Text preview for : TT600RE_SM_2004.pdf part of Yamaha TT600RE Service Manual (Wiring Diagram) (Manual de Taller) (Stromlaufplan) - General Information, Specifications, Periodic Inspection and Adjustments, Chassis, Engine, Carburetion, electrical, Troubleshooting - (10.648Kb) Part 1/5 - pag. 382
Back to : moto_600cc_®_.part1.rar | Home
2004
TT600RE 5CH5-ME1
SERVICE MANUAL
EASB0000
TT600RE
SERVICE MANUAL
© 2003 by Belgarda S.p.A.
First edition, July 2003
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Belgarda S.p.A.
is expressly prohibited.
Printed in Italy
EASB0001
NOTICE
This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali-
fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,
anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page
indicate the current chapter.
Refer to "SYMBOLS".
2 Each chapter is divided into sections. The current section title is shown at the top of each page, except
in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a dis-
assembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,
notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
1 2 ILLUSTRATED SYMBOLS
The following symbols are not relevant to every
GEN vehicle.
SPEC
INFO Illustrated symbols 1 to 8 are printed on the top
right of each page and indicate the subject of
3 4 each chapter.
1 General information
INSP CHAS 2 Specifications
ADJ 3 Periodic inspections and adjustments
5 6 4 Chassis
5 Engine
6 Carburetor
ENG CARB 7 Electrical system
8 Troubleshooting
7 8
ELEC TRBL
SHTG ? Illustrated symbols 9 to y are used to identify
9 0 the specifications appearing in the text.
9 Can be serviced with engine mounted
0 Filling fluid
q Lubricant
q w w Special tool
e Torque
r Wear limit, clearance
t Engine speed
y Electrical data
e r
t y
u i o Illustrated symbols u to s in the exploded dia-
grams indicate the types of lubricants and lubrica-
tion points.
u Apply engine oil
p a s i Apply gear oil
o Apply molybdenum disulfide oil
p Apply wheel bearing grease
a Apply lightweight lithium-soap base grease
s Apply molybdenum disulfide grease
d f
Illustrated symbols d to f in the exploded dia-
New grams indicate the following:
d Apply locking agent (LOCTITE®)
f Replace the part
TABLE OF CONTENTS
E004000
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS
SPEC 2
PERIODIC INSPECTION
AND ADJUSTMENTS INSP
ADJ 3
CHASSIS
CHAS 4
ENGINE
ENG 5
CARBURETION
CARB 6
ELECTRICAL
ELEC 7
TROUBLESHOOTING
?
TRBL
SHTG 8
GEN
INFO 1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ......................................................................................1-1
VEHICLE IDENTIFICATION NUMBER..........................................................................1-1
MODEL LABEL ..............................................................................................................1-1
IMPORTANT INFORMATION ..............................................................................................1-2
PREPARATION FOR REMOVAL PROCEDURES ........................................................1-2
REPLACEMENT PARTS ..............................................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ........................................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ........................................................1-3
BEARINGS AND OIL SEALS ........................................................................................1-3
CIRCLIPS ......................................................................................................................1-3
CHECKING OF CONNECTIONS ........................................................................................1-4
SPECIAL TOOLS..................................................................................................................1-5
GEN
INFO
GEN
VEHICLE IDENTIFICATION INFO
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped in-
to the frame.
MODEL LABEL
The model label 1 is affixed to the frame under
1 the seat.
This information will be needed to order spare
parts.
1-1
GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign materi-
al before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to the "SPECIAL TOOLS" section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been "mated" through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4. During machine disassembly, clean all parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.
1-2
GEN
IMPORTANT INFORMATION INFO
EB101030
LOCK WASHERS/PLATES AND COTTER PINS
1. Replace all lock washers/plates 1 and cotter
pins after removal. Bend lock tabs along the
OR bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the man-
ufacturer's marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip 1, make sure that the sharp-edged
corner 2 is positioned opposite the thrust 3
it receives. See sectional view.
4 Shaft
1-3
GEN
CHECKING OF CONNECTIONS INFO
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:
· connector
2. Check:
· connector
Moisture Dry each terminal with an air
blower.
Stains/rust Connect and disconnect the
terminals several times.
3. Check:
· connector leads
Looseness Bend up the pin 1 and con-
nect the terminals.
4. Connect:
· connector terminals
NOTE:
The two terminals "click" together.
5. Check:
· continuity (using a pocket tester)
NOTE:
· If there is no continuity, clean the terminals.
· When checking the wire harness be sure to
perform steps 1 to 3.
· As a quick remedy, use a contact revitalizer
available at most part stores.
· Check the connector with a pocket tester as
shown.
