Yamaha RXZ135 2001 SP PDF [PDF]

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2002



RX Z SUPPLEMENTARY SERVICE MANUAL 55K-F8197-E1



FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the RXZ (2002). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.



RX-Z (’85) SERVICE MANUAL: 55K-28197-W0



RX-Z (2002) SUPPLEMENTARY SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. First Edition, December 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.



NOTICE This manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so persons using this book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.



HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation.



NOTE:



A NOTE provides key information to make procedures easier or clearer.



cC



A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.



fWARNING:



A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle.



PARTICULARLY IMPORTANT INFORMATION All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this reversed format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 8 Bearings Pitting/Damage → Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.



1



ILLUSTRATED SYMBOLS (Refer to the illustration)



2



GEN INFO



INSP ADJ



3



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



4



ENG



1 2 3 4 5 6 7 8



COOL



5



6



CARB



CHAS



7



8



ELEC



APPX



9



0



q



w



e



r



y



u



i



o



p LS



a LT



Illustrated symbols 9 to r are used to identify the specifications appearing in the text. 9 Filling fluid 0 Lubricant q Tightening w Wear limit, clearance e Engine speed r Ω, V, A



t



B



General information Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Appendices



Illustrated symbols t to a in the exploded diagrams indicate the types of lubricants and lubrication points.



M



t Apply engine oil y Apply gear oil u Apply molybdenum disulfide oil i Apply wheel bearing grease o Apply lightweight lithium-soap base grease p Apply molybdenum disulfide grease a Apply locking agent (LOCTITE®)



CONTENTS GENERAL INFORMATION .......................................................................1 MOTORCYCLE IDENTIFICATION ..............................................................1 FRAME SERIAL NUMBER.....................................................................1 ENGINE SERIAL NUMBER ...................................................................1



PERIODIC INSPECTIONS AND ADJUSTMENT................................2 PERIODIC MAINTENANCE/LUBRICATION...............................................2



CHASSIS ........................................................................................................6 REAR WHEEL .............................................................................................6 FRONT FORK..............................................................................................7 HANDLEBARS ............................................................................................8 INSTALLATION.......................................................................................9 STEERING HEAD......................................................................................11 REAR SHOCK ABSORBER AND SWINGARM .......................................12



APPENDICES .............................................................................................13 SPECIFICATIONS .....................................................................................13 GENERAL SPECIFICATIONS...................................................................13 MAINTENANCE SPECIFICATIONS..........................................................14 ENGINE................................................................................................14 TIGHTENING TORQUE .......................................................................15 CHASSIS..............................................................................................16 TIGHTENING TORQUE .......................................................................16 ELECTRICAL .......................................................................................17



MOTORCYCLE IDENTIFICATION



GEN INFO



GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is stamped into the steering head pipe.



1



ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right rear section of the engine.



1



NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.



Starting Serial Number: 5PV-000101



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



–1–



INSP ADJ



PERIODIC MAINTENANCE/LUBRICATION



PERIODIC INSPECTIONS AND ADJUSTMENT PERIODIC MAINTENANCE/LUBRICATION EVERY No.



ITEM



CHECKS AND MAINTENANCE JOBS



1 * Fuel line



9 Check fuel hoses for cracks or damage. 9 Replace if necessary.



2



Spark plug



9 Check condition. 9 Clean, regap or replace if necessary.



3



Air filter



Initial (1,000 km)



6,000 km or 6 months (Whichever comes first)



12,000 km or 12 months (Whichever comes first)



√



√



√



√



9 Clean or replace if necessary.



√



√



4 * Battery



9 Check electrolyte level and specific gravity. 9 Correct or recharge if necessary. 9 Make sure that the breather hose is properly routed.



√



√



5



9 Check operation. 9 Adjust or replace cable.



√



√



√



6 * Front brake



9 Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-5.) 9 Correct accordingly. 9 Replace brake pads if necessary.



