Table of Contents

Advertisement

Quick Links

'03
TZR50
X-POWER
'03
5WX-AE1
SERVICE MANUAL

Advertisement

Table of Contents
loading

Summary of Contents for Yamaha TZR50 '03

  • Page 1 ’03 TZR50 X-POWER ’03 5WX-AE1 SERVICE MANUAL...
  • Page 2 TZR50’03 / X-POWER’03 SERVICE MANUAL © 2003 by Yamaha Motor España, S.A. 1st Edition, December 2003 All rights reserved Any reproduction or non-authorised use of this material is expressly prohibited without the consent of Yamaha Motor España, S.A.
  • Page 3: How To Use This Manual

    WARNING This manual has been issued by Yamaha Motor España, S.A., mainly for its use by Yamaha /MBK dealers and their qualified mechanics. It is not possible to include the full training of a mechanic in a manual, for which reason we take it for granted that the persons who use...
  • Page 4 MANUAL FORMAT All the procedures included in this manual are arranged in sequential format, divided into stages. The information presented has been grouped together in order to give the mecha- nic a reference that is easy to read and convenient to handle, containing exhaustive expla- nations of all the operations for dismantling, repair, assembly and inspection.
  • Page 5 SYMBOLS ILLUSTRATED (See the ilustration) SPEC INFO Symbols are designed as thumb tabs, in order to show the number of the chapter INSP/ and index General information Specifications Regular inspection and adjustments General engine servicing CARB CHAS Carburation Chassis Electrical system Troubleshooting - location and repair of ELEC TRBL...
  • Page 6 INDEX GENERAL INFORMATION GEN/ INFO SPECIFICATIONS SPEC REGULAR INSPECTIONS INSP AND ADJUSTMENTS DISMANTLING THE ENGINE COOLING SYSTEM COOL CARBURATION CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC...
  • Page 7 GEN/ INFO...
  • Page 8: Table Of Contents

    GEN/ INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION OF THE MOTORCYCLE …………………………………1-1 FRAME SERIAL NUMBER ……………………………………………………1-1 ENGINE SERIAL NUMBER……………………………………………………1-1 IMPORTANT INFORMATION …………………………………………………1-2 PREPARATION FOR REMOVAL AND DISMANTLING ……………………1-2 SPARES …………………………………………………………………………1-3 GASKETS, OIL SEALS AND O RINGS………………………………………1-3 WASHERS, LOCKING PLATES AND SPLIT PINS …………………………1-3 BEARINGS AND OIL SEALS …………………………………………………1-3 CIRCLIPS ………………………………………………………………………1-4 SPECIAL TOOLS …………………………………………………………………1-4...
  • Page 9: General Information

    GEN/ IDENTIFICATION OF THE MOTORCYCLE INFO GENERAL INFORMATION IDENTIFICATION OF THE MOTORCYCLE FRAME SERIAL NUMBER The chassis serial number is printed on the right-hand side of the steering head. ENGINE SERIAL NUMBER The engine serial number is printed on the left-hand side of the engine.
  • Page 10: Important Information

    GEN/ IMPORTANT INFORMATION INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISMANTLING 1. Before starting removal and dismantling, remove any dirt, mud, dust and foreign bodies. 2. Use appropriate tools and cleaning equip- ment See “SPECIAL TOOLS” 3. When dismantling the motorcycle, keep any matching parts together.
  • Page 11: Spares

    GEN/ IMPORTANT INFORMATION INFO SPARES 1. Use only original Yamaha/MBK spares for all changes. Use the oils and /or greases recommended Yamaha/MBK assembly and adjustments. Other makes may have the same function and appearan- ce but nevertheless be of lower quality.
  • Page 12: Circlips

    GEN/ SPECIAL TOOLS INFO CIRCLIPS 1. All circlips must be carefully inspected befo- re installing these again. Always change the ones on the piston rods when these are worn. Change any circlip that has become deformed. When installing a circlip make sure that the sharp edge is facing opposite the direction of the thrust that this receives.
  • Page 13 GEN/ SPECIAL TOOLS INFO 2. Flywheel (rotor) holding tool Ref. 90890-01235 This tool is used when the securing screw for the magnetic flywheel magneto has to be tigh- tened or loosened. 3. Magnetic flywheel extractor Ref. 90890-11031 This tool is used for dismantling the magnetic flywheel.
  • Page 14 GEN/ SPECIAL TOOLS INFO 7. Crankcase remover tool Ref. 90890-11030 This tool is used for dismantling the crankshaft or removing the crankcase. 8. Tools for installing the crankshaft. Ref. 90890-01284 These tools are used for installing the cranks- haft. 9. Crankcase installer (Magnetic flywheel side) Ref.
  • Page 15: For Chassis Service

    GEN/ SPECIAL TOOLS INFO 12. Seal installer (Clutch lever) Ref. 90890-11035 13. Seal installer (Clutch side of crankshaft) Ref. 90890-11036) FOR CHASSIS SERVICE 1. “T” tool ––––––––––––––––––––––––––––– Ref. 90890-01326––––––––––––––––––––– Front fork cylinder holder –––––––––––––– Ref. 90890-01294 This tool is used to loosen and tighten the fixing bolts for the cylinders of the front fork.
  • Page 16: For Electrical Components

    GEN/ SPECIAL TOOLS INFO FOR ELECTRICAL COMPONENTS 1. Pocket tester Ref. 90890-03112 This tester is an invaluable help for checking the electrical system. 2. Stroboscopic lamp Ref. 90891-03141 This tool is required for checking the ignition advance. OTHER TOOLS 1. Micrometer Ref.
  • Page 18 SPEC...
  • Page 19 SPEC CHAPTER 2 GENERAL SPECIFICATIONS SPECIFICATIONS ………………………………………………………………2-1 GENERAL SPECIFICATIONS …………………………………………………2-1 MAINTENANCE SPECIFICATIONS ……………………………………………2-4 ENGINE …………………………………………………………………………2-4 CHASSIS ………………………………………………………………………2-7 TIGHTENING TORQUES ……………………………………………………2-9 ELECTRICAL SYSTEM ………………………………………………………2-11 GENERAL SPECIFICATIONS OF TIGHTENING TORQUES/ DEFINITION OF THE UNITS …………………………………………………2-13 LUBRICATION POINTS AND TYPE OF LUBRICANT ……………………2-14 ENGINE ………………………………………………………………………2-14 CHASSIS ………………………………………………………………………2-15 CABLE ROUTING ………………………………………………………………2-16...
  • Page 20: General Specifications

    Compression ratio 6.85:1 Starting system Electric Lubrication system Independent lubrication Motor oil Type Yamaha 2 stroke oil or oil for air-cooled 2 stro- ke engines Capacity 1.35 L Transmission oil: Type Engine oil SAE 10W30 SE type Capacity: Regular oil change 0.75 L...
  • Page 21 SPEC GENERAL SPECIFICATIONS Model TZR50 / X-POWER Fuel: Type Unleaded gasoline Capacity of the fuel tank: Full 13.8 L Reserve 2.2 L Carburettor : Type / Number PHBN 16 NS/1 Manufacturer DELLORTO Spark plug Type / Number BR9ES/1 piece Manufacturer N.G.K.
  • Page 22 SPEC GENERAL SPECIFICATIONS Model TZR50 / X-POWER Brakes: Type of front brake Single disc Front brake action Right hand Type of rear brake Single disc Rear brake action Right foot Suspension: Front suspension type Telescopic fork Rear suspension type Swinging arm (Monocross suspension) Damping: Front shock absorber Spiral spring / oil shock absorber...
  • Page 23: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model TZR50 / X-POWER Cylinder head: Max. waparge 0.03 mm * Lines indicate straightedge measurement. Cylinder: Bore size 40,293 ~40,312 mm <Limit> <40.4mm> Taper limit 0.05 mm Out of round limit 0.01 mm Piston: Piston size “D”...
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Model TZR50 / X-POWER Crankshaft: Crank width “A” 41.90 ~ 42.0 mm Runout limit “B” 0.03 mm Small end free play “D” 0.20 ~ 0.61 mm Big end side clearance “C” 0.015 ~0.026 mm Clutch: Friction plate: Thickness 2.9 ~ 3.1 mm Number...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Model TZR50 / X-POWER Carburettor: Identification mark PHBN12HS/Dellorto Main jet (M.J.) # 88 Air screw turns 2-1/8 Fuel level 5 mm Float height (F.H.) 14.3 ± 0.5 mm Idling speed 1850 ± 150 rpm Idling jet # 32 Starter jet # 45 Air jet...
  • Page 26: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model TZR50 / X-POWER Steering system: Steering type Ball bearings Size of the balls (number): Upper 1/4 inch (19 units) Lower 1/4 inch (19 units) Front suspension: Front fork travel 130.0 mm Fork free leng 515.1 mm <Limit>...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Model TZR50 / X-POWER Rear wheel: Type Cast Wheel size MT3.50 x 17 Wheel material Aluminium Runout limit Vertical 1.0 mm Lateral 1.0 mm Drive chain: Type / Manufacturer 415H90R/Regina Number of links Chain slack 20 ~ 25mm Front disc brake: Type Single disc...
  • Page 28: Tightening Torques

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Items to tighen Number Thread pitch Tightening Observations torque m•kg Spark plug M14 x 1.25 Cylinder head Nuts M7 x 1.0 Cylinder Bolts M8 x 1.25 Coolant draining plug M6 x 1.0 Water pump cover Screw M6 x 1.0 Thermostat bolt...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Items to tighten Number Thread pitch Tightening Observations torque m•kg Upper bracket and forks Allen screw M8 x 1.25 Upper bracket and shaft M14 x 1.25 Steering shaft Initial 37 Nm and nut M25 x 1.0 Loosen and tighten Handlebar to forks...
  • Page 30: Electrical System

