mz service manual -...

SERVICE MANUAL

r--'M \

~--------------------'/CJt "--

{f

ENGINE4NN I MuZ 660 E • YAMAHA

FOR MuZ

SKORPION TOUR, TRAVELLER, SPORT, REPLICA, CUP

AND

MuZ650 E

BAGHIRA, MASTIFF

Motorrad- undZweiradwerk GmbH

..--_._---YAMAHA MOTOR CO., LTD

.._ _ ~ - -

SERViCE MANUAL660E.doc

IMPORTANT REMARK

The repair manual you got is reprinted from the below mentioned mikroflchebecause of that and the only possible method of repnnting the text is unfortunatelynot in a very good quality.Nevertheless this manual will be helpful for you to maintain our MuZ SKORPIONresp. MuZ S60E BAGHIRA and MASTIFF.

Partly reprint of microficheSkorpion Motor MuZ660UK 06/1994 [SERVICE MANUAL YAMAHA XTZ 660(91),Part engine]Equipped with new pictures, created by MuZ GmbH, Service DepartmentDeadline 1998-06-03

© 1991 by YAMAHA Motor Co, Ltd (Text and drawings)© 1998 by Motorrad- und Zweiradwerk GmbH, Zschopau (pictures)and KARLHEINZ MOLLER (photos as basis of all new pictures)

All rights reserved. Any unauthorised reprinting or use without the written permissionof Yamaha Motor Co., Ltd, Motorrad- und Zweiradwerk GmbH, Zschopau, isexpressly prohihibited.

2

SERVICE MANUAL660E.doc

NOTICE

This manual was written by the Yamaha Motor Company primarly for use by Yamahaand MuZ dealers and their qualified mechanics. It is not possible to put an enliremechanic's education into one manual. so it is assumed that persons using this bookto perform maintenance and repairs on Yamaha resp. MuZ motorcycle have a basicunderstanding of the mechanical concepts and procedures inherent in motorcyclerepair technology. Without such knowledge, attempted repairs or service to thismodel may render it unfit to use andl or unsafe.

Yamaha Motor Company, Ltd and MuZ GmbH are continually striving to improve allmodels manufactured by Yamaha resp. MuZ.Modifications and significant changes in specifications or procedures will beforwarded to all authorized MuZ dealers and will, where applicable in future editionsof this manual.

PARTICULARLY IMPORTANT INFORMA1"ION

This material is distinguished by the following notation.

The Safety alert symbol means ATTENTIO! BECOMEALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNIG instruction could result insevere injUry or death to the motorcycle operator, abystander or a person inspecting or repairing themotorcycle.

CAUTION

NOTE

A CAUTION indicates special precautionsthat must be taken to avoid damage to the motorcycle.

A NOTE provides key information to make procedureseasier or clearer.

3


CONTENTS

ILLUSTRATED SYMBOLS

MAINTENANCE SPECIFICATIONSENGINECARBURETORLUBRICATION SYSTEMCOOLING SYSTEMCRANKCASE TIGHTENING SEQUENCEELECTRICAL SYSTEMLUBRICATION POINTS

ENGINE DISASSEMBLYPIPE,STARTER MOTOR AND HOSESCYUN DER HEAD AND CYLINDERROTOR AND STARTER DRIVESOIL FILTER AND WATER PUMPCLUTCH AND BALANCER GEARSHIFT LEVER AND OIL PUMPCRANKCASE (RIGHT)OIL STRAINERBALANCER, TRANMISSION AND SHIFTERCRANKSHAFTROCKER ARMVALVES

INSPECTION AND REPAIRCYLINDER HEADVALVE SEATVALVE AND VALVE GUIDEVALVE SPRINGCAMSHAFTDECOMPRESSIONROCKER ARM AND ROCKER ARM SHAFTTIMING CHAIN, SPROCKET AND CHAIN GUIDECYLINDER AND PISTONCRANKSHAFTBALANCER GEARSELECTRIC STARTER DRIVEPRIMARY DRIVECLUTCHTRANSMISSION AND SHIFTEROIL PUMP, WATER PUMP AND STRAINEROIL DELIVERY PIPESCRANKCASEBEARING AND OIL SEALCIRCLIP AND WASHER

ENGINE ASSEMBLY AND ADJUSTMENTVALVE AND ROCKER ARMVALVESROCKER ARMCRANKSHAFTBALANCER AND TRANSMISSION

PAGE

6

YAMTD001

YAMTD001YAMTD005YAMTD005YAMTD005YAMTD006YAMTD007YAMTD009

DE01

DE01DE02DE06DEOaDE10DE12DE14DE16DE16DE17DE18DE19

DE21

DE21DE22DE25DE27DE28DE30DE30DE31DE32DE3SDE37DE3?DE38DE38DE40DE42DE44DE44DE44DE44

DE45

DE45DE46DE48DE49DE51

4


CONTENTS

SHIFTERBALANCER. TRANSMISSION AND SHIFTEROIL STRAINERCRANKCASESHIFT LEVER AND OIL PUMPOIL STRAINERCRANKCASE (RIGHT)SHIFT LEVER AND OIL PUMPBALANCER GEARCLUTCHCLUTCH AND BALANCER GEAROIL FILTER AND WATER PUMPROTOR AND STARTER DRIVESCYLINDERCYLINDER HEADCAMSHAFT AND TIMING CHAINPIPES AND HOSES

WATER PUMP

CARBURETORDISASSEMBLYPRIMARY CARBURETORSECONDARY CARBURETORINSPECTIONASSEMBLYMEASUREMENT AND ADJUSTMENT STEPSINSTALLATIONFUELLEVELADJUSTMENT

FUEL PUMP

ELECTRICAL STARTER SYSTEMSTARTER MOTORDISASSEMBLYINSPECTION AND REPAIRASSEMBLY

CHARGING SYSTEM

TROUBLE SHOOTINGSTARTING FAILURE/HARD STARTINGPOOR IDLE SPEED PERFORMANCEPOOR MEDIUM AND HIGH SPEED PERFORMANCEFAULTY GEAR SHI FTINGCLUTCH SLIPPING/DRAGGINGOVERHEATING OR OVERCOOLINGFAULTY BRAKEFRONT FORK MALFUNCTIONINSTABLE HANDLINGFAULTY SIGNAL AND LIGHTING SYSTEM

PAGE

DE53DE55DE56DE57DE58DE58DE59DE62DE63DE64DE6SDE70DE74DE75DE7SDE83

DW1

DC1

DC4

DCSDC6DC?DC9DC13DC15DC16

DCn

DSTART1

DSTART1

DSTART2DSTART3DSTART5

DCHARGO

TROUBLE01

TROUBLE01

TROUBLE03TROUBLE03TROUBLE04TROUBLE04TROUBLE05TROUBLE06TROUBLE06TROUBLEO?TROUBLE08

5


ILLUSTRATED SYMBOLS(Refer to the illustration)

..~~~_ ..

1 [1iJ2

~3

~4

~5

~6 [g] 7

~j

8 1 9 1 10 1 ,

m @) e11

~

14Ia

121;;Tj;;:

13

YAMSYMB.COf

Illustrated symbols 1 to 16 are used toidentify the specificationsappearing in the text

1 filling fluid2 Lubricant3 Special tooi4 Tightening5 Wear limit, clearance6 Engine speed7 n,V,A

lllustrated symbols 8 to 14 in theexploded diagram indicate grade oflubricant and location of lubricationpoint.

8 Apply engine oil9 Apply gear oil10 Apply molybdenium disulfide oil11 Apply wheel bearing grease12 Apply lightweight lithium soap base

grease13 Apply molybdenuim disulfide grease14 Apply locking agent (Ioctite)

"

MAINTENANCE SPECIFICATIONS

Model 4NN MuZ 660

Cylinder head:Warp limit. * 0,03 mm (0,0012 ii'll

* Linos indicate straightedge measurementt , , ,*

T~v1 ".I i "

Cylinder:Bore size/Measuring point * 100,005-100,045 mm 13,9372-3,9388 inl

[]J*50 mm 11,97 in)

< Wear limit :> 100,1 mm 13,941 in)mmmmmmmcc _

Camshaft:Drivemethod Chain drive (left)

!Camshaft outside diameter 22,967 - 22,980 mm 10,9042 - 0,9047 In)

.Shaft to cap clearance O,020-0,ll54 mm 10,0008-0,0021 ii'llCam dimensions: Intake A" 35,69-35,79 mm 11,4051-1,4091 ii'll

"~ < Umit > 35,54 mm 11,3992 ii'll

sn 30,06- 30,16 mm 11,1835-1,1874 ii'll

1\1 "<'Limit :> 29,91 mm 11,1776 In)en 5,74 mm 10,2260 In)

~'"

Exhaust A" 36,50-36,60 mm 11.4370-1,44C-9 In)"< Limit> 36,35 mm 11,4311 in)6" 30,11-30,21 mm 1t,t854-1.1894 in)"

,

<Limit .> 29,96 mm 11,1795 in)C" 6,55 mm 10,2579 in)..

Camshaft runcut limit 0,03 mm 10,0012 in)

Jl ff¢-t>j~:Z'::f:: .

lJ 8

llmlng chain:Chain typel No. Of links 75 RH 2015/126 LinksChain adjustment method Automatic

Rocker arm! rocker arm shall:Rocker arm inside dlam. 12,000-12,018 mm (0.472-0,473 in)Shall outside dlam. 11,976-11,991 mm (0,471-0,472 ii'llArm to shall clearance

0,009-0,042 mm 10,0004-0,0020 in)

YAMTDOOl

MAINTFNANCE SPECIFICATIONS

Modeli 4NN MuZ.660

Valve, valve seat, valve guide:

IN 0,10-0,15 mm 10,004-0,006 in)EX 0,15-0,20 mm (0,006-0,008 in)

Valve clearence (cold):

Valve dimensions:

AUHead alameter

~8'Face width

!" , CS'Seat'width

!\D"

Margin thicknJs~'

Stem runout limit

GUide inside diam.

<limit>

< Limit >

IN ! 29,9-30,1 mm (1,1772-1,1850 in)EX 31,9-32,1 mm 11,2560-1,2638 in)IN 2,25 mm (0,0886 in)EX 2,26 mm (0,0890 in)IN 0,9-1,1 mm 10,035-0,043 in)EX 0,9-1,1 mm 10,035-0,043 in)IN 0,85-1,15 mm 10,0335-0,0453 in)EX 0,85-1,15 mm (0,0335-0,0453 In)IN 5,975-5,990 mm (0,2352-0,2358 in)EX 5,960-5,975 mm 10,2346-0,2352 in)IN 5,95 mm (0,234 in)EX 5,93 mm 10,233 in)IN 6,000-6,012 mm (0,2362-0,2367 in)EX 6,000-6,012 mm (0,2362-0,2367 in)IN 6,05 mm (0,238 in)EX 6,55 mm 10,258 in)IN 0,010-0,037 mm (0,0004-0,0015 in)EX 0,025-0,052 mm lO,0010-0,0020 in)IN O,OB mm (0,003 in)EX 0,1 mm (0,004 in)

0,01 mm (0,0004 il;l).

Bu

"

C""Seat width

~ ~!.......... 'ljII' i 1!

Face width

AuHead diameter "

Stem to guide clearance

Margin thickness ,,0"limit

Stem outside diam.

< Limit>

Valve seat width INEX

0,9-1,1 mm (O,035-0,oi in)0,9 -1,1 mm 10,035 - 0,00 in)

YAMT0002

Model

Valve spring:leng'ltl

Set lengtl> (valve closed)

Compressed pressure(valve closed)

Tlltlimi!


." 4NN MuZ 850--------1

IN 32,63 mm {1,285 in)EX 36,46 mm n,435 in)IN 27,50 mm {Ul63 in)EX 31.00 mm 11 ,220 in)IN 10,2-11,8 kg 122,49-26,01 Ib)EX 12,3-14,1 kg 127,12-31,08 IblIN 2,5 0 /1,4 mm 12.5"/0,055 inlEX 2.5"/1.6 mm 12,5"/0,063 inl

Direction of winding(top view)

IN Clockwise 0Clockwise 0

Piston:Piston size "D"

Meclsuring point"H"

Piston off setPiston off set directionPiston to cylinder clearance< Limit >

,+,-+H

99,945 - 99,985 mm {3,935 - 3,936 in)2,5 mm (O,OOO in)

1 mm 10,04 in)INSIDE0,050 - 0,070 mm 10,0020 - 0,0028 in)<0,15 mm (0,0059 inl>

Piston ring:Top ringTypeDimensions laxT)End gap (Installed)

Borell1,2x3,8 mm lO,047xO,l50 in)0,30-0,45 mm 10,012-0,018 Inl

Side clearance (Installed)

2nd ring:TypeDimenSIOns (BxT)End gap (installed)

T

0,04-0,08 mm 10,002-0,003 in)

Taper1,2x4,0 mm (0,047xO,157 in!0,30-0,45 mm (0,012 - 0,018 in)

0,03-0,07 mm 10,001-0,003 in)

Oil ring:Dimensions (BxT) ~ C i't8End gap (installed) I. ~----!.

clearance (installed] T

2,5 x 3,4 mm {0,098 x0,134 in)0,2-0,7 mm {0,008-0,028 in)0,015-0,042 mm (0,0000-0,0017 inl

VAMTDCCl3

AU"

Model

CrankshaftCrank width

Runout limit"C"Big end side clearance "D" ...f-Big end radial clearance" E" © t;.Small end ~

free play "F" U E'

+Jf..+D~A-l

Balancer:Drive method

Ciiiich:Friklion plateThicknessQuatity

Wear limit

Frlktlon plateThicknessQuantitywear JImit

Clutch plateThicknessQuantitywear limit

Clutch spring.Free lengthQuantityMinimum free length

Clutch release melhod

TransmissionMain axle n./frout limitDrive axle runout limit

Shifter:Type


4NN MuZ660

74,95 - 75,00 mm (2,951 - 2,953 inl0,03 mm (0,0012 in)0,35-0,65 mm (0,014-0,026 in)0,01 - 0,025 mm (0,0004 - 0,0010 Inl0,8-1,0 mm (0,0315-0,0394 in!

gear

2,74-2,86 mm 10,108-0,113 in)6 pes2,6 mm (0,102 inl

2,94-3,06 mmlO,116-0,120 in)2 pCS

2,8 mm (0,110 inl

1,2 mm 10,047 in)7 pes

0,2 mm (0,008 in)

42,8 mm (1,685 in)5 pes40,8 mm (1,606 in)Ouler pUll, raCK and pinion pull

O,OB mm 10,003 in)0,08 mm (0,003 in)

Cam drum and gUide bar

i

I

!

I

•Decompression device

Type Automatics:

YAMTD004

I

Carburetor:ID mar"

Model~~~~


4NN MuZ660

3YF 00, 4BW 00 (AHCH)

Primary , Secondary

Main jet (M.J.1 #130 ! #165

Main air jet (MAJJ </>1,0 <i> t ,0Jet needle (J.N.! 5D96·3/5 5X7C·315

5D97·3/5 iAHCHI

Needle jet (N.J.) VOO ¢2,7

Pilot jet IP.J.! #48 -Pilot air jet IPAJ.! 00,6

Bypass (B.P.! <1>1,0 -Pilot screw (p.S.l 2 und 1/2 Turns open -Carburetor diameter 26 mm (0.97 In) 35 mm (137 in )

Valve seat(v.S') 4>2,5 -

Starter et(G.S.! #76

Pilot outlet(P.O.1 00,8

Fuel level IF.Ll 6,0-8,0 mm (0,24-0,31 inl

Float heightBelow from the float chamber mating surface

(F.H.l 25-27 mm 10,98-1,06 in!1.250-1.350 r/min

Vacuum pressure at Idllng speed26,6- 34,6 kPa1200-260 mmHg, 7,87-10,24 inHgl

Lubrication system011 filter type Paper type

011 pump type Trochoid· Pump type

Tip clearance 0,12 mm IO,D05 in!

Side clearance 0,03-0,08 mm 10,001-0,003 inl

Bypass valve setting pressure 80-120 kPa(0,B-l,2 kg/em', 11,3B-17,07 psi)

Cooling system Water

radiator Skorplon 1 pesBaghiral Mastiff 2pcs

fan Skorplon 2 pesBaghlral Mastiff 1pes

Water pumpType Single suction centrifugal pump

Reduction ratio 33/34 10,971)Thermostat

17LB1°C (160.. 178°F)Opening temperatur

YAMTOOOS


Model 4NN MuZ 660

Lubrication chart: q Pressured feed

.. Splashed

II

Connecting rod

Rocker arm

1 j

i II III! III

"III I

,------·JIOne way clutch _ I

"i-Jii.._ f'II

j I-III

-II,I"..~

Crank

, Balancer

Shift fork shaft ~ Gear f ,~======~I"i :

Main axle ' Clutch I'-------' >11

, Drive aXle ===========:;.:., __-...J

Bypassvalve

Check valve

IIIIII• I....

IReUe! valveIIj I

II r-:===~II I r t II J ; I

II "' ...IIIIIIIIIIf I ; iII 'I I r""'----.,I 11'-'~":;;:~:.:.J---........1.'.:C::a::.:.m:..:s~h:::aft~.-J11....

Feed pump

! Oil strainer!

Crankcase tightening sequence:

Crankcase (left) Crankcase (right)

YAMTOOO6

ELEKTRICAL

Model

VoltageIgnition system:

Ignition timing (B.T.D.C.)Advanced timing (B,T.D.C.)Advancer type


4NN Mul 660

12V

12° at 1.300 U/min (Rpm)38° at 6.500 U/min (Rpm)Electrical type

rpm

I •I f

Engine speed (x 10' rpm )

IgnitorPickup coil resistance(Colour)Ignitor unit I Manufacturer

Ignition coilModel/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistanceSpark plug gapTypeResistance

Charging systemType

1184-2760 at 200 e (68°FI

(Blue/yellow ·GreenlwhitElTNDF13/NlPPONDENSO

J0268/NlPPONDENSO6 mm 10,24 in)3,4-4,60 at 20°C (68°F)10,4-15,6kO bel 200 e {68°FI

Resin type10kO at 200 e {68°FI

AC. Magneto generator

YAMTOOO7


!4NN MuZ eooModel

AC. GeneratorModell manufacturer TLMZ551NIPPONDENSOnominal output 14V 24,5A at 5.000

, !,

I ,26 I

C24, , I _'I22

<ll 20-, - 18::J ,<..l 16 , ' ,] 14 I , ,

12

C10 , ,S I I ,

6<I2 , , ' i ,o 1 2345578

Engine speed \ x 10' rpm )

Stator coil resistance (colour) I 0,20 - O,JOP. At 2Qac !6l:lc F} t VI.'hite· whj!"~m.

Rectifier /regulator i

Model/manufacturer SH569/SINOENGEN

Type Semi conductor -short circuit ripeVoltage regulator

No load regulated vottage 14,3-15,3VRectifierCapacity 25AWithstand voltage 240V

BatteryiIlI!I1.28kg/l (1,23 kgli for tropical countriesspecific gravity

Electrical starter system:TypeStarter motor

Model/manufacturer SM·13iMlTSUBAOutput 0,8 kW

Brush- overall lenght 12,5 mm (0,49 inl

<Limit :> <5 mm 10,20 inl>Commutator diameter 28,0 mm (1,10 inl

Wear limit 27,0 mm (1,06 in)Mica undercut 0,7 mm 10,028 in)

Starter relayModel/manufacturer MS5D·1911HITACH)

Amperage rating l00A

1-

ENGINE

LUBRICATION POINTS AND LUBRICANT TYPE

LUBRICATION POINTS (part name) LUBRICANT TYPE

Oil seal lips (all) ~~" MM••~"m

-(!]Bearing retainer!---------- -1mCrank pin

~

-Ie!]Connecting rod (big end)

"'""j -1mPiston and piston ring

i

~.. "mmm,,~~_ .......-

Boss (balancer dove gear)~..

