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EASB0001 NOTICE This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
ILLUSTRATED SYMBOLS The following symbols are not relevant to every vehicle. SPEC INFO Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 General information INSP CHAS 2 Specifications 3 Periodic inspections and adjustments 4 Chassis 5 Engine...
E004000 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION INSP AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETION CARB ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
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INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER................1-1 MODEL LABEL ......................1-1 IMPORTANT INFORMATION ....................1-2 PREPARATION FOR REMOVAL PROCEDURES ............1-2 REPLACEMENT PARTS ....................1-2 GASKETS, OIL SEALS AND O-RINGS ................1-2 LOCK WASHERS/PLATES AND COTTER PINS ............1-3 BEARINGS AND OIL SEALS ..................1-3 CIRCLIPS ........................1-3 CHECKING OF CONNECTIONS ..................1-4 SPECIAL TOOLS........................1-5...
INFO VEHICLE IDENTIFICATION GENERAL INFORMATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped in- to the frame. MODEL LABEL The model label 1 is affixed to the frame under the seat. This information will be needed to order spare parts.
5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
INFO IMPORTANT INFORMATION EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.
INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1. Disconnect: • connector 2. Check: • connector Moisture Dry each terminal with an air blower. Stains/rust Connect and disconnect the terminals several times. 3.
INFO SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or impro- vised techniques. When placing an order, refer to the list provided below to avoid any mistakes.
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INFO SPECIAL TOOLS Tool name / Usage Illustration Tool No. Rocker arm shaft puller bolt 90890-01083 These tools are used when removing the rocker arm shafts. Weight 90890-01084 These tools are used when removing the rocker arm shafts. Valve spring compressor 90890-04019 These tools are used when removing or installing the valve and the valve spring.
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This tool is used to install the crankshaft. Crank spacer 90890-04081 This tool is used to install the crankshaft. SEALANT (QUICK GASKET) ® Yamaha Bond No. 1215 ® 90890-85505 This sealant (adhesive) is used for crankcase mating surfaces etc. Ringnut wrench...
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INFO SPECIAL TOOLS Tool No. Tool name / Usage Illustration T-handle 90890-01326 This tool is needed to loosen and tighten the front fork damper rod holding bolt. Front fork damper rod holder 90890-01460 This tool is needed to hold the front fork damper rod when loosening and tightening the holding bolt.
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model TT600RE: 5CH5 Dimensions Overall length 2,220 mm ••• Overall width 865 mm ••• Overall height 1,195 mm ••• Seat height 890 mm ••• Wheelbase 1,480 mm ••• Ground clearance 280 mm •••...
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SPEC GENERAL SPECIFICATIONS Item Standard Limit Spark plug Manufacturer/model NGK/DPR8EA-9 or NGK/DPR9EA-9 0.8–0.9 mm ••• Clutch type Wet. Multiple-disc Transmission Primary reduction system Spur gear Primary reduction ratio 71/34 (2.088) Secondary reduction system Chain drive Secondary reduction ratio 47/15 (3.133) Number of drive chain sprocket teeth (front/rear) 15/47...
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SPEC GENERAL SPECIFICATIONS Item Standard Limit Brakes Front: Type Single Ø 267 mm disk brake, 2 x 28 mm Operation Right hand Fluid DOT 4 Rear: Type Single Ø 220 mm disk brake, 1 x 34 mm caliper Operation Right foot Fluid DOT 4 Suspension...
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head Max. warpage ••• 0.03 mm Cylinder Bore 94.970 - 95.020 mm 95.10 mm Measuring point 50 mm ••• Camshaft Drive system Chain drive (left) Camshaft cap inside diameter 23.000 - 23.021 mm •••...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 75-010/126 Tensioning system Automatic Rocker arm/rocker arm shaft Arm inside diameter 12.000 - 12.018 mm ••• Shaft outside diameter 11.976 - 11.991 mm ••• Arm-to-shaft clearance 0.009 - 0.042 mm •••...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring Inner spring: Free length intake 40.10 mm 38.10 mm exhaust 40.10 mm 38.10 mm Installed length (valve closed) intake 22.70 mm ••• exhaust 22.70 mm ••• Compressed spring force (installed) intake 164.80 - 190.20 N •••...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston ring Top ring: Ring type Barrel Dimensions (B x T) 1.20 x 3.80 mm ••• End gap (installed) 0.30 - 0.45 mm 0.70 mm Ring side clearance 0.040 - 0.080 mm 0.130 mm ring: Ring type Plain...
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SPEC MAINTENANCE SPECIFICATIONS ENGINE Cylinder head tightening steps: Crankcase tightening steps: Left crankcase Right crankcase...
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SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Part to be tightened Thread size Remarks name Cylinder head Washer based bol M8 x 1.25 Cylinder head Stud bolt M10 x 1.25 Cylinder head Hexagon socket head screw M6 x 1.0 Cylinder head Stud bolt M6 x 1.0...
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SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Part to be tightened Thread size Remarks name Stator (pick-up coil) Hexagon socket head screw M6 x 1.0 Engine oil pipe 1 Hexagon socket head screw M6 x 1.0 Engine oil pipe 2 Union screw M12 x 1.25 Oil delivery pipe Union bolt...
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering Steering bearing type Taper roller bearing Lock to lock angle (left) 45° ••• Lock to lock angle (right) 45° ••• Front suspension Front fork travel 277 - 283 mm ••• Fork spring free length 530 mm •••...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Drive chain Type/manufacturer 520 135ORSB / Regina Chain Link quantity Drive chain slack 30.0 - 40.0 mm ••• Front disc brake Disc outside diameter x thickness 267 x 4 mm ••• Max. deflection ••• 0.15 mm Brake pad lining thickness-inner 7.5 mm...
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SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Remarks size · · Engine mounting and rear frame: Engine front/Stay engine M10 x 1.25 Stay engine (engine front)/Frame M10 x 1.25 Engine rear under/Frame M10 x 1.25 Engine top/Stay engine M10 x 1.25 Engine protector/Frame...
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SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size · · Front brake: Front hub/Disc brake M6 x 1.0 Front caliper/Front fork M8 x 1.25 Front caliper/Bleeder tightening M10 x 1.0 Union bolt tightening (front) M10 x 1.0 Rear brake: Rear hub/Disc brake M6 x 1.0...
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SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size · · Starting motor cord/Starting motor M6 x 1.0 Wire minus lead (-)/Starting motor M6 x 1.0 Front flasher lights/Stay, headlight M6 x 1.0 0.15 Clutch wire/Engine M6 x 1.0 Assist grip (Standing handle)/Rear frame M8 x 1.25 Speedometer...
GENERAL TORQUE SPECIFICATIONS/ SPEC CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE This chart specifies torque for standard fasteners All specification data in this manual are listed in SI with standard I.S.O. pitch threads. Torque specifi- and METRIC UNITS. Use this table to convert cations for special components or assemblies are METRIC unit data to IMPERIAL unit data.
Shift cam and bearing (gearshift cam) Shift shaft Bonding agent (rapid seal adhesive) ® Rod housing coupled surfaces Yamaha bond No. 1215 ® Bonding agent (rapid seal adhesive) ® Coupled surfaces (cylinder head and cylinder head cover) Yamaha bond No. 1215 ®...
SPEC LUBRlCATlON POINTS AND LUBRICANT TYPE CHASSIS Lubrication points (part name) Lubricant type Gear unit (tachometer) Oil seal edges (completely) Wheel axle (front and rear wheels) Rear wheel hub and clutch Bearings brasses (rear arm) and bearing push cover Front footrest Pivot points (brake pedal and shift pedal) Bearings (steering head) Pivot points (brake lever and clutch lever)
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INSP ELECTRICAL SYSTEM ....................3-47 CHECKING AND CHARGING THE BATTERY ..........3-47 CHECKING THE FUSES ..................3-53 REPLACING THE HEADLIGHT BULBS ............3-54 REPLACING THE TURN INDICATOR LIGHT BULB..........3-56 REPLACING THE TAIL/BRAKE LIGHT BULB............3-57...
INSP INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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• Check operation. and switches • Adjust headlight beam. * Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NOTE: • The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead.
INSP SEAT, FUEL TANK AND REAR COWLING SEAT, FUEL TANK AND REAR COWLING Order Job name/Part name Q.ty Remarks Seat, fuel tank and rear cowling Remove the parts in order. removal Seat Fuel pipe NOTE: Be sure the cap is properly tightened and the fuel cock is in the “OFF”...
INSP VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: • Valve clearance must be adjusted when the engine is at ambient temperature. • Adjust valve clearance with the piston under compression at top dead centre (T.D.C.). WARNING Hold the motorcycle firmly in place to prevent it falling over during the operation.
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INSP VALVE CLEARANCE ADJUSTMENT 6. Align: • Reference mark “T” on the flywheel (1) with the fixed reference mark on the crankcase (2). NOTE: Check that the piston is under compression at top dead centre (T.D.C.). (3) Ignition timing reference mark 7.
INSP DRIVE CHAIN ADJUSTMENT IDLE SPEED ADJUSTMENT DRIVE CHAIN ADJUSTMENT The drive chain does not need to be adjusted. IDLE SPEED ADJUSTMENT 1. Start the engine and let it heat. 2. Connect: • The inductive engine speed indicator to the spark plug cable Special tool: P/N.
INSP THROTTLE CABLE FREE PLAY ADJUSTMENT THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, adjust the engine idle speed. 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”. 2. Check: •...
INSP SPARK PLUG INSPECTION SPARK PLUG INSPECTION 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”. 2. Disconnect: • Spark plug cap 3. Remove: • Spark plug (1) CAUTION: Before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug wells to prevent it from falling into the cylinder.
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INSP SPARK PLUG INSPECTION 8. Lock tighten: • Spark plug Before installing the spark plug, clean the surface and thread. Spark plug: 18 Nm (1.8 mkg) NOTE: Tighten the spark plug by hand before torquing to specification. 9. Connect: • Spark plug cap 10.