1-4
GEN
SPECIAL TOOLS INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or impro-
vised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name / Usage Illustration
Engine tachometer
90890-03113
This tool is needed for detecting engine rpm.
Timing light
90890-03141
This tool is needed for detecting ignition
timing.
Pocket tester
90890-03112
These instruments are invaluable for check-
ing the electrical system.
Ignition checker
90890-06754
This instrument is necessary for checking
the ignition system components.
Compression gauge
90890-03081
These tools are used to measure the engine
compression.
Adapter (compression gauge)
90890-04082
This tool serves to measure the engine com-
pression.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel level
in the float chamber.
Piston pin clip puller
90890-01304
This tool serves for removing the piston pin
clip.
1-5
GEN
SPECIAL TOOLS INFO
Tool No. Tool name / Usage Illustration
Rocker arm shaft puller bolt
90890-01083
These tools are used when removing the
rocker arm shafts.
Weight
90890-01084
These tools are used when removing the
rocker arm shafts.
Valve spring compressor
90890-04019
These tools are used when removing or
installing the valve and the valve spring.
7 mm (0.28 in) valve guide puller
90890-01225
This tool is used to remove the valve guides.
7 mm (0.28 in) valve guide installer
90890-04017
This tool is necessary to install the valve
slides properly.
7 mm (0.28 in) valve guide reamer
90890-01227
This tool is used to re-ream the new valve
guide.
Valve adjusting tool
90890-01311
This tool is necessary for adjusting valve
clearance.
Rotor holder
90890-01701
This tool is used for loosing and tightening
the rotor nut.
Rotor screw puller
90890-01362
This tool is used to disassemble the magne-
to flywheel rotor.
1-6
GEN
SPECIAL TOOLS INFO
Tool No. Tool name / Usage Illustration
All-purpose clutch holder
90890-04086
This tool is used to lock the clutch, when the
clutch boss lock nut is being loosened or
tightened.
Crankcase separating tool
90890-01135
This tool is necessary to disassemble the
crankcase.
Crankshaft installation hose
90890-01274
This tool is used to install the crankshaft.
Crankshaft installation bolt
90890-01275
This tool is used to install the crankshaft.
#10 (M14) adapter
90890-04059
This tool is used to install the crankshaft.
Crank spacer
90890-04081
This tool is used to install the crankshaft.
SEALANT (QUICK GASKET) ®
Yamaha Bond No. 1215 ®
90890-85505
This sealant (adhesive) is used for crankcase
mating surfaces etc.
Ringnut wrench
90890-01268
This tool is used to loosen and tighten the
steering ringnut.
Ringnut wrench
90890-01348
This tool is used to loosen and tighten the
steering ringnut.
1-7
GEN
SPECIAL TOOLS INFO
Tool No. Tool name / Usage Illustration
T-handle
90890-01326
This tool is needed to loosen and tighten the
front fork damper rod holding bolt.
Front fork damper rod holder
90890-01460
This tool is needed to hold the front fork
damper rod when loosening and tightening
the holding bolt.
DU bush/oil seal guide
90890-11043
This tool is used to install the DU bush and
the fork oil seal.
1-8
SPEC 2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ............................................................................................ 2-1
MAINTENANCE SPECIFICATIONS ....................................................................................2-4
ENGINE ........................................................................................................................2-4
CHASSIS ....................................................................................................................2-12
