TT600RE

2004
TT600RE
5CH5-ME1
SERVICE MANUAL
EASB0000
TT600RE
SERVICE MANUAL
© 2003 by Belgarda S.p.A.
First edition, July 2003
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Belgarda S.p.A.
is expressly prohibited.
Printed in Italy
EASB0001
NOTICE
This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,
anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations 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. An abbreviation and symbol in the upper right corner of each page
indicate the current chapter.
Refer to "SYMBOLS".
2 Each chapter is divided into sections. The current section title is shown at the top of each page, except
in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,
notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
1
ILLUSTRATED SYMBOLS
2
GEN
INFO
SPEC
3
4
INSP
ADJ
CHAS
5
6
ENG
CARB
7
8
TRBL
SHTG
ELEC
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
The following symbols are not relevant to every
vehicle.
Illustrated symbols 1 to 8 are printed on the top
right of each page and indicate the subject of
each chapter.
1 General information
2 Specifications
3 Periodic inspections and adjustments
4 Chassis
5 Engine
6 Carburetor
7 Electrical system
8 Troubleshooting
?
f
New
Illustrated symbols 9 to y are used to identify
the specifications appearing in the text.
9 Can be serviced with engine mounted
0 Filling fluid
q Lubricant
w Special tool
e Torque
r Wear limit, clearance
t Engine speed
y Electrical data
Illustrated symbols u to s in the exploded diagrams indicate the types of lubricants and lubrication points.
u Apply engine oil
i Apply gear oil
o Apply molybdenum disulfide oil
p Apply wheel bearing grease
a Apply lightweight lithium-soap base grease
s Apply molybdenum disulfide grease
Illustrated symbols d to f in the exploded diagrams indicate the following:
d Apply locking agent (LOCTITE®)
f Replace the part
E004000
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION
AND ADJUSTMENTS
CHASSIS
ENGINE
CARBURETION
ELECTRICAL
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
INSP
ADJ
3
CHAS
4
ENG
5
CARB
6
ELEC
7
?
TRBL
SHTG
8
GEN
INFO
1
GEN
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
GEN
INFO
VEHICLE IDENTIFICATION
GEN
INFO
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped into 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.
1
1-1
IMPORTANT INFORMATION
GEN
INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4. During machine disassembly, clean all parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal
lips.
1-2
IMPORTANT INFORMATION
GEN
INFO
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.
OR
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip 1, make sure that the sharp-edged
corner 2 is positioned opposite the thrust 3
it receives. See sectional view.
4 Shaft
1-3
CHECKING OF CONNECTIONS
GEN
INFO
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. Check:
• connector leads
Looseness → Bend up the pin 1 and connect the terminals.
4. Connect:
• connector terminals
NOTE:
The two terminals “click” together.
5. Check:
• continuity (using a pocket tester)
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness be sure to
perform steps 1 to 3.
• As a quick remedy, use a contact revitalizer
available at most part stores.
• Check the connector with a pocket tester as
shown.
1-4
SPECIAL TOOLS
GEN
INFO
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 improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name / Usage
Engine tachometer
90890-03113
This tool is needed for detecting engine rpm.
Timing light
90890-03141
This tool is needed for detecting ignition
timing.
Pocket tester
90890-03112
These instruments are invaluable for checking the electrical system.
Ignition checker
90890-06754
This instrument is necessary for checking
the ignition system components.
Compression gauge
90890-03081
These tools are used to measure the engine
compression.
Adapter (compression gauge)
90890-04082
This tool serves to measure the engine compression.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel level
in the float chamber.
Piston pin clip puller
90890-01304
This tool serves for removing the piston pin
clip.
1-5
Illustration
SPECIAL TOOLS
Tool name / Usage
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.
7 mm (0.28 in) valve guide puller
90890-01225
This tool is used to remove the valve guides.
7 mm (0.28 in) valve guide installer
90890-04017
This tool is necessary to install the valve
slides properly.
7 mm (0.28 in) valve guide reamer
90890-01227
This tool is used to re-ream the new valve
guide.
Valve adjusting tool
90890-01311
This tool is necessary for adjusting valve
clearance.
Rotor holder
90890-01701
This tool is used for loosing and tightening
the rotor nut.
Rotor screw puller
90890-01362
This tool is used to disassemble the magneto flywheel rotor.
1-6
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name / Usage
All-purpose clutch holder
90890-04086
This tool is used to lock the clutch, when the
clutch boss lock nut is being loosened or
tightened.
Crankcase separating tool
90890-01135
This tool is necessary to disassemble the
crankcase.
Crankshaft installation hose
90890-01274
This tool is used to install the crankshaft.
Crankshaft installation bolt
90890-01275
This tool is used to install the crankshaft.
#10 (M14) adapter
90890-04059
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
90890-01268
This tool is used to loosen and tighten the
steering ringnut.
Ringnut wrench
90890-01348
This tool is used to loosen and tighten the
steering ringnut.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool name / Usage
Tool No.
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.
DU bush/oil seal guide
90890-11043
This tool is used to install the DU bush and
the fork oil seal.
1-8
GEN
INFO
Illustration
SPEC
2
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
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
Limit
TT600RE: 5CH5
Model
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
2,220 mm
865 mm
1,195 mm
890 mm
1,480 mm
280 mm
3,300 mm (right)
3,100 mm (left)
•••
•••
•••
•••
•••
•••
Basic weight (with oil and full
fuel tank)
164.5 kg
•••
Engine
Engine type
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Starting system
Lubrication system
Air cooled 4-stroke, SOHC
Forward inclined single cylinder
595 cm3
95.0 x 84.0 mm
8.5 : 1
Electric starter
Dry sump with separate oil tank
•••
•••
•••
SAE20W40SE or SAE10W30SE
•••
Recommended engine oil classification
Quantity:
Without oil filter cartridge
replacement
With oil filter cartridge
replacement
Total amount (dry engine)
API Service SE, SF, SG or higher
•••
2.4 L
•••
2.5 L
3.0 L
•••
•••
Air filter
Wet type element
Fuel
Type
Fuel tank capacity
Fuel reserve amount
Regular unleaded gasoline
10 L
3.0 L
Carburetor
Manufacturer
Model x quantity
TEIKEI
Y30PV-2ATK x 1
Engine oil
Type
Temp.
°C
2-1
•••
•••
•••
GENERAL SPECIFICATIONS
Item
Standard
Limit
Spark plug
Manufacturer/model
Gap
NGK/DPR8EA-9 or NGK/DPR9EA-9
0.8–0.9 mm
Clutch type
Wet. Multiple-disc
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Number of drive chain sprocket
teeth (front/rear)
Transmission type
Operation
Gear ratio
Chassis
Frame type
Caster angle
Trail
Tires
Front:
Type
Size
Manufacturer/model
Rear:
Type
Size
Manufacturer/model
Maximum load*
Tire air pressure
(measured on cold tires):
Up to 90 kg*
Front
Rear
90 kg–maximum*
Front
Rear
Off-road riding
Front
Rear
High-speed riding
Front
Rear
* Total weight of rider, passenger,
cargo and accessories
Wheels
Front:
Type
Size
Rear:
Type
Size
SPEC
•••
Spur gear
71/34 (2.088)
Chain drive
47/15 (3.133)
1st
2nd
3rd
4th
5th
15/47
Constant mesh 5-speed
Left foot
2.583
1.588
1.200
0.955
0.792
Open cradle backbone frame/detachable
rear frame
27°
117 mm
•••
•••
With tube
90/90-21-(54R) / 90/90-21-(54S)
Pirelli / MT70 - Michelin / T63
With tube
130/80-18-(66R) / 130/80-18-(66S)
Pirelli / MT70 - Michelin / T63
180 kg
•••
200
220
210
240
150
160
210
240
•••
•••
•••
•••
•••
•••
•••
•••
kPa;
kPa;
kPa;
kPa;
kPa;
kPa;
kPa;
kPa;
2.00
2.20
2.10
2.40
1.50
1.60
2.10
2.40
Spoke wheel
21” x 1.85
Spoke wheel
18” x MT 2.50
2-2
kgf/cm2;
kgf/cm2;
kgf/cm2;
kgf/cm2;
kgf/cm2;
kgf/cm2;
kgf/cm2;
kgf/cm2;
2.00
2.20
2.10
2.40
1.50
1.60
2.10
2.40
bar
bar
bar
bar
bar
bar
bar
bar
GENERAL SPECIFICATIONS
Item
Brakes
Front:
Type
Operation
Fluid
Rear:
Type
Operation
Fluid
Suspension
Front
Rear
Spring/shock absorber
Front
Rear
Wheel travel
Front
Rear
SPEC
Standard
Limit
Single Ø 267 mm disk brake,
2 x 28 mm
Right hand
DOT 4
Single Ø 220 mm disk brake,
1 x 34 mm caliper
Right foot
DOT 4
Telescopic fork Outside tube
dia. 46 mm
Deltabox Swingarm with
adjustable shock absorber
Coil spring / oil damper
Coil spring / gas-oil damper, spring
preload adjustable
230 mm
230 mm
•••
•••
Electrical system
Ignition system
Charging system:
Type
Standard output
Battery:
Model
Voltage, capacity
A.C. magneto
14V, 13.5A at 5.000 r/min
•••
GT9B-4
12V, 8Ah
•••
Headlight type
Quartz bulb (halogen)
Bulb voltage, wattage x quantity
Headlight
Tail/brake light
Turn signal light
Auxiliary light
Meter lighting
Turn signal indicator light
Neutral indicator light
Auxiliary indicator light
High beam indicator light
12V
12V
12V
12V
12V
12V
12V
12V
12V
Fuse
20A
Transistorized coil ignition (digital)
60W / 55W x 1
5W / 21W x 1
10W x 4
5W x 1
3W x 1
1.2W x 1
1.2W x 1
1.2W x 1
1.2W x 1
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
2-3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Limit
Cylinder head
Max. warpage
•••
0.03 mm
Cylinder
Bore
Measuring point
94.970 - 95.020 mm
50 mm
95.10 mm
•••
Chain drive (left)
23.000 - 23.021 mm
22.967 - 22.980 mm
•••
•••
0.020 - 0.054 mm
•••
Camshaft
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap
clearance
Camshaft lobe dimensions:
Intake-measurement
Intake-measurement
Intake-measurement
A
B
C
36.470 - 36.570 mm
30.060 - 30.160 mm
6.41 mm
•••
•••
•••
Exhaust-measurement
Exhaust-measurement
Exhaust-measurement
Max. camshaft runout
A
B
C
36.620 - 36.720 mm
30.110 - 30.210 mm
6.51 mm
•••
•••
•••
•••
0.030 mm
2-4
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Timing chain
Model/number of links
Tensioning system
75-010/126
Automatic
Rocker arm/rocker arm shaft
Arm inside diameter
Shaft outside diameter
Arm-to-shaft clearance
12.000 - 12.018 mm
11.976 - 11.991 mm
0.009 - 0.042 mm
•••
•••
•••
Valve, valve seat, valve guide
Valve clearance (cold)
intake
exhaust
0.05 - 0.10 mm
0.12 - 0.17 mm
•••
•••
intake
exhaust
intake
exhaust
intake
exhaust
intake
exhaust
intake
exhaust
36.90 - 37.10 mm
31.90 - 32.10 mm
2.260 mm
2.260 mm
1.00 - 1.20 mm
1.00 - 1.20 mm
1.00 - 1.40 mm
0.80 - 1.20 mm
6.975 - 6.990 mm
6.955 - 6.970 mm
•••
•••
•••
•••
1.80 mm
1.80 mm
0.80 mm
0.65 mm
6.995 mm
6.925 mm
intake
exhaust
7.000 - 7.012 mm
7.000 - 7.012 mm
7.042 mm
7.042 mm
intake
exhaust
0.010 - 0.037 mm
0.030 - 0.057 mm
0.08 mm
0.10 mm
•••
0.010 mm
1.10 mm
1.10 mm
1.80 mm
1.80 mm
Valve dimensions:
Valve head diameter A
Valve face width B
Valve seat width C
Valve margin thickness D
Valve stem diameter
Valve guide inside
diameter
Valve stem to valve
guide clearance
Valve stem runout
Valve seat width
intake
exhaust
2-5
MAINTENANCE SPECIFICATIONS
Item
Valve spring
Inner spring:
Free length
Installed length
(valve closed)
Compressed spring force
(installed)
Standard
Winding direction
(top view)
Outer spring:
Free length intake
Installed length
(valve closed)
Compressed spring force
(installed)
40.10 mm
40.10 mm
38.10 mm
38.10 mm
intake
exhaust
22.70 mm
22.70 mm
•••
•••
intake
intake
exhaust
164.80 - 190.20 N
16.80 - 19.39 kg
164.80 - 190.20 N
16.80 - 19.39 kg
•••
•••
•••
•••
•••
•••
2.5 °/1.7 mm
2.5 °/1.7 mm
intake
exhaust
Clockwise
Clockwise
intake
exhaust
43.80 mm
43.80 mm
38.10 mm
38.10 mm
intake
exhaust
intake
intake
exhaust
34.20 mm
34.20 mm
71.60 - 87.30 N
7.3 - 8,9 kg
149.10 - 182.40 N
15.2 - 18.6 kg
•••
•••
•••
•••
•••
•••
•••
•••
2.5 °/1.7 mm
2.5 °/1.9 mm
intake
exhaust
Counterclockwise
Counterclockwise
exhaust
Spring tilt
Winding direction
(top view)
Limit
intake
exhaust
exhaust
Spring tilt intake
SPEC
Piston
Piston-to-cylinder clearance
Diameter D
Height H
Piston pin bore inside diameter
Offset
Offset direction
Piston pin outside diameter
0.045 - 0.065 mm
94.915 - 94.965 mm
5.0 mm
0.15 mm
•••
•••
22.004 - 22.015 mm
2.00 mm
Intake side
21.991 - 22.000 mm
•••
•••
2-6
•••
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Piston ring
Top ring:
Ring type
Dimensions (B x T)
End gap
(installed)
Ring side clearance
2nd ring:
Ring type
Dimensions (B x T)
End gap
(installed)
Ring side clearance
Oil ring:
Dimensions (B x T)
End gap
(installed)
Ring side clearance
Barrel
1.20 x 3.80 mm
•••
0.30 - 0.45 mm
0.040 - 0.080 mm
0.70 mm
0.130 mm
Plain
1.20 x 3.80 mm
•••
0.30 - 0.45 mm
0.030 - 0.070 mm
0.80 mm
0.130 mm
2.50 x 3.40 mm
•••
0.20 - 0.70 mm
0.020 - 0.060 mm
•••
•••
74.95 - 75.00 mm
•••
0.350 - 0.650 mm
0.010 - 0.025 mm
0.80 mm
•••
0.030 mm
•••
•••
•••
Crankshaft
Width A
Max. runout C
Big end side clearance D
Big end radial clearance
Small end free play F
2-7
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Ballancer
Ballancer drive method
Gear
Clutch
Clutch release method
Friction plate thickness
Wear limit
Plate quantity
Friction plate thickness
Wear limit
Plate quantity
Clutch plate thickness
Plate quantity
Max. warpage
Clutch spring free length
Plate quantity
Clutch housing thrust clearance
Inner push, cam push
2.72 - 2.88 mm
•••
6 pcs
2.94 - 3.06 mm
•••
2 pcs
1.20 mm
7 pcs
•••
42.8 mm
5 pcs
0.070 - 0.071 mm
Transmission
Max. main axle runout
Max. drive axle runout
Shift mechanism type
•••
•••
Cam drum and guide bar
Carburetor
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Cutaway
Pilot air jet 1
Pilot jet
Bypass 1
Pilot screw turns out
Valve seat size
Starter jet 1
Float height
5CH5 10
#1:#150 #2:#145
#1:1.0 #2:0.9
#1:5C5A-3/5 #2:5Y18-3/5
2.600
4.00
# 0.8 mm
# 50
# 1.0
2-3/4 +/- 1/2
2.5
# 74
6.0 - 8.0 mm
•••
Engine idle speed
CO%
Intake vacuum
1,150-1,450 r/min
1.5 - 3
30.6-33.36 kPa - 230-250 mm Hg
•••
•••
•••
Lubrication system
Oil filter type
Oil pump:
Oil pump type
Inner rotor to outer rotor tip clearance
Outer rotor to pump housing
clearance
Bypass valve opening pressure
Relief valve operating pressure
Oil pressure (hot)
Pressure check location
Dry sump
Paper type
•••
2.60 mm
•••
2.8 mm
•••
0.20 mm
•••
•••
0.08 mm
0.08 mm
Trochoid type
0.12 mm
0.20 mm
0.030 - 0.080 mm
80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm2)
80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm2)
13.0 kPa (0.13 kgf/cm2)/1,300 r/min
Oil filter chamber
0.150 mm
•••
•••
•••
•••
2-8
MAINTENANCE SPECIFICATIONS
SPEC
ENGINE
Cylinder head tightening steps:
Crankcase tightening steps:
Left crankcase
Right crankcase
2-9
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Part to be tightened
Cylinder head
Cylinder head
Cylinder head
Cylinder head
Cylinder head:
Cap (oil check)
Spark plug
Cylinder head cover
Tappet cover (intake)
Tappet cover (exhaust)
Cylinder
Cylinder
Cylinder
Weight drive gear
Rotor (A.C. magneto)
Lock nut (valve adjusting screw)
Cam chain sprocket
Cam chain stopper guide
Cam chain stopper guide
Rocker shaft
Oil pump
Oil delivery/retrieval pipe
Oil draining pipe
Oil filter cover
Bleed screw (oil filter cover)
Push lever (clutch)
Push rod (clutch)
Sprocket
Lock washer (oil seal)
Stop lever
Shift cam
Stator
Part
name
Thread size
Washer
based bol
Stud bolt
Hexagon socket
head screw
Stud bolt
Union bolt
–
Hexagon socket
head screw
Hexagon socket
head screw
–
Crown nut
Nut
Hexagon socket
head screw
Hexagon nut
Hexagon nut
Hexagon nut
Washer based
bolt
Hexagon socket
head screw
Washer based
screw
Hexagon socket
head screw
Hexagon socket
head screw
Pan screw
Washer based
screw
Hexagon socket
head screw
Hexagon screw
Pan screw
Hexagon nut
Hexagon nut
Hexagon screw
Bolt
Hexagon screw
Pan head (+)
screw
2-10
Tightening
torque
Nm
mkg
M8 x 1.25
M10 x 1.25
29
20
2.9
2.0
M6 x 1.0
M6 x 1.0
10
7
1.0
0.7
M6 x 1.0
M12 x 1.25
7
18
0.7
1.8
M6 x 1.0
10
1.0
M6 x 1.0
M32 x 1.5
M8 x 1.25
M10 x 1.25
10
12
22
42
1.0
1.2
2.2
4.2
M6 x 1.0
M16 x 1.0
M14 x 1.5
M6 x 1.0
10
60
120
14
1.0
6.0
12.0
1.4
M7 x 1.0
20
2.0
M6 x 1.0
10
1.0
M16 x 1.0
20
2.0
M6 x 1.0
10
1.0
M6 x 1.0
M6 x 1.0
10
7
1.0
0.7
M14 x 1.5
30
3.0
M6 x 1.0
M5 x 0.8
M8 x 1.0
M6 x 1.0
M18 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
10
5
12
8
115
10
10
10
1.0
0.5
1.2
0.8
11.5
1.0
1.0
1.0
M5 x 0.8
5
0.5
Remarks
MAINTENANCE SPECIFICATIONS
Part to be tightened
Part
name
Thread size
Hexagon socket
head screw
SPEC
Tightening
torque
Nm
mkg
M6 x 1.0
7
0.7
Hexagon socket
head screw
M6 x 1.0
10
1.0
Engine oil pipe 2
Union screw
M12 x 1.25
35
3.5
Oil delivery pipe
Union bolt
M8 x 1.25
18
1.8
Carburetor joints
Hexagon socket
head screw
M6 x 1.0
10
1.0
Air filter case (frame)
Hexagon screw
M6 x 1.0
10
1.0
Air filter case (frame)
Washer based
screw
M6 x 1.0
10
1.0
Washer based
nut
M6 x 1.0
10
1.0
Pan head (+)
screw
M6 x 1.0
7
0.7
Hexagon socket
head screw
M8 x 1.25
23
2.3
Nut, nylon
M8 x 1.25
23
2.3
Washer based
screw
Stator (pick-up coil)
Engine oil pipe 1
Exhaust pipe
Exhaust pipe protector
Muffler
Muffler (band)
Muffler
M8 x 1.25
23
2.3
Crankcase
Hexagon socket
head screw
M6 x 1.0
10
1.0
Crankcase
Stud bolt
M10 x 1.25
20
2.0
Hexagon socket
head screw
M6 x 1.0
10
1.0
Hexagon socket
head screw
M6 x 1.0
10
1.0
Hexagon socket
head screw
M6 x 1.0
10
1.0
Stop washer (bearing)
Flat headscrew
M6 x 1.0
7
0.7
Pressure plate
Washer based
screw
M6 x 1.0
8
0.8
Clutch housing
Hexagon nut
M20 x 1.0
90
9.0
Primary drive gear
Hexagon nut
M20 x 1.0
120
12.0
Crankcase cover (right)
Crankcase cover (left)
Sprocket cover
2-11
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Item
Standard
Steering
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (right)
Front suspension
Front fork travel
Fork spring free length
Spring rate
Spring stroke
Spring rate
Optional spring available
Recommended oil
Quantity
Level
< min - max >
Taper roller bearing
45°
45°
(K1)
(K1)
(K2)
Rear suspension
Rear shock absorber assembly travel
Spring free length
Installed length
Spring rate
(K)
Optional spring available
277 - 283 mm
530 mm
7.0 N/mm (0.71 kgf/mm)
330 mm
11.2 N/mm (1.14 kgf/mm)
No
Liqui Moly Racing suspension oil SAE 7,5
650 cc
180 mm
170-190 mm (from upper edge of inner
tube, fully compressed without spring)
Limit
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
83 mm
224 mm
211 mm
80 N/mm (8.1 kgf/mm)
No
•••
± 1.5 mm
•••
Swingarm
Free play limit (at the end of
the swingarm)-radial
Free play limit (at the end of
the swingarm)-axial
•••
1.0 mm
0.4 - 0.7 mm
•••
Front wheel
Wheel type
Rim size
Rim material
Max. radial wheel runout
Max. lateral wheel runout
Spoke wheel
21 x 1.85
Aluminium
1.0 mm
0.5 mm
•••
•••
Rear wheel
Wheel type
Rim size
Rim material
Max. radial wheel runout
Max. lateral wheel runout
Spoke wheel
18 x MT2.50
Aluminium
1.0 mm
0.5 mm
•••
•••
2-12
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Drive chain
Type/manufacturer
Link quantity
Drive chain slack
520 135ORSB / Regina Chain
114
30.0 - 40.0 mm
•••
Front disc brake
Disc outside diameter x thickness
Max. deflection
Brake pad lining thickness-inner
Brake pad lining thickness-outer
267 x 4 mm
•••
7.5 mm
7.5 mm
•••
0.15 mm
* 3.7 mm
* 3.7 mm
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
13 mm
28 mm x 2
DOT 4
Rear disc brake
Disc outside diameter x thickness
Max. deflection
Brake pad lining thickness-inner
Brake pad lining thickness-outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
220.0 x 5.0 mm
•••
9.0 mm
9.0 mm
•••
0.15 mm
* 4.5 mm
* 4.5 mm
12.7 mm
34 mm
DOT 4
Front brake lever
Adjustable
Brake pedal lever
Brake pedal position
10 mm (below the footrest plane)
•••
Clutch lever
Clutch lever free play (lever end)
10.0 - 15.0 mm
•••
Throttle grip
Throttle cable free play
3.0 - 5.0 mm
•••
2-13
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Thread
size
Part to be tightened
Tightening
torque
N·m
m·kg
Engine mounting and rear frame:
Engine front/Stay engine
Stay engine (engine front)/Frame
Engine rear under/Frame
Engine top/Stay engine
Engine protector/Frame
Chain tensioner top/Frame
Chain tensioner under/Frame
Frame/Rear frame (upper)
Frame/Rear frame (under)
Rear frame/Air filter assy
M10 x 1.25
M10 x 1.25
M10 x 1.25
M10 x 1.25
M6 x 1.0
M8 x 1.25
M8 x 1.25
M8 x 1.25
M8 x 1.25
M6 x 1.0
64
64
68
64
7
23
23
23
23
5
6.4
6.4
6.8
6.4
0.7
2.3
2.3
2.3
2.3
0.5
Front fork and steering:
Handle crown/Inner tube
Handle crown/Steering shaft
Steering shaft/Ring nut
Holder handle upper/Crown handle
Holder handle under/Crown handle
Front fork under bracket/Inner tube
Front master cylinder/Cap
Front master cylinder/Handle
Union bolt tightening
Front fender/Front fork
Stay headlight/Handle crown
Stay headlight/Bracket meter
Headlight/Stay headlight
M8 x 1.25
M28 x 1.5
M36 x 1.5
M8 x 1.25
M10 x 1.5
M8 x 1.25
M4 x 0.7
M6 x 1.0
M10 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
28
4
115
20
40
23
1.5
9
20
7
10
6
10
2.8
0.4
11.5
2.0
4.0
2.3
0.15
0.9
2.0
0.7
1.0
0.6
1.0
Rear arm and cushion:
Pivot shaft/Frame
Arm relay/Frame
Arm relay/Rod connecting
Arm relay/Shock absorber
Rod connecting/Rear arm
Shock absorber upper/Frame
Seal guard/Rear arm
Support chain/Rear arm
Chain case/Rear arm
M14 x 1.5
M10 x 1.25
M10 x 1.25
M10 x 1.25
M12 x 1.25
M12 x 1.25
M6 x 1.0
M6 x 1.0
M6 x 1.0
90
60
52
59
66
66
4
9
9
9.0
6.0
5.2
5.9
6.6
6.6
0.4
0.9
0.9
Front wheel:
Front wheel shaft/Front fork
Axle holder//Front fork
M16 x 1.5
M6 x 1.0
59
9
5.9
0.9
Rear wheel:
Rear wheel shaft/Nut
M18 x 1.5
115
11.5
Clutch hub/Sprocket
M10 x 1.25
48
4.8
2-14
Remarks
See “NOTE”
MAINTENANCE SPECIFICATIONS
Thread
size
Part to be tightened
Tightening
torque
N·m
m·kg
Front brake:
Front hub/Disc brake
Front caliper/Front fork
Front caliper/Bleeder tightening
Union bolt tightening (front)
M6 x 1.0
M8 x 1.25
M10 x 1.0
M10 x 1.0
12
25
14
20
1.2
2.5
1.4
2.0
Rear brake:
Rear hub/Disc brake
Rear master cylinder/Frame
Rear stop switch/Rear master cylinder
Rear caliper/Bleeder tightening
Protector rear caliper/Rear caliper
Union bolt tightening (rear)
Rear brake tank reserve/Air cleaner assy
Brake pedal/Frame
M6 x 1.0
M6 x 1.0
M10 x 1.0
M10 x 1.0
M6 x 1.0
M10 x 1.0
M6 x 1.0
M10 x 1.25
12
10
20
14
10
20
5
48
1.2
1.0
2.0
1.4
1.0
2.0
0.5
4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame
Sidestand mounting bolt/Nut
Sidestand switch/Frame
Rear footrest/Rear frame
Bracket 1 (main footrest)/Frame
Bracket 2 (main footrest)/Frame
Footrest cover/Footrest
M12 x 1.25
M12 x 1.25
M5 x 0.8
M8 x 1.25
M10 x 1.25
M10 x 1.25
M6 x 1.0
40
40
8
30
48
48
10
4.0
4.0
0.8
3.0
4.8
4.8
1.0
Seat, fuel tank and oil tank:
Seat/Frame
Bolt (guide seat)/Fuel tank
Fuel tank/Rear frame
Damper fuel tank (front)/Frame
Fuel tank/Fuel cock
Oil tank/Sub-oil tank
Union bolt (oil hose 2)/Oil tank assy/Engine
Oil hose 1/Oil tank/Engine
Oil tank/Rear frame
M6 x 1.0
M6 x 1.0
M6 x 1.0
M8 x 1.25
M6 x 1.0
M6 x 1.0
M12 x 1.25
M6 x 1.0
M12 x 1.5
10
5
12
15
7
7
35
10
20
1.0
0.5
1.2
1.5
0.7
0.7
3.5
1.0
2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame
Rear fender compl. (upper)/Rear frame
Bracket, license/Rear frame
Bracket, license/Rear flasher
Horn/Frame
Regulator/Frame
Igniton coil/Frame
Battery box/Rear frame
Igniter cover/Battery box
Main switch/Frame
Tail light (lense)/Rear fender compl.
Starter switch/Red wire
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M8 x 1.25
M5 x 0.8
M6 x 1.0
M4
M24 x 1.0
M3.5
M6 x 1.0
2
7
10
10
13
7
13
7
1
1
1
7
0.2
0.7
1.0
1.0
1.3
0.7
1.3
0.7
0.1
0.1
0.1
0.7
2-15
SPEC
Remarks
MAINTENANCE SPECIFICATIONS
Thread
size
Part to be tightened
Starting motor cord/Starting motor
Wire minus lead (-)/Starting motor
Front flasher lights/Stay, headlight
Clutch wire/Engine
Assist grip (Standing handle)/Rear frame
Speedometer
Air filter case 1/Air filter case 2 (L = 13 mm)
Air filter case 1/Air filter case 2 (L = 19 mm)
Hose clamp/Joint, carburator
Hose clamp/Air cleaner/Carburator
Battery (+)/(-)
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M8 x 1.25
M5 x 0.8
M3.9
M3.9
M4 x 0.7
M5 x 0.8
M6 x 1.0
Tightening
torque
N·m
m·kg
11
10
1.5
7
23
4
0.5
1
0.6
0.8
2.5
1.1
1.0
0.15
0.7
2.3
0.4
0.05
0.1
0.06
0.08
0.25
SPEC
Remarks
NOTE:
1. First tighten the ring nut approximately 38 Nm (3.8 mkg) by using the torque wrench, then loosen the
ring nut one turn.
2. Final tighten the ring nut at the torque of 4 Nm (0.4 mkg).
2-16
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
Standard
Limit
Ignition system
Ignition timing (B.T.D.C.)
Advanced timing (B.T.D.C.)
Advancer type
12° / 1,300 r/min
31° / 7,500 r/min
Electrical type
•••
•••
Transistorized coil ignition
Pickup coil resistance
T.C.I. unit model/manufacturer
230 Ω ± 20% L/Y-G/W
TNDF09 / NIPPON DENSO
•••
Ignition coil
Model/manufacturer
Primary coil resistance
Secondary coil resistance
JO300 / NIPPON DENSO
4 Ω ± 15%
13 kΩ ± 20%
•••
•••
Spark plug cap
Material
Resistance
Resin
10 kΩ
•••
Charging system
Type
Model/manufacturer
Standard output
Stator coil resistance
A.C. magneto
TLMZ48 / NIPPON DENSO
14.0 V 13.5 A 5,000 r/min
0.65 Ω ± 20% W-W
•••
•••
Rectifier/regulator
Regulator type
Model/manufacturer
No load regulated voltage
Rectifier capacity
Withstand voltage
Semi conductor-short circuit
SH629A-12/SHINDENGEN
14.5 ± 0.4 V
25 A
240 V
•••
•••
•••
Battery
Specific gravity
1.320
•••
Electric starting system
System type
Starter motor:
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Brush spring force
Commutator diameter
Mica undercut (depth)
Starter relay:
Model/manufacturer
Amperage
Coil resistance
Constant mesh
SM-13/MITSUBA
0.80 kW
0.03 - 0.04 Ω
10.0 mm
8.82 N (899 gf)
28.0 mm
0.70 mm
•••
•••
5 mm
•••
27 mm
•••
MS5F-721 / JIDECO
180 A
4,4 Ω ± 5%
•••
•••
2-17
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Horn
Horn type
Quantity
Manufacturer
Max. amperage
Plane
1 pcs
LEONELLI
1.5 A
•••
Flasher relay
Type
Model/manufacturer
Self cancelling device
Flasher frequency
Wattage
Semi-transistor
FB222M/NIPPONDENSO
No
75 - 95 cycle/min
10 W 2 + 3.4 W
•••
•••
•••
•••
•••
Daylight switch relay
Model/manufacturer
ACA12151-1-MATSUSHITA DENKOU
Circuit breaker
Type
Amperage for fuse
Reserve
Fuse
20 A
20 A
•••
•••
2-18
GENERAL TORQUE SPECIFICATIONS/
CONVERSION TABLE
SPEC
GENERAL TORQUE SPECIFICATIONS
CONVERSION TABLE
This chart specifies torque for standard fasteners
with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are
provided for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in a
crisscross fashion, in progressive stages, until the
specified torque is reached. Unless otherwise
specified, torque specifications require clean, dry
threads. Components should be at room temperature.
