MZ Service Manual -...
Transcript of MZ Service Manual -...
SERVICE MANUAL
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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.
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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.
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SERVICE MANUAL660E.doc
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
SERVICE MANUAL660E.doc
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
SERVICE MANUAL660E.doc
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!
MAINTENANCE SPECIFICATIONS
." 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
MAINTENANCE SPECIFICATIONS
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~~~~
MAINTENANCE SPECIFICATIONS
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
MAINTENANCE SPECIFICATIONS
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
MAINTENANCE SPECIFICATIONS
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
MAINTENANCE SPECIFICATIONS
!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
INSPECTION AND REPAIR
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.
INSPECTION AND REPAIR
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~)
INSPECTION AND REPAIR
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- $urfa,c.esi
P'rtlng Wear Damage •Replace,
J, Check-Starte' 1;lvlCh operat;on. '.
Chetkmg step.:.ln51all the 'Slaller Wheel gear to, the S1arte'
clutch. and hold lhe star1erclutch-- When turning trle Starlf;l1 wheel gear CtOCfo; W'!se
.A', ,the starter ~Ich imd the wheel gear shouldOe engaged,it nol, tim statte,. dUICh is faolly ,~eplace It
OEJ7!E51)
INSPECTION AND REPAIR
.Wnen tUrn'ng th~starter wheel ge"r COU!"Jerdock'AliSe .'8' tb~ starter Cll;lcn gear shoy'C i\J;-f1
. .' -. ._teel"11 no!. the Slarter clutch 1$ 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)
. ~ . .. -
ENGINE ASSEMBLY AND ADJUSTMENT
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
~~';$talt the cable ~l~n~p on "the boll N;J 4
DE59(E781
ENGtN~ASSEMalY AND ADJUSTMENT
2. App;.,t4, StrOKe !mgtnc ct!
Ho me .oIl passa}}t::'s lH o,.t" tf<5'~jq; as€';,
~UTlON:
Apply "/lb"ral lImol.ll'1t.of 4 ."ok" ,,"g'''. oilto the"oil pump PS!UUfyeS in the crankcas~
Q/the eng';n& may be damaged
3 Apply .+4,-sHoke eng-m,e Oli
ito th@ oil jl.aSSitgBS l!"'l tnr: 0,1 r.vmfJ)
, 4 In'Slall
·G~skel 1·0 'dn9 ,-2-O!I pU'T1p 3..ali p:ump gevf, 4
-C"ClIP .5
Bolt loll pump! "---"]
'--'L-_1_O_N_",_, !1_0_rn_·_k.:;\l_._7_2_,_1'_,._lb_'__.1.
:) instal!
~ReHHn 50J';II'9
-Coil.' ,2·Slnppt'l lp.v~'r 3
NOTE
Ser rh' Spt!(Hf fHul "'1onnt-'! !s:vw dl pr-ilp.;; fl-{;
SltH)fl
DE60(E79)
ENGINE ASSEMBLY AND ADJUSTMENT
6 lnstall
ePJatfi washer 1
• TGf~IOn spnog 2• Shltf leye! :1-CtrChp' 4
NOTE: -.,.. _
W~n rnslaHmg the S'll+t lever dllgn the puncnert
rnar~ OIl ,the 'Shift levPl wl1h tMe pu.l1f:Oed fl\sh
on the,_sflif! 'shaff
DE61(E80)
ENGINE ASSEMBLY AND ADJUSTMENT
BALANCER GEAA
1 Key2 Balancer gear3 Plate4 Lock washer5 NUl6 Plate washer7 Key
8 Plate9 Balancer driv~ gear10 Plate11 Primal)' drive gear12 lock washer13 Nul
ji>.! USE NEW ONE I6iJ Nm (11.0 m-kg, 43 h .Ibl
F'I USE NEW ONE Ir
/ ®
®i
Oe€2fE81I
m_ _
ENGINE ASSEMBLY AND ADJI.!STMENT
CLUTCH1 Clutch SftlH1iJ2 Pressure piaH:l3 Pull B"';o
4 Pull, "lSio'er -
5 PUll kt...e:1 ade6 fn{'"!lon pia.te : ~vt:re .Ai7 Wavtt "plate
8 .c-'iftch rJJw9 ~riC'flo11p'are IIYfiE' 1:$: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
ENGINE ASSEMBLY AND ADJUSTMENT
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;
ENGINE ASSEMBLY AND ADJUSTMENT
-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,
ENGINE ASSEMBLY AND ADJUSTMENT
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
ENGINE ASSEMBLY AND ADJUSTMENT
.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
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SKORPION :Tour !Traveller, Sport, Raplica
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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
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