Yamaha TZR125 and DT125R Service and Repair Manual (Haynes Manuals)

Yamaha TZR125 &

DT125R Service and Repair Manual by Mark Coombs with an aclditlonal chapter on the 1997,00 DT125A models by Phil Mather

Model. covered TZR125. 124«. M arch 1987 10 AugusI 1993

DT125 R. 124cc.April l 988on

M...,

Not..· rht/ TZR 125 R. IflltOducr!d in April 1993. IS nor

( 1655 - 11AB5)

Heyn" PYbl ishing Sparkford Nt Yeovil

Somerset BA22 7JJ England H.yn" Public'tion" Inc 861 Law rence Dfive Newbury Park California91320 USA

ctJ~tlnId

by this

AdlnowIedgem_ts Our IMnb _ due to APS MoIoteydeI; of w.... s-w.... n ~ MotooqodM of PoeM. 00rMI. wno IU!lPIied the ~ '-'nd in

1l1li Manuel ThIonI<. _ liiio dull to Mit"'; MIchinery s.lw1U1Q Lid wt>o ptOYIded lhe - - V ~ InlormlbOO...cI (I'Ve ~ to~ "*'Vd the ~OrrNingl UNd. The Avon Rubber Cornpeny tuppIied kTfomIttion on Iyrt caN end fi"ing. ...cI NGK Sptrk Pluga IUK) LId ~ informetion on plug electrode eonditiona.

"*"1__ .....

Prlnt~

In tn. USA

AI rights

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No

tr-...ItW In . ., tom.

pIIrt of tt,;. book ....,. be ~ or ...... eIec:t.-lc or I\'MC~

or by _

-dine or by ..., InfClnMtion Itor.,. or .-ttiwal .,.." ..... wtthout ptmIiNIon In writI. . from eopyright IncIudInrg photocopylne.

.......

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ISBN 1 15910 11-47 3 IIritIth

utw..., Cat. . . . . in Publatlon Go..

A Q\.aIogue ..cord for lhol booIIlI ....... from the 8nwh I..lbrary

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w. take ....' pride In IN - . c y 01' Informa'tlon ...- In ........... but mo'orcycle manutactur.n ...... -"...,1oN ........ cNoneM do.riItg the production .... 01 • pllrtlculM motorqocle of which tMy 60 not Worm ... No .....hy can be -.ned by the .moor. or puWWMorsIor lost, ~ or ...., c-.d by .., ....... In.oromlMloMf--. IN ~ gIwn.

Contents Inlroduc tory pIg . . About 11'1" menu,' Introduction ' 0 11>11 Yamaha TZ RI 2 S and

0T12S R mod.l, ModfIl dimensions and _'lIhts O,dllfing ' PI'" parll

Saletv ",.." ToolI and wOI'k,ng 1I,,;:"i,... Span,...,.

Ii., comPII"lOn

Standard 1000qutl letting. ChOOSIng Illd lott Ing accesso,,"

Faull diagnosis Roullne lnIIintenanc.

Ch I p", 1 Eng,ne, clutch and

gearbo~

Chlpte.2 Cooling system Chapter 3 FLIfI! Jy$tem and lubtiCition

"" "" " 39

" 78

Chapter 4

Ign,uon 1y$lem Chapt.r 5 F.ame am:! forks

"

..

Chapte r 8 Wheel., brakes Ind Iy\'M Chlpter 7 Elect!lcal system

Chapt.r 8 The 1997-on DT1 25 A models

",

""

Wiring diagram.

144

Convention factor.

151

Index

152

v....aII. TZR12SIlPC1! modIl

v......... DT125 A IlANZ) model

About this manual The purpose of this manuel is to P<--" the OWnll< wilh • cone;.., and 9'.~ guide ..... No;h will_bill him 10 lact ...... y operatton

from basic: 'OUIi .......... tenanco 10 • m.;or ove
'hII'

.nd.

Iu""""

u ...... rcised.

The .... Ihar Iorrot hi, motorcycle mechanics 0\1 .... numbotrof yo ..... lKed wilh the same difficulties and .... ng 1irniI.I. Iac:ililiel to thaM _nte<e
lUIhoi' unden""" I ronside"bIe amount of research in ordef tNII the ma.imum ',,-nt of dati CIII be inf;luded In the ........... , A comptehensiY. MICtion, preceding the main !WI of the ..........L deteribel proced .... e!! lor f;I"Y'ng out tne rout'ne """'tenance at IIIe machine .t Int"",115 of tme ..-d mileage. This Metlon Is Included ~"icullrly lor tho5e ow,""" who wi-" to - .... the efficient day-today n.o'Ining of their motow{c:ie, but who chooIe no! to undeee it rnede 'See Section 6.10' h meen, Section 6. ~.agraph 10 in the _ Chap' .... H I/IOt"" Chapter were Intended. the Allerenc. would ..-d. lor e x..... pie, 'See Chapu" 2, Section 6. 10'. All the photograp/ll ar, f;lptioned Ind right·1>and description, of the n"IIChTneI and their <:OmPOl\llnl5 reler to thelelt end right of. given machine wi*> the ride< ", ... lIed nonn.lly. Motorcycle meno.AKIU ...... conl~".,.h cI\engeI to specIIicItlon •• nd racommendatlonl. and theM, wi*> notified. Ire incorporated into DUI' men ...... " the ee
Introduction to the Yamaha TZR125 and DT125 R models For Information relating to the 1997-on DT125 R models, see Chapter 8 Bel,,", 1982 the 125«: Ull)Kily c .... 01 motorey.:le w ill not particuIIrly popular in the UK, linea the machinel _re too slow 10 .!lrlCl In

.. rge nurnbe<.the 'fOU"'9I" ridef-.looI
",t;!& to be .mlCli,.. to the <:Ommuter or nor>-enthualest ride<.

Thi, lilUitlon Mtered radQlly in 1982 when new legislation dic·

tiled thlt .1I1e.mermocorcyclilll pwchllling new motorcydel were to be .... u icted to machines 01 ......xifT1!Jm engine lize of 125 cc. the _ e r output being restricted to 9 tW II 2.2 bhpl. AImoat immedilotetv the maon lour J.par>eM manufactuAlrs ,KPOOded with. seleclion of new modeiIlO <:Omply with this new legillllion. V........ off..-.d ,he ROl25lC and DTl25lC mode .... Both modeII UIfId lingle cylinder, wat ... cooled enoines end were lQUiIlIled wilh V..... ha·. MonocfOll ~ They proved 10 be very IUCatIIful and 11.'(1(1 In production untit earty 1987 and 1988 wilen they _ e sup&r' sedIM:I by the TZR125 and 0T125 R modell, The DT125 R model iI......, simile. in appeIftInCe 10 ill pn,d"clllOl" ............ ,he TZR125 model hal beencompletely redesigned. The main deIign change to lhe TZR model was in the use of • 'Oehaoox' type lame, constntCted in IhinwlU steel. To complete the apo
,_wol<.

'U'

.'Ioy

rotted. whtch could accept tubelell tv ..... Aper\ f,om coamelic cI\angeI. the 1991 TZR125(modeIcode 3I'C3fwesuncl\anged ff()fllillpredeces~.

The original 0T125 R lcode 30Bl1 model wes ."pleced in 1989 by the 3RNt model. Apan f.om new ~in\Wor1l end graphics the on.." change wes to the top end of ,he engine. togelhe< with I nll·tIide cerbo.o:ettor. The 3RNI model was superMded by the 3RN2 al the beginning 01 1990. the only ehenoe bWIg in colour end grIPIjcI. further 0T125 R 1T'CdeI$. Wltroduced betwe.\ January 1991 end Nov«nber 1995 and listed WI the IoIowWIg table. differed only WI colour and gmphIc$ with the excep!oon of minor modlflca!iOOI to the fn:wlt IDr1<s and .winging arm. The power vatve w .... madft opN>II'ioruol nn ..... 3RM9 model Introduced in November 1996 lOt the 1997 pnxIuctoon y6llt. FQr det8l1s 01 this and subsequenl 1T'CdeI$. r91e< to CtwI¢er 8. To help OW ..... ldenlify their machi ..... exlClly. lhe lPPfo";"",,, datM 01 ImpOrt lMe gi ...... below, with the init... engine ..-d f ....... ......ber with which NCh model', production run commenced. Note thlt whir, necessary. modeit _ identified by the;' code numbers (eg 2RK) Il!roughout thil ............ Modal Oal" of lmpot1 Enginelfnwne no. TZR1252RK Mar '8710 Mar '89 2RK-OOO I OI TZR I 253PC I M,,'89 10 Feb '90 2RK.(IIIIOI TZR 125 3PC2 Feb '90 to Dec '90 2RK.(I18101 TZR1253PC3 .w. '91 ' oAug '93 2RK.(I25101 DT125 R lOBI API -seto M.y·89 308-000101 DT125 R 3RNI M,y '89 to Feb '90 3 MO·OOO101 DT125 R 3RN2 Feb '90 to Dec '90 3 MO-OOB 101 DT125 R 3RN4 .lin '91 to Feb '93 3 MO-OI8IOI DTl25 R 3RN6 Feb '93 to J ... '94 3 MO-036101 DT125 R 3RN7 .lin '94 to Nov 114 3 MO·037101 0T125 R 3RNB Nov '94 to Oct '95 3MD-03910\ OT125 R 3RN'9 Nov '95 10 Oct '96 3M0-041101

Model dimensions and weights For information relating to the 1997-00 DT125 R models,

see Chapter 8 TZRmod.1 {2RI(,3PC1)

~:::: ~3tt-:::::::~-:::::-_~::::::::::::=::::::::::::::::::::::::=:::::::::::::::::::::

Overall helllht _.. _ ...... _ ... ___ .____ ..... S..t hlllght ,_._ ..............................._ Wh.elballl...........................................

Z021} mm (79.5 Inj 695 mm (27.4 In) 1005 mm (39.6Inl 760 mm 129.9 in)

1340mmI52.8ini 135mmIS.3in) 120 kg 12651bl

Gro und cle.ran clI .. KerbwlIlght

TZR model 13PC2. 3PC3) 2025 mm (79.7in) 695 mm127.4 in) 1005 mm (39.61n) 766 mm (30.1 in) 1340 mm (52.6 in) 140mmIS.5in) 121 kll1267 Ib)

OTmodel 2160 mm (85.0 In)

B30 mm 132.7 in) 1255 mm {49A Inl 885 mm 134.8Inl 1415 mm (55.7 in) 315mrn112.41nl 119 kg 1262 Ib)

Ordering spare parts When ordering spa'" pa"s it is tKtvisabloo 10 deal direct with an &u1horiz8d Yemaha deale •• who will be able 10 ma"" of 1M items requif1ld 1I~",'ock. 1\ is 8dYisabIe to gett ..::q..... inted with tM Ioc.ol Yamaha eleale,. 8nd to rely on his edvioe when purchuing ~'". Ha is In 8 belle< poei!On to specify 8>
Use only ""n. of genuit>ll Vlmllha manuiltClure. A lew pallem parts "'" 1IV8ilable. sometimes al cheaper prices. but II>e,a ill 00 g..... rlntee they will giva such good HrVica 81 the originats they repIece. RaISin any worn or broken part. untillhe ",placements have been obtained: they 11<8 sometimea naeOed M a pettern 10 help identify 1M coneel ",placement when da..ign changes have bean made during I production run. Some of tM mo,. expandable pans such as spark ptUOI. bulbs. lyres. oHs and ",el"lelt. can be obtained from accessory lhops and moto,leetor.. who hive convenient opening hours. and can often be fcwnd nQl fa, from home. II Is also PQesiolelo ~Ialn P""' on • Mail Order basis f,om 8 number 01 speciatists who edYsnill regutarly In the motorcycle ma{lllllne"

Location of Irlme numbe,

Location of engine number

."'1'Pv

Safety first! P,olO$loona' mo'O! mec;h."g a .. u.,110811 in ...1. worIcUlij proce· du,". How ...... enthusiastic: y.... ""'V t.. about 98111ng on ... "h ,he Job III "-Rd. do~. ,he "me to ..,SUr, 1M! you .... r.ty IS no! put at risk. A momenr. Ia<;k of anenllon can faUlt in.., accident. as can I"'ur. 10 ~ precautions. TheOInt. do nol pretend 10 be • eGmpo-ahens,,,,, hi' 01 ,II ""ngllfS. they .r. ,n.ended ,a,,,,, 10 mal<e yOU awe .. of ,he ....... and 10 encourage, aa""v·conoclOU. 'l>Pfoach 10 . 11 wO
....'.'n ._n,.IY

Essenti8/ DOs lind DON'Ts DON ' T , 'an ,he eng"" wllhou. h", asc,""n,ng 1M. ,he transm, ..ion .. in neutr.I

DON ' T sudderoly '&mOVe ,he filler cap from • hot coolIng IYS'_ co...... it will>. clo.h and reINse the P',",ur'g,Mlu,11y ,,,... 01 you....., get scalded by esc'PI"" coolant CON 'T IttemPl to d"m oi' unll' you ,r, IUr' I' t.aa cooltod sullie ..""y 10 avf)Id scald'ng you . CON ' T grasp any JNlf1 01 ,he eno,ne, a.he"'t 01 a.olencer wlthou. hr., esc6r1a,n'ng 'h81 I' illlUll':l... d~ cool 10 ...00 bu,n,"II ~ou. DON ' T bC Componenll DO N' T ..,phon IOX;C l'ouldl luCh., fu.'. bm1)OlWln1 whreh n-..y be beyond YOU' Cllpabrl,ry - (leI ,,,,,,,nc.. DON'T ,ulh 10 fon .. h • lob. 0< I .... un_,IIed lhort Cull. DON'T Illow ch,idran '" ,n,~I. ,n '" around In unl"._ ""hiele. DON'T infla" I IV" 10. pt6ISUta a""", .ac...........- ~ .i mum . Apa,' "om ov-.
.'Iow

I""

Iwrzatd

00 keep loose clolh,"iI (culls. "a IIC) and Ionll ha" wall oul of lhe WIlY ollTlO'l'''iI maclwrnical panl. 00 '11m""" ""ill. wrrsrwatch erc. befOf' work'''iI on lhe ""hrele es.pac,ally IhI elIct,rc.aIIYSlem. 00 keep you, work •• aa l;,j~ - it is ""'~ 100 _y 10 1III ov" Irlic,... 11ft ty'''iI .. ound . DO ....c'sa cal/l!Of1 when comprasa'll\I iIP<'l>OI 10< , _ . 1 Of ,nlllll."on E"", •• Ihll IhI ,_,'''' is applied .nd .eINSId in • conrrollfld manner. u"nll 1001. whreh preclud. lhe _,brl "y oil",," spr'''iI eseap,ng v,oifIfIlly DO ansu.e IIwn .... y Irl"ng 1<>CIt1. used ""a work'ng toed ,",ng adeQuate 10< lhe lOb. DO get someone 10 check P8<,odre.'1y Itwn all is wall. when WO
"""bit

hi.,

Asbestos Cena,n froc"on. ,n""II'ng, ...I,ng.• nd otller produc'. - weh .. brake "n,nlll. clulCh lin'nol. g .....1I. .Ie - ,ontain asbesl.... Ed_ CM. ffNJlI ba t""" 10 avOld ;"h#''''o" of dUll luch product'li_ i! i. MI"dou, 10 h#al/h. If in r:Ioubi. _ .... that thay do cont.,n .. best ....

I,,,,,,

Fin, Remember a, all InTles thai petrol (gasoI,,,,,) is h'\lhly Il.IImmabie. N..... omoka. 0< IIIva ,ny k,nd of ... ked llama llound. when wOfking on lhe v.... lCIe. 8u, IhI.1Ik does not and thefe - a..,.rk CIIuMd by In alec"re.I short,cireu". b~ IWO meral"'rlaces ,0ntlCli"il uch other. by CII,al... use 01 10011. 0< ....... by .,a"c electrre,ty buill Ul> in vou' body under ce1', ';"'1 e.,inguisher 01. type lu'Ubie 10< luel Ind aleclrical I,," .. klpl IIIntly In lhe 11"111' Of wonQlace II ,II t'mes Nr:tII .. Iry 10 ex"nlluilh. 'ual 0< "ectrica'li'a w,Ih wll ... Note: A"y ,#f..."", to • 'IOfch' .ppeIT,fIg i" ,,.,., ",,"u.'l/Iould ba 10 h#"d,h#1d bafl"Y, opera/ed alec/ric ~ IN lI.sJoJ;ghl II doIs no l """" a ...ldlflfll fllS Iort;h Of blow/amp

.tw.r, ''',n me." • Fumes

"1

Cenaon lu ..... highly 10Xic ,nd c,n Qu,ckly cause unconscioul· ...... ,nd evan deeth if inhaled 10 .ny ..' .... , . ""trot (lIuo"na) v'pOU' coma ,n'O th,. Cllegory, II do the v,paul1l l.om ~nlin soIvants luch u trrehlo
The bat/ery Nr:tII .. cause, IJ)IIII<. Of Illow • n.bld l'IIhL "", lhe vehrele'l bett...,. It willl\Of~lIy ~ II'V'''iI off. ce
,at.

Mams electricity and electrical equipment W""n In'll\I In atecure PO_ 1001. inlPlClion lighl IIC. alw ..... ensure 'MI 'ha apphance is Co<,eclly Connecltrd 10 its "'UII anod lhal. wllerlt neclllNry. it is pr-opepIr.nces mael lhe ' ........ nl ... tional Nllary ,"nd.,ds.

Ignition HT voltage A"", ... elIct.re.hock can ,esult from IOUCh'fIII CWlain IM"I of '''''" 'lin ",,,,, SyI'&m. such .. the HT INds, when '''''" IIIl1ina is .unniflll 0< be,ng cranktrd. lM"reula,1y ~ compaoem. Ira damp 0< IhI ,nsular,"" IS clelecuve. Whe<e ,n elecl.onre 'ilnllron II'(lt ..... II foned, IhI HT vol'lge IS much h'gher ,nod could prOlla faill.

Tools and working facilities The fif'lt priority when undertaking melm_oce or repair worIo; of any eort on. motorcycle is to have 8 clean, dry, _1I.rot workln.g .ru. Woo u.ried out in PNCIt.nd quiet In the well-orde<ed llmo.p!>er. of I IIOOd worUhop will give ITIOf'9 Hlis/action Ind mud> ~tt., 'QUits than un ulu.11y bclltChklVed in poe< worti"g c;onditiona. A good worbhop mUll hive • clun H.l WQtkben.;h Dr It solidly con,In,H;lo
convunlent wortlng hel;ht. ThB wotkbench Dr tabl, .hould be equipped with 8 vice whi<;h htI.1 jew OpUning of ,11",,, 41n (1 GO mm). A tel 01 Jaw COVIll. Should be m.ae frcm soft metal lueh a. aluminium alloy Dr ropP\lr, or from wood. Thes~ covers will minimise the 1nl1l1dng or damllQlng ollOft or deliute compon8ntl which may be cllmpad in the viea. Some eI.an, dry. SIOtaIl" 1j)&U will be required 10' 1001.. lubricants and di...... ntled component •. It will be nec ....1V during I mejor oYBf' tlaul to lay out 'ngineJgearbox components lor ulmll\8tloo and to teep them whertotheywHi remain undisturbed fo<,.1ong8l1Ineceuary. To this anll It I, recommended that a supply of metal or plaltlc contaiJ18fS oIsultabil ,ize is collected. A supply 01 elun. lint-tree. rags lor cleaning PUrpoMllnd some -.papers. other raga.. or paper towalilor mapping up .plilagft IhouId also be klpt. If working on I hard cone"'te floor oota that both the floor Ind one', k...... can be protected In>m oil 1Ij)0111lQll.nd wear by cutting Opeflilarge cardboard boK and .preeding it flat on the ftoor under the machine Or worlriminorrep8irtooi kit can be built-up Inlo I RtlfJlir lind overhiJuI tool kit over e considelllble parlod 01 time without any majorcalh outlays.. The uperienced home mechanic will hlv. a tool kit good enough for "-I repair Ind overhaul procedu .... and wiD add tools In>m the .pecIoli~ed category when he leeI,the e.~ Ie jullilled by the amount of UH theae toob; wiN be put to. II is obuious/y r>OI possible t<;l {:(IV$!" the iUbjKt of I~' fully OOrll. For those who wist> 10 leam more aboul 1001s and their use the", is a book entitled Molorryde W~ Pr9ctice Techbook jBook no 34 701 lMIilable hom the pubiishers 01 this manual. k .., on:IVides 81'1 inm>-

8'"

I'"

duction to basic workshop P<8Crice which wi. be of internl to I home mechanic wcrllng on anv type of motor vehicia. A5a general rull.111s bett.r to bllV the mora upellllva. good lj~ll1Y tool$. Giuon renonabll lIM, euch tools will last for I very long lima, whel"llBll lhe chHpar, poor lIpannerS/lpp!ng off the nul and damaging It lor thi, .....,., lione ring spanne ... Ire to be prefarTed. ldeallv. the home mlChanlc ahould acquire I $01 of each, but if •• pa ..... rules thi'OUI' .st of comblna~on lpanners (O!lIn-ended II one .nd and with a ring of Ihe .. me 111111 II Ihe ether) will provide 8 good ~om­ promlss. Aooths( Ilem which 11110 useful il should be conlldered In assenllal rlClul",ment for any home mechllnic i, a ae! 01 lockellpan. nalll. Thess a",avaUable In I variety of drive sizO(l. 11II 'ecommended that thsl·lnch d,iva type I, purchllsed 10 begin with IS allhough bulkier and mo", IKpenllve thlln lhe t·lnch type, 1M la'oer Ilze I. 1'1 mo,e common and will accept a g ...ler variety of torque wrenchel, eKIansion pIec.. and IOCklt liz ... The IOCkel aet lhould compriae IIOCteta of sizes between 8 Ind 24 mm. a revsrsiblt! "'tcitet drive, In e.l_ion lis, of about I 0 Inch.. 1n length. I ,perl< p!UQlIOCket with I rubber InM"- Ind a uniu ..... J joint. Otherattachmentl can be addecIlO the aelat I Iller dale.

MaintenanCB and minor repair toollrft Sst of spa,.".,. 8 - 24 mm Sst of :webt. end IttIKhmenr. 14 mm spart plug $pMlfrfH" with rubber insen Adju&lM1ie 5PIJfJ"'"

C-$pIIt1n8flpin spanmK TfN'QoJe wrench (UrT/fJ ~ze drive .... sockets) Set of ICfIW<Jriven ~t blttdttl Set of JCt"tIWdrlven {cro5$"'-
S«ofAlllHlkrl"#4 - IOmm Impact _driwlr.r>ri bits &llpeIn~ - 21b

H~wqun/olJ S8H~ pJitn Pf~

Mole {Jfip& or va {Jfip&

combinetKN!

Pf~

_

f1Hd,.1lO8I

1 Tools and working fa ci lities W,,,, brush (small) Safr·brisrledbrush

ShOp. An altsmativ8 is for a group of friend. or 8 motOfCYCle club to join in the purchsse.

Tyrepump FlvwhOf!I rotor pu/~r

Ty", preSSUffl gauge

TyffJ I"",d depth gauge

Clutch holding tool

Oi/elfn

Pis/on ring compressor Univf1fS8/ be/mng pu/~r Cylmder bore honing atriIChmtmt (for e/e<;trk driU) MICrometer set VemJer calipers DuN gauge set Cylinder compression gauge VilCuum gauge set

Fin" emery cloth Funnel (medium size) OnprrllY

GrHSlIgun

Set of feeler gauges Bralte bleeding kll 51robe liming light Continuity re~W {dry btJlltt<J//J} Saldering iron and so/der WI'" stripper or crafl kn/ttl

Mulli"",r...

Dwell mtJI8rhachometer

PVC insulating tapti

Care and maintenance of tools

Assortment of spill pins, nuts, bollS, and w<Mhers

Wh
Repair and overhaul toolkit The tools in this ~st are yirtually assenrillllo< anyone undertaking Il'\IIjor '"pail'S to " motorcycle and are additional 10 the loots lisled

above. Plastic Of rubber sofr·/aced mallet

Pliers

electrician"s sirlecullors

C!rclip pliers

internal/s/raight Or right-angled liPS em eVlJllable)

Circlippliers external

-

CoIdchisel

Centre punch

Pmpunch

& raplJf' (made from 110ft metal weh as alummwm 01' coppe;)

Soft metal dn" Steel rulelsr",ightedge Assorrment of files El6t;/fIc drill and bilS Wife brush Ilargel Sofl wire brush (SImiliN to those 11m for cleaning slJ6de shoos) Sfm6r of piate glass Hacksew llarge} Valve grinding fool Valve gn"nding compound fCOlJ($8 and fine} Stvd eJt.f{eCfor sef fE·Z oufJ

Specialized tools Thil is nOI a list of the lools made by Ihe machine's manUfltClurer to carry out a specific task On a limited range of models. Occasional raferenCOI ara made to such tools in the teKt of this manual and. in ganaral, an alternative method of carrying OUt Ihe task without the manufacturer's tool is given where possible. The toots mentioned in Ihis liSlara those which are not used ragularly and ara expensive 10 buy in view of their infrequent use. Whe.s Ihls is the case il may be possi~e to hl'8 or bonow the loois against a deposil from a local deale. 0< tool hire

Fastening systems FastenafS, basicallV, are nUI5, boilS and 6Crewt; used to hold IWO or more pam tOgelher. There are 8 few Ihings 10 keep in mind when working willi fltllieners. Almosl all 01 them use a locking device of some Iype; eilhe' a lock wastier, locknut locking lab Or thread adhesive. All threaded lastenolS shOUld be clean, streighl, havo undamaged threads and undamaged comers on the hexagon head where tha SP8nner /its, Develop Ihe habit 01 replacing all damaged nulS and bolts wilh new Onll'5. Rusted nuta and bolt. should bo IIeated with a ruS! penelrating fluid to ease ,emoval and prevent breakllge. Alter applying the rust panetrant. lei il 'woo' for 8 few minulBs before Irying to loosen the 1>\11 0< boil. Badly rustOO fasteners may have to bechiseled off 0' removad with a special nul breaker, available 811001 sllop$. Flat W8.hers and lock washers, when removad from an assembly should alway. be 'eplaced exactly a5 removed. Replace any damllged washers wilh new ones. Always u,," a lIal washer between a lock washer and any soft metal sur/aco 15""h aluminium), thin sheet metal Or plastic, Speciollocknuts can only be used once 0' twice b
8"

M

Spanner size comparison J,"'"",,p(lnl

.,'"

00.945 .' "

Sptln.... _

linAF

L"

0.276 0.313 0.316

0,.,

'mm

H in AF;, in Whitworth

1.010 1.024 L063

OJ..

9mm

1.100

0.375

I lnAF IOmm Ilmm

1.181

0_

,~

hinAF

0.'" 0.'"

hlnAF

0.""

12mm J InAF 13mm

0.445 0.472 0.512 0.525 0.551

0."" 0.591

0.000 0.625 0.0" 0.669 0.... 0.709

to In Wtdtworth; I

1.125 "'00

1 inAF

to In Whitworth; t in aSf 26mm Ih inAf; 27mm h In Whitworth; H In 8SF IlinAf

"'mm H inWhitwOf1h; I in aSF 11 irlM 32mm

1.313

'.mm

1.417

"mm

15mm h in WhitwOl1h; i in 8Sf

...00 1.575 1.8\4 1.625 1.670

l in WhitwOl1I\; to in 8Sf

L"" ...

.,

hln BSF

I lnAF ,,~

Umm

L ... 1.811

HInAF ,,~

I in WhitWO<1h; .. In BSF

0.748 0.750 0.813 0.820

19mm

f inAF »inAF

0.875

i

.

...,.,..

24mm

lin WhItworth; i In BSF IhlnAF H In WhilWGfth; tt In aSF

0:110

,. ,.,.

.,., "''''

In BSF

+finAF

h

in Wh~wonh; ; in

lhinAF

i in Whitworth; , In BSF II InAF 40 mm; H In Whitworth 41mm l11nAF 1 In Whi,wonh; 1 i in 8Sf I HlnAF "mm

IHlnAF

1.813

..,oo

\1 1n Whitworth;

1.875

II InAF

1.969

"'mm

2.165 2.362

"mm 60mm

22.050 ."

BSF

22mm inAf f in Whitworth; h in BSF

11 in aSF

2 inAF 11 in WhilWOrth; II in BSF

Standard torque settings SpecifIC torque Mllingll will be found .1 the M>d of lhe &peeifocalionlMClion of Ndl chlopter. Where no flgUf' ill given. It I.hould be MCUftd _ding to II>. I,bIe below.

Fu".... IVpe (11).ead d;'mele
'''m

.~.

0.45 - 0.6

3.5 4.5

0.8 - 1.2

. -9 13 - 18

1.8 - 2.5 3.0 - 4.0 5.0 - 6.0 0.35 - 0.5 0.1 - 1.1 1.0 - 1A 2.4 - 3.0 3.5 - 4.5

22 - 29

...

30 -" 2.5 - 3.6 1 _ 10 17 - 22 25 - 33

Choosing and fitting accessories The . . . . of _ _ _ avaiIabN 10 11'11 modIIm lTIOIon:yc:iIl .. ~1 . . . . . . . lind bewildenng .. the . . . . c4 moton:ydM. Thill Section IIlntended 10....,!he owner;" ~ theCOfT«:l1lQUtPO'l'Mlfl1 for . . ......cIoI end 10 .....,;,t lOIN oIlhe miltak.. "*'- .,.. ,......,. ric*s

wtwon Mkting _ _ 10 theit MKhina h ..... be ~t IhM the

Section

'*' ontv COYer 11'11 suIJjecI in thllmost generI!It_ Ind 80 it is

'kO""'.oded '''''11'11 owner. having ~ ,hilt I'll "'..,1110 fit, for

...... pIe.• IugQIoge rD

C8tfier. INks 11'11 ~ of ........ IocIII cIuIerIlnd 11'11 ~ oI ........,.....chinn. ThoI "",I gr.. IIJOOd idea 01 """'1 milk.. 01 carrlet ar. eMily ...ailllble, and" """', price. Tlno"ll to other ow ....... wii gi\1lOm11lnsight "'10 'I'll dr_bKq or IJOOd poiota 01 JonV _"""1 A w&lk round the moIOtCyC'" in cat pad. Of outaide. deel., will 01'1 ... _Niti'll same 10ft of Inl0000000Hon The fila. ptIo
.:c_...

'*"""

'or

w. t'-

Not'I"'litillnnow~'CWlomiDng~,bul......tv-utoout'"

the P"Kloc.I conai
.ft.......

rt.,

wn.n

.od,"II

Fairmgs and wmdscreens A llOnng ia PClS"b/v 11'1111"1110, molt • • ptnl"". ,fte<""Ret 111m to

fIQIJO'"

til liltld '0 ..,v motOfCVCIe Ind. thl'tIiOfil. thl mOIl lhought blfore fliringl Qn til dlvldld inlO IWO mfin grOUPf,' lront Ion. mounted hlnllletHI, I~ringt InII Wlndlle'""'" and Iri.... mountld

purc'-

I.mn;..

Thl flrs, 1tfOUP. IhI lronl Ion. rnQImtld ........... bIeominoiI fl< POIIOM< I"'" w.. ono;e It.. caM. . . !hey Off.......... idvInlaglll _ IhI..,;ond IIfOUP Fronl fort mountld flOntlQl 0'f*IIIy ... much _ lind qu,c:k"IO fit. invOlve 111M mod,flClllOn 10 till motorcycle. do not " , ..... ,.tno;l IhI ,,--.g Iod. peOI'I .. lhe I,..,.... mounted tvPN. ..' ..... 011.. ..,.,. .tor-gl opace. Ind.lf poorly fitted Of .... tUf.11y Inc:omPl'· ~. eln IWI ___ In atN .... IffllCt on the Itlbilitv of the motorcVCIe. The IICOnd grouP. the "lmI mounted Illrlngs. If' HCu,ed 10 rigidly to the ""in I,ame of the motorcVCIe Ihit lhey eln offer I .... blltantlll.mouniof prO!lICtion to motorcycle and ndef In thl .... nt of • crnh They off.. limoll complele p!'otllCTlOn lrom lhe _Ihe< and. if doubIIHk ....... In OQrnIlrucllOn. Qn provide I Ql'11I dNI of .-lui "or-gI Tn.'1IIIng of peace. QUill and completl ...... oon tnCOUonttNd ....... riding betWId I good lui IMlng .... to bI ex· penenoICI to bI bIIoIwod. For !hoi .-on I~ I.. ringt ... conside<ed ~ ... by moat KItInng moron:ydi&lIlnd by fI\II'IV I*JPII who nile ........ round n. ....... dotadvantagel 01 tM tvlM .. I thlt linll'lQ Qn Ulkl • long 1ImI. often InvoMng . - a I or modificItoon of ItandII'd moton:ycle componInl&, lhey Nitric' lhe IIMnr1Q1lock Ind lhey Qn add up to 1Oou140 II to the we;ghl 01 till meclline They do fIOl .......... ,"IICI Itlblhtv Of IhI mechlnl toany Ql'UI Ixllnt 0f'0CI the lront tyte p" ......... nd IUspenIIOI'I hav. been edjUlied to comPlfllolIl for the ITIOftI

"'*"

m.

I>IDI weight. but Qn bI atf«ted by SIdewJndL n. flrst thing to look few wnen ~ I lIInI'Ig ill till QUIIitv of the fittingl. A 000d IIIflfIQ wit havl IIIOt1(j. IUbltemilillfldllll c:or.. structed hom "-'V'9IUII'I tubinG: till bmmllUI II .. mounlll'lQ pOIn\t. AlIO be car.f\IIlO ehIICt IhI! thl WIndIIC_ it ~ by boIu which wiI ""P on ompI!;t 10 thet It.. windIIC_ wi! tw.ek _IV lind fIOI . . . . . PIIQOnII ........ 1n lhe _10I"'~1. Havng pun;haMd....- I..""" or ~ tAd It.. manufllC' II....... fitlonginllruct_ VtrY ~ Ind ehIICt !hil you ......... It.. rc--v b
m.

wnen

'''''''''1'11

flU"

u"" """rial

"""It:

wi.

m.

inluucbonl _

lolowed ~ II ..........tIgI

flO _ _

ptObIems

ahouId be _ l i e d fIernImbar IhI, hydflUlic ~ thet have bien diIconnacled ......1 til ~ ,..!JQIhlenad and ,he IIydfauIic ..,..,.", pu
w.

_lie""",

Luggage racks or camers c.na.. _ POII
II.", 10 bI 1;111d to modern motorcyela They vII'( IfIOf1fIOUIiy in sill, CIfTY"'II CIPIICItv. II'Id ~. Whtn MiacIOng I CIfI'IIf. INiIYlIook lor _ which. mIIdI aptICIflCllly IOf ....- mac:1Iine Ind which II boItld on WIth .. 1_ l19l'i1' tnck.,. .. POUiQIe. n. ~1yPIt car ..... Wllh ~I ...... of tw.:keta Ind adaptor p;..;.e, will """'...., pro.-. tOO ....... to bI 01 "'" ......... A good ......... ahouId bolt 10 the ""'" 1TItne. gIfIItrIJIy using lhe tWO IUIoPIf'IIOtI UfII\ tOP mountingllnd a mudguard movnt· ing boll .. anldlmlnt point .. Ind havl IlIivgogagI plltlorm _low and

Choo.lng .nd littjn~ KC"lOrin

12 the effect 01

~ Ioed on !he ~' ••~ look lot WOOd~, '-"Y ~ to.bina. good weIding..,;l good finish. u..t the ~ Itt. not ~I OI*W'II of the _I. aidepIIneII. or ~ ~I," ~t • . When LISIng • _rier, be ve
.. f. forward .. pouibIe 10

nwwnoH

"*' __

Luggage MoIow,ode Iugjpge ~ be grOO.Optd unde< two

rv- ...

~

IIOh and

t..rd. BoIh ~ in ......., Ii... ..-.d 1ry\M lind I'IIw tdY~..,;IdisIdY ... ~in ...... SOlI ~ • now bto;omong ve
"'1aIHWI

_fl.

wt..~.oft~looklorgood~ .... ler\III,~

YinvI Of nylon. wtth llrong. ~IIJI<;hed It!aChmen1 PQinta. It .. ~ UMfuI \0 have POd
w..

tllIt~

Hard ~ ;. conf.".d to two type.: pannieno, and lOP bo . . . or tailll\l
t'- 11_ !he baa;. 01 whoch iI geNraIIy INn fTWIUIeclln,'1 own ~~

tid. V8<\l100". CII'I this ,'''''''' occw in !he loom of ...,.... 1 . . - for lhe benet" quIIi!y pennier&, Of quicUydetec:hebIe Iugoe(te. 8nd in liN 8nd ~ capec>tv. Herd ~ oflers I renonMlIe degr. . of _ t v 8(IaIO'II111'oeh 8Ild good proIec:lootI 8Ild ec:e;.o.n, dernage. Car..,.v.g cepec:rty iI (I
...' _,her

""ad

pan""

HllndlelNJrs T.... occupItoonol fin"", III_live typlloIl\IIndIebet ill>
Whet ....... !he I'MSot\, tt>eq ... - - ' oonsIderItioO'lllO be borne in mind when chIngong !he hendlebl .. of yoo..- rntehinII. If litlIng low ... bIrw, ct.ck Clfill",V Il\It !he ,Wllo- ...... CIbIoI do not IWlhe pelrol lri CII'I lull lock Inc! IhI! !he "",pius lenglh 01 ClbIe. brlk. pipe. ...... eleclrICII wiring ... lmoothly Ind Ildily dllPOMd 01. A"oId lighl kinks In CibleOO bnok. pipn which WIll ~ Iliff controls or ,''' prImIlUfiI and dIIIIIl.- ,........ 01 ... 0\180'$" ...... componenl. If _ r y. _ ! h e pel10l tenk....:l ... roul. lhe CIbIe from I'" engint/gINrbo. "'"" uPWlrdl.-.ring IImOOIhgentlel;UVfll'" ~. InIXl_ - . il;wiII be.---yIO~IIhon ... brab popIlOCMIrCOITIII this ~ In lIMo case 01 hogher har'IdIIbers thin luondIrd iI; will ""'-'. CIttainIy be -..erv 10 purc'- I",ended CII* 8Ild braII. pipe&. Fon .....,eIy. nwny Illnderd mocon:yeiel: ........ s CUllom ...-siorI wtlIdt will be equipped will'll'llgltef llandlebars and. lhefll«e.lec:tory· bulk •• comPl'<*1I1 wiN be .....1ebIe !TOm your loCI! dH..... 1\ Is not u ..... ,ty nec:esury 10 1K!lInd eieclriCll wiri!"IQ." .wilch cluill.. mlV be UHd CII'I ......... difl .......1 motorcydel.1O
,.nded

This IJCWII should be borne in mind now...... ......... fining I>'eI In I'" ,.onl brlk......1... eylinder • ..,...... ....... 10 8\Ioid InV ttltnc. 01 .... entering lhe hydflUlIc: . .... tem. Alto c:hecII !hal IhI cebfoM; ... edjlA;.ed c:orr.o;Ity end 1"" .. hendIebar O(lnlfolll ".,....11 COITK.ty and CIrl be .-iIy ...,hed when

......

"""'''''''

CrMhbers. Il1o knowtt .. engone PfOlec:lOf bani. IngIne guerds, Of c..e ............ It>CINmIIy UMfulI! ...... 0I11QUipmem whido CIrl o;on.

lribule protect_lo the mec/'Iine'l .lfUCl.... it I CfHh OCt .... n..y. not. .. t>H been inl .... eeI in thl US. po ........1 IhI rider lrom crashing. 00 nee_'iIy preII ....1 ride. Injury should s ul6h occur. II Ie .ecommended Itltl only '''' ......... .,..ter. eng;"" protlCtor type 01 c.1Ihbef Is eor.ideJeeI. This type ¥oil off« proteclion while ... tncl"'llo"~lo. .. IsPOUible._lotheengoneendthelT\lc:h!ne·. ground deer...,;e. The~ should be deIIgned lor .-specH"1CIIy CII'I yoo..- mec:hint. end should be _lfUClMI of ........,~ tuboflg WIIh 1\lOng, 1m", mounlong brKbtI. Whetw PQI:IibIe. lhey should bolt 10. IlI'Ong lug CII'II ... , ...... ......-ltv It !he eng"" mounling bolts. The 111_...... type of aasnt.r iI the IIrVI' CIgI type.. This Iype Is not recommended in lPiIe 01 their ~ which promiIeI _ PfOllII:Uon '0 t ... fide< III well .. 10 the IT\Ic:h' .... The teroe' smounl 01 ......... lmpQlld bV Ihllire 0' thlltypeol c.I6h"-. Inc_lhe rl.k 0' ......... lrame dam&gfl in !he ........ 01 an ec:c:idenl. This Iype Il1o dec:_ IhllT\Ic:h!ne'. ground deer.nce....:l '.lncl.1CCISI 10 lhe engine T .... amounl 01 proteebon IftoI'dIId Ihi rider iI 10 _ doubt .. lhI dIIogo Ie bIIed on .... prIrTIIIIl .... IIIe rider wiIIltay in'he ~ _ed poIItlOf'l during anll::Ciclenl. end the cnsI'I bIr .INCI .... .... not iIMfllti. Neolhlt rMlAt can in InV w~ be "u...."'.... .... I e-nerel f\IIe. etways ~ the but. III ......-ltv the In»I I>
"'*'

Exhaust systems The fiH"'II 01 ,hlJnnlfl<et ........, .....1...... ;.; _hit ............. popuAIr PMI .... IrTIOngII moIorqdela. The -....I motiIIe Is 10 ""' more ~ from I'" engine but 01 ..... COnIM:IetaIioni ... to P" more ground ~ 10 .... weoght from the motorcyde, 10 obtain I more dliIIflClIII ..........1 noll or 10 lind • cheepef "temat;"1 to lhe menufecl ....... 'or9nei equipmenl e~hIuII .....t..... 0rlgineI equipment ... hIu5l Iytlem, Ohln COllI more Ind may wen "-,,•• IlNli\le!y IhotI Iif • • It .hould be noled IMI ~ Ie .... lor .n merirel e.hIu5t .yst..... alone 10 gMI I notlceebIe inc_ In thl POWe' OIIIput. Modern rnototcyCIeI ... de&igned 10 go;...e the highesl pOW ... (lUlpU' ~ ~ lor leclotl such .. quieI_ 1Ulli1llXlnClmy.1IQId 01 powet. snd IIon(t-Ierm ~.If I........... rn.sgoc: Ionnu6I whoch &lowed lhe I>
I"...'"'11',.'.

Pott

~0I1hii

Ihlw1'IoIe~inllfMldetail.

WhlI ...... yoo..- moiNe lot w;stung .0 fll. .... IIIIm11i11t ..neu.1 sysl ..... be ..... 10 . . . I><......., .YSlem manufecturtlr " ... centI01 IUPPIv . . quate/v specrfic InlotmahOIl ~ it reetOntbIe 10 lllSUms IhIIll"llulfidenl deveIopmenl wort t>H been cerried (IU~ and 1....1 particular mlk' should be l\fOIded . 01 .... fectotl to be borne In mind ere wtlethe. ,''' 1.1'IIuI1 .ysl..... slow. the .... 01 both cen!.. Ind .1de.\Inds. whll ....

ChOOIJlng .nd fitting .ee."

• tIIIows lUlf'oc_t _ _ 10 pe<xtly, 'PIIC8fS mult be IIItn;.tl!l to Ulk. up the d,ff....-. 00 not lorc:e IhI rylllmirtlo pIIee .. thl"'IMthus ~ will '1PidIY -... CllCki 8nd lPIits 10 a.ppea, ()nr;e .11 the mount'"", ... IooMIy I",Id, tighllr'l Ille ' Itllning nutl Of bolt' secu.eIy. be,,,!! c".luI nol 10 o"'rtight'n lhem. WhIt.. themoton;yo;le """""lac"..."", IOfqol lett'"", ........ ita· bIe. IhIM Ihould bt used. Do nol IOf""t to c.ny out .ny Cl
_"I\'IIo....

-'II'.

Electrical equipment The .....1 'Jnge 01 ellClricIIlqUOprnetll ....1iIMlII 10 motorcyclisll is 10 IIrge 8nd so dMIrM thll only Ihi n'IO&t genonI OUt ..... CIIl bellJ'lll" ...... ElIClricIIlCCeUOrioIs ...1t'y kom eleclfONo; ignouon b" "ned to replace contlCl bouklf poonts, 10 llddilionil lightng .1 the I.onl II'Id _. _ poweon.. YIricJuI . .I .......... " Ind gM'II'ft. docl .. ..-II-Iheft IVlI ........... tl!l dott.ng. CB rIdioI., radio)..QosMtl. ~ 8nd inllfroll'\ SVlI ....... 10 name but •• ew 01 the more POPUt.< It.,..... 01

--,.

or;"

13

'1QW1I' MpaOf." .........

AI will be otYICIInt, it would 10 COIIIt 11>01 ...t.,ect alone Ind I.... uc:1IOn islhe<"O
lhe lCCeuorift you ......;u. 10 fiL The molorcycle', mlnUflCtUfIf Of importe< IhouId belblllo fumi'" Imoon 01 inlonnllion II'Id mIV Il1o be able 10off.. 1dv1Cl on uprltiflg tile electrical .ystlll'l'l. F"~ng ttv... good dealltO< Ille acclllOfY mlnUflCl...-e< mIV be.bIe 10 help. In some c.ses. powerful ""nefitOf c:omponlr'lll may be,vIJilable, perhllM I.om ITIOI ..... molOfCyo;le in ltie .......... ICI...-..... tinge. T.... MCOnd considerll;on .. I.... """lIQuor...... nll in fcw-ce In your ..... T.... IocII I)OIir;e mIV be p".pe.1d 10 help with Ihis point. In lhe UK IOf ulf1lIlIe. ther...1 llric:t 'III;lIMI_lIOIIIftIInQ the OQS4I;on end ... of lUlClIiIry nr:ting iIm9Iend tampa. When lill"'ll lilclricll ~ IIwIyJ disconnIc:l lhe bill..... (..sIlO ~ the nsIo 0I11ho
mot.

.og

a..

Accessories general A.cce&J.oriII 11I1er:!to you< molorcycle wi. flpodly dIIeriorlll

~

not

_eel ' Of. Regout.< wlllhong end polishing will ma,nllin the finish 8nd wlII provide ... OppOf!unrly 10 chKt tNtl eI moun",,!! boIIJ end nul. . . . uc:UfI/y '' '1.....:1. Aff't IIgnI 01 chafing Of W.... IhouId bewlltr;hed lor. 8nd lhe _ _ CutId .. 1OOtI . . poMibIe beiorelll'ioul ~ occur.. AI. genet.. lUll. do not "PlCI the ...... v..... 01 your moIon:.,.:II 10 increIIe by ... IrTIOUf'II proponionll 10 lhe _ of money end etlOfl put 1n10 (111"'11 _ _ h • ........., Illeelll!hll an IbeoIullly IIIT1d1rd moton:yc!e wllill motI eMily II. bellir price thin _ t.... t hili bIItr modified. II you III in I .... heOO of uo:hingong your maoo:hine lor ITIOt ..... II frequent inl .......... lhol flCtor IhouId be borne in tTIInd 10 IVOid loA 01 money

Fault diagnosis

,.-

~orpintong

.. ""_w~'~~~~~ No~.~pIuojj

Abnormal noise Clutch nolle transmiSSIOn ._, _____________ _ T..",miuion nolle ,_,_,_"_,_, __ ,.,,,_

W .... II!W1<.tp!ug

Com".....,,,,,, Engine stalls (fft8f stBrting

Exhaust smokes IJxcoS$ive/y

~*~~----------------------

,

Poor running at idle and low speed w... 1\ plug or .... IOC IIriI'Ig _ __

Fuel.iK

""

incon':~~~=====::­

"""'t..... _ ~Iow

........---------------AcceJerstiOn poor

Knocking or pinking

a - . I cause. __ .______________

Flfinglnc:omlcl_~~~~~~~~~;== c._

F......... ,.,;,.I"'.~t

Clutdl-'ip -=============

Jot 35

~vibr'~Of--'t"

311

"

Poor lront fork p t I r l _ front fork;uddlf wt.l tw.mg

37

""

Abnormal frame and suspttflsion noise frorlllnd nooN

40

16

Brake problems

.,

Rur_PtntiOn noise __________________ .

drum brak..

o.um Brall brKI induc:..:I fork judder

"

Gear selection problems

..

