Page 1 TTR230T SERVICE MANUAL LIT-11616-18-40 -11616-18-40 -11616-18-40 -11616-18-40 -11616-18-40 1C6-F8197-10 1C6-F8197-10 1C6-F8197-10 1C6-F8197-10 1C6-F8197-10...
Page 2 TTR 230(T) SERVICE MANUAL Feb/2005 - Yamaha Motor da Amazônia Ltda Post-Sales Service Department All rights reserved. The copy or reproduction of all contents in this manual is forbidden without the previous written authorization from Yamaha Motor da Amazônia Ltda.
Page 3: Important Information
YAMAHA MOTOR DA AMAZÔNIA LTDA. will make its best efforts to enhance continuously all products in its line. The significant changes and modifications in the specifications or procedures will be informed to all YAMAHA Dealers, and will be included in the proper places in future editions of this manual.
Page 4: How To Use This Manual
HOW TO USE THIS MANUAL MANUAL FORMAT This manual is constituted by chapters for the major subject categories. (See “Illustrative Symbols”) 1st title 1: This is the chapter title with the symbol in the upper right corner in each page. 2nd title 2:This title indicates the section in each chapter and only appears on the first page of each section.
Page 5: General Information
ILLUSTRATIVE SYMBOLS INFO The illustrative symbols from 1 to 8 are SPEC assigned as per the table aside, in order to indicate the chapter numbers and contents. General information INSP Specifications ENGINE ADJUS Periodic inspection and adjustments Engine Carburation Frame Electric system CARB CHAS...
Page 6 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENTS INSP ADJUS ENGINE INSPECTION ENGINE CARBURATION CARB FRAME CHAS ELECTRIC SYSTEM ELECT TROUBLESHOOTING PROB...
Page 7: Table Of Contents
INFO CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 FRAME NUMBER ................1-1 MODEL IDENTIFICATION ..............1-1 IMPORTANT INFORMATION ................. 1-2 PREPARING FOR REMOVING AND DISMOUNTING ..... 1-2 REPLACEMENT PARTS ..............1-3 GASKETS, RETAINERS AND O-RINGS .......... 1-3 LOCK WASHERS/SPACERS AND COTTER PINS ......1-3 ROLLER BEARINGS AND RETAINERS ..........
Page 8: Chapter 1. General Information
INFO MOTORCYCLE IDENTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME NUMBER The serial number of the frame 1 is engraved on the tube of the steering column. NOTE: The vehicle’s ID number is used to identify the motorcycle, when registering and licensing it with the local traffic authority. MODEL IDENTIFICATION The model ID label 1 is stuck on the frame.
Page 9: Important Information
INFO IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARING FOR REMOVING AND DISMOUNTING 1. Clean all dirty, mud, dust and other materials before removing dismounting. 2. Use the proper tools and cleaning equipment. See the “SPECIAL TOOLS” section. 3. When dismounting the motorcycle, keep the matching parts together.
Page 10: Replacement Parts
INFO IMPORTANT INFORMATION REPLACEMENT PARTS 1. Use only YAMAHA genuine parts for replacement. Use oils/greases reco- mmended by YAMAHA for mounting and adjusting. Other brands may seem similar in terms of function and appearance, but have lower quality. GASKETS, RETAINERS AND O-RINGS 1.
Page 11: Lock Rings
INFO IMPORTANT INFORMATION LOCK RINGS 1. All lock rings must be carefully checked before remounting. Always replace the piston pin locks after every use. Replace warped locks. When installing a lock 1 , make sure that the side with sharp corner 2 is positioned opposingly to the force 3 applied on it.
Page 12: For Engine Services
INFO SPECIAL TOOLS 4. Compression meter 90890-03081 - 1 Adapter: 90890-04082 - 2 This meter is used for measuring the engine compression. 5. Fuel level meter 90890-01312 This meter is used to measure the fuel level in the carburetor bowl. 6.
Page 13 INFO SPECIAL TOOLS 3. Rotor puller 90890-01080 This tool is used for removing the magnet rotor. 4. Universal clutch fastener 90890-04086 This tool is used to hold the clutch when removing or installing the clutch hub fastening nut. 5. Crankcase separator 90890-01135 This tool is required for separating the crankcases.
Page 14 INFO SPECIAL TOOLS 8. Valve spring clamp 90890-04019 This tool is required for removing and installing valves. 9. Guide remover for 6-mm valve 90890-04064 This tool is required to remove the valve guides. 10. Guide expander for 6-mm valve 90890-04066 This tool is used for grinding the new valve guides.
Page 15: For Frame Services
This tool is used for installing the crankshaft. 14. Crankshaft spacer 90890-04081 This tool is used for installing the crankshaft. 15. Glue Yamaha Bond nº1215 ® 90890-85505 This glue is used for gluing the crankcases. FOR FRAME SERVICES 1. Internal tube cylinder fastener...
Page 16: For Electric Components
INFO SPECIAL TOOLS 3. Adjustment nut wrench 90890-1403 This tool is used for loosening or tightening the handle bar adjusting nut. 4. Transmission chain pin puller 90890-01286 This tool is used for mounting and dismounting the transmission chain. FOR ELECTRIC COMPONENTS 1.
Page 17 SPEC CONTENTS CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ................. 2-1 MAINTENANCE SPECIFICATIONS ............... 2-4 ENGINE .................... 2-4 FRAME ................... 2-11 ELECTRIC SYSTEM ............... 2-15 GENERAL TORQUE SPECIFICATIONS ............2-17 UNIT DEFINITION ..................2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-18 ENGINE ..................
Page 18: Chapter 2. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: TTR230T Model code: TT-R230 1C61 USA 1C63 CDN 1C64 AUS Dimensions: Total length 2,065 mm (81.30 in) Total width 800 mm (31.50 in) Total height 1,180 mm (46.46 in) Seat height 870 mm (34.25 in) Wheel base: 1,385 mm (54.53) Minimum height from ground...
Page 19 SPEC GENERAL SPECIFICATIONS Fuel: Type Gasoline with additive Fuel tank capacity Reserve volume 1.8L Carburetor: Type Y26P x 1 Manufacturer TEIKEI Spark plug: Type DR8EA Manufacturer Electrode gap 0.6 ~ 0.7 mm Clutch type: wet, multiple discs Transmission: Type 6-gera constant mesh Command Left foot drive Primary reduction system...
Page 20 SPEC GENERAL SPECIFICATIONS Air filter: Wet-type element Wheels: Front type Spoked size 21 x 1.60 Rear type Spoked size 18 x 1.85 Brakes: Front type Disc brake (single) operation Right-hand drive Rear type Drum brake operation Right foot drive Suspension: Front Telescopic fork Rear...
Page 21: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model TTR 230T Head: <0.03 mm> Warping threshold * The lines indicate measurement in right angle Cylinder: Diameter 69.970~70.020 mm <Wear threshold> <70.100 mm> Measuring point(a) 40 mm Camshaft: Transmission By link(LE) External shaft diameter 24.960~24.980 mm Shaft clearance - bearing 0.020~0.061 mm...
Page 22 SPEC MAINTENANCE SPECIFICATIONS Model TTR230T Exhaust Head diameter ”A” 28.4~28.6 mm Face width ”B” 2.260 mm Seat width ”C” 0.9~1.1 mm Edge thickness “D” 0.8~1.2 mm External stem diameter INTAKE 5.975~5.990 mm EXHAUST 5.960~5.975 mm Internal guide diameter INTAKE 6.000~6.012 mm EXHAUST 6.000~6.012 mm Stem –...
Page 23 SPEC MAINTENANCE SPECIFICATIONS Model TTR230T Piston: Piston diameter “D” 69.925~69.975 mm Measuring point “H” 4.0 mm Piston offset 0.5 mm Piston offset position Intake side Cylinder – piston clearance 0.035~0.055 mm <Clearance limit> <0.15 mm> Piston rings: Type: Top ring Round Secondary ring Flat...
Page 24 SPEC MAINTENANCE SPECIFICATIONS Model TTR230T Clutch: Friction discs: Thickness 2.90~3.10 mm Quantity 6-piece <Wear threshold> <2.80 mm> Steel discs: Thickness 1.50~1.70 mm Quantity 5-piece <Warping threshold> <0.20 mm> Clutch springs: Free length 37.3 mm Quantity 4-piece Minimum free length 35.3 mm Clutch hub: Clearance 0.010~0.044 mm...
Page 25 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE ENGINE Tightening torque Part to be tightened Description Qty Note N.m Kgf.m ft.lb Spark plug 17.5 1.75 12.9 Oil flow bolt Hexagonal bolt Head and cylinder Bolt Apply oil on the washer Head Bolt Oil inspection Cylinder head cover Bolt Valve cover...
Page 26 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Description Note N.m Kgf.m ft.lb Side cover - right Bolt 0.70 Side cover - right Bolt 2.30 Side cover - left Bolt 2.30 Side cover - left Bolt 0.70 Battery case Bolt 0.70 Crankcase...
Page 27 SPEC MAINTENANCE SPECIFICATIONS Tightening sequence: Head Crankcase Right side Left side Lubrication scheme: Forced feeding Sprinkle Clutch Main shaft Gear Shifting fork Secondary shaft Gear Oil pump Starting clutch Connecting rod Crankshaft (lower portion) Connecting rod (upper portion) Bypass valve Balancer Camshaft Oil filter...
Page 28: Frame
SPEC MAINTENANCE SPECIFICATIONS FRAME Steering system: Roller bearing type conical top and bottom Front suspension: Suspension travel 240 mm Free suspension spring length 614.2 mm (k1) 3.43 N/mm (0.34 Kg/m) Spring force/travel (k2) 4.80 N/mm (0.48 Kg/m) 161 mm Oil level Oil capacity 352 cm suspension oil 10W or equivalent...
Page 29 SPEC MAINTENANCE SPECIFICATIONS Front disc brake: Type single Disc external diameter 220 mm Disc thickness 3.5 mm Disc pad thickness 5.2 mm <Wear threshold> <0.8 mm> Master cylinder internal diameter 11 mm Disc brake caliper internal diameter 25.4 x 2 mm Brake fluid type DOT Nº...
Page 30 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE Tightening torque Part to be tightened Description Note N.m Kgf.m ft.lb Engine support (front and bottom) and frame Self-locking nut 33.9 Engine support (front and bottom) and engine Self-locking nut 33.9 37.5 Engine support (front and top) and frame Bolt 27.7 3.25...
Page 31 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Note Description Kgf.m ft.lb Front wheel axle Brake pedal 22.1 Shaft Shift lever Bolt 4.35 Side stand Self-locking nut 4.75 Footboard Flange bolt Brake cylinder Bolt Bleeding bolt Bolt Dowel pin, Disc brake caliper 13.2 Front disc brake Flange bolt...
Page 32 29.5° at 7,500 rpm Advance type Electric C.D.I.: Model/Manufacturer AZ071000-2680/DENSO Pulse coil resistance (COR) 192~288 ohm at 20°C (Blue/yellow-green) Ignition coil: 2JN/YAMAHA Model/Manufacturer 0.18~0.28 ohm at 20°C Primary winding resistance 6.3~9.5 K ohm at 20°C Secondary winding resistance 6.0 mm...
Page 33: Electric System
SPEC MAINTENANCE SPECIFICATIONS TTR230T Model Electric starting system: Type Constant mesh Starting motor: Model/Manufacturer 1C6/YAMAHA Output power: 0.4 KW Brush length 10.0 mm <Limit> <3.5 mm> Switch diameter 22.0 mm <Limit> <21.0 mm> Mica depth 1.5 mm Starting relay: Model/Manufacturer...
Page 34: General Torque Specifications
SPEC GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS This attachment specifies the tightening General torque torque for ISO Standard threads. The specifications torque specifications for components or (Nut) (Bolt) Kg.m ft.lb special assemblies are included in the respective sections of this manual. To 10 mm 6 mm prevent warping, tighten the assembly bo-...
Page 35: Lubrication Points And Lubricant Types
Piston and piston rings Piston pin Valve stem and guides Retainer (valve stem) Rocker shaft and rocker Cams and roller bearing (Camshaft) O-ring (Drain plug) Clutch bar Primary gear and main shaft Gearbox Shift lever Crankcase surfaces Yamaha Bond nº1215 Glue 2-18...
Page 36: Frame
SPEC LUBRICATION POINTS AND LUBRICANT TYPES FRAME Lubrication points Symbol Speedometer Retainer lips (all) Wheel axle (front and rear) Rear wheel hub Brake shoe plate, shaft and pin Bushes (balance) and covers Spacer (balance) Pivot shaft (balance) Bush (shock absorber) Cap (Shock absorber and relay arm) Bush (relay arm and union arm) Bush (relay arm and union arm)
Page 37: Lubrication Diagram
SPEC LUBRICATION DIAGRAM LUBRICATION DIAGRAM 1 Oil pump 2-20...
Page 38 SPEC LUBRICATION DIAGRAM Oil pump Oil filter Filter cover O-ring Bolt O-ring Gear cover Pump cover gasket Oil strainer Spring O-ring Drain plug 2-21...
