Ybr 125 suplementary

SUPPLEMENTARY SERVICE MANUAL

FAZER SUPPLEMENTARY SERVICE MANUAL YAMAHA MOTOR INDIA PVT. LIMITED All rights reserved.

Any reprinting or unauthorised use without the written permission of YAMAHA MOTOR INDIA PVT. LIMITED is expressly prohibited.

FOREWORD

This Supplementary Service Manual has been prepared for use by the Yamaha Motor India Private Ltd. Authorised Dealerships and their service personnel to attend to servicing of Fazer Motorcycles. It is not possible to include entire service education into this Manual. It is assumed that persons using this book to perform maintenance and repairs on Fazer Deluxe/Flame Motorcycles have a basic understanding of mechanical concepts and procedures inherent to Motorcycle repair technology.

For complete Service information procedures of Fazer Deluxe/Flame it is necessary to use this supplementary Service Manual together with following manual.

FAZER 5YY2 - Service Manual

Service Department Yamaha Motor India Private Ltd.

HOW TO USE THIS MANUAL MANUAL ORGANISATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the Title of the Chapter with its symbol on the upper right corner of each page.

2nd title 2 : This title indicates the Section of the chapter and only appears on the first page of each section. It is located in the centre of the page.

3rd title 3 : This title indicates a Subsection that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are Exploded Diagrams at start of each Removal and Disassembly section.

1. An easy-to-see Exploded Diagram 4 is provided for Disassembly and Assembly jobs.

2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed by a circle indicates a part.

3. An explanation of jobs and notes are presented in an easy-to-read way by the use of Symbol Marks 6 . The meaning of the Symbol Marks are given on the next page.

4. For jobs requiring more information, the step-by-step format supplements 7 are given in 1 addition to the exploded diagram.

2

FRONT BRAKE / CALIPER ASSEMBLY

4

CHAS

CALIPER DIASSEMBLY Á

1.

Remove: • Bolt ¿ • Copper Washers À

3

NOTE:

¿

Place the container under the caliper to catch the standing brake fluid.

2. Disconnet: • Brake hose Á 3. Remove: • Clip pin  • Retaining pin à • Brake pads Ä • Pad spring 4. Remove • Bolts Å • Brake Caliper Body.

5. Remove: • Piston Æ • Piston seal Ç

À

Ä 5

à Â

7 3. ¿ 6

Remove • C.D.I. Magneto ¿ • Wood-ruff key

WARNING CAUTION: • Cover the crankshaft end with the spacer.

Magneto Puller : YSST - 628

ILLUSTRATED SYMBOLS Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content.

1. General Information

GEN INFO

2. Specifications

3. Periodic inspection and adjustment

INSP ADJ

4. Engine

ENG

5. Carburetion

CARB

6. Chassis

CHAS

7. Electrical

ELEC

8. Troubleshooting

TRBL SHTG

SPEC

Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.

9. Filling fluid

10.Lubricant

11.Special Tool

12.Torque

13.Wear Limit, Clearance

14.Engine speed

15.Resistance, Voltage, Current Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and lubrication points.

16. Apply engine oil

19. Apply wheel bearing grease

17. Apply gear oil

20.Apply lightweight lithium-soap base grease

18. Apply molybdenum disulfide oil

21. Apply molybdenum disulfide grease

Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking agent and when to install new parts 22. Apply locking agent (LOCKTITE*)

23. Use New One

INDEX GENERAL INFORMATION

SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE

CARBURETION

CHASSIS

ELECTRICAL

TROUBLE SHOOTING

GEN INFO

GEN INFO

1

SPEC

2

INSP ADJ

3

ENG

4

CARB

5

CHAS

6

ELEC

7

TRBL SHTG

8

CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER ..........................................................1-1 ENGINE SERIAL NUMBER .........................................................1-1 IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY ........................................1-2 ALL REPLACEMENT PARTS .....................................................1-3 GASKETS, OIL SEALS, AND O-RINGS ......................................1-3 LOCK WASHERS/PLATES AND COTTER PINS .......................1-3 BEARINGS AND OIL SEALS ......................................................1-3 CIRCLIPS ....................................................................................1-3 SPECIAL TOOLS SPECIAL SERVICE TOOLS .......................................................1-4

MOTORCYCLE IDENTIFICATION

GEN INFO

MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The Frame Serial Number ¿ is stamped into the right side of the Steering Head Pipe.

ENGINE SERIAL NUMBER The Engine Serial Number À is stamped on the top portion of RH Crankcase. ( Engine Serial Number does not contain Year and Month of production)

XX

X

5YY

2XXXXX

YEAR OF PRODUCTION

MONTH CODE

MODEL CODE

UNIT PRODUCTION NUMBER

Year of Production

:

Month Code

:

Starting Serial Number

:

2 Digits standing for last two digits of year Eg. 0 0 - 2000, 0 1 - 2001 ......

One alphabet standing for Month Eg. A - January, B - February........

M - December ( I - Not Used for Month) 5YY 200001

WARNING Do not tamper with any of these numbers. It may lead to legal action.

NOTE : Designs and sepecifications are subject to change without notice.

1-1

IMPORTANT INFORMATION

GEN INFO

IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY 1. Remove all dirt, mud, dust and foreign material before disassembly.

2. Use proper Tools and Cleaning Equipment.

Refer to “YAMAHA SPECIAL SERVICE TOOLS”.

3. When disassembling the Motorcycle, keep mated parts together. This includes gears, Cylinder, Piston and other mated parts that have been “mated” through normal wear.

Mated parts must be reused as an assembly or replaced.

4. During the Motorcycle disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep Motorcycle and its parts away from any source of fire.

1-2

IMPORTANT INFORMATION

GEN INFO

ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use Yamalube Oil and Grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.

GASKETS, OIL SEALS, AND O-RINGS 1. All Gaskets, Seals and O-rings should be replaced when the Engine is overhauled.

2. All surfaces where Gasket, Oil Seal lips and O-rings contact must be cleaned and Lubricated.

LOCK WASHERS/PLATES AND COTTER PINS 1. All Lock Washers/plates ¿ and Cotter Pins must be replaced when they are removed.

Lock tab (s) should be bent along the Bolt

BEARINGS AND OIL SEALS 1. Install the bearing (s) ¿ and Oil Seal (s) À with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing Oil Seal (s), lubricate a light coating of lightweight lithium base grease to the seal lip(s). Oil the Bearings liberally when installing.

CAUTION: WARNING Do not use compressed air to spin the Bearings dry. This causes damage to the Bearing surfaces.

CIRCLIPS 1. All Circlips should be inspected carefully before reassembly. Always replace Piston Pin Clips after one use. Replace distorted Circlips. When installing a circlip ¿, make sure that the sharp-edged corner À is positioned opposite to the thrust Á it receives. See the sectional view of shaft Â.

WARNING If the Circlip is fitted the wrong way it would cause it to jump off its groove and damage related components.

1-3

YAMAHA SPECIAL SERVICE TOOLS

GEN INFO

YAMAHA SPECIAL SERVICE TOOLS The appropriate Yamaha Special Service Tools are necessary for proper maintenance of the Motorcycle.

Using the correct Yamaha Special Service Tool will help to prevent damage caused by the use of improper tools or improvised techniques. The following is the detailed list of all Yamaha Special Service Tools with their application for only 5YY2 model.

Refer to the list provided to avoid errors when placing an order for Yamaha Special service tools.

1. Magneto Holder YSST -601-B

2. Magneto Puller with Spacer YSST-628

This tool is used to hold the Magneto when removing or installing the Magneto Securing Nut and Primary Drive Gear Nut

This tool is used to remove the Magneto

1-4

SPEC

CHAPTER 2.

SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................... 2-1 GENERAL TORQUE SPECIFICATIONS • ENGINE .................................................................................. 2-4 • CHASSIS ................................................................................2-4 MAINTENANCE SPECIFICATIONS ELECTRICAL ............................................................................2-5 CABLE ROUTING ............................................................................2-7

GENERAL SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS DESCRIPTION Model : Model Code : Engine model code: DIMENSIONS: Overall length Overall width Overall height Seat height (Upto Rider) Seat height (Upto Pillion Rider) Wheelbase Minimum ground clearance Minimum turning radius Dry weight : Basic weight : (With Oil and full Fuel Tank) ENGINE : Engine type Cylinder arrangement Displacement Bore X Stroke Compression ratio Starting system Lubrication system Max power Torque Oil type or grade : Engine oil

SPECIFICATION FAZER - Deluxe / Flame 5YY2 5YY2 2065 730 1060 800 870 1300 160 2065 115 125

mm mm mm mm mm mm mm mm kg kg

Air-cooled 4-stroke, SOHC Forward-inclined, single cylinder 123.7 cm³ 54 X 54 mm 10:1 Kick starter / Electrical Starter Wet sump 11 BHP (8.0 KW) @ 8500 RPM 1.06 Kgm, 10.4 NM @ 6500 rpm Yamalube 4-stroke Oil (20W40 Type SG)

Oil capacity : Engine oil Periodic oil replacement Total amount Air filter :

1.0 L 1.2 L Washable, Dual Foam, Wet type (Oil soaked)

FUEL : Fuel Tank capacity Fuel reserve amount Carburetor : Type

BS-25

Spark plug : Type/manufacturer Spark Plug gap

R-CR7HSA / NGK 0.6 ~ 0.7 mm

13 Ltrs.

1.2 Ltrs.

2-1

GENERAL SPECIFICATIONS DESCRIPTION Clutch type : Transmission : Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio

SPEC

SPECIFICATION Wet, Multiple disc Helical gear 68/19 (3.579 : 1) Chain drive 45/14 (3.214 : 1) Constant mesh 4-speed Left foot operation 33/12 (2.750) 27/16 (1.688) 24/20 (1.200) 21/23 (0.913)

1st 2nd 3rd 4th

Primary Drive Grading

Matching of Grades

DRIVEN GEAR ASSY.

Gear Primary Drive

B C

GRADE

D E F

GEAR PRIMARY DRIVE

Chassis : Frame type Caster angle Trail Tyre : Type Size Manufacturer Type

Primary Driven Gear Assy.

GRADE

A B C D E

Diamond 26.4º 83 mm

Front Rear Front Rear Front Rear

With tube 2.75 - 18, 4 PR 3.00 - 18, 6 PR LOCAL MADE LOCAL MADE RIB TYPE / ZAPPER TYPE UNIVERSAL / ZAPPER TYPE

Front Rear

25 PSI (1.75 kgf/cm²) 32 PSI (2.30 kgf/cm²)

Tyre pressure (cold tyre) :

2-2

GENERAL SPECIFICATIONS DESCRIPTION Brake : Front brake

Rear brake

SPEC

SPECIFICATION Type Operation Oil Type Operation

Disc Brake Right hand lever operation Dot-3 Drum brake (Dia 130 mm) Right foot operation

Suspension : Front suspension Rear suspension Shock absorbser : Front shock absorber Rear shock absorber Wheel travel : Front wheel travel Rear wheel travel Electrical : Ignition system Generator system Battery type Battery capacity Headlight type : Headlight bulb type Bulb (voltage - wattage x quantity) : Headlight Tail/Brake light Flasher light Meter light “NEUTRAL” indicator light “HIGH BEAM” indicator light “TURN” indicator light

Telescopic fork Swingarm Coil spring/Oil damper Coil spring/Oil damper 120 mm 90 mm CDI (Digital) Flywheel magneto LOCAL MADE - LEAD ACID 12V - 5 AH Bulb type S-1 Type Bulb 12V - 25W/25W x 2 12V - 5W/21W x 1 12V - 10W x 4 12V - 3.4W x 2 12V - 3.4W x 1 12V - 3.4W x 1 12V - 1.7W x 2

HORN FUSE

12V - 1.5 Amp 10 Amp.

2-3

MAINTENANCE SPECIFICATIONS

SPEC

TIGHTENING TORQUE (ENGINE) PARTS TO BE TIGHTENED

PART NAME

THREAD SIZE

QTY

Plate Idle Gear

Screw

M6

2

7

0.7

5

Bolt

M6

2

10

1.0

7.2

Bolt Hex

M8

3

30

3.0

21

Screw

M6

2

4

0.4

3.0

Crank Case Cover-1

Bolt

M6

7

10

1.0

7.2

Rotor

Nut

M 12

1

70

7.0

51

PART NAME

THREAD SIZE

QTY

Bleed Screw

Bolt

M6

1

6

0.6

4.3

Front Wheel Axle

Nut

M14

1

80

8.0

58

-

-

36

3

0.3

2.0

Brake Disc

Allen

M6

6

13

1.3

9.3

Union Bolt

Bolt

M8

2

25

2.5

18

Caliper Bracket

Bolt

M 10

2

28

2.8

20

Starter Motor Assembly Starter One Way Assembly Switch Handle- 2

TIGHTENING TORQUE Nm m.kg ft.lb

TIGHTENING TORQUE (CHASSIS) PARTS TO BE TIGHTENED

Nipple

2-4

TIGHTENING TORQUE Nm m.kg ft.lb

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL DESCRIPTION Voltage : Ignition system : Ignition timing (B.T. D. C) Advancer Type CDI : Magneto model/manufacturer Sensor Coil (Color) CDI Unit Model/manufacturer IgnitionCoil : Model/Manufacturer Primary Coil Resistance Secondary Coil Resistance Spark Plug Cap : Type Resistance Charging System : Type Flywheel Magneto : Model/Manufacturer Charging Voltage Charging Coil Resistance Lighting : Lighting Voltage

SPECIFICATION 12V 7º ± 2º BTDC at 1400 rpm.

Electrical type Digitally Controlled 5YY/DENSO 240 Ω ± 20% 5KA/ Denso 5YY/Wings Automobiles Pvt. Ltd. 0.22 Ω ± 15% 3.0 KΩ ± 20% Resistance Type 5 kΩ at 20 ºC (68ºF) Flywheel Magneto 5YY/DENSO 14 ~ 15V @ 5000 RPM 0.75 Ω ± 20% (68ºF) 14 V ± 0.5 @ 5000 RPM

Lighting Coil Resistance Rectifier/Regulator : Type Model/Manufacturer No load regulated voltage Capacity Withstand voltage Battery : Specific Gravity Horn: Type Quantity Model/Manufacturer Maximum Amperage Flasher relay: Type Model/Manufacturer Self cancelling device Flasher frequency Wattage

0.62Ω ± 20 % (68ºF) Semi conductor-Short Circuit Type 5YY / Nappino Auto 14.5 ± 0.5 V at 5000 rpm 8A 400 V 1.280 Plane type 1 pc.

5YY/Local Made 1.5 A Semi transistor type Local Made No 85 ± 15 cycles/min 10W X 2

2-5

MAINTENANCE SPECIFICATIONS Circuit Breaker : Type Amperage for individual circuit X quantity : Main Reserve

Fuse 10A X 1pc.

10A X 1pc.

2-6

SPEC

SPEC

CABLE ROUTING CABLE ROUTING

É Flasher light lead (left) B Pass the Throttle Cable Å, Ê Flasher Light and the Brake Hose Ä and Ë Flasher Light lead (right) the Front Brake switch lead Ì Master Cylinder Æ through the Cable Guide of Í Kill Switch the right side.

A Pass the Clutch Cable À, C Clamp Wireharness È and Starter wire Á and front fork.

Handle-bar Switch Lead D Pass the Wireharness È and through the cable guide of Clutch Cable À. the left side.

¿ Handlebar switch (left) À Clutch cable Á Starter Wire  Speedometer à Tachometer Ä Brake Hose Å Throttle cable Æ Brake switch lead Ç Speedometer cable È Wireharness

Â

Ã

A

B

À

Å Ä

¿

Ì

Í Æ

Á Ã

Â

Ì

Å

Ê É

Ê

Á Ë

À C

È À

D

2-7

SPEC

CABLE ROUTING ¿ Headlight assembly À Handlebar switch lead Á Speedometer cable  Cable guide à Clutch cable Ä Horn Å Fuse Æ CDI unit Ç Clamp Battery È Stop/tail light É Flasher light lead (LH) Ê Flasher light Ë Battery Ì Battery breather hose Í Starter Motor Lead Wire

Î Starter Relay Ï H.T. Coil Ð Air Induction system Ñ Relay Assembly Ò Battery (+ve) lead Ó Battery (-ve) lead A Pass the wireharness through the cable guide.