Jumping OUI 01(168< ~ .• _ ... _._ .. _. __ .. __ .~_._.~." __ ~._".* *."

tolhe_common

IOlryand_-'l_"""'""'WQI,OIo;I~.b9ok.lnOMd,.numbtr t..v. bMn wrltI... on ~

s..-eufull.ull ~ ;. not • """,'eriow 'bIKk .rI' bo.n. It. ~Ion 01 • bit 01 knowledge ~ wi\tl • JY1ltfN1OC and

...,.."" .." os

52

25

floUftllhM _ ~k"" \0 8ffiict VOlW~. 0tr0ti0uIIy. , .... oppotIuno~ ... 1IImoIt lirnitleu for f8UIU IOOOCUt • • r-..tI of obKur. t....... and

41

.."""

~!

Inlroducllon

u..

38 39

Poor_~ptIrl_

dilc:br•• " D*:brlk.noiM " ~t.:.:.c::_=O,,=.. c..... ;::O..;::;_O '"" =:::::=noiM.-;;;;;;:::====:-_

"

Cluldldr-u _

TlWS«IIon~..,..,.referenc~

33

Poor handling or roadholding

lI<.k. . _~Of .... fflCt...

Clutch optff3ting problems

I

32

BlKk amokllCM>Md by O\I . .·rich mlXI .....)

1Iq. . '-".. Of ~

llltltahon ~I' M____

30

"

Whntlblue ....01<. teao.4fd by oil bvmingl________

Btlk. . . . lpongy Of InetflCtivtl diIc btli
OvttfheBtmg

"" "

OotKIionIII"'-t8biloly_.. St...-g bIN 10 110ft Of right

"