Piston pin -1Ci]r· ..

Valve stem and valve gUIde._~ .....

-€]Oil seal (valve stem end) -18~ .. m ______

....~Rocker arm shaft and rocker arm -1Ci]__m"~"",,___ ----- ._--._......-

Cam and bearing [camsr.aft) I -I~

Decamp cam and decamp shaft

!-I~

Rotor and rotor housing (oil pump)...n_..

-IG.].._ ... ---_...

Push rod I --!I'iiC~r--:-- ......._ ........-IG.]Primary driven gear and maIn axle I

Sliding gear (transmission) I -GFree movement gear (transmission) -G

.......-i

Driven gear and drive gear (tachometer gear unit) I ~~

Shift fork and guide bar -IG.]Shift cam and bearing (shift cam) i -1mShift shaft -iCi]- ...

Crankcase mating surfacesSealant (Quick gasket)'"

I

Yamaha Bond Nr. 1215

Mating surfaces (cylinder head and Sealant [Quick gasketl$cylinder head cover) i Yamaha Bond Nr. 1215

YAMTDOO9

~ENGINE DISASSEMBLY

ENGINE OIS,l,\SSEMBLYPIPE. STARTER fI/IO:r:OR ANO HOSES

1 Remove'--Oii pme

i: -Reruov-8:'

''OJ! Pine:

.,3 .i-:t-emo~e ~

.*SuHier "fOt1,)f

4 Removft-0,1 hose 1-Breather hn$€ 2 {crank.case'"Breather -hoSe 3 I (ill tank.}

,5 Remove-COOil;:ifH _hOi\~-'~,

DE 01(E17)

ENGINE DISASSEMBLY

C1'LINOER,'l;:iEAD, CYLINDER ANDPISTONNOTE','_'~ _

With'. t~e engine I1'lOunted the cyiHK)e r head

;ove'r:"camShati and cy1mder h-elHj Gan bfc malt,.tained 'bY: removing HlP 1nJiO'V\lH1~ ports

!'"Seat '.," Side c'.overs '-Air::' sccl'opsoFuet .tanK.·

, .; .... E-ng'~e gt.Jarri• Radlsior' .• E.tl~u~i' PIp"S

.,gmti6.n:cOil, .,-0,1 ,Ilmi<: breather 'h,,'se

" ,.-C;:arbn'~10l

- l' Re'11(}ve.. Spark Jilun'-

2 R.emuvf~·

- .Irq~ke friapd(')lr:'!s

3 Rf'!lIO\:P

-1" achQrll~ttf' HHol llfld

D02(E1Sj

ENGINE DISASSEMBLY

4, Remove:;,. rIming ,plug.{'Iug Icenter) 2

5. Tum:·C,ankshat!

tuntil TDC·mar~ 3: IS a'ilSFlea wl1h·statli.,ln

iH;Y po,nter 4)

6· Rem",,!,"Tappet CDver (intake) 1

• Tappet 'cove' !c-~ilal~str

. '7 ..;Rernove.

·Cvhf~del he~d COver ';NOTE: __,.,,-_"'- _

WorkH'lg-ln a crisscross uansro. ioose-t1 the Oolts1>4 ,f~tti- each. Rel'?"ovn' tnem af~pr all aff;loosened "

8 Loosen

·BOllS l I~al~ S;proc'kCll

9 -loos.en'"Cap bOl1 J !chi'H11 1enStoner

10 RemQve

"fCnain tertsJoner 2

ENGINE DISASSEMBLY

:{~ "Remove"··Cl!m SDr:.lik~t

'C~mshall 2NOn: _

• fasten a safe1Y w.Fe 3 to trle timIng .:r{lP1 to~pre",e-nt if from fa1~lng';nto the <f.ankcase

-£10 noHaii the !i!oPDe' g",d~ plsle ~ 101:; 111.

crankcase' 'When f~m(}V;11Q tne ool'\s 1cai'''spfOCJ<~!1

12 Remove- Chain guide"1 (.illadSl).

13 Rempv~:

'P4Ie, i- Q'rlng','Boll& ':I-,an!ls 3-,Solis ~

NOTe' '-- ~--__

WOtkmg in ~ Cfi$Woss pattern loos~n the fmlU;

1/4 tum ear.h Remnvf' lhcm aft{>t fltl ~ire'

IQOsel;leo.

14 R'P.mov~'

.CY,hndt,r. hetH;

004(£20)

.ENGINE DlSASSEMBLY

.15. Remo....e-Gasket· 1 IcyhntJ(!'~ neadj., DOwel pjns. 2

'ur, Ramovt7:':~P{PI! '1

17,: ~'e~ove:. ·'Batts. 'I'. , .

.•B"""''''2. -NOTE: --?l'.,-".....-------\lvo;kmg on n,ct<ls-scrCSS pattern, loostiH1 the nalts

1M- t~rn ~ch ~e~ove.them a{ter al' 'aut !()O~nd

18 • R-emov.e

~Cyhnrle'

1$ ·Remo"t"If,Ga$~et I tC'ylmti-ef~

- Dowel Dlr;s 2

D05(E211

ENGINE DJSASSeMBLY

•

cAUTiON:

20 '!'lemove'e!'-lstOtl pip C!H':!IP 1.~lSt6n pi~,2

;. PIStO!" .3

Piston pin putler:piN.~·YU-01JCi4, 908oo-0T304

"NOTE: __

-Bctorf;ft"emoving the piston pln4.C;lfciJp. Gover Ine

c'rankc';se wnh a ciann rag ro-ptP..venLtI'le (:11 f

clip lrcm faUirw inw the cranKcaS!1 cavity

• Befo~eremoving the p,siil" lJm. deb,,;,'toe ci,p

gre.oved and.'.;)jn, hol~' area If· the pl?t"" plr~groove IS debutr.ed and pisron pin'ls ~t1jj ctl~flC.lJlt,. '-

lo:.femove.. _~se the p,ston pin puller

, - . .Do ;,ot'u1le a'hatnmer to drive the piston pin

:out.

ROTOR AND STARTER, DRI\(ERSNOT!,: ........:..-~---7.',. _

With 'the engine mounted. fhe A( !"',aqnp!o allcJ

steHler oHves 'can he maint(olrned rJ'y rCn~O\lin}i "the'following par.t

• EnCl,,'e guard

1 Remove

"Cover 1

DE06(E22)

ENGINE DISASSEMBLV

CAUnON:

Do not allow .the. rotor "Qld", to touch theprOlltctionsj 1)n the rotor

6' Remove

-Nui 1 Irotor;NOTE _--- ""-__

Loosefllb-e mit irotOrJ While- hofGlnfl the rotOt With

the rOWf ho'der 2

lRotor hold.."PIN. YS-0188D 9OS91M17£1

5 Remove:,. Slaf~er id~ ge.ar 2• Needle bearing 2·ShalT .3..~t- 4' tcrankcase CGv~!i·O,?wel pinS' '!l"

'·O·rings If

2 Remove;• s.tarter lote gear 1"NeeC!<e bearmg 2·Shaft 3~Gaskei ""Dowel pm S'

3 O~sconnece

• ~eutra: sWitl;.h lead,4'. ReQlove: '.

• CIa'nkcase: ",Nt"r ~. 1I&l1!NOTE':;.'_""- .,-.

VVofk-ing in a Cfls?crdss' pattefn. loosen rhe bOltS1;'4 turn' 'ein:h. Remove them alter all ari:IOCH!el1l!(L

DE07(23)

ENGINE DISASSEMBLY

, "

7. Remove:• Rotor 1.. '

• W"oonl'H !<oy . :2Use the H')tOf p~U~ J en~ adarHt" t. '

r--::~"";'''-'"-~-,----------_'----'.

, ;Rritpr\ pUIl*l;~ .; I"

~--' ?PJJ''t. Ytl'33271L 9089001362'Adapt"r: j. ··PIN, YM~3,P.: 9OOllO,0400:'1

'N0'rE:-~~~-~--~-Tighten the lOp; hokbn!j !mIll' lluim.k~ st~e lfl.'the to?1 body 15 para"ltetwith,H1€ fotOt' l! ne~:BS,

~fy. one S<;J'~Wmay- be jJaf'k-erj out to 1ft\'

~"i IO~' ;b.iY· " , ...,

B ~Remove

• V,Jr.e-e1 'r:reor• Needle b",,''''g :2·Washer j

9. 'Mp.inove.• Ch'~lfJ HUlrlB'

-Tml1ng dln,ln."2

OIL fi;l TER ANO.WArE R PUM PNOn '_......,. _

VVnh the Cf',gtrlt' rnOHnt~d' trw ","iHt·, (HHt1lJ {.-1;;

he nlamtameo by '~mQv,nq rhf' iOUnWllj~ ptill

"ErlgtTlP guard' . •" •

1.. Ren,uve-O:!l fllt~r fOVPf

ENGtNE D1SASSEMBty

i .. RernQ"1i"::>' .Oir rUte;i.o.,"t!.-r»,;j, .

3. R<lmo:V,,".• V;k't<;'f·pumlS'. "over~

" - .

4. RemD~e:

-0-0, ftt~

1

- '5 Remove:It Wate, pump nOU5loq 1

6 Rem(.ive• CHchp"

-Wattu pump" t.:tea,· 2. '-Pm ·3'.q~G~P '4'Wa"'!~r "lltUp housing. ;5~ Impeller shaft 1\

ENGiNE OlSASSEMsLY

CLUTCH AND BALANCER'GE'ARNOTE ,....:...__-'---~ _

Wllh the eng~mountPod, The Ciutcri. can bf': malr

la~nec py·'removmg the. followIng pa\"ts,

"Cklrcn cah!e-Engine guard

-Water pur;.p tlou~ng

.~Footrest (flghtloBrake pMal ..

Remove:

'Ci~lip1

'Wa&h~r 2- pull lever '3,.RetlJrFj'jpn;ng '4-Washer; 5

2. Remove:

, "Crankcase cover, 1 .lrlgh1LNOTE: __~----'-__'--

, WO~l\tl"'tg.4n a Crisscross 'pattN!" loascrUhe bolts-, 1'/4 turn each Remove - fhem' ·'afJ~r all areloosehed' .

!.,Remove.-Gask'et 1 ''\c:rani<;casf: >Gover!'-Oowel pins

4, RemoveoBol1 1

-Washer 2do Pull ,i;ver axle' :1. [from ~ran~case coven

DE10(E26j

ENGINE DISASSEMBLY

" 5, R"f"Ove• BoLes -i• Outen springs ~.P,eSSU!" p1ale" '3·~asner ~A

"6ea"ng':5•• Pull rod' 6-Fnc:tJon plate. 1,:

". auich p!a,e ~.,,.CushiOnllPHrig,: 9':

NOTE, " ",,:, , ,;

W~'l<inglil';lCJ'1SS1:;"s.,~~".IQ\1."" lhe ball:;,

1i II ~lJr'; ~,ll""'';;'''' ,lhll':'1ill1,.' e( dr.,(OOS~'

:' 6~$r(ill!'il\lell.,L.i.>i:k, 'wi.stlllr~ah'.- .... " . ~ ..

'7,loosen:• NUl Jl.elUl.!:b DOS",

!'JOlt! _

l~~: IHeri>J.j rdJi", J;<)SifW~~ h61diti;1.tO<:~ "'.. .. '..',., '.' . .. '.' ...' ..,~lul,H cpu:wilIi 'urllverllaLclu,lch flcldar .;l ,'". ., . . . :~

Ul'li....l'$al . clu~#t ~I~:."",P/N;YM·91042: \lll89o.~"

a Refl'\QVll',.r;wt 'l,lcluIChh~'·b,C>. wasn~ 2

:'CIWICh bo~,as$e;:u:nr'J• Thr~", pl.,e 4' ,,~ Cltit~h.h<:rusi!il1S

:EN~iNE:;DIS:A$SEMBLY:-----------::9:"8i,(.,:tgfll"n:,:'j~2idk:*:~Shlit, rabs '10;jl:.tioSl'!","

"'NUt,:".02;: i'Grankshaltf

:N<);~I"J,,/~~ri~e~ sti~;i I

:'R~~:iol~~("g~f~{>liriii;;\:lm: pr3let>et~~"•• ., ,~.. .' ~ •. '. ,'.__ d,} " _. _ _.

'tl'\e;ti;~1hot'1he blllanc~r (jilve'gu<" anti ,balance":_" ?_ f' _

gef¥,"'f.ill<.~q,!ei;Ml' to dilroa!;l": thegeaf !C",t~

",:" ",':: .H",·--:,,1'L:Req,pVll,. ,', ~!"amary :dlf~e':gillji ;"1;

"'l"lare'2,,·-o.Salanc!i,"if'iWl'lleal- :3'~P'I~e4" - ", "

~K~l!l>j5 ,,·pja!~: wasj)"'~ iL,'·PfatfL·· ')': . '.

'B~an;::~ :ge~f~:;,"j(ey1'!; ,

SHiFT.LEVEl'l AND GIL PUMPNOTE: -

Wl,tn th~' eflgme mount~~.t 1he 011 pump :;~n he

maiIHlllrlS'd -by femov"y the fOliowifllJ lJ'"i,'Clutch,c,able): - ~ "

• En9'inv g\,aH! •<,.' o'- ... '--f" '.' ,~Watur pump ho

" - '-Footrest \righll·,Btak.e pedal '

OE12(E28)

ENGINE DISASSEMBLY

1 Remove,-Cltcl,p .!• Stull >eve' ;).~ TonHon 5p1'tng 3·Washet 4:

1

•

2. Remove.• Stopper levei' 1,

-Co_ar '2ill Rerum (pnn9 3

3. Remov<;,

·Circlip 'f'0,1 pump Ilea> 2

q Remove

-Oii pump assembly 1

5. Remove'-Gasket-O·fings .2

DE 13tE:2f:lj

ENGINE. DISASSEMBLY

NOTE:

NOTE

A. CnanK'tase 11lghl!

B Cn:u"fktusc ll.P.ft!

Crankcase sepllrating toolPIN, YU·01135·A, 90890.01135

---'

CIl,ANKl:;ASE IRIGHT)1, Remove'

-Bni1s lr:rankcas.e:

" Remove'·C·IClJp 1

·Colla t ~

-ClfClIP 3 ~

'l.oosen 1he bon:; 1 4 tlJrn Biler] nod r?mOVe themafter all are looseoef:l

• Loosen the bolts slanln5i w.1h me h!ghesi' rlvf"'l"\

bered one.tThe embossed numbers In tlii; crankCfu.,e fles,.g

nct,';; the~tigh1enlng s.equ$f\te

'2 An.til,

-Cnmkcasc separahng lO<)1

3 Rerno~:

·Cranke••" lnghll 2

Turn the shift t:am tc; the PCSI!lot\ Shtfv·,,·,,: m tr-.eflgDr~ ~c 'that It doos not C(H1tHC'~ (h~ rlj.m;.ca-s.e

whe-n sepanUtt)ij. rhf: cr attkcasc:

ENGINE DISASSEMBLYNOTE: ~ _

.fully 11ghum the too! hold"'9 bolts, but makesure the roo' body,s parallel ,,11M' the Case IInecessary. one screw m'ay oe backed OUI<llight'y

to level 1001 bodv,• Ai'pressure IS- aPl)lled. allerr;alely tap 0" me,

front engine ",{)Unting boss, lransm...ion shatts,MId shift ,cam,

CAUTION:'

Use. lOott h~mme, to flip on the case half, Tap

o"ly on rei~for'cedPQrtions of case" Do 1101

tap on gllSket mating su.rface, Work slowlyand carefully, Make !Iure'the cas'e hal""ssepa,ate eV<l"'ly. If one end "hangs up:' take

. pressure off the !)llSh screw, r'eali~li, andstart over. If the "-5 do 1'101 separate,check for II remaming Clll~e ser.,,,,,, dr fitting,Do not force,

1

4 Remolle'-Oowel DU,S- ,1

"'Dowel pIn 2-Q'ring '3

ENGINE DISASSEMBLY

Oil.: .STRAINER1.. Remove

- Oil $traIf1~r t'Oil pas~ag~ COVel .2

'2: Remove'• Ga$k~l' f .\oil. ;;varn~r)

BALANCER. TRANSMISSION' AND. -SHIF.TI'RJ R'emove:

• Shih sMa.!! f, "

. • ShlO shaft 2 '2!

2, Remove

-Gulfflfbjl' Ishort)• Guide bar ;1 00119 i

-Sh'l' cam '3-Sh,lt.lark 2 "C' 4·.Sh;!' lork 3R' 5

-Shilt lor." "'l" 6

3. Remove*M,,;n axle assembly

DE1srE321

a~

I

.,<..:

ENGINE DISASSEMBLY

, ,Remo\le.

• D7Ive axle 8sse1TIQlv 1

·Coitar 2

3

,5 Rernpve'• BalafT~ef shaft :1

EL 'Rt'fm9vf!''.,N""fral:swl'ch l'

CRANKSHAFl 'Ra;mo:"e~

• Crani<shah a.sembl, ,U~ the "cfa~'k"ase ·_~eparat!ng t~l- 2" andaaaprel,3

'Crank",."" ,.""ratlng 1001:"P/I'\I',YU·Ot135-A, 9Qll9O.0H3!5. .Al1l>ptl!r

PIN,' YM~,A.!I069O~J.

NOTE, -'-----T-~--~;..r,gMel'l the lQol hOl<1tngl:li;)lllJ, bUt mlIke sur~ IliatUle ,lnOlb,lK!y IS v";:i,cal wlil1 the C'i>nl<$~alt IfnaclltSSB!'V4- one :;t:rew rnay ~e 1Hici(6ti otll-~IJ9ht.!y to '~vehoo"bO<'lY ,,' , ..

.. .

ROCKER ,ARMNO:rl;;'_' _

WIth thf~ri9'''tr mowltqd ,the ",cke<arf1" can oe'~ini8ine,d,tiy removing thff;t~mowing paft.::~Sit8t'

-!sidi:'co~ers

•Afr~ct"OPs<i:u';;{ l;'~k '"

• '. < •••• '1:-':E°9Ul'(gI,t;;rc!"Fli'd"'tot' ,·Exl'laus1 'P'I>il5.tgnlt~9ncoil

,,~.oil lan~,:fu.eati'l~r 'lOse·Cyltnde','head cove'

J Rerrtove• Plug 1

2. ,RetnOlte'< ,

.Boli ,I. {rod,,,, ",o,',h.;;:

"

ENGINE DiSASSEMBLY

-:>. r\ert'K,)Ve~

'. AOC';;81 lllm shafl• Roder arm

~9TE; _

'Remove tt1e rOCKer -arm shaft 0'1 the slide ham

mern"l:' J.' and weIgl'!! 2

Slide'hsmmllr set:piN YU-ll1ll83-A

Slide hamme. boll'~',. P/N.90S90..01083

Weight,

P! N, 9OO1lO-!l1l:1B4

VALVES'NOTE, .,,- _

8e{Qr.e rernOV!l~~ !he.~rHernat Pilr1S lv-give. v;1t\te

spring, valvp. seat etc. j of the cyHnder J'H,:adThe 'valve sealing snou'ld lae, checked • •

Check• valva sea! Ing

leakage al valve seat "lns~ecl ;00 valv~

faca; valile .eat.al1ovalve sea! width,Refe'1o lhe "iNS:PE~Tlo.N'AND REPAIRVALVE SEAT"

1::11",,1<1,n9 st~psi.• Pour a clean $Of~iTt . 1 inW n··H~·"t:Ta~.eRnd ex

hauST pons,

.. [neck 100 valve sealing, ,

Jlle';;'~h¢.m'Jihe no I""".ge aHl>e ",..I"~"""at

ENGINE DISASSEMBLY

2. llemove:. ;'Valve -Cotters

NOTE: .,..-

-Remove_~hevalve cotters whIte compresSlf)g the

v_ai~ ;sPflnQ _~'f.h the. Witv~ 5prioy co~pre$s'cr

Valve SWil1lPlo.mpressol: .f'I~. YM-04019, !1089l)-04O,li

3 Re;nove.:·Valve reta'joers't Valve- spong 2'·Vah/e 3·Oliseal .4• Spnng sea! 5

NOTE

idef"1,tify eqch part Po~ill()n "Verv CBretully so thar

It can be -relnstafled In'I!S origInal place

~I.NSPECTION AND- REPAIR

INspeCTION ,AND REPAIRCYLiNDER liEAQ.,1. Eliminate:

• Catb';n dl>pasi'

Itrom combustion oharnbe'luSe 'QW1ded ,scraper

NOTE·' ..-

Do nQt vSl!a-sroarp lnS!lwnen; and avO;d aamag:;"9 0' se,att:t1ing.:'Spafil plugth,eaoI). 'VaNe _seat

~ "1 ~nspecj;,

'I' Cy'-,hn der head

SCt'Hr:h~,Darr-.age • Replace

~ \rVater facke[

, ,.cr~Sj of m4naraiS RuSl . ElJrnmiiHf?

