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2004 yamaha tt600 service manual

1. 1x3 SS3NuVH SS3NHVH NIV 7 11 IGNITION SYSTEM ELEC The diagram illustrates the ignition circuit inside the motorcycles electric system NOTE For the colour code and legend see page 7 2 1 AC generator Pickup coil 12 Clutch switch 2 Rectifier Regulator 13 Sidestand switch 3 Battery 14 Neutral switch 6 Fuse 15 Diode 7 Main switch 16 Ignitor unit 9 Engine stop switch 17 Igniti
2. 1X3 SSINYYH 1H9I1Q0V3H NIV 18 2 ERAN 7 51 The diagram shows the signal system circuit inside the electric system of the motorcycle NOTE SIGNAL SYSTEM ELEC For the colour codes and complete legend see page 7 2 3 Battery 6 Fuse 7 Main switch 1 Diode Neutral switch Diode Left handlebar
3. 1x3 SSINYYH HOM SSINYVH m p d mE Z OECEZL 7 21 ELECTRICAL STARTING SYSTEM ELEC The diagram illustrates the electrical starting system circuit inside the motorcycles electric system NOTE For the colour code and legend see page 7 2 3 Battery 10 Starter switch 4 Starter relay 11 Diode b Starting motor 12 Clutch switch 6 Fuse 13 Sidestand switch 7 Main switch 14 Neutral switch 9 Engine st
4. SSINYYH Wen 7 41 The diagram shows the light system circuit inside the electric system of the motorcycle NOTE For the colour codes and complete legend see page 7 2 3 Battery 22 Dimmer switch 6 Fuse 26 Headlight 7 Main switch 28 Relay assy 18 Left handlebar switch 31 Tail stop light 20 Diode 32 Meter 21 Pass switch 7 42 LIGHT SYSTEM ELEC DIAGNOSTICS THE HIGH BEAM LIGHT PARKING INDICATOR LIGHT REAR LIGHT FRONT PARKING LIGHT AND OR INSTRUMENT LIGHTS FAIL TO TURN ON Procedure Inspect gt Dipped high beam light and dimmer switch 1 Fuse Relay assy 2 Battery Harness connections full system of connec 3 Main switch tions Before starting inspections remove the following parts Seat Rear cowling Cowling headlight Tail light cover To check for defects use the following special tools GJ Pocket tester S P N 90890 03112 oR WH NO e Check the fuse
5. SSINYVH LH9I1 m 3f 7 E OZECEZL NAWY 7 35 CHARGING SYSTEM ELEC The diagram illustrates the charging circuit inside the motorcycles electric system NOTE For the colour code and legend see page 7 2 AC generator Pickup coil 1 2 Rectifier Regulator 3 Battery 6 Fuse 7 36 CHARGING SYSTEM ELEC DIAGNOSTICS Procedure Inspect 1 Fuse 4 Stator winding resistance 2 Battery 5 Harness connection 3 Charging voltage whole connection sys
6. 9 JI 9 C4 OFF JO lt 0f d d L 6 6 G6 6G amp 6G 6 S OG OG OG OG OG OH GE Oe CH ee CH E E GC cy 9 1 H Bre Gi ol 5 SC I 9 BY 9 12viow ero review he t B CO es 90 12V10W on 9 69 COLOR CODE Buen Black ay see Gray Hone Red B W Black White Br Y Brown Yellow Brown Blue Sb uus Sky blue BN eg Black Yellow LIB Blue Black Red Black Gh s us Chocolate RE Light green Wee White POR Brown Black Blue Red Bi uie Red Green Dark green E Orange Ys Yellow Bt Brown Blue LAN Blu
7. 1H917 SS3NUVH NIV sh Ak 7 1 AC generator Pickup coil Rectifier Regulator Battery Starter relay Starting motor Fuse Main switch Right handlebar switch Engine stop switch Starter switch Diode Clutch switch Sidestand switch Neutral switch T De Te e D Diode Ignitor unit sch sch sch OO UO oof W COLOUR CODE Black ELECTRICAL CIRCUIT DIAGRAM ELEC 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Ignition coil Left handlebar switch Horn switch Diode Pass switch Dimmer switch Flasher switch Horn Flasher relay Headlight Flasher light Relay assy Front brake switch Rear brake switch Tail stop light Meter Black Yellow Brown Brown Black Chocolate Brown White Deep green Green Black Green Green Red Grey Green White Blue
8. 5 41 VALVES AND ROCKER 5 5 41 VALVES eae cee Ge 5 42 ROGKERARMS TT 5 43 CRANKSHAFT AND BALANCER SHAFT 5 44 TRANSMISSION emer mm ree re mcr 5 46 GEARBOX s shaw ee eee ke bee be ERE M AE dees 5 47 TRANSMISSION AND 5 48 ENGINE OIL PUMP AND OIL 5 5 49 sony piel 5 50 ENGINE OIL STRAINER ees Rt Rer ERE ba bed ees EG 5 51 22 be ac ib x eux ce gue ede UE deesse bas wa 5 51 SHIFT SHAFT AND 5 52 TIMING CHAIN bases EE Ear EORR ke ee ee 5 54 PISTON AND RINGS 2 wee So ee ed ee 5 55 CY PINDER EE 5 56 CYLINDER HEAD 5 57 CAMSHAFT AND TIMING 5 58 PISTON CYLINDER CYLINDER HEAD AND 5 59 AC GENERATOR crea reves RE RARO REOR RR RR ROG ER ee wae E 5 65 OIE FILTER AND OIL HOSES 1e SN E px RR ee 5 67 BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR Rt Ex E EE EE RUE RE ERES 5 68 eS 5 70 STARTER GEARS oe eruere puni RUE dep ce e ette ie
9. 6 5 CARBURETOR DISASSEMBLY CARB CARBURETOR DISASSEMBLY 1 Remove Support plate 1 front Support plate 2 rear 2 Separate e Primary carburetor e Secondary carburetor Primary carburetor 1 Remove e Float chamber 1 e Float pin 2 e Float 3 NOTE H Remove the float needle in the direction of the arrow 6 6 CARBURETOR DISASSEMBLY CARB 2 Needle valve set Valve seat 1 e Main jet Main nozzle 1 2 e Pilot jet 3 e Pilot screw set 4 e O Ring 5 3 Remove e Stop screw 1 e Starter set 2 4 Remove e Cover 1 enrichment Spring 2 e Diaphragm 3 5 Remove e Top cover 1 e Cover gasket 2 e Screw 3 connecter comp 6 Remove e Throttle lever 1 e Collar 2 e Cable holder 3 6 7 CARBURETOR DISASSEMBLY CARB 7 Remove e Throttle shaft 1 e Spring 2 8 Remove e Connecter comp 1 e Needle jet 2 e Throttle valve 3 Secondary carburetor 1 Remove e Drain plug 1 e Main jet 2 2 Remove e Top cover 1 Spring 2 3 Remove e Diaphragm 1 e Needle jet 2 2 6 8 CARBURETOR INSPECTION CARB CARBURETOR INSPECTION 1 Inspect e Carburetor body Soiled gt Clean NOTE _ 7 Use petroleum based solutions to clean Clean all passages and jets with compressed air 2 Inspect e Valve seat 1 e Needle valve set 2
10. 6 16 CARBURETOR REMOVAL CARB CARBURETOR CARBURETOR REMOVAL Job ramel Pan Carburetor removal Remove the parts in order Seat Refer to SEAT FUEL TANK AND REAR COWLING section in CHAPTER 3 Fuel pipe 77 Fuel tank Be sure the cap is properly tightened and the fuel cock is in the OFF position before removing the fuel tank Lock nut Loosen Throttle cable adjuster Screw Throttle cable Hose clamp Loosen 6 1 CARBURETOR REMOVAL CARB NOTE o S Move carburetor manifold clamps towards the rear side Reverse the removal procedure for installa tion Adjust throttle cable free play refer to THROTTLE CABLE FREE PLAY ADJUST MENT section in CHAPTER 3 Adjust idle speed refer to IDLE SPEED AD JUSTMENT section in CHAPTER 3 6 2 TYPE Y30PV 2ATK MANUFACTURER TEIKEI carsuretor CARB 2 Nm 0 2 m kg 1 4 ft lb EN E E Ge 2098 B Ui Se UL 2Nm 0 2 m kg 1 4 ft lb 28 9 Nm 0 9 m kg 6 3 ft lb Pus 2 Nm 0 2 m kg 1 4 ft lb SY 3 5 Nm 0 35 m kg 2 5 ft lb 4 d SCH 2 Nm 0 2 m kg 1 4 ft lb 6 3 We 18 Q AMET 6 Nm 0 6 m kg 4 3 ft lb 8 Nm 0 8 m kg 5 9 ft lb CARB 1 Carburetor 13 Throttle valve 27 Spring as
11. CHECK OR MAINTENANCE J Rear shock absorber assembly Check operation and shock absorber for oil leakage V sull ammortizzatore Rear suspension relay arm and connecting arm pivoting points Lubricate with lithium soap based grease Check operation Carburator Check starter choke operation Adjust engine idling speed Change Engine oil Check oil level and oil leakage Engine oil filter element Replace Front and rear brake switches Check operation Moving parts and cables e Lubricate Throttle grip Check operation and free play housing and Adjust the throttle cable free play if necessary cable Lubricate the throttle grip housing and cable Muffler and exhaust pipe Check the screw clamp for looseness Lights signals Check operation and switches Adjust headlight beam Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NOTE The annual checks must be performed every year except if a kilometer based maintenance is per formed instead From 50 000 km repeat the maintenance intervals starting from 10 000 km The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system Check the brake fluid level regularly and fill as re
12. 8 2 POOR ENGINE 4 4 8 2 POOR PERFORMANCE AT IDLE SPEED 8 3 UNSATISFACTORY PERFORMANCE AT MEDIUM HIGH SPEED 8 3 DIFFICULTIES IN SHIFTING 8 4 SHIFTING IMPOSSIBEE Wes oe ee doe eek SE ES ee wee ee eS 8 4 THE SHIFT PEDAL FAILS TO MOVE 8 4 DISENGAGING GEARS 8 4 CLUTCH SLIDES OR FAILS TO RELEASE 8 5 CLUTCH SLIDES 5 2253 22 4 awed 8 5 CLUTCH FAILS TO RELEASE 8 5 DEFECTIVE BRAKES TN e EEN NEEN 224 eee weed 8 6 POOR BBAKING RR ha 8 6 OIL LEAKS OR MALFUNCTIONING OF FRONT 8 6 QILLEAKS essere andes Sot me et ad Rs E SUR RE ERU 8 6 MALFU NGTIGONING te urine uote Ge usa Qo eee 8 6 UNSTABLE STEERING 8 7 DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS 8 8 POOR HEADLIGHT ILLUMINATION 8 8 FREQUENT BURNING OF BULB 8 8 DIRECTION INDICATORS FAIL TO TURN
13. mw ee eed cx n eee EN 4 72 SHOCK ABSORBER REMOVAL 4 73 SHOCK ABSORBER 4 74 SHOCK ABSORBER 4 74 SWINGARM occ ie ee Ga Meade Wa eee eR ee re ERE e bos e wes 4 76 SWINGARM REMOVAL 0 etapi emi det tee ee 4 77 SWINGARM INSPEC TION 4 78 LATERAL FREE PLAY ADJUSTMENT 4 79 SWINGARM INSTALLATION 2 4 80 DRIVE CHAIN DRIVE SPROCKET AND REAR WHEEL SPROCKET 4 82 DRIVE CHAIN REMOVAL 4 82 DRIVE CHAIN INSPECTION 4 83 DRIVE CHAIN INSTALLATION 4 85 FRONT WHEEL AND BRAKE DISC CHAS CHASSIS FRONT WHEEL AND BRAKE DISC 12 Nm 1 2 mg Job name Part name Front wheel and brake disc removal Remarks Remove the parts in order A WARNING Securely support the motorcycle so there is no danger of it falling over Disconnect Loosen Speedometer cable Pinch bolt Wheel axle Front wheel assembly Collar Gear unit assembly Brake disc screw Brake disc Ring Refer to FRONT WHEEL INSTALLATION section Reverse the removal procedure for instal lation lt
14. Make sure the special washer tabs are in the slots AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 6 Install e Upper bracket e Fork legs left and right 1 NOTE ee Temporarily install the under bracket pinch bolt to achieve the correct fork position Front fork top end a standard 0 mm 7 Install e Plate washer 1 e Steering axle nut 2 Use the lock nut wrench 4 Lock nut wrench 4 7 90890 01348 MEM Set the torque wrench to the lock nut wrench so that they form a right angle Steering axle nut 2 115 Nm 11 5 mkg 4 68 STEERING CHAS 8 After tightening the nut check the steering for smooth movement If it is not smooth adjust by progressively loosening the lower ring nut 9 Tighten e Pinch bolts upper and lower bracket Pinch bolt upper bracket 28 Nm 2 8 mkg Pinch bolt under bracket 23 Nm 2 3 mkg NOTE Always tighten the lower pinch bolt to the pre scribed torque and then the upper one to the prescribed torque and then retighten the lower one to the prescribed torque CAUTION Tighten the pinch bolt to specified torque If torqued too much it may cause malfunction ing of the front fork 10 Install e Handlebar holder e Handlebar e Handlebar upper holder Fitting nut handle lower holder 2 40 Nm 4 0 mkg Flange bolt handlebar holder 20 Nm 2 0 mkg CAUTION First tighten the
15. CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EN 1 1 VEHICLE IDENTIFICATION NUMBER rr tnt rene tnnc 1 1 MODI EAB EL E 1 1 IMPORTANT INFORMATION 4 22 22 1 2 PREPARATION FOR REMOVAL PROCEDURES 1 2 el e GESCHT KE 1 2 GASKETS OIL SEALS AND O RIINGS 55 ates 1 2 LOCK WASHERS PLATES AND COTTER PINS emen 1 3 BEARINGS ANB OIL SEALS 1 3 ee LI 1 3 CHECKING OF CONNECTIONS erede teretes 1 4 SPECIAL TOOLS R P 1 5 VEHICLE IDENTIFICATION Pe GENERAL INFORMATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped in to the frame MODEL LABEL The model label 1 is affixed to the frame under the seat This information will be needed to order spare parts IMPORTANT INFORMATION Nro Pe EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1 Remove all dirt mud dust and foreign materi al before removal and disassembly Use proper tools and cleaning equipment Refer to the SPECIAL TOOLS section When disassembling the machine always keep mated parts together This includes gears cylind
16. Standard 4 Maximum hard 5 6 7 8 9 10 4 60 STEERING CHAS TIGHTENING PROCEDURE Initial tightening 38 Nm 3 8 mkg Loosen 1 turn Final tightening 4 Nm 0 4 mkg Job name Steering removal Front wheel Fork legs Cowling Meter unit Front fender Handle upper holder Handle lower holder Handlebar Nut Upper bracket Special washer sch sch sch sch 4 61 Remove the parts in order Park the motorcycle on a level surface A WARNING Securely support the motorcycle to pre vent it falling over Refer to FRONT WHEEL REMOVAL sec tion Refer to FRONT FORK section Displace Displace STEERING CHAS TIGHTENING PROCEDURE Initial tightening 38 Nm 3 8 mkg Loosen 1 turn Final tightening 4 Nm 0 4 mkg Job name Part name Qy Remarks Upper ring nut Refer to STEERING REMOVAL INSTAL Lower ring nut LATION section Ball race cover Lower bracket Steering axle Bearing upper Bearing lower Reverse the removal procedure for instal lation 4 62 1 Handle upper holder 2 Handle lower holder 3 Spacer 4 Nut 5 Plate washer 6 Upper bracket Ma 40 Nm 4 0 kgm STEERING CHAS 7 Brake hose holder 13 Bearings 8 Plate washer 14 Steering lock 9 Special washer 15 Steering axle 10 Upper ring nut 16 Wire guide 11 Lower ring nut 12
17. YES 4 Amplitude of the ignition spark e Detach the spark plug cap from the spark plug e Connect the dynamic spark tester 1 as shown in the figure 2 Spark plug cover 3 Spark plug e Turn the main switch ON Check the amplitude of the ignition spark IN COMPLIANCE WITH SPECIFICATIONS Start the engine and increase the ampli tude until the ignition becomes discontin uous Spark amplitude if the ignition Minimum spark amplitude system is efficient 6 0 mm THE IGNITION SYSTEM IS INEFFICIENT 4 OR THERE IS SPARK 7 14 IGNITION SYSTEM ELEC e Remove the spark plug cap e Connect the pocket tester Q x 1k to the spark plug cap OUT OF SPECIFICATION The spark plug cap is defective e Check that the spark plug cap has the Replace specified resistance Resistance of spark plug cap 4 10 at 20 C 68 F o IN COMPLIANCE WITH SPECIFICATIONS 6 Ignition winding resistance e Disconnect the ignition coil cables from the wire harness e Connect the pocket tester Q x 1 to the ignition coil Tester terminal gt Pole Tester terminal gt Pole e Check that the primary coil has the speci fied resistance 7 15 IGNITION SYSTEM ELEC Primary winding resistance 4 1596 at 20 C 68 F Terminal Terminal e Connect the pocket tester 1 to the ignition coil Tester terminal gt Spark plug cable 1 Tester ter
18. 2 Wave washer 11 Lower valve spring 3 Rocker shaft intake retainer 4 Rocker arm n 1 12 Rocker shaft b Valve cotters exhaust 6 Upper valve spring 13 Rocker arm n 4 retainer 14 Rocker arm n 3 7 Oil seal 15 Rocker shaft 8 Inner valve spring exhaust 9 Outer valve spring 16 Valve exhaust VALVE SPRING TILT LIMIT VALVE CLEARANCE COLD Inner spring Intake 0 05 0 10 mm 0 002 0 004 2 5 or 1 7 mm 0 067 in Exhaust 0 12 0 17 mm 0 005 0 008 in Outer spring 2 5 or 1 9 mm 0 075 STEM RUNOUT LIMIT 0 01 mm 0 0004 in VALVE SEAT WIDTH 1 0 1 2 mm 0 04 0 05 in 5 41 ENGINE ASSEMBLY AND SETTING ENG 4 5 42 VALVES 1 Burrs e Valve stem tip leave the valve stem tip with an oil stone 2 Lubricate e Valve stem and oil seal apply high quality molybdenum disulfide oil 3 Install Oil seal 1 Valves 2 Lower valve spring retainer 3 Inner valve spring 4 Outer valve spring 5 Upper valve spring retainer 6 NOTE SE Install the innner and outer springs with the widest thread upwards 7 Higher pitch 8 Lower pitch 4 Install e Valve cotters 1 NOTE 1 1 1 Compress the valve spring with the specific tool 2 to fit the cotters Valve spring compressor e P N 90890 04019 ENGINE ASSEMBLY AND SETTING ENG ROCKER ARMS 1 Lubricate e Rocker shaft apply engine oil 2 Install
19. 4 38 CALIPER INSPECTION ede eek Gea Ghd RR eee eee RE ER s 4 38 CALIPER ASSEMBLY ues iR pls ede ee eee bw Re ena 4 39 CALIPER INSTALLATION 4 39 FRONT FORK eee ce ee ks Bex be Bes EELER e RO SE 4 42 FRONT FORK REMOVAL uuo RR 4 42 FRONT FORK DISASSEMBLY 4 43 FRONT FORK REMOVAL sarera nrar pari darian bese ra RR dade atten gee 4 45 OIL REPLACEMENT sca got gie 224054 0000445550094 SR eee a ae Soret 4 46 CLEANING THE DUST 4 49 SEAL AND BUSH 4 50 OIL LEAKAGE FROM DUST SEAL 4 56 ANOMALOUS HYDRAULIC BRAKING 4 56 FRONT FORK INSPECTION ce haat esa Ee ee RE DRE RED ee 4 57 FRONT FORK INSTALLATION e RR eG A eed E 4 59 FRONT FORK ADJUSTMENT 4 60 cupid cc CP m 4 61 STEERING REMOVAL 4 64 STEERING INSPECTION wince das cener Rob ees RR EORR Re RR RC EN 4 65 STEERING INSTALLATION 4 65 REAR SHOCK 5 4 69 NOTE ON DISPOSAL x
20. 5 Apply 4 stroke engine oil to the connecting rod pin the bearing and the oil passage 6 Check Gearbox and transmission functioning Jerky functioning gt Replace SHIFT SHAFT AND OIL PUMP 1 Install e Spring 1 e Collar 2 e Stopper lever 3 Stopper lever screw 4 2 10 Nm 1 0 mkg NOTE __ Place the stopper lever and the spring in the cor rect position 2 Install e Plate washer 1 e Spring 2 Shift lever 3 e Circlip 4 5 52 ENGINE ASSEMBLY AND SETTING 4 5 53 NOTE _ When installing the shift lever align the mark the lever with that on the shift shaft 3 Install e Circlip 1 to the driving axle e Spacer 2 e Circlip 3 4 Apply e 4 stroke engine oil oil pipes in crankcase CAUTION To avoid damage to the engine lubricate the oil pump pipes in the crankcase liberally with 4 stroke engine oil 5 Apply e 4 stroke engine oil oil pump pipes 6 Apply e O Ring 1 e Oil pump 2 Oil pump gear 3 e Circlip 4 Screw 5 oil pump Ze 10 1 0 mkg ENGINE ASSEMBLY AND SETTING 4 TIMING CHAIN 1 Install e Timing chain 1 e Chain guide 2 5 54 ENGINE ASSEMBLY AND SETTING ENG 4 PISTON AND RINGS PISTON SIZE 1 Ring upper 94 915 94 965 mm 2 Ring lower PISTON RING END GAP 3 Scraper TOP 0 30 0 45 mm 4 Piston 2ND 0 30 0 45 mm 5 Piston pin OI
21. 5 17 OILSTRAINER ees ee ace o s 5 17 ROCKER ARMS esl 5 18 CG EE 5 19 INSPECTION AND 5 21 CYLINDER 5 21 VALVES AND VALVE GUIDES 5 22 VALVESEAT GENEE 5 23 VALVE SPRINGS cea rae es prae Mee ge 5 27 CAMSHAFT 2 2 5 28 ROCKER ARMS AND ROCKER 5 28 CAMSHAFT CHAIN AND SPROCKET 5 29 CAMSHAFT CHAIN GUIDE 5 30 CYLINDER AND 2 5 30 Gei 5 32 PIBTONPIN Lo crei box wx do See ged Ee REST ERIS EE 5 33 CLUTCH eeng 5 33 EE EE EE 5 35 PRIMARY TRANSMISSION 2 2 5 35 TRANSMISSION AND 5 36 SHIFT SHAFT AND STOPPER 5 37 STARTER TRANSMISSION 2 5 38 2 22 22 2 5 39 BALANCER SHAFT DRIVE AND DRIVEN GEARS 5 40 CRANKCASE EE 5 40 BEARING AND OIL 6 5 40 ENGINE ASSEMBLY AND
22. A 3 5 Nm 0 35 mkg 16 Adjust e Synchronisation of secondary carburetor Adjustment e Move the primary throttle valve 1 to a height of 7 0 mm as shown in the figure e Tighten or loosen the synchronisation screw 1 until the secondary throttle valve 2 starts to open e Check that the secondary throttle valve is open horizontally a b when the primary throttle valve is completely open AAA A A A A A A A A A A A A A A A A A A A A A A A A A A CARBURETOR ASSEMBLY CARB 6 16 FUEL LEVEL ADJ USTMENT CARBURE TOR INSTALLED 1 Place the motorcycle on a level surface 2 Make sure that the carburetor is in a horizon tal position by placing a hydraulic jack under the engine 3 Connect the fuel level gauge 1 to the carbu rettor nipple CZ Fuel level gauge E P N 90890 01312 4 Loosen drain screw 2 and heat the engine 5 Measure e Fuel level a Out of specification gt Adjust Fuel level 6 0 8 0 mm Under the edge of the carburetor body 6 Adjust e Fuel level VVVVVVVVVVVVVVVVVVVVVVVVVVYVVY Fuel level adjustment Remove carburetor assembly Inspect valve seat and needle valve set If either of the two is worn replace both If both are perfect adjust float height by bend ing the wing tab of the float itself 1 e Recheck the fuel level A AA A A A A A A A A A A A A A A A A A A A A A A A A A A C
23. e Insufficient battery capacity battery almost flat e Bulb front or rear burnt out e Direction indicator switch defective 8 8 DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS TRBL OVERHEATING OF ENGINE SHTG DELAYED TURNING ON OF INDICATORS PROBABLE CAUSES e Indicator lamp relay defective e Insufficient battery capacity battery almost flat e Incorrect bulb e Main switch or direction indicator switch defec tive EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY PROBABLE CAUSES e Incorrect bulb Indicator lamp relay defective THE HORN FAILS TO WORK PROBABLE CAUSES e Battery flat e Main switch or horn switch defective e Horn wrongly set e Defective horn e Harness cut off OVERHEATING OF ENGINE PROBABLE CAUSES Ignition system e Incorrect electrode gap of spark plug e Spark plug thermal gradation wrong e Ignition unit defective Fuel feed system e Incorrect carburetor main jet incorrect setting e Incorrect fuel level e Air filter element obstructed Engine compression e Excess of carbon deposits Engine oil Incorrect oil level e Incorrect oil viscosity Incorrect oil gradation Brake e Pads fail to return freely remains blocked 8 9 SYSTEM TT600RE WIRING DIAGRAM ELECTRICAL AC generator Pickup coil Rectifier Regulator Battery Starter relay Starting motor Fuse Main switch Right handlebar sw
24. e Rocker arm e Rocker shaft Nyy Screws 1 rocker shaft A 10 Nm 1 0 kgm NOTE Each rocker arm is numbered e Install Cap 1 5 43 ENGINE ASSEMBLY AND SETTING 4 CRANKSHAFT AND BALANCER SHAFT 1 Connecting rod 5 Bearing 2 Crank left 6 Bearing 3 Connecting rod 7 Balancer shaft 4 Bearing 8 Bearing CRANK WIDTH 74 95 75 00 mm 2 950 2 953 n RUNOUT LIMIT 0 03 mm 0 0012 in SMALL END FREE PLAY 0 8 mm 0 031 in BIG END SIDE CLEARANCE 0 35 0 65 mm 0 013 0 026 in 0 35 0 75 mm 0 013 0 030in A 5 44 ENGINE ASSEMBLY AND SETTING 4 CRANKSHAFT AND BALANCER SHAFT 1 Install e Crankshaft s 7 Crankshaft installation tool 1 P N Y U 90050 Crankshaft installation tool spacer 2 P N 90890 01274 Crankshaft installation tool bolt 3 P N 90890 01275 Adapter 10 MI 4 4 P N Y M 90069 P N 90890 04059 Crank spacer 5 P N YM 91044 P N 90890 04081 Spacer 6 P N 90890 01016 NOTE Hold the connecting rod at top dead centre with one hand and turn the assembly tool nut with the other Work on the assembly tool until the lower part of the crankshaft enters into contact with the bear ings CAUTION To protect the crankshaft from scratches and facilitate assembly operations apply grease to the edges of the oil seals and engine oil to the bearings 2 Install e Balance
25. 3 46 ELECTRICAL SYSTEM 5 oet P E OE 3 47 CHECKING AND CHARGING THE BATTERY 3 47 CHECKING THE FUSES 3 53 REPLACING THE HEADLIGHT BULBS 3 54 REPLACING THE TURN INDICATOR LIGHT 3 56 REPLACING THE TAIL BRAKE LIGHT BULB 3 57 INTRODUCTION PERIODIC MAINTENANCE LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJ USTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments These preventive maintenance procedures if followed will ensure more reliable vehicle operation and a longer service life The need for costly overhaul work will be greatly reduced This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service techni cians should be familiar with this entire chapter PERIODIC MAINTENANCE LUBRICATION INTERVALS ODOMETER READING x 1 000 km 1 ITEM CHECK OR MAINTENANCE J OB Fuel line Check fuel hoses for cracks or damage Check condition Spurk plug Clean and regap Replace Check valve clearance Valves Adjust Clean Air filter element Replace Check operation Clutch Adjust Check operation fluid level and vehicle for fluid leakeage Front brake See N
26. Jobs requiring more information such as special tools and technical data are described sequentially ENG 4 49 CLUTCH DEE CLUTCH REMOVAL 1 Straighten UEUTGH COVER Lock washer tab 2 Loosen Nut clutch boss Loosen the nut clutch boss while hold ing tha clutch boss with the clutch hold ing too Clutch holding tool 50890 04086 PRIMARY DRIVE GEAR REMOVAL 1 Straighten Lock washer tab 2 Loosen Nut iprimary drive gear NOTE Place copper plate between the teeth of the primary drive gear and primary driven gear to lock them CLUTCH INSPECTION Inspect Friction plates Wearfdamage Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates asa set Job namefPart name 1 Measure at four places Clutch cover removal Stand the motorcycte on a level surface Thickness piste Wear fimit gt 2 6 mm Securely support the motorcycle so there is no danger of it falling over Clutch plate Engine oil Refer to ENGINE OIL REPLACE Darnage Replace the clutch plates as MENT in CHAPTER 3 set Mutter assembly 1 2 n 3 t 4 Measure Ve dem TR Refer to ENGINE REMOVAL Clutch plata warpage filter cover plate Out of specification gt Replace the clutch fiter cover 1470 mm x 1 65 mm x 1 26 mm x 3 plates set Oring
27. Piston Piston to cylinder clearance 0 045 0 065 mm Diameter D 94 915 94 965 mm Height H 5 0 mm Piston pin bore inside diameter 22 004 22 015 mm Offset 2 00 mm Offset direction Intake side Piston pin outside diameter 21 991 22 000 mm MAINTENANCE SPECIFICATIONS SPEC ve Standard Piston ring Top ring bed Ring type Barrel Dimensions B x T 1 20 x 3 80 mm End gap installed 0 30 0 45 mm 0 70 mm Ring side clearance 0 040 0 080 mm 0 130 mm 2 ring te a Ring type Plain Dimensions B x T 1 20 x 3 80 mm End gap installed 0 30 0 45 mm 0 80 mm Ring side clearance 0 030 0 070 mm 0 130 mm Oil ring Dimensions B x T 2 50 x 3 40 mm End gap installed 0 20 0 70 mm Ring side clearance 0 020 0 060 mm Crankshaft F Width 74 95 75 00 eee Max runout C 4 0 030 mm Big end side clearance D 0 350 0 650 mm Big end radial clearance 0 010 0 025 mm Small end free play F 0 80 mm MAINTENANCE sPECIFICATIONs SPEC ve Item Standard Ballancer Ballancer drive method Clutch Clutch release method Friction plate thickness Wear limit Plate quantity Friction plate thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Max warpage Clutch spring free length Plate quantity Clutch housing thrust clearance Inner push cam push 2 72 2 88 mm 6 pcs 2 94 3 06 mm 2 pcs 1 20 mm 7 pcs 42 8 mm 5 pcs 0 07
28. YAMAHA 2004 6 SERVICE MANUAL 5 0000 TT600RE SERVICE MANUAL 2003 by Belgarda S p A First edition J uly 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Belgarda S p A is expressly prohibited Printed in Italy 5 0001 This manual was produced by the Belgarda S p A primarily for use by Yamaha dealers and their quali fied mechanics It is not possible to include all the knowledge of a mechanic in one manual Therefore anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles Repair and mainte nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use Belgarda S p A is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFE TY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury
29. der connector is defective Repair A When the lights switch commutator is at position HI B When the lights switch commutator is at position LO 7 46 LIGHT SYSTEM ELEC e Turn the main switch to ON Turn the lights switch to LO or Check the voltage 12V on the Green and Yellow cable at the bulbholder ter minals SPECIFICATIONS 12V The circuit is efficient IN COMPLIANCE WITH 2 The instrument light and or the parking indica tor light fails to turn on 1 Bulb and bulbholder DISCONTINUITY e Check the continuity of the bulb and bulb holder Refer to BULB INSPECTION section Replace the bulb and or the bulbholder CONTINUITY 2 Voltage e Connect the pocket tester DC 20V to the bulbholder connector Tester terminal 2 Blue cable 1 Tester terminal 2 Black cable 2 OUT OF SPECIFICATION The circuit from the main switch to the bulbhol der connector is defective Repair e Turn the main switch to ON e Check the voltage 12V on the Blue cable of the bulbholder connector IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient 7 47 LIGHT SYSTEM ELEC DISCONTINUITY 1 Bulb and bulbholder e Check the continuity of the bulb and bulb holder Refer to BULB INSPECTION section Replace the bulb and or bulbholder CONTINUITY 2 Voltage e Connect the pocket tester
30. tion Remove e Shock absorber fastening nut 1 e Lower mounting bolt Remove e Upper mounting bolt 1 e Rear shock absorber REAR SHOCK ABSORBER CHAS SHOCK ABSORBER INSPECTION 1 Inspect e Shock absorber Oil leak Damaged Replace REAR SHOCK ABSORBER ADJ USTMENT This shock absorber is equipped with a spring pre load adjuster CAUTION Never attempt to turn an adjusting mecha nism beyond the maximum or minimum set tings Adjust the spring preload as follows 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b NOTE e Use the special wrench included in the owner s tool kit to make the adjustment e The spring preload setting is determined by measuring distance A shown in the illustra tion The longer distance A is the lower the spring preload the shorter distance A is the higher the spring preload With each com plete turn of the adjusting nut distance A changes by 1 5 mm Spring preload Minimum soft Distance 217 mm Standard Distance A 211 mm Maximum hard Distance A 205 mm 4 74 REAR SHOCK ABSORBER CHAS 4 75 2 Tighten the locknut to the specified torque Y Locknut A 45 Nm 4 5 m kgf CAUTION Always tighten the locknut against the adjust ing nut and the
31. 16 should be placed inside the second friction plate lt Friction plate Type np Quantity 2 Internal diameter 0 NOTE SSS Align the mark on the clutch boss 17 with the arrow 18 on the pressure plate 3 Adjust e Clutch free play See section CLUTCH ADJUSTMENT in CHAPTER 3 4 Install Straight key Gasket Crankcase cover right 1 O Ring Oil filter Filter cover 2 with O Ring See section Engine oil replacement with oil filter change in CHAPTER 3 Ww Bolt crankcase cover amp 10 Nm 1 0 mkg ENGINE ASSEMBLY AND SETTING ENG STARTER GEARS 1 Starter gear 2 Starter neutral gear 1 3 Starter neutral gear 2 4 Starter gear 5 Starter clutch 5 73 ENGINE ASSEMBLY AND SETTING 4 STARTER NEUTRAL GEAR CRANKCASE COVER L 1 Install e Stator winding 1 e Pick up coil 2 e Cable clamp 3 Screws stator and coil 7 Nm 0 7 mkg Use LOCTITE amp Screw cable clamp 7 Nm 0 7 mkg 2 Install Bearing 1 e Intermediate starter gear 2 2 3 Install e Centring pin 1 Gasket 2 O Ring 3 Crankcase cover L 4 Plugs Ny Bolt crankcase cover S 10 Nm 1 0 mkg A WARNING Always use a new gasket 5 74 ENGINE ASSEMBLY AND SETTING ENG 4 Install e Neutral switch cable 1 5 Install Shaft 1 e Bearing 2 e Starter intermed