ELECTRICAL ..............................................................................................................2-17
GENERAL TORQUE SPECIFICATIONS............................................................................2-19
CONVERSION TABLE........................................................................................................2-19
LUBRICATION POINTS AND LUBRICANT TYPES..........................................................2-20
ENGINE ......................................................................................................................2-20
CHASSIS ....................................................................................................................2-21
LUBRICATION LAYOUT ....................................................................................................2-22
CABLE ROUTING ..............................................................................................................2-26
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model TT600RE: 5CH5
Dimensions
Overall length 2,220 mm ···
Overall width 865 mm ···
Overall height 1,195 mm ···
Seat height 890 mm ···
Wheelbase 1,480 mm ···
Ground clearance 280 mm ···
Minimum turning radius 3,300 mm (right)
3,100 mm (left) ···
Basic weight (with oil and full
fuel tank) 164.5 kg ···
Engine
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 595 cm3 ···
Bore x stroke 95.0 x 84.0 mm ···
Compression ratio 8.5 : 1 ···
Starting system Electric starter
Lubrication system Dry sump with separate oil tank
Engine oil
Type SAE20W40SE or SAE10W30SE ···
Temp. °C
Recommended engine oil classification API Service SE, SF, SG or higher ···
Quantity:
Without oil filter cartridge
replacement 2.4 L ···
With oil filter cartridge
replacement 2.5 L ···
Total amount (dry engine) 3.0 L ···
Air filter Wet type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 10 L ···
Fuel reserve amount 3.0 L ···
Carburetor
Manufacturer TEIKEI
Model x quantity Y30PV-2ATK x 1
2-1
GENERAL SPECIFICATIONS
SPEC
Item Standard Limit
Spark plug
Manufacturer/model NGK/DPR8EA-9 or NGK/DPR9EA-9
Gap 0.80.9 mm ···
Clutch type Wet. Multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 71/34 (2.088)
Secondary reduction system Chain drive
Secondary reduction ratio 47/15 (3.133)
Number of drive chain sprocket
teeth (front/rear) 15/47
Transmission type Constant mesh 5-speed
Operation Left foot
Gear ratio 1st 2.583
2nd 1.588
3rd 1.200
4th 0.955
5th 0.792
Chassis
Frame type Open cradle backbone frame/detachable
rear frame
Caster angle 27° ···
Trail 117 mm ···
Tires
Front:
Type With tube
Size 90/90-21-(54R) / 90/90-21-(54S)
Manufacturer/model Pirelli / MT70 - Michelin / T63
Rear:
Type With tube
Size 130/80-18-(66R) / 130/80-18-(66S)
Manufacturer/model Pirelli / MT70 - Michelin / T63
Maximum load* 180 kg ···
Tire air pressure
(measured on cold tires):
Up to 90 kg* Front 200 kPa; 2.00 kgf/cm2; 2.00 bar ···
Rear 220 kPa; 2.20 kgf/cm2; 2.20 bar ···
90 kgmaximum* Front 210 kPa; 2.10 kgf/cm2; 2.10 bar ···
Rear 240 kPa; 2.40 kgf/cm2; 2.40 bar ···
Off-road riding Front 150 kPa; 1.50 kgf/cm2; 1.50 bar ···
Rear 160 kPa; 1.60 kgf/cm2; 1.60 bar ···
High-speed riding Front 210 kPa; 2.10 kgf/cm2; 2.10 bar ···
Rear 240 kPa; 2.40 kgf/cm2; 2.40 bar ···
* Total weight of rider, passenger,
cargo and accessories
Wheels
Front:
Type Spoke wheel
Size 21" x 1.85
Rear:
Type Spoke wheel
Size 18" x MT 2.50
2-2
GENERAL SPECIFICATIONS
SPEC
Item Standard Limit
Brakes
Front:
Type Single Ø 267 mm disk brake,
2 x 28 mm
Operation Right hand
Fluid DOT 4
Rear:
Type Single Ø 220 mm disk brake,
1 x 34 mm caliper
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork Outside tube
dia. 46 mm
