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Yamaha TT-R230, Service Manual

The Yamaha TT-R230 Owner's Manual is an essential guide for maintaining and operating this off-road motorcycle. Available for free download from manualshive.com, this comprehensive manual provides step-by-step instructions, safety guidelines, and valuable insights to ensure a smooth and safe riding experience with your Yamaha TT-R230.

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ENGINE

ENGINE DISMOUNTING

4-13

5. Remove:

• Rotor 

1

• Key 

2

Use the rotor fastener 

3

 and the rotor

puller 

4

.

3. Remove:

• Dowel pins 

1

• Gasket 

2

 (case cover)

• Spacer 

3

• Shaft 

4

• Starting gear 

5

4. Remove:

• Bolt 1 (rotor)

2

1

3

NOTE:

Loosen the rotor bolt holding the rotor with
the fastener 

2

.

Rotor fastener:

90890-01701

CAUTION:

Prevent the rotor fastener from touching
the cam 

3

 on the rotor.

Rotor puller:

90890-01080

3

4

5

Prevent the rotor fastener from touching
the cam 

5

.

CAUTION:

2

3

5

1

4

1

2

Summary of Contents for TT-R230

Page 1: ...SERVICE MANUAL 1C6 F8197 10 1C6 F8197 10 1C6 F8197 10 1C6 F8197 10 1C6 F8197 10 TTR230T LIT LIT LIT LIT LIT 11616 18 40 11616 18 40 11616 18 40 11616 18 40 11616 18 40 ...

Page 2: ...ia Ltda Post Sales Service Department All rights reserved The copy or reproduction of all contents in this manual is forbidden without the previous written authorization from Yamaha Motor da Amazônia Ltda Printed in Brazil LIT 11616 18 40 TTR 230 T ...

Page 3: ... people reading this manual to execute maintenance and repair services on the Yamaha motorcycles have a basic knowledge of the mechanical conceptions and procedures inherent to the motorcycle repair technology Without these knowledge any repair or service attempt on this model could cause difficulties for its utilization and or safety YAMAHA MOTOR DA AMAZÔNIA LTDA will make its best efforts to enh...

Page 4: ...s provided 8 in addition to the exploded view diagram and instruction chart This manual is constituted by chapters for the major subject categories See Illustrative Symbols 1st title 1 This is the chapter title with the symbol in the upper right corner in each page 2nd title 2 This title indicates the section in each chapter and only appears on the first page of each section It is located in the u...

Page 5: ...ents 9 Replenish with fluid 0 Lubricant A Special tool B Tighten with torque wrench C Wear limit clearance D Engine speed E Ω V A The illustrative symbols from 9 to E are used to identify the specifications appearing in the text F Apply locking agent LOCTITE G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply grease for wheel roller bearing K Apply lithium based grease L A...

Page 6: ...RMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE INSPECTION CARBURATION FRAME ELECTRIC SYSTEM TROUBLESHOOTING INFO GEN SPEC ENGINE CARB CHAS ELECT PROB INSP ADJUS 1 2 3 4 5 6 7 8 TABLE OF CONTENTS ...

Page 7: ...EMOVING AND DISMOUNTING 1 2 REPLACEMENT PARTS 1 3 GASKETS RETAINERS AND O RINGS 1 3 LOCK WASHERS SPACERS AND COTTER PINS 1 3 ROLLER BEARINGS AND RETAINERS 1 3 LOCK RINGS 1 4 SPECIAL TOOLS 1 4 FOR ADJUSTING 1 4 FOR ENGINE SERVICES 1 5 FOR FRAME SERVICES 1 8 FOR ELECTRIC COMPONENTS 1 9 CONTENTS CHAPTER 1 GENERAL INFORMATION ...

Page 8: ...he steering column MOTORCYCLE IDENTIFICATION FRAME NUMBER 1 1 MODEL IDENTIFICATION The model ID label 1 is stuck on the frame This information will be required for replacement part orders The vehicle s ID number is used to identify the motorcycle when registering and licensing it with the local traffic authority NOTE ...

Page 9: ...pistons and other matching parts that suffered natural wear together The matching parts must be remounted as an assembly or replaced 4 When dismounting the motorcycle clean all parts and put them on trays by keeping the dismounting order This will speed the mounting and will assure the correct part installation 5 Keep fire sources away IMPORTANT INFORMATION 1 Clean all dirty mud dust and other mat...

Page 10: ...lean 2 Apply oil on all points and roller bearings when mounting Apply grease on the retainers lips Do not use compressed air for drying the roller bearings This will cause damages to the roller bearing surfaces CAUTION 1 Install the roller bearings 1 and retainers 2 with the manufacturer s marks facing out In other words the stamped letters must be exposed for facilitating the identi fication Whe...

Page 11: ... used for checking the ignition point 1 All lock rings must be carefully checked before remounting Always replace the piston pin locks after every use Replace warped locks When installing a lock 1 make sure that the side with sharp corner 2 is positioned opposingly to the force 3 applied on it See the aside figure 4 Shaft 1 Valve clearance adjuster 90890 01311 09 This tool is required for adjustin...

Page 12: ...l is used for removing the handle bar nut 5 Fuel level meter 90890 01312 This meter is used to measure the fuel level in the carburetor bowl 4 Compression meter 90890 03081 1 Adapter 90890 04082 2 This meter is used for measuring the engine compression 2 Rotor fastener 90890 01701 This tool is used to fasten the rotor when removing or installing the rotor fastening nut ...

Page 13: ...for separating the crankcases 4 Universal clutch fastener 90890 04086 This tool is used to hold the clutch when removing or installing the clutch hub fastening nut 3 Rotor puller 90890 01080 This tool is used for removing the magnet rotor 7 Sliding hammer set Sliding hammer bolt 90890 01083 1 Weight 90890 01084 2 These tools are used for removing the rockers shaft ...

Page 14: ...er for 6 mm valve 90890 04064 This tool is required to remove the valve guides 8 Valve spring clamp 90890 04019 This tool is required for removing and installing valves 11 Guide installer for 6 mm valve 90890 04065 This tool is required for installing the valve guides in a proper way 12 Crankshaft puller 90890 01274 1 Bolt 90890 01275 2 ...

Page 15: ...L TOOLS 1 8 14 Crankshaft spacer 90890 04081 This tool is used for installing the crankshaft 1 Internal tube cylinder fastener 90890 01326 1 Fastener 90890 01294 2 This tool is used for loosening and tightening the front fork bar fastening bolt 2 Sliding hammer for the fork retaining installer 90890 01367 1 Adapter 36mm 90890 01370 2 These tools are used when installing the fork retainer ...

Page 16: ...dismounting the transmission chain 1 Dynamic spark tester 90890 06754 This equipment is used for checking ignition system components 3 Adjustment nut wrench 90890 1403 This tool is used for loosening or tightening the handle bar adjusting nut 2 Multi tester 90890 03112 This equipment is used for testing the electric system 1 9 ...

Page 17: ...NERAL TORQUE SPECIFICATIONS 2 17 UNIT DEFINITION 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ENGINE 2 18 FRAME 2 19 LUBRICATION DIAGRAM 2 20 CABLE ROUTING 2 22 HANDLE BAR 2 22 FRONT 2 23 MOTORCYCLE RIGHT SIDE 2 24 MOTORCYCLE LEFT SIDE 2 25 INTERNAL OPENING 2 26 BATTERY AND COMPONENTS 2 27 CHAPTER 2 SPECIFICATIONS ...

Page 18: ...e cylinder front inclined 223cm3 70x58mm 9 5 1 1 200 kPa 12kg cm at 1000 rpm Electric start Engine Type Cylinderarrangement Displacement Diameter vs stroke Compression rate Compression pressure STD Starting system 110 Kg 116 Kg Basic weight Basic weight With oil and full fuel tank Minimumturningradius 2 100 mm Modelcode Dimensions Total length Total width Total height Seat height Wheel base Minimu...

Page 19: ...esh Left foot drive Square teeth gears 73 22 3 318 Transmissionchain 49 13 3 769 38 13 2 923 34 18 1 889 30 21 1 428 27 24 1 125 25 27 0 925 23 29 0 793 Clutch type wet multiple discs Sparkplug Type Manufacturer Electrodegap DR8EA NGK 0 6 0 7 mm Carburetor Type Manufacturer Y26P x 1 TEIKEI Fuel Type Fuel tank capacity Reservevolume Gasoline with additive 8 L 1 8L FRONT MT320H Pirelli With tube 80 ...

Page 20: ...ing Hydraulic shock absorber with gas Suspension Front Rear Brakes Front type operation Rear type operation Disc brake single Right handdrive Drum brake Right foot drive Wet type element Air filter Electric Ignition system Charging system Battery type Battery capacity Fuse Suspension travel Front Rear 240 mm 220 mm Wheels Front type size Rear type size Spoked 21 x 1 60 Spoked 18 x 1 85 ...

Page 21: ...er A Face width B Seat width C Edge thickness D 0 05 0 09 mm 0 15 0 19 mm 33 9 34 1 mm 2 260 mm 0 9 1 1 mm 0 8 1 2 mm Rocker Rocker shaft Internal diameter of the rocker hole External diameter of the rocker shaft Clearance between the rocker and rocker shaft Commandchain Commandchaintype of links Chain adjustment method DID25SH 104 links Automatic By link LE 24 960 24 980 mm 0 020 0 061 mm 36 510 ...

Page 22: ... 052 mm 0 010 mm 0 9 1 1 mm 0 9 1 1 mm Valve springs Free length INTAKE EXHAUST Length valve closed INTAKE EXHAUST 2 5 Model TTR230T Directions of the turns top view Inclination limit INTAKE EXHAUST Exhaust Head diameter A Face width B Seat width C Edge thickness D 28 4 28 6 mm 2 260 mm 0 9 1 1 mm 0 8 1 2 mm External springs Internal spring Counterclockwise Clockwise 2 5 1 6 mm 2 5 1 6 mm 2 5 1 6 ...

Page 23: ... tipgap installed Compressionring Scraper ring Oilring Side clearance installed Topring Secondaryring Crankshaft Width A Misalignment threshold C Connecting rod lower clearance D Upper clearance limit F Balancer Balancingmethod Transmission Main shaft warping limit Secondary shaft warping limit Round Flat B 1 2 mm T 2 8 mm B 1 2 mm T 2 8 mm B 2 5 mm T 2 8 mm 0 15 0 30 mm 0 15 0 30 mm 0 30 0 90 mm ...

Page 24: ... mm MJ MAJ JN NJ PJ PAJ1 PO BP1 PS NS GS1 GS2 FL Lubrication system Oil filter Type Oilpump Type Rotor seat clearance Side clearance Pressure measuring location Steel mesh Trochoidal 0 15 mm 0 04 0 09 mm Head Carburetor Type High speedadjustingnozzle Main air adjusting nozzle Needle lock position Diffuser Low speed adjusting nozzle Pilot air adjusting nozzle Pilot output Bypass 1 Air pilot screw A...

Page 25: ...hain Part to be tightened Description Qty Tightening torque Note N m Kgf m 1 4 1 2 2 2 3 1 2 1 2 4 3 3 2 1 3 2 1 1 4 1 1 1 1 1 2 3 1 1 1 1 75 0 7 2 2 2 0 1 0 1 0 0 8 0 70 4 30 1 00 1 00 1 2 5 0 70 1 00 4 00 1 60 0 70 1 00 7 00 0 80 0 60 6 00 1 2 5 0 5 0 1 0 1 00 3 00 1 00 0 80 6 00 17 5 7 22 20 10 10 8 7 43 10 10 10 25 7 10 40 16 7 10 70 8 6 60 12 50 50 10 10 30 10 8 60 12 9 5 1 17 14 7 2 7 2 5 8 ...

Page 26: ...oil Part to be tightened Description Qty Tightening torque Note N m Kgf m 2 1 1 1 2 6 1 2 1 5 3 1 2 5 3 2 5 2 0 70 2 30 2 30 0 70 0 70 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 00 1 00 7 23 23 7 7 10 10 10 10 10 10 10 10 10 10 10 10 10 5 1 16 16 5 1 5 1 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 7 2 ft lb Bolt Bolt Bolt Bolt Bolt Flange bolt Flange bolt Flange bolt Flange bolt Flange bolt...

Page 27: ...ECIFICATIONS Lubrication scheme Forcedfeeding Sprinkle Oilpump Crankshaft Oil filter Oil strainer Bypass valve Camshaft Main shaft Secondary shaft Clutch Gear Gear Shifting fork Connecting rod lower portion Starting clutch Connecting rod upper portion Balancer Rocker Oil crankcase ...

Page 28: ...CIFICATIONS FRAME 2 11 Steering system Rollerbearingtype Front suspension Suspensiontravel Free suspension spring length Spring force travel Oil level Oil capacity Oil type Rear suspension Shock absorber travel Free spring length Installed length Spring force travel Gas pressure Front wheel Type Wheelringdimensions Ringmaterial Ring warping limit Vertical Side Rear wheel Type Wheelringdimensions R...

Page 29: ...Front disc brake Type Disc external diameter Disc thickness Disc pad thickness Wear threshold Master cylinder internal diameter Disc brake caliper internal diameter Brake fluid type Rear drum brake Type Drum s internal diameter Limit Brake lining thickness Limit Free shoe spring length Brake lever and pedal Pedalposition Pedal clearance Clutch and accelerator lever Lever clearance Accelerator grip...

Page 30: ...e Valve base and external tube Part to be tightened Description Tightening torque Note N m Kgf m 4 6 4 6 37 5 3 25 4 6 5 45 0 7 2 3 5 25 5 25 5 25 0 7 0 7 8 0 4 3 45 3 45 11 2 3 2 0 7 0 7 0 7 2 2 2 46 46 38 33 46 55 7 23 53 53 52 7 7 80 4 35 35 110 23 20 7 7 7 20 20 20 33 9 33 9 27 7 24 33 9 40 2 5 1 16 9 38 7 38 7 38 3 5 1 5 1 59 2 9 25 5 25 5 81 1 16 9 14 7 5 1 5 1 5 1 14 7 14 7 14 7 ft lb Self ...

Page 31: ...egulator Neutral switch Qty Nut Shaft Bolt Self locking nut Flange bolt Bolt Bolt Pin Flange bolt Flange bolt Bolt Bolt Bolt Self locking nut Bolt Bolt Self tapping screw Threaded bolt Bolt Bolt Bolt Bolt Bolt Bolt Flange bolt Flange bolt Flange bolt Tightening torque N m Kgf m ft lb Note 1 1 1 1 2 2 1 2 6 2 4 4 2 1 6 2 4 3 1 1 2 2 2 2 2 2 1 1 80 30 7 44 48 7 6 18 13 40 7 7 3 80 35 10 25 7 7 7 7 1...

Page 32: ... Manufacturer Output current Coil resistance Rectifier voltage regulator Model Manufacturer Voltage regulator Type Battery Specific density 2 15 TTR230T Model ELECTRIC MAINTENANCE SPECIFICATIONS 12V 9 at 1 500 rpm 29 5 at 7 500 rpm Electric AZ071000 2680 DENSO 192 288 ohm at 20 C Blue yellow green 2JN YAMAHA 0 18 0 28 ohm at 20 C 6 3 9 5 K ohm at 20 C 6 0 mm Magnet flywheel Resin 10K at 20 C 1C6 D...

Page 33: ...180 A Fuse 10 A 10 A 2 16 TTR230T Model Electric starting system Type Starting motor Model Manufacturer Output power Brushlength Limit Switch diameter Limit Mica depth Starting relay Model Manufacturer Current rate Protection circuit Type Fuse Main fuse Reserve fuse MAINTENANCE SPECIFICATIONS ...

Page 34: ...room temperature GENERAL TORQUE SPECIFICATIONS 10 mm 6mm 6 0 6 4 3 12 mm 8mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 N m General torque specifications A Nut B Bolt Kg m A Distance between plans B External thread diameter ft lb mm cm kg N N m Kgm Pa N mm L cm3 r p m millimeter centimeter Kilogram Newton Newton Meter Kilogram Meter Pascal N...