Page 39: Cable Routing
SPEC CABLE ROUTING HANDLE BAR 1 Accelerator cable - Main A Route the cables into the slot. 2 Accelerator cable - Return 3 Starting switch harness B Fasten the harnesses with the tie wrap. 4 Cable routing slot 5 Clutch cable 6 Engine stop harness 7 Clutch switch harness 8 Ignition switch...
Page 40: Front
SPEC CABLE ROUTING FRONT 1 Accelerator cable 2 Brake hose 3 Starting switch harness A Route the cables into the slot 4 Clutch cable B Route the hose into the support 5 Starting switch connector C Fasten the connectors in the support 6 Ignition switch connector D Route the harness through the opening 7 Clutch switch connector...
Page 41: Motorcycle - Right Side
SPEC CABLE ROUTING MOTORCYCLE (RIGHT SIDE) A The harness should not touch the bolt 1 Clutch cable B Fasten the cables by using the clamps 2 Negative cable (ground) C The accelerator cable should not touch 3 Ignition coil the ignition coil 4 AC magnet harness 5 Starting motor cable 6 High voltage cable...
Page 42: Motorcycle - Left Side
SPEC CABLE ROUTING MOTORCYCLE (LEFT SIDE) 1 Main harness Route the brake hose through the guide. 2 Tank breather hose Fasten the brake hose as per the figure. 3 Accelerator cables (main and return) The final draining hose cutting shall face the motorcycle 4 Carburetor draining hose rear side.
Page 43: Internal Opening
SPEC CABLE ROUTING INTERNAL OPENING 1 Clutch cable 2 Main harness 3 Regulating rectifier harness 4 Starting motor cable 5 Negative cable (ground) 6 AC magnet harness 2-26...
Page 44: Battery And Components
SPEC CABLE ROUTING BATTERY AND COMPONENTS 1 CDI Unit A Starting relay connection with the 2 Negative cable (ground) battery positive pole. 3 Harness negative wire 4 Positive cable 5 AC magnet harness 6 Main harness 7 Starting motor cable 8 Starting relay harness 9 Safety fuses 2-27...
Page 45 INSP ADJUS CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTS INTRODUCTION ..................3-1 PERIODIC MAINTENANCE / POLLUTANT EMISSION CONTROL ..3-1 GENERAL MAINTENANCE / LUBRICATION ..........3-2 SEAT, FUEL TANK AND COVERS ............. 3-3 REMOVAL ................... 3-3 INSTALLATION ................... 3-5 ENGINE ....................... 3-6 VALVE CLEARANCE ADJUSTMENT..........
Page 46: Electric System
INSP ADJUS WHEEL INSPECTION .............. 3-40 WHEEL SPOKE INSPECTION AND TIGHTENING ......3-40 CABLE INSPECTION AND LUBRICATION........3-40 PEDAL/LEVER AND SIDE SUPPORT LUBRICATION....3-41 REAR SUSPENSION LUBRICATION .......... 3-41 ELECTRIC SYSTEM ................ 3-42 BATTERY INSPECTION ..............3-42 FUSE INSPECTION ................ 3-45...
Page 47: Periodic Inspection And Adjustments
NOTE: From 4,200 mi. (7,000 km) or 9 months, repeat the maintenance intervals at each 1,800 mi (300 km) or 3 months. We recommend that items marked with an (*) be overhauled at a Yamaha authorized dealer shop. INITIAL EACH...
Page 48: General Maintenance / Lubrication
Lubricate the lever and the cable. We recommend that these items be overhauled at a Yamaha authorized dealer shop. NOTE: Increase the frequency of air filter maintenance when it is used in dust or mud.
Page 49: Seat, Fuel Tank And Covers
INSP SEAT, FUEL TANK, AND COVERS ADJUS SEAT, FUEL TANK AND COVERS REMOVAL WARNING Support the motorcycle firmly preventing it from falling. 1. Remove: Side cover (LH) Remove the bolts 1 NOTE: Pull the cover towards you. To simplify, use the opening 3 on the side cover 4.
Page 50 INSP SEAT, FUEL TANK AND COVERS ADJUS 3. Remove: Seat Loosen the setscrews on both sides 1 . Remove the seat, pulling it towards the rear of the motorcycle. NOTE: Observe the fittings on the tank 1 and frame 2, indicated in the figure. 4.
Page 51: Installation
INSP SEAT, FUEL TANK AND COVERS ADJUS 7. Remove: Setscrews on both sides 1 Rubber belt. Remove the fuel tank. INSTALLATION Reverse the “REMOVAL” procedures. Check the following items: 1. Install: Fuel tank Fuel tank bolt 10 N.m (1.0 Kg.m ; 7.2 ft.lb) 2.
Page 52: Engine
INSP VALVE CLEARANCE ADJUSTMENT ADJUS ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: The valve clearance should be measured with the engine cold. Adjust the valve clearance with the piston at the top dead center (TDC) at the compression stroke. WARNING Support the motorcycle firmly preventing it from falling.
Page 53 INSP VALVE CLEARANCE ADJUSTMENT ADJUS Align the “T” mark 1 on the rotor with the stationary mark 2 on the case cover. With the “T” mark aligned with the stationary mark, the piston is at the top dead center (TDC). NOTE: TDC checking at the compression stroke: Both rockers should allow for a clearance...
Page 54 INSP VALVE CLEARANCE ADJUSTMENT ADJUS Lock-nut: 13.5 N.m (1.35 Kg.m; 7.2 ft.lb) Measure the valve clearance. If the clearance is incorrect, repeat the steps above until the specified clearance is established. ************************************ 7. Install: Reverse the removal steps: Case cover covers Head covers Head cover bolts: 10N.m (1,0 Kg.m;...
Page 55: Camshaft Chain Adjustment
CAMSHAFT CHAIN ADJUSTMENT INSP / IDLE SPEED ADJUS CAMSHAFT CHAIN ADJUSTMENT Automatic adjustment. IDLE SPEED ADJUSTMENT Let the engine run for some minutes for warming up. 1. Connect: Tachometer 1 to spark plug cable Tachometer: 90890-03113 2. Check: Idle speed Out of specification =>...
Page 56: Throttle Cable Free Play Adjustment
INSP THROTTLE CABLE FREE PLAY ADJUSTMENT ADJUS 4. Remove: Tachometer 5. Adjust: Throttle cable free play See Section “THROTTLE CABLE FREE PLAY ADJUSTMENT.” THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, adjust the idle speed. 1.
Page 57 INSP THROTTLE CABLE FREE PLAY ADJUSTMENT ADJUS ************************************* Adjustment steps: NOTE: Resting the throttle cable # 1 1 is extended and cable # 2 2 is retracted relative to the driving support. 1st step: Loosen the lock-nut 3 of cable #2. Turn the adjuster 4 and completely eliminate the cable #2 free play.
Page 58: Spark Plug Inspection
INSP SPARK PLUG INSPECTION ADJUS SPARK PLUG INSPECTION 1. Disconnect: Spark plug cap 1 2. Remove: Spark plug CAUTION: When removing the spark plug, take care to prevent objects from falling into the engine. 3. Inspect: Spark plug - Type Incorrect =>...
Page 59: Ignition Point Inspection
INSP IGNITION POINT INSPECTION ADJUS 7. Tighten: Spark plug Spark plug 17.5N.m (1.75Kg.m) NOTE: Before installing the spark plug, clean the spark plug thread and gasket surfaces. If no torquemeter is available, a good estimate for the correct torque is as follows: Tighten from ¼...
Page 60: Compression Pressure Measurement
IGNITION PRESSURE CHECK/COMPRESSION PRESSURE INSP MEASUREMENT ADJUS ************************************* Checking steps: Remove the cover 1 Start the engine. Engine rotation: 1,400 rpm CAUTION: Under severe conditions, oil may be sprayed while the engine is running. Therefore, take care when carrying out this check. Using the strobe light check if the stationary point 2 stays within the ignition range 3 indicated in the magnet...
Page 61 INSP COMPRESSION PRESSURE MEASUREMENT ADJUS 2. Let the engine run for some minutes for warming up. 3. Turn the engine off. 4. Disconnect: Spark plug cap 5. Remove: Spark plug See Section “SPARK PLUG INSPECTION”. 6. Connect: Compression meter1 Adapter 2 Compression meter: 90890-03081 Adapter...
Page 62 INSP COMPRESSION PRESSURE MEASUREMENT ADJUS Compression pressure (at sea level) Standard: 1,200 KPa (12 kg/cm², 171 psi) Minimum: 960 KPa (9.6 kg/cm², 128 psi) Maximum: 1,300 KPa (13 kg/cm², 185 psi) If the pressure is below the minimum level: 1) Pour some drops of oil into the affected cylinder.
Page 63: Engine Oil Level Check
INSP ENGINE OIL LEVEL CHECK ADJUS ENGINE OIL LEVEL CHECK CAUTION: Do not apply additives. The engine oil also lubricates the clutch and additives can cause the clutch to slip. Prevent dust from entering the engine. 1. Place the motorcycle on a flat area. 2.
Page 64: Engine Oil Change
INSP ENGINE OIL CHANGE ADJUS 5. Let the engine run for some minutes for warming up. CAUTION: Do not start the engine if the oil reservoir is empty. 6. Stop the engine and check the oil level again. Amount of oil: Periodic change =>...
Page 65 INSP ENGINE OIL CHANGE ADJUS 3. Remove: Oil filling screw1 Drain plug 2 NOTE: When removing the drain plug 2, the spring 3, oil strainer 4, and O-ring 5 will come out. Take care not to lose these parts. 4. Drain: Engine oil 5.
Page 66 INSP ENGINE OIL CHANGE ADJUS Bolts (oil filter cover) 10N.m (1.0 Kg.m ; 7.2 ft.lb) Drain plug: 43N.m (4.3 Kg.m ; 31ft.lb) 9. Replenish with oil. Recommended engine oil: YAMALUBE4, SAE10W30 or SAE20W40 (for USA/CAN) SAE10W30 or SAE10W40 or SAE20W40 or SAE20W50 (for AUS) CAUTION: Do not apply additives.
Page 67 INSP ENGINE OIL CHANGE ADJUS Engine oil change (with filter replacement) 1. Place the motorcycle on a flat area. 2. Warm up the engine for some minutes and, then, stop the engine. Place a tray under the drain plug. 3. Remove: •...
Page 68 INSP ENGINE OIL CHANGE ADJUS 7. Check: • O-rings 1 • Damage => Replace. 8. Clean: •Oil filter 2 Clean using kerosene Clogging/damages => Replace. 9. Install: • Oil filter 1 CAUTION: Install the oil filter as shown. • Oil filter cover •...
Page 69: Oil Pressure Check
OIL PRESSURE CHECK / INSP CLUTCH ADJUSTMENT ADJUS 11. Install: • Oil filling screw 12. Check: • Oil level See Section “ENGINE OIL LEVEL CHECK.” • Oil pressure See Section “OIL PRESSURE CHECK.” • Oil leakage OIL PRESSURE CHECK 1. Remove: •...
Page 70: Air Filter Cleaning
INSP AIR FILTER CLEANING ADJUS NOTE: If the clutch cable free play is incorrect, adjust it using the adjuster (close to the clutch lever). 2. Adjust: • Clutch cable free play ************************************ Main lever adjuster: • Loosen the lock-nut 1 •...
Page 71 INSP AIR FILTER CLEANING ADJUS 2. Remove: • Thumb nut 1 • Washer 2 • Air filter element 3 • Air filter guide 4 CAUTION: Do not start the engine without the air filter element, since this allows non-filtered air to enter, resulting in wear and potential damage to the engine.
Page 72: Carburetor Connection Check
CARBURETOR CONNECTION CHECK /FUEL HOSE / INSP BREATHER HOSE ADJUS 6. Install: •Air filter element, reverse procedures in “Remove.” NOTE: • When installing the element in the filter box, fasten it firmly in the seat. 7. Install: •Air filter box cover See Section “SEAT, FUEL TANK AND COVERS.”...
Page 73: Exhaust System Check
EXHAUST SYSTEM CHECK/ CORE CLEARING INSP ADJUS EXHAUST SYSTEM CHECK 1. Check: • Exhaust tube 1 • Muffler 2 Damage/breakage => Replace. • Gasket 3 Gas leakage => Replace. Bolt 4 (exhaust tube and cylinder): 10N.m (1.0 Kg.m; 7.2 ft.lb) Bolt 5 (muffler and frame): 40N.m (4.0 Kg.m;...
Page 74: Front Brake Pad Check
FRONT BRAKE FLUID LEVEL CHECK/FRONT BRAKE PAD INSP CHECK ADJUS FRONT BRAKE FLUID LEVEL CHECK 1. Place the motorcycle on a flat area. NOTE: • Place the motorcycle upright when checking the brake fluid level. • When checking the brake fluid level, make sure the top of the master cylinder is in the horizontal.