Rear Deltabox Swingarm with
adjustable shock absorber
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper, spring
preload adjustable
Wheel travel
Front 230 mm ···
Rear 230 mm ···
Electrical system
Ignition system Transistorized coil ignition (digital)
Charging system:
Type A.C. magneto
Standard output 14V, 13.5A at 5.000 r/min ···
Battery:
Model GT9B-4
Voltage, capacity 12V, 8Ah ···
Headlight type Quartz bulb (halogen)
Bulb voltage, wattage x quantity
Headlight 12V 60W / 55W x 1 ···
Tail/brake light 12V 5W / 21W x 1 ···
Turn signal light 12V 10W x 4 ···
Auxiliary light 12V 5W x 1 ···
Meter lighting 12V 3W x 1 ···
Turn signal indicator light 12V 1.2W x 1 ···
Neutral indicator light 12V 1.2W x 1 ···
Auxiliary indicator light 12V 1.2W x 1 ···
High beam indicator light 12V 1.2W x 1 ···
Fuse 20A ···
2-3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head
Max. warpage ··· 0.03 mm
Cylinder
Bore 94.970 - 95.020 mm 95.10 mm
Measuring point 50 mm ···
Camshaft
Drive system Chain drive (left)
Camshaft cap inside diameter 23.000 - 23.021 mm ···
Camshaft journal diameter 22.967 - 22.980 mm ···
Camshaft-journal-to-camshaft-cap
clearance 0.020 - 0.054 mm ···
Camshaft lobe dimensions:
Intake-measurement A 36.470 - 36.570 mm ···
Intake-measurement B 30.060 - 30.160 mm ···
Intake-measurement C 6.41 mm ···
Exhaust-measurement A 36.620 - 36.720 mm ···
Exhaust-measurement B 30.110 - 30.210 mm ···
Exhaust-measurement C 6.51 mm ···
Max. camshaft runout ··· 0.030 mm
2-4
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Timing chain
Model/number of links 75-010/126
Tensioning system Automatic
Rocker arm/rocker arm shaft
Arm inside diameter 12.000 - 12.018 mm ···
Shaft outside diameter 11.976 - 11.991 mm ···
Arm-to-shaft clearance 0.009 - 0.042 mm ···
Valve, valve seat, valve guide
Valve clearance (cold) intake 0.05 - 0.10 mm ···
exhaust 0.12 - 0.17 mm ···
Valve dimensions:
Valve head diameter A intake 36.90 - 37.10 mm ···
exhaust 31.90 - 32.10 mm ···
Valve face width B intake 2.260 mm ···
exhaust 2.260 mm ···
Valve seat width C intake 1.00 - 1.20 mm 1.80 mm
exhaust 1.00 - 1.20 mm 1.80 mm
Valve margin thickness D intake 1.00 - 1.40 mm 0.80 mm
exhaust 0.80 - 1.20 mm 0.65 mm
Valve stem diameter intake 6.975 - 6.990 mm 6.995 mm
exhaust 6.955 - 6.970 mm 6.925 mm
Valve guide inside
diameter intake 7.000 - 7.012 mm 7.042 mm
exhaust 7.000 - 7.012 mm 7.042 mm
Valve stem to valve
guide clearance intake 0.010 - 0.037 mm 0.08 mm
exhaust 0.030 - 0.057 mm 0.10 mm
Valve stem runout ··· 0.010 mm
Valve seat width intake 1.10 mm 1.80 mm
exhaust 1.10 mm 1.80 mm
2-5
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Valve spring
Inner spring:
Free length intake 40.10 mm 38.10 mm
exhaust 40.10 mm 38.10 mm
Installed length
(valve closed) intake 22.70 mm ···
exhaust 22.70 mm ···
Compressed spring force
(installed) intake 164.80 - 190.20 N ···
16.80 - 19.39 kg ···
exhaust 164.80 - 190.20 N ···
16.80 - 19.39 kg ···
Spring tilt intake intake ··· 2.5 °/1.7 mm
exhaust ··· 2.5 °/1.7 mm
Winding direction
(top view) intake Clockwise
exhaust Clockwise
Outer spring:
Free length intake intake 43.80 mm 38.10 mm
exhaust 43.80 mm 38.10 mm
Installed length
(valve closed) intake 34.20 mm ···
exhaust 34.20 mm ···
Compressed spring force intake 71.60 - 87.30 N ···
(installed) 7.3 - 8,9 kg ···
exhaust 149.10 - 182.40 N ···
15.2 - 18.6 kg ···
Spring tilt intake ··· 2.5 °/1.7 mm
exhaust ··· 2.5 °/1.9 mm
Winding direction
(top view) intake Counterclockwise
exhaust Counterclockwise
Piston
Piston-to-cylinder clearance 0.045 - 0.065 mm 0.15 mm
Diameter D 94.915 - 94.965 mm ···
Height H 5.0 mm ···
Piston pin bore inside diameter 22.004 - 22.015 mm ···
Offset 2.00 mm ···
