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YAMAHA TT600R Service Manual

M.y 1997-2007.
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YAMAHA
──────────
TT600R
──────────
M.Y 1997-2007
SERVICE MANUAL

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Chapters

   Summary of Contents for YAMAHA TT600R

  • Page 1

    YAMAHA ────────── TT600R ────────── M.Y 1997-2007 SERVICE MANUAL...

  • Page 2

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 3: General Information

    ILLUSTRATED SYMBOLS The following symbols are not relevant to every vehicle. SPEC INFO Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 General information INSP CHAS 2 Specifications 3 Periodic inspections and adjustments 4 Chassis 5 Engine...

  • Page 4: Table Of Contents

    E004000 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION INSP AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETION CARB ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 6: Gen Info

    INFO...

  • Page 7

    INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER................1-1 MODEL LABEL ......................1-1 IMPORTANT INFORMATION ....................1-2 PREPARATION FOR REMOVAL PROCEDURES ............1-2 REPLACEMENT PARTS ....................1-2 GASKETS, OIL SEALS AND O-RINGS ................1-2 LOCK WASHERS/PLATES AND COTTER PINS ............1-3 BEARINGS AND OIL SEALS ..................1-3 CIRCLIPS ........................1-3 CHECKING OF CONNECTIONS ..................1-4 SPECIAL TOOLS........................1-5...

  • Page 8

    INFO...

  • Page 9: Vehicle Identification Number

    INFO VEHICLE IDENTIFICATION GENERAL INFORMATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped in- to the frame. MODEL LABEL The model label 1 is affixed to the frame under the seat. This information will be needed to order spare parts.

  • Page 10: Important Information

    5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 11: Lock Washers/plates And Cotter Pins

    INFO IMPORTANT INFORMATION EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.

  • Page 12: Checking Of Connections

    INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1. Disconnect: • connector 2. Check: • connector Moisture Dry each terminal with an air blower. Stains/rust Connect and disconnect the terminals several times. 3.

  • Page 13: Special Tools

    INFO SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or impro- vised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 14

    INFO SPECIAL TOOLS Tool name / Usage Illustration Tool No. Rocker arm shaft puller bolt 90890-01083 These tools are used when removing the rocker arm shafts. Weight 90890-01084 These tools are used when removing the rocker arm shafts. Valve spring compressor 90890-04019 These tools are used when removing or installing the valve and the valve spring.

  • Page 15

    This tool is used to install the crankshaft. Crank spacer 90890-04081 This tool is used to install the crankshaft. SEALANT (QUICK GASKET) ® Yamaha Bond No. 1215 ® 90890-85505 This sealant (adhesive) is used for crankcase mating surfaces etc. Ringnut wrench...

  • Page 16

    INFO SPECIAL TOOLS Tool No. Tool name / Usage Illustration T-handle 90890-01326 This tool is needed to loosen and tighten the front fork damper rod holding bolt. Front fork damper rod holder 90890-01460 This tool is needed to hold the front fork damper rod when loosening and tightening the holding bolt.

  • Page 17

    SPEC...

  • Page 18

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

  • Page 19

    SPEC...

  • Page 20: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model TT600RE: 5CH5 Dimensions Overall length 2,220 mm ••• Overall width 865 mm ••• Overall height 1,195 mm ••• Seat height 890 mm ••• Wheelbase 1,480 mm ••• Ground clearance 280 mm •••...

  • Page 21

    SPEC GENERAL SPECIFICATIONS Item Standard Limit Spark plug Manufacturer/model NGK/DPR8EA-9 or NGK/DPR9EA-9 0.8–0.9 mm ••• Clutch type Wet. Multiple-disc Transmission Primary reduction system Spur gear Primary reduction ratio 71/34 (2.088) Secondary reduction system Chain drive Secondary reduction ratio 47/15 (3.133) Number of drive chain sprocket teeth (front/rear) 15/47...

  • Page 22

    SPEC GENERAL SPECIFICATIONS Item Standard Limit Brakes Front: Type Single Ø 267 mm disk brake, 2 x 28 mm Operation Right hand Fluid DOT 4 Rear: Type Single Ø 220 mm disk brake, 1 x 34 mm caliper Operation Right foot Fluid DOT 4 Suspension...

  • Page 23: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head Max. warpage ••• 0.03 mm Cylinder Bore 94.970 - 95.020 mm 95.10 mm Measuring point 50 mm ••• Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 23.000 - 23.021 mm •••...

  • Page 24

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 75-010/126 Tensioning system Automatic Rocker arm/rocker arm shaft Arm inside diameter 12.000 - 12.018 mm ••• Shaft outside diameter 11.976 - 11.991 mm ••• Arm-to-shaft clearance 0.009 - 0.042 mm •••...

  • Page 25

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring Inner spring: Free length intake 40.10 mm 38.10 mm exhaust 40.10 mm 38.10 mm Installed length (valve closed) intake 22.70 mm ••• exhaust 22.70 mm ••• Compressed spring force (installed) intake 164.80 - 190.20 N •••...

  • Page 26

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston ring Top ring: Ring type Barrel Dimensions (B x T) 1.20 x 3.80 mm ••• End gap (installed) 0.30 - 0.45 mm 0.70 mm Ring side clearance 0.040 - 0.080 mm 0.130 mm ring: Ring type Plain...

  • Page 27

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Ballancer Ballancer drive method Gear Clutch Clutch release method Inner push, cam push Friction plate thickness 2.72 - 2.88 mm ••• Wear limit ••• 2.60 mm Plate quantity 6 pcs Friction plate thickness 2.94 - 3.06 mm •••...

  • Page 28

    SPEC MAINTENANCE SPECIFICATIONS ENGINE Cylinder head tightening steps: Crankcase tightening steps: Left crankcase Right crankcase...

  • Page 29

    SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Part to be tightened Thread size Remarks name Cylinder head Washer based bol M8 x 1.25 Cylinder head Stud bolt M10 x 1.25 Cylinder head Hexagon socket head screw M6 x 1.0 Cylinder head Stud bolt M6 x 1.0...

  • Page 30

    SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Part to be tightened Thread size Remarks name Stator (pick-up coil) Hexagon socket head screw M6 x 1.0 Engine oil pipe 1 Hexagon socket head screw M6 x 1.0 Engine oil pipe 2 Union screw M12 x 1.25 Oil delivery pipe Union bolt...

  • Page 31: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering Steering bearing type Taper roller bearing Lock to lock angle (left) 45° ••• Lock to lock angle (right) 45° ••• Front suspension Front fork travel 277 - 283 mm ••• Fork spring free length 530 mm •••...

  • Page 32

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Drive chain Type/manufacturer 520 135ORSB / Regina Chain Link quantity Drive chain slack 30.0 - 40.0 mm ••• Front disc brake Disc outside diameter x thickness 267 x 4 mm ••• Max. deflection ••• 0.15 mm Brake pad lining thickness-inner 7.5 mm...

  • Page 33

    SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Remarks size · · Engine mounting and rear frame: Engine front/Stay engine M10 x 1.25 Stay engine (engine front)/Frame M10 x 1.25 Engine rear under/Frame M10 x 1.25 Engine top/Stay engine M10 x 1.25 Engine protector/Frame...

  • Page 34

    SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size · · Front brake: Front hub/Disc brake M6 x 1.0 Front caliper/Front fork M8 x 1.25 Front caliper/Bleeder tightening M10 x 1.0 Union bolt tightening (front) M10 x 1.0 Rear brake: Rear hub/Disc brake M6 x 1.0...

  • Page 35

    SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size · · Starting motor cord/Starting motor M6 x 1.0 Wire minus lead (-)/Starting motor M6 x 1.0 Front flasher lights/Stay, headlight M6 x 1.0 0.15 Clutch wire/Engine M6 x 1.0 Assist grip (Standing handle)/Rear frame M8 x 1.25 Speedometer...

  • Page 36: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Ignition system Ignition timing (B.T.D.C.) 12° / 1,300 r/min ••• Advanced timing (B.T.D.C.) 31° / 7,500 r/min ••• Advancer type Electrical type Transistorized coil ignition 230 Ω ± 20% L/Y-G/W Pickup coil resistance •••...

  • Page 37

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn Horn type Plane Quantity 1 pcs Manufacturer LEONELLI Max. amperage 1.5 A ••• Flasher relay Type Semi-transistor ••• Model/manufacturer FB222M/NIPPONDENSO ••• Self cancelling device ••• Flasher frequency 75 - 95 cycle/min ••• Wattage 10 W 2 + 3.4 W •••...

  • Page 38: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE This chart specifies torque for standard fasteners All specification data in this manual are listed in SI with standard I.S.O. pitch threads. Torque specifi- and METRIC UNITS. Use this table to convert cations for special components or assemblies are METRIC unit data to IMPERIAL unit data.

  • Page 39: Engine

    Shift cam and bearing (gearshift cam) Shift shaft Bonding agent (rapid seal adhesive) ® Rod housing coupled surfaces Yamaha bond No. 1215 ® Bonding agent (rapid seal adhesive) ® Coupled surfaces (cylinder head and cylinder head cover) Yamaha bond No. 1215 ®...

  • Page 40: Chassis

    SPEC LUBRlCATlON POINTS AND LUBRICANT TYPE CHASSIS Lubrication points (part name) Lubricant type Gear unit (tachometer) Oil seal edges (completely) Wheel axle (front and rear wheels) Rear wheel hub and clutch Bearings brasses (rear arm) and bearing push cover Front footrest Pivot points (brake pedal and shift pedal) Bearings (steering head) Pivot points (brake lever and clutch lever)

  • Page 41: Lubrication Layout

    SPEC LUBRICATION LAYOUT LUBRICATION LAYOUT (1) Oil tank [A] DELIVERY (2) Oil pump [B] RETRIEVAL (3) Oil filter (oil tank) (4) Oil strainer (engine) (5) Oil vapour retrieval hose (6) Oil blow-by retrieval hose 2-22...

  • Page 42

    SPEC LUBRICATION LAYOUT (1) Oil pump [A] DELIVERY (2) Oil filter [B] RETRIEVAL (3) Camshaft (4) Oil delivery hose (5) Main driving shaft (6) Drive shaft 2-23...

  • Page 43

    SPEC LUBRICATION LAYOUT (1) Oil filter [A] DELIVERY (2) Camshaft [B] RETRIEVAL (3) Connecting rod pin (4) Main driving shaft (5) Secondary drive shaft (6) Drain plug 2-24...

  • Page 44

    SPEC LUBRICATION LAYOUT (1) Oil pump [A] DELIVERY (2) Oil filter [B] RETRIEVAL (3) Oil delivery hose (4) Transmission (5) Oil strainer 2-25...

  • Page 45: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Clutch cable Tachometer/ (14) Right turn light (20) Clutch switch odometer cable connector connector Brake hose holder Complete wire (15) Meter wire harness (21) Brake switch Brake hose harness connector connector Throttle cables (10) Socket cover (16) Main switch wire (22) Clip harness connector...

  • Page 46

    SPEC CABLE ROUTING Front brake hose (11) Fuel pipe from fuel (19) Oil hose (oil tank to (28) Wire extension cock engine) Brake hose holder (29) Battery plus cable (12) Flasher relay (20) Oil hose (engine to Left tube guard Lay the brake hose oil tank) (13) Main relay...

  • Page 47

    SPEC CABLE ROUTING Tachometer/ Carburetor suction (12) Rear brake hose Insert the odometer cable pipe holders tachometer/ odometer cable into Tachometer/ Main wire harness (13) Pipe the band 3 and the odometer cable band (14) Air breather pipe holder 2. holder Rear brake switch (15) Spark plug ignition...

  • Page 48

    SPEC CABLE ROUTING Rectifier Right turn wire Wire extension Screw protection 3 harness after setting wiring Wire harness bands Starter power properly. Tail light wire cables Protection harness (10) Engine cables and Left turn wire Air breather pipe side stand switch harness (carburetor) 2-29...

  • Page 49

    SPEC...

  • Page 50: Insp Adj

    INSP...

  • Page 51

    INSP CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTS INTRODUCTION......................3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........3-1 SEAT, FUEL TANK AND REAR COWLING ..............3-3 REMOVAL ......................3-3 INSTALLATION ....................3-3 ENGINE ........................3-4 VALVE CLEARANCE ADJUSTMENT ..............3-4 DRIVE CHAIN ADJUSTMENT ................3-7 IDLE SPEED ADJUSTMENT ................3-7 THROTTLE CABLE FREE PLAY ADJUSTMENT ..........3-8 SPARK PLUG INSPECTION ................3-9 IGNITION TIMING CHECK ................3-11 COMPRESSION INSPECTION ................3-12...

  • Page 52

    INSP ELECTRICAL SYSTEM ....................3-47 CHECKING AND CHARGING THE BATTERY ..........3-47 CHECKING THE FUSES ..................3-53 REPLACING THE HEADLIGHT BULBS ............3-54 REPLACING THE TURN INDICATOR LIGHT BULB..........3-56 REPLACING THE TAIL/BRAKE LIGHT BULB............3-57...

  • Page 53: Chapter 3. Periodic Inspection And Adjustments

    INSP INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.

  • Page 54

    • Check operation. and switches • Adjust headlight beam. * Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NOTE: • The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead.

  • Page 55: Seat, Fuel Tank And Rear Cowling

    INSP SEAT, FUEL TANK AND REAR COWLING SEAT, FUEL TANK AND REAR COWLING Order Job name/Part name Q.ty Remarks Seat, fuel tank and rear cowling Remove the parts in order. removal Seat Fuel pipe NOTE: Be sure the cap is properly tightened and the fuel cock is in the “OFF”...

  • Page 56: Engine

    INSP VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: • Valve clearance must be adjusted when the engine is at ambient temperature. • Adjust valve clearance with the piston under compression at top dead centre (T.D.C.). WARNING Hold the motorcycle firmly in place to prevent it falling over during the operation.

  • Page 57

    INSP VALVE CLEARANCE ADJUSTMENT 6. Align: • Reference mark “T” on the flywheel (1) with the fixed reference mark on the crankcase (2). NOTE: Check that the piston is under compression at top dead centre (T.D.C.). (3) Ignition timing reference mark 7.

