAKE VALVE – 0.08 ~ 0.12 mm
• EXHAUST VALVE – 0.10 ~ 0.14 mm

ADJUSTMENT
Adjustment steps :
• Loosen the lock nut 
• Turn the adjuster in ƒ or out with the valve clearance
adjusting tool (YSST - 606) ‚ until specified clearance is
obtained.
(Feel of Metal to Metal contact)

Turning in Valve clearance is decreased

Turning out Valve clearance is increased

11. BALANCER

• The main source of engine vibrations are the inertia

generated by the reciprocal movements of the
piston and connecting rod and that generated by
the crankshaft rotation. The balancer provides a
weight which rotates in the opposite direction of
the crankshaft to cancel out these inertia.

• A balancer weight is provided on a shaft separate

from the crankshaft to cancel out both the up-and-
down and front-to-back inertia at the same time to
keep the engine's vibrations low.

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 12. CLUTCH MECHANISM ADJUSTMENTS
For proper and effective clutch functioning, there are two adjustments to be ensured.

A. ALIGNMENT OF PUSH LEVER MARK WITH MARK ON CRANKCASE L.H.

B. FREE PLAY OF CLUTCH LEVER AT HANDLE BAR.

A. ALIGNMENT OF PUSH LEVER MARK WITH

MARK ON CRANKCASE L.H.
I. Removal of Clutch Cable from Push Lever
• At handlebar loosen the locknut  and Screw in the adjuster ‚
completely to loosen the cable clutch.

• Detach the clutch cable ƒ from push lever „

4
3
II. Check Alignment
Press the Push Lever end by thumb gently for ensuring no free play
between both the push rods and check for the alignment of Push Lever
mark a with mark b on Crankcase L.H..

• If aligned then attach the Clutch Cable and follow step B.

• If not aligned then follow below mentioned procedure.

PROCEDURE

• Drain the Engine Oil

– Loosen the drain plug  and completely drain out the engine oil.
– Tighten the drain plug 

• Open the R.H. Crankcase Cover

– Remove the kick Crank Assy. by opening nut.

– Open the bolts (9 off) (crankcase cover R.H.) shown in figure.

E Don’t Rotate Cover Foot Rest R.H. while removing Crank

case cover R.H.

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 12. CLUTCH MECHANISM ADJUSTMENTS
III. Alignment of Push Lever Marks
• Loosen the lock nut ‚.
• Press the push lever end by thumb gently ensuring no free
play between both the push rods.
• While keeping the push lever gently pressed Screw In or Out
the rod push - 1 ƒ where the push lever mark a is aligned
with mark b on the crankcase L.H.
• Hold Rod Push-1 ƒ in this position and tighten the lock nut
‚.
• Connect the clutch cable to the Push Lever and adjust the
Clutch Lever free play as per step B.
• Ensured dowel pin (2 nos.) are on Crank Case R.H. before
assembling the Crank Case Cover R.H. To avoid damage
to oilseal fitted in crank case cover R.H.
• Fill the recommended quantity of Yamalube 4 stroke (SF
Grade) engine oil (1000 ml) and check oil level.
• Install kick Crank Assy.

Not Aligned Aligned

B) FREE PLAY OF CLUTCH LEVER AT HANDLE BAR

PROCEDURE

• Loosen the Lock Nut  and screw in or out the adjuster ‚.

To get the free play; a at the clutch lever end to 10~15 mm.

• Tighten the Lock Nut .

• If not possible to achieve free play a of the Clutch Lever at

handle bar
Then
Either Detach Clutch Cable from Handle Bar
Or Detach Clutch Cable from Push lever
• Increase or decrease the length of the Clutch Cable Outer as
shown in figure by loosening lock nut ƒ and screwing in or out
adjuster „.
• Tighten the lock nut.
• Attach the Clutch Cable ends and adjust the free play a as
recommended.

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 14. CARBURETTOR

1. PRINCIPLE OF CARBURETTOR
Carburettor uses the principle of aerosol sprayer
operation.

Air
petrol
mixture

Aerosol sprayer Carburettor

2. PRODUCING VACUUM/SUCKING PETROL

Fast air flow produces vacuum (low air
pressure).
Speed of air flow : Speed at B is higher than
speed at A.
Air Air Pressure : Pressure at B is lower than
petrol pressure at A.
mixture
• Atmospheric pressure at C.
• Vacuum at B
• Fuel is sucked from C into B.