INSP COMPRESSION INSPECTION COMPRESSION INSPECTION NOTE: Insufficient compression causes a loss of per- formance. WARNING Set the motorcycle firmly in place to prevent it falling during the operation. 1. Remove: • Seat • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”.
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INSP COMPRESSION INSPECTION 8. Check: • Pressure under compression Inspection: • Turn the main switch to "ON". • With the throttle wide open, crank the engine until the reading on the compression gauge stabilized. WARNING While operating the starter, disconnect the spark plug cap to avoid sparks.
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INSP COMPRESSION INSPECTION Pressure under compression: (after adding oil to the cylinder) Reading Diagnosis Pressure higher Piston worn or than before damaged. Pressure same Cylinder head or as before piston rings, valves, gaskets may be faulty. Pressure above Inspect cylinder maximum value head, valve sur- faces, piston rim to...
INSP ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL CHECK CAUTION: Do not put additives into the engine oil. The latter also lubricates the clutch and additives might cause it to slide. WARNING Never remove the oil tank cap when the engine is hot.
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INSP ENGINE OIL LEVEL CHECK If the oil level is below minimum Add oil up to maximum level. Recommended oil: SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature. API Standard: API SE, SF, SG or higher grade CAUTION: •...
INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT CAUTION: Do not put additives into the engine oil. The latter also lubricates the clutch and additives might cause it to slide. WARNING Never remove the oil tank cap when the engine is hot. The boiling oil might spill over, causing burns.
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INSP ENGINE OIL REPLACEMENT Fastening torques: Drain plug (engine): 30 Nm (3.0 mkg) Oil tank hose (flange): 10 Nm (1.0 mkg) Oil filter cover air bleeder screw: 5 Nm (0.5 mkg) 9. Fill: • Oil tank Recommended oil: SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature.
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INSP ENGINE OIL REPLACEMENT Engine oil replacement (with oil filter replace- ment) 1. Warm up the engine for a few minutes. 2. Stop the engine. Place an oil pan under the engine and remove the oil filler cap. 3. Remove the drain plug (1) and drain the engine oil.
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INSP ENGINE OIL REPLACEMENT 11. Fill: • Oil tank Recommended oil: SAE20W40SE or SAE10W30SE Refer to the chart for selection of the oils suited to the atmospheric temperature. API Standard: API SE, SF, SG or higher grade Oil capacity: Total: 3.0 litres Periodic oil change: 2.4 litres...
INSP ENGINE OIL PRESSURE CHECK/ CLUTCH ADJUSTMENT ENGINE OIL PRESSURE CHECK 1. Remove: • Bleeder screw (1) 2. Start the engine and keep it idling until oil flows out of the bleed hole. 3. Inspect: • Conditions of oil at bleeder hole. Oil leakage Oil pressure good.
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INSP CLUTCH ADJUSTMENT NOTE: After adjustment, recheck lever free play to make sure that it works smoothly and progressively. If it is impossible to obtain the required adjust- ment or if the clutch does not work properly, adjust the internal mechanism. Internal mechanism adjustment 1.
INSP AIR FILTER CLEANING AIR FILTER CLEANING 1. Remove: • Fast screws (1) • Air filter box cap (2) 2. Pull out: • Filtering element (3) from its seat 3. Wash: • Filtering element (with water biodegradable liquid soap) NOTE: Rinse properly and dry perfectly by squeezing the filtering element, without twisting it! 4.
INSP AIR FILTER CLEANING/ FUEL FILTER CLEANING CAUTION: Periodically check wheter the sleeve on the bottom of the air filter case is empty. Remove the plug (5) and clean it if dirt or water accu- mulate. FUEL FILTER CLEANING 1. Turn the fuel cock to "OFF". 2.
INSP ENGINE OIL TANK FILTER CLEANING ENGINE OIL TANK FILTER CLEANING WARNING Securely support the motorcycle so there is no danger of it falling over. 1. Drain: • Engine oil See section “ENGINE OIL REPLACE- MENT”. 2. Remove: • Seat •...
INSP ADJUSTING THE FRONT BRAKE CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • Brake lever position (distance a between the brake lever and the handlebar grip) a. Turn the adjusting dial 1 while holding the lever pushed away from the handlebar grip NOTE: Align the setting on the adjusting dial with the arrow mark 2...
INSP ADJUSTING THE REAR BRAKE ADJUSTING THE REAR BRAKE 1. Check: • Brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification Adjust. Brake pedal position (below the top of the rider footrest): 10 mm 2.
INSP CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Check: • Brake fluid level Below the minimum level mark a the recommended brake fluid to the prop- er level.
INSP BRAKE PAD WEAR INSPECTION/ BRAKE HOSING INSPECTION 1. Operate the brake lever or brake pedal. 2. Check: • Thickness of frictional material Out of specification Replace. Wear limit (a): Front: 1.0 mm Rear: 1.0 mm For brake pad replacement, see section “BRAKE REPLACEMENT”...
INSP BRAKE CIRCUIT BLEEDING BRAKE CIRCUIT BLEEDING WARNING If the brake lever or brake pedal has a soft or slack feel, this means that there is air in the brake system. It should be bled away before using the motorcycle. Air in the system seri- ously affects the effectiveness of braking and may cause loss of control of the motorcycle.
INSP DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT NOTE: If bleeing proves difficult, it may be necessary to allow the brake fluid system to stabilise for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. Top up fluid to the maximum level.
INSP DRIVE CHAIN SLACK INSPECTION AND ADJUSTMENT/ DRIVE CHAIN LUBRICATION • Loosen the axle nut (1). • Loosen the locknuts (2) on each side. To tight- en the chain, turn the chain adjusting bolts (3) in direction (a). Loosen the locknuts on each side.
INSP FRONT FORK INSPECTION/ FRONT FORK ADJUSTMENT FRONT FORK INSPECTION WARNING When inspecting the front fork, hold the motorcycle firmly to prevent it falling over. 1. Place the motorcycle on a level surface. 2. Check: • Inner tube Scratches/Damage Replace. •...
INSP REAR SHOCK ABSORBER ADJUSTMENT REAR SHOCK ABSORBER ADJUSTMENT WARNING This shock absorber contains highly pressur- ized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The man- ufacturer cannot be held responsible for prop- erty damage or personal injury that may result from improper handling.
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INSP REAR SHOCK ABSORBER ADJUSTMENT NOTE: • Use the special wrench included in the owner's tool kit to make the adjustment. • The spring preload setting is determined by measuring distance A, shown in the illustra- tion. The longer distance A is, the lower the spring preload;...
INSP STEERING INSPECTION STEERING INSPECTION WARNING Hold the motorcycle firmly in place to prevent it falling over. 1. Raise the front wheel and place a support under the engine. 2. Check: • Steering bearings Grasp the bottoms of the front fork legs and rock back and forward.
• A list of tyres approved for this model fol- lowing severe testing by Yamaha is provid- ed. There can be no guarantee of safe road- holding if a combination of tyres different from those indicated is used.
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INSP TYRE INSPECTION 1. Check: • Tyre pressure Out of specification Adjust. Tire air pressure (measured on cold tires) Load* Front Rear 200 kPa 220 kPa Up to 90 kg (2.00 kgf/cm , (2.20 kgf/cm 2.00 bar) 2.20 bar) 210 kPa 240 kPa 90 kg-maximum (2.10 kgf/cm...
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INSP TYRE INSPECTION Minimum track thickness: (front and rear) 1,6 mm NOTE: These limits may be different by regulation from country to country. If so, conform to the limits specified by the regulations of your own country. (1) Track thickness (2) Side (3) Wear indicators WARNING...
INSP WHEEL INSPECTION/ SPOKE INSPECTION AND TIGHTENING WHEEL INSPECTION 1. Inspect: • Wheels Damage/Deformation Replace. NOTE: Always balance the wheel after the replacement or reassembly of a tyre or rim. WARNING Never try to repair a rim in any way. Bearing inspection Check the front and rear wheel bearings periodi- cally to make sure that they do not have free play...
INSP CABLE INSPECTION/ LEVER AND PEDAL LUBRICATION CABLE INSPECTION WARNING If the cable sheath is damaged, corrosion might ensue or the cable might not run freely. To avoid such drawbacks, replaced damaged cables as quickly as possible. 1. Inspect: • Cable sheath Damaged Replace the cable assembly.
INSP SIDESTAND LUBRICATION/ REAR SUSPENSION LUBRICATION SIDESTAND LUBRICATION Lubricate the sidestand pivoting and mating parts. Check to see that the sidestand moves up and down smoothly. Recommended lubricant: SAE 10W30 motor oil REAR SUSPENSION LUBRICATION Lubricate the pivoting parts. Recommended lubricant: Molybdenum disulfide grease 3-46...
INSP CHECKING AND CHARGING THE BATTERY ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
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INSP CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by meas- uring the voltage at the battery terminals.
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INSP CHECKING AND CHARGING THE BATTERY WARNING Ambient Do not quick charge a battery. temperature 20 °C CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger. They force a high-amperage current into 30 2520 the battery quickly and can cause battery Condition of charge in battery (%)
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INSP CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Charger NOTE: Measure the open-circuit meter Voltage should be measured 30 minutes voltage prior to charging. after the machine is stopped. NOTE: Connect a charger and AMP Set the charging voltage at 16 ~ 17 V (if the setting is lower, charging will be meter to the battery and start...
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INSP CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- voltage prior to charging. utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
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INSP CHECKING AND CHARGING THE BATTERY 6. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 2, then the negative lead 1. 7. Check: • Battery terminals Dirt Clean with a wire brush. Loose connection Connect properly.
INSP CHECKING THE FUSES CHECKING THE FUSES CAUTION: To avoid a short circuit, always turn the main switch to "OFF" when checking or replacing a fuse. 1. Remove: • Seat • Panel 1 2. Check: • Fuse a. Connect the pocket tester to the fuse and check it for continuity.