3 Measure'_1lWarpagt:

Ou: of specii'icat!on ~ Re5"J!'-fa.ce

Cylinder head ""a,page'Leas than 0,03 mm IlHI012 inl

4 Resurfate'·Cy~tnd~f head

s ••••• r.~ •• ~~ ••• , •• ~~-,R:esu~acement 'Steps.. Piae>.> II 400 - 600 gm wet sandpaper on If>e SUI'

face plaIa, "ndresurtace Ihe heBe using aligure-e,gh1 sanding patte'"

INSPECnOJIIANOREPAIRNOTE: _

Rotate the head. several times to 8yold mmo.vmg

roo much 'material from one SlelL'

VALVE SEAT1 Eiimlnatt?',

-Carbon deoosrt

(·from valve 1acI: and v,qlve'senff

2 lf1$peCI'

-Va'ive seat

. Pf!tin$JfYVear •Rela.cc the valve seal

3. Measure

eValve.. sea1 width a

Out of specrflcatron • Re-tace H1% vaive seal

Valve ."qt,width.Intake

0,9 - 1.1 mm 10,035· 0.043 InlE¥hau.t, "Q,g.- 1,1 mm JO,035 ~ 0043 inl

• .. •• .. •••••••... t .. ~f •••

Measuremeot staps:• Apply the MechaniCS bhJlng oye IDY"em'

to the V.a\\I€: face

• ~S!ah the valve Into the ~yltnder heap.. Press the valv.e through'1he, valve gUide and

onto the valve seal to make a cleat' pattern .

• Measure the yalve sea! w;dth Wherever t~e

valv.e'seat and -valve fac€: rnaOf> contaCl 1l!tJ

HIll wiil have been relXl,o\f8d

.'lfthe \/!Jlve seat wtdth:s too Wide, too naf/OW.

or seat has not centereo. ffu: v.arve Seat mUSI

he f~faced.

0£22!E38)

INSPECTIOIII AND.REPAtR

,,4 Remc,,"*Valve·seat

Usa 8 ;))Q,,4QV and SOC VafV$ seat cutter

When .tWt.S~fl9 cutter k'$:ep an 8''''$''' dowfl,wtI,q'pr..""",,, (4 ".4kg) to prevefV( chattermsrks,

--.Cut Mctionas follows I

,Section I CutU", I1

A 3ll" .i) B ~~ .;.-" i. .

C : $0 1-t: > .l"

Refacing .teps:A. Vaive $$a1. TS' ~;antered -on \ta~ve faoe bul

.1 .~s. tOO wi~~.

;8 valVe sea'! is 'n the 'Midie of Ihe lace hutit i,s .1,00 narrow

..~

\latve seat cutter ,et 'OiHitao ,reS'ult

Tn ftchkfve !t uniformUs. 46" -t;utt1tr v.llw selr w'dth of

1 II mm 100000lni

@-----

INSPECTiON AND REPAIR

·c 'Va~~se<J1 .$ too narrow and Ii IS nea~

valve m8!gm

V.'ve ...t euytef lJet , O".'t'('l:d lesutt

fln,,· To cenl., the :9.81:

U.e 30° c;:utter and tp • .chi-eve its

Second' width ot 1 \l mm ,~ cutter' fO.039 inl

o VaJve saar IS rqo 1l8rf6.... ann :.1 IS ·toclHen"" near the- boHClm' e.dge ot lhe vah.... F<lU>

V.WIl seat cutter SfJ1, Desired r8t\ul\

: Ant:

U••i lOP cun~r To CflMler the SinH liU1C

I' Sec~md: increase its widt",

I i .~o cutter

, '..5. Lap·

·Valve face-Valve sea.t, .

NOTE· -,- _

Aher r-efacing the valve seal 01 replacing the valveand \;6lve."'gwde, lne valve seat and val\re tacE:shQuld 'be lapped

Lappin£! .....pa:

• Appty acoarse lappIng compounn to, rhp. valveface.

cAuTlOI\h-. ..

B:Q sure n'o compoynd ent$fS the gap be,tween the valve stem and guide.

• Apply a.molybdenum dJsulfied Ott to,the valw:stem.'

• !oSlatr thl? valve 'Into 1he cyHnd~, noaa• Turn 1he- vatv"e,~ntil the val....e fa~e ann valve seat

are '·.eVt'!'1h,. polished then' c1ean uH allcompdund,

0E24{E40j

tNSPECTIQN' AND REPAIR

!'lOTe, --__,__Tv obta'" the !:lest lapping rewlls, hghllY tao the.valve SlIal while ,otallng Ih",,,alve back /l!OO lort;,'be_n youl hand.,

.. Apply line lapping compound 10 tn" valve laceand re»e!ll Ihe !lbOve,Slws

NOTE.8e s",e 10 clEia""H all,comoolJ",t!tom the valve,lace and ""'ve seal, ane' every iaPP.ng """,Otlon','

"Appll',a'Ml;<:ha"'C:s bl~mll dye lOykam. to,lhe'valve IBce, ' , '

• InsleI1.lnev.;l>l1e in1" the' cylinder ~""'d ,

<IlP.tesstM va,~e lhtccgh'lhe ,vaive g....Jde and

,ontolhe,I111I"e sea! lo,mai<e ii cleal I:\atlem.. Measure the Ital"'" seafWiolt\ again' '

Ii Ihe valve seal width ,,"1,01 specificalH.:m,~'efa:ce and tap the vatve seat.. ' '

VALVE AND VALliE GUIDEMeasl"e.~te.m~to·gutde- ctearance

Stem-to,guide clearanc.. =

V"lvlt ,guide iMide dl,ametn, 8V..lve litem diamat"r b',

Stem-Io-guide cl...rance'In\6ke:.'

0;1)10 -1l.l137 mm1ll,00ll4 - 0,0014 in)

•<: limit>, Ollil mm (0,lm1 11'11Exh,u,"t:

OJl2S - 0,052 m rntIl,Oll1 ":tUlll2 in).:' limit;. , lUll mm Ill,llOO9 in!

OE2S(!41j

lNSP,ECTIONAND REPAIR

2. Replace-• Vaiveguide

Rsp!aeemem nep..NOTE '-- _

Heat the cyhnder head m an overt to jO()f'::

(2i~i.'Fl to ease- gu,de re:.rnovaf and installatIon and

ttl ma,ntain correct !flier'ere-nee fit,

.. Remove.the v~.gU;(:leUsfng"thevaiv-e guiQe

remove" .1-j'nstalJ the ",naive gutde tnewJ USlt19 t-he \islve

gutde'ln:rtal\et 2. and vaive 9.uld~ rem"ove' 1• t\her IrtstaUing the valve guttie. bpre t he valve

gUide ueing the varve guide rellmier 3' I" "0. t~in proner.stem·lo·,guide ch~ar~nae

Velv$lIuid'e TBmOVel II mm{~24 i"l:

PiN YM-04064-A. !lOO:9O.()4(l64Valve guide tSlIme, (; mm11).24 inl:

PIN. VM·04066. i!!Oll9O-04066Valve .golde-instaile, 6 'mm.10.24 iI,1.

PIN YM·04066, A !lll8!lll-ll4ll

NOTE - __" _

Aetace the \talv~ .Sflin a-fte!. rep1acU1g the 'v~t¥e

.\I"rd" .

3 EI.m'nat"-Carbon (ti,po~li

11rom .alv" fa~i;l

4 Inspect

.Valve tac€'P"t;"9 Wear ··G",io the lace .

•Valve "Iem endMuSOtOQn"l shape 9' <harnet9t lar~ ~h¥', res~

of ~tl!rn 'Rep,lace

INSPEctiON AND REPAIR

5 Measurll::>Margin lhic~~'"0,,' 01. $pe<:djcal,,,,,, .• ""'plac",

, Margin tb!ekn_:'LImit: ();II, rnm'IO:032 inl

. 6- ~e",!",re:

-FlU,nQVT 1\1lJ1Vl! slem,ru;l oJ spllCil10lllIQn .. A11p1a(:e

Note: -:- _

•Alw~ leoJace~ gUldell the vai~e "' replaced.• ""!",ays replace Ihe 0,1 seal il the va;.e isremoVed,

,Runo!!t:,_I.e•• than 0,01 m'm 1iP.OOO4 In]

'----....l®

IIALve._SPRING,I Measure

!FJ/,e''''''9Ih " ,,,alve springlOut 01 specif,calion·' Replace

..Fm.. '."gth 'l/slvlI Jlpringl:Intak,,:

32,llJ mm 11.2llS in!ExllllU1iI'

3llA6 mm 11435 inl

I"NSPECTION ANO REPAIR

2.iMeasui~,

.·Compr~ed.gorce waNe spnngl -1

. Out of spedficstlon r Reolace,

t fs installed ~n9th

I

Compressed 10'C8(imake: ,

102 -lUl kg 1,2?49· 26.011b)at VJill mm IUl83 in). .

Exhaust:,12.3 - 141 kg \27.12 - 31.08 Ib Ial 31,00 rnm11.2:20 Ii'll.

®

3. Measure-Spring IiI: aOui ,of spe1:;ific3t10r. '. Replace'

Spring llit:'1nt;,ke: .

lllSS·th~,d.4 mm tll..056 ii'll.Exhaust, .

'.Le1l. t1)8n1.6 mm 10.063 In!.~"

CAMSHAF'r",i. "'soect:..•·

oCllr:l 'lobs

'PHiing-,S<;ralches Blue. 0Iscolor81,.oii ..Rf\plac6.

2. MeaSure,.~Comldb!,s 111iiglh a anti h..OUI olspeclflCalion -Replace.

,CiliTlJoblls length:. iliiltke: .. ' . .

.~. JiUl6 - 3O~'1l in'tTl11.1l13s"1.1874 in)

"b"3U9- 35:1ll rom .. ll.4051.~ 14091 in)

•• . crt

INSPECTION ANO REPAIR

.l;~~ .Cam l~b':" length:rAl bheul!l'

.. 30.11 - 30.21 mm11.1ll54 -1.1894.ln)

. b 3I!.5lJ-36.6lt romIl.4m-1.44O!I i,,1

3 Mea$ure~

-Ronoot lcamshaft!-_OU1 of s~ihetrtlo'" .. Ae.ptace;

lIu""'" Icam'haltl:lit". I""n 0.03 mm ·1Il.ll012 in;

~, Mea~te';"

.CiID1$haft~ to-:capC'~aT$l'.\c~

-riut of S~cltWittfQn' ;Measure ~j'ing th'ameter fcam~naf1i '-

. - -~

;,. ~ "' ,.~ 4;,.0',,""" ".-."'"~S,,!, ,. ,..-

Mea5ute-men~5t:ep3:-llmoll 1M camshalt onlo Ihe p,ilinder head.. PosHlon . 'I .S'i~lp . pf ·f'laJiliglil.!Il" '<}fiIO !he

c,,""'ball ' .• )n$~a~'1f'e "(fOW6! p~ns and cvlihdet head:covef

-1loll'!cyllnde, ""..d. eover',10 Nm (1.0 m.kg: 7,2 ft;(bl

.NOTE ---:. _. .

~TlgI11"n the oohs (cylinder nead'coverl", a cnS$-cross 'pa;u"rn -from- mnermost 10 OUter_

itDc nat tlJtrnhe ea~s~af1 when,measuri'ng dl,1ar·once with t"e' fHast>g3uge:'

.. Remove the cytind!3f -haaet COvel Bnd measurew,dlh of. the Pllmigaugl!'

@

INSPECTION AND REPAIR

5. K'teasufE

:'.Baanng dtam(tl't:i" a ;cam:Hlatt.Oul oJ st>eethcahon ·~Rep;aLe ccffishahW,tnln specriIClltlOO -Rep",ce <,lind.., hea"

. a...~dng diameter (camshaft)22.961 - 22.!ll'll) tTl m

109042· 0.9047 'n:

4

DECOM~R£SSION

1 Inspect:

"Spnng 1, Damage-Aep'"ce• DecomPressIon" 'pin .2.. DecompresSIon fever .3.; OecompresslLin cam 4

DalTlilge' 8enrls Wear •R~n:a,e

2 Check

• 0eco.m~~551Df) play

Play ""SIS • Repjat"e

ROCKER 411"", ANO ROCKER ARM SHAFiInspect'III Roc~er am} shaft

Blue OISCOIotillion Grooves: 'ReplacelrnminspecT hJoricatton syst~m

2 InspeCi

-Bllckl.'r arm .shah ~Iole I

• Cam lobe contact Slirface ;>• Adjuster svrlace 3

Wear PittIng' SCI&I~t>e5 1'l1;".,. diS"O:O'"!tOP. ..• RUoiace, t~n l/'l$P&cf lUnr;CtlHorr{r,.vs1em

INSPECTION ANO REPAII'l

3. Measel,eo• Arm-to-shah cli;a,anc".

Ar-m·l(HtJ".aft eiearance #:

Rocker 3rm msrde dlat't\fiu;,r<! Roek&r arm shah OUU.ll~ diameter 0

OUl of specificatlOfi -..Reptace as a sel

Arm·to-s:haft clearance:•0.00!l;' n.OoI2 mm

IO:Q904 ,O.OO2IJ in;

T1MlNGCHAlN. SPROCKET AND CHAINGUIDE1, lnspe<:1";

.-rimmg Chain

St!ff, Cracks" Replace tlm!flg chatn andsprocket as a set

'2 mspec1, .. Cam sprOC~~1

Wear, Darrta~",,'Repiace cam sprocket andhmll"'lg Cham,as a set

3 '''SDeCI

·ehaln gutde 'l h?xhai)Sl side!-,Cham gUide- :2 -(.make 51deJ

O£31(&47)

P

UOl J


C =(X + Y)/2

• If out of specifcatlon, rebore or replacethe cylinder and the piston and piston nngs asa set

2nd steps

.. Measure the piston skirt diameter "P" with a~crometer

® 2.5 mm (0.098 In) from the piston bottom edgE

Piston skirt diameter "P"

99.945 99.985 mm(3.935 3.936 in)

'" If out of specification replace the pistonand piston rings as a set

3rd steps.. Find the piston to cylinder clearance with for

lowing formula.

Piston to cylinder clearance ==Cylinder bore "e" .Piston skirt diameter "P"

Piston to cylinder clearance:0.060 ...0.070 mm(0.0020 ...0.0028 in)

Limit: 0.15 mm (0.00589 in)

• If out of the specification, rebore or replace thecylinder and replace the piston and piston ringas a set

PISTON RING1 Measure:

Side clearanceout of specificatlon-+ Replace piston andpiston rings as a set

NOTE:

Clean carbon from piston ring grooves and ringsbefore measuring side clearance.


CVLlNDER AND PISTONl: Eliminate

'!f CaJ:bol'" deposus

11tc.m the plSH':m CH3Y..ff"} "ind tlny ytft(}\If:'£. i

2 Insp€'cr.•Piston waf!

We.tH Scratches Damaqe ~ Replace

3 Ehm1-i\B1"

," Scorf.'! f'.T'U1fks- iHld, fHU1-W-er f"eopO~.lts

rtrom the- side of t.ne J)Jston ;Use II 600 - 800 gn! "'1'1 slInQP"Pl'!

.NOTE~ « -- ~"l.•

Sand 1M' ku,:riSSC1QSS pattE-in 00 not sam; ex(;t1S. .sl\ie.ly

4 Inspect:·Cyltnder wlfle.t jl>"kel

C,rUSf Q( mlOera,ls Rus! - Remo\'e

• Cyhnder waft

wfla., SCt.(jtChf.?'5 • Rehofe Of replace-

5: MttesVT€--

·Pistor:- io-cvlltlOOI dea(orH.:e

..._.........•..•.••._ i. • •

Measuf.ement stepsFirat sleps• Measure ~he_cyllnder bore' C with a Cllllnder

bm~ gauge_a 50 mlTI' \ 1 97 ~hl fron, tbp ~nde!" to<)Non: .Measure the t;:yit~der Dore .,(" !no par-ailf;"1 to and

at nght at>gies.1C the ctat>ksh"ttThen find tne· pV~f~~9~ of' Hle rr:~astJrem~n(?,

Cvlinde, bo'" "C;"100.006.- 100:045 mm13.9m - 3.!l38ll inl

• <:: limit:l00.1 mm 13.941 in)

IN'SPECTION ANO'REPAiR

2, Measu.r'e~

• Piston pin ·to-pist,pJi t,ie-arsnce

Mauur.8ment stepa:.'MeaSure the plstonp", OI.l!s'de,dil!meter a,

If out o~ specification, repiaee me PtstOrt pm,

Outside dlarrniter Ipi$tOfl pinl:. 21 JI9t - 2i.l'lOO mrn·

10.11658 - 0.11661 In.l

• Measure the "'$\on, "',jde diameter b,• Calculate tne' piston pH'H,O·""SIOfl clearance

with follow,,,g formula:

. Pillton pin-to-platon clearance ~

Bore $In lpi<rton pinl bOutsIde diameter (piston pinl Ii

Piston "in-to-plston clearance:O.OO4-~mm

10,0002 ... o.liIbII fn ILimit: [1.07 "'mia.oro in)

OE3SIE4~)


Side clearanceTop ring:

0.04'H008 mm(0.00LO.003 in)

2nd ring:O,03'HO.07 mm)(0.00LO.003 tn)

2. Position

• Piston ring(into the cylinder)

NOTE _

Push the ring with the piston crown so that thering will be at a right angle to cylinder bore

00 mm (0.8 in)

3, Measure

• End gapout of specffication _ Replace

NOTE _

You cannot measure end gap on expander spacerof oil control ring If oil control ring rails show excessive gap, replace all three rings.

End gap:Top ring

0.30.,0.45 mm(0.012...0.018 In)

2nd ring:0.30,.0.45 mm(0.012.,0.018 in)

Oil ring:0.2...0.7 mm(0.008'HOO18 in)

PISTON PIN

1. Inspect• Piston pin

Blue discoloration groove _ Replace, theninspect lubrication system

INSPECTION A:ND REPAIR

CRANKSHAFT1 Measu'e'

"£rail1< width AOLl! of 5P~dlicatlo" .• Replate n ankshan

Crank. width.14.95-75.00 mm12.951 - 2.95:\ inl, .

~Runout COut 01 specificatIon" Replace crankshat!andlOr bearing.. . .