g: ~~=;;,I:':~:::"'."":;:-------

~~~:====::--=-=-

PistOl'! tJap or rIIu\ong from cyIinde< ... OI ..... ~

F..... not ...,;hong cyInder Engine IIooding

"*"

"

Abnormal eng,ne flO/58

Engine dotJs not start when tumed ov~

Iogir.ll 89PfOIICh to tt.. ~m. Approsd> "''1' f.ull ~ by Ilrst _ _ tely Identifying tt.. Iymptom and then checlo"" thtough tt..list of pouible - - . ttsrtlllg with It.. simplest 01 ..--t ~ and progrnaing In I~ to lhe..--t compIp. Tik. nothing for Wl"'tld, but tobO\Ie "IIIIPIY liblrel qusnw. of COITVTIOII _ . Ths ..... Iymplom of • 1M ;. grven In It.. 1_ .. I ""'tOf hNdIng below which _ SlCtion hNdingt, m. v"""- .....t _ Of ..... whdI mIy contIin m. 1Nt. oI..ctI ~ (;10M 101 • 1M and the ~ ICtoon to III tIkIn _ ~ In brill. In the ~ below NCh SlCtion IIudIng. furthlr in!OfTJ\Itoon should III IiOUQhI in the ........"t Chipt ...

""lid, ..

o.n.

hult diagnosis

Engine doe. not st.rt when turned oller 2

5

Nofl>elflo.. IO~"or

w..

• F..... """ 0I1itt.. blocked, ~ rmv bIo ..... 10 KCUmUletron 01 ....1 Of PIonI ftII<. hom the tanIr'. inner owrI-.;e Of 0110<. . . . .uer lrom OXInI........ ted 1..... 1\emoIIio the tap and c ..... 01 and the loIt ... Look .-010< ...1., droplet, in lhe I..... • Fuel PIpe blocked 8Ioc:UQe 01 lhe I..... pope" more tilltty 10 ...... from I kinl in lhe pope ..11wIf thin the ICC ..........."on of debN.

3

F... I not , . .c hing cylinde.

• FIof,I chImbet not filling. c.....ed by no.t ~ 0< 1\011:1 ttocking in till P05Itk1n. Thil rmv occur the ~ .... ' - " lett ftIIn(hng 10< an lIC'Iended Ierlgth 01 Irme IIIcrw'tng lhe I..... 10 evaporlt •. When IhiI occurs • gunvny ....0... if, ohen left whoch "-denI 10 , " .........Iike 1UbI_. c:ordtoon rmv bIo WOO'-.d by c.O
,h.

--

no..

temOY"

• 810cklgeln lI1'1ing c;,.;",!, slow running cilWll 0< \Ita. Blocklgl 01 lheM II ..... rmv bIo .ttributable 10 debntl trom lhe iuellink by.plNing ,he rolter ..... t.m 0< to gummIng UP" deIc,ibed In I*IIQ. ,. Waler droplet, in lhe I..... wi. Il1o block jell and pe'SIgft. The Cll'buretlOl IhouId be di ........ lled 10< clHning. • Fuel level 100 low The fuel lev. in the lloal chembl.1I conlrolled by /I0Il1 he;ghl, The rmv onr;,.... w,lh wee< 01 <*nIge bul wi • IhrA.1ow fuel ......... an .......... I .. the< than ~ o;:ondrtoon CIMock lhe /I0Il1 herght. ...-.ng lhe /I0Il1 01 ...edle if ...

....

........ ..ooce.

•E,..

• Ignruon 1""lch 001 on.

• Fuel lank MlIPtvor level 100 low. CIMock 1M! the tap .lumId 10'On' OI'FlueN" poIIhOn ...equOred " ir'I doubt. pnM oft lhe luellfNtd pipe .llhe Clrburluorltl'ld and check lhet fuel ru .... from,1'Ie PIpe when lhe 1111 Is lu"'ed on • T... liller ClI' "en, obItruc,ed, This Cln pr.... enl Ii.... hom flowing inlO the CI,txwettor IIof,I cl'lembel' beCIoAe ,if cannot enter the luel lank to.~ It. The p
-

"

Nosplf'lrllplug

'\III .......

til SWllch ofl • Fuse blown. Selwwrng dillgrlm. 01. • SsHrt plug dirty. OIled or louled. BeCluse lhe induction IWCHlrok. """'" '-Inclined to be 01 • ralhe. oily NIIu" it • COI'Il\*"Itively ...... 10 fout the plug eleclrodes. .. pecilily whe .. tlwlf. hIv. been Ittempll to 111<1 the eng,ne. A mechlne used 10< Ihort joornevs _ bIo ,,-. prone to louting beCIouIe lhe e<>gI .... rmv ........ I"MCh lui opeqllng 1.....,...11...... and the depoM, wiN not bum 011 . On ....~. c ..... 01 plug gr..:Io rmv be reQUi<ed bul lhe II<Mce of • _ .toouId be -.ght befoUJMoon on lhe_1 0I1ouIing problems. • SpIrt plug I........ Clean 1'- ~ plug thoroughI'( and _ lhe elecUodoI gIP. Ref. to lhe ~ plug section in Roubne _ I f the~ plug Ihortf; in*,*", 0< .... _timed .....tIle <*nIge 10 It. .tecuodes. COI1I 0< cerImIr; ......10< II IhouId bIo .......ci. On ...... _ I plug lhel ~ 10 t.pIrt ..-igorouIty ... 111110 do 10 wI\erI 10 lhe ~ end IUbflcled 10 It. c:ompteMIOII preIIUf"I in the cyInder. • SpIrt plug CIllO< high t...,.;on !Hn teed I..... ty. CIMock o;:onditoon end secun,y. RepIece 1/ deleriOtllron '- widenl. MOIl IPIrt plug CIPI hev. In in' .....1 resislo< designed to inhibit eIecIl1cIIlnlerf.rence wlth fedio Ind television set •. On . ... OCCMoon. the ,"'-tOl mlV breek down. t""pr....."ting If)IrtJng. 11th.. '- luspected, Iii II . - Clp " I ~I ion. • Spert plug Clp 100M, ChecIt Ilwrt the tpII1r. plug CIP fill sec ........ 0\11" the plug end. where Ilttld. lhe tcrewell termini! on the plug end Is

mi.,,,,.

"""ted

..r",ed

~.

• Shortrng due 10 moosl ..... Ceruin peril of the Ignitoon ..... tem ... 1UICeP"" 10 Ihortrng ........ lhe mKhinI • ridden or pertced in _ I _!her. ChecIt pII1ic"""'" the _ from the tpII1r. plug CIP btck to the ;gnrtoon coil A ...ter ~I ~ rmv be \lied to dry out ..., .logged torrIP'OI*'llI. Reco.Ir....-oce 01 the problem can bIo jIfIIIe
• Ignrtron 0< engine krI IWllch Ihorted. MII'f be ~ by Wfl .. or weer Wit., ~1 1nd contacl d6Inong."...,. rmv be used II lhil I .... 10 overa:rrM the pn>bIem dismanlling and ........ inIpec:'ron 01 lhe.WIlC.... wiI be reQUired. • ShortJng or 0I)In el..:u.1 in wifrng failure in Iny wire connecting any of IhI!gnrtoon comPOl*1I1 will CIUM Ignolion maHun(lion. Check Il1O thai III connectront I •• cletn, dry and l !gln. • Ign'toon o;ooIlail ..... ChecIt lhe coil. ",f"";ng 10 • CDI U.... II .... IV

I;lOITOIOOII

ChIp,., ...

• Feebil IPI"""IJ II the plug rmv be - - ' by ...... 01 the I....,. ........... ooned on the po-lCg the mot! ' kitty cutprit

".Ive

• !'1oI, needIII wom OIlIuck CJP8'"I< A prec:e 01 lUll 01 otlwlf debN can po-_nl COIrecl lU"ng oIlhe needle JOIinIl the v,tv. MIl ,he.eby pe'""'t,,,,,, .n unconlrolled flow 01 ,..... S<mll.I1V•• wom needle 0< needle .... t WIll prevenl valv. cIoIur •. OtsmIntt. the Clrbu'lttOl flolIl thembel' for ciNnlng and, if _ r y , _WIt 01 the wom compo-'II. • fuel ...... 100 Ngh. The fuel level .. conlrolled by the III»t he9>1 whodI mly ItICfuH ..... 10 _ 01 the 111»1 ...edII. pivol poll 01 opeqh'>g tlt>g- CIMock the b l herght. and mMe ...... nec-v edJUStmen!II.Aillltingllolt wiII_ an nco- on I........... and u...

...............

• CokIIIIect the choIr;. til..,. ~ lor correcl ~oon If the ~ jIms on !tie 'On' poI#\oon ...... quent IIl11ing 01 • hot . . . . . wiI bIo d,fI"ocutt • BIocted .... fit. A bIdIV rMlflCIed ... filter ... ClUMlfIooding. CIMock the filter end dun o r . -. . req";'ed. A coI8pMd onIet hoM wi ........ I .......... effecl. CIMoct lhellhe ... Iitt.. inlet hal 001 become blocked by • .eg or similar ;1....,

1 COmp'....1on low

• SsHrt plug 100M. T.... wiI be oeIf...-.nden1 on inlpe(:11OII, and n'III'f be ICCQmI)Inred by ...... ng noiM when the en.g;... ilr lurned 0\11". Rem<J\/'I the plug Ind check tM! the tlvNdl in the ~ held ... not dIn"IIgId. CIMock eIto tn.t the plug MIIing w ....... in IPJd condihon. • Cylinder held gIIket INking. T"" c:oncMion. otten.,.;omplAied bv , hogh pitched IqUMII; from IfOInI the cylinder hied and oIIloe1, - ' rmv be -.-d by ~tlV tighlened cylinder hied I..t _ I wwped cyIindrIt held 0< ~ I..... of Ihi gIIket mlierili.

Re-I~ the f'''_10 the oorrect specif\Cltoon rmv MIl the INI< in ..... i n I _ bul If dImIge .... oc:c:....-..IlhiI-..... of lC1ion wII

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hult di-onosil • R«IuoId , .... flow II reduc:uon in the maunum fuM flow from the futI c.nk to the Ci
.... "

ro MiK.......-.C....... • RIKIieIOt filii dogged. Accumulated debris in the radlalO1' ~ will gr.clually ' ..:!UCI III abiliTy 10 dis.ipa tl heat generlted bV , .... tnQ'lIO. It is worth no1lng that during lIMo IUmm6r motIlhil dead can ~M .......ny lI"oblemi in 'hi....peel" road d in and mud duoing the wIn,.,.. Cleaning ia tlftl _lied out by dIIIodging the debnI wlll"l. hlQl'l II"IIUUrft I - . from lhe b.,;k of ,he .1d..101'. Once cleaned it • worth lhe

in....,,,

paoli'' ' '

Knocking or pinking

"""riwWI\h .'-t~t mMt ~ ,*,,1 boll> '0_1 cnoIino-

topr ..."", . ., ...... oooro.lon. T"'fi\\lngof_lOtIofmn.h~rdwili help Pfav«It ,he finl lrom ~ dogged. but male, ...... Ihal , .... daMno! itMIf ~ ~.cooIing.

G......ICWIM

• CMIon build""" in oombuillOl'l cNtntNw. "her high ........ have bNn-.d. a.rge acc""""',oon of ewbotI may OCCU' T.... mav vkrad hoi and _ _ cnn'IIture igniIion of lh111uM'a1< mOO .... in 1Idv~ of I'l0l' ..... firin8 by the apart plug. CyIinde< hud . - - ' wtI be _rwd to -'low inspection and cleaning. • Fuel ~I. A low grede fuel. Of one of poor quality may N&Uh in wmp ...1ion Induced deiORelion of the fuel , ...,ltiflg in knockIng and pinLng noises. Old fuel UtI U
Fuel/air mlxt ..... Inc:Of'ect

• "It

be <eQUired.

rrh .. bIdIv litted Of omolled. O>eck tnII Ille fiI, ..........., ;. in pIKe and lilli, and ,he ...ur.!. lilter 110. cove< er.....rng OOIfeclly. Arrf _1 _ _it.WNltmi.I • Induc,ion 10.....a. O>eck lhe ..,;urirv 0 1 the t;erbure\IOf mounli. . and hoM COMICliona, and lor erae ... and IJI/ill in lhe '-n. ChICk &Ito IlIItlhe CII.bu.. nOf lOP it; ..,;ure. • Fuel level 100 low. See Section 3. • Fuel I..... k lillerCilp lit ""'" oborllUC,ed. C\eer bIoo;I!lg4I.

"

Clutch IIIlp

• No cknctllev.. play. Ad)"'1 clulCtl "",,,. end ~ KCQrd",O 10 lhe procedu.e In Rouu ... mainlenance. • Fnctlon pial" wom Of wa.ped. Oveffiltrl clulttl ..sembly ••e-piKing pial" OUI of epeelfallon. • PIa", pial" worn Of werped. 0vert\IuI clutttl -..b/y. ~ing pial" OUI of epeci!allOO. • Cluten sp
RouI ..... "....,_.

• Outen innetcable snIo(IIgIng. CeuIed by .I~ cable Of kJnIcedoul. cable. A _ tile cable. Repw 01 el~ no'lCknMd. • Outen ....... mec:1IeniIm deleeuve.. Wom Of derneged I*tIr in tile clutch ....... mec: ........... could include 11le1ift"'ll ....... """"' IfN'inII Of l>U$hood. nec.....-y • Outetl """ .. &rid out.. d""" worn. Severe IndenliliOn by lhe clulctl plale 'angII 01 tllecl\lnntl.1n lhecent<.&rId drum ceu.. ..-.g.gongol Ille piaU" Pf......ling OOI".eet engegement. 1/ Ih" !Ie..... occ:ura. .enewal oIlhe worn componenl. "required. • Lubric&rltlnc:Of.ltCl. UN of. 1' ....,.,iuO'r Iubo";c.nl Olhe< It\In 11111 SPeCIfied ..,.., ellow lhe pilI" 10 tlip .

wi.

Clutch d.eg

• Slow - " " """'...... t<ength incooTec:t. AdjuII plot . . _ _ • M..-1 itt wrong ..... The QIbuIettOf II jetled lor _ level et· ...-pIlIIric: condiI_ For h;gh 1M...... ~ ~ 5000 tt. • ......... mIIin jet wIM

"

'*-'*', ..

Fiflng incOf'K'

• ~.k plug fouled. deleet''''' Of rTlltedrusled. See Sec:toon 5. • ~.k plug lypelnc:oflOCI. Ael .. lo lhe Spec:ifrcallOfllend en&ufl lhal tile OOI"..,;:t piug Iype It filled. • fncolfoctignltion IJtrurrg See Chepler 4.

..

Clutch ~'.ting problems

'*>Ie.

Ove,hNling

"

•...........on oil 10 btl dr.wn in10 the crricaM
Comp'.1I1on low

• SeeSec:IOO 1.

..

...

17

~

LLtbricellon~1I

_.,Ile QUIll"''''

• Oil pump "II""", Inoooec,. The oil pump "II""", .... 01 11'"' ImportIACll of oil bwrg injeCled ... ....., ....... Arrf ....... 00II In 01 delivery wIM hr<e e tigrIoticent effecl "'" ,Ile . . . . . ReI .. 10 Chlrpt.. 3 lor further Inlom'rl\iorl. • Oil ...... empty Of low. TIIiI d I\IrYe "'1..".. COI'IMoqIMIC&I II left unnotICed. CIIedr: IOd replenish I r i reguIetty • T ~ oil low Of worn out. O>eck Ille lev .. . eguIerIv and inV"ligoIrli any loa Oil oil 11 Ille oil level ~ W;lh 01 •• lemaI INkllll\t h II likely Ihil lhe CQr'Iksheft mtin bNring oiIlfI&II ..e worn.

no.

" ........,

• CIu,ch IeWf

.-v ."......... AdIUf1 lever 1\ b¥I Of .1 cable end II

• Clulch pUln _pad Of demeged. ThiI d _ _ • dtag "'" Ille cIu'd\ C&UWIg tile n'IIrchont 10<;tMp. 0vert\IuI clutch HHmbIV • Dutch IIj)fing , _ _ . u....IIy o;NMd by. legged Ofbfolr;.., -pring

Chec:~

-..cI . _ """""" .......,

".namiNIon

• T _ i o n oil del..."..ted. a.dIy oont........,ed oil and • Ileavy depoail Oil oil tIudgre on lhe pYl.,. wi. _ plal. IIlCklng. The oil .ecommended lor 11"1 rnechi ... " 0 1 the delergenl type. Iller.· 1"",.,;, unlikely 11111 Ihil problem wi" &rid "",", " 'Ollia. 011 ~rnrngn ereneglec:ted • T .....,.,it;.ion oil viloololy 100 high. Drag in lhe pla,.. will •.-.11 hom 11le ..... Oil.., oil W,lh 100 I,;gh. 'f1ICOeity. Itr 'I'&t\I cold _Ihe< Clulch (keg "'IV oc:cut unt~ Ille ""Il'Ol 11M leeched opetelong lemperalure. • aul<;:h eonl.. and OUI. dtum worn. indenliloon by 1l1li clulen pUl. tengI Oil ,''' choer>neIIln the _ t .. and drum .wi ~, _y pUll ~L II lhe demIrge II !oght the effecled ..... ..,.., be dressed _h I r... He. Mottr ptOf>I)Uf>C«I d8fnIge d ~I'" '_"OiIthe~ ...

• Dutttl out.. dtum Mited 10 Ihett. Leek of tubriClltron,. _ _ _ Of d8fn1gecen_ lhedrum to ..... to the ""It. 0vemIuI dIlle dutch. and p8fhepIlht ,,.........,,.., "'IV be necessetV 10 repa .. damege. • CIu,ch , ...... meo;hanoem delOCI""," Wom Of dlmIged . IINM rMd\IniIm pan,. CIn .Ilck &rid lIiIIO p
-,.

notl,

"

• ' - - dutcl'l ,.n. c.- drum tnd cent.. miNhgnme"t, putl....., .. drag on , .... engo ..... e~1 Mlj ... lmenI c:onlonually .... , . Over-

AbnormlJ/engine noise

haul cluIch auembIy

"

Gu, ulfICtion problflms 21

• s..s.c\lOn 16

G.., kv .. ctoe. not .. tum

'*- m.1I(Inng.

or...-.

• WuIc or btot ... fWlum sprong. • GNrc..... .n.tI bent 0...",_ 01 ..... ~ shell ott... oocuno if the dn:IppId huority on the IJNI' ........ ~ thM ct.mIogt" not of the ....h is petmI$-

-

KnockingOlpu;l;lng

"*'-" ..

-.11•••"1'.,......

"

Piltoro . . . 01 •• tllIng from cyllnd..

Cy\ond;Ir bor"'IWIO<1 dMrwIu _ pwu.I ........ ThiI oondot;on Ron ott ... be •

_Ie

24 0... HlKtIon diftk:uh or impM.ibIe • Outdlnol ~ lully.

hom ... _. 01

....

s.. Steuon 22.

• a..rchlnge - " " ben!. Th .. oft.., oox .... iI' tIM I'MCIIine i& drowed he.1IiIy on the gNI' leve<, S".I"I'II.,I"" (It tM lhah is pem'lillible If the a.m.g. It not 100 ",Nt. ~""nge 1Wm0t pins - . , or damaged. W_ or btuQgeof theM II ..... ""'Y _ dilli(:uhy in "*tong one Of fTIOf1I geatl. Ovemaul\ ....

•

..lector meoctwoni ...., • Selec:lor drum !Itt.." I.m dImIoged. Flilu ••. 'lThet ,"'" we .. "'ltV 110m the df",", 111..-,.., Pf_ung gNfchlong,ng or CIUIing false MIIc,;on high tPMd.

I'

~"'"

,-;;I •• high, -.pod '-'II corr.o;t-..

noiM""""""he . . . . . . under~I ... OInoko;d. ~iQMfty_~ ",..t begonIw>g to be 1PPied· Rebonng 10 the ...., IhoukI be CIITIId 0l.Il .,1(1, new PIIItOll fiulll • ConnecI"",1OcI bent T'- QII be c.IUMd by _ . .-wong. toying", .tIg' beril c:onnec:ting rod .... not ,toommended C...1uI ~I;on 01 !hi CfII'lItshI;ft IhouId be midi bel
'*'

• SeleeIOt fort, bent or Hlzed. Thia be cauMd bv df'OPl)'''II the rnactw. heavily on the gN
• Gudgeon pOll. PIllion boa bore 01 pnf/I..-.d bNrInII ........ or . .nn beIM c"',-, 01 bet ......, notmlil moving pans d theM It ..... .,." _ _ ctlnt.nuo:Ka or ~lIrmi1lenl tlll\lU"l(j ....,.... AIpid ....,.. 01 ..,;"'.. ;. CIUMd by lubncltion II_,iOn • Pl$ton ri"IP worn. btoken or . ,;;:k;"II R_w the nng. after QfefuI 'nspecbon 01 lhe PlStO<1 'M ~ .

1*""1'" ..."'..

" 0""... _

u.~inll'le~drumc.nIudIO~MIeo;llOnlf\d,

• 8;g-tnd 1Ieanog ....... A pronounced knock hom ... ,tkln the crri· c.. which _ _ _ .ap;dly illndlclt",. 0I1);g-end bMMg I........... r-..tt of eKI • .,... notmII_ OIIubriC1iI;on IlOIure. Remer:IoIiI..:tJOn .. lhe loon 01 • bottom end ~ IhouId be ~ .... cont,nuoftg to lUll lhe wog;ne will INd 10 Iut1het ciImIgI IncIudong the pouiboI;ty
'

connec:tinU lOcI brMIi;• • • Main bMn"II f...... Ext...... no<mIII _

'*'

lubritellon. Though ,ar.. bendIr>g of .. WI, r-..II from .. mI$Md ge.rc...... or ,.... selection II hogh ~. • Selector fort end tnd pin _ Pronounced _ of , , - it..... rd

_"UIIIty. no MlKlion. A..-aI of the worn c:omponentl will be

.......

"'Iion

• Slrucnnl lltilufe. f ...... 01..., one component 011 .... oeIIctor rod ..-.d chIongIo mechanWro.vil tMUIt In Imptoptor Of 1"""'-'1 gNI'

• Del","...., -..bIy worn or~' W_ of IN Mm tnd !he ~ wolh which it 1Dc:Io,.. 1tnd twlllllegto of ,......,""' sprong c.n _ _ impnoc:. . gotar '-':110" I'MI>It.ong in iurnPonQ OUI 01 gMr. A _ "'"

• GMr p;n;on aog. worn Roo.ndIng oft the dog odgIIII.-.d --~ the mMlng . - In MlIK*'I pillion INd 10 .... , of gear 01 ~.

Ron

~

when under !oed. The ~ IhouId be intp«1ed ..-d ..--.cI. AItempting 10 .-prof.,he dogIiI no! , _ , • Selec:IOI lon. .. drum end pinion IIfOCI'Y'" worn. Exl...,... _ of t ' Inten:onoec:led It..... c.n 0CCUf .tl" hogh .......,.. ~ wI1ett lubrical;on .... bHn neglec;IMI. The _ n C()InpDniIflIl iTIUIt be . .

.,,,,oded

-". • <>-

pinion-. bv"- end an.tlli worn. R _ lhe wom component.. • Benl llN'Chenge ""'1. Ollen c:au..d by d,opp;ng the machineO<1 th41 goarlev ... pinion lOOth btok .... ChipJM(l tMth .... unli~e/y 10 _ jump.. Ing out 01 gNi" lhe~. '"'- bHn ulecled lutly:. looth which I. ;;:ompiete/y btoken olf. however. rney _ _ ~ In th .. 'espe;;:t IfId In I
• a.a,

onc:, _ I

01 I...... of lhe ..... ~ilct.liCl_taIV~by'''''''''''romtheald·

c..1fId 1IiltM;on .... through lhe 1...... 1fId

*_ ReNw 1101_

c""kIhIft. • C
~IndClllryout.very~l~trOnoilhe

.,.".,·.-wongOl ~Irom ... ....,... cyI;ndoM COOIporoetII orguttD. I...... 0ImIge ..... .-. r--'t lrom dtopp;nog the ........:/'Ioow on ..",., ~ftlnd SIfaIghI....-gol theCl"lnbhlh .. not ~innortnll dm.n>I_ _ I~1 n.... 1houId be rt'llMl • E<9nI mounl"'lliooM Tlghttn .. lhe tngone mClUnt.ng nutS Ind

......

• Cylindir lINd ~1I1ealong. The _ _ ....,., oft... _ M l ........ IiNU>g lINd ~tt II • hogh pnc:hli:f 1QUUIIiflG. -"hough ..., 00noiIe COIWdlent filii being loreed out unde< Il'ftSUfe lrom ....... onfiat ..... 11.0 be emitted. Glsliet INt. . . oft ... ~ by 01 ~ I..-orn IouId be looIi:ecllor

Wi'"

:

;

Ii I

Abnormal trlJnsmission noise

" ""'''' ..... • Clutch outer drvnVfnctlOtl pille "'''' c:IMr...ce ... ~ • Clutch OUI. drumiItvuIl ......... clIIr..- e><~

• PrirrIIoydrM gIIf IM"'''''''''OI~.

'-

"

31

Trln'min ion noi..

• BeMing Of bu.Ms worn or damaged. R_w lhe , ' fKled component•. • Gear pioionl worn Of chipped. R_w the go.. piniont.. • Metll chips jammed in gelr teeth. Th;' C{Itl occur when I)iecft of melli /rom any ' ailed comPOnent are pio;kod UP by • mHhing pinion. lead 10 rapid bearing _ I f Of . .rty 110" f.~ure. The condition • Tf.""",il.ion oil level too low. Top up immedi".1y to p<eVtln! damaoe 10 go, rbo" and engine. • Q<. ahouId be laken without delr,l. • Chain magging on Of cycle p.lltU. A!»dly worn chain or one thin is • • CflSliwlly loose ..... y ItIa9 Of smack "!IIIin" ad~nt compoMm •.

wi"

-=-

_1

Exhaus t smokes flKCflssivflly n

WhlltlblUI .moh !CluHd by all burningl

• Oil pump H llingl incotTec1. C'-k and ,,,"I tho oil pump n delCribed ion ChapUtf 3. • C'.""shaft main bufing oil Hal. worn. Wear in the main bearing oil leals. often in coojunclion wnh wear in tile be.ringI themHlves. can .lIow tr-",,"ion oil to find ill way intO the cr,nI
33

Black s moh!cauHd by ....... ·rlch mixture)

• Ai. filte. element clogged. Clean or renew tho! Ilement. • Main jet loose or too Ia.~. Remove the Oo.t chamber to check for tightnfl" of the jet. If the machlnfl is used 1\ hlOh altitudel rejening w ill be .equlfed 10 compensata for the lower .tmospheric pressure. • Cold Itan mechan,sm j.rImrned on. Check lhal the mechanism wof.eetly. • Fuel level tOO high. The fuel level is c:ontrolled by the I~t he'ght wt.;ch can inc_ " . rnult 01 wear or dama!Ie. Remove tho! floilt chamber and check lhe flo&t heighl. Check also lhat fIoati have not punctured; a punctured Ilo&t will lose buoyancy and allow an increased luallevel. • Float valve needle Sh ICk open. C&used by din or a wom valve. Clean tho! fIoet ch.mberor renew the needlaand. if neceSlllry. the vaN. luI.

Poor handling or roadholding 34

Oi •.., llonal lnl tability

• St_,ng head bearing adlustmenl 100 tight. Thi. will cause roIlil'lg or weaving at low lpeedS. Re·adjust the bearinQI. • St_ing head be."ng worn or d&maged. Correct adjustment 01 the ba&ring w ill PfO"e impossible 10 achieve 1/ w Ur or dlmage hili occu.red. lnconsistent handling will occu' including rolling or weaving at low speed and poor di.eetional control.1 indewminall higher lj)8eds. The lleering head be.ring lhould be dilmantled lor inspect;';'" and ~ ~ requlfed. lubr'icat;';'" Iohould 1110 be carried out. • Bearing races pined or d""ted. Impact damage caused. Plfhapa. by ron accident or .iding 011 .. a pot·hoIe can cause Indent.t;';'" 01 the bearing. .......11y in one position. Thil lhould be noled II notct>inesa when the handlebers are tumed. Renflw and lubricate the bearings.

• Steering Item bent. This witl OCCU' ontv lllhe machine .. IUbjected to a high impact .uch .. hlll,ng. ke9SlbushM worn. OiHicul1V in holding linfl. paflicularly when comerlng or when chlng'ng power MlII"'QI indicat. w .... in the bearings or bu&heI. The IW'ngtng arm/Ionkage 5houId be removed Irom the machine and the buflngsibu"'- renflwed. • Swinging arm filMing. The ,ymploml giv"" in the precedirlll pal'agntph wiM allO OCCtr. if the ,,.,inging arm fO<1< nun bat:IIy. This can be caused by Ilruccu..1wuknass&l' result of COfroaion. Isugue or Impact damage. or becau.. the ... r wc-t ,prndle illiack. • WMeI bearingt worn. R _ lhe wom bearings. • loo&e WMeIIpO\c" OT model. Tho! apot.:01 thould be tightened evenly to ma'ntain t-.on and I~ 01 the rim. • Ty,es uf\IUitabie for machinfl. Not 811 .... ailable tv," w;illtrit the ch.&racterisltCI of the Irame and _pension. indeed. some ty ... or tyre combinallonl may ca .... I tr/lllSlorma!ion in lhe handhng characteris· tics. 1/ harldllng problems OCCur Immediately liter Charllling to • new tv •• type or make . . .....n to the orig,nal IVr" to ' " whether .n improvement c"" be noted. In some ;",1_ 1 chlnge 10 what Ire, In lact, suitable IV'" may give rile to handling deflcienciat.ln Ihis C&II a thorough check lhould be made of all Irlme and suspension lie ..... which aHeet.lability.

35

StHring bl.l to left Of .Ight

• Rllr wc-t out oI.lignment. Caused by unflven adjustment 01 ehairr tentione< ..:fju$lers lilowing the whee! 10 be asl<ew In lhe 10<1< endl. A bent rea< wheel spindle w~1 also milll;gn the wc-t In the sWIf"9ng arm. • Wheell out 01 alignment. Th" can be clused by impact damage to tho! f....... 5w'''IIing a'm. wheel spindle, or front 10<1<s. Although occasionally .......It of male"'l failure Of «>frosion il Is usually 81 I ,"ult 01 ac ....h. • Front 10000Itwifted in the lIf/efing vo\
Th"

3a

Handlebar vib .. t • • o. oscillat ••

• Ty.es wom or out 01 t>.IIInce. E'ther COf\dition. paflicular1y In the lronl Iy ... win promota shakingof tho! fO<1< _mbly and IhUllha handlebers. A sudden OOIIIt of ,hiking can result if. balance we,ght is displaced during ..... • Ty ... badly pOo.itioned on the wheel rims. A moulded line on each wall 01 a ty.a .. jlfOllided 10 lilow visull veriflCltlon thlt the tv ... iI eoneetly poa,uoned 00 the rim. A check can be mI
iii °foo P o ~··l ° • !f~'f.'\:l.n!!! 8 ~~'f,j!ljHi ' ,

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.ft.

lit...,

• T_ted c.eIoper Sl4)pOn bracket. TNoI ill ID 00Qjt only ""P'C1 ..... ~.No."emptshouklbll~IO' ...... m.~ the brachlshoukl be~.

" ...

Br.... pedal PUlul. . In operatlon

d",m brill..

'*' .......,

• Drum warped or oval TI* ll'Ofl"I oven-ung or Impect or . . - . 1I)0I0;. t-'on. Thill condition is diffICUlt 10 0Gn'I(:t, IIthoo.ogh ~ light ovelity oroIy occ ...... ",mmo"ll thollUl1_ 01 t... drum prOYlde • cur •. ThillI won. lot. ~i'I~. R~" of the wf'lllll1I I'lOfmIIIy the only 1I1"'ec:tory IOIution.

'*'

• DOle w .. peeI or Irregularlv WOi'n. T .... dlK mull be renewed • VIIheeI apindlil bent. T.... ~ ....... bII .tr.lghtened provided l,ruclurellY"..,. tIM occ:unlld.

no

49

D",m br." noIli

50

Br.... indvced I.... Juddet

'*'

• ar.I<. MJlIMl This be CIIUMd by !I'll' omiIoIoon or irw;:cwTKt ..... ___ 1On 01' ..........1QU8III shotna. SquuIing CIon . . , bot Cf\IMd by dull on the 1*11, ~ in «WI'IbinItoon ....'h gIaHod peds. 00' olhe< oom....",.."on from 001. ~ 1:Qk, IIuod or COtIOIIoo'I. , , -,_ lQUUIong whoch CM1nOt be Iroced to..-.y 01, ... notmIII _ _ c.n oft.. be c ..... by applying. thon ~ 01 high lempelMIil. silicone QfHH 10 the __ 011Il0l PIdL M..... btohJleIy ~WlI"'1 no~" -'lowed 10 Cont.mOnIlltM brakIng IIIJrf..::. 01 , .... I*b. • Glazed paOI. Th .. ;' ....uolly <;aU""; by high I~tu ... or conl""';1\111I0I'l. The pad .urf~ ""'V be roughened u.lng vI_peperll< • Ii". file. II this 'PPOOKI'I do-. not ,fte<;1 • c...... lhe !)lid, .hould be renewed. • OIIC .... rped This can caute • cNn.nng. clickIng or In\ermill .... ' ICIUMl8nd 1I.....uv IoC:COmpIInio:o by. pUiMl"'II brlk, .... or pede! or ............ bfHng The ddc: .....1 boo .-wed. • B.-, I*k fined incorTec:Ily 01 undtorIu •. Longolt••d..... pIrf in the

• Worn lronl loA ~ 8f>d legs. or - . . or bIdIy IIdjo.oIted II-'ng held buringoI,. TheM oondltiont, «WYIbIned .... Ih uneven or pulsat,ng braking as detcribed in SecIIonl 44 end 48 wilioduc. more or ,... juddM when lhol br.k..... applied. dependenl on lhe deoW" 01 _ and poor br.k. "",,"ion. Attention should boo given to both . , _ of malfunction. See lhe ' ....enl Sectlonl.

EI6Ctric.1 problems

poo;k;MloornillO'lofthe ...l;....me..,....,~fit'ldIor _ _

p..:b of the wmng ...n hrIe been fined w i I _ llIOngIt ~ noON ..-..y ,..... the brake iI ~led.1nlpKl1he paOI Jor~ ;"\.III!I\JOn

",,-,

.. 8."H ... opongyotineffKtN, dn,imb<..." • Wom brake hn,,,,,,. Detennine lining _

UIIng tM .xtltfNl bnlke

w_lndica,or on the br.kel»ckplate, or by .emovong tN wheeland witlld,awing the bnlh "-ckpl" •. A _ ,he ahoe.'IlnIng """I.' pair if t"'I'~"I-..~ t""~llmIt.

• Wono brlh c:amshlft. W.., bet_ t ... CIMIheIt Iond the bNring 1UI1_ wiI...:kQ br.kl '.e! ..... ~ OI*lt"'ll .mclency. ~aI 01_ or both 'temI will boo reqund to -=tJfy the 1M.. • Wono br.tcl cam ItId li'i0i' ...... R _ t ... - . . c:tWT"IPO'*'ta.

. l.lnongtcon~1Id wlthdu5tor~.Any~tlonloldu5t ~ be dMnIId loom the Inkl ~ ItId drum I.IUIII 1 petrol ~ doth. 00 not blow ot bnM 011 t'" ctu.t it ;.

*"-

..... t.. booMd Iond t"'-- hlrmfulil inhIIId. Ugm contlmOnloon loom ~ be ~ "om m. ......_ 01 thollnklliningoJ I.IUIII 1 ..,.",.,,~ Ittemptllt ...-noW>g '-"* cont....,.".ion _ ,.. ...tv to

'*'

......,.-.c.

• a.tt ...... IMJIty. Ban...... lit. IhouId not be ~ed 10 pOled 3 10 • ........ GtIdueI sulphation of lhol piat", 8f>d -'menl depoeit. will ~ thol bellery perlormence. Plall ItId ;,..qlot demege CIn often occ............11 01 vlbr,'ion. CompIeII _ _ I..... or Inte<mitlent leil ....., "...., be due to. broIIen bln er, terminal. Uc:k of electro/vtl wII I)rClvont lhol battery _,nlllning charge. • a.l\ery 1Nd, _king poor conlact.. Remove lhe battery INdlIond Clun them ..... lhe lenni ...... removing III t"':eI: 01 ~ and Lomith. RKONIICI the lelds Ind Ipply. COIling of pelroleum jelly 10

t1.lerminall. • L.oIId •• otM/vI. If tdditlonellt ...... wch .. IpoI ,..,.,... are lintd. wlich ~ IhoIIOtIII.-:tnc.l1oed IboYI the ...... Imum lit_tor output. the bin..... will laillO .....,..,. lui "*111. R.ouc. the IIecIrIceI lcM.:lto"';' Ihe""tricllClpklty • Recbfierl.a...... • AlI_lOt ",",",!.-.g c:ok ~ ot shorted. • ~ cl!cuit short"", ot open circun.. Thill "...., be -..eel by hyed or broten wwing. ditty ~totl or a .MJIty Ignition twltcll. The 1yII..., IhouId be t..ted in .1ogicII ............ See Section ~

boo~.hJ"'--_oIm.lubricarltwilllllvto"""~bv

.hoI ~nIng _t .... which _

....

the "'Itung~.

• I_eet Idtuatmem. R...adjult thol brHI _ _ IJ"II ~

• o.um warped ot oval. filii CIn ,etuh .rom ov.n-t,"11 or impect or

t..-..oo1 01 thol whMI &pOke&. Thol oondltion ;'d,tllcuh to COffect. Ilthough If elight ovllity oroIy occurs. Rimming m.1UI1_ 01 It. braltl drum CIn provIcM 1 cure. This;. WOttt for Ilf*iIIift ~ ~ 01 thol ~tl whMI;' normaIy m. ody 1I".feetory .... uon. br .... 1I'IoI' mum Ij)I'ingL Thill will ...... _ _ m. brttk. lin_ . "om puIIirlg-.yfrom m.drum

unevton

.W ....

"'II'~

PfWMII"'"",

ill'IIIIIed f"''''''''''III~be...-.d. • Brak. c:am.hIoft ot pede! pivot poortv lubriceted. F.a..... 10 Itlltld .0 regular lubricellotl 01 U - . _ will inc_ operatin(l '-'1nC1 which. wl'lln oompooncIed."...., cause tanty operation Iond poor . . . .

-,

• Regulator ....Ity. Overeharging is indicilled ~ the banery ~ hoi or It II noliced thaI lhe -'ec!roIytl level ......"..!edly boo!ween m. balle
• F... blown. Check m. mIin !we. If • ,aut! hal ooeurNd. It .......1 be ,ectified before ........ " - ,. Iftled. • Balleryl....tty. SeeSection 51. • Elnh laiI\n. Check thM lhe mtin Arth llrap ;'IIICUNIy . 1f1.1Id 10 I'" I...... and is _king. good contact..

Feult diagnosis

22

• Ignition SWlich 01 POW"- Circuit failu .... Check for cu.rent flow through the ~uery posih". lead (fed) 10 II.. ignition IWI\CIt. Check lhe

ign,,,onlwi\chforcontinu,ty

circU'1 fUM is liued. Replace lhe fUM. " blown. only IIft..- the , ....It has been identified end rect,lied

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

55 Bulb, blowing r.p..tedly

• ViM''''''' • Cable " ilure. Rala. 101M mac:hir.e', wiring d;a.gf1lm and clMK:k tIM circuit OO<1\,ouily. Open c,.-cuil' ere I fHUh 01 100M 01 corroded COOr'IeCtior>l •• ither .1 l&rmill&ll or in-liOfl COOI'H!ICIOQ. Of becauH 01 broke" wi_. Occaaionllily. tile COfe of . wire.wl break wnl>oullhe<e beu'U .nv llIiN',en\ dIwnage to the oute, pIft~ CO'IIef • Switch f'ilure. All IWllchM ,.,.y be checked for continu,' Y in uch IWI\Ch POSItion, 'ef.....;ng 10 lite SWItCh posltion bo~" iocorpoIn lhe wiring di"ll"m lor the rTlKhi ..... Switch f,ilu....... y be. fewll of meckanical twe,kage, corro&Ion or wale' • FUM blown. Rete< 10 the wiring doag.. m 10 d-.eck whether Of not.

'Of

",.,;1

_It.,

fa~UI'.,

Ttm is ollan an inher.", ' ....1\ 'Nled 10 lhe ... lOral

ViMlion charac;len.lo;l of the engine.,..;l ' .. me Ind I.. lit ..... d,'ficuIIIO ,esoIve. Mod,lk;.otiornl oIlhe '-""p mounl'rIg, 10 e~ge lhe damping chafkt8fislOcs, may help • Intltrm,n"", eanh, Repealltd la,I" .. 01 one bulb, panIC"""", w ..... lhe bulb is IItd difllCtly from the """".alor, Indical ... lhal. POOl' . .nh e~istl somewhere in the eire.."" Check Iha, • good contact I. avallllbM al each eanhing poin, in lhe circulI • Reduced volu,ge Whe-re a q.... nt·halogen bulb i" filted lhe vollage 10 the bulb ahouId be mainla,ned or Nrty failUleol lhe bulb will oct...- Do no! 0VfI~ lhe '~tam w,lh .cId,lionaI.lec:trical flQUipmenl in e~CfII.I 01 the S'{$lem', J)OWet capac'lV and .nWtelh" all circ"il connec:toOna ..e ma,nt.alned clean and loghl,

Routine maintenance For Information relating 10 the 1997-on DT125 R models, see Chapter 8

Engine

OTmodll1

$pItrk plug: NGK ..............................._... _... _._

Nippon

Denso ........ _

SPllrk plug electrode gap Idle speed •.. ThroWe cable free play - 81 t wistgnpflanga ..

Clutch cable ',oa play

at handlebar Ie~er bun end ...

BRSES or BR9ES W24ESR·U orW27ESR·U 0.7 O.B mm 10.02B 0.031 in) 1300 1400rpm 2 5 mm (O.OS 0.20 In) 2 - 3mmI0.08 0.12In)

BR9ES W27ESFl·U 0.7 0.8 mm (0.02B 0.031 In) 1300 - I400rpm 2 5 mm (O.OB - 0.20 In) 2 - 3 mm 10.OB _ 0.12 Inl

2 5 mm (0.08 0.20 in) 41 mm (1.6 inl 20 30 mm lO.8 1.2 in) 30 35 mm 11.2 1.4) in) 0.5 rom 10m;.,) 2.0 mm 10.081n)

2 5 mm 10.08 0.20 in) 15mm(0.6in)

No!applicable

25 psi 11.75 lIg/em') 28psi 11.96 i<Wcm,) 25 psi 11.75 kg/cm') 32 psi 12.24 kg/em')

18 psi (1.26 kwcm') 22 psi 11 .54 kWcm,) 22 psi (1 .54kWcrn') 26 psi (I .B2 kWcm,)

Cycle psrts Front btak" lever free play a\ lave< tip._ .. ~, ............... ,.. " .... _.... _... __ .. . Rea. brake pedal height below lop of fooir8lt ............. ,," ___ ............ Rea. brake pedal fraeplay - 8\ ped~ tip (drum b<8ka model.l ......... _. Final drive Win free plaY . _________ .___

._H...'_ . "._. __ _

Brake pad hic:lion mal&rial S81"11ice limit_. ___ .___ .. ___ .. _ .. _. Brake shoe I,icllon mllieria\ service Umil (drum bfaka modelsl __ .__ Tyte pr.,..u",. tV'eI cold: Front (I0I01 up 10 90 kg (198 Ib) 1oad..... _ .........

_ H _ .....H ... _ _ _ _ • _ _

Rearl ......) up to 90 kg(19B Ib) load ._.. _ front (pillionl90 kg - ""'" l""eL ................ ~ ... * ... _ ... . Rearlpltlton) 90 kg max load Mulmum load: TZR model . .................................... ..... ..................................... . QTmodols ...

Not applicable

25 4Ommll .0 O.S mm 10.03 in)

1.61n

193kg(425Ib) Iron! 47 kg (104Ib). r8M 134 kg (2951bl Nole; F(}( off·tOf.Id riding. DT model pressures should be 18 P'i /front) and 22 psi (r8M) Re<:ommended lubricents Ind flu id s Fuel grade ._. __ ... _...... __ ..... _ Englnllubricatl!ln: Oil tank capacity _. __ .__ .. ____ ._. ___ ._. ____ ._ .. ___ .__ _ Recommended oil ._" . ~ _ ____ .._ ... _. _ _ _ _ ._.. ____ _ Transmission lubrication: Capacity. At 011 el\eoo8 _ .._. __ .. _ .__ .____ .__ .. _______ ._ _ _ Aller rebuild Idryl _______ ._ Racommendedoil ... Coolon' ....................... _...... _ Front lorh capl'City per lag:

Unleaded, minimum octane 'Bting 91IRON/R M) 1.2 11112.1 Imp p') Yamaha 2T oil or equivltlent good QUality air..cooled 2·$l1Oke engine 011 7SO cc n .3 Imp pI) 800 CC 11 .4 Imp pt) SAE IOW/30 SE molO< olt s...,Chop,,,.2

TZRmod~l.

238 CC IB,41mpll 01)

Early OT modol (30Bl) ..

486ccl17.1ImpllOI) 495 cc (\1.5 Imp fl o~) 10Wlorkoll

Lator OT modols (3RNI onward) ...

Recommended oil... Fork oil level : TZR model . ................... ................ __ ._... _

Early OT modeI130Bl) ..... __ ...... _ .... ~ uter OT mod~1113RNl Dnward) ___ ... _ Drive chain lubrication: S,ar>
149 mm 15,B7 in) 175 mm 16.89 in! 165.5 mm 16.52 in! SAE 10W!30 SE motor 011 0< aerosol chain lubricant SAE 30 - SOW motor oil 0< 88I060I chain lubricam suitable 10< O-ring chains DOT 4 (rt not available DOT 3 may be usedl SAE 10WI3O SE motor 011

Good QualitV h~h melting·poiot lithium·based grease General purpose grease Engine oIlor light ml'Chineoil

"

Routine maintenBnce

Torque s ettings Component Spark ptug ._•.__ ._.__ ... _ ... _.... _._ .. _ .. _. __ ._.. _..._ .. _.._ .. _. __ .__ ._ .. _ Brake calipm mounting botts ..............___ •• _ Brake pad retaining pins(2RKand lPCl models) ...... _..._... _ ._ .. _ Bra~e caliper body retaining boit Front wheel spindle ...... _.... _.... Rearwhefll spindle nut ..................................................................._.... Transmission oil drain plug .. . Coolant drein plug ...

Introduction Peliodlc rOUlir.e mainienollCe is a eonlinUOl.J$ process which should commence immediatelv the """,hine is used. The object is to mainlain all iKljuslrnenta and 10 diagnose and rectify minor defects before Ihey deveqJ InlO JTIOfe ext&nsive. and often more expensive, problems. It lollows that if the machine is mainlained property. it will both run and perlorm with Optimum eff.:iency. and be less prone to unexpected breakdowns. Regular inspection of lhe machine will lhow up anv pIIrt,. which are wearing and. and with a linle experience, il is possible 10 Obtain lhe maximum lile from any DOecompcnnnt, renewing it when it becomes 10 worn thai il is liabj" to fail. Regula' cleaning can be considered es Important as mechanical mDlntenance. This will ensure that all tho cycle pIIrts are inspecled regularly and ore kept Iree from BCCumulations of road dirt and grime. Ali lasks a'e grouped under various mileage headings, all of which are also given calender-bas!!d iOlervals; if the machine only covers 11 low mileage malnlenance should be carried out according to the calendar headings inSlead . All intervals are intended as a guide only; as a machine gets older it deyelops individual faults wit",h rllQuire more freQuent atlemion and if used under particularly arduous conditions it is advisable to reduoce the period between each check . For ease of reference, mosl servic:a operations are desc:ribed in detail under the rel(IVanl heading. However. if lurther general infOfmation is rsquired. this can be found under the pertinem Section heading and Chapt ... in lhe main tSxt. Although no special toots are required fOf routine mainlenance, a good selec\lon of general workshop lools is essemial. Included in the tools muot be a range of melric ring Or combinalion spanners. a selection of crosshead screwdrivers, and two peirs of cirdip pliers. ona external opening and Ihe olhol internal opening. One funher ilem of equipment Ihsl can be regarded as essential fo' Owners of these models Isa siand of some sort that can hold the machine securely In sn uprighl position with enough heighllo pe,mil the wheals to be removnd. This can be anything from sn old milk crate toa pu'pose·buill paddock·tyPl' melDI stand.

T2R mod" ls kglm

,., '.0 ,.0

H

It is recommended that lhe follOwing ilems are checkad whenever lhe machine is about 10 be used. This Is imponant 10 pr(IVenl Ihe risk of une~pecled lailure of any componant while riding the machine and, with e~perience. can be reduced to a simple checklist which will only lake a few moments 10 complete. For those owner. who are nol inclined 10 cheCk all items with such frequency. it is suggested that Ihe best course i. to carry Out the checks in the form of a service which can be underlaken each week Or before any long journey. II is assentielthat a ll ilems are checked and serviced with reDsonable frequency.

1 Check the engine oil level Although a warning lamp is fined to give prior warning that the oit level is running low, Ihis may not allow suffoeient reserve to allow you to find soma more. Accordingly il is recommended lhatlhe tank be kepI topped UP elelll,mes; lhe lrue \eve-! can be seen Ihrough the translucent ~iIlilK:of lhe Ifnk, On TZR models unlock and remove the seat to gain l>C<;ess 10 Ihe filler cap. On DT models the oil lank is mounted on the right·hand side of the frame just behind Ihe sleering head. Uns.crew the cap Dnd add the speci~edg'ade of oil up tothe bonom of Ihe fil,,"r neck. Tighten the cap

"" "" ""

'~ m

' .0

NOIapplic.able Not ai>i>!ic.abie

,,.,. '0 ,.,,.,

Ibltt

"

""" ""

securety on 'elil1lng.11 is useful to keep" spare contolnerol oil with the machine so that a supply i. always available. Note : If the lo w oil warning Indicaror illum!",,!es when riding 1m mllChine 6I1$Ule lhill lhlloilllJntis repienishedwilhoul d/jlay. In Ihe evern of the oil level falling low enough for air to 8flter the pipe between lhe oil lank and pump, the system must be bled before the machine I, ridden. The bleeding OpIll"lllion i. described in Chapter 3.

2

Check the coolant level

Although the cooling system is semi·sealed end should nol requirs frequent toppir.g up, II Is still necessary 10 che-c:k the ,,"vel at re-gular intervals. A separate e~panslon tank is fitted to allow for e~panslon of the coolant when Ihe engine Is hot. the displscfld liquid being drawn back into the system when il cools. It is Iherefore the level of coolanll" the eKpansion tank w hich is to be checked; the tank Is conat'uclcd of trans lucent plastic SO lhat Ihe coolant level can b-e seen eusily In 'elation to the upper and lower level lines marked On its side. Ch«* l/'eclJO/am level only whe" lhe engi"" is cold. On TZR modelS the expansion tank is siluated under the right. hand sidepanel. acees. to lhe tank can be gained by removing the .... al and sidepanel. On OT models il will be necessary to remove the left· hand si
3 Da ily Ipre·ridelc hecks

"

Notapplic.abie

...,.,,.,

DTmode ls Ibltt

Check the fuel level

Checking lhe petroileveJ may seem obvious, bul it is all too easy to forgel. Ensure thai you have enough petrol to complete youl journey. or "tleaslto get you to the nearesl petrol stalion.

4

Check the battery

The i»Il1ery is located on the right·hand side of Ihe mschina, underneath Ihe sidepanel. The seat (TZR onlv) and sidepanet muSI be removed to check the elect'olyte level On all modelS. whenever Ihe battery is disc<>nnected, remember 10 disoonneCI Ihe ne-gativa ( ) terminal first. to prevent the possibility of shorl circuilS. The electrolyte level. visible through the IranSlucent casing. must be between the two level marks. If necessary ,emove the cell caps and lop up 10 the upper level usinllonlv dislilled wat8f. Check that Ihe lerminals are clean and apply a thin smear of petro,,"um jelly (not g'easello each 10 prevent corrosion. On refitting. check that the vent hose is nol blocked Ind lhat it Os correctly routed with no kinks. also lhat it har.gs well below any other component, P<'r1iwterty the chain or e~haust system. Secure lhe banery and fuse holder with lhe rubbef strap. Remember elways 10 connect the negative ( ) lermlnal lasl when re~ning the battery. Always check Ihat the terminals are tight and that the rubbef cove", are cor,ectly refined. also that the fuse connections are clean and tighl.

• • ,•"

-

Ute only goOd QUIII,tv tWO-Itfo!<. oil when tOPPing UP TZR rnodeIlhown

chili the t ... iI ot the correct f"'r"IQ and in good

cond,,~.nd

_III .....bleon the .....:.... IhouId'he need ....

,M,.

checIIt"',

Al ~ WlI_III11.....o'<1' the bette
"'I'Y

8nd . _ .",..1... cy\tndef .-vain

a-t. fluid IewIIiI in the Iron!

ElKttOtvt. level must be b e _ !T\IfU on bell..., ca.ong

•,.It...,

5 Check the brakes ChKlc \hI1 , ... front 8nd _ bfak.. ""'CIr1< effect,.,..,., aod wothout bind"",_ E........ thel ,he rod inbge r_ drum br• •) .. IutIr1Qled lind ~~IO
,,,,,,,'w ....

.......... IeveI~not I " pnl ~ .......

I.... IfUd deptll w ,llIin 1.... legaIlimlli 01 , mm of depth ovtII" III .... wil h no IoIQI'I of bIId poMc'-. M...... r'derI COI'IIidet _ 2 mm 10 bt the hmit 10< HCU<e tOIdIIoIciInQ. IraCtoon. 8nd bfal.ng. ~ In adverM _ I"""

--

qu.I01 .... oIl .... lfUd WJdth arouOO 1........1'.. ci<wml .. _

T he tyra IhouId bt ...-.d wn.-.. lhey _ dImIoged 01 exceaiYI/y _!HI 0>IpI.. 1Q.

Iound 10 bt

7 Check th8 controls o-k I.... Ihronll8nd dutcll cablel and Ieve<s. t .... gear liver and I.... fOOl...11 10 . . -.. lhet lhey .re Mljualed COfT1IClly. funclionlng correctly. 8nd 1.... l l hey ... _ety I.tllled II. bolt .. QOII'III IO won: 100M. 0< • CIbiIINj). it .. betl er 1....1 It ;. diIcovertd 111M ItIQII WIlh till
I"""

...

...,.oo ....

..

'-ding.

6 Check the tyres o-k lhe tyIlI prnsu. . wIth. ~ ''''I iI known to be _ .1.

tt ill wortt>whiJe purct\MIog. pocket gMIgII fof thos purpoH bK..-the ~

on gw-.ge fo,~ ~ ... nC)I(lfioul1y

pr-..... IhouId be chec:ted

w"h the

tyfe. cold.

INccunot. The mileI

Even • f_

1.......,_~upthetvr-IO.poinIwt>e<e~IrIc_8nd

"'~.~wilresuh

Allhe ....... time .. \hI Jyfe ~ _ chlcked. ex .......... lhe lyrIIl ............... o-k lhem 101 dIoInaQe. npeciIIIV for qJIiIMQ of the ~ .~ .tonw 01 othe< roed debri. c.ugM ~ lween the 1...0.. Th"" I*!OC:ut.rty Import.nt on lilt ' IUI' Iy ... whe<. fII)Id dellttion due 10 01 the IIV"I8f lube will -'moel ce<1,;nIy _ _ 101" 10M of ~11Ol Whtn chtclting \he Iyrw for ~. they IhouId bt ••...,;n.d 1011.... depth for UK ~ II iI om .. 10 kllP

&!dew.... Remove

""""""I()II

8 LegM chec/r 0 -. II'IIoI "IighU.lumsignlols.hom 1Ind~1"_worbng

10

""'''''1

correctly mill. \he ~~'Mlh .. 1IIPI ~ ......... in 'M fMCIICt.. (:Net ...., INI \he lletdl..-np ;. correctly Iomtd. Rote1l the UfII* ~ ed~'ong ~ 10 ...... the horIlon\.lll 8Iigr'Iment the .....,ic:IIlim mull bt ItIigntd .0 lhet 'Mlh lhe ~ llII'Iding on ftl wlleell on level ".ound witII lhe ride. land pillion PIIIIIlI/8f"- If one II rlQUl..-ty carriedl MIlled normally. I.... dit:I blINn cent •• In shown on • w all 25 feet mult be 1\ t he same heigohl fromllllground ll l heC8fllreofthe hHdlamp ftNlf_ Thililadjusted by tnOther JPtlnIt"IotdId adjusting _ _ l"Ulled .1 IIIe bonOlTl of t ....

_ ....

_.yl

Routine maintanance

The eK8C1 in!arvalal which the final drive chain will '8Qui'e lubficatiol\ adjustment and flInewal ;s anti,ely dependent on lhe usage 10 wMch the machine is put and on Ihe amounl of ca,a devoted to chain maintenance, tn some cases the chain will requi,e daily lubrication. in otherca58s It need only be lubricated at weekly intorvels. Tho best ,ule to follow Is that II the chain follers look dry. then the chain nellfoughly and re·pecked with cha,n grease as described below. o-ringcha,ns a'a wido' and have small O-rings 581 I>IIlWeen the ,nner and cute, sideplatM of aach link to seal lhe gre8$O InlO Ihe bearings lor the life of the chain. These are easily identified by the presence of the a·rings and 'equira a fipecialaPOroach in lOme aspecl. of mainlenance. Although fiull
",mplifoed 'f a worn out length is temporarily connected 10 i,. As IhI o,.;g;nal chain is pulled olf the sPfockets, the worn-out chain will followit and remain in place whilG lhe ,ask of cleaning and examination I, carned out. On r.... ssembly. lhe procllSll is repe3111
Clunlno Although dl" and old lubricanl may be washed off the chain while il Is In place on the machine. this is not really satisfactory. acpecial,y wilh standard chains where the grease may be washed OUI 01 Iha bearing', To clean the chain thoroughly disconnactlt at its conn&c:ting link end remove it h om the machine. Note that rafiUing the cha,n is grMtly

Checking forwu, The chain consist. of 8 multitude of small bearing IUrface, which will wear rapidly. and eKpensively. if Iho chain is nol regularly lub,ic.tltad and adjusted.

Do not omit a·rings Iwhere fined) lrom final drive chain joining link

Refit spring clip with closed end ;nno"",,1 dire<:tion of chain t ..".1

Every 300 mllHI500 kmJ

I

Check. adjust and lubricate the final drive chain

Sil'ing clip.

Routine ma intenance

On OT model use numbe<ed eUIOUIl in Inail camllO &nIU<e wheel iI aligned

Use rmtb provided for w'-l elignmenl TZR model

On TZR models. wllh lhe chaln fully lubricated ..-d COtrecUy ad,..sled III dIIIc.ibed billow. anempt to pull tha chain t..ckw..m. off the tNr s.procklll. Yamaha recommend that if the distance between the cha,n and sprocl(et iI g.e8ter than haM tha Pltd! of the sprocht t""th. it .......1 be considefad worn OUt and renewed. The chain fined to Of moDels II checked by ~ring. 10·link IengU'oI lhaehail> (II matt any one pin. count off 1\ pins and meltSUre lhe dlltaoce between tha two). Thil can be dorte with the chain fiued to !he machine. T el>sOon the ehall> by hand and than meHUfe tha diltance betweel> the inside of lhe tWO pint. Repeat the operation on ""ve.al d,fferent 1 0 link seclions of tha ehail>. If any secuon 01 tha chain iI found 10 be over 120 mm (4.72 In) It mull be coos;de<ed WOfl> OUt .nd

_woO

Renewal II the eha'I> il found to be worn out. Of il any bnb are klnkad Of It~1 t/wOlJ9h IItck of lubrication. Of If damage IUCh asaplit Of milling rollers Of ...:Ie plates is found. the chain muSt be ,_ad. This should be done .Iw~ys in COI»UflChon with both sprockets &lJ'ICe the rumling tOgEUI>er of new and pan·worn components g.eatly inc.eases the fata of wear of all three iterm, resulling In even goruter e~pend;tu.e than l'lllClluary. When pun;h ... ng • new chalI> .lways quote lhe lize. lhe I>"",be< of ~nk •• 0000001fed and the machine 10 wh.ich the chall> It to be finad. Standard chain I"es are given in the SpecifICatiOn. Seeliol> of Chapter I. bul note thltl the gearing may well heYe beer> aUe lubricanll can be .pphed. wh,~ the cha'I> is In ptace on lhe mlChine. II should be applied II lealt 0fICCI 8 week. aNI daoIy if the machine is used in wet _athe< condition •. Engine oil can be uted IOf this task, but remembe< that it il flung off the chain far more e_1y than grellSll. t""'- mak,ng the '88. end of the machine un_rily dirtv. and reqtJ"es mo<e freq .... nt app!lcahon If it it perfOfm itl t.... ltdeQuately. Also remembe< that sufplus oil wijl eventually find ill way on to the tyre. w,th qu,,, diSlltrouti CGnII'IqIItmCM. While thto will serve III estop-gill' meiKOre. it doel not reach the in"'" bear'ng surlaceo of the chain. These can be lubric.lltad correctly only by removing and clean,ng the chain .. described above and by imrn&rSing II in " motlen bIIth of spe<;ial chain lubricant such as Chaingua.d Of linklyfe. thio should bedoneal inlervlil of SOO 1000 milel for nonnaI road use and more frllQUllntly If the machine is UIad in wet weather or pOor condllionl. Follow carefully tha manufacturer'. instructOoni whfm USing Chainguard Of linklvfe and take g,eal elfe to lwi. the cha,n 9M>tly in the motlen 'ub"eant 10 ensure ~hltl i~ panel'''H to .. bearing surlaces. Wipe off the SUfplUS belOfe refin'ng the chain to lhemachi ..... Although g.ease iI sealad inl0 the in.- beanngo of O-ring chain .. remov'ng lhe need IOf regula. immetlion in molten lubricant. these eha'I>1 must . Iill be lubricated at dally Of wlltlkly mtervall to klltlp the O·ringosupple and 10 prevent wear between the rollers and sprock.. teeth. With the machine supported so lhal the .ear wheel io clear of the ground. ,evofye the wheel and allow cillO dribble on to the .oIle", "nd between the sideplatH umil the ehain io CQrnp!elely oily ell along III length. Use only the IIP8Cllied oil for this PUfpolll. Wlfninll: some aerosol lubricantl conteil> chemicals which will anack the ().rmg.

causing 10M of SIIIIed_in lubrical>t and pretrl8tu. e chain wear. lake care to pun;hase 0fMI whM:h io dearly marked .. being IUitable fOf O·ring chai .... Ad!u ...... nl It is neceISMY to check the chain tension al .egular intervals to cornpensale fOf w ..... S'J'ICe thil wear doH not Ulke place evenly along the length of the d!", ... tighl_tl witl """'" which mUll be compen· saled for whfm adjustmftnt il made. Chain tensOon it checked with tha trlMmiuion in neutral and with tha machine standing on ill wheeII. Find the tightest spot on the chain by pushing the maehinealong Ind feeling the amount 01 f.ee play presem on the bol1orn run ollhe chli ... midway belWMI> the sprockel•. tHllng aIor>g the enti.e length of tha ehall>. When the lightHl1pol has beer> found. me8su.e the total up and down moveme... available; thil should be between the ~mill gi"",,1n the SpecifIClIIOnl if nQl tha chaln mult be IIdjusted as loIIowt. T2Jl modal Remove lhe splil pin and lIacIoen lhe .ea. wheellpindle nul by juSt e<>ough to PII!I<mit the spindle 10 be moved. On late. models w ith a disc brake 81 lhe fear it will also be noceuarv to slacken the brah e.IiPl!< mounting bolt to allow the ealiPl!< bracket 10 move freely. Stackan tha chain adjusler IocknulS and tightel> both d.awbolll equally to draw the spindle back by the fequi. ed amount to Ulke up e~cetllchaUl slack. To preserve 1ICCU,.te wheelaligl>mel>lansure that lhe notches lIamped in lhe chain Idjulte<s line up with lhe same lines lIamped on each Iw'nging arm fort end. Whal> tha chain is COtflClly ten&iOfMtd. tightel> the whaellpindle rnn 10 the lpecifoad torque selling and fit . new split pin. Note thaI on modell with a drum braka II will be necHsary to apply lhe rea. brake flrmly tocentf.lise the brake thoeI whOlSt the nul is tightened. Addilion· any it might .Iso be necKUlY to adjust the .ear brake and Slop lamp , Wlld! ~ the chain has beer> IlI9nificanUy adjulled; lhese Ml1,ngolhould be checked befOfe taking the machine on tha foad. rtgt>len the lIdiu"., Iocknu, • ..-d brake callpe. rr:tOUf>t'ng b
A _ - -_ --.~-~~~~:~:___-

s-p

Cann_

-~-~-:~:-

--

Method of c"-<:klng wheelalignm"nt

Routine mainte n a n ce

28

DTmode l Remo .... tile Iplit pin and alacken the .... wheel spindle n .. t by jull enough to permit the opindler to be moved. then draw the spindle back by rotating the _iI calTlll by the oame amount Or'\ both IiOes. Use the numb&f"l 'limped in the c;a"", to _ .... that the ume cam cutOUl engages with the 1I0PPe' pin in tach .winging .. m fort end. lhut preserving aoc:ur1rte wheelllignmenL When the chitin Is o;oneclly tensioned. tight&nlhe ,piodle n ..1 to lhe ,ec;ommended t.... QUe setting Ind fit I new aplil pin. Finally check lIIat the wheel spon, f.eeIy and thet the .. Ire no tight spoil In lhe chain. All mod. l, On ,II rn<>
The electrode gap c;an be .........ed uaing feeler \j&IIgM. II _ flOry, alta. thoo 9It> by bending the outer alecl.oo.. praferably .. sing I Propel" elKtl"QoIId, CGlI the th.N
Six -monthly. CM" every.ooo mil" 16500 km)

2 Rep"81 all prnioul meintenance tRkS, then c.ny out the foIowing:

Check the spark plug Thelpart plug ....ppliad II original equipment will prOIf8 utislactory In mosl ope
,,1<1\1_

I! to c....., I new 191<e IPIrt plug Or'\ lhe machine. IIa"';ng first set lhe llleclrodel to lhe correct gap. WhiIIt IP8fk pIugtI do not often fail. I new .ep\acem8flt Is well worth having ~,breakdown doll occu •. £......... thai the IlPI
On TZR models remove screws and lilt Ii. fiher COlI.,.. away _

Clean the air fifter

On TZR it will be neeHUry to flll1O\'flll\e 1811. sidepeoell and /vel tank togain acceu 10 the ai.lilte. c.sing. Remove lhe rlllele.eWl which sec .... tlwl filter eo...e. and lift the eo... ... _avo The foam elemenl can then be removed. On DT modele. the Ii. lilt ... casing II llluated under the left-hand sldepanel. To release the lilt&< element. remove the IidapaneIlnd the Ih.H screWi which fIIai" the Ii, filler COlI ... and lifl the COlIer IWay. The loam "'emenl c.n theo be wlthd._n along with III holder ,nd guide. RetnOlre the wingnul which secures Ilia foam etement to the hoIde< ond separate them. Check ""t the element iI not JPliL IIa.dened or deteriorated thnlugl\ age .... severe clogging; renew it ~ it Is damaged in th" way. Soak it in. non-fltmmabie .... high l\ash-pOint IDIvent &ueh I I while spirit (petrol II not recommended because 01 tho! Ii.. ri.k) sq.-ling ~ gently to '0fTID'If8 III old DiI,nd din. Remove extlll IOIvent by a.q.-liog IN element betw",," Ihtr palmi 01 the hands; wringing it out will damage it. P..t tlla element to one side to alloy any remaining 1OI\I&n1 to IVlponnl. When it iI comptet.,.." dry, IOIk tile element in clean SAE I{)WJ3() SE mot .... oil,nd gently 1<1.... «1 oul any ItIrpIuo to lea .... it onty Ilightly ciI:'/ tothe touch. Refit the elemenl to ill holder (DT model,) and reassembll with the guida. Apply a light CO/IIing of ~lhium-baHd gffIII8 to both the element Ind guide seat before refitling. NOle. the r,lte. c.sirIg Or'\ lhe OT

._ foam alement c.n lhen be removed

gray firing enc:Ilndicatas that the

qlne is in good concIition lind that the plug type Ie QOITlICt

A.sh 0ep0sitI - I..Ight brown daposiIa tlnCfU$ted on the tIIactroda and !naulator. leading to mi,fir. and hesitation. Caused by excasslve amounts of olin the combustion chambar Of poor quality luelIoiI

fouling - Dfy, black IIOOty deposltlleading to misfire and weak spark, Caused by an over-rlch fueVair mixture, faulty choke operation Of blocked air titter

CaoAed by oiIlaakaga past piston rings Of 'o'IlIIIe guides (4-stroke engine).