Offset direction Intake side
Piston pin outside diameter 21.991 - 22.000 mm ···
2-6
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Piston ring
Top ring:
Ring type Barrel
Dimensions (B x T) 1.20 x 3.80 mm ···
End gap
(installed) 0.30 - 0.45 mm 0.70 mm
Ring side clearance 0.040 - 0.080 mm 0.130 mm
2nd ring:
Ring type Plain
Dimensions (B x T) 1.20 x 3.80 mm ···
End gap
(installed) 0.30 - 0.45 mm 0.80 mm
Ring side clearance 0.030 - 0.070 mm 0.130 mm
Oil ring:
Dimensions (B x T) 2.50 x 3.40 mm ···
End gap
(installed) 0.20 - 0.70 mm ···
Ring side clearance 0.020 - 0.060 mm ···
Crankshaft
Width A 74.95 - 75.00 mm ···
Max. runout C ··· 0.030 mm
Big end side clearance D 0.350 - 0.650 mm ···
Big end radial clearance 0.010 - 0.025 mm ···
Small end free play F 0.80 mm ···
2-7
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Ballancer
Ballancer drive method Gear
Clutch
Clutch release method Inner push, cam push
Friction plate thickness 2.72 - 2.88 mm ···
Wear limit ··· 2.60 mm
Plate quantity 6 pcs
Friction plate thickness 2.94 - 3.06 mm ···
Wear limit ··· 2.8 mm
Plate quantity 2 pcs
Clutch plate thickness 1.20 mm ···
Plate quantity 7 pcs
Max. warpage ··· 0.20 mm
Clutch spring free length 42.8 mm ···
Plate quantity 5 pcs
Clutch housing thrust clearance 0.070 - 0.071 mm ···
Transmission
Max. main axle runout ··· 0.08 mm
Max. drive axle runout ··· 0.08 mm
Shift mechanism type Cam drum and guide bar
Carburetor
ID mark 5CH5 10
Main jet #1:#150 #2:#145
Main air jet #1:1.0 #2:0.9
Jet needle #1:5C5A-3/5 #2:5Y18-3/5
Needle jet 2.600
Cutaway 4.00
Pilot air jet 1 # 0.8 mm
Pilot jet # 50
Bypass 1 # 1.0
Pilot screw turns out 2-3/4 +/- 1/2
Valve seat size 2.5
Starter jet 1 # 74
Float height 6.0 - 8.0 mm ···
Engine idle speed 1,150-1,450 r/min ···
CO% 1.5 - 3 ···
Intake vacuum 30.6-33.36 kPa - 230-250 mm Hg ···
Lubrication system Dry sump
Oil filter type Paper type
Oil pump:
Oil pump type Trochoid type
Inner rotor to outer rotor tip clearance 0.12 mm 0.20 mm
Outer rotor to pump housing
clearance 0.030 - 0.080 mm 0.150 mm
Bypass valve opening pressure 80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm2) ···
Relief valve operating pressure 80.0 - 120.0 kPa (0.8 - 1.2 kgf/cm2) ···
Oil pressure (hot) 13.0 kPa (0.13 kgf/cm2)/1,300 r/min ···
Pressure check location Oil filter chamber ···
2-8
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Cylinder head tightening steps:
Crankcase tightening steps:
Left crankcase Right crankcase
2-9
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Tightening
Part torque
Part to be tightened Thread size Remarks
name
Nm mkg
Cylinder head Washer
based bol M8 x 1.25 29 2.9
Cylinder head Stud bolt M10 x 1.25 20 2.0
Cylinder head Hexagon socket
head screw M6 x 1.0 10 1.0
Cylinder head Stud bolt M6 x 1.0 7 0.7
Cylinder head:
Cap (oil check) Union bolt M6 x 1.0 7 0.7
Spark plug M12 x 1.25 18 1.8
Cylinder head cover Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (intake) Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (exhaust) M32 x 1.5 12 1.2
Cylinder Crown nut M8 x 1.25 22 2.2
Cylinder Nut M10 x 1.25 42 4.2
Cylinder Hexagon socket
head screw M6 x 1.0 10 1.0
Weight drive gear Hexagon nut M16 x 1.0 60 6.0
Rotor (A.C. magneto) Hexagon nut M14 x 1.5 120 12.0
Lock nut (valve adjusting screw) Hexagon nut M6 x 1.0 14 1.4
Cam chain sprocket Washer based
bolt M7 x 1.0 20 2.0
Cam chain stopper guide Hexagon socket
head screw M6 x 1.0 10 1.0
Cam chain stopper guide Washer based
screw M16 x 1.0 20 2.0
Rocker shaft Hexagon socket
head screw M6 x 1.0 10 1.0
Oil pump Hexagon socket
head screw M6 x 1.0 10 1.0
Oil delivery/retrieval pipe Pan screw M6 x 1.0 7 0.7
Oil draining pipe Washer based