32. 2 intake Tappet covers 3 exhaust Cylinder head cover 4 Cap 5 Pins 6 Loosen e Bolt 1 chain tensioner Remove e Chain tensioner 2 ENGINE DISASSEMBLY oD 4 Remove Cam sprocket 1 Camshaft 2 e Caps left crankcase cover NOTE n Fix a safety wire 3 to the timing chain to prevent it falling into the crankcase 5 Remove e Chain stopper guide 1 6 Remove e Cylinder head NOTE Loosen all bolts by a 1 4 turn and remove once all are loosened 5 6 ENGINE DISASSEMBLY oD 5 7 7 Remove e Gasket 1 cylinder head Pins 2 e Cylinder 3 e Gasket 4 cylinder 8 Remove e Pins 1 9 Remove e Pin ring 1 NOTE Before removing the pin ring cover the crankcase with a clean cloth to prevent the ring falling into the crankcase cavity 10 Remove e 1 e Piston 2 NOTE Before removing the pin burr the pin housing groove If it is hard to pull out the pin even with the groove burred use the pin puller ENGINE DISASSEMBLY OD 22 Piston pin puller set P N 90890 01304 CAUTION Avoid using the hammer to pull the pin out INTERMEDIATE STARTER GEAR CRANKCASE COVER L AND GENERATOR STATOR NOTE With the engine installed maintenance of the inter mediate starter gear and the crankcase cover L may be performed by removing the following parts e Exhaust pipe e Starter e Spro
33. 20 2 0 mkg 4 20 FRONT BRAKE CHAS A WARNING Check that the brake hose routing is correct Refer to CABLE ROUTING section 2 2 Fill e Brake fluid reservoir Recommended brake fluid DOTA CAUTION Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately A WARNING e Use only designated quality brake fluid Otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and lead to poor perform ance Be careful that water does not enter the significantly lower the boiling point of the fluid may result in vapor lock 3 Air bleed e Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 4 Inspect e Brake fluid level Lower than MIN mark gt Fill Refer to BRAKE FLUID INSPECTION section in CHAPTER 3 a Minimum level mark MIN REAR WHEEL AND BRAKE DISC CHAS HH REAR WHEEL AND BRAKE DISC Job name Part name Rear wheel and brake disc removal Remove the parts in order A WARNING Securely support the motorcycle so there is no danger of it falling over Axle nut Wheel axle Push the wheel forward and remove the Drive chain chain Collar Refer to REAR WHEEL INSTALLATION Rear wheel assembly section Brake disc Reverse the removal procedure for insta
34. 3 DISCONTINUITY 4 The main switch is defective Replace CORRECT UNCERTAIN CONNECTIONS 4 Harness connections e Check the connections of the entire signal system 1 Check the condition of each signal system Refer to ELECTRICAL CIRCUIT DIAGRAM section 7 54 SIGNAL SYSTEM ELEC SIGNAL SYSTEM CONTROL 1 The horn does not work 1 Horn switch Disconnect the left handlebar switch con nector from the wire harness e Connect the pocket tester 1 to the switch terminals Check the switch component for conti nuity between Pink 1 and Black 2 Refer to SWITCH CHECK section DISCONTINUITY The horn switch is defective Replace the left handlebar switch 2 Voltage e Connect the pocket tester DC 20V to the horn cable Tester terminal gt Brown terminal 1 Tester terminal Earth OUT OF SPECIFICATIONS The circuit from the main switch to the horn ter Turn the main switch to ON minal is defective Repair Check the voltage 12V on the Brown terminal of the horn IN COMPLIANCE WITH SPECIFICATIONS 12V 7 55 e Disconnect the Pink cable from horn ter minal e Connect a special cable 1 to the horn terminal and earth the cable e Turn the main switch to ON THE HORN DOES JL NOT WORK 4 Voltage Connect the pocket tester DC 20V to the Pink terminal of the horn Tester termi
35. 4 1 222222222 FRONT WHEEL AND BRAKE DISC CHAS Job name Part name Remarks Front wheel disassembly Remove the parts in order Oil seal Bearing Spacer Oil seal Bearing Refer to FRONT WHEEL DISASSEMBLY ASSEMBLY section Reverse the removal procedure for instal lation 4 2 4 3 FRONT WHEEL AND BRAKE DISC 5 FRONT WHEEL DISASSEMBLY 1 Remove e Oil seal e Bearing 1 e Spacer Removal procedure e Clean the outside of the hub Remove the dust cover with a flat headed screwdriver NOTE Place a rag on the outside to avoid damaging the hub e Disassemble the bearing 1 with a normal puller 2 AAA A A A A A A A A A A A A A A A A A A A A A A A A A A FRONT WHEEL INSPECTION 1 Inspect e Front wheel axle by rolling it on a flat surface Bends gt Replace A WARNING Do not attempt to straighten a bent axle 2 Inspect e Front tire Wear damage gt Replace Refer to TIRE INSPECTION in CHAP TER 3 e Front wheel Refer to WHEEL INSPECTION in CHAPTER 3 3 Inspect Spoke s Bent Damaged gt Replace Loose spoke s gt Tighten Turn the wheel and hit the spokes gently with a screwdriver NOTE A well tightened spoke makes distinct sharp noise a loose spoke makes a dull muffled noise 4 4 FRONT WHEEL AND BRAKE DISC CHAS 4 4 Tighten e Loose spoke
36. 8 Tighten e Wheel axle nut Wheel axle nut 2 115 11 5 4 27 ws ano nae CHAS WHEEL STATIC BALANCE USTMENT NOTE MM e After replacing the tire and or rim the wheel static balance should be adjusted e Adjust the rear wheel static balance with the brake disc installed 1 Remove e Balancing weight 2 Set e Wheel on a suitable stand 3 Find e Heavy spot VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Procedure a Spin the wheel and wait for it to rest b Put an X mark on the wheel s bottom spot Turn the wheel so that the X mark is 90 up d Release the wheel and wait for it to rest Put an X mark on the wheel s bottom spot e Repeat the above b c and d several times until all marks come to the same spot f This spot is the wheel s heavy spot X A A A A A A A A A 4 Adjust e Wheel static balance VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Adjusting steps e Install a balancing weight 1 on the rim exact ly opposite to the heavy spot X NOTE Start with the smallest weight e Turn the wheel so that the heavy spot is 90 up e Check that the heavy spot is at rest there If not try another weight until the wheel is bal anced AAA A A A A A A A 4 28 nen wes AD nae CHAS 5 Check e Wheel static bal
37. If absolutely necessary repair with the utmost care and replace the tube as quickly as possible with another with the same charac teristics 4 Tighten e Valve stem lock nut Lock nut valve stem A 1 5 Nm 0 15 kgm FRONT Manufacture Size PIRELLI 90 90 21 54R MT70 MICHELIN 90 90 21 54S T63 REAR Manufacture Size Type PIRELLI 130 80 18 66R MT70 MICHELIN 130 80 18 66S T63 A WARNING After assembling the new tyres drive slowly to allow them to adapt well to the rim and yjus ensure maximum holding WHEEL INSPECTION SPOKE INSPECTION AND TIGHTENING WHEEL INSPECTION 1 Inspect e Wheels Damage Deformation gt Replace NOTE Always balance the wheel after the replacement or reassembly of a tyre or rim A WARNING Never try to repair a rim in any way Bearing inspection Check the front and rear wheel bearings periodi cally to make sure that they do not have free play in the hub and that the wheel turns smoothly with out sticking Wheel bearings must always be checked in accordance with the maintenance table SPOKE INSPECTION AND TIGHTENING 1 Inspect Spokes 1 Curvature Damaged gt Replace Loose spoke gt Tighten 2 Tighten Spoke s NOTE Tighten the spokes before and after the break in period Spoke 3 44 CABLE INSPECTION LEVER AND PEDAL LUBRICATION CABLE INSPECTION A WARNING If the cable sheath is da
38. If there is any charge in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after having left the battery un used for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery 3 50 CHECKING AND CHARGING THE BATTERY NSP ei Charging method using a constant voltage type charger i Measure the open circuit Voltage should be measured 30 min voltage prior to charging utes after the machine is stopped Connect a charger meter to the battery and start charging Make sure the current is YES higher than the standard NO charging current written on the battery Y Charge the battery until the battery s This type of battery charger cannot charging voltage is 15 V charge the MF battery A variable volt NOTE Set the charging time at 20 hours max imum Measure the battery open circuit volt age after having left the battery unused for more than 30 minutes 12 8 V or more Charging is com plete 12 7 V or less Recharging is re Voltmeter quired Under 12 0 V Replace the battery AMP meter Charging method using a constant current type charger This type of battery charger cannot charge the MF battery 3 51
39. MASTER CYLINDER INSTAL Brake hose LATION section Master cylinder Reverse the removal procedure for instal lation FRONT BRAKE CHAS Jab name Par name Master cylinder disassembly Remove the parts in order Reservoir cap Diaphragm Master cylinder boot Refer to MASTER CYLINDER ASSEM Circlip BLY section Master cylinder assembly Spring Reverse the disassembly procedure for assembly 4 12 4 13 FRONT BRAKE CHAS MASTER CYLINDER INSPECTION 1 Inspect e Master cylinder assembly Wear scratches Replace the master cylinder assembly e Master cylinder body Cracks damage Replace the master cylinder assembly e Fluid delivery passage master cylinder Obstruction gt Clean with a jet of com pressed air Inspect e Master cylinder piston unit 1 Scratches wear damage Replace the master cylinder assembly Inspect e Diaphragm Wear damage gt Replace Inspect e Brake hose Cracks wear damage gt Replace MASTER CYLINDER ASSEMBLY A WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 In case of non correct operation of the brake master cylinder replace the master cylinder assembly Install e Spring 1 e Master cylinder 2 4 14 FRONT BRAKE CHAS 2 Install e Circlip 1 e Master cylinder boot 2 MASTER CYLINDER INSTALLATION 1 Install e Mast
40. Plate 60 Nm 6 0 m 60 Nm 6 0 43 ft Ib 60 Nm 6 0 43 ft Ib 120 Nm 12 0 85 ft Ib 5 68 ENGINE ASSEMBLY AND SETTING ENG 4 5 69 BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR 1 Install Key 1 Balancer shaft gear 2 Plate 3 Lock washer 4 Nut 5 balancer shaft gear Washer 6 Key 7 Plate 8 Balancer shaft drive gear 9 Plate 10 Primary drive gear 11 Lock washer 12 Nut 13 primary drive gear Nut balancer shaft gear 60 Nm 6 0 mkg Nut primary drive gear 120 Nm 12 0 mkg NOTE When installing the drive gear align the mark on it 14 with that of the balancer shaft gear 15 AA WARNING Always use a new lock washer NOTE To tighten nuts 5 and 13 keep the AC genera tor rotor still with the special tool 16 Sheave holder P N 90890 01701 CAUTION Be careful not to touch the jutting part 17 of the rotor with the sheave holder 2 Bend the lock washer tab along the face of the nut ENGINE ASSEMBLY AND SETTING ENG CLUTCH Compression spring 9 Clutch boss Pressure plate 10 Thrust plate Push rod 11 Primary driven gear Ball comp Friction plate type A 12 Push rod Clutch boss spring 13 Push lever Clutch plate 14 Primary drive gear Friction plate type B S Wear Limi FREE LENGTH Type SE ear 42 8 mm 1 685 in e 3 m
41. SEN To remove the bulb press it into place and turn it counterclockwise a 2 Install e New bulb NOTE To install the bulb press it into place and turn it clockwise b e Lens e Screws lens fixing CAUTION Do not overtighten the screws otherwise the lens may break 3 57 INSP CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC 4 1 FRONT WHEEL AND BRAKE DISC REMOVAL 4 1 FRONT WHEEL 4 3 FRONT WHEEL INSPECTION gt us ERE 4 3 BRAKE DISC INSPECTION RR RR RE XE ERES 4 5 FRONT WHEEL ASSEMBLY 2222 22 542460800694 4 5 FRONT WHEEL 4 6 WHEEL STATIC BALANCE 905 4 6 FRONT BRAKE oues Rabe AR br us 4 8 BRAKE PAD REMOVAL 4 8 BRAKE PAD REPLACEMENT 4 9 MASTER CYLINDER ze neu ee eee EE ee S 4 11 MASTER CYLINDER INSPECTION 4 13 MASTER CYLINDER 4 13 MASTER CYLINDER INSTALLATION 4 14 BRAKE CALIPER uoc re Ep oue dunes e 4 16 BRAKE CALIPER DISASSEMB
42. Spark plug Cylinder head cover Tappet cover intake Tappet cover exhaust Oylinder Cylinder Cylinder Weight drive gear Rotor A C magneto Lock nut valve adjusting screw Cam chain sprocket Cam chain stopper guide Cam chain stopper guide Rocker shaft Oil pump Oil delivery retrieval pipe Oil draining pipe Oil filter cover Bleed screw oil filter cover Push lever clutch Push rod clutch Sprocket Lock washer oil seal Stop lever Shift cam Stator Washer based bol Stud bolt Hexagon socket head screw Stud bolt Union bolt Hexagon socket head screw Hexagon socket head screw Crown nut Nut Hexagon socket head screw Hexagon nut Hexagon nut Hexagon nut Washer based bolt Hexagon socket head screw Washer based screw Hexagon socket head screw Hexagon socket head screw Pan screw Washer based screw Hexagon socket head screw Hexagon screw Pan screw Hexagon nut Hexagon nut Hexagon screw Bolt Hexagon screw Pan head screw 2 10 M8 x 1 25 M10 x 1 25 M6 x 1 0 M6 x 1 0 M6 x 1 0 M12 x 1 25 M6 x 1 0 M6 x 1 0 M32 x 1 5 M8 x 1 25 M10 x 1 25 M6 x 1 0 M16 x 1 0 M14 x 1 5 M6 x 1 0 M7 x 1 0 M6 x 1 0 M16 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M14 x 1 5 M6 x 1 0 M5 x 0 8 M8 x 1 0 M6 x 1 0 M18 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M5 x 0 8 29 2 9 20 2 0 1 0 0 7 0 7 1 8 1 0 1 0 1 2 2 2 4
43. The longer distance A is the lower the spring preload the shorter distance A is the higher the spring preload With each com plete turn of the adjusting nut distance A changes by 1 5 mm Spring preload Minimum soft Distance A 217 mm Standard Distance A 211 mm Maximum hard Distance A 205 mm 2 Tighten the locknut to the specified torque Locknut A 45 Nm 4 5 m kgf CAUTION Always tighten the locknut against the adjust ing nut and then tighten the locknut to the specified torque 3 39 STEERING INSPECTION ei 3 40 STEERING INSPECTION A WARNING Hold the motorcycle firmly in place to prevent it falling over 1 Raise the front wheel and place a support under the engine 2 Check e Steering bearings Grasp the bottoms of the front fork legs and rock back and forward Free play gt Adjust steering bearing 3 Adjust e Steering bearing VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Adjustment e Remove the fuel tank See section SEAT FUEL TANK AND REAR COWLING e Loosen steering axle nut 1 and fork upper bracket screws 2 e Tighten the ring nut 3 with the special wrench Ringnut wrench P N 90890 01268 P N 90890 01348 The torque wrench and the ringnut wrench should form a right angle Ring nut initial tightening 25 38 Nm 3 8 mkg e Loosen the ring nut one turn e Retighten the ring nut using the special wrench A WARNING Do not
44. Wear Corrosion gt Replace e O Ring 3 Damaged gt Replace NOTE Always replace the needle valve set and the valve seat together 3 Inspect e Starter piston 1 Wear Damage gt Replace e Stop screw 2 A E Damaged gt Replace 4 Inspect e Diaphragm 1 piston valve e Diaphragm 2 enrichment Damaged gt Replace 5 Inspect e Needle jet 1 primary e Needle jet 2 secondary P Curvature Wear Replace 6 9 CARBURETOR INSPECTION CARB 6 Inspect Throttle valve 1 primary Diaphragm 2 secondary ear Damaged gt Replace 7 Check Free movement Hampered gt Replace Fit the throttle valve and diaphragm into the carburetor body and check that move ment is free A Primary carburetor B Secondary carburetor 8 Inspect 6 10 NOTE Clean jets with compressed air Float 1 Damaged gt Replace 9 Inspect Main jet 1 primary Main jet 2 secondary Main nozzle 3 primary Main nozzle 4 secondary Pilot jet 5 CARBURETOR ASSEMBLY CARB CARBURETOR ASSEMBLY Perform CARBURETOR DISASSEMBLY opera tions in reverse order Pay attention to the follow ing points CAUTION Wash all parts with clean petrol prior to reassembly Secondary carburetor 1 Install e Needle jet 1 e Diaphragm 2 e Spring NOTE Draw the diaphragm tab level with the notch on the secondary carburetor 2 Install e Top cover S
45. a Spin the wheel and wait for it to rest b Put an X mark on the wheel s bottom spot the wheel so that the X mark is 90 up d Release the wheel and wait for it to rest Put an X mark on the wheel s bottom spot e Repeat the above b c and d several times until all marks come to the same spot f This spot is the wheel s heavy spot X AAA A A A A 4 Adjust e Wheel static balance VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Adjusting steps e Install a balancing weight 1 on the rim exact ly opposite to the heavy spot X NOTE Start with the smallest weight e Turn the wheel so that the heavy spot is 90 up e Check that the heavy spot is at rest there If not try another weight until the wheel is bal anced 5 Check e Wheel static balance VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Checking steps e Turn the wheel so that it comes to each point as shown e Check that the wheel is at rest at each point If not readjust the front wheel static balance AAA A A A A A A A A A A A A A A A A A A A A A A A A A A FRONT BRAKE CHAS FRONT BRAKE BRAKE PAD 25 Nm 2 5 m kg Job name Par Brake pad removal Remove the parts in order Brake caliper screw Brake caliper Pad pin retainer Refer to BRAKE PAD REPLACEMENT Pad pin section Bra
46. e Oil level not the same in both tubes e Spring broken e Front fork crooked Tyre pressure incorrect for type of road e Tyre pressure incorrect e Tyres worn non uniformly e Wheels balanced incorrectly e Wheel deformed Bearing loose e Wheel axle deformed or loose e Wheels excessively off centre Deformed e Head tube damaged e Ball track installed incorrectly e Bushes or bearings consumed e Deformed or damaged e Spring yielded e Spring preloaded e Oil leak Chain set incorrectly TRBL DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS SHTG DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS HEADLIGHT DOES NOT LIGHT PROBABLE CAUSES e Incorrect bulb e Excessive absorption of electrical accessories e Difficulties in charging charging coil broken and or rectifier regulator defective e Uncertain connections e Wrong negative earthing e Insufficient contacts main switch e Bulb gone FREQUENT BURNING OF BULB PROBABLE CAUSES e Light relay diode defective e Incorrect bulb e Rectifier regulator defective e Wrong negative earthing Main switch defective e Bulbs gone DIRECTION INDICATORS FAIL TO TURN ON PROBABLE CAUSES e Wrong negative earthing e Battery flat e Defective direction indicator switch e Indicator lamp relay defective e Harness cut off Connector loose e Bulb gone DIRECTION INDICATORS FAIL TO TURN OFF PROBABLE CAUSES e Indicator lamp relay defective
47. facilitate the removal and installation of the guides and to maintain correct locking interference e Remove the valve guide using the special punch 1 e Install the new guide using the special instal lation tool 2 e After installing the valve guide bore with spe cial tool 3 to obtain valve guide free play 24 Valve guide remover 7 mm 7 90890 01225 Valve guide installer P N 90890 04017 Valve guide reamer 7 mm P N 90890 01227 A AAA A A A A A A A A A A A A A A A A A A A A A A A A A INSPECTION AND REPAIR 5 23 2 Clean the valve surfaces of the carbon deposits 3 Inspect e Valve seal surface Pitting Wear gt Grind the valve seal sur face 4 Measure e Edge thickness a Out of specification Replace valve Edge thickness Intake 1 0 14 mm Limit 0 8 mm Exhaust 0 8 1 2 mm Limit 0 65 mm 5 Check e Valve stem tip Deformed mushroom shaped or with a higher diameter than the rest of the stem Replace valve e Misalignment Out of specification gt Replace valve lt Stem offsetting Limit 0 01 mm NOTE _ e Changing the valve replace also the valve guide e Pulling the valve out replace the stem seal VALVE SEAT 1 Clean the valve surface and seat of carbon deposits 2 Inspect e Valve seat Pitting Wear gt Renew valve seat INSPECTION AND REPAIR oD 5 24 3 Measure e Valve seat width a Out
48. indicates the terminals between which there is electrical continuity ie a closed circuit on the respective switch positions For example in this table R and Br are continuous when the switch is at ON L and R B are continuous when the switch is at ON R and L are continuous when the switch is at PARK Terminals are not continuous when the switch is at OFF MAIN SWITCH INSPECTION Before inspecting the switch see the connection table shown above and check the terminal con nections closed circuit by the colour combination 7 6 SWITCH CHECK ELEC 1 Detach the main switch connector from the harness connector CAUTION When detaching the connector do not pull by the cables This way the cables might discon nect from the terminals inside the connector itself 2 Check to see if any cables are disconnected from their terminal inside the connector Reconnect if necessary NOTE T If the connector is blocked up with mud or dust clean it with a jet of compressed air 3 Use the connection table to check the combi nation of colours for continuity closed circuit In this example continuity is as follows and are continuous when the switch is at ON L and R B are continuous when the switch is at ON R and L are continuous when the switch is at PARK Note that there is no continuity open circuit for any of the combinations of
49. 0 2 mkg CARBURETOR ASSEMBLY CARB 6 14 10 Install e Float pin 1 NOTE _ ____________ Assemble the float in the opposite direction to the arrow 11 Measure e Float height a Out of specification gt Adjust Kl Float height 27 0 29 0 mm Measurement and adjustment e Hold the carburetor upside down e Measure the distance from the joint plane of the float chamber without the gasket and the top of the float NOTE 2 The float arm must rest the neeedle valve without being pressed If the float height is out of tolerance check the valve seat and the needle valve e f either is worn replace both e f both are perfect adjust the float height by bending the wing tab of the float itself 1 e Recheck the float height A A 12 Install e Float chamber Ny Screw float chamber QJ 2 Nm 0 2 mkg 13 Adjust e Pilot air screw 1 VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Adjustment e Turn the screw until it is slightly locked e Unscrew by 3 and 1 2 turns AAA A A A A A CARBURETOR ASSEMBLY CARB 6 15 14 Install e Primary carburetor e Secondary carburetor 15 Install e Support plate front 1 e Support plate rear 2 Screw Support plate
50. 0 8799 0 2199 oz IMP lig cu in qt IMP lig gal IMP liq kg mm kg cm Centigrade 55 997 14 2234 9 5 C 32 Ib in psi Ib in Fahrenheit F LUBRICATION POINTS AND LUBRICANT TYPE SPEC ve LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points part name Lubricant type Oil seal edges completely Bearing retainer Rod pins Rod big end Piston and piston rings Hub weight drive sprocket Piston pin Valve stim and guide Oil seal valve stim end Rocker shaft and rocker arm Cam and bearing camshaft Rotor and rotor housing oil pump Push rod clutch Primary driven gear and main shaft Sliding gear transmission Idle gear transmission Shift forks and bar Shift cam and bearing gearshift cam Shift shaft Rod housing coupled surfaces Bonding agent rapid seal adhesive Yamaha bond No 12159 Coupled surfaces cylinder head and cylinder head cover Bonding agent rapid seal adhesive Yamaha bond No 12159 2 20 LUBRICATION POINTS AND LUBRICANT TYPE SPEC ve CHASSIS Lubrication points part name Lubricant type Gear unit tachometer Oil seal edges completely Wheel axle front and rear wheels Rear wheel hub and clutch Bearings brasses rear arm and bearing push cover Front footrest Pivot points brake pedal and shift pedal Bearing
51. 2 1 0 6 0 1 4 2 0 1 0 2 0 1 0 1 0 0 7 3 0 1 0 0 5 1 2 0 8 1 0 1 0 1 0 0 5 MAINTENANCE SPECIFICATIONS SPEC ve Part to be tightened Thread size Tightening torque Nm mkg Remarks Stator pick up coil Engine oil pipe 1 Engine oil pipe 2 Oil delivery pipe Carburetor joints Air filter case frame Air filter case frame Exhaust pipe Exhaust pipe protector Muffler Muffler band Muffler Crankcase Crankcase Crankcase cover right Crankcase cover left Sprocket cover Stop washer bearing Pressure plate Clutch housing Primary drive gear Hexagon socket head screw Hexagon socket head screw Union screw Union bolt Hexagon socket head screw Hexagon screw Washer based Screw Washer based nut Pan head Screw Hexagon socket head screw Nut nylon Washer based Screw Hexagon socket head screw Stud bolt Hexagon socket head screw Hexagon socket head screw Hexagon socket head screw Flat headscrew Washer based Screw Hexagon nut Hexagon nut 2 11 M6 x 1 0 M6 x 1 0 M12 x 1 25 M8 x 1 25 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M8 x 1 25 M8 x 1 25 M8 x 1 25 M6 x 1 0 M10 x 1 25 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M20 x 1 0 M20 x 1 0 0 7 1 0 3 5 1 8 1 0 1 0 1 0 1 0 0 7 2 3 2 3 2 3 1 0 2 0 1 0 1 0 1 0 0 7 0 8
52. 5 73 STARTER NEUTRAL GEAR AND CRANKCASE COVER L 5 74 ENGINE 55 5 76 ENGINE ENGINE REMOVAL CD ENGINE REMOVAL MUFFLER EXHAUST PIPE ENGINE PROTECTOR DRIVE SPROCKET CRANKCASE COVER DRIVE SPROCKET AND SHIFT PEDAL 10 Nm 1 0 mg Job name Part name Remarks Muffler exhaust pipe engine Remove the parts in order protector drive sprocket crankcase cover drive sprocket and shift pedal removal Park the motorcycle in a stable and level position A WARNING Securely support the motorcycle so there is no danger of it falling over 5 1 G ENGINE REMOVAL CD CENE 10 Nm 1 0 mg 7 Nm 0 7 m kg Job namel Pan name Drain the engine oil refer to ENGINE OIL REPLACEMENT section in CHAPTER 3 Remove the seat the fuel tank and the rear cowling refer to SEAT FUEL TANK AND REAR COWLING section in CHAPTER 3 Battery leads connector Disconnect Muffler Exhaust pipe Engine protector Shift pedal Drive sprocket crankcase cover Drive sprocket Clutch cable Plug cap Displace the drive chain Disconnect Disconnect Om A OO N oct zech E 10 11 12 13 14 7 Nm 0 7 m kg G ENGINE REMOVAL CD Job rame 2 Starter leads Starter Connectors of engine wire harness Oil delivery hose Oil ret
53. A Front B Rear d Place the other end of the hose in a container e Slowly pull the brake lever or press the brake pedal several times f Pull the brake lever right in or press the pedal right down and hold in position g Loosen the bleeder screw and allow the lever or pedal to travel slowly towards its limit h Tighten the bleeder screw when the lever or pedal limit has been reached then release the lever or pedal Y Bleeder screw A 14 Nm 1 4 mkg i Repeat operations e to h until all the air bubbles have disappeared from the clear plastic hose 1 3 35 DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT IT ei NOTE __ If bleeing proves difficult it may be necessary to allow the brake fluid system to stabilise for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeared j Top up fluid to the maximum level DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT Inspecting slack NOTE __ 0 0 Before checking and or adjusting the chain rotate the rear wheel through several revolutions and check the slack several times to find the point on the wheel where chain slack is highest Check and or adjust chain slack with rear wheel in this tight chain position 1 Check e Drive chain slack Out of specification gt Adjust Drive chain slack 30 40 mm NOTE To check chain slack the motorcycle must stand in an upright position with its two wheels touching
54. A A A A A A A A A WARNING If the brake brake pedal has a soft or slack feel this means that there is air in the brake system It should be bled away before using the motorcycle Air in the system seriously affects the effectiveness of braking and may cause loss of control of the motorcycle 3 32 CHECKING THE BRAKE FLUID LEVEL ei CHECKING THE BRAKE FLUID LEVEL 1 Stand the motorcycle on a level surface NOTE e Place the motorcycle on a suitable stand e Make sure that the motorcycle is upright 2 Check e Brake fluid level Below the minimum level mark a gt Add the recommended brake fluid to the prop er level Recommended brake fluid DOT4 A Front brake B Rear brake A WARNING e Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure that the top of the reser
55. A A A A A A A A A 5 Measure e Brush lenght Out of specification gt Replace all brus hes at once Kl Brush lenght limit a 5 0 mm 6 Inspect e Brush spring strength Worn out gt Replace all springs at once Brush spring strength 8 82 N 899 gf Inspect Bearings 1 e Oil seal 2 e O Rings e Bush 8 ELECTRICAL STARTING SYSTEM ELEC 7 33 Assembly Revert the disassembly procedure Pay attention to the following points 1 Install e Brush housing NOTE _ Align the jutting surface on the brush housing with the slot 2 2 Install e Stator 1 e Front bracket 2 NOTE M Align the reference marks 3 on the stator with the corresponding reference marks on the cover 4 3 Install e Screws 1 Screw stator Z 7Nm 0 7 kgm Installation 1 Install e Starter motor NOTE Slightly grease the O Ring 1 Screw starter motor 2 10 Nm 1 0 kgm 7 34 CHARGING SYSTEM ELEC CHARGING SYSTEM CIRCUIT DIAGRAM
56. CHECK CLUTCH ADJUSTMENT ENGINE OIL PRESSURE CHECK 1 Remove Bleeder screw 1 2 Start the engine and keep it idling until oil flows out of the bleed hole 3 Inspect e Conditions of oil at bleeder hole Oil leakage gt Oil pressure good No leakage Pressure insufficient CAUTION If the oil does not come out after one minute stop the engine immediately to prevent seizure 4 Tighten e Bleeder screw IN Bleeder screw A 5 Nm 0 5 kgm CLUTCH ADJUSTMENT Cable free play adjustment 1 Check e Clutch free play adjustment a Out of specification gt Adjust Free play 10 15 mm 2 Adjust e Clutch cable free play Adjustment e Loosen lock nuts 1 e Turn the adjuster 2 either way to obtain cor rect free play e Tighten lock nuts after adjustment A AAA A A A A A A A A A A A A A A A A A A A A A A A A A CLUTCH ADJUSTMENT ei After adjustment recheck lever free play to make sure that it works smoothly and progressively If it is impossible to obtain the required adjust ment or if the clutch does not work properly adjust the internal mechanism Internal mechanism adjustment 1 Loosen e Lock nuts on the lever cable adjuster and crankcase adjuster 2 Fully tighten e Adjusters 3 Drain off e Engine oil See section ENGINE OIL REPLACE MENT 4 Remove e Footrest right 1 e En
57. CHECKING AND CHARGING THE BATTERY ei 6 Connect e Battery leads to the battery terminals CAUTION First connect the positive lead 2 then the negative lead 7 Check e Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 8 Lubricate e Battery terminals Recommended lubricant Dielectric grease 9 Install e Panel e Seat 3 52 CHECKING THE FUSES NSP ei CHECKING THE FUSES CAUTION To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Remove e Seat Panel D 2 Check e Fuse VVVVVVVVVVVVVVVVVVVVVVVYVVVYVVY a Connect the pocket tester to the fuse and check it for continuity NOTE Set the pocket tester selector to Q x 1 b If the pocket tester indicates oo replace the fuse AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 3 Replace e Blown fuse VVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Turn off the ignition b Install a new fuse of the correct amperage rat ing c Turn on the switches to verify if the electrical circuit is operational d Ifthe fuse immediately blows again check the electrical circuit A AA A A A A A A A A A A A A A A A A A A A A A A A A A A Amperage rating Main 1 20A Reserve 2 20A Quantity Fuses 3 53 3 54 CHECKING THE FUSES REPLACING THE HEADLIGHT BULBS A WARNING Never use a fuse with an amperage rating o