Page 35: ...ps all Rollerbearings all Bolts head Crankshaft pin Connecting rod lower portion Piston and piston rings Piston pin Valve stem and guides Retainer valve stem Rocker shaft and rocker Cams and roller bearing Camshaft O ring Drainplug Clutch bar Primary gear and main shaft Gearbox Shift lever Crankcase surfaces Yamaha Bond nº1215 Glue ...

Page 36: ...ap Shock absorber and relay arm Bush relay arm and union arm Bush relay arm and union arm Bush union arm and frame Spacer union arm and frame Bushes relay arm and frame and cover Spacers relay arm and balance Articulated points brake pedal shaft and frame Balls and raceways steering bearing Guide tube accelerator grip Articulated points brake and clutch levers Articulated points side stand Bushes ...

Page 37: ...SPEC 2 20 LUBRICATION DIAGRAM LUBRICATION DIAGRAM 1 Oil pump ...

Page 38: ...SPEC 2 21 LUBRICATION DIAGRAM 1 Oil pump 2 Oil filter 3 Filter cover 4 O ring 5 Bolt 6 O ring 7 Gear cover 8 Pump cover gasket 9 Oil strainer 0 Spring A O ring B Drain plug ...

Page 39: ...erator cable Return 3 Starting switch harness 4 Cable routing slot 5 Clutch cable 6 Engine stop harness 7 Clutch switch harness 8 Ignition switch 9 Breather hose A Route the cables into the slot B Fasten the harnesses with the tie wrap 9 4 3 5 2 1 6 7 8 A B B 2 22 ...

Page 40: ...r 6 Ignition switch connector 7 Clutch switch connector 8 Engine stop switch connector 9 Main harness FRONT A Route the cables into the slot B Route the hose into the support C Fasten the connectors in the support D Route the harness through the opening E Mount with tie wraps both sides 1 A 3 4 5 6 7 8 9 2 B D C E 2 23 ...

Page 41: ...oil 4 AC magnet harness 5 Starting motor cable 6 High voltage cable 7 Main harness MOTORCYCLE RIGHT SIDE A The harness should not touch the bolt B Fasten the cables by using the clamps C The accelerator cable should not touch the ignition coil 1 2 3 6 B C A 7 5 8 4 3 2 24 ...

Page 42: ...aining hose right side 6 Carburetor draining hose left side 7 Engine breather hose 8 Dead point switch wire CABLE ROUTING MOTORCYCLE LEFT SIDE A Route the brake hose through the guide B Fasten the brake hose as per the figure C The final draining hose cutting shall face the motorcycle rear side 4 1 C B A 3 2 8 6 7 5 2 25 ...

Page 43: ...SPEC CABLE ROUTING 1 Clutch cable 2 Main harness 3 Regulating rectifier harness 4 Starting motor cable 5 Negative cable ground 6 AC magnet harness INTERNAL OPENING 2 3 4 5 6 1 2 26 ...

Page 44: ...ound 3 Harness negative wire 4 Positive cable 5 AC magnet harness 6 Main harness 7 Starting motor cable 8 Starting relay harness 9 Safety fuses BATTERY AND COMPONENTS 1 9 2 3 6 5 A 7 8 4 2 27 A Starting relay connection with the battery positive pole ...

Page 45: ...ESSURE MEASUREMENT 3 14 ENGINE OIL LEVEL CHECK 3 17 ENGINE OIL CHANGE 3 18 OIL PRESSURE CHECK 3 23 CLUTCH ADJUSTMENT 3 23 AIR FILTER CLEANING 3 24 CARBURETOR CONNECTION CHECK 3 26 FUEL HOSE CHECK 3 26 ENGINE BREATHER HOSE CHECK 3 26 EXHAUST SYSTEM CHECK 3 27 CORE CLEARING 3 27 FRAME 3 28 FRONT BRAKE ADJUSTMENT 3 28 FRONT BRAKE PAD CHECK 3 28 AIR BLEEDING FRONT BRAKE SYSTEM 3 29 REAR BRAKE ADJUSTME...

Page 46: ...3 40 WHEEL SPOKE INSPECTION AND TIGHTENING 3 40 CABLE INSPECTION AND LUBRICATION 3 40 PEDAL LEVER AND SIDE SUPPORT LUBRICATION 3 41 REAR SUSPENSION LUBRICATION 3 41 ELECTRIC SYSTEM 3 42 BATTERY INSPECTION 3 42 FUSE INSPECTION 3 45 ...

Page 47: ...ficiency The pollutant emission control services are listed in a single table as follows NOTE From 4 200 mi 7 000 km or 9 months repeat the maintenance intervals at each 1 800 mi 300 km or 3 months We recommend that items marked with an be overhauled at a Yamaha authorized dealer shop PERIODIC MAINTENANCE POLLUTANT EMISSION CONTROL INITIAL 600 mi 1 000 km or 1 month 1 800 mi 3 000 km or 3 months 3...

Page 48: ...fix or replace 7 Wheel roller bearings Check the clearance free play and damage If necessary replace 8 Pivot roller bearing Check the clearance free play and apply a moderate quantity of lithium based grease 9 Transmission chain Check the clearance free play and wear Adjust and apply the specified lubricant 10 Steering roller bearing Check clearance free play and damage Apply lithium based grease ...

Page 49: ...E Pull the cover towards you To simplify use the opening 3 on the side cover 4 Push the cover in the direction indicated to release the tongues 5 Installation Place the cover in the original position and install the bolts Verify that the air filter cover is firmly installed otherwise dust can enter the filter resulting in engine damage V WARNING 1 1 2 3 4 Installation Install the cover under the s...

Page 50: ... seat pulling it towards the rear of the motorcycle 1 1 2 1 2 V WARNING Gasoline is highly inflammable Prevent the fuel from being poured on the hot engine 6 Disconnect Fuel tank breather hose 1 NOTE Place a dry cloth on the engine in order to absorb the splattered fuel 4 Remove Fuel tank Adjust the fuel cock to OFF 1 5 Disconnect Fuel hose 1 pressing the clip 2 1 1 LH RH 1 2 1 ...

Page 51: ...n both sides 1 Rubber belt Remove the fuel tank INSTALLATION Reverse the REMOVAL procedures Check the following items 1 Install Fuel tank 2 Install Seat 1 Side covers Fuel tank bolt 10 N m 1 0 Kg m 7 2 ft lb Seat and side cover bolts 7N m 0 7 Kg m 5 1 ft lb 1 1 1 ...

Page 52: ...he valve clearance with the piston at the top dead center TDC at the compression stroke TDC Alignment steps Using a screwdriver turn the crankshaft counterclockwise 1 Remove Side covers Seat Fuel tank See Section SEAT FUEL TANK AND COVERS 2 Remove Valve cover 1 Exhaust Valve cover 2 Intake 3 Remove Cover 1 with O ring Cover 2 with O ring 4 Align T mark on the rotor with the stationary mark on the ...

Page 53: ...th the T mark aligned with the stationary mark the piston is at the top dead center TDC 5 Check Valve clearance For clearance measurement use a sheet gage 1 Out of specification Adjust Adjustment steps Loosen the lock nut 1 Insert a sheet gage 2 between the adjuster tip and the valve end Turn the adjuster 3 clockwise or counterclockwise using the clearance adjusting tool 4 until the specified clea...

Page 54: ...ished 7 Install Reverse the removal steps Case cover covers Head covers 8 Install Fuel tank Seat Side covers See Section SEAT FUEL TANK AND COVERS A Intake B Exhaust NOTE Install the head covers with the cams up 1 1 1 B A is is Lock nut 13 5 N m 1 35 Kg m 7 2 ft lb Head cover bolts 10N m 1 0 Kg m 7 2 ft lb Bolts tank seat and side covers 7N m 0 7 Kg m 5 1 ft lb ...

Page 55: ...AIN ADJUSTMENT IDLE SPEED 3 9 CAMSHAFT CHAIN ADJUSTMENT Automatic adjustment IDLE SPEED ADJUSTMENT Let the engine run for some minutes for warming up 1 Connect Tachometer 1 to spark plug cable 2 Check Idle speed Out of specification Adjust 3 Adjust Idle speed Pilot screw 2 0 turns outward Turning inward Increases the idle speed Turning outward Decreases the idle speed Tachometer 90890 03113 Idle s...

Page 56: ...meter 5 Adjust Throttle cable free play See Section THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE Before adjusting the throttle cable free play adjust the idle speed 1 Check Throttle cable free play 1 Out of specification Adjust 2 Adjust Throttle cable free play 1 Throttle cable free play 3 5 mm 0 12 0 20 in ...

Page 57: ...bove on the handle bars To turn inward Increases the free play To turn outward Reduces the free play 1st step Loosen the lock nut 3 of cable 2 Turn the adjuster 4 and completely eliminate the cable 2 free play 2nd step Loosen the lock nut 5 of cable 1 Turn the adjuster 6 and establish the specified throttle cable free play Adjustment steps NOTE Resting the throttle cable 1 1 is extended and cable ...

Page 58: ...ts from falling into the engine 4 Inspect Electrodes 1 Wear damage Replace Insulator 2 Abnormal color Replace Normal color Brown clear to medium shade 5 Clean the spark plug using a plug cleaner or a wire brush 6 Measure Electrode clearance a Use a sheet gage or a cylindrical tip gage Out of specification Adjust 1 Disconnect Spark plug cap 1 2 Remove Spark plug Electrode clearance 0 6 0 7mm 1 1 ...

Page 59: ...ust the idle speed and the throttle cable free play IGNITION POINT INSPECTION 8 Connect Spark plug cap NOTE Before installing the spark plug clean the spark plug thread and gasket surfaces If no torquemeter is available a good estimate for the correct torque is as follows Tighten from to turn after tightening the spark plug manually 3 Check Ignition point Spark plug 17 5N m 1 75Kg m Tachometer 908...

Page 60: ...esult in performance loss COMPRESSION PRESSURE MEASUREMENT NOTE The ignition point cannot be adjusted Under severe conditions oil may be sprayed while the engine is running Therefore take care when carrying out this check CAUTION Using the strobe light check if the stationary point 2 stays within the ignition range 3 indicated in the magnet wheel Incorrect Check the pulse coil Checking steps Remov...

Page 61: ...k Compression COMPRESSION PRESSURE MEASUREMENT 3 15 Compare the readings with the specified levels see tables V WARNING When starting the engine ground the spark plug cable in order to prevent sparks Checking steps Start the engine using the start button make sure the battery is totally charged and with the throttle completely open until the meter stabilizes Compression meter 90890 03081 Adapter 9...

Page 62: ...nto the affected cylinder 2 Measure the compression again Above the maximum level Compression pressure with oil poured into the cylinder Reading Diagnostic Higher than without oil Worn or damaged piston Same as without oil Ring valve head or piston gasket worn or damaged Inspect head and valve surfaces or carbon fouling on the piston head 8 Install Spark plug See Section SPARK PLUG INSPECTION 9 Co...

Page 63: ...il also lubricates the clutch and additives can cause the clutch to slip Prevent dust from entering the engine CAUTION 4 Inspect Oil level The oil level should be between the maximum 2 and minimum 3 marks Low oil level Add oil 1 Place the motorcycle on a flat area 2 Warm up the engine for some minutes 3 Stop the engine and check the oil level through the visor 1 Recommended engine oil YAMALUBE4 SA...

Page 64: ...ntering the engine CAUTION ENGINE OIL CHANGE 6 Stop the engine and check the oil level again Do not start the engine if the oil reservoir is empty CAUTION Engine oil change without filter replacement 1 Place the motorcycle on a flat area 2 Warm up the engine for some minutes and then stop the engine Place a tray under the drain plug Amount of oil Periodic change 1 0 l Change with filter 1 1 l Tota...

Page 65: ...pring 3 oil strainer 4 and O ring 5 will come out Take care not to lose these parts 4 Drain Engine oil 5 Remove Bolt 1 oil filter cover NOTE The oil filter cover is fastened by 3 bolts The bolt 1 should be removed in order to drain the oil filter cavity 6 Inspect O ring Drain plug Damages Replace 7 Clean Oil strainer Clean using kerosene Clogging damage Replace 8 Install Bolt 1 oil filter cover Dr...

Page 66: ...ditives The engine oil also lubricates the clutch and additives can cause the clutch to slip Prevent dust from entering the engine 9 Replenish with oil ENGINE OIL CHANGE Bolts oil filter cover 10N m 1 0 Kg m 7 2 ft lb Drain plug 43N m 4 3 Kg m 31ft lb Recommended engine oil YAMALUBE4 SAE10W30 or SAE20W40 for USA CAN SAE10W30 or SAE10W40 or SAE20W40 or SAE20W50 for AUS 3 20 ...

Page 67: ...ove Oil filling screw 1 Drain plug 2 6 Remove Oil filter cover 1 Oil filter 2 O ring 3 5 Remove Bolt 1 oil filter cover 4 Drain Engine oil ENGINE OIL CHANGE NOTE The oil filter cover is fastened by 3 bolts The bolt 1 should be removed in order to drain the oil filter cavity NOTE When removing the drain plug 2 the spring 3 oil strainer 4 and O ring 5 will fall Take care not to lose these parts 2 1 ...

Page 68: ...nstall the O ring 2 spring 3 and oil strainer 4 CAUTION Bolt filter cover lower 10N m 1 0 Kg m 7 2 ft lb Bolt filter cover other 10N m 1 0 Kg m 7 2 ft lb Drain plug 43N m 4 3 Kg m 31 ft lb Recommended engine oil YAMALUBE4 SAE10W30 or SAE20W40 for USA CAN SAE10W30 or SAE10W40 or SAE20W40 or SAE20W50 for AUS Do not apply additives The engine oil also lubricates the clutch and additives can cause the...

Page 69: ...cification Adjust CLUTCH ADJUSTMENT 4 Tighten Oil check screw If no oil flows after 1 minute turn off the engine immediately CAUTION Oil check screw 7N m 0 7 Kg m 5 1 ft lb Free play 10 15mm at the lever end 1 Remove Oil check screw 1 2 Start the engine and let it at idle speed for several minutes 3 Check Oil condition at the inspection hole Oil flowing Oil pressure correct Oil does not flow Oil p...

Page 70: ...rn outward Reduces the free play Secondary lever adjuster Loosen the lock nut 3 Turn the adjuster 4 inward or outward until establish the specified free play Tighten the lock nut 3 NOTE If the clutch cable free play is incorrect adjust it using the adjuster close to the clutch lever NOTE In addition to the maintenance specified in the periodic revision table check the checking hose 1 under the air...

Page 71: ...r filter element 3 Damages Replace 4 Clean Air filter element Wash with kerosene Do not twist the element CAUTION Do not use gasoline to clean the air filter element Gasoline may cause fire or explosion V WARNING Recommended oil SAE 20W40 Do not start the engine without the air filter element since this allows non filtered air to enter resulting in wear and potential damage to the engine In additi...

Page 72: ...filter element reverse the procedures in Remove 1 Check Carburetor connection 1 2 O Ring 5 Damage cuts Replace CARBURETOR CONNECTION CHECK 7 Install Air filter box cover See Section SEAT FUEL TANK AND COVERS 3 26 Bolt side cover 7N m 0 7 Kg m 5 1 ft lb Bolt 3 10N m 1 0 Kg m 7 2 ft lb Tie wrap bolt 4 2N m 0 2 Kg m 1 4 ft lb NOTE When installing the element in the filter box fasten it firmly in the ...

Page 73: ...Core bolt 10N M 1 0 Kg m 7 2 ft lb 1 2 CORE CLEARING 1 Verify that the exhaust is cold 2 Remove Exhaust core loosening the 3 bolts 1 3 Clean Exhaust core 2 using a wire brush 4 Install Exhaust cover 1 Exhaust core 2 Exhaust core bolt 7N m 0 7 Kg m 5 1 ft lb 1 5 Remove Cleaning bolt 1 6 Close the outlet using a rag start the engine and increase the rotation twenty times generating a temporary press...