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL SYSTEM Model TZR50 / X-POWER Voltage: 12 V Ignition system Ignition data: Type of advance arrangement: Electronic Ignition: 14º/2000 r/min Advance: 24º/2000 r/min CDI: Magneto model / manufacturer MORIC 5WX Ω(WR-WL) Pickup resistance (color) 350 ± 20% 0.36 ±...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Model TZR50 / X-POWER Charge system: Flywheel magneto Voltage regulator: Model / manufacturer SH 671 - 12/SHIN DEN GEN Battery: Type MF (no maintenance) Horn: Type Plain type Amount Model/Manufacturer GH/12/NIKKO Maximum amperage 1.5A Flasher relay: Model / Manufacturer 0.1 - 2336/GUILERA Self-cancelling device Flashing frequency...
  • Page 32: Conversion Tables

    SPEC CONVERSION TABLES GENERAL CHARACTERISTICS General characteristics of the tightening torques OF TIGHTENING TORQUES (nut) (bolt) m • kg lb•foot This table specifies the tightening torques for ordinary fixings with standard ISO pitch thre- 10 mm 6 mm ads. The characteristics of the tightening tor- 12 mm 8 mm ques of special components or assemblies are...
  • Page 33: Lubrication Points And Type Of Lubricant

    Drive shaft (water pump) Shaft (mixing pump) Clutch casing Thrust rod Thrust lever shaft Sliding gear (transmission) Free gear (transmission) Guide bar (transmission forks) Connection ball (shift pedal) Rotation points (shift pedal) Crankcase matching surfaces Yamaha nº 4 adhesive 2-14...
  • Page 34: Chassis

    SPEC LUBRICATION POINTS AND TYPE OF LUBRICANT CHASSIS Lubrication point (name of the part) Type of lubricant Ball bearings (steering column) Lips of the oil seals (front and rear wheels) Rotation points (brake pedal) Rotation points (side stand) Right end of handlebar End of the throttle cable (throttle twist grip) Rotation axle (clutch lever) Rotation axle (brake handle)
  • Page 35: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Thread the horn cable through the support of the air filter casing DC-CDI Thread the installation through the clamps Regulator-rectifier or bridles on the frame Battery Thread the left-hand switch cable through Starter relay the frame clamps Fuse box The mark for installing the system must Horn...
  • Page 36 SPEC CABLE ROUTING Speedometer connector Clamp the generator cable to the frame Connector for headlight and front indicator Clamp the neutral switch cable to the lights frame Connector for the speedometer sensor Thread the stand and neutral cables Ground cable through the frame clamps Electrical installation Thread the following cables through the...
  • Page 37 SPEC CABLE ROUTING Thread the oil pipe through the frame clamps Clamp the starter motor cable to the frame Clamp the cable of the speedometer sensor through the rubber Clamp the main switch cable, the head of the clamp must be at the bottom 2-18...
  • Page 39 INSP...
  • Page 40 INSP CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS INTRODUCTION/REGULAR MAINTENANCE/LUBRICATION ……………3-1 SIDE COVERS ……………………………………………………………………3-2 DISMANTLING …………………………………………………………………3-2 ASSEMBLY ……………………………………………………………………3-2 ENGINE ……………………………………………………………………………3-3 ADJUSTING THE IDLING SPEED ……………………………………………3-3 ADJUSTING THE AUTOLUBE PUMP CABLE ……………………………3-4 ADJUSTING THE FREE PLAY OF THE THROTTLE CABLE ……………3-5 BLEEDING THE AUTOLUBE PUMP …………………………………………3-6 ADJUSTING THE FREE PLAY OF THE STARTER CABLE ………………3-7 INSPECTING THE SPARK PLUG ……………………………………………3-7 INSPECTING THE ENGINE OIL LEVEL ……………………………………3-9...
  • Page 41: Introduction/Regular Maintenance/Lubrication

    √ √ √ • Adjust the headlight beam * We recommend these articles being serviced by an authorised Yamaha/MBK distributor. ** Apply medium weight bearing oil NOTE: • The air filter requires more frequent servicing when the vehicle is used in particularly wet or dusty areas.
  • Page 42: Side Covers

    INSP SIDE COVERS SIDE COVERS DISMANTLING 1. Take off: • The seat NOTE: To open the seat lock, insert the key into this and turn clockwise 2. Dismantle: • The grip strap 3. Remove: • Screws that secure each side cover and take these out 4.
  • Page 43: Adjusting The Idling Speed

    INSP ADJUSTING THE IDLING SPEED ADJUSTING THE IDLING SPEED 1. Tighten • The air screw Tighten the screw until it gently abuts the end of its travel 2. Loosen: • The air screw Partly unscrew this from its slightly abut- ting position Turns the screw should be loose- ned:...
  • Page 44: Adjusting The Autolube Pump Cable

    INSP ADJUSTING THE AUTOLUBE PUMP CABLE ADJUSTING THE AUTOLUBE PUMP CABLE NOTE: Before adjusting the automatic mixture pump cable, you must first adjust the free play of the throttle cable. 1. Remove: • Cowlings See the section on “FAIRING”, “DISMAN- TLING”...
  • Page 45: Adjusting The Free Play Of The Throttle Cable

    INSP ADJUST THE FREE PLAY OF THE THROTTLE CABLE 6. Adjust: • The engine idling speed ADJUSTING THE FREE PLAY OF THE THROTTLE CABLE 1. Check: • The free play (a) of the throttle cable Out of specification Adjust Free play of throttle cable: 2 ~ 5 mm 2.
  • Page 46: Bleeding The Autolube Pump

    INSP BLEEDING THE AUTOLUBE PUMP BLEEDING THE AUTOLUBE PUMP NOTE: The automatic mixing pump and its hoses must be bled in the following cases: • When taking a new motorcycle out of its pac- kaging. • Whenever the oil tank is completely emptied •...
  • Page 47: Inspecting The Spark Plug

    ADJUSTING THE FREE PLAY OF THE CHOKE CABLE / INSP INSPECTING THE SPARK PLUG ADJUSTING THE FREE PLAY OF THE CHOKE CABLE / INSPECTING THE SPARK PLUG 1. Check • Free play of the choke cable Out of specification Adjust Free play: 1.5 ~ 3.5 mm Adjustment steps:...
  • Page 48 INSP INSPECTING THE SPARK PLUG 6. Tighten: • The spark plug Before installing a spark plug, clean the surfaces of the gasket and of the spark plug itself Tightening torque: 23 Nm (2.3 m • kg) NOTE: Make the sparkplug finger-tight before tighte- ning this to the specified degree.
  • Page 49: Inspecting The Engine Oil Level

    1. Check: • The oil level Oil level low top up with sufficient oil. Recommended oil: Yamaha 2 stroke oil Capacity of the oil tank: 1.2 L METHOD FOR CHECKING THE OIL LEVEL INDICATOR Main switch “ON” The warning light...
  • Page 50: Inspecting The Transmission Oil Level

    INSPECTING THE OIL LEVEL OF THE TRANSMIS- INSP SION/CHANGING THE TRANSMISSION OIL INSPECTING THE OIL LEVEL OF THE TRANSMISSION 1. Heat up the engine for one minute and then stop this 2. Keep the motorcycle horizontal and take out the level screw 3.
  • Page 51: Changing The Transmission Oil

    CHANGING THE TRANSMISSION OIL/ INSP ADJUSTING THE CLUTCH 5. Inspect: • The O ring (of the oil filling cap) Damage replace 6. Install: • The drainage cap gasket NOTE: Always use a new gasket • Oil drain plug Oil draing plug: 1.7 kg •...
  • Page 52: Adjusting The Clutch

    ADJUSTING THE CLUTCH / INSP CLEANING THE AIR FILTER Tightening increases free play Loosening reduces free play • Tighten the locknut NOTE: Normally, after properly adjusting the regulator for the length of the clutch cable (crankcase) the only adjustment required is to keep the right free play by means of the clutch cable tensor (handlebar lever).
  • Page 53 INSP CLEANING THE AIR FILTER 3. Remove: • The cover of the air filter case 4. Take out: • The filter element CAUTION Never let the engine run without the filter element of the air filter as unfiltered air would get into the engine, which would lead to early wear and possible motor faults.
  • Page 54 CLEANING THE AIR FILTER / INSPECTING THE CAR- INSP BURETTOR GASKET • Apply SAE 10 W30 engine oil • Drain off any excess oil NOTE: The element should be damp but not soa- ked. 7. Install: • The filter element of the air filter CAUTION Make sure that the edge of the element fits in the corresponding slot of the filter box...
  • Page 55: Inspecting The Carburettor Gasket

    INSPECTING THE CARBURETTOR GASKET / INSP INSPECTING THE FUEL HOSES 3. Inspect: • The carburettor joint Cracks/damage Replace See the section on “CARBURETTOR” - DISMANTLING THE ENGINE in CHAP- TER 4 4. Install: • The air filter case • The fuel tank 5.
  • Page 56: Inspecting The Exhaust System

    INSPECTING THE EXHAUST SYSTEM / INSPECTING INSP THE LEVEL OF COOLANT INSPECTING THE EXHAUST SYSTEM 1. Inspect: • The exhaust pipe • The muffler Cracks / Damage Replace gaskets Leakages of exhaust gases Replace Replacement steps: Dismantle the exhaust assembly Install a new exhaust assembly Screw 1.5 kg •...
  • Page 57: Changing The Coolant Liquid