All specification data in this manual are listed in SI
and METRIC UNITS. Use this table to convert
METRIC unit data to IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
IMP
** mm
0.03937
=
** in
2 mm
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMP
Known
A: Distance between flats
B: Outside thread diameter
A
(nut)
B
(Bolt)
m·kg
10 mm
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
2-19
Result
Torque
m·kg
m·kg
cm·kg
cm·kg
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Distance
km/hr
km
m
m
cm
mm
0.6214
0.6214
3.281
1.094
0.3937
0.03937
mph
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneous
kg/mm
55.997
lb/in
14.2234
psi (lb/in2)
kg/cm2
Centigrade 9/5 (°C) + 32 Fahrenheit (°F)
General torque
specifications
N·m
Multiplier
LUBRlCATlON POINTS AND LUBRICANT TYPE
SPEC
LUBRlCATlON POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points (part name)
Lubricant type
Oil seal edges (completely)
Bearing retainer
Rod pins
Rod (big end)
Piston and piston rings
Hub (weight drive sprocket)
Piston pin
Valve stim and guide
Oil seal (valve stim end)
Rocker shaft and rocker arm
Cam and bearing (camshaft)
Rotor and rotor housing (oil pump)
Push rod (clutch)
Primary driven gear and main shaft
Sliding gear (transmission)
Idle gear (transmission)
Shift forks and bar
Shift cam and bearing (gearshift cam)
Shift shaft
Rod housing coupled surfaces
Bonding agent (rapid seal adhesive)®
Yamaha bond No. 1215®
Coupled surfaces (cylinder head and cylinder head cover)
Bonding agent (rapid seal adhesive)®
Yamaha bond No. 1215®
2-20
LUBRlCATlON POINTS AND LUBRICANT TYPE
SPEC
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)
Clutch cable end
Pivot points (sidestand)
Grease nipples (rear arm-front axle)
2-21
LUBRICATION LAYOUT
LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
(6)
Oil
Oil
Oil
Oil
Oil
Oil
tank
pump
filter (oil tank)
strainer (engine)
vapour retrieval hose
blow-by retrieval hose
[A] DELIVERY
[B] RETRIEVAL
2-22
SPEC
LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
(6)
Oil pump
Oil filter
Camshaft
Oil delivery hose
Main driving shaft
Drive shaft
SPEC
[A] DELIVERY
[B] RETRIEVAL
A
B
2-23
LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
(6)
Oil filter
Camshaft
Connecting rod pin
Main driving shaft
Secondary drive shaft
Drain plug
SPEC
[A] DELIVERY
[B] RETRIEVAL
A
B
2-24
LUBRICATION LAYOUT
(1)
(2)
(3)
(4)
(5)
Oil pump
Oil filter
Oil delivery hose
Transmission
Oil strainer
[A] DELIVERY
[B] RETRIEVAL
A
B
2-25
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
(1)
Clutch cable
(2)
Brake hose holder
(3)
Brake hose
(4)
Throttle cables
(10) Socket cover
(5)
Bands
(6)
Lighting wire
harness
(11) Engine stop switch
connector
(7)
Brake and engine
stop switch wire
harness
(8)
Tachometer/
odometer cable
(14) Right turn light
connector
(20) Clutch switch
connector
(9)
Complete wire
harness
(15) Meter wire harness
connector
(21) Brake switch
connector
(16) Main switch wire
harness connector
(22) Clip
[A]
(17) Clutch switch
(12) Headlight wire
harness connector
(18) Headlight connector
(19) Side/taillight
connector
(13) Left turn light
connector
A2
3
4
1
4
22
6
3
1
Lay the brake hose
throught the holder
on the handle
crown.
5
5
5
7
17
6
21
5
5
16
14
9
11
20
8
13
15
12
10
19
18
2-26
CABLE ROUTING
(1)
(2)
(3)
(4)
(5)
(6)
Front brake hose
Brake hose holder
Left tube guard
Plastic plate
Throttle cables
Tachometer/
odometer cable
(7) Clutch cable
(8) Clutch cable holder
(9) Throttle cables
holder
(10) Wire harness band
(11) Fuel pipe from fuel
cock
(12) Flasher relay
(13) Main relay
(14) Sidestand switch
(15) Diodes (n. 3)
(16) A.C. generator wire
harness (engine)
(17) Engine oil breather
pipe (to engine oil
tank)
(18) Main switch
(19) Oil hose (oil tank to
engine)
(20) Oil hose (engine to
oil tank)
(21) C.D.I. unit
(22) Starting motor plus
cable
(23) Starting motor
minus cable
(24) Battery
(25) Starting relay
(26) Fuse (reserve)
(27) Fuse (main)
23
SPEC
(28) Wire extension
(29) Battery plus cable
[A]
[B]
[C]
[D]
Lay the brake hose
behind the left tube
guard and fasten it
down by means of
the plate 4.
Attach throttle
cables 5.
Fasten the fuel pipe
11 to the tank.
Fit the 3 diodes
inside the chassis,
against the coil clip.
28
30
29
22
25
26
27
24
1
2
D
18 9 15 13
12
10
A3
B 10 11 C
5
17
20
4
8
6
16
7
19
2-27
14
CABLE ROUTING
(1)
(2)
(3)
(4)
(5)
(6)
Tachometer/
odometer cable
Tachometer/
odometer cable
holder
Tachometer/
odometer cable
band
Right tube guard
Spark plug cable
Horn
(7)
Carburetor suction
pipe
(8) Main wire harness
band
(9) Rear brake switch
wire harness
(10) Rear brake fluid
tank hose
(11) Hose from rear
master cylinder to
caliper
(12) Rear brake hose
holders
(13) Pipe
(14) Air breather pipe
(15) Spark plug ignition
coil
(16) Chassis ground
(17) Engine oil
breather pipe
(to air filer case)
7
8
[A]
SPEC
Insert the
tachometer/
odometer cable into
the band 3 and the
holder 2.
15
16
3A
9
4
10
5
11
6
12
A2
1
17
13
14
2-28
SPEC
CABLE ROUTING
(1)
Rectifier
(2)
Wire harness bands
(3)
Protection
(4)
Left turn wire
harness
(5)
Right turn wire
harness
(6)
Tail light wire
harness
(7)
Air breather pipe
(carburetor)
(8)
Wire extension
(9)
Starter power
cables
[A]
Screw protection 3
after setting wiring
properly.
(10) Engine cables and
side stand switch
1
2
7
2
4
10
5
8
6
9
3 A
2-29
SPEC
INSP
ADJ
3
INSP
ADJ
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
ENGINE OIL LEVEL CHECK ..............................................................................3-15
ENGINE OIL REPLACEMENT............................................................................3-17
ENGINE OIL PRESSURE CHECK ....................................................................3-21
CLUTCH ADJUSTMENT ....................................................................................3-21
AIR FILTER CLEANING......................................................................................3-24
FUEL FILTER CLEANING ..................................................................................3-25
ENGINE OIL TANK FILTER CLEANING ............................................................3-26
SUCTION HOSE AND MANIFOLD INSPECTION..............................................3-28
FUEL LINE INSPECTION ..................................................................................3-28
CRANKCASE VENTILATION HOSE INSPECTION ..........................................3-29
EXHAUST SYSTEM INSPECTION ....................................................................3-29
CHASSIS ....................................................................................................................3-30
ADJUSTING THE FRONT BRAKE ....................................................................3-30
ADJUSTING THE REAR BRAKE ......................................................................3-31
CHECKING THE BRAKE FLUID LEVEL ............................................................3-32
BRAKE PAD WEAR INSPECTION ....................................................................3-33
BRAKE HOSING INSPECTION..........................................................................3-33
BRAKE CIRCUIT BLEEDING ............................................................................3-34
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT ..................................3-35
DRIVE CHAIN LUBRICATION ............................................................................3-36
FRONT FORK INSPECTION ..............................................................................3-37
ADJUSTING THE FRONT FORK ......................................................................3-37
REAR SHOCK ABSORBER ADJUSTMENT ......................................................3-38
STEERING INSPECTION ..................................................................................3-40
TYRE INSPECTION............................................................................................3-41
WHEEL INSPECTION ........................................................................................3-44
SPOKE INSPECTION AND TIGHTENING ........................................................3-44
CABLE INSPECTION..........................................................................................3-45
LEVER AND PEDAL LUBRICATION ..................................................................3-45
SIDESTAND LUBRICATION ..............................................................................3-46
REAR SUSPENSION LUBRICATION ................................................................3-46
INSP
ADJ
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
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
INSP
ADJ
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. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ODOMETER READING (x 1,000 km)
N0.
1
ITEM
*
2
CHECK OR MAINTENANCE JOB
1
10
20
30
40
✓
✓
✓
Fuel line
• Check fuel hoses for cracks or damage.
✓
• Check condition.
• Clean and regap.
✓
Spurk plug
3
*
Valves
• Check valve clearance.
• Adjust.
✓
• Clean.
✓
✓
✓
✓
✓
✓
4
Air filter element
5
Clutch
• Check operation.
• Adjust.
✓
✓
✓
✓
✓
Front brake
• Check operation, fluid level and vehicle for fluid leakeage.
• (See NOTE).
✓
✓
✓
✓
✓
6
*
✓
• Replace.
• Replace brake pads.
7
*
Rear brake
8
*
Brake hoses
9
*
Wheels
10
*
Tyres
11
*
Wheel bearings
12
*
✓ •
✓
✓
• Replace.
ANNUAL
CHECK
✓
✓ •
Whenever worm to the limit
• Check operation, fluid level and vehicle
• for fluid leakage.
• (See NOTE).
✓
✓
✓
✓
✓
• Replace brake pads.
Whenever worm to the limit
• Check for cracks or damage.
✓
• Replace. (See NOTE).
✓
✓
✓
✓
✓
Every 4 years
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
✓
✓
✓
✓
✓
✓
✓
✓
✓
• Check bearing for looseness or damage.
✓
✓
✓
✓
Swingarm
• Check operation and for excessive play.
✓
✓
✓
✓
• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.
•
•
•
•
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Every 500 km and after washing the
motorcycle or riding in the rain.
13
*
Drive chain
14
*
Steering
bearings
• Lubrificate with lithium-soap-based grease.
15
*
Chassis
fasteners
• Make sure that all nuts, bolts and screws are properly
• tightened.
✓
✓
✓
✓
✓
Sidestand
• Check operation.
• Lubricate.
✓
✓
✓
✓
✓
Sidestand
switch
• Check operation and for oil leakage.
✓
✓
✓
✓
✓
16
17
*
• Check bearing play and steering for roughness.
✓
✓
✓
✓
Every 20,000 km
✓
3-1
✓
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
INSP
ADJ
ODOMETER READING (x 1,000 km)
N0.
ITEM
CHECK OR MAINTENANCE JOB
1
10
20
30
40
18
* Rear brake
• Check operation, fluid level and vehicle for fluid leakage.
✓
✓
✓
✓
19
Rear shock
* absorber
assembly
• Check operation and shock absorber for oil leakage.
sull’ammortizzatore.
✓
✓
✓
✓
Rear suspension • Check operation.
* relay arm and
connecting arm
• Lubricate with lithium-soap-based grease.
pivoting points
✓
✓
✓
✓
20
21
* Carburator
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
Engine oil
• Change.
• Check oil level and oil leakage.
✓
23
Engine oil filter
element
• Replace.
✓
•• Check operation.
✓
Front and rear
* brake switches
25
Moving parts
and cables
✓
• Check starter (choke) operation.
• Adjust engine idling speed.
22
24
ANNUAL
CHECK
✓
✓
✓
✓
✓
✓
✓
• Lubricate.
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
26
Throttle grip
* housing and
cable
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
27
Muffler and
* exhaust pipe
• Check the screw clamp for looseness.
✓
28
Lights, signals
* and switches
• Check operation.
• 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 performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
3-2
SEAT, FUEL TANK AND REAR COWLING
INSP
ADJ
SEAT, FUEL TANK AND REAR COWLING
Order
Job name/Part name
Q.ty
Remarks
Remove the parts in order.
Seat, fuel tank and rear cowling
removal
1
Seat
1
2
Fuel pipe
1
3
Fuel tank
1
4
Lamp connector
1
Disconnect.
5
Rear cowling
1
NOTE:
Widen the rear cowling body sides carefully
to extract rear cowling from the chassis.
NOTE:
Be sure the cap is properly tightened
and the fuel cock is in the “OFF” position
before removing the tank.
Reverse the removal procedure for installation.
3-3
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
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.
2
1. Remove:
• Seat
• Fuel tank
See the section “ SEAT, FUEL TANK AND
REAR COWLING”.
2. Disconnect:
• Spark plug cap (1)
3. Remove:
• Spark plug
• Tappet cover (2) (intake)
• Tappet covers (3) (exhaust)
1
3
CAUTION:
When removing the spark plug and tappet
cover, be careful not to drop foreign objects
inside the engine.
1
4. Remove:
• Cap (1)
• Cap (2)
2
5. Turn the crankshaft anticlockwise using a
wrench.
3-4
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
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. Check:
• Valve clearance
Out of specification ➔ Adjust.
Valve clearance (cold):
Intake:
0.05 ~ 0.10 mm
Exhaust:
0.12 ~ 0.17 mm
8. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
• Loosen the lock nut (1).
• Fit a thickness gauge (2) between the rocker
arm and the valve stem.
• Turn the adjuster (1) clockwise or anticlockwise using the special tool (2) to obtain the
required clearance.
Special tool:
P/N. 90890-01311
•
Holding the adjuster firmly in place, lock tighten lock nut.
Lock nut:
14 Nm (1.4 mkg)
•
Measure valve clearance.
If the clearance is incorrect, repeat the previous stages to achieve the required value.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-5
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
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.
10. Connect:
• Spark plug cap
11. Reassemble:
• Fuel tank
• Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
Seat screws:
10 Nm (1.0 mkg)
3-6
DRIVE CHAIN ADJUSTMENT
IDLE SPEED ADJUSTMENT
INSP
ADJ
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. 90890-03113
3. Check:
• The engine idle speed.
Out of specification ➔ Adjust.
Engine idle speed:
1,150 ~ 1,450 rpm
4. Adjust:
• Engine idle speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
• Turn the throttle stop screw (1) either way to
obtain the idle speed required.
Screwing (a)
Increases idle speed
Unscrewing (b)
Decreases idle speed
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
After setting the idle speed, adjust the accelerator
cable free play.
5. Disconnect:
• Inductive engine speed indicator
3-7
THROTTLE CABLE FREE PLAY ADJUSTMENT
INSP
ADJ
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:
• Throttle cable free play (a)
Out of specification ➔ Adjust.
Throttle cable free play:
3 ~ 5 mm (at the grip flange)
a
3. Adjust:
• Throttle cable free play
2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5
Adjustment:
• Loosen the throttle cable (2) lock nuts (1).
• Turn the adjuster (3) clockwise or anticlockwise to obtain the required free play.
• If after loosening the adjuster by 5 mm, the
free play is still not correct, tighten the
adjuster (4) on the throttle cable (5) once
more.
• Tighten the lock nuts.
3
4
6
(1), (6) Lock nuts
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Reassemble:
• Fuel tank
• Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
Seat screws:
10 Nm (1,0 mkg)
3-8
SPARK PLUG INSPECTION
INSP
ADJ
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:
1
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from
falling into the cylinder.
CAUTION:
When removing the spark plug, be careful not
to drop foreign objects inside the engine.
4. Inspect:
• Type of spark plug
Incorrect ➔ Replace.
Standard spark plug:
DPR8EA-9 (N.G.K.) or DPR9EA-9 (N.G.K.)
5. Inspect:
• Electrodes (1)
Wear and tear/damage ➔ Replace.
• Insulator (2)
Normal insulator (2) colour is light tan.
6. Clean the spark plug with a suitable tool and a
steel brush.
7. Measure:
• Spark plug electrode gap (a)
Use a wire or thickness gauge.
Out of specification ➔ Regap.
Electrode gap:
0.8 ~ 0.9 mm
3-9
SPARK PLUG INSPECTION
INSP
ADJ
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. Install:
• Fuel tank
• Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
Seat screws:
10 Nm (1.0 mkg)
3-10
IGNITION TIMING CHECK
INSP
ADJ
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:
• Cap (1)
CAUTION:
1
In certain conditions, the oil might spray out
when the cap is removed. Be careful therefore
when removing the cap.
4. Check:
• Ignition advance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Check:
• Heat engine and let it run to the number of
revs required.
Engine idle speed:
1,150 ~ 1,450 rpm
•
Check that reference (1) is in the mobile field
of reference (2) on the flywheel.
Incorrect ignition timing ➔ Check the ignition
coil unit.
NOTE:
Ignition timing cannot be adjusted.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Cap
6. Remove:
• Stroboscopic lamp
• Inductive engine speed indicator
3-11
COMPRESSION INSPECTION
INSP
ADJ
COMPRESSION INSPECTION
NOTE:
Insufficient compression causes a loss of performance.
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”.
2. Check:
• Valve clearance
Out of specification ➔ Adjust.
See section “VALVE CLEARANCE ADJUSTMENT”.
3. Install:
• Secondary fuel tank
4. Start engine and let it heat.
• Switch off engine.
5. Disconnect:
• Spark plug cap
6. Remove:
• Spark plug (1)
CAUTION:
When removing the spark plug, be careful to
prevent foreign bodies from dropping inside
the engine.
1
7. Apply:
• Pressure gauge (1)
• Adapter (2)
Pressure gauge:
P/N. 90890-03081
Adapter:
P/N. 90890-04082
3-12
COMPRESSION INSPECTION
INSP
ADJ
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.
•
Compare the pressure reading with those in
the table.
Pressure under compression:
Standard
1,100 kPa (11 kg/cm2, 156 psi)
Minimum
900 kPa (9 kg/cm2, 128 psi)
Maximum
1.200 kPa (12 kg/cm2, 171 psi)
•
If the pressure reading is lower than minimum:
1) Add a few drops of oil to the cylinder through
the hole in the spark plug.
2) Measure the compression again.
3) Compare the new reading with the first, then
proceed according to the indications in the
table.
3-13
COMPRESSION INSPECTION
INSP
ADJ
Pressure under compression:
(after adding oil to the cylinder)
Reading
Diagnosis
Pressure higher
than before
Piston worn or
damaged.
Pressure same
as before
Cylinder head or
piston rings, valves,
gaskets may be
faulty.
Pressure above
maximum value
Inspect cylinder
head, valve surfaces, piston rim to
check for carbon
deposits.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Remove:
• Secondary fuel tank
• Pressure gauge (with adapter)
10. Reassemble:
• Spark plug
See section “SPARK PLUG INSPECTION”.
Spark plug:
18 Nm (1.8 mkg)
11. Connect:
• Spark plug cap
12. Reassemble:
• Fuel tank
• Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
Seat screws:
10 Nm (1.0 mkg)
3-14
ENGINE OIL LEVEL CHECK
INSP
ADJ
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. The boiling oil might spill over,
causing burns. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
This model is fitted with a dry crankcase lubrication system. A feed pump delivers oil to the engine; after fully lubricating the latter, the oil is returned to the tank by a scavenge pump. The oil
level must therefore be checked in the oil tank.
1. Start the engine and warm up until the oil temperature rises to approximately 60°C (140°F).
2. Idle the engine for at least 10 seconds while
keeping the motorcycle upright. After stop the
engine and check the oil level through the
level window (3) located on the left side of the
oil tank assy and(or) by oil level gauge.
NOTE:
Be sure the motorcycle is positioned straight up
when checking the oil level. A slight tilt toward the
side can result in false readings.
3. The oil level should be between the maximum
(1) and minimum (2) marks.
3-15
ENGINE OIL LEVEL CHECK
INSP
ADJ
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:
•
•
•
Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
Be sure no foreign material enters the
crankcase.
4. Reassemble the oil tank cap.
CAUTION:
Never start the engine when the oil tank is
empty.
Oil capacity:
Total:
3.0 litres
Periodic oil change:
2.4 litres
With oil filter change:
2.5 litres
3-16
ENGINE OIL REPLACEMENT
INSP
ADJ
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. Wait for the oil to cool to at
least 60°C (140°F) or thereabouts.
Engine oil replacement (without replacing filter
oil)
1. Warm up the engine for a few minutes.
2. Stop the engine. Place an oil pan under the
engine and remove the oil filler cap.
3. Remove the drain plug (1) and drain the
engine oil.
4. Remove two bolts (2) and O-ring of the oil
hose flange, and drain the oil from oil tank.
5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
3
4
7. Inspect:
• All gaskets
Damaged ➔ Replace.
8. Reassemble:
• Oil filter cover bleeder screw
• Engine oil drain plug
• Oil tank hose and O-ring
3-17
ENGINE OIL REPLACEMENT
INSP
ADJ
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.
API Standard:
API SE, SF, SG or higher grade
Oil capacity:
Periodic change = 2.4 litres
CAUTION:
•
•
•
Do not put in any chemical additives or
use oils with a grade of CD (a) or higher.
Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
Be sure no foreign material enters the
crankcase.
10. Install:
• Oil tank tap
11. Check:
• Oil level
See section “ENGINE OIL LEVEL
CHECK”.
• Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
• Oil leakage
3-18
ENGINE OIL REPLACEMENT
INSP
ADJ
Engine oil replacement (with oil filter replacement)
1. Warm up the engine for a few minutes.
2. Stop the engine. Place an oil pan under the
engine and remove the oil filler cap.
3. Remove the drain plug (1) and drain the
engine oil.
4. Remove two bolts (2) and O-ring of the oil
hose flange, and drain the oil from oil tank.
5. Remove the air bleed screw (3) attached to
the oil filter cover (4).
6. Wait until the oil has completely drained.
3
NOTE:
The oil filter cover is secured by three screws (5).
The lower one should be removed so that the filter cavity will drain.
4
5
7. Remove the other filter cover screws and
remove the oil filter cover.
8. Remove the oil filter (6) and O-ring (7).
9. Inspect:
• All gaskets
• O-rings
Damaged ➔ Replace.
6
7
10. Reassemble:
• (New) filter cartridge
• Filter cover screw
• Oil filter cover bleeder screw
• Engine drain plug
• Oil tank hose
Fastening torques:
Drain plug (engine):
30 Nm (3.0 mkg)
Oil tank hose (flange):
10 Nm (1.0 mkg)
Filter cover screw:
10 Nm (1.0 mkg)
Oil filter cover bleeder screw:
5 Nm (0.5 mkg)
3-19
ENGINE OIL REPLACEMENT
INSP
ADJ
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
With oil filter change:
2.5 litres
CAUTION:
•
•
•
Do not put in any chemical additives or use
oils with a grade of CD (a) or higher.
Be sure not to use oils labeled “ENERGY
CONSERVING II” (b) or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
Be sure no foreign material enters the
crankcase.
12. Install:
• Oil tank cap
13. Check:
• Oil level
See section “ENGINE OIL LEVEL
CHECK”.
• Oil pressure
See section “ENGINE OIL PRESSURE
CHECK”.
• Oil leakage
3-20
ENGINE OIL PRESSURE CHECK/
CLUTCH ADJUSTMENT
INSP
ADJ
ENGINE OIL PRESSURE CHECK
1. Remove:
• Bleeder screw (1)
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.
No leakage ➔ Pressure insufficient.
CAUTION:
If the oil does not come out after one minute,
stop the engine immediately to prevent
seizure.
4. Tighten:
• Bleeder screw
Bleeder screw:
5 Nm (0.5 kgm)
2
CLUTCH ADJUSTMENT
Cable free play adjustment
1
1. Check:
• Clutch free play adjustment (a)
Out of specification ➔ Adjust.
a
Free play:
10 ~ 15 mm
2. Adjust:
• Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
1
•
•
2
•
Loosen lock nuts (1).
Turn the adjuster (2) either way to obtain correct free play.
Tighten lock nuts after adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-21
CLUTCH ADJUSTMENT
INSP
ADJ
NOTE:
After adjustment, recheck lever free play to make
sure that it works smoothly and progressively.
If it is impossible to obtain the required adjustment or if the clutch does not work properly,
adjust the internal mechanism.
Internal mechanism adjustment
1. Loosen:
• Lock nuts on the lever cable adjuster and
crankcase adjuster
2. Fully tighten:
• Adjusters
3. Drain off:
• Engine oil
See section “ENGINE OIL REPLACEMENT”.
4. Remove:
• Footrest (right) (1)
• Engine protector (2)
5. Disconnect:
• Brake pedal return spring (3)
6. Remove:
• Rear master cylinder fastening screws (4)
• Oil delivery hose fastening screw (5)
• Right crankcase cover fastening screws
• Right crankcase cover (6)
7. Loosen:
• Lock nut (1)
8. Push the engine clutch control lever forward
to the stop point.
9. Adjust:
• Free play
With the lever in this position, turn the
adjuster (2) either way until the marks on
the lever (3) and crankcase (4) are
aligned.
10. Tighten:
• Lock nut (1)
Lock nut:
8 Nm (0.8 mkg)
3-22
CLUTCH ADJUSTMENT
INSP
ADJ
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
• Rear master cylinder
Screw (rear master cylinder):
10 Nm (1.0 mkg)
13. Reassemble:
• Footrest (right)
Bolt (footrest):
48 Nm (4.8 mkg)
•
Engine protector
14. Fill:
•
Engine oil tank
See section “ENGINE OIL REPLACEMENT”.
15. Adjust:
• Clutch cable free play
Free play (at lever tip):
10 ~ 15 mm
See section “Cable free play adjustment”.
3-23
AIR FILTER CLEANING
INSP
ADJ
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)
1
2
and
NOTE:
Rinse properly and dry perfectly by squeezing the
filtering element, without twisting it!
3
4. Inspect:
• Filtering element
Damaged ➔ Replace.
5. Apply:
• SAE 20W50 engine oil or special filter oil
all over filter surface
6. Squeeze out:
• Excess oil
NOTE:
The filtering element should be wet but not dripping.
7. Install:
• Filtering element (4) in its case
4
NOTE:
When installing the filtering element in its case, follow the direction indicated by the arrows, make sure
that the flame-trap net is set forward and that the
cap is properly assembled.
8. Reassemble:
• Air filter box cap
• Fast screws
CAUTION:
Make sure the air filter is properly seated in
the air filter case.
The engine should never be run without the
air filter installed. Excessive piston and/or
cylinder wear may result.
3-24
AIR FILTER CLEANING/
FUEL FILTER CLEANING
INSP
ADJ
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 accumulate.
5
FUEL FILTER CLEANING
OFF
1. Turn the fuel cock to "OFF".
2. Disconnect:
• Fuel pipe from cock
3. Place a fuel pan under the fuel tank and turn
the fuel cock to "RES" to drain the fuel.
OFF
CAUTION:
Do not bring naked flames or possible
sources of sparks near to the fuel tank: FIRE
AND EXPLOSION RISK! Be careful not to spill
fuel from the tank.
Always wipe off spilled fuel immediately with
a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic.
RES
RES
4. Disassemble:
• The fuel cock from the fuel tank
5. Wash:
• Fuel filter (1) with solvent
6. Inspect:
• Fuel filter (1)
• Gasket (2)
Damaged ➔ Replace.
7. Reassemble:
• Fuel cock to tank
• Fuel pipe to cock
NOTE:
When reassembling the cock, be careful not to
tighten the fastening screws unduly, as the gasket
might leave its housing and cause fuel leakage.
3-25
ENGINE OIL TANK FILTER CLEANING
INSP
ADJ
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 REPLACEMENT”.
2. Remove:
• Seat
• Rear cowling
See section “SEAT, FUEL TANK AND
REAR COWLING”.
• Rear wire harness
• Exhaust muffler
• Exhaust pipe
• Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
• Joint air cleaner clamps
• Rear frame
• Engine oil tank
3. Loosen:
• Stay (rear left side cover) fastening
screws
4. Remove:
• Oil tank cap (1)
• Oil return hose (2)
• Oil return hose flange (4) fastening screw
(3)
• Oil delivery hose flange (6) fastening
screws (5)
• Oil tank filter (7)
• OR gaskets (8)
5. Clean:
• Oil tank filter (with solvent)
• Oil tank (with solvent)
NOTE:
After cleaning the inside of the oil tank, remove
the remaining solvent.
6. Inspect:
• OR gaskets
Damaged ➔ Replace.
3-26
ENGINE OIL TANK FILTER CLEANING
INSP
ADJ
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. Tighten:
• Stay (rear left side cover) fastening
screws
9. Reassemble:
• Engine oil tank
• Rear frame
• Joint air cleaner clamps
• Rear shock absorber
See section “REAR SHOCK ABSORBER”
in Chapter 4.
• Exhaust pipe
• Exhaust muffler
• Rear wire harness
• Rear cowling
• Seat
See section “SEAT, FUEL TANK AND
Screw (seat):
10 Nm (1.0 mkg)
REAR COWLING”.
10. Fill:
•
Engine oil
See section “ENGINE OIL REPLACEMENT”.
11. Reassemble:
• Engine tank cap
3-27
SUCTION HOSE AND MANIFOLD INSPECTION/
FUEL LINE INSPECTION
INSP
ADJ
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)
3. Reassemble:
• Fuel tank
• Seat
See section “SEAT, FUEL TANK AND
REAR COWLING”.
Seat screws:
10 Nm (1.0 mkg)
FUEL LINE INSPECTION
1
1. Inspect:
• Fuel pipe (1)
Cracked/Damaged ➔ Replace.
3-28
CRANCKCASE VENTILATION HOSE INSPECTION/
EXHAUST SYSTEM INSPECTION
INSP
ADJ
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.
Nut (4) (exhaust pipe):
10 Nm (1.0 mkg)
Screw (5) (muffler):
23 Nm (2.3 mkg)
Bolt (6) (flange):
23 Nm (2.3 mkg)
(apply molybdenum disulfide
grease)
Screw (7) (protection):
7 Nm (0.7 mkg)
Use LOCTITE®.
Nut (8) (muffler):
23 Nm (2.3 mkg)
3-29
ADJUSTING THE FRONT BRAKE
INSP
ADJ
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• Brake lever position
(distance a between the brake lever and
the handlebar grip)
2
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting dial 1 while holding the
lever pushed away from the handlebar grip
1
NOTE:
Align the setting on the adjusting dial with the
arrow mark 2
Posizione n. 1
La distanza a è la
massima.
Posizione n. 4
La distanza a è la
minima.
WARNING
After adjusting the brake lever position, make
sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake system. Before the vehicle is operated, the air
must be removed by bleeding the brake system. Air in the brake system will considerably
reduce braking performance and could result
in loss of control and possibly an accident.