Page 74: ... chemical reaction on the components and brake efficiency loss Make sure to prevent water from entering the master cylinder when replenishing it Water decreases the fluid boiling point and may result in accidents The brake fluid may damage painted or plastic surfaces Remove the splattered brake fluid immediately 2 Check Brake fluid level Brake fluid level below the LOWER mark 1 replenish NOTE Plac...

Page 75: ...d of the hose in a container e Apply a moderate pressure to the brake lever f Pull and hold the lever g Loosen the bleeding screw and let the lever reach its limit h When the lever reaches its limit tighten the bleeding screw Then loosen the lever 1 Bleed Brake system Bleed the brake system if The is dismounted The brake hose is loose or replaced The brake fluid level is too low The brake is malfu...

Page 76: ...t of specification Adjust REAR BRAKE ADJUSTMENT j Replenish the brake fluid up to the level Adjustment steps Loosen the lock nut2 Turn the adjuster 1 inward or outward until establish the specified height To turn inward Increases the pedal height To turn outward Reduces the pedal height REAR BRAKE ADJUSTMENT Recommended brake fluid DOT 4 Check the brake system operation after the bleeding V WARNIN...

Page 77: ...HECK Brake pedal free play adjustment steps Turn the adjuster 1 until the free play is within the specification 4 Adjust Brake pedal free play 3 Check Brake pedal free play b Out of specification Adjust 3 31 Lock nut 7N m 0 7 Kg m 5 1 ft lb After adjusting the height adjust the free play of the brake pedal V WARNING NOTE Before adjusting the free play adjust the height of the brake pedal Brake ped...

Page 78: ... rotate the rear wheel some turns and check the free play at various points until find the tightest point Check and or adjust the chain free play with the rear wheel at its tightest position NOTE During the transmission chain free play adjustment the motorcycle should be positioned upright and with no weight on it 2 Move the rear wheel pushing the motorcycle and find the point with the highest ten...

Page 79: ...LUBRICATION The chain consists of many parts that operate together If not properly maintained the chain wears quickly Therefore it should be periodically lubricated This service is specially necessary when riding through uneven ground dust mud stones etc The motorcycle has a transmission chain equipped with small rubber O rings between its plates Steam and high pressure jet cleaning and some solve...

Page 80: ... handle bars 1 Nut handle bars board 2 Bolts suspension 3 Handle bars board 4 3 34 STEERING COLUMN ADJUSTMENT Support the motorcycle firmly preventing it from falling V WARNING NOTE Fit the torquemeter on the ring nut at a right angle Adjustment tool 90890 01403 Lower ring nut 4 initial torque 43N m 4 3 Kg m 31 ft Ib Remove the lock washer 1 Remove the ring nut upper 2 and the spacer 3 then loosen...

Page 81: ... turn Tighten the ring nut lower again using the special tool Avoid excessive torque V WARNING Ring nut lower final torque 6 5N m 0 65 Kg m 4 7 ft Ib Check the steering column turning the front tire from side to side after the adjustment above If the movement is difficult dismount the fastening assembly upper and lower ring nuts and check roller bearings and tracks If the movement is too free repe...

Page 82: ...e the suspension downwards repeatedly Irregular operation Repair See Section FRONTSUSPENSION CHAPTER 6 6 Install Dust cover Clamps See Section FRONT SUSPENSION INSTALLATION CHAPTER 6 REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload Shock absorbing 3 36 FRONT SUSPENSION INSPECTION The motorcycle should be firmly supported in order to prevent falls V WARNING CAUTION Always use new clamps The m...

Page 83: ... preload NOTE The spring installed length varies 1 0mm for each turn of the adjuster Measurement length a Standard 204 mm 80 in Minimum 194 mm 7 6 in Maximum 206 mm 8 1 in Never try to turn the adjuster more and less than the maximum and minimum adjustments respectively CAUTION Lock nut 43 N m 4 3 Kg m 31 7 ft Ib Always tighten the lock nut against the spring adjuster Apply torque to the lock nut ...

Page 84: ...y objects not packed properly that may be displaced Fasten your heavier load firmly close to the center of the motorcycle distributing the weight uniformly on both sides Adjust the suspension according to the load and check the conditions and pressure of the tires NEVER OVERLOAD YOUR MOTORCYCLE Make sure that the total weight of load driver passenger and accessories fairing side bags etc when appr...

Page 85: ...ch take care and replace the tire tube with a new high quality tire tube as soon as possible V WARNING Manufacturer Type Measure PIRELLI w tire tube 80 100 21NHS Manufacturer Type Measure PIRELLI w tire tube 110 100 18NHS Ride with care after installing a tire allowing it to lay properly on the rim Otherwise an accident may occur resulting in damage to the motorcycle and injuries to the driver Aft...

Page 86: ... Check Cable operation Irregular operation Lubricate 3 40 WHEEL INSPECTION 1 Check Wheels Damage warping Replace Damaged cable caps may result in corrosion obstruction to movement of cables and consequently hazardous conditions Replace the cables as soon as possible V WARNING Do not try to carry out repairs to the wheels even small repairs V WARNING Nipple 3 25 N m 0 32 Kg m 2 35 ft Ib Recommended...

Page 87: ...R SUSPENSION LUBRICATION PEDAL LEVER AND SIDE SUPPORT LUBRICATION REAR SUSPENSION LUBRICATION Lubricate hinges Lubricate the rear balance 1 3 41 Recommended lubricant Lithium based grease Recommended lubricant Lithium based grease 1 1 Grease fitting 1 ...

Page 88: ...add water If distilled water is added the chemical reaction in the battery will divert from the ideal impairing the efficiency The MF battery charging time current and voltage are different from those of a conventional battery The MF battery should be charged as described in Charging the Battery If the electrolyte level is too low the battery may be overcharged Therefore take special care when cha...

Page 89: ...NTERNAL Drink great quantities of water or milk followed by milk of magnesia mixed with egg white or vegetable oil Look for medical help immediately Batteries also generate explosive hydrogen gas Therefore observe the following preventive measures Charge the battery in a ventilated area Keep batteries away from fire sparks and flames DO NOT SMOKE while charging or handling batteries KEEP AWAY FROM...

Page 90: ...s according to the instructions in the figures Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge conditions of the battery 20 30 5 Charging method for the MF battery CAUTION If the standard current charge cannot be stabilized make sure not to exceed it Remove the battery from the motorcycle before charging it If for any reason it is necessary to charge the battery on the motorcycl...

Page 91: ... battery after charging are shown in the figure The open voltage circuit will be stabilized 30 minutes after the conclusion of the charging process Therefore in order to check the conditions of the battery carry out the measurement in the circuit after this period 6 Check Battery terminals Dust dirt clean using a wire brush Poor contact fix NOTE After cleaning apply conventional grease to the term...

Page 92: ...mperage Turn on the main switch and check the operation of the electric system If the fuse burns verify the circuit 3 46 NOTE Adjust the switch to x1 W If the device indicates the fuse is burnt Replace Do not use a fuse with higher amperage or any other material Using an improper fuse may result in damage to the electric system including fire V WARNING Multimeter 90890 01312 Fuse 10 A X 1 part 5 I...

Page 93: ... 4 5 ENGINE REMOVAL 4 6 ENGINE DISMOUNTING 4 8 HEAD CYLINDER AND PISTON 4 8 MAGNET ROTOR AND STARTING GEARS 4 12 OIL FILTER 4 14 CLUTCH OIL PUMP AND BALANCER GEAR 4 15 SHIFT SHAFT 4 18 CASE RIGHT 4 19 BALANCER TRANSMISSION AND SHIFTING FORK 4 20 CRANKSHAFT 4 21 ROCKER AND CAMSHAFT 4 22 VALVES 4 23 INSPECTION AND REPAIR 4 25 HEAD 4 25 VALVE SEAT 4 26 VALVES AND VALVE GUIDES 4 29 VALVE SPRING 4 31 C...

Page 94: ...TRAINER 4 45 ELECTRIC STARTING GEARS 4 46 CASES 4 47 ROLLER BEARINGS AND RETAINERS 4 47 LOCKS AND WASHERS 4 47 ENGINE MOUNTING AND ADJUSTMENTS 4 48 VALVES 4 49 ROCKER 4 50 CRANKSHAFT 4 52 BALANCER AND TRANSMISSION 4 54 BALANCER TRANSMISSION AND SHIFTING FORK 4 56 CASES 4 59 SHIFT SHAFT 4 61 CLUTCH OIL PUMP AND BALANCER GEAR 4 66 OIL FILTER 4 71 MAGNET ROTOR AND STARTING GEARS 4 72 HEAD CYLINDER AN...

Page 95: ... to remove the following components Head Cylinder Piston Clutch Oil pump Magnet rotor ENGINE REMOVAL 1 Remove Side covers Seat Fuel tank SEAT FUEL TANK AND COVERS 1 Remove Crankcase guard 1 CRANKCASE GUARD 1 Remove Oil filling screw 1 Drain plug 2 See Section ENGINE OIL CHANGE CHAPTER 3 ENGINE OIL 1 2 ...

Page 96: ...ENGINE ENGINE REMOVAL 4 2 BATTERY CABLES 1 Disconnect Battery negative cable 1 EXHAUST TUBE AND MUFFLER 1 Remove Bolt 1 tie wrap Bolt 2 exhaust tube Muffler 3 Exhaust tube 4 1 1 3 4 2 ...

Page 97: ...RETOR 1 Disconnect Engine breather hose 1 2 Drain Fuel bowl chamber 3 Loosen Bolts 1 carburetor connections NOTE Move the carburetor tie wrap 2 back 4 Loosen Bolts 3 intake manifold 5 Disconnect Carburetor through the left side of the motorcycle 1 Loosen Nut 1 Adjuster 2 cable adjusting screw 2 Disconnect Clutch cable clutch lever and cable fastener 1 1 3 2 3 4 1 2 ...

Page 98: ...ENGINE ENGINE REMOVAL 4 4 1 3 Disconnect Spark plug cap 1 4 Disconnect Magnet connectors 1 5 Remove Starter motor wire 2 Starter motor 3 6 Disconnect Ground wire Starter motor wire 3 2 ...

Page 99: ... 1 Loosen Shaft castellated nut 1 2 Remove Shift lever 1 Case cover 2 3 Remove Bolts 1 Pinion gear fastener 2 Transmission chain 3 4 Remove Adjuster 1 Pin 2 Spring 3 5 Remove Cotter pin 4 Corrugated washer 5 Flat washer 6 Brake pedal shaft 7 Rear brake pedal 8 6 Disconnect Spring 9 1 2 1 2 3 4 6 5 7 8 9 ...

Page 100: ...G 1 Place a suitable support under the engine NOTE The engine and the rear balance are installed on the same shaft Therefore the shaft should be carefully displaced just enough to remove the engine 1 1 1 2 Remove Setscrews 1 front lower 3 Remove Setscrews 1 rear lower 4 Remove Setscrews 1 front upper 5 Remove Shaft 1 1 ...

Page 101: ...ENGINE ENGINE REMOVAL 4 7 6 Remove Engine through the right side of the motorcycle NOTE After the engine has been removed place the other side of the balance properly using a suitable shaft ...

Page 102: ...Remove Covers 1 and 2 ENGINE DISMOUNTING NOTE With the engine mounted the head camshaft and cylinder overhauling is possible removing the following parts Side covers Seat Fuel tank Exhaust tube Carburetor Clutch cable Spark plug cable Engine support HEAD CYLINDER AND PISTON 1 1 1 2 ...

Page 103: ...he crankshaft counterclockwise Align the T mark 1 on the rotor with the stationary mark 2 on the case cover With the T mark aligned the piston is at the top dead center TDC NOTE Check the compression stroke at the TDC Both rockers should allow for clearance when the camshaft gear mark 3 is aligned with the head mark 4 Otherwise rotate the crankshaft one more turn in order to establish the conditio...

Page 104: ...her numbers first The numbers on the head indicate the tightening order 10 Remove Bolts 11 Remove Head 1 2 1 2 3 1 7 Loosen Tensioner cover bolt 1 8 Remove Chain tensioner 2 9 Remove Bolt 1 Camshaft gear 2 NOTE Fasten to the camshaft chain 3 using a wire in order to prevent it from falling into the case 1 ...

Page 105: ...OUNTING 4 11 12 Remove Camshaft chain guide Exhaust 1 Dowel pins 2 Seal 3 Head gasket 4 13 Remove Bolts 1 Clutch cable fastener 2 14 Remove Cylinder 1 15 Remove O ring 1 Dowel pins 2 Cylinder gasket 3 1 2 1 1 3 2 2 1 4 3 ...

Page 106: ... cover RH Seat Crankcase guard MAGNET ROTOR AND STARTING GEARS Do not use a hammer to remove the piston pin CAUTION NOTE Before removing the piston pin lock cover the case using a cloth in order to prevent the lock from falling into the case Use an appropriate puller to remove the piston pin 16 Remove Piston pin lock 1 Piston pin 2 Piston 3 1 Disconnect Neutral switch wire 1 2 Remove Case cover 2 ...

Page 107: ...se cover Spacer 3 Shaft 4 Starting gear 5 4 Remove Bolt 1 rotor 2 1 3 NOTE Loosen the rotor bolt holding the rotor with the fastener 2 Rotor fastener 90890 01701 CAUTION Prevent the rotor fastener from touching the cam 3 on the rotor Rotor puller 90890 01080 3 4 5 Prevent the rotor fastener from touching the cam 5 CAUTION 2 3 5 1 4 1 2 ...

Page 108: ...ENGINE ENGINE DISMOUNTING 4 14 6 Remove Gear 1 Washer 2 7 Remove Chain guide 1 Intake Camshaft chain 2 1 Remove Oil filter cover 1 2 Remove Oil filter 1 O rings 2 OIL FILTER 2 1 1 1 2 ...

Page 109: ...then remove the bolts 2 Remove Dowel pins 1 Gaskets 2 case cover 3 Remove Bolts 1 Springs 2 Pressure plate 3 Friction discs 4 type A Pressure spring 5 Separators 6 Friction disc 7 type B Ball 8 Stem 9 1 Remove Case cover 1 RH NOTE With the engine installed on the frame the clutch and oil pump overhauling is possible removing the following parts Crankcase guard Brake pedal 1 1 2 ...

Page 110: ... clutch hub Lock washer 2 Clutch hub 3 Spacer 4 Driven gear 5 sleeve 4 Remove Clutch drive stem 1 5 Straighten out Lock washer flange 1 6 Loosen Nut 2 clutch hub 1 3 1 2 NOTE Loosen the nut from the clutch hub holding the clutch hub with the universal clutch fastener 3 Universal clutch fastener 90890 04086 1 ...

Page 111: ... plate between the teeth of the primary and balancer shaft gears Take care not to damage the teeth of the gears 9 Remove Oil pump assembly 1 10 Remove Gasket 1 oil pump 11 Straighten out Lock washer flange 1 12 Loosen Nut 2 Crankshaft Nut 3 Balancer shaft 1 1 1 3 2 ...

Page 112: ...frame the shift shaft overhauling is possible removing the following parts Crankcase guard Brake pedal Clutch Oil pump SHIFT SHAFT 13 Remove Primary gear 1 Special washer 2 Balancer gear and impact hub 3 Key 4 Special washer 5 Plate 6 Balancer gear 7 Key 8 1 Remove Shift shaft 1 Washer 2 Spring 3 Stop 4 Washer 5 Lock 6 Torsion spring 7 Spacer 8 1 4 ...

Page 113: ...ith higher numbers first The numbers on the case indicate the tightening order 1 Remove Bolts case CASE RIGHT NOTE When removing the section the dowel pin 2 may fall Take care not to lose it 2 Remove Section 1 Use a wrench 3 Remove Lock 1 Spacer 2 Driving shaft Lock 3 1 1 2 3 3 8 7 1 6 5 4 10 2 9 2 ...