    INSPECTING THE COOLANT LEVEL / INSP CHANGING THE COOLANT NOTE: To check the level of coolant, place the motorcycle in a vertical position; if it leans to one side, however little this may be, the rea- dings may be false. CAUTION Water with impurities is damaging for the engine components.
  • Page 58 INSP CHANGING THE COOLANT 1. Disconnect: • The breather pipe 2. Drain the coolant reservoir tank. 3. Remove: • The securing screw • The radiator cap 4. Remove: • The drainage screw 5. Drain: • The coolant NOTE: Empty out the coolant with the motorcycle slightly tilted to the right.
  • Page 59 INSP CHANGING THE COOLANT Coolant recommended: high quality ethylene glycol anti- freeze, containing corrosion inhibi- tors for aluminium engines. Coolant and distilled water. Mixing proportion: 50 % / 50 % Total amount: 0.7 L Capacity of reservoir tank: 0.47 L Notes on handling the coolant liquid: The coolant is harmful and should thus be handled with special care.
  • Page 60 INSP CHANGING THE COOLANT Stages in filling with coolant: • Remove the screw of the radiator cap • Pour the coolant into the radiator Drainage screw: 0.5 kg • m • Pour the coolant into the radiator until the level specified is reached •...
  • Page 61: Inspecting The Cooling System

    INSPECTING THE COOLING SYSTEM / ADJUSTING INSP THE REAR BRAKE / INSPECTING THE BRAKE LIQUID INSPECTING THE COOLING SYSTEM 1. Inspect: • The radiator • The inlet hose • The outlet hose Cracks / Damage Replace See the section on “COOLING SYSTEM” in CHAPTER 5 ADJUSTING THE REAR BRAKE Adjusting the free play of the rear brake...
  • Page 62: Inspecting The Brake Liquid

    INSPECTING THE BRAKE LIQUID / INSP BLEEDING THE AIR NOTE: • Place the motorcycle vertically to check the level of the brake liquid • When checking the front brake liquid level, make sure that the top side of the master cylinder is horizontal, moving the handlebar if necessary CAUTION...
  • Page 63: Inspecting The Brake Pads

    INSP BLEEDING THE AIR / INSPECTING THE BRAKE PADS Bleeding air steps: a. Add brake liquid of the appropriate type to the tank b. Install the diaphragm. Take care not to spill the liquid and for the tank not to overflow c.
  • Page 64: Adjusting The Brake Light Switch

    ADJUSTING THE BRAKE LIGHT SWITCH / INSP INSPECTING THE BRAKE HOSES ADJUSTING THE BRAKE LIGHT SWITCH NOTE: The brake light switch is activated by the movement of the brake pedal. This is properly adjusted when the brake light comes on immediately before the brake starts to work.
  • Page 65 INSP ADJUSTING THE DRIVE CHAIN SLACK ADJUSTING THE DRIVE CHAIN SLACK NOTE: Before checking and/or adjusting the chain, make the rear wheel turn several times and check the tension at several points until you find the place where this is most tense. Check and /or adjust the chain with the rear wheel in this position of maximum tension.
  • Page 66 INSP ADJUSTING THE DRIVE CHAIN SLACK • Tighten the axle nut Axle nut: 85 Nm (8.5 kg • m) NOTE: Tighten the axle nut while keeping the chain taut with your hand so as to keep the pro- per play of the chain. •...
  • Page 67: Adjusting The Steering

    LUBRICATING THE DRIVE CHAIN / INSP ADJUSTING THE STEERING LUBRICATING THE DRIVE CHAIN The chain consists of a large number of parts that work in constant contact with each other. If it does not get proper maintenance it will wear quickly. This is why one should acquire the habit of checking the chain regularly.
  • Page 68 INSP ADJUSTING THE STEERING Adjusting the steering head 1. Adjust: • The steering head Adjustment steps: • Loosen the screw of the handlebar clamp, the screw of the upper steering shank and the screw of the steering shaft. • Take off the fuel tank. •...
  • Page 69: Changing The Fork Oil

    INSP CHANGING THE FORK OIL CHANGING THE FORK OIL s WARNING • Leaks of oil from the fork may give rise to drops in stability and reduce driving safety. Any problems found must be corrected before using the motorcycle. • Stand the motorcycle up firmly to avoid any danger of it falling over.
  • Page 70 INSP CHANGING THE FORK OIL 7. After removing most of the oil, pump up and down with the fork to get any remai- ning oil out. 8. Inspect: • The O ring (plug) Damages Replace 9. Fill up with: • Fork oil Oil capacity of the front fork (each arm): 235 cm...
  • Page 71: Inspecting The Tyres

    INSP INSPECTING THE TYRES INSPECTING THE TIRE 1. Measure: • The air pressure Out of specification Adjust Basic weight: With oil and fuel tank full 124.2 kg. Maximum load* 195 kg. Cold tyre pressure Front Rear Up to 90 kg. (198 lb) load (1.8kg/cm ) (2.0kg/cm...
  • Page 72: Inspecting The Wheels

    INSPECTING WHEELS / INSP INSPECTING CABLES INSPECTING WHEELS 1. Inspect: • The wheels Damage / deformations Replace NOTE: After changing the tire or the wheel always balance the wheel. s WARNING Do not attempt to repair a deffective wheel. INSPECTING CABLES 1.
  • Page 73: Lubrication

    INSP LUBRICATION LUBRICATION Lubrication of cables Lubricating steps: • Keep the cable in vertical position • Apply lubricant to the upper end of the cable • Keep this in a vertical position until the oil comes out of the other end •...
  • Page 74: Electrical System

    INSP ELECTRICAL SYSTEM ELECTRICAL SYSTEM INSPECTING THE BATTERY 1. Remove: • The seat 2. Inspect: • The battery terminals Dirty terminals Clean with a metal brush Bad connection Correct NOTE: After cleaning the terminals, apply grease lightly Change the battery in the following case: •...
  • Page 75 INSP INSPECTING THE BATTERY s WARNING The electrolyte in the battery is dangerous: it contains sulphuric acid and is conse- quently poisonous and very caustic. Always observe the following preventive measures: • Avoid any physical contact with the elec- trolyte as it may cause serious burns or permanent eye injuries: •...
  • Page 76: Inspecting The Fuses

    INSP INSPECTING THE FUSES INSPECTING THE FUSES 1. Remove: • The seat 2. Remove: • The fuse 3. Inspect: • The fuse Stages in inspection • Connect the pocket tester to the fuse and check if the continuity is correct. NOTE: Place the tester selector in position “Ω...
  • Page 77: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM / INSP CHANGING A HEADLIGHT BULB ADJUSTING THE RIGHT-HAND HEADLIGHT BEAM 1. Adjust : • The headlight beam (vertical) To raise beam Turn the adjustment screw clockwise To lower the beam Turn the adjustment screw anti-clock- wise ADJUSTING THE LEFT-HAND HEADLIGHT BEAM...
  • Page 79 CHAPTER 4 ENGINE REMOVING THE ENGINE ………………………………………………………4-1 PREPARING FOR REMOVAL…………………………………………………4-1 PETROL TANK …………………………………………………………………4-2 AIR FILTER ……………………………………………………………………4-3 EXHAUST PIPE ………………………………………………………………4-4 COOLANT PIPES ………………………………………………………………4-4 SPARK PLUG AND THERMOCONTACT CABLE …………………………4-5 NEUTRAL SWITCH CABLE …………………………………………………4-5 OIL PUMP ………………………………………………………………………4-5 CARBURETTOR ………………………………………………………………4-6 SHIFT LEVER, DRIVE CHAIN AND CLUTCH CABLE ……………………4-6 ENGINE REMOVAL ……………………………………………………………4-7 DISMANTLING THE ENGINE …………………………………………………4-7 OIL PUMP ………………………………………………………………………4-7...
  • Page 80 REMOVING THE ENGINE ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine to take out the following components: • Cylinder head • Cylinder • Piston PREPARATION FOR REMOVAL 1. Remove all the dirt, mud, dust and foreign bodies before removing and dismantling the engine.
  • Page 81 REMOVING THE ENGINE PETROL TANK 1. Remove: • Seat • Grip strap • Side covers (left / right) 2. Remove the fuel tank cap 3. Remove the bolts of the fuel tank and of its cover 4. Lift up the cover of the fuel tank as shown in the drawing and remove the tray and the fuel overflow pipe from its original posi- tion.
  • Page 82 REMOVING THE ENGINE AIR FILTER 1. Remove: • Securing screw 2. Take out: • Clip 3. Disconnect: • Rubber pipe ◗ 4. Remove • Filter casing...
  • Page 83: Removing The Engine

    REMOVING THE ENGINE EXHAUST PIPE 1. Remove: • Springs • Clamp of the AIS system 2. Remove: • Exhaust pipe screws • Exhaust pipe COOLANT PIPES 1. Remove: • Fairing • Drainage screw 2. Drain: • Coolant liquid 3. Disconnect: •...
  • Page 84: Spark Plug And Thermocontact Cable

    REMOVING THE ENGINE SPARK PLUG AND THERMOCONTACT CABLE 1. Disconnect • Spark plug cable • Thermocontact cable 2. Loosen: • Spark plug CDI CABLE 1. Disconnect: • CDI cable NEUTRAL SWITCH CABLE 1. Disconnect: • Neutral switch cable OIL PUMP 1.
  • Page 85: Carburettor

    REMOVING THE ENGINE CARBURETTOR 1. Loosen: • Carburettor securing screw 2. Remove: • Upper carburettor cover • Throttle cable • Tube for supplying the oil pump • Coolant pipes • Starter cover • Starter cable 3. Remove: • Carburetor • Carburetor joint •...
  • Page 86: Dismantling The Engine

    REMOVING THE ENGINE / DISMANTLING THE ENGINE 4. Disconnect: • Clutch cable First disconnect the cable of the crank- case side and then the end at the hand- lebar lever REMOVING THE ENGINE 1. Remove: • Front engine mounting screw •...
  • Page 87 DISMANTLING THE ENGINE 2. Remove • Clip • Washer • Water pump driven gear • Pin • Washer • Water pump shaft • Clip • Oil pump driven gear • Pin • Washer • Oil pump shaft • Washer • Clip •...
  • Page 88 REMOVING THE ENGINE 4. Remove: • Clutch boss safety nut • Washer • Clutch boss • Washer • Clutch housing • Washer • Conical spring washer s WARNING Pay attention to the position of the conical spring washer. Install as shown in the figu- 5.
  • Page 89: Cdi Magneto