INSP CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical sys- tem, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
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INSP REPLACING THE HEADLIGHT BULBS 7. Install: • Headlight bulb (new) • Headlight bulb holder (by turning it clock- wise (b)) CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
INSP REPLACING THE TURN INDICATOR LIGHT BULB 4. Install: • Bulb (new) (by pushing it in and turning it clockwise) • Bulb holder • Upper side of the cowling (onto the meter bracket) • Headlight (adjust the headlight beam if necessary) 5.
INSP REPLACING THE TAIL/ BRAKE LIGHT BULB REPLACING THE TAIL/BRAKE LIGHT BULB 1. Remove: • Screws (1) (lens fixing) • Lens (2) • Bulb (3) NOTE: To remove the bulb press it into place and turn it counterclockwise (a). 2. Install: •...
CHAS FRONT WHEEL AND BRAKE DISC CHASSIS - FRONT WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Front wheel and brake disc Remove the parts in order. removal WARNING Securely support the motorcycle so there is no danger of it falling over. Speedometer cable Disconnect.
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CHAS FRONT WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Front wheel disassembly Remove the parts in order. Oil seal Bearing Refer to “FRONT WHEEL DISASSEMBLY/ Spacer ASSEMBLY” section. Oil seal Bearing Reverse the removal procedure for instal- lation.
CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL DISASSEMBLY 1. Remove: • Oil seal • Bearing (1) • Spacer Removal procedure: • Clean the outside of the hub. • Remove the dust cover with a flat-headed screwdriver. NOTE: Place a rag on the outside to avoid damaging the hub.
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CHAS FRONT WHEEL AND BRAKE DISC 4. Tighten: • Loose spokes Spoke: 2 Nm (0.2 mkg) NOTE: After tightening the spokes, check the centring of the wheel. 5. Measure: • Front wheel runout Over the specified limits Replace. Front wheel runout limits: Radial (1) : 1.0 mm Lateral (2) : 0.5 mm 6.
CHAS FRONT WHEEL AND BRAKE DISC BRAKE DISC INSPECTION 1. Inspect: • Brake disc Wear/Damage Replace. 2. Measure: • Brake disc deflection (a) If over envisaged limits Verify wheel centring. If the wheel centring is correct, replace the brake disc. Maximum deflection (brake disc): 0.15 mm Misure at 2 mm from disc edge...
CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL INSTALLATION 1. Install: • Brake disc (1) Screw (brake disc): 12 Nm (1.2 mkg) NOTE: • ® Apply LOCTITE to the threads of brake disc screw. • Tighten the screws (brake disc) in stage using a crisscross pattern.
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CHAS FRONT WHEEL AND BRAKE DISC Procedure: a. Spin the wheel and wait for it to rest. b. Put an “X ” mark on the wheel’s bottom spot. c. Turn the wheel so that the “X ” mark is 90° up. d.
CHAS FRONT BRAKE FRONT BRAKE BRAKE PAD 25 Nm (2.5 m • Order Job name/Part name Q.ty Remarks Remove the parts in order. Brake pad removal Brake caliper screw Brake caliper Refer to “BRAKE PAD REPLACEMENT” Pad pin retainer section. Pad pin Brake pad Pad spring...
CHAS FRONT BRAKE CAUTION: Brake components must not be disassembled. The builder declines every responsibility after brake components disassembly (brake master cylinder or brake caliper) or in case of use of non original parts. DO NOT: • Remove brake components from the motorcycle unless is absolutely necessary.
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CHAS FRONT BRAKE 3. Lubricate: • Guide pins (1) Lithium-base grease 4. Install: • Pin bracket (2) (on the caliper body (3)) NOTE: Fit the rubber protections (4) when installing the caliper body. 5. Install: • Pad springs (1) (new) •...
CHAS FRONT BRAKE MASTER CYLINDER 9 Nm (0.9 m • 20 Nm (2.0 m • Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order. Brake fluid Drain. Rear view mirror (right)/ Master cylinder bracket Brake lever Brake switch Union bolt Plain washer...
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CHAS FRONT BRAKE 1.5 Nm (0.15 m • Order Job name/Part name Q.ty Remarks Master cylinder disassembly Remove the parts in order. Reservoir cap Diaphragm Master cylinder boot Refer to “MASTER CYLINDER ASSEM- Circlip BLY” section. Master cylinder assembly Spring Reverse the disassembly procedure for assembly.
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CHAS FRONT BRAKE CAUTION: Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING • Use only designated quality brake fluid. Otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.
CHAS FRONT BRAKE BRAKE CALIPER 20 Nm (2.0 m • 25 Nm (2.5 m • Order Job name/Part name Q.ty Remarks Remove the parts in order. Caliper removal Brake fluid Drain. Union bolt Plain washer Refer to “CALIPER INSTALLATION” sec- Brake hose tion Caliper support bolt...
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CHAS FRONT BRAKE 14 Nm (1.4 m • Order Job name/Part name Q.ty Remarks Caliper disassembly Remove the parts in order. Brake pad Refer to “BRAKE PAD” section. Pad spring Caliper piston Refer to “BRAKE CALIPER DISASSEM- Dust seal BLY/ASSEMBLY” section. Piston seal Bleed screw Refer the disassembly procedure for as-...
CHAS FRONT BRAKE BRAKE CALIPER DISASSEMBLY 1. Remove: • Brake caliper piston • Dust seal (1) • Piston seal (2) Removal procedure: • Blow compressed air into the hose joint open- ing to force out the caliper piston from the brake caliper body.
CHAS FRONT BRAKE • Fluid delivery passage (caliper) Obstruction Clean with compressed air. WARNING In case of non correct operation of the brake caliper, replace the brake caliper assembly. CALIPER ASSEMBLY WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
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CHAS FRONT BRAKE WARNING Check that the brake hose routing is correct. Refer to “CABLE ROUTING” section. 2. Fill: • Brake fluid reservoir Recommended brake fluid: DOT 4 CAUTION: Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Rear wheel and brake disc removal Remove the parts in order. WARNING Securely support the motorcycle so there is no danger of it falling over. Axle nut Wheel axle Push the wheel forward and remove the...
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CHAS REAR WHEEL AND BRAKE DISC Order Job name/Part name Q.ty Remarks Rear wheel disassembly Remove the parts in order. Driven sprocket Damper Spacer Refer to “REAR WHEEL DISASSEMBLY/AS- Oil seal SEMBLY” section. Bearing Bearing Hub dust cover Oil seal Bearing Reverse the removal procedure for installa- Bearing spacer...
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CHAS REAR WHEEL AND BRAKE DISC 4. Lubricate: • Wheel axle • Bearings • Edge of hub dust cover Lithium-base grease CAUTION: Check that the brake caliper support has stayed in the correct position on the rear arm. 5. Install: •...
CHAS REAR WHEEL AND BRAKE DISC WHEEL STATIC BALANCE ADJUSTMENT NOTE: • After replacing the tire and/or rim, the wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc installed. 1. Remove: • Balancing weight 2.
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CHAS REAR WHEEL AND BRAKE DISC 5. Check: • Wheel static balance Checking steps: • Turn the wheel so that it comes to each point as shown. • Check that the wheel is at rest at each point. If not, readjust the rear wheel static balance. 4-28...
CHAS REAR BRAKE REAR BRAKE BRAKE PAD Order Job name/Part name Q.ty Remarks Remove the parts in order. Brake pad removal Rear wheel Refer to “REAR WHEEL REMOVAL” section. Brake hose Remove from clamp. Caliper protector Pad pin retainer Pad pin Refer to “BRAKE PAD REPLACEMENT”...
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CHAS REAR BRAKE CAUTION: Brake components must not be disassem- bled. The builder declines every responsibility after brake components disassembly (brake master cylinder or brake caliper) or in case of use of non original parts. DO NOT: • Remove brake components from the motorcycle unless is absolutely necessary.
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CHAS REAR BRAKE 3. Install: • Brake pads • Pad support Installation procedure: • Connect the hose (1) firmly to the caliper bleeder screw (2). Place the other end of the hose in an open container. • Loosen the caliper bleeder screw and push the piston into the caliper with your finger.
CHAS REAR BRAKE MASTER CYLINDER 20 Nm (2.0 m • 4 Nm (0.4 m • 10 Nm (1.0 m • 45 Nm (4.5 m • Order Job name/Part name Q.ty Remarks Master cylinder removal Remove the parts in order. Brake fluid Drain.
CHAS REAR BRAKE MASTER CYLINDER INSTALLATION 1. Install: • Brake pedal (refer to “BRAKE PEDAL REMOVAL” section in this Chapter). NOTE: Lubricate the pin of the brake pedal with lithium- base grease. • Master cylinder • Brake fluid reserve tank •...
CHAS REAR BRAKE 3. Air bleed: • Brake system Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)” in Chapter 3. 4. Inspect: • Brake fluid level Lower than “MIN” mark (1) Fill. Refer to “BRAKE FLUID INSPECTION” section in Chapter 3. (1) Minimum level mark “MIN”...
CHAS REAR BRAKE BRAKE CALIPER Order Job name/Part name Q.ty Remarks Remove the parts in order. Caliper removal Rear wheel Refer to “REAR WHEEL REMOVAL” sec- tion. Brake fluid Drain. Brake hose Remove from clamp. Caliper protector Brake caliper Remove from caliper support. Union bolt Refer to “BRAKE CALIPER INSTALLA- Plain washer...
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CHAS REAR BRAKE 14 Nm (1.4 m • 10 Nm (1.0 m • Order Job name/Part name Q.ty Remarks Caliper disassembly Remove the parts in order. Caliper protector Brake pad support Brake pad Refer to “BRAKE PAD” section. Pad support Refer to “BRAKE CALIPER DISASSEM- Caliper piston BLY/ASSEMBLY”...
CHAS REAR BRAKE BRAKE CALIPER DISASSEMBLY 1. Remove: • Brake caliper piston (1) • Dust seal (3) • Piston seal (2) Removal procedure: • Blow compressed air into the hose joint open- ing to force out the caliper piston from the brake caliper body.