DESCRIPTION SPECIFICATION

CARBURETTOR SIZE VM - 20SS

MAIN JET (M.J) # 92.5

MAIN AIR JET (M.A.J) 0.8

JET NEEDLE (J.N.) 5 H148 - 3

NEEDLE JET (N.J) N-6

CUT AWAY (C.A.) 2.5

PILOT OUTLET (P.O) 1.0

PILOT JET (P.J) # 17.5

STARTER JET (S.J) # 27.5

FLOAT HEIGHT 21.8 ± 1 mm

IDLE R.P.M. 1300 ~ 1500 rpm

INTAKE VACCUM 220~260 mm Hg

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 14. CARBURETTOR

A – CUT-SECTION

Throttle stop screw

Mixing Chamber

Throttle valve

Jet needle

Pilot bypass

Throttle valve cutaway

Main air hole Pilot outlet

Pilot air hole

Pilot Screw

Air screw (Blocked)

Pilot jet
Needle valve

Main jet
Float Chamber

Float

B– CUT-SECTION
(Starter Circuit)

Starter air passage hole

Starter pipe

Starter jet

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 14. CARBURETTOR
‘CO’ MEASUREMENT AND ADJUSTMENT
1. Start the engine and let it warm up for several minutes.
2. Attach : Tachometer to the spark plug lead.
3. Check : Engine idling speed
If out of specification Adjust

Engine Idling Speed

1300 ~ 1500 rpm

ADJUSTMENT STEPS
Turn the throttle stop screw  in or out until specified idling
speed is obtained.

Turning In RPM Increases

Turning Out RPM Decreases

4. Insert : Sampling probe ‚ of ‘CO’ tester (calibrated) to the

exhaust pipe ƒ using suitable adapter „

‘CO’ density
< 1.5 %

If out of specification Adjust

5. Adjust : ‘CO’ density thru Pilot Screw.

ADJUSTMENT STEPS

• Turn the pilot screw … in or out until specified ‘CO’ density

is achieved.

Turning In ‘CO’ Density Decreases

Turning Out ‘CO’ Density Increases

• Re-set idling speed as per specification.

CAUTION
● Do not disturb settings of the carburettor if the engine performance is O.K.
● If required, must record the existing setting (No. of turns) of pilot screw.
● To counter check the setting of pilot screw, follow the ‘CO’ adjustment procedure.
● Ensure proper clamping of blind plug.

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15. LUBRICATION

1. NEED FOR LUBRICATION

a) Engine is made of various metals.
b) Engine has many rotating and contacting
parts.

c) Six (6) Effects of lubricant :

1. Anti-friction
2. Cooling
3. Cleaning
4. Sealing
5. Anti-corrosion
6. Buffer

2. DIRECT CONTACT BETWEEN METALS

Strong friction produces :
a) Large resistance.
b) Much heat.
c) Much wear

3. PREVENTION OF DIRECT CONTACT

BETWEEN METALS
Oil film (lubrication) prevents direct contact
between metals and reduces friction; i.e.

a) Reduces resistance,

b) Produces less heat,

c) Reduces wear.

4. PREVENTION OF DIRECT CONTACT

BETWEEN PARTS
Oil film (lubricant) prevents direct contact
between parts; i.e.

a) Reduces resistance.

b) Produces less heat.

c) Reduces wear.

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 15. LUBRICATION ROUTE
LUBRICATION ROUTE

BALANCER

MEGNETO
& COIL

OIL PUMP

• Oil pump is driven by the rotation of the engine, its

function is to supply oil with pressure so that it can be
forced into the areas which need lubrication. Yamaha
Motor India Pvt. Ltd. uses a compact & highly reliable
trochoid type of oil pump.

TROCHOID PUMP
• It is a type of rotor pump in which the inner and outer
rotors mesh together as illustrated. As the inner (drive)
rotor rotates, the outer (driven) rotor also rotates, but
with different speed. Accordingly, the volumetric change
created between the two rotors is utilised to draw in oil
from the suction hole and push it out through the
discharge hole.