Page 75: Air Bleeding (Front Brake System)
INSP AIR BLEEDING ADJUS AIR BLEEDING (FRONT BRAKE SYSTEM) WARNING Bleed the brake system if: • The is dismounted. • The brake hose is loose or replaced. • The brake fluid level is too low. • The brake is malfunctioning. A hazardous efficiency loss may occur if the system does not bleed properly.
Page 76: Rear Brake Adjustment
INSP REAR BRAKE ADJUSTMENT ADJUS NOTE: If the bleeding is difficult, it may be necessary to let the brake system stabilize for some hours. Repeat the bleeding proce- dure when the small bobbles have vanished from the system. Replenish the brake fluid up to the level. Recommended brake fluid: DOT #4 WARNING...
Page 77: Brake Lining Check
INSP BRAKE LINING CHECK ADJUS • Tighten the lock-nut. Lock-nut: 7N.m (0.7 Kg.m ; 5.1 ft.lb) WARNING After adjusting the height, adjust the free play of the brake pedal. ************************************* 3. Check: • Brake pedal free play b Out of specification => Adjust. Brake pedal height: 20 ~ 30 mm (0.8 ~1.2 in) NOTE:...
Page 78: Transmission Chain Free Play Adjustment
TRANSMISSION CHAIN FREE PLAY ADJUSTMENT / INSP TRANSMISSION CHAIN LUBRICATION ADJUS TRANSMISSION CHAIN FREE PLAY ADJUSTMENT NOTE: The transmission chain should be inspected before each trip and, if necessary, adjusted. Before checking and/or adjusting, place the transmission at the dead center, rotate the rear wheel some turns and check the free play at various points until find the tightest point.
Page 79: Transmission Chain Lubrication
TRANSMISSION CHAIN FREE PLAY ADJUSTMENT / INSP TRANSMISSION CHAIN LUBRICATION ADJUS 3. Adjust: • Transmission chain free play ************************************ Adjustment steps: • Loosen the rear brake adjuster 1 and the shaft nut 2. • Turn the tighteners 3 clockwise or counterclockwise until establish the specified free play.
Page 80: Steering Column Adjustment
INSP STEERING COLUMN ADJUSTMENT ADJUS STEERING COLUMN ADJUSTMENT WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area. 2. Lift the front wheel placing a support under the engine. 3. Check: • Steering column roller bearing Hold the front fork and move it gently to and fro.
Page 81 INSP STEERING COLUMN ADJUSTMENT ADJUS • Loosen the ring nut (lower) one turn. • Tighten the ring nut (lower) again using the special tool. WARNING Avoid excessive torque. Ring nut (lower) (final torque): 6.5N.m (0.65 Kg.m; 4.7 ft.Ib) • Check the steering column turning the front tire from side to side, after the adjustment above.
Page 82: Front Suspension Inspection
INSP FRONT SUSPENSION INSPECTION ADJUS FRONT SUSPENSION INSPECTION WARNING The motorcycle should be firmly supported in order to prevent falls. 1. Place the motorcycle on a flat area. 2. Remove: • Clamp 1 • Dust cover 2 3. Check: • Internal tube 1 Scratches/damage =>...
Page 83 INSP REAR SHOCK ABSORBER ADJUSTMENT ADJUS ************************************ Adjustment steps: Spring preload • Loosen the lock-nut 2 using the tool: 90890-01443. • Turn the adjuster 1 inward or outward. Adjustment tool: 90890-01443 To turn inward => Increases the spring preload. To turn outward => Reduces the spring preload.
Page 84: Tire Inspection
INSP TIRE INSPECTION ADJUS TIRE INSPECTION 1. Measure: • Tire pressure Out of specification => Adjust. CAUTION: The pressure should be checked and corrected when the tire temperature equals to the room temperature. The pressure should be compatible with the total weight of load, driver, passenger, and accessories (fairing, side bags, etc., when approved for this model) and the speed of the vehicle.
Page 85 INSP TIRE INSPECTION ADJUS 2. Inspect • Tire surfaces Wear/damages => Replace. Minimum groove depth (front and rear): 0.4 mm (0.16 in) 1 Groove depth 2 Side cover WARNING 1. Riding with worn tires is dangerous. When the tire grooves show lines, replace the tire immediately.
Page 86: Wheel Inspection
WHEEL INSPECTION/ WHEEL SPOKE INSPECTION AND INSP TIGHTENING/ CABLE INSPECTION AND LUBRICATION ADJUS WHEEL INSPECTION 1. Check: • Wheels Damage/warping => Replace. NOTE: Carry out the wheel swinging after each tire replacement. WARNING Do not try to carry out repairs to the wheels, even small repairs.
Page 87: Pedal/Lever And Side Support Lubrication
PEDAL AND SIDE SUPPORT LUBRICATION/ REAR INSP SUSPENSION LUBRICATION ADJUS PEDAL, LEVER AND SIDE SUPPORT LUBRICATION Lubricate hinges Recommended lubricant: Lithium-based grease REAR SUSPENSION LUBRICATION Lubricate the rear balance 1 Recommended lubricant: Lithium-based grease Grease fitting 1 3-41...
Page 88: Electric System
INSP BATTERY INSPECTION ADJUS ELECTRIC SYSTEM BATTERY INSPECTION NOTE: The battery is a sealed MF type battery. Therefore, it is possible to measure the specific gravity of the electrolyte in a testing sequence. Then, in order to check the conditions of the battery, measure the voltage at the terminals.
Page 89 INSP BATTERY INSPECTION ADJUS WARNING The battery solution is a hazardous substance, containing hydrogen sulfate. It is highly toxic and caustic. Observe the following preventive measures: • Avoid the contact of body parts with the electrolyte, since burning or permanent damage to the eyes may result.
Page 90 INSP BATTERY INSPECTION ADJUS 4. Check: • The battery conditions ************************************ Check steps: • Connect the voltmeter to the battery terminals. Testing terminal (+) => Battery terminal (+) Testing terminal (-) => Battery terminal NOTE: The conditions of a discharged MF battery can be checked through the measurement of the voltage in the open circuit (voltage measured with the positive terminal...
Page 91: Fuse Inspection
INSP BATTERY INSPECTION/ FUSE INSPECTION ADJUS • Take special care to make sure the jaws contact efficiently the battery terminals and do not short. (A corroded jaw may cause the battery terminal to overheat. A weak jaw spring may generate sparks.) •...
Page 92 INSP FUSE INSPECTION ADJUS 3. Inspect: • Fuse ************************************ Inspection steps: • Connect a multimeter to the fuse and check the continuity. NOTE: Adjust the switch to “ x1”. Multimeter: 90890-01312 If the device indicates, the fuse is burnt. ¥ Replace.
Page 93: Engine Inspection
ENGINE CHAPTER 4. ENGINE INSPECTION ENGINE REMOVAL ................4-1 SEAT, FUEL TANK AND COVERS ..........4-1 CRANKCASE GUARD ..............4-1 ENGINE OIL ................4-1 BATTERY CABLES ..............4-2 EXHAUST TUBE AND MUFFLER ..........4-2 BREATHER HOSE AND CARBURETOR ........4-3 CABLES AND WIRING ..............4-3 TRANSMISSION CHAIN .............4-5 ENGINE REMOVAL ..............4-6 ENGINE DISMOUNTING ..............4-8 HEAD, CYLINDER AND PISTON ..........4-8...
Page 94 ENGINE CAMSHAFT CHAIN, GEAR, CHAIN GUIDE AND TENSIONER ............4-34 CYLINDER AND PISTON ..............4-35 PISTON RINGS ..................4-37 PISTON PIN ..................4-38 CRANKSHAFT..................4-39 BALANCER GEARS ................4-40 PRIMARY GEAR .................. 4-40 CLUTCH ....................4-41 TRANSMISSION AND SHIFTING FORK ..........4-43 OIL PUMP AND FILTER STRAINER .............
Page 95: Chapter 4. Engine Inspection
ENGINE ENGINE REMOVAL ENGINE INSPECTION ENGINE REMOVAL NOTE: It is not necessary to remove the engine order remove following components: • Head • Cylinder • Piston • Clutch • Oil pump • Magnet rotor SEAT, FUEL TANK AND COVERS 1. Remove: •...
Page 96: Battery Cables
ENGINE ENGINE REMOVAL BATTERY CABLES 1. Disconnect: • Battery negative cable 1 EXHAUST TUBE AND MUFFLER 1. Remove: • Bolt 1 (tie wrap) • Bolt 2 (exhaust tube) • Muffler 3 • Exhaust tube 4...
Page 97: Breather Hose And Carburetor
ENGINE ENGINE REMOVAL BREATHER HOSE AND CARBURETOR 1. Disconnect: • Engine breather hose 1 2. Drain: • Fuel (bowl chamber) 3. Loosen: • Bolts 1 (carburetor connections) NOTE: Move the carburetor tie wrap 2 back. 4. Loosen: • Bolts 3 (intake manifold) 5.
Page 98 ENGINE ENGINE REMOVAL 3. Disconnect: • Spark plug cap 1 4. Disconnect: • Magnet connectors 1 5. Remove: • Starter motor wire 2 • Starter motor 3 6. Disconnect: • Ground wire • Starter motor wire...
Page 99: Transmission Chain
ENGINE ENGINE REMOVAL TRANSMISSION CHAIN 1. Loosen: • Shaft castellated nut 1 2. Remove: • Shift lever 1 • Case cover 2 3. Remove: • Bolts 1 • Pinion gear fastener 2 • Transmission chain 3 NOTE: Loosen the bolt while engaging the rear brake.
Page 100: Engine Removal
ENGINE ENGINE REMOVAL ENGINE REMOVAL 1. Place a suitable support under the engine. WARNING The motorcycle should be firmly supported in order to prevent falls. 2. Remove: • Setscrews 1 (front lower) 3. Remove: • Setscrews 1 (rear lower) 4. Remove: •...
Page 101 ENGINE ENGINE REMOVAL 6. Remove: • Engine (through the right side of the motorcycle) NOTE: After the engine has been removed, place the other side of the balance properly using a suitable shaft.
Page 102: Engine Dismounting
ENGINE ENGINE DISMOUNTING ENGINE DISMOUNTING HEAD, CYLINDER, AND PISTON NOTE: With the engine mounted, the head, camshaft, and cylinder overhauling is possible, removing the following parts: • Side covers • Seat • Fuel tank • Exhaust tube • Carburetor • Clutch cable •...
Page 103 ENGINE DISMOUNTING ENGINE 4. Remove: • Valve cover (Intake) 1 • Valve cover (Exhaust) 2 5. Remove: • Head cover 1 • O-ring 2 6. Align: • “T” mark on the rotor with the stationary mark on the case cover. ************************************ Steps for PMS alignment: •...
Page 104 ENGINE ENGINE DISMOUNTING 7. Loosen: • Tensioner cover bolt 1 8. Remove: • Chain tensioner 2 9. Remove: • Bolt 1 • Camshaft gear 2 NOTE: Fasten to the camshaft chain 3 using a wire in order to prevent it from falling into the case.
Page 105 ENGINE ENGINE DISMOUNTING 12. Remove: • Camshaft chain guide (Exhaust) 1 • Dowel pins 2 • Seal 3 • Head gasket 4 13. Remove: • Bolts 1 • Clutch cable fastener 2 14. Remove: • Cylinder 1 15. Remove: • O-ring 1 •...
Page 106: Magnet Rotor And Starting Gears
ENGINE ENGINE DISMOUNTING 16. Remove: • Piston pin lock 1 • Piston pin 2 • Piston 3 NOTE: • Before removing the piston pin lock, cover the case using a cloth in order to prevent the lock from falling into the case. •...
Page 107 ENGINE ENGINE DISMOUNTING 3. Remove: • Dowel pins 1 • Gasket 2 (case cover) • Spacer 3 • Shaft 4 • Starting gear 5 4. Remove: • Bolt 1 (rotor) NOTE: Loosen the rotor bolt holding the rotor with the fastener 2. Rotor fastener: 90890-01701 CAUTION:...
Page 108 ENGINE ENGINE DISMOUNTING 6. Remove: • Gear 1 • Washer 2 7. Remove: • Chain guide 1 (Intake) • Camshaft chain 2 OIL FILTER 1. Remove: • Oil filter cover 1 2. Remove: • Oil filter 1 • O-rings 2 4-14...
Page 109: Clutch, Oil Pump And Balancer Gear
ENGINE ENGINE DISMOUNTING CLUTCH, OIL PUMP AND BALANCER GEAR NOTE: With the engine installed on the frame, the clutch and oil pump overhauling is possible, removing the following parts: • Crankcase guard • Brake pedal 1. Remove: • Case cover 1 (RH) NOTE: Loosen the bolts ¼...
Page 110 ENGINE ENGINE DISMOUNTING 4. Remove: • Clutch drive stem 1 5. Straighten out: • Lock washer flange 1 6. Loosen: • Nut 2 (clutch hub) NOTE: Loosen the nut (from the clutch hub) holding the clutch hub with the universal clutch fastener 3.
