Yamaha Libero Instruction manual

WORKSHOP
MANUAL

R-1
FOREWORD
This Workshop Manual has been prepared for use by the Yamaha Motor
India Private Ltd. Authorised Dealerships and their service personnel to attend
to servicing of Crux 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 Crux Motorcycles have a basic
understanding of mechanical concepts and procedures inherent to Motorcycle
repair technology. Without such knowledge, attempted repairs or service of
this model may render it unfit for use and / or unsafe.
Yamaha Motor India Private Ltd. continually strives to improve all its
models. Modifications and significant changes in specifications or procedures
will be informed to all Yamaha Motor India Private Ltd. Authorised Dealerships
through Service Actions and will wherever considered necessary, appear in
future editions of this Workshop Manual.
Service Department
Yamaha Motor India Private Ltd.

L-2
ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence
 Expander Spacer (Oil Ring) ¿
 Side Rails (Oil Ring) À
 2nd Ring Á
 Top Ring Â
NOTE :
• Make sure to install the Piston Rings so that
the GTP TOP1/GTP-TOP 2 marks are lo-
cated on the upper side of the 2nd Ring/Top
Ring
• Lubricate the Piston and Piston Rings with
Engine Oil.
2. Install :
 Piston ¿
 Piston Pin Àusing piston pin tool
 Piston Pin Circlip ÁNew
Piston Pin replacer tool
YSST - 207
ENGINE ASSEMBLY
1
3
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 en-
closed 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 7are given in
addition to the exploded diagram.
4
2
5
7
6

R-3
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapters number
and content.
GEN
INFO SPEC
INSP
ADJ ENG
CARB CHAS
ELEC TRBL
SHTG
Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and
lubrication points.
1. General
Information 2. Specifications
7. Electrical 8. Troubleshooting
5. Carburetion 6. Chassis
3. Periodic inspection
and adjustment 4. Engine
9. Filling fluid 11.Special Tool
15.Resistance,
Voltage, Current
12.Torque 13.Wear Limit,
Clearance
10.Lubricant
14.Engine speed
Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.
16. Apply engine oil 17. Apply gear oil 18. Apply molybdenum
disulfide oil
19. Apply wheel
bearing grease 20.Applylightweight
lithium-soap base
grease
21. Apply molyb-
denum disulfide
grease
22. Apply locking
agent (LOCKTITE*)
Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking
agent and when to install new parts
23. Use New One

L-4 INDEX
GENERAL INFORMATION GEN
INFO 1
TROUBLE SHOOTING TRBL
SHTG 8
ELECTRICAL ELEC 7
CHASSIS CHAS 6
CARBURETION CARB 5
ENGINE ENG 4
PERIODIC INSPECTION
AND ADJUSTMENTS INSP
ADJ 3
SPECIFICATIONS SPEC 2

R-5
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
SERVICE INSTRUMENTS........................................................ 1-7
SPECIAL SERVICE MATERIALS ............................................. 1-8

GEN
INFO
L-6
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)
NOTE :
Designs and sepecifications are subject to
change without notice.
MOTORCYCLE IDENTIFICATION
MOTORCYCLE IDENTIFICATION
Do not tamper with any of these numbers. It
may lead to legal action.
Year of Production : 2 Digits standing for last two digits of year
Eg. 0 0 - 2000, 0 1 - 2001 ......
Month Code : One alphabet standing for Month
Eg. A- January, B- February........
M- December ( I- Not Used for Month)
Starting Serial Number : 5KA 000101
X5KA
XX
YEAR OF
PRODUCTION MONTH CODE MODEL
CODE UNIT PRODUCTION
NUMBER
XXXXXX
WARNING
1-1

GEN
INFO
R-7
PREPARATION FOR DISASSEMBLY
1. Remove all dirt, mud, dust and foreign ma-
terial before disassembly.
2. Use proper Tools and Cleaning Equipment.
Refer to “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 assem-
bly or replaced.
4. During the Motorcycle disassembly, clean
all parts and place them in trays in the or-
der of disassembly. This will speed up as-
sembly time and help assure that all parts
are correctly reinstalled.
5. Keep Motorcycle and its parts away from
any source of fire.
IMPORTANT INFORMATION
IMPORTANT INFORMATION
1-2

GEN
INFO
L-8
IMPORTANT INFORMATION
1-3
WARNING
If the Circlip is fitted the wrong way it would
cause it to jump off its groove and damage
related components.
WARNING
CAUTION:
Do not use compressed air to spin the
Bearings dry. This causes damage to the
Bearing surfaces.
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.
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.