  • Page 58

    INSP VALVE CLEARANCE ADJUSTMENT 9. Reassemble: • Caps • Tappet cover (intake) • Tappet covers (exhaust) • Spark plug Tappet cover (exhaust): 12 Nm (1.2 mkg) Bolt (tappet cover - intake): 10 Nm (1.0 mkg) Spark plug: 18 Nm (1.8 mkg) NOTE: The tappet cover (intake) should be mounted with arrow (1) pointing upwards.

  • Page 59: Drive Chain Adjustment

    INSP DRIVE CHAIN ADJUSTMENT IDLE SPEED ADJUSTMENT DRIVE CHAIN ADJUSTMENT The drive chain does not need to be adjusted. IDLE SPEED ADJUSTMENT 1. Start the engine and let it heat. 2. Connect: • The inductive engine speed indicator to the spark plug cable Special tool: P/N.

  • Page 60: Throttle Cable Free Play Adjustment

    INSP THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, adjust the engine idle speed. 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”. 2. Check: •...

  • Page 61: Spark Plug Inspection

    INSP SPARK PLUG INSPECTION SPARK PLUG INSPECTION 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”. 2. Disconnect: • Spark plug cap 3. Remove: • Spark plug (1) CAUTION: Before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinder.

  • Page 62

    INSP SPARK PLUG INSPECTION 8. Lock tighten: • Spark plug Before installing the spark plug, clean the surface and thread. Spark plug: 18 Nm (1.8 mkg) NOTE: Tighten the spark plug by hand before torquing to specification. 9. Connect: • Spark plug cap 10.

  • Page 63: Ignition Timing Check

    INSP IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Start the engine and let it heat. 2. Connect: • Inductive rev counter • Stroboscopic lamp to spark plug cable Inductive engine speed indicator: P/N. 90890-03113 Stroboscopic lamp: P/N. 90890-03141 3. Remove: •...

  • Page 64: Compression Inspection

    INSP COMPRESSION INSPECTION COMPRESSION INSPECTION NOTE: Insufficient compression causes a loss of per- formance. WARNING Set the motorcycle firmly in place to prevent it falling during the operation. 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”.

  • Page 65

    INSP COMPRESSION INSPECTION 8. Check: • Pressure under compression Inspection: • Turn the main switch to "ON". • With the throttle wide open, crank the engine until the reading on the compression gauge stabilized. WARNING While operating the starter, disconnect the spark plug cap to avoid sparks.

  • Page 66

    INSP COMPRESSION INSPECTION Pressure under compression: (after adding oil to the cylinder) Reading Diagnosis Pressure higher Piston worn or than before damaged. Pressure same Cylinder head or as before piston rings, valves, gaskets may be faulty. Pressure above Inspect cylinder maximum value head, valve sur- faces, piston rim to...

  • Page 67: Engine Oil Level Check

    INSP ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL CHECK CAUTION: Do not put additives into the engine oil. The latter also lubricates the clutch and additives might cause it to slide. WARNING Never remove the oil tank cap when the engine is hot.

  • Page 68

    INSP ENGINE OIL LEVEL CHECK If the oil level is below minimum Add oil up to maximum level. Recommended oil: SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature. API Standard: API SE, SF, SG or higher grade CAUTION: •...

  • Page 69: Engine Oil Replacement

    INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT CAUTION: Do not put additives into the engine oil. The latter also lubricates the clutch and additives might cause it to slide. WARNING Never remove the oil tank cap when the engine is hot. The boiling oil might spill over, causing burns.

  • Page 70

    INSP ENGINE OIL REPLACEMENT Fastening torques: Drain plug (engine): 30 Nm (3.0 mkg) Oil tank hose (flange): 10 Nm (1.0 mkg) Oil filter cover air bleeder screw: 5 Nm (0.5 mkg) 9. Fill: • Oil tank Recommended oil: SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature.

  • Page 71

    INSP ENGINE OIL REPLACEMENT Engine oil replacement (with oil filter replace- ment) 1. Warm up the engine for a few minutes. 2. Stop the engine. Place an oil pan under the engine and remove the oil filler cap. 3. Remove the drain plug (1) and drain the engine oil.

  • Page 72

    INSP ENGINE OIL REPLACEMENT 11. Fill: • Oil tank Recommended oil: SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature. API Standard: API SE, SF, SG or higher grade Oil capacity: Total: 3.0 litres Periodic oil change: 2.4 litres...

  • Page 73: Engine Oil Pressure Check

    INSP ENGINE OIL PRESSURE CHECK/ CLUTCH ADJUSTMENT ENGINE OIL PRESSURE CHECK 1. Remove: • Bleeder screw (1) 2. Start the engine and keep it idling until oil flows out of the bleed hole. 3. Inspect: • Conditions of oil at bleeder hole. Oil leakage Oil pressure good.

  • Page 74

    INSP CLUTCH ADJUSTMENT NOTE: After adjustment, recheck lever free play to make sure that it works smoothly and progressively. If it is impossible to obtain the required adjust- ment or if the clutch does not work properly, adjust the internal mechanism. Internal mechanism adjustment 1.

  • Page 75

    INSP CLUTCH ADJUSTMENT 11. Install: • Right crankcase cover • Right crankcase cover fastening screws • Oil delivery hose fastening screw Screw (crankcase cover): 10 Nm (1.0 mkg) Oil delivery hose screw: 18 Nm (1.8 mkg) 12. Connect: • Brake pedal return spring •...

  • Page 76: Air Filter Cleaning

    INSP AIR FILTER CLEANING AIR FILTER CLEANING 1. Remove: • Fast screws (1) • Air filter box cap (2) 2. Pull out: • Filtering element (3) from its seat 3. Wash: • Filtering element (with water biodegradable liquid soap) NOTE: Rinse properly and dry perfectly by squeezing the filtering element, without twisting it! 4.

  • Page 77: Fuel Filter Cleaning

    INSP AIR FILTER CLEANING/ FUEL FILTER CLEANING CAUTION: Periodically check wheter the sleeve on the bottom of the air filter case is empty. Remove the plug (5) and clean it if dirt or water accu- mulate. FUEL FILTER CLEANING 1. Turn the fuel cock to "OFF". 2.

  • Page 78: Engine Oil Tank Filter Cleaning

    INSP ENGINE OIL TANK FILTER CLEANING ENGINE OIL TANK FILTER CLEANING WARNING Securely support the motorcycle so there is no danger of it falling over. 1. Drain: • Engine oil See section “ENGINE OIL REPLACE- MENT”. 2. Remove: • Seat •...

  • Page 79

    INSP ENGINE OIL TANK FILTER CLEANING 7. Reassemble: • OR gaskets • Oil tank filter • Oil delivery hose flange fastening screws Screw (oil delivery hose flange): 10 Nm (1.0 mkg) • Oil return hose • Oil return hose flange fastening screws Screw (oil return hose flange): 35 Nm (3.5 mkg) 8.

  • Page 80: Suction Hose And Manifold Inspection

    INSP SUCTION HOSE AND MANIFOLD INSPECTION/ FUEL LINE INSPECTION SUCTION HOSE AND MANIFOLD INSPECTION 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”. 2. Inspect: • Suction hoses (1) Cracked/damaged Replace. Screw (2) (carburetor manifold): 10 Nm (1.0 mkg) Screw (3) (clamp): 2 Nm (0.2 mkg)

  • Page 81: Exhaust System Inspection

    INSP CRANCKCASE VENTILATION HOSE INSPECTION/ EXHAUST SYSTEM INSPECTION CRANCKCASE VENTILATION HOSE INSPECTION 1. Inspect: • Crankcase ventilation hoses (1) Cracked/Damaged Replace. EXHAUST SYSTEM INSPECTION 1. Inspect: • Exhaust pipe (1) • Muffer (2) Cracks/Damage Replace. • Gaskets (3) Exhaust gas leakage Replace.

  • Page 82: Chassis

    INSP ADJUSTING THE FRONT BRAKE CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • Brake lever position (distance a between the brake lever and the handlebar grip) a. Turn the adjusting dial 1 while holding the lever pushed away from the handlebar grip NOTE: Align the setting on the adjusting dial with the arrow mark 2...

  • Page 83: Adjusting The Rear Brake

    INSP ADJUSTING THE REAR BRAKE ADJUSTING THE REAR BRAKE 1. Check: • Brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification Adjust. Brake pedal position (below the top of the rider footrest): 10 mm 2.

  • Page 84: Checking The Brake Fluid Level

    INSP CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Check: • Brake fluid level Below the minimum level mark a the recommended brake fluid to the prop- er level.

  • Page 85: Brake Pad Wear Inspection

    INSP BRAKE PAD WEAR INSPECTION/ BRAKE HOSING INSPECTION 1. Operate the brake lever or brake pedal. 2. Check: • Thickness of frictional material Out of specification Replace. Wear limit (a): Front: 1.0 mm Rear: 1.0 mm For brake pad replacement, see section “BRAKE REPLACEMENT”...

  • Page 86: Brake Circuit Bleeding

    INSP BRAKE CIRCUIT BLEEDING BRAKE CIRCUIT BLEEDING WARNING If the brake lever or brake pedal has a soft or slack feel, this means that there is air in the brake system. It should be bled away before using the motorcycle. Air in the system seri- ously affects the effectiveness of braking and may cause loss of control of the motorcycle.

  • Page 87: Drive Chain Slack Inspection And Adjustment

    INSP DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT NOTE: If bleeing proves difficult, it may be necessary to allow the brake fluid system to stabilise for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. Top up fluid to the maximum level.

  • Page 88: Drive Chain Lubrication

    INSP DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/ DRIVE CHAIN LUBRICATION • Loosen the axle nut (1). • Loosen the locknuts (2) on each side. To tight- en the chain, turn the chain adjusting bolts (3) in direction (a). Loosen the locknuts on each side.

  • Page 89: Front Fork Inspection

    INSP FRONT FORK INSPECTION/ FRONT FORK ADJUSTMENT FRONT FORK INSPECTION WARNING When inspecting the front fork, hold the motorcycle firmly to prevent it falling over. 1. Place the motorcycle on a level surface. 2. Check: • Inner tube Scratches/Damage Replace. •...

  • Page 90: Rear Shock Absorber Adjustment

    INSP REAR SHOCK ABSORBER ADJUSTMENT REAR SHOCK ABSORBER ADJUSTMENT WARNING This shock absorber contains highly pressur- ized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The man- ufacturer cannot be held responsible for prop- erty damage or personal injury that may result from improper handling.

  • Page 91

    INSP REAR SHOCK ABSORBER ADJUSTMENT NOTE: • Use the special wrench included in the owner's tool kit to make the adjustment. • The spring preload setting is determined by measuring distance A, shown in the illustra- tion. The longer distance A is, the lower the spring preload;...

  • Page 92: Steering Inspection

    INSP STEERING INSPECTION STEERING INSPECTION WARNING Hold the motorcycle firmly in place to prevent it falling over. 1. Raise the front wheel and place a support under the engine. 2. Check: • Steering bearings Grasp the bottoms of the front fork legs and rock back and forward.

  • Page 93: Tyre Inspection

    • A list of tyres approved for this model fol- lowing severe testing by Yamaha is provid- ed. There can be no guarantee of safe road- holding if a combination of tyres different from those indicated is used.

  • Page 94

    INSP TYRE INSPECTION 1. Check: • Tyre pressure Out of specification Adjust. Tire air pressure (measured on cold tires) Load* Front Rear 200 kPa 220 kPa Up to 90 kg (2.00 kgf/cm , (2.20 kgf/cm 2.00 bar) 2.20 bar) 210 kPa 240 kPa 90 kg-maximum (2.10 kgf/cm...

  • Page 95

    INSP TYRE INSPECTION Minimum track thickness: (front and rear) 1,6 mm NOTE: These limits may be different by regulation from country to country. If so, conform to the limits specified by the regulations of your own country. (1) Track thickness (2) Side (3) Wear indicators WARNING...

  • Page 96: Wheel Inspection

    INSP WHEEL INSPECTION/ SPOKE INSPECTION AND TIGHTENING WHEEL INSPECTION 1. Inspect: • Wheels Damage/Deformation Replace. NOTE: Always balance the wheel after the replacement or reassembly of a tyre or rim. WARNING Never try to repair a rim in any way. Bearing inspection Check the front and rear wheel bearings periodi- cally to make sure that they do not have free play...

  • Page 97: Cable Inspection

    INSP CABLE INSPECTION/ LEVER AND PEDAL LUBRICATION CABLE INSPECTION WARNING If the cable sheath is damaged, corrosion might ensue or the cable might not run freely. To avoid such drawbacks, replaced damaged cables as quickly as possible. 1. Inspect: • Cable sheath Damaged Replace the cable assembly.

  • Page 98: Sidestand Lubrication

    INSP SIDESTAND LUBRICATION/ REAR SUSPENSION LUBRICATION SIDESTAND LUBRICATION Lubricate the sidestand pivoting and mating parts. Check to see that the sidestand moves up and down smoothly. Recommended lubricant: SAE 10W30 motor oil REAR SUSPENSION LUBRICATION Lubricate the pivoting parts. Recommended lubricant: Molybdenum disulfide grease 3-46...

  • Page 99: Electrical System

    INSP CHECKING AND CHARGING THE BATTERY ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.

  • Page 100

    INSP CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by meas- uring the voltage at the battery terminals.

  • Page 101

    INSP CHECKING AND CHARGING THE BATTERY WARNING Ambient Do not quick charge a battery. temperature 20 °C CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger. They force a high-amperage current into 30 2520 the battery quickly and can cause battery Condition of charge in battery (%)

  • Page 102

    INSP CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Charger NOTE: Measure the open-circuit meter Voltage should be measured 30 minutes voltage prior to charging. after the machine is stopped. NOTE: Connect a charger and AMP Set the charging voltage at 16 ~ 17 V (if the setting is lower, charging will be meter to the battery and start...

  • Page 103

    INSP CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- voltage prior to charging. utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.

  • Page 104

    INSP CHECKING AND CHARGING THE BATTERY 6. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 2, then the negative lead 1. 7. Check: • Battery terminals Dirt Clean with a wire brush. Loose connection Connect properly.

  • Page 105: Checking The Fuses

    INSP CHECKING THE FUSES CHECKING THE FUSES CAUTION: To avoid a short circuit, always turn the main switch to "OFF" when checking or replacing a fuse. 1. Remove: • Seat • Panel 1 2. Check: • Fuse a. Connect the pocket tester to the fuse and check it for continuity.