Normal condition - A brown, tWl

Of

Ove ..... .Ung _ A blls'e<ed white In80latOf end glazed electrod&s. C$JMd by IgrItIon system fautt Incotrect fuel. Of cooling system fault

011 fouling _ Wei oily deposits leading to mIsfire and weak sparl<. Of 8X01!1$111o.b1can1

C2-stroi<e engone)

Routine

mHinten~nce

model is fitted wilh e check hose. If duSI or weter has accumulated in tho hoso, Ihe air filter casing must also be cleaned before Ihe filler i, refitted. On reassemblv, ensura lho elemenl i8 correctlv seated in tho filter elISe rrZR models). On DT models fil lhe Bir mlar assemblv IniO the ~sing. making sure its handle is fllCing ootwa,ds. Refil the cover. checkillQ thallhe aeaUng D·rillQ (where fined) il in good conditiof"O and Haled correclly. Apply a Smear of greasfllo lho COver sealing edges to provide additional protection, then lighten Ihe relaining SCrewS secura· Iy. Refit Ihe sidepanel. Remember lhat the filter element and cove, musl be positioned correctly to provide a good seal so thai unfiltered air cannot carry di" into the engioo. also lhat Tho caroureltO< i. ielted to compensaTe fo< the pres&ufe of lho air filler. serious dam&ge will occur to tho engine through OV8fhoahtl{j as 0 result of tho weak mixturo which will result if the filter is damaged or bypassed in this way. For thesa reasons the engioo should never be run with Ihe air filter removOO or disconnectOO. This interval is the maMimum for filter cleaning; if the machine Is used In wet weather or In very dirty or dusty conditions, tho filter must be cleaned much more frequentlV.

3

Check the fuel and engine oil pipes

Give the pipe which connects the fuellBp and carbureltor a close Visu8111xamination and check 101 crackl 01 anv SigM olleakage. In lime. the synthetic rubber pipe will tend 10 deteriorale. and will eventually leak . AJ>IIrt from the obvious fire riSk, the leaking fuel will sllect fuel flConomy. The pip<'! will usually splil only allhe ends; if there is suffiCient spara lenglh the dBmS{I8d ponion can be Cui off and the pipe refitted. The seal is effflCtoo by the inlerference fil oIlho pipe on the spi(JOt although lhe wire clips are only an """itional security measure thay should always be rallned colTBCtiy and should be renewed if damagOO. twislOO Or no longer effective. If the pipe is 10 be renewed, always use Ihe correct replacement Iype and slzo 01 neoprene tubing to ensure 8 good leak·proof fit . Never use natural riJbber tubing. as this breaks up when in contact with petrol and will obstruct the carburettor jet•• or clear plsstic tubing which Sliffens to the point of being brillie when in cont""t with pelro'.nd will prod""e lea'" that are dlffocult to cure. Worting as described 101 the fuel line, check lhe engine oilleel! and detivO'V pipes very carefully. Check Ihat the fitting clamps and wire clips are securely fastened and thallhe pil>O$ are secured by any clamps or liB6 provided; ensure Ihat no pan ollhe tubing is chafing on anv pan of the engine or f,ame. Any damaged piping musl immedialely be reo newed. If sign. of oil leakage or il air bubbles Or din in Ihe pipes ere lound. Ihe lault musl be cured immediately.

4 Check the carburet/or settings and throtrleand oi' pump cable adiustment NOla: petrol rs extretnetv flemmebte. especra/tv when in Iha fann of vapour. Take all pre<:aution$ 10 prevent the risk of fire and read Ihe $sfew firsr! saclion of Illis manval before 5/""ing work. II rough running of tho engine has developed, some adjustment of tho carburenor pilot screw setting and klie speed may be required. II this it lho case .efer to ChaPler 3 for delails. 00 not make these

adjustmonts unless Ihoy are obviously required; there is linle to be gained by unwarranted attention to the carburenor. Complele carburetlor maintenance by removing lhe drain plug on Ihe floal chamber. tuming tho petrol on, and allowing a small amount of fuel 10 drain through. thus nushillQ any water or din Irom thl! carburettor. Refil the drain ~ug securely and Switch" the petrol off. Once Ihe carburettor has been checked and resat II necessary. the throttle cable Ir&8 play can be checked. Open and close Ihe Ihrottle several times. a llowing it to snap shul under its own pressure. Ensure that it is able 10 shllt off qllfckly ami fllilyal all handlebar positions. then check thot there is Ihe specified amount of Ir&8 play measurOO in lerma of twist grip rOiatiO"- Use the adjuster at the tW(6tgrlp 10 achieve lhe correcl setlrng then open anti close the thrOitie again to settle the cable and che<:k thot lhe adjustmenl has; not altered. Removing il$ Ihr&8 relaini"ll screws, withdraw the 011 pump cover from the fronl 01 lhe crankcase right-hand cover and check the pump adjustment 85 follows. T2R modal The pump pulley has three alignment markS.:II .ound dot and two engrltVed lines, one each side of Ihe dol. Tho pump alignment mark is lho shoner and low ... of the engraved lines. To check lhe J>Ilmp synchronizalion. rotate lho twislgrip slightly unlil all "&8p1ay has been removed from Ihe cable. Allhi. poIni thealienment mSrkon 1M pulley should be directly in lioo with the pin wh>ch prolriJdes from the cenlre pivOI of Ihe pulley. If this Is nOI Ihe case.• IJcken the cab le edjuster locknut and turn the adjuster, situated on lap of the casln{/. to obtain the required setting. Open and close the Ihrottle a few times. then recheck tM setting. Aepeal the adjuslment procedura as described, Ihen lighten the pump cable adjusler locknut.

DTmodel The 011 pump selling is controlled by a cable connected via a junction box to Ihe Ihrottle cable. Thle junction box automallcally compensatel fa' wear in the cables and ensures thai the oil pump Is synchronised accurately with the carburettor al all times. As there is no need for adjustmenl. il is only possible to che<:k that the pump is operating correclly. To do this. slowly rolBte lhe twistgrip whilst watching the J>Ilmp J>Ililoy closely. Tho J>Illiev Ihotrld stan 10 ,otate jusl as Ihe throttle cable lakfll up ilS free play and 118ns to lift lhe throllie valva. FuliV opIIn It.e Ihrollia. The pulley should rolala smoolhly to Ihe fully open posi· tion. Bnd should return equally smoothly to ils fullV closed position when the twistgrip is releaSffij end allowe<:J to snap Shut under spring pres""re. If Ihe operation of lho oil pump is incorrect. Ihe fault is probably in the junction box 01 the thronle cable. The junctlrln box can be found under IhI! fuel lenk. and although no spare pans are availabfe fOf lhe box. it can be oxamined and cleaned by releasing the four scrt!ws and removing its cove •. Check tho boM for signs 01 ..... ear or corrosion; ~ damaged, Ihecomplete throttle cable assembly must be renewOO.11 a~ appeara 10 be well. lubricate the junction bo)( components with 8 synthellc aerosollubrican\ soch 8s WD40, do not apply any I!rease oroil as these could have an adverse effect on the operaHon 01 the box. Refit the junction box cove. and recheck the operation of lhe oil pump pulley. If the pulley is still not opereting smoothly tho throttle cable muSI be renewed.

~

If r

"

l

or modIII

Ad!uII oil po,n!p c-. untlI tpeCrfoeod ........ """ lit COfrKIlhn»\IIo 111*10011 TZFI model

~ ••mood'lly

5 Check (he transmission 011 level

in) (II f,eepIay '-tween thflleYer butt Ind IIOd Its mounting bracket. II

W,th the ....chine ~ on level ground. s,an the..-.go .... tnd allow ~ to ~ 14' to ~ope<.I"'IiI t~t ..... SIOPlt1e"'9"'" _ I I 1IW1UI.1or the I'....,...;on oiIllrvellO ..!tit. tnd lhero cm.ck thllIrveI ... the lightglaa art"'I" w. the light-hand CUI.. c:awog. With the ......... ~ ......,tIy uprIgIII. the IeWllIhouId bI ' * - the """"""'" Ind""""""",, m.U on the ..... cllhe ga.L11 the oil ....... IUO low ....- the filM C8(I WId add ~I oil 10 . . . . n 10 the ....-eel ....... lIMoniv. good q.,aI,ty oil o!lhIIllMd/ied ~_ ~ !he 1_ cap 0.""9 lind rer.w n II.-..y. Refu The filler Uj).

.....tmMIt ..

.-thtoItleClible iooctkln boo: ~ puleydoftnol

6 Ad;ust the clutch

11'*-'V,..-lju$I~""ICh~

....haNsm \1M te>
Thecltn~hlll~ledCGrnlCIly~I"" • • 2

3mm(O.oe 0.20

Noqulred. ... the hIIndIebIot eocI ~Ie< 00'1 the ....... mounlong brackltt. IIItIet1I III nwtfc..nt tange in the ",*-1'" ICtew It ~ inw.... Ind _ 1"- lowe< 1IdjIAt.., mount.-! on the left·hand side ben.. to tJl
cI,"

beld,..._

"

ROt.Il lne maintenance

32 lei Ibi

SllcklH\ fuIy boIh cable adjul'''' RItfI'IO¥fI!he oil pump CO¥« Mod dOlCOO"O'*llhiI 001 """'" caI* lIIdoolp,pes

lei

Ot_tMtr~oiI

Idl 1111

0..... Ihe coolrIg 1)'Slem Ootconnect the radiator '-" "om lhe . . _ _

ttl

~

1111

RemoIIe

ihekjd:&tlif1leveo" the ngh\.1\ao(j C.-ankClOH coY«

C8f1'..

Tht clutch ..Ie... mec ......... MI,USlet .. ",.... ted In the of ,..., ~ .. plitt!! end is -'Justed .. loIIowa; 51Kk"" , .... ponhtod ..:I,USIe< locknut end push the clutch 1",,,'19 arm .. 11K lorw ..d .. possible. Thee tih,,'!! .. m, the Inn ~ c:on-ectlv Idj
on lhe ,.anke... end "ghten the locknut. Complete MI .... tment bV 'udt"I"'9lhe~ .. ~ above If Ihe'IIQUO.-:I~lol lreel>lW1 .... f;.....ot t..obtWled ...--U.. duu:h cable... It. problem lhe dutch ~ be dilrnantltd and e • ....-.ed .. ~ '" 1

_IS"

muI'

a..m..

and W<1h
f,.....,

s.eaIId 00II'''' lIfM:e IUd is IIygro5oopic. whoch II1NIl5 tlllt II abo ...ro. moos, ..... f.em ,he ..., lherefore old fluid ....... hro'e ' - ' " 0Dn1_t.:l to...,;h . . . . ,1\11 rts boiling poonI ' - bNn tow..tI

1_

10 . . """"......., R""",,,* Il1o IhIe l;qj;elUd is . . .oaoIInt ~ II""",, and ...... , tad plett;;;: cuml)Ofllflta: with IWfI1Iny IQiIed IIuod lfTIf'I1O!Idoately Wllh ~ 1I'*''''_d w"er When lhe ...... II conIC\, dHn and dry lhe ditph."",," fold" inlo iU; cumprHlld .... Ieand I~ 1110 Ihe.fII$fVQIf Rer" ,he ~ WIler tnd loohlen 1fICUfIIy, bul do rIO! O\I"''9hl'" lhe Kf ___ To Che<:k tt.. degr .. o! !*I _ ' on TZR model1;,l0010 ckJMlo;l II !hi pad. hom bel\ind lhe ~,pe., Wu. lim'l f1\&fkl lire provio:led on !hi o:orner. d the metll bkk,no ol lhe peds. If lheM merk...... makirqor are doN 10 makotog C(In\ll;l wllh lhe dilC, the pIdI mUliI be...-ed.

.".,n"",

IHI.

On !h.

or model Cilipet',

Uterll IS I remov.tlle

rubbet'

plug

lor

inIpecIing the PIdL The _ indicator ior on the form o! I II'W" ......,;ngdownln.cen' .. dthlllricl""'melerill lf lhel*»hro'ewomto lhe poor'Ol wtIerI thoa grooYe .. uPQllld. the ped$ ....... , be........, •• ~.

7 Check snd ad/US! the brakes F'onllM .... T.... hvdt...-.:: br.... , _ no'~ ...... tmenta, /M'd _ .. oompenuled lor by the .o,lIomIIlM; .mry of In(q IIuid intO the .....I8m from IIIe IIuod rltMNOH' AH m.t IS - . . r y IS 10 "";nl..., • 'l!Ig\llar check on tile fluid leY .. end It.. degree 01 To clMlc:\ the fluid level, lurn tile haodle~ unullhe _"'01' is 110"1001111 (f,onl mke only) end c'*k 11\111 tho livid level. .. '"" through llle rewlVOir body. II nol below the IowtIr le\rel mt/L Remem· be< lNoI whole tll
p..t_,

'aIIs

.

,all

E _ 1h11 doIphragm IS CDfNC!!v POIJiIJonlld bIIore.ef'I!"'II I;w"'elluod ' - - _

To _ I h e pada on _ _ TZR modeIIl2Rk lind 3PCl L . . . . boIh Clliper moutIlotog bolla and """08UYrI lh' I;qj;. uoI;per 011 !hi doK. Whilst lUPPOf'Iong lhe CIIiper 10 1M it not hang by III hyd •...-: 110M. stack" and remove lhe IWO brl'" pi(! .elaonong bola

'**

The pads thouId now be fIll end CIn be sj;;j out 101' •••mlnllloon or _ _ -'; note lhe POIJihon. oIlhe 1f\I;.IQUe" ",iffil, On lhe " IIII' TZR modi .. (JPC2 lind JPC3t the brake pads eat til 'lIITIO\Ied from lhe c.hper whilll lhe CIlipe< it lilled to the ~

L _ 011 the CO\IIII' hom lhe lopo! the Cllipe. 10 'liveallhe!*ls Ind pili xwtng RC!TlO\'iI the two R·c~Pllrom the pad retain.."", pil'll and WIIf'I. drew the po", and !*I JPnng The I;qj;e peds een now be lofted aut aI I"" CIIlpel' lor •• _Ioon or •..-a.. No!1I the JXMlt_ oIlhe pili ..,.,no lind . .u.~ . . . . II • guode 10'1IIS8fYIbIV On OT modfIII, _ lhe dIIC _ fIII-.nong ICffIWS end _

both lhe diK lind ~ COYef'S. St.clten and remove In. CIIoper bocIr reunng boll.. lhe .....1* lhen be rotlllid ........I~ direct"", 10""'" lhe br .... pads. The peds CIn lhen be.1IffiO\IId t.o.I

On TZR model br• • ca5per .......1 be viewed

I.om _

tochoeck PId_

'*'

-

On Of model remove tubber plug 10 inIpI;a

......

Rouline m.inlen.nc:e

·••

u

~

•o.

, ", >

•, o

Ihe _\JAg bt.tet IIIong .... Ih lhe PId spr\ngI. Mak• • 001. 01 how 1he'P'''9 _ _ llWIlooned.1 ~ 10'eaMmbty llihe I)I(t. _ worn 10 lhe limo! A\lJb.IouIed .... Ih oil OJ ~. OJ '-YIIv I(.(Q(I OJ ~ bydirt IOd debt-., !hey MoAI be _ e d . I ac..1heJ•• 00 ....I~OJV w-v 01 degre.ing h'icllOJl ....tena. II the IMdI can beUMd 8gWI,....,..,!hem....eiully..-.v. fine W'If8 brush 111M • C()JfIflitI ......, " 01 oil OJ 11'_ ROJT\O'\/e .. 01 roed dlfl IOd lhen ..... POInted OJI$lrumenlIO"""" out lhe Qf'OO'o'e in lhe tncll()Jl mil .... fTZR modeIf.llOd lodlg OUI eny embedded IM"'lodn 01 .....eIgn mille< Anv .. _ 01 ~"ng mIV be removed IJIlng emery cloth. MeulHe lhe IhlCk_ollhe pad lrictlon JOIII ...... 11 Mhe. pad 11M WOJn 10 Of beyond lhe 1MttV~ limit. " .... en In lhe $peI;1'iclollon .. lhe pIIIb ......1 be ...-.d .. I sel. On tlllMmblv. " new pIIIb _e 10 be .ined. I'" eeliI- PlSlonj.1 .......1 f'IOW be puahed IlIck II •_ _ poUibilt inlO lhe c:ebPe< bOJe(lj to provIOe lhe c . . ._ neceMIty 10 eccommodIlllhe unworn pedI. II IhouId be pouibIe 10 do It. .... Ih hind preuuo. IIone. lIenv unduII iI encountered lhe CIIiper IISSM'ibIv IhouId be ~11ed 'Of ...........,.II()JI _ deIaibIId in Chaplet 6 WhIt pu&IwIg lhe IIIIlonill bid:. ..--!.-, I c.lIlui walen on the lkMI ..... in I'" handIebIt _ _ II lhe _ _ _ ..... ' - ' oveoflled. lhe SUtfIIuI fIw:j will powetIllhe "",001 tfllUfTW>IIluiv 1Od .....1 be tfIffIOYed it up Wllh I clun cloth. T"I c.e 10 prevent lIuod~. A;lpIv I IhIn ...- 01 c:ebPe< "''''10 lhe edges 1Od._ SlMfece of lhe pedI and. 00 TZR modeI&.lOlhe PId.It!""""pOna. T"'ecare 10 epplyceliper~ 10 lhe mela! IlIckl"ll 01 The peds ontv end not 10 allow any " ' _ to conl""',,-Ie the "ICIIOO mete"a!. FII lilt! Pldl by ,,,,,,iP"II lhe r&mOYaI~. Nole 11111 VlmllII recommend 11111 lhe shiml (wtMmt lilledlend Pldl\lfll"lllllhould be renewed neh tlme .... w pads ..e fiUed. On TZR modeIl -...e thai the pedl IocIle COJt8C11y ~I lhe Inli·SQueallhiml end thai lhe enli. fin" I-Pfrng ~ 00tf1tC11y ....11IIed in the ce6Pe<. On "I.. modeII (lPC2 IIt'Id 3PC31 not. lhal The Inti-fln" Sjlnf'IQ mual be filled wilh The " .... ped ...ow poinl"", '" lhe ditec:tlon 01 wi-' tOtIllOJI. Ptec:. the I*b in the ~ IOd relit lhe bt.... ped 'el-'ll boIU, l""'lenrng lhem 10 lhe -,"red IOJQUII MIll"", (2RIC end 3PCl modeIII. OJ lhe bt"e PId <et..-.g pinI end R.pinI (3PC2 end 3PC3 rnocWI.I. On lhe . . - . TlR ~ (lRIC IOd 3PCIJ. <elit the ceIipeo _s.nbIV 10 lhe mlChone ........"'" lhe! the pedI engage COfrectly on lhe diK end lhat the ' - it; 001 I_led. lhen ref" lhe _ I " " , boI~ IOd l'llhlen lhem 10 lhol _,,"red 10tQUe MIll"",. On DT mode .. note lkel the tOIJfIded side 01 lhol I)I(t.IhouId . _ lrom thol cMc. Checlc 11\.01 the lWO ped III)riI"llll"e Ioc:Ited COf'eclly IIt'Id IWlng lhe eahPe< body back down inlO I)OIIilion Relil lhe CIIipeJ body .11"fllng boIlI ....... ,ng Ii... t ll!>Plied I I","' of cellfMIJ lI'e_ 10 ill IlIInk Tighten lhe rel8
tr_

tOJ.-,

",tl.-

by"""'"

ew..,

.uII 110",

_so....

..,..,t.

CIte'' '

5O-1OO ..... 101If'IIbIe lhol pedilobed infuly RHobJ"'l The __ bt.., 'VSlem lillld 10 lhe DT ~ 10 ....1Ton1 end .... , ......... madecen be applied in molt lespecIa. To g.ton _ 10 the __ ceIiP8f" it will 'lrst be neceMIty lo....-Ihecelrpet IIUIfd pII1. whICh • bolted 10 lhe .-nging ..... ROJT\O'\/e the ~ body re""""" bolt end pivot lhol caliper 1,IpWII'r;b 10 g.ton tICC8II 10 lhol 1)I(t.. Re'''' .0 lhe del_lI"'en IOJ lhe 'ront brlk. ~ not"", l!wrllhe btak, pad on lhe Plllon side 01 lhe celipe< (ouISideI ~ fitted Wllh en ...IJ·tq....... hlm. ThII,hould ~ ...-ed each time I .... W MIl ol pIIIb. fitted. Mak ...... e 1,",llhe 'hIm" filled COf'ectly Ind to the COJ,eo;l bflk,

model.

""'"'"

""'.

EIf\v TZR modeIII (2RIC. 3I'C11 ..e .illed wllh. d ....... btlllte whet_ let" models (JPC2 end 3PC31 .... I dISC btate. T'" 'ea< btate CII;p.,. II baIoc:aUy lhe same II the "001 eel"", on ....., TlR ~ (2RIC end 3PClll'" rernarU made PtfIYOOUIIV CItl t/w'el ..... be applied. T... _drumbJ ..eliltedlolhol....,modeIIlhouIdbe~

_'oIows:

0I0ck I",," condotlOJl of the brakl opIfat"", linlregl. ............ t..... II c:omponents "I in good condollOJl. propIfIy IubnCIIId end _ ..... '1S1ened o..menlll .... __ brlk. pedal pivot end 11"_ illt! ...... inl...v.... Note thIt lhe 0':1110111"", mechanism 1111 III l"I'I0I1 efficienl when. WI,h I'" btel:;e COJJKI/y ed\l4ted end lPPlied lhe engle b f l _ the CIbII OJ rod end the opetIIIfIg ann on lhe btalcl blcl
'uly.

,.ceed

..m ',om lhe btake Clmshait end tOt"'''II It bv one OJ two sprrnes ..... ,~

lhe engle ~ COJ. 1tC1 EniUfe 11111,,1 componenls ..e cor,ectly MlClHed on

,eassemblv Drum btlkl shoe we .... checked by eppty;"II lhe btal<e firmly end Ioolung II lhe we .. lndiclolOJ mitt. on lile IlIck~le . II the IndOC:IIOJ poinT" on lhecemlhlfl It aligned Wllh. OJ hal moved beyond ..... 1J.ed inde>< ""'" ClSI 00 lhe IlIckINII. lhe shoes ... WOI'n out end .......1 be ....--ed II I perl. Tt. in¥ONes lhol .emovll of the wheel "om .he mIChone • deIaibIId in Chapl". 6 110 lhal the br.... componants CII'I

lhen be ditmenlled. dNned. a-ted lor _ . end

~

1'*

Iowrng lhe ".ItUC!tOJ'II grven in lhol ..... ChIpI., 1'1 II importenl 11\.01 moving PIfI' such _Ihe btalc. eamthlh "Ilubriceled WIth I . . . - of high meIi"'ll"POOnI W - on .....embIy (see lWO-yelfly hINI:IingI.

To ........ lhe , _ btl6.e, suppon .... mIChone 110 thel the'HI" wheel isclell' oItheground,lIQOtI the wheel end l""'len the adJIII!Jng nul unlill rubbrng .ound is hoIlItd _ lhe Ihoes begin 10 "",,1.1 lhe drum. then llec:ken the nUl by one Of tWO I ...... unl~ lhe IOUnd 0faMI. SPIn lhe wheel end applv the brel:;e t1Ifd 10 MIllie lhe componanlL Check 11\.01 the edjuslmotnl has not elle,ed end lighlen _etv an dlSlurbed fasl_ ... Thli IIhouId eppro.imall the lj)(lCIlied sailIng ot 1_ pIev be'OJe lhe brake begins to engage lhe drum (see $peI;1. iclotionll. Swilch on I'" ignition end check I..... lhol lIoplamp lighll juS11i III t... plav hal been '-"en up end lhe bJltU II beginning to 1If19IIIII. Tl'NI .adjusled by holding ste.ctv t... IIOp limp , _ IWllen body end tOt""'" I'" plHtlC sleeve nullO ...... OJ IoweJ the IWllen II f'MICIt&8ty; do not allow lhe body 10 rotl" OJ itllem'MnII will be ciIo'Noged. Check lhe _en ..""", the _ bJ"e is Idjusled. CompIe" breI. • ....,1 __ by r::hed.ng that the wheaIII ..e f_ 10 tOtlllllllily.end ItrenlubnClll lllioUoe pivog. To~t the . . of oil finding ill wrt on 10 the lyra OJ the btII<e Ihoe linings do not oiIlhe brake component • •..-vetv: I few dtOpl 01 oil It! uch poinl wII suffICe. LubnC/lle lhe IIOPIemp &wilen WIth I wal" ~I Hurd

wne.-

"""-..,.,

B.,k,leve. end ped.1 edju. , menu . 11 model. TO g)mpiete brake """;menance il w,1I be neceaury to c/lec~ thai the brak e lever and pedal Ire cor.ec.1y edjuIted The front brake lever i& ediuSted by a ICrew and locknut .. tuated on the handleba< lever. When propertv adjUSted thera ahould be 2 5 nvn W.08 0.20 in) h eeplay. meat.u<ed al the t,p of the br'ke leve. II nol _k8f1 the lockout and edlU5t the ICrCW untU the COllect amount of f_plav Ia obt.lned Once conecl'V Idjusle<:!. loghlen the locknut IIfICf check lhe operation of lhe brake before llkir>g 11>0 machine on the road On lhe rea. drum brake II wiU firsl be netISNty 10 cn.ck that tho pedalia Hlallhe conec. heighl. The tip of the brake pedal ahould be 41 mm (1 .6Inl below 11>0 lop of lhe fOOI ..., . •f nol. the POdaI height can be ,lle.ed by alackenlr>g illlocknUI and movir>glhe ..... te ... tUBted on tile foo"..t bnlckll. Once 11>0 ped,l height is known be coneclthe brake pedal f.ee plIoV <:In be checked. The .. should be 20 30 mm (008 \.2 In) of f. " plaV. _ured .t the brake pedal tit> before the brake Ihoas eo0 'III disc brake chick IIIaI lhe ..a' brake pedalla.., 10 the correcl heighl IS Ihown in the SpecificlltiOnl. If nol. '1>0 brake pedal can be adjusted using the IWO nuu on lhe bollom of lhe master c:vI,nde. openoling rod. On TZR model"he lop nut iI the locknut end the bollom nut 11>0 adjuster, wher.,. on OT model, the bottom nut i.,he locknut and the pedal is adjusted ,-",ng the lop nul. Sla<;ken the Iocknul and move lhe Idjusle' unt~ the cort9C'l pedal heoght IS obtained. Once lhe pedal height is 101. make a vilulll check to _ thaI the adjustment mechanism is oo
'0

co"eclly and adj .... t Itt POS'tion ~ necessary: use lila InlOf"ll"-..lion In tile drum brake Heloon lor dellill. Thoroughly check lila operallOfl of tile 'N' brake before liking the machine on Ihe .oad

8

Check (he wheels and wheel bearings

PGI
'''''''''' More than slight adJUSlment ClUIO lila spoke end, 10 protrvdt through Ilia nipple and chafe lila Inner lube, ClUSing • punctu ... will

Remo\Ie lila tv,e arid tube.nd file oil lhe p0l<. 'mrriediate1v because the !old liken by "wiN be tnonsl,ned to adJIklInI lPOkes whoch may lail in lu,n.

Rou tine maintenance

""- ,

35

EnIure IhIt lhe fron. fo
c..IuIv ~ thewmplettl wt..I lor Uk'" and chipping. PII"IICU....., _ the tPOke roo .. and \he lOdge of the lim. Aa a genefIII rule a ~ wbMI ...... t 1M .-wed .. Uk'" wiI _ _ 11_ poont. ""'-;h rnty laid 10 II,Idden failure tIfIdeo huvy Ioed. SmalI'OICItI rnty be .-....d......way with I line foil and {No600 No 1000110 ........ !he II.... Note lhill wiI desU'Oy \he palmed firlllh of the wt>eeI 11M the wt>HI wi. thuol reQUlfI toud1in11 in wnh ..... tlble paim. 1I there • InV do\KIt .. to the condition 01 I wt1MI. Idvicl IhouId be IOUIIJht ffom a ' ....tllb'- deale< or.pecial;st repllirer. Check the IKIaI ,unout i l lhe rim by tpitll1ing the wtW end piecing I fixed pormM dOH to the rim edOe. Il lhe muimum runout "II'Nt&/ thII"t lhe lpecltied hmlt. the lI'IIII Ie. howe\Ie<.' r;ounsel 01 parlecllon; I runout lOmllwhll grNlM than Ihit can probably beeccommodorled withou! nOllc"loll elleel on 1I-.rIII No ~ is IV'"""'- lor .u.;gtr11l1inQ I warped whMI wilhoul ..orting 10 !he .. ~ of hIVrng lhe whMI sk, .......... on both fec_ II ~ w .. .....-I by imper;t during 1l'l1IXidrIn~ lhe II 10 . . . - the wheel COITIPIeI•. Wom wheellxIIringI tnrf _ _ rim I\JIIOI.I\. T ' - IhouId 1M ..-.d.

......,,1>11*

wf., _

"'I modell

An OUI-o!'tIIIIr>o» wheel wiI produce. ~ elllC! Ihrough !he "1Ofing " high speed. Spin Ihi wheel _ I I I...... A well bIlanced wheel will come 10 resl in ...... posilron. en. Ihll ~ 10 ,..., in the .. me po&Ilion will hive it. helVieit pIIf\ dow ........ d and welghll mult btl Idded 10 I porrri diamelrically oppoe!te untH ~ iI echMIved Whe' 1 the ty'. hal I billarrce ....... k on IlIlkIIw!llliu_11y a coloured .pot!. check II " In ~ne wilh the vllve. Tocheck the wheel bnrings.II"ISP eech whlel li,mIy lithe lOP and botlom and Inampl 10 rock it from tide 10 IkII; II'IY I , " play indicat.. worn bNringi which ......, be _ e d .. det<;.lbed In ChapIM II.

pumping !hem up end down whikl\he """t brMe;' held on. Any I...... revealed by .... ~ should btl InYIIt9Iled immediIully: Nler 10 O>.pler 5. PIIIico.IIIrty if !he oiI ..... _Iuting. On TZR modeIIin
pKl the .tanc:noor..lookJng lor IIIgrr-.. of chipI or other dIrnIga. then UI lhe dull e>
.11 .hI,..

w.-.

10 Check the cooling sySfem The cooling Iystem should be checlr;ed for IIIgrr-.. 01 leakllll or damIgI and lI'Iy - . -1hr:IaH RefM 10 Chlpt.. 2 for fUfl her

_wed.

informltron.

9 Check the steenng and suspension II.- lhe lront wheel ott of \he ground by ~ thrI mardIine on • _1toII.Uind and M(Unf'Ig the mardIine frm'IIV o.:k the It-wrg held beanng ldjullmenl by II'MP"'Q the bottom 01' boI:h lort lower . . lhen pulling and ~ in I fen end aft dir1rcllon;...., I," play should be fell b e t _ the IorIt boI:lom yoke end the Ir8me held lug. Check for overtighlened bNt\ngI by piacrng the 1orIt. In lhe ,',..;ghtahelod po&Ilion and lipping lighlly on ont handlebar end. the lort.1houId fall IWey smoothly end NIiIy to the 0l>>0I11' lock. IIIking Inlo lCCourrl lhe elleel of c.tIbIeIand wi ..."" Wllh IfIK8$ 01 nolch ....... II IIICHIIfY. IdjUlI lhe steering held be.ri"", .... ,ng the Inlor .... lion In Chlpl.. 5

no

t

~ -· '-- PIo.'1C ""9

.ounct out", . -

'""'-~,

't " ' . . ·, -~­ '1'0"''-'_

I(

Lubricate thecontroJ and instrument drive cables

'*""

._11 ;.

U .

wi.

'-. ,

"

Check lhe OUI.. lor IIIgrr-.. of dIrnIga. then • ...,....,. Ihi ... PONd POtIrcn of Inner CIbIeI. Any IigM of kri.ong or f,eyIng wiI irdrcate Itltt required. T oob! .... """""""' end.eIiItriIify lrom 1M CIbIIIlhey IhouId btl thoroughly Iubric:Illd. To do the job property end quickly UII one oI lhe hydraulic cable oIIert .... lllab11 from mosl motorcycle IhopI. F.ee one and 01 .111 cable and .nemble . he c.abII oiIet .. dIIc.ibId by 1M maoulecl""..•• i"IIIUClionl. ()penrll lhe oiler untIl oil _11'1 h om lhe lower end. Indicaling lhal lhe ClbIe " lubricated throughoul it. III"Igth. Thil prOCHI w i" e Kpet I ny dirt or II"IOI$tu,. Ind PflVenlllllUbiequenl 1"11'"'II • cable oiler is not IVlilabie. 11'1 allernative iI to remo-rl the cable lrom Ihll'l"IIdWIe. Hllllllhe cable uprighl end """. UP' ""'" lunnIf ~I ...-..g pialllClne or by tapping I pialtlr; bag "ourrd the upPIf and. fill thrI t"""", WIth oil end !live it OYIfTIight lo""rr Ihrough. Notllhet ~ nyIon-linedClblll_ fmed. they should be UIId dryor iubnClled WIth • IiIif;onrt.bMId lubricanl SUItable lor this tppIieation. On ordi....., engiM oil ber::IoMI thill w i I _ thrIliner 10 lWeI. pondwIg the CIbII. On DTI25 modeII onty• .........00. 10 inIpact end 10 IubricIte.1I necMIIrV.\he thronleo'oil pump cItoII junctron bo. . . deIcribId under lIem. 011'" Section. SimiIIrIv. 10 - . . e Ihi ~fIet and lCC.... te operilion of lhe s.peedorneler end techorM .... lhe drive ClbIeI ........1 btl ,1IfIIO¥ed from Ihi meclune .. dIIcribed in Section 18 of ChlplM 5 end IlreIIId. Rernembtrr 10 but lhe uppe-r at. irrchel 01 the ClbIe 10 pteVeI"Il ~ to lhe I",\fument held.

Oiling' conlfol cable

no_,..

1I,_.n

12

Check and lubric8te the side stand p ivot

It iI --.llIIlhal the 1ITIOOIh. ..fe. ~11on 01 the IIidII .1Ind ;. ....... ed by regular lubric:ltion. wM;h w il_,wo fIUIlXIIK. ThllIirIt. end .....a.1 important. II Itltl • ...,., 0111"_ wiI preven. the ONe! 01 COfJOIiron wtIoch would _ _ !he o;:ontroIs 10 bacomIlliff end jIrty In operIlron.lI'Id .hllIICOtId ;. Ihillubricllron wiI minimise I h I _ thll wiI "-'tlbly occur on tnV bearing ...-fece.. IMmImle, clean end IlIUM !he side stand pivot " drIIcrlbed in Section 180f Chapt.. 5. Chectt lhal lhe IIidII.Uind .Wltch iI lurrctroning oomrct!y end Iubr>Cite ~ wilh I Wile< ~lllurd IUCh .. W04O.

Lubricatll tidHtand pivot end apply II wBtllf-ilil(Mlf'Pnt "uid to switch

Annually, or""VV 8000 miles (13 000 km) Tile annual maintefUu"ICIII opefetion IhouId be regarded as II minor ovlIfheuI. Carry out llilihe epplicab:e lasks listed In the previous mileageltime saMce headings. lhan complete the following:

,

Change the transmission oi(

Oil ~hengn _ much QUickllf end more efficient if the mac:hine is lak"" lor e journey long enoo.>gh to WlNTTI the oil up to normal OPIIf'Iting temPllfllIll<"";ne 1\-4 plug Maling w..ner end ._w il diwnitged. nit the machine slighlly 10 the righl 10 allow lhe oil 10 drain lully. On complelion 01 draining . efil the drain plug and .....ting lighlllning il 10 lhe lorque selling giY"" in lhe Specifoeationa. F~I the gearbox with lhes.poclfled IHTIOUfllol SAE IOWllO SEengineoiLa-t lhe oitlevel as ~bed in lhe lIix·monll;llvl4000 milo! ....ioI inlerval and refil lhe fitleor plug. a.eck c.efully lor env aignI 01 oiIleab.

wasn...

2 Renew the brake fluid It Is roecesNI'/ to ~ the btell.1I IIuid III lhi, 1n1e
TrIIIlIITIis.&io oil drlloirl plug Is situated" bottom of right·nand

c..mkca. cover

3 Change the front fork oi( Not.: On 3RN811>Odeb rhe
15and 16).

PIece II ","t 01 cardboard IIIPln$t the ~llo keep oil 0/1 the brIb or t~. piece II suiUOble c;ontei.... uncle< the fork leg and , _ !hi drain plug which is. small _ _ Illhe IIide of the lort lower leg. OepreaItle .ork._altl.... lolll<1< spring.lpring SlalII'Id _ . followed by lhe lap plug and cin:1ip or lOP boll. MOYI !hi mec;hine 0/1 of ill . tend, apply lhe fronl btake end pump tile forb w and down unli/the damping eIIlCI cen be fell 10 be fully restored.

r..

fork oil level dipstick can be fabricated "om II length of wi.., as shown

I

,,

Routine maintenance 4 Renew the spark plug The spaflt plug should be __ wed IIC this .... Ierval, regardless 0' itl IW8
5 Clean the fuel filters Not.: petrol is 1"'r6mtIIy filNnmllble.

II'1sptKlIJ/Iy when lit I"" 101m of -.poor. T-'celJll P'fICllUlioIIs IOpmvlNl' .IIiI nsk of IrI'tI tH>d ~Ihos..f"ry fiN! sac/tOt> of lhis ~ before s/lIrfmg wtxk.

Remove the fuel \80 hom the fuel "'nk as de$cribed in Section J of Chaput< J. Remove both tile tubular r...."lilt ... hom the lip and dean them carefully in I'IfIw patrol. ROJ/", to ~\ef J, Section 3 and r.fillhe /it0fS and tap; check lor ''''''' leak"'9" before laking the rmchine OUI on !he,Dad. On the llal &Iide type carbu.ellOt lined 10 lilt".. OT moOO/s, lher. is ....,,, fuel lille< lined 10 the .:arbureuOf body. Thilllill ... ill sitUllled on Illllluel inlet side end can be removed hom the c.rnu.llttloronce the fuel lap has been , .... ned ot1 and the luel pipe has '-" disconne<::led from its ~el1Of union. RemovfI1M filtll'l'. c ........ il in new pfltrallK>d relll il 10 the carburenor. Coooecl the fuel pipe and tUfn on the fuel 180. Thoroughly exemine lhe fuel tap end pope lor IeMS before IOlonglllo """;',ne on lhe road.

"0

•

Two-yearly, or .~.ry 16 000 mlln12S 000 km) Compkne lhe tau. lisled under the pte~OOO$ he;odings. lhen C8fry OUl lhe loIlowing:

,

Grease the steering head bearings

Rele"ing to the relevant Sections 01 a..pt"" 5, dismantle tllo steering hNd, dean an compon8flts and chedc lhem lor wear, renewIng ..,y wOm items. Reas$8mble. pacting lhe 51e&ring hNd beMingl with "ash ",ease.

2 Renew thecooJant To min,mise the build.up 01 ~15 in lhe cooling system and to ..-.slife maximum ptotetl!on "9'!,nst its lreelOng. the coolant VoouId be d
damage and new coolant mixed for relilling. Ref"" 10 ChaPle< 2 lor details.

"

arises. A machIne de&r>ed regularly will not only 5t.>CCumb IesI s.peedily 10 lhe inevitable COfTOSion 01 exl""nat wrf-. and hence maintain its m&rlcel ~alue, but will be far more aJ>l)foach.ilble when lhe t,me comes lor maintenance or Mlmee work. furthermore. loose or lai~ng componan" are nwwe readily SPOl!ed when nol P&r1ially obscured by. mantla 01 ,oad grime and oil. Surface d,n should be removed us.ing • 1ponge and wann, soapy wate<, the lal1e< beong.~ copiousty to remove lhe particlasof grit whio;h moght othefw,se cause damllgll to the ~ntwort .nd polished SUrfllCM. Oil and 111_ are removed mo61 easily by lhe .pplicaHon 01 a eleamng soIvttnt su::h lIS 'Gunk' or 'Jlzer'. The so/IIenl Voould be .pplied when the parts a", s lill dry and worked in W,lh • Iliff blush. lar!lC! quantities of walflt should be used when rins.ing olt lak'ng care Ihal wate< does not enter thecarbur~l1or, arr fille< or ~lecvic,. Application 01 a wax polish to the cVCIe pans Ind a (IOOd chrom~ clear- to the chrome p8f1S woll alsogrv~ a good finish. AlwaVS wipelhe machine down if used in tn.. weI. and ma~a sur~ the chain;' we-ll oiled. There is IesI chanee of watl!< getllng imo control cables if In..y "'~ regularty lubricated. which will p«ovent stifl_ 01 Ktion.

2 Decarbonisation The oily nalu. e 01 any Iwc)oStroi< e engine" eohault Iuds to Iay_ nl carbon being d8\Xlliled in the combustion chamber and ~.hlu5t IVStem. If not removed 11 regulilt imervalslhesadepc)lits will built up 10 the point where the machine', performance and ecooomy &r~ signij;c..,11y reduced, 11;' very difficult 10 give. precise interval for dec&rboniutoon as so many differenl laclOed Of eXlended as ne<:1I$$8O"V. NOI~ that il may not be necessary to decarbonlill the exkau$t as frequently as the engIne. or vice versa, SO the two can be llealed " sepalllte il.,..".., with their OWO"Ischedules.

once.

Cylinder n..ad and barrel Reier to Ch.apte< 1 and ,1It1"OO\IiO the cylinder head and btlrre!. It is nao:euary 10 remov~ all carbon from the head.lHorr&l and poSlon crOWO"l whilst avoiding , _ a t ollhe metal . urface on which it;. deDoIoled. Tata care when dealing wilh lhe IOh alloy heed and piston. Nev~r SIee1SC, aper or lCrewciriver. A hardwood, MSS or aluminium sa,per is kJeal as thesa are harder than the CIO\led, 1>1_ wire blush. F;"ish the head and pillon worh melat polish,. polished surface will slow the subseQuem build-up 01 carbon. Clean out the barr~1 POff1 to ptevem !he r"tfICtion 0/ gas flow and clean the VPVS componenl1. Remove atl debril by washing each compon8fll in paraffin whilst observing lhe neceuary /i,e preeautoon ... Renew the pilton rings. if necassary, on <eassembly.

usa.

3 Grease wheel bearings, speedometer drive and brake camshaft To ptoiong their life lIS on..::h lIS POS$ObIII, the lront and reilt wheeII t.hoold be removed from the machine 110 that lhe .. be¥Ing$ can be driven oot cle&ned, checked for we ... and r~ if necessary. then repao::loed wilh the recommended 9 r _ and rellned. At the same time the ~Ie< drive s.houId be deaned and packed wolh grease. and on drum lII"ek8$ only, lhe blate camwh s.houId be removed. cleaned and lighlly greased. Refer 10 the rele~&rll Sections 01 Dlapter 6.

usa.

Exhaust • .,.I1em

Certain "u. do nol fall under lhe pteviot/$ mileageltime headings as they concern ,tems whICh deteriofate with "98, whether the machine is used • IIrH! deal. or hardly al all.

,

Cleaning the machine

Keep;ng the motOfq'CIe clean should be oon&idered "an impOrtanl pan ol lhe rooune mainlenance, to be C8f"ried oot whenever the need

first check thee lhe e xheust system is securely fastened and lhal ther. ara no axl\ilust leat ... Renew lhe ax!\aust pOrt 98lkel and, on DT models only, lhe rubber seal between lhe tWO P&r1' of the ..... tem. if leak...a found 11 either oIlhesa poinlS. Some idea of tn..condilion 01 tn.. .xhausl can be ga,ned by Iook'ng 81 the tlitp;pe. It the mixture and oil pump MIllings .... COff8CI, and the machine ;. ridden normally, the", 5hoo1d be • th'" film 01Il001.,. black CI
38

Routine maintenance

oeceuary. On the Oilier hand, ilthe rea, oItha ed,. ... , js excessIvely oily t8 loom of carbon, Of the INChine .. being ridden too &lowly which j)foduces the seme fymplDmS, If the engine HIIings .re known 10 be M,il' lICIOIY thank' 10 the previous Roul,ne Maintenance ope\! depoa,u; .r" Yilry oily, o;or>Sl$tl of lIushing the SV"""' wit" a petrolipa,..ffin mixrufOJ. It will be evid&nt tt.at g,..,..t «I'. mult be Ulk"" tQ prev""t tile 'isk of fire when USIng th,. method. and thet the system must be hung overnight In auch a WIY thet all the mi.tu,a wiJl d,ain away. It will be naceua
delall in the followlng paragraphs. TQ clean the silancer CMlng.nd e.hausl pipe assembly. remove the Iyllem from the mach .... and _pend ll irom ill ailenc&r and Block up lhe end of lhe uha",t pipe willi. corlr; or wood"" bung." wood ill used. allow an OUtl"'" Protecl""" of th'" or lour tncl\es witll wlllCh 11,1 (IItISP tll8 bung lor ,emoval. IINr in mioo lhat it Is very important 11,1 lake '\Ir68t cere when using caustic soda as it Is. very dengell911 Willi clean. lresh wlter. The clelning OpII<1Ilion is now complete.

3 Renew lhe brake celiper seals and master cylinder seals Yamaha recommend that tll8 blake cellper and mast • • cylinder'" lhould be at twQ.yearly int"",all, . . a u lely precaution agal",t their IUdd"" lailure. The brah celiper and mlSler cylinderCIII be ovlfhauled" delcribed in Chapter 6.

,_wed

4

Renew the hydraulic brake hoses

Yamaha ,ecommend lhet the hyd.. ulic br.ke hoses lhoukl be .-wed every lour Y_I f
."" ."" ,.., ,,~

,ins

live ~.

'ear ~.

!Iv. ",h

,., Chapter 1 Engine. clutch and gearbox

,," '"""

,.

",m

".

... '.

"'"' • •

"

For information relating to the 1997-on DT125 R models, see Chapter 8

Gene. &ldescription ____ .___ .. _. ___________ .__ ()pe
Euminllion and ntnOVlloon: f;tlln~ . ________ .___ e,..minalion lind ntnOVIlion: pri....,y drivllltlld "-I.ncer .kaft goN" wminllion and ntnOVllion: dulCh _ Eumlnalion lind ntnOVllion: kJo;QI¥\_. _ _ _ _ _ _ _ _ Eumlnalion and IlInovllion: gearbox compgnenll _ _ _ _ Gearbox shlllta: dilmanlling and _mblv _ . _ _ _ _ IleM$embiing Ihe~boJC unit:generaI _ _ _ _ _ _ ReaMembiong !he~x unit: preplring the crllnk_ . ReaMltmbling !he engi....gItIIIbox unit: IIIfming lhe ctankJIhifl. baIitnc>e< 'hlft and gNI"boIc CQmpgnenll _ _ _ _ _ _ _ _ R_mblong !he engine/grIarbox unit: joining !he crankClIlfl

26 27 " " ., " 32

10

ItMOITlbly _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

35

FleMMtmbling lhe ~~ unit: rertlling the gerwalOr __ R........t>Iing lhe engi....~ unit: refilling lhe flXlemll gear lOIIIIe1orcomponen" _ _ _ _ _ _ _ _ _ _ _ _ _

J6

1\

()pe<.tlons with U.. I'tIQ'nelgearbox unit removed lrom the "'me AemcMng the 8n9inolgearbox unit from the f ......... _ _ _ _ _ ." Dilmanl~ng the engine/gNobox unit: preilminloriel_H. __ •__ ._,,, Dismantling the engine/gearbox unit: removing the cylinder lINd, bIorreI end IMlon, _____ .... H. _ _ _ _ _ •• _ _ _ _ H _ _ _ _

Oiamantling engine!oe.
H

Oiamantliog the enginelgelrl»x unit: removiog the crankcllse righHI..-.dCOVe<.H. __ .____ .• _______ ._ _ _ __ ~lli~I~~~. unil: removing thedutch end pnm.try dnve ponIorI. ___ . _ _ _ _ _ _ _ _ _ _ _ _ _

Ditmantling the engine/oN
H. _ _ _ _ .. _ . _ _ _ H .. _ _ _ _ ' _ _ _ _ _

Dismantling the ~.rbo ....niI: removing the biol'nee< "'-fI ~. H

. __.___"....H._.H_..._.H.._"_' __._.____ . __._____

DismanTling the enginel~tbo" unit: removing the t..::homete, drive 111'_. ______ .____ .____________

Oiatmntling lhe engi~arboJC unil: remewing the

"

1M"'.... goN' "

MiectOf~" ______________

Dismanlling lhe engi .....gearbo>r unrt: remoY'ng the ""I*1Itor. _ DiImarltiing lhe engi .... unrt: .. mewing the reed vllve _ DiImarllling lhe engi .....gearbo.o unit: seprw.ting the c .. nkCMfl

ge.mo.c

""'"

-------Di ....... lling \he engi ....gearbox unit: remoYing the crllnkshaft

,nd goNrbox comPOflllllS _ _ _ _ _ _ _ _ _ _ _ _ _ . DiImarllling \he engi .....""atbox unit: removing oil ..... In
14 15

"

17 18

19 20 21

U 23

,..,..._------------------R....uembling lhe engi ....gearbox unit: rertlling the reed veIwI

RllasHmbllng !he enginIIIge.rbox reHlling Ihe tloChomelllr drivege _ _______ .. __ ._____ ... _..unit: _______ .. ____ .___

J9

R_mllling the ltOQI""'geatbox unit: relining ,he kicQt.art auemblv .nd idler gear .______________________

40

R....."."bIIng the enQi""'gearbox unit: refilling 'heclu,ch .. __ .__ RuuembIing the enQine/1JHfboJC ......It: refitting the righl·hInd crlnkcase OO\Ier •.. _ ... _ ... ___ ._______ ._._._.. ______ . __ .. __

42

RlIIoMIM"bIing lhe engine/ge_box unit: .....______ fin ing the._ VPVS componenll_. ___ ._____ ._____ ... _._____

43

bit""

RlINIIIMbIing the enQineigeatbo" ..,it; refilling the p;.lon, cyIInOot lind heed .. _ ... ___ .__ .. __ ._.. _ .. _._____ Refilllng'he~unil l n\hetramll _ _ _ _ _ _ _ $I.-IIng lAd running lhe rebuilt lingo"" .________ .___ .... _ Taiung lhe rebuilt machine on \he road .___________

Eng ine 124ccl7.6cu inl

La,erOT modell13RN1 onwlrdl. _ _ _ _ _ _ _ _ _ Siroke: TZR and IIWty OT modeI&(308 11_ _ _ _ _ _ _ _ LaterOT modell (JRN1 oowardl _ _ _ _ _ _ _ ._ _ _ _ ComPfanion .... tiD: TZR modeI. _ _ _ _ _ _ _ _ _ _ _ __ OTmodell. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

CylindClf helld Geske' f _

ma~i"",m

werpaQII ••• __ "_. __ •. _. ___________ ..

J7

38

SpKiflc:.n ion.

TZR IndIlWty OT modeII (3081 1_ _ _ _ _ _ _ _ _ _

"

"

ReaMltmbling lhe engi ....geartx;»r unil: refilling Ihe prirnIrv drive lind broIBrIott shaft geItI _ _ _ _ . _ _ _ _ _ _ _ _ _

24

'-" 11«11:

25

S6.A mm 12.22 inl 56.0 mm 12.20 inl

SO.O mmtl .91 ,nl SO.7 mm 12.00 inl 5.9;1 6.8:'

0.03 mm 10.0012 inl

41

44

45 46 47

.

Chapter'

Engine, dutc:h.net V"fbOli

S6AO 56A2mml2.2205 222ll;,,1 $6.00 56.02 mm 12.2G47 2.2051i Inl

"'I

56.SO mm (2.2244 56.10 mm (2.2087 inl 0.045 0.05Omm((l.0018 0.0020;"1 0.1 mm (0.004 inl 0.05 mm to.OO2O in! 0.01 mm fO.OOO4 in)

Piston S~OO:

~-:;i=~~=II_--_-_--_-----

DT modeIIlRN4 OflWIfdl______.____. 2nd~'= ----""ot.....DT rnodIIIlYI~~~-::.~.:::======== lit oversil l piston: lit...

lit...

~_

Pillon ,ingl

S6.14 5eAOmml2.2181

2.22051n1

&6.950 &S.956mm(2.202 7 2.2029;"1 56.25 mm (2.2 14610) 56.65 mm (2.230310) 56.50 mm 12..224410) S6.90mml2..2.0.2in) nRlrlClelrlyOT

lit.. OT model

modeI.130BI )

I3RNt onw..d)

Klyltoroe 1.2 mm (0.0472 In) 2.2 mm(0.08661n)

Klylloroe 1.2 mm (0.0472 in) 2.4 mm (0.0945 inl

...

"""

1.2 mm 100472 in) 1.2mm(0.0472inl 2.2 mm 1O.086e in) UmmlO.074Bin) O..JO 0.45 ...... 10-0118 o.olnin)

0.020 0.080 mm (0.0008 0.0024 in! 0.035 0.070 mm (0.001 4 0.002t inl

Cr.nklh.ft

Cank width

__ "

RVOCIO.lIIimII

1lIg-end •• 111 deIw..- (eno:IfIoIll ~ rod ........ defleclIOO

57.90 ~7.9Smm(2..2100 2..2815in) 0.02 mm ((l.0008 in! 0..20 0.70mmlO.oo79 0.0278in) 0.8 1.0 mm to.OllS 0.03!M in)

Prima", drive _ _ _ _ _ _ _ _ _ _ _ _ __ Rlduclionratio l.227;1 (71122T)

,,"" ......... •

, •,

OTrnodel.

2.9 l .I ...... (0.1142 0.1220iol 2.7mmlO·106lin) 1.05 l.35mmlO.0413 0.0531 in) 0.05 mm (0.0020 in! l4.5mm(l.l583 in) 32.0mm (1.2598 in) 0.15 mm (O.OO5t in)

K(c:kl t.rt Spring dip tenaion

.......

Ind autputWft runClUllimII _ _ _ _ _ _ _ __

~

''''' >d ''''~~

""

""""

0.8

1.2kll(I.78 2.651b)

G.08mm IO.DOll in)

""-

2.8ll:11l4I12n 1.8ll:1 t29116T) 1.368:1 (2tI19T) 1.143:1 (24/2 1T) 1.000:1 (2312lT) 0.917" 122124T)

Df_ 2.8ll:1(l4112T)

1.875 1 1»1

en

1.4121 (24117T) 1.143:1 (2412 1T) 0.957; 1 (22123T) 0.818:1 (18122T)

Chepter 1

Engine. clutch .nd ge.rbo.

"

2.813:114$116n 2.23S:1Issrl7n 3.s63:1IS1f16n . 26U_""

,.,

'" ,,..

'~h

'~m >2

..

..•• ......••........,,

,."

,.• ,.•

..,

.,."

3.' U

,,.. ,.,

,

.."

,.,,.,.,

."

.3

0»

"...

.. .......,.,..,, ..,.

U

LA

"

•• ... .....,

".,"'2"

,n

'2 '2

" "" " "" "

'-'

U

32

'3 32

"" ""

3.3 3.3

,

0..-.. dncription

The V........ nRl2s.nd OTl2S R modeIII employ. W.'e< <:OOIed. lingkt cylinder. two-wolle engine buill in ....,it Wllh lhe primery drive. clulch and ge&rboII. The cylinde< hNd ,nd berrel enl"'", ... 01' ligh\ ~ c:oro.truc:tion IM>d Incorporete c.sl-in PI"IIIIIS 10< the c:ocNnl. The cyIinde< tJ."rei heI. c.stlron liner and iI rtlted WI\h lhe V........ Power V...... SV-tom. "'hough 10 cornpIv with Uk IIogoIIMIon the power "live iI P'ggIId in pIeo;e and lhus CIfV\OI ~ .. The t;trish.h II 01' _iOnIII dIslgn. hew>g needle roIIr '-ingI1I the otWII"«t""ll rod biQ-and .......... endiisupponed bytwobelljoumlol ..... ~ A 11M'" driven tongII sheh primr( '*-- iI fi"ed 10 ~_ cne ~ whic:h exis,. in .. songIe-cyIinder If"9"& PrirnIIfy drfvoI II by heIicekut ~ 10 the _ mtJIti..plete do.rtc;t. fI"ICUIled on the ..,.;I 01' the gNrbox inpu! .n.tt.. The QINIbo>t II 01 the 1Ix~ QOnS'-"'I ...... type ..-.d is IubriI;Ited by oil beth ~ with the poi......., drive. the oil bIong c:on~ In • _ loomed by the maon c.ri~ c.sl.... The engonI oil and Wile< po.om~ ... "-"'led

on lhe cnnkc:MI righl-hInd _ _ ..-.d .e driven bom the f;flnbhlft via t.... pnmary drive pinion and f>yIon Idle< 08IQ.

'*'

The folowing h. . . be . emo>Ied with lhe engonWgeerbo_ unil in lhe"-: lei Cylinder held, _""..-.d pillon IbI CarburIlIO< and .Ied " ...... lei Clutch .-nbIy ..... primary driwt gur

1111 Oil """'" lei W .... pump If)

Igj

!hi

iii

iii

kiclt&tM1..-..........

G4rar ~ ............. ~emllc:ornponen,.

o.n..-

-.nbIy ..... .....".. swilch FinII ........ ~1 s.IIncer thlfl drive gurl

Ch'pl.,1

" 'r.m.

3 Ope,.tlon. wkh the .nllin./~.rbo. unit ' ,moved

Engine. dutch .nd gearbox

',om 1M

It is necessary 10 remove lhe eng;ne..geafbo. unll from the ha .... .nd 10 HIM.al. the cqnkcese halvell 10 gaIn access to the followIng component-=

(I) (b)

Crallkl.hafL main bean"Ol and 011 _Is Gearbox clusler..-.d bN,;ngs

le1 G&ar MIe<:IOI drum .nd fort. (dl BaIIlflCCl' shalt

"

Removing the .ngine/itt.mo. unit from the "-me

1 If the ....chIne is dirty. wasil it tho
........ 6

DIacoonect the bat18fy (negative IllI'minalli.,.1} to p'event any ris.k

ol7d Reltt...., \We lront mounting nutl ,.,

4.7e

01 ohon CIrcUIts II the "'III:h,... iI to be out of se lhe flow of oil Disconnecttn. VEIS hose 01' chambe< from lhe inlel flub .nd rerTlOVlt the chambe, I,om the mKhine 81 d1tKribed in Chaple,3, 9 Slacken In. clutCh cable adjulIlll' mounted on the !ell·hand SIo:Ie 01 the cyfonde< barrel and disconnect the cable lrom tn. clutch Ioll,ng twm UnKrew ill knurled ,,,\.lining ring and ,itlealllt tn. tachometer cable hom ill drive on the nght·hand c,ankcaillt half; Wl thdraw the cable and oil MIl. Allow the clulCh cable to hang down from the hont of the III"... and poIIt>on lhe tachomete, cable clear 01 the engine so necMr lingo....emoval. 10 Marting its ....11 so thai it ean be ,afitted in lhe same POI"toon, remove the kick,.." lever retaining nut and pull the ""'Ill' off lhe shaft ,pli ..... 11 Release its clip and POlithe expansion tank pipe off ill un>on on the ,adiator neck. [);tcOnnect the tOl> and bottom radiator I'IoMs hom the engine and r"mov" the .ad.. lor I.om the "'III:hi.... 15 dllKribed in Chapte, 2. 10 that the hosM ntmBln ."ached to the .adialo<. Stanirlg lrom the c,an~call tr~ the generalOl' wiring up the lrame luba, ,eiea&ong II f,om I
,emove both the Iront

4.71 ... and 'ea, mounting boI",.nd manoeuvre aKhauSl of f..me

cle.,

41St DT125 NIt10Vtt lOP II1\(II1'18 mountong btac:kll..-d fronl moun""" boll _

DT _

u..

18 SlId... 8Ad.....- I.... three bolls whoc:h MCUN lOP engone mounl'ng 8Ad _ bracket. R-.. both 1M Iron! 8Ad IDwtw . _ mounling boll.. INving the eng;n. only IIfICUfed by 1M lwinging 8fTTI pivot BelOftI remcMng I.... .-ngong ."'" piY01 ""ft. fioll. lU'UObly tiled fOIl 01' poegj of lo.K>Ing of 1M lime ,.,..1\11 dia~ .... t.... pivot bolt. which <;an be "...d 1(1 WPPOfI ,.... IwlOQing •• m ()fICI I.... pivot botl " INro.lly •• """,.0. 19 A _ . , ......... w ....... and puli lM swlnging ..m ""It oot 'pproJChne'eIy au. Inc,,", lhen inMf1 the fOIl Of ~ of lubing Ihrough 1M f.ame 10 aupportlhe Iw.ngong ...... bin n(1I f ir enough 1(1 IUpporI 1M . - ~ mounling. SIowtv withdraw tI'III swingong ..... piY01 .".11 unl~ 1M engine II _1(1 drop elighlly_ T ........... now free 10 be tift.o
br«_.,

u..

""ft.

,.nd

u..

~_.
1>(11.10 be mecIe 8Ad ~.,\.IdlId where 1lICaNOV- /It suPtlIv 01 dun rag"lIIcl .-quoted l BelOftI ~ work. .... Ihrou\Jh lhe 1PPfOPRI\I Meloon t(I lhal .orne IOu of the - V procedure UWI be 1IIi'lId. ...."., rItIlO\Iing lhe vIriouI8flgine componenll it IhIIuId be not.o lhal ~I 10fC' it HIdIIm r.Ql/lted. unIHI specified. In ...."" c...... compo. ....,1·. reluctance 10 be ..""",ed 1,10001o;'lI iv, of.., Incorrec:l eww<:h 01 removal melhod. !lin I"" doubt. ..-cheo;k wilh lhe lUI .

5

OIsmIontllng lhe .,.lne/gaarl>o. unit:

hHd, . . . .1 and pltlon

""""'inti the ,ytlnder

1 Thne ~_ CIfI be removed Wllh the eng;n. on 01' dIr """ wi ........ t be diKOIVlICted, II be I'IIICIIUIIV '0 . - . the opoer lll\(llne motIfltong bt«ket. whodI HCUreI the cyIind8f held 10 lhe If....... 10 allow lhe 10 be withdrlwn. On TZR modeiIlhe lor lilt.. CftIIahould.1to be 'tmO\I.o III lhil conliderlbty 'ell ric1, _ _ 10 the o;:yIinder hoed end befl"tl. Att_ to Secloon _ ol lh" ctw'pllf 'or 'unhe< Inl.,......,oon. 2 Re""",. lhe fl)frk plug. Worklng in • dilgonal Mquenu 'IIc:nn NC:h 01 lhe cyl,nder held ..,.,n'ng by J oil I.... m unlil" ha .... bMn 1ooIenId. A _ I lhe nut, and w~tnd loft ..... "." lhe o;:yI,nd8f held. Diseard the held lIIIket. I new one thooId be filted on ~ N lhe held j"tuck to the do noUtlempt 10 Ievet IIIWFf IItuIo "" joinl by mill,"" the qIIf1( plug 8Ad turning the engona over. """II its ~ to ...... lhe IlIId. or by UIpping il QllfltIv WIth I a:Ift. IICIId meIIet. Be "illY Clfaful when handling the cyIondef IlIId. II II • dIIoIiaole QlI""8 end could IMiy be di$lorted 01' erecked by c.reIeN

wIt_

n..-...

1 BefOftlIfty dismlnlhng worit ;. undert ....... I.... ,.,..1\11 ...01_ of lhe un,' Ihould be lhotooghlv o;INned 8Ad dig...... TNI wlM prey.." l he conl.mI ... ,oon of ,he If'9ine inll"...... 011 will Il1o make woo-king • ..-d clea ...... _ A high n.h.poon\ to/ven1. IUC:h .. patllfin 10' (kltg medium II'IcIuId be 1VOIdId. ~ Ihe\'lP
_II'

-'""'-

2 WheII dun..-.d dIy. . . . . . t .... lIfIII on the wottbendt.IIIIIIng' ourtabIII dIIr .... lot WOfking.. Glther • Mlecloon of ItnIIt eonlainln 8Ad ,*1lC bIgI ., llIet perU <;an be 1IfOUI*I1.1..... in .... MIiIy identofllll* mennct<. Some PIfJII .00 I pen II'IcIuId be on hoInd 10 pem'\l1

flU"

--.

n..-...

l 8Ia btac:hlpo)lJiloon CII'I lheleft·hand_atud IOlhll "Clflberefillodin Ihe_poIIUC.... T""

Cha pter '

e

Fig. 1.2 Cyllr>da' head ar>d batral T2R modal (DT modal , lmil• •1

,~2 Nul SoH 3 Wnher 50" " HHd~"r 5 Stud Soff

67

""'''''' Ctt/~1RmII

8 9 10 " 12

88ugMkel SIIJd 201( Dowlllpiit 20ft Stud 20"

CJurcltt;"~k"r

13 Nul

40ff

" """

15 W..u.e. 16 80Ir 20"

17 L"Ir.Jotlndv.lveup /8 G.9s.ter 19B'It$$~

20 PowtrvttNe 21 ().rrn9 22 Rl{Jhr·flMdvlllvecl'P

" """

os

Engine, eluteh a nd gearboll

!he b......1gently with" sofI·leced mallei \0 brNl< the seal and lilt it just InOUgh 10e~poM lhe bottom 01 the piston &l<8mi .... 'ion. II the ;lnos Ire .,uck in lhei. grooves bv O!>
....

CNpter 1

Engine, clutch Ind plrbo. deKribId .. Roul ..........1 - - . ~II'" oil

pUmp

IIId pop.,

8ndc:on'roI~.dr_the~l._theradoa'oroutllllbot'~

_'hi

hoMend kicbllrt ....... ,rom itI ...... , _ Sectron CI. On Df rnodehIlt _1iIo bI - . . . y 10 ....",... tI're _ """,, PIdII _h Q return IIPfIng, ....:110 . - . , ... me ....

--..

~I

PIPI from , ... _, ..

Working in I doIgonII - . _ III , ... C......CMI_ SClews. S'ar. them in • ~d lemplatl 01 , ... cove< 10 pnMdt I ~ 10 I ...... POrJItJons on ...-nbly. Also ......., • nota 01 where I'" oiI llId PIPI clMnp MId b<"I .... 110M guide .., lined 10 IheM CIon be ,efined In ,..... origi"" """ioo.., 3 PuillhI I;O\IOf I""V compIele Wllh ,... oiIend wll .. pumpe, IIPIJIOII genlly wilh llOfl'/feed millet '0 bruk ,he IIMI. 00 not anempl lo """ I'" 1;0\1. . I W.y" ,hit! wiN ,,"-, oenaonly damage , ... ""orlQ ,_ C'-k 'hfrl lhere I .. no \lVu1l _ ...... or 01.... """" CO!1lPOf*l" 5ucl"ng lOI"'lnIodeof , ... 1;0\1... Peel ofI8nd d_d IhlQKket POMibII_ ,... two IocelorlQ doweIIlrom I'" cr.nkCIIII end ltonI ,him WIth the~ 2

COr1'K'

and.

,

DIsmantling me lAlllneflJUfbox _it: ..moving 'hi cI.nch MId

prim..., elm. II1II'

1 OI.men lling t"- engin,' oeNbox un/'l: "movlnglh, VPVS tomponen ' .

wmponen'"

1 Allhough ,lie C'(Iinde< btn'eI is lined """h , ... 'I'M I'" vllvio ~ ~ pegQed in pi«:e ....:I does not move, Therefora ,I should nol requorelOy . nemion,lpMt from regouII< dKMbonoaing 1\ , ... .~ int....... WI\ochc-.bot~out Wllh , ........... "Uedlo I'" bin ... II _red. 'hI ...1IIve cen be ......oved .. folowf; 2 ~ IhI cyIIncIw heId....:l bIr.lI" deIc:ribed in Sto:uon ~ of

ItwO\lpt.. 3 SIK . .... ....:I....- I... bolt ....:I wnher lrom the CII'I1r' of the left-hind ........ c.p.1Iemove both the ........ ClIP NlIirIirIg boIts....:lJift theCIP....:I brIM ...... out of I'" 1lImII. ReINM ,... bolt whoch ....... I'" r'ogtIl-hInd ......... CIP....:I remove the r'ogtIl·hInd ClIP 10 gam _ _ 10 I ... long A .... bolt whoch sec.... IhI IWO ......... 01 I'" v..... logel .... 4 Slack..,lnd 'emova,hisboh ... hilsl holding ''''lelt-I\fnd tndOf ,he v..... Wllh • IUillbly ..ad operr-en.ded spanner II , ... Allin boI' is ....,usua'ly tlgh, •• hfrrdwood . nip can be pi«:ed ' hrough ,..... hfrull pot! ' 0 Wldge lhe ... alvio in pi«:'. 5 T... lWO ... lIvl "-"'" cen ,herr be I'ImOIIId 'rom uch IidI of lhe blttl!. TI . ' cere no, two ImIII dowel 11'''' ",hoch 1191 I'" ....Ivio ..........

'0 loll''''

1_

• Dilm",,'ing ''''If\fIinlloeNbox unit: "moving '''' c.....c_ ritlhHIMelc_ 1 TtIioJ ....... be doni WI,h IhI/tngInt! in or out of IhI'..-, but .. the IormIr CMI it wil be - V 10 IQI d ..... 'hi 01. ..

, Ttw CIon be doni WI,h'hI engone in or OUI o i l'" 1 - . .It.. \III C,ankCIH ngh,-1\Ind wver ' - bten rfImO\Ied .. described in '''' prrtrvioul Seclion. 2 Before Ihi elu' ch is .emoved ,..... is one eonalde",ion whoch should be remembered, If ,he won is be'ngundertlken"""h , .... tngine in I.... ' time ,''' nut which 118CU... I'" primeoy drive getr be Wdr;1ItMId II "'" 1\.Ioge II It is "'1$1\ed 10 remove Ihi oe-' To PN'IIIII crri.... tt .Ollioon .. IhI nut ...........1Id. Mlecl IC9 guo Ind ~ lilt b
mu.'

Ie_

'hi

IICO,WI'' '

mil'"

"'...... 10 IhIIl

''''"emp1d

na".... " 101.,.

4 Remov. I... Clulch Incloon .nd plein pial" lrom 'hi cIulch ........ bIy nolong lot ' ut"", , e f _ 'hi w.v in which uch III fiUed Tt. /IpplIn plrtocullrly l1li ....,11 pie'" pie, ... lift 'hi plet. out _ by _ end pUl IhIm 10 _Iide 10 .......1 e~ lIYWIIloon MId ..-nbIy 5 If me~ unit .tobl ~ ~llId.or If W1IhIcI

'0

It"

10 "'...,..lhI dulch kttong..-........... ,'" compDnIIIIao/ ,'" fnICht. niIm ......, be - - . d . The sompIesl method II '0 lIP l1li _ ginl.grurboJt unit on ," ngtn·hInd 5odI1D 'l'1li IhI bIIIlnd - . : I puI/InXI will ddlout of I'" input: shift cenl,..1f "'" ill nol poMibIe. or' it doeI nor: wort correctly. find .1onQ.1lim.1I11l rod WI\och will ~I inIidI

.,

Chapl ... 1 Engine. duleh .nd gnrboll

• "

holding lhe cen, ......... \ to. deviled. v ........... P
"

Alte""tivtlly, ,he home-~ equIvalent lhown In the tcCOmp¥'ying

U k

k

•••

• ••, k

iII..tnltlOtlltfld photo 41..Jr, ""'" p<0vtI ~Iy . Hectlve. The toot wal

....0. tIP 'rom 1 in • l in mild 1lee1 "'ip. the edgM of the tongIed JI..... being IJfOU"d 10 fit en4'f In ,he dutch cent......... An MSiIUtIt ...

-:::.~

W

•

be .eqtII<MlIO hold the dutch c.nt.. wnh me ~ loot while the

nut is removed. T .... care IIOt to IIIow me 1001 10 IIip Of me 10ft 8Ioy

spIiI-. _

be~.

cen'"

. . _·_· t(-_."._". o·

,,~,("

<&., ... .,,,""'

~.Fitl. 1.3 F8brieat.-l clutch holding tool