58. Centring of seat and attainment of 1 0 mm width If the valve surface is like this it means that the valve seat is too narrow and close to the edge of the valve Intervention on the valve seat 30 before Centring of seat and Pd l attainment of 1 0 mm type 45 width Desired effect D If the valve surface is like this it means that the valve seat is too narrow and situated low down near the lower edge of the valve sur face Intervention on the valve seat Desired effect 60 first Centring of seat and Ped vey attainment of 1 0 mm Ap width 5 25 INSPECTION AND REPAIR 5 e Valve seal surface e Valve seat NOTE If the valve seat is renewed the valve and guide replaced the valve seat and seal surface must be lapped A AAA A A A A A A A A A A A A A A A A A A A A A A A A A Lapping steps e Apply rough lapping compound to the valve seal surface CAUTION Make sure the lapping compound does not run into the space between the guide and valve stem Apply oil to the molybdenum disulfide on the valve stem e Install the valve in the cylinder head B e Turn the valve until face and surface are not evenly polished Then clean away all the lap ping compound NOTE n For best results during lapping repeatedly apply light pressure to the valve seat turning the valve backwards and forwards by h
59. Drive chain slack Refer to DRIVE CHAIN SLACK ADJUST MENT section in CHAPTER 3 Drive chain slack 30 40 mm DRIVE CHAIN DRIVE SPROCKET C HAS dioe AND REAR WHEEL SPROCKET O 5 Tighten e Rear wheel axle nut EN Rear wheel axle nut A 115 Nm 11 5 mkg Refer to REAR WHEEL INSTALLATION section 7 Install e Cover drive sprocket 51 pedal Screws drive sprocket cover 10 Nm 1 0 mkg Bolt shift pedal 10 Nm 1 0 mkg 4 86 CHAPTER 5 ENGINE ENGINE REMOVAL 5 1 MUFFLER EXHAUST PIPE ENGINE PROTECTOR DRIVE SPROCKET CRANKCASE COVER DRIVE SPROCKET AND SHIFT PEDAL 5 1 ENGINE MOUNTING BOLT 2 2 5 4 ENGINE DISASSEMBLY 5 5 CYLINDER HEAD CYLINDER CAMSHAFT AND 5 5 5 INTERMEDIATE STARTER GEAR CRANKCASE COVER L AND GENERATOR 5 5 8 CRANKCASE COVER R CLUTCH PRIMARY DRIVE GEAR AND BALANCER SHAFT 5 9 OIL PUMP AND SHIFT 5 12 AC GENERATOR AND TIMING 5 13 VERTS 5 14 GEARBOX AND 5 5 16 BALANCER SHAFT AND CRANKSHAFT
60. Front disc brake Disc outside diameter x thickness Max deflection Brake pad lining thickness inner Brake pad lining thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid 267 x 4mm 7 5 mm 7 5 mm 13 mm 28mmx2 DOT 4 Rear disc brake Disc outside diameter x thickness Max deflection Brake pad lining thickness inner Brake pad lining thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Front brake lever 220 0 x 5 0 mm 9 0 mm 9 0 mm Adjustable Brake pedal lever Brake pedal position Clutch lever Clutch lever free play lever end 10 mm below the footrest plane 10 0 15 0 mm Throttle grip Throttle cable free play 3 0 5 0 mm 2 13 MAINTENANCE SPECIFICATIONS SPEC ve Tightening torques Part to be tightened Tightening torque Nam m kg Remarks Engine mounting and rear frame Engine front Stay engine Stay engine engine front Frame Engine rear under Frame Engine top Stay engine Engine protector Frame Chain tensioner top Frame Chain tensioner under Frame Frame Rear frame upper Frame Rear frame under Rear frame Air filter assy M10 x 1 25 M10 x 1 25 M10 x 1 25 M10 x 1 25 M6 x 1 0 M8 x 1 25 M8 x 1 25 M8 x 1 25 M8 x 1 25 M6 x 1 0 64 6 4 64 6 4 68 6 8 64 6 4 7 0 7 23 2 3 23 2 3 23 2 3 23 2 3 5 0 5 Front fork and steering Handle crown Inner tub
61. Green Yellow Orange Blue Red Pink Blue White Red Blue Yellow Sky blue Yellow Red Black Red White Red Yellow Black Red White Blue Black White 7 2 Yellow Red ELECTRICAL COMPONENTS ELEC BATTERY CAPACITY 12V 8Ah ELECTRICAL COMPONENTS 1 Main wire harness SPECIFIC GRAVITY 1 320 Diodes Extension wire harness Rectifier Regulator CDI ignition unit Battery 12V 8Ah Starter relay Fuse 20A ELECTRICAL COMPONENTS ELEC Ignition coil Spark plug cap IGNITION COIL Flasher relay Primary winding resistance Horn 4 Q 15 at 20 C 68 F Clutch switch Secondary winding resistance Relay assy 1 20 at 20 Sidestand switch STR Neutral switch Main switch 7 4 7 5 SWITCH CHECK ELEC SWITCH CHECK Check the continuity between the switch terminals to verify whether connections are correct To check the switch read the following points SWITCH CONNECTION The table shown here contains the connections between the switch terminals eg main switch handlebar switches brake switch light switch etc The column on the far left shows the positions of the main switch and the top line indicates the colours of the cables connected with the terminals of the switch itself o o
62. OIL PUMP AND OIL STRAINER 1 Oil strainer 2 Oil pump 3 Oil pump gear OIL PUMP TIP CLEARANCE 0 12 mm 0 005 in SIDE CLEARANCE 0 03 0 08 mm 0 001 0 003 in 5 49 ENGINE ASSEMBLY AND SETTING ENG 4 CRANKCASE 1 Crankcase R 2 Crankcase L 8 Crankcase ventilation hose 4 Dowel pin b Dowel pin 6 Dowel pin 7 Bearing cover plate 8 Collar 9 Lock plate 5 50 5 51 ENGINE ASSEMBLY AND SETTING ENG ENGINE OIL STRAINER 1 Install e Oil strainer 1 e Oil passage cover 2 Screw oil strainer 7 Nm 0 7 mkg Screw oil passage cover 7 Nm 0 7 mkg A WARNING Always use a new gasket CRANKCASE 1 Apply e Yamaha bond 1215 1 on the crankcase mating surfaces 24 Yamaha bond 1215 2 90890 85505 2 Install Dowel pin 2 3 Assemble the left crankcase to the right Beat gently with a soft hammer NOTE Turn the shift cam as shown in the figure so that it does not interfere with the crankcase during assembly CAUTION Before installing and tightening the fastening screws be sure that the transmission is work ing properly by hand turning the shift cam in both directions ENGINE ASSEMBLY AND SETTING 4 4 Tighten e Screws crankcase 1 14 NOTE Tighten the screws beginning with the one with the lowest number Ny Screw crankcase 2 10 Nm 1 0 mkg
63. ON 8 8 DIRECTION INDICATORS FAIL TO TURN OFF 8 8 DELAYED TURNING ON OF INDICATORS 8 9 EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY 8 9 THE HORN FAILS TO WORK 1 8 9 OVERHEATING OF ENGINE 8 9 NOTE FAILURE TO START TRBL DIFFICULTIES IN STARTING SHTG TROUBLESHOOTING The troubleshooting tables that follow do not identify every cause of trouble They may however prove helpful as a guide to identifying trouble To inspect adjust or replace parts refer to the appropriate sec tion in the manual FAILURE TO START DIFFICULTIES IN STARTING PROBABLE CAUSES FUEL SYSTEM Fuel tank Fuel cock Carburetor Air filter 8 1 Empty Fuel filter obstructed Fuel tank air cap passage obstructed Petrol contains water or impurities or is adulterated Hose obstructed e Fuel filter obstructed Petrol contains water or impurities or is adulterated Pilot jet obstructed Pilot air passage obstructed Infiltrations of air Deformation of float Needle valve worn or scratched Needle valve seat insufficiently sealed Fuel level set wrongly Pilot jet set wrongly Starter jet obstructed Malfunctioning of the starter piston Air filter element obstructed FAILURE TO START TRBL DIFFICULTIES IN STARTING SHTG PROBABLE CAUSE
64. Regulator Frame Igniton coil Frame Battery box Rear frame Igniter cover Battery box Main switch Frame Tail light lense Rear fender compl Starter switch Red wire 2 15 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M8 x 1 25 M5 x 0 8 M6 x 1 0 M4 M24 x 1 0 5 M6 x 1 0 0 2 0 7 1 0 1 0 1 3 0 7 1 3 0 7 0 1 0 1 0 1 0 7 MAINTENANCE SPECIFICATIONS SPEC ve Tightening Part to be tightened Thread torque Remarks size N m m kg Starting motor cord Starting motor M6 x 1 0 11 1 1 Wire minus lead Starting motor M6 x 1 0 10 1 0 Front flasher lights Stay headlight M6 x 1 0 1 5 0 15 Clutch wire Engine M6 x 1 0 7 0 7 Assist grip Standing handle Rear frame M8 x 1 25 23 2 3 Speedometer M5 x 0 8 4 0 4 Air filter case 1 Air filter case 2 L 18 mm M3 9 0 5 0 05 Air filter case 1 Air filter case 2 L 19 mm M3 9 1 0 1 Hose clamp Joint carburator M4 x 0 7 0 6 0 06 Hose clamp Air cleaner Carburator M5 x 0 8 0 8 0 08 Battery M6 x 1 0 2 5 0 25 NOTE n 1 First tighten the ring nut approximately 38 Nm 3 8 mkg by using the torque wrench then loosen the ring nut one turn 2 Final tighten the ring nut at the torque of 4 Nm 0 4 2 16 MAINTENANCE SPECIFICATIONS SPEC ve ELECTRICAL Item Standard Ignition system Ignition timing B T D C Advanced timing B T D C Advancer type 12 1 300 r min 31 7 500 r min Electrical type Tr
65. Replace STEERING INSTALLATION 1 Install e Bearing 1 e Ball race cover 2 NOTE 5 Apply lithium soap base grease to the bearing and ball race cover lip 2 Install e Lower bracket 1 NOTE n Apply lithium soap base grease to the bearing 4 65 STEERING CHAS 3 Install e Ring nut lower 1 Use the ring nut wrench 2 4 66 QK Ring nut wrench 4 90890 01268 Apply the lithium soap base grease to the steer ing axle thread VVVVVVVVVVVVVVVVVVVVVVVVVVYVVY Lower ring nut tightening steps e Tighten the ring nut 1 using the ring nut wrench Ring nut lower initial tightening 38 Nm 3 8 mkg e Loosen the ring nut completely and retighten it to specification A WARNING Do not tighten excessively Ring nut lower final tightening 4 Nm 0 4 mkg A AAA A A A A A A A A A A A A A A A A A A A A A A A A A 4 Check the steering axle by turning it lock to lock If there is any binding remove the steer ing axle assembly and inspect the steering bearings Install e Ring nut upper 1 e Special washer 2 4 67 STEERING CHAS VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Installation steps Install the ring nut upper 1 e Finger tighten the ring nut upper then align the slots of both ring nuts If not aligned hold the lower ring nut and tighten the other until they are aligned e Install the special washer NOTE
66. Rinse properly and dry perfectly by squeezing the filtering element without twisting it 4 Inspect e Filtering element Damaged gt Replace 5 Apply e SAE 20W50 engine oil or special filter oil all over filter surface 6 Squeeze out e Excess oil NOTE The filtering element should be wet but not drip ping 7 Install e Filtering element 4 in its case 2 OY d 4 d d VW SN de So 5 e Xs d Or lt 5 X NOTE When installing the filtering element in its case fol low the direction indicated by the arrows make sure that the flame trap net is set forward and that the cap is properly assembled oe s 99900 ERIS 2950 MRNA So d de m XS n Oo OR d 5 Y d x 9 00 SN NN 555 ck GE i Wey 55590 M S GON M e M M 5 SM e 4 25 X W 55 06 5 Kox 50 Kik 8 Reassemble e Air filter box cap e Fast screws CAUTION Make sure the air filter is properly seated in the air filter case The engine should never be run without the air filter installed Excessive piston and or cylinder wear may result 3 24 AIR FILTER CLEANING FUEL FILTER CLEANING 3 25 CAUTION Periodically check wheter the sleeve on the bottom of the air filter case is empty Remove the plug 5 and clean it if dirt or water accu mulate FUEL FILTER C
67. a 60 0 mm e Fit the second sprocket 4 and fifth sprocket b to the main shaft 3 b 90 5 mm A A 8 Inspect e Circlip Damage Loosening Bending gt Replace SHAFT AND STOPPER LEVER 1 Inspect e Shift shaft Bent Wear Damage gt Replace 2 Inspect e Stopper lever 1 The roller rotates jerkily Replace Bent Damage Replace 3 Inspect e Return spring 2 Damage Cracks gt Replace 5 37 4 INSPECTION AND REPAIR OL STARTER TRANSMISSION 1 Check Starter clutch functioning 1 Turn the clutch in the direction indicated at gt e by the arrow Irregular functioning Damage gt Replace the clutch VVVVVVVVVVVVVVVVVVVVVVVVVVVVY e Install the starter rim on the gear and hold the gear firm e When turning the gear rim in a clockwise direction A the gear and rim must be meshed Otherwise the gear is faulty and must be replaced e When the gear rim is turned in a anti clockwise direction B it must turn freely Otherwise the gear is faulty and must be replaced 2 Inspect e Starter neutral gear teeth 1 e Starter neutral gear teeth 2 e Starter rim teeth 3 Burrs Shavings Roughness Wear gt Replace 3 Inspect e Starter rim contact surfaces Pitting Wear Damage gt Replace 5 38 IN
68. bore C with a cylinder gauge QD 1 50 mm from top of cylinder NOTE s Measure bore parallel and at right angles to the driving shaft Then calculate average measure ment NEN E 94 97 95 02 mm 95 1 mm e f the measurements are out of tolerance replace the cylinder liner piston and circlips all together Second step e Measure diameter P of the piston skirt with a micrometer 1 5 mm from the lower edge of the piston Piston size Standard 94 915 94 965 mm 5 30 INSPECTION AND REPAIR e f the measurements are out of tolerance replace the piston and circlips all together e Calculate the piston cylinder free play accord ing to the following formula Piston cylinder clearance Cylinder boring C Piston skirt diameter P Piston cylinder clearance 0 045 0 065 mm lt Limit gt 0 15 mm e f the measurements are out of tolerance replace the cylinder liner piston and circlips all together A A 5 31 5 32 INSPECTION AND REPAIR OD PISTON RINGS 1 Measure e Side clearance of rings Use a thickness gauge Out of specification gt Replace piston NOTE ee Before measuring side clearance remove carbon deposits from the piston ring seats and from the rings themselves Piston ring side clearance installed Upper ri
69. e Cap bolt e O ring Wear Damage gt Replace 4 58 FRONT Fork CHAS FRONT FORK INSTALLATION 1 Install e Front fork 1 Temporarily tighten the pinch bolts lower 2 Tighten e Cap bolt Cap bolt 2 20 Nm 2 0 kgm Do not tighten the pinch bolt upper yet 3 Adjust e Front fork top end a Front fork top end a Standard 0 mm 4 Tighten e Pinch bolt upper and lower bracket Pinch bolt upper bracket 28 Nm 2 8 mkg Pinch bolt under bracket 23 Nm 2 3 mkg NOTE n Always tighten the lower pinch bolt to the pre scribed torque and then the upper one to the prescribed torque and then retighten the lower one to the prescribed torque 5 Install e Front wheel e Caliper e Brake hose e Tachometer cable Refer to FRONT WHEEL and FRONT BRAKE sections in this CHAPTER 4 59 FRONT Fork ADJ USTING THE FRONT FORK This front fork is equipped with spring pre load ad justing bolts A WARNING Always adjust both fork legs equally other wise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby hard en the suspension turn the adjusting bolt on each fork leg in direction To decrease the spring preload and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b Setting Minimum soft 1 2 3
70. installed by removing the following parts Seat e Fuel tank e Cylinder head cover 1 Remove 1 2 Remove e Bolts 1 rocker shaft 3 Remove e Rocker shaft e Rocker arms NOTE See Remove the rocker shaft using sliding hammer 1 and weight 2 Sliding hammer bolt P N 90890 01083 Weight P N 90890 01084 5 18 ENGINE DISASSEMBLY 5 19 VALVES NOTE 2 The valves may be inspected with the engine installed by removing the following parts Seat Fuel tank Exhaust pipe Carburetor Cylinder head cover Cylinder head Check e Valve seal Leakage from valve seats Inspect the valve surface the seat and seat width See section VALVE SEAT INSPECTION AND REPAIR NOTE __ Check the valve seal before assembling the inter nal parts of the cylinder head valves valve springs spring retainer etc VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Inspection steps e Pour clean solvent 1 into the intake and exhaust ports e Check the valve seal There must be no blow bys from the valve seats 2 A A A ENGINE DISASSEMBLY oD 5 20 2 Remove Cotters 1 Top spring retainer 2 Internal spring 3 External spring 4 Lower spring retainer 5 Valve 6 Valve stem seal 7 NOTE Mark each part and its position so that each may reassembled as before NOTE Ls C
71. is inserted correctly in its seat on the end of the inner tube 11 Mount the tool 1 on the inner tube 2 with the side 3 matching the DU outer tube bush 4 and clamp it keeping the two joints 5 at the top and bottom never towards the jaws of the vice and make it protrude by at least 40 mm at the sides lt gt DU bush oil seal driver 1 90890 11043 CSS 4 53 om od SINAN GSC EE eS 4 54 FRONT Fork 12 The vice tightened grip the outer tube and with a few strong blows hit it against the tool 3 until the DU outer tube bush 4 is correct ly positioned in its seat 13 Remove the fork leg from the vice and remove the tool 1 Insert the new washer 3 and the new oil seal 4 as shown on the inner tube 2 NOTE _ Apply lightweight lithium soap base grease to the oil seal before installing it 14 Mount the tool 1 on the inner tube 2 with the side 5 matching the oil seal 4 and clamp it keeping the two joints 6 at the top and bot tom never towards the jaws of the vice and make it protrude by at least 40 mm at the sides 2 DU bush oil seal driver 1 90890 11043 15 The vice tightened grip the outer tube and with a few strong blows hit it against the tool 1 After each blow rotate the outer tube slightly in order to
72. kgf cm 2 20 bar 90 kg maximum Front 210 kPa 2 10 kgf cm 2 10 bar Rear 240 kPa 2 40 kgf cm 2 40 bar Off road riding Front 150 kPa 1 50 kgf cm 1 50 bar Rear 160 kPa 1 60 kgf cm 1 60 bar High speed riding Front 210 kPa 2 10 kgf cm 2 10 bar Rear 240 kPa 2 40 kgf cm 2 40 bar Total weight of rider passenger cargo and accessories Wheels Front Type Spoke wheel Size 21 x 1 85 Rear Type Spoke wheel Size 18 x MT 2 50 GENERAL SPECIFICATIONS SPEC ve Standard Brakes Front Type Operation Fluid Rear Type Operation Fluid Single 267 mm disk brake 2 x 28 mm Right hand DOT 4 Single 220 mm disk brake 1 x 34 mm caliper Right foot DOT 4 Suspension Front Rear Telescopic fork Outside tube dia 46 mm Deltabox Swingarm with adjustable shock absorber Spring shock absorber Front Rear Wheel travel Front Rear Coil spring oil damper Coil spring gas oil damper spring preload adjustable 230 mm 230 mm Electrical system Ignition system Charging system Type Standard output Battery Model Voltage capacity Transistorized coil ignition digital A C magneto 14V 13 5A at 5 000 r min GT9B 4 12V 8Ah Headlight type Quartz bulb halogen Bulb voltage wattage x quantity Headlight Tail brake light Turn signal light Auxiliary light Meter lighting Turn signal indicator light Neutral indicator light Auxilia
73. no foreign material enters the crankcase 4 Reassemble the oil tank cap CAUTION Never start the engine when the oil tank is empty Oil capacity Total 3 0 litres Periodic oil change 2 4 litres With oil filter change 2 5 litres 3 16 ENGINE OIL REPLACEMENT NSP ei ENGINE OIL REPLACEMENT CAUTION Do not put additives into the engine oil The latter also lubricates the clutch and additives might cause it to slide A WARNING Never remove the oil tank cap when the engine is hot The boiling oil might spill over causing burns Wait for the oil to cool to at least 60 C 140 F or thereabouts Engine oil replacement without replacing filter oil 1 Warm up the engine for a few minutes 2 Stop the engine Place an oil pan under the engine and remove the oil filler cap 3 Remove the drain plug 1 and drain the engine oil 4 Remove two bolts 2 and O ring of the oil hose flange and drain the oil from oil tank 5 Remove the air bleed screw 3 attached to the oil filter cover 4 6 Wait until the oil has completely drained 7 Inspect e All gaskets Damaged gt Replace 8 Reassemble e Oil filter cover bleeder screw e Engine oil drain plug e Oil tank hose and O ring 3 17 20 Temp 10 0 10 20 30 10W 30 D 1 D D D D 1 D 4 1 10w 40 1 1 D D 1 i D 1 ENGINE OIL REPLACEMENT ei Fastening torques Drain plug engine 30 N
74. of specification gt Renew valve seat ee Intake 1 0 1 2 mm Limit 1 8 mm Exhaust 1 0 1 2 mm Limit 1 8 mm WWVVVVVVVVVVVVVVVVVVVVVVVYVYVVYN Measurement steps e Apply Prussian blue Dykem to the valve seat e Install the valve in the cylinder head e Press the valve onto the housing through the guide to leave a clear outline e Measure the width of the valve seat Where there is contatc between valve and seat the Prussian blue is wiped away e fthe valve seat is too narrow wide or off cen tre the valve seat must be renewed AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 4 Renew e Valve seat Use the special tool 1 to renew the valve seat with 30 45 and 60 mills CAUTION Turning the cutter maintain uniform pressure about 4 5 kg to avoid leaving marks on the valve seat INSPECTION AND REPAIR Mill the valve seat as follows Cutter VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Valve seat faults recorded by analysing the valve seal surface A If the valve surface resembles that shown in the figure this means that the valve seat is centred on the surface but is too wide Intervention on the valve seat Desired effect Cutter 30 Reduce valve seat type 60 width to 1 0 mm B If the valve surface is like this it means that the valve seat is centred on the valve surface but is too narrow Intervention on the valve seat Desired effect
75. or death to the motorcycle operator a bystander or a person checking or repairing the motorcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive ex planations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order D The manual is divided into chapters An abbreviation and symbol in the upper right corner of each page indicate the current chapter Refer to SYMBOLS 2 Each chapter is divided into sections The current section title is shown at the top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears Sub section titles appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a dis assembly step 6 Symbols indicate parts to be lubricated or replaced Refer to SYMBOLS job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc
76. piston unit 4 34 REAR BRAKE CHAS MASTER CYLINDER INSTALLATION 1 Install e Brake pedal refer to BRAKE PEDAL REMOVAL section in this Chapter NOTE n Lubricate the pin of the brake pedal with lithium base grease e Master cylinder e Brake fluid reserve tank e Plain washers 1 new e Brake hose 2 e Stop switch to mount the brake hose 3 Brake switch brake hose 20 Nm 2 0 mkg Master cylinder mounting bolt 10 Nm 1 0 mkg Reserve tank mounting bolt 4 Nm 0 4 mkg 2 Fill e Brake fluid reserve tank Recommended brake fluid DOTA CAUTION Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately A WARNING e Use only designated quality brake fluid Otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and lead to poor perform ance e Be careful that water does not enter the significantly lower the boiling point of the fluid may result in vapor lock 4 35 REAR BRAKE CHAS 3 Air bleed e Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in Chapter 3 4 Inspect e Brake fluid level Lower than MIN mark 1 gt Fill Refer to BRAKE FLUID INSPECTION section in Chapter 3 1 Minimum level mark MIN 5 Adjust Brake pedal height a below the to
77. rotor lock the rotor with the special tool 7 24 Sheave holder 90890 01701 CAUTION Be careful notto touch the jutting edges 8 on the rotor with the special tool NOTE Remove the rotor with the puller 1 22 Flywheel puller G P N 90890 01362 2 Remove e Chain guide 1 e Timing chain 2 5 13 ENGINE DISASSEMBLY oD CRANKCASE R 1 Remove e Crankcase NOTE e Loosen nuts starting from the one with the highest number e Loosen all by 1 4 turn and then remove Removal procedure e Set the crankcase separating tool 1 in place 4 2 4 Crankcase separating tool 0 P N 90890 01135 NOTE __ 22 5 When tightening the support bolts of the separat ing tool be sure to keep the tool body parallel to the engine crankcase If necessary a screw may be slightly loosened to put the tool body on level e Applying pressure strike the front engine assembly flange the drive shafts and the gear cam plate with a rubber hammer Then remove the crankcase NOTE e fthe crankcase fails come out lever at points 2 being careful not to damage the crankcase e Turn the gear cam plate as shown in the fig ure to prevent it interfering with the crankcase ENGINE DISASSEMBLY 5 15 CAUTION Be careful not to damage surfaces in con tact with the crankcase Use a soft h
78. switch Horn switch 1 14 15 18 19 7 52 23 Flasher switch 24 Horn 25 Flasher relay 27 Flasher light 29 Front brake switch 80 Rear brake switch 31 Tail stop light 32 Meter SIGNAL SYSTEM ELEC DIAGNOSTICS e THE FLASHER LIGHTS BRAKE LIGHT AND OR WARNING LIGHTS FAIL TO TURN ON e THE HORN FAILS TO SOUND Procedure Check 1 Fuse 2 Battery 3 Main switch 4 Harness connections entire system of con nections NOTE Before starting inspections remove the following parts Seat Rear cowling Cowling headlight Tail light cover To check for operating faults use the following special tools Pocket tester P N 90890 03112 e e Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 e 5 the fuse OK YES Check the condition of the battery Refer to CHECKING AND CHARGING HO THE BATTERY in Chapter 3 Min open circuit voltage DUNS at 20 eee e Clean the battery terminals e Recharge or replace the battery Replace the fuse 2 Battery 7 53 SIGNAL SYSTEM ELEC 3 Main switch e Disconnect the main switch connector Blue Red and Brown from the wire har ness e Connect the pocket tester 1 to the main switch cables Refer to SWITCH CHECK section Tester terminal gt Red cable 1 Tester terminal gt Brown cable 2 Tester terminal 2 Blue cable
79. ter cavity will drain Remove the other filter cover screws and remove the oil filter cover Remove the oil filter 6 and O ring 7 Inspect e All gaskets e O rings Damaged gt Replace Reassemble e New filter cartridge Filter cover screw Oil filter cover bleeder screw Engine drain plug Oil tank hose Fastening torques Drain plug engine 30 Nm 3 0 mkg Oil tank hose flange 10 Nm 1 0 mkg Filter cover screw 10 Nm 1 0 mkg Oil filter cover bleeder screw 5 Nm 0 5 mkg ENGINE OIL REPLACEMENT ei 11 x 20 10 0 10 20 30 e Oil tank 10W 30 Recommended oil SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature API Standard API SE SF SG or higher grade D D D D H 1 1 1 1 1 10W 40 Oil capacity Total 3 0 litres Periodic oil change 2 4 litres With oil filter change 2 5 litres CAUTION Do not putin any chemical additives or use oils with a grade of CD a or higher e Be sure not to use oils labeled ENERGY CONSERVING II b or higher Engine oil also lubricates the clutch and additives could cause clutch slippage e Be sure no foreign material enters the crankcase 12 Install e Oil tank cap 13 Check e Oil level See section ENGINE OIL LEVEL CHECK e Oil pressure See section ENGINE OIL PRESSURE CHECK e Oil leakage 3 20 ENGINE OIL PRESSURE
80. the crankshaft anticlockwise using a wrench 3 4 3 5 VALVE CLEARANCE ADJUSTMENT wq 6 Align e Reference mark on the flywheel 1 with the fixed reference mark on the crankcase 2 NOTE n Check that the piston is under compression at top dead centre T D C 3 Ignition timing reference mark 7 Check e Valve clearance Out of specification gt Adjust Valve clearance cold Intake 0 05 0 10 mm Exhaust 0 12 0 17 mm 8 Adjust e Valve clearance Adjustment e Loosen the lock nut 1 e Fita thickness gauge 2 between the rocker arm and the valve stem e Turn the adjuster 1 clockwise or anticlock wise using the special tool 2 to obtain the required clearance Special tool P N 90890 01311 e Holding the adjuster firmly in place lock tight en lock nut Lock nut 25 14 Nm 1 4 mkg e Measure valve clearance If the clearance is incorrect repeat the previ ous stages to achieve the required value AAA A A A A A A A A A A A A A A A A A A A A A A A A A A VALVE CLEARANCE ADJ USTMENT ei 3 6 9 Reassemble e Caps Tappet cover intake Tappet covers exhaust e Spark plug Tappet cover exhaust 12 Nm 1 2 mkg Bolt tappet cover intake 10 Nm 1 0 mkg Spark plug 18 Nm 1 8 mkg NOTE The tappet cover intake should be mounted with arr
81. the ground and no one sitting on it Check slack in the position shown in the figure 2 Adjust e Drive chain slack Slack adjustment CAUTION Too little chain slack will overload the engine and other vital parts Keep the slack within the specified limits 24 Di NS 3 36 DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT DRIVE CHAIN LUBRICATION Loosen the axle nut 1 e Loosen the locknuts 2 on each side To tight en the chain turn the chain adjusting bolts 3 in direction a Loosen the locknuts on each side To loosen the chain turn the chain adjusting bolts in direction b and push the wheel forward e After adjusting tighten the locknuts 2 Then tighten the axle nut 1 to the specified torque NN Rear wheel axle nut a 115 Nm 11 5 mkg e Turn each adjusting bolt exactly the same amount to maintain correct axle alignment There are marks on each side of the swingarm Use these marks to align the rear wheel DRIVE CHAIN LUBRICATION The chain consists of many parts which work with each other If the chain is not maintained properly it will wear out quickly Therefore the chain must be serviced regularly This service is especially necessary when riding in dusty areas This motor cycle has a drive chain with small rubber O Rings between the chain plates Steam cleaning high pressure washing and certain solvents can dam age these O Rings Use only kerosene to clean th
82. the pressure reading is lower than minimum 1 Add a few drops of oil to the cylinder through the hole in the spark plug 2 Measure the compression again 3 Compare the new reading with the first then proceed according to the indications in the table COMPRESSION INSPECTION ei 3 14 Pressure under compression after adding oil to the cylinder Reading Diagnosis Pressure higher Piston worn or than before damaged Pressure same Cylinder head or as before piston rings valves gaskets may be faulty Pressure above Inspect cylinder maximum value head valve sur faces piston rim to check for carbon deposits AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 9 Remove e Secondary fuel tank e Pressure gauge with adapter 10 Reassemble Spark plug See section SPARK PLUG INSPEC TION Spark plug 2 18 Nm 1 8 mkg 11 Connect e Spark plug cap 12 Reassemble e Fueltank e Seat See section SEAT FUEL TANK AND REAR COWLING NS Seat screws 2 10 Nm 1 0 mkg ENGI 3 15 NE OIL LEVEL NSP QU ENGINE OIL LEVEL CHECK CAUTION Do not put additives into the engine oil The latter also lubricates the clutch and additives might cause it to slide A WARNING Never remove the oil tank cap when the engine is hot The boiling oil might spill over causing burns Wait for the oil to cool to at least 60 C 140 F or thereabouts This model
