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Yamaha SZR 660, Service Manual

The Yamaha SZR 660 is an iconic motorcycle with a powerful engine and sleek design. To ensure optimal performance and maintenance, grab the comprehensive Service Manual. Download it for free at manualshive.com, your ultimate destination for user manuals, offering hassle-free access to the essential resources you need.

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Summary of Contents for SZR 660

Page 1: ...or unauthorised use without the written permission ol Belgarda S p A is expressly prohibited Although some of the drawings andphotographs used in this manual are taken from other manuals and do not refer directly to the mode in question me procedures described and the details illustrated are nonetheless relevant and suitable to the user s purposes ...

Page 2: ...top right hand corner of each page identifies the chapter graphically This title appears at the top of each page to the left of the chapter symbol The final caption in the chapter Periodic inspection and adjustment FORMAT All the procedures suggested in this manual are arranged in a sequential step by step order The information is written in such a way as to provide the mechanic with a handy easy ...

Page 3: ...l tool 13 Screw tightening 14 Wear and tear limit clearance 15 Engine speed 16 Resistance fi Voltage V Electric Current A Symbols 17 to 23 in the exploded diagram indicate type of lubricant and location of lubrication point 17 Appfy engine oil 18 Apply gear oil 19 Apply molybdenum disulfide oil 20 Apply wheel bearing grease 21 Apply lightweight lithium soap grease 22 Apply molybdenum disulfide gre...

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Page 5: ...LE A 6 IDENTIFICATION NUMBER A 6 ENGINE SERIAL NUMBER A 6 IMPORTANT INFORMATION A 6 PREPARATION FOR DISASSEMBLY AND REASSEMBLY A 6 SPARE PARTS A 7 GASKETS OIL SEALS AND O RINGS A 7 LOCK WASHERS PLATES AND COTTER PINS A 7 BEARINGS AND OIL SEALS A 7 CIRCUPS A 7 SPECIAL TOOLS A 7 ...

Page 6: ... the other digits form the progressive production number of the unit Diagrams and specifications may be altered without prior warning IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR DISASSEMBLY AND REASSEMBLY 1 Remove all dirt mud dust and foreign objects prior to disassembly 2 Use proper material and toots Refer to sec tion SPECIAL TOOLS 3 When disassembling the cycle keep to...

Page 7: ...eight lithium based grease to the seal lips Oil the bearings liberally when installing 1 Oil seals 1 f J I CAUTION Do not use compressed air to dry the bearings This damages their outer surface 1 Bearing IMPORTANT INFORMATION SPECIAL TOOLS GEN INFO g N 5 CIRCLIPS 1 All cirdips should be inspected carefully prior to reassembly Always replace piston ring clips after one use Replace twisted cirdips W...

Page 8: ... FOR PRESSURE GAUGE FUEL LEVEL GAUGE Illustration FUEL LEVEL GAUGE PISTON PIN CLIP PULLER 9 O n SPECIAL TOOLS GEN INFO JN5 Tool number 90890 01304 YS 01880 90890 01 701 YU 33270 90890 01362 YM 04063 A 90890 04063 YM 91042 90890 04086 YU 01135 A Tool name PISTON PIN CUP PULLER ROTOR HOLDER ROTOR HOLDER ROTOR SCREW PULLER ROTOR SCREW PULLER ADAPTER FOR ROTOR SCREW PULLER ADAPTER FOR ROTOR SCREW PULL...

Page 9: ... 6 mm 0 24 in VALVE GUIDE PULLER 6 mm 0 24 in VALVE GUIDE REAMER IV ri j On SPECIAL TOOLS GEN INFO 5 Tool number 90890 04066 YM 04065 A 90890 04065 YU 90050 90890 01274 90890 01275 YM 90069 90890 04059 YM 91044 90890 04081 Tool name 6 mm 0 24 in VALVE GUIDE REAMER 6 mm 0 24 in VALVE GUfDE INSTALLER 6 mm 0 24 in VALVE GUIDE INSTALLER DRIVING SHAFT INSTALLATION UNIT DRIVING SHAFT INSTALLATION HOSE D...

Page 10: ...n RADIATOR CAP TESTER RADIATOR CAP TESTER ADAPTER FOR RADIATOR CAP TESTER 90890 01352 ADAPTER FOR RADIATOR CAP TESTER 4SU F8120 W0 YU 01268 90890 01268 FRONT FORK SERVICE KIT ASSY RING NUT WRENCH RING NUT WRENCH Tool number 90890 01385 YM 34487 90890 03144 YU 031 1 2 90890 03112 Tool name RING NUT WRENCH D1NAM1C SPARK TESTER IGNITION CHECKER POCKET TESTER POCKET TESTER SPECIAL TOOLS GEN INFO 5 Ill...

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Page 12: ...CE SPECIFICATIONS A 14 ENGINE A 14 ELECTRIC SYSTEM A 16 CHASSIS B 2 TIGHTENING TORQUES B 3 GENERAL TORQUE SPECIFICATIONS B 6 DEFINITION OF MEASUREMENT UNITS B 6 LUBRICATION POINTS AND TYPE OF LUBRICANT B 7 ENGINE B 7 CHASSIS B 7 LUBRICATION LAYOUT B 8 COOLING LAYOUT B 10 CABLE ROUTING 8 11 ...

Page 13: ... or higher can be used 14 liters 2 5 liters Carburetor Type Manufacturer Y26PV 3J TEIKEI Spark plug Type Manufacturer Electrode gap DPR8EA 9 or DPR9EA 9 NGK 0 8 0 9 mm Clutch Type Wet multi disc Transmission Type Constant mesh 5 speed Primary reduction system Straight tooth gears Primary reduction ratio 71 34 2 088 Secondary reduction system Chain drive Secondary reduction ratio 39 15 2 600 Operat...

Page 14: ...where you have to site the measuring slide rule 100 1 mm 35 54 mm 29 91 mm 36 35 mm 29 96 mm 0 03 mm MAINTENANCE SPECIFICATIONS Part Standard Valves valve seats valve guide Valve clearance cold Suction Exhaust Valve sizes Suction A a head diameter B face width M C seat width M D M edge thickness Exhaust A head diameter B face width G seat width D edge thickness 0 10 0 15 mm 0 15 0 20 mm 29 9 30 1 ...

Page 15: ...MAINTENANCE SPECIFICATIONS Part Standard Limit End clearance with mounted ring Upper ring Lower ring Scraper ring Side backlash with installed ring Upper ring Lower ring Scraper ring 0 30 0 45 mm 0 30 0 45 mm 0 20 0 70 mm 0 04 0 08 mm 0 03 0 07 mm 0 015 0 042 mm Main shaft A shaft width JT C off centring nln limit t_o 1 D h backlash 1 T small end JJ backlash K 1 74 95 75 00 mm 0 35 0 65 mm 0 8 1 0...

Page 16: ...O 0 6 Pilot jet P J 50 Pilot output P O 0 8 By pass B P 01 0 Pilot screw P S ca 3 turns open Valve seat V S 2 5 Starter jet G S 76 Fuel level F L 6 0 8 0 mm under float chamber matching surface Float height F H 25 0 27 0 mm Engine idle speed 1 300 50 rpm Suction pressure at engine idie speed 26 6 34 6 kPa 200 260 mmHg MAINTENANCE SPECIFICATIONS SPEC 09 ELECTRIC SYSTEM Part Voltage Standard 12V Lim...

Page 17: ...ot charged adjusted voltage Rectifier Capacity Resistance voltage SH650A SHINDENGEN Short circuit semiconductor 14 2 15 2V 25A 240V 1 320 Constant mesh gear SM 13 MITSU8A 0 8 kW 12 5 mm 28 mm 0 7 mm MS5D 191 HITACHI 100A Flat 220 CEV PAGAN 2 5A 5 mm 27 mm MAINTENANCE SPECIFICATIONS SPEC 0Y Pari Standard Limit Turn light relay Type Model Manufacturer Automatic stop device Flashing frequency Power W...

Page 18: ... Wheel eccentricity limit Vertical Lateral Light alloy 3 00x17 Aluminium 0 5 mm 0 5 mm Part Standard Limit Rear wheel Type Light alloy Rim size 4 00x17 Wheel material Aluminium Wheel eccentricity limit Vertical 0 5 mm Lateral 0 5 mm Drive chain Type Manufacturer 135 ORS A REGINA CHAIN Number of finks 110 Chain slack 25 40 mm Front disk brake Type Single External disk diameter 320 mm Disk thickness...

Page 19: ...6 2 10 1 0 Cooling liquid pump Socket head bolt M6 3 10 1 0 1 tube Socket head bolt M6 1 10 1 0 2 tube Flange bolt M6 1 10 1 0 Thermostat assembly Flange bolt M6 2 10 1 0 Part to be tightened Thread Q ty Tightening torque Note size Nm mkg Filler coolant Cylindrical socked head bolt M6 1 10 1 0 Oil pump Socket head bolt M6 2 10 1 0 Oil delivery return hose Truncated cone head screw M6 2 7 0 7 Drain...

Page 20: ...2 10 1 0 Bearing cover plate Flat head screw M6 3 7 0 7 3 Locking plate Socket head bolt M6 2 10 1 0 Clutch spring Screw with washer M6 5 8 0 8 Clutch hub Nut M20 1 90 9 0 Use a lock Primary transmission gear washer Nut M20 1 120 12 0 Use a lock Thrust lever assembly stop washer Bolt M6 1 6 5 0 65 Thrust lever assembly Screw M8 1 12 1 2 Thrpari Tightening torque Part to be tightened It Q J Q ty No...

Page 21: ...rame Fuel tank to frame Fuel tank to rear small frame Fuel pump to bracket Bracket to fuel tank Front small frame and headlight Front small frame and instrumentation Front small frame and mirrors Side panel to frame bracket Bracket to frame Air connection to front small frame Side panel air connection to bracket Front fork handle bar Handle crown and fork Handle crown and handle bar fastening M8 x...

Page 22: ... arm axle and main frame Ml8x 1 5 1 110 11 Axle t locknut Rear arm and connecting rods M10x 1 25 1 40 4 0 Boit locknut Relay arm and connecting rods M10x t 25 1 40 4 0 Bolt locknut Relay arm and frame M10x 1 25 1 40 4 0 Bolt locknut Relay arm and shock absorber M10x 1 25 1 40 4 0 Boit locknut Shock absorber and frame M10x1 25 1 40 4 0 Boit locknut Chain guard seal and rear arm M6 xl O 1 5 0 5 Hexa...

Page 23: ... cylinder head cover SPEC 0 Lubricant type Si 3 3 3 Q 3 Q i mJ E Q 3 O G E E l 3 Bonding agent rapid seal adhesive Yamaha bond No 1215 Bonding agent rapid seal adhesive Yamaha bond No 121 LUBRICATION POINTS AND LUBRICANT TYPE CHASSIS Lubrication points part name Gear unit tachometer Oil seal edges completely Wheel axie front and rear wheels Rear wheel hub and clutch Bearing brasses rear arm and re...

Page 24: ... pump strainer engine LUBRICATION LAYOUT A INTAKE B RETRIEVAL SPEC Pf 1 Camshaft 2 Oil delivery hose 3 Oil filter 4 Oil pump 5 Main driving shaft 6 Drive shaft 7 Oil hose 8 Oil delivery hose LUBRICATION LAYOUT SPEC pf A INTAKE B RETRIEVAL 2 23 2 24 ...