  • Page 106: Replacing The Headlight Bulbs

    INSP CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical sys- tem, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 107

    INSP REPLACING THE HEADLIGHT BULBS 7. Install: • Headlight bulb (new) • Headlight bulb holder (by turning it clock- wise (b)) CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.

  • Page 108: Replacing The Turn Indicator Light Bulb

    INSP REPLACING THE TURN INDICATOR LIGHT BULB 4. Install: • Bulb (new) (by pushing it in and turning it clockwise) • Bulb holder • Upper side of the cowling (onto the meter bracket) • Headlight (adjust the headlight beam if necessary) 5.

  • Page 109: Replacing The Tail/brake Light Bulb

    INSP REPLACING THE TAIL/ BRAKE LIGHT BULB REPLACING THE TAIL/BRAKE LIGHT BULB 1. Remove: • Screws (1) (lens fixing) • Lens (2) • Bulb (3) NOTE: To remove the bulb press it into place and turn it counterclockwise (a). 2. Install: •...

  • Page 110

    INSP...

  • Page 111: Chas

    CHAS...

  • Page 112

    CHAS CHAPTER 4. CHASSIS FRONT WHEEL AND BRAKE DISC ........4-1 FRONT WHEEL AND BRAKE DISC REMOVAL .

  • Page 113

    CHAS FRONT FORK ............4-42 FRONT FORK REMOVAL .

  • Page 114: Front Wheel And Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC CHASSIS - FRONT WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Front wheel and brake disc Remove the parts in order. removal WARNING Securely support the motorcycle so there is no danger of it falling over. Speedometer cable Disconnect.

  • Page 115

    CHAS FRONT WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Front wheel disassembly Remove the parts in order. Oil seal Bearing Refer to “FRONT WHEEL DISASSEMBLY/ Spacer ASSEMBLY” section. Oil seal Bearing Reverse the removal procedure for instal- lation.

  • Page 116: Front Wheel Disassembly

    CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL DISASSEMBLY 1. Remove: • Oil seal • Bearing (1) • Spacer Removal procedure: • Clean the outside of the hub. • Remove the dust cover with a flat-headed screwdriver. NOTE: Place a rag on the outside to avoid damaging the hub.

  • Page 117

    CHAS FRONT WHEEL AND BRAKE DISC 4. Tighten: • Loose spokes Spoke: 2 Nm (0.2 mkg) NOTE: After tightening the spokes, check the centring of the wheel. 5. Measure: • Front wheel runout Over the specified limits Replace. Front wheel runout limits: Radial (1) : 1.0 mm Lateral (2) : 0.5 mm 6.

  • Page 118: Brake Disc Inspection

    CHAS FRONT WHEEL AND BRAKE DISC BRAKE DISC INSPECTION 1. Inspect: • Brake disc Wear/Damage Replace. 2. Measure: • Brake disc deflection (a) If over envisaged limits Verify wheel centring. If the wheel centring is correct, replace the brake disc. Maximum deflection (brake disc): 0.15 mm Misure at 2 mm from disc edge...

  • Page 119: Front Wheel Assembly

    CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL INSTALLATION 1. Install: • Brake disc (1) Screw (brake disc): 12 Nm (1.2 mkg) NOTE: • ® Apply LOCTITE to the threads of brake disc screw. • Tighten the screws (brake disc) in stage using a crisscross pattern.

  • Page 120

    CHAS FRONT WHEEL AND BRAKE DISC Procedure: a. Spin the wheel and wait for it to rest. b. Put an “X ” mark on the wheel’s bottom spot. c. Turn the wheel so that the “X ” mark is 90° up. d.

  • Page 121: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE BRAKE PAD 25 Nm (2.5 m • Order Job name/Part name Q.ty Remarks Remove the parts in order. Brake pad removal Brake caliper screw Brake caliper Refer to “BRAKE PAD REPLACEMENT” Pad pin retainer section. Pad pin Brake pad Pad spring...

  • Page 122: Brake Pad Replacement

    CHAS FRONT BRAKE CAUTION: Brake components must not be disassembled. The builder declines every responsibility after brake components disassembly (brake master cylinder or brake caliper) or in case of use of non original parts. DO NOT: • Remove brake components from the motorcycle unless is absolutely necessary.

  • Page 123

    CHAS FRONT BRAKE 3. Lubricate: • Guide pins (1) Lithium-base grease 4. Install: • Pin bracket (2) (on the caliper body (3)) NOTE: Fit the rubber protections (4) when installing the caliper body. 5. Install: • Pad springs (1) (new) •...

  • Page 124: Master Cylinder

    CHAS FRONT BRAKE MASTER CYLINDER 9 Nm (0.9 m • 20 Nm (2.0 m • Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order. Brake fluid Drain. Rear view mirror (right)/ Master cylinder bracket Brake lever Brake switch Union bolt Plain washer...

  • Page 125

    CHAS FRONT BRAKE 1.5 Nm (0.15 m • Order Job name/Part name Q.ty Remarks Master cylinder disassembly Remove the parts in order. Reservoir cap Diaphragm Master cylinder boot Refer to “MASTER CYLINDER ASSEM- Circlip BLY” section. Master cylinder assembly Spring Reverse the disassembly procedure for assembly.

  • Page 126: Master Cylinder Inspection

    CHAS FRONT BRAKE MASTER CYLINDER INSPECTION 1. Inspect: • Master cylinder assembly Wear/scratches Replace the master cylinder assembly. • Master cylinder body Cracks/damage Replace the master cylinder assembly. • Fluid delivery passage (master cylinder) Obstruction Clean with a jet of com- pressed air.

  • Page 127: Master Cylinder Installation

    CHAS FRONT BRAKE 2. Install: • Circlip (1) • Master cylinder boot (2) MASTER CYLINDER INSTALLATION 1. Install: • Master cylinder (1) • Master cylinder bracket (2) Screw (master cylinder bracket): 9 Nm (0.9 mkg) 2. Install: • Plain washer (1) (new) •...

  • Page 128

    CHAS FRONT BRAKE CAUTION: Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING • Use only designated quality brake fluid. Otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.

  • Page 129: Brake Caliper

    CHAS FRONT BRAKE BRAKE CALIPER 20 Nm (2.0 m • 25 Nm (2.5 m • Order Job name/Part name Q.ty Remarks Remove the parts in order. Caliper removal Brake fluid Drain. Union bolt Plain washer Refer to “CALIPER INSTALLATION” sec- Brake hose tion Caliper support bolt...

  • Page 130

    CHAS FRONT BRAKE 14 Nm (1.4 m • Order Job name/Part name Q.ty Remarks Caliper disassembly Remove the parts in order. Brake pad Refer to “BRAKE PAD” section. Pad spring Caliper piston Refer to “BRAKE CALIPER DISASSEM- Dust seal BLY/ASSEMBLY” section. Piston seal Bleed screw Refer the disassembly procedure for as-...

  • Page 131: Brake Caliper Disassembly

    CHAS FRONT BRAKE BRAKE CALIPER DISASSEMBLY 1. Remove: • Brake caliper piston • Dust seal (1) • Piston seal (2) Removal procedure: • Blow compressed air into the hose joint open- ing to force out the caliper piston from the brake caliper body.

  • Page 132: Caliper Assembly

    CHAS FRONT BRAKE • Fluid delivery passage (caliper) Obstruction Clean with compressed air. WARNING In case of non correct operation of the brake caliper, replace the brake caliper assembly. CALIPER ASSEMBLY WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.

  • Page 133

    CHAS FRONT BRAKE WARNING Check that the brake hose routing is correct. Refer to “CABLE ROUTING” section. 2. Fill: • Brake fluid reservoir Recommended brake fluid: DOT 4 CAUTION: Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.

  • Page 134: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Rear wheel and brake disc removal Remove the parts in order. WARNING Securely support the motorcycle so there is no danger of it falling over. Axle nut Wheel axle Push the wheel forward and remove the...

  • Page 135

    CHAS REAR WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Rear wheel disassembly Remove the parts in order. Driven sprocket Damper Spacer Refer to “REAR WHEEL DISASSEMBLY/AS- Oil seal SEMBLY” section. Bearing Bearing Hub dust cover Oil seal Bearing Reverse the removal procedure for installa- Bearing spacer...

  • Page 136: Rear Wheel Disassembly

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL DISASSEMBLY 1. Remove: • Hub and driven sprocket • Dampers • Hub spacer • Oil seal • Hub bearing • Wheel bearing • Wheel spacer • Wheel bearing • Dust cover • Oil seal •...

  • Page 137: Brake Disc Inspection

    CHAS REAR WHEEL AND BRAKE DISC 4. Tighten: • Loose spokes Spoke: 2 Nm (0.2 mkg) NOTE: After tightening the spokes, check the centring of the wheel. 5. Measure: • Rear wheel runout Over the specified limits Replace. Rear wheel runout limits: Radial (1) : 1.0 mm Lateral (2) : 0.5 mm 6.

  • Page 138: Rear Wheel Assembly

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL ASSEMBLY 1. Install: • Wheel spacer • Wheel bearing • Oil seal • Dust cover • Wheel bearing • Wheel spacer • Wheel bearing • Hub bearing • Oil seal • Hub spacer •...

  • Page 139

    CHAS REAR WHEEL AND BRAKE DISC 4. Lubricate: • Wheel axle • Bearings • Edge of hub dust cover Lithium-base grease CAUTION: Check that the brake caliper support has stayed in the correct position on the rear arm. 5. Install: •...

  • Page 140: Wheel Static Balance Adjustment

    CHAS REAR WHEEL AND BRAKE DISC WHEEL STATIC BALANCE ADJUSTMENT NOTE: • After replacing the tire and/or rim, the wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc installed. 1. Remove: • Balancing weight 2.

  • Page 141

    CHAS REAR WHEEL AND BRAKE DISC 5. Check: • Wheel static balance Checking steps: • Turn the wheel so that it comes to each point as shown. • Check that the wheel is at rest at each point. If not, readjust the rear wheel static balance. 4-28...

  • Page 142: Rear Brake

    CHAS REAR BRAKE REAR BRAKE BRAKE PAD Order Job name/Part name Q.ty Remarks Remove the parts in order. Brake pad removal Rear wheel Refer to “REAR WHEEL REMOVAL” section. Brake hose Remove from clamp. Caliper protector Pad pin retainer Pad pin Refer to “BRAKE PAD REPLACEMENT”...

  • Page 143

    CHAS REAR BRAKE CAUTION: Brake components must not be disassem- bled. The builder declines every responsibility after brake components disassembly (brake master cylinder or brake caliper) or in case of use of non original parts. DO NOT: • Remove brake components from the motorcycle unless is absolutely necessary.

  • Page 144

    CHAS REAR BRAKE 3. Install: • Brake pads • Pad support Installation procedure: • Connect the hose (1) firmly to the caliper bleeder screw (2). Place the other end of the hose in an open container. • Loosen the caliper bleeder screw and push the piston into the caliper with your finger.

  • Page 145: Master Cylinder

    CHAS REAR BRAKE MASTER CYLINDER 20 Nm (2.0 m • 4 Nm (0.4 m • 10 Nm (1.0 m • 45 Nm (4.5 m • Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order. Brake fluid Drain.

  • Page 146: Master Cylinder Inspection

    CHAS REAR BRAKE MASTER CYLINDER INSPECTION 1. Inspect: • Master cylinder assembly Wear/scratches Replace the master cylinder assembly. • Master cylinder body Cracks/damage Replace the master cylinder assembly. • Fluid delivery passage (master cylinder) Obstruction Clean with a jet of com- pressed air.

  • Page 147: Master Cylinder Installation

    CHAS REAR BRAKE MASTER CYLINDER INSTALLATION 1. Install: • Brake pedal (refer to “BRAKE PEDAL REMOVAL” section in this Chapter). NOTE: Lubricate the pin of the brake pedal with lithium- base grease. • Master cylinder • Brake fluid reserve tank •...

  • Page 148: Brake Pedal Removal

    CHAS REAR BRAKE 3. Air bleed: • Brake system Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)” in Chapter 3. 4. Inspect: • Brake fluid level Lower than “MIN” mark (1) Fill. Refer to “BRAKE FLUID INSPECTION” section in Chapter 3. (1) Minimum level mark “MIN”...

  • Page 149: Brake Caliper

    CHAS REAR BRAKE BRAKE CALIPER Order Job name/Part name Q.ty Remarks Remove the parts in order. Caliper removal Rear wheel Refer to “REAR WHEEL REMOVAL” sec- tion. Brake fluid Drain. Brake hose Remove from clamp. Caliper protector Brake caliper Remove from caliper support. Union bolt Refer to “BRAKE CALIPER INSTALLA- Plain washer...

  • Page 150

    CHAS REAR BRAKE 14 Nm (1.4 m • 10 Nm (1.0 m • Order Job name/Part name Q.ty Remarks Caliper disassembly Remove the parts in order. Caliper protector Brake pad support Brake pad Refer to “BRAKE PAD” section. Pad support Refer to “BRAKE CALIPER DISASSEM- Caliper piston BLY/ASSEMBLY”...

  • Page 151: Brake Caliper Disassembly

    CHAS REAR BRAKE BRAKE CALIPER DISASSEMBLY 1. Remove: • Brake caliper piston (1) • Dust seal (3) • Piston seal (2) Removal procedure: • Blow compressed air into the hose joint open- ing to force out the caliper piston from the brake caliper body.

  • Page 152: Caliper Installation

    CHAS REAR BRAKE • Fluid delivery passage (caliper) Obstruction Clean with compressed air. WARNING In case of non correct operation of the brake caliper, replace the brake caliper assembly. BRAKE CALIPER ASSEMBLY WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.

  • Page 153

    CHAS REAR BRAKE CAUTION: Check that the brake hose has stayed in cor- rect position with the pipe-fitting matching the projection (a) of the caliper. WARNING Check that the brake hose routing is correct. Refer to “CABLE ROUTING” section. 2. Fill: •...

  • Page 154

    CHAS REAR BRAKE 4. Inspect: • Brake fluid level Lower than “MIN” mark (1) Fill. Refer to “BRAKE FLUID INSPECTION” section in Chapter 3. (1) Minimum level mark “MIN” 4-41...