CHAS REAR BRAKE • Fluid delivery passage (caliper) Obstruction Clean with compressed air. WARNING In case of non correct operation of the brake caliper, replace the brake caliper assembly. BRAKE CALIPER ASSEMBLY WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
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CHAS REAR BRAKE CAUTION: Check that the brake hose has stayed in cor- rect position with the pipe-fitting matching the projection (a) of the caliper. WARNING Check that the brake hose routing is correct. Refer to “CABLE ROUTING” section. 2. Fill: •...
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CHAS REAR BRAKE 4. Inspect: • Brake fluid level Lower than “MIN” mark (1) Fill. Refer to “BRAKE FLUID INSPECTION” section in Chapter 3. (1) Minimum level mark “MIN” 4-41...
CHAS FRONT FORK FRONT FORK FRONT FORK REMOVAL Order Job name/Part name Q.ty Remarks Remove the parts in order. Front fork removal Front wheel Refer to “FRONT WHEEL” section. Inner tube protector Brake hose guide Protector guide Brake caliper assembly Cowling (displace) Pinch bolt (upper bracket) Cap bolt (loosen)
CHAS FRONT FORK FRONT FORK DISASSEMBLY Order Job name/Part name Q.ty Remarks Front fork disassembly Remove the parts in order. Refer to “FRONT FORK REMOVAL/INSTAL- LATION”. Cap bolt Seat Spacer Refer to “OIL REPLACEMENT” section. Seat Fork spring Bolt O-ring Damper adjusting cylinder Refer to “SEAL AND BUSH REPLACE- Taper spindle...
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CHAS FRONT FORK Order Job name/Part name Q.ty Remarks Inner tube Inner tube bushing Oil seal Refer to “SEAL AND BUSH REPLACE- Washer MENT” section. Outer tube bushing Outer tube Reverse the removal procedure for instal- lation. 4-44...
CHAS FRONT FORK OIL CAPACITY (IN EACH FORK LEG): 650 cm RECOMMENDED OIL: Liqui Moly Racing suspension oil SAE 7,5 FRONT FORK OIL LEVEL STANDARD 180 mm MINIMUM 190 mm MAXIMUM 170 mm From top of inner tube with inner tube fully com- pressed without spring.
CHAS FRONT FORK OIL REPLACEMENT NOTE: The quality of the fork oil is of fundamental impor- tance for obtaining the maximum performance and functioning. For this reason it needs to be replaced after the first 3÷4 hours to eliminate any residues due to the adaptation of the internal components and successively every 8 hours for motor-cross and every 20 hours for enduro.
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CHAS FRONT FORK 7. Fill: • Part of the new oil (with the fork leg in a vertical position) Recommended oil: Liqui Moly Racing suspension oil SAE 7,5 8. Using the inner tube pump back and forth until a regular drag is felt on the return stroke. 9.
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CHAS FRONT FORK 14. Tighten: • Pinch bolt (upper and lower bracket) Pinch bolt (upper bracket): 28 Nm (2.8 mkg) Pinch bolt (under bracket): 23 Nm (2.3 mkg) NOTE: Always tighten the lower pinch bolt (to the pre- scribed torque) and then the upper one (to the prescribed torque) and then retighten the lower one (to the prescribed torque).
CHAS FRONT FORK CLEANING THE DUST SEAL NOTE: After using the motorcycle it is necessary to clean the dust seal carefully in order to maintain the fork at maximum efficiency. In fact, if dust infiltrates to the inside of the dust seal it can compromise the smoothness and therefore the sensitivity of the fork, and also cause the premature wear of the underlying oil...
CHAS FRONT FORK 4. Using a small screwdriver take a small amount of silicon grease and insert it under the lip paying attention not to scratch it. Lubricate the dust seal by rotating it in such a manner that the grease is distributed in the inner part of the lip.
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CHAS FRONT FORK 3. Insert an Allen key in the bolt (3) at the bottom of the outer tube and the special tool (1) with the holder (2) on the damper cylinder assem- bly and unscrew the bolt completely. CAUTION: Before unscrewing the bolt ensure that the end of the damper rod holder is correctly engaged on the damper cylinder assembly.
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CHAS FRONT FORK WARNING Never tamper with the damper cylinder assembly! Tampering with the damper cylinder assembly by non authorized personnel can compromise tha safety of the fork. In order not to cause damage to the environment collect the used oil and take it to a collection centre. 6.
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CHAS FRONT FORK 9. With a few sharp blows withdraw the inner tube (2) from the outer tube (3). NOTE: The oil seal (4), the washer (5), the outer tube DU bush (6) and the inner tube DU bush (7) are installed on the inner tube and must be removed and replaced with new one.
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CHAS FRONT FORK 12. The vice tightened, grip the outer tube and with a few strong blows hit it against the tool (3) until the DU outer tube bush (4) is correct- ly positioned in its seat. ~ 40 mm 13.
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CHAS FRONT FORK 16. Tightly clamp the fork leg horizontally fasten- ing it by caliper attachment on the outer tube. 17. Install: • Snap ring (1) CAUTION: Check that the snap ring is correctly seated. 18. Install: • Dust seal (1) (new) NOTE: Apply lightweight lithium-soap base grease to the dust seal before installing it.
CHAS FRONT FORK 19. Insert: • Damper cylinder assembly (in the inner tube) 20. Insert an Allen key in the bolt (3) at the bot- tom of the outer tube and the special tool (1) with the holder (2) on the damper cylinder assembly and screw the bolt completely.
CHAS FRONT FORK FRONT FORK INSPECTION CAUTION: The front fork has a very sophisticated inter- nal construction and is particularly sensitive to foreign bodies. Use enough care to prevent foreign bodies entering when replacing oil or disassembling and reassembling the front fork. 1.
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CHAS FRONT FORK WARNING Do not attempt to straighten a bent inner tube as this may have dangerous consequences. 4. Inspect: • Outer tube (1) Score marks/Wear/Damage Replace. 5. Inspect: • Cap bolt • O-ring Wear/Damage Replace. 4-58...
CHAS FRONT FORK FRONT FORK INSTALLATION 1. Install: • Front fork (1) Temporarily tighten the pinch bolts (lower). 2. Tighten: • Cap bolt Cap bolt: 20 Nm (2.0 kgm) NOTE: Do not tighten the pinch bolt (upper) yet. 3. Adjust: •...
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CHAS FRONT FORK ADJUSTING THE FRONT FORK This front fork is equipped with spring pre-load ad- justing bolts. WARNING Always adjust both fork legs equally, other- wise poor handling and loss of stability may result. Adjust the spring preload as follows. To increase the spring preload and thereby hard- en the suspension, turn the adjusting bolt on each fork leg in direction a.
CHAS STEERING TIGHTENING PROCEDURE • Initial tightening 38 Nm (3.8 mkg) • Loosen 1 turn • Final tightening 4 Nm (0.4 mkg) Order Job name/Part name Q.ty Remarks Steering removal Remove the parts in order. Park the motorcycle on a level surface. WARNING Securely support the motorcycle to pre- vent it falling over.
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CHAS STEERING TIGHTENING PROCEDURE • Initial tightening 38 Nm (3.8 mkg) • Loosen 1 turn • Final tightening 4 Nm (0.4 mkg) Order Job name/Part name Q.ty Remarks Upper ring nut Refer to “STEERING REMOVAL/INSTAL- Lower ring nut LATION” section. Ball race cover Lower bracket/Steering axle Bearing (upper)
CHAS STEERING STEERING REMOVAL 1. Park the motorcycle on a level surface. WARNING Support the motorcycle securely to prevent it falling over. 2. Raise the front wheel placing a suitable sup- port under the engine. 3. Remove: • Front wheel Refer to “FRONT WHEEL-REMOVAL”...
CHAS STEERING 7. Remove: • Ring nut (lower) (1) • Use the ring nut wrench (2) Ring nut wrench (2): 90890-01268 WARNING Support the steering axle to prevent it falling. STEERING INSPECTION 1. Wash the bearings in solvent. 2. Inspect: •...
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CHAS STEERING 3. Install: • Ring nut (lower) (1) Use the ring nut wrench (2). Ring nut wrench: 90890-01268 NOTE: Apply the lithium soap-base grease to the steer- ing axle thread. Lower ring nut tightening steps: • Tighten the ring nut (1) using the ring nut wrench.
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CHAS STEERING Installation steps: • Install the ring nut (upper) (1). • Finger tighten the ring nut (upper), then align the slots of both ring nuts. If not aligned, hold the lower ring nut and tighten the other until they are aligned. •...
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CHAS STEERING 8. After tightening the nut, check the steering for smooth movement. If it is not smooth, adjust by progressively loosening the (lower) ring nut. 9. Tighten: • Pinch bolts (upper and lower bracket) Pinch bolt (upper bracket): 28 Nm (2.8 mkg) Pinch bolt (under bracket): 23 Nm (2.3 mkg) NOTE:...
CHAS REAR SHOCK ABSORBER Order Job name/Part name Q.ty Remarks Shock absorber removal Remove the parts in order. WARNING Securely support the motorcycle so there is no danger of it falling over. Seat Refer to “SEAT, FUEL TANK AND REAR Fuel tank COWLING”...
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CHAS REAR SHOCK ABSORBER Order Job name/Part name Q.ty Remarks Lower bolt Upper bolt Reverse the removal procedure for instal- lation. 4-70...
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CHAS REAR SHOCK ABSORBER (1) Rear shock absorber (2) Spring (3) Spring adjuster ring nut (4) Lock ring nut (5) End of stroke buffer (6) Special spanner 4-71...
CHAS REAR SHOCK ABSORBER WARNING This shock absorber contains high-pressure nitrogen gas. Read the following information carefully before handling it. The manufacturer cannot be held responsible for any damage or injury that may result from improper handling. • Never tamper with or attempt to open the cylinder or the tank.
CHAS REAR SHOCK ABSORBER SHOCK ABSORBER REMOVAL WARNING Support the motorcycle securely to prevent it from falling over. 1. Park the motorcycle on a level surface. 2. Remove: • Seat • Rear cowling • Fuel tank See section “SEAT, FUEL TANK AND REAR COWLING”...