83. tighten the ring nut excessively Ring nut final tightening 2 4 Nm 0 4 mkg STEERING INSPECTION 8 41 TYRE INSPECTION NSP Q Tighten the steering axle nut and the front fork bracket screws Nut steering axle 115 Nm 11 5 mkg Screws front fork bracket 28 Nm 2 8 mkg Reassemble the fuel tank See section SEAT FUEL TANK AND REAR COWLING NOTE LN Check the steering head for looseness or binding by turning it all the way in both directions If it binds remove the steering axle assembly and inspect the steering bearings Refer to STEERING HEAD in Chapter 6 AAA A A A A A A A A A A A A A A A A A A A A A A A A A A TYRE INSPECTION A WARNING Tyre pressure must be checked when the tyres are at ambient temperature Pressure must be adjusted according to the total weight of luggage driver passenger and accessories fairings bags if approved for this model and speed of the motorcycle A list of tyres approved for this model fol lowing severe testing by Yamaha is provid ed There can be no guarantee of safe road holding if a combination of tyres different from those indicated is used Front and rear tyres must have the same design and be of the same make The use of valves and valve stems other than those indicated might cause the loss of tyre pressure at high speeds Use only original or compatible spare parts Replace the valve cap securely to prevent losses of tyre pressure a
84. 0 0 071 mm Transmission Max main axle runout Max drive axle runout Shift mechanism type Cam drum and guide bar Carburetor ID mark Main jet Main air jet Jet needle Needle jet Cutaway Pilot air jet 1 Pilot jet Bypass 1 Pilot screw turns out Valve seat size Starter jet 1 Float height 5CH5 10 1 150 8230145 1 1 0 2 0 9 1 5C5A 3 5 2 5Y18 3 5 2 600 4 00 0 8 mm 50 1 0 2 3 4 1 2 2 5 74 6 0 8 0 mm Engine idle speed Intake vacuum 1 150 1 450 r min 1 5 3 30 6 33 36 kPa 230 250 mm Hg Lubrication system Oil filter type Oil pump Oil pump type Inner rotor to outer rotor tip clearance Outer rotor to pump housing clearance Bypass valve opening pressure Relief valve operating pressure Oil pressure hot Pressure check location Dry sump Paper type Trochoid type 0 12 mm 0 030 0 080 mm 80 0 120 0 kPa 0 8 1 2 kgf cm 80 0 120 0 kPa 0 8 1 2 kgf cm 13 0 kPa 0 13 kgf cm 1 300 r min Oil filter chamber 0 20 mm 0 150 mm MAINTENANCE SPECIFICATIONS ve ENGINE Cylinder head tightening steps Crankcase tightening steps Left crankcase Right crankcase 2 9 MAINTENANCE SPECIFICATIONS SPEC ve Tightening torques Part to be tightened Part name Thread size Tightening torque Nm mkg Remarks Oylinder head Oylinder head Oylinder head Cylinder head Cylinder head Cap oil check
85. 01227 This tool is used to re ream the new valve guide Valve adjusting tool 90890 01311 This tool is necessary for adjusting valve clearance Rotor holder 90890 01701 This tool is used for loosing and tightening the rotor nut Rotor screw puller 90890 01362 This tool is used to disassemble the magne to flywheel rotor 1 6 SPECIAL TOOLS G All purpose clutch holder This tool is used to lock the clutch when the clutch boss lock nut is being loosened or tightened Crankcase separating tool This tool is necessary to disassemble the crankcase Crankshaft installation hose This tool is used to install the crankshaft Crankshaft installation bolt This tool is used to install the crankshaft 10 M14 adapter This tool is used to install the crankshaft Crank spacer This tool is used to install the crankshaft SEALANT QUICK GASKET amp Yamaha Bond No 1215 This sealant adhesive is used for crankcase mating surfaces etc Ringnut wrench This tool is used to loosen and tighten the steering ringnut Ringnut wrench This tool is used to loosen and tighten the steering ringnut 1 7 SPECIAL TOOLS det T handle 90890 01326 This tool is needed to loosen and tighten the front fork damper rod holding bolt Front fork damper rod holder 2074 This tool is needed to hold the front fork damper rod when loosening and tightening the holding bolt DU bush oil seal guide 90890 11043
86. 1 gt Fill Refer to BRAKE FLUID INSPECTION section in Chapter 3 1 Minimum level mark MIN 4 41 FRONT Fork FRONT FORK FRONT FORK REMOVAL Job namel Par Front fork removal Remove the parts in order Front wheel Refer to FRONT WHEEL section Inner tube protector Brake hose guide Protector guide Brake caliper assembly Cowling displace Pinch bolt upper bracket Cap bolt loosen Refer to FRONT FORK INSTALLATION section Pinch bolt under bracket loosen Fork leg Reverse the removal procedure for instal lation 4 42 FRONT Fork CHAS FRONT FORK DISASSEMBLY Job name Part name Front fork disassembly Remove the parts in order Refer to FRONT FORK REMOVAL INSTAL LATION Cap bolt Seat Spacer Seat Fork spring Bolt O ring Damper adjusting cylinder Taper spindle Dust seal Snap ring to OIL REPLACEMENT section Refer to SEAL AND BUSH REPLACE MENT section ON sch oo zech sch sch ech e 4 43 FRONT Fork order Job namsPar rame 12 Inner tube 13 Inner tube bushing 14 Oil seal Refer to SEAL AND BUSH REPLACE 15 Washer MENT section 16 Outer tube bushing 17 Outer tube Reverse the removal procedure for instal lation 4 44 4 45 FRONT Fork OIL CAPACITY IN EACH FORK LEG 650 cm RECOMMENDED OIL Liqui M
87. 2 ENGINE OIL LEVEL CHECK 8 15 ENGINE OIL REPLACEMENT 3 17 ENGINE OIL PRESSURE CHECK 3 21 CLUTCH ADJUSTMENT 3 21 AIR FILTER CLEANING ettet 8 24 FUEL FILTER CLEANING 8 25 ENGINE OIL TANK FILTER CLEANING nes 3 26 SUCTION HOSE AND MANIFOLD INSPECTION 3 28 FUEL LINE INSPECTION 3 28 CRANKCASE VENTILATION HOSE INSPECTION 3 29 EXHAUST SYSTEM 3 29 CHASSIS ADJUSTING THE FRONT BRAKE 3 30 ADJUSTING THE REAR BRAKE tne 3 31 CHECKING THE BRAKE FLUID LEVEL 3 32 BRAKE PAD WEAR INSPECTION tt 3 33 BRAKE HOSING INSPECTION 3 33 BRAKE CIRCUIT BLEEDING tette 3 34 DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT 3 35 DRIVE CHAIN LUBRICATION 3 36 FRONT FORK INSPECTION 3 37 ADJUSTING THE FRONT FORK 3 37 REAR SHOCK ABSORBER ADJUSTMENT 3 38 STEERING INSPECTION 3 40 TY FE INSPECTION aaa rosa oet ets ra 8 41 WHEEL INSPECTION ttt ttt ttt 8 44 SPOKE INSPECTION AND TIGHTENING 8 44 CABLE INSPECTION 3 45 LEVER AND PEDAL LUBRICATION ttn 8 45 BIDESTANEHEUBRICATION 1 asc recreate ltr dada e tns 3 46 REAR SUSPENSION
88. 3 Starting motor 10 Starter switch 4 Starter relay 11 Harness connections 5 Main switch NOTE Before starting inspections remove the following parts 1 Seat 3 Fuel tank 2 Rear cowling 4 Cowling headlight e To check for defects use the following special tools GJ Pocket tester A P N 90890 03112 Remove fuse Connect the pocket tester Q x 1 to the DISCONTINUTY fuse Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Replace the fuse CONTINUITY INCORRECT e Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter Clean the battery terminals Recharge or replace the battery Min open circuit voltage Refer to BATTERY INSPECTION in 12 8 V or more at 20 C 68 F Chapter 3 CORRECT 7 24 ELECTRICAL STARTING SYSTEM ELEC 3 Starter A WARNING A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure that no flammable gas or fluid is in the vicinity e Connect the positive terminal of the bat tery 1 and the starter cable 2 using a connection cable 3 IT FAILS TO RUN 4 The starter is defective Repair or replace 4 Starter relay Disconnect the starter relay connector e Connect the battery and frame to the starter relay connector us
89. 5 Withdraw e Seat 2 e Spacer 3 e Spring 4 from the inner tube 5 NOTE The spring being immersed in oil could cause oil to drip onto the work surface when withdrawn It is advisable therefore to withdraw it slowly and to dry it with a clean cloth 6 Pour the oil into a tray whilst at the same time moving the inner tube 1 backwards and for wards CAUTION In order not to cause damage to the environ ment collect the used oil and take it to a col lection centre 4 47 FRONT Fork CHAS 7 Fill e Part of the new oil with the fork leg in a vertical position Recommended oil Liqui Moly Racing suspension oil SAE 7 5 8 Using the inner tube pump back and forth until a regular drag is felt on the return stroke 9 With the fork leg in a perfectly upright position insert the inner tube 1 in the outer tube 2 completely to the end of the stroke 10 Finish topping up the oil bringing it to the pre scribed level from the upper edge measured with a graduated dipstick or ruler 3 Recommended oil Liqui Moly Racing suspension oil SAE 7 5 Standard Minimum Maximum From top of inner tube with inner tube fully inserted without spring 11 Insert e Spring 1 into the inner tube 2 e Seat 3 e Spacer 4 NOTE Usually there is no particular sense in which the spring is mounted and so it may be inserted from either end If there is a hem however moun
90. 8 x 1 25 M10 x 1 0 M10 x 1 0 12 1 2 25 2 5 14 1 4 20 2 0 Rear brake Rear hub Disc brake Rear master cylinder Frame Rear stop switch Rear master cylinder Rear caliper Bleeder tightening Protector rear caliper Rear caliper Union bolt tightening rear Rear brake tank reserve Air cleaner assy Brake pedal Frame M6 x 1 0 M6 x 1 0 M10 x 1 0 M10 x 1 0 M6 x 1 0 M10 x 1 0 M6 x 1 0 M10 x 1 25 12 1 2 10 1 0 20 2 0 14 1 4 10 1 0 20 2 0 5 0 5 48 4 8 Sidestand Footrest Sidestand mounting bolt Frame Sidestand mounting bolt Nut Sidestand switch Frame Rear footrest Rear frame Bracket 1 main footrest Frame Bracket 2 main footrest Frame Footrest cover Footrest M12 x 1 25 M12 x 1 25 M5 x 0 8 M8 x 1 25 M10 x 1 25 M10 x 1 25 M6 x 1 0 40 4 0 40 4 0 8 0 8 30 3 0 48 4 8 48 4 8 10 1 0 Seat fuel tank and oil tank Seat Frame Bolt guide seat Fuel tank Fuel tank Rear frame Damper fuel tank front Frame Fuel tank Fuel cock Oil tank Sub oil tank Union bolt oil hose 2 Oil tank assy Engine Oil hose 1 Oil tank Engine Oil tank Rear frame M6 x 1 0 M6 x 1 0 M6 x 1 0 M8 x 1 25 M6 x 1 0 M6 x 1 0 M12 x 1 25 M6 x 1 0 M12 x 1 5 10 1 0 5 0 5 12 1 2 15 1 5 7 0 7 7 0 7 35 3 5 10 1 0 20 2 0 Frame rear fender compl and lights Rear fender compl under Rear frame Rear fender compl upper Rear frame Bracket license Rear frame Bracket license Rear flasher Horn Frame
91. 9 0 MAINTENANCE sPECIFICATIONs SPEC ve CHASSIS Item Standard Steering Steering bearing type Lock to lock angle left Lock to lock angle right Taper roller bearing 45 45 Front suspension Front fork travel Fork spring free length Spring rate Spring stroke Spring rate Optional spring available Recommended oil Quantity Level min max 277 283 mm 530 mm 7 0 N mm 0 71 kgf mm 330 mm 11 2 N mm 1 14 kgf mm No Liqui Moly Racing suspension oil SAE 7 5 650 cc 180 mm 170 190 mm from upper edge of inner tube fully compressed without spring Rear suspension Rear shock absorber assembly travel Spring free length Installed length Spring rate K Optional spring available 83 mm 224 mm 211 mm 80 N mm 8 1 kgf mm No Swingarm Free play limit at the end of the swingarm radial Free play limit at the end of the swingarm axial 0 4 0 7 mm Front wheel Wheel type Rim size Rim material Max radial wheel runout Max lateral wheel runout Spoke wheel 21 x 1 85 Aluminium 1 0 mm 0 5 mm Rear wheel Wheel type Rim size Rim material Max radial wheel runout Max lateral wheel runout Spoke wheel 18 x MT2 50 Aluminium 1 0 mm 0 5 mm 2 12 MAINTENANCE SPEC ve Item Standard Drive chain Type manufacturer Link quantity Drive chain slack 520 135ORSB Regina Chain 114 30 0 40 0 mm
92. AGRAM Au Gas Se ee we RR a eee 7 41 SE Eeer Bote es 7 43 LIGHT SYSTEM INSPECTION s 244 ened eee eee dee 7 46 SIGNALLING SYSTEM erg E EES AR UTERE 7 51 CIRCUIT DIAGBAM rr oe ee REP Ee iia ok Be a ee Pe EE 7 51 DIAGNOSTICS ve uu acumen ae ee eee tme ard wal ar re 7 53 SIGNAL SYSTEM 7 55 ELECTRICAL CIRCUIT DIAGRAM ELEC REN ELECTRICAL ELECTRICAL CIRCUIT DIAGRAM SSINYYH a EI H
93. Ball race cover 20 Nm 2 0 kgm SS S 115 Nm 11 5 kgm ES 28 Nm 2 8 kgm TIGHTENING PROCEDURE Initial tightening 38 Nm 8 mkg Loosen 1 turn Final tightening 4 Nm 0 4 mkg 4 63 STEERING CHAS STEERING REMOVAL 1 Park the motorcycle on a level surface A WARNING Support the motorcycle securely to prevent it falling over 2 Raise the front wheel placing a suitable sup port under the engine 3 Remove e Front wheel Refer to FRONT WHEEL REMOVAL section e Front fork Refer to FRONT FORK REMOVAL sec tion 4 Remove e Front fender e Cowling e Handlebar e Meter assembly 5 Remove e Steering axle nut 1 Use the ring nut wrench 3 CZ Ring nut wrench 3 90890 01348 6 Remove e Ring nut upper 1 e Use the ring nut wrench 2 CZ Ring nut wrench 2 90890 01268 4 64 4 STEERING CHAS 7 Remove e Ring nut lower 1 e Use the ring nut wrench 2 Ring nut wrench 2 90890 01268 A WARNING Support the steering axle to prevent it falling STEERING INSPECTION 1 Wash the bearings in solvent 2 Inspect e Bearing upper and lower 1 Corrosion Damage gt Replace races and bearing Install the bearings in the races Spin the bearing by hand If the bearing rises or fails to run freely in the race replace bearing and race 3 Inspect e Steering axle 1 Bend Damage gt
94. DC 20V to the bulbholder connector Tester terminal gt Blue terminal 1 Tester terminal gt Black terminal 2 3 The parking light fails to turn on OUT OF SPECIFICATION The circuit from the main switch to the bulbhol der connector is defective Repair e Turn the main switch to ON e Check the voltage 12V on the Blue cable of the bulbholder connector IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient 7 48 LIGHT SYSTEM ELEC 4 The rear light fails to turn on DISCONTINUITY 1 Bulb and bulbholder e Check the continuity of the bulb and bulb holder 1 Refer to BULB INSPECTION section Replace the bulb and or bulbholder CONTINUITY 2 Voltage e Connect the pocket tester DC 20V to the bulbholder connector Tester terminal gt Blue terminal 1 Tester terminal gt Black terminal 2 OUT OF SPECIFICATION The circuit from the main switch to the bulbhol der connector is defective Repair e Turn the main switch to ON e Check the voltage 12V on the Blue cable of the bulbholder connector IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient 7 49 7 50 SIGNAL SYSTEM ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM
95. Disconnect the neutral switch cable from the wire harness e Connect the pocket tester O x 1 to the neutral switch cables e Check the switch component for continuity between Sky blue 1 and earth Refer to SWITCH CHECK section 4 The N neutral light fails to turn on 2 Neutral switch INCORRECT 4 The neutral switch is defective Replace 3 Voltage e Connect the pocket tester DC 20V to the bulbholder connector Tester terminal gt Brown cable 1 Tester terminal gt Earth 7 62 SIGNAL SYSTEM ELEC e Turn the main switch to ON OUT OF SPECIFICATION e Check the voltage 12V on the Brown ca ble of the bulbholder connector IN COMPLIANCE WITH The circuit from the main switch to the bulbhol SPECIFICATIONS 12V ger connector is defective Repair 4 Neutral switch cable Disconnect the neutral switch connector from the wire harness and the bulbholder connector e Connect the pocket tester x 1 to the neutral switch cable on the harness side and the bulbholder connector 1 DISCONTINUITY The circuit from the bulb to the neutral switch cable is defective Repair CONTINUITY The circuit is efficient 7 63 7 64 CHAPTER 8 TROUBLESHOOTING FAILURE TO START DIFFICULTIES IN STARTING 8 1 PUBL HR EE eee ee aes MEAM QNT EUM ELS 8 1 ELECTRICAL SYSTEM
96. HAPTER 7 ELECTRICAL ELECTRICAL CIRCUIT 74 COLOUR CODE MEE ED 7 2 ELECTRICAL COMPONENTS 7 8 gs 7 5 SWITCH CONNECTION Mee Dexter PR e PRA oo ERO Rat 7 5 MAIN SWITCH INSPECTION NENNEN E xn enn ER a ens 7 5 LIGHT INSPECTION HEADLIGHTS TAIL LIGHT AND BRAKE LIGHTS DIRECTION INDICATOR LIGHTS INSTRUMENT LIGHTS ETC 7 8 BULB TYPES text ae die ec tare esta a io aera ure um EEG Ws Nr 7 8 BULB INSPECTION othe ERES e ERI ETE 7 8 IGNITION SYSTEM este gee cates dace ERR de Gus keh eae Ra E aes UR s 7 11 CIRCUM DIAGRAM wis eub de gU a Ree RR e eed OS 7 11 DAGNOSUCS rera teed e EN ea ce eee LM ae OD D ME UN I MD 7 13 ELECTRICAL STARTING 5 5 7 21 CIRCUM DIAGRAM 2 ce Ne bee oy RR ER Rei Er an 7 21 STARTING CIRCUIT 7 23 DIAGNOSTICS uu etre ciere Soe dG tet ee baleen es 7 24 STARTER MOTOR dus See we ee beate Foederis 7 30 CHARGING SYSTEM RER 7 35 CIRCUIT 7 35 DIAGNOSTICS eee beg EEG er EEN weeks 7 37 LIGHT SYSTEM s RR RR ek eke ee baw eee ave RD ES 7 41 CIRCUM DI
97. IDLE SPEED TRBL UNSATISFACTORY PERFORMANCE AT MEDIUM HIGH SPEED SHTG PROBABLE CAUSES POOR PERFORMANCE AT IDLE SPEED Carburetor Electrical system Valves The starter piston fails to return freely Pilot jet obstructed or loose Pilot jet obstructed Pilot air screw wrongly set Idle speed wrongly set throttle valve stop screw Throttle cable free play wrongly set Carburetor flooded Defective battery Defective spark plug Defective ignition unit Defective AC magneto Defective ignition coil Valve clearance wrongly set UNSATISFACTORY PERFORMANCE AT MEDIUM HIGH SPEED See FAILURE TO START DIFFICULTIES IN STARTING FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM and Valve clearance Carburetor Air filter PROBABLE CAUSES Petrol contains water or impurities or is adulterated Infiltrations of air Deformation of float Defective diaphragm Needle valve worn or scratched Needle valve seat insufficiently sealed Needle stop position incorrect Fuel level set wrongly Main jet obstructed or loose Main nozzle obstructed or loose Air filter element obstructed DIFFICULTIES IN SHIFTING SHIFTING IMPOSSIBLE TRBL DIFFICULTIES IN SHIFTING SHTG PROBABLE CAUSES Clutch Engine oil THE SHIFT PEDAL FAILS TO MOVE Shift shaft Clutch cable wrongly set Wrong position of push lever Irregular engagement of push lever and push rod Pre
98. L 0 20 0 70 mm 6 Circlip PISTON RING SIDE CLEARANCE TOP 0 04 0 08 mm 2ND 0 03 0 07 mm D USE NEW ONE 5 55 G ENGINE ASSEMBLY AND SETTING 4 CYLINDER Gasket Cylinder O Ring Gasket Dowel pin Dowel pin TIGHTENING SEQUENCE BORE SIZE 94 97 95 02 mm 3 739 3 741 87 00 87 02 mm 3 425 3 426 in A LIMIT 95 1 mm 3 744 in 87 1 mm 3 429 PISTON TO CYLINDER CLEARANCE 0 045 0 065 mm 0 002 0 003 in LIMIT 0 15 mm 0 006 in gt 42 Nm 4 2 mekg 30 ft lb 22 Nm 2 2 16 ft Ib 5 56 ENGINE ASSEMBLY AND SETTING ENG CYLINDER HEAD 1 Cylinder head cover 7 Oylinder head 2 O Ring 8 Valve guide 3 Tappet cover intake valve intake 9 Valve guide 4 Tappet covers exhaust exhaust valve b O Ring 10 Spark plug 6 Cap 11 Dowel pin 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 20 Nm 2 0 m kg 14 ft lb 5 57 ENGINE ASSEMBLY AND SETTING ENG CAMSHAFT AND TIMING CHAIN 1 2 3 4 b 6 7 Net Ne Ns e Camshaft Cam chain sprocket Chain stopper guide Timing chain Chain stopper guide Gasket Chain tensioner 10 Nm 1 0 m kg 7 2 ftelb D a 2 P7 a 5 58 ENGINE ASSEMBLY AND SETTING 4 5 59 PISTON CYLINDER CYLINDER HEAD AND CAMSHAFT 1 Apply 4 stroke engine oil on piston pin 2 In
99. L SYSTEM ELEC 4 Voltage Connect the pocket tester DC 20V to the bulbholder connector Tester terminal gt Brown White terminal 1 Tester terminal gt Earth OUT OF SPECIFICATION The direction indi Ve eN indicator lamp relay is defective e Check the voltage 12V on the Blue cable to the bulbholder connector IN COMPLIANCE WITH SPECIFICATIONS 12V 7 60 SIGNAL SYSTEM ELEC 5 Voltage e Connect the pocket tester DC 20V to the bulbholder connector Connect the left handlebar switch connec tor to the wire harness To the left flasher light Tester terminal gt Green Black terminal 1 Tester terminal gt Earth To the right flasher light Tester terminal gt Brown Black terminal 1 Tester terminal gt Earth OUT OF SPECIFICATION 4 The circuit from the direction indicator switch to the bulbholder is defective Repair Turn the main switch to ON Turn the direction indicator switch to L or Check the voltage it flashes at 2 8V on the Green Black or Brown Black cable at the bulbholder connector SPECIFICATIONS 12V The circuit is efficient IN COMPLIANCE WITH 7 61 SIGNAL SYSTEM ELEC DISCONTINUITY 1 Bulb and bulbholder e Check the continuity of the bulb and bulb holder 1 Refer to BULB INSPECTION section Replace the bulb and or bulbholder CONTINUITY
100. LEANING 1 Turn the fuel cock to OFF 2 Disconnect e Fuel pipe from cock 3 Place a fuel pan under the fuel tank and turn the fuel cock to RES to drain the fuel CAUTION Do not bring naked flames or possible sources of sparks near to the fuel tank FIRE AND EXPLOSION RISK Be careful not to spill fuel from the tank Always wipe off spilled fuel immediately with a dry and clean soft cloth Fuel may deterio rate painted surfaces or plastic 4 Disassemble e The fuel cock from the fuel tank 5 Wash e Fuel filter 1 with solvent 6 Inspect e Fuel filter 1 e Gasket 2 Damaged gt Replace 7 Reassemble e Fuel cock to tank e Fuel pipe to cock NOTE When reassembling the cock be careful not to tighten the fastening screws unduly as the gasket might leave its housing and cause fuel leakage ENGINE OIL TANK FILTER CLEANING ei ENGINE OIL TANK FILTER CLEANING A WARNING Securely support the motorcycle so there is no danger of it falling over 1 Drain e Engine oil See section ENGINE OIL REPLACE MENT 2 Remove e Seat e Rear cowling See section SEAT FUEL TANK AND REAR COWLING Rear wire harness Exhaust muffler Exhaust pipe Rear shock absorber See section REAR SHOCK ABSORBER in Chapter 4 e Joint air cleaner clamps e Rear frame e Engine oil tank 3 Loosen e Stay rear left side cover fastening screws 4 Remove Oil tank cap 1 e Oil return h
101. LFUNCTIONING OF FRONT FORK SHTG DEFECTIVE BRAKES POOR BRAKING PROBABLE CAUSES e Brake pads worn e Brake disc worn e Water in the brake fluid e Brake fluid leak e Brake fluid tank defective e Bleed cap not sealed to calipers e Union bolt loose e Brake hose cracked e Brake disc dirty or greasy e Brake pads dirty or greasy _ Incorrect brake fluid level OIL LEAKS OR MALFUNCTIONING OF FRONT FORK OIL LEAKS PROBABLE CAUSES Inner tube deformed damaged or rusty Outer tube damaged or cracked Oil seal lip damaged Oil seal assembled incorrectly e Oil level incorrect excessive e Shock absorber rod stop bolt loose e O ring on cap bolt broken MALFUNCTIONING PROBABLE CAUSES e Inner tube deformed damaged or rusty e Outer tube deformed or damaged e Fork spring damaged e Piston worn or damaged e Shock absorber rod deformed or damaged e Incorrect oil viscosity e Incorrect oil level 8 6 UNSTABLE STEERING Handlebar Steering Front fork Tyres Wheels Frame t Rear arm 1 Rear shock absorber Drive chain 8 7 TRBL UNSTABLE STEERING SHTG PROBABLE CAUSES e Assembled crooked or incorrectly e Handlebar crown assembled incorrectly Lower bracket crooked Lower steering column installed incorrectly threaded ring nuts not tightened correctly e Bearing or bearing tracks damaged
102. LY 4 18 CALIPER INSPECTION zs esr mr aac ee beet ieee Sines DERE EE an 4 18 CALIPER ASSEMBLY 2 02 4 0 06 Re eed Ge mem Rade hed ee ee eee 4 19 CALIPER INSTALLATION 1 4 19 REAR WHEEL AND BRAKE DISC 4 21 REAR WHEEL AND BRAKE DISC 4 21 REAR WHEEL DISASSEMBLY 4 23 REAR WHEEL INSPECTION 4 23 BRAKE DISG INSPECTION iess iere ees oen mmt EIER ms 4 24 REAR WEEEL ASSEMBLY 252555554 ec deemed geek ORG EUER 4 25 REAR WHEEL 4 25 WHEEL STATIC BALANCE 0 ene 4 27 REAR BRAKE ees eh wands eue uer d aUe e eg aes 4 29 BRAKE PAD REMOVAL 4 29 BRAKE PAD REPLACEMENT 4 30 MASTER CYLINDER eee ee 4 32 MASTER CYLINDER 4 33 MASTER CYLINDER ASSEMBLY 4 33 MASTER CYLINDER INSTALLATION 4 34 BRAKE PEDAL REMOVAL EE erii ERR ENDER eee eats 4 35 BRAKE CALIPER ge ure stata bedeutet espe tos se URS go EVE 4 36 BRAKE CALIPER DISASSEMBLY
103. NOTE EE Fit the rubber protections 4 when installing the caliper body 5 Install e Pad springs 1 new Brake pads 2 new e Pad fastening pin 3 e Pin retainers 4 VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Installation procedure e Connect the hose 1 firmly to the caliper bleeder screw 2 Place the other end of the hose in an open container Loosen the caliper bleeder screw and push the pistons into the caliper with your finger e Retighten the bleeder screw 2 Caliper bleeder screw 2 14 Nm 1 4 mkg Install the new brake pads and new springs Fit the pad fastening pin well into its housing by hammering with a punch with a suitable diameter Install the new pin retainers e Install the caliper and screws Caliper fastening screw 2 25 Nm 2 5 kgm A AA A A A A A A A A A A A A A 6 Check e Level of brake fluid in reservoir See section BRAKE FLUID LEVEL INSPECTION in CHAPTER 3 a Lower minimum level MIN 7 Check e Brake lever operation Lever soft and spongy Bleed air from brake circuit See section AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 10 FRONT BRAKE CHAS MASTER CYLINDER 9 Nm 0 9 m kg Remarks Master cylinder removal Remove the parts in order Brake fluid Drain Rear view mirror right Master cylinder bracket Brake lever Brake switch Union bolt Plain washer Refer to
104. Nm 6 6 mkg Nut relay arm connecting rod 52 Nm 5 2 mkg Bolt chain case 9 Nm 0 9 mkg Nut swingarm pivot shaft 90 Nm 9 0 mkg Bolt chain support 4 Nm 0 4 mkg Nut relay arm frame 60 Nm 6 0 mkg Bolt rear shock absorber 59 Nm 5 9 mkg Screw chain case 4 Nm 0 4 mkg iili e Install e Rear wheel Refer to REAR WHEEL INSTALLATION section 4 80 4 81 g SWINGARM CHAS 4 Adjust e Drive chain slack Drive chain slack 30 40 mm Refer to DRIVE CHAIN SLACK ADJUST MENT in CHAPTER 3 x 5 Install e Fuel tank e Rear cowling e Seat Bolt seat Refer to SEAT FUEL TANK REAR COWLING section in CHAPTER DRIVE CHAIN DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET o 4 82 DRIVE CHAIN DRIVE SPROCKET AND REAR WHEEL SPROCKET NOTE Before removing the drive chain drive sprocket and rear wheel sprocket it is necessary to meas ure the free play and length of the 10 links in the chain DRIVE CHAIN REMOVAL 1 Park the motorcycle upright on an even sur face 2 Remove e Shift pedal 1 e Cover 2 drive sprocket 3 Remove e Drive sprocket 1 NOTE ee e Before removing the sprocket nut straighten the tab on the lock washer Loosen the nut with the rear brake pulled 4 Raise the rear wheel placing a suitable sup port under the engine A WARNING Set the motorcycle up securely
105. ON der connector is defective Repair The brake lever is pulled or the brake pedal is pressed Check the voltage 12V on the Green Yellow cable of the bulbholder connector IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient 3 The direction indicator light and or the direc tion indicator light fail to flash DISCONTINUITY 1 Bulb and bulbholder e Check the continuity of the bulb and bulb holder 1 Refer to BULB INSPECTION section Replace the bulb and or bulbholder CONTINUITY 2 Direction indicator switch e Disconnect the left handlebar switch con nector from the wire harness e Connect the pocket tester 1 to the left handlebar switch cables 7 58 SIGNAL SYSTEM ELEC Check the switch component for conti nuity between Brown White 1 and Brown Black 2 and Brown White 1 and Green Black 3 Refer to SWITCH CHECK section INCORRECT The direction indicator switch is defective Replace 3 Direction indicator lamp relay Connect the pocket tester DC 20V to the indicator lamp relay Tester terminal gt Brown terminal 1 Tester terminal gt Earth OUT OF SPECIFICATION Las Four the gt The circuit from the main switch to the lamp re Kid dS ey OB e s lay connector is defective Repair cable to the indicator lamp relay terminal IN COMPLIANCE WITH SPECIFICATIONS 12V 7 59 SIGNA
106. OTE v 4 d Replace brake pads never worm to the limit Check operation fluid level and vehicle for fluid leakage Rear brake See NOTE Replace brake pads never worm to the limit Check for cracks or damage P4 P4 Brake hoses Replace See NOTE Every 4 years Check runout spoke tightness and for damage Tighten spokes if necessary 4 Wheels Check tread depth and for damage Tyres Replace if necessary Check air pressure Correct if necessary Wheel bearings Check bearing for looseness or damage Swingarm Check operation and for excessive play 4 Check chain slack E k hing th Drive chain Make sure that the rear wheel is properly aligned vey n E no DE Clean and lubricate Steering Check bearing play and steering for roughness bearings Lubrificate with lithium soap based grease Every 20 000 km Chassis Make sure that all nuts bolts and screws are properly fasteners tightened 4 4 Check operation Sidestand Lubricate 4 Sidestand switch Check operation and for oil leakage 3 1 INTRODUCTION PERIODIC MAINTENANCE LUBRICATION INTERVALS ODOMETER READING x 1000 km ANNUAL 1 10 20 30 40 CHECK Rear brake Check operation fluid level and vehicle for fluid leakage
107. S ELECTRICAL SYSTEM Spark plug Ignition coil Ignition unit 1 Switches and cables Starter motor POOR ENGINE COMPRESSION Oylinder and cylinder head Piston and piston rings Crankcase and valves crankshaft s Electrodes gap not correct Electrodes worn Feed cable interrupted Wrong thermal grading of spark plug Defective spark plug cap Primary or secondary winding interrupted High voltage cable defective Defective coil Defective unit Defective pick up coil Woodruff key broken Main switch defective Emergency stop engine switch defective Harness with cable interrupted Neutral switch defective Sidestand switch defective Clutch switch defective Starter switch defective e Starter motor defective e Starter motor relay defective Diodes defectives e Starter one way bearing defective PROBABLE CAUSES Spark plug tightening insufficiently Cylinder head or cylinder insufficiently tightened Cylinder head gasket broken Cylinder gasket broken Cylinder worn damaged or seized Piston rings wrongly assembled Piston rings worn yielded or broken Piston rings stuck together Piston seized or damaged Poor crankcase sealing Crankshaft oil seal edge damaged Poor valve sealing Valve and seat with insufficient contact Valve timing wrongly Valve spring broken Crankshaft seized Camshaft seized POOR PERFORMANCE AT