Page 25: ...ting rod pin 5 Main driving shaft 6 Secondary drive shaft 7 Drain plug LUBRICATION LAYOUT SPEC 09 A INTAKE B RETRIEVAL 1 Oil delivery hose 2 Oi filter 3 Oil pump 4 Transmission 5 Oil pump strainer LUBRICATION LAYOUT SPEC pf A INTAKE B RETRIEVAL 2 25 2 26 ...

Page 26: ...COOLING LAYOUT 1 Thermostat 2 Radiator 3 Electric fan 4 Pump 5 Inlet hose 6 Outlet hose COOLING LAYOUT SPEC Pf SPEC 09 2 27 ...

Page 27: ...M Cfr page 2 32 1 Recovery tank breather pipe 2 Clamp 3 Clutch cable 4 Coil 5 Cfamp 6 Throttle cables 7 Oil retrieval hose CABLES ROUTING 8 Starter motor cabfe 9 Battery cable Starter relay 1 0 Starter relay 11 Flasher relay 12 Taiilight connector 13 Rear brake hose 14 Battery 15 Cables holder 16 Side stand switch 17 Breather pipes 18 Cables holder 19 Oil delivery hose 20 Engine oil breather pipe ...

Page 28: ...switch 22 Rear brake supply hose CABLES ROUTING SPEC 0y 1 Carburetor suction connection hose 2 Clutch cable 3 Clamp 4 Fuel lap suction connection hose 5 Low fuel signal connector cable 6 Earth cable 7 Battery bleeder pipe 8 Fuel impulse pipe 9 Fuel tank water discharge pipe 10 Cables holder 1 1 Starter motor cable 12 Recovery tank breather pipe 13 Instrumentation lighting connector cabie 14 Clamp ...

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Page 30: ...RANKCASE VENTILATION HOSE INSPECTION C 12 EXHAUST SYSTEM INSPECTION C 12 CHECKING THE COOLANT LEVEL C 12 CHANGING THE COOLANT C 13 COOLING SYSTEM INSPECTION C 14 CHASSIS C 15 FRONT BRAKE ADJUSTMENT C 15 REAR BRAKE ADJUSTMENT C 15 BRAKE FLUID LEVEL CHECK C 16 BRAKE PAD WEAR INSPECTION C 16 BRAKE HOSING INSPECTION C 16 BRAKE CIRCUIT BLEEDING D 1 DRIVE CHAIN TIGHTNESS INSPECTION AND ADJUSTMENT D 1 DR...

Page 31: ...necessary o Rear arm axle Check that the rear arm unit is not loose Correct if necessary Grease moderately o o PERIODIC MAINTENANCE LUBRICATION INTERVALS INSP ADJ 1 9 PART NOTES AFTER RUNNING 1 000 km 600 mi EVERY 6 000 km 4 000 mi or 6 months 12 000 km 8 000 mi or 1 2 months Rear suspension connection pins Check functioning Grease moderately O O m i Wheels Check balancing damage run out Repair if...

Page 32: ...el pipe 1 1 1 1 1 NOTF Turn the key anticlockwise to remove the seat and clockwise to reinstall it NHTF Before removing the fuel pipe close the tap by turning the ring nut screw tightly clockwise 6 Suction pressure intake pipe 1 7 Low fuel warning light connector 1 8 Tap water discharge pipe 1 9 Fuel tank 1 10 Screw 2 11 12 Pressure fasteners Pressure fasteners 2 2 NOTE Press down the rear cowling...

Page 33: ... in the order shown The right and left semifairings may be removed separately 1 Nut 2 2 Rear view mirror R 1 3 Screw 1 4 Screw 1 5 Screw 2 6 Side panel R 1 7 Nut 2 8 Rear view mirror L 1 9 Screw 1 10 Screw 1 11 Screw 2 12 Side panel L 1 13 Window front 1 14 Screw 1 15 Screw 2 16 Air flap 1 Reverse the removal procedure or instal lation 3 5 3 6 ...

Page 34: ... assembly 6 Air panel 7 VALVE CLEARANCE ADJUSTMENT INSP ADJ pa 9 Turn Driving shaft anticlockwise using a wrench 10 Align Reference mark T f on the flywheel 1 with the fixed reference mark on the crank case 2 NOTE Check that the piston is under compression at top dead centre 3 Ignition timing reference mark 11 Check Valve clearance using the special gauge T Out of specification Adjust Valve cleara...

Page 35: ...tat assembly 10 Nm 1 0 mkg Screws fuel tank 10 Nm 1 0 mkg Screws cowling 10 Nm 1 0 mkg 4 DRIVE CHAIN ADJUSTMENT The drive chain does not need to be adjusted IDLE SPEED ADJUSTMENT 1 Start the engine and let it heat 2 Connect The inductive engine speed indicator to the spark plug cable Inductive engine speed indicator P N YU 08036 A P N 90890 03113 3 Check The engine idle speed Out of specification ...

Page 36: ...hten the lock nuts 1 6 Lock nuts ft R ft ft ft A ft THROTTLE CABLE FREE PLAY ADJUSTMENT SPARK PLUG INSPECTION 4 Reassemble Air panel Air cleaner case Fuel tank Seat INSP ADJ pa Bolt air cleaner case 5 Nm 0 5 mkg Carburetor manifold clamp L 2 Nm 0 2 mkg Carburetor manifold clamp R 5 Nm 0 5 mkg Screws fuel tank 10 Nm 1 0 mkg SPARK PLUG INSPECTION 1 Remove Seat Fuel tank Air cleaner case Air panel Se...

Page 37: ...ITION TIMING CHECK NOTE Before checking the ignition timing adjust thethrottle cable free play and the engine idle speed 1 Start the engine and let it heat 2 Connect Inductive rev counter Stroboscopic lamp to spark plug cable Inductive engine speed indicator P N YU 08036 A P N 90890 03113 Stroboscopic lamp P N YM 33277 A P N 90890 03141 3 Remove Cap 1 CAUTION In certain conditions the oi might spr...

Page 38: ...G While operating the starter disconnect the spark plug cap to avoid sparks Compare the pressure reading with those in the table Pressure under compression at sealevel Standard 1 100 kPa 11 kg cm 156 psi Minimum 900 kPa 9 kg cm2 128 psi Maximum 1 200 kPa 1 2 kg cm2 171 psi 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 Me...

Page 39: ...pump The oil level must therefore be checked in the oil tank 1 Set the motorcycle level and hold it upright 2 Unscrew the oil tank cap 1 and clean the cap stem 3 Insert the cap sucker rod into the tank Do not unscrew simply place on the filler 4 Pull out the rod and check the oil level The latter must be between the minimum 3 and maximum 2 levels NOTE ____ To check the oil level place the cap with...

Page 40: ... Oil inlet hose fastening screw 2 Oil sump drainage bolt 3 Oil filter cover bleeder screw 4 Filter cover screw 5 NOTE The oil filter cover is secured by three screws The lowest one should be removed first so that the filter will drain 4 Drain Engine oil completely 5 Replace Oil inlet hose gaskets Oil sump drainage bolt gasket engine 6 Inspect All gaskets Damaged Replace Oil tank Oil filter housing...

Page 41: ...1 new CAUTION Install the new oil filter as shown A OUTER B INNER Oil filter cover screws Oil sump drainage screw Oil inlet hose screw ENGINE OIL REPLACEMENT INSP ADJ ra Oil sump drainage screw engine 30Nm 3 0 mkg Oil inlet hose screw 30 Nm 3 0 mkg Oil filter cover screws 10 Nm 1 0 mkg 9 Fill Oil tank Oil filter housing by bleeder hole Recommended engine oil SHELL SUPER 4TX 20W S0 Oil capacity Tot...

Page 42: ...TCH ADJUSTMENT Cable free play adjustment 1 Check Clutch free play adjustment A Out of specification Adjust Free play at the lever end 10 15 mm 2 Adjust Clutch cable free play Adjustment Loosen lock nut 1 Turn the adjuster 2 either way to obtain correct free play Tighten lock nut after adjustment If free play is still incorrect turn the crankcase adjusterfoilowing the same procedure described for ...

Page 43: ...element modifies the carburation causing poor performance and overheating 5 Inspect Fitter element Damaged Replace 6 Clean Filter element by blowing compressed air from the small metal net side 7 install Filter element in the filter case Filter case cover NOTE When installing the filter case cover be sure that the seal is mounted to prevent air from entering 8 Tighten Filter case cover fastening s...

Page 44: ...rences on the reser voir tank interna side are visible even if the side panels are mounted Recommended coolant High quality ethylene glycol antifreeze solution containing corrosion inhibitors for aluminium engines Coolant and water mixed ratio 50 50 Total amount 1 4 litres Reservoir tank capacity 0 55 litres From LOW to FULL level 0 210 litres 5 4 3 r J 3 2 _ I i i 1 6 1 M 1 3 1 1 1 r r 4 3 i 3 9 ...

Page 45: ... from the water pump case 5 Detach Pipe 3 from the base of the reservoir tank 6 Drain Reservoir tank All the cooling circuit Engine CHANGING THE COOLANT INSP ADJ WSk 7 Wash All the cooling circuit Use tap water 8 Inspect Gasket of drain bolt Damaged Replace 9 install Drain bolt and gasket Drain bolt water pump 10Nm 1 0mkg 10 Replace Supply pipe to the reservoir tank 11 Fill Cooling circuit through...

Page 46: ...o the health and must be used with care A WARNING If the coolant enters into contact with the eyes wash them with water and calf a doctor If you should swallow the coolant try to be sick and go to a doctor immediately If the coolant enters into contact with clothes wash them immediately with water then with soap COOLING CIRCUIT INSPECTION INSP ADJ pa COOLING CIRCUIT INSPECTION 1 Inspect Radiator 1...

Page 47: ...t and bleed the system if necessary REAR BRAKE ADJUSTMENT INSP ADJ 09 REAR BRAKE ADJUSTMENT 1 Check Free play of brake pedal A Out of specification Adjust Brake pedal free play A 0 5 1 mm 2 Adjust Brake pedal free play Adjustment Loose the eccentric screw 2 Turn the eccentric either way to obtain the correct free play Tighten the eccentric screw Recheck brake pedal free play t NOTE ft m A Factory ...

Page 48: ...NSPECTION 1 Operate the brake lever or brake pedal 2 Check Thickness of frictional material Out of specification Replace Wear limit A Front 0 8 mm Rear 0 8 mm For brake pad replacement see the section BRAKE PAD REPLACEMENT in chapter 7 A Front brake Bj Rear brake BRAKE HOSING INSPECTION 1 Inspect Brake hosing Cracks Damage Replace To replace hosing see the section FRONT AND REAR BRAKE in chapter 7...

Page 49: ...difficult it may be necessary to allow the brake fluid system to stabilise lor a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeared Top up fluid to the maximum level DRIVE CHAIN TIGHTNESS INSPECTION AND ADJUSTMENT INSP ADJ pa DRIVE CHAIN TIGHTNESS INSPECTION AND ADJUSTMENT Inspecting tightness NOTE Before checking and or adjusting the chain rotate the rear...

Page 50: ... AND ADJUSTMENT A WARNING When inspecting the front fork hold the motor cycle firmly to prevent it falling over Visual inspection 1 Check Inner tubes Scratches Dents Damage Replace Oil seals Undue oil leakage Replace Operating inspection 1 Check Proper functioning With the motorcycle in a level upright posi tion and with your hands on the handle bar operate the front brake Then compress and releas...

