’03 TZR50 X-POWER ’03 5WX-AE1 SERVICE MANUAL
TZR50’03 / X-POWER’03 SERVICE MANUAL © 2003 by Yamaha Motor España, S.A. 1st Edition, December 2003 All rights reserved Any reproduction or non-authorised use of this material is expressly prohibited without the consent of Yamaha Motor España, S.A.
WARNING This manual has been issued by Yamaha Motor España, S.A., mainly for its use by Yamaha /MBK dealers and their qualified mechanics. It is not possible to include the full training of a mechanic in a manual, for which reason we take it for granted that the persons who use this manual to carry out maintenance and repair work on Yamaha /MBK motorcycles basically understand mechanical concepts and procedures inherent to motorcycle repair technology.
MANUAL FORMAT All the procedures included in this manual are arranged in sequential format, divided into stages. The information presented has been grouped together in order to give the mechanic a reference that is easy to read and convenient to handle, containing exhaustive explanations of all the operations for dismantling, repair, assembly and inspection.
SYMBOLS ILLUSTRATED (See the ilustration) GEN INFO SPEC Symbols to are designed as thumb tabs, in order to show the number of the chapter and index INSP/ ADJ ENG General information Specifications Regular inspection and adjustments General engine servicing Carburation Chassis Electrical system Troubleshooting - location and repair of faults CARB CHAS ELEC TRBL 10 Symbols to 15 are used to identify the specifications appearing in the text 11 12 1
INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTIONS AND ADJUSTMENTS DISMANTLING THE ENGINE COOLING SYSTEM CARBURATION CHASSIS ELECTRICAL SYSTEM GEN/ INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8
GEN/ INFO 1
GEN/ INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION OF THE MOTORCYCLE …………………………………1-1 FRAME SERIAL NUMBER ……………………………………………………1-1 ENGINE SERIAL NUMBER……………………………………………………1-1 IMPORTANT INFORMATION …………………………………………………1-2 PREPARATION FOR REMOVAL AND DISMANTLING ……………………1-2 SPARES …………………………………………………………………………1-3 GASKETS, OIL SEALS AND O RINGS………………………………………1-3 WASHERS, LOCKING PLATES AND SPLIT PINS …………………………1-3 BEARINGS AND OIL SEALS …………………………………………………1-3 CIRCLIPS ………………………………………………………………………1-4 SPECIAL TO
IDENTIFICATION OF THE MOTORCYCLE GEN/ INFO GENERAL INFORMATION IDENTIFICATION OF THE MOTORCYCLE FRAME SERIAL NUMBER The chassis serial number is printed on the right-hand side of the steering head. ENGINE SERIAL NUMBER The engine serial number is printed on the left-hand side of the engine. NOTE: The first three figures of these numbers are for identifying the model: the others are the machine manufacturing number. NOTE: Design and characteristics subject to modification at no prior notice.
IMPORTANT INFORMATION GEN/ INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISMANTLING 1. Before starting removal and dismantling, remove any dirt, mud, dust and foreign bodies. 2. Use appropriate tools and cleaning equipment See “SPECIAL TOOLS” 3. When dismantling the motorcycle, keep any matching parts together. This refers to gears, cylinders and pistons and other items which work together and undergo the same normal wear. Matching parts must be assembled or replaced together. 4.
IMPORTANT INFORMATION GEN/ INFO SPARES 1. Use only original Yamaha/MBK spares for all changes. Use the oils and /or greases recommended by Yamaha/MBK for assembly and adjustments. Other makes may have the same function and appearance but nevertheless be of lower quality. GASKETS, OIL SEALS AND O RINGS 1. When an engine is dismantled, all the gaskets, oil seals and O rings must be replaced. All the surfaces of all the gaskets and the lips of oil seals and O rings must also be cleaned. 2.
SPECIAL TOOLS GEN/ INFO CIRCLIPS 1. All circlips must be carefully inspected before installing these again. Always change the ones on the piston rods when these are worn. Change any circlip that has become deformed. When installing a circlip make sure that the sharp edge is facing opposite the direction of the thrust that this receives. See the section drawing. Axis SPECIAL TOOLS For full and accurate tuning and installing the appropriate special tools must be used.
SPECIAL TOOLS GEN/ INFO 2. Flywheel (rotor) holding tool Ref. 90890-01235 This tool is used when the securing screw for the magnetic flywheel magneto has to be tightened or loosened. 3. Magnetic flywheel extractor Ref. 90890-11031 This tool is used for dismantling the magnetic flywheel. 4. Pin extractor Ref. 90890-01304 This tool is used for removing the piston pin. 5. Cooling system checker Ref. 90890-01325 This tool is required for checking the cooling system. 6. Adapter Ref.
SPECIAL TOOLS GEN/ INFO 7. Crankcase remover tool Ref. 90890-11030 This tool is used for dismantling the crankshaft or removing the crankcase. 8. Tools for installing the crankshaft. Ref. 90890-01284 These tools are used for installing the crankshaft. 9. Crankcase installer (Magnetic flywheel side) Ref. 90890-11032 10. Seal installer (Selector axle) Ref. 90890-11033 11. Seal installer (Water pump) Ref.
SPECIAL TOOLS GEN/ INFO 12. Seal installer (Clutch lever) Ref. 90890-11035 13. Seal installer (Clutch side of crankshaft) Ref. 90890-11036) FOR CHASSIS SERVICE 1. “T” tool ––––––––––––––––––––––––––––– Ref. 90890-01326––––––––––––––––––––– Front fork cylinder holder –––––––––––––– Ref. 90890-01294 This tool is used to loosen and tighten the fixing bolts for the cylinders of the front fork. 2. Front fork seal fitter (weight) ––––––––––– Ref.
SPECIAL TOOLS GEN/ INFO FOR ELECTRICAL COMPONENTS 1. Pocket tester Ref. 90890-03112 This tester is an invaluable help for checking the electrical system. 2. Stroboscopic lamp Ref. 90891-03141 This tool is required for checking the ignition advance. OTHER TOOLS 1. Micrometer Ref. 90896 - 03008 2. Feeler gauge Ref.
SPEC 2
SPEC CHAPTER 2 GENERAL SPECIFICATIONS SPECIFICATIONS ………………………………………………………………2-1 GENERAL SPECIFICATIONS …………………………………………………2-1 MAINTENANCE SPECIFICATIONS ……………………………………………2-4 ENGINE …………………………………………………………………………2-4 CHASSIS ………………………………………………………………………2-7 TIGHTENING TORQUES ……………………………………………………2-9 ELECTRICAL SYSTEM ………………………………………………………2-11 GENERAL SPECIFICATIONS OF TIGHTENING TORQUES/ DEFINITION OF THE UNITS …………………………………………………2-13 LUBRICATION POINTS AND TYPE OF LUBRICANT ……………………2-14 ENGINE ……………………………………………
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model TZR50 / X-POWER Model code number 5WX Frame serial number Yamaha MBK UTLRA031000000001 UTLRA032000000001 Dimensions: Total length Total width Total height Height of the seat Distance between axles Minimum ground clearance 2007 mm 675 mm 1065 mm 815 mm 1330 mm 144 mm Basic weight: With oil and full fuel tank 124.2 kg.
GENERAL SPECIFICATIONS Model SPEC TZR50 / X-POWER Fuel: Type Capacity of the fuel tank: Full Reserve Unleaded gasoline 13.8 L 2.2 L Carburettor : Type / Number Manufacturer PHBN 16 NS/1 DELLORTO Spark plug Type / Number Manufacturer Spark plug gap BR9ES/1 piece N.G.K. 0.6 ~ 0.
GENERAL SPECIFICATIONS Model SPEC TZR50 / X-POWER Brakes: Type of front brake Front brake action Type of rear brake Rear brake action Single disc Right hand Single disc Right foot Suspension: Front suspension type Rear suspension type Telescopic fork Swinging arm (Monocross suspension) Damping: Front shock absorber Rear shock absorber Spiral spring / oil shock absorber Spiral spring and gas/oil damping Wheel travel: Front wheel Rear wheel 130 mm 102 mm Electrical system Ignition system Charging s
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model TZR50 / X-POWER Cylinder head: Max. waparge 0.03 mm * Lines indicate straightedge measurement. Cylinder: Bore size 40,293 ~40,312 mm <40.4mm> 0.05 mm 0.01 mm Taper limit Out of round limit Piston: Piston size “D” Measurement point “*” 40.237 ~ 40.257 mm 12 mm * Piston to cylinder clearance 0.049 ~0.062 mm <0.1 mm> 40.60 mm 40.80 mm 1st oversize 2nd oversize Rings: Top ring Chrome plated type B = 1.
MAINTENANCE SPECIFICATIONS Model SPEC TZR50 / X-POWER Crankshaft: Crank width “A” 41.90 ~ 42.0 mm Runout limit “B” 0.03 mm Small end free play “D” 0.20 ~ 0.61 mm Big end side clearance “C” 0.015 ~0.026 mm Clutch: Friction plate: Thickness Number Wear limit Clutch plate: Thickness Number Wear limit Clutch spring: Free length Number 2.9 ~ 3.1 mm 4 pieces 2.7 mm 1.05 ~ 1.35 mm 3 pieces 0.05 mm 30.0 mm 4 pieces Clutch release method: Pushrod bending limit Internal pusher, cam pusher 0.
MAINTENANCE SPECIFICATIONS Model SPEC TZR50 / X-POWER Carburettor: Identification mark Main jet Air screw turns Fuel level Float height Idling speed Idling jet Starter jet Air jet Needle jet Jet needle Section Bypass 1 Valve seat size PHBN12HS/Dellorto (M.J.) # 88 2-1/8 5 mm (F.H.) 14.3 ± 0.5 mm 1850 ± 150 rpm # 32 # 45 100 A13 210FQ 4 0.80 150 Reed valve: Valve thickness Valve stopper height Valve bending limit 0.3 mm 6.28 m 0.1 ~ 0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model TZR50 / X-POWER Steering system: Steering type Size of the balls (number): Upper Lower Ball bearings 1/4 inch (19 units) 1/4 inch (19 units) Front suspension: Front fork travel Fork free leng 515.1 mm Spring rate (K1) (K2) Spiring stroke (K1) (K2) Optional spring Oil capacity Oil level 130.0 mm <508 mm> 0.4 kg/mm 0.55 kg/mm 0.0 ~ 70 mm 70 ~ 130 mm No 254 cm3 150 mm From the top edge of the lower tube, fully compressed, without spring.
MAINTENANCE SPECIFICATIONS Model SPEC TZR50 / X-POWER Rear wheel: Type Wheel size Wheel material Runout limit Vertical Lateral 1.0 mm 1.0 mm Drive chain: Type / Manufacturer Number of links Chain slack 415H90R/Regina 133 20 ~ 25mm Front disc brake: Type Thickness Brake pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Recomended fluid Single disc 280.0 x 4,0 mm 4.3 mm <0.5mm> 12.0 mm 25.
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Items to tighen Spark plug Cylinder head Nuts Cylinder Bolts Coolant draining plug Water pump cover Screw Thermostat bolt Water pump Bolt Carburetor joint Screw Crankcase (left right) Screw Bolt Crankcase cover 1 Bolt Crankcase cover 2 Bolt Crankcase cover 3 Crankcase cover 1 Oil drain plug Intermediate shaft Nut Clutch Nut Screw Push rod nut Shift pedal Screw Starter motor Screw Flywheel Number Thread pitch 1 M14 x 1.25 23 2.3 4 M7 x 1.0 17 1.
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Items to tighten Upper bracket and forks Allen screw Upper bracket and shaft Steering shaft and nut Handlebar to forks Handlebar to upper bracket Handlebar to brake pump Front fairing bracket Engine to frame holder Engine to front holder Engine to rear holder frame Engine to rear frame holder Swing arm to frame Shock absorber to swingarm Shock absorber to frame Fuel tank cap to fuel tank Front wheel axle to fork Rear wheel axle and nut Disc brake to wheel
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL SYSTEM Model Voltage: TZR50 / X-POWER 12 V Ignition system Ignition data: Type of advance arrangement: Ignition: Advance: Electronic 14º/2000 r/min 24º/2000 r/min CDI: Magneto model / manufacturer Pickup resistance (color) Charge coil resistance (color) Lighting coil resistance (color) MORIC 5WX 350 ± 20% Ω(WR-WL) 0.36 ± 20% Ω(W) 0.28 ± 20% Ω(YR) Ignition coil: Model / Manufacturer Secondary coil resistance MORIC 5WX 7.