GEN
INFO
R-9
SPECIAL SERVICE TOOLS
SPECIAL TOOLS
1-4
SPECIAL SERVICE TOOLS
The appropriate Special Service Tools are necessary for proper maintenance of the Motorcycle.
Using the correct 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 Special Service Tools with
their application.
Refer to the list provided to avoid errors when placing an order for Special service tools.
This tool is used to hold the Magneto when re-
moving or installing the Magneto Securing Nut
1. Magnet o Holder
This tool is used to adjust Valve clear-
ance.
5. Valve Clearance AdjustingTool.
YSST - 606
This tool is used to replace Piston Pin.
6. Piston Pin Replacer
This tool is used to remove the Magneto
2. Magneto Puller with Spacer
YSST - 602
This tool is used to to remove and install
Valve Spring Assemblies.
3. Valve Spring Compressor
YSST - 603
This tool is needed to support the Piston
while installing Cylinder.
4. Piston Base
YSST - 604
This tool is used to hold the Clutch Hub when
removing or installing Clutch Main Shaft Nut.
8. Clutch Hub Holder
YSST - 233
This tool is used to remove Rocker Arm Shaft.
7. Rocker Arm Shaft Puller
YSST - 608 (Old)YSST - 608A (New)

GEN
INFO
L-10
SPECIAL SERVICE TOOLS
1-5
This tool is used to remove the Crank Shaft
from the Crank Case.
9. Crank Shaft Removal Tool.
YSST - 265
These tools are used for installation of
Crank Shaft.
10. Crank Shaft Installing Tool with spacer
(a)YSST - 266
(b) YSST - 267
To adjust Carburettor Pilot Screw.
12. Screw Driver (small).
YSST - 609
This tool is used to hold the Driving Sprocket when
removing or installing Driving Sprocket Nut
11. Driving Sprocket Holder
YSST- 605
This tool is used to loosen or tighten the
Cam Shifter Segment Screw.
13.Torx Bit (T - 30)
YSST - 611
This tool is used to loosen or tighten the
Steering Ring Nut.
16. Steering Nut Socket
YSST - 621
This tool is used for scraping the sealent
from Crankcase surface.
14. Scraper
YSST - 612
This tool is used to check Valve
Clearance.
15. Feeler Gauge
YSST - 615
çè

GEN
INFO
R-11
SPECIAL SERVICE TOOLS
1-6
This tool is used to hold the TFF plunger
for loosening and tightening of Hex
Socket Head Bolt
18. T -Handle
YSST - 213
This tool is used to remove T.F.F. oil seal.
19. T.F.F. Oil Seal Removing Tool.
YSST - 270
This tool is used when installing the TFF
Oil Seal.
20. T.F.F. Oil Seal Installation Tool
YSST-275
This tool is used to loosen or tighten the
Speedometer Gear Nut.
21.Spanner - Speedometer Gear Nut.
YSST - 237
This tool is used to adjust spring preload
of Rear Shock Absorbers.
17. Rear Shock Absorber Adjuster
YSST 221
This fixture is used to hold the Engine
for its disassembly and assembly.
22.Engine Stand
This tool is used to install Oil Seal in
Crank Case Cover#2.
23.Oil Seal Installing Tool.
YSST - 622
This tool is used to remove/install the Center
Plug from Crank case Cover#1 (L.H.)
26.Center Plug Spanner
YSST-625
This tool is used to remove the Bearing
6201 of the Axle Main.
24.Bearing Puller
YSST - 623
This tool is used to remove the Bearing
6202 of the Axle Drive
25.Bearing Puller
YSST - 624

GEN
INFO
L-12
SERVICE INSTRUMENTS
The following Service Instruments are necessary for complete and accurate tune up of Motorcycle
SERVICE INSTRUMENTS
1-7
This Instrument is used for checking the
Engine RPM
1. Tachometer
YSST - 613
2. Timing light
(SKC S14-121)
3. Compression Gauge
4. Mutimeter
5.Vernier Calliper
(150 mm)
6. Micrometer
(0-25 mm) & (50-75 mm)
7. ’CO’ Gas Analyser
8.Hydrometer
This instrument is used for checking
ignition timing
This instrument is used for checking the
engine compression
This instrument is used for checking the
electrical system.
This instrument is used for measuring
length, width & thickness of components
This instrument is used for measuring
Piston size, Valve stem size etc.
This instrument is used for measuring ‘CO’
concentration in exhaust of motorcycle
This instrument is used for measuring
specific gravity of Battery Electrolyte