Page 51: ...lockwise To reduce it turn anticlockwise The spring preload changes by 1 mm per turn of the adjuster NOTE For adjustment purposes use the special wrench provided with the motorcycle After adjusting screw lock nut 2 to the adjuster 1 and tighten to prescribed torque Shock absorber lock nut 42 Nm 4 2 mkg CAUTION SHOCK ABSORBER INSPECTION AND ADJUSTMENT A WARNING This shock absorber contains highly c...

Page 52: ...Ring nut wrench 4r P N YU 01268 P N 90890 01268 Ring nut initial tightening 38 Nm 3 8 mkg Loosen the ring nut one turn Retighten the ring nut using the special wrench A WARNING Do not tighten the ring nut excessively Ring nut final tightening 3 Nm 0 3 mkg Tighten the steering column nut and he front fork plate screws 4 s 3 m STEERING INSPECTION A WARNING Hold the motorcycle firmly in place to prev...

Page 53: ...re parts Replace the valve cap securely to prevent losses of tyre pressure at high speed 1 Check Tyre pressure Out of specification Adjust INFLATING PRESSURES m bar psi With driver only Front Rear 2 28 2 2 32 With driver and passenger 2 2 32 2 5 37 2 Adjust Air pressure TYRE INSPECTION m it Adjustment Remove the valve cap Use an air pump or compressed air pis tol Increase air pressure Eliminate ai...

Page 54: ...s must always be checked in accordance with the maintenance table SIDE STAND LUBRICATION Lubricate the side stand and articulations Recommended lubricant SAE10W30 engine oil SWING ARM LUBRICATION Lubricate the swing and connection arm pivots CABLE INSPECTION AND LUBRICATION A WARNING If the cable sheath is damaged corrosion might ensue or the cable might not run freely To avoid such drawbacks repl...

Page 55: ...roac the setting screw 3 in the rear part of the headlight 2 Screw or unscrew Adjusting screw 3 Screw Increase the headlight beam Unscrew Decrease the headlight beam FUSE INSPECTION AND REPLACEMENT 1 Remove Seat Fuse box 1 main 2 fan motor Fuse from fuse box 2 Inspect Fuse A Intact fuse B Broken off fuse 3 Replace Broken fuse Replacement Disconnect the main switch OFF position Replace the fuse wit...

Page 56: ...e of the battery If an electrolyte with a specific density of 1 32 or over were used the battery plates would be corroded and the battery would last less BATTERY INSPECTION INSP ADJ WA A WARNING The electrolyte in the battery is dangerous it contains sulphuric acid and is thus poisonous and extremely corrosive Always observe the following prevention meas ures Avoid physical contact with the electr...

Page 57: ...o charging con ditions are shown in the figure 5 MF battery charging method CAUTION If jt is impossible to obtain the envisaged charge current voltage charge the battery according to the instructions In the section Charging with a constant voltage battery charger INSP ADJ 0 9 1 Charging time Room temperatufe 25 L _ _ _ _ J 1 1 B j 1 u j 1 I i w w i j JL W V H 1 fr Checfr tf e open cireuil voltage ...

Page 58: ... charge level 1A or less I Check the amperage for 3 5 min utes to see if the standard charge current is reached 1A or more If the current is higher than 1A regulate the voltage to 16 17V and continue to charge Set the timer to the charging time suitable for the open circuit volt age After 5 minutes regulate the voltage to 1 6 17V and con tinue to charge Charge the battery until the charg ing volta...

Page 59: ...et the charging time by following the instructions specified for the battery charger If the nominal current fails to flow replace the battery Measure the open circuit battery voltage after leaving the battery unused for over 30 minutes 12 8V or more Charging complete 12 7V or less Recharging necessary Under 12 0V Replace battery Battery charger o Arnperometer 7 Install Battery NOTE _____ _____ To ...

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Page 61: ...IN GUIDE E 15 CAMSHAFT CHAIN GUIDE E 16 CYLINDER AND PISTON E 16 PISTON RiNGS F 1 PISTON PIN F 2 CRANKSHAFT F 2 BALANCER DRIVE GEAR AND BALANCER GEAR F 3 ELECTRIC STARTER DRIVE F 3 PRIMARY DRIVE F 3 CLUTCH F 3 TRANSMISSION AND GEARBOX F 5 OIL PUMP WATER PUMP AND STRAINER F 6 OIL DELIVERY PIPES F 6 CRANKCASE F 6 BEARINGS AND OIL SEALS F 6 CIRCLIP AND WASHER F 6 ENGINE ASSEMBLY AND SETTING F 7 VALVE...

Page 62: ...AND REAR COWLING in chapter 3 ENGINE OIL 1 Drain Engine oil See the section ENGINE OIL REPLACE MENT in chapter 3 COOLING CIRCUIT 1 Drain Cooling circuit See the section CHANGING THE COOLANT in chapter 3 BATTERY CABLES 1 Disconnect Battery cables CAUTION _ Disconnect first the negative cable then the positive cable 2 Remove Battery ENGINE REMOVAL ENG w RADIATOR JOB INSTRUCTION CHART Order Job name ...

Page 63: ...r panef 3 3 Disconnect Engine idle speed control knob bracket 4 Starter control knob bracket 5 4 Loosen Carburetor joint clamps 6 5 Remove Carburetors 7 NOTE Cover the carburetor with a rag to prevent dirt or foreign bodies entering CLUTCH CABLE 1 Loosen Nut 1 2 Disconnect Clutch cable 2 from lever and bracket DRIVE CHAIN Loosen Rear wheel axle nut 1 Lock nut 2 of the chain stretchers Chain stretc...

Page 64: ...very hose 5 Screw oil delivery hose 6 Oil tank 7 Spark plug cable 8 Wire harness connector 3 9 Starter plus leadwire 10 Shift pedal 11 Bolt engine mounting 12 Screw engine mounting 13 Screw engine upper mounting 2 14 Axle engine front mounting 15 Engine 16 Bolt engine upper mounting stay 17 Engine upper mounting stay 18 Bolt engine front mounting stay 2 19 Engine front mounting stay 1 Reverse the ...

Page 65: ...ngine mounted the cylinder head cover camshaft and cylinder head can be maintained by removing the following parts Seat Fuel tank Cowling Radiator Exhaust pipe Ignition coil Air filter case Air panel Carburetor 3 Remove Starter motor 1 1 Remove Sparkplug 1 4 Remove Oil hose 1 Breather hose 3 crankcase 2 Remove Intake manifolds 1 5 Remove Coolant hose 1 3 Remove CapO 4 7 4 8 ...

Page 66: ...e stopper guide plate 4 into Ihe crankcase when removing the bolts cam sprocket 12 Remove Chain guide 1 exhaust s w ka N 7 Remove Cylinder head cover 1 NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 8 Loosen Bolts 1 cam sprocket 13 Remove Pipe i O Ring Bolts 2 Bolts 3 Bolts 4 NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each...

Page 67: ...th a clean rag to prevent the circlip from falling into the crankcase cavity Before removing the piston pin deburr the clip grooved and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use the piston pin puifer y Piston pin pufler P N YU 01304 90890 01304 CAUTION Do not use a hammer to drive the piston pi n out 18 Remove Cylinder 1 ROTOR AND STARTER DR...

Page 68: ... Rotor holder P N YS 01880 90890 01701 CAUTION Do not allow the rotor holder to touch the projection 3 on the rotor ENGINE DISASSEMBLY ENG m m UiiiX iM1 t 7 Remove Rotor 1 Woodruff key 2 Use the rotor puller 3 and adapter 4 Rotor puller PfN YU 33270 90890 01362 Adapter P N YM 04063 A 90890 04063 NOTE Tighten the tool holding bolts but make sure that the tool body is parallel with the rotor If nece...

Page 69: ...ing 1 Remove Circlip 1 Washer 2 Pull lever 3 Return spring 4 Washer 5 2 Remove Crankcase cover 1 right NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened asflaffl aw a 5 Remove Water pump housing 1 3 Remove Gasket 1 crankcase cover Dowel pins 2 m o M y fy m V o 6 Remove Circlip 1 Water pump gear 2 Pin 3 Circlip 4 Water pump housing 5 Impeller sha...

Page 70: ...P N YM 91042 90890 04086 8 Remove Nut 1 clutch boss Lock washer 2 Clutch boss assembly 3 Thrust plate 4 Clutch housing 5 ENGINE DISASSEMBLY ENG 9 Straighten Lock washer tabs 1 10 Loosen Nut 2 crankshaft Nut 3 balancer shaft NOTE Place a folded rag or aluminum plate between the teeth of the balancer drive gear and balancer gear Take care not to damage the gear teeth 1 1 Remove Primary drive gear 1 ...

Page 71: ...crankcase El Crankcase right IB Crankcase left NOTE Loosen the bolts 1 4 turn each and remove them after all are loosened Loosen the bolts starting with the highest numbered one The embossed numbers in the crankcase desi gnate the tightening sequence NOTE __ Turn the shift cam to the position shown in the figure so that it does not contact the crankcase when separating the crankcase 2 Attach Crank...

Page 72: ...se half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hans up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force 2 Remove Gasket 1 oil strainer m oc mti A Remove Dowel pins 1 Dowel pin 2 O ring 3 Xf B...

Page 73: ... P N YU 01135 A 90890 01135 Adapter P N YM 04063 A 90890 04063 NOTE Tighten the tool holding bolts but make sure that the tool body is vertical with the crankshaft If necessary one screw may be backed out slightly to level tool body ROCKER ARM NOTE With the engine mounted the rocker arm can be maintained by removing the following parts Cowling Seat Fuel tank Radiator Exhaust pipes Cylinder head co...

Page 74: ...ES NOTE Before removing the internal parts valve valve spring valve seat etc of the cylinder head the valve sealing should be checked 1 Check Valve sealing Leakage at valve seat Inspect the valve face valve seat and valve seat width Refer to the INSPECTION ANO REPAIR VALVE SEAT section 1 j cry V J 2 3 Remove Valve retainer 1 Valve spring 2 Valve 3 Oil seal 4 Spring seat 5 NOTE _ _ Identify each pa...

Page 75: ...times INSPECTION AND REPAIR ENG m VALVES AND VALVE GUIDES 1 Measure Clearance between stem and guide Internal diameter of valve guide a Diameter of valve stem b Out of specification guide Replace valve Clearance between stem and guide Intake 0 010 0 037 Limit 0 08 mm Exhaust 0 025 0 052 Limit 0 10 mm 1 Bore gauge 2 Replace Vatve guide Replacement NOTE Heat the cylinder head in an oven at 100 C to ...

Page 76: ...ace and seat of carbon deposits 2 Inspect Valve seat Pitting Wear Renew valve seat INSPECTION AND REPAIR ENG m 3 Measure Valve seat width a Out of specification Renew valve seat Valve seat width Intake 0 9 1 1 mm Exhaust 0 9 1 1 mm Measurement stages Apply Prussian blue Dykem to the valve seat 1 Install the valve in the cylinder head Press the valve onto the seat through the guide to leave a clear...

Page 77: ...lve seat is too narrow and situated low down near the lower edge of the valve surface Intervention on the valve seat Desired effect Mill type 60 before Centring of seat and attainment of 1 0 mm width 45 INSPECTION AND REPAIR ENG m 5 Emery Principal valve surface Valve seat NOTE If the valve seat is renewed or the valve and guide replaced the vatve seat and seal surface must be lapped Lapping Apply...