√



√



√



7 * Rear brake



9 Check operation. 9 Adjust cable and replace brake shoes if necessary.



√



√



√



8 * Wheels



9 Check balance, runout, spoke tightness and for damage. 9 Tighten spokes and rebalance, replace if necessary.



√



√



9 * Tires



9 Check tread depth and for damage. 9 Replace if necessary. 9 Check air pressure. 9 Correct if necessary.



√



√



10 * Wheel bearings



9 Check bearing for looseness or damage. 9 Replace if necessary.



√



√



11 * Swingarm



9 Check swingarm pivoting point for play. 9 Correct if necessary. 9 Lubricate with lithium soap based grease.



√



√



12



Drive chain



9 Check chain slack. 9 Adjust if necessary. Make sure that the rear wheel is properly aligned. 9 Clean and lubricate.



Every 500 km and after washing the motorcycle or riding in the rain



13 * Steering bearings



9 Check bearing play and steering for roughness. 9 Correct accordingly. 9 Lubricate with lithium soap based grease every 24,000 km or 24 months (whichever comes first).



√



√



14 * Chassis fasteners



9 Make sure that all nuts, bolts and screws are properly tightened. 9 Tighten if necessary.



√



√



15



9 Check operation. 9 Lubricate and repair if necessary.



√



√



9 Check operation and for oil leakage. 9 Correct accordingly.



√



√



9 Check operation and shock absorbers for oil leakage. 9 Replace shock absorber assembly if necessary.



√



√



Clutch



Sidestand/centerstand



16 * Front fork 17 *



Rear shock absorber assemblies



√



18 * Carburetor



9 Check engine idling speed and starter operation. 9 Adjust if necessary.



√



√



√



19 * Autolube pump



9 Check operation. 9 Correct if necessary. 9 Bleed if necessary.



√



√



√



20



9 Check oil level and vehicle for oil leakage. 9 Correct accordingly. 9 Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first).



√



√



√



Transmission oil



*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.



–2–



PERIODIC MAINTENANCE/LUBRICATION



INSP ADJ



NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Brake fluid replacement 1. When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. 2. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 3. Replace the brake hoses every four years or if cracked or damaged.



–3–



INSP ADJ



PERIODIC MAINTENANCE/LUBRICATION



q q



1 5 ~ 8 mm (0.2 ~ 0.3 in)



1 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)



1 20 ~ 30 mm (0.8 ~ 1.2 in)



q



1 0.30 ~ 0.35 mm (0.012 ~ 0.014 in)



q



–4–



PERIODIC MAINTENANCE/LUBRICATION



INSP ADJ



1 2 ~ 3 mm (0.08 ~ 0.12 in)



q



q



1 Front = 175 kPa (1.75 kg/cm2, 25 psi) Rear = 200 kPa (2.0 kg/cm2, 28 psi)



1 20 ~ 30 mm (0.8 ~ 1.2 in)



q



–5–



CHAS



REAR WHEEL



CHASSIS REAR WHEEL 1 2 3 4 5 6 7 8 9



0 q w e r t y u i



Chain puller Stopper Cam lever Wear indicator Spacer collar Tension bar Brake lining plate Brake cam shaft Brake lining



o p a s



Oil seal Bearing Spacer flange Bearing spacer Bearing Damper Sprocket shaft Sprocket hub Driven sprocket



10 Nm (1.0 kg•m,7.2 ft•lb)



Drive chain Bearing Oil seal Collar



4



TIRE SIZE: 90/90 - 18 51P



B



3



C RIM SIZE: 1.40 X 18



2 1



LINING WEAR LIMIT: 2.0 mm (0.08 in)



D LS



A USE NEW ONE



20 Nm (2.0 kg•m,14 ft•lb) 5 8 7 6



LS



9



A USE NEW ONE



20 Nm (2.0 kg•m,14 ft•lb)



0 q B6202 w e



r B6202Z LS



t



y



u



i



o



B6202Z p a



E



RIM RUNOUT LIMIT:



F



VERTICAL: 2.0 mm (0.078 in)



s



G LATERAL: 2.0 mm (0.078 in) LS



26 Nm (2.6 kg•m,19 ft•lb) H



DRIVE CHAIN FREE PLAY: 20 ~ 30 mm (0.8 ~ 1.2 in)



–6–



85 Nm (8.5 kg•m,61 ft•lb)



FRONT FORK



CHAS



FRONT FORK 1 2 3 4 5 6 7



Rubber cap Cap bolt O-ring Spacer Washer Fork spring Rebound spring



8 9 0 q w e r



t Slide metal y Outer tube u Damper rod bolt



Damper rod Inner tube Oil lock piece Dust seal Retaining clip Oil seal Plate washer



23 Nm (2.3 kg•m,17 ft•lb)



1 2 3 4 5 6



7 8



30 Nm (3.0 kg•m,22 ft•lb)



q w e r t 9



y



A



FORK OIL CAPACITY (EACH FORK): 165 cm3 (5.82 Imp oz, 5.78 US oz)



B



RECOMENDED OIL: SAE 10W30 TYPE SE MOTOR OIL



C



FORK SPRING MINIMUM LENGTH: 428.1 mm (16.9 in)



0 u 23 Nm (2.3 kg•m,17 ft•lb)



–7–



CHAS



HANDLEBARS



HANDLEBARS 1 2 3 4



5 Handlebar (right) 6 Throttle and oil pump cable assembly 7 Adjuster



Handlebar grip end Grip rubber Leaf ring Throttle guide tube



8 9 0 q



Locknut Clutch cable Handlebar (left) Collar



25 Nm (2.5 kg•m,18 ft•lb) 1 2



3



9 Nm (0.9 kg•m,6.5 ft•lb)



4 LS



5 0 q 2



6



7



8 LS



20 Nm (2.0 kg•m,14 ft•lb)



9



–8–



HANDLEBARS



CHAS



INSTALLATION 1. Install: 9 Handlebars



4



2



3



2. 9 9 9 9



1



Install: Lever holder 1 (left) Handlebar grip 2 (left) Handlebar switch 3 (left) Handlebar grip end 4 (left)



Left handlebar install steps: 8Install the lever holder 1 to the handlebar. Bolt (lever holder): 6.5 Nm (0.65 m•kg, 4.7 ft•lb) 8Apply a light coat of an adhesive for rubber to the handlebar. 8Fit the handlebar grip fully over the handlebar end. NOTE: Wipe off the excess adhesive with the clean rag.



1



:WARNING: Leave the handlebar intact until the adhesive becomes dry enough to make the grip and handlebar stuck securely. 8Install the handlebar grip end (left). Handlebar grip end: 25 Nm (2.5 m•kg, 18 ft•lb) 8Install the handlebar switch (left).



–9–



CHAS



HANDLEBARS 3. 9 9 9



Install: Handlebar grip (right) Throttle cable Handlebar switch (right)



NOTE: Before installing the handlebar grip (right), apply a light coat of lithium - soap base grease onto the handlebar end.



:WARNING: Provide the clearance of 1 mm (0.04 in) between the handlebar grip 1 and the handlebar grip end 2. Otherwise, the grip may not move. 2 1



4. Tighten: 9 Handlebar grip end (right) Handlebar grip end: 25 Nm (2.5 m•kg, 18 ft•lb) 9 Front brake master cylinder Bolt (master cylinder bracket): 23 Nm (2.3 m•kg, 17 ft•lb)



5. Install: 9 Clutch cable NOTE: Apply a light coat of lithium - soap base grease onto the clutch cable end.



6. Adjust: 9 Clutch cable free play Refer to the “CLUTCH ADJUSTMENT”.



–10–



CHAS



STEERING HEAD STEERING HEAD 1 2 3 4 5 6 7



Stem nut Handle crown Ring nut Ball race cover Ball race (lower - top) Balls Ball race (upper - bottom)