Inpu~ It..f~. MlIgne"M ~he ,od by wok.ng i' "",,'tv ICIOH ,he IIIIgneIJ 01 ,he II'In.... ~Of .0~Of MId pulh I, in,o ,he Inpu, ...." AI ,he

een"• •

7 Stta9"en the locking tab.ncr ......,.". the dutch etainInQ IIOt and tlb wallie. The elutell cen tllen be pulled oH the Input Iho't, lolowed by the Iphned tNwI wbhe< ItfId the clutell OUI.' drum. Behond the clutchOl.ll.. drum In..-. II. r...., .... lhfull WHIIe<.ncr dil.hed WIIIIwN. SIIdt me t""-t wHher off the .... tt end """"" the dil.hed WIIIIwN betWId me key. IIOt.ong thet It II IittMl WIth Itl «WWeJ< ~ I_..dllthe « ....... WIll. Slooo."me duteh o;ompOnentltogetlle< In • dun containe< to IVOid bIing Of ~ them. 8 $leek.., end remove the pnmIfy drive geII nut aI dncribed .boYI, removelhe WlI ...... .ncr ~'V drive gNf. Not.thel if thee...,k_ Ire to to. W.t. the 1)ri"""Y drill,;e .. mUll be Ieflln ~Itlon unt~ the bllla",,*"thIIfI nul kn bMn ~r_ Soc:tjon I II

10 DI ........llIntI the engIneJgHftIoo .......it: _Ins! the lIid1.tart .... mbly Iftd Id~. gear

It..

•"

• ••" " •••

,

I

rod II wIIhdntWn gently 1\ thouId bring ~he bel MId then ~he ~ WI,h It. When lhe bill end pUShrod t..ve bMn ,emoved, ~ the dlnch 1iII>I"Ig1ever ..t ...... 1oI)fIng from me ~.ri ..... ~op.ncr IifI ~he lever

WVIV. compIet. WIth IIJ .... urn ~ .ncr ,he p..n w-.. I Belore the dutch centre nut UOI to. removed. ...... method of

1 The kick l~11'1 eu.embIV end !dl.. gel' eIIn be removed with tM enginelll'll'OO)[ unit In Of OUI of the heme. once tile «,nkcese righthIInd cov .. kn ' - " WIthdrawn .. described In Soc:tjon 8 of this Ch!Ip ••. Not. thM while lhe kek ..... Ihott can be removed with the duteh ~ In SIt"" if the kekl"" idIet ON' II '0 be ....-.-ed. the du\eh InUIt to. Wlthdr-" tnt

,-1 1

Fig_1... Clutch

Solf A Spnng 5 oIf A

lJoIr

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6 , 8

9

W. . . . PtAhrod /Hr. 1M TMJwWw

a..-nn(J

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"13 c-. Splir.edf""~ 14 Our... """,, IS ThttnfW.w-

16 Dtshedw~ '1 afr-hMld pusNod '8 SrNIt»6

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21 RtlfUmfPnt'lll

21 W.,. 13 OJSHI

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21 Prttn.y6-rwtlN' A 40Hon TZRmotJ.Is

Chapter 1

48

Engine. clutch .nd gearbox

2 To fflmove the kicut." .ssemblv, use ..... itfble pair 01 piiel"l tO unilool< the OUtl. en<:l of the kickst." ffllum ,pring lrom lliloceting hole ill the c.ankcue w all then allow the spring to .al.... " sJowIy to ill relaxed position. Ow. ill required" thill poinl .. the IJIrinu ill under moderately s trong t-oo. T he kiculll" assembly may lhen be lifted out of the crankcase. 3 Slide lhe while nylon spring guide down the length of the shalt .00 .emove il. Dlseng.ege the Inrwr end 01 the spring I.om the hole io the kicks!a" sl\&fI and fflmove the IIpring. .... king I nola olthe w~ in which it ill lined. Slide oM thllarge plain washe •• 00 the kick,,," pinion. the Ietler complete with ii, frictIOn clip. 4 If removal of t he kichtl" idler,,",iII requi. ed, thill can be done only -'tar thl clutch hIK been 'erTICI\'ed. Using I p&ir 01 eircijp pliers. fflmove the o;irc~pl'om the output shalt right-hand end. then withdraw the lil"ll thrust washer, the Idlergeer itself, an<:lthe second tl>ru&t washer. W ily. use the circ~p pllel"l to remove lhe in.... retaining circlip lrom lhe OIfIpui thafl end. Becau... both circliPi .nd both thru.t washetl.re identical componeml, there ill no need to differenloata between the I........ an<:l outer pans. S tore all thl klchtan components together In • clean COntlirwr 10 Iklt nothing is last or dllmaged.

11 Ois m.ntllng .... flg.e.1"I

u.. e ngi",' gearbo. "", It: .emovlnglhe bel"",e .

I nw.can bedone with the .....g;ne in orout of thl f,ame_ Fil"ll it will be necess.a'Y to 'emove the rlght-I\&nd cr.nkcase cover and the dutch as r:IeIcribed in previous Sections of thill Chapter. If !he lOP en<:l 01 the engine 11M no! bMtI .emoved. e tool will be required 10 hold the gene.lancer allaft driven gear, lift off lil"ll the tab washer. Ihttn the gea' itseN. Prise thl 6hort. "IUI'e-section Woodruff key the baIanc.. thaft keyw...". Siore tile two gtOUpI of componentl. those from the crankshaft and those from the t>.1.ncer thafl.. In separete conlaine.s 10.-.oid anv PQUibilitV 01 conlusion on "es.sembly.

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IIhouId be pulktd out with. twiltOng motion. II ~ UnllefflwHIg it. 00 not .UempttO lever it OUt .. the plet;tic: moulding would only be da~

m.

13 Dllmantli"l! englne/g.e.rbox unit: .emoving g.e....leet ... componenU

m. . IR. mel

t The componenll of the geM Mlector mecklnism which can be removed wilhoutseparaHng the crankcase kllv" COfIIiIt of IhI gearchange thafl..lf"ICOfj)Of1Iting the aeleclor claw _mbly.• n<:Ilh1seleetor

detent ...... Either componenl mey be removed Wllh tile en9inelgearbo~ unil in lhe frame or on IhI won:bench. bul in MCh CIIH ~ w~1 be necftU'Y lil"ll to remove lhe crankcase righI-hind COlI . . end lhe clutch assembly. as des<::ribed in previous Section. of IhiIChapt... 1f 1111 gearchangeallalt il lo be removed it wiM be _ ' Y , of cou ..... to tile gearc:hange pedal or linkage lrom the sholl lelt-hand end 2 When the Pfelimin&ry d ismantling hal been cerned OUI and the seleelor clew assembly 01 the ge~henge thalt Is e~posed. as.... Ille 11111 of the thaft relum spring by applying PfHIIUffI lil"ll downward .. and then upwards. to lheclaw en<:l of lhe thalt.ln bolh c - . ..... au 1111 &haft and il lo .etu,n under spring presstl,. to IhI cenlral pOIrtoon before applying prllSUre in the OPpOIIte di,,,,,ion. The shaft IIhouId cenlre Itself quicklV and POS!lrvetv, w,th no \Ieee of Ir" P!av in lhe cenlre pOIilion or of wllk..... in the spring. If env '!lUll II apparent lhe s.pr;ng mUSI be renewed on reassembly. Thill l'"'t is quick an<:l -v 10 carry out. and ....... , be conIide. ed .ssential if lhe .,ngine!gearbo>r ""il iI !)e;ng "ripped to lrace I 1....11 in the selector mechanism. 1 The gearchange ahafl can be pulled from lhe c. ankCII .... by hand. On OT model' Ilol6 lhe "*10. lorI! akeft whICh protrudes lrom cr.nkca .... ...milsl removing IhI geaochange thalt. ThIS will prevent lhe aelector 100 thalt !)e;ng wilhdrawn .Iong wilh thl gearcklnge .kllt. resultOng In lhe aelector 'ortl ,.,Iing from poIition. 4 The selector deiertt lfm il tan&ioned by a he.avy spring .nd pivots on .lIhoulde<ed boll. Nole ca,efully IhI WIV in which thl spring ill filted. then 9'adualtv lIec.en lhe bolt until ihe spring pr.. " .." . can be released by eIIowing lhe delent arm to ride over the HI.,tor cam. Slacken l..-y the boll end remov. The bolt. the arm. an<:l the ,pring" • complet.

,.Iease

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14

Oll m.ntfinglhe e~ine/V".rbo~ unit: . e movlng lhe vene rllor

1 Thegenerllor _mbly can be . emoved wilh tile engine unil io Of out of lhe lrame. In the tor ...... case it win lil"ll be necesNry 10 remov. lhe gean:klnge ~nIutge or lever and tile lefl-hand erankCIIH cover, anti 10 lI",e and disconnect tile generalor wiring if lhe 'Ul(or Is to be removed. A rotor e>
12 Ols m.ntling the e ngine lll" rbo~ unit: removing the t",hom.t • • driv. g.e'1"I I The t",homel" ill driven from tile clutch ouler drum. lhil drive being Iterlsmilled via I white nvton drive gear 10 I venicaltv-moo.rnted drivan ge~' which is ~hined " thltop to ICC
Fig. 1.5 Fabficat.ci flVW ..... , .oto. holding lool lSec 14)

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.",.,. " . 'lop and • f_ boll, Ind nted no! be """V 1IIIbora11. If you prlflr. you CIrrI buy I ~ I0OI of type I..... YImIhI .........

Pert Number!1089Q..012l!i. 3 In lhe IbIence of I holding 1001. end with me ............ In lhe fraome. Mlecl lOP year Ind IPIIlY the _ brat. to IocIr; lhe o:ranbhIlt. II lhe cyllnder ....... 1nd pillion 1IIvI .... removed. pau. smooth round 11M Ih
unscr_

III...,

draw on it • rOtogh OUI'" of lhe Cr8fIk~ rigl!1·hlKld atde, ..... 10"11 !he pO&Il_ of ur:h of lhe 1Crewt.. PU
onrul&Of'l'obty. 3 UIir1g only .1Oh·1.,;ed millet. 1I(I ....11v on IhI ~..,,;jJ of lhe cranhhlh and gearbox -.haIlS and .. -.ound the joonl .... of thl IWO CfIr"IkClle twrlva unlilinilial MPffIIIOn " echrev.due difficulty II ....countered. IIIP 11M CIIM beck logIIhe< and 111<1 IgIIIn. If . . tIM f..... I.... lhe essembly 10 .., IUlhoriMd V........ dealer for lhe CIIM to be lIPI'IIed using spec:IeI looIP"Number~113S.

It difficulty II encoum..ed in ICho!I\Irng initial MP8I1It.oon. It mly lit bec:Il.e COffOIion hal formed on the focat"", dowel .... AwtY I

•

quantity of penelrating fluid to lhe joinl .... end inIide IhI vlrioul mounting boll pauegeI. IIow lime for It ,0 wort Ind Illn again.

5 When lhe Clling i. r&mOYed. ch«k Itwrl lherl ..' no ~ compo. .... m l such II dow"IO< Ihrusl wuhlfs which mighl dJOj)clea, Ind lit loll. A~ such CGmpone
"f,

I The .eM! v ...... can lit .~ Wllh !hi engone In or out of the 11....., but in lhe lormercne It willlifal 1It.-...-y 10 rwmo..e lhe_t. ~ fuelllnllind CIfbu .. llor II detocribId in o..pler 3

2

Remove the fOUl boIli whir;tl ,_n the Inlel llut> to the crankcne IOPWffece. Ufl 011 lhe Inlet 1I11bend .eed v.tv. cage. Peel oH lhe reed Velvl gIIk .. and diKl,d it; • new gn.k.. Ihould lit fined on •.......,. bIy. If lhe engr..... no! 10 lit dltmtntled funhor". pIr.>g the cr..,kcne openrng Wllh clean -.g to prev..,1 l he .,.Iry of din. 3 Refer 10 ChIrpIer 3 for del. of reer:f valv. axemrNlion.

11

11 Oitm..,tJing ttMr anglne' gel
Dilm..,tlin$! ttMr .......... I
....n , The engiM/gearbox unil mutl lit ~moved Irom lhe frlme Ind IU ~hminllfy di ..... mlinu operllionl CMried out before lIMo C'lntcase l'1li"" un lit se""raled. T ' - operl11Qn1 arl described in Slclionl5 15 of IhiI; Chapler. When IIMo ......gNrbo.oc uniI halbeendiSrr\ll"lded • ~ make I flNoI c'*'< 10 ....... IhlI nodllng ..... ~ omon. . wt.:h moghI ot.UUC:I openol-' Rolli' me Mlector drum . , IhlI me prOIruding MrS on lhe Mleclor c.m _ IIigned wnh !he WI_In lhoo crri~ will. lliIuN 10 da 10 wiI ...... In cr.... ~ demegI due 10 lhoo MIecIor c.m contaCting me calting. PIece twoc'-' wooden bIoc:hon the wonbench Inc! IIUPPOfIlhe ~x unol on them 10 thll lhe aankelse righl·hInd atde ill uppermoet. 2 Sleeten lhe crankca_ II<:r_ .... entv and in I diIgonIllIIqIHIf1Ce. Be' orl lhe C,..,kcaM f...."'ng II(:r,_ ... removed. lher. ill I Irmple deva which c.., be used to _ IhIt norMI ... loll Ind IhlI uch 1I<:r8W ;. relined in ilS 00f"fKI Find I ~ I o. cardl)ofrd Inc!

_,\JOn.

16. 1 ROllleMilclor d rum 10 enableillo ""MlhroughWloul,in cnnkcne

Chapte.l

Engine, clutch and gearbox

2 Stan by po,IIling oul lhe fronl and Ie.. Mie<:lor fon .... ft. Pivot all Ihree Hleclor forb aboull""" respetlivl pinlOnllllO INollhe IJUide pirt$ come away from the HlecIOl" drum and prQ\IK!e fUffw;;"nt clolnorw;e fo< IhI drum 10 bI w lthdrlWn. ThiI is ......., by po,IIling lhe drum out of ill locating hoII in the crankcase. 3 Wilhdraw lhe seie<:IOI" Ion •. IHing greal care 10 nole exactly where eacl'I 001 is filled and in what way it is filled. It ia uufullo deg<_ uc:h fon ItS it is withdrawn and 10 marl< iI wilh a april·based felt PIn" a ""ide 10 Correcl _mbly. bul note lNoI IIIe 1lleet0l" fon. fined 10 lhe machi.... fNlured in lhe pholographs were identtf...:l by numbl .. and model eodll CUI in IlICh aide. lind if auo::h ia found 10 billie CHI on lhe mec:hi.... being worked on. lhese mIIrl<. will bllUHieilnl Pfovided notll are made 01 Iheir- lX*ition. AI IIK:h Ion ill idenlOflld lind withdrawn. replace II on it, ahlfllO prevent any c:onfution on reas&&mbly. 4 The II"' elUlte ... thouId bI removed now. Carelully pulilhim OUI of theeeesUry ,otap on ,hi OUlput shaft lefl·hllnd end to lreelhe ,helilrom its bearing. S Thl bllteno;:e, ahafl can be lifled OUI Nlily by hIInd. Ie,v;ng only lhe cranksholt to be removed I,om the cran~case left·hand elde. The manufacturer recommend, the use of the ume apecial tool used fo< sepaorlling the c'ankcase """". The IWO mounting boilS of the loot should be th,"lIded into lhe drilled drilled Ind tapped holes of the two bosMt caSI on lithe' IIIde of the lelt."-'«:essiYa force and do not allow lhe csankshoft 10 drop away. 7 Put III lhe removed eomponentl 10 001 side 10 _ail examinallon and reessembly.

fI,.

18..2 Oil seals should be removed with a flat·bIaOed Ie,ewdriver prlllUlI 10 the bearing inner 'ace; In auo::h cases closely inspect !hi bearing fOl' sigrt$ of dfmttge befora using it 19Iin. When drifling I bearing from ill housing it mUSI be hpl SQUI, e 10 IhI housing 10 prevent tying In the hooting whh the resultIng risk 01 damage. WhInI pa."bIe; use I .ubula, drift auo::h H .. IOtkel spanner wnio;h bea ... only on the bNring outer 'ace; if thia ia not lX*.ibll. lap evenly Iround.hI OUIe< rICIlo ocItieve lhe _ rtIIUlt. 7 In eatIS wherl bearingtl e<e pressed InlO blind hoIet. they may be removed by huling the CUling and tapping It fllCe dowllW1lrds on 10. clean wooden IUrface (0 dialoDga lhe bearing unde< iU own weighL II lhis ia not tueeetllfulthecasting should bllaken .oa mot~ serviQI e~ who hH lhe conlCt inlernally exp.llnding be.ring puller. II. bearing lIich 10 ill sh.8ft on removal. il can only be Sltfely removed Uling a knife«lged bearing puller.

l'

DOlmantiing In. ~nl/gtl atbox un/!: llmoving 011 . .ai , and b. .,inll'

, BafOfI rllfT>OYinganyolillOltlOf bNring. check Wilt is not SllCU,ed by a retaining ~te. If lhis isl'" CMI. l,IMIan impac. driverOf 5p.11nner... 6PPc belrings 1 ' 1 I press fit In lheir respec:tive c'ankcaseloctttiont. To remova I bearing. I'" crantcue culing mU51 be heated IJO lhat i. Up.llnds Ind ,aIaases its gripon lhe bHoring. wnio;h can lhen be drihed or pulled out. S To prevent casting distortion. it mUll be huted ovenly 10 a temperalUII of about lOO·C by plec:lng it in an 0>Ien; if an OII1In 1$ nol av.iteble. place .he CIIIling in a suitable container and carefully POU' boiling Wile< OVM It ""Ililt ia ,vbmerged. Note that II hul ia used in this wey. ca'" mull be tHen firlllO ..,....;>VI any companents flOm lhe casling which would be dl$tfOY$! by exc_ heat. e.g. the ne\llral_rtch. 6 Taking care 10 prevenl p&rsonal injury when kindling huled componenlS, lay lhe calling on I dean turface and tap outtha bearing using a IIIImmer and a aultable drilL If lhe bla,ing illO be ,...aId apply the drift only 10 the buring outer ,ace. where thi' iI accnsible. 10 avoid damaging the bearing. In _ cases It will be noces$IKy 10 aooIy

1 Baloro .ny componenll$ examIned. it must be cleaned thoroughly. Being ca'oful not 10 marl< or damage the kem In QUetllion. use I blum..ctged .craper (an old kitchen knife or I broken piatlic ruler can btl very useluQ to 'amove Iny caked-on dapositl of din orolt IDilowed by I good ICrubwith I toll wire bruth II braSI wirl bruah oIlhe type IOId for cleaning ,uede ,hoes ill best. with an auorrmenl of botlll-cieaning ~ fOl' ports. cooI.nt ,,"sages olcl. Take carl not 10 ,emove In'! p.IIinl code mIIrl<, flOm Imernal componenll. 2 SoItt the component In • toIvenl 10 'lIfT>OYe the bulk of tlla ,emei". ing din Of oil. If 001 of the proprie\.lry engine deg ........ lauo::h .. G.... 01" Ji.1If\ ill not available. a high fla,t..po!nl .alvent IUCh I t jIa,lfftll (kefOll'lnfl) should bI used. The use of petrolH I cleaning agent cannot be 'ICOmmandad becauIa of 1M fi,e risk. Wilh .11 ol lhe above cleaning IgIflllteh ",NI carllO p
13

Check an cooI..,t jlasaagel and ailw8yl lor blockagll. u .. ng CorTI' pressed lir to dear lhem. or Implemanll auo::h as pipe clMnera. 4 If there ill Ilia slighilit doubt .bout lhe lubrication '\'Itern. far l>temple if I lauh Ippeatl tO have been caused by a failure of tM OIl s upply. all components should be dismantled 10 IN! lhe oilw8ylc.ln btl checked and cleared of any POI$ibll obstructions. Raf... tOChaptM 3 for delails of the lubricalion fytllem. Alwaytl use clean. lim-I'ee rag for cleaning and drying companenlS to p<event t .... rill< of ,maft p.IIniclee obslructing ailways. 5 Exami .... ca,"fully each part to dallrml.... tlte a",ent of wear, checking with the tolentnco ftgureslisted in lhe Speclflc.ll
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."

Chlpte,1

52

Engine. clut~h Ind g . . .oox

mtJ5I be IiflNed Ihllt tllilClle tlMl bore lightly 10 provide. fine ~fOH·halched su
...,.11 24

7 Measure ring _ r by inserting eech ring Into pan 01 the bore which fa unwom Ind measuring the gap ~t_n the ring eods willi I leelet (IIU98. II the measursmenl e~ce«ls thai given In SpecfficatlOIlI. renew

the ring. Uselhe pislon ~rown to IocIle the ring SQUa.ely In tlMo bote Ipproximately 20 mm (0.8 in) from tile OIsI<e\ ",rl_. a Reject any nng. wl\id1 show discoloured pal~"" on tlleir malJng ",rl_ lhese IIhouId be briglltly polished from firm contact with tile ~ylindef bore. 9 00 nol ............ wI\en filling new rings thai lheir end OIIK wijl be COt'eeI; IIIe Inslelled end QlP mtJlt be ....H\ffed •• dftcrlbed eboYe 10 en",re thai it it wilhin lIMo apecified tolenlnees; if tile OIP iltoo wide .nolher piston ring HI must be obtlined (having checked IIOIln thlll the bore II within .pecifled _ r limilll. but if tlMo OIP illoo narmw it fT1IJIt be w;dened by the Cllrelul use oil flOe file .

h a minltion I nd ' I novatlon: piston and rings

O,,,ega.d the existing POSlon end riO(,lS il a rebore fa _ r v : lhey will be repleced w,11I oYMSile items. Note 1110 thai it fa considfI,OId a WO
An.,.

nev.,

1 8ig-end lailvre fa Cha.IClerised by I pronounced knock which will be fTlINt noticeable when lhe engine i. worked hard. The USualCIUIH 01 flil ..... I" normalwea., Of failure 01 the lubrication ",ppty.ln lhe CISlo! the IaUM, tile noise will become Ippa.ent ve
A

f ig. 1.1 C•• nk""tt mealUremenl polnll

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right·'*>c! POShtod 10 with the dUl~h as.emb/v. 1>\11 not Vlnsmlt thit rot¥y motIOn 10 the "'1·lwond pushrod. thull Pf'OIKI"'" the

lift""' ...... 01 the ....... ~ o-t thaI the

bil .

I*f.c:tlyroo.ond Nov n.w. In the bIIII wiI . . - the! IIIT"1U$I be....-.d. All 1 ' - d\llo;h 1 i f I " " , _ u IT"IU$I bewellll'.-..:I on...-..bly

, The t ocklllrt mec"-'>llm Is • robusl n.sembly end Ihould not normtllv ~ .. luenlion. Apen from obYiouI dele<:lllIUCh . . . broI<en '~um apnng. the hicuon glP '" lhe only companenl fitely 10 . . probiemI 1111 bec_ worn Of WNl<ened. The dip .lnl...,;!td to IfIPIv I known ImOUIII 01 dr'll on 1'- tockt'lf1 pinion. c-.-.g 1'- "II.. to...., up itl quick thread IIId into engIgIIfTIIIIt when the kII;kI....,..........

opeK.edUllflllIIl)ring-""-.Hoot_..-dolthe '*"- onl0 the Icq)ed ..-d 01 the lriction dip. PuI on 1'- "... ..-d 01 the b.a..-1IId note 1'- .tldong II the POinI w ..... " ' - . _ .

con- lhe ~rip'l 1lISIS11onOa. II lhe fNdlng •

outside the IPIClfoed ~""I' Ind lhe mechan ..... h.u been n"IIlfl,lflClIOnIng. renew the elip II I PfICIUIk>n. Do not Iltllmpl to IIdJuII • worn dip by binding il. 1 Ex...... lhe kicksl ... pinion IOf Of ........ ~ ' O

w_

d_k II In eOtIj\HICllon Wlth the OUlpUt ..... 't-rnounle
_w

, Givl lhe gHK.ed 'or t.....-by ~""' .. !hI compOnIIfll.l lrom the....,., IS dllc:ribed in 3O.1f1<1 "1I1ng 1M llllalt up In V-bIoI:h. SIDwIv tum the .....1' whil.t "","suring any runout wllh. dill geq.1I the ruflOUl"'CMdI ,he IIPKllied limillhe wit mult bI.enewed.

s.ct"'"

Ch.pter'

Engine, chltch .nd g•• rbo.

"

29.5 Exlml". MlecIOf foril. and .•

4 CIIec. lhe HIeeIor fort ."'Ilt lor " .. Ighl ..... by roIUng lhem on • .....1 of IMII gIast. A benl lllall will CfUM diffICulty In ..lecll'lllgea .... and will ....k. the gNo_ Nil been run for. period with I Plrticullrly low oil coni..,\. 6 The t'lCkl In lhe lIIIctor drum. with whic:t1 \he seleclor forb tnQIIII. IhouId nol show Iny undue ""'" of _ 1.1 ...... naglecl hit led 10 unPIr lubricllion of lhe gearboOl. Cheek the bNMg fillid 10 lhe right·hInd end of the llilctor drum for InV tIgn of _ . This beIring ctnnOI be .emoved from 11'01 lII«:tor drum and the compIet, MIectot dnrmlllOMbly ...... , bI.-wedif 11'01 bNMgill flllltV. 7 Ex ....... 11'01 getr NllcIOf dew IIMrnb/v nIXing Iklt worn or rounded endI; on the ~W'*' Iud 10 in'IpteciM guo- uIIWDn. SimillrIy d>ectI lhe ~ p;n. In 11'01 ..:.eclor drum end. TI'oI tpringa In the MlectOl" mechtNtm and I'" dl\1IfI1 Of lIopper 1m! ahouId bot unbtol"" ...,;I nIX ditlOtlId or bIrlt in 1nV ......

sequence It obvlout Illd lhe riA of PltUI being flllid \1'01 wrong W'Y round or in lhe wrong IIQUIIncl It tvolded. lhould be • • erclted when 'emoving clrcUps ,0.voId "'IinI"9 or blndi"9 lhem .-~v. The dpe ...... t be openId jutl ... tliclenl~ 10 .llow IhIm 10 be,11d off \he ahaft. NoI" thel V.....hII ...:ommend tn.1 .u 11'01 clrclipl IIhouId be .-wed '~Ieu of their condilion. btmine all ltoon.l w ........ lor II'Iy Iign& of or dtmIge. ,~ !hem " 1MICIAItV. 3 Having ,umIned 11'01 gearbol! COOIponIfIlI II deICribed In the previous Secllon. r-..mbII uch II'IIft .. <*c:ribed bilow, referring ro lhe ~~". drawing and plIOtogr.,... for~. Noll tn.1 when fining • drcIip to • tpIined !Nfl. the circlip ............t be positioned in the mlddleoof one of 11'01 "". . 10 '""'"' thelll'ol drdIp It II oecure .. ~ on Itt II'IIft. Et.ure IIv! 11'01 blowing ....... _ of each 00fT\pCIfWnI .... libertlv oiled befor. fiulfle, 4 If probIem& ant. in iltentifvW>g the v~ guo- p;n;on. which cannot be teIOIYed by ''''''-':'10 the ~ photogrtophl end ....I..u.:.." the .......tIe< of tNth on each pinion will IOIntify them. Count IhII'IUI'I'Iber of !Mlh on lhe pInioft and c:ompere this figure with thet given in 11'01 ~ Section 01 !hit Chap ..... remembering h i the output ....h pinions ... _lid fin.t, IoIowed by ~ on lhe ir'IfItII ....h. TI'oI prOblem of IdIntiliutlon of 11'01 vlrioul ~~ IIhoukt not ..... howeve<, if the qtn.octiont given In perlQrlPh 2 of tlW

ThegN
..put ....h

c."

w"'

Seclion"lf~CII"efuIv.

I

30.610 THI the bfr, input Ihah and tIidI on the 5th getf pinion _

-

g'"

5 The Input .... ft ;. ..lily IdInliflld bv III inlegrtilll1 pinion. Hold 11'01 tlv8lded eod of lhe aNll triglll.hInd ..,.;1\ end tilde 11'01 COfI"IPOtIII"~ on from

the ot:JI)OIitl eod Ot h ·1\IfId tnd\ w.Ing 11'01 loIow·

ing procedure. 6 Slide 11'01 5th getr pinion IIong 11'01 w ft. with Itt dogs on the left·hand tide 01 \1'01 pinion, followed bv' Itoon.l wlt$her. s.cUfi the gee, eod Ihrust wlt$her wilh t cln:dp. srodl lhe 3rd141h pinion onto

30.6b _ foIowed by. Ihrusl wllSher and

""It

3O.6c RlfilltdAth lIN' pinion _

Chapter 1

30.Sa Take the bare OUtput stlah and slide on the 2nd 9SIIrplnion ...

Engine, clutch and geerbox

30.8b •. followed by a thrust washer and circlip

30.8e

*. and secure them bellh with a circlip

3O.8h Refit 5th gear pinion •.

30.8<:: Refit6th gear pinion and secure It with another circlip

CMp1lr 1

Engine, clutch and lIearbox

"

OutpuioNtt 7 Hold 1M spIinId ....:I of the Wft (Iett.t.nd end) 8fId . . . tt.. components on lrom the ~e end [right-hand end) UI5ing 1M IoIowing proclduf • • 6 Slide the 2nd gMt p;n;on onto I.... wft. making lUre that it. rtIoCeSSIId , _ II on Ille ~-hand side. Refil Ille Itvu.I wlllhef MIl _ . Ille Ihrusl wnhe< MIl ON' wiItI. eitdip. SIlde lhe 61h tN' pinion onlO It..1ha/t 110 lhal lhe ON' it"" 11; poaitioned III~I 10 the 2nd lIN'" pinion. lind _ . with. c\,dp. R,lil the tplined IhfUli wnhet tond 4th gea, pinion Iflat ",tlac. on tt.. righl·hand 1io:Ie1, _ing them with anolher cifl:' ip. loIlowed by the 3«1 gea' pinion (flat ""'ac. on the

,.' t·hand 1io:Ie1. ,pilned Ih",." wither n:I cin;lip. Slide thl 5th 011' pinion onto tht wl ~ 110 thttt tht wlector lort gf"OD\le , _ tht l,d 11"' pinion. 8fId refittht I.t ON' pinion. Note!he oiIw..,. in tile tliNd cent" ...... on _ tkII of the 111 011' pinion; \heM should be on Ihi righl·ht!nd .;de of tt.. gel<. f'''*'v ref'llM thrust washer ~ it wi\h • drdip.

I Bel.... r-..mbly of !hi tInQineIvearbox unit iI ~ 1M vlOrioul c:ompotIItIl IIhoukI be cleaned thofoughIy aod ~ on. ~I of dNn 1'11*. eIoIt to the wuting area.

\he th,h 110 ~two~ ~ht . 'Ight'" .....11e< of ~he twogea,,11; on ~ht right·hfnd ..... 01 tht pinion. Fit a cirdip to tINt second groov. In lrom tht ,.It ·hfnd on
Fig. 1.8 Gearbox .n.tu; I

2 3 4

5 6

1np<JI wft nghl·"->d bHmg 8Hnng-.JaIt,.,Scntw 20ft

Inpurwh Inpur $I1.h 5rll (/Hr Thrust w.~ 2 off

Ctf;/ip 3011 Inputlhlft 3trI/41h fIN'" 9 InputWft6thgHr 10 fIIpuIlhlh2f1dgH' I 1 Input IhIh leh-hlnd bHnnfI 12 Outpurwhr>(Jhl·hMtd~

1 8

13~

14 Thnmw.m.r

15 16 11 18 19 20 21 22 23

Ol.lqwuh.ft ISfflN'" Outpurwh51hflN' ~ 40ff SpIin«IlhNslw~20ft

OuIPl.lflhlh3rdgHr Outpullhlh 41h gH' Outpur IhIh 6rh (}Hr ThruJr wMhlr 0u/pU1 IhIh 2f1d gt/"8f

U Ou/pufwh 25 Outputlhlhleh-hlndbHtiolg 26 0iI1HI 21 GHrl:>o.ot IPfOCA:ft .. 28 l.«bn(J pIM• . . 29 Belt 20" "

",_l> 31

Gwrl1o,,~

32 T.tow.m.r

"MAl> .. TZR n\OdfIII

6.

DTmDdtJIJ

6.

6

tr_'*"

2 Make "',. 1M of old gaPet. t..v. been removed and thttltht mating ",tI\ICeII .re de,n and und.~. Great thouId be leten when "rnovirIg old gI.ket f;Ompound nol 10 darTllOge lhe .... llng ",tlacl. MoIII g"ht comPQUndt can t>II soh M>ed utlng I willbla sokIent IoUCh I I melhyllttd lpiri' a. acetone ... "elluloH thinl\lf. Tht type 01 sokI .... ' leQUiftd won d.tpend on tht type 01 compound UMd.

f;IO,.

Ch.Iptell

58

Engine. clutch .nd gllrbo.:

Gaske~

compound 01 1M ,-,·N.deoing type ean be removed using I soh brau-wire bnJt.h of lhe type UIfId 10< cleaning ....oe JhoeI.. A considerable amoum 01 scrubbing CIIn take place without fear 01 hMming the ....1;"11 surface.. Some difficulty mey be encoume<ed when Inemptlng 10 .emova gasketl of the S&/f·vulanising type. the " " of which is becoming wiOeIpisel wilh. finely honed edge. Do not. howe""" .HOrt 10 scraping with. sharp ""'INmonl unless _ r y . 3 Gallier together ellihll necessary 1001. lWId ... ve Ivailable.., oil can ~1Ied with C,"" engi .... oil. Me" ..... that eM new gas!<etl and oil ..... a .. to hend, ,110 ,II new partl requIred. Nothing ;. mo

nenllhould be lubricated Ihotough1v" il il fined into POSition. 4 Make ""11 thel the reassembly &lIN it clean and thai the .. is .t.qUII'1I worIting &pace. Refll< 101M torque and clearance Hnings wile,.,...,. they ... " given. Many of !he lffillief bolls arll eaaily sheared if O\I\Htightened. Always use the COI'fIlCI si!e screwdriver bil lor tile crou-head &Crl!_ and MV8f an ordiNry acrewdtive. or punch. If the e.isting screws &how evidence of malt .... tment In the PIIII. it '- .elviN' bIe to .enew them III e complete Mt.

12

~IIHmbli"il the

wrease

'l'>SIiNlgelrbox l.ln!t: p",paring t ... A........bling the angl"" .... boxl.lnit: .elitling Ih, c. ankshaft. balancer ....h .nd U..fbox tGmpoMnll

33

e•• n ..:....

1

3 Oil Mall ... " rrtted Into a cold CIIlng in I similar malVle<. AP9iY a thin ......... 01 to lhe _ , circumlerence to aid the talk. then t.p the seat Into i'l housing using. ham....,.. and. tubula' drift which bel" only on the hard out ... edge oIlhe Mal. thus .... oiding Iny riP 01 the .... being dislorted. T.p each sell Into pIIce unlil itl flat out .... unx,, ;. "'" nl.OJh with lhe IoIJoffOUnding <;«Inkuose, Of "",lml"l Iof;ating s.houIder, wt>ere appropriat •. Oil ...... ar .. rtlled with the I pring-ioeded lit> toward. thtt liquid IOf gill being .ellined. Ie with the manullCll.If""l mark. Of n..mberl lxing outwards. Not". maka lU.e thaI the righl·hand main belring doubJe.lippedl seat II fined correctly. lithe _I is ..a,"" ined elouly. il will belseen tll&l on one.ide the _I is marked OUTSIOE. The _I should bel lined with this side Ixlng outwards. away I.om tM crankshaft. 4 Whef1I ratainlng pial88 are employed to MC:ure belri"91 Of oil ..... I.IICh II the input lhatt righl·t>anen.II belrings Ind oil iNil have been litted end 5eCured.lightty lubricate the bellrings with clean engine 011 and epply, lhin tmeIf 01 g.ease to the _ling li~ 01each _I. 6 Suppon thtt crankcau left·hand hall on tWO wooden block, pI~ on the wort ",n~; there mull be ",If"",nl cI".rMIC
AI th;' ""118 the >;fa"',,::.e caotl"91 should bel clean and dry with

lIfIY damJgCI, I.IICn II WOfn threeds. r"p&ired. II any belarings ... " to bel

relined. the c.ankcau CII.til'>Sl mlill1 bel heated li"t I I described in Sec:tion 18. 2 PIIce the heated wooden

,I\&t the bearing ;'

33.1 fit c.anbhalt and g
33.31 Ll.lbricate bearing end insl'U belancOt

"".

33.3b fit ge.rbox lhaft ..... mbliel .. a single unit

Ch.pt" 1 Eng;"', dutch . nc! ge.rbo.

be dtIwn Into pIIoce..-ing the COtfec:t --.Ace tool. 2 the u~ It litl.o. ,1tfT"IOYtI\he protec:tjng nut ..,.;I t;hec:k !hI1 the c........... ft revolve. wilh no IfK'I of dif;lonlon. 3 Check ""I the bIo'--< ahIft "Mw,nd bMring It lul>ric:tled ..,.;I ~ lhe~ ..... ft Inloi\..OIec:k thol the.n.tI~"""'..,.;1 l..-!y. Chec:t ""I ItIt gtIIrbo>c InPliI ..,.;I OUlpUt ..... ft Itft·hJnd btaringl .., 1~lod Ind lhililhe oil ""' ....1 10 lhe OUlput .... ft belring h8II plenty 01 g'..lIon itt 1I.ling lips. Tempgr.rily WQlP' ~ver 01 LlpeoY'" the OUlpUl .... ft .pli.... to PfOIec:1 the 011 IIHI IIPI on Inll.IlII!on. lhen mtIh both ahaft_ 1.1111<. ItfIllJring tMI au .... Iching gea, pinion_ I f ' conec:tly ITIItlld. Ind InIIn. thlshaft. intO IheIr ~ U"ling Ihi IWO . . . aingllllllln\bly. T ..... gr.-I carl not 10 dlnllG" 11M II the OUtput shaft apli .... PIIIlhrough it....,.;1 tip gently on the ahaft,·

w.-

-:v

oil""

59

right·"-'d endt, if .--....y, 10 drive t/IIfn Into pilei. 4 Relil thel'llec:l.... 1orb to lheIr -,;v. pinion IIf'lOYW, utIng lhe not"" mIdoo on dismlmling I.... guidInce. If ..will w..-e mIdoo not. IMt on the mllChi ... .t.own In lhe photogfapM fNIIt., _ providIId In 11M form 01. number Call into one 1Uff_ of NCh 1m. ThllIort mlflr.1Id 1 ;. fined 10 ItIt OUlPUl shaft 6th gNr pinion (botlom Icrt). Ihil fNIIt.ed 3 ;. filled 10 the OUtpUt thlft 5th ge .. pinion(1OO 10fIt)1nd ItIt 10ft .......1Id 2 ill filled 10 11M Input shaft 3.d/4Ih gear pinion. Alilorb ... fitilld with the num~ Iec:;ng low .. ds the left·hlnd crenkcase (downw..-dtj. Inlllil 11M selec:1.... drum Ind .lIIil 11M ... leel.... , ......... InlO lheir ' flI)ec:tw. IIfOOYIl in lhe drum.. Fllllil the MIIet .... br\ ,hlftl. S When III COITIp(ll"Mlflll ... r~11Id, chl!lc:k Ihil the Mlec:lor drum ilin \he ...... lraI poIirion Ind Ihtl both shaft ..... , _ 10 rotall. then 101.1. lhe dnno 10t;hec:k Ihit II gu.rs carl be Mlec:l1Id with reIIll v . _. Rlturn to tIM neuUIII poIition 8nd Iubriuot. thoroughty ... bMringI end

sa

bNrinQ 1Uff_.

34

""......... blingllM engIIM' V-..t.c.c joining 1M

c,...."'"

.....n

I Apply I lhin ' ilm oI ...lIng COfT"IPOUnd 10 lhe IIMklt 1Uff_ oIlhe IIIII·htnd CtII"Ik_lwolf, then prIM lhe two locating 00... .. firmtv Inlo lhei. ' ec:_ In lhe C"nkCIH .... ting lOrllC'. MI •• ' 'inel cll.ck thtl ,M COITIponenll ... in POIoltlon.nd IMI III beilnng. Ind butlng ",rI_ .... lubricatitd. 2 Low", the ...,.,... C....... CIM hili inlO po.i6on. uIinQ firm hind prenur. only to puIh II home. It "...... be necIIA'V to gn. •• few genl\e LIPI witll.lOft-flCld mIDIt 10 ~ ttoe cnlno fully Inlo pile • • 00 not ......~ force: inlteed t;hec:k IhIt .. shIIIu end dowell Ire correc:dylitt«l..,.;l-=urlltly 1Iigned...-d m.1 lhe ~CIM """. . . . . IQCt/y ~ to _h OIlIer. If - r v ; PIA_IV the...,.,... cnnk.. c.ne hIIf to rec:tity IhI problem before ,t...-ting ~ 3 !he two hIIveI hIvto joined correctly 8nd without ,.,it the ~ ,,!lining _ _ utIng ... ca< COITIp(ll"Mlflil. II • f)If1lculor IhIh '- Iliff to 101111.' ......, liP on each end using .1oIt-11C1d .... nel wifl contral'" lhe .... '1 In II, btaring. If 1l1li; does nol if eny Olher problem II; encountertld. ItIt uenkca .... fTIInl be MPI'"od ~n 10 find ..,.;I 'ec:liIy lhe IwIt. PlN;k ct.... "II into the c . ...... _ moulh 10 prevenl\he enuy of dirt. Ilion ,,' il lhe u..miMIon oil dr ... plug. if remo'4d. tighlening it 10 lhe '9Kified lorque ... t~

",1In,

w.-

won.. ....

fig. , .. Gear ... lIet.... .....,.......... 1

;

J 4

s-c,."Dhun s-c,." ton ftputwlt kdl4lh l1N'

,

Pivotbolf

9

0..,.,.".,

""-ton

I; R«""rptII"Ig 13 Gd!p /4 Oil ...

s./«,." ton ..." s./«,." ton tMP
s.l«fOI

6 1

""-

outpUt wit

SMIIctfl' ton IhIft Gd!p

10 RItufn~ " ~IhIIt(OTmodtII

.....,

--

3S ""........ bI"'" tM ....inllgMrboJo: unit: ""'It\ing the reed ........

I I'IlIIil tIM reed "'..... end inlet lIub Nsernbly to \he C'''''''I*M utIng , . - g.IIkll. Tlghlen lhe lour mounting bolt. In • dilgonll MQUInCI.

to the tecommended torque Htting. 2 tf the wort ~ beIog Clmed out wnh the er9rl111geafbo~ tIIl;t ;n the ff ...... it wi~ now be nee_IV to . eauembitl .. tlloM component. lIo........ tIed .. dncribed In Section 15 of this CNpter. the.-..-y wort being delcribed In Secto. 45 and 43 of this O>apter.

1 o.g._ the rolO< and c,lnkah81t lipefa Ind flfit the Wood.ulf kay IntO the cnonkWfI. 2 RaIoc&tl the ItltO< In its originel poalnon. tiling the wi""", . . . guodoI. and " ' _ tn. rubboIr winr MIllIng ~II intO their CUtOUll1n the crantCIM wal_ Relit and tJght .... the twO .t.tor rnc,..·,,"'9 screws to lhe speaf'1Iid IO
an" gen""

3 Deg.ease the rotOf and c'.... kshIlt ..... Ilng sutfKel and .....ave met .. perticlel Of IWart from lhe 'OtOf magnet • . Align the slot In the
GIn""

"""t...

....-.g the 8CCOI'fltloIt1V photogr~ and the not" fNdI on cfiI.. 1TIIII1\11ng AppIv • lew d~ of ttwNd-locklng compound 10 lhe IhlNdl of lhe ~ pivot bolt and 111 ..1Ihroe patU . . . lingle 1IHfTlb/'f Screw lhe bolt In .. I.... poaibie. lhen PIlI Of tev.. lhe del ....1 ....... Ihill the toler on It, tip~ inlOOClf<el;I oon!lll;l wnh the HlecIO< eMTL 0-1< 'hII' the ~ ;. COfNCIlv P<*Iiof"IIid. lhen loghten the pMx bolt 10 ill fIIl«:if'lIid IOrque I0Il1"'9 Check till! the detent arm ill_ t o _

-

-

2 If 1'- gIoIfcNnge lllaft ..,um spnng was removed IOf ....... reason It muIIt now be "lilted. Enwte Ihllt the Spring ilfilled the OCIf<eI;t way round and lhalhl end, M1\IIIIt COfreetly with the protruding tlr>g 01 the '-tor ,IIw pille. Reli, lhe retaining circlip using I IUlllbIe Plir 0/

3 Wrap the sp;r..11 the end 01 t'- ~ IINtIIn IlIrIp of PVC r.uIit"", !ape 01" . - • '-Y 8PP1C1tion of go_ to protect !hi IMIing lips of the oil HIlI in the crlonkCIM Iett~ hili. c..r.fIAv " - t lhe ge.IfC~shaft.-nbly end puIh It Int O~ tat"'9gtNI __ 10 .... I sight twillinQI ection .. lllalt spIir-. PIIIthroogh the 011 MIl. Thil wiH minimise the . ilk 01 dIrnttgino the dellcat. .Nling liiM 01 lhe ..... it UPWlfott. end downwan::ll. 4 WI\en the shaft is In ~. ,~II uc:h lIme. 10 ct.ct the oper.tion of the MIec\Of ~ The lllaft should <Mum quickI'f end poIitr..IY to the -,I.. I)OIIitlon Wlthno t . - oil,.. pllyOf~

t'-

lI"I0\I'

311 R..... mblln-g ...... nglnel gelfbo~ un"': ..flnln-glna prima
37

R..... mbll"1lllhe eneiMIvelfttol unit: r.flttlng I.... nt..-nal

ge_MMctOl" com~1I

311.1 Fit Woodn.IIf kay to the~ .

36.2 _ end fWfit IlIIorpllt.--.bIy. AwtY IhreId-IocLngcompound lolhe~~

Chapter 1

.,

Engine. clutch Ind g . .mo.

ttvough tM connecting rod amaII-end 8ytI Ind ... ting tM~' Of\ two woodfin blocks pllced IICfOU lMc.. nkcue mouth, Iithou(llt if tM WOf1c it being CIOffied out with tM .rogineJgeaIft drive ~ to tM c""'Uhlf~ ...... ,ng IUtII tlllt 1111 t;m;ng punch n'IIfIr. ;. Of\ the outwetd ,_ . Ref" the pr\mIf'y drive gur..... she<...." nut. roghtllfl tM nut to the -.pedfIed

'PIC".,.....,

timing mart Of\ 1M baIIncer lllaft drive gear IIC.. lhe balincer lllah ilHlf. Paniallv !oeat.the bIIIonc.. lllalt drive-n gelr oY&r the Woodruff key. milking lu .. ,1II1 the timing mart dol iI Of\ the oulwl.d , _. Rotlt. lhe driYe-n gear unl~~' liming .......rt dol aligns wilh the correspooding dot 00'11111 drive IIU'. then push the dri\4 geIr Iulty Into poeilion 10 11111 the two ..II 01 leelh meah Ind check tlllt lhe two timing mart. ...

1OfCI\HI ..tting. 3 I....., the Mort. aquar&-HClion Woodrutl key 1n10 lhe '*"IhIft keyw .... Ind I.... 1111 CQr'Ikshift 10 tM TOC lK*\ion 10 thet till

4 When lhe beIIncer lllalt timing ;. correctty .. ~ ,efit 1 new \.lib ........ ...." lhe nut 10 till beIIncet shift. Nota 11111 the tab w ...... mull be inslllled 10 tIIIl the tlf'oll Of\ lhe ... 01 lhe w ...... frll Into the keyw.., of the '*"- ahlft. Loct ~... crrishIft ...." tight ... the blllncerlhlft nut to the specified tOfQUOl ..ning. Usong 1 hImmet...." 1

conICIty lIigned.

31.2 EnIuNr gurdIInge lllaft .., .... spring II

correctly fmed

31.4 Chect. till ope
J8.2c Fit bIIareet IhIft drive gur """ing ...... punch fNrt facesoutwardl _

Chapte,l

Engine, clutch and gearbox

38.Jb lOCIte ~"'nc .. 1oIwIi! driven gear on

38.J. Fie thoftsquar.soc:tion Woodruff k..." co ~"'nce< shah keywllV

k..."._

38.4a Fit a new tab weihe< _

J8.4b ._ end tighten nut to lIPfloctfoed torque setting soc:ure with ehe "b w.. her

lUitable punch. lock the drivengear retaining nut by bending e portion of itl tab washer up eoeinst one 01 the '''',, of the nUl. S finally rer.tthe 011 baIf1e to the c .. nkc.tslll having fi"t applied Ilew dropt. of thr.ad-Iocking compound to the threadl of itl rlltainong ICrews. Tigheen the ICrews tothe specifoed torQUII setting.

pi".

19 R..ssembllr>g lhe engine'gelrbo. unil: re fitting tM IKhome lerdrive gH"

t When relitting the IIIChornell" driVflassembly,l;gtotly 011 the vertical driven ge&r Ind in$en il down through the opening in the crankcase top IUrllCII into ill hauling. lhen check the condition of the sealing O-ring lin"'; around the spigot olthe black plastic housing. Renew the O-ring ~ neces5IIfV, eppfy athin .me.. 01 gollHII IO the housing spigoe and lit the

housing with. twistIng mobon .. 11 ICrewing it In; use 9 ' _ to _ _ the UI5k. When the houslng It fully In place, fll and tighten the aingII reteining bolt to the specllied WQue seiling. Do not ovenighten thl boil. or the housing w~1 crack-lithe clutch It not in p~ the white nylon drive gear ..... V be assambIed on ill shaft WIth a thrvtlt wIISI1er on eodt Ilde Ind offered up III complete assembly. 2 If, how8Vflr, the clutch illn piece, I .Iightly dilferent procedure most be used. Place one 01 ehe thrust wHhe" on the crankClStl wllil lroo..ng thlt i, rnaheI correctly WIth both the clutch outer d .... m and th6 venical driven gIIIf. Ind hold il in ~e while pushing the shah into place. The second tlwust washe< ..... V then be fllted oYfIf the lhah tnd to r6St '!I&ilti! 1116 drivt goNi". Tlke grNI care locheck lhat the _mbly illlill in place bel"... the crankcase righl·hand coYfIf is refilled. II it It only the "'n.r.....tlich reel!irl$ the drive gear assembly

CMptir 1 Engine. duto;h Ind geerbox

"

39.1 b Fit I pIWlllwull wMhor _

39.11 Fit drivItl gAf and pllstichousing. Avo;.;! oYtI'tiglnening tilt .. \.lining bolt

40 "--mbI1ng I"" englnLlgurbo_ unh:: "lInlno the kldlll¥1 ....... bIy...cl1d1e< v-r

I

UIing '1Uit1" pIir of Qrdip p/ieQ, refit the clrdip on I"" w..m-I 01 tilt tWO grOOVH IT\IctIined in lhe oulpU! "'-" rlght"'-d.-.d. " ' - . thnnl wither oYer lilt ~I ontavily ~"""feI1eo;I lot wort. it mutl now be rebuilt and off&r1td up 10 1M CQn~ N 1 tingle unit. PIKe tilt kk:h1Mt pinion on I"" WO
_'t

""It

....

_-

40.1b _ foIowId

a.rge pIlOn wHhe< whldlloQtNIgIinsc!he """ thouIdIf. "'-\"" klculan return IIPri"II _ the """ with both IIPri"II .... flClng inwatdl. towatdIl'" Iarge~., 1IPIi-. and n.t the apMg Ihott innI< lind inlO i1elocating"" in I'" kic:kaan WIt. Refl\ \'- whit, nyton spring guide onlO I'" Wft. -.ring 1_ I'" CUl-oo.rt on _ lind III f8Cing inwardllnd ~ with the apring innI< and. 3 L~tI 811 blaring fUr/_ of I'" klckell" Hlftmbly and inN" lhe KIImbIy Inlo \'" crankCIII. N 1M end of I'" 1II,1t fi,. 1n10 it, hauling In I'" CtlMet.. WIlli, ensure 1"'1 IIIfge lIoppet .. m Iocat" COI'l'CI(:tly . ' MII'" 1I0Il CHI In the ~tln.ketM w .... tnd \h" lhe friction c!;p looped and 1111 1n10 the t " * , , prOYidood lor it. MIke, quk:lc check 10 ......... 1"'1 lhe klcu1.atl .uembIy ;. _ _ ling eotrIClly bv tOtet.ing lhe ""11 II lit II ~ 1Itltk:b::tcw;u. The ""t! thouId tOtell IITIOOtht'f' Ind MIlly unt~ the 1iq:Jper Inn ~ 1n10 _ with ill MCOnd 1I01l. end '''' klck"l" pinion &houIcI _ - " y up II, ""11 \0 Ifl(II9t with I'" \Mlh of !he Idler gAf. Rittum the """ 10 its notmII poIit;on bv rotMing II cIockwiM Ind ... ,1UitIbIe poW of pIiert 10 bring the ,,'um tpring long ~ end eround so IhIt II Clflbe

t""

"'*-

bv fint plain Ihrusl w ......

""It

Chapter 1

64

Engine, clutch and gearbox

4O.2d Slide nylon guide imo place ensu~ng

Ihal notch on9ll9~ with innvr .. ndol kic~slart spring engaged in illloc:a ling ~e in the aankcase wall. Take Care 811his poim 10 ensu,. lhallhe spring end is hooked firmly Imo the locating hole. as Iha spring will be under quite heavy Pf8Ssu.e.

41

Rnssembllng Ih, engin"llea.bo~ unit: refitting tile clutch

1 Commence reassembly bV fiuing Ihe dished washer and thruSt washer over the input shaft nght_hand end, noting that Iha dishe"ctivlI Slits of tellth on Ihe oute< drum. Refit tha second. splinad, thrust wash"r with its slightly chamfered surfacII facing outwards, then lit tha clutch canlre over the shah lind. fit II nllw teb wHsher with its small protruding tang located In tM cul·OUt in the clutch centre bo$., whereupon lhe retaining nut may be replaced On the &haft lind and lightllned down as far a5 possible by hand. 3 Lock the Clutch Centre using the melhod IImployed on dismantling and tighten lhe retaining nut to the recommended lotq .... oeuing. Secl-'ra the nut by bending a portion of the tab washer up against one 01 the flatS of the nut. Check thet the clutch OUtllr drum and the clutch centre can retata freely. easily, and indlll>"ndllntly 01 ona another Thoroughly grease the left·hand pushrod and insen il Into the input Shah. followed by the steel bell. 4 The clulch plain and friction plates should becoated with transmis· sion oil prior 10 insl8l1alion. II will be nOled Ihaillach olthll plain plalell

~~a~: :~~~I~~i:~I\~'o~~g;1 ~~~:i:~C~U~i:;:r:~~~!i~e~~ ~:~~~~~ Fig. 1.10 Kick"." mechanism K/CksrlYt/ever

7

Nm

8 9

OilstMI Spring guide Rerum spring

W"'"'

/(icilsum pinion FricrioncJip Kicks/an $haft /0 Csldip 20" II Thrust washer 2 oH

Ol-'Iwards under the centrifugallorce and Ihus reducing clutch noise. Tn preventtha whola clulch f,om glllling oul of I>oI"ncII il i. necessary In arrange Ihe plales so Ihal Ihe ma-chined araas ara spa-ced evenly areur.d ils circumference. This can be achieved by arranging each cutaway arN 10 be approximalely 60 0 lOT models) and 72 0 (TlR models) away from the previous one. (See fig. 1.1 I.) Sianing wilh a friclion p481e, and thana plain plate, insen lhe plat" in succession unlil all are fi\ted. NOle on DT modoelsthallke friclion plale w ith the larger intemel diameler, should be the second friction p1atelo be inSlalled inlO Ike clUlch oule. drum. along with theclulch damper ring.

12 IdJergN'

41 .1. fit dished wltSher to input shah righl·hand end ..

41 .1 b ... followed by -II thrust washer

41 .28 Refit clutch outer drum ..

5

When fitting IheclutclI preM.iJ<' pill', not,tl\e! IIIe ..row merIo: call

on it musl align witll llle ,tamped cifculet ....rt on tile petipnety of lile cluldl ceo"l. ~ tile rigIIH1.MId pushtod, IIU$hIod pill" wMlle< WId Ioctnut on the duldl _ _ _ pille; MCUtI tile Ioctnut by hend only. ThoroughIv ~ tile _Yod. " - t it Into tile input "'-It. and

guide IIIe pt ......... pillIlnlo piece. ....uring o..t it filt 0\1 . . the cluldl ~ pia... and ~ with the dutdl ceou. merIo: II the ...... I..... R,'ittlle dvldl tPrinIP and their retaining bot1$. 5eo»'. IIIe ane
42 RI .. tembIin
2

I Mak" Ilnal cIIecJI 11\101 aU COn'IpOnenlt .., ""rec:11y In place. sec... ety I..tenld. and lubricaled. Enture thIol the two Iocaling dow ... . . sec:urety In place in theo-kll Ike of thecrankcae righl.t\atld half 8nd check 11\Io1 11Ie 1Khomet.. drive OUletlNwI wllhe< ilnil in poeition. 2 TIIoroughI'v cINn boI:h ~II ......._ end place a new gesltll on IIIe u ....~ ... rong 1_ . UIino;J a ...... of ~ 10 "let il in pIac,. Smu. a amaH amount 01 grMll on lile WIlling II~ of lile kic k".., 1lii0i1 oil MIl, .,..; lit>er.lly 0 ' _ lhe Ill*- ollhe kicqlln ....It itself. Ofler up lile COY .., IIItlng greet c:ere nol to damage I'" oil .... lips .. lhe kicqterl 1lii0i1 PIIIIS IhrougIIllIem.. E _ 8110 m.11'" WI' .. IU"P

'*-'

andoilpUmpdrive~~COOT«ttywitlllhecrenbhlft~

4 fig. , .,, Co
OT

moOeI !Sec 41 I Note allG punch meo1t lII .... peeI on c""eh cent.. A

""'"ing the~ if~ 10 achieve tII& 3 Onc:e the COYer iI fuIy home, ..tit tile re!lining ICrIWI in their COfI'ICI 1oca1i0n5. not forgelling lhe oiIleed pipe clwnp end breiolher hoae guidt. Tlghlen the flllII.,;ng ICfewl tO 1"'1pII;if...:t lorquelllling in P'OO'H""I lieges and won.ing from lile c:enl" OUIW.rCi 46 of tIIiI ChIoiH...

.

Chapter 1

Engine. clutch and goorboll

, pressure plaia

43

R•• nembllng the 009;no/gu,bo. unit: ,elinlnglt.. YPVS

components

photographs) as II i, possible to lock the valve 180" OUt 01 pOt;ition which will drastically ."0<:1 perfonnance. If the valve is found to bo positioned incorrectly simply remove the lIalve cap and r01818 Ihe valve 180· before folilling il. RafTt tho 1181v8 cap centre bottond Ihe right-hand 118lve cap and Allan K'OW. Tighlen all SCfeWS 10 Ihei. recommended

torque "nlngs

44 Reassembling the .ngln./ge.rbo~ unit: ,el illing Iha pillon, cylinder b ......1and h •• d

43.1."'' ' ~"~~''''

43.1 b Aer" the vaNe as shown laking cere 0>01 to dmp dowel pins

43.28 Ensure slot on blll55 sleevelociiuHI with peg on inside of left.hand end cap

Chl pt. /l

Engin • • clutch .nd lIeI/boa

dIM '~M . -.. 1tId 11'II11heir end 1IIfII_1ou11ld c:orrec:!Iy by !hi l'lleining pega. The top ring;' oIlhe KeyslOM 1YPI1tId;' of IIIP8
_,'roII. oilmen

-="

(IV""

"

!he anew eMl in the pillon aown poin:& 10 lIMo from.. ." IOWanll tlMo ex ......t pOr1. ItId IKUfI It by puIhing lhe ~ pin llIrough the ~ bNring end lhe pilton ItMif. FII new ~ -...ring Ih&i they .... c;orfKllv _11Id. 00 fIO( . . . . . f/",,_.,q, 01 rile 0fdj:I1V Iw

posnlDnMlinlhellol PfO'o1~fot"adP"""""_, 4 O>e<:k INI lhe pillon ring& ... 1Ii11 comedy po.ilioned in lheir grooves and lhen lutlri<:ate bolh 11>11 pilton ringllnd CVIinde< bo-. wilh froth two-llro111 Oil. Low.,.. lhe qiindef barrel ov.,.. !he pillon wNIIl pressing lhe pillon ring endl 1000001her. This &houId not IKe ... liv, f(lt(:l 10 if Iny dillic::",ltv i. 1tIC000nt.,..1Id ,emov, lhe banal and dO\l~ ehec;k INllhe rir"lgl'" CGn"ec:tiy lined bef.", Irying ItgIirI.. Onet balh ri"ll' ... f....1y .~ in tl>II bor., rerTlOlll 11>11 r-.g from the Cfankcasfl moulh and puah lhe blnal carefully down 10 rell on lhe

11<1"'"

.

Chapter 1

Engine, clutch end gearbox

44.510 Fill new head gaUl! _

44.5b _ and tighten cylinder head ""II to specified torque Mtli"""

crankcase mouth. Refit the clutch cable brachl on the cylinder left· hind ntar mounling stud. then r~ and lighten the four cylinde< ."laining nulL The null .houId t.. li"tnened in I diagonal """""",," 10 their recommended torque selling. S Rota,e the crank.hm 10 tMllh11 piston is II the lopof and wipe away IllY IUrplUi oil. Check lhal the maling aurfllCei of the cylind&r head lind ba,," are c ...... and dry. lhero place. new cylinder head ~k.' in position ave< the studl. Rllf~ the cylinder lINd, plain washe ... "nd tIomed nUlL Tighten the cylinder lINd null evenly in " d'-oonll HqUe< unit In the frame, it will now be _ r y to ,_mb!e &II !hoM component. d~nUed ..
Ieh·1\and aide. On Of models g _ the ,winging arm pivot akalt Wlth , high meIIing'POint lithi"",,·1N5Od gr_ INlore lIiding It through It. reM engine mounting bou. On TZR rnolH(l.locking compound to their thr1leds end refit lhe two r'!linlng bolt .. lock the engine to prevem rotllion wtlile lhey Ire lightened 10 lhe.pacifled torQUe Mlling. Ott II models refit tllfl ronal drive chain end edjUSt tllfl d\ain tension. rear braIc. adjustment end 110jl lamp I wilCh letting I I described in Rout ... mainteMrM;e. II the ehai .... joining link was diKonneclad. the . prinR C~p'l closed end must lace tllfl normal direc;tion 01 eha,n \rille! on refilling.

its"..,.,,,

45

Refitting lIMo .ngl.... 'gurbo . unit In 1ho1 fr .....

f,_

The eng.inelgeart:>o>c is ..,!ltled \0 the by revlDf'Sing lhe remova' aequenc • . PoI.ition tile m.,;:hine MlCur&ly, ptef".-,,!v uPright, rather lhen on it. side Itend, and ease tile engi .... inlO piece. Align the engine with ill mou."ings end relit the mouonling boIli from the 1

45.3 Refn gearcl\enge pedal using lhe marks made on dismeroUiog 10 position il correctly

Ch.pt.,l

Engi.,., dutch .nd go.mox

.s,7. ~ clutdl CIbIe to lift"", Ifm .,..;I bend up tab IIn'owedJ

·••• ;.

d d

d d

•

• d

;,

•

,•

3 Aefitlhe Ith ,t..nd C'riCIHtover. "';ng. new QMk.1 and tighlln the Ier8WII In • dilgonll S8QUfIIlCI. Ll$ing the mI..... mIde on dis.....,11Ing. relillhe ""teh.,. ptd.1 Of linQ.ge lronl arm III Ippropri• 1.)10 Ille gearehlnge thall apti.-.nd lighten Ille pinch boil. a Aoule lhe mlin gtnItlIlOf lead lrom tile C.-Melle up 10 lhe I.-me. -....:t It IOgIin to tI"IIt mlin loom .,..;I HCur' it with ""'" cII end remounl lhe cable on lhe bteckll Illuated on lhe teft·"-nd.- cyIinde< berfII out.. Adjusl I.... CIbIe II dIIeribed in Routine m l i n l _. ....... lhe tacnomfIl" CIbIe Into it. housing on Ihe lop of!he right.n.r.d Ctricase. noIlofvelling to lifst ref.. the oil ..... II IYMghI PtoYII r«eMWV to tum the . . . . . _ on tile u::kslllrl toengtge the dri¥e Ind CIbIe. Once ~!o. eotrectIy engaQed wi:h its driv •• securely light.. its knurled

.....u

8 Aefil the .........t syslem. u.. grNM to lI;ck • new QMkIl to the ..........t port end rot the mountings 1ooMI'(. TIght. . the 1>1'-1 port 1..1--. lirl!. thtn lhe remeining mountings. On OT 125 mocIeII. donol lorv-I to chick tI"IIt IUbuli..... between the .........1 pipe .nd Iitencor; Ihis .....1 be .-wed if damaged. aptil Of bfok .... Tlghlen .U •• hausl mounting bolts .nd null 10 lhe apecifled tOfqut HI1~ 9 Connect t1'4 bal1enI QIVIOI be .-....ed ICCUtIleIy use I.... light~ II dIIeribed in Rou\irIe Nlllnl~ bul noI. tllel the tev.I wiI drOQ eft.. the . . . . . " - ' - ' run for me r...1 lime II t .... oil if dislributed ..-ound the vlrioul oomponenll .,..;I wiI thereforto requ;,. carllul ~ Relit !hoi fkpll.og. 10 Aef. me radiIlOf.,..;l1Xplonlion!¥>ll1l deIeribed in ChIIpte< 2 but do noI ret refi! the ..... IOf C8P IS the ~ ...... wil l" ~ the engine II run for Ihe lifsltime. 11 Refit me I..... Iri II dnCfibed in Chapler 3. tum on Ihe luel tIP and cl'«k for InY IeeItI ~ musl be cu,ed lmmIdille1y.

45.7b Do noI omIl oil .... when refitting IIChomeler d ...... CIbIe 12 M I •• I r..... chICk 1"-1" components have been refilled end t"-I .D ani coneelly adlu.ted and HCL>I'eIy In toned; tile ••ce~tion .... 1111 componentS 01 lhe Inglne lubrication and cooling SVStem, whkll ... lIiU to rocaNe. final chick befOf. IIIe ..-.cNne is flidy IOf ,,".

1 AlIomp\ to .1111 the . . . . . UIing the usuet pnx:.ed\n idopted fot. cold . . . . .. Do noI be diIiIIuIioned if the<e if no IIign "" Iif. irOtlaltv. A cenIin -.nounl of ~ may PtoYII - - V 10 __ I....

engine InIO eclMty ....... if new parU; ...... not been rmld. Should the engine Pltllatln noI liMing. chICk that the span plug hn not become louted by I.... oil lINd during ...-..bIy. Failing lhill go Ihrough the flUlt ~ _ion .,..;I wutt OUI wt.1 the problem if mIlhodQ\ly. 2 When Ihe engine doH"ln, keep it running asllowty .. poaalbIe 10 eHow I.... 011 10 clrcula... ()pen IIIe clIott. II soon as !hot engine wi' run wilhout it. During lhe 1niI... running. 1 can.in .mounl of Imok. may be in evidence due 10 I .... oil uted in I .... rensembIv sequence being burnt aw.v. Till ' .... ltlng Imokl should gradually fUbside. 3 Check I.... engine fOf blowing gaShl1 end coolant Of oil It,k.. aelOfI \>lIng t1'4 mac:hine on Ille told. chICk 1"-, .. IIIe ge'rI IIIICI ~. and tllell .... controls lunction correclly. AI soon 1111'4 engine up 10 normal operating temperalure and if running ImODIlllyltopit.,..;lc'-l! lhe f~ a ThI ~ Ievet IhouId drop II the engine fUI'II. ~ II lOon IS the the<mofll1 opetII, . . lhecootantll dislribuled IfOInIt ....... pISUgI5 "" the system. TfIPped air wiI be expelled in Ihe form of bubbles Ind .....t be .-owed to 8ICIPfI bel.". the radillOf C8P II ,.,lItlld. As 1000 II the l""-\I wch II .... IIC:OOPI. sidepanels. lairing ............. Iltlldland lhe MIL

"- w""'"

.no.-

41 THin
70 have ' - " refitted in !hoi< original orde<. For 'hi, raMOn It ;. highly the machi ... gently IOf tho! first few miles 10 emure "'. lKIviubie to has circulated throughout the lubrication IV$lem and Ih./It new lined haVil begun to bed down. 2 Even ",HIM ill MCeUary il the hal ' - ' "bored 01 if • new c,ank,klil has been fined. In 1M CHoAo, the engine will have 10 1M run in again. as 111M machine WflrfI r>IIW. This meaM 9'Ut&l use of the gearbox &rid I '8Suaining tlaoo on the lmotlle until II least 500 miles have been COV8fed. The<e is no poinl in keeping 10 any HI speed limit; the main ,equi.emern illO keepllighlloadlng Or'IIM 8f\9intl &nd 10 gradually wort up pees8 recommeodalior'l can be lessened 10 an UI8fl1 when only. new crankshaft is fined. Experience;' the best guide"nee iI ill easv 10 'an when ..,.engine Is running ffM/y. 3 Remember the\. good MIll between the piston and the cylinder barrel ill essentilol for the correct functioning of the engIne. A rebole
t_,

pa".

eat.

"'II'''''

.r,..

engine wi ...... dUfing the first hundred miles If the .r>gi.... ill pernlIIted to wort hard. 4 11" an.,. lime • lubrication f.ilure ill wspected. Stop the enginl immedilote/V.no:! Inv"tig!ote the c.use. If an engine II run wnhout oi. fo< • short period. Irreparable eng,ne dama(Jfl is i.......otabla. S Dono! on any .c<:oomt IKkI oil to the petrol uncle< the mistaken belief that . lillie extra oil will improve the engine lubrication. APIdjust I"Y CO<11foll which may haVI Allied down during inrt ..1 use II'Id re-check the coolant l1li.. in thfl rad"tor and the "ansmiHion oiIle\leI.

....en

eng,,,,,

.rr

·,"

• " """

•

·•"

""' "

"

.

., ~

"'" '0

'"

'",'.

Chapter 2 Cooling system a......

_ _ _ _ _ _ _ _ _ _ _ _ _ __ CooIing .yst ....:drllining _ _ _ ._ _ _ _ _ _ _ _ _ _ _ Cooling *V$1....: nu.hing _ _ _ _ _ _ _ _ _ _ _ I~plion

..---.--..·-.-·...-_