    REMOVING THE ENGINE CDI MAGNETO 1. Remove: • Left-hand crankcase cover and gasket • Flywheel securing nut. Use the flywheel-holding tool 90890-01235 2. Remove: • CDI flywheel Use the flywheel extractor tool 90890 - 01189 and the flywheel fixer 90890-01235 •...
  • Page 90: Cylinder Head And Cylinder

    DISMANTLING THE ENGINE CYLINDER HEAD AND CYLINDER 1. Remove: • Spark plug • Nuts and washers • Thermocontact NOTE: Following the order stated in the drawing (a, b, c,d), loosen each screw ¨ of a turn and then fully unscrew them. 2.
  • Page 91: Piston Pin And Piston

    DISMANTLING THE ENGINE PISTON PIN AND PISTON 1. Take out: • Piston pin clip NOTE: Before removing the pin clip from the piston, cover the crankcase with a clean cloth to pre- vent the clip from falling into the crankcase. 2.
  • Page 92: Selector And Shift

    DISMANTLING THE ENGINE CAUTION Use a soft hammer to hit the crankcase lightly. Only tap the reinforced parts. Do not tap the closing surface. Work slowly and carefully. Make sure that the crankcase comes apart gently. If the crankcase does not come apart, make sure that no screws or locator have been left in.
  • Page 93: Bearings And Oil Seals

    DISMANTLING THE ENGINE / INSPECTION AND REPAIR BEARINGS AND OIL SEALS NOTE: • It is not necessary to take out the bearings and oil seals unless these are damaged. See the section on “BEARINGS AND OIL SEALS” in CHAPTER 1. 1.
  • Page 94: Piston

    INSPECTION AND REPAIR Measuring warping and steps for sanding the surface: • Put a straightedge and a thickness gauge on the cylinder head • Measure the warpage Outside specifications Sand / Replace Maximum cylinder head warpage: 0.03 mm • Place nº 400~600 wet sandpaper on the surface and sand this down in a figure eight shape.
  • Page 95: Cylinder

    INSPECTION AND REPAIR CYLINDER 1. Eliminate: • Any carbon deposits Use a rounded scrap 2. Inspect: • The cylinder Mineral deposited / rust Remove • Wall of the cylinder Wear / scratches grind or replace 3. Measure: • Diameter of the cylinder “C” Outside specifications Grind Use internal gauge...
  • Page 96: Piston Rings

    INSPECTION AND REPAIR 5. Measure • Piston free play: Outside specifications Grind the cylinder or replace the piston Piston clearance = C- P: 0.049 ~ 0.062 mm C: Internal cylinder diameter P: External piston diameter PISTON RINGS 1. Measure: • Lateral clearance Out of specifications Replace the pis- ton and/or rings...
  • Page 97: Autolube Pump

    INSPECTION AND REPAIR 3. Check: • Free play There should not be any considerable play Free play exists check to see if the con rod is worn / change the pin, bearing and/or con rod, if necessary. 4. Install: • Piston pin (on the piston) 5.
  • Page 98 INSPECTION AND REPAIR 2. Measure: • Thickness of the friction disc Out of specifications Change the full set of friction discs. Measure at 4 points Wear limit : 2.7 mm 3. Inspect: • Clutch disc Damaged change the full set of clutch discs 4.
  • Page 99: Selector

    INSPECTION AND REPAIR 7. Inspect: • Slots in the clutch drum Cracks / wear / damaged remove deburr or change • Bearing of the clutch drum Scraping / Wear / Damaged Replace 8. Inspect: • Splines in the clutch boss Scratches/Wear/Damaged Change the clutch boss...
  • Page 100: Crankshaft

    INSPECTION AND REPAIR 4. Measure: • Run out of the shaft Outside specifications Change Use the centring tool and the compara- tor (90890 - 03097) Eccentricity limit: 0.08 mm 5. Inspect: • Gearing Damaged / Wear Change 6. Check: • Operation of the gearing Operation stiff Change 7.
  • Page 101: Bearings And Oil Seals

    INSPECTION AND REPAIR BEARINGS AND OIL SEALS 1. Inspect: • Bearing Perforated / Damaged Change • Oil seal lips Damaged / Worn Change CRANKCASE 1. Thoroughly wash the halves of the crank- case with mild solvent. 2. Clean the whole surface of the joints and the crankcase.
  • Page 102: Assembling And Adjusting The Engine

    ASSEMBLING AND ADJUSTING THE ENGINE ASSEMBLING AND ADJUSTING THE ENGINE CRANKSHAFT Crankshaft Rings Balancer Con rod Bearing Bearing Circlip Bearing Bearing Bearing Gear Seal Seal Piston Traction gearing A: CLEARANCE BETWEEN PISTON AND CYLINDER D: CRANKSHAFT 0.49 ~ 0.62 mm A: 41.90 ~ 42.0 mm B: PISTON RING END GAP: C: 0.03 mm...
  • Page 103 ASSEMBLING AND ADJUSTING THE ENGINE CAUTION To protect the crankshaft from scratching or facilitate the installation operation, apply grease to the lips of the oil ring and engine oil on each bearing 1. Position: • Crankshaft installing tool (90890 - 01274, 90890 - 01278) 2.
  • Page 104: Shift And Selector

    ASSEMBLING AND ADJUSTING THE ENGINE SHIFT AND SELECTOR SHIFT Primary Secondary Circlip 5th gear 1st wheel gear Washer 3rd gear 5th wheel gear Washer 6th gear 4th wheel gear Circlip 2nd gear 3rd wheel gear Bearing Circlip 6th wheel gear Bearing Circlip 2nd wheel gear...
  • Page 105 ASSEMBLING AND ADJUSTING THE ENGINE SELECTOR Shift drum Shift fork guide bar 1 Washer Shift fork guide bar 2 Neutral Washer Spring Ball Shift fork 1 Shift fork 2 Shift fork 3 4-26...
  • Page 106: Crankcase

    3. Check: • Operation of the selector Operates incorrectly Repair CRANKCASE 1. Apply: • Yamaha Bond nº 4 paste (90890-05143) on the sealing surfaces of the two hal- ves. 2. Install • Locators 3. Install the left hand crankcase gently into the right.
  • Page 107 ASSEMBLING AND ADJUSTING THE ENGINE CAUTION Before installing and tightening the crank- case securing screws, do not forget to check if the shift works properly by manually turning the selector cam in both directions 4. Tighten • Crankcase securing screws (following a crisscross pattern) Crankcase securing screws : 1.0 m •...
  • Page 108: Starter Motor

    ASSEMBLING AND ADJUSTING THE ENGINE STARTER MOTOR Starter motor Screw Magnetic flywheel Screw 4-29...
  • Page 109: Cdi Magneto

    ASSEMBLING AND ADJUSTING THE ENGINE STARTER MOTOR 1. Install: • Starter motor 2. Install: • Coil plate in the crankcase Coil screw: 0.9 m • kg CAUTION Install the coil holder plate so that the marks on the plate and on the crankcase, made during the dismantling process, coin- cide.
  • Page 110 ASSEMBLING AND ADJUSTING THE ENGINE CLUTCH AND PRIMARY DRIVE GEARING Primary drive gearing Pressure plate Tensor Bush Spring O ring Screw with washer Ball Pusher plate Push rod 2 Clutch housing Conical washer Push lever shaft Thrust washer Conical washer Spring Clutch boss Flat washer...
  • Page 111 ASSEMBLING AND ADJUSTING THE ENGINE NOTE: To tighten the CDI magneto nut use the flyw- heel holder 90890-01235 and without relea- sing this also tighten the nuts of the balancer shaft and that of the crankshaft gear CDI magneto nut: 5.2 m •...
  • Page 112 ASSEMBLING AND ADJUSTING THE ENGINE 4. Install: • Conical spring washer • Washer • Primary drive gear • Washer • Clutch boss • Washer • Clutch boss nut 5. Tighten: • Clutch boss nut Use the universal clutch holder Clutch holder: 90890 - 04086 To hold the clutch boss Clutch boss nut...
  • Page 113 ASSEMBLING AND ADJUSTING THE ENGINE 7. Install: • Clutch discs • Friction discs • Push rod nº 1 • Pressure plate • Washer • Nut • Clutch springs • Screws for securing the clutch spring NOTE: • Install the clutch discs and the friction discs alternately in the clutch boss starting and ending with a friction disc •...
  • Page 114 ASSEMBLING AND ADJUSTING THE ENGINE 8. Adjusting the clutch lever: • Loosen locknut • Tighten the screw until it reaches the • Loosen the screw 1/4 turn • Tighten the locknut SHAFT OF THE WATER PUMP, SHAFT OF THE OIL PUMP AND RIGHT-HAND CRANK- CASE COVER 1.
  • Page 115: Right-Hand Crankcase Cover

    ASSEMBLING AND ADJUSTING THE ENGINE 3. Install: • Right-hand crankcase cover • Screws NOTE: Tighten the securing screws of the crankcase cover following a crisscross pattern Screws of the crankcase cover: 1.0 m • kg. WATER PUMP COVER 1. Install: •...
  • Page 116: Piston Pin And Piston

    PISTON PIN AND PISTON PISTON PIN AND PISTON 1. Apply: • 2 stroke engine oil To the piston pin, bearing, piston ring slots and piston 2. Install: • Con rod little end bearing • Piston • Piston pin • Piston pin clip NOTE: •...
  • Page 117: Cylinder Head And Cylinder