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 15. LUBRICATION
LUBRICATION ROUTE

ADDITION

F IMPORTANT : FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL (SG GRADE)
3
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4
 15. LUBRICATION
LUBRICATION ROUTE

AXLE DRIVE

AXLE MAIN

STRAINER

F CAUTION : DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START.
37
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 ELECTRICAL WIRING
STARTING CIRCUIT (ON POSITION)

MASTER SWITCH
KILL SWITCH

ON ON
• •
BLACK/WHITE
OFF • • OFF

• •
Black

SOURCE COIL GREEN GREEN/WHITE

ORANGE
1

BROWN BLACK/RED SECONDARY

PRIMARY
3

COIL COIL
CDI UNIT
WHITE/BLUE
WHITE H.T. LEAD

Black
SPARK PLUG
PICK UP COIL RED WHITE/RED ~
Black

D
HIGH TENSION
COIL
STATOR

CDI UNIT
38
39
ELECTRICAL WIRING
LIGHTING CIRCUIT - DC INDICATOR REAR RH
INDICATOR FRONT RH (12V - 10W)
(12V - 10W)
DARK GREEN

PILOT BROWN Black

INDICATOR
Black 12V-3.4W
DARK BULB
NEUTRAL LIGHT
GREEN 14V-3W YELLOW /
Sb BROWN GREEN
OFF ON
BROWN / D BRAKE SWITCH-FR
WHITE NEUTRAL FLASHER
SWITCH
BROWN /
WHITE Black YELLOW

INDICATOR
SWITCH BROWN / HORN (12V DC) 2.5A Black
RH WHITE
DARK GREEN • BROWN
BRAKE SWITCH-RR BRAKE LIGHT
(12V-21W)
• PINK YELLOW /
2

CHOCKLATE GREEN
LH
•
3

BROWN
PINK

• •
CHOCLATE

OFF FUSE (10AMP)

HORN
Black •
BUTTON ON
• • • •
RED RED
HANDLE MASTER
SWITCH SWITCH + - Black

BATTERY (12V-2.5)
AH
CHOCLATE

Black Black

INDICATOR FRONT LH INDICATOR REAR LH

(12V - 10W) (12V - 10W)
 3. ELECTRICAL WIRING
LIGHT CIRCUIT - A.C. TAIL LIGHT(12V-5W)
SPEEDOMETER
BLUE
LIGHT BLUE
(12V-3.4W) BLACK

BLACK
LIGHT SWITCH
PO ON OFF
o o
o RECTIFIER CUM
o
REGULATOR
o
HI BEAM YELLOW
YELLOW/
(12V-3.4W) PASSING L.T. SWITCH RED
BLACK ON OFF
o (LIGHTING COIL)
HEAD LIGHT o BLUE/
YELLOW/ BLACK
BLACK (Y / B)
(12V-35W / 35W) RED
DIMMER SWITCH YELLOW
YELLOW HI LO YELLOW/RED
o
o WHITE
GREEN
o o STATOR
BLUE / RED

BLACK
PARK LIGHT BLACK
12V - 4W
HANDLE SWITCH

CHARGING CIRCUIT

RECTIFIER CUM
REGULATOR

YELLOW
BLACK

FUSE 10 AMP.
RED RED WHITE
STATOR
( CHARGING COIL)
BLACK - + W-B
BLACK

BATTERY
(12V-2.5AH)

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 17. ELECTRICAL SYSTEM – CHECKING (Contd.)
COIL CHECKING

• Remove, L.H. / R.H. Side cover.

• Disconnect magneto-stator wiring harness from

main wiring harness.

• Checking the coil resistance as the wire

connections given below :

COIL WIRE MULTIMETER RESISTANCE

COLOUR CONNECTION (OHMS- Ω )

SOURCE Brown + 860 Ω ± 20%

COIL Green ––

PICKUP Red + 180 Ω ± 20%

LIGHTING COIL (Y-B) COIL White ––

CHARGING COIL (W-B) LIGHTING Yellow + 0.35 Ω ± 20%

COIL Black ––
NEUTRAL SWITCH (Sb)
CHARGING White + 0.4 Ω ± 20%
COIL EARTHING (B)
COIL Black ––

IGNITION COIL CHECKING

• Remove, Side cover L.H. & R.H. saddle, fuel tank.

• Remove spark plug adopter from H.T. lead.

• Check primary coil and secondary coil as

connections given below.