MAINTENANCE SPECIFICATIONS Model SPEC TZR50 / X-POWER Charge system: Flywheel magneto Voltage regulator: Model / manufacturer SH 671 - 12/SHIN DEN GEN Battery: Type MF (no maintenance) Horn: Type Amount Model/Manufacturer Maximum amperage Plain type 1 GH/12/NIKKO 1.5A Flasher relay: Model / Manufacturer Self-cancelling device Flashing frequency Power in watts 0.1 - 2336/GUILERA No 60 ~ 120 cycles per minute 10W + 16W + 1.2 W Oil level switch: Model / Manufacturer 21.57.057.
SPEC CONVERSION TABLES GENERAL CHARACTERISTICS OF TIGHTENING TORQUES A (nut) This table specifies the tightening torques for ordinary fixings with standard ISO pitch threads. The characteristics of the tightening torques of special components or assemblies are stated in the relevant sections of this manual. To avoid any deformation, tighten the assemblies with several fixing points in a cross pattern and in gradual stages, until the final tightening torque is reached.
SPEC LUBRICATION POINTS AND TYPE OF LUBRICANT LUBRICATION POINTS AND TYPE OF LUBRICANT ENGINE Lubrication point (name of the part) Type of lubricant Oil seal lips (all) “O” rings (all) Bearing seals E Crankshaft bearings (left and central) E Needle bearings (con rod) G Primary shaft bearings G Secondary shaft bearings G Thrust cam bearing Crankshaft journals E Rings, pins and pistons E Drive shaft (water pump) G Shaft (mixing pump) E Clutch casing G Thrust rod G Thrust lever shaft
LUBRICATION POINTS AND TYPE OF LUBRICANT SPEC CHASSIS Lubrication point (name of the part) Type of lubricant Ball bearings (steering column) Lips of the oil seals (front and rear wheels) Rotation points (brake pedal) Rotation points (side stand) Right end of handlebar End of the throttle cable (throttle twist grip) Rotation axle (clutch lever) Rotation axle (brake handle) Anchorages (rear shock) Swingarm Bearing (swingarm) Front wheel axle Rear wheel axle Bush (front wheel) Speedometer gear unit 2-15
CABLE ROUTING SPEC A Thread the horn cable through the support CABLE ROUTING of the air filter casing DC-CDI Regulator-rectifier Battery Starter relay Fuse box Horn Flasher relay Neutral relay B Thread the installation through the clamps or bridles on the frame C Thread the left-hand switch cable through the frame clamps D The mark for installing the system must coincide with the frame clamp A D C 2-16 B
CABLE ROUTING Speedometer connector Connector for headlight and front indicator lights Connector for the speedometer sensor Ground cable Electrical installation Tank overflow pipe Carburettor overflow pipe Engine breather pipe SPEC A Clamp the generator cable to the frame B Clamp the neutral switch cable to the frame C Thread the stand and neutral cables through the frame clamps D Thread the following cables through the frame clamp: Rear brake switch Stand switch Neutral switch Sta
CABLE ROUTING SPEC A Thread the oil pipe through the frame clamps B Clamp the starter motor cable to the frame C Clamp the cable of the speedometer sensor through the rubber D Clamp the main switch cable, the head of the clamp must be at the bottom D A C B 2-18
INSP ADJ 3
INSP ADJ CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS INTRODUCTION/REGULAR MAINTENANCE/LUBRICATION ……………3-1 SIDE COVERS ……………………………………………………………………3-2 DISMANTLING …………………………………………………………………3-2 ASSEMBLY ……………………………………………………………………3-2 ENGINE ……………………………………………………………………………3-3 ADJUSTING THE IDLING SPEED ……………………………………………3-3 ADJUSTING THE AUTOLUBE PUMP CABLE ……………………………3-4 ADJUSTING THE FREE PLAY OF THE THROTTLE CABLE ……………3-5 BLEEDING THE AUTOLUBE PUMP …………………………………………3-6 ADJUSTING THE FREE PLAY OF THE STARTER CABL
INTRODUCTION/REGULAR MAINTENANCE/ LUBRICATION INSP ADJ REGULAR INSPECTION AND ADJUSTMENT INTRODUCTION This chapter contains all the information required to carry out the recommended services and adjustments. By following these preventive maintenance procedures you will ensure greater operating reliability for the vehicle and a longer useful life, considerably reducing the need for costly repairs. This information is applicable to both vehicles already in service and ones that are being prepared for sale.
SIDE COVERS INSP ADJ SIDE COVERS DISMANTLING 1. Take off: • The seat NOTE: To open the seat lock, insert the key into this and turn clockwise 2. Dismantle: • The grip strap 3. Remove: • Screws that secure each side cover and take these out 4. Release: • The seat locking cable ASSEMBLY Follow the same procedure as in “DISMANTLING” but inversely. Observe the following points: 1. Install: • The side covers (left and right-hand side), and tighten the screws. • The seat locking cable 2.
ADJUSTING THE IDLING SPEED INSP ADJ ADJUSTING THE IDLING SPEED 1. Tighten • The air screw Tighten the screw until it gently abuts the end of its travel 2. Loosen: • The air screw Partly unscrew this from its slightly abutting position Turns the screw should be loosened: 2 1/8 turns 3. Start the engine up and let this warm up. 4. Connect: • The engine tachometer to the spark plug cable Engine tachometer: 90890-03113 5.
ADJUSTING THE AUTOLUBE PUMP CABLE INSP ADJ ADJUSTING THE AUTOLUBE PUMP CABLE NOTE: Before adjusting the automatic mixture pump cable, you must first adjust the free play of the throttle cable. 1. Remove: • Cowlings See the section on “FAIRING”, “DISMANTLING” • The oil pump cover 2. Adjust: • The throttle cable 3. Check: • The free play while keeping the throttle in the idle position. This is not adjusted Adjust the pump cable 4.
ADJUST THE FREE PLAY OF THE THROTTLE CABLE INSP ADJ 6. Adjust: • The engine idling speed . ADJUSTING THE FREE PLAY OF THE THROTTLE CABLE 1. Check: • The free play (a) of the throttle cable Out of specification Adjust Free play of throttle cable: 2 ~ 5 mm a 2.
BLEEDING THE AUTOLUBE PUMP INSP ADJ BLEEDING THE AUTOLUBE PUMP NOTE: The automatic mixing pump and its hoses must be bled in the following cases: • When taking a new motorcycle out of its packaging. • Whenever the oil tank is completely emptied • Whenever any part of the engine oil supply system is disconnected. 1. Remove: • The oil pump cover 2.
ADJUSTING THE FREE PLAY OF THE CHOKE CABLE / INSPECTING THE SPARK PLUG INSP ADJ ADJUSTING THE FREE PLAY OF THE CHOKE CABLE / INSPECTING THE SPARK PLUG 1. Check • Free play of the choke cable Out of specification Adjust Free play: 1.5 ~ 3.
INSPECTING THE SPARK PLUG INSP ADJ 6. Tighten: • The spark plug Before installing a spark plug, clean the surfaces of the gasket and of the spark plug itself Tightening torque: 23 Nm (2.3 m • kg) NOTE: Make the sparkplug finger-tight before tightening this to the specified degree.
INSP ADJ CHECKING THE ENGINE OIL LEVEL INSPECTING THE ENGINE OIL LEVEL (MIXTURE) 1. Check: • The oil level Oil level low top up with sufficient oil. Recommended oil: Yamaha 2 stroke oil Capacity of the oil tank: 1.
INSPECTING THE OIL LEVEL OF THE TRANSMISSION/CHANGING THE TRANSMISSION OIL INSP ADJ INSPECTING THE OIL LEVEL OF THE TRANSMISSION 1. Heat up the engine for one minute and then stop this 2. Keep the motorcycle horizontal and take out the level screw 3. Inspect: • The oil level The oil level must be enough to overflow when taking out the level screw Oil level too low top up with sufficient oil to re-establish the right level. Recommended oil: SAE 10W 30 SE type engine oil.
CHANGING THE TRANSMISSION OIL/ ADJUSTING THE CLUTCH INSP ADJ 5. Inspect: • The O ring (of the oil filling cap) Damage replace 6. Install: • The drainage cap gasket NOTE: Always use a new gasket • Oil drain plug Oil draing plug: 1.7 kg • m 7. Fill up with: • The transmission oil Recommended oil: SAW/0W30 SE type engine oil Total amount: 0.82 L Regular oil change: 0.75 L 8. Install: • The O ring of the filling cap • The oil filler cap a ADJUSTING THE CLUTCH 1.
ADJUSTING THE CLUTCH / CLEANING THE AIR FILTER INSP ADJ Tightening increases free play Loosening reduces free play • Tighten the locknut NOTE: Normally, after properly adjusting the regulator for the length of the clutch cable (crankcase) the only adjustment required is to keep the right free play by means of the clutch cable tensor (handlebar lever).
CLEANING THE AIR FILTER INSP ADJ 3. Remove: • The cover of the air filter case 4. Take out: • The filter element CAUTION Never let the engine run without the filter element of the air filter as unfiltered air would get into the engine, which would lead to early wear and possible motor faults. Apart from this, running without the filter element affects the tuning of the carburation, thus reducing the efficiency and possibly making the engine overheat. 5.
CLEANING THE AIR FILTER / INSPECTING THE CARBURETTOR GASKET INSP ADJ • Apply SAE 10 W30 engine oil • Drain off any excess oil NOTE: The element should be damp but not soaked. 7. Install: • The filter element of the air filter CAUTION Make sure that the edge of the element fits in the corresponding slot of the filter box 8. Install: • Air filter case cover • The fuel tank 9.
INSPECTING THE CARBURETTOR GASKET / INSPECTING THE FUEL HOSES 3. Inspect: • The carburettor joint Cracks/damage Replace See the section on “CARBURETTOR” DISMANTLING THE ENGINE in CHAPTER 4 INSP ADJ 4. Install: • The air filter case • The fuel tank 5. Install: • The side covers (left and right-hand) • The seat See the section on “SIDE COVERS ASSEMBLY” INSPECTING THE FUEL HOSES 1. Dismantle: • The seat • The small left-hand side cover ON FUEL OFF RES 2.
INSPECTING THE EXHAUST SYSTEM / INSPECTING THE LEVEL OF COOLANT INSP ADJ INSPECTING THE EXHAUST SYSTEM 1. Inspect: • The exhaust pipe • The muffler Cracks / Damage Replace gaskets Leakages of exhaust gases Replace Replacement steps: Dismantle the exhaust assembly Install a new exhaust assembly Screw : 1.5 kg • m Screw : 2.3 kg • m INSPECTING THE COOLANT LEVEL 1. Place the motorcycle on a level surface. 2.
INSPECTING THE COOLANT LEVEL / CHANGING THE COOLANT INSP ADJ NOTE: To check the level of coolant, place the motorcycle in a vertical position; if it leans to one side, however little this may be, the readings may be false. CAUTION Water with impurities is damaging for the engine components. You can use boiled or distilled water 3. Add: • Water to the cooling circuit Until the level of liquid reaches the “MAX” maximum mark MAX Capacity of the reservoir tank: Total: 0.
CHANGING THE COOLANT INSP ADJ 1. Disconnect: • The breather pipe 2. Drain the coolant reservoir tank. 3. Remove: • The securing screw • The radiator cap 4. Remove: • The drainage screw 5. Drain: • The coolant NOTE: Empty out the coolant with the motorcycle slightly tilted to the right. 6. Install: • The gasket (new) • The drainage screw Drainage screw: 0.5 kg • m CAUTION • Always install a new gasket • Install the gasket as shown in the illustration 7.
CHANGING THE COOLANT INSP ADJ Coolant recommended: high quality ethylene glycol antifreeze, containing corrosion inhibitors for aluminium engines. Coolant and distilled water. Mixing proportion: 50 % / 50 % Total amount: 0.7 L Capacity of reservoir tank: 0.47 L Notes on handling the coolant liquid: The coolant is harmful and should thus be handled with special care. s WARNING • If the coolant liquid gets in someone’s eyes, wash these out thoroughly with water and see a doctor.
CHANGING THE COOLANT INSP ADJ Stages in filling with coolant: • Remove the screw of the radiator cap • Pour the coolant into the radiator Drainage screw: 0.
