YAMAHA

TT&OO E ~~~

REPAIR MANUAL

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

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

A WARNING

CAuiiN:~

NOTE:

Th1s safety alert symbol means ATIENTIONI BE CAREFUL' YOUR SAFETY IS AT RISKI

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

HOW TO USE THIS MANUAL LAYOUT Thts manual conststs of chapters on the pnnctpal cycle components (see "Symbol Legend~)

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

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

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

FORMA T Ali the procedures suggested m thts manual are arranged m a sequenttal, step by step arder The mformatiOn ts wrrtten t n such a way as t o provtde the mechamc Wtth a handy, easy t o 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 ""

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 (9)

EXPLODED DIAGRAMS In some chapters the dJsassembly sectron rs preceded by exploded d1agrams These are desrgned to a1d zdentlflcatJon o t components for pro per assembly, as w eli as the assembly procedures themselves

A-3

G) Gl

1~~~~1~1 lsPeciPfl Gl @

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

ICARBif l lcHAsiAI 0 @

l ELEC liiii l ~~~~~~ ?l Gl

~ @

~

~ @

~ @

~ @

[0] @

11] @ @ @

~ ~ l a @

~ ~ ~

SIMBOL LEGEND

(Referto lllustrations)

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

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)

CONTENTS,

GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

PERIODIC INSPECTION ANO ADJUSTMENT

ENGINE OVERHAUL

CARBURETTOR

CHASSIS

ELECTRICALS

TROUBLESHOOTING

SPEC

INSP ADJ

l A-41

CHAPTER 1 GENERAL INFORMATION

IDENTIFICATION CF MOTORCYCLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER

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

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

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

A-6 A-6 A-6

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

A-7 A-7 A-8 A-9

A-10

__________ ,,~~~~~'

Motorcyc!e 1dentlf!cat10n number

2 Eng1ne senal number

IDENTIFICATION OF MOTOR~CLE ~~~~~ ~~~

1-1

IDENTIFICATION OF MOTORCYCLE

IDENTIFICATION NUMBER

The tdentlflcatiOn number 1s stamped o n the nght of the steermg head p1pe

Progress1ve sena! number TT600 E EUROPE BL-4LW-025101 SPAIN ZD04LW300S0095101

ENGINE SERIAL NUMBER

The engme senal number 1S stamped o n the nght of the engme

Progress1ve engme senal number TT 600 E 4GV-010101

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 WLth-out pnor warmng

A-6 IMPORTANT INFORMATION ~~~~~ ~~~

IMPORTANT INFORMATION

1-2

PREPARATION FOR DISASSEMBLY ANO REASSEMBLY

Remove ali d1rt, mud, dust an d fore1gn obJects pnor to d1sassembly

2 Use propermatenal an d tools Referto sectiOn 'SPECIAL TOOLS'

3 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

4 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

5 Keep away from f1re and sources of heat

IMPORTANT INFORM:ION ~~~~~ ~~~

1 '

SPARE PARTS

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 func-tton and appearance mtght be tnfenor m quahty

GASKETS, OIL SEALS ANO OAINGS

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

2 Properly oli ali matmg parts and beanngs dunng reassembly Apply grease to otl seal hps

LOCK WASHERS, PLATES ANO COTTER PINS

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 tJght-ened

BEARINGS ANO OIL SEALS

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 o ti seals, apply a hghtcoatmg of hghtwetght llthtum~based grease to the seal hps 011 the beanngs hberally when mstalhng

{1) 011 seals

cAuTio~:j ____________________ __ Do not use compressed airto dry the bearings. Thls damages their outer surface.

(1) Beanng

A-7

1 4

SPECIALTOOLSII~~~ \~\ CIRCLIPS

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

(4) Shalt

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

lnducttve stroboscopcc lamp P/N YM-33277-A P/N 90890031 09

ThES tool serves to tune up ttmmg

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

Thts toolts used to measure the level of the fuei m the float chamber

3 lnduct1ve engtne speed md1cator P/N YU-08036-A P/N 9089003113

Thts tool serves to measure engme speed

1-5

SPECIAL ~LS~I~~~ ~~~ 4 Pressure gauge

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

5 Valve adJustment tool P/N YM-08035 P/N 90890-01311

These tools serve to adjust valve free play

FOR OISASSEMBLY OF THE ENGINE

AIIMpurpose clutch holder PIN YM-91042 P/N 9089004086

Th1s tool1s used to lock the clutch, when the clutch boss lock nut 1s be1ng loosened or ttghtened

2 Crankcase separatmg tool P/N. YU-01135-A P/N 90890-01135

Thts tool1s necessary to disassembla the crank-case

3 Valve spnng compressJon clamp P/N YM-04019 P/N 9089004019

Th1s tool1s necessary to remove and 1nstall val ves

A-8 SPECIALTOOLSII~~~ 1~1 ;::===============:;----.;4~7;:m:m~(~0~2~8~:n)~v:a:lv:e:gulde puller

~ ~ o l~lllllll H;ttlO~ Lw~

1 6

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

Th1s tool ls used to remava valve gu1des

5 7 mm (O 28m) valve QUide reamer P/N YM01227 P/N 9089001227

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

6 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

7 Valve hous1ng cutter P/N YM-91043

Th1s tool1s used to gnnd the valve housmg

8 P1ston p1n chp puller P/N YU-01304 P/N 90890-01304

Th1s tool serves far removmg the p1ston pm chp

1-7

1 O Dnvmg shatt mstallabon un t t P/N YU-90050- (1) Dnvmg shaft mstallatiOn hose P/N 90890-01274- (2) Dnvtng shaft mstallatton boli P/N 90890-01275- (3)

11 #10 (M14) adapter P/N YM-90069 P/N 90890-04059

Thts toolts used to tnstall the dnvmg shaft

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

Thts toolts used to prevent the rotar frorn rotatmg dunng remava! or tnstallatton of the secunng boli

1-8

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

15 Sealant (Outck Gasket) P/N ACC-11001-01 Yamaha Band No 1215 P/N 90890-85505

Thts sealant (adhestve) ts used for crankcase mat-tng surfaces etc

FOR DISASSEMBLY OF THE CHASSIS

1 Fork seal gwde P/N YM-38853 P/N 90890-01442

Thts tool serves to mstall the fork otl seal

2 Damper rod holder P/N 90890-0!463

Thts toolts used to dtsassemble or reassemble the fork damper rod

3 Rod holder P/N YM-01434 P/N 90890-01434

Th1s tool 1s used to hold the fork spnng

1 9

SPECIAr'ooLsll~~~ ~~~ l A-1 Q l 4 Fork rod puller and adapter

P/N YM-01437 P/N 90890-01437 Rod puller adapter P/N 90890-01436

These tools are used t o d1sassemble the fork damper 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

6 Rmg nut wrench P/N YM-38520 P/N 90890-01443

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

the prescnbed torque

7 Lock nut wrench P/N YM-38519 P/N 90890-01348

Th1s wrench 1s used to remove an d n sta Il the steer-mg umt nut

1 10

SPECIAL TOOLSII~~~ 1~1 FOR ELECTRICAL SYSTEM

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

Th1s tester 1s necessary for checkmg IQntiiOn sys-tem components

2 Pocket tester P/N YU-03112 P/N 90890-03112

Th1s tester serves to check electnc crcu1ts

3 DynamJC spark tester P/N YM-34487 P/N 90890 03144

Ths tool serves to check the plug spark v1sually

CHAPTER2 TECHNICAL SPECIFICATIONS

GENERAL SPECJFJCATJONS

MAINTENANCE SPECJFICATJONS ENGJNE ELECTRICALS CHASSIS

TIGHTENJNG TOROUES GENERAL TORQUE SPECJFICATIONS

DEFINITJON OF MEASUREMENT UNJTS

LUBRICATJON POINTS ANO TYPE OF LUBRICANT ENGJNE CHASSIS

LUBRICATJON LAYOUT

CABLE ROUTING

A12

A-14 A-14

B-1 B-2

B-3 B-5

B-5

B-6 B-6 B-6

B-7

B-9

'-' 1 1m~ l l A-12l GENERAL SPECIFICATIONSSPEC f l GENERAL sPECIFlcATioNs jsPecj Pf l TECHNICAL SPECIFICATIONS Mode l TT600 (E)('94)

GENERAL SPECIFICATIONS Transmtss1on

Mode l TT600 (E)('94) Type Constant mesh 5speed Pnmary reduct1on system Stra1ght -tooth gears

Model code number 4LW3 Pnmary reductiOn rat1o 71/34 (2 088) lmttal eng1ne stamp number EUROPE Bl-4LW-025101 Secondary reductiOn system Cham dnve

SPAIN ZD04LW300S00951 01 Secondary reductiOn rat10 47/15 (3 133) lnLtLal frame stamp number 4GV-010101 Opera M n Left foot operatlan

DLmensLons Gear rallo

Overall length 2,240mm Overall wtdth 840mm

1" 31112 (2 583) 2~ 27117 (1 588)

Overall he1ght 1,200mm Seat hesght 890mm Wheel base 1 480 mm

3" 24/20 (1 200) 4" 21/22 (O 954) 5" 19/24 (O 792)

Mm1mum ground clearance 270mm Frame

Bas1c we1ght 147 kg

M1mmum tum1ng rad1us 220m

Frame type Open-cradle backbone frame Casier angle 28' Tra1l 121 mm

Eng1ne Tyres Eng1ne type A1r cooled 4-stroke

4 valve, SOHC Type Wlthtube SiZ6

Mode l 4GV2 Cylmder tayout Smgle cyhnder, 1nchned forward

Front 90/90 21 (54R) PIRELLI MT70 Rear 130/80 18 (66R) PIRELLI MT70

Capac1ty 595cc Bore x stroke 95x84mm Tyre mflat1on pressure (cold tyres) bar- kg/cm

2 (ps1) Front Rear

CompresSLon ral10 8 51 Startmg system Electnc start

Lubncat1on

R1deronly 2 (28) 22 (32)

W1th passenger 21 (30) 24 (35)

Type Dry SL.Imp WLth separate otltank Off-road 1 5 (22) 1 6 (23)

Recommended eng1ne 011 SHELL SU PER 4TX 20W/50 Brakes Capac1ty

Penod1c 011 change 2 2 htres Front brake type Smgle d1a 267 mm d1sk brake OperaiiOn Rtght hand operat1on

W1th 011 f1lter replacement 2311tres Rear brake type S1ngle d1a 220 mm d1sk brake 011 tank 1 8 htres OperatiOn R1ght foot operallon Total capac1ty 2 8 htres Front suspens1on Adjustable, ups1de down

AITfJlter telescop1c fork, Type 01led fllter element d1a 43 mm

Fu el Type Premtum Grade Fuel

Tank capac1ty

Rear suspens1on Deltabox alum1mum sw1ngarm w1th adJustable gaslo1! mano shock absorber

Total 12 htres Wheel travel Reserve 2 htres Front 270mm

Rear 209mm Carburettor

Type Y26PV2M Manufacturer TEIKEI

Spark plug Type/Manufacturer DPR8EA9 or DPR9EA9/NGK Electrode gap 08-09mm

Clutch Type Wet, multi d1sc

2-1 2-2

GENERALSPECIFICATIONS SPEC p-; IA-131 Mode l TT600 (E)('94)

Electnc system lgmbon system T C l (Dtgttal) Battery type CTX9 85 Battery capac1ty 12V BAh Fuse 20A Generator AC 12V Headhght Wtth quartz (halogen) lamp

Bulb spectflcat1ons Headhght 12V-55/60W TatVBrake hght 12V21/5W Turn hghts 12V-10W Front parkmg hght 12V-5W "N' (neutra!) lamp 12V-1 2W "Htgh Beam~ lamp 12V1 2W "Parkmg hghts" lamp 12V-1 2W "Tum hghts" lamp 12V1 2W

2-3

"-' l jtnOj IA-141 MAINTENANCE SPECIFICATIONS SPEC t l MAINTENANCE SPECIFICATIONS jsPECj fJ f l

MAINTENANCE SPECIFICATIONS Mode l TI 600 (E) ('94) Valves, valve housmg valve gwde

ENGINE Valve backlash (cold) SuctlOn 005-010mm

Mode l TI 600 (E) ( 94)

Cyhnderhead Exhaust O 12-017 mm

< Deformatton llmst > * The hnes show where you have to s1te the Valve SIZ8S

a* measunng shde rule Suct1on "A" head d1ameter 369-371 mm 'B~ face Wldth 226mm ~c" housmg w1dth 10-12mm

Cyhnder "D' edge th1ckness 1 0-14mm

Bore

m 9497-9502mm < Wear llm1t > Measurement pomt (a) (a)= 50 mm Exhaust "A" head d1ameter 319-321 mm "B' tace w1dth 226mm ''C" housmg w1dth 10-12mm Cam shaft "D" edge th1ckness 08-12mm

Advance method Cham advance (left)

Cam shaft outer d1ameter 22 967 - 22 980 mm

Backlash between cam shaft and cap 0020-0054mm

Suct1on cam s1ze Suctson "A" 3647-3657mm ~ b~a ~C" ~"D"

'8' 15 \ 3006-30 16mm

c {/ 641 mm Exhaust "A"

A 3662-3672mm

Rod outer d1ameter Suct1on 6 975-6 990 mm

'8" '\.. / 3011-3021 mm "C" B 651 mm

Exhaust 6955-6970mm

GUide 1nner d1ameter Suctlon 7000-7012mm

< Cam shaft eccentnc1ty hmtt > Exhaust 7000-7012mm

T1mmgcham T1mmg cham type 75-010 Backlash between rod and gwde Lmk number 126 hnks Suct1on 0010-0037mm T1mmg chatn adjustment method Automat1c

Exhaust O 030- O 057 mm Rocker/rocker shaft

Rocker outer d1ameter 12 000-12 018 mm < Rod eccentnc1ty hm1t > Valve housmg standard w1dth

Rocker shaft mner d1ameter 11976-11991 mm Suct1on 1 1 mm

Rockershaft backlash 0009-0042mm Exhaust 11 mm

26

'-" j jtno-jiA-151 MAINTENANCE SPECIFICATIONS SPEC f l MAINTENANCE SPECIFICATIONS jsPECj p~ l

Mode l TI 600 (E) ('94) Mode l TI 600 (E) ('94)

Valve spnngs lnner spnng Outer spnng End clearance (wllh mounted nng)

Free length Upper nng 030-045mm

Suctton 401 mm 438mm Exhaust 401 mm 438mm

Lower nng 030-045mm

Posttlon stze {wtth closed valve) Scaper nng 020-070mm Suctton 227mm 342mm Exhaust 227mm 342mm S1de backlash (w1th mounted nng)

W1nd1ng sense (top vtew) Clockwtse Counterclockwse Upper nng 004-00Bmm

o o < Slope llm1t >

Suctton

Exhaust < 2 5/1 9 mm >

P 1st an

Lower nng 003-007mm

Scapernng 002-006mm

Mam shaft .f. uA' shaft w1dth

+ 74 95-75 00 mm

< 2 6 mm >

Clutch d1scs Th1ckness 2 94-3 06 mm Ouant1ty 2 parts

P1ston allowance 20mm < Wear hm1t >

Ptston p1n off centnng Suctton Stde Clutch d1scs

P1ston-cyhnder backlash 0045-0065mm Thtckness 12 mm

< Llmtt > Quanttty 7 parts

< Wearhmlt> Rmgs

Type Upper nng Trapezo1dal Lower nng Rectangular

Clutch spnngs Free length 428mm Quanttty 5 parts Wearhmtt 408mm

S1zes (B x T) Upper nng cyB B = 1 2 mm T=38mm

1-r . Lower nng CJ]s B = 1 2 mm

1-r_..j T=38mm

Clutch plate Thrust backlash 0070-0071 mm

Clutch release method lnner cam push1ng

Gear box < Pnncspal ax1s off-centnng llm1t >

Scraper nng ~] 8= 25mm \..-r-1

T= 34mm

< lntermed1ate shatt off-centnng hm1t >

Selector

Type Drum w1th cam and gUide bar

2-7 28

MAINTENANcE sPECIFI~;,.;oNslsPEcj)Of l l A-16l Mode l TT600 (E)('94)

LubncatiOn system Otlfllter Type Paper type

Otl pump Type Trochotdal type End backlash O 12mm Stde backlash 003-00Smm

Shunt valve callbratton pressure 80-120 kPa (08-1 2 kg/cm2 , 11 -17 pst)

Safety valve callbratton pressure BO- 120 kPa (08-12kg/cm2, 11-17pst)

Otl pressure 13 kPa (O 13 kg/cm2 1 8 pst) at 1,300 rpm Pressure check potnt Ot! fllter chamber Carburettor

ldenttftcatiOn 1mttals 4GVOO MatnJet (MJ)

Pnmary carburettor #145 Secondary carburettor #110

Mam BIT jet (MAJ) Pnmary carburettor 01 o Secondary carburettor 009

Jet needle (J N) Pnmary carburettor 5098-3/5 Secondary carburettor 5Y16-3/5

Nozzle Jet (N J) Pnmary carburettor V-00 Secondary carburettor 00

Cutaway (CA) 55 Ptlot atr J91 (PAJ) 006 PIIOtjet (P J) #48 Ptlot output (PC) 08 Bypass 1 (BP 1) 1 o Pllot screw (PS) Approx 2 5 turns open Valve seat (VS) 025 Starter Jet (GS) #76 Fuellevel (F L) 60-SOmm Float he1ght (FH) 250-270mm Engme 1dle speed 1 200- 1 400 rpm

MAINTENANCE SPECIFI~ONS /sPEC/ j5fj l ELECTRICALS

M od el TT600 (E)('94)

Vollage 12V

lgnstJon system

Msnsmum spark advance (P M S l )

Break t1mmg

10-14 al 1,350 rpm

6,900-7,100rpm

Electnc type Spark advance devtce

23 7 - 2a 7 at 0,000 rpm

40 Break --

MAINTENANCE SPECIFIC:;;ONS lsPECI f>f l l B-21 MAINTENANCE SPECIFICATIONS lsPECI 95f l CHASSIS Mode! TI600 (E)('94)

Mode l TI600 (E)('94)

Steenng Beanng type Taper rolhng bearmg

Rear wheel Type Spoke wheel Wheel SIZe 2 50x18 Wheel matenal Alum1n1um

Front suspens10n Fork travel 270mm Vert1cal Fork spnng free length 460mm Latera l Spnng constant {K) K=40N/mm

(O 4 kg/mm) Optronal spnng None Ori amount 510 eu cm Orllevel 90mm

Dnve cham Type/Manufacturer 135 ORS-A REGINA CHAIN Number of hnks 110 Cham slack 30-40 mm

80-130mm From upper edge of rnner tube (fully compressed wrthout sprmg)

Ori type ~01" suspensron or! Tube external drameter 43mm

Front diSC brake Type Smgle External d1sc dtameter 267mm Dtsc th1ckness 4mm Pad th1ckness 75 mm Internai master cyhnder d1ameter 12mm

Rear suspensron Shock absorber travel 61 mm Free spnng length 240mm

Internai cahper cyhnder d1ameter 28mm Quanbty 2 p1eces

Brake fJUid type DOT #4 or DOT # 3

Adjustment length 222mm Spnng constant (K) 73 N/mm (7 3 kg/mm) Travel (K) Zero- 95 mm

Front brake lever Brake lever backlash (travel) 10-15mm

at the lever end Optional spnng None Gas pressure 12 kg/sq cm (170 psr) Rear d1sc brake

Aear arm Type S1ngle External d1sc d1ameter 220mm

al the rear arm end Move rear arm from srde to srde

Srde clearance 04-0?mm at the rear arm prvot

D1sk th1ckness Smm Pad th1ckness 60mm Internai master cyhnder d1ameter 127mm Internai cahper cyhnder d1ameter 3023 mm Brake fiUid type DOT#4orDOT#3

Front wheel Type Spoke wheel Wheel s1ze 1 85x21

Brake pedallever Brake tever free play (travel) 12-15mm

at the tever end Wheel matenal Alum1mum

Brake pedal poS1110n 15mm betow the footrest

Vertlcal p tane Latera!

Clutch lever and throttte gnp Clutch lever free ptay 20-30mm Throttte cable free ptay 30-50mm

at the gnp flange

2-14

MAINTENANCE SPECIFI~ONS ISPECI 95~ l B-3 MAINTENANCE SPECIFICATIONsiSPECI 95~ l TIGHTENING TORQUES

Mode l TI600 (E)('94)

Mode l TI600 (E)('94) T1ghtenmg toque

Part to be t1ghtened Thread Tightening torque

Note SiZS N m mk9

Part lo be t1ghtened Thread T1ghten1ng torque Note SIZ8 N m mk9

Oilprpe Hexagon socket head screw M6 x 1 o 10 1 o

Otl deltvery ptpe Head Jotnt bolts MB x 1 25 1B 1 B

Boli w1th flange M8X125 29 29 Carburettor umon Stud boli M10x 125 20 20 Salt M6 X10 10 1 o Hexagon socket head screw M6 x 1 O 10 1 o Stud bolt M6 x 1 O 7 07

Clamp (carburettor umon) Sere w M4 x07 2 02

Spark plug M12X125 1B 1 B Atr cleaner case Cyhnder head covar

Hexagon socket head screw M6 x 1 o 10 1 o Bolt w1th flange M6 x 1 o 10 1 o Exhaust pipe

Tappet covar (1ntake) Bolt with flange M6 x10 10 1 o Hexagon socket head screw M6 x 1 O 10 1 o

Tappe! cover (exhaust) M32 X 1 5 12 1 2 Exhaust ptpe guard a Cross-slotted screw M6 X10 7 07

Cyhnder Cap nut M8x125 22 22

S1lencer protecMn a Cross-slotted screw M6 x 1 o 7 07 Nut M10x 125 42 42 Clamp {exhaust ptpe and Sllencer) Hexagon nut M10X125 42 42 Bolt w1th flange MB x 1 25 20 20 Hexagon socket head screw M6 x 1 O 10 1 o Slencer

Balancmg sprocket Hexagon nut M16 x 1 O 60 60

Bolt w1th flange MB x 1 25 40 40 a Hexagon socket head screw MB x 1 25 40 40 Rotar {A C magnet) Crankcase

Hexagon nut M14 x 1 5 120 12 o Lock nut (valve clearance adJuster)

Hexagon socket head screw M6 x 1 O 10 1 o Stud bolt M10x 125 20 20

Hexagon nut M6 x 1 o 14 14 T1mmg sprocket

Crankcase cover {nght) Hexagon socket head screw M6 x 1 o 10 1 o

Bolt w1th flange M7 x 1 o 20 20 Crankcase cover (left) T1m1ng cham tens1oner

Hexagon socket head screw M6 x 1 O 10 1 o Bolt w1th flange M16 x 1 O 20 20

Hexagon socket head screw M6 X10 10 1 o T ab washer (beanng) a Flat headscrew M6 x10 7 07

Rock1ng levar shaft Pressure plate Hexagon socket head screw M6 X10 10 1 o

Oil pump Bolt w1th flange M6 x 1 o 8 OB

Clutch hub Hexagon socket head screw M6 X10 10 1 o Hexagon nut M20 x 1 O 90 90

Oil dellvery/return pipe Pan screw M6 X10 7 07

Pnmary dnve gear Hexagon nut M20x 1 O 120 12 o

Oischarge hole (crankcase) M14 x 1 5 30 30 Orl fllter covar

Hexagon socket head screw M6 X10 10 1 o Bleed screw M5 XOB 5 05

2 15 2-16

Mode l

Part to be t1ghtened

Pushlever Pan screw

D1sengagement contro! rod Hexagon nut

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 e ad

MAINTENANCE SPECIFI:riONsiSPECI p~ l l B-4 l TT600 (E)('94)

Thread T1ghten1ng torque Note SIZS N m mkg

MB x 1 o 12 1 2

M6 x10 B 08

M18 x 1 O 110 11 o

M6 x10 10 1 o M6 x 1 o 10 1 o

M6 x10 10 1 o M6 x 1 o 7 07 a M6 x 1 O 7 07 a M10 x 1 25 20 20

M6x 1 o 10 1 o

MAINTENANCE SPECIFICATIONSISPECI p~ l Mode l TT600 (E)('94)

Part to be t1ghtened Thread T1ghtenmg torque Note SIZ9 N m mkg Front fork/Handlebar Upper plate and fork shder MB x125 23 23 Upper plate and lower handlebar fastemng M10x125 40 40 Lower plate and fork shder MB x 1 25 23 23 Upper handlebar fastenmg MB x 1 25 20 20 Upper steenng nng nut and upper plate M36x10 115 11 5 see

"NOTE" Upper steenng nng nut and steenng column M28x15 se e

~NOTE"

Lower steenng nng nut and steenng column M2Bx15 Upper fork shder nut (cap) M46x 1 O 30 30 Lower fork shder nut (cap) M22x 1 O 55 55 Upper fork pumpmg element nut M10 x 1 O 15 1 5 Shder and tube guard screw MB x 1 O 7 07 Brake hose and fork guard screws M6 x 1 o 7 07 Front brake pump and bracket for fastenmg

to handlebar M6 x 1 o 9 09 Front brake pump 011 tank cover M4 x07 2 02 Front brake pump and hose M10 x 1 O 23 23 Front brake cahper and hose M10 x 1 O 23 23 Front and rear brake pump 011 bleeder screw M10 x 1 O 6 06 Hexagon socket head screw far fastemng

front and rear pads M10x 125 18 1 8 Front brake cahper and fork support braket MB x125 23 23 Front brake cahper and support braket M6 x 1 o 9 09 Front wheet axle nut M14 x 1 5 59 59 U boli far fastemng wheel axle and fork Ma x125 15 1 5 a FrontiRear brake d1sc and hub M6 x10 12 1 2 Rear brake pedal/frame/footrest M10x 125 45 45 Rear brake pump and frame M6 x 1 O 10 1 o Rear brake 011 tank and frame M6 x 1 O 4 04 Rear brake cahper and bracket MB x125 23 23 Rear brake cahper and hose M10 x 1 25 26 26 Rear brake pump and hose M10 x 1 O 23 23 Brake cahper guard and rear arm M6 x 1 o 12 1 2 Sprocket wheel/flange and hub M10x 125 30 30 Rear wheel axle nut M18 x 1 5 115 11 5

Shock absorber/Rear arm Rear arm p1Votlrear arm and frame M16 x 1 5 85 85 Rear arm and shock arm M12 x 1 25 58 58 Shock arm and shock hnk M10x 125 32 32 Shock lmkand frame M10x 125 58 58 Shock arm and shock absorber M10 x 1 25 32 32 Shock absorber and frame M10 x 1 25 32 32 Cham shder and rear arm M6 x 1 O 5 05 Cha1n gwde and rear arm M6 x 1 o 9 09 Cham gusde jomt M6 x10 3 03 Cham covar and rear arm M6 x10 9 09

Headhght support and headhght M6 x 1 o 7 07

2 18

MAINTENANCE SPECIFI~IONSISPEC) j)f l B-5 Mode l TT600 (E)('94)

Part to be tsghtened Tllread Tsghtensng torque Note ssze N m mkg

Engsne assembly (Front) engsne mount and frame M10 x 1 25 64 64 (Front) engme mount and eng1ne M10x 125 64 64 (Upper) engsne mount and frame M10x 125 64 64 (Upper) engme mount and engsne M10x 125 64 64 (Rear) engsne and frame M10X125 64 64 Engsne guard on frame M6 x 1 O 10 1 o Rsder s footrest and frame M10 x 1 25 45 45 Passenger s tootrest and frame M8x125 20 20

Tank/Saddle/Cover/Mudguard Rear mudguard and frame M6 X10 7 07 Frame and number plate holder M6 x 1 o 5 05 Tank and asr ducts M6 X10 5 05 Front mudguard and headhght holder M6 X10 2 02

Seat and trame M6 X10 4 04 Battery holder frame and trame MB x 1 25 20 20 Fuel tank and fuel tap M6 X10 7 07 Fuel tank and frame M6 x 1 o 7 07 Helmet holder and frame M6 x10 7 07 Clutch cable and crankcase cover M6 X10 10 1 o Number plate holder and taslhght M6 x 1 o 7 07 Start sw1tch and w1res M6 x 1 o 3 03 Regulator and frame M6 x10 7 07

lnstruments/Horn lnstruments and handlebar crown M6 X10 7 07 Horn and frame MS x 1 o 7 07

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

2 19

GENERA L SPECIFICATIONS ABOUT TIGHTENING jsPECj

LUBRicATioN PoiNTs ANo LUBRICA~YPE jsPEcl Pf l LUBRICATION POINTS ANO LUBRICANT TYPE ENGINE

Lubncatton pomts (part name) Lubncant type

Otl seal edges (completely) ~

Beanng retatner -m Rod ptns -m Rod (btg end) -m Ptstons and ptston rmgs -m Hub (balancer dnve sprocket) -m Ptston ptns -m Valve stem and gUJde -e Otl seal (valve stem end) -e Rocktng lever shaft and rocktng lever -m Cam and beanng (camshatt) -m Rotar and rotar houstng (ati pump) -m Dtsengagement contro! rod ~ Pnmary dnven gear and pnmary shaft -m Slldtng gear (transmtsston) --El Free gear (transmtsston) -e Selector torks and ptlot bar -m Gearshtft cam and beanng (gearshlft cam) -m Gearshlft shaft -m 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

B-6 LUBRICATioN POINTs ANo LUBRICANr TYPE lsPEcl Pf l

CHASSIS

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 ~

P1vot po1nts (brake lever and clutch lever) ~ Clutch cabla end ~

P1vot po1nts (s1destand) ~

Beanng brasses (cha1n tens1oner) ~

Grease n1pple (rear arm) ~

Grease n1pple (shock arm) ~

Grease n1pple (shock llnk) ~

222

LUBRICATION LAYOUT (1) 011 tank (2) Olf pump (3) Olf flfter (o1f tank) (4) Otl pump suctton (engtne) (5) Dra1n plug (6) Otl vapour retneval hose (7} Od blow-by retr!Elval hose

LUBRICATION :::vour!SPECI ji}fj' l [A) INTAKE [B) RETRJEVAL

2 23

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

LUBRICATION LAYOUTISPECI p~ l fA) JNTAKE (B) RETRIEVAL

224

__________ L_u_aR_,c_AT_,o_N_;=;_v_ou_T!sPEcjp~j l B-8 l (1) 011 fr/ter (2) Camshafi {3) Connectmg rod pm (4} Mam dnv1ng shatt (5) Secondary dnve shaft (6) Drarn plug

? 25

[A) INTAKE [8[ RETRIEVAL

::-::*:*~*'

(1) Ori pump (2) 01/ fllter (3} 011 delivery hose (4} /ransmss1on (5) Oli pump suct10n

waRtcATION LAvouT!specj Pf l [AJ INTAKE [B) RETRIEVAL

226

l 89 "-' lsPEciJDf l ''-' CABLE ROUTING ISPECIJi'f l CABLE ROUTING CABLE ROUTING 11 Complete harness harness connector shroud and secure 1 Front brake hose 16 lnterrmttence !Xl Lay the brake hose [[] Lay the eng1ne osi

12 Rubber shroud 22 Ma1n swstch hamess the latter by means 2 Brake hose QUides 17 Engme 011 breather beh1nd the lett tube breather pspe 17 1 Clutch cable 13 Clamp connector of the clamp 3 Left tube guard p1pe (lo eng1ne 011 guard and fasten 11 above the 2 Brake hose gwdes 14 Engtne stop SWIICh 23 Clutch SWIICh [[] Lay the complete 4 Metal plate tank) by means of the four compensatlon pspe 3 Brake hose connectors harness connector harness between the 18 Engme 011 breather clamps prov1ded on located on the 4 Throttle cables 15 Headhght harness [E Lay the clutch cable mudguard (m the 5 Throttle cables p1pe (to a1r cleaner the latter carburetor base, and 5 Throttle cables connector m front of the prov1ded seat) and 6 Tachometer/ case) [ID Lay the hose behmd take 1t to the upper

gu1de 16 Left turn hght harness the lower fork plate Odometer cable 19 Sidestand SWIICh the metal plate mlet of the eng1ne 011 6 Ughtmg harness connectors [ID Lay the brake hose 7 Clutch cable screwed on the tube tank 20 Engme generator 7 Clamps 17 R1ght turn hght through the gu1des 8 Clutch cable fa1rlead harness (1n the m1ddle o1 the III Lay the eng1ne 011 8 Engme stop and connectors on the fork plates 9 Clutch cable stop (on 21 Overflow p1pe

two fastenmg breathar p1pe 18 eng1ne start1ng 18 Fa1rlead screws) behmd the ang1ne 011 sw1tch harness 19 Harness fastenmg @] Lay the harness on ang1ne) (carburetor) @] Attach throttle cable tank and take 11 to

9 lnstruments lamps clamps the nght of the mam 10 CDI u011 22 Fasten1ng clamp for 1 and 2 the upper part of the hamess 20 Front brake sw1tch

SWliCh 11 Fa1rlead carburetor overflow [Q] Fasten the overflow a1r cleaner case 10 Tachometer/ harness connector [Q] Close the connectors 12 Horn harness ptpe (to engtne 011 ptpe (carburetor) to

Odometer cable 21 lnstruments lamps 1nto the rubber tank) the eng1ne 011 tank 13 Clamp 23 Dtode (ustng clamp 22) and 14 Fuse 24 Battery lay 11 between the 15 Fuel p1pe from tank 25 Relay shock arm and the

tap raar arm shock llnks

7

2-27 2 28

1~l~~~r;l~~~~~~:~~~ag~::~::--:1~2~t~'~r~br;ea~1~he:r~p;,p:es;---:;~C~A~'--../~B~L~E~~RO~U~T~I~N~G ISPECijUf l l 81 Q l 3 Tachometer/ 1143~ R{';~~~etor) ~ fonnect to fuel tank . . 4

Odometer cable ea b ap throuqh the Tachometer/ h r rake sw,tch "" clamp prov,ded Odometer cable 15 R amess ~ lnsert mto the rear f.,rlead h~:: brake flu'd tank "" arm gwdes

5 R'ghttube guard 16 Ho f 8 lnsert the overtlow 6 lgmt,on co,l se rom rear brake P'Pe between shock 7 Spark plug cable 17 ~ump to cahper ahrm and rear arm 8 Horn ear brake hose s ock hnks

gurdes

9 Fuel prpe 18 Rea b 10 Carb 19 0 r rake swrtch uretor suctlan verflow hose prpe (carburetor)

11 Engme breather b~~ (to "" cleaner 0 ~nsert the tachometer ~~ble mto the slot on

e nght tube guard

2 29

Rear hamess fastensng clam

2 Rectrfrer earth P wrre

3 Rectlfrer

4 Rrght tum hght harness

5 Left tum hght hamess

6 T ari hght harness

~ :n~ert the rear turn t~e ~~~~~ess through

2-30

_________ '-._/_lm\PJJ\ 1s-111 CHAPTER 3

PERIODI C INSPECTION ANO ADJUSTMENT

PERIOOIC MAINTENANCEJLUBRICATION INTERVALS

SIDE PANELS, AIA DUCTS, SEAT ANO FUEL TANK REMOVAL ANO INSTALLATION

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

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

B-12

B-13 B 13

B-14 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 c 14 c 15 C-16

D-1 D-1 D-2 D-2

--------------------------------AEAR SWING ARM LUBRICATION

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

\m\PM~I D-2

D2 D-2 D-3 D-4

PERIODIC MAINTENANCE/LUBRICATION INTE~Lsl m IIIJI!'ll l 8 12 1 PERIODI C INSPECTIONS ANO ADJUSTMENTS

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

EVERY AFTER

PART NOTES RUNNING 6,000 km 12,000 km (1000 km) or 6 months or 12 months

Valves Check valve clearance o o o Adjust 1f necessary

Spark plug Check cond1t10ns o o o Clean or replace 1f necessary

A1rfllter Clean Replace lf necessary o o Carburettor~ Check 1dle speed and starter o o o

Adjust 1f necessary

Petrol hne" Check petrol hoses o o Replace 1f necessary

Eng1ne 011 Replace (heat engme pnor to o o o dumpmg 011)

Eng1ne o1l Replace ftlter element and clean 011 o o o fllter*/011 fllter fllter

Brakes* Check functiOnmg/leakage o o See NOTE Correct 1f necessary

Clutch Check functlonmg/AdJUSt 1f necessary o o

Rear arm pm* Check that the rear arm un1t 1S not o o o loose Correct 1f necessary Grease and t1ghten moderately "**

Rear suspens1on Check funct1on1ng o o o connect1on pms** Grease and t1ghten

moderately ....

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

3-1

YERIODIC MAINTENANCE/LUBRICATION INTERVALsl 1~~~ IIIJI!'ll EVERY

AFTE A PART NOTES RUNNING 6,000 km 12,000 km

(1000 km) or 6 months or12 months

Wheel beanngs* Check beanng clearance/damage o o Replace 1f damaged

Steenng beanngs Check beanng clearance o o Correct 1f necessary Lubncate moderately every 24 000 km or 24 months

Front fork" Check funct!onmg/Oilleakage o o Repa1r lf necessary

Rear shock absorber Check functJonJng/ollleakage o o Repa1r 1f necessary

Dnve cha1n Check cha1n free play/ahgnment Adjust 1f necessary Every 500 km Clean and lubncate

Assembhes/ Check an assembhes and clamps o o clamps T1ghten 1f necessary

Latera! stand* Check functtonmg o o Repa1r 1f necessary

Latera! stand Check funct1onmg o o SWitCh" 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

o

o

o

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

'-..../ IINSP l l SIOE PANELS, AIR OUCTS, SEAT ANO FUEL TANK ADJ lf!'.l

123 Pane! fastenmg po1nts

Panel fastemng to a1r duct

Tank fastemng screw 2 Tank fastenmg flap 3 Panel tasten1ng flap

3

l

3-3

SIDE PANELS, AIR OUCTS, SEAT ANO FUEL TANK

REMOVAL ANO INSTALLATION

Hold the motorblke f1rmly In piace to prevent lt fall1ng

S1de panels

The s1de panels are pressure-sealed at three fas-tenlng po1nts 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 p art ofthe panel mto flap and then press on the fastenmg po1nts to f1x them properly mto the1r hous1ngs

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

IB-131 SIOE PANELS, AIR OUCTS, SEAT ANO FUEL TANKI 1~5~ jl!!'.lj

Seat fastenmg screws

2 Fuel tank fasten1ng hole 3 Chass1s fastemng flap

Rear fasten1ng screw 2 Fuel hose

3 Front fastemng rubbers

34

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 m piace, checkmg that the fuel tank pm f1ts mto the ho le on the se a t and that the seatflapf1ts mto the correspondmg hollow m the chass1s Lower the rear of the seat and fasten w1th 2 screws

Before usmg the motorcycle, check that the seat ls f1rm1y in piace.

/xl Seat screws 4 Nm (0.4 mkg)

Fuel tank

Before d1sassembhng the tank remove the seat f1rst

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.

Unscrew the rear fastemng screw on the tank, detach the eia m 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

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.

lxi Fuel tank 7 Nm (0.7 kgm)

VALVE CLEARANCE ADJU~MENT 1m l ~!i~ l 1 a-141 ENGINE

3-5

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:

When removmg the spark plug an d tappe t cover, be careful not t o drop fore1gn objects 1nslde the engme.

''''Mh1t1't1i -----------Hold the motorcycle f1rmly m piace t o prevent l t falhng over dunng the operat1on

Aemove S1de panels A1r ducts Seat Fuel tank See the sectiOn "SIDE PANELS, AIR

OUCTS, SEAT ANO FUEL TANK' above

2 DISCOnnect Spark plug cap (1)

3 Remove Spark plug Tappet cover (2) (suctiOn) Tappet cover (3) (exhaust)

4 Remove Cap (1) Cap (2)

VALVECLEARANCEADJUSTMENT~I~8f ifii

3-6

5 Turn the dnvmg shaft antJclockw1se usmg a wrench

6 Ahgn Reference mark 'T on the flywheel (1)

Wl t h the f1xed reference mark o n the crank-case (2)

NOTE. Check that the p1ston IS under compressron at top dead centre

(3) lgnlton t1mmg reference mark

7 Check Valve clearance

Out of specLflcatLon ""') AdJUSt

8 AdjUSt

Valve free play {cold) Suct1on

0.05-010 mm Exhaust

012-0.17mm

Valve clearance

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

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

Spec1al tool P/N YM-08035 P/N 90890-01311

Hold1ng the adJUSter frrmly 1n piace lock t1ghten lock nut

1~1 Lock nut: 14 N m (1 4 mkg) Measure valve c!earance lf the clearance ts mcorrect, repeat the preveous

stages to acheeve the reqwed value

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

10 Connect Spark plug cap

.~ l Tappet cover {exhaust): ~ 12 Nm (1.2 mkg)

NOTE:

Bolt (tappet cover): 10 Nm (1.0 mkg)

Spark plug. 18 Nm (1 8 mkg)

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

11 Reassemble Fuel tank Seat Aer ducts Stde panels See secteon 'SIDE PANELS, AIA DUCTS,

SEAT AND FUEL TANK"

1~1 Seat screws: 4 Nm (0.4 mkg)

- .,.._ -. --' ...

DRIVE CHAIN ADJUSTMENTIINSP ~~~ IDLE SPEED ADJUSTMENT. ADJ . ~.

38

DRIVE CHAIN ADJUSTMENT The dnve cham does not need to be adJUsted

IDLE SPEED ADJUSTMENT Start the engene and let et heat

2 Connect The enductlve engrne speed endecator to

the spark plug cable

3 Check

Spec1al tool P/N. YU08036A P/N. 9089003113

The engme tdle speed Out of spectftcatton -7 Adjust

4 AdjUSt

Engme tdle speed: 1,200-1,400 rpm

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

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

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

5 Otsconnect lnducttve engme speed tndtcator

THROTTLE CAB LE FREE PLAY ADJJs'TMENT 1 m 1111 1 8 -1&1 THROTTLE CABLE FREE PLAY

3-9

ADJUSTMENT

NOTA-Before adjustlng the throttle cable free p!ay adjust the engme 1dle speed

Remove S1de panels A1rducts Seat Fuel tank See sectJon SI DE PANELS, AIA DUCTS

SEAT AND FUEL TANK

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

3 AdjUSt

Throttle cable free play 3-5mm

Throttle cable free play

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

(1), (6) Lock nuts

SPARK PLUG INSPECTIONI m 1111

3 10

4 Reassemble Fueltank Seat A1r ducts S1de panels

1~1 Seat screws. 4Nm (O 4 mkg) SPARK PLUG INSPECTION

Remove S1de panels A1r ducts Seat Fuel tank See sect1on' SI DE PANELS, AIR DUCTS

SEAT AND FUEL TANK"

2 D1sconnect Spark plug cap

3 Remove Spark plug (1)

CAUTJON:

When remov1ngthe spark plug, be careful no t t o drop fore1gn objects ms1de the engme

4 lnspect Type of spark plug lncorrect-? Replace

Standard spark plug DPR8EA-9(N G K ), DPR9EA-9(N G.K.)

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

3 11

6 Clean the spark plug w1th a swtable tool and a steel brush

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

Electrode gap: 0.8-09 mm

a Lock ttghten Spark plug Before mstallmg the spark plug, c!ean the

surtace and thread

1~1 Spark plug 18 Nm (1.8 mkg) NOTE Ttghten the spark plug by hand before torqutng to spectftcatton

9 Connect Spark plug cap

10 lnstall Fuel tank

Seat A1r ducts Stde panels

1~1 Seat screws. 4 Nm (O 4 mkg)

C-1 IGNITION TIMING CHECK l m l fil

IGNITION TIMING CHECK

3-12

1 Start the engme and let 1t heat 2 Connect

lnducttve rev counter Stroboscoptc lamp to spark plug cable

lnductive engme speed mdtcator: P/N. YU-08036-A P/N. 90890-03113

Stroboscop1c lamp. P/N. YM-33277-A P/N. 90890-03109

3 Remove Cap (1)

CAUTION:

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

4 Check Advance tgmtton

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

reqUJred

Engme tdle speed 1,200-1,400 g~n/mm

Check that reference mobile (1) ts m the mobtle fteld of reference (2) on the flywheel

lncorrect tgnttlonttmtng ~Check the tgnttton cotl untt

NOTE: lgmtton ltmtng cannot be adJusted

~~~~

5 lnstall

Cap 6 Remove

Stroboscoptc lamp lnducttve engme speed mdtcator

COMPRESSION INSP~ION l m 111.!!11 COMPRESSION INSPECTION

NOTE lnsuff1C1ent compresston causes a loss of perform-ance

lti'Mhhi@N 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" 2 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 6 Remove

Spark plug

CAUTION:

When removmg the spark plug, be careful to prevent fore1gn bod1es from droppmg ms1de theengme.

7 Apply Pressure gauge (1) Adapter (2)

313

C-2 COMPRESSION ADJUSTMENT~I~~~ i fil

t::J Pressure gauge: P/N. YU33223 P/N. 9089003081

Adapter P/N. YU332233 Extenston P/N. 9089004082

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

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/cm2, 156 pst)

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

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

Pressure under compressaon (after addmg 011 to the cyhnder)

Readmg D1agnos1s

Pressure h1gher P1ston worn or than before. damaged.

Pressure as sa me Cylmder h e ad or before p1ston rmgs, valves,

gaskets may be faulty.

Pressure above ma x- lnspectcyhnderhead, mumvalue valvesurfaces, p1ston

nm to check for car-bon depos1ts

.................................. 9 Remove

Secondary fuel tank Pressure gauge (w1th adapter)

1 O Reassemble Spark plug See sect1on 'SPARK PLUG INSPECTION'

1~1 Spark plug 18 (1 8 mkg) 11 Connect

Spark plug cap

12 Reassemble Fuel tank Seat A1r ducts S1de panels

1~1 Seat screws 4 Nm (O 4 mkg)

3-14

ENGINE OIL LEVEL -:;;:ECK l m l ~!~!~il ENGINE OIL LEVEL CHECK

315

CAUTION:

Do not put addittves lnto the englne oli The latter also lubncates the clutch and addttlves might cause lt to shde

''"'';'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

Thts mode l ts fitte d wtth a dry crankcase lubncatiOn system A teed pump deltvers o tito the engme, after fully lubncatlng the laner the otlts returned to the tank by a scavenge pump The Oti leve! must therefore be checked m the otltank

Set the motorcycle level and hotd tt upnght 2 Unscrewthe otl tank cap (1) and clean the cap

stem 3 lnsert the cap sucker rod mto the tank Do not

unscrew, stmply piace on the ftller 4 Pull out the rod and check the otl leve! The

latter must be between the m1n1mum and max1mum levels (2) and (3)

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

C-3 ENGINE OIL LEVEL CHECK l m l ~!~!~il

lf the mllevel1s below mm1mum ~ Add 011

3 16

up to max1mum level

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

5 Reassemble the mi tank cap

6 Startthe eng1ne and heat untll the temperature reaches 60C or thereabouts

;CAUTION:

Never start the englne when the oli tank 1s empty

7 Run the engme at Id le speed for about 1 O seconds, holdmg the motorcycle f1rmly up-nght Turn off the eng1ne and add 011 up to the max1mum level

8 Replace the 011 tank cap

011 capac1ty. Total

2.8l1tres

Penod1c 011 change 2.2 htres

W1th f1lter oli change: 2.3 htres

011 tank capaclty 1.8 lltres

__________ E_N_G_IN_E_O,_L R_E_P_LA_~_EM_E_NTI m 1&1 1 c-4 1 ENGINE OIL REPLACEMENT

CAUTION:

Do not put addlttves tnto the englne oli The latter also lubncates the clutch and additlves mtght cause lt to sllde.

W!*M';lf!!Ni -------,----Never remove the otl tank cap when the engme ts hot. The boiling oli mtght spii l over, causlng burns. Walt far the oli to cool to at least 60 or thereabouts.

Englne oli replacement (wtthout replacmg fllter oli).

Start the engme heat ti far a few mtnutes then swttch off

2 Piace a contamer under the engme and oli tank

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

4 Dram Eng1ne 011 completely

3-17

ENGINE OIL REPLACEMENTI m 1&1

318

5 lnspect Ali gaskets

Damaged ~ Replace

6 Reassemble Fslter cover screw Otl fllter cover bleeder screw Engtne dratn screw 011 tank dram screw

7 Ftll

Fastenmg torques.

Oram screw (englne) 30 Nm (3.0 mkg)

Dram screw (otl tank} 18 Nm (1.8 mkg)

Fllter cover screw 10 Nm (1.0 mkg)

Cover atr bleeder screw 5 Nm (0.5 mkg)

011 tank

Recommended oli SHELL SU PER 4TX 20W/50

Oli capac1ty Penod1c change 2 2 lltres

CAUTION:

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 addl-ttves may make it sllde.

ENGINE OIL REPLAC~ENTI m 1 ... 1

3 19

8 lnstall 011 tank tap

9 Check Oillevel

See sect1on "ENGINE OIL LEVEL CHECK" 011 pressure

See sectton "ENGINE OIL PRESSURE CHECK"

Ollleakage

Englne oli replacement (with oli f1lter replacement)

1 Start the engme, heat 1t up fora few m1ntues, then turn 1t off

2 Piace a contamer under the engme and ol tank

3 Aemove 011 tank cap 011 tank dram screw (1) Engme dram screw (2) Osi f1lter covar bleeder screw (3) F1lter covar screw (4)

4 Dra1n Eng1ne 011 completely

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

C-5 ENGINE OIL REPLACEMENT l m l ~!~~!'i~ l

3 20

5 lnspect Ali gaskets

Damaged ~ Replace

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

7 lnspect Ali gaskets Onngs (7) Damaged ? Replace

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

Fastemng torques.

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)

Cover bleeder screw: 5 N m (0.5 mkg)

ENGINE OIL REPL~MENT l m 11!511 9 F1ll

3-21

011 tank

CAUTION:

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

O ti capaclty. Total

2.8 htres

Penodtc oal change: 2 2 htres

Wlth 011 f1lter change 2 3 htres

011 tank capacaty 1.8 htres

Be careful to prevent fore1gn bod1es dropp1ng mto the engme crankcase Do no t ad d addit1ves t o the eng1ne 011. The latter al so lubncates the clutch an d the add1t1ves may make 1t shde

1 o lnstall 011 tank cap

11 Check Oillevel

See sect1on 'ENGINE OIL LEVEL CHECK'

011 pressure See sectiOn 'ENGINE OIL PAESSURE CHECK"

011 leakage

C-6 ENGINE OIL PRESSURE CHECKJIINSP 1~1 CLUTCHADJUSTMENT ADJ -~-

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

3 22

ENGINE OIL PRESSURE CHECK Remove Bleeder sere w ( 1)

2 Start the eng1ne and let tt run at 1dle speed tar a few seconds

3 lnspect Condtons of 011 at bleeder hole

01! leakage -+ Otl pressure good No leakage ~ Pressure msuff1C1ent

CAUTION:

lf the 011 does not come out atter one mmute, stop the englne 1mmed1ately t o prevent se1zure

4 T1ghten Bleeder screw

/~l Bleeder screw 5 Nm (O 5 kgm)

CLUTCH ADJUSTMENT

Cable free play adJUStment

1 Check Clutch free play adjustment {A)

Out of speCifiCatiOn -? AdjuSt

~ Freeplay 10-15mm

2 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

CLUTCH ADJ;;s,:MENTI m Jl!!!lliiJ 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

3 23

Internai mechamsm adJustment

1 Loosen Lock nuts (1) on the lever cable adJUSters

and crankcase

2 Fully ttghten AdJusters

3 Dram oft Eng1ne oli

See sectron 'ENGINE OIL REPLACE MENT

4 Remove Footrest (nght) (2)

5 DJsconnect Brake pedal return spnng

6 Remove 011 dellvery hose tastenmg screw (3) Rtght crankcase cover (4)

7 Loosen Locknut(1)

8 Push the engtne clutch controllevel forward to the stop po1nt

9 AdjUSt 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 Locknut(1)

\~\ Lock nut. 8 N m (O 8 mkg)

C-7 CLUTCH ADJUSTMENTI m jl!!!llilj

11 lnstall

R1ght crankcase cover 011 dehvery hose fastemng screw

Screw (crankcase cover). 10 Nm (1.0 mkg)

Oli dehvery hose screw 18 Nm (1 8 mkg)

12 Connect Brake pedal return spnng

13 Reassemble Footrest (nght)

\~\ Bolt (footrest) 45 Nm (4 5 mkg) 14 F1ll

Engme 011 tank

3-24

See sectiOn 'ENGINE OIL REPLACE MENT

15 AdJUSt Clutch cable free play

Free play (at lever t1p) 10 ..... 15 mm

Se e se etiO n CABLE FREE PLA Y AD JUSTMENT

AIRFILTERCL~INGII~~~ lgl AIR FILTER CLEANING

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

2 Unscrew Wmg nut (3)

3 Pull out Fdter element (4)

'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.

4 Separate The f1ltenng element from 1ts gu1de

5 Wash The ffltenng element w1th solvent

NOTE: After clean1ng, remove the remammg solvent by squeezmg, but not tw1St1ng the element

6 lnspect F1lter element

Damaged ~ Replace

7 Apply

3-25

SAE 10W/30 engme mi ali aver f1lter sur fa ce

8 Squeeze aut Excess 011

NOTE: The element should be wet but not dnpp1ng

C-8

---9> l _,

---

l~ 9,

AIR FILTER CLEANING/1 lNSP ~~~ FUEL FILTER CLEANING '- '-'A,_,D~J

~

t

ENGINEOILTANKFILTERCL~INGimli!!al 1 c-9 1 ENGINE OIL TANK FILTER CLEANING

327

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

NOTE: After cleamng the ms1de remove the remasnmg solvent

4 Reassemble

01ltank Carburettor 011 hose connecttons 011 dra1n hose

011 hose connectlons: 50 Nm (5.0 mkg)

011 drain hose: 18 Nm (1.8 mkg)

5 Fili

Engme 011 tank See sect1on uENGINE OIL REPLACE-MENT

6 Reassemble

011 tank cap

SUCTION HOSE ANO MANIFOLO INSPECTIONi,JNSP ~~~ FUEL LINE INSPECTION ADJ ~

t'\ '

SUCTION HOSE ANO MANIFOLO INSPECTION

1 Remove

Stde panels Atr ducts Se a t Fuel tank

See sect10n uSI DE PANELS, AIA DUCTS,

3 28

SEAT ANO FUEL TANK"

2 lnspect

SuctiOn hoses (1) Cracked/damaged-+ Replace

~ Screw (2) (carburettor mamfold)

10 Nm (1.0 mkg)

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

3 Reassemble Fuel tank Seat A1r ducts Stde panels

1~1 Seat screws. 4 Nm (O 4 mkg) FUEL UNE INSPECTION

Aemove A1r ducts

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

2 lnspect Fuel hosmg (1)

Cracked/Damaged -+ Replace

3 Reassemble A1r ducts

CRANCKCASE VENTILATION HOSE INSf~ ION/IINSP 1~1 l C-1 o l EXHAUST SYSTEM INSPECTION .__ '-A"-'0"-J"'-.J_'-~----'-

3-29

CRANCKCASE VENTILATION HOSE INSPECTION

lnspect Crankcase ventllallon hose (i)

Cracked/Damaged -+ Replace

EXHAUST SYSTEM INSPECTION lnspect Exhaust p1pe (1) S1lencer (2)

Cracks/Damage -+ Replace Gaskets (3)

Exhaust gas leakage -+ Replace

Nut (4) (exhaust p1pe). 10 Nm (1.0 mkg)

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

Boli (6) (flange). 20 Nm (2 O mkg)

Screw (7) (protect1on). 7 Nm (0.7 mkg) Use LOCTITE

Screw (8) (protect1on). 7 Nm (O 7 mkg) Use LOCTITE

FRONT BRAKE ADJUSTMENTi,INSP ~~~ REAR BRAKE ADJUSTMENT _ ADJ . ~.

330

CHASSIS

FRONT BRAKE ADJUSTMENT

Check Free play at t1p of brake lever (a)

Out of specfcat1on -+ AdJUSt

Free play (at t1p of lever). 10-15mm

2 AdjUSt Brake lever free play

AdJustment. Turn the adJUSter (1) elther way to obtam the

correct free play

Free play damm1shes

Free play mcreases

CAUTION

Proper lever free play 1s essent1al to avo1d undue brake pad fnct1on

REAR BRAKE ADJUSTMENT

Check Brake pedal he1ght (a)

Out of spec1f1caton ~ AdJust

Brake pedal he1ght 15mm

Under top of the footrest

2 AdjUSt Brake pedal he1ght

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

correct pedal he1ght

FRONT

REAR

REAR BRAKE ADJL ~ENT/IINSP 1~1 l C-11 l BRAKE FLUID LEVEt-HECK ADJ ~

3 31

Free play (a) dJmJmshes

Free play (a) mcreases

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 Lock nut. 26 N m (2 6 kgm)

BRAKE FLUID LEVEL CHECK

NOTE. When checkmg the level of the fiUid make certan 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

lnspect Level of brake flwd

lf the level1s below the m1n1mum LOWER" (1)-+ F11l

Recommended brake fiUid' DOT No 4 or DOT No. 3

CAUTIDN:

The brake fiUid may corrode pamted surtaces and plast1c parts

{A]

{B)

BRAKE PAD WEAR INSPECTIONI m l ~~!!i~ l W!fii;W@1 ----------- 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 W a ter would iower the boiling point, generating vapour bubbles durmg brakmg

BRAKE PAD WEAR JNSPECTIDN

Operate the brake iever or brake pedal 2 Check

Th1ckness of fncttonal matenal Out of spec1f1caton -+ Replace

3-32

Wear lim1t (a). Front 1 O mm Rear O 8 mm

(b) Wear 10d1cator

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

[A} Front brake (8] Rear brake

BRAKE HOSING INS' ,flON/IINSP 1~1 l C-121 BRAKE CIRCUIT BCI!EDING _ ADJ _ ~.

3 33

BRAKE HOSING INSPECTION

lnspect Brake hostng

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

!Al Fronl [8] Rear

BRAKE CIRCUIT BLEEDING

t!W1f.1;HIIN1 --:--:----:----~-lt the brake lever or brake pedal has a soft or slack feel, thts means that there ts atr m the 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. A brake hose has been Joosened or removed The brake flutd m the tank ts at a very low

leve! Brake operatton ts faulty.

BRAKE CIRCUIT BLEEDING l ~ l fil

3-34

Atr bleedmg procedures

a Top up the level of the flUid m the tank to max1mum

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

Pull the brake lever nght m or press the pedal nght down and hold 1n pos1t1on

g Loosen the bleeder screw and allow the lever or pedal to travel slowly towards 1ts llm1t

h T1ghten the bleeder screw when the lever or pedal llm1t has been reached, then release the lever or pedal

1~1 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)

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

J Top up fiUid to the max1mum tevel

DRIVE CHAIN TIGHTNESS INSPECTkJNDIINSP j~j l C-131 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

3-35

Check Dnve cham slack (a)

Out of specdJcatJon ~ AdJuSt

lU\_ ~ Onve c ha in slack. (61 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 o ne s1tttng on 11 Check ttghtness m the pos1t1on shown m the f1gure

2 AdjUSt Dnve cham t1ghtness

Tightness adJUStment:

CAUTIONi __________________ _

An unduly tight c ha m W ili 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)

,..;..,._ ~

D )CD

DRIVE CHAIN LUBRICATION l m l ~!!!al DRIVE CHAIN LUBRICA TI ON The cham COOSISIS of ma ny small parts wh1ch

lf 1t 1s not properly ly lt 1s thus necessary nce work on the cham,

e 1S often dnven over cl e 1s f1tted w1th a cha1n

the plates Cleamng

operate one over another mamtaned, 1t w111 wear qu1ck t o carry out regular ma1ntena especally 1f the motorcycl dusty surtaces The motorcy w1th small 0-nngs between w1th steam p essu products and some sol r nsed

3 36

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

(1) ORongs

FRONT FORK INSPECTION ANO AOJU~ENTI mIRI 1 c-141 FRONT FORK INSPECTION ANO AOJUSTMENT

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

Vlsuallnspect1on

1 Check Slem (1)

Scratches/Damage -+ Replace 011 seat (2)

Undue mlleakage ~ Replace

Operating mspect1on

1 Check Proper funct1omng

W1th the motorcycle 1n a leve! upnght pos1 tiOn an d w1th your hands o n the handlebar, operate the front brake Then compress and release the front fork severa! t1mes lrregularljerky funct1on1ng-+ Repa1r

Adjustment

Be sure that both the front fork stems are adjusted to the same settlng. A non-unlform adJUStment may cause poor handhng and loss of stab1hty

Adfustment ot extens10n dampmg effect

O n 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

AOJUSTMENT FIELO

Maxlmum Mlnlmum

Screw completely Screw turned 20 t1ghtened m ctockw1se chcks 1n antiCIOCkwlse dJrectiOn (A) d1rect10n (B)

Standard adjustment: 12 cllcks from maximum

~ 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 ca p (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 antt-clockwlse (B)

3 38

(1) Settmg screw (2) Rubber cap

AOJUSTMENT FIELO

Max1mum Fully turned 1n poSJIIOn

Standard adjustment a chcks from max1mum

Mlnlmum 20 cilcks antJclockwlse (B) from max1mum

CAUTION:

Do no t force the adjustment screws beyond the minimum or max1mum settmgs.

,CAUTION:

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

SHOCK ABSORBER INSPECTION ANO AOJUSTMENT

''*&'dd'di Ths shock absorber contams hlghly com-pressed 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 no t 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 Jeopard-se the dampmg effect.

SHOCK ABSORBER INSPECTION ANO AOJU~ENTI m 1 ... 1 1 c-151 NOTE: The shock absorber spnng preload may be ad-JUSted accord1ng to the dnver's preferences, to the wetghts be1ng carned and to road condltlons

Ho l d the motorcycle f1rmly In piace to prevent i t falhng.

Spnng preload adjustment

Adjust the spnng preload as fo!lows Loosen the lock nut (2) To mcrease the preload, turn the adjuster

clockw1se (A) T o reduce 1t, turn anbclockw1se (B)

The spnng preload changes by 1 mm per turn of the adjuster

3 39

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)

1CAUTION:

Never attempt to turn the adJuster beyond the maxlmum or mlnimum settmg

Sprmg length w1th preload

Standard length 222mm

Mm1mum iength 210mm

Max1mum length 238mm

~ocK ABSORBER INSPECTION ANO AOJUSTMENT/IINsP Imi STEERING INSPECTION .__ ~A,_,O:.>J

STEERING INS::;TIONI m l ~!!iii 1 c-1s1 r=~~~~;l~~~~~~~f=::::::~--~A~d;J~u:s~tm~en~t;:----------

Loosen steenng column nut (1} and upper fork plate screws (2)

T1ghten lockmg nut (3) w1th the spec1ai wrench

NOTE

Locking nut wrench: P/N. YU-33975 P/N 90890-01403

The torque wrench and the tock1ng nut wrench should forma nght angte

Locking nut (lnltlal tlghtenlng) 38 Nm (3.8 kgm)

Loosen the lockmg nut one turn Ret1ghten the lockmg nut us1ng the spec1al

wrench

Do not tlghten the locklng nut excesslvely.

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

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)

FRONT

Make Measurement

PIRELLI 90/9021 (54R)

REAR

Make Measurement

PIRELLI 130/80-18 (66R)

Type

MT70

Type

MT70

TYRE INSPECTIONI m l ~!!iii TYRE INSPECTION

Tyre pressure must be checked when the tyres are at amb1ent temperature. Pressure must beadJUSted accordlng tothetotal welght of luggage, driver, passenger and accesso-nes (falrlngs, bags,lf approvedforthls model) and speed of the motorcycle

A llst of tyres approved for thls m o del follow-mg severe testtng by Belgarda S.p.A 1s pro-vJded There can be no guarantee of safe roadholdlng lf a comblnatlon of tyres dlfter-ent 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

Check Tyre pressure

Out of spec1flcat1on -+ Adjust

INFLATING PRESSURES (bars) (pso)

Wtth dnver only Front Rear 2 (28) 22 (32)

Wlth dnver 2 1 (30) 24 (35)

and passenger

Wlth dnver 1 5 (22) 1 6 (23)

and passenger

2 AdjUSt A1r pressure ............................................

TYREINS~TION~I~~r IIJ!lll AdJUStment: Remove the valve cap

Use an alr pump or lncrease alr compressed alr p1s- pressure tol.

Eliminate alr by Alr pressure presslng valve tube dlmlnlshes stem

lnstall valve caps securely

3 lnspect Tyre surtace

Wear/Damage -+ Replace

Mimmum track thickness: (front and rear)

2,5mm

(1) Track th1ckness (2) S1de (3) Wear md1cators

''*Mh#'!di The use of worn tyres reduces stablhty an d may cause a Joss of contro!.

343

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.

4 T1ghten Valve stem lock nut

~~~ 1.5 Nm (0.15 kgm)

After assembling the new tyres, drive slowly to allow them to adapt well to the rlm and yjus ensure maximum holding

D-1 WHEEL INSPECTION/IINSP 1~1 CABLE INSPECTION ANO LUBRICATION ADJ_ ~

WHEEL INSPECTION lnspect Wheels

Damage/Deformat1on -+ Replace

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

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

3 44

CABLE INSPECTION ANO LUBRICATION

lfthe cab le sheath IS damaged, corrosion might e n sue orthe cab le mlght not run freely. T o avo id such drawbacks, replaced damaged cables as qutckly as posslble.

lnspect Cable sheath

Damaged -+ Replace

2 Check

Cable tunctiOmng Does not run freely -+ Lubncate

Recommended lubrlcant. SAE 10W30 engme oli

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

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 1 OW30 engme oli

LATERAL STANO LUBRICATION Lubncate the latera! stand and artcutat1ons

Recommended lubncant: SAE 10W30 englne oli

SWING ARM LUBRICATION Lubncate the sw1ng and connect1on arm p1vots

~~l Llght llth1um-soap grease

ELECTRICALS

HEADLIGHT. LAMP REPLACEMENT ANO SETTING

Headlamp replacement

1 D1sassemble Chass1s dome

NOTE. To d1sassemble the dome loosen screw (1) from beneath the mudguard an d ra1se 1t t o chck onta the flap (2)

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

D-2 HEAOLIGHT: LAMP REPLACEMENT ANO SETTING l m l n l

NOTE. T o remove the lamp, turn counterclockwtse

3 lnstalt New lamp (turn ctockw1se) Rubber cover Lamp connector

4 lnstaU Dome

Do not touch the lamp when on and keep ali inftammable products well away.

;cAUTION:

Do no t 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.

Front parkmg llght lamp replacement

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

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

Headllght settlng

1 Loosen Screws (1) (headllght f1xmg)

2 AdjUSt Vertlcaf headhght setllng (1)

3 Tghten Headl1ght fasten1ng screws

Headhght fastenlng screws: 7 Nm (0.7 mkg)

~ -+

-r

\.._./

FUSE INSPECTION ANO REPLACEMENT l~ /~!~li~/ FUSE INSPECTION ANO REPLACEMENT

J-

Remove S1de panel (left)

See sectiOn "SI DE PANELS, AIA DUCTS SEAT AND FUEL TANK"

Fusebox(1) Fuse (from fuse box)

2 lnspect Fuse

lnspect1on

Connect the pocket tester to the fuse to check f1lament cont1nU1ty

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

~ J Pocket t ester. L_j P/N. YU-03112

P/N. 90890-03112

lf the 1nstrument shows mf1n1te res1stance, the fuse 1s burnt aut and needs to be replaced

3 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

D-3 FUSE INSPECTION ANO REPLACEMENTI~~~r /n/

t!tW.i;Widii

3 48

Do not use fuses wl t h an amperage higher t han that prescrlbed. Such fuses mtght cause dam-age to the motorcycle and even f1re

4 lnstall Fuse box Stde panel

\.__/

BA TTERY INSPECTION ~~~~~ l ~~~l~~ l BATTERY INSPECTION

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

CAUTION.

CHARGING METHOD

The battery ts of the sealed (MF) type Do not remove caps dunng chargmg lf the caps are removed, the balance et the battery ts not mam-tatned and tts performance progresstvely dtmm tshes

Never addwater, noteven d1stllled water Other-wtse, the chemtcal reactlOns t n the batterywt!l not take piace normally, maktng regular functtontng tmposstble

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

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

D-4 BATTERY INSPECTION ~~~~~ l~!~\

"l oO

''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

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.

SKIN ~ Rtnse w1th water.

EYES ~ Rtnse w1th water for 15 minutes and cali a doctor 1mmed1ately.

(INTERNAL) ANTIDOTO

Dnnk coplous amounts of water or m1fk fol~ lowed by mllk of magnes1a, scrambled eggs or vegetable 011 Cali a doctor immed1ately

Battenes generate explos1ve hydrogen gas. ob~ serve the follow1ng prevent1on measures.

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.

DO NOT SMOKE when charging or handilng battenes

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

Remo ve S1de panel (Jeft)

Seesect1on SJDE PANELS, AIA DUCTS, SEAT AND FUEL TANK"

Battery cover fastemng belt (1)

2:

f ~ o

il o

"

1 Retatl(l(lStl

__________ ___::B.:..:.ATT.:..:..:::ER.:..:.Y_::IN.:..:.s.:..:.W::.:c:.:.T:=:..:ION l m \~!i\ l D-& Method for charg1ng w1th a vanable voltage battery charger

NOTE

EJ Measure the open crcutt voltage belare chargtng

The current musi be measured 30 m1nutes after stoppmg the cycle

o o 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)

AdJUSt the voltage so thatthe cur renttsatthestandardcharge leve l

1A or less

Turnmg the charge voltage regu latiOn contrai set the chargmg voltage to 20 -25V

Check the amperage !or 3 5 mm ute:; te see 1f the standard charge current IS reached

1Aormorel

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

NOT

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 con-tinue te charge

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

BATTERY INSPECTIONI ~l ~!il Method for charg1ng wlth a constant voltage battery charger

NOTE Measure the open Clrcwt voltage belare charg~ng

The current must be measured 30 mmutes after stopp1ng the cycle

VES

Charge the battery untll the charg mg voltage 1S 16V or more

NOTE Set the chargtng !t me at 20 hours (maxtmum)

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

3 54

NOT

Th1s type ol battery charger cannot recharge an MF:' battery A vanable voltage or constant current bat tery charger 1s recommended

Amperometer

BATIERY INS~;;'TION l~ l ~~~~~al Method for charg~ng wtth a constant current battery charger (exclustvely for MF battenes)

VES

Measure the open CirCUII vo!tage belare chargng

j Connect the battery charger and amperometer to the battery and start to charge

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

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

NOT

Smce the chargtnQ current IS constant the charg1n9 tme vanes accordmg to the ca

Il Il the nomnal current fals to tlow replace the Il battery

pac1ty o the battery Sei the charg1ng t1me by fo!lowng the mstrucllons spec1f1ed !or the battery charger

Measure the open CirCUII battery volta8e Amperometer after leavmg the battery unused !or over O o o B ~ha.ge, mmutes 12 BV or more Chargmg complete 12 7V or less Rechargmg necessary

' ' Under 12 OV Replace battery ..!!.. ~

3 55

l D-71 BATTERY INSPECTIONI 1~~~ l ~~~~~al

356

6 lnspect Battery poles

NOTE.

Dtrty poles .-+ Clean wtth steel brush Uncertam connecttons .-+ Ttghten termt-nals

After cleamng the poles, grease them shghtly

7 lnstall Battery

8 Connect Battery cables

CAUTION:

Connect ftrst the posttlve cable, then the nega-ttve cable

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

ENG l\. l l 0-8 CHAPTER 4

ENGINE OVERHAUL

ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... D9 D9 D9 D9 D9 D9 D9

0-10

ENGINE OIL SEAT AND FUEL TANK BA TTERY CABLES CARBURETTOR CLUTCH CABLE EXHAUST PIPE STARTER OIL BREATHER HOSES, CABLES AND HARNESSES DRIVE CHAIN ENGINE PROTECTION AND FOOTREST BRAKE PEDAL ENGINE FASTENINGS

ENGINE DISASSEMBLY.. .. .. .. .. .. . . . .. .. .. .. . CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON INTERMEDIA TE 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 VAL VES

INSPECTION ANO REPAIR . . .......... .. CYLINDER HEAD VAL VES 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 10 D10 D10 D11 D11

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

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 ........... . VAL VES 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 .. .. .. .. .. .. .