Page 111 ENGINE ENGINE DISMOUNTING 9. Remove: • Oil pump assembly 1 10. Remove: • Gasket 1 (oil pump) 11. Straighten out: • Lock washer flange 1 12. Loosen: • Nut 2 (Crankshaft) • Nut 3 (Balancer shaft) NOTE: • Place a cloth or an aluminum plate between the teeth of the primary and balancer shaft gears.
Page 112 ENGINE ENGINE DISMOUNTING 13. Remove: • Primary gear 1 • Special washer 2 • Balancer gear and impact hub 3 • Key 4 • Special washer 5 • Plate 6 • Balancer gear 7 • Key 8 SHIFT SHAFT NOTE: With the engine installed on the frame, the shift shaft overhauling is possible, removing the following parts:...
Page 113: Case (Right)
ENGINE ENGINE DISMOUNTING 2. Remove: • Section 1 Use a wrench. NOTE: When removing the section, the dowel pin 2 may fall. Take care not to lose it. 3. Remove: • Lock 1 • Spacer 2 (Driving shaft) • Lock 3 CASE (RIGHT) 1.
Page 114: Balancer, Transmission And Shifting Fork
ENGINE ENGINE DISMOUNTING 2. Remove: • Case: The slots 1 are specific for separating the cases. Use a screwdriver 2, applying the same force on both sides in order to separate the cases. CAUTION: • The cases should be separated by removing the right case.
Page 115: Crankshaft
ENGINE ENGINE DISMOUNTING 3. Remove: • Secondary shaft assembly 1 • Washer 2 4. Remove: • Balancer shaft 1 5. Remove: • Dead center switch 1 CRANKSHAFT 1. Remove: • Crankshaft assembly 1 Use the case separator 2 and the adapter 3.
Page 116: Rocker And Camshaft
ENGINE ENGINE DISMOUNTING 2. Remove: • Elastic pin 1 • Pin with hole 2 • Spring 3 ROCKER AND CAMSHAFT NOTE: With the engine installed on the frame, the camshaft and rocker overhauling is possible, removing the following parts: • Side covers •...
Page 117: Valves
ENGINE ENGINE DISMOUNTING 4. Remove: • Rocker shaft • Rocker NOTE: Remove the rocker shaft, using the sliding hammer 1 and weight 2. Sliding hammer: 90890-01083 Weight: 90890-01084 VALVES NOTE: Before removing the internal parts (valves, springs, valve seat, etc.) from the head, check the valve seal.
Page 118 ENGINE ENGINE DISMOUNTING 2. Remove: • Valve locks 1 NOTE: Remove the valve locks when compressing the springs using the spring clamp 2. Valve spring clamp: 90890-04019 3. Remove: • Valve retainer 1 • Valve spring 2 (External) • Valve spring 3 (Internal) •...
Page 119: Inspection And Repair
ENGINE INSPECTION AND REPAIR INSPECTION AND REPAIR HEAD 1. Remove: • Carbon fouling (from the combustion chamber) Use a round scraper 1. NOTE: Do not use pointed instruments and avoid producing scratches on: • Spark plug thread • Valve seat 2.
Page 120: Valve Seat
ENGINE INSPECTION AND REPAIR NOTE: Rotate the head some turns in order to avoid excessive removal of material only on one side. VALVE SEAT 1. Remove: • Carbon fouling (from the valve and seat) 2. Inspect: • Valve seat Wear => Grind the seat. 3.
Page 121 ENGINE INSPECTION AND REPAIR 4. Grind: • Valve seat Use 30°, 45° and 60° valve grinders 1. Valve seat milling cutter: YM - 91043 CAUTION: When turning the milling cutter, keep a 4~5 kg pressure. Mill the seat as follows: Section Cutting 30°...
Page 122 ENGINE INSPECTION AND REPAIR C The seat is thin and is resting on the external side of the valve face. Milling cutter Desired result 30° To center the seat and establish an 1,0 mm 45° width D The seat is thin and is resting on the valve internal face.
Page 123: Valves And Valve Guides
ENGINE INSPECTION AND REPAIR NOTE: In order to achieve the best polishing results, occasionally and lightly, beat the valve face on the seat while turning the valve in both directions between the hands. • Apply fine abrasive paste to the valve face and repeat the same steps.
Page 124 ENGINE INSPECTION AND REPAIR 2. Replace: • Valve guide 1 ************************************ Replacement steps: NOTE: Heat the cylinder in an oven at 100° C (212° F) in order to facilitate the removal and installation of the guide and ensure the correct relationship. •...
Page 125: Valve Spring
ENGINE INSPECTION AND REPAIR 5. Measure: • Thickness a Out of specification => Replace. Thickness: 0.8-1.2 mm (0.031 ~ 0.047 in) 6. Measure: • Warping (valve stem) Out of specification => Replace. Warping: Less than 0.010 mm NOTE: • Replace the guide and retainers whenever the valve is replaced.
Page 126: Camshaft
ENGINE INSPECTION AND REPAIR 2. Measure: • Spring load 1 Out of specification => Replace. a installed spring length. Spring load: Internal External 30.5 mm 32.0 mm Intake 7.7~9.4 mm 13.1~16.1 mm Exhaust 7.7~9.4 mm 13.1~16.1 mm 3. Measure: • Spring inclination a •...
Page 127: Rocker And Rocker Shaft
ENGINE INSPECTION AND REPAIR Cam height Exhaust: a 30.15~30.25 mm b 36.51~36.61 mm 3. Measure: • Warping (Camshaft) Out of specification => Replace. Warping (Camshaft) Less than 0.03 mm 4. Measure: • Clearance between camshaft and bearing Out of specification => Measure the camshaft bearing diameter.
Page 128: Camshaft Chain, Gear, Chain Guide And Tensioner
ENGINE INSPECTION AND REPAIR 2. Check: • Rocker shaft hole 1 • Shaft contact surface 2 • Adjuster surface 3 Wear/dots/scratches/blue color => Replace and inspect the lubrication system. 3. Measure: • Shaft-rocker clearance Shaft-rocker clearance = Internal rocker diameter a External shaft diameter b Out of specification =>...
Page 129: Cylinder And Piston
ENGINE INSPECTION AND REPAIR 3. Check: • Chain guide 1 (Exhaust side) • Chain guide 2 (Intake side) Wear/damages => Replace. 4. Check: • Camshaft chain tensioner clearance ************************************ Checking steps: • Use a screwdriver 1, turning clockwise, to pull and lock the tensioner system. •...
Page 130 ENGINE INSPECTION AND REPAIR 3. Check: • Cylinder liner Wear/scratches => Replace or buff. 4. Measure: • Cylinder – piston clearance ************************************* Measurement steps: • Measure the cylinder diameter “C” using a suitable instrument. a 40 mm from the top of the cylinder. NOTE: Measure the cylinder diameter “C”...
Page 131: Piston Rings
ENGINE INSPECTION AND REPAIR • Determine the cylinder – piston clearance using the following formula: Cylinder – piston clearance = Cylinder diameter “C” Piston skirt diameter “P” Cylinder – piston clearance: 0.035~0.055 mm <limit>: 0,15 mm • If out of specification, grind or replace cylinder, piston, and rings.
Page 132: Piston Pin
ENGINE INSPECTION AND REPAIR 3. Measure: • Inter-tip gap Out of specification => Replace. NOTE: It is not possible to measure the inter-tip gap of the oil ring expander. If the grooved rails of the oil ring have an excessive clearance, replace the 3 rings.
Page 133: Crankshaft
ENGINE INSPECTION AND REPAIR CRANKSHAFT 1. Measure: • Crankshaft width A Out of specification => Replace crankshaft. Crankshaft width: 55.95~56.00 mm • Warping C Out of specification => Replace crankshaft and/or roller bearings. Warping limit: 0.03 mm • Connecting-rod side clearance D Out of specification =>...
Page 134: Balancer Gears
ENGINE INSPECTION AND REPAIR ************************************* Crankshaft mounting: The crankshaft 1 and the crankshaft pin oil passage 2 should be correctly aligned with a maximum tolerance of 1 mm. ************************************* BALANCER GEARS 1. Check: • Balancer driving gear teeth 1 • Balancer gear teeth 2 Wear/damages =>...
Page 135: Clutch
INSPECTION AND REPAIR ENGINE CLUTCH 1. Check: • Friction discs Wear/damages => Replace friction disc assembly. 2. Measure: • Friction disc thickness Out of specification => Replace friction disc assembly. Measure at four tips. Spring free length: Wear Thickness limit Type “A”...
Page 136 ENGINE INSPECTION AND REPAIR 5. Check: • Clutch springs Damages => Replace spring assembly. 6. Measure: • Spring free length a Out of specification => Replace spring assembly. Free length (clutch springs): 37.3 mm < Limit: 35.3 mm > 7. Check: •...
Page 137: Transmission And Shifting Fork
INSPECTION AND REPAIR ENGINE 9. Check: • Pressure plate 1 • Plate 2 • O-ring 3 • Stem 1 4 • Ball 5 Wear/damages => Replace. • Stem 2 6 • Clutch stem 7 Wear/warping/damages => Replace. TRANSMISSION AND SHIFTING FORK 1.
Page 138 ENGINE INSPECTION AND REPAIR 4. Check: • Guide bars Roll the bar on a flat surface Warping => Replace. WARNING Do not try to straighten out the bars. 5. Measure: • Warping (Driving and driven shaft) Out of specification => Replace. Warping: Less than 0,08 mm WARNING...
Page 139: Oil Pump And Filter Strainer
INSPECTION AND REPAIR ENGINE 7. Check: • Shift shaft 1 • Stop stem 2 Damages/warping/wear => Replace. • Torsion spring 3 • Return spring 4 Breakage/damages => Replace. OIL PUMP AND FILTER STRAINER 1. Measure: • Clearance a (between the internal rotor 1 and the external rotor 2) •...
Page 140 ENGINE INSPECTION AND REPAIR ELECTRIC STARTING SYSTEM GEARS 1. Check: • Starting gear teeth 1 • Starting gear teeth 2 Burrs/Roughness/Wear => Replace. 2. Check: • Starting gear (contact surface) Scratches/wear/damages => Replace. 3. Check: • Starting clutch assembly 1 •...
Page 141: Cases
ENGINE INSPECTION AND REPAIR 5. Check: • Pulse coil 1 Charging coil/stator 2 Damages => Replace. CASES 1. Wash the cases thoroughly using kerosene. 2. Clean all gasket surfaces and the contact surfaces of the cases. 3. Check: • Cases Breakage/damages =>...
Page 142: Engine Mounting And Adjustments
ENGINE ENGINE MOUNTING AND ADJUSTMENTS ENGINE MOUNTING AND ADJUSTMENTS VALVES, ROCKER, AND CAMSHAFT 1Valve lock 8 Valve (exhaust) E Lock 2 Valve spring retainer 9 Lock-nut F Valve guide 3 Retainer 0 Adjuster G Camshaft 4 Internal spring A Rocker H Spacer 5 External spring B Rocker shaft...
Page 143: Valves
ENGINE ENGINE MOUNTING AND ADJUSTMENTS ENGINE MOUNTING AND ADJUSTMENTS WARNING engine mounting requires replacement of the following parts with new ones: • O-ring • Gaskets • Retainer • Copper washers • Lock washers • Locks VALVES 1. Remove burrs: • Valve stem head 2.
Page 144: Rocker
ENGINE ENGINE MOUNTING AND ADJUSTMENTS NOTE: Install the valve spring with the longest pitch 7 up. 8 Shorter pitch. 4. Install: • Valve locks 1 NOTE: Install the valve locks while pressing the spring using the valve spring clamp 2. Valve spring clamp: 90890-04019 5.
Page 145 ENGINE ENGINE MOUNTING AND ADJUSTMENTS NOTE: Align the slot 6 of the intake rocker shaft with the head bolt hole 7 and install the rocker shaft. CAUTION: Do not confound the installation direction of the rocker shaft. Take care to install the threaded part facing outward.
Page 146: Crankshaft
ENGINE ENGINE MOUNTING AND ADJUSTMENTS CRANKSHAFT 1 Crankshaft pin 2 Left crankshaft 3 Connecting-rod 4 Lower connecting-rod roller bearing 5 Crankshaft roller bearing 6 Spring 7 Pin with hole 8 Dowel pin CRANKSHAFT WIDTH: < 55.95 ~ 56 mm > WARPING LIMIT: <...
Page 147 ENGINE ENGINE MOUNTING AND ADJUSTMENTS CRANKSHAFT 1. Install: • Crankshaft puller Crankshaft puller assembly: YU-90050 Spacer 1: 90890-04081 Adapter # 12 2: YM-01383 Adapter 3: 90890-01274 Bolt 4: 90890-01275 2. Install: • Crankshaft NOTE: Hold the connecting-rod in the top dead center using one hand while turning the tool nut with the other.