~ Runout Jmit;. .

[6J.. ·O.03mm 10.001 in)

• Small'end free play 0Out of 5Pedf<caho~··· Replace big end bearIng. crank pon and'or conneC.l'!'\g rod

Small end free piay;. {LS mm 10.031 inl

1

-13lg end rad,al clearance ~

· OtJl 01 specification.· Replace connecting.roo. big. end bearon" and'or crank pon,

. Bill end radial "Iaarance0.01 - 0.025 mm ,

, 10.0004 -'0.0010 in)•

• SIde c111arance j:'Ol.ll of .spacificalion •Replace conr>ectlnllrOd.

. Big. end s'de clea'80tHl' .0.35':"0.65 mm 10.014-0.026 in!

Crankshaft' reassembling pointthe e'ankshaf1 ·1' end the CTllnx pon 2 '011 p~sages 'must b.e .p,operly mlerc'onneCled wiTh atolerance of less' ihm lmm ro.04 inl

OE36(E50)

INSPECTIO NAND.REPAIR

BALANCER DRIVE GEAR AND BALANCERGEAll

,I Inspect:• Bal9ncer drive gear Jeetb

• Balancer gear leeth 2,Wear IOamage : Replace both gears

1 2, Chec,• Match ma;k~ 1'If Ihey are.nol aligned, -AI,gn mmen mar;,s. ,as shown

HECTfUC STAatER-OR1V.{1 Inspect' _

• Starter- gea' 1 leeth 1.

• Starler 'die lIear 2teelh :I·StllMer wheel gear leeth J

Bu'rs 'enipS:· Roughness '~e... ," Replace

2, inspect:eStaf1:et 'wheat gear

(con,tactmg- $urfa,c.esi

P'rtlng Wear Damage •Replace,

J, Check-Starte' 1;lvlCh operat;on. '.

Chetkmg step.:.ln51all the 'Slaller Wheel gear to, the S1arte'

clutch. and hold lhe star1erclutch-- When turning trle Starlf;l1 wheel gear CtOCfo; W'!se

.A', ,the starter ~Ich imd the wheel gear shouldOe engaged,it nol, tim statte,. dUICh is faolly ,~eplace It

OEJ7!E51)


.Wnen tUrn'ng th~starter wheel ge"r COU!"Jerdock'AliSe .'8' tb~ starter Cll;lcn gear shoy'C i\J;-f1

. .' -. ._teel"11 no!. the Slarter clutch 1$ tauHv '?eDiac~ It

,PRIMARY'I:HHV£.':" inspect; .:

, .Pumarv drIVe'gllllr teeth 1 ,.Pnma,i d,wl"ri gea, 'teeth , 2Weal ;Vamllge '~!1eplace oolh ,gears'Excess,iva,flb!$l1$ dunn\? operation ,·Replace

bOl~, gears

,GIUTCH

I 'Inspect;~;:rlclu)ri plate,D<JmaQe: Wear ,~ Repiace j"clion "Iaie as a

":"" , ,

.w_limit".2.8 mm

10 1111 in;i.~ fOm

Ilrlll2 'n'

'; , Thlckne",s

f--lI..I,·. " t ; .,.,.-, ., t-

Typ.,; "A' ,U.. - 3.tJli -mm.: 12, pc~,! _ :JIUt6· 0 120 '"I,. 'Jv'~; "13" • i.74" 2':ll6mm :.;j~.p;'''J: 'Ill. lOS.'• 0.113 \"1

:(;'Me"St.lfB~j:.f;criOn pl3/e rt,;ckness'i~t'c\f~peCjfica!Jo~ :Replace Ir 'Clion pia te:as ;,~. '.' . / .1" ,~

MeasJrl! :n "lilt 100' po.nts, . .- . .,:,r. •

DE311IE52)

'INSPECTION AND aEPAiR'

3 ,lllsp"e!:-ClutCh -plate

Damage. :,ReDlace clurcW plate as B sel

.Warp limit:la"" than·O,z mmlq.OO8 In}

4, Measur,,:.•Clilte"': pI.IIle '''Blpage

Out "f llPacilt.;ation·;:RePlac-e efutch plateas a~, ,~ B surface piateeand teeler gauge 1

" :() . .

S. In.pe<: I:

• Clutch s""ngOarr18{15 ~ Rep;.ace as "e set,. .

"'---..... @

, 6. Measure: ,

.Clutch tprmg ,Iree lenl'/ffl "".Oul "j sp&#icaOon . Rep:a.;e 'SIlTIng os aset. - ,',:'

,Free length ·iCIOteh./lj:lringl42.8 mm (1:. inl ,

... <·limit: 4O.S mm 11.6D(l inl;>.

·7 tnspec-t:..CrOg$ 'cn H'" cr'u Ie,," hollsrng _Scof\ngi,Weli,iD"mage"~urr or replace.

NOTE' '.:' .

~o.img·on the-cll.t'''''' hous,ng'Cl09;wil!'cau~e el.<, . . ~. ' ' - >" -''pVC ..op~tatlon

DE39(ES3)

• Reolace

iNSPECTION A'ND REPAIR

'S,lnspect:. ~'; ci~lcn boss" splines

Sconn91Vve~,Damage.. hO"'~,' "', .-

NOn", "--_~,,,..~ """"":~--'-_

• • I •

Seoring on the clutch bO$S sPhnes WtH~cai.lst' et"ratic operatfof). ' ;

9 Cru!ck*Cm::umfarenhai play •.. Free' play J:.xi.slS ·,Repfa'ce.'

, ~ ,

10, 'l<1soeO! ,, .. ' .. ••J. 1 •

-Oe;1f fee!h !'pul! lever fllde 1 J

• G",.i; ie9tf"ipl.l1l 'odl :I,Wea,! D<!malle ' "Replace '8S, a s,""

'iI,'fliiiecr·g~'f\1i 1 "pnll ."d''.W«'; Dilmatl€'~.f\""tace

Transmission 'ANO:,SHIFTrnInspect.' " ,• Sl1iit:f(I,k'''an' iollOWlff f. . .. - .'.. ShIh tqdr pawl· 2. ,Scarin~ '8enos, Wt~r, ·.R~f)~C:~". _

lNSP,ECTIQN ANtLRE'PAIR

2 Ir.Sll~t,

"Sh'ftt cam J:J'foove.•.:St"tt cam.$eSm~mW~.r, D"-Se",Rep'ocp.

J~'Check: '• S hitl ltlrk "",'leT"nlUnsmooth' 'i!r>erahen ~Repj~e 'Stil:: -fOtk;

'.illl\d 'or guide bar·.'

.:i Inspect'-rGLi-1de Oaf

ROIL the"'9~de: bar on 'a flat SlH1ac::~

lllillti:ts·'fleptllCe '

,~----~---.po ,,!<l!' att"mp! 10 straight"" a bent guid"

, blfT.

5 Measure• RunOUi !dd~ _a~re:·Bn-c maIn a:<:el

~r_sDet;iflcatjon .' Replace

Runaut'le•• th"" 0:08 mm 4OJlO3.in)

~ -,,-----"'--,Do not attempt. to straighten a befit a,de

0, Inspect:

:"G~ar tooro'Blue'~d~cOiOl'at.ori': p.nmg Wear "~ep1ace

'Mal~ oogsRoyn~ ~gges era,s::s jv1rsslng portion$. .Repl/lce

OE41(E55i

"INSPEc:nON AND. REPAIR

_'~"".~.'~"..,"." ••• "4"~""'''.~ '".- ..ReSlSs.Sm bJirig,,'paint:• ~re$s the 2'('l<1'Plnlpn gear 1- 1M: the f),8Jr. a)i(l(i

;!.•as sho~ ..• ';~ •• ~ ... 4" •• ~

.7..~lnSpect; .'!Spring:T .:.Oama~·.'!l.l'p"'ce ..• Shlft leve!".?:·., :.'.:Damagel'SendsLWear •Repl~ce,'~'.. , ""',

,S'!hspect• Shih 'shal1

Sends· Weai Damage ,Repl~ce

9 lnS;1ect."St·opper iev'er', l·.Boller r,i:~s ,?ughiy . ',R<lp!.i'c.

· Ben<l!i[)amage'" "Ifpl;,ce.~ ReMn:;'Po,mg ;:2 . ,.Darriage' Ctacks •Replace' .

OIL PIJMf'.WATER F'UMP'AND:STflAINER. 1. Me1l\l(J'e: .'

• 'TIp cleari'l1r:ea- ".~ f,betweerj'irmer rare!"' f"'and pvl£r rOtor 2.. I

-Side <Iesiance .b·~tA~·~en txJ!er,:ro!pf ~:r '~nd_Ptfriip ho'~Slflg";1'1

".b.ut dt-"sp~tflcaiions "~R~Djace 'OJ' p\!rr!p', i

DE42(E56)

INSPECTION ANOREPAIR

I~ Tip clearance:"0.12 mm 10.005 in) .

Sid.. cl.... r~;,c..: '• :O.03.,O:llll mm Ul.OO1 - 0.003 inf

1

2 rnspecf:.•'Qif pump -drive gear '1

• Oil pump ClI.....en gea;' "{Wear!Crack5!Dam~.ge~Replace.

3, inspect

~.O·rmg "-1·.vv:.ater .l?ump hou$Jng 2

!II Water pump gear4 3

CraC"s Wear O~mage'" Re;face,

4 Inspect

.Od strainer i

l;Jamage" Replace

DE43(E57)

INSPECTioN ANt> REPAIR

OIL 'OEUVERY PIPESi. ·lnspect

• Oil del ivery pipes.CrackslDamalles -. ReolaceClog" Blowout with compressec aor

CRANKCi<SE1. ~hotOLJgh!y wash the case halves Hi mild

solvent.

2. Clean all th/! gas,et mating suriace and crank·

.CPSe mating surtoce thoroughh

3. Inspect:-Crankcase~racksiDamage"·Replace

• Oil ifelrvery passages

C~og" Blowout wit.h compressed air

BEARING AND OIL SEAL,1. Inspect:

·~arings

Clean ar,d lubnr.ate, then rotate Hiner racewith fingef'.RouQhness •Replace

2. Inspect-Oil sealsDamage/Weal

CIRCUP AIVO WASHER1 Inspel:l

-e'n;llpS:

-W&v.ttrs

O~ge,'looseoe$ll," BM'lits •Replat:t;

DE44(ES8)

i Valve (intake!.Spn~ Hat ,,Acl:ck~ .,tnt Shatt lexbaU$tJRtl'Ci:et,&(f'r\ #.;HoCker at'm d3ROCket arm shaft reJl:haust;

.~, ~ Vakie +extlauS1}~

ENGINE ASSEMBLY AND ~DJUSTMENT

ENGINE ASSEMBLY AND.ADJUSTMENTIIll.tltE AND ROCKER ARM ,;T, Rocker arm #. 2 .~ Wave wesner "~"ROCXet arm shatt {tr.rake}.,~i Roektll arm .. :. ..·t Vatve cotter:4: V~j\ffi. ret'lf'l(N

'~ o_1 sea! '"\! yatve Sptlflg ,

!VALVE SPRING TILT LIMIT:

linn". spring:

B Ul" or 1.4 mm 10.055 inl, Outer spring:I 2.5" or 1.6 mm (lU163 inl

14 Nm 11.4 m-kg. 10 h-lbl

110 Nm 11.0 m-k", 7.2 ft-lbl I

C STEM RVNOUT UMIT:0.01 mm (0.0004 inl

o VAl.VE SEAT WIDTH:I 0.9-1.1 mm ro.03S-0.043lnl

VALVE CLEARANCE (COLDI:A Intek.: 0.10-0.15 rom 10.llll4 - 0.006 in)

Exhaullt: 0.15-0.20 mm 10.006-0.008 inl

DE45(E60)

'ENGINE AS'SEM8Lv AND ADJUSTMENT

ENGINE ASSEMBLY ANDAO"U.JSTMENT

.~

For"tmgine reassembly. nrplaclf lhe foUow·

In\; parti; witnnew' <me$..~O·fing·

-Gasket.-all >oeal-c.opper:was"",-lock llYn"....-Cireiip

VALVESl·.:Deburr:

,;,Vahte: stem end,'UilIl 8~' oil·st~ne to smOoth the 5,em end

'" . .. .

2. "Apply:- MolybdMum disuif;de Ol;lonto 1Ialve .tern alld oii seat!

3: Install:

.. i"Sptlflg "ea'~Oheai2-Valve-V1ri,;esprlnll.4-Valve reta'''er, ',,' ,

1""0 cylllld<:?, flea'dl

•

ENG1~E; ASSEMBlY'AN'O ADJUSTMENT

NOTE' _~_,........_~ _

-,Make sure that tnjeaeh valve IS ;nsta~ied >0 Its

. 'O!'I\tH,\al pla~e b¥ u~f~rence to'H, em~OS$ed iQen,

tificaw~m matk," as toflow,100al$.e :I>/1'-t~na"$t 3VF

-Install the valve spru)Q \IV.t" larger pitch 6 lac

. lnH upwaid! Sri'ldlier pfH:h

4 Hlstafl

-VaJve cotter,? -1 .

NOTE: -'- _

Ins:'t,aU the v()lve cotters<wh.uR coropressmg ihE:

vaive With the vidvf; 50fmy 'Of'!'lPI8SS0t

Valve spring compressorPiN. YM·0401§ 90890·04019

5: Sec\.He the valve (On!:' an to the valve stem

by Tt3PPH)9 if ~9htlv wnh a pt,:,ce of' wood

.NOT!' .,.... ~

On not hd so much 11'5 to ~.amage the \o\?lve

DE47(E62)

ENGINE'ASS~MBLYAN6 -ADJUSTMENt.. ' .

." ..

. ROCKER ARMJ l'Ubnc8te

..Engme Drl

'HO t.he. rocker arm S1">.,ft;

2_ I"stall: .• riocker· al"1"T'

, ~ ~CKef' ·aJIT'>' shat '\

BpI! 1 lroc'ker arm shahl10 N.m no m'!<g. 7.2 fl.lbl

1 # 1-2 .2~ ~34 R4

:; .jnStall·

'Plu;' 1

ENGINE ASSEMBLY AND ADJUSTMEN'

CRANKSHAFT

1 Crank pin2 Crank (left)3 Connecting4 Bearing5 Bearing

ICRANK WIDTH:

A 14.95 - 75.00 mOl 12.Sl5O - 2.953 inl

B ' RUII/OUT LIMIT:0.03 mOl 10.0012 in)

C SMAlJ. END FREE PLAY:0.11 mOl 10.031 Inl

BIG END RADIAL CLEARANCE:o 1),(11-0.025 mm 10.0004 -0.0010 inl

BIG END SIDE CLEARANCE:E 0.35 - 0.65 mOl 10.013 - 0.026 inl

1CD

I11/37-45-221

\\

1\

i1m

\ @~

~ I!150 Nm 115.0 m·kll. 110 tt.lbl I

DE49!E64)

ENGINE ASSEMBLY. AND ADJUSTMENT

CRANKSHAFTAttach:.. Crankshaft- l(iS1a1h<ig tOni

~rankBkaft if\staller setPIN. YU-!IOO5O

Crank POt spac", 1.PIN. YM-91044PIN, 9089ll·.D4061

Adapt", .. 10 2PIN YM·90069PIN !Illll9O-04059

C'anksllaf.t instaUe, pot 3PIN. 90890-01274

Crank.hal't instill I.., bolt 4PIN, 9089ll-01275

Space, .5PIN, 9089ll-012l18

NOTE: _'--- -:- ,-

H9ld the 'conne(:ttng rod a1 lOP dead (ante! with

one hand wfllie !Urr1lfitJ th~ nut of tOe installing

tool wjth the 6ther~peratethe !nstalhng tool Untff

half of the 5;rankshaf'1:beanng $ IS Inserter! Il1tO

lhf+ Gran:Xc:as~ as.. ~hown Thfm aod the s.pacer5 ',6S;,5hown and 'ep~raH" 1h~ tnSlarhflH too! \lntll

the ~kshaft uou~ms against rhp. t,~anng

CAlITlON:TO'protect th" crllnkshafl against .cratch"s0' -to facilitate the oper81io'n of the i~stal.httion.Appfv the grease to ~h. 011 .",>1 lips. ana ap.ply.t'tle,"engine oil to each be"a.ling

DE50(E65)

ENGJNE ASSEM9 YAND ADJUSTMENT

Il~LANCEFl A~D TRAI'tSMISSION

\1m

c IUSE New ONE

A DRIVE AXl.E flUNOUT LIMIT:0.118 mm 10.003 Inl

IB630SNRX1C31

IB6305SH2 I

B MAIN AXLE RUNOUT LIMIT:0.118 mm 1ll.003 inl

ENGINE ASSEMBLY AND ADJUSTMENT

SHIl'TER

1 Guide Oaf Ooogl2. Shitl lor' *' 3 "if:> SI'!i!1 10'0 .. I"L4$;"111 ,om5 Guide bar i shurt'5 Sh"'l"'" # ziC·7 Snill shat<, 28 Shift snair9 011 1;1;81

1m

DES2(EGS)

. ~ . .. -


BALAN:CER: TRANSMISSION ANDSHIFT'ER

1. Install

"Neulral ;-.;wi,ch 1

2 Instal;'

"Sai,mcer !;hatt 1

'3 lr1stalL.. Collar 1.

• Or.ive al< ie assel1lt>'Y 2

"1. InSTall

"M.un a:.:le assemt)lv' 1. .

5 Apply.. Engine "oil

lonto gwde barsi

ENGINe ASSEMBLY AND ADJUSTMENT

S. inSlaH., Shih torI< ""i.'

• Shit! tOtk 3 .. R' ']

'Sh"l fork 2"C 3-Shift cam ~

-Guloe bar HOflq I ~

·G,jld~ ha: •snort , 6

!IIOTE

f!1'S>tCftl t~ shih h,rk.!> wHM1'hft tH1\I.H)~:'i~'11ndrk or)

Hadl $hl,h foo tat."lfl1J figh1 !u'lc et' fhi:: -r:n-ginc_

7 1"5toll-ShIh srl-at,l 2 ."Shift sJi.lft 2

8 Check.,;r1~f)!!;mlSsioq Opp:r<tl;nn ,t~5'nomt1·Q~rr.1;'1.·

•f)en.<;p

DE54IE701

OIL STRAINER

M~8~l~Y~A~N~~O~A~D~J~U~!ST:!:M~~E~N~T:'- _ENGINE ASSE~_=:;-_... mmm

,,

11 Nm 10.7 m.kg. .

.~'-' :~"""""'r

II

5 1 ft·lbl I

.•

DE55iE72i

ENGfNE ASSEMBLy. ANd.a.OJUSTMENT

CRANKCASI'

1 8U!lfl~Vi()V1!P piaU)2 locli plate:3 CtaNi.case V~Hlatlon hOse.4 -cab;e c~mp

5 CranKuse6 Coiiat

7 DQ:w6r pin

e O'Owei pin·9 Of'tl"'IIii

jA ITIGHTENING SEQUENCE: I4}

DE56!E73\

ENGINE ASSEMalY AND ADJUSTMENT

SHIFT U5VE9 AND OIL f'lIMPf StOP~ ~t

~ (!"HUt. .~ • ~~,jf , '!r.41f'\\'g

4 ·Cc1l.aft. '~h1P '~Rf

6 Tor~O'Il '.s~H'nQ~.~ ,-' ...! v~"~t"

.§' . D, ~~I"lg(.

9., O{~cPt,l m£:)ra- C-ij~ro.WrtP~it!"