  • Page 155: Front Fork

    CHAS FRONT FORK FRONT FORK FRONT FORK REMOVAL Order Job name/Part name Q.ty Remarks Remove the parts in order. Front fork removal Front wheel Refer to “FRONT WHEEL” section. Inner tube protector Brake hose guide Protector guide Brake caliper assembly Cowling (displace) Pinch bolt (upper bracket) Cap bolt (loosen)

  • Page 156: Front Fork Disassembly

    CHAS FRONT FORK FRONT FORK DISASSEMBLY Order Job name/Part name Q.ty Remarks Front fork disassembly Remove the parts in order. Refer to “FRONT FORK REMOVAL/INSTAL- LATION”. Cap bolt Seat Spacer Refer to “OIL REPLACEMENT” section. Seat Fork spring Bolt O-ring Damper adjusting cylinder Refer to “SEAL AND BUSH REPLACE- Taper spindle...

  • Page 157

    CHAS FRONT FORK Order Job name/Part name Q.ty Remarks Inner tube Inner tube bushing Oil seal Refer to “SEAL AND BUSH REPLACE- Washer MENT” section. Outer tube bushing Outer tube Reverse the removal procedure for instal- lation. 4-44...

  • Page 158: Front Fork Removal

    CHAS FRONT FORK OIL CAPACITY (IN EACH FORK LEG): 650 cm RECOMMENDED OIL: Liqui Moly Racing suspension oil SAE 7,5 FRONT FORK OIL LEVEL STANDARD 180 mm MINIMUM 190 mm MAXIMUM 170 mm From top of inner tube with inner tube fully com- pressed without spring.

  • Page 159: Oil Replacement

    CHAS FRONT FORK OIL REPLACEMENT NOTE: The quality of the fork oil is of fundamental impor- tance for obtaining the maximum performance and functioning. For this reason it needs to be replaced after the first 3÷4 hours to eliminate any residues due to the adaptation of the internal components and successively every 8 hours for motor-cross and every 20 hours for enduro.

  • Page 160

    CHAS FRONT FORK 7. Fill: • Part of the new oil (with the fork leg in a vertical position) Recommended oil: Liqui Moly Racing suspension oil SAE 7,5 8. Using the inner tube pump back and forth until a regular drag is felt on the return stroke. 9.

  • Page 161

    CHAS FRONT FORK 14. Tighten: • Pinch bolt (upper and lower bracket) Pinch bolt (upper bracket): 28 Nm (2.8 mkg) Pinch bolt (under bracket): 23 Nm (2.3 mkg) NOTE: Always tighten the lower pinch bolt (to the pre- scribed torque) and then the upper one (to the prescribed torque) and then retighten the lower one (to the prescribed torque).

  • Page 162: Cleaning The Dust Seal

    CHAS FRONT FORK CLEANING THE DUST SEAL NOTE: After using the motorcycle it is necessary to clean the dust seal carefully in order to maintain the fork at maximum efficiency. In fact, if dust infiltrates to the inside of the dust seal it can compromise the smoothness and therefore the sensitivity of the fork, and also cause the premature wear of the underlying oil...

  • Page 163: Seal And Bush Replacement

    CHAS FRONT FORK 4. Using a small screwdriver take a small amount of silicon grease and insert it under the lip paying attention not to scratch it. Lubricate the dust seal by rotating it in such a manner that the grease is distributed in the inner part of the lip.

  • Page 164

    CHAS FRONT FORK 3. Insert an Allen key in the bolt (3) at the bottom of the outer tube and the special tool (1) with the holder (2) on the damper cylinder assem- bly and unscrew the bolt completely. CAUTION: Before unscrewing the bolt ensure that the end of the damper rod holder is correctly engaged on the damper cylinder assembly.

  • Page 165

    CHAS FRONT FORK WARNING Never tamper with the damper cylinder assembly! Tampering with the damper cylinder assembly by non authorized personnel can compromise tha safety of the fork. In order not to cause damage to the environment collect the used oil and take it to a collection centre. 6.

  • Page 166

    CHAS FRONT FORK 9. With a few sharp blows withdraw the inner tube (2) from the outer tube (3). NOTE: The oil seal (4), the washer (5), the outer tube DU bush (6) and the inner tube DU bush (7) are installed on the inner tube and must be removed and replaced with new one.

  • Page 167

    CHAS FRONT FORK 12. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool (3) until the DU outer tube bush (4) is correct- ly positioned in its seat. ~ 40 mm 13.

  • Page 168

    CHAS FRONT FORK 16. Tightly clamp the fork leg horizontally fasten- ing it by caliper attachment on the outer tube. 17. Install: • Snap ring (1) CAUTION: Check that the snap ring is correctly seated. 18. Install: • Dust seal (1) (new) NOTE: Apply lightweight lithium-soap base grease to the dust seal before installing it.

  • Page 169: Oil Leakage From Dust Seal

    CHAS FRONT FORK 19. Insert: • Damper cylinder assembly (in the inner tube) 20. Insert an Allen key in the bolt (3) at the bot- tom of the outer tube and the special tool (1) with the holder (2) on the damper cylinder assembly and screw the bolt completely.

  • Page 170: Front Fork Inspection

    CHAS FRONT FORK FRONT FORK INSPECTION CAUTION: The front fork has a very sophisticated inter- nal construction and is particularly sensitive to foreign bodies. Use enough care to prevent foreign bodies entering when replacing oil or disassembling and reassembling the front fork. 1.

  • Page 171

    CHAS FRONT FORK WARNING Do not attempt to straighten a bent inner tube as this may have dangerous consequences. 4. Inspect: • Outer tube (1) Score marks/Wear/Damage Replace. 5. Inspect: • Cap bolt • O-ring Wear/Damage Replace. 4-58...

  • Page 172: Front Fork Installation

    CHAS FRONT FORK FRONT FORK INSTALLATION 1. Install: • Front fork (1) Temporarily tighten the pinch bolts (lower). 2. Tighten: • Cap bolt Cap bolt: 20 Nm (2.0 kgm) NOTE: Do not tighten the pinch bolt (upper) yet. 3. Adjust: •...

  • Page 173

    CHAS FRONT FORK ADJUSTING THE FRONT FORK This front fork is equipped with spring pre-load ad- justing bolts. WARNING Always adjust both fork legs equally, other- wise poor handling and loss of stability may result. Adjust the spring preload as follows. To increase the spring preload and thereby hard- en the suspension, turn the adjusting bolt on each fork leg in direction a.

  • Page 174: Steering

    CHAS STEERING TIGHTENING PROCEDURE • Initial tightening 38 Nm (3.8 mkg) • Loosen 1 turn • Final tightening 4 Nm (0.4 mkg) Order Job name/Part name Q.ty Remarks Steering removal Remove the parts in order. Park the motorcycle on a level surface. WARNING Securely support the motorcycle to pre- vent it falling over.

  • Page 175

    CHAS STEERING TIGHTENING PROCEDURE • Initial tightening 38 Nm (3.8 mkg) • Loosen 1 turn • Final tightening 4 Nm (0.4 mkg) Order Job name/Part name Q.ty Remarks Upper ring nut Refer to “STEERING REMOVAL/INSTAL- Lower ring nut LATION” section. Ball race cover Lower bracket/Steering axle Bearing (upper)

  • Page 176

    CHAS STEERING (1) Handle upper holder (7) Brake hose holder (13) Bearings (2) Handle lower holder (8) Plate washer (14) Steering lock (3) Spacer (9) Special washer (15) Steering axle (4) Nut (10) Upper ring nut (16) Wire guide (5) Plate washer (11) Lower ring nut (6) Upper bracket (12) Ball race cover...

  • Page 177: Steering Removal

    CHAS STEERING STEERING REMOVAL 1. Park the motorcycle on a level surface. WARNING Support the motorcycle securely to prevent it falling over. 2. Raise the front wheel placing a suitable sup- port under the engine. 3. Remove: • Front wheel Refer to “FRONT WHEEL-REMOVAL”...

  • Page 178: Steering Inspection

    CHAS STEERING 7. Remove: • Ring nut (lower) (1) • Use the ring nut wrench (2) Ring nut wrench (2): 90890-01268 WARNING Support the steering axle to prevent it falling. STEERING INSPECTION 1. Wash the bearings in solvent. 2. Inspect: •...

  • Page 179

    CHAS STEERING 3. Install: • Ring nut (lower) (1) Use the ring nut wrench (2). Ring nut wrench: 90890-01268 NOTE: Apply the lithium soap-base grease to the steer- ing axle thread. Lower ring nut tightening steps: • Tighten the ring nut (1) using the ring nut wrench.

  • Page 180

    CHAS STEERING Installation steps: • Install the ring nut (upper) (1). • Finger tighten the ring nut (upper), then align the slots of both ring nuts. If not aligned, hold the lower ring nut and tighten the other until they are aligned. •...

  • Page 181

    CHAS STEERING 8. After tightening the nut, check the steering for smooth movement. If it is not smooth, adjust by progressively loosening the (lower) ring nut. 9. Tighten: • Pinch bolts (upper and lower bracket) Pinch bolt (upper bracket): 28 Nm (2.8 mkg) Pinch bolt (under bracket): 23 Nm (2.3 mkg) NOTE:...

  • Page 182: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order. WARNING Securely support the motorcycle so there is no danger of it falling over. Seat Refer to “SEAT, FUEL TANK AND REAR Fuel tank COWLING”...

  • Page 183

    CHAS REAR SHOCK ABSORBER Order Job name/Part name Q.ty Remarks Lower bolt Upper bolt Reverse the removal procedure for instal- lation. 4-70...

  • Page 184

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

  • Page 185: Note On Disposal

    CHAS REAR SHOCK ABSORBER WARNING This shock absorber contains high-pressure nitrogen gas. Read the following information carefully before handling it. The manufacturer cannot be held responsible for any damage or injury that may result from improper handling. • Never tamper with or attempt to open the cylinder or the tank.

  • Page 186: Shock Absorber Removal

    CHAS REAR SHOCK ABSORBER SHOCK ABSORBER REMOVAL WARNING Support the motorcycle securely to prevent it from falling over. 1. Park the motorcycle on a level surface. 2. Remove: • Seat • Rear cowling • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”...

  • Page 187: Shock Absorber Inspection

    CHAS REAR SHOCK ABSORBER SHOCK ABSORBER INSPECTION 1. Inspect: • Shock absorber Oil leak/Damaged Replace. REAR SHOCK ABSORBER ADJUSTMENT This shock absorber is equipped with a spring pre- load adjuster. CAUTION: Never attempt to turn an adjusting mecha- nism beyond the maximum or minimum set- tings.

  • Page 188

    CHAS REAR SHOCK ABSORBER 2. Tighten the locknut to the specified torque. Locknut: 45 Nm (4.5 m·kgf) CAUTION: Always tighten the locknut against the adjust- ing nut, and then tighten the locknut to the specified torque. 4-75...

  • Page 189: Swingarm

    CHAS SWINGARM SWINGARM (1) Upper chain case (4) Swingarm guard seal [A] LATERAL FREE PLAY (END): 1.0 mm (2) Swingarm (5) Connecting rod [B] LATERAL FREE PLAY: 0.4 ~ 0.7 mm (3) Chain support (6) Relay arm 4-76...

  • Page 190: Swingarm Removal

    CHAS SWINGARM SWINGARM REMOVAL NOTE Check free play and remove swingarm, if neces- sary, after removing the rear shock absorber. 1. Remove: • Swingarm connecting rod bolt (1) 2. Check: • Swingarm free play Inspection procedure: • Check the tightening torque of the nut which fastens the swingarm pivot shaft (1).

  • Page 191: Swingarm Inspection

    CHAS SWINGARM 3. Remove: • Upper chain case (1) • Chain support (2) 4. Remove: • Swingarm pivot shaft • Swingarm SWINGARM INSPECTION 1. Inspect: • Swingarm Deformation/Cracks/Damage Replace. 2. Inspect: • Connecting rod (1) • Relay arm (2) Deformation/Cracks/Damage Replace.

  • Page 192: Lateral Free Play Adjustment

    CHAS SWINGARM LATERAL FREE PLAY ADJUSTMENT 1. Measure: • Length of bushes A1 and A2 Out of specification Replace. Length of bushes: A1 = 76.70 ~ 76.85 mm A2 = 74.90 ~ 75.00 mm 2. Measure: • Length B1 and B2 3.

  • Page 193: Swingarm Installation

    CHAS SWINGARM SWINGARM INSTALLATION Perform “removal” operations in reverse order. Note the following points. 1. Lubricate: • Bearings • Bushes • Thrust cover (inside) • Flange • Swingarm pivot shaft • Bolt (connecting rod) • Bolt (relay arm) • Bolt (shock absorber) Lithium-base grease 2.

  • Page 194

    CHAS SWINGARM 4. Adjust: • Drive chain slack Drive chain slack: 30 ~ 40 mm Refer to “DRIVE CHAIN SLACK ADJUST- MENT” in CHAPTER 3. 5. Install: • Fuel tank • Rear cowling • Seat Bolt (seat): 10 Nm (1.0 mkg) Refer to “SEAT, FUEL TANK AND REAR COWLING”...

  • Page 195: Drive Chain, Drive Sprocket And Rear Wheel Sprocket

    DRIVE CHAIN, DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET NOTE: Before removing the drive chain, drive sprocket and rear wheel sprocket, it is necessary to meas- ure the free play and length of the 10 links in the chain.

  • Page 196: Drive Chain Inspection

    DRIVE CHAIN, DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET 6. Remove: • Swingarm • Drive chain Refer to “REAR SHOCK ABSORBER REMOVAL” and “SWINGARM REMOVAL” sections. DRIVE CHAIN INSPECTION 1. Measure: • Length of 10 links (drive chain) Out of specification Replace drive chain.

  • Page 197

    DRIVE CHAIN, DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET 3. Inspect: • Seal rings (1) (drive chain) Damaged Replace drive chain. • Rollers (2) • Lateral plates (3) Damage/Wear Replace drive chain. 4. Lubricate: • Drive chain Lubricant for drive chain: SAE 80W/90 engine oil or special lubricant for O-Ring chains.