Page 78: ...nclination of spring a Out of specification Replace Inclination of spring Intake Exhaust Lower than 1 4 mm Lower than 1 6 mm INSPECTION AND REPAIR ENG m T Af z 0 JlJLLJR CAMSHAFT 1 Inspect Cam eccentrics Pitting Scratches Blue colour camshaft Replace 2 Measure Cam eccentrics Out of specification Replace camshaft a b Intake 35 69 35 79 mm 30 06 30 1 6 mm Exhaust 36 50 36 60 mm 30 11 30 21 mm 3 Meas...

Page 79: ...cams 4 Damage Bends Wear Replace 2 Check Decompression play Play exists 4 Replace INSPECTION AND REPAIR ROCKER ARM AND ROCKER ARM SHAFT 1 Inspect Rocker arm shaft Blue colour Grooves Replace shaft and check lubrication system 2 inspect Rocker arm shaft slot 1 Surface in contact with cam eccentric 2 Adjuster surface 3 Pitting Wear Scratches BJue colour Re place and check lubrication system 3 Measur...

Page 80: ... water jacket Crust of minerals Rust Remove Cylinder wall Wear Scratches Rebore or replace 5 Measure Piston to cyiinder clearance INSPECTION AND REPAIR ENG m Measurement stages First stage Measure cylinder bore C with a cylindergauge 1 50 mm from top of cylinder NOTE Measure bore parallel and at right angles to the driving shaft Then calculate average measure ment m Standard Wear limit Cylinder bo...

Page 81: ...ing lateral clearance remove car bon deposits from the piston ring seats and from the rings themselves s Piston ring lateral clearance Upper ring 0 04 0 08 mm Lower ring 0 03 0 07 mm i _ fc I j i rf i V 2 Position Ring into cylinder NOTE Fit each ring into the cylindsrand push it to about20 mm from the top edge of the cylinder Push the ring into the cylinder with the piston so that it is perfectly...

Page 82: ...EPAIR ENG m F Tiff c 5 E It J L A CRANKSHAFT 1 Measure Crank width A Out of specification Replace crankshaft 5 Crank width 74 95 75 00 mm Runout C Out of specification Replace crankshaft and or width bearing s Runout limit 0 03 mm Small end free play D Out of specification Replace big end bearing crank pin and or connecting rod Small end free play 0 8 mm Big end radial clearance E Out of specifica...

Page 83: ...pect Starter idle gear 1 teeth 1 Starter idle gear 2 teeth 2 Starter wheel gear teeth 3 Burrs Chips Roughness Wear Replace PRIMARY DRIVE 1 Inspect Primary drive gear teeth 1 Primary driven gear teeth 2 Wear Damage Replace both gears Excessive noises duringoperation Replace both gears 2 Inspect Starter wheel gear contacting surfaces Pitttng Wear Damage Replace 3 Check Starter clutch operation Check...

Page 84: ...E Scoring on the clutch boss splines will cause erratic operation 9 Check Circumferential play Free play exists Replace 10 Inspect Gear teeth 1 pull ever axle Gear teeth 2 pull rod Wear Damage Replace as a set ci tH v 111 i i I __ _ J V f 1 i J 1 f 1 1 i T f f i 6 Measure Clutch spring free length a Out of specification Replace springs as a set Free length clutch spring 42 8 mm Limit 40 8 mm 7 Ins...

Page 85: ...ting clutches Rounded edges Cracks Missing frag ments Replace 7 Check Proper mating of each gear with corre sponding part Gear movemenl Roughness Replace Transmission gear assembly stages Ft the 2nd pinion gear 1 to the propeller shaft 2 as shown in the figure 8 Inspect Spring 1 Damage Replace Shift lever 2 Damage Bends Wear Replace 9 inspect Shift shaft Benl Wear Damage Replace F J 5 Measure Tran...

Page 86: ... Water pump gear 3 Cracks Wear Damage Replace INSPECTION AND REPAIR ENG m OIL DELIVERY PIPES 1 Inspect Oil delivery pipes Cracks Damages Replace Clog Blow out with compressed air CRANKCASE t Thoroughly wash the case halves in mild solvent 2 Clean all the gasket mating surface and crank case mating surface thoroughly 3 Inspect Crankcase Cracks Damage Replace Oil delivery passages Clog Blow out whit...

Page 87: ...2 5 or 1 6 mm 0 063 in VALVE CLEARANCE COLD Intake 0 10 0 15 mm 0 004 0 006 in Exhaust 0 15 0 20 mm 0 006 0 008 in 14 Nm 1 4m kg f 1 ft lb 14 Nm 1 4nrkg 10fWb E 1 D STEM RUNOOT LIMIT 0 01 mm 0 0004 in VALVE SEAT WIDTH 0 9 1 1mm 0 035 0 043 in ENGINE ASSEMBLY AND SETTING ENG m WARNING For engine reassembly replace the following parts whit new one O ring Gasket Oil sea Key Lock washer Circlip VALVES...

Page 88: ...e valve cotters while compressing the valve spring with the valve spring compressor Valve spring compressor P N YM 04019 90890 04019 5 Secure the valve cotters on to the valve stem by tapping it lightly with a piece of wood CAUTION Do not hit so much as to damage the valve ENGINE ASSEMBLY AND SETTING ENG m ROCKER ARMS 1 Lubricate Rocker shaft with engine oil 2 Install Rocker arm Rocker shaft Screw...

Page 89: ... P N YM 91044 P N 90890 04081 Adapter 10 2 P N YM 90069 P N 90890 04059 Crankshaft installer pot 3 P N 90890 01274 Crankshaft installer bolt 4 P N 90890 01275 Spacer 5 P N 90890 01288 NOTE __ _______ Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until half of the crankshaft bearing 6 is inserted into...

Page 90: ... 13 Fifth sprocket gear 14 Third sprocket gear 15 Fourth sprocket gear 16 Main shaft 17 Bearing 18 Bearing 19 Bearing 20 Bearing 1 Guide bar long 7 Gear shalt 2 2 Selector fork 3 R 8 Gear shaft 1 3 Selector fork 1 1 9 Oil seal 4 Gear cam 5 Guide bar short 6 Selector fork 2 C B6305 10Nm 1 0m kg 7 2ft lb B6004 B6305NRX1C3 B C USE NEW ONE 0 m kg 80 1Mb DRIVE AXLE RUNOUT LIMIT 0 08 mm 0 003 in MAIN AX...

Page 91: ...hift fork 3 R 2 Shift fork 2 C 3 Gear cam 4 Guide bar long 5 Guide bar short 6 NOTE Install the shift forks with the embossed mark on each shift fork facing right side of the engine M 3 Install Cottar 1 Drive axle a sembly 2 4 Install Main axle assembly 1 7 Install Shift shaft 2 1 Shift shaft 1 2 8 Check Transmission operation Unsmooth operation Repair 5 Apply Engine oil onto guide bars 4 59 4 60 ...

Page 92: ...GINE ASSEMBLY AND SETTING CRANKCASE 1 Bearing cover piate 2 Lock plate 3 Crankcase ventilation hose 4 Clamp 5 Crankcase 6 Collar 7 Dowel pin 8 Dowel pin 9 O ring ENG m A TIGHTENING SEQUENCE 7 Nm 0 7 rmkg 5 1 ft lb 10Nm 1 0m kg 7 2fflb B SEALANT QUICK GASKET YAMAHA BOND NO 121 5 e 4 61 4 62 ...

Page 93: ...E 1 Apply Bonding agent on the semicrank mating surfaces Bonding agent Quick Gasket PfU ACC 11001 01 Yamaha bond N 1215 P N 90890 85505 NOTE Do not allow any sealant to come in contact whit the oil gallery 2 Install O ring 1 Dowel pin 2 Dowel pins 3 3 Assemble the left semicrank to the right semicrank Beat gently with a soft hammer NOTE Turn the gear cam as shown in the figure so that it does not ...

Page 94: ...oke engine oil to the oil pipes in crankcase CAUTION To avoid damage to the engine lubricate the oil pump pipes in the crankcase liberally with 4 stroke engine oil 3 Apply 4 stroke engine oil to the oil pump pipes ENGINE ASSEMBLY AND SETTING ENG m m pp 4 Install Gasket 1 O rings 2 Oil pump 3 Oil pump gear 4 Circlip 5 Screw oil pump 10 Nm 1 0 mkg 5 Install Spring 1 Collar 2 Stop lever 3 Stop lever ...

Page 95: ...h lever 12 Gear assy 5 Push lever axle 13 Primary transmission gear 6 Friction plate type A 7 Clutch boss spring 8 Clutch plate USE NEW ONE 60 Nm 6 0 m kg T 43fflb USE NEW ONE 120 Nm 12 0 m kg 85 fWb A FRICTION PLATE Type Thickness Wear Limit A 2 pes 2 94 3 06 mm 0 116 0 120 in 2 8 0 110 In B 6 pes 2 74 2 86 mm 0 108 0 113 in 2 6 mm 0 102 in 2 6 B CLUTCH SPRING MINIMUM FREE LENGTH 40 8 mm 1 606 in...

Page 96: ...etween the teeth of the balancer drive gear and balancer gear Take care not to damage the gear teeth 2 Bend the lock washer tab along the nut fiat 16 ENG 3 Apply Engine oil onto bearing and gear teeth 4 Install Clutch housing 1 Thrust plate 2 Clutch boss assembly 3 Lock washer 4 Nut 5 dutch boss NOTE Fit the tabs of the lock washer to the groove of the clutch boss 5 Tighten Nut l clutch boss NOTE ...

Page 97: ...he inside of the second friction plate Friction plate Type A Type B Quantity 2 pes 6 pes Inside diameter D 116 mm 113 mm ENGINE ASSEMBLY AND SETTING ENG m s NOTE Align the punched mark 1 2 on the clutch boss with the arrow mark on the clutch pressure plate 13 Screw pressure plate 8 Nm 0 8 mkg 9 Apply Lithium soap base grease onto seal lips in crankcase cover Engine oil onto bearings in crankcase c...

Page 98: ...the pull lever whit the UP mark 8 facing upward OIL FILTER AND WATER PUMP 1 Install Impeller shaft 1 Water pump housing 2 Circlip 3 Pin 4 Water pump gear 5 Circlip 6 NOTE install the water pump with embossed side 7 facing to inside 8 INSIDE 2 Apply Molybdenum disulfide grease onto impeller shaft end Install Water pump housing 1 Water pump cover 2 A Bolt water pump 10Nm 1 0mkg 5 Install Oil fitter ...

Page 99: ...wire 3 to the timing chain to prevent it from falling into crankcase 2 Apply Lithium soap base grease onto bearing on starter drives 3 Install Washer 1 Needle bearing 2 Wheel gear 3 4 Install Woodruff key 1 Rotor 2 NOTE When installing the magneto rotor make sure thet the woodruff key is properly seated in the keyway of the crankshaft 5 Install Nut 1 rotor Nut rotor 150 Nm 15 0 mkg NOTE Tighten th...

Page 100: ...t starter idle gear Needle bearing 2 Starter idle gear 3 Gasket 4 Dowel pin 5 10 Install Cover 1 Bolt cover 10Nm 1 0mkg ENGINE ASSEMBLY AND SETTING ENG m CYLINDER 1 Cylinder head gasket 2 Cylinder 3 O fing 4 Cylinder gasket 5 Dowel pin TIGHTENING SEQUENCE B BORE SIZE 100 005 T00 045 mm 3 9372 3 9388 in LIMIT 100 1 mm 3 941 in PISTON TO CYLINDER CLEARANCE 0 005 0 070 mm 0 0020 0 0028 in LIMIT 0 15 ...