108. SPECTION AND REPAIR CRANKSHAFT 1 Measure e Width of crank A Out of specification Replace crankshaft M Width of crank 74 95 75 00 mm Runout Out of specification gt Replace crankshaft and or crank bearing Crankshaft runout lt Limit gt 0 03 mm Connecting rod small end clearance C Out of specification gt Replace connecting rod big end bearing connecting rod pin and or connecting rod Connecting rod small end clearance 0 8 mm e Side clearance D Out of specification gt Replace connecting rod Connecting rod big end clearance 0 35 0 65 mm Crankshaft assembly procedure The passages of crankshaft 1 oil and con necting rod pin 2 oil must coincide with a tol erance of less than 1 0 mm 5 39 INSPECTION AND REPAIR oD BALANCER SHAFT DRIVE AND DRIVEN GEARS 2 l 1 Inspect e Drive gear teeth 1 i 2 Driven gear teeth 2 E L Wear damage gt Replace both gears 3 2 Check Marks 1 If they are not aligned gt Align the marks as shown in the figure CRANKCASE 1 Inspect Crankcase e Bearing housing Damaged gt Replace BEARING AND OIL SEAL 1 Inspect e Bearing Roughness Pitting Damage gt Replace Oil seal edge Damage Wear gt Replace 5 40 ENGINE ASSEMBLY AND SETTING ENG ENGINE ASSEMBLY AND SETTING VALVES AND ROCKER ARMS 1 Rocker arm n 2 10 Valve intake
109. This tool is used to install the DU bush and the fork oil seal CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS EE 2 1 MAINTENANCE SPECIFICATIONS 2 4 DUI E 2 4 cocco Mew 2 12 Nel MOOR 2 17 GENERAL TORQUE SPECIEIC ATIONS 2 19 CONVERSION TABLE iode asi nde 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE ao seen een hanced acetates 2 20 ee 2 21 LUBRICATION LAYOUT iiid RR erae AUR UELUT ERE 2 22 CABLE ROUTING iniit satu nine act Pe Pr ee Eee meet ee ne S 2 26 SPEC ve GENERAL SPECIFICATIONS GENERAL sPECIFICATIONs SPEC ve SPECIFICATIONS Standard Model TT600RE 5CH5 Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2 220 mm 865 mm 1 195 mm 890 mm 1 480 mm 280 mm 3 300 mm right 3 100 mm left Basic weight with oil and full fuel tank 164 5 kg Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system Air cooled 4 stroke SOHC Forward inclined single cylinder 595 cm 95 0 x 84 0 mm 8 5 1 Electric starter Dry sump with separate oil tank Engine oil Type 20 10 0 10 20 30 40 4 4 1 1 DH 1 1 1 D 1 1 4 1 1 20 50 Recommended eng
110. Use a surface plate and a fooler gauge 0 Oil filter 2 C AS Warp limit te Warp limit clutch plate Crankcase cover right L t mm x 1 55 mm x 1 45 mm x 4 Less than 0 2 mm 30mmx4 Los ILLUSTRATED SYMBOLS The following symbols are not relevant to every vehicle Illustrated symbols to 8 are printed on the top right of each page and indicate the subject of each chapter D General information 2 Specifications Periodic inspections and adjustments Chassis 5 Engine Carburetor Electrical system Troubleshooting Illustrated symbols 9 to 0 are used to identify the specifications appearing in the text 9 Can be serviced with engine mounted Filling fluid Lubricant Special tool 3 Torque Wear limit clearance 5 Engine speed Electrical data Illustrated symbols 7 to in the exploded dia grams indicate the types of lubricants and lubrica tion points 7 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium soap base grease Apply molybdenum disulfide grease Illustrated symbols 3 to the exploded dia grams indicate the following 03 Apply locking agent LOCTITE Replace the part GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJ USTMENTS CHASSIS M Ss gt N CARBURETION ELECTRICAL TROUBLESHOOTING L
111. a colour differ ent from those mentioned and when the switch is at OFF 4 Check the switch component for continuity between R and Br Control procedure e Repeatedly shift the switch key to the various positions ON OFF and PARK e Shift the tester selector to Ox1 e Connect the tester positive cable to the terminal of cable R of the connector and the negative cable to cable terminal Br 7 7 SWITCH CHECK ELEC NOTE Use the thin tester terminals to check continuity as the terminals might come into contact with oth ers inside the connector Check continuity between and at switch positions ON 1 OFF 2 and PARK 3 There must be continuity ie the tester must show 0 at ON and there must be no continu ity ie the tester must show co at OFF and PARK Something is not working between R and Br if there is no continuity between these two points at position ON or if there is some continuity in one of the other positions OFF or PARK NOTE Check switch continuity various times AAA A A A A 5 Continue to check continuity between R and C and L and in the respective switch positions in the manner described above If anything wrong is noted in any of the com binations replace the switch compo
112. ame or other source of heat This might cause the pressurised gas to explode e Do not deform or damage the cylinder any way Damage to the cylinder would impair the damping effect careful not to scratch the surface of the rod this would cause the oil to leak Before disposing of the shock absorber read the section NOTES ON DISPOSAL NOTE ON DISPOSAL VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Before neutralising the rear shock absorber The gas pressure must be discharged before dis posing of the shock absorber it is necessary to dis charge the gas pressure To do this bore a hole of 2 3 mm through the cylinder wall about 15 20 mm from the bottom of the gas chamber A WARNING Wear protective goggles to avoid eye injuries from escaping gas and or metal chips AAA A A A A A A A A A A A A A A A A A A A A A A A A A A REAR SHOCK ABSORBER CHAS SHOCK ABSORBER REMOVAL A WARNING Support the motorcycle securely to prevent it from falling over 4 73 1 2 Park the motorcycle on level surface Remove e Seat e Rear cowling e Fuel tank See section SEAT FUEL TANK AND REAR COWLING in CHAPTER 3 Disconnect e Battery leads NOTE n First disconnect the negative lead then the posi tive lead 4 Remove e Exhaust pipe assembly e Rear frame e Air filter case Raise the rear wheel placing a suitable sup port under the engine Remove e Rear wheel Refer to REAR WHEEL REMOVAL sec
113. ammer to hit the engine crankcase Only hit the reinforced parts Do not hit the surface in contact with the gasket Work slowly and carefully Be care ful to perform the separation uniformly If one end locks remove pressure from the thrust screw realign and recommence If it is impossible to separate the crankcase check that all screws and components have been disassembled Do not use force ENGINE DISASSEMBLY oD GEARBOX AND TRANSMISSION 1 Remove e Guide bar 1 Shift cam 2 Selector fork 3 3 Selector fork 2 4 Selector fork 1 5 S 2 Remove e Transmission assembly unit 1 3 Remove e Shift shaft 1 1 e Shift shaft 2 2 5 16 ENGINE DISASSEMBLY oD BALANCER SHAFT AND CRANKSHAFT 1 Remove e Balancer shaft 1 2 Remove Crankshaft 1 NOTE e Remove the crankshaft by using the crankcase separating tool 2 24 Crankcase separating tool 90890 01135 e Tighten the separating tool bolts making sure that the tool body is parallel with the engine crankcase If necessary a screw may be backed out slightly to level tool body OIL STRAINER NOTE SE It is advisable to replace the oil strainer every time the engine is disassembled 1 Remove e Oil strainer 1 e Oil passage cover 2 e Gasket ENGINE DISASSEMBLY ROCKER ARMS NOTE The rocker arms may be examined with the engine
114. ance VWVVVVVVVVVVVVVVVVVVVVVVVVVVYN Checking steps e Turn the wheel so that it comes to each point as shown e Check that the wheel is at rest at each point If not readjust the rear wheel static balance AA AA A A A A A A A A A A A A A A A A A A A A A A A A A REAR BRAKE CHAS REAR BRAKE BRAKE PAD Job name Par name Brake pad removal Remove the parts in order Rear wheel Refer to REAR WHEEL REMOVAL section Brake hose Remove from clamp Caliper protector Pad pin retainer Pad pin Brake pad Brake caliper remove from caliper support Brake pad support Refer to BRAKE PAD REPLACEMENT section Reverse the removal procedure for instal lation 4 29 4 30 REAR BRAKE CHAS CAUTION Brake components must not be disassem bled The builder declines every responsibility after brake components disassembly brake master cylinder or brake caliper or in case of use of non original parts DO NOT e Remove brake components from the motorcycle unless is absolutely necessary e Use solvents on internal brake components e Use brake fluid already used for bleeding e Allow brake fluid to come into contact with the eyes as it may cause injury e Allow brake fluid to come into contact with painted or plastic parts as it may damage them e Disconnect any hydraulic connection other wise the whole system must be disassem bled drained cleaned then properly filled and bled after reass
115. and e Apply a fine lapping compound on the valve seal surface and repeat the procedures described above NOTE Be sure to remove all the lapping compound from the valve surface after every lapping operation 5 26 INSPECTION AND REPAIR e Apply Prussian blue Dykem to the valve seal surface e Install the valve in the cylinder head e Press the valve onto the housing through the guide to leave a clear outline e Measure the valve seat width once more If the width of the valve is out of specification alter and relap AAA A A A A A A A A A A A A A A A A A A A A A A A A A A VALVE SPRINGS 1 Measure e Free width of valve springs a Out of specification Replace X Free width of valve springs intake and exhaust Internal spring External spring 40 1 mm 43 8 mm 2 Measure e Spring load Out of specification Replace b Length of loaded spring Valve spring load Internal spring intake and exhaust 164 8 190 2 N 16 80 19 39 kgf at 22 7 mm External spring intake 71 6 87 3 7 3 8 9 kgf at 34 2 mm External spring exhaust 149 1 182 4 N 15 2 18 6 kgf at 34 2 mm 3 Measure e Inclination of spring a Out of specification gt Replace Spring inclination limit Internal spring External spring 2 5 1 7 mm 2 52 1 9 mm 5 27 INSPECTION AND REPAIR OD CAMSHAFT 1 Inspect e Cam eccentrics Pitting Scratches Blue colour gt Replace cams
116. ansistorized coil ignition Pickup coil resistance unit model manufacturer 230 Q 20 L Y G W 9 NIPPON DENSO Ignition coil Model manufacturer Primary coil resistance Secondary coil resistance JO300 NIPPON DENSO 4 15 13 20 Spark plug cap Material Resistance Resin 10 kQ Charging system Type Model manufacturer Standard output Stator coil resistance A C magneto TLMZA8 NIPPON DENSO 14 0 V 18 5 A 5 000 r min 0 65 20 W W Rectifier regulator Regulator type Model manufacturer No load regulated voltage Rectifier capacity Withstand voltage Semi conductor short circuit SH629A 12 SHINDENGEN 14 5 0 4 V 25 240 V Battery Specific gravity 1 320 Electric starting system System type Starter motor Model manufacturer Power output Armature coil resistance Brush overall length Brush spring force Commutator diameter Mica undercut depth Starter relay Model manufacturer Amperage Coil resistance Constant mesh SM 13 MITSUBA 0 80 kW 0 03 0 04 Q 10 0 mm 8 82 N 899 gf 28 0 mm 0 70 mm MS5F 721 JIDECO 180A 4 4 5 2 17 MAINTENANCE SPECIFICATIONS SPEC ve Standard Horn Horn type Quantity Manufacturer Max amperage Flasher relay Type Model manufacturer Self cancelling device Flasher frequency Wattage Plane 1 pcs LEONELLI 1 5A Semi transistor FB222M NIPPONDENSO No 75 95 cycle m
117. atteries e KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External e SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION e This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate e Charging time charging amperage and charging voltage for a MF battery are dif ferent from those of conventional batter ies The MF battery should be charged as explained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charg ing the battery CHECKING AND CHARGING THE BATTERY ei Voltmeter Relationship between open circuit voltage and charging time at 20 C 5 6 5 10 Charging time Hours This varies depending on the temperature the state of charge in battery plates and the electrolyte level Open circuit voltage 3 48 NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte T
118. ble Check the clutch switch component for continuity between Black 1 and Black Refer to SWITCH CHECK in Chapter CORRECT IGNITION SYSTEM ELEC INCORRECT 4 The neutral switch is defective Replace INCORRECT mmm 7 18 The clutch switch is defective Replace IGNITION SYSTEM ELEC 12 Pick up coil resistance Disconnect the generator connector Green White and Blue Yellow e Connect the pocket tester x 100 to pick up coil cables Tester terminal gt Blue Yellow cable 1 Tester terminal gt Green White cable 2 Pick up coil resistance 230 20 at 20 C 68 F Green White Blue Yellow The pick up coil is defective Replace COMPLY WITH JL SPECIFICATIONS UNCERTAIN CONNECTIONS 13 Wiring connections Check the connections of the entire ignition system Refer to ELECTRICAL CIRCUIT J CORRECT The CDI unit is defective Replace e Check that the pick up coil resistance is as OUT OF SPECIFICATIONS 7 19 7 20 ELECTRICAL STARTING system ELEC ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM
119. bleeder screw oil filter cover Screw tappet cover 10 Nm 1 0 mkg Air bleeder screw oil filter cover 5 Nm 0 5 mkg 8 Adjust e Clutch cable free play X Free play at end of lever 10 15 mm See section CLUTCH ADJUSTMENT in CHAPTER 3 5 78 ENGINE REASSEMBLY M e 9 Install e Carburetor Screw clamp QJ 2 Nm 0 2 mkg See section CARBURETOR INSTALLA TION in CHAPTER 6 10 Adjust e Throttle cable free play Free play 3 5mm See section THROTTLE CABLE FREE PLAY ADJUSTMENT in CHAPTER 3 11 Install e Fuel tank CAUTION Do not start the engine until it is filled with oil 12 Fill with e Engine oil Amount of oil total 3 0 litres See section ENGINE OIL REPLACE MENT in CHAPTER 3 13 Check e Engine idle speed C Engine idle speed 1 150 1 450 rpm See section IDLE SPEED ADJUST MENT in CHAPTER 3 14 Install Seat Screw seat 2 10 Nm 1 0 mkg CHAPTER 6 CARBURETOR auicm n i tactile 6 1 TECHNICAL SPECIFICATIONS TIGHTENING TORQUES EXPLODED VIEW 6 3 SECTION VIEW MM T 6 5 CARBURETOR 1 5 1 ttt 6 6 CARBURETOR INSPECTION ssss ttt 6 9 CARBURETOR 55 1 ttt 6 11 FUEL LEVEL ADJ USTMENT CARBURETOR INSTALLED
120. ch gear assy NOTE nN Pitting of the gear assy teeth causes irregular functioning 5 33 INSPECTION AND REPAIR 2 Inspect e Clutch gear assy bearing Damaged gt Replace 3 Inspect Groove in clutch boss Pitting Moderate gt Burr Accentuated gt Replace clutch boss NOTE E Pitting of the clutch boss grooves causes irregular functioning 4 Measure e Thickness of friction plates Out of specification Replace all plates Zope Type _ 6 parts 2 72 2 88 mm 5 Measure Deformation of clutch plates Out of specification Replace all plates lt Clutch plates deformation Limit 0 2 mm 6 Measure Runout limit of clutch push rod Turn clutch push rod on two V blocks Y Clutch push rod runout lt Limit gt 0 2 mm 5 34 INSPECTION AND REPAIR Q 7 Measure e Free length of clutch compression springs a Out of specification gt Replace all springs Free length of clutch compression spring a 42 8 mm OIL PUMP 1 Measure e Clearance between rotors a Between the internal rotor 1 and the external rotor 2 e Side clearance b Between the external rotor 2 and the pump stator 3 Out of specification gt Replace oil pump Oil pump clearances Clearance between 0 12 mm rotors a Limit 0 2 mm 0 03 0 08 mm Limit 0 15 mm Side clearance b 2 Inspec
121. cket cover 1 Remove e Cover 1 intermediate starter gear Centring pins e Gasket 2 Remove e Intermediate starter gear 1 e Bearing 2 e Distributor shaft 3 3 Remove e Neutral gear switch cable 1 5 8 ENGINE DISASSEMBLY oD 4 Remove Crankcase cover gasket 1 L e Centring pins Seal ring and O ring e Gasket 5 Remove e Intermediate starter gear 1 e Bearing 2 e Distributor shaft 3 6 Remove e Cable clamp 1 e Coil 2 e Stator 3 CRANKCASE COVER R CLUTCH PRIMARY DRIVE GEAR AND BALANCER SHAFT GEAR NOTE Ee The clutch the primary gear and the balance gear may be inspected with the engine installed by removing the following parts Footrest R e Oil delivery hose screw 5 9 ENGINE DISASSEMBLY 1 Remove Engine oil delivery hose screw Copper washer Oil filter cover 1 Oil filter Seal ring and O Ring Crankcase cover 2 R 2 Remove Compression spring 1 Pressure plate 2 Ball 3 Friction plate 4 Clutch plate 5 Clutch boss spring 6 Clutch boss 7 Thrust plate 8 Clutch shroud 9 Push rod 10 NOTE e Before loosening the nut 11 clutch shroud straighten the washer lock tab e To loosen the nut clutch boss block the clutch boss using the special tool 12 Z4 Clutch holding tool P N 90890 04086 5 10 ENGINE DISASSEMBLY oD 3 Remove Primary drive gear 1 Disc 2 Balanc
122. compressed air into the hose joint open ing to force out the caliper piston from the brake caliper body A WARNING e Never try to pry out the caliper piston e Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the master cylinder e Remove the piston seal A A A A A A A A A CALIPER INSPECTION Recommended programme for the replacement of brake system components Brake pads When necessary Brake hose Every four years Replace every Brake fluid 24 000 km or 24 months and whenever the brake is disassembled A WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Do not use solvents to prevent sealing elements from becoming mis shapen or swollen 1 Inspect e Caliper piston Scratches wear rust gt Replace caliper assembly e Caliper cylinder Scratches wear gt Replace caliper assem bly e Caliper Cracks damaged gt Replace REAR BRAKE CHAS e Fluid delivery passage caliper Obstruction gt Clean with compressed air A WARNING In case of non correct operation of the brake Caliper replace the brake caliper assembly 7 BRAKE CALIPER ASSEMBLY A WARNING e All internal brake components should be cleaned and lubricated with new brake fluid only before installation Liquido freni raccomandato DOT 4 In case o
123. crew top cover A 2 0 2 mkg 3 Install e Main jet secondary e Drain vavle Main jet secondary 2 Nm 0 2 mkg Drain valve 9 Nm 0 9 mkg CARBURETOR ASSEMBLY CARB Primary carburetor 1 Install e Needle jet 1 e Connecter comp 2 NOTE n Check that the connecter comp 1 is in the posi tion shown in the figure 2 Install e Throttle valve 3 Install e Spring e Throttle shaft NOTE n Assemble the spring as shown in the illustration 4 Install e Screw connecter comp Turn the throttle shaft clockwise 1 2 turn to pre load the spring and then holding it in position assemble the screw connecter comp Screw connecter camp A 2Nm 0 2 mkg 6 12 CARBURETOR ASSEMBLY CARB 5 Install e Cable holder e Collar e Throttle lever NOTE Check that the throttle shaft lever 2 and the adjuster bolt 3 are aligned when tightening the throttle nut 1 Y Screw cable holder 3 Nm 0 3 mkg 6 Install e Top cover Screw top cover Pe 2 0 2 mkg 7 Install e Diaphragm 1 enrichment NOTE Make the diaphragm tab coincide with the gravity enricher notch 8 Install e Starter set e Stop screw Starter piston 26 6 Nm 0 6 mkg Install e Pilot screw set 1 Pilot jet 2 Main nozzle 1 3 Main jet primary 4 Valve seat 5 Main nozzle 1 2 Nm 0 2 mkg Screw valve seat 2 Nm
124. ctrode gap a Use a wire or thickness gauge Out of specification gt Regap lt Electrode 0 8 0 9 mm 3 9 SPARK PLUG INSPECTION ei 3 10 8 Lock tighten Spark plug Before installing the spark plug clean the surface and thread Spark plug 2 18 Nm 1 8 mkg NOTE Tighten the spark plug by hand before torquing to specification 9 Connect e Spark plug cap 10 Install e Fuel tank e Seat See section SEAT FUEL TANK AND REAR COWLING Seat screws A 10 Nm 1 0 mkg IGNITION TIMING CHECK NSP ei IGNITION TIMING CHECK 1 Start the engine and let it heat 2 Connect e Inductive rev counter e Stroboscopic lamp to spark plug cable Inductive engine speed indicator P N 90890 03113 Stroboscopic lamp P N 90890 03141 3 Remove e Cap 1 CAUTION In certain conditions the oil might spray out when the cap is removed Be careful therefore when removing the cap 4 Check e Ignition advance Check e Heat engine and let it run to the number of revs required me Engine idle speed 1 150 1 450 rpm e Check that reference 1 is in the mobile field of reference 2 on the flywheel Incorrect ignition timing gt Check the ignition coil unit NOTE Ignition timing cannot be adjusted AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 5 Install e Cap 6 Remove S
125. dal soft and spongy gt Bleed air from brake circuit Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in Chapter 3 REAR BRAKE CHAS MASTER CYLINDER Job namel Pan Master cylinder removal Remove the parts in order Brake fluid Drain Rear stop switch connector Rear stop switch Plain washer Refer to MASTER CYLINDER INSTALLA Brake hose TION section Brake fluid reserve tank Brake master cylinder Brake pedal spring io to BRAKE PEDAL REMOVAL sec tion Reverse the removal procedure for installa tion 4 32 4 33 REAR BRAKE CHAS MASTER CYLINDER INSPECTION 1 Inspect e Master cylinder assembly Wear scratches Replace the master cylinder assembly e Master cylinder body Cracks damage Replace the master cylinder assembly e Fluid delivery passage master cylinder Obstruction gt Clean with a jet of com pressed air 2 Inspect e Master cylinder piston unit Scratches wear damage Replace the master cylinder assembly 3 Inspect e Diaphragm 1 Wear damage gt Replace 4 Inspect e Brake hose Cracks wear damage gt Replace MASTER CYLINDER ASSEMBLY A WARNING e All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 e In case of non correct operation of the brake master cylinder replace the master cylinder assembly 1 Install e Spring e Master cylinder
126. e Handle crown Steering shaft Steering shaft Ring nut Holder handle upper Crown handle Holder handle under Crown handle Front fork under bracket Inner tube Front master cylinder Cap Front master cylinder Handle Union bolt tightening Front fender Front fork Stay headlight Handle crown Stay headlight Bracket meter Headlight Stay headlight M8 x 1 25 M28 x 1 5 M36 x 1 5 M8 x 1 25 M10 x 1 5 M8 x 1 25 M4 x 0 7 M6 x 1 0 M10 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 28 2 8 4 0 4 11 5 20 2 0 40 4 0 23 2 3 1 5 0 15 9 0 9 20 2 0 7 0 7 10 1 0 6 0 6 10 1 0 See NOTE Rear arm and cushion Pivot shaft Frame Arm relay Frame Arm relay Rod connecting Arm relay Shock absorber Rod connecting Rear arm Shock absorber upper Frame Seal guard Rear arm Support chain Rear arm Chain case Rear arm M14 x 1 5 M10 x 1 25 M10 x 1 25 M10 x 1 25 M12 x 1 25 M12 x 1 25 M6 x 1 0 M6 x 1 0 M6 x 1 0 90 9 0 60 6 0 5 2 5 9 6 6 6 6 0 4 0 9 0 9 Front wheel Front wheel shaft Front fork Axle holder Front fork Rear wheel Rear wheel shaft Nut Clutch hub Sprocket 2 14 M16 x 1 5 M6 x 1 0 M18 x 1 5 M10 x 1 25 5 9 0 9 MAINTENANCE SPECIFICATIONS SPEC ve Part to be tightened Thread size Tightening torque Nam m kg Remarks Front brake Front hub Disc brake Front caliper Front fork Front caliper Bleeder tightening Union bolt tightening front M6 x 1 0 M
127. e White DAN Red White CH Green Pu Pink Black Blue Br W Brown White Blue Yellow Red Yellow
128. e drive chain Wipe it dry and thoroughly lubri cate it with SAE 80 90W motor oil or special lu bricant for O Ring chains Do not use any other lu bricants on the drive chain They may contain sol vents that could damage the O Rings Recommended lubricant SAE 80W 90 engine oil or special lubricant for O Ring chains FRONT FORK INSPECTION FRONT FORK ADJUSTMENT FRONT FORK INSPECTION A WARNING When inspecting the front fork hold the motorcycle firmly to prevent it falling over 1 Place the motorcycle on a level surface 2 Check e Inner tube Scratches Damage gt Replace e Oil seal Undue oil leakage gt Replace 3 With the motorcycle in a level upright position operate the front brake 4 Check e Proper functioning Compress and release the front fork sev eral times Irregular jerky functioning gt Repair See section FRONT FORK in Chapter 4 ADJ USTING THE FRONT FORK This front fork is equipped with spring pre load ad justing bolts A WARNING Always adjust both fork legs equally other wise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby hard en the suspension turn the adjusting bolt on each fork leg in direction To decrease the spring preload and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b Setting Minimum soft 1 2 3 S
129. embly BRAKE PAD REPLACEMENT NOTE It is unnecessary to disassemble the brake hose to replace the pads 1 Remove e Rear wheel refer to REAR WHEEL REMOVAL section Bolt caliper protector 1 Brake caliper protector 2 Pad pin retainer 3 Brake pad pin 4 Remove the caliper in the illustrated direc tion 2 Remove Brake pads 5 e Pad support 6 NOTE f you replace the pads also replace the pad support e f one of the two pads has to be replaced because it is worn replace both A 4 31 3 REAR BRAKE CHAS Install e Brake pads e support VWVVVVVVVVVVVVVVVVVVVVVVVVVVYN Installation procedure Connect the hose 1 firmly to the caliper bleeder screw 2 Place the other end of the hose in an open container Loosen the caliper bleeder screw and push the piston into the caliper with your finger Retighten the bleeder screw 2 Ny Caliper bleeder screw A 14 Nm 1 4 mkg Install the new brake pads and new pad support Install the caliper 3 and the pad pin 4 Install the new pin retainer 5 Install the caliper protector 6 Caliper protector bolt A 10 Nm 1 0 mkg AAA A A A A A A A A A A A A A A A A A A A A A A A A A A A e Check e Brake fluid level Refer to BRAKE FLUID INSPECTION section in Chapter 3 a Minimum level mark MIN b Maximum level mark MAX Check e Brake pedal operation Pe
130. er cylinder 1 e Master cylinder bracket 2 Screw master cylinder bracket 2A 9Nm 0 9 mkg 2 Install washer 1 new e Brake hose 2 e Union bolt 3 Union bolt brake hose dl 20 2 0 mkg NOTE e When tightening the union bolt be sure to put the brake hose in the correct position e Check that the brake hose has stayed in the correct position Adjust if necessary A WARNING e Check that the brake hose routing is as described Refer to CABLE ROUTING section e Always use new plain washers 3 Fill e Brake fluid reservoir Recommended brake fluid DOT 4 FRONT BRAKE CHAS CAUTION Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately A WARNING e Use only designated quality brake fluid Otherwise the rubber seals may deterio rate causing leakage and poor brake per formance e Refill with the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and lead to poor perform ance e Be careful that water does not enter the significantly lower the boiling point of the fluid may result in vapor lock 4 Air bleed e Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 5 Inspect e Brake fluid level Lower than MIN mark gt Fill Refer to BRAKE FLUID INSPECTION section in CHAPTER 3 a Minimum level mark MIN 6 Ins
131. er drive gear 3 Disc 4 Key 5 Disc washer 6 Disc 7 Balancer gear 8 Straight key 9 NOTE __ Before loosening the nut 9 primary drive gear and nut 10 balancer gear straighten the wash lock tab NOTE To loosen nuts 9 and 10 hold the rotor CA magneto firmly in place using special tool 11 Sheave holder P N 90890 01701 CAUTION Be careful not to touch jutting edges 12 on the rotor with the sheave holder 4 Remove e Push lever 1 e Spring e Flat washer NOTE Loosen the screw to remove the push rod ENGINE DISASSEMBLY OIL PUMP AND SHIFT LEVER NOTE The oil pump and shift lever may be checked with the engine installed by removing the following parts Footrest e Oil delivery hose screw e Crankcase R e Clutch 1 Remove e Circlip 1 e Oil pump gear 2 e Oil pump 3 e O rings 4 2 Remove e Circlip 1 from drive shaft e Ring 2 e Circlip 3 3 Remove e Circlip 1 e Shift lever 2 Spring 3 e Flat washer 4 4 Remove e Stopper lever 1 Ring 2 Spring 3 5 12 ENGINE DISASSEMBLY oD AC GENERATOR AND TIMING CHAIN NOTE _ The AC generator may be inspected with the engine installed by removing the following parts e Crankcase L 1 Remove Nut 1 Washer 2 Rotor 3 with starter gear Bearing 4 Shim adjustment washer 5 Key 6 NOTE n To loosen the nut
132. ers pistons and other parts that have been mated through normal wear Mated parts must always be reused or replaced as an assembly During machine disassembly clean all parts and place them in trays in the order of disas sembly This will speed up assembly and allow for the correct installation of all parts Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EB101020 GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals and O rings when overhauling the engine All gasket surfaces oil seal lips and O rings must be cleaned Properly oil all mating parts and bearings dur ing reassembly Apply grease to the oil seal lips IMPORTANT INFORMATION Nro EB101030 LOCK WASHERS PLATES AND COTTER PINS 1 Replace all lock washers plates 1 and cotter pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification 300 000 EB101040 BEARINGS AND OIL SEALS 1 Install bearings and oil seals so that the man ufacturers marks or numbers are visible When installing oil seals apply a light coating of lightweight lithium base grease to the seal Lp N lips Oil bearings liberally when installing if EE appropriate D Oil
133. es after charging has been completed Therefore wait 30 min utes after charging is completed before measuring the open circuit voltage CHECKING AND CHARGING THE BATTERY ei Charging method using a variable current voltage type charger Charger AMP h n circui NOTE Ls Measure tne Ope circuit Voltage should be measured 30 minutes voltage prior to charging after the machine is stopped NOTE _ _ _ __ Connect a charger and AMP Set the charging voltage at 16 17 V if the setting is lower charging will be meter to the battery and start insufficient If too high the battery will be charging over charged Make sure the current is higher than the standard NO charging current written on the battery By turning the charging voltage adjust dial set the charging voltage at 20 25 V y Y Monitor the amperage for 3 5 EE Wie vodaga co ihal YES minutes to check if the standard current is at standard charg 4 charging current is reached ing level NO Set the timer according to If the current does the charging time suitable for not exceed standard the open circuit voltage charging current af Refer to Battery condition ter 5 minutes re checking steps place the battery In case that charging requires than 5 hours it is advisable to check the charging current after a lapse of 5 hours
