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Yamaha 2003 TZR50, Service Manual

The Yamaha 2003 TZR50 Service Manual is a comprehensive guide packed with essential information for maintaining and repairing your motorcycle. This manual is available for instant download, absolutely free, from manualshive.com, ensuring easy access to the instructions you need to keep your TZR50 running at its best.

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CHAS

FRONT FORK

7-28

INSTALLING

Use the “EXTRACTION” procedure inversely.
Take into account the following points.
1.

Install:
• The fork

Provisionally tighten the clamp screws of
the handlebars.

NOTE:

Maintain the inner tube.

2.

Tighten:
• The (handlebar) clamp screws 

• The clamp screws (upper shank of the

handlebar) 

3.

Tighten:
• The clamp screw (lower shank) 

4.

Install:
• The front mudguard

5.

Install:
• The front wheel

See the section on “FRONT WHEEL -
FITTING”

(Handlebar) clamp screws: 

2.0 kg • m

Clamp screws (upper shank of the
handlebar): 

2.0 kg • m

Clamp screw (lower shank): 

3.0 kg • m

Screws (front mudguard):

0.8 kg • m

Wheel axle: 

7.4 kg • m

Screws (brake caliper): 

3.5 kg • m

Summary of Contents for 2003 TZR50

Page 1: ...SERVICE MANUAL TZR50 X POWER 03 5WX AE1 03 ...

Page 2: ... SERVICE MANUAL 2003 by Yamaha Motor España S A 1st Edition December 2003 All rights reserved Any reproduction or non authorised use of this material is expressly prohibited without the consent of Yamaha Motor España S A ...

Page 3: ...s that it manu factures Any significant modifications and changes which are brought into the specifica tions or procedures will be made known to all Authorised Yamaha MBK dealers and will appear where applicable in future editions of this manual TECHNICAL PUBLICATIONS AFTER SALES SERVICE YAMAHA MOTOR ESPAÑA S A HOW TO USE THIS MANUAL INFORMATION OF PARTICULAR IMPORTANCE This material is distinguis...

Page 4: ...ning exhaustive expla nations of all the operations for dismantling repair assembly and inspection In this reviewed format the condition of each faulty component is followed by an arrow which will in turn be followed by the operation required for example Bearing Pitting Deterioration Replace EXPLODED VIEWS Each chapter includes exploded views before each dismantling section to facilitate iden tifi...

Page 5: ...n the text Filling liquid 10 Lubricant 11 Special tool 12 Tightening 13 Limit of wear or clearance 14 Engine speed 15 Ω V A Symbols 16 to 23 of the detailed diagrams indicate the grade of lubricant and the loca tion of the lubrication point 16 Apply engine oil 17 Apply gearbox oil 18 Apply molybdenum bisulphide oil 19 Apply grease for wheel bearings 20 Apply lightweight lithium soap based grease 2...

Page 6: ...SPECIFICATIONS INSP ADJ 3 REGULAR INSPECTIONS AND ADJUSTMENTS ENG 4 DISMANTLING THE ENGINE COOL 5 COOLING SYSTEM CARB 6 CARBURATION CHAS 7 CHASSIS INDEX ELEC 8 ELECTRICAL SYSTEM GENERAL INFORMATION GEN INFO 1 ...

Page 7: ...GEN INFO 1 ...

Page 8: ...UMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISMANTLING 1 2 SPARES 1 3 GASKETS OIL SEALS AND O RINGS 1 3 WASHERS LOCKING PLATES AND SPLIT PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 4 SPECIAL TOOLS 1 4 FOR TUNING 1 4 FOR ENGINE SERVICE 1 4 FOR CHASSIS SERVICE 1 7 FOR ELECTRICAL COMPONENTS 1 8 ...

Page 9: ...is printed on the right hand side of the steering head ENGINE SERIAL NUMBER The engine serial number is printed on the left hand side of the engine NOTE The first three figures of these numbers are for identifying the model the others are the machine manufacturing number NOTE Design and characteristics subject to modifi cation at no prior notice ...

Page 10: ...cycle keep any matching parts together This refers to gears cylinders and pistons and other items which work together and undergo the same normal wear Matching parts must be assembled or replaced together 4 As you dismantle the motorcycle clean all the parts and place them in trays in the same order in which these are dismantled This will cut down the time required for assembly and will make it ea...

Page 11: ...rings and matching parts Apply grease to the lips of oil seals WASHERS AND LOCKING TABS AND SPLIT PINS 1 All washers locking tabs 1 and split pins have to be replaced and when locking tabs are removed and replaced they must be fol ded over the sides of the bolts or nuts after these have been properly tightened BEARINGS AND OIL SEALS 1 Install the bearings and oil seals with the makes or manufactur...

Page 12: ...or full and accurate tuning and installing the appropriate special tools must be used This will prevent any damage that could arise from using inappropriate tools or improvised techni ques FOR TUNING 1 Comparator set Ref 90890 01252 This tool is used for installing the comparator and tune the motor 2 Digital tachometer for the engine Ref 90890 03113 This tool is required for determining the engine...

Page 13: ...ned or loosened 3 Magnetic flywheel extractor Ref 90890 11031 This tool is used for dismantling the magnetic flywheel 4 Pin extractor Ref 90890 01304 This tool is used for removing the piston pin 5 Cooling system checker Ref 90890 01325 This tool is required for checking the cooling system 6 Adapter Ref 90890 01352 This system is used for checking the cooling system ...

Page 14: ...g the crankshaft or removing the crankcase 8 Tools for installing the crankshaft Ref 90890 01284 These tools are used for installing the cranks haft 9 Crankcase installer Magnetic flywheel side Ref 90890 11032 10 Seal installer Selector axle Ref 90890 11033 11 Seal installer Water pump Ref 90890 11034 ...

Page 15: ...nt fork cylinder holder Ref 90890 01294 This tool is used to loosen and tighten the fixing bolts for the cylinders of the front fork 2 Front fork seal fitter weight Ref 90890 01367 Adapter Ref 90890 01400 These tools are used for installing the seals on the front fork 3 Wrench for circular nuts Ref 90890 01403 This tool is used for loosening and tightening the circular steering nut ...

Page 16: ...ket tester Ref 90890 03112 This tester is an invaluable help for checking the electrical system 2 Stroboscopic lamp Ref 90891 03141 This tool is required for checking the ignition advance OTHER TOOLS 1 Micrometer Ref 90896 03008 2 Feeler gauge Ref 90890 03079 ...

Page 17: ......

Page 18: ...SPEC 2 ...

Page 19: ...ATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 7 TIGHTENING TORQUES 2 9 ELECTRICAL SYSTEM 2 11 GENERAL SPECIFICATIONS OF TIGHTENING TORQUES DEFINITION OF THE UNITS 2 13 LUBRICATION POINTS AND TYPE OF LUBRICANT 2 14 ENGINE 2 14 CHASSIS 2 15 CABLE ROUTING 2 16 ...

Page 20: ...ne Type of engine 2 stroke petrol liquid cooled Admission system Reed valve Cylinder arrangement Single cylinder slanting forwards Cylinder capacity 49 7 cm3 Bore x stroke 40 3 x 39 mm Compression ratio 6 85 1 Starting system Electric Lubrication system Independent lubrication Motor oil Type Yamaha 2 stroke oil or oil for air cooled 2 stro ke engines Capacity 1 35 L Transmission oil Type Engine oi...

Page 21: ...tem Helical gear Primary reduction ratio 71 20 3 550 Secondary reduction system Drive chain Secondary reduction ratio 47 12 3 916 Action Left foot Gear reduction ratio 1st 36 12 3 000 2nd 33 16 2 062 3rd 29 19 1 526 4th 27 22 1 227 5th 25 24 1 041 6th 24 25 0 960 Chassis Frame type Double cradle Deltabox Caster angle 25º Trail 92 mm Tyres Type Tubeless Dimensions Front 100 80 17 52H Rear 130 70 17...

Page 22: ...shock absorber Rear shock absorber Spiral spring and gas oil damping Wheel travel Front wheel 130 mm Rear wheel 102 mm Electrical system Ignition system C D I Charging system AC Magneto Battery Type YT4L BS Capacity 12V 3A Headlights Type Dual filament bulb Bulb voltage wattage x quantity Headlight 25 25W x 2 Tail and brake light 5 21Wx 1 Indicators 10Wx 4 Instrument panel light 1 2W x 2 Neutral i...

Page 23: ... 01 mm Piston Piston size D 40 237 40 257 mm Measurement point 12 mm Piston to cylinder clearance 0 049 0 062 mm Limit 0 1 mm 1st oversize 40 60 mm 2nd oversize 40 80 mm Rings Top ring Chrome plated type B 1 2 mm T 1 6 mm Second ring Chromed type B 1 2 mm T 1 6 mm End gap installed Top ring 0 15 0 30 mm 2nd ring 0 15 0 30 mm Side clearance Upper ring 0 03 0 06 mm 2nd ring 0 03 0 06 mm MAINTENANCE ...

Page 24: ... 9 3 1 mm Number 4 pieces Wear limit 2 7 mm Clutch plate Thickness 1 05 1 35 mm Number 3 pieces Wear limit 0 05 mm Clutch spring Free length 30 0 mm Number 4 pieces Clutch release method Internal pusher cam pusher Pushrod bending limit 0 15 mm Transmission Eccentricity limit of the primary shaft 0 08 mm Eccentricity limit of the secondary shaft 0 08 mm Selector Type Drum Air filter Oil type Oil fo...

Page 25: ... seat size 150 Reed valve Valve thickness 0 3 mm Valve stopper height 6 28 m Valve bending limit 0 1 0 7 mm Lubrication system Autolube pump Piston diameter 2 5 mm Minimum flow at 3000 rpm 6 cc h Maximum flow at 3000 rpm 28 cc h Pulley adjusting wark By keeping the throttle twist grip closed Cooling system Radiator core width 160 0 mm Radiator core height 160 0 mm Radiator core thickness 32 0 mm R...

Page 26: ...ng No Oil capacity 254 cm3 Oil level 150 mm From the top edge of the lower tube fully com pressed without spring Oil type Fork oil 10W or equivalent Rear suspension Rear shock absorber assembly travel 102 mm Spring free lenght 147 mm Limit 132 mm Installed lenght 134 mm Spring rate K1 14 kg mm Spring stroke K1 28 mm Optional spring No Swingarm Limit of free play end of the swingarm 1 0 mm Move the...

Page 27: ...cylinder inside diameter 12 0 mm Caliper cylinder inside diameter 25 0 mm Recomended fluid DOT 4 Rear disc brake Type Single disc Thickness 220 0 x 4 0 mm Brake pads thickness 4 mm Wear limit 0 5 mm Master cylinder inside diameter 12 0 mm Caliper cylinder inside diameter 30 0 mm Recomended fluid DOT 4 Front lever brake Rear brake pedal Free play front lever brake 2 5 mm At the end of the brake han...

Page 28: ...5 x 0 8 7 0 7 Carburetor joint Screw 4 M6 x 1 0 10 1 0 Crankcase left right Screw 13 M6 x 1 0 10 1 0 Bolt 4 M7 x 1 0 12 1 2 Crankcase cover 1 Bolt 5 M5 x 0 8 5 0 5 Crankcase cover 2 Bolt 4 M6 x 1 0 10 1 0 Crankcase cover 3 Crankcase cover 1 2 M5 x 98 4 5 0 45 Oil drain plug 1 M8 x 1 25 17 1 7 Intermediate shaft Nut 1 M12 x 1 0 60 6 0 Clutch Nut 1 M12 x 1 25 75 7 5 Screw 4 M5 x 0 8 4 0 4 Push rod n...

Page 29: ...M8 x 1 25 25 2 5 Upper Engine to rear frame holder 1 M8 x 1 25 25 2 5 Lower Swing arm to frame 1 M8 x 1 25 60 6 0 Shock absorber to swingarm 1 M8 x 1 25 60 6 0 Shock absorber to frame 1 M8 x 1 25 40 4 0 Fuel tank cap to fuel tank 1 M6 x 1 0 6 5 0 65 Front wheel axle to fork 1 M12 x 1 25 65 6 5 Rear wheel axle and nut 1 M14 x 1 25 90 9 0 Disc brake to wheel 5 M6 x 1 0 12 1 2 Brake caliper to bracke...

Page 30: ...14º 2000 r min Advance 24º 2000 r min CDI Magneto model manufacturer MORIC 5WX Pickup resistance color 350 20 Ω WR WL Charge coil resistance color 0 36 20 Ω W Lighting coil resistance color 0 28 20 Ω YR Ignition coil Model Manufacturer MORIC 5WX Secondary coil resistance 7 9 KΩ Spark plug pipe Type Resin Resistance 5 K W at 20 ºC ELECTRICAL SYSTEM ...

Page 31: ... 1 5A Flasher relay Model Manufacturer 0 1 2336 GUILERA Self cancelling device No Flashing frequency 60 120 cycles per minute Power in watts 10W 16W 1 2 W Oil level switch Model Manufacturer 21 57 057 A PAIOLI Temperature sensor Model Manufacturer 5017520 Anglí Starter relay Model Manufacturer 12V 50A Guilera Circuit breaker Type Fuse Circuit fuse MAIN 10 A Electrical start system Type Constant me...

Page 32: ...able specifies the tightening torques for ordinary fixings with standard ISO pitch thre ads The characteristics of the tightening tor ques of special components or assemblies are stated in the relevant sections of this manual To avoid any deformation tighten the assem blies with several fixing points in a cross pat tern and in gradual stages until the final tigh tening torque is reached Unless spe...

Page 33: ... Secondary shaft bearings Thrust cam bearing Crankshaft journals Rings pins and pistons Drive shaft water pump Shaft mixing pump Clutch casing Thrust rod Thrust lever shaft Sliding gear transmission Free gear transmission Guide bar transmission forks Connection ball shift pedal Rotation points shift pedal Crankcase matching surfaces Yamaha nº 4 adhesive E E G G G E E G E G G G M M G LUBRICATION PO...

Page 34: ... the oil seals front and rear wheels Rotation points brake pedal Rotation points side stand Right end of handlebar End of the throttle cable throttle twist grip Rotation axle clutch lever Rotation axle brake handle Anchorages rear shock Swingarm Bearing swingarm Front wheel axle Rear wheel axle Bush front wheel Speedometer gear unit CHASSIS ...

Page 35: ...asher relay Neutral relay A Thread the horn cable through the support of the air filter casing B Thread the installation through the clamps or bridles on the frame C Thread the left hand switch cable through the frame clamps D The mark for installing the system must coincide with the frame clamp A D C B ...

Page 36: ...overflow pipe Engine breather pipe A Clamp the generator cable to the frame B Clamp the neutral switch cable to the frame C Thread the stand and neutral cables through the frame clamps D Thread the following cables through the frame clamp Rear brake switch Stand switch Neutral switch Starter motor E Thread the cables described in point D plus the engine breather pipe through the frame clamp A B D ...

Page 37: ...ead the oil pipe through the frame clamps B Clamp the starter motor cable to the frame C Clamp the cable of the speedometer sensor through the rubber D Clamp the main switch cable the head of the clamp must be at the bottom A B C D ...

Page 38: ......

Page 39: ...INSP ADJ 3 ...

Page 40: ...KET 3 14 INSPECTING THE FUEL HOSES 3 15 INSPECTING THE EXHAUST SYSTEM 3 16 INSPECTING THE LEVEL OF THE COOLANT 3 16 CHANGING THE COOLANT LIQUID 3 17 INSPECTING THE COOLING SYSTEM 3 21 CHASSIS 3 21 ADJUSTING THE REAR BRAKE 3 21 INSPECTING THE BRAKE LIQUID 3 21 BLEEDING THE AIR 3 22 INSPECTING THE BRAKE PADS 3 23 ADJUSTING THE BRAKE LIGHT SWITCH 3 24 INSPECTING THE BRAKE HOSES 3 24 ADJUSTING THE VOL...

Page 41: ...if play is excessive Lubricate with molybdenum bisulphide grease Every 24 000 km 12 Transmission chain Check the chain tension Check that the rear wheel is properly aligned Every 500 km and after washing Clean and grease the motorcycle or using in rain 13 Steering bearings Check the bearing play and to see if the steering is stiff Lubricate with lithium soap based grease Every 24 000 km 14 Chassis...

Page 42: ...ch side cover and take these out 4 Release The seat locking cable ASSEMBLY Follow the same procedure as in DISMAN TLING but inversely Observe the following points 1 Install The side covers left and right hand side and tighten the screws The seat locking cable 2 Install The seat NOTE Insert the projection of the seat into the recess made in the chassis for this purpose and press the seat downwards ...

Page 43: ...Loosen The air screw Partly unscrew this from its slightly abut ting position 3 Start the engine up and let this warm up 4 Connect The engine tachometer to the spark plug cable 5 Check The engine idling speed Out of specification Adjust Engine tachometer 90890 03113 Engine idling speed TZR50 1700 2000 r min Turns the screw should be loose ned 2 1 8 turns ...

Page 44: ...s See the section on FAIRING DISMAN TLING The oil pump cover 2 Adjust The throttle cable 3 Check The free play while keeping the throttle in the idle position This is not adjusted Adjust the pump cable 4 Adjust The pump cable Stages in the Adjustment Loosen the locknut Tighten or loosen the tensor until getting the minimum play in operation Tighten the locknut 5 Check Adjust the cable of the lubri...

Page 45: ... CABLE 1 Check The free play a of the throttle cable Out of specification Adjust 2 Adjust Throttle cable free play Free play of throttle cable 2 5 mm Adjustment steps Loosen the locknut Loosen or tighten the tensor until you get the right free play Tighten Increases the free play Loosen Reduces the free play Loosen the locknut a ...

Page 46: ...pply system is disconnected 1 Remove The oil pump cover 2 Bleed the air From the pump casing and or the oil hose Bleeding air steps Loosen the bleeding screw Start the engine up Let the oil out until the air bubbles disap pear After the air bubbles have been comple tely removed tighten the bleeding screw Stop the engine NOTE Check the O ring of the bleeding screw and if any damage can be seen chan...

Page 47: ...stall the tensor casing INSPECTING THE SPARK PLUG 1 Remove The spark plug 2 Inspect The type of spark plug Incorrect Change 3 Inspect The electrode Wear damage replace The insulation Abnormal colour Replace The normal colour is a medium light beige 4 Clean the spark plug with a special tool for this or with a metal brush 5 Measure The gap between electrodes a Use a wire or feeler gauge This does n...

Page 48: ... 8 6 Tighten The spark plug Before installing a spark plug clean the surfaces of the gasket and of the spark plug itself NOTE Make the sparkplug finger tight before tighte ning this to the specified degree Tightening torque 23 Nm 2 3 m kg ...

Page 49: ...INDICATOR Main switch ON The warning light does not come on Ask the Yamaha MBK dealer to inspect the electrical circuit The warning light comes on Wait a few seconds The warning light goes off The warning light stays on Add engine oil The engine oil level and electrical circuit are OK OIL level indicator CAUTION Always use the same type of engine oil Mixtures of different oils may give rise to det...

Page 50: ...el too low top up with sufficient oil to re establish the right level CAUTION Do not add chemical additives The trans mission oil also lubricates the clutch and the additives could make it slip Make sure that no foreign bodies get into the crankcase CHANGING THE TRANSMISSION OIL 1 Warm up the engine for a few minutes 2 Place an open recipient under the engine 3 Remove The oil filler cap Oil drain ...

Page 51: ...nstall The O ring of the filling cap The oil filler cap ADJUSTING THE CLUTCH 1 Check The clutch lever free play a Out of specified value Adjust 2 Adjust The free play of the clutch lever Oil draing plug 1 7 kg m Recommended oil SAW 0W30 SE type engine oil Total amount 0 82 L Regular oil change 0 75 L Free play 10 15 mm Adjustment steps Loosen the locknut Turn the tensor in one direction or the oth...

Page 52: ...ribed will enable you to get the maximum free play of the clutch cable to be able to adjust the clutch action mechanism properly See the section DISMANTLING THE ENGINE ASSEMBLING AND ADJUSTING THE ENGI NE in CHAPTER 4 CLEANING THE AIR FILTER 1 Remove The seat The side covers left and right hand See the section on SIDE COVERS DISMANTLING 2 Dismantle The fuel tank See the section REMOVING THE ENGI N...

Page 53: ...r element affects the tuning of the carbura tion thus reducing the efficiency and pos sibly making the engine overheat 5 Inspect The filter element Damage replace 6 Clean The air filter element Cleaning steps Wash the element carefully but tho roughly with solvent s s WARNING Never use solvent with an excessively low flash point like petrol to clean the filter element This kind of solvents may lea...

Page 54: ...edge of the element fits in the corresponding slot of the filter box 8 Install Air filter case cover The fuel tank 9 Install The side covers left and right hand The tank The seat See the section on SIDE COVERS ASSEMBLY INSPECTING THE CARBURETTOR GASKET 1 Dismantle The seat The side covers left and right hand See the section on SIDE COVERS DIS MANTLING 2 Dismantle The fuel tank The air filter cse S...

Page 55: ...NTLING THE ENGINE in CHAP TER 4 4 Install The air filter case The fuel tank 5 Install The side covers left and right hand The seat See the section on SIDE COVERS ASSEMBLY INSPECTING THE FUEL HOSES 1 Dismantle The seat The small left hand side cover 2 Inspect The fuel inlet pipe Cracks Damage Replace 3 Install The small left hand side cover The seat ON RES OFF FUEL ...

Page 56: ...place gaskets Leakages of exhaust gases Replace INSPECTING THE COOLANT LEVEL 1 Place the motorcycle on a level surface 2 Inspect The level of coolant The level of coolant is under the mini mum mark Remove panel Add water for the cooling circuit Replacement steps Dismantle the exhaust assembly Install a new exhaust assembly Screw 1 5 kg m Screw 2 3 kg m MIN MAX ...

Page 57: ...CHANGING THE COOLANT s s WARNING Do not remove the radiator cap while this and the engine are hot Hot vapour and liquid could emerge with consequent dan ger of serious injury When the engine has cooled off open the radiator tap as follows place a thick cloth for example a towel over the cap and turn this as far as it will go slowly anti clockwise This procedure will let any residual pressure relea...

Page 58: ...w The radiator cap 4 Remove The drainage screw 5 Drain The coolant NOTE Empty out the coolant with the motorcycle slightly tilted to the right 6 Install The gasket new The drainage screw CAUTION Always install a new gasket Install the gasket as shown in the illustra tion 7 Install The radiator The engine Drainage screw 0 5 kg m ...

Page 59: ...freeze containing corrosion inhibi tors for aluminium engines Coolant and distilled water Mixing proportion 50 50 Total amount 0 7 L Capacity of reservoir tank 0 47 L Notes on handling the coolant liquid The coolant is harmful and should thus be handled with special care s s WARNING If the coolant liquid gets in someone s eyes wash these out thoroughly with water and see a doctor If the coolant sp...

Page 60: ...e coolant into the radiator until the level specified is reached Connect the breather pipe Install the radiator cap Fill the reservoir tank with coolant until the level reaches the MAX maximum mark Start the engine and leave it to warm up Stop the engine and check the coolant liquid level NOTE Wait a few minutes until the coolant liquid level has stabilised before making the check MIN MAX ...

Page 61: ...Check The free play of the brake pedal a Out of specification Adjust 2 Adjust Free play of the rear brake pedal INSPECTING THE BRAKE LIQUID 1 Place the motorcycle on a flat surface 2 Check 3 Brake liquid level The level is under the MIN mark fill up Adjustment steps Turn the adjustment device located in the lever pusher by means of the nut and lock nut system Tighten Increases the free play of the...

Page 62: ...tion in the effectiveness of the brakes Fill up again with liquid of the same type the mixture of different liquids might give rise to detrimental chemical reactions and a consequent drop in efficiency Take care that water does not get into the master cylinder when filling up Water makes the boiling point of the liquid drop considerably and may give rise to an obstruction through vapour BLEEDING T...

Page 63: ... to the end of its travel h Tighten the drain screw when the lever has reached the limit then release the lever i Repeat stages e to h until any air bub bles have disappeared from the system NOTE If you have trouble bleeding the system you might need to leave all the brake system liquid to stand for a few hours Repeat the bleeding procedure when the tiny bubbles contained in the system have disapp...

Page 64: ...the brake pedal This is properly adjusted when the brake light comes on immediately before the brake starts to work 1 Hold the switch body still with your hand so that this does not rotate and turn the adjustment nut in direction b CAUTION After adjusting make sure that this comes on INSPECTING THE BRAKE HOSES 1 Inspect The brake hoses Cracks Wear Damage Replace a b ...

Page 65: ...s not match the specified value Adjust 3 Adjust The drive chain slack a Adjustment steps CAUTION If the chain is too taut the loads on the engine and other vital components increase excessively so keep the chain slack within the limits specified Remove the pin Loosen the axle nut 2 and the locknut Turn the tensor 4 in one direction or the other until the tension specified is obtai ned Tighten Incr...

Page 66: ...Install the pin use a new one Adjust the free play of the brake pedal See ADJUSTING THE REAR BRAKE NOTE Do not loosen the axle nut after tightening to the specified torque If the nut slot does not coincide with the hole for the pin found in the axle line both of these up by tighte ning the nut s s WARNING Always use a new pin for the axle nut Check the operation of the brake light after adjusting ...

Page 67: ...spray the lubri cant between both rows of side plates above all the central rollers 2 To clean the chain take this off the machi ne submerge it in solvent and get rid of all the dirt possible Take the chain out of the solvent and dry it Immediately lubricate this to prevent it from rusting ADJUSTING THE STEERING Inspecting the steering head s s WARNING Stand the motorcycle in a safe place to avoid...

Page 68: ...g ned for this NOTE Apply the torque wrench to the ring nut wrench so that both form a right angle Loosen the ring nut one turn Retighten the ring nut using the special wrench for this s s WARNING Do not tighten excessively Tighten screw steering shaft screw upper shank and screw handle bar Wrench for ring nut 90890 01403 Ring nut initial tightening 2 0 kg m Screw steering shaft 5 6 kg m Clamp scr...

Page 69: ...front wheel placing a suitable support under the engine 2 Remove The rubber cover 3 Loosen The clamp screw handlebar 4 Remove The circlip The plug NOTE Press the plug with an appropriate bar and remove the circlip 1 with a fine screwdriver 5 Remove Forks 6 Drain Oil s s WARNING Do not let the oil get in touch with the com ponents of the disc brake If oil gets on the brake components remove this be...

Page 70: ...place 9 Fill up with Fork oil 10 After filling this pump the fork up and down slowly to distribute the oil 11 Install The plug The circlip s s WARNING Always use a new circlip 12 Tighten The clamp screw upper and lower stee ring shank Oil capacity of the front fork each arm 235 cm3 Recommended oil 10W fork oil or equivalent Clamp screw upper steering shank 2 2 kg m ...

Page 71: ... tire pressure must be checked and adjusted when the tire is at ambient tempe rature This must be adjusted depending on the total weight of the equipment driver and accessories fairing cases etc if these have been approved for this model as well as on the speed of the vehicle 2 Inspect The surfaces of the tires Wear damage replace 1 Depth of the tread 2 Lateral 3 Wear indicator s s WARNING It is d...

Page 72: ...ing the tire or the wheel always balance the wheel s s WARNING Do not attempt to repair a deffective wheel INSPECTING CABLES 1 Inspect The throttle cable The tachometer cable The clutch cable The speedometer cable Check any damage in the cable sheaths Corrosion Damage Replace Obstruction Change the route Lack of smoothness Lubricate ...

Page 73: ...f the other end Leave any excess oil to drain off and then reinstall the cable Lubrication of levers and pedals Lubricate the rotating parts of each lever and pedal Lubrication of the side stand Lubricate the rotating parts Lubricating the swingarm Lubricate the rotating points of the swingarm Engine oil SAE 10W30 of SE type Engine oil SE type SAE 10W30 Engine oil SE type SAE 10W30 Grease Light wi...

Page 74: ...on Correct NOTE After cleaning the terminals apply grease lightly Change the battery in the following case When the voltage does not reach the value specified even after many hours charging CAUTION This battery is the M F no maintenance type Never take the cover off After sealing when inserting the electrolyte this should never be opened again M F battery charger 90890 03150 ...

Page 75: ...xternal SKIN Wash with water EYES Wash off with water for 15 minutes and immediately consult the doctor Antidote INTERNAL Drink large amounts of water or milk followed by milk of magnesia beaten egg or vegetable oil Immediately see a doctor Batteries ALSO generate explosive hydro gen gas for which reason the preventive measures must always be taken Charge batteries in a well ventilated area Keep b...

Page 76: ... check if the continuity is correct NOTE Place the tester selector in position Ω X 1 If the tester indicates the fuse will have blown change this 4 Replace The blown fuse s s WARNING Do not use fuses with a higher amperage than the value specified Installing a fuse with the wrong amperage could cause damage to the electrical sys tem and even fires Pocket tester 90890 03112 ...

Page 77: ...G THE LEFT HAND HEADLIGHT BEAM 1 Repeat the same operations as for the right hand headlight CHANGING A HEADLIGHT BULB 1 Remove The dust cover and the connection 2 Take out The bulb s s WARNING Keep the bulb away from inflammable pro ducts and the hands while this is on since it will be hot Do not touch the bulb until it has gone cold 3 Install The bulb a new one Install the bulb in the bulb socket...

Page 78: ...ENG 4 ...

Page 79: ...N AND PISTON 4 12 CRANKCASE 4 12 SELECTOR AND SHIFT 4 13 CRANKSHAFT 4 13 BEARINGS AND OIL SEALS 4 14 INSPECTION AND REPAIR 4 14 CYLINDER HEAD 4 14 PISTON 4 15 CYLINDER 4 16 PISTON RINGS 4 17 PISTON PIN AND BEARING 4 17 AUTOLUBE PUMP 4 18 CLUTCH 4 18 SELECTOR 4 20 SHIFT 4 20 CRANKSHAFT 4 21 REVOLUTION COUNTER SENDER 4 21 BEARINGS AND OIL SEALS 4 22 CRANKCASE 4 22 ASSEMBLING AND ADJUSTING THE ENGINE...

Page 80: ... other items that have been coupled due to common wear These items must be installed as an assembly or should be replaced by new ones 3 When dismantling the engine clean all the parts and place these in trays in the dis mantling order This will reduce the assembly time and ensure that all the parts removed are properly fitted in the engine again 4 Remove the lower fairing Place the engine on a sui...

Page 81: ...nk as shown in the drawing and remove the tray and the fuel overflow pipe from its original posi tion NOTE Do not remove the lower part of the overflow pipe from its original position 5 Locate the fuel tap in the closed position OFF and take the lever out of this 6 Provisionally lift up the fuel tank and its cover disconnect the fuel pipe and remo ve the tank and the cover ON RES OFF FUEL ON RES O...

Page 82: ...ENG REMOVING THE ENGINE 4 3 AIR FILTER 1 Remove Securing screw 2 Take out Clip 3 Disconnect Rubber pipe 4 Remove Filter casing ...

Page 83: ... 4 4 EXHAUST PIPE 1 Remove Springs Clamp of the AIS system 2 Remove Exhaust pipe screws and Exhaust pipe COOLANT PIPES 1 Remove Fairing Drainage screw 2 Drain Coolant liquid 3 Disconnect Coolant pipe inlet Coolant pipe outlet ...

Page 84: ... cable 2 Loosen Spark plug CDI CABLE 1 Disconnect CDI cable NEUTRAL SWITCH CABLE 1 Disconnect Neutral switch cable OIL PUMP 1 Remove Cover of the oil pump 2 Remove Cable of the oil pump 3 Disconnect Oil inlet tube to the pump NOTE Plug the oil inlet pipe to the pump so the oil from the tank does not get out ...

Page 85: ...pplying the oil pump Coolant pipes Starter cover Starter cable 3 Remove Carburetor Carburetor joint Plate casing NOTE Cover the carburetor with a clean cloth to pre vent dirt from getting into this SHIFT CAM DRIVE CHAIN AND CLUTCH CABLE 1 Remove Shift cam Pinion cover 2 Loosen Rear axle nut Chain tensor Drive chain 3 Remove Drive chain ...

Page 86: ...bar lever REMOVING THE ENGINE 1 Remove Front engine mounting screw Rear lower engine mounting screw Rear upper engine mounting screw Engine assembly OIL PUMP 1 Remove Oil pump cover Oil pump assembly WATER PUMP COVER 1 Remove Water pump cover Water pump cover gasket RIGHT CRANKCASE COVER OIL PUMP SHAFT AND WATER PUMP SHAFT 1 Remove Right hand oil pump cover ...

Page 87: ...ntermediate gear 15 Washer 16 3 Remove Locators Gasket CLUTCH AND PRIMARY TRACTION GEA RING 1 Remove Securing screws for the clutch springs Clutch springs Pressure plate Push rod nº 1 Friction discs Clutch discs 2 Remove Push rod ball Push rod Nº 2 Shaft set of the clutch push lever 3 Loosen Safety nut of the clutch casing Use the universal clutch holder 90890 04086 to hold the clutch cone ...

Page 88: ...ention to the position of the conical spring washer Install as shown in the figu re 5 Loosen Balancer shaft nut 6 Remove Primary traction gear nut Primary traction gear Key Balancer shaft drive gear Balancer shaft washer and nut Balancer shaft driven gear Key 7 Remove Washer Tachometer worm gear Washer 8 Remove Magnetic flywheel cover Neutral switch ...

Page 89: ...nut 2 Remove CDI flywheel Crankshaft key Stator coils Coil holder plate NOTE Mark the coil holder plate and the crankcase with a pointed instrument STARTER MOTOR 1 Remove Securing screws Use the flywheel holding tool 90890 01235 Use the flywheel extractor tool 90890 01189 and the flywheel fixer 90890 01235 ...

Page 90: ...n the drawing a b c d loosen each screw of a turn and then fully unscrew them 2 Remove Cylinder head O rings Thermostat s s WARNING Handle the thermocontact with special care Do not grip it too tightly or drop it If it is dropped it must be replaced with a new one 3 Remove Cylinder 4 Remove Cylinder gasket 5 Remove Reed valve assembly a b c d ...

Page 91: ... the pin remove any burrs from the slot of the clip and the pin hole If it were still difficult to take out the pin after removing any burrs use the piston pin extrac tor 90980 01304 CAUTION Do not use a hammer to take out the piston pin CRANKCASE 1 Take out Circlip The output gear Circlip 2 Take out The crankcase securing screws NOTE Loosen each of the screws a quarter of a turn Then unscrew them...

Page 92: ... not come apart make sure that no screws or locator have been left in Do not force this 4 Take out Locators 5 Take out Balancing shaft SELECTOR AND SHIFT 1 Take out Guide bars Secondary shaft primary shaft selector cam and set of selector forks Shift selector NOTE Take note of the position of each part Pay special attention to the location and direction of the selector forks CRANKSHAFT 1 Take out ...

Page 93: ...screwdriver so as not to damage the crankcase 2 Take out The bearings NOTE To facilitate removal and installing first heat up the crankcase to roughly 95 125ºC Heat it up slowly to this temperature INSPECTION AND REPAIR CYLINDER HEAD 1 Eliminate Any carbon deposited Use a rounded scrap NOTE Do not use any sharp tool and avoid damaging or scratching the Spark plug thread Cylinder head 2 Inspect Cyl...

Page 94: ...is down in a figure eight shape NOTE Turn the cylinder head round several times so as not to take too much material off only one side PISTON 1 Eliminate Any carbon deposited on the piston and the ring slots 2 Eliminate Scratches and deposits found on the wall of the piston Use nº 600 800 water sandpaper NOTE Sand this in a cross shape and do not sand excessively 3 Inspect The piston wall Wear Scra...

Page 95: ...se internal gauge C D maximun T D1 or D2 maximum D5 or D6 minimum R D1 D3 or D5 maxim D2 D4 or D6 minimum 4 Measure Outside piston diameter P Outside specifications Replace Use the micrometer NOTE The measurement should be taken 5 mm from the lower edge of the piston Size Standard 40 25 mm Oversize 1 40 6 mm Oversize 2 40 8 mm Diameter of cylinder C Diameter of cylinder T Ovalling R Standard 40 29...

Page 96: ...e thickness gauge 2 Install The piston ring in the slot for the ring Push the ring with the piston crown 3 Measure Clearance between ends Out of specifications Change set of rings Use the feeler gauge PISTON PIN AND BEARING 1 Lubricate The piston pin The bearing 2 Install The piston pin Bearing on the little end Piston clearance C P 0 049 0 062 mm Feeler gauge 90890 03079 Clearance between ends Up...

Page 97: ... and bearing Blued by heat Replace AUTOLUBE PUMP Wear or an internal malfunction may alter the factory set flow of the pump However this is not a very common situation If you suspect the flow is incorrect check the following items 1 Check Feed pipe Obstruction Clear Supply pipe Obstruction Unblock Autolube pump Damaged Change 2 Inspect If there is air There is air Bleed Flow Minimum outlet 200 str...

Page 98: ...Warpage of the clutch disc Out of specifications Change the full set of clutch discs Use the surface and feeler gauge 5 Measure Free length of the clutch spring Out of specifications Change the full set of springs 6 Measure Run out long rod Out of specifications Replace Use V blocks and a comparator 90890 03097 Wear limit 2 7 mm Warpage limit 0 05 mm 0 002 inches Minimum length of clutch spring 30...

Page 99: ... operation SELECTOR 1 Inspect Return spring of the selector Damaged Change Shift shaft Damaged Curved Worn Change CHANGE 1 Inspect Forks of the selector contact surface of the gearing and the selector cam Wear Scraping Curved Damaged Change Guide bars Curved Worn Change 2 Check Movement of the selector forks in their respective guide bar Operation not smooth Change selec tor fork and or bar guide ...

Page 100: ...easure Run out limit C Clearance of the con rod big end D Limit of play of the con rod little end F Outside specifications Change Use V blocks the Comparator 90890 03097 and a feeler gauge TACHOMETER GEAR 1 Inspect Drive gear and driven gear Damaged worn Change 2 Check Operation of the sender Operation stiff Change Eccentricity limit 0 08 mm Width between blades A 41 90 42 00 mm Eccentricity limit...

Page 101: ...ed Damaged Change Oil seal lips Damaged Worn Change CRANKCASE 1 Thoroughly wash the halves of the crank case with mild solvent 2 Clean the whole surface of the joints and the crankcase 3 Inspect Crankcase Cracks Damaged Change Oil supply conduits blocked Unblock with compressed air ...

Page 102: ... 16 Bearing Bearing 10 Circlip 17 Bearing Bearing 11 Bearing 18 Gear Seal 12 Key 19 Key Seal 13 Key Piston 14 Traction gearing D CRANKSHAFT A 41 90 42 0 mm C 0 03 mm D 0 015 0 026 mm F 0 20 0 61 mm A CLEARANCE BETWEEN PISTON AND CYLINDER 0 49 0 62 mm B PISTON RING END GAP 0 15 0 30 mm C LATERAL CLEARANCE OF PIS TON RING 0 03 0 06mm ...

Page 103: ...e lips of the oil ring and engine oil on each bearing 1 Position Crankshaft installing tool 90890 01274 90890 01278 2 Assemble Crankshaft on the left hand side of the crankcase NOTE Hold the con rod at top dead centre with one hand while you use your other hand to turn the nut of the tool until the crankshaft has gone all the way and touches the bea ring ...

Page 104: ...gear 21 Washer 6th gear 13 4th wheel gear 22 Circlip 2nd gear 14 3rd wheel gear 23 Bearing Circlip 15 6th wheel gear 24 Bearing Circlip 16 2nd wheel gear 25 Seal Bearing 17 Circlip 26 Sprocket Bearing 18 Washer 27 Circlip SHIFT AND SELECTOR SHIFT A RUN OUT LIMIT OF THE SECONDARY SHAFT 0 02 mm B RUN OUT LIMIT OF THE PRIMARY SHAFT 0 02 mm ...

Page 105: ...ENG ASSEMBLING AND ADJUSTING THE ENGINE 4 26 SELECTOR Shift drum Shift fork guide bar 1 Washer 10 Shift fork guide bar 2 Neutral 11 Washer Spring 12 Nut Ball Shift fork 1 Shift fork 2 Shift fork 3 ...

Page 106: ...ctor and balancer shaft in the right hand half of the crankcase NOTE It is highly important to follow the assembly sequence as stated in the breakdown of the SHIFT AND SELECTOR section 3 Check Operation of the selector Operates incorrectly Repair CRANKCASE 1 Apply Yamaha Bond nº 4 paste 90890 05143 on the sealing surfaces of the two hal ves 2 Install Locators 3 Install the left hand crankcase gent...

Page 107: ...by manually turning the selector cam in both directions 4 Tighten Crankcase securing screws following a crisscross pattern 5 Apply 2 stroke engine oil to the crankshaft pin bearing and oil feed bore 6 Check Operation of the crankshaft and shift This works incorrectly repair 7 Install Neutral switch 8 Install Circlip Sprocket Circlip Crankcase securing screws 1 0 m kg ...

Page 108: ...ENG ASSEMBLING AND ADJUSTING THE ENGINE 4 29 STARTER MOTOR Starter motor Screw Magnetic flywheel Screw Nut ...

Page 109: ...Starter motor 2 Install Coil plate in the crankcase CAUTION Install the coil holder plate so that the marks on the plate and on the crankcase made during the dismantling process coin cide CDI MAGNETO 1 Install Coil plate 2 Install Key CDI flywheel Nut Coil screw 0 9 m kg ...

Page 110: ...w with washer 21 Ball Nut 13 Pusher plate 22 Push rod 2 Clutch housing 14 Conical washer 23 Push lever shaft Thrust washer 15 Conical washer 24 Spring Clutch boss 16 Nut 25 Flat washer Friction disc 17 Pusher plate 26 Seal Clutch disc 18 Push rod 1 A LIMIT OF FREE LENGTH OF CLUTCH SPRING 30 0 mm B LIMIT OF FRICTION DISC WEAR 2 7 mm C LIMIT OF DISC WARPAGE 0 05 mm ...

Page 111: ...lso tighten the nuts of the balancer shaft and that of the crankshaft gear 1 Install Washer Tachometer gear Washer 2 Install Key Driven gear of balancer Washer Nut 3 Install O ring Bush Drive gear Key Primary transmission gear Nut NOTE The driven and drive gears must have the two marks aligned CDI magneto nut 5 2 m kg Crankshaft gear nut 6 0 m kg ...

Page 112: ...h boss Washer Clutch boss nut 5 Tighten Clutch boss nut Use the universal clutch holder 6 Install Shaft assembly of the clutch push lever Push rod nº Ball of the push rod ASSEMBLING AND ADJUSTING THE ENGINE Clutch boss nut 7 5 m kg Clutch holder 90890 04086 To hold the clutch boss ...

Page 113: ...clutch discs and the friction discs alternately in the clutch boss starting and ending with a friction disc Install the clutch discs so that each of these is 120º offset with the previous one NOTE Line up the engraved mark of the clutch boss with the arrow of the clutch pressure plate ASSEMBLING AND ADJUSTING THE ENGINE Clutch spring securing screw 0 4 m kg ...

Page 114: ...the screw 1 4 turn Tighten the locknut SHAFT OF THE WATER PUMP SHAFT OF THE OIL PUMP AND RIGHT HAND CRANK CASE COVER 1 Install Locators Gasket 2 Install Washer 16 Intermediate gearing 15 Washer 14 Clip 13 Washer 12 Oil pump shaft 11 Washer 10 Pin Driven gear of oil pump Clip Water pump shaft Washer Pin Driven gear of water pump Washer Clip ...

Page 115: ...r gasket Water pump cover 2 Install Screws for water pump cover NOTE Use a new washer on the coolant drain screw OIL PUMP 1 Install Oil pump assembly Oil pump cover 2 Connect Tube for oil supply to the carburettor Tube for oil inlet to the pump 3 Bleed Lubrication pump bleed screw Screws of the crankcase cover 1 0 m kg Screws for the water pump cover 0 5 m kg Pump securing screw 0 7 m kg Cover sec...

Page 116: ...2 Install Con rod little end bearing Piston Piston pin Piston pin clip NOTE The arrow marked on the piston must point to the front of the engine Before installing the piston pin clip cover the crankcase with a clean cloth so that neither the piston clip nor anything else can fall inside the crankcase Always use a new piston pin clip NEW ...

Page 117: ...park plug 10 Flat washer Water pipe 11 Cylinder Head gasket 12 Cylinder gasket Head gasket 13 Thermostat ASSEMBLING AND ADJUSTING THE ENGINE A SPARK PLUG GAP 0 6 0 7 mm B STANDARD SPARK PLUG BR9ES NGK 2 0 m kg C LIMIT OF CYLINDER HEAD WAR PAGE 0 03 mm ...

Page 118: ...facturer number engraved on the rings are on the top side of these Before installing the cylinder apply a good layer of 2 stroke engine oil to the piston rings 2 Install Cylinder NOTE Install the cylinder with one hand while you tighten the piston rings with the other 3 Install Locators 2 units O rings Thermostat ...

Page 119: ...ermocontact 8 Install Reed valve assembly NOTE Tighten the screws for securing the reed valve in a crisscross pattern 9 Install Carburetor Connect all the pipes oil water etc Starter cable 10 Install C D I magnetic flywheel cover INSTALLING THE ENGINE When you install the engine follow the remo val process inversely Pay attention to the following points 1 Install Engine assembly screws Engine asse...

Page 120: ...all Oil pump cover Spark plug Exhaust pipe Springs AIS pipe 5 Add Transmission oil Coolant Screws for securing crankcase cover 2 0 5 m kg Screws for securing output gear cover 0 5 m kg Shift cam screw 0 6 m kg Pump cover securing screw 0 4 m kg Spark plug 2 0 m kg Screws for securing the exhaust pipe to the chassis 2 1 m kg 3 0 m kg Transmission oil total 0 82 L Total amount of coolant 0 7 L Screw...

Page 121: ...ENG ASSEMBLING AND ADJUSTING THE ENGINE 4 42 6 Inspect Oil leaks Coolant leaks 7 Connect Neutral cable NOTE Before starting the engine up bleed the lubri cation system ...

Page 122: ......

Page 123: ...COOL 5 ...

Page 124: ...CHAPTER 5 COOLANT SYSTEM CHANGING THE COOLANT 5 1 WATER PUMP 5 3 DISMANTLING 5 4 INSPECTION 5 5 ASSEMBLY 5 6 THERMOSTAT AND RADIATOR 5 8 INSPECTION 5 9 ASSEMBLY 5 10 COOL ...

Page 125: ... over the cap and turn this as far as it will go slowly to the left This procedure will let any residual pressure release When the whistling sound has stopped tighten the cap downwards making it turn left at the same time to open it 1 Place an open recipient under the engine 2 Wait until the radiator cools down 3 Take off Radiator cap 4 Remove Drain screw 5 Drain Coolant completely NOTE Fully wash...

Page 126: ... the top of the radiator 12 Fill up with Coolant Top up the coolant up to the FULL level in the expansion tank 13 Install Radiator cap 14 Inspect Coolant system Leakage of coolant Repair CAUTION Before starting up the engine always check the coolant level and see if there are any leakages of this Drain screw water pump cover 1 4 m kg Recommended coolant High quality ethylene glycol anti freeze sol...

Page 127: ...ER PUMP Impeller shaft Gasket Oil seal 10 Screw Pin 11 Screw Washer 12 Drain screw Circlip 13 Gasket Impeller shaft gear 14 Connection Cover of the water pump body 15 O ring Locator 16 Screw A USE A NEW ONE 1 6 m kg 1 0 m kg A USE A NEW ONE ...

Page 128: ...erved such as excessive variations in temperature and or volume of the coolant liquid its decolouring or a milky look to the transmission oil 1 Drain Crankcase See the section on CHANGING THE TRANSMISSION OIL in CHAPTER 3 Cooling system See the section on CHANGING THE COOLANT in CHAPTER 3 2 Remove The output hose ...

Page 129: ...aking care that this does not splash the autolube pump 4 Dismantle The circlip The gear of the impeller shaft The flat washer 5 Dismantle The pin The flat washer 6 Dismantle The impeller shaft 7 Eliminate any deposits incrusted on the shaft and the body of the water pump INSPECTION 1 Inspection The impeller Cracks wear damage replace ...

Page 130: ...ver tapping this lightly outwards Install the new seal with the WATER SIDE mark outwards NOTE Apply light lithium grease to the outside of the oil seal Press install the seal until it comes into contact with the base ASSEMBLY Apply the DISMANTLING procedure inversely bearing in mind the following points 1 Apply Light lithium grease to the lips of the seal and to the impeller shaft ...

Page 131: ...e cover right hand The cover of the water pump body CAUTION Always use new gaskets 4 Fill up The transmission oil See the section on CHANGING THE TRANSMISSION OIL in CHAPTER 3 The coolant See the section on CHAN GING THE COOLANT in Chapter 3 5 Bleed the air Autolube pump See the section on BLEEDING THE AIR FROM THE AUTOMATIC MIXING PUMP in CHAPTER 3 Screw crankcase cover 0 5 kg m Screw water pump ...

Page 132: ...D RADIATOR Radiator Protector ring Cap Bush Stop Protector ring Bolt Screw Washer 10 Washer B COOLANT CAPACITY Including all the conduits 0 7 L C THERMOSTAT OPENING TEMPERATURE 98 ºC A OPENING PRESSURE OF THE RADIATOR CAP 0 75 1 05 KG CM2 0 8 m kg ...

Page 133: ... 3 Measure The opening pressure of the radiator cap Measurement steps Connect the tester of the cooling sys tem and the adapter to the radiator cap Apply the specified pressure for ten seconds and make sure that this does not drop 4 Inspect The thermostat See the section on DISMANTLING THE ENGINE in CHAPTER 4 CYLINDER HEAD AND CYLINDER The valve does not open replace Radiator cap opening pressure ...

Page 134: ...t is sealed and rating this is a job for a specialist If you have any doubts about its accuracy replace it A faulty valve could cause very harmful overheating or over cooling ASSEMBLY Follow the same procedure as in DISMAN TLING but inversely Take into account the following points 1 Tighten The screws of the thermostat 2 Assemble The radiator 3 Tighten The screws radiator Screws of the thermostat ...

Page 135: ... THE COOLANT in CHAPTER 3 5 Inspect The cooling system Reduce the pressure leaks Repair as required Inspection steps Connect the cooling system tester to the radiator Apply 1 0 kg cm2 pressure Measure the pressure with the manometer 6 Install The seat Cooling system tester 90890 01325 ...

Page 136: ...CARB 6 ...

Page 137: ...ATION CARBURETOR 6 1 REMOVAL 6 2 DISMANTLING 6 2 INSPECTION 6 2 ASSEMBLY 6 3 INSTALLATION 6 3 ADJUSTING THE PETROL LEVEL 6 3 REED VALVE 6 4 REMOVAL 6 4 DISMANTLING 6 4 INSPECTION 6 4 ASSEMBLY 6 5 INSTALLATION 6 6 CARB ...

Page 138: ...r 14 Spring Carburetor cover 13 Casing Needle valve 15 Choke jet Float chamber 24 Idling screw Main jet 27 Float pin Diffuser 26 Float 10 Idling jet SPECIFICATIONS Main jet M J 88 Pilot air screw P A S 2 1 8 Fuel level F L 13 14 mm Idling speed 1850 150 ...

Page 139: ...Float chamber Float pin Float Water valve Gasket Main jet Idling jet Choke jet INSPECTION 1 Inspect Carburetor body Dirty clean NOTE Use a petroleum type solvent for cleaning Clean all the holes and jets with compressed air 2 Inspect Valve seat float valve Wear Dirt Change NOTE Always change the float chamber valve and valve seat as a set ...

Page 140: ...ert the plunger into the carburetor body 6 Inspect Float Damaged Change O ring Damaged Change ASSEMBLY 1 Install Follow the dismantling procedure inver sely INSTALLATION 1 Install Carburetor assembly Apply the removal procedure inversely ADJUSTING THE FUEL LEVEL 1 Measure Float height Outside specifications Service Float height FH 13 14 mm ...

Page 141: ...ve assembly See the engine removal section DISMANTLING 1 Remove Reed valve stop Reed valve INSPECTION 1 Inspect Rubber gasket Deteriorated Change Reed valve Ageing cracks Change Inspection steps Visually inspect the reed valve NOTE A proper reed valve should install in aligned or almost aligned with the neoprene base In the event of any doubt about sealing apply suction to the part in the carburet...

Page 142: ...e specifications Change ASSEMBLY When the reed valve is fitted apply the dis mantling procedure inversely 1 Install The reed valve The reed valve stop NOTE Pay attention to the cut at the lower corner of the reed and the reed stop 2 Tighten Safety screws of the reed valve NOTE Tighten each screw gradually to prevent defor mations Height of the valve stop 6 28 mm Curve limit of the reed valve 0 4 0...

Page 143: ...ve follow the procedure for removal inversely Pay attention to the follo wing points 1 Install A new gasket 2 Tighten Safety screws of the reed valve body NOTE Tighten each screw gradually to prevent defor mation Safety screws of the reed valve body 0 8 m kg ...

Page 144: ......

Page 145: ...CHAS 7 ...

Page 146: ...D REPAIRING THE BRAKE 7 15 ASSEMBLY 7 17 FRONT FORK 7 20 REMOVAL 7 21 DISMANTLING 7 22 INSPECTION 7 22 ASSEMBLY 7 24 INSTALLATION 7 28 STEERING HEAD AND HANDLEBARS 7 29 DISMANTLING 7 31 INSPECTION 7 31 ASSEMBLY 7 34 REAR SHOCK ABSORBER AND SWINGING ARM 7 40 OBSERVATIONS ON HANDLING 7 41 OBSERVATIONS ON ELIMINATION 7 41 DISMANTLING 7 42 INSPECTION 7 44 ASSEMBLY 7 44 CHAIN AND TRANSMISSION CROWN WHE...

Page 147: ... MAXIMUM LOAD 195 kg 428 pounds COLD TIRE PRESSURE FRONT REAR UP TO 90 KG 198 pounds load 1 8 kg cm2 2 0 kg cm2 FROM 90 kg 198 pounds MAX LOAD 1 9 kg cm2 2 3 kg cm2 Load means the total weight of equipment driver and accessories A TIRE SIZES 100 80 17 B WHEEL SIZES MT 2 75 X 17 C RUN OUT LIMIT OF THE WHEEL D VERTICAL 1 0 mm E LATERAL 1 0 mm 65 Nm 6 5 m kg 1 7 2 4 5 6 3 3 ...

Page 148: ...ot press the brake lever without the wheel being fitted on the motorcycle since if you do the pads would be in contact 3 Loosen The pressure bolt The screw wheel axle 4 Dismantle The axle of the front wheel The front wheel INSPECTION 1 Inspect The tire The running strip of the tire has transver sal strips minimum tread pattern depth Cracks Replace Depth of tread pattern Lateral wall Wear indicator...

Page 149: ...ure The run out of the wheel This does not coincide with what is spe cified Check the play of the wheel and bearing 6 Check The wheel bearings The bearings have some play at the wheel hub or are hard to turn Replace Replacing steps Clean the outside of the wheel hub Dismantle the bearing with a universal extractor Install the new bearing NOTE Use a socket wrench the right size for the outer diamet...

Page 150: ...heel unbalanced Install the relevant balancing counterweights at the lightest part top NOTE Balance the wheel with the brake disc fit ted s s WARNING After installing a tire drive carefully until it adapts to the wheel properly If this is not done there could be an accident possibly damaging the motorcycle and injuring the rider After repairing or replacing a tire tighten the locknut of the valve ...

Page 151: ...ometer sensor NOTE Make sure that the projections on the insi de of the sensor coincide with the flat sides of the wheel hub 3 Assemble The front wheel assembly NOTE Make sure that the projection of the fork cylinder fits in correctly with the sensor positioning slot 4 Tighten The wheel axle The pressure bolt The screws brake caliper Wheel axle 6 5 m kg Pressure bolt 2 3 km kg Screws brake caliper...

Page 152: ... Bearing 12 Wheel axle Bearing 13 Chain tensioner Rear wheel sprocket 14 Screw Washer 15 Nut Screw 16 Nut Seal 17 Key Seal 18 Bush A TIRE SIZE 130 70 17 B WHEEL SIZE 3 50 MT X 17 C RUN OUT LIMIT OF THE WHEEL E VERTICAL 2 0 mm 0 08 inch F LATERAL 2 0 mm 0 08 inch G USE A NEW ONE ...

Page 153: ... The nut wheel axle The chain tensioner The wheel axle 3 Dismantle The rear wheel NOTE Before removing the rear wheel push this forwards and dismantle the transmission chain NOTE Do not press the brake lever without the wheel being fitted as this would mean the pads would be in contact INSPECTION 1 Inspect The tire The rear wheel axle The wheel See the section on FRONT WHEEL INSPECTION ...

Page 154: ...ply the same procedure as for dismantling but inversely Take into account the following points 1 Apply Lithium grease Apply the grease lightly to the lips of the oil seal 2 Adjust The transmission chain tension with the rear wheel resting on the ground See the section on TIGHTENING THE TRANSMISSION CHAIN in CHAPTER 3 3 Tighten The axle nut The locknut wheel axle Transmission chain tension 20 25 mm...

Page 155: ... 9 4 Install The pin a new one s s WARNING Always use a new pin for the wheel axle 5 Adjust The free play of the brake pedal See the section on ADJUSTING THE REAR BRAKE in CHAPTER 3 Free play of the brake pedal 10 15 mm ...

Page 156: ...FRONT BRAKE Disc brake Drain screw Screw Pin Complete brake caliper Through screw Complete pistons Seal Brake pads 10 Screw C WEAR LIMIT OF THE BRAKE DISC 3 5 mm B WEAR LIMIT OF THE BRAKE PADS 0 5 mm A CHANGE AS AN ASSEMBLY ...

Page 157: ... this clean it and then fill it and bleed it properly Do not use solvents to clean the components Solvents make seals swell and deform Only use clean brake liquid for cleaning Take care with brake liquid as this is harm ful for the eyes and damages painted surfa ces and plastic parts CHANGING THE BRAKE PADS NOTE To change the brake pads the line does not need to be taken off 1 Dismantle The screws...

Page 158: ...imit 3 Firmly connect a suitable tube 1 to the caliper bleeding screw Then insert the other end of the tube into an open reci pient 4 Unscrew the bleed screw of the caliper and press the piston with your finger to make it go into this 5 Tighten The caliper bleeding screw 6 Assembly The brake pads new The retaining screw The retaining pin Wear limit 0 5 mm Caliper bleeding screw 0 5 m kg M a ...

Page 159: ...CHAPTER 3 9 Check The operation of the brake lever If this is soft or spongy bleed the brake sys tem See the section on BLEEDING THE AIR in CHAPTER 3 DISMANTLING THE CALIPER 1 Remove The coupling screw The copper washers NOTE Place the open end of the line in a recipient and carefully pump to remove the old liquid Screws brake caliper 3 5 kg m min ...

Page 160: ...the caliper Insert the piston a few mm and lock it with a cloth to prevent it from getting out Repeat the previous steps with the piston for the right hand side to force it out of the caliper s s WARNING Never attempt to take the piston out of the caliper by levering this with a tool Cover the piston with a cloth Take care to avoid injuries by the piston being ejected out of the cylinder 4 Remove ...

Page 161: ...t of pump components INSPECTION AND REPAIR s s WARNING The internal items should be cleaned only with unused brake liquid Do not use sol vents because these would make the seals expand and deform Recommended schedule for replacing the brake components Pads As required Piston seals and Every two years dustcover Lines Every four years Brake lines Change only when the brake is disman tled ...

Page 162: ...stons of the caliper Rusting Wear Damage Replace s s WARNING Change the piston seals whenever the cali per is dismantled 3 Inspect Set of pump components Pump body Scratching Wear Replace Brake line Cracks Wear Damage Replace 4 Inspect The brake disc If this does not match the value specified Replace Wear limit 0 5 mm Maximum deviation A 0 15 mm Minimum disc thickness B 3 5 mm A B M a ...

Page 163: ...ted with brake liquid when assembled Change the piston seals whenever the caliper is dismantled 1 Assemble The seals The pistons The screws 2 Assemble The retaining pin The retaining screw The brake caliper See the section on CHANGING THE BRAKE PADS 3 Assemble The set of pump components The circlip Brake liquid DOT nº 4 Screw brake caliper 3 5 kg m ...

Page 164: ...5 Assemble The line The copper washers The coupling screw s s WARNING Always use new copper washers 6 Assemble The brake switch The brake lever NOTE Apply lithium soap grease to the brake lever rotation spindle Screws pump support 0 9 kg m Coupling screws 2 6 kg m ...

Page 165: ...g efficiency Always fill up with brake liquid of the same type mixing liquids could give rise to harmful chemical reactions and reduce efficiency Take care that water does not get into the master cylinder when filling up Water considerably reduces the boiling tempe rature of the liquid and could give rise to obstruction through bubbles 8 Assemble The rubber seal The pump cover 9 Bleed The air See ...

Page 166: ...pe Damper rod full cylinder 16 Draining screw Rebound spring 17 Screw Damper rod Inner tube 18 Steering axle A OIL CAPACITY OF THE FORK EACH LEG 235 cm2 B OIL LEVEL IN THE FORK FROM THE TOP OF THE INNER TUBE FULLY COM PRESSED WITHOUT THE FORK SPRING 154 mm C RECOMMENDED OIL FORK OIL 10 WT E USE A NEW ONE E USE A NEW ONE E USE A NEW ONE 2 4 m kg D FREE HEIGHT OF THE FORK SPRING LIMIT 515 mm 3 0 m k...

Page 167: ...appro priate support under the engine 2 Dismantle The front wheel See the section on DISMANTLING THE FRONT WHEEL 3 Dismantle The front mudguard 4 Dismantle The lever left hand The lever right hand 5 Loosen The clamp screw left hand The clamp screw right hand 6 Loosen The clamp screw lower shank s s WARNING Hold the fork before loosening the clamp screw ...

Page 168: ...k spring Dismantling steps Hold the fork leg in a vertical position Hold the inner tube in a vice with soft clamps CAUTION Do not damage the surface of the inter nal tube Apply pressure to the plug with a sui table bar Keep the plug in position and remove the clip with a fine screwdriver Remove the plug and the fork spring Install a tray for the oil under the fork place this upside down and drain ...

Page 169: ... scratch the inner tube 4 Remove The screw damper rod Use the fixing tool and the T tool to lock the damper rod 5 Dismantle The inner tube The damper rod 6 Dismantle The conical spindle Guide bush Oil seal CAUTION When dismantling the oil seal and the guide bush do not scratch the wall of the outer tube T tool 90890 01326 Fixing tool 90890 01294 ...

Page 170: ...e Scratching Deformations Damage Replace Fork spring If this exceeds the limit specified Replace 2 Inspect The damper rod Wear Damage Replace Dirt Blow all the items with compres sed air 3 Inspect The O ring of the plug The tapered spindle Damage Replace ASSEMBLY Apply the same procedure as for DISMAN TLING but inversely Take into account the following points Free height of the fork spring limit 5...

Page 171: ...Install The fork spring The damper rod Let the rod slide slowly along the tube until it comes out of the bottom Tapered spindle Install the tapered spindle over the dam per rod coming out at the end of the inner tube 2 Install The inner tube in the cylinder outer tube 3 Tighten The screw damping pipe Use the fixing tool and the T tool to lock the damper rod T tool 90890 01326 Fixing tool 90890 012...

Page 172: ...unterweight for installing the fork seals and the adapter 6 Fill up the fork NOTE After filling the fork up with oil pump this slowly up and down to distribute this Counterweight for installing the fork seals 90890 01367 Adapter 90890 01400 Counterweight for installing the fork seals 90890 01367 Adapter 90890 01400 Capacity of fork oil 235 cm2 Type 10W or equivalent fork oil ...

Page 173: ...old the fork leg up vertically Set the inner pipe in a vice with soft clamps CAUTION Avoid damaging the surface of the inner tube Install the fork spring 1 in the inner tube NOTE Install the fork spring with the side with narrower aperture upwards Inspect the O ring of the plug If this is damaged replace this Install the plug onto the spring press the plug with a suitable bar Install the plug and ...

Page 174: ...be 2 Tighten The handlebar clamp screws The clamp screws upper shank of the handlebar 3 Tighten The clamp screw lower shank 4 Install The front mudguard 5 Install The front wheel See the section on FRONT WHEEL FITTING Handlebar clamp screws 2 0 kg m Clamp screws upper shank of the handlebar 2 0 kg m Clamp screw lower shank 3 0 kg m Screws front mudguard 0 8 kg m Wheel axle 7 4 kg m Screws brake ca...

Page 175: ...EAD AND HANDLEBARS HANDLEBARS Handlebar left hand Set of throttle cable Handlebar right hand and mixing pump Handlebar counterweight 10 Clutch cable Guide tube of the acceleration cable 13 Tensor Rubber twist grip 14 Locknut 2 0 m kg 2 0 m kg 0 9 m kg ...

Page 176: ... Lower race of the bearing Upper shank of the handlebar Ball bearing Steering nut Cover of the ball bearing race A BEARING DIMENSIONS 1 4 inch NUMBER OF BALLS LOWER 19 units UPPER 19 units 5 4 m kg 2 0 m kg B TIGHTENING STAGES Tighten the annular nut 2 0 kg m Unscrew one turn Tighten this again 1 0 kg m ...

Page 177: ...on FRONT WHEEL DISMANTLING 3 Remove The screws brake pump support 4 Dismantle The counterweight of the end of the handlebar right hand The switch of the handlebar on the right hand side The throttle cable The throttle twist grip right hand 5 Loosen The locknut The tensor 6 Dismantle The clutch cable 7 Dismantle The switch of the handlebar on the left hand side Twist grip left hand Support of the c...

Page 178: ...ebars left and right hand 11 Dismantle The fairing See the section on REMOVING THE FAIRING 12 Dismantle The fork See the section on FRONT FORK REMOVAL 13 Dismantle The rear view mirrors 14 Disconnect The headlight connectors 15 Remove The front of the fairing 16 Dismantle The clamp of the brake line 17 Dismantle The upper crown ...

Page 179: ...ut Use the wrench for ring nuts WARNING Support the steering axle so that this can not fall 19 Dismantle The cover of the bearing races The upper race of the bearing The balls 20 Dismantle The steering axle The ball bearings Wrench for annular nuts 90890 01403 ...

Page 180: ... hammer as shown in the figure Dismantle the bearing race fitted on the lower support with a chisel 2 and a ham mer as shown in the illustration Install the new dust cover seal and the new races 3 Inspect The handlebars Deformations Cracks Damage Replace s s WARNING Do not attempt to straighten the handlebars if these are deformed as this could consi derably weaken them ASSEMBLY Apply the procedur...

Page 181: ...t using the wrench for annular nuts NOTE Couple the torque wrench to the wrench for annular nuts so that these form a right angle Turn the steering 2 or 3 times Loosen the nut half a turn Tighten the annular nut again with the spe cial wrench s s WARNING Do not tighten excessively Nº and dimensions of the balls 19 units above 1 4 inch 19 units below 1 4 inch Wrench for annular nuts 90890 01403 Rin...

Page 182: ...ection on FITTING THE FORK 8 Install The handlebars 9 Install The support of the clutch lever The twist grip left hand The twist grip counterweight left hand The control unit 4 of the left hand twist grip Screw steering axle 5 4 kg m Screw headlight support 1 0 kg m Clamp screw steering axle 3 0 kg m Clamp screw upper shank of the handlebar 2 0 kg m Clamp screw handlebar 2 0 kg m Screws handlebar ...

Page 183: ...it will go NOTE Clean off the excess adhesive with a clean cloth s s WARNING Do not touch the handlebar until the adhesive has dried enough to ensure the twist grip is firmly adhered Install the counterweight of the handlebar twist grip left hand Install the switches of the left hand hand lebar 10 Install The twist grip right hand The throttle cable The switches of the right hand handlebar NOTE Be...

Page 184: ... The front mudguard 14 Install The front wheel See the section on FRONT WHEEL FITTING 15 Install The clutch cable NOTE Apply a light layer of lithium soap grease to the end of the clutch cable 16 Install The front of the fairing 17 Connect The headlight connectors 18 Install The rear view mirrors Counterweight of the twist grip 2 0 kg m Screw brake pump support 0 8 kg m Screw Front mudguard 0 8 kg...

Page 185: ...STEERING HEAD AND HANDLEBARS 7 39 19 Adjust The free play of the clutch cable See the section on ADJUSTING THE CLUTCH in CHAPTER 3 20 Install The fairing See the section on FAIRING FITTING Free play 10 15 mm ...

Page 186: ...earing 10 Flat washer 18 Washer Thrust cover 11 Bolt with washer 19 Self locking nut Hub 12 Full shock absorber Swinging arm axle 13 Bolt Self locking nut 14 Bush Cover 15 Flat washer Chain protector 16 Self locking nut A SWINGARM LIMIT OF FREE PLAY B LATERAL PLAY 1 0 mm 0 04 inch 6 0 m kg 6 0 m kg 4 0 m kg ...

Page 187: ...ion through excessive pressure Do not deform the cylinder or allow this to deteriorate in any way Any damage to the cylinder will reduce the efficiency of dam ping Take care not to scratch the contact sur face of the piston with the cylinder as there could be oil leaks If you wish to get rid of the shock absor ber see the section on OBSERVATIONS ON ELIMINATION OBSERVATIONS ON ELIMINATION Eliminati...

Page 188: ...owlings left and right hand See the section on SIDE COVERS DISMANTLING in CHAPTER 3 2 Lift up the rear wheel installing an appro priate support under the engine 3 Dismantle The rear wheel See section on REAR WHEEL DIS MANTLING 4 Dismantle The footrest support left and right hand The chain guard 5 Remove The screw rear lower shock absorber 6 Remove The screw rear upper shock absorber ...

Page 189: ...le The rear wheel See the section on REAR WHEEL DIS MANTLING 4 Check The swingarm lateral play Move the swinging arm from one side to another Out of specification Change the bearings 5 Check The swingarm vertical oscillation Move the swingarm up and down Difficult to move sticking scraping replace the bearings 6 Dismantle The covers of the swingarm axle The swingarm axle 7 Dismantle The swingarm L...

Page 190: ...il seals Damage Replace The thrust covers Damage Replace The bushes Scratches Damage Replace The bushes Pitting Damage Replace INSTALLING Swingarm Apply the same procedure as for DISMAN TLING but inversely Take into account the following points 1 Apply Lithium soap grease to the oil seals the bushes and the insi de of the thrust covers 2 Install The swingarm Swingarm axle 7 4 kg m ...

Page 191: ...hium soap grease to the oil seals and bush 2 Install The rear shock absorber 3 Install The rear wheel See the section on REAR WHEEL FIT TING 4 Adjust The tension of the drive chain See the section on TIGHTENING THE TRANS MISSION CHAIN in CHAPTER 3 Rear shock absorber upper 6 0 kg m Rear shock absorber lower 6 0 kg m Nut wheel axle 9 0 kg m Tension of drive chain 20 25 mm ...

Page 192: ...CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN 7 46 REAR WHEEL SPROCKET AND DRIVE CHAIN Rear sprocket Holder 10 Drive chain 11 Chain coupling E USE A NEW ONE E USE A NEW ONE ...

Page 193: ...he rear wheel sprocket the chain sloack should be checked DISMANTLING 1 Dismantle The cover of the output sprocket 2 Dismantle The circlip The sprocket 3 Dismantle The retaining clip The coupling plate 4 Dismantle The drive chain 5 Dismantle The rear wheel See the section on REAR WHEEL DIS MANTLING ...

Page 194: ...ent and use a brush to clean off as much dirt as possi ble Then take the chain out of the sol vent and dry it 3 Inspect The clip Drive chain Damage Replace the drive chain The rollers The side plates Damage Wear Replace the drive chain 4 Check Chain sticking Clean and grease the chain and hold this as shown in the illustration Sticking Replace the chain 5 Inspect The sprocket and rear wheel sprock...

Page 195: ...procket and the locknut ASSEMBLY Apply the procedure for DISMANTLING inversely Bear in mind the following points 1 Install The sprocket The circlip 2 Install The sprocket cover 3 Install The rear wheel See the section on REAR WHEEL FIT TING Nut rear crown wheel sprocket 6 3 kg m Screw sprocket cover 0 5 kg m Screw sender 1 0 kg m Nut wheel axle 9 0 kg m ...

Page 196: ... link of the chain The chain clip Rotation direction s s WARNING Make sure that the clip is installed in the right position Otherwise the transmission chain would open 5 Adjust The chain slack See the section on TIGHTENING The TRANSMISSION CHAIN in CHAPTER 3 Drive chain slack 20 25 mm ...

Page 197: ......

Page 198: ...ELEC 8 ...

Page 199: ...CTRIC STARTING SYSTEM 8 8 TROUBLESHOOTING 8 9 CHARGING SYSTEM 8 12 TROUBLESHOOTING 8 14 LIGHTING SYSTEM 8 18 LOCATING BREAKDOWNS 8 20 CHECKING AND TESTING THE LIGHTING SYSTEM 8 23 SIGNALING SYSTEM 8 28 TROUBLESHOOTING 8 30 CHECKING AND TESTING THE SIGNALING SYSTEM 8 32 COOLING SYSTEM 8 46 TROUBLESHOOTING 8 48 ELEC ...

Page 200: ......

Page 201: ...ELEC ELECTRICAL DIAGRAM 8 2 ELECTRICAL DIAGRAM ...

Page 202: ... 26 Thermocontact 12 Front headlight flasher rh 27 Oil level switch 13 Neutral switch 28 Coil 14 Rear indicator lh 29 Starter motor 15 Rear indicator rh 30 Speedometer sensor B Black B Br Black brown W R White Red R Red Sb Sky blue W B White Black O Orange Br Brown W G White Green L Blue L B Blue Black Y L Yellow Blue P Pink L W Blue White Y R Yellow Red Y Yellow L Y Blue Yellow G R Green Red G Gr...

Page 203: ...ry Spark plug pipe 15 Regulator Rectifier Neutral switch 17 Main switch O ring 20 Rear brake light switch Thermostat switch Starter motor ELECTRICAL COMPONENTS 1 STARTER COIL PRIMARY COIL RESISTANCE 0 23 W 20ºC SECONDARY COIL RESISTANCE 7 9 K W ...

Page 204: ...ICAL COMPONENTS 8 5 21 Electrical installation 29 Side stand switch 23 Fuse 31 Relay 24 Diode 32 Indicator flasher relay 27 Oil level switch 33 Horn ELECTRICAL COMPONENTS 1 BATTERY CAPACITY 12 V 3AH NO MAINTENANCE ...

Page 205: ...ELEC IGNITION AND STARTING SYSTEM 8 6 CIRCUIT DIAGRAM The following circuit diagram shows the ignition and starting system ...

Page 206: ...TION AND STARTING SYSTEM 8 7 NOTE For the colour codes please see the electrical diagram C D I magneto Starter relay Main switch C D I Spark plug Handlebar switch RH 21 Battery 28 Coil 29 Starter motor 29 21 28 ...

Page 207: ...ART SYSTEM 8 8 ELECTRIC START SYSTEM CIRCUIT DIAGRAM Starter relay Fuse Main switch Diodes Engine starter stop switch 13 Neutral switch 20 Neutral relay 21 Battery 24 Clutch switch 25 Side stand switch 29 Starter motor ...

Page 208: ...er 90890 03112 Change the fuse 2 Battery Check the condition of the battery See INSPECTING THE BATTERY in CHAPTER 3 OK NOT OK Charge or change the battery OK NOT OK Repair or change the starter motor 4 Neutral relay Remove the relay Use the battery to supply terminals Br and Sb Then check the continuity between GB and BW OK NOT OK Change the neutral relay 5 Starter relay Remove the relay Use the b...

Page 209: ...ch Check the continuity Light blue ground OK NOT OK Change the neutral switch 7 Engine kill switch Separate connections Check the continuity between BW and B OK NOT OK Repair the handlebar switch Right 9 Side stand switch Check the continuity between B and B OK NOT OK Repair the side stand switch Place in RUN position not pressed Separate the blue connection Fold up the side stand ...

Page 210: ...air the side stand switch 11 Starter switch Check the continuity between WG and BG Separate the connection Press the switch OK NOT OK Change the handlebar switch right hand 12 Connections of the system Check all the connections of the starting system See CIRCUIT DIAGRAM OK NOT OK Correct Separate the yellow connection ...

Page 211: ...ELEC CHARGING SYSTEM 8 12 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 212: ...ELEC CHARGING SYSTEM 8 13 NOTE For the colour codes please see the electrical diagram C D I magneto Regulator Rectifier Fuse CDI Spark plug 21 Battery 28 Coil 28 21 ...

Page 213: ... tank To solve these problems use the following special tools THE BATTERY IS FLAT Pocket tester 90890 03112 Tachometer for engine 90890 03113 1 Fuse Remove the fuse Connect the pocket tester Ω x 1 to the fuse Check if the continuity is correct in the fuse NO CONTINUITY Replace the fuse CONTINUITY OK 2 Battery Check the condition of the battery See the section on INSPECTING THE BATTERY in CHAPTER 3...

Page 214: ...f the battery Start the engine up and rev up to about 3 000 r min Check the charge voltage Charge voltage 14 0 V at 5000 rpm MATCHES SPECIFICATION Replace the battery DOES NOT MATCH SPECIFICATIONS 4 Resistance of the stator coil Disconnect the stator coil coupler from the connector Connect the pocket tester Ω x 1 to the stator coil Stator coil probe of tester Yellow black terminal probe of tester ...

Page 215: ...DOES NOT MATCH SPECIFICATION Replace the stator coil MATCHES SPECIFICATION 5 Cable connections Check the connections of the charging system See the section on CABLE DIAGRAM BAD CONNECTIONS Correct these Change the rectifier regulator CORRECT Resistance of the stator coil 0 4 0 6 Ω at 20º C ...

Page 216: ......

Page 217: ...ELEC LIGHTING SYSTEM 8 18 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 218: ...ease see the electrical diagram Fuse Main switch 11 Front headlight indicator LH 12 Front headlight indicator RH 14 Rear indicator LH 15 Rear indicator RH 16 Front brake switch 17 Rear brake switch 18 Tail light 19 Instrument panel 17 18 16 12 11 15 14 ...

Page 219: ...cket tester 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Ω x 1 to the fuse Check to see if the continuity is correct in the fuse NO CONTINUITY Replace the fuse CONTINUITY OK 2 Light switch LIGHTS Disconnect the coupling of the light switch LIGHTS from the connector yellow Check low beam headlights Place the switch in LOW position k Check the continuity between L and G Check high be...

Page 220: ...vated X X Continuity X no continuity Check main beam probe of tester Red yellow terminal probe of tester Blue terminal probe of tester Red yellow terminal probe of tester Blue black terminal Place the lights switch LIGHTS in positions ON and OFF successively Check to see if the continuity is correct in the lights switch Position of In good In bad the switch condition condition Activated X X Deacti...

Page 221: ... 8 22 3 Cable connections Check the cable connections of the whole light system See the section on WIRING DIAGRAM CONNECTIONS IN BAD CONDITION Correct these CORRECT See the section on CHECKING AND TESTING THE LIGHT SYSTEM ...

Page 222: ...he ON position Place the light change switch in the LOW LO beam position Connect the pocket tester DC 20V to the headlight coupler probe of tester Green terminal probe of tester Black terminal MATCHES SPECIFICATIONS The light system is in good condition CHECKING AND TESTING THE LIGHT SYSTEM 1 Headlight do not come on 2 The headlights do not come on 1 Check the bulbs see previous point ...

Page 223: ...ange switch LIGHTS With the headlight change switch LIGHTS in position HI probe of tester Blue terminal probe of tester Yellow terminal With the headlight change switch LIGHTS in position LO probe of tester Blue terminal probe of tester Green terminal Place the headlight change switch LIGHTS in posi tions HI high beam LO low beam successively Check to see if the continuity is correct in the switch...

Page 224: ... light probe of tester Terminal probe of tester Terminal probe of tester Terminal probe of tester Terminal Check if the continuity is correct in the bulb of the brake light tail light NO CONTINUITY Replace the bulb of the brake light tail light 3 The tail light does not come on CONTINUITY OK 2 Voltage Disconnect the connector of the tail light Start the engine Connect the pocket tester 20 VDC to t...

Page 225: ...n ELECTRICAL DIAGRAM MATCHES THE SPECIFICATION CONTINUITY OK 1 Instrument light bulb Remove each bulb from the instrument panel Connect the pocket tester Ω x 1 to the bulb probe of tester Terminal probe of tester Terminal See if the continuity is correct in the bulb of the ins trument panel Replace service the tail light 4 The instrument lights do not come on NO CONTINUITY Replace the bulb of the ...

Page 226: ...n Connect the pocket tester DC 20V to the instrument light coupler Check the voltage between Br and B Voltage of the instrument panel 12 0 V DOES NOT MATCH SPECIFICATION 3 Cable connections Check the connections of the whole light system See the ELECTRICAL DIA GRAM section Replace the instrument panel MATCHES SPECIFICATION ...

Page 227: ...ELEC SIGNALING SYSTEM 8 28 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 228: ...Tail light Brake light 10 Handlebar switch 19 Instrument panel 11 Front headlight indicator LH 20 Neutral relay 12 Front headlight indicator RH 21 Battery 13 Neutral switch 22 Horn 14 Rear indicator LH 23 Indicator relay 15 Rear indicator RH 26 Thermocontact 16 Front brake switch 27 Oil level switch 22 27 19 23 20 21 26 13 ...

Page 229: ... NEUTRAL INDICATOR PILOT LIGHT TURN INDICATOR PILOT LIGHT AND THE OIL PRESSURE INDICATOR OIL DO NOT COME ON AND THE HORN DOES NOT WORK Pocket tester 90890 03112 1 Fuse Remove the fuse Connect the pocket tester W x 1 to the fuse Check whether the continuity is correct in the fuse NO CONTINUITY Replace the fuse CONTINUITY OK 2 Battery Check the condition of the battery See the section on INSPECTING ...

Page 230: ...OFF successively Check if the continuity is correct between the red and brown cables only in the ON position IN BAD CONDITION Replace the main switch 4 Cable connections Check the connections of the full signalling system See the section on WIRING DIAGRAM See the section on CHECKING AND TESTING THE SIGNALLING SYSTEM IN GOOD CONDITION CORRECT CONNECTIONS INCORRECT Correct these ...

Page 231: ...lb holder bush of the indicator Place the bulb in the holder Disconnect the indicator wires chocolate and black or dark green and black Connect the pocket tester Ω x 1 to the indicator cables To check the right indicator probe of tester Dark green cable probe of tester Black cable To check the left hand indicator probe of tester Chocolate cable probe of tester Black cable CHECKING AND TESTING THE ...

Page 232: ... turn switch in position probe of tester Brown white terminal probe of tester Dark green terminal With the turn switch in position probe of tester Brown white terminal probe of tester Chocolate terminal Place the TURN switch in positions d and c suc cessively Check if the continuity is correct in the TURN switch Switch In good In bad position condition condition d right X X c left X X Continuity X...

Page 233: ... MATCHES THE SPECIFICATION DOES NOT MATCH THE SPECIFICATION 5 Cable connections Check the connections of the whole light system See the ELECTRICAL DIAGRAM section 1 Tail light brake light bulb Remove the bulb of the tail light brake light Connect the pocket tester Ω x 1 to the bulb probe of tester Terminal probe of tester Terminal probe of tester Terminal probe of tester Terminal 2 The brake light...

Page 234: ...switch brown and green yellow of the connector Connect the pocket tester W x 1 to the cables of the brake switch probe of tester Brown terminal probe of tester Green yellow terminal Check whether the continuity is correct in the brake switch Switch In good In bad position condition condition Applying front brake X X Not applying front b X X Continuity X There is no continuity IN BAD CONDITION Repl...

Page 235: ...e of tester To ground check the front brake voltage Sidelight voltage 12 0v MATCHES SPECIFICATION DOES NOT MATCH SPECIFICATION 4 Cable connections Check the connections of the whole system See the ELECTRI CAL DIAGRAM section 5 Rear brake switch Disconnect the cables of the rear brake switch brown and green yellow of the connector Connect the pocket tester Ω x 1 to the cable of the brake switch ...

Page 236: ...e rear brake switch IN GOOD CONDITION 6 Voltage Apply the rear brake Connect the pocket tester DC 20V to the rear brake switch probe of tester Brown terminal probe of tester To ground Check replace the rear brake light Rear brake voltage 12 0v MATCHES SPECIFICATION DOES NOT MATCH SPECIFICATION 7 Cable connections Check the connections of the whole system See the ELECTRI CAL DIAGRAM section Replace...

Page 237: ...ight blue terminal probe of tester To ground Put the transmission successively into neutral and then into gear Check whether the continuity is correct in the NEU TRAL switch Switch In good In bad position condition condition Neutral X X In gear X X Continuity X There is no continuity IN BAD CONDITION Replace the neutral switch IN GOOD CONDITION 3 The NEUTRAL indicator does not come on ...

Page 238: ...DC 20V to the instrument panel coupler probe of tester Brown terminal probe of tester Black terminal Check the voltage of the front brake Instrument panel voltage 12 0 V MATCHES SPECIFICATION DOES NOT MATCH SPECIFICATION 3 Cable connections Check the connections of the whole system See the ELECTRICAL DIAGRAM section Change the instrument panel ...

Page 239: ... in position d probe of tester Brown white terminal probe of tester Dark green terminal With the TURN switch in position probe of tester Brown white terminal probe of tester Chocolate terminal Place the TURN switch in positions d and c successively Check if the continuity is correct in the TURN switch Switch In good In bad position condition condition d right X X c left X X Continuity X No continu...

Page 240: ...ltage 12 0 V MATCHES SPECIFICATION DOES NOT MATCH SPECIFICATION 3 Cable connections Check the connections of the whole system See the ELECTRICAL DIAGRAM section MATCHES SPECIFICATION DOES NOT MATCH SPECIFICATION Replace the indicator relay 4 Indicator relay Line up the relay probe of tester Brown terminal probe of tester Brown white terminal The indicator can be heard to operate Change the instrum...

Page 241: ... correct in the oil level switch CONTINUITY OK 5 The oil level indicator light does not come on 2 Voltage Disconnect the instrument panel coupler Place the main switch in the ON position Connect the pocket tester DC 20V to the instrument panel coupler probe of tester Brown terminal probe of tester Black terminal Check the voltage of the front brake Instrument panel voltage 12 0 V MATCHES SPECIFICA...

Page 242: ...dition Horn switch on X X Horn switch not on X X Continuity X No continuity CONTINUITY OK IN BAD CONDITION Replace the handlebar switch 6 The horn does not sound when the HORN switch is pressed 2 Voltage Connect the pocket tester DC 20V to the horn con nector probe of tester Brown terminal probe of tester To ground Check the voltage of the horn Horn voltage 12 0 V DOES NOT MATCH SPECIFICATION 3 Ca...

Page 243: ...d 5 Voltage Connect the pocket tester DC 20V to the pink horn terminal probe of tester Pink terminal probe of tester To ground THE HORN DOES NOT SOUND THE HORN SOUNDS The horn is in good condition DOES NOT MATCH SPECIFICATION Replace the horn Check the voltage of the pink terminal Horn voltage 12 0 V MATCHES SPECIFICATION Adjust or replace the horn ...

Page 244: ......

Page 245: ...ELEC COOLING SYSTEM 8 46 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 246: ...ELEC COOLING SYSTEM 8 47 NOTE For the colour codes please see the electrical diagram Fuse Main switch 19 Instrument panel 21 Battery 26 Thermocontact 19 26 ...

Page 247: ...reakdown use the following special tool THE TEMPERATURE LIGHT DOES NOT COME ON WHEN THE ENGINE IS HOT Pocket tester 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Ω x 1 to the fuse Check to see if the continuity is correct in the fuse NO CONTINUITY Replace the fuse CONTINUITY OK 2 Battery Check the state of the battery See the section on INSPECTING THE BATTERY in CHAPTER 3 INCORRECT ...

Page 248: ... good In bad position condition condition ON X X OFF X X Continuity X No continuity IN BAD CONDITION Replace the main switch 4 Temperature indicator Disconnect the thermosensor cable green red from the connector Connect the cable to ground chassis with a bridge cable Place the main switch in ON position Check whether the temperature indicator comes on IN GOOD CONDITION CORRECT INCORRECT 5 Cable co...

Page 249: ...C No continuity Continuity THE RESISTANCES MATCH SPECIFICATIONS s s WARNING Handle the thermostat with special care Never let this receive any impacts or fall If it does accidentally fall replace it CAUTION After replacing the thermosensor check the level of the coolant liquid in the radiator and see if there are any leaks UNDER 115 C OVER 115 C Replace the thermosensor 7 Cable connections Check t...

Page 250: ......

Page 251: ... 19 Instrument panel 20 Neutral relay 21 Battery 22 Horn 23 Flasher relay ó turn signal indicator light 24 Clutch switch 25 Side stand switch 26 Thermocontact 27 Oil level switch 28 Coil 29 Starter motor 30 Speedometer sensor COLOUR CODE B Black B R Black red R Red B W Black white L Blue G R Green red G Green G Y Green yellow O Orange Br W Brown white Y Yellow W R White red P Pink W B White black ...

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