8 9 0 q



Ball race (lower - top) Balls Ball race (lower - bottom) Under bracket



40 Nm (4.0 kg•m,29 ft•lb) 2 1



25 Nm (2.5 kg•m,18 ft•lb)



38 Nm (3.8 kg•m,27 ft•lb)



3 4



LS



5 6 7 8 9



LS



q



0



–11–



CHAS



REAR SHOCK ABSORBER AND SWINGARM



REAR SHOCK ABSORBER AND SWINGARM 1 2 3 4 5



6 7 8 9 0



Chain adjuster Chain adjuster Chain guard Shock absorber Swingarm



Thrust cover Bearing Collar Oil seal Nipple



A SWING ARM FREE PLAY LIMIT: B END: 1.0 mm (0.04 in) C SIDE: 1.0 mm (0.04 in)



3



40 Nm (4.0 kg•m,29 ft•lb) 2 1



4 5



LS LS



0



6



7 8



40 Nm (4.0 kg•m,29 ft•lb)



9 6 LS



7



0 LS



8



43 Nm (4.3 kg•m,31 ft•lb)



7 6



–12–



SPECIFICATIONS



APPX



APPENDICES SPECIFICATIONS GENERAL SPECIFICATIONS RX-Z



Model Model Code Number:



5PV



Frame and Engine Starting Serial Number:



5PV-000101



Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance



1,990 mm (78.3 in) 725 mm (28.5 in) 1,160 mm (45.7 in) 770 mm (30.3 in) 1,300 mm (51.2 in) 175 mm ( 6.9 in)



Basic weight: With Oil and Full Fuel Tank



118 kg (261 lb)



Spark plug: Type/Manufacturer Gap Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Gear Ratio 1st 2nd 3nd 4th 5th 6th



BR9ES/NGK 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Herical gear 71/22 (3.227) Chain drive 46/16 (2.875) Constant mesh, 6-Speed Left foot operation 34/12 (2.833) 29/16 (1.813) 26/19 (1.368) 24/21 (1.143) 23/23 (1.000) 22/24 (0.917)



Electrical: Ignition System Generator System Battery Type or Model Battery Capacity



C.D.I. A.C. Magneto YB3L-B 12V, 3AH



Bulb Wattage/Quantity: Headlight Tail/Brake Light Flasher Light Meter Light



12V 35W/30W x 1 12V 5W/21W x 1 12V 10W x 4 12V 1.7W x 3



–13–



APPX



SPECIFICATIONS Model



Indicator Light Wattage/Quantity: “NEUTRAL” “HIGH BEAM” “OIL” “TURN”



RX-Z 14V 3W x 1 14V 3W x 1 14V 3W x 1 14V 3W x 1



MAINTENANCE SPECIFICATIONS ENGINE RX-Z



Model Piston: Piston size “D”/Measuring Point ”H”



55.964 ~ 55.986 mm (2.203 ~ 2.204 in)/ 10 mm (0.41 in)



Piston Clearance



0.034 ~ 0.036 mm (0.00134 ~ 0.00142 in)



Piston Offset



0.5 mm (0.02 in) “IN” side



Carburtor: Type/Manufacturer/Quantity I.D. Mark Main Jet (M.J.) Main Air Jet (M.A.J.) Jet Needle-clip position (J.N.) Needle Jet (N.J.) Pilot Jet (P.J.) Pilot Air Screw (P.A.S.) Float Height (F.H.) Fuel Level (F.L.) Engine Idling Speed



VM26SS/MIKUNI/1 5PV1 00 # 195 ø 0.5 5FHE5-2 O-8M # 22.5 1 and 1/4 21.0 ± 1.0mm (0.2 in) 0.5 mm (0.02 in) (above the carburetor body edge) 1,250 ~ 1,350 r/min



Reed Valve: Thickness* Valve Stopper Height Valve Bending Limit



0.42 mm (0.017 in) 10.0 ~ 10.6 mm (0.39 ~ 0.42 in) 0.8 mm (0.031 in)



–14–



APPX



SPECIFICATIONS RX-Z



Model Lubrication System: Autolube Pump: Color Code Minimum Stroke Maximum Stroke Minimum Output/200 Stroke