GEN
INFO
R-13
SERVICE INSTRUMENTS
1-8
9. Tyre pressure gauge
10. Vaccum Gauge
11. Torque Wrench
(10-50 Ft-Lb)
(20-100 Ft-Lb)
12. Feeler gauge
This instrument is used for checking the
Tyre Pressure
This instrument is used for checking
intake vaccum.
This tool is used to tighten the Nuts/Bolts
at a specified torque.
This instrument is used to check clear-
ance/ gaps between parts.
SPECIAL SERVICE MATERIAL
The following Service material are necessary to use at the time of assembly of various parts.
1. YAMAHA Bond
TG-1215
This adhesive is used on mating surfaces
while assembling Crankcase#1 and #2. This adhesive is used for Torx Screw tightening.
2. LOCTITE
Three Bond 1322
YAMAHA BOND
TG-1215
THREE
BOND

CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................2-1
MAINTENANCE SPECIFICATIONS
ENGINE ...................................................................................... 2-4
CHASSIS ....................................................................................2-10
ELECTRICAL .............................................................................. 2-13
GENERAL TORQUE SPECIFICATIONS ................................... 2-15
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE ...................................................................................... 2-16
CHASSIS ....................................................................................2-17
ENGINE LUBRICATION ROUTE .....................................................2-18
ENGINE BEARINGS ........................................................................2-20
CABLE ROUTING ............................................................................2-21

SPEC
R-15
DESCRIPTION SPECIFICATION
Model : CRUX
Model Code : 5KA1
Engine model code: 5KA
DIMENSIONS:
Overall length 1997 mm
Overall width 735 mm
Overall height 1055 mm
Seat height 780 mm
Wheelbase 1247 mm
Minimum ground clearance 150 mm
Minimum turning radius 2000 mm
Dry weight : 105.5 kg
Basic weight :113kg
(With Oil and full Fuel Tank)
ENGINE :
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined, single cylinder
Displacement 105.6 cm³
Bore X Stroke 49 X 56 mm
Compression ratio 9:1
Starting system Kick starter
Lubrication system Wet sump
Max power 7.6 BHP @ 7500 RPM
Torque 8 Nm @ 6000 rpm
Oil type or grade :
Engine oil Yamalube 4-stroke Oil
(20W50 Type SF)
Oil capacity :
Engine oil
Periodic oil replacement 1.0 L
Total amount 1.2 L
Air filter : Washable, dual Foam, Wet type
(Oil soaked)
FUEL :
Fuel Tank capacity 11 L
Fuel reserve amount 1.4 L
Carburetor :
Type/ quantity VM17SH/1
Manufacturer (UCAL)
Spark plug :
Type/manufacturer DPR7EA/NGK
Spark Plug gap 0.7 mm
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
2-1

SPEC
L-16
DESCRIPTION SPECIFICATION
Clutch type : Wet, Multiple disc
Transmission :
Primary reduction system Helical gear
Primary reduction ratio 68/18 (3.778 : 1)
Secondary reduction system Chain drive
Secondary reduction ratio 42/14 (3.00 : 1)
Transmission type Constant mesh 4-speed
Operation Left foot operation
Gear ratio 1st 33/11 (3.000)
2nd 27/16 (1.688)
3rd 24/20 (1.200)
4th 21/23 (0.913)
Primary Drive Grading
Chassis :
Frame type Double cradle
Caster angle 26.4º
Trail 83 mm
Tyre :
Type With tube
Size Front 2.50 - 18, 4 PR
Rear 2.75 - 18, 6 PR
Manufacturer Front LOCAL MADE
Rear LOCAL MADE
Type Front RIB TYPE
Rear RIB LUG TYPE
Tyre pressure (cold tyre) :
Loading condition A* 0 ~ 90 kg (0 ~ 198 lbs)
Front 24 PSI (1.70 kgf/cm²)
Rear 28 PSI (2.00 kgf/cm²)
Loading condition B* 90 ~ 162 kg (198~408 lbs)
Front 24 PSI (1.70 kgf/cm²)
Rear 32 PSI (2.30 kgf/cm²)
*Load is total weight of cargo, rider, passenger and accessories.
GENERAL SPECIFICATIONS
2-2
Matching of Grades
Gear Primary
Drive
Primary Driven
Gear Assy.
A