Page 101: ...Nm 3 8 m kg 27 ft lb 17 5 Nm 1 75 m kg 13 ft lb J Nm 0 7 m kg 5 1 ft lb j SEALANT QUICK GASKET YAMAHA BOND NO 1215 ENGINE ASSEMBLY AND SETTING ENG m CAMSHAFT AND CAMSHAFT CHAIN 1 Camshaft 9 Guide stopper plates 2 Spring 10 Guide stopper 0 Decompression lever pin intake W Decompression lever 11 Timing chain 5 Cam chain sprocket 12 Guide stopper 6 Decompression cam exhaust Spring 13 Gasket 8 Tension...

Page 102: ...ing end upper 4 2nd ring end 6 install Cylinder 1 3 Install Piston 1 Piston pin 2 Circlips 3 NOTE The allow 4 on the piston must point to the front of the engine Before installing the circlip cover the crankcase with aclean towei or rag so you will not accidentally drop the pin dip and material into the crankcase 4 install Gasket 1 cylinder Dowel pins 2 NOTE Install the cylinder while compressing ...

Page 103: ...ter 4 Align the maich mark on the camshaft with the punched mark on the decompression lever Fit the timing chain onto cam sprocket and install the cam sprocket on he camshaft NOTE When installing the cam sprocket keep the timing chain as tense as possible on the exhaust side Align the pins 7 on the decompression lever with the slots 8 in the decompression cam Set the respective match marks 9 to be...

Page 104: ...et PfU ACC 11001 01 Yamaha Bond N 1215 P N 90890 85505 19 install Dowel pins 2 20 Install Cylinder head cover 1 NOTE Tighten the bolts in stage using a crisscross pattern Bolt cylinder head cover 10 Nm 1 0 mkg 15 Tighten Bolts 1 cam sprocket Bolts cam sprocket 20 Nm 2 0 mkg 21 Install Timing plug 1 Plug 2 16 Check Valve timing Out o alignment Adjust Refer to above steps 13 15 17 Check Valve cleara...

Page 105: ... oil pipes 2 Install Coolant hose 1 3 Install Breather hose 1 crankcase Oil hose 3 Bolts oil hose 10 Nm 1 0 mkg 5 install Starter motor 1 Bolt starter motor 10 Nm 1 0 mkg 6 Install Oil pipe 1 Union bolt oil pipe 20 Nm 2 0 mkg Bolt 10 Nm 1 0 mkg 7 Install Oil pipe 1 Union bolt oil pipe 20 Nm 2 0 mkg SSS 4 Apply Lithium soap base grease onto O ring on starter motor 4 87 4 88 ...

Page 106: ...rew 2 oil filter cover 2 Apply 4 stroke engine oil to the camshaft upper side and into the oil filter chamber A WARNING Apply a liberal amount of 4 stroke engine oil to the oil passage in the crankcase or the engine may be damaged Oil quantity Camshaft 0 1 L Oil filter chamber 0 06 L 3 Install Tappet cover intake Air bleed screw oil filter cover Bolt tapped cover 10 Nm 1 0 mkg Air bleed screw 5 Nm...

Page 107: ...joints to carburetors ENGINE ASSEMBLY AND SETTING ENG m iv l V v v _ J i r rrO y a f J 1 t b il v il V V I I I few T its M Jvn fepl I Screw carburetor manifold clamp left 2 Nm 0 2 mkg Screw carburetor manifold clamp right 5 Nm 0 5 mkg 13 Install Exhaust pipe 1 Muffler 2 Nuts 3 exhaust pipe 10 Nm 1 0 mkg Muffler mounting bolts 4 40 Nm 4 0 mkg Bolt 5 23 Nm 2 3 mkg Bolt 6 clamp 10 Nm 1 0 mkg 14 Insta...

Page 108: ......

Page 109: ...EM G 14 RADIATOR G 15 JOB INSTRUCTION CHART G 15 INSPECTION G 16 ASSEMBLY G 16 WATER PUMP H 1 JOB INSTRUCTION CHART H 1 REMOVAL H 1 INSPECTION H 2 ASSEMBLY H 2 THERMOSTAT H 2 JOB INSTRUCTION CHART H 2 REMOVAL H 3 INSPECTION H 3 ASSEMBLY H 3 ...

Page 110: ... to 7 Hose from cylinder water pump head 20 Hose from water pump 8 Pipe cylinder head to cylinder 9 Hose Irom radiator to 21 Water pump assembly thermostat assembly 22 O ring 10 Thermostat housing 23 Dowel pin 11 Hose from conduction to 24 Circlip thermostat assembly 25 O ring 12 Thermostat 26 Impeller shaft gear 13 O ring 27 Drain bolt 14 Thermostat cover 28 Gasket COOLANT AND WATER MIXED RATIO 5...

Page 111: ...r instal lation NOTF After installing the radiator fill the cooling system with the specified coolant See the section COOLANT CHANGE in chapter 3 A WARNING Do not remove the radiator cap when the engine and radiator are hot Scalding hot fluid and steam maybe blown out underpressure which could cause serious injury When open the radiator cap note the following points Wait until the engine has coole...

Page 112: ...ion to the following points 1 Tighten Radiator bolts Drain bolts A Bolts radiator and drain 10Nm 1 Omkg NOTE __ Replace copper seal gasket every time bolts are removed 2 Fill Cooling circuit with prescribed coolant See the section COOLANT CHANGE in chapter 3 3 Inspect Cooling system for leakage Radiator cap vaive opens at a pressure below the specified pressure Replace Cap vafve opening pressure 9...

Page 113: ...t See the section COOLANT CHANGE in chapter 3 4 Cover 1 5 Water pump housing 1 Reverse the removal procedure for installation NOTE After installing the water pump fill the cooling circuit with specified coofant See the section COOLANT CHANGE in chapter 3 D 7 a m a REMOVAL 1 Remove Crrclip 1 Impeller shaft gear 2 Dowel pin 3 Circlip 4 Water pump housing 5 Impeller shaft 6 T 2 Eliminate Fur deposits...

Page 114: ...crew Screw Clamp Hose detach Clip Hose Thermostat assembly with radiator cap assembly Q ty 1 1 2 2 1 1 1 Remarks Remove the parts in the order NOTE When removing the thermostat drain off the cooling circuit See the section COOLANT CHANGE in chapter 3 NOTE To approach the thermostat assembly remove side panel R of cowling See the section COWLING in chapter 3 Reverse the removal procedure for instal...

Page 115: ... he water Observe the thermometer while continually stirring the water 1 Thermometer 2 Full opening temperature 3 Start opening 4 Water 5 Thermostatic valve 6 Vessel A FULL OPENING B CLOSE THERMOSTAT ASSEMBLY Performance REMOVAL operations in reverse order 1 Install Thermostat into housing O ring Thermostat cover 2 Tighten Screws cover Screws housing cover 10Nm 1 0mkg NOTE ___ __ The thermostatic ...

Page 116: ......

Page 117: ...ATIONS TIGHTENING TORQUES EXPLODED VIEW H 6 SECTION VIEW H 6 REMOVAL H 7 DISASSEMBLY H 8 INSPECTION H 9 ASSEMBLY H 10 INSTALLATION H 13 FUEL LEVEL ADJUSTMENT H 13 FUEL PUMP H 14 CHECKING THE PUMP OPERATION H 14 REMOVAL H 14 INSPECTION H 14 INSTALLATION H 14 ...

Page 118: ...27 Washer spring 28 Spring 29 Bolt 30 Hose 31 Hose 32 Screw 33 Screw 34 Hose 35 Clamp 36 Main jet FIRST 37 Needle jet 1 38 Throttle valve 1 39 Pilot jet 40 Main jet SEC 41 Needle jet 2 42 Pilot adjuster 43 Needle valve set jet needle 44 Stop screw knob 45 Throttle screw set 46 Diaphragm 1 47 Needle jet 48 Needle jet 49 Starter set 50 Bracket gas lever 51 Air intake hose SECTION VIEW 1 Needle jet p...

Page 119: ... the carburetors remove seat and fuel tank See the section SEAT FUEL TANK AND 1 Ciamp air cleaner joint 2 REAR COWLING in chapter 3 2 Air cleaner case 1 3 Panel 1 4 Lock nut loosen 4 5 Throttle control cable disconnect 2 6 Screw starter knob 1 7 Screw idle speed knob 1 8 Clamp intake manifold 2 9 Carburetor 2 Reverse the removal procedure for installation 6 3 6 4 ...

Page 120: ...t Support plate 6 rear 3 Detach Pipe 1 Pipe 2 Connecting bracket 3 Separate Primary carburetor 4 Secondary carburetor 5 CARBURETOR Ife 2 2 r 3 V I 1 V V t Primary carburetor 1 Remove Float chamber 1 Float pin 2 Float 3 NOTE Remove the float needle in the direction of the arrow 2 Remove Needle valve Valve housing 1 Main jet FIRST Needte jet 2 Pilot jet 3 Idle speed screw 4 O ring 5 3 4 Disconnect T...

Page 121: ...ver 1 Spring 2 3 Remove Piston valve 1 Needle jet 2 INSPECTION 1 Inspect Carburetor body Soiled Clean Float chamber Cracks Damage Replace Fuel passages Obstructed Clean NOTE Use petroleum based solutions to clean carburetor body never use caustic solution Clean all passages and jets with compressed air 2 Inspect Valve housing 1 Needle valve 2 Wear Corrosion Replace O Ring 3 Damaged Replace NOTE Al...

Page 122: ...imary Main jet 2 secondary Needle jet 1 3 primary Needle jet 2 4 secondary O ring 5 needle jet 1 Piiot jet 6 NOTE Clean jets with compressed air ASSEMBLY Perform DISASSEMBLY operations in reverse order Pay attention to the following points CAUTION Wash all parts with clean petrol prior to reassembly Always use new gaskets Secondary carburetor 1 Install Needle jet 1 Piston valve 2 NOTE Draw the dia...

Page 123: ...olding it in position tighten the screw connecter comp Screw connecter comp 2 Nm 0 2 mkg 6 11 m 8fe w CARBURETOR 5 Install Cable support 1 Roller 2 Throttle lever 3 NOTE Check that the throttle shaft lever 4 and the adjuster bolt 5 are aligned when tightening the throttle lever nut 6 Screw cable support 3 Nm Q 3 mkg Nut throttle lever 3 5 Nm 0 35 mkg t 6 Install Gasket 1 Top cover 2 Screw top cove...

Page 124: ...alve housing 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 6 13 w CARBURETOR 13 Install Float chamber Screw float chamber 2 Nm 0 2 mkg 14 Adjust Pilot air screw 1 Adjustment Turn the screw until it is slightly locked Unscrew by specified turns Pilot air screw unscrew Unscrew3 tu...

Page 125: ...crew clamp right joint 5 Nm 0 5 mkg 2 Install The air cleaner hose to the carburetor moving the air filter case towards the front part Screw clamp left manifold 2 Nm 0 2 mkg Screw clamp right manifold 5 Nm 0 5 mkg 3 Install Throttle cable 1 Starter cable knob 2 FUEL LEVEL ADJUSTMENT 1 Place the motorcycle on a level surface 2 Make sure that the carburetor is in a horizontal position by placing a j...

Page 126: ...tion REMOVAL 1 Remove Seat Fuel tank See the section SEAT FUEL TANK AND REAR COWLING in chapter 3 2 Disconnect Fuel delivery pipe 1 to carburetor Suction pipe 2 Fuel delivery pipe 3 from fuel cock to pump 3 Remove Nuts 4 fuef pump Fuel pump assembly 5 FUEL PUMP INSPECTION 1 Inspect Fue pipes Suction pipe Cracks Wear Damage Replace 2 Inspect Fuel pump assembly 1 Cracks Damage Replace INSTALLATION P...