134. f non correct operation of the brake caliper replace the brake caliper assembly k Install e Piston seal 1 e Dust seal 2 Caliper piston 3 CALIPER INSTALLATION Install e Brake caliper 1 Caliper support 2 Brake hose 3 Plain washers 4 new Union bolt 5 Nyy Union bolt 22 20 Nm 2 0 mkg Caliper protector 4 39 4 40 REAR BRAKE CHAS CAUTION Check that the brake hose has stayed in cor rect position with the pipe fitting matching the projection a of the caliper A WARNING Check that the brake hose routing is correct Refer to CABLE ROUTING section 2 Fill e Brake fluid reserve tank Recommended brake fluid DOT 4 CAUTION Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately A WARNING e Use only designated quality brake fluid Otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and lead to poor perform ance Be careful that water does not enter the significantly lower the boiling point of the fluid may result in vapor lock 3 Air bleed e Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER REAR BRAKE CHAS 7 AE 4 Inspect Y e Brake fluid level VN n Lower than MIN mark
135. for continuity Refer to CHECKING THE FUSES in Chapter 3 e 5 the fuse OK YES Check the condition of the battery Refer to CHECKING AND CHARGING Ne THE BATTERY in Chapter 3 Min open circuit voltage 12 8 Vor more abel e Clean the battery terminals e Recharge or replace the battery Replace the fuse 2 Battery 7 43 LIGHT SYSTEM ELEC e Disconnect the main switch connector from the wire harness e Connect the pocket tester 1 to the switch cables Refer to SWITCH CHECK in CHAPTER INCORRECT Y The main switch is defective Replace Disconnect the left handlebar switch con nector from the wire harness e Connect the pocket tester 1 to the left handlebar switch terminals e Check the switch component for conti nuity between Brown 1 and Yellow 2 Brown Blue 3 and Green 4 Brown Blue 3 and Yellow 2 Refer to SWITCH CHECK in CHAPTER INCORRECT The dipped high beam commutator and or the dimmer switch are defective Replace the left handlebar switch CORRECT 7 44 LIGHT SYSTEM ELEC 5 Starter circuit cut off relay e Connect the pocket tester DC 20V and the battery 12V to the cut off relay con nector terminal of the starter circuit Battery terminal gt White Black terminal 1 Battery terminal gt Black terminal 2 Tester terminal gt Brown ter
136. front bolt on the handlebar holder then tighten the rear bolt REAR SHOCK ABSORBER CHAS Job ramelan Shock absorber removal Remove the parts in order A WARNING Securely support the motorcycle so there is no danger of it falling over Seat Refer to SEAT FUEL TANK AND REAR dine COWLING section in Chapter 3 Battery leads Disconnect NOTE First disconnect the negative lead then the positive lead Muffler Exhaust pipe assembly Refer to REAR SHOCK ABSORBER RE Rear frame OVAL section Brake fluid reserve tank Secure the brake fluid tank to the frame in Air filter case an upright position to avoid air entering the hydraulic system 4 69 REAR SHOCK ABSORBER CHAS Job ramelPart Lower bolt Upper bolt Reverse the removal procedure for instal lation 4 70 REAR SHOCK ABSORBER C HAS Rear shock absorber Spring Spring adjuster ring nut Lock ring nut End of stroke buffer Special spanner 66 Nm 6 6 mg 8 59 Nm 5 9 mg Cu 4 71 REAR SHOCK ABSORBER CHAS 4 72 A WARNING This shock absorber contains high pressure nitrogen gas Read the following information carefully before handling it The manufacturer cannot be held responsible for any damage or injury that may result from improper handling e Never tamper with or attempt to open the cylinder or the tank e Never expose the shock absorber to a naked fl
137. g the disassembly procedures in reverse order NOTE Use a wrench 1 with an external diameter equal to that of the bearing dust cover and oil seal CAUTION Do not strike the bearing inner race 2 or balls 3 The contact must only be made with the outer race 4 A A REAR WHEEL INSTALLATION 1 Install e Brake disc 1 26 12 Nm 1 2 mkg NOTE IL e Apply LOCTITE to the threads of brake disc screw Tighten the screws brake disc in stage using a crisscross pattern N Install e Hub spacer 1 e Driven sprocket 2 e Hub and driven sprocket Nyy Screw driven sprocket A 48 Nm 4 8 mkg 3 Install e Collar 4 26 wes AID nae CHASSO 4 Lubricate e Wheel axle e Bearings e Edge of hub dust cover Lithium base grease CAUTION Check that the brake caliper support has stayed in the correct position on the rear arm 5 Install e Rear wheel assembly in the rear arm e Bearing e Edge of the hub dust cover CAUTION Check that the brake disc is driving through the brake pads 6 Install e Drive chain on the driven sprocket e Rear wheel axle left side CAUTION Make sure the collars and chain pullers are positioned correctly 7 Adjust e Drive chain slack Drive chain slack 30 40 mm Refer to DRIVE CHAIN SLACK INSPEC TION AND ADJUSTMENT section in Chapter 3
138. g the dust seal 4 50 FRONT Fork 4 Using a small screwdriver take a small amount of silicon grease and insert it under the lip paying attention not to scratch it Lubricate the dust seal by rotating it in such a manner that the grease is distributed in the inner part of the lip 5 Remount the dust seal inserting it with force into the oil seal seat CAUTION Check that the oil seal housing edge of the dust seal adheres perfectly to the oil seal seat SEAL AND BUSH REPLACEMENT NOTE Il To ensure maximum efficiency to the fork and therefore a longer duration and greater safety every year unless there are leakages it is nec essary to replace all the seals and slide bushes To carry out this operation it is recommended to use the proper tools CAUTION To remove the fork leg from the steering unit the cap bolt the spring and to drain and refill the oil follow the procedures indicated in the preceding pages scrupulously 1 Drain e Fork leg oil Refer to OIL REPLACEMENT section 2 Clamp e Fork leg in a vice in a horizontal position CAUTION Protect the outer tube with a clean rag to avoid damaging FRONT Fork CHAS 3 Insert an Allen key in the bolt 3 at the bottom of the outer tube and the special tool 1 with the holder 2 on the damper cylinder assem bly and unscrew the bolt completely CAUTION Before unscrewing the bolt ensure that the end of the damper r
139. gently with a screwdriver NOTE A well tightened spoke makes a distinct sharp noise a loose spoke makes a dull muffled noise 4 24 nen ws ano nae CHASSO 4 Tighten e Loose spokes Spoke NOTE ss After tightening the spokes check the centring of the wheel 5 Measure e Rear wheel runout Over the specified limits gt Replace Rear wheel runout limits Radial 1 1 0 mm Lateral 2 0 5 mm 6 Inspect e Rear wheel bearings Bearings allow free play in the wheel hub or the wheel does not turn smoothly gt Replace e Hub dust cover Wear damage gt Replace e Oil seal Wear damage gt Replace BRAKE DISC INSPECTION 1 Inspect e Brake disc Wear Damage gt Replace 2 Measure e Brake disc deflection a If over envisaged limits gt Verify wheel centring If the wheel centring is correct replace the brake disc Maximum deflection brake disc 0 15 mm Misure at 2 mm from disc edge e Brake disc thickness b If out of specified limits gt Replace Kl Minimum thickness brake disc 4 5 mm 4 25 nen wt ano ae CHAS REAR WHEEL ASSEMBLY 1 Install e Wheel spacer Wheel bearing Oil seal Dust cover Wheel bearing Wheel spacer Wheel bearing Hub bearing Oil seal Hub spacer Dampers Hub and driven sprocket VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Assembly procedure e Install the new bearing the dust cover and the oil seal by followin
140. gine protector 2 5 Disconnect e Brake pedal return spring 3 6 Remove e Rear master cylinder fastening screws 4 e Oil delivery hose fastening screw 5 e Right crankcase cover fastening screws e Right crankcase cover 6 7 Loosen e Lock nut 1 8 Push the engine clutch control lever forward to the stop point 9 Adjust e Free play With the lever in this position turn the adjuster 2 either way until the marks on the lever 3 and crankcase 4 are aligned 10 Tighten e Lock nut 1 Ny Lock nut Q 8 Nm 0 8 mkg CLUTCH ADJUSTMENT NSP ei 11 Install e Right crankcase cover e Right crankcase cover fastening screws e Oil delivery hose fastening screw Screw crankcase cover 10 Nm 1 0 mkg Oil delivery hose screw 18 Nm 1 8 mkg 12 Connect e Brake pedal return spring e Rear master cylinder Screw rear master cylinder 2 10 Nm 1 0 mkg 13 Reassemble e Footrest right Bolt footrest 2 48 Nm 4 8 mkg e Engine protector 14 Fill e Engine oil tank See section ENGINE OIL REPLACE MENT 15 Adjust Clutch cable free play X Free play at lever tip 10 15 mm See section Cable free play adjustment 3 23 AIR FILTER CLEANING AIR FILTER CLEANING 1 Remove e Fast screws 1 e filter box 2 2 Pull out e Filtering element 3 from its seat 3 Wash e Filtering element with water and biodegradable liquid soap NOTE SS
141. grip flange 3 Adjust e Throttle cable free play VVVVVVVVVVVVVVVVVVVVVVVVVVVY Adjustment e Loosen the throttle cable 2 lock nuts 1 e Turn the adjuster 3 clockwise or anticlock wise to obtain the required free play e f after loosening the adjuster by 5 mm the free play is still not correct tighten the adjuster 4 on the throttle cable 5 once more e Tighten the lock nuts 1 6 Lock nuts A A 4 Reassemble e Fuel tank e Seat See section SEAT FUEL TANK AND REAR COWLING Y Seat screws A 10 Nm 1 0 mkg SPARK PLUG INSPECTION NSP ei SPARK PLUG INSPECTION 1 Remove e Seat e Fuel tank See section SEAT FUEL TANK AND REAR COWLING 2 Disconnect e Spark plug cap 3 Remove Spark plug 1 CAUTION Before removing the spark plug use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinder CAUTION When removing the spark plug be careful not to drop foreign objects inside the engine 4 Inspect Type of spark plug Incorrect gt Replace Standard spark plug DPR8EA 9 N G K or DPR9EA 9 N G K 5 Inspect e Electrodes 1 Wear and tear damage gt Replace e Insulator 2 Normal insulator 2 colour is light tan D Clean the spark plug with a suitable tool and a steel brush Measure e Spark plug ele
142. haft 2 Measure e Cam eccentrics Out of specification gt Replace camshaft ROCKER ARMS AND ROCKER SHAFT 1 Inspect e Rocker shafts Blue colour Grooves gt Replace shafts and check lubrication system 2 Inspect Rocker shaft slot 1 e Surface in contact with cam eccentric 2 e Adjuster surface 3 Pitting Wear Scratches Blue colour gt Replace and check lubrication system 5 28 INSPECTION AND REPAIR OD 5 29 3 Measure e Rocker arm shaft clearance Rocker arm shaft clearance Internal diameter a of rocker arm External diameter b of shaft Out of specification gt Replace whole unit Rocker shaft clearance 0 009 0 042 mm CAMSHAFT CHAIN AND SPROCKET 1 Inspect e Chain Stiffness Cracks gt Replace timing chain and sprocket 2 Inspect Sprocket Wear Damage gt Replace timing chain and sprocket 1 4 tooth maximum New sprocket tooth profile Roller Sprocket 1 2 3 2 Dm NH 4 INSPECTION AND REPAIR ENG Su CAMSHAFT CHAIN GUIDE 1 Inspect e Side chain guide exhaust 1 A e Side chain guide intake 2 Wear Damage gt Replace CYLINDER AND PISTON 1 Inspect e Piston and cylinder walls Vertical scratches Replace cylinder liner and piston 2 Measure e Piston cylinder clearance Measurement steps C 2 First step ER e Measure cylinder
143. he replace ment of brake system components Brake pads When necessary Brake hoses Every four years Replace every 24 000 km or 24 Brake fluid months and when ever the brake is disassembled A WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Do not use solvents to prevent sealing elements from becoming mis shapen or swollen 1 Inspect e Caliper piston 1 Scratches wear rust gt Replace caliper assembly e Caliper cylinder 2 Scratches wear gt Replace caliper assem bly e Caliper 3 Cracks damaged Replace the brake caliper assembly 4 19 FRONT BRAKE CHAS e Fluid delivery passage caliper Obstruction gt Clean with compressed air A WARNING In case of non correct operation of the brake Caliper replace the brake caliper assembly CALIPER ASSEMBLY A WARNING e All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 e In case of non correct operation of the brake caliper replace the brake caliper assembly Install e Piston seals 1 e Dust seals 2 2 Install e Brake caliper pistons 1 CALIPER INSTALLATION 1 Install e Brake caliper 1 e Caliper support bolts 2 Nyy Bolt caliper support dl 25Nm 2 5 mkg Brake hose 3 e Plain washers 4 new e Union bolt 5 Nyy Union bolt 22
144. herefore the charge of the battery has to be checked by meas uring the voltage at the battery terminals 1 Remove e Seat Panel 2 Disconnect e Battery leads from the battery terminals CAUTION First disconnect the negative lead 1 then the positive lead 2 3 Remove e Battery 4 Check e Battery charge VWVVVVVVVVVVVVVVVVVVVVVVVVVYVVYVYN a Connect a pocket tester to the battery termi nals Tester positive gt Battery positive lead terminal Tester negative gt Battery negative lead terminal NOTE e The charge state of a MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected e No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e Charge of the battery 20 30 A A 5 Charge e Battery refer to the appropriate charging method illustration Open circuit voltage V 5 o gt 2 e o E o Q o bk o Ambient temperature 100 75 50 30 2520 Condition of charge in battery Charging Ambient temperature 20 C 40 50 60 Time mi
145. iate gear 1 3 6 Install Centring pins e Gasket e Cover 1 starter intermediate gear ok Screw cover QJ 10 Nm 1 0 mkg 5 75 ENGINE REASSEMBLY oD ENGINE REASSEMBLY To reassemble the engine repeat the procedures described in the paragraph ENGINE REMOVAL in this chapter in reverse order Pay attention to the following points 1 Install Sprocket 1 e Drive chain Ngy Nut sprocket A 110 Nm 11 0 mkg NOTE n Bend the lock washer tab along the face of the nut A WARNING Always use a new lock washer 2 Install Cover sprocket e Shift pedal Footrest L Screw sprocket cover 10 Nm 1 0 mkg Use LOCTITE Screw shift ptidal 10 Nm 1 0 mkg Screw footrest 48 Nm 4 8 mkg 3 Adjust e Drive chain slack Drive chain slack 30 40 mm See section DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT in CHAPTER 5 76 5 77 ENGINE REASSEMBLY oD 4 Install e Oil delivery hose 1 Union bolt 2 18 Nm 1 8 mkg 5 Remove Tappet cover intake e Air bleeder screw oil filter cover 6 Apply e 4 stroke engine oil e on the top side of the camshaft and in the oil filter housing CAUTION Liberally apply 4 stroke engine oil in the oil passage in the crankcase to prevent damage to the engine Amount of oil Camshaft 0 1 litres Oil filter housing 0 06 litres 7 Install Tappet cover intake e Air
146. in 10W 2 3 4 Daylight switch relay Model manufacturer ACA12151 1 MATSUSHITA DENKOU Circuit breaker Type Amperage for fuse Reserve Fuse 20A 20A 2 18 GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard 1 5 0 pitch threads Torque specifi cations for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room tempera ture A Distance between flats B Outside thread diameter General torque specifications N m m kg 6 0 6 15 1 5 30 3 0 55 55 85 8 5 13 0 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER x 0 03937 2mm x 0 03937 CONVERSION TABLE METRIC TO IMP spec ue IMP in 0 08 in Known Multiplier 7 233 86 794 0 0723 0 8679 Result Weight 2 205 0 03527 Distance 0 6214 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm cc cm It liter It liter 0 03527 0 06102
147. ine oil classification Quantity Without oil filter cartridge replacement With oil filter cartridge replacement Total amount dry engine Temp C SAE20W40SE or SAE10W30SE API Service SE SF SG or higher 2 4L 2 5L 3 0L Air filter Wet type element Fuel Type Fuel tank capacity Fuel reserve amount Regular unleaded gasoline 10L 3 0L Carburetor Manufacturer Model x quantity TEIKEI Y30PV 2ATK x 1 2 1 Item GENERAL SPECIFICATIONS SPEC ve Standard Spark plug Manufacturer model Gap Clutch type NGK DPR8EA 9 or NGK DPR9EA 9 0 8 0 9 mm Wet Multiple disc Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Number of drive chain sprocket teeth front rear Transmission type Operation Spur gear 71 34 2 088 Chain drive 47 15 3 133 15 47 Constant mesh 5 speed Left foot Gear ratio 2 583 1 588 1 200 0 955 0 792 Chassis Frame type Open cradle backbone frame detachable rear frame Caster angle 27 Trail 117 mm Tires Front Type With tube Size 90 90 21 54 90 90 21 545 Manufacturer model Pirelli MT70 Michelin T63 Rear Type With tube Size 130 80 18 66R 130 80 18 66S Manufacturer model Pirelli MT70 Michelin T63 Maximum load 180 kg Tire air pressure measured on cold tires Up to 90 kg Front 200 kPa 2 00 kgf cm 2 00 bar Rear 220 kPa 2 20
148. ing a connec tion cable 1 as shown Battery terminal 7 2 2 Red Black terminal 3 Frame 2 Blue White terminal 4 IT FAILS TO RUN 4 The starter relay is defective Replace e Check the functioning of the starter IT RUNS 7 25 ELECTRICAL STARTING SYSTEM ELEC 5 Main switch e Disconnect the main switch connector from the wire harness Connect the pocket tester O x 1 to the main switch cables Refer to SWITCH CHECK in Chapter INCORRECT The main switch is defective Replace CORRECT 6 Emergency stop engine switch Disconnect the emergency stop engine switch connector Brown Green Yellow and Red Black from the wire harness e Connect the pocket tester O x 1 to the switch cables Refer to SWITCH CHECK in Chapter Tester terminal gt Red Black 1 cable Tester terminal gt Brown cable 2 INCORRECT The emergency stop engine switch is defective Replace the right handlebar switch CORRECT 7 26 ELECTRICAL STARTING SYSTEM ELEC 7 Sidestand switch e Disconnect the sidestand switch connec tor Black and Black from the wire har ness Connect the pocket tester O x 1 to the sidestand switch cables Refer to SWITCH CHECK in Chapter INCORRECT 4 The sidestand switch is defective Replace 8 Neutral switch e Disconnect the neutral switch cable Sky blue e Con
149. install the oil seal 4 cor rectly and until it is completely inserted in its seat FRONT Fork 16 Tightly clamp the fork leg horizontally fasten ing it by caliper attachment on the outer tube 17 Install Snapring 1 CAUTION Check that the snap ring is correctly seated 18 Install e Dust seal 1 new NOTE SS Apply lightweight lithium soap base grease to the dust seal before installing it NOTE ee Taking care to insert completely the dust seal 1 with force in the outer tube 2 4 55 4 56 FRONT Fork 19 Insert e Damper cylinder assembly in the inner tube 20 Insert an Allen key in the bolt 3 at the bot tom of the outer tube and the special tool 1 with the holder 2 on the damper cylinder assembly and screw the bolt completely CAUTION During tightening the bolt ensure that the end of the damper rod holder is correctly engaged on the damper cylinder assembly YL T handle 1 90890 01326 Front fork damper rod holder 2 90890 01460 Damper cylinder assembly bolt 3 2 25 Nm 2 5 kgm 21 Fill e Fork leg oil Refer to OIL REPLACEMENT section OIL LEAKAGE FROM DUST SEAL If there is a leakage of oil from between the dust seal 1 and the inner tube 2 replace the oil seal refer to SEAL AND BUSH REPLACEMENT section ANOMALOUS HYDRAULIC BRAKING If the fork shows an anomalous hydraulic braking effect it
150. is fitted with a dry crankcase lubrica tion system A feed pump delivers oil to the en gine after fully lubricating the latter the oil is re turned to the tank by a scavenge pump The oil level must therefore be checked in the oil tank 1 Start the engine and warm up until the oil tem perature rises to approximately 60 C 140 F 2 Idle the engine for at least 10 seconds while keeping the motorcycle upright After stop the engine and check the oil level through the level window 3 located on the left side of the oil tank assy and or by oil level gauge NOTE Be sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings 3 The oil level should be between the maximum 1 and minimum 2 marks 20 Temp 10 0 10 20 30 10W 30 D D D D H 1 1 1 1 1 10W 40 1 1 D D 1 D 1 ENGINE OIL LEVEL CHECK INSP ei If the oil level is below minimum gt Add up to maximum level Recommended oil SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature API Standard API SE SF SG or higher grade CAUTION Donotputin any chemical additives or use oils with a grade of CD a or higher e Be sure not to use oils labeled ENERGY CONSERVING II b or higher Engine oil also lubricates the clutch and additives could cause clutch slippage e Be sure
151. is necessary to overhaul the damper cylin der assembly A WARNING Never tamper with the damper cylinder assembly This operation should be done by authorized personnel Tampering with the damper cylinder assembly by non authorized personnel can compromise the safety of the front fork The building firm will not assume any responsibility for any damages resulting from such action 4 57 FRONT Fork CHAS FRONT FORK INSPECTION CAUTION The front fork has a very sophisticated inter nal construction and is particularly sensitive to foreign bodies Use enough care to prevent foreign bodies entering when replacing oil or disassembling and reassembling the front fork 1 Inspect e Cap bolt inner tube Wear Damage gt Replace e O Rings Damage gt Replace 2 Measure e Fork spring free length a Out of specification gt Replace Fork spring free length 530 mm 3 Inspect e Inner tube surface Score marks gt Repair or replace Use 1 000 grit wet sandpaper Damaged oil seal surface gt Replace e Inner tube bending Out of specification gt Replace Use a dial gauge 1 Y Inner tube bending limit 0 2 mm NOTE The bending value is shown by one half of the dial gauge reading FRONT Fork A WARNING Do not attempt to straighten a bent inner tube as this may have dangerous consequences 4 Inspect e Outer tube 1 Score marks Wear Damage gt Replace 5 Inspect
152. itch Engine stop switch Starter switch Diode Clutch switch Sidestand switch Neutral switch Diode Ignitor unit Ignition coil Left handlebar switch Horn switch Diode Pass switch Dimmer switch Flasher switch Horn Flasher relay Headlight Flasher light Relay assy Front brake switch Rear brake switch Tail stop light Meter SCH x m LY ow ml w w N m FF w Ex Gate L B vg A D 28 SE 49 Ee al 9 78 172320 2 9 o Zu w ow LY 0 1 D lt MAIN HARNESS HEAD LIGHT m BE d 0 i d RE T D lt HEE E E d ER RUN 7 OFF Icv tn dev m FR T 2 start IOC 42 5 Le MAIN HARNESS EXT CORD
153. its housing firmly Never pull the cable as it might detach from the terminal inside the connector A WARNING Keep inflammable products and hands well away from bulbs when they are on danger of burns and fire Do not touch the bulb before it is cool 2 Check the continuity between the bulb termi nals Control procedure e Set the tester selector to Q x 1 e Connect the tester terminals to the bulb pins Take for example a three pin bulb as shown in the figure First check continuity between pins 1 and 2 connecting tester terminal to pin 1 and terminal to pole 2 Then check the continuity between poles 1 and 3 again connecting tester terminal to pole 1 and terminal to pole 3 If the tester indicates even in one case only the bulb must be replaced AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 3 Check the bulb attachment by installing a test bulb Furthermore during inspection of the bulbs connect the tester terminals to the respective socket cables and check continuity as described 7 10 IGNITION SYSTEM ELEC CIRCUIT DIAGRAM IGNITION SYSTEM
154. justing the brake lever position make sure the pin on the brake lever holder is firm ly inserted in the hole in the adjusting dial AAA A A A A A WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys tem Before the vehicle is operated the air must be removed by bleeding the brake sys tem Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident Therefore inspect and if necessary bleed the brake system After adjusting the brake lever free play make sure that there is no brake drag 3 31 ADJ USTING THE REAR BRAKE NSP ei ADJ USTING THE REAR BRAKE 1 Check e Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification gt Adjust Brake pedal position below the top of the rider footrest 10 mm 2 Adjust e Brake pedal position e Loosen lock nut 1 e Turn the adjuster 2 either way to obtain the correct pedal height Unscrewing Height a diminishes Screwing Height a increases e Tighten lock nut Ny Lock nut vi 20 Nm 2 0 mkg CAUTION After adjusting the brake pedal position make sure the brake doesn t oppose resistance AAA A A A A A A A A A A A A A A A A A A
155. ke pad Pad spring Reverse the removal procedure for instal lation 4 8 4 9 FRONT BRAKE CHAS CAUTION Brake components must not be disassembled The builder declines every responsibility after brake components disassembly brake master cylinder or brake caliper or in case of use of non original parts DO NOT e Remove brake components from the motorcycle unless is absolutely necessary e Use solvents on internal brake compo nents e Use brake fluid already used for bleeding e Allow brake fluid to come into contact with the eyes as it may cause injury e Allow brake fluid to come into contact with painted or plastic parts as it may damage them e Disconnect any hydraulic connection other wise the whole system must be disassem bled drained cleaned then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE n It is unnecessary to disassemble the brake hose to replace the pads 1 Remove e Caliper bracket fastening screws 1 deplace the caliper 2 Remove e Pin retainers 2 Pad fastening pin 3 e Brake pads 4 e Pad springs 5 e Caliper bracket 6 NOTE f you replace the pads also replace the springs e f one of the two pads has to be replaced because it is worn replace both X Wear limit a 3 7 mm FRONT BRAKE CHAS 3 Lubricate e Guide pins 1 Lithium base grease 4 Install e Pin bracket 2 on the caliper body 3
156. llation 4 21 nen wes AID nae CHASSO Job name Par name Rear wheel disassembly Remove the parts in order Driven sprocket Hub Damper Spacer Oil seal Bearing Bearing Hub dust cover Oil seal Bearing Bearing spacer Refer to REAR WHEEL DISASSEMBLY AS SEMBLY section Reverse the removal procedure for installa tion Om P GO sch ck sch sch ck JP ck sch 4 22 4 23 nen west ano nae CHAS REAR WHEEL DISASSEMBLY 1 Remove Hub and driven sprocket Dampers Hub spacer Oil seal Hub bearing Wheel bearing Wheel spacer Wheel bearing Dust cover Oil seal Wheel bearing e Wheel spacer Removal procedure e Clean the outside of the hub e Remove the dust cover with a flat headed screw driver NOTE LLL Place a rag on the outside to avoid damaging the hub e Disassemble the bearing 1 with a normal puller 2 A A A A A A A A A A A A A A A A A A A A A A A A A A A A A REAR WHEEL INSPECTION 1 Inspect e Rear wheel axle by rolling it on a flat surface Bends gt Replace A WARNING Do not attempt to straighten a bent axle 2 Inspect e Rear tire Refer to TIRE INSPECTION in CHAP TER 3 e Rear wheel Refer to WHEEL INSPECTION in CHAPTER 3 3 Inspect Spoke s Bent Damaged gt Replace Loose spoke s gt Tighten Turn the wheel and hit the spokes
157. m 0 116 0 120 in 2 8 mm 0 110 in CLUTCH PLATE 272 2 88 mm i WARPAGE LIMIT 0 107 0 113 in 2 6 mm 0 102 0 2 mm 10 008 in A FRICTION PLATE e CLUTCH SPRING MINIMUM A B 8 Nm 0 8 mekg 5 8 16 8 Nm 0 8 m kg 5 8 ft lb 2 PUSH ROD RUNOUT LIMIT 0 2 mm 0 008 in 5 70 ENGINE ASSEMBLY AND SETTING 4 CLUTCH 1 Install e Plain washer e Spring e Push lever 1 Ny Screw push lever S 12 Nm 1 2 mkg Install Push rod 1 Primary driven gear comp 2 Thrust plate 3 Clutch boss 4 Lock washer 5 Nut 6 clutch boss Clutch boss spring 7 Clutch plate 8 Friction plate 9 Ball 10 Pressure plate 11 Compression spring 12 Screw pressure plate 13 m Nut clutch boss 90 Nm 9 0 mkg Pressure plate screw 8 Nm 0 8 mkg NOTE _ _ _ e To tighten the nut clutch boss lock the clutch drum with the special tool 14 CZ Clutch holding tool 90890 04086 Bendthe lock washer tab along the face of the nut A WARNING Always use a new lock washer 5 71 ENGINE ASSEMBLY AND SETTING 4 5 72 NOTE Install the friction and clutch plates to the clutch boss beginning and ending with a friction plate CAUTION e The two friction plates type A 15 with the widest internal diameter should be assembled in second and last place e The clutch boss spring
158. m 0 7 m kg 5 1 ft Ib 7 30 ELECTRICAL STARTING SYSTEM ELEC 7 31 Removal 1 Remove e The starter motor Refer to the ENGINE REMOVAL sec tion in CHAPTER 5 Disassembly 1 Remove e Circlip 1 Drive gear 2 Screws 3 Rear bracket 4 Washers 5 Brushes housing 6 Brushes 7 Front bracket 8 Washers 9 Armature 10 Stator 11 Inspection and repair 1 Inspect e Manifold Dirty Clean with sandpaper no 600 2 Measure e Diameter of the commutator Out of specification gt Replace the motor Wear limit of commutator a 27mm 3 Measure e The mica undercut b Out of specification gt Level the undercut to the correct value using a hacksaw lt Mica undercut b 0 7 mm NOTE _ The mica insulation of the commutator must have an undercut to ensure proper functioning of the commutator ELECTRICAL STARTING SYSTEM ELEC uo Q x1kQ 7 32 4 Inspect e Armature coils insulation continuity Out of specification gt Replace the motor How to inspect the excitation coils e Connect the pocket tester and check continuity 1 and insulation 2 e Check the armature resistance Armature coil resistance Continuity check 1 0 at 20 C 68 F Insulation check 2 Over 1 MQ at 20 C 68 F e resistance is not correct replace the starter motor AAA A A A A A A A A A A A A A A A A A
159. m 3 0 mkg Oil tank hose flange 10 Nm 1 0 mkg Cil filter cover air bleeder screw 5 Nm 0 5 mkg 9 Fill e Oil tank Recommended oil SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature API Standard API SE SF SG or higher grade Oil capacity Periodic change 2 4 litres CAUTION Do not put in any chemical additives or use oils with a grade of CD a or higher e sure not to use oils labeled ENERGY CONSERVING II b or higher Engine oil also lubricates the clutch and additives could cause clutch slippage e Be sure no foreign material enters the crankcase 10 Install e Oil tank tap 11 Check e Oil level See section ENGINE OIL LEVEL CHECK e Oil pressure See section ENGINE OIL PRESSURE CHECK e Oil leakage 3 18 ENGINE OIL REPLACEMENT NSP ei Engine oil replacement with oil filter replace ment 3 19 Warm up the engine for a few minutes Stop the engine Place an oil pan under the engine and remove the oil filler cap Remove the drain plug 1 and drain the engine oil Remove two bolts 2 and O ring of the oil hose flange and drain the oil from oil tank Remove the air bleed screw 3 attached to the oil filter cover 4 Wait until the oil has completely drained NOTE 2 The oil filter cover is secured by three screws 5 The lower one should be removed so that the fil