Page 114: ...g fork guide bar 1 short Shifting fork guide bar 2 long Shifting fork 3 Shifting fork 1 4 Shifting fork 2 5 Shifting fork 3 6 2 Remove Main shaft assembly 1 1 1 The cases should be separated by removing the right case Separate the cases after verifying that the main shaft lock and the shifting fork section have been removed Use the screwdriver only in the slots 1 shown in the figure above Prevent ...

Page 115: ...with the crankshaft center line CRANKSHAFT 3 Remove Secondary shaft assembly 1 Washer 2 4 Remove Balancer shaft 1 5 Remove Dead center switch 1 1 Remove Crankshaft assembly 1 Use the case separator 2 and the adapter 3 1 1 2 1 1 Case separator 90890 03081 Adapter 90890 01382 2 3 ...

Page 116: ...the frame the camshaft and rocker overhauling is possible removing the following parts Side covers Seat Fuel tank Valve covers Side head cover ROCKER AND CAMSHAFT 2 Remove Elastic pin 1 Pin with hole 2 Spring 3 1 Straighten out Lock washer flange 2 Remove Bolts 1 Lock washer 2 Plate 3 3 Remove Camshaft 1 Spacer 2 6 2 1 3 2 3 1 ...

Page 117: ...LVE SEAT NOTE Before removing the internal parts valves springs valve seat etc from the head check the valve seal VALVES Checking steps Pour gasoline 1 into the intake and exhaust manifolds Check the valve seal The valve seats should be free from leakage 2 2 1 NOTE Remove the rocker shaft using the sliding hammer 1 and weight 2 Sliding hammer 90890 01083 Weight 90890 01084 ...

Page 118: ...l it in the original place 2 Remove Valve locks 1 3 Remove Valve retainer 1 Valve spring 2 External Valve spring 3 Internal Valve 4 Oil retainer 5 Spring seat 6 2 1 NOTE Remove the valve locks when compressing the springs using the spring clamp 2 Valve spring clamp 90890 04019 ...

Page 119: ...ead sanding it in an 8 pattern 4 Flatten Head 2 Check Head Damages scratches Replace 3 Measure Warping Out of specification Flatten NOTE Do not use pointed instruments and avoid producing scratches on Spark plug thread Valve seat HEAD 1 Remove Carbon fouling from the combustion chamber Use a round scraper 1 Head warping Less than 0 03 mm ...

Page 120: ...Press the valve through the guide to the valve seat Measure the valve seat width If the valve seat width is too thin or too thick or off center the valve seat should be redone VALVE SEAT 1 Remove Carbon fouling from the valve and seat 2 Inspect Valve seat Wear Grind the seat 3 Measure Valve seat width a Out of specification Grind the seat Valve seat width Intake 0 9 1 1 mm 0 035 0 043 in Exhaust 0...

Page 121: ...tter B The seat is centered but thin Valve seat grinding steps CAUTION When turning the milling cutter keep a 4 5 kg pressure Valve seat milling cutter YM 91043 Section A B C Cutting 30 45 60 Mill the seat as follows Reduce the seat width to 1 0 mm 30 60 Desired result Milling cutter A The valve face indicates that the seat is centered but too wide A B ...

Page 122: ...to prevent the paste from entering into the gap between the valve stem and the guide Polishing steps grinding Apply a coarse abrasive paste to the valve face NOTE After the valve seat milling or the valve and valve guide replacement the valve seat and face should be polished To center the seat and establish an 1 0 mm width 30 45 Desired result Milling cutter To center the seat and increase the wid...

Page 123: ... specification mill and polish the valve again NOTE Remove the paste from the valve face and seat after each polishing work Apply fine abrasive paste to the valve face and repeat the same steps NOTE In order to achieve the best polishing results occasionally and lightly beat the valve face on the seat while turning the valve in both directions between the hands Stem guide clearance Internal guide ...

Page 124: ...o facilitate the removal and installation of the guide and ensure the correct relationship Replacement steps Remove the valve guide using the valve guide puller 1 Install the valve guide new using the valve guide puller 2 and remover 1 After installing the valve guide buff the valve guide using the valve guide reamer 3 in order to establish the appropriate stem guide clearance Valve guide puller 6...

Page 125: ...he guide and retainers whenever the valve is replaced 5 Measure Thickness a Out of specification Replace 6 Measure Warping valve stem Out of specification Replace Thickness 0 8 1 2 mm 0 031 0 047 in Warping Less than 0 010 mm Spring free length Internal External 36 17 mm 36 63 mm 36 17 mm 36 63 mm Intake Exhaust a ...

Page 126: ...e 1 Out of specification Replace 1 Check Shaft cams Scratches blue color Replace 2 Measure Cam height a and b Out of specification Replace Spring inclination Intake Less than 1 6 mm Exhaust Less than 1 6 mm Cam height Intake a 30 10 30 20 mm b 36 51 36 61 mm Spring load Internal 30 5 mm External 32 0 mm 7 7 9 4 mm 13 1 16 1 mm 7 7 9 4 mm 13 1 16 1 mm Intake Exhaust ...

Page 127: ...n Replace camshaft As per specification Replace bearing spacer 4 Measure Clearance between camshaft and bearing Out of specification Measure the camshaft bearing diameter 3 Measure Warping Camshaft Out of specification Replace Cam height Exhaust a 30 15 30 25 mm b 36 51 36 61 mm Warping Camshaft Less than 0 03 mm Camshaft clearance bearing 0 020 0 061 mm Camshaft bearing diameter 24 960 24 980 mm ...

Page 128: ...ace 3 Wear dots scratches blue color Replace and inspect the lubrication system 3 Measure Shaft rocker clearance 1 Check Camshaft chain Cracks warping Replace chain and gear 2 Check Camshaft gear Damages wear Replace gear and chain 1 tooth 2 Correct 3 Link roller 4 Gear Shaft rocker clearance 0 009 0 037 mm Shaft rocker clearance Internal rocker diameter a External shaft diameter b ...

Page 129: ...YLINDER AND PISTON 3 Check Chain guide 1 Exhaust side Chain guide 2 Intake side Wear damages Replace 4 Check Camshaft chain tensioner clearance Checking steps Use a screwdriver 1 turning clockwise to pull and lock the tensioner system Press the stem and verify the smoothness of the movement If the test result is unsatisfactory replace the assembly ...

Page 130: ...40 mm from the top of the cylinder and determine the measurement average Measurement steps Measure the cylinder diameter C using a suitable instrument a 40 mm from the top of the cylinder If out of specification grind or replace cylinder piston and rings Measure the lower end diameter of the piston P using a micrometer b 4 0 mm C X Y 2 Cylinder diameter C 69 970 70 020 mm limit 70 1 mm Piston skir...

Page 131: ...ure Side clearance Out of specification Replace piston and rings PISTON RINGS If out of specification grind or replace cylinder piston and rings Cylinder piston clearance 0 035 0 055 mm limit 0 15 mm Side clearance Top ring 0 03 0 07 mm Secondary ring 0 02 0 06 mm Cylinder piston clearance Cylinder diameter C Piston skirt diameter P NOTE Use the piston head and the guide to place the ring on the c...

Page 132: ...rails of the oil ring have an excessive clearance replace the 3 rings 1 Micrometer 1 Check Piston pin 1 Blue color scratches Replace and inspect the lubrication system 2 Measure External diameter of the piston pin Out of specification Replace Inter tip gap Compression ring top 0 15 0 30 mm Scraper ring secondary 0 15 0 30 mm Oil ring 0 30 0 90 mm External diameter of the piston pin 15 991 16 000 m...

Page 133: ... Connecting rod deflection F Out of specification Replace connecting rod Connecting rod side clearance D Out of specification Replace rollers on connecting rod crankshaft pin and or connecting rod Warping C Out of specification Replace crankshaft and or roller bearings 1 Measure Crankshaft width A Out of specification Replace crankshaft Crankshaft width 55 95 56 00 mm Warping limit 0 03 mm Connect...

Page 134: ... mm 1 Check Primary gear teeth 1 Driven gear teeth sleeve 2 Wear damages Replace both gears Excessive running noise Replace both gears PRIMARY GEAR 1 Check Balancer driving gear teeth 1 Balancer gear teeth 2 Wear damages Replace gears BALANCER GEARS 2 Check Impact hub 1 Spring 2 Dowel pin 3 Wear breakage damages Replace 3 Check Dot marks 1 Align the marks 2 1 1 2 1 ...

Page 135: ...separators Damage Replace assembly 2 Measure Friction disc thickness Out of specification Replace friction disc assembly Measure at four tips 1 Check Friction discs Wear damages Replace friction disc assembly INSPECTION AND REPAIR Warping limit Less than 0 2 mm Spring free length Type B Type A Thickness Wear limit 2 90 3 10 mm 2 90 3 10 mm 2 8 mm 2 8 mm ...

Page 136: ... disc sockets 1 Burrs wear damages Clean or replace Clutch hub sockets 2 Burrs wear damages Replace clutch hub 6 Measure Spring free length a Out of specification Replace spring assembly INSPECTION AND REPAIR Free length clutch springs 37 3 mm Limit 35 3 mm NOTE Burrs on friction disc sockets and clutch hub will result in irregular operation 1 2 a ...

Page 137: ...m 7 Wear warping damages Replace 1 Check Fork follower 1 Fork tips 2 Burrs warping wear Replace TRANSMISSION AND SHIFTING FORK INSPECTION AND REPAIR 3 Check Fork movement Irregular operation Replace fork and or guide bar 2 Check Shifting fork channels 1 Dowel pins 2 Shifting fork section 3 Wear Damages Replace ...

Page 138: ... Gear teeth Blue color Wear Replace Sockets Round broken edges Replace Do not try to straighten out the shaft 5 Measure Warping Driving and driven shaft Out of specification Replace Do not try to straighten out the bars INSPECTION AND REPAIR V WARNING V WARNING Warping Less than 0 08 mm ...

Page 139: ...nternal rotor 1 and the external rotor 2 Side clearance b between the external rotor 2 and the pump case 3 Out of specification Replace oil pump OIL PUMP AND FILTER STRAINER 7 Check Shift shaft 1 Stop stem 2 Damages warping wear Replace Torsion spring 3 Return spring 4 Breakage damages Replace Clearance a 0 15 mm Side clearance b 0 04 0 09 mm ...

Page 140: ...ear damages Replace 1 Check Starting gear teeth 1 Starting gear teeth 2 Burrs Roughness Wear Replace 1 2 2 4 3 1 A B Checking steps Install the starting gear driven on the starting clutch Hold the clutch When turning the starting gear clockwise A the clutch and the gear should be meshed Otherwise the clutch is damaged Replace When turning the starting gear counterclockwise B the gear should turn f...

Page 141: ...aces 1 Check Roller bearings Clean lubricate and manually turn the internal raceway Irregular rotation Replace ROLLER BEARINGS AND RETAINERS 3 Check Cases Breakage damages Replace Oil passages Clogging Blow using compressed air 1 Wash the cases thoroughly using kerosene 2 Clean all gasket surfaces and the contact surfaces of the cases CASES CAUTION LOCKS AND WASHERS 1 Check Locks Washers Damages c...

Page 142: ...Rocker B Rocker shaft C O ring D Rocker shaft E Lock F Valve guide G Camshaft H Spacer I Plate J Lock washer 4 48 Stem warping limit 0 01 mm C Valve seat width 0 9 1 1 mm D Valve inclination limit Internal spring 2 5 or 1 6 mm External spring 2 5 or 1 6 mm B Valve clearance Intake 0 05 0 09 mm Exhaust 0 15 0 19 mm A 8N m 0 8 Kg m 176 78 cm lb USE A NEW ONE E USE A NEW ONE E USE A NEW ONE E USE A N...

Page 143: ...e valve guide Valve 6 Lower spring seat 5 Internal spring 3 External spring 4 Upper spring seat 1 2 Apply Molybdenum disulfide based oil to stem and retainer VALVES 1 Remove burrs Valve stem head The engine mounting requires the replacement of the following parts with new ones O ring Gaskets Retainer Copper washers Lock washers Locks V V V V V WARNING 1 2 3 4 5 6 ...

Page 144: ... 4 Rocker shaft 5 Intake ROCKER NOTE Avoid beating excessively in order to prevent valve damage 5 Fasten the valve lock beating slightly using a plastic hammer NOTE Install the valve locks while pressing the spring using the valve spring clamp 2 4 Install Valve locks 1 2 1 NOTE Install the valve spring with the longest pitch 7 up 8 Shorter pitch Valve spring clamp 90890 04019 ...

Page 145: ...Pin 3 NOTE Align the slot 6 of the intake rocker shaft with the head bolt hole 7 and install the rocker shaft Do not confound the installation direction of the rocker shaft Take care to install the threaded part facing outward CAUTION 4 3 2 1 NOTE Align the camshaft pin 3 with the mark 4 on the head and install the pin Always use a new lock washer V WARNING Bolt 3 camshaft 8 N m 0 8 Kg m 5 8 ft Ib...

Page 146: ...nnecting rod 4 Lower connecting rod roller bearing 5 Crankshaft roller bearing 6 Spring 7 Pin with hole 8 Dowel pin 4 52 50 N m 5 0 Kg m 1 097 28 cm Ib B WARPING LIMIT 0 03 mm A CRANKSHAFT WIDTH 55 95 56mm C CONNECTING ROD DEFLECTION LIMIT 0 08 mm D CONNECTING ROD SIDE CLEARANCE 0 35 0 65mm ...

Page 147: ...3 4 2 Crankshaft puller assembly YU 90050 Spacer 1 90890 04081 Adapter 12 2 YM 01383 Adapter 3 90890 01274 Bolt 4 90890 01275 NOTE Hold the connecting rod in the top dead center using one hand while turning the tool nut with the other Continue using the tool until the crankshaft touches the roller bearing In order to protect the crankshaft against hazards or facilitate the installation operation A...

Page 148: ...ear 8 4th driven gear 9 6th driven gear 0 1st driven gear A Roller bearing B Retainer C Roller bearing D 2nd driving gear E 5th driving gear F 3rd driving gear G 4th driving gear H Main shaft I Roller bearing J Roller bearing K Balancer L Roller bearing ENGINE MOUNTING AND ADJUSTMENTS 4 54 Warping limit of the main and driven shafts 0 08 mm ...

Page 149: ...ENGINE SHIFTING FORK 1 Fork guide bar long 2 Fork 3 3 Fork 1 4 Shifting fork 5 Fork guide bar short 6 Fork 2 ENGINE MOUNTING AND ADJUSTMENTS 4 55 ...

Page 150: ... facing the gear 3 3 Apply Molybdenum disulfide based oil to main and driven shafts and gears 4 Install Driven shaft assembly 1 Main shaft assembly 2 2 Install Balancer shaft 1 1 Install Dead center switch 1 ENGINE MOUNTING AND ADJUSTMENTS 4 56 1 1 1 Always use a new lock V WARNING ...

Page 151: ...ork 2 2 Fork 1 3 Shifting fork 4 Fork guide bar long 5 Fork guide bar short 6 7 Apply Engine oil 4 T to fork guide bars 6 Install Main shaft assembly 1 5 Install Washer 1 Shaft assembly 2 4 57 Do not open the lock more than necessary CAUTION 1 5 2 4 6 3 1 NOTE Install the forks with their marks facing the left side of the engine 2 1 ...

Page 152: ...ENGINE 9 Check Transmission operation Irregular operation Repair ENGINE MOUNTING AND ADJUSTMENTS 4 58 ...

Page 153: ...Case R H 2 Dowel pin 3 Breather hose 4 Case L H 5 Hose fastener 4 59 T i g h t e n i n g sequence A Glue Yamaha Bond 1215 D 10 N m 1 0 Kg m 7 2 ft lb B Tighten the bolt together with the starter motor C Tighten the bolt together with the ground wire ...

Page 154: ...es 3 Fit the right case to the left case Beat slightly using a plastic hammer 4 Tighten Bolts 1 10 ENGINE MOUNTING AND ADJUSTMENTS 4 60 Glue Yamaha Bond 1215 90890 85505 NOTE Prevent glue from touching the oil galleries 3 8 7 1 6 5 4 10 2 9 Bolts case 10 N m 1 0 Kg m 219 46 cm Ib 2 2 1 NOTE Tighten the bolts with lower numbers first Install the clutch cable fastener on bolt 9 and the hose fastener...