COIL WIRE MULTIMETER RESISTANCE

COLOUR CONNECTION (OHMS - Ω )

Primary Orange + 1.0 Ω ± 10%

Coil Ground ––

Secondary H.T. Lead + 6.0 k Ω ± 20%

Coil Ground ––

41
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17. ELECTRICAL SYSTEM – CHECKING
BATTERY - CHECKING
• Remove Side Cover L.H.
• Make connections as given below :

WIRE DESCRIPTION MULTIMETER

CONNECTION
Parallel with Red wire connected to battery +
Ground ––

• Check battery voltage.

BATTERY VOLTAGE - More than 12 V

• If less than specifications, charge the battery.

R.R. UNIT CHECKING
Charging Voltage - Checking (with full AC load)
• Remove side cover L.H.
• Make connections as given below :

WIRE DESCRIPTION MULTIMETER

CONNECTION
Parallel with Red wire connected to battery +
Ground ––

• Start the engine and check charging voltage.

Charging Voltage - 14 ~ 15 V at 5000 RPM

(with full AC load) and full charged Battery
• If less than specification check charging coil, If more than
specification check coil resistance, (If found O.K.), replace
RR unit.

LIGHTING VOLTAGE – CHECKING (with full AC load)

• Remove side cover L.H/R.H. & saddle

• Make connections as given below :

WIRE DESCRIPTION MULTIMETER

CONNECTION
Blue wire going to tail light +
Black wire going to tail light ––

• Put light switch in 'ON' position

• Start the Engine and check lighting voltage.

Lighting Voltage - 13 ~ 14 V at 5000 RPM

(with full AC load) and full charged Battery
• If less than specification, check lighting coil resistance and wire
connections (if found OK) then replace RR unit
• If more than specification, check wire connections & coil resistance.
(if found OK) then replace RR unit.

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 18. BATTERY MAINTENANCE
BATTERY CHARGING (Initial)
• Fill Electrolyte of specific gravity (1.230 ± 0.005) in each
cell upto upper level
• Soaking period – Half an hour.
• Top of each cell with same electrolyte upto upper level
• Charging rate :

Ampere 0.25 A
Voltage 12 V
Charging time 8 ~ 12 hrs.
(Approx.)

Final specific gravity – 1.230 ± 0.005

BATTERY CHARGING (Maintenance)

• Fill Distilled water in each cell upto upper level

• Charging rate :

Ampere 0.25 A
Voltage 12 V

• Final specific gravity – 1.230 ± 0.005

NOTE :
• BATTERY FULLY CHARGED CONDITION CAN ALSO BE OBSERVED WHEN BATTERY CELLS
SHOW NO DROP IN SPECIFIC GRAVITY / VOLTAGE OVER 3 SUCCESSIVE HOURLY READINGS.
• MAKE SURE THAT BATTERY BREATHER PIPE IS ROUTED CORRECTLY.

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 19. TIGHTENING TORQUES – ENGINE
S. TIGHTENING TORQUE
PARTS TO BE TIGHTENED PART NAME SIZE QTY
No. Nm Kgm. (LB-FT)