.A

/::

j

ENGJN.£.ASSEM8lV ANOAOJU~MENT

Gil STRAINER1 '''''!'<ill:

'-G",*e/. 1-0::1 suatt'ffiJ 2,.Oil pa~age: t-o<ve l . 3

Boltla" sUll;ns" ' J7 Nm'jO.1m.kg.5.1 !t.lb)

BQl:noil pa!is:-ge Ctlv"d, .,1 Nm 10.7 m·kg.:!W·!:t.lb, .~i" .- _"0 ... , _.

CRANKCASE IRIGHTII Apply

• Sealant

lome ma1t:,g surt;,1t..~ (11 hD-~\: ;';"-'l~ halves i

'NOTI'. .-"c....:--_-'--_-'-- _

DO' ~OT -Al:LOVV any seai;'HH W r:t;)m~ If! CmHtlt:!

WIlh ,he ",I.gaU"IV.

..S"ah.nl·l'luiCk 1l".I<e'VI· ,

..PIN.ACC-nOOH)1• Vama'h. Bond No, 121~'

pI N 9llll9O-85505.

Quick Gasket

~ IM!all

'0 ""ll I·-OGwal ",n ~ 2'-D{)wel.pms 3

l Fit fhe 1t!11 naHkt"a~t! unto lfw nttl;! (;16(' Tap

'~lqhihr ,un 'th+- t;a~ "'.IIth rl SOfr ~\i;rnfnel ..

OE58(E75)

ENGINE ASSEM BLVAND ADJUSTMENT

NOTE- --,. ---

Twirl' the shift cam to' the POSHll',;:H1 shown in tbe

figure"Sd' that it does nor contact The cf.arikc.as'ewhe~ !r1sta'lling. try"e cranl(c~se '

C~VTION:

Bet.,..., "'''tailing ,end torquing the crankc""e-tlOldinll'Sc'llWlt, 'be stire to check whether

H\:'lO\!'jf 'rIle transmission Is fu...:tion"'g properly bymanually faUlting the mi'!!, ""m,'a'ther wey,

4 Tighten

~Bolt tcral1~ca$el 1 ...14

5 Apply

64 SHOkl; engme oil

. Ito-..t,he mank ytn, ~arln9 ~no oil de'tvery

, Bolts'./.crankCMlel10'Nml',O'm:kg,1,2,ft.ibl

6Chec,-·Crankshaft a~d transmlsSlon operatIon

Unsmooth opefiltion ·-Repalr,

SHIFTLEVHl AND OIL PUMP1. Instali

·Cirt;lip '.1 ito dnvp. aXle!')-Collar '2·ClI'"hp J

NOTE: -'-

® •Tighte~ th~'.b?kS Sf.af.!ing ~t.th fha InweSl T"\U~lber-ec one

~~';$talt the cable ~l~n~p on "the boll N;J 4

DE59(E781

ENGtN~ASSEMalY AND ADJUSTMENT

2. App;.,t4, StrOKe !mgtnc ct!

Ho me .oIl passa}}t::'s lH o,.t" tf<5'~jq; as€';,

~UTlON:

Apply "/lb"ral lImol.ll'1t.of 4 ."ok" ,,"g'''. oilto the"oil pump PS!UUfyeS in the crankcas~

Q/the eng';n& may be damaged

3 Apply .+4,-sHoke eng-m,e Oli

ito th@ oil jl.aSSitgBS l!"'l tnr: 0,1 r.vmfJ)

, 4 In'Slall

·G~skel 1·0 'dn9 ,-2-O!I pU'T1p 3..ali p:ump gevf, 4

-C"ClIP .5

Bolt loll pump! "---"]

'--'L-_1_O_N_",_, !1_0_rn_·_k.:;\l_._7_2_,_1'_,._lb_'__.1.

:) instal!

~ReHHn 50J';II'9

-Coil.' ,2·Slnppt'l lp.v~'r 3

NOTE

Ser rh' Spt!(Hf fHul "'1onnt-'! !s:vw dl pr-ilp.;; fl-{;

SltH)fl

DE60(E79)


6 lnstall

ePJatfi washer 1

• TGf~IOn spnog 2• Shltf leye! :1-CtrChp' 4

NOTE: -.,.. _

W~n rnslaHmg the S'll+t lever dllgn the puncnert

rnar~ OIl ,the 'Shift levPl wl1h tMe pu.l1f:Oed fl\sh

on the,_sflif! 'shaff

DE61(E80)


BALANCER GEAA

1 Key2 Balancer gear3 Plate4 Lock washer5 NUl6 Plate washer7 Key

8 Plate9 Balancer driv~ gear10 Plate11 Primal)' drive gear12 lock washer13 Nul

ji>.! USE NEW ONE I6iJ Nm (11.0 m-kg, 43 h .Ibl

F'I USE NEW ONE Ir

/ ®

®i

Oe€2fE81I

m_ _

ENGINE ASSEMBLY AND ADJI.!STMENT

CLUTCH1 Clutch SftlH1iJ2 Pressure piaH:l3 Pull B"';o

4 Pull, "lSio'er -

5 PUll kt...e:1 ade6 fn{'"!lon pia.te : ~vt:re .Ai7 Wavtt "plate

8 .c-'iftch rJJw9 ~riC'flo11p'are IIYfiE' 1:$:10 Ciutc-h hos!J11 throst wastltH, 2 OHler-. I"lCUS'n<J

13 Pmnary dllv~ ~le£!t

A 1 FRICTION PLATE:

Type ! Thickneu Wear Limit

A 2.94-:U16 mm 2.8 mm 10.110 in)2 pes.. 10.116-0.120 inl

B 2.74 - 2.86 mm i 2.6 mm 11l.1ll2 inl6 pes.. 10.108- 0.113 inl I

Is Nm 11l.8 m·kg. 5.8 tt.lbl I•

\ <D, I

I

1120 111m 112.0 mokll. 85 tt·lb) I

10 IUSE NEW ONE I

CLUTCH SPRING MINIMUMS FREE LENGTH:

40.8 mm 11.606 in)

CLUTCH PLATEC WARPAGE LIMIT:

C.l mm 10.008 inl

]6.5 Nm 10.&5 rookg. 4.7 tt·lbl I

/~/ ® ~

~~I~~i'~

l~e lui USE NEW ONEI


3 AOP'Y.,~n9Ine 0.;

"Onto hearrtlg and y~at taft'h)

4 Instal:

·CiutCh housing! Thws1' pt~n1J' :2

-CI"tch "U55 "s~"mbl, 3-lock waSher .;

-tJl.u1 eli' Idutc); bossl

NOTE ..'fifthe laos Oflh€ tOCk washer to'The Q'oove oftne: Clutch bOSE.

5 Tighte~~

--Nut ~f 'S:i~.tH::h bos.si,

'2

Universal clutch holder', F:/N YM,91042. 90890-04086

III "t.( clutch boss!:90 111m. (9,0 m.kg, OS 1t·jbl ~

6 Ben?,:"-Lock washer fab 0

(along nl!t fraU

7 Apply

• M(llvtHjenul'r: rt\~UHlde q'HI1${'

{<»1109€HH ieCl'h of mill tmil• Ef\gJ!ie Otl

!ontQ bearing iPtltl {t~rtlt

DE5S(E83;


-CLUTCH AND BALANCER GEAR

'1 lns",II'-Key 1• Batancer gear .?,-Plale 3,"'Lock washer 4-Nut 5 Ibalancer 'gear;• Plate washer 6-Key ,7

-Plate '.6"~Balan~" drive 'geer 9- Plate it}.,Primary dnve gear -I!- Lock washer '12

".- .'.··Nut ~~, .1 primary drlye gear)

Nut lbalancer lle.,rl60 Nm [6,0 m-kg. 4.3 fHbl

Nut jprimarydrive gea'l:120 Nm [12.0m-kll, 85 /t·lbl

NOTE: . '

-When Instalitng the dnve gear. align the puncher:!mark "iff on the dnve gear. ..Mfh the punched mark

1} on the tlalancer ge~r ,• Place a fol~ed tag or alummum plate b€iWeen

ihe teeth of the MIMce, dnve gear and balance!

.gea"-Take cale no! 10 damage the 'gear teelh.,

c Bend the lock washer. tab along th'f nut liaTS'iii . .

DE64(E84;

ENGINE,a.SS£MBlY AND AD:.JUSTMfNTNOTE' _

. Align !~e punches mark 12 on .me C;.Jtcn DOSS

with the arrow mark oh -the dutch p(eS~tJfP pJate

13

.91)1t lpress~re-plalOl·

8 Nm <08 m.kg .. 5.8 fHbiI-....::L.__....,.:..-.:..-_..=.c'-- -'-_J

g A,pply_

·-L1thft.!m ..s~ap- ba~e. greas.e(onto Oil seal lips in cranx;taSf: cOvetl

• Englf:uB;'011 .

tontO bea~jnsis Hl (;ran-kf-~SoF: covet \

2-·_....:

&~Tii

1{) InsleH

• Rulllevcr •• Ie-' Imto .crankcase covetl~_Washef -2,'f> Bo~{ 3

·Bl)lt 'pull Jever a~lel6.5 Nm 1065 li1.kg; 47 fHbl

11~.lnSlajL

11 Gasket." (crankcase- cnVp.1 j

-D)j\l\flil Pi"S 2

12 If'lslal!.

• Crankcase Cover 1 !tl~,tl! i.. .

NOTE

Tighten the bOlts U:rankcase c~ve(! in d 'cnsscro?-!>pattern •

Bolt (crankcase cover I

10 Nm (10 m.kg. 7.2 It ·Ibl

DE67(E861

ENGINE ASSEMBly AND ADJUSTMENT

1II0TE: ~ _

Install the clutch plates and friction plales ailernatefy on IHe,2hitcn bOss. startrng \Allth d- irlc..tlon

plate a"nd ending wuh a tllC:1l0n' plate

•The friction pilltes Itype Ai 1/1'. with the lerg·er of tlie insllJediemeler must.oe installedin the second ann last pla~es.

oThe clJ!'hion.spriog it must be placed on

Ille inside of ~hl!' second I'Lelion plate

8 I'nstall.

-.Foctlon olat~

• Clutch pla,es 2• ClJtShlon sJ:!ring '3• PlJII rQ<l •4

'.Be~rlng ';;; {null rodl. "-WaSh'lr 6,- Pressure plale 7• .c~ui:ctt surmg 8oSollS 9:

.CAUTION: .

.~Friction 'Pjate

. Typ. "A" . TYl1o"S"...Quantity ..

2 "c~. .. 6 pC'S.InsidEr' '," , - < "116 mm 113 mm

DfS1!'eter "0" 1457 inl " (4,45 in;, ...

OE66rE85]

ENGINE ASSeMBLY AND ADJUSTMENT

13 'rlstall.Wasner 1

• Return Spnng 2• Pull lever 3.iNash~( .4

-C"chpo

NOTE _

,t\Make- sure tt;at me.ma',lI:'6 on tt)e puillevF:f is

cHigned WIlh' lhe emb<?'sseQ mark 7 on 'Thecrank~se.-wh'!e" pvshm.g the pull lever t{ notchange t.tte. pull lever POsition

• Install 1he pullleve'wIlh lhe ·UP rna" 8 lac

'flg upward.

Oft. FilTER AIIIO WATER PUM PJ Instali-

• Impeller shaft 1

• Wat~r pump housmg 2"Circhp- -3

.•PTn.A.-• Water pump gea' 5·

·:oCrn::lip· $

;,.NOTE: _

• Install the w-!tfE;T pump gear wnh embossed sAd€'

:.,,7,. faCing to rnslde .

2 Apply·'

• Molybrlenum dISulfide grllilS~

(\)fIIO IrTJpeller .shaft endl.,... .

DE68(E87)

,ENGINE ASSEMBlY,AND ADJUSTME,NT

L>.-_--1

3: In'tall-0 f1t19 • 1

"Bol~ iwater. pump)'10 lIfm i1.0 m.kg-J.?,lt.lbl

4 'Inslal(

, AWa{er-'p~u."nO h6ustng 1~~ "'!Water' pumo cO\,,:;[ '2

,,;': .

.Install

4011 liller, r-0' ru1~S:"2'

1

-, ,. ~ . ,CAUnON:. ---,....-_~ _

tn~;tilHl the oil fil~e'f' as shown

6"jnstall, .. Oii--fjhe~ co'"e'( ,

Bolt (oil lilter 'cD""rl10 Nm n.o ",..kg, 7,2 ft-I!:>I-

DE69(E88)

, EN,GIN!:', ,o.:SSEMBlY ANO,AtijlJ$tM~NT

ROTOR,AND STAR1"ERiQRlVES,1 Starter Gear2 Start"r 'dl" gear 13 Starter ,d'e gear 24 Starter wheel gear5 Starter clutch6 Rotor (A, C G,)

DE701E89)

EII.IG.INE:"'ASSEMBl;YAND MJJUSTMENT

< gull lc~njlllJid"l:" :llHlm (i;Om,l<g, ],2 fl·lh'

NElTE:'":;,,,,--~..;---- -,.Fas·teh~a saf~;,~fe.:~ ~o the il,!,,-l"ng ,(:j1~n1: 10 .

~f.ellfr;i ~r~~~:r:'~fatfitl9.lnto .1'~e.C_fan~r:ase· .'"

<l'l()TOR AND SO,TARTER DRIVES.1< InS1811.

.• TIm,ng cha,,, 1• Cha,n gwde 2

2 ~ply;,

'E";g,ne oll.!9~te·-bia,.mg. on statttlf·~Ir\lesi.

j ",stali·WashtJl ,,1":':',flNeedi~ -Q;~tIf'l9 ·'2e.\J\!heel"gea f '3 .'

, "

4,),OSlall

";W?odrvtf key·,HOIOf 2

N'O;TE::,,_--------:-__~Wh~QIn&l8jliogti'ie tnagnctu rotor ",taKe :sura that

lhe woo:dfUlf ktW 'IS properly sedlen In Ihe kBl"

w,,~ QLllle.0~,*shaft.' ,. . .

5 InSlal1

aN4t 1 'rot~j,

TtghtfID the nut {Rotor)vvMII~f'-otdmq !he rOIOf wit'tithe rotor ,holder. -2, . , "' . .' <

'. -

ENGINE ASSEMBLY AND ~DJUSTMENT

,

~ Rotor holder. .lJ'""J PIN. YS'01,880, 90890-01701

CAuTION:.

00 not aUow the rotor h()lder'to touch the

projection!t 3 on the rotor.

6. Install- Starter idle gea, 2-Needle oearlng 2'-Shaf, 3-Gasket 4' '"CrankC<JSI:' cQ~e'-1

·Oowel pIns 5-0 "ngs 6

NOTE

7 lnstail:

-Crankcase COver 1 Ileft]

Tighten the boHs Icrankcase COv8t.11f\ a Crisscross.parrern

Boh tcrankcase tover)

10 Nm 1'.0 m.kg. 72 !t·Jbl

8 Connect

·~euJrBi .S'!h"Hch 2

9 Instail

• Shah ! 1Si(U1er loie qean• Needle bearing 2., Starter "'tHe gear j

-Gasket 4·Dowel pm 5

DE72lE91)

,ENGINE ASSEMBLY AND ADJUSTMENT

10. Instal!.

-Cover 1

Bolt lcover)..10 Nrn.ll0 m.kg. 7.2 ft·lbl '

DE73(E92)

ENGINE ASS!;M8lY AND AB;>JU5TMENT-. .

/,)

10 Nm 11.0 m·kg. 7.2 ft.lbl

BORE SIZE:8 10IUXl5-11lO.045 mm 13.9372-3.9388 in}

<LIMIT>:<:100.1 mm 13.941 Inb

PISTON-YO-CYLINDER CLEARANCE:C 0.050-0.070 mm 10.1lO2ll-0.0ll28 inl

<:L1MIT>:<11.16 mm 10.0059 inl>

/0 IUSE NEW ONE ,--~

)0 i USE NEW OlliE

138 Nm 13.8 m.kg. 'Z1 ft.lbl 11-----

A ITIGHTENING SEQUENCE;

®(j)

@j ;

!) ~~ L!)1_.,,~~Q

~C~ ~ ~

~,I~~~/ ~

e Varve ~ide tmtake valve)9 Va-ive' gliH:Wt ~axhaust valve I1(). Spa,,, plvg11 Oqwef p.ir,


CYLINDER MEAD1 Cyiindef nead cowr2 l.,.ppet c:o\ler Hntil}el

3 o."'ng4 rap~t (;ovef lemaYs~:

5 Q.nng.6 Tachomet", gea' umr (not for MuZ app;ieabon)7 Cytmdet head

SPARK PLUG TYPE:II>. DPAlIEII>..9 DPR9EA-9 INGKI

SPARK PLUG GAP:B 0.8-0.9 mm (0.031-0.036 Inl

CYLINDER HEAD WARPAGEC LIMIT:

1l.1l3 mm lO.llO12 Inl

112 Nm 11.2 m-kg. 8.7 tt.lbl!

111lllm11.0 m.kg. 7.2 ft·lbl

1M

38 111m(J.S m-k;g. 27 ft.lbl

D SEALANT !QUICK GASKET)"':YAMAHA BOND NO. 1215"

DE75(E94)

ENGINE 4SSEMBLY AND ADJO.ST~NT. . " ,~

l::1ltMSl-lAFf AlIID TIMING CHAI!'!'l'; Ca(11""iIf>. (8. Sh.1lt~. SpflflQ . tj. 510P<>ef,;lbi<le pta,,,~;D13Comp,esSlOo pm, iftt ChaIn guidEr \t.n!a~l(4"; OecompresSitl'f'l Kf"e- ~ TimlP\g·ch8't(l ,$ Cam '"Sptocke'L _ ;1Jt~~tn ijUlOe i~.xhaustl'll' O."''''",....oQ.oarn 1} Gas~E!':'" '!iR"ng . tJ~ eN,,,CI.nlilOMr,

StlAFT-To-CAP CLEARANCE:A 0.020-0.054 mm

10.0008 - 0.0021 inl

a CAMSHAFT RUNOUT LIMIT:0.03 mm 10.00'l2 inl

20 Nm 12.0 ",·kg. 14 it·lbl

j20 Nm (2.0 ",-kg. 14 it.lbO

/~

\110 Nm 11.0 m .kg. 7.2 it-Ibl I

.@ 18 Nm 10.1l m-kg. 5.8 ito/bl I~

OE76{E95i

CYClNOER HEAD. CYLINDER AND PISTON~t .Apply <"

.£f1gltle Oli

. !onto PiSton flnS-i aHd lJlSttllt ;')1(1&'

2. Install.P~SIOD' ling!>

NOTE· __-'--__-,-. _

Be·S~ile til irst8}1 nng So ~h~r mi.m~Jh.!Clvr"?"S 'nark~

Of",gumbers an; ~tXato:rl or< I"t" rOD !itt"!", of rh·p •

lings

. 3.If1Slal

.'Plston·...PISton pm>·CHChPS . 3:

NO'l't

"The ,arlow 4 01"1 the 015iO(1 muSt ilO.1ll141 flit:'

Irom at. ~the engme

•. ~t?re Instal~H1g the ~irClj::t COVe! H\fl crankcal,W

\wtth a clean towel or fag So you Wlij nOi d1Z'Ctden

ti:;Hy drop the pin chp am"! materral trllo tht-'eran;kcase

4' Instate

-Casket ~ l:f:Vlmd~l!

