Yamaha 5KR2-AE1 Manuals

Manuals and User Guides for Yamaha 5KR2-AE1. We have 1 Yamaha 5KR2-AE1 manual available for free PDF download: Service Manual

Yamaha 5KR2-AE1 Service Manual

Yamaha 5KR2-AE1 Service Manual (332 pages)

Brand: Yamaha | Category: Motorcycle | Size: 8.83 MB

Table of Contents

Table of Contents
10
General Information
12
Model Code
12
Motorcycle Identification
12
Vehicle Identification Number
12
Gaskets, Oil Seals and O-Rings
13
Important Information
13
Preparation for Removal Procedures
13
Replacement Parts
13
Bearings and Oil Seals
14
Circlips
14
Lock Washer/Plate and Cotter Pins
14
Checking the Connections
15
Special Tools
16
Chapter 2. Specifications

23
- General Specifications
  23
- Engine Specifications
  24
- Chassis Specifications
  31
- Electrical Specificatons
  34
- General Torque Specifications
  36
- Conversion Table
  36
- Maintenance Specifications
  39
- Engine
  42
- Chassis
  43
- Engine Oil Lubrication Chart Specifications
  44
- Engine Oil Flow Diagrams
  45
- Cable Routing
  48
- Rider and Passenger Seats
  62
- Fuel Tank and Air Filter
  63
- Removal
  64
- Installation
  64
- Engine
  65
- Adjusting the Valve Clearance
  65
- Adjusting the Engine Idling Speed
  68
- Adjusting the Throttle Cable Free Play
  70
- Checking the Spark Pugs
  71
- Checking the Ignition Timing
  73
- Measuring the Compression Pressure
  74
- Checking the Engine Oil Level
  76
- Changing the Engine Oil
  77
- Adjusting the Clutch Cable Free Play
  78
- Cleaning the Air Filter Element
  79
- Checking the Carburetor Joint and Intake Manifold
  80
- Checking the Fuel Hoses
  81
- Checking the Crankcase Breather Hose
  81
- Checking the Exhaust System
  82
- Chassis
  83
- Adjusting the Front Brake
  83
- Adjusting the Rear Brake
  83
- Checking the Brake Fluid Level
  85
- Checking the Brake Pads
  86
- Checking the Brake Shoes
  86
- Adjusting the Rear Brake Light Switch
  86
- Checking the Brake Hose
  87
- Bleeding the Hydraulic Brake System
  87
- Adjusting the Shift Pedal
  89
- Adjusting the Drive Chain Slack
  89
- Lubricating the Drive Chain
  91
- Checking and Adjusting the Steering Head
  91
- Checking the Front Fork
  93
- Adjusting the Rear Shock Absorber Assembly
  94
- Checking the Tires
  95
- Checking and Tightening the Spokes
  97
- Checking and Lubricating the Cables
  98
Chapter 4. Chassis

111
- Front Wheel and Brake Disc
  111
- Removing the Front Wheel
  113
- Checking the Front Wheel
  113
- Checking the Brake Disc
  115
- Checking the Speedometer Gear Unit
  117
- Installing the Front Wheel
  117
- Adjusting the Front Wheel Static Balance
  119
- Rear Wheel and Rear Brake
  121
- Rear Wheel
  121
- Rear Brake and Rear Wheel Sprocket
  122
- Removing the Rear Wheel
  125
- Checking the Rear Wheel
  126
- Checking the Rear Wheel Drive Hub
  126
- Checking and Replacing the Rear Wheel Sprocket
  126
- Checking the Brake
  127
- Assemblilng the Brake Shoe Plate
  128
- Installing the Rear Wheel
  129
- Adjusting the Rear Wheel Static Balance
  129
- Front and Rear Brakes
  130
- Front Brake Pads
  130
- Replacing the Front Brake Pads
  132
- Front Brake Master Cylinder
  134
- Removing the Front Brake Master Cylinder
  136
- Checking the Front Brake Master Cylinders
  137
- Installing the Front Brake Master Cylinder
  138
- Front Brake Caliper
  140
- Disassembling the Front Brake Caliper
  142
- Checking the Front Brake Calipers
  143
- Assemblling and Installilng the Front Brake Caliper
  144
- Front Fork
  146
- Removing the Front Fork Legs
  149
- Disassembling the Front Fork Legs
  149
- Checking the Front Fork Legs
  151
- Assemblilng the Front Fork Legs
  151
- Installing the Front Fork Legs
  155
- Handlebar
  156
- Removing the Handlebar
  158
- Checking the Handlebar
  158
- Installing the Handlebar
  159
- Steering Head
  162
- Lower Bracket
  162
- Removing the Lower Bracket
  164
- Checking the Steering Head
  164
- Installing the Steering Head
  165
- Rear Shock Absorber and Swingarm
  167
- Rear Shock Absorber Assembly
  167
- Swingarm
  168
- Handling the Rear Shock Absorber
  169
- Removing the Rear Shock Absorber Assemblies
  170
- Removing the Drive Chain
  170
- Removing the Swingarm
  171
- Checking the Rear Shock Absorber Assembly
  172
- Checking the Swingarm
  172
- Checking the Drive Chain
  174
- Installing the Swingarm
  176
- Installing the Drive Chain
  177
Chapter 5. Engine