ENGINE
1. Cylinder Head (Top) Bolt-Flange M8 x 1.25 4 22.0 2.2 17.0
2. Cylinder Head (Chain Side) Screw - Allen M6 x 1.0 2 10.0 1.0 7.2
3. Spark Plug Spark Plug M10 x 1.0 1 12.5 1.25 9.0
4. Cover Cylinder Head (Cam Spkt cover) Bolt-Flange M6 x 1.0 2 10.0 1.0 7.2
5. Cover Cylinder head (Rocker Arm) Cover M45 x 1.5 2 17.5 1.75 13.0
6. Rotor Nut-Flange M12 x 1.25 1 70.0 7.0 51.0
7. Guide Stopper Bolt-Flange M6 x 1.0 1 10.0 1.0 7.2
8. Adjust Screw (Valve clearance) Nut-Hex M5 x 0.5 2 8.0 0.8 5.8
9. Sprocket - Cam Bolt-Hex M8 x 1.25 1 20.0 2.0 14.5
10. Plate to Head Cylinder (Cam Stopper Plate) Screw-Allen M6 x 1.0 1 10.0 1.0 7.2
11. Chain Tensioner Assly. – Plug Bolt - Flange M8 x 1.25 1 8.0 0.8 5.8
12. Chain Tensioner Mounting Bolt-Flange M6 x 1.0 2 10.0 1.0 7.2
13. Oil Pump Assembly Screw - Philips M6 x 1.0 2 7.0 0.7 5.1
14. Drain Plug Bolt-Flange M12 x 1.5 1 20.0 2.0 14.5
15. Cover Pump Screw-Philips M5 x 0.8 1 4.0 0.4 3.0
16. Joint Carburettor (Cylinder Head side) Bolt Flange M6 x 1.0 2 10.0 4.0 7.2
17. Joint Carburettor (Carburettor side) Bolt Flange M6 x 1.0 2 7.0 0.7 5.1
18. Joint with Air Filter Housing Clamp M4 x 0.7 1 2.0 0.2 1.5
19. Air Filter Assly. Mounting Bolt-Hex M6 x 1.0 2 7.0 0.7 5.1
20. Muffler Assly. (Cylinder Head Side) Screw-Allen M6 x 1.0 2 7.0 0.7 5.1
21. Muffler Assly. Mounting Bolt-Flange M8 x 1.25 1 15.0 1.5 11.0
22. Crank Case (LH) and Crank Case (RH) Screw - Philips M6 x 1.0 10 10.0 1.0 7.2
23. Cover Crank Case (LH) Bolt-Flange M6 x 1.0 7 10.0 1.0 7.2
24. Cover Chain Case (LH) Screw-Philips M6 x 1.0 2 7.0 0.7 5.1
25. Cover Crank Case (RH) Bolt-Flange M6 x 1.0 9 10.0 1.0 7.2
26. Timing Mark Cap Plug M14 x 1.5 1 7.0 0.7 5.1
27. Crank Centre Cap Plug M32 x 1.5 1 7.0 0.7 5.1
28. Kick Crank Assly. Nut-Flange M12 x 1.0 1 50.0 5.0 36.0
29. Gear Primary Drive Nut-Flange M12 x 1.0 1 70.0 7.0 51.0
30. Plate Pressure Bolt-Hex M6 x 1.0 4 6.0 0.6 4.3
31. Boss Clutch Nut-Hex M12 x 1.0 1 60.0 6.0 43.5
32. Rod Push Nut-Hex M6 x 1.0 1 8.0 0.8 5.8
33. Sprocket Driving Bolt-Flange M6 x 1.0 1 10.0 1.0 7.2
34. Pedal Shift Bolt-hex M6 x 1.0 1 10.0 1.0 7.2
35. Segment (Cam Shifter) Screw-Torx M6 x 1.0 1 12.5 1.25 9.0
36. Stopper lever Bolt-Flange M6 x 1.0 1 10.0 1.0 7.2
37. Pulser Assly. Screw-Allen M6 x 1.0 2 10.0 1.0 7.2
38. Neutral Switch Assly. Switch Assly. M10 x 1.25 1 4.0 0.4 3.0
39. Stator Screw-Allen M6 x 1.0 3 10.0 1.0 7.2

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 19. TIGHTENING TORQUES – FRAME
S. TIGHTENING TORQUE
PARTS TO BE TIGHTENED PART NAME SIZE QTY
No. Nm Kgm. (LB-FT)

FRONT FORK, HANDLE

1. Handle Bar Screw Allen M8 x 1.25 4 23.0 2.3 17.0
2. Crown Handle and Inner Tube Bolt-Flange M8 x 1.25 2 30 3.0 21.6
3. Front Fender and Outer Tube Bolt-Flange M6 x 1.0 4 7.0 0.7 5.1
4. Main Switch Bolt-Hex M6 x 1.0 2 10 1.0 7.2
5. Crown Handle and Steering Shaft Bolt-Hex M10 x 1.25 1 54 5.4 39.0
6. Under Bracket and Inner Tube Bolt-Hex M10 x 1.25 2 30 3.0 21.6
7. *Steering Shaft Ring Nut Ring-Nut M25 x 1.0 2 15.5 1.55 11.2
8. Front Flasher Mounting Nut-Hex M12 x 1.25 2 7.0 0.7 5.1
9. Speedo Meter Cable and Speedometer Nut M12 x 1.0 1 2.5 0.25 2.0

ENGINE MOUNTS
10. Engine Mount Front & Stay Front Nut-Flange & M8 x 1.25 2 32 3.2 23.0
Bolt-flange
11. Stay Engine Front & Frame Nut-Flange & M10 x 1.25 2 55.0 5.5 39.0
Bolt-Flange
12. Engine Mount Rear and Frame Nut-Flange & M8 x 1.25 2 32 3.2 23.0
Bolt-Flange
13. Engine Mount Upper and Stay Nut-Flange & M8 x 1.25 1 32 3.2 23.0
Engine Upper Bolt-flange
14. Stay Engine Upper and Frame Nut-Flange & M8 x 1.25 2 32 3.2 23.0
Bolt-Flange