Therefore, inspect and, if necessary, bleed the
brake system. After adjusting the brake lever
free play, make sure that there is no brake
drag.
3-30
ADJUSTING THE REAR BRAKE
INSP
ADJ
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.
a
Brake pedal position
(below the top of the rider footrest):
10 mm
2. Adjust:
• Brake pedal position
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
•
•
Loosen lock nut (1).
Turn the adjuster (2) either way to obtain the
correct pedal height.
Unscrewing
Height (a) diminishes.
Screwing
Height (a) increases.
•
Tighten lock nut.
Lock nut:
20 Nm (2.0 mkg)
CAUTION:
After adjusting the brake pedal position, make
sure the brake doesn't oppose resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
If the brake brake pedal has a soft or slack
feel, this means that there is air in the brake
system. It should be bled away before using
the motorcycle. Air in the system seriously
affects the effectiveness of braking and may
cause loss of control of the motorcycle.
3-31
CHECKING THE BRAKE FLUID LEVEL
INSP
ADJ
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 ➔ Add
the recommended brake fluid to the proper level.
A
MIN
Recommended brake fluid:
DOT4
a
[A] Front brake
[B] Rear brake
2
3
4
WARNING
•
B
•
a
•
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the reservoir. Water will significantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and
plastic parts. Therefore, always clean up any
spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reservoir
is horizontal.
3-32
1
BRAKE PAD WEAR INSPECTION/
BRAKE HOSING INSPECTION
INSP
ADJ
1. Operate the brake lever or brake pedal.
2. Check:
• Thickness of frictional material
Out of specification ➔ Replace.
A
Wear limit (a):
Front: 1.0 mm
Rear: 1.0 mm
a
For brake pad replacement, see section
“BRAKE PAD REPLACEMENT” in
Chapter 4.
B
[A] Front brake
[B] Rear brake
a
BRAKE HOSING INSPECTION
A
1. Inspect:
• Brake hosing
Cracks/Damage ➔ Replace.
To replace hosing, see section “FRONT
AND REAR BRAKE” in Chapter 4.
[A] Front brake
[B] Rear brake
B
3-33
BRAKE CIRCUIT BLEEDING
INSP
ADJ
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 seriously affects the effectiveness of braking and
may cause loss of control of the motorcycle.
In all cases, bleed the brake system if:
• The system has been disassembled.
• A brake hose has been loosened or
removed.
• The brake fluid in the tank is at a very low
level.
• Brake operation is faulty.
Air bleeding procedures:
A
1
B
a. Top up the level of the fluid in the tank to maximum.
b. Install the diaphragm. Be careful not to spill
fluid or let it overflow from the tank.
c. Connect the clear plastic hose (1) to the
caliper bleeder screw.
[A] Front
[B] Rear
d. Place the other end of the hose in a container.
e. Slowly pull the brake lever or press the brake
pedal several times.
f. Pull the brake lever right in or press the pedal
right down and hold in position.
g. Loosen the bleeder screw and allow the lever
or pedal to travel slowly towards its limit.
h. Tighten the bleeder screw when the lever or
pedal limit has been reached, then release the
lever or pedal.
1
Bleeder screw:
14 Nm (1.4 mkg)
i.
3-34
Repeat operations (e) to (h) until all the air
bubbles have disappeared from the clear
plastic hose (1).
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT
INSP
ADJ
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.
j.
Top up fluid to the maximum level.
DRIVE CHAIN SLACK INSPECTION AND
ADJUSTMENT
Inspecting slack:
NOTE:
Before checking and/or adjusting the chain, rotate
the rear wheel through several revolutions and
check the slack several times to find the point on
the wheel where chain slack is highest.
Check and/or adjust chain slack with rear wheel in
this “tight chain” position.
1. Check:
• Drive chain slack (a)
Out of specification ➔ Adjust.
Drive chain slack:
30 ~ 40 mm
NOTE:
To check chain slack, the motorcycle must stand
in an upright position with its two wheels touching
the ground and no one sitting on it. Check slack in
the position shown in the figure.
a
2. Adjust:
• Drive chain slack
Slack adjustment:
CAUTION:
Too little chain slack will overload the engine
and other vital parts. Keep the slack within the
specified limits.
3-35
DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/
DRIVE CHAIN LUBRICATION
•
•
2
➩
a
➩
b
•
1
3
INSP
ADJ
Loosen the axle nut (1).
Loosen the locknuts (2) on each side. To tighten the chain, turn the chain adjusting bolts (3)
in direction (a). Loosen the locknuts on each
side. To loosen the chain, turn the chain
adjusting bolts in direction (b) and push the
wheel forward.
After adjusting, tighten the locknuts (2). Then
tighten the axle nut (1) to the specified torque.
Rear wheel axle nut:
115 Nm (11.5 mkg)
•
Turn each adjusting bolt exactly the same
amount to maintain correct axle alignment.
There are marks on each side of the
swingarm. Use these marks to align the rear
wheel.
DRIVE CHAIN LUBRICATION
The chain consists of many parts which work with
each other. If the chain is not maintained properly,
it will wear out quickly. Therefore, the chain must
be serviced regularly. This service is especially
necessary when riding in dusty areas. This motorcycle has a drive chain with small rubber O-Rings
between the chain plates. Steam cleaning, highpressure washing and certain solvents can damage these O-Rings. Use only kerosene to clean
the drive chain. Wipe it dry, and thoroughly lubricate it with SAE 80 ~ 90W motor oil or special lubricant for O-Ring chains. Do not use any other lubricants on the drive chain. They may contain solvents that could damage the O-Rings.
Recommended lubricant:
SAE 80W/90 engine oil or
special lubricant for
O-Ring chains.
(1) O-Rings
3-36
FRONT FORK INSPECTION/
FRONT FORK ADJUSTMENT
INSP
ADJ
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.
• Oil seal
Undue oil leakage ➔ Replace.
3. With the motorcycle in a level upright position
operate the front brake.
4. Check:
• Proper functioning
Compress and release the front fork several times.
Irregular/jerky functioning ➔ Repair.
See section “FRONT FORK” in Chapter 4.
ADJUSTING THE FRONT FORK
This front fork is equipped with spring pre-load adjusting bolts.
WARNING0
b
a
1
b
Always adjust both fork legs equally, otherwise poor handling and loss of stability may
result.
a
Adjust the spring preload as follows.
To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each
fork leg in direction a. To decrease the spring
preload and thereby soften the suspension, turn
the adjusting bolt on each fork leg in direction b.
Minimum (soft)
Standard
Maximum (hard)
3-37
Setting
1-2-3
4
5-6-7-8-9-10
REAR SHOCK ABSORBER ADJUSTMENT
INSP
ADJ
REAR SHOCK ABSORBER ADJUSTMENT
WARNING
2
a
b
This shock absorber contains highly pressurized nitrogen gas. For proper handling, read
and understand the following information
before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result
from improper handling.
• Do not tamper with or attempt to open the
gas cylinder.
• Do not subject the shock absorber to an
open flame or other high heat sources,
otherwise it may explode due to excessive
gas pressure.
• Do not deform or damage the gas cylinder
in any way, as this will result in poor damping performance.
A
1
This shock absorber assembly is equipped with a
spring preload adjusting nut.
CAUTION:
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and thereby
harden the suspension, turn the adjusting nut
in direction a. To decrease the spring preload
and thereby soften the suspension, turn the
adjusting nut in direction b.
3-38
REAR SHOCK ABSORBER ADJUSTMENT
INSP
ADJ
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 illustration. The longer distance A is, the lower the
spring preload; the shorter distance A is, the
higher the spring preload. With each complete turn of the adjusting nut, distance A
changes by 1.5 mm.
Spring preload:
Minimum (soft):
Distance A = 217 mm
Standard:
Distance A = 211 mm
Maximum (hard):
Distance A = 205 mm
2. Tighten the locknut to the specified torque.
Locknut:
45 Nm (4.5 m·kgf)
CAUTION:
Always tighten the locknut against the adjusting nut, and then tighten the locknut to the
specified torque.
3-39
STEERING INSPECTION
INSP
ADJ
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.
Free play ➔ Adjust steering bearing.
3. Adjust:
• Steering bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
Adjustment:
•
2
•
1
3
•
Remove the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
Loosen steering axle nut (1) and fork upper
bracket screws (2).
Tighten the ring nut (3) with the special
wrench.
Ringnut wrench:
P/N. 90890-01268
P/N. 90890-01348
NOTE:
The torque wrench and the ringnut wrench should
form a right angle.
Ring nut (initial tightening):
38 Nm (3.8 mkg)
•
•
Loosen the ring nut one turn.
Retighten the ring nut using the special
wrench.
WARNING
Do not tighten the ring nut excessively.
Ring nut (final tightening):
4 Nm (0.4 mkg)
3-40
STEERING INSPECTION/
TYRE INSPECTION
•
INSP
ADJ
Tighten the steering axle nut and the front fork
bracket screws.
Nut (steering axle):
115 Nm (11.5 mkg)
Screws (front fork bracket):
28 Nm (2.8 mkg)
•
Reassemble the fuel tank.
See section “SEAT, FUEL TANK AND REAR
COWLING”.
NOTE:
Check the steering head for looseness or binding
by turning it all the way in both directions. If it
binds, remove the steering axle assembly and
inspect the steering bearings.
Refer to “STEERING HEAD” in Chapter 6.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TYRE INSPECTION
WARNING
•
•
•
•
•
3-41
Tyre pressure must be checked when the
tyres are at ambient temperature. Pressure
must be adjusted according to the total
weight of luggage, driver, passenger and
accessories (fairings, bags, if approved for
this model) and speed of the motorcycle.
A list of tyres approved for this model following severe testing by Yamaha is provided. There can be no guarantee of safe roadholding if a combination of tyres different
from those indicated is used.
Front and rear tyres must have the same
design and be of the same make.
The use of valves and valve stems other
than those indicated might cause the loss
of tyre pressure at high speeds. Use only
original or compatible spare parts.
Replace the valve cap securely to prevent
losses of tyre pressure at high speed.
TYRE INSPECTION
INSP
ADJ
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/cm2, (2.20 kgf/cm2,
2.00 bar)
2.20 bar)
210 kPa
240 kPa
90 kg-maximum (2.10 kgf/cm2, (2.40 kgf/cm2,
2.10 bar)
2.40 bar)
150 kPa
160 kPa
Off-road riding
(1.50 kgf/cm2, (1.60 kgf/cm2,
1.50 bar)
1.60 bar)
210 kPa
240 kPa
High-speed
(2.10 kgf/cm2, (2.40 kgf/cm2
riding
2.10 bar)
2.40 bar)
Maximum load*
180 kg
* Total weight of rider, passenger, cargo and accessories.
2. Adjust:
• Air pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
• Remove the valve cap.
•
Use an air pump or
compressed air pistol.
Increase air
pressure
Eliminate air by
pressing valve tube
stem
Air pressure
diminishes
Install valve caps securely.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Inspect:
• Tyre surface
Wear/Damage ➔ Replace.
3-42
TYRE INSPECTION
INSP
ADJ
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
The use of worn tyres reduces stability and
may cause a loss of control.
It is not advisable to repair a punctured air
tube. If absolutely necessary, repair with the
utmost care and replace the tube as quickly as
possible with another with the same characteristics.
4. Tighten:
• Valve stem lock nut
Lock nut (valve stem)
1.5 Nm (0.15 kgm)
FRONT:
Manufacture
PIRELLI
MICHELIN
Size
90/90-21 54R
90/90-21 54S
Type
MT70
T63
Size
130/80-18 66R
130/80-18 66S
Type
MT70
T63
REAR:
Manufacture
PIRELLI
MICHELIN
WARNING
After assembling the new tyres, drive slowly
to allow them to adapt well to the rim and yjus
ensure maximum holding.
3-43
WHEEL INSPECTION/
SPOKE INSPECTION AND TIGHTENING
INSP
ADJ
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 periodically to make sure that they do not have free play
in the hub and that the wheel turns smoothly without sticking. Wheel bearings must always be
checked in accordance with the maintenance
table.
SPOKE INSPECTION AND TIGHTENING
1. Inspect:
• Spokes (1)
Curvature/Damaged ➔ Replace.
Loose spoke ➔ Tighten.
2. Tighten:
• Spoke (s)
NOTE:
Tighten the spokes before and after the break-in
period.
Spoke:
3 Nm (0.3 mkg)
3-44
CABLE INSPECTION/
LEVER AND PEDAL LUBRICATION
INSP
ADJ
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.
2. Check:
• Cable functioning
Does not run freely ➔ Replace the cable
assembly.
LEVER AND PEDAL LUBRICATION
1. Lubricate the pivoting parts:
• Clutch lever
• Front brake lever
• Rear brake pedal
• Shift pedal
Recommended lubricant:
SAE 10W30 motor oil
3-45
SIDESTAND LUBRICATION/
REAR SUSPENSION LUBRICATION
INSP
ADJ
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.
1
Recommended lubricant:
Molybdenum disulfide grease
3-46
CHECKING AND CHARGING THE BATTERY
INSP
ADJ
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO
NOT SMOKE when charging or han•
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
• SKIN – Wash with water.
• EYES – Flush with water for 15 minutes
and get immediate medical attention.
Internal
Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical attention.
CAUTION:
•
•
3-47
This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
Charging time, charging amperage and
charging voltage for a MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
CHECKING AND CHARGING THE BATTERY
INSP
ADJ
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 measuring the voltage at the battery terminals.
1
1. Remove:
• Seat
• Panel 1
2. Disconnect:
• Battery leads
(from the battery terminals)
1
2
CAUTION:
First, disconnect the negative lead 1, then the
positive lead 2.
3. Remove:
• Battery
4. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery terminals.
Open-circuit voltage
Battery positive
terminal
Tester negative ➔
lead
Battery negative
terminal
NOTE:
• The charge state of a MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
Voltmeter
13,0
Tester positive ➔
lead
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30 %
Relationship between open-circuit
voltage and charging time at 20 °C
12,5
12,0
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method
illustration)
11,5
5 6,5
10
Charging time (Hours)
• This varies depending on the temperature, the state of
charge in battery plates and the electrolyte level.
3-48
CHECKING AND CHARGING THE BATTERY
WARNING
14
Ambient
temperature
20 °C
Open-circuit voltage (V)
13
Do not quick charge a battery.
12
CAUTION:
11
•
•
10
100
75
50 30 2520
Condition of charge in battery (%)
Charging
0
•
Ambient
temperature 20 °C
18
Open-circuit voltage (V)
INSP
ADJ
17
•
16
15
14
13
12
11
10
0
10
20
30
40
50
60 Time (minutes)
•
Check the open-circuit
voltage
•
•
•
•
3-49
Never remove the MF battery sealing caps.
Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to
remove it from the motorcycle (if charging
has to be done with the battery mounted
on the motorcycle, disconnect the negative lead from the battery terminal).
To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
Make sure that the battery charger lead
clips are in full contact with the battery
terminal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
If the battery becomes hot to the touch at
any time during the charging process, disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
As shown in the following illustration, the
open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
CHECKING AND CHARGING THE BATTERY
INSP
ADJ
Charging method using a variable-current (voltage) type charger
Charger
AMP
meter
YES
Measure the open-circuit
voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes
after the machine is stopped.
Connect a charger and AMP
meter to the battery and start
charging.
NOTE:
Set the charging voltage at 16 ~ 17 V (if
the setting is lower, charging will be
insufficient. If too high, the battery will be
over-charged.)
Make sure the current is
higher than the standard
charging current written on
the battery.
NO
By turning the charging voltage
adjust dial, set the charging
voltage at 20 ~ 25 V.
Adjust the voltage so that
current is at standard charging level.
YES
Monitor the amperage for 3 ~ 5
minutes to check if the standard
charging current is reached.
NO
Set the timer according to
the charging time suitable for
the open-circuit voltage.
Refer to "Battery condition
checking steps."
If the current does
not exceed standard
charging current after 5 minutes, replace the battery.
In case that charging requires more than 5 hours, it is advisable to check
the charging current after a lapse of 5 hours.
If there is any charge in the amperage, readjust the voltage to obtain the
standard charging current.
Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
3-50
CHECKING AND CHARGING THE BATTERY
INSP
ADJ
Charging method using a constant-voltage type charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and AMP
meter to the battery and start
charging.
YES
Make sure the current is
higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.
NO
This type of battery charger cannot
charge the MF battery. A variable volt-
NOTE:
Set the charging time at 20 hours (maximum).
Measure the battery open-circuit voltage after having left the battery unused
for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Charger
AMP meter
Voltmeter
Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.
3-51
CHECKING AND CHARGING THE BATTERY
INSP
ADJ
6. Connect:
• Battery leads
(to the battery terminals)
1
2
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.
8. Lubricate:
• Battery terminals
Recommended lubricant
Dielectric grease
9. Install:
• Panel
• Seat
3-52
CHECKING THE FUSES
INSP
ADJ
CHECKING THE FUSES
CAUTION:
To avoid a short circuit, always turn the main
switch to "OFF" when checking or replacing a
fuse.
1
1. Remove:
• Seat
• Panel 1
2. Check:
• Fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the pocket tester selector to “Ω 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates "∞", replace the
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn off the ignition.
b. Install a new fuse of the correct amperage rating.
c. Turn on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check the
electrical circuit.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
Fuses
2
Main (1)
Reserve (2)
3-53
Amperage
rating
20 A
20 A
Quantity
1
1
CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
INSP
ADJ
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 system, cause the lighting and ignition systems
to malfunction and could possibly cause a fire.
4. Install:
• Pannel
• Seat
REPLACING THE HEADLIGHT BULBS
1
Low beam/high beam
3
1. Remove:
• Cowling screws (1)
2. Remove:
• Cowling (from the meter bracket)
4
1
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
2
a
b
3. Remove:
• Headlight (2)
4. Disconnect:
• Headlight coupler (3)
5. Remove:
• Headlight bulb cover (4)
6. Remove:
• Headlight bulb holder (5) (by turning it
counterclockwise (a))
• Headlight bulb
5
WARNING
Headlight bulbs get very hot. Therefore, keep
flammable products away from a lit headlight
bulb, and do not touch the bulb until it has
cooled down.
3-54
REPLACING THE HEADLIGHT BULBS
INSP
ADJ
7. Install:
• Headlight bulb (new)
• Headlight bulb holder (by turning it clockwise (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. Thoroughly clean off any dirt and
fingerprints on the headlight bulb using a
cloth moistened with alcohol or thinner.
8. Install:
• Headlight bulb cover
9. Connect:
• Headlight coupler
10. Install:
• Upper side of the cowling (onto the meter
bracket)
• Headlight (adjust the headlight beam if
necessary)
11. Install:
• Cowling screws
Cowling screws:
10 Nm (1.0 kgm)
1
Auxiliary light bulb
1. Remove:
• Cowling screws (1)
2. Remove:
• Cowling (from the meter bracket)
3
1
NOTE:
Remove the cowling from the meter bracket by
lowering it to disengage it, and then lifting it up.
2
3. Remove:
• Headlight (2)
• Auxiliary light socket (3)
NOTE:
Remove the auxiliary light socket (together with
the bulb) without disconnecting the leads.
•
3-55
Bulb (by pushing it in and turning it counterclockwise)
REPLACING THE TURN INDICATOR LIGHT BULB
INSP
ADJ
4. Install:
• Bulb (new) (by pushing it in and turning it
clockwise)
• Bulb holder
• Upper side of the cowling (onto the meter
bracket)
• Headlight (adjust the headlight beam if
necessary)
5. Install:
• Cowling screws
Cowling screws:
10 Nm (1.0 kgm)
REPLACING THE TURN INDICATOR LIGHT
BULB
2
1. Remove:
• Lens screw (1)
• Lens (2)
• Bulb (3)
1
NOTE:
To remove the bulb press it into place and turn it
counterclockwise.
2. Install:
• New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise.
3
•
•
Lens
Lens screw
CAUTION:
Do not overtighten the screw, otherwise the
lens may break.
3-56
REPLACING THE TAIL/
BRAKE LIGHT BULB
INSP
ADJ
REPLACING THE TAIL/BRAKE LIGHT BULB
1. Remove:
• Screws (1) (lens fixing)
• Lens (2)
• Bulb (3)
2
NOTE:
To remove the bulb press it into place and turn it
counterclockwise (a).
1
2. Install:
• New bulb
NOTE:
To install the bulb press it into place and turn it
clockwise (b).
3
•
•
a
b
Lens
Screws (lens fixing)
CAUTION:
Do not overtighten the screws, otherwise the
lens may break.
3-57
INSP
ADJ
CHAS
4
CHAS
CHAPTER 4.
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL AND BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-3
4-3
4-5
4-5
4-6
4-6
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . .
REAR WHEEL AND BRAKE DISC REMOVAL .
REAR WHEEL DISASSEMBLY . . . . . . . . . . . .
REAR WHEEL INSPECTION . . . . . . . . . . . . .
BRAKE DISC INSPECTION . . . . . . . . . . . . . .
REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . .
REAR WHEEL INSTALLATION . . . . . . . . . . . .
WHEEL STATIC BALANCE ADJUSTMENT . . .
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REAR BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
4-21
4-23
4-23
4-24
4-25
4-25
4-27
4-29
4-29
4-30
4-32
4-33
4-33
4-34
4-35
4-36
4-38
4-38
4-39
4-39
CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK REMOVAL . . . . . . . . . .
FRONT FORK DISASSEMBLY . . . . . .
FRONT FORK REMOVAL . . . . . . . . . .
OIL REPLACEMENT . . . . . . . . . . . . . .
CLEANING THE DUST SEAL . . . . . . .
SEAL AND BUSH REPLACEMENT . . .
OIL LEAKAGE FROM DUST SEAL . . .
ANOMALOUS HYDRAULIC BRAKING
FRONT FORK INSPECTION . . . . . . .
FRONT FORK INSTALLATION . . . . . .
FRONT FORK ADJUSTMENT . . . . . .
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4-42
4-42
4-43
4-45
4-46
4-49
4-50
4-56
4-56
4-57
4-59
4-60
STEERING . . . . . . . . . . . . . . . . .
STEERING REMOVAL . . . .
STEERING INSPECTION . .
STEERING INSTALLATION
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4-61
4-64
4-65
4-65
REAR SHOCK ABSORBER . . . . . . . . . .
NOTE ON DISPOSAL . . . . . . . . . . .
SHOCK ABSORBER REMOVAL . . .
SHOCK ABSORBER INSPECTION .
SHOCK ABSORBER ADJUSTMENT
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4-69
4-72
4-73
4-74
4-74
SWINGARM . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM REMOVAL . . . . . . . . . . . .
SWINGARM INSPECTION . . . . . . . . .
LATERAL FREE PLAY ADJUSTMENT
SWINGARM INSTALLATION . . . . . . .
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4-76
4-77
4-78
4-79
4-80
DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET
DRIVE CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
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4-82
4-82
4-83
4-85
FRONT WHEEL AND BRAKE DISC
CHAS
CHASSIS - FRONT WHEEL AND BRAKE DISC
Order
Job name/Part name
Q.ty
Remarks
Remove the parts in order.
Front wheel and brake disc
removal
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1
2
3
4
5
6
7
8
9
Speedometer cable
Pinch bolt
Wheel axle
Front wheel assembly
Collar
Gear unit assembly
Brake disc screw
Brake disc
Ring
1
2
1
1
1
1
6
1
1
4-1
Disconnect.
Loosen.
Refer to “FRONT WHEEL INSTALLATION”
section.
Reverse the removal procedure for installation.
FRONT WHEEL AND BRAKE DISC
CHAS
1
2
3
4
5
Order
1
2
3
4
5
Job name/Part name
Q.ty
Remarks
Remove the parts in order.
Front wheel disassembly
Oil seal
Bearing
Spacer
Oil seal
Bearing
1
1
1
1
1
Refer to “FRONT WHEEL DISASSEMBLY/
ASSEMBLY” section.
Reverse the removal procedure for installation.
4-2
FRONT WHEEL AND BRAKE DISC
CHAS
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.
•
Disassemble the bearing (1) with a normal
puller (2).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
FRONT WHEEL INSPECTION
1. Inspect:
• Front wheel axle
(by rolling it on a flat surface)
Bends ➔ Replace.
WARNING
Do not attempt to straighten a bent axle.
2. Inspect:
• Front tire
Wear/damage ➔ Replace.
Refer to “TIRE INSPECTION” in CHAPTER 3.
• Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Inspect:
• Spoke(s)
Bent/Damaged ➔ Replace.
Loose spoke(s) ➔ Tighten.
Turn the wheel and hit the spokes gently
with a screwdriver.
NOTE:
A well tightened spoke makes a distinct, sharp
noise: a loose spoke makes a dull, muffled noise.
4-3
FRONT WHEEL AND BRAKE DISC
CHAS
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. Inspect:
• Front wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly ➔
Replace.
• Oil seal
Wear/damage ➔ Replace.
WARNING
•
•
After assembling a tyre, drive slowly to
allow it to adapt to the rim. If this precaution is not observed, damage might be
caused to the motorcycle and accidents to
the driver.
After repairing or changing a tyre, do not
forget to tighten the valve lock nut (1) to
the prescribed torque.
Valve lock nut:
1.5 Nm (0.15 mkg)
4-4
FRONT WHEEL AND BRAKE DISC
CHAS
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
Brake disc thickness (b)
If out of specified limits ➔ Replace.
Minimum thickness (brake disc):
3.6 mm
IFRONT WHEEL ASSEMBLY
1. Install:
• Spacer
• Bearings
• Oil seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Assembly procedure:
• Install the new bearing and the dust cover by following the disassembly procedures in reverse
order.
NOTE:
Use a wrench (1) with an external diameter equal to
that of the bearing and dust cover.
CAUTION:
Do not strike the bearing inner race (2) or balls
(3). The contact must only be made with the
outer race (4).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-5
FRONT WHEEL AND BRAKE DISC
CHAS
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.
1
2. Install:
• Speedometer gear unit (1)
NOTE:
Make sure that the wheel hub and the speedometer gear unit are installed with the projections
meshed into the slots.
3. Tighten:
• Front wheel
• Front wheel axle
Front wheel axle:
59 Nm (5.9 mkg)
NOTE:
Make sure that the slot (a) in the speedometer
gear unit fits under the stopper on the front fork
outer tube.
a
•
Pinch bolt
Pinch bolt:
9 Nm (0.9 mkg)
WHEEL STATIC BALANCE ADJUSTMENT
NOTE:
• After replacing the tire and/or rim, the wheel
static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing weight
2. Set:
• Wheel (on a suitable stand)
3. Find:
• Heavy spot
4-6
FRONT WHEEL AND BRAKE DISC
CHAS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X1” mark is 90° up.
d. Release the wheel and wait for it to rest.
Put an “X2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times
until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Adjust:
• Wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjusting steps:
• Install a balancing weight (1) on the rim exactly opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
•
•
Turn the wheel so that the heavy spot is 90°
up.
Check that the heavy spot is at rest there. If
not, try another weight until the wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check:
• Wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Checking steps:
• Turn the wheel so that it comes to each point
as shown.
• Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-7
FRONT BRAKE
CHAS
FRONT BRAKE
BRAKE PAD
2
6
3
1
4
5
25 Nm (2.5 m•kg)
Order
Job name/Part name
Q.ty
Remove the parts in order.
Brake pad removal
1
2
3
4
5
6
Remarks
Brake caliper screw
Brake caliper
Pad pin retainer
Pad pin
Brake pad
Pad spring
2
1
2
1
2
2
Refer to “BRAKE PAD REPLACEMENT”
section.
Reverse the removal procedure for installation.
4-8
FRONT BRAKE
CHAS
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.
• Use solvents on internal brake components.
• Use brake fluid already used for bleeding.
• Allow brake fluid to come into contact with
the eyes as it may cause injury.
• Allow brake fluid to come into contact with
painted or plastic parts as it may damage
them.
• Disconnect any hydraulic connection, otherwise the whole system must be disassembled, drained, cleaned, then properly filled
and bled after reassembly.
BRAKE PAD REPLACEMENT
NOTE:
It is unnecessary to disassemble the brake hose
to replace the pads.
1. Remove:
• Caliper bracket fastening screws (1)
(deplace the caliper)
2. Remove:
• Pin retainers (2)
• Pad fastening pin (3)
• Brake pads (4)
• Pad springs (5)
• Caliper bracket (6)
NOTE:
• If you replace the pads, also replace the
springs.
• If one of the two pads has to be replaced
because it is worn, replace both.
Wear limit (a):
3.7 mm
4-9
FRONT BRAKE
CHAS
3. Lubricate:
• Guide pins (1)
1
Lithium-base grease
4
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)
• Brake pads (2) (new)
• Pad fastening pin (3)
• Pin retainers (4)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Installation procedure:
• Connect the hose (1) firmly to the caliper
bleeder screw (2). Place the other end of the
hose in an open container.
• Loosen the caliper bleeder screw and push
the pistons into the caliper with your finger.
• Retighten the bleeder screw (2).
Caliper bleeder screw:
14 Nm (1.4 mkg)
•
•
•
•
Install the (new) brake pads and (new)
springs.
Fit the pad fastening pin well into its housing
by hammering with a punch with a suitable
diameter.
Install the (new) pin retainers.
Install the caliper and screws.
Caliper fastening screw:
25 Nm (2.5 kgm)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Check:
• Level of brake fluid in reservoir.
See section “BRAKE FLUID LEVEL
INSPECTION” in CHAPTER 3.
(a) Lower minimum level “MIN”
7. Check:
• Brake lever operation
Lever soft and spongy ➔ Bleed air from
brake circuit.
See section “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
a
4-10
FRONT BRAKE
CHAS
MASTER CYLINDER
9 Nm (0.9 m•kg)
1
6
2
7
4
20 Nm (2.0 m•kg)
3
5
New
Order
1
2
3
4
5
6
7
Job name/Part name
Master cylinder removal
Brake fluid
Rear view mirror (right)/
Master cylinder bracket
Brake lever
Brake switch
Union bolt
Plain washer
Brake hose
Master cylinder
Q.ty
Remarks
Remove the parts in order.
Drain.
1/1
1
1
1
2
1
1
Refer to “MASTER CYLINDER INSTALLATION” section.
Reverse the removal procedure for installation.
4-11
FRONT BRAKE
CHAS
1.5 Nm (0.15 m•kg)
1
6
3
2
4
5
Order
Job name/Part name
Q.ty
Remove the parts in order.
Master cylinder disassembly
1
2
3
4
5
6
Remarks
Reservoir cap
Diaphragm
Master cylinder boot
Circlip
Master cylinder assembly
Spring
1
1
1
1
1
2
Refer to “MASTER CYLINDER ASSEMBLY” section.
Reverse the disassembly procedure for
assembly.
4-12
FRONT BRAKE
CHAS
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 compressed air.
2. Inspect:
• Master cylinder piston unit (1)
Scratches/wear/damage ➔ Replace the
master cylinder assembly.
3. Inspect:
• Diaphragm
Wear/damage ➔ Replace.
4. Inspect:
• Brake hose
Cracks/wear/damage ➔ Replace.
MASTER CYLINDER ASSEMBLY
WARNING
•
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid:
DOT 4
•
In case of non correct operation of the
brake master cylinder, replace the master
cylinder assembly.
1. Install:
• Spring (1)
• Master cylinder (2)
4-13
FRONT BRAKE
CHAS
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)
• Brake hose (2)
• Union bolt (3)
2
Union bolt (brake hose):
20 Nm (2.0 mkg)
3
NOTE:
• When tightening the union bolt be sure to put
the brake hose in the correct position.
• Check that the brake hose has stayed in the
correct position. Adjust if necessary.
1
WARNING
•
•
Check that the brake hose routing is as
described. Refer to “CABLE ROUTING”
section.