~~~=I~I~:: ="'O,,=,;="'=.=.~·~------------

Radiator and cap: cleaning and e><8m;nalion __ .__ ._ _ _ .__ HoHs arid conl'l&(;lion&; eXlmiNItiol'!. removal .nd refitting _..... ThIHmostat removal testing and rertttiI'G .. _ ... _ ................ _ .... _..... Wile. pump: removal ovemeul end refitting ._.......... _........................ Coolant I.... oauoe end sende< unII: geneool ......... _........ _..

pe<.'.....

6 7 8 9 10

Coo
Miltture type __ .__ _

SO 'llo dill~1ed wat .... SO'llo o;OfTOIion inhibited ethylene gIya>I ,ntilreela

Totel capacity of IVitam: TZR modeII _._.. _

1.0 lilll.7 Imp pi) 0.92 IiI (1.6 Imp pI}

OT modell ........ __

a.di.tor T .. tingpreu.ure _ _ _ _ _ _ _ _ _ _ _ _ _ _ ._.

. ___

_____==~_-_-_-__-.-..

~J:::~ _ _;"' _"_~ "~~_=_-._-_-_-

"""-

1 .0k~m'1 14.2~1 0.9 k~m' II2.8~1

0.75 - 1.05kWCm' ll 0.7 - 14.9pt.ij

Torqu8 H tti lt9' Coolant drain plug ... _. __ ._... __ ._... _ ..... _ •.••. _........ _... __ ..... _ __ Water pump cover screws .. _._ .............. _ .. _. ____ .......... ____ .. Radiator mounting bolt" TZR Df modeII .... _ .. _. __ ._._....... _... __ .•. __ .. ___ .__ .. __ .__ ._.. _. _ _ Rao:Iiator cap I tappet bolt ._ .. ___ .__ .. _ .• ~ .. *_ .. *... *_._. ___ "._" "Thetmo&l.t housing sc. eW1l .. _... _........*... _ .. __ ._._... __ .__ ._ .. _ . _ . Cooling ayt:lam bleed bolt - TZR modal.*... _ .. *... *... ___ ... _... __ .. _ .. Carburettor warmer pipe union boItl __ .__ ._ _ _ _ _ _ . _ Tam~u.e Ii/llUOtI sender "",it .* ..._.*. ____ ._ _ _ _ _ _

rnod&I._._._. .__.__. _..........._. ___.............__. _._. __

,

~dHc: rip tJon

The liquid cooling Iystem util; " a wala,' anlif. H l a cooIInt to c.nv • w • .,. aXf;fIA ~ produced .. m. form 01 heal The cytinde< II bv • w iler jacket lrom which lhe healed cooI&nt .. ci<cu· '-ted bv thefmo.~ IClion in cQnjunction with • wate< pump fitted In m. engine righl·hand CO'>'$I" and driven via a pinion and thalt from • cranktha" mounled pinion. The hot coolant peRfIl upw..ds through flexible pipes to lhe lOP of lhe radiator w hich il mounted on the If....., downtubellO Ulk" advan"'IrB of maximum ai. flow. The cooIInt than peRfIl downw ..d" through the radiator cora. where It ilcooled bv the pening and lhen 10 lhe w"", pump and engine wtle<1 the cycle llrepNled. The flow of cooI&nl .. regulated bv • m.rmCllUII. • tempe
.1"

'~m

,'-,.. ,,... ,,... ,., ,..,..

....,...,, ...•

Ibllt

'-'

••• "

w"""

The hot coolant .. oIsa used 10 the c.rbu.enor. The cooI.nt flows through a small·bore pipe lrom t"- cytinde. hied. 10 lhe c.rbut"et· tor. circulates around the corburauor bo
"_'-
1 It will be ~ry 10 drain lhe tooling lvat""' on infrequent OCCAionII, eilher to change lhe cooI&nl I I lhe .ecommandad int81\1.1 or 10 pannit engine ove hot cooI~nl ncaping under p ...........

Chapte r 2

72

Cooling I Vlte m

2 OoOTmodelsilwillbe.-urv 10'etnoYfIlhe left-hand .., KOOI). Thil is ffllalned!lv Ih,ee Ie,ews and can be rotted awey oncfIlhe SCfflws hive been removed. 3 Carefully retnoYfl lhe fldialor cap lIopper bolt. Noll Ihli iI lhe lOQine h8I been run recl<1l1v. IhIffI will be IIOO'MI residual prllUlJffI in !he IVllem.lf IhllOQine is hot. lilam and boi!;ng waler mlV be ejecled and can cause scaldillg. As a preceullon. pIIee IIOO'MI rag over lhe cap and .amove it slowly to preu.ure 10 escape. 4 Place a IUflaDle coni ...... under lhe eooianl drain plug 'flualed on ,he bonom of lhe water pump housing and remove the drain plug. Tilt lhe machine Slightly 10 lhe righllO allow the coolant 10 drain fully. 5 tllhe sYSlem is being d.81ned belore an engine overhaul ~1I1e elll:l need be done e , Ihis 111191. tllhe coolant ill .easonabIy new it can be •• ·used lilt Is kept clean and uncontaminaled. II. however. lhe sYSlem ill; 10 be refilled Wllh new cooIent il isadvilable 10 gi.oe it lhofough lIushing wilh liP walar./f posslble using a hose wtlich can be left running lor e wtlile.I ' lhe machine h8I done a f..rty high mileage I. may be advisable to carry 001 a more thorough lIushing proceu .. described in lhe loIIowing sec.ion.

.,Iow

3

Coolini system: nushl""

aerve.

1 AftM ..Iended lhe coohng Iyslem will -.lowly 10M elfoeJer>. cy. due 10 lhe buikI·up of 1CIoIe. de"",,11 lrom lhe wate. and Olhe, lore;gn mattlr which w~llIdhera 10 lhe intemailUrllICM of lhe radiltor Ind watl. channell. Thi, will be partictJl&rIy 10 iI dil1111ed Wiler h8I nol been used 1110 limes. Removal oIthe de~fI'can be carried ool ...ily. using I lUilabie lIushing agent in lhe lollowi"" mlnner 2 Aftar allowing 11M cooIl"" .yltem 10 dr"'" relil!he drain plug.nd ,efillthe ,ys.em with clean wiler and e quantfly 01 nushing agaoL Any propr;a'irv lIushing agent in eilher IIQuod or
.. CooI1nllfyf"m; filling t Before lilling the "yslem, ,e/il the drain plug USIng. new ..... ling washer under ill hud Fil andlighlen 11M drain plug 10 lhe wacifiod lorque selling. and check III the hose 2 Fill lhe syl18m IIIowfv 10 ,educe lhe amounl of iii. whw;h wiH be lrapped in lhe water jacke.. Slackl<1 oflthe bleed boll on ttlt thermos"l housing (TZR model&) or IIIICklln !he carburellor warmar pipe hose union boll on lhe lhermoslll houIing tOT models) untillhe nc:ap;ng cooIent shoWl no aign 01 iii, bubble&, IhI<1 l;gnlero lhe boll to lhe lPGCilled lorque Mning. Note thll the cootant mi~tu.e will a"lICk PDinted ,urfaces 01 the mac~ if any tpilt cootan. is nol mopped up Immed;.t ...... WhI<1 lhe coolant level is up to thfllowe. edge 01 the rlldl~tor fitle' noel<. run lhe angine for about to minutes el idle speed. 111(:_ engine revolution, 'or lIMiest 30 second,lo 1lCee!e."e the rale ~t which any t.apped air is eKpelled. Stop the engine and .eplenish the cooIent ....... again 10 the bo\lom of ttoe fille' neck. Relin the a"Plnsion Utnk UP to 11M ·Fun' level mart.. Refit the radiator cap. ensuring thll ilis lumld clockwise es far at possible. Reflilhe rlld;'lor aop 1I00000t bolt and tlghtl<1 10 thto ~jfiod torque. 3 Ideally, distilled water should be used basis for the cootanl. If lhis is not ,.adily av"leble. raIn w".r. caughl In. nor>--metaUic recep.lacle. i, an adequale ,ut>.litu" I I il o;onlaifll only limlled _moun" 01 mineral impurit_. Slmila.ly. ilis Pflfmissible to use tap w" .. whw;h h.as bean thoroughly boiled and allowed 10 coot dowro. In """"'9llfllie5 only, liP WSIM can be used. MPCIC;'11y if it is known to be 01 IhfI IIOh Iype. Using lIOrHIistilled wll ... will inev"'bIy leIICIlo early ·furring·up· oIlhe .ystem and 11M fIIItId for more f,,,,,",,,nl lIushing. The comtCt wile< antifrleze mixture is!iOl5O; do not allow the anillreelilevel to lall below 4O'Ifo IS lhe a",i-.:llion propenie5 ol lhecoolanl will be reduced to lin

cI....

4.2. MI~ coolant .. described in leKI and lillthe Iystem via IhfI rad;'ICIf neck OT modeIlhown

!til.

=v::=~.:;.t:!:':'::':"~t!~~i~:,,:.hould

4.2b Relit rad;'lorcap andslOll98rboll!tll thawn

Ch'p",2 Cooling sysum

73

4 Slaeken tnd . - , both ,.,tiator ~.nng boIur tnd , _ , lhe MilIOI h'om 1M kamIo. Tht bel.. _tlvough mr;IUfIli"G rubbed; the ord8J of tMuIO tllloll~ rlldialor an be nlfinlld cor_tty. Tht TZII model ...... an additionM mounling -' 1M lop wIIidIt. . . the form of • Ioc:Irting PlIO tnd Ioc:Irt. . .., • mounting rubber. S Ref" the ~tOf by • .-.uI of the mnovaI ~ mlking ..... that the mounlirog rubbI
not.

DrWII~ cooling ..... t.,., • ~ \he .. ~

t""

dHcribed in SKlion 2 of cn.pt... from \he f .... ~ In
1 1

...-.It ' -

5.2. ~t ' _PIInslon t."k hoM from 1Jdiat00neck ...

Fig. 2..1 RldiatOf TV! mo6el

, """ 2 .sa.w

4 0N

3 1M 40N 4 BoIr 20ff 5

1 8 9

W..",.,. 20" 20ff Moun/in(} I"IJbbM 2 off RMIi,/O' Moun/Ing tUbbtIr

10

c.,,~

6

~

1/ EqMIUIO(ItMlk~

12 0j:I 20" 13 lOp'-~ 14 HO$H'-'. 40ff 15 l"-'-1MhousIng

" '"""

/1 T"-'-IM

18 O-ring 19 BolfomhoM/outlel) 20 30N ~_

2 I 8Ie«J boll 22 SHImg WlshM 23 C¥tJur.tror wanner pipI - 2 o ff 24 Clip 4 0ff 25 boll 2 off 26 SNIing wlSIw 4 oN 2J Pipe uniotI 2 oN

u.-

5..2b .* follow«! by top ...

If.

74

Cnapter 2 Cooling system

--""'-

Fie. U RMlIMOf

8011 20" W.",.,. 20" Iobmlmg~ 201f Sp«et 201f Eltl»fUlOl'llllnllpipe

9 10

ToplloM/fiNed 2 oN

'** tMmp

"'-'-tM~

" ...... "

~ 30ff

13~M

"15 ",.,. IJotrom ' - (oudMJ Ht».~ 2011 17 MM.bomImhoMl

15

"

",.,. 19~ 20" 20 CMDunItf<)rw_p;p. 21 CI;;I 401f 22 IJnIonboir 201f 23 SNl/ngwHlw 4 0" 24 P>peutlion 20"

o...pter 2

Cooling . v . tlm c:omponen~

, TIlt inttrior 01 the ..cIiMor c.-. rnc.t eMiy be ~ whiIIlhe rDMor it on the moI~ uP>g the fIuIhitIg proctdurt dMcribfld in s.etion 3 01 IhiI et.p.... Additionll f\ushing c.n III canltd out by pIIocing the hoM in the liIItt ntek and aIowing the wlter.o flow Ihrough lor lbout Itn minut ... linder no drc ...... _ IhouId 'I'l0l hoM III «II'II'IfCled ' 0 the filler neck ~1Iy ........ IUdden bIocklgllln 1M rIdiIlor 0<111411 would tubject the rediato< to the lull PI ...... I of tM maint wPP/Y libout SO P5il. The radiator should not be t.Ited to g.l.ter !No t .O kg/em' 114.2 paol. 2 Generally. ~ tM radiator if; lound to be IoIIkln;. r&pIIr .Impg 110ft tOkIer. InIV be used for QUIo,ing"'~ Iultpe. BadIv damaged fi .... cannot be .epaired. I! bent or damIgIId II", obttruct'M tit flow more tllart 20 '110. I new radiator will ""'. to be lilted. S InllH'Ct the ,td'etor mounting rubb&rt ' Of perillhing Of compaclion. Renew lhe rubbt" ~ there II OIly doubt .. '0 their condilion. The rdltOf......, MJffer Irom the tffec:t 01 vibration ~ the IIoIIoting eh&rac. ttrittics of lhe rubber ... .....:toc:ed. , I! the rMliator ~ it wtpI(t, hII .... it tn.ed bv ...... thorized y....... he dialer. Thit job rlQUw.. ~t equipment ..-.d cannot be cIontr .. hcln'I&. T... only all_1M if; to Iry, new c.tp.

15

or cooItnt. TIIt ..pa.wion tri pipe ill' ....... pulh-fJ\ on

tht ..cliltot 8<>d tri ~ 8nd it IMCU<Wd bv a difl81 uch end. S On..tln-.g ' - - tnl tIidt "" dtonpt on to the ho:Ia4r 8nd Il'IIn

wut it on iU; ....-tivt tpIgott. Do not .... 1ubric8n1 0/ tny 1ypt; tht hoM CIA be softened bv IOtking it in boiling _Itr btofort refirq

tIthough cerl. obIriousty r.quired to pw..ern the rIU of persontIlnfury when doing 1"'-. When 1M hoM it fined. 1'0111' ~ 10 ..,tIt it on Itt spigo~ .nc! check IhlI 1M two com~lI being joined ... seo:u ...... I.tlned 10 thlll '''' hoM it oorractly fitted befOft its climpt ..llIid inlO ~ l kIn 8<>d tighttned _ ...... 6 The ctrburtnor Wlrmer pipn peN cooIenl .... Ihe unkln on tM cylinderhHd 10 t"' cerbu", tor celllng.Ad then back 10 1M IhInnoItat hauling vlllnOther union. A fP"Ing clip II etch pipe end _ n lhe pipe to iU; union or ctrburtnor SQUIll" '''' clip ..... logelher to

......

.,ub;

I The IhInnoIlII it Mltomllic In operalion 8nd IhouId g/VI mtny requiring attention. In the event of. I.u.. lhe vatv. will probtbfy bteomt iImmId opetI. in which ce.. ,he engin4I wi. take much longer then normtI to w.rm "". If. conv....ly. lhe vltvl~" jammed lihue, lhe cooIlnt win be unable to circullte normally 8<>d lhe engine wiH lend 10 O\II""'t bldly. Neit ..... c:ondilion it IOCfIPlabit. end lhe Iluh IhouId be Invn.'lltted prompl,.,.. 2 RIJ'J'IOVI tM tldtplnlll. ...tlnd futlltok.OnOTrnodeIt It mty be advln\lgBOUl 10 _ the I wheUIII SYSlem. .lthough lhit it not '{eMI'1orVIce without

11ric:t1y.-...ary. 3 Drain tM cooling .yst...... cIncribtd in Seetion 2. Then ~I both Ihi eooItnt inlet hoM (IOQ '-I8ndctrbureltor Wtrmlr pipe from

the lhlnnoeuo. ~ RfImooVI thel"'" thtrmottlOt houtirog I'I18ining ICf'ewt 8 n d _ the hauling. Lih 1M thermotUOI and ().ring 0U1 of Ihi cytinOer hNd. 5 Examine the II'IIormcIf;UOt viIutIIV btfore-cerrying 0U1 I..tt.. If " remaInt in lhe open potibon ., room I~I""" it IhouId be dilcttded. Suspend the t..... rnc.lIl bv a piKe 01 wi,. in • conttintr of cold _ter (He 8COOJ'IlPInving n.... t..,ion!. f'IIo;t, thtrmomtt.. 1n the Wit.. 10 IhIIl tM bulb it doIIlO Ihi thlnnolll~ HeIII t... Wiler, noting when 1M thermaltat opens and lhe lemperature., which lhe thlnnolill it lully open. I! 1M IhInnoIt.,I, aper.ting correctly il should 111<1 to open 8t 63 - 67°C (1'*6 - 15J° F). 6 Refil the thermal'" 8nd iU; hauling by rlvlrtlng the removal

•

1 The hosn should be inspected periodie8lfy and '_""
""*'

OPEN

------ --- ----- - ------.---

compItle1y.

• To diIoonnIet the top and botlom hosn. .... , ICNWdrfve< to lIIcten thl clIon\fM lhen tIidt them along the hoM dNt of the union apigoI. CtmuIy wut '''' '-off inI SPigota,l'OlIting it tlighlly 10 btuI< the Mal. Thl ~ c.n be wuted off with reIIIivt _ when new. or when hot do not. how_an""", to~t 1... sy1I .... when it. 1101 .. IhIrto ill , high riak of porwntI injury through contact wilh IIot

nos£o ' o<'C '«IP,rll"", (I1S°(j _un .

76

Chapter 2

Cooling system

8.4a Remove thermostat housing s<:rews and lift housing clear

B.4b Thermostat Cln then be removed along with O-ring

sequence. Use 8 new O-ring il the original is damagBd and renew the housing gasket 8S 8 mettll' of course. Fill Ihe c:ooling systam 8S described In S&clion 4, then run lilt! engine 10 check Iha1 Ihe thermosts! operates norma lly end Ih8' there are no leaks.

the pump. drain I he coolen\ end transmiSSion oil fully. then remove the right-hand crankcase cover 8S described in Secl ion 8 01 Chapter 1. Note

1 The water pump w ill not normally require attention unitt" there is obvioullaaluoge of coolant into the transmission oil. To gain access to

9.5 G.eaH impella. spindle and oil seal lip before fitting impeller

that il access to Ihe pump COver gasket only is required. there w ill be no need to I1!move the cran kcase right -hend cOvSr. 2 The welsr pump Is located immediately below rhe oil pump. Iha two sharing a common d,lve pinion Olline crank. rosh. Todismam llilhe waler pump it will flrsl be OK8ssary 10 remova ~s driven II"r 800 washer by displacing the circlip w hi<;h secures them to the pump spindle. The loca1ing pin should be removed by pushing It through8OO out of the spindle. Remove the second washer from the spindle. 3 UnS(:'8w the WDler pump cover S(:rews and remove the cover and

9Ab Ensure seal is lilted cOfTflCtly as deS(:ribed in text

9.41: If necessary drih seal into POSition using e .... itably sized socket

9.611 Relil first plain washer and secure it with locating pin

9.Gb Ensure driven gear locates with pin ...

plket. The Impeller and Ij)irldIe may now bedi~ed and removed, • Check the seal 'Ot weer Ot damage and ' - w HnecHNl'{.11 Cln be rernooor«I by genlly ~ oulw".baMd g r _ and po.'Ih the _Into pIIIce. Not. thIIlhe .... ;. ~ WATER SIDE on ..... , __ Indllll5thou1<1loq o..w'l" pUmp impoIIoIr.H.-urv. lhe .... can be ~ gently into pIoq; ........... w-ntd oquaNIy...:l • properly _ttd In lhe t;Ming. 5 o..n lhe impeller ...:Ilpindie. boring ~"k:uilrly canolul to 0InIUI" lhal .ny oorfOl.lon lhal may MYII lormtd lround lhe seal I ... ;. rernooor«I and thltlPindie leh oornp!etely ItTlOOth. H !hit apindle II bedly pnltd in 11115 _ it may be .-..arv 10 ..--... it to avoid rIPid MIl _ The apindIe...:l MIl lip III'IcloM be grUMd prior to instlllllion ...:I care should be exlOtiud cUW'og linong to ....... dwnIge to till seal , __ I R-..b/Ie 0.. pump by ~ lhe . -.. MqUII"OCe. Not. IhIoI 1111 walllr pump _ gaUet should be .....-.d and lhet 'I'....tIII It'IC,fy lhat the driven QIUr releining circr.p No be ..-ed. T\ehlen" ' . .1 _1 10 the IOtqUOl lIII,i"", given in lhe apIIcifatlonilt thltll'" 01 Ihil Chapter. Replenilh lhe coolant (Section 4) and t.."",,1aIIon 011 (f'Iou, ... ","",_I and chIdi; 'Ot .....1 before \.Iking tllllnKhine out on the roed.

m. . . ;.

t WII.,loml*llur." monitored by In llecirlclllyoperated IiI'U(II in lhe inslrumenl pIIn8I contrOlled by. IIIrICIIIr unit wtlich IC ....... into lhe cyIindItr ' - " watllr jKket. A deIocription ...:IlMt procedufe 011'cornpotIIInll will be found in O\Iptllr 1.

, "'I

Pumpc:o .....

3

"'-

4

Dowe/pin 20H

5 GIU.r IS ar.inbolt 7 SHlingw-..

,!l

LDutIl>{JIW>

" '"" /I

:~

='*"

WIShltr 20H

Chapter 3 Fuel system and lubrication For Information relating to the 1997-()() 0T125 R models, Cont..,u GeMrllldelcription _ _ _ _ _ _ __

see Chapter 8

..

AIr filler: gene<1II

11IIl'ICN'' '

f .... tank: .~tJon end reflltirIg f .... ap Mel ' - I pipe: ntn'IOV... .....wwtion.oo <ef\nirIe - -

..::::...::::-= =::::::---

~~=-::::~~

~tlY5t"""~

"" " "" ----- "

Oil ..... ....-111 tnI..rrmn; Oil ...... w"""",, Mnde< unit: llIfTIOYailnd refilling Oil pump: _ _III end ..tin"", Oil pump: cn.e1ung Ind lIdjIaIing Iht strole Oilpump:~

Gearbox lubrication: generlll

" ....... 12-2 101i1

1,.,.,(1811

'.8Iit\OA lmp~

Fuel gr.cle _ _ _ _ _ _ _ __

M".

TZR_' Mikun;

OT rnocIeIllDBt) Milcuoi

DT rnockII3RN, Mikunl

VM26SS

VM26SS

38NOO

...

......,.

,.'" .,"

' MUSS 3MOOO

,.'"',

"..." 0-, "" "22.5

Cwbu"norl

..... ---..~~~~~~~~~~~~~~~~~ . -.......-... -.'

...... ..... T""

'D .....

TIIrotl.. " ...... a.t8wav

-

A1f ",.w!",...... OUII __ S\tf1.. ~t FloIot height .,. ~

,...

Eng;.. .... spMd .. ~

,,,., DO

,. ".

'00

N

."

22.S

"

" 21 mm1O.181 " "20_Seclion7 lJOO

0.821ir11

." "

1oQI rptn

EngI_lubrication _ ~,-:=============

OiIgrtde

OiI ....

Pump c:ode: TZIIcoIou< modeIf; ,_ ___ _ _ _ _ _ _ _ _ • _ _ _ _ _ __

1.2~(O.1Slrnpll'll

V....... 2T oil or --",,*">I good QUIIIirv ... -c:ooIed

....

2·-'.... englne oil

,

;;;;;;;:======== ....... ''''

E..ty P0811onw..d) Lt.... DT OT modot. modeI5l3RNl Mfninuon .trol<e:

rno_ !~..~.~D~T~_~~P~'~N~'~.~'w~.~~~====

E.ty DT modeIf; MaIcimum .frO/I:e

poa, I

-.

T ~smi"1on lubrication A.oil chInge _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Alter'ebuild _ _ .________ ... ______ Reconvnendod 01 _____________ .____ .____ _

H. _ _ _ • • • H H . _

0.15 020mmlO.OO6 020 O.2SmmlO.QQ8 1.85 2.05",",10.073

0.006 .... , 0.010 .... , 0.081 inI

750ccl1.3lmpplnU 800« IUO Imp pim) SAE 1OWllO SE molor oil

onw.,d\

Chapte r 3

Fuel . yl tem and lubric.etion

"

Reedvslve

VaIv.thlc~ ....... ':: ___ ._._ .......... _. __ ... __ ._._.... _ Valve bend limit ... _... _____ ... _._. __ ._._... _ Stoooe< plate height: T2R modeIf; _____ .. __ .__ .. _ _ .__ ._ ... _ DT modeIf;. __ .. ____ ._.. __ .. _ .. __ •.. _ ... __ ToIenonce. _ _ _ _ _ _ .. ___________ _

Torque settingl Component

Oil pump mounting screws. ___ ... _ ......•......•.. __ ...... _...... _. __ ...... _. CIIrborenor warmer ",pe union boIli __ .____ .______ ._

Reed valve SMembly boIlI __ ._._ ... _._ ... _ ... _._. __ ._... _.. _... _ ... _ ... _... _...

,

0.4 mm (0.02 In. 0.5 mm 10.02 in, 8.3 mm 10.327 in, 6.8 mm 10.268 In) :I; 0.4 mm (0.02 in,

'om 0.5

,~.

3.5 8.6

L'

'-'

LO

Reed fattening K.IlWI ___ ._._. __ .. _. _ _ _ _ _ _ _ .__ _ Transmission oil drain plug _______ .__ .. _____ ._._._. _ _ _ Exhaust ff1;lflt mounling nutl ____ .__ ._... __ ._______ _ Exhaust pipe •.,.. moun"ng bolt T2R modeI ________ .. Exhaulrt PIpe .1III.mounting bolt DT modttI. _________ .

0.'

General d..criptlon

leaks. .nd .,. now Ivailablll through IUPPI_ who IdveniH regularly 10 lhe molorcycle P
The fuel ''($trtm r;ompriwtr • pelrol tonk, from wtlic:h petrol is fed by grlllII1y to the fIoal chamber of the Mikuni OIIrboreltor. vilo a thtee posilion petrol top. The OIIrburenor ilof COfW""tion-' concenlric: deiign, lhe floel o;hambe< berng integnol wilh lhe~. PIIn of the ...mu.onor. Cold SI.ning is U$i5led by . M91"IIe ,taning citwit wtlic:h II.fWIin lhe ~ fuef.ric:h mi>r\ure when the 'dlOko' is opetIIled. lIIler DT modell Ire filted wllh I flat o.Iide type OIIrbu.ettor of simiter design. UCflJlt for IOfM minor diffe.enc" in construcllon. Ai. ,,"Irtnng IheOllrbureltor PII_ through an oil-imp.egnaled foam .i. filter. Thill offllCti\frllv removel any airborne dust. which would otherwise enter the ""IIi'" and OIIuse premature w ...... Theai. cktlner .Iso helps IIilencfI induction noise .• r;ommon probIrtm inherenl with tWOo-ltroke engines. The induction I Vl lf:lm filted 10 the mlehines delcribed in Ihill Manual he$ IWO funhe. f.,.turet: lhe YEIS chembe<.

0.'

L5

'-' '.5 '.0

lNting

compOUnds

""" "

are I much more AtisfltClory melhod 01 curing

painting the u~ntr: ..... tching of modern painl r... ishel, rllpec:ially mel811ic:

ones, is. very diffICult lask not 10 be lighlly underUokeo by lhe average by lhe

owner. I. II therefore recommended '''-Ilhe \.I~ be removed

and a reed valve assembly

Engine k.rbric:atron isOllIOred lor by lhe YIIm&ha AUloklbe Iyltem. Oil

"om alllp/lfllla tenk is led by an oil pump 10 a smaH in;acllon "oule in lhe OIIrburenor body. The pump illinked 10 the Ihronle lWislgrip. and Ihil conIroItilhe volume of oil led 10 lhe engine. The eKhatrst ''($11tfIl fined 10 lhe TZR modeIl is • lingle unil comprising lhe OK"""'I pipe Ind hPllflllon chlmbe
NOle: Prllroi is IJlIteme!y f~ IJS{J«JaIIy whet! ;" the fomt of ,,~ T#JJre.n~lOn&topteventlhe"sJtoflinlandraMJlheS.f«y

lim! S«/tOIl of this matI<JlII before SIMJt1fJ worlt.

\ Remove bolh Iid&paroeII and lhe dual$eaL On DT model, it will also be rlllCesliry 10 removflthe ai.~. 2 Check lhal Ille iuelllp is HI 10 lhe OFF posiliorl. then using a suil&ble PIli. o. plietI. rel_lhe wire petrol pipe .staining clip. Slide lhe c~p down lhe petrol pipe until II is cle..- of the petrol \.Op spigot and Clfsfully pull I'" pipe away from lhe I.p. Oro T2R mode!I.lt WI" .'so be necessary 10 disconroecllhe bo" .... lhe. pipe from the rae. of the ivelllnlr.. Sllcken.nd remove li>e Ilngle la"" ...... moundng boll. lhen litt IW.Y and pul 10 one &ida the boll. washe .. and damping rubbe •. Lilt 1M 11fl~ up llihe ra •• and _ I t backwards oft illlf1;lfll mounli"",. liking OIIre not 10 d'm1{18 the palnlwoO: as lhe mountings.re very light when new and have a naslV habit of .elealing lhei. grip 10 thai lhe ' .... k c _

.wav suddenly

3 Inspecllhe lank mounting rubbers for ligns of darna{18 or deterioralion and. ~ neceuary . •_ w them before lhe link iI rafitted_ 4 In the lvenl 11>11 II I. flrlCrIISIfY 10 remove the pelrollink for "'PIli.. lhe following poinll Ihould be noled. Petrol link repai •. whether necMSitlled by accidenl or by palrolleaks. is elas!< for lhe ptofaslional. Welding or bralirog II nol recommended unlesllhe tank II purged of ,II pelrol vapour: whic:h is I diffteull condilion 10 achieve. Resin_based lan.k

2.2a Check that luell&p is H\ to lhe OFF posillon _.

Ro· • .1 F... II....

T2R model,

ChI>ptet' 3

Fig 3.2 F... II.... I

Fuelsvstem and lubriutlon

81

DT modal

F
"left., , '"" 2

4 ,

Spnngw~

6

R.r.-.g~"

B

FfOfI! m(lUnl"'fl grommtIf 2 oN

W.....

Moun,,,,,, NbbttT

'-1

107ri".,..,~

" RIght.'-'d_Kl1OP 12 Sawwendwas/w 60ft 13 I.4fr-MltdMrKl1OP

'4 "-,,.,.

15 a-t.... 16.su.w 20N 17 W4Sher 20ft 20"

18.sa....

19 F
20 Chp 20"

lhen ,...... '0 I ITIOlotqCioo d6eIer or ........ upton lor proIeuioneIlllafIlloo. RfPNIed COIII ....... tiOll 01 lhe fuel lap filt .. ..-.d ClfburettOl by W~II" or!\lSl .1Id pei"1 flak .. llldical.. lhallhe 18Ilk lhould be .....aved for llush''''' wilh elMn fuelllld i"lemai k1lpectlon RUI' probIemI e.n be cu,ed by uli
01 the fuel taro • • '" the ....... t 01 ,leak orOlher problem, Uy to wort out lhe molt Ii • ..., .... oIlhe 'lUll befo
5

...... amoun, or-

taro.

bu"_ s.c...

t'"

Notl: Petrol,. 1Jt1reme/r IIammabM. apeaMJy wlw> In the fonn 01 oapout"_ 7• pt"«4VIIOIWIOPf8VlMllhe rtSko( fnMldrNd the s.fMy finlf ~"'" of IhIs",.,.../»fote .Mf/llf1 wort;

.n

1

n.. fuel tap ill fllliMd by twoc_hIId _ t o the ~

3.1 F.... tapiol.--roed by twoC1OAhud1CflWa

F.... I . y.t.....nd lubriuotlon

Chapl ... J

82

tap.

it wit tot - V to ...,..,... the fuel tank. WId to Ihin 1M lull Into • ~ IhQtAd bt ~ during ___10;)0'\. BeIonI the

~

oonuo..lIUi:UobIetorholdingpeuol bt~alOI9. ~thII twO......,;ng crews MllIih!he 1IIP -.y, ~ QI1I not to o.m.g. the fihtrI whdI prtIfIICt into !he twok..

mo .........

2 ReItMe the . . . _ _ whM:h ret8Ww IhI! tap ODIltroi knob...cl PIA it off tIM 1fJind". ReIIeM the two _ _ whdl hold lhe tap poIition indiclolClr dIIC WId ,1IITIOVtI it. The tap rotor can !hen bt wh~n !rom ;1:1 body, complete with a-ring and 1Pring.1f the lap .... been 1nIIing, the rl'K»lli ...... _ I a I worn or damaged O-ring between lhe 1"1l rotor MIl the body. Till. CM\ be purchased N9M.tety from the tap MMtl'lbiv • • can the oval O-ring betw_ the lap body and the fu.l tank. l)ut l _ 0It>e< "~I 1MIt....

..,.1*.

,,-

3 The toe! tap ~ on OT ~ ..... be ll'M1od • • -.Ied unit. the oNv ~ pert ........... *'II the bel_ the tap body WId the fuel W*. If the tap i t _ be ...-..1

"'Utv ov" ....

........... •

The fuel I...:!

po","

........, -

WId

lap

filt-.1IhouId bt ~ f'II(jUUrty lor In ~ n'\IIinl _ _ 8nd

Pgntol_orNltrlonolion.~

5 8elor. refining the fuel lap. ~ m.t .. the PI!1' ... c:tean. ~ tilt fuel filt_1Ind main WId _ intalc... II Do not _Igh."'...., oIlhe lap component. during re~. Tt... .,.In. ,i_baNd alloy. wtuch wiN IrK'.... eMily ~ oYefMo.! OO;O;U. _ the """It of deltctive . . .

ca",,,,,, ."esMd.

INI<..,

Not., Pwt1oI .....

-.wr ~ ~ ""'*' .. m./onn of

vlJPOUI' T""~ 1OpteVf1nt the rrslta( _and...-l

fit#f ~_ of/Iws ntMtWIl#r:n ~ -*.

I

u. s.tery

Remoo.oe the fuel tank _ deKribed In Sectoon 2

S!Kken the c...-npe wtokh I8ClOre the ~nor \0 the Inlet .tub WId W lil\e< '-e. Thon remove the boll which moun" the filter to the tr.me WId mwooelNre the complete . . 1~1e< MMmbIv out 0I11Ie

w

,_.

...It.8

1"101 normIIy . - y to

ClIbII,IM it

0iK0nnec1 the c.bo.nttOO' _ " ' - holM ..-d the oil deI~ pipe from the cerbuHlltOf body. It wiI be neceISr1 to plug the ends of the ~ to ~t theo/llfld cooIInt ~ 10 hrJe ....... _1OtI of IUItabIe plug ~ • cIIIn _ _ Of bolt of the COfTK1 diImIt. II IdNI !Of thll purpoM. Mop lIP ..., IPiIt 011 Of DOOIInt mrn.dIMeIy. The ~ thin be puIId ..-w.o. 1M ... mDII'Id from the inIM Itub. Plug the inIII .cub IIPI'I.... with • w-.l of dNn r-u1O ~ thelfttryof dirt intothe . . . . .. ~ To ...... Ihe CiIIburlmor body, fully ....-.c:rew the 1tw0lded car· btntlO< the thtoItk....,..-nbIy, It • no! normIIy - V to .....ave thol from the ~" ~ be 11ft _uoen.d 1M ~dNr of the ....... HowIYer, if """",II. - - V PfOC"d3

the throttII v.... from tt.

_

'*' bellft 81uoc:1'111C1end ~ cINr of the . . . . . Howwv.,

if """",II .. -..v ...... \(I

mo_. 2

routing It dHr 01 the ClrburlttOf. Remove thl tlChonlltM' drive oil .... ..-d _""""" It !Of IIgnI 01 wflar Of darNge. renew;ng II If JlICeHPV 7 DiKon...e1 the CfrburIttor -.nil" hoMI and oil dlliYlIfY pipe • dtttcribId In perlQll'aph 3 01 1l1li Section. SIIc1en the ~ wftkh _ _ the ettrburlltor to IN ""1.Iub Ind .... fit... ~ . The c:arbur«. IOf CIIn then be rMlttd " .. of the rubbIr ld8PIcq Ind pert\IfIy .....-.d. To ...... IN certMntlOf body, UI"IICtew!he tlnlded c:.. btntlOf lop" wilhInw!he throttll YIIIYe~. Plug the .... lIubllPl'lunl with. wad of deIf'I r-u to p.eyent theenlty 01 dirt Into tt.

penograpn 5 of m;. Section.

lit., DT ....... PRNl onw ... dI 9 RerncMo thl YEI$ e/'Iamber from the"'t lIub end dIIoonoIct till ca
'*'

'*'

,S

lOP" ....-

Hofdlng

the c.ltfburet10f top,

'*'

00fT>PI1I'H

Ihe tlwoUIl ""um Ipring

'II'i....I it and hold it in ~ I91M .... I the top. !""en the tltronll va/wl

and thtk_ 0IIt the ptn.Mld "eel IIIJring II1II1. ThiI t:OmPOfllflt MrYItI to ~t the CIIbfI from '-"ing detlChld wt-.n In PO$ilion and once oulol Ihe the e.bfI be pushed down 1M IIIid 0IIt of itsloc8!ing ",DOVe. The ~ 1*" now be removed Ind IhouId be pfIIC8d with theClllbtnltOf

'*' '*'

w.-v

Early DT modIIl3DtI1J 6 the~tlOf, it. firet - - v 10 . . tad! the _ TOgllfl-. tnt _ _ _tofrom ill I ..... mountlng Ind 10 diIconnId the ~. ~ RImo;tow the bolt w1W;h ....... the _ InkI .-voir to Ihi "...... ..... ~ it .-.. of the o::awtlu'InOf wtoikl keIIJMnO It upr\ghI; if - V, Tie t h e . . - - 10 the""'" 10 I\IOId llraming the t.ydraIIiI: ....... II"'- ill knurted ring IfId pull the tao:hometer ~ its drfv" on the f ; f r i _ ~ t~1y

"om

1IIcfc", Qernpe whidI MCUfe ettrburettor 10 InIIIt stub Ind .... l iIt. ~ _

1.21 TlR modi!

Chlpter 3

Fuel5V1tlm and lubrica tion

OJ

., ••"-

.-•

•"

•

"

11 II requil'9d the 1/Wonle v.tv. Cln be MPI'aied from the ClbIe II ~ribed In J»f-waph S of Ih~ SectlOlL II not, it CIoII be lett anlChed 10 lhe ClbIe .nd I.pad clell. 01 the engi .....

•

All modals 12 The CI
•·•,.

"

.ft"

v_

NOla: Perrol4ulnm>e!y fI~ ~ when in r". form of T.,.aJ/~lOlISfOpre"",rt"'nskofm..,)(fflMir"'S.f«y

fir$fl soctlOfl of (hIS man<MII belore SIMmp wort.

I Remove the cel'burellor from lhe machine as described in the pre'
2

"'''011'''

If.

·"'"i·t!'!~"I'I' I a.~»:s3~gl~g~1&.2..~ ~

!~!!"';.f:~

f

¥~~!~!i~"~'lllil ~·.l:~§;~!i~slt~]~.~l

il a·~~ ~~ [ll~!; ~:[i

ll! .li,,,~, i'll~m i·>~! i 1I ~hL . H~ .1
.
oj

r<"I'~"'l "'!i

iiiiii~;'i.~'lll~ "i'" .•. ,J,. : ' ·'.f.,''."""1, ~·!I!· ~li'lill"1

.!~.: l!~!.~:tl'~ ',g, '-1""".2.

i- ••• ili_';~'.li

m~~ Hiihl[ih ii~ ~~I~L! ~~~~i!!. ~ ir:ri&'

Ii!

i~'r! - I'li'!iJ~i'

'O!-j[~=if~:'i'i" ~iJr;~~i~ ~ll_~~i 11·'li'~!. ~. oi5 "" 1i..

1.:",·1 ~ l&':'~ II:

-lI' .,,

Hii •• ,! a""' "., ,} " h· I, o'

!!.q.l''!!. 11~!~2.'~!

Hl~·" :~ iO~

~~~~[~~~;i~;~~f~
,. ;·i~" 1.15.·' s'&i'4' .B~,,'Cf~" i i igi' "U· "~§!.'i~I;J! .§ it'lil"=" J'I~I~J ,,~ ~:~£~" Il~ .. i.l:ls

iI"

a::

.llilii:!i=r: ~~.~'t.3

11!'I;lljill"~i~ li~!ii1i..f!l:· a<:l~iI·l';I:

I'~Ijljii pm~!~ ., •. !• ·I"j •.. ~g~I'il! ,~"",.~ Hl .H.

~l:H\ Ii.l

f w

i

:

~ i

f

g"

os

/I 10 Its

ClrIS/INI

~I"*,'--

poMlOn; IhiI wiI _

. . . bIiM 101'

fix""

~I

The POWt< jet " Iwter ~I ... Into lhe IIoet ~. Neither jet ..... to. r - . d but bolh -"ouId to. ......-.d to ....... eur. ,"-,they ... clNn ..-d ,... from obsUucho.... 10

'1

Befor.

m. {M!;u-l1tOf •

~

..-.g U. I - . . d doa-

....mq poocedur-.II should be cINned OUI I~. ptefetably by

IheUMofcompr-..ed ... _AvoId~ •• ~~U"' •• .twaysriU 01 m. I*1Icln of Ion! obstructing !he Intemel" ~ Of Ilw jet orificeI. Check _-'ully the condition of !he carburetl.. body end fIoIot

86

Chapte r 3 Fuel system and lubrication

a particularly adve<se afflICt on lhe running of any two-stroke engine. A week mixture will C{lUse ",pid ovemeating which may event ... lly p .... mote engine sellU<e. Refe<ence to Routine maintenance will show how the condition 01 the spark plug CIIn be used 8S a feliable gukle to carburet\or mixlu<e SI.ength. 4 Whe.e non'5\11nlng Items such as an aftermarket exhaust system or air filler have been fined to a machine. some alterations 10 carburDlion may be required. Arriving alllle correct seuings otten raquifO' lrial end error. a melhod which demands skill borne of previous experience. In many cases the manufacturer ollhe non·standard equlpmenl will be ab!a to ad~i5e OIl correct carburation change5.

1

C.rburetlor. .djuttment

Note; Petrol is e>rlrerne/ot Ilammabie. eSpecially when in lhe form 01 lIaptJw. TtJte till pt"KIJUllOm ro prevenl lhens/< 01 liM Imd rtUId lhe S8lefy firstl sect.icm of this marwlJi before stiNting wort. 5.12 Ensure cutaway on needle jet al igns with peg inC8.bureno. body

1 The first &Iap In CIIrbu<e\lor adjustment ts 10:> ensu.e Ih~t the jet 5iles. needle posilion and 110111 height are correct. which will requi.e the removal and dismantling of Iha carburanor as described in S\l<:tions 4 ~nd

chamber. looking 10. di.toned or damaged mming su n aces Or any other signs of wea •. If sevo,s domege Of wear is round. the carburettor assembly will havelo be renewed. Check the condition of all Q.ri"llS and

gaskets, renewing any thS!8'8 worn a,di.toned. 12 Never use 8 piece 01 wire or sharp metal object to cles. 8 blocked jet. It is only tOO easy 10 enlarge the jet unde. these circumstances and

il1(:'8850 the .alo of petrol consumption. Alw8y5 uN compreS$Gd air to dea, a blockage: II IV'e pump makes an admif8bl8 substitute when a

5.

2 Belo<e any dismantling o. adjustment is underta ken eliminate ali other poss ible CBUSe! of running problems. checking in pDrticular Iha Sp;Jrk plug. air liller and the exhaust system. Checking and c leaning these ilems 8S appropriate will often resolve a myste~ous flal apot or misfire. J If the carbllfl,lllor has b&en fOmoved lor the pllfPOse 01 checking jet sizes. the float heighl.hould be measu.ed atlhe ... me lime. It i.unlikely thaI once this is set up COfr&elly. the.e will be a significant amounl of

COfT1j)fHlled ai. line is not available. 00 not use a~c(t$llive force when reassembling the carburetto< because il is Quite CNtSV to shear 1m. small jets Of some oltha smaller S(:i'8WS.

A

13 Refit the carbur8tll)f to the machine ItS described in the previous Section.

6 C.rbu",tlor: s eUings 1 Some of the earbur8no. settings. such as the 91~a of the needle je1. main jet and n&adle position are predete rmined bV Ihe manufacturer. Under normel circumstances it is unlikely thaI these senings will require modification. even though there is provision made. If a change appears neces.ary. if can of len be traced 10 a developing engine fault. 2 Asa rough guide. lhe ped; tlle.e is a CIII1ain amounl of overlap between the CIIrtK... 8Uor components involved. J Always err on Iha side of a rich mixlure because a weak mixture has

Fig. 3.S FIOIII height mnsu<ement A

Adjusting lang

8

Float needle

X Float height ...... SpecificatIOns

Ct..pter J

Fuel &ystem and lubrication

"

~~ L __

Fig. 3.6 Fuel level measure",.nl variation, unl8$ll lhe floal needle 0< seal lwIve worn. These ohould be checked and renewed as required. Wrth lhe fIoal chamber removad slowly rolDle Ihe CII.bureno< until gravity acling on lhe 11oa15 mollll$lhe fIoal unlil Ihe valva is ju" closed. bul not so far Ih81 lhe neadle's spring·loadad pin is compressed. MeMure Ihe distance between the gasket face and Ihe bonom ollhe flOilI with Dn accurale .uler. The corract Ronlng shoold be as given in the SpDcifications Section. If adjuRlmenl Is reQuired il can be made by bending, by 0 very small amount, tho small lang 10 which Ihe flOilI need read /hi! Safety firstlll«tion of thiJ mamlal before staffing work.

fig. 3.1 Reed valve assembly I

Screw 60ff

6

GasJrer

2 3

Sprong wBShfH" 6 off Srop{NN plate 2 off Re&d petal 2011

7 8

Inlerstub 80lt 401( Wash6r 40ft

c.~

9 10 YEIShoseciip

1 The reed valve assembly i. a precision component. and a& s-uch should not be d~manlled unneo::euarily. The valves are Iocal8d in the inlettract.covered by the inlet stub. 2. Remove the reed valve IISBIImbly ... described '" Dlapter 1. Section

"

J The vaivee can now be washed in dean petroilo lacililllle funtler e~aminalion. Thay IIhouId be handled with gr.... t care, and on no accouot dropped. The IlDi ...... sleeI .eeds shouid be ,_I..:! for signsof cracking or faligue. and if 5_1.. should he renowed. Remem. ber thai any pan 01 the assembly wIlieh breaks 01/ in Hrvice will almosl cer1ainly be drawn inlo the engine, causing elClensive damage. The reeds should resl flush against Iheir seats. although a slighl gap is QUile normal, Check Ihe Inlel stub for signs of cmcking. perishing or Olher deterioration and rGnew if nucessary. II lunhe,dismantling Is n0!C8S$11ry proceed as follows: 4 Working on ona side 91 8 time to 8vold Ihe sccidenlallnterchonge of compOnents. remove tha Ihree cross-head screws ",,",uring the valve stopper aOO reed 10 Iheease. Handle the reed carefully loavold bending. All components shoold be refitted in their original poIInions. Lay the reed carefully to one Bide if it is to he fe-Used. Examine lhe naop.-en!I seating feee wIl;ch. II defective. will necessitate the renewal oIlhe complele alloy case. to wIlich " is heat·bonDpl ..... Check the valve case mating surfaces for w..-ping. .--wing or resurlacing as necesaary. 7 Although the roed, should seal flush against the case a small 9"P Is Quite normal. This ,hould not however e~ceed the specofoed limi~ measured between lhe lip of the reeds and the reed valva case. If the gap is larger lhan thai specified lhe reeds should be '_wed. 8 Refining lhe reed valva assembly to the engine Is a stnlightforwan:l reversal of the removal procedure. Always frt new gastats 10 prevent induC1;on leaks and be CIIrlllul not 10 ovenighten Ihe Inlel Slub bolts;

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Chepter 3 Fuel s ys tem and lubriution

I

Screw 30ff

2

EIrtt._"<:uv,,,

3

s..IIngnng

• c-,._ 5 SHIin(} ritJg

., w_

, W""""" -.",

ee.r-t IIoItJN

" .....

9

Fig.. 3.9 AI. liller OT mod,I, I I An- filt", c.MJnfI

...

12 AIr;"••,

""'" "

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16 Ch«khostJ 17 Screw t.off /8 CMourr1ltOl ~or

"

Chmp

"-I elloo;llY' finilh. The bell are thole which requite the pe
12. Oil unk, .. moval and ..fitting

I The oil ..... k mUlt be efthe< drained of oil prior to removll or llenglh of I)fe-pt.pared pope oI.imil6r Intemel diameter. with one end plUllQed. can be IUbsliMeo:! lor the 'ank to pump' feed pipe. TZRmod,1 2 Tt.. odlank iI "'I.... ted und .. tt..left·hand aidepanel. Togain ec<:eM to the link il will be neceMIKY to remove the _ I enc:! sidepanet. 3 Disconnect lhe Mn
,,.,,.., 2 3

Slud 20" Nul 20ff

...

&hNstsystem

... • W""" ,

6

s-/ingwiUMr

9 Nul 10 WiUMr

OTmod,1 4 To 9ain ec<:eM to It.. oil tank,. remove the th.", screws whicl\ sec ...... the rigl>t.1\and ai. ICOOP to the fuel tank and .emove the Ii. $iCOOp. Disconnect the Mn
Chapter 3 Fuel system and lubrication

90

132 Oil level HnOar unit is push til in 10f' of oj! lank

OT mocIellhown

Temporarily refit the oil tank and mounting boilS whilst the sender unil isremol/ed. OTmDdel 4 Remove Ihe fueltsnkas described in Section 2. S Dlsconnectlhe oillel/el sender unil from the main wiring loom and pUlitha unil out of Iheolltank. All models 6 RefertoChltpler 7 for details of lila senderunil tesl procedure.

Fig 3.11 ,

• 2 3 4 5 6

E~hDU51

system

E'xhltUsr mBinsf!(:/"''' G8Iikel

Stud 20" Nul 20ft 80lf From mounting Imtclret

, "',

or models 12 Silencer lkJlt 20/1

13 14 '5 15

I]

18

, W""'"

IS 20

ID Mounrl"fJrubber

21

,

"

S_

Wttshl1r 20ft Hff/Jl$hield Screw 20ft W ..sher 4 off Hoor shlefd Scr/tW 20" WMher 20" W.uher 20ff

.Jounng $/eevtt

All models 5 The tenk is ,.IIltad by reversing the removal sequence. Note Ihat to p'6Vent oil -'8NIHion on initial stan-up. il will be necessary 10 blfHKI the oil pump belo.. uSB. ReIer 10 Section 16 of this Chapter

13

DIII,val wlllning sandB,unit: removele"" ... IIIIlng

1 The k)w all level warning system, comprises \hll lan~·moumed sender unit. the warning lamp in the insll\lment panel and lhe relevant wiring. 2 Tl>esendo. unit 158 push iii in the lOP of the oil lank. To remove/he sen.der uni\, proceed as follows. T2Jl model Remove the Mat and IoII1·hand &ide~fIEIl aM 1&1&_ 1M oil IBM from lIS mounlings esdescribed in lho previous Secuon. NOle Ihal il is nol necesNry 10 disconnect Ihe oillaed pipe. Unplug tlla oil level sender unit from the mein wiring loom and pull Ihe unil OUI of lila oil tank.

:}

14 1

Oil pump' ,emov.l.nd refitting II is rarely naceassry 10 retnOl/e the oil PLJmp unless specific

attention to i\ is r8<juired.1I Should be noled Ihallhe pump Should be considered a Haled unit pans are n01 al/ailable and Ihus II Is nOI praClicable 10 repal, It. The pump ilself can be remOlled quile easily leal/ing Ihe drilleshah and pinion In piece in Iha right·hand out8r casing. If Ihese lauer components require Buention il will be necessary to drain lila cooling syStem and transmission oil 50 that Ihe righl·hend Ouler casing can be ramolled. Refer 10 Chllpte, 1 forfunher del ails. 2 To gain eccesllO tlla oil pump. remolle the sc,e-wo which secure the pump COlIer 10 lhe right·hand OUler casing. 3 Displace lhe s .... lI.pring Steel clip. which secures tho oil deliver-., pipe to tho pump OUllet, Ihen"se lho pipe off the OUllel slub using I small screwdriver. The "'roe faed pipe I.om lila oil lank is remol!ed in I similar fashion. OOt before ramoving il hal/e some sort of plug handy (such as a dean $Crew of wit able silello push intO the end 01 lhe pipe. This will p.evenllhB oillrpm the lank bEii~g Jo!it. Pull Or"l lh& puMI'l uble inner to rOl818 lho pump pulley. Holding tho pulley in il. lully open position relea&elhe cable and disengage il I.om the pulley '<:ICe_s. On DT models Ihere Is a small spring clip which locales the pump cable 10 Ihe pulloy; this must be remOlled before Ihe cable Can be freed 4 The pump Is secured to rhe casing by lwo SCrewS which Ihrough ;ts mounling flange. O.-.ce lhese halle been removed Iha pump Can be removed. noling Ihat il may prolle neeesSilry 10 lurn tha pump slighlly tofr .... il from il. driv8$hafl. 5 Funha.- diSlT\8ntlmg is not practiCilble. and il will be necessary 10 renew tho pump if il io obviously damaged. Mainlenar>ee must be confined 10 keeping lhe pump clear of air, and con-ectly adjusted. II described in Seclion 16 and Routine maintenance respectively. 6 Refillhe oil pump 10 the crankCilSB COll8r. using galkel., tho oil PllmplcrankellSl! colier joint. Replace af\d tighten Ilia IWO cro!lsllalld mounling screws 10 the specified lorque. TIla remainda.- ollhe rgs. sembty is IICcompliShed by f8\/ersing the dismantling procedure. bUI do not replace lhe pump COIle. al Ihis slage because Ihe oil pump must be

pe."

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Chapter 3

92

Fuel 'va tem and lubrication

Fig. 3.12 011 pump

_..

OiIpump Scn!w 20"

"""', W"""" ,

...

Dnvepm

.,," 9

"'

Csrdip 20ff 10 OrivegHr 1/ NUl 12 Spnng WIIsMr

13 AtijuslmgplalB /4 $/lIm

IJSteqUiMt/

15 Sprrngchp 6

168Jeed_6 /7 SHlingwWltlr 18 19 20 21

A

8/Hd1Cl'eW ....

s-IIngww- .... OJ ftIf#d pipit {from /enld CJ;p

22 S,MltJ.H .. 23 Spnng .... 24 UnIOn ... 25 Spnngefip 26 OJ~pIPt1(1oengme} .a. TZR~

6 OTmodeis

range givtln in the SpeciflQll""" a' tM s t8ft 01 this Chaptlt<. II not. remove the adlll$ler plale Ioc;k,,'9 nul and Spring washer,lIdlusting pIa,e end p,imjl •• Add 01' .... btlao;:t ........ to bring the Muing within the If)ef;lfoed limi~; VIi,.,. can be purdlased from In Vamaha

' ' horiMd

d1. I. described in Roul>ne

mainl81111'1Cf1. and ,efilthecovlf.

'6 011 pump: bleed ing 1 11 is nllCtiS8fy 10 bleed the oil pump ltYety lime the main feed pipe from tile oil link is disturbed. Thi. is because air wi" be trapped in \heoil pipe. no mau" what cafe is Ulken when the pipe I, removed. 2 Check 11\111 the oil IMd pipe is connected COI'I'OClly, Wllh the 'eta'n. 1"11 clip in position. Then .emove the croa·head.crew in lhe OUIet or upper fllCe oIlhe pump body with lhe flbfe wMher beneIIth the heMI . This is file oil bleed ICr8W. 3 a-IIlh.ellhe oil Ulnk is lOPPed up 10 the c:omoct level. lhen piece • con"i".,r below lhoe oil bleed hole 10 c;oIlec;llhe oiIlhat is expelled • • Ihe pUmp is bled. AIbw 1M oil 10 Irick'" OUI of !he bleed hole. checking for air bubble&.. The bubbles IIhouId IIYllntua!ly disappelt I I the 'ir is displ.lced by hesn oil. When delr of ..... refillhe bleed 1U1IW. Do 001 ..piece the lront portion of the c ..... kcase covet" until the pump cable IItting hal been Checked. I I descoibed in Routi"., maimenance. 4 Note alto that il will be neceu.ary to ......... lhat the oil deliYe
16..2 Bleeding lheoil pUmp TZR model shown e"teSI oil wlR make the axhaUit smoke heavily for e while. Indical"", lhal the pump is delivering oil 10 the engi".,.

17 Geerbo. lubrlculon: !Jene ra. The gontbo><. c"'tcll end p
Chapter 4 Ignition system For information re/ating to /he 1997-on DTf25 R models, see Chapter 8 Contents General detcripOOn _ ___ .• _. ___ . _ _ _ _ _ COl ,ystem: _______ ._______ ._ _ . COl 'yltem: checking IhI! wiring _______________ , IgnitOl HT coil: Iocetion &nd 1"ling .____________. _ _ Sourcecoil: lHt;"g _ _ _ _ ._. ___ ... PulNfcoit ,esling ._____ ._____ ,,,_ .. ________ ._ fllUl!d~

_.H ___.______

,

2 3

• 5

•

Gen."tot PulMrcoilreslitaroce _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Source coiI ....tllnCll: TZA modetI bfown 10 yeIow .______ .". _____

.H _ _

TZA modeIs- bllICkhOld toblacll _ _ _ _ _ ._ _ _ _ _ _ gr8Wllwtlllll 10 bIioc;khed._. ____ .H. __ ._____ _

or modeII

Ignition timing__{BlOC! TZA modeIII .________ .• E.,.., DT models (3081'. _____ ... ____________ Later DT models (3RN1 onw..dl .. __ ._ _ _ _ _ _ _ _ __

ignition HT eoil

011) -------__________ _

Mifllmum IIJoI(k Pnmary winding ' ....I.nce. _ _ _ _ _ _ _ _ ._. ___ .. ___ ._ Sec:oodary winding " 'SlStano;e ._ _ _ _ _ _ _ ._. _______ .

S~rk

Ignition ,nd.-.gino UI ,wild!: 'Hting _ _ _ _ _ _ _ _ _ _ COl unit: tasting "_ _ _ ._. _______ ._ .. ___ .___. _ _ _ _ _

,

•

::::::==:_l~ting..:~=:::=::::=:== 1~

HT INd lItId IlIpprnsorc.p: ........ 'nation.__________

Sparlc plug: gener•.. ____ .•. __

'H._H._._._______ 11"

280 420ohm020oCI68 °F)

48 12 ohm 0 20· C 168°F) 520 - 780 ohm 0 20°C (68° F) 192 288ohm0200C(68°F) IS "O l 3SQrpm

19"0 13SO,pm 11 0 0 13SQrpm

Smm!O.24in1 0.7 1.1 ohm 0 20°C 168°F) 5.7 8.5 1( ohm 0 20°C 168°F)

plug

T~:

NOK

Gep-.c.... eIoclrodef;" __ •_____ ,, _ _ _ _ _ _ _ _ _ _

RReES 0< RR9ES RR9ES 0.7 0.8mmIO,028 0.03'1n1 "'0 - 6.0 I(ohm. 20 0 ,68"F)

TZflmodeIs ___ ._. ___ ._ _ _ _ _ _ _ _ _ _ DTmodet.. __ ._. __ ,,_ ... _ . _ _ _ _ _ _ _ _ _ _ __

Suppreuorcap

resis~

____ ._"... __________

The machi.- deIc:ribed in IhiI MIonu.l .,.. eQUiPQOd wilh fully electronIC cepacitOt discharge IgnitKon ICDllsystems. This .... ngemet\1 ~ , mate powerlul .nd KCIJ,ltI ignition ,V'lem If>d cen be consideted meinll<1lr'Ce·'ree. TZRmod" Ened ill inlegrlOl with thIo f'oOIfnIII "'t..... to< windings.. It ;. I IwIHIligII 8rr8ng11ment. hiving low ~ and high ~ ...... n d . The low ~ windingl ~ • high 0IJq)U\ vol"", II low eroone speed&. Ihis voltage dropping off .. thIo engi.,. buoldli up lpeed. ThetoOgh ~ windmg.. on .he 01 ..... hind. produce ~ttle -II'( II low engine ~. but thIo OUlput voltage rites along with """'"' qIMd. The two outputl combined. offselting uch Ofher to g;v., f,l"", conltanl OUlput voltage. thill being thIo sum of the output 01 lid> sel 01 WlOdings. The - . . _ coil NSembIy feeds the CO. unit. , sealed eIectfOni<: IlUemblv which fQffl1l thIo hel<1 of the 1V'lem. This uni. contai.... amongst <>the< lhings. • C8j)ICltOt lind • thyri&IOt. Ot silicon cont...tlet::l

If'

NippOn DeMo W24ESR-U orW27ESR·U W27ESR·U

reo;Iifie< (SCR). The ClPlCho< t. cllerglld with IhI high voltage output f,om thIo _ _ coiIlSS&fY\bfy. The Ihyriltor. or SCR. ill in afflle' In _lfOfIic; Swilch. When ~RIIed .1ec1~11v by the pull« coiL ~ IlIows . he cepec;110< to d~'", thtoogh the pri ......... windinus oIlhe ignilion coil. This in lum induces. high I~ pulse in the secondary wind0\g5. which ill fld 10 the ~ plug. The puI_. or pidup. compriset; • '""" coil mounted outside IN genentlO< rDlOf on , prgjeo;tion from the IIIIOf. A ptlfmIr'Ie<1l megnel embedded in the flywheel 'OIOf is ......-.oed to j)I5I cloH 10 tN pull« coil. As the mlgnCtl _ _ lhe pulse< coil. • wHl Cumtflill generated lind it IlIhiI tNt 0. uMCI to lrigger the thy';JlOt in the COl unit. DTrnodel The DT model ignibon I'{$lem ope.. UII on lhe principlea II 1M TlR model bu. diff_ in Ih" onlyone IOUfCI coil i1fi\led. TM coil ;. not In integ
Mm.

."

.....

If'

Both machOequipped WIth In ignition cont'oI Iystem. incor· pofIled . . . safely 1$111"',. The ignition contfOllV'lem Circuit coosiS11 of 1M ignition contrOl unit. neutr" ,witch end sidesllnd twilch. ".

"

Chapter 4

Ignition system

tholJgh on later models the conuoi unit i5 an inlegral part of the COl unit. The conlloisV$t8m will8tJlomat;c,,11y ""nh tha cunenl from lhe sourea coil if the 1I11OSmission is put into gear w ilh the sideslllnd down. This effeclivaly brllak$ lhe ignition system and kills the engina.

2 CDI.ySlam: flull diagnosis , As no means of adjuslment is available, any failure of the syslem Can only be !raced 10 the failure of a syslem componenl or a simple wiring fault. 01 Ihe 11'10 possibilities, Iha lauer is by fm Iha mOSlllkely. In the event of failure, check the system in a 100il;lll fashion, as described balow. 2 Ramove Ihe spark plUg, giving il a Quick visual check noting any obvious signs 01 ~ooding Dr oiling. ~it Ihe ~ug intO the plug I;IIp and rest it on the cvtinder head so that Iha metal body of tha plug 15 in good contact with Ihe cylinder head melal. The electrode end of the plug should be pOSilioned so that spartingl;lln ba chacked as the IIngine is spun over uaing the kicksl8n. 3 Import.nt nOle ThttenetyY levels in eleclronic $y$lems can be vO[Y high. On no "COUnt shouldlhttignition beswilch«lOn whilsllhe plug or plug CIJp is being held. Shocks from lhe HT circuil CII/! be most unpleaSlJnL S«ondly, il IS VilaJ lhal the plug is soundly earthed wlHm lhe sy$lem is checked for sparking. The COl unil c.n b. ",;"",,.,. d.ma9,d

If lhe HT circulI b6€omes isolaled.

4 Having observed the above precautions, tum Ihe Ignition switch 10 'On' and kick Ihe engi"" over. If the system is in good condllion Bregular, fal blue spark should ba "'videnl al Ihe plug eleclrodes. If the spark appaarslhin or yellowish, or is non·existent, firsl subslitute a brand new plug of the specified make Bnd type and repaDI Ihe last. If Ihis fails 10 work try a new $uppreosor I;IIp. If Ihere is Slill no sport, further inv ... tigalion will be .equired. Before proceeding further, turn the ig"i. tion off and ramove the key as a safely measu.e. S Ign~ion faulls I;IIn be divided into two calegories. namely those where the ignition syslem has failed completely, and those which are due to a partial failure. The likely faullS e.e listed balow, SlDning with the mosl probable SOUr<:\! of failure. Work through lhe list 'V$lemat;c"lIy, referring to lhe subsequent sections for full deteils of the necessary chocks and lest&. Ie) lOO$8, corroded or damaged wiring connections, broken or shoned wiring balween any of Ihe component parts of the Ignition 'Vstem (bl FaUlty Ig"ilion HT coil (c) Faulty.ourcecoil Idl Faulty pulsercoll Ie) Faulty Ig"ilkm swilCh 111 Fauhy ig"ilion control system Igi Faull'! COl ..,,,il

4

Ignition HT coil: loc"ion .nd lesting

I If the ignition coil il suspected 01 having failed it I;IIn be tesled by measuring lhe resist8r1Cf1 of ilS primary and secondary windings. The test can ba perlo.med with Ihe coil in place on the frame, having finn disconnecled the HT lead allhe spart plug and the o",nge lead Ifom Ihe ignitico coil. The ignition HT Coil Is located under lhe fuel tank whe'll it is mounted balween the f",ma tubes. 2 Sel the mete. to the ohms" 1 scale, connecl one 01 the mela. probes 10 the eHnh On ,he coil's centre pole and the other to the low lension terminal. This will give a .esistance reading of Ihe primary windings and $hould ba within the limits given in the Specificalions. 3 Unsc.ew th", suppressor cap from Ihe end 01 Ihe HT lead. Set the meter to the K ohm scale, connect one of the mete. probes to lhe HT lead and the olher 10 earth on the coil's centre pole. Thi$ will measure the secondary winding resistance and should compa.e with the vslue given in lhe Specilicalions.
5 Source coil: lelling I

Trace Ihe genetntoroutput wiring bllCk 10 theconneClor blOCk. Bnd the main wiring harness. Make Iha tesls on Iha gene'Bto. side ollhe conneclor.

disconn~cllhe generBlDr wiring from

3 CDII",,'em:checking tha wi,ing 1 The wiring should becheckad visually, noting eny signs of conosion a.ound tllfl various te.minals Dnd connectDl!l. IIlha faull h... developed in wet condilions. it follows Ihal water mBY have e"'erod any ollhe conneclors Or swilches,l;IIusing a short ci.cuit. A tamporary cure can ba effected by sprevlng the relevanl area with one of the proprietary de.wate.lng aerosols such as W040 o. similar. A mo.e permanenl solution is 10 dismanlie Ihe owilch or connector and cO!ltlhe exposed pans wilh silicone grease to prevent the ingress ofwate •. The exposed ba<:ks of conneclors Can be sealed off using a silicone rubber sealant. 2 light corrD6ion can normally ba cured by scraping or sanding the affected area, ,hoogh in serious cases it may p.ova nece5l;llry 10 renew tllfl switch Or connector affected. Check the wiring for chafing or breakage, particularly whe.e it passes close 10 part of Ihe frBme or its filtings. A. 8 temporary measure damaged insulation can be repaired with PVC lape, OOIIIlfI wire concemed sholJld be renewed at the earliesl opportunity. 3 Using the wiring diagrnm at the 8f1d of the manual, check each wira for breakage or stIort ci.cuits using a multimeter set on Ihe resistance scateore dry b8![ary and bulb wired as shown in Fig. 7.1. In each case, there should becDnlinuity between the endsof each wire.

ot.t Ignition HT Coil location TZR model

Primary Winding

Secondary Winding

Fig. 4.1 Ignition HT coil windings lelt

Ch.pter. Ignition system

9S

5.4 On OT modi!. IIIMrIlor 0:0;11 can be rIneWId IndMduaUv SOUrt:fl coil_owed Fie . • ,2 FIywhHI oene.. tor TZR modell

Rm~

7

Saew - 20ff PubtNooiI Saew - 2 off

SU'lor ~Ie Md r;oIb

8

Sprinf}w~

N~

w....

4

5 6

""".,.,., 2 Set the mete< to the 011"" • 10 .c.1o. " -...... the

AJlmoMl, 4 If 1111 resulll obt.inld dilfe< widely from IhoM I.PIClf'oed 1111 coil mull be rlNWed. ChIck ,i...1, however, that the fault II not dUi 10 . brokllO wi .. or connICtion. Thie will necHe/II,e till I'1Imova! of ,he genetttor rolOt . . dHcribltd in o..pler 1. Section 14. In the use of lhe OT modeIlhe SOOfte coil can be obtalnld". MPe..'e part. e!though on TZR modeIIl' wi" be necHN
betwOIIn the bfown Ind yellow IoII
It.. reading. NUl, with the mete< MI on lhe 011 ..... 100 .c.1o........... the resllt..-.ce betw-, the bh.cklred end bIKk ~ (low ,peed

I

PulHr coW, ,.sUnll

windingsl. The rudi"ll' should COITIPlI" wilh 1'-egi'vlIOln 1M Specjfj· ~~.

DTmodel Sellhe mete< 10 the ohmI • 100 Kale and """HU" the re&iltanCl belWflln thol II'lIHVwhile and bIao;kI.-d iladL Compa.. 1111 reading obl.,nId wilh thai 9IY*'t in thol SpecifocationL 3

"'" W"'"' ROfOl

"""""",on

I..ighI~ooiIs

Soow Soow

,on

$retorp/Me

Saew 201f 10 Pu_coII

9

" Sctew 201f 12 Sprinf}wMlw 201f

1 Trece the generalor outjlOJl wiring bact tO,he conneclor block, end dllconnec:l,he genettlor wiring from lhe mein wiring harnan. Mlh the following ,est on lhe genettlOt Iide of lhe wiring 2 Identify lhe IWO jlOJlser coil wires. whilel.-d and wtoilelgr-, fOt till TZR modell. end whiteiblUllnd whi,ehed for OT modeII. Muwl'1llllI teIis_ betweetllhem using I mu"imeter HI on the ohm. 100 .c.1e. The puller coil mull be rIneWId if !he I'1IedIng obtainld diff . ... greally

-.. i -5',· 1 ! - . ·I··f-···-·······I"·t •• · ••••• -a~-·I·-l·. ! I" .". ,-" •• "~ ;-·-."U .. •• Lo ,-"" " "co!:!" i! ::;~~~ti§ - !!. ~:~i'~~!i5!l~~~-91~:~ ~ Ii,! g ~: ~i'; -H. K~' ~ h~'.lH n~:'~1 f 'i3;~' :~ i". 6.~E~~J~~i"l~:I~~i~.i~. ~~§·~ii:;;. ~. ~ &!~_

l~"

:f'[ ~·H

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~

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l·'t"i'l -!]"I~i ;. . ;"~~l"

H[h~!1 =I~!.o ~f

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aJ

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dH it fHlU UmH H~mUimi 1

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H&F gl:~iI

'j

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co -

l!~~ ;5" _~~. :rJ~;;. ~il;{i'i i!;i[:· ~: 3&-i· 1f. !j_i i~ IJlil! 1~lli~1 !'I;i~llt:l!r

ilJ~ ~!~ [!~!il

~:oil" ~.!l il~~S:! ~i!~. ag'j~5'llSi .~ 8i.~-1. ~-l~! .... ~ :7 lS.:;I •• ,1 __ [~. g. Ii.il!1 , .... I"I,~J~ i. i.!l~l . i. ..

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3

&

1m iH! HUH ~

~

Chapter 5 Frame and forks

""'-

~<*cription

1

Fn;wttforb;....-rI Fronl forb: ......llinglnd~ Fn)nI.lorb: .......t;,;,n....t ..........Mion Fronllorb: retiWflll S--.u ' - t diImIndng SIMMg hNd boMringI: - - - . ..........uon lind refining _ _

:2 3 • 5

"" "

"" "

6 ,

Sl-w.g"-d: ~

" "

8

F_:~tionM1d NnOY.tion

Swinging Irm lind -.-.ion lintage: , _ I I SwinginQ ..... ....:I ~Iinl.: .... mw..lionllnd

,enov.tlon

""

9

10

,1

"" ......

l~mmI5.5~

515.lmml2O.31111 51D.Omml2Q.lin1

238 ec IIL39I1 or) '~mml5.871n1

SA£1f1WlotIIoil

R••WhMi t _pe.n.1on t'ave' __ ,_____________________ _

---

OT ...... 13081' 270mm(101l1n1 178 mm(lBJ1inI 173 mm !18.61n1

OT rnodM I3RH l .~ 270nvnC1O.8in1

503mmI19.8in1 ~mmfla.'1nI

"ccln,"OlI 175 mm(6.891n1

49!iccflUlftOll 1655 mm Il-Slln,

SAE tOWlorltoil

SAEIOWfortoil

100 mm (3.9 in)

260 mm (10.2 111)

35 mm 11.39 in) 15t~I2'3~

93 mrn {l.66in) 245 mm !9.65in) 243 mm 19.51 in! 15k\iCm' (213

1.0 rnmlO.04inI

'.Omm!O.~inI

~unII:

......... r",. ~~~~~~~~~~~~~~~ Spring "... lengIh

171 mmf$.13in1 169 mmIfUSInI

..n

-- .. .... . . .. ..........-- .. .. --. .__r~·~mA~~~~~~~~~~~ . .,. . mA ...-......-

SwW>ging .....

Torque ..

maxmum free play M Ior1t ...ch

rung.

foIllOPboIt~~~~~~~~~~~~~~

Front fait d«npIf rod AIen bolt

Top yoU pinch baIuI F ront yoIcl pinch boIh Bottom

S~'I.m""tllrnut~·

SIeMInu .1.m ....' .. nuI final Mtting" _ _ _ _ _ _ _ _ StNring "lmfl8oQe nutlbolt. _ _ _ ._ _ _ _ _ _ _ _

Clip-on IIandIeber to top yote Allen bolts ___ H' ___ 'H_'H_"_"_H CIIP'O" tIandIIobar pinch boIt. __ H _ _ _ _ _ _ _ _ _ _ __

IiIondlebefcawnp.

_ _ _ _ _ _ _ _ _ __

..""........... ... 2A

2.0 10

,., <0

,.,.'A

NolflllllliUble

"

"" .....•""

H

~.....,

" ' - ....--... unit mounting I'IUh.

SwingIng..", pivot

f _ l brKllI'I bolt. Torque....., to swinging..", bolt

,.• ' .0

"

2.'

0.' '.0

No! applicable

2' '.0

......

10 framIo bolt

R.-,......, 10 _ i n g rod nut SwIngIng..", to _ i n g rod nut

.,.," ...... ,"..

""

"

o n - Mtmg. CIIn only 1M _ I I ' " obtained with the IWvIce tool spacified 1_ SKtion 81 TIghI..,!he . . . .11If nut to

thllII*lfiId ~ IO
"" "

..,"" "

.,.,"" ., ""

..

C","pte.5 Frame end forti. t

WO
Gtntrel6tKript1on

upperdtmplnd puI t.... gIIIl .. downw...n.lor

The T2A model ~ • "DtItIbox" IVP" 1 _ OOtIIuucllld of thInwaI.t .... and l irengd!ened in ctrtaIn ..... T .... OT oonv .... tooNI welded lubular IlIleI kamI F.ont IoUIptI'
modeI.-.

.....

,

RBir IUlPtnlIOtI .. by s"glllly d'ffering ~ of lhe YImIIhIo Monocro.l _penslon_ The rear SUsptl'lllOtl uno! It • De t.rbon type Mrogeo'I p.-HSUrilid coil I prung un,1" and tilt l wong'ng Ifm if of boK-MCloon OOtIIltUCloon

_In-._

t .... .pt dtmpt "'" be ~ - ' WIth e ~ fIM·bIttItd IC_· driYer, -'though"'t _ _ _ ....... t be ta. . not todistort or tract ... t .... QSlong. On OT ~ it lhe tori< legs MI 10 be dilmlnOtd II II prel... ~ 10 slICk", lheir lop bolts whkl they ... held in the yok_

3

Front Ion..: dllfntnUlng .MI ....... mbly

1 Always dllmlntle the lort ItgI separalety 10 evoid Inle<e/langong PIN and IhuI caue.ng an ecceItralltd fltl of wear Siore all oomponer11S on otpIfal" durIy fl'IIfktd. oontIinerL

,, ,• , 6 6

9

,

o

""CIImc:I .......

2 Ffonl Iorio. femow"t , Support IhI ~ MCUfI/y on 1 strong wooden boo: pIaoId ............ Ih IhI engo-1JII'bOK .....1.. 10 I"" IhI f.-ont """'" II cIeIr of the gn;IO.Ifld. On T?R modeII' ........... reqo.elhe ~ of t .... lower

IIOfing tond ",,,-, .Yllt..... 2 RImoYI Ihe IfOOI whMI tond bralI CIioper,. dllcribltd In o..pW 6 Rernove tht brake hoM dtmp or IIoIde< llId lie I.... CIIiper to t .... lrame. to ItVOId ,"I''''ng lhe hydflUlic hoM_ PlICI e wooden wedge belW"" the ~, J*II to p
--

"'1OIW>g

"'*'"

• SI.c~ .... "" lOP and DOllom yolo. p;ncn DOlts "'" . . . . - IhlIorI
2 thol IIIf'IChaI MCUfI/y in e wice tqUIppId wttI'I 10ft jaws. being c:..efuI not 10 _oghten or _ I h e 1U'f_ of IhIItIfIChion. 3 R _ l h e rut.t. plug from IhIlop of IhI .IIf'IChaIIO ........ Ihe circ:5p and lOP plug o.p.-... thollop plug wtlh .....tIbIy IiHd and . _ lhol ardip. Go-ItduIIy ....... p.-1IUUrI on lhol top plug to aIcJoN it to be slowly lorced out of Ihi .tenchion by IhIlor!< spring. 4 Wothd,ew Ihltori< spring. RltfI'IOYIlhi lort kom IhI wice and invert It ewer 1 d •• ", l..-y_Pump IhI.tlnchlon vigorously untillhol lor!< oil hII dra,oed. R~ lhe dull l1li .nd uslng I lhin-bIttItd screwdriver .emove lhe oil INI ,etl,,,ing clrcl;p. taloing C&fl flOt to dImIoge the surflCIoI the ltenchlon. 5 Or>ce the oil 1\11 d.elned, _k .... I.... AlIen-hNded bolt which ~ up thtough lhe bottom 01 the lower leg and into lhe damper JOd. I!;' qujlelikely that I.... dIrnper rod wIIlend 10 rot.Ileln IhlIowI< leg and u.u.1mpIIde the f _ I I oIlh1 bolt. If tI'OI problem ...... dtmp the -.sembIy In. wice I*ng loft IIWII0hoid IhlIower leg by IhI c.eIiper tnOUflllllg lugs. Obuon 1 ~h of wooOIn ctow.I Ibout I IndI In diImet .. 1nd form 1 \.IIpIf on "'" end. S P_ IhI OOWII dowrIlhI llIfIChion Ind preult hlfd togW
--

2.31TZA'2!i toptnTOlfort.....-.ovllf.-ont

2.4b _.. and bottom yoke. 10 reIeIIe fort IegI

OT model thowrI

'*

_c.nl""""

--

2.3b ___ end dip-oo I'IIordebIrI ......, fitlt be

fig. 5.1 front

,,-

'oR,

---

TZR ..........

15 uh·hNtdJow.,., " AlMboIt

,,.........

o ...,-rod Mid ~ $pNIfI

17~""MhM

1110...._ 19 .s....;.,g tIIIMIw 2'0 R.ghl-hMtd

...

, ""'"

Iot/l,.,

'0 WMhM " " Oust ... 12 WMhM" /3 Oil ...

WMhM 20H

23 ~tIIIMIw

Of IIimiIM eM> IMo UMd to obtM> IlUtfICiolnI ....... 8fId pr---. Once the ..a.oning bolt ' - t.wI ~ wfthdraw Ihe ~-..aIy rrom Ihe lower leg. 7 The loR oil .... eM> be levered out ot.-llion ...""'" large filii· bIIded ICreWdrIY .... whIIlt tlkiJ1fl CMfI not to .......... IIIe lUrfacl 01 the loR leg. The guide bush eM> &110 be rernoyed in • IimIIk W'Y. &gIin I~ lII..t CMfI. FiNltv.llp lhe
..

AIt... c:hecting IhI Ion componenl. IOf _ Of dIrnIgI .. deICntI&d in the .... >tt MCtion...-nbIy eM! COI"I"I/"nII"O E _ Ilvt .. 00",.,0'*11"1 . . dMn 8fId thM \tilly . . 1iI111d 10 the fort II"Om wtKh they _ _ '1IfI'OWId. Alw8y"l fit. new oil .... The bush ~ eM> bot ~ only if ill perlKt oondition II'though it ............ odIId thM it bot .........c:I • • prllCallioNry - . 9 "" thI t.oo...d ..,Mg _ thI dImper rod 8fId Mp it In IhI .\Inl;hIon. p_ .1&ngIh 01 dowel d&ICribIId IboY&J up through thI.\IIIdIIon to hold !hi ~ rod in ~, thin lit !hi cIemper rod Oil the.1MlChIon 8fId support It ~caIy whh Ihe dlrnper rod 8

c-

_ I.

'oR,

~

13 OiISHI

"n ""'"

Fig. $.2 Front

T""",

lmo.-.

14 W. v . 15 TopbuU! 16 LlIhllM!dlowtw~ 17 A ..... bolt 18

s-IwIII""""

190.-_' 20 ~tIIIMIw·

,,-

21 RI(Iht./wttlIot/lIef 22 Sp.rtdtdwnp 23 NtA

40H

'N« fifr«J to 3RNN9 """""" " NoflittedlO lRN9/I"IIIdM

~ . SiItIIhe lower leg _ the .!IIdMon ....,bIv and . . thI d&mper rod bolt uWIu • new II8Iing w ...... InI&r III hAd. \.III Loctill "" lhe bolt Ih ...... 8fId light.... to thI.".afIed lorque MII"'II 10 Oi' Ihlguide bu$h.nd'-- ;I down_lhe I itnehion. To fit .... bush in ;1. _ _ it will IMo - - V to devi"", .., ..1..... live to IN iubul&rdrfft loo! uaIId by Y.meN deIIen. The _ I ....Ihoc! it 10 ...... length 01 t u bing IIigohtlv bIpf in dillmel... tlwlthe 'lInChion. IIrgI plain"". . . . ~t the bush 8fId tIW1 tIop it I"Iom4o """'" lhe MIt ... forme4 ~hIrnrne< T. . e... not 101Cf1l<;h theltenchion dt.lrI-t thOl operatiot\: it .. bMt to "*'- .... Nllhe .1MlChIOn .. poAhIId Ur irNvwdIlO TIIIIany aoetdtnlll tooring .. oonfined 10 the _ ......

""'*.

-

11 Once lhe guide bush .. _led, the new oil .... etn till fin.4 lubric&t& thI .... 1ipI. IhIn IIidoo it down ...... the ItInChion.. T. . . . . taO! to ciItnIgI the .... Iipot dunng fitt.ne. The ... IhoukI be I'IIPII' Qll'"ltIv 8fId IQUINfy Into IhllOp of thllower leg. UIing • luIlouIM drill o-It tNtthlo .... _Mfl*1IID thelower leg -.d TIIII it _ U\' then fit Ihe .. \lining clrd;p -.d IlidlIhe dutl l6lll inlO "..,...

CMpter 5 frame.nd fork,

....

-

lAb PriM out oil .... ret8ining circIip UIing I

m.

12 Add IN spKIfoed gr-.M and IITIOI.IflI of fort oil 10 lort and aIowIy pump lIMo fort up and down 10 dislribull theoll. Clw:k!he oil II WI lIMo c:orNCI 1IIHI below lIMo lOP of the IIInCIW)n, wilh lIMo fort fuIy CO!TIj)fIllHd and held venally _ ROllun, fNinlenancl. 13 Cilmp lIMo IIl1"1C:hion lIICurlly in , VI(I Ind retil lIMo fort '-Prin\I. ma~ lng ..... tlMo III/hU'" ~ _ Uppetrn(»I. F~ • new O-ring 10 lIMo lOP plug II"Id InIlf1 II In lIMo IIl1"1Chion. Dept_ lIMo plug Ind fR lIMo cin:lip. Fi ....11y Nflt lIMo eap

,,-

,. RernovtIlIMo fill ... bv 1IIKl-.g IhllOP Ind bollom dImpr; Ind lliding It off lIMo IIMIChion.

..•

t 5 CIImp lIMo lWochion in • Yice equopped with .m __ being c:...-efuI not lOoven;ghlM or _ tf"ll1UI1_ of l"stInChion.l.JnIcrww tf"II top bolt from IhI .~ whiIIl tIk.ng care not to IIIow It 10 be ul*led forcibly by IPMII preuuta. _ IN '-' Il"w.-ciI of IhI bolt _ \II"IIICIeWeCI. The IPK*.1jlring _ Ind fort IPfIng ean.-- be wlthdrawn from lIMo lIanc:1"1C1n. 16 Invert lhe lort leg oY8f I aunab/II COlli _lind Yl(jOrOUIIy pump lIMo leg 10 remove _ rnuc:h oil _ pouibIe

" Once lIMo oil 11M Mined. IIIKlIII lIMo I\I1M\·hMded bolt which PIIIft up Ihtough lIMo boIIom of lhliower IIg II"Id Inlo lhe damptlf tOO. II II quill likely IhelllMo dImper rod w~llend 10 roIlI.ln IhI low.. IIg and lhullmpede lIMo removal of lhe bolt. If Ihis jl
-~ 19 To""",,"tf"11lt11"1Chionfromthelowerlegllwilbe.-...v 10 ~

IhllOP buIh lind the oil ..... The lower buIh .r.ouId not pIA Ihrough !he lOP bush. ,nd I"" ean be UIId 10 gOOd ,1fIo;t.. I'Inh lhe

3.7. lIM.1erve ftat·bIIOId ~ 10 ItYIr out 011 .... _

llInChoon gemly Inwlrdl until it II.,.,. IgIiMI tf"II damper rod _ . T .... CIAO ncn 10 do I'" forcibly or lIMo _ may be ctam.ged. Now puI lhe ltanchion Ioh«pIy OUI~ unlil lhe lower buIh llrik" tf"II lOP buI.h. Repull'" operIloon until IN top buill 1I"Id ....... lipped out of lhe lower leg. With lhe ltanchion rImOYed lhe 00.1 ..... wllhet. 011 MIl. wISher end lOP buIh ean be ..id off III upper end 20 Ah ... checking lhe fort componenl. 10< _ or dImI9t " delc:ribld In lhe .....1 IIICIIOI"I,. .1MIIMbIy can commenc:.. E _ lhel II cotr"IPOI"III"IU ... cIun end lhet 1"-'/_ filled to lhe fort from which Ih I y - . _ed.AJw~fII._oiI"", The bwheIean befWlld orr/:of If in per/ed condition lllhough It lI.ecommended thlll"-'/lOO_ .-eel • • ~t-v ~ Thelowlr buIh 11.110 IIIow f1ttingover the Ind of 1"1tII1oChIon. 00 not _ the _1IIY_1hIn lllIAM1"' l o _ 1I 1n10~ 21 Fit thl Nbound lPMIIover the dImpw rod Inddtop it inlO pIIQ in tf"IIstano:hion. P_.1II"IgItI of dowel up throug/Ilhe I~ 10 hold I" dImpef rod in pIIa. t .... f1t lhe dImpw rod - . Oil the ItInCI>Ion Ind buIh. II1d IUPPM It ver11c11y wrth the dImpef rod uPI*TT'OI\.. Slide IhilowIr leg _ lhe l!lnChion .......bIy Ind refit the damper rod boll ...sing. _ SHIIng wan... unde< ill heed.1JaIng 1.oo;tJt, on lhe boIIlhrudlll1d light ... 10 lhe IoPIdfied tOfQUl lIt'\ing. 22 Oil I'" lOP IJw.h Ind IIide It do:Mrn 0\1. . lhe l!lnChoon. To fill'" buill In iu . - II be nocNIIHY 10 deYi.. In .11......1.... 10 I'" luIIt.Q
wi.

.23 Once

thltop buIh II _11d.1hI_ oil .... ean bllinld. F" !hi

pIaoin WIIhIr with IhI cNmllfed ~ fICing upwa
end ~ifdip.

3.9<1 Apply thread-locking compound 10

dIIm~ rod Allen bolt and ti(lhten to &peCified torQUe RIlling

" ..~,,~:::,~~::;;;;:;;;;;;;;;;;;;;;;;,

II

3.20 Bollom bush I. 'PIil to< "IV remov.1

3.22 Oil 1011 bus h llberallv before sliding into

,","

3.25& Refit fort spnn.g and spring Mal ._

24 Add 1he _ i fled "'~ and amatln( oIlort oil 10 the fort .nd slowly pump the fort up end down todistributelhe oil. Chect the oil is al the 00.....0;:1 level top of the .lanchion, with the Ion: fully comp<essed and held venQlIy " " Routine mainletl8f'lC
below''''

AII~' .

26 When 'eastemb\y ;'complete refjtthe lor1Ilega into tile for1( yokes as described in Section 5.

3.25b ._ followed by

~

II F,onllork e: eomln.tiof! and ,.novatlon 1 II the Iorir., lIIIye been damaged In an lOCCident. it is essential \0 m.peo;l both fort VOIce.. the Il&I1Chioniand the Iowa. legs. for dillOfloon and halrtine crackl. OisIOfted compone
I '03 CIIUSed by dirt trapped below I ~ 0< worn dust . . . and Qln t. ....oided by ensuring th., it is .-wed whenever ,heoil HfII is _wed. If there lias been Impact damage. cl\ecll: Ilia! lhe ItanchlOnl I.e llraiglhl by roU;ng them on .lIat lUl'fece. A blmltaMlllon must be ,enewed; do

not .,tempt to ",aoghten it. The oil seals lhould be .eoewed wI1&nev8t they Ire dl$lurbed ... should all IHIing O-ri"", and seahng WI"*". Cheek car.fully the condItlOO of Nell dampeo- rod Pilton ring and renew it if IlI&Ia is anV doubt .bout ilS cond,uon, Wher. lined. eheck 1M dUll ."dueler and fork galt .... lor JigAl of wear or darna(18 and ,anew !hem if I'IIICfISUfy. S MulO'. the 19<'''11 free lengthl; 1I.,,1ler hal Milled 10 leu than the 4

._wed.

soeo;jroed length both epn"QI R'IU$\ be 6 Tho
"". 5

'0< reassem-

Front IGrtoI: ,.fining

6

StH,1nfj held: dl,mlntJlng

1 BelO<1t dismantling the 11-"'11 heed. it is ldYiubie to remove lhe lue1tlnk to prevent d1m1(18 to ill paintwo.l<. 2 Remove the front 10fIt, II described in Section 2 oIlhi1 chapter. TZJlmodel 3 " I fairing is lilled this must lirst be ,1f'r'IOYtIOd .. deacribed IIle, in this Chapter. Remove the headllmp unil from itl Ihell bv releasing lhe tWO ,etaining 1oC'........ unplug the headlamp end parking lamp wiring oonnec:tO<1lnd tift lhe unit clea<. 4 OiloConnec1 IU lhe electricllleldllrom in&ide the headl8mp aheII and remove the Ihell from itl mounting brKket .. Release the knurled ri"{lll ret.ining the Ij)IIdomeler and tachometer cable. to the underaide of the i....trumant panellnd puU the ClbIeIlrH. 5 Removl it, retaining bolt Ind dilc:onnec1 ill wiring to removl the hom. Remove the front bf.ke hole clamp lrom the heldfamp lIay. then ...... the tWO headllmp Illy mounting boIU and manoeuvre the ltay clea' ollhe yok ... 6 Removl the IU,ering lIem lOP bolt. The tOP yoke and I.... trument

Relining the lorq iI accomplished by .ev..;ng the removal . . fo
ql,lltflO;4l. Slide lhe

TZRmodel 2 Refit the t..n<:IIeber CMI.ngs. and '.gillen the C8ltong 10 top yoke Allen boilS 10 the lI)Kiflod torque letting. I'o6ition the lIancllioollO that t hey protrude 10 mm (04 in) &bowl the top 0/ the I>Indleba. castir>gs and '"",'a" the llandlebet pinch boIli to the apecifoed lOfQU8 WIling. J rtghten the tOP and bottom vok. pinch boIli 10 their specified 100que HlUrIgS. A..tillhe mvdgw,l;I. InmOCl~

4 POIilion each Ilanchion 110 lhal ill (01) edge ;. flush wilh lhe (01) surface of lhe 101) yoke. and !J9hlen the bouom yoke ponch bolts 10 lhe specified to
All model' 6 Refit the front wheel Ind bflke c.h~ .. deacnbed in Chapter 6. Refl! the brlke hole clamp 0< holder and move lhe rnfChine 011 it, support. Thorougl\lv chee. the operatIOn of the front fOflt, Ind brake before "I"ng the R"IlIChine 0IrI on the road

,~

...

Fig. 5.3 SIH,;ng held

,~.,...

AlJenbolt ZoH

4

s-.ng adiutr. nul

S

Du$lctwer

13 HHdi¥npst"r 14 t..ff·hM>dhMdlMnp

6 TOP~ 1 Top bHring!HI 19 oH 8 Top bHnng cup 9 Lower bHnttg cup 5.2 TZR model 'tanchionl1hould protrude 10 mm above hendleblr casti"{lll

10 LowerfNNlmlgl»ll

TZJl modtol,

If w....erbNring(;O(lfl 12 Lower~~$t"'"

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moun15 lhe re"'y .rm 10 lho f'&me and remova Iha 'NY ...... from I""

f.ame.

1 t Swinging .,m and IUllfMn.1on linkagl' . . .mlnnlon and renovMIon 1 Thoroughly c1Hn III componlfltl, removing III traces of dirt. conoaion Ind grease. 2 Ins.p6C1a1 componertts cloHly. looking tor 00,,;0.,. Jig .... o f _ such .. haa\oy scoriog, or for ~ such .. cnock, or distortion due to accidental impeoct. Any obviously damaged or worn component must be If tho painled finllh hal dateriorlled it II worth likIng the opportunily to 'epaint tho ,lfeeled ar. . ensuring that the ,""_ is correctly ptePl'red betorar..nd. 3 Check the pi'lOl ahal1 tor wear. If the Ihltnk of the ahaft ~ seen 10 be tlepped or badly scored. it ........1 be .enewed. Remove all I'acet 01 COI'f'OI,IOfl WId he.daned glNIII f.om lhe .... 11 before checking il ftr llno!ghl_ by roilIng it on e fill ",rl_. such ... theet of ~Ie gLou. ~ 1111 not perfeelly "'light ~ mUSI be .enewed. Check allO thIIl illlllreldJ and those of the rec.inlng nut ..a in good condition 4 LIVer out tho g t _ seaII. using • f"'I·b1.ded screwd ........ lAd e~amine lhem for Jig .... of _ or damage and renew ~ n-v Worn 110 __ or bellri'9 In eithe< the swinging arm or lho vll'ioul linkage pivolS un bedrifled out of lho .. borel. bul nota thlrl .elnOllaiwili deslroy them; new bulhetr ,hould be obllined before work commencos. The new br.*- thould be preIMd or oown InlO thel. txw.. ",the< lhan driven into p/a<;e. In tho .t>sence of a pretI, a tui\.lbltr d",wbolt • .,engemenl CIIn be made up ., clelCribed below. 5 It WIll be neceAIfY 10 obliln ,long bolt or a length ollhfNded rod lrom alor;al engi~ worh or ....... other wppjier. The bolt or rod ,hould be about 1 inc;h Ionger thltn the combined Ieng1h of the ~ tube and one bush. Also required are IUII.bItr nuU and IWO ...."" lAd robuSt WISIIen.. In tho CIH of threaded rod. fit one nut to one end of It. rod and if fflQUi,ed. l uka it in place lor conv"'iIInc
._wed.

Flo. 5.' Swin\ll~ Irm Ind "Ir ItIlIIMn.1on unit T2R model. I'Notwft GrHuulll 20"

...-.

" .,.

131nnt1f'~

BHring - 20" Swmging ...... a..;nbuffel'

15 8U11>

w_

" "'" .,.

, "'"

10 SpringwMht/r 11 WI&hH

14 GrNws.l 20" 20"

16W~

" """

20 WH/ItIr

" "'"

be r&mOYtId from lhe ,,,,,.,..If lhe pivol shaft .... IllICit firmly in !Nee •e ' - it .. deso;ribod ebov, for lho TZR model. 6 Remove tho boll wlMch _ the IWO connecting ...... 10 tho .eLly arm and 'erTlO\le both ........ Then .amove the pivot boll which

man,

DT mo6llll only 8 On DT modell it will be 1"IICI6Ia'V 10 checlc the l winglng a"" lids clelrance before tellHmbly. Remove the itrrrer ......" from It. .wlngIng arm Iugt by genlly tapping lhem out. Assuming thlt It. 11ee........ OIherw11e undamaged. 1I"IfI.IU. a lhai< length. In bolh caw Ihillhould bewil hin 'hoQI"I(I8of66.•5 66.75 mm (2.616 2.628o.t~ not. lhe ......" muSI be.-wed along with IhIIi< bushel. Measure the width of lhe _engine mounting boll. which lhe lwinglng .rm pivot lhaft PIISSI$ Ihrough. and adcIlltO lhe length 01 both Inne< .......... 9 Check the thick...,.. of lhe pIIIln wllhe
Chapter 5 F.eme end '0"" Fig. S 1 Swlnol"fl ....... ~tIon 1lnk-oe

...eI ....it · OT moct.l.

...

•

"

101

I

S w;"gmg.""

2

PWotlhllff

3 4

Thrtm~ -

6

"""'-IMII 20ff

20H

Shim ~~ 5 wuh¥ 20ff

7 I",...wv. - 2 off 8 s..nng 20H 9 Bu$It - 20ff 10 ~ruI 20N 11 GIHse nipple 12 W.uher " ChaingJNde MA 14 15 BoIf 20N 16 Chainbufter 11 BoIf - 20N 18 W~JIw 20N

,,-

20 BoIf - 20N 21 Scnrw 20N 2 off 23 RMay.""

22 W4S/Nrr

... "' ...

24~.~-

"

26 """",,,", - 20N 27 iJHnrI{I 20ff

28 1Mtw.sloMve

" W"'"' 31 c.--.."'Pf)Je

20ff

32 PMJrbolr 20ff 33 1Mtw#tltlw 20N

:u

Gru.6MI 40N

35 Bu$It "off 36 37 38 39

R/fIhr-"-'>d ronn«flf>g"'" WashoJr 201f Nut 201f 14h-lHlnd conntICting.""

... ." ...

4(1 Su!t{MMiorl

"42

unit

HHdedinHfl

20N

"., MA W"'"' .."

47 W4S/Nrr

' " NO

-Nollitrfld 10 3RNf}.on

~

11.2 &.mille ell componelI1t fOt Iigns of _rOtdllm1{j8

11 A

Sut,-.nd t>.i'9 c.-. be 1><....-.:1 out

of ooaition if retIeYtI,l is required

',.8 M-..ring width

of the ' N ' erogine boa

Chapter 5 Frame .nd forlll

I ..

Fig. 5.1 h brical&d d<~ 1001 lor removing or . itfiftln, I winglng •• m snd , • • , . u ~.1on bu. h..

.._ed.

In). if not they mu.1 be Meio..... U.. piIIOI width 01 the swingong ...... and .add it 10 the thickness of both w~ SubI'1ICI this figure (two pI$n w.~ SwingIng arm pivot) from the one OOt';ned ...tie< (two in...,.. sleeves .. engine bon) to obtain the Iw,nglng arm

side cleafance. The aide cle¥ance thould be bel"""" 0.4 0.7 mm ({l.OI6 0.028 in). If no!. Ih~!;IIn be ed;usted by lill'ng thims between the ,hwlt ca~ and plain wasne... JI required. ,hl",- <;lin be P\lrchased from an authorized Vam&ha deal..... When lilting the thims. they IIhouId be poailiooed evenly on Meh aide of the pivot. II In.. is In odd number of ahimI. put 1M .J<1n1 one on the rigln·hand aide of IhII swinging arm.

, 2 S winging . ,m ,nil ... ~. Ion linkage: •.tilting

, Tile swingIng a,m is r.fined by rttY8<$ing the remov.1 1OQI.l8fICe. M&k. sure an bH.;ng., buJ'- and ........ refilled in their COI'fllC\ poaitiom., " 'lIning 10 lhe ac:compa.nV"'9 iII... t"'tionlland photognlPhs tOf guidancgllml.. 2 Relitthe ,Ny arm and connecting f'Od. (OT modeIII onlyl. 1",..11 the 1""""9i"ll arm In thl f"me end relit the pivo! shI!\. followed by the walhef and nut. Tl(lhilln the nullO the o.pecifoed torque _ling and check that the swinging ami moves up and down freely and does fIOl have en ItlCcessive amount of IIide play. 3 Reconnect the fUr s.uspenlion unil and refit the wMel. " ferring to the "levant sections of Chapters 5 and 6 lor lunhM informallon.

12.1b G _ inside 01thnnt ~ befor, ,.f1ning them to the lwingir>g arm

Chapter 5

'09

Fr.me .nd forb

I

n"hllm all bolt, 10 ,'''''' lpec;,lied IOfq.,. MIn . . On OT model.. Ubric:ate the lwing;ng and relav a"", by pumping greasa intO the greUII nipplal ptOYidad. 4 ChIck thin the , ........ W&Mion &mOO!hly bafore taking the machina OIl! on the 1OId.

mov"

,

Remove the duelseat and boIh IiOepenel&.

TlAmod.'

Should ~ become _ r y 10 dispoM of ,he cylinder do not juI, tl\row it away. It if lirlt necessary to release lhe 11M prnsUrl! end the manufect"' .... recommend thaI the loIIowing procedu •• II followed, 3 Rei ... 10 the accompanving fi(lu.e and martc 1 poinl 15 20 mm lbo\'e the boItom of the cyIIndet. Place the unit securely In • 'lice. eecaping 11M .-.dIor .... t.&I Wearing proper eye protection particln. drill. 2 3 mm hole through,he pre'o'lously martced point on the C'(IInde<. 4 Check au the buahM Ind pIIIol boll. IOf damage and corroP:In end ..-11 necessary. If 'enewalla 'equ',ad. the busheI.hould be pressed out of poIIlion 118 described In Seclion 1 I. Oil and dull ...... fT1U$1 also be e~.mined lor ~mege Of deteriorlotion; . . - if '-eMIlY. 2

ega'''''

2 Remova'he rear wMII... OelCribed in Section 4 of Chapter 6. Note ,n.t It if neeenery to remove ,he Ieft·1\end mounting bracket _ c ..... inwua'O '0 98'" ....... '0 ,he _ , IUI_iorI u"';l "'-"'I;ng bolt. Firl' ,emove ,he IjIUrchange lev... pivo' boll from the lootres, bracket. then .emove both bftcket mounung bolls and HIt I, deat 01 ,he f'lme. Remove the IWO chaiO(/UlJd ret.ining IC'_ end reonove lhe

foo,_,

lPJIi,d.

3 Stacken end remove ,he low.. ausponaion unl' moun"ng boll. followed bv the upper one. The ..... penoion unl, can now be removed ff(lm the f.......

DTmod.. 4 Uft the wheel deer 01 the ground bv pt"clng ..... 't.bho Iloppor\ under ,he engine/gearbox unit. Remove ,he tee' wMII .. deacribad In Chopl.,. 6. Remove I..... ...,10 .. detcribed In O>.p,er 3. S Remove,he boll which socures the IWO connecting ."'" to the undaf'lide 01 the Iwing;ng arm and rot"a the '''''' claar 01 the lower IUIf)InUon unit mounting bolt. 6 Slick.., end.emovtI the 1ow...... 'I)tIMion unit mounting boll whilsl holding the l winging arm, "" liIat il does not drop downwards onc:a the boll is removed. Then remove the upper IUSpe... ion unit mountIng boll. 1 The .... r wspension Unil can now be ,emoved by lift'ng lhe swinging arm and lowering lhe unit OUI Ihf0U9h lhol space between the swir>ging arm and relay Irm.

'Ga'

I.

, The rwr .uspansion unit II .efiued by ........."'9 lhe removal IIquance. Apply • li\hium·blSed grease 10 all oil ....... buIheI end to the Inside aurf_ 01 .. washe
let,,,,,,,

R.., ....... n.1on unit: ••• mln.tlon and .. novation

1 wm,ne the ~ ~Ion unit to. sig ... 01 oil leakage or damage. The un~ is 01 ....Ied com'tuCtion and cannot be repaired; if faulty ,he unit mUlt be renewed ,

Fig. 5.9 PoIhion 01 drilling on ......... pan.ion unit

OJmen&ionK

151020mm

" .4 Examine .... spenaion uno! bus.... lor WUr or corroaion ~.....,

. - if

i';·I~·!!~!·i··il· ~ !l~§'l"·i'~ -· _•• 11,."- ~- o o' " "~ l ,_,"';!a<;I;I~.!· "'- '" ~·-··'.l· 1~ 3 o ~ ~o ~'-il ~if~lirii".&l- ~ 0 i-

., ~"~j! l!..,

l~

"

, •

i.·j·· il· ·~j'~ .~. ­ "'!":"!:? " l -'~&~l:i-I .:-.' iI- •..• ~. " , lill! ,~ f'; &,.&! !!~li:;:~gg' !§i~ i ~, ~.} _fJ!rli I~I~ . " ~ ~_. ~2',_'" J-~~ .3 f~i~ ;, d~i .1"~ ii .~

I;!II~~ ~III

Ii

i~

~lIq

I ;'fH; 3