Page 127: ......

Page 128: ... 6 REAR BRAKE CALIPER I 6 BRAKE PAD REPLACEMENT I 7 FRONT BRAKE CALIPER DISASSEMBLY I 9 REAR BRAKE CALIPER DISASSEMBLY 1 10 FRONT MASTER CYLINDER DISASSEMBLY 1 11 REAR MASTER CSLINDER DISASSEMBLY 1 12 INSPECTION AND REPAIR 1 13 FRONT FORK 1 15 REMOVAL 1 16 OIL CHANGE J 1 CLEANING THE DUST SEAL J 3 REPLACING THE SEALS AND BUSHES J 4 ADJUSTMENT J 10 STEERING J 1 1 REMOVAL J 1 1 INSPECTION J 12 INSTA...

Page 129: ...L 0 5 mm INFLATION PRESSURE JN bar kg cm2 psi WITH DRIVER ONLY 2 28 WITH DRIVER AND PASSENGER 2 2 32 JOB INSTRUCTION CHART Order Job name Part name Q ty Remarks 1 2 3 4 5 Removal of front wheel Odometer cap detach Odometer cable Axle retainer screw loosen Wheel axle Wheel Remove the parts in the order I A WARNING I H H Support the motorcycle securely so that it does not fall over when the wheel is...

Page 130: ...ONT WHEEL How to replace wheel bearings and dust covers Clean the outside of the hub Remove the dust cover 1 with a flat headed screw driver NOTE Place a rag on the outside to avoid damaging the dust cover Disassemble the bearing 1 with a normal puller 2 Install the new bearing and the dust cover by following the disassembly procedures in reverse order NOTE Use a wrench 4 with an external diameter...

Page 131: ... ends at 90 to the perpendicular Check that the heavy point does not shift Otherwise try with another weight until the wheel is balanced 5 Check Wheel balancing Control procedure Set the wheel into any of the positions shown in the figure Check that in each of the points the wheel is still Otherwise balance the wheel once again REAR WHEEL 1 Wheel axle 2 Flat washer 3 Chain stretcher 4 Spacer 5 Dus...

Page 132: ...push the rear wheel forward NOTF The brake caliper bracket must be supported when the wheel is removed CAUTION Do not operate the brake pedal when the wheel is removed Reverse the removal procedure for installation CAUTION Adjust drive chain slack Make sure that the chain stretchers are putted in the same position INSPECTION 1 Inspect Rear wheel See section TION FRONT WHEEL tNSPEC 2 3 Check Tyre W...

Page 133: ... CYLINDER IS REMOVED BRAKE FLUID DOT 4 BI FRONT AND REAR BRAKE FRONT BRAKE CALIPER 1 Brake disk 2 Brake pad lock pin 3 Bleeder screw 4 Brake pads 5 Pad spring 6 Pad pin lock spring 7 Brake caliper piston unit A PISTON GASKETS NOT SUPPLIED REPLACE ENTIRE CALIPER UNIT IF NECESSARY BRAKE FLUID DOT 4 BRAKE PAD WEAR LIMIT 0 8 mm BRAKE DISK WEAR LIMIT 3 5 mm BRAKE DISK RUNOUT LIMIT 0 3 mm B USELOCTITE 2...

Page 134: ... 3 Brake fluid tank A PUMPER ASSEMBLY MASTER CYLINDER IS 3 Brake pad lock pin 0 Cylinder BRAKE DISK WEAR LIMIT 4 mm 4 Hose NOT SUPPLIED RE REMOVED 4 Brake pad A CYLINDER GASKETS NOT BRAKE DISK RUNOUT LIMIT 5 Stop light switch PLACEWHOLE MASTER BRAKE FLUID DOT 4 5 Brake caliper SUPPLIED REPLACE WHOLE 0 3 mm 6 Brake hose CYLINDER UNIT IF 6 8rake caliper bracket BRAKE CALIPER ASSEMBLY B USE LOCTITE 2...

Page 135: ...ake pads new Pad spring new Pad fastening pin Pad pin lock spring BRAKE PAD REPLACEMENT NOTE It is unnecessary to disassemble the brake caliper and hose to replace the pads A WARNING Support the motorcycle securely to prevent it falling over Front brake 1 Remove Pad pin lock spring 1 2 Remove Pad fastening pin 2 NOTE To remove the pad fastening pin strike from the inside with punch with a suitable...

Page 136: ...er of he two pads has to be replaced because it is worn replace both Wear limit a 0 8 mm FRONT AND REAR BRAKE Installation procedure Connect the hose firmly to the caliper bleeder screw 1 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 Caliper bleeder screw 6Nm 0 6mkg Install th...

Page 137: ...in off the fluid from the braking circuit WARNING Support the motorcycle securely to pre vent It falling over NOTE Blowing compressed air into the hose connection make the piston leave the body of the caliper WARNING Do not force the piston out with a lever or other tools Cover the piston with a rag Be careful to prevent the piston from damaging the cylinder as it leaves it Reverse the procedure f...

Page 138: ... WARNING Support the motorcycle securely to pre vent it falling over NOTE Blowing compressed air into the hose connection make the piston leave the body of the caliper A WARNING Do not force the piston out with a lever or other tools Cover the piston with a rag Be careful to prevent the piston from damaging the cylinder as it leaves it Reverse the procedure for assembling and installation NOTE Aft...

Page 139: ...securely to prevent it falling oven 1 Nut 2 Bolt 3 Brake lever 4 Screw 2 5 6 7 Stop switch Rubber cover detach Screw 8 Brake hose 9 10 Joint whit gasket Screw 11 Screw 12 Screw 2 13 Cover 14 15 Diaphragm Fluid tank 16 Screw 2 17 Bracket 18 Master cylinder unit Reverse the procedure for assembling and installation A WARNING Replace the copper seal gaskets of brake hose fastening screw every time th...

Page 140: ...e the parts in the order NOTE _ Before removing the master cylinder drain off the fluid from the braking circuit WARNING Support the motorcycle securely to prevent It falling over NOTE Before removing the brake switch disconnect the switch connector Reverse the procedure for assembling and installation WARNING Replace the copper seal gaskets of brake hose fastening screw every time the screw is re...

Page 141: ... Wear Replace caliper as sembly Front Rear Inspect Caliper body 3 Cracks Damage Replace Guide pin 4 Rust Damage Repface Lock spring 5 Rust Damage Replace Dust seals 6 Cracks Wear Damage Repface Oil delivery passages caliper body Clean with compressed air WARNING Replace the piston sealing element and dust seals every time the caliper is disassembled FRONT AND REAR BRAKE B 3 Inspect Master cylinder...

Page 142: ...luid Xj Brake fluid DOT 4 Always use new copper washers Always use new piston gaskets and dust covers NOTE Apply lithium soap base grease to Ihe brake lever pin CAUTtOM The brake fluid may corrode painted surfaces and plastic parts If it spills clean immediately WARNING The quality of the brake fluid used must conform to the prescribed standards other wise the rubber gaskets risk deteriorating thu...

Page 143: ...7 Dust seal 18 Wheel axle fastening screw 20 22 Nm 2 0 2 2 m kg 1 2 i 23 Nm 2 3 mkg if ff rO 23 Nm 2 3 mkg m is t i 20 22 Nm 2 0 2 2 mkg CJ 4 _ L i 5 20 22 Nm 2 0 2 2 mkg 12 11 10 10 31 W 4 v 15Nm 1 5mkg c FRONT FORK FORK OIL CAPACITY IN EACH TUBE 300 cc RECOMMENDED OIL BEL RAY MC 10 SAE5 FORK OIL LEVEL STANDARD 130 mm From top of outer tube with inner tube and damper rod fully compressed without ...

Page 144: ...front wheel see REMOVAL FRONT WHEEL in this chapter NHTP Loosen the cap bolts before disassembling the front fork from the motorcycle CAUTION Secure the brake caliper to frame to avoid damaging the brake hose MHTF Secure odometer cable to frame to avoid damaging it Reverse the removal procedure for In stallation MHTF Tighten the cap botts after assembling the front fork to the motorcycle CAUTION T...

Page 145: ...a 26 mm open ended spanner on cap bolt and a 1 4 mm open ended spanner on lock nut 2 Block Suspension fork 1 in a vice in the fixing zone of the fower bracket CAUTION Place a cloth between the teeth of the vice to protect the surface of the outer tube Tighten the vice moderately in order not to ovalfze the outer tube 3 Remove Cap bolt 2 loosen the cap bolt before disassembling the fork from the cy...

Page 146: ...rod 2 completely to the end of the stroke 15 Complete Topping up of oil Topping up procedure Keep the fork in a perfectly upright position Bring the level to 130 mm from the upper edge measured with a graduated dipstick or ruler Only when the fork is completely dismounted in order to replace the seals bushes or the inner tube can one use 300 cc of oil without measuring the level with a ruler In al...

Page 147: ...s a space of about 1 2 mm between the cap bolt 1 and the lock nut 2 so ensuring that the cap bolt is completely tightened onto rod 3 CAUTION This check ensures a maximum traction seal Lower the spring using force keeping the spacer 4 tight against the spring 5 then insert a 14 mm open ended spanner on lock nut 2 and a 26 mm open ended spanner on cap bolt 1 tighten the two components to the specifi...

Page 148: ...ssary to replace all the seals and slide bushes CAUTION The operations sequence shown in the draw ings in the following paragraph refer to the disassembly and reassembly of the left arm It is fundamental to remember that the parts dis assembled from this arm should be reassem bled on it and not on the right arm since as it is possible to note when disassembling the arms the adjustment rod of the l...

Page 149: ... spring being immersed in oil could cause oil to drip onto the work surface when withdrawn It is advisable therefore to withdraw it slowly and to dry it with a cloth 10 Remove Outer tube from the vice Keep the cap bolt end upwards 11 Pour Oil into a tray NOTE While pouring the oil at the same time move the rod 1 backwards and forwards 12 Block Suspension fork 1 in a vice m horizontal position in t...

Page 150: ...ep a finger over the hole on the end of rod 3 to avoid oil splashes FRONT FORK 19 Cfean Outer tube inside Cartridge outside Cleaning procedure Clean the inside of the outer tube and the outside of the cartridge with cfean petrol taking care not to let petrol enter the inside of the cartridge through the two lower holes as it would seriously jeopardize its functioning WARNING Never tamper with the ...

Page 151: ...ve to be fitted to the inner tube in a specific direc tion This must be respected at all times avoid compromising the functioning of the front fork FRONT FORK 26 Assemble DU bush 5 into the outer tube Sequence of DU bush assembly Take the outertube DU bush 5 by the outertube housing side and assemble the special tool 8 supplied in the kit to the inner tube 2 Fork service kit assy P N4SU F8120 W0 A...

Page 152: ...0 mm from the vice After having tightened the vice grip the outer tube and with a few energetic blows hit it against the tool after each blow rotate the outer tube slightly in order to mount the oil seal correctly and until it is completely in its seat Remove the suspension fork from the vice and disassemble the tool FRONT FORK 28 Clamp Suspension fork NOTE Clamp the suspension horizontally in the...

Page 153: ...at the end of the spanner 4 is correctly engaged on the car tridge 1 FRONT FORK 32 Insert Spring 1 in the outer tube 2 NOTE Usually there is no particular sense in which the spring is mounted and so it may be inserted from either end 33 Install one at a time Spacer 3 Plastic spring guide 4 onto inner tube 5 Spacer 6 with holes corresponding wilh those on the rod 34 Screw Lock nut 7 down to bottom ...