Always use new plain washers.
3. Fill:
•
Brake fluid reservoir
Recommended brake fluid:
DOT 4
4-14
FRONT BRAKE
CHAS
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 deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid:
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Air bleed:
• Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
5. Inspect:
• Brake fluid level
Lower than “MIN” mark ➔ Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
a
2
6. Install:
• Diaphragm (1)
• Master cylinder cap (2)
• Screw (3) (cap)
3
1
Screw (master cylinder cap):
1.5 Nm (0.15 mkg)
4-15
FRONT BRAKE
CHAS
BRAKE CALIPER
20 Nm (2.0 m•kg)
1
3
2
New
4
5
25 Nm (2.5 m•kg)
Order
1
2
3
4
5
Job name/Part name
Q.ty
Remarks
Remove the parts in order.
Drain.
Caliper removal
Brake fluid
Union bolt
Plain washer
Brake hose
Caliper support bolt
Caliper assembly
1
2
1
2
1
Refer to “CALIPER INSTALLATION” section
Reverse the removal procedure for installation.
4-16
FRONT BRAKE
CHAS
1
14 Nm (1.4 m•kg)
3
4
5
2
Order
Job name/Part name
Q.ty
Remove the parts in order.
Refer to “BRAKE PAD” section.
Caliper disassembly
Brake pad
1
2
3
4
5
Remarks
Pad spring
Caliper piston
Dust seal
Piston seal
Bleed screw
2
2
2
2
1
Refer to “BRAKE CALIPER DISASSEMBLY/ASSEMBLY” section.
Refer the disassembly procedure for assembly.
4-17
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 opening to force out the caliper piston from the
brake caliper body.
•
WARNING
•
•
Never try to pry out the caliper piston.
Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
•
Remove the piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CALIPER INSPECTION
Recommended programme for the replacement of brake system components:
Brake pads
When necessary
Brake hoses
Every four years
Brake fluid
Replace every
24,000 km or 24
months and whenever the brake is
disassembled.
WARNING
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation. Do not use solvents to
prevent sealing elements from becoming misshapen or swollen.
1. Inspect:
• Caliper piston (1)
Scratches/wear/rust ➔ Replace caliper
assembly.
• Caliper cylinder (2)
Scratches/wear ➔ Replace caliper assembly.
• Caliper (3)
Cracks/damaged ➔ Replace the brake
caliper assembly..
4-18
FRONT BRAKE
•
CHAS
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.
Recommended brake fluid:
DOT 4
•
In case of non correct operation of the
brake caliper, replace the brake caliper
assembly.
1. Install:
• Piston seals (1)
• Dust seals (2)
2. Install:
• Brake caliper pistons (1)
CALIPER INSTALLATION
1. Install:
• Brake caliper (1)
• Caliper support bolts (2)
3
4
Bolt (caliper support):
25 Nm (2.5 mkg)
5
•
•
•
2
Brake hose (3)
Plain washers (4) (new)
Union bolt (5)
Union bolt:
20 Nm (2.0 mkg)
1
4-19
FRONT BRAKE
CHAS
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.
WARNING
•
•
•
Use only designated quality brake fluid.
Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid:
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
3. Air bleed:
• Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
4. Inspect:
• Brake fluid level
Lower than “MIN” mark ➔ Fill.
Refer to “BRAKE FLUID INSPECTION”
section in CHAPTER 3.
(a) Minimum level mark “MIN”
a
4-20
REAR WHEEL AND BRAKE DISC
CHAS
REAR WHEEL AND BRAKE DISC
Order
Job name/Part name
Q.ty
Remarks
Remove the parts in order.
Rear wheel and brake disc removal
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1
Axle nut
1
2
Wheel axle
1
3
Drive chain
-
4
Collar
2
5
Rear wheel assembly
1
6
Brake disc
1
4-21
Push the wheel forward and remove the
chain.
Refer to “REAR WHEEL INSTALLATION”
section.
Reverse the
installation.
removal
procedure
for
REAR WHEEL AND BRAKE DISC
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Q.ty
CHAS
Remarks
Remove the parts in order.
Rear wheel disassembly
Driven sprocket
Hub
Damper
Spacer
Oil seal
Bearing
Bearing
Hub dust cover
Oil seal
Bearing
Bearing spacer
1
1
4
1
1
1
1
1
1
1
1
4-22
Refer to “REAR WHEEL DISASSEMBLY/ASSEMBLY” section.
Reverse the removal procedure for installation.
REAR WHEEL AND BRAKE DISC
CHAS
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
• Wheel bearing
• Wheel spacer
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Removal procedure:
• Clean the outside of the hub.
• Remove the dust cover with a flat-headed screw
driver.
NOTE:
Place a rag on the outside to avoid damaging the
hub.
•
Disassemble the bearing (1) with a normal
puller (2).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
REAR WHEEL INSPECTION
1. Inspect:
• Rear wheel axle
(by rolling it on a flat surface)
Bends ➔ Replace.
WARNING
Do not attempt to straighten a bent axle.
2. Inspect:
• Rear tire
Refer to “TIRE INSPECTION” in CHAPTER 3.
• Rear wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Inspect:
• Spoke(s)
Bent/Damaged ➔ Replace.
Loose spoke(s) ➔ Tighten.
Turn the wheel and hit the spokes gently
with a screwdriver.
NOTE:
A well tightened spoke makes a distinct, sharp
noise: a loose spoke makes a dull, muffled noise.
4-23
REAR WHEEL AND BRAKE DISC
CHAS
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. Inspect:
• Rear wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly ➔
Replace.
• Hub dust cover
Wear/damage ➔ Replace.
• Oil seal
Wear/damage ➔ Replace.
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
Brake disc thickness (b)
If out of specified limits ➔ Replace.
Minimum thickness (brake disc):
4.5 mm
4-24
REAR WHEEL AND BRAKE DISC
CHAS
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
• Dampers
• Hub and driven sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Assembly procedure:
• Install the new bearing, the dust cover and the oil
seal by following the disassembly procedures in
reverse order.
NOTE:
Use a wrench (1) with an external diameter equal to
that of the bearing, dust cover and oil seal.
CAUTION:
Do not strike the bearing inner race (2) or balls
(3). The contact must only be made with the
outer race (4).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
REAR 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.
2. Install:
• Hub spacer (1)
• Driven sprocket (2)
• Hub and driven sprocket
Screw (driven sprocket):
48 Nm (4.8 mkg)
3. Install:
• Collar
4-25
REAR WHEEL AND BRAKE DISC
CHAS
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:
• Rear wheel assembly (in the rear arm)
• Bearing
• Edge of the hub dust cover
CAUTION:
Check that the brake disc is driving through
the brake pads.
6. Install:
• Drive chain (on the driven sprocket)
• Rear wheel axle (left side)
CAUTION:
Make sure the collars and chain pullers are
positioned correctly.
7. Adjust:
• Drive chain slack
Drive chain slack:
30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT” section in
Chapter 3.
8. Tighten:
• Wheel axle nut
Wheel axle nut:
115 Nm (11.5 mkg)
4-26
REAR WHEEL AND BRAKE DISC
CHAS
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. Set:
• Wheel (on a suitable stand)
3. Find:
• Heavy spot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom spot.
c. Turn the wheel so that the “X1” mark is 90° up.
d. Release the wheel and wait for it to rest.
Put an “X2” mark on the wheel’s bottom spot.
e. Repeat the above b., c., and d. several times
until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Adjust:
• Wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjusting steps:
• Install a balancing weight (1) on the rim exactly opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
•
•
Turn the wheel so that the heavy spot is 90°
up.
Check that the heavy spot is at rest there. If
not, try another weight until the wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-27
REAR WHEEL AND BRAKE DISC
CHAS
5. Check:
• Wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Checking steps:
• Turn the wheel so that it comes to each point
as shown.
• Check that the wheel is at rest at each point.
If not, readjust the rear wheel static balance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-28
REAR BRAKE
CHAS
REAR BRAKE
BRAKE PAD
Order
Job name/Part name
Q.ty
Remove the parts in order.
Refer to “REAR WHEEL REMOVAL”
section.
Remove from clamp.
Brake pad removal
Rear wheel
Brake hose
1
2
3
4
5
6
Remarks
Caliper protector
Pad pin retainer
Pad pin
Brake pad
Brake caliper (remove from caliper
support)
Brake pad support
1
1
1
1
2
Refer to “BRAKE PAD REPLACEMENT”
section.
1
Reverse the removal procedure for installation.
4-29
REAR BRAKE
CHAS
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.
• Use solvents on internal brake components.
• Use brake fluid already used for bleeding.
• Allow brake fluid to come into contact with
the eyes as it may cause injury.
• Allow brake fluid to come into contact with
painted or plastic parts as it may damage
them.
• Disconnect any hydraulic connection, otherwise the whole system must be disassembled, drained, cleaned, then properly filled
and bled after reassembly.
3
BRAKE PAD REPLACEMENT
4
6
2
NOTE:
It is unnecessary to disassemble the brake hose
to replace the pads.
5
1
1. Remove:
• Rear wheel (refer to “REAR WHEEL
REMOVAL” section).
• Bolt (caliper protector) (1)
• Brake caliper protector (2)
• Pad pin retainer (3)
• Brake pad pin (4)
Remove the caliper in the illustrated direction.
2. Remove:
• Brake pads (5)
• Pad support (6)
NOTE:
• If you replace the pads, also replace the pad
support.
• If one of the two pads has to be replaced
because it is worn, replace both.
4-30
REAR BRAKE
CHAS
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.
• Retighten the bleeder screw (2).
Caliper bleeder screw:
14 Nm (1.4 mkg)
•
•
•
•
5
6
Install the (new) brake pads and (new) pad
support.
Install the caliper (3) and the pad pin (4).
Install the (new) pin retainer (5)
Install the caliper protector (6).
Caliper protector bolt:
10 Nm (1.0 mkg)
4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
3
4. Check:
• Brake fluid level
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(a) Minimum level mark “MIN”
(b) Maximum level mark “MAX”
b
a
5. Check:
• Brake pedal operation
Pedal soft and spongy ➔ Bleed air from
brake circuit.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in Chapter 3.
4-31
REAR BRAKE
CHAS
MASTER CYLINDER
20 Nm (2.0 m•kg)
New
4 Nm (0.4 m•kg)
10 Nm (1.0 m•kg)
New
45 Nm (4.5 m•kg)
Order
Job name/Part name
1
2
3
4
5
6
Master cylinder removal
Brake fluid
Rear stop switch connector
Rear stop switch
Plain washer
Brake hose
Brake fluid reserve tank
Brake master cylinder
7
Brake pedal/spring
Q.ty
Remarks
Remove the parts in order.
Drain.
1
1
2
1
1
1
Refer to “MASTER CYLINDER INSTALLATION” section.
1/1
Refer to “BRAKE PEDAL REMOVAL” section.
Reverse the removal procedure for installation.
4-32
REAR BRAKE
CHAS
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 compressed air.
2. Inspect:
• Master cylinder piston unit
Scratches/wear/damage ➔ Replace the
master cylinder assembly.
3. Inspect:
• Diaphragm (1)
Wear/damage ➔ Replace.
4. Inspect:
• Brake hose
Cracks/wear/damage ➔ Replace.
MASTER CYLINDER ASSEMBLY
WARNING
•
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid:
DOT 4
•
In case of non correct operation of the
brake master cylinder, replace the master
cylinder assembly.
1. Install:
• Spring
• Master cylinder piston unit
4-33
REAR BRAKE
CHAS
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 lithiumbase grease.
•
•
•
•
•
New
Master cylinder
Brake fluid reserve tank
Plain washers (1) (new)
Brake hose (2)
Stop switch (to mount the brake hose) (3)
Brake switch (brake hose):
20 Nm (2.0 mkg)
Master cylinder mounting bolt:
10 Nm (1.0 mkg)
Reserve tank mounting bolt:
4 Nm (0.4 mkg)
2. Fill:
•
Brake fluid reserve tank
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
WARNING
•
•
•
4-34
Use only designated quality brake fluid.
Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid:
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
REAR BRAKE
CHAS
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”
1
5. Adjust:
• Brake pedal height (a)
(below the top of the footrest)
a
Brake pedal height:
10 mm
BRAKE PEDAL REMOVAL
1. Remove:
• Split pin (1) (new)
• Plain washer (2)
• Pin (3)
2. Unscrew:
• Bolt (4)
3. Remove:
• Spring (5)
4. Remove:
• Brake pedal (6) from chassis
NOTE:
Pull the brake pedal from the lower part of the
chassis, causing it to rotate progressively as it
comes away.
4-35
REAR BRAKE
CHAS
BRAKE CALIPER
Order
Job name/Part name
Q.ty
Remove the parts in order.
Refer to “REAR WHEEL REMOVAL” section.
Drain.
Remove from clamp.
Caliper removal
Rear wheel
Brake fluid
Brake hose
1
2
3
4
5
6
Remarks
Caliper protector
Brake caliper
Union bolt
Plain washer
Brake hose
Brake pad support
1
1
1
2
1
1
Remove from caliper support.
Refer to “BRAKE CALIPER INSTALLATION” section.
Reverse the removal procedure for installation.
4-36
REAR BRAKE
CHAS
New
14 Nm (1.4 m•kg)
2
10 Nm (1.0 m•kg)
Order
Job name/Part name
Q.ty
Remove the parts in order.
Caliper disassembly
1
2
3
4
5
6
7
8
Remarks
Caliper protector
Brake pad support
Brake pad
Pad support
Caliper piston
Dust seal
Piston seal
Bleed screw
1
1
2
1
1
1
1
1
Refer to “BRAKE PAD” section.
Refer to “BRAKE CALIPER DISASSEMBLY/ASSEMBLY” section.
Reverse the removal procedure for installation.
4-37
REAR BRAKE
CHAS
BRAKE CALIPER DISASSEMBLY
1. Remove:
• Brake caliper piston (1)
• Dust seal (3)
• Piston seal (2)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Removal procedure:
• Blow compressed air into the hose joint opening to force out the caliper piston from the
brake caliper body.
WARNING
•
•
Never try to pry out the caliper piston.
Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
•
Remove the piston seal
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CALIPER INSPECTION
Recommended programme for the
replacement of brake system components:
Brake pads
When necessary
Brake hose
Every four years
Replace every
24,000 km or 24
Brake fluid
months and
whenever the brake
is disassembled.
WARNING
All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation. Do not use solvents to
prevent sealing elements from becoming misshapen or swollen.
1. Inspect:
• Caliper piston
Scratches/wear/rust ➔ Replace caliper
assembly.
• Caliper cylinder
Scratches/wear ➔ Replace caliper assembly.
• Caliper
Cracks/damaged ➔ Replace.
4-38
REAR BRAKE
•
CHAS
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.
Liquido freni raccomandato:
DOT 4
•
In case of non correct operation of the
brake caliper, replace the brake caliper
assembly.
1. Install:
• Piston seal (1)
• Dust seal (2)
• Caliper piston (3)
5
4
CALIPER INSTALLATION
1. Install:
• Brake caliper (1)
• Caliper support (2)
• Brake hose (3)
• Plain washers (4) (new)
• Union bolt (5)
1
2
3
Union bolt:
20 Nm (2.0 mkg)
•
4-39
Caliper protector
REAR BRAKE
CHAS
CAUTION:
Check that the brake hose has stayed in correct 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.
a
2. Fill:
•
Brake fluid reserve tank
Recommended brake fluid:
DOT 4
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 deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid:
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
3. Air bleed:
• Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
4-40
REAR BRAKE
CHAS
4. Inspect:
• Brake fluid level
Lower than “MIN” mark (1) ➔ Fill.
Refer to “BRAKE FLUID INSPECTION”
section in Chapter 3.
(1) Minimum level mark “MIN”
1
4-41
FRONT FORK
CHAS
FRONT FORK
FRONT FORK REMOVAL
Order
Job name/Part name
Q.ty
Remarks
Remove the parts in order.
Refer to “FRONT WHEEL” section.
1
2
3
4
5
6
7
Front fork removal
Front wheel
Inner tube protector
Brake hose guide
Protector guide
Brake caliper assembly
Cowling (displace)
Pinch bolt (upper bracket)
Cap bolt (loosen)
1
1
2
1
1
4
2
8
9
Pinch bolt (under bracket) (loosen)
Fork leg
4
2
Refer to "FRONT FORK INSTALLATION"
section.
Reverse the removal procedure for installation.
4-42
FRONT FORK
CHAS
FRONT FORK DISASSEMBLY
Order
Job name/Part name
Q.ty
Remove the parts in order.
Refer to “FRONT FORK REMOVAL/INSTALLATION”.
Front fork disassembly
1
2
3
4
5
6
7
8
9
10
11
Remarks
Cap bolt
Seat
Spacer
Seat
Fork spring
Bolt
O-ring
Damper adjusting cylinder
Taper spindle
Dust seal
Snap ring
1
1
1
1
1
1
1
1
1
1
1
4-43
Refer to “OIL REPLACEMENT” section.
Refer to “SEAL AND BUSH REPLACEMENT” section.
FRONT FORK
Order
12
13
14
15
16
17
Job name/Part name
CHAS
Q.ty
Remarks
1
1
1
1
1
1
Refer to “SEAL AND BUSH REPLACEMENT” section.
Inner tube
Inner tube bushing
Oil seal
Washer
Outer tube bushing
Outer tube
Reverse the removal procedure for installation.
4-44
FRONT FORK
CHAS
OIL CAPACITY (IN EACH FORK LEG): 650 cm3
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 compressed without spring.
MINIMUM FORK SPRING FREE LENGTH:
530 mm
INNER TUBE BENDING LIMIT:
0.2 mm
FRONT FORK REMOVAL
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Park the motorcycle on a level surface.
2. Raise the front wheel by placing a suitable
support under the engine.
3. Remove:
• Front wheel
Refer to “FRONT WHEEL REMOVAL”
section.
4. Remove:
• Inner tube protector
• Protector guide
• Gear unit assembly and cable
• Brake caliper and hose
5. Loosen:
• Cap bolt
• Pinch bolt (upper and lower bracket)
4-45
FRONT FORK
CHAS
OIL REPLACEMENT
NOTE:
The quality of the fork oil is of fundamental importance 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.
CAUTION:
Using oil with different technical specifications will compromise the good efficiency of
the fork.
1. Generally clean the front fork.
2. Loosen:
• Cap bolt (inner tube)
3. Remove:
• Fork leg
4. Unscrew:
• Cap bolt (1) (completely)
NOTE:
Place the components in a clean area.
5. Withdraw:
• Seat (2)
• Spacer (3)
• Spring (4) (from the inner tube (5))
NOTE:
The spring, being immersed in oil could cause oil
to drip onto the work surface when withdrawn. It
is advisable therefore to withdraw it slowly and to
dry it with a clean cloth.
6. Pour the oil into a tray whilst at the same time
moving the inner tube (1) backwards and forwards.
CAUTION:
In order not to cause damage to the environment collect the used oil and take it to a collection centre.
4-46
FRONT FORK
CHAS
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. With the fork leg in a perfectly upright position,
insert the inner tube (1) in the outer tube (2)
completely to the end of the stroke.
10. Finish topping up the oil bringing it to the prescribed level from the upper edge measured
with a graduated dipstick or ruler (3).
Recommended oil:
Liqui Moly Racing suspension
oil SAE 7,5
Oil level:
Standard
180 mm
Minimum
190 mm
Maximum
170 mm
From top of inner tube with inner tube fully
inserted without spring.
11. Insert:
• Spring (1) (into the inner tube (2))
• Seat (3)
• Spacer (4)
NOTE:
Usually there is no particular sense in which the
spring is mounted and so it may be inserted from
either end. If there is a hem, however mount it
keeping the hemmed parts towards the top.
12. Screw:
• Cap bolts (5)
(on inner tube, without tighten)
13. Install:
• Fork leg
4-47
FRONT FORK
CHAS
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 prescribed torque) and then the upper one (to the
prescribed torque) and then retighten the lower
one (to the prescribed torque).
15. Tighten:
• Cap bolt (on inner tube)
Cap bolt (on inner tube):
20 Nm (2.0 mkg)
4-48
FRONT FORK
CHAS
CLEANING THE DUST SEAL
1
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
seal.
Just a few simple operations then, guided by the
following indications are necessary to maintain
the optimum functioning of the fork with time.
2
1
1. With a screwdriver prise the dust seal (1) from
the oil seal seat (2) and then withdraw it using
force.
1
2
2
2. Using a low pressure jet of compressed air
clean the inside of the dust seal and the oil
seal seat.
3. Insert the edge of a cloth under the lip and
keeping the cloth steady, carefully clean the
lip by rotating the dust seal.
4-49
FRONT FORK
CHAS
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.
5. Remount the dust seal inserting it with force
into the oil seal seat.
CAUTION:
Check that the oil seal housing edge of the
dust seal adheres perfectly to the oil seal
seat.
SEAL AND BUSH REPLACEMENT
NOTE:
To ensure maximum efficiency to the fork and
therefore a longer duration and greater safety,
every year (unless there are leakages) it is necessary to replace all the seals and slide bushes.
To carry out this operation it is recommended to
use the proper tools.
CAUTION:
To remove the fork leg from the steering unit,
the cap bolt, the spring and to drain and refill
the oil, follow the procedures indicated in the
preceding pages scrupulously.
1. Drain:
• Fork leg oil
Refer to “OIL REPLACEMENT”section.
2. Clamp:
• Fork leg in a vice (in a horizontal position)
CAUTION:
Protect the outer tube with a clean rag to
avoid damaging.
4-50
FRONT FORK
CHAS
2
1
3
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 assembly 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.
T-handle (1):
90890-01326
Front fork damper rod holder (2):
90890-01460
4. Remove:
• Damper cylinder assembly (from inner
tube)
5. Clean the inside of the outer tube and the outside of the damper cylinder assembly with
petrol.
CAUTION:
Taking care not to let petrol enter the inside of
the damper cylinder assembly as it would
seriously compromise its functioning.
4-51
FRONT FORK
CHAS
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. Tightly clamp the fork leg horizontally fastening it by caliper attachment on the outer tube.
4
5
7. Using a screwdriver prise the dust seal (4)
from the edge of the oil seal seat (5).
Then withdraw the dust seal using force.
5
4
1
2
8. Remove:
• Snap ring (1) (using a screwdriver)
1
4-52
FRONT FORK
9. With a few sharp blows withdraw the inner
tube (2) from the outer tube (3).
3
7
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.
6
4
2
CHAS
5
10. Install:
• Outer tube DU bush (6) (new)
• Inner tube DU bush (7) (new)
6
CAUTION:
Check that the inner tube bush (7) is inserted
correctly in its seat on the end of the inner
tube.
7
3
11. Mount the tool (1) on the inner tube (2) with the
side (3) matching the DU outer tube bush (4)
and clamp it keeping the two joints (5) at the
top and bottom (never towards the jaws of the
vice) and make it protrude by at least 40 mm
at the sides.
4
DU bush/oil seal driver (1):
90890-11043
3
4
1
2
4-53
FRONT FORK
5
CHAS
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 correctly positioned in its seat.
4
3
~ 40 mm
1
2
13. Remove the fork leg from the vice and remove
the tool (1). Insert the new washer (3) and the
new oil seal (4) as shown on the inner tube (2).
4
NOTE:
Apply lightweight lithium-soap base grease to the
oil seal before installing it.
14. Mount the tool (1) on the inner tube (2) with the
side (5) matching the oil seal (4) and clamp it
keeping the two joints (6) at the top and bottom (never towards the jaws of the vice) and
make it protrude by at least 40 mm at the
sides.
5
DU bush/oil seal driver (1):
90890-11043
3
4
1
2
15. The vice tightened, grip the outer tube and
with a few strong blows hit it against the tool
(1). After each blow rotate the outer tube
slightly in order to install the oil seal (4) correctly and until it is completely inserted in its
seat.
3
6
4
1
2
~ 40 mm
4-54
FRONT FORK
CHAS
16. Tightly clamp the fork leg horizontally fastening it by caliper attachment on the outer tube.
17. Install:
• Snap ring (1)
1
CAUTION:
Check that the snap ring is correctly seated.
18. Install:
• Dust seal (1) (new)
1
NOTE:
Apply lightweight lithium-soap base grease to the
dust seal before installing it.
NOTE:
Taking care to insert completely the dust seal (1)
with force in the outer tube (2).
2
1
2
1
3
4-55
FRONT FORK
CHAS
19. Insert:
• Damper cylinder assembly (in the inner
tube)
20. 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
assembly and screw the bolt completely.
CAUTION:
During tightening the bolt ensure that the end
of the damper rod holder is correctly engaged
on the damper cylinder assembly.
T-handle (1):
90890-01326
Front fork damper rod holder (2):
90890-01460
Damper cylinder assembly bolt (3):
25 Nm (2.5 kgm)
21. Fill:
•
Fork leg oil
Refer to “OIL REPLACEMENT”section.
OIL LEAKAGE FROM DUST SEAL
If there is a leakage of oil from between the dust
seal (1) and the inner tube (2) replace the oil seal
(refer to “SEAL AND BUSH REPLACEMENT”
section).
2
ANOMALOUS HYDRAULIC BRAKING
If the fork shows an anomalous hydraulic braking
effect it is necessary to overhaul the damper cylinder assembly.
1
WARNING
Never tamper with the damper cylinder
assembly! This operation should be done by
authorized personnel. Tampering with the
damper cylinder assembly by non authorized
personnel can compromise the safety of the
front fork. The building firm will not assume
any responsibility for any damages resulting
from such action.
4-56
FRONT FORK
CHAS
FRONT FORK INSPECTION
CAUTION:
The front fork has a very sophisticated internal 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. Inspect:
• Cap bolt (inner tube)
Wear/Damage ➔ Replace.
• O-Rings
Damage ➔ Replace.
2. Measure:
• Fork spring free length (a)
Out of specification ➔ Replace.
Fork spring free length:
530 mm
3. Inspect:
• Inner tube surface
Score marks ➔ Repair or replace.
Use #1.000 grit wet sandpaper.
Damaged oil seal surface ➔ Replace.
• Inner tube bending
Out of specification ➔ Replace.
Use a dial gauge (1).
Inner tube bending limit:
0.2 mm
NOTE:
The bending value is shown by one half of the dial
gauge reading.
4-57
FRONT FORK
CHAS
WARNING
Do not attempt to straighten a bent inner tube
as this may have dangerous consequences.
4. Inspect:
• Outer tube (1)
Score marks/Wear/Damage ➔ Replace.
5. Inspect:
• Cap bolt
• O-ring
Wear/Damage ➔ Replace.
4-58
FRONT FORK
CHAS
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:
• Front fork top end (a)
Front fork top end (a)
(Standard):
0 mm
4. Tighten:
• Pinch bolt (upper and lower bracket)
Pinch bolt (upper bracket):
28 Nm (2.8 mkg)
Pinch bolt (under bracket):
23 Nm (2.3 mkg)
NOTE:
Always tighten the lower pinch bolt (to the prescribed torque) and then the upper one (to the
prescribed torque) and then retighten the lower
one (to the prescribed torque).
5. Install:
• Front wheel
• Caliper
• Brake hose
• Tachometer cable
Refer to “FRONT WHEEL” and “FRONT
BRAKE” sections in this CHAPTER.
4-59
FRONT FORK
CHAS
ADJUSTING THE FRONT FORK
This front fork is equipped with spring pre-load adjusting bolts.
WARNING
b
a
1
b
Always adjust both fork legs equally, otherwise poor handling and loss of stability may
result.
a
Adjust the spring preload as follows.
To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each
fork leg in direction a. To decrease the spring
preload and thereby soften the suspension, turn
the adjusting bolt on each fork leg in direction b.
Minimum (soft)
Standard
Maximum (hard)
4-60
Setting
1-2-3
4
5-6-7-8-9-10
STEERING
CHAS
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
Remove the parts in order.
Park the motorcycle on a level surface.
Steering removal
WARNING
Securely support the motorcycle to prevent it falling over.
Front wheel
1
2
3
4
5
6
7
8
Fork legs
Cowling/Meter unit
Front fender
Handle upper holder
Handle lower holder
Handlebar
Nut
Upper bracket
Special washer
1
1
2
1
1
1
1
1
4-61
Refer to “FRONT WHEEL REMOVAL” section.
Refer to “FRONT FORK” section.
Displace.
Displace.
STEERING
CHAS
TIGHTENING PROCEDURE
• Initial tightening 38 Nm (3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm (0.4 mkg)
Order
9
10
11
12
13
14
Job name/Part name
Q.ty
Remarks
1
1
1
1
1
1
Refer to “STEERING REMOVAL/INSTALLATION” section.
Upper ring nut
Lower ring nut
Ball race cover
Lower bracket/Steering axle
Bearing (upper)
Bearing (lower)
Reverse the removal procedure for installation.
4-62
STEERING
(1)
(2)
(3)
(4)
(5)
(6)
Handle upper holder
Handle lower holder
Spacer
Nut
Plate washer
Upper bracket
(7) Brake hose holder
(8) Plate washer
(9) Special washer
(10) Upper ring nut
(11) Lower ring nut
(12) Ball race cover
(13)
(14)
(15)
(16)
CHAS
Bearings
Steering lock
Steering axle
Wire guide
TIGHTENING PROCEDURE
• Initial tightening 38 Nm
(3.8 mkg)
• Loosen 1 turn
• Final tightening 4 Nm
(0.4 mkg)
4-63
STEERING
CHAS
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 support under the engine.
3. Remove:
• Front wheel
Refer to “FRONT WHEEL-REMOVAL”
section.
• Front fork
Refer to “FRONT FORK-REMOVAL” section.
4. Remove:
• Front fender
• Cowling
• Handlebar
• Meter assembly
5. Remove:
• Steering axle nut (1)
Use the ring nut wrench (3).
Ring nut wrench (3):
90890-01348
6. Remove:
• Ring nut (upper) (1)
• Use the ring nut wrench (2)
Ring nut wrench (2):
90890-01268
4-64
STEERING
CHAS
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:
• Bearing (upper and lower) (1)
Corrosion/Damage ➔ Replace races and
bearing.
Install the bearings in the races. Spin the
bearing by hand.
If the bearing rises or fails to run freely in
the race, replace bearing and race.
3. Inspect:
• Steering axle (1)
Bend/Damage ➔ Replace.
STEERING INSTALLATION
1. Install:
• Bearing (1)
• Ball race cover (2)
NOTE:
Apply lithium soap-base grease to the bearing
and ball race cover lip.
2. Install:
• Lower bracket (1)
NOTE:
Apply lithium soap-base grease to the bearing.
4-65
STEERING
CHAS
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 steering axle thread.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Lower ring nut tightening steps:
•
Tighten the ring nut (1) using the ring nut
wrench.
Ring nut (lower)
(initial tightening):
38 Nm (3.8 mkg)
•
Loosen the ring nut completely and retighten
it to specification.
WARNING
Do not tighten excessively.
Ring nut (lower)
(final tightening):
4 Nm (0.4 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check the steering axle by turning it lock to
lock. If there is any binding, remove the steering axle assembly and inspect the steering
bearings.
5. Install:
• Ring nut (upper) (1)
• Special washer (2)
4-66
STEERING
CHAS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
Install the special washer.
NOTE:
Make sure the special washer tabs are in the
slots.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Upper bracket
• Fork legs (left and right) (1)
NOTE:
Temporarily install the under bracket pinch bolt to
achieve the correct fork position.
Front fork top end (a) (standard):
0 mm
7. Install:
• Plate washer (1)
• Steering axle nut (2)
Use the lock nut wrench (4).
Lock nut wrench (4):
90890-01348
NOTE:
Set the torque wrench to the lock nut wrench so that
they form a right angle.