CHAS REAR SHOCK ABSORBER SHOCK ABSORBER INSPECTION 1. Inspect: • Shock absorber Oil leak/Damaged Replace. REAR SHOCK ABSORBER ADJUSTMENT This shock absorber is equipped with a spring pre- load adjuster. CAUTION: Never attempt to turn an adjusting mecha- nism beyond the maximum or minimum set- tings.
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CHAS REAR SHOCK ABSORBER 2. Tighten the locknut to the specified torque. Locknut: 45 Nm (4.5 m·kgf) CAUTION: Always tighten the locknut against the adjust- ing nut, and then tighten the locknut to the specified torque. 4-75...
CHAS SWINGARM SWINGARM (1) Upper chain case (4) Swingarm guard seal [A] LATERAL FREE PLAY (END): 1.0 mm (2) Swingarm (5) Connecting rod [B] LATERAL FREE PLAY: 0.4 ~ 0.7 mm (3) Chain support (6) Relay arm 4-76...
CHAS SWINGARM SWINGARM REMOVAL NOTE Check free play and remove swingarm, if neces- sary, after removing the rear shock absorber. 1. Remove: • Swingarm connecting rod bolt (1) 2. Check: • Swingarm free play Inspection procedure: • Check the tightening torque of the nut which fastens the swingarm pivot shaft (1).
CHAS SWINGARM LATERAL FREE PLAY ADJUSTMENT 1. Measure: • Length of bushes A1 and A2 Out of specification Replace. Length of bushes: A1 = 76.70 ~ 76.85 mm A2 = 74.90 ~ 75.00 mm 2. Measure: • Length B1 and B2 3.
DRIVE CHAIN, DRIVE SPROCKET CHAS AND REAR WHEEL SPROCKET DRIVE CHAIN, DRIVE SPROCKET AND REAR WHEEL SPROCKET NOTE: Before removing the drive chain, drive sprocket and rear wheel sprocket, it is necessary to meas- ure the free play and length of the 10 links in the chain.
ENGINE REMOVAL ENGINE ENGINE REMOVAL MUFFLER, EXHAUST PIPE, ENGINE PROTECTOR, DRIVE SPROCKET CRANKCASE COVER, DRIVE SPROCKET AND SHIFT PEDAL Order Job name/Part name Q.ty Remarks Muffler, exhaust pipe, engine Remove the parts in order. protector, drive sprocket crankcase cover, drive sprocket and shift pedal removal Park the motorcycle in a stable and level position.
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ENGINE REMOVAL Order Job name/Part name Q.ty Remarks Drain the engine oil (refer to “ENGINE OIL REPLACEMENT” section in CHAPTER 3). Remove the seat, the fuel tank and the rear cowling (refer to “SEAT, FUEL TANK AND REAR COWLING” section in CHAPTER 3).
ENGINE REMOVAL ENGINE MOUNTING BOLT Order Job name/Part name Q.ty Remarks CAUTION: The engine and rear arm are assembled together on the rear pivot shaft. When removing the pivot shaft, it is thus necessary to pay special care with the rear arm.
ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD, CYLINDER, CAMSHAFT AND PISTON NOTE: The cylinder head, cylinder, camshaft and piston can be examined with the engine installed by removing the following parts. • Seat • Fuel tank • Rear cowling • Carburetor •...
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ENGINE DISASSEMBLY 4. Remove: • Cam sprocket (1) • Camshaft (2) • Caps (left crankcase cover) NOTE: Fix a safety wire (3) to the timing chain to prevent it falling into the crankcase. 5. Remove: • Chain stopper guide (1) 6.
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ENGINE DISASSEMBLY 7. Remove: • Gasket (1) (cylinder head) • Pins (2) • Cylinder (3) • Gasket (4) (cylinder) 8. Remove: • Pins (1) 9. Remove: • Pin ring (1) NOTE: Before removing the pin ring, cover the crankcase with a clean cloth to prevent the ring falling into the crankcase cavity.
ENGINE DISASSEMBLY Piston pin puller set: P/N. 90890-01304 CAUTION: Avoid using the hammer to pull the pin out. INTERMEDIATE STARTER GEAR, CRANKCASE COVER (L) AND GENERATOR STATOR NOTE: With the engine installed, maintenance of the inter- mediate starter gear and the crankcase cover (L) may be performed by removing the following parts.
ENGINE DISASSEMBLY OIL PUMP AND SHIFT LEVER NOTE: The oil pump and shift lever may be checked with the engine installed by removing the following parts: • Footrest (R) • Oil delivery hose screw • Crankcase (R) • Clutch 1. Remove: •...
ENGINE DISASSEMBLY AC GENERATOR AND TIMING CHAIN NOTE: The AC generator may be inspected with the engine installed by removing the following parts: • Crankcase (L) 1. Remove: • Nut (1) • Washer (2) • Rotor (3) (with starter gear) •...
ENGINE DISASSEMBLY CRANKCASE (R) 1. Remove: • Crankcase (R) NOTE: • Loosen nuts starting from the one with the highest number. • Loosen all by 1/4 turn and then remove. Removal procedure: • Set the crankcase separating tool (1) in place. Crankcase separating tool: P/N.
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ENGINE DISASSEMBLY CAUTION: • Be careful not to damage surfaces in con- tact with the crankcase. • Use a soft hammer to hit the engine crankcase. Only hit the reinforced parts. Do not hit the surface in contact with the gasket.
ENGINE DISASSEMBLY BALANCER SHAFT AND CRANKSHAFT 1. Remove: • Balancer shaft (1) 2. Remove: • Crankshaft (1) NOTE: • Remove the crankshaft by using the crankcase separating tool (2). Crankcase separating tool: P/N. 90890-01135 • Tighten the separating tool bolts, making sure that the tool body is parallel with the engine crankcase.
ENGINE DISASSEMBLY ROCKER ARMS NOTE: The rocker arms may be examined with the engine installed by removing the following parts. • Seat • Fuel tank • Cylinder head cover 1. Remove: • Cap (1) 2. Remove: • Bolts (1) (rocker shaft) 3.
ENGINE DISASSEMBLY VALVES NOTE: The valves may be inspected with the engine installed by removing the following parts. • Seat • Fuel tank • Exhaust pipe • Carburetor • Cylinder head cover • Cylinder head 1. Check: • Valve seal Leakage from valve seats’...
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ENGINE DISASSEMBLY 2. Remove: • Cotters (1) • Top spring retainer (2) • Internal spring (3) • External spring (4) • Lower spring retainer (5) • Valve (6) • Valve stem seal (7) NOTE: Mark each part and its position so that each may reassembled as before.
INSPECTION AND REPAIR INSPECTION AND REPAIR CYLINDER HEAD 1. Eliminate: • Carbon deposits (from combustion chamber) Use a rounded scraper (1). NOTE: Do not use a pointed tool to avoid damaging or scratching: • spark plug thread • valve seats •...
INSPECTION AND REPAIR VALVES AND VALVE GUIDES 1. Measure: • Clearance between stem and guide Clearance between stem and guide = Internal diameter of valve guide (a) – Diameter of valve stem (b) Out of specification Replace valve guide. Clearance between stem and guide: Intake: 0.010 ~ 0.037 mm <Limit>: 0.08 mm...
INSPECTION AND REPAIR 2. Clean the valve surfaces of the carbon deposits. 3. Inspect: • Valve seal surface Pitting/Wear Grind the valve seal sur- face. 4. Measure: • Edge thickness (a) Out of specification Replace valve. Edge thickness (a): Intake: 1.0 ~ 1.4 mm <Limit>: 0.8 mm Exhaust:...
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INSPECTION AND REPAIR 3. Measure: • Valve seat width (a) Out of specification Renew valve seat. Valve seat width (a): Intake: 1.0 ~ 1.2 mm <Limit>: 1.8 mm Exhaust: 1.0 ~ 1.2 mm <Limit>: 1.8 mm Measurement steps: • Apply Prussian blue (Dykem) to the valve seat.
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INSPECTION AND REPAIR Mill the valve seat as follows: Section Cutter 30° 45° 60° Valve seat faults recorded by analysing the valve seal surface: [A] If the valve surface resembles that shown in the figure, this means that the valve seat is centred on the surface but is too wide.
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INSPECTION AND REPAIR 5. Emery: • Valve seal surface • Valve seat NOTE: If the valve seat is renewed or the valve and guide replaced, the valve seat and seal surface must be lapped. Lapping steps: • Apply rough-lapping compound to the valve seal surface.
INSPECTION AND REPAIR • Apply Prussian blue (Dykem) to the valve seal surface. • Install the valve in the cylinder head. • Press the valve onto the housing through the guide to leave a clear outline. • Measure the valve seat width once more. If the width of the valve is out of specification alter and relap.
INSPECTION AND REPAIR 3. Measure: • Rocker arm-shaft clearance Rocker arm-shaft clearance Internal diameter (a) of rocker arm – External diameter (b) of shaft Out of specification Replace whole unit. Rocker shaft clearance: 0.009 ~ 0.042 mm CAMSHAFT CHAIN AND SPROCKET 1.
INSPECTION AND REPAIR CAMSHAFT CHAIN GUIDE 1. Inspect: • Side chain guide (exhaust) (1) • Side chain guide (intake) (2) Wear/Damage Replace. CYLINDER AND PISTON 1. Inspect: • Piston and cylinder walls Vertical scratches Replace cylinder liner and piston. 2. Measure: •...
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INSPECTION AND REPAIR • If the measurements are out of tolerance, replace the piston and circlips all together. Third step • Calculate the piston-cylinder free play accord- ing to the following formula. Piston-cylinder clearance = Cylinder boring “C” – Piston skirt diameter “P” Piston-cylinder clearance: 0.045 ~ 0.065 mm <Limit>: 0.15 mm...