B Pass the speedometer cable Á and front brake cable Î through the Cable Guide.

C Align the white marking of Wireharness with the frame clamp

D Connect the battery negative (-) lead and positive (+) lead with the wireharness.

E Pass the battery breather hose Ì through the hole of the lower left side of the Battery Box F Pass the magneto lead to the outside of the flange of the chain cover.

À Ã

Ï

¿

Æ Ð C

É

Ó Å

Î Ñ

È

Ä Á Ê A

Ò Ë Ç

Á

Ì

 Í

E

F

2-8

D

SPEC

CABLE ROUTING ¿ Throttle cable À High tension cord Á Ignition Coil  Band - C.D.I. à Brake Hose front Ä Speedometer Å Brake switch lead Æ Clutch cable Ç Rr Brake Switch

È A.I.S. Unit É Starter wire Ê Carburettor Breather Pipe. Ë Caliper Ì Disc

A Pass the high tension cord À through the cable guide and starter wire.

B Pass the throttle cable ¿ and starter wire É through cable guide.

C Pass the clutch cable Æ through cable guide.

D Pass breather hose through upper right side hole of frame bracket engine.

E Clamp the hose front brake with front mudguard.

Ä Ã

A

Å Â

B

É

È

¿ E

C

Ç Ê

Á Æ Ã

¿ D

Ë À

Ì

2-9

CABLE ROUTING

SPEC

¿ C.D.I. Unit À Rectifier regulator Á Flasher relay  Flasher light lead A Clamp the Wire Harness lead.

B Pass the Wire Harness between Frame and Rear Fender

¿ À Å Ä A

 Á B

 à Æ

2-10

INSP ADJ

CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENTS FRONT BRAKE FLUID LEVEL ...................................................3-1 FRONT BRAKE PAD INSPECTION ............................................3-1 AIR BLEEDING (FRONT BRAKE SYSTEM ................................3-2 CABLE INSPECTION AND LUBRICATION .................................3-3 BATTERY INSPECTION .............................................................. 3-4 FUSE INSPECTION ....................................................................3-6

FRONT BRAKE FLUID LEVEL I

INSP ADJ

FRONT BRAKE FLUID LEVEL INSPECTION 1. Place the motorcycle on a level place.

NOTE : • Position the motorcycle straight up when inspecting the brake fluid level.

• When inspecting the front brake fluid level make sure the master cylinder top is horizontal by turning the handlebars.

2. Inspect: • Brake fluid level • Fluid level is under “LOWER”level line ¿ Ÿ Fill up.

¿

Recommended brake fluid: DOT - 3

CAUTION: WARNING Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

WARNING • Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

• Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.

• Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

FRONT BRAKE PAD INSPECTION 1.

2. ¿ ç

Activate the brake lever Inspect : • Brake pad Wear indicator ¿ almost contacts brake disc -> Replace brake pad as a set.

Thickness : ç New 7.4 - 7.7 mm Min - 3.8 mm Refer to the “BRAKE PAD REPLACEMENT” section on Page No.:

3-1

AIR BLEEDING AIR BLEEDING SYSTEM)

INSP ADJ (FRONT

BRAKE

WARNING Bleed the brake system if : • The system has been disassembled.

• A brake hose has been loosened or removed.

• The brake fluid is very low.

• The brake operation is faulty.

A dangerous loss of braking performance may occur if the brake system is not properly bleed.

1. Bleed • Brake system ææææææææææææææææææææææææææææææææææ Air bleeding steps : a. Add proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic tube ¿ tightly to the caliper bleed screw À. d. Place the other end of the tube into a container. e. Slowly apply the brake lever several times. f. Pull the lever in. Hold the lever in position. g. Loosen the bleed screw and allow the lever to travel towards its limit. h. Tighten the bleed screw when the lever limit has been reached; then release the lever.

À

À

Bleed screw: 6 Nm (0.6 m.kg., 4.0 ft.lb) i. Repeat steps (e) to (h) untill all of the air bubles have been removed from the system.

¿

NOTE: If the bleeding is difficult, it may be necessary to let the brake fluid system stablize for a few hours. Repeat the bleeding procedure when the tiny bubles in the system have disappeared. j. Add brake fluid to proper level Recommended brake fluid: DOT - 3

3-2

CABLE INSPECTION AND LUBRICATION

INSP ADJ

CABLE INSPECTION LUBRICATION

AND

WARNING Damaged cable sheth may cause corrosion and interfere with the cable movement. An unsafe condition may result so replace such cable as soon as possible.

1. Inspect: • Cable sheath ¿ Damage Ÿ Replace.

¿

2. Check: • Cable operation Unsmooth operation Ÿ Lubricate.

Recommended lubricant: Yamaha Chain and Cable Lube or motor oil SAE 20W40 ¿ NOTE: Hold cable end high and apply several drops of lubricant to cable.

LEVER LUBRICATION Lubricate the lever ¿ at their pivoting points.

Recommended lubricant: Yamaha Chain and Cable Lube or motor oil SAE 20W40

3-3

BATTERY INSPECTION

INSP ADJ

BATTERY INSPECTION 1. Remove: • Side Cover (left) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section in 5YY1 Fazer Manual.

2. Inspect: • Electrolyte level Electrolyte level should be between the upper ¿ and lower À level marks.

Electrolyte level is too low Ÿ Add distilled Water to proper level.

WARNING

CAUTION: Refill with distilled water only. Tap water contains minerals which are harmful to a battery.

3. Inspect: • Battery terminals Dirt Ÿ Clean with a wire brush.

Poor connection Ÿ Correct

NOTE :

¿

After cleaning the terminals, apply a light coat of grease to the terminals.

À

4. Inspect: • Breather hose Á Obstruction Ÿ Remove Damage Ÿ Replace

Á

CAUTION: When inspecting the battery, make sure that the breather hose is routed correctly. If the breather hose is positioned in such a way as to allow battery electrolyte or gas to come into contact with the frame, this could damage the motorcycle and ruin its finish.

5. Connect: • Breather hose Á Make sure tha the hose is properly attached and routed.

6. Check: • Specific gravity Less than 1.280 g/dm3 Ÿ Recharge the battery.

Charging Current : 0.50 amp.

Specific Gravity: 1.280 g/dm3 to 20o C

3-4

BATTERY INSPECTION

INSP ADJ

ææææææææææææææææææææææææææææææææææ

Replace the battery if: • Battery voltage will not rise to a specific value or bubbles fail to rise during charging.

• Sulphation of one or more cells occurs, (as indicated by the plates turning white, or material accumulating in the bottom of the cell).

• Specific gravity readings after a long, slow charge indicate that one cell is charged lower than the rest.

• Warpage or buckling of plates or insulators is evident. ææææææææææææææææææææææææææææææææææ

CAUTION: Always charge a new battery before using it to ensure maximum performance.

WARNING Battery electrolyte is dangerous. It contains sulfuric acid which is poisonous and highly caustic. always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns and permanent eye injury.

• Wear protective eye wear when handling or working near batteries.

• Antidote (EXTERNAL): • SKIN - Flush with water.

• EYES - Flush with water for 15 minutes and get immediate medical attention.

• Antidote (INTERNAL): • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegitable oil. Get immediate medical attention.

• Batteries generate explosive hydrogen gas.

• Always follow these preventive measures: • Charge batteries in a well - ventilated area.

• Keep batteries away from fire, sparks or open flames (e.g. welding equipment, lighted cigarettes, etc.)

• DO NOT SMOKE when charging or handling batteries.

• KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

3-5

BATTERY CHARGING / FUSE INSPECTION

INSP ADJ

7. Install: • Battery 8. Connect: • Battery leads

CAUTION: À

Connect the positive lead ¿ first and then connect the negative lead À.

¿

9. Connect: • Breather hose Be sure the hose is propely attached and routed.

Refer to “CABLE ROUTING” Chapter 2 Page 2-8.

10. Install: • Side cover (left) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section in 5YY1 Fazer Service Manual.

FUSE INSPECTION

CAUTION: Always turn off the main switch when checking or replacing the fuse. Otherwise, a short circuit may occur 1. Remove: • Side Cover (LH) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section in 5YY1 Fazer Service Manual.

• Fuse Holder ¿ 2. Inspect: • Fuse ææææææææææææææææææææææææææææææææææ Inspection steps : • Connect the Multimeter to the fuse and check it for continuity.