    ASSEMBLING AND ADJUSTING THE ENGINE CYLINDER HEAD AND CYLINDER Cylinder Spark plug Flat washer Water pipe Cylinder Head gasket Cylinder gasket Head gasket Thermostat A: SPARK PLUG GAP: C: LIMIT OF CYLINDER HEAD WAR- 0.6 ~ 0.7 mm PAGE: 0.03 mm B: STANDARD SPARK PLUG: BR9ES (NGK) 2.0 m •...
  • Page 118 ASSEMBLING AND ADJUSTING THE ENGINE 1. Install: • Cylinder head gasket NOTE: • Make sure that the mark and manufacturer number engraved on the rings are on the top side of these. • Before installing the cylinder, apply a good layer of 2 stroke engine oil to the piston rings.
  • Page 119: Installing The Engine

    ASSEMBLING AND ADJUSTING THE ENGINE s WARNING Handle the thermostat with special care. Never hold this tightly or drop it. If it falls replace it with a new one. 5. Install: • Cylinder head • Washers 6. Tighten: • Cylinder head nuts Tightening torque for cylinder head nuts: 2.2 m •...
  • Page 120 ASSEMBLING AND ADJUSTING THE ENGINE 2. Install: • Drive chain NOTE: After installing the drive chain adjust the ten- sion of the chain. See “ADJUSTING CHAIN” in Chapter 6. 3. Install: • Crankcase cover 2 (left) Screws for securing crankcase cover 2 0.5 m •...
  • Page 121 ASSEMBLING AND ADJUSTING THE ENGINE 6. Inspect: • Oil leaks • Coolant leaks 7. Connect: • Neutral cable NOTE: Before starting the engine up, bleed the lubri- cation system. 4-42...
  • Page 123 COOL...
  • Page 124 COOL CHAPTER 5 COOLANT SYSTEM CHANGING THE COOLANT ……………………………………………………5-1 WATER PUMP ……………………………………………………………………5-3 DISMANTLING …………………………………………………………………5-4 INSPECTION……………………………………………………………………5-5 ASSEMBLY ……………………………………………………………………5-6 THERMOSTAT AND RADIATOR ………………………………………………5-8 INSPECTION …………………………………………………………………5-9 ASSEMBLY ……………………………………………………………………5-10...
  • Page 125: Changing The Coolant

    COOL COOLANT COOLING SYSTEM COOLANT CHANGING THE COOLANT s WARNING Do not remove the radiator cap while this and the engine are hot. Boiling liquid and vapour could emerge with consequent dan- ger of serious injury. When the engine has cooled off, open the radiator tap as follows: place a thick cloth, for example a towel, over the cap and turn this as far as it will go,...
  • Page 126 COOL COOLANT Drain screw (water pump cover): 1.4 m • kg 8. Fill up with: • Coolant liquid (in the radiator) Recommended coolant: High quality ethylene glycol anti- freeze solution containing anti- corrosive materials for aluminium alloy engines. Proportion for mixing coolant and water: 50% / 50% Total volume:...
  • Page 127: Water Pump

    COOL WATER PUMP COOLING SYSTEM WATER PUMP Impeller shaft Gasket Oil seal Screw Screw Washer Drain screw Circlip Gasket Impeller shaft gear Connection Cover of the water pump body O ring Locator Screw A: USE A NEW ONE 1.0 m • kg 1.6 m •...
  • Page 128: Dismantling

    COOL WATER PUMP DISMANTLING NOTE: There is no need to dismantle the water pump unless anomalies have been observed, such as excessive variations in temperature and/or volume of the coolant liquid, its decolouring or a milky look to the transmission oil. 1.
  • Page 129: Inspection

    COOL WATER PUMP 3. Dismantle: • The cover of the water pump body • The crankcase cover CAUTION Remove the coolant from the water pump taking care that this does not splash the autolube pump. 4. Dismantle. • The circlip •...
  • Page 130: Assembly

    COOL WATER PUMP 2. Inspect: • The gear of the impeller shaft Cracks/Wear/Damage replace 3. Inspect: • The seal Wear / Damage Replace Replacement steps: • Remove the seal from the crankcase cover, tapping this lightly outwards. • Install the new seal, with the “WATER SIDE”...
  • Page 131 COOL WATER PUMP 2. Install: • The impeller shaft Turn the shaft during assembly NOTE: Proceed with care so as not to damage the lip of the seal and so that the spring does not come out of position 3. Install: •...
  • Page 132: Thermostat And Radiator

    COOL THERMOSTAT AND RADIATOR THERMOSTAT AND RADIATOR Radiator Protector ring Bush Stop Protector ring Bolt Screw Washer Washer B: COOLANT CAPACITY A: OPENING PRESSURE OF THE RADIATOR CAP Including all the conduits: 0.7 L 0.75 ~ 1.05 KG / CM C: THERMOSTAT OPENING TEMPERATURE: 98 ºC 0.8 m •...
  • Page 133: Inspection

    COOL THERMOSTAT AND RADIATOR INSPECTION 1. Inspect: • The radiator core Obstruction Eliminate this with com- pressed air, blowing from the rear of the radiator. Squashed fins repair / replace 2. Inspect: • The inlet hose Cracks / damage Replace •...
  • Page 134: Assembly

    COOL THERMOSTAT AND RADIATOR Inspection steps: • Hang the thermostat in a recipient • Submerge a reliable thermometer in water • Heat up the water slowly • Observe the thermometer without cea- sing to agitate the water NOTE: The thermostat is sealed and rating this is a job for a specialist.
  • Page 135 COOL THERMOSTAT AND RADIATOR 4. Fill up: • The coolant See the section on “CHANGING THE COOLANT” in CHAPTER 3. 5. Inspect: • The cooling system Reduce the pressure (leaks) Repair as required. Inspection steps: • Connect the cooling system tester the radiator Cooling system tester: 90890 - 01325...
  • Page 136 CARB...
  • Page 137 CARB CHAPTER 6 CARBURATION CARBURETOR ……………………………………………………………………6-1 REMOVAL ………………………………………………………………………6-2 DISMANTLING …………………………………………………………………6-2 INSPECTION……………………………………………………………………6-2 ASSEMBLY ……………………………………………………………………6-3 INSTALLATION …………………………………………………………………6-3 ADJUSTING THE PETROL LEVEL …………………………………………6-3 REED VALVE ………………………………………………………………………6-4 REMOVAL ………………………………………………………………………6-4 DISMANTLING …………………………………………………………………6-4 INSPECTION……………………………………………………………………6-4 ASSEMBLY ……………………………………………………………………6-5 INSTALLATION …………………………………………………………………6-6...
  • Page 138: Carburetor

    CARB CARBURETOR CARBURATION CARBURETOR Carburetor Spring SPECIFICATIONS Carburetor cover Casing Main jet (M.J.) # 88 Needle valve Choke jet Pilot air screw (P.A.S.) 2 1/8 Float chamber Idling screw Fuel level (F.L.) 13 ~14 mm Main jet Float pin Idling speed 1850 ±...
  • Page 139: Removal

    CARB CARBURETOR REMOVAL 1. Remove: • Carburetor assembly See the section on engine removal DISMANTLING 1. Remove: • Idling stop screw 2. Remove: • Float chamber • Float pin • Float • Water valve • Gasket • Main jet • Idling jet •...
  • Page 140: Assembly

    CARB CARBURETOR 3. Inspect • Jets Wear / Dirt Change / Clean 4. Inspect: • Plunger • Wear/damage Replace 5. Check: • Free movement Difficulty Change Insert the plunger into the carburetor body. 6. Inspect • Float Damaged Change • O ring Damaged Change ASSEMBLY...
  • Page 141: Reed Valve

    CARB CARBURETOR / REED VALVE Adjustment steps: • Take out the carburetor • Inspect the valve seat and the float cham- ber valve. • If either of the two parts is worn, change both. • Check the petrol level again REED VALVE REMOVAL 1.
  • Page 142: Assembly

    CARB REED VALVE 2. Measure: • Height of the valve stop Outside specifications Adjust/ chan- ge the stop of the valve Height of the valve stop: 6.28 mm NOTE: If the height is 0.4 mm greater or lower than what is specified, change the valve stop. 3.
  • Page 143: Installation

    CARB REED VALVE INSTALLATION To install the reed valve, follow the procedure for removal inversely. Pay attention to the follo- wing points. 1. Install: • A new gasket 2. Tighten: • Safety screws of the reed valve body. Safety screws of the reed valve body: 0.8 m •...
  • Page 145 CHAS...
  • Page 146 CHAS CHAPTER 7 CHASSIS FRONT WHEEL …………………………………………………………………7-1 DISMANTLING …………………………………………………………………7-2 INSPECTION……………………………………………………………………7-2 ASSEMBLY ……………………………………………………………………7-5 REAR WHEEL ……………………………………………………………………7-6 DISMANTLING …………………………………………………………………7-7 INSPECTION……………………………………………………………………7-7 ASSEMBLY ……………………………………………………………………7-8 FRONT BRAKE …………………………………………………………………7-10 CHANGING THE BRAKE PADS ……………………………………………7-11 DISMANTLING THE CALIPER………………………………………………7-13 DISMANTLING THE BRAKE PUMP ………………………………………7-14 INSPECTING AND REPAIRING THE BRAKE ……………………………7-15 ASSEMBLY ……………………………………………………………………7-17 FRONT FORK ……………………………………………………………………7-20 REMOVAL ……………………………………………………………………7-21...
  • Page 147: Front Wheel

    CHAS FRONT WHEEL CHASSIS FRONT WHEEL AIR PRESSURE IN THE TIRES Front wheel BASIC WEIGHT: Spacer WITH OIL AND Bearing FULL TANK 124.2 kg. (272 pounds) Bearing Seal MAXIMUM LOAD * 195 kg. (428 pounds) Bush Axle COLD TIRE PRESSURE FRONT REAR UP TO 90 KG...
  • Page 148: Dismantling

