YAMAHA

TT&OO E ~~~
REPAIR
MANUAL

A-2
WARNING
Thts manual has been wntten by Belgarda S p A mamly far use by Yamaha dealers and the1r sktlled
mechamcs lt 1s tmposstble to provtde a mechamc wtth ali the tnformataon necessary tn a stngle manual
Presumably, though, the peoplewho use thrs manual torthe mamtenance and repatrofYamahamotorcycles

wtll already have elementary knowledge of the pnnctples of mechamcs and the procedures for motorcycle
repatrtechntques Wtthoutthts knowledge, repatr or matntenance work on thts model could prove tnefftctent
and *Or dangerous
Yamaha makes constant efforts to tmprove an tts models lmportant alterattons or changes to procedures
charactensttcs wtll be communtcated to an Yamaha dealers and pubhshed m future edtttons of thts manual
Espectally tmportant tnformatton 1n th1s manual1s htghltghted by the graphtcs shown below

TECHNICAL PUBLICATIONS
R&D TECHNICAL DIVISION
MOTORCYCLE GROUP
BELGARDA S.p.A.

PARTICULARLY IMPORTANT INFORMATION

The manual tncludes the followtng symbols and relattve remarks
Th1s safety alert symbol means ATIENTIONI BE CAREFUL' YOUR SAFETY IS
AT RISKI

WARNING

CAuiiN:~
NOTE:

TI600(E) ('94)
REPAIR MANUAL
1995 BELGARDA S.p.A.
R&d TECHNICAL DIVISION

1st edation July 1995

Ali nghts reserved.
Any reprlntlng or unauthorlsed use
without the wntten permisston of
Belgarda S.p.A. is
expressly prohtbtted.

Although some of the drawmgs and photographs used m th!s manuat ara taken !rom other manuals and do not refer d~rect/y to the mode/
m questJon the procedures descnbed and the det81fs Illustra led aro nonetheless rolevant and swtable to the user's purposes

The WARNING symboltndtcates spectal procedures to be followed to avotd mJury

to the nder or the person tnspecttng or repatnng the cycle
CAUTION tndtcates spectal precauttons to be taken to avotd damage to the cycle
A NOTE provtdes key tnformatton destgned to make procedures easter or clearer

A-3

HOW TO USE THIS MANUAL

LAYOUT
Thts manual conststs of chapters on the pnnctpal cycle components (see "Symbol

Legend~)

SIMBOL LEGEND

Gl

G)

1~~~~1~1 lsPeciPfl

(1) Thts symbol, tn the top nghthand corner of each page, tdenttftes the chapter graphtcally

Gl

(2)

(3) The ftnal captiOn m the chapter 'Penodtc mspectiOn and penodtc adjustmenf

l'~~~ IIIPJ) l l ENG l'-1

FORMAT

Ali the procedures suggested m thts manual are arranged m a sequenttal, step by step arder The mformatiOn
ts wrrtten tn such a way as t o provtde the mechamc Wtth a handy, easy to rea d reference contatntng
explanattons on ali dtsassembly, repatr, assembly and mspectton operattons
Parttcularly tmportant procedure sequences (4) are shown between two rows of astensks (*) and each
procdure rs preceded by the symbol ""

ICARBif l lcHAsiAI

Thts tttle appears at the top of each page to the left of the chapter symbol

IMPORTANT SPECIFICATIONS
Ali data and spec1al tools are contamed m msets preceded by the speclfrc symbol (5)
A number rnscnbed m a crrcle mdrcates (6) the number of a part, whereas a letter of the alphabet mdrcates
allgnment data or marks (7), further mdJcatJons are SJgnalled by a letter eclosed m an 1nset (8)
The cond1tron of a taulty component precedes an arrowfollowed by the procedure reqwred and the symbol

Gl

In some chapters the dJsassembly sectron rs preceded by exploded d1agrams These are desrgned to a1d
zdentlflcatJon ot components for pro per assembly, as weli as the assembly procedures themselves

~
~
~

~
~
[0]

11]
@

Symbols (1) to (8) are used to mdrcate chapter

number and content
(1) Generai mformatiOn
(2) Technrcal spec1frcatrons
(3) Penodrc rnspectron and adjustment
(4) Engrne
(5) Carburettor
(6) Chassrs
(7) Electncals
(8) Troubleshootmg

lELEC liiii l ~~~~~~ ?l

(9)

EXPLODED DIAGRAMS

(Referto lllustrations)

~ ~

Symbols (9) to (15) serve to specrfy the followrng

elements
(9) Flu1d
(10) Lubncant
(11) Specral tool
(12) Screw trghtenrng
(13) Wear and tear llmrt, clearance
(14) Engme speed
(15) Resrstance (Q), Voltage (V), Electnc Current (A)

Symbols (16) to (22) m the exploded dragram

mdrcate type of lubncant and locatron of lubncatiOn
pomt
(16) Apply engme ori
(17) Apply gear 011
(18) Apply molybdenum drsulfrde mi
(19) Apply wheel beanng grease
(20) Apply llghtwe1ght llthrum-soap grease
(21) Apply molybdenum drsulflde grease
(22) Apply lock1ng hqu1d (LOCTITE)

l A-41
CONTENTS,
GENERAL INFORMATION

TECHNICAL SPECIFICATIONS
PERIODIC INSPECTION
ANO ADJUSTMENT
ENGINE OVERHAUL

CARBURETTOR

CHASSIS

ELECTRICALS

TROUBLESHOOTING

SPEC

INSP
ADJ

~~~~~ ~~~ l A-5 l

CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION CF MOTORCYCLE
IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER

A-6
A-6
A-6

IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY ANO REASSEMBLY
SPARE PARTS
GASKETS, OIL SEALS ANO 0-RINGS
LOCK WASHERS, PLATES ANO COTTE A PINS
BEARINGS ANO OIL SEALS
CIRCLIPS

A-6
A-6
A-7
A-7
A-7
A-7
A-7

SPECIAL TOOLS
FORTUNE UP
FOR ENGINE OISASSEMBLY
FOR CHASSIS OISASSEMBLY
FOR THE ELECTRICAL SYSTEM

A-7
A-7

A-8
A-9
A-10

__________ ,,~~~~~'

IDENTIFICATION OF

MOTOR~CLE ~~~~~ ~~~

A-6

IMPORTANT INFORMATION

~~~~~ ~~~

IDENTIFICATION OF MOTORCYCLE

IMPORTANT INFORMATION

IDENTIFICATION NUMBER

PREPARATION FOR DISASSEMBLY ANO

REASSEMBLY

The tdentlflcatiOn number 1s stamped on the nght of

the steermg head p1pe

Remove ali d1rt, mud, dust an d fore1gn obJects

pnor to d1sassembly

Progress1ve sena! number

TT600 E
EUROPE BL-4LW-025101
SPAIN
ZD04LW300S0095101

Motorcyc!e 1dentlf!cat10n number

Use propermatenal an d tools Referto sectiOn

'SPECIAL TOOLS'

When d1sassembhng the cycle, keep together

mated parts gears, cyhnders, p1stons and
other parts 'mated' m the course of normal
wear and tear Such parts must be e1ther re
used together or comptetely replaced

Ounng d1sassembly clean ali parts and piace

them 1n trays 1n arder of d1sassembly Th1s
makes reassembly qwcker and helps assure
that ali parts are assembled properly

Keep away from f1re and sources of heat

ENGINE SERIAL NUMBER

The engme senal number 1S stamped on the nght of

the engme

Progress1ve engme senal number

TT 600 E
4GV-010101

2 Eng1ne senal number

NOTE:
The f1rst three d1g1tS tn these numbers 1dent1fy the
mode!, the other d1gtts form the progress1ve
product1on number ot the u01t
01agramsand speclf1cat10ns may bealtered WLthout pnor warmng

1-1

1-2

IMPORTANT INFORM:ION

~~~~~ ~~~

SPECIALTOOLSII~~~ \~\

A-7

SPARE PARTS

CIRCLIPS

We recommend ongtnal Yamaha parts far ali

replacements Use the otl and grease recomM
mended by Yamaha far ali assembly and
ad1ustment operattons
Products of other makes wlth the same functton and appearance mtght be tnfenor m
quahty

AU mchps should be mspected carefully pnor

to reassembly Always replace ptston rmg
chps after one use
Replace twtsted ctrchps When mstalhng a
ctrchp (1), make sure that the sharpedged
corner (2) ES posthoned oppos1te the thrust (3)
tt recetves See the tllustratton here

GASKETS, OIL SEALS ANO OAINGS

(4)

Ali gaskets, oli seals and 0-nngs should be

reptaced dunng engtne overhauls Ali gasket
surtaces, otl seal llps and 0-rmgs must be
cleaned pnor to assembly
Properly oli ali matmg parts and beanngs
dunng reassembly Apply grease to otl seal
hps

SPECIAL TOOLS
Spectal tools are requtred to pertorm proper dtsas~
sembiy and reassembly operattons and for proper
tumng up The use of such tools avotds damage
due to the use of unsuttable tools and/or makeshtft
techntques

FORTUNE UP

LOCK WASHERS, PLATES ANO COTTER PINS

lnducttve stroboscopcc lamp

Ali lock washers, plates (1) and cotter pms

must be replaced once removed Lock tabs
must be bent along the bolt or nut surfaces
after the bolt or nut has been properly tJghtened

P/N YM-33277-A

P/N 90890031 09
ThES tool serves to tune up ttmmg

BEARINGS ANO OIL SEALS

Thts toolts used to measure the level of the fuei m

the float chamber

011 seals
3

cAuTio~:j

______________________

1 '

lnduct1ve engtne speed md1cator

P/N YU-08036-A
P/N 9089003113

Do not use compressed airto dry the bearings.

Thls damages their outer surface.
(1)

Fuel gauge
P/N YM-01312-A
P/N 90890-01312

Ftt beanngs and 011 seals w1th the manufactur~

er's mark or number factng outwards (te, the
stampe d letters must be vtstble) When mstall~
tng oti seals, apply a hghtcoatmg of hghtwetght
llthtum~based grease to the seal hps 011 the
beanngs hberally when mstalhng
{1)

Shalt

Thts tool serves to measure engme speed

Beanng

14

SPECIAL
4

~LS~I~~~ ~~~

Pressure gauge

A-8

SPECIALTOOLSII~~~ 1~1

;::===============:;----.;4~7;:m:m~(~0~2~8~:n)~v:a:lv:e:gulde puller

P/N YU-33223
P/N 90890-03081 - (1)
Adapter (M12)
P/N YU-33223-3
P/N 90890-04082 - (2)
Th1s tool1s used to measure engme compresston

P/N YM01225-A
P/N 90890-01225

Th1s tool ls used to remava valve gu1des

Valve adJustment tool

P/N YM-08035
P/N 90890-01311

7 mm (O 28m) valve QUide reamer

P/N YM01227
P/N 9089001227

Th1s tool IS used to re-ream the new valve gUide

These tools serve to adjust valve free play

FOR OISASSEMBLY OF THE ENGINE

AIIMpurpose clutch holder

PIN YM-91042

P/N 9089004086

7 mm valve (O 28m) valve gwde mstaller

P/N YM-04017
P/N 9089004017

Ths tool 1s necessary to mstall the valve shdes

properly

Th1s tool1s used to lock the clutch, when the clutch

boss lock nut 1s be1ng loosened or ttghtened

Crankcase separatmg tool

P/N. YU-01135-A
P/N 90890-01135

Thts tool1s necessary to disassembla the crank-

case

Valve hous1ng cutter

P/N YM-91043

~ ~
o l~lllllll

Th1s tool1s used to gnnd the valve housmg

H;ttlO~

Lw~
3

Valve spnng compressJon clamp

P/N YM-04019
P/N 9089004019

Th1s tool1s necessary to remove and 1nstall val ves

1-5

P1ston p1n chp puller

P/N YU-01304
P/N 90890-01304

Th1s tool serves far removmg the p1ston pm chp

16

SPECIAL

TOOLSII~~~ 1~1

14 Rotar screw puller

P/N YU-33270
P/N 90890-01362

Thts tool ts used to dsassemble the magnete

flywheel rotar

1O Dnvmg shatt mstallabon un tt

15 Sealant (Outck Gasket)

P/N ACC-11001-01
Yamaha Band No 1215
P/N 90890-85505

P/N YU-90050- (1)

Dnvmg shaft mstallatiOn hose

P/N 90890-01274- (2)

Dnvtng shaft mstallatton boli

Thts sealant (adhestve) ts used for crankcase mattng surfaces etc

P/N 90890-01275- (3)

FOR DISASSEMBLY OF THE CHASSIS

11 #10 (M14) adapter

P/N YM-90069
P/N 90890-04059

Fork seal gwde

P/N YM-38853
P/N 90890-01442

Thts toolts used to tnstall the dnvmg shaft

Thts tool serves to mstall the fork otl seal

12 Crank spacer
P/N YM-91044
P/N 90890-04081 - (1)

Damper rod holder

P/N 90890-0!463

Thts toolts used to dtsassemble or reassemble the

fork damper rod

Spacer
P/N 90890-01016- (2)

Thts toolts used to tnstall the dnvmg shaft

13 Rotar holder
P/N YS-01880
P/N 90890-01701

P/N YM-01434
P/N 90890-01434

Th1s tool 1s used to hold the fork spnng

Thts toolts used to prevent the rotar frorn rotatmg

dunng remava! or tnstallatton of the secunng boli

1-7

Rod holder

1-8

SPECIAr'ooLsll~~~ ~~~ lA-1 Q l

4

SPECIAL

FOR ELECTRICAL SYSTEM

Fork rod puller and adapter

P/N YM-01437
P/N 90890-01437

T ester

P/N YU-33260-A
P/N 90890-03021

Rod puller adapter

P/N 90890-01436
These tools are used t o d1sassemble the fork damper

TOOLSII~~~ 1~1

Th1s tester 1s necessary for checkmg IQntiiOn system components

rod

5 Rmg nut wrench

P/N YU-01268
P/N 90890-01268
Th1s tool1s used to t1ghten the steenng nng nut to
the prescnbed torque

Pocket tester
P/N YU-03112
P/N 90890-03112
Th1s tester serves to check electnc crcu1ts

Rmg nut wrench

P/N YM-38520
P/N 90890-01443

P/N YM-34487
P/N 90890 03144

Th1s tool 1s used to t1ghten the steenng nng nut to

the prescnbed torque

Ths tool serves to check the plug spark v1sually

7 Lock nut wrench

P/N YM-38519
P/N 90890-01348
Th1s wrench 1s used to remove an d n sta Il the steermg umt nut

19

DynamJC spark tester

1 10

CHAPTER2
TECHNICAL SPECIFICATIONS
GENERAL SPECJFJCATJONS

A12

MAINTENANCE SPECJFICATJONS
ENGJNE
ELECTRICALS
CHASSIS

A-14
A-14

B-1
B-2

TIGHTENJNG TOROUES
GENERAL TORQUE SPECJFICATIONS

B-3
B-5

DEFINITJON OF MEASUREMENT UNJTS

B-5

LUBRICATJON POINTS ANO TYPE OF LUBRICANT

ENGJNE
CHASSIS

B-6
B-6
B-6

LUBRICATJON LAYOUT

B-7

CABLE ROUTING

B-9

'-' 1

GENERAL SPECIFICATIONSSPEC

1m~
f l l lA-12l

GENERAL sPECIFlcATioNs jsPecj

TECHNICAL SPECIFICATIONS

Mode l

GENERAL SPECIFICATIONS
TT600 (E)('94)

Mode l

Model code number

lmttal eng1ne stamp number

4LW3
EUROPE
SPAIN

Bl-4LW-025101
ZD04LW300S00951 01

lnLtLal frame stamp number

4GV-010101

DLmensLons
Overall length
Overall wtdth
Overall he1ght
Seat hesght
Wheel base
Mm1mum ground clearance

2,240mm
840mm
1,200mm
890mm
1 480 mm
270mm

Bas1c we1ght

147 kg

M1mmum tum1ng rad1us

220m

Frame
Frame type
Casier angle
Tra1l

A1r cooled 4-stroke

4 valve, SOHC
4GV2
Smgle cyhnder, 1nchned forward

Tyres
Type
SiZ6
Front
Rear

Eng1ne
Eng1ne type
Model
Cylmder tayout
Capac1ty
Bore x stroke
CompresSLon ral10

595cc
95x84mm
8 51
Electnc start

Startmg system
Lubncat1on
Type
Recommended eng1ne 011

Dry SL.Imp WLth separate otltank

SHELL SU PER 4TX 20W/50

Capac1ty
Penod1c 011 change
W1th 011 f1lter replacement
011 tank
Total capac1ty

2 2 htres
2311tres
1 8 htres
2 8 htres

AITfJlter
Type

TT600 (E)('94)

Transmtss1on
Type
Pnmary reduct1on system
Pnmary reductiOn rat1o
Secondary reductiOn system
Secondary reductiOn rat10
OperaM n
Gear rallo
1"

Constant mesh 5speed

Stra1ght -tooth gears
71/34 (2 088)
Cham dnve
47/15 (3 133)
Left foot operatlan
31112 (2
27117 (1
24/20 (1
21/22 (O
19/24 (O

2~

3"
4"
5"

Open-cradle backbone frame

28'
121 mm
Wlthtube
90/90 21 (54R) PIRELLI MT70
130/80 18 (66R) PIRELLI MT70

Tyre mflat1on pressure (cold tyres) bar- kg/cm 2 (ps1)

Front

Rear

2 (28)

22 (32)

W1th passenger

21 (30)

24 (35)

Off-road

1 5 (22)

1 6 (23)

R1deronly

Brakes
Front brake type
OperaiiOn
Rear brake type
OperatiOn

Smgle d1a 267 mm d1sk brake

Rtght hand operat1on
S1ngle d1a 220 mm d1sk brake
R1ght foot operallon

Front suspens1on

Adjustable, ups1de down

telescop1c fork,
d1a 43 mm
Deltabox alum1mum sw1ngarm
w1th adJustable
gaslo1! mano shock absorber

01led fllter element

Rear suspens1on

Fuel
Type
Tank capac1ty
Total
Reserve

Premtum Grade Fuel

12 htres
2 htres

Carburettor
Type
Manufacturer

Y26PV2M
TEIKEI

Spark plug
Type/Manufacturer
Electrode gap

DPR8EA9 or DPR9EA9/NGK
08-09mm

Clutch
Type

Wet, multi d1sc

2-1

583)
588)
200)
954)
792)

Wheel travel
Front
Rear

270mm
209mm

2-2

Pf l

GENERALSPECIFICATIONS
Mode l
Electnc system
lgmbon system
Battery type
Battery capac1ty
Fuse
Generator
Headhght
Bulb spectflcat1ons
Headhght
TatVBrake hght
Turn hghts
Front parkmg hght
"N' (neutra!) lamp
"Htgh Beam~ lamp
"Parkmg hghts" lamp
"Tum hghts" lamp

SPEC

TT600 (E)('94)
T C l (Dtgttal)
CTX9 85
12V BAh
20A
AC 12V
Wtth quartz (halogen) lamp
12V-55/60W
12V21/5W
12V-10W

12V-5W
12V-1 2W
12V1 2W
12V-1 2W
12V1 2W

2-3

p-;

IA-131

"-' lSPEC jtnOj

t l IA-141

MAINTENANCE SPECIFICATIONS jsPECj

MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS

TI 600 (E) ( 94)

Mode l

Cyhnderhead
< Deformatton llmst >

Cyhnder
Bore
< Wear llm1t >
Measurement pomt (a)

Cam shaft
Advance method

a*
m

<003mm>
* The hnes show where you have to s1te the
measunng shde rule

005-010mm

Exhaust

O 12-017 mm

Valve SIZ8S
Suct1on
"A" head d1ameter

369-371 mm

'B~

face Wldth

226mm

~c"

housmg w1dth

10-12mm
1 0-14mm

"D' edge th1ckness

9497-9502mm

<951 mm>
(a)= 50 mm

Exhaust
"A" head d1ameter

319-321 mm

"B' tace w1dth

226mm

''C" housmg w1dth

10-12mm

"D" edge th1ckness

08-12mm

Cham advance (left)

Cam shaft outer d1ameter

22 967 - 22 980 mm

Backlash between cam shaft and cap

0020-0054mm

Suct1on cam s1ze

"A"
Suctson

3647-3657mm

'8'

c
Exhaust

TI 600 (E) ('94)

Mode l
Valves, valve housmg valve gwde
Valve backlash (cold)
SuctlOn

ENGINE

fJ f l

15
{/

"A"

'8"

'\..

"C"

< Cam shaft eccentnc1ty hmtt >

T1mmgcham
T1mmg cham type

Lmk number
T1mmg chatn adjustment method
Rocker/rocker shaft
Rocker outer d1ameter

3006-30 16mm

641 mm
A

~C"

b~a

Rod outer d1ameter

Suct1on

6 975-6 990 mm

3662-3672mm
3011-3021 mm

651 mm

6955-6970mm

Exhaust
GUide 1nner d1ameter
Suctlon

7000-7012mm

<003mm>

7000-7012mm

Exhaust

75-010
126 hnks
Automat1c

Backlash between rod and gwde

Suct1on

12 000-12 018 mm

< Rod eccentnc1ty hm1t >

Valve housmg standard w1dth
Suct1on

Rocker shaft mner d1ameter

11976-11991 mm

Rockershaft backlash

0009-0042mm

0010-0037mm
O 030- O 057 mm

Exhaust

<001 mm>
1 1 mm

Exhaust

11 mm

26

~"D"

'-"

MAINTENANCE SPECIFICATIONS

jSPEC

jtno-jiA-151
fl

TI 600 (E) ('94)

Mode l

lnner spnng

Valve spnngs

Suctton
Exhaust

401 mm
401 mm

438mm

227mm
227mm
Clockwtse

342mm

438mm

Posttlon stze {wtth closed valve)

Suctton
Exhaust
W1nd1ng sense (top vtew)

< Slope llm1t >

342mm
Counterclockwse

Suctton

<25/17mm>

<25/19mm>

Exhaust

<25/17mm>

< 2 5/1 9 mm >

P 1stan
uo~ ptston dtameter

2"' Overstze
4 Overstze

960mm

P1ston allowance
Ptston p1n off centnng
P1ston-cyhnder backlash

20mm
Suctton Stde

< Llmtt >

<O 1 mm >

0045-0065mm

Rmgs
Type
Upper nng
Lower nng

020-070mm

S1de backlash (w1th mounted nng)

Upper nng

004-00Bmm
003-007mm

Lower nng
Scapernng
Mam shaft
uA' shaft w1dth
<'C" off-centnng
llm1t>
'D" backlash
'P' small end backlash

002-006mm

.f.

74 95-75 00 mm
<003mm>
035-065mm
OBmm

Cyllnder gear

272-288mm
6 parts
< 2 6 mm >
2 94-3 06 mm
2 parts
<28mm>
12 mm
7 parts
<02mm>

Clutch spnngs
Free length
Quanttty
Wearhmtt

428mm
5 parts
408mm

cyB

B = 1 2 mm
T=38mm

Clutch plate
Thrust backlash

0070-0071 mm

CJ]s

Clutch release method

lnner cam push1ng

B = 1 2 mm

T=38mm

1-r_..j
Scraper nng

Scaper nng

Trapezo1dal
Rectangular

1-r

Lower nng

030-045mm

Clutch
Clutch d1scs
Th1ckness
Quanttty
< Wear hmtt >
Clutch d1scs
Th1ckness
Ouant1ty
< Wear hm1t >
Clutch d1scs
Thtckness
Quanttty
< Wearhmlt>

955 mm

gl~"

030-045mm

Lower nng

Balancmg we1ght
Advance method

50mm

S1zes (B x T)
Upper nng

End clearance (wllh mounted nng)

Upper nng

94 915-94 965 mm

measurement potnt

TI 600 (E) ('94)

Mode l

Outer spnng

Free length

~H"

MAINTENANCE SPECIFICATIONS jsPECj

~]

8= 25mm
T= 34mm

\..-r-1

2-7

Gear box
< Pnncspal ax1s off-centnng llm1t >
< lntermed1ate shatt off-centnng hm1t >

<OOBmm>
<OOBmm>

Selector
Type

Drum w1th cam and gUide bar

28

p~ l

MAINTENANcE sPECIFI~;,.;oNslsPEcj)Of l
TT600 (E)('94)

Mode l
LubncatiOn system
Otlfllter
Type
Otl pump

Paper type
Trochotdal type
O 12mm
003-00Smm

Type
End backlash
Stde backlash
Shunt valve callbratton pressure

80-120 kPa
(08-1 2 kg/cm 2 , 11 -17 pst)
BO- 120 kPa
(08-12kg/cm 2, 11-17pst)
13 kPa (O 13 kg/cm 2 1 8 pst) at 1,300 rpm
Ot! fllter chamber

Safety valve callbratton pressure

Otl pressure
Pressure check potnt
Carburettor
ldenttftcatiOn 1mttals
MatnJet
Pnmary carburettor
Secondary carburettor
Mam BIT jet
Pnmary carburettor
Secondary carburettor
Jet needle
Pnmary carburettor
Secondary carburettor
Nozzle Jet
Pnmary carburettor
Secondary carburettor

Cutaway
Ptlot atr J91
PIIOtjet
Ptlot output
Bypass 1
Pllot screw
Valve seat
Starter Jet
Fuellevel
Float he1ght
Engme 1dle speed

4GVOO

(MJ)

#145
#110
(MAJ)

01 o
009

(J N)
5098-3/5
5Y16-3/5

(N J)
V-00

(CA)
(PAJ)
(P J)
(PC)
(BP 1)
(PS)
(VS)
(GS)
(F L)
(FH)

00
55
006
#48
08
1o
Approx 2 5 turns open

025
#76
60-SOmm
250-270mm
1 200- 1 400 rpm

lA-16l

MAINTENANCE

SPECIFI~ONS /sPEC/ j5fj l B-1

MAINTENANCE SPECIFICATIONsiSPEC'

ELECTRICALS

Mod el

12V

Vollage

lgnstJon system
Msnsmum spark advance (P M S l )

10-14 al 1,350 rpm

Break t1mmg

6,900-7,100rpm

Spark advance devtce

Electnc type

23 7 - 2a 7 at 0,000 rpm

--

40

<f)

::;;
~
o
c

>
u"
"

"""c.
<f)

Break

94-124at700rpm

30

/---z::

20
/

LWat2745-3,145rpm

10
13-47at350rpm

4
6
7
Eng1ne speed (x 1,000 rpm)

10

Spark UnLt
Modei/Manufacturer

TNDF09/NIPPONDENS0

Psck-up co1l reststance

184- 276 n at 20C (68F)

(colour)

(Green/Whtte, Blue!Yellow)

lgn1110n COli

Modet!Manufacturer

J0268/N!PPONDENSO

Pnmary cOli ressstance

3 4-4,6 n at 20C (68F)

Secondary co11 res1stance

10 4-15 6 n at 2ooc (68F)

TT600 (E)('94)

Voltage regulator/Rectdter
Modei/Manufacturer
Voltage regulator
Type
Uncharged regulated voltage
AeCI1f1er
Capac1ty
Res1stance voltage

TT600 (E)('94)

Model

SH569/SHINDENGEN
Sem1conductors 1n short ctrcUit
143-153V

25A
240V

Battery
Electrolyte dens1ty

1 320

Electnc start1ng system

Type

constant mesh gear

Starter
ModeVManufacturer
Power
Total !ength of brush
<L1m1t>
Man1fold d1ameter
<Limll>
Mtca cut (depth)

SM-13/MITSUBA
08kW
12mm
<5mm>
2Bmm
<27 mm>
07mm

Starter SWIICh
ModeVManufacturer
Rated amperage

MS50 191/HITACHI
100A

Horn
Type
ModeVManufacturer
Max1mum mtenstty

3WW/NIKKO
2 SA

lnd1cator relay
Type
ModeVManufacturer
Automattc stop dev1ce
Flashmg frequency
Power

Hot w1re
301877102/CEV PAGANI
None
60- 120 cycles/m1n
10WX2+34W

CirCUII SWI!Ch d9VIC9

Type
lnd1V1dual amperage

20A

Flat

Fuse

Spark plug cap

Type

Res1n

Spark plug cap res1stance

10 kn at 2aoc (68F)

Charge system
AC magnete generator

Type
AC alternator
ModeVManulacturer

LMZ48/NIPPONDENSO

Recharge output

14V 13,5A at 5,000 rpm

Starter co1l res1stance (wmd1ng)

o 52 -o 78 n at 2ooc (68F)

(colour)

(Whlte- Wh1te)

? 11

2 12

95? l

MAINTENANCE SPECIFIC:;;ONS

lsPECI f>f l l B-21

MAINTENANCE SPECIFICATIONS

CHASSIS

TI600 (E)('94)

Mode!

TI600 (E)('94)

Mode l
Steenng
Beanng type
Front suspens10n
Fork travel
Fork spnng free length
Spnng constant {K)

Optronal spnng
Ori amount
Orllevel

<MIN -MAX >

270mm

460mm
K=40N/mm
(O 4 kg/mm)
None
510 eu cm
90mm
80-130mm
From upper edge
of rnner tube
(fully compressed
wrthout sprmg)

Ori type
Tube external drameter
Rear suspensron
Shock absorber travel
Free spnng length
Adjustment length
Spnng constant (K)
Travel (K)
Optional spnng
Gas pressure

~01" suspensron or!

43mm

61 mm
240mm
222mm
73 N/mm (7 3 kg/mm)
Zero- 95 mm
None
12 kg/sq cm (170 psr)

<1 O mm>
al the rear arm end
Move rear arm from
srde to srde

Srde clearance

04-0?mm
at the rear arm prvot

Front wheel
Type
Wheel s1ze
Wheel matenal
<Wheel eccentnc1ty hm1t>
Vertlcal
Latera!

Wheel SIZe
Wheel matenal
<Wheel eccentnctty hmtt>
Vert1cal
Latera l

Spoke wheel
1 85x21
Alum1mum

Spoke wheel
2 50x18
Alum1n1um
<2 O mm>
<20 mm>

Dnve cham
Type/Manufacturer
Number of hnks
Cham slack

135 ORS-A REGINA CHAIN

110
30-40 mm

Front diSC brake

Type
External d1sc dtameter
Dtsc th1ckness
Pad th1ckness
<Wear hmtt>
Internai master cyhnder d1ameter
Internai cahper cyhnder d1ameter
Quanbty
Brake fJUid type

Smgle
267mm
4mm
75 mm
<3 7 mm>
12mm
28mm
2 p1eces
DOT #4 or DOT # 3

Front brake lever

Brake lever backlash (travel)

10-15mm
at the lever end

Rear d1sc brake

Type

Aear arm

<Ciearance llmrt>

Rear wheel

Type
Taper rolhng bearmg

External d1sc d1ameter

D1sk th1ckness
Pad th1ckness
<Wear hmtt>
Internai master cyhnder d1ameter
Internai cahper cyhnder d1ameter
Brake fiUid type
Brake pedallever
Brake tever free play (travel)
Brake pedal poS1110n

<2 Omm>
<2 Omm>
Clutch lever and throttte gnp
Clutch lever free ptay
Throttte cable free ptay

lsPECI 95f l

S1ngle
220mm
Smm
60mm
<1 mm>
127mm
3023 mm
DOT#4orDOT#3
12-15mm
at the tever end
15mm
betow the footrest
p tane
20-30mm
30-50mm
at the gnp flange

2-14

MAINTENANCE

SPECIFI~ONS ISPECI 95~ l B-3

TIGHTENING TORQUES

MAINTENANCE SPECIFICATIONsiSPECI
TI600 (E)('94)

Mode l

Mode l

TI600 (E)('94)

Thread
SiZS

Part to be t1ghtened

Thread

T1ghten1ng torque

SIZ8

Nm

mk9

M8X125

M12X125

29
20
10
7
1B

29
20
1o
07
1B

M6 x 1 o

10

1o

M6 x 1 O
M32 X 1 5

10
12

1o
12

M8x125
M10x 125
M10X125

x1 O

22
42
42
10

22
42
42
1o

M16 x 1 O

60

60

120

12 o

Head
Boli w1th flange
Stud boli
Hexagon socket head screw
Stud bolt
Spark plug

M10x 125
M6 x 1 O
M6 x 1 O

Cyhnder head covar

Hexagon socket head screw
Tappet covar (1ntake)
Hexagon socket head screw
Tappe! cover (exhaust)
Cyhnder
Cap nut
Nut
Hexagon nut
Hexagon socket head screw
Balancmg sprocket
Hexagon nut
Rotar {A C magnet)
Hexagon nut
Lock nut (valve clearance adJuster)
Hexagon nut

T1mmg sprocket
Bolt w1th flange
T1m1ng cham tens1oner
Hexagon socket head screw
Bolt w1th flange

M6

M14

x15

M6 x 1 o

14

14

M7 x 1 o

20

20

x1O
M16 x 1 O

10
20

1o
20

M6 X10

10

1o

M6 X10

10

1o

M6 X10
M14 x 1 5

7
30

07
30

M6 X10
M5 XOB

10
5

1o
05

M6

Rock1ng levar shaft

Hexagon socket head screw
Oil pump
Hexagon socket head screw
Oil dellvery/return pipe
Pan screw
Oischarge hole (crankcase)
Orl fllter covar
Hexagon socket head screw
Bleed screw

2 15

Note

Oilprpe
Hexagon socket head screw
Otl deltvery ptpe
Jotnt bolts
Carburettor umon
Salt
Clamp (carburettor umon)
Sere w
Atr cleaner case
Bolt w1th flange
Exhaust pipe
Bolt with flange
Exhaust ptpe guard
Cross-slotted screw
S1lencer protecMn
Cross-slotted screw
Clamp {exhaust ptpe and Sllencer)
Bolt w1th flange
Slencer
Bolt w1th flange
Hexagon socket head screw
Crankcase
Hexagon socket head screw
Stud bolt
Crankcase cover {nght)
Hexagon socket head screw
Crankcase cover (left)
Hexagon socket head screw
T ab washer (beanng)
Flat headscrew
Pressure plate
Bolt w1th flange
Clutch hub
Hexagon nut
Pnmary dnve gear
Hexagon nut

Tightening torque

Nm

mk9

M6 x 1 o

10

1o

MB x 1 25

1B

1B

M6 X10

10

1o

M4 x07

02

M6 x 1 o

10

1o

M6 x10

10

1o

M6 X10

07

M6 x 1 o

07

MB x 1 25

20

20

MB x 1 25
MB x 1 25

40
40

40
40

M6 x 1 O
M10x 125

10

20

1o
20

M6 x 1 o

10

1o

M6 X10

10

1o

M6 x10

07

M6 x 1 o

OB

M20 x 1 O

90

90

M20x 1 O

120

12 o

T1ghtenmg toque
Part lo be t1ghtened

95~ l

2-16

Note

a
a
a
a

MAINTENANCE SPECIFI:riONsiSPECI
Mode l
Part to be t1ghtened

Pushlever
Pan screw

D1sengagement contro! rod

Hexagon nut

TT600 (E)('94)
Thread

T1ghten1ng torque

SIZS

Nm

mkg

MB x 1 o

12

12

M6 x10

M18 x 1 O

110

M6 x10

10

M6 x 1 o

10

M6 x10

10

o
1o
1o
1o

M6 x 1 o

07

x1O
x 1 25

7
20

07
20

10

1o

Dnve sprocket
Hexagon nut

T ab washer (011 seal)

Hexagon nut
Stop levar

Bolt
Gearshlft selector
Hexagon bolt
Statorco1l
Pan screw
PlCk

up COli

Pan screw
Neutra! swttch
Starter

Bolt w1th flange

T1ghten1ng sequence
H ead

p~ l

M6
M10

M6x 1 o

l B-4 l

MAINTENANCE SPECIFICATIONSISPECI
Mode l

Note

08
11

TT600 (E)('94)
Thread

Part to be t1ghtened
Front fork/Handlebar
Upper plate and fork shder
Upper plate and lower handlebar fastemng
Lower plate and fork shder
Upper handlebar fastenmg
Upper steenng nng nut and upper plate

p~ l

T1ghtenmg torque

SIZ9

Nm

mkg

MB x125

23
40
23
20
115

23
40
23
20
11 5

M10x125
MB x 1 25
MB

x 1 25

M36x10

Note

see
"NOTE"

Upper steenng nng nut and steenng column

se e

M28x15

~NOTE"

a
a

Lower steenng nng nut and steenng column

Upper fork shder nut (cap)
Lower fork shder nut (cap)
Upper fork pumpmg element nut
Shder and tube guard screw
Brake hose and fork guard screws
Front brake pump and bracket for fastenmg
to handlebar
Front brake pump 011 tank cover
Front brake pump and hose
Front brake cahper and hose
Front and rear brake pump 011 bleeder screw
Hexagon socket head screw far fastemng
front and rear pads
Front brake cahper and fork support braket
Front brake cahper and support braket
Front wheet axle nut
U boli far fastemng wheel axle and fork
FrontiRear brake d1sc and hub
Rear brake pedal/frame/footrest
Rear brake pump and frame
Rear brake 011 tank and frame
Rear brake cahper and bracket
Rear brake cahper and hose
Rear brake pump and hose
Brake cahper guard and rear arm
Sprocket wheel/flange and hub
Rear wheel axle nut
Shock absorber/Rear arm
Rear arm p1Votlrear arm and frame
Rear arm and shock arm
Shock arm and shock hnk
Shock lmkand frame
Shock arm and shock absorber
Shock absorber and frame
Cham shder and rear arm
Cha1n gwde and rear arm
Cham gusde jomt
Cham covar and rear arm
Headhght support and headhght

M2Bx15
M46x 1 O
M22x 1 O
M10 x 1 O
MB x 1 O

M6 x 1 o

30
55
15
07
07

M6 x 1 o
M4 x07

9
2
23
23
6

09
02
23
23
06

18
23
9
59
15
12
45
4
23
26
23
12
30
115

18
23
09
59
15
12
45
1o
04
23
26
23
12
30
11 5

85
58
32
58
32
32
5
9
3
9
7

85
58
32
58
32
32
05
09
03
09
07

M10 x 1 O
M10 x 1 O
M10 x 1 O
M10x 125
MB x125

M6 x 1 o

M14 x 1 5
Ma x125

M6 x10
M10x 125
M6 x 1 O
M6 x 1 O
MB x125
M10 x 1 25
M10 x 1 O

M6 x 1 o

M10x 125
M18 x 1 5

M16 x 1 5
M12 x 1 25
M10x 125
M10x 125
M10 x 1 25
M10 x 1 25
M6 x 1 O

M6
M6
M6
M6

2 18

x1o
x10
x10
x1o

30
55
15
7

10

MAINTENANCE

SPECIFI~IONSISPEC) j)f l

Tllread

Part to be tsghtened

ssze

Engsne assembly
(Front) engsne mount and frame
(Front) engme mount and eng1ne
(Upper) engsne mount and frame
(Upper) engme mount and engsne
(Rear) engsne and frame
Engsne guard on frame
Rsder s footrest and frame
Passenger s tootrest and frame

M10 x 1 25

X10
x1o
x10
X10
x1o
x1o
x10

7
5
5
2
4
20
7
7
7
10
7
3
7

07
05
05
02
04
20
07
07
07
1o
07
03
07

M6 X10
MS x 1 o

7
7

07
07

M8x125

M6
M6
M6
M6
M6
MB
M6
M6
M6
M6
M6
M6
M6

Battery holder frame and trame

Fuel tank and fuel tap
Fuel tank and frame
Helmet holder and frame
Clutch cable and crankcase cover

Number plate holder and taslhght

Start sw1tch and w1res
Regulator and frame
lnstruments/Horn
lnstruments and handlebar crown
Horn and frame

mkg

10
45
20

M10X125
M6 x 1 O
M10 x 1 25

Seat and trame

Nm

64
64
64
64
64
1o
45
20

M10x 125
M10x 125
M10x 125

Tank/Saddle/Cover/Mudguard
Rear mudguard and frame
Frame and number plate holder
Tank and asr ducts
Front mudguard and headhght holder

Tsghtensng torque

X10
x1o
X10
X10
X10

x 1 25

64
64
64
64
64

GENERA L SPECIFICATIONS ABOUT TIGHTENING jsPECj

TORQUES/DEFINITION OF UNITS
GENERAL SPECIFICATIONS
ABOUT TIGHTENING TORQUES

TT600 (E)('94)

Mode l

B-5

Note
Th1s table Lnd1cates thetLghtenLng torques forstandard attachments w1th 180-pLtch thread Torque
specLfLcatLons far spec1al components or umts are
md1cated m the related sect1ons of th1s manual
In arder to avo1d any damage, t1ghten those unLts
w1th many fastemngs by follow1ng a progress1ve
cross sequence, unt1l the fmal t1ghtemng torque
LS obtamed Unless otherw1se specLfLed, the t1ghtenmg torques g1ven are meant for clean and dry
threads Ali components must beat amb1ent temperature

(Nut)

(Boli)

Generai specLfLcatLon
about bghten1ng torques

Nm
6
15

mkg
06

12 mm

6mm
8mm

14mm

10mm

30

17mm

12mm

19 mm

14mm

22mm

16 mm

55
85
130

30
55

10mm

A DLstance between flat parts

B Extemal thread d1ameter

NOTE
1 F1rst tLghten the nng nut at about 38 Nm (3 8 mkg) by us1ng a dynamometnc wrench then loosen
the nng nut by one turn

2 Tighten the rmg nut agam at the specLfLed torque

DEFINITION OF UNITS OF MEASUREMENT

UnLt

mm
cm
kg
N
Nm
mkg
Pa
N/m m

cm'
'P m

2 19

Deftmhon

Meamng
mLihmetre
centLmetre

Measure

10-3 metres
10-2 metres

Length
Length
We1ght

k1logram

1<r'grams

Newton

1 kg x m/se&

Force

Newton-metre
metre per kllo

Nxm

Torque
Torque

mxkg

Paskal
Newton per mm

Nlm 2

Nlmm

Pressure
Spnng constant

L1tre
Cub1c centtmetres

Volume or capactty

Revolutlons per m1nute

Eng1ne speed

2-20

<nO

f' f

15

85
13 o

LUBRicATioN PoiNTs ANo

LUBRICA~YPE jsPEcl Pf l B-6

LUBRICATION POINTS ANO LUBRICANT TYPE

ENGINE
Lubncatton pomts (part name)

LUBRICATioN POINTs ANo LUBRICANr TYPE

CHASSIS

Lubncant type

Otl seal edges (completely)

-m
-m
-m
-m
-m
-m

Beanng retatner
Rod ptns

Rod (btg end)

Ptstons and ptston rmgs
Hub (balancer dnve sprocket)

Ptston ptns

-e
-e

Valve stem and gUJde

Otl seal (valve stem end)

-m
-m
-m

Rocktng lever shaft and rocktng lever

Cam and beanng (camshatt)

Rotar and rotar houstng (ati pump)

lsPEcl Pf l

Lubncat1on pomts (part name)

Lubncant type

Gear umt (tachometer)

011 seal edges (completely)

Wheel axle (front and rear wheels)

Rear wheel hub and clutch

Beanng brasses (rear arm) and push cover

P1vot rod (rear arm)

Beanng brasses (rear shock absorber)

Beanng brasses (shock arm and llnk)

Bearmg (shock arm and llnk)

P1vot pomts (brake pedat and gearshlft selector)

Beanngs (steeenng head)

Gnp end

Dtsengagement contro! rod

P1vot po1nts (brake lever and clutch lever)

Pnmary dnven gear and pnmary shaft

-m

Clutch cabla end

Slldtng gear (transmtsston)

--El

P1vot po1nts (s1destand)

Beanng brasses (cha1n tens1oner)

Grease n1pple (rear arm)

Grease n1pple (shock arm)

Grease n1pple (shock llnk)

-e

Free gear (transmtsston)

-m
-m
-m

Selector torks and ptlot bar

Gearshtft cam and beanng (gearshlft cam)

Gearshlft shaft
Rod houstng coupled surfaces

Bondmg agent (raptd seal adhestve)

Yamaha band No 1215

Coupled surfaces (cyllnder head and cyllnder head covar)

Bondmg agent (raptd seal adhes1ve)

Yamaha bond No 1215

2-21

222

LUBRICATION:::vour!SPECI
LUBRICATION LAYOUT
(1)

011 tank

(2)
(3)
(4)
(5)
(6)
(7}

Olf pump
Olf flfter (o1f tank)
Otl pump suctton (engtne)
Dra1n plug
Otl vapour retneval hose
Od blow-by retr!Elval hose

[A) INTAKE
[B) RETRJEVAL

2 23

ji}fj' l B-7

LUBRICATION LAYOUTISPECI
(1) 0.1 pump
(2) Olffllter
(3) Camshaft
{4) Otl dehvery hose
(5) Mam dnvmg shatt
(6) Ot1ve shatt
(7) 0.1 hose

fA)
(B)

224

JNTAKE
RETRIEVAL

p~ l

__________L_u_aR_,c_AT_,o_N_;=;_v_ou_T!sPEcjp~j
(1)
(2)
{3)
(4}
(5)
(6)

[A) INTAKE
[8[ RETRIEVAL

011 fr/ter

Camshafi

l B-8 l

waRtcATION LAvouT!specj
(1)
(2)
(3}
(4}
(5)

Connectmg rod pm
Mam dnv1ng shatt
Secondary dnve shaft
Drarn plug

Ori pump
01/ fllter
011 delivery hose
/ransmss1on
Oli pump suct10n

[AJ INTAKE
[B) RETRIEVAL

::-::*:*~*'

? 25

226

Pf l

"-'

CABLE ROUTING
11 Complete harness

CABLE ROUTING
1
2
3
4
5
6
7
8
9
10

12 Rubber shroud
13 Clamp
14 Engtne stop SWIICh

Clutch cable
Brake hose gwdes
Brake hose

connectors
15 Headhght harness
connector
16 Left turn hght
connectors
17 R1ght turn hght
connectors
18 Fa1rlead
19 Harness fastenmg
clamps
20 Front brake sw1tch
harness connector
21 lnstruments lamps

Throttle cables
Throttle cables
gu1de
Ughtmg harness
Clamps
Engme stop and
eng1ne start1ng
sw1tch harness
lnstruments lamps
hamess
Tachometer/
Odometer cable

harness connector

22 Ma1n swstch hamess

connector
23 Clutch SWIICh
harness connector

[E Lay the clutch cable

m front of the
harness

[ID Lay the brake hose

through the gu1des
on the fork plates

@]

Lay the harness on

the nght of the mam
SWliCh

[Q] Close the connectors

1nto the rubber

89
l
lsPEciJDf l
shroud and secure
the latter by means
of the clamp

[[] Lay the complete

harness between the
mudguard (m the
prov1ded seat) and
the lower fork plate

''-'

CABLE ROUTING
1
2
3
4
5
6

Front brake hose

Brake hose QUides
Left tube guard
Metal plate

Throttle cables
Tachometer/
Odometer cable
7 Clutch cable
8 Clutch cable fa1rlead
9 Clutch cable stop (on
ang1ne)
10 CDI u011
11 Fa1rlead
12 Horn harness
13 Clamp

14 Fuse
15 Fuel p1pe from tank
tap

16 lnterrmttence
17 Engme 011 breather

!Xl Lay the brake hose

p1pe (lo eng1ne 011

tank)

18 Engme 011 breather

19
20
21
22

23
24
25

p1pe (to a1r cleaner

case)
Sidestand SWIICh
Engme generator
harness
Overflow p1pe
(carburetor)
Fasten1ng clamp for
carburetor overflow
ptpe (to engtne 011
tank)
Dtode
Battery
Relay

[ID

@]

[Q]

2-27

2 28

beh1nd the lett tube

guard and fasten 11
by means of the four
clamps prov1ded on
the latter
Lay the hose behmd
the metal plate
screwed on the tube
(1n the m1ddle o1 the
two fastenmg
screws)
Attach throttle cable
1 and 2
Fasten the overflow
ptpe (carburetor) to
the eng1ne 011 tank
(ustng clamp 22) and
lay 11 between the
shock arm and the
raar arm shock llnks

ISPECIJi'f l

[[] Lay the eng1ne osi

III

breather pspe 17
above the
compensatlon pspe
located on the
carburetor base, and
take 1t to the upper
mlet of the eng1ne 011
tank
Lay the eng1ne 011
breathar p1pe 18
behmd the ang1ne 011
tank and take 11 to
the upper part of the
a1r cleaner case

1~l~ ~r;l~ ~ ~ :~ ~ag~: ~: - :1~1143~2~t~'R{';~~~etor)

~r~br;ea~1 he:r~p;,p:es;- -:~;~C~A~'- . /~B~L~E~ RO~U~T~I~N~G ISPECijUf l l 81

3 Tachometer/
Odometer cable
Tachometer/
Odometer cable
4 f.,rlead
5 R'ghttube guard
6 lgmt,on co,l
7 Spark plug cable
8 Horn

ea b
h r rake sw,tch
15 Ramess
brake flu'd tank
16 Ho f
se rom rear brake
17
to cahper
ear brake hose

9
10 Fuel
Carb prpe
uretor suctlan
prpe

18
1
0 r brake swrtch
9 Rea
verflow hose
(carburetor)

b~~ (to "" cleaner

11 Engme breather

h~::

~ump

gurdes

fonnect to fuel tank

ap throuqh the
"" clamp prov,ded
lnsert mto the rear
"" arm gwdes
8 lnsert the overtlow
P'Pe between shock
ahrm and rear arm
s ock hnks

Rear hamess
2
3

fastensng clam
Rectrfrer earth P
wrre
Rectlfrer

4
5

Rrght tum hght

harness
Left tum hght

~ :n~ert the rear turn

t~e ~~~~~ess through

hamess
6

T ari hght harness

0 ~nsert
the tachometer
~~ble mto the slot on
e nght tube guard

2 29

2-30

_________'-._/_lm\PJJ\
CHAPTER 3
PERIODI C INSPECTION ANO ADJUSTMENT

AEAR SWING ARM LUBRICATION

PERIOOIC MAINTENANCEJLUBRICATION INTERVALS

B-12

SIDE PANELS, AIA DUCTS, SEAT ANO FUEL TANK

REMOVAL ANO INSTALLATION

B-13
B 13

ENGINE
VALVE CLEARANCE ADJUSTMENT
DRIVE CHAIN ADJUSTMENT
IDLE SPEED ADJUSTMENT
THROTTLE CABLE FREE PLA Y ADJUSTMENT
SPAAK PLUG INSPECTION
IGNITION TIMING CHECK
COMPRESSION INSPECTION
ENGINE OIL LEVEL CHECK
ENGINE OIL AEPLACEMENT
ENGINE OIL PRESSURE CHECK
CLUTCH ADJUSTMENT
AIA FILTEA CLEANING
FUEL FILTEA CLEANING
ENGINE OIL TANK FILTER CLEANING
SUCTION HOSE ANO MANIFOLD INSPECTION
FUEL LI NE INSPECTION
CRANKCASE VENTILATION HOSE INSPECTION
EXHAUST SYSTEM INSPECTION

B-14

CHASSIS
FRONT BRAKE ADJUSTMENT
REAR BRAKE ADJUSTMENT
BAAKE FLUI D LEVEL CHECK
BAAKE PAD WEAA INSPECTION
BAAKE HOSING INSPECTION
BAAKE CIACUIT BLEEDING
DRIVE C HAI N TIGHTNESS INSPECTION ANO ADJUSTMENT
DRIVE CHAIN LUBRICATION
FRONT FOAK INSPECTION AND ADJUSTMENT
SHOCK ABSOABEA INSPECTION ANO ADJUSTMENT
STEEAING INSPECTION
TYRE INSPECTION
WHEEL INSPECTION
CABLE INSPECTION AND LUBRICATION
LEVERANO PEDAL LUBAICATION
LATEAAL STANO LUBAICATION

1s-111 -------------------------------- \m\PM~I

B-14
8-15

B-15
B-16
B-16
C1
C-2
C-3
C-4
C6
C6

CB
C-8
C9
C-9
C-9
C-10
C-10
C-10

c 10
C-10

c 11
c 11
C-12
C-12
C-13
C-13
C-14

14

c 15
C-16
D-1
D-1
D-2
D-2

ELECTRICALS
HEADLIGHT LAMP AEPLACEMENT ANO SETTING
FUSE INSPECTION ANO AEPLACEMENT
BATTEAY INSPECTION

D-2

D2
D-2
D-3
D-4

PERIODIC MAINTENANCE/LUBRICATION

INTE~Lsl

IIIJI!'ll

8 12 1

YERIODIC MAINTENANCE/LUBRICATION

INTERVALsl 1~~~ IIIJI!'ll

PERIODI C INSPECTIONS ANO ADJUSTMENTS

EVERY
PART

AFTE A
RUNNING
(1000 km)

NOTES

INTRODUCTION
Th1s chapter l1sts the procedures necessary to perform the recommended mspect1ons and adjustments
Observance of these preventcve mamtenance procedures w1ll ensure proper funct1onmg and tonger !ife far
the veh1c!e
The need far generai overhauls w11l also be conscderab!y reduced
The mformatton whcch foltows apphes to motorb1kes already 1n use and new ones ready far sale
Ali mamtenance personnel should be fam1!1ar w1th the 1nstructcons conta1ned 1n thcs chapter

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Valves

AFTER
6,000 km
12,000 km
RUNNING
(1000 km) or 6 months or 12 months

NOTES

Check valve clearance

o
o

o
o

Adjust 1f necessary
Spark plug

Check cond1t10ns
Clean or replace 1f necessary

A1rfllter

Clean Replace lf necessary

Carburettor~

Check 1dle speed and starter

Adjust 1f necessary

Petrol hne"

Check petrol hoses

Replace 1f necessary

Eng1ne 011

Replace (heat engme pnor to

dumpmg 011)

Eng1ne o1l
fllter*/011 fllter

Replace ftlter element and clean 011

fllter

Brakes*

Check functiOnmg/leakage
See NOTE Correct 1f necessary

Clutch

Check functlonmg/AdJUSt 1f necessary

Rear arm pm*

Check that the rear arm un1t 1S not

loose
Correct 1f necessary Grease and
t1ghten moderately "**

Rear suspens1on
connect1on pms**

Check funct1on1ng
Grease and t1ghten
moderately ....

Wheels"

Check balanc1ng/damage/run-ouV
spoke t1ghteness
Repa1r 1f necessary

3-1

Wheel beanngs*

Check beanng clearance/damage

Replace 1f damaged

Steenng beanngs

Check beanng clearance

Correct 1f necessary
Lubncate moderately every 24 000 km
or 24 months

Front fork"

Check funct!onmg/Oilleakage
Repa1r lf necessary

Rear shock absorber

Check functJonJng/ollleakage
Repa1r 1f necessary

Dnve cha1n

Check cha1n free play/ahgnment

Adjust 1f necessary
Clean and lubncate

EVERY
PART

6,000 km 12,000 km
or 6 months or12 months

Every 500 km

Assembhes/
clamps

Check an assembhes and clamps

T1ghten 1f necessary

Latera! stand*

Check functtonmg
Repa1r 1f necessary

Latera! stand
SWitCh"

Check funct1onmg
C!ean or replace 1f necessary

Ma1ntenance work on these elements should be performed by a Yamaha dealer

Med1um-cons1stency beanng grease
L11h1um soap-based grease
NOTE:
Brake hqUid replacement
1 After d1sassembhng the pump and cahper cyhnders, replace the brake hqUid Check the level of the
hqUid regularly and top up 1f necessary
2 Replace the gaskets IOSJde the pump and cahper cyllnders every 2 years
3 Replace the brake hoses every four years or when they are cracked or damaged

3-2

'-..../

SIOE PANELS, AIR OUCTS, SEAT ANO FUEL TANK

IINSP
ADJ

llf!'.ll IB-131

SIOE PANELS, AIR OUCTS, SEAT ANO FUEL

SIDE PANELS, AIR OUCTS, SEAT ANO

FUEL TANK

Seat
After removmg the s1de panels, unscrew the 2
fastenmg screws on the rear cf the seat
Ra1se the rear of the saddle and free the front by
pressmg downwards T o reassemble set the front
of the seat mpiace, checkmg that the fuel tank pm
f1ts mto the ho le on the se at and that the seatflapf1ts
mto the correspondmg hollow m the chass1s Lower
the rear of the seat and fasten w1th 2 screws

REMOVAL ANO INSTALLATION

3
Hold the motorblke f1rmly In piace to prevent lt
fall1ng

l
123 Pane! fastenmg po1nts

TANKI 1~5~ jl!!'.lj

Seat fastenmg screws

S1de panels

The s1de panels are pressure-sealed at three fastenlng po1nts

Before usmg the motorcycle, check that the

seat ls f1rm1y in piace.

T o remove, release the 2 rear pomts and then the

frontone, freemg them from the a1r duct fastemng
flap on the fuel tank
T o reassemble f1t the front part ofthe panel mto flap
and then press on the fastenmg po1nts to f1x them

/xl

Seat screws

4 Nm (0.4 mkg)

properly mto the1r hous1ngs

2 Fuel tank fasten1ng hole
3 Chass1s fastemng flap

Panel fastemng to a1r duct

Fuel tank
Before d1sassembhng the tank remove the seat
f1rst

Alr ducts
T o remove the a1r ducts remove the two fastenmg
screws and free the flaps tram tank and s1de panel
When remstalhng the atr duct, f1t the rear flap m the
pane l and the tastemng flap to the tank, then t1ghten
the fastemng screws

I!Wft.i;lil@i --,.---,.----,.-eetore d1sassembhng the tank, check that the

flller cap ls firmly screwed and that the tap ls In
the OFF posltlon.
Rear fasten1ng screw
2 Fuel hose

Unscrew the rear fastemng screw on the tank,

detach the eiam p from the fu el ho se shde the latter
from the tap and remove the tank by ra1s1ng 1t
backwards and releasmg 1t from the front rubbers
T o reassemble, f1tthe front t o the fasten1ng rubbers
and t1ghten the rear screw

Tank fastemng screw

2 Tank fastenmg flap

3 Panel tasten1ng flap

I!IWt.i;IN@1
After reassembllng the tank, reconnect the fu el
ho se by fittlng lt flrmly onta the tap and Jockmg
lt with the clamp.

3 Front fastemng rubbers

lxi
3-3

34

Fuel tank

7 Nm (0.7 kgm)

VALVE CLEARANCE

ADJU~MENT 1m l~!i~ l 1a-141

VALVECLEARANCEADJUSTMENT~I~8f ifii

ENGINE

Turn the dnvmg shaft antJclockw1se usmg a

wrench
VALVE CLEARANCE ADJUSTMENT

NOTE:
Valve clearance must be adjusted when the

eng1ne 1s at amb1ent temperature

Adjust valve clearance w1th the p1ston under

compress1on at top dead centre

CAUTION:

Ahgn
Reference mark 'T on the flywheel (1)
Wl th the f1xed reference mark on the crankcase (2)

When removmg the spark plug an d tappe t cover,

be careful not t o drop fore1gn objects 1nslde the

NOTE.

engme.

Check that the p1ston IS under compressron at top

dead centre

11 1
''''Mh
t't i ----------Hold the motorcycle f1rmly m piace t o prevent l t
falhng over dunng the operat1on

(3)

lgnlton t1mmg reference mark

Check
Valve clearance
Out of specLflcatLon ""') AdJUSt

Aemove

S1de panels

A1r ducts

Seat

Fuel tank
See the sectiOn "SIDE PANELS, AIR

Valve free play {cold)

Suct1on
0.05-010 mm

Exhaust
012-0.17mm

OUCTS, SEAT ANO FUEL TANK' above

8
2

DISCOnnect

*. *. * * * ** "* * *'** * * .....

AdJUStment:
Loosen the lock nut ( 1)
F1ta thrcknessgauge (2) between the rockerarm
and the valve spmdle
Turn the adjuster (1) clockwse or antlelockwlse
usmg the spec1al tool (2) to obtam the req01red
clearance

Remove
Spark plug
Tappet cover (2) (suctiOn)

Spark plug cap (1)

AdjUSt
Valve clearance

Tappet cover (3) (exhaust)

Remove
Cap (1)
Cap (2)

Spec1al tool
P/N YM-08035
P/N 90890-01311
Hold1ng the adJUSter frrmly 1n piace lock t1ghten
lock nut

3-5

3-6

DRIVE CHAIN ADJUSTMENTIINSP ~~~

IDLE SPEED ADJUSTMENT. ADJ .~.

1~1

DRIVE CHAIN ADJUSTMENT

Lock nut:

The dnve cham does not need to be adJUsted

14 N m (1 4 mkg)

Measure valve c!earance

lf the clearance ts mcorrect, repeat the preveous

stages to acheeve the reqwed value

Reassemble

IDLE SPEED ADJUSTMENT

Start the engene and let et heat
2 Connect

Caps
Tappet cover (sucMn)
Tappet cover (exhaust)
Spark plug

10 Connect

Spark plug cap

Spec1al tool
P/N. YU08036A

.~ Tappet cover {exhaust):

~ 12 Nm (1.2 mkg)

P/N. 9089003113
3

Bolt (tappet cover):

Check
The engme tdle speed
Out of spectftcatton -7 Adjust

10 Nm (1.0 mkg)

Spark plug.
18 Nm (1 8 mkg)

Engme tdle speed:

NOTE:
The tappet cover (suctlan) should be mounted weth
arrow (1) pomt1ng upwards

The enductlve engrne speed endecator to

the spark plug cable

1,200-1,400 rpm

.,.._

.-...

AdjUSt
Engme td!e speed

AdJUStment:
Turn the thrott!e arrest screw (1) etther way to

'

obtatn the tdle speed reqUJred

lncreases tdle speed
Decreases tdle speed

11 Reassemble
Fuel tank

Seat
Aer ducts

Stde panels

See secteon 'SIDE PANELS, AIA DUCTS,

SEAT AND FUEL TANK"

1~1

..............................................
NOTE:
After settmg the tdle speed adjust the accelerator
cable free play

Seat screws:

4 Nm (0.4 mkg)

38

Otsconnect
lnducttve engme speed tndtcator

THROTTLE CAB LE FREE PLAY ADJJs'TMENT

1 1111 18 -1 &1

SPARK PLUG INSPECTIONI

THROTTLE CABLE FREE PLAY

ADJUSTMENT

NOTA-

Before adjustlng the throttle cable free p!ay adjust

the engme 1dle speed

Seat
Fuel tank

Seat

A1r ducts
S1de panels

Seat screws.
4Nm (O 4 mkg)

Remove
S1de panels
A1r ducts
Seat
Fuel tank
See sect1on' SI DE PANELS, AIR DUCTS
SEAT AND FUEL TANK"

See sectJon SI DE PANELS, AIA DUCTS

SEAT AND FUEL TANK

SPARK PLUG INSPECTION

A1rducts

Reassemble
Fueltank

1~1

Remove
S1de panels

m1111

Check
Throttle cable free play (a)
Out of spec1flcatLon-+ AdJuSt

Throttle cable free play

D1sconnect
Spark plug cap

Remove
Spark plug (1)

3-5mm

CAUTJON:
3

When remov1ngthe spark plug, be careful not t o

drop fore1gn objects ms1de the engme

AdjUSt

Throttle cable free play

4
Adjustment
Loosen the throttle cable (2) lock nuts (1)
T urn the adJuster (3) clockw1se or ant1clockw1Se

to obta1n the reqUired free play

lf after toosenmg the adJuster by 5mm, the free
ptay 1S stili notcorrect, t1ghten the adjuster (4) on
the throttle cable (5) once more
T1ghten the lock nuts

Standard spark plug

DPR8EA-9(N G K ), DPR9EA-9(N G.K.)

(1), (6) Lock nuts

3-9

lnspect
Type of spark plug
lncorrect-? Replace

3 10

lnspect
Electrodes (1)
Wear and tear/damage -? Replace
lnsulator (2)
Normal1nsulator (2) colour 1s hght tan

C-1
6

Clean the spark plug w1th a swtable tool and a

steel brush

Measure
Spark plug electrode gap (a)
Use a wtre or thtckness gauge
Out of speclfJCatton -7 Regap

IGNITION TIMING CHECK

lmlfil

IGNITION TIMING CHECK

1

Start the engme and let 1t heat

Connect
lnducttve rev counter
Stroboscoptc lamp to spark plug cable

lnductive engme speed mdtcator:

Electrode gap:
0.8-09 mm

P/N. YU-08036-A
P/N. 90890-03113

Stroboscop1c lamp.
Lock ttghten
Spark plug
Before mstallmg the spark plug, c!ean the
surtace and thread

1~1

P/N. YM-33277-A
P/N. 90890-03109

Spark plug
18 Nm (1.8 mkg)

CAUTION:
In certam cond1tions, the otl mtght spray out
when the cap is removed. Be careful therefore
when removmg the cap

NOTE
Ttghten the spark plug by hand before torqutng to
spectftcatton

Remove
Cap (1)

Connect
Spark plug cap

Check
Advance tgmtton

10 lnstall

Check:

Fuel tank
Seat
A1r ducts
Stde panels

Heat engtne and lei 1t run to the number of revs

reqUJred

Engme tdle speed

1,200-1,400

1~1

g~n/mm

Seat screws.
Check that reference mobile (1) ts m the mobtle
fteld of reference (2) on the flywheel
lncorrect tgnttlonttmtng ~Check the tgnttton cotl
untt

4 Nm (O 4 mkg)

NOTE:
lgmtton ltmtng cannot be adJusted
~~~~

5
6

3 11

3-12

lnstall
Cap
Remove
Stroboscoptc lamp
lnducttve engme speed mdtcator

COMPRESSION

INSP~ION l

111.!!11

COMPRESSION INSPECTION
NOTE

C-2

COMPRESSION

t::J

lnsuff1C1ent compresston causes a loss of performance

Set the motorcycle firmly 1n piace to prevent 1t

falllng durmg the operatJon.

Remove
S1de panels

Atr ducts
Seat

Fuel tank
See sectiOn 'SI DE PANELS, AIA DUCTS,

SEAT ANO FUEL TANK"

Check
Valve clearance
Out of specfcatiOn-? AdJUSt
See sectiOn "VALVE CLEARANCE AD
JUSTMENT
3 lnstall
Secondary fuel tank
4 Start engme and let 11 heat
Sw1tch off engme
5 Dtsconnect

Spark plug cap

Remove
Spark plug

CAUTION:

When removmg the spark plug, be careful to

prevent fore1gn bod1es from droppmg ms1de
theengme.

Apply

313

Pressure gauge (1)

Adapter (2)

Pressure under compressaon

(after addmg 011 to the cyhnder)

Pressure gauge:
P/N. YU33223
P/N. 9089003081
Adapter
P/N. YU332233
Extenston
P/N. 9089004082

lti'Mhhi@N
8

Check
Pressure under compress1on

* * *. * * * * ** * * * * ** .... * * * * *

lnspectton
Check that the battery 1s fuUy charged and rev
the engme w1th the starter Hold down the
accelerator untll the readmg on the pressure
gauge ts stable

Readmg
Pressure h1gher
than before.

D1agnos1s
P1ston worn or
damaged.

Pressure sa me as
before

Cylmder h e ad or
p1ston rmgs, valves,
gaskets may be
faulty.

Pressure above ma xmumvalue

lnspectcyhnderhead,
valvesurfaces, p1ston
nm to check for carbon depos1ts

..................................
9

l!fii;W@N -:-:--,..---..,.,---..,.
Wh1le operat1ng the starter, dtsconnect the spark
plug capto avo1d sparks

Compare the pressure readmg wth those m the

table
Pressure under compress!on.
Standard:
1,100 kPa (11 kg/cm 2 , 156 pst)

Remove
Secondary fuel tank
Pressure gauge (w1th adapter)

1O Reassemble

1~1

Spark plug
See sect1on 'SPARK PLUG INSPECTION'
Spark plug
18 (1 8 mkg)

11 Connect

Mm1mum.
900 kPa (9 kg/cm', 128 ps1)

Spark plug cap

12 Reassemble

Max1mum
1,200 kPa (12 kg/cm~. 171 ps1)
lf the pressure read1ng IS lower than mm1mum
1) Adda few drops of 011 to the cyhnder through
the ho!e m the spark plug
2) Measure the compresston agam
3) Compare the new readmg wth the f1rst then
proceed accordmg to the md1cattons 1n the
table

ADJUSTMENT~I~~~ ifil

1~1

3-14

Fuel tank
Seat
A1r ducts
S1de panels
Seat screws
4 Nm (O 4 mkg)

ENGINE OIL LEVEL-:;;:ECK

lml~!~!~il

ENGINE OIL LEVEL CHECK

C-3

ENGINE OIL LEVEL CHECK

lf the mllevel1s below mm1mum ~ Add 011

up to max1mum level

CAUTION:

Recommended 011:
SHELL SU PER 4TX 20W/50

Do not put addittves lnto the englne oli The

latter also lubncates the clutch and addttlves
might cause lt to shde

Reassemble the mi tank cap

Startthe eng1ne and heat untll the temperature

reaches 60C or thereabouts

''"'';'tl@1
----------Never remove the oli tank cap when the engme
IS hot The boillng oli maght sptll over, causmg
burns. Wait for the oli to cool to at least 60 or

thereabouts

lml~!~!~il

;CAUTION:
Never start the englne when the oli tank 1s
empty

Thts mode l ts fitte d wtth a dry crankcase lubncatiOn

system A teed pump deltvers otito the engme, after

Run the engme at Id le speed for about 1O

seconds, holdmg the motorcycle f1rmly upnght Turn off the eng1ne and add 011 up to the
max1mum level

Replace the 011 tank cap

fully lubncatlng the laner the otlts returned to the

tank by a scavenge pump The Oti leve! must
therefore be checked m the otltank

2
3

Set the motorcycle level and hotd tt upnght

Unscrewthe otl tank cap (1) and clean the cap
stem
lnsert the cap sucker rod mto the tank Do not
unscrew, stmply piace on the ftller
Pull out the rod and check the otl leve! The
latter must be between the m1n1mum and
max1mum levels (2) and (3)

011 capac1ty.
Total
2.8l1tres
Penod1c 011 change
2.2 htres
W1th f1lter oli change:
2.3 htres

NOTE
T o check the Olllevel, piace the capw1th the rod on
the f1ller w1thout unscrewmg 1t
For an exact check, hold the cycle upnght

315

011 tank capaclty

1.8 lltres

3 16

R_E_P_LA_~_EM_E_NTI m1&1 1 c-4

_ _ _ _ _ _ _ _ _ _E_N_G_IN_E_O,_L

ENGINE OIL REPLACEMENTI

ENGINE OIL REPLACEMENT

m1&1

lnspect

Ali gaskets
Damaged ~ Replace

CAUTION:

Do not put addlttves tnto the englne oli The

latter also lubncates the clutch and additlves
mtght cause lt to sllde.

Reassemble

Fslter cover screw

Otl fllter cover bleeder screw
Engtne dratn screw

011 tank dram screw

W!*M';lf!!Ni -------,----

Fastenmg torques.

Never remove the otl tank cap when the engme

Oram screw (englne)

30 Nm (3.0 mkg)

ts hot. The boiling oli mtght spii l over, causlng

burns. Walt far the oli to cool to at least 60 or
thereabouts.

Dram screw (otl tank}

18 Nm (1.8 mkg)
Fllter cover screw
10 Nm (1.0 mkg)

Englne oli replacement (wtthout replacmg fllter

oli).
Start the engme heat ti far a few mtnutes then
swttch off
2

Cover atr bleeder screw

5 Nm (0.5 mkg)

Piace a contamer under the engme and oli

3-17

Ftll

tank
Remove
011 tank cap
011 tank dram screw (1)
Engme dram screw (2)
011 fllter cover bleeder screw (3)
F1lter cover screw (4)

011 tank

Recommended oli
SHELL SU PER 4TX 20W/50

Oli capac1ty
Penod1c change 2 2 lltres

CAUTION:

Dram
Eng1ne 011 completely

Be careful to prevent fore1gn bod1es droppmg

mto the englne.
Do not put add1t1ves lnto the engme oli. The
latter also lubncates the clutch and the addlttves may make it sllde.

318

ENGINE OIL

REPLAC~ENTI

1. . . 1

lnstall
011 tank tap

Check
Oillevel
See sect1on "ENGINE OIL LEVEL CHECK"
011 pressure
See sectton "ENGINE OIL PRESSURE
CHECK"
Ollleakage

C-5

ENGINE OIL REPLACEMENT

Englne oli replacement (with oli f1lter

1

Start the engme, heat 1t up fora few m1ntues,

then turn 1t off

Piace a contamer under the engme and ol

tank

Aemove
011 tank cap
011 tank dram screw (1)
Engme dram screw (2)

Osi f1lter covar bleeder screw (3)

F1lter covar screw (4)

Remove
011 fllter cover (5)
F1lter cartndge (6)

lnspect
Ali gaskets

Onngs (7)

Damaged ? Replace

Reassemble
(New) ftlter cartrtdge
Ftlter cover screw
Otl ftlter cover bleeder screw
Engtne dratn screw
Otl tank dratn screw

Draln screw (englne):

30 Nm (3.0 mkg)
Dra1n screw {oli tank)
18 Nm (1 8 mkg)
F1lter cover screw
10 Nm (1.0 mkg)

Eng1ne 011 completely

Cover bleeder screw:

5 N m (0.5 mkg)

NOTE
The 011 fllter covar 1s fastened w1th 3 screws The
lower sere w must be removed f1rst to allow the f1lter
to dra1n

3 19

lnspect
Ali gaskets
Damaged ~ Replace

Fastemng torques.

Dra1n

replacement)

lm l~!~~!'i~ l

3 20

ENGINE OIL
9

m11!511

REPL~MENT l

C-6

ENGINE OIL PRESSURE CHECKJIINSP 1~1

CLUTCHADJUSTMENT ADJ -~-

'----'--'=.;,'---'-----'

ENGINE OIL PRESSURE CHECK

F1ll
011 tank

Remove
Bleeder sere w ( 1)

Recommended o l
SHELL SU PER 4TX 20W/50

Oti capaclty.
Total
2.8 htres

Start the eng1ne and let tt run at 1dle speed tar

a few seconds

lnspect
Condtons of 011 at bleeder hole
01! leakage -+ Otl pressure good
No leakage ~ Pressure msuff1C1ent

Penodtc oal change:

2 2 htres
Wlth 011 f1lter change

2 3 htres

CAUTION:

011 tank capacaty

1.8 htres

lf the 011 does not come out atter one mmute,

stop the englne 1mmed1ately t o prevent se1zure

CAUTION:
4

Be careful to prevent fore1gn bod1es dropp1ng

mto the engme crankcase
Do not ad d addit1ves t o the eng1ne 011. The latter
al so lubncates the clutch an d the add1t1ves may
make 1t shde

T1ghten
Bleeder screw

/~l

Bleeder screw
5 Nm (O 5 kgm)

1 o lnstall

011 tank cap

CLUTCH ADJUSTMENT

11 Check
Oillevel
See sect1on 'ENGINE OIL LEVEL
CHECK'
011 pressure
See sectiOn 'ENGINE OIL PAESSURE
CHECK"
011 leakage

Cable free play adJUStment

1

Check
Clutch free play adjustment {A)
Out of speCifiCatiOn -? AdjuSt

~
2

Freeplay
10-15mm

AdjUSt
Clutch cable free play

AdJustment
Loosen lock nut {1)
Turn the adjuster {2) e1ther way to obta1n correct
free play
T1ghten lock nut after adjustment

3-21

3 22

CLUTCH ADJ;;s,:MENTI

Jl!!!lliiJ

C-7

CLUTCH ADJUSTMENTI

m jl!!!llilj

11 lnstall
R1ght crankcase cover
011 dehvery hose fastemng screw

NOTE.

After ad)ustment, recheck lever free play to make

sure that 1t works smoothly and progresstvely
lf 1t 1s tmpossJble to obtam the reqUired ad]ustment
or 1f the clutch does not work properly, adJust the
Jnternal mechamsm

Screw (crankcase cover).

10 Nm (1.0 mkg)

Oli dehvery hose screw

Internai mechamsm adJustment

18 Nm (1 8 mkg)

1 Loosen

Lock nuts (1) on the lever cable adJUSters

12 Connect
Brake pedal return spnng

and crankcase
2
3

Fully ttghten
AdJusters

Dram oft

Eng1ne oli
See sectron 'ENGINE OIL REPLACE

MENT
4

13 Reassemble

\~\

Remove

DJsconnect
Brake pedal return spnng

Remove
011 dellvery hose tastenmg screw (3)

MENT
15 AdJUSt

Rtght crankcase cover (4)

7 Loosen

Clutch cable free play

Free play (at lever t1p)

Locknut(1)

10 ..... 15 mm

Push the engtne clutch controllevel forward to

the stop po1nt

Se e se etiO n CABLE FREE PLA Y AD

AdjUSt

JUSTMENT

Free play
Wtth the lever m th1s postt1on turn the
adJUSter (2) elther way untll the marks on
the lever (3) an d crankcase (4) are ahgned

10 T1ghten

\~\

3 23

Bolt (footrest)
45 Nm (4 5 mkg)

14 F1ll

Engme 011 tank

See sectiOn 'ENGINE OIL REPLACE

Footrest (nght) (2)

Footrest (nght)

Locknut(1)
Lock nut.
8 N m (O 8 mkg)

3-24

AIRFILTERCL~INGII~~~ lgl

AIR FILTER CLEANING/1 lNSP ~~~

FUEL FILTER CLEANING '-'-'A,_,D~J<-L.~---'

C-8

AIR FILTER CLEANING

2 Unscrew

Apply

Commongreasetofllterelementsealedge
10 lnstall
F1lter element mto housmg
11 Screw
W1ng nut
12 Reassemble
F1lter case cover
F1lter case cover fastenmg clamp
S1de panel (nght)

Remove.
S1de panel (nght)
F1lter case cover fastenmg belt (1)
F1lter case cover (2)
Wmg nut (3)

3 Pull out
Fdter element (4)

NOTE:
When mstalllng the fllter element mto 1ts case be
su re that the surtace of the seal f1ts to the matchmg
surtace on the case to prevent a1r from entenng

'CAUTION:
The engme must never be started wlthout the

alr fllter element, as thls would cause undue

wear and tear of the piston and/or cyhnder.

FUEL FILTER CLEANING

4 Separate
The f1ltenng element from 1ts gu1de

Turn the fuel tap to "OFF'

Remove
Rtght-han tank arr duct
3 Dsconnect
Fuel hose from tap
4 Drsassemble
Tank tap
5 Wash
Fuel fdter (1) w1th solvent
6 lnspect
Fuelfllter(1)
Gasket (2)
Damaged ~ Replace
7 Reassemble
Fuel f1lter to tap
Tap to tank
Fuel hose to tank
R1ght a1r duct to tank

5 Wash

The ffltenng element w1th solvent

NOTE:

After clean1ng, remove the remammg solvent by

squeezmg, but not tw1St1ng the element

9>

6 lnspect
F1lter element
Damaged ~ Replace
7 Apply
SAE 10W/30 engme mi ali aver f1lter sur
fa ce
8

--- ---

_,

l~

9,

Squeeze aut
Excess 011

NOTE
When reassembllng thetap, be careful nottot1ghten
the fastemng screws unduly, as the gasket m1ght
leave rts hous1ng and cause fuelleakage

NOTE:

The element should be wet but not dnpp1ng

3-25

3 26

ENGINEOILTANKFILTERCL~INGimli!!al 1 c-9

SUCTION HOSE ANO MANIFOLO INSPECTIONi,JNSP ~~~

FUEL LINE INSPECTION ADJ ~

ENGINE OIL TANK FILTER CLEANING

SUCTION HOSE
INSPECTION

Piace a co'ltane= under the 011 tank

2

Remove
011 tank cap
Ori dram cap (1)
Dratn the mi from the tank
011 hose connecttons (2)
Tank fasten1ng screws (3)

Carburettor
Otl tank

3 Clean

Otl ftlter (4)

Cleantheftlterbyblowtngwtthcompressed
a1r

011 tank (5) wtth solvent

t'\ '

Reassemble
01ltank
Carburettor
011 hose connecttons
011 dra1n hose

Atr ducts

Se at
Fuel tank
See sect10n uSI DE PANELS, AIA DUCTS,
SEAT ANO FUEL TANK"

lnspect
SuctiOn hoses (1)
Cracked/damaged-+ Replace

Stde panels

NOTE:
After cleamng the ms1de remove the remasnmg
solvent

MANIFOLO

Remove

ANO

Screw (2) (carburettor mamfold)

10 Nm (1.0 mkg)
Screw (3) (flange)
2 Nm (O 2 mkg)

Reassemble
Fuel tank
Seat
A1r ducts
Stde panels

1~1

Seat screws.
4 Nm (O 4 mkg)

011 hose connectlons:

FUEL UNE INSPECTION

50 Nm (5.0 mkg)

011 drain hose:

Aemove
A1r ducts
See sectlan "SI DE PANELS AIA DUCTS,
SEAT ANO FUEL TANK"

18 Nm (1.8 mkg)

Fili

Engme 011 tank

See sect1on uENGINE OIL REPLACEMENT

Reassemble
011 tank cap

327

3 28

lnspect
Fuel hosmg (1)
Cracked/Damaged
Reassemble
A1r ducts

-+ Replace

INSf~

1~1

CRANCKCASE VENTILATION HOSE

ION/IINSP
EXHAUST SYSTEM INSPECTION .__'-A"-'0"-J"'-.J_'-~----'-

lC-1 ol

FRONT BRAKE ADJUSTMENTi,INSP ~~~

REAR BRAKE ADJUSTMENT _ ADJ .~.
CHASSIS

CRANCKCASE VENTILATION HOSE

INSPECTION

FRONT BRAKE ADJUSTMENT

lnspect

Check

Crankcase ventllallon hose (i)

Cracked/Damaged -+ Replace

Free play at t1p of brake lever (a)

Out of specfcat1on -+ AdJUSt
Free play (at t1p of lever).

10-15mm
2

EXHAUST SYSTEM INSPECTION

lnspect
Exhaust p1pe (1)

AdJustment.

S1lencer (2)

Gaskets (3)
Exhaust gas leakage

Cracks/Damage

AdjUSt
Brake lever free play

Turn the adJUSter (1) elther way to obtam the

correct free play

-+ Replace
-+

Free play damm1shes

Replace

Free play mcreases

Nut (4) (exhaust p1pe).

10 Nm (1.0 mkg)
Screw (5) (sllencer)
40 Nm (4 O mkg)

CAUTION

Proper lever free play 1s essent1al to avo1d

Boli (6) (flange).

undue brake pad fnct1on

20 Nm (2 O mkg)
Screw (7) (protect1on).
7 Nm (0.7 mkg)
Use LOCTITE

REAR BRAKE ADJUSTMENT

Check
Brake pedal he1ght (a)
Out of spec1f1caton ~ AdJust

Screw (8) (protect1on).

7 Nm (O 7 mkg)
Use LOCTITE

Brake pedal he1ght

15mm
Under top of the footrest

AdjUSt
Brake pedal he1ght

AdJustment.
Loosen lock nut (1)
Turn the adJuster (2) e1ther way to obtam the
correct pedal he1ght

3-29

330

~ENT/IINSP
1~1
ADJ ~

REAR BRAKE ADJL

BRAKE FLUID LEVEt-HECK

lC-11 l

BRAKE PAD WEAR INSPECTIONI

Free play (a) dJmJmshes

W!fii;W@1 -----------

Free play (a) mcreases

Use only brake fiUid in conform1ty with pre

scribed standards, otherw1se the rubber gas
kets risk detenoratmg, causmg fluld leakage
and poor brake performance
Always use the same brand of fiUid The
m1xmg of flu1ds could provoke a chemcal
react1on wh1ch would, tn turn, result 10 poor
brake pertormance
When addlng flu1d be sure that no water or
foreign bodres enter the the pump tank Wa
ter would iower the boiling point, generating
vapour bubbles durmg brakmg

ftld;if!!Nj
Atter adJUStmg brake peda\ he1ght, observe the

t1p of the ad)uster through hole (1) m the con

nectlon holder support The t1p of the adJUSter
should appear In the hole.
T1ghten lock nut

1~1

ml~~!!i~l

Lock nut.
26 N m (2 6 kgm)

BRAKE PAD WEAR JNSPECTIDN

{A]

BRAKE FLUID LEVEL CHECK

FRONT

NOTE.
When checkmg the level of the fiUid make certan

Wear lim1t (a).

Front 1 O mm
Rear O8 mm

that the pos1t1on of the motorcycle lS leve\ and

pertectly upnght and, turnmg the handlebars, that
the top of the front pump cover 1s 1n a honzontal
pOSIIOO

(b)

{B)

lf the level1s below the m1n1mum LOWER"

(1)-+ F11l

[A}
(8]

Recommended brake fiUid'

DOT No 4 or DOT No. 3

CAUTIDN:

The brake fiUid may corrode pamted surtaces

and plast1c parts

3 31

Wear 10d1cator
Far brake pad replacement, see secbon
"'BRAKE PAD REPLACEMENT" In Chap
ter6

lnspect
Level of brake flwd

REAR

Operate the brake iever or brake pedal

Check
Th1ckness of fncttonal matenal
Out of spec1f1caton -+ Replace

3-32

Front brake
Rear brake

1~1

BRAKE HOSING INS'

,flON/IINSP
BRAKE CIRCUIT BCI!EDING _ ADJ _~.

lC-121

BRAKE CIRCUIT BLEEDING

BRAKE HOSING INSPECTION

Atr bleedmg procedures

lnspect

l~ lfil

a Top up the level of the flUid m the tank to

max1mum

Brake hostng
Cracks/Damage ~ Replace
To replace hosmg, see sectton "FRONT
AND REAR BAAKE' m Chapter 6

b lnstall the d1aphragm Be careful not to sp1ll fiUid

or let 1t overflow from the tank
c Connect the clear plast1c hose (1) to the callper
bleeder screw
[A]

Front

IBJ Rear
d Piace the other end of the hose m a contamer
e Slowly pull the brake lever or press the brake
pedal several tlmes

!Al Fronl
[8]

Pull the brake lever nght m or press the pedal

nght down and hold 1n pos1t1on

Rear

g Loosen the bleeder screw and allow the lever or

pedal to travel slowly towards 1ts llm1t

BRAKE CIRCUIT BLEEDING

t!W1f.1;HIIN1 --:--:----:----~-

h T1ghten the bleeder screw when the lever or

pedal llm1t has been reached, then release the
lever or pedal

lt the brake lever or brake pedal has a soft or

slack feel, thts means that there ts atr m the

1~1

brake system. lt should be bled away before

usmg the cycle Atr m the system senously
affects the effectlveness of brakmg and may
cause loss of contro! of the motorcycle.
In ali cases, bleed the brake system tf
The system has been dtsassembled.

Bleeder screw:
6 Nm(O 6 mkg)

1 Repeat operattons (e) to (h) unt1l ali the a1r

bubbles have dtsappeared from the clear plast1c
hose (1)

A brake hose has been Joosened or removed

The brake flutd m the tank ts at a very low
leve!

NOTE
lf bleemg proves dlff1cull, 11 may be necessary lo
allow lhe brake flu1d system to stab11ise far a few
hours Repeat the bleed1ng procedure when the
ttny bubbles 1n the system have d1sappeared

Brake operatton ts faulty.

J Top up fiUid to the max1mum tevel

3 33

3-34

j~j

DRIVE CHAIN TIGHTNESS INSPECTkJNDIINSP

ADJUSTMENT ADJ .~

DRIVE CHAIN TIGHTNESS INSPECTION ANO

ADJUSTMENT

lnspectlng tlghtness
NOTE.

Before check1ng and/or adJUStlng the cham, rotate

the rear wheel through severa! revolutJons and

check the t1ghtness several t1mes to f1nd the pomt

on the wheel where cham t1ghtness 1S h1ghest
Check anc:tlor adjust chaJntJghtness w1th rearwheel
In lhiS "t1ght Ch810~ pOSIIOO

Check
Dnve cham slack (a)

Out of specdJcatJon

AdJuSt

lU\_~ Onve c ha in slack.

(61

lC-131

DRIVE CHAIN LUBRICATION

,..;..,._

DRIVE CHAIN LUBRICATI ON

)CD

The cham COOSISIS of ma ny small parts wh1ch

operate one over another lf 1t 1s not properly
mamtaned, 1t w111 wear qu1ck ly lt 1s thus necessary
t o carry out regular ma1ntena nce work on the cham,
especally 1f the motorcycl e 1S often dnven over
dusty surtaces The motorcycl e 1s f1tted w1th a cha1n
w1th small 0-nngs between the plates Cleamng
w1th steam p r essu nsed products and some sol
vents may damage these nngs Clean the cham
w1th kerosene only Atter cleamng, dry the cham
w1th compressed a1r, then lubncate well w1th SAE
BOW/90 eng1ne 011 or a specallubncant tor cha1ns
w1th 0-Rmgs Never use other lubncants smce they
may contam solvents harmful to the 0-Rmgs
Recommended lubncant
SAE BOW/90 englne oli

30-4Dmm

NOTE.
To check cham t1ghtness, the motorcycle must
stand m an upnght pos1tton w1th 1ts two wheels
touch1ng the graun d and no one s1tttng on 11 Check
ttghtness m the pos1t1on shown m the f1gure
2

(1) ORongs

AdjUSt

Dnve cham t1ghtness

Tightness adJUStment:

CAUTIONi ___________________

An unduly tight c ha m Wili overload and damage

theeng1ne an d drive members. Becareful there-fore to keep chaln tightness wlthin the llm1ts
speclfied.
Loosen the rear wheel pm nut (1)
Turn both cha1n stretchers (A and L) (2) by the
same amount to obtam the reqwred t1ghtness
Atter adJUStmg, screw the rear wheel p1n nut to
the reqwred torque

l"-l
. ........

Rea l wheel p in nut:

115 Nm (11.5 kgm)

NOTE:
Turn the two cha1n stretchers (2) 1n exactly the
same way to keep the wheel properly centred
(Reference marks on eJther s1de of the front fork
and cham stretchers show whether the wheel 1s
properly centred)

3-35

lml~!!!al

3 36

FRONT FORK INSPECTION ANO

AOJU~ENTI

mIRI

FRONT FORK INSPECTION ANO AOJUSTMENT

ftiW.iiN!!fti
When inspecttng the front fork, hoId the motor~
cycle flrmly to prevent lt falling over.
Vlsuallnspect1on

1c-141

FRONT FORK INSPECTION ANO AOJUSTMENT/IJNSP l~~

SHOCK ABSORBER INSPECTION ANO AOJUSTMENT
~

ADJ

Compress1on dampmg effect adjustment

In the lower area of each stem 1s a screw (1)
protected by a rubber cap (2) wh1ch serves to adJUSt
the compress1on dampmg effect
To 1ncrease the damp1ng effect, turn the adJUSter
c!ockw1se (A), to reduce 11 turn the ad)uster anttclockwlse (B)

Check
Slem (1)

(1)
(2)

Scratches/Damage -+ Replace
011 seat (2)

Settmg screw
Rubber cap
AOJUSTMENT FIELO

Undue mlleakage ~ Replace

Max1mum
Fully turned 1n poSJIIOn

Operating mspect1on

1 Check

Standard adjustment

Proper funct1omng

a chcks from max1mum

W1th the motorcycle 1n a leve! upnght pos1

tiOn an d w1th your hands on the handlebar,

Mlnlmum

20 cilcks antJclockwlse (B) from max1mum

operate the front brake Then compress

and release the front fork severa! t1mes

lrregularljerky funct1on1ng-+ Repa1r

CAUTION:
Do not force the adjustment screws beyond the
minimum or max1mum settmgs.

Adjustment

Be sure that both the front fork stems are

adjusted to the same settlng. A non-unlform

,CAUTION:
After adJUStlng, be sure to msert the rubber
protectlon caps to avoid malfunctlomng due to
dust and dirt

adJUStment may cause poor handhng and loss

of stab1hty

Adfustment ot extens10n dampmg effect

On the ca p of each stem IS a screw (1) wh1ch adjusts
dampmg effect dunng front fork extens1on
Turmng the screw clockw1Se (A), the dampmg ef
fect mcreases, antlclockw1se (B) 1t decreases
The breather cap (2) serves to ehmmate
overpressure ms1de the front tork lt must be un
screwed penod1cally

SHOCK ABSORBER
AOJUSTMENT

''*&'dd'di

Mlnlmum

Screw completely
t1ghtened m ctockw1se
dJrectiOn (A)

Screw turned 20
chcks 1n antiCIOCkwlse
d1rect10n (B)

ANO

Ths shock absorber contams hlghly compressed nitrogen gas

Read these warmngs carefully before handllng
the shockabsorber. The manufacturerdecllnes
ali responslblhty for damage or wounds due to
lmproper handling.
Do nottamperwlthortrytoopen thecyhnder.
This may cause damage or wounds to the
operator
Do not expo se the shock absorbers t o naked
flames or any other heat sources: excess gas
pressure might cause lt to explode
Do not deform or damage the cyllnder m any
way. Damage t o the cyllnder mlght Jeopardse the dampmg effect.

AOJUSTMENT FIELO

Maxlmum

INSPECTION

Standard adjustment: 12 cllcks from maximum

3 38

SHOCK ABSORBER INSPECTION ANO

AOJU~ENTI

1. . . 1

1c-1 51

~ocK ABSORBER INSPECTION ANO AOJUSTMENT/IINsP

Imi
STEERING INSPECTION .__~A,_,O:.>J<-J...~---'

JUSted accord1ng to the dnver's preferences, to the

wetghts be1ng carned and to road condltlons

Extenslon damplng effect adjustment

To mcrease the extens1on dampmg effect, turn the
settmg (1) at the base of the shock absorber clockwse (A) To reduce 1t turn anttclockwtse (B)

Ho ld the motorcycle f1rmly In piace to prevent i t

falhng.

Adjustment f1eld
Max1mum effect adjuster (1} futly turned m
Standard adjustment adJUSter (1) turned 15 chcks
out from maxmum

NOTE:
The shock absorber spnng preload may be ad-

Spnng preload adjustment

Adjust the spnng preload as fo!lows
Loosen the lock nut (2)
To mcrease the preload, turn the adjuster
clockw1se (A) To reduce 1t, turn anbclockw1se
(B)
The spnng preload changes by 1 mm per turn of
the adjuster

NOTE.
For ad]ustment purposes use the spec1al wrench
prov1ded wtth the motorcycle
After adJustmg, screw lock nut (2) to the adjuster

(1) and t1ghten to prescnbed torque

Shock absorber lock nut
42 Nm (4.2 kgm)

STEERING INSPECTION
1

CAUTION:

'''Wi;@ldi

Never attempt to turn the adJuster beyond the

maxlmum or mlnimum settmg

Ho ld the motorcycle f1rmly 1n piace to prevent l t

falhng over.

Sprmg length w1th preload

3 39

Ratse the front wheei and piace a support

under the engtne

Standard length

222mm

Mm1mum iength

210mm

Max1mum length

238mm

3-40

Check
Steenng beanngs
Grasp the bottoms of the front fork stems
and rock back and forward
Free play-+ AdJUSt steenng beanng

AdjUSt
Steenng beanng

STEERING INS::;TIONI

r=~~~~;l~~~~~~~f=::::::~--~A~d;J~u:s~tm~en~t;:----------

ml~!!iii 1c-1s1

Loosen steenng column nut (1} and upper fork

plate screws (2)

T1ghten lockmg nut (3) w1th the spec1ai wrench

TYRE INSPECTIONI
TYRE INSPECTION
FRONT
Make

Locking nut wrench:

P/N. YU-33975
P/N 90890-01403
NOTE
The torque wrench and the tock1ng nut wrench
should forma nght angte

PIRELLI

38 Nm (3.8 kgm)

Loosen the lockmg nut one turn

Ret1ghten the lockmg nut us1ng the spec1al

wrench

Measurement

Type

90/9021 (54R)

MT70

Measurement

Type

130/80-18 (66R)

MT70

REAR

Make

Locking nut (lnltlal tlghtenlng)

ml~!!iii

PIRELLI

Tyre pressure must be checked when the

tyres are at amb1ent temperature. Pressure
must beadJUSted accordlng tothetotal welght
of luggage, driver, passenger and accessones (falrlngs, bags,lf approvedforthls model)
and speed of the motorcycle
A llst of tyres approved for thls m o del followmg severe testtng by Belgarda S.p.A 1s provJded There can be no guarantee of safe
roadholdlng lf a comblnatlon of tyres dlfterent from those lndlcated ls used
Front and rear tyres must have the same
destgn and be of the same make.
The use of val ves an d valve stems other than
those lnd1cated m1ght cause the loss of tyre
pressure at high speeds. Useonly originai or
compatlble spare parts.
Replace the valve cap securely to prevent
losses of tyre pressure at high speed

Do not tlghten the locklng nut excesslvely.

Locklng nut (fina! t1ghtenmg):
6 Nm (O 6 mkg)

Check
Tyre pressure
Out of spec1flcat1on -+ Adjust

T1ghten the steerrng column nut and the

front tork plate screws

Nut (steermg column):

115 Nm (11.5 mkg)

Screws {front fork plate)

23 Nm (2.3 mkg)

INFLATING PRESSURES (bars) (pso)

Wtth dnver only

Wlth dnver
and passenger
Wlth dnver
and passenger

AdjUSt
A1r pressure

Front
2 (28)

Rear
22 (32)

2 1 (30)

24 (35)

1 5 (22)

1 6 (23)

............................................

TYREINS~TION~I~~r IIJ!lll

D-1

WHEEL INSPECTION/IINSP 1~1

CABLE INSPECTION ANO LUBRICATION ADJ_ ~
WHEEL INSPECTION

AdJUStment:

Remove the valve cap

Use an alr pump or
compressed alr p1s-

lncrease alr
pressure

tol.

Eliminate alr by
presslng valve tube

lnspect
Wheels
Damage/Deformat1on -+ Replace

Alr pressure
dlmlnlshes

NOTE:
Aiways balance the wheei after the repiacement or
reassembly of a tyre or nm

stem

lnstall valve caps securely

3

lnspect
Tyre surtace
Wear/Damage -+ Replace
Mimmum track thickness:
(front and rear)
2,5mm

I!IW';'t''t'i --:--:--------Never try to repa1r a rlm In any way.

Bearlng lnspection
Check the front and rear wheels penod1cally to
make su re that they do not h ave free play m the hub
and that the wheel turns smoothly wlthout st1Ck1ng
Wheel hubs must always be checked 1n accord
ance w1th the ma1ntenance table

(1) Track th1ckness

(2) S1de
(3) Wear md1cators

CABLE INSPECTION ANO LUBRICATION

''*Mh#'!di

lfthe cab le sheath IS damaged, corrosion might

The use of worn tyres reduces stablhty an d may

e n sue orthe cab le mlght not run freely. To avoid

cause a Joss of contro!.

l t ls not advlsable to repair a punctured alrtube.
lf absolutely necessary, repalr wlth the utmost
care an d replace thetube as qulckly as posslble
wlth another wlth the same characteristlcs.

such drawbacks, replaced damaged cables as

qutckly as posslble.

lnspect
Cable sheath
Damaged -+ Replace

T1ghten
Valve stem lock nut

~~~

1.5 Nm (0.15 kgm)

Recommended lubrlcant.
SAE 10W30 engme oli

After assembling the new tyres, drive slowly to

allow them to adapt well to the rlm and yjus
ensure maximum holding

343

Check
Cable tunctiOmng
Does not run freely -+ Lubncate

NOTE:
Hold the cable vert1cal and apply a few drops of
lubncant

3 44

LEVERANO PEOAL LUBRICATION/LATERAL STANO/SWIWARMJIINSP ~~~

HEAOLIGHT: LAMP REPLACEMENT ANO SETTING '-A"-'-"0"-'J"--l..-~--'.
LEVERANO PEOAL LUBRICATION
Lubncate alllever and pedal prns
Recommended lubncant:
SAE 1OW30 engme oli

D-2

HEAOLIGHT: LAMP REPLACEMENT ANO SETTING

NOTE.
T o remove the lamp, turn counterclockwtse

lnstalt
New lamp (turn ctockw1se)
Rubber cover
Lamp connector

lnstaU
Dome

LATERAL STANO LUBRICATION

Lubncate the latera! stand and artcutat1ons

mln

Recommended lubncant:
SAE 10W30 englne oli
Do not touch the lamp when on and keep ali
inftammable products well away.

SWING ARM LUBRICATION

Lubncate the sw1ng and connect1on arm p1vots

;cAUTION:

~~l

Do not touch the glass part of the la m p wl t h the

fngers and becareful notto solllt.lf lt ls sol led,
clean thoroughly wlth a cloth soaked in alcohol
before reassembhng.

Llght llth1um-soap grease

Front parkmg llght lamp replacement

ELECTRICALS

Remove
Lamp holder (1) (chcks 1nto piace)
Lamp (cllcks mto piace)

lnstall
New lamp (chcks mto piace)
Lamp holder (chcks 1nto piace)

HEADLIGHT. LAMP REPLACEMENT ANO

SETTING
Headlamp replacement
1 D1sassemble
Chass1s dome
NOTE.
To d1sassemble the dome loosen screw (1) from
beneath the mudguard and ra1se 1t to chck onta the
flap (2)
2

Remove
Lamp connector (3)
Rear rubber headhght cover (5)
Lamp (4)

Headllght settlng
1 Loosen
Screws (1) (headllght f1xmg)
2

AdjUSt
Vertlcaf headhght setllng (1)

Tghten
Headl1ght fasten1ng screws
Headhght fastenlng screws:
7 Nm (0.7 mkg)

\.._./

FUSE INSPECTION ANO REPLACEMENT

l~ /~!~li~/

FUSE INSPECTION ANO REPLACEMENT

D-3

FUSE INSPECTION ANO

Do not use fuses wl th an amperage higher than

that prescrlbed. Such fuses mtght cause damage to the motorcycle and even f1re

~
-+

lnspect

Fuse

lnspect1on
Connect the pocket tester to the fuse to check

-r

f1lament cont1nU1ty

J-

NOTE:
Set the tester sw1tch at the ".0. x 1" pos1t10n

~J
L_j

Pocket tester.
P/N. YU-03112

P/N. 90890-03112
lf the 1nstrument shows mf1n1te res1stance, the

fuse 1s burnt aut and needs to be replaced

/n/

t!tW.i;Widii

Remove
S1de panel (left)
See sectiOn "SI DE PANELS, AIA DUCTS
SEAT AND FUEL TANK"
Fusebox(1)
Fuse (from fuse box)

REPLACEMENTI~~~r

Replace
Broken fuse

Replacement.
DISCOnnect the matn SWI1Ch (OFF pOSIIOn)
Replace the fuse w1th a new one w1th SUitable

amperage
Prescnbed fuse. 20A

Turn on mam sw1tch (ON pos1t1on)

Operate the vanous sw1tches, turmng on an

electnc dev1ces to check that they are workmg

lf the fuse burns aut agam, check the ctrcUit m
questton

3 48

lnstall
Fuse box
Stde panel

\.__/

BATTERY INSPECTION

~~~~~ l~~~l~~ l

D-4

BATTERY INSPECTION

BATTERY INSPECTION

~~~~~ l~!~\

''Wi;JJI!f!fi
The electrolyte m the battery 1s dangerous: 1t
contams sulphunc ac1d and IS thus poJsonous
and extremely corrosive
Always observe the followlng preventlon meas~
ures

NOTE:
The battery mounted on the motorcycle ts of the
matntenance-free sealed type (MF) lt 1s thus tm
posstble to measure electrolyte dens1ty to check
the battery charge The battery charge ts checked
by measunng the voltage at the battery termtnals

Avod physlcalcontactwlth theelectrolyteas

1t may cause senous burns or permanent
damage to the eyes
Wear eye protect1ons when handhng or work~
mg wtth battenes.
(EXTERNAL) ANTIDOTO.

CAUTION.

SKIN

Rtnse w1th water.

EYES ~ Rtnse w1th water for 15 minutes and

cali a doctor 1mmed1ately.

CHARGING METHOD
The battery ts of the sealed (MF) type Do not
remove caps dunng chargmg lf the caps are

(INTERNAL) ANTIDOTO

removed, the balance et the battery ts not mam-

Dnnk coplous amounts of water or m1fk fol~

lowed by mllk of magnes1a, scrambled eggs
or vegetable 011
Cali a doctor immed1ately

tatned and tts performance progresstvely dtmm

tshes
Never addwater, noteven d1stllled water Otherwtse, the chemtcal reactlOns tn the batterywt!l not
take piace normally, maktng regular functtontng

Battenes generate explos1ve hydrogen gas. ob~

serve the follow1ng prevent1on measures.

tmposstble
The chargmg ttme, current and voltage of an MF
battery are dtfferent from those of a norma!

Charge the battery m a

well~a1red

space

Do not allow f1re, sparks or flames (eg weld~

mg eqUJpment, l!t c1garettes etc) near to the
battenes.

battery
The MF battery must be charged as descnbed m
the secMn Chargmg method' lf the battery
were overcharged the tevel of the electrolyte
would drop conslderably Pay careful attent1on
theretore wh1le charg1ng the battery

DO NOT SMOKE when charging or handilng

battenes
KEEP THE BATTERY ANO ELECTROLYTE
WELL OUT OF THE REACH OF CHILDREN

Avo1d usmg electrolyte other than that spec1f1ed

The spec1f1c dens1ty of the electrolyte m the
battery 1s 1 32 at 20C (the spec1f1c dens1ty of
electrolyte for normal battenes IS 1 28) lf an
electrolyte of spec1f1c dens1ty lower than 1 32
were used the sulphunc ac1d would d!m1msh,
thus reducmg the pertormance of the battery lf
an etectrolyte w1th a spec1fsc denSity of 1 32 or
aver were used, the battei)' plates would be
corroded and the batery would last less

Remo ve
S1de panel (Jeft)
Seesect1on SJDE PANELS, AIA DUCTS,
SEAT AND FUEL TANK"
Battery cover fastemng belt (1)

"l oO

'-..-/

BATIERY INSPECTION
2

~~~gj l~!!!~il

Dtsconnect

BATTERYINSPECTIONI'~gj !&l

D-5
~ngt<me

Battery cables

Room temperature

-~25'

CAUTION:
D1sconnect f1rst the negative cable, then the

positive cable
3 Remove

The battery

4 Check

The condtttons of the battery

Battery condttlon check stages.

Connect the pocket tester to the battery termt
nals
Tester(+) ware -7 Battery termmal (+)
Tester(-) wue -7 Battery termmal (-}

NOTE:
The chargtng t tme fora parttally ortotally MF battery

Retatl(l(lStl<p between open-c~rcuot

may be checked by measunng the open ctrCUit

voltage (the voltage measured Wtth the postttve
termmal dtsconnected)

vollage end Chargong t me

2: "

f~
o

il
o

Thos vanes dependng

on the temperature

the stata

ot chluge

Open-clrCUit
voltage

Chargmg t1me

12 SV or more

Charg1ng unnecessary

127V-115V

Fewer than 11 5V

15- 20 hours

10 hours

tn

bat1ery plates ami IM etecuolyle leve!

Battenng charg1ng t1mes accordmg to chargmg

condJbons are shown m the f1gure
Room t(lmperature

O'C-4oc

r.:::::::

.
"

"

"

Chargng eonchtons Ol the batlery (0 o)

MF battery chargmg method

Check the open-<:orcut vonage

CAUTION:
lf 1t as amposslble to obtam the envasaged
charge current voltage, charge the battery
accordmg to the fo llowlng the lnstruct1ons an
the sectaon "CHARGING WITH A CONSTANT
VOLTAGE BATIERY CHARGER".
When chargmg the battery, remove tt from
the motorcycle.lf 1t ls necessary to recharge
the battery on the motorcycle, be sure to
disconnect the negat1ve termmal.
Never remove the battery caps
Make sure that the battery charger pmcers
are f1rm1y m contact w1th the termmals and
are not m short Clrcuit An oxld1sed p1ncer
may generate heat on the surface of the con~
tact A pmcer w1th a weak spnng may cause
sparks
Before removmg the pmcers from the battery
termmals, turn off the battery charger.
Voltage readmgs are shown 10 the d1agram.
The open crcu1t voltage stablhses about 30
mmutes after the cycle has been completed.
Thus, to check the cond1hons of the battery,
measure the open C1rcu1t voltage 30 mmutes
after the chargmg has been completed

_ _ _ _ _ _ _ _ _ ____::B.:..:.ATT.:..:..:::ER.:..:.Y_::IN.:..:.s.:..:.W::.:c:.:.T:=:..:ION
Method for charg1ng w1th a vanable voltage battery charger
Measure the open crcutt voltage
belare chargtng

EJ
o o

lm\~!i\ l D-&

BATTERY INSPECTIONI

~l ~!il

Method for charg1ng wlth a constant voltage battery charger

NOTE

NOTE

The current musi be measured 30

m1nutes after stoppmg the cycle

Measure the open Clrcwt voltage

belare charg~ng

The current must be measured 30

mmutes after stopp1ng the cycle

NOTE

Set the charge voltage at 16 17V

(Il the settlng IS lower lhe charge

wtll be nsufflctent Il the sett1ng IS

too h tg h, the battery 1soverloaded)
NOT

VES

Turnmg the charge voltage regu

Charge the battery untll the charg

mg voltage 1S 16V or more

latiOn contrai set the chargmg

voltage to 20 -25V

AdJUSt the voltage so thatthe cur

renttsatthestandardcharge leve l

NOTE

Check the amperage !or 3 5 mm

ute:; te see 1f the standard charge
current IS reached

Set the chargtng !t me at 20 hours

(maxtmum)

NOT

1Aormorel
1A or less
Il the current 1s htgher t han 1A
regulate the voltage to 16 17V
and conttnue te charge

Set the t1mer to the chargmg t1me

SUitab!e !or the open CirCuii voli
ago

Afler 5 m1nutes regulate the

voltage to 16 17V and continue te charge

Th1s type ol battery charger cannot recharge

an MF:' battery
A vanable voltage or constant current bat
tery charger 1s recommended

Measure the open CirCuii battery vo!tage

atter !eav1ng the battery unused !or over 30
mmutes
12 BV or more Chargmg complete
12 7V or !ess Rechargmg necessary
Under 12 OV - Replace battery

Amperometer

Il the current does not ex

ceed standard charge cur
rent atter 5 m1nutes replace
the battery

Il chargtng takes more than 5 hours 11 1s advtsable to check the charge current alter
5 hours Il there are changes m amperage regulatethe voltage to obtatn the standard
charge current

Measure the open CirCUII battery voltage alter leav1ng the battery unused
for over 30 mmutes
12 SV or more Charg1ng complete
12 7V or less Rechargmg necessary
Under 12 OV Replace battery

3-53

3 54

BATIERY
Method for

charg~ng

INS~;;'TION l~ l~~~~~al

l D-71

BATTERY

wtth a constant current battery charger (exclustvely for MF battenes)

Measure the open CirCUII vo!tage

belare chargng

NOTE
The current must be measured 30
m1nutes atter stopp1ng the cycle

J
Alter an hour s chargmg check
that the nom1nal char\)1ng current
of the battery charger 1s flowmg by
checkmg the amperometer

Il

Smce the chargtnQ current IS constant the

charg1n9 tme vanes accordmg to the ca
pac1ty o the battery Sei the charg1ng t1me
by fo!lowng the mstrucllons spec1f1ed !or
the battery charger

lnspect
Battery poles
Dtrty poles .-+ Clean wtth steel brush
Uncertam connecttons .-+ Ttghten termtnals

NOTE.
After cleamng the poles, grease them shghtly

Connect the battery charger and

amperometer to the battery and
start to charge

VES

INSPECTIONI 1~~~ l~~~~~al

lnstall
Battery

Connect
Battery cables

NOT

Il the nomnal current fals to tlow replace the

battery

Il

CAUTION:

Connect ftrst the posttlve cable, then the negattve cable

9

Amperometer

Measure the open CirCUII battery volta8e

after leavmg the battery unused !or over O
mmutes
12 BV or more Chargmg complete
12 7V or less Rechargmg necessary
Under 12 OV Replace battery

'

3 55

B
'

~ha.ge,

..!!..

356

lnstalt
Elasttc belt (1) fastemng battery cover
Stde panel (left)

ENG l\. l l 0-8

CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... D9
ENGINE OIL
D9
SEAT AND FUEL TANK
D9
BATTERY CABLES
D9
CARBURETTOR
D9
CLUTCH CABLE
D9
EXHAUST PIPE
D9
STARTER
0-10
OIL BREATHER HOSES, CABLES AND HARNESSES
D 10
DRIVE CHAIN
D10
ENGINE PROTECTION AND FOOTREST
D10
BRAKE PEDAL
D11
ENGINE FASTENINGS
D11
ENGINE DISASSEMBLY..
.. .. .. .. .. . . . .. .. .. .. .
CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON
INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L)
AND GENERATOR STATOR
CRANKCASE COVER (R) CLUTCH, PRIMARY DRIVE GEAR
AND BALANCER SHAFT GEAR
OIL PUMP AND GEAR SELECTOR
AC GENERATOR AND TIMING CHAIN
CRANKCASE (R)
GEARBOX AND TRANSMISSION
BALANCER SHAFT AND DRIVING SHAFT
OIL FILTER
ROCKERARMS
VALVES
INSPECTION ANO REPAIR . . .......... ..
CYLINDER HEAD
VALVES AND VALVE GUIDES
VALVE HOUSING
VALVE SPRINGS
CAMSHAFT
ROCKER ARMS AND ROCKER ARM SHAFT
CAMSHAFT CHAIN AND SPROCKET
CAMSHAFT CHAIN GUIDE
CYLINDER AND PISTON
PISTON SEGMENTS
PISTON PIN
CLUTCH

D-13
D14
D15
D16
E1
E1
E2
E2
E2
E3
.............. E4
E4
E4
ES

E7
E7
E7
E8
E8
E8

E9
E10
E-10

/ENG/\.1
OILPUMP
PRIMARY TRANSMISSION
TRANSMISSION AND GEARBOX
STARTER TRANSMISSION
CRANKSHAFT
BALANCER SHAFT DRIVE AND DRIVEN GEARS
CRANKCASE
BEARING AND OIL SEAL
ENGINE ASSEMBL V ANO SETTING ........... .
VALVES
ROCKERARMS
DRIVING SHAFT AND BALANCER SHAFT
TRANSMISSION
GEARBOX
TRANSMISSION AND GEARBOX
ENGINE OIL PUMP AND PUMP SUCTION
CRANKCASE
ENGINE OIL PUMP SUCTION
CRANKCASE
GEAR LEVE A AND OIL PUMP
TIMING CHAIN
PISTON AND PISTON RINGS
CYLINDER
CVLINDER HEAD
CAMSHAFT AND TIMING CHAIN
PISTON, CYLINDER HEAD, AND CAMSHAFT
AC GENERATOR
OIL FILTER AND OIL HOSING
BALANCER SHAFT GEAR AND
PRIMARY TRANSMISSION GEAR
CLUTCH
STARTER GEARS
STARTER NEUTRAL GEAR AND CRANKCASE COVER (L)
ENGINE REASSEMBLV .. .. .. .. .. .. .. . .

E11
E11
E11
E12
E-13
E13
E-13
E-13
........... E14
E-14
E15
E-15
E16
F1
F1
F2
F2
F3
F3
F3
F4
F5
F5
F6
F6

F7
F10
F11
F11
F12
F-14

F-14

. F 15

E_NG_IN_E_R_~VA_LIENGI~I l D-9

______________________

__

ENGINEREMOVALI ENG

ENGINE OVERHAUL

1~1

CARBURETTOR
Remove

Carburettor
See sect10n "CARBURETTOR REMOVAL" m CHAPTER 5

ENGINE REMOVAL
NOTE:
lt rs not necessary to detach the eng1ne from the

chass1s to remove the follow1ng parts

Cyllnder head
Cyllnder

CLUTCH CABLE
Remove

Clutch cable fasten1ng screws (1)

Clutch cable (1)

P1ston/P1ston nngs
Clutch
Starter dnve gear

011 pump
Gear shaft

Alternator

'''""i;@if!j
Support the motorcycle securely to prevent 1t

fall1ng aver.

NOTE:
Remove the end of the clutch cable by pushmg 1t
towards the clamp (2)

ENGINE OIL
D ram

D1sconnect
End of clutch cable (1)

Engme 011
See sectiOn "ENGINE OIL REPLACEMENT" 1n CHAPTER 3

SEAT ANO FUEL TANK

Remove

S1de panel
A1r ducts

Seat

Fuel tank
See sectJon SI DE PANELS, AIA DUCTS,
SEAT AND FUEL TANK" m CHAPTER 3

EXHAUST PIPEO
Remove

Exhaust p1pe (1)

BATTERY CABLES

D1sconnect

Battery cables

NOTE:
01sconnect frrst the negatiVe cable (-), then the
pos1t1ve cable (+)

2 Remove
Battery

4-1

4-2

ENGINE REMOVALI
4

ENG

l'\.1

D1sconnect
Harnessmg connectors

NOTE.
Pos1t1on the harnesses so that they cannot be
damaged dunng engme remava!

DRIVE CHAIN
2

DISconnect
Starter pos1t1ve cable (1)
Dead ground (2)

Remove
Starter (3)

Remove
Gear pedal (1)
Sprocket cover (2}

2
BREATHER HOSES, CABLES ANO HARNESSES
Remove
Breather hose (1)
Breather hose (2)

Remove
Sprocket (1)

NOTE
Before removmg the sprocket nut stra1ghten the
lock washer tab to lock
Loosen the sprocket nut w1th the rear brake
down
ENGINE PROTECTION ANO FOOTREST

Remove
011 hose (1) (mtake)
011 hose (2) (outlet)

Remove
Spark plug cable (1)

Remove
Engme protect1on (1)

44

Remove
Footrest (1) (l)

'-. . - l

ENGINE REMOVAL

l~

-1 ID-111

ENG ,._

ENGINEREMOVALI

3 Remove

ENG

l'-1

ENGINE FASTENINGS

Footrest (2) (R)

fti'Mi;ldldii
Support the motorcycle securely to prevent 1t
falhng over
Piace a swtable support under the eng1ne

2
BRAKEPEDAL

Remove

Remove

Rear brake pump (1)

Rear brake pedal (2)

Engme support (1) (top)

Remove

Engme support (1) (front)

D1sconnect
Return spnng (brake pedal)

Remove

Bolt (1)
Rear fasten1ng pm (2)

Remove
Complete eng1ne (from the chassts)

NOTE
The engme and swmg arm are assembled on the
pm When removmg the pm, 11 1s thus necessary to
pay specal care w1th the swmg arm

4S

46

l -1

DISA~MBLY ENG ~
,..

------------------------------- l
ENGINE

ID-121

ENGINEDISASSEMBLYI

ENGINE DISASSEMBLY

NOTE:
The cyhnder head, cyhnder, camshaft and ptston
can be examtned wtth the engme mstalled by re
movtng the fo!lowtng parts
Stde panels
Atr ducts

l'-1

Remove

CYLINOER HEAO, CYLINOER, CAMSHAFT ANO

PISTON

ENG

Cam sprocket (1)

Camshaft (2)
Caps (left crankcase covar)

NOTE.
F1x a safety w1re (3) to the ttmtng cham to prevent 11
falhng 1nto the crankcase

Seat
Fuel tank
Carburettor
Exhaust ptpe
Remove
Spark plug (1)
Tappet cover (2) (suctton)
Tappet cover (3) (exhaust)
Cyhnder head cover (4)
Cap
Pms (6)

Remove

Cham gUide (1)

Remove
Cyhnder head

2 Loosen

Bo1t (1) (cham stretcher)

3 Remove

4-7

NOTE
Loosen an bolts by a 1/4 turn and remove once ali
are loosened

Chatn stretcher (2)

4-8

~~

ENGINE DISASSEMBLY

l ENG 14-1
~

ID-131

ENGINEDISASSEMBLYI

~::::::::::::::::::::::::::::::~--~7~:R:e:m=o~ve:----:---

~~

Gasket (1) (cyl1nder head)

P1ns (2)

Cyhnder (3)
Gasket (4) (cyhnder)

ENG

l'-1

Piston pln puller:

P/N. YU01304
P/N. 9089().()1304

:cf!t!i19(, ___________
Avold uslng the hammer to pull the pln out

INTERMEDIATEST ARTER GEAR, CRANKCASE

COVER (L) ANO GENERATOR STATOR
NOTE:

W1th the engme mstalled, mamtenance ot the mter

med1ate starter gear and the crankcase covar (L)

may be performed by removtng the followtng parts

Exhaust p1pe
8

Starter
Sprocket cover

Remove

(1)
Remove

Covar {1) mtermedtate starter gear

Centnng pms
Gasket

Remove
Ptn nng (1)

Aemove

lntermedtate starter gear (1)

Beanng (2)
D1stnbutor shaft (3)

Aemove
Neutral gear cable (1)

NOTE:

Before removmg the prn nng, covar the crankcase

w1th a clean cloth to prevent the nng talhng rnto the
crankcase cavrty

10 Remove
P1n (1)
Prston (2)
NOTE:

Before removmg the p1n, burr the ptn housmg

groove lf tt 1s hard to pull aut the pm even w1th the
groove burred, use the pm puller

4-10

EN_G_IN_E_o_lsA_s_~_EM_B_Lv\ENGJ~J ID-14 1

_____________________

ENGINEDISASSEMBLYI ENG

Remove

Crankcase cover gasket (1) (L)

Centnng ptns
Seal nng and O nng
Gasket

\~\

Remove

Engme 011 dehvery hose screw

Copper washer

Otl ftlter cover (1)

Otl ftlter
Seal nng and ORmg

Crankcase cover (2) (R)

--IlsfL.
:J-1

Remove
lntermedtate starter gear (1)

Remove
Clutch spnng (1)
Pressure plate (2)
Sphere (3)

Beanng (2)

Dtstnbut!On shaft (3)

Fnctlon dtscs (4)

Clutch dtscs (5)

Ondulated plate {6)
Ctutch hub (7)
Thrust washer (8)
Clutch shroud (9)

Remove

Dtsengagement control rod (10)

Cable clamp (1)

Co1l (2)
Stator (3)

NOTE

Before loosemng the nut (11) (clutch shroud),

stra1ghten the washer lock tab
To loosen the nut (clutch hub) block the clutch
hub us1ng the spec1al tool (12)
Unlversal clutch lock bracket.
P/N. YM-91 042
P/N 90890-04086

CRANKCASE COVER (R), CLUTCH, PRIMARY

DRIVE GEAR ANO BALANCER SHAFT GEAR
NOTE:

The clutch, the pnmary gear and the balance gear

may be tnspected wtth the engtne mstalled by
removmg the followmg parts
Footrest (R)
Otl dellvery hose screw

4 12

~ j
~~-jiD-151
;: ===========:::;-..::E:::.N~G..::IN:E=D=I=SA--S:._:S_E:::.M:::.B.:.:..:.LY ENG . . .
3 Remove
lJISC (2)
Balancer dnve gear (3)
DISC (4)
Key (5)
D1sc washer (6)
DISC (7)

ENGINE DISASSEMBLY
4

l l'-1
ENG

Remove
Thrust lever (1)
Spnng (2)
Flat washer (3)

NOTE:

Loosen screw (4) to remove the thrust rod

Balancer gear (8)

Key (9)
OIL PUMP ANO GEAR SELECTOR
NOTE:
The 011 pump and gear selector may be checked

w1th the engme 1nstal!ed by remov1ng the follow1ng

parts
Footrest (R)

011 dehvery hose screw

Crankcase (R)
Clutch
Remo ve
C1rchp {i)
011 pump gear (2)
OLI pump (3)
0-nngs (4)

NOTE
Before loosen1ng the nut (9) (pnmary dnve gear)
and nut (10) (balancer gear), stra1ghten the wash
lock tab

NOTE

To loosen nuts (9) and (10), hold the rotar (CA

magnete) f1rmly 1n piace usmg spec1al tool
(11)

Remove
C1rchp (i) (from dnve shaft)
R1ng (2)
C1rchp (3)

Remove

Rotar arrest support

P/N YS-01660
P/N. 9069001701

CAUTION:

Be careful not t o touch JUtlmg edges (12) o n the

rotar with the rotar support 1tself.

C~rcllp (1)

4-11

4-14

Gear selector (2)

Spnng (3)
Flat washer (4)

-. . _/ lENG ,~_,,0-161

ENGINEDISASSEMBLY
4

ENGINE DISASSEMBLY

Remove

l l'-1
ENG

NOTE
Remove the rotar Wlth the puller (1)

Stop lever (1)

Rong (2)

Spnng {3)

Rotar puller.
P/N. YU-33270

P/N. 90890-01362

2
AC GENERATOR ANO TIMING CHAIN
NOTE
The AC generator may be mspected wtth the en
gme mstalled by removmg the followtng parts

Se at
S1de cover (R)
Crankcase (L)

Remove

Nut (1)
Washer (2)
Rotar (3) (w1th starter gear)
Beanng (4)

Sh1m adjustment washer (5)

Key (6)

NOTE:

To loosen the nut (rotar) lock the rotar wtth the

spec1al tool (7)
Rotar stop support
P/N YS-01880
P/N 90890.01701

CAUTION:
Be careful not to touch the JUttlng edges (8) on

the rotar of the spec1al tool

4 15

4-16

Remove
Cha1n gwde (1)
T1mmg charn (2)

ENGINEDISAS~BLYI ENG ~~-1 l E-1 l

ENGINEDISASSEMBLYI

CRANKCASE (R)

Remove
Crankcase (R)
NOTE:

Loosen nuts starttng from the one w1th the htgh

est number
Loosen ali by 1/4 turn and then remove

ENG

l"-1

CAUTION:

Be careful not to damage surfaces m contact

w1th the crankcase.
Use a soH hammer to h&t the engme crank~
case. Only hlt the remforced parts. Do not h1t
the surtace '" contact w1th the gasket. Work
slowly and carefully. Be careful to pertorm
the separatlon umformly. lf one end locks,
remove pressure from the thrust screw , rea~
hgn and recommence. lf it is lmposs1ble to
separate the crankcase, checkthat ali screws
and components have been dlsassembled.
Do not use force.

GEARBOX ANO TRANSMISSION

Remove
Gwde bar (1)
Gear selector (2)
Setector fork # 3 (3)
Selector fork # 2 (4)
Se!ector fork # 1 (5)

Removal:
Set the crankcase dtsassembly tool (1) m piace

Crankcase dJsassembly tool

P/N. YU01135A
P/N 9089001135
NOTE:

When t1ghtenmg the support bolts of the dtsassembly tool, be su re t o keep the tool body parai!el to the
engme crankcase lf necessary, a screw may be
shghtly loosened to put the tool body on level

Applymg pressure, stnke the front engtne assembly flange, the dnve shafts and the gear ca m
plate w1th a rubber hammer Then remove the
crankcase

NOTE:
lf the crankcase fatls come aut, lever at potnts

(2), bemg careful not to damage the crankcase

Turn the gear cam plate as shown m the ftgure t o
prevent 1t 1nterfenng w1th the crankcase

4 18

Remove
Transm1sS10n assembly unlt (1)

ENGINE DISASSEMBLY

1ENG ~~....-l

l E-2 l

ENGINE DISASSEMBLYI

3 Remove
Gearshaft#1 {1)
Gear shaft # 2 (2)

ENG ' ' - '

ROCKER ARMS
NOTE

The rocker arms may be exammed w1th the engme

1nstafled by remov1ng the followmg parts
S1de panels
A1r ducts

Seat
Fuel tank

Cylmder head cover

BALANCER SHAFT ANO DRIVING SHAFT
Remove
Cap (1)

Remove
Balancer shafl (1)

2 Remove
2

Crankshatt (1)

Remove

Bolts (1) (rocker arm support shaft)

NOTE.

Remove the dnv1ng shaft by usmg the crankcase

separatlng tool (2)

~~
~

Crankcase separatmg tool

P/N YU-01135-A
P/N. 9089Q-01135

T1ghten the separatmg tool bolts, makmg sure

that the the tool body IS parallel w1th the eng1ne
crankcase lf necessary, a sere w may be backed
out shghtly to level tool body

Remove
Rocker arm shaft
Rocker arms

NOTE:

Remove the rocker arm shaft us1ng shd1ng hammer

(1) and we1ght (2)
OIL FILTER

Shdmg hammer k1t.

P/N. YU-01 083-A

NOTE.

Shdmg hammer
P/N. 90890-01083

lt 1s adv1sable to replace the 011 f1lter every t1me the

engme 1s d1sassembled

We1ght
P/N 90890-01084

Remove
01 f1lter (1)
011 passage cover (2)

4 19

Gasket

420

ENGINEDISA~MBLYI ENG l'-1 l E-3

ENGINE DISASSEMBLY

VAL VES

NOTE:

The valves may be mspected w1th the engme

mstatled by removmg the tollowmg parts
S1de panels
A1r ducts

l l'-1
ENG

Remove

Cotters (1)
Top spnng retamer (2)
Internai spnng (3)

External spnng (4)

Lower spnng retamer (5)
Valve (6)

011 seal (7)

Seat
Fuel tank
Exhaust p1pe

NOTE

Mark each part and 1ts pos1t1on so that each may

reassembled as before

Carburettor

Cyhnder head cover

Cyllnder head
Check
Valve seal

Leakage t rom valve housmgs- lnspect the

valve suriace the housmg and housmg
Wldth
See sectton 'VALVE HOUSING INSPEC-

NOTE

Compress the valve spnng usmg tool (8) to remove

the cotters

TION ANO REPAIR"

Valve sprmg compress1on clamp

NOTE
Check the valve seal before assembllng the Inter-

P/N. YM-04019

P/N 90890-04019

nai parts of the cyhnder head (valves, valve spnngs,

spnng housmgs etc)

lnspectlon stages
Pour clean solvent (1) mto the suct!On and exhaust ports

Check the valve seal There must be no blow-bys

from the valve hous1ngs (2)

4-21

4-22

,_NS_P_E_CT_IO_N_A_N_~_R_E_P_AI_RI ENG l'-1 l E-4

___________

INSPECTIONANDREPAIRI

ENG

l'-1

VAL VES ANO VALVE GUIDES

INSPECTION ANO REPAIR

Measure

Clearance between stem and QUJde

CYLINDER HEAD

Ehmrnate
Carbon depos1ts
(from combust1on chamber)
Use a rounded scraper (1)

Clearance between stem end gUide =

Internai d1ameter of valve guide (a)Dsameter of valve stem (b)

NOTE
Out of spec1f1cat1on
QUI de

Do not use a pornted tool to avo1d damagrng or

scratchrng
spark plug thread
valve housrngs
combustiOn chamber
2 lnspect
Cylrnder head
Scratches/Damage
3

Replace valve

o 010-0.037
0.030 - 0.057

-+ Replace

Bore gauge

(1)

Measure
Deformat1on
Out ot spec1f1Cat10n-+ Rework the surface

Replacement.
NOTE.
Heat the cylmder head m an oven at 100C to
faCilitate the removal and 1nstallat10n of the QUides
and to mamtam correct lockmg mterference

Cyhnder head deformat1on.

Less than 0.03 mm

Remove the valve QUide us1ng the spec1al punch

(1 l

lnstall the new gu1de usmg the spec1al mstallatlon tool (2)
After mstalhng the valve gUide, bore w1th spec1al
tool (3) to obtam valve gUide free play

Surtace
Cyhnder head

Levelhng
Level the cyhnder head w1th wet 400 ,.... 600 emery

paper 1n a f1gure-8 d1rect1on

7 m m gu1de valve puller.

P/N YM01225A
P/N. 9089001225

NOTE
To avo1d removrng too much matenal on one s1de
only, turn the cyhnder head a number of ttmes

Valve guide installer.

P/N YM04017
P/N. 90890.04017
7 mm valve gu1de borer
P/N. YM01227
P/N 9089D-01227

4 24

INSPECTION ANO :AIR

----------------------------------~--

l l'-1 l E-5
ENG

INSPECTIONANDREPAIRI

Clea, the valve surfaces of the carbon depos-

l'-1

Measure

lts

ENG

Valve housmg w1dth (a)

Out ot speC1frcat10n -+ Aenew valve hous

lnspect
Valve seal su riace
P1tt1ng!VVear ~ Gnnd the valve seal sur-

tace

mg

4 Measure
Edge th1ckness (a)
Out of speclfJcatJon -+ Aeplace valve
Edge thlckness hmlt:
07mm

1.0- 1.2 mm
1.0-1.2 mm

Measurement stages

Apply Pruss1an blue (Dykem) to the valve hous

mg
4s"

Check
Valve stem t1p
Deformed, mushroom-shaped or w1th a

h1gher d1ameter than the rest of the stem

-+ Replace valve

lnstall the valve 1n the cyhnder head

Press the valve onta the hous1ng through the
gu1de to leave a clear outllne
Measure the w1dth of the valve hous1ng Where
there 1s contate between valve and housmg the
Pruss1an blue 1s w1ped away
lf the valve housmg LS too narrow, w1de or off
centre, the valve housmg must be renewed

M1sallgnment

Out ot speclflcaMn

-+ Replace valve
4

Stem offsett1ng limlt:

0.01 mm

Renew
Valve housmg
Use the spec1al tool to renew the valve
housmg (1) w1th 30", 45" and 60" mdls

NOTE:

Chang1ng thevalve, replace alsothe valve gu1de

Pulhng the valve aut, replace the oli seal

VALVE HOUSING

Cle an the valve surface and housmg of carbon

depos1ts
2

lnspect
Valve hous1ng
P1ttmg!Wear-+ Renew valve hous1ng

Valve houslng mllhng unlt:

P/N YM-91 043

[_<:UTtN:
Turn1ngthe mllllng tool, maintaln uniform pres
sure (about 4~5 kg) to avold leavlng marks on
the valve housing.

INSPECTIONAN>REPAIRI

m~
A/

l'-1 l E-6

INSPECTION ANO REPAIR

5

Mlll the valve houslng as follows

Section
Mili
A
30
45
B
60
c

""

l l'-1
ENG

Emery
Pnnc1pat valve surtace
Valve housmg

NOTE:
lf the valve hous1ng 1s renewed or the valve and
gwde replaced, the valve housmg and seal suriace
must be lapped

................................. ,..
Valve houslng faults recorded by analysmg the
valve seal surface

[A]

~~
:':f''*~'" ,,~

lf the valve surface resembles that shown m

the frgure, thrs means that the valve housmg rs
centred an the surface but rs too wrde

lnterventron on the
valve housmg

Mrll
type

!ID

ENG

Lappmg
Apply rough-lapptng compound t o the valve se al
su riace

Desrred effect

iAUTION:

30

Reduce valve housrng

60

wrdth to 1 O mm

Make sure the lappmg compound does not run

into the space between the guide and valve
stem.

lf thevalve surface rs hke thrs, rt means that the

[B]

valve housmg rs centred an the valve surface

but rs too narrow

~~ ~

lnterventlon on the

valve housrng

M!ll
type
[C]

45

Apply mi to the molybdenum d1sulflde on the

valve stem
lnsta11 the valve m the cyhnder head

Oesrred effect
lncrease valve housrng
wrdth to 1 omm

lf the valve surtace rs llkethrs, rt means thatthe

valve housrng rs too narrow and ctose to the

edge of the valve
lnteJVent1on on the
valve housmg
M11t
type

30" (before)

45

Turn the valve unt1l face and surtace are not

evenly pohshed Then clean away ali the lappmg
compound

Oes1red effect
Centnng of housmg
and atta1nment of 1 O
mmw1dth

NOTE
For best results, dunng lappmg, repeatedly apply
(hght) pressure to the valve housmg, turmng the
valve backwards and forwards by hand

(D] lf thevatve surtace 1s hke th1s, 1t means that the

valve housmg 1s too narrow and stuated tow
down nearthe lower edge otthe valve surtace
lnteJVentiOn an the
valve housmg
M11i
type

4-27

60" (before)
45

Apply a fme-lappmg compound o n the valve se al

surtace and repeat the procedures descnbed
abave

Des1red effect

NOTE.

Centnng of hous1ng
and attamment of 1 o
mmw1dth

Be su re to remove ali the tapp1ng compound from

the valve surtace after every lappmg operatton

4 28

INSPECTION AND,-;;PAIR

l l'-1 l E-7
ENG

INSPECTION ANO REPAIRI

Apply Pruss1an blue (Dykem) to the valve seal

surface
lnstalt the valve 1n the cyhnder head

l"-1

ENG

Measure
lnchnatJon of spnng (a)
Out of speclfJcatJon -+ Replace

Press the valve onta the housmg through the

guJde to leave a clear outhne

lncllnation of spnng:

Measure the valve housmg wrdth once more lf

the w1dth of the valve JS aut of specJfiCSIJon alter

Internai sprmg

and relap

External sprlng

Lower than di 1 7 mm Lower than dl1.9 mm

CAMSHAFT
lnspect

Cam eccentncs
P1tbng/Scratches/Biue colour
camshaft

VALVE SPRINGS

1 Measure
Free w1dth of valve spnngs (a)
Out of specJfJcabon -+ Replace
2

~ _ Free wldth of valve spnngs:

Internai spnng

43.8mm

2 Measure

-+

Replace

Replace camshaft

External sprlng

40.1 mm

Measure
Cam eccentncs
Out of specfcatiOn

-+

Spnng load
Out of specJflcatton

-+ Replace

(a)

(b)

Suct1on

3647-36.57mm 30.06-30.16mm

Exhaust

36.62-36.72mm 3011-3021 mm

(b) Length of loaded spnng

Valve spring load

Internai sprlng
(b)

22.7 mm

l
l

External spring

(c)

(b)

18.1 kg

34.2 mm

l
l

(c)

16.9 kg
ROCKER ARMS ANO ROCKER ARM SHAFT
1

[11--l_

4 ?9

____,;

4-30

lnspect
Rocker arm shafts
Blue colour/Grooves -+ Replace shafts
and check lubncatiOn system

INSPECTIONAND::PAIRI
2

ENG

l'-1 l E-8

lnspect
Rocker arm shatt slot (1)
Surtace 1n contact w1th cam eccentnc (2)
AdJUSter surtace (3)
PLttmg!Wear/Scratches/Biue colour 4 Repiace and check lubncat1on system

INSPECTIONANDREPAIRI

l'-1

ENG

CAMSHAFT CHAIN GUIDE

y~
.,/
.-

lnspect
Latera! cham gwde (exhaust) (1)

Latera! cham gwde (1ntake) (2)

Wear/Damage ~ Replace

CYLINDER ANO PISTON

lnspect
P1ston and cyllnder wans
Vertlcal scratches ~ Reptace cyl1nderllner
and p1ston

3 Measure
Rocker arm shatt clearance

Measure

P1ston-cyllnder clearance

Rocker arm-shaft clearance

Internai d1ameter (a) of rocker armExternal d1ameter (b) of shaft

Measurement stages

l F1rst stage l
Measure cyl1nderbore "C" w1th a cyhnder gauge

Out of speCifiCatiOn ...,) Replace whole umt

( 1)

Rocker arm shaft clearance

0009-0042mm

NOTE
Measure bore parallel and at nght angles to the
dnvmg shaft Then calculate average measurement

CAMSHAFT CHAIN ANO SPROCKET

lnspect
Cham
Stlffness/Cracks
and sprocket

-+

50 m m from top o t cyhnder

Cylmder
bore "C"

Standard

Wear
hmlt

9497-9502mm

95.1 mm

C= X+ y
2

Replace t1mmg cham

lf the measurements are out of tolerance, re

piace the cyhnder hner, p1ston and c1rchps ali
together

lnspect
Sprocket
Wear/Damage -+ Replace t1m1ng cham
and sprocket

(1)
(2)
(3)
(4)

1/4 tooth (maxtmum)

New sprocket tooth prof1le
Roller
Sprocket

4 32

INSPECTION ANO

~AIR lENG l'-1 l E-9

INSPECTION ANO REPAIR

~:::;::::::::::::::::::::::::::;---~IS;e;c;o~n;d~st;a~g;e~I------P

l l'\.1
ENG

PISTON RINGS

Measure
Latera! clearance of nngs

Measure d1ameter P" of the p1ston s!.1rt w1th a

m1crometer

Use a thtckness gauge

( 1) 5 O mm from the lower edge of the p1ston

Out of speclfLcatJon

Replace pzston

NOTE

P1ston "P" SIZ8

94 915 .... 94.965 mm

Before measunng lateral clearance remove car

bon depoSits trom the p1ston nng housmgs and
from the nngs themselves

lf the measurements are aut of tolerance re

piace the p1ston and ClrC!Ips an together

l Th1rd stage!

Upper nng

Calculate the p1ston cyhnder free play accordmg

to the followrng formula
P1ston-cyhnder clearance

P1ston nng lateral clearance

0.04-00Bmm

Lower rmg

O 03 .... 0.07 m m

011 scraper

002-006mm

=
2

Cyhnder bonng "C" -

POSIIIOO

R1ng
(In cyllnder)

P1ston sk1rt d1ameter "P"

P1ston-cylmder clearance

NOTE

O 045 .... 0.065 mm

F11 each nng mto the cyllnder an d pus h 1t lo about 20

mm from the top edge of the cyllnder Push the nng
1nto the cyllnderw1th the p1ston so that 1t 1s perfectly
perpend1cular to the cyllnder ax1s

Max1mum hm1t

01 mm
lf the measurements are aut ot tolerance re
piace the cyhnder lrner, p1ston and Clrcllps all
together

(a)

20mm

Measure
Rmg t1p port
Out of spec1f1cat1on

Replace

NOTE

lt JS 1mposs1ble to measure the 011 scraper t1p port

lf the 011 scraper port appears too large, replace ali
three nngs

4 33

4 34

P1ston rmg t1p port

(ftted mto cyhnder)

Upper rmg

0.30 - 0.45 mm

Lower nng

0.30..., 0.45 mm

011 scraper (tracks)

0.20 .... 0.70 mm

'- -./ l l"' -l lE-1 O l

INSPECTION ANO REPAIR

ENG . . .

INSPECTION ANO REPAIR

PISTON PIN

Check
Ptston pm
Bluecolour/Grooves-+ Replace andcheck
lubncat1on system

l l"-1
ENG

lnspect
Clutch d rum beanng
Damaged-+ Aeplace

2 Measure
External d1ameter (a) of ptn
Out of spectflcatiOn -+ Replace

lnspect
Groove 10 clutch drum
Psttlng
Moderate ~ Burr
Accentuated ~ Replace clutch d rum

NOTE.
Psttmg of the mternal drum grooves causes srregular functsomng

External d1ameter (ptn).

21 991 .... 22.000 mm

3 Measure
Clearance between ptston pm and ptston
housmg
Out of speclftcat1on -+ Replace

Clearance between p1ston pm and

p1ston =
D1ameter on ptston (b)D1ameter of pm (a}

Measure
Thtckness of fnctson plates
Out of spectftcatson ~ Replace ali plates

Clearance between p lsto n p1n an d

p1ston
0.004- O 024 mm

Thtckness

Wear
hm1t

Type "A"
(2 elements)

294-3.06mm

28mm

Type "8"
(6 elements)

272-2.88mm

2.6mm

Maxtmum clearance.

0.07mm

Measure
Deformat!On of clutch plates
Out of specJfscatiOn ~ Replace ali plates
Deformat1on ilm1ts of clutch
plates
02mm

CLUTCH

lnspect
Clutch gear assy teeth
Cracks/Ptttmg (on edges}
Moderate -+ Burr
Accentuated-+ Replace clutch gear assy

NOTE

P1tt1ng o! the gear assy teeth causes 1rregular funcliOnlng

Measure
Runout ltmst of clutch release rod
Turn clutch release rod on two V blocks

Runout limit.
0.2mm

4 36

INSPECTIONAND';;;PAIRI
7

ENG

l'-1 lE-111

Measure
Free length of clutch spnngs (a)
Out of speclfJcatiOn ....:. Replace ali spnngs
Clutch sprmg (a} mm1mum
length
40.8 mm

INSPECTION ANO REPAIRI

ENG

l"-1

TRANSMISSION ANO GEARBOX

lnspect
Gear fork cam ptn (1)

CD-~~~
_f.

Gear fork pawl (2)

Lmes/Creases/lfo/ear-+ Replace

\3

OILPUMP

lnspect
Drum groove
Gear cam pms
Wear/Damage -+ Replace

Check
Gear fork movement
Rough functlomng -+ Replace gear forks
and/or gutde bars

lnspect
GUide bar
Turn on a flat surface
Curvature-+ Replace

Measure
Clearance between rotors (a)
(Between the tnternal rotar (1) and the
external rotar (2))

Latera! clearance (b)

(Between the external rotar (2) and the

pump stator (3))

Out of spectfJcatJon

Replace DII pump

011 pump clearances

Latera! clearance (b)

2

O03,.., 0.08 m m

lnspect
Otl pump dnve gear (1)
011 pump dnven gear (2)
Wear/Crac\<:s/Damage -+ Replace

PRIMARY TRANSMISSION

Do notattempt t o stratghten the deformed gUide

lnspect
Pnmary dnve gear teeth (1)
Pnmary dnven gear teeth (2)
Wear/Damage -+ Replace both gears
Excess notse dunng functlomng -+ Repiace both gears

bar

Measure
Transmtsston shah eccentnc1ty
Use the centnng tool and mtcrometer
Out of spectftcatton-+ Replace bent shah

Eccentnctty hmtt.
O.OSmm

4 37

4-38

INSPECTIONAN~~PAIRI ENG ' ' - ' IE-121

6

INSPECTION ANO REPAIRI

lnspect
Gear teeth
Brown colounng/Pittmg!Wear-7 A
Matlng clutches
eplace
Aounded ed ges/Cracks/M1ssmg frag
ments -+ Aeplace

Check
Proper matlng of each gear (WIIh
spond1ng part)
corre

ENG ' " - '

STARTER TRANSMISSION

...

Check
Starter clutch functlomng ( 1)
Thurn the clutch In the dlrectlon mdlcated by
e arrow
'lrregular tunctiOnlng/Damage-> R l
clutch
ep ace

,'

Gear movement
Aoughness -+ Aeplace

lnsta1l the starter n m on th

the gear flrm
e gear and hold
When turmng the gear nm l
d1rect on {A) the
n a clockw1se
1
meshed
,
gear and nm must be

*****************

Transm1SS1on gear ass:~~~~ ::; * * *

Flt the second gear (2) t
ges

as shown m the figure o the propeller shaft (1)

(a) 60 O mm

Otherwlse, the gear IS faulty and must be

replaced
When the gear n m IS turned In an anttclockWISB dtrectton (B) 11 must turn freely Oth
erwlse the gear IS faulty and must b
replaced
e

F1t the second sprock (

to the mam shaft (3) et 4) and flfth sprocket (5)

Il

(b)

905mm

...................
8 lnspect

C1rchp
Damage/Loosenlng/Bendlng -,
~ Rep lace

GEAR SHAFT ANO STOP LEVER

1

lnspect
Gear shaft
BentMiear/Damage -? Aeplace

2 lnspect
Stop lever (l)
The roller rotates Jerklly -+ Replace
BenVDamage -+ Replace
3

4-39

lnspect
Return spnng (2)
Damage/Cracks -+ Replace

4-40

lnspect
Starter neutral gear teeth (1)
Starter neutral gear teeth (2)
Starter nm teeth (3)
Burrs/Shavtngs/Roughness/W
piace
ear

lnspect
Starter nm (contact surfaces)
PttllngN.Jear/Damage -7 Replace

-+

Re

''-...../

INSPECTION ANO REPAIR

'-

l>C

~~

"12

Measure
W1dth of crank (A)
Out of spec!flcatiOn
shaft

C
:-

lE-131
INSPECTION ANO REPAIRI

CRANKSHAFT

-,.---

la
Il]

~~._,

ENG ~

1'-" '-l

ENG ' " - '

BALANCER SHAFT DRIVE ANO DRIVEN GEARS

lnspect
Dnve gear teeth (1)
Dnven gear teeth (2)
Wear/damage ~ Replace both gears

-+ Reptace dnvmg

W1dth of crank

74 95-75.00 mm

Runout (B)

Out of spec1flcat10n -+ Reptace dnvmg

shaft and/or lever beanng
Runout hm1t.

0.03mm

Check
Marks (1)
lf they are not allgned ~ Altgn the marks as
shown m the ftgure

Connectmg rod foot clearance (C)

Out ot speclflcatton-+ Replace connect1ng

rod head beanng, connectmg rod pm and/

or connect1ng rod
CRANKCASE

Connectmg rod foot clearance

lnspect
Sem1cranks
Beanng housmg
Damaged -io Replace

oamm
Lateral clearance (D)

Out of speclfLcatton-+ Replace connectlng

rod

BEARING ANO OIL SEAL

Connect1ng rod head clearance.

0.35- 0.65 mm

lnspect
Beanng
Roughness/P!ttlng/Damage
Otl seal edge
Damage/VVear ~ Replace

Dnvmg shaft assembly stage

The passages of dnv1ng shatt (1) 011 and con
necttng rod pm (2) 011 must comc1de w1th a

tolerance of less than 1 O mm

4 41

4 42

Replace

ENGINE ASSEMBLY ANO:;ITINGI

ENG

l"-l lE-141

ENGINE ASSEMBLY ANO SETTING

ENGINE ASSEMBL Y ANO SETTING

ENG

~~l

VAL VES

Burrs
Valve stem head

VAL VES ANO ROCKER ARMS

(1)
(2)

Rocker arm n 2
Wave washer

(11) Lower valve spnng

(3)

Rocker shaft (mtake)

(12) Rocker shaft

(exhaust)

{4) Rocker arm n 1

(5) Valve cotters
(6) Upper valve spnng

Leave the valve stem head w1th an 011

stone

reta1ner

(7)

011 seal

(13) Rocker arm n 4

(14) Rocker arm n 3
(15) Rocker shaft

(8)
(9)

Internai spnng
External spnng

(exhaust)
(16) Valve (exhaust)

reta~ner

Lubncat1on
Apply h1gh qualrty molybdenum d1sulfide 01!
(to the valve stem and 011 seal)

lnstall

011 sea! (1)

Valves (2)
Lower valve cap (3)

Interna! spnng (4)

External spnng (5)
Upper valve cap (6)

(10) Valve (mtake)

VALVE CLEARANCE !COLO)

VALVE SPRING TILT LIMIT

lnnet spr1ng
B
25or17mm(0067m)
Outer sprmg
2 5 or1 9mm(O 075m)

lntaka

005-010mm{0002~0004m)

Exhaust O 12-0 17 mm (0 005-0 008 in)

10 ftlb)

10 Nm 11 O mkg

NOTE
lnstall the mterna! and external spnngs Wllh the
Wldest thread upwards

(7)
(8)

H1gher p1tch
Lower PliCh

lnstall

Valve cotters (1)

NOTE
Compress the valve spnng w1th the spec1f1c tool (2)
to flt the cotters
C STEM RUNOUT LIMIT
O 01 m m (0 0004 m)

Valve sprlng compress1on clamp

10 Nm 11 O mkg 7 2 ftlb)

P/N YM-04019
P/N. 90890-04019
D

VALVE SEAT WIOTH

10-12 mm IO 04-0 05 1nl

4 41

4 44

'-.../ 1ENG 14."a-1 lE-151

ENGINE ASSEMBLY ANO SETIING

ROCKER ARMS
Lubncate

Engme 011
(far rocker shaft)

lnstatl

ENGINEASSEMBLYANDSETIINGI

(1) Connectmg rod pm

(2) Crank (left)
(3) Connectlng rod
(4) Beanng

A
8

c
NOTE:
Each rocker arm 1s numbered
D

(5)
(6)
(7)
(B)

Beanng
Beanng
Balancer shaft
Beanng

CRANK WIDTH
74 95-75 00 mm 12 950-2 9531n)

RUNOUT UMIT
O 03 m m IO 0012 m)
SMALL END FREE PLAY
O 8 mm (0 031 m)

BIG END SI DE CLEARANCE

O 35-0 65 mm (0 013-0 026 1n)
O 35-0 75 mm (0 013-0 030tn)(A)

f)

(1)
(2)
(3)
(4)

1~1

CRANKSHAFT ANO BALANCER SHAFT

Rocker arm
Rocker shatt

Screws (1) (rocker shaft)

10 Nm (1.0 kgm)

ENG

#1
#2

#3
#4

~
f"~ ({i~o

lnstall
Cap (1)

'
120 Nm (12 O mkg, 85 ft-lb)

440

4-46

ENGINE ASSEMBLY ANO SETTING

1ENG 14-IIE-1&1
'"a

CRANKSHAFT ANO BALANCER SHAFT

lnstall
Crankshaft

Crankshaft mstallat1on tool (1):

P/N YU-90050
Crankshaft mstallabon tool nut (2)

P/N. 90890-0127 4
Crankshaft mstallat1on tool bolt (3)'

P/N 90890-01275

ENGINE ASSEMBLY ANO SETTING

lENG ,.._,

TRANSMISSION

(1) Sprocket
(2) 011 seal
(3) Beanng
(4) Second wheel gear
(5) Secondary shaft
(6) Ftfth wheel gear
(7) Th1rd wheel gear

(11) Beanng
(12) Second sprocket gear
(13) F1fth sprocket gear
(14) Th1rd sprocket gear
(15) Fourth sprocket gear
(16) Ma.n shaft
(17) Beanng

(8) Fourth wheel gear

(9) F1rst wheel gear
(10) Beanng

Adapter# 10 (4)
P/N. YM-90069
P/N. 90890-04059
Crank spacer (5)

10 Nm (1 O mkg, 7 2 fHb)

P/N YM-91 044

P/N. 90890-04081

Spacer (6)
P/N 90890-01016

NOTE
Ho!d the connectmg rod at top dead centre w1th
one hand and turn the assembly tool nut w1th the
other

Work on the assembly tool unti l the lower part of the

dnvmg shaft enters mto contact wth the beanngs

CAUTION:

To protectthe dnvmg shattfrom scratches and

facilitate assembly operabons, apply grease to
the edges of the oli seals and eng1ne oli to the

beanngs

2 lnstall

Balancer shaft (1)

B MAIN AXLE RUNOUT LIMIT

O 08 mm {0 003 n l

4 47

4-48

ENGINE ASSEMBLY ANO S;:;.ING

Stop lever

(2)

GUJde bar

(3) Selector fork #3

(4) Selector fork #i
(5) Gear cam
(6) Gwde bar

ENG

ENGINEASSEMBLY ANDSETIINGI

ENG

l"-l

TRANSMISSION ANO GEARBOX

GEARBOX

(1)

l l"-1 l F-1

lnstall
TransmiSSJon assembly (1)

(7) Selector fork #2

(B) Gear shaft #1
(9) Gear shaft #2
{10) 011 seal
(11) Gear !ever

lnstall

Selector fork #1 {1)

Selector fork #2 (2)

Selector tork #3 (3)

Gear cam (4)

Gwde bar (5)

NOTE

Eaeh gear fork IS 1dent1f1ed by the number stamped

on 1ts s1de Ali numbers must tace left

lnstall

Gear shaft #1 (1)

Gear shaft #2 (2)

NOTE

Al1gn mark (3) on the gear selector shaft w1th that on

the gear shaft

<::./

Jerky functiOnmg

110Nm(1.0mkg.72ftlblj

4 40

Check
TransmiSSIOn funct10mng

4-50

Repa1r

ENGINE ASSEMBLY ANO

ENGINE OIL PUMP ANO PUMP SUCTION
(1)

011 pump suctiOn

(2)
(3)

011 pump
011 pump gear

s~~ING lENG l\.1 l F-2

ENGINE ASSEMBLY ANO SETTING

l l'-1
ENG

CRANKCASE

(1) R1ght sem1crank

(2) Left sem1crank
(3) Crankcase vent1lat1on hose
(4) Dowel pm
(5) Dowel pm
(6) Dowel pm
(7) Bearmg cover plate
(8) Collar
(9) Lock plate

lA lTIGHTENING SEOUENCE l

OIL PUMP
TIP CLEARANCE
A
O 12 m m IO 005 m l
SIDE CLEARANCE
O 03-0 08 m m IO 001-0 003 m)

7 Nm

IO 7 mkg, 51 ftlbl
l

a
20 Nm 12 O mkg. 14 ftlbl

4-51

ENGINEASSEMBLYAND::rriNGI

ENG

l~ l l F-3

ENGINE ASSEMBLY ANO SETTINGI

ENGINE OIL PUMP SUCTION

1 lnstal!

Otl pump suctton (1)

Otl passage cover (2)

Ttghten
Screws (crankcase) (1)

l"-1

(14)

NOTE
Ttghten the screws begmntng wtth the one wtth the
lowest number

Screw (pump suctton}.

7 Nm (0.7 mkg)

Screw (crankcase) (4)

10 N m (1 O mkg)

Screw (oli passage cover)

7 Nm (07 mkg)

ftiiMi;l~lidi -----------

Apply

Aiways use a new gasket.

CRANKCASE

Apply

ENG

Yamaha bond W 1215 (1)

4 stroke engme Otl

(tothe connecttng rod pm the beanng and
the otl passage)

Check
Gearbox and transmtsston funcbomng
Jerky functtonmg 4 Repatr

(on the semtcranl< contact surfaces)

GEAR LEVER ANO OIL PUMP

Bondmg agent {Qu1ck Gasket)

P/N ACC-11001-01

lnstall
Spnng(1)
Gallar (2)
Stop lever (3)

Yamaha band W 1215

P/N 90890-85505

lnstall

1~1

Dowel ptn (2)

Assemble the left semtcrank to the nght

semtcrank Beat gent!y wtth a soft hammer

Stop lever screw (4)

10 Nm (1 O mkg)

NOTE
Piace the gearbox lock lever and the spnng m the
correct poSitton

NOTE.

Turn the gearbox cam plate as shown m the ftgure

so that tt does not mtertere wtth the crankcase
durmg assembly
CAUTION:

Before mstaltmg and t1ghtenmg the fastemng

screws, be sure that the transmss1on ls workM
mg properly by hand, turnmg the gearbox cam
plate m both dtrect1ons

4 54

lnstall
Flat washer ( 1)
Spnng (2)
Gear lever (3)
Ctrchp (4)

ENGINEASSEMBLYAND~TTINGI ENG \"-\ l F-4

ENGINEASSEMBLYANDSETTINGI

ENGINE ASSEMBLY ANO SETTING

NOTE:

When msto.lllng the gear lever, allgn the mark on the

lnsta!l

lever w1th that on the gear shaft

lnstall
C1rchp (1) (to the dnv1ng axle)
Flange (2)
C1rchp (3)

Apply
4 stroke eng1ne 011
(oli p1pes 1n crankcase)

CAUTJON

To avo1d damage to theenglne, lubncate the 011

pump p1pes m the crankcase hberally w1th 4w

stroke engme 011

Apply
4stroke engme 011
(oli pump p1pes)

Apply

ORing (1)

011 pump (2)

01l pump gear (3)
C1rchp (4)
Screw {5) (011 pump)
10 Nm (1 O mkg)

4 55

ENG

4 56

T1m1ng cha1n (1)

Cha1n gwde (2)

\~\

'--./

ENGINE ASSEMBLY ANO SETTING

l l"-1 l F-5
ENG

ENGINE ASSEMBLY ANO SETTINGI

PISTON ANO RINGS

CYLINDER

(1)
(2)
(3)
(4)
(5)
(6)

(1)
(2)

ENG ' " - '

Gasket
Cyhnder
(3) 0-R,ng
(4) Gasket
(5) Dowel pm
(6) Dowelw p1n

R'ng (upper)
R'ng (lower)
Scraper
P1ston
P1ston pm
C"chp

A TIGHTENING SEOUENCE

BORE SIZE

94 97-95 02 mm (3 739-3 741 m)

8
PJSTON SIZE

94 915-94 965 mm
(3 737-3 739 m)
86 945-86 965 mm
(3 423-3 424 m)(AJ

PISTON AING END GAP

Top O 30~0 45 mm (O 012~0 018 m)
O 30-o 50 mm (0 012~0 020 m) (A)
B 2nd O 30-o 45 mm (0 012-0 018 1n)
O 30-0 50 mm (O 012-0 020 m) (Al
011 o 20-0 10 mm 10 ooa-o 028 m)

PISTON-TO-CYLINDEA CLEARANCE

o 20-o 90 mm 10 oos-o oas m) !Al

PISTON RING SIDE CLEARANCE

C

87 00-87 02 mm {3 425-3 426 m)(A)

<LIMIT>
<95 1 mm (3 744 m)
<87 1 mm (3 429 ln)>(A)

Top O 04-0 08 mm (0 002.....0 003m}

2nd O 03-0 07 mm (O 001-0 003m)
011 o 02-0 06 mm (0 oos-o 002m)

cf:
l22 Nm 122 mkg,16

ftlbll~

4 58

O 045-0 065 mm (0.002-0 003 an)

<LIMIT>
<01 mm {0004 m)>

ENGINEASSEMBLYANDS'::.INGI ENG'I'-1
CYLINDER HEAD

l F-6

ENGINE ASSEMBLY ANO SEITING ENG l ' - 1

CAMSHAFT ANO CAMSHAFT CHAIN

(1) Cyhnder head cover

(2) Tappet cover
(mtake)
(3) 0-R~ng
(4) Tappet cover (exhaust)
(5) O-R1ng
(6) Cap

(7) Cyhnder head

(8) Valve gwde
(9)

(exhaust valve)
Valve gu1de

(mtake valve)
(10) Spark plug
(11) Dowel p1n

(1)

Camshaft

(2)
(3)
(4)
{5)

Camshaft contrai sprocket

Cha1n gwde
T1mmg cham
Cham gUide
Gasket

(6)
(7)

Cham tens1oner

10 Nm 11 O mkg 7 2 ftlb)
A

SHAFT-TO-CAP CLEARANCE
O 020-0 054 mm

IO 0008-0 0021 m)

10Nm
(1 Omkg

7 Nm (07 mkg

SEALANT (QUICK GASKET)

A YAMAHA BONO NO 1215
l

_____ j l
20 Nm 12 O mkg, 14 ftlbl

,f.sg

4-60

ENGINEASSEMBLYAND:;TTINGI

ENG

l"-1 l F-7

ENGINE ASSEMBLY ANO SETTING

PISTON, CYLINDER, CYLINDER HEAD ANO

CAMSHAFT

l l"-1
ENG

Offset the p1ston nng ports as 1Uustrated m the

f1gure

Apply

NOTE
Check that the marks and numbers stamped by
the manufacturer on the p1ston nngs face up
wards
Before mstalhng the cyhnder, lubncate the p1ston
nngs hbera!ly w1th 4-stroke engme 011

4 stroke engme 011

(an ptn)

lnstall
P1ston (1)
Ptn (2)
C1rchp (3)

(l)
{2)

NOTE.
Arrow (4) on the p1ston must po1nt towards the
tront of the engme
Before mstalllng pm nngs cover the crankcase
w1th a clean cloth to prevent fore1gn bod1es
fa!ltng mto 11

(3)
{ 4)

''*'';!~l@!f

----------

Aiways use new crchps far the pm

3

lnstall
Cyhnder (1)

NOTE
lnstall the cyhnder to the p1ston w1th one hand
wh1le one hand wh1le compressmg the p1ston
nngs w1th the other
B1nd the tlmtng eh am w1th w1re and sltp 1t through
the appropnate slot

lnstall

Upper nng
Scraper (lower nng)
Scraper (upper nng)
Lower nng

Dowel pms (1)

ORtng (2)

Screw (2)
10 Nm (1.0 mkg)

Cap nut (3)

42 Nm (4.2 mkg)

Nut (4)
42 Nm (4.2 mkg)

lnstall
Gasket (1) (cyhnder)

NOTE
lnstall the cyhnder gasket as shown m the tllustra-

tLon

61

4 62

ENGINE ASSEMBLY ANO';TTING

7

l l'-1 l F-B
ENG

lnstall
Dowel pms { 1)

0-Rrng (2)

Gasket (3) (cyhnder head)

lnstall
Cyhnder head

ENGINE ASSEMBLY ANO SETTINGI

ENG

l'-1

lnstall the gear wheel w1th the t1mmg marks as

shown m the f1gure and t1ghten the screws on the
gear wheel by hand
(3)

Upper cyhnder head su riace

(4)

T1m1ng marks

(5)

Upper posttlen mark

When pushmg the cham tens1oner be sure that

the t1mes on the t1m1ng gearwheel are allgned
w1th the top surface of the cyllnder head
lf the marks are allgned, tghten the t1mmg gearwheel screws

NOTE

Screw (tmmg gearwheet)

T1ghten screws begmmng wlth the one w1th the

lowest number

Screw (1), (2), (3) and (4)

29 Nm (2 9 mkg)

20 Nm (2 o mkg)

lf the marks are not aligned replace the t1mmg

gear wheel matmg p1ston and cham

Nut (5) and (6)

22 Nm (2 2 mkg)
Screw (7)
10 Nm (1 O mkg)

lnstall
Chatn gUJde

Camshaft

Camshatt sprocket

10 Apply

T1mmg cham mstallat1on

lnstall the ttmmg cham on the cyhnder head as
111ustrated (compress1on phase t1mmg)
Run the ttmmg shaft m an ant1clockwse d1rect10n
unttl the mark on the era nkcase (1) and the pomt
on the ttmmg cha1n gearwheel (2) are ahgned

Yamaha Band N 1215 (1)

(an the contaci surfaces)
Sealant (OUick Gasket).
P/N ACC-11001-01

Yamaha Band W 1215

P/N. 9089085505

11 lnstall
Dowel pms (2)
12 tnstall
Cap
Cyllnder head cover
NOTE.

Cross-t1ghten the screws repeatedly

Screw (cyhnder head cover)

10 Nm (1 O mkg)

4 63

4-64

ENGINEASSEMBLYAND:TTINGI

ENG ' " - '

l F-9

ENGINE ASSEMBLY ANO SETTING

f i f
<41

ENG

~~l

15 lnsta!l

13 lnstall
Cham tenstoner

'""""'"""'"""' o

Tappet cover (1) (exhaust)

Tappet cover (2) (mtake)
Spark plug (3)

lnstallat1on sequence

Remove the cham tenstoner screw (1) the

Tappet cover (exhaust):

12 Nm (1.2 mkg)
Screw (tappet cover-antake).
10 Nm (1 o mkg)

washer (2) and the spnng (3)

Release the eh amtenstoneruntdtrecttonal cam

(4) and push the thrust rod (5)

lnstall the chatn tenstoner m the cyhnder wtth
a new gasket

Screw (cham tens1oner body)

10 Nm (1.0 mkg)

Spark plug
18 Nm (1.8 mkg)
NOTE
The tappet cover (1ntake) should be assembled
w1th the arrow (4) po1ntmg upwards

Always use a new gasket

lnstall the spnng the washer and the cham

tenstoner

Cham tenstoner screw

20 Nm (2 O mkg)

14 AdjUSt

Valve clearance
lntake.

0.05-010 mm
Exhaust
o 12-0.17
See secMn 'VALVE CLEARANCE AD
JUSTMENT

1n CHAPTER

4 66

ENGINE ASSEMBLY ANO:;TTING

l l"-1 lF-1 ol
ENG

ENGINEASSEMBLY ANDSETTINGI

AC GENERATOR

ENG

l"-l

AC GENERATOR

(1)

Rotar

(2)
(3)

PICkUp COl!
Stator w1ndmg

lnstall
Key (1)
Washer (2)
Beanng (3)
Rotor (4) (w1th starter gear)
Washer (5)
Nut (6)
NOTE.

PICKUP CO! L RESISTANCE

When mstalhng the AC generator rotar, check that

the key f1ts properly 1nto 1ts housmg on the dnv1ng
shaft Apply a thn layer of hth1um soap-based
grease on the comcal tp of the dnvmg shaft

184-2760 at 20 c (68'F)
(Green/Whlte - Blue/Yellow)

T1ghten
Nut (rotar)

'~'

Nut (rotar)
120 Nm (12.0 mkg)

NOTE
To tLghten the nut lock the rotar w1th the specal
clamp (1)

(')

l ~~
~

Rotar clamp
P/N YS-01880

P/N. 90890-01701
CAUTION:

Be careful not to touch the JUttmg edges (2) on

the rotar wdh the rotor c\amp tool

STATOR COl L RESJSTANCE

O 52--..0 780 at 20'C (68'F)
(Wh1te - Wh1tel

4 67

4 68

ENGINE ASSEMBLY ANO S:ING

l l"-1 lF-11 l
ENG

ENGINE ASSEMBLY ANO SETTING

OIL FILTER ANO OIL HOSES

BALANCER SHAFT GEAR ANO PRIMARY TRANSMISSION GEAR

(t) 011 f1lter

(2) F1lter cover
(3) 011 hose
(4) 011 hose
(5) 011 dehvery hose

(t) Key
(2) Balancer shaft gear
(3) Plate
(4) Lock washer
(5) Nut
(6) Washer
(7) Key

(6) 011 dram plug

(8)
(9)
(10)
(11)
(12)

Balancer shaft transm1sS10n gear

Plate
Pnmary transmiSSIOn gear
Lock washer

(13) Nut

r~
J.---,-:-.,..--,::-:-:-..,..,-,

'(' ls Nm IO 5 mkg

10 Nm (1 O mkg 7 2 ftlbl

3 6 ftlbl

A USE NEW ONE

10 Nm 11 O mkg. 7 2 ftlb)

120 N m (12 O mkg, 85 ft-lb)

4 70

ENG

Plate

!AIUSE NEW ONE

10 Nm (1 O mkg 7 2 ftlb}

~~l

'-"

ENG

l\.1 lF-121

E
SETTINGI
GEAR ANO PRIMARY
NGINE ASSEMBL y ANO
R SHAFT
BALAN;I;SION GEAR
TRANS

CLUTCH
(1)
(2)
(3)

lnstall

Key
(1) shaft gear (2)
Balancer
Plate (3)
)
4
Lock washer (
haft gear)
Nut (5) (balancer s
washer (6)
Key (7)
Plate (8)

Balancer sha

___________!E~N~G~I~N~EA~S~S~E~M~B~L~Y------

-----~=:

ANO SETTING L - - - - -

Spnng
Pressure p!ate
Push rod

(9) Clutch boss

(10) Washer

~~~IIOn

(12) Clutch release

(11) Gear assy

(4))
plate (type A)
(5
(6) Clutc h boss spnng
Cl tch plate

(7)
(S)

shaft

levt~:nsmtsston gear

(13) Push
(14) Pnmary

u
Fnct1on
pia te (type B)

ft dnve gear (9)

Plate (10)
sstongear{11)
Pnmarytransmt
MINJMUM
CLUTCH SPRING
H
FREE lENrr~:83 ml
326 mm

A FRJCTION PLATE

Lock washer (12) transmtsston gear)

Nut (13) (pnmary

Type

Nut (balancer s h aft gear).

60 Nm (6.0 mkg) lsslon gear)
Nut (proma ry transm
kg)

Thlckness

Wear l1m1t

294-3
l
10116-0120m
2 72-2 88 mm
10107-0113mJ

2 8 mm IO 110 n l

06 mm

CH PLATE
CLUTPAGE LIMIT
C WAR
IO 008 ml
02mm

26mm 10 102m)

L_____~12~0~N~m~(1~2:-0~m~~----~=-WOTE
Nhen mstalllng the
(14)wttht ha t ofthe

dbna~=n~er

ear, ahgn the mark on tt

shaft gear (15)

''*.Z.1;1f!!f1f
- - - - -. - use a new---:;h::.:;,-_
lock was
Always
NOTE:
and(13),keeptheACgenerator
To1tghten nuts (5) ectal tool {16)

rotar stili wtth the sp

Rotor clamp:
P/N YS01880
P/N. 9089001701

jutllngpart(17)oflherotor
''CAUTJON:
ttotouchthe
Becarefulno
l
withtherotorlocktoo.
2

Bend the lock wa sher tab along the fa ce of the

nut

4 71

4 72

ENGINEASSEMBLYANDS~NGI ENG 1
..1 lF-131

ENGINE ASSEMBLY ANO SETTINGI

CLUTCH

1~1
2

Flat washer
Sprrng
Push tever (1)

CAUTION:

Screw (push lever)

12 Nm (1 2 mkg)

lnstall

1"'-1

NOTE.
lnstall the drrven and dnve plates to the Internai
drum begmnmg and end1ng w1th a dnve plate

lnstaU

ENG

The two dnve plates (type A) (15) w1th the

w1dest Internai d1ametershould be assembled
1n second and last piace
The wave plate (16) should be placed ms1de
the second dnve d1sc.

Push rod (1)

Gear assy (2)
Thrust ptate (3)
Clutch boss (4)
Lock washer (5)
Nut (6) (clutch boss)
W ave plate (7)
Clutch plate (8)
FnctJon plate (9)
Bali (10)
Pressure plate (11)
Clutch sprrng (12)
Screw (clutch pressure d1sc) (13)

Fnct1on plate

Type "A

Type "B"

Ouant1ty

Internai
d1ameter "O"

116mm

113mm

Nut {clutch boss)

90 Nm (9.0 mkg)
NOTE
Ahgn the mark on the 1nternal drum (17) w1th the
arrow (18) on the clutch pressure diSC

Clutch pressure d1sc screw:

8 Nm (0.8 mkg)
NOTE:
T o t1ghten the nut (clutch boss), lock the ctutch

Adrust

drum wth the all*purpose tool (14)

Clutch clamp.

P/N. YM-91042
P/N 90890-04086
Bend the lock washer tab atong the face of the

nut

Always use a new lock washer

Clutch (free pray)

See sect1on "CLUTCH ADJUSTMENT 1n
CHAPTER3

lnstan
Stra1ght key

Gasket

Crankcase cover (nght) (1)

O Rmg
011 fllter

F1lter cover (2) (w1th 0-Rmg)

See sec110n 'Engme 011 change {w1th 011
f1lter)" 10 CHAPTER 3

Bolt (crankcase cover):

10 Nm (1 o mkg)

4-73

4-74

ENGINEASSEMBLYANDS~NGI ENG l'-1 l F-141

ENGINE ASSEMBLY ANO SETTING

l l'-1
ENG

STARTER NEUTRAL GEAR ANO CRANKCASE

COVER (L)

STARTER GEARS
(1) Starter gear
(2) Starter neutra! gear 1
(3) Starter neutra! gear 2
(4) Starter gear
(5) Starter clutch

lnstall
Stator wmdtng (1)
Ptck-up COli {2)
Cable clamp (3)

Screws (stator and cotl)

7 Nm (07 mkg)
Use LOCTITE
Screw (cable clamp)
,--~-------------

-------------

7 Nm (07 mkg)

''
'
''

''
'
2

lnstall
Beanng (1)

lntermed1ate starter gear 2 (2)

lnstall
Centnng pm (1)
Gasket (2)
0-Rmg (3)
Crankcase cover (L) (4)
Plugs

Bolt {crankcase cover).

10 Nm(1 O mkg)

.Q. WARNING
Always use a new gasket

120 Nm (12 O mkg, 85 ftlb)

4 75

4-76

ENGINEASSEMBLYANDS~INGI ENG ,.... , l F-151

:
..

'

.,.,

~~ .

r'

\~/

S)

~.

ENGINEREASSEMBLYI

ENG ' " - '

ENGINE REASSEMBL Y

lnstall
Neutral sw1tch cable (1)

To reassemble the engme, repeat the procedures

descnbed 10 the paragraph 'ENGINE REMOVAL"

1n th1s chapter 1n reverse arder Pay attenMn tothe

followmg po1nts

~(.r?
6.
_/

AWARNING
Set the motorcycle up flrmly t o prevent 1t falhng
aver

.1/"-"t'.J.~.r1

lnstall
Shaft (1)
Beanng (2)
Starter 1ntermed1ate gear 1 (3)

lnstall

Engme
Rear fastenng pm (1)

NOTE.
Apply grease to the rear fastemng p1n

Nut (2) (front)

64 Nm (6.4 mkg)
Nut (3) (upper)
64 Nm (6 4 mkg)

lnstall
Centrmg p1ns
Gasket
Cover (1) (starter 1ntermed1ate gear)

1~1

Nut (4) (lower).

64 Nm (6 4 mkg)

Screw (cover).
10 Nm (1.0 mkg)

Nut (5) (axle shaft):

85 N m (8 5 mkg)

lnstall
Engme protectiOn (1)

Screw (engme protect1on)

10 Nm (1 O mkg)

477

478

Connect
Engme harness

ENGINEREASS~LYI ENG ' " - '

4

l f-

16

ENGINEREASSEMBLYI
8

lnstall
Spari< p!ug ca p ( 1)

1~1

Sprocket (1)

l'\.1

lnstall

lnstall

ENG

Otl hose (1) (mtake)

Otl hose (2) (outlet)

Screw (ati hose)

10 Nm (1 o mkg)

Dnve cham

1~1

Nut (sprocket):
110 Nm (11.0 mkg)

lnstatl

Starter (1)

NOTE:
Bend the lock washer tab along the face of the

nut

1~1

Starter nut
10 Nm (1.0 mkg)

l!i!fd;U!Witi - - - - - - - - - Atways use a new lock washer.

o lnstall

lnstall

i'"" l

Cover (1) (sprocket)

Gear pedal (2)
Footrest (L)

Screw (gear pedal):

10 Nm (1.0 mkg)

18 Nm (1 8 mkg)

Tappet cover (exhaust)

Atr bleeder screw (ati ftlter cover)

12 Apply
4 stroke engtne otl

Screw (footrest)
45 Nm (4 5 mkg)

(an the tops1de of the camshaft and m the

011 f1lter compartment)

Adjust
Dnve chatn ttg htness

CAUTION
L1berally apply 4-stroke engme 011 in the 011
passage 1n the crankcase t o prevent damage t o
the engme.

Drive cham tightness

30-40 mm

Amount of 011
Camshaft
0.1 htres

Seesectlan "DRIVE CHAIN !NSPECTION

ANO ADJUSTMENT'

Connectton screws:

11 Remove

Screw (cover).
10 Nm (1 O mkg)

011 dellvery hose (1)

1n CHAPTER

011 f1lter compartment

0.06 htres

4 79

480

--------------------~E~NG=IN~E~R=E~As~s=EM=~~LviENG~~~ l G-1
13 lnstall
Tappet cover (exhaust)
A1r bleeder screw (011 f1lter cover)

ENGINEREASSEMBLYI ENG
20 AdJUSt
Throttte cable free play

[b;.l(d

See sectlOn 'THROTTLE FREE PLAY

ADJUSTMENT' 1n CHAPTER 3

Screw (a1r bleeder screw)

14 Connect

Return spnng (brake pedal)

15 lnstall
Footrest (R) (1)

Rear brake pump (2)

Screw (footrest):

Free play
3.-.Smm

r.bJ

Screw (tappet cover)

10 Nm (1 o mkg)
5 Nm (0.5 mkg)

1. .1

21 lnstaH
Battery
22 Connect
Battery cables

CAUTION:
Connect ftrst the postttve (+) cable, then the
negative (-) cable.
See sectiOn BATTERY INSPECTION 10
CHAPTER3

45 Nm (4.5 mkg)

Screw (rear brake pump)

23 lnstall
Fuel tank

20 Nm (2.0 mkg)

16 lnstal!

Exhaust p1pe (1)

CAUTION
Do not start the engme unttl tt ts ftlled wtth otl.

Nut (exhaust p1pe).

10 Nm (1 o mkg)

24 F1ll wtlh

Bolt (rear exhaust p1pe)

20 Nm (2.0 mkg)

Engme 011
Amount of otl (tn the engtne)
2.3 htres

17 lnstall
Clutch cable

In the oli tank:

1 8 lltres

18 AdjUSt
Clutch cable free play

See sectlon 'ENGINE OIL CHANGE' 10

CHAPTER3

Free play (at end of tever):

10-15mm

25 Check
Engme 1dle speed

See sectJon 'CLUTCH ADJUSTMENT' m

Engme 1dle speed.

1,200-1,400 rpm

CHAPTER 3

19 lnstall

1~1

Se e sect1on "IDLE SPEED ADJUSTMENT'

Carburettor

m CHAPTER 3
26 lnstall

Screw (clamp):
2 Nm (02 mkg)

See secMn "CARBURETIOR-INSTAL

LATION"1n CHAPTER 5

4 81

1~1
482

Se at
A1r ducts
Stde panels
Screw {seat}:
10 Nm (1.0 mkg)

jcARsj f j l G-2 l __'__/ _______ ,CARBifl

CHAPTER 5o
CARBURETTOR
CARBURETTOR
TECHNICAL SPECIFICATIONSITIGHTENING TORQUES/ EXPLODED VIEW
SECTION VIEW
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
FUEL LEVEL ADJUSTMENT

G3
G3
G-3
G-4
G-4
G6
G7
G-9
G-10

.____/

cARBUREnoR
TYPE: Y26 PV-2M
MANUFACTURER:
TEIKEI
2
3
4
5
6
7
8

9
10

11

12 Serew
13 Gasket
14 Throttle valve

Carburettor assy
Cover gasket
Gasket nozzle

Float
Floatpm
Float chamber gasket
Screw
Float chamber
fastenmg screw
Washer, spnng
Ho se
Spacer

15
16
17
18
19
20
21
22
23
24
25

spnng
Washer
Nut
Gasket
Sere w
Lock screw
Nut
A1r adjuster screw

Hose
D1aphragm
Cover
Connecter comp

26
27
28
29
30
31
32
33

Washer
Washer spnng

34

Hose

35
36
37
38
39
40

Clamp
Maln)et
Needle jet 1
Throttle valve
PllOtjet
Starter Jet

Spnng
Boli

Ho se

Hose
Screw
Screw

jcARsj

41
42
43
44
45
46
47
48
49
50

Need!e JB12
P1lot adJUSter

Needle valve set

Lock screw
Throttle screw set

D1aphragm
Needle Jet
Needle Jet
Startercontrollever
Ho se

l G-3 l

'---'
cAReuREnoR
SECTION VIEW
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Needle Jet (pnmary)

Valve housmg

(8) Mam n1pple (secondary)

(9) Mam Jet (secondary)

Needle valve
Ma1n n1pple (pnmary)
Ma1n )et (pnmary)

(8]

P1lot a1r screw

Need!e Jet (secondary)

SPECIFICATIONS

l"
l

L..::'"N"m'-'IO:c3:ck::;9e:m:cl_

ldenllflcallon number
Mam1et
S!arter 1et
Jet need1e
Needle 1e1
PIIOI)et
P1lot a1r screw
Float he1ght
Fuellevel
ldle speed
Throt11e valve housmg

4GVOO
#145 FIRST 110 SEC
#110
5098 315 (FIRST)
5Y16 315 (SEC)
V00/00

#48
about 2 5 revs open
25-27mm
6-Smm
1 200 1 400 rpm
025mm

(A]

Pnmary carburettor
Secondary carburettor

<:== A1r
-Fuel
M1xture

:;::

(A]
2 Nm(02kgm)

jcARsj

(B)

_____________c_A_R_su_,~_E_n_oR)cARBjf)
REMOVAL

l G-4

CARBURETIORICARB\fl

;:=:=:=:=::==:=:=:~==~~==~====~----~5~~R~e~m~o~v~.~~~~~

Screws (a1r fllter case) (1) (2)

Carburettor man1fold ft om carburettor

NOTE.

movrng the a1r fl!ter case towards the rear

The followmg parts must be cleaned and exammed

w1thout removmg the carburettor from the engme
D1aphragm (ennchment)

of the motorcycle

Starter contrai un1t

Remove
Carburettor

Throttle lock screw

ldle speed screw

DJSASSEMBLY

Remove
S1de panels
A1r ducts

Remove
Support plate (1) (front)
Support plate (2) {rear)

Seat
Fuel tank
SeesectiOn SIOEPANELS AIRDUCTS,

SEAT ANO FUEL TANK" 1n CHAPTER 3

2 Loosen
Lock nuts (1)

Remove
Throttle contrai cables (2)

4 Loosen
Screws (flange) (1)
NOTE.
Move carburettor mantfold clamps (2) towards the

rear s1de
2

_,
...
t~.,

"~"

53

54

Separate
Pnmary carburettor
Secondary carburettor

'----./
1
1
CARBURETTORCARB

f l. G-5 l.
1

Pnmary carburettor

1 Remove

Float chamber (1)

Float prn (2)
Float (3)

'-..../

cARsuRETTOR icARBI

~f)
~~;~~

Remove
Top cover (1)
Gasket (2)
Screw (3) (connecter comp)

~,~~
"'"

NOTE

Remove the float needle rn the drrectton of the

arrow

Remove
Throttle lever (1)
Roller (2)
Cable support (3)

Remove
Throttle shaft (1)
Spnng (2)

~~Vi

'@~

Remove

Needle valveNalve housmg (1)

Mam 1eVMam mpple (2)

Remove
Throttle lock screw (1)
Contro! starter unlt {2)

Remove
Connecter comp (1)

Needle Jet (2)

Throttle valve (3)

Secondary carburettor

Remove

55

Pllot Jet (3)

ldle speed screw (4)
O Rmg (5)

Cover (1) (ennchment)

Spnng (2)
Draphragm (3)

56

Remove
Plug (t)
Marn Jet (2)

fl

CARBU~ORICARB/fl l G-6

CARBURETTOR ICARBI

~=:=:::=:=:::=:=:::=:=:::=:=:::=:=;----2~~R~e~m=o=v~e~---------

lnspect
D1aphragm (1) (p1ston valve)
D1aphragm (2) (ennchment)
Damaged -+ Replace

lnspect

Top cover (1)

Spnng (2)

Remove
P1ston valve (1)
Needle Jet (2)

Needle Jet (1) (pnmary)

Needle Jet (2) (secondary)

Curvature/Wear-+ Replace

INSPECTION

lnspect
Throttle valve (1) (pnmary)
P1ston valve (2) (secondary)
Wear/Damaged ~ Replace

lnspect
Carburettor body
Sa~led ~ Clean

'

NOTE
Use petroleumbased solutiOns to clean C!ean ali

'

passages and Jets w1th compressed a1r

lnspect

Check
Free movement
Hampered ~ Replace
F1t the throttle valve and p1ston valve mto
the carburettor body and check that
movement 1s free
[A] Pnmary carburettor
[B] Secondary carburettor

lnspect
Float (1)
Damaged

Valve housmg (1)

Needle valve (2)

Wear/Corros1on -+ Aeplace
0-Rng (3)

Damaged

-+ Replace

NOTE

Always replace the needle valve and the valve

housmg together

lnspect
Starter cyllnder (1)

Wear/Damage-+ Replace
Throttle lock screw (2)
Damaged -7 Replace

5-7

5-8

-+

Replace

_____________c_A_R_eu_R_Y_TT_o_RjcARBjfjl G-7
9

____'--_/___________c_A_R_e_uR_E_TT_o_R ICARBI

lnspect

Pnmary carburettor

Matn jet (1) (pnmary)

Ma1n Jet (2) (secondary)

Mam n1ppte (3) (pnmary)
Mam n1pple (4) (secondary)

lnstall
Connecter com p

(1)

Needte 1et (2)

PIIOtjet {5)
NOTE

Clean JBis wth compressed a1r

NOTE
Check that the connecter umt (1) IS m the pos1t1on
shown m the ftgure

ASSEMBLY

Perform 'DISASSEMBLY operattons 1n reverse

arder Pay attent1on to the followmg pomts
CAUTION:

Wash ali parts w1th clean petrol pnor to

reassembly
Secondary carburettor
1

lnstaU

lnstall
Throttle valve

Needle Jet (1)

P1ston valve (2)
Spnng

NOTE:
Draw the dtaphragm tab leve! w1th the notch on the
secondary carburettor

lnstall

Top cover

1~1
3

lnstall
Spnng
Throttte shaft

Screw (top cover):

2 Nm (02 mkg)

NOTE
Assemble the spnng as shown m the 11lustrat10n

lnstaH
Mam JBI
Plug

Mal n Jet

2 N m (0.2 mkg)

Ptug:

lnstall
Screw (connecter comp )

NOTE
Turn the thrust shaft clockw1se (1/2 turn) to preload
the spnng and then, holdmg 11m pos1tlon assemble
the screw (connecter comp )

9 N m (O 9 mkg)

Screw (connecter comp)

2 Nm (O 2 mkg)

59

510

_____________c_A_R_s~_R_E_rr_oRicARBif
5

lnstall

l G-B -------------------------------CARBURETTORICARBifl
9

Cable support

Ao!ler
Throttle lever

lnstall
P1lot screw (1)
P1lot )et (2)
Mam n1pple (3)
Maln)et (4)

Valve houstng (5)

NOTE:

Check that the throttle shaft lever (2) and the

adjuster bo!t (3) are allgned when t1ghten1ng the
throttle nut (1)

Maln n1pple
2 Nm (0.2 mkg)

Screw (valve housmg).

2 Nm (O 2 mkg)

Sprmg (cable support)

3 Nm (0.3 mkg)

10 lnstall
6

lnstall

Float pm (1)

Top cover

1~1
7

NOTE
Assemble the float ptn 1n the appoSite d1rec110n to
the arrow

Screw (top cover)

2 Nm (O 2 mkg)

lnstall
D1aphragm (1) (ennchment)

11 Measure
NOTE.
Make the d1aphragm tab cOtOCide w1th the grav1ty

enncher notch
8

Float he1ght (a)

Out of spectflcatlon

1~1

lnstall
Starter uOit
Throttle lock screw

\~\

Starter p1ston.

Adjust

Float he1ght

25 0-27 o mm

Measurement and ad)ustment

Hold the carburettor ups1de down
Measure the d1stance from the JOint piane of the
float chamber (w1thout the gasket) an d the top of
the float

6 Nm (0.6 mkg)

NOTE
The float arm musi rest on the neeedle valve
Wlthout bemg pressed
lf the float he1ght 1S out of tolerance, check the
valve hous1ng and the needle valve
lf e1ther 1s worn replace both
lf both are perfect, adJust the float he1ght by
bendmg the wmg tab of the float 1tself (1)
Recheck the float he1ght

5-11

5-12

CARBUR~ORICARBifl l G-9

-------------------------------12 lnstall

cARsuRmoR !cARe!

..

f l

Ttghten or loosen the synchron1satton screw (1)

unt1l the secondary accelerator valve (2) starts to

Float chamber

open

Screw (float chamber)

Check that the secondary valve 15 open

honzonta!ly (a)=(b) when the pnmary carburettor
valve 1s completely open

2 N m (0.2 mkg)

13 Ad]USI
P1lot a1r screw (1)

*. * * *

* * *

*. *

* * * * * * *

Regolazone
Turn the screw unt111t IS sllghtly locked

Unscrew by 2 and 1/2 turns

14 lnstall
Pnmary carburettor

Secondary carburettor

INSTALLATION
Perform the "REMOVAL' procedures m reverse
arder, paymg attenbon to the followmg pomts
lnstall
Carburettor unt

15 lnsta!l

1~1

Support plate (front) (1)

Support plate (rear) (2)

1~1

Screw (support plate).

3 Nm (O 3 kgm)

Screw (flange)
2 N m (O 2 kgm)

Jnstall
The carburettor hose to the carburettor
mov1ng the a1r f1lter case towards the front

part
Screws (a1r f1lter case) (1) (2)
16 AdjUSt

Salt (a1r f11ter case)

SynchronsatlOn of secondary carburettor

10 Nm (1 o kgm)

Screw (flange).

AdJUStment:
Move the pnmary thrott!e valve (1) to a he1ght of
7 O mm as shown 1n the ftgure

2 Nm(02 kgm)

lnstall

5 13

5 14

Throttle cab!e (1)

l 1.\ IG-101

CARBU=refroRCARB
4

AdjUSt

Throttle cabla free play

See sectiOn "THROTTLE CABLE FREE
PLAY ADJUSTMENT' 1n CHAPTER 3
Throttle cable free play:

3-5mm

CARBURETTORICARBifl

AdjUSt

ldle speed
Seesect1on 'IDLESPEEDADJUSTMENr
1n CHAPTER 3

1,200 - 1,400 rpm

FUEL LEVEL ADJUSTMENT

Piace the motorcycle on a leve! surface

Make su re thatthe carburettor IS 10 a honzontal

pos1t1on by placmg a hydrauhc JaCk under the
engme
Connect the fuel level gauge (1) to the

carburettor mpple

~~ Fuellevel gauge:
~ P/N. YM01312A

P/N. 90890-01312
4

Loosen dramer screw (2) and heat the

engme

Measure
Fuel leve! (a)

Out ot spec1flcat1on

-+ AdJUSt

Fuellevel:

6.0-S.Omm
Under the edge of the
carburettor body

5-15

Fuellevel

Fuellevel adJUStment:
Remove carburettor un1t
lnspect valve housmg and needle valve
lf e1ther of the two 1s worn, replace both
lf both are perfect, ad]USt float he1ght by bend1ng
the wmg tab of the float 1tself (1)
Recheck the fuellevel

Engme 1dle:

Adjust

516

-------------------------------------- !cHAs!A!

CHAPTER 6
CHASSIS
FRONTWHEEL
REMOVAL
INSPECTION
STATIC BALANCING
INSTALLATI ON

G12
G12
G13
G-14
G-15

REARWHEEL .. ....................................... .
REMOVAL
INSPECTION
INSTALLATION

G-16
G16
H1
H1

FRONT ANO REAR BRAKE

FRONT MASTER CYLINOER
FRONT BRAKE CALIPER
REAR MASTER CYLINOER
REAR BRAKE CALI PER
BRAKE PAO REPLACEMENT
BRAKE CALI PER OISASSEMBLY
MASTER CYLINOER OISASSEMBLY
INSPECTION ANO REPAIR
BRAKE CALI PER ANO MASTER CYLINOER ASSEMBLY
REAR BRAKE'fEOAL OISASSEMBLY

H2
H2
H2
H-3
H3
H4
H-6
H-8
H9
H-11
H12

FRONTFORK . . . .
REMOVAL
OISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION

H-13
H-13
H-13

H14
H-15

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL
INSPECTION
INSTALLATI ON

13
14
14
15
15

REAR SHOCK ABSORBER ANO SWING ARM

REAR SHOCK ABSORBER
NOTE ON OISPOSAL
REMOVAL
INSPECTION
SWINGARM
REMOVAL
INSPECTION
LATERAL FREE PLAY AOJUSTMENT
INSTALLATION
DRIVE CHAIN, SPROCKET ANO CROWN
REMOVAL
INSPECTION
INSTALLATION

17
17

18
18
19
19
1-10

110
1-11
1-12

113
113
1-13

114

l.s---j lG-121

_______________
FR_O_N_T_'vr'_H_E_EL CHAS

~'"'~:)

FRONT

CHASSIS

WHEELjCHASj~ l

REMOVAL

FRONTWHEEL
[A]

WHEEL AXLE SCREW TIGHTENING

TORQUE
15 Nm (1 5 mkg)
[8] WHEEL AXLE TIGTHENING TORQUE
59 N m (59 mkg)
TYRE MEASUREMENT
90/90 21 (54R)
RUNOUT LIMIT
VERTICAL 2 O mm
LATERAL 2 O m m
INFLATION PRESSURE IN barscm'ikg (ps1)
WITH DRIVER ONLY 2(28)
WITH DRIVER ANO PASSENGER 2 1(30)
OFF-ROAD 1 5(22)

(1) Wheel axle screw

(2) Wheel axle
(3) Front wheel
(4)
(5)

(6)
(7)
(8)

Puller
Dust covar (011 seal)
Beanng
Flange
Spacer

Support the machlne securely so that t does

not fall over when the wheel ls removed.
Park the cycle on a perfectly leve! surface

Ra1se the front wheet and piace a secure,

stabia support under the engme

Remove

Tachometer cabla lock screw (1)

Tachometer cab le (2)

Loosen

Screws (1) (wheel axle support)

Remove

Wheel axle (2)

Front wheel

NOTE:

Do not pull the brake levar when the wheel IS

d1sassembled as th1s would cause the brake pads
to close

Remove

[A]

[8]

61

6-2

Flange (1 )[8]
Tachometer socket (2) [A}

R1ght
Left

-.k-...~ . G-131.
FRoNnvHiiEL lCHAS e>'-'f:>

~::::::::::::::::::::::::::::~~I~N~S:P;EC~T;,I~O~N~-----

FRONT

6. Measure
Wheel runout
Out of spec1hcat10n -+ Check the wheet
and beanng free play

Ehmmate any traces of ox1d1sat10n from the

parts

lnspect
Wheel axle
Turn the axle on a leve! surface
Curvature -7 Replace

Rlm runout llm1ts:

Vertlcal (1): 2 o mm
Latera! (2): 2.0 mm

l!fi1iU!@f - - - - - - - - - -

*''WhWIUN

Never attempt to straighten an axle.

3

Atter assembllng a tyre, dnve slowly to allow

it to adapt to the rlm.lf this precautlon ls not

observed, damage mlght be caused to the
cycle and accldents to the dnver.
After repalnng or changlng a tyre, do not
forget to bghten the valve lock nut (1) to the
prescnbed torque

lnspect
Tyre
Wear/Damaged -+ Replace
See sect!On "TYRE INSPECTION" m

CHAPTER3

WHEELICHASI~I

Wheel
Cracks/Deformatlon!Curvature-+ Replace
See sectiOn "WHEEL INSPECTION" 1n

CHAPTER3

lxi
4

lnspect!On
Spoke(s)
BenVDamaged -+ Reptace
Loose spoke(s) -+ T1ghten
Turn the wheel and M the spokes gently
w1th a screwdnver

NOTE:
A well tlghtened spoke makes a d1st1nct, sharp
no1se a loose spoke makes a dull, muffted no1se
5

Tighten
Loose spokes

lxi

Spoke:
2 Nm (0.2 mkg)

NOTE:

After t1ghtemng the spokes, check the centnng of

the wheel

63

64

Valve lock nut:

1.5 Nm (0.15 mkg)

lnspect
Wheel beanngs
Free ptay 1n wheel hub or wheel wh1ch
does not turn smoothly-+ Reptace
011 seal
Wear/Damage--+ Replace

l l l lG-141

---------------FR_O_N_T_~_H_E_E_LCHAS v'
_$-.r.

FRONT

~::::::::::::::::::::::::::::::::~----;-~R:e~m:o:v:.:----------

How to replace wheel bearings and dust covers:

Clean the outs1de of the hub
Remove the dust cover (1) w1th a flat-headed
screw dnver

2
3

"'"'.

NOTE:
Piace a rag (2) an the outs1de to avo1d damag1ng the
dust cover

lnstall the new beanng and the dust cover by

followmg the d1sassembly procedures 10 reverse

arder
NOTE:
Use a wrench (4) w1th an external d1ameter equal to
that ot the beanng and dust cover
1

Balancmg wetght
Set the wheet on a suttable support
Look far
The heavtest pomt~
~

.......................... , .. .

Procedure:
a Turn the wheel and watt far tt to stop
b Make a mark "X1" on the lowest pomt of the
wheel
c Move the mark "X1' to an angle of 90 to the
startmg posttton
d Let the wheel go and watt unttl tt stops
Make a mark "X2 on the lowest pomt
e Repeat the precedtng operatlons b, c and d
vanous ttmes unttl the two marks meet
Thts potnt ts heavy pomt "X"

01sassemb!e the beanng (1) w1th a norma! puller

(2)

CAUTION:

WHEELICHASI~ l

Carryout
Wheel balancmg

-----------

Do not strike the bearmg lnner race (5) or balls

(6). The contact must only be made with the
outer race (7).

Balancmg procedure:
lnstall a balancmg wetght (1) on the nm at the
potnt exactly oppostte "X'

NOTE.
Start wtth the ltghtest wetght avatlable

9 Examme
Tachometer socket
Wear/Damage ~ Replace

Turn the wheel so that the heavy pomt ends at

goo to the perpendtcular
Check that the heavy pomt does not shtft
Otherwtse, trywtth another wetght unttl the wheel
ts balanced

Check
Wheel balancmg

~ ..

Contrai procedure:
Set the wheeltnto any of the postttons shown m
the ftgure
Check that m each of the pomts the w he el ts sttll
Otherwtse, balance the wheel once agam

STATIC BALANCING
NOTE:
After replacmg the tyre and/or nm, 1t 1s necessary
to balance the wheel
Balance the wheel wtth the brake dtsc tnstalled

65

......................................

66

'~

_______________F_RO_N_T_W_H_E_E_L 1
CHAS1..&-.r-1
'-'f:)
INSTALLATION

lG-151
-

FRONT

~;:~;:==~==~:;;;~;;~;;~====~----~5~T~I=g=ht=e=n~~~~===

Perform the 'Removal" operat1ons m reverse arder

Note the fol1ow1ng pomts
1 Lubncate
Wheel axle
Beanngs

WHEELICHASI~ l

lxi

Wheel axle support screws (1)

Screw {axle support)
15 Nm (1.5 mkg)

~~9~~---~----------

Edge of duct covar

Tachometer socket

Beforetlghtenlngthewheelaxlesupportscrews,
compress the fork a few ti mesto check that lt ls
worklng properly and to allow the wheels to

~~~ Llthium~base grease

setti e.
2

lnstall

Tachometer socket

>"--~~

,!?~YJEt!:,J

NOTE:
Check that the JUttmg edges on the tachometer

socket gear mesh w1th the wheel hub housrngs

lnstall

Brake dtsc between the brake pads

NOTE:
Check that there 1s suff1clent space between the
brake pads before ftttlng the d1sc
NOTE:

Check thatthe tachometer socket clamp (1) hlts the

cross on the fork stem
Check that the tachometer cabla has an
unaccentuated curvature, otherw1se the t1ghtemng
of the rns1de w1re (dunng fork tra vel) may cause 1t t o
break

4 T1ghten

Wheel axle (1)

/xl

6-7

__________

Check that the tachometer cable routing ls as

prescrlbed.
Refer to sect1on "Cable routing" In Chapter 2.

Wheelaxle
59 Nm (5.9 mkg)

6-8

l ~ IIG-1&1

REAR'vvttEEL CHAS '-'0

REARWHEEL
{1) Self-lockmg nut
(2) Flat washer
(3) Chatn stretcher
(4)

Collar

(5)

Oust covar

(6)

Oli seal

(7) Beanng
(8)
(9)
(10)
(11)
(12)
(13)

Spacer
Damper
Hub clutch
Dnven sprocket
Wheel pm
Dnve cham

[A]

WHEEL AXLE SC!i1EW TIGHTENING TORQUE

115 Nm (11 5 mkg)
[B] DRIVEN SPROCKET SCREW TIGTHENING TORQUE
35 Nm (3 5 mkg)
INFLATI ON PRESSURE IN bars-cm'!kg (psr)
WITH DRIVER ONLY 2 2 (32)
WITH DRIVER AND PASSENGER 2 4 (35)
OFFROAD 1 6 (23)
TYRE MEASUREMENT 130/80 18 (66R)
RUNOUT LIMIT
LATERAL 2 O m m
VERTICAL 2 O mm
DRIVE CHAIN TIGHTNESS 30- 40 mm

. _ _ _ _ _ _ _ _ _ _ _ _ _ _....:R....:e....:A_R..:..w....:H_ee....:LICHASIAI
REMOVAL

I!B;Ui@Ci - - - - - - - - - The cycle must be supported securely so that Jt

does not lose balance and fall over when the
wheells removed.
Park the cycle on a pertectly leve! surtace

Ratse the front wheel and piace a secure,

stable support under the engme

Remove

Wheel axle nut (1)

Rtght cham stretcher (2)

Remove

Dnven sprocket chatn (1) (push the wheel

forward)
Wheel axle (2)
Left cham stretcher (3)

NOTE:
Do not operate the brake pedal when the wheelts
dtsassembled as thts would cause the brake pads
to close
5

Remove
Rear wheel

NOTE.
Before removmg the rear wheel push 1t forward
and lower the drtven sprocket dnve cham

69

610

REAwHEELjcHAsj~ l H-1
6

Remava
Flange(1)
Flange (2)

[A] R1ght s1de

[B] Left Slde

INSPECTION

R_E_A_R_W_H_EE_LICHAS~~~

_______________

INSTALLATION

Perform "Removal" operat1ons 1n reverse arder

Note the follow1ng pomts
1 Lubncate

Wheel axle
Beanngs

Edge of dust covar

~~l

Llthium-base grease

NOTE:

Examme

When mstalhng thecham stretchers, be su re to put

them m the correct pos1t1ons (nght and left)

Rear wheel
See sectiOn "FRONT WHEELINSPECTION"

Examme
Tyre
Wheel
See sectton "FRONT WHEEL-INSPECTION"

Exam1ne
Spoke(s)
See sectlOn "FRONT WHEEL INSPEC
TION"

CAUTION:
Check that the brake caliper has stayed m the
correct pos1tlon wlth the clamp perfectly centred on the fork.
2

AdjUSt
Dnve chrun t1ghtness

Dnve cha1n t1ghtness

30-40mm

4 Measure

'

'
5

Wheel runout
See sectlan "FRONT WHEEL-INSPECTION"

See sectiOn "DRIVE CHAIN TIGHTNESS

INSPECTION ANO ADJUSTMENT" 1n
CHAPTER3

Check
Dust covar

Wheelbeanngs
See sectiOn "FRONT WHEEL-INSPEC
TION"

l~l

6 Check

6-11

T1ghten
Wheel axle nut

Wheel balancmg
See sectiOn "FRONT WHEEL-STATIC
BALANCING"

6 12

Wheel axle nut:

115 Nm (11.5 mkg)

FRONT ANO REAR

'--./ j

j.-f:--1 l H-2 l

BRAKECHAS V

FRONT MASTER CYLINDER

[A]

PUMPER NOT SUPPLIED REPLACE

WHOLE MASTER CYLINDER UNIT IF NECESSARY
BRAKE FLUID
DOT #4 OR DOT#3

(1) Brake controltever

(2) Handlebar master cyhnder fastenmg bracket
(3)

Stop hght swttch

Otaphragm

jcHASibel

FRONT BRAKE CALIPER

FRONT ANO REAR BRAKE

(4)

FRONT ANO REAR BRAKE

(5) Brake flwd tank cover

(6) Brake hose

(1) Brake dtsc

(2) Brake hose fastenmg
bracket
(3) Brake pad lock pm

(5)
(6)
(7)
(8)

Pad spnngs
Brake cahper ptston umt
Brake cahper bracket
Bleeder screw

(4)

[A]

PISTON GASKETS NOT

SUPPLIED
REPLACE ENTIRECALIPER
UNIT, IF NECESSARY

Brake pads

BRAKE FLUID
DOT#4 OR DOT#3
BRAKE PAD WEAR LIMIT
1 mm
BRAKE DISC WEAR LIMIT
36mm
BRAKE DISC RUNOUT
LIMIT 03 mm

2 Nm (0,2 kgm)

23 N m (2,3 kgm)

12 Nm (1,2 kgm)

126 N m (2,6 kgm)

6-13

FRONT ANO REAR

~KE jcHASjA l H-3

REAR MASTER CYLINDER

ICHASjA l

REAR BRAKE CALIPER

(1) Brake flwd tank covar

(7)

(2)

(8) Master cyltnder

01aphragm

(3) Brake flwd tank

(4)

FRONT ANO REAR BRAKE

[A]

Brake hose

(9) Brake pedal

(10) Cotter p1n

Hose

(5) Stop hght sw1tch

(6) Hose fastenmg bracket

PUMPER NOT SUPPLIED REPLACE W HO LE MASTER CYLINDER UNIT IF NECESSARY

BRAKE FLUID
DOT #4 OR DOT#3

(1)

(2)
(3)
(4)
(5)

Brake d1sc
Brake cahper

Brake pad
Pad spnng

(6)
(7)
(8)

Cyhnder
Brake pad lock p1n
Bleeder screw

(9) Brake cal1per protecMn

Brake cahper cyllnder

gaskets

[A]

USE A NEW ONE

BRAKE FLUID
DOT#4 OR DOT#3
BRAKE PAD WEAR LIMIT 1 O mm
BRAKE DISC WEAR LIMIT 5 mm
BRAKE DISC RUNOUT LIMIT

03mm

10 Nm (1 kgm)
\

12 Nm (1,2 kgm)

6-15

6-16

H-4

FRONT ANO REAR

1~~!~~~~-----------------

Brake components rarely require dlsassembly.

DONOT:
Dlsassemble brake components unless ab~
solutely necessary.
Use solvents on internai brake components.
Use brake flu1d already used for bleedlng.
Allow brake fluld to come into contact w1th
the eyes as it may cause injury.
Allow brake flu1d to come mto contact wlth
painted or plastlc parts as it may damage
them.
Dlsconnect any hydraullc connectlon, other
wlse the whole system must be disassembled, dralned, cleaned, then properly fllled
and bled after reassembly.

Wear llmit {a).

1.0mm

r!Uh'M!Mi ___________

'

over.

Front brake

1 Remove
2

Cali per fastemng screws from fork (1)

Remove
Pad fastenmg pm (2)

NOTE:
To remove the pad fastenmg p1n, stnke from the
outs1de w1th punch w1th a SUitable d1ameter, bemg
careful not to damage the brake hosng

617

Lithium-base grease

tnstall
Pm bracket {2) (on the cahper body (3))

NOTE:
F1t the rubber protect1ons (4) when 1nstallmg the
cahper body

Support the cycle securely to prevent 11 falllng

Lubncate
GUide pms (1)

~~~
5

'

Remove
Brake pads ( 1)
Pad spnngs (2)
Callper bracket (3)

NOTE:
lf you replace the pads, al so replace the spnngs
lf o ne of the two pads has to be replaced because
1t 1s worn, replace both

BRAKE PAD REPLACEMENT

NOTE:
lt 1s unnecessary to dtsassemble the brake ca11per
and hose to replace the pads

BRAKEICHAS~~~

618

lnstatl
Pad spnngs (1) (new)
Brake pads (2) (new)
Pad fastenmg pm (3)

FRONT ANO REAR

~KEICHAS~~~

H-5

FRONT ANO REAR

BRAKEICHAS~~~

Rear brake
lnstallat1on procedure:

Remove
o Clip (1)
o Ptn (2) (pull)

Remove
Brake pads (3)
Pad spnng (4)

Connectthe hose (1) ftrmlyto the caltper bleeder

screw Piace the otherend ofthe hose m an open
contamer
Loosen the cal1per bleeder screw and push the
ptstons mto the cahper wtth your fmger
Rettghten the bleeder screw
Caliper bleeder screw:
6 Nm (0.6 mkg)

lnstall the (new) brake pads and (new) spnngs

Fttthe pad fastemng p1n (2) wel1 mto 1ts housmg by
hammenng wtth a punch wtth a sUitable d1ameter

7 lnstall
Cahper fastemng screws to fork (1)
8 Ttghten
Cahper fastenmg screws (1) (to fork)
NOTE
lf you replace the pads, also replace the spnng
lf e1ther of the tNo pads has to be replaced
because 1t IS worn, replace both

Callper fastemng screws:

23 Nm (2 3 mkg)

9 Check

Leve! of brake f!Uid 1n tank

See sectiOn "BRAKE FLUID

Wear llm1t (a)

1 Omm

LEVE L

CHECK" 1n CHAPTER 3
(1) "LOWER"

mm1mum

tevel

10 Check

Brake levar funct10n1ng

~~l

Levar soft and spongy ~ Bleed a1r from

brake C1rcwt
See sectiOn "AIA BLEEOING' 1n CHAP
TER3

6-19

Lubncate
Gu1de p1n

6-20

LJthlumbase grease

FRONT ANO REAR

~KE ICHAS,~ l

H-6

FRONT ANo REAR sRAKEicHAsl<t:YI

BRAKE CALI PER DISASSEMBLY

lnstallatron procedure:

Connect the hose (4) f1rmly to the cali per bleeder

screw (5) Piace the other end of the hose 1n an
open contamer
Loosen the cal1per bleeder screw and push the
p1stons rnto the cahper w1th your fmger
Rettghten the bleeder screw

NOTE:

Befare dtsassembhng the front or rear brake cahpers,

dra1n the fiUid from the brakmg ClfCUit

''''MhWWii ___________
Support the cycle securely to prevent 1t falllng
over.
Front brake

lnstall the (new) spnng and (new) brake pads

F1t the pad fastemng pm well mto 1ts hous1ng by
hammenng w1th a punch w1th a su1table dJam-

Loosen
Hose fastemng screw (1)

eter

lnstall the chp on the ptn

NOTE:

Loosen gently to prevent brake fiUid from leak1ng

4 Check
Leve! of brake fiUid m tank
See sect1on "BRAKE FLUIO LEVEL
CHECK"

Max1mum level
(2) M1n1mum levet

Check
Brake pedal functtomng
Pedal soft and pongy ~ Bleed a1r tram

brake c1rcwt
See sectJon "AIA BLEEDING" m CHAP
TER3

6-21

Remove
Brake pad fastemng pm (3)

Remove
Brake pads (1)
Brake pad sprmgs (2)
Cahper bracket (3)
See sect1on ~BRAKE PAD REPL.ACEMENT', 1n th1s CHAPTER

1n CHAPTER 3

{1)

6-22

Callper tasten1ng screws (2)

H-7
4

FRONT ANo REAR sRAKe!cHAslctY0I

Remove
Hose fastemng screw (1)

Rear brake

Remove
Chp (t)
P1n (2) (pull)
Brake pads (3)
Pad spnng (4)
See sectton "BRAKE PAD REPLACEMENr m th1s CHAPTER

Remove
Hose fastemng screw (1)
Copper seal gaskets (2)

Copper seal gaskets (2)

NOTE:
Piace a contamer under the cali per to collect brake
ltqUid

Remove
Ptstons (2)
Oust cover (3)
Seal nngs (4)

~ ~*
Remove:
Blowtng compresse d a1r mto the hose connectton, make the p1ston leave the body of the
cahper

''*MWdlf!il ___________
Do not force the p1ston out wlth a lever or
other tools.
Cover the piston w1th a rag. Be careful to
prevent the p1ston from damagmg the cyllnder as it leaves 1t.

NOTE:
Piace a contamer under the cahper to collect brake
hqUid

Remove
PIStOn (t)

Seal nng (2)

Oust cover (3)
NOTE:
Remove ftrst the p1ston, then the seal nng and dust
cover
Remove:
Blowtng compressed a1r mto the hose connectiOn, make the p1ston leave the body of the
cahper

l!''h@@!N ___________
Do not force the p1ston aut w&th a lever or
other tools.
Cover the p1ston with a rag. Be careful to
prevent the p1ston from damaging the cyhnder as 1t leaves al

"

6 23

6-24

... "" . " ..................................... """

FRONT ANO REAR BRAKE

J.:.--1 l H-8 l
lCHASI~
.

MASTER CYLINDER DISASSEMBLY

Remove

NOTE:

Before d1sassembhng the front or rear master cyllnder, dram the flwd from the brak1ng c1rcwt

l!fii;Jflld+ -----------

Support the cycle securely to prevent lt falhng

Nut (1)
Screw (2)
Levar (3)
Sw1tch fastemng screws (4)
Sw1tch (5)

Loosen
Brake hose attachment (6)

over.
NOTE:

Loosen gently to prevent brake fiUJd leak1ng

Front brake

Remove
Handlebar master cyl1nder fasten1ng
screws (7)

Handlebar master cyhnder fastenmg

bracket (8)

Remove
Brake hose attachment (6)

NOTE:
Piace a contamer under the master cyl1nder to
collect the brake flwd

Remove
Brake flu1d covar screws (1)

6-25

626

Brake flwd tank covar (2)

D1aphragm (3)

Connector {4)

FRONT ANO REAR

~KEICHASIAI

H-9

FRONT ANo REAR sRAKE icHASIA

3

Rear brake

Remove
Master cyltnder fastenmg screw (5)
Brake swstch (4)
Copper gaskets (6)

NOTE:

Piace a contamer under the master cyhnder to

collect the brake flwd
4

Dtsconnect
Tank to master cyhnder hose {7)

NOTE:

Piace a contatner under the tank hose to collect the

brake flwd

Remove
Tank fastentng screw (1)

Tank plug (2)

Dtaphragm {3)

Gasket (4)

Otsconnect
Tank hose (5)

NOTE:
Placa a contamer under the tank t o colle et the brake

flwd
INSPECTION ANO REPAIR

Recommended programma far the replacement of

brake system components
Pads

When necessary

Seallng elements,
rear cal1per dust
cover

Every 2 years

In the event of brake

Front and rear master
cyhnder umt, front cali per fiUid leakage
Remove
Cotter pm (1)
Washer (2)
Ptn (3)

NOTE:

Far dtsassembly of the brake pedal and sts remo val

from the chassts, see page 634

Brake hoses
Brake f1Uid

2 Loosen

WtfihUI@ii -----------

Brake swstch (4)

Internai parts must be washed only w1th clean

brake flu1d. Do not use solvents to prevent
seallng elements from becommg misshapen or
swollen.

NOTE:

Loosen gently to prevent the brake flwd leakmg

6-27

Every 4 years
Replace only after
d1sassembhng brake

6-28

l IJO-_,

FRONT ANO REAR \:rnAKECHAS

'-'

IH-101
.

FRONT ANO REAR

BRAKE/CHAS~~~

Examme

Cahper p1stons (1)

assembly
Cahper cyllnder (2)

Rust/Wear/Damage ~ Replace cahper

Scratchmg/Wear

-+

Replace cahper as-

sembly
[A] Front
[B] Rear

[BJ

Examme

[A]

Cahper body (1)

Cracks/Damage -+ Replace
Cahper bracket (2)

-+ Replace

Cracks/Damage

Gu1de pms (3)

Rust!Damage-+ RepJace
Rubber protect1ons (4)

Cracks!Wear/Damage -+ Replace

011 dehvery passages (cahper body)

Clean w1th compressed a1r

Exam1ne
Front d1aphragm (1)
Rear d1aphragm (2)
Wear/Damage -+ Rep!ace

Tank (3)

Cracks/Damage -+ Replace
[A]
[B]

[A]

[B]

Rear brake

t!tfN;UIW!iJ ----------Replace the p1ston seallng element and dust

Front
Rear

Examsne
Brake hoses (1)
Tank hose (2)
Cracks/Wear/Damage -+ Replace

covers every t1me the cahper ls dlsassembled.

[A]

Front

[B] Rear

lnspect
Master cyhnder (1)
Wear/Scratches -+ Replace master cyhn

Front

[B]

Rear

[B]

der umt
Master cyhnder body (2)
Cracks/Damage -+ Replace

011 feed passage (ma1n cyhnder)

Clean w1th a Jet of compressed ar
[A] Front
[B] Rear

[A]

lnspect
Master cyllnder p1ston umt
ScratcheSIWear/Damage-+ Re place master cylsnder umt

[A]

Measure
Brake pad thtckness
Out of spec1ftcat10n -+ Replace
Pad wear lim1t (a):

Front

[A] Front brake

1 Omm
Rear:
1.0mm

6-29

6-30

-.Jf-.,-_1
1

FRONT ANO REAR BRAKE CHAS {9'-'G}

~[B=]========================~~N:O~T~E~:~~~~~~~~~-=----------- Whenever you have t o re piace the pads, replace

9L-I_ _ _

IH-111
-

FRONT ANO REAR

BRAKE CALIPER ANO MASTER CYLINDER

ASSEMBLY

1 To reassemblethe brake callpers and master

the spnng too

8oth pads have to be replaced even 1f only one

___,~

cylmders, carry aut the d1sassembly pracedures 1n rverse arder pay1ng specml attentlan ta the below
See sectiOns "CALIPER DISASSEMBLY",
"MASTER CYLINDER DISASSEMBLY" and
"BRAKE PAD REPLACEMENT"

15 worn aver the env1saged hm1t

[A] Front
[B] Rear

t! 1 'M'* 1idCI

8 Exam1ne

Brake dtsc (front an d rear) (1)

Wear/Damage

-+ Aeptace

___________

Ali internai parts must be cleaned usmg only

new brake flu1d.
Before reassemblmg the components, lubncate w1th brake fiUid

IN"'\> l

[Al Front
[B] Rear

BRAKEICHAS,~0~

Brake f!Uid.
1f OOT #4 IS not ava1lable, DOT #3

may also be used.

9 Measure
Brake diSC wobbhng
lf aver env1saged hm1ts -+ Venfy wheel

Always use new copper washers.

Always use new piston gaskets and dust
covers.

centnng

Front master cyltnder

lf the wheel centnng ts correct, replace the

brake dtsc

Hose fastening nut:

26 Nm (2.6 mkg)

Maxtmum wobbhng.
0.15 mm

Master cyllnder bracket fastenlng

screws:

Brake d1sc thtckness

lf aut of spec1f1ed hmtts -+ Aeplace

1 Nm (0.7 mkg)

Tank cover fastenmg screws:

2 Nm (O 2 mkg)

Mimmum thtckness (a):

Front: 3.6 mm
Rear: 5 mm

NOTE.
Apply llthtum soap-base grease to the brake lever
p<n

(1) Otal gauge

NOTE:

Rear master cyhnder

Tighten the brake dtsc screws m several succes-

stve stages '" cross aver arder

Brake sw1tch (hose fastemng):

26 Nm (2.6 mkg)

Screws (brake disc}:

Front:

Master cyltnder fastenmg screws:

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

Tank fastenmg screw

Aear:

4 N m (O 4 mkg)

10 Nm (1.0 mkg)

LOCTITE

6 31

6 32

l IJ.:-_, lH-121

-------------FR_O_N_T_A_N_D_R_E_A_R_e---'_R_A_K_ECHAS @\..1@

FRONT ANO REAR BRAKEICHASIAI

Front callper

Fork cali per fastenlng screws:

23 Nm (2.3 mkg)

After completmg the reassembly operat1ons,

bleed the a1r frorn the c1rcwt
See sect1on "AIA BLEEDING" lnCHAPTER3

Hose fastening screw:

26 Nm (2.6 mkg)

Front tankcoverfastenlng screws:

2 Nm (0.2 mkg)

Rear cahper
REAR BRAKE PEOAL DISASSEMBLY
1 Remava
Cotter p1n (1)
Washer (2)

Hose fastemng screw:

23 Nm (2.3 mkg)

Cali per protectlon fastenlng screws:

12 Nm (1.2 mkg)

~~~

Brakefluld:
lf DOT #41s not avallable, DOT #3
may also be used.

"9AT1:0"NJ ----------------

The brake fluld may corrode painted surtaces

and plastlc parts. lf lt spllls, clean immed1ately.

'

'

6-33

Remove
Brake pedal (6) from chass1s

NOTE
Pull the brake pedal from the lower part of the
chass1s, causmg 11 to rotate progress1vely as 1t
comes away

ftMd;W'dN -----------

The quallty of the brake fiUid used must

conform to the prescribed standards, other~
wlse the rubber gaskets risk deterlorating,
thus causing fluid leakage and poor brake
functloning
Always use the same make of fluld. The mixing of dlfferent fluids may cause a chemical
reactlon harmful to the functlonlng of the
brake.
When addlng flu1d, be careful not to allow
water to enter the tank. Water lowers the
boillng point considerably provoking the socalled "vapour plug" phenomenon.

P1n (3)

Unscrew
Screw (4)
01SCOnnect
Spnng (5)

6-34

1 ~-1 IH-131

_ _ _ _ _ _ _ _ _ _ _ _ ___:_F:_RO:_N_T'f'6_:_:_RKCHAS '-'{!)
FRONTFORK
(8)

(2)
(3)

(9) Cap bolt

(4) Cap bolt

(5) Pmch bolt (under bracket)
(6)
(7)

Front fork (R)

Onng

FORK OIL CAPACITY (IN EACH TUBE)

(1) Protector
Brake hose protectton
Pmch bolt (handle crown)

(15) Bush
(16) Prston

Spnng

(10) Damper rod

(11) Gasket
(12) Rrng
(13) Ori seal
(14) Washer

(17) lnnertube

51 Dcc

REMOVAL

t!Ui;WIMiiJ

RECOMMENDED OIL
Suspenston otl "01'

Support the cycle securel y to prevent it falling

aver.

(18) Outer tube

FORK OIL LEVEL
STANDARD

90mm

MINIMUM

120mm

MAXIMUM

aomm

From top of outer tube Wtth mner tube and

damper rod fully compressed wtthout spnng

1 Park the cycle an a level su riace

2 Ratse the cycle by plact ng a sUitable support

under the engme
3 Remove
Front wheel
See sectton "FRONT WHEEL REMOVAL"

4 Remove

MINIMUM FORK SPRING FREE LENGTH

485mm
INNER TUBE BENDING LIMIT

Protector (R and L)
Tachometer socket an d cable
Front brake callper an d hose

5 Loosen

02mm

Fork cap bolts

Fork fastemn g screws

DISASSEMBLY
TOP CAP BOLT

1 Remove

l1s Nm (1,5 kgm) l

Top cap bolt (1) from outer tube

NOTE.
Loosen the cap bolt (1) before d1sassembhng the
front fork from the cycle

2 Remove

Top cap bolt (1)

NOTE:
Set the rod holder (2) between the lock nut (3)
and the spnng gUide (4)
Hold the lock nut (3) and remove the cap bolt (1)

Rod holder:
YM-()1434/90890-01434

6 35

636

---------------F-R_o_N_"Fb_o_R_K

.k-.\ l. H-141.
lCHASl'-'0

FRONT FORK
2

NOTE:
The front fork reqUtres careful attent1on lt IS advsabte to have any ma~ntenance work performed on
1t at Yamaha dealers

CAUTION::

Remove

----------------

CAUTION:; - - - - - - - - - - - - Do not bottom aut the mner tube in the

above operatlon or the oli seal ptece w1ll be
damaged

ies.
Use enough care to prevent foreagn bodies
entenng when replacmg od or dlsassembling
and reassembling the front fork.
Before removlng the ca p bolts or front forks,
be su re t o extra et the a1r from the a1 r chamber
completely.

Remove

BASE VALVE

Remo ve

Otl seal

O il seal removal sequence:

Push the tnner tube m slowly (a) unttl tt
reaches the bottom, then pull aut qwckly
(b)
Repeat thts operaMn untcl the tnner tube
can be pulled aut of the outer tube

To prevent an acc1dental explosaon of alr, the

followlng tnstructlons should be followed:
The front fork with its built~ln p1ston rod has
a very sophistlcated Internai construction
and 1s partacutarly sensitive to forelgn bod-

'

\cHAS\~ l

Base valve (1)

Use a damper rod holder (2) to lock the rod

Metal ptston (1)

Metal bush (2)

011 seal washer (3)

Oti seal (4)

Stopper nng (5)
Dust covar (6)

assembly

l~l

INSPECTION

Damper rod holder:

90890-01463

CONNECTING ROD

lnspect

OILSEAL

Dust seal (1)

Stappar nng (2)
Usa a slotted-head screwdnver

Replace rod

CAUTION:
The front fork Wllh ats butlt-ln piston rod has a
very sophlstlcated mternal construction and ts
particularly sensttlve to foretgn bodtes.
Use enough care to prevent foreign bodles
entermg when replacmg oli or disassembllng
and reassembling the front fork.

CAUTION:'j - - - - - - - - - - - - - Take care not to scratch the 1nner tube.

6-37

Connecttng rod (1)

Bendmg/Damage

1 Remove

6-38

'-...-/ iCHAS ~~-~ lH-15!

________________
FR_O_N_T_F_O_R_K

(9'-'G)

FRoNr FORK

BASE VALVE

OUTERTUBE

lnspect
Valve assembly (1)
Wear/Damage ~ Replace
O-R1ng (2)
Damage -+ Replace

lnspect

Measure

!cHAs!A l

Outer tube (1)

Score marks!Wear/Damage-+ Replace

CAP BOLT

Fork spnng free length (a)

Out of spec1flcat10n -+ Replace

lnspect

Fork spring free length.

Cap bolt (t)

O nng (2)
A1r bleed screw (3)
Wear/Damage ~ Replace

Standard

495mm

485mm

INNERTUBE

ASSEMBLY

lnspect
lnner tube surface
Score marks -+ Repa1r or replace
Use #1 000 gnt wet sandpaper
Damaged oli seal p1ece -+ Replace
lnner tube bend1ng
Out of speclfLcatLon -+ Replace
Use d1al gauge (1)

FRONTFORK
1
2

lnner tube bendtng llm1t

0.2mm

NOTE
Lubncate the mner tube w1th fork mi
When mstalhng the mi seal (2) use a plastle ftlm
(1) lubncated wtth fork oli to pro te et the oli se al hp
lnstall the 011 seal wtth 1ts manufacturer's marks
or sena\ number factng the axle holder stde

NOTE:

The bend1ng value IS shown by one half of the d1al

gauge readmg

6-39

Wash ali the parts wtth a clean solvent

lnstall
Dust cover (1)
Stopper nng (2)
Otl seal (3)
Plam washer (4)
Metal busmng (5)

fQi;ib@ti -----------

CAUTION: ; _ _ _ _ _ _ _ _ _ __

oo not attemptto straighten a ben t mnertubeas

th1s may have dangerous consequences

Always use a new od seal and metal bushmg

6-40

J;...r.l l. H-161.
I

________________F_Ro_N_-r--'_F_o_R_K CHAS '-'0

3

_____________

__;_F..:.:R.::.oN.::.T..:.:F..::.o.:...:.RKICHASI~I

lnstall

lnstall

Outer tube (1)

lnner tube (2)

Meta! ptston (1)

NOTE:
lnstall the ptston onta the slot an the mner tube
CAUTI O N:
Always use a new metal p1ston.

lnstall
lnnertube (1)

lnstall

Damper rod (2)

Meta! bush1ng (1)

Pla1n washer (2) m outer tube seat

CAUTION:

To install the damper rod assembly into the

lnner tube, hold the mner tube aslant. lf the
mner tube 1s held vertlcally, the rod assembly
may fall into it, damagmg the valve mslde.

iO lnstall
5

Copper washer (1)

O nng
Base valve
to mner tube

NOTE:
Always use a new copper washer

Oamper rod holder:

90890-01463

l'Xl

Base valve:
3();{l5 Nm (3.0+3.5 mkg)

6 41

~~ ) Fork seal dnver:

~

Base valve ( 1)
Use the damper mner tube holder (2) to
lock the rod assembly

1~1

011 seal (1]

NOTE.
Press the 011 seal mto the outer tube w1th the fork
seal dnver (2), (3)

Ttghten

\=1!!!!1

lnstall

[A}
[B]

YM-38853 ................................ (2)

9089001442.. ..... .... ........ . ....(3)

Far USA and Canada

Except far USA and Canada

11 lnstall
Stopper nng (1)

lnstall
Spnng QUide (1)
Lock nut (2) to p1ston rod

NOTE:
F1t the stappar nng correctlv 1nto the groave m the
outer tube

642

1-1
12 lnstall
Dust cover (1)

18 Afterftlhng, pump the outertube (1) slowly

up and down (wtlh a stroke of about 200
mm) to dtstnbute the fork od once more
NOTE:
Be careful not to compress excess1vely A stroke ot
200 mm or more would cause atr to enter
In thts case repeat operattons 15 to 18

13 Check
lnner tube smooth movement
Tlghtness/Bmdtng/Rough spots-+ Repeat
operattons 2 to 12

19 Watt 1o mtnutes uniti the atr bubbles have

d1sappeared tram the front fork and the otl has
spread evenly before topptng up the recom
mended otllevet
NOTE:
FtU wtth the fori<. o ti up tothe top end ofthe outertube
or the fork mi wtll not spread aver every p art of the
front forks, thus makmg 1t tmposstble to obtam the
correct leve l
Be su re to ftll wtth the the fork mi up to the top of the
outer tube and to bleed the front forks

14 Compress the front tork fu!ly

15 Ftll Wllh
Front tork 011
Ftll the front fork up to the top edge of the
outer tube wtth the oli recommended (1)

20 Measure
Otllevel (L and R) (a)
Out of spec1ftcatlon -+ AdJUSt

Recommended otl:
Suspenston od "01"

Standard

Mlmmum
Maxtmum

CAUTION: ' - - - - - - - - - Be sure to use the recommended fork otl. lf

other otls are used, they may have an exces~
slvely adverse effect on front fork perform~
ance.
Never allo w foresgn bodies t o enter the front
fork.

90mm
120mm

aomm

From top of outer tube wtth lnner tube and

damper rod (1) fully compressed wlthout
sprmg.
NOTE:
Be su re to mstall the spnng gutde (2) when check
mg the otllevel

16 Afterftlhng, pump the damper rod (1) slowly up

and down more than 1O ttmes to dtstnbute the
forkotl
17 Ftll wtth
Front fork ati Refili the fork to the top edge
ofthe outertubewtth the ati recommended

6-43

Fork olllevel.

ft+U.i;i~llftil ----------Never fad to make the otllevet adJustment be-tween the max1mum and mlntmum leve! and
always adJUSt each front fork to the same set~
ttng. Even adjustment can cause poor handltng
and loss of stablhty.

6-44

1-2
21 lnstall

26 T1ghten
Cap bolt (1)

Fork spnng (1)

Spnng gwde (2)

NOTE:
Set the rod holder (2) between the nut (3) an d the
spnng gu1de (4)
Hold f1rm the lock nut (3) and t1ghten the cap bott
(1) to the spec1f1ed torque

22 Pull aut the damper rod (1) wsth rod puller (2)
and rod puller adapter (3)
Rod puller:

YM01437/9089001437
Rod puller adapter:

9089001436

IJ4'/

'~'

Rod holder:

YM-01434/9089001434

Cap bott
20 Nm (2.0 mkg)

27 lnstall
Cap bolt (1)
T o outer tube
Temporanly bghten the cap bolt

23 Measure

D1stance (a)
Out of spec1fscat1on ~ Screw the lock nut
Dlstance (a):
18 mm or more between top of
da m per rod (1) and top of Jock

nut (2).

28 lnstall
Protectorgwde (1)

24 Loosen
Rebound dampsng adjuster (1)

NOTE:
Loosen the rebound dampsng adJUster w1th a
slotted-head screwdnver
Recordthe se t posltlonoftheadjuster(theamount
of turmng aut from the fully turned pOS1t1on)

25 lnstall
Capbolt(1)
Fully ttghten the cap bolt onto the damper
rod by hand

NOTE:
Make sure there IS a clearance (a) of O to 1 mm
between the cap and the nut (2)

645

646

FRONTYoRKjCHAS\~1

1-3

FRONT

~::::::::::::::::::::::::::::~~I:N;S;TA:L~L~A~T~IO~N:-------

Install

Front fork (1)

Temporanlyt1ghten the pine h bolts (lower)

T1ghten

FORK\CHAS\~ l

lnstall
Protect1on (1)

Salt (protector) (2)

Hose covar (3)

Bolt (hose cover) (4)

Cap bolt

Bolts {pro1ector}:

1~1

7 Nm (0.7 mkg)

Cap bolt:
30 N m (3.0 mkg)

Bolts (hose cover):

7 Nm (0.7 mkg)

NOTE:
Do not t1ghten the pmch bolt (upper) yet
3

AdjUSt

NOTE:

Front fork top end (a)

Front fork top end (a)
(Standard):

Turn m the dampmg adJUSter fmger-ttght and then

turn aut to the ong1nal poSltton

Omm

T1ghten

Pmch bolt (handle crown) (1)

Pmch bolt (under bracket) (2)

Plnch bolt (handle crown):

23 Nm (2.3 mkg)

Plnch bolt (under bracket):

20 Nm (2 o mkg)

CAUTION: '----------

Tighten the screws of the under bracket to

spec1fled torque. Excess torque may cause
malfunctiomng of the front fork
5

6-47

Ad]ust
Rebound damp1ng adjuster (1)

lnstall
Front wheel
Cal1per
Brake hose
Tachometer cable
See sect1ons "FRONT WHEEL" and
"FRONT BAAKE" 1n thts CHAPTEA

648

1-4

STEERING

--------------------------------------

STEERING

ICHAS~~ l

REMOVAL

(1)
(2)

Handlebar holder
Handlebar holder

(3)
(4)

Rmg nut
Washer

(9) Lock nut

(5)
(6)
(7)

Upper front fork crown

Brake hose bracket
Nut safety washer

(11) Bearmgs

(8)

Rmg nut

(12) Steenng axle

(10) Cover

1!1~ 1J.1;itl@i - - - - - - - - - support the cycle securely to prevent lt fallmg

ave.
Park the cycle on a level surface
2
3

Ra1se the front wheel placmg a su1table support under the engme
Remove

Front wheel

See sect1on "FRONT WHEEL RE

MOVAL"

/ 40 Nm (4 mkg)

Front fork
See sect1on "FRONT FORK-AEMOVAL"
Remove
Front fender
Famng
Handlebar
lnstrumentatiOn assembly

D1sconnect

Mam IQMIOO SWitCh

Harness

Remove

Steenng rude nut (1)

Use the lock nut wrench (2), (3)

1 ~~

(A]
[B]

6-49

6-50

Lock nut wrench:

YM-38519 .....(2)
90890-01348 . . (3)

For USA and CANADA

Except for USA and CANADA

----------------ST_E'-------'_E_RI_N_G/CHAS/~1

1-5

STEERING

Remo ve

INSTALLATION

UNDER BRACKET

Rmg nut (upper) (1)

Usa the nng nut wrench (2)

Ring nut wrench:

ICHAS~~ l

lnstall
Beanng (1)
Bali race cover (2)

YU-01268/9089001268

NOTE:

Apply hthtum soapbase grease to the beanng and

bali race cover hp

Remava

Rmg nut (lower) (1)

Use the nng nut wrench (2)

Rlng nut wrench:

YU-01268/9089001268

lnstall
Under bracket (1)

NOTE:

Apply hthtum soap-base grease to the bearmg

f!ifj.j;Ui@ij ----------Support the steerlng axle to prevent 1t falling

INSPECTION

3
BEARINGS

lnstall
Rtng nut (lower) (1)
Use the nng nut wrench (2)

Wash the beanngs m solvent

Ring nut wrench:

2 lnspect

--

YM-38520/90890-01443

Beanng (upper and lower) (1)

Corroston/Damage ~ Replace races and

beanng

NOTE:

install the beanngs '" the races Spm the

beanng by hand

Apply the hthtum soapbase grease to the steenng

axle thread

lf the beanng nses or fatls to run freely m

the race, replace beanng and race
Loosen the rmg nut (1) completely and rettghten
1t to spectf1Catl0n

Ring nut t1ghtening sequence:

STEERING AXLE

IlDI

1 lnspect
Steenng axle (1)
Bend/Damage ~ Replace

------(i)

NOTE:

Set the torque wrench to the nng nut wrench to

form a nght angle

t!W';iMWi
Do not tlghten excessively.

Ttghten the nng nut ustng the nng nut wrench

Rlng nut (lower)

(imtal tightening):

4 Nm (G.4 mkg)

38 Nm (3.8 mkgl

6-51

Rmg nut (lower)

(flnal tlghtenlng):

652

sr_E'_ER_IN_aiCHAS~~~

_______________
4

1-6

STEERING
7

Check the steenng axle by turnmg 1t lock to

lock lfthere 1s any bmdmg, remvoe the steer-

lnstall

'"9 axle assembly and mspect the steenng

beanngs

Plam washer (1)

Steenng axle nut (2)

Use the !ock nut wrench (3) and (4)

1

~~

5 lnstall

ICHAS~~~

Lock nut wrench:

YM-38519 .......... (3)
90890-01348 ...... (4)

[Al For USA and CANADA

[8] Except USA and CANADA

Rmg nut (upper) (1)

Lock washer (2)

NOTE:

lnstallatlon sequence
lnstall the nng nut (upper) (1)
Fmger ttghten the nng nut (upper), then ahgn

Set the torque wrench to the !ock nut wrench so that

they form a nght angle

the slots of both nng nuts lf not ahgned, hold

Steerlng axle nut:

115 Nm (11.5 mkg)

the lower nng nut and ttghten the other unt1l

they are ahgned
lnstall the lock washer

Atter t1ghtenmg the nut, check the steenng far

smooth movement lf 1t IS not smooth, adjust
by progress1vely loosenmg the (lower) nng

nut

NOTE:
Make sure the lock washer tab

1s m the slots

9 T1ghten
Pmch bolt (handle crown) (1)
Pmch bo!t (under bracket) (2)
Pmch bolt {handle crown)
23 Nm (2.3 mkg)
Pmch bolt (under bracket):
20 Nm (2.0 mkg)

lnstall

Handle crown

Front fork (left and nght) (1)

CAUTION:
Tighten the under bracket t o specafaed torque.lf
torqued too much, at may cause malfunctaomng
of the front fork.

Front fork top end (a)

(Standard)
Omm

10 lnstall
Handlebar (1)
Handlebar holder (2)

NOTE:

Temporanly 1nstall the under bracket screws to

achteve the correct fork posltton

6-53

6-54

1-7
Screws (handlebar holder):
23 Nm (2.3 mkg)

NOTE:
The upper handlebar holder must be mstalled wcth

REAR SHOCK ABSORBER ANO SWING ARM

\cHAS~~ l

REAR SHOCK ABSORBER

(1)
(2)
(3)
(4)

Shock absorber
Spnng
Spnng ad]uster nut
End of stroke buffer

the punched mark (a) forward

Set the tank breather hose (b) m piace

CAUTI<?N: : _ _ _ _ _ _ _ _ __

~ Nm (3.2 mkg) l

F1rst tlghten the front screws on the handlebar

holder, then tighten the rear screws.

LOWER HANDLEBAR HOLDER

lnstall

Lowerhandlebar holder (1)

Plam washer (2)
Nut (3)
Cotter pcn (4)
Nut (lower handlebar holder):
40 Nm (4.0 mkg)

W!tMi:NildN __________
Always use a new cotter pm.

'\

6-55

6-56

REAR SHOCK ABSORBER ANO

SW~ ARM jcHAS~~ l

''*'i;i~lldil -"----------

Thls shock absorber contams hlgh-pressure

nitrogen gas. Read the followlng informat1on
carefully before handllng 1t. The manufacturer
cannot be held responslble for any damage or
lnJUry that may result from lmproper handlmg.
Never tamper wlth or attempt to open the
cyllnder or the tank.

1-8

REAR SHOCK ABSORBER ANO SWING ARM

jcHAS~~ l

REMOVAL

t!Wil';'fi'Mi ___________
Support the cycle securely to prevent tt from
falhng over.

Park the cycle on a level surface

Never expo se the shock absorber to a naked

Remove
Seat
Stde panels
A1r ducts
Fuel tank
See sectton "SI DE PANELS, AIA DUCTS,
SEAT ANO FUEL TANK' m CHAPTER 3

Ratsethefrontwheel placmg a suttable support

under the engme

Remove
Rearwheel
Se e sect1on "REAR WHEEL REMOVAL"

Remove
Shock absorber fastemng nut (1)
Lower shock absorber screw

Remove
Shock absorber fastenmg nut (1)
Upper shock absorber screw

flame or other source of heat. This m1ght

cause the pressurised gas to explode
Do not deform or damage the cyhnder m any
way. Damageto the cyllnder would 1mpa1rthe

dampmg effect.
Be careful not to scratch the surface of the
rod: thts would cause the 011 to leak.
Before dtsposmg ofthe shockabsorber, rea d
the sectlon "NOTES ON OISPOSAL".

NOTE ON DISPOSAL

,. * * * * * * * ** * * * * *. * * * * * * *. *. * * * *
Before neutrahsing the rear shock absorber.

The gas pressure must be dtscharged before

d1sposmg of the shock absorber 1t ts necessal)' to
d1scharge the gas pressure To do th1s, bore a hoie
of 2-3 mm through the cylmder wall about 15-20
mm from the botto m of the gas chamber.

f!W&.1iUI@1 - - - - - - - - - - wear protectiVe goggles to avoid eye mjur~es

from escaplng gas and/or metal chlps

6 57

6 58

REAR sHocK AesoRBER ANo

sw,~ ARM JcHAsJ~J

INSPECTION
1

Examtne

Shock absorber
Oilleak/Damaged -+ Aeplace

1-9

REAR SHOCK ABSORBER ANO SWING ARM

JcHASI~ l

SWINGARM
(1)
(2)
(3)

Upper cham cover

Sw1ng arm
Lower cham cover

(4)

Swmg arm protect1on

(5)

Swmg arm art1culatton

(6)

Artleulated rod

[A] LATERAL FREE PLAY (END) 1 O mm

[8] LATERAL FREE PLAY
01-03mm

85 N m (8 5 mkg)

660

"-../ l

REAR SHOCK ABSORBER ANO SWING ARMCHAS

l~
'-"~ l

11-10

REAR SHOCK ABSORBER ANO SWING ARM

REMOVAL

jcHAS~~ l

Remove
Upper cham cover (1)
Lower cham cover (2)

Remove
Swmg arm pm
Swtng arm

NOTE:
Check free ptayand removeswrng arm, rf necessary,
atter removmg the rear shock absorber

Remove

Swrng arm artrculatiOn bolt (1)

lnspect
Swtng arm free play

** *** *. ** * * * * * * * *. * * * *,.. * * *
INSPECTION

lnspection procedure:

Check the trghtemng torque of the nut whrch

fastens the swmg arm prn (1)

1'-1
.

~.

Examtne
Sw1ng arm
OeformatiOn/Cracks/Oamage-+ Replace

Nut (pm shaft):

85 N m (8.5 mkg)

Check the latera! free play [A] of the swmg arm

movrng rt laterally
lf the free play seems excessrve, venfy the
collar, beanngs, washer and thrust cover

Exam1ne
ArtlculatiOn (1)
Rod (2)
Deformat10n/Cracks/Damage-+ Replace

Examtne
011 seals
Wear/Damaged .o+ Replace
Washers
Thrust cover
Wear/Damaged -+ Replace
Bushes
Scratches/Damaged -+ Replace
Beanngs
P1tt1ng/Damaged -+ Replace

Examme
Cham gUide
Cham protect1on roller
Cha1n protectiOn
Wear/Oamage .o+ Replace

Lateral free play

(at end of swrng arm):
Limit: 1.0 mm

6-61

Check the vertlcal movement [B) of the swrng

arm, movmg rt up and down
lf the movement seems ngrd, unsmooth or
1erky, mspect the mternal collar, the beanngs,
the washer and the thrust cover

662

'-....J

REAR SHOCK ABSORBER ANO SWING ARM

lCHAS)-"--)
~

11-11

REAR SHOCK ABSORBER ANO SWING ARM ICHAS\cP

LATERAL FREE PLAY AOJUSTMENT

Measure

Length of bushes A1 and A2.

Out of spectf1Catton "':) Replace

Length of bushes:
Al= 76.70-76.85 mm
A2 = 74.90- 75.00 mm

E
2

Measure

l'M'Il

specml shtms
Use the followmg formula

l'
l
eS

61

A1

C= (A1+A2) (B1+B2)
Swing arm latera! free play C:

01-0.3nm

Latera! s1de play usmg one or more adjust

ShlmS (1)

l'
G
l'
l

Measurement of adJUSt shim {1)

0.3mm

'

NOTE:
When only one sh1m IS used, mstall 1t on the left

51de, when two sh1ms are used, 1nstall one on each

ssde

82

A2

l
l~
'

AdjUSt

Latera! swtng arm SH:ie play C

Out of spec1flcatlon-+ AdJuSt free play Wlth

'

'

Length 81 and 82

Calcuiate

6-64

'--J

,-_s...,_, 11-12 l

REAR SHOCK ABSORBER ANO SWING ARMCHAS '-'1:1

REAR SHOCK ABSORBER ANO SWING ARM

INSTALLATION
Perform "removal" operattons
Note the followmg pomts

Screw (cham cover):

4 N m (0.4 mkg)

m reverse arder
3

Lubncate
Beanngs

Bushes

Thrust covar (ms1de)

Flange
Swmg arm pm

Bolt (art1culatton)

Bolt (rod)

Bolt (shock absorber)

~~~
2

'

LATION"
4

AdjUSt

Dnve cha1n t1ghtness

Drive chatn tightness:
3o-40mm

See sectton "DRIVE CHAIN TlGHTNESS

ADJUSTMENT" on CHAPTER 3

Ttghten

lnstall
Fuel tank

A1r ducts
Stde panels

Seat

lxi

Bolt (seat)
10 Nm(1.0 mkg)

See sect1on "SIOE PANELS, AIA DUCTS,

SEAT ANO FUEL TANK" on CHAPTER 3

Bolt (cham gutde):

7 N m (0.7 mkg)
Nut (rod-chassis):
32 Nm (3.2 mkg)
Bolt (rear shock absorber):
59 Nm (5.9 mkg)

665

Rearwheel
See sectton "REAR WHEEL - INSTAL-

Nut (swmg arm pin):

85 Nm (8.5 mkg)

'

lnstall

Lithium-base grease

Nut (relay arm-swmg arm):

59 Nm (5.9 mkg)
Nut (relay arm-rod)
32 Nm (3.2 mkg)
Bolt (chain protectlon):
7 Nm (0.7 mkg)

\CHAS~~ l

666

'

DRIVE CHAIN, SPROCKET ANO "R"owNCHAS

,~_,
~

11-131

DRIVE CHAIN, SPROCKET ANO CROWN

DRIVE CHAIN, SPROCKET ANO CROWN

NOTE:
Before removmg the dnve cham, sprocket and
crown, 11 1s necessary to measure the free play and
length of the 1O llnks m the eh am

Remove
Swmg arm
Dnve chatn
See sect1on "AEAR SHOCK ABSORBER
ANO SWING AAM-REMOVAL"

INSPECTION
Measure

REMOVAL
Park the cycle upnght on an even suriace
2

jcHAS~~ l

Length of 10 lmks (dnve cham)

Out of speclf1cat10n -+ Replace dnve cham

Remove
Gear pedal (1)
Cover (2) (sprocket)

Maximum lenght of 10 links (a):

150.2 mm

NOTE
3 Remove
Sprocket (1)
NOTE:
Before remov1ng the sprocket nut, stra1ghten the
tab on the lock washer
loosen the nut wtth the rear brake pulled

Stretch the cha1n by hand to measure 1t

The length of the 1 O hnks IS recorded between
the ms1de of the hnk pms (1) and (11) as shown
The length of the 1O hnks IS measured at vanous
po1nts

GJ~!<ll

~~

@J~ Ho ')@:)!:
~---=-~

_ __,

H )f:)2)

2
4

Ratse the rearwheel p!actng a swtable support

under the engtne

Clean
Dnve cham
Immerge 1n kerosene and brush thoroughly
to remove as much d1rt as poss1bie
Remove from kerosene and allow to dry

Set the cycle up securely to prevent it fallmg

ove r.

,CAUTION:
5

6 67

Remove
Rear wheel

Crown

Spacer
See sectiOn "REAR WHEEL-R.EMOVAL"

Th1s cycle 1s f1tted with a cham wlth small 0Rmgs (1) fltted between its plates. Vapour
cleaning, pressurlsedwashmg and certa m types
of solvents may damage these seal rlngs.
To clean the transmlssJon chain use only
kerosene

D l
6-68

,'--._/ 1

I..E-.r-1

DRIVE CHAIN, SPROCKET ANO CROWNCHAS '-'@

3

l l

Examme
Seal nngs (1) (dnve cha1n)
Damaged -+ Replace dnve cha1n
Rollers (2)
Latera! plates (3)
Damage/Wear -+ Replace dnve cham

11-14 1

DRIVE CHAI N, SPROCKET ANO CROWN

T1ghten
Crown fastemng screws

Crown fastenmg screws:

35 Nm (3.5 mkg)

T1ghten

lxi

" ..... * * * * * * * * * * * * *

jcHAS~~ l

Wheel p1n nut

Wheel pln nut:

115 Nm (11.5 mkg)

See sect1on "REAR WHEEL-INSTALLATION"

INSTALLATION
4

Lubncate
Dnve cham

Perform "REMOVAL" operat10ns 1n reverse arder

Pay spec1al attent1on to the followmg pomts
lnstatl
Dnvecham
Swmg arm

Lubrlcant for drive cham:

Englne oli SAE 30W- 50

'

,..--<))

''

Wear aver 1/4 tooth (1)-+ Replace

Teeth bent-+ Replace

(2) Undamaged tooth prof1le

(3) Roller
(4) Sprocket

How to replace the crown:

W1th wheel dtsassembled
1 Remove
Screws (1)
Crown (2)
2 lnstall
New crown (2)
Crown fastemng screws {1)

lnstan
Rearwheel
See sect1on "REAR WHEEL-INSTALLATION"

lnstall
Sprocket

\xl

Nut (sprocket):
110 Nm (11.0 mkg)

l!ifd;I@UN ----------Aiways use a new safety washer.

NOTE:
T1ghten the sprocket nut w1th the rear brake
pulled
After t1ghtemng the nut, band the tab on the
safety washer once more over the faces of the

nut
4

AdjUSt
Onve cha1n ttghtness
See sect1on "DRIVE CHAIN TIGHTNESS
ADJUSTMENT" 1n CHAPTER 3
Drive chaln ttghtness:
30-40 mm

669

lnstall
Covar (sprocket)
Gear pedal
Screws (sprocket cover):
10 Nm (U mkg)
Salt (sprocket cover)
10 Nm (1.0 mkg)

Nut (swing arm pin):

85 Nm (8.5 mkg)
Nut (chlssis-rod):
32 Nm (3.2 mkg)

Examrne
Dnve charn
Rtgtd -+ Clean and lubncate, replace 1f
oecessary

Examrne
Sprocket
Crown

670

IELEci iiii l
CHAPTER 7
ELECTRICALS
ELECTRICAL CIRCUIT DIAGRAM
COLOURCODE

1-16
1-16

ELECTRICAL COMPONENTS

J-1

SWITCH CHECK
SWITCH CONNECTION
MAIN SWITCH INSPECTION

J-2
J2
J-2

LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT ANO BRAKE LIGHTS,

DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC)
BULB TYPES
BULB INSPECTION

J-3
J-3
J-3

IGNITION SYSTEM
CIRCUIT DIAGRAM
DIAGNOSTICS

J-4
J-4
J-5

ELECTRICAL STARTING SYSTEM

CIRCUIT DIAGRAM
STARTING Cll;tCUIT FUNCTIONING
DIAGNOSTICS:
STARTER MOTOR

J-9
J-9
J-10
J-10
J-13

CHARGING SYSTEM
CIRCUIT DIAGRAM
DIAGNOSTICS

J-16
J-16
K-1

LIGHT SYSTEM
CIRCUIT SYSTEM
DIAGNOSTICS
LIGHTING SYSTEM INSPECTION

K-3
K-3
K-4
K-5

SIGNALLING SYSTEM
CIRCUIT DIAGRAM
DIAGNOSTICS
SIGNALLING SYSTEM CONTROL

K-8
K-8
K-9
K-10

ELECTRICAL SYSTEM DIAGRAM

K-15

11-151

lELECI iiii l

ELECTRICAL CIRCUIT 01,\Gf;AM ELE C

ELECTRICALS
ELECTRICAL CIRCUIT DIAGRAM

l ili l

11-161

ELECTRICALCIRCUITDIAGRAMIELECI
(19)
(20)
(21)
(22)

(5)
(6)

(23) Front parkmg hght

CDI umt
1gmtl0n COli
Spark plug

(24) "LIGHTS" swttch

(25) Dlpped/htgh beam commutator
(26) lnstrument ltght
(27) Headlrght (drpped/hrgh beam)
(28) "HIGH BEAM" llght
(29) "STARr' swrtch
(30) Starter relay
(31) Starter
(32) Battery
(33) Fuse
(34) "ENGlNE STOP" emergency sw1tch
(35) Starter c1rcwt cut-off relay

(7)
{8) Clutch sw1tch
(9)

/R-

RO=WQ~LN

~GJW

W
W

B
Br

ilr-1;=====+---RIW

Drode

(10) "NEUTRAL" llght

~R~

"'

"HORN" swrtch
Front brake swttch
Rear brake swttch
Rear brake/tatlllght

(1) Matn SWltCh

(2) Recttfter/Regulator
(3) AC generator
(4) PtC< up COli

"NEUTRAL" swrtch
Latera! stand swttch
Dtrectton tndtcators mtermtttence
"TUAN" dtrectton mdtcators swttch
"TURN" dtrectton tndtcator llght
DtrectiOn mdtcators (R)
DtrectiOn mdtcators (L)
(18) Horn

(11)
(12)
(13)
(14}
(15)
(16)
(17)

RCN

COLOUR CODE

t---,'"
@=

se
L/W 8

57 ART

l 0:-!:Q_I

h@

@~

L_

Br~ W

~@)=JIPj[B

eh ertN o
L

ON

71

Black

Br

Brown

B/W

Ch

Chocolate

BN

BlackfYellow

Dg

Dark grey

Br/W

Brown/Whste

Green

G/W

Green!Wh1te

Blue

GN

Green/Yellow

Orange

UR

Blue/Red

Yellow
BlackfNhlte

Psnk

LfY

Blue/Yellow

Re d

lfW

BlueJWhlte

Sb

Sky blue

RJW

Red/Whste

Whste

RN

Red/Yellow

Gy

Grey

72

ili

ELECTRICAL COMPONENTS
-.___/
ELECTRICAL
(1) Harness
COMPONENTS
(~

(5
6

~~

lELECiiii l

IGNITION COIL

WIN~

3.4- . n ati~;~ESISTANCE
46

PRIMARV

Mam SWitCh
Recbfler/R
lgnttton cot?gulator
Spark plug ca
Starter c 1rc P
Fuse box (~g;)ut-off relay

SECONDARV W
{68oF)
10.4-15 6 ~NDING RESISTANCE
at 20oc (68oF)

f9) ~~DI !Qnltton umt

arter relay
f10) Battery (12V8Ah)

l J-1

L COMPONENTS
(1) Clutch swttch
(2) Horn
(3) DtreqtiOn mdtcators
Lateral stand s
tntermtttence
(4)
"NEUT
" WltCh
RAL SWltCh
(5)

BATTERY CAP ACITY 12V BAh

ELECTROLYTE DENSITY :1,320

'-;---r-~
/

~~

~
~
--

7-3

@~
izo Nm (2 0 mkg)l

7-4

ELECiiii l

SWITCH~CKIELECiiii l l J-2
SWITCH CHECK

SWITCHCHECKjELECjlii l
~::::::::::::::::::::::::;---~C~A~UT=f~oi~N~=U~-:_-:_-:_-:_-:_~----~--~~

Check the contmUity between the swttch termmals

When detachlng the connector, do not pull by

the cables. Thls way the cables m1ght dlscon
nect from the termmals insade the connector
itself.

to venfy whether connectiOns are correct

To check the swttch, rea d the followlllQ pomts

SWITCH CONNECTION
2

The table shown here contams the connectEons

between the swttch termtnals (eg mam swttch,

handlebar swttches, brake swttch, ltght swttch etc)
Thecolumn o n the far left shows the postttons of the
mam swttch an d the top hne mdtcates the colours of

NOTE:
lf the connector ss blocked up w1th mud or dust,
clean tt wtth a Jet of compressed a1r

the cables connected w1th the termtnals of the

SWI!Ch ttself

o--o tndtcates the termtnals between whtch there

respecttve swttch postttons

Use the connecllon table to check the combt

nattan of colours for contmUity (closed ctrCUit)
ln thts example, conttnUity 1s as follows

Far exampte, m thts table

"R and Br'' and "L an d UR" are contlnuous when the

"R and Br" and "L and UR" are contmuous

when the SWitCh IS at ON

ts electncal contmutty, te a closed ctrCUit on the

SWI!Ch IS

at ON

"R and UR" are contmuous when the sw1tch 1S at

PARK

MAIN SWITCH INSPECTION

---

R "'
ON
OFF
LOCK
p

Before mspectmg the sw1tch, see the connect1on

table shown abave and check the termmal connecbons (closed ClrCUit) by the colour combmat1on
1 Oetach the mam swttch connector from the
harness connector

L LIA

Check to see 1f any cables are d1sconnected

from the1r term1nal1nstde the connector Reconnect, 1f necessary

R "'
ON
OFF
LOCK
p

"R and UR" are conttnuous when the sw1tch IS

at PARK

L L/A

Note that there ts no contlnUity (open c1rCU1l)

for any of the combmat1ons of a colour dlfferent from those ment1oned

_j

~l'

Check the sw1tch component far contmUJty

between "R and Br" and "L and UR" and
"Rand UR"

lA
Contro! procedure:
Repeatedly shlft the sw1tch key to the vanous
poslbons ON, OFF, LOCK and P
Shtft the tester selector to nx1
Connect the tester pos1ttve cab! e(+) to the terminai of cab te R of the connector, and the negative
cable (-) to cable term1nal Br

~'

7-5

7-6

BULB INSPECTIONjELECjliii
NOTE:

Usa the thm testertermmals to checkcontlnUity, as

the terrmnals m1ght come mto contact wtth others
1nstde the connector
Check cont1nu1ty between "R and Br" at sw1tch
poSitiOns ON (1), OFF (2), LOCK (3) and PARK
(4) There must be contmwty (1e the tester must
show "O") at ON and there must be no cont1nu1ty
(1e the tester must show "oo" ) at OFF, LOCK

and PARK Someth1ng ts not work1ng between

"R and Br" 1f there 1s no contrnwty between these
two po1nts at pos1t10n ON, or 1f there 1s some
contmu1ty m o ne of the other pos1ttons OFF,

'"'" *** "**** **** ........ *""""*** .... ****

BULB INSPECTION

Contro! procedure:
Set the tester selectar to n x 1
Cannect the tester termmals ta the bulb pms
Take, far example, a three pm bulb as shown m
the figure FlrstcheckcantlnUity between pms (1)
and (2), cannectmg tester termmal (+) ta pm (1)
and termmal (-) ta pale (2) Then check the
contlnwty between poles (1) and (3), agam cannectlng testertermmal (+) to pale (1), and terminai (-) to pota (3) lf the tester tndJCates oo, even
m one case anly, the bulb must be replaced

Remove the bulb m quest!On

NOTE:
Bulbs af type (A) and (B) usa spec1al supports
(bulbholders) Remove the bulbholder befare
remavmg the bulb Mast af these bulbholders
may be remaved by turnmg m an anttclackw1se
d~rect1an

Most bulbs af type (C) and (D) may be removed

from thetr hausmg by push1ng them and turn~ng
them m an ant1clackw1se d1rect!an
Bulbs af type (E) may be removed stmply by
pulhng them aut

LOCKor PARK
c~uTf~]

NOTE:

Check sw1tch contrnwty vanous t1mes

Continue to check contlnwty between "L and

UR" and "R and UR" rn the respectJVe sw1tch

pos1t10ns m the manner descnbed above
6 lf anythmg wrong 1s noted rn any of the combt
naMns, replace the sw1tch component

_________

When remaving a bulb be careful to hald the

bulbholder or lts houstng flrmly. Never pull the
cabla, as it m1ght detach from the termmal
mside the connector.

'''9"';'Midi ___________
Keep lnflammable products and hands well
away from bulbs when they are on (danger of
burns and fife). Do not touch the bulb before tt
1s cool.
2

Check the cantmwty between the bulb termtnals

LIGHT INSPECTION (HEADLIGHTS, TAIL

LIGHT ANO BRAKE LIGHTS, DIRECTION
INDICATOR LIGHTS, INSTRUMENT
LIGHTS, ETC)

Check the contmwty between the bulb termmals ta

see that they are undamaged
BULBTYPES
The bulbs used are class1fled as shown ta the left
accordmg to type ot attachment
(A) and (B) are used ma1nly far headhghts

(C) 1s used ma1nly far dtrect!On md1catar i1ghts and

the rear and brakmg hghts
(D) and (E) are used espec1ally far mstrument and
other tndtcat!On hghts

7-7

78

Check the bulb attachment by mstalhng a test

bulb Furthermore, durmg mspect!On af the
buibs, connect the tester term1nats to the respectlve socket cables and check contmwty
as descnbed

IGNITIONSYSTE0LECI

iii l

l J4

IGNITION SYSTEM ELEC

l iii l

The dtagram tllustrates the tgnltton mcwt mstde the motorcycles electnc system

IGNITION SYSTEM
CIRCUIT OIAGRAM

NOTE:
Far the colour cOde and legend, se e page 7-2
(1)

CDE~~;i:,J"~'~'~'j''~'

(2)
(3)
(4)

LOCK

,------4+-1---"
IR

0=6
w

-:~E~;:

(5)
(6)
(7)

(8)
(9)
(11)
(12)
(32)
(33)
(34)

Mam swttch
Recttfter/Regulator
AC generator (source coli)
Ptck-up COli
CDI unlt
lgnltton emi
Spark plug

RIW

,,

'"
PO

'"

v
Hl
LO

7-9

7-10

Clutch swttch
Doode
"NEUTRAL" swotch
Latera! stand swttch
BatteiY
Fuse
"ENGINE STOP" emergency swttch

_ _ _ _ _ _ _ _ _ _ _ _a_N_Ir_o_N_;_vs_r_EMIELECiiiJI

l J-5

IGNITION SYSTEMIELECIIill

DIAGNOSTICS
IF THE IGNITION SYSTEM WERE TO STOP WORKING
(NO OR INTERMIITENT SPARK))
Procedure
Check
1 Fuse
2 Battery
3 Spark plug
4 Amphtude of 1Qn1t1on spark
5 Spark plug cap res1stance
6 lgmtiOn wmd1ng res1stance
7

Check the cond1t1ons of the spark plug

Check the type of spark plug used
Check the electrodes gap
See the sect1on on CHAPTER 3 on "SPARK
PLUG INSPECTION "

8 "ENGINE STOP" SWitch

9 Lateral stand sw1tch
1o Neutral sw1tch
11 Clutch SWitCh
12 P1ck-up COLI res1stance
13 W1nng connect1ons (whole connectJon system)

Mam SWitCh

Connect the pocket tester (Qx1)

,-----~___:;___

to the fuse

Replace the fuse

Electrodes gap:
0.8-0.9 mm

__

~------,

Correct the electrodes gap or replace the spark

plug

CORRECT

Amphtude of the 1Qnlt1on spark

Connectthe dynam1csparktester (1) asshown

rn the f1gure
(2) Spark plug cover (3) Spark plug
Turn the mam SWIICh ON

DISCONTINUITY

Check the contmUJty ot the fuse

See sect1on "INSPECTION ANO
REPLACEMENT OF FUSE" 1n CHAPTER
3

INCORRECT

Detach the spark plug cap from the spark

plug

P/N. YU-03112
P/N. 90890-03112

Fuse

~
4

Pocket tester.

Remove the fuse

Standard spark plug:

DPR8EA9 (NGK), DPR9EA9 (NGK)

NOTE:
Before makmg the mspecMns menttoned, remove the followmg parts
1 Stde famngs (lett and nght)
4 Fuel tank
5 Cowhng (headhght)
2 A1r ducts (left and nght)
3 Seat
Before checkmg funcbonmg defects, use the fol!owmg spec1al toots
Dlnam1c spark tester.
P/N YM-34487
P/N 90890-03144

Spark plug

______,

CONTINUITY

r~~
1--vif Check the ampl1tude of the 1gmt10n spark

INCORRECT

2 Battery
Check the battery
Refer to the correspond1ng sect1on 1n
CHAPTER3

Clean the battery termmals

Recharge or replace the battery
Refer to the correspondmg sect1on m
CHAPTER3

Voltage
12.8V or more at 20C (68F)

IN COMPLIANCE WITH SPECIFICATIONS

Start the engme and mcrease the amphtude

unt1l the IQmtiOn becomes automat1c

Spark amplltude lf the lgnltlon

system is eff1clent:

l Mm1mum spark amplltude

6.0mm

THE IGNITION SYSTEM IS INEFFICIENT OR

THERE IS NO SPARK

CORRECT

7 11

7-12

IGNITIONSYSTEMIELECjlii
5

'

Spark plug cap reststance

Remove the spark plug cap

Connect the pocket tester (Ox1 k) to the spark
plug cap

~
""'

lgM1on wtndtng res1stance

Dlsconnect the tgmtton co1l cables from the

bundle of cables
Connectthe pockettester (O:x1) tothe tgnltton
COli

~i

Tester termmal (-)-+Polo(-)

Resistance of spark plug cap:

10 kO at 20C (68F)

Checkthatthespark plugcap has the spectf1ed

reststance

lmJ

Tester terminai(+)-+ Polo(+)

OUT OF SPECIFICATION

J The spark plug cap 1s defectcve

IN COMPLIANCE
WITH SPECIFICATIONS

e+(~ c:J
-@ f-

Re piace

''

Check that the pnmary co1l has the spec1hed

res1stance

lm.J

Pnmary winding res1stance:

3.4 - 4.6 n at 2oc (68F)
(Terminai(+)- Terminai H)

Connectthe pockettester (Ox1) to the 1gmt1on

COli

Tester terminai(+)-+ Spark plug cable (1)

Tester terminai(-)~ Pole (+)

...,

/('<P'

(---<D

Q
r

'

-@~

OUT OF SPECiFiCATIO N

Checkthatthe secondarycoll hasthespec1fied

res1stance

mJ

Secondary w1ndmg resistance:

10.4-15.6 kn at 20'C (68'F)
(Spark plug cable- Pole (+))

D
*

80TH RESiSTANCE
VALUES ARE CORRECT

7-14

~---

The IQnltiOn COli IS defect l ve

Replace

________________________r_aN_IT_ro_N_~_vs_T__
EMIELECiiiil

l J-7

IGNITION SYSTEMIELECIIii l

D
9

Dtsconnect the mam swttch connector from

the bundle of cables
Con ne et the pocket tester (Qx1) to the mam
swttch cables
See sectton "SWITCH CHECK"

Latera! stand swttch

Dtsconnect the latera! stand swttch connector

(Biack and Black) from the bundle of cables
Connect the pockettester (nx1) to the latera!
stand swttch cables
T ester terminai(+)~ Black cable (1)
Tester terminai(-)-+ Biack cable (2)
B

INCORRECT
INCORRECT

l The mam SWttch IS defectlve Replace

The latera! stand sw1tch 1S defect1ve Replace

Dtsconnectthe"ENGINESTOP"swstchcables
(Red/Whlte and Brown) from the bundle of
cab les
Connect the pocket tester (Qx1) to the
"ENGINE
"swttch cables

D1sconnectthe neutra! sw1tch cab! e (Sky blue)

from CDI un1t
Connect the pockettester (.Qx1) to the neutra!
sw1tch cables

Tester termmal (+) 7

Red/Whlte (1) cab le
Tester termmal
.-+ Brown cable

Tester terminai(+) Sky blue cabla (1)

Tester termmal (-) Earth

Sb

INCORRECT
INCORRECT

The "ENGINE STOP" swttch ts defect1ve

Replace the nght handlebar swttch

CORRECT

The neutra! sw1tch 1s detective Replace

7 15

CORRECT

7-16

IGNITIONS~EMIELECiiiiii l l J-8

IGNITION SYSTEM lELEC liiiii l

------------------------------------- Dtsconnect the ctutch swttch connector tram

the hamess
Connect the pocket tester (Ox1) to the clutch
swttch cabla
Check the clutch swttch component far
contlnutty between "Biack (1 ) and Black/Yellow
" See sectiOn "SWITCH CHECK"

Dtsconnect the generator connector (Blue/

Yellow and GreeniWhlte) from the CDI un1t

Con ne et the pocket tester (Ox1) to plck-up

emi cables
T ester term1nal (+)-+

BlueNellow cable (1)

T ester termmal (-)-+
Green/White cable (2)

l l

INCORRECT

Jd;

The clutch swttch 1s defecttve Replace

D
*

Check that the ptck-up coli res1stance IS as

speclfted

Pick-up coli res1stance:

184- 276 n al 20C (68F)
(Biue/Yellow- Green/Whate)

D
*

COMPLYWITH
SPECIFICATIONS
UNCERTAIN CONNECTIONS

13 Wmng connectJons

Check the connecttons ot the enttre tgnttlon

system See the "ELECTRICAL CIRCUIT

DIAGRAM" secMn

\ Correct
CORRECT

l The CDI un1t 1s defecttVe Replace

7-17

7-18

ELECTRICALSTARTING~TEMIELECiiiiiiil l J-9

ELECTRICAL STARTING SYSTEM l ELEC liiiiii l

The d1agram 1llustrates the electncal startmg system-<:1rcu1t ms1de the molorcycles electnc system

ELECTRICAL STARTING SYSTEM

NOTE:

CIRCUIT DIAGRAM

For the colour code an d Jegend, see page 7-2

R9r~LIR

ON

CD '"

!..OCK

Jj,_}:

(~)

Mam SWitCh

(8)
(9)

Clutch sw1tch
D1ode

(11)

"NEUTRAL" SWIICh

(30) Starter relay

(31) Starter
(32) Battery
(33) Fuse

(12)

Lateral stand sw1tch

(34)

(29)

"START" sw1tch

(35)

'-r--'-!-

J:-t-t-r--t---!91Y ~D-9/W

"'

.. L1

~::

l@

7-19

7-20

"ENGINE STOP" emergency sw1tch

Starter wcu1t cut-off relay

1~1IJ-1ol

ELECTRICAL STARTING SYSTEM ELEC . .

;:::===========:::::;---:S:::TA~R;::T;:;E:;:R:-:C::I:::R:;:CU::r:::T-::F~UNCTIONING
The startmg CirCuii of th1s mode! cons1sts of the
starter, 1ts relay sw1tch and the relay umt (to mterrupt the startmg c1rcUJt) lf the engme emergency
stop sw1tch and ma m swrtch are both off, the starter
can only work 1f
The gear rs 1n neutra! (neutra! sw1tch off)

or if
theclutch levar 1s completely up agamstthe handlebar (clutch swJtch off) and the latera! stand ts rarsed
(stand swJtch off)
l

The break relay rn the starter c1rcUJt prevents the

starterfrom start1ng when none of these cond1bons

l
L_

1s met In th1s case the break relay of the starter

CirCUII rs on, so that the starterfeed IS off When one

--...J

or both of these cond1t1ons are met, the break relay

1n the starter c1rcUJt stays off and the motor eng1ne
may be started by press1ng the "START" button

ELECTRICALSTARTINGSYSTEMIELECI

iiii l

DIAGNOSTICS
THE STARTER FAILS TO WORK

Procedure
Check
1 Fuse
2 Battery
3 Starter
4 Starter relay
5 Matn sw1tch contmwty contro!
6 Emergency "ENGINE STOP" SWIICh
7 Latera! stand sw1tch

8
9
10
11
12

"NEUTRAL" SWIICh
Clutch sw1tch
Starter CirCUII cut-off SWitCh
"START" SWitCh
Harness connect1on contrai (ent1re starter
system)

NOTE:

Before startmg mspect10ns, remove the follow1ng parts

1 S1de panets (left and nght)
2 A1r ducts (left and nght)
3 Seat
4 Fuel tank
5 Cowhng (headhght)

'
\

To mspect any operatmg faults defects use the followmg spec1al tools
~ WITH THE GEAR IN NEUTRAL

Pocket tester:

WITHTHESTANDRAISEDANDTHE
CLUTCH LEVER PULLED

(1)

Battery

(2)
(3)

Mamsw1tch
Engme emergency stop sw1tch

(4)

Starter relay

(5)

Starter C1rcu1t break relay

(6)

"START" sw1tch

(7)

Starter

(8)

Neutra! sw1tch

(9)

Clutch SWIICh

P/N. YU-{)3112
P/N. 9089().03112

Fuse

Remove fuse
Connect the pocket tester (O.x1) to the fuse
Check fuse contmwty

DISCONTINUITY

See the "FUSE INSPECTION ANO RE

PLACEMENT" sect1on m CHAPTER 3

Replace the fuse

CONTINUITY
INCORRECT

(10) Latera! stand sw1tch

(A)

To the starter c1rcwt break relay

(B)

To the starter relay

Check the cond1t1ons of the battery

Consu!t the "BATTERY INSPECTION" sect1on m CHAPTER 3

Battery

~-----,

Clean the battery termmals

Recharge or replace battenes
Consult the "BATTE RY INSPECTION" sect1on 10 CHAPTER 3

Voltage:
12.8V or more at 20C (68F)

D
*
721

CORRECT

722

'~

l lIii l l J-11 l

ELECTRICAL STARTING SYSTEMjELECjlilii

ELECTRICAL STARTING SYSTEM ELEC

*
3

Starter

Connect the postbve termmal of the battery

(1) and the starter cable (2) usmg a connec

tton cab!e (3)

itfi!;IM!Mii
The connectlon cable used must havea sectaon

equa! or supenor to that of the battery cable,

whlch mlght otherwlse get burnt.
Thls lnspectlon ls llable t o produce sparks an d
should therefore be performed well away from
lnflammable substances.

Drsconnect the mam swrtch connector from

the harness
Connect the pocket tester (Ox1) t o the mam
sw1tch term1nal
Check the swrtch component far contmwty
between "Aed (1) and Brown (2)" See the
"SWITCH CHECK" sectron

INCORRECT
IT FAILS TO RUN

Check the funcbonrng of the starter (Blue/

Wh1te)

D
4

The starter ts defect1ve Reparr or replace

ITRUNS

Starter relay

Otsconnect the starter relay connector

Connect the battery and frame to the starter

Drsconnect the nght handlebar swrtch connector tram the harness

Connect the pocket tester (.O:x1) to the emergency engrne stop swrtch termrnal
Check the swrtch component tor contrnurty
between "Aed/Whrte (1) and Red/Whlte (2)"
See the "SWITCH CHECK" sect1on

relay connector, ustng a connectton cab1e (1)

as shown

Battery terminai (+) (2)-+

Red/Whlte termmal {3)
Frame-+ Blue/White terminai (4)

IT FAILS TO RUN
INCORRECT

The starter relay rs defect1ve Reparr

The "ENGINE STOP" swrtch rs defect1ve Re
piace the rrght handlebar swrtch

Check the functtonmg of the starter

D
*

CORRECT

ITRUNS

7-23

7 24

' -. .-/ l lg l lJ-121

ELECTRICAL STARTING SYSTEM ELEC -

ELECTRICALSTARTINGSYSTEMIELECiiii

D1sconnect the clutch sw1tch connector from

D1sconnect the latera! sw1tch connector from

the harness
Connect the pocket tester (Qx1) to the latera!
stand termmal

the harness
Connect the pockettester (Ox1) to the clutch

termmal
Checkthe clutch swstch componentfor contlnulty between "Biack (1) and Black/Yellow'' (2)
See the "SWITCH CHECK" sectiOn

Check the sw1tch component far contmUity

between "Biack (1) and Black (2)"

See the "SWITCH CHECK" sect!On

INCORRECT

INCORRECT

The clutch sw1tch 1s defecttve Replace

\

CORRECT

'

CORRECT

1O Starter CITCUit cut-off relay

Connect the pocket tester (DC 20V) to the cut
off relay connectorterrmnal of the starter ctrcwt

01sconnect the neutra! sw1tch cable from the

harness
Connect the pockettester (.O:x1) to the neutra!
sw1tch term1na!

Battery termmal (+)-+

Red/Whlte terminai (1)
Battery terminai (-) -+
Sky blue terminai (2)
Testercable (+)-+e
RedNellow terminai (3)
Tester cable (-)-+ Earth

Check the sw1tch component far contmUity

between "Sky blue (1) and Earth"

See the "SWITCH CHECK" sect1on

Sb

INCORRECT

The neutra! sw1tch 1s defectNe Replace

CORRECT

7-25

B/Y R/Y
Sb

RIW

3
-Q)

r-EBI-

DISCONTINUITY

+--,-~----::--~

The starter CITCUit SWttCh relay 1s defect1ve Re

piace

'--'

ELECTRICAL STARTING SYSTEM

ELEC 1 ~

ELECTRICALSTARTINGSYSTEMIELECIIii
STARTER MOTOR

Turn the mam swttch to ON

Check the voltage (12V) on the "Red/\Nhtte"
and "AedNellow" cablato the connector termtnal of the starter CtTCUit mterruptlon relay

IIJ-131
(1)
(2)
(3)
(4)

Brushes
Armature
Stator
0-nng

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

Dtsconnect the swttch connector from the

harness
Connect the pocket tester (Qx1) to the handlebar swttch termtnal
Check the "STARr' swrtch componentfor conttnurty between "BiueMihlte (1) and Black (2)"
See the "SWITCH CHECK" sectron

A BRUSH LENGHT LIMIT:

5 mm (020 1n)
B COMMUTATORWEAR LIMIT:
27mm(1 0610)
C MICA UNDERCUT:
07mm(0027~n)

D ARMATURE COIL RESISTANCE:

O n at 20'C (6B'F)
INCORRECT

CORRECT
UNCERTAIN CONNECTIONS
Check the connecttons of the whole starter

system
See "ELECTRICAL CIRCUIT DIAGRAM" sec-

tton

7-27

Correct

7-28

ELECTRICAL

STA~G SYSTEMJELECjliiii!j

ELECTRICAL sTARTING svsTEMJ ELecjliiii!j

3 Measure
The m1ca undercut (b)
Out of specftcatron -+ Level the undercut to
the corree! value usmg a hacksaw

Removal
Remove
The starter motor
Referto the "ENGINE AEMOVAL ANO
SETTING" sect10n 10 CHAPTER 4

M1ca undercut (b):

07mm
NOTE:

The m1ca msulatton of the commutator must have

an undercut to ensure proper funct1omng of the
commutator

D1sassembly

1 Remove
The c1rchp {1)

The dnve gear (2)

Remove

Screws (1)
Washers (2)
Washers (3)
Washers (4)
Brushes (5)
Armature (6)
Stator (7)

1 MU or more

:'<I)
'

"
~

on

EJ
"',
o

How to inspect the excitatlon c01ls:

@xH1

l<j>-xlkll+<j>

l:" <t:> L-J

lnspect
Armature co1IS (msulat1on/contmwty)
Defect1ve ~ Replace the motor

Connect the pocket tester and check contmwty

(1) and msutat1on (2)
Check the armature res1stance

Armature co11 res1stance.

Continu1ty check (1):
o n at 20C (68F)
lnsulat1on check (2):
Over 1 MQ at 20C (68F)

lfthe res1stance 1S not normai, re piace the starte

motor

*"*****"*"***********************

5 Measure

lnspectlon and repar

Brush length
Out of spec1flcat10n -7 Replace

lnspect
Mamfold
D1rty -+ Clean wtth sandpaper no 600

Brush length llmit (a)

SOmm

Measure

Dtameter of the commutator

Out of spec1f1caton-+ Aeplace the motor

Wear hmlt of commutator (a).

6 lnspect
Brush spnng strength
Wornout ~ Replace ali spnngs at once

27mm

7-29

7-30

'-. _./

ELECTRICAL STARTING SYSTEM

7

lELEC lliiiii llJ-151

lnspect
B~nngs (1)
011 seal (2)
0-nngs

Bush (3)

ELECTRICAL STARTING SYSTEM

lELECl~~iii

lnstallaton
1

lnstall

Ett'i
--r~

Starter motor

NOTE

Sl1ghtly grease the Onng (1)

Shghtly grease the 0-rlng:
10 Nm (1.0 mkg)

Assembly

Seethe "ENGINE SETTING ENGINE INSTALLi

TION" sectiOn m CHAPTER 4

Revert the d1sassembly procedure

Pay attentton to the fo!lowmg potnts
1 lnstall

Brush hous1ng

NOTE

Allgn the JUtttng surface an the brush housmg w1th

the slot (2)
\
\

lnstall

Stator (1)
Cover (2)

NOTE:

Ahgn the reference marks (3) on the stator Wl t h the

correspondmg reference marks on the cover (4)

lnstall

lxi

731

Screws (1)

Screw (stator):
7 Nm (0.7 mkg)

7-32

l lIii l IJ-1&1

cH_A_R_G_IN_G_~_v_s_TE__
M ELEC

___________________________

CHARGING SYSTEM
The dtagram shows the chargmg ctrcUit tnstde the motorcycle electnc system

CHARGING SYSTEM
CIRCUIT DIAGRAM

NOTE:
For the colour codes an d complete legend, se e page 7-2
(2)
(3)
(32)
(33)

R 9r L L!R

CD "

Off

LOCK
p

,------'-+f-+----8

..

--

iR

'

O= Q
w
w

JM__foRIW

r-

sJv~o-eJW-

1fl l

'"

o@

BF

L/W B

S7ART!

Q-101

' ,,

OFF
PO
ON

~
,,

@'h@

,;w

RUN

~;;,

'

"'

(0

5))

Recttfter/Regulator
AC Generator
Batlery
Fuse

4@
p

'--

@
p B

ON

'"
'"

"'

LO

7-33

eh Br"'

GJY

'1~~1
~~

~;

$
B

*- *- *1

7-34

lELEC liii l

CHARGINGSYSTEMIELECiiii

n*

DIAGNOSTICS
THE UNCHARGED BATTERY

Chargmg voltage

Con ne et the mduct1ve revcounterto the spark

Procedure
lnspect
1 Fuse
2 Battery
3 Chargrng voltage

plug cable
4

Stator w1ndmg res1stance

Hamess connect10n
(whole connecbon system)

Connect the pocket tester (DC 20V) to the

battery

Tester cable (+) Battery terminai(+)

Tester cable (-) Battery termmal {-)

NOTE:
Before carryrng out mspect1ons, remove the follow1ng parts
1) Seat
2} S1de panel (left)
T o check for funct1onmg defects, use the followmg spec1al tools

=loc2ovJ

fUr-

Pocket tester.
P/N. YU03112
P/N. 9089003112

lnduct1ve rev counter

P/N. YU-08036-A
P/N. 90890-03113

\._

Start the engme and rev to about 5,000 rpm

Check the chargmg voltage

Fuse

DISCONTINUITY

Remove the fuse

Connect the pocket tester (.O: 1) t o the fuse
Check fuse contmwty
See the "FUSE INSPECTION AND RE
PLACEMENT" sectlon m CHAPTER 3

~----

Replace the fuse

J
INCORRECT

Battery

~------,

Clean the battery termmals

Recharge or replace t he battery
See the "BATTERY IN SPECTION" sectlon m
CHAPTER3

Voltage.
12.8V or over at 20C (68F)

CORRECT

l Replace the defecttve clutch sw1tch

Use a fully charged battery

CONTINUITY

Check the cond1ttons of the battery

See the "BATIERY INSPECTION" sect1on 1n
CHAPTER3

IN COMPLIANCE WITH
SPECIFICATIONS

Charging voltage:
14.0 V at 5,000 rpm

NOTE:

OUT OF SPECIFICATIONS

Stator cotl res1stance

Otsconnect the AC generator connector from

the harness
Connect the pocket tester (O:X1} to the stat or

Stator colls (1)

Tester cable (+)-+ White cable (1)
Tester cable (-)-+ Whlte cable (2)
Stator COIIS (2)
Tester cable (+)-+ Whlte cable (1)
Tester cable (-)-) Whlte cable (3)

7 35

736

'-..../

CHARGING SYSTEM

Checkthatthe w1ndmg res1stance otthe stator

comphes w1th specJftcatJon

lELEC l lil 1

l K-2 l

OUT OF SPECIFICATIONS

Stator coli res1stance:

Wh1te (1) White (2)

0.52.., 0.780 at 20C (68F)

Stator wmdmg 1s defect1ve Replace

Whlte (1) White (3)

0.52- O 78Q at 20"C (68'F)

D
5

IN COMPLIANCE WITH
SPECIFICATIONS

'
UNCERTAIN CONNECTIONS

Connecttons

Check the connect1ons of the ent1re IQOitlon

system
See the ""ELECTRICAL CIRCUIT DIAGRAM"'

l Correct

OK

The rect1f1er/regulator 1S defecttve Replace

7-37

LIGHTSYSTEM\ELEC\Iiii
LIGHT SYSTEM

The dtagram shows the hght system ctrcutt mstde the electnc system of the motorcycle

CIRCUIT DIAGRAM

NOTE:
For the colour codes and complete legend, see page 7-2

(1) Mam swttch

(22) Rear tatl/stop hght
(23) Front parkmg hght
(24) "LIGHTS" SWitCh
(25) Dtpped/htgh beam hght swttch

(26)
(27)
(28)
(32)
(33)

se

~@

@ile

OFF

p B

PO

O>
!

Hl

LO

'

''-' .. _ ~

14:,1Iu~
l@

7-39

7-40

lnstrument hght
Dppedlhtgh beam hght
"HIGH BEAM" hght

Battery
Fuse

'----' LIGHTSYSTEMIELEC\Iii

l K-4

DIAGNOSTICS
THE HIGH BEAM LIGHT, REAR LIGHT, FRONT PARKING
LIGHT ANO/OR INSTRUMENT LIGHTS FAIL TO TURN ON
Otscannect the matn swttch cannectar fram
the harness
Cannect the packet tester (nx1) to the mam
swttch termmals
Check the swrtch component far conttnutty between "Red (1) and Brawn (2)", "Blue (3) and
Blue/Red (4)" and "Red (1) and Blue/Red (4)"
See the "SWJTCH CHECKn secttan

Procedure
lnspect
1 Fuse
2 Battery
3 Mam swrtch
4 "LIGHTS" swttch and dtppedlhtgh beam hght
5 Harness connect10ns (full system of connecbons)

NOTE:
Before begmnmg mspectrons, remove the 1ollowrng parts
1 Stde panels
2 Atr ducts
3 Cowhng (headhght)
4 Tati hght cover

INCORRECT

T o check far defects use the followmg spectal too!s

CORRECT

Pocket tester:
4

P/N. YU03112
P/N. 9089003112

Fuse

DISCONTINUITY

Remove the fuse

Connect the pocket tester (Qx1) to the fuse

Check fuse conttnULty
See the "FUSE INSPECTION ANO
REPLACEMENT" sectiOn m CHAPTER 3

l Replace the fuse

~- - - - -

CONTINUITY

INCORRECT

Battery

~--------,

Check the condttrons of the battery

See the "BATTERY INSPECTION" sectton m
CHAPTER3

Clean the battery termmals

Recharge or replace the battery
See the "BATTERY INSPECTION" sectiOn m
CHAPTER3

Voltage:
12 SV or aver at 20C (68F)

CORRECT

*
7-41

'UGHTS swttchanddtppedlhtghbeamcom
mutatar

Dtscannect the lett handlebar swttch cannec

tar and the cable fram the harness
Cannect the pocket tester {Qx1) ta lhe left
handlebar swttch termmals
Check the swttch component far cantmUJty
between "Brown (1) and Blue (2)", "Brown (1)
and Green (3)", "Brown (1) and Yellow {4)'
See the "SWITCH CHECK" sectton

The !;'am swttch ts defect1ve Replace

_____________
Lt_GH_T_;-'_vs_r_EMIELECI

iii l

l K-S

LIGHTSYSTEMIELECI

iii

LIGHT SYSTEM INSPECT\ON

,,

V L G

"'

LO

ON

G Bo/
p

..(i} (4)_ j_

' "L -

The "LIGHTS" sw1tch and/or d1ppedlh1gh beam

commutator are defect1ve Replace the left
handlebar sw1tch

::11

l Replace the bulb and/or t"'"h-e"'"b-ul::-b,-ho""'l-,de-r----,

2 Voltage

BEAM" SWitCh

DEFECTIVE CONNECTIONS

Check the connect1ons of the ent1re 1gntt1on

system

CONTINUITY

Connect the pocket tester (DC 20V) to the

front headhght connectors and the "HIGH

CORRECT

Harness connect1ons

Checkthe cont1nu1tyotthe bulb and bulbho!der

See the ".BULB INSPECTION"

'3'

-u.t...J.!l.J

DISCONTINUITY

Bulb and bulbholder

INCORRECT

The front headllght and the "H:GH BEAM" warmng llght fa1l to tum on

1
L L

OFF
PO

l Correct
CORRECT

::11

1-lead llght:

Tester termmal (+)-+

Green (1) or Yellow (2) cable
Tester terminai(-)-+ Black cable (3)

"HIGH BEAM" light:

Tester terminai(+)-+ Yellow cable (4)

Tester terminai(-)-+ Black cable (5)

Check the cond1bons of each c1rcu1t forthe ent1re

hght system
See the "ELECTRIC CIRCUIT DIAGRAM"

[A]

OUT OF SPECIFICATION

Thewcwtfrom the ma1n sw1tch tothe bulbholder

connector 1s defecttve Repa1r
[B]

[A] When the "LIGHTS" sw1tch (commutator)

IS at pos1t1on "Hl"
[B] When the "LlGHTS" sw1tch (commutator)
IS at pOSibOn "LO"

7-43

7-44

;==:=:=:=:=:=:=:=:;---=LI=GH:.:..T...:.S--:.:.:s~TE:::M~LEC\Iii l .:. :K: . .-6.=. . . .~ ----------------------------=LI=GH~T~S~Y=ST~E=M\ELEC\iiil

L-1

The parkmg hght falls to tum on

Turn the matn swttch to ON

DISCONTINUITY

Tum the "LIGHTS" swttch to ON

Bulb and bulbholder.

Tum the "LIGHTS" swttch to "LO" or "Hl"

Check the voltage (12V) on the green and

Check the conttnutty of the bulb and bulbholder

See the "BULB INSPECTION" sect1on

yellow cable at the bulbholder termmals

l The

D
CITCUit IS

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

6ffiCI90t

CONTINUITY

-----,

The bulb anci/or bulbholder are defecttve

Replace

Voltage

Connect the pocket tester (DC 20V) to the

bulbholder connector
2

The tnstrument llght fatls to turn on

T ester terminai(+) o+
Blue/Red terminai (1)
T ester terminai (-)-+ Black terminai (2)

DISCONTINUITY

Bulb and bulbholder

Check the contmUity of the bulb and
bulbholder
See the "BULB INSPECTION" secMn

D
2

l Replace the bulb ancilor bulbholder

CONTINUITY
IOC20V

Voltage

;;@!.;

~8

Connect the pocket tester (DC 20V) to the

bulbholder connector

OUT OF SPECIFIQATION

/k
l

T ester terminai(+)-} Blue cable (1)

Tum the mam swttch to ON

Turn the "LIGHTS" swttch to "PO"
Check the voltage (12V) on the Blue/Red
cabla of the bulbholder connector

Tester terminai (-)-+Biack cable (2)

R
~~k
D

OUT OF SPECIFICATIO N

~---

l The c1rcutt ts eff1c1ent

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

! Thectrcwtfromthemam swttch tothe bulbholder

connector ts detecttve Repatr

l l

Tum the mam swttch to ON

Turn the "UGHTS" SWIICh to "PO" or "ON"
Check the voltage (12V) on the blue cabla of
the bulbholder connector

D
) The ctrcwt ts effictent

~-----:--:-::~-,---,

Thectrcultfromthemam swttch to the bulbholder

connector ts defecttve Repatr

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

7-46

jeLec\liii l
4

The ta1l hght fatls to turn on

DISCONTINUITY

1. Bulb and bulbholder

Check the contmutty of the bulb and
bulbholder
See the "BULB INSPECTION" sectron

+- - - - -

The bulb an<:l/or bulbholder are defecttve

1 Re placa

CONTINUITY

2 Voltage
Connect the pocket tester (DC 20V) to the
bulbholder connector
T ester terminai(+)-+
Blue/Red terminai (1)
T ester terminai(-)-+ Black term1nal (2)

)J)

"1'.Qlj

OUT OF SPECIFICATIO N

rr==

Q
' - -~

Turn the mam swttch to ON

Turn the "LIGHTS" swttch to "ON"
Check the voltage (12V) on the Blue cable of
the bulbholder connector

l The

D
CJTCUit IS

effiCJent

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

7-47

~:..___

__

ThectrcUitfromthemam swttch to the bulbholder

connector JS defecttve Repatr

''

s_IG_N_A_LL_IN_~_~_vs_T_EMI

___________

E LE

Cl iliill l K-8

siGNALLINGsvsTEMieLeci

SIGNALLING SYSTEM

The d1agram shows the s1gnalhng system ctrCUit rns1de the electnc system of the motorcycle

CIRCUIT DIAGRAM

NOTE:
For the colour codes and complete legend, see page 72
(1)
(10)
(11)
(13)
(14)
(15)
(16)
(17)

,,

orr

@r
'

r-

''
'

RIY

o@ .,

(18)
(19)
(20)
(21)
(22)
(32)
(33)

BIY~o-~-

R/W

Jti,_l;=

'

RUN

Man sw1tch
"NEUTRAL" hght
"NEUTRAL" SWitCh
D1rect10n mdtcators nterm1ttence
"TURN" dtrect1on 1nd1cator sw1tch
"TURN" d1rectton 1nd1cator hght
Dtrectton 1nd1cator (R)
D1rectron 1ndcator (L)

'1l;f<t--l

LIW 8
S7ART

.;J

L 9<

orr
PO
ON

7-49

7-50

Horn
"HORN" SWitCh
Front brake sw1tch
Rear brake swttch
Rear taVstop llght
Battery

Fuse

iiiil

_ _ _ _ _ _ _ _ _ _ _s_IG_N_A_LL_:_G_s_vs_T_EMjELEcJ

iii j

l K-g

SIGNALLINGSYSTEMjELECjlililj

DIAGNOSTICS
o THE FLASHER LIGHTS, BRAKE LIGHT ANO/OR WARNING LIGHTS FAIL TO TURN ON.
THE HORN FAILS TO SOUND.

D1sconnect the mam sw1tch connector from

the harness
Connect the pocket tester (OX1) to the mam
sw1tch termmals
Check the sw1tch component for contlnwty
between "Red (1) and Brown (2)"
See the "SWITCH CHECK" sectton

Procedure
Check
1 Fuse
2 Battery
3
4

Ma1n SWitCh
Hamess connect10ns

(entre system of connectiOns)

RBrllfR
ON

NOTE:

OFF

Belare startmg mspecbons, remove the followmg parts

1 Stde panels
2 Seat
3 Cowhng (headltght)
4 Tali hght covar
T o check far operatmg faults use the follow1ng spectal tools

LOCK
p

DISCONTINUITY

CORRECT

Pocket tester:

UNCERTAIN CONNECTIONS

P/N. YU.03112
P/N 90891)-03112

Harness connecttons

Check the connectLons of the ent1re gnLtLon

system

Fuse

See the "ELECTRICAL CIRCUIT DIAGRAM"

DISCONTINUITY

Remove fuse
Connect the pocket tester (Qx1) t o the fuse

Check fuse conttnu1ty

See the "FUSE INSPECTION ANO REPLACEMENT" sectiOn tn CHAPTER 3

Replace fuse

~-------,

se cMn

CORRECT

Check the cond1t10ns of each sgnathng system

ClrCUlt

See the "SIGNALLING SYSTEM CONTROL"

secMn

CONTINUITY

j Correct

INCORRECT

Battery

Check the condt110ns of the battery

Consult the "BATIERY INSPECTION" sect1on tn CHAPTER 3

Clean the battery termmals

Recharge or replace battenes

Voltage:
12.8V or more at 20C (68F)

Consult the "BATIER V INSPECTION" sec-

t1on m CHAPTER 3

CORRECT

7 51

7-52

~-----..,

IK-101

SIGNALLING SYSTEMIELECiiiiiiii

SIGNALLING SYSTEM CONTROL

The horn does not work

Detach the Pmk cable from horn cable

Connect a spec1al cabla (1) tothe horn cable
and earth the cable
Turn the mam sWJtch to ON

Detach the left handlebar sw1tch connector

from the harness
Connect the pocket tester (Ox1) to the sw1tch
termmals
Check the sw1tch component far contmwty
between "P1nk (1) and Black (2)"
See the ~swiTCH CHECK" sect1on

~
(o)

DISCONTINUITY

The nHORN" IS defectve Replace the left handlebar sw1tch

CORRECT

Horn

THE HORN WORKS

-Q;
J

--=THE HORN DOES

NOTWORK

The horn s eff1c1ent

~-------,

\
\

Voltage

Connect the pocket tester (DC 20V) to the

Pmk terrrunal of the horn

Voltage

Tester termmal (+)-+ Pink cable (1)

Tester terminai(-)-+ Earth on the frame

Connect the pocket tester (DC 20V) to the

horn

1:--(\)

BeT P/

Tester terminai(+).-+
Brown termmal (1)
Tester terminai{-)~ Earth on the frame

<D

l l
DC20V

-~.; -

~T

~
(Q)

OUT OF SPECIFICATIONS

7-53

R epa1r
l The horn s defectve~-------,

-::!;:-

The c1rcutt from the ma m swttch to the horn

termmal1s defect1ve Re patr

l Repar or replace the horn

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

OUT OF SPECIFICATION

e Turn the mam SWIICh to ON

Checkthevoltage (12V) on the Red tennmal
of the horn

Turn the mam sw1tch to ON

Check the voltage (12V) an the Brown term1nal of the horn

D
*

lOC20V l
~<i;!;

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

7-54

"--/ lELEC liil l .IK-111

SIGNALLING SYSTEM
2

SIGNALLING SYSTEM

lELEcl iill

The brake llght falls to tum an

DISCONTINUITY

Check the contmwty of the bulb and

bulbholder
See the "BULB INSPECTION" sect1on

Voltage

Connect the pocket tester (DC 20V) to the

l Aeplace the bulb and/or bulbholder

CONTINUITY

bulbholder connector

Tester terminai(+)-+
GreenNellow cable (1)
T ester terminai(-)-+ Black terminai (2)

(Z~~

0Jsconnect the brake sw1tch cables and connectors from the harness

-r:rF

Connect the pocket tester {Ox1) to the brake

sw1tch term1nals
Check the SWJtch camponent far contmwty
between "Green/Yellow (1) and Brown (2)", or
"Biack (3) and Black (4)"
See the "SWITCH CHECK" sect1on

bc2oJ
~

.,

ON

(StepdownJ

~--.,.....,~

ThecJrcwtfromthemam swttch to the bulbholder

connector 1s defect1ve Aepatr

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

ClTCUlt lS etfiCient
l
l~.The
---------------B

lo fo

3 The dtrectiOn tndtcator hg ht and/orthe "TUAN"

warmng llght fa11 to flash

OFF(Free)

~~
' G/Y
'
Sr
[A] Front brake sw1tch
[B] Aear brake sw1tch

D
*

Turn the mam sw1tch to ON

The brake lever JS pulled or the brake pedal1s
pressed
Check the voltage (12V) on the GreenNellow
cable of the bulbholder connector

OUT OF SPECIFICATIO N

1--------..
INCORRECT

Check the cont1nU1ty of the bulb and

bulbholder
See the "BULB INSPECTION" sectton

l The brake swttch 1s defechve Replace

CORRECT

DISCONTINUITY

Bulb and bulbholder

D
2

l Aeplace the bulb and/or bulbholder

CONTINUITY

"TURN" md1cator SWitch

Dtsconnect the left handlebar sw1tch connector from the harness

Connect the pocket tester (.O.X1) to the left
handlebar sw1tch cables

7 56

"--' l lIii l IK-121

,-~--------------------------S_IG_N_A_LL_I_NG__sv_s_T_E_MELEC
::

Check the swJtch component far contmUJty

between nsrownM'hlte (1) and Chocolate (2)"
and BrowrvWhtte (1) and Dark Green (3)
See the "SWITCH CHECK" sect1on

SIGNALLINGSYSTEMIELECI

iii l

Voltage

Connect the pocket tester (DC 20V) to the

bulbholder connector

INCORRECT

Tester terminai(+)-+
Brown/Whlte terminai (1)
T ester terminai(-)-+ Earth on frame

l
The "TURN" md1cator sw1tch 1s defectlve
Repiace
CORRECT

''"'u

lDC20VI
~~ti-

-f

DJrectJon md1cator JntermJttence

OUT OF SPECIFICATIO N

~--=----,
ectJVe Repa1r
l The mtermJttence 1s det

Connect the pocket tester (DC 20V) to the

md1cator mtenmttence

D
*

TI 'T'Q)

Turn the mam sw1tch to ON.

Check the voltage (12V) on the Blue cablato
the bulbholder connector

T ester term1nal (+) -7

Brown terminai (1)
T ester termmal (-) -7 Earth on frame

OUT OF SPECIFICATION

-~1-

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

OC20VI

-f

The ClrCuJt from the mam sw1tch to the J!"ltermttence connector 1s defectJve Repatr

Turn the marn sw1tch to ON

Check the voltage (12V) on the Brown cabla
to the mterm1ttence termmal

D
*

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

7-57

758

SIGNALLING~TEMIELECiiii
l K~-1. :. .3;: :. . .
-------------------------------1..,;1

The "NEUTRAL" wamtng llght tali~~ turn on

Check the contmUity of the bulb and

bulbholder
See the "BULB INSPECTION" sectton

bulbholder connector
Connect the left handlebar swttch connector
to the hamess

To the left flasher llght:

Tester terminai (+)-+
Chocolate terminai {1}
Tester termmal (-)-+ Earth on frame

Dtsconnect the neutral swrtch cable from the

harness
Connectthe pocket tester (.Qx1) to the neutral
swttch termtnals
Check the swrtch component far contmu1ty
between "Sky blue (1} and earth"
See the "SWITCH CHECK" sectton

Dark green terminai (2)

Tester terminai(-)-+ Earth on frame

DC20V

OUT OF SPECIFICATIO N

OC20V

~~

The ctrcutt from the "TURN" SWIICh to the

bulbholder ts defect1ve Repa1r

~~r'

~-~

Turn the matn swtch to ON

Turn the "TURN" SW1tch to "L" or "R"

Check the voltage (tt flashes at 28V) on the

"Chocolate" or "Dark green" cabla at the
bulbholder connector

l The

D
CITCUlt IS &ff1C190t

l Replace the bulb andlor bulbholder

CONTINUITY

2 Neutral swttch

To the right flasher light:

Tester terminai(+)-+

DISCONTINUITY

Sulb and bulbholder

Voltage

Connect the pocket tester (DC 20V) to the

l l

SIGNALLING SYSTEM ELEC i i i

'\

Sb
In gear
Neutra!

rly
'Q

INCORRECT

l The neutral swttch rs defect1ve

CORRECT

3 Voltage

IN COMPLIANCE WITH
SPECIFICATIONS (12V)

Connect the pocket tester (DC 20V) to the

bulbholder connector
T ester termmal (+}-+
Brown cable (1)
T ester terminai(-)-+ Earth on frame

Br Dg B
G Ch Sb

le;
,j,

7-59

G Ch Sb
Br Dg B

l!!.f

7-60

Replace

___________s,_GN_A_LL_IN_G_:_vs_T_EMIELECii i l lK-14l _ _ _ _ _ _ _ _ _ _ IELEcliii l

OUT OF SPECIFICAJION

Tum the mam sw1tch to ON

Check the voltage (12V) on the Brown cabla
of the butbholder connector

IN COMPLIANCE WITH TheCITCUitfromthemamswJtchtothebulbholder

,---,----,---_;;::__::S::..P.:E.:C::..IF_:I.:C:..:A::_T:.:IO:.:N::..S"-(12V) connector JS defectJve Repa1r
Dsconnect the neutra! sw1tch connectorfrom
the harness and the bulbholder connector
Connectthe pocket tester (nx1) tothe neutra!
sw1tch cable (on the harness stde) and the
bulbholder connector

DISCONTINUITY

The c1rcUJt from the ma msw1tch to the bulbholder

connector ts detective Repa1r

l The

CONTINUITY

CITCUI IS effiCIBnt

7-61

''

'- - " lELEC l~ l lK-151

ELECTRICAL SYSTEM DIAGRAM

ELECTRICAL SYSTEM DIAGRAM

lELE Cl iiii l

ELECTRICAL SYSTEM DIAGRAM

COLOURS
B
Br
Ch
DG
G
L

Black
Brown
Chocolate
Dark green
Green

y
L/W

Yellow
BlueJ\IVhLte

BN
BrNVUR

Black/Yellow
Brown/Whlte
Blue/Red
GreenNe!low
Blue/Yellow

Blue
Orange
Pmk

GN

o
R
Sb

Red
Sky blue

Wh1te

BIR
BIW

Black!Red
Black!Whlte

YIR
GIR
GIW
W/L

UY
RIW

Red/VI/h1te
Yellow/Red
Green/Red

Green!Wh1te
Whlte/Biue

''

~~~
'

nuT

CDI Umt
Mam SWitCh

3 Clutch sw1tch
4 Front brake sw1tch
5 lgmtLon COLI
6 Spark plug
7 Rear brake SWLtch
8 Latera! stand sw1tch
9 AC Generator
10 RectLfLer/Regulator

11
12
13
14
15
16
17
18
19
20
7-63

Talllght/stop
R1ght rear d1rect10n md1cator

21
22

Emergency "ENGINE STOP" swLtch

"HORN" SWitch

Left rear dLrectton mdLcator

23

"TURN" dLrect1on sw1tch

Battery

24

Fuse

26
27

DLpped/high beam hght commutator

"UGHTS" switch
Horn
D1rect1on md1cator relays
Front left d1rect10n 1nd1cator
Front nght d1rect1on md1cator
1nstrumentat1on l1ght

Starter relay
Starter

Neutra! SWLtCh
Starter CLTCUit SWLtCh relay

"START" SWitCh

28
29
30
31

32
33
34

35
36
37
38

7-64

H1gh headlight warmng l!ght

"TUAN" d1rect10n md1cator warnmg hght
"NEUTRAL" warnmg hght
L1ghts on warn1ng l!ght
Front parkmg hght
H1gh/d1pped beam l!ght
D1ode

~~~~~~ ? l IK-1&1
CHAPTER

so

TROUBLESHOOTING
FAILURE TO START/DIFFICULTIES IN STARTING
FUELSYSTEM
ELECTRICAL SYSTEM
POOR ENGINE COMPRESSION

L-1
L-1
L-1
L-1

POOR PERFORMANCE AT IDLE SPEED

L-2

UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED

L-2

DIFFICULTIES IN CHANGING GEAR

GEAA CHANGE IMPOSSIBLE
THE GEAA PEDAL FAILS TO MOVE
DISENGAGING GEARS

L-2
L-2
L-2
L-2

CLUTCH SUD ES OR FAILS TO RELEASE

CLUTCH SUDES
CLUTCH FAILS TO RELEASE

L-3
L-3
L-3

DEFECTIVE BRAKES
POOR BRAKING

L-3
L-3

'

OIL LEAKS OR MALFUNCTIONING OF FRONT FORK

OILLEAKS
MALFUNCTIONING

L-3
L-3
L-3

UNSTABLE STEERING

L-4

DEFECTIVE FUNCTIONING OF LIGHTS ANO INDICATORS

POOR HEADLIGHT ILLUMINATION
FREOUENT BUANING OF BULB
THE DIRECTION INDICATORS FAI L TO TURN ON
THE DIAECTION INDICATOAS FAIL TO TURN OFF
DELAYED TUANING ON OF INDICATOAS
EXCESSIVE INDICATOA INTEAMITTENCE FREOUENCY
THE HORN FAILS TO WORK

L-4
L-4
L-4
L-4
L-4
L-5
L-5
L-5

OVERHEATING OF ENGINE

L-5

FAILURE TO s'---".T'l TRBL l

DIFFICULTIES IN STARTING SHTG

?. .l

TROUBLESHOOTING
NOTE:
The troubleshootlng tables that follow do not tdenttfy every cause oftroubte They may howeverprove helpful
as a QU1de to 1denttfymg trouble T o mspect, adjust or replace parts, referto the appropnate sectton tn the
manual.

FAILURE TO START/DIFFICULTIES IN STARTING

FUEL SYSTEM

l L-1

FAILURE TO START/1 TRBL l

DIFFICULTIES IN STARTING SHTG
ELECTRICAL SYSTEM

Fuel fllter obstructed

Fuel tank a~r cap passage obstructed

Petrol contams wateror tmpunt!es or ts adulterated

lgmtlon co1l - - - - - - - - - - - . - Pnmary or secondary w1nd1ng mterrupted

H1gh voltage cable defect1ve
Defect1ve cml

Carburettor - - - - - - - - - - - , - Petrol contatns waterortmpuntes orts adulterated

Ptlot atr )et obstructed
Pllot atr passage obstructed
lnftltratcons of atr

'"\

Deformatton of float
Needle valve wom or scratched
Needle valve msufficently sealed
Fuellevet set wrongly
Pllot JBt set wrongly

Starter Jet obstructed

Malfunct1omng of the starter p1ston

lgn1t1on unlt ---------~~ Defect1ve un1t

Defect1ve p1ck-up c01l
Woodruff tongue broken
Sw1tches and conductors

Fuel tap - - - - - - - - - - - - , - - - Hose obstructed

Fuel fllter obstructed

PROBABLE CAUSES

Spark plug - - - - - - - - - - , - - Electrodes gap not correct

Electrodes worn
Feed cable mterrupted
Wrong thermal gradmg of spark plug
Defect1ve spark plug cap

PROBABLE CAUSES

Fuel tank - - - - - - - - - - - . - Empty

? l

Starter - - - - - - - - - - - - - . . , -

POOR ENGINE COMPRESSION

Cyhnder and cyhnder head t1ghtened

Starter defect1ve
Defect1ve starter relay
C1rcUtt open1ng relay detectiVe (m relay)
Starter clutch detectiVe

.
1

PROBABLE CAUSES

A1r f1lter - - - - - - - - - - - - A1r fllter element obstructed

Mam sw1tch defect1ve

"ENGINE STOP" sw1tch defect1ve
Harness w1th cable mterrupted
Neutral sw1tch defect1ve
"START" sw1tch defect1ve
Latera! stand sw1tch defect1ve
Clutch sw1tch defect1ve

Spark plug t1ghten1ng 1nsuff1C1ently

Cyhnder head or cyhnder msuff1c1ent1y t1ghtened
Cyhnder head gasket broken
Cyhnder gasket broken
Cyhnder worn, damaged or se1zed

P1ston and p1ston nngs - - - - - - , , - P1ston

P1ston
P1ston
P1ston

Crankcase and valves, crankshaft

8-2

nngs wrongly assembled

nngs worn, y1elded or broken
nngs stuck together
se1zed or damaged

Poor crankcase seahng

Borders of dnve shaft 011 seal damaged
Poor valve seahng
Valves and housmg w1th 1nsuff1C1ent contact
Valves out of phase
Valve spnng broken
Crankshaft se1zed
Camshaft se1zed

.:.o/l SHTG
TRBL l ? l

POOR PERFORMANCE AT IDLE ...__

UNSATISFACTORY PERFORMANCE AT MEDIUMHIGH SPEED
POOR PERFORMANCE AT IDLE SPEED

PROBABLE CAUSES

Carburettor - - - - - - - - - , -

The starter ptston fatls to return freely

Ptston Jet obstructed or loose
Ptlot atr J6t obstructed
Pllot screw wrongly set
ldle speed wrongly set
(throttle valve locktng screw)
Throttte cabla free play wrongly set
Carburettor flooded

Electncal system'--------,- Defecttve battery

Defecttve spark plug
Defecttve tgmtton umt

Defectlve AC magnete
Defecttve tgnttton emi

Valves - - - - - - - - - - - - Valve free play wrongly set

UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED

l L-2

DIFFICULTIES IN CHANGING GEAR

l~~~~ l ?

DIFFICULTIES IN CHANGING GEAR

GEAR

C~ANGE

IMPOSSIBLE

PROBABLE CAUSES

Clutch - - - - - - - - - - , . - Clutch cabla wrongly set

Wrong posttton of dnvmg levar
lrregular engagement of push lever and push
rod
Pressure plate deformed
Clutch spnngs not preloaded umformly
Reference marks not allgned
Push rod broken
Clutch gear assy nut loose or thrust rod de
forme d
Pnmary dnven gear beanng defecttve
Dnven plates deformed
Dnvmg plates deformed
Clutch cabla rumed
Engme o t l - - - - - - - - - - , - Olllevel aver maxtmum
(High VISCOSity)
Degradatton

See "FAILURE TO START/DIFFICULTIES IN STARTING" (FUEL SYSTEM, ELECTRICAL

SYSTEM, COMPAESSION SYSTEM and Valve ctearance)

THE GEAR PEDAL FAILS TO MOVE

PROBABLE CAUSES

Gear shaft - - - - - - - - - - - Gear shaft deformed

PROBABLE CAUSES
Carburettor ---',',-.-----,---- Petrol contatns waterortmpunes or1sadulterated
'
lnfiltrattons of a1r
Deformatton of float
OefectJVe dtaphragm

Needle valve wom or scratched

Needle valve housmg msufftctently sealed
Needle lock posttton tncorrect
Fuel leve! set wrongly
Mam Jet obstructed or loose
'----- Matn nozzle obstructed or loose

Atr fllter - - - - - - - - - - - - Atr ftlter element obstructed

Gear cam, gear fork - - - - - - - , - - Groove w1th 1mpunttes or foretgn

Gear fork stuck
Gearchange fork gwde bar deformed

Transmtsston - - - - - - - - - , - - Transmtsston gears struck

Gears stuck by 1mpunt1es or foretgn bodtes
Wrong transm1sston assembly

DISENGAGING GEARS

PROBABLE CAUSES

Gear shaft - - - - - - - - - , - Gear ever set wrongly

Drum stop levar fatls to return freely

Gear fork - - - - - - - - - - - Gear forks worn

Gear cam - - - - - - - - - - - - , - Shaft cam w1th thrust free play
Gear cam groove wom

Transm1sston - - - - - - - - - - Gear clutches wom

8-4

8-3

'-../

CLUTCH SLIDES OR FAILS TO RELEASE

CLUTCH SLIDES OR FAILS TO RELEASE

ITRBL
SHTG

CLUTCH SLIDES
PROBABLE CAUSES
Clutch - - - - - - - - - - - T - Clutch cabla wrongly set
Clutch spnngs loose
Clutch spnng y1elded
Fnctlon plates worn
Clutch plates worn
Clutch 1mproperly assembled

l ? l l L-3

DEFECTIVE BRAKES/1
'--!L LEAKS OR MALFUNCTIONING OF FRONT FORK

TRBL
SHT~

l ?l

DEFECTIVE BRAKES
PROBABLE CAUSES

POOR BBAKING

L-------------~- Brake pads wom

Eng1ne 011 - - - - - - - - - - . - - 01llevel below m1mmum

lncorrect gradaMn (low v1scostty)
Degradat1on

Brake diSC worn

Water 10 the brake fiUid
Brake flu1d leak
Brake flwd tank defect1ve
Bleed cap not sealed to cahpers
Fastemng bolt loose
Brake hose cracked
Brake d1sc dtrty or greasy
Brake pads duty or greasy
In corree! brake flwd leve!

OIL LEAKS OR MALFUNCTIONING OF FRONT FORK

CLUTCH FAILS TO RELEASE

See "GEAR CHANGE IMPOSSIBLE"

PROBABLE CAUSES

OILLEAKS

L-------------~- lnner tube deformed, damaged or rusty

''

PROBABLE CAUSES
lnner tube deformed, damaged or rusty
Outer tube deformed or damaged
Fork spnng damaged
P1ston worn or damaged
Shock-absorber rod deformed or damaged
lncorrect oli v1scos1ty
lncorrect o1llevel

MALFUNCTIONING

L-------------,--

8-5

Outer tube damaged or cracked

OLI seal hp damaged
011 seal assembled 1ncorrect1y
Oillevelmcorrect (excess1ve)
Shock-absorber rod stop bolt loose
0-nng an cap broken
Ora1n bolt loose
Dra1n bolt gasket damaged

8-6

\. . .- ITRBL
l ?. l_ l L-4
SHTG

UNSTABLE STEERING
UNSTABLE STEERING

,~/

OEFECTIVE FUNCTIONING OF LIGHTS ANO INOICATORS

ITRBLI
?
SHTG

OEFECTIVE FUNCTIONING OF LIGHTS ANO INOICATORS

PROBABLE CAUSES

H a n d l e b a r - - - - - - - - - - - Assembled crooked or 1ncorrectly

Steenng - - - - - - - - - - . . . , - Handlebar crown assembled mcorrectly
Lower bracket crooked

Lower steermg column mstalled mcorrectly

(threaded nng nuts not t1ghtened correctly)
Beanng or beanng tracks damaged

POOR HEADLIGHT ILLUMINATION

PROBABLE CAUSES

' - - - - - - - - - - - - - - - , - - lncorrect bulb

Excess1ve absorptiOn af electncal accessones
D1fflculttes m chargmg (chargmg co11 broken andl
or rect1fer/regulator defect1ve)
Uncertam connectmns
Wrong negabve earthmg
lnsuff1C1ent contacts (mam sw1tch or hght
SWitCh)
Bulb gane

Front fork - - - - - - - - - - ; ; - Oillevel not the same m both tubes

Spnng broken
Front fork crooked

Tyres - - - - - - - - - - - , - Tyre pressure mcorrect far type of road

Tyre pressure mcorrect

Tyres worn non-un1formly
Wheels

FREQUENT BURNING OF BULB

PROBABLE CAUSES

'---------------,--

lncorrect bulb
Defect1ve battery
Rect1t1er/regulator defecttve
Wrong negat1ve earthmg
Mam SWitCh anci/or "LIGHT$" SWitCh detectiVe
Bulbs gane

-----------r- Wheels balanced mcorrectly

Wheel deformed
Beanng loose
Wheel axle deformed or loose

Wheels excess1vely off-centre

'

'

F r a m e - - - - - - - - - - - . - - De1ormed
Head tube damaged

Ball track mstalled mcorrectly

Rear fork - - - - - - - - - - , - Bushes or beanngs consumed
Deformed or damaged

Rear shock absorber - - - - - - . - Spnng y1elded

Spnng prelaaded
Ollleak
Transm1ss1an cham

DIRECTION INDICATORS FAIL TO TURN ON

PROBABLE CAUSES

'---------------,--

DIRECTION INDICATORS FAIL TO TURN OFF

PROBABLE CAUSES

' - - - - - - - - - - - - - - - , - - lnd1cator relay defectNe

lnsuff1c1ent battery capac1ty
(battery almost tlat)
Bulb (front or rear) burnt aut
"TURN" SWitCh detective

Cham set mcarrectly

8-7

Wrong negat1ve earth1ng

Battery tlat
Detective "TURN" SWitch
lnd1catar relay detective
Harness cut off
Caupler connecttan loose
Bulb burnt aut

8-8

DEFECTIVE FUNCTIONING OF LIGHTS ANO INDI>dORS/1 TRBL

OVERHEATING OF ENGINE. SHTG
DELAYEDTURNING ON OF INDICATORS

l ?. l l L-5
.

PROBABLE CAUSES

L - - - - - - - - - - - - - , - - lndJcatof relay detctwe

lnsufftctent battery capactty
(battery almost flat)

lncorrect bulb
Mam or "TURN" tndtcator swJtch defectve

PROBABLE CAUSES

EXCESSIVE INDICATOR
INTERMITTENCE FREQUENCY

L - - - - - - - - - - - - - , - - lncorrect bulb
lndEcator relay defect1ve
PROBABLE CAUSES
THE HORN FAILS TO WORK
L - - - - - - - - - - - - - . . , - Detective battery
Mam or "HORN" mdscator swttch detect1ve
Horn wrongly set
Detective horn
Hamess cut off

OVERHEATING OF ENGINE

PROBABLE CAUSES

JgnJtson system - - - - - - - - , - - lncorrect electrode gap of spark plug

Spark plug thermal gradatiOn wrong
IQnltlon umt defectJVe
Fuel teed system - - - - - - - - . - Jncorrect carburettor mam Jet (mcorrect settmg)
lncorrect fuellevel
Atr fllter element obstructed

Eng1ne compresston - - - - - - - Excess of carbon depos1ts

Engme 011 - - - - - - - - - - , - lncorrect otllevel
lncorrect o11 vscos1ty
lncorrect 011 gradat1on
Brake - - - - - - - - - - - - Pads fa1l to return freely (rema1ns blocked)

89

'"