"powel OinS ", 2

DE77(E96)

ENGINE ASSEMBty AIIlOADJUSTMEIIIT

.. 5' POSI'hOl\ '

*Tim rill;• 11l<l ""'9«Offset the prst,OD nl\9 ~r;d 9GPS as s.now""

1 r90 HnQ .,nd2. '0<1 "n~ .",1 (Lower)3,Od ri"ll oM (IIpper)4" 2nd r~ f!Mq

6.' hr,St.a4t'

·.CYlmoe t

NOTE' ~,..;.- _

1'~~d:,'th6 cyhhder while cornoressH'lY tl"w" piston

by 'ho """d

7 lrrstan

--Bolts-SOilS t

~.",' .. ,

~ "42"Nrn 14.1 ",,-k1l, 30 .It-illiBolts :I.

iO Nm tl0 rn-kg, 72 h·lbl

~on::

['I/hlen Ine halts

~,1lt lpipel'10 Nm (1,0 m-kg. 1.2 h-llli

DE78(E97}

ENGINE ASSfMBLY AND ADJUSTMENT

"9 1nS1afi

-Gask€t 1 1 l.vJJ(lrye;' heao-Dowe1 pms-2

10 hl$laH-Cyii,nrb;. ~hl;i1rf

II In~all:

'SOllS

-Bol' ';1-Bolts "3-• 0 ""9 (Pipe 4}-PIpe 4

Bolts 1 J"311 Nm l31l m .kg, :n lHbi

Iloh .210 Nm 11.0 m.kg, 7.2 fl.lbl

NOTE·,AOpIV the englt"li? oli unfo lhe 0 :Ill.\~

.Tt$hter! the botts 1 'm a cnss~t"bSS' p-iHl€,fn

12 jrl:Sial~

·Charn 9W~ i It''::a:.hci'f!-ti

ENGINE ASSEM,BlV -AND AOJUSTMENT

1

•

'1 J lns!a!l.-Cam sprocket 1.C8"",ha!; 2

InstlliHng SU!J1S

• Turn the crankst)af't ep'~ruerc~"kWlse untli theTOC mar' 3 IS ,,~d wi1h the SUltllll'>ll"fpomtar ,4 ,

.. Alig,.. the match mar. 5 .on tt.. c~mr;h&ft"'.ththe, puncne(f mal"k 6' OM the deC'ornpresStuM

lever

.. Fit the. \tml~ cham onto cam sprocket al7l(1lo

s~all tbe uam,sprock(H on the ,arnshaHHOTE: ~_-'..- _

-when ;r,stlilling lneC/im·wrodet. io.eeo the tim

'119 enemllS teflS'!. as. pouitlh;' O"li/1e ",Nus,Side.

-AhSn-, to& p,ml 7 On t~t; decompresSion iev-¢r

wlUi tt:!e !tots a if'l the decompr el1s10r; cam

,-Set the rapec'tl~matcf:."'nit'rks 9 to be plJ:ralietwtln the Case, surtac:e o~ thE' correspcndmg

Sides, and aligh !J'~ r:~Decw...ce ma'n:h 1'narks'1\1'10 h~ vert)Cai, , .

CAUTION:00 not ILlrn t~ cranllShah during the camsl'llrsm lnuallation. Oa mage' or imp,.,!>.".va,lve timing wlll ,'''SUli. •. •

• Whl~e hokitog the camshaft, temporary.ughterr lh~ botts

14 1nstall'

·'Chalr tenSl('mef

¥~ .... *., ..... ~-_ .. _... >-.

Instaffing steps

• Remov~rme cap oqlt 2 washer a am) spnng4

.. ReieasR t!1¢ far01i?1 5 and push .the tf.:'r'!sl.on.

ro-r1 6

ENGINE ASSEMBLY-AND ADJUSTMENT

.Instan t,he cham l.eflSJ;oner with tne ratr.ner en'.:)

tactng downward

• T19~':e(i thtt nons"

'"Bolt Ichain tension'srL .

10 111m (10 m.kg. 7,2 h.jbl

Cap bolt {timing "hi\.in,tensloner420 111m (2:0 ",.kg. 14 ftdb)

lS' i,gh\ur..

4Soits '1 i:,am ~pt(rc~.pr",,'

,8olt leam sprocke'tl.20 111m 120 m.kg. 14 It.lbl'

16 C"",.,• Vaht€- 'tIH+lnSi

OUi, of ajj9nm~f1! : A<}lllSl

- R;f.el to anovp, h! l-'f;~ 1J _" 15

n Ch~d...

-:Y a lvt'! , r:llj.Uf~ml-f'

Out Of spt~-ClfiCiHlt}11 -Mjll,)!

R"I"'>fnVAlVE CLEARANce ADJUSTME,NT -.!\ertlO!1 if' tho CHAPTER\}

In$taU valve Icold)

0.10 . 015· mm 10004 . 0006 in'E~haust valve lcold'!. .

0.15·, 0.20 m"'; 10006 . 0.006 m)

DE81(E100:

EN.GINE ASSEMBLY AND ADJUSTMENT

42 '",nail,-Tachomets! gear tJnj~

Bolt hlylloo8' nead): .'lU~1'I) 11.G m;'k,: H ft·lbl

S8,81ant Iqulcl< gaskell'" PIN A.CC~11001~1

Yamaha Bo"ti No. IllS"f' f.1\l. '9089O-llS505

18, Apply:-Sealant. 1jontO lhe cyunaer ncaa ",aung surfaces'

, .

19 tristall

•• Do-Ael '1'" '220, InstalL

"Cvlrnae' head coverNOTE, _'_''_'_-,-'--__-,-'-__Tignteti -tne 'boas in ,s~q~e. 'usmg n Cflss(;rOS'S

pal1l!rfl

r'-,.----'-C------.:......--,Boh Ivylinder haad (;Dved_

tll N~ IUJ m'ki. 7.2 It·tbl

::n 'In~ralj;

• Til'Tll"Q pit/II.Plug :2

23lrislall.• imake.manrloh:ls 1

'. Bolt (intak" manifoldl10Nm n.o m'1<!!, 7.2 11-Ibl

DE82fE1Q1\

EN6JNrASSEMBLv ·AND ADJUSTMENT

24. 1""tolL.... Scark .P~uQ "1

Sparl< .plog:

17.5 111m 1175 m.kg. 1.2.5 ftolbl

f!if'£S.ANO HOSES1A~ptv: .' '" .

• ~Jthju.'n soap base gHit15-e

.1<Jrl,IO O·"ng an,p,i p,pe'S!

.2 Install.t"Qial1l.h~5e .1

;$ lnStali'l3,e8lhef .MOO!! 1 1,,,1 !dm I

• Breather hose 2" Irt.(jIlkc.aS€-1

"011 hO!lll j

Soil loll h"""I:10 111m 11 0 m.kg. 7.2 fHbl

4 Appiy

·L,rnlllm soap b'aSE \I'ease [OHm 0 flOg on, starter mOlor J •

O!!B31!!1021


.Ul1lon bQlt ,,,i1 pipel';liHlm (2<0 m·kg.< 14 ft.lb)

Boh tst80-t.tr motoj'i

<' 1,0 Nm 11'.0 m·kg. 72 ltolb!

UnIon bolt:20 111m ILO m:kl/. 14 ft.lbl

Bolt: .,

11) !11m 110 m 'kg 7<2 ft.lb)

5 InSlal1-SUther mO!Or 1

6 Instilll

'0,1' pIpe 1

7< Install:-Od pipe j

REMOUNTING E.l\lGfNE\<Vhen t(fl1100fltlr19 rhe engIne, reverse the removal

prOCedure:, No,(e tnt' fnnowjn~ pun),:;;;

OE84(E103)

WATER PUMPDISASSEM BlY- 1 Ft~c>~e_

'Sl*l!'• Sid~~.?oVftr':£

-AH'SCOmis"fUElI 13(lk

"E"91O~,gvard

Referto I~' COOtANT R!'PlACEMENTSBeIlO" tr1 Ih~CHAPtER 'l

NOTE: _

BaS,ute to nralfl t~ 'C90lao1 lJtaJ!:)(~ OIi,iiS.semtHy

of n'le COOil.l':19 system cQtnpcmems

2 D,scc>n,,'ect

• RadllllOr',tlOse '1, ilf0r;' ra(!laID:

*Fled'a'lprhose 2 '10 tvli"~erllilt water drain screw 3

DW1(Elllj

WAIERPUMP

:I 6""'0';;' ,.c.ovet (~ajef pump) 1

1

-~ Rerno"'e. oO,,,,,g 1

5 Remove

"~'Valef pVt"C;p r,(Hi~H~g

6 A"move:'-elrel,,, :1ItWat~' pump "gear "2"Prn 3,·C:rC'fp 4

"Water pump h0951r'lQ 51l1rnpeli€1 6

7 fhmmat~

iii DepoSlt'S.

Frotti the tf")uei1+>.r and Wn,fer Dvrnp hff~'S I ng

DV>J2(E112j

YAM4-1D-.6

WATERPUMP

JNSPECTioN1. Inspect

-O·rinQ 1

-Water pump hOlJsmg 2.W~ler pump gear 3Crac:k~ We-a! t;lBrnaye • Repii::;Cf; ,

ASSeMBLYReve"e 'he' DISASSEMBlY; procedu,e

1 ApPly

<Molybdenum disulfide greaselon,o ,mpeller shaft ;>nOI,

,2 Fill:,It Cooling syste.m

Reier to the ':COOLANT Rf-PLACEMENTsec,;'b""n 'he CHr.-PlER 3 '

DW3(E113)

CARBURETOR._~ _ _ ~ ~~~_.~~~~ ~~~- ~~-

CARBURETIOIVCARBURETOR

1 Cqnnectlf\Q arm2 .i4t _Ie "'"3 "thrQttfe va;..re4 Coasting enocher5 v.iw selll _mb!y6 N..eclil·jel7 0''';''98 1.1.", jel9 !'ilol I.lt

10 PifO. !!C'.'" "".11 rhrtmle stop-sere'"12 Floal .'13 Srane. Plunger set.14 -Drein screw .15 Main jel~

16 NeOOle.ji1'17 Pi5!Qn,valve18 Jet "".<ile ... '

, .SPECIFICATlONS

10 MARK . 9'1'1'-00. 4liWlllJ IAI ICHI"

. PRIMARY , SECONOMIY

MAIN JET IM,J,I .. '" 1lI0 )II 1.

PI~or JET IP..J.l .... ~

,JET NEEOl.£ IJ,NJ ' '60!J6..3/li SX7C·3f5.' 6D97·!l11i I~J ICHI .

NEEDLE ,JET IIll.J,1 , V!lO . ¢2.7PILOT SCREW IP.Sj 2. .....d, 112 lur"" ""I -RQAT HEIG~ .IF.H! 11l-V mm',q.1l8-1.D8ir'l1 .FVEL LEVEL .11'.1;.,1' 'llll·a.O mm 10.34":0.31 inl

, a"low fro", th" flo"t ~ha"'be" :'Jilting. .vnllc. "- p

;:NG11$~ IDlING'SI!fEO, 12!1ll-1.81 '1m,,, ,

@--

2Nm(0.2 mokS. 1.4 ft.lb)

I19 Nm (U rookS. 11.5 ft·lbl I~'"

r~~

I13 Nm 10.3 ro.kS. 2.2 ft.!b) I

3.5 Nm10.35 mokS. 2.5 ft.lbl

3Nm;;;z:; 10.3 mokg. 2.2 tt-lbl

II Nm Ill.S m·ke. 4.3 ft·lbJ..,.-- ,

CARBURETOR

A. POl'Nt'Y carbule!ot[!f SecMOary ~ carburetor'

CARBURETOR

B. OlSCCmn1K'!:

.Vacuun} hose·,DelivE>'Y hose 2• Carbv<etor 'lissemO'y

, I from intake In?f\llolrll

DISASS"MBlYNOTE _

:n",,'!oUowing pans can be Cleane~ allli "",soectedwllhour drsasSlilmbly,• Diaph'au.rrl,lCoasHhg ennch"ri·S!~rter p'unger-TtlrOlfl" SlOp screw .

1. Disconrie;:t

·'Air ver\t hnse ."'*"VactJom':nose~'2·Alf. ven~' pipe :3

'~Olfer flow 1\""" 4

2, ,AemQlfe:,<Stay plate ,5 (rear;,-Slay plale '6 Bronll

3. 'Dl:;con,.,ect.. ,~ .<P,pe t-Pipe 2-tir\k rod :3

4: SllParale:'. Pt,mary carUvrel<;ft, 4

~~ Secondary C2rbtJfetO~ 5

DC4(E120)

CARBURETOR.

Primary c:arbUrS1'Of1. 'Remove:

..Float chamber ,i .•R~ nin ' 'i"

p' ..

• Float 3

NOTE: ~~ _

2, Remove~

#Needle valve/Valve ~eat

-. Main le11 Nee<ji~ "je: "~

'Pilot jet.3'··pact Screw 4·O:rino ;

3 DiSconneot·..Throttle stop $Crtl""

4, ,Remove:;-siii;i;;; pl.;,;g;;, 2.'. {fromlhe'starte, cableI

5 Remoye:-Cover.. i {coasting ~n"c.h"-Spring ~~j .., '·Oiaphrl!gm . ,3.. .

DCS{Et21 )

CARBURETOR

6. Remove.-Too cover 1·GasKe1 2."Sctew 3 (connecting arm)

7 Remoye.• Thr01tle ie~ef

-Colla, 2• Cable holde' 3

8 Remove'aT;,roltle shall-Spring 2.

• Thr~tle valve IWHh -t;onnectrnQ arm)

g..Remove:.·

• CCinnectln\l"arrrr 1".lel freed!e 2-Throttle ",ilve" ,3

Secondary carburetor1, .Remove

·Plug", r"Gaskel "2aMain jel 3

.-Nee'!'e jel 4

DC6(E1221

v

CARBURETOR

2, "emo",,:• Top cover .1.~p"ng 2

3 Remove:,• Piston ''''aive J• JeI needie 2

INSPECTION, InsPect: ' '

-Ca'Ov'elof DO,dy.. Float .chamhef",C,a.cksfOamag~ • Replace

, • Fue' passage, ,Conta~irnilion "Crean

IIIOTE: ,..- ---__

Use a pei,olel.\ih based soiven!'!"r 'c,eanlng (Donofuse. any eauSli~ca(bl!r"IOrc,*,mng sOlUlicui.l.Blowout'all passages'ano let,s"wm; compressedair .

t2 1

J. &t-4IPl

3

2' ll1$peC1 ,

~ Val"" seal' 1• Needle "alve 2-0-"n9 ..~DamagelWellr 1C,lntamlf'atlon :.Replace"sa'sel

t' .NOTE: -;---- -,-

A1wai's',,,place,,if,e needle valve and valve seat.,as a,setThe luel strainer 4 has 10 be always clean!

CARBURETOR-----"' ..~~--~~~-

:3. IflSP~C!;

·Stljl1er plunge, 1WllarJOamage -RePlaCe

"Ttn'fltlle ';loP screw i0a.mage ··Replace .

2

b

4. In.p*lel.'RIJl)btJr diap!"lr.agm 1 Ip1S10,", valve;~Rubb';" diaphragm 2 \coasling enrich.rI~ Tears i Oamage '. Replace

" - :, ' _" • t

5_ln$p~c!.

.. J,n needle ,. ·(pwTlaryl.• J!H needte ~ {secondary;. Bends :Wear .Darnag~ ."lepiace

1-1

6:- lospec!"-

. •Throttle valve 1 tptlmary j, . ~

-'·,P1SlOh valve '2 (sf:!condarylScratches!Ww:Damage •Repiace.

'7. Check'• Ffe~ mov-ernerir '... . .. Slick • Replace. .

In'lm!h" throttle valve and pISIOr, valli" ,nt"the. carbure.lD'· body, a""o cr;eck lor I,e'"r.n'overnent,

~; Pritn~ry~ ca,bl)r~<:f ,'i:~: SeGcndaty carbUretor

DC8{E124)

CARBURETOR

8 Ins>!ect;-Float 1

Damage .....Repi.acf:l:

9. Inspect·oMain jet '1 (primary)

-Main let 2 (secondaryl-Needle jet' j (pr,ma/yl

- Needle jet ~ lsecondarvl-O-flOg' 5· tprlmary)

- Pilot ·,et 6Wear/D-amag,;:· Replace·

ContamtrlatloD '- Biow QUi ,ets Wlm cpm0" 'pressed ,air I

ASSEMBLYReverse thl:: "OISASSEMBLy" procedUles Noletha following points

CAU110N:

-Belore reassembling, wash the all parts In

clean petroleum based solvent.Always use a new !lasket."" '" ' ,

Secondarycarburatorj. 'nstan; r.

-Jet needi~ '1-Piston. valve 2

NOTE' __....:.-'-- _

Matc~·lhe tab 011 the rubber diaphragm to th~

matching recess In. the Secondary carburetor i

SCrew hop cover};2 N 10.2 m-kg, 1.4 It-II;I .. .

2_ Install;·-SPMi! :1..~-Top cover .;2'

DC9(E125)

CARBURETOR

3.ln"Sllail:

- Needle let 1- Ma.lf> je: :I.-Plug 3·

Ma,,, jet:

.~ Nm IQ2 m·kg. VI fl-lb,

~I"ll"9. !'1m 109 "'-kg. lUi !Hbl

Prlm~rY carbutetor1 In.,all,

- Jet noodle 1~C'o~nec;Jng 'arITj 2tto fhrot1~ val",,fl;

SClew h::onnecttng afm;: JG.l!Nm 1(l0ll m'Kg, 0.6 fHbl .

-

NOTE: -'- _

Make ~ure'lhat,the corole.cung arm assertil:'1v '31$ ai the mustrinf?O pas-Won~ " ,~. '

2: InslaH.• ;h~O~'B va!ve 1

J lnstal~\

-Spr"'\ll,-Throttle shait::!

NOTE: ....,.,-.:. _

Set 'the sonng~ Shovv,l.

DC101E125)

CARBVRETOR

Screw {conntH;::ting srm)

2 111m 10.2 m·kg. 1'1 ft.lt;\

,L instllll:-SC~tlW

1II0TE,, ,..---- _

Turn 1he 1hro~h! sha~ ~ l2·turn <::lockwlse to giVepreload t9 the sorln,g am~ hold 11 _.~

Then. instan the SCr~w tconnectiog afm"

4

5 Insta!1!\) Cabie hOldel 1

-Colla' 2'ItT:;ronle ie'\ier J

NOTE; --' _

6 E!e sure throttle shatt i~e, .4 and adjusting boit5 I CIre Iil!igned when tightening thwttie shaft nu1

~ . '

Sc,,,w Icable holde,J:3 'Nm 10..3 m.kg. 2.2 ft·lbl

'Nut lthtQ1'thi leve'l:3.5 Nm 10.35 m·kg. 2.5 ft·lbl

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

. ';>"n,w Itoll CO"!,'I:2 Nm ICl:2·m.!ill. 1.4 It·lal

6. in.s1all:

.-Gasket.rT00 'C·over 2

DCllIEl:!?)

CARBURETOR

7. Install'.l1:ubbtH dicph!agm

NonMalCh Ihe Illb <>n Ihe fubbef dlaphregm to Ihematching fe_cess to the coasling -e,uict1et

a. 'Cannect;.·Starter pivnger {to me Slaner caDle)

B. InslaH:~Tlrro!tle stop screw

10, I"s~.l!:

01'1101 Sc'flW I·• PHol iel 2 <'NeeCle lei 3°Maln fe: .(

.>,V~lva 'S'1at 5> Noo(lle' v.,:ve' 6.

!wiih 1loaO --

Ne",dl. jor;2 "11)1 .10,2 m.kg, lkR·lbl

.Main jet! : ,<

'.6 IIfrnle ..16-m:kQ. "'2fHblScrew' tvalye seat'.

Z Nm 102 m.kg" 1.4 h .i~!

11 lruitall~Float Pin 1

NOTE: ''';';_~__...,.-~ _

install the U,put '~~'n ,aver~e' Jo the -tifr-OW .•

DC12(E128)

CARBURETOR

12~~ Measure:.l'iO~\ /'lelght a

0141 o! sP<>cdl<;llliQn - AdjuSl

Mllaliu,emel'lt and ..djustmerlt steps:• HOld the ~urQt"r in an ull..sii:le down oosillon.111 Measure the dlslllnl:e from !be mating sunace

olthjil'f!oat 'cHamber' 19asket ,em';"'ed) to t"~toil'l:ll the flOlill. -

Nmi; -. " .

The fIo«l.arm sh~ tie rest"'9 on the ·"p,e.'1lev"lve. ,!:>vI no! cOr;l"PleSslng.!he needle ""lve

, ' ''', . ~ .

,I'loetf'leight IF. H.}:25.0 - 27.0 mm 10.• - 1.~ in)

eu the iioa(height is ~a1 with,;speciiicariqn.•n. specl ttle valve sea! a'1d needle valve• II eltllar is worn: lePlace lhemboth,ilIlI hom a;e fine. adjust the float hfOiglH bv~nd

Ing ihe fio~l l<l~g .1. on t~Jlaal ... Aecheck the: float he.g'h,

13 Install'g Float chamber

Screw IfloBt, cham!,e;I:,.2 Nrn to.2·IT\·kg. 14. ft .Ibl

14, :AajuSl.

·-ElIOt Sc'£!W~ '1

Pilot s.crew (turn .oull;.2 snd..l1-2 tllms out

Adjustment'steps-:.. Tum in~thll pilol SC'!!\'V unlil Illsligl1Uy lieated

.. !lack out ~the speciffe<lnbmber of tjJ!'ns.. . -. -. . . .

DC13{E129)

...............-(.J...f----, 6.0 mm"""l",j,."""'~_--l.10.24 in)

.CARBU.RETOR

15 Install'

• Primary caroureto.-Secondary carburetor ;{

16. 10SI,,1I •

~SI.Y plate fl;anti 1"Stav plale {rearl ?

Screw ·lstay pla,al3 Nt'" Ill.3 m.kg. 2.2 h·lbl

1II0TE ,;;;.-.

Ahef !I:g-hte:ro~ng. chec~ the 1hronte l€Over al1dthroWe va.]v€: tm smooth action

17 Connect.. Over l'o.Vv hose ...

• Au veni ptpe 4;;oVacuum hose '5

• Au vetlt t:0S€ 6

18. Adjus!-SCco!}dary ..catbvfetor $vnChrO()~lrt!H')n

,+ ,. , " ~~ .. ~ \

'Adjustment steps,• Raise the primary ''!fottie: vcil,te 1 to i~ helgm

-"I 61l mm 1024 inl as ,,"kala"

e. Tum me sVfichromz;ng scrt.:~' 1, if1 or.out so'hal' secondary Ihrotlle valve iii. "l)l!!l\ln. toopen

DC14t£130

CARBURETOR

• Mlltq~ S'iHt: that the sp.condarv VaNe- IS openedhon.lonti:!'l1y \ a -t,! '; when ~he pnrnar'Y cart:.H.,i

tetOr -1i.!jVtt 1$ tullY oPened

INSTALLATION

Reverse thf!" >'REMOVAL' prOCCH'1v;es Notp HI'":'

follOWing pomlS

Inslall

*Carbure10r. (tS$embt~

Screw Iloir1t bend'le/ti2 Nm 10,'2 m.kg, 1,4 It ,fbi

Screw (joiO! b"nd-ri9h H5 Nm 105 m.kg. 36 fl.lbl,

Instali

-Carburetor /O,m to UHthH€tOl by m(htlngforward

3 Inslall,

• ThrOlll€ cabie 1

-Srarter plunge! 2

Starter plunger,6 Nm lUi m'''g. 4,3 11.fbJ

DCl5{E131)

CARBURETOR

4 Ad,u>l.ihtQttie l.ahl~' 1-4'~ pia"

Reiet to H~~ 'THROTTLE CA8~E ,H'EfPlA Y ADJUS- TMENT ~er.lf(Jn l:n t;-l,,::

CHANER 3

Ttlrott.., cable"Ir"" play;I . 5 mm 10 1:l . (l.2(L!n'

5 AdJIJSI

.I<lle speed'

Rete< to~helDU SPEtD AOJUS"rMEN1

secttOl'1 ;n'the Ct1APffR 3.

Eng"'" idle spe..d1.25O··1.J5lll·hn",

FUEL LEVEl AOJUS'hV1ENT. . ,I Place th~ motu:t~yc!c-on a 4eve-; pl~{CCl' ...

2' U&e}he 3U1tabk? s:faJ';{flJ.t}de, 'the fr~rT)fl:~nd'e:ngtfH? tD ensvre rhV'.! mit' " IS PUSI~

tloned .v€:r!H.:a:;fv

:1 C(,lnnecr the Fuel Lt""v£'l Gauy,p rn'lht,' float

,-chamber dt~Hn P1PP..:,

Ftie' lever gauge,~~

PiN. YM·01312·A.P /N 90890·0131.

. ..4. Loosen lhe.m'Hfi Sqh\.~ 2. ,H1M >Ndr:,l,~ ,Jp ih("

Q.ng!ile !or sevef.ii.njJ!}!ll-f'.!;i,

5 H01Q 1ht' .ga~q~ "'",:e(ne"~~y·nexi kl >tne fk)il1

chQmQe~ tl){Hmg s-~,d1tn: ..

6 MeasLJrEL

• t ll~I.l£'v~ ;J

Uui of St:H::~cliJulnon •Ad,t'Sl

Fuel level:,6·0·-1l~D.mm 10.24,031 inlB"low !,om' th" float cham be'malting suri aCe

1 Adj".,.~Fue> levtll

Adjustm&nt 3181""

f Rl;!mcr\lf' ~t~ c.ar04JtelOl.11\~Pf't'( m~ 'J-L~ seat ;1(\0 needle 'I.f!fvf!

• H e.~her m wOfn~· tepiat~ ~lJem 1.:01\"1

elf bo-ttl at€'. fmc:. atijJst tN> float t:elghr·hY¥l,,·priiflgJhe Hom u,ng 1 .on t"he.f!£lai

., R@,C~Ck 'ih~ 'hie: 'level I

DC16(E132)

FUEL PUMP

FUEL PUMPPUMP OP,EAATION INSPECTION

1 Inspec1

··Fue~ PUn'll: operatIon

Op..,atiO" inspection ~te):l<l'

.. 'lJ~n '.tl'w'!",,1 cod< to "ON

.·O'$:COhl1cct the dehvery hO$~' from 1M$';' c.d'. ' ,

. bur.etor (fvel p'u.m.p , ~arbufl?tor

lI.Ji?lace. th~ receP.tacle under thfi delivery hOSt:

end.~T-ytn lhe m,Wl SWitch .10' - 'ON• PuStr 'the starter swltr:t"t

.. Check t~e tuP.J flu}N r~Ul· jron, the ~lf;il\if.!ry h(J5i? "

end'.

U. fuel-do~ rwr'lollv -oui. taplace ti"lff l-u~~f)tJH'1'p

asse.':"bly or .ref.er to'tNSRECTlOt'/'usecr,on

REMOVAL

'[).,.l;col1l:-eC1 '

"::Vac\!.um 'lOse'. tmi'" Intake nftm'if,.oid

:O-etivt!ry husf7 if,om' {;tirbJ.IH.Hor. .. . -

~. Rem""",,Fue/'plimp as"Olbly

INSPECTIQN,. ~!'1$PtCl

"F've;~h~5e

·VatuLrn 'nose··,Dellvery 'llOse

Crack Wear ~Oamage ·R'Cplace2 Jnspec~

.. Fu£!j f,h!'t1Q It!%SB!?lbl't' 1

erfle'; 6ama~1" ."ReDIac.f!

"SSfMlllYq'everse the "REMOVAL~ :~rQcedu/e Note m~totl.~!n9 ~:';l~ .'.

l....ConMer:;·vac~h()sr.·-;'Th:tlive,y~~:_~flJef t\o!ii

Note,8e-sure 10 t.'urmect ttle hO'$e Q.'lu-et't'Y.'wh(ln ':on

neCli~

2' IriSlillJ·Fue! tank

·Ait scoops··SH1e coven.-Seal

DC17(Et34)

STARTER MOTOR1 0- Rng2 Armalure3 O-Ring4 Yoke5 O-RIng6 Brush

ELECTRICAL STARTING SYSTEM

A BRUSH WEAR LIMIT:5.0 mm 10.20 inl

B COMMUTATOR WEAR LIMIT:1:1 mm 11.06 In)

C MICA UNDERCUT:0.7 mm 10.027 inl

D ARMATURE COil RESISTANCE:00 at 2O"C l611oF)

5 Nm 10,5 m.kg. 3.6 tt.lbl

El,ECJBtCAL STARTfNG :SYSTEM

Removal1,::fremove:'

·Sta.:ter:motor. Refer to , fhe. "HiGH\lE OVEI'lHAUi:ENGINE DISASSEMBi,.Y" .section in thaCHAPTER 4.

1 Oi9assern 0.11'

l. P"t identifying marks .,. on the brackets iii!reassemoly as shown,

2

1

2. RemO~!l: ..• Cirelip !.l..·.Starler·drl"egear :,:?

1

3, Remove,'801::s :1·. '. . .

DSTART2(E16'i

ELECTRICAL. STARTING SYSTEM

4, RernOve~.B,acklll .(*Washers(t,·• Shn'!ls·,j3·•.B,acket:(!.• $~',. i5~'

~um$ "_.'_

',aArmature ([,'O-rings ,'t::"•Yoki (ij)'

: 5. Rem.ove:• Brush holder sel 1

Il'lsp.ection and ulpair-1.1nspecr

-Commutator

Dkly-Cleanti witn "'600 g"l sandpape,

2.lVleaiure:'~Commutalo, diamatet ,~a

ou,ms~ifiiiat'Q~ -Replace starter~

'Commutator wear. timIt;

TI mmf1.06inJ

DSTART3(E162)

ELECTRICAL STARTING SYSTEM

1 MO or more 00

I , Its=zj

nx1 0

@X1tdlx10 +

2, Mea.sl.ir.~

oM,ca'und"'cw'.Oul of sp.edflcat:on ,', Scrape- ihe rruC-a ,to'

'proper V~Hue use Jf ha('k~w olad-e car: be

gr~nd 19 fIt ..

NOT£: _

.T,ht: rraca:-in$lJlation ot'the COs-Timutalo1 mus1 be, ' ,

vndetcut. to' ensure proper operatIOn of com·mu'@zor

4: 'nspect:'~.Armatutll col'i tinf>U~at'OfI!COl'1t;n1JltVI

i. ,;. " Defec~_~'I'RepJace starter motoL

'.n"pe¢lnll"tel'~:",e,COOOeCl. tbe,_p~Ket. tester fOf conhnultV 'ciWc:k""'~- • - -. .. '.,' "te'",:!"" _", - "~.,_' -,::.t::and: insula/Jon, c,he,k r~>

., .M:easvr~ the :aTrnature resIstances

A;~atureMcon rasistance:C~ntirltlity check 1. '

: 'Oil at '2O"CI611"F,I' ., " " '" . 'Insulation check 2'·: "~.

",M,,,r~:th"n 1MU at 2{I·;C .,,·,'""IM""I ':' ,", , ,~

- ,. _.- '.

lil,i the i~artie'iS' incorrilCt, replac~ the start ~,,, motOr,""'''"' ,"" ' , • '

S, Measure: ' :• Brush 1""Ilth

Oot <:>f"ilp€'ci!icallon -. Rilplace..

El'ru~h I.enllth limit:"'5:0',,;m IO.ZO inl

OSTART4(E.163)

ELECTRlCAl STARTU\lG SYSTEM

S'Measu!e• Q';.Jsb- lll'ring for.ce::f.ilI1~uejO!J.l of .specificalion· "'leplace'as a••Q!-

1 2'oBTtlS~ -Spring fOl"ee>

680-!l2!J g 124.0-32.4 oZ'.

7, lnspeC\:

'Bearm>l .1'·OiI.sear.2 .• 8",sh' [:1'. '._ii~m~e'.-R;'pll!ltg ihe br~d"00 r'.n/,.s4.Wear/O.magl\l ~Re;m,,;~

A$'$emblvReserve ~tw "RemQviH"Note·'the follo""in9,pomls..1 . I" . procedure. _ InSlll.. .

-S'"." holiler setNOTE, •

llAiign the b~h Pla're 1 v.rnn t!'e siat 2 em theyoke as shown

• Ii!lgo the projection .3' on tM otush seat wIththe slOl .4 9" the housirig

2

.2. IAstall:

-Yoke I

-l'lrackets 2,'- Stanmg drtve, gear '3,

NOTE; _---'-_'--_" on Ihe yoke with Ihe

]Bolt I~f..rt"r motOr),

, 10 Nm il,QjT"'kg, 7.Z'ff·lbl

·Align the match "'''''sInstallation

J. l"~tall:

'. Siarter ,/notor1II0T!?: .Apply a bghfly ~rea$-e to the O·~j!iO'

OSTART5(EI641

1 AC, Magneto2 Regtifierl regulator3 Battery4 Fuse box5 Main switch

CHARGING SYSTEM

MUZ 660 Skorpion

MuZ 660 E Baghira

CHARGIll,iG SYSTE:'I\II

TRDUBLESHOOTllllG

1 THE BATTERY IS NOT·CHARGED.tJ.

ProcedureChed<.

1. Fuse !mainl2. Barrery3. ChargIng voltage4. Stator coil resrstance'

5. Wirin.9 connectionIEntire chargmg system'

NOTE: _

-Remove Ihe following pans palore ttoublllShoo!i119

11 Seat21 Side ~ov"r lIoftl

-Use the 101l0w,n9 sol!I::iai loolls' Ifl rh.s troubleshooting

Inductive tachometer:PIN YU-ll8Q:i6-A, !lllflllO.0311J

Pocket tester:

PIN VU:0:3112. 9Oll9O·03112

NOCONTINUITY... I:'e:tTH).... e< tl'Uit use, , !

.1*Connect the: pocke\tesletH~ ~-_ 1) t'3 {he ·fuse, :-Check 1~ f~ fo~ eem~nuit'Y·_ .:,

Reeler lo·The --FUSE INpPECrlON" section InJ fuse i. faulty: replaCe il. Ithe CrtAPTEF! 3.

,JJ CONTIN\Jl"rY

t ,. 2. Ballery .. , iNCORRECT

- Check the battery eO"';'llOn, -So.Refe' to tho "8.<1. rTERY INS PECTioN sec· .ta:m In the CHAPTER J " -Clean 'baltl1fY terminalS

'.,.

-Recharge or '''J)!.ace battery.Volt""", -Refe' to rhe :'SATTEBY INSPECTION' l>fH:

12.8 V a' high", III 2O"C 'llllQl'l . lIOn on the CHAPTER 3:.. .

~. CORRECT

DC;-tARG1{El5111

CHARGING SYSTEM

3. C~at9ing voltage

.. COfl,oeit thEt inductive tachomen:tr to ~he

sparl< plug toocL'Connect the pocket tester lOC20V) .to tt1e,Denary.

/ ,Testar 14 I.hiad -Battery! + I terminalTetlter I -I lilad'-"Sattery I - Harmlna.l

,'Stan the eog"111 ""~ accelerate .to a.oout,5,000 timin. '

-Check charginlJ 1IoitilQs.

E::S' Charging volta\111>:<i'\' 1<1.0 V at 5,000 rI min

MEETS SPECIFICATiON

NOTE: _

1 OIJ.'r OF ..SPECIFICATION

!u~ s fuHcr·atge:d ba,t~_ery.

i

4 Starot .coll rftSt-Stanc:e

"* D~Qf'i:nec i Ihe state; coil CQUpfe. from The

wh'eharness.

• Connec! the pOCket tester "H ..~ T" to fhe siBtor coils.

.Meas~re the Slato' CO!l resiStances1

.

. Teliter ( +1 lead -Whiti! lead 1TeSler 1 . ) lead .4Whlt" lead '2

- T"sta, 1• I llllad-W/li,a l"..d 1"Tast.., 1 I I"ad -'Whlte. lead 3

OCHAAG2(E169)

Stator coil resistance:0.2-0.30 lOGe 168GFl

. BOTH MEETSPECIFICAnONS

> 5. Winng connectioh ;

CHARGING SYSTEM

OUT OF SPECIFICATIOl\

, 1I,Stat~r,COil i,s faulty, replace it.

,POOR CONNECTION

Check' the e~~ir~ igriitiOh system -fnT con~'ne-ctlons.." ~

Reier 10 I"" "WIRING DIAGRAM' section, '" .

Replace rGc'titier.-! regulator

:J

DCHARG3(E170j

TROUBLESHOOTI NG

,STARTiNG FAlLURElHARD STARTIN,G

NOTE:. 1 ,

The,loil(lw,ng Iroubl"""ootin\1 ;ioas not cover ,~~ thil posslb!ll,causes'ot 1foubl": It shnuldbe"e'lllui.Mowever,as a guide to tfoubtesttootin,g Refer to the re,lativeproced'UN3 -,n this mantJ.:!1 10.; lnSpeC1!On

t.djustmant afld reptacerrnm! 'ot parts:

,STARTINGFAILUREJHARD STARTiNGFUEL SV;;TEM , ' ,!"RO!i~J!~E !:;P!9S!'

j-'Fuel lanK -EmpIV.,,1 ' • "CIOllgedfue\ hlter! "'Clogg<!d fuel wlt,joe'I ·CIQ9lled IU81b,eDther h<;s~1 ·OeumQr8t~d flJE::i Qf h,H;J c,on'alrHn~ W<'\-lPf ~H

k f(}N!'ll." mater,al. It r ;:UO' CoCk---------r-Oogged tUfil~ hosO'

1 <Clog.pad 1",,1 liltfl!

L.. C('lfh\irt1~t)f ----'~-----._r ·Oe1etlOlated fu~L .hte\ c-rmt8,n~Hp wM-i", OJ:

tore~11 m3t~(tal

• Cloggfl(1 0"01 ie!.. Cloggun Pilot Sif P.;tsS\.:~~~·Si.H;;ked-l0 ;:Uf-

- Ol!fom''''l flbal• Groove, wofn, nflmHc val\H+

-lrnprontnJy seal.ed lI,tivn S~AT

• Impfor;erly adlU,l\htd fuel l-eve';-Improperly set !>f1t,1 1[11

-Clogged St(tr1~f i~t

- Star1e; plunger ma!f\)n{~lIOfi

• Improperly Jl<1iusted SiRtl!H ,:~lhlf'

'.~~~- ..-. Clogged

' ,_e Faully hJel purnp

·CH:}Hgt~d V,'h':WHl! hn~r·~

TROUBLE01 (E198)

TROUBLESHOOTING

STARTING FAILUREfHARO .STARTING.

I~l9nltt'H'SY;nem---~----TL···'FallIlY 19011°' lIoh

, • FaUltv pici< ,loiD COli

'l' !lBrOken W01:>OruH tt_~'r

. 'Switct;"s ami w'''~n''--~--i-FaUlty J'nl3l!1 s\"vllt"hi •i ·Faulty f<Et.GiNE SlOP' ,wllel;I '.... 8rox\'n or shmted ''''ionq

'1' -ratdtv lHJ\ltNl'l ];Wjtl;~h-FO'lvHv "STAR1" !lWlh.,:h

-r.f\uHy siop.stant1 .swlh'h

L "'FnuHv dUle.:l: s""."1h~h

--_·_····-,.f-ai.l11\t !'1Zlrtm I1M)l",

"h'lJ!tY $lmi~! mlH\-Fml!1\,>' 01\',\.11.1 '(\It (H! IPl;l\

.Fm'lty 1"H!rwr cfmdl ;

ElECTAIFA~ SYSTEM. !!ROBABI.E CAUSE

r·Spark piug--'---------,i-··lrnp;ope' p1ug ..!tllP. ·'WOfP elecnode:&

l~. ·Wtre between letmmais of¢k.en

~. I '''',mproper 'neat range' . '- .~aulfY, spar~ plug cap

,: Ignit:o" ·otiil---.----.----,,' *Sroxerfor 'Shoncd.. ort''f)~fV Sf.!corH,1;v)'

.i '1 • Faulty soarli I1lu9. 1".<1L--Brokenhoov

PROllABLE CAUSE

T -I,n"f~)fffty ~{IulC(l cl,Jntc\:u:s\;

'I .Dan~ap(!'d (;-f~ll<$!H1~t Oil ~(\1 l~l

r f- t,mpr~rlv ~~dloo vn/vi.'!