Page 148: Balancer And Transmission
ENGINE ENGINE MOUNTING AND ADJUSTMENTS BALANCER AND TRANSMISSION 1 Pinion gear 8 4th driven gear E 5th driving gear 9 6th driven gear F 3rd driving gear 2 Retainer 0 1st driven gear G 4th driving gear 3 Roller bearing A Roller bearing H Main shaft 4 2nd driven gear...
Page 149 ENGINE MOUNTING AND ADJUSTMENTS ENGINE SHIFTING FORK 1 Fork guide bar (long) 2 Fork # 3 3 Fork # 1 4 Shifting fork 5 Fork guide bar (short) 6 Fork # 2 4-55...
Page 150: Balancer, Transmission And Shifting Fork
ENGINE ENGINE MOUNTING AND ADJUSTMENTS BALANCER, TRANSMISSION AND SHIFTING FORK 1. Install: • Dead center switch 1 2. Install: • Balancer shaft 1 3. Apply: • Molybdenum disulfide-based oil (to main and driven shafts and gears) 4. Install: • Driven shaft assembly 1 •...
Page 151 ENGINE MOUNTING AND ADJUSTMENTS ENGINE • Lock 1 • Special washer 2 I n s t a l l t h e l o c k t i p o n t h e s p e c i a l washer center.
Page 152 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 9. Check: • Transmission operation Irregular operation => Repair. 4-58...
Page 153: Cases
Tighten the bolt together with the 4 Case (L.H.) ground wire. 5 Hose fastener T i g h t e n i n g sequence Glue: 10 N.m      Yamaha Bond # 1215 (1.0 Kg.m ; 7.2 ft.lb) 4-59...
Page 154 CASE (R.H.) 1. Apply: • Glue 1 (to case closing surfaces) Glue: ® Yamaha Bond # 1215 90890-85505 NOTE: Prevent glue from touching the oil galleries. 2. Install: • Dowel pins 2 3. Fit the right case to the left case. Beat slightly using a plastic hammer.
Page 155: Shift Shaft
ENGINE MOUNTING AND ADJUSTMENTS ENGINE SHIFT SHAFT 1 Section 2 Dowel pin (short) 3 Dowel pin (long) 4 Spacer 5 Shift shaft 6 Torsion spring 7 Stop stem 8 Return spring 12N.m (1.2Kg.m ; 8.7 ft.lb) 4-61...
Page 156 ENGINE ENGINE MOUNTING AND ADJUSTMENTS SHIFT SHAFT 1. Install: • Lock 1 • Spacer 2 • Lock 3 2. Install: • Section 1 • Dowel pin (long) 2 • Dowel pin (short) 3 NOTE: Install the long dowel pin 2 on the mark 3.
Page 157 ENGINE MOUNTING AND ADJUSTMENTS ENGINE 6. Install • Stop stem 1 • Return spring 2 • Shift shaft 3 • Torsion spring 4 NOTE: • Place the return spring 2 and the stop stem 1 in the correct position. • Push the shift shaft arm and the stop stem in the arrow direction and install them on the section.
Page 158 ENGINE ENGINE MOUNTING AND ADJUSTMENTS BALANCER GEAR 1 Key 8 Impact hub 2 Balancer gear 9 Special washer 3 Plate 0 Key 4 Lock washer A Primary Gear 5 Nut B Lock washer 6 Special washer C Nut 7 Balancer driving gear Balancer gear installation USE A NEW ONE 50N.m (5.0 Kg.m;...
Page 159 ENGINE MOUNTING AND ADJUSTMENTS ENGINE CLUTCH AND OIL PUMP 1 Spring A Clutch hub 2 Pressure plate B Driven clutch (sleeve) 3 Plate C Ball 4O-ring D Stem 2 5 Stem 1 E Clutch stem 6 Friction disc (type A) F Primary gear 7 Expansion spring G Oil pump gear cover...
Page 160: Clutch, Oil Pump And Balancer Gear
ENGINE ENGINE MOUNTING AND ADJUSTMENTS CLUTCH, OIL PUMP AND BALANCER GEAR 1. Install: • Key 1 • Balancer gear 2 • Plate 3 • Lock washer 4 • Nut 5 (balancer gear) • Special washer 6 • Key 7 • Balancer driving gear and impact hub 8 •...
Page 161 ENGINE MOUNTING AND ADJUSTMENTS ENGINE 3. Apply: • Engine oil 4 T (to internal parts of the oil pump) 4. Install: • Rotor seat 1 • External rotor 2 • Internal rotor 3 • Dowel pins 4 • Oil pump gear 5 •...
Page 162 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 8. Apply: • Engine oil 4T (to gear teeth) 9. Install: • Driven gear (sleeve) 1 • Washer 2 • Clutch hub 3 • Lock washer 4 • Nut 5 (clutch hub) NOTE: Fold the lock washer flanges on the clutch hub channel.
Page 163 ENGINE MOUNTING AND ADJUSTMENTS ENGINE 13. Install: • Clutch stem 1 Bolt (clutch stem): 12N.m (1.2 Kg.m; 8.7 ft.Ib) 14. Install: • Stem 2 1 • Ball 2 • Friction disc 3 (type b) • Separators 4 • Expansion spring 5 •...
Page 164 ENGINE ENGINE MOUNTING AND ADJUSTMENTS NOTE: Tighten the bolts in a cross pattern. Screws (pressure plate): 6N.m (0.6 Kg.m; 4.3 ft.Ib) 15. Check: • Clutch stem position • Push the clutch stem assembly in the arrow direction. Make sure the adjusting marks are aligned.
Page 165: Oil Filter
ENGINE MOUNTING AND ADJUSTMENTS ENGINE 18. Install: • Case cover (RH) 1 Bolt (case cover): 10N.m (1.0 Kg.m; 7.2 ft.Ib) NOTE: Tighten the bolts (case cover) in a cross pattern. OIL FILTER 1. Apply: • Engine oil 4T (to oil filter and oil passage) 2.
Page 166: Magnet Rotor And Starting Gears
ENGINE ENGINE MOUNTING AND ADJUSTMENTS MAGNET ROTOR AND STARTING GEARS 1Camshaft chain 9 Spring 2 Belt guide (intake) 0 Magnet rotor 3 Key A Starting gear 1 4 Washer B Shaft 5 Starting gear 2 C Spacer 6 One-way gear D Loading coil 7 Dowel pin E Stator...
Page 167 ENGINE MOUNTING AND ADJUSTMENTS ENGINE MAGNET ROTOR AND STARTING GEARS 1. Install: • Chain guide 1 • Camshaft chain 2 Bolt (chain guide): 8N.m (0,8 Kg.m; 5,8 ft.Ib) NOTE: Fasten to the camshaft chain 3 using a wire in order to prevent it from falling into the case.
Page 168 ENGINE ENGINE MOUNTING AND ADJUSTMENTS NOTE: Install rotor 1 aligning the slot and the key. Turn starting gear 2 2 clockwise and install rotor and starting gear. 6. Install: • Bolt 1 (rotor) Bolt (rotor): 50 N.m (5.0 Kg.m; 36 ft.Ib) NOTE: Tighten the bolt (rotor) holding the rotor with the fastener 2.
Page 169 ENGINE MOUNTING AND ADJUSTMENTS ENGINE CYLINDER AND PISTON 1 Cylinder 2 Cylinder bolt 3 O-ring 4 Cylinder gasket 5 Dowel pins 6 O-ring 7 Piston rings 8 Piston pin locks 9 Piston 0 Piston pin Cylinder diameter: 69.925~69.975 mm Cylinder – piston clearance: 0.035~0.055 mm <limit: 0,10 mm>...
Page 170 ENGINE ENGINE MOUNTING AND ADJUSTMENTS HEAD 1 Bolts 8 Head 2 Washer 9 Dowel pin 3 Spark plug 0 Grommet 4 Cover (intake) A Head gasket 5O-ring B O-ring 6 Oil check bolt C Side head cover 7 Cover (exhaust) Spark plug: Tightening sequence DR8EA (N.G.K.),...
Page 171 ENGINE MOUNTING AND ADJUSTMENTS ENGINE CAMSHAFT AND CAMSHAFT CHAIN 1 Gasket 2Chain tensioner 3 Gasket 4 Chain guide (intake) 5 Camshaft 6 Pin 7 Gear 8Camshaft chain 9 Chain guide (exhaust) Shaft-spacer clearance 0.020~0.061 mm Camshaft warping limit 0.03 mm 7N.m (0,7 Kg.m ;...
Page 172: Head, Cylinder And Piston
ENGINE ENGINE MOUNTING AND ADJUSTMENTS HEAD, CYLINDER, AND PISTON 1. Apply: • Engine oil 4T (Piston rings and pin) 2. Install: • Piston rings NOTE: Install the rings with the brand mark up. 3. Install: • Piston 1 • Piston pin 2 •...
Page 173 ENGINE MOUNTING AND ADJUSTMENTS ENGINE 5. Install: • Dowel pins 1 • Gasket 2 (cylinder) • O-ring 3 6. Install: • Cylinder 1 NOTE: Pressing the piston rings manually, install the cylinder. WARNING During this operation, take care not to hurt your hands.
Page 174 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 9. Install: • Head 1 10. Install: • Bolts Bolt 1 ~ 4: 22N.m (2.2 Kg.m; 16 ft.Ib) Bolt 5 ~ 6: 20N.m (2,0 Kg.m; 426,72 cm.Ib) NOTE: • Apply engine oil 4T to the washers. •...
Page 175 ENGINE MOUNTING AND ADJUSTMENTS ENGINE CAUTION: Do not turn the crankshaft while installing the camshaft, otherwise, damage or incorrect valve timing can result. • Tighten the bolt 7. Bolt (camshaft gear): 60N.m (6.0 Kg.m; 43 ft.Ib) • Remove the safety wire 8 from the camshaft chain.
Page 176 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 13. Check: • Camshaft point Out of line => Adjust. Repeat Items 11 and 12. 14. Check: • Valve clearance Out of specification => Adjust. Section “VALVE CLEARANCE ADJUSTMENT” CHAPTER 3. Intake valve (cold): 0.05 ~ 0.09 mm Exhaust valve (cold): 0.15 ~ 0.19 mm 15.
Page 177: Reinstalling The Engine
ENGINE MOUNTING AND ADJUSTMENTS ENGINE 18. Install: • Cover 1 • Cover 2 19. Install: • Intake manifold 1 Bolt (intake manifold) 10N.m (1.0 Kg.m; 7.2 ft.Ib) 20. Install: • Spark plug 1 Spark plug: 17,5N.m (1,75 Kg.m; 381,00 cm.Ib) 21.
Page 178 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 1. Install: • Hinge shafts 1 • Setscrews 2 (front upper) • Setscrews 3 (rear lower) • Setscrews 4 (front lower) NOTE: Install all bolts and nuts and, then, apply the specified torque. Nut (hinge shaft): 80N.m (8.0 Kg.m;...
Page 179 ENGINE MOUNTING AND ADJUSTMENTS ENGINE 4. Install: • Spring 6 • Pin 7 • Adjuster 8 5. Adjust: • Brake pedal free play: Section ”REAR BRAKE ADJUSTMENT” CHAPTER 3. Brake pedal free play: 20 ~ 30 mm 6. Install: • Transmission chain 1 (with pinion gear) •...
Page 180 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 9. Connect: • Ground wire 1 • Starter motor wire 2 to case Bolt: 7N.m (0,7 Kg.m; 155,45 cm.Ib) 10. Apply: • Lithium-based grease (to starter motor O-ring) 11. Install: • Starter motor 1 Bolt (starter motor): 7N.m (0.7 Kg.m;...
Page 181 ENGINE MOUNTING AND ADJUSTMENTS ENGINE 16. Install: • Carburetor 1 • Hose 2 Bolt (carburetor tie wrap): 2N.m (0.2 Kg.m; 1.4 ft.Ib) 17. Connect: • Breather hose 1 18. Install: • Exhaust tube 1 • Bolt 2 Bolt (exhaust tube) 10N.m (1.0 Kg.m;...
Page 182 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 20. Connect: • Battery negative cable 1 See Section ”BATTERY INSPECTION” CHAPTER 3. 21. Install: • Crankcase guard 1 See Section “ENGINE OIL CHANGE” CHAPTER 3. Bolt (crankcase guard): 54.5N.m (5.45 Kg.m; 39.50 ft.Ib) 22. Replenish: •...
Page 183 ENGINE ENGINE MOUNTING AND ADJUSTMENTS 23. Install: • Fuel tank • Seat • Side covers See Section ”SEAT, FUEL TANK, AND COVERS” CHAPTER 3. Bolts 7N.m (0.7 Kg.m ; 5.1 ft.lb) 24. Check: • Idle speed Section ”IDLE SPEED ADJUSTMENT” CHAPTER 3. Idle speed: 1,300 to 1,500 rpm 4-89...
Page 184: Carburation
CARB CARBURETOR CHAPTER 5. CARBURATION CARBURETOR ....................5-1 REMOVAL ....................... 5-2 DISMOUNTING ....................5-3 INSPECTION ....................5-5 MOUNTING ....................5-7 INSTALLATION ....................5-9 FUEL LEVEL ADJUSTEMENT ..............5-10...