  • Page 198: Drive Chain Installation

    DRIVE CHAIN, DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET 3. Tighten: • Rear wheel sprocket fastening bolts Rear wheel sprocket fastening bolts: 48 Nm (4.8 mkg) DRIVE CHAIN INSTALLATION Perform “REMOVAL” operations in reverse order. Pay special attention to the following points. 1.

  • Page 199

    DRIVE CHAIN, DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET 5. Tighten: • Rear wheel axle nut Rear wheel axle nut: 115 Nm (11.5 mkg) Refer to “REAR WHEEL INSTALLATION” section. 7. Install: • Cover (drive sprocket) • Shift pedal Screws (drive sprocket cover): 10 Nm (1.0 mkg) Bolt (shift pedal): 10 Nm (1.0 mkg)

  • Page 201

    CHAPTER 5. ENGINE ENGINE REMOVAL ........... . . 5-1 MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET, CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL .

  • Page 202

    ENGINE ASSEMBLY AND SETTING ........5-41 VALVES AND ROCKER ARMS .

  • Page 203: Engine Removal

    ENGINE REMOVAL ENGINE ENGINE REMOVAL MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL Order Job name/Part name Q.ty Remarks Muffler, exhaust pipe, engine Remove the parts in order. protector, drive sprocket crankcase cover, drive sprocket and shift pedal removal Park the motorcycle in a stable and level position.

  • Page 204

    ENGINE REMOVAL Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL REPLACEMENT” section in CHAPTER 3). Remove the seat, the fuel tank and the rear cowling (refer to “SEAT, FUEL TANK AND REAR COWLING” section in CHAPTER 3).

  • Page 205

    ENGINE REMOVAL Order Job name/Part name Q.ty Remarks – Starter leads Disconnect. – Starter Remove. Connectors of engine wire harness Disconnect. Oil delivery hose Disconnect. Oil return hose Disconnect. Oil breather pipe (to oil tank) – Disconnect. Oil breather pipe (to air filter box) –...

  • Page 206: Engine Mounting Bolt

    ENGINE REMOVAL ENGINE MOUNTING BOLT Order Job name/Part name Q.ty Remarks CAUTION: The engine and rear arm are assembled together on the rear pivot shaft. When removing the pivot shaft, it is thus necessary to pay special care with the rear arm.

  • Page 207: Engine Disassembly

    ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON NOTE: The cylinder head, cylinder, camshaft and piston can be examined with the engine installed by removing the following parts. • Seat • Fuel tank • Rear cowling • Carburetor •...

  • Page 208

    ENGINE DISASSEMBLY 4. Remove: • Cam sprocket (1) • Camshaft (2) • Caps (left crankcase cover) NOTE: Fix a safety wire (3) to the timing chain to prevent it falling into the crankcase. 5. Remove: • Chain stopper guide (1) 6.

  • Page 209

    ENGINE DISASSEMBLY 7. Remove: • Gasket (1) (cylinder head) • Pins (2) • Cylinder (3) • Gasket (4) (cylinder) 8. Remove: • Pins (1) 9. Remove: • Pin ring (1) NOTE: Before removing the pin ring, cover the crankcase with a clean cloth to prevent the ring falling into the crankcase cavity.

  • Page 210: Intermediate Starter Gear, Crankcase Cover (l) And Generator Stator

    ENGINE DISASSEMBLY Piston pin puller set: P/N. 90890-01304 CAUTION: Avoid using the hammer to pull the pin out. INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L) AND GENERATOR STATOR NOTE: With the engine installed, maintenance of the inter- mediate starter gear and the crankcase cover (L) may be performed by removing the following parts.

  • Page 211: Crankcase Cover (r), Clutch, Primary Drive Gear And Balancer Shaft Gear

    ENGINE DISASSEMBLY 4. Remove: • Crankcase cover gasket (1) (L) • Centring pins • Seal ring and O-ring • Gasket 5. Remove: • Intermediate starter gear (1) • Bearing (2) • Distributor shaft (3) 6. Remove: • Cable clamp (1) •...

  • Page 212

    ENGINE DISASSEMBLY 1. Remove: • Engine oil delivery hose screw • Copper washer • Oil filter cover (1) • Oil filter • Seal ring and O-Ring • Crankcase cover (2) (R) 2. Remove: • Compression spring (1) • Pressure plate (2) •...

  • Page 213

    ENGINE DISASSEMBLY 3. Remove • Primary drive gear (1) • Disc (2) • Balancer drive gear (3) • Disc (4) • Key (5) • Disc washer (6) • Disc (7) • Balancer gear (8) • Straight key (9) NOTE: Before loosening the nut (9) (primary drive gear) and nut (10) (balancer gear), straighten the wash lock tab.

  • Page 214: Oil Pump And Shift Lever

    ENGINE DISASSEMBLY OIL PUMP AND SHIFT LEVER NOTE: The oil pump and shift lever may be checked with the engine installed by removing the following parts: • Footrest (R) • Oil delivery hose screw • Crankcase (R) • Clutch 1. Remove: •...

  • Page 215: Ac Generator And Timing Chain

    ENGINE DISASSEMBLY AC GENERATOR AND TIMING CHAIN NOTE: The AC generator may be inspected with the engine installed by removing the following parts: • Crankcase (L) 1. Remove: • Nut (1) • Washer (2) • Rotor (3) (with starter gear) •...

  • Page 216: Crankcase(r)

    ENGINE DISASSEMBLY CRANKCASE (R) 1. Remove: • Crankcase (R) NOTE: • Loosen nuts starting from the one with the highest number. • Loosen all by 1/4 turn and then remove. Removal procedure: • Set the crankcase separating tool (1) in place. Crankcase separating tool: P/N.

  • Page 217

    ENGINE DISASSEMBLY CAUTION: • Be careful not to damage surfaces in con- tact with the crankcase. • Use a soft hammer to hit the engine crankcase. Only hit the reinforced parts. Do not hit the surface in contact with the gasket.

  • Page 218: Gearbox And Transmission

    ENGINE DISASSEMBLY GEARBOX AND TRANSMISSION 1. Remove: • Guide bar (1) • Shift cam (2) • Selector fork # 3 (3) • Selector fork # 2 (4) • Selector fork # 1 (5) 2. Remove: • Transmission assembly unit (1) 3.

  • Page 219: Balancer Shaft And Crankshaft

    ENGINE DISASSEMBLY BALANCER SHAFT AND CRANKSHAFT 1. Remove: • Balancer shaft (1) 2. Remove: • Crankshaft (1) NOTE: • Remove the crankshaft by using the crankcase separating tool (2). Crankcase separating tool: P/N. 90890-01135 • Tighten the separating tool bolts, making sure that the tool body is parallel with the engine crankcase.

  • Page 220: Rocker Arms

    ENGINE DISASSEMBLY ROCKER ARMS NOTE: The rocker arms may be examined with the engine installed by removing the following parts. • Seat • Fuel tank • Cylinder head cover 1. Remove: • Cap (1) 2. Remove: • Bolts (1) (rocker shaft) 3.

  • Page 221: Valves

    ENGINE DISASSEMBLY VALVES NOTE: The valves may be inspected with the engine installed by removing the following parts. • Seat • Fuel tank • Exhaust pipe • Carburetor • Cylinder head cover • Cylinder head 1. Check: • Valve seal Leakage from valve seats’...

  • Page 222

    ENGINE DISASSEMBLY 2. Remove: • Cotters (1) • Top spring retainer (2) • Internal spring (3) • External spring (4) • Lower spring retainer (5) • Valve (6) • Valve stem seal (7) NOTE: Mark each part and its position so that each may reassembled as before.

  • Page 223: Inspection And Repair

    INSPECTION AND REPAIR INSPECTION AND REPAIR CYLINDER HEAD 1. Eliminate: • Carbon deposits (from combustion chamber) Use a rounded scraper (1). NOTE: Do not use a pointed tool to avoid damaging or scratching: • spark plug thread • valve seats •...

  • Page 224: Valves And Valve Guides

    INSPECTION AND REPAIR VALVES AND VALVE GUIDES 1. Measure: • Clearance between stem and guide Clearance between stem and guide = Internal diameter of valve guide (a) – Diameter of valve stem (b) Out of specification Replace valve guide. Clearance between stem and guide: Intake: 0.010 ~ 0.037 mm <Limit>: 0.08 mm...

  • Page 225: Valveseat

    INSPECTION AND REPAIR 2. Clean the valve surfaces of the carbon deposits. 3. Inspect: • Valve seal surface Pitting/Wear Grind the valve seal sur- face. 4. Measure: • Edge thickness (a) Out of specification Replace valve. Edge thickness (a): Intake: 1.0 ~ 1.4 mm <Limit>: 0.8 mm Exhaust:...

  • Page 226

    INSPECTION AND REPAIR 3. Measure: • Valve seat width (a) Out of specification Renew valve seat. Valve seat width (a): Intake: 1.0 ~ 1.2 mm <Limit>: 1.8 mm Exhaust: 1.0 ~ 1.2 mm <Limit>: 1.8 mm Measurement steps: • Apply Prussian blue (Dykem) to the valve seat.

  • Page 227

    INSPECTION AND REPAIR Mill the valve seat as follows: Section Cutter 30° 45° 60° Valve seat faults recorded by analysing the valve seal surface: [A] If the valve surface resembles that shown in the figure, this means that the valve seat is centred on the surface but is too wide.

  • Page 228

    INSPECTION AND REPAIR 5. Emery: • Valve seal surface • Valve seat NOTE: If the valve seat is renewed or the valve and guide replaced, the valve seat and seal surface must be lapped. Lapping steps: • Apply rough-lapping compound to the valve seal surface.

  • Page 229: Valve Springs

    INSPECTION AND REPAIR • Apply Prussian blue (Dykem) to the valve seal surface. • Install the valve in the cylinder head. • Press the valve onto the housing through the guide to leave a clear outline. • Measure the valve seat width once more. If the width of the valve is out of specification alter and relap.

  • Page 230: Camshaft

    INSPECTION AND REPAIR CAMSHAFT 1. Inspect: • Cam eccentrics Pitting/Scratches/Blue colour Replace camshaft. 2. Measure: • Cam eccentrics Out of specification Replace camshaft. Intake: 36.47~36.57 mm 30.06~30.16 mm Exhaust: 36.62~36.72 mm 30.11~30.21 mm ROCKER ARMS AND ROCKER SHAFT 1. Inspect: •...

  • Page 231: Camshaft Chain And Sprocket

    INSPECTION AND REPAIR 3. Measure: • Rocker arm-shaft clearance Rocker arm-shaft clearance Internal diameter (a) of rocker arm – External diameter (b) of shaft Out of specification Replace whole unit. Rocker shaft clearance: 0.009 ~ 0.042 mm CAMSHAFT CHAIN AND SPROCKET 1.

  • Page 232: Camshaft Chain Guide

    INSPECTION AND REPAIR CAMSHAFT CHAIN GUIDE 1. Inspect: • Side chain guide (exhaust) (1) • Side chain guide (intake) (2) Wear/Damage Replace. CYLINDER AND PISTON 1. Inspect: • Piston and cylinder walls Vertical scratches Replace cylinder liner and piston. 2. Measure: •...

  • Page 233

    INSPECTION AND REPAIR • If the measurements are out of tolerance, replace the piston and circlips all together. Third step • Calculate the piston-cylinder free play accord- ing to the following formula. Piston-cylinder clearance = Cylinder boring “C” – Piston skirt diameter “P” Piston-cylinder clearance: 0.045 ~ 0.065 mm <Limit>: 0.15 mm...

  • Page 234: Piston Rings

    INSPECTION AND REPAIR PISTON RINGS 1. Measure: • Side clearance of rings Use a thickness gauge. Out of specification Replace piston. NOTE: Before measuring side clearance, remove carbon deposits from the piston ring seats and from the rings themselves. Piston ring side clearance (installed): Upper ring 0.04 ~ 0.08 mm...

  • Page 235: Pistonpin

    INSPECTION AND REPAIR PISTON PIN 1. Check: • Piston pin Blue colour/Grooves Replace and check lubrication system. 2. Measure: • External diameter (a) of pin Out of specification Replace. External diameter (pin): 21.991 ~ 22.000 mm 3. Measure: • Clearance between piston pin and pin seat Out of specification Replace.

  • Page 236

    INSPECTION AND REPAIR 2. Inspect: • Clutch gear assy bearing Damaged Replace. 3. Inspect: • Groove in clutch boss. Pitting: Moderate Burr. Accentuated Replace clutch boss. NOTE: Pitting of the clutch boss grooves causes irregular functioning. 4. Measure: • Thickness of friction plates Out of specification Replace all plates.

  • Page 237: Oilpump

    INSPECTION AND REPAIR 7. Measure: • Free length of clutch compression springs Out of specification Replace all springs. Free length of clutch compression spring (a): 42.8 mm OIL PUMP 1. Measure: • Clearance between rotors (a) (Between the internal rotor (1) and the external rotor (2)) •...

  • Page 238: Transmission And Gearbox

    INSPECTION AND REPAIR TRANSMISSION AND GEARBOX 1. Inspect: • Shift fork pin (1) • Shift fork pawl (2) Lines/Creases/Wear Replace. 2. Inspect: • Shift cam groove • Shift cam pins Wear/Damage Replace. 3. Check: • Shift fork movement Rough functioning Replace shift forks and/or guide bars.

  • Page 239

    INSPECTION AND REPAIR 6. Inspect: • Gear teeth Brown colouring/Pitting/Wear Replace. • Mating clutches Rounded edges/Cracks/Missing frag- ments Replace. 7. Check: • Proper mating of each gear (with corre- sponding part) • Gear movement Roughness Replace. Transmission gear assembly steps: •...

  • Page 240: Starter Transmission

    INSPECTION AND REPAIR STARTER TRANSMISSION 1. Check: • Starter clutch functioning (1). Turn the clutch in the direction indicated by the arrow. Irregular functioning/Damage Replace the clutch. • Install the starter rim on the gear and hold the gear firm. •...

  • Page 241: Crankshaft

    INSPECTION AND REPAIR CRANKSHAFT 1. Measure: • Width of crank (A) Out of specification Replace crankshaft. Width of crank: 74.95 ~ 75.00 mm • Runout (B) Out of specification Replace crankshaft and/or crank bearing. Crankshaft runout: <Limit>: 0.03 mm • Connecting rod small end clearance (C) Out of specification Replace connecting...