A
B

B
C

C
D

D
E

E
DRIVEN GEAR ASSY.
GEAR PRIMARY DRIVE
GRADE
GRADE

SPEC
R-17
DESCRIPTION SPECIFICATION
Brake :
Front brake Type Drum Brake (Dia 130 mm)
Operation Right hand operation
Rear brake Type Drum brake (Dia 130 mm)
Operation Right foot operation
Suspension :
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorbser :
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel :
Front wheel travel 110 mm
Rear wheel travel 70 mm
Electrical :
Ignition system CDI (Digital)
Generator system Flywheel magneto
Battery type LOCAL MADE
Battery capacity 12V - 2.5 AH
Headlight type : Bulb type
Headlight bulb type Krypton bulb
Bulb (voltage - wattage x quantity) :
Headlight 12V - 35W/35W x 1
Tail/Brake light 12V - 5W/21W x 1
Flasher light 12V - 10W x 4
Meter light 12V - 2W x 1
“NEUTRAL” indicator light 12V - 3.4W x 1
“HIGH BEAM” indicator light 12V - 3.4W x 1
“TURN” indicator light 12V - 3.4W x 1
GENERAL SPECIFICATIONS
2-3

SPEC
L-18
DESCRIPTION SPECIFICATION
Cylinder :
Bore size 49.000 ~ 49.020 mm
(in five grades)
Piston :
Piston to Cylinder Clearance 0.017 ~ 0.021 mm
<Limit> <0.12mm>
Piston size “D” 48.962 ~ 48.981 mm
Cylinder Piston Grading (in five grades)
Measuring point “H” 4.5 mm
Piston offset 0.5 mm
Piston offset direction Intake side
Piston pin bore inside diameter 13.002 ~13.013 mm
Piston pin outside diameter 12.996 ~ 13.000 mm
Piston rings :
Top ring :
Type Barrel
Dimensions (B x T) 1.0 x 1.95 mm
End gap (installed) 0.10 ~ 0.25 mm
<Limit> <0.35mm>
Side clearance (installed) 0.030 ~ 0.065 mm
<Limit> <0.115m>
2nd ring :
Type Taper
Dimensions (B x T) 1.0 x 1.9 mm
End gap (installed) 0.25 ~ 0.40 mm
<Limit> <0.50mm>
Side clearance 0.020 ~ 0.065 mm
<Limit> <0.115mm>
Oil ring :
Dimensions (B x T) 2.0 x 2.15 mm
End gap (installed) 0.2 ~ 0.7 mm
Side Clearance 0.040
(For Rail Upper and Rail Lower)
MAINTENANCE SPECIFICATIONS
ENGINE
Matching of Grades
Piston Cylinder
Red A
Orange B
Green C
Violet D
Colour Mark Letter
Punch Mark
Blue E
MAINTENANCE SPECIFICATIONS
2-4
Punch
M
a
rk
Colour Mark
H
D
B
T
B
T
B
T

SPEC
R-19
DESCRIPTION SPECIFICATION
Cylinder head :
<Warp limit> <0.03 mm (0.0012 in)>
*Lines indicate straightedge
measurement.
Camshaft :
Drive method Chain Drive
Cam dimensions
Intake “ A ” 25.356 ~ 25.456 mm
<Limit> <25.326 mm>
“ B “ 20.989 ~ 21.089 mm
<Limit> <20.959 mm>
“ C “ 4.4055 mm
Exhaust “ A “ 21.360 ~ 21.460 mm
<Limit> <21.330 mm>
“ B “ 21.001 ~ 21.101 mm
<Limit> <20.971 mm>
“ C “ 4.4114 mm
Rocker Arm/ Rocker Arm Shaft :
Inside diameter (Rocker Arm) 10.000 ~ 10.015 mm
<Limit> <10.03 mm>
Outside diameter (Rocker Armshaft) 9.981 ~ 9.991 mm
<Limit> <9.95 mm>
Cam chain :
Cam chain type/No. of links BUSH CHAIN / 90
Cam chain adjustment method Automatic
Valve, Valve Seat, Valve Guide :
Valve clearance (cold) IN 0.08 ~ 0.12 mm
EX 0.10 ~ 0.14 mm
Valve dimensions :
Head Dia. Face Width Seat Width Margin Thickness
“A” head diameter IN 22.90 ~ 23.10 mm
EX 19.90 ~ 19.10 mm
“B” face width IN 1.98 mm
EX 2.26 mm
“C” seat width IN 0.9 ~ 1.1 mm
EX 0.9 ~ 1.1 mm
“D” margin thickness IN 0.60 mm
EX 1.00 mm
2-5
MAINTENANCE SPECIFICATIONS
B
B
C
A
B
C
D