screw M14 x 1.5 30 3.0
Oil filter cover Hexagon socket
head screw M6 x 1.0 10 1.0
Bleed screw (oil filter cover) Hexagon screw M5 x 0.8 5 0.5
Push lever (clutch) Pan screw M8 x 1.0 12 1.2
Push rod (clutch) Hexagon nut M6 x 1.0 8 0.8
Sprocket Hexagon nut M18 x 1.0 115 11.5
Lock washer (oil seal) Hexagon screw M6 x 1.0 10 1.0
Stop lever Bolt M6 x 1.0 10 1.0
Shift cam Hexagon screw M6 x 1.0 10 1.0
Stator Pan head (+)
screw M5 x 0.8 5 0.5
2-10
MAINTENANCE SPECIFICATIONS
SPEC
Tightening
Part torque
Part to be tightened Thread size Remarks
name
Nm mkg
Stator (pick-up coil) Hexagon socket
head screw M6 x 1.0 7 0.7
Engine oil pipe 1 Hexagon socket
head screw M6 x 1.0 10 1.0
Engine oil pipe 2 Union screw M12 x 1.25 35 3.5
Oil delivery pipe Union bolt M8 x 1.25 18 1.8
Carburetor joints Hexagon socket
head screw M6 x 1.0 10 1.0
Air filter case (frame) Hexagon screw M6 x 1.0 10 1.0
Air filter case (frame) Washer based
screw M6 x 1.0 10 1.0
Exhaust pipe Washer based
nut M6 x 1.0 10 1.0
Exhaust pipe protector Pan head (+)
screw M6 x 1.0 7 0.7
Muffler Hexagon socket
head screw M8 x 1.25 23 2.3
Muffler (band) Nut, nylon M8 x 1.25 23 2.3
Muffler Washer based
screw M8 x 1.25 23 2.3
Crankcase Hexagon socket
head screw M6 x 1.0 10 1.0
Crankcase Stud bolt M10 x 1.25 20 2.0
Crankcase cover (right) Hexagon socket
head screw M6 x 1.0 10 1.0
Crankcase cover (left) Hexagon socket
head screw M6 x 1.0 10 1.0
Sprocket cover Hexagon socket
head screw M6 x 1.0 10 1.0
Stop washer (bearing) Flat headscrew M6 x 1.0 7 0.7
Pressure plate Washer based
screw M6 x 1.0 8 0.8
Clutch housing Hexagon nut M20 x 1.0 90 9.0
Primary drive gear Hexagon nut M20 x 1.0 120 12.0
2-11
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Item Standard Limit
Steering
Steering bearing type Taper roller bearing
Lock to lock angle (left) 45° ···
Lock to lock angle (right) 45° ···
Front suspension
Front fork travel 277 - 283 mm ···
Fork spring free length 530 mm ···
Spring rate (K1) 7.0 N/mm (0.71 kgf/mm) ···
Spring stroke (K1) 330 mm ···
Spring rate (K2) 11.2 N/mm (1.14 kgf/mm) ···
Optional spring available No
Recommended oil Liqui Moly Racing suspension oil SAE 7,5
Quantity 650 cc ···
Level 180 mm ···
< min - max > 170-190 mm (from upper edge of inner ···
tube, fully compressed without spring)
Rear suspension
Rear shock absorber assembly travel 83 mm
Spring free length 224 mm ···
Installed length 211 mm ± 1.5 mm
Spring rate (K) 80 N/mm (8.1 kgf/mm) ···
Optional spring available No
Swingarm
Free play limit (at the end of
the swingarm)-radial ··· 1.0 mm
Free play limit (at the end of
the swingarm)-axial 0.4 - 0.7 mm ···
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.85
Rim material Aluminium
Max. radial wheel runout 1.0 mm ···
Max. lateral wheel runout 0.5 mm ···
Rear wheel
Wheel type Spoke wheel
Rim size 18 x MT2.50
Rim material Aluminium
Max. radial wheel runout 1.0 mm ···
Max. lateral wheel runout 0.5 mm ···
2-12
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Drive chain
Type/manufacturer 520 135ORSB / Regina Chain
Link quantity 114
Drive chain slack 30.0 - 40.0 mm ···
Front disc brake
Disc outside diameter x thickness 267 x 4 mm ···
Max. deflection ··· 0.15 mm
Brake pad lining thickness-inner 7.5 mm * 3.7 mm
Brake pad lining thickness-outer 7.5 mm * 3.7 mm
Master cylinder inside diameter 13 mm
Caliper cylinder inside diameter 28 mm x 2
Recommended fluid DOT 4
Rear disc brake
Disc outside diameter x thickness 220.0 x 5.0 mm ···
Max. deflection ··· 0.15 mm
Brake pad lining thickness-inner 9.0 mm * 4.5 mm
Brake pad lining thickness-outer 9.0 mm * 4.5 mm
Master cylinder inside diameter 12.7 mm
Caliper cylinder inside diameter 34 mm
Recommended fluid DOT 4