    CHAS FRONT WHEEL DISMANTLING s WARNING Support the motorcycle firmly to avoid any risk of falling over. 1. Lift up the front wheel, placing an appro- priate support under the engine. 2. Remove : • The screws (brake caliper) NOTE: Do not press the brake lever without the wheel being fitted on the motorcycle since if you do the pads would be in contact.
  • Page 149 CHAS FRONT WHEEL 2. Get rid of any corrosion on the parts. 3. Inspect: • The front axle Make the axle turn on a flat surface Deformations Replace s WARNING Do not attempt to straighten the axle if this is deformed 4.
  • Page 150 CHAS RUEDA DELANTERA CAUTION Do not tap the inner race of the bearing. Contact should only be with the outer race. 7. Check: • The wheel balance If the wheel stops at the same point again, after several light turns, the static balance is not correct.
  • Page 151: Assembly

    CHAS FRONT WHEEL INSTALLING Repeat the dismantling procedure, inversely. Take into account the following points: 1. Apply: • Lithium grease Lightly grease the oil seal and the gea- ring unit 2. Assemble: • The speedometer sensor. NOTE: Make sure that the projections on the insi- de of the sensor coincide with the flat sides of the wheel hub.
  • Page 152 CHAS REAR WHEEL REAR WHEEL Rear wheel Chain Bush Spacer Coupling Bearing Wheel axle Bearing Chain tensioner Rear wheel sprocket Screw Washer Screw Seal Seal Bush A: TIRE SIZE: 130 / 70 - 17 B: WHEEL SIZE: 3.50 MT X 17 C: RUN OUT LIMIT OF THE WHEEL E: VERTICAL: 2.0 mm (0.08 inch) F: LATERAL: 2.0 mm (0.08 inch)
  • Page 153: Dismantling

    CHAS REAR WHEEL DISMANTLING s WARNING Support the motorcycle firmly so it does not fall over 1. Lift the rear wheel and place a suitable support under the engine. 2. Dismantle: • The pin • The nut (wheel axle) • The chain tensioner •...
  • Page 154: Assembly

    CHAS REAR WHEEL 2. Measure: • The run out of the wheel See the section on “FRONT WHEEL - INSPECTION” 3. Check: • The wheel bearings • The wheel balancing See the section on “FRONT WHEEL - INSPECTION” • The brake disc See the section “FRONT WHEEL - INS- PECTION”...
  • Page 155 CHAS REAR WHEEL 4. Install: • The pin (a new one) s WARNING Always use a new pin for the wheel axle. 5. Adjust: • The free play of the brake pedal See the section on “ADJUSTING THE REAR BRAKE” in CHAPTER 3. Free play of the brake pedal: 10 ~ 15 mm...
  • Page 156: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE Disc brake Drain screw Screw Complete brake caliper Through screw Complete pistons Seal Brake pads Screw A: CHANGE AS AN ASSEMBLY B; WEAR LIMIT OF THE BRAKE PADS: C: WEAR LIMIT 0.5 mm BRAKE DISC: 3.5 mm 7-10...
  • Page 157: Changing The Brake Pads

    CHAS FRONT BRAKE CAUTION The components of the disk brake rarely need to be dismantled. Do not do so unless this is absolutely necessary. If any of the hydraulic coupling components of the sys- tem is disconnected the whole system must be dismantled to drain this, clean it and then fill it and bleed it properly.
  • Page 158 CHAS FRONT BRAKE 2. Measure: • The thickness (a) of the pads: If this does not match the value specified replace ◗ NOTE: • Replace the pads as a set, if you find that any of them is worn beyond the limit. Wear limit: 0.5 mm 3.
  • Page 159: Dismantling The Caliper

    CHAS FRONT BRAKE 7. Install: • The screws (brake caliper) Screws (brake caliper): 3.5 kg • m 8. Inspect: • The level of the brake liquid See the section on “INSPECTING THE BRAKE LIQUID” in CHAPTER 3. min. 9. Check: •...
  • Page 160: Dismantling The Brake Pump

    CHAS FRONT BRAKE 2. Dismantle: • The screws (brake caliper) • The brake pads See the section on “CHANGING THE BRAKE PADS” 3. Dismantle: • Pistons Dismantling steps: • Use a cloth to block the piston on the right-hand side. •...
  • Page 161 CHAS FRONT BRAKE 1. Dismantle: • The brake switch • The brake lever • The coupling screw • The copper washers 2. Dismantle: • The pump cover • The rubber seal • The pump 3. Dismantle: • The circlip • The set of pump components INSPECTION AND REPAIR Recommended schedule for replacing the brake components:...
  • Page 162 CHAS FRONT BRAKE 1. Measure: • The brake pads (thickness) (a) Out of specification replace ◗ NOTE: • Change the pads as a set, whenever any of these is worn down beyond the limit. Wear limit: 0.5 mm 2. Inspect: •...
  • Page 163: Assembly

    CHAS FRONT BRAKE ASSEMBLY s WARNING • All the internal components must be clea- ned only with new brake liquid. • The internal items must be lubricated with brake liquid when assembled. Brake liquid: DOT nº 4 • Change the piston seals whenever the caliper is dismantled.
  • Page 164 CHAS FRONT BRAKE 4. Assemble: • The dust seal • The brake pump Screws (pump support) : 0.9 kg • m 5. Assemble: • The line • The copper washers • The coupling screw Coupling screws: 2.6 kg • m s WARNING Always use new copper washers 6.
  • Page 165 CHAS FRONT BRAKE 7. Fill up: • Brake liquid Recommended brake liquid: DOT nº 4 CAUTION The brake liquid could erode painted surfa- ces and plastic parts. Always clean any liquid spilt. s WARNING • Use only brake liquid of the specified qua- lity: otherwise the rubber seals could deteriorate and give rise to leaks and reduction of the braking efficiency.
  • Page 166: Front Fork

    CHAS FRONT FORK FRONT FORK Rubber plug Tapered spindle Circlip Dust sealing plug Plug screw Retaining clip O ring Oil seal Fork spring Guide bush Ring of the damper rod Outer pipe Damper rod (full cylinder) Draining screw Rebound spring Screw (Damper rod) Inner tube Steering axle...
  • Page 167: Removal

    CHAS FRONT FORK REMOVAL s WARNING Stand the motorcycle up firmly so that there is no risk of it falling over. 1. Lift up the front wheel placing an appro- priate support under the engine. 2. Dismantle: • The front wheel See the section on “DISMANTLING THE FRONT WHEEL”...
  • Page 168: Dismantling

    CHAS FRONT FORK NOTE: When the fork legs are dismantled, also remo- ve the screws (brake line clamp) and odometer cable. 7. Dismantle: • The front fork DISMANTLING 1. Remove: • The rubber plug • The clip • The plug •...
  • Page 169 CHAS FRONT FORK 2. Drain: • The oil out of the fork 3. Remove: • The dust sealing cover • The retainer clip Use a fine screwdriver and take care not to scratch the inner tube. 4. Remove: • The screw (damper rod) Use the fixing tool and the “T”...
  • Page 170: Inspection

    CHAS FRONT FORK INSPECTION 1. Inspect: • The inner tube Scratching / Deformations Replace s WARNING Do not try to straighten the inner tube if this is bent, as it could be dangerously weake- ned. • Outer tube Scratching / Deformations / Damage Replace •...
  • Page 171 CHAS FRONT FORK NOTE: • When putting the fork back on, make sure that you replace the following items with new ones. • Guide bush • Oil seal • Dust protection seal • Make sure that all the components are clean before installing these again.
  • Page 172 CHAS FRONT FORK 4. Install: • The guide sleeve Use the counterweight for installing fork 4 seals and the adapter 5. Inner tube Outer tube Counterweight for installing the fork seals: 90890 - 01367 Adapter: 90890 - 01400 5. Install: •...
  • Page 173: Installation

    CHAS FRONT FORK 7. Measure: • The oil level (a) If this does not coincide with the value specified add or remove oil. Oil level: 154 mm Measurements from the top of the inner tube. NOTE: • To measure the oil level, thoroughly check the inner tube, without the fork spring.
  • Page 174 CHAS FRONT FORK INSTALLING Use the “EXTRACTION” procedure inversely. Take into account the following points. 1. Install: • The fork Provisionally tighten the clamp screws of the handlebars. NOTE: Maintain the inner tube. 2. Tighten: • The (handlebar) clamp screws •...
  • Page 175: Steering Head And Handlebars

    CHAS STEERING HEAD AND HANDLEBARS STEERING HEAD AND HANDLEBARS HANDLEBARS Handlebar (left-hand) Set of throttle cable Handlebar (right-hand) and mixing pump Handlebar counterweight Clutch cable Guide tube of the acceleration cable Tensor Rubber twist grip Locknut 2.0 m • kg 0.9 m •...
  • Page 176: Steering Head

    CHAS STEERING HEAD AND HANDLEBARS STEERING HEAD Upper race of the bearing Steering adjustment nut Lower race of the bearing Upper shank of the handlebar Ball bearing Steering nut Cover of the ball bearing race 5.4 m • kg A: BEARING DIMENSIONS: 1/4 inch NUMBER OF BALLS: LOWER: 19 units...
  • Page 177: Dismantling

    CHAS STEERING HEAD AND HANDLEBARS DISMANTLING s WARNING Stand the motorcycle up firmly to prevent it from falling over 1. Lift the front wheel up installing an appro- priate support under the engine. 2. Dismantle: • The front wheel See the section on “FRONT WHEEL - DISMANTLING”...
  • Page 178 CHAS STEERING HEAD AND HANDLEBAR 8. Loosen: • The clamp screws (handlebars) 9. Remove: • The screws (handlebars) 10. Dismantle: • The handlebars (left and right-hand) 11. Dismantle: • The fairing See the section on “REMOVING THE FAIRING” 12. Dismantle: •...
  • Page 179 CHAS STEERING HEAD AND HANDLEBARS 18. Remove: • The ring nut Use the wrench for ring nuts Wrench for annular nuts : 90890 - 01403 WARNING Support the steering axle so that this can- not fall 19. Dismantle: • The cover of the bearing races •...
  • Page 180: Inspection