Page 185: Carburetor
CARB CARBURETOR CARBURETOR CARBURETOR Specifications 1 Throttle valve High-speed adjusting nozzle (M.J.) # 125,0 2 Needle assembly Low-speed adjusting nozzle (P.J.) # 36 3 Diffuser Needle / lock position (J.N.) F-21 -3/5 4 Main adjusting nozzle (#125) Diffuser (N.J.) V 95 5 Pilot adjusting nozzle (#36) Pilot Screw (P.S.) 6 Pilot screw assembly...
Page 186: Removal
CARB CARBURETOR REMOVAL 1. Drain: • Fuel (bowl) See Section “ENGINE REMOVAL,” CHAPTER 4. 2. Loosen: • Lock-nut 1 (throttle cable) 3. Disconnect: • Throttle main cable 2 • Throttle return cable 3 • Breather hose • Fuel hose 4 •...
Page 187: Dismounting
CARB CARBURETOR DISMOUNTING NOTE: The following parts can be cleaned and checked with no need for dismounting: • Pilot screw • Choke • Idle speed screw 1. Disconnect: • Choke assembly 1 2. Remove: • Carburetor bowl 1 • Pilot screw 2 3.
Page 188 CARB CARBURETOR 5. Remove: • Upper cover 1 6. Remove: • Bolt (drive arm) 1 7. Remove: • Bolts (throttle valve) 1 8. Remove: • Throttle valve 1 • Ring 2 • Needle 3 • Needle fastener 4 • Spring 5 9.
Page 189: Inspection
CARB CARBURETOR INSPECTION 1. Check: • Mixing chamber body • Float chamber (Bowl) Contamination => Clean passages using compressed air. NOTE: Use kerosene for cleaning. Blow passages and adjusting nozzles using compressed air. CAUTION: • The starting adjusting nozzle is press fastened on its seat.
Page 190 CARB CARBURETOR 5. Check: • Needle valve seat 1 • Needle valve 2 • O-ring 3 Damage/wear => Replace assembly. NOTE: Replace the needle valve and its seat as a whole. 6. Check: • Choke assembly 1 Warping/wear/damage => Replace. •...
Page 191: Mounting
CARB CARBURETOR MOUNTING Reverse the “DISMOUNTING” procedures. Check the following items: CAUTION: • Wash the parts with kerosene before mounting. 1. Install: • Diffuser 1 • Main adjusting nozzle 2 • Pilot adjusting nozzle 3 Pilot adjusting nozzle: 1 N.m (0.1 Kg.m; 0.7 ft.Ib) Main adjusting nozzle: 1.8 N.m (0.18 Kg.m;...
Page 192 CARB CARBURETOR 5. Install: • Spring 1 • Diaphragm 2 • Diaphragm spring 3 • Cover 4 • Bolt 5 6. Install: • Choke assembly 1 7. Install: • Throttle valve 1 • Ring 2 • Needle 3 8. Install: •...
Page 193: Installation
CARB CARBURETOR 10. Install: • Breather hose • Fuel hose • Drain hose INSTALLATION 1. Install: • Carburetor assembly See Section “ENGINE REMOVAL” Chapter 2. Install: • Throttle cables 1 See Section “CABLE ROUTING” Chapter 3. Adjust: • Throttle cable free play See Section “THROTTLE CABLE FREE PLAY ADJUSTMENT”...
Page 194: Fuel Level Adjustement
CARB CARBURETOR FUEL LEVEL ADJUSTMENT 1. Place the motorcycle on a flat area. 2. Place a support under the frame in order to maintain the carburetor upright. 3. Connect the fuel level meter 1 to the drain nozzle of the float bowl. Fuel level meter: 90890-01312 4.
Page 195 FRAME CHAPTER 6 FRAME FRONT WHEEL ....................6-1 REMOVAL ..................... 6-2 INSPECTION ..................6-3 INSTALLATION ..................6-5 STATIC WHEEL BALANCING .............. 6-6 FRONT BRAKE ....................6-8 BRAKE PAD REPLACEMENT ..............6-9 BRAKE CALIPER DISMOUNTING ............6-12 MASTER CYLINDER DISMOUNTING ..........6-14 INSPECTION AND REPAIRS ...............
Page 196: Front Wheel
FRAME FRONT WHEEL FRAME FRONT WHEEL Tire pressure (cold) 1 Axle Maximum load - 2 Spacer 90kg (198 lb) 3 Dust protector except the 4 Retainer motorcycle 5 Roller bearing Rear Front Tire pressure (cold) 6 Spacer 7 Front wheel 8 Washer Off-road riding 100 kPa...
Page 197: Removal
FRAME FRONT WHEEL REMOVAL V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area 2. Lift the front wheel placing a support under the engine. 3. Remove • Nut 1 •...
Page 198: Inspection
FRAME FRONT WHEEL INSPECTION 1. Remove corrosion from parts. 2. Verify: • Axle Roll the axle on a flat surface. Warping => Replace. V V V V V WARNING Do not try to straighten out the axle. 3.Check: • Tire Damage/wear =>...
Page 199 FRAME FRONT WHEEL V V V V V WARNING Ride with care after installing a tire allowing it to lay properly on the rim. Otherwise, an accident may occur resulting in damage to the motorcycle and injuries to the driver. After repairing or replacing a tire, make sure to apply the proper torque to the valve stem lock-nu 1 1 1 1 1 .
Page 200 FRAME FRONT WHEEL CAUTION: Do not touch the internal race 5 or bearing balls 6. The contact should occur on the external race only 7. ************************************* INSTALLATION Reverse the "REMOVAL" procedure. 1. Lubricate: • Axle 1 • Retainer lips 2 •...
Page 201: Static Wheel Balancing
FRAME FRONT WHEEL STATIC WHEEL BALANCING NOTE: After replacing tires and rims, carry out the static wheel balancing. The brake disc should be installed. 1. Remove: • Pesos antigos para balanceamento 2. Place the wheel on an appropriate support. 3. Find: •...
Page 202 FRAME FRONT WHEEL 4. Adjust: • Static wheel balancing ************************************ Adjustment steps: • Install a balancing weight on the point of the rim symmetrical to the weight point found. NOTE: Install the most light weight available. • Turn the wheel and place the "X" mark at 90 degrees from its original position.
Page 203: Front Brake
FRAME FRONT BRAKE FRONT BRAKE 1 Master cylinder assembly 0 Bleeding screw 2 Master cylinder cover A Brake pads 3 Diaphragm B Brake pad pin 4 Master cylinder kit C Brake disc 5 Brake hose 6 Brake caliper assembly 7 Caliper piston 8 Retainer kit 9 Pad spring Brake fluid:...
Page 204: Brake Pad Replacement
FRAME FRONT BRAKE CAUTION: Generally, the brake disc components do not need to be dismounted. • Do not dismount components, unless absolutely necessary. • Do not apply solvents to the brake internal components. • Do not use contaminated brake fluid for cleaning.
Page 205 FRAME FRONT BRAKE 2. Remove: • Bolt 1 • Brake caliper 2 3. Remove: • Pad pins • Brake pads 1 • Brake pad spring 2 NOTE: • If replacing the pads, replace the springs. • Replace the pads in case of wear or if the wear limit has been reached.
Page 206 FRAME FRONT BRAKE 7. Install: • Brake pad spring 1 • Brake pads 2 • Brake pad pin Brake pad pins: 18 N.m (1.8 kgf.m; 13 ft.lb) NOTE: Install the brake pad (internal) with its fastener a facing the support pin b ************************************ Installation steps: •...
Page 207: Brake Caliper Dismounting
FRAME FRONT BRAKE 9. Check: • Brake fluid level. See Section "FRONT BRAKE FLUID LEVEL CHECK," CHAPTER 3. LOWER 1 Low level "LOWER." 10. Check: • Brake lever operation Soft, spongy touch => Bleed the brake See Section "AIR BLEEDING," CHAPTER 3. BRAKE CALIPER DISMOUNTING NOTE: Before dismounting the brake caliper, drain...
Page 208 FRAME FRONT BRAKE 5. Remove: • Pads • Springs See Section "BRAKE PAD REPLACEMENT." 6. Remove: • Caliper support 1 7. Remove: • Pistons 1 ************************************ Removal steps: • Blow compressed air through the connection tube in order to force the ejection of the pistons.
Page 209: Master Cylinder Dismounting
FRAME FRONT BRAKE MASTER CYLINDER DISMOUNTING NOTE: Before dismounting the master cylinder, drain the brake fluid. V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Remove: • Connection screw 1 • Copper washers 2 2.
Page 210: Inspection And Repairs
FRAME FRONT BRAKE INSPECTION AND REPAIRS V V V V V WARNING All internal parts should be cleaned using new brake fluid. Do not use solvents, since this will result in deformations. 1. Check: • Caliper cylinder • Wear/scratches = > Replace the caliper assembly •...
Page 211 FRAME FRONT BRAKE 3. Check: • Brake fluid passage (master cylinder) 1 Blow with compressed air. Wear/scratches = > Replace the master cylinder assembly • Master cylinder reservoir Wear/scratches = > Replace the master cylinder assembly 4. Check: • Master cylinder kit 1 Scratches/wear/damage =>...
Page 212: Caliper Mounting
FRAME FRONT BRAKE 8. Check: • Brake disc Damage => Replace 9. Measure: • Brake disc warping Out of specification => Check for warping Warping = > Replace the disc. Maximum warping: 0.3 mm 1 Dial gage • Brake disc thickness Out of specification =>...
Page 213 FRAME FRONT BRAKE 1. Install: • Piston retainer 1 • Piston 2 NOTE: First, mount the piston retainer and, then, the piston. Stop when almost finishing and connect the dust protector. While moving the piston to its position, mount the dust protector on the assembly.
Page 214 FRAME FRONT BRAKE 4. Install: • Brake caliper 1 • Copper washers 2 • Brake hose 3 • Connection screw 4 Screw: 27 N.m (2.7 kgf.m; 19 ft.lb) V V V V V WARNING • Route the brake hose properly in order to ensure the safe riding.
Page 215: Master Cylinder Mounting
FRAME FRONT BRAKE • Make sure to prevent water from entering the master cylinder when filling it. Water decreases the fluid boiling point and may result in plugging. 8. Air bleeding: • Brake system See Section "AIR BLEEDING," CHAPTER 3. 9.
Page 216 FRAME FRONT BRAKE 2. Install: • Master cylinder 1 NOTE: Install the master cylinder with the "UP" mark up. Tighten the upper screw first. Screw (master cylinder support): 7 N.m (0.7 kgf.m; 5.1 ft.lb) 3. Install: • Copper washers • Brake hose •...
Page 217 FRAME REAR WHEEL FRAME REAR WHEEL Tire pressure (cold) Driving lever Tighteners Maximum load 90kg Wear indicator Spacer Front Rear Brake stem Tire pressure Adjuster Spring (15psi) (15psi) Shoe plate Spacer Camshaft Rear wheel Brake shoe Bearing * Load is the total weight of driver, Spring Retainer passenger and accessories.
Page 218: Rear Wheel
FRAME REAR WHEEL REAR WHEEL REMOVAL V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area. 2. Lift the rear wheel placing a support under the engine. 3. Remove: •...
Page 219: Inspection
FRAME REAR WHEEL REAR BRAKE 1. Remove: • Brake shoes 1 • Springs 2 NOTE: Remove the shoes pulling them up, using the hinge pin 3 and the camshaft stem 4 as support points, in the arrow direction. 2. Remove: •...
Page 220 FRAME REAR WHEEL 5. Check: • Shoe plate 1 • Hinge pin 2 • Camshaft 3 Damage => Replace. 6. Check: • Brake shoe 1 Springs 2 Damage/wear => Replace. NOTE: When replacing the brake shoes, replace the springs. 7. Check: •...
Page 221: Mounting
FRAME REAR WHEEL 9. Check: • Internal surface of the brake drum Oil/scratches = > Replace. Clean using a cloth damped with solvent or thinner. Scratches Polish, using light sandpaper. 10. Measure: • Internal diameter of the brake drum Out of specification = > Replace. Internal diameter of the brake drum: Standard: 110 mm Limit: 111 mm...
Page 222 FRAME REAR WHEEL 2. Install: • Brake shoes 1 • Spring 2 NOTE: • When installing the camshaft, make sure the channel 3 is facing the wear indicator. • When installing the brake shoes, use the hinge pin 4 and the camshaft 5 as support points, pressing the shoes in the arrow direction.
Page 223: Installation
FRAME REAR WHEEL INSTALLATION Reverse the "REMOVAL" procedure. 1. Lubricate: • Axle • Bearings • Retainer lips Lithium-based grease 2. Adjust: • Transmission chain free play Transmission chain free play: 45 ~ 60 mm See Section "TRANSMISSION CHAIN FREE PLAY ADJUSTMENT," CHAPTER 3. 3.