Steering axle nut:
115 Nm (11.5 mkg)
4-67
STEERING
CHAS
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:
Always tighten the lower pinch bolt (to the prescribed torque) and then the upper one (to the
prescribed torque) and then retighten the lower
one (to the prescribed torque).
CAUTION:
Tighten the pinch bolt to specified torque. If
torqued too much, it may cause malfunctioning of the front fork.
10. Install:
• Handlebar holder
• Handlebar
• Handlebar upper holder
Fitting nut (handle lower holder):
40 Nm (4.0 mkg)
Flange bolt (handlebar holder):
20 Nm (2.0 mkg)
CAUTION:
First tighten the front bolt on the handlebar
holder, then tighten the rear bolt.
4-68
REAR SHOCK ABSORBER
Order
Job name/Part name
Q.ty
CHAS
Remarks
Remove the parts in order.
Shock absorber removal
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
1
2
3
4
5
Seat
Fuel tank
Rear cowling
Battery leads
2
Muffler
Exhaust pipe assembly
Rear frame
Brake fluid reserve tank
Air filter case
1
1
1
1
1
Refer to “SEAT, FUEL TANK AND REAR
COWLING” section in Chapter 3.
4-69
Disconnect.
NOTE:
First, disconnect the negative lead, then the
positive lead.
Refer to “REAR SHOCK ABSORBER REMOVAL” section.
Secure the brake fluid tank to the frame in
an upright position to avoid air entering the
hydraulic system.
REAR SHOCK ABSORBER
Order
6
7
Job name/Part name
Q.ty
Lower bolt
Upper bolt
CHAS
Remarks
1
1
Reverse the removal procedure for installation.
4-70
REAR SHOCK ABSORBER
(1)
(2)
(3)
(4)
(5)
(6)
Rear shock absorber
Spring
Spring adjuster ring nut
Lock ring nut
End of stroke buffer
Special spanner
4-71
CHAS
REAR SHOCK ABSORBER
CHAS
WARNING
This shock absorber contains high-pressure
nitrogen gas. Read the following information
carefully before handling it. The manufacturer
cannot be held responsible for any damage or
injury that may result from improper handling.
• Never tamper with or attempt to open the
cylinder or the tank.
• Never expose the shock absorber to a
naked flame or other source of heat. This
might cause the pressurised gas to
explode.
• Do not deform or damage the cylinder in
any way. Damage to the cylinder would
impair the damping effect.
• Be careful not to scratch the surface of the
rod: this would cause the oil to leak.
• Before disposing of the shock absorber,
read the section “NOTES ON DISPOSAL”.
NOTE ON DISPOSAL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Before neutralising the rear shock absorber:
The gas pressure must be discharged before disposing of the shock absorber it is necessary to discharge the gas pressure. To do this, bore a hole of
2~3 mm through the cylinder wall about 15~20
mm from the bottom of the gas chamber.
WARNING
Wear protective goggles to avoid eye injuries
from escaping gas and/or metal chips.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-72
REAR SHOCK ABSORBER
CHAS
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” in CHAPTER 3.
3. Disconnect:
• Battery leads
NOTE:
First, disconnect the negative lead, then the positive lead.
4. Remove:
• Exhaust pipe assembly
• Rear frame
• Air filter case
5. Raise the rear wheel placing a suitable support under the engine.
6. Remove:
• Rear wheel
Refer to “REAR WHEEL REMOVAL” section.
7. Remove:
• Shock absorber fastening nut (1)
• Lower mounting bolt
1
8. Remove:
• Upper mounting bolt (1)
• Rear shock absorber
4-73
REAR SHOCK ABSORBER
CHAS
SHOCK ABSORBER INSPECTION
1. Inspect:
• Shock absorber
Oil leak/Damaged ➔ Replace.
REAR SHOCK ABSORBER ADJUSTMENT
This shock absorber is equipped with a spring preload adjuster.
2
a
b
CAUTION:
A
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
1
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and thereby
harden the suspension, turn the adjusting nut
in direction a. To decrease the spring preload
and thereby soften the suspension, turn the
adjusting nut in direction b.
NOTE:
• Use the special wrench included in the
owner's tool kit to make the adjustment.
• The spring preload setting is determined by
measuring distance A, shown in the illustration. The longer distance A is, the lower the
spring preload; the shorter distance A is, the
higher the spring preload. With each complete turn of the adjusting nut, distance A
changes by 1.5 mm.
Spring preload:
Minimum (soft):
Distance A = 217 mm
Standard:
Distance A = 211 mm
Maximum (hard):
Distance A = 205 mm
4-74
REAR SHOCK ABSORBER
CHAS
2. Tighten the locknut to the specified torque.
Locknut:
45 Nm (4.5 m·kgf)
CAUTION:
Always tighten the locknut against the adjusting nut, and then tighten the locknut to the
specified torque.
4-75
SWINGARM
CHAS
SWINGARM
(1) Upper chain case
(2) Swingarm
(3) Chain support
(4) Swingarm guard seal
(5) Connecting rod
(6) Relay arm
4-76
[A] LATERAL FREE PLAY (END): 1.0 mm
[B] LATERAL FREE PLAY: 0.4 ~ 0.7 mm
SWINGARM
CHAS
SWINGARM REMOVAL
NOTE
Check free play and remove swingarm, if necessary, after removing the rear shock absorber.
1. Remove:
• Swingarm connecting rod bolt (1)
1
1
2. Check:
• Swingarm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Inspection procedure:
•
Check the tightening torque of the nut which
fastens the swingarm pivot shaft (1).
Nut (pivot shaft):
90 Nm (9.0 mkg)
•
Check the lateral free play [A] of the swingarm
moving it laterally.
If the free play seems excessive, verify the
collar, bearings, washer and thrust cover.
Lateral free play
(at end of swing arm):
Limit: 1.0 mm
•
Check the vertical movement [B] of the
swingarm, moving it up and down.
If the movement seems rigid, unsmooth or
jerky, inspect the internal collar, the bearings,
the washer and the thrust cover.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-77
SWINGARM
CHAS
3. Remove:
• Upper chain case (1)
• Chain support (2)
1
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.
3. Inspect:
• Oil seals
Wear/Damaged ➔ Replace.
• Washers
• Thrust cover
Wear/Damaged ➔ Replace.
• Bushes
Scratches/Damaged ➔ Replace.
• Bearings
Pitting/Damaged ➔ Replace.
4. Inspect:
• Chain guard seal
• Chain case and support
Wear/Damage ➔ Replace.
4-78
SWINGARM
CHAS
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. Calculate:
• Lateral swing arm side play C.
Out of specification ➔ Adjust free play with
special shims.
Use the following formula:
C = (A1+A2) – (B1+B2)
Swing arm lateral free play C:
0.4 ~ 0.7 mm
4. Adjust:
• Lateral side play using one or more adjust
shims (1)
Measurement of adjust shim (1):
0.3 mm
NOTE:
When only one shim is used, install it on the left
side; when two shims are used, install one on
each side.
4-79
SWINGARM
CHAS
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. Tighten:
Nut (relay arm-swingarm):
66 Nm (6.6 mkg)
Nut (relay arm - connecting rod):
52 Nm (5.2 mkg)
Bolt (chain case):
9 Nm (0.9 mkg)
Nut (swingarm pivot shaft):
90 Nm (9.0 mkg)
Bolt (chain support):
4 Nm (0.4 mkg)
Nut (relay arm-frame):
60 Nm (6.0 mkg)
Bolt (rear shock absorber):
59 Nm (5.9 mkg)
Screw (chain case):
4 Nm (0.4 mkg)
3. Install:
• Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
4-80
SWINGARM
CHAS
4. Adjust:
• Drive chain slack
Drive chain slack:
30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK ADJUSTMENT” in CHAPTER 3.
5. Install:
• Fuel tank
• Rear cowling
• Seat
Bolt (seat):
10 Nm (1.0 mkg)
Refer to “SEAT, FUEL TANK AND REAR
COWLING” section in CHAPTER 3.
4-81
DRIVE CHAIN, DRIVE SPROCKET
AND REAR WHEEL SPROCKET
CHAS
DRIVE CHAIN, DRIVE SPROCKET AND
REAR WHEEL SPROCKET
NOTE:
Before removing the drive chain, drive sprocket
and rear wheel sprocket, it is necessary to measure the free play and length of the 10 links in the
chain.
DRIVE CHAIN REMOVAL
2
1. Park the motorcycle upright on an even surface.
2. Remove:
• Shift pedal (1)
• Cover (2) (drive sprocket)
1
3. Remove:
• Drive sprocket (1)
NOTE:
• Before removing the sprocket nut, straighten
the tab on the lock washer.
• Loosen the nut with the rear brake pulled.
4. Raise the rear wheel placing a suitable support under the engine.
WARNING
Set the motorcycle up securely to prevent it
falling over.
5. Remove:
• Rear wheel
• Rear wheel sprocket
• Hub
• Damper
• Spacer
Refer to “REAR WHEEL REMOVAL” section.
4-82
DRIVE CHAIN, DRIVE SPROCKET
AND REAR WHEEL SPROCKET
CHAS
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.
Maximum lenght of 10 links (a):
150.2 mm
a
NOTE:
• Stretch the chain by hand to measure it.
• The length of the 10 links is recorded between
the inside of the link pins (1) and (11) as
shown.
• The length of the 10 links is measured at various points.
2. Clean:
• Drive chain
Immerge in kerosene and brush thoroughly to remove as much dirt as possible.
Remove from kerosene and allow to dry.
CAUTION:
This motorcycle is fitted with a chain with
small O-Rings (1) fitted between its plates.
Vapour cleaning, pressurised washing and
certain types of solvents may damage these
seal rings.
To clean the transmission chain use only
kerosene.
4-83
DRIVE CHAIN, DRIVE SPROCKET
AND REAR WHEEL SPROCKET
CHAS
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.
5. Inspect:
• Drive chain
Rigid ➔ Clean and lubricate, replace if
necessary.
6. Inspect:
• Drive sprocket
• Rear wheel sprocket
Wear over 1/4 tooth (1) ➔ Replace.
Teeth bent ➔ Replace.
(2) Undamaged tooth profile
(3) Roller
(4) Sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
How to replace the rear wheel sprocket:
With wheel removed:
1. Remove:
• Hub (1)
• Sprocket fastening bolts (2)
• Rear wheel sprocket (3)
2. Install:
• New sprocket (3)
• Sprocket fastening bolts (2)
• Hub (1)
4-84
DRIVE CHAIN, DRIVE SPROCKET
AND REAR WHEEL SPROCKET
CHAS
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. Install:
• Drive chain
• Swingarm
Nut (swingarm pivot shaft):
90 Nm (9.0 mkg)
Nut (frame-relay arm):
60 Nm (6.0 mkg)
2. Install:
• Rear wheel
Refer to “REAR WHEEL INSTALLATION”
section.
3. Install:
• Drive sprocket
Nut (drive sprocket):
110 Nm (11.0 mkg)
WARNING
Always use a new lock washer.
NOTE:
• Tighten the drive sprocket nut with the rear
brake pulled.
• After tightening the nut, bend the tab on the
lock washer once more over the faces of the
nut.
4. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in CHAPTER 3.
Drive chain slack:
30 ~ 40 mm
4-85
DRIVE CHAIN, DRIVE SPROCKET
AND REAR WHEEL SPROCKET
CHAS
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)
4-86
ENG
5
ENG
CHAPTER 5.
ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET,
CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL . . . . . . . . . . . . . . . 5-1
ENGINE MOUNTING BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON. . . . . . . . . . . . . . . . . . . . 5-5
INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L)
AND GENERATOR STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CRANKCASE COVER (R), CLUTCH, PRIMARY DRIVE GEAR
AND BALANCER SHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
OIL PUMP AND SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
AC GENERATOR AND TIMING CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CRANKCASE(R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
GEARBOX AND TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
BALANCER SHAFT AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
OILSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
INSPECTION AND REPAIR . . . . . . . . . . . . . .
CYLINDER HEAD. . . . . . . . . . . . . . . . . .
VALVES AND VALVE GUIDES . . . . . . . .
VALVESEAT . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS AND ROCKER SHAFT .
CAMSHAFT CHAIN AND SPROCKET . .
CAMSHAFT CHAIN GUIDE . . . . . . . . . .
CYLINDER AND PISTON . . . . . . . . . . . .
PISTON RINGS . . . . . . . . . . . . . . . . . . .
PISTONPIN . . . . . . . . . . . . . . . . . . . . . .
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . .
OILPUMP . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY TRANSMISSION . . . . . . . . . .
TRANSMISSION AND GEARBOX. . . . . .
SHIFT SHAFT AND STOPPER LEVER . .
STARTER TRANSMISSION . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . .
BALANCER SHAFT DRIVE
AND DRIVEN GEARS . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . .
BEARING AND OIL SEAL . . . . . . . . . . . .
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5-21
5-21
5-22
5-23
5-27
5-28
5-28
5-29
5-30
5-30
5-32
5-33
5-33
5-35
5-35
5-36
5-37
5-38
5-39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
ENG
ENGINE ASSEMBLY AND SETTING . . . . . . . . . . . . . . . . . . . . . .
VALVES AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . .
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . . . .
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION AND GEARBOX. . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PUMP AND OIL STRAINER . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL STRAINER. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . .
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT AND TIMING CHAIN . . . . . . . . . . . . . . . . . . . . .
PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT. .
AC GENERATOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTER AND OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER SHAFT GEAR AND PRIMARY
TRANSMISSION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER NEUTRAL GEAR AND CRANKCASE COVER (L)
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. . . . . . . . . . . 5-41
. . . . . . . . . . . 5-41
. . . . . . . . . . . 5-42
. . . . . . . . . . . 5-43
. . . . . . . . . . . 5-44
. . . . . . . . . . . 5-46
. . . . . . . . . . . 5-47
. . . . . . . . . . . 5-48
. . . . . . . . . . . 5-49
. . . . . . . . . . . 5-50
. . . . . . . . . . . 5-51
. . . . . . . . . . . 5-51
. . . . . . . . . . . 5-52
. . . . . . . . . . . 5-54
. . . . . . . . . . . 5-55
. . . . . . . . . . . 5-56
. . . . . . . . . . . 5-57
. . . . . . . . . . . 5-58
. . . . . . . . . . . 5-59
. . . . . . . . . . . 5-65
. . . . . . . . . . . 5-67
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. . . . . 5-68
. . . . . 5-70
. . . . . 5-73
. . . . . 5-74
ENGINE REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET CRANKCASE COVER,
DRIVE SPROCKET AND SHIFT PEDAL
Order
Job name/Part name
Q.ty
Muffler, exhaust pipe, engine
protector, drive sprocket crankcase
cover, drive sprocket and shift
pedal removal
Remarks
Remove the parts in order.
Park the motorcycle in a stable and level
position.
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
5-1
ENGINE REMOVAL
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Q.ty
Battery leads connector
Muffler
Exhaust pipe
Engine protector
Shift pedal
Drive sprocket crankcase cover
Drive sprocket
Clutch cable
Plug cap
1
1
1
1
1
1
1
1
1
5-2
ENG
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).
Disconnect.
Displace the drive chain.
Disconnect.
Disconnect.
ENGINE REMOVAL
Order
Job name/Part name
Q.ty
ENG
Remarks
–
Starter leads
2
Disconnect.
–
Starter
1
Remove.
10
Connectors of engine wire harness
2
Disconnect.
11
Oil delivery hose
1
Disconnect.
12
Oil return hose
1
Disconnect.
13
Oil breather pipe (to oil tank)
14
Oil breather pipe (to air filter box)
– Disconnect.
–
5-3
Disconnect.
Reverse the
installation.
removal
procedure
for
ENGINE REMOVAL
ENG
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.
1
Stay of oil tank
–
Remove the mounting screws (to engine).
2
Hose clamp (carburetor)
2
Loosen.
3
Pivot shaft (rear - top)
1
4
Engine mounting bolt
(rear - lower)
Engine stay
(front - lower)
Engine stay
(front - top/right/left)
Engine assembly
1
5
6
7
1
1
1
5-4
NOTE:
Remove the engine from the lower side.
Reverse the
installation.
removal
procedure
for
ENGINE DISASSEMBLY
ENG
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
• Exhaust pipe
1. Remove:
• Spark plug (1)
• Tappet cover (2) (intake)
• Tappet covers (3) (exhaust)
• Cylinder head cover (4)
• Cap (5)
• Pins (6)
2. Loosen:
• Bolt (1) (chain tensioner)
3. Remove:
• Chain tensioner (2)
5-5
ENGINE DISASSEMBLY
ENG
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. Remove:
• Cylinder head
NOTE:
Loosen all bolts by a 1/4 turn and remove once all
are loosened.
5-6
ENGINE DISASSEMBLY
ENG
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.
10. Remove:
• Pin (1)
• Piston (2)
NOTE:
Before removing the pin, burr the pin housing
groove. If it is hard to pull out the pin even with the
groove burred, use the pin puller.
5-7
ENGINE DISASSEMBLY
ENG
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 intermediate starter gear and the crankcase cover (L)
may be performed by removing the following parts.
• Exhaust pipe
• Starter
• Sprocket cover
1. Remove:
• Cover (1) intermediate starter gear
• Centring pins
• Gasket
2. Remove:
• Intermediate starter gear (1)
• Bearing (2)
• Distributor shaft (3)
3. Remove:
• Neutral gear switch cable (1)
5-8
ENGINE DISASSEMBLY
ENG
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)
• Coil (2)
• Stator (3)
CRANKCASE COVER (R), CLUTCH, PRIMARY
DRIVE GEAR AND BALANCER SHAFT GEAR
NOTE:
The clutch, the primary gear and the balance gear
may be inspected with the engine installed by
removing the following parts.
• Footrest (R)
• Oil delivery hose screw
5-9
ENGINE DISASSEMBLY
ENG
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)
• Ball (3)
• Friction plate (4)
• Clutch plate (5)
• Clutch boss spring (6)
• Clutch boss (7)
• Thrust plate (8)
• Clutch shroud (9)
• Push rod (10)
NOTE:
• Before loosening the nut (11) (clutch shroud),
straighten the washer lock tab.
• To loosen the nut (clutch boss), block the
clutch boss using the special tool (12).
Clutch holding tool:
P/N. 90890-04086
5-10
ENGINE DISASSEMBLY
ENG
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.
NOTE:
To loosen nuts (9) and (10), hold the rotor (CA
magneto) firmly in place using special tool (11).
Sheave holder:
P/N. 90890-01701
CAUTION:
Be careful not to touch jutting edges (12) on
the rotor with the sheave holder.
4. Remove:
• Push lever (1)
• Spring
• Flat washer
NOTE:
Loosen the screw to remove the push rod.
5-11
ENGINE DISASSEMBLY
ENG
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:
• Circlip (1)
• Oil pump gear (2)
• Oil pump (3)
• O-rings (4)
2. Remove:
• Circlip (1) (from drive shaft)
• Ring (2)
• Circlip (3)
3. Remove:
• Circlip (1)
• Shift lever (2)
• Spring (3)
• Flat washer (4)
4. Remove:
• Stopper lever (1)
• Ring (2)
• Spring (3)
5-12
ENGINE DISASSEMBLY
ENG
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)
• Bearing (4)
• Shim adjustment washer (5)
• Key (6)
NOTE:
To loosen the nut (rotor), lock the rotor with the
special tool (7).
Sheave holder:
P/N. 90890-01701
CAUTION:
Be careful not to touch the jutting edges (8) on
the rotor with the special tool.
NOTE:
Remove the rotor with the puller (1).
Flywheel puller:
P/N. 90890-01362
2. Remove:
• Chain guide (1)
• Timing chain (2)
5-13
ENGINE DISASSEMBLY
ENG
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. 90890-01135
NOTE:
When tightening the support bolts of the separating tool, be sure to keep the tool body parallel to
the engine crankcase. If necessary, a screw may
be slightly loosened to put the tool body on level.
•
Applying pressure, strike the front engine
assembly flange, the drive shafts and the gear
cam plate with a rubber hammer. Then
remove the crankcase.
NOTE:
• If the crankcase fails come out, lever at points
(2), being careful not to damage the
crankcase.
• Turn the gear cam plate as shown in the figure to prevent it interfering with the crankcase.
5-14
ENGINE DISASSEMBLY
ENG
CAUTION:
•
•
5-15
Be careful not to damage surfaces in contact 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. Work slowly and carefully. Be careful to perform the separation uniformly. If
one end locks, remove pressure from the
thrust screw, realign and recommence. If it
is impossible to separate the crankcase,
check that all screws and components
have been disassembled. Do not use force.
ENGINE DISASSEMBLY
ENG
GEARBOX AND TRANSMISSION
1. Remove:
• Guide bar (1)
• Shift cam (2)
• Selector fork # 3 (3)
• Selector fork # 2 (4)
• Selector fork # 1 (5)
2. Remove:
• Transmission assembly unit (1)
3. Remove:
• Shift shaft # 1 (1)
• Shift shaft # 2 (2)
5-16
ENGINE DISASSEMBLY
ENG
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
• Balancer shaft (1)
2. Remove:
• Crankshaft (1)
NOTE:
• Remove the crankshaft by
crankcase separating tool (2).
using
the
Crankcase separating tool:
P/N. 90890-01135
•
Tighten the separating tool bolts, making sure
that the tool body is parallel with the engine
crankcase. If necessary, a screw may be
backed out slightly to level tool body.
OIL STRAINER
NOTE:
It is advisable to replace the oil strainer every time
the engine is disassembled.
1. Remove:
• Oil strainer (1)
• Oil passage cover (2)
• Gasket
5-17
ENGINE DISASSEMBLY
ENG
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. Remove:
• Rocker shaft
• Rocker arms
NOTE:
Remove the rocker shaft using sliding hammer (1)
and weight (2).
Sliding hammer bolt:
P/N. 90890-01083
Weight:
P/N. 90890-01084
5-18
ENGINE DISASSEMBLY
ENG
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’ Inspect the
valve surface, the seat and seat width.
See section “VALVE SEAT INSPECTION
AND REPAIR”.
NOTE:
Check the valve seal before assembling the internal parts of the cylinder head (valves, valve
springs, spring retainer etc).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Inspection steps:
• Pour clean solvent (1) into the intake and
exhaust ports.
• Check the valve seal. There must be no blowbys from the valve seats (2).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-19
ENGINE DISASSEMBLY
ENG
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.
NOTE:
Compress the valve spring using tool (8) to
remove the cotters.
Valve spring compressor:
P/N. 90890-04019
5-20
INSPECTION AND REPAIR
ENG
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
• combustion chamber
2. Inspect:
• Cylinder head
Scratches/Damage ➔ Replace.
3. Measure:
• Deformation
Out of specification ➔ Rework the surface.
Cylinder head deformation:
Less than 0.03 mm
4. Surface:
• Cylinder head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Levelling:
Level the cylinder head with wet 400 ~ 600 emery
paper in a figure-8 direction.
NOTE:
To avoid removing too much material on one side
only, turn the cylinder head a number of times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-21
INSPECTION AND REPAIR
ENG
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
Exhaust:
0.030 ~ 0.057 mm
<Limit>: 0.10 mm
(1)
Bore gauge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Replacement steps:
NOTE:
Heat the cylinder head in an oven at 100°C to
facilitate the removal and installation of the guides
and to maintain correct locking interference.
•
•
•
Remove the valve guide using the special
punch (1).
Install the new guide using the special installation tool (2).
After installing the valve guide, bore with special tool (3) to obtain valve-guide free play.
Valve guide remover (7 mm):
P/N. 90890-01225
Valve guide installer:
P/N. 90890-04017
Valve guide reamer (7 mm):
P/N. 90890-01227
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-22
INSPECTION AND REPAIR
ENG
2. Clean the valve surfaces of the carbon
deposits.
3. Inspect:
• Valve seal surface
Pitting/Wear ➔ Grind the valve seal surface.
4. Measure:
• Edge thickness (a)
Out of specification ➔ Replace valve.
Edge thickness (a):
Intake:
1.0 ~ 1.4 mm
<Limit>: 0.8 mm
Exhaust:
0.8 ~ 1.2 mm
<Limit>: 0.65 mm
5. Check:
• Valve stem tip
Deformed, mushroom-shaped or with a
higher diameter than the rest of the stem
➔ Replace valve.
• Misalignment:
Out of specification ➔ Replace valve.
Stem offsetting:
<Limit>: 0.01 mm
NOTE:
• Changing the valve, replace also the valve
guide.
• Pulling the valve out, replace the stem seal.
VALVE SEAT
1. Clean the valve surface and seat of carbon
deposits.
2. Inspect:
• Valve seat
Pitting/Wear ➔ Renew valve seat.
5-23
INSPECTION AND REPAIR
ENG
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.
Install the valve in the cylinder head.
Press the valve onto the housing through the
guide to leave a clear outline.
Measure the width of the valve seat. Where
there is contatc between valve and seat the
Prussian blue is wiped away.
If the valve seat is too narrow, wide or off-centre, the valve seat must be renewed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Renew:
• Valve seat
Use the special tool (1) to renew the valve
seat with 30°, 45° and 60° mills.
CAUTION:
Turning the cutter, maintain uniform pressure
(about 4-5 kg) to avoid leaving marks on the
valve seat.
5-24
INSPECTION AND REPAIR
ENG
Mill the valve seat as follows:
Section
Cutter
A
30°
B
45°
C
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.
Intervention
on the valve seat
Cutter
type:
30°
60°
Desired effect
Reduce valve seat
width to 1.0 mm
[B] If the valve surface is like this, it means that
the valve seat is centred on the valve surface
but is too narrow.
Intervention
on the valve seat
Cutter
type:
45°
Desired effect
Centring of seat and
attainment of 1.0 mm
width
[C] If the valve surface is like this, it means that
the valve seat is too narrow and close to the
edge of the valve.
Intervention
on the valve seat
Cutter
type:
Desired effect
30° (before) Centring of seat and
attainment of 1.0 mm
45°
width
[D] If the valve surface is like this, it means that
the valve seat is too narrow and situated low
down near the lower edge of the valve surface.
Intervention
on the valve seat
Cutter
type:
5-25
60° (first)
45°
Desired effect
Centring of seat and
attainment of 1.0 mm
width
INSPECTION AND REPAIR
ENG
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.
CAUTION:
Make sure the lapping compound does not
run into the space between the guide and
valve stem.
•
•
•
Apply oil to the molybdenum disulfide on the
valve stem.
Install the valve in the cylinder head.
Turn the valve until face and surface are not
evenly polished. Then clean away all the lapping compound.
NOTE:
For best results, during lapping, repeatedly apply
(light) pressure to the valve seat, turning the valve
backwards and forwards by hand.
•
Apply a fine-lapping compound on the valve
seal surface and repeat the procedures
described above.
NOTE:
Be sure to remove all the lapping compound from
the valve surface after every lapping operation.
5-26
INSPECTION AND REPAIR
•
•
•
•
ENG
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
VALVE SPRINGS
1. Measure:
• Free width of valve springs (a)
Out of specification ➔ Replace.
Free width of valve springs
(intake and exhaust):
Internal spring
External spring
40.1 mm
43.8 mm
2. Measure:
• Spring load
Out of specification ➔ Replace.
(b) Length of loaded spring
Valve spring load:
Internal spring (intake and exhaust)
164.8 ~ 190.2 N
(16.80 ~ 19.39 kgf) at 22.7 mm
External spring (intake)
71.6 ~ 87.3 N
(7.3 ~ 8.9 kgf) at 34.2 mm
External spring (exhaust)
149.1 ~ 182.4 N
(15.2 ~ 18.6 kgf) at 34.2 mm
3. Measure:
• Inclination of spring (a)
Out of specification ➔ Replace.
Spring inclination limit:
5-27
Internal spring
External spring
2.5°/1.7 mm
2.5°/1.9 mm
INSPECTION AND REPAIR
ENG
CAMSHAFT
1. Inspect:
• Cam eccentrics
Pitting/Scratches/Blue colour ➔ Replace
camshaft.
2. Measure:
• Cam eccentrics
Out of specification ➔ Replace camshaft.
(a)
(b)
Intake:
36.47~36.57 mm 30.06~30.16 mm
Exhaust:
36.62~36.72 mm 30.11~30.21 mm
ROCKER ARMS AND ROCKER SHAFT
1. Inspect:
• Rocker shafts
Blue colour/Grooves ➔ Replace shafts
and check lubrication system.
2. Inspect:
• Rocker shaft slot (1)
• Surface in contact with cam eccentric (2)
• Adjuster surface (3)
Pitting/Wear/Scratches/Blue colour ➔
Replace and check lubrication system.
5-28
INSPECTION AND REPAIR
ENG
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. Inspect:
• Chain
Stiffness/Cracks ➔ Replace timing chain
and sprocket.
2. Inspect:
• Sprocket
Wear/Damage ➔ Replace timing chain
and sprocket.
(1)
(2)
(3)
(4)
5-29
1/4 tooth (maximum)
New sprocket tooth profile
Roller
Sprocket
INSPECTION AND REPAIR
ENG
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:
• Piston-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Measurement steps:
First step
C
X
•
Measure cylinder bore “C” with a cylinder
gauge.
(1) 50 mm from top of cylinder
Y
NOTE:
Measure bore parallel and at right angles to the
driving shaft. Then calculate average measurement.
Cylinder
bore “C”
Standard
Wear
limit
94.97 ~ 95.02 mm
95.1 mm
C=X+Y
2
•
If the measurements are out of tolerance,
replace the cylinder liner, piston and circlips
all together.
Second step
•
Measure diameter “P” of the piston skirt with a
micrometer.
(1) 5 mm from the lower edge of the piston
Piston “P” size:
Standard
5-30
94.915 ~ 94.965 mm
INSPECTION AND REPAIR
•
ENG
If the measurements are out of tolerance,
replace the piston and circlips all together.
Third step
•
Calculate the piston-cylinder free play according 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
•
If the measurements are out of tolerance,
replace the cylinder liner, piston and circlips
all together.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-31
ENG
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
Lower ring
0.03 ~ 0.07 mm
<Limit>: 0.13 mm
Oil scraper
0.02 ~ 0.06 mm
2. Install:
• Ring (into the cylinder)
NOTE:
Fit each ring into the cylinder and push it to about
20 mm from the top edge of the cylinder. Push the
ring into the cylinder with the piston so that it is
perfectly perpendicular to the cylinder axis.
(a) 20 mm
3. Measure:
• Ring end gap
Out of specification ➔ Replace.
NOTE:
It is impossible to measure the oil scraper end
gap. If the oil scraper port appears too large,
replace all three rings.
Piston ring end gap
(fitted into cylinder):
5-32
Upper ring
0.30 ~ 0.45 mm
<Limit>: 0.7 mm
Lower ring
0.30 ~ 0.45 mm
<Limit>: 0.8 mm
Oil scraper (tracks)
0.20 ~ 0.70 mm
INSPECTION AND REPAIR
ENG
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.
Clearance between piston pin and
piston =
Diameter of pin seat on piston (b) –
Diameter of pin (a)
Clearance between piston pin and pin
seat on piston:
0.004 ~ 0.024 mm
<Limit>: 0.07 mm
CLUTCH
1. Inspect:
• Clutch gear assy teeth
Cracks/Pitting (on edges):
Moderate ➔ Burr.
Accentuated ➔ Replace clutch gear assy.
NOTE:
Pitting of the gear assy teeth causes irregular
functioning.
5-33
INSPECTION AND REPAIR
ENG
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.
Thickness
Wear
limit
Type “A”
(2 parts)
2.94 ~ 3.06 mm
2.8 mm
Type “B”
(6 parts)
2.72 ~ 2.88 mm
2.6 mm
5. Measure:
• Deformation of clutch plates
Out of specification ➔ Replace all plates.
Clutch plates deformation:
<Limit>: 0.2 mm
6. Measure:
• Runout limit of clutch push rod.
Turn clutch push rod on two V blocks.
Clutch push rod runout:
<Limit>: 0.2 mm
5-34
ENG
INSPECTION AND REPAIR
7. Measure:
• Free length of clutch compression springs
(a)
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))
• Side clearance (b)
(Between the external rotor (2) and the
pump stator (3))
Out of specification ➔ Replace oil pump.
Oil pump clearances:
Clearance between
rotors (a)
0.12 mm
<Limit>: 0.2 mm
Side clearance (b)
0.03 ~ 0.08 mm
<Limit>: 0.15 mm
2. Inspect:
• Oil pump drive gear (1)
• Oil pump driven gear (2)
Wear/Cracks/Damage ➔ Replace.
PRIMARY TRANSMISSION
1. Inspect:
• Primary drive gear teeth (1)
• Primary driven gear teeth (2)
Wear/Damage ➔ Replace both gears.
Excess noise during functioning ➔
Replace both gears.
5-35
INSPECTION AND REPAIR
ENG
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.
4. Inspect:
• Guide bar
Turn on a flat surface.
Curvature ➔ Replace.
WARNING
Do not attempt to straighten the deformed
guide bar.
5. Measure:
• Transmission shaft eccentricity.
Use the centring tool and micrometer.
Out of specification ➔ Replace bent shaft.
Transmission shaft eccentricity:
<Limit>: 0.08 mm
5-36
INSPECTION AND REPAIR
ENG
6. Inspect:
• Gear teeth
Brown colouring/Pitting/Wear ➔ Replace.
• Mating clutches
Rounded edges/Cracks/Missing fragments ➔ Replace.
7. Check:
• Proper mating of each gear (with corresponding part)
• Gear movement
Roughness ➔ Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Transmission gear assembly steps:
•
Fit the second gear (2) to the propeller shaft
(1) as shown in the figure.
(a) 60.0 mm
•
Fit the second sprocket (4) and fifth sprocket
(5) to the main shaft (3).
(b) 90.5 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Inspect:
• Circlip
Damage/Loosening/Bending ➔ Replace.
SHAFT AND STOPPER LEVER
1. Inspect:
• Shift shaft
Bent/Wear/Damage ➔ Replace.
2. Inspect:
• Stopper lever (1)
The roller rotates jerkily ➔ Replace.
Bent/Damage ➔ Replace.
3. Inspect:
• Return spring (2)
Damage/Cracks ➔ Replace.
5-37
INSPECTION AND REPAIR
ENG
STARTER TRANSMISSION
1. Check:
• Starter clutch functioning (1).
Turn the clutch in the direction indicated
by the arrow.
Irregular functioning/Damage ➔ Replace
the clutch.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
•
•
•
Install the starter rim on the gear and hold
the gear firm.
When turning the gear rim in a clockwise
direction (A), the gear and rim must be
meshed. Otherwise, the gear is faulty and
must be replaced.
When the gear rim is turned in a anticlockwise direction (B), it must turn freely.
Otherwise, the gear is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Inspect:
• Starter neutral gear teeth (1)
• Starter neutral gear teeth (2)
• Starter rim teeth (3)
Burrs/Shavings/Roughness/Wear ➔
Replace.
3. Inspect:
• Starter rim (contact surfaces)
Pitting/Wear/Damage ➔ Replace.
5-38
INSPECTION AND REPAIR
ENG
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
rod big end bearing, connecting rod pin
and/or connecting rod.
Connecting rod small end clearance:
0.8 mm
•
Side clearance (D)
Out of specification ➔ Replace connecting
rod.
Connecting rod big end clearance:
0.35 ~ 0.65 mm
Crankshaft assembly procedure:
The passages of crankshaft (1) oil and connecting rod pin (2) oil must coincide with a tolerance of less than 1.0 mm.
5-39
INSPECTION AND REPAIR
ENG
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. Inspect:
• Crankcase
• Bearing housing
Damaged ➔ Replace.
BEARING AND OIL SEAL
1. Inspect:
• Bearing
Roughness/Pitting/Damage ➔ Replace.
• Oil seal edge
Damage/Wear ➔ Replace.
5-40
ENGINE ASSEMBLY AND SETTING
ENGINE ASSEMBLY AND SETTING
VALVES AND ROCKER ARMS
(1)
(2)
(3)
(4)
(5)
(6)
Rocker arm n. 2
Wave washer
Rocker shaft (intake)
Rocker arm n. 1
Valve cotters
Upper valve spring
retainer
(7) Oil seal
(8) Inner valve spring
(9) Outer valve spring
(10) Valve (intake)
(11) Lower valve spring
retainer
(12) Rocker shaft
(exhaust)
(13) Rocker arm n. 4
(14) Rocker arm n. 3
(15) Rocker shaft
(exhaust)
(16) Valve (exhaust)
5-41
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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)
• Valves (2)
• Lower valve spring retainer (3)
• Inner valve spring (4)
• Outer valve spring (5)
• Upper valve spring retainer (6)
NOTE:
Install the innner and outer springs with the widest
thread upwards.
(7) Higher pitch
(8) Lower pitch
4. Install:
• Valve cotters (1)
NOTE:
Compress the valve spring with the specific tool
(2) to fit the cotters.
Valve spring compressor:
P/N. 90890-04019
5-42
ENGINE ASSEMBLY AND SETTING
ENG
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)
(2)
(3)
(4)
#
#
#
#
1
2
3
4
3. Install:
• Cap (1)
5-43
ENGINE ASSEMBLY AND SETTING
CRANKSHAFT AND BALANCER SHAFT
(1)
(2)
(3)
(4)
Connecting rod pin (5) Bearing
Crank (left)
(6) Bearing
Connecting rod
(7) Balancer shaft
Bearing
(8) Bearing
5-44
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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. 90890-04059
Crank spacer (5):
P/N. YM-91044
P/N. 90890-04081
Spacer (6):
P/N. 90890-01016
NOTE:
Hold the connecting rod at top dead centre with
one hand and turn the assembly tool nut with the
other.
Work on the assembly tool until the lower part of
the crankshaft enters into contact with the bearings.
CAUTION:
To protect the crankshaft from scratches and
facilitate assembly operations, apply grease
to the edges of the oil seals and engine oil to
the bearings.
2. Install:
• Balancer shaft (1)
5-45
ENGINE ASSEMBLY AND SETTING
TRANSMISSION
(1) Sprocket
(2) Oil seal
(3) Bearing
(4) Second wheel gear
(5) Secondary shaft
(6) Fifth wheel gear
(7) Third wheel gear
(8) Fourth wheel gear
(9) First wheel gear
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Bearing
Bearing
Second sprocket gear
Fifth sprocket gear
Third sprocket gear
Fourth sprocket gear
Main shaft
Bearing
5-46
ENG
ENGINE ASSEMBLY AND SETTING
GEARBOX
(1) Stopper lever
(2) Guide bar
(3) Shift fork #3
(4) Shift fork #1
(5) Shift cam
(6) Guide bar
(7) Shift fork #2
(8)
(9)
(10)
(11)
Shift shaft #1
Shift shaft #2
Oil seal
Shift lever
5-47
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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. All numbers must face left.
3. Install:
• Shift shaft #1 (1)
• Shift shaft #2 (2)
NOTE:
Align mark (3) on the shift lever shaft with that on
the shift shaft.
4. Check:
• Transmission functioning
Jerky functioning ➔ Repair.
5-48
ENGINE ASSEMBLY AND SETTING
ENGINE OIL PUMP AND OIL STRAINER
(1) Oil strainer
(2) Oil pump
(3) Oil pump gear
5-49
ENG
ENGINE ASSEMBLY AND SETTING
CRANKCASE
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Crankcase (R)
Crankcase (L)
Crankcase ventilation hose
Dowel pin
Dowel pin
Dowel pin
Bearing cover plate
Collar
Lock plate
5-50
ENG
ENGINE ASSEMBLY AND SETTING
ENG
ENGINE OIL STRAINER
1. Install:
• Oil strainer (1)
• Oil passage cover (2)
Screw (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
2
Install:
• Dowel pin (2)
3. Assemble the left crankcase to the right. Beat
gently with a soft hammer.
NOTE:
Turn the shift cam as shown in the figure so that
it does not interfere with the crankcase during
assembly.
CAUTION:
Before installing and tightening the fastening
screws, be sure that the transmission is working properly by hand, turning the shift cam in
both directions.
5-51
ENGINE ASSEMBLY AND SETTING
ENG
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).
6. Check:
• Gearbox and transmission functioning
Jerky functioning ➔ Replace.
SHIFT SHAFT AND OIL PUMP
1. Install
• Spring (1)
• Collar (2)
• Stopper lever (3)
Stopper lever screw (4):
10 Nm (1.0 mkg)
NOTE:
Place the stopper lever and the spring in the correct position.
2. Install:
• Plate washer (1)
• Spring (2)
• Shift lever (3)
• Circlip (4)
5-52
ENGINE ASSEMBLY AND SETTING
ENG
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:
To avoid damage to the engine, lubricate the
oil pump pipes in the crankcase liberally with
4-stroke engine oil.
5. Apply:
• 4-stroke engine oil
(oil pump pipes)
6. Apply:
• O-Ring (1)
• Oil pump (2)
• Oil pump gear (3)
• Circlip (4)
Screw (5) (oil pump):
10 Nm (1.0 mkg)
5-53
ENGINE ASSEMBLY AND SETTING
TIMING CHAIN
1. Install:
• Timing chain (1)
• Chain guide (2)
5-54
ENG
ENGINE ASSEMBLY AND SETTING
PISTON AND RINGS
(1)
(2)
(3)
(4)
(5)
(6)
ENG
PISTON SIZE:
94.915 ~ 94.965 mm
PISTON RING END GAP:
TOP: 0.30 ~ 0.45 mm
2ND: 0.30 ~ 0.45 mm
OIL: 0.20 ~ 0.70 mm
PISTON RING SIDE CLEARANCE:
TOP: 0.04 ~ 0.08 mm
2ND: 0.03 ~ 0.07 mm
Ring (upper)
Ring (lower)
Scraper
Piston
Piston pin
Circlip
5-55
ENGINE ASSEMBLY AND SETTING
CYLINDER
(1) Gasket
(2) Cylinder
(3) O-Ring
(4) Gasket
(5) Dowel pin
(6) Dowel pin
5-56
ENG
ENGINE ASSEMBLY AND SETTING
ENG
CYLINDER HEAD
(1) Cylinder head cover
(2) O-Ring
(3) Tappet cover
(intake)
(4) Tappet covers (exhaust)
(5) O-Ring
(6) Cap
(7) Cylinder head
(8) Valve guide
(intake valve)
(9) Valve guide
(exhaust valve)
(10) Spark plug
(11) Dowel pin
10 Nm (1.0 m•kg 7.2 ft•lb)
10 Nm (1.0 m•kg 7.2 ft•lb)
10 Nm (1.0 m•kg 7.2 ft•lb)
12 Nm (1.2 m•kg 8.7 ft•lb)
10 Nm
(1.0 m•kg 7.2 ft•lb)
10 Nm
(1.0 m•kg 7.2 ft•lb)
18 Nm (1.8 m•kg 13 ft•lb)
7 Nm (0.7 m•kg 5.1 ft•lb)
®
A SEALANT (QUICK GASKET)
20 Nm (2.0 m•kg 14 ft•lb)
5-57
ENGINE ASSEMBLY AND SETTING
CAMSHAFT AND TIMING CHAIN
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Camshaft
Cam chain sprocket
Chain stopper guide
Timing chain
Chain stopper guide
Gasket
Chain tensioner
5-58
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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.
• Before installing the piston pin circlips, cover
the crankcase with a clean cloth to prevent
foreign bodies falling into it.
•
WARNING
Always use new circlips for the piston pin.
3. Install:
• Dowel pins (1)
• O-Ring (2)
4. Install:
• Gasket (1) (cylinder)
NOTE:
Install the cylinder gasket as shown in the illustration.
5-59
ENGINE ASSEMBLY AND SETTING
ENG
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 piston rings liberally with 4-stroke engine oil.
(1)
(2)
(3)
(4)
Upper ring
Scraper (lower ring)
Scraper (upper ring)
Lower ring
6. Install:
• Cylinder (1)
NOTE:
• Install the cylinder to the piston with one hand
while one hand while compressing the piston
rings with the other.
• Bind the timing chain with wire and slip it
through the appropriate slot.
Cylinder:
Screw (2):
10 Nm (1.0 mkg)
Cap nut (3):
42 Nm (4.2 mkg)
Nut (4):
42 Nm (4.2 mkg)
5-60
ENGINE ASSEMBLY AND SETTING
ENG
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)
Screw (7):
10 Nm (1.0 mkg)
9. Install:
• Chain stopper guide
• Camshaft
• Cam chain sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Timing chain installation:
•
•
5-61
Install the cam chain on the cylinder head as
illustrated (compression phase timing).
Run the cam shaft in an anticlockwise direction until the mark on the crankcase (1) and
the point on the cam chain gearwheel (2) are
aligned.
ENGINE ASSEMBLY AND SETTING
ENG
•
Install the gear wheel with the timing marks as
shown in the figure and tighten the screws on
the gear wheel by hand.
(3) Upper cylinder head surface
(4) Timing marks
(5) Upper position mark
•
•
When pushing the chain tensioner be sure
that the marks on the cam chain sprocket are
aligned with the top surface of the cylinder
head.
If the marks are aligned, tighten the cam chain
sprocket bolts.
Bolt (cam chain sprocket):
20 Nm (2.0 mkg)
•
If the marks are not aligned, replace the chain
sprocket mating piston and chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10. Apply:
• Yamaha Bond N° 1215® (1)
(on the mating surfaces)
Sigillante (Quick Gasket)®
Yamaha bond N° 1215®:
P/N. 90890-85505
11. Install:
• Dowel pins (2)
12. Install:
• Cap
• Cylinder head cover
NOTE:
Cross-tighten the screws repeatedly.
Bolt (cylinder head cover):
10 Nm (1.0 mkg)
5-62
ENGINE ASSEMBLY AND SETTING
ENG
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.
Screw (chain tensioner body):
10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
•
Install the spring, the washer and the chain
tensioner.
Chain tensioner screw:
20 Nm (2.0 mkg)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
14. Adjust:
• Valve clearance
Valve clearance:
Intake
0.05 ~ 0.10 mm
Exhaust
0.12 - 0.17 mm
See section “VALVE CLEARANCE
ADJUSTMENT” in CHAPTER 3.
5-63
ENGINE ASSEMBLY AND SETTING
ENG
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.
5-64
ENGINE ASSEMBLY AND SETTING
AC GENERATOR
ENG
PICKUP COIL RESISTANCE:
230 Ω ± 20% at 20°C (68°F)
(Blue/Yellow - Green/White)
(1) Rotor
(2) Pick-up coil
(3) Stator winding
CHARGING COIL RESISTANCE:
0.65 Ω ± 20% at 20°C (68°F)
(White - White)
5-65
ENGINE ASSEMBLY AND SETTING
ENG
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. Apply a thin layer of lithium soapbased grease on the conical tip of the crankshaft.
2. Tighten:
• Nut (rotor)
Nut (rotor):
120 Nm (12.0 mkg)
NOTE:
To tighten the nut, lock the rotor with the special
tool (1).
Sheave holder:
P/N. 90890-01701
CAUTION:
Be careful not to touch the jutting edges (2) on
the rotor with the sheave holder.
5-66
ENGINE ASSEMBLY AND SETTING
OIL FILTER AND OIL HOSES
(1)
(2)
(3)
(4)
(5)
(6)
Oil filter
Filter cover
Oil hose
Oil hose
Oil delivery hose
Oil drain plug
5-67
ENG
ENGINE ASSEMBLY AND SETTING
BALANCER SHAFT GEAR AND PRIMARY TRANSMISSION GEAR
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Straight key
Balancer shaft gear
Breather plate
Lock washer
Nut
Plate washer
Straight key
Plate
(9)
(10)
(11)
(12)
(13)
5-68
Balancer shaft drive gear
Plate
Primary drive gear
Lock washer
Nut
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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)
• Plate (8)
• Balancer shaft drive gear (9)
• Plate (10)
• Primary drive gear (11)
• Lock washer (12)
• Nut (13) (primary drive gear)
Nut (balancer shaft gear):
60 Nm (6.0 mkg)
Nut (primary drive gear):
120 Nm (12.0 mkg)
NOTE:
When installing the drive gear, align the mark on
it (14) with that of the balancer shaft gear (15).
WARNING
Always use a new lock washer.
NOTE:
To tighten nuts (5) and (13), keep the AC generator rotor still with the special tool (16).
Sheave holder:
P/N. 90890-01701
CAUTION:
Be careful not to touch the jutting part (17) of
the rotor with the sheave holder.
2. Bend the lock washer tab along the face of the
nut.
5-69
ENGINE ASSEMBLY AND SETTING
CLUTCH
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Compression spring
Pressure plate
Push rod
Ball
Friction plate (type A)
Clutch boss spring
Clutch plate
Friction plate (type B)
(9) Clutch boss
(10) Thrust plate
(11) Primary driven gear
comp.
(12) Push rod
(13) Push lever
(14) Primary drive gear
5-70
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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)
• Lock washer (5)
• Nut (6) (clutch boss)
• Clutch boss spring (7)
• Clutch plate (8)
• Friction plate (9)
• Ball (10)
• Pressure plate (11)
• Compression spring (12)
• Screw (pressure plate) (13)
Nut (clutch boss):
90 Nm (9.0 mkg)
Pressure plate screw:
8 Nm (0.8 mkg)
NOTE:
• To tighten the nut (clutch boss), lock the clutch
drum with the special tool (14).
Clutch holding tool:
P/N. 90890-04086
•
Bend the lock washer tab along the face of the
nut.
WARNING
Always use a new lock washer.
5-71
ENGINE ASSEMBLY AND SETTING
ENG
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.
The clutch boss spring (16) should be
placed inside the second friction plate.
16
15
Friction plate
Type “A”
Type “B”
Quantity
Internal
diameter “D”
2
6
116 mm
113 mm
NOTE:
Align the mark on the clutch boss (17) with the
arrow (18) on the pressure plate.
3. Adjust:
• Clutch (free play)
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
4. Install:
• Straight key
• Gasket
• Crankcase cover (right) (1)
• O-Ring
• Oil filter
• Filter cover (2) (with O-Ring)
See section “Engine oil replacement (with
oil filter change)” in CHAPTER 3.
Bolt (crankcase cover):
10 Nm (1.0 mkg)
5-72
ENGINE ASSEMBLY AND SETTING
STARTER GEARS
(1)
(2)
(3)
(4)
(5)
Starter
Starter
Starter
Starter
Starter
gear
neutral gear 1
neutral gear 2
gear
clutch
5-73
ENG
ENGINE ASSEMBLY AND SETTING
ENG
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. Install:
• Bearing (1)
• Intermediate starter gear 2 (2)
3. Install:
• Centring pin (1)
• Gasket (2)
• O-Ring (3)
• Crankcase cover (L) (4)
• Plugs
Bolt (crankcase cover):
10 Nm (1.0 mkg)
WARNING
Always use a new gasket.
5-74
ENGINE ASSEMBLY AND SETTING
ENG
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
ENGINE REASSEMBLY
ENG
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
nut.
WARNING
Always use a new lock washer.
2. Install:
• Cover (sprocket)
• Shift pedal
• Footrest (L)
Screw (sprocket cover):
10 Nm (1.0 mkg)
Use LOCTlTE®
Screw (shift ptidal):
10 Nm (1.0 mkg)
Screw (footrest):
48 Nm (4.8 mkg)
3. Adjust:
• Drive chain slack
Drive chain slack:
30 ~ 40 mm
See section “DRIVE CHAIN SLACK
INSPECTION AND ADJUSTMENT” in
CHAPTER
5-76
ENGINE REASSEMBLY
ENG
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).
CAUTION:
Liberally apply 4-stroke engine oil in the oil
passage in the crankcase to prevent damage
to the engine.
Amount of oil:
Camshaft
0.1 litres
Oil filter housing
0.06 litres
7. Install:
• Tappet cover (intake)
• Air bleeder screw (oil filter cover)
Screw (tappet cover):
10 Nm (1.0 mkg)
Air bleeder screw (oil filter cover):
5 Nm (0.5 mkg)
8. Adjust:
• Clutch cable free play
Free play (at end of lever):
10 ~ 15 mm
See section “CLUTCH ADJUSTMENT” in
CHAPTER 3.
5-77
ENGINE REASSEMBLY
ENG
9. Install:
• Carburetor
Screw (clamp):
2 Nm (0.2 mkg)
See section “CARBURETOR-INSTALLATION” 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. Install:
• Fuel tank
CAUTION:
Do not start the engine until it is filled with oil.
12. Fill with:
• Engine oil
Amount of oil (total):
3.0 litres
See section “ENGINE OIL REPLACEMENT” in CHAPTER 3.
13. Check:
• Engine idle speed
Engine idle speed:
1.150 ~ 1.450 rpm
See section “IDLE SPEED ADJUSTMENT” in CHAPTER 3.
14. Install:
• Seat
Screw (seat):
10 Nm (1.0 mkg)
5-78
CARB
6
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
CARB
CARBURETOR REMOVAL
CARB
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.
NOTE:
Be sure the cap is properly tightened and
the fuel cock is in the “OFF” position before
removing the fuel tank.
Fuel pipe
Fuel tank
1
Lock nut
4
Loosen.
2
Throttle cable adjuster
2
Screw.
3
Throttle cable
2
4
Hose clamp
2
6-1
Loosen.
CARBURETOR REMOVAL
Order
Job name/Part name
CARB
Q.ty
Remarks
Loosen.
NOTE:
Move carburetor manifold clamps towards
the rear side.
5
Hose clamp
2
6
Carburetor
2
Reverse the removal procedure for installation.
Adjust throttle cable free play (refer to
THROTTLE CABLE FREE PLAY ADJUSTMENT” section in CHAPTER 3).
Adjust idle speed (refer to “IDLE SPEED ADJUSTMENT” section in CHAPTER 3).
6-2
CARBURETOR
CARB
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
(0.2 m.kg,
1.4 ft.lb)
9 Nm (0.9 m.kg, 6.3 ft.lb)
2 Nm (0.2 m.kg,
1.4 ft.lb)
6 Nm (0.6 m.kg, 4.3 ft.lb)
8 Nm (0.8 m.kg, 5.9 ft.lb)
3,5 Nm (0.35 m.kg, 2.5 ft.lb)
2 Nm (0.2 m.kg, 1.4 ft.lb)
6-3
CARBURETOR
(1)
Carburetor
assembly
(2)
Cover gasket
(3)
Gasket, nozzle
(4)
Float
(5)
Float pin
(6)
Float chamber
gasket
(7)
Screw
(8)
Float chamber
fastening screw
(9)
Spring washer
(10) Collar
(11) Screw
(12) Gasket
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(13) Throttle valve
spring
(14) Spring washer
(15) Nut
(16) Gasket
(17) Screw
(18) Stop screw
(19) Nut
(20) Screw
(21) Hose
(22) Diaphragm
(23) Cover
(24) Bracket
(25) O-ring
(26) Spring washer
SPECIFICATIONS
Main jet
#150 FIRST
#145 SEC.
Starter jet
#74
Needle jet
5C5A-3/5 ( FIRST)
5Y18-3/5 (SEC.)
Main nozzle
ø 2,6
Pilot jet
#50
Pilot air screw
2,75 ± 0,5 revs approx.,
open
Float height
27~29 mm
Fuel level
6~8 mm
Engine idle speed
1.150~1.450 r/min
Throttle valve seat
ø 2,5 mm
6-4
Spring
Drain valve
Pipe
Pipe
Screw
Screw
Pipe
Clip
Main jet 1
Main nozzle 1
Throttle valve
Pilot jet
Main jet 2
Main nozzle 2
Pilot screw set
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
CARB
Needle valve set
Stop screw set
Throttle screw set
Diaphragm
Needle set 1
Needle set 2
Starter set
Way 3
Hose
Hose
Hose
Clip
Breather pipe
O-ring
Pipe
CARBURETOR
CARB
SECTION VIEW
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8) Main nozzle (secondary)
(9) Main jet (secondary)
Needle jet (primary)
Valve seat
Needle valve
Main nozzle (primary)
Main jet (primary)
Pilot air screw
Needle jet (secondary)
[A] Primary carburetor
[B] Secondary carburetor
Air
Fuel
Mixture
A
B
6-5
CARBURETOR DISASSEMBLY
CARB
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.
6-6
CARBURETOR DISASSEMBLY
CARB
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:
• Cover (1) (enrichment)
• Spring (2)
• Diaphragm (3)
5. Remove:
• Top cover (1)
• Cover gasket (2)
• Screw (3) (connecter comp.)
6. Remove:
• Throttle lever (1)
• Collar (2)
• Cable holder (3)
6-7
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:
• Top cover (1)
• Spring (2)
3. Remove:
• Diaphragm (1)
• Needle jet 2 (2)
6-8
CARB
CARBURETOR INSPECTION
CARB
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.
NOTE:
Always replace the needle valve set and the valve
seat together.
3. Inspect:
• Starter piston (1)
Wear/Damage ➔ Replace
• Stop screw (2)
Damaged ➔ Replace.
4. Inspect:
• Diaphragm (1) (piston valve)
• Diaphragm (2) (enrichment)
Damaged ➔ Replace.
5. Inspect:
• Needle jet (1) (primary)
• Needle jet (2) (secondary)
Curvature/Wear ➔ Replace.
6-9
CARBURETOR INSPECTION
CARB
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 movement is free.
[A] Primary carburetor
[B] Secondary carburetor
8. Inspect:
• Float (1)
Damaged ➔ Replace.
9. Inspect:
• Main jet (1) (primary)
• Main jet (2) (secondary)
• Main nozzle (3) (primary)
• Main nozzle (4) (secondary)
• Pilot jet (5)
NOTE:
Clean jets with compressed air.
6-10
CARBURETOR ASSEMBLY
CARB
CARBURETOR ASSEMBLY
Perform “CARBURETOR DISASSEMBLY” operations in reverse order. Pay attention to the following points.
CAUTION:
Wash all parts with clean petrol prior to
reassembly.
Secondary carburetor
1. Install:
• Needle jet (1)
• Diaphragm (2)
• Spring
NOTE:
Draw the diaphragm tab level with the notch on
the secondary carburetor.
2. Install:
• Top cover
Screw (top cover):
2 Nm (0.2 mkg)
3. Install:
• Main jet (secondary)
• Drain vavle
Main jet (secondary):
2 Nm (0.2 mkg)
Drain valve:
9 Nm (0.9 mkg)
6-11
CARBURETOR ASSEMBLY
CARB
Primary carburetor
1. Install:
• Needle jet (1)
• Connecter comp. (2)
NOTE:
Check that the connecter comp. (1) is in the position shown in the figure.
2. Install:
• Throttle valve
3. Install:
• Spring
• Throttle shaft
NOTE:
Assemble the spring as shown in the illustration.
4. Install:
• Screw (connecter comp.)
NOTE:
Turn the throttle shaft clockwise (1/2 turn) to preload the spring and then, holding it in position,
assemble the screw (connecter comp.).
Screw (connecter camp.):
2 Nm (0.2 mkg)
6-12
CARBURETOR ASSEMBLY
CARB
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. Install:
• Top cover
Screw (top cover):
2 Nm (0.2 mkg)
7. Install:
• Diaphragm (1) (enrichment)
NOTE:
Make the diaphragm tab coincide with the gravity
enricher notch.
8. Install:
• Starter set
• Stop screw
Starter piston:
6 Nm (0.6 mkg)
9. Install:
• Pilot screw set (1)
• Pilot jet (2)
• Main nozzle 1 (3)
• Main jet (primary) (4)
• Valve seat (5)
Main nozzle 1:
2 Nm (0.2 mkg)
Screw (valve seat):
2 Nm (0.2 mkg)
6-13
CARBURETOR ASSEMBLY
CARB
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:
• Hold the carburetor upside down.
• Measure the distance from the joint plane of
the float chamber (without the gasket) and the
top of the float.
NOTE:
The float arm must rest on the neeedle valve
without being pressed.
•
•
•
•
If the float height is out of tolerance, check the
valve seat and the needle valve.
If either is worn, replace both.
If both are perfect, adjust the float height by
bending the wing tab of the float itself (1).
Recheck the float height.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
12. Install:
• Float chamber
Screw (float chamber):
2 Nm (0.2 mkg)
13. Adjust:
• Pilot air screw (1)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Adjustment:
•
•
Turn the screw until it is slightly locked.
Unscrew by 3 and 1/2 turns.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-14
CARBURETOR ASSEMBLY
CARB
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.
•
Tighten or loosen the synchronisation screw
(1) until the secondary throttle valve (2) starts
to open.
•
Check that the secondary throttle valve is
open horizontally (a)=(b) when the primary
throttle valve is completely open
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-15
CARBURETOR ASSEMBLY
CARB
FUEL LEVEL ADJUSTMENT (CARBURETOR INSTALLED
1. Place the motorcycle on a level surface.
2. Make sure that the carburetor is in a horizontal position by placing a hydraulic jack under
the engine.
3. Connect the fuel level gauge (1) to the carburettor nipple.
Fuel level gauge:
P/N. 90890-01312
4. Loosen drain screw (2) and heat the engine.
5. Measure:
• Fuel level (a)
Out of specification ➔ Adjust.
Fuel level:
6.0 ~ 8.0 mm
Under the edge of the carburetor
body.
6. Adjust:
• Fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Fuel level adjustment:
•
•
•
•
•
Remove carburetor assembly.
Inspect valve seat and needle valve set.
If either of the two is worn, replace both.
If both are perfect, adjust float height by bending the wing tab of the float itself (1).
Recheck the fuel level.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-16
ELEC
7
ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
COLOUR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
SWITCH CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
MAIN SWITCH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHTS,
DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) . . . . . . . . . . . . . . . . . 7-8
BULB TYPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
BULB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
ELECTRICAL STARTING SYSTEM. . . .
CIRCUIT DIAGRAM . . . . . . . . . . . .
STARTING CIRCUIT OPERATION .
DIAGNOSTICS . . . . . . . . . . . . . . .
STARTER MOTOR. . . . . . . . . . . . .
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7-21
7-21
7-23
7-24
7-30
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
LIGHT SYSTEM . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . .
LIGHT SYSTEM INSPECTION .
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SIGNALLING SYSTEM . . . . . . . .
CIRCUIT DIAGRAM . . . . . . .
DIAGNOSTICS . . . . . . . . . . .
SIGNAL SYSTEM CONTROL
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7-41
7-41
7-43
7-46
7-51
7-51
7-53
7-55
ELEC
W
W
W
7-1
20
W
W
W
B
R
WB
BrL W
2
W
W
BrL
WB
W
W
1
B
B
B
WB
GW
LY
GW
GW
B
R
4
B
28
B BrL
WB Br
P
GB Y
Y GB
B BrL
G BrW BrB
P
BrB BrW G
5
B
BrL B
18
BrL
Br
3
6
R
ON
OFF
21
26
LW
LW
Br
Br
L
L
Y
G
B
B
12V5W
B
A
B
B
G
Y
OFF
OFF
RUN
R
BrB
BrB
B
B
GB
B
BrB
B
BrB
B
B
LW
27
LY
BY
B
GB
B
GB
B
LB
RB
B
GB
GB
B
B
B
LY
B
B
12V10W
B
B B
GW LY
B
B
B
B
L
GY
GY
GY
Br
GY
B
GW LY -
B
L
L
LR
Sb
B
31
Or
LB - -
15
L
LR
Sb
Sb
LY BY
GY
30
Sb
Sb
LY
- B
Or RB
16
GW LY
14
11
B
B
BY
GB
B
(BLUE)
B
B
LY
B
B
RB
LB
12
12V10W
LY
B
13
GB
GB
B
Br
BrW
BY
GB
B
12V10W
BrB
12V10W
BrB
BrB
B
BrB
BrB
R
N
L
OFF
B
Br
BrW
23
ON
LW
BY
P
19
BY
RB
BY
GY
RB
Br
GY
Br
BrW
B
GY
Br
25
187
187
RB
P
Br
Br
Br L
START
29
9
10
24
LW
8
12V60/55W
G
G
A
Y
A
L
A
L
L
G
Y
BrL
Y
LOW
HIGH
22
RB
B
B
RB
Br
RB LW
R
7
R
PARK
RB
L Br
BrL
R
OFF
ON
Or
RW
205
17
Y
Ch
Dg
Br
TURN
HIGH
NEU.
ILL.
B
BrB GB
Y
BrSb
32
467C4B5CAMP403D494A4856 172320-2
B
Y
GB BrB
B
LRBr
LR
OrLW
EXT. CORD
B
MAIN HARNESS
R
B
R
RB LY
LB GW
LY RB
GW LB
HEAD LIGHT
LW Or
MAIN HARNESS
G Y
L B
B L
B
A
G
Y
ELECTRICAL -
W
W
W
W
W
W
R
W
LY
LY
ELECTRICAL CIRCUIT DIAGRAM
ELEC
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
(17) Ignition coil
(18) Left handlebar switch
(19) Horn switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(23) Flasher switch
(24) Horn
(25) Flasher relay
(26) Headlight
(27) Flasher light
(28) Relay assy
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
(1) AC generator/Pickup coil
(2) Rectifier/Regulator
(3) Battery
(4) Starter relay
(5) Starting motor
(6) Fuse
(7) Main switch
(8) Right handlebar switch
(9) Engine stop switch
(10) Starter switch
(11) Diode
(12) Clutch switch
(13) Sidestand switch
(14) Neutral switch
(15) Diode
(16) Ignitor unit
COLOUR CODE
B
Black
B/Y
Black/Yellow
Br
Brown
Br/B
Brown/Black
Ch
Chocolate
Br/W
Brown/White
Dg
Deep green
G/B
Green/Black
G
Green
G/R
Green/Red
Gy
Grey
G/W
Green/White
L
Blue
G/Y
Green/Yellow
Or
Orange
L/R
Blue/Red
P
Pink
L/W
Blue/White
R
Red
L/Y
Blue/Yellow
Sb
Sky-blue
R/B
Red/Black
W
White
R/W
Red/White
Y
Yellow
R/Y
Red/Yellow
B/R
Black/Red
W/L
White/Blue
B/W
Black/White
Y/R
Yellow/Red
7-2
ELEC
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
ELEC
BATTERY: CAPACITY 12V – 8Ah
SPECIFIC GRAVITY: 1.320
Main wire harness
Diodes
Extension wire harness
Rectifier/Regulator
CDI ignition unit
Battery (12V – 8Ah)
Starter relay
Fuse (20A)
7-3
ELECTRICAL COMPONENTS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Ignition coil
Spark plug cap
Flasher relay
Horn
Clutch switch
Relay assy
Sidestand switch
Neutral switch
Main switch
ELEC
IGNITION COIL:
Primary winding resistance:
4 Ω ± 15% at 20°C (68°F)
Secondary winding resistance:
Ω ± 20% at 20°C (68°F)
13 kΩ
7-4
SWITCH CHECK
ELEC
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).
The column on the far left shows the positions of
the main switch and the top line indicates the
colours of the cables connected with the terminals
of the switch itself.
“o––––o” indicates the terminals between which
there is electrical continuity, ie a closed circuit on
the respective switch positions.
For example, in this table:
“R” and “Br” are continuous when the switch is at
ON.
“L” and “R/B” are continuous when the switch is at
ON.
R
Br
L
R/B
“R” and “L” are continuous when the switch is at
PARK.
ON
Terminals are not continuous when the switch is at
OFF.
OFF
PARK
MAIN SWITCH INSPECTION
Before inspecting the switch, see the connection
table shown above and check the terminal connections (closed circuit) by the colour combination.
7-5
SWITCH CHECK
ELEC
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 disconnect from the terminals inside the connector
itself.
2. Check to see if any cables are disconnected
from their terminal inside the connector.
Reconnect, if necessary.
NOTE:
If the connector is blocked up with mud or dust,
clean it with a jet of compressed air.
R
Br
L
3. Use the connection table to check the combination of colours for continuity (closed circuit).
In this example, continuity is as follows:
“R” and “Br” are continuous when the switch is
at ON.
“L” and “R/B” are continuous when the switch
is at ON.
“R” and “L” are continuous when the switch is
at PARK.
Note that there is no continuity (open circuit)
for any of the combinations of a colour different from those mentioned and when the
switch is at OFF.
R/B
ON
OFF
PARK
4. Check the switch component for continuity
between “R” and “Br”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
R
Control procedure:
• Repeatedly shift the switch key to the various
positions - ON, OFF and PARK.
• Shift the tester selector to “Ωx1”.
• Connect the tester positive cable (+) to the
terminal of cable “R” of the connector, and the
negative cable (–) to cable terminal “Br”.
L
Br
7-6
SWITCH CHECK
ELEC
NOTE:
Use the thin tester terminals to check continuity,
as the terminals might come into contact with others 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 continuity (ie the tester must show “∞” ) at OFF and
PARK. Something is not working between “R
and Br” if there is no continuity between these
two points at position ON, or if there is some
continuity in one of the other positions OFF or
PARK.
NOTE:
Check switch continuity various times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
5. Continue to check continuity between “R” and
“L” and “L” and “Br” in the respective switch
positions in the manner described above.
3
6. If anything wrong is noted in any of the combinations, replace the switch component.
OF
F
2
IGNICTION
7-7
LIGHT INSPECTION
ELEC
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.
(B) is H4 type halogen bulb (12V - 55/60W) and it
is used for headlight.
CAUTION:
A
B
Avoid touching the glass part of a bulb. Keep it
free from oil; otherwise, the transparency of
the glass, life of the bulb, and luminous flux will
be adversely affected. If oil gets on a bulb,
thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
C
(A) and (C) are used mainly for headlights.
(D) is used mainly for direction indicator lights and
the rear and braking lights.
(E) and (F) are used especially for instrument and
other indication lights.
D
E
BULB INSPECTION
F
1. Remove the bulb.
NOTE:
• Bulbs of type (B) and (C) use special supports
(bulbholders). Remove the bulbholder before
removing the bulb. Most of these bulbholders
may be removed by turning in an anticlockwise
direction.
• Most bulbs of type (A), (D) and (E) may be
removed from their housing by pushing them
and turning them in an anticlockwise direction.
• Bulbs of type (F) may be removed simply by
pulling them out.
7-8
LIGHT INSPECTION
ELEC
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). Do not touch the bulb before it
is cool.
2. Check the continuity between the bulb terminals.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Control procedure:
• Set the tester selector to Ω x 1”.
• Connect the tester terminals to the bulb pins.
Take, for example, a three pin bulb as shown
in the figure. First check continuity between
pins (1) and (2), connecting tester terminal (+)
to pin (1) and terminal (–) to pole (2). Then
check the continuity between poles (1) and
(3), again connecting tester terminal (+) to
pole (1), and terminal (–) to pole (3). If the
tester indicates “∞”, even in one case only, the
bulb must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. . Check the bulb attachment by installing a
test bulb. Furthermore, during inspection of
the bulbs, connect the tester terminals to the
respective socket cables and check continuity
as described.
7-9
ELEC
7-10
W
W
W
7-11
20
W
W
W
W
W
W
R
W
W
W
W
B
R
WB
BrL W
2
W
W
BrL
WB
W
W
1
B
B
B
GW
GW
WB
GW
LY
LY
LY
B
R
4
B
28
B BrL
WB Br
P
GB Y
Y GB
B BrL
G BrW BrB
P
BrB BrW G
5
B
BrL B
18
BrL
Br
3
6
R
ON
OFF
21
26
LW
LW
Br
Br
L
L
RB
Y
G
B
B
12V5W
B
A
B
B
G
Y
OFF
OFF
RUN
R
Br
BrB
B
Br
BrB
B
B
BrB
B
BrB
B
B
LW
27
LY
BY
B
GB
B
GB
B
LB
RB
B
GB
GB
B
B
B
LY
B
B
12V10W
B
B B
GW LY
B
B
B
B
L
B
GY
GY
GY
GY
Br
B
L
L
LR
Sb
B
31
Or
LB - -
GW LY -
15
L
LR
Sb
Sb
LY BY
GY
30
Sb
Sb
LY
- B
Or RB
16
GW LY
14
11
B
B
BY
GB
B
(BLUE)
B
B
LY
B
B
RB
LB
12
12V10W
LY
B
13
GB
GB
B
Br
BrW
BY
GB
B
12V10W
BrB
12V10W
BrB
BrB
B
GB
BrB
R
BrB
L
OFF
N
23
ON
LW
BY
BrW
19
BY
RB
BY
GY
RB
Br
GY
Br
P
B
GY
Br
25
187
187
RB
BrW
Br
L
P
Br
B
START
29
9
10
24
LW
8
12V60/55W
G
G
A
Y
A
L
A
L
L
G
Y
BrL
Y
LOW
HIGH
22
RB
B
B
RB
Br
RB LW
R
BrL
R
PARK
7
L Br
OFF
ON
R
Or
RW
205
17
Y
Ch
Dg
Br
TURN
HIGH
NEU.
ILL.
B
BrB GB
Y
BrSb
32
467C4B5CAMP403D494A4856 172320-2
B
Y
GB BrB
B
LRBr
LR
B
OrLW
EXT. CORD
B
MAIN HARNESS
R
B
R
RB LY
LB GW
LY RB
GW LB
HEAD LIGHT
LW Or
MAIN HARNESS
G Y
L B
G
B L
Y
A
IGNITION SYSTEM
ELEC
IGNITION SYSTEM - CIRCUIT DIAGRAM
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.
(1)
(2)
(3)
(6)
(7)
(9)
(11)
AC generator/Pickup coil
Rectifier/Regulator
Battery
Fuse
Main switch
Engine stop switch
Diode
12
(12)
(13)
(14)
(15)
(16)
(17)
Clutch switch
Sidestand switch
Neutral switch
Diode
Ignitor unit
Ignition coil
11 15
6
3
1
14
13
9
17
2
7-12
7
16
IGNITION SYSTEM
ELEC
DIAGNOSTICS
IF THE IGNITION SYSTEM WERE TO STOP WORKING
(NO OR INTERMITTENT SPARK)
Procedure
Check:
1. Fuse
2. Battery
3. Spark plug
4. Amplitude of ignition spark
5. Spark plug cap resistance
6. Ignition winding resistance
7. Main switch
8. Engine stop switch
9. Sidestand switch
10. Neutral switch
11. Clutch switch
12. Pick-up coil resistance
13. Wiring connections (whole connection system)
NOTE:
Before making the inspections mentioned, remove the following parts:
1. Seat
2. Rear cowling
•
3. Fuel tank
4. Cowling (headlight)
To check functioning defects use the following special tools.
Dinamic spark tester:
P/N. 90890-06754
Pocket tester:
P/N. 90890-03112
1. Fuse
•
•
NO
Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
Is the fuse OK?
Replace the fuse.
YES
2. Battery
•
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
NO
Min. open-circuit voltage:
2.8 V or more at 20°C (68°F)
•
•
•
Is the battery OK?
YES
*
7-13
Clean the battery terminals.
Recharge or replace the battery.
IGNITION SYSTEM
ELEC
*
3. Spark plug.
• Check the conditions of the spark plug.
• Check the type of spark plug used.
• Check the electrodes gap.
Standard spark plug:
DPR8EA-9 (NGK), DPR9EA-9
OUT OF SPECIFICATION
Electrodes gap:
DPR8EA-9, DPR9EA-9 (NGK)
0.8 ~ 0.9 mm
Correct the electrodes gap or replace the spark
plug.
YES
4. Amplitude of the ignition spark.
• Detach the spark plug cap from the spark
plug.
• Connect the dynamic spark tester (1) as
shown in the figure.
(2) Spark plug cover (3) Spark plug
• Turn the main switch ON.
•
•
Check the amplitude of the ignition spark.
Start the engine and increase the amplitude until the ignition becomes discontinuous.
IN COMPLIANCE WITH SPECIFICATIONS
Minimum spark amplitude.
Spark amplitude if the ignition
system is efficient:
6.0 mm
THE IGNITION SYSTEM IS INEFFICIENT
OR THERE IS NO SPARK
*
7-14
IGNITION SYSTEM
ELEC
*
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.
Resistance of spark plug cap:
10 kΩ at 20°C (68°F)
IN COMPLIANCE
WITH SPECIFICATIONS
6. Ignition winding resistance.
•
•
Disconnect the ignition coil cables from
the wire harness.
Connect the pocket tester (Ω x 1) to the
ignition coil.
Tester terminal (+) ➔ Pole (+)
Tester terminal (–) ➔ Pole (–)
•
Check that the primary coil has the specified resistance.
7-15
IGNITION SYSTEM
ELEC
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
Check that the secondary coil has the
specified resistance
Secondary winding resistance:
13 kΩ ± 20% at 20°C (68°F)
(Spark plug cable – Terminal (–))
The ignition coil is defective.
Replace.
BOTH RESISTANCE
VALUES ARE CORRECT
7. Main switch.
•
•
Disconnect the main switch connector
from the wire harness.
Connect the pocket tester (Ω x 1) to the
main switch cables.
Refer to “SWITCH CHECK” in Chapter 3.
ON
OFF
PARK
INCORRECT
Br L
R
Br L
R
The main switch is defective. Replace.
CORRECT
*
7-16
IGNITION SYSTEM
ELEC
*
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 (–) ➔ Brown cable (2)
OFF
RUN
INCORRECT
1
2
Br GY RB
The emergency stop engine switch is defective.
Replace the right handlebar switch.
Br GY RB
CORRECT
9. Sidestand switch.
•
•
Disconnect the sidestand switch connector (Black and Black) from the wire harness.
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 (–) ➔ Black cable (2)
B B
UP
DOWN
INCORRECT
B
1
B
2
The sidestand switch is defective. Replace.
CORRECT
*
7-17
IGNITION SYSTEM
ELEC
*
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
Sb
In gear
Neutral
INCORRECT
Sb
1
The neutral switch is defective. Replace.
CORRECT
11. Clutch switch.
•
Disconnect the clutch switch connector
from the harness.
•
Connect the pocket tester (Ω x 1) to the
clutch switch cable.
•
Check the clutch switch component for
continuity between “Black (1)” and “Black
(2)”.
Refer to “SWITCH CHECK” in Chapter 3.
B B
Release
Hold
INCORRECT
1
B
B
2
The clutch switch is defective. Replace.
CORRECT
*
7-18
IGNITION SYSTEM
ELEC
*
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
specified.
OUT OF SPECIFICATIONS
Pick-up coil resistance:
230 Ω ± 20% at 20°C (68°F)
(Green/White - Blue/Yellow)
The pick-up coil is defective. Replace.
COMPLY WITH
SPECIFICATIONS
UNCERTAIN CONNECTIONS
13. Wiring connections.
Check the connections of the entire ignition
system. Refer to “ELECTRICAL CIRCUIT
DIAGRAM” section.
Correct.
CORRECT
The CDI unit is defective. Replace.
7-19
ELEC
7-20
W
W
W
7-21
20
W
W
W
W
W
W
R
W
W
W
W
B
R
WB
BrL W
2
W
W
BrL
WB
W
W
1
B
B
B
GW
GW
WB
GW
LY
LY
LY
B
28
B BrL
GB Y
P
BrB BrW G
BrL B
R
4
B
WB Br
18
BrL
Br
3
6
R
B BrL
Y GB
P
G BrW BrB
5
B
ON
OFF
21
26
LW
LW
Br
Br
L
L
Y
G
B
B
12V5W
B
A
B
B
G
Y
OFF
OFF
RUN
R
Br
BrB
B
BrB
B
B
BrB
B
BrB
B
B
LW
27
LY
BY
B
GB
B
B
B
GB
B
B
RB
LB
B
GB
GB
B
B
B
LY
B
B
12V10W
B
B B
GW LY
B
B
B
B
L
B
GY
GY
GY
GY
Br
B
L
L
LR
Sb
B
31
Or
LB - -
GW LY -
15
L
LR
Sb
Sb
LY BY
GY
30
Sb
Sb
LY
- B
Or RB
16
GW LY
14
11
B
BY
GB
B
(BLUE)
B
B
LY
RB
LB
12
12V10W
LY
B
13
GB
GB
B
Br
BrW
BY
GB
B
12V10W
BrB
12V10W
BrB
BrB
B
GB
BrB
R
BrB
L
OFF
N
23
ON
Br
BY
LW
BrW
19
BY
RB
BY
RB
GY
Br
GY
Br
P
B
GY
25
187
187
Br
RB
BrW
Br
L
P
Br
B
START
29
9
10
24
LW
8
12V60/55W
G
G
A
Y
A
L
A
L
L
G
Y
BrL
Y
LOW
HIGH
22
RB
B
B
RB
Br
RB LW
R
7
R
PARK
RB
L Br
BrL
R
OFF
ON
Or
RW
205
17
Y
Ch
Dg
Br
TURN
HIGH
NEU.
ILL.
B
BrB GB
Y
BrSb
32
467C4B5CAMP403D494A4856 172320-2
B
Y
GB BrB
B
LRBr
LR
B
MAIN HARNESS
EXT. CORD
R
B
RB LY
B
OrLW
LY RB
R
LB GW
LW Or
HEAD LIGHT
GW LB
MAIN HARNESS
G Y
L B
G
B L
Y
A
ELECTRICAL STARTING SYSTEM
ELEC
ELECTRICAL STARTING SYSTEM - CIRCUIT DIAGRAM
ELECTRICAL STARTING SYSTEM
ELEC
The diagram illustrates the electrical starting system-circuit inside the motorcycles electric system.
NOTE:
For the colour code and legend, see page 7-2.
(3)
(4)
(5)
(6)
(7)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Battery
Starter relay
Starting motor
Fuse
Main switch
Engine stop switch
Starter switch
Diode
Clutch switch
Sidestand switch
Neutral switch
Diode
12
5
11 15
14
3
6 4
13
9 10
7
7-22
ELECTRICAL STARTING SYSTEM
ELEC
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).
or if
The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
The starting circuit cut-off relay prevents the
starter from operating when neither of these conditions have been met. In this instance, the starting circuit cut-off relay is open so current cannot
reach the starter motor.
When at least one of the above conditions have
been met however, the starting circuit cut-off relay
is closed, and the engine can be started by pressing the starter switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED IN
1
2
3
4
5
6
7
8
9
0
7-23
Battery
Main switch
Engine stop switch
Starter relay
Starting circuit cut-off relay
Start switch
Starter motor
Neutral switch
Clutch switch
Sidestand switch
ELECTRICAL STARTING SYSTEM
ELEC
DIAGNOSTICS
THE STARTER FAILS TO WORK
Procedure
Inspect:
(1) Fuse
(2) Battery
(3) Starting motor
(4) Starter relay
(5) Main switch
(6) Engine stop switch
(7) Sidestand switch
(8) Neutral switch
(9) Clutch switch
(10) Starter switch
(11) Harness connections
NOTE:
Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
•
3. Fuel tank
4. Cowling (headlight)
To check for defects use the following special tools.
Pocket tester:
P/N. 90890-03112
1. Fuse.
• Remove fuse.
• Connect the pocket tester (Ω x 1) to the
fuse.
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
DISCONTINUTY
Replace the fuse.
CONTINUITY
INCORRECT
2. Battery.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
•
•
Min. open-circuit voltage:
12.8 V or more at 20°C (68°F)
CORRECT
*
7-24
Clean the battery terminals.
Recharge or replace the battery.
Refer to “BATTERY INSPECTION” in
Chapter 3.
ELECTRICAL STARTING SYSTEM
ELEC
*
*
WARNING
3. Starter
•
• A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
Connect the positive terminal of the battery (1) and the starter cable (2) using a
connection cable (3) *.
IT FAILS TO RUN
•
The starter is defective. Repair or replace.
Check the functioning of the starter.
IT RUNS
4. Starter relay.
•
•
Disconnect the starter relay connector.
Connect the battery and frame to the
starter relay connector, using a connection cable (1) as shown.
Battery terminal (+) (2) ➔
Red/Black terminal (3)
Frame ➔ Blue/White terminal (4)
IT FAILS TO RUN
The starter relay is defective. Replace.
•
Check the functioning of the starter.
IT RUNS
*
7-25
ELECTRICAL STARTING SYSTEM
ELEC
*
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.
ON
OFF
PARK
INCORRECT
Br L
R
Br L
R
The main switch is defective. Replace.
CORRECT
6. Emergency stop engine switch.
•
•
Disconnect the emergency stop engine
switch connector (Brown, Green/Yellow
and Red/Black) from the wire harness.
Connect the pocket tester (Ω x 1) to the
switch cables.
Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔
Red/Black (1) cable
Tester terminal (–) ➔ Brown cable (2)
OFF
RUN
INCORRECT
1
2
Br GY RB
The emergency stop engine switch is defective.
Replace the right handlebar switch.
Br GY RB
CORRECT
*
7-26
ELECTRICAL STARTING SYSTEM
ELEC
*
7. Sidestand switch.
•
•
Disconnect the sidestand switch connector (Black and Black) from the wire harness.
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 (–) ➔ Black cable (2)
B B
UP
DOWN
INCORRECT
B
B
2
1
The sidestand switch is defective. Replace.
CORRECT
8. Neutral switch.
•
•
Disconnect the neutral switch cable (Sky
blue).
Connect the pocket tester (Ω x 1) to the
neutral switch cables.
Refer to “SWITCH CHECK” in Chapter 3.
Tester terminal (+) ➔ Sky blue cable (1)
Tester terminal (–) ➔ Earth
Sb
In gear
Neutral
INCORRECT
Sb
1
The neutral switch is defective. Replace.
CORRECT
*
7-27
ELECTRICAL STARTING SYSTEM
ELEC
*
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)”.
Refer to “SWITCH CHECK” in Chapter 3.
B B
Release
Hold
INCORRECT
1
B
B
2
The clutch switch is defective. Replace.
CORRECT
10. Start switch.
•
Disconnect the start switch connector
from the harness.
•
Connect the pocket tester (Ω x 1) to the
handlebar switch terminal.
•
Check the start switch component for continuity between “Blue/White (1)” and
“Black/Yellow (2)”.
Refer to “SWITCH CHECK” in Chapter 3.
L/W BY
Free
Pushed in
INCORRECT
LW BY
1
The start switch is defective. Replace the right
handlebar switch.
2
CORRECT
*
7-28
ELECTRICAL STARTING SYSTEM
ELEC
*
11. Harness connections.
Check the connections of the entire starter
system.
See the “ELECTRIC CIRCUIT DIAGRAM”.
UNCERTAIN CONNECTIONS
Correct.
7-29
ELECTRICAL STARTING SYSTEM
STARTER MOTOR
ELEC
BRUSH LENGHT LIMIT
5 mm (0.20 in)
(1) Brushes
(2) Armature
(3) Stator
(4) O-Ring
COMMUTATOR WEAR LIMIT:
27 mm (1.06 in)
MICA UNDERCUT:
0.7 mm (0.027 in)
ARMATURE COIL RESISTANCE:
0.03 ~ 0.04 Ω at 20°C (68°F)
7-30
ELECTRICAL STARTING SYSTEM
ELEC
Removal
1. Remove:
• The starter motor
Refer to the “ENGINE REMOVAL” section in CHAPTER 5.
Disassembly
1. Remove:
• Circlip (1)
• Drive gear (2)
• Screws (3)
• Rear bracket (4)
• Washers (5)
• Brushes housing (6)
• Brushes (7)
• Front bracket (8)
• Washers (9)
• Armature (10)
• Stator (11)
Inspection and repair
1. Inspect:
• Manifold
Dirty ➔ Clean with sandpaper no. 600.
2. Measure:
• Diameter of the commutator
Out of specification ➔ Replace the motor.
Wear limit of commutator (a):
27 mm
3. Measure:
• The mica undercut (b).
Out of specification ➔ Level the undercut
to the correct value using a hacksaw.
Mica undercut (b):
0.7 mm
NOTE:
The mica insulation of the commutator must have
an undercut to ensure proper functioning of the
commutator.
7-31
ELECTRICAL STARTING SYSTEM
ELEC
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 at 20°C (68°F)
Insulation check (2):
Over 1 MΩ at 20°C (68°F)
•
If the resistance is not correct, replace
the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Brush lenght
Out of specification ➔ Replace all brushes at once.
Brush lenght limit (a):
5.0 mm
6. Inspect:
• Brush spring strength
Worn out ➔ Replace all springs at once.
Brush spring strength:
8.82 N (899 gf)
7. Inspect:
• Bearings (1)
• Oil seal (2)
• O-Rings
• Bush (3)
7-32
ELECTRICAL STARTING SYSTEM
ELEC
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
(4).
3. Install:
• Screws (1)
Screw (stator):
7 Nm (0.7 kgm)
Installation
1. Install:
• Starter motor.
NOTE:
Slightly grease the O-Ring (1)
Screw (starter motor):
10 Nm (1.0 kgm)
7-33
ELEC
7-34
W
W
W
7-35
20
W
W
W
W
W
W
R
W
W
W
W
B
R
WB
BrL W
2
W
W
BrL
WB
W
W
1
B
B
B
GW
GW
WB
GW
LY
LY
LY
B
R
4
B
28
B BrL
WB Br
P
GB Y
Y GB
B BrL
G BrW BrB
P
BrB BrW G
5
B
BrL B
18
BrL
Br
3
6
R
ON
OFF
21
26
LW
LW
Br
Br
L
Y
G
B
B
12V5W
B
A
B
B
G
Y
OFF
OFF
RUN
R
Br
BrB
B
BrB
B
B
BrB
B
BrB
B
B
LW
27
LY
BY
B
GB
B
B
B
GB
B
LB
RB
B
GB
GB
B
B
B
LY
B
B
12V10W
B
B B
GW LY
B
B
B
B
L
B
GY
GY
GY
GY
Br
B
L
L
LR
Sb
B
31
Or
LB - -
GW LY -
15
L
LR
Sb
Sb
LY BY
GY
30
Sb
Sb
LY
- B
Or RB
16
GW LY
14
11
B
B
BY
GB
B
(BLUE)
B
B
LY
RB
LB
12
12V10W
LY
B
13
GB
GB
B
Br
BrW
BY
GB
B
12V10W
BrB
12V10W
BrB
BrB
B
GB
BrB
R
BrB
L
OFF
N
23
ON
Br
BY
LW
BrW
19
BY
RB
RB
BY
GY
Br
GY
Br
P
B
GY
Br
25
187
187
RB
BrW
Br
L
P
Br
B
START
29
9
10
24
LW
8
12V60/55W
G
G
A
Y
A
L
A
L
L
G
Y
BrL
Y
LOW
HIGH
22
RB
B
B
RB
Br
RB LW
R
L
RB
R
PARK
7
L Br
BrL
R
OFF
ON
Or
RW
205
17
Y
Ch
Dg
Br
TURN
HIGH
NEU.
ILL.
B
BrB GB
Y
BrSb
32
467C4B5CAMP403D494A4856 172320-2
B
Y
GB BrB
B
LRBr
LR
B
MAIN HARNESS
EXT. CORD
R
B
RB LY
B
OrLW
LY RB
R
LB GW
GW LB
HEAD LIGHT
LW Or
MAIN HARNESS
G Y
L B
G
B L
Y
A
CHARGING SYSTEM
ELEC
CHARGING SYSTEM – CIRCUIT DIAGRAM
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.
(1)
(2)
(3)
(6)
AC generator/Pickup coil
Rectifier/Regulator
Battery
Fuse
6
2
1
7-36
3
CHARGING SYSTEM
ELEC
DIAGNOSTICS
THE BATTERY IS NOT BEING CHARGED
Procedure
Inspect:
1. Fuse
2. Battery
3. Charging voltage
4. Stator winding resistance
5. Harness connection
(whole connection system)
NOTE:
Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
•
To check for defects use the following special tools.
Inductive rev counter:
P/N. 90890-03113
Pocket tester:
P/N. 90890-03112
1. Fuse
•
•
NO
Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
Is the fuse OK?
Replace the fuse.
YES
2. Battery
•
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
NO
Min. open-circuit voltage:
12.8 V or more at 20°C (68°F)
•
•
•
Is the battery OK?
YES
*
7-37
Clean the battery terminals.
Recharge or replace the battery.
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 (-)
•
•
Start the engine and rev to about 5,000 rpm.
Check the charging voltage.
IN COMPLIANCE WITH
SPECIFICATIONS
Charging voltage:
14.0V at 5,000 rpm
NOTE:
Use a fully charged battery.
Replace the battery.
OUT OF SPECIFICATIONS
4. Stator coil resistance.
•
Disconnect the AC generator connector
from the harness.
•
Connect the pocket tester (Ω x 1) to the stator coils.
Stator coils (1)
Tester terminal (+) ➔ White cable (1)
Tester terminal (-) ➔ White cable (2))
7-38
ELEC
CHARGING SYSTEM
ELEC
Stator coils (2)
Tester terminal (+) ➔ White cable (1)
Tester terminal (-) ➔ White cable (3)
2
3
W
W
W
1
•
Check that the winding resistance of the
stator complies with specifications.
Stator coil resistance:
White (1) – White (2)
0.65 Ω ± 20% at 20°C (68°F)
White (1) – White (3)
0.65 Ω ± 20% at 20°C (68°F)
OUT OF SPECIFICATIONS
Stator winding is defective. Replace.
IN COMPLIANCE
WITH SPECIFICATIONS
5. Wiring connections.
•
UNCERTAIN CONNECTIONS
Check the connections of the entire charging system.
Refer to “ELECTRICAL CIRCUIT DIAGRAM” section.
Correct.
CORRECT
The rectifier/regulator is defective. Replace.
7-39
ELEC
7-40
W
W
W
7-41
20
W
W
W
W
W
W
R
W
W
W
W
B
R
WB
BrL W
2
W
W
BrL
WB
W
W
1
B
B
B
GW
GW
WB
GW
LY
LY
LY
B
28
B BrL
GB Y
P
BrB BrW G
BrL B
R
4
B
WB Br
18
BrL
Br
3
6
R
B BrL
Y GB
P
G BrW BrB
5
B
ON
OFF
21
26
LW
LW
Br
Br
L
Y
G
B
B
12V5W
B
A
B
B
G
Y
OFF
OFF
RUN
R
Br
BrB
B
BrB
B
B
BrB
B
BrB
B
B
LW
27
LY
BY
B
GB
B
B
B
GB
B
LB
RB
B
GB
GB
B
B
B
LY
B
B
12V10W
B
B B
GW LY
B
B
B
B
L
B
GY
GY
GY
GY
Br
B
L
L
LR
Sb
B
31
Or
LB - -
GW LY -
15
L
LR
Sb
Sb
LY BY
GY
30
Sb
Sb
LY
- B
Or RB
16
GW LY
14
11
B
B
BY
GB
B
(BLUE)
B
B
LY
RB
LB
12
12V10W
LY
B
13
GB
GB
B
Br
BrW
BY
GB
B
12V10W
BrB
12V10W
BrB
BrB
B
GB
BrB
R
BrB
L
OFF
N
23
ON
Br
BY
LW
BrW
19
BY
RB
RB
BY
GY
Br
GY
Br
P
B
GY
Br
25
187
187
RB
BrW
Br
L
P
Br
B
START
29
9
10
24
LW
8
12V60/55W
G
G
A
Y
A
L
A
L
L
G
Y
BrL
Y
LOW
HIGH
22
RB
B
B
RB
Br
RB LW
R
L
RB
R
PARK
7
L Br
BrL
R
OFF
ON
Or
RW
205
17
Y
Ch
Dg
Br
TURN
HIGH
NEU.
ILL.
B
BrB GB
Y
BrSb
32
467C4B5CAMP403D494A4856 172320-2
B
Y
GB BrB
B
LRBr
LR
B
MAIN HARNESS
EXT. CORD
R
B
RB LY
B
OrLW
LY RB
R
LB GW
GW LB
HEAD LIGHT
LW Or
MAIN HARNESS
G Y
L B
G
B L
Y
A
LIGHT SYSTEM
ELEC
LIGHT SYSTEM - CIRCUIT DIAGRAM
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
(6) Fuse
(7) Main switch
(18) Left handlebar switch
(20) Diode
(21) Pass switch
(22) Dimmer switch
(26) Headlight
(28) Relay assy
(31) Tail/stop light
(32) Meter
18 21 22
28
3
6
26
20
32
7
7-42
31
LIGHT SYSTEM
ELEC
DIAGNOSTICS
THE HIGH BEAM LIGHT, PARKING INDICATOR LIGHT, REAR LIGHT, FRONT PARKING
LIGHT AND/OR INSTRUMENT LIGHTS FAIL TO TURN ON.
Procedure
Inspect:
1. Fuse
2. Battery
3. Main switch
4. Dipped/high beam light and dimmer switch
5. Relay assy
6. Harness connections (full system of connections)
NOTE:
• Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
• To check for defects use the following special tools.
Pocket tester:
P/N. 90890-03112
1. Fuse
•
•
NO
Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
Is the fuse OK?
Replace the fuse.
YES
2. Battery
•
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
NO
Min. open-circuit voltage:
12.8 V or more at 20°C (68°F)
•
•
•
Is the battery OK?
YES
*
7-43
Clean the battery terminals.
Recharge or replace the battery.
LIGHT SYSTEM
ELEC
*
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
3.
ON
OFF
PARK
INCORRECT
Br L
R
Br L
R
The main switch is defective. Replace.
CORRECT
4. Dipped/high beam commutator and dimmer switch.
•
•
•
Disconnect the left handlebar switch connector from the wire harness.
Connect the pocket tester (Ω x 1) to the
left handlebar switch terminals.
Check the switch component for continuity between “Brown (1)” and “Yellow
(2)”, “Brown/Blue (3)” and “Green (4)”,
“Brown/Blue (3)” and “Yellow (2)”.
Refer to “SWITCH CHECK” in CHAPTER
3.
4
3
G BrW BrB
P
B BrL
Y GB
2
BrL
Br
OFF
ON
INCORRECT
HIGH
LOW
Y
The dipped/high beam commutator and/or the
dimmer switch are defective. Replace the left
handlebar switch.
G
CORRECT
*
7-44
LIGHT SYSTEM
ELEC
*
5. Starter circuit cut-off relay.
•
Connect the pocket tester (DC 20V) and
the battery (12V) to the cut-off relay connector terminal of the starter circuit.
Battery terminal (+) ➔
White/Black terminal (1)
Battery terminal (–) ➔ Black terminal (2)
Tester terminal (+) ➔ Brown terminal (3)
Tester terminal (–) ➔ Earth
DISCONTINUITY
The starter circuit cut-off relay is defective.
Replace.
•
•
Turn the main switch to ON.
Check the voltage (12V) on the
“Brown/Blue” and “Brown” cable to the
connector terminal of the starter circuit
cut-off relay.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
DEFECTIVE CONNECTIONS
6. Harness connections.
• Check the connections of the entire light
system.
Repair.
CORRECT
Check the conditions of each circuit for the
entire light system.
See the “ELECTRIC CIRCUIT DIAGRAM”.
7-45
LIGHT SYSTEM
ELEC
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. The front headlight and the high beam light fail to turn on.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or the bulbholder.
CONTINUITY
2. Voltage.
•
Connect the pocket tester (DC 20V) to the
front headlight connectors and the high
beam switch.
Headlight:
Tester terminal (+) ➔
Green (2) or Yellow (1) cable
Tester terminal (–) ➔ Black cable (3)
High beam light:
Tester terminal (+) ➔ Yellow cable (4)
Tester terminal (–) ➔ Black cable (5)
A
OUT OF SPECIFICATION
The circuit from the main switch to the bulbholder connector is defective. Repair.
B
[A] When the lights switch (commutator) is at
position “HI”.
[B] When the lights switch (commutator) is at
position “LO”.
7-46
LIGHT SYSTEM
•
•
•
ELEC
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 terminals.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
2. The instrument light and/or the parking indicator light fails to turn on.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or the bulbholder.
CONTINUITY
2. Voltage.
•
Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔ Blue cable (1)
Tester terminal (–) ➔ Black cable (2)
OUT OF SPECIFICATION
•
•
The circuit from the main switch to the bulbholder connector is defective. Repair.
Turn the main switch to ON.
Check the voltage (12V) on the “Blue”
cable of the bulbholder connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
7-47
LIGHT SYSTEM
ELEC
3. The parking light fails to turn on.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or bulbholder.
CONTINUITY
2. Voltage.
•
Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔ Blue terminal (1)
Tester terminal (–) ➔ Black terminal (2)
OUT OF SPECIFICATION
•
•
The circuit from the main switch to the bulbholder connector is defective. Repair.
Turn the main switch to ON.
Check the voltage (12V) on the “Blue”
cable of the bulbholder connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
7-48
LIGHT SYSTEM
ELEC
4. The rear light fails to turn on.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or bulbholder.
CONTINUITY
2. Voltage.
•
Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔ Blue terminal (1)
Tester terminal (–) ➔ Black terminal (2)
OUT OF SPECIFICATION
•
•
The circuit from the main switch to the bulbholder connector is defective. Repair.
Turn the main switch to ON.
Check the voltage (12V) on the “Blue”
cable of the bulbholder connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
7-49
ELEC
7-50
W
W
W
7-51
20
W
W
W
W
W
W
R
W
W
W
W
B
R
WB
BrL W
2
W
W
BrL
WB
W
W
1
B
B
B
GW
GW
WB
GW
LY
LY
LY
B
28
B BrL
GB Y
P
BrB BrW G
BrL B
R
4
B
WB Br
18
BrL
Br
3
6
R
B BrL
Y GB
P
G BrW BrB
5
B
ON
OFF
21
26
LW
LW
Br
Br
L
Y
G
B
B
12V5W
B
A
B
B
G
Y
OFF
OFF
RUN
R
Br
BrB
B
BrB
B
B
BrB
B
BrB
B
B
LW
27
LY
BY
B
GB
B
B
B
GB
B
LB
RB
B
GB
GB
B
B
B
LY
B
B
12V10W
B
B B
GW LY
B
B
B
B
L
B
GY
GY
GY
GY
Br
B
L
L
LR
Sb
B
31
Or
LB - -
GW LY -
15
L
LR
Sb
Sb
LY BY
GY
30
Sb
Sb
LY
- B
Or RB
16
GW LY
14
11
B
B
BY
GB
B
(BLUE)
B
B
LY
RB
LB
12
12V10W
LY
B
13
GB
GB
B
Br
BrW
BY
GB
B
12V10W
BrB
12V10W
BrB
BrB
B
GB
BrB
R
BrB
L
OFF
N
23
ON
Br
BY
LW
BrW
19
BY
RB
RB
BY
GY
Br
GY
Br
P
B
GY
Br
25
187
187
RB
BrW
Br
L
P
Br
B
START
29
9
10
24
LW
8
12V60/55W
G
G
A
Y
A
L
A
L
L
G
Y
BrL
Y
LOW
HIGH
22
RB
B
B
RB
Br
RB LW
R
L
RB
R
PARK
7
L Br
BrL
R
OFF
ON
Or
RW
205
17
Y
Ch
Dg
Br
TURN
HIGH
NEU.
ILL.
B
BrB GB
Y
BrSb
32
467C4B5CAMP403D494A4856 172320-2
B
Y
GB BrB
B
LRBr
LR
B
MAIN HARNESS
EXT. CORD
R
B
RB LY
B
OrLW
LY RB
R
LB GW
GW LB
HEAD LIGHT
LW Or
MAIN HARNESS
G Y
L B
G
B L
Y
A
SIGNAL SYSTEM
ELEC
SIGNAL SYSTEM - CIRCUIT DIAGRAM
SIGNAL SYSTEM
ELEC
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.
(23) Flasher switch
(24) Horn
(25) Flasher relay
(27) Flasher light
(29) Front brake switch
(30) Rear brake switch
(31) Tail/stop light
(32) Meter
(3) Battery
(6) Fuse
(7) Main switch
(11) Diode
(14) Neutral switch
(15) Diode
(18) Left handlebar switch
(19) Horn switch
18 19 23
25
3
6
27
11 15
14
29
31
32
24
7
30
7-52
27
SIGNAL SYSTEM
ELEC
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 connections)
NOTE:
• Before starting inspections, remove the following parts:
1. Seat
2. Rear cowling
3. Cowling (headlight)
4. Tail light cover
• To check for operating faults use the following special tools.
Pocket tester:
P/N. 90890-03112
1. Fuse
•
•
NO
Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in
Chapter 3.
Is the fuse OK?
Replace the fuse.
YES
2. Battery.
•
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in Chapter 3.
NO
Min. open-circuit voltage:
12.8 V or more at 20°C (68°F)
•
•
•
Is the battery OK?
YES
*
7-53
Clean the battery terminals.
Recharge or replace the battery.
SIGNAL SYSTEM
ELEC
*
3. Main switch.
•
•
Disconnect the main switch connector
(Blue, Red and Brown) from the wire harness.
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)
Tester terminal (–) ➔ Blue cable (3)
ON
OFF
PARK
3
L Br
2
DISCONTINUITY
R
1
Br L
R
The main switch is defective. Replace.
CORRECT
UNCERTAIN CONNECTIONS
4. Harness connections
• Check the connections of the entire signal
system.
Repair.
CORRECT
Check the condition of each signal system.
Refer to “ELECTRICAL CIRCUIT DIAGRAM”
section.
7-54
SIGNAL SYSTEM
ELEC
SIGNAL SYSTEM CONTROL
1. The horn does not work.
1. Horn switch.
•
•
•
Disconnect the left handlebar switch connector from the wire harness.
Connect the pocket tester (Ω x 1) to the
switch terminals.
Check the switch component for continuity between “Pink (1)” and “Black (2)”.
Refer to “SWITCH CHECK” section.
P B
OFF
ON
DISCONTINUITY
1
G BrW BrB
P
2
B BrL
The horn switch is defective. Replace the left
handlebar switch.
Y GB
CORRECT
2. Voltage.
•
Connect the pocket tester (DC 20V) to the
horn cable.
Tester terminal (+) ➔ Brown terminal (1)
Tester terminal (–) ➔ Earth
OUT OF SPECIFICATIONS
•
•
The circuit from the main switch to the horn terminal is defective. Repair.
Turn the main switch to ON.
Check the voltage (12V) on the “Brown”
terminal of the horn.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*
7-55
SIGNAL SYSTEM
ELEC
*
3. Horn.
•
•
•
Disconnect the “Pink” cable from horn terminal.
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. Voltage.
•
Connect the pocket tester (DC 20V) to the
“Pink” terminal of the horn.
Tester terminal (+) ➔ Pink cable (1)
Tester terminal (–) ➔ Earth
OUT OF SPECIFICATION
The horn is defective. Repair.
•
•
Turn the main switch to ON.
Check the voltage (12V) on the “Pink” terminal of the horn.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
Repair or replace the horn.
7-56
SIGNAL SYSTEM
ELEC
2. The rear stop light fails to turn on.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or bulbholder.
CONTINUITY
2. Brake switch.
•
•
•
Disconnect the brake switch cables and
the connector from the wire harness.
Connect the pocket tester (Ω x 1) to the
brake switch terminals.
Check the switch component for continuity between “Green/Yellow (1)” and
“Brown (2)”, or “Black (3)” and “Black (4)”.
Refer to “SWITCH CHECK” section.
A
Br
G/Y
OFF (Free)
ON (Pull in)
Br G/Y RW
1
2
B
B
B
B
B
ON (Step down)
OFF (Free)
3
4
G/Y
INCORRECT
Br
[A] Front brake switch
[B] Rear brake switch
The brake switch is defective. Replace.
*
7-57
SIGNAL SYSTEM
ELEC
*
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 bulbholder connector is defective. Repair.
Turn the main switch to ON.
The brake lever is pulled or the brake
pedal is pressed.
Check the voltage (12V) on the
“Green/Yellow” cable of the bulbholder
connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
3. The direction indicator light and/or the direction indicator light fail to flash.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or bulbholder.
CONTINUITY
2. Direction indicator switch.
•
•
Disconnect the left handlebar switch connector from the wire harness.
Connect the pocket tester (Ω x 1) to the
left handlebar switch cables.
7-58
SIGNAL SYSTEM
•
ELEC
Check the switch component for continuity between “Brown/White (1)” and
“Brown/Black (2)” and “Brown/White (1)”
and “Green/Black (3)”.
Refer to “SWITCH CHECK” section.
1
3
2
G BrW BrB
P
B BrL
Y GB
INCORRECT
L
N
R
The direction indicator switch is defective.
Replace.
CORRECT
3. Direction indicator lamp relay.
•
Connect the pocket tester (DC 20V) to the
indicator lamp relay.
Tester terminal (+) ➔ Brown terminal (1)
Tester terminal (–) ➔ Earth
OUT OF SPECIFICATION
•
•
Turn the main switch to ON.
Check the voltage (12V) on the “Brown”
cable to the indicator lamp relay terminal.
The circuit from the main switch to the lamp relay connector is defective. Repair.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*
7-59
SIGNAL SYSTEM
ELEC
*
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.
Replace.
Turn the main switch to ON.
Check the voltage (12V) on the “Blue”
cable to the bulbholder connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
*
7-60
SIGNAL SYSTEM
ELEC
*
5. Voltage.
•
•
Connect the pocket tester (DC 20V) to the
bulbholder connector.
Connect the left handlebar switch connector to the wire harness.
To the left flasher light:
Tester terminal (+) ➔
Green/Black terminal (1)
Tester terminal (–) ➔ Earth
To the right flasher light:
Tester terminal (+) ➔
Brown/Black terminal (1)
Tester terminal (–) ➔ Earth
OUT OF SPECIFICATION
GB
BrB
The circuit from the direction indicator switch to
the bulbholder is defective. Repair.
•
•
•
Turn the main switch to ON.
Turn the direction indicator switch to “L” or
“R”.
Check the voltage (it flashes at 2-8V) on
the “Green/Black” or “Brown/Black” cable
at the bulbholder connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
The circuit is efficient.
7-61
SIGNAL SYSTEM
ELEC
4. The “N” neutral light fails to turn on.
DISCONTINUITY
1. Bulb and bulbholder.
•
Check the continuity of the bulb and bulbholder.
Refer to “BULB INSPECTION” section.
Replace the bulb and/or bulbholder.
CONTINUITY
2. Neutral switch.
•
•
•
Disconnect the neutral switch cable from
the wire harness.
Connect the pocket tester (Ω x 1) to the
neutral switch cables.
Check the switch component for continuity
between “Sky blue (1)” and “earth”.
Refer to “SWITCH CHECK” section.
Sb
In gear
Neutral
INCORRECT
Sb
1
The neutral switch is defective. Replace.
CORRECT
3. Voltage.
•
Connect the pocket tester (DC 20V) to the
bulbholder connector.
Tester terminal (+) ➔ Brown cable (1)
Tester terminal (–) ➔ Earth
1
Br Y BrB
LR B GB
LR B GB
Br Y BrB
7-62
SIGNAL SYSTEM
•
•
Turn the main switch to ON.
Check the voltage (12V) on the Brown cable of the bulbholder connector.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
ELEC
OUT OF SPECIFICATION
The circuit from the main switch to the bulbholder connector is defective. Repair.
4. Neutral switch cable.
•
•
Disconnect the neutral switch connector
from the wire harness and the bulbholder
connector.
Connect the pocket tester (Ω x 1) to the
neutral switch cable (on the harness side)
and the bulbholder connector (1).
DISCONTINUITY
The circuit from the bulb to the neutral switch
cable is defective. Repair.
CONTINUITY
The circuit is efficient.
7-63
ELEC
7-64
?
TRBL
SHTG
8
?
TRBL
SHTG
CHAPTER 8°
TROUBLESHOOTING
FAILURE TO START/DIFFICULTIES IN STARTING
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . .
POOR ENGINE COMPRESSION . . . . . . . . . . .
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8-1
8-1
8-2
8-2
POOR PERFORMANCE AT IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED . . . . . . . . . . . . . . . . . 8-3
DIFFICULTIES IN SHIFTING . . . . . . . . . .
SHIFTING IMPOSSIBLE . . . . . . . . . .
THE SHIFT PEDAL FAILS TO MOVE
DISENGAGING GEARS . . . . . . . . . .
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8-4
8-4
8-4
8-4
CLUTCH SLIDES OR FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CLUTCH FAILS TO RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
DEFECTIVE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
POOR BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
OIL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
MALFUNCTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
UNSTABLE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS . .
POOR HEADLIGHT ILLUMINATION . . . . . . . . . . . . . . . . .
FREQUENT BURNING OF BULB . . . . . . . . . . . . . . . . . . .
DIRECTION INDICATORS FAIL TO TURN ON . . . . . . . . . .
DIRECTION INDICATORS FAIL TO TURN OFF . . . . . . . . .
DELAYED TURNING ON OF INDICATORS . . . . . . . . . . . .
EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY
THE HORN FAILS TO WORK . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . 8-8
. . . . . . . . . . . . . 8-8
. . . . . . . . . . . . . 8-8
. . . . . . . . . . . . . 8-8
. . . . . . . . . . . . . 8-8
. . . . . . . . . . . . . 8-9
. . . . . . . . . . . . . 8-9
. . . . . . . . . . . . . 8-9
OVERHEATING OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
TRBL
SHTG
?
FAILURE TO START/
DIFFICULTIES IN STARTING
TRBL
SHTG
?
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 section in the manual.
FAILURE TO START/DIFFICULTIES IN STARTING
FUEL SYSTEM
PROBABLE CAUSES
Fuel tank
•
•
•
•
Empty
Fuel filter obstructed
Fuel tank air cap passage obstructed
Petrol contains water or impurities or is adulterated
Fuel cock
•
•
Hose obstructed
Fuel filter obstructed
Carburetor
•
•
•
•
•
•
•
•
•
•
•
Petrol contains water or impurities or is adulterated
Pilot jet obstructed
Pilot air passage obstructed
Infiltrations of air
Deformation of float
Needle valve worn or scratched
Needle valve seat insufficiently sealed
Fuel level set wrongly
Pilot jet set wrongly
Starter jet obstructed
Malfunctioning of the starter piston
Air filter
•
Air filter element obstructed
8-1
FAILURE TO START/
DIFFICULTIES IN STARTING
ELECTRICAL SYSTEM
TRBL
SHTG
?
PROBABLE CAUSES
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
High voltage cable defective
Defective coil
Ignition unit
•
•
•
Defective unit
Defective pick-up coil
Woodruff key broken
Switches and cables
•
•
•
•
•
•
•
Main switch defective
Emergency stop engine switch defective
Harness with cable interrupted
Neutral switch defective
Sidestand switch defective
Clutch switch defective
Starter switch defective
Starter motor
• Starter motor defective
• Starter motor relay defective
• Diodes defectives
• Starter one-way bearing defective
POOR ENGINE COMPRESSION
PROBABLE CAUSES
Cylinder and cylinder head
•
•
•
•
•
Spark plug tightening insufficiently
Cylinder head or cylinder insufficiently tightened
Cylinder head gasket broken
Cylinder gasket broken
Cylinder worn, damaged or seized
Piston and piston rings
•
•
•
•
Piston
Piston
Piston
Piston
Crankcase and valves, crankshaft
•
•
•
•
•
•
•
•
Poor crankcase sealing
Crankshaft oil seal edge damaged
Poor valve sealing
Valve and seat with insufficient contact
Valve timing wrongly
Valve spring broken
Crankshaft seized
Camshaft seized
8-2
rings wrongly assembled
rings worn, yielded or broken
rings stuck together
seized or damaged
POOR PERFORMANCE AT IDLE SPEED/
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
POOR PERFORMANCE AT IDLE SPEED
Carburetor
Valves
?
PROBABLE CAUSES
•
•
•
•
•
•
•
Electrical system
TRBL
SHTG
The starter piston fails to return freely
Pilot jet obstructed or loose
Pilot jet obstructed
Pilot air screw wrongly set
Idle speed wrongly set
(throttle valve stop screw)
Throttle cable free play wrongly set
Carburetor flooded
•
•
•
•
•
Defective battery
•
Valve clearance wrongly set
Defective spark plug
Defective ignition unit
Defective AC magneto
Defective ignition coil
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED
See “FAILURE TO START/DIFFICULTIES IN STARTING”.
(FUEL SYSTEM, ELECTRICAL SYSTEM, COMPRESSION SYSTEM and Valve clearance)
PROBABLE CAUSES
Carburetor
Air filter
•
•
•
•
•
•
•
•
•
•
Petrol contains water or impurities or is adulterated
•
Air filter element obstructed
8-3
Infiltrations of air
Deformation of float
Defective diaphragm
Needle valve worn or scratched
Needle valve seat insufficiently sealed
Needle stop position incorrect
Fuel level set wrongly
Main jet obstructed or loose
Main nozzle obstructed or loose
DIFFICULTIES IN SHIFTING
TRBL
SHTG
?
DIFFICULTIES IN SHIFTING
PROBABLE CAUSES
SHIFTING IMPOSSIBLE
•
•
•
Clutch
•
•
•
•
•
•
•
•
•
•
•
•
Engine oil
THE SHIFT PEDAL FAILS TO MOVE
Clutch cable wrongly set
Wrong position of push lever
Irregular engagement of push lever and push
rod
Pressure plate deformed
Clutch springs not preloaded uniformly
Reference marks not aligned
Push rod broken
Clutch gear assy nut loose or push rod deformed
Primary driven gear bearing defective
Driven plates deformed
Driving plates deformed
Clutch cable damaged
Oil level over maximum
Incorrect gradation (high viscosity)
Degradation
PROBABLE CAUSES
Shift shaft
•
Shift shaft deformed
Shift cam, shift fork
•
•
•
Groove with impurities or foreign bodies
•
•
•
Transmission gears struck
Transmission
DISENGAGING GEARS
Shift fork stuck
Shift fork guide bar deformed
Gears stuck by impurities or foreign bodies
Wrong transmission assembly
PROBABLE CAUSES
•
•
Shift lever set wrongly
Shift fork
•
Shift forks worn
Shift cam
•
•
Shaft cam with thrust free play
•
Gear clutches worn
Shift shaft
Transmission
8-4
Shift cam stop lever fails to return freely
Shift cam groove worn
CLUTCH SLIDES OR FAILS TO RELEASE
TRBL
SHTG
CLUTCH SLIDES OR FAILS TO RELEASE
CLUTCH SLIDES
Clutch
Engine oil
PROBABLE CAUSES
•
•
•
•
•
•
•
•
•
CLUTCH FAILS TO RELEASE
Refer to “SHIFTING IMPOSSIBLE” section.
8-5
Clutch cable wrongly set
Clutch springs loose
Clutch spring yielded
Friction plates worn
Clutch plates worn
Clutch improperly assembled
Oil level below minimum
Incorrect gradation (low viscosity)
Degradation
?
DEFECTIVE BRAKES/
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
TRBL
SHTG
?
DEFECTIVE BRAKES
POOR BRAKING
PROBABLE CAUSES
•
•
•
•
•
•
•
•
•
•
•
Brake pads worn
Brake disc worn
Water in the brake fluid
Brake fluid leak
Brake fluid tank defective
Bleed cap not sealed to calipers
Union bolt loose
Brake hose cracked
Brake disc dirty or greasy
Brake pads dirty or greasy
Incorrect brake fluid level
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK
OIL LEAKS
PROBABLE CAUSES
•
•
•
•
•
•
•
MALFUNCTIONING
Inner tube deformed, damaged or rusty
Outer tube damaged or cracked
Oil seal lip damaged
Oil seal assembled incorrectly
Oil level incorrect (excessive)
Shock-absorber rod stop bolt loose
O-ring on cap bolt broken
PROBABLE CAUSES
•
•
•
•
•
•
•
8-6
Inner tube deformed, damaged or rusty
Outer tube deformed or damaged
Fork spring damaged
Piston worn or damaged
Shock-absorber rod deformed or damaged
Incorrect oil viscosity
Incorrect oil level
UNSTABLE STEERING
TRBL
SHTG
?
UNSTABLE STEERING
PROBABLE CAUSES
Handlebar
•
Assembled crooked or incorrectly
Steering
•
•
•
Handlebar crown assembled incorrectly
Front fork
Tyres
Wheels
Frame
Rear arm
Rear shock absorber
Drive chain
Lower bracket crooked
Lower steering column installed incorrectly
(threaded ring nuts not tightened correctly)
•
Bearing or bearing tracks damaged
•
•
•
Oil level not the same in both tubes
•
•
•
Tyre pressure incorrect for type of road
•
•
•
•
•
Wheels balanced incorrectly
•
•
•
Deformed
•
•
Bushes or bearings consumed
•
•
•
Spring yielded
•
Chain set incorrectly
8-7
Spring broken
Front fork crooked
Tyre pressure incorrect
Tyres worn non-uniformly
Wheel deformed
Bearing loose
Wheel axle deformed or loose
Wheels excessively off-centre
Head tube damaged
Ball track installed incorrectly
Deformed or damaged
Spring preloaded
Oil leak
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
TRBL
SHTG
?
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS
HEADLIGHT DOES NOT LIGHT
PROBABLE CAUSES
•
•
•
•
•
•
•
FREQUENT BURNING OF BULB
Difficulties in charging (charging coil broken
and/or rectifier/regulator defective)
Uncertain connections
Wrong negative earthing
Insufficient contacts (main switch)
Bulb gone
Light relay/diode defective
Incorrect bulb
Rectifier/regulator defective
Wrong negative earthing
Main switch defective
Bulbs gone
PROBABLE CAUSES
•
•
•
•
•
•
•
DIRECTION INDICATORS FAIL TO TURN OFF
Excessive absorption of electrical accessories
PROBABLE CAUSES
•
•
•
•
•
•
DIRECTION INDICATORS FAIL TO TURN ON
Incorrect bulb
Wrong negative earthing
Battery flat
Defective direction indicator switch
Indicator lamp relay defective
Harness cut off
Connector loose
Bulb gone
PROBABLE CAUSES
•
•
•
•
8-8
Indicator lamp relay defective
Insufficient battery capacity
(battery almost flat)
Bulb (front or rear) burnt out
Direction indicator switch defective
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS/
OVERHEATING OF ENGINE
DELAYED TURNING ON OF INDICATORS
TRBL
SHTG
?
PROBABLE CAUSES
•
•
•
•
Indicator lamp relay defective
Insufficient battery capacity
(battery almost flat)
Incorrect bulb
Main switch or direction indicator switch defective
EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY
PROBABLE CAUSES
•
•
THE HORN FAILS TO WORK
Indicator lamp relay defective
PROBABLE CAUSES
•
•
•
•
•
OVERHEATING OF ENGINE
Incorrect bulb
Battery flat
Main switch or horn switch defective
Horn wrongly set
Defective horn
Harness cut off
PROBABLE CAUSES
•
•
•
Incorrect electrode gap of spark plug
•
•
•
Incorrect carburetor main jet (incorrect setting)
Air filter element obstructed
Engine compression
•
Excess of carbon deposits
Engine oil
•
•
•
Incorrect oil level
•
Pads fail to return freely (remains blocked)
Ignition system
Fuel feed system
Brake
8-9
Spark plug thermal gradation wrong
Ignition unit defective
Incorrect fuel level
Incorrect oil viscosity
Incorrect oil gradation
TRBL
SHTG
?
ELECTRICAL SYSTEM
DIAGRAM
TT600RE WIRING DIAGRAM
LY
LY
GW
GW
LY
GW
Br L
L Br
R
LY
W
W
W
ON
OFF
PARK
GW
W
B
W
W
B
W
Or RB
LY
W
GW
W
R
1
- B
GW LY LB - -
A
467C4B5CAMP403D494A4856 172320-2
R
L
Br
G Y
L B
RB
B
RB
LB
B
LB
Or
16
B
Or
MAIN HARNESS
HEAD LIGHT
205
LY
BB
17
B
7
2
RB
BrL
R
W
W
W
W
W
RW
B
W
R
G
B L
Y
W
Br
R
11
R
9
RUN
Br
Br
OFF
GY
GY
RB
RB
10
OFF
RB LW
3
RB
B
RB
LW
B
LW
12
START
BY
BY
BY
BY
B
LY
B
B
GY
LW
BY
Sb
B
B
187
LY
B
13
14
B
B
LY
B
R
B
B
MAIN HARNESS
EXT. CORD
LR
B
29
R
Sb
LY
5
RB LY
15
Sb
187
B
B
Br
4
LW
OrLW
LY RB
Sb
B
LW
LB GW
LW Or
LR
6
LY BY
Sb
B
GW LB
BY
R
RB
B
8
B
(BLUE)
Br
Br
WB
ILL.
Br
WB Br
Br
25
BrL W
WB
24
Br
Dg
TURN
21
18
BrB BrW G
G BrW BrB
BrL B
P
BrW
GY
30
Y
HIGH
23
19
BrSb
OFF
HIGH
OFF
L
ON
LOW
ON
N
B BrL
Y
B
BrB GB
LRBr
B
Y
GB BrB
R
Y GB
GB
B
GY
G
L
GB
GB
L
L
GY
GY
B
B
B
B
B
B
B
B
BrB
BrB
GB
GB
GB
GB
COLOR CODE
B ...........Black
Br ..........Brown
Ch .........Chocolate
Dg .........Dark green
G...........Green
Gy .........Gray
L............Blue
Lg..........Light green
O...........Orange
P ...........Pink
R...........Red
Sb .........Sky blue
W..........White
Y ...........Yellow
B/L ........Black/Blue
B
27
B
B
B
B
B
B A B
G
Y
31
B
B
BrB
B
B
BrB
B
B
B
B
12V10W
12V10W
GB
BrB
GB
BrB
BrB
G
BrB
12V10W
26
12V10W
12V5W
12V60/55W
L
Y
GY
Y
G A
L
L A
Y A
Y
G
BrB
GB Y
22
Ch
L
P
P
Br
BrL
BrL
BrW
P
B
28
BrL
20
LR
NEU.
BrW
Br
B BrL
W
B
WB
Br
L
32
B/W.......Black/White
B/Y........Black/Yellow
Br/B.......Brown/Black
Br/L .......Brown/Blue
Br/W......Brown/White
Br/Y.......Brown/Yellow
L/B ........Blue/Black
L/R ........Blue/Red
L/W .......Blue/White
L/Y ........Blue/Yellow
R/B........Red/Black
R/G .......Red/Green
R/W.......Red/White
R/Y........Red/Yellow
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
f
g
h
j
k
l
;
z
x
AC generator/Pickup coil
Rectifier/Regulator
Battery
Starter relay
Starting motor
Fuse
Main switch
Right handlebar switch
Engine stop switch
Starter switch
Diode
Clutch switch
Sidestand switch
Neutral switch
Diode
Ignitor unit
Ignition coil
Left handlebar switch
Horn switch
Diode
Pass switch
Dimmer switch
Flasher switch
Horn
Flasher relay
Headlight
Flasher light
Relay assy
Front brake switch
Rear brake switch
Tail/stop light
Meter