White 0.30 ~ 0.35 mm (0.012 ~ 0.014 in) 1.85 ~ 2.05 mm (0.073 ~ 0.081 in) 0.76 ~ 0.90 cm3 (0.027 ~ 0.032 Imp oz, 0.062 ~ 0.030 US oz) 4.65 ~ 5.15 cm3 (0.163 ~ 0.180 Imp oz, 0.158 ~ 0.175 US oz) Square Mark



Maximum Output/200 Stroke Adjusting mark (at idle)



TIGHTENING TORQUE Part to be Tightened Spark Plug Reed Valve Exhaust Pipe Drain Plug Push Rod #1 Bearing Cover Plate Tachometer Housing Stopper Lever C.D.I. Magneto



Part Name



Bolt Stud bolt Bolt Nut Screw Bolt Bolt Nut



Tightening Torque Thread Q'ty Size Nm m•kg ft•lb M14 M6 M8 M12 M6 M6 M6 M6 M12



–15–



1 4 2 2 1 2 1 1 1



25 10 7 20 7 7 5 10 83



2.5 1.0 0.7 2.0 0.7 0.7 0.5 1.0 8.3



18 7.2 5.1 14 5.1 5.1 3.6 7.2 60



Remarks



APPX



SPECIFICATIONS



CHASSIS Model Front Suspension: Front Fork Travel Front Spring Free Length



Spring rate/Stroke



Optional Spring Oil Capacity Oil Level



Oil Grade



RX-Z 140 mm (5.51 in) 432.4 mm (17.0 in)



K1 = 7.4 N/mm (0.75 kg/mm, 42.0 lb/in) 0 ~ 120 mm (0 ~ 4.72 in) K2 = 10.8 N/mm (1.1 kg/mm, 61.6 lb/in) 120~155 mm (4.72 ~ 6.1 in) No 165 cm3 (5.82 Imp oz, 5.78 US oz) 165 mm (6.5 in) (From top of inner tube fully compressed without spring) Fork oil 10W or equivalent



TIGHTENING TORQUE Tightening Torque Part to be Tightened



Thread Size Q'ty



Remarks Nm m•kg ft•lb



Engine Mounting: Front Rear Rear Arm and Frame Handle Crown and Inner Tube Under Bracket and Inner Tube Master Cylinder and Brake Hose Brake Hose and Brake Caliper Footrest Bracket and Frame Footrest Bracket and Rear Bracket Front Hub and Front Disk Handle Crown and Main Switch Handlebar and Inner Tube Handlebar and Handle Crown End Grip and Handlebar Side Stand and Frame: Bolt Nut



M8 M8 M12 M8 M8 M10 M10 M10 M10 M8 M6 M8 M6 M16



1 1 1 4 4 1 1 4 2 4 2 2 2 2



30 25 43 25 30 26 26 43 43 23 13 20 9 25



3.0 2.5 4.3 2.5 3.0 2.6 2.6 4.3 4.3 2.3 1.3 2.0 0.9 2.5



22 18 31 18 22 19 19 31 31 17 10 14 6.5 18



M10 M10



1 1



23 40



2.3 4.0



17 29



–16–



SPECIFICATIONS



APPX



ELECTRICAL RX-Z



Model Ignition System: Ignition Timing (B.T.D.C.) Advancer Type



14° at 1,500 r/min Digital



C.D.I.: Magneto-Model/Manufacturer Pickup Coil Resistance/Color Source Coil Resistance/Color C.D.I. Unit-Model/Manufacturer



F5PV/YAMAHA 310 Ω ± 10 % at 20°C (68°F) / W/L - W/R 860 Ω ± 10 % at 20°C (68°F) / G/W - B/R 5PV/YAMAHA



Ignition coil: Model/Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance



4BE/YAMAHA 6mm (0.24 in) at 1,300 r/min 0.23 Ω ± 20 % at 20°C (68°F) 7.9 kΩ ± 20 % at 20°C (68°F)



Charging System: Type Charging Current



C.D.I. Magneto



Charging Current (A)