NOTE : Set the Multimeter selector to “Ω x 1” position

¿

Multimeter.

If the Multimeter is indicated at ∝ , replace the fuse. ææææææææææææææææææææææææææææææææææ •

3-6

FUSE INSPECTION

INSP ADJ

3. Replace: • Blown fuse ææææææææææææææææææææææææææææææææææ Replacement steps: • Turn off the main switch.

• Install a new fuse with the proper current rating.

• Turn on switches to verify operation of related electrical devices.

• If the fuse blows again immediately, check the electrical circuit.

WARNING Never use a fuse with a rating other than that specified. Never use other materials in place of a fuse. An improper fuse may cause extensive damage to the electrical system, malfunction of lighting and ignition systems and could possibly cause a fire.

4. Install: • Fuse holder • Side cover (LH) Refer to “SEAT, SIDE COVERS AND FUEL TANK” section in 5YY1 “Fazer” Service Manual.

3-7

ENG

CHAPTER 4 ENGINE

C.D.I. MAGNETO ........................................................................4-1 C.D.I. MAGNETO REMOVAL ...................................................... 4-2 STARTER IDLE GEAR INSPECTION.......................................... 4-3 ROTOR & STARTER GEAR INSTALLATION ...............................4-3

ENGINE

ENG

CDI MAGNETO ¿ À Á Â Ã

Ä Å Æ Ç

Starter idle gear 1 Plate Washer Starter wheel gear 2 CDI Magneto rotor

Stator assembly Gasket Dowel pin Crankcase cover

Á Â Ã

¿ À Ä Ç

Å

Æ

4-1

ENGINE

ENG

CDI MAGNETO REMOVAL 1. Remove : • Screw - 2 Nos. ¿ • Chain cover (Half) À

¿ À

NOTE : The CDI magneto can be removed while the engine is mounted by removing the shift pedal.

Magneto Holder : YSST - 601 - B 2.

Á

À Ã Â

¿

3.

¿

Remove • Crank case cover #1 • Neutral switch lead ¿ • Gasket À • Dowel Á • Nut (magneto)  • Plain washer à Remove • C.D.I. Magneto ¿ • Wood-ruff key

WARNING CAUTION: • Cover the crankshaft end with the spacer.

Magneto Puller : YSST - 628

NOTE : • Á •

À

Remove the magneto using the flywheel puller À with spacer Á.

Center the flywheel puller over the magneto.

Make sure after installing the holding bolts that the clearance between the flywheel puller and the magneto is the same everywhere. If necessary, one holding bolt may be turned out slightly to adjust the flywheel puller’s position.

Ã

À

¿

4. Remove : • Starter idler gear ¿ • Washer À 5. Remove • Screw - 2 Nos. Á • Plate  • Starter idler gear Ã

Â

Á

4-2

ENGINE

ENG

STARTER IDLE GEAR INSPECTION

è

1. Inspect: • Gear teeth ç, è and é Burrs/chips/roughness/wear Ÿ Replace 2. Check • Starter clutch operation

é

ç

ææææææææææææææææææææææææææææææææææææ Checking steps : • Install the starter wheel gear ¿ to the starter clutch À, and hold the starter clutch.

• When turning the starter wheel gear clockwise A , the starter clutch and the wheel gear should be engaged. If not, the starter clutch is faulty. Replace it.

• When turning the starter wheel gear counter closckwise B , the starter clutch gear should turn freely. If not, the starter clutch is faulty. Replace it. ææææææææææææææææææææææææææææææææææææ

À B

A ¿

Á ¿

ROTOR AND STARTER IDLE GEAR INSTALLATION 1. Install • Starter idle gear ¿.

• Plate À • Screw - 2 Nos. Á

À

¿ 2. Apply • 4-stroke engine oil. (onto journal and starter drives) 3. Install • Washer ¿ • Starter idle gear À 4. Install: • Wood-ruff key • Magneto rotor Á

NOTE :

À

Á

Temporarily install the rotor aligning the key way of the rotor with the wood-ruff key. Turn the starter wheel gear clockwise and install the rotor to the start wheel gear.

Á

4-3

ENGINE

ENG

5. Tighten : • Nut (rotor) ¿

Nut (rotor): 70 Nm ( 7.0 m. kg., 51 ft.lb)

¿ À Á

NOTE : • Tighten the nut (rotor) ¿ while holding the rotor À with the magneto holder Á.

Magneto Holder : YSST 601 - B

6. Install: • Dowl pin ¿ • Gasket À • Crankcase cover (LH) • Bolts - Seven Nos.

À

¿ Bolt (left crankcase cover): 10 Nm (1.0 m.kg, 7.2 ft.lb) Á 7. Connect: • Neutral switch lead Á ¿

8. Install • Cover (Half) chain ¿

À

9. Tighten Screw - 2 Nos. À

4-4

CARBURETION

CHAPTER 5 CARBURETION

REFER CHAPTER-5 FROM 5YY1 - FAZER SERVICE MANUAL

CARB

FRONT WHEEL AND FRONT BRAKES

CHAS

CHAPTER 6 CHASSIS FRONT WHEEL .......................................................................... 6-1 REMOVAL ...................................................................................6-2 FRONT WHEEL INSPECTION ....................................................6-3 INSTALLATION ............................................................................6-5 FRONT BRAKE ...........................................................................6-7 BRAKE PAD REPLACEMENT ...................................................6-8 CALIPPER DISASSEMBLY ........................................................6-10 MASTER CYULINDER DISASSEMBLY ...................................... 6-11 INSPECTION AND REPAIR ......................................................... 6-12 CALIPER ASSEMBLY ................................................................. 6-14

FRONT WHEEL AND FRONT BRAKES

CHAS

FRONT WHEEL ¿ À Á Â Ã Ä Å Æ

Wheel axle Collar Dust Cover Oil Seal Bearing Spacer Collar Front Wheel Bearing

Ç È É

Gear Unit (Speedometer) Axle Nut Split Pin

¿

À Á Â

à Ä

Æ Ç È É Å

6-1

FRONT WHEEL AND FRONT BRAKES

CHAS

REMOVAL

WARNING Securely support the motorcycle so there is no danger of it falling over.

¿

1. Place the motorcycle on a level place.

2. Elevate the front wheel by placing suitable stand under the frame and engine.

3. Remove: • Speedometer Cable ¿ • Split pin À • Nut Á

Á

À

4. Remove: • Wheel axle  • Front Wheel Ã

Â

NOTE: Do not depress the brake level when the wheel is off the motorcycle otherwise the brake pads will be forced shut.

Ã

5. Remove: • Collar ¿ • Dust Cover À • Gear Unit (Speedometer) Á B

A Á

A Right side B Left Side

À ¿

6-2

FRONT WHEEL AND FRONT BRAKES

CHAS

INSPECTION 1. Eliminate any corrosion from parts.

2. Inspect: ò Wheel axle Roll the axle on a flat surface.

Bends Ÿ Bends

WARNING Do not attempt to straighten a bent axle.

3. Inspect: • Tyre Wear/Damage Ÿ Replace.

•

Wheel Bends/Damage Ÿ Replace.

4. Check: • Spoke(s) Bend/Damage Ÿ Replace.

Loose spoke(s) ŸRetighten.

Turn the wheel and tap the spokes with a screw driver.

NOTE: A tight spoke will emit a clear, ringing tone; a lookse spoke will sound flat.

5. Tighten: • Loose spokes

Nipple : 3 Nm (0.3 m.kg. -2.0 lbft) NOTE: Check the wheel runout after tightening spoke.

6. Measure: • Wheel runout Out of specification Ÿ check the wheel and bearing play.

Rim runout limits: Vertical ¿ : 1.0 mm Lateral À : 0.5 mm

6-3

FRONT WHEEL AND FRONT BRAKES

CHAS

WARNING After mounting a tyre, ride conservatively to allow proper tyre to rim seating. Failure to do so may cause an accident resulting in motorcycle damage and possible operator injury.

After a tyre repair or replacement, be sure to torque tighten the valve stem locknut ¿ to specification Valve stem locknut: 3 Nm (0.3 m.kg. - 2 ft.lb)

7. Check • Wheel bearings ¿ • Abnormal noise/turn roughly/free play Ÿ replace.

• Oil seal À Wear/damage Ÿ replace.