Page 224: Front Fork
FRAME FRONT FORK FRONT FORK Piston spring 23 Front fork (LH) Plastic belt Damper stem Dust cover E Cut the plastic belt Return spring Tie wrap Internal tube Front fork (RH) Oil retainer Cover Dust protector Lock ring Lock ring Handle-bars board Retainer Handle-bars board...
Page 225: Removal
FRAME GARFO DIANTEIRO REMOVAL V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area. 2. Lift the front wheel placing a support under the engine. 3. Remove: • Front wheel See Section "REMOVAL - FRONT WHEEL."...
Page 226: Dismounting
FRAME FRONT FORK DISMOUNTING 1. Remove: • Dust over 1 2. Remove: • Lock ring 1 • Spring seat 2 • Spring 3 NOTE: Press the spring seat and remove the lock ring. Take care because the part may jump. 3.
Page 227 FRAME FRONT FORK 5. Remove: • Lock 1 NOTE: Use a thin screwdriver. Take care not to scratch the internal tube. 6. Remove: • Screw 1 • Washer 2 NOTE: Hold the damper stem to loosen the screw (from the damper stem) using the "T" wrench 3 and the fastener 4 .
Page 228 FRAME FRONT FORK 8. Remove: • Internal tube ************************************ Removal steps • Hold the fork horizontally. • Fasten the external tube in a bench vise, protecting its surface. • C a r e f u l l y , p u l l t h e i n t e r n a l t u b e vigorously.
Page 229: Inspection
FRAME FRONT FORK INSPECTION 1. Check: • Internal tube • External tube 2 Scratches/warping/damage => Replace. V V V V V WARNING Do not try to straighten out the internal tube, since it may be impaired. 2. Measure: • Spring free length a Out of specification = >...
Page 230: Mounting
FRAME FRONT FORK MOUNTING Reverse the "DISMOUNTING" procedures. NOTE: • When mounting the front fork, the following new parts should be used: * Guide bushing * Retainer * Dust protector • Clean all components before mounting. 1. Install: • Oil retainer 1 (on the damper stem 2) 2.
Page 231 FRAME FRONT FORK 6. Lubricate: • Internal tube (external surface) 1 Suspension oil 10W or equivalent. 7. Install: • Guide bushing • Spacer 3 8. Install: • Retainer 1 Use the sliding hammer 2 and the adapter 3. Sliding hammer: 90890-01367 Adapter 36 mm: 90890-01370...
Page 232 FRAME FRONT FORK 10. Install: • Dust protector 1 Use the sliding hammer 1 and the adapter 1. Sliding hammer: 90890-01367 Adapter 36 mm: 90890-01370 11. Fill: • Front fork Each fork: 352 ± 10 cc After filling, pump the fork up and down slowly in order to distribute the oil.
Page 233: Installation
FRAME FRONT FORK NOTE: • Install the spring with the longest pitch 4 up. 5 shorter pitch. • Before installing the spring seat, apply grease to the O-ring. • Compress the spring seat and install the lock ring. 13. Install: •...
Page 234 FRAME FRONT FORK 2. Tighten: • Screws 1 (lower board) • Screws 2 (upper board) Screw (lower board): 20 N.m (2.0 kg.m; 14 ft.lb) Screw (upper board): 23 N.m (2.3 kg.m; 17 ft.lb) 3. Install: • Screws 1 (brake caliper) •...
Page 235: Steering Column And Handle-Bars
FRAME STEERING COLUMN AND HANDLE-BARS STEERING COLUMN AND HANDLE-BARS Grip (RH) Bearing Handle-bars fastener Fairing Handle-bars Cable support Grip (LH) Lower support Upper board Brake hose fastener Lock washer Adjusting nut Washer Ring nut Bearing cap 23 N.m (2.3 kgf.m; 16.6 ft.lb) 110 N.m (11 kgf.m;...
Page 236: Removal
FRAME STEERING COLUMN AND HANDLE-BARS REMOVAL HANDLE-BARS V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area. 2. Remove:: • Plastic belt 1 3. Remove: • Master cylinder screws 2 •...
Page 237: Steering Column
FRAME STEERING COLUMN AND HANDLE-BARS 9. Remove: • Engine stop switch 1 10. Remove: • Handle-bars • Throttle grip STEERING COLUMN V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area 2.
Page 238 FRAME STEERING COLUMN AND HANDLE-BARS 6. Remove: • · Fender 1 1 1 1 1 1 7. Remove: • Front frock See Section "REMOVAL - FRONT FORK." 8. Disconnect: • Main harness connectors 9. Remove: • Main switch 1 6-43...
Page 239 FRAME STEERING COLUMN AND HANDLE-BARS NOTE: • Loosen the nut 8 and remove the upper board 1. Use the special tool 9 to remo- ve the ring and adjusting nuts. Adjusting nut wrench: 90890-01403 10. Remover: • Lock washer 2 •...
Page 240: Inspection
FRAME STEERING COLUMN AND HANDLE-BARS INSPECTION 1. Check: • Handle-bars 1 Warping/cracks/damage = > Replace. V V V V V WARNING Do not try to straighten out a bent handle- bars, since it may be impaired, resulting in a hazardous condition. ************************************* Replacement steps: •...
Page 241 FRAME STEERING COLUMN AND HANDLE-BARS 3. Check: • Bearing (lower) 1 Damage/protuberances/wear = > Replace the assembly. • Bearing race (lower) 2 Damage/protuberances/wear > Replace the assembly. ************************************* Replacement steps: • Remove the bearing races from its fittings on the tube, using a long stem 1 and a hammer.
Page 242: Installation
FRAME COLUNA DE DIREÇÃO E GUIDÃO INSTALLATION HANDLE-BARS Reverse the "REMOVAL" procedures. 1. Lubricate: • Handle-bars Lithium-based grease NOTE: Before installing the throttle grip on the handle-bars, apply a thin layer of lithium- based grease to the right end of the handle- bars.
Page 243 FRAME COLUNA DE DIREÇÃO E GUIDÃO 3. Install: • Engine stop switch (LH) • Clutch grip fastener • Clutch cable NOTE: Apply a thin layer of lithium-based grease to the end of the clutch cable. 4. Install: • Plastic belts •...
Page 244 FRAME STEERING COLUMN AND HANDLE-BARS 8. Adjust: • Clutch cable free play Free play: 10 ~ 15 mm at the grip end See Section "CLUTCH ADJUSTMENT," CHAPTER 3. Steering Column Reverse the "REMOVAL" procedures. 1. Lubricate: • Lower and upper bearings 1 •...
Page 245 FRAME STEERING COLUMN AND HANDLE-BARS NOTE: Attach the torquemeter to the adjusting nut wrench, forming a right angle (90°). Adjusting nut (initial torque): 43 N.m (4.3 kgf.m; 31.1 ft.lb) • Turn the lower board to the right and to the left, making sure there is no irregular movement.
Page 246 FRAME STEERING COLUMN AND HANDLE-BARS 5. Install: • Main switch 1 6. Connect: • Main switch connector 7. Install: • Front fork See Section "INSTALLATION - FRONT FORK." NOTE: Tighten the lower and upper board screws temporarily. 8. Tighten • Upper board anchor nut 1 Upper board anchor nut: 110 N.m (11 kgf.m;...
Page 247 FRAME STEERING COLUMN AND HANDLE-BARS 9. Tighten: • Lower and upper board screws. Screw (lower board): 20 N.m (2.0 kgf.m; 14 ft.lb) Screw (upper board): 20 N.m (2.0 kgf.m; 14.4 ft.lb) 10. Install: • Brake caliper • Fastener (brake hose) •...
Page 248: Rear Shock Absorber And Balance
FRAME REAR SHOCK ABSORBER AND BALANCE REAR SHOCK ABSORBER AND BALANCE 1 Shock absorber 35 N.m (3.5 kgf.m; 25.4 ft.lb) 6-53...
Page 249 FRAME REAR SHOCK ABSORBER AND BALANCE Relay arm Rear balance Bushing Lubricating screw Spacer Chain guide Spacer Chain guard Retainer Dust protector Bearing Hinge shaft Spacer Balance shaft Screw (shock absorber - relay arm) Stop cap Screw (relay arm connection - relay arm) Shim Screw (frame - relay arm) Bushing...
Page 250: Notes On Handling
FRAME REAR SHOCK ABSORBER AND BALANCE NOTES ON HANDLING V V V V V WARNING •This shock absorber contains nitrogen gas at high pressure. Read and understand the following information before handling. The manufacturer assumes no liability for injuri- es or damage resulting from mishandling. •Do not try to pierce or open the shock absorber assembly.
Page 251: Removal
FRAME REAR SHOCK ABSORBER AND BALANCE REMOVAL Shock Absorber V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area. 2. Remove: • LH side cover • Seat See Section "SEAT, FUEL TANK AND COVERS,"...
Page 252 FRAME REAR SHOCK ABSORBER AND BALANCE REAR BALANCE V V V V V WARNING Support the motorcycle firmly preventing it from falling. 1. Place the motorcycle on a flat area. 2. Lift the rear wheel placing a support under the engine. 3.
Page 253 FRAME REAR SHOCK ABSORBER AND BALANCE • Check the side free play A , moving the balance from side to side. • While checking the free play, verify the internal spacer, bearing, washer and stop cap. Side free play: Limit: 1.0 mm •...
Page 254: Inspection
FRAME REAR SHOCK ABSORBER AND BALANCE INSPECTION 1. Check: • · Shock absorber 1 Leakage/damage = > Replace. V V V V V WARNING This shock absorber contains nitrogen gas at high pressure. Do not disassemble the shock absorber. 2. Check: •...
Page 255: Installation
FRAME REAR SHOCK ABSORBER AND BALANCE INSTALLATION Shock Absorber Reverse the "REMOVAL" procedures. 1. Lubricate: • Bushing (internal surface) Lithium-based grease 2. Install: • Shock absorber 1 (upper part) 3. Tighten: • Nut 2 Nut 2 2 2 2 2 (upper part): 34.5 N.m (3.4 kgf.m;...
Page 256 FRAME REAR SHOCK ABSORBER AND BALANCE Rear Balance Reverse the "REMOVAL" procedure. 1. Lubricate • Retainer • Bearings • Stop caps (inside) • Spacers • Shafts • Hinges Lithium-based grease 2. Tighten: • Nut (connection arm - relay arm) Nut: 52.5 N.m (5.2 kgf.m;...
Page 257 FRAME REAR SHOCK ABSORBER AND BALANCE 7. Tighten: • Bolt 1 (chain guide) Bolt 1 1 1 1 1 : 7 N.m (0.7 kgf.m; 5.0 ft.lb) 8. Install: • Shock absorber See Section "REAR SHOCK ABSORBER." 9. Install: • Rear wheel See Section "REAR WHEEL."...
Page 258: Transmission Ratio
FRAME TRANSMISSION RATIO TRANSMISSION RATIO Rear wheel Sprocket Chain seam Transmission chain Pinion gear fastener Pinion gear Transmission chain Type: 520V2 Number of links: Chain free play: 45 ~ 60 mm 34.5 N.m (3.4Kgf.m ; 25 ft.lb) USE A NEW ONE 10N.m (1.0Kgf.m ;...
Page 259: Removal
FRAME TRANSMISSION RATIO NOTE: Before removing the transmission chain and gears, measure the transmission chain free play. REMOVAL 1. Lift the rear wheel placing a support under the engine. V V V V V WARNING Support the motorcycle firmly preventing it from falling.
Page 260: Inspection
FRAME TRANSMISSION RATIO 5. Remove: • Chain seam lock 1 6. Remove: • Chain seam Use the chain pin puller 1. Chain pin puller: 90890-01286 7. Remove: • Link plate 1 • O-ring 2 • Seam 3 • Transmission chain 4 8.
Page 261 FRAME TRANSMISSION RATIO NOTE: • Pull the chain manually in order to measure it. • The measurement a of the 10 links should be taken between the internal rollers 1 to (11). • Measure the 10 links at two or three different positions.
Page 262: Installation
FRAME TRANSMISSION RATIO 4. Check: • Climbing of the transmission chain links - Clean and lubricate or replace. 5. Check: • Pinion gear • Sprocket Wear over ¼ of tooth = > Replace ratio. Inclined tooth = > Replace ratio. 2 Correct 3 Roller 4 Pinion gear...
Page 263 FRAME TRANSMISSION RATIO 2. Install: • Rear wheel See Section "REAR WHEEL." 3. Install: • Transmission chain • Pinion gear 2 • Pinion gear fastener 3 • Screws (pinion gear) 4 Pinion gear screw: 10 N.m (1.0 kgf.m; 7.2 ft.lb) 4.
Page 264 FRAME TRANSMISSION RATIO 6. Adjust: • Transmission chain free play Chain free play: 45 ~ 60 mm CAUTION: A too small free play will result in overload on the engine and other essential parts. Keep the free play within the specified limits.