Page 155: ...ENGINE ENGINE MOUNTING AND ADJUSTMENTS SHIFT SHAFT 1 Section 2 Dowel pin short 3 Dowel pin long 4 Spacer 5 Shift shaft 6 Torsion spring 7 Stop stem 8 Return spring 4 61 12N m 1 2Kg m 8 7 ft lb ...

Page 156: ...ection 1 1 Install Lock 1 Spacer 2 Lock 3 2 Install Section 1 Dowel pin long 2 Dowel pin short 3 4 62 NOTE Install the long dowel pin 2 on the mark 4 1 2 3 NOTE Place the dowel pin long 2 in the installation hole 3 and install the section 1 Bolt 12 N m 1 2 Kg m 8 7 ft Ib Use LOCTITE NOTE Install the torsion spring 3 firmly in order to hold both sides of the guide plate 9 3 1 3 2 4 ...

Page 157: ... position Push the shift shaft arm and the stop stem in the arrow direction and install them on the section Install the torsion spring 4 on the dowel pin 5 6 Install Stop stem 1 Return spring 2 Shift shaft 3 Torsion spring 4 ENGINE MOUNTING AND ADJUSTMENTS 4 63 5 4 3 1 2 1 ...

Page 158: ... gear 3 Plate 4 Lock washer 5 Nut 6 Special washer 7 Balancer driving gear 8 Impact hub 9 Special washer 0 Key A Primary Gear B Lock washer C Nut 4 64 USE A NEW ONE A USE A NEW ONE A 50N m 5 0 Kg m 1 097 28 cm lb 60N m 6 0 Kg m 1 325 88 cm lb Balancer gear installation B ...

Page 159: ...ll D Stem 2 E Clutch stem F Primary gear G Oil pump gear cover H Oil pump driven gear I Oil pump J Gaskets 4 65 12 N m 1 2 Kg m 8 7 ft lb 70 N m 7 0 Kg m 50 ft lb Spring minimum free length 35 3 mm B Separatorwarpinglimit 0 2 mm C 7 N m 0 7 Kg m 5 1 ft lb USE A NEW ONE D 6 N m 0 6 Kg m 4 3 ft lb 8 N m 0 8 Kg m 5 8 ft lb USE A NEW ONE D Type A FRICTION DISCS A 1 piece Thickness 2 9 3 1 mm Wear limi...

Page 160: ... impact hub 8 Special washer 9 Primary gear 0 Lock washer A Nut B primary gear 4 66 Nut balancer gear 50N m 5 0 Kg m 36 ft Ib Nut primary gear 60N m 6 0 Kg m 43 5 ft Ib 14 13 NOTE When installing the primary gear align the punch mark C of the driving gear with the punch mark D of the balancer gear Place a cloth or an aluminum plate between the teeth of the primary and balancer shaft gears Take car...

Page 161: ...NTING AND ADJUSTMENTS 7 Install Gasket 1 Oil pump assembly 2 Bolts 3 Oil pump cover 4 6 Apply Engine oil 4 T to oil passages of the oil pump 5 Apply Engine oil 4T to oil passages of the case 4 67 Bolt 7N m 0 7 Kg m 5 1 ft Ib Apply an appropriate amount of engine oil 4 T to the oil passages on the case in order to prevent the engine from being damaged CAUTION Bolt oil pump 7N m 0 7 Kg m 5 1 ft Ib ...

Page 162: ...k washer flange 12 Apply Engine oil 4T to roller bearing 1 and stem Lithium based grease to stem retainer NOTE Tighten the nut clutch hub holding the clutch hub with the universal clutch fastener2 10 Tighten Nut 1 clutch hub 4 68 NOTE Fold the lock washer flanges on the clutch hub channel 2 1 Universal clutch fastener 90890 04086 Nut clutch hub 70N m 7 0 Kg m 50 ft Ib 1 ...

Page 163: ...m 8 7 ft Ib NOTE Apply engine oil 4T to the separators Install the separators and friction discs alternately on the clutch hub starting and finishing with a friction disc The friction disc type A 6 with the wider internal diameter should be installed in the 3rd position The expansion spring 5 should be placed inside the 3rd friction disc CAUTION Friction disc Quantity Type A Type B 1 piece 5 piece...

Page 164: ...tighten the lock nut firmly 15 Check Clutch stem position Push the clutch stem assembly in the arrow direction Make sure the adjusting marks are aligned Out of line Adjust 1 Clutch stem assembly indicator 2 Case mark 16 Adjust Clutch stem position 4 70 NOTE Tighten the bolts in a cross pattern Screws pressure plate 6N m 0 6 Kg m 4 3 ft Ib Do not overtighten the adjuster 2 and eliminate the clearan...

Page 165: ...to oil filter and oil passage OIL FILTER Bolt 2 10N m 1 0 Kg m 219 46 cm Ib Bolt 3 10N m 1 0 Kg m 219 46 cm Ib ENGINE MOUNTING AND ADJUSTMENTS 4 71 1 Bolt case cover 10N m 1 0 Kg m 7 2 ft Ib NOTE Tighten the bolts case cover in a cross pattern 1 2 Install the oil filter as shown in the figure CAUTION 1 2 3 1 B internal ...

Page 166: ... chain 2 Belt guide intake 3 Key 4 Washer 5 Starting gear 2 6 One way gear 7 Dowel pin 8 Spring cover MAGNET ROTOR AND STARTING GEARS ENGINE MOUNTING AND ADJUSTMENTS 4 72 10 N m 1 0 Kg m 219 46 cm lb 8 N m 0 8 Kg m 5 8 ft lb 30 N m 3 0 Kg m 670 56 cm lb 50 N m 5 0 Kg m 1 097 28 cm lb 10 N m 1 0 Kg m 219 46 cm lb ...

Page 167: ...ing pin 1 Spring 2 Fastener 3 3 Install Washer 1 Starting gear 2 2 2 Apply Engine oil 4T to starting gears 1 Install Chain guide 1 Camshaft chain 2 4 73 2 1 3 Bolt chain guide 8N m 0 8 Kg m 5 8 ft Ib NOTE Fasten to the camshaft chain 3 using a wire in order to prevent it from falling into the case 1 3 2 2 1 2 1 2 1 3 ...

Page 168: ...r 1 aligning the slot and the key Turn starting gear 2 2 clockwise and install rotor and starting gear Bolt rotor 50 N m 5 0 Kg m 36 ft Ib 2 1 3 NOTE Tighten the bolt rotor holding the rotor with the fastener 2 Rotor fastener 90890 01701 Prevent the rotor fastener from touching the cams 3 on the rotor CAUTION 5 3 1 4 2 Bolt case cover 10N m 1 0 Kg m 219 46 cm Ib NOTE Tighten the bolts case cover i...

Page 169: ... Cylinder 2 Cylinder bolt 3 O ring 4 Cylinder gasket 5 Dowel pins 6 O ring 7 Piston rings 8 Piston pin locks 9 Piston 0 Piston pin Cylinder diameter 69 925 69 975 mm A Cylinder piston clearance 0 035 0 055 mm limit 0 10 mm B C USE A NEW ONE 10N m 1 0 Kg m 7 2 ft lb 2 ...

Page 170: ...pin 0 Grommet A Head gasket B O ring C Side head cover 4 76 22N m 2 2 Kg m 16ft lb Head warping limit 0 3 mm C Tightening sequence B 4 1 2 3 10N m 1 0 Kg m 219 46 cm lb 10N m 1 0 Kg m 219 46 cm lb 7N m 0 7 Kg m 155 45 cm lb 20N m 2 0 Kg m 426 72 cm lb 10N m 1 0 Kg m 219 46 cm lb Spark plug DR8EA N G K A Electrode gap 0 6 0 7 mm B E USE A NEW ONE ...

Page 171: ...hain guide intake 5 Camshaft 6 Pin 7 Gear 8Camshaft chain 9 Chain guide exhaust ENGINE MOUNTING AND ADJUSTMENTS 4 77 10N m 1 0 Kg m 219 46 cm lb 7N m 0 7 Kg m 155 45 cm lb Shaft spacer clearance 0 020 0 061 mm A Camshaft warping limit 0 03 mm B 60N m 6 0 Kg m 1 310 64 cm lb ...

Page 172: ...ng top 3 Scraper ring 4 3 Install Piston 1 Piston pin 2 Piston pin locks 3 2 Install Piston rings 1 Apply Engine oil 4T Piston rings and pin 4 78 NOTE Install the rings with the brand mark up NOTE The piston arrow 4 should be facing the front part of the engine Before installing the piston pin locks cover the engine case using a cloth in order to prevent the locks from falling into the engine ...

Page 173: ... 8 Install Dowel pins 1 Grommet 2 Gasket 3 head Chain guide 4 exhaust 7 Install Bolts 1 6 Install Cylinder 1 4 79 NOTE Pressing the piston rings manually install the cylinder Bolts 1 10N m 1 0 Kg m 7 2 ft Ib 3 2 1 1 During this operation take care not to hurt your hands V WARNING 1 1 4 3 2 ...

Page 174: ...until mark PMS 1 aligns with the stationary mark on the case 2 Align the camshaft pin 3 with the stationary mark 4 on the head Place the camshaft chain on the camshaft gear and install the gear on the camshaft 11 Install Camshaft gear 10 Install Bolts ENGINE MOUNTING AND ADJUSTMENTS 4 80 1 Bolt 1 4 22N m 2 2 Kg m 16 ft Ib Bolt 5 6 20N m 2 0 Kg m 426 72 cm Ib NOTE Apply engine oil 4T to the washers...

Page 175: ...stall the gasket 5 and tighten the bolt 6 applying the specified torque 12 Install Camshaft chain tensioner Remove the safety wire 8 from the camshaft chain Tighten the bolt 7 ENGINE MOUNTING AND ADJUSTMENTS 4 81 4 5 6 3 Do not turn the crankshaft while installing the camshaft otherwise damage or incorrect valve timing can result CAUTION Bolt camshaft gear 60N m 6 0 Kg m 43 ft Ib 8 7 Bolt chain te...

Page 176: ...CLEARANCE ADJUSTMENT CHAPTER 3 17 Install Valve covers 1 and 2 16 Apply Engine oil 4T to camshaft 15 Install O ring 1 Side head cover 2 ENGINE MOUNTING AND ADJUSTMENTS 4 82 Intake valve cold 0 05 0 09 mm Exhaust valve cold 0 15 0 19 mm 2 1 Bolt side head cover 10N m 1 0 Kg m 72 ft Ib Amount of oil 0 5 l 1 2 Bolt covers 10N m 1 0 Kg m 7 2 ft Ib ...

Page 177: ...verse the removal process Observe the following 21 Install Oil strainer 1 Spring 2 O ring 3 Drain plug 4 20 Install Spark plug 1 19 Install Intake manifold 1 4 83 2 1 1 Bolt intake manifold 10N m 1 0 Kg m 7 2 ft Ib 1 Spark plug 17 5N m 1 75 Kg m 381 00 cm Ib Drain plug 43N m 4 3 Kg m 31 ft Ib ...

Page 178: ...ll Corrugated washer 1 Brake pedal 2 Brake pedal shaft 3 Flat washer 4 Cotter pin 5 4 84 NOTE Install all bolts and nuts and then apply the specified torque 2 3 Nut hinge shaft 80N m 8 0 Kg m 58 ft Ib Bolt engine support upper 38N m 3 8 Kg m 27 ft Ib Nut setscrew 46N m 3 25 Kg m 23 5 ft Ib 4 4 Brake pedal shaft 30N m 3 0 Kg m 22 ft Ib 1 4 2 3 5 ...

Page 179: ...E PLAY ADJUSTMENT CHAPTER 3 6 Install Transmission chain 1 with pinion gear Pinion gear fastener 2 Bolts 3 5 Adjust Brake pedal free play See Section REAR BRAKE ADJUSTMENT CHAPTER 3 4 85 6 8 7 Brake pedal free play 20 30 mm 1 2 3 Bolt 10N m 1 0 Kg m 219 46 cm Ib Transmission chain free play 45 60 mm Bolt pinion gear cover 10N m 1 0 Kg m 7 2 ft Ib Bolt shift lever 7N m 0 7 Kg m 5 1 ft Ib 2 1 ...

Page 180: ...11 Install Starter motor 1 10 Apply Lithium based grease to starter motor O ring 13 Connect Magnet harness 1 Plastic belt 2 Spark plug cap 3 Bolt 7N m 0 7 Kg m 155 45 cm Ib Bolt starter motor 7N m 0 7 Kg m 5 1 ft Ib 14 Install Clutch cable 15 Adjust Clutch cable free play See Section CLUTCH ADJUSTMENT CHAPTER 3 Clutch lever end free play 10 15 mm 2 1 1 1 2 3 ...

Page 181: ...ffler 3 Bolt 4 18 Install Exhaust tube 1 Bolt 2 17 Connect Breather hose 1 16 Install Carburetor 1 Hose 2 Bolt carburetor tie wrap 2N m 0 2 Kg m 1 4 ft Ib 2 1 1 Bolt muffler tie wrap 16N m 1 6 Kg m 11 6 ft Ib Bolt exhaust tube 10N m 1 0 Kg m 7 2 ft Ib 1 3 2 4 ...

Page 182: ...N CHAPTER 3 21 Install Crankcase guard 1 See Section ENGINE OIL CHANGE CHAPTER 3 20 Connect Battery negative cable 1 See Section BATTERY INSPECTION CHAPTER 3 4 88 Bolt crankcase guard 54 5N m 5 45 Kg m 39 50 ft Ib Amount of oil Total capacity 1 3 l Bolt oil check 7N m 0 7 Kg m 5 1 ft Ib Do not start the engine without oil CAUTION 1 ...

Page 183: ... See Section IDLE SPEED ADJUSTMENT CHAPTER 3 23 Install Fuel tank Seat Side covers See Section SEAT FUEL TANK AND COVERS CHAPTER 3 4 89 ENGINE MOUNTING AND ADJUSTMENTS Bolts 7N m 0 7 Kg m 5 1 ft lb Idle speed 1 300 to 1 500 rpm ...

Page 184: ...CARB CARBURETOR CHAPTER 5 CARBURATION CARBURETOR 5 1 REMOVAL 5 2 DISMOUNTING 5 3 INSPECTION 5 5 MOUNTING 5 7 INSTALLATION 5 9 FUEL LEVEL ADJUSTEMENT 5 10 ...

Page 185: ... assembly D Diaphragm assembly E Main adjusting nozzle washer Specifications High speed adjusting nozzle M J Low speed adjusting nozzle P J Needle lock position J N Diffuser N J Pilot Screw P S Fuel level F L Idle speed 125 0 36 F 21 3 5 V 95 2 0 9 0 11 0 mm Under the float bowl front face 1 400 1 600rpm 2N m 0 2 Kg m 1 4 ft lb 2N m 0 2 Kg m 1 4 ft lb 1 8N m 0 18 Kg m 39 62 cm lb 1N m 0 1Kg m 21 3...

Page 186: ...NE REMOVAL CHAPTER 4 2 Loosen Lock nut 1 throttle cable 3 Disconnect Throttle main cable 2 Throttle return cable 3 Breather hose Fuel hose 4 Drain hose 4 Loosen Connection bolts 5 5 Remove Carburetor NOTE Move the carburetor tie wrap back REMOVAL 1 2 3 4 5 ...

Page 187: ...ove Carburetor bowl 1 Pilot screw 2 3 Remove Float pin 1 Float 2 Needle valve assembly 3 NOTE The following parts can be cleaned and checked with no need for dismounting Pilot screw Choke Idle speed screw DISMOUNTING 4 Remove Main adjusting nozzle 1 Pilot adjusting nozzle 2 Diffuser 3 Needle valve seat 4 ...