Ich (A) 4 3



Ich



2 1 0



2



4



6



8



10



Engine Speed ( x 103 r/min)



Charging Coil Resistance (Color) Lighting Coil Resistance (Color)



0.4 Ω ± 20 % at 20°C (68°F) / B-W 0.3 Ω ± 20 % at 20°C (68°F) / Y/R - B



–17–



APPX



SPECIFICATIONS Model



Rectifier Regulator: Model/Manufacture No Load Regulated Voltage Capacity



RX-Z



(Charging) (Lighting) (Charging) (Lighting)



SH671 - 12/SHINDENGEN 14.0~15.0 V Less than 13.3 V 8A 12 A



Battery: Capacity Specific Gravity



12 V, 3 AH 1.260



Horn: Type/Quantity Model/Manufacturer Maximum Amperage



Plain type/1 5PV/NIKKO 5A



Oil Level Switch: Model/Manufacturer



3FY/STANLEY



Circuit Breaker: Type Amperage for Individual/Quantity Main Reserve



Fuse 7Ax1 7Ax1



–18–



RX-Z (2002) WIRING DIAGRAM



1



B/R



B



Or



W/R



B/W W/L



G/W B/W



B Br R



Br B R



LOCK OFF ON



B/W



W/L W/R



W Sb Y/R B



Sb W B Y/R



W/R W/L G/W B/R



B/R G/W



B/W



q



B/W Or



Br R B R



R



7



W B R Y/R



2



B/W



W



W



Y/R



Y/R



8



B



A B



9



Sb



P Br



P Br



MAIN HARNESS



B



4



w



B



B



RUN OFF



3



0



B



5 6



R



W/L W/R G/W B/R



W/L W/R G/W B/R



SUB HARNESS



B



Br



s



Br A Br



L



Br



y



t



Br Dg Ch



G B L



Sb B/R Br



Dg Ch



P Br/W Br



Sb B/R Br



G B L



g



j k



f



u



d



h B/R



l



G



L



o



HI LO



Dg Sb



Y/R



L



i



Ch



B



P A P



OFF ON



p



a



OFF PUSH



L N R



B G B



G B



Y



Y/R L B P



G



Dg Ch Br/W



L Y/R P B



Dg Ch Br/W



Y G



Dg



Ch



G/Y



B



e



Dg



Dg



Dg



Ch



Ch



G/Y G/Y L



Y



Ch



B Y G



B Ch Dg Y G



Sb Y G B



m



B Sb B/R



B



G/Y



;



B Sb B/R



Br



r



B



Sb



Br



Br/W



Y G



Y



Br



Y G B



n



Ch B Dg G Y



Ch



cx



z B



B B



B



Dg



Ch



b



v



COLOR CODE B...................Black Br .................Brown Ch ................Chocolate Dg ................Dark green G ..................Green L ...................Blue O ..................Orange



P...................Pink R ..................Red Sb.................Sky blue W..................White Y...................Yellow B/R ...............Black/Red B/W ..............Black/White



Br/W .............Brown/White G/W..............Green/White G/Y...............Green/Yellow W/L...............White/Blue W/R ..............White/Red Y/R ...............Yellow/Red



L G/Y Dg



L G/Y Dg



B



Ch



1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b n m



Main switch Fuse Battery Ground lead Handlebar switch (right) Engine stop switch Rectifier/Regulator C.D.I. Magneto Neutral switch C.D.I. Unit Ignition coil Spark plug Rear brake switch Front brake switch Turn signal relay Horn Handlebar switch (left) “LIGHTS” dimmer switch “PASS” switch “HORN” switch “TURN” signal switch Meter ass’y “TURN” signal indicator light “HI BEAM” indicator light Meter light “FUEL” meter “OIL” warning indicator light “NEUTRAL” indicator light Fuel sender Oil level gauge Tail/Brake light Rear turn signal light (right) Rear turn signal light (left) Front turn signal light (left) Front turn signal light (right) Sub lead wire Headlight



YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN