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Yamaha 2004 TT600RE, Service Manual

The Yamaha 2004 TT600RE Service Manual is an essential resource for owners of this high-performance motorcycle. With detailed instructions and diagrams, this manual provides everything you need to maintain and repair your Yamaha TT600RE. Download the manual for free from manualshive.com and keep your bike running smoothly.

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REAR SHOCK ABSORBER

4-72

CHAS

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. 

•

Never tamper with or attempt to open the
cylinder or the tank. 

•

Never expose the shock absorber to a
naked flame or other source of heat. This
might cause the pressurised gas to
explode. 

•

Do not deform or damage the cylinder in
any way. Damage to the cylinder would
impair the damping effect.

•

Be 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

▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼

▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

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.

WARNING

Wear protective goggles to avoid eye injuries
from escaping gas and/or metal chips.

Summary of Contents for 2004 TT600RE

Page 1: ...TT600RE 2004 5CH5 ME1 SERVICE MANUAL ...

Page 2: ...00RE SERVICE MANUAL 2003 by Belgarda S p A First edition July 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Belgarda S p A is expressly prohibited Printed in Italy ...

Page 3: ...ications 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 The Safety Alert Symbol me...

Page 4: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 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 indicate...

Page 5: ...ith engine mounted 0 Filling fluid q Lubricant w Special tool e Torque r Wear limit clearance t Engine speed y Electrical data Illustrated symbols u to s in the exploded dia grams indicate the types of lubricants and lubrica tion points u Apply engine oil i Apply gear oil o Apply molybdenum disulfide oil p Apply wheel bearing grease a Apply lightweight lithium soap base grease s Apply molybdenum d...

Page 6: ...INFORMATION TABLE OF CONTENTS GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENTS INSP ADJ 3 ENGINE ENG 5 CARBURETION CARB 6 CHASSIS CHAS 4 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG 8 E004000 ...

Page 7: ......

Page 8: ...1 GEN INFO ...

Page 9: ...IFICATION NUMBER 1 1 MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL PROCEDURES 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 10: ...GEN INFO ...

Page 11: ...NFORMATION 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 ...

Page 12: ...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 5 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 ap...

Page 13: ...sible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropriate 1 Oil seal Do not use compressed air to spin the bear ings dry This will damage the bearing sur faces 1 Bearing CAUTION EB101050 CIRCLIPS 1 Check all circlips carefully before reassembly Always replace piston pin clips after one use Replace...

Page 14: ...erminals several times 3 Check connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect connector terminals NOTE The two terminals click together 5 Check continuity using a pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores C...

Page 15: ...ming light This tool is needed for detecting ignition timing 90890 03112 Pocket tester These instruments are invaluable for check ing the electrical system 90890 06754 Ignition checker This instrument is necessary for checking the ignition system components Tool name Usage Illustration 90890 03081 Compression gauge These tools are used to measure the engine compression 90890 04082 Adapter compress...

Page 16: ...ng 90890 01225 7 mm 0 28 in valve guide puller This tool is used to remove the valve guides 90890 04017 7 mm 0 28 in valve guide installer This tool is necessary to install the valve slides properly 90890 01227 7 mm 0 28 in valve guide reamer This tool is used to re ream the new valve guide 90890 01311 Valve adjusting tool This tool is necessary for adjusting valve clearance 90890 01701 Rotor hold...

Page 17: ...sed to install the crankshaft 90890 01275 Crankshaft installation bolt This tool is used to install the crankshaft 90890 04059 10 M14 adapter This tool is used to install the crankshaft 90890 04081 Crank spacer This tool is used to install the crankshaft 90890 85505 SEALANT QUICK GASKET Yamaha Bond No 1215 This sealant adhesive is used for crankcase mating surfaces etc 90890 01268 Ringnut wrench T...

Page 18: ...s tool is used to install the DU bush and the fork oil seal 90890 01326 T handle This tool is needed to loosen and tighten the front fork damper rod holding bolt 90890 01460 Front fork damper rod holder This tool is needed to hold the front fork damper rod when loosening and tightening the holding bolt ...

Page 19: ...2 SPEC ...

Page 20: ...TIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 12 ELECTRICAL 2 17 GENERAL TORQUE SPECIFICATIONS 2 19 CONVERSION TABLE 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 21 LUBRICATION LAYOUT 2 22 CABLE ROUTING 2 26 ...

Page 21: ...SPEC ...

Page 22: ...nt Forward inclined single cylinder Displacement 595 cm3 Bore x stroke 95 0 x 84 0 mm Compression ratio 8 5 1 Starting system Electric starter Lubrication system Dry sump with separate oil tank Engine oil Type Temp C SAE20W40SE or SAE10W30SE Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 4 L With oil filter cartridge replace...

Page 23: ... angle 27 Trail 117 mm Tires Front Type With tube Size 90 90 21 54R 90 90 21 54S 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 cm2 2 00 bar Rear 220 kPa 2 20 kgf cm2 2 20 bar 90 kg maximum Front 210 kPa 2 10...

Page 24: ...ring preload adjustable Wheel travel Front 230 mm Rear 230 mm Electrical system Ignition system Transistorized coil ignition digital Charging system Type A C magneto Standard output 14V 13 5A at 5 000 r min Battery Model GT9B 4 Voltage capacity 12V 8Ah Headlight type Quartz bulb halogen Bulb voltage wattage x quantity Headlight 12V 60W 55W x 1 Tail brake light 12V 5W 21W x 1 Turn signal light 12V ...

Page 25: ...e 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 A 36 470 36 570 mm Intake measurement B 30 060 30 160 mm Intake measurement C 6 41 mm Exhaust measurement A 36 620 36 720 mm Exhaust measurement B 30 110 30 210 mm Exhaust measurement C 6 51 mm Max cams...

Page 26: ... 36 90 37 10 mm exhaust 31 90 32 10 mm Valve face width B intake 2 260 mm exhaust 2 260 mm Valve seat width C intake 1 00 1 20 mm 1 80 mm exhaust 1 00 1 20 mm 1 80 mm Valve margin thickness D intake 1 00 1 40 mm 0 80 mm exhaust 0 80 1 20 mm 0 65 mm Valve stem diameter intake 6 975 6 990 mm 6 995 mm exhaust 6 955 6 970 mm 6 925 mm Valve guide inside diameter intake 7 000 7 012 mm 7 042 mm exhaust 7...

Page 27: ...t 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 2 5 1 7 mm exhaust 2 5 1 9 mm Winding direction top view intake Counterclockwise exhaust Counterclockwise Piston Piston ...

Page 28: ...nd ring 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 Width A 74 95 75 00 mm Max runout C 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 pla...

Page 29: ...rburetor ID mark 5CH5 10 Main jet 1 150 2 145 Main air jet 1 1 0 2 0 9 Jet needle 1 5C5A 3 5 2 5Y18 3 5 Needle jet 2 600 Cutaway 4 00 Pilot air jet 1 0 8 mm Pilot jet 50 Bypass 1 1 0 Pilot screw turns out 2 3 4 1 2 Valve seat size 2 5 Starter jet 1 74 Float height 6 0 8 0 mm Engine idle speed 1 150 1 450 r min CO 1 5 3 Intake vacuum 30 6 33 36 kPa 230 250 mm Hg Lubrication system Dry sump Oil filt...

Page 30: ...2 9 SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening steps Crankcase tightening steps Right crankcase Left crankcase ENGINE ...

Page 31: ...A C magneto Hexagon nut M14 x 1 5 120 12 0 Lock nut valve adjusting screw Hexagon nut M6 x 1 0 14 1 4 Cam chain sprocket Washer based bolt M7 x 1 0 20 2 0 Cam chain stopper guide Hexagon socket head screw M6 x 1 0 10 1 0 Cam chain stopper guide Washer based screw M16 x 1 0 20 2 0 Rocker shaft Hexagon socket head screw M6 x 1 0 10 1 0 Oil pump Hexagon socket head screw M6 x 1 0 10 1 0 Oil delivery ...

Page 32: ...xhaust pipe Washer based nut M6 x 1 0 10 1 0 Exhaust pipe protector Pan head screw M6 x 1 0 7 0 7 Muffler Hexagon socket head screw M8 x 1 25 23 2 3 Muffler band Nut nylon M8 x 1 25 23 2 3 Muffler Washer based screw M8 x 1 25 23 2 3 Crankcase Hexagon socket head screw M6 x 1 0 10 1 0 Crankcase Stud bolt M10 x 1 25 20 2 0 Crankcase cover right Hexagon socket head screw M6 x 1 0 10 1 0 Crankcase cov...

Page 33: ...70 190 mm from upper edge of inner tube fully compressed without spring Rear suspension Rear shock absorber assembly travel 83 mm Spring free length 224 mm Installed length 211 mm 1 5 mm Spring rate K 80 N mm 8 1 kgf mm Optional spring available No Swingarm Free play limit at the end of the swingarm radial 1 0 mm Free play limit at the end of the swingarm axial 0 4 0 7 mm Front wheel Wheel type Sp...

Page 34: ...ter 13 mm Caliper cylinder inside diameter 28 mm x 2 Recommended fluid DOT 4 Rear disc brake Disc outside diameter x thickness 220 0 x 5 0 mm Max deflection 0 15 mm Brake pad lining thickness inner 9 0 mm 4 5 mm Brake pad lining thickness outer 9 0 mm 4 5 mm Master cylinder inside diameter 12 7 mm Caliper cylinder inside diameter 34 mm Recommended fluid DOT 4 Front brake lever Adjustable Brake ped...

Page 35: ...Holder handle under Crown handle M10 x 1 5 40 4 0 Front fork under bracket Inner tube M8 x 1 25 23 2 3 Front master cylinder Cap M4 x 0 7 1 5 0 15 Front master cylinder Handle M6 x 1 0 9 0 9 Union bolt tightening M10 x 1 0 20 2 0 Front fender Front fork M6 x 1 0 7 0 7 Stay headlight Handle crown M6 x 1 0 10 1 0 Stay headlight Bracket meter M6 x 1 0 6 0 6 Headlight Stay headlight M6 x 1 0 10 1 0 Re...

Page 36: ...8 x 1 25 30 3 0 Bracket 1 main footrest Frame M10 x 1 25 48 4 8 Bracket 2 main footrest Frame M10 x 1 25 48 4 8 Footrest cover Footrest M6 x 1 0 10 1 0 Seat fuel tank and oil tank Seat Frame M6 x 1 0 10 1 0 Bolt guide seat Fuel tank M6 x 1 0 5 0 5 Fuel tank Rear frame M6 x 1 0 12 1 2 Damper fuel tank front Frame M8 x 1 25 15 1 5 Fuel tank Fuel cock M6 x 1 0 7 0 7 Oil tank Sub oil tank M6 x 1 0 7 0...

Page 37: ...st 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 13 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 1 First tighten the ring nut approximately 38 Nm 3 8 mkg by using the torque wr...

Page 38: ...acturer TLMZ48 NIPPON DENSO Standard output 14 0 V 13 5 A 5 000 r min Stator coil resistance 0 65 Ω 20 W W Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH629A 12 SHINDENGEN No load regulated voltage 14 5 0 4 V Rectifier capacity 25 A Withstand voltage 240 V Battery Specific gravity 1 320 Electric starting system System type Constant mesh Starter motor Model ma...

Page 39: ...NELLI Max amperage 1 5 A Flasher relay Type Semi transistor Model manufacturer FB222M NIPPONDENSO Self cancelling device No Flasher frequency 75 95 cycle min Wattage 10 W 2 3 4 W Daylight switch relay Model manufacturer ACA12151 1 MATSUSHITA DENKOU Circuit breaker Type Fuse Amperage for fuse 20 A Reserve 20 A ...

Page 40: ...1 5 14 mm 10 mm 30 3 0 17 mm 12 mm 55 5 5 19 mm 14 mm 85 8 5 22 mm 16 mm 130 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 IMP mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMP Known Multiplier Result m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0...

Page 41: ...d 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 1215 Coupled surfaces cylinder head ...

Page 42: ... 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 Bearings steering head Pivot points brake lever and clutch lever Clutch cable end Pivot points sidestand Grease nipples rear arm front axle ...

Page 43: ...2 22 SPEC LUBRICATION LAYOUT LUBRICATION LAYOUT 1 Oil tank 2 Oil pump 3 Oil filter oil tank 4 Oil strainer engine 5 Oil vapour retrieval hose 6 Oil blow by retrieval hose A DELIVERY B RETRIEVAL ...

Page 44: ...SPEC LUBRICATION LAYOUT 2 23 1 Oil pump 2 Oil filter 3 Camshaft 4 Oil delivery hose 5 Main driving shaft 6 Drive shaft A DELIVERY B RETRIEVAL A B ...

Page 45: ...SPEC LUBRICATION LAYOUT 2 24 1 Oil filter 2 Camshaft 3 Connecting rod pin 4 Main driving shaft 5 Secondary drive shaft 6 Drain plug A DELIVERY B RETRIEVAL A B ...

Page 46: ...SPEC LUBRICATION LAYOUT 2 25 1 Oil pump 2 Oil filter 3 Oil delivery hose 4 Transmission 5 Oil strainer A DELIVERY B RETRIEVAL A B ...

Page 47: ... 8 Tachometer odometer cable 9 Complete wire harness 10 Socket cover 11 Engine stop switch connector 12 Headlight wire harness connector 13 Left turn light connector 14 Right turn light connector 15 Meter wire harness connector 16 Main switch wire harness connector 17 Clutch switch 18 Headlight connector 19 Side taillight connector 20 Clutch switch connector 21 Brake switch connector 22 Clip A Lay...

Page 48: ...Sidestand switch 15 Diodes n 3 16 A C generator wire harness engine 17 Engine oil breather pipe to engine oil tank 18 Main switch 19 Oil hose oil tank to engine 20 Oil hose engine to oil tank 21 C D I unit 22 Starting motor plus cable 23 Starting motor minus cable 24 Battery 25 Starting relay 26 Fuse reserve 27 Fuse main 28 Wire extension 29 Battery plus cable A Lay the brake hose behind the left ...

Page 49: ...ain wire harness band 9 Rear brake switch wire harness 10 Rear brake fluid tank hose 11 Hose from rear master cylinder to caliper 12 Rear brake hose holders 13 Pipe 14 Air breather pipe 15 Spark plug ignition coil 16 Chassis ground 17 Engine oil breather pipe to air filer case A Insert the tachometer odometer cable into the band 3 and the holder 2 1 2 4 3 15 16 7 8 9 14 10 12 11 6 5 13 17 A A ...

Page 50: ...tion 4 Left turn wire harness 5 Right turn wire harness 6 Tail light wire harness 7 Air breather pipe carburetor 8 Wire extension 9 Starter power cables 10 Engine cables and side stand switch A Screw protection 3 after setting wiring properly 1 2 2 3 4 5 6 7 8 9 10 A ...

Page 51: ...SPEC ...

Page 52: ...3 INSP ADJ ...

Page 53: ...GINE OIL TANK FILTER CLEANING 3 26 SUCTION HOSE AND MANIFOLD INSPECTION 3 28 FUEL LINE INSPECTION 3 28 CRANKCASE VENTILATION HOSE INSPECTION 3 29 EXHAUST SYSTEM INSPECTION 3 29 CHASSIS 3 30 ADJUSTING THE FRONT BRAKE 3 30 ADJUSTING THE REAR BRAKE 3 31 CHECKING THE BRAKE FLUID LEVEL 3 32 BRAKE PAD WEAR INSPECTION 3 33 BRAKE HOSING INSPECTION 3 33 BRAKE CIRCUIT BLEEDING 3 34 DRIVE CHAIN SLACK INSPECT...

Page 54: ...J ELECTRICAL SYSTEM 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 BULB 3 56 REPLACING THE TAIL BRAKE LIGHT BULB 3 57 ...

Page 55: ...eration Adjust Check operation fluid level and vehicle for fluid leakeage 6 Front brake See NOTE Replace brake pads Whenever worm to the limit Check operation fluid level and vehicle for fluid leakage 7 Rear brake See NOTE Replace brake pads Whenever worm to the limit 8 Brake hoses Check for cracks or damage Replace See NOTE Every 4 years 9 Wheels Check runout spoke tightness and for damage Tighte...

Page 56: ...eration and free play 26 housing and Adjust the throttle cable free play if necessary cable Lubricate the throttle grip housing and cable 27 Muffler and Check the screw clamp for looseness exhaust pipe 28 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...

Page 57: ...he parts in order removal 1 Seat 1 2 Fuel pipe 1 NOTE Be sure the cap is properly tightened and the fuel cock is in the OFF position before removing the tank 3 Fuel tank 1 4 Lamp connector 1 Disconnect 5 Rear cowling 1 NOTE Widen the rear cowling body sides carefully to extract rear cowling from the chassis Reverse the removal procedure for instal lation ...

Page 58: ... Hold the motorcycle firmly in place to prevent it falling over during the operation 1 Remove Seat Fuel tank See the section SEAT FUEL TANK AND REAR COWLING 2 Disconnect Spark plug cap 1 3 Remove Spark plug Tappet cover 2 intake Tappet covers 3 exhaust When removing the spark plug and tappet cover be careful not to drop foreign objects inside the engine 4 Remove Cap 1 Cap 2 CAUTION 5 Turn the cran...

Page 59: ...nce cold Intake 0 05 0 10 mm Exhaust 0 12 0 17 mm 8 Adjust Valve clearance Adjustment Loosen the lock nut 1 Fit a thickness gauge 2 between the rocker arm and the valve stem Turn the adjuster 1 clockwise or anticlock wise using the special tool 2 to obtain the required clearance Special tool P N 90890 01311 Holding the adjuster firmly in place lock tight en lock nut Lock nut 14 Nm 1 4 mkg Measure ...

Page 60: ... 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 arrow 1 pointing upwards 10 Connect Spark plug cap 11 Reassemble Fuel tank Seat See section SEAT FUEL TANK AND REAR COWLING Seat screws 10 Nm 1 0 mkg ...

Page 61: ... spark plug cable Special tool P N 90890 03113 Engine idle speed 1 150 1 450 rpm 3 Check The engine idle speed Out of specification Adjust 4 Adjust Engine idle speed Adjustment Turn the throttle stop screw 1 either way to obtain the idle speed required Screwing a Increases idle speed Unscrewing b Decreases idle speed NOTE After setting the idle speed adjust the accelerator cable free play 5 Discon...

Page 62: ... Throttle cable free play 3 5 mm at the grip flange 3 Adjust Throttle cable free play Adjustment Loosen the throttle cable 2 lock nuts 1 Turn the adjuster 3 clockwise or anticlock wise to obtain the required free play If 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 Tighten the lock nuts 1 6 Lock nuts 4 Reassemble F...

Page 63: ...ing into the cylinder When removing the spark plug be careful not to drop foreign objects inside the engine 4 Inspect Type of spark plug Incorrect Replace CAUTION CAUTION Standard spark plug DPR8EA 9 N G K or DPR9EA 9 N G K 5 Inspect Electrodes 1 Wear and tear damage Replace Insulator 2 Normal insulator 2 colour is light tan 6 Clean the spark plug with a suitable tool and a steel brush 7 Measure S...

Page 64: ... installing the spark plug clean the surface and thread Spark plug 18 Nm 1 8 mkg Seat screws 10 Nm 1 0 mkg NOTE Tighten the spark plug by hand before torquing to specification 9 Connect Spark plug cap 10 Install Fuel tank Seat See section SEAT FUEL TANK AND REAR COWLING ...

Page 65: ...ditions the oil might spray out when the cap is removed Be careful therefore when removing the cap 4 Check Ignition advance CAUTION Check Heat engine and let it run to the number of revs required Engine idle speed 1 150 1 450 rpm Check that reference 1 is in the mobile field of reference 2 on the flywheel Incorrect ignition timing Check the ignition coil unit NOTE Ignition timing cannot be adjuste...

Page 66: ...T FUEL TANK AND REAR COWLING 2 Check Valve clearance Out of specification Adjust See section VALVE CLEARANCE AD JUSTMENT 3 Install Secondary fuel tank 4 Start engine and let it heat Switch off engine 5 Disconnect Spark plug cap 6 Remove Spark plug 1 When removing the spark plug be careful to prevent foreign bodies from dropping inside the engine CAUTION 1 7 Apply Pressure gauge 1 Adapter 2 Pressur...

Page 67: ...e the pressure reading with those in the table Pressure under compression Standard 1 100 kPa 11 kg cm2 156 psi Minimum 900 kPa 9 kg cm2 128 psi Maximum 1 200 kPa 12 kg cm2 171 psi 8 Check Pressure under compression If 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 ...

Page 68: ...nnect Spark plug cap 12 Reassemble Fuel tank Seat See section SEAT FUEL TANK AND REAR COWLING 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 car...

Page 69: ...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 ...

Page 70: ... Do not put in any chemical additives or use oils with a grade of CD a or higher 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 Be sure no foreign material enters the crankcase 4 Reassemble the oil tank cap Never start the engine when the oil tank is empty CAUTION CAUTION Oil capacity Total 3 0 litres...

Page 71: ...gine 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 CAUTION 7 Inspect All gaskets Damaged Replace 8 Reassemble Oil filter cover bleeder screw E...

Page 72: ...ure API Standard API SE SF SG or higher grade Oil capacity Periodic change 2 4 litres Do not put in any chemical additives or use oils with a grade of CD a or higher 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 Be sure no foreign material enters the crankcase CAUTION 10 Install Oil tank tap 11 Check...

Page 73: ...er 4 6 Wait until the oil has completely drained NOTE The oil filter cover is secured by three screws 5 The lower one should be removed so that the fil ter cavity will drain 5 3 4 7 Remove the other filter cover screws and remove the oil filter cover 8 Remove the oil filter 6 and O ring 7 9 Inspect All gaskets O rings Damaged Replace 10 Reassemble New filter cartridge Filter cover screw Oil filter...

Page 74: ... oil filter change 2 5 litres Do not put in any chemical additives or use oils with a grade of CD a or higher 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 Be sure no foreign material enters the crankcase CAUTION 12 Install Oil tank cap 13 Check Oil level See section ENGINE OIL LEVEL CHECK Oil pressu...

Page 75: ...o leakage Pressure insufficient If the oil does not come out after one minute stop the engine immediately to prevent seizure 4 Tighten Bleeder screw CAUTION Bleeder screw 5 Nm 0 5 kgm CLUTCH ADJUSTMENT Cable free play adjustment 1 Check Clutch free play adjustment a Out of specification Adjust Free play 10 15 mm 2 Adjust Clutch cable free play Adjustment Loosen lock nuts 1 Turn the adjuster 2 eith...

Page 76: ... Adjusters 3 Drain off Engine oil See section ENGINE OIL REPLACE MENT 4 Remove Footrest right 1 Engine protector 2 5 Disconnect Brake pedal return spring 3 6 Remove Rear master cylinder fastening screws 4 Oil delivery hose fastening screw 5 Right crankcase cover fastening screws Right crankcase cover 6 7 Loosen Lock nut 1 8 Push the engine clutch control lever forward to the stop point 9 Adjust Fr...

Page 77: ... Oil delivery hose screw 18 Nm 1 8 mkg Screw rear master cylinder 10 Nm 1 0 mkg Bolt footrest 48 Nm 4 8 mkg 12 Connect Brake pedal return spring Rear master cylinder 13 Reassemble Footrest right Free play at lever tip 10 15 mm See section Cable free play adjustment Engine protector 14 Fill Engine oil tank See section ENGINE OIL REPLACE MENT 15 Adjust Clutch cable free play ...

Page 78: ...al filter oil all over filter surface 6 Squeeze out Excess oil NOTE The filtering element should be wet but not drip ping 3 4 7 Install Filtering element 4 in its case 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 8 Reassemble Air filter box cap Fast screws...

Page 79: ...ames 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 The fuel cock from the fuel tank 5 Wash Fuel filter 1 with solvent 6 Inspect Fuel filter 1 Gasket 2 Damaged Replace 7 Reassemble Fuel cock ...

Page 80: ...er Exhaust pipe Rear shock absorber See section REAR SHOCK ABSORBER in Chapter 4 Joint air cleaner clamps Rear frame Engine oil tank 3 Loosen Stay rear left side cover fastening screws 4 Remove Oil tank cap 1 Oil return hose 2 Oil return hose flange 4 fastening screw 3 Oil delivery hose flange 6 fastening screws 5 Oil tank filter 7 OR gaskets 8 5 Clean Oil tank filter with solvent Oil tank with so...

Page 81: ...return hose flange fastening screws 8 Tighten Stay rear left side cover fastening screws 9 Reassemble Engine oil tank Rear frame Joint air cleaner clamps 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 REAR COWLING 10 Fill Engine oil See section ENGINE OIL REPLACE MENT 11 Reassemble Eng...

Page 82: ...nk See section SEAT FUEL TANK AND REAR COWLING 2 Inspect Suction hoses 1 Cracked damaged Replace Screw 2 carburetor manifold 10 Nm 1 0 mkg Screw 3 clamp 2 Nm 0 2 mkg 3 Reassemble Fuel tank Seat See section SEAT FUEL TANK AND REAR COWLING FUEL LINE INSPECTION 1 Inspect Fuel pipe 1 Cracked Damaged Replace Seat screws 10 Nm 1 0 mkg 1 ...

Page 83: ...n hoses 1 Cracked Damaged Replace EXHAUST SYSTEM INSPECTION 1 Inspect Exhaust pipe 1 Muffer 2 Cracks Damage Replace 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 ...

Page 84: ...er holder is firm ly inserted in the hole in the adjusting dial 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 inspe...

Page 85: ...se resistance CAUTION Loosen lock nut 1 Turn the adjuster 2 either way to obtain the correct pedal height 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 Brake pedal position be...

Page 86: ...akage 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 Brake fluid may damage painted surfa...

Page 87: ...rial Out of specification Replace BRAKE HOSING INSPECTION 1 Inspect Brake hosing Cracks Damage Replace To replace hosing see section FRONT AND REAR BRAKE in Chapter 4 B B A a Wear limit a 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 A Front brake B Rear brake a A ...

Page 88: ...edures 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 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 ri...

Page 89: ...ugh 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 Drive chain slack 30 40 mm NOTE To check chain slack the motorcycle must stand in an upright position with its two wheels touching the ground and no one sitting on it Check slack in the position shown in t...

Page 90: ...tween the chain plates Steam cleaning high pressure washing and certain solvents can dam age these O Rings Use only kerosene to clean the 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 e...

Page 91: ...ont fork sev eral times Irregular jerky functioning Repair See section FRONT FORK in Chapter 4 ADJUSTING THE FRONT FORK This front fork is equipped with spring pre load ad justing bolts WARNING0 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 th...

Page 92: ...he shock absorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure 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 Never attempt to turn an adjusting mecha nism beyond the maximum or minimum set tings Adjust the spring p...

Page 93: ...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 Always tighten the locknut against the adjust ing nut and then tighten the locknut to the ...

Page 94: ...ring bearing Adjustment Remove the fuel tank See section SEAT FUEL TANK AND REAR COWLING Loosen steering axle nut 1 and fork upper bracket screws 2 Tighten the ring nut 3 with the special wrench 1 3 2 2 Ring nut final tightening 4 Nm 0 4 mkg Ring nut initial tightening 38 Nm 3 8 mkg Ringnut wrench P N 90890 01268 P N 90890 01348 NOTE The torque wrench and the ringnut wrench should form a right ang...

Page 95: ...ked 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 in...

Page 96: ... 150 kPa 160 kPa Off road riding 1 50 kgf cm2 1 60 kgf cm2 1 50 bar 1 60 bar High speed 210 kPa 240 kPa riding 2 10 kgf cm2 2 40 kgf cm2 2 10 bar 2 40 bar Maximum load 180 kg Total weight of rider passenger cargo and ac cessories 2 Adjust Air pressure Adjustment Remove the valve cap Use an air pump or Increase air compressed air pistol pressure Eliminate air by Air pressure pressing valve tube dim...

Page 97: ...trol It is not advisable to repair a punctured air tube 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 Valve stem lock nut Lock nut valve stem 1 5 Nm 0 15 kgm REAR Manufacture Size Type PIRELLI 90 90 21 54R MT70 MICHELIN 90 90 21 54S T63 Manufacture Size Type PIRELLI 130 80 18 66R MT70 MICHELIN 1...

Page 98: ...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 Replace Loose spoke Tighten 2 Tighten Spoke s NOTE Tighten the spokes b...

Page 99: ...eely To avoid such drawbacks replaced damaged cables as quickly as possible 1 Inspect Cable sheath Damaged Replace the cable assembly 2 Check Cable functioning Does not run freely Replace the cable assembly LEVER AND PEDAL LUBRICATION 1 Lubricate the pivoting parts Clutch lever Front brake lever Rear brake pedal Shift pedal Recommended lubricant SAE 10W30 motor oil ...

Page 100: ...D 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 1 REAR SUSPENSION LUBRICATION Lubricate the pivoting parts Recommended lubricant Molybdenum disulfide grease ...

Page 101: ... can cause severe burns or permanent eye injury First aid in case of bodily contact External 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 This is a sealed battery Never remove the sealing caps because the bala...

Page 102: ...checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected 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 5 Charge Battery refer to the appropr...

Page 103: ...d 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 conn...

Page 104: ...5 V Monitor the amperage for 3 5 minutes to check if the standard charging current is reached Adjust the voltage so that current is at standard charg ing level Set the timer according to the charging time suitable for the open circuit voltage Refer to Battery condition checking steps If the current does not exceed standard charging current af ter 5 minutes re place the battery In case that chargin...

Page 105: ...e is 15 V This type of battery charger cannot charge the MF battery A variable volt NOTE Voltage should be measured 30 min utes after the machine is stopped 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 quired Under 12 0 V Replace the battery NOTE Set the charging time at ...

Page 106: ...o the battery terminals First connect the positive lead 2 then the negative lead 1 7 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 8 Lubricate Battery terminals CAUTION 9 Install Panel Seat 1 2 Recommended lubricant Dielectric grease ...

Page 107: ...t for continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse 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 If the fuse immediately blows again check the electrical circuit Pocket tester 90890 03112 Fuses Amperage Quantity r...

Page 108: ...Seat REPLACING THE HEADLIGHT BULBS Low beam high beam 1 Remove Cowling screws 1 2 Remove Cowling from the meter bracket NOTE Remove the cowling from the meter bracket by lowering it to disengage it and then lifting it up 3 Remove Headlight 2 4 Disconnect Headlight coupler 3 5 Remove Headlight bulb cover 4 6 Remove Headlight bulb holder 5 by turning it counterclockwise a Headlight bulb WARNING Head...

Page 109: ...erclockwise Cowling screws 10 Nm 1 0 kgm 7 Install Headlight bulb new Headlight bulb holder by turning it clock wise b 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 w...

Page 110: ...lockwise 2 Install New bulb NOTE To install the bulb press it into place and turn it clockwise Lens Lens screw Do not overtighten the screw otherwise the lens may break CAUTION 4 Install Bulb new by pushing it in and turning it clockwise Bulb holder Upper side of the cowling onto the meter bracket Headlight adjust the headlight beam if necessary 5 Install Cowling screws Cowling screws 10 Nm 1 0 kg...

Page 111: ...1 Remove Screws 1 lens fixing Lens 2 Bulb 3 NOTE To remove the bulb press it into place and turn it counterclockwise a 2 Install New bulb NOTE To install the bulb press it into place and turn it clockwise b Lens Screws lens fixing Do not overtighten the screws otherwise the lens may break CAUTION ...

Page 112: ...INSP ADJ ...

Page 113: ...4 CHAS ...

Page 114: ... CALIPER DISASSEMBLY 4 18 CALIPER INSPECTION 4 18 CALIPER ASSEMBLY 4 19 CALIPER INSTALLATION 4 19 REAR WHEEL AND BRAKE DISC 4 21 REAR WHEEL AND BRAKE DISC REMOVAL 4 21 REAR WHEEL DISASSEMBLY 4 23 REAR WHEEL INSPECTION 4 23 BRAKE DISC INSPECTION 4 24 REAR WHEEL ASSEMBLY 4 25 REAR WHEEL INSTALLATION 4 25 WHEEL STATIC BALANCE ADJUSTMENT 4 27 REAR BRAKE 4 29 BRAKE PAD REMOVAL 4 29 BRAKE PAD REPLACEMEN...

Page 115: ...FORK ADJUSTMENT 4 60 STEERING 4 61 STEERING REMOVAL 4 64 STEERING INSPECTION 4 65 STEERING INSTALLATION 4 65 REAR SHOCK ABSORBER 4 69 NOTE ON DISPOSAL 4 72 SHOCK ABSORBER REMOVAL 4 73 SHOCK ABSORBER INSPECTION 4 74 SHOCK ABSORBER ADJUSTMENT 4 74 SWINGARM 4 76 SWINGARM REMOVAL 4 77 SWINGARM INSPECTION 4 78 LATERAL FREE PLAY ADJUSTMENT 4 79 SWINGARM INSTALLATION 4 80 DRIVE CHAIN DRIVE SPROCKET AND R...

Page 116: ...order removal WARNING Securely support the motorcycle so there is no danger of it falling over 1 Speedometer cable 1 Disconnect 2 Pinch bolt 2 Loosen 3 Wheel axle 1 4 Front wheel assembly 1 Refer to FRONT WHEEL INSTALLATION 5 Collar 1 section 6 Gear unit assembly 1 7 Brake disc screw 6 8 Brake disc 1 9 Ring 1 Reverse the removal procedure for instal lation ...

Page 117: ... name Part name Q ty Remarks Front wheel disassembly Remove the parts in order 1 Oil seal 1 2 Bearing 1 3 Spacer 1 Refer to FRONT WHEEL DISASSEMBLY 4 Oil seal 1 ASSEMBLY section 5 Bearing 1 Reverse the removal procedure for instal lation 1 2 3 5 4 ...

Page 118: ... hub FRONT WHEEL INSPECTION 1 Inspect Front wheel axle by rolling it on a flat surface Bends Replace WARNING Do not attempt to straighten a bent axle 2 Inspect Front tire Wear damage Replace Refer to TIRE INSPECTION in CHAP TER 3 Front wheel Refer to WHEEL INSPECTION in CHAPTER 3 3 Inspect Spoke s Bent Damaged Replace Loose spoke s Tighten Turn the wheel and hit the spokes gently with a screwdrive...

Page 119: ... the wheel hub or the wheel does not turn smoothly Replace Oil seal Wear damage Replace Front wheel runout limits Radial 1 1 0 mm Lateral 2 0 5 mm WARNING 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 After repairing or changing a tyre do not forget to tighten the valve l...

Page 120: ... b If out of specified limits Replace Maximum deflection brake disc 0 15 mm Minimum thickness brake disc 3 6 mm IFRONT WHEEL ASSEMBLY 1 Install Spacer Bearings Oil seal Assembly procedure Install the new bearing and the dust cover by fol lowing the disassembly procedures in reverse order NOTE Use a wrench 1 with an external diameter equal to that of the bearing and dust cover Do not strike the bea...

Page 121: ...el hub and the speedome ter gear unit are installed with the projections meshed into the slots Pinch bolt Front wheel axle 59 Nm 5 9 mkg NOTE Make sure that the slot a in the speedometer gear unit fits under the stopper on the front fork outer tube Pinch bolt 9 Nm 0 9 mkg a WHEEL STATIC BALANCE ADJUSTMENT 1 Remove Balancing weight 2 Set Wheel on a suitable stand 3 Find Heavy spot NOTE After replac...

Page 122: ...t 5 Check Wheel static balance Checking steps Turn the wheel so that it comes to each point as shown Check that the wheel is at rest at each point If not readjust the front wheel static balance Procedure a Spin the wheel and wait for it to rest b Put an X1 mark on the wheel s bottom spot c Turn the wheel so that the X1 mark is 90 up d Release the wheel and wait for it to rest Put an X2 mark on the...

Page 123: ...ty Remarks Brake pad removal Remove the parts in order 1 Brake caliper screw 2 2 Brake caliper 1 3 Pad pin retainer 2 Refer to BRAKE PAD REPLACEMENT 4 Pad pin 1 section 5 Brake pad 2 6 Pad spring 2 Reverse the removal procedure for instal lation 25 Nm 2 5 m kg 6 3 5 4 1 2 ...

Page 124: ...se injury Allow brake fluid to come into contact with painted or plastic parts as it may damage them Disconnect any hydraulic connection other wise the whole system must be disassem bled drained cleaned then properly filled and bled after reassembly CAUTION NOTE It is unnecessary to disassemble the brake hose to replace the pads NOTE If you replace the pads also replace the springs If one of the t...

Page 125: ...spongy Bleed air from brake circuit See section AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 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 pistons into the caliper with your finger Retighten the bleeder screw 2 Caliper bleeder screw 14 Nm 1 4 mkg Caliper fastenin...

Page 126: ...n order Brake fluid Drain 1 Rear view mirror right Master cylinder bracket 1 1 2 Brake lever 1 3 Brake switch 1 4 Union bolt 1 5 Plain washer 2 Refer to MASTER CYLINDER INSTAL 6 Brake hose 1 LATION section 7 Master cylinder 1 Reverse the removal procedure for instal lation 2 6 4 7 1 9 Nm 0 9 m kg 20 Nm 2 0 m kg 3 5 New ...

Page 127: ...inder disassembly Remove the parts in order 1 Reservoir cap 1 2 Diaphragm 1 3 Master cylinder boot 1 Refer to MASTER CYLINDER ASSEM 4 Circlip 1 BLY section 5 Master cylinder assembly 1 6 Spring 2 Reverse the disassembly procedure for assembly 1 5 Nm 0 15 m kg 6 3 5 4 1 2 ...

Page 128: ... 2 Inspect Master cylinder piston unit 1 Scratches wear damage Replace the master cylinder assembly 3 Inspect Diaphragm Wear damage Replace 4 Inspect Brake hose Cracks wear damage Replace MASTER CYLINDER ASSEMBLY 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 ...

Page 129: ...ew Brake hose 2 Union bolt 3 Union bolt brake hose 20 Nm 2 0 mkg NOTE When tightening the union bolt be sure to put the brake hose in the correct position Check that the brake hose has stayed in the correct position Adjust if necessary WARNING Check that the brake hose routing is as described Refer to CABLE ROUTING section Always use new plain washers 3 Fill Brake fluid reservoir Recommended brake...

Page 130: ...uids 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 4 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM section in CHAPTER 3 5 Inspect Brake fluid level Lower than MIN mark Fill Refer to BRAKE FLUID INSPECTION section in CHAPTER 3 a Minimu...

Page 131: ...per removal Remove the parts in order Brake fluid Drain 1 Union bolt 1 2 Plain washer 2 3 Brake hose 1 Refer to CALIPER INSTALLATION sec 4 Caliper support bolt 2 tion 5 Caliper assembly 1 Reverse the removal procedure for instal lation 20 Nm 2 0 m kg 2 5 1 25 Nm 2 5 m kg 3 4 New ...

Page 132: ...ssembly Remove the parts in order Brake pad Refer to BRAKE PAD section 1 Pad spring 2 2 Caliper piston 2 3 Dust seal 2 Refer to BRAKE CALIPER DISASSEM 4 Piston seal 2 BLY ASSEMBLY section 5 Bleed screw 1 Refer the disassembly procedure for as sembly 2 5 14 Nm 1 4 m kg 3 4 1 ...

Page 133: ...damaged Replace the brake caliper assembly Recommended programme for the 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 WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Do not use solvents to pre...

Page 134: ...peration of the brake caliper replace the brake caliper assembly Recommended brake fluid DOT 4 2 Install Brake caliper pistons 1 CALIPER INSTALLATION 1 Install Brake caliper 1 Caliper support bolts 2 Bolt caliper support 25 Nm 2 5 mkg Union bolt 20 Nm 2 0 mkg WARNING In case of non correct operation of the brake caliper replace the brake caliper assembly 1 Install Piston seals 1 Dust seals 2 Brake...

Page 135: ...e 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 4 Inspect Brake fluid level Lower than MIN mark Fill Refer to BRAKE FLUID I...

Page 136: ...al Remove the parts in order WARNING Securely support the motorcycle so there is no danger of it falling over 1 Axle nut 1 2 Wheel axle 1 3 Drive chain 4 Collar 2 5 Rear wheel assembly 1 6 Brake disc 1 Push the wheel forward and remove the chain Refer to REAR WHEEL INSTALLATION section Reverse the removal procedure for installation ...

Page 137: ...disassembly Remove the parts in order 1 Driven sprocket 1 2 Hub 1 3 Damper 4 4 Spacer 1 Refer to REAR WHEEL DISASSEMBLY AS 5 Oil seal 1 SEMBLY section 6 Bearing 1 7 Bearing 1 8 Hub dust cover 1 9 Oil seal 1 10 Bearing 1 Reverse the removal procedure for installa 11 Bearing spacer 1 tion ...

Page 138: ...side to avoid damaging the hub WARNING Do not attempt to straighten a bent axle Disassemble the bearing 1 with a normal puller 2 REAR WHEEL INSPECTION 1 Inspect Rear wheel axle by rolling it on a flat surface Bends Replace 2 Inspect Rear tire Refer to TIRE INSPECTION in CHAP TER 3 Rear wheel Refer to WHEEL INSPECTION in CHAPTER 3 3 Inspect Spoke s Bent Damaged Replace Loose spoke s Tighten Turn th...

Page 139: ...rn smoothly Replace Hub dust cover Wear damage Replace Oil seal Wear damage Replace Rear wheel runout limits Radial 1 1 0 mm Lateral 2 0 5 mm BRAKE DISC INSPECTION 1 Inspect Brake disc Wear Damage Replace 2 Measure Brake disc deflection a If over envisaged limits Verify wheel centring If the wheel centring is correct replace the brake disc Misure at 2 mm from disc edge Brake disc thickness b If ou...

Page 140: ...reverse order REAR WHEEL INSTALLATION 1 Install Brake disc 1 NOTE Use a wrench 1 with an external diameter equal to that of the bearing dust cover and oil seal Do not strike the bearing inner race 2 or balls 3 The contact must only be made with the outer race 4 CAUTION 2 Install Hub spacer 1 Driven sprocket 2 Hub and driven sprocket Screw brake disc 12 Nm 1 2 mkg NOTE Apply LOCTITE to the threads ...

Page 141: ...at the brake disc is driving through the brake pads CAUTION Make sure the collars and chain pullers are positioned correctly CAUTION 6 Install Drive chain on the driven sprocket Rear wheel axle left side 7 Adjust Drive chain slack Drive chain slack 30 40 mm Refer to DRIVE CHAIN SLACK INSPEC TION AND ADJUSTMENT section in Chapter 3 8 Tighten Wheel axle nut Wheel axle nut 115 Nm 11 5 mkg 4 Lubricate...

Page 142: ...eel s bottom spot c Turn the wheel so that the X1 mark is 90 up d Release the wheel and wait for it to rest Put an X2 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 4 Adjust Wheel static balance Adjusting steps Install a balancing weight 1 on the rim exact ly opposite to the heavy spot X Turn ...

Page 143: ...ND BRAKE DISC 4 28 CHAS 5 Check Wheel static balance Checking steps Turn the wheel so that it comes to each point as shown Check that the wheel is at rest at each point If not readjust the rear wheel static balance ...

Page 144: ...rts in order Rear wheel Refer to REAR WHEEL REMOVAL section Brake hose Remove from clamp 1 Caliper protector 1 2 Pad pin retainer 1 3 Pad pin 1 4 Brake pad 1 Refer to BRAKE PAD REPLACEMENT 5 Brake caliper remove from caliper 2 section support 6 Brake pad support 1 Reverse the removal procedure for instal lation ...

Page 145: ... into contact with painted or plastic parts as it may damage them Disconnect any hydraulic connection other wise the whole system must be disassem bled drained cleaned then properly filled and bled after reassembly CAUTION NOTE It is unnecessary to disassemble the brake hose to replace the pads NOTE If you replace the pads also replace the pad support If one of the two pads has to be replaced beca...

Page 146: ...r bleeder screw 14 Nm 1 4 mkg Caliper protector bolt 10 Nm 1 0 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 3 Install Brake pads Pad support 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 calipe...

Page 147: ...op switch connector 1 2 Rear stop switch 1 3 Plain washer 2 Refer to MASTER CYLINDER INSTALLA 4 Brake hose 1 TION section 5 Brake fluid reserve tank 1 6 Brake master cylinder 1 Refer to BRAKE PEDAL REMOVAL sec 7 Brake pedal spring 1 1 tion Reverse the removal procedure for installa tion New New 20 Nm 2 0 m kg 45 Nm 4 5 m kg 10 Nm 1 0 m kg 4 Nm 0 4 m kg ...

Page 148: ...nspect Master cylinder piston unit Scratches wear damage Replace the master cylinder assembly 3 Inspect Diaphragm 1 Wear damage Replace 4 Inspect Brake hose Cracks wear damage Replace MASTER CYLINDER ASSEMBLY 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 brak...

Page 149: ...ve tank mounting bolt 4 Nm 0 4 mkg New 2 Fill Brake fluid reserve tank Recommended brake fluid DOT 4 Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately CAUTION WARNING 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 flu...

Page 150: ...ION section in Chapter 3 1 Minimum level mark MIN BRAKE PEDAL REMOVAL 1 Remove Split pin 1 new Plain washer 2 Pin 3 2 Unscrew Bolt 4 3 Remove Spring 5 4 Remove 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 a 1 5 Adjust Brake pedal height a below the top of the footrest Brake pedal height 10 mm ...

Page 151: ... wheel Refer to REAR WHEEL REMOVAL sec tion Brake fluid Drain Brake hose Remove from clamp 1 Caliper protector 1 2 Brake caliper 1 Remove from caliper support 3 Union bolt 1 Refer to BRAKE CALIPER INSTALLA 4 Plain washer 2 TION section 5 Brake hose 1 6 Brake pad support 1 Reverse the removal procedure for installa tion ...

Page 152: ...r 1 Caliper protector 1 2 Brake pad support 1 3 Brake pad 2 Refer to BRAKE PAD section 4 Pad support 1 5 Caliper piston 1 Refer to BRAKE CALIPER DISASSEM 6 Dust seal 1 BLY ASSEMBLY section 7 Piston seal 1 8 Bleed screw 1 Reverse the removal procedure for installa tion New 14 Nm 1 4 m kg 2 10 Nm 1 0 m kg ...

Page 153: ...iper Cracks damaged Replace 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 WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Do not use solvents to prevent sealing eleme...

Page 154: ... case of non correct operation of the brake caliper replace the brake caliper assembly Liquido freni raccomandato DOT 4 CALIPER INSTALLATION 1 Install Brake caliper 1 Caliper support 2 Brake hose 3 Plain washers 4 new Union bolt 5 Union bolt 20 Nm 2 0 mkg WARNING In case of non correct operation of the brake caliper replace the brake caliper assembly 1 Install Piston seal 1 Dust seal 2 Caliper pis...

Page 155: ... or plastic parts Always clean up spilled fluid immediately CAUTION WARNING 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 boi...

Page 156: ...CHAS REAR BRAKE 4 41 4 Inspect Brake fluid level Lower than MIN mark 1 Fill Refer to BRAKE FLUID INSPECTION section in Chapter 3 1 Minimum level mark MIN 1 ...

Page 157: ...nt wheel Refer to FRONT WHEEL section 1 Inner tube protector 1 2 Brake hose guide 1 3 Protector guide 2 4 Brake caliper assembly 1 5 Cowling displace 1 6 Pinch bolt upper bracket 4 7 Cap bolt loosen 2 Refer to FRONT FORK INSTALLATION section 8 Pinch bolt under bracket loosen 4 9 Fork leg 2 Reverse the removal procedure for instal lation ...

Page 158: ...order Refer to FRONT FORK REMOVAL INSTAL LATION 1 Cap bolt 1 2 Seat 1 3 Spacer 1 Refer to OIL REPLACEMENT section 4 Seat 1 5 Fork spring 1 6 Bolt 1 7 O ring 1 8 Damper adjusting cylinder 1 Refer to SEAL AND BUSH REPLACE 9 Taper spindle 1 MENT section 10 Dust seal 1 11 Snap ring 1 FRONT FORK DISASSEMBLY ...

Page 159: ...Job name Part name Q ty Remarks 12 Inner tube 1 13 Inner tube bushing 1 14 Oil seal 1 Refer to SEAL AND BUSH REPLACE 15 Washer 1 MENT section 16 Outer tube bushing 1 17 Outer tube 1 Reverse the removal procedure for instal lation ...

Page 160: ...NG FREE LENGTH 530 mm INNER TUBE BENDING LIMIT 0 2 mm 1 Park the motorcycle on a level surface 2 Raise the front wheel by placing a suitable support under the engine 3 Remove Front wheel Refer to FRONT WHEEL REMOVAL section 4 Remove Inner tube protector Protector guide Gear unit assembly and cable Brake caliper and hose 5 Loosen Cap bolt Pinch bolt upper and lower bracket WARNING Securely support ...

Page 161: ...e good efficiency of the fork CAUTION 1 Generally clean the front fork 2 Loosen Cap bolt inner tube 3 Remove Fork leg 4 Unscrew Cap bolt 1 completely NOTE Place the components in a clean area 5 Withdraw Seat 2 Spacer 3 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...

Page 162: ...y 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 Oil level Standard 180 mm Minimum 190 mm Maximum 170 mm From top of inner tube with inner tube fully inserted without spring 12 Screw Cap bolts 5 on inner tube without tighten 13 Install Fork leg 11 Insert Spring 1 into the inner tube 2 Seat...

Page 163: ... 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 Cap bolt on inner tube 14 Tighten Pinch bolt upper and lower bracket Pinch bolt upper bracket 28 Nm 2 8 mkg Pinch bolt under bracket 23 Nm 2 3 mkg ...

Page 164: ...e 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...

Page 165: ... SEAL AND BUSH REPLACEMENT NOTE 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 To remove the fork leg from the steering unit the cap bolt the spring and to drain and refill the oil follow t...

Page 166: ...he end of the damper rod holder is correctly engaged on the damper cylinder assembly CAUTION 4 Remove 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 T handle 1 90890 01326 Front fork damper rod holder 2 90890 01460 Taking care not to let petrol enter the inside of the damper cylinder assembly as it would se...

Page 167: ...e oil seal seat 5 Then withdraw the dust seal using force 5 4 5 4 1 2 8 Remove Snap ring 1 using a screwdriver 1 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 ...

Page 168: ...Install Outer tube DU bush 6 new Inner tube DU bush 7 new Check that the inner tube bush 7 is inserted correctly in its seat on the end of the inner tube CAUTION 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 D...

Page 169: ...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 DU bush oil seal driver 1 90890 11043 5 4 3 40 mm 1 2 4 5 4 3 2 1 15 The vice tightened grip the outer tube and with a few strong blows hit it...

Page 170: ... the outer tube 17 Install Snap ring 1 Check that the snap ring is correctly seated CAUTION 18 Install Dust seal 1 new NOTE Apply lightweight lithium soap base grease to the dust seal before installing it NOTE Taking care to insert completely the dust seal 1 with force in the outer tube 2 1 1 1 2 3 2 1 ...

Page 171: ...on 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 2 1 19 Insert 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 During...

Page 172: ...ork CAUTION 1 Inspect Cap bolt inner tube Wear Damage Replace O Rings Damage Replace 2 Measure Fork spring free length a Out of specification Replace Fork spring free length 530 mm Inner tube bending limit 0 2 mm 3 Inspect Inner tube surface Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil seal surface Replace Inner tube bending Out of specification Replace Use a dial gauge 1...

Page 173: ...ORK 4 58 CHAS WARNING Do not attempt to straighten a bent inner tube as this may have dangerous consequences 4 Inspect Outer tube 1 Score marks Wear Damage Replace 5 Inspect Cap bolt O ring Wear Damage Replace ...

Page 174: ...top end a Standard 0 mm 4 Tighten 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 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 Front wheel Caliper Brake hose Tachometer cable Refer to FRONT WHEEL a...

Page 175: ...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 a 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 Standard 4 Maximum hard 5 6 7 8 9 10 ...

Page 176: ... to pre vent it falling over Front wheel Refer to FRONT WHEEL REMOVAL sec tion Fork legs Refer to FRONT FORK section 1 Cowling Meter unit 1 Displace 2 Front fender 1 3 Handle upper holder 2 4 Handle lower holder 1 5 Handlebar 1 Displace 6 Nut 1 7 Upper bracket 1 8 Special washer 1 TIGHTENING PROCEDURE Initial tightening 38 Nm 3 8 mkg Loosen 1 turn Final tightening 4 Nm 0 4 mkg ...

Page 177: ...ING REMOVAL INSTAL 10 Lower ring nut 1 LATION section 11 Ball race cover 1 12 Lower bracket Steering axle 1 13 Bearing upper 1 14 Bearing lower 1 Reverse the removal procedure for instal lation TIGHTENING PROCEDURE Initial tightening 38 Nm 3 8 mkg Loosen 1 turn Final tightening 4 Nm 0 4 mkg ...

Page 178: ...washer 6 Upper bracket 7 Brake hose holder 8 Plate washer 9 Special washer 10 Upper ring nut 11 Lower ring nut 12 Ball race cover 13 Bearings 14 Steering lock 15 Steering axle 16 Wire guide TIGHTENING PROCEDURE Initial tightening 38 Nm 3 8 mkg Loosen 1 turn Final tightening 4 Nm 0 4 mkg ...

Page 179: ...fer to FRONT WHEEL REMOVAL section Front fork Refer to FRONT FORK REMOVAL sec tion 4 Remove Front fender Cowling Handlebar Meter assembly Ring nut wrench 3 90890 01348 5 Remove Steering axle nut 1 Use the ring nut wrench 3 WARNING Support the motorcycle securely to prevent it falling over 6 Remove Ring nut upper 1 Use the ring nut wrench 2 Ring nut wrench 2 90890 01268 ...

Page 180: ... 1 Corrosion Damage 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 Steering axle 1 Bend Damage Replace STEERING INSTALLATION 1 Install Bearing 1 Ball race cover 2 NOTE Apply lithium soap base grease to the bearing and ball race cover lip 2 Install Lower bracket 1 NOTE Ap...

Page 181: ...ng nut 1 using the ring nut wrench Ring nut lower initial tightening 38 Nm 3 8 mkg Loosen the ring nut completely and retighten it to specification WARNING Do not tighten excessively Ring nut lower final tightening 4 Nm 0 4 mkg 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 5 Install Ring nut upper 1...

Page 182: ...r NOTE Make sure the special washer tabs are in the slots 6 Install Upper bracket Fork legs left and right 1 NOTE Temporarily install the under bracket pinch bolt to achieve the correct fork position Front fork top end a standard 0 mm 7 Install Plate washer 1 Steering axle nut 2 Use the lock nut wrench 4 Lock nut wrench 4 90890 01348 NOTE Set the torque wrench to the lock nut wrench so that they f...

Page 183: ...er holder 40 Nm 4 0 mkg Flange bolt handlebar holder 20 Nm 2 0 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 Tighten the pinch bolt to specified torque If torqued too much it may cause malfunction ing of the front fork 10 Install Handlebar holder Handlebar Handlebar up...

Page 184: ...T FUEL TANK AND REAR Fuel tank Rear cowling COWLING section in Chapter 3 Battery leads 2 Disconnect NOTE First disconnect the negative lead then the positive lead 1 Muffler 1 2 Exhaust pipe assembly 1 Refer to REAR SHOCK ABSORBER RE 3 Rear frame 1 MOVAL section 4 Brake fluid reserve tank 1 Secure the brake fluid tank to the frame in 5 Air filter case 1 an upright position to avoid air entering the...

Page 185: ...REAR SHOCK ABSORBER 4 70 CHAS Order Job name Part name Q ty Remarks 6 Lower bolt 1 7 Upper bolt 1 Reverse the removal procedure for instal lation ...

Page 186: ...CHAS REAR SHOCK ABSORBER 4 71 1 Rear shock absorber 2 Spring 3 Spring adjuster ring nut 4 Lock ring nut 5 End of stroke buffer 6 Special spanner ...

Page 187: ...e Do not deform or damage the cylinder in any way Damage to the cylinder would impair the damping effect Be 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 Before neutralising the rear shock absorber The gas pressure must be discharged before dis posing of the shock absorber it...

Page 188: ...EL TANK AND REAR COWLING in CHAPTER 3 3 Disconnect Battery leads 8 Remove Upper mounting bolt 1 Rear shock absorber 1 NOTE First disconnect the negative lead then the posi tive lead 4 Remove Exhaust pipe assembly Rear frame Air filter case 5 Raise the rear wheel placing a suitable sup port under the engine 6 Remove Rear wheel Refer to REAR WHEEL REMOVAL sec tion 7 Remove Shock absorber fastening n...

Page 189: ...e 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 Use the special wrench included in the owner s tool kit to make the adjustment 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 dist...

Page 190: ...EAR SHOCK ABSORBER 4 75 2 Tighten the locknut to the specified torque Locknut 45 Nm 4 5 m kgf Always tighten the locknut against the adjust ing nut and then tighten the locknut to the specified torque CAUTION ...

Page 191: ...SWINGARM 4 76 CHAS SWINGARM 1 Upper chain case 2 Swingarm 3 Chain support 4 Swingarm guard seal 5 Connecting rod 6 Relay arm A LATERAL FREE PLAY END 1 0 mm B LATERAL FREE PLAY 0 4 0 7 mm ...

Page 192: ...ich fastens the swingarm pivot shaft 1 Nut pivot shaft 90 Nm 9 0 mkg Lateral free play at end of swing arm Limit 1 0 mm 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 Check the vertical movement B of the swingarm moving it up and down If the movement seems rigid unsmooth or jerky inspect the inte...

Page 193: ...ingarm Deformation Cracks Damage Replace 2 Inspect Connecting rod 1 Relay arm 2 Deformation Cracks Damage Replace 3 Inspect Oil seals Wear Damaged Replace Washers Thrust cover Wear Damaged Replace Bushes Scratches Damaged Replace Bearings Pitting Damaged Replace 4 Inspect Chain guard seal Chain case and support Wear Damage Replace 1 2 ...

Page 194: ...e play C 0 4 0 7 mm Measurement of adjust shim 1 0 3 mm 2 Measure Length B1 and B2 3 Calculate Lateral swing arm side play C Out of specification Adjust free play with special shims Use the following formula C A1 A2 B1 B2 4 Adjust Lateral side play using one or more adjust shims 1 NOTE When only one shim is used install it on the left side when two shims are used install one on each side ...

Page 195: ...Bolt relay arm Bolt shock absorber Lithium base grease 2 Tighten Nut relay arm swingarm 66 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 Screw chain case 4 Nm 0 4 mkg Nut relay arm frame 60 Nm 6 0 mkg Bolt rear shock absorber 59 Nm 5 9 mkg 3 Install Rear wheel Refer to REAR WHEEL INSTALLATIO...

Page 196: ...e chain slack 30 40 mm Refer to DRIVE CHAIN SLACK ADJUST MENT in CHAPTER 3 5 Install Fuel tank Rear cowling Seat Bolt seat 10 Nm 1 0 mkg Refer to SEAT FUEL TANK AND REAR COWLING section in CHAPTER 3 4 Adjust Drive chain slack ...

Page 197: ...N REMOVAL 1 Park the motorcycle upright on an even sur face 2 Remove Shift pedal 1 Cover 2 drive sprocket 3 Remove Drive sprocket 1 NOTE 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 WARNING Set the motorcycle up securely to prevent it falling over 5 Remove Rear wh...

Page 198: ...o measure it The length of the 10 links is recorded between the inside of the link pins 1 and 11 as shown The length of the 10 links is measured at var ious points 2 Clean Drive chain Immerge in kerosene and brush thorough ly to remove as much dirt as possible Remove from kerosene and allow to dry This motorcycle is fitted with a chain with small O Rings 1 fitted between its plates Vapour cleaning...

Page 199: ... 90 engine oil or special lubricant for O Ring chains 5 Inspect Drive chain Rigid Clean and lubricate replace if necessary 6 Inspect Drive sprocket Rear wheel sprocket Wear over 1 4 tooth 1 Replace Teeth bent Replace 2 Undamaged tooth profile 3 Roller 4 Sprocket How to replace the rear wheel sprocket With wheel removed 1 Remove Hub 1 Sprocket fastening bolts 2 Rear wheel sprocket 3 2 Install New s...

Page 200: ...OVAL operations in reverse order Pay special attention to the following points 1 Install Drive chain Swingarm 2 Install Rear wheel Refer to REAR WHEEL INSTALLATION section 3 Install Drive sprocket WARNING Always use a new lock washer NOTE Tighten the drive sprocket nut with the rear brake pulled After tightening the nut bend the tab on the lock washer once more over the faces of the nut 4 Adjust D...

Page 201: ... SPROCKET 4 86 CHAS 5 Tighten Rear wheel axle nut Rear wheel axle nut 115 Nm 11 5 mkg Screws drive sprocket cover 10 Nm 1 0 mkg Bolt shift pedal 10 Nm 1 0 mkg Refer to REAR WHEEL INSTALLATION section 7 Install Cover drive sprocket Shift pedal ...

Page 202: ...ENG 5 ...

Page 203: ...3 CRANKCASE R 5 14 GEARBOX AND TRANSMISSION 5 16 BALANCER SHAFT AND CRANKSHAFT 5 17 OILSTRAINER 5 17 ROCKER ARMS 5 18 VALVES 5 19 INSPECTION AND REPAIR 5 21 CYLINDER HEAD 5 21 VALVES AND VALVE GUIDES 5 22 VALVESEAT 5 23 VALVE SPRINGS 5 27 CAMSHAFT 5 28 ROCKER ARMS AND ROCKER SHAFT 5 28 CAMSHAFT CHAIN AND SPROCKET 5 29 CAMSHAFT CHAIN GUIDE 5 30 CYLINDER AND PISTON 5 30 PISTON RINGS 5 32 PISTONPIN 5...

Page 204: ...ASE 5 50 ENGINE OIL STRAINER 5 51 CRANKCASE 5 51 SHIFT SHAFT AND OIL PUMP 5 52 TIMING CHAIN 5 54 PISTON AND RINGS 5 55 CYLINDER 5 56 CYLINDER HEAD 5 57 CAMSHAFT AND TIMING CHAIN 5 58 PISTON CYLINDER CYLINDER HEAD AND CAMSHAFT 5 59 AC GENERATOR 5 65 OIL FILTER AND OIL HOSES 5 67 BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR 5 68 CLUTCH 5 70 STARTER GEARS 5 73 STARTER NEUTRAL GEAR AND CRANKCASE ...

Page 205: ...OCKET AND SHIFT PEDAL Order Job name Part name Q ty 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 WARNING Securely support the motorcycle so there is no danger of it falling over ...

Page 206: ... the seat the fuel tank and the rear cowling refer to SEAT FUEL TANK AND REAR COWLING section in CHAPTER 3 1 Battery leads connector 1 Disconnect 2 Muffler 1 3 Exhaust pipe 1 4 Engine protector 1 5 Shift pedal 1 6 Drive sprocket crankcase cover 1 7 Drive sprocket 1 Displace the drive chain 8 Clutch cable 1 Disconnect 9 Plug cap 1 Disconnect ...

Page 207: ...connect Starter 1 Remove 10 Connectors of engine wire harness 2 Disconnect 11 Oil delivery hose 1 Disconnect 12 Oil return hose 1 Disconnect 13 Oil breather pipe to oil tank Disconnect 14 Oil breather pipe to air filter box Disconnect Reverse the removal procedure for installation ...

Page 208: ...pay special care with the rear arm 1 Stay of oil tank Remove the mounting screws to engine 2 Hose clamp carburetor 2 Loosen 3 Pivot shaft rear top 1 4 Engine mounting bolt 1 rear lower 5 Engine stay front lower 1 6 Engine stay front top right left 1 7 Engine assembly 1 CAUTION ENGINE MOUNTING BOLT NOTE Remove the engine from the lower side Reverse the removal procedure for installation ...

Page 209: ...ylinder camshaft and piston can be examined with the engine installed by removing the following parts Seat Fuel tank Rear cowling Carburetor Exhaust pipe 1 Remove Spark plug 1 Tappet cover 2 intake Tappet covers 3 exhaust Cylinder head cover 4 Cap 5 Pins 6 2 Loosen Bolt 1 chain tensioner 3 Remove Chain tensioner 2 ...

Page 210: ...t 1 Camshaft 2 Caps left crankcase cover NOTE Fix a safety wire 3 to the timing chain to prevent it falling into the crankcase 5 Remove Chain stopper guide 1 6 Remove Cylinder head NOTE Loosen all bolts by a 1 4 turn and remove once all are loosened ...

Page 211: ...1 9 Remove 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 Pin 1 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 ...

Page 212: ...mediate starter gear 1 Bearing 2 Distributor shaft 3 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 Exhaust pipe Starter Sprocket cover 1 Remove Cover 1 intermediate starter gear Centring pins Gasket ...

Page 213: ...clamp 1 Coil 2 Stator 3 CRANKCASE COVER R CLUTCH PRIMARY DRIVE GEAR AND BALANCER SHAFT GEAR NOTE The clutch the primary gear and the balance gear may be inspected with the engine installed by removing the following parts Footrest R Oil delivery hose screw 5 Remove Intermediate starter gear 1 Bearing 2 Distributor shaft 3 ...

Page 214: ...st plate 8 Clutch shroud 9 Push rod 10 1 Remove Engine oil delivery hose screw Copper washer Oil filter cover 1 Oil filter Seal ring and O Ring Crankcase cover 2 R NOTE Before loosening the nut 11 clutch shroud straighten the washer lock tab To loosen the nut clutch boss block the clutch boss using the special tool 12 Clutch holding tool P N 90890 04086 ...

Page 215: ...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 Be careful not to touch jutting edges 12 on the rotor with the sheave holder CAUTION 4 Remove Push lever 1 Spring Flat washer NOTE Loosen the screw to remove the push rod ...

Page 216: ...e engine installed by removing the following parts Footrest R Oil delivery hose screw Crankcase R Clutch 1 Remove Circlip 1 Oil pump gear 2 Oil pump 3 O rings 4 2 Remove Circlip 1 from drive shaft Ring 2 Circlip 3 3 Remove Circlip 1 Shift lever 2 Spring 3 Flat washer 4 4 Remove Stopper lever 1 Ring 2 Spring 3 ...

Page 217: ... Nut 1 Washer 2 Rotor 3 with starter gear Bearing 4 Shim adjustment washer 5 Key 6 NOTE To loosen the nut rotor lock the rotor with the special tool 7 Sheave holder P N 90890 01701 Flywheel puller P N 90890 01362 Be careful not to touch the jutting edges 8 on the rotor with the special tool CAUTION NOTE Remove the rotor with the puller 1 2 Remove Chain guide 1 Timing chain 2 ...

Page 218: ...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 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 If the crankcase fails come out lever at points 2 being careful not to damage the...

Page 219: ...e 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 CAUTION ...

Page 220: ...ISASSEMBLY 5 16 ENG GEARBOX AND TRANSMISSION 1 Remove Guide bar 1 Shift cam 2 Selector fork 3 3 Selector fork 2 4 Selector fork 1 5 2 Remove Transmission assembly unit 1 3 Remove Shift shaft 1 1 Shift shaft 2 2 ...

Page 221: ...tool 2 Crankcase separating tool P N 90890 01135 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 It is advisable to replace the oil strainer every time the engine is disassembled 1 Remove Oil strainer 1 Oil passage cover 2 Gasket ...

Page 222: ... engine installed by removing the following parts Seat Fuel tank Cylinder head cover 1 Remove Cap 1 2 Remove Bolts 1 rocker shaft 3 Remove Rocker shaft Rocker arms NOTE Remove the rocker shaft using sliding hammer 1 and weight 2 Sliding hammer bolt P N 90890 01083 Weight P N 90890 01084 ...

Page 223: ...heck 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 Inspection steps Pour clean solvent 1 into the intake and exhaust ports Check the valve seal There must be no blow bys from the valve seat...

Page 224: ...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 Compress the valve spring using tool 8 to remove the cotters Valve spring compressor P N 90890 04019 ...

Page 225: ...rk plug thread valve seats combustion chamber 2 Inspect Cylinder head Scratches Damage Replace 3 Measure Deformation Out of specification Rework the surface Cylinder head deformation Less than 0 03 mm 4 Surface Cylinder head 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 numbe...

Page 226: ...57 mm Limit 0 10 mm 1 Bore gauge Replacement steps NOTE Heat the cylinder head in an oven at 100 C to facilitate the removal and installation of the guides and to maintain correct locking interference Remove the valve guide using the special punch 1 Install the new guide using the special instal lation tool 2 After installing the valve guide bore with spe cial tool 3 to obtain valve guide free pla...

Page 227: ... Limit 0 8 mm Exhaust 0 8 1 2 mm Limit 0 65 mm 5 Check Valve stem tip Deformed mushroom shaped or with a higher diameter than the rest of the stem Replace valve Misalignment Out of specification Replace valve Stem offsetting Limit 0 01 mm NOTE Changing the valve replace also the valve guide Pulling the valve out replace the stem seal VALVE SEAT 1 Clean the valve surface and seat of carbon deposits...

Page 228: ...r head Press the valve onto the housing through the guide to leave a clear outline Measure the width of the valve seat Where there is contatc between valve and seat the Prussian blue is wiped away If the valve seat is too narrow wide or off cen tre the valve seat must be renewed 4 Renew Valve seat Use the special tool 1 to renew the valve seat with 30 45 and 60 mills Turning the cutter maintain un...

Page 229: ...tring of seat and type attainment of 1 0 mm 45 width Intervention Desired effect on the valve seat Cutter 60 first Centring of seat and type attainment of 1 0 mm 45 width Intervention Desired effect on the valve seat Cutter Centring of seat and type 45 attainment of 1 0 mm width B If the valve surface is like this it means that the valve seat is centred on the valve surface but is too narrow C If ...

Page 230: ...m CAUTION Apply oil to the molybdenum disulfide on the valve stem Install the valve in the cylinder head Turn the valve until face and surface are not evenly polished Then clean away all the lap ping compound NOTE For best results during lapping repeatedly apply light pressure to the valve seat turning the valve backwards and forwards by hand Apply a fine lapping compound on the valve seal surface...

Page 231: ... Out of specification Replace Free width of valve springs intake and exhaust Internal spring External spring 40 1 mm 43 8 mm 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 N 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 2 Measure Spring load Out of specification Replace b Length ...

Page 232: ... camshaft a b Intake 36 47 36 57 mm 30 06 30 16 mm Exhaust 36 62 36 72 mm 30 11 30 21 mm ROCKER ARMS AND ROCKER SHAFT 1 Inspect Rocker shafts Blue colour Grooves Replace shafts and check lubrication system 2 Inspect Rocker shaft slot 1 Surface in contact with cam eccentric 2 Adjuster surface 3 Pitting Wear Scratches Blue colour Replace and check lubrication system ...

Page 233: ...ternal diameter b of shaft Out of specification Replace whole unit Rocker shaft clearance 0 009 0 042 mm CAMSHAFT CHAIN AND SPROCKET 1 Inspect Chain Stiffness Cracks Replace timing chain and sprocket 2 Inspect Sprocket Wear Damage Replace timing chain and sprocket 1 1 4 tooth maximum 2 New sprocket tooth profile 3 Roller 4 Sprocket ...

Page 234: ... cylinder bore C with a cylinder gauge 1 50 mm from top of cylinder NOTE Measure bore parallel and at right angles to the driving shaft Then calculate average measure ment First step Standard Wear limit Cylinder 94 97 95 02 mm 95 1 mm bore C C X Y 2 If the measurements are out of tolerance replace the cylinder liner piston and circlips all together Measure diameter P of the piston skirt with a mic...

Page 235: ...her Calculate the piston cylinder free play accord ing to the following formula Third step Piston cylinder clearance Cylinder boring C Piston skirt diameter P Piston cylinder clearance 0 045 0 065 mm Limit 0 15 mm If the measurements are out of tolerance replace the cylinder liner piston and circlips all together ...

Page 236: ...06 mm Piston ring end gap fitted into cylinder Upper ring 0 30 0 45 mm Limit 0 7 mm Lower ring 0 30 0 45 mm Limit 0 8 mm Oil scraper tracks 0 20 0 70 mm 2 Install Ring into the cylinder NOTE 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...

Page 237: ...it 0 07 mm 2 Measure External diameter a of pin Out of specification Replace 3 Measure 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 CLUTCH 1 Inspect Clutch gear assy teeth Cracks Pitting on edges Moderate Burr Accentuated Replace clutch gear assy NOTE Pitting of the gear assy teeth ...

Page 238: ...gular functioning 4 Measure Thickness of friction plates Out of specification Replace all plates Thickness Wear limit Type A 2 94 3 06 mm 2 8 mm 2 parts Type B 2 72 2 88 mm 2 6 mm 6 parts 5 Measure Deformation of clutch plates Out of specification Replace all plates Clutch plates deformation Limit 0 2 mm Clutch push rod runout Limit 0 2 mm 6 Measure Runout limit of clutch push rod Turn clutch push...

Page 239: ... and the pump stator 3 Out of specification Replace oil pump Free length of clutch compression spring a 42 8 mm Oil pump clearances Clearance between 0 12 mm rotors a Limit 0 2 mm Side clearance b 0 03 0 08 mm Limit 0 15 mm 2 Inspect Oil pump drive gear 1 Oil pump driven gear 2 Wear Cracks Damage Replace PRIMARY TRANSMISSION 1 Inspect Primary drive gear teeth 1 Primary driven gear teeth 2 Wear Dam...

Page 240: ...ge Replace 3 Check Shift fork movement Rough functioning Replace shift forks and or guide bars 4 Inspect Guide bar Turn on a flat surface Curvature Replace WARNING Do not attempt to straighten the deformed guide bar 5 Measure Transmission shaft eccentricity Use the centring tool and micrometer Out of specification Replace bent shaft Transmission shaft eccentricity Limit 0 08 mm ...

Page 241: ...ce Transmission gear assembly steps Fit the second gear 2 to the propeller shaft 1 as shown in the figure a 60 0 mm Fit the second sprocket 4 and fifth sprocket 5 to the main shaft 3 b 90 5 mm 8 Inspect Circlip Damage Loosening Bending Replace SHAFT AND STOPPER LEVER 1 Inspect Shift shaft Bent Wear Damage Replace 2 Inspect Stopper lever 1 The roller rotates jerkily Replace Bent Damage Replace 3 In...

Page 242: ... it must turn freely Otherwise the gear is faulty and must be replaced INSPECTION AND REPAIR 5 38 ENG STARTER TRANSMISSION 1 Check Starter clutch functioning 1 Turn the clutch in the direction indicated by the arrow Irregular functioning Damage Replace the clutch 2 Inspect Starter neutral gear teeth 1 Starter neutral gear teeth 2 Starter rim teeth 3 Burrs Shavings Roughness Wear Replace 3 Inspect ...

Page 243: ... clearance 0 35 0 65 mm Runout B Out of specification Replace crankshaft and or crank bearing Connecting rod small end clearance C Out of specification Replace connecting rod big end bearing connecting rod pin and or connecting rod Side clearance D Out of specification Replace connecting rod Crankshaft assembly procedure The passages of crankshaft 1 oil and con necting rod pin 2 oil must coincide ...

Page 244: ... Driven gear teeth 2 Wear damage Replace both gears 2 Check Marks 1 If they are not aligned Align the marks as shown in the figure CRANKCASE 1 Inspect Crankcase Bearing housing Damaged Replace BEARING AND OIL SEAL 1 Inspect Bearing Roughness Pitting Damage Replace Oil seal edge Damage Wear Replace ...

Page 245: ...n 2 2 Wave washer 3 Rocker shaft intake 4 Rocker arm n 1 5 Valve cotters 6 Upper valve spring retainer 7 Oil seal 8 Inner valve spring 9 Outer valve spring 10 Valve intake 11 Lower valve spring retainer 12 Rocker shaft exhaust 13 Rocker arm n 4 14 Rocker arm n 3 15 Rocker shaft exhaust 16 Valve exhaust ...

Page 246: ...fide 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 Install the innner and outer springs with the widest thread upwards 4 Install Valve cotters 1 NOTE Compress the valve spring with the specific tool 2 to fit the cotters Valve spring compressor P N 90890 04019 7 Higher pitch 8 Lower pitch ...

Page 247: ...SSEMBLY AND SETTING 5 43 ROCKER ARMS 1 Lubricate Rocker shaft apply engine oil 2 Install Rocker arm Rocker shaft Screws 1 rocker shaft 10 Nm 1 0 kgm NOTE Each rocker arm is numbered 1 1 2 2 3 3 4 4 3 Install Cap 1 ...

Page 248: ...ENGINE ASSEMBLY AND SETTING 5 44 ENG CRANKSHAFT AND BALANCER SHAFT 1 Connecting rod pin 2 Crank left 3 Connecting rod 4 Bearing 5 Bearing 6 Bearing 7 Balancer shaft 8 Bearing ...

Page 249: ...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 To protect the crankshaft from scratches and facilitate assembly operations apply grease to the edges of th...

Page 250: ...eal 3 Bearing 4 Second wheel gear 5 Secondary shaft 6 Fifth wheel gear 7 Third wheel gear 8 Fourth wheel gear 9 First wheel gear 10 Bearing 11 Bearing 12 Second sprocket gear 13 Fifth sprocket gear 14 Third sprocket gear 15 Fourth sprocket gear 16 Main shaft 17 Bearing ...

Page 251: ...ENG ENGINE ASSEMBLY AND SETTING 5 47 GEARBOX 1 Stopper lever 2 Guide bar 3 Shift fork 3 4 Shift fork 1 5 Shift cam 6 Guide bar 7 Shift fork 2 8 Shift shaft 1 9 Shift shaft 2 10 Oil seal 11 Shift lever ...

Page 252: ... 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 Shift shaft 1 1 Shift shaft 2 2 NOTE Align mark 3 on the shift lever shaft with that on the shift shaft 4 Check Transmission functioning Jerky functioning Repair ...

Page 253: ...ENG ENGINE ASSEMBLY AND SETTING 5 49 ENGINE OIL PUMP AND OIL STRAINER 1 Oil strainer 2 Oil pump 3 Oil pump gear ...

Page 254: ...ENGINE ASSEMBLY AND SETTING 5 50 ENG CRANKCASE 1 Crankcase R 2 Crankcase L 3 Crankcase ventilation hose 4 Dowel pin 5 Dowel pin 6 Dowel pin 7 Bearing cover plate 8 Collar 9 Lock plate ...

Page 255: ... 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 CRANKCASE 1 Apply Yamaha bond N 1215 1 on the crankcase mating surfaces Before installing and tightening the fastening screws be sure that the transmission is work ing properly by hand turning ...

Page 256: ...ever screw 4 10 Nm 1 0 mkg 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 Replace SHIFT SHAFT AND OIL PUMP 1 Install Spring 1 Collar 2 Stopper lever 3 NOTE Place the stopper lever and the spring in the cor rect position 2 Install Plate washer 1 Spring 2 Shift lever 3 Circlip 4 ...

Page 257: ...rclip 1 to the driving axle Spacer 2 Circlip 3 4 Apply 4 stroke engine oil oil pipes in crankcase To avoid damage to the engine lubricate the oil pump pipes in the crankcase liberally with 4 stroke engine oil CAUTION 5 Apply 4 stroke engine oil oil pump pipes 6 Apply O Ring 1 Oil pump 2 Oil pump gear 3 Circlip 4 Screw 5 oil pump 10 Nm 1 0 mkg ...

Page 258: ...ENGINE ASSEMBLY AND SETTING 5 54 ENG TIMING CHAIN 1 Install Timing chain 1 Chain guide 2 ...

Page 259: ...TON AND RINGS 1 Ring upper 2 Ring lower 3 Scraper 4 Piston 5 Piston pin 6 Circlip PISTON SIZE 94 915 94 965 mm PISTON RING END GAP TOP 0 30 0 45 mm 2ND 0 30 0 45 mm OIL 0 20 0 70 mm PISTON RING SIDE CLEARANCE TOP 0 04 0 08 mm 2ND 0 03 0 07 mm ...

Page 260: ...ENGINE ASSEMBLY AND SETTING 5 56 ENG CYLINDER 1 Gasket 2 Cylinder 3 O Ring 4 Gasket 5 Dowel pin 6 Dowel pin ...

Page 261: ... 7 Cylinder head 8 Valve guide intake valve 9 Valve guide exhaust valve 10 Spark plug 11 Dowel pin 10 Nm 1 0 m kg 7 2 ft lb A 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 18 Nm 1 8 m kg 13 ft lb 7 Nm 0 7 m kg 5 1 ft lb 20 Nm 2 0 m kg 14 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb SEALANT QUICK GASKET ...

Page 262: ...ENGINE ASSEMBLY AND SETTING 5 58 ENG CAMSHAFT AND TIMING CHAIN 1 Camshaft 2 Cam chain sprocket 3 Chain stopper guide 4 Timing chain 5 Chain stopper guide 6 Gasket 7 Chain tensioner ...

Page 263: ... Arrow 4 on the piston must point towards the front of the engine Before installing the piston pin circlips cover the crankcase with a clean cloth to prevent foreign bodies falling into it WARNING Always use new circlips for the piston pin 3 Install Dowel pins 1 O Ring 2 4 Install Gasket 1 cylinder NOTE Install the cylinder gasket as shown in the illustra tion ...

Page 264: ...linder lubricate the pis ton rings liberally with 4 stroke engine oil 1 Upper ring 2 Scraper lower ring 3 Scraper upper ring 4 Lower ring 6 Install Cylinder 1 NOTE Install the cylinder to the piston with one hand while one hand while compressing the piston rings with the other 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 ...

Page 265: ...nstall Cylinder head NOTE Tighten screws beginning with the one with the lowest number 9 Install Chain stopper guide Camshaft Cam chain sprocket Timing chain installation Install the cam chain on the cylinder head as illustrated compression phase timing 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 ...

Page 266: ... sprocket are aligned with the top surface of the cylinder head If the marks are aligned tighten the cam chain sprocket bolts Bolt cam chain sprocket 20 Nm 2 0 mkg If the marks are not aligned replace the chain sprocket mating piston and chain 10 Apply Yamaha Bond N 1215 1 on the mating surfaces Sigillante Quick Gasket Yamaha bond N 1215 P N 90890 85505 11 Install Dowel pins 2 12 Install Cap Cylin...

Page 267: ...am 4 and push the thrust rod 5 Install the chain tensioner in the cylinder with a new gasket Screw chain tensioner body 10 Nm 1 0 mkg Chain tensioner screw 20 Nm 2 0 mkg WARNING Always use a new gasket Install the spring the washer and the chain tensioner 14 Adjust Valve clearance Valve clearance Intake 0 05 0 10 mm Exhaust 0 12 0 17 mm See section VALVE CLEARANCE ADJUSTMENT in CHAPTER 3 ...

Page 268: ...all 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 ...

Page 269: ...NE ASSEMBLY AND SETTING 5 65 AC GENERATOR 1 Rotor 2 Pick up coil 3 Stator winding PICKUP COIL RESISTANCE 230 Ω 20 at 20 C 68 F Blue Yellow Green White CHARGING COIL RESISTANCE 0 65 Ω 20 at 20 C 68 F White White ...

Page 270: ...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 Nut rotor Nut rotor 120 Nm 12 0 mkg NOTE To tighten the nut lock the rotor with the special tool 1 Sheave holder P N 90890 01701 Be careful not to touch the jutting edges 2 on the rotor with the sheave holder CAUTION ...

Page 271: ...ENG ENGINE ASSEMBLY AND SETTING 5 67 OIL FILTER AND OIL HOSES 1 Oil filter 2 Filter cover 3 Oil hose 4 Oil hose 5 Oil delivery hose 6 Oil drain plug ...

Page 272: ...LANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR 1 Straight key 2 Balancer shaft gear 3 Breather plate 4 Lock washer 5 Nut 6 Plate washer 7 Straight key 8 Plate 9 Balancer shaft drive gear 10 Plate 11 Primary drive gear 12 Lock washer 13 Nut ...

Page 273: ... 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 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 Be careful not to touch the jutting part 17 of the rot...

Page 274: ...1 Compression spring 2 Pressure plate 3 Push rod 4 Ball 5 Friction plate type A 6 Clutch boss spring 7 Clutch plate 8 Friction plate type B 9 Clutch boss 10 Thrust plate 11 Primary driven gear comp 12 Push rod 13 Push lever 14 Primary drive gear ...

Page 275: ...ut 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 Nut clutch boss 90 Nm 9 0 mkg Pressure plate screw 8 Nm 0 8 mkg NOTE To tighten the nut clutch boss lock the clutch drum with the special tool 14 Clutch holding tool P N 90890 04086 Bend the lock washer tab along the face of the nut WARNING Always use a new ...

Page 276: ... be placed inside the second friction plate CAUTION Friction plate Type A Type B Quantity 2 6 Internal 116 mm 113 mm diameter D NOTE Align the mark on the clutch boss 17 with the arrow 18 on the pressure plate 3 Adjust 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...

Page 277: ...ENG ENGINE ASSEMBLY AND SETTING 5 73 STARTER GEARS 1 Starter gear 2 Starter neutral gear 1 3 Starter neutral gear 2 4 Starter gear 5 Starter clutch ...

Page 278: ...nding 1 Pick up coil 2 Cable clamp 3 2 Install Bearing 1 Intermediate starter gear 2 2 Screws stator and coil 7 Nm 0 7 mkg Use LOCTITE Screw cable clamp 7 Nm 0 7 mkg 3 Install Centring pin 1 Gasket 2 O Ring 3 Crankcase cover L 4 Plugs Bolt crankcase cover 10 Nm 1 0 mkg WARNING Always use a new gasket ...

Page 279: ...NE ASSEMBLY AND SETTING 5 75 4 Install Neutral switch cable 1 5 Install Shaft 1 Bearing 2 Starter intermediate gear 1 3 6 Install Centring pins Gasket Cover 1 starter intermediate gear Screw cover 10 Nm 1 0 mkg ...

Page 280: ...ocket 1 Drive chain Nut sprocket 110 Nm 11 0 mkg Drive chain slack 30 40 mm Screw sprocket cover 10 Nm 1 0 mkg Use LOCTlTE Screw shift ptidal 10 Nm 1 0 mkg Screw footrest 48 Nm 4 8 mkg NOTE Bend the lock washer tab along the face of the nut WARNING Always use a new lock washer 2 Install Cover sprocket Shift pedal Footrest L 3 Adjust Drive chain slack See section DRIVE CHAIN SLACK INSPECTION AND AD...

Page 281: ...ove Tappet cover intake Air bleeder screw oil filter cover 6 Apply 4 stroke engine oil on the top side of the camshaft and in the oil filter housing Liberally apply 4 stroke engine oil in the oil passage in the crankcase to prevent damage to the engine CAUTION 7 Install Tappet cover intake Air bleeder screw oil filter cover 8 Adjust Clutch cable free play Free play at end of lever 10 15 mm See sec...

Page 282: ...ree play 3 5 mm Engine idle speed 1 150 1 450 rpm See section THROTTLE CABLE FREE PLAY ADJUSTMENT in CHAPTER 3 11 Install Fuel tank Do not start the engine until it is filled with oil CAUTION 12 Fill with Engine oil Amount of oil total 3 0 litres 13 Check Engine idle speed See section IDLE SPEED ADJUST MENT in CHAPTER 3 14 Install Seat See section ENGINE OIL REPLACE MENT in CHAPTER 3 ...

Page 283: ...6 CARB ...

Page 284: ...CARBURETOR REMOVAL 6 1 TECHNICAL SPECIFICATIONS TIGHTENING TORQUES EXPLODED VIEW 6 3 SECTION VIEW 6 5 CARBURETOR DISASSEMBLY 6 6 CARBURETOR INSPECTION 6 9 CARBURETOR ASSEMBLY 6 11 FUEL LEVEL ADJUSTMENT CARBURETOR INSTALLED 6 16 ...

Page 285: ...CARB ...

Page 286: ...move the parts in order Seat Refer to SEAT FUEL TANK AND REAR COWLING section in CHAPTER 3 Fuel pipe NOTE Fuel tank Be sure the cap is properly tightened and the fuel cock is in the OFF position before removing the fuel tank 1 Lock nut 4 Loosen 2 Throttle cable adjuster 2 Screw 3 Throttle cable 2 4 Hose clamp 2 Loosen ...

Page 287: ...OTE Move carburetor manifold clamps towards the rear side 6 Carburetor 2 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 ...

Page 288: ...MANUFACTURER TEIKEI 3 5 Nm 0 35 m kg 2 5 ft lb 6 Nm 0 6 m kg 4 3 ft lb 8 Nm 0 8 m kg 5 9 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 9 Nm 0 9 m kg 6 3 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 3 Nm 0 3 m kg 2 1 ft lb ...

Page 289: ...Screw 32 Screw 33 Pipe 34 Clip 35 Main jet 1 36 Main nozzle 1 37 Throttle valve 38 Pilot jet 39 Main jet 2 40 Main nozzle 2 41 Pilot screw set 42 Needle valve set 43 Stop screw set 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 SPECIFICATIONS Main jet 150 FIRST 145 SEC Starter jet 74 Need...

Page 290: ...eedle jet primary 2 Valve seat 3 Needle valve 4 Main nozzle primary 5 Main jet primary 6 Pilot air screw 7 Needle jet secondary 8 Main nozzle secondary 9 Main jet secondary A Primary carburetor B Secondary carburetor Air Fuel Mixture A B ...

Page 291: ...TOR DISASSEMBLY 1 Remove Support plate 1 front Support plate 2 rear 2 Separate Primary carburetor Secondary carburetor Primary carburetor 1 Remove Float chamber 1 Float pin 2 Float 3 NOTE Remove the float needle in the direction of the arrow ...

Page 292: ... seat 1 Main jet Main nozzle 1 2 Pilot jet 3 Pilot screw set 4 O Ring 5 3 Remove Stop screw 1 Starter set 2 4 Remove Cover 1 enrichment Spring 2 Diaphragm 3 5 Remove Top cover 1 Cover gasket 2 Screw 3 connecter comp 6 Remove Throttle lever 1 Collar 2 Cable holder 3 ...

Page 293: ...LY 6 8 CARB 7 Remove Throttle shaft 1 Spring 2 8 Remove Connecter comp 1 Needle jet 2 Throttle valve 3 Secondary carburetor 1 Remove Drain plug 1 Main jet 2 2 Remove Top cover 1 Spring 2 3 Remove Diaphragm 1 Needle jet 2 2 ...

Page 294: ...2 Inspect Valve seat 1 Needle valve set 2 Wear Corrosion Replace O Ring 3 Damaged Replace NOTE Always replace the needle valve set and the valve seat together 3 Inspect Starter piston 1 Wear Damage Replace Stop screw 2 Damaged Replace 4 Inspect Diaphragm 1 piston valve Diaphragm 2 enrichment Damaged Replace 5 Inspect Needle jet 1 primary Needle jet 2 secondary Curvature Wear Replace ...

Page 295: ...Hampered 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 Float 1 Damaged Replace 9 Inspect Main jet 1 primary Main jet 2 secondary Main nozzle 3 primary Main nozzle 4 secondary Pilot jet 5 NOTE Clean jets with compressed air ...

Page 296: ...s Wash all parts with clean petrol prior to reassembly CAUTION Secondary carburetor 1 Install Needle jet 1 Diaphragm 2 Spring NOTE Draw the diaphragm tab level with the notch on the secondary carburetor 2 Install Top cover Screw top cover 2 Nm 0 2 mkg Main jet secondary 2 Nm 0 2 mkg Drain valve 9 Nm 0 9 mkg 3 Install Main jet secondary Drain vavle ...

Page 297: ...si tion shown in the figure 2 Install Throttle valve 3 Install Spring Throttle shaft NOTE Assemble the spring as shown in the illustration 4 Install Screw connecter comp NOTE 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 2 Nm 0 2 mkg ...

Page 298: ... Screw cable holder 3 Nm 0 3 mkg Screw top cover 2 Nm 0 2 mkg Starter piston 6 Nm 0 6 mkg Main nozzle 1 2 Nm 0 2 mkg Screw valve seat 2 Nm 0 2 mkg 6 Install Top cover 7 Install Diaphragm 1 enrichment NOTE Make the diaphragm tab coincide with the gravity enricher notch 9 Install Pilot screw set 1 Pilot jet 2 Main nozzle 1 3 Main jet primary 4 Valve seat 5 8 Install Starter set Stop screw ...

Page 299: ...hamber without the gasket and the top of the float NOTE The float arm must rest on the neeedle valve without being pressed If the float height is out of tolerance check the valve seat and the needle valve If either is worn replace both If both are perfect adjust the float height by bending the wing tab of the float itself 1 Recheck the float height 12 Install Float chamber Screw float chamber 2 Nm...

Page 300: ... 0 35 mkg 16 Adjust Synchronisation of secondary carburetor Adjustment Move the primary throttle valve 1 to a height of 7 0 mm as shown in the figure Tighten or loosen the synchronisation screw 1 until the secondary throttle valve 2 starts to open Check that the secondary throttle valve is open horizontally a b when the primary throttle valve is completely open ...

Page 301: ...drain screw 2 and heat the engine 5 Measure Fuel level a Out of specification Adjust Fuel level 6 0 8 0 mm Under the edge of the carburetor body 6 Adjust Fuel level 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 Recheck the fuel ...

Page 302: ...7 ELEC ...

Page 303: ...LIGHTS ETC 7 8 BULB TYPES 7 8 BULB INSPECTION 7 8 IGNITION SYSTEM 7 11 CIRCUIT DIAGRAM 7 11 DIAGNOSTICS 7 13 ELECTRICAL STARTING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 STARTING CIRCUIT OPERATION 7 23 DIAGNOSTICS 7 24 STARTER MOTOR 7 30 CHARGING SYSTEM 7 35 CIRCUIT DIAGRAM 7 35 DIAGNOSTICS 7 37 LIGHT SYSTEM 7 41 CIRCUIT DIAGRAM 7 41 DIAGNOSTICS 7 43 LIGHT SYSTEM INSPECTION 7 46 SIGNALLING SYSTEM 7 51 CIR...

Page 304: ...ELEC ...

Page 305: ... BrL GB Sb B BrB Y Br BrB Y Br GB B Ch Dg Br Y BrB HIGH TURN NEU ILL B BrL BrL L B BY LY LB LY GW B RB Or 205 B RB L BrL Br PARK OFF ON ON ON Sb L GB GY G Y RB LY BY LY BY RUN LW B B LY BY L Br R R LW RB GB R B GW Br BrW WB Br LY WB Sb B GW LY BLUE B B LY B OFF Br RB LW RB Y P G GB B BrW BrL BrB W W W GY Br GY Y P G GB B BrW BrL BrB Y N R L LOW HIGH BrW Br P P Br LY B GW LY Or RB Br LW BY BY START...

Page 306: ...White Blue B W Black White Y R Yellow Red 1 AC generator Pickup coil 2 Rectifier Regulator 3 Battery 4 Starter relay 5 Starting motor 6 Fuse 7 Main switch 8 Right handlebar switch 9 Engine stop switch 10 Starter switch 11 Diode 12 Clutch switch 13 Sidestand switch 14 Neutral switch 15 Diode 16 Ignitor unit COLOUR CODE 17 Ignition coil 18 Left handlebar switch 19 Horn switch 20 Diode 21 Pass switch...

Page 307: ...ONENTS 7 3 ELECTRICAL COMPONENTS 1 Main wire harness 2 Diodes 3 Extension wire harness 4 Rectifier Regulator 5 CDI ignition unit 6 Battery 12V 8Ah 7 Starter relay 8 Fuse 20A BATTERY CAPACITY 12V 8Ah SPECIFIC GRAVITY 1 320 ...

Page 308: ...COIL Primary winding resistance 4 Ω Ω 15 at 20 C 68 F Secondary winding resistance 13 kΩ Ω 20 at 20 C 68 F 1 Ignition coil 2 Spark plug cap 3 Flasher relay 4 Horn 5 Clutch switch 6 Relay assy 7 Sidestand switch 8 Neutral switch 9 Main switch ...

Page 309: ... the top line indicates the colours of the cables connected with the terminals of the switch itself o o 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 PA...

Page 310: ... nation of colours for continuity closed circuit In this example continuity is as follows 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 Note that there is no continuity open circuit for any of the combinations of a colour differ ent from those mentioned and when the switch is at OFF 4 Check the s...

Page 311: ... and there must be no continu ity ie the tester must show 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 5 Continue to check continuity between R and L and L and Br in the respective switch positions in the ...

Page 312: ...y 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 Bulbs of type B and C use special supports bulbholders Remove t...

Page 313: ...the tester selector to Ω x 1 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 b...

Page 314: ...7 10 ELEC ...

Page 315: ...rL GB Sb B BrB Y Br BrB Y Br GB B Ch Dg Br Y BrB HIGH TURN NEU ILL B BrL BrL L B BY LY LB LY GW B RB Or 205 B RB L BrL Br PARK OFF ON ON ON Sb L GB GY G Y RB LY BY LY BY RUN LW B B LY BY L Br R R LW RB GB R B GW Br BrW WB Br LY WB Sb B GW LY BLUE B B LY B OFF Br RB LW RB Y P G GB B BrW BrL BrB W W W GY Br GY Y P G GB B BrW BrL BrB Y N R L LOW HIGH BrW Br P P Br LY B GW LY Or RB Br LW BY BY START O...

Page 316: ...tric system NOTE For the colour code and legend see page 7 2 1 AC generator Pickup coil 2 Rectifier Regulator 3 Battery 6 Fuse 7 Main switch 9 Engine stop switch 11 Diode 12 Clutch switch 13 Sidestand switch 14 Neutral switch 15 Diode 16 Ignitor unit 17 Ignition coil 9 17 7 2 3 6 11 1 12 15 16 14 13 ...

Page 317: ...OTE Before making the inspections mentioned remove the following parts 1 Seat 2 Rear cowling 3 Fuel tank 4 Cowling headlight To check functioning defects use the following special tools Dinamic spark tester P N 90890 06754 Pocket tester P N 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Is the fuse OK YES 2 Battery Check the condition of the battery Refer...

Page 318: ...own in the figure 2 Spark plug cover 3 Spark plug Turn the main switch ON Check the amplitude of the ignition spark Start the engine and increase the ampli tude until the ignition becomes discontin uous Electrodes gap DPR8EA 9 DPR9EA 9 NGK 0 8 0 9 mm YES OUT OF SPECIFICATION Correct the electrodes gap or replace the spark plug Spark amplitude if the ignition system is efficient 6 0 mm THE IGNITION...

Page 319: ...k plug cap has the specified resistance OUT OF SPECIFICATION The spark plug cap is defective Replace Resistance of spark plug cap 10 kΩ at 20 C 68 F 6 Ignition winding resistance Disconnect the ignition coil cables from the wire harness Connect the pocket tester Ω x 1 to the ignition coil Tester terminal Pole Tester terminal Pole Check that the primary coil has the speci fied resistance ...

Page 320: ...C 68 F Spark plug cable Terminal BOTH RESISTANCE VALUES ARE CORRECT OUT OF SPECIFICATION The ignition coil is defective Replace Primary winding resistance 4 Ω 15 at 20 C 68 F Terminal Terminal 7 Main switch Disconnect the main switch connector from the wire harness Connect the pocket tester Ω x 1 to the main switch cables Refer to SWITCH CHECK in Chapter 3 CORRECT INCORRECT The main switch is defe...

Page 321: ...ble Tester terminal Brown cable 2 CORRECT INCORRECT The emergency stop engine switch is defective Replace the right handlebar switch INCORRECT The sidestand switch is defective Replace 9 Sidestand switch Disconnect the sidestand switch connec tor Black and Black from the wire har ness Connect the pocket tester Ω x 1 to the sidestand switch cables Refer to SWITCH CHECK in Chapter 3 Tester terminal ...

Page 322: ...r terminal Earth CORRECT INCORRECT The neutral switch is defective Replace 1 In gear Neutral Sb Sb 11 Clutch switch Disconnect the clutch switch connector from the harness Connect the pocket tester Ω x 1 to the clutch switch cable Check the clutch switch component for continuity between Black 1 and Black 2 Refer to SWITCH CHECK in Chapter 3 INCORRECT The clutch switch is defective Replace Release ...

Page 323: ...al Green White cable 2 Check that the pick up coil resistance is as specified Pick up coil resistance 230 Ω 20 at 20 C 68 F Green White Blue Yellow COMPLY WITH SPECIFICATIONS CORRECT OUT OF SPECIFICATIONS The pick up coil is defective Replace UNCERTAIN CONNECTIONS Correct 13 Wiring connections Check the connections of the entire ignition system Refer to ELECTRICAL CIRCUIT DIAGRAM section The CDI u...

Page 324: ...7 20 ELEC ...

Page 325: ...rL GB Sb B BrB Y Br BrB Y Br GB B Ch Dg Br Y BrB HIGH TURN NEU ILL B BrL BrL L B BY LY LB LY GW B RB Or 205 B RB L BrL Br PARK OFF ON ON ON Sb L GB GY G Y RB LY BY LY BY RUN LW B B LY BY L Br R R LW RB GB R B GW Br BrW WB Br LY WB Sb B GW LY BLUE B B LY B OFF Br RB LW RB Y P G GB B BrW BrL BrB W W W GY Br GY Y P G GB B BrW BrL BrB Y N R L LOW HIGH BrW Br P P Br LY B GW LY Or RB Br LW BY BY START O...

Page 326: ...uit inside the motorcycles electric system NOTE For the colour code and legend see page 7 2 3 Battery 4 Starter relay 5 Starting motor 6 Fuse 7 Main switch 9 Engine stop switch 10 Starter switch 11 Diode 12 Clutch switch 13 Sidestand switch 14 Neutral switch 15 Diode 9 10 7 3 6 5 12 11 14 13 15 4 ...

Page 327: ...s 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 IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN 1 Battery 2 Main switch 3 Engine stop switch 4 Starter relay 5 Starting circuit cut o...

Page 328: ...el tank 4 Cowling headlight To check for defects use the following special tools Pocket tester P N 90890 03112 1 Fuse Remove fuse Connect the pocket tester Ω x 1 to the fuse Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F C...

Page 329: ...NING 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 4 Starter relay Disconnect the starter relay connector Connect the battery and frame to the starter relay connector using a connec tion cable 1 as shown Bat...

Page 330: ...eplace ON OFF PARK Br L R Br L R 6 Emergency stop engine switch Disconnect the emergency stop engine switch connector Brown Green Yellow and Red Black from the wire harness Connect the pocket tester Ω x 1 to the switch cables Refer to SWITCH CHECK in Chapter 3 Tester terminal Red Black 1 cable Tester terminal Brown cable 2 INCORRECT The emergency stop engine switch is defective Replace the right h...

Page 331: ...Chapter 3 Tester terminal Black cable 1 Tester terminal Black cable 2 8 Neutral switch Disconnect the neutral switch cable Sky blue Connect the pocket tester Ω x 1 to the neutral switch cables Refer to SWITCH CHECK in Chapter 3 Tester terminal Sky blue cable 1 Tester terminal Earth CORRECT INCORRECT The neutral switch is defective Replace 1 In gear Neutral Sb Sb UP DOWN B B B B 1 2 INCORRECT The s...

Page 332: ...tch is defective Replace Release Hold B B B B 1 2 CORRECT 7 28 ELEC ELECTRICAL STARTING SYSTEM INCORRECT The start switch is defective Replace the right handlebar switch 10 Start switch Disconnect the start switch connector from the harness Connect the pocket tester Ω x 1 to the handlebar switch terminal Check the start switch component for con tinuity between Blue White 1 and Black Yellow 2 Refer...

Page 333: ...ELEC 7 29 ELECTRICAL STARTING SYSTEM 11 Harness connections Check the connections of the entire starter system See the ELECTRIC CIRCUIT DIAGRAM UNCERTAIN CONNECTIONS Correct ...

Page 334: ...G SYSTEM 7 30 ELEC STARTER MOTOR 1 Brushes 2 Armature 3 Stator 4 O Ring BRUSH LENGHT LIMIT 5 mm 0 20 in COMMUTATOR WEAR LIMIT 27 mm 1 06 in MICA UNDERCUT 0 7 mm 0 027 in ARMATURE COIL RESISTANCE 0 03 0 04 Ω at 20 C 68 F ...

Page 335: ...Replace the motor 3 Measure The mica undercut b Out of specification Level the undercut to the correct value using a hacksaw Wear limit of commutator a 27 mm Mica undercut b 0 7 mm NOTE The mica insulation of the commutator must have an undercut to ensure proper functioning of the commutator Disassembly 1 Remove Circlip 1 Drive gear 2 Screws 3 Rear bracket 4 Washers 5 Brushes housing 6 Brushes 7 F...

Page 336: ...ut Replace all springs at once 7 Inspect Bearings 1 Oil seal 2 O Rings Bush 3 How to inspect the excitation coils Connect the pocket tester and check continuity 1 and insulation 2 Check the armature resistance If the resistance is not correct replace the starter motor Armature coil resistance Continuity check 1 0 Ω at 20 C 68 F Insulation check 2 Over 1 MΩ at 20 C 68 F Brush spring strength 8 82 N...

Page 337: ...tall Stator 1 Front bracket 2 NOTE Align the jutting surface on the brush housing with the slot 2 NOTE Align the reference marks 3 on the stator with the corresponding reference marks on the cover 4 3 Install Screws 1 Installation 1 Install Starter motor Screw stator 7 Nm 0 7 kgm Screw starter motor 10 Nm 1 0 kgm NOTE Slightly grease the O Ring 1 ...

Page 338: ...7 34 ELEC ...

Page 339: ...rL GB Sb B BrB Y Br BrB Y Br GB B Ch Dg Br Y BrB HIGH TURN NEU ILL B BrL BrL L B BY LY LB LY GW B RB Or 205 B RB L BrL Br PARK OFF ON ON ON Sb L GB GY G Y RB LY BY LY BY RUN LW B B LY BY L Br R R LW RB GB R B GW Br BrW WB Br LY WB Sb B GW LY BLUE B B LY B OFF Br RB LW RB Y P G GB B BrW BrL BrB W W W GY Br GY Y P G GB B BrW BrL BrB Y N R L LOW HIGH BrW Br P P Br LY B GW LY Or RB Br LW BY BY START O...

Page 340: ... 7 36 ELEC The diagram illustrates the charging circuit inside the motorcycles electric system NOTE For the colour code and legend see page 7 2 1 AC generator Pickup coil 2 Rectifier Regulator 3 Battery 6 Fuse 3 6 2 1 ...

Page 341: ...ng To check for defects use the following special tools Inductive rev counter P N 90890 03113 Pocket tester P N 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Is the fuse OK YES 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK NO Repl...

Page 342: ...l Start the engine and rev to about 5 000 rpm Check the charging voltage Charging voltage 14 0V at 5 000 rpm 4 Stator coil resistance Disconnect the AC generator connector from the harness Connect the pocket tester Ω x 1 to the sta tor coils Stator coils 1 Tester terminal White cable 1 Tester terminal White cable 2 NOTE Use a fully charged battery OUT OF SPECIFICATIONS IN COMPLIANCE WITH SPECIFICA...

Page 343: ...e cable 1 Tester terminal White cable 3 Check that the winding resistance of the stator complies with specifications Stator coil resistance White 1 White 2 0 65 Ω 20 at 20 C 68 F White 1 White 3 0 65 Ω 20 at 20 C 68 F W W W 3 2 1 5 Wiring connections Check the connections of the entire char ging system Refer to ELECTRICAL CIRCUIT DIA GRAM section The rectifier regulator is defective Replace ...

Page 344: ...ELEC 7 40 ...

Page 345: ...rL GB Sb B BrB Y Br BrB Y Br GB B Ch Dg Br Y BrB HIGH TURN NEU ILL B BrL BrL L B BY LY LB LY GW B RB Or 205 B RB L BrL Br PARK OFF ON ON ON Sb L GB GY G Y RB LY BY LY BY RUN LW B B LY BY L Br R R LW RB GB R B GW Br BrW WB Br LY WB Sb B GW LY BLUE B B LY B OFF Br RB LW RB Y P G GB B BrW BrL BrB W W W GY Br GY Y P G GB B BrW BrL BrB Y N R L LOW HIGH BrW Br P P Br LY B GW LY Or RB Br LW BY BY START O...

Page 346: ...e electric system of the motorcycle NOTE For the colour codes and complete legend see page 7 2 3 Battery 6 Fuse 7 Main switch 18 Left handlebar switch 20 Diode 21 Pass switch 3 6 31 22 21 18 26 28 20 32 7 22 Dimmer switch 26 Headlight 28 Relay assy 31 Tail stop light 32 Meter ...

Page 347: ...ctions remove the following parts 1 Seat 2 Rear cowling 3 Cowling headlight 4 Tail light cover To check for defects use the following special tools Pocket tester P N 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Is the fuse OK YES 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage...

Page 348: ...and dim mer switch Disconnect the left handlebar switch con nector from the wire harness Connect the pocket tester Ω x 1 to the left handlebar switch terminals 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 3 INCORRECT The dipped high beam commutator and or the dimmer switch are defective R...

Page 349: ... tester DC 20V and the battery 12V to the cut off relay con nector terminal of the starter circuit Battery terminal White Black terminal 1 Battery terminal Black terminal 2 Tester terminal Brown terminal 3 Tester terminal 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 ter...

Page 350: ...er 1 Bulb and bulbholder Check the continuity of the bulb and bulb holder Refer to BULB INSPECTION section 2 Voltage Connect the pocket tester DC 20V to the front headlight connectors and the high beam switch Headlight Tester terminal Green 2 or Yellow 1 cable Tester terminal Black cable 3 High beam light Tester terminal Yellow cable 4 Tester terminal Black cable 5 A When the lights switch commuta...

Page 351: ...ain switch to ON Check the voltage 12V on the Blue cable of the bulbholder connector OUT OF SPECIFICATION The circuit from the main switch to the bulbhol der connector is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12V on the Green and Yellow cable at the bulbholder ter minals The circuit is efficient IN COM...

Page 352: ...pocket tester DC 20V to the bulbholder connector Tester terminal Blue terminal 1 Tester terminal Black terminal 2 Turn the main switch to ON Check the voltage 12V on the Blue cable of the bulbholder connector OUT OF SPECIFICATION The circuit from the main switch to the bulbhol der connector is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient 3 The parking light fails...

Page 353: ... pocket tester DC 20V to the bulbholder connector Tester terminal Blue terminal 1 Tester terminal Black terminal 2 Turn the main switch to ON Check the voltage 12V on the Blue cable of the bulbholder connector OUT OF SPECIFICATION The circuit from the main switch to the bulbhol der connector is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient 4 The rear light fails t...

Page 354: ...7 50 ELEC ...

Page 355: ...rL GB Sb B BrB Y Br BrB Y Br GB B Ch Dg Br Y BrB HIGH TURN NEU ILL B BrL BrL L B BY LY LB LY GW B RB Or 205 B RB L BrL Br PARK OFF ON ON ON Sb L GB GY G Y RB LY BY LY BY RUN LW B B LY BY L Br R R LW RB GB R B GW Br BrW WB Br LY WB Sb B GW LY BLUE B B LY B OFF Br RB LW RB Y P G GB B BrW BrL BrB W W W GY Br GY Y P G GB B BrW BrL BrB Y N R L LOW HIGH BrW Br P P Br LY B GW LY Or RB Br LW BY BY START O...

Page 356: ...our codes and complete legend see page 7 2 3 Battery 6 Fuse 7 Main switch 11 Diode 14 Neutral switch 15 Diode 18 Left handlebar switch 19 Horn switch 23 Flasher switch 24 Horn 25 Flasher relay 27 Flasher light 29 Front brake switch 30 Rear brake switch 31 Tail stop light 32 Meter 7 29 24 7 30 32 31 3 6 25 23 11 14 15 19 18 27 27 ...

Page 357: ...Rear cowling 3 Cowling headlight 4 Tail light cover To check for operating faults use the following special tools Pocket tester P N 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Is the fuse OK YES 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Is th...

Page 358: ...CH CHECK section Tester terminal Red cable 1 Tester terminal Brown cable 2 Tester terminal Blue cable 3 CORRECT DISCONTINUITY The main switch is defective Replace CORRECT UNCERTAIN CONNECTIONS Repair 4 Harness connections Check the connections of the entire signal system Check the condition of each signal system Refer to ELECTRICAL CIRCUIT DIAGRAM section ON OFF PARK Br L R Br L R 3 2 1 ...

Page 359: ...fer to SWITCH CHECK section CORRECT DISCONTINUITY The horn switch is defective Replace the left handlebar switch 2 Voltage Connect the pocket tester DC 20V to the horn cable Tester terminal Brown terminal 1 Tester terminal Earth Turn the main switch to ON Check the voltage 12V on the Brown terminal of the horn OUT OF SPECIFICATIONS The circuit from the main switch to the horn ter minal is defectiv...

Page 360: ...RN DOES NOT WORK THE HORN WORKS The horn is efficient 4 Voltage Connect the pocket tester DC 20V to the Pink terminal of the horn Tester terminal Pink cable 1 Tester terminal Earth Turn the main switch to ON Check the voltage 12V on the Pink ter minal of the horn OUT OF SPECIFICATION The horn is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V Repair or replace the horn ...

Page 361: ... Disconnect the brake switch cables and the connector from the wire harness Connect the pocket tester Ω 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 A Front brake switch B Rear brake switch INCORRECT The brake switch is defective Replace ON Step down OFF Free B B B B G Y Br 3 4 2...

Page 362: ...rcuit from the main switch to the bulbhol der connector is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient CONTINUITY DISCONTINUITY Replace the bulb and or bulbholder 3 The direction indicator light and or the direc tion indicator light fail to flash 1 Bulb and bulbholder Check the continuity of the bulb and bulb holder Refer to BULB INSPECTION section 2 Direction i...

Page 363: ...ster DC 20V to the indicator lamp relay Tester terminal Brown terminal 1 Tester terminal Earth Turn the main switch to ON Check the voltage 12V on the Brown cable to the indicator lamp relay terminal OUT OF SPECIFICATION The circuit from the main switch to the lamp re lay connector is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V 3 1 G Y GB P B BrL BrB BrW L 2 N R INCORRECT The direction ...

Page 364: ... defective Replace IN COMPLIANCE WITH SPECIFICATIONS 12V 4 Voltage Connect the pocket tester DC 20V to the bulbholder connector Tester terminal Brown White terminal 1 Tester terminal Earth Turn the main switch to ON Check the voltage 12V on the Blue cable to the bulbholder connector ...

Page 365: ...th To the right flasher light Tester terminal Brown Black terminal 1 Tester terminal Earth Turn the main switch to ON Turn the direction indicator switch to L or R Check the voltage it flashes at 2 8V on the Green Black or Brown Black cable at the bulbholder connector OUT OF SPECIFICATION The circuit from the direction indicator switch to the bulbholder is defective Repair IN COMPLIANCE WITH SPECI...

Page 366: ...ire harness Connect the pocket tester Ω x 1 to the neutral switch cables Check the switch component for continuity between Sky blue 1 and earth Refer to SWITCH CHECK section INCORRECT The neutral switch is defective Replace CORRECT 4 The N neutral light fails to turn on 3 Voltage Connect the pocket tester DC 20V to the bulbholder connector Tester terminal Brown cable 1 Tester terminal Earth 1 In g...

Page 367: ...switch to ON Check the voltage 12V on the Brown ca ble of the bulbholder connector 4 Neutral switch cable Disconnect the neutral switch connector from the wire harness and the bulbholder connector Connect the pocket tester Ω 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 CONT...

Page 368: ...7 64 ELEC ...

Page 369: ...8 TRBL SHTG ...

Page 370: ...H SLIDES OR FAILS TO RELEASE 8 5 CLUTCH SLIDES 8 5 CLUTCH FAILS TO RELEASE 8 5 DEFECTIVE BRAKES 8 6 POOR BRAKING 8 6 OIL LEAKS OR MALFUNCTIONING OF FRONT FORK 8 6 OIL LEAKS 8 6 MALFUNCTIONING 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 ON 8 8 DIRECTION INDICATORS FAIL TO ...

Page 371: ...TRBL SHTG ...

Page 372: ...tank Fuel cock Carburetor Air filter PROBABLE CAUSES Empty Fuel filter obstructed Fuel tank air cap passage obstructed Petrol contains water or impurities or is adulterated Hose obstructed 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 valv...

Page 373: ...itch defective Harness with cable interrupted Neutral switch defective Sidestand switch defective Clutch switch defective Starter switch defective ELECTRICAL SYSTEM Cylinder and cylinder head Piston and piston rings Crankcase and valves crankshaft PROBABLE CAUSES Spark plug tightening insufficiently Cylinder head or cylinder insufficiently tightened Cylinder head gasket broken Cylinder gasket brok...

Page 374: ...ucted POOR PERFORMANCE AT IDLE SPEED See FAILURE TO START DIFFICULTIES IN STARTING FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM and Valve clearance Carburetor 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 Fue...

Page 375: ...el over maximum Incorrect gradation high viscosity Degradation SHIFTING IMPOSSIBLE DIFFICULTIES IN SHIFTING Shift shaft Shift cam shift fork PROBABLE CAUSES Shift shaft deformed Groove with impurities or foreign bodies Shift fork stuck Shift fork guide bar deformed THE SHIFT PEDAL FAILS TO MOVE Transmission Transmission gears struck Gears stuck by impurities or foreign bodies Wrong transmission as...

Page 376: ...ongly set Clutch springs loose Clutch spring yielded Friction plates worn Clutch plates worn Clutch improperly assembled Oil level below minimum Incorrect gradation low viscosity Degradation CLUTCH SLIDES CLUTCH SLIDES OR FAILS TO RELEASE Refer to SHIFTING IMPOSSIBLE section CLUTCH FAILS TO RELEASE ...

Page 377: ...evel POOR BRAKING DEFECTIVE BRAKES PROBABLE CAUSES Inner tube deformed damaged or rusty Outer tube damaged or cracked Oil seal lip damaged Oil seal assembled incorrectly Oil level incorrect excessive Shock absorber rod stop bolt loose O ring on cap bolt broken OIL LEAKS PROBABLE CAUSES Inner tube deformed damaged or rusty Outer tube deformed or damaged Fork spring damaged Piston worn or damaged Sh...

Page 378: ...he same in both tubes Spring broken Front fork crooked Tyres Tyre pressure incorrect for type of road Tyre pressure incorrect Tyres worn non uniformly Wheels Wheels balanced incorrectly Wheel deformed Bearing loose Wheel axle deformed or loose Wheels excessively off centre Frame Deformed Head tube damaged Ball track installed incorrectly Rear shock absorber Spring yielded Spring preloaded Oil leak...

Page 379: ...ive Incorrect bulb Rectifier regulator defective Wrong negative earthing Main switch defective Bulbs gone FREQUENT BURNING OF BULB PROBABLE CAUSES Wrong negative earthing Battery flat Defective direction indicator switch Indicator lamp relay defective Harness cut off Connector loose Bulb gone DIRECTION INDICATORS FAIL TO TURN ON PROBABLE CAUSES Indicator lamp relay defective Insufficient battery c...

Page 380: ...rness cut off THE HORN FAILS TO WORK OVERHEATING OF ENGINE PROBABLE CAUSES Incorrect bulb Indicator lamp relay defective EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY Ignition system Fuel feed system PROBABLE CAUSES Incorrect electrode gap of spark plug Spark plug thermal gradation wrong Ignition unit defective Incorrect carburetor main jet incorrect setting Incorrect fuel level Air filter element o...

Page 381: ...TRBL SHTG ...

Page 382: ... W Sb B Sb B BrB B B LR W R W B A L L GY LB Br WB RB MAIN HARNESS A HEAD LIGHT B B BrB 17 16 11 12 13 14 15 9 10 29 8 5 3 1 2 6 4 28 20 21 22 19 23 25 24 30 31 27 26 7 32 18 ELECTRICAL SYSTEM DIAGRAM 1 AC generator Pickup coil 2 Rectifier Regulator 3 Battery 4 Starter relay 5 Starting motor 6 Fuse 7 Main switch 8 Right handlebar switch 9 Engine stop switch 0 Starter switch q Diode w Clutch switch ...

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