INSPECTING THE COOLING SYSTEM / ADJUSTING THE REAR BRAKE / INSPECTING THE BRAKE LIQUID INSP ADJ INSPECTING THE COOLING SYSTEM 1. Inspect: • The radiator • The inlet hose • The outlet hose Cracks / Damage Replace See the section on “COOLING SYSTEM” in CHAPTER 5 ADJUSTING THE REAR BRAKE Adjusting the free play of the rear brake pedal 1. Check: • The free play of the brake pedal (a) Out of specification Adjust Free play of the brake pedal: 10 ~ 15 mm a 2.
INSPECTING THE BRAKE LIQUID / BLEEDING THE AIR INSP ADJ NOTE: • Place the motorcycle vertically to check the level of the brake liquid • When checking the front brake liquid level, make sure that the top side of the master cylinder is horizontal, moving the handlebar if necessary CAUTION The brake liquid can erode the painted surfaces and the plastic parts: always immediately clean any liquid spilt.
BLEEDING THE AIR / INSPECTING THE BRAKE PADS INSP ADJ Bleeding air steps: a. Add brake liquid of the appropriate type to the tank b. Install the diaphragm. Take care not to spill the liquid and for the tank not to overflow c. Connect the transparent plastic tube firmly to the calliper bleeding screw d. Install the other end of the tube into a recipient e. Activate the brake lever slowly several times f. Pull the handle. Keep it in this position. g.
ADJUSTING THE BRAKE LIGHT SWITCH / INSPECTING THE BRAKE HOSES INSP ADJ ADJUSTING THE BRAKE LIGHT SWITCH NOTE: The brake light switch is activated by the movement of the brake pedal. This is properly adjusted when the brake light comes on immediately before the brake starts to work. 1. Hold the switch body still with your hand so that this does not rotate and turn the adjustment nut in direction (b). CAUTION After adjusting make sure that this comes on. a b INSPECTING THE BRAKE HOSES 1.
ADJUSTING THE DRIVE CHAIN SLACK INSP ADJ ADJUSTING THE DRIVE CHAIN SLACK NOTE: Before checking and/or adjusting the chain, make the rear wheel turn several times and check the tension at several points until you find the place where this is most tense. Check and /or adjust the chain with the rear wheel in this position of maximum tension. 1. Place the motorcycle on a flat surface and in vertical position. NOTE: Both wheels must be supported on the ground and with no rider seated. a 2.
ADJUSTING THE DRIVE CHAIN SLACK INSP ADJ • Tighten the axle nut Axle nut: 85 Nm (8.5 kg • m) NOTE: Tighten the axle nut while keeping the chain taut with your hand so as to keep the proper play of the chain. • Tighten the tensor Tensor: 0.5 kg • m • Tighten the locknut Locknut: 1.
LUBRICATING THE DRIVE CHAIN / ADJUSTING THE STEERING INSP ADJ LUBRICATING THE DRIVE CHAIN The chain consists of a large number of parts that work in constant contact with each other. If it does not get proper maintenance it will wear quickly. This is why one should acquire the habit of checking the chain regularly. These checks are particularly necessary when driving through dusty areas. 1. Use a chain lubricant in aerosol form.
ADJUSTING THE STEERING INSP ADJ Adjusting the steering head 1. Adjust: • The steering head Adjustment steps: • Loosen the screw of the handlebar clamp, the screw of the upper steering shank and the screw of the steering shaft. • Take off the fuel tank. • Tighten the ring nut with the wrench designed for this . Wrench for ring nut: 90890 - 01403 NOTE: Apply the torque wrench to the ring nut wrench so that both form a right angle. Ring nut (initial tightening): 2.
CHANGING THE FORK OIL INSP ADJ CHANGING THE FORK OIL s WARNING • Leaks of oil from the fork may give rise to drops in stability and reduce driving safety. Any problems found must be corrected before using the motorcycle. • Stand the motorcycle up firmly to avoid any danger of it falling over. 1. Lift up the front wheel placing a suitable support under the engine. 2. Remove: • The rubber cover 3. Loosen: • The clamp screw (handlebar) 4.
CHANGING THE FORK OIL INSP ADJ 7. After removing most of the oil, pump up and down with the fork to get any remaining oil out. 8. Inspect: • The O ring (plug) Damages Replace 9. Fill up with: • Fork oil Oil capacity of the front fork (each arm): 235 cm3 Recommended oil: 10W fork oil or equivalent 10. After filling this, pump the fork up and down slowly, to distribute the oil. 11. Install: • The plug • The circlip s WARNING Always use a new circlip 12.
INSP ADJ INSPECTING THE TYRES INSPECTING THE TIRE 1. Measure: • The air pressure Out of specification Adjust Basic weight: With oil and fuel tank full 124.2 kg. Maximum load* 195 kg. Cold tyre pressure Up to 90 kg. (198 lb) load Front Rear (1.8kg/cm2) (2.0kg/cm2) From 90 kg (198 lb) up to maximum load* (1.9kg/cm2) (2.
INSPECTING WHEELS / INSPECTING CABLES INSP ADJ INSPECTING WHEELS 1. Inspect: • The wheels Damage / deformations Replace NOTE: After changing the tire or the wheel always balance the wheel. s WARNING Do not attempt to repair a deffective wheel. INSPECTING CABLES 1. Inspect: • The throttle cable • The tachometer cable • The clutch cable • The speedometer cable Check any damage in the cable sheaths.
LUBRICATION INSP ADJ LUBRICATION Lubrication of cables Lubricating steps: • Keep the cable in vertical position • Apply lubricant to the upper end of the cable • Keep this in a vertical position until the oil comes out of the other end • Leave any excess oil to drain off and then reinstall the cable. Engine oil: SAE 10W30 of SE type Lubrication of levers and pedals Lubricate the rotating parts of each lever and pedal.
INSP ADJ ELECTRICAL SYSTEM ELECTRICAL SYSTEM INSPECTING THE BATTERY 1. Remove: • The seat 2. Inspect: • The battery terminals Dirty terminals brush Bad connection Clean with a metal Correct NOTE: After cleaning the terminals, apply grease lightly Change the battery in the following case: • When the voltage does not reach the value specified, even after many hours charging. M/F battery charger: 90890-03150 CAUTION This battery is the M/F no maintenance type. Never take the cover off.
INSPECTING THE BATTERY INSP ADJ s WARNING The electrolyte in the battery is dangerous: it contains sulphuric acid and is consequently poisonous and very caustic. Always observe the following preventive measures: • Avoid any physical contact with the electrolyte as it may cause serious burns or permanent eye injuries: • Use protective goggles when you handle batteries or work close to these.
INSPECTING THE FUSES INSP ADJ INSPECTING THE FUSES 1. Remove: • The seat 2. Remove: • The fuse 3. Inspect: • The fuse Stages in inspection • Connect the pocket tester to the fuse and check if the continuity is correct. NOTE: Place the tester selector in position “Ω X 1” Pocket tester: 90890 - 03112 • If the tester indicates ∞ the fuse will have blown - change this. 4. Replace: • The blown fuse s WARNING Do not use fuses with a higher amperage than the value specified.
ADJUSTING THE HEADLIGHT BEAM / CHANGING A HEADLIGHT BULB INSP ADJ ADJUSTING THE RIGHT-HAND HEADLIGHT BEAM 1. Adjust : • The headlight beam (vertical) To raise beam Turn the adjustment screw clockwise To lower the beam Turn the adjustment screw anti-clockwise ADJUSTING THE LEFT-HAND HEADLIGHT BEAM 1. Repeat the same operations as for the right-hand headlight CHANGING A HEADLIGHT BULB 1. Remove: • The dust cover and the connection . 2.
ENG 4
ENG CHAPTER 4 ENGINE REMOVING THE ENGINE ………………………………………………………4-1 PREPARING FOR REMOVAL…………………………………………………4-1 PETROL TANK …………………………………………………………………4-2 AIR FILTER ……………………………………………………………………4-3 EXHAUST PIPE ………………………………………………………………4-4 COOLANT PIPES ………………………………………………………………4-4 SPARK PLUG AND THERMOCONTACT CABLE …………………………4-5 NEUTRAL SWITCH CABLE …………………………………………………4-5 OIL PUMP ………………………………………………………………………4-5 CARBURETTOR ………………………………………………………………4-6 SHIFT LEVER, DRIVE CHAIN AND CLUTCH CABLE ……………………4-6 ENGINE REM
REMOVING THE ENGINE ENG ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine to take out the following components: • Cylinder head • Cylinder • Piston PREPARATION FOR REMOVAL 1. Remove all the dirt, mud, dust and foreign bodies before removing and dismantling the engine. 2. Use the proper tools and cleaning materials. See “CHAPTER 1. GENERAL INFORMATION - SPECIAL TOOLS”. NOTE: When the engine is dismantled keep associated parts together.
REMOVING THE ENGINE PETROL TANK 1. Remove: • Seat • Grip strap • Side covers (left / right) ON FUEL OFF ENG RES 2. Remove the fuel tank cap 3. Remove the bolts of the fuel tank and and of its cover . 4. Lift up the cover of the fuel tank as shown in the drawing and remove the tray and the fuel overflow pipe from its original position. NOTE: Do not remove the lower part of the overflow pipe from its original position 5.
REMOVING THE ENGINE AIR FILTER 1. Remove: • Securing screw 2. Take out: • Clip 3. Disconnect: • Rubber pipe ◗ 4.
REMOVING THE ENGINE ENG EXHAUST PIPE 1. Remove: • Springs • Clamp of the AIS system 2. Remove: • Exhaust pipe screws and • Exhaust pipe COOLANT PIPES 1. Remove: • Fairing • Drainage screw 2. Drain: • Coolant liquid 3.
REMOVING THE ENGINE ENG SPARK PLUG AND THERMOCONTACT CABLE 1. Disconnect • Spark plug cable • Thermocontact cable 2. Loosen: • Spark plug CDI CABLE 1. Disconnect: • CDI cable NEUTRAL SWITCH CABLE 1. Disconnect: • Neutral switch cable OIL PUMP 1. Remove: • Cover of the oil pump 2. Remove: • Cable of the oil pump 3. Disconnect: • Oil inlet tube to the pump NOTE: Plug the oil inlet pipe to the pump so the oil from the tank does not get out.
REMOVING THE ENGINE ENG CARBURETTOR 1. Loosen: • Carburettor securing screw 2. Remove: • Upper carburettor cover • Throttle cable • Tube for supplying the oil pump • Coolant pipes • Starter cover • Starter cable 3. Remove: • Carburetor • Carburetor joint • Plate casing NOTE: Cover the carburetor with a clean cloth to prevent dirt from getting into this. SHIFT CAM, DRIVE CHAIN AND CLUTCH CABLE 1. Remove: • Shift cam • Pinion cover 2.
REMOVING THE ENGINE / DISMANTLING THE ENGINE ENG 4. Disconnect: • Clutch cable First disconnect the cable of the crankcase side and then the end at the handlebar lever REMOVING THE ENGINE 1. Remove: • Front engine mounting screw • Rear lower engine mounting screw • Rear upper engine mounting screw • Engine assembly OIL PUMP 1. Remove: • Oil pump cover • Oil pump assembly WATER PUMP COVER 1.
DISMANTLING THE ENGINE 2. Remove • Clip • Washer • Water pump driven gear • Pin • Washer • Water pump shaft • Clip • Oil pump driven gear • Pin • Washer 10 • Oil pump shaft 11 • Washer 12 • Clip 13 • Washer 14) • Intermediate gear 15 • Washer 16) 3. Remove: • Locators • Gasket ENG CLUTCH AND PRIMARY TRACTION GEARING 1.
REMOVING THE ENGINE 4. Remove: • Clutch boss safety nut • Washer • Clutch boss • Washer • Clutch housing • Washer • Conical spring washer ENG s WARNING Pay attention to the position of the conical spring washer. Install as shown in the figure. 5. Loosen: • Balancer shaft nut 6. Remove: • Primary traction gear nut • Primary traction gear • Key • Balancer shaft drive gear • Balancer shaft washer and nut • Balancer shaft driven gear • Key 7.
REMOVING THE ENGINE ENG CDI MAGNETO 1. Remove: • Left-hand crankcase cover and gasket • Flywheel securing nut. Use the flywheel-holding tool 90890-01235 2. Remove: • CDI flywheel Use the flywheel extractor tool 90890 - 01189 and the flywheel fixer 90890-01235 • Crankshaft key • Stator coils • Coil holder plate NOTE: Mark the coil holder plate and the crankcase with a pointed instrument STARTER MOTOR 1.