182
- Engine Removal
  182
- Drive Sprocket and Exhaust Pipes
  182
- Leads, Shift Pedal and Clutch Cable
  184
- Engine
  185
- Installing the Engine
  186
- Cylinder Heads
  187
- Front Cylinder Head
  187
- Rear Cylinder Head
  188
- Removing the Cylinder Heads
  189
- Checking the Cylinder Heads
  191
- Checking the Timing Chain Tensioner
  192
- Rocker Arms and Camshaft
  196
- Removing the Rocker Arms and Camshaft
  197
- Checking the Camshaft
  197
- Checking the Rocker Arms and Rocker Arm Shafts
  198
- Installing the Camshaft and Rocker Arms
  199
- Valves and Valve Springs
  201
- Removing the Valves
  202
- Checking the Valves and Valve Guides
  202
- Checking the Valve Seats
  204
- Checking the Valve Springs
  206
- Installing the Valves
  206
- Removing the Pistons
  209
- Checking the Cylinders and Pistons
  209
- Checking the Piston Rings
  211
- Checking the Piston Pins
  212
- Installing the Pistons and Cylinders
  212
- Generator and Starter Clutch
  214
- Stator Coil and Pickup Coil
  214
- Generator Rotor and Starter Clutch
  215
- Removing the Generator
  216
- Checking the Starter Clutch
  217
- Installing the Generator
  218
- Clutch
  219
- Clutch Cover
  219
- Push Lever Shaft
  223
- Removing the Clutch
  224
- Removing the Primary Drive Gear
  224
- Checking the Friction Plates
  225
- Checking the Clutch Plates
  225
- Checking the Clutch Springs
  226
- Checking the Clutch Housing
  226
- Checking the Clutch Boss
  226
- Checking the Pressure Plate
  227
- Checking the Clutch Push Rods
  227
- Checking the Primary Drive Gear
  227
- Installing the Primary Drive Gear
  228
- Oil Pump
  231
- Checking the Oil Pump
  233
- Assembling the Oil Pump
  233
- Installing the Oil Pump
  234
- Shift Shaft
  235
- Shift Shaft and Stopper Lever
  235
- Checking the Shift Shaft
  237
- Checking the Shift Lever
  237
- Crankshaft and Connecting Rods
  238
- Crankshaft Assembly
  238
- Disassembling the Crankcase
  241
- Checking the Crankshaft and Connecting Rod
  242
- Checking the Bearings and Oil Seals
  243
- Checking the Timing Chain, Camshaft Sprocket and Timing Chain Guides
  243
- Installing the Crankshaft
  244
- Assembling the Crankcase
  244
- Transmission
  245
- Transmission, Shift Drum Assembly and Shift Forks
  245
- Removing the Transmission
  247
- Checking the Shift Forks
  247
- Checking the Shift Drum Assembly
  247
- Checking the Transmission
  248
- Installing the Transmission, Shift Forks and Shift Drum Assembly
  249
Chapter 6. Carburetor

253
- Carburetor
  253
- Checking the Carburetor
  256
- Assembling the Carburetor
  258
- Installing the Carburetor
  259
- Measuring and Adjusting the Fuel Level
  259
- Checking and Adjusting the Throttle Position Sensor
  261
- Fuel Pump
  264
- Checking the Fuel Pump
  264
- Disassembling the Fuel Pump
  264
- Assembling the Fuel Pump
  265
- Air Induction System
  266
- Air Induction System Diagrams
  268
- Air Induction Assembly
  269
- Checking the Air Induction System
  271
- Installing the Air Induction System
  272
Chapter 7. Electrical

278
- Electrical Components
  278
- Switches
  279
- Checking Switch Continuity
  279
- Checking the Switches
  280
- Checking the Bulbs and Sockets
  282
- Types of Bulbs
  282
- Checking the Condition of the Bulbs
  282
- Checking the Condition of the Bulb Sockets
  284
- Ignition System
  285
- Circuit Diagram
  285
- Troubleshooting
  286
- Electric Starting System
  290
- Circuit Diagram
  290
- Starting Circuit Operation
  291
- Troubleshooting
  292
- Starter Motor
  296
- Checking the Starter Motor
  297
- Assembling the Starter Motor
  298
- Charging System
  300
- Circuit Diagram
  300
- Troubleshooting
  301
- Lighting System
  303
- Circuit Diagram
  303
- Troubleshooting
  304
- Checking the Lighting System
  305
- Signaling System
  308
- Circuit Diagram
  308
- Troubleshooting
  310
- Checking the Signaling System
  311
- Carburetor Heater System
  315
- Circuit Diagram
  315
- Troubleshooting
  316
- Self-Diagnosis
  318
- Troubleshooting
  323
- Starting Problems
  325
- Engine
  325
- Fuel System
  325
- Electrical Systems
  325
- Incorrect Engine Idling Speed
  326
- Engine
  326
- Fuel System
  326
- Electrical Systems
  326
- Poor Medium-And-High-Speed Performance
  326
- Faulty Gear Shifting
  326
- Shifting Is Difficult
  326
- Shift Pedal Does Not Move
  326
- Jumps out of Gear
  326
- Faulty Clutch
  327
- Clutch Slips
  327
- Clutch Drags
  327
- Overheating
  327
- Engine
  327
- Fuel System
  327
- Chassis
  327
- Electrical Systems
  327
- Poor Braking Performance
  328
- Faulty Front Legs
  328
- Leaking Oil
  328
- Malfunction
  328
- Unstable Handling
  328
- Headlight Does Not Light
  329
- Headlight Bulb Burnt out
  329
- Tail/Brake Light Does Not Light
  329
- Tail/Brake Light Bulb Burnt out
  329
- Turn Signal Does Not Light
  329
- Turn Signal Blinks Slowly
  329
- Turn Signal Remains Lit
  329
- Turn Signal Blinks Quickly
  329
- Horn Does Not Sound
  329

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