Page 154: ...torque Cap bolt 20 22 Nm 2 0 2 2 mkg NOTE Tighten the cap bolts after assembling the front fork to the motorcycle FRONT FORK ADJUSTMENT Fork damper adjustable both in extension right stem adjustment and compression left stem ad justment CAUTION Do not force the adjusting screw beyond the minimum and maximum limits ADJUSTING THE REBOUND DAMPING EFFECT 1 Adjusting screw rebound damping effect A Incr...

Page 155: ...the order WARNING Support the motorcycle securely to prevent it from falling over NOTE Before removing the steering parts remove the cowling see COWLING in chapter 3 the front wheel and the suspension forks see REMOVAL FRONT WHEEL and H RE MOVAL FRONT FORK in this Chapter NOTE If the handle crown does not need to be replaced do not disassemble the main switch which is fixed with two special screws...

Page 156: ...t Bearing upper and lower 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 repface bearing and race STEERING AXLE 1 Inspect Steering axie 1 Bend Damage Replace INSTALLATION Perform REMOVAL operations in reverse order Note the following points UNDER BRACKET 1 Install Bearing 1 Ball race co...

Page 157: ...lock to lock If there is any binding remove the steer ing axle assembly and inspect the steering bearings STEERING 5 Install Plate washer Ring nut upper 1 Lock washer 2 Installation sequence Install the plate washer on the lower ring nut Install the ring nut upper 1 Finger tighten the ring nut upper then align the slots of both ring nuts If not aligned hold the lower ring nut and tighten the upper...

Page 158: ...ut 40 Nm 4 0 mkg 42Nm 4 2mkg A WARNING This shock absorber contains high pressure nitrogen gas Read the following information carefully before handling it The manufacturer cannot be held responsible for any damage or injury that may result from improper handling Never tamper with or attempt to open the cylinder or the tank Never expose the shock absorber to a naked fiame or other source of heat Th...

Page 159: ...wrench provided One complete turn of the adjuster will change the preload by 1 mm 1 Adjuster 2 Lock nut Spring adjuster lock nut 42 Nm 4 2 mkg Spring length with preload Standard length 166 mm Minimum length 161 mm Maximum length 170 mm REBOUND DAMPING EFFECT ADJUSTMENT To increase the rebound damping effect turn clockwise A the adjuster 3 located on the base of the shock absorber to decrease it t...

Page 160: ...ng arm axle Swing arm 2 1 1 1 1 Remove the parts in the order A WARNING j Support the motorcycle securely to prevent it from falling over NOTFr Before removing the swing arm remove the rearwheel see REMOVAL REAR WHEEL and REAR SHOCK ABSORBER in this chapter CAUTION After detaching the rear brake hose secure the rear brake caliper to chassis to avoid damaging the brake hose Reverse the removal proc...

Page 161: ...ion Wear Damage Repface Nut swing arm axle 110 Nm 11 0 mkg Check the lateral free play of the swing arm moving it laterally If the free play seems excessive verify the collar bearings washers and thrust covers Lateral free play at end of swing arm Limit 1 0 mm Check the vertical movement of the swing arm moving it up and down If the movement seems rigid unsmooth or jerky inspect the internal colla...

Page 162: ... over NOTE Check drive chain wear before removing it see INSPECTION in the next page 1 Screw sprocket cover 2 2 Sprocket cover 1 3 Lock washer 4 straight the tab 1 4 Sprocket nut 1 MOTF Loosen the sprocket nut with the rear brake pulled 5 Chain joint 1 6 Drive chain 1 7 Sprocket gear 1 8 Nut wheel axle 1 9 Chain stretcher loosen 2 10 Wheel axle 1 11 Wheel 1 12 Screw 6 13 Crown wheel 1 Reverse the ...

Page 163: ...with a chain with small O rings 1 fitted between its plates Vapour cleaning pressurised washing and certain types of solvents may damage these seal rings To clean the transmission chain use only kerosene 3 Inspect Seal rings 1 drive chain Damaged Replace drive chain Rollers 2 Lateral plates 3 Damage Wear Replace drive chain DRIVE CHAIN SPROCKET AND CROWN WHEEL 4 Inspect Chain joint Damage Wear Dis...

Page 164: ......

Page 165: ...BULB INSPECTION K 9 IGNITION SYSTEM K 10 CIRCUIT DIAGRAM K 10 DIAGNOSTICS K 11 ELECTRICAL STARTING SYSTEM K 15 CIRCUIT DIAGRAM K 15 STARTING CIRCUIT FUNCTIONING K 16 DIAGNOSTICS K 16 STARTER MOTOR L 3 CHARGING SYSTEM L 6 CIRCUIT DIAGRAM L 6 DIAGNOSTICS L 7 LIGHT SYSTEM L 9 CIRCUIT SYSTEM L 9 DIAGNOSTICS L 10 SIGNALLING SYSTEM L 12 CIRCUIT DIAGRAM L 12 DIAGNOSTICS L 13 SIGNALLING SYSTEM CONTROL L 1...

Page 166: ...27 Horn switch 28 Direction indicator tights switch 29 Driving beam dimmers lights switch 30 Lights switch 31 Low fuel warning light switch 32 Horn 33 Direction indicator lights relay 34 Left front direction indicator light 35 Right front direction indicator light 36 Engine temperature cooling liquid indicator 37 Driving beam light 38 N neutral light 39 Low fuel light 40 Control light 41 Front par...

Page 167: ...e 20A main 9 Rectifier Regulator 10 CD ignition unit 11 Battery 12V 8Ah IGNITION COIL PRIMARY WINDING RESISTANCE 3 4 4 6 Q at 20 C 68 F SECONDARY WINDING RESISTANCE 10 4 15 6 kil at 20 C 68T BATTERY CAPACITY 12V 8Ah ELECTROLYTE DENSITY 1 320 1 Starting motor relay assembly 2 Thermo switch 3 Thermo unit W Flasher relay assembly 5 Horn 6 Neutral switch 7 Side stand switch 8 3 8 4 ...

Page 168: ...main switch connector from the harness connector SWITCH CHECK CAUTION Br L L FI ON 0 O o 0 OFF LOCK P vl I r 1 J L lfl _ I 1 1 L L RJ R j Br When detaching the connector do not pull by the cables This way the cables might discon nect from the terminals inside the connector itself 2 Check to see if any cables are disconnected from their terminal inside the connector Re connect if necessary NOTE If ...

Page 169: ...re used especially for instrument and other indication lights BULB INSPECTION 1 Remove the bulb in question NOTE Bulbs of type A and B use special supports bulbhotders Remove the bulbholder before removing the bulb Most of these bulbholders may be removed by turning in an anticlockwise direction Most bulbs of type C and D may be removed from their housing by pushing them and turning them in an ant...

Page 170: ...Si i 11 ftI IGNITION SYSTEM The diagram illustrates the ignition circuit inside the motorcycle electric system ELEC For the colour code and complete legend see page 8 2 1 CDIunit 19 Fuse 20A main 6 Main switch 22 1 Diode 9 ignition coil 23 Neutral switch 10 Sparkplug 24 2 Diode 1 2 Side stand switch 26 Engine stop emergency switch 1 3 AC generator source coil pick up coil 18 Battery 9 26 19 22 23 ...

Page 171: ...ace the fuse o CONTINUITY 2 Battery Check the battery Refertothe section BATTERY INSPECTION in CHAPTER 3 Voltage 12 8V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery Refer to the corresponding section in CHAPTER 3 oCORRECT IGNITION SYSTEM 3 Spark plug Check the conditions of the spark plug Check the type of spark plug used Check the electrodes gap See th...

Page 172: ... cables Connect the pocket tester 2x1 tothe ignition coii Tester terminal Pole Tester terminal Pole Check that the primary coil winding has the specified resistance E3 ft 2 Primary winding resistance 3 4 4 6 Q at 20 C 68 F Terminal Terminal Connect the pocket tester ix1 to the ignition coil Tester terminal Spark plug cable 1 Tester terminal Pole Check that the secondary coil winding has the specif...

Page 173: ...ngine stop emergency switch is defective Replace the right handlebar switch IGNITION SYSTEM 9 Side stand switch Disconnect the side stand switch connector Biack White and Black from the bundle of cables Connect the pocket tester 1x1 to the side stand switch cables Tester terminal Black White cable 1 Tester terminal Black cable 2 UP DOWN B W B o o CORRECT 10 Neutral switch Disconnect the neutral sw...

Page 174: ...lace INCORRECT I The diode is defective Replace IGNITION SYSTEM 13 Pick up coil resistance Disconnect the generator connector Blue Yellow and Green White from the CD unit Connect the pocket tester l x 1 00 to pick up coif cables Tester terminal Blue Yellow cable 1 Tester terminal Green White cable 2 L Y GA 1 L Y G W TET Check that the pick up coil resistance is as specified E3l 6 Pick up coil resi...

Page 175: ...ram illustrates the electrical starting system circuit inside the motorcycle electric system NOTE For the colour code and complete legend see page 8 2 6 Main switch Clutch switch 12 Side stand switch 18 Battery 19 Fuse 20A main 20 Starter relay 21 Starter motor 22 1 Diode 23 Neutral switch 25 Starter switch 26 Engine stop emergency switch 19 22 20 18 23 12 8 19 8 20 ...

Page 176: ...main 2 Battery 3 Starter 4 Starter relay 5 Main switch 6 Engine stop emergency switch 7 Side stand switch 8 Neutral switch 9 Clutch switch 10 Starter switch 11 1 Diode 12 Harness connection control entire starter system NOTE Before starting inspections remove the following parts 1 Side panels left and right 2 Seat 3 Rear cowling 4 Fuel tank 5 Air filter case To inspect any operating faults defects...

Page 177: ...well away from inflammable substances IT FAILS TO RUN The starter is defective Repair or replace IT FAILS TO RUN The starter relay is defective Repair ELECTRICAL STARTING SYSTEM ELEC M G 5 Main switch Disconnect the main switch connector from the harness Connect the pocket tester 2x1 to the main switch terminal Check the switch component for continuity between Red 1 and Brown 2 See the SWITCH CHEC...

Page 178: ...e stand switch is defective Replace INCORRECT The neutral switch is defective Replace ELECTRICAL STARTING SYSTEM ELEC 9 Clutch switch Disconnect the clutch switch connector from the harness Connect the pocket tester 0x1 to the clutch switch terminal Check the clutch switch for continuity between Black 1 and Black Yellow 2 See the SWITCH CHECK section B B Y Release Holt 0 0 J5L CORRECT 10 Start swi...

Page 179: ... connection Check the connections of the whole starter system See ELECTRICAL CIRCUIT DIAGRAM sec tion INCORRECT The diode is defective Replace UNCERTAIN CONNECTIONS Correct STARTER MOTOR 1 O ring 2 Armature 3 O ring 4 Stator 5 O ring 6 Brushes ELECTRICAL STARTING SYSTEM ELEC A BRUSH WEAR LIMIT 5 0 mm 0 20 In B COMMUTATOR WEAR LIMIT 27 mm 1 06 in C MICA UNDERCUT 0 7 mm 0 027 in D ARMATURE COIL RESI...