Page 188: ...cover 1 6 Remove Bolt drive arm 1 7 Remove Bolts throttle valve 1 8 Remove Throttle valve 1 Ring 2 Needle 3 Needle fastener 4 Spring 5 9 Remove Diaphragm cover bolt 1 Diaphragm cover 2 Diaphragm spring 3 Diaphragm 4 Spring 5 5 1 4 3 2 1 ...

Page 189: ...e wear Replace assembly Dust Clean using compressed air 1 Check Mixing chamber body Float chamber Bowl Contamination Clean passages using compressed air NOTE Use kerosene for cleaning Blow passages and adjusting nozzles using compressed air 3 Check Starting injector 1 Contamination clean NOTE The starting injector is a stationary type injector 4 Check Throttle valve 1 Scratches wear damage Replace...

Page 190: ...ping wear damage Replace Spring 2 Damage Replace 7 Check Diaphragm 1 Damage Replace Spring 2 Damage Replace 8 Check Float 1 Float arm 2 Damage Replace 9 Observe Movement smoothness Irregular Replace Insert the throttle valve in the carburetor and check the movement smoothness NOTE Replace the needle valve and its seat as a whole ...

Page 191: ...zzle 2 Pilot adjusting nozzle 3 CAUTION Wash the parts with kerosene before mounting Reverse the DISMOUNTING procedures Check the following items MOUNTING Pilot adjusting nozzle 1 N m 0 1 Kg m 0 7 ft Ib Main adjusting nozzle 1 8 N m 0 18 Kg m 1 3 ft Ib Bolt needle valve fastening 2 N m 0 2 Kg m 1 4 ft Ib NOTE Install the float pin in the direction indicated 4 Install Float bowl 1 Pilot screw 2 ...

Page 192: ...cover 2 Bolt 3 6 Install Choke assembly 1 5 Install Spring 1 Diaphragm 2 Diaphragm spring 3 Cover 4 Bolt 5 1 2 3 4 5 7 Install Throttle valve 1 Ring 2 Needle 3 8 Install Throttle valve 1 Drive arm 2 1 2 3 Bolt upper cover 2 N m 0 2 Kg m 1 4 ft Ib ...

Page 193: ...ection THROTTLE CABLE FREE PLAY ADJUSTMENT Chapter 3 5 9 INSTALLATION 1 Install Carburetor assembly See Section ENGINE REMOVAL Chapter 4 2 Install Throttle cables 1 See Section CABLE ROUTING Chapter 2 10 Install Breather hose Fuel hose Drain hose Idle speed 1 400 1 600 rpm Throttle cable free play 3 5 mm 0 12 5 08 mm 1 ...

Page 194: ...evel meter close to the bowl with the graduated face pointing towards you 7 Measure Fuel level a Out of specification Adjust 8 Adjust Fuel level 5 10 FUEL LEVEL ADJUSTMENT Adjustment steps Remove the carburetor Check the valve seat and needle valve If one is damaged replace both If in good conditions adjust the float bending the float arm stop 1 Measure the fuel level again Fuel level meter 90890 ...

Page 195: ... 22 REAR WHEEL REMOVAL 6 23 INSPECTION 6 24 MOUNTING 6 26 INSTALLATION 6 28 FRONT FORK 6 29 REMOVAL 6 30 DISMOUNTING 6 31 INSPECTION 6 34 MOUNTING 6 35 INSTALLATION 6 38 STEERING COLUMN AND HANDLE BARS 6 40 REMOVAL 6 41 STEERING COLUMN 6 42 INSPECTION 6 45 INSTALLATION 6 47 REAR SHOCK ABSORBER AND BALANCE 6 53 NOTES ON HANDLING 6 55 NOTES ON DISCARDING 6 55 REMOVAL 6 56 INSPECTION 6 59 INSTALLATIO...

Page 196: ... kgf cm2 15 psi 100 kPa 1 kgf cm2 15 psi 1 Axle 2 Spacer 3 Dust protector 4 Retainer 5 Roller bearing 6 Spacer 7 Front wheel 8 Washer 9 Nut 0 Disc A Bolt B Rim dimensions 1 85 x 21 A Tire Specif 80 100 21 NHS C Rim warping limit Vertical 2 0 mm Side 2 0 mm D Wear limit 0 8 mm 1 2 3 4 5 6 7 5 9 0 A B 3 2N m 0 32Kgf m 2 3 ft lb 80N m 8 0Kgf m 57 9 ft lb 13 N m 1 3 Kgf m 9 4 ft lb 2 N m 0 2 Kgf m 1 4...

Page 197: ...torcycle Otherwise the brake pads will be forced V V V V V WARNING Support the motorcycle firmly preventing it from falling 1 Place the motorcycle on a flat area 2 Lift the front wheel placing a support under the engine 3 Remove Nut 1 Axle 2 Front wheel 4 Romove Spacer 1 Dust protector 2 1 2 1 2 ...

Page 198: ...If a sharp metallic sound is heard the spoke is tight If a deep metallic sound is heard the spoke is loose 3 Check Tire Damage wear Replace See Section TIRE INSPECTION CHAPTER 3 Wheel Warping damage Replace See Section WHEEL INSPECTION CHAPTER 3 4 Check Spokes Warping damage Replace Loose spokes Tighten Turn the wheel and beat the spokes using a screwdriver V V V V V WARNING Do not try to straight...

Page 199: ...o apply the proper torque to the valve stem lock nu 1 1 1 1 1 V V V V V WARNING NOTE Use a socket wrench 4 that fits the outside diameter of the race and the retainer Remove the roller bearings 3 using the roller bearing puller Install the new roller bearing and the new retainer reversing the steps above Replacement steps Wheel retainer and roller bearing Clean the external surface of the wheel hu...

Page 200: ...ngs 3 Do not touch the internal race 5 or bearing balls 6 The contact should occur on the external race only 7 CAUTION 1 2 3 2 Install Spacer 1 Dust protector 2 Nut axle 80 N m 8 0 kgf m 57 9 ft lb NOTE Install the oil retainer taking care not to damage or fold the lips 3 Install Axle 1 Washer 2 Nut 3 4 Tighten Nut 3 1 2 2 3 1 ...

Page 201: ...and rims carry out the static wheel balancing The brake disc should be installed Procedure a Turn the wheel and wait until it stops b Mark a X1 on the lower point found c Turn the wheel placing the X1 at 90 degrees d Free the wheel and wait until it stops Mark a X2 on the new point found e Repeat steps b c and d until the marks begin coincide f The average point found is the weight point ...

Page 202: ...tment steps Install a balancing weight on the point of the rim symmetrical to the weight point found Turn the wheel and place the X mark at 90 degrees from its original position Observe if the weight point stays on the same position Repeat the previous steps until the weight point unbalance is eliminated NOTE For the first and second measurements install the balancing weight s on the opposite side...

Page 203: ...on 8 Retainer kit 9 Pad spring 0 Bleeding screw A Brake pads B Brake pad pin C Brake disc 7 N m 0 7 kgf m 5 0 ft lb 27 N m 2 7 kgf m 19 5 ft lb 18 N m 1 8 kgf m 13 0 ft lb Pad wear limit 0 8 mm B A Brake fluid DOT 4 40 N m 4 0 Kgf m 28 9 ft lb C USE A NEW ONE 27 N m 2 7 kgf m 19 5 ft lb 6 N m 0 6 kgf m 4 3 ft lb 13 N m 1 3 Kgf m 9 4 ft lb USE A NEW ONE C C USE A NEW ONE ...

Page 204: ...e fluid from reaching the eyes Prevent the brake fluid from contacting painted or plastic surfaces Do not disconnect any hydraulic system component Otherwise it will be necessary to dismount drain clean and then replenish with fluid and bleed properly CAUTION V V V V V WARNING Support the motorcycle firmly preventing it from falling BRAKE PAD REPLACEMENT 1 Loosen Pad pins 1 NOTE The disconnection ...

Page 205: ... reached Wear limit a a a a a 1 0 mm 2 Remove Bolt 1 Brake caliper 2 3 Remove Pad pins Brake pads 1 Brake pad spring 2 4 Check Brake caliper 1 Cracks damage Replace the assembly Rubber protector 2 Cracks damage Replace Caliper support 3 5 Lubricate Dowel pins 6 Install Caliper support NOTE Fasten the rubber protector 2 firmly to the sliding spacer seat ...

Page 206: ...nnect a clear plastic tube 1 firmly to the bleeding screw Then place the other end of the tube in a container Loosen the bleeding screw and push the piston against the caliper manually Tighten the bleeding screw Brake pad pins 18 N m 1 8 kgf m 13 ft lb V V V V V WARNING Route the brake hose properly in order to ensure the safe riding NOTE Install the brake pad internal with its fastener a facing t...

Page 207: ...om leaking 4 Remove Screws 3 Connection screw 4 and copper washers 1 Remove Screws 1 brake hose fastening Brake hose fastener 2 3 Loosen Connection screws 4 9 Check Brake fluid level See Section FRONT BRAKE FLUID LEVEL CHECK CHAPTER 3 1 Low level LOWER 10 Check Brake lever operation Soft spongy touch Bleed the brake See Section AIR BLEEDING CHAPTER 3 LOWER NOTE Place a container under the caliper ...

Page 208: ...on BRAKE PAD REPLACEMENT 6 Remove Caliper support 1 7 Remove Pistons 1 1 CAUTION Remove the piston retainer pushing it manually Do not use a screwdriver 8 Remove Repair kit 1 dust protector V V V V V WARNING Do not try to force the removal of the piston Cover the piston with a cloth Take care to prevent the piston from being damaged when ejected from the caliper ...

Page 209: ... to collect the remaining brake fluid NOTE Remove the lock ring using a pair of pliers for internal lock ring FRONT BRAKE 6 14 V V V V V WARNING Support the motorcycle firmly preventing it from falling NOTE Before dismounting the master cylinder drain the brake fluid MASTER CYLINDER DISMOUNTING 1 Remove Connection screw 1 Copper washers 2 2 Remove Master cylinder 1 1 ...

Page 210: ... brake fluid Do not use solvents since this will result in deformations 1 Check Caliper cylinder Wear scratches Replace the caliper assembly Caliper piston Scratches corrosion wear Replace the caliper assembly 2 Check Caliper support Damage Replace the caliper assembly Caliper body Damage Replace the caliper assembly Rubber protectors Damage wear Replace Brake fluid passages caliper Blow with comp...

Page 211: ... Wear scratches Replace the master cylinder assembly 4 Check Master cylinder kit 1 Scratches wear damage Replace as an assembly 5 Check Diaphragm 1 Damage Replace 6 Check Brake hoses 1 Damage Replace 7 Measure Brake pad thickness Out of specification Replace 1 1 a Pad wear limit a 0 8 mm NOTE Replace the pad assembly in case of wear or if the wear limit has been reached ...

Page 212: ... of specification Check for warping Warping Replace the disc 1 Dial gage Brake disc thickness Out of specification Replace 1 Micrometer Brake fluid DOT 4 V V V V V WARNING All internal parts should be cleaned using new brake fluid Internal parts should be lubricated with brake fluid before being reinstalled When dismounting the caliper replace the piston retainer and the dust protector 1 1 a Brake...

Page 213: ... the piston Stop when almost finishing and connect the dust protector While moving the piston to its position mount the dust protector on the assembly Mount the dust protector ring 2 Install Caliper support 1 3 Install Pad springs 1 Brake pads 2 Brake pad pins 3 See Section BRAKE PAD REPLACEMENT 1 Install Piston retainer 1 Piston 2 Screw 18 N m 1 8 kgf m 13 0 ft lb ...

Page 214: ...ance loss Screw brake hose fastener 7 N m 0 7 kgf m 5 1 ft lb Screw 27 N m 2 7 kgf m 19 ft lb 5 Connect Brake hose 1 6 Install Screws 2 brake hose fastener 7 Fill Brake fluid CAUTION Brake fluid can damage plastic or painted surfaces Recommended brake fluid DOT 4 V V V V V WARNING 4 Install Brake caliper 1 Copper washers 2 Brake hose 3 Connection screw 4 1 2 V V V V V WARNING Route the brake hose ...

Page 215: ...1 1 ft lb MASTER CYLINDER MOUNTING V V V V V WARNING All internal parts should be cleaned using new brake fluid Internal parts should be lubricated with brake fluid when installed 9 Check Brake fluid level Brake fluid level below the LOWER mark Fill See Section BRAKE FLUID INSPECTION CHAPTER 3 1 Install Master cylinder kit 1 Lock ring 2 Dust protector 3 Plate 4 NOTE When installing the plate 4 pus...

Page 216: ...cylinder support 7 N m 0 7 kgf m 5 1 ft lb NOTE Install the master cylinder with the UP mark up Tighten the upper screw first 2 Install Master cylinder 1 Screw master cylinder cover 1 5 N m 0 15 kgf m 1 1 ft lb 4 Fill Brake fluid 5 Air bleeding Brake system See Section AIR BLEEDING CHAPTER 3 10 LOWER 7 Install Diaphragm 1 Master cylinder cover 2 Screws 3 6 Check Brake fluid level 3 Install Copper ...

Page 217: ...Brakeshoe Spring Bearing Tighteners Spacer Brakestem Spring Spacer Rearwheel Bearing Retainer Dustprotector Spacer Axle 10 11 12 13 14 15 16 17 1 8 1 9 2 0 10N m 1 0Kgf m 7 2 ft lb 80N m 8 0Kgf m 57 9 ft lb 30N m 3 0Kgf m 21 7 ft lb 1 2 3 4 5 6 7 8 9 A B C D E F H I 0 F USAR NOVA J G D Wear limit 0 8 mm E Transmission chain free play 45 60 mm B Rim dimensions 2 15 x 18 A Tire dimensions 110 100 18...

Page 218: ... firmly preventing it from falling 6 Remove Spacer dust protector 1 5 Remove Rear wheel 1 Shoe plate 2 NOTE When removing the axle the spacer 3 may fall 1 Place the motorcycle on a flat area 2 Lift the rear wheel placing a support under the engine 3 Remove Axle nut 1 Washer 2 Chain Puller 3 Adjuster 4 Pin 5 Spring 6 4 Remove Axle 1 Chain puller 2 Spacer 3 1 2 3 5 6 4 2 1 3 2 1 1 ...

Page 219: ... Wheel warping See Section INSPECTION FRONT WHEEL 4 Check Wheel bearings Retainers See Section INSPECTION FRONT WHEEL INSPECTION 1 Remove Brake shoes 1 Springs 2 NOTE Remove the shoes pulling them up using the hinge pin 3 and the camshaft stem 4 as support points in the arrow direction 2 Remove Driving lever 1 Wear indicator 2 Camshaft 3 1 3 2 3 4 1 2 ...

Page 220: ...ng the brake shoes replace the springs NOTE If the wear limit has been reached replace the shoes NOTE After using the sandpaper remove the glazed particles with a cloth 7 Check Brake shoe surface Glazed areas Remove Use coarse sandpaper 8 Measure Brake shoe thickness Out of specification Replace 1 Measurement point Brake shoe thickness 4 0 mm Wear limit 2 0 mm ...

Page 221: ... Clean using a cloth damped with solvent or thinner Polish using light sandpaper 10 Measure Internal diameter of the brake drum a Out of specification Replace CAUTION Install the camshaft and the hinge pin with a small quantity of grease Remove the excessive grease Lithium based grease MOUNTING Rear brake Reverse the REMOVAL procedures 1 Lubricate Camshaft 1 Hinge pin 2 ...

Page 222: ...ion Do not apply grease to the shoe surfaces CAUTION NOTE When installing the camshaft make sure the channel 3 is facing the wear indicator When installing the brake shoes use the hinge pin 4 and the camshaft 5 as support points pressing the shoes in the arrow direction 4 Install Driving lever 1 NOTE When installing the wear indicator place the salience in the camshaft channel and align the pointe...