INSPECTION AND REPAIR PISTON RINGS 1. Measure: • Side clearance of rings Use a thickness gauge. Out of specification Replace piston. NOTE: Before measuring side clearance, remove carbon deposits from the piston ring seats and from the rings themselves. Piston ring side clearance (installed): Upper ring 0.04 ~ 0.08 mm...
INSPECTION AND REPAIR PISTON PIN 1. Check: • Piston pin Blue colour/Grooves Replace and check lubrication system. 2. Measure: • External diameter (a) of pin Out of specification Replace. External diameter (pin): 21.991 ~ 22.000 mm 3. Measure: • Clearance between piston pin and pin seat Out of specification Replace.
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INSPECTION AND REPAIR 2. Inspect: • Clutch gear assy bearing Damaged Replace. 3. Inspect: • Groove in clutch boss. Pitting: Moderate Burr. Accentuated Replace clutch boss. NOTE: Pitting of the clutch boss grooves causes irregular functioning. 4. Measure: • Thickness of friction plates Out of specification Replace all plates.
INSPECTION AND REPAIR 7. Measure: • Free length of clutch compression springs Out of specification Replace all springs. Free length of clutch compression spring (a): 42.8 mm OIL PUMP 1. Measure: • Clearance between rotors (a) (Between the internal rotor (1) and the external rotor (2)) •...
INSPECTION AND REPAIR STARTER TRANSMISSION 1. Check: • Starter clutch functioning (1). Turn the clutch in the direction indicated by the arrow. Irregular functioning/Damage Replace the clutch. • Install the starter rim on the gear and hold the gear firm. •...
INSPECTION AND REPAIR CRANKSHAFT 1. Measure: • Width of crank (A) Out of specification Replace crankshaft. Width of crank: 74.95 ~ 75.00 mm • Runout (B) Out of specification Replace crankshaft and/or crank bearing. Crankshaft runout: <Limit>: 0.03 mm • Connecting rod small end clearance (C) Out of specification Replace connecting...
INSPECTION AND REPAIR BALANCER SHAFT DRIVE AND DRIVEN GEARS 1. Inspect: • Drive gear teeth (1) • Driven gear teeth (2) Wear/damage Replace both gears. 2. Check: • Marks (1) If they are not aligned Align the marks as shown in the figure. CRANKCASE 1.
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ENGINE ASSEMBLY AND SETTING ENGINE ASSEMBLY AND SETTING VALVES AND ROCKER ARMS (1) Rocker arm n. 2 (10) Valve (intake) (2) Wave washer (11) Lower valve spring (3) Rocker shaft (intake) retainer (4) Rocker arm n. 1 (12) Rocker shaft (5) Valve cotters (exhaust) (6) Upper valve spring...
ENGINE ASSEMBLY AND SETTING VALVES 1. Burrs: • Valve stem tip (leave the valve stem tip with an oil stone). 2. Lubricate: • Valve stem and oil seal (apply high quality molybdenum disulfide oil) 3. Install: • Oil seal (1) •...
ENGINE ASSEMBLY AND SETTING 4. Tighten: • Screws (crankcase) (1) ~ (14) NOTE: Tighten the screws beginning with the one with the lowest number. Screw (crankcase): 10 Nm (1.0 mkg) 5. Apply: • 4-stroke engine oil (to the connecting rod pin, the bearing and the oil passage).
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ENGINE ASSEMBLY AND SETTING NOTE: When installing the shift lever, align the mark on the lever with that on the shift shaft. 3. Install: • Circlip (1) (to the driving axle) • Spacer (2) • Circlip (3) 4. Apply: • 4-stroke engine oil (oil pipes in crankcase) CAUTION:...
ENGINE ASSEMBLY AND SETTING PISTON AND RINGS PISTON SIZE: 94.915 ~ 94.965 mm (1) Ring (upper) PISTON RING END GAP: (2) Ring (lower) TOP: 0.30 ~ 0.45 mm (3) Scraper 2ND: 0.30 ~ 0.45 mm (4) Piston OIL: 0.20 ~ 0.70 mm (5) Piston pin PISTON RING SIDE CLEARANCE: (6) Circlip...
ENGINE ASSEMBLY AND SETTING PISTON, CYLINDER, CYLINDER HEAD AND CAMSHAFT 1. Apply: • 4-stroke engine oil (on piston pin). 2. Install: • Piston (1) • Pin (2) • Circlip (3) NOTE: • Arrow (4) on the piston must point towards the front of the engine.
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ENGINE ASSEMBLY AND SETTING 5. Offset the piston ring end gaps as illustrated in the figure. NOTE: • Check that the marks and numbers stamped by the manufacturer on the piston rings face upwards. • Before installing the cylinder, lubricate the pis- ton rings liberally with 4-stroke engine oil.
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ENGINE ASSEMBLY AND SETTING 7. Install: • Dowel pins (1) • O-Ring (2) • Gasket (3) (cylinder head) 8. Install: • Cylinder head NOTE: Tighten screws beginning with the one with the lowest number. Cylinder head: Screw (l), (2), (3) and (4): 29 Nm (2.9 mkg) Nut (5) and (6): 22 Nm (2.2 mkg)
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20 Nm (2.0 mkg) • If the marks are not aligned, replace the chain sprocket mating piston and chain. 10. Apply: Yamaha Bond N° 1215 ® (1) • (on the mating surfaces) Sigillante (Quick Gasket) ® Yamaha bond N° 1215 ® : P/N.
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ENGINE ASSEMBLY AND SETTING 13. Install: • Chain tensioner Assembly steps: • Remove the chain tensioner screw (1), the washer (2) and the spring (3). • Release the chain tensioner unidirectional cam (4) and push the thrust rod (5). • Install the chain tensioner in the cylinder with a new gasket.
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ENGINE ASSEMBLY AND SETTING 15. Install: • Tappet covers (1) (exhaust) • Tappet cover (2) (intake) • Spark plug (3) Tappet cover (exhaust): 12 Nm (1.2 mkg) Screw (tappet cover-intake): 10 Nm (1.0 mkg) Spark plug: 18 Nm (1.8 mkg) NOTE: The tappet cover (intake) should be assembled with the arrow (4) pointing upwards.
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ENGINE ASSEMBLY AND SETTING AC GENERATOR 1. Install: • Woodruff key (1) • Washer (2) • Bearing (3) • Rotor (4) • Washer (5) • Nut (6) NOTE: When installing the AC generator rotor, check that the woodruff key fits properly into its seat on the crankshaft.
ENGINE ASSEMBLY AND SETTING CLUTCH (1) Compression spring (9) Clutch boss (2) Pressure plate (10) Thrust plate (3) Push rod (11) Primary driven gear (4) Ball comp. (5) Friction plate (type A) (12) Push rod (6) Clutch boss spring (13) Push lever (7) Clutch plate (14) Primary drive gear (8) Friction plate (type B)
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ENGINE ASSEMBLY AND SETTING CLUTCH 1. Install: • Plain washer • Spring • Push lever (1) Screw (push lever): 12 Nm (1.2 mkg) 2. Install: • Push rod (1) • Primary driven gear comp. (2) • Thrust plate (3) • Clutch boss (4) •...
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ENGINE ASSEMBLY AND SETTING NOTE: Install the friction and clutch plates to the clutch boss, beginning and ending with a friction plate. CAUTION: • The two friction plates (type A) (15) with the widest internal diameter should be assembled in second and last place. •...
ENGINE REASSEMBLY ENGINE REASSEMBLY To reassemble the engine, repeat the procedures described in the paragraph “ ENGINE REMOVAL” in this chapter in reverse order. Pay attention to the following points. 1. Install: • Sprocket (1) • Drive chain Nut (sprocket): 110 Nm (11.0 mkg) NOTE: Bend the lock washer tab along the face of the...
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ENGINE REASSEMBLY 4. Install: • Oil delivery hose (1) Union bolt: 18 Nm (1.8 mkg) 5. Remove: • Tappet cover (intake) • Air bleeder screw (oil filter cover) 6. Apply: • 4-stroke engine oil • (on the top side of the camshaft and in the oil filter housing).
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ENGINE REASSEMBLY 9. Install: • Carburetor Screw (clamp): 2 Nm (0.2 mkg) See section “CARBURETOR-INSTALLA- TION” in CHAPTER 6. 10. Adjust: • Throttle cable free play Free play: 3 ~ 5 mm See section “THROTTLE CABLE FREE PLAY ADJUSTMENT” in CHAPTER 3. 11.
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CARB CARBURETOR REMOVAL CARBURETOR CARBURETOR REMOVAL Order Job name/Part name Q.ty Remarks Carburetor removal Remove the parts in order. Seat Refer to “SEAT, FUEL TANK AND REAR COWLING" section in CHAPTER 3. Fuel pipe NOTE: Fuel tank Be sure the cap is properly tightened and the fuel cock is in the “OFF”...
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CARB CARBURETOR REMOVAL Order Job name/Part name Q.ty Remarks Hose clamp Loosen. NOTE: Move carburetor manifold clamps towards the rear side. Carburetor Reverse the removal procedure for installa- tion. Adjust throttle cable free play (refer to THROTTLE CABLE FREE PLAY ADJUST- MENT”...
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CARB CARBURETOR TYPE: Y30PV-2ATK MANUFACTURER: TEIKEI 2 Nm (0.2 m . kg, 1.4 ft . lb) 3 Nm (0.3 m . kg, 2.1 ft . lb) 2 Nm m . kg, (0.2 1.4 ft . lb m . kg, 6.3 ft . lb 9 Nm (0.9 m .
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CARB CARBURETOR Carburetor (13) Throttle valve (27) Spring (42) Needle valve set assembly spring (28) Drain valve (43) Stop screw set (14) Spring washer Cover gasket (44) Throttle screw set (29) Pipe (15) Nut Gasket, nozzle (30) Pipe (45) Diaphragm (16) Gasket Float (46) Needle set 1...
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CARB CARBURETOR SECTION VIEW (8) Main nozzle (secondary) (1) Needle jet (primary) (2) Valve seat (9) Main jet (secondary) (3) Needle valve [A] Primary carburetor (4) Main nozzle (primary) [B] Secondary carburetor (5) Main jet (primary) (6) Pilot air screw Fuel (7) Needle jet (secondary) Mixture...