Page 265: Electric System
ELECT CHAPTER 7. ELECTRIC SYSTEM ELECTRIC CIRCUIT DIAGRAM TTR230 ..........7-1 COLOR CODE................7-1 ELECTRIC COMPONENTS............7-2 SWITCH CHECKS ................7-3 UNDERSTANDING THE SWITCH CONNECTIONS ......7-3 CHECKING THE SWITCH CONNECTIONS ........7-4 IGNITION SYSTEM ................7-6 IGNITION CIRCUIT OPERATION ..........7-6 TROUBLESHOOTING ..............
Page 266: Electric Circuit Diagram Ttr230
ELECT ELECTRIC CIRCUIT DIAGRAM - TTR230 ELECTRIC ELECTRIC CIRCUIT DIAGRAM - TTR230 Magnet Main fuse Starter motor Main switch Rectifier/Regulator Neutral switch Clutch switch Starting relay C.D.I. unit “START” switch Ignition coil “ENGINE STOP” switch Spark plug White Orange Black/White...
Page 267: Electric Components
ELECT ELECTRIC COMPONENTS Harness BATTERY: C.D.I. unit Capacity: 12 V 4 Ah Battery Solution Density: 1.320 Neutral switch Main switch IGNITION COIL: Primary winding resistance: Ignition coil Ω 0,18 ~ 0,28 at 20°C Spark plug cap Secondary winding resistance: Rectifier/Regulator Ω...
Page 268: Switch Checks
ELECT SWITCH CHECKS SWITCH CHECKS Check the switches for continuity between terminals. Read the following text in order to check the switches properly. UNDERSTANDING THE SWITCH CONNECTIONS This manual contains the connection tables as shown to the left. The switch terminal connections are shown.
Page 269: Checking The Switch Connections
ELECT SWITCH CHECKS CHECKING THE SWITCH CONNECTIONS Before checking the switches, see the connection table and check the color combinations. To understand how to check the switches, see the following example: CAUTION: Do not disconnect the couplings by pulling them by the wires, otherwise the wires may separate from their terminals.
Page 270 ELECT SWITCH CHECKS 3. See the connection table and check the color combinations and continuity. See the example: Br/L “R” and “Br/L” and “L/B and L/Y” have LOCK continuity at switch “ON” position. Observe that there is no continuity (open circuit) for color combinations other than those aforementioned.
Page 271: Ignition System
ELECT IGNITION SYSTEM IGNITION CIRCUIT OPERATION The ignition control circuit of this model consists of: ignition control unit (C.D.I.), neutral switch, and neutral light. If the “ENGINE STOP” switch and the main switch are set to “ON,” the spark will flash only if: •...
Page 272: Troubleshooting
ELECT IGNITION SYSTEM TROUBLESHOOTING IF THE IGNITION SYSTEM STOPS OPERATING (WITH NO SPARK OR INTERMITTENT SPARKS) Procedures Check: 1. Fuse Main switch 2. Battery “ENGINE STOP” switch 3. Spark plug Neutral switch 4. Spark 10. Clutch switch 5. Cap resistance 11.
Page 273 ELECT IGNITION SYSTEM 3. Spark plug • Check the spark plug conditions. • Check the spark plug type. • Check the electrode clearance. See Section “SPARK PLUG CHECK,” INCORRECT CHAPTER 3. Spark plug DR8EA Defective spark plug, replace or Electrode clearance: calibrate the electrode clearance.
Page 274 ELECT IGNITION SYSTEM 5. Cap resistance • Remove cap. Ω • Connect the multimeter ( x1) to the cap. OUT OF SPECIFICATION Cap resistance: Ω Defective cap – replace. 10 K at 20° C ACCORDING TO SPECIFICATION 6. Ignition coil resistance •...
Page 275 ELECT IGNITION SYSTEM Ω Connect the multimeter ( x1) to the ignition coil. Terminal (+) spark plug cable Terminal (-) body ground INCORRECT • Check secondary winding resistance. Secondary winding resistance: Ω Ignition coil defective – Replace. 6.32k~9.48k at 20° C ACCORDING TO SPECIFICATIONS 7.
Page 276 ELECT IGNITION SYSTEM 8. “ENGINE STOP” switch • Disconnect the handle-bars switch connector (LH) from the harness. • Check the continuity between wires “BLACK/WHITE (B/W) and “BLACK ‘ (B) See Section “SWITCH CHECKS.” INCORRECT B BW “ENGINE STOP” switch defective – Replace.
Page 277 ELECT IGNITION SYSTEM 10. Pulse coil resistance • Disconnect the field coil connector from the harness. Ω • Connect the multimeter ( x 100) to the field coil terminal. Terminal (+) Blue/Yellow wire Terminal (-) Green wire • Check the pulse coil resistance. Pulse coil resistance: OUT OF SPECIFICATIONS Ω...
Page 278 ELECT ELECTRIC STARTING SYSTEM TROUBLESHOOTING THE STARTER MOTOR DOES NOT OPERATE Check: 1. Main fuse 6. “ENGINE STOP” switch 2. Battery 7. Neutral switch 3. Starter motor 8. Clutch switch 4. Starting relay 9. Connections 5. Starting switch NOTE: • Remove the following parts before starting the analysis: 1) Side covers 2) Seat •...
Page 279 ELECT ELECTRIC STARTING SYSTEM WARNING The jumper wire capacity should be compatible with the starter motor capacity. 3. Starter motor Otherwise, it may blow. • Connect the battery positive terminal 1 and the starter motor cable 2 using a jumper wire 3 *as shown. DOES NOT START Starter motor defective –...
Page 280: Electric Starting System
ELECT ELECTRIC STARTING SYSTEM 5. Neutral switch • Disconnect the neutral switch wire from the harness. • Check the continuity between wires “LIGHT BLUE” 1 and “GROUND.” See Section “SWITCH CHECKS.” INCORRECT Neutral switch defective – Replace. CORRECT 6. Clutch switch •...
Page 281 ELECT ELECTRIC STARTING SYSTEM 7. Starting switch • Disconnect the handle-bars switch connector (RH) from the harness. • Check the starting switch continuity between the wires. “BLUE/WHITE (LW) and BLUE (L).” See Section “SWITCH CHECKS.” INCORRECT Starting switch defective – Replace. CORRECT 8.
Page 282: Starter Motor
ELECT ELECTRIC STARTING SYSTEM STARTER MOTOR Starter motor Rotor assembly Rear support Shim Spring Lock washer Brush assembly Front support O-ring O-ring Stator assembly Minimum brush length limit 3.5 mm Switch wear limit 21.0 mm Mica depth 1.5 mm Rotor coil resistance Ω...
Page 283 ELECT ELECTRIC STARTING SYSTEM REMOVAL 1. Remove: • Crankcase guard See Section “ENGINE OIL CHANGE” CHAPTER 3. 2. Disconnect: • Battery negative cable 1 See Section “BATTERY INSPECTION,” CHAPTER 3. 3. Remove: • Starter motor cable 1 • Starter motor 2 Disassembly: 1.
Page 284 ELECT ELECTRIC STARTING SYSTEM 3. Remove: • Lock washer 1 • Shim 2 4. Remove: • Rear support 1 5. Remove: • Rotor assembly • Stator assembly 2 6. Remove: • Springs 1 Inspection and repairs: 1. Check: • Armature Dirt =>...
Page 285 ELECT ELECTRIC STARTING SYSTEM 3. Measure: • Mica depth a Out of specification => Scrape the mica using a band saw. Mica depth: 1.5 mm NOTE: The switch mica insulation should have the proper depth in order to enable the proper switch operation.
Page 286 ELECT ELECTRIC STARTING SYSTEM 6. Measure: • Brush spring load Fatigue/out of specification => Replace assembly. Spring load: 560~840g 7. Check: • Roller bearing • Retainer • Bushing • Damage => Replace support. • O-ring Damage/wear => Replace. Mounting Reverse the “REMOVAL” procedures. 1.
Page 287 ELECT ELECTRIC STARTING SYSTEM 3. Install: • O-ring 1 CAUTION: Always use new O-rings. 4. Install: • Stator assembly 1 NOTE: Align the stator marks with those on the rear support. 5. Install: • Lock washer 1 • Shim 2 •...
Page 288 ELECT ELECTRIC STARTING SYSTEM 2. Install: • Starter motor 1 • Starter motor cable 2 Bolt (starter motor): 7 N.m (0.7 Kgf.m; 5.1 ft.Ib) 3. Connect: • Battery negative cable See Section “BATTERY INSPECTION,” CHAPTER 3. 4. Install: • Crankcase guard See Section “ENGINE OIL CHANGE”...
Page 289 ELECT CHARGING SYSTEM TROUBLESHOOTING BATTERY NOT CHARGING Procedures Check: 1. Fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. System connections NOTE: • Remove the following parts before starting the analysis: 1) Side covers (RH) 2) Seat • Use the following device for analysis: Inductive tachometer: Multimeter: 90890-03113...
Page 290: Charging System
ELECT CHARGING SYSTEM 3. Charging voltage • Connect the inductive tachometer to the spark plug cable. • Connect the multimeter (DC20V) to the battery. Terminal (+) Battery terminal (+) Terminal ( - ) Battery terminal (-) • Start the engine and speed up to 5,000 rpm.
Page 291 ELECT CHARGING SYSTEM OUT OF SPECIFICATIONS Charging coil resistance: Ω Ω Ω Ω Ω 0.72 ~ 1.08 at 20° C ACCORDING TO SPECIFICATIONS Charging coil defective – Replace. 5. Connections • Check the charging system connections. INCORRECT CONNECTION See Section “CIRCUIT DIAGRAM.”...
Page 292: Troubleshooting
PROB CHAPTER 8. TROUBLESHOOTING STARTING FAILURE / DIFFICULTY ............... 8-1 FUEL SYSTEM ..................8-1 ELECTRIC SYSTEM ................8-2 COMPRESSION SYSTEM ..............8-2 POOR PERFORMANCE AT IDLE SPEED ..........8-3 POOR PERFORMANCE AT MEDIUM AND HIGH SPEEDS ....8-3 GEAR SHIFTING DIFFICULTY ............... 8-4 UNSTABLE GEAR..................
Page 293: Chapter 8. Troubleshooting
PROB STARTING FAILURE / DIFFICULTY TROUBLESHOOTING NOTE: This chapter does not cover all possible causes of problems. Nevertheless, it will help as a troubleshooting guide. STARTING FAILURE / DIFFICULTY FUEL SYSTEM POSSIBLE CAUSE Fuel tank • Empty • Clogged fuel filter •...
Page 294: Electric System
PROB STARTING FAILURE / DIFFICULTY ELECTRIC SYSTEM POSSIBLE CAUSE Spark plug • Wrong cap • Worn electrode • Broken cable between terminals • Wrong thermal grade • Defective cap Ignition coil • Broken or shorted primary/secondary winding • Defective spark plug cable •...
Page 295: Poor Performance At Idle Speed
POOR PERFORMANCE AT IDLE SPEED / POOR PROB PERFORMANCE AT MEDIUM AND HIGH SPEEDS POOR PERFORMANCE AT IDLE SPEED POSSIBLE CAUSE Carburetor • Improper choke return • Improper choke cable free play • Loose low-speed adjusting nozzle • Clogged low-speed adjusting nozzle •...
Page 296: Gear Shifting Difficulty
GEAR SHIFTING DIFFICULTY/CLUTCH PROBLEMS PROB POSSIBLE CAUSE GEAR SHIFTING DIFFICULTY • Locked shaft Shift shaft • Obstructed channels Shifting fork/forks • Damaged fork • Locked guide bar • Damaged clutch Transmission • Dirt • Improperly mounted transmission UNSTABLE GEAR POSSIBLE CAUSE Shift shaft •...
Page 297: Dragging Clutch
PROB OVERHEATING DRAGGING CLUTCH POSSIBLE CAUSE Clutch • Bent pressure plate • Improper tension on clutch springs • Loose clutch hub nut • Burnt sleeve bushing • Bent separator • Too thick friction disc • Broken clutch hub • High oil level Engine oil •...
Page 298: Brake Fault
BRAKE FAULT/ PROB LEAKAGE ON THE FRONT FORK BRAKE FAULT DEFECTIVE BRAKING SYSTEM POSSIBLE CAUSE Disc brake • Worn brake pads • Worn brake disc • Air in brake fluid • Brake fluid leakage • Defective master cylinder cover • Defective caliper retainer •...
Page 299: Unstable Driving
PROB UNSTABLE DRIVING UNSTABLE DRIVING POSSIBLE CAUSE HANDLE-BARS • Improperly installed or bent Steering column • Improperly installed upper base • Bent steering column • Improperly installed steering column (Adjusting nut not adjusted) • Damaged raceway or roller bearing Front fork •...
Page 300 YAMAHA MOTOR DO BRASIL LTDA PRINTED IN BRAZIL...

Yamaha ttr230 Service Manual

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Table of Contents

Chapter 3. Periodic Inspection and Adjustments

Engine Inspection

Carburation

Chapter 6 Frame

Electric System

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