160. m diameter intake exhaust Valve guide inside diameter intake exhaust Valve stem to valve guide clearance intake exhaust Valve stem runout Valve seat width intake exhaust 0 05 0 10 mm 0 12 0 17 mm 36 90 37 10 mm 31 90 32 10 mm 2 260 mm 2 260 mm 1 00 1 20 mm 1 00 1 20 mm 1 00 1 40 mm 0 80 1 20 mm 6 975 6 990 mm 6 955 6 970 mm 7 000 7 012 mm 7 000 7 012 mm 0 010 0 037 mm 0 030 0 057 mm 1 80 mm 1 80 mm 0 80 mm 0 65 mm 6 995 mm 6 925 mm 7 042 mm 7 042 mm 0 08 mm 0 10 mm 0 010 mm MAINTENANCE SPECIFICATIONS SPEC ve Standard Valve spring Inner spring Free length intake 40 10 mm exhaust 40 10 mm Installed length valve closed intake 22 70 mm exhaust 22 70 mm Compressed spring force installed intake 164 80 190 20 N 16 80 19 39 kg exhaust 164 80 190 20 N 16 80 19 39 kg Spring tilt intake intake eve 2 5 91 7 exhaust 2 2 5 91 7 Winding direction top view intake Clockwise exhaust Clockwise Outer spring Free length intake intake 43 80 mm 38 10 mm exhaust 43 80 mm 38 10 mm Installed length valve closed intake 34 20 mm exhaust 34 20 mm Compressed spring force intake 71 60 87 30 N installed 7 3 8 9 kg exhaust 149 10 182 40 N 15 2 18 6 kg Spring tilt intake eve 2 5 91 7 eve 2 5 71 9 mm Winding direction top view intake Counterclockwise exhaust Counterclockwise
161. maged corrosion might ensue or the cable might not run freely To avoid such drawbacks replaced damaged cables as quickly as possible 1 Inspect e Cable sheath Damaged gt Replace the cable assembly 2 Check e Cable functioning Does not run freely gt Replace the cable assembly LEVER AND PEDAL LUBRICATION 1 Lubricate the pivoting parts e Clutch lever e Front brake lever e Rear brake pedal Shift pedal Recommended lubricant SAE 10W30 motor oil An E 2 LAS 3 45 3 46 SIDESTAND LUBRICATION REAR SUSPENSION LUBRICATION SIDESTAND LUBRICATION Lubricate the sidestand pivoting and mating parts Check to see that the sidestand moves up and down smoothly Recommended lubricant SAE 10W30 motor oil REAR SUSPENSION LUBRICATION Lubricate the pivoting parts Recommended lubricant Molybdenum disulfide grease 3 47 CHECKING AND CHARGING THE BATTERY NSP ei ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY A WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi sonous and highly caustic sulfuric acid Therefore always follow these preventive measures e Wear protective eye gear when handling or working near batteries e Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes e DO NOT SMOKE when charging or han dling b
162. minal gt Pole OUT OF SPECIFICATION Secondary winding resistance 1 eee ote The ignition coil is defective BOTH RESISTANCE JL VALUES ARE CORRECT 7 Main switch e Disconnect the main switch connector from the wire harness Connect the pocket tester O x 1 to the main switch cables Refer to SWITCH CHECK in Chapter INCORRECT 4 The main switch is defective Replace CORRECT 7 16 Disconnect the emergency stop engine switch connector Brown Green Yellow and Red Black from the wire harness Connect the pocket tester O x 1 to the switch cables Refer to SWITCH CHECK in Chapter 9 Sidestand switch Disconnect the sidestand switch connec tor Black and Black from the wire har ness Connect the pocket tester O x 1 to the sidestand switch cables Refer to SWITCH CHECK in Chapter CORRECT IGNITION SYSTEM ELEC INCORRECT mm The emergency stop engine switch is defective Replace the right handlebar switch INCORRECT 4 The sidestand switch is defective Replace Disconnect the neutral switch cable Sky blue Connect the pocket tester O x 1 to the neutral switch cables Refer to SWITCH CHECK in Chapter 11 Clutch switch Disconnect the clutch switch connector from the harness Connect the pocket tester O x 1 to the clutch switch ca
163. minal 3 Tester terminal gt Earth DISCONTINUITY The starter circuit cut off relay is defective Replace Turn the main switch to ON Check the voltage 12V on the Brown Blue and Brown cable to the connector terminal of the starter circuit cut off relay IN COMPLIANCE WITH SPECIFICATIONS 12V DEFECTIVE CONNECTIONS 6 Harness connections e Check the connections of the entire light system poen Check the conditions of each circuit for the entire light system See the ELECTRIC CIRCUIT DIAGRAM 7 45 LIGHT SYSTEM ELEC LIGHT SYSTEM INSPECTION NOTE M To proceed to the control of the light system start the engine and then stop it by the emergency engine stop switch In this way the light relay remains excited and it is possible to check the light system 1 The front headlight and the high beam light fail to turn on 1 Bulb and bulbholder DISCONTINUITY e Check the continuity of the bulb and bulb holder RON Replace the bulb and or the bulbholder CONTINUITY 2 Voltage Connect the pocket tester DC 20V to the front headlight connectors and the high beam switch Headlight Tester terminal gt Green 2 or Yellow 1 cable Tester terminal gt Black cable 3 High beam light Tester terminal gt Yellow cable 4 Tester terminal gt Black cable 5 OUT OF SPECIFICATION The circuit from the main switch to the bulbhol
164. n tighten the locknut to the specified torque SWINGARM CHAS SWINGARM 1 Upper chain case 4 Swingarm guard seal A LATERAL FREE PLAY END 1 0 mm 2 Swingarm b Connecting rod B LATERAL FREE PLAY 0 4 0 7 mm 3 Chain support 6 Relay arm 9 Nm 0 9 mkg P 2 60 Nm 6 0 m kg 4 76 4 77 SWINGARM CHAS SWINGARM REMOVAL NOTE Check free play and remove swingarm if neces sary after removing the rear shock absorber 1 Remove e Swingarm connecting rod bolt 1 2 Check e Swingarm free play VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Inspection procedure e Check the tightening torque of the nut which fastens the swingarm pivot shaft 1 Nyy Nut pivot shaft 25 90Nm 9 0 mkg e Check the lateral free play A of the swingarm moving it laterally If the free play seems excessive verify the collar bearings washer and thrust cover Lateral free play at end of swing arm Limit 1 0 mm e Check the vertical movement B of the swingarm moving it up and down If the movement seems rigid unsmooth or jerky inspect the internal collar the bearings the washer and the thrust cover SWINGARM CHAS 3 Remove e Upper chain case 1 e Chain support 2 4 Remove Swingarm pivot shaft e Swingarm SWINGARM INSPECTION 1 Inspect e Swingarm Deformation Crack
165. nal gt Pink cable 1 Tester terminal gt Earth e Turn the main switch to ON e Check the voltage 12V on the Pink ter minal of the horn IN COMPLIANCE WITH SIGNAL SYSTEM ELEC THE HORN WORKS mmm The horn is efficient OUT OF SPECIFICATION The horn is defective Repair SPECIFICATIONS 12V Repair or replace the horn 7 56 SIGNAL SYSTEM ELEC DISCONTINUITY 1 Bulb and bulbholder e Check the continuity of the bulb and bulb holder 1 Refer to BULB INSPECTION section Replace the bulb and or bulbholder CONTINUITY 2 Brake switch e Disconnect the brake switch cables and the connector from the wire harness Connect the pocket tester O x 1 to the brake switch terminals Check the switch component for conti nuity between Green Yellow 1 and Brown 2 or Black 3 and Black 4 Refer to SWITCH CHECK section 2 The rear stop light fails to turn on INCORRECT K S A Front brake switch 1 B Rear brake switch The brake switch is defective Replace 7 57 SIGNAL SYSTEM ELEC 3 Voltage e Connect the pocket tester DC 20V to the bulbholder connector Tester terminal gt Green Yellow cable 1 Tester terminal gt Black terminal 2 OUT OF SPECIFICATION The circuit from the main switch to the bulbhol Turn the main switch to
166. nect the pocket tester Q x 1 to the neutral switch cables Refer to SWITCH CHECK in Chapter 3 INCORRECT mmm The neutral switch is defective Replace CORRECT ELECTRICAL STARTING SYSTEM ELEC 9 Clutch switch Disconnect the clutch switch connector from the harness Connect the pocket tester O x 1 to the clutch switch cable Check the clutch switch component for continuity between Black 1 and Black Refer to SWITCH CHECK in Chapter 3 Release Hold 00 INCORRECT 4 The clutch switch is defective Replace Disconnect the start switch connector from the harness Connect the pocket tester O x 1 to the handlebar switch terminal Check the start switch component for con tinuity between Blue White 1 and Black Yellow 2 Refer to SWITCH CHECK in Chapter INCORRECT The start switch is defective Replace the right handlebar switch CORRECT 7 28 ELECTRICAL STARTING SYSTEM ELEC UNCERTAIN CONNECTIONS Check the connections of the entire starter system See the ELECTRIC CIRCUIT DIAGRAM 7 29 ELECTRICAL STARTING SYSTEM ELEC STARTER MOTOR BRUSH LENGHT LIMIT 1 Brushes 5 mm 0 20 in 2 Armature COMMUTATOR WEAR LIMIT Ge 27 mm 1 06 in Ring MICA UNDERCUT 0 7 mm 0 027 in ARMATURE COIL RESISTANCE 0 03 0 04 Q at 20 C 68 F 7 N
167. nent 7 8 LIGHT INSPECTION ELEC LIGHT INSPECTION HEADLIGHTS TAIL LIGHT AND BRAKE LIGHTS DIRECTION INDICATOR LIGHTS INSTRUMENT LIGHTS ETC Check the continuity between the bulb terminals to see that they are undamaged BULB TYPES The bulbs used are classified as shown to the left according to type of attachment B is H4 type halogen bulb 12V 55 60W and it is used for headlight CAUTION Avoid touching the glass part of a bulb Keep it free from oil otherwise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on a bulb thoroughly clean it with a cloth moistened with alcohol or lacquer thinner A and C are used mainly for headlights D is used mainly for direction indicator lights and the rear and braking lights E and F are used especially for instrument and other indication lights BULB INSPECTION 1 Remove the bulb NOTE 95 e Bulbs of type and C use special supports bulbholders Remove the bulbholder before removing the bulb Most of these bulbholders may be removed by turning in an anticlockwise direction Most bulbs of type A D and may be removed from their housing by pushing them and turning them in an anticlockwise direction e Bulbs of type F may be removed simply by pulling them out 7 9 LIGHT INSPECTION ELEC CAUTION When removing a bulb be careful to hold the bulbholder or
168. ng 0 04 0 08 mm Lower ring 0 03 0 07 mm lt Limit gt 0 13 mm Oil scraper 0 02 0 06 mm 2 Install e Ring into the cylinder NOTE Ls Fit each ring into the cylinder and push it to about 20 mm from the top edge of the cylinder Push the ring into the cylinder with the piston so that it is perfectly perpendicular to the cylinder axis a 20 mm 3 Measure e Ring end Out of specification Replace NOTE It is impossible to measure the oil end gap If the oil scraper port appears too large replace all three rings Piston ring end gap fitted into cylinder 0 30 0 45 mm Limit 0 7 mm 0 30 0 45 mm Limit 0 8 mm Upper ring Lower ring Oil scraper tracks 0 20 0 70 mm INSPECTION AND REPAIR 1 Check Piston pin Blue colour Grooves Replace and check lubrication system 2 Measure e External diameter a of pin Out of specification Replace External diameter pin 21 991 22 000 mm 3 Measure e Clearance between piston pin and pin seat Out of specification Replace Clearance between piston pin and piston Diameter of pin seat on piston b Diameter of pin a Clearance between piston pin and pin seat on piston 0 004 0 024 mm Limit 0 07 mm CLUTCH 1 Inspect e Clutch gear assy teeth Cracks Pitting on edges Moderate gt Burr Accentuated gt Replace clut
169. nutes Check the open circuit voltage 3 49 CHECKING AND CHARGING THE BATTERY INSP ei A WARNING Do not quick charge a battery CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charger They force a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the motorcycle if charging has to be done with the battery mounted on the motorcycle disconnect the nega tive lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the bat tery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a MF battery stabi lizes about 30 minut
170. od holder is correctly engaged on the damper cylinder assembly lt 4 T handle 1 90890 01326 Front fork damper rod holder 2 90890 01460 4 Remove e Damper cylinder assembly from inner tube 5 Clean the inside of the outer tube and the out side of the damper cylinder assembly with petrol CAUTION Taking care not to let petrol enter the inside of the damper cylinder assembly as it would seriously compromise its functioning 4 51 FRONT Fork A WARNING Never tamper with the damper cylinder assembly Tampering with the damper cylinder assembly by non authorized personnel can compromise tha safety of the fork In order not to cause damage to the environment collect the used oil and take it to a collection centre 6 Tightly clamp the fork leg horizontally fasten ing it by caliper attachment on the outer tube 7 Using a screwdriver prise the dust seal 4 from the edge of the oil seal seat 5 Then withdraw the dust seal using force 8 Remove e Snap ring 1 using a screwdriver 4 52 FRONT Fork CHAS 9 With a few sharp blows withdraw the inner tube 2 from the outer tube 3 NOTE The oil seal 4 the washer 5 the outer tube DU bush 6 and the inner tube DU bush 7 are installed on the inner tube and must be removed and replaced with new one 10 Install e Outer tube DU bush 6 new e Inner tube DU bush 7 new CAUTION Check that the inner tube bush 7
171. odometer cable pipe holders tachometer odometer cable into 2 Tachometer 8 Main wire harness 13 Pipe odometer cable band the band 3 and the holder 14 Air breather pipe holder 2 9 Rear brake switch nitt 3 wire harness 15 Se ignition odometer cable 10 Rear brake fluid pana tank hose Ges WEE 4 Right tube guard 11 Hose from rear 17 SUR b Spark plug cable master cylinder to to air filer case 6 Horn caliper 2 28 CABLE ROUTING SPEC ve 1 Rectifier 5 Right turn wire 8 Wire extension A Screw protection 3 2 Wire harness bands harness 9 Starter power REN wiring 3 Protecii 6 Tail light wire cables propery 3 Protection Bates ie 4 Left turn wire 10 Engine cables an harness 7 Air breather pipe side stand switch carburetor 2 29 SPEC ve EW CHAPTER 3 PERIODIC INSPECTION AND ADJ USTMENTS Te de RE 841 PERIODIC MAINTENANCE LUBRICATION INTERVALS 8 1 SEAT FUEL TANK AND REAR COWLING 3 3 EEUU 3 3 3 3 ENGINE VALVE CLEARANCE ADJUSTMENT 3 4 DRIVE CHAIN ADJUSTMENT 3 7 IDLE SPEED ADJUSTMENT 8 7 THROTTLE CABLE FREE PLAY ADJUSTMENT en 3 8 SPARK PLUG INSPECTION ttt ttn 3 9 IGNITION TIMING CHECK 3 11 COMPRESSION INSPECTION 8 1
172. oly Racing suspension oil SAE 7 5 FRONT FORK OIL LEVEL STANDARD 180 mm MINIMUM 190 mm MAXIMUM 170 mm From top of inner tube with inner tube fully com pressed without spring MINIMUM FORK SPRING FREE LENGTH 530 mm INNER TUBE BENDING LIMIT 0 2 mm FRONT FORK REMOVAL A WARNING Securely support the motorcycle so there is no danger of it falling over 1 2 Park the motorcycle on a level surface Raise the front wheel by placing a suitable support under the engine Remove e Front wheel Refer to FRONT WHEEL REMOVAL section Remove e Inner tube protector e Protector guide e Gear unit assembly and cable e Brake caliper and hose Loosen e Cap bolt e Pinch bolt upper and lower bracket 4 46 FRONT Fork OIL REPLACEMENT NOTE The quality of the fork oil is of fundamental impor tance for obtaining the maximum performance and functioning For this reason it needs to be replaced after the first 3 4 hours to eliminate any residues due to the adaptation of the internal components and successively every 8 hours for motor cross and every 20 hours for enduro CAUTION Using oil with different technical specifica tions will compromise the good efficiency of the fork 1 Generally clean the front fork 2 Loosen e Cap bolt inner tube 3 Remove e Fork leg 4 Unscrew e Cap bolt 1 completely NOTE Place the components in a clean area
173. ompress the valve spring using tool 8 to remove the cotters 22 Valve spring compressor 90890 04019 INSPECTION AND REPAIR oD 5 21 INSPECTION AND REPAIR CYLINDER HEAD 1 Eliminate Carbon deposits from combustion chamber Use a rounded scraper 1 NOTE Do not use a pointed tool to avoid damaging or scratching e spark plug thread e valve seats combustion chamber 2 Inspect e Cylinder head Scratches Damage gt Replace 3 Measure Deformation Out of specification gt Rework the surface X Cylinder head deformation Less than 0 03 mm 4 Surface e Cylinder head VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Levelling Level the cylinder head with wet 400 600 emery paper in a figure 8 direction NOTE To avoid removing too much material on one side only turn the cylinder head a number of times AAA A A A A A A A A A A A A A A A A A A A A A A A A A A INSPECTION AND REPAIR ENG 5 22 VALVES AND VALVE GUIDES 1 Measure e Clearance between stem and guide Clearance between stem and guide Internal diameter of valve guide a Diameter of valve stem b Out of specification Replace valve guide Clearance between stem and guide 0 010 0 037 mm Limit 0 08 mm 0 030 0 057 mm Limit 0 10 mm Bore gauge VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Replacement steps NOTE 22 2 Heat the cylinder head oven at 100 C to
174. on coil 11 Diode 7 12 IGNITION SYSTEM ELEC DIAGNOSTICS IF THE IGNITION SYSTEM WERE TO STOP WORKING NO OR INTERMITTENT SPARK Procedure 7 Main switch Check 8 Engine stop switch 1 Fuse 9 Sidestand switch 2 Battery 10 Neutral switch 3 Spark plug 11 Clutch switch 4 Amplitude of ignition spark 12 Pick up coil resistance 5 Spark plug cap resistance 13 Wiring connections whole connection sys 6 Ignition winding resistance tem NOTE Before making the inspections mentioned remove the following parts 1 Seat 3 Fuel tank 2 Rear cowling 4 Cowling headlight e To check functioning defects use the following special tools Dinamic spark tester GJ Pocket tester P N 90890 06754 P N 90890 03112 NO e Check the fuse for continuity Refer to CHECKING THE FUSES in 3 SE 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage Zo V Grm aped 890 e Clean the battery terminals e 15 the battery OK e Recharge or replace the battery 7 13 IGNITION SYSTEM ELEC 3 Spark plug e Check the conditions of the spark plug e Check the type of spark plug used e Check the electrodes gap T OF SPECIFICATION DPR8EA 9 DPR9EA 9 OUT OF SPECIFICATIO Electrodes gap DPRSEA 9 DPR9EA 9 NGK 0 8 0 9 mm Correct the electrodes gap or replace the spark lug
175. op switch 15 Diode 7 22 ELECTRICAL STARTING SYSTEM ELEC 7 23 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor starter relay and the starting circuit cut off relay If the engine stop switch is on RUN and the main switch is on ON both switches are closed the starter motor can operate only if The transmission is in neutral the neutral switch is closed or if The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter from operating when neither of these con ditions have been met In this instance the start ing circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by press ing the starter switch WHEN THE TRANSMISSION 15 IN x NEUTRAL xx WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN D Battery Main switch Engine stop switch 4 Starter relay Starting circuit cut off relay Start switch Starter motor Neutral switch 9 Clutch switch Sidestand switch ELECTRICAL STARTING SYSTEM ELEC DIAGNOSTICS Procedure 6 Engine stop switch Inspect 7 Sidestand switch 1 Fuse 8 Neutral switch 2 Battery 9 Clutch switch
176. ose 2 Oil return hose flange 4 fastening screw 3 e Oil delivery hose flange 6 fastening screws 5 e Oil tank filter 7 e OR gaskets 8 5 Clean e Oil tank filter with solvent e Oil tank with solvent NOTE After cleaning the inside of the oil tank remove the remaining solvent 6 Inspect e OR gaskets Damaged gt Replace Ne 3 26 ENGINE OIL TA 3 27 NK FILTER CLEANING wq 7 Reassemble e OR gaskets e Oil tank filter Oil delivery hose flange fastening screws Screw oil delivery hose flange 2 10 Nm 1 0 mkg e Oil return hose e Oil return hose flange fastening screws Y Screw oil return hose flange A 35 Nm 3 5 mkg 8 Tighten e Stay rear left side cover fastening screws Reassemble e Engine oil tank e Rear frame e Joint air cleaner clamps e Rear shock absorber See section REAR SHOCK ABSORBER in Chapter 4 Exhaust pipe Exhaust muffler Rear wire harness Rear cowling Seat See section SEAT FUEL TANK AND Screw seat 2 10 Nm 1 0 mkg REAR COWLING 10 Fill e Engine oil See section ENGINE OIL REPLACE MENT 11 Reassemble e Engine tank cap SUCTION HOSE AND MANIFOLD INSPECTION FUEL LINE INSPECTION SUCTION HOSE AND MANIFOLD INSPECTION 1 Remove e Seat e Fuel tank See section SEAT FUEL TANK AND REAR COWLING 2 Inspect e Suction hoses 1 Cracked damaged gt Replace Scre
177. over NOTE Cross tighten the screws repeatedly Bolt cylinder head cover 2 10 Nm 1 0 mkg ENGINE ASSEMBLY AND SETTING 5 63 13 Install e Chain tensioner Assembly steps Remove the chain tensioner screw 1 the washer 2 and the spring 3 Release the chain tensioner unidirectional cam 4 and push the thrust rod 5 Install the chain tensioner in the cylinder with a new gasket Screw chain tensioner body 2 10 Nm 1 0 mkg A WARNING Always use a new gasket E e Install the spring the washer and the chain tensioner Chain tensioner screw 20 Nm 2 0 mkg A A 14 Adjust e Valve clearance Z Valve clearance Intake 0 05 0 10 mm Exhaust 0 12 0 17 mm See section VALVE CLEARANCE ADJUSTMENT in CHAPTER 3 ENGINE ASSEMBLY AND SETTING ENG 4 15 Install e Tappet covers 1 exhaust Tappet cover 2 intake Spark plug 3 Tappet cover exhaust 12 Nm 1 2 mkg Screw tappet cover intake 10 Nm 1 0 mkg Spark plug 18 Nm 1 8 mkg NOTE The tappet cover intake should be assembled with the arrow 4 pointing upwards 5 64 ENGINE ASSEMBLY AND SETTING ENG AC GENERATOR PICKUP COIL RESISTANCE 1 Rotor 230 20 at 20 C 68 2 Pick up coil Blue Yellow G
178. ow 1 pointing upwards 10 Connect e Spark plug cap 11 Reassemble e Fuel tank e Seat See section SEAT FUEL TANK AND REAR COWLING NC Seat screws 2 10 Nm 1 0 mkg DRIVE CHAIN ADJUSTMENT IDLE SPEED ADJUSTMENT 3 7 DRIVE CHAIN ADJ USTMENT The drive chain does not need to be adjusted IDLE SPEED ADJ USTMENT 1 Start the engine and let it heat 2 Connect e The inductive engine speed indicator to the spark plug cable 24 Special tool 7 P N 90890 03113 3 Check e The engine idle speed Out of specification Adjust A Engine idle speed 1 150 1 450 rpm 4 Adjust e Engine idle speed Adjustment e Turn the throttle stop screw 1 either way to obtain the idle speed required Screwing a Increases idle speed Unscrewing b Decreases idle speed AAAAAAAAAAAAAAAAAAAAAAAAAAAAA NOTE After setting the idle speed adjust the accelerator cable free play 5 Disconnect e Inductive engine speed indicator BEG 30 3 8 THROTTLE CABLE FREE PLAY ADJ USTMENT ei THROTTLE CABLE FREE PLAY ADJ USTMENT NOTE Before adjusting the throttle cable free play adjust the engine idle speed 1 Remove e Seat e Fuel tank See section SEAT FUEL TANK AND REAR COWLING 2 Check e Throttle cable free play a Out of specification gt Adjust lt Throttle cable free play 3 5 mm at the
179. p of the footrest Brake pedal height 10 mm BRAKE PEDAL REMOVAL 1 Remove e Split pin 1 new washer 2 e Pin 3 2 Unscrew e Bolt 4 3 Remove Spring 5 4 Remove e Brake pedal 6 from chassis NOTE _ __ Pull the brake pedal from the lower part of the chassis causing it to rotate progressively as it comes away REAR BRAKE CHAS BRAKE CALIPER v Job name Par name Caliper removal Remove the parts in order Rear wheel Refer to REAR WHEEL REMOVAL sec tion Brake fluid Drain Brake hose Remove from clamp Caliper protector Brake caliper Remove from caliper support Union bolt Blain washer EN to BRAKE CALIPER INSTALLA Brake hose TION section Brake pad support Reverse the removal procedure for installa tion 4 36 10 Nm 1 0 m kg 1 2 3 4 5 6 7 8 Job name Part name Caliper disassembly Caliper protector Brake pad support Brake pad Pad support Caliper piston Dust seal Piston seal Bleed screw REAR BRAKE CHAS 4 37 ech sch sch Remove the parts in order Refer to BRAKE PAD section Refer to BRAKE CALIPER DISASSEM BLY ASSEMBLY section Reverse the removal procedure for installa tion 4 38 REAR BRAKE CHAS BRAKE CALIPER DISASSEMBLY 1 Remove e Brake caliper piston 1 e Dust seal 3 e Piston seal 2 VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Removal procedure e Blow
180. quired Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 3 2 SEAT FUEL TANK AND REAR COWLING NSP ei SEAT FUEL TANK AND REAR COWLING Job name Part name Seat fuel tank and rear cowling Remove the parts in order removal 1 Seat 2 Fuel pipe NOTE Be sure the cap is properly tightened and the fuel cock is in the OFF position before removing the tank 3 Fuel tank 4 Lamp connector Disconnect 5 Rear cowling NOTE Widen the rear cowling body sides carefully to extract rear cowling from the chassis Reverse the removal procedure for instal lation 3 3 VALVE CLEARANCE ADJ USTMENT ei ENGINE VALVE CLEARANCE ADJ USTMENT NOTE e Valve clearance must be adjusted when the engine is at ambient temperature e Adjust valve clearance with the piston under compression at top dead centre T D C A WARNING Hold the motorcycle firmly in place to prevent it falling over during the operation 1 Remove e Seat e Fueltank See the section SEAT FUEL TANK AND REAR COWLING 2 Disconnect e Spark plug cap 1 3 Remove Spark plug Tappet cover 2 intake e Tappet covers 3 exhaust CAUTION When removing the spark plug and tappet cover be careful not to drop foreign objects inside the engine 4 Remove Cap 1 2 5 Turn
181. r shaft 1 TRANSMISSION 1 2 3 4 5 6 7 8 9 Sprocket Oil seal Bearing Second wheel gear Secondary shaft Fifth wheel gear Third wheel gear Fourth wheel gear First wheel gear G ENGINE ASSEMBLY AND SETTING ENG 4 Bearing Bearing Second sprocket gear Fifth sprocket gear Third sprocket gear Fourth sprocket gear Main shaft Bearing 10 11 12 13 14 15 16 17 5 46 ENGINE ASSEMBLY AND SETTING ENG GEARBOX 1 Stopper lever 2 Guide bar 3 Shift fork 3 4 Shift fork 1 5 Shift cam 6 Guide bar 7 Shift fork 42 Shift shaft 1 Shift shaft 42 0 Oil seal 1 8 9 1 11 Shift lever 10 Nm 1 0 m kg 7 2 ft Ib 72 ft lb ad of 12 Nm 1 2 mekg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 5 47 ENGINE ASSEMBLY AND SETTING ENG TRANSMISSION AND GEARBOX 1 Install Transmission assembly 1 2 Install e Shift fork 1 1 Shift fork 2 2 Shift fork 3 3 Shift cam 4 Guide bar 5 NOTE Each shift fork is identified by the number stamped on its side All numbers must face left 3 Install e Shift shaft 1 1 e Shift shaft 2 2 NOTE Align mark 3 on the shift lever shaft with that on the shift shaft 4 Check e Transmission functioning Jerky functioning Repair 5 48 ENGINE ASSEMBLY AND SETTING ENG ENGINE
182. reen White 3 Stator winding CHARGING COIL RESISTANCE 0 65 20 at 20 C 68 F White White Nm 0 7 m kg 5 1 ft Ib 5 65 5 66 ENGINE ASSEMBLY AND SETTING ENG AC GENERATOR 1 Install Woodruff key 1 Washer 2 Bearing 3 Rotor 4 Washer 5 Nut 6 NOTE n When installing the AC generator rotor check that the woodruff key fits properly into its seat on the crankshaft Apply a thin layer of lithium soap based grease on the conical tip of the crankshaft 2 Tighten e Nut rotor Ngy Nut rotor 26 120 Nm 12 0 NOTE _ To tighten the nut lock the rotor with the special tool 1 6 Sheave holder 90890 01701 CAUTION Be careful notto touch the jutting edges 2 on the rotor with the sheave holder ENGINE ASSEMBLY AND SETTING ENG OIL FILTER AND OIL HOSES Oil filter Filter cover Oil hose Oil hose Cil delivery hose Oil drain plug 10 Nm 1 0 m kg 7 2 ft lb 35 Nm 3 5 m kg 25 2 ft lb 18 Nm 1 8 m kg 13 ft Ib 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 416 5 67 ENGINE ASSEMBLY AND SETTING ENG 4 BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR 1 Straight key 9 Balancer shaft drive gear 2 Balancer shaft gear 10 Plate 3 Breather plate 11 Primary drive gear 4 Lock washer 12 Lock washer b Nut 13 Nut 6 Plate washer 7 Straight key 8
183. ry indicator light High beam indicator light 12V 60W 55W x 1 12V 5W 21W x 1 12V 10W x 4 12V 5W x 1 12V 3W x 1 12V 1 2W x 1 12V 1 2W x 1 12V 1 2W x 1 12V 1 2W x 1 Fuse 20A MAINTENANCE SPECIFICATIONS SPEC ve MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head Max warpage Cylinder Bore 94 970 95 020 mm Measuring point 3X 50 mm Camshaft Drive system Chain drive left Camshaft cap inside diameter 23 000 23 021 mm Camshaft journal diameter 22 967 22 980 mm Camshaft journal to camshaft cap clearance 0 020 0 054 mm Camshaft lobe dimensions Intake measurement 36 470 36 570 mm Intake measurement 30 060 30 160 mm Intake measurement 6 41 mm Exhaust measurement 36 620 36 720 mm Exhaust measurement 30 110 30 210 mm Exhaust measurement 6 51 mm Max camshaft runout 4 0 030 MAINTENANCE SPEC ve Item Standard Timing chain Model number of links Tensioning system Rocker arm rocker arm shaft Arm inside diameter Shaft outside diameter Arm to shaft clearance 75 010 126 Automatic 12 000 12 018 mm 11 976 11 991 mm 0 009 0 042 mm Valve valve seat valve guide Valve clearance cold intake exhaust APO Valve dimensions Valve head diameter A intake exhaust Valve face width B intake exhaust Valve seat width C intake exhaust Valve margin thickness D intake exhaust Valve ste
184. s Spoke NOTE D After tightening the spokes check the centring of the wheel 5 Measure e Front wheel runout Over the specified limits gt Replace Front wheel runout limits Radial 1 1 0 mm Lateral 2 0 5 mm 6 Inspect e Front wheel bearings Bearings allow free play in the wheel hub or the wheel does not turn smoothly gt Replace e Oil seal Wear damage gt Replace A WARNING e After assembling a tyre drive slowly to allow it to adapt to the rim If this precau tion is not observed damage might be caused to the motorcycle and accidents to the driver e After repairing or changing a tyre do not forget to tighten the valve lock nut 1 to the prescribed torque Valve lock nut A 1 5 Nm 0 15 mkg 4 5 22222 FRONT WHEEL AND BRAKE DISC 5 BRAKE DISC INSPECTION 1 Inspect e Brake disc Wear Damage gt Replace 2 Measure e Brake disc deflection a If over envisaged limits gt Verify wheel centring If the wheel centring is correct replace the brake disc Maximum deflection brake disc 0 15 mm Misure at 2 mm from disc edge e Brake disc thickness b If out of specified limits gt Replace Kl Minimum thickness brake disc 3 6 mm IFRONT WHEEL ASSEMBLY 1 Install e Spacer e Bearings e Oil seal Assembly procedure e Install the new bearing and the dust cover by fol lowing the disassembl