DISMANTLING THE ENGINE CYLINDER HEAD AND CYLINDER 1. Remove: • Spark plug • Nuts and washers • Thermocontact a c d b ENG NOTE: Following the order stated in the drawing (a, b, c,d), loosen each screw ¨ of a turn and then fully unscrew them. 2. Remove: • Cylinder head • O rings • Thermostat s WARNING Handle the thermocontact with special care. Do not grip it too tightly or drop it. If it is dropped it must be replaced with a new one. 3. Remove: • Cylinder 4.
DISMANTLING THE ENGINE ENG PISTON PIN AND PISTON 1. Take out: • Piston pin clip NOTE: Before removing the pin clip from the piston, cover the crankcase with a clean cloth to prevent the clip from falling into the crankcase. 2. Take out: • The piston pin • Piston • Bearing NOTE: Before taking out the pin, remove any burrs from the slot of the clip and the pin hole.
DISMANTLING THE ENGINE ENG CAUTION Use a soft hammer to hit the crankcase lightly. Only tap the reinforced parts. Do not tap the closing surface. Work slowly and carefully. Make sure that the crankcase comes apart gently. If the crankcase does not come apart, make sure that no screws or locator have been left in. Do not force this. 4. Take out: • Locators 5. Take out: • Balancing shaft SELECTOR AND SHIFT 1. Take out: • Guide bars • Secondary shaft, primary shaft, selector cam and set of selector forks.
DISMANTLING THE ENGINE / INSPECTION AND REPAIR ENG BEARINGS AND OIL SEALS NOTE: • It is not necessary to take out the bearings and oil seals unless these are damaged. See the section on “BEARINGS AND OIL SEALS” in CHAPTER 1. 1. Take out: • The oil rings CAUTION • Use a screwdriver to take out the seal. • Place a piece of wood under the screwdriver so as not to damage the crankcase 2. Take out: • The bearings NOTE: • To facilitate removal and installing first heat up the crankcase to roughly 95 ~125ºC.
INSPECTION AND REPAIR ENG Measuring warping and steps for sanding the surface: • Put a straightedge and a thickness gauge on the cylinder head • Measure the warpage Outside specifications Sand / Replace Maximum cylinder head warpage: 0.03 mm • Place nº 400~600 wet sandpaper on the surface and sand this down in a figure eight shape. NOTE Turn the cylinder head round several times so as not to take too much material off only one side. PISTON 1.
ENG INSPECTION AND REPAIR CYLINDER 1. Eliminate: • Any carbon deposits Use a rounded scrap 2. Inspect: • The cylinder Mineral deposited / rust Remove • Wall of the cylinder Wear / scratches grind or replace 3. Measure: • Diameter of the cylinder “C” Outside specifications Grind Use internal gauge Standard Diameter of cylinder “C” 40.293 ~ 40.312 Wear limit 40.4 mm Diameter of cylinder “T” –– 0.05 mm Ovalling“R” –– 0.
INSPECTION AND REPAIR ENG 5. Measure • Piston free play: Outside specifications Grind the cylinder or replace the piston Piston clearance = C- P: 0.049 ~ 0.062 mm C: Internal cylinder diameter P: External piston diameter PISTON RINGS 1. Measure: • Lateral clearance Out of specifications Replace the piston and/or rings Use the thickness gauge Feeler gauge: 90890 - 03079 Lateral clearance: Upper ring / 2nd ring 0.03 ~ 0.06 mm 2.
ENG INSPECTION AND REPAIR 3. Check: • Free play There should not be any considerable play Free play exists check to see if the con rod is worn / change the pin, bearing and/or con rod, if necessary. 4. Install: • Piston pin (on the piston) 5. Check: • Free play (after the pin has been fitted on the piston) There should not be any considerable free play There is free play change the pin, and/or piston. 6.
INSPECTION AND REPAIR ENG 2. Measure: • Thickness of the friction disc Out of specifications Change the full set of friction discs. Measure at 4 points Wear limit : 2.7 mm 3. Inspect: • Clutch disc Damaged change the full set of clutch discs 4. Measure: • Warpage of the clutch disc Out of specifications Change the full set of clutch discs. Use the surface and feeler gauge Warpage limit: 0.05 mm (0.002 inches) 5.
INSPECTION AND REPAIR ENG 7. Inspect: • Slots in the clutch drum Cracks / wear / damaged deburr or change • Bearing of the clutch drum Scraping / Wear / Damaged 8. Inspect: • Splines in the clutch boss Scratches/Wear/Damaged the clutch boss remove Replace Change NOTE: Scratching in the clutch boss cause faulty operation splines will SELECTOR 1. Inspect: • Return spring of the selector Damaged Change • Shift shaft Damaged / Curved / Worn Change CHANGE 1.
INSPECTION AND REPAIR ENG 4. Measure: • Run out of the shaft Outside specifications Change Use the centring tool and the comparator (90890 - 03097) Eccentricity limit: 0.08 mm 5. Inspect: • Gearing Damaged / Wear Change 6. Check: • Operation of the gearing Operation stiff Change 7. Inspect: • Coupling lugs Cracks / Wear / Damaged Change CRANKSHAFT 1.
INSPECTION AND REPAIR ENG BEARINGS AND OIL SEALS 1. Inspect: • Bearing Perforated / Damaged Change • Oil seal lips Damaged / Worn Change CRANKCASE 1. Thoroughly wash the halves of the crankcase with mild solvent. 2. Clean the whole surface of the joints and the crankcase. 3.
ASSEMBLING AND ADJUSTING THE ENGINE ASSEMBLING AND ADJUSTING THE ENGINE CRANKSHAFT Crankshaft Con rod Bearing Bearing Seal Seal Piston Rings Pin 10 Circlip 11 Bearing 12 Key 13 Key 14 Traction gearing 15 Balancer 16 Bearing 17 Bearing 18 Gear 19 Key A: CLEARANCE BETWEEN PISTON AND CYLINDER 0.49 ~ 0.62 mm D: CRANKSHAFT B: PISTON RING END GAP: 0.15 ~ 0.30 mm A: 41.90 ~ 42.0 mm C: 0.03 mm D: 0.015 ~ 0.026 mm F: 0.20 ~ 0.61 mm C: LATERAL CLEARANCE OF PISTON RING: 0.
ASSEMBLING AND ADJUSTING THE ENGINE ENG CAUTION To protect the crankshaft from scratching or facilitate the installation operation, apply grease to the lips of the oil ring and engine oil on each bearing 1. Position: • Crankshaft installing tool (90890 - 01274, 90890 - 01278) 2. Assemble: • Crankshaft on the left-hand side of the crankcase.
ASSEMBLING AND ADJUSTING THE ENGINE ENG SHIFT AND SELECTOR SHIFT Primary 5th gear 3rd gear 6th gear 2nd gear Circlip Circlip Bearing Bearing 10 Secondary 11 1st wheel gear 12 5th wheel gear 13 4th wheel gear 14 3rd wheel gear 15 6th wheel gear 16 2nd wheel gear 17 Circlip 18 Washer 19 Circlip 20 Washer 21 Washer 22 Circlip 23 Bearing 24 Bearing 25 Seal 26 Sprocket 27 Circlip B: RUN OUT LIMIT OF THE PRIMARY SHAFT: 0.
ASSEMBLING AND ADJUSTING THE ENGINE SELECTOR Shift drum Washer Neutral Spring Ball Shift fork 1 Shift fork 2 Shift fork 3 Shift fork guide bar 1 10 Shift fork guide bar 2 11 Washer 12 Nut 4-26 ENG
ASSEMBLING AND ADJUSTING THE ENGINE ENG NOTE: When you install the secondary shaft on the crankcase pay attention to the lip of the oil seal of the crankcase. 2. Install: • Secondary shaft, primary shaft, cam of the shift shaft, selector fork set, guide bars, selector and balancer shaft in the right-hand half of the crankcase. NOTE: It is highly important to follow the assembly sequence as stated in the breakdown of the “SHIFT AND SELECTOR” section. 3.
ASSEMBLING AND ADJUSTING THE ENGINE ENG CAUTION Before installing and tightening the crankcase securing screws, do not forget to check if the shift works properly by manually turning the selector cam in both directions 4. Tighten • Crankcase securing screws (following a crisscross pattern) Crankcase securing screws : 1.0 m • kg 5. Apply: • 2 stroke engine oil to the crankshaft pin, bearing and oil feed bore. 6. Check: • Operation of the crankshaft and shift. This works incorrectly repair 7.
ASSEMBLING AND ADJUSTING THE ENGINE STARTER MOTOR Starter motor Screw Magnetic flywheel Screw Nut 4-29 ENG
ASSEMBLING AND ADJUSTING THE ENGINE ENG STARTER MOTOR 1. Install: • Starter motor 2. Install: • Coil plate in the crankcase Coil screw: 0.9 m • kg CAUTION Install the coil holder plate so that the marks on the plate and on the crankcase, made during the dismantling process, coincide. CDI MAGNETO 1. Install: • Coil plate 2.
ASSEMBLING AND ADJUSTING THE ENGINE ENG CLUTCH AND PRIMARY DRIVE GEARING Primary drive gearing Bush O ring Nut Clutch housing Thrust washer Clutch boss Friction disc Clutch disc 10 Pressure plate 11 Spring 12 Screw with washer 13 Pusher plate 14 Conical washer 15 Conical washer 16 Nut 17 Pusher plate 18 Push rod 1 19 Tensor 20 Nut 21 Ball 22 Push rod 2 23 Push lever shaft 24 Spring 25 Flat washer 26 Seal A: LIMIT OF FREE LENGTH OF CLUTCH SPRING: 30.
ASSEMBLING AND ADJUSTING THE ENGINE ENG NOTE: To tighten the CDI magneto nut use the flywheel holder 90890-01235 and without releasing this also tighten the nuts of the balancer shaft and that of the crankshaft gear CDI magneto nut: 5.2 m • kg Crankshaft gear nut: 6.0 m • kg 1. Install: • Washer • Tachometer gear • Washer 2. Install: • Key • Driven gear of balancer • Washer • Nut 3.
ASSEMBLING AND ADJUSTING THE ENGINE ENG 4. Install: • Conical spring washer • Washer • Primary drive gear • Washer • Clutch boss • Washer • Clutch boss nut 5. Tighten: • Clutch boss nut Use the universal clutch holder Clutch holder: 90890 - 04086 To hold the clutch boss Clutch boss nut 7.5 m • kg 6.
ASSEMBLING AND ADJUSTING THE ENGINE 7. Install: • Clutch discs • Friction discs • Push rod nº 1 • Pressure plate • Washer • Nut • Clutch springs • Screws for securing the clutch spring ENG NOTE: • Install the clutch discs and the friction discs alternately in the clutch boss starting and ending with a friction disc • Install the clutch discs so that each of these is 120º offset with the previous one.
ASSEMBLING AND ADJUSTING THE ENGINE ENG 8. Adjusting the clutch lever: • Loosen locknut • Tighten the screw until it reaches the end • Loosen the screw 1/4 turn • Tighten the locknut SHAFT OF THE WATER PUMP, SHAFT OF THE OIL PUMP AND RIGHT-HAND CRANKCASE COVER 1. Install: • Locators • Gasket 2.
ASSEMBLING AND ADJUSTING THE ENGINE ENG 3. Install: • Right-hand crankcase cover • Screws NOTE: Tighten the securing screws of the crankcase cover following a crisscross pattern Screws of the crankcase cover: 1.0 m • kg. WATER PUMP COVER 1. Install: • Water pump cover gasket • Water pump cover 2. Install: • Screws for water pump cover Screws for the water pump cover: 0.5 m • kg NOTE: Use a new washer on the coolant drain screw OIL PUMP 1. Install: • Oil pump assembly Pump securing screw: 0.
PISTON PIN AND PISTON ENG PISTON PIN AND PISTON 1. Apply: • 2 stroke engine oil To the piston pin, bearing, piston ring slots and piston NEW 2. Install: • Con rod little end bearing • Piston • Piston pin • Piston pin clip NOTE: • The arrow marked on the piston must point to the front of the engine • Before installing the piston pin clip, cover the crankcase with a clean cloth so that neither the piston clip nor anything else can fall inside the crankcase.
ASSEMBLING AND ADJUSTING THE ENGINE ENG CYLINDER HEAD AND CYLINDER Cylinder Spark plug Water pipe Head gasket Head gasket Nut 10 Flat washer 11 Cylinder 12 Cylinder gasket 13 Thermostat A: SPARK PLUG GAP: 0.6 ~ 0.7 mm C: LIMIT OF CYLINDER HEAD WARPAGE: 0.03 mm B: STANDARD SPARK PLUG: BR9ES (NGK) 2.
ASSEMBLING AND ADJUSTING THE ENGINE ENG 1. Install: • Cylinder head gasket NOTE: • Make sure that the mark and manufacturer number engraved on the rings are on the top side of these. • Before installing the cylinder, apply a good layer of 2 stroke engine oil to the piston rings. 2. Install: • Cylinder NOTE: Install the cylinder with one hand while you tighten the piston rings with the other. 3.
ASSEMBLING AND ADJUSTING THE ENGINE ENG s WARNING Handle the thermostat with special care. Never hold this tightly or drop it. If it falls replace it with a new one. 5. Install: • Cylinder head • Washers 6. Tighten: • Cylinder head nuts Tightening torque for cylinder head nuts: 2.2 m • kg NOTE: Tighten the cylinder head nuts in a crisscross pattern. 7. Install: • Thermocontact 8.
ASSEMBLING AND ADJUSTING THE ENGINE ENG 2. Install: • Drive chain NOTE: After installing the drive chain adjust the tension of the chain. See “ADJUSTING CHAIN” in Chapter 6. 3. Install: • Crankcase cover 2 (left) Screws for securing crankcase cover 2 0.5 m • kg • Output gear cover Screws for securing output gear cover 0.5 m • kg • Shift cam Shift cam screw. 0.6 m • kg 4. Install: • Oil pump cover Pump cover securing screw: 0.4 m • kg • Spark plug Spark plug: 2.
ASSEMBLING AND ADJUSTING THE ENGINE ENG 6. Inspect: • Oil leaks • Coolant leaks 7. Connect: • Neutral cable NOTE: Before starting the engine up, bleed the lubrication system.
COOL 5
COOL CHAPTER 5 COOLANT SYSTEM CHANGING THE COOLANT ……………………………………………………5-1 WATER PUMP ……………………………………………………………………5-3 DISMANTLING …………………………………………………………………5-4 INSPECTION……………………………………………………………………5-5 ASSEMBLY ……………………………………………………………………5-6 THERMOSTAT AND RADIATOR ………………………………………………5-8 INSPECTION …………………………………………………………………5-9 ASSEMBLY ……………………………………………………………………5-10
COOLANT COOL COOLING SYSTEM COOLANT CHANGING THE COOLANT s WARNING Do not remove the radiator cap while this and the engine are hot. Boiling liquid and vapour could emerge with consequent danger of serious injury. When the engine has cooled off, open the radiator tap as follows: place a thick cloth, for example a towel, over the cap and turn this as far as it will go, slowly, to the left. This procedure will let any residual pressure release.
COOLANT COOL Drain screw (water pump cover): 1.4 m • kg 8. Fill up with: • Coolant liquid (in the radiator) Recommended coolant: High quality ethylene glycol antifreeze solution containing anticorrosive materials for aluminium alloy engines. Proportion for mixing coolant and water: 50% / 50% Total volume: 0.71 L Capacity of expansion tank: 0.42 L From “LOW” level to “FULL” level: 0.18 L CAUTION Water with impurities is harmful for the engine. If you cannot get distilled water, use boiled water.
WATER PUMP COOL COOLING SYSTEM WATER PUMP Impeller shaft Oil seal Pin Washer Circlip Impeller shaft gear Cover of the water pump body Locator Gasket 10 Screw 11 Screw 12 Drain screw 13 Gasket 14 Connection 15 O ring 16 Screw A: USE A NEW ONE 1.0 m • kg 1.
WATER PUMP COOL DISMANTLING NOTE: There is no need to dismantle the water pump unless anomalies have been observed, such as excessive variations in temperature and/or volume of the coolant liquid, its decolouring or a milky look to the transmission oil. 1. Drain: • Crankcase See the section on “CHANGING THE TRANSMISSION OIL” in CHAPTER 3. • Cooling system See the section on “CHANGING THE COOLANT” in CHAPTER 3. 2.
WATER PUMP COOL 3. Dismantle: • The cover of the water pump body • The crankcase cover CAUTION Remove the coolant from the water pump taking care that this does not splash the autolube pump. 4. Dismantle. • The circlip • The gear of the impeller shaft • The flat washer 5. Dismantle: • The pin • The flat washer 6. Dismantle: • The impeller shaft 7. Eliminate any deposits incrusted on the shaft and the body of the water pump INSPECTION 1.
COOL WATER PUMP 2. Inspect: • The gear of the impeller shaft Cracks/Wear/Damage replace 3. Inspect: • The seal Wear / Damage Replace Replacement steps: • Remove the seal from the crankcase cover, tapping this lightly outwards. • Install the new seal, with the “WATER SIDE” mark outwards. NOTE: • Apply light lithium grease to the outside of the oil seal.
WATER PUMP COOL 2. Install: • The impeller shaft Turn the shaft during assembly NOTE: Proceed with care so as not to damage the lip of the seal and so that the spring does not come out of position 3. Install: • The crankcase cover (right hand) • The cover of the water pump body Screw (crankcase cover): 0.5 kg • m Screw (water pump body cover): 0.5 kg • m CAUTION Always use new gaskets 4. Fill up: • The transmission oil See the section on “CHANGING THE TRANSMISSION OIL” in CHAPTER 3.
THERMOSTAT AND RADIATOR COOL THERMOSTAT AND RADIATOR Protector ring Bush Protector ring Screw 10 Washer Radiator Cap Stop Bolt Washer A: OPENING PRESSURE OF THE RADIATOR CAP 0.75 ~ 1.05 KG / CM2 B: COOLANT CAPACITY Including all the conduits: 0.7 L C: THERMOSTAT OPENING TEMPERATURE: 98 ºC 0.
COOL THERMOSTAT AND RADIATOR INSPECTION 1. Inspect: • The radiator core Obstruction Eliminate this with compressed air, blowing from the rear of the radiator. Squashed fins repair / replace 2. Inspect: • The inlet hose Cracks / damage • Output sleeve Cracks / Damage Replace Replace 3. Measure: • The opening pressure of the radiator cap Radiator cap opening pressure: 0.75 ~ 1.05 kg/cm2 Measurement steps: • Connect the tester of the cooling system and the adapter to the radiator cap .
THERMOSTAT AND RADIATOR COOL Inspection steps: • Hang the thermostat in a recipient • Submerge a reliable thermometer in water • Heat up the water slowly • Observe the thermometer without ceasing to agitate the water NOTE: The thermostat is sealed and rating this is a job for a specialist. If you have any doubts about its accuracy, replace it. A faulty valve could cause very harmful overheating or overcooling. Screws (of the thermostat): 2.
THERMOSTAT AND RADIATOR COOL 4. Fill up: • The coolant See the section on “CHANGING THE COOLANT” in CHAPTER 3. 5. Inspect: • The cooling system Reduce the pressure (leaks) as required. Repair Inspection steps: • Connect the cooling system tester to the radiator Cooling system tester: 90890 - 01325 • Apply 1.0 kg/cm2 pressure • Measure the pressure with the manometer. 6.
CARB 6
CARB CHAPTER 6 CARBURATION CARBURETOR ……………………………………………………………………6-1 REMOVAL ………………………………………………………………………6-2 DISMANTLING …………………………………………………………………6-2 INSPECTION……………………………………………………………………6-2 ASSEMBLY ……………………………………………………………………6-3 INSTALLATION …………………………………………………………………6-3 ADJUSTING THE PETROL LEVEL …………………………………………6-3 REED VALVE ………………………………………………………………………6-4 REMOVAL ………………………………………………………………………6-4 DISMANTLING …………………………………………………………………6-4 INSPECTION……………………………………………………………………6-4 ASSEMBLY …………………………………………………………………
CARBURETOR CARB CARBURATION CARBURETOR Carburetor Carburetor cover Needle valve Float chamber Main jet Diffuser 10 Idling jet 14 13 15 24 27 26 Spring Casing Choke jet Idling screw Float pin Float SPECIFICATIONS Main jet (M.J.) Pilot air screw (P.A.S.) Fuel level (F.L.
CARBURETOR CARB REMOVAL 1. Remove: • Carburetor assembly See the section on engine removal DISMANTLING 1. Remove: • Idling stop screw 2. Remove: • Float chamber • Float pin • Float • Water valve • Gasket • Main jet • Idling jet • Choke jet INSPECTION 1. Inspect: • Carburetor body Dirty clean NOTE: Use a petroleum type solvent for cleaning. Clean all the holes and jets with compressed air. 2.
CARBURETOR 3. Inspect • Jets Wear / Dirt CARB Change / Clean 4. Inspect: • Plunger • Wear/damage Replace 5. Check: • Free movement Difficulty Change Insert the plunger into the carburetor body. 6. Inspect • Float Damaged • O ring Damaged Change Change ASSEMBLY 1. Install: • Follow the dismantling procedure inversely INSTALLATION 1. Install: • Carburetor assembly Apply the removal procedure inversely ADJUSTING THE FUEL LEVEL 1.
CARBURETOR / REED VALVE CARB Adjustment steps: • Take out the carburetor • Inspect the valve seat and the float chamber valve. • If either of the two parts is worn, change both. • Check the petrol level again REED VALVE REMOVAL 1. Remove: • Reed valve assembly See the engine removal section DISMANTLING 1. Remove: • Reed valve stop • Reed valve INSPECTION 1.
REED VALVE CARB 2. Measure: • Height of the valve stop Outside specifications Adjust/ change the stop of the valve Height of the valve stop: 6.28 mm NOTE: If the height is 0.4 mm greater or lower than what is specified, change the valve stop. 3. Measure: • Curve limit of the reed valve Outside specifications Change Curve limit of the reed valve: 0.4 ± 0.3 mm ASSEMBLY When the reed valve is fitted, apply the dismantling procedure inversely. 1. Install: • The reed valve • The reed valve stop.
REED VALVE CARB INSTALLATION To install the reed valve, follow the procedure for removal inversely. Pay attention to the following points. 1. Install: • A new gasket 2. Tighten: • Safety screws of the reed valve body. Safety screws of the reed valve body: 0.
CHAS 7
CHAS CHAPTER 7 CHASSIS FRONT WHEEL …………………………………………………………………7-1 DISMANTLING …………………………………………………………………7-2 INSPECTION……………………………………………………………………7-2 ASSEMBLY ……………………………………………………………………7-5 REAR WHEEL ……………………………………………………………………7-6 DISMANTLING …………………………………………………………………7-7 INSPECTION……………………………………………………………………7-7 ASSEMBLY ……………………………………………………………………7-8 FRONT BRAKE …………………………………………………………………7-10 CHANGING THE BRAKE PADS ……………………………………………7-11 DISMANTLING THE CALIPER………………………………………………7-13 DISMANTLING THE BRAKE PUMP ………………
FRONT WHEEL CHAS CHASSIS FRONT WHEEL AIR PRESSURE IN THE TIRES Front wheel Spacer Bearing Bearing Seal Bush Axle BASIC WEIGHT: WITH OIL AND FULL TANK 124.2 kg. (272 pounds) MAXIMUM LOAD * 195 kg. (428 pounds) COLD TIRE PRESSURE FRONT REAR UP TO 90 KG (198 pounds) load * 1.8 kg/cm2 2.0 kg/cm2 FROM 90 kg (198 pounds) ~ MAX. LOAD 1.9 kg/cm2 2.3 kg/cm2 * Load means the total weight of equipment, driver and accessories 1 65 Nm (6.
FRONT WHEEL CHAS DISMANTLING s WARNING Support the motorcycle firmly to avoid any risk of falling over. 1. Lift up the front wheel, placing an appropriate support under the engine. 2. Remove : • The screws (brake caliper) NOTE: Do not press the brake lever without the wheel being fitted on the motorcycle since if you do the pads would be in contact. 3. Loosen: • The pressure bolt • The screw (wheel axle) 4. Dismantle • The axle of the front wheel • The front wheel INSPECTION 1.
FRONT WHEEL CHAS 2. Get rid of any corrosion on the parts. 3. Inspect: • The front axle Make the axle turn on a flat surface Deformations Replace s WARNING Do not attempt to straighten the axle if this is deformed 4. Inspect: • The wheel Cracks/Deformations/Warping Replace 5. Measure: • The run out of the wheel This does not coincide with what is specified Check the play of the wheel and bearing. Run out limit of the wheel: Radial : 2.0 mm Lateral : 2.0 mm 6.
RUEDA DELANTERA CHAS CAUTION Do not tap the inner race of the bearing. Contact should only be with the outer race. 7. Check: • The wheel balance If the wheel stops at the same point again, after several light turns, the static balance is not correct. Wheel unbalanced. Install the relevant balancing counterweights at the lightest part (top). NOTE: Balance the wheel with the brake disc fitted. s WARNING • After installing a tire, drive carefully until it adapts to the wheel properly.
FRONT WHEEL CHAS INSTALLING Repeat the dismantling procedure, inversely. Take into account the following points: 1. Apply: • Lithium grease Lightly grease the oil seal and the gearing unit 2. Assemble: • The speedometer sensor. NOTE: Make sure that the projections on the inside of the sensor coincide with the flat sides of the wheel hub. 3. Assemble: • The front wheel assembly NOTE: Make sure that the projection of the fork cylinder fits in correctly with the sensor positioning slot. 4.
REAR WHEEL REAR WHEEL Rear wheel Spacer Bearing Bearing Rear wheel sprocket Washer Screw Seal Seal 10 11 12 13 14 15 16 17 18 Chain Coupling Wheel axle Chain tensioner Screw Nut Nut Key Bush A: TIRE SIZE: 130 / 70 - 17 B: WHEEL SIZE: 3.50 MT X 17 C: RUN OUT LIMIT OF THE WHEEL E: VERTICAL: 2.0 mm (0.08 inch) F: LATERAL: 2.0 mm (0.
REAR WHEEL CHAS DISMANTLING s WARNING Support the motorcycle firmly so it does not fall over 1. Lift the rear wheel and place a suitable support under the engine. 2. Dismantle: • The pin • The nut (wheel axle) • The chain tensioner • The wheel axle 3. Dismantle: • The rear wheel NOTE: Before removing the rear wheel, push this forwards and dismantle the transmission chain.
REAR WHEEL CHAS 2. Measure: • The run out of the wheel See the section on “FRONT WHEEL INSPECTION” 3. Check: • The wheel bearings • The wheel balancing See the section on “FRONT WHEEL INSPECTION” • The brake disc See the section “FRONT WHEEL - INSPECTION” ASSEMBLY Apply the same procedure as for dismantling but inversely. Take into account the following points: 1. Apply: • Lithium grease Apply the grease lightly to the lips of the oil seal 2.
REAR WHEEL CHAS 4. Install: • The pin (a new one) s WARNING Always use a new pin for the wheel axle. 5. Adjust: • The free play of the brake pedal See the section on “ADJUSTING THE REAR BRAKE” in CHAPTER 3.
FRONT BRAKE CHAS FRONT BRAKE Disc brake Screw Complete brake caliper Complete pistons Brake pads Drain screw Pin Through screw Seal 10 Screw A: CHANGE AS AN ASSEMBLY B; WEAR LIMIT OF THE BRAKE PADS: 0.5 mm 7-10 C: WEAR LIMIT BRAKE DISC: 3.
FRONT BRAKE CHAS CAUTION The components of the disk brake rarely need to be dismantled. Do not do so unless this is absolutely necessary. If any of the hydraulic coupling components of the system is disconnected the whole system must be dismantled to drain this, clean it and then fill it and bleed it properly. Do not use solvents to clean the components. Solvents make seals swell and deform. Only use clean brake liquid for cleaning.
FRONT BRAKE a CHAS 2. Measure: • The thickness (a) of the pads: If this does not match the value specified replace ◗ M NOTE: • Replace the pads as a set, if you find that any of them is worn beyond the limit. Wear limit: 0.5 mm 3. Firmly connect a suitable tube 1 to the caliper bleeding screw. Then insert the other end of the tube into an open recipient. 4. Unscrew the bleed screw of the caliper and press the piston with your finger to make it go into this. 5.
FRONT BRAKE CHAS 7. Install: • The screws (brake caliper) Screws (brake caliper): 3.5 kg • m 8. Inspect: • The level of the brake liquid See the section on “INSPECTING THE BRAKE LIQUID” in CHAPTER 3. min. 9. Check: • The operation of the brake lever. If this is soft or spongy bleed the brake system. See the section on “BLEEDING THE AIR” in CHAPTER 3. DISMANTLING THE CALIPER 1.
FRONT BRAKE CHAS 2. Dismantle: • The screws (brake caliper) • The brake pads See the section on “CHANGING THE BRAKE PADS” 3. Dismantle: • Pistons Dismantling steps: • Use a cloth to block the piston on the right-hand side. • Blow compressed air in through the coupling hole of the line to force the piston on the left-hand side out of the caliper. • Insert the piston a few mm and lock it with a cloth to prevent it from getting out.
CHAS FRONT BRAKE 1. Dismantle: • The brake switch • The brake lever • The coupling screw • The copper washers 2. Dismantle: • The pump cover • The rubber seal • The pump 3.
FRONT BRAKE CHAS 1. Measure: • The brake pads (thickness) (a) Out of specification replace ◗ M a NOTE: • Change the pads as a set, whenever any of these is worn down beyond the limit. Wear limit: 0.5 mm 2. Inspect: • The pistons of the caliper Rusting / Wear / Damage Replace s WARNING Change the piston seals whenever the caliper is dismantled. 3.
FRONT BRAKE CHAS ASSEMBLY s WARNING • All the internal components must be cleaned only with new brake liquid. • The internal items must be lubricated with brake liquid when assembled. Brake liquid: DOT nº 4 • Change the piston seals whenever the caliper is dismantled. 1. Assemble: • The seals • The pistons • The screws 2. Assemble: • The retaining pin • The retaining screw • The brake caliper See the section on “CHANGING THE BRAKE PADS” Screw (brake caliper): 3.5 kg • m 3.
FRONT BRAKE CHAS 4. Assemble: • The dust seal • The brake pump Screws (pump support) : 0.9 kg • m 5. Assemble: • The line • The copper washers • The coupling screw Coupling screws: 2.6 kg • m s WARNING Always use new copper washers 6.
FRONT BRAKE CHAS 7. Fill up: • Brake liquid Recommended brake liquid: DOT nº 4 CAUTION The brake liquid could erode painted surfaces and plastic parts. Always clean any liquid spilt. s WARNING • Use only brake liquid of the specified quality: otherwise the rubber seals could deteriorate and give rise to leaks and reduction of the braking efficiency. • Always fill up with brake liquid of the same type: mixing liquids could give rise to harmful chemical reactions and reduce efficiency.
FRONT FORK CHAS FRONT FORK Rubber plug Circlip Plug screw O ring Fork spring Ring of the damper rod Damper rod (full cylinder) Rebound spring Inner tube 10 11 12 13 14 15 16 17 18 Tapered spindle Dust sealing plug Retaining clip Oil seal Guide bush Outer pipe Draining screw Screw (Damper rod) Steering axle A: OIL CAPACITY OF THE FORK (EACH LEG): 235 cm2 B: OIL LEVEL IN THE FORK (FROM THE TOP OF THE INNER TUBE FULLY COMPRESSED WITHOUT THE FORK SPRING): 154 mm C: RECOMME
FRONT FORK CHAS REMOVAL s WARNING Stand the motorcycle up firmly so that there is no risk of it falling over. 1. Lift up the front wheel placing an appropriate support under the engine. 2. Dismantle: • The front wheel See the section on “DISMANTLING THE FRONT WHEEL” 3. Dismantle: • The front mudguard 4. Dismantle: • The lever (left-hand) • The lever (right-hand) 5. Loosen: • The clamp screw (left-hand) • The clamp screw (right-hand) 6.
FRONT FORK CHAS NOTE: When the fork legs are dismantled, also remove the screws (brake line clamp) and odometer cable. 7. Dismantle: • The front fork DISMANTLING 1. Remove: • The rubber plug • The clip • The plug • The fork spring Dismantling steps: • Hold the fork leg in a vertical position • Hold the inner tube in a vice with soft clamps CAUTION Do not damage the surface of the internal tube.
FRONT FORK CHAS 2. Drain: • The oil out of the fork 3. Remove: • The dust sealing cover • The retainer clip Use a fine screwdriver and take care not to scratch the inner tube. 4. Remove: • The screw (damper rod) Use the fixing tool and the “T” tool to lock the damper rod. “T” tool 90890 - 01326 Fixing tool: 90890 - 01294 5. Dismantle: • The inner tube • The damper rod 6.
FRONT FORK CHAS INSPECTION 1. Inspect: • The inner tube Scratching / Deformations Replace s WARNING Do not try to straighten the inner tube if this is bent, as it could be dangerously weakened. • Outer tube Scratching / Deformations / Damage Replace • Fork spring If this exceeds the limit specified Replace Free height of the fork spring: (limit): 508 mm 2. Inspect: • The damper rod Wear / Damage Replace Dirt Blow all the items with compressed air 3.
FRONT FORK CHAS NOTE: • When putting the fork back on, make sure that you replace the following items with new ones. • Guide bush • Oil seal • Dust protection seal • Make sure that all the components are clean before installing these again. 1. Install: • The fork spring • The damper rod Let the rod slide slowly along the tube until it comes out of the bottom. • Tapered spindle Install the tapered spindle over the damper rod coming out at the end of the inner tube. 2.
FRONT FORK CHAS 4. Install: • The guide sleeve Use the counterweight for installing fork 4 seals and the adapter 5. Inner tube Outer tube Counterweight for installing the fork seals: 90890 - 01367 Adapter: 90890 - 01400 5. Install: • The oil seal (new) Use the counterweight for installing the fork seals and the adapter . Counterweight for installing the fork seals: 90890 - 01367 Adapter: 90890 - 01400 6.
FRONT FORK CHAS 7. Measure: • The oil level (a) If this does not coincide with the value specified add or remove oil. Oil level: 154 mm Measurements from the top of the inner tube. NOTE: • To measure the oil level, thoroughly check the inner tube, without the fork spring. • Install the fork in vertical position. 8.
FRONT FORK CHAS INSTALLING Use the “EXTRACTION” procedure inversely. Take into account the following points. 1. Install: • The fork Provisionally tighten the clamp screws of the handlebars. NOTE: Maintain the inner tube. 2. Tighten: • The (handlebar) clamp screws • The clamp screws (upper shank of the handlebar) (Handlebar) clamp screws: 2.0 kg • m Clamp screws (upper shank of the handlebar): 2.0 kg • m 3. Tighten: • The clamp screw (lower shank) Clamp screw (lower shank): 3.
STEERING HEAD AND HANDLEBARS CHAS STEERING HEAD AND HANDLEBARS HANDLEBARS Handlebar (left-hand) Handlebar (right-hand) Handlebar counterweight Guide tube of the acceleration cable Rubber twist grip Set of throttle cable and mixing pump 10 Clutch cable 13 Tensor 14 Locknut 2.0 m • kg 0.9 m • kg 2.
STEERING HEAD AND HANDLEBARS CHAS STEERING HEAD Upper race of the bearing Lower race of the bearing Ball bearing Cover of the ball bearing race Steering adjustment nut Upper shank of the handlebar Steering nut 5.4 m • kg A: BEARING DIMENSIONS: 1/4 inch NUMBER OF BALLS: LOWER: 19 units UPPER: 19 units B: TIGHTENING STAGES: • Tighten the annular nut: 2.0 kg • m • Unscrew one turn • Tighten this again: 1.0 kg • m 2.
STEERING HEAD AND HANDLEBARS CHAS DISMANTLING s WARNING Stand the motorcycle up firmly to prevent it from falling over 1. Lift the front wheel up installing an appropriate support under the engine. 2. Dismantle: • The front wheel See the section on “FRONT WHEEL DISMANTLING” 3. Remove: • The screws (brake pump support) 4.
STEERING HEAD AND HANDLEBAR CHAS 8. Loosen: • The clamp screws (handlebars) 9. Remove: • The screws (handlebars) 10. Dismantle: • The handlebars (left and right-hand) 11. Dismantle: • The fairing See the section on “REMOVING THE FAIRING” 12. Dismantle: • The fork See the section on “FRONT FORK REMOVAL” 13. Dismantle: • The rear-view mirrors 14. Disconnect: • The headlight connectors 15. Remove: • The front of the fairing 16. Dismantle: • The clamp of the brake line 17.