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CARB CARBURETOR DISASSEMBLY CARBURETOR DISASSEMBLY 1. Remove: • Support plate (1) (front) • Support plate (2) (rear) 2. Separate: • Primary carburetor • Secondary carburetor Primary carburetor 1. Remove: • Float chamber (1) • Float pin (2) • Float (3) NOTE: Remove the float needle in the direction of the arrow.
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CARB CARBURETOR DISASSEMBLY 2. Remove: • Needle valve set/Valve seat (1) • Main jet/Main nozzle 1 (2) • Pilot jet (3) • Pilot screw set (4) • O-Ring (5) 3. Remove: • Stop screw (1) • Starter set (2) 4. Remove: •...
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CARB CARBURETOR INSPECTION CARBURETOR INSPECTION 1. Inspect: • Carburetor body Soiled Clean. NOTE: Use petroleum-based solutions to clean. Clean all passages and jets with compressed air. 2. Inspect: • Valve seat (1) • Needle valve set (2) Wear/Corrosion Replace. • O-Ring (3) Damaged Replace.
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CARB CARBURETOR INSPECTION 6. Inspect: • Throttle valve (1) (primary) • Diaphragm (2) (secondary) ear/Damaged Replace. 7. Check: • Free movement Hampered Replace. Fit the throttle valve and diaphragm into the carburetor body and check that move- ment is free. [A] Primary carburetor [B] Secondary carburetor 8.
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CARB CARBURETOR ASSEMBLY CARBURETOR ASSEMBLY Perform “CARBURETOR DISASSEMBLY” opera- tions in reverse order. Pay attention to the follow- ing points. CAUTION: Wash all parts with clean petrol prior to reassembly. Secondary carburetor 1. Install: • Needle jet (1) • Diaphragm (2) •...
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CARB CARBURETOR ASSEMBLY Primary carburetor 1. Install: • Needle jet (1) • Connecter comp. (2) NOTE: Check that the connecter comp. (1) is in the posi- tion shown in the figure. 2. Install: • Throttle valve 3. Install: • Spring •...
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CARB CARBURETOR ASSEMBLY 5. Install: • Cable holder • Collar • Throttle lever NOTE: Check that the throttle shaft lever (2) and the adjuster bolt (3) are aligned when tightening the throttle nut (1). Screw (cable holder): 3 Nm (0.3 mkg) 6.
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CARB CARBURETOR ASSEMBLY 10. Install: • Float pin (1) NOTE: Assemble the float pin in the opposite direction to the arrow. 11. Measure: • Float height (a) Out of specification Adjust. Float height: 27.0 - 29.0 mm Measurement and adjustment: •...
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CARB CARBURETOR ASSEMBLY 14. Install: • Primary carburetor • Secondary carburetor 15. Install: • Support plate (front) (1) • Support plate (rear) (2) Screw (support plate): 3.5 Nm (0.35 mkg) 16. Adjust: • Synchronisation of secondary carburetor Adjustment: • Move the primary throttle valve (1) to a height of 7.0 mm as shown in the figure.
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CARB CARBURETOR ASSEMBLY FUEL LEVEL ADJUSTMENT (CARBURE- TOR INSTALLED 1. Place the motorcycle on a level surface. 2. Make sure that the carburetor is in a horizon- tal position by placing a hydraulic jack under the engine. 3. Connect the fuel level gauge (1) to the carbu- rettor nipple.
ELEC SWITCH CHECK SWITCH CHECK Check the continuity between the switch terminals to verify whether connections are correct. To check the switch, read the following points. SWITCH CONNECTION The table shown here contains the connections between the switch terminals (eg main switch, handlebar switches, brake switch, light switch etc).
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ELEC SWITCH CHECK 1. Detach the main switch connector from the harness connector. CAUTION When detaching the connector, do not pull by the cables. This way the cables might discon- nect from the terminals inside the connector itself. 2. Check to see if any cables are disconnected from their terminal inside the connector.
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ELEC SWITCH CHECK NOTE: Use the thin tester terminals to check continuity, as the terminals might come into contact with oth- ers inside the connector. • Check continuity between “R” and “Br” at switch positions ON (1), OFF (2) and PARK (3). There must be continuity (ie the tester must show “0”) at ON and there must be no continu- ity (ie the tester must show “∞”...
ELEC LIGHT INSPECTION LIGHT INSPECTION (HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHTS, DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) Check the continuity between the bulb terminals to see that they are undamaged. BULB TYPES The bulbs used are classified as shown to the left according to type of attachment.
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ELEC LIGHT INSPECTION CAUTION: When removing a bulb be careful to hold the bulbholder or its housing firmly. Never pull the cable, as it might detach from the terminal inside the connector. WARNING Keep inflammable products and hands well away from bulbs when they are on (danger of burns and fire).
ELEC IGNITION SYSTEM IGNITION SYSTEM - CIRCUIT DIAGRAM 7-11...
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ELEC IGNITION SYSTEM The diagram illustrates the ignition circuit inside the motorcycles electric system. NOTE: For the colour code and legend, see page 7-2. AC generator/Pickup coil (12) Clutch switch Rectifier/Regulator (13) Sidestand switch Battery (14) Neutral switch Fuse (15) Diode Main switch (16) Ignitor unit Engine stop switch...
ELEC IGNITION SYSTEM DIAGNOSTICS IF THE IGNITION SYSTEM WERE TO STOP WORKING (NO OR INTERMITTENT SPARK) Procedure 7. Main switch Check: 8. Engine stop switch 1. Fuse 9. Sidestand switch 2. Battery 10. Neutral switch 3. Spark plug 11. Clutch switch 4.
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ELEC IGNITION SYSTEM 3. Spark plug. • Check the conditions of the spark plug. • Check the type of spark plug used. • Check the electrodes gap. Standard spark plug: OUT OF SPECIFICATION DPR8EA-9 (NGK), DPR9EA-9 Electrodes gap: DPR8EA-9, DPR9EA-9 (NGK) 0.8 ~ 0.9 mm Correct the electrodes gap or replace the spark plug.
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ELEC IGNITION SYSTEM 5. Spark plug cap resistance. • Remove the spark plug cap. • Connect the pocket tester (Ω x 1k) to the spark plug cap. OUT OF SPECIFICATION The spark plug cap is defective. Replace. • Check that the spark plug cap has the specified resistance.
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ELEC IGNITION SYSTEM Primary winding resistance: 4 Ω ± ± 15% at 20°C (68°F) (Terminal (+) – Terminal (–)) • Connect the pocket tester (Ω x 1) to the ignition coil. Tester terminal (+) Spark plug cable (1) Tester terminal (–) Pole (+) OUT OF SPECIFICATION •...
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ELEC IGNITION SYSTEM 8. Emergency stop engine switch. • Disconnect the emergency stop engine switch connector (Brown, Green/Yellow and Red/Black) from the wire harness. • Connect the pocket tester (Ω x 1) to the switch cables. Refer to “SWITCH CHECK” in Chapter 3. Tester terminal (+) Red/Black (1) cable Tester terminal (–)
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ELEC IGNITION SYSTEM 10. Neutral switch. • Disconnect the neutral switch cable (Sky blue). • Connect the pocket tester (Ω x 1) to the neutral switch cables. Refer to “SWITCH CHECK” in Chapter 3. Tester terminal (+) Sky blue cable (1) Tester terminal (–) Earth In gear...
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ELEC IGNITION SYSTEM 12. Pick-up coil resistance. • Disconnect the generator connector (Green/White and Blue/Yellow). • Connect the pocket tester (Ω x 100) to pick-up coil cables. Tester terminal (+) Blue/Yellow cable (1) Tester terminal (–) Green/White cable (2) • Check that the pick-up coil resistance is as OUT OF SPECIFICATIONS specified.
ELEC ELECTRICAL STARTING SYSTEM ELECTRICAL STARTING SYSTEM - CIRCUIT DIAGRAM 7-21...
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ELEC ELECTRICAL STARTING SYSTEM The diagram illustrates the electrical starting system-circuit inside the motorcycles electric system. NOTE: For the colour code and legend, see page 7-2. Battery (10) Starter switch Starter relay (11) Diode Starting motor (12) Clutch switch Fuse (13) Sidestand switch Main switch (14) Neutral switch...
ELEC ELECTRICAL STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed).
ELEC ELECTRICAL STARTING SYSTEM DIAGNOSTICS THE STARTER FAILS TO WORK Procedure (6) Engine stop switch Inspect: (7) Sidestand switch (1) Fuse (8) Neutral switch (2) Battery (9) Clutch switch (3) Starting motor (10) Starter switch (4) Starter relay (11) Harness connections (5) Main switch NOTE: Before starting inspections, remove the following parts:...
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ELEC ELECTRICAL STARTING SYSTEM WARNING 3. Starter • A wire that is used as a jumper lead must • Connect the positive terminal of the bat- have at least the same capacity of the bat- tery (1) and the starter cable (2) using a tery lead, otherwise the jumper lead may connection cable (3) *.
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ELEC ELECTRICAL STARTING SYSTEM 5. Main switch • Disconnect the main switch connector from the wire harness. • Connect the pocket tester (Ω x 1) to the main switch cables. Refer to “SWITCH CHECK” in Chapter 3. PARK INCORRECT Br L Br L The main switch is defective.
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ELEC ELECTRICAL STARTING SYSTEM 7. Sidestand switch. • Disconnect the sidestand switch connec- tor (Black and Black) from the wire har- ness. • Connect the pocket tester (Ω x 1) to the sidestand switch cables. Refer to “SWITCH CHECK” in Chapter 3. Tester terminal (+) Black cable (1) Tester terminal (–)
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ELEC ELECTRICAL STARTING SYSTEM 9. Clutch switch. • Disconnect the clutch switch connector from the harness. • Connect the pocket tester (Ω x 1) to the clutch switch cable. • Check the clutch switch component for continuity between “Black (1)” and “Black (2)”.