Front brake lever Adjustable
Brake pedal lever
Brake pedal position 10 mm (below the footrest plane) ···
Clutch lever
Clutch lever free play (lever end) 10.0 - 15.0 mm ···
Throttle grip
Throttle cable free play 3.0 - 5.0 mm ···
2-13
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Tightening
Part to be tightened Thread torque Remarks
size
N·m m·kg
Engine mounting and rear frame:
Engine front/Stay engine M10 x 1.25 64 6.4
Stay engine (engine front)/Frame M10 x 1.25 64 6.4
Engine rear under/Frame M10 x 1.25 68 6.8
Engine top/Stay engine M10 x 1.25 64 6.4
Engine protector/Frame M6 x 1.0 7 0.7
Chain tensioner top/Frame M8 x 1.25 23 2.3
Chain tensioner under/Frame M8 x 1.25 23 2.3
Frame/Rear frame (upper) M8 x 1.25 23 2.3
Frame/Rear frame (under) M8 x 1.25 23 2.3
Rear frame/Air filter assy M6 x 1.0 5 0.5
Front fork and steering:
Handle crown/Inner tube M8 x 1.25 28 2.8
Handle crown/Steering shaft M28 x 1.5 4 0.4 See "NOTE"
Steering shaft/Ring nut M36 x 1.5 115 11.5
Holder handle upper/Crown handle M8 x 1.25 20 2.0
Holder handle under/Crown handle M10 x 1.5 40 4.0
Front fork under bracket/Inner tube M8 x 1.25 23 2.3
Front master cylinder/Cap M4 x 0.7 1.5 0.15
Front master cylinder/Handle M6 x 1.0 9 0.9
Union bolt tightening M10 x 1.0 20 2.0
Front fender/Front fork M6 x 1.0 7 0.7
Stay headlight/Handle crown M6 x 1.0 10 1.0
Stay headlight/Bracket meter M6 x 1.0 6 0.6
Headlight/Stay headlight M6 x 1.0 10 1.0
Rear arm and cushion:
Pivot shaft/Frame M14 x 1.5 90 9.0
Arm relay/Frame M10 x 1.25 60 6.0
Arm relay/Rod connecting M10 x 1.25 52 5.2
Arm relay/Shock absorber M10 x 1.25 59 5.9
Rod connecting/Rear arm M12 x 1.25 66 6.6
Shock absorber upper/Frame M12 x 1.25 66 6.6
Seal guard/Rear arm M6 x 1.0 4 0.4
Support chain/Rear arm M6 x 1.0 9 0.9
Chain case/Rear arm M6 x 1.0 9 0.9
Front wheel:
Front wheel shaft/Front fork M16 x 1.5 59 5.9
Axle holder//Front fork M6 x 1.0 9 0.9
Rear wheel:
Rear wheel shaft/Nut M18 x 1.5 115 11.5
Clutch hub/Sprocket M10 x 1.25 48 4.8
2-14
MAINTENANCE SPECIFICATIONS
SPEC
Tightening
Part to be tightened Thread torque Remarks
size
N·m m·kg
Front brake:
Front hub/Disc brake M6 x 1.0 12 1.2
Front caliper/Front fork M8 x 1.25 25 2.5
Front caliper/Bleeder tightening M10 x 1.0 14 1.4
Union bolt tightening (front) M10 x 1.0 20 2.0
Rear brake:
Rear hub/Disc brake M6 x 1.0 12 1.2
Rear master cylinder/Frame M6 x 1.0 10 1.0
Rear stop switch/Rear master cylinder M10 x 1.0 20 2.0
Rear caliper/Bleeder tightening M10 x 1.0 14 1.4
Protector rear caliper/Rear caliper M6 x 1.0 10 1.0
Union bolt tightening (rear) M10 x 1.0 20 2.0
Rear brake tank reserve/Air cleaner assy M6 x 1.0 5 0.5
Brake pedal/Frame M10 x 1.25 48 4.8
Sidestand/Footrest:
Sidestand mounting bolt/Frame M12 x 1.25 40 4.0
Sidestand mounting bolt/Nut M12 x 1.25 40 4.0
Sidestand switch/Frame M5 x 0.8 8 0.8
Rear footrest/Rear frame M8 x 1.25 30 3.0
Bracket 1 (main footrest)/Frame M10 x 1.25 48 4.8
Bracket 2 (main footrest)/Frame M10 x 1.25 48 4.8
Footrest cover/Footrest M6 x 1.0 10 1.0
Seat, fuel tank and oil tank:
Seat/Frame M6 x 1.0 10 1.0
Bolt (guide seat)/Fuel tank M6 x 1.0 5 0.5
Fuel tank/Rear frame M6 x 1.0 12 1.2
Damper fuel tank (front)/Frame M8 x 1.25 15 1.5
Fuel tank/Fuel cock M6 x 1.0 7 0.7
Oil tank/Sub-oil tank M6 x 1.0 7 0.7
Union bolt (oil hose 2)/Oil tank assy/Engine M12 x 1.25 35 3.5
Oil hose 1/Oil tank/Engine M6 x 1.0 10 1.0
Oil tank/Rear frame M12 x 1.5 20 2.0
Frame, rear fender compl. and lights:
Rear fender compl. (under)/Rear frame M6 x 1.0 2 0.2
Rear fender compl. (upper)/Rear frame M6 x 1.0 7 0.7
Bracket, license/Rear frame M6 x 1.0 10 1.0
Bracket, license/Rear flasher M6 x 1.0 10 1.0
Horn/Frame M6 x 1.0 13 1.3