STEERING HEAD AND HANDLEBARS CHAS 18. Remove: • The ring nut Use the wrench for ring nuts Wrench for annular nuts : 90890 - 01403 WARNING Support the steering axle so that this cannot fall 19. Dismantle: • The cover of the bearing races • The upper race of the bearing • The balls 20.
STEERING HEAD AND HANDLEBARS CHAS INSPECTION 1. Wash the ball bearings and races with solvents. 2. Inspect: • The ball bearings • The bearing races Pitting / Damage Replace NOTE: Always replace the bearings and races as a set Replacement steps: • Dismantle the bearing races from the steering arm with a long rod 1 and a hammer, as shown in the figure. • Dismantle the bearing race fitted on the lower support with a chisel 2 and a hammer, as shown in the illustration.
STEERING HEAD AND HANDLEBARS CHAS 2. Install: • The bearings Install the balls on the race and apply more grease Nº and dimensions of the balls: 19 units above / 1/4 inch 19 units below 1/4 inch 3. Install: • The steering axle s WARNING Immobilise the steering axle until this is fixed. 4.
STEERING HEAD AND HANDLEBARS CHAS 5. Install: • The upper crown Screw (steering axle ): 5.4 kg • m NOTE: Provisionally tighten nut 2 of the steering axle. 6. Install: • The headlight support • The clamp of the brake line Screw (headlight support): 1.0 kg. • m 7. Install: • The fork See the section on “FITTING THE FORK” Clamp screw (steering axle): 3.0 kg • m Clamp screw (upper shank of the handlebar): 2.0 kg • m 8. Install: • The handlebars Clamp screw (handlebar) 2.
STEERING HEAD AND HANDLEBARS CHAS Stages in replacing the left-hand handlebar: • Couple the lever support to the handlebar, as shown in the illustration. • Align the mark of the handlebar with the support of the clutch lever. Screw (handlebar support): 0.9 kg • m • Apply a light layer of some special adhesive for rubber to the end of the handlebar, as shown in the illustration. • Insert the twist grip into the end of the handlebar as far as it will go.
STEERING HEAD AND HANDLEBARS CHAS s WARNING Leave a space of 1 mm between the twist grip and the counterweight . Otherwise the twist grip could stick. 1 mm 11. Install: • The counterweight of the twist grip (right-hand) Counterweight of the twist grip: 2.0 kg • m 12. Install: • The front brake pump Screw (brake pump support): 0.8 kg • m 13. Install: • The front mudguard Screw: (Front mudguard): 0.8 kg • m 14. Install: • The front wheel See the section on “FRONT WHEEL FITTING” Wheel axle: 6.
STEERING HEAD AND HANDLEBARS CHAS 19. Adjust: • The free play of the clutch cable See the section on “ADJUSTING THE CLUTCH” in CHAPTER 3 Free play: 10 ~ 15 mm 20. Install: • The fairing See the section on “FAIRING - FITTING”.
REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM Swingarm Roller bearing Thrust cover Hub Swinging arm axle Self-locking nut Cover Chain protector 10 11 12 13 14 15 16 Bush Flat washer Bolt with washer Full shock absorber Bolt Bush Flat washer Self-locking nut 17 Screw 18 Washer 19 Self-locking nut 4.0 m • kg A: SWINGARM / LIMIT OF FREE PLAY: 6.0 m • kg B: LATERAL PLAY: 1.0 mm (0.04 inch) 6.
REAR SHOCK ABSORBER AND SWINGARM CHAS OBSERVATIONS ON HANDLING s WARNING This shock absorber contains gaseous nitrogen at high pressure. Before handling it, read and understand the following information. The manufacturer will not accept any liability for damage to property or personal injuries stemming from improper handling. • Do not tamper with or attempt to open the cylinder assembly. • Do not let the shock absorber get in contact with flames or other sources of intense heat.
REAR SHOCK ABSORBER AND SWINGARM CHAS DISMANTLING Rear swingarm s WARNING Stand the motorcycle up firmly so that it does not fall over. 1. Dismantle: • The seat • The side covers or cowlings (left and right-hand) See the section on “SIDE COVERS DISMANTLING” in CHAPTER 3. 2. Lift up the rear wheel, installing an appropriate support under the engine. 3. Dismantle: • The rear wheel See section on “REAR WHEEL - DISMANTLING” 4. Dismantle: • The footrest support (left and right-hand ) • The chain guard 5.
REAR SHOCK ABSORBER AND SWINGARM CHAS Swingarm s WARNING Stand the motorcycle up firmly so that it does not fall over. 1. Lift up the rear wheel, installing an appropriate support under the engine. 2. Dismantle: • The rear shock absorber 3. Dismantle: • The rear wheel See the section on “REAR WHEEL - DISMANTLING” 4. Check: • The swingarm (lateral play) Move the swinging arm from one side to another. Out of specification Change the bearings Lateral play (at the end of the swinging arm): 1.
REAR SHOCK ABSORBER AND SWINGARM CHAS INSPECTION 1. Inspect: • The shock absorber Oil leaks / damage replace 2. Inspect: • The swingarm Deformations / Cracks / damage replace 3. Inspect: • The oil seals Damage Replace • The thrust covers Damage Replace • The bushes Scratches / Damage Replace • The bushes Pitting / Damage Replace INSTALLING Swingarm Apply the same procedure as for “DISMANTLING” but inversely. Take into account the following points: 1.
REAR SHOCK ABSORBER AND SWINGARM CHAS Rear shock absorber Apply the same procedure as in “DISMANTLING” but inversely. Take into account the following points: 1. Apply: • Lithium soap grease to the oil seals and bush 2. Install: • The rear shock absorber Rear shock absorber - upper: 6.0 kg • m Rear shock absorber- lower: 6.0 kg • m 3. Install: • The rear wheel See the section on “REAR WHEEL - FITTING” Nut (wheel axle): 9.0 kg • m 4. Adjust: • The tension of the drive chain.
REAR WHEEL SPROCKET AND DRIVE CHAIN CHAS REAR WHEEL SPROCKET AND DRIVE CHAIN Rear sprocket Holder 10 Drive chain 11 Chain coupling E: USE A NEW ONE E: USE A NEW ONE 7-46
REAR WHEEL SPROCKET AND DRIVE CHAIN CHAS NOTE: Before dismantling the sprocket, the chain and the rear wheel sprocket, the chain sloack should be checked. DISMANTLING 1. Dismantle: • The cover of the output sprocket 2. Dismantle • The circlip • The sprocket 3. Dismantle: • The retaining clip • The coupling plate 4. Dismantle: • The drive chain 5.
REAR WHEEL SPROCKET AND DRIVE CHAIN CHAS INSPECTION 1. Check: • The chain stretching Pull the chain to separate this from the crown wheel. Distance between chain/crown wheel greater than half the tooth replace the chain. 2. Clean: • The drive chain Submerge this in solvent and use a brush to clean off as much dirt as possible. Then take the chain out of the solvent and dry it. 3.
REAR WHEEL SPROCKET AND DRIVE CHAIN CHAS Replacing steps: • Straighten the tab of the locknut and take off the crown wheel • Install the new rear wheel sprocket and the locknut Nut (rear crown wheel sprocket): 6.3 kg • m ASSEMBLY Apply the procedure for “DISMANTLING” inversely. Bear in mind the following points: 1. Install: • The sprocket • The circlip 2. Install: • The sprocket cover Screw (sprocket cover): 0.5 kg • m Screw ( sender ) 1.0 kg • m 3.
REAR WHEEL SPROCKET AND DRIVE CHAIN CHAS 4. Install: • The drive chain • The coupling link of the chain • The chain clip Rotation direction s WARNING Make sure that the clip is installed in the right position. Otherwise the transmission chain would open. 5. Adjust: • The chain slack See the section on “TIGHTENING The TRANSMISSION CHAIN” in CHAPTER 3.
ELEC 8
ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL DIAGRAM ………………………………………………………8-2 ELECTRICAL COMPONENTS …………………………………………………8-4 IGNITION AND STARTING SYSTEM …………………………………………8-6 ELECTRIC STARTING SYSTEM ………………………………………………8-8 TROUBLESHOOTING …………………………………………………………8-9 CHARGING SYSTEM …………………………………………………………8-12 TROUBLESHOOTING ………………………………………………………8-14 LIGHTING SYSTEM ……………………………………………………………8-18 LOCATING BREAKDOWNS …………………………………………………8-20 CHECKING AND TESTING THE LIGHTING SYSTEM …………………8-23 SIGNALING SYSTEM ………………………
ELECTRICAL DIAGRAM ELECTRICAL DIAGRAM 8-2 ELEC
ELECTRICAL DIAGRAM 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Magnetic flywheel Regulator / Rectifier Starting relay Fuse Main switch CDI Diode x 2 Spark plug Handlebar switch (rh) Handlebar switch (lh) Front headlight / flasher (lh) Front headlight (flasher rh) Neutral switch Rear indicator (lh) Rear indicator (rh) B R O L P Y G W Ch Dg Black Red Orange Blue Pink Yellow Green White Chocolate Dark green B/Br Sb Br L/B L/W L/Y
ELECTRICAL COMPONENTS ELEC ELECTRICAL COMPONENTS (1) CDI Spark plug pipe Neutral switch O ring Thermostat switch Starter motor 12 Battery 15 Regulator/Rectifier 17 Main switch 20 Rear brake light switch STARTER COIL PRIMARY COIL RESISTANCE: 0.23 W + 20ºC SECONDARY COIL RESISTANCE: 7.
ELECTRICAL COMPONENTS ELEC ELECTRICAL COMPONENTS (1) 21 Electrical installation 23 Fuse 24 Diode 27 Oil level switch 29 31 32 33 Side stand switch Relay Indicator flasher relay Horn 8-5 BATTERY: CAPACITY: 12 V 3AH NO MAINTENANCE
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM The following circuit diagram shows the ignition and starting system 8-6 ELEC
IGNITION AND STARTING SYSTEM ELEC NOTE: For the colour codes, please see the electrical diagram C.D.I. magneto Starter relay Main switch C.D.I.
ELECTRIC START SYSTEM ELECTRIC START SYSTEM CIRCUIT DIAGRAM 13 20 21 24 25 29 Starter relay Fuse Main switch Diodes Engine/starter stop switch Neutral switch Neutral relay Battery Clutch switch Side stand switch Starter motor 8-8 ELEC
ELECTRIC START SYSTEM TROUBLESHOOTING ELEC 4. Neutral relay THE STARTER MOTOR DOES NOT WORK • Remove the relay NOTE: • Use the following tools in this fault location Pocket tester: 90890 -03112 • Use the battery to supply terminals Br and Sb. • Then check the continuity between GB and BW 1. Fuse (main) • Check the condition of the fuse. See “INSPECTING THE FUSE” in CHAPTER 3. OK NOT OK NOT OK OK Change the fuse Change the neutral relay 2. Battery • Check the condition of the battery.
ELECTRIC START SYSTEM 6. Main switch ELEC 8. Neutral switch • Place in the ON position • Separate the connections • Check the continuity between R and Br NOT OK OK • Check the continuity: • Light blue ground Repair the main switch NOT OK OK Change the neutral switch 9. Side stand switch 7. Engine kill switch • Place in RUN position (not pressed) • Separate the blue connection • Fold up the side stand • Separate connections • Check the continuity between BW and B.
ELECTRIC START SYSTEM 10. Clutch switch • Separate the yellow connection • Press the clutch • Check the continuity between BG and LY NOT OK OK Repair the side stand switch 11. Starter switch • Separate the connection • Press the switch • Check the continuity between WG and BG NOT OK OK Change the handlebar switch (right hand) 12. Connections of the system • Check all the connections of the starting system.
CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 8-12 ELEC
CHARGING SYSTEM ELEC NOTE: For the colour codes please see the electrical diagram C.D.I.
CHARGING SYSTEM ELEC TROUBLESHOOTING THE BATTERY IS FLAT Procedure (1) Check: 1. The fuse 2. The battery 3. The charging voltage 4. The resistance of the stator coil 5. The cable connections (charge system) NOTE: • Dismantle the following components, before locating the fault. 1) The seat 2) The fuel tank • To solve these problems use the following special tools: Pocket tester: 90890-03112 Tachometer for engine: 90890 - 03113 1. Fuse • Remove the fuse • Connect the pocket tester (Ω x 1) to the fuse.