Page 223: ...r applying torque If the nut hole is not aligned with the axle hole tighten the nut until the holes are aligned See Section TRANSMISSION CHAIN FREE PLAY ADJUSTMENT CHAPTER 3 3 Tighten Axle nut Transmission chain free play 45 60 mm Lithium based grease INSTALLATION Reverse the REMOVAL procedure 1 Lubricate Axle Bearings Retainer lips ...

Page 224: ...Spacer Guidebushing Externaltube 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Front fork LH E Cut the plastic belt FRONT FORK A Oil capacity each fork 352 cm3 From the top of the internal tube totally compressed without spring B Spring minimal free length 614 2 mm C Oil level each fork 161 mm From the top of the internal tube totallycompressed without spring 20N m 2 0 Kgf m 14 ft lb 23N m 2 3Kgf m 17...

Page 225: ...mly preventing it from falling 1 Place the motorcycle on a flat area 2 Lift the front wheel placing a support under the engine 3 Remove Front wheel See Section REMOVAL FRONT WHEEL 4 Remove Screws 1 brake hose fastener Fastener 2 brake hose Screw 3 brake caliper 6 Remove Front forks 1 5 Loosen Screws 1 upper board Screws 2 lower board 1 1 2 2 1 3 ...

Page 226: ...crewdriver Take care not to scratch the external tube NOTE Press the spring seat and remove the lock ring Take care because the part may jump 3 Drain Fork oil 4 Remove Dust protector 1 1 Remove Dust over 1 2 Remove Lock ring 1 Spring seat 2 Spring 3 ...

Page 227: ... 01294 NOTE Use a thin screwdriver Take care not to scratch the internal tube 5 Remove Lock 1 6 Remove Screw 1 Washer 2 NOTE Hold the damper stem to loosen the screw from the damper stem using the T wrench 3 and the fastener 4 7 Remove Damper stem 1 Return spring 2 ...

Page 228: ...When removing do not force the internal tube up to the end of stroke since this may damage the oil retainer Removal steps Hold the fork horizontally Fasten the external tube in a bench vise protecting its surface Carefully pull the internal tube vigorously 9 Remove Retainer 1 Spacer 2 Guide bushing 3 Oil retainer 4 ...

Page 229: ...2 1 1 2 INSPECTION V V V V V WARNING Do not try to straighten out the damper stem since this may impair the tube V V V V V WARNING Do not try to straighten out the internal tube since it may be impaired 1 Check Internal tube 1 External tube 2 Scratches warping damage Replace 4 Check Return spring 1 Damage Replace 5 Check Oil retainer 1 O ring 2 Damage Replace 1 2 1 Spring free length a 614 2 mm ...

Page 230: ...T FORK 6 35 NOTE When mounting the front fork the following new parts should be used Guide bushing Retainer Dust protector Clean all components before mounting 1 Install Oil retainer 1 on the damper stem 2 Reverse the DISMOUNTING procedures MOUNTING 1 2 1 2 4 3 3 Lubricate Internal tube external surface 3 4 Install Internal tube in the external tube 4 5 Tighten Screw damper stem Hold the damper st...

Page 231: ...l Retainer 1 Use the sliding hammer 2 and the adapter 3 Retainer 3 NOTE Install the lock ring 1 properly in the external tube channel 2 9 Install Lock ring 1 Install the retainer with the numbered face up NOTE Before installing the retainer apply lithium based grease to the retainer lips CAUTION Sliding hammer 90890 01367 Adapter 36 mm 90890 01370 1 ...

Page 232: ... Install Dust protector 1 Use the sliding hammer 1 and the adapter 1 12 Install Spring 1 Spring seat 2 Lock ring 3 1 Internal tube 2 Oil 11 Fill Front fork Sliding hammer 90890 01367 Adapter 36 mm 90890 01370 Oil level at 161 mm From the top of the internal tube with the external tube totally compressed without spring 1 3 ...

Page 233: ...he lock ring INSTALLATION Always use a new plastic belt NOTE Install the tie wrap and the plastic belt as shown in the figure Cut the plastic belt end 3 13 Install Dust cover 1 LH Tie wrap 2 Plastic belt 3 V V V V V WARNING Reverse the REMOVAL procedure NOTE Adjust the internal tube flush a with the top of the upper handle bars board 1 Install Front fork Tighten the board screws temporarily ...

Page 234: ... Screws 1 brake caliper Fastener 2 brake hose Screws 3 brake hose fastener Screw lower board 20 N m 2 0 kg m 14 ft lb Screw upper board 23 N m 2 3 kg m 17 ft lb Screw brake caliper 35 N m 3 5 kg m 25 ft lb Screw fastener 7 N m 0 7 kg m 5 1 ft lb Nut axle 80 N m 8 0 kgf m 58 ft lb Route the hose properly in order to ensure the safe riding V V V V V WARNING ...

Page 235: ...g nut Bearing cap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Bearing Fairing Cable support Lower support Brake hose fastener 23 N m 2 3 kgf m 16 6 ft lb 7 N m 0 7 kgf m 5 1 ft lb Pitch A Tighten the adjusting nut 43 N m 4 3 kgf m 31 ft lb Loosen 1 turn Tighten 6 5 N m 0 65 kgf m 4 7 ft lb 20 N m 2 0 kgf m 14 4 ft lb 110 N m 11 kgf m 79 7 ft lb 1 2 3 5 4 6 7 8 9 10 11 12 13 15 14 ...

Page 236: ...emove Master cylinder screws 2 Master cylinder 3 Support the motorcycle firmly preventing it from falling V V V V V WARNING 1 Place the motorcycle on a flat area 4 Remove Starting switch 4 LD 6 Remove Plastic belt 7 Loosen Lock nut 1 clutch cable Adjuster 2 clutch cable 8 Remove Clutch cable 3 Clutch switch 4 2 1 3 1 4 1 2 3 4 ...

Page 237: ...gine 3 Remove Handle bars See Section REMOVAL HANDLE BARS 4 Remove Fuel tank See Section SEAT FUEL TANK AND COVERS CHAPTER 3 5 Remove Front wheel See Section REMOVAL FRONT WHEEL Support the motorcycle firmly preventing it from falling STEERING COLUMN 10 Remove Handle bars Throttle grip V V V V V WARNING 9 Remove Engine stop switch 1 1 ...

Page 238: ...FRAME 9 Remove Main switch 1 1 6 43 6 Remove Fender 1 7 Remove Front frock See Section REMOVAL FRONT FORK 8 Disconnect Main harness connectors STEERING COLUMN AND HANDLE BARS 1 1 1 1 1 ...

Page 239: ...remo ve the ring and adjusting nuts 10 Remover Lock washer 2 Adjusting nut 3 Washer 4 Ring nut 5 Bearing cap 6 Bearing 7 Adjusting nut wrench 90890 01403 6 44 3 9 2 3 4 5 6 7 8 1 1 Support the lower board 3 preventing it from falling V V V V V WARNING 3 STEERING COLUMN AND HANDLE BARS ...

Page 240: ...Apply a thin layer of rubber glue to the left end of the new handle bars Install the grips Do not try to straighten out a bent handle bars since it may be impaired resulting in a hazardous condition INSPECTION 1 Check Handle bars 1 Warping cracks damage Replace V V V V V WARNING 1 Do not touch the handle bars until the glue is sufficiently cured in order to ensure that the grip is firmly in place ...

Page 241: ...ce bearings races and dust protectors as an assembly Installing bearings and races inclined may damage the frame Therefore install these components horizontally Do not beat balls or bearing faces Replacement steps Remove the bearing races from its fittings on the tube using a long stem 1 and a hammer Remove the bearing race from the lower board using a chisel 2 and a hammer Install the new bearing...

Page 242: ...e REMOVAL procedures 1 Lubricate Handle bars Lithium based grease Screw handle bars 15 N m 1 5 kgf m 11 ft lb 2 1 3 Tighten the front handle bars fastener screws first and then tighten the rear screws 2 Front CAUTION NOTE The upper handle bars fastener should be installed with the punch mark 1 towards the front part NOTE Align the mark 2 on the handle bars 1 with the upper end of the lower right h...

Page 243: ...der support with the UP mark up Tighten the upper screw first 6 Install Brake master cylinder 3 NOTE When installing the starting switch make sure it is properly fastened 5 Install Throttle grip 1 Starting switch 2 4 Install Plastic belts Throttle case V V V V V WARNING Screw master cylinder support 7 N m 0 7 kgf m 5 1 ft lb UP 2 4 3 1 NOTE Apply a thin layer of lithium based grease to the end of ...

Page 244: ...oard 1 Upper bearing 2 Bearing cap 3 Ring nut 4 Washer 5 Adjusting nut 6 Steering Column Reverse the REMOVAL procedures 1 Lubricate Lower and upper bearings 1 Bearing race 2 See Section CLUTCH ADJUSTMENT CHAPTER 3 Adjusting nut wrench 90890 01403 Lithium based grease STEERING COLUMN AND HANDLE BARS 1 2 1 2 3 4 5 6 Free play 10 15 mm at the grip end ...

Page 245: ...e right and to the left making sure there is no irregular movement Then loosen the nut one turn Tighten the adjusting nut using the adjusting nut wrench Adjusting nut initial torque 43 N m 4 3 kgf m 31 1 ft lb Adjusting nut final torque 6 5 N m 0 65 kgf m 4 7 ft lb V V V V V WARNING 1 NOTE Check the steering column turning it from side to side after its adjustment If the movement is difficult loos...

Page 246: ...HANDLE BARS 6 51 NOTE Tighten the lower and upper board screws temporarily 7 Install Front fork See Section INSTALLATION FRONT FORK 6 Connect Main switch connector 8 Tighten Upper board anchor nut 1 Upper board anchor nut 110 N m 11 kgf m 79 7 ft lb 1 ...

Page 247: ...7 kgf m 5 0 ft lb 6 52 14 Install Fuel tank See Section SEAT FUEL TANK AND COVERS CHAPTER 3 13 Install Handle bars See Section INSTALLATION HANDLE BARS 12 Install Front wheel See Section INSTALLATION FRONT WHEEL Axle nut 80 N m 8 0 kgf m 57 9 ft lb STEERING COLUMN AND HANDLE BARS 1 Screw brake caliper 40 N m 4 0 kgf m 28 9 ft lb Screw fastener 7 N m 0 7 kgf m 5 1 ft lb Screw handle bars 23 N m 2 3...

Page 248: ...FRAME 6 53 REAR SHOCK ABSORBER AND BALANCE REAR SHOCK ABSORBER AND BALANCE 1 Shock absorber 35 N m 3 5 kgf m 25 4 ft lb ...

Page 249: ...w shock absorber relay arm Screw relay arm connection relay arm Screw frame relay arm Relay arm connection REAR SHOCK ABSORBER AND BALANCE Relay arm 2 1 6 54 10 52 5N m 5 2Kgf m 37 6 ft lb 7 N m 0 7 Kgf m 5 1 ft lb 80 N m 8 0 Kgf m 58 ft lb 34 5 N m 3 4 Kgf m 25 ft lb 52 5N m 5 2Kgf m 37 6 ft lb 1 0 A 7 6 2 8 9 B 3 5 E D F E F E F J E F K 4 4 N m 0 4 Kgf m 2 9 ft lb 52 5N m 5 2Kgf m 37 6 ft lb A 0...

Page 250: ...mation before handling The manufacturer assumes no liability for injuri es or damage resulting from mishandling Do not try to pierce or open the shock absorber assembly Do not subject the shock absorber to flames or other high temperature sources since this may result in explosion of the unit due to excessive gas pressure Do not deform or damage the cylinder in any way Damage to the cylinder will ...

Page 251: ...ut 1 Washer 2 Lower screw 3 1 Place the motorcycle on a flat area 2 Remove LH side cover Seat See Section SEAT FUEL TANK AND COVERS CHAPTER 3 3 Lift the rear wheel placing a support under the engine 4 Remove Air filter box 2 Support the motorcycle firmly preventing it from falling V V V V V WARNING Shock Absorber 1 2 3 4 3 2 1 2 ...

Page 252: ...ower nut 1 Washer 2 Lower screw 3 Upper nut 4 Washer 5 Upper screw 6 Rear shock absorber 7 5 Remove Rear wheel See Section REMOVAL REAR WHEEL 1 Place the motorcycle on a flat area 2 Lifttherearwheelplacingasupportundertheengine 3 Remove LH side cover Seat Air filter box See Section SEAT FUEL TANK AND COVERS CHAPTER 3 Support the motorcycle firmly preventing it from falling V V V V V WARNING 1 2 3 ...

Page 253: ... SHOCK ABSORBER AND BALANCE A B 1 Check the side free play A moving the balance from side to side While checking the free play verify the internal spacer bearing washer and stop cap Check the vertical displacement B of the rear balance moving it up and down In case of irregular movement check the internal spacer bearing washer and stop cap ...

Page 254: ...s Replace 3 Check Relay arm Relay arm connection Warping cracks damage Replace Dust protector Wear damage Replace 2 Check Rear balance 1 Warping cracks damage Replace Spacers 2 Bushings Shims Wear damage Replace This shock absorber contains nitrogen gas at high pressure Do not disassemble the shock absorber V V V V V WARNING 1 Check Shock absorber 1 Leakage damage Replace 2 2 1 1 1 1 ...

Page 255: ...sed grease 6 60 REAR SHOCK ABSORBER AND BALANCE 2 Install Shock absorber 1 upper part 3 Tighten Nut 2 4 Install Shock absorber 1 lower part 5 Tighten Nut 2 6 Install Air filter box Seat LH side cover 1 2 1 2 Nut 2 2 2 2 2 lower part 34 5 N m 3 4 kgf m 25 ft lb Nut 2 2 2 2 2 upper part 34 5 N m 3 4 kgf m 25 ft lb ...

Page 256: ...OCK ABSORBER AND BALANCE 5 Tighten Balance shaft 1 3 Tighten Nut balance relay arm 4 Install Rubber caps 1 Lubricate Retainer Bearings Stop caps inside Spacers Shafts Hinges Lithium based grease Nut 52 N m 5 2 kgf m 37 6 ft lb 1 6 Tighten Nut frame relay arm connection Nut 1 80 N m 8 0 kgf m 48 ft lb Nut 52 N m 5 2 kgf m 37 6 ft lb ...

Page 257: ...ission chain free play See Section TRANSMISSION CHAIN FREE PLAY ADJUSTMENT CHAPTER 3 7 Tighten Bolt 1 chain guide 6 62 REAR SHOCK ABSORBER AND BALANCE 11 Install Air filter box LH side cover Seat See Section SEAT FUEL TANK AND COVERS CHAPTER 3 Bolt 1 1 1 1 1 7 N m 0 7 kgf m 5 0 ft lb Transmission chain free play 45 60 mm 2 ...

Page 258: ...r wheel Sprocket Chain seam Transmission chain Pinion gear fastener Pinion gear 1 2 3 4 5 6 10N m 1 0Kgf m 7 2 ft lb E USE A NEW ONE 34 5 N m 3 4Kgf m 25 ft lb B A Transmission chain C D Type 520V2 Number of links 106 Chain free play 45 60 mm 2 6 3 5 1 4 ...

Page 259: ...e screw pinion gear while actuating the rear brake 4 Remove Screws 1 pinion gear Pinion gear fastener 2 Pinion gear 3 3 Loosen Transmission chain 2 Remove Shift lever 1 Pinion gear cover 3 Support the motorcycle firmly preventing it from falling REMOVAL 1 Lift the rear wheel placing a support under the engine V V V V V WARNING 3 2 1 2 3 1 ...

Page 260: ...ION 1 Measure 10 link length a Out of specification Replace the chain 8 Remove Rear wheel 7 Remove Link plate 1 O ring 2 Seam 3 Transmission chain 4 6 Remove Chain seam Use the chain pin puller 1 10 link length limit 119 7 mm 1 Chain pin puller 90890 01286 1 2 3 2 4 ...

Page 261: ...e the chain in kerosene and brush it removing the dirt Then dry the chain CAUTION NOTE Pull the chain manually in order to measure it The measurement a of the 10 links should be taken between the internal rollers 1 to 11 Measure the 10 links at two or three different positions This motorcycle is equipped with a transmission chain with small rubber O rings 1 between its plates Cleaning with steam h...