  • Page 242: Balancer Shaft Drive And Driven Gears

    INSPECTION AND REPAIR BALANCER SHAFT DRIVE AND DRIVEN GEARS 1. Inspect: • Drive gear teeth (1) • Driven gear teeth (2) Wear/damage Replace both gears. 2. Check: • Marks (1) If they are not aligned Align the marks as shown in the figure. CRANKCASE 1.

  • Page 243

    ENGINE ASSEMBLY AND SETTING ENGINE ASSEMBLY AND SETTING VALVES AND ROCKER ARMS (1) Rocker arm n. 2 (10) Valve (intake) (2) Wave washer (11) Lower valve spring (3) Rocker shaft (intake) retainer (4) Rocker arm n. 1 (12) Rocker shaft (5) Valve cotters (exhaust) (6) Upper valve spring...

  • Page 244: Engine Assembly And Setting

    ENGINE ASSEMBLY AND SETTING VALVES 1. Burrs: • Valve stem tip (leave the valve stem tip with an oil stone). 2. Lubricate: • Valve stem and oil seal (apply high quality molybdenum disulfide oil) 3. Install: • Oil seal (1) •...

  • Page 245: Rocker Arms

    ENGINE ASSEMBLY AND SETTING ROCKER ARMS 1. Lubricate: • Rocker shaft (apply engine oil) 2. Install: • Rocker arm • Rocker shaft Screws (1) (rocker shaft): 10 Nm (1.0 kgm) NOTE: Each rocker arm is numbered. (1) # 1 (2) # 2 (3) # 3 (4) # 4 3.

  • Page 246: Crankshaft And Balancer Shaft

    ENGINE ASSEMBLY AND SETTING CRANKSHAFT AND BALANCER SHAFT (1) Connecting rod pin (5) Bearing (2) Crank (left) (6) Bearing (3) Connecting rod (7) Balancer shaft (4) Bearing (8) Bearing 5-44...

  • Page 247

    ENGINE ASSEMBLY AND SETTING CRANKSHAFT AND BALANCER SHAFT 1. Install: • Crankshaft Crankshaft installation tool (1): P/N. Y U-90050 Crankshaft installation tool spacer (2): P/N. 90890-01274 Crankshaft installation tool bolt (3): P/N. 90890-01275 Adapter # 10 (Ml 4) (4): P/N. Y M-90069 P/N.

  • Page 248: Transmission

    ENGINE ASSEMBLY AND SETTING TRANSMISSION (1) Sprocket (10) Bearing (2) Oil seal (11) Bearing (3) Bearing (12) Second sprocket gear (4) Second wheel gear (13) Fifth sprocket gear (5) Secondary shaft (14) Third sprocket gear (6) Fifth wheel gear (15) Fourth sprocket gear (7) Third wheel gear (16) Main shaft (8) Fourth wheel gear...

  • Page 249: Gearbox

    ENGINE ASSEMBLY AND SETTING GEARBOX (1) Stopper lever (8) Shift shaft #1 (2) Guide bar (9) Shift shaft #2 (3) Shift fork #3 (10) Oil seal (4) Shift fork #1 (11) Shift lever (5) Shift cam (6) Guide bar (7) Shift fork #2 5-47...

  • Page 250: Transmission And Gearbox

    ENGINE ASSEMBLY AND SETTING TRANSMISSION AND GEARBOX 1. Install: • Transmission assembly (1) 2. Install: • Shift fork #1 (1) • Shift fork #2 (2) • Shift fork #3 (3) • Shift cam (4) • Guide bar (5) NOTE: Each shift fork is identified by the number stamped on its side.

  • Page 251: Engine Oil Pump And Oil Strainer

    ENGINE ASSEMBLY AND SETTING ENGINE OIL PUMP AND OIL STRAINER (1) Oil strainer (2) Oil pump (3) Oil pump gear 5-49...

  • Page 252: Crankcase

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

  • Page 253: Engine Oil Strainer

    7 Nm (0.7 mkg) Screw (oil passage cover): 7 Nm (0.7 mkg) WARNING Always use a new gasket. CRANKCASE 1. Apply: Yamaha bond N° 1215 ® (1) • (on the crankcase mating surfaces) Yamaha bond N° 1215 ® : P/N. 90890-85505 Install: •...

  • Page 254: Shift Shaft And Oil Pump

    ENGINE ASSEMBLY AND SETTING 4. Tighten: • Screws (crankcase) (1) ~ (14) NOTE: Tighten the screws beginning with the one with the lowest number. Screw (crankcase): 10 Nm (1.0 mkg) 5. Apply: • 4-stroke engine oil (to the connecting rod pin, the bearing and the oil passage).

  • Page 255

    ENGINE ASSEMBLY AND SETTING NOTE: When installing the shift lever, align the mark on the lever with that on the shift shaft. 3. Install: • Circlip (1) (to the driving axle) • Spacer (2) • Circlip (3) 4. Apply: • 4-stroke engine oil (oil pipes in crankcase) CAUTION:...

  • Page 256: Timing Chain

    ENGINE ASSEMBLY AND SETTING TIMING CHAIN 1. Install: • Timing chain (1) • Chain guide (2) 5-54...

  • Page 257: Piston And Rings

    ENGINE ASSEMBLY AND SETTING PISTON AND RINGS PISTON SIZE: 94.915 ~ 94.965 mm (1) Ring (upper) PISTON RING END GAP: (2) Ring (lower) TOP: 0.30 ~ 0.45 mm (3) Scraper 2ND: 0.30 ~ 0.45 mm (4) Piston OIL: 0.20 ~ 0.70 mm (5) Piston pin PISTON RING SIDE CLEARANCE: (6) Circlip...

  • Page 258: Cylinder

    ENGINE ASSEMBLY AND SETTING CYLINDER (1) Gasket (2) Cylinder (3) O-Ring (4) Gasket (5) Dowel pin (6) Dowel pin 5-56...

  • Page 259: Cylinder Head

    ENGINE ASSEMBLY AND SETTING CYLINDER HEAD (1) Cylinder head cover (7) Cylinder head (2) O-Ring (8) Valve guide (3) Tappet cover (intake valve) (intake) (9) Valve guide (4) Tappet covers (exhaust) (exhaust valve) (5) O-Ring (10) Spark plug (6) Cap (11) Dowel pin 10 Nm (1.0 m kg 7.2 ft...

  • Page 260: Camshaft And Timing Chain

    ENGINE ASSEMBLY AND SETTING CAMSHAFT AND TIMING CHAIN (1) Camshaft (2) Cam chain sprocket (3) Chain stopper guide (4) Timing chain (5) Chain stopper guide (6) Gasket (7) Chain tensioner 5-58...

  • Page 261: Piston, Cylinder, Cylinder Head And Camshaft

    ENGINE ASSEMBLY AND SETTING PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT 1. Apply: • 4-stroke engine oil (on piston pin). 2. Install: • Piston (1) • Pin (2) • Circlip (3) NOTE: • Arrow (4) on the piston must point towards the front of the engine.

  • Page 262

    ENGINE ASSEMBLY AND SETTING 5. Offset the piston ring end gaps as illustrated in the figure. NOTE: • Check that the marks and numbers stamped by the manufacturer on the piston rings face upwards. • Before installing the cylinder, lubricate the pis- ton rings liberally with 4-stroke engine oil.

  • Page 263

    ENGINE ASSEMBLY AND SETTING 7. Install: • Dowel pins (1) • O-Ring (2) • Gasket (3) (cylinder head) 8. Install: • Cylinder head NOTE: Tighten screws beginning with the one with the lowest number. Cylinder head: Screw (l), (2), (3) and (4): 29 Nm (2.9 mkg) Nut (5) and (6): 22 Nm (2.2 mkg)

  • Page 264

    20 Nm (2.0 mkg) • If the marks are not aligned, replace the chain sprocket mating piston and chain. 10. Apply: Yamaha Bond N° 1215 ® (1) • (on the mating surfaces) Sigillante (Quick Gasket) ® Yamaha bond N° 1215 ® : P/N.

  • Page 265

    ENGINE ASSEMBLY AND SETTING 13. Install: • Chain tensioner Assembly steps: • Remove the chain tensioner screw (1), the washer (2) and the spring (3). • Release the chain tensioner unidirectional cam (4) and push the thrust rod (5). • Install the chain tensioner in the cylinder with a new gasket.

  • Page 266

    ENGINE ASSEMBLY AND SETTING 15. Install: • Tappet covers (1) (exhaust) • Tappet cover (2) (intake) • Spark plug (3) Tappet cover (exhaust): 12 Nm (1.2 mkg) Screw (tappet cover-intake): 10 Nm (1.0 mkg) Spark plug: 18 Nm (1.8 mkg) NOTE: The tappet cover (intake) should be assembled with the arrow (4) pointing upwards.

  • Page 267: Ac Generator

    ENGINE ASSEMBLY AND SETTING AC GENERATOR PICKUP COIL RESISTANCE: 230 Ω ± 20% at 20°C (68°F) (1) Rotor (Blue/Yellow - Green/White) (2) Pick-up coil (3) Stator winding CHARGING COIL RESISTANCE: 0.65 Ω ± 20% at 20°C (68°F) (White - White) 5-65...

  • Page 268

    ENGINE ASSEMBLY AND SETTING AC GENERATOR 1. Install: • Woodruff key (1) • Washer (2) • Bearing (3) • Rotor (4) • Washer (5) • Nut (6) NOTE: When installing the AC generator rotor, check that the woodruff key fits properly into its seat on the crankshaft.

  • Page 269: Oil Filter And Oil Hoses

    ENGINE ASSEMBLY AND SETTING OIL FILTER AND OIL HOSES (1) Oil filter (2) Filter cover (3) Oil hose (4) Oil hose (5) Oil delivery hose (6) Oil drain plug 5-67...

  • Page 270: Balancer Shaft Gear And Primary Transmission Gear

    ENGINE ASSEMBLY AND SETTING BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR (1) Straight key (9) Balancer shaft drive gear (2) Balancer shaft gear (10) Plate (3) Breather plate (11) Primary drive gear (4) Lock washer (12) Lock washer (5) Nut (13) Nut (6) Plate washer (7) Straight key...

  • Page 271

    ENGINE ASSEMBLY AND SETTING BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR 1. Install: • Key (1) • Balancer shaft gear (2) • Plate (3) • Lock washer (4) • Nut (5) (balancer shaft gear) • Washer (6) • Key (7) •...

  • Page 272: Clutch

    ENGINE ASSEMBLY AND SETTING CLUTCH (1) Compression spring (9) Clutch boss (2) Pressure plate (10) Thrust plate (3) Push rod (11) Primary driven gear (4) Ball comp. (5) Friction plate (type A) (12) Push rod (6) Clutch boss spring (13) Push lever (7) Clutch plate (14) Primary drive gear (8) Friction plate (type B)

  • Page 273

    ENGINE ASSEMBLY AND SETTING CLUTCH 1. Install: • Plain washer • Spring • Push lever (1) Screw (push lever): 12 Nm (1.2 mkg) 2. Install: • Push rod (1) • Primary driven gear comp. (2) • Thrust plate (3) • Clutch boss (4) •...

  • Page 274

    ENGINE ASSEMBLY AND SETTING NOTE: Install the friction and clutch plates to the clutch boss, beginning and ending with a friction plate. CAUTION: • The two friction plates (type A) (15) with the widest internal diameter should be assembled in second and last place. •...

  • Page 275: Starter Gears

    ENGINE ASSEMBLY AND SETTING STARTER GEARS (1) Starter gear (2) Starter neutral gear 1 (3) Starter neutral gear 2 (4) Starter gear (5) Starter clutch 5-73...

  • Page 276: Starter Neutral Gear And Crankcase Cover (l)

    ENGINE ASSEMBLY AND SETTING STARTER NEUTRAL GEAR AND CRANKCASE COVER (L)) 1. Install: • Stator winding (1) • Pick-up coil (2) • Cable clamp (3) Screws (stator and coil): 7 Nm (0.7 mkg) Use LOCTITE ® Screw (cable clamp): 7 Nm (0.7 mkg) 2.

  • Page 277

    ENGINE ASSEMBLY AND SETTING 4. Install: • Neutral switch cable (1) 5. Install: • Shaft (1) • Bearing (2) • Starter intermediate gear 1 (3) 6. Install: • Centring pins • Gasket • Cover (1) (starter intermediate gear) Screw (cover): 10 Nm (1.0 mkg) 5-75...

  • Page 278: Engine Reassembly

    ENGINE REASSEMBLY ENGINE REASSEMBLY To reassemble the engine, repeat the procedures described in the paragraph “ ENGINE REMOVAL” in this chapter in reverse order. Pay attention to the following points. 1. Install: • Sprocket (1) • Drive chain Nut (sprocket): 110 Nm (11.0 mkg) NOTE: Bend the lock washer tab along the face of the...

  • Page 279

    ENGINE REASSEMBLY 4. Install: • Oil delivery hose (1) Union bolt: 18 Nm (1.8 mkg) 5. Remove: • Tappet cover (intake) • Air bleeder screw (oil filter cover) 6. Apply: • 4-stroke engine oil • (on the top side of the camshaft and in the oil filter housing).

  • Page 280

    ENGINE REASSEMBLY 9. Install: • Carburetor Screw (clamp): 2 Nm (0.2 mkg) See section “CARBURETOR-INSTALLA- TION” in CHAPTER 6. 10. Adjust: • Throttle cable free play Free play: 3 ~ 5 mm See section “THROTTLE CABLE FREE PLAY ADJUSTMENT” in CHAPTER 3. 11.

  • Page 281: Carb

    CARB...

  • Page 282

    CARB CHAPTER 6 CARBURETOR CARBURETOR REMOVAL....................6-1 TECHNICAL SPECIFICATIONS/TIGHTENING TORQUES/EXPLODED VIEW ....6-3 SECTION VIEW ......................6-5 CARBURETOR DISASSEMBLY ..................6-6 CARBURETOR INSPECTION ..................6-9 CARBURETOR ASSEMBLY ....................6-11 FUEL LEVEL ADJUSTMENT (CARBURETOR INSTALLED) .......... 6-16...

  • Page 283

    CARB...

