CHAPTER 4
ENGINE
SEAT, FUEL TANK AND SIDE
COVERS.....................................................4-1
EXHAUST PIPE AND SILENCER..............4-3
RADIATOR..................................................4-4
CARBURETOR AND REED VALVE...........4-7
CYLINDER HEAD , CYLINDER AND
PISTON.....................................................4-17
CLUTCH AND PRIMARY DRIVEN
GEAR.......................................................4-30
KICK AXLE, SHIFT SHAFT AND
PRIMARY DRIVE GEAR...........................4-37
YPVS GOVERNOR...................................4-45
WATER PUMP..........................................4-48
CDI MAGNETO.........................................4-52
ENGINE REMOVAL..................................4-56
CRANKCASE AND CRANKSHAFT.........4-61
TRANSMISSION, SHIFT CAM AND
SHIFT FORK.............................................4-69
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL........5-1
FRONT BRAKE AND REAR BRAKE.......5-10
FRONT FORK...........................................5-26
HANDLEBAR............................................5-42
STEERING................................................5-50
SWINGARM..............................................5-55
REAR SHOCK ABSORBER.....................5-63
1C3-9-32-0 4/28/06 9:45 AM Page 20
2-4
SPECMAINTENANCE SPECIFICATIONS
Item Standard Limit
Transmission:
Main axle deflection limit…
0.01 mm (0.0004 in)
Drive axle deflection limit…
0.01 mm (0.0004 in)
Shifter:
Shifting type Cam drum and guide bar…
Guide bar bending limit…
0.05 mm (0.0020 in)
Kick starter type: Kick and mesh type…
Kick clip friction force P=0.8~1.2 kg (1.8~2.6 lb)…
Air filter oil grade (oiled filter): Foam-air-filter oil or equivalent oil…
Carburetor: USA, CDN EUROPEAUS, NZ, ZA
Type/ManufacturerTMXχ
38SS←←
/MIKUNI
I.D. mark 1C35 30 1C36 40 1C37 50…
Main jet (M.J.) #410 #430←…
Jet needle-clip position (J.N.)
6BFY42-74-3 6BFY43-74-3←…
Cutaway (C.A.) 4.0←←…
Pilot jet (P.J.) #40 #45 #40…
Pilot air screw (P.A.S.) 2-1/4←←…
Valve seat size (V.S.) ø3.8 mm ←←…
(0.15 in)
Starter jet (G.S.) #80←←…
Fuel level (F.L.)
9.5~10.5 mm←←…
(0.37~0.41 in)
Reed valve:
Thickness* 0.47 mm (0.019 in)…
Valve stopper height 8.2~8.6 mm (0.323~0.339 in)…
Valve bending limit…
0.2 mm (0.008 in)
Cooling:
Radiator core size:
Width 107.8 mm (4.24 in)…
Height (left) 240 mm (9.45 in)…
(right) 220 mm (8.66 in)…
Thickness 32 mm (1.26 in)…
Radiator cap opening pressure 95~125 kPa…
(0.95~1.25 kg/cm
2, 13.5~17.8 psi)
Radiator capacity (total) 0.56 L (0.49 Imp qt, 0.59 US qt)…
Water pump:
Type Single-suction centrifugal pump…
1C3-9-32-2A 4/29/06 10:17 AM Page 5