A Free Play ææææææææææææææææææææææææææææææææææ Oil seal and wheel bearing replacement steps: • Clean the outside of the wheel hub.

• Remove the oil seals ¿.

• Remove the bearing À .

• Install the new bearing and new oil seal.

¿

À

6-4

FRONT WHEEL AND FRONT BRAKES

CHAS

NOTE:

Ä

Use a socket Ä that matches the outside diameter of the race of the bearing and oil seal. à Á  WARNING CAUTION: Do not strike the centre race Á or balls  of the bearing. Contact should be made only with the outer race Ã. ææææææææææææææææææææææææææææææææææ

INSTALLATION Reverse the “Removal” procedure.

1. Lubricate: • Wheel Axle ¿ • Oil Seal (Lip) À • Bearings Á • Driven Gear  (speedometer)

Lithium Soap base grease

2. Install: • Gear unit assembly ¿. è

ç ¿

WARNING NOTE: Make sure the projections on the meter clutch ç and meshed with the flats in the wheel hub è

6-5

FRONT WHEEL AND FRONT BRAKES

CHAS

3. Install : • Collar ¿ • Dust Cover À

NOTE :

À

Install the oil seal taking care not to damage or reverse the lips.

¿ 4. Install : • Front wheel assembly

ç

NOTE : Be sure the boss on the outer fork tube ç correctly engages with the locating slot on the gear unit assembly è.

è

5. Install : • Wheel axle ¿ • Axle nut À

¿

6.

Tighten • Nut À Nut (wheel axle) : 80 Nm (8.0m.kg, 58 ft.lb)

7. À

Install: • Split Pin Á • Speedometer cable Â

À

CAUTION: WARNING Á

Â

Make sure that the speedometer cable  is routed properly.

6-6

CHAS

FRONT BRAKE FRONT BRAKE ¿ À Á Â Ã Ä Å Æ

ÇRubber boot ÈBrake caliper body ÉBleed Screw ÊPad spring ËBrake pads ÌPiston seal ÍPiston ÎBrake disc

Master cylinder cap Diaphragm Master cylinder kit Master cylinder Brake hose Holder (brake hose and meter cable) Caliper bracket Retaining bolt

¿ À Á

Â

à Ä

Å

Æ Ç

É È

Ê Ë

Î

Ì Í

6-7

FRONT BRAKE

CHAS

WARNING CAUTION: Disc brake components rarely require disassembly. DO NOT: • Disassembly components unless absolutely necessary.

• Use solvents on internal brake component.

• Allow brake fluid to come in contact with the eyes otherwise eye injury may occur.

• Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.

• Disconnect any hydraulic connection otherwise the entire system must be disassembly, drained, cleaned, and then properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

¿

NOTE : It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.

1.

Remove: • Front wheel ¿ - Refer Chapter-6 Page No. 6-2.

WARNING Securely support the motorcycle there is no danger of falling over.

¿

2.

Remove: • Clip Pins - 2 Nos ¿.

• Retaining Pin À.

3.

Remove: • Brake Pads Á.

• Pad Spring Â.

¿ À

Á

À ¿

Â

6-8

FRONT BRAKE

CHAS

NOTE: WARNING • Replace the pad spring if the pad replacement is required.

• Replace the pads as a set if either is found to be worn to the wear limit.

¿ ç

Thickness : ç New 7.4 - 7.7 mm Min - 3.8 mm 3.

Install: • Pad Spring ¿ • Brake pads À

4.

Install / Lubricate: • Retaining pin Á • Clip pin - 2 Nos. Â

À

Á Â

¿

Recommended lubricant : Lithium soap base grease ææææææææææææææææææææææææææææææææææ Installation steps: • Connect the clear plastic tube ç tightly to the caliper bleedscrew è. Then, place the other end of this hose into an open container.

• Loosen the caliper bleed screw and push the piston into the caliper by your finger.

• Tighten the caliper bleed screw.

• Install pad spring and brake pads. ææææææææææææææææææææææææææææææææææ

ç è

ç

Caliper bleed screw : 6 Nm (0.6m.kg, 4 ft.lb) 5.

6.

¿

7.

6-9

Install: • Retaining pin Inspect: • Brake fluid level ç Refer to the Brake Fluid Inspection on Chapter 3 Page No.: 3-1 ¿ “LOWER” level line.

Check: • Brake lever operation ¿ A softy or spongy feeling Ÿ Bleed brake system.

Refer to the Air Bleeding section on Chapte 3Page No.: 3-2

FRONT BRAKE / CALIPER ASSEMBLY

CHAS

CALIPER DIASSEMBLY NOTE:

À

Before disassembling the front brake caliper, drain the brake system of its brake fluid.

WARNING

¿

Securely support the motorcycle there is no danger of falling over.

Á

Á

1. Á

Remove: • Bolt ¿ • Copper Washers 2 Nos. À

NOTE: ¿ À

Place the container under the caliper to catch the standing brake fluid.

Â

2.

Disconnet: • Brake hose Á 3. Remove: • Clip pin  • Retaining pin à • Brake pads Ä • Pad spring 4. Remove • Bolts Å • Brake Caliper Body.

5. Remove: • Piston Æ • Piston seal Ç ææææææææææææææææææææææææææææææææææ

Ä

à Â

Removal steps: • Å

Blow compressed air into the Bleeding Bolt opening to force out the piston from the caliper body.

WARNING • • Ç

Never try to pull out the piston.

Cover the piston with a rag. Use care so that piston does not cause injury as it is come out from the CaIiper Body.

WARNING CAUTION: Æ

Remove the piston seal by pushing it in with finger. Do not use a screwdriver. ææææææææææææææææææææææææææææææææææ

6-10

FRONT BRAKE / MASTER CYLINDER

CHAS

MASTER CYLINDER DISASSEMBLY ¿ WARNING NOTE: Before disassembling the front brake master cylinder, drain the brake system of the brake fluid.

WARNING

Á

À

Á

¿

Securely support the motorcycle so there is no danger of it falling over.

1.

Remove: • Mirror (right) ¿ • Brake lever cover • Brake switch À

2.

Loosen: • Union bolt Á

3.

Remove: • Master cylinder ¿ • Union bolt À • Copper washer - 2 Nos. Á

Á À

NOTE: WARNING Place a container under the master cylinder to catch the standing brake fluid. ¿

À

4.

Remove • Screw ¿ • Cover master cylinder À • Diaphragm Á

5.

Remove • Bolt ¿ • Brake Lever À • Brake Lever Pin with spring, boot Á • Circlip Lock  • Master Cylinder Kit Ã

Á

¿

À

Á Ã

Â

6-11

FRONT BRAKE / NSPECTION

CHAS

INSPECTION AND REPAIR ¿

WARNING All internal parts should be cleaned in new brake fluid only. Do not use solvents will cause seals to swell and distort.

1. Á À

À

Á

Inspect: • Caliper cylinder Wear / scratches Ÿ Replace caliper assembly.

• Caliper piston À Scratches/rust/wearŸReplace caliper assembly • Caliper body Á Cracks/damage ŸReplace brake caliper assembly.

• Rubber boots • Cracks/wear/damageŸReplace • Oil delivery passage (caliper body) Â Blow out with compressed air.

WARNING Â

Replace the piston seal and dust boot whenever a caliper is disassembled.

2. Inspect : • Caliper bracket Cracks / damage ŸReplace brake caliper assembly

¿

3. Inspect : • Master cylinder ¿ Wear/ScratchesŸReplace master cylinder assembly.

• Oil delivery passage (master cylinder body) Blow out with compressed air.

¿

6-12

FRONT BRAKE / INSPECTION

CHAS

4. Inspect : • Diaphragm ¿ • Master Cylinder Kit À • Spring Á Wear/damage Ÿ Replace

Á

¿

À 5. Inspect : • Brake hoses ¿ Cracks/wear/damage ŸReplace

¿

6. Measure : • Brake pad thickness ç Out of specification ŸReplace ¿ Thickness : ç New 7.4 - 7.7 mm Min - 3.8 mm

ç

WARNING NOTE:

¿

Replace the pads ¿ as a set either if found to be worn to the wear limit.

7. Inspect : • Brake disc ¿ Galling/damage ŸReplace

¿

6-13

FRONT BRAKE / CALIPER ASSEMBLY

CHAS

9. Measure : • Brake disc deflection Out of specificationŸInspect wheel runout.

DeflectionŸreplace.

Maximum deflection 0.3 mm ¿ Dial gauge • Brake disc thickness ç Out of specification Ÿ replace.

Brake Disc thickness ç 5.0 mm <Wear Limit:3.5 mm>

ç

WARNING NOTE: Tighten the bolts (brake disc) in stage using a crissross pattern.

Bolt (brake disc): 13 Nm (1.3 m.kg, 9 ft.lb)

CALIPER ASSEMBLY

¿

WARNING •

All internal parts should be cleaned in new brake fluid only.

Brake Fluid : DOT # 3

• • À

Internal parts should be lubricated with brake fluid when installed.

Replace the piston seal and dust boot whenever a caliper is disassembled.

1. Install: • Piston seal ¿ • Piston À • Dust boot Á

WARNING NOTE: Always use new piston seal.

2. Install: • Caliper bracket  • Brake caliper body à • Bolt Ä • Brake hose • Union bolt with Copper washer

 Á

Ä Ã

Bolt (Caliper bracket): 28 Nm(2.8 m.kg., 20 ft.lb) Union Bolt: 25 Nm (2.5 m.kg., 18 ft.lb) 6-14

FRONT BRAKE / CALIPER ASSEMBLY

CHAS

WARNING • Proper hose routing is essential to insure safe motorcycle operation.

• Always use new copper washers.

3.

4.

¿

Install: • Pad spring ¿ • Brake pads À • Retaining pin Á • Clip  Fill: • Brake fluid

Brake Fluid : DOT # 3

WARNING CAUTION: À

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

WARNING • Á

Â

•

•

5.

6.

6-15

Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

Refill with the same type of brake fluid; mixing fluids may result in a harmful chemcial reaction and lead to poor performance.

Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

Air bleed: • Brake system Refer to the Air Bleeding section on Chapter-3, Page No. 3-2 Install: • Brake fluid level Refer to the Brake Fluid Inspection section on Chapter 3, Page No. 3-1

FRONT BRAKE / MASTER CYLINDER

CHAS

WARNING • All internal parts should be cleaned in new brake fluid only.

• Internal parts should be lubricated with brake fluid when installed.

Brake fluid : DOT # 3 1.

Á

¿

À

2.

Install: • Master cylinder kit ¿ • Circlip À • Brake lever with spring & Pin, Boot Á • Master cylinder Install: • Brake switch ¿ • Mirror (right) À

Bolt (master cylinder bracket) : 10 Nm(1.0 m.kg. 7.2 lbft)

À ¿ 3. Â 4.

Ã

Tighten • Bolt Á • Nut Install: • Copper washers

Á

• Brake hose  • Copper washers • Union bolt à Union bolt: 25 Nm(2.5 m.kg. - 18 lbft)

NOTE: WARNING Always use new copper washers.

WARNING Proper hose routing is essential t insure safe motorcycle operation. Refer to the Cable Routing section in the Chapter 2, Page No. 5.

6-16

Fill: • Brake fluid

FRONT BRAKE / MASTER CYLINDER

CHAS

6.

Install: • Brake system Refer to the Air Bleeding section in the Chapter 3 Page No. 3-2.

7.

Inspect: • Brake fluid level ¿

6-17

ELEC

CHAPTER 7 ELECTRICAL CIRCUIT DIAGRAM .....................................................................7-1 LOCATION OF ELECTRICAL COMPONENTS ........................... 7-2 CHECKING OF CONNECTIONS ................................................ 7-3 CHECKING OF SWITCHES ........................................................ 7-4 STARTING CIRCUIT CUT OFF SYSTEM .................................... 7-5 IGNITION SYSTEM / CHARGING SYSTEM •

CIRCUIT DIAGRAM .............................................................. 7-6

•

TROUBLE SHOOTING .......................................................... 7-7

STARTER MOTOR COMPONENTS ........................................... 7-15 REMOVAL OF STARTER MOTOR .............................................. 7-16 INSPECTION OF STARTER MOTOR .......................................... 7-16 ASSEMBLY OF STARTER MOTOR ............................................ 7-18

CIRCUIT DIAGRAM ELECTRICAL WIRING CIRCUIT

7-1

ELEC

ELEC

ELECTRICAL COMPONENTS LOCATION OF ELECTRICAL COMPONENTS ¿ À Á Â Ã Ä Å

Main Switch Horn Ignition Coil Assy.

Spark Plug Cap Stop Switch Rear Neutral Switch Assy.

Fuse

Æ Ç È É Ê Ë Ì

Battery Starter Relay Relay - A Flasher Relay Assy.

CDI Unit Assy.

Rectifier / Regulator Assy.

Throttle Position Sensor (TPS)

Ë

¿ Ê

É

Ì À

È

Á Ç

Â

Æ Ã Å

Ä

7-2

CHECKING OF CONNECTIONS

ELEC

CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect: • Connector 2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two or three.

4. Pull the lead to check that it will not come off.

5. If the terminal comes off, bend up the pin ¿ and re-insert the terminal into the connector.

Multitester:

6. Connect: • Connector NOTE: The two connectors “click” together.

7. Check for continuity with a tester.

NOTE: • If there is no continuity, clean the terminals.

• Be sure to perform the steps 1 to 7 listed above when checking the wireharness.

• For a field remedy, use a contact revitalizer available on the market.

• Use the tester on the connector as shown.

7-3

CHECKING OF SWITCHES

ELEC

CHECKING OF SWITCHES CHECKING STEPS Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch.

NOTE: • • •

Turn the switch key to the “ON” and “OFF” several times.

Set the pocket tester selector to the “Ohm x 1 Set the pocket tester to “0” before starting the test.

SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches (e.g., main switch, handlebar switch, bracket switch, lighting switch etc.)

The extreme left column indicates the switch positions and the top line indicates the colors of leads of connectes with the terminals in the switch component. ” indicates the terminals between “ which there is a continuity of electricity; i.e.,a closed circuit at the respective switch positions.

In this chart: “Br” and “R” are continuous with the “ON” switch position.

7-4

ELECTRIC STARTING SYSTEM

ELEC

STARTING CIRCUIT CUTOFF SYSTEM OPERATION Ã

Ä

¿ À Á Â Ã Ä Å Æ Ç È

Æ

 Å

Ç

Battery Fuse(main) Main Switch Kill Switch Neutral Light Switch Clutch Switch Starter Switch Relay-1 Starter Relay Starter Motor

È

Conition-1 Vehicle in Neutral Gear The main switch Á and kill switch  is set to “ON” position then Press the starter switch Å to operate the starter motor È.

Condition-2 Vehicle in Gear The main switch Á and kill switch  set “ON” position and press the clutch lever to operate the clutch switch Ä then press the starter switch Å simultaniously to operate the starter motor È.

Á À

¿

COLOUR CODE R

Red

B/L

Brown/Blue

Br

Brown

LB

Blue/Black

RW

Red/White

LW

Blue/White

Sb

Sky Blue

RB

Red/Blue

7-5

IGNITION SYSTEM / CHARGING SYSTEM

IGNITION SYSTEM, CHARGING SYSTEM AND TACHOMETER CIRCUIT

CIRCUIT DIAGRAM ¿ Magneto À Rectifier / Regulator Á Battery  Main switch à “Engine Stop” switch Ä C.D.I. unit

Å Æ Ç È É Ê Ë Ì

Ignition coil and Spark plug Fuse Starter Relay Assy.

Relay-A Clutch Switch Neutral Switch Starter Motor Starter Switch

É Å È

Ã Ä Ì

Â Ë Ç

Æ

Á

À

¿

Ê

7-6

ELEC

IGNTION SYSTEM / CHARGING SYSTEM

ELEC

IF THE IGNITION SYSTEM FAILS TO OPERATE. (NO SPARK OR INTERMITTENT SPARK) Procedure Check: 1.

Fuse 2.

Battery 3.

Spark plug 4.

Spark plug cap resistance 5.

Ignition coil resistance 6.

Main switch

7.

8.

9.

10.

11.

12.

13.

Sensor coil resistance Charging coil resistance Rectivier cum Regulator Unit Wiring connection (entire ignition system) CDI Unit Tachometer Engine stop switch

NOTE: • Remove the following parts before troubleshooting: 1) Side covers (LH/RH) 2) Saddle 3) Fuel Tank • Use the special tools specified in this troubleshooting Multemeter

1. FUSE • Remove the fuse. Ω x1) to the • Connect the pocket tester (Ω fuse.

• Check the fuse for continuity.

Refer to the Fuse inspection section in Chapter 3 Page No. 3-6.

NON CONTINUITY

Fuse is faulty, replace it.

CONTINUITY

2.BATTERY • Check the battery condition.

Voltage:12.8V Specifc gravity: 1.280 g/dm³ Electrolyte level

INCORRECT

CORRECT • Clean battery terminals.

• Recharge or replace battery.

• Refil with distilled water.

7-7

ELEC

IGNITION SYSTEM

Standard spark plug: CR7HSA/NGK 3. SPARK PLUG • Check the spark plug condition.

• Check the spark plug type.

• Check the spark plug gap.

Refer to the “SPARK PLUG INSPECTION” section in the Fazer 5YY Service Manual

OUT OF SPECIFICATION

Spark pulg gap: 0.6 ~ 0.7 mm

Adjust or replace the Spark Plug

CORRECT

Multimeter (+) lead → Multimeter (-) lead →

Spark Plug side ¿ High Tension Cord side À

4. SPARK PLUG CAP RESISTANCE • Remove the spark plug cap. Ωx1K) to the • Connect the pocket tester (Ω spark plug cap..

À

NOTE: • When removing the spark plug cap, do not pull the spark plug cap from high tension cord.

Remove → Turning counterclockwise.

Connect → Turning clockwise.

• Check the high tension cord when connecting the spark plug cap.

• When connecting the spark plug cap, cut the high tension cord about 5 mm.

¿

OUT OF SPECIFICATION

Spark pulg cap resistance: Ω ± 20% a 20o C 5 KΩ

Replace the spark plug cap.

MEETS SPECIFICATION

7-8

IGNITION SYSTEM / CHARGING SYSTEM

æ

ELEC

Multimeter (+) lead Ÿ Black/Blue Terminal ¿ Multimeter (-) lead Ÿ Green Terminal À

5A. IGNITION COIL RESISTANCE (Primary) • Disconnect the Ignition Coil Connector From the Wire harness • Connect the Multimeter to the Ignition Coil.

• Check the primary Coil resistance ¿

Primary coil resistance : 0.22 Ω ± 15 %

À

5B. IGNITION COIL RESISTANCE (Secondary) • Connect the Multimeter to the Ignition Coil • Check the secondary coil resistance

Multimeter (+) lead Ÿ High Tension lead ¿ Multimeter (-) lead Ÿ Green Terminal À

À Secondary coil resistance : Ω ± 20% (at 20 º C) 3.0 kΩ ¿

OUT OF SPECIFICATION BOTH MEET SPECIFICATIONS Ignition Coil OK

Replace the Ignition Coil

6. MAIN SWITCH • Check for Continuity of Switch ON position Multimeter (+) Multimeter (-)

R BR/L

NO CONTINUITY

• Check for ignition “ON” “OFF” position Replace the Main Switch CONTINUITY Main Switch OK

7-9

ELEC

IGNITION SYSTEM/ CHARGING SYSTEM

Mutimeter (+) lead ŸWhite/Blue terminal ¿ Multimeter (-) lead Ÿ Earth À

7. SENSOR COIL RESISTANCE • Disconnect the sensor Coil Coupler from the Wiring Harness • Connect the Multimeter (Ω X 100) to the sensor coil coupler • Check the sensor coil resistance

Sensor coil resistance : 240 Ω ± 20 % (at 20ºC)

À

¿

OUT OF SPECIFICATION

MEETS SPECIFICATION Sensor coil is OK

Replace the Sensor Coil Assembly

8. CHARGING COIL RESISTANCE

Multimeter (+) lead Ÿ White Terminal ¿ Multimeter (-) lead Ÿ Black Terminal À

• Remove the Charging Coil coupler from the Wire Harness • Connect the Multimeter to the charging coil • Measure the charging coil resistance

À

¿

Charging coil resistance 0.75 Ω ± 20 % (at 20ºC) OUT OF SPECIFICATION MEETS SPECIFICATIONS Replace the Charging CoiL

Charging coil is OK

æ

7-10

IGNITION SYSTEM / CHARGING SYSTEM

ELEC

æ Multimeter (+) lead Ÿ Battery (+) terminal ¿ Multimeter (-) lead Ÿ Battery (-) terminal À

9. RECTIFIER CUM REGULATOR UNIT • Check the Charging Voltage Procedure Steps • Connect the Tachometer to Spark plug lead • Connect the Multimeter ( DC 20V) to Battery Red Wire.

Measure the Battery Voltage : 12.8 V If less than specifications, charge the Battery • Start the engine and accelearte the Engine up to 5000 RPM .

• Check the Charging voltage : Charging voltage : 14 ~ 15 V at 5000RPM

À ¿

MEETS SPECIFICATIONS

OUT OF SPECIFICATION Rectifier cum Regulator unit is faulty.

• Replace RR unit

Charging Circuit and Rectifier cum Regulator are OK

10. WIRING CONNECTIONS • Check the connection for entire Ignition and Charging System “REFER TO CIRCUIT DIAGRAM” Page 7-6 POOR CONNECTIONS IF CORRECT Repair/ Replace the Harness

11. CDI UNIT • Check CDI unit “REFER IGNITION TIMING PROCEDURE Chapter 3, Page 5YY1 - FAZER SERVICE MANUAL

IF NOT WORKING 12. TACHOMETER • Check Tachometer Operation and entire connection

Replace Tachometer

7-11

IGNITION SYSTEM / CHARGING SYSTEM

ELEC

13. ENGINE STOP SWITCH • Check the Engine Stop Switch for continuity.

• Is the Engine Stop Switch OK?

YES

NO Replace the Right Handlebar Switch

TROUBLE SHOOTING The Starter motor fails to turn ON. Check: 1. Main fuse 2. Battery 3. Starter motor 4. Relay -A 5. Starter relay 6. Main switch 7. Engine Stop switch 8. Starter Switch 9. Wiring connections (Entire starting system)

NOTE: • Before troubleshooting, remove the following part(s): 1. Side panel (LH/RH) 2. Saddle 3. Fuel Tank • Troubleshoot with the following special tools(s)

1. FUSE • Check the fuse for continuity.

Refer to Fuse inspection section in Chapter-3 Page No. 3-6.

YES

NO Replace the fuse

2. BATTERY • Check the condition of the battery.

Refer to Checking and charging the battery in chapter 3 Page No. 3-4.

Minimum open-circuit voltae : 12.8V or more at 20o C • Is the battery OK?

Multemeter :

YES

NO • Clean the battery terminals.

• Recharge or replace the battery.

7-12

IGNITION SYSTEM / CHARGING SYSTEM

ELEC

4. RELAY - A • Disconnect the Relay-A coupler from the wire harness. Ω x 1) and • Connect the pocket tester (Ω battery (12 V) to the Relay-A coupler as shown.

3. STARTER MOTOR • Connect the positive battery terminal ¿ and starter motor lead À with a jumper lead Á.

Positive Battery Terminal Ÿ blue/black ¿ Negative Battery Terminal Ÿ red/black À Multimeter (+) Ÿ Multimeter (-) Ÿ

blue/black Á red/white Â

RW RB

WARNING LB SB • A wire that is used as a jumper lead must have atleast the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.

• This check is likely to produce sparks, therefore, make sure nothing flammable is in the vicinity.

• Does the Relay-A have continuity between blue/black and red/white

• Does the starter motor turn?

YES

YES

NO Replace the Relay-A

NO Repair or replace the starter motor.

5. STARTER RELAY • Disconnect the starter relay coupler from the harness. Ω x 1) and battery • Connect the Multimeter (Ω (12 V) to the starter relay coupler as shown.

Positive Battery Terminal Ÿ blue/white ¿ Negative Battery Terminal Ÿ red/white À Multimeter (+) Ÿ Multimeter (-) Ÿ

7-13

red Á red Â

ELEC IGNITION SYSTEM / CHARGING SYSTEM 8. START SWITCH • Check the Start Switch for continuity.

• Is the Start Switch OK?