Page 262: ...e screws 1 Remove sprocket Install a new sprocket 5 Check Pinion gear Sprocket Wear over of tooth Replace ratio Inclined tooth Replace ratio 2 Correct 3 Roller 4 Pinion gear Screws sprocket 34 5 N m 3 45 kgf m 25 ft lb TRANSMISSION RATIO 6 67 Reverse the REMOVAL procedures 1 Lubricate Transmission chain Chain seam new 1 Transmission chain lubricant Engine oil SAE 20W40 ...

Page 263: ...direction shown in the figure 5 Install Chain seam lock 1 4 Install Chain seam 1 O ring 2 Link plate 3 Use the chain pin puller 4 3 Install Transmission chain 1 Pinion gear 2 Pinion gear fastener 3 Screws pinion gear 4 CAUTION Chain pin puller 90890 01286 6 68 2 1 2 2 3 1 2 4 3 A 1 Pinion gear screw 10 N m 1 0 kgf m 7 2 ft lb ...

Page 264: ...hten Axle nut Chain free play 45 60 mm Axle nut 80 N m 8 0 kgf m 57 9 ft lb 1 3 2 A too small free play will result in overload on the engine and other essential parts Keep the free play within the specified limits CAUTION Screw shift lever 10 N m 1 0 kgf m 7 2 ft lb Screw pinion gear cover 10 N m 1 0 kgf m 7 2 ft lb ...

Page 265: ...CKS 7 3 UNDERSTANDING THE SWITCH CONNECTIONS 7 3 CHECKING THE SWITCH CONNECTIONS 7 4 IGNITION SYSTEM 7 6 IGNITION CIRCUIT OPERATION 7 6 TROUBLESHOOTING 7 7 ELECTRIC STARTING SYSTEM 7 13 TROUBLESHOOTING 7 13 STARTER MOTOR 7 17 CHARGING SYSTEM 7 24 TROUBLESHOOTING 7 24 CHAPTER 7 ELECTRIC SYSTEM ...

Page 266: ...in fuse Main switch Neutral switch Clutch switch C D I unit Ignition coil Spark plug 8 9 10 11 12 13 14 White W Black B Red R Green G Blue Yellow LY Orange Light blue Sb Br Yellow Y Black White BW Black Yellow BY Brown White BrW Blue White LW Blue Yellow LY Red White RW O Brown Red Black RB Blue L 1 2 3 5 6 7 8 9 0 A B C D W R B G LY B R B LW B O B B Br Br B B 4 LY L B RB RB R Br RB Br ...

Page 267: ...20 IGNITION COIL Primary winding resistance 0 18 0 28 at 20 C Secondary winding resistance 6 32 9 48 k at 20 C Ω Ω Harness C D I unit Battery Neutral switch Main switch Ignition coil Spark plug cap 1 2 3 4 5 6 7 Rectifier Regulator Starting relay Fuse 8 9 10 6 7 2 8 5 1 10 9 4 3 ...

Page 268: ...ections are shown The column to the left indicates the switch position and the upper row indicates the colors of the wires connected to the switch terminals O O indicates the terminals between which there is electrical continuity UNDERSTANDING THE SWITCH CONNECTIONS Check the switches for continuity between terminals Read the following text in order to check the switches properly Br L R L B L Y LO...

Page 269: ... If a wire is disconnected repair it Before checking the switches see the connection table and check the color combinations To understand how to check the switches see the following example CAUTION Do not disconnect the couplings by pulling them by the wires otherwise the wires may separate from their terminals NOTE If the coupling is dirty with mud or dust blow it with compressed air ...

Page 270: ...aforementioned 4 Check for continuity between wires R and Br L in the switch Br L R L B L Y LOCK OFF ON L Y R L B Br L 5 If data other than that specified is read replace the switch Checking steps Set the switch to ON and OFF positions Set the multimeter to x1 Connect the multimeter terminal to the wire R terminal in the connector and terminal to the wire Br terminal W Check the continuity between...

Page 271: ...l switch and neutral light If the ENGINE STOP switch and the main switch are set to ON the spark will flash only if The transmission is set to neutral the neutral switch is ON Ignition control unit Thyristor Neutral switch Ignition coil Spark plug 7 8 9 10 11 Bypass current Field coil current With the motorcycle engaged the starting relay will not activate the starter motor preventing the engine f...

Page 272: ...Spark plug 9 Neutral switch 4 Spark 10 Clutch switch 5 Cap resistance 11 Connections 6 Ignition coil resistance IF THE IGNITION SYSTEM STOPS OPERATING WITH NO SPARK OR INTERMITTENT SPARKS 1 Fuse Remove fuse Connect tester x1 to the fuse Check the fuse for continuity See Section FUSE INSPECTION CHAPTER 3 Ω Defective fuse replace 2 Battery Check battery conditions Minimum tension 12 8 V Clean termin...

Page 273: ...alibrate the electrode clearance INCORRECT CORRECT Electrode clearance 0 6 0 7 mm 4 Spark clearance Disconnect the spark plug cap Connect the dynamic spark tester 1 Spark plug 3 Set the button to ON The ignition system is in good conditions ACCORDING TO SPECIFICATION OUT OF SPECIFICATION OR NO SPARK Check spark Start the engine and increase the clearance until the spark become intermittent Minimum...

Page 274: ...ary winding resistance Cap resistance 10 K at 20 C Ω Disconnect the coil from its wires Connect the multimeter x1 to the coil Terminal terminal 1 Terminal body ground 2 Ω Primary winding resistance 0 18 0 28 at 20 C Ω ACCORDING TO SPECIFICATION 5 Cap resistance Remove cap Connect the multimeter x1 to the cap Ω ...

Page 275: ...uld not be tested See Section SWITCH CHECKS CORRECT Ignition coil defective Replace INCORRECT Check the secondary winding resistance Connect the multimeter x1 to the ignition coil Terminal spark plug cable Terminal body ground Ω ACCORDING TO SPECIFICATIONS Secondary winding resistance 6 32k 9 48k at 20 C Ω Main switch defective Replace INCORRECT ON R Br OFF LED RB Br ...

Page 276: ...om the harness Check the continuity between wires BLACK WHITE B W and BLACK B See Section SWITCH CHECKS CORRECT Neutral switch defective Replace INCORRECT 9 Neutral switch Disconnect the neutral switch wire from the harness Check the continuity between wires LIGHT BLUE and GROUND See Section SWITCH CHECKS CORRECT ON B BW OFF NEUTRAL Sb ENGAGED ...

Page 277: ...e coil resistance Terminal Blue Yellow wire Terminal Green wire Disconnect the field coil connector from the harness Connect the multimeter x 100 to the field coil terminal Check the pulse coil resistance Ω Ω Ω Ω Ω Ω 11 Connections Check the ignition system connections See Section SWITCH CHECKS Correct INCORRECT CONNECTION CORRECT Replace the CDI unit ...

Page 278: ...e starting the analysis 1 Side covers 2 Seat Use the following device for analysis Multimeter 90890 03112 1 Fuse Remove fuse Connect the multimeter x1 to the fuse Check the fuse for continuity See Section FUSE INSPECTION CHAPTER 3 Ω Defective fuse replace 2 Battery Check battery conditions See Section BATTERY INSPECTION CHAPTER 3 Minimum tension 12 8 V Clean terminals Recharge or replace battery R...

Page 279: ...tarting relay Disconnect the starting relay connector from the harness Connect the battery to the starting relay using jumper wires 1 Check the starter motor operation Starting relay defective Replace DOES NOT START Take care not to invert the connections Take care not to short circuit the positive and negative terminals when connecting the battery and relay V WARNING The jumper wire capacity shou...

Page 280: ...een wires LIGHT BLUE 1 and GROUND See Section SWITCH CHECKS CORRECT 6 Clutch switch Disconnect the clutch switch connector from the harness Check the continuity between wires BLUE YELLOW LY and BLACK B See Section SWITCH CHECKS Neutral switch defective Replace INCORRECT CORRECT Clutch switch defective Replace INCORRECT ON B LY OFF ...

Page 281: ...ng switch Disconnect the handle bars switch connector RH from the harness Check the starting switch continuity between the wires BLUE WHITE LW and BLUE L See Section SWITCH CHECKS ON L LW OFF 8 Connections Check the ignition system connections See Section SWITCH CHECKS Correct INCORRECT CONNECTION ...

Page 282: ... Rear support Spring Brush assembly O ring Stator assembly 1 2 3 4 5 6 Rotor assembly Shim Lock washer Front support O ring 7 8 9 10 11 Minimum brush length limit 3 5 mm Switch wear limit 21 0 mm Mica depth 1 5 mm Rotor coil resistance 0 017 0 021 at 20 C Ω A B C D ...

Page 283: ...GINE OIL CHANGE CHAPTER 3 2 Disconnect Battery negative cable 1 See Section BATTERY INSPECTION CHAPTER 3 3 Remove Starter motor cable 1 Starter motor 2 Disassembly 1 Trace identification marks 1 on the supports in order to facilitate the assembly as shown in the figure 2 Remove Front support 1 ...

Page 284: ... 21 mm Inspection and repairs 1 Check Armature Dirt Clean using a sandpaper 600 2 Measure Armature diameter a Out of specification Replace starter motor 3 Remove Lock washer 1 Shim 2 4 Remove Rear support 1 5 Remove Rotor assembly 1 Stator assembly 2 6 Remove Springs 1 ...

Page 285: ...e side is welded Checking steps Connect the multimeter as shown in order to check the continuity 1 and insulation 2 Measure the rotor resistance If the resistance is not correct replace the starter motor 4 Check Rotor coil insulation continuity Defects Replace starter motor Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Rotor coil resistance Continuity test 1 0 017 0 021 at 20 C Insulation test 2 More than 1M at 20 C 5 Meas...

Page 286: ... the rotor press the brushes using a thin screwdriver in order to prevent damage Spring load 560 840g 1 5 6 4 2 3 1 Mounting Reverse the REMOVAL procedures 1 Install Spring 1 Brushes 2 and 3 NOTE When installing the brush 2 route its wire outside the salience 4 on the brush spring fastener When installing the brush 3 rest the wire terminal of brush 5 on the salience 6 beside the brush spring faste...

Page 287: ...e O ring 1 4 1 1 2 3 1 CAUTION Always use new O rings 3 Install O ring 1 NOTE Align the stator marks with those on the rear support 4 Install Stator assembly 1 5 Install Lock washer 1 Shim 2 Front support 3 NOTE Align the lock washer salience 1 with the slot on the front support 3 and install Align the stator marks 4 with those on the supports ...

Page 288: ... 55 N m 5 5 Kgf m 40 2 ft Ib 2 Install Starter motor 1 Starter motor cable 2 3 Connect Battery negative cable See Section BATTERY INSPECTION CHAPTER 3 4 Install Crankcase guard See Section ENGINE OIL CHANGE CHAPTER 3 Bolt starter motor 7 N m 0 7 Kgf m 5 1 ft Ib ...

Page 289: ...ection FUSE INSPECTION CHAPTER 3 Ω Defective fuse replace NO CONTINUITY CONTINUITY NOTE Remove the following parts before starting the analysis 1 Side covers RH 2 Seat Use the following device for analysis Inductive tachometer 90890 03113 Multimeter 90890 03112 2 Battery Check battery conditions See Section BATTERY INSPECTION CHAPTER 3 Minimum tension 12 8 V Clean terminals Recharge or replace bat...

Page 290: ...nductive tachometer to the spark plug cable Connect the multimeter DC20V to the battery Terminal Battery terminal Terminal Battery terminal NOTE Use a fully charged battery Charging voltage 14 0V at 5 000 rpm 4 Charging coil resistance Terminal white wire W Terminal ground B Ω Disconnect the charging coil connector from the harness Connect the multimeter x1 to the charging coil Measure the chargin...

Page 291: ...ging coil resistance 0 72 1 08 at 20 C Ω Ω Ω Ω Ω Charging coil defective Replace OUT OF SPECIFICATIONS 5 Connections Check the charging system connections See Section CIRCUIT DIAGRAM Correct INCORRECT CONNECTION OUT OF SPECIFICATIONS Replace regulator rectifier ...

Page 292: ...MANCE AT MEDIUM AND HIGH SPEEDS 8 3 GEAR SHIFTING DIFFICULTY 8 4 UNSTABLE GEAR 8 4 CLUTCH PROBLEMS 8 4 SLIPPING CLUTCH 8 4 DRAGGING CLUTCH 8 5 OVERHEATING 8 5 OVERHEATING 8 5 BRAKE FAULT 8 6 DEFECTIVE BRAKING SYSTEM 8 6 LEAKAGE ON THE FRONT FORK AND MALFUNCTION 8 6 OIL LEAKAGE 8 6 MALFUNCTION 8 6 UNSTABLE DRIVING 8 7 CHAPTER 8 TROUBLESHOOTING ...

Page 293: ... Empty Clogged fuel filter Clogged breather Fuel contaminated with water or other substance Clogged fuel hose Clogged fuel filter Fuel contaminated with water or other substance Clogged low speed adjusting nozzle Clogged passage in the air adjusting nozzle False air entrance Deformed float Worn float valve The float valve does not seal Irregular fuel level Wrong low speed adjusting nozzle Clogged ...

Page 294: ...ked crankshaft ELECTRIC SYSTEM Spark plug Ignition coil C D I system Switch and wires Starter motor POSSIBLE CAUSE Wrong cap Worn electrode Broken cable between terminals Wrong thermal grade Defective cap Broken or shorted primary secondary winding Defective spark plug cable Broken body Defective C D I unit Defective pulse coil Defective charging coil Broken crankshaft key Defective main switch De...

Page 295: ...ged air adjusting nozzle Idle speed improperly adjusted Carburation Defective battery Defective spark plug Defective C D I unit Defective pulse coil Defective charging coil Defective ignition coil Improper valve clearance POOR PERFORMANCE AT MEDIUM AND HIGH SPEEDS Carburetor Air filter POSSIBLE CAUSE Wrong piston lock position Diaphragm malfunction Improper fuel level Loose or clogged high speed a...

Page 296: ...d transmission UNSTABLE GEAR Shift shaft Fork Shifting fork Transmission POSSIBLE CAUSE Worn shaft stem Improper stop stem return Worn fork Improper thrust washer clearance Worn shifting fork channel Worn clutch claw SLIPPING CLUTCH Clutch Engine oil POSSIBLE CAUSE Loose clutch spring Fatigue in the clutch spring Worn clutch disc Worn separator Improperly mounted clutch Low oil level Low viscosity...

Page 297: ...tch hub High oil level High viscosity oil Deteriorated oil OVERHEATING OVERHEATING Ignition system Fuel system Compression system Engine oil Brake POSSIBLE CAUSE Improper electrode clearance Wrong spark plug thermal grade Defective C D I unit Wrong high speed adjusting nozzle Improper fuel level Clogged air filter element Excessive carbonization Improper oil level Improper oil viscosity Low qualit...

Page 298: ... spring Oil or grease on brake shoe Oil or grease on brake drum LEAKAGE ON THE FRONT FORK AND MALFUNCTION OIL LEAKAGE POSSIBLE CAUSE The internal tube is corroded bent or damaged The external tube is damaged or broken Damaged retainer lip Improperly installed retainer High oil level Loose stem setscrew Damaged spring seat O ring Loose drain bolt Damaged drain bolt gasket MALFUNCTION POSSIBLE CAUSE...

Page 299: ...ent steering column Improperly installed steering column Adjusting nut not adjusted Damaged raceway or roller bearing Different oil levels Broken spring Twisted front forks Different pressure levels Improper pressure Uneven wear Twisted Damaged pipe Improperly installed raceway or roller bearings Worn spacer or roller bearings Bent or damaged Fatigue in spring 1 Oil and gas leakage Improperly adju...

Page 300: ...YAMAHA MOTOR DO BRASIL LTDA PRINTED IN BRAZIL ...

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