Page 180: ...ning of he commutator 4 Inspect Armature coils insulation continuity Defective Replace the motor How to inspect the excitation coils Connect the pocket tester and check continuity 1 and insulation 2 Check the armature resistance S3 A Armature coil resistance Continuity check 1 a at 20 C 68 F Insulation check 2 Over 1 H12 at 20X 68 F If the resistance is incorrect replace the starter motor Inspecti...

Page 181: ...ECTRICAL STARTING SYSTEM Installation 1 Install Starter motor NOTE Slightly grease the O ring 1 jbf Bolt starter motor 10Nm 1 0mkg See the ENGINE OVERHAUL ENGINE INSTAL LATION section in CHAPTER 4 Align the jutting surface 1 on the brush housing with the Slot 2 2 Install Stator 1 Cover 2 NOTE Align the reference marks 3 on the stator with the corresponding reference marks on the cover 4 3 Install ...

Page 182: ...UIT DIAGRAM CD CHARGING SYSTEM The diagram shows the charging circuit inside the motorcycle electric system NOTE For the colour codes and complete legend see page 8 2 13 AC Generator 14 Rectifier Regulator 18 Battery 19 Fuse 20A main 8 33 8 34 ...

Page 183: ...3 Voltage 1 2 8V or over at 20 C 68 F J L CORRECT DISCONTINUITY I Replace the fuse INCORRECT ELEC l Clean the battery terminals Recharge or replace the battery See the BATTERY INSPECTION section in CHAPTER 3 CHARGING SYSTEM 3 Charging voltage Connect the pocket tester DC 20V to the battery Tester cable Battery terminal Tester cable Battery terminal Start the engine and rev to about 5 000 rpm Check...

Page 184: ...F OUT OF SPECIFICATIONS o IN COMPLIANCE WITH SPECIFICATIONS Stator winding is defective Replace 5 Connections Check the connections of the entire charging system Seethe ELECTRlCAlCtRCUfTDIAGRAM UNCERTAIN CONNECTIONS g OK The rectifier regulator is defective Replace 8 37 ...

Page 185: ... system of the motorcycle NOTE ELEC For the colour codes and complete legend see page 8 2 6 Main switch 15 Rear tail stop light 18 Battery 19 Fuse 20A main 29 Dipped high beam light switch 30 Lights switch 37 High beam light 40 Instrument fight 41 Front parking light 42 Dipped high beam light 45 Number plate light 8 39 8 40 ...

Page 186: ...ket tester 2x1 to the fuse Check fuse continuity See the FUSE INSPECTION AND REPLACEMENT section in CHAPTER 3 DISCONTINUITY Replace the fuse o CONTINUITY LIGHT SYSTEM Q 3 Battery Check the conditions of the battery See the BATTERY INSPECTION section in CHAPTER 3 Voltage 12 8V or over at 20 C 68 F Jl CORRECT 4 Main switch Disconnect the main switch connector from the harness Connect the pocket test...

Page 187: ... entire light system o CORRECT Check the conditions of each circuit for he entire light system See the ELECTRIC CIRCUIT DIAGRAM INCORRECT The lights switch and or dipped high beam commutator are defective Replace the left handlebar switch DEFECTIVE CONNECTIONS Repair 8 43 ...

Page 188: ...circuit inside the electric system of the motorcycle NOTE For the colour codes and complete legend see page 8 2 6 Main switch 8 Front brake switch 1 1 Rear brake switch 15 Rear tail stop light 16 Right rear direction indicator light 17 Left rear direction indicator light 18 Battery 19 Fuse 20A main 23 Neutral switch 27 Horn switch 28 Turn direction indicator switch 32 Horn 33 Direction indicators ...

Page 189: ...Y Replace the fuse o CONTINUITY 2 Battery INCORRECT Check the conditions of the battery Consult the BATTERY INSPECTION sec tion in CHAPTER 3 Voltage 12 8V or more at 20 C 68 F Clean the battery terminals Recharge or replace battery Consult the BATTERY INSPECTION sec Hon in CHAPTER 3 Jl CORRECT SIGNALLING SYSTEM V V 3 Main switch Disconnect the main switch connector from the harness Connect the poc...

Page 190: ... is defective Replace the left handle bar switch OUT OF SPECIFICATIONS The circuit from the main switch to the horn terminal is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V SIGNALLING SYSTEM 3 Horn Detach the Pink cable from horn terminal Connect a special cable 1 to the horn cable and earth the cable Turn the main switch to ON THE HORN DOES NOT WORK 4 Voltage Connect the pocket tester D...

Page 191: ...SIGNALLING SYSTEM 3 Voltage Connect the pocket tester DC 20V to the bulbholder connector Tester terminal Green Yellow cable 1 Tester terminal Black cable 2 Turn the main switch to ON The brake lever is pulled or the brake pedal is pressed Check the voltage 1 2V on the Green Yellow cable of the bulbholder connector OUT OF SPECIFICATION The circuit from the main switch tothe bulbholder connector is ...

Page 192: ...e to the intermittence terminal INCORRECT The direction indicator switch is defective Replace OUT OF SPECIFICATIONS The circuit from the main switch to the intermit tence connector is defective Repair g IN COMPLIANCE WITH SPECIFICATIONS 12V SIGNALLING SYSTEM 4 Voltage Connect the pocket tester DC 20V to the bulbholder connector Tester terminal Brown White terminal 1 Tester terminal Earth on frame ...

Page 193: ... to the bulbholder is defective Repair IN COMPLIANCE WITH SPECIFICATIONS 12V The circuit is efficient SIGNALLING SYSTEM 4 The neutral warning light N fails to turn on 1 Bulb and bulbholder Check the continuity of the bulb and bulbholder See the BULB INSPECTION section CONTINUITY 2 Neutral switch Disconnect the neutral switch cable from the harness Connect the pocket tester Qx1 to the neutral switc...

Page 194: ...nector from the harness and the bulbholder connector Connect the pocket tester 2x1 to the neutraf switch cable on the harness side 1 and the bulbholder connector 2 sr Y Gr 5 Y Oi W3 D9 n S Gffli B l i x f T 2ZZZZZZZ2ZZZZ The circuit from the main switch to the bulbholder connector is defective Repair DISCONTINUITY Thecircuitfrom the bulb connectorto the neutral switch cable is defective Repair o C...

Page 195: ...he cooling system circuit inside the electric system of the motorcycle NOTE For the colour codes and complete legend see page 8 2 2 Fan motor 3 Fuse 7 5A fan motor 4 Thermo switch 5 Thermo unit 6 Main switch 18 Battery 19 Fuse 20A main 36 Engine temperature cooling liquid indicator 8 59 8 60 ...

Page 196: ...CHAPTER 3 DISCONTINUITY 1 Replace the fuse es g CONTINUITY 2 Battery Check the conditions of the battery See the BATTERY INSPECTION section in CHAPTER 3 Voltage 12 8V or over at 20 C 68 F INCORRECT 1 Clean the battery terminals Recharge or replace the battery See the BATTERY INSPECTION section in CHAPTER 3 JT CORRECT COOLING SYSTEM 3 Main switch Disconnect the main switch connector from the harnes...

Page 197: ...ture Correct 1 Less than 105 3 C 221 0 5 4 F X 2 More than 105 3 C 221 0 5 4 F 3 From 105to98 C From 221 0 to 208 4 F 4 Less than 98 C 208 4 F X 1st and 2nd steps overheating test 3rd and 4th steps cooling test 0 Continuity X Discontinuity IT FAILS TO RUN The circuit from the main switch to the fan motor terminals is defective Repair BAD CONDITIONS The thermo switch is defective Replace a GOOD CON...

Page 198: ...ON section in CHAPTER 3 Voltage 12 8V or over at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery Seethe BATTERYINSPECT10N sectionin CHAPTER 3 oCORRECT 3 Main switch Disconnect the main switch connector from the harness Connect the pocket tester Qx1 to the main switch terminals See the SWITCH CHECK section COOLING SYSTEM CORRECT 4 Thermo unit Remove the thermo unit A...

Page 199: ...ster terminate Brown cable 1 Tester terminale Black cable 2 Turn the main switch to ON Check the voltage 1 2 V on the Brown cable of the temperature gauge connector OUT OF SPECIFICATIONS The circuit from the main switch to the tempera ture gauge connector is defective Repair g IN COMPLIANCE WITH SPECIFICATIONS 8 Harness connections Check the connections of the entire cooling system See the ELECTRI...

Page 200: ...r circuit 32 13 AC generator 23 Neutra switch 33 14 Rectifier Regulator 24 2 diode ignition circuit 34 15 Rear stop tatMight 25 Starter switch 35 16 Right rear direction indicator light 26 Engine stop emergency switch 36 1 7 Left rear direction indicator light 27 Horn switch 37 18 Battery 28 Direction indicator tights switch 38 19 Fuse main 29 Drrvtng beam dimmers tights switch 39 20 Starter motor...

Page 201: ......

Page 202: ... FAILS TO RELEASE M 13 CLUTCH SLIDES M 13 CLUTCH FAILS TO RELEASE M 13 OVERHEATING OF ENGINE M 13 EXCESSIVE ENGINE COOLING M 13 DEFECTIVE BRAKES M 14 POOR BRAKING M 14 OIL LEAKS OR MALFUNCTIONING OF FRONT FORK M 14 OIL LEAKS M 14 MALFUNCTIONING M 14 UNSTABLE STEERING M 14 DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS M 15 POOR HEADLIGHT ILLUMINATION M 15 FREQUENT BURNING OF BULB M 15 THE DIRECTIO...

Page 203: ...nd cylinder head Air filter element obstructed Fuel pump defective Suction hose obstructed Piston and piston rings Crankcase and valves crankshaft TRBL SHTG m PROBABLE CAUSES Electrodes gap not correct Electrodes worn Feed cable interrupted Wrong thermal grading of spar1 plug Defective spark plug cap Primary or secondary winding interrupted High voltage cable defective Defective coil Defective uni...

Page 204: ...ched Needle valve housing insufficiently sealed Needle stop position incorrect Needle clip position incorrect Fuel level set wrongly Main jet obstructed or loose Main nozzle obstructed or foose Gear cam gear fork Transmission DISENGAGING GEARS Gear shaft Air filter Air fitter element obstructed Fuel pump Fuel pump defective Gear fork Gear cam PROBABLE CAUSES Clutch cable wrongly set clutch fails r...

Page 205: ...ession Engine oil Brake Cooling system Oil level over maximum Excessive viscosity of engine oil Degradation TRBL SHTG PROBABLE CAUSES Incorrect electrode gap of spark plug Spa piug thermal gradation wrong Ignition unit defective incorrect carburetor main jet incorrect setting Incorrect fue level Air filter element obstructed Excess of carbon deposits Incorrect oiflevel Incorrect oil viscosity Inco...

Page 206: ...ged Fork spring damaged Piston worn or damaged Shock absorber rod deformed or damaged Incorrect oil viscosity Incorrect oil level Cartridge defective overhaul Handle bar Steering Front fork Tyres Wheels Frame UNSTABLE STEERING TRBL SHTG 9 PROBABLE CAUSES Assembled crooked or incorrectly Handle bar crown assembled incorrectly Lower bracket crooked Lower steering column installed incorrectly ring nu...

Page 207: ...flat Incorrect bulb Main or direction indicator switch defective PROBABLE CAUSES Incorrect bulb Indicator relay defective FREQUENT BURNING OF BULB PROBABLE CAUSES Incorrect bulb Defective battery Rectifier regulator defective Wrong negative earthing Main switch and or light switch defective Bulbs gone THE HORN FAILS TO WORK PROBABLE CAUSES Defective battery Main or horn switch defective Horn wrong...

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