CHARGING SYSTEM ELEC 3. Charging voltage • Connect the engine tachometer to the spark plug cable • Connect the pocket tester (DC, 20V) to the battery (+) probe of tester (+) terminal of the battery (-) probe of tester (-) terminal of the battery MATCHES SPECIFICATION Replace the battery • Start the engine up and rev. up to about 3.000 r/min. • Check the charge voltage • Charge voltage: 14.0 V at 5000 rpm DOES NOT MATCH SPECIFICATIONS 4. Resistance of the stator coil.
CHARGING SYSTEM ELEC • Check to see if the stator coil has the specified resistance. DOES NOT MATCH SPECIFICATION Resistance of the stator coil: 0.4 ~ 0.6 Ω at 20º C Replace the stator coil MATCHES SPECIFICATION 5. Cable connections • Check the connections of the charging system See the section on “CABLE DIAGRAM” CORRECT BAD CONNECTIONS Correct these.
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 8-18 ELEC
LIGHTING SYSTEM ELEC NOTE: For colour codes please see the electrical diagram Fuse Main switch 11 Front headlight / indicator (LH) 12 Front headlight / indicator (RH) 14 Rear indicator (LH) 15 Rear indicator (RH) 16 Front brake switch 17 Rear brake switch 18 Tail light 19 Instrument panel 16 18 11 12 15 14 17 8-19
LIGHTING SYSTEM ELEC TROUBLESHOOTING THE HEADLIGHTS, THE SIDE LIGHTS OR THE INSTRUMENT PANEL DO NOT LIGHT UP Procedure Check: 1.The fuse 2.The light switch “LIGHTS” 3.The cable connections (lighting system) NOTE: • Dismantle the following components before locating the fault. 1)The seat 2)The fuel tank 3)The front bulb holders • Use the following special tool for solving this fault. Pocket tester: 90890 - 03112 1. Fuse • Remove the fuse • Connect the pocket tester (Ω x 1 ) to the fuse.
LIGHTING SYSTEM ELEC (+) probe of tester Red / yellow terminal (-) probe of tester Blue terminal • Place the lights switch “LIGHTS” in positions “POS” and “OFF”, successively. • Check to see if the continuity is correct in the lights switch.
LIGHTING SYSTEM ELEC 3. Cable connections • Check the cable connections of the whole light system See the section on “WIRING DIAGRAM” CONNECTIONS IN BAD CONDITION Correct these.
LIGHTING SYSTEM ELEC CHECKING AND TESTING THE LIGHT SYSTEM 1. Headlight do not come on 1. Headlight bulb • Check the continuity between B and Y and between B and G THERE IS NO CONTINUITY Replace the headlight bulb. 2. The headlights do not come on 1. Check the bulbs (see previous point). 2.
LIGHTING SYSTEM ELEC • Check the headlight voltage Headlight voltage: 12.0 V DOES NOT MATCH THE SPECIFICATION 3.
LIGHTING SYSTEM ELEC 4. Cable connections • Check the wiring connections of the whole lighting system. See the “ELECTRICAL DIAGRAM” section 3. The tail light does not come on 1.
LIGHTING SYSTEM ELEC DOES NOT MATCH THE SPECIFICATION • Check the voltage of the tail light 3. Cable connections Check the connections of the whole light system. See the section on “ELECTRICAL DIAGRAM” Voltage of the tail light: 12.0 V MATCHES THE SPECIFICATION Replace / service the tail light. 4. The instrument lights do not come on 1. Instrument light bulb • Remove each bulb from the instrument panel • Connect the pocket tester (Ω x 1 ) to the bulb.
LIGHTING SYSTEM ELEC 2. Voltage • Disconnect the coupler of the instrument panel • Place the main switch in the ON position. • Connect the pocket tester (DC 20V) to the instrument light coupler. • Check the voltage between Br and B Voltage of the instrument panel: 12.0 V DOES NOT MATCH SPECIFICATION MATCHES SPECIFICATION 3. Cable connections • Check the connections of the whole light system. See the “ELECTRICAL DIAGRAM” section Replace the instrument panel.
SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM 8-28 ELEC
ELEC SIGNALING SYSTEM NOTE: For the colour codes please see the electrical diagram 17 18 19 20 21 22 23 26 27 Fuse Switch 10 Handlebar switch 11 Front headlight/indicator (LH) 12 Front headlight/indicator (RH 13 Neutral switch 14 Rear indicator (LH) 15 Rear indicator (RH) 16 Front brake switch 22 23 20 19 26 Rear brake switch Tail light / Brake light Instrument panel Neutral relay Battery Horn Indicator relay Thermocontact Oil level switch 27
SIGNALING SYSTEM ELEC TROUBLESHOOTING THE INDICATORS, THE BRAKE LIGHT, THE “NEUTRAL” INDICATOR PILOT LIGHT, “TURN” INDICATOR PILOT LIGHT AND THE OIL PRESSURE INDICATOR “OIL” DO NOT COME ON AND THE HORN DOES NOT WORK Procedure Check: 1.The fuse 2.The battery 3.Main switch 4.Wiring connections (signalling system) NOTE: • Remove the following items before locating the fault. 1 The seat 3 The front fairing 2 The tank • To repair these faults use the following special tool: Pocket tester: 90890 - 03112 1.
SIGNALING SYSTEM ELEC 3. Main switch • Disconnect the connector of the main switch • Connect the pocket tester (Ω x 1) to the main switch • Place the main switch in positions “ON” and “OFF” successively. • Check if the continuity is correct between the red and brown cables only in the “ON” position. IN GOOD CONDITION IN BAD CONDITION Replace the main switch. 4.
SIGNALING SYSTEM ELEC CHECKING AND TESTING THE SIGNALING SYSTEM 1. The indicators do not flash 1. Indicator bulb • Remove the indicator bulb • Connect the pocket tester (Ω x 1) to the bulb (+) probe of tester Terminal (-) probe of tester Terminal NO CONTINUITY • Check whether the continuity is correct in the headlight bulb Replace the indicator bulb. CONTINUITY OK 2.
SIGNALING SYSTEM ELEC • Check if the continuity is correct in the bulb holder bush of the indicator. CONTINUITY OK 3.
SIGNALING SYSTEM ELEC 4. Voltage • Place the main switch in the “ON” position • Connect the pocket tester (DC, 20 V) to the coupler of the indicator relay. (+) probe of tester brown terminal (-) probe of tester to ground DOES NOT MATCH THE SPECIFICATION 5. Cable connections • Check the voltage of the indicator relay Check the connections of the whole light system. See the “ELECTRICAL DIAGRAM” section Voltage of the indicator relay: 12.
SIGNALING SYSTEM ELEC NO CONTINUITY • Remove the bulb of the tail light/ brake light • Connect the pocket tester (Ω x 1) to the bulb Replace the tail light / brake light bulb CONTINUITY OK 2. Front brake switch • Disconnect the coupler of the front switch (brown and green/yellow) of the connector.
SIGNALING SYSTEM ELEC 3. Voltage • Place the main switch in the ON position. • Apply the front brake • Connect the pocket tester (DC, 20V) to the front brake switch. (+) probe of tester Brown terminal (-) probe of tester To ground DOES NOT MATCH SPECIFICATION 4. Cable connections Check the connections of the whole system. See the “ELECTRICAL DIAGRAM” section • check the front brake voltage. Sidelight voltage: 12.0v MATCHES SPECIFICATION 5.
SIGNALING SYSTEM ELEC • Check whether the continuity is correct in the brake switch Switch position Applying rear brake Not applying rear b. : Continuity In good condition In bad condition IN BAD CONDITION X X X X X : There is no continuity Replace the rear brake switch. IN GOOD CONDITION 6. Voltage • Apply the rear brake • Connect the pocket tester (DC, 20V) to the rear brake switch.
SIGNALING SYSTEM ELEC 3. The NEUTRAL indicator does not come on 1. Neutral switch • Disconnect the cable of the neutral switch (light blue) of the connector • Connect the pocket tester (Ω x 1) to the neutral switch. (+) probe of tester Light blue terminal (-) probe of tester To ground • Put the transmission successively into neutral and then into gear • Check whether the continuity is correct in the “NEUTRAL” switch Switch position Neutral In gear.
SIGNALING SYSTEM ELEC 2. Voltage • Disconnect the instrument panel coupler. • Place the main switch in the “ON” position • Connect the pocket tester (DC, 20V) to the instrument panel coupler. (+) probe of tester Brown terminal (-) probe of tester Black terminal DOES NOT MATCH SPECIFICATION • Check the voltage of the front brake. Instrument panel voltage: 12.0 V 3. Cable connections MATCHES SPECIFICATION Change the instrument panel. 8-39 Check the connections of the whole system.
SIGNALING SYSTEM ELEC 4. The turning indicator pilot light “TURN” does not come on 1. Turning switch “TURN” • Disconnect the large coupler (yellow) from the lefthand switch on the handlebars.
SIGNALING SYSTEM ELEC 2. Voltage • Place the main switch in the “ON” position • Connect the pocket tester (+) probe of tester Brown terminal (-) probe of tester Ground DOES NOT MATCH SPECIFICATION • Check the voltage of the front brake. 3. Cable connections Indicator voltage: 12.0 V MATCHES SPECIFICATION Check the connections of the whole system. See the “ELECTRICAL DIAGRAM” section 4.
SIGNALING SYSTEM ELEC 5. The oil level indicator light does not come on 1. Oil level switch • Remove the oil level switch from the oil tank • Disconnect the switch coupler (black, black/red) from the connector. • Connect the pocket tester (Ω x 1) to the oil level switch. Check 1 (+) probe of tester Black/red terminal (-) probe of tester Black terminal • Check if the continuity is correct in the oil level switch NO CONTINUITY CONTINUITY OK Replace the oil level switch. 2.
SIGNALING SYSTEM ELEC 6. The horn does not sound when the HORN switch is pressed 1. HORN switch • Disconnect the handlebar switch connector from the connector • Connect the pocket tester (Ω x 1) to the HORN switch.
SIGNALING SYSTEM ELEC 4. Horn • Disconnect the pink cable from the horn terminal • Connect a bridge cable to the horn terminal and lead this to ground. THE HORN SOUNDS THE HORN DOES NOT SOUND The horn is in good condition 5. Voltage • Connect the pocket tester (DC, 20V) to the pink horn terminal. (+) probe of tester Pink terminal (-) probe of tester To ground • Check the voltage of the pink terminal. DOES NOT MATCH SPECIFICATION Horn voltage: 12.0 V Replace the horn.
COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 8-46 ELEC
COOLING SYSTEM ELEC NOTE: For the colour codes please see the electrical diagram Fuse Main switch 19 Instrument panel 21 Battery 26 Thermocontact 19 26 8-47
COOLING SYSTEM ELEC TROUBLESHOOTING THE TEMPERATURE LIGHT DOES NOT COME ON WHEN THE ENGINE IS HOT Procedure Check: 1.The seat 2.The tank 3.The front fairing NOTE: • Remove the following items before locating the fault. 1) The seat 3) The side fairing (right) 2) The side fairing (left) 4) The headlight assembly • To solve this breakdown, use the following special tool: Pocket tester: 90890 - 03112 1. Fuse • Remove the fuse • Connect the pocket tester (Ω x 1) to the fuse.
ELEC COOLING SYSTEM 3. Main switch • Disconnect the coupler from the main switch • Connect the pocket tester (Ω x 1) to the main switch (+) probe of tester Red terminal (-) probe of tester Brown terminal • Put the main switch into the “ON” and “OFF” positions alternatively. • Check to see if there is continuity in the main switch. Switch position ON OFF : Continuity In good condition In bad condition X X X : No continuity X X IN BAD CONDITION Replace the main switch.
COOLING SYSTEM s WARNING 6. Thermosensor • Remove the thermosensor from its housing. • Connect the pocket tester (Ω x 1) to the thermosensor • Submerge the thermosensor in water • Measure the resistances. • Take note of the temperatures while the water is heated up with the thermosensor in 3. Up to 115ºC No continuity ELEC Handle the thermostat with special care. Never let this receive any impacts or fall. If it does accidentally fall, replace it.
ELECTRICAL DIAGRAM TZR50 COLOUR CODE B R L G O Y P Br Ch Sb Dg W B/Br B/Y Black Red Blue Green Orange Yellow Pink Brown Chocolate Sky blue Dark green White Black/brown Black/yellow 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 B/R B/W G/R G/Y Br/W W/R W/B W/G Y/L Y/R L/B L/R L/W L/Y Black/red Black/white Green/red Green/yellow Brown/white White/red White/black White/green Yellow/blue Yellow/red Blue/Black Blue/red Blue/white Blue/