YES

Replace the Right Handlebar Switch

• Does the starter relay have continuity between red Á and red  ?

YES

NO

NO Replace the starter relay.

6. MAIN SWITCH • Check the main switch for continuity.

Refer to Fazer 5YY1 Service Manual • Is the Main Switch OK?

YES

9. WIRING • Check the entire starting system’s wiring.

Refer to “CIRCUIT DIAGRAM”. Page 7-6.

• Is the starting system’s wiring properly connected and without defects?

YES

NO

The starting system circuit is OK.

Replace the Main Switch.

7. ENGINE STOP SWITCH • Check the Engine Stop Switch for continuity.

• Is the Engine Stop Switch OK?

YES

NO Replace the Right Handlebar Switch

7-14

NO Properly connect or repair/replace the Wiring Harness.

ELEC

STARTER MOTOR COMPONENTS ¿ À Á Â Ã Ä Å

Starter motor assembly Rear bracket Brush set O-ring Yoke Armature Shim

Æ Ç È É Ê Ë

Oil Seal Bearing Front bracket O-ring Bolt Harness

1

6 7

8

9 4 12

10 11

2

3

4 5

13

7-15

STARTER MOTOR

ELEC

REMOVAL 1. Remove • Starter Motor lead ¿ À

Á

2. Remove • Bolts À • Starter Motor Á

¿

Á

¿

Â

DISASSEMBLY 1. Put identifying marks on the brackets for reassembly.

Ã

2. Remove: • Bolts - 2 Nos. ¿ • Front bracket À • Shim Á • Washer Â

À Å

Ä

3. Remove: • Armature à • Yoke Ä • Rear bracket Å

¿

4. Remove: • Screw - 2 Nos ¿ • Brush spring set À À

INSPECTION AND REPAIR 1. Inspect: • Commutator ¿ Dirty Ÿ Clean ith with # 600 grit sandpaper.

2. Measure: • Commutator diameter ç Out of specification Ÿ Replace starter motor

¿

Commutator wear limit : 21 mm

ç

7-16

STARTER MOTOR

ELEC

3. Measure: • Mica undercut ç Out of specification Ÿ Scrape the mica to proper value use a hacksaw blade can be ground to fit.

Mica Undercut 0.7 mm

4. Inspect: • Armature coil (insulation/continuity) Defects Ÿ Replace starte motor. ææææææææææææææææææææææææææææææææææ Inspecting steps : • Connect the Multimeter for continuity check ¿ and insulation check À.

• Measure the armature resistances.

• If the resistance is incorect, replace the starter motor.

Armature coil resistance: Continuity check ¿: 0.017 ~ 0.021 Ω at 20oC Insulation check À: More than 1 M Ω at 20oC

ææææææææææææææææææææææææææææææææææ 5. Armature Insulation Test Use 110 Volts AC mains and a 15W bulb with two probes and check as shown in figure. Bulb must not glow when the probes are connected between any one of the commutator segments and Armature core. If the bulb glows the fault is with the insulation.

NOTE: The brush dust in the armature should be throughly cleaned before this test.

7-17

STARTER MOTOR ç

ELEC

6. Measure: • Brush length ç Out of specification Ÿ Replace as a set Brush length limit : New Length - 7 mm Minimum Length - 3 mm

NOTE: When replacing the brush, take care as one side soldered.

7. Measure: • Brush spring force Fatigue/Out of specification Ÿ Replace as a set.

Brush spring force: 560 ~ 840 g

¿

À

Â

Á

8. Inspect: • Bearing ¿ • Oil Seal À • Bush Á Damage ŸReplace the bracket.

• O-Ring  Wear/damageŸReplace

ASSEMBLY Reverse the “REMOVAL”procedure.

1. Install: • Brush springs ¿ • Brush set À

¿

À

7-18

STARTER MOTOR

ELEC

2. Install: • Screw ¿ • Nut À ¿

À

3. Install: • Armature ¿

NOTE: When installing the brush, pass the brush lead outside of the projection on the brush spring holder. During installing the brush, install the brush lead terminal to the projection on the side of brush spring holder.

¿

NOTE: When installing the armature, press the brush with thin screwdriver, etc. to avoid damage to the brush and install.

3. Install: • O-ring

CAUTION: Always use O-rings.

¿

4. Install: • Yoke ¿

NOTE: Align the match mark on the yoke with the match mark on the rear bracket.

7-19

STARTER MOTOR À

Â

¿

ELEC

5. Install • Washer ¿ • Shim À • Front bracket Á • Bolt 2 Nos - Â

Á NOTE: • Align the projection of the washer with the slot of the front bracket and install.

• Align the match mark ç on to yoke with the match mark è on the front bracket.

Bolt : 5 Nm (0.5 m.kg. --- lbft)

INSTALLATION 1. Install: • Starter motor - ¿

ç

NOTE: Apply a lightly grease to the O-ring.

è

¿

À

2. Install: • Starter motor bolts À • Starter motor lead Á Bolt (Starter Motor) : 7 Nm (0.7 m.kg.)

Á

7-20

TRBL SHTG

CHAPTER 8 TROUBLE SHOOTING

BRAKE ........................................................................................8-1 •

NOISY

•

POOR BRAKE EFFICIENCY

•

PADS NOT RETURN TO ORIGINAL POSITION

STARTER MOTOR ...................................................................... 8-2 •

NOT WORKING

•

MOVEMENT SLOW

•

DO NOT ROTATE ENGINE EFFICTIVELY

STARTING FAILURE / HARD STARTING

TRBL SHTG

NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection, adjustment and replacement of parts.

BRAKE BRAKE NOISY •

Glazed brake pads

•

Excessive brake disc run out

•

Barke caliper incorrectly installed

•

Pad Worn out.

BRAKE PADS NOT ORIGINAL POSITION

POOR BRAKE EFICIENCY •

Low level of Brake Fluid.

•

Leakage of Brake fluid thru hose pipe & joints.

•

Oily Brake Disc.

•

Leakage of Brake fluid due to damaged seal position & seal wiper (Brake Caliper).

•

Air entrapped in the system.

•

Damaged Primary Cup / O-ring (Master Cylinder)

•

Blocked-Air Vent, Return Port, Intake Port and Cylinder Outlet (Master Cylinder).

•

Excessive free play at Brake lever.

•

Improper grde of Brake fluid.

•

Worn out pads.

•

Pistons (Brake caliper) - Movement Sticky

•

Glazed Pads.

8-1

RETURN

TO

•

Week Return Spring (Master Cylinder).

•

Blocked-Vent Hole / Return Port / cylinder Outlet / Inlet Port (Master Cylinder).

•

Piston (Master Cylinder) movement sticky.

POOR IDLE SPEED PERFORMANCE

TRBL SHTG

STARTER MOTOR STARTER MOTOR NOT WORKING •

Battery discharged

•

Fuse blown off

•

Main switch defective

•

Kill switch defective

•

Start switch defective

•

Neutral switch defective

•

Clutch switch defective (if engine is in gear)

•

Relay-A defective

•

Starter Relay - defective

•

Starter motor defective

•

Improper earthing / loose connections

STARTER MOTOR DO NOT ROTATE ENGINE EFFECTIVELY •

Teeth damaged -

Gear Idle-1

-

Gear Idle-2

-

Motor shaft

•

Crank shaft rotation sticky

•

Battery not fully charged

•

Carbon deposite in switches -

Main Switch

-

Kill Switch

-

Start Switch

STARTER MOTOR MOVEMENT-SLOW

-

Neutral Switch

•

Battery not fully charged

-

Clutch Switch

•

Carbon deposite in switches •

Motor defective

-

Main Switch

-

Kill Switch

-

Carbon bushes worn out

-

Start Switch

-

Motor-shot

-

Neutral Switch

-

Armature weak

-

Clutch Switch

-

Damaged bearing/bush

•

Motor defective

•

Carbon bushes worn out Motor-shot Armature weak Damaged bearing/bush Improper earthing / loose connections

•

8-2

Improper earthing / loose connections

YAMAHA MOTOR INDIA PVT. LIMITED 19/6, Mathura Road, Faridabad - 121 006 INDIA PRINTED IN INDIA 5YY (FAZER) 1Y16(WM-01)-213-03-05-E

SUPPLIMNTARY SERVICE MANUAL

E SP

IN

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