  • Page 284

    CARB CARBURETOR REMOVAL CARBURETOR CARBURETOR REMOVAL Order Job name/Part name Q.ty Remarks Carburetor removal Remove the parts in order. Seat Refer to “SEAT, FUEL TANK AND REAR COWLING" section in CHAPTER 3. Fuel pipe NOTE: Fuel tank Be sure the cap is properly tightened and the fuel cock is in the “OFF”...

  • Page 285

    CARB CARBURETOR REMOVAL Order Job name/Part name Q.ty Remarks Hose clamp Loosen. NOTE: Move carburetor manifold clamps towards the rear side. Carburetor Reverse the removal procedure for installa- tion. Adjust throttle cable free play (refer to THROTTLE CABLE FREE PLAY ADJUST- MENT”...

  • Page 286

    CARB CARBURETOR TYPE: Y30PV-2ATK MANUFACTURER: TEIKEI 2 Nm (0.2 m . kg, 1.4 ft . lb) 3 Nm (0.3 m . kg, 2.1 ft . lb) 2 Nm m . kg, (0.2 1.4 ft . lb m . kg, 6.3 ft . lb 9 Nm (0.9 m .

  • Page 287

    CARB CARBURETOR Carburetor (13) Throttle valve (27) Spring (42) Needle valve set assembly spring (28) Drain valve (43) Stop screw set (14) Spring washer Cover gasket (44) Throttle screw set (29) Pipe (15) Nut Gasket, nozzle (30) Pipe (45) Diaphragm (16) Gasket Float (46) Needle set 1...

  • Page 288

    CARB CARBURETOR SECTION VIEW (8) Main nozzle (secondary) (1) Needle jet (primary) (2) Valve seat (9) Main jet (secondary) (3) Needle valve [A] Primary carburetor (4) Main nozzle (primary) [B] Secondary carburetor (5) Main jet (primary) (6) Pilot air screw Fuel (7) Needle jet (secondary) Mixture...

  • Page 289

    CARB CARBURETOR DISASSEMBLY CARBURETOR DISASSEMBLY 1. Remove: • Support plate (1) (front) • Support plate (2) (rear) 2. Separate: • Primary carburetor • Secondary carburetor Primary carburetor 1. Remove: • Float chamber (1) • Float pin (2) • Float (3) NOTE: Remove the float needle in the direction of the arrow.

  • Page 290

    CARB CARBURETOR DISASSEMBLY 2. Remove: • Needle valve set/Valve seat (1) • Main jet/Main nozzle 1 (2) • Pilot jet (3) • Pilot screw set (4) • O-Ring (5) 3. Remove: • Stop screw (1) • Starter set (2) 4. Remove: •...

  • Page 291

    CARB CARBURETOR DISASSEMBLY 7. Remove: • Throttle shaft (1) • Spring (2) 8. Remove: • Connecter comp. (1) • Needle jet (2) • Throttle valve (3) Secondary carburetor 1. Remove: • Drain plug (1) • Main jet (2) 2. Remove: •...

  • Page 292

    CARB CARBURETOR INSPECTION CARBURETOR INSPECTION 1. Inspect: • Carburetor body Soiled Clean. NOTE: Use petroleum-based solutions to clean. Clean all passages and jets with compressed air. 2. Inspect: • Valve seat (1) • Needle valve set (2) Wear/Corrosion Replace. • O-Ring (3) Damaged Replace.

  • Page 293

    CARB CARBURETOR INSPECTION 6. Inspect: • Throttle valve (1) (primary) • Diaphragm (2) (secondary) ear/Damaged Replace. 7. Check: • Free movement Hampered Replace. Fit the throttle valve and diaphragm into the carburetor body and check that move- ment is free. [A] Primary carburetor [B] Secondary carburetor 8.

  • Page 294

    CARB CARBURETOR ASSEMBLY CARBURETOR ASSEMBLY Perform “CARBURETOR DISASSEMBLY” opera- tions in reverse order. Pay attention to the follow- ing points. CAUTION: Wash all parts with clean petrol prior to reassembly. Secondary carburetor 1. Install: • Needle jet (1) • Diaphragm (2) •...

  • Page 295

    CARB CARBURETOR ASSEMBLY Primary carburetor 1. Install: • Needle jet (1) • Connecter comp. (2) NOTE: Check that the connecter comp. (1) is in the posi- tion shown in the figure. 2. Install: • Throttle valve 3. Install: • Spring •...

  • Page 296

    CARB CARBURETOR ASSEMBLY 5. Install: • Cable holder • Collar • Throttle lever NOTE: Check that the throttle shaft lever (2) and the adjuster bolt (3) are aligned when tightening the throttle nut (1). Screw (cable holder): 3 Nm (0.3 mkg) 6.

  • Page 297

    CARB CARBURETOR ASSEMBLY 10. Install: • Float pin (1) NOTE: Assemble the float pin in the opposite direction to the arrow. 11. Measure: • Float height (a) Out of specification Adjust. Float height: 27.0 - 29.0 mm Measurement and adjustment: •...

  • Page 298

    CARB CARBURETOR ASSEMBLY 14. Install: • Primary carburetor • Secondary carburetor 15. Install: • Support plate (front) (1) • Support plate (rear) (2) Screw (support plate): 3.5 Nm (0.35 mkg) 16. Adjust: • Synchronisation of secondary carburetor Adjustment: • Move the primary throttle valve (1) to a height of 7.0 mm as shown in the figure.

  • Page 299

    CARB CARBURETOR ASSEMBLY FUEL LEVEL ADJUSTMENT (CARBURE- TOR INSTALLED 1. Place the motorcycle on a level surface. 2. Make sure that the carburetor is in a horizon- tal position by placing a hydraulic jack under the engine. 3. Connect the fuel level gauge (1) to the carbu- rettor nipple.

  • Page 300: Elec

    ELEC...

  • Page 301

    ELEC CHAPTER 7 ELECTRICAL ELECTRICAL CIRCUIT DIAGRAM ......... 7-1 COLOUR CODE .

  • Page 302

    ELEC...

  • Page 303: Electrical Circuit Diagram

    ELEC ELECTRICAL CIRCUIT DIAGRAM ELECTRICAL - ELECTRICAL CIRCUIT DIAGRAM...

  • Page 304: Colour Code

    ELEC ELECTRICAL CIRCUIT DIAGRAM (1) AC generator/Pickup coil (17) Ignition coil (2) Rectifier/Regulator (18) Left handlebar switch (3) Battery (19) Horn switch (4) Starter relay (20) Diode (5) Starting motor (21) Pass switch (6) Fuse (22) Dimmer switch (7) Main switch (23) Flasher switch (8) Right handlebar switch (24) Horn...

  • Page 305: Electrical Components

    ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS BATTERY: CAPACITY 12V – 8Ah (1) Main wire harness SPECIFIC GRAVITY: 1.320 (2) Diodes (3) Extension wire harness (4) Rectifier/Regulator (5) CDI ignition unit (6) Battery (12V – 8Ah) (7) Starter relay (8) Fuse (20A)

  • Page 306

    ELEC ELECTRICAL COMPONENTS (1) Ignition coil IGNITION COIL: (2) Spark plug cap Primary winding resistance: (3) Flasher relay 4 Ω Ω ± 15% at 20°C (68°F) (4) Horn (5) Clutch switch Secondary winding resistance: (6) Relay assy 13 kΩ Ω ± 20% at 20°C (68°F) (7) Sidestand switch (8) Neutral switch (9) Main switch...

  • Page 307: Switch Check

    ELEC SWITCH CHECK SWITCH CHECK Check the continuity between the switch terminals to verify whether connections are correct. To check the switch, read the following points. SWITCH CONNECTION The table shown here contains the connections between the switch terminals (eg main switch, handlebar switches, brake switch, light switch etc).

  • Page 308

    ELEC SWITCH CHECK 1. Detach the main switch connector from the harness connector. CAUTION When detaching the connector, do not pull by the cables. This way the cables might discon- nect from the terminals inside the connector itself. 2. Check to see if any cables are disconnected from their terminal inside the connector.

  • Page 309

    ELEC SWITCH CHECK NOTE: Use the thin tester terminals to check continuity, as the terminals might come into contact with oth- ers inside the connector. • Check continuity between “R” and “Br” at switch positions ON (1), OFF (2) and PARK (3). There must be continuity (ie the tester must show “0”) at ON and there must be no continu- ity (ie the tester must show “∞”...

  • Page 310: Light Inspection (headlights, Tail Light And Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)

    ELEC LIGHT INSPECTION LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHTS, DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) Check the continuity between the bulb terminals to see that they are undamaged. BULB TYPES The bulbs used are classified as shown to the left according to type of attachment.

  • Page 311

    ELEC LIGHT INSPECTION CAUTION: When removing a bulb be careful to hold the bulbholder or its housing firmly. Never pull the cable, as it might detach from the terminal inside the connector. WARNING Keep inflammable products and hands well away from bulbs when they are on (danger of burns and fire).

  • Page 312

    ELEC 7-10...

  • Page 313: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM - CIRCUIT DIAGRAM 7-11...

  • Page 314

    ELEC IGNITION SYSTEM The diagram illustrates the ignition circuit inside the motorcycles electric system. NOTE: For the colour code and legend, see page 7-2. AC generator/Pickup coil (12) Clutch switch Rectifier/Regulator (13) Sidestand switch Battery (14) Neutral switch Fuse (15) Diode Main switch (16) Ignitor unit Engine stop switch...

  • Page 315: Diagnostics

    ELEC IGNITION SYSTEM DIAGNOSTICS IF THE IGNITION SYSTEM WERE TO STOP WORKING (NO OR INTERMITTENT SPARK) Procedure 7. Main switch Check: 8. Engine stop switch 1. Fuse 9. Sidestand switch 2. Battery 10. Neutral switch 3. Spark plug 11. Clutch switch 4.

  • Page 316

    ELEC IGNITION SYSTEM 3. Spark plug. • Check the conditions of the spark plug. • Check the type of spark plug used. • Check the electrodes gap. Standard spark plug: OUT OF SPECIFICATION DPR8EA-9 (NGK), DPR9EA-9 Electrodes gap: DPR8EA-9, DPR9EA-9 (NGK) 0.8 ~ 0.9 mm Correct the electrodes gap or replace the spark plug.

  • Page 317

    ELEC IGNITION SYSTEM 5. Spark plug cap resistance. • Remove the spark plug cap. • Connect the pocket tester (Ω x 1k) to the spark plug cap. OUT OF SPECIFICATION The spark plug cap is defective. Replace. • Check that the spark plug cap has the specified resistance.

  • Page 318

    ELEC IGNITION SYSTEM Primary winding resistance: 4 Ω ± ± 15% at 20°C (68°F) (Terminal (+) – Terminal (–)) • Connect the pocket tester (Ω x 1) to the ignition coil. Tester terminal (+) Spark plug cable (1) Tester terminal (–) Pole (+) OUT OF SPECIFICATION •...

  • Page 319

    ELEC IGNITION SYSTEM 8. Emergency stop engine switch. • Disconnect the emergency stop engine switch connector (Brown, Green/Yellow and Red/Black) from the wire harness. • Connect the pocket tester (Ω x 1) to the switch cables. Refer to “SWITCH CHECK” in Chapter 3. Tester terminal (+) Red/Black (1) cable Tester terminal (–)

  • Page 320

    ELEC IGNITION SYSTEM 10. Neutral switch. • Disconnect the neutral switch cable (Sky blue). • Connect the pocket tester (Ω x 1) to the neutral switch cables. Refer to “SWITCH CHECK” in Chapter 3. Tester terminal (+) Sky blue cable (1) Tester terminal (–) Earth In gear...

  • Page 321

    ELEC IGNITION SYSTEM 12. Pick-up coil resistance. • Disconnect the generator connector (Green/White and Blue/Yellow). • Connect the pocket tester (Ω x 100) to pick-up coil cables. Tester terminal (+) Blue/Yellow cable (1) Tester terminal (–) Green/White cable (2) • Check that the pick-up coil resistance is as OUT OF SPECIFICATIONS specified.

  • Page 322

    ELEC 7-20...

  • Page 323: Electrical Starting System

    ELEC ELECTRICAL STARTING SYSTEM ELECTRICAL STARTING SYSTEM - CIRCUIT DIAGRAM 7-21...

  • Page 324

    ELEC ELECTRICAL STARTING SYSTEM The diagram illustrates the electrical starting system-circuit inside the motorcycles electric system. NOTE: For the colour code and legend, see page 7-2. Battery (10) Starter switch Starter relay (11) Diode Starting motor (12) Clutch switch Fuse (13) Sidestand switch Main switch (14) Neutral switch...

  • Page 325: Starting Circuit Operation

    ELEC ELECTRICAL STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed).

  • Page 326: Diagnostics

    ELEC ELECTRICAL STARTING SYSTEM DIAGNOSTICS THE STARTER FAILS TO WORK Procedure (6) Engine stop switch Inspect: (7) Sidestand switch (1) Fuse (8) Neutral switch (2) Battery (9) Clutch switch (3) Starting motor (10) Starter switch (4) Starter relay (11) Harness connections (5) Main switch NOTE: Before starting inspections, remove the following parts:...

  • Page 327

    ELEC ELECTRICAL STARTING SYSTEM WARNING 3. Starter • A wire that is used as a jumper lead must • Connect the positive terminal of the bat- have at least the same capacity of the bat- tery (1) and the starter cable (2) using a tery lead, otherwise the jumper lead may connection cable (3) *.

  • Page 328

    ELEC ELECTRICAL STARTING SYSTEM 5. Main switch • Disconnect the main switch connector from the wire harness. • Connect the pocket tester (Ω x 1) to the main switch cables. Refer to “SWITCH CHECK” in Chapter 3. PARK INCORRECT Br L Br L The main switch is defective.

  • Page 329

    ELEC ELECTRICAL STARTING SYSTEM 7. Sidestand switch. • Disconnect the sidestand switch connec- tor (Black and Black) from the wire har- ness. • Connect the pocket tester (Ω x 1) to the sidestand switch cables. Refer to “SWITCH CHECK” in Chapter 3. Tester terminal (+) Black cable (1) Tester terminal (–)

  • Page 330

    ELEC ELECTRICAL STARTING SYSTEM 9. Clutch switch. • Disconnect the clutch switch connector from the harness. • Connect the pocket tester (Ω x 1) to the clutch switch cable. • Check the clutch switch component for continuity between “Black (1)” and “Black (2)”.