REAR SHOCKER, REAR ARM

15. Rear Swing arm Pivot Shaft Nut-Hex M12 x 1.25 1 59.0 5.9 43.0
16. Rear Shocker (Lower mounting) Nut-Crown M10 x 1.25 2 40.0 4.0 29.0
17. Rear Shocker (Upper Mounting) Nut-Crown M10 x 1.25 2 40.0 4.0 29.0
18. Tension bar and Rear Arm Nut-Hex & M8 x 1.25 1 19.0 1.9 14.0
Bolt-Hex

TANK, REAR FENDER, IGNITION

COIL/BATTERY BOX
19. Fuel Tank and Fuel Cock Screw-Phillips M6 x 1.0 2 7.0 0.7 5.1
20. Ignition Coil Screw-Phillips M6 x 1.0 2 4.0 0.4 3.0
21. Box Battery Bolt-Hex M6 x 1.0 2 4.0 0.4 3.0
22. Rear Fender Bolt-Hex M6 x 1.0 5 4.0 0.4 3.0

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 19. TIGHTENING TORQUES – FRAME
S. TIGHTENING TORQUE
PARTS TO BE TIGHTENED PART NAME SIZE QTY
No. Nm Kgm. (LB-FT)

BRAKE, WHEEL
23. Front Wheel Axle Nut-Castle M14 x 1.5 1 91.0 9.1 66.0
24. Rear Wheel Axle Nut-Castle M14 x 1.5 1 91.0 9.1 66.0
25. Sprocket and clutch Hub Nut-Hex & M8 x 1.25 4 32 3.2 23.0
Bolt-Hex
26. Tension Bar and Brake Shoe Plate Nut Hex & M8 x 1.25 1 19.0 1.9 14.0
Bolt-Hex
27. Brake shoe cam and Lever Nut - Hex & M6 x 1.0 2 9.0 0.9 7.1
Bolt - Hex

FOOT REST, PEDAL

28. Side Stand Nut-Hex & M10 x 1.25 1 40.0 4.0 29.0
Bolt-Hex
29. Foot Rest Bolt-Flange M8 x 1.25 2 32.0 3.2 23.0

*1. First tighten the ring nut (lower) (Torque - 32.3 lb-ft.) using SST YSST-621 & Torque wrench then
loosen the ring nut (lower) one turn.
2. Retighten the ring nut (lower) (Torque - 11.2 lb-ft.) using SST YSST-621 & Torque wrench.
3. Ring nut upper should be hand tightened.

46
3
3
 20. TROUBLE SHOOTING
ENGINE FAILS TO START

FUEL SYSTEM COMPRESSION SYSTEM

IGNITION SYSTEM
No Spark
• Defective ignition switch/
moisture in ignition
switch.
• Defective H.T. coil/H.T.
Lead
• Defective spark plug
• Defective CDI
• Defective Pickup coil
• Defective Source coil
• Disconnection of wires
• Improper earthing
Spark not good
• No wood-ruff key
• Broken wood-ruff key
• Sparkplug adopter-crack
• Improper spark plug gap
• Loose connections
• Improper earthing
• Spark plug loose
• Leakage through
cylinder head
• Defective cylinder head
gasket
• Insufficient valve
clearance
• Valve sticky
• Carbon build up in
valve seat/valve burnt
• Defective valve spring
• Piston rings-sticky
• Worn out cylinder
• Improper installation of
piston rings
• Blow hole in cylinder
head, cylinder & piston

Fuel not reaching Improper fuel flow from Contaminated Petrol

carburettor Carburettor - to - Engine
• Water mixed with petrol
• No fuel in tank • Stuck Needle Valve
• Broken or Bend fuel • Improper float height
pipes
• Clogged pilot jet, main
• Clogged fuel cock jet & its galleries
• Clogged fuel filter • Improper carburettor
adjustments
• Clogged Air vent hole in
Tank cap
• Fuel tank rusty

47
1
1
NOTES
 YAMAHA MOTOR INDIA PVT. LTD.
19/6, MATHURA ROAD, FARIDABAD - 121 006, HARYANA, INDIA.

1Y13(SG-01) 129-0802-E