    CHAS STEERING HEAD AND HANDLEBARS INSPECTION 1. Wash the ball bearings and races with sol- vents. 2. Inspect: • The ball bearings • The bearing races Pitting / Damage Replace NOTE: Always replace the bearings and races as a set Replacement steps: •...
  • Page 181 CHAS STEERING HEAD AND HANDLEBARS 2. Install: • The bearings Install the balls on the race and apply more grease Nº and dimensions of the balls: 19 units above / 1/4 inch 19 units below 1/4 inch 3. Install: • The steering axle s WARNING Immobilise the steering axle until this is fixed.
  • Page 182 CHAS STEERING HEAD AND HANDLEBARS 5. Install: • The upper crown Screw (steering axle ): 5.4 kg • m NOTE: Provisionally tighten nut 2 of the steering axle. 6. Install: • The headlight support • The clamp of the brake line Screw (headlight support): 1.0 kg.
  • Page 183 CHAS STEERING HEAD AND HANDLEBARS Stages in replacing the left-hand handle- bar: • Couple the lever support to the handle- bar, as shown in the illustration. • Align the mark of the handlebar with the support of the clutch lever. Screw (handlebar support): 0.9 kg •...
  • Page 184 CHAS STEERING HEAD AND HANDLEBARS s WARNING Leave a space of 1 mm between the twist 1 mm grip and the counterweight . Otherwise the twist grip could stick. 11. Install: • The counterweight of the twist grip (right-hand) Counterweight of the twist grip: 2.0 kg •...
  • Page 185 CHAS STEERING HEAD AND HANDLEBARS 19. Adjust: • The free play of the clutch cable See the section on “ADJUSTING THE CLUTCH” in CHAPTER 3 Free play: 10 ~ 15 mm 20. Install: • The fairing See the section on “FAIRING - FITTING”. 7-39...
  • Page 186: Rear Shock Absorber And Swinging Arm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Swingarm Bush Screw Roller bearing Flat washer Washer Thrust cover Bolt with washer Self-locking nut Full shock absorber Swinging arm axle Bolt Self-locking nut Bush Cover Flat washer Chain protector Self-locking nut 4.0 m •...
  • Page 187: Observations On Handling

    CHAS REAR SHOCK ABSORBER AND SWINGARM OBSERVATIONS ON HANDLING s WARNING This shock absorber contains gaseous nitrogen at high pressure. Before handling it, read and understand the following infor- mation. The manufacturer will not accept any liability for damage to property or per- sonal injuries stemming from improper handling.
  • Page 188: Dismantling

    CHAS REAR SHOCK ABSORBER AND SWINGARM DISMANTLING Rear swingarm s WARNING Stand the motorcycle up firmly so that it does not fall over. 1. Dismantle: • The seat • The side covers or cowlings (left and right-hand) See the section on “SIDE COVERS - DISMANTLING”...
  • Page 189 CHAS REAR SHOCK ABSORBER AND SWINGARM Swingarm s WARNING Stand the motorcycle up firmly so that it does not fall over. 1. Lift up the rear wheel, installing an appro- priate support under the engine. 2. Dismantle: • The rear shock absorber 3.
  • Page 190: Inspection

    CHAS REAR SHOCK ABSORBER AND SWINGARM INSPECTION 1. Inspect: • The shock absorber Oil leaks / damage replace 2. Inspect: • The swingarm Deformations / Cracks / damage replace 3. Inspect: • The oil seals Damage Replace • The thrust covers Damage Replace •...
  • Page 191 CHAS REAR SHOCK ABSORBER AND SWINGARM Rear shock absorber Apply the same procedure as in “DISMAN- TLING” but inversely. Take into account the following points: 1. Apply: • Lithium soap grease to the oil seals and bush 2. Install: • The rear shock absorber Rear shock absorber - upper: 6.0 kg •...
  • Page 192 CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN REAR WHEEL SPROCKET AND DRIVE CHAIN Rear sprocket Holder Drive chain Chain coupling E: USE A NEW ONE E: USE A NEW ONE 7-46...
  • Page 193: Dismantling

    CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN NOTE: Before dismantling the sprocket, the chain and the rear wheel sprocket, the chain sloack should be checked. DISMANTLING 1. Dismantle: • The cover of the output sprocket 2. Dismantle • The circlip •...
  • Page 194: Inspection

    CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN INSPECTION 1. Check: • The chain stretching Pull the chain to separate this from the crown wheel. Distance between chain/crown wheel greater than half the tooth replace the chain. 2. Clean: • The drive chain Submerge this in solvent and use a brush to clean off as much dirt as possi- ble.
  • Page 195: Assembly

    CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN Replacing steps: • Straighten the tab of the locknut and take off the crown wheel • Install the new rear wheel sprocket and the locknut Nut (rear crown wheel sprocket): 6.3 kg • m ASSEMBLY Apply the procedure for “DISMANTLING”...
  • Page 196 CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN 4. Install: • The drive chain • The coupling link of the chain • The chain clip Rotation direction s WARNING Make sure that the clip is installed in the right position. Otherwise the transmission chain would open.
  • Page 198 ELEC...
  • Page 199 ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL DIAGRAM ………………………………………………………8-2 ELECTRICAL COMPONENTS …………………………………………………8-4 IGNITION AND STARTING SYSTEM …………………………………………8-6 ELECTRIC STARTING SYSTEM ………………………………………………8-8 TROUBLESHOOTING …………………………………………………………8-9 CHARGING SYSTEM …………………………………………………………8-12 TROUBLESHOOTING ………………………………………………………8-14 LIGHTING SYSTEM ……………………………………………………………8-18 LOCATING BREAKDOWNS …………………………………………………8-20 CHECKING AND TESTING THE LIGHTING SYSTEM …………………8-23 SIGNALING SYSTEM …………………………………………………………8-28 TROUBLESHOOTING ………………………………………………………8-30 CHECKING AND TESTING THE SIGNALING SYSTEM …………………8-32...
  • Page 201 ELEC ELECTRICAL DIAGRAM ELECTRICAL DIAGRAM...
  • Page 202: Electrical Diagram

    ELEC ELECTRICAL DIAGRAM Magnetic flywheel Front brake switch Regulator / Rectifier Rear brake switch Starting relay Tail light Fuse Instrument panel Main switch Neutral relay Battery Diode x 2 Horn Spark plug Flasher relay Handlebar switch (rh) Clutch switch Handlebar switch (lh) Side stand switch Front headlight / flasher (lh) Thermocontact...
  • Page 203: Electrical Components

    ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (1) Battery STARTER COIL Spark plug pipe Regulator/Rectifier Neutral switch Main switch PRIMARY COIL RESISTANCE: O ring Rear brake light switch 0.23 W + 20ºC Thermostat switch SECONDARY COIL Starter motor RESISTANCE: 7.9 K W...
  • Page 204 ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (1) BATTERY: Electrical installation Side stand switch CAPACITY: Fuse Relay 12 V 3AH NO MAINTENANCE Diode Indicator flasher relay Oil level switch Horn...
  • Page 205: Ignition And Starting System

    ELEC IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM The following circuit diagram shows the ignition and starting system...
  • Page 206 ELEC IGNITION AND STARTING SYSTEM NOTE: For the colour codes, please see the electrical diagram C.D.I. magneto Starter relay Main switch C.D.I. Spark plug Handlebar switch (RH) Battery Coil Starter motor...
  • Page 207: Electric Starting System

    ELEC ELECTRIC START SYSTEM ELECTRIC START SYSTEM CIRCUIT DIAGRAM Starter relay Fuse Main switch Diodes Engine/starter stop switch Neutral switch Neutral relay Battery Clutch switch Side stand switch Starter motor...
  • Page 208: Troubleshooting

    ELEC ELECTRIC START SYSTEM TROUBLESHOOTING 4. Neutral relay THE STARTER MOTOR DOES NOT WORK • Remove the relay NOTE: • Use the following tools in this fault location Pocket tester: 90890 -03112 • Use the battery to supply terminals Br 1.
  • Page 209 ELEC ELECTRIC START SYSTEM 6. Main switch 8. Neutral switch • Place in the ON position • Separate the connections • Check the continuity between R and Br • Check the continuity: • Light blue ground Repair the main switch Change the neutral switch 7.
  • Page 210 ELEC ELECTRIC START SYSTEM 10. Clutch switch • Separate the yellow connection • Press the clutch • Check the continuity between BG and LY Repair the side stand switch 11. Starter switch • Separate the connection • Press the switch •...
  • Page 211: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 8-12...
  • Page 212 ELEC CHARGING SYSTEM NOTE: For the colour codes please see the electrical diagram C.D.I. magneto Regulator / Rectifier Fuse Spark plug Battery Coil 8-13...
  • Page 213: Troubleshooting

    ELEC CHARGING SYSTEM TROUBLESHOOTING THE BATTERY IS FLAT Procedure (1) Check: 1. The fuse 4. The resistance of the stator coil 2. The battery 5. The cable connections (charge system) 3. The charging voltage NOTE: • Dismantle the following components, before locating the fault. 1) The seat 2) The fuel tank •...
  • Page 214 ELEC CHARGING SYSTEM 3. Charging voltage • Connect the engine tachometer to the spark plug cable • Connect the pocket tester (DC, 20V) to the battery (+) probe of tester (+) terminal of the battery (-) probe of tester (-) terminal of the battery MATCHES SPECIFICATION Replace the battery •...
  • Page 215 ELEC CHARGING SYSTEM • Check to see if the stator coil has the specified resis- tance. DOES NOT MATCH SPECIFICATION Resistance of the stator coil: 0.4 ~ 0.6 Ω at 20º C Replace the stator coil MATCHES SPECIFICATION 5. Cable connections •...
  • Page 217: Lighting System

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 8-18...
  • Page 218 ELEC LIGHTING SYSTEM NOTE: For colour codes please see the electrical diagram Fuse Main switch Front headlight / indicator (LH) Front headlight / indicator (RH) Rear indicator (LH) Rear indicator (RH) Front brake switch Rear brake switch Tail light Instrument panel 8-19...
  • Page 219 ELEC LIGHTING SYSTEM TROUBLESHOOTING THE HEADLIGHTS, THE SIDE LIGHTS OR THE INSTRUMENT PANEL DO NOT LIGHT UP Procedure Check: 1.The fuse 2.The light switch “LIGHTS” 3.The cable connections (lighting system) NOTE: • Dismantle the following components before locating the fault. 1)The seat 2)The fuel tank 3)The front bulb holders...
  • Page 220 ELEC LIGHTING SYSTEM (+) probe of tester Red / yellow terminal (-) probe of tester Blue terminal • Place the lights switch “LIGHTS” in positions “POS” and “OFF”, successively. • Check to see if the continuity is correct in the lights switch.
  • Page 221 ELEC LIGHTING SYSTEM 3. Cable connections • Check the cable connections of the whole light CONNECTIONS IN BAD system CONDITION See the section on “WIRING DIAGRAM” Correct these. CORRECT See the section on “CHECKING AND TESTING THE LIGHT SYSTEM” 8-22...
  • Page 222: Checking And Testing The Lighting System

    ELEC LIGHTING SYSTEM CHECKING AND TESTING THE LIGHT SYSTEM 1. Headlight do not come on 1. Headlight bulb THERE IS NO CONTINUITY • Check the continuity between B and Y and between B and G Replace the headlight bulb. 2. The headlights do not come on 1.
  • Page 223 ELEC LIGHTING SYSTEM • Check the headlight voltage Headlight voltage: 12.0 V DOES NOT MATCH THE SPECIFICATION 3. Headlight change switch “LIGHTS” • Disconnect the connectors of the handlebar switches and the connector cables • Connect the pocket tester (Ω x 1 ) to the headlight change switch (“LIGHTS”) With the headlight change switch “LIGHTS”...
  • Page 224 ELEC LIGHTING SYSTEM 4. Cable connections • Check the wiring connections of the whole lighting system. See the “ELECTRICAL DIAGRAM” section 3. The tail light does not come on 1. Brake light tail light bulb • Remove the bulb of the brake light tail light •...
  • Page 225 ELEC LIGHTING SYSTEM DOES NOT MATCH THE SPECIFICATION • Check the voltage of the tail light 3. Cable connections Check the connections of the Voltage of the tail light: whole light system. See the sec- 12.0 V tion on “ELECTRICAL DIAGRAM” MATCHES THE SPECIFICATION Replace / service the tail light.
  • Page 226 ELEC LIGHTING SYSTEM 2. Voltage • Disconnect the coupler of the instrument panel • Place the main switch in the ON position. • Connect the pocket tester (DC 20V) to the instrument light coupler. • Check the voltage between Br and B Voltage of the instrument panel: DOES NOT MATCH SPECIFICATION 12.0 V...
  • Page 227: Signaling System

    ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM 8-28...
  • Page 228 ELEC SIGNALING SYSTEM NOTE: For the colour codes please see the electrical diagram Fuse Rear brake switch Switch Tail light / Brake light Handlebar switch Instrument panel Front headlight/indicator (LH) Neutral relay Front headlight/indicator (RH Battery Neutral switch Horn Rear indicator (LH) Indicator relay Rear indicator (RH) Thermocontact...
  • Page 229: Troubleshooting

    ELEC SIGNALING SYSTEM TROUBLESHOOTING THE INDICATORS, THE BRAKE LIGHT, THE “NEUTRAL” INDICATOR PILOT LIGHT, “TURN” INDICATOR PILOT LIGHT AND THE OIL PRESSURE INDICATOR “OIL” DO NOT COME ON AND THE HORN DOES NOT WORK Procedure Check: 1.The fuse 2.The battery 3.Main switch 4.Wiring connections (signalling system) NOTE:...
  • Page 230 ELEC SIGNALING SYSTEM 3. Main switch • Disconnect the connector of the main switch • Connect the pocket tester (Ω x 1) to the main switch • Place the main switch in positions “ON” and “OFF” successively. • Check if the continuity is correct between the red and IN BAD CONDITION brown cables only in the “ON”...
  • Page 231: Checking And Testing The Signaling System

    ELEC SIGNALING SYSTEM CHECKING AND TESTING THE SIGNALING SYSTEM 1. The indicators do not flash 1. Indicator bulb • Remove the indicator bulb • Connect the pocket tester (Ω x 1) to the bulb (+) probe of tester Terminal (-) probe of tester Terminal NO CONTINUITY •...
  • Page 232 ELEC SIGNALING SYSTEM • Check if the continuity is correct in the bulb holder bush of the indicator. CONTINUITY OK 3. Turning switch “TURN” • Disconnect the large coupler (yellow) from the left- hand switch on the handlebars • Connect the pocket tester (Ω x 1) to the turning switch “TURN”...
  • Page 233 ELEC SIGNALING SYSTEM 4. Voltage • Place the main switch in the “ON” position • Connect the pocket tester (DC, 20 V) to the coupler of the indicator relay. (+) probe of tester brown terminal (-) probe of tester to ground DOES NOT MATCH THE SPECIFICATION 5.
  • Page 234 ELEC SIGNALING SYSTEM NO CONTINUITY • Remove the bulb of the tail light/ brake light • Connect the pocket tester (Ω x 1) to the bulb Replace the tail light / brake light bulb CONTINUITY OK 2. Front brake switch •...
  • Page 235 ELEC SIGNALING SYSTEM 3. Voltage • Place the main switch in the ON position. • Apply the front brake • Connect the pocket tester (DC, 20V) to the front brake switch. (+) probe of tester Brown terminal (-) probe of tester To ground DOES NOT MATCH SPECIFICATION 4.
  • Page 236 ELEC SIGNALING SYSTEM • Check whether the continuity is correct in the brake switch Switch In good In bad position condition condition IN BAD CONDITION Applying rear brake Not applying rear b. : Continuity X : There is no continuity Replace the rear brake switch.
  • Page 237 ELEC SIGNALING SYSTEM 3. The NEUTRAL indicator does not come on 1. Neutral switch • Disconnect the cable of the neutral switch (light blue) of the connector • Connect the pocket tester (Ω x 1) to the neutral switch. (+) probe of tester Light blue terminal (-) probe of tester To ground...
  • Page 238 ELEC SIGNALING SYSTEM 2. Voltage • Disconnect the instrument panel coupler. • Place the main switch in the “ON” position • Connect the pocket tester (DC, 20V) to the instrument panel coupler. (+) probe of tester Brown terminal (-) probe of tester Black terminal DOES NOT MATCH SPECIFICATION •...
  • Page 239 ELEC SIGNALING SYSTEM 4. The turning indicator pilot light “TURN” does not come on 1. Turning switch “TURN” • Disconnect the large coupler (yellow) from the left- hand switch on the handlebars. • Connect the pocket tester (Ω x 1) to the turning switch “TURN”...
  • Page 240 ELEC SIGNALING SYSTEM 2. Voltage • Place the main switch in the “ON” position • Connect the pocket tester (+) probe of tester Brown terminal (-) probe of tester Ground DOES NOT MATCH SPECIFICATION • Check the voltage of the front brake. 3.
  • Page 241 ELEC SIGNALING SYSTEM 5. The oil level indicator light does not come on 1. Oil level switch • Remove the oil level switch from the oil tank • Disconnect the switch coupler (black, black/red) from the connector. • Connect the pocket tester (Ω x 1) to the oil level switch.
  • Page 242 ELEC SIGNALING SYSTEM 6. The horn does not sound when the HORN switch is pressed 1. HORN switch • Disconnect the handlebar switch connector from the connector • Connect the pocket tester (Ω x 1) to the HORN switch. (+) probe of tester Pink terminal (-) probe of tester Black terminal...
  • Page 243 ELEC SIGNALING SYSTEM 4. Horn • Disconnect the pink cable from the horn terminal • Connect a bridge cable to the horn terminal and lead this to ground. THE HORN SOUNDS The horn is in good condition THE HORN DOES NOT SOUND 5.
  • Page 245: Cooling System

    ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 8-46...
  • Page 246 ELEC COOLING SYSTEM NOTE: For the colour codes please see the electrical diagram Fuse Main switch Instrument panel Battery Thermocontact 8-47...
  • Page 247: Troubleshooting

    ELEC COOLING SYSTEM TROUBLESHOOTING THE TEMPERATURE LIGHT DOES NOT COME ON WHEN THE ENGINE IS HOT Procedure Check: 1.The seat 2.The tank 3.The front fairing NOTE: • Remove the following items before locating the fault. 1) The seat 3) The side fairing (right) 2) The side fairing (left) 4) The headlight assembly •...
  • Page 248: Chassis

    ELEC COOLING SYSTEM 3. Main switch • Disconnect the coupler from the main switch • Connect the pocket tester (Ω x 1) to the main switch (+) probe of tester Red terminal (-) probe of tester Brown terminal • Put the main switch into the “ON” and “OFF” posi- tions alternatively.
  • Page 249 ELEC COOLING SYSTEM s WARNING 6. Thermosensor Handle the thermostat with special • Remove the thermosensor from its housing. care. Never let this receive any • Connect the pocket tester (Ω x 1) to the thermosensor impacts or fall. If it does accidentally fall, replace it.
  • Page 251 ELECTRICAL DIAGRAM TZR50 COLOUR CODE Black Black/red Black/white Blue Green/red Green Green/yellow Orange Br/W Brown/white Yellow White/red Pink White/black Brown White/green Chocolate Yellow/blue Sky blue Yellow/red Dark green Blue/Black White Blue/red B/Br Black/brown Blue/white Black/yellow Blue/yellow Magnetic flywheel Regulator/ rectifier Starter relay Fuse Main switch...

This manual is also suitable for:

X-power '03 5wx-ae12003 tzr502003 x-power

Table of Contents