185. s steering head Pivot points brake lever and clutch lever Clutch cable end Pivot points sidestand Grease nipples rear arm front axle 2 21 LUBRICATION LAYOUT SPEC ve 1 Oil tank A DELIVERY 2 Oil pump B RETRIEVAL 3 Oil filter oil tank 4 Oil strainer engine 5 6 LUBRICATION LAYOUT Oil vapour retrieval hose Oil blow by retrieval hose 2 22 LUBRICATION LAYOUT SPEC ve 1 Oil pump A DELIVERY 2 Oil filter B RETRIEVAL 3 Camshaft 4 Oil delivery hose 5 Main driving shaft 6 Drive shaft 2 23 LUBRICATION LAYOUT SPEC ve Oil filter A DELIVERY Camshaft B RETRIEVAL Connecting rod pin Main driving shaft Secondary drive shaft Drain plug a Ee 2 24 LUBRICATION LAYOUT SPEC 1 Oil pump A DELIVERY 2 Oil filter B RETRIEVAL 3 Oil delivery hose 4 Transmission 5 Oil strainer 2 25 CABLE ROUTING SPEC ve CABLE ROUTING 1 Clutch cable 8 14 Right turn light 20 Clutch switch 2 Brake hose holder odometer cable connector connector 9 Complete wire 15 Meter wire harness 21 Brake switch 3 Brake hose harness connector connector 4 Throttle cables 10 Socket cover 16 Main switch wire _ 22 5 Bands 11 Engine stop switch harness connector the brake hose 6 Lighting wire connector 17 Clutch swi
186. s Damage gt Replace 2 Inspect e Connecting rod 1 e Relay arm 2 Deformation Cracks Damage gt Replace 3 Inspect e Oil seals Wear Damaged gt Replace e Washers e Thrust cover Wear Damaged gt Replace e Bushes Scratches Damaged gt Replace e Bearings Pitting Damaged gt Replace 4 Inspect e Chain guard seal e Chain case and support Wear Damage gt Replace 4 78 4 79 SWINGARM CHAS LATERAL FREE PLAY ADJUSTMENT 1 Measure e Length of bushes A1 and A2 Out of specification Replace Length of bushes Al 76 70 76 85 mm A2 74 90 75 00 mm 2 Measure e Length B1 and B2 3 Calculate e Lateral swing arm side play C Out of specification gt Adjust free play with special shims Use the following formula C 1 2 B1 B2 Swing arm lateral free play C 0 4 0 7 mm e Lateral side play using one or more adjust shims 1 Measurement of adjust shim 1 0 3 mm When only one shim is used install it on the left side when two shims are used install one on each side A gt e c o SWINGARM CHAS SWINGARM INSTALLATION Perform removal operations in reverse order Note the following points J o Lubricate Bearings Bushes Thrust cover inside Flange Swingarm pivot shaft Bolt connecting rod Bolt relay arm Bolt shock absorber Lithium base grease Tighten N Nut relay arm swingarm 66
187. seal CAUTION Do not use compressed air to spin the bear ings dry This will damage the bearing sur faces D Bearing 300 002 EB101050 CIRCLIPS 1 Check all circlips carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip D make sure that the sharp edged corner 2 is positioned opposite the thrust 3 it receives See sectional view 300 001 4 Shaft 1 3 CHECKING OF CONNECTIONS Nro Pe EB801000 CHECKING OF CONNECTIONS Check the connectors for stains rust moisture etc 1 Disconnect e connector 2 Check e connector Moisture gt Dry each terminal with an air blower Stains rust Connect and disconnect the terminals several times 3 Check e connector leads Looseness gt Bend up the pin and con nect the terminals 4 Connect e connector terminals NOTE The two terminals click together 5 Check e continuity using a pocket tester NOTE ___ e fthere is no continuity clean the terminals e When checking the wire harness be sure to perform steps 1 to 3 e As a quick remedy use a contact revitalizer available at most part stores e Check the connector with a pocket tester as shown SPECIAL TOOLS G SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropriate special tools this will help prevent damage caused by
188. sembly spring 28 Drain valve 2 Cover gasket 14 Spring washer 29 Pipe 3 Gasket nozzle 15 Nut 30 Pipe 4 Float 16 Gasket 31 Screw 5b Float pin 17 Screw 32 Screw 6 Float chamber 18 Stop screw 33 Pipe gasket 19 Nut 34 Clip 7 Screw 20 Screw 35 Main jet 1 8 Float chamber 21 Hose 36 Main nozzle 1 fastening screw 22 Diaphragm 37 Throttle valve 9 Spring washer 23 Cover 38 Pilot jet 10 Collar 24 Bracket 39 Main jet 2 11 Screw 25 O ring 40 Main nozzle 2 12 Gasket 26 Spring washer 41 Pilot screw set SPECIFICATIONS Main jet 150 FIRST 145 SEC Starter jet 74 Needle jet 5C5A 3 5 FIRST 5Y 18 3 5 SEC Main nozzle 9 2 6 Pilot jet 50 Pilot air screw 2 75 0 5 revs approx open Float height 27 29 mm Fuel level 6 8 mm Engine idle speed Throttle valve seat 1 150 1 450 r min 2 5mm 6 4 42 Needle valve set 43 Stop screw set 42 43 44 Throttle screw set 45 Diaphragm 46 Needle set 1 47 Needle set 2 48 Starter set 49 Way 3 50 Hose 51 Hose 52 Hose 53 Clip 54 Breather pipe 55 O ring 56 Pipe canBUnETOR CARB SECTION VIEW 1 Needle jet primary 8 Main nozzle secondary 2 Valve seat 9 Main jet secondary 3 Needle valve A Primary carburetor 4 Main nozzle primary B Secondary carburetor b Main jet primary lt 1 Air 6 Pilot air screw mm Fuel 7 Needle jet secondary ae uu Mixture
189. special lubricant for O Ring chains 5 Inspect e Drive chain Rigid gt Clean and lubricate replace if necessary 6 Inspect e Drive sprocket e Rear wheel sprocket Wear over 1 4 tooth 1 gt Replace Teeth bent gt Replace 2 Undamaged tooth profile 3 Roller 4 Sprocket How to replace the rear wheel sprocket With wheel removed 1 Remove Hub 1 e Sprocket fastening bolts 2 e Rear wheel sprocket 3 2 Install e New sprocket 3 e Sprocket fastening bolts 2 Hub 1 DRIVE CHAIN DRIVE SPROCKET 4 85 AND REAR WHEEL SPROCKET CHAS 3 Tighten e Rear wheel sprocket fastening bolts A Rear wheel sprocket fastening bolts 2 48 Nm 4 8 mkg AAAAAAAAAAAAAAAAAAAAAAAAAAAAA DRIVE CHAIN INSTALLATION Perform REMOVAL operations in reverse order Pay special attention to the following points 1 Install e Drive chain e Swingarm Nut swingarm pivot shaft 90 Nm 9 0 mkg Nut frame relay arm 60 Nm 6 0 mkg 2 Install e Rear wheel Refer to REAR WHEEL INSTALLATION section 3 Install e Drive sprocket Nut drive sprocket 2 110 Nm 11 0 mkg A WARNING Always use a new lock washer NOTE _ e Tighten the drive sprocket nut with the rear brake pulled e After tightening the nut bend the tab the lock washer once more over the faces of the nut 4 Adjust e
190. ssure plate deformed Clutch springs not preloaded uniformly Reference marks not aligned Push rod broken Clutch gear assy nut loose or push rod deformed Primary driven gear bearing defective Driven plates deformed Driving plates deformed Clutch cable damaged Oil level over maximum Incorrect gradation high viscosity Degradation PROBABLE CAUSES Shift cam shift fork Transmission DISENGAGING GEARS Shift shaft deformed Groove with impurities or foreign bodies Shift fork stuck Shift fork guide bar deformed Transmission gears struck Gears stuck by impurities or foreign bodies Wrong transmission assembly PROBABLE CAUSES t Shift shaft Shift fork Shift cam Transmission 8 4 Shift lever set wrongly Shift cam stop lever fails to return freely Shift forks worn Shaft cam with thrust free play Shift cam groove worn Gear clutches worn TRBL CLUTCH SLIDES OR FAILS TO RELEASE SHTG CLUTCH SLIDES OR FAILS TO RELEASE CLUTCH SLIDES PROBABLE CAUSES Clutch e Clutch cable wrongly set e Clutch springs loose e Clutch spring yielded e Friction plates worn e Clutch plates worn e Clutch improperly assembled Engine oil Oil level below minimum e Incorrect gradation low viscosity Degradation CLUTCH FAILS TO RELEASE Refer to SHIFTING IMPOSSIBLE section 8 5 DEFECTIVE BRAKES TRBL OIL LEAKS OR MA
191. stall e Piston 1 e Pin 2 e Circlip 3 NOTE c e Arrow 4 on the piston must point towards the front of the engine e Before installing the piston pin circlips cover the crankcase with a clean cloth to prevent foreign bodies falling into it A WARNING Always use new circlips for the piston pin 3 Install e Dowel pins 1 e O Ring 2 4 Install e Gasket 1 cylinder NOTE l Install the cylinder gasket as shown in the illustra tion ENGINE ASSEMBLY AND SETTING ENG 5 Offset the piston ring end gaps as illustrated in the figure NOTE n e Check that the marks and numbers stamped by the manufacturer on the piston rings face upwards e Before installing the cylinder lubricate the pis ton rings liberally with 4 stroke engine oil Upper ring Scraper lower ring Scraper upper ring Lower ring 1 2 3 2 oL NH 4 6 Install e Cylinder 1 NOTE c e Install the cylinder to the piston with one hand while one hand while compressing the piston rings with the other e Bind the timing chain with wire and slip it through the appropriate slot Cylinder Screw 2 10 Nm 1 0 mkg Cap nut 3 42 Nm 4 2 mkg Nut 4 42 Nm 4 2 mkg 5 60 ENGINE ASSEMBLY AND SETTING ENG ae 7 Install e Dowel pins 1 e O Ring 2 e Gasket 3 cylinder head 8 Install e Cylinder head NOTE Tighten scre
192. t Oil pump drive gear 1 e Oil pump driven gear 2 Wear Cracks Damage gt Replace PRIMARY TRANSMISSION 1 Inspect e Primary drive gear teeth 1 e Primary driven gear teeth 2 Wear Damage Replace both gears Excess noise during functioning Replace both gears 5 35 INSPECTION AND REPAIR OD TRANSMISSION AND GEARBOX 1 Inspect 6 e Shift fork pin 1 e Shift fork pawl 2 2 Lines Creases Wear gt Replace ORe 2 Inspect e Shift cam groove e Shift cam pins Wear Damage gt Replace 3 Check e Shift fork movement Rough functioning gt Replace shift forks and or guide bars 4 Inspect e Guide bar Turn on a flat surface Curvature gt Replace PES A WARNING Do not attempt to straighten the deformed Pl guide bar 5 Measure e Transmission shaft eccentricity Use the centring tool and micrometer Out of specification Replace bent shaft Transmission shaft eccentricity Limit 0 08 mm 5 36 INSPECTION AND REPAIR 6 Inspect e Gear teeth Brown colouring Pitting Wear gt Replace e Mating clutches Rounded edges Cracks Missing frag ments gt Replace 7 Check e Proper mating of each gear with corre sponding part e Gear movement Roughness Replace Transmission gear assembly steps e Fit the second gear 2 to the propeller shaft 1 as shown in the figure
193. t high speed 3 42 TYRE INSPECTION ei Check Tyre pressure Out of specification gt Adjust 1 Tire air pressure measured on cold tires Load Front 200 kPa 220 kPa Up to 90 kg 2 00 kgf cm 2 20 kgf cm 2 00 bar 2 20 bar 210 kPa 240 kPa 90 kg maximum 2 10 kgf cm 2 40 kgf cm 2 10 bar 2 40 bar 150 kPa 160 kPa Off road riding 1 50 kgf cm 1 60 kgf cm 1 50 bar 1 60 bar 210 240 kPa High speed 2 10 kgf cm 2 40 kgf cm riding 240bar 240bar Maximum load 180 kg Total weight of rider passenger cargo and ac cessories 2 Adjust Air pressure VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Adjustment Remove the valve cap Use an air pump or compressed air pistol Increase air pressure Eliminate air by pressing valve tube stem e Install valve caps secure Air pressure diminishes ly AAA A A A A A A A A A A A A A A A A A A A A A A A A A A 3 Inspect Tyre surface Wear Damage gt Replace TYRE INSPECTION NSP ei Minimum track thickness 2 front and rear 3 43 1 6 mm NOTE These limits may be different by regulation from country to country If so conform to the limits specified by the regulations of your own country 1 Track thickness 2 Side 3 Wear indicators A WARNING The use of worn tyres reduces stability and may cause a loss of control It is not advisable to repair a punctured air tube
194. t it keeping the hemmed parts towards the top 12 Screw e Cap bolts 5 on inner tube without tighten 13 Install e Fork leg FRONT Fork 14 Tighten e Pinch bolt upper and lower bracket Pinch bolt upper bracket 28 Nm 2 8 mkg Pinch bolt under bracket 23 Nm 2 3 mkg 4 48 NOTE Always tighten the lower pinch bolt to the pre scribed torque and then the upper one to the prescribed torque and then retighten the lower one to the prescribed torque 15 Tighten e Cap bolt on inner tube Ww Cap bolt on inner tube QJ 20 Nm 2 0 mkg 4 49 FRONT Fork CHAS CLEANING THE DUST SEAL NOTE _ After using the motorcycle it is necessary to clean the dust seal carefully in order to maintain the fork at maximum efficiency In fact if dust infiltrates to the inside of the dust seal it can compromise the smoothness and therefore the sensitivity of the fork and also cause the premature wear of the underlying oil seal Just a few simple operations then guided by the following indications are necessary to maintain the optimum functioning of the fork with time 1 With a screwdriver prise the dust seal 1 from the oil seal seat 2 and then withdraw it using force 2 Using a low pressure jet of compressed air clean the inside of the dust seal and the oil seal seat 3 Insert the edge of a cloth under the lip and keeping the cloth steady carefully clean the lip by rotatin
195. tall e Diaphragm 1 e Master cylinder cap 2 e Screw 3 cap Screw master cylinder cap A 1 5 Nm 0 15 mkg 4 15 FRONT BRAKE CHAS BRAKE CALIPER 25 Nm 2 5 m kg Job name Par name Caliper removal Remove the parts in order Brake fluid Drain Union bolt Plain washer Brake hose Caliper support bolt Caliper assembly Refer to CALIPER INSTALLATION sec tion Reverse the removal procedure for instal lation 4 16 FRONT BRAKE CHAS Job ramel Pan Caliper disassembly Remove the parts in order Brake pad Refer to BRAKE PAD section Pad spring Caper piston p to BRAKE CALIPER DISASSEM Dust seal Piston seal BLY ASSEMBLY section Bleed screw Refer the disassembly procedure for as sembly 4 18 FRONT BRAKE CHAS BRAKE CALIPER DISASSEMBLY 1 Remove e Brake caliper piston e Dust seal 1 e Piston seal 2 Removal procedure e Blow compressed air into the hose joint open ing to force out the caliper piston from the brake caliper body A WARNING e Never try to pry out the caliper piston e Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the master cylinder e Remove the piston seal A A AA A A A A A CALIPER INSPECTION Recommended programme for t
196. tandard 4 3 37 Maximum hard 5 6 7 8 9 10 3 38 REAR SHOCK ABSORBER ADJ USTMENT ei REAR SHOCK ABSORBER ADJ USTMENT WARNING This shock absorber contains highly pressur ized nitrogen gas For proper handling read and understand the following information before handling the shock absorber The man ufacturer cannot be held responsible for prop erty damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder e Do not subject the shock absorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure e Do not deform or damage the gas cylinder in any way as this will result in poor damp ing performance This shock absorber assembly is equipped with a spring preload adjusting nut CAUTION Never attempt to turn an adjusting mecha nism beyond the maximum or minimum set tings Adjust the spring preload as follows 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b REAR SHOCK ABSORBER ADJ USTMENT IT ei NOTE SE e Use the special wrench included in the owner s tool kit to make the adjustment e The spring preload setting is determined by measuring distance A shown in the illustra tion
197. tator complies with specifications Stator coil resistance White 1 White 2 0 65 20 at 20 C 68 F White 1 White 3 0 65 Q 20 at 20 C 68 F IN COMPLIANCE CHARGING SYSTEM ELEC OUT OF SPECIFICATIONS mmm Stator winding is defective Replace WITH SPECIFICATIONS 5 Wiring connections e Check the connections of the entire char ging system Refer to ELECTRICAL CIRCUIT DIA GRAM section CORRECT The rectifier regulator is defective Replace UNCERTAIN CONNECTIONS V 7 39 7 40 LIGHT SYSTEM ELEC LIGHT SYSTEM CIRCUIT DIAGRAM 1X3 SS3NHVH
198. tch throught the holder harness 12 Headlight wire 18 Headlight connector handle 7 Brake and engine harness connector Sion switch wire 19 Side taillight Gr 2 13 Left turn light connector connector NES yy J 2 gt A V 2 26 CABLE ROUTING SPEC ve ech Front brake hose 11 Fuel pipe from fuel 19 Oil hose oil tank to 28 Wire extension 1 2 Brake hose holder cock engine 29 Battery plus cable 3 Left tube guard 12 Flasher relay 20 1 engine to A Lay the brake hose 4 Plastic plate 13 Main relay behind the left tube 5 Throttle cables 14 Sidestand switch 21 unit guard and fasten it 6 Tachometer 15 Diodes n 3 22 Starting motor plus down by means of odometer cable 16 A C generator wire cane the plate 4 7 Clutch cable harness engine 23 Starting motor B Attach throttle 8 Clutch cable holder 17 Engine oil breather nung case pope 8 Clutch cable holder pipe to engine oil 24 Battery C Fasten the fuel pipe 9 Throttle cables tank 25 Starting relay 11 to the tank 18 Main switch 26 Fuse reserv a 0309 lodos 10 Wire harness band 26 age inside the chassis 27 Fuse main against the coil clip 14 2 27 CABLE ROUTING SPEC ve 1 Tachometer 7 Carburetor suction 12 Rear brake hose A Insert the
199. tem NOTE Before starting inspections remove the following parts 1 Seat 2 Rear cowling e To check for defects use the following special tools 4 2 Inductive rev counter 4 2 Pocket tester P N 90890 03113 90890 03112 Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 a 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING NO THE BATTERY in Chapter Min open circuit voltage 159 V Or More RES ech e Clean the battery terminals e 15 the battery OK e Recharge or replace the battery 7 37 3 CHARGING SYSTEM ELEC Charging voltage Connect the inductive rev counter to the spark plug cable Connect the pocket tester DC 20V to the battery as shown Start the engine and rev to about 5 000 rpm Check the charging voltage IN COMPLIANCE WITH Charging voltage SPECIFICATIONS amp 14 0V at 5 000 rpm T NOTE p Use a fully charged battery Replace the battery OUT OF SPECIFICATIONS 4 Stator coil resistance e Disconnect the AC generator connector from the harness Connect the pocket tester x 1 to the sta tor coils Stator coils 1 Tester terminal 2 White cable 1 Tester terminal 2 White cable 2 7 38 Stator coils 2 Tester terminal 2 White cable 1 Tester terminal 2 White cable 3 e Check that the winding resistance of the s
200. ter bracket e Headlight adjust the headlight beam if necessary 11 Install e Cowling screws Y Cowling screws A 10 Nm 1 0 kgm Auxiliary light bulb 1 Remove e Cowling screws 1 2 Remove e Cowling from the meter bracket Remove the cowling from the meter bracket by lowering it to disengage it and then lifting it up 3 Remove e Headlight 2 e Auxiliary light socket 3 NOTE _________________________ Remove the auxiliary light socket together with the bulb without disconnecting the leads e Bulb by pushing it in and turning it coun terclockwise 3 55 3 56 REPLACING THE TURN INDICATOR LIGHT BULB ei 4 Install e Bulb new by pushing it in and turning it clockwise e Bulb holder e Upper side of the cowling onto the meter bracket Headlight adjust the headlight beam if necessary 5 Install e Cowling screws XS Cowling screws 4 10 Nm 1 0 kgm REPLACING THE TURN INDICATOR LIGHT BULB 1 Remove e Lens screw 1 Lens 2 e Bulb 3 NOTE MEME To remove the bulb press it into place and turn it counterclockwise 2 Install e New bulb NOTE pu To install the bulb press it into place and turn it clockwise e lens e Lens screw CAUTION Do not overtighten the screw otherwise the lens may break REPLACING THE TAIL BRAKE LIGHT BULB REPLACING THE TAIL BRAKE LIGHT BULB 1 Remove e Screws 1 lens fixing Lens 2 Bulb 3 NOTE
201. the use of inappropriate tools or impro vised techniques When placing an order refer to the list provided below to avoid any mistakes Engine tachometer 90890 03113 This tool is needed for detecting engine rpm Timing light 90890 03141 This tool is needed for detecting ignition timing Pocket tester 90890 03112 These instruments are invaluable for check ing the electrical system Ignition checker 90890 06754 This instrument is necessary for checking the ignition system components Compression gauge 90890 03081 These tools are used to measure the engine compression Adapter compression gauge 90890 04082 This tool serves to measure the engine com pression Fuel level gauge 90890 01312 This gauge is used to measure the fuel level in the float chamber Piston pin clip puller 90890 01304 This tool serves for removing the piston pin clip SPECIAL TOOLS dft Tool No Tool name Usage Rocker arm shaft puller bolt 90890 01083 These tools are used when removing the rocker arm shafts 90890 01084 These tools are used when removing the rocker arm shafts Valve spring compressor 90890 04019 These tools are used when removing or installing the valve and the valve spring 7 mm 0 28 in valve guide puller 90890 01225 This tool is used to remove the valve guides 7 mm 0 28 in valve guide installer 90890 04017 This tool is necessary to install the valve slides properly 7 mm 0 28 in valve guide reamer 90890
202. ther than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical sys tem cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install e e Seat REPLACING THE HEADLIGHT BULBS Low beam high beam 1 Remove e Cowling screws 1 2 Remove e Cowling from the meter bracket Remove the cowling from the meter bracket by lowering it to disengage it and then lifting it up 3 Remove e Headlight 2 4 Disconnect e Headlight coupler 3 5 Remove e Headlight bulb cover 4 6 Remove e Headlight bulb holder 5 by turning it counterclockwise a e Headlight bulb A WARNING Headlight bulbs get very hot Therefore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down REPLACING THE HEADLIGHT BULBS wq 7 Install e Headlight bulb new e Headlight bulb holder by turning it clock wise b CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 8 Install e Headlight bulb cover 9 Connect e Headlight coupler 10 Install e Upper side of the cowling onto the me
203. to prevent it falling over 5 Remove e Rear wheel Rear wheel sprocket Hub Damper Spacer Refer to REAR WHEEL REMOVAL sec tion DRIVE CHAIN DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET o 4 83 6 Remove e Swingarm e Drive chain Refer to REAR SHOCK ABSORBER REMOVAL and SWINGARM REMOVAL sections DRIVE CHAIN INSPECTION 1 Measure e Length of 10 links drive chain Out of specification gt Replace drive chain Maximum lenght of 10 links a 150 2 mm NOTE _ e Stretch the chain by hand to measure it e Thelength of the 10 links is recorded between the inside of the link pins 1 and 11 as shown e length of the 10 links is measured at var ious points 2 Clean e Drive chain Immerge in kerosene and brush thorough ly to remove as much dirt as possible Remove from kerosene and allow to dry CAUTION This motorcycle is fitted with a chain with small O Rings 1 fitted between its plates Vapour cleaning pressurised washing and certain types of solvents may damage these seal rings To clean the transmission chain use only kerosene DRIVE CHAIN DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET o 4 84 3 Inspect e Seal rings 1 drive chain Damaged gt Replace drive chain e Rollers 2 e Lateral plates 3 Damage Wear gt Replace drive chain 4 Lubricate e Drive chain Lubricant for drive chain SAE 80W 90 engine oil or
204. troboscopic lamp e Inductive engine speed indicator COMPRESSION INSPECTION INSP ei COMPRESSION INSPECTION NOTE Insufficient compression causes a loss of formance A WARNING Set the motorcycle firmly in place to prevent it falling during the operation 1 Remove e Seat e Fuel tank See section SEAT FUEL TANK AND REAR COWLING 2 Check e Valve clearance Out of specification gt Adjust See section VALVE CLEARANCE AD JUSTMENT 3 Install e Secondary fuel tank 4 Start engine and let it heat Switch off engine 5 Disconnect e Spark plug cap 6 Remove Spark plug 1 CAUTION When removing the spark plug be careful to prevent foreign bodies from dropping inside the engine 7 Apply e Pressure gauge 1 e Adapter 2 CZ Pressure gauge 90890 03081 Adapter P N 90890 04082 3 12 COMPRESSION INSPECTION NSP ei 3 13 8 Check e Pressure under compression VVVVVVVVVVVVVVVVVVVVVVVVVVVY Inspection e Turn the main switch to ON e With the throttle wide open crank the engine until the reading on the compression gauge stabilized A WARNING While operating the starter disconnect the spark plug cap to avoid sparks e Compare the pressure reading with those in the table Pressure under compression Standard 1 100 kPa 11 kg cm 156 psi Minimum 900 kPa 9 kg cm 128 psi Maximum 1 200 kPa 12 kg cm 171 psi If
205. urn hose Oil breather pipe to oil tank Oil breather pipe to air filter box Disconnect Remove Disconnect Disconnect Disconnect Disconnect Disconnect Reverse the installation removal procedure for o ENGINE REMOVAL ENGINE MOUNTING BOLT for procedure removal the necessary to pay special care with the Remove the mounting screws to engine rear arm Remove the engine from the lower side removing the pivot shaft it is thus CAUTION The engine and rear arm are assembled installation together on the rear pivot shaft When Reverse o x E 19 Y d d M S gt SS SAINI WOW LA S 42 C Lak E M A F z ec ENS ocr SN AN 3 44 y 4 7 M D7 2 SN UE d E SQ Job name Part name Stay of oil tank Hose clamp carburetor Pivot shaft rear top Engine mounting bolt rear lower Engine stay front lower Engine stay front top right left Engine assembly 5 4 ENGINE DISASSEMBLY oD ENGINE DISASSEMBLY 5 5 CYLINDER HEAD CYLINDER CAMSHAFT AND PISTON NOTE M The cylinder head cylinder camshaft and piston can be examined with the engine installed by removing the following parts Seat Fuel tank Rear cowling Carburetor Exhaust pipe Remove Spark plug 1 Tappet cover
206. voir is horizontal BRAKE PAD WEAR INSPECTION BRAKE HOSING INSPECTION 1 Operate the brake lever or brake pedal 2 Check e Thickness of frictional material Out of specification gt Replace Wear limit Front 1 0 mm Rear 1 0 mm For brake pad replacement see section BRAKE PAD REPLACEMENT in Chapter 4 A Front brake B Rear brake BES 5 i x BRAKE HOSING INSPECTION 1 Inspect e Brake hosing Cracks Damage gt Replace To replace hosing see section FRONT AND REAR BRAKE in Chapter 4 S LS e yj B A Front brake B Rear brake 3 33 BRAKE CIRCUIT BLEEDING ei 3 34 BRAKE CIRCUIT BLEEDING A WARNING If the brake lever or brake pedal has a soft or slack feel this means that there is air in the brake system It should be bled away before using the motorcycle Air in the system seri ously affects the effectiveness of braking and may cause loss of control of the motorcycle In all cases bleed the brake system if e The system has been disassembled e A brake hose has been loosened or removed e The brake fluid in the tank is at a very low level e Brake operation is faulty Air bleeding procedures a Top up the level of the fluid in the tank to max imum b Install the diaphragm Be careful not to spill fluid or let it overflow from the tank c Connect the clear plastic hose 1 to the caliper bleeder screw
207. w 2 carburetor manifold 10 Nm 1 0 mkg Screw 3 clamp 2 Nm 0 2 mkg 3 Reassemble e Fuel tank e Seat See section SEAT FUEL TANK AND REAR COWLING Ny Seat screws amp 10 Nm 1 0 mkg FUEL LINE INSPECTION 1 Inspect e Fuel pipe 1 Cracked Damaged gt Replace 3 28 CRANCKCASE VENTILATION HOSE INSPECTION 1 Inspect e Crankcase ventilation hoses 1 Cracked Damaged gt Replace CRANCKCASE VENTILATION HOSE INSPECTION EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM INSPECTION 1 Inspect e Exhaust pipe 1 e Muffer 2 Cracks Damage Replace e Gaskets 3 Exhaust gas leakage Replace Nut 4 exhaust pipe 10 Nm 1 0 mkg Screw 5 muffler 23 Nm 2 3 mkg Bolt 6 flange 23 Nm 2 3 mkg apply molybdenum disulfide grease Screw 7 protection 7 Nm 0 7 mkg Use LOCTITE Nut 8 muffler 23 Nm 2 3 mkg 3 29 3 30 ADJ USTING THE FRONT BRAKE ei CHASSIS ADJ USTING THE FRONT BRAKE 1 Adjust Brake lever position distance 8 between the brake lever and the handlebar grip Turn the adjusting dial while holding the lever pushed away from the handlebar grip NOTE n Align the setting on the adjusting dial with the arrow mark Posizione n 1 La distanza a la massima Posizione n 4 La distanza la minima A WARNING After ad
208. ws beginning with the one with the lowest number Cylinder head Screw 1 2 3 and 4 29 Nm 2 9 mkg Nut 5 and 6 22 Nm 2 2 mkg Screw 7 10 Nm 1 0 mkg 9 Install e Chain stopper guide Camshaft Cam chain sprocket VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Timing chain installation e Install the cam chain on the cylinder head as illustrated compression phase timing e Run the cam shaft in an anticlockwise direc tion until the mark on the crankcase 1 and the point on the cam chain gearwheel 2 are aligned 5 62 ENGINE ASSEMBLY AND SETTING ENG e Install the gear wheel with the timing marks as shown in the figure and tighten the screws on the gear wheel by hand 3 Upper cylinder head surface 4 Timing marks 5 Upper position mark e When pushing the chain tensioner be sure that the marks on the cam chain sprocket are aligned with the top surface of the cylinder head e fthe marks are aligned tighten the cam chain sprocket bolts Bolt cam chain sprocket 2 20 Nm 2 0 mkg e fthe marks are not aligned replace the chain sprocket mating piston and chain A AA A A A A A A A A A A A A A A A A A A A A A A A A A A 10 Apply e Yamaha Bond 12159 1 on the mating surfaces 2 4 Sigillante Quick Gasket Yamaha bond N 12159 P N 90890 85505 11 Install e Dowel pins 2 12 Install e Cap e Cylinder head c
209. y procedures in reverse order NOTE EE UOI Use a wrench 1 with an external diameter equal to that of the bearing and dust cover CAUTION Do not strike the bearing inner race 2 or balls 3 The contact must only be made with the outer race 4 AAA A A A A A A A A A A A A A A A A A A A A A A A A A A FRONT WHEEL AND BRAKE DISC CHAS HH 4 6 FRONT WHEEL INSTALLATION 1 Install e Brake disc 1 EE Screw brake disc V 12Nm 1 2 NOTE TET e Apply LOCTITE to the threads of brake disc screw Tighten the screws brake disc in stage using a crisscross pattern N Install e Speedometer gear unit 1 NOTE aa eee Make sure that the wheel hub and the speedome ter gear unit are installed with the projections meshed into the slots 3 Tighten e Front wheel e Front wheel axle N Front wheel axle di 59 Nm 5 9 mkg NOTE EE UOI Make sure that the slot a in the speedometer gear unit fits under the stopper on the front fork outer tube e Pinch bolt Pinch bolt 2A 9Nm 0 9 mkg WHEEL STATIC BALANCE ADJ USTMENT e After replacing the tire and or rim the wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed Remove e Balancing weight Set e Wheel on a suitable stand Find e Heavy spot N w 4 7 _ FRONT WHEEL AND BRAKE DISC 5 VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Procedure

2004 yamaha tt600 service manual

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