  • Page 331

    ELEC ELECTRICAL STARTING SYSTEM 11. Harness connections. UNCERTAIN CONNECTIONS Check the connections of the entire starter system. See the “ELECTRIC CIRCUIT DIAGRAM”. Correct. 7-29...

  • Page 332: Starter Motor

    ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR BRUSH LENGHT LIMIT (1) Brushes 5 mm (0.20 in) (2) Armature COMMUTATOR WEAR LIMIT: (3) Stator 27 mm (1.06 in) (4) O-Ring MICA UNDERCUT: 0.7 mm (0.027 in) ARMATURE COIL RESISTANCE: 0.03 ~ 0.04 Ω at 20°C (68°F) 7-30...

  • Page 333

    ELEC ELECTRICAL STARTING SYSTEM Removal 1. Remove: • The starter motor Refer to the “ENGINE REMOVAL” sec- tion in CHAPTER 5. Disassembly 1. Remove: • Circlip (1) • Drive gear (2) • Screws (3) • Rear bracket (4) • Washers (5) •...

  • Page 334

    ELEC ELECTRICAL STARTING SYSTEM 4. Inspect: • Armature coils (insulation/continuity). Out of specification Replace the motor. How to inspect the excitation coils: • Connect the pocket tester and check continuity (1) and insulation (2). • Check the armature resistance: Armature coil resistance: Continuity check (1): 0 Ω...

  • Page 335

    ELEC ELECTRICAL STARTING SYSTEM Assembly Revert the disassembly procedure. Pay attention to the following points: 1. Install: • Brush housing NOTE: Align the jutting surface on the brush housing with the slot (2). 2. Install: • Stator (1) • Front bracket (2) NOTE: Align the reference marks (3) on the stator with the corresponding reference marks on the cover...

  • Page 336

    ELEC 7-34...

  • Page 337: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM – CIRCUIT DIAGRAM 7-35...

  • Page 338

    ELEC CHARGING SYSTEM The diagram illustrates the charging circuit inside the motorcycles electric system. NOTE: For the colour code and legend, see page 7-2. AC generator/Pickup coil Rectifier/Regulator Battery Fuse 7-36...

  • Page 339: Diagnostics

    ELEC CHARGING SYSTEM DIAGNOSTICS THE BATTERY IS NOT BEING CHARGED Procedure Inspect: 1. Fuse 4. Stator winding resistance 5. Harness connection 2. Battery 3. Charging voltage (whole connection system) NOTE: Before starting inspections, remove the following parts: 1. Seat 2. Rear cowling •...

  • Page 340

    ELEC CHARGING SYSTEM 3. Charging voltage • Connect the inductive rev counter to the spark plug cable. • Connect the pocket tester (DC 20V) to the battery, as shown. Tester terminal (+) Battery terminal (+) Tester terminal (-) Battery terminal (-) •...

  • Page 341

    ELEC CHARGING SYSTEM Stator coils (2) Tester terminal (+) White cable (1) Tester terminal (-) White cable (3) • Check that the winding resistance of the stator complies with specifications. Stator coil resistance: OUT OF SPECIFICATIONS White (1) – White (2) 0.65 Ω...

  • Page 342

    ELEC 7-40...

  • Page 343: Light System

    ELEC LIGHT SYSTEM LIGHT SYSTEM - CIRCUIT DIAGRAM 7-41...

  • Page 344

    ELEC LIGHT SYSTEM The diagram shows the light system circuit inside the electric system of the motorcycle. NOTE: For the colour codes and complete legend, see page 7-2. (3) Battery (22) Dimmer switch (6) Fuse (26) Headlight (7) Main switch (28) Relay assy (18) Left handlebar switch (31) Tail/stop light...

  • Page 345: Diagnostics

    ELEC LIGHT SYSTEM DIAGNOSTICS THE HIGH BEAM LIGHT, PARKING INDICATOR LIGHT, REAR LIGHT, FRONT PARKING LIGHT AND/OR INSTRUMENT LIGHTS FAIL TO TURN ON. Procedure Inspect: 4. Dipped/high beam light and dimmer switch 1. Fuse 5. Relay assy 2. Battery 6. Harness connections (full system of connec- 3.

  • Page 346

    ELEC LIGHT SYSTEM 3. Main switch. • Disconnect the main switch connector from the wire harness. • Connect the pocket tester (Ω x 1) to the switch cables. Refer to “SWITCH CHECK” in CHAPTER PARK INCORRECT Br L Br L The main switch is defective.

  • Page 347

    ELEC LIGHT SYSTEM 5. Starter circuit cut-off relay. • Connect the pocket tester (DC 20V) and the battery (12V) to the cut-off relay con- nector terminal of the starter circuit. Battery terminal (+) White/Black terminal (1) Battery terminal (–) Black terminal (2) Tester terminal (+) Brown terminal (3) Tester terminal (–)

  • Page 348: Light System Inspection

    ELEC LIGHT SYSTEM LIGHT SYSTEM INSPECTION NOTE: To proceed to the control of the light system, start the engine and then stop it by the emergency engine stop switch. In this way the light relay remains excited and it is possible to check the light system. 1.

  • Page 349

    ELEC LIGHT SYSTEM • Turn the main switch to ON. • Turn the lights switch to “LO” or “HI”. • Check the voltage (12V) on the “Green” and “Yellow” cable at the bulbholder ter- minals. IN COMPLIANCE WITH SPECIFICATIONS (12V) The circuit is efficient.

  • Page 350

    ELEC LIGHT SYSTEM 3. The parking light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Replace the bulb and/or bulbholder. Refer to “BULB INSPECTION” section. CONTINUITY 2. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector.

  • Page 351

    ELEC LIGHT SYSTEM 4. The rear light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Refer to “BULB INSPECTION” section. Replace the bulb and/or bulbholder. CONTINUITY 2. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector.

  • Page 352

    ELEC 7-50...

  • Page 353: Circuit Diagram

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM - CIRCUIT DIAGRAM 7-51...

  • Page 354

    ELEC SIGNAL SYSTEM The diagram shows the signal system circuit inside the electric system of the motorcycle. NOTE: For the colour codes and complete legend, see page 7-2. (3) Battery (23) Flasher switch (6) Fuse (24) Horn (7) Main switch (25) Flasher relay (11) Diode (27) Flasher light...

  • Page 355: Diagnostics

    ELEC SIGNAL SYSTEM DIAGNOSTICS • THE FLASHER LIGHTS, BRAKE LIGHT AND/OR WARNING LIGHTS FAIL TO TURN ON. • THE HORN FAILS TO SOUND. Procedure Check: 1. Fuse 2. Battery 3. Main switch 4. Harness connections (entire system of con- nections) NOTE: •...

  • Page 356

    ELEC SIGNAL SYSTEM 3. Main switch. • Disconnect the main switch connector (Blue, Red and Brown) from the wire har- ness. • Connect the pocket tester (Ω x 1) to the main switch cables. Refer to “SWITCH CHECK” section. Tester terminal (+) Red cable (1) Tester terminal (–) Brown cable (2)

  • Page 357: Signal System Control

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CONTROL 1. The horn does not work. 1. Horn switch. • Disconnect the left handlebar switch con- nector from the wire harness. • Connect the pocket tester (Ω x 1) to the switch terminals. • Check the switch component for conti- nuity between “Pink (1)”...

  • Page 358

    ELEC SIGNAL SYSTEM 3. Horn. • Disconnect the “Pink” cable from horn ter- minal. • Connect a special cable (1) to the horn terminal and earth the cable. • Turn the main switch to ON. THE HORN WORKS The horn is efficient. THE HORN DOES NOT WORK 4.

  • Page 359

    ELEC SIGNAL SYSTEM 2. The rear stop light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Refer to “BULB INSPECTION” section. Replace the bulb and/or bulbholder. CONTINUITY 2. Brake switch. •...

  • Page 360

    ELEC SIGNAL SYSTEM 3. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector. Tester terminal (+) Green/Yellow cable (1) Tester terminal (–) Black terminal (2) OUT OF SPECIFICATION The circuit from the main switch to the bulbhol- •...

  • Page 361

    ELEC SIGNAL SYSTEM • Check the switch component for conti- nuity between “Brown/White (1)” and “Brown/Black (2)” and “Brown/White (1)” and “Green/Black (3)”. Refer to “SWITCH CHECK” section. Y GB INCORRECT The direction indicator switch is defective. Replace. CORRECT 3. Direction indicator lamp relay. •...

  • Page 362

    ELEC SIGNAL SYSTEM 4. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector. Tester terminal (+) Brown/White terminal (1) Tester terminal (–) Earth OUT OF SPECIFICATION The direction indicator lamp relay is defective. • Turn the main switch to ON. Replace.

  • Page 363

    ELEC SIGNAL SYSTEM 5. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector. • Connect the left handlebar switch connec- tor to the wire harness. To the left flasher light: Tester terminal (+) ➔ Green/Black terminal (1) Tester terminal (–) ➔...

  • Page 364

    ELEC SIGNAL SYSTEM 4. The “N” neutral light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Refer to “BULB INSPECTION” section. Replace the bulb and/or bulbholder. CONTINUITY 2. Neutral switch. •...

  • Page 365

    ELEC SIGNAL SYSTEM OUT OF SPECIFICATION • Turn the main switch to ON. • Check the voltage (12V) on the Brown ca- ble of the bulbholder connector. IN COMPLIANCE WITH The circuit from the main switch to the bulbhol- SPECIFICATIONS (12V) der connector is defective.

  • Page 366

    ELEC 7-64...

  • Page 367: Trbl Shtg

    TRBL SHTG...

  • Page 368

    TRBL SHTG CHAPTER 8° TROUBLESHOOTING FAILURE TO START/DIFFICULTIES IN STARTING ......8-1 FUEL SYSTEM ........... . 8-1 ELECTRICAL SYSTEM .

  • Page 369

    TRBL SHTG...

  • Page 370: Failure To Start/difficulties In Starting

    TRBL FAILURE TO START/ SHTG DIFFICULTIES IN STARTING TROUBLESHOOTING NOTE: The troubleshooting tables that follow do not identify every cause of trouble. They may however prove helpful as a guide to identifying trouble. To inspect, adjust or replace parts, refer to the appropriate sec- tion in the manual.

  • Page 371: Electrical System

    TRBL FAILURE TO START/ SHTG DIFFICULTIES IN STARTING PROBABLE CAUSES ELECTRICAL SYSTEM • Spark plug Electrodes gap not correct • Electrodes worn • Feed cable interrupted • Wrong thermal grading of spark plug • Defective spark plug cap • Ignition coil Primary or secondary winding interrupted •...

  • Page 372: Poor Performance At Idle Speed

    TRBL POOR PERFORMANCE AT IDLE SPEED/ SHTG UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED POOR PERFORMANCE AT IDLE SPEED PROBABLE CAUSES • Carburetor The starter piston fails to return freely • Pilot jet obstructed or loose • Pilot jet obstructed • Pilot air screw wrongly set •...

  • Page 373: Difficulties In Shifting

    TRBL SHTG DIFFICULTIES IN SHIFTING DIFFICULTIES IN SHIFTING SHIFTING IMPOSSIBLE PROBABLE CAUSES • Clutch Clutch cable wrongly set • Wrong position of push lever • Irregular engagement of push lever and push • Pressure plate deformed • Clutch springs not preloaded uniformly •...

  • Page 374: Clutch Slides Or Fails To Release

    TRBL SHTG CLUTCH SLIDES OR FAILS TO RELEASE CLUTCH SLIDES OR FAILS TO RELEASE PROBABLE CAUSES CLUTCH SLIDES • Clutch Clutch cable wrongly set • Clutch springs loose • Clutch spring yielded • Friction plates worn • Clutch plates worn •...

  • Page 375: Defective Brakes

    TRBL DEFECTIVE BRAKES/ SHTG OIL LEAKS OR MALFUNCTIONING OF FRONT FORK DEFECTIVE BRAKES PROBABLE CAUSES POOR BRAKING • Brake pads worn • Brake disc worn • Water in the brake fluid • Brake fluid leak • Brake fluid tank defective •...

  • Page 376: Unstable Steering

    TRBL SHTG UNSTABLE STEERING UNSTABLE STEERING PROBABLE CAUSES • Handlebar Assembled crooked or incorrectly • Steering Handlebar crown assembled incorrectly • Lower bracket crooked • Lower steering column installed incorrectly (threaded ring nuts not tightened correctly) • Bearing or bearing tracks damaged •...

  • Page 377: Defective Functioning Of Lights And Indicators

    TRBL SHTG DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS PROBABLE CAUSES HEADLIGHT DOES NOT LIGHT • Incorrect bulb • Excessive absorption of electrical accessories • Difficulties in charging (charging coil broken and/or rectifier/regulator defective) • Uncertain connections •...

  • Page 378: Delayed Turning On Of Indicators

    TRBL DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/ SHTG OVERHEATING OF ENGINE PROBABLE CAUSES DELAYED TURNING ON OF INDICATORS • Indicator lamp relay defective • Insufficient battery capacity (battery almost flat) • Incorrect bulb • Main switch or direction indicator switch defec- tive EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY...

  • Page 379

    TRBL SHTG...

  • Page 380

    TT600RE WIRING DIAGRAM ELECTRICAL SYSTEM DIAGRAM AC generator/Pickup coil Rectifier/Regulator Battery Starter relay Starting motor 467C4B5CAMP403D494A4856 172320-2 L Br Fuse PARK Main switch Right handlebar switch MAIN HARNESS HEAD LIGHT Engine stop switch Starter switch Diode Clutch switch RB LY Sidestand switch Neutral switch START...

This manual also for:

2004 tt600re

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  • Saverio Scaccianoce Sep 21, 2017 03:39:
    Hello there,
    Thi​s manual is for Yamaha TT600RE olny.
    In fact there isn't any section for decompress​or setting, that the TT600R have. And as you can see in the circuit diagram section, there is a battery that the TT600R do not have at all.

    Than​k you
    Regard​s
  • Domenico Jun 27, 2017 03:33:
    Bongiorno ragazzi mi servirebbe manuale ttr
  • Domenico Jun 27, 2017 03:32:
    Manuale ttr 600 mi servirebbe tanto. Grazie