-lmprnoer1v i..:On1fldud VnlV{i .ann \,',11\1'1' h~i';H

, "*lm})mjml vnM~ tlnHti\1I .l -BmklJtl l,.'aJvc i:>D,Jl)(.)

L-£t;!!'(1(1 rtttnhsf;"H •

~ $pi.lf~i ~:;m1-Sh;lt!

.~~~-r- "'\'fl~IOl'tt'!rly lnfiHlile\j PIFlnf) nnl;l

~ -WUnt, t~Hgu'ed ti1 hHl~pn (»~hll; ltf.~)i .Slilum1 ~r51()n H'''l~l

L -St111Pt1 tlf liap"~i)e'fl jll:l".l;'lI1

l ..crallk(:a~f' ami O)II1~~htlf!',

COMP~ESSiON SYSTEM'

j~ (Vlind(1'! a~~rl cVtlnoer ,bead ~<--.,- ·Luose spi;f"i\ piuq

-LoOSit cylindtH tH;,f(j (t4 \;yluitlPI

I ··.BrOIH_'f1-c:yknd'ttr hflnn ~J<1Sk~{

1 "\>VOfli, dH!na(fHf1 Of :-;ell"'[~ ,~v,;.,di"1

~'Pistnl'- m~f r-.~WH ~ lPH, .

TROUBLE02(E199j

TROUBLESHOOTING

POORrDLE SPEED PERFORMAfijCEIPOOR MED.UM AND HIGH SPEED PERFORMANCE

f>.OORIDLESPEEDPERFORMANCE,f?OOB IOl.E, SPEED, PERfORMANCE PR.OjUl.,B.U £~l,lSf;

f.- Garb<>!elQf----,...,.----r, 'ImpropS,ly,'retumeo, stane, piuf'\J'"

I •LCIi>Se pilOl J<tt'C1ll"lIl'd ,PilOI ai"jet

I ,'i 'Im;ope,~ .ynchran'red eart>4,elOisJ .improper.yadjustoo Idl1l speed '

, II : f:'fhrotfle StoP. s~n1Wf', Li .a:!mpr:oper thr'o~Mle.G:able play

\ 'Fl<X1(led carbureto,

~ Eleclrical SYSlem-.,.-----,...,., • FauiTy ballary.~S\Jtty 5.t'J&l'k' plug.

'l-FaHJty jgnlt~f UOil

lIFauhy pickup coil

:.- ..fAulty ,gnitlt;;" ::Ol(

LValve tr.m---- '----"}mprooerly ~d~~jsted vmve cfC(,}'.:mce

PRO!lAflLE CAUSE'~CarbtH{.l:!OI ------·---,.,.'Ill~rnJ.,itopetfet needli.~ chp POS!t\\1fi

'. D~.aphragm f~.affH"f:tkH"'l '-Jmp,operly ,adjtlsted fli~l levu'

• Clo~ged "Of loose rn8nl jf'!i

• Oeteflofill efi fHP! r.ofHaimfiU WMP' O~ fHm~If'\

rn-ate-nal

POOR MEDIUM AND HIGH SPEED PERFQRMANCEPOOR MEOlUMANO fllGH SPEED 'PfRFORMANCE

IRef'" to thl', "STARTINQ FAILURE!HARD STARTING'" "",1

PERFORMANCE "aM\ train '''eMn

i

[

Alf c!tntOW ----...-.'~----- -CiO}Jgffd 'W fjltP.1 eloment

Fuel pumi) -----.- .;"oul(y fllel pldnp

TROU8LE03(E200i

TROUBLESHOOTING

FAULTY GEAR SHIFTING!CLUTCH SLIPPING/DRAGGING

fAULTY GEAR SHIFTING.HAf.\O SHQ'TlNG

·R.f,,, to,l". "CLt,iTCH SL:IPPINGIDRAGGING·CLUTCH DRAGGING" se,'M,'

SHIFT'PEDAL DOE1H"CIT MOVE PROBABLE. CAUSE". tShih Sha'f~ ""Bent shih ~=ilh

'." ~hjtt earn. $tutt fork----''''1-Groove l"mr;ll!O ""'til 'm;"moe,.

I · .StHz(U1 ~tllh forki • -Sent Shtft tork gutde bitr

LTrlmsmis"on -S"ized If."sm,SS"'" 9".'·J~mrrwd ni:1ntfUlles

''a'![)f;mr.,ctl'r asserllhip.r1 ttansnj:t!i";li l1!

JUMP·OUT GEAR pRO!lAelE CAUSE

~ Shih Shith .lnmmpe:rly .HillH'IHd ~hUt il'Vl11 Pll~jt!{~'\. ·lnlp~untHlv !(~lWHUd /:;IOi)I'I;1 ll'\'t't

[I StutT fork ------ .~ , "Wmll ~hltf kui<

- Sru/t f"nn,,,-, ~~~.--..~ '~~--r- O'ltHpt,J(Hi! IhH,~~ pia\,

LI ran"",,,,,m, __"" _,_", ," ::::::: :::~: ::::' \111)('",

CLUTCH SUPPING/DRAGGINGClUTCH SUPPING PROBABLE CAUSEr ClliN:h--- 7_'.,__............!-.__,"I' .loose l~hfH'h $IHli\!j

, , "f;'Utpqed rI\Jtt'!l 'SPHq~:[ --WOfl1 frklkm pJ.IW

t -Worn ('l:~h'h pf.'ltl'

llllin1.;Qflt"~U\ ,lRl":t:I'nbied \',!utt'i\

L F1iqm~ oil --"--·---"·-"~"~r.t,......... \1.1 i"Hl'1

-Irnpt tlpm (1i'~11J1\ 11 '\)\. '>'i~~' H~I!\ 1

·n...·tl·Il\1l.111'1I1

TROUBLE04(E201 )

TROUBLESHOOTING

OVERH.EATING'OR OVER"C.OOLING

·f

CLUT.CH DIlAClClING P.ROIlAJlLE£~~SE

'r' C1Y'Sh-'---,::,;""'-,-~-'.---""",,,-,wilr~ preriure pi.:llVl' '.Uneven1y"'tensioned CiVHJh sprIngst: -Ma1C". ma'ks, no~ai'!ln"" .

! 1 -loose dutch boss, nut"•Buint prim,nYdrtve<> goa' tl<Jshlng

~ r --Bant'du.tch .pu.,..t~ .1· -SWOlien iriChooojat6-j '. "",,-

'- .Sro,ken clur<;t1 bass

L ef1~Jme, 0,1 ''--.-~-~--.,~...,.- • r'ilgli' Of! io\'(.~-Improper \ll1;),tJ"t {High, VJscosttvl

• De'tfl:r1ora1Hj.fl

-----.,.i--lnwroper j~arh:Hutol nillln 1m. ~ w"prOfjrH !lftHmn)

l !lII{Jnp!operly adJusterl fu(~1 ll~\lel

:- "'C19flQfff1 iiU fmm .ol~men:

.., [<F"',lhY WrH~r It:mpp.fAl-.>Il' Hil\H)l'

'-Fall'ty lhf"llH!} l.-lnH

i ·lncorrflcl Cl:)Olt"nt tevp!

-'f.UHtly Ihern'Klst.H

·t:;luHy th;;tnw ~Wttdl

·Ct~n~(l or darm10rHl fOOIZJtn.~o)\lh'r' f:irtiainr",::np

.. S~I/P-ff .1IrJPfllkJ ~h.1t;

I, il'lIiol)t-mH!V1~ 1m1 rnl)tOt

Ir F\Hd :;y'{tCJi1

IJ':

~- 'CinlHJrl'~~t1 H\ :-''r'~,t';lr'"'''' .------.- *HtM,t:';! .(Al'fi1<'l'\ hwtd.up

't !''';'''''' '''l·,,---··· .._... - .....'T· -11l""''''C' Of' :"".,1"lfj1P~()fM~J n;l VlS.Cf)1-11lv

. ·Inf~(tn, oil qUili!tv

OVERHEATING OROVER·COOLINGOVERHEATING Pl\09ASllE CAliSErhp 1tluln t>V$tPH'~ T.t~~~er :spn;k pluQ Hap

·llnploo~r .spark nh'lq heAl l"lt111!"'

",t::nuttv t!ll'irOf Hf\t'

OVERCOOUNG

L... r:n{)tlt1~ ~" ... t('lIi

PROBABlf CAliSEP·~-,~-·r:HHllV WfJtnf' tmnf~~~HH\lfn WIH~W

IPhtllHv iharmo ulHl

.. tnuhv tht'rnHl~tMI •

·fIlllity ~hm111O SWJtcl)

q ;{toppriHi....~, ftm lt~)J,OI

TRQUaLE05(E202)

TROUBLESHOOTING

FAULTY BRAKE/FRONT FORK OIL LEAKAGE, AND FRONT FGRK MALFUNCTION

FAULTY 'BRAKEP,OOR BRAlQlllG EFFECT 1"l'!9IlA!ll~ CAUSE

. L{)i~~ b,ak"--·-'-c==,,~---:--rl-· -WIl,n Otak" pari

""'W~rn b~a~'~ dISC'.,A", ',n br~ke fh,,ud,', .'Leaktng:btake' f;t~ld

• ~3011y 1;vbnder .klt CtlP

·;:;aulty ,cahper kit sea]-loose union bdk' -• BtOken brake hO$.€J

·Olly, or greasy brake 01$(-Qih':-Qr greasy brake pm.J

"ImpropEr' hfak~ fillllt It''vP!

FRONT FORK all: lEAKAGE ANO FRONT FORK MALFUNCTIONOIL PROBAi'!lLI' CAUSE

,,,.--..---- -"'--"""------r- «'St!nt d({mfl~H~i Of ft/St\ 1(Hl{'1 hJt11'

·Oill'!h:~Jnl1 {'H ,'!;11'"ft1 ~;!ltl'l llihr

.. rhlmagt~(J ~1l! sri;l! lljl

-jl)iprmitf.ly tl)::-11alll'li PIt 'd!.H

.1mprOl;t'! Hil 'tN.>! !1d('l lHill llJ

·1..\0'$0 t~Hmpl'l H;'!n;i t1tJld,l'l\1 htlli

.. HH)kl~n ('ill> huh 0 1iH~\

• LUti!\{' riauj', hnlt

'-- "Dnm.f~1~~~ ~:tllt(fLt~lH ~f'fSM11

MALFUNCTIONL .....

PROBABLE CAUSE..--~.._- ._--~-~-·St.m. .tittlo-nn~(l Of tl'Hn~HW·t! Hlt}{ll lq-hf'

r .B,>f\t' 0' -dt~hllnu;\i \HH~tJ ;'\Ji~'I ·Oarnat.lntt h)j'~ SPUf,'J\lI .. \A"r~1f1 ~nt d'Hna~'t:}t1 l;~!Hit' thlsh; -Sttm!\t OAlfHl{lttff n:trnptl1 Wtl

OhnpttJpfll oil Vl's.emufv

L .h,;r'I)J~I~1 uil "",\'Vl

TROUBLE06iE203)

TROUBLESHOOTI NG

IIItSTA8LEHANDlING

····.. 1·TWl5IOd• Dilfllilgect head ptpe

"lmpfO(lltrly inSHtltcrj bHfJrlll~J

r.u.np.v_~n tire nresSur~ dn boO; SH1HS

• !~cDm~C! tH'O pr~ltSure

~ ·Unevenlv ,worn nr~s

----·T*~i){:Ofmc ..l wh-{3~i balillll'C

I -Dufmmed wtreel

I -Loose 1}e8fln\.f

; .. Bent" or 'OO!l>~ whoel ;~)(h-\

L "Excessive 'WhetM nm out

S!)fK~ ilh:.;mlJ(:)! --~~T'II F<1ft9UOO stmnH

.. ~tllpf~'rHnly adius~E:'iJ. SPflflO prp.ioadl.. It 0,1 and gaR leak'age' .

INSTABLE HANl;rllNGf'l!Q.BA.BL~ eAliSE'I- Mandl.ti.~s --~~--~--- ~ ImproOarly ';nslall"", Or nen,

·.·fi-~Jeertng , •.. - , .lmproPerly ,nst~Ueo haqdlebar CfOWI'"I .. Ben~ steerine·-stem

L'',' .tmprapefiy' instaiJea steetlng stem

l .,flmpfOJ)erlY; bghteneq nUl!.•Damaged bearing

'I.: Frnnt ro,~s.,-":"~~...:..,.:.e~--,--,,-·Uneven oil .levels Ofl'.bort1. sides

i rBroken springL .Twlsted front forks

rTj'CS

IrWhf:e,£--

I

~""---'~I'f'.~ SWln~Flrm --··---,·------.,--Worn he,rfrln!J 0' bu~1l

$' Rem O! tiRP1Rj.JOO'

L- Ri1ill

[

: - DI,IVI~ dhi,n --~._--'" ----.~._-Olm;)fOnefIY i.I(IIII!:;iP.~,j"I.jt/un ~Ii~:k

Cnwflr'H -"--- .._-~'~-'[ .Oam<tgorl ~t l:l(~rm.,.. ""-01 lBt;tly H1J'HilJmd

TROUBLE07(E204)

TROUBLESHOOTING

FAULTY SIGNAL AND l.IGHTING SY$TEM

HEAOUGHTOARK. PROBABLE CAUSELI-..,..--·----_-,:""'__...,._~~;;;prO;"~b~lb ..

"\1 ;,.Too. many-tele,etti:: accessone~-Haro Charging tfr(o,lo:,erl sratol co'l! .ann or faulty

1,

1. re.ctlfief/reg·...il:a~ti<(I'lncorrect COOfliiCt!on

• frOOroperly gtou~dfl~

"Poor contacts -imSH":.(If ··~JQf--:'-.TS'· SW;ft,hi

. L ~Btl16 "life 8(t)tr-ed

SUlB BURNT OUT PRge~lllE CAUSEL,~ .:.- ._~_,... <I"'f)'ope, b,ilh

·" ~au IIv balll!':;r.

I-FihihY"1?Cfrber regumtof

.• hl1propeHy il!rmH~r1~.t·

, ·,r':tui~v (NW'; iimt f1t

L -Bulb lift> tJi,piffhf

FLASHER DOES I\IOT LIGHT

FLASHER KEEPS 01\1

PJ'IOBABLE C"'USE~......_-_. rml'iVp4.-~!})' Hf\)lil1dttd

• DiSl:tvuyp.d b;u ff~f\

\'JF3-\..HIf "lunrf- f\W~h:h

-Fa-utfy fl<~5h~1 rcJ;lY

·8Jolo.l!!ltl Wlif!'nitrn/.l'~{'·,

'" Loo5f'llv 1:·o.nn(~n;~.~ \'t)Uplt'l1

• Pillh butnf' l'~ii

f'R06ABlE CAUSfc_~~~,__~ .~~--.".-__,_ -t:!iUifr- 'fjashe, r~Jiiv-

. "J!~~Hth.jFlli hnt1ftr\t ':i)FHh~th

,tl'ieaHy -UI!H::h~Hg£'di

-A\jlh,twml OUt

TROU6LE08(E205,

TROUBLESHOOTING

FAULT'( SIGNALAND lIGHTINGSYST.£M

:l'LASHE~ WINKS SLOWEIl - !,~OSABJ.E tl:.tI,l,.ISE-'-'~---'-"'------~,,,,-. > FilUltv flasher rela\l.

1, -insuffteient 6~t'te!y l~aoaciJvlinearly diSChargedlt .'mproOet 'bulb .L:-''~'Fautty :rnain ,'andto; "XURN" $Wrtch

FLASI-l~ WINKS QUiCKER PROSA,S!;E CA.U.Sf~.------------[>Improp.r bulb

-F."lty flasher 'llilly

HORN IS II\lOPEI'tATlVe PROBABLE CAuse! .~.---:- ..,--~ ~---_>.faultv bart;',,\,

!!'Faulty mnl;'; arH'f ,m "ryOi1N" ~WHCt:

*'mnropet,!y, adjusted fl0fh

t IP!7aulty Morn

:.... --fhuken wlr~hi'm;.*S

TR0116kE09(E2D6)

TECHNISCHE DATEN UND FOLLMENGENTECHNICAL DATA AND FILLING VOLUMES

SKORPION :Tour I Traveller. Sport, Replica

MOTORAAD- UNO ZWEIRAOWERK GMBH~/$eMc&4ep4:ftmem.0312S149918

PoriUach/POB 70

D-09401 bcbopau.Hohndod STAND f OEAOUNE 05196

BLAn /PAGE 1

'VERGASERCAR8URETTOR

Haupldu.elinkslrecht. 1301165

.~=;;:~liOuse!\lllldfllpoSldorHlx;jer,needle ~Ji,ght:·{1NadeldOselL••r1auldus. Prim,:YOO

mm

:~~i~!!'!.'!~!!l~"'JIB~''III!IIllii' ••:Milllli;'I~!:~~;~~Synchronisation( point of throttle valv. openingsecondal)' carburellor)

UBERSETZUNGENTRANSMrSSION

, .,.... "'w~·"'·"'··_·''f_.fil.·'''!~'''(@!lil_'M')J:0071A.;·tl'' 1,'''''' .,'9jh~.~!'~,%'&t~~···, 'j"!'tl'!iV"";~~~~t;i;m~~:~;A1~ll.bt41f_~.·.. ,;.j.'~~i.~,oa~4~,Ie:CjWC~"~~!t~.~~;~ktZ~!~lj;:,!t~·~{,Jy,,'Kene, Anz.hl der GIIeder 110 his (up fo) Mod, '94: 108,518"><114", Q.Rlng endIos (endleS1S)chain, boo 108, 5/8".114",

" ,fl~_.&t~~~~less.[W£*1l~'~W~~wl~A

SKORPION :Tour !Traveller, Sport, Raplica

BLAn / PAGE 2

TECHNISCHE DATEN UND FOLLMENGENTECHNICAL DATA AND FILLING VOLUMES

MOTORRAD- UNO ZWEIRAOWEAK GMBHKLndendienst/seMce depilttmenllt 03725149918P051Sactl1 POB 70

0-09401 Z8cb0paLHiohndol1 STAND JDEADLINE 05196

20ndzeitpunklignition time

°v.OT bei Ulmin·V.D.C. at rpm

Hinten (Bel. 1 ader 2 Pers. zu je 75kg)rear (1 or 2 persons at 75 kg each!Hinten (bei maX: zul. Achslast) '<;' .rear ral max. load). , .•

kPaibar 240/2,4 23012,3

ICWSKORPION: Tour ITraveller, Sport, Replica

ANZUGSMOMENTESCREW TIGHTENING TORQUES

MOTOAAAo- UNO ZWEIRAOWERK GMBHKundemiemt ISelVk:edepaftment 2 03725149918P<1slfach /poe 70

D4401 l:::hop$u4tc.·m¢W1 $1AND JOEAOUNE l)5J'9(l

mz service manual -...

Documents