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ELEC ELECTRICAL STARTING SYSTEM 11. Harness connections. UNCERTAIN CONNECTIONS Check the connections of the entire starter system. See the “ELECTRIC CIRCUIT DIAGRAM”. Correct. 7-29...
ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR BRUSH LENGHT LIMIT (1) Brushes 5 mm (0.20 in) (2) Armature COMMUTATOR WEAR LIMIT: (3) Stator 27 mm (1.06 in) (4) O-Ring MICA UNDERCUT: 0.7 mm (0.027 in) ARMATURE COIL RESISTANCE: 0.03 ~ 0.04 Ω at 20°C (68°F) 7-30...
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ELEC ELECTRICAL STARTING SYSTEM Removal 1. Remove: • The starter motor Refer to the “ENGINE REMOVAL” sec- tion in CHAPTER 5. Disassembly 1. Remove: • Circlip (1) • Drive gear (2) • Screws (3) • Rear bracket (4) • Washers (5) •...
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ELEC ELECTRICAL STARTING SYSTEM 4. Inspect: • Armature coils (insulation/continuity). Out of specification Replace the motor. How to inspect the excitation coils: • Connect the pocket tester and check continuity (1) and insulation (2). • Check the armature resistance: Armature coil resistance: Continuity check (1): 0 Ω...
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ELEC ELECTRICAL STARTING SYSTEM Assembly Revert the disassembly procedure. Pay attention to the following points: 1. Install: • Brush housing NOTE: Align the jutting surface on the brush housing with the slot (2). 2. Install: • Stator (1) • Front bracket (2) NOTE: Align the reference marks (3) on the stator with the corresponding reference marks on the cover...
ELEC CHARGING SYSTEM CHARGING SYSTEM – CIRCUIT DIAGRAM 7-35...
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ELEC CHARGING SYSTEM The diagram illustrates the charging circuit inside the motorcycles electric system. NOTE: For the colour code and legend, see page 7-2. AC generator/Pickup coil Rectifier/Regulator Battery Fuse 7-36...
ELEC CHARGING SYSTEM DIAGNOSTICS THE BATTERY IS NOT BEING CHARGED Procedure Inspect: 1. Fuse 4. Stator winding resistance 5. Harness connection 2. Battery 3. Charging voltage (whole connection system) NOTE: Before starting inspections, remove the following parts: 1. Seat 2. Rear cowling •...
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ELEC CHARGING SYSTEM 3. Charging voltage • Connect the inductive rev counter to the spark plug cable. • Connect the pocket tester (DC 20V) to the battery, as shown. Tester terminal (+) Battery terminal (+) Tester terminal (-) Battery terminal (-) •...
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ELEC CHARGING SYSTEM Stator coils (2) Tester terminal (+) White cable (1) Tester terminal (-) White cable (3) • Check that the winding resistance of the stator complies with specifications. Stator coil resistance: OUT OF SPECIFICATIONS White (1) – White (2) 0.65 Ω...
ELEC LIGHT SYSTEM LIGHT SYSTEM - CIRCUIT DIAGRAM 7-41...
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ELEC LIGHT SYSTEM The diagram shows the light system circuit inside the electric system of the motorcycle. NOTE: For the colour codes and complete legend, see page 7-2. (3) Battery (22) Dimmer switch (6) Fuse (26) Headlight (7) Main switch (28) Relay assy (18) Left handlebar switch (31) Tail/stop light...
ELEC LIGHT SYSTEM DIAGNOSTICS THE HIGH BEAM LIGHT, PARKING INDICATOR LIGHT, REAR LIGHT, FRONT PARKING LIGHT AND/OR INSTRUMENT LIGHTS FAIL TO TURN ON. Procedure Inspect: 4. Dipped/high beam light and dimmer switch 1. Fuse 5. Relay assy 2. Battery 6. Harness connections (full system of connec- 3.
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ELEC LIGHT SYSTEM 3. Main switch. • Disconnect the main switch connector from the wire harness. • Connect the pocket tester (Ω x 1) to the switch cables. Refer to “SWITCH CHECK” in CHAPTER PARK INCORRECT Br L Br L The main switch is defective.
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ELEC LIGHT SYSTEM 5. Starter circuit cut-off relay. • Connect the pocket tester (DC 20V) and the battery (12V) to the cut-off relay con- nector terminal of the starter circuit. Battery terminal (+) White/Black terminal (1) Battery terminal (–) Black terminal (2) Tester terminal (+) Brown terminal (3) Tester terminal (–)
ELEC LIGHT SYSTEM LIGHT SYSTEM INSPECTION NOTE: To proceed to the control of the light system, start the engine and then stop it by the emergency engine stop switch. In this way the light relay remains excited and it is possible to check the light system. 1.
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ELEC LIGHT SYSTEM • Turn the main switch to ON. • Turn the lights switch to “LO” or “HI”. • Check the voltage (12V) on the “Green” and “Yellow” cable at the bulbholder ter- minals. IN COMPLIANCE WITH SPECIFICATIONS (12V) The circuit is efficient.
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ELEC LIGHT SYSTEM 3. The parking light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Replace the bulb and/or bulbholder. Refer to “BULB INSPECTION” section. CONTINUITY 2. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector.
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ELEC LIGHT SYSTEM 4. The rear light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Refer to “BULB INSPECTION” section. Replace the bulb and/or bulbholder. CONTINUITY 2. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector.
ELEC SIGNAL SYSTEM SIGNAL SYSTEM - CIRCUIT DIAGRAM 7-51...
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ELEC SIGNAL SYSTEM The diagram shows the signal system circuit inside the electric system of the motorcycle. NOTE: For the colour codes and complete legend, see page 7-2. (3) Battery (23) Flasher switch (6) Fuse (24) Horn (7) Main switch (25) Flasher relay (11) Diode (27) Flasher light...
ELEC SIGNAL SYSTEM DIAGNOSTICS • THE FLASHER LIGHTS, BRAKE LIGHT AND/OR WARNING LIGHTS FAIL TO TURN ON. • THE HORN FAILS TO SOUND. Procedure Check: 1. Fuse 2. Battery 3. Main switch 4. Harness connections (entire system of con- nections) NOTE: •...
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ELEC SIGNAL SYSTEM 3. Main switch. • Disconnect the main switch connector (Blue, Red and Brown) from the wire har- ness. • Connect the pocket tester (Ω x 1) to the main switch cables. Refer to “SWITCH CHECK” section. Tester terminal (+) Red cable (1) Tester terminal (–) Brown cable (2)
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CONTROL 1. The horn does not work. 1. Horn switch. • Disconnect the left handlebar switch con- nector from the wire harness. • Connect the pocket tester (Ω x 1) to the switch terminals. • Check the switch component for conti- nuity between “Pink (1)”...
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ELEC SIGNAL SYSTEM 3. Horn. • Disconnect the “Pink” cable from horn ter- minal. • Connect a special cable (1) to the horn terminal and earth the cable. • Turn the main switch to ON. THE HORN WORKS The horn is efficient. THE HORN DOES NOT WORK 4.
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ELEC SIGNAL SYSTEM 2. The rear stop light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Refer to “BULB INSPECTION” section. Replace the bulb and/or bulbholder. CONTINUITY 2. Brake switch. •...
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ELEC SIGNAL SYSTEM 3. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector. Tester terminal (+) Green/Yellow cable (1) Tester terminal (–) Black terminal (2) OUT OF SPECIFICATION The circuit from the main switch to the bulbhol- •...
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ELEC SIGNAL SYSTEM • Check the switch component for conti- nuity between “Brown/White (1)” and “Brown/Black (2)” and “Brown/White (1)” and “Green/Black (3)”. Refer to “SWITCH CHECK” section. Y GB INCORRECT The direction indicator switch is defective. Replace. CORRECT 3. Direction indicator lamp relay. •...
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ELEC SIGNAL SYSTEM 4. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector. Tester terminal (+) Brown/White terminal (1) Tester terminal (–) Earth OUT OF SPECIFICATION The direction indicator lamp relay is defective. • Turn the main switch to ON. Replace.
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ELEC SIGNAL SYSTEM 5. Voltage. • Connect the pocket tester (DC 20V) to the bulbholder connector. • Connect the left handlebar switch connec- tor to the wire harness. To the left flasher light: Tester terminal (+) ➔ Green/Black terminal (1) Tester terminal (–) ➔...
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ELEC SIGNAL SYSTEM 4. The “N” neutral light fails to turn on. DISCONTINUITY 1. Bulb and bulbholder. • Check the continuity of the bulb and bulb- holder. Refer to “BULB INSPECTION” section. Replace the bulb and/or bulbholder. CONTINUITY 2. Neutral switch. •...
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ELEC SIGNAL SYSTEM OUT OF SPECIFICATION • Turn the main switch to ON. • Check the voltage (12V) on the Brown ca- ble of the bulbholder connector. IN COMPLIANCE WITH The circuit from the main switch to the bulbhol- SPECIFICATIONS (12V) der connector is defective.
TRBL FAILURE TO START/ SHTG DIFFICULTIES IN STARTING TROUBLESHOOTING NOTE: The troubleshooting tables that follow do not identify every cause of trouble. They may however prove helpful as a guide to identifying trouble. To inspect, adjust or replace parts, refer to the appropriate sec- tion in the manual.
TRBL POOR PERFORMANCE AT IDLE SPEED/ SHTG UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED POOR PERFORMANCE AT IDLE SPEED PROBABLE CAUSES • Carburetor The starter piston fails to return freely • Pilot jet obstructed or loose • Pilot jet obstructed • Pilot air screw wrongly set •...
TRBL SHTG DIFFICULTIES IN SHIFTING DIFFICULTIES IN SHIFTING SHIFTING IMPOSSIBLE PROBABLE CAUSES • Clutch Clutch cable wrongly set • Wrong position of push lever • Irregular engagement of push lever and push • Pressure plate deformed • Clutch springs not preloaded uniformly •...