Regulator/Frame M8 x 1.25 7 0.7
Igniton coil/Frame M5 x 0.8 13 1.3
Battery box/Rear frame M6 x 1.0 7 0.7
Igniter cover/Battery box M4 1 0.1
Main switch/Frame M24 x 1.0 1 0.1
Tail light (lense)/Rear fender compl. M3.5 1 0.1
Starter switch/Red wire M6 x 1.0 7 0.7
2-15
MAINTENANCE SPECIFICATIONS
SPEC
Tightening
Part to be tightened Thread torque Remarks
size
N·m m·kg
Starting motor cord/Starting motor M6 x 1.0 11 1.1
Wire minus lead (-)/Starting motor M6 x 1.0 10 1.0
Front flasher lights/Stay, headlight M6 x 1.0 1.5 0.15
Clutch wire/Engine M6 x 1.0 7 0.7
Assist grip (Standing handle)/Rear frame M8 x 1.25 23 2.3
Speedometer M5 x 0.8 4 0.4
Air filter case 1/Air filter case 2 (L = 13 mm) M3.9 0.5 0.05
Air filter case 1/Air filter case 2 (L = 19 mm) M3.9 1 0.1
Hose clamp/Joint, carburator M4 x 0.7 0.6 0.06
Hose clamp/Air cleaner/Carburator M5 x 0.8 0.8 0.08
Battery (+)/(-) M6 x 1.0 2.5 0.25
NOTE:
1. First tighten the ring nut approximately 38 Nm (3.8 mkg) by using the torque wrench, then loosen the
ring nut one turn.
2. Final tighten the ring nut at the torque of 4 Nm (0.4 mkg).
2-16
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item Standard Limit
Ignition system
Ignition timing (B.T.D.C.) 12° / 1,300 r/min ···
Advanced timing (B.T.D.C.) 31° / 7,500 r/min ···
Advancer type Electrical type
Transistorized coil ignition
Pickup coil resistance 230 ± 20% L/Y-G/W ···
T.C.I. unit model/manufacturer TNDF09 / NIPPON DENSO
Ignition coil
Model/manufacturer JO300 / NIPPON DENSO
Primary coil resistance 4 ± 15% ···
Secondary coil resistance 13 k ± 20% ···
Spark plug cap
Material Resin
Resistance 10 k ···
Charging system
Type A.C. magneto
Model/manufacturer TLMZ48 / NIPPON DENSO
Standard output 14.0 V 13.5 A 5,000 r/min ···
Stator coil resistance 0.65 ± 20% W-W ···
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH629A-12/SHINDENGEN
No load regulated voltage 14.5 ± 0.4 V ···
Rectifier capacity 25 A ···
Withstand voltage 240 V ···
Battery
Specific gravity 1.320 ···
Electric starting system
System type Constant mesh
Starter motor:
Model/manufacturer SM-13/MITSUBA
Power output 0.80 kW ···
Armature coil resistance 0.03 - 0.04 ···
Brush overall length 10.0 mm 5 mm
Brush spring force 8.82 N (899 gf) ···
Commutator diameter 28.0 mm 27 mm
Mica undercut (depth) 0.70 mm ···
Starter relay:
Model/manufacturer MS5F-721 / JIDECO
Amperage 180 A ···
Coil resistance 4,4 ± 5% ···
2-17
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Horn
Horn type Plane
Quantity 1 pcs
Manufacturer LEONELLI
Max. amperage 1.5 A ···
Flasher relay
Type Semi-transistor ···
Model/manufacturer FB222M/NIPPONDENSO ···
Self cancelling device No ···
Flasher frequency 75 - 95 cycle/min ···
Wattage 10 W 2 + 3.4 W ···
Daylight switch relay
Model/manufacturer ACA12151-1-MATSUSHITA DENKOU
Circuit breaker
Type Fuse
Amperage for fuse 20 A ···
Reserve 20 A ···
2-18
GENERAL TORQUE SPECIFICATIONS/
CONVERSION TABLE
SPEC
GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE
This chart specifies torque for standard fasteners All specification data in this manual are listed in SI
with standard I.S.O. pitch threads. Torque specifi- and METRIC UNITS. Use this table to convert
cations for special components or assemblies are METRIC unit data to IMPERIAL unit data.
provided for each chapter of this manual. To avoid
Ex.
warpage, tighten multi-fastener assemblies in a
crisscross fashion, in progressive stages, until the METRIC MULTIPLIER IMP
specified torque is reached. Unless otherwise ** mm 0.03937 = ** in
specified, torque specifications require clean, dry 2 mm 0.03937 = 0.08 in
threads. Components should be at room tempera-
ture.
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result