~~~" :ag,i:;,~~l .10_'""'a.~,t~!!i2.li:~ 1",-

~fii"'IQ,~!._t:3'

"lc~I""JH • '~Iq~hl ~Ii[!l! ~Iil [i I··.·!.-<,,! ~'!-. ofii\·~t& ~~:1.!!_ !'!' '. ~~ ii~1 ~i i~i' ~: :~

ii

., .... 1'1' ~3tla::;:

/';,2~ii

~ g~;~f~ ~. _ l_o.

j-i

~~_m-ii

1

7~.~

~3

3~

!~

i' ~~, ~!f~! iiS

~'H'··i·~~· !.mli Jif

iJJ[ '1'1~1 i' ~ ~. I! i!-li~J ~~i.~, ,h, >i li ;·!.il ii" . ..."., ;... ;),~g 1~~3fl ~i!~ lJ a: l ~iH!

cs ......... "' ......... "'-

~!m{fm ~·Hl 'if ~ · .a~

f

Hirjiiii! ! Ill_ - ,l. ," -, j;n .·• ..'~~:'i:'

.,~

~

i

;& • ;

'

~

'

..

,0-.I"·;a:;:~·."'-2.Qli~ I .. o j.j ., • . . • •

'~.·>[H 1j ! g~H' ~~~~>
l'·.h·l~iC·~i'·f· , ••• !Ii~~!l_.!"~

~~

'!l·-c' 1- 2 --.I,-'!"_ ~.

i&~-~~~~a-

'!<;;.§ ~ i

&~$.li.i-.e §:fi

l~!J~: ".! •. .' -••

!ii~~~f;if

11·1!~l;[II~i![:1

~·[s ~. ~ .'" ::.!-og:~

'~i

""' '~l,~.

3..

-"

I"'''!.!~ '-

"'!- !

&.~§""'-

·lh·;~'U!: I i~t&."ii .. 'i!· i;r.i l~'!~i:~a~ ,,~

_OOj-

i

I'! ![! ~Iii~l ~[i:~ ~!~~

;[Fima~

'h

~lr~i~ ~II[I !.~!

•,~~~";'!l _H, &, '.1.

~~~~~~

§:2i~· ~C"l°::'!. jlli!.

~~Sitf als · 1 ~j~i

,-,'" I' ii:

~C!~;

~',!-

~·~i!2i· ~~_.~

~~[~

". -!.p."-

\I.'!:9. _1 ••••• ... !. ~oi" ! §~~~~i ~i~<&

'"

i'E"d!<

~-

f~[~[' ~~.!!j I[!~ ~~l i i :;!. i~=l

ili

!!ls- ;1. 30-

!~~pH~l! ••. _3""_,.!-. .. [ ass

~

~~~ c"!

alii

• I.~

l!· j

?" .....

~'I'W _= :i ~%<~~-"'-.!iJ! i:3" ~~

.•![-

=" -'"

.!ii&1 :,.!i" ~~i~!ti!2 --f-

-.

.. ~

, _s •

'l!~!.

,.l __ 3 .&_ ~ ..:..2._ ~" !i:.;.iii!i . ~i 313

i·n'~·l! ~ n~::: 3 ... i:5!.!t

~

0

d l~~~ ~ll!i ~l i2.&..ii~-,·;;- .. J;!g:ii

!~~~[~ 8iQ.Ji~;~~

"._R' ~!I;!. ',n' II~~!

l'I

--!iI·.···.!·,· " 131al-! ~[li

" " ..• 3

ii~~:ci:!I~" !!.~~~~

IH!~b;~'~IlH h~~ ljl~i!1'i~:a[l ~Hha ii}h~I~.

"l'·h, •• a.,!~

'HH;';Fhid

'''-I·!--l".n 'i""-i!'~'ii"" ~·~·5!.~." 6.i-3!!!'5"

~[hh'·:H!~1

.< .

,~"i,.HH~;H '-·"-1' ~ .3." .'" ", g i:i~!r. !;3i!i&OI

1UH Umh

~pt.,

5 F,eme end lorlt.

'"

• •, •

,

,---.... .

,_ ,_

4 5

....

MIl 30ft Spnng INMIw 30ft

1

~NI:Jbet

".""....-

9 Bonom_ 10 80Ir 20ft

II~~

12 WasIw 40ft 13 R.pin 401f

401f

Chapte.5 18

Instrument drive ublas: eumlnedon end maintenanee

1 II en Instrument fails to operata sudden I.... O. il ils movement Is jerky o. sluggish. check that tna cable i. not brol
'9

Instrument d,lvo.: e.emlnatlon and maintenance

Speedometer d.ive gaarbox I The speedomaterdrive gearbox is mounted an tho right·hand side of the hub on OT models, and on Ihe lelt·hand side of Ihe hub on TZR models. The gearbox muSt be '&{Iarded 8S 8 sealed unil and rDquires nO maintenance e~cept tor packing with Ihe recommended gre8Se when· e""'lhe wheel bearings a.e lubricatod. Individual parts are nOI available separalely on lhe OT modol. although on T2R moo:!els lhe dri"" ring. retainer and oil seal which fit irulda lhe fronl wheel hub <::an be oblained separalely. 2 The drive ring fitted in lhe hub can be removed as 60011 as the hub dust SIIal has been levered OUt. On mfittlng. ensure Ihat Ihe dri"" ring tabs are located correctly in tile slots in the hub and lhat lhe grease seal i••enewed. Smear a &m&I1 amount of g,alt58 over the drive ring and seal lips before refitting the wheel to tna machine. NOle thaI the comrYlOr\8$t faull wilh Ihis Iy~ 015peeOometer drive i51hi111ite dIM! ring'$ rltised ears are f1snatm by ca.eless re/illing 01 the gearbort; lhe ears can be bent back into pooition 11 care i, exercised. Tachometer drive 1 The t""homele' dri"" assembly consists of a worm mechanism driven by the clutch OUler drum. and a gear mounted verticall ... in the crtlnkca5ll. This mechanl&m" tubricated by the gea.box oit and Ihe, ... fore requi.es no maintenance 8t al" tf Ihe driva IIS5IImbl ... is at fault. lhe righi-hand c.antca511 cove. mUSI be ,amoved to inspect the mechanism lIS described in Chapter I. 20

Fal.iflg: .emovel end .. lIlIlng TZR model

I Although a fairing is not fitted as original equipment. Yamaha do p.oduce a fairing and fi~ing kit for Ihe T2R125. If fittod. the fairing will

Frame and forks severely .estrict &e<:ess to thecarbu.ollor and engine/gearbox unit and it will be necessary to partially or totall ....emove il belore certain operations are undertaken, The lairing can be removed using lhe following procedure. 2 Slacken end remove Ihe two Alliin bolts which secure the right and left-hand fai.ing Iowe<s togelher_ and ,em""" Ihe th.ee Allen bolts which join the righI-hand lowe. to the upper fairing. The right·hand lower can be 'ell'lOlled by .eleasing its Iwo mounling bolts and pUlling il backwards to disengage the pins on its bottom edge. 1 Rell'lOlle the Ih ..... Allen bolts which join lhe laft·hand lowe. and upper fairing. The left·hand Iowi!. can then be .emoved by .eleasing the two Allen bolts which secu'e it 10 Its mounting brackets and lilting ~ dea •. With both the right and left·hand fairing lowers removt!ing. otherwise the fal.ing may be dDmll9lKi. M.ke !ure that the pins on the boltom of the fairing lowers engogo correctl ... when refitting the right_hand lairing lowe •. Finally. chack Iha Qp£r.atlon 01 the turn signats belo.e laking the machine on the .oad.

21

Seat end sidepenels: removel end .elilling

Seat T2R model. I Unlock lhe seal via Ihe lock set in ill left side and lift it off lhe motorcycle. On refitting. engage the prong on the f.ont underside oflhs seal wilh lhe lrame and push down on the .aa. of the seal 10 lock it in POSition. Seat DTmodels 2 Remove both sidepanels (l18li below) 10 ttCCeS6 the seat mounting bolt on each side. RentO\ttl the mounting bolts, lift lhe seal up at lhe tlI8f and disengage its lront mounting prongs. 1 Refrt in a .everse of tna removal !>focedu'e, noting thai lhe seat fronl mounting !>fangs muSI angage with the brackets on lhe fuel lanI; and frame. $idCtpanels T2R models 4 Each side panel is .erained by a single screw and three pegs which pUsh inlO grommels ... in the I.ame end fuet lank_ Ensure Ihal the pega locale fully with their g10mmetS On .efitting. $idepanels DT models 5 The right·hand .idepanel,. secured by a single screw. a peg at 1M front and a hook at the .ea •. Thelalt.hand .idapanet Is secured bya bolt at the rear and a peg at its f.ont edge. Ensu.e that I ha pegs and hook fIrS localed correctly with the g,ommet on ,efitting. 6 The air scoops a.e securad by a srngle !II:'ew at the front and by twO sc.eW$ to .he fuel lank,

•

•"

• •" Chapter 6 Wheels, brakes and tyres For Information relating to the 1997-00 0T125 R mode/s, General dMcriptoon _ _ _ _ _ _ •. __ •____ ,"_, __ •__ .• _. ___ ._ Front whHI: remoYM _ _ _ _ _ .__ .__ .. ___________ Front wMeI: nrfining _ _ _ _ ._.. __ ... __________ Rearwhee!: _ _ _ _ _ _ _ _ •___ '" _____ ._ Rea.wheeI: relin"'9-_ _ _ .____ .. _ _ _ .__ ,___ Wh", boaring,.: ..mov'" eumi ... tlon..-d refin;"I1_______ Rei' aprocter: lion ....:I ..littill8 Culh drive; eumin81ion "nd renov,tion TZR model only .___ Brake caliper: removlll. (Wem.t,ol..-d rellning .. __ ," ___ .. _____ FronT brak" .....1... cylonder. remov'" overheuI and I1Ifin"'ll _ _

I 2 3 •

f1IfTlOY~

H_______

.en\Q\I'" ........

5 6 1 8 S 10

WheelS SilO' &tty TZR modeltl2Rk tond lPC1) ," _____ ... __ .____ _ t.le< TZR modeII (lPC2 Ir.d lPC3) _. ___________ _ OTmodeIII __ .________ Rm ruro.ot ,..:1;..1..,.;1,,,;..1 __ ._____ ._______ •__ .__

.* ___________ _

see Chapler 8 Rei. brat" mas.er cy\indIIr. remov'" ovem.uI..-d ..filling,,____ Brat" diles: &xamin81ion and •.._lOI ______ ._. ___ .. _ Bleeding 11M hvdolUlie bnIk. .yst6m __ Ra. drum brake: •• an'Mnll ion and T2R 2RIC:....:I

ff,,_,,1on -

Dilcthict-= Earty TZR .......... t.(2RK ..,.;I3PCI) ______ .. ____ LllerTZR modets 13PC2 ~ 3PC3) _ _ _ _ _ _ _ _ _ "_ .. DTmodeIII_. _ _ _ _ _ _ _ _ _ _ _ _ .. _ . _ .• _... _._ ~_.

Service 11mII: Ea!ty TZR modeIII t2RK end 3PCIl _ _ _ _ _ _ _ _ _ _ _ LIter TZR models (JPC2 &nd 3PC3) DT modeIII •. __ •_ _ _ _ •• _ .. _ _ • _ _ _ _ _ _ _ __

OoK ...... imum runout lroot Ind rea.: TZR modele • __ * •••. _ _ _ _ _ _ _ _ _ _ _ _ _ _ DT modeIs_. _ _ ... __ *. Clhper barllO;

=======

LIte, TZR .......... t. I2 (JPC2 and 3PC3) urlyTZRmodeIs RKend3PCI ) DT models_. __ * •• _ •. __ _ Maslercylinder barltD lrool.nd fUr ._ _ _ . _ _ __ Brat, pad frietion ITIIIterielthlcknns: Eertv TZR models 12RK end 3PC1)_" _ _ _ _ _ _ _ __

.. _

14

15 16

3f'C'~

,-

.....

1.85 .. 16 2.15017 1.60.21 2 mmtO.08inJ

2.15.18 2.50.18 1.85.18 2 rrrn 10.08 in)

4.0rrrnCO.16in) 5.0 mm CO.20 in) 3.5 mm CO.141n)

5.0 rrrn 10.20 in)

3.5mmlO.14in) 4.5mmlO.IBIn) 3.0 mm 10.12 In)

Not~

4.5mmI0.18in) Not~

4.5 mm 10.18 inJ 4.0 mmfO.16 in)

0.50 rrrn 10.020 in) 0.15 rrrn 10.006 in)

38.1 rnm 11.50 In) 42.8 rnmll .69 jn) 34.9 mm 11.37 In) 12.7 mm 10.50 InJ

5.5 mm 10.22 in)

Not eppIIcebie 38.lrnml1.50inJ 30.2 rnm 11.19 in)

""'-

~~~.~..!.~~~.~~":-.======= Servio;e limit front end

5.3mmlO.2Iin) 6.0mmCO.24in)

TZR modell_____ ___ "._ .• DTmodeII; BrKl Huid typI.____ • _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

0.5 mm CO.02 In) 0.8 mm CO.OJ In) DOT 4 ~I not IVlllabie DOT 3 InDY be UIId)

few;

.-======

*_._.. _____

H. _ _ _ _ " . _ . _ _ _ _ _

Drumb,.k,

""""'0

Service Wmil. Shoe lining IhCt ..... _ _ _ _ _ _ _ _ _ _

_H_._. *. ______ ._.

1

l

m

~

e

c

i

v

.

___________________ . Relumspring'reetength _ _ _ _ _ HH* _ _ _ _ _ • _ _ _ _

11 12 13

Tubed tyrea: removal. repalr..-d flIffning_.________ TubeIeM Iyree: removal and refjnJng____________ Tubeleu Iyrel: puncture .-pair lind tyl'e renewol ____ .... ___ TyrevaIYu:o-neral Wheel balancing

DIK brake

.

,:

s

•

130 mm 15.12 inj 131 JOOlI5.16inj 4.0mmCO. I6in) 2.0mmCO.08in) 36.5 mm Cl .44 lnJ

5.5 nvn 10.22 In) 6.0mmI024;1I)

17

18 19

Chaplet 6

'"

Wheels , brakes and lyres

TV res SOr.,:

,~.

Early TZR models (2RK lind lPC 1) ._________ ._ Later TZR models {3PC211Od 3PC31_______ ... _.... ___ _ DT modeIs ___ .. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

..... HIOi9(l·1856P lOO19(l.18S6S

90/90·18 48P 9M!O· I 746S 2.75,,2 1 4PR

410" 184PR

Ty.e p.ess.u.el Torque $elting!ll Component .________ .________ _

model.________ .______________ _ Front wllool pinch bolt nR mOI"'I. _ _ _ _ _ _ __ OT

~ nd1!I

Front w'-I s poinclle clamp IMS DT model _ _ _ _ _ _ _ _ Re. wheel6llindle nut TZR model

_. __ ...... _ ........ _.. ___ .. _._._ .. _._. __ _

OT model .... __ ...... ___ ..... _. __ ........ __ .. __ .___. _ Re...- aprocklll nulsJbolts: _._._. _ _ _ _ _ _ TZR mode' OT model•.. _........... _

_. _ _ _ _ _ _ .__

Brake ClIoI,per mounting bolts

TZR model . .. _ _ _ _ .. ____ .__

Reao Qlipe< bu,,;lutt to swinging .. m boll TZR mooel. ______ .. _ Bnlke cail"". body bolt

OT model

Sw.ng;ng ",m end 1IC'0l'WS OT model .... ___ ._._.. __ .__ .. _ .. _ .... _ Front brlll

ReM

II;ro~

Bleed NPpift..

_ _ _ _ _ _ __ .. _H_. _ _ H _ _ H_. _

••• _ _ ....

_ _ H.H_H._.H •• HH. '_"HH

S.ake d,,,,, IICI"ewsibolt. _ _ _. _.. H.H_._.. H .. Omm ~e c. ""Mh ponch bolt ._ _ _ _ _ _ _ .H_.HH •• _. Drum bnKe tOfQlHllfm to b.oclcplate nut .H _ _ ._.. _ _ H_ •• H.H_HH .... 1

.~.

•• m

f,onl ..... heeI spind le T2R model

., "" ,., ""

,..,. ,., ....,, ,.,.,, ""..• ,",.., " ,."",. H

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Gen.r.' descrlplion

The TZR modet. Itfe !il1ed wilh cast aluminium wMelt.. Eeoi;e. rnodo-Is (2RI< and 3PC1) use . 16 inch diamete< Iront wheel lrod In t 8 inch diamete< reIN" wOOel; both CItrTy tubed tv'" The Iront brlkl it In hydn.ulicallv operaled dilC and the rear i. a drum brakl. opet8ted by a rod tintage from the brHe pedeI. Later rZR modeII !JPt2 ond 3PCJI ore litted With I 17 oneh I.ont wheel and an 18 i1>ch rea. wtIe&I. designed to accept tubeleu tvrea. 80th f.ont and 'N< brakes arl hyd'aulically oper81ed d,scs. The OT modeillf. ,illed with w'-il 01 COIW.nhonal w,rtt·spoked construcllOn. uaing ch.omed IIMI rims 01 21 inch diamete< I1lhe lront, and 18 inch dlllmfllflf 81 the 'N<. 80th wr-Isarl litted With tubed tVres. 80lh I.ont and ree' bnK" If. hydraulically operated d i..: ..

2 front wheel: ........... 1 I Support the ...-..c:hi..... on a wong wooden bo" or " milar , uppor! to hole:! the machine securely SO thaI its front wIW Os clear 01 the ground the rttmoval 01 the lower lainng belOfehand and poss,bIy the I xhaust l yatem

On the TZR model thi' mav ",

'IIQU".

.......

2 Remove the two 1>0115 which '"a,n the bral<e calipe' to lhe lorI< leg. Uft lhe cehPl' clear of lhe w'-\ and IOfh. IV'ng it to the I,ame to .... OK! pl8c:ing undue it ...... on the hyd.aulic hoM. Before proceed"", !urthe,. i ...." I wooden wedge betweeft lhe brakl pads; th~ W>l1 prevent lhe pistons being expelled ~ lhe bral
Fig. 6.1 F.on. wh"1 TZR mod. I_{2:RK.nd 3PCI model shown 3PC2 and 3PC3 _imil ••1

w_ _ _

Rlf1ht·hM>d~

""""'...,

-"....

8Nnng 20"

OTmodel 4 Remove the tWO bolts which cl¥np the dose cover to the fork teo and the lront hall 01 the coYfIf. Pull the speeOomete< cable from

retnOY.

'-"'''''

7 8

9

~tttrdnvepUl.

RtltBIrItIf"

"""'...,

IO~tttrdmltl

..-'

II BnIJr. dtsc 12 8011 60ft

Chapte, 6 Wheel$, b,ake$ and tyres

'"

,I. g.earbox afte< releasol'l9 I'" knuried relalOlI'l9 ring. T... cable ~ be ralHsed ' ,om il' holder on lhe righl·hand lork leg iI W bliowarod 10 11M grOUnd and lilled eln' 01 11M fork •. Before proo;eed;ng funher, I....., • wooden wedge belween lhe brake pads. This will prevenl lhe pistons beil'l9 •• perlacl illhe brak.lever;" opIfllacl accrdenUIIIy.

'rom

All model. Refer 10 Rouline m.'nl'~ for !Ielalls of wlleol ..amIOlllion.

6

3

Front w ..... l: refittinll

The wheel ill ..finacl boo' .....",il'l9 In., 'emoval ~. Befofining lhe speedom..'" dnvtlll"llrbox to Ihe wheel. lhe drivtr "'-Ie lings iogrll o;orreclly in lhei. IIoIs in lhe hub. Refil lhe wheel in lheir COITacl PQaitiontr and, .emov. lhe woodIIn wedge 'rom lhe bnrI lugs on ,he spoedomeW gearbox, On OT models _Iso che<;k ,he bnrkl disc ill f;OfrtIClly IlOI'Ioonld in I'" ClIllper. 3 Insen lhe wheeI,pindle and lighlen lhe nul by hand only II Ihis 11"11'1. On TZR modeIs .. move lhe wooden wedge from belween lhe bnrk. pad. and refil ,he bnrkl .... liper. Ilghl",,;ng 115 mounlil'l9 boll. 10 .he .pecifoed lorque Sllt!ng. On OT models refillhe fronl ....If of lhe disc I

'pac
FIf! . •5.2 F. onl w ....1 OT model.

, 6 7

8 9

3. I a R.fil speedornel.' d
"'-Ou$'UIII L.h·Mnd_ 8tlllt.d
~.

" Movl lhe .....chIne off ill stand.nd with the hont brake applied, comp..,.. the fronl lork. l1'li.... Ii ...... to set'le lhe componenll. Then l'!Ihlen lhe Wlleollprndle and prnch boll tor clamp nulS as appropriala) 10 ,,,, fPlCifild lorQue SIttings. On DT modeillrghten U.. top null of

3_1b_.lndlPltC8f TZRmodeIlhown

(arrowed(, .

3.2b DT model ",*,100 disc eo
3."" TZR model lighlen lhe wMel SPIndle and pinch boll 10 lhe specrflld IOfquele\ll1'l9

3.4b OT model chec:k spindle clamp is o;orrectly filled (arrow facll'l9 up) and lighl"" null as described in IIxl

Chapter6 Wheel •. brake. and tvres

'"

the spindle clamp first. then the tower two. Note that the gap between the 'on: leg end tower part 01 the clamp is Intenlional. Finally . econnect thespeedome.er cable.nd the operation 01 the brakes and 'orb before taking the machif'll!l out on the tOIKI.

chI!IC.

•

R..rwhe
1

RaIse the wheel CleM of.he ground by placing , he machine on.

"'ong wood"" OOIf. or SImilar wpport placed under the ""1I""I&'oearOO"

u"';1. On lhe TZR modei,his may reQUIre lhe lemov~ 0' the lower fairing ....:I exhaust IVltam TZflmodels 2 On eartv "1Odell I2RK ....:I3PCH. unscrew the brake adjuster nul

'rom.he brake.od end.nd di5l)lace the rod 'rom the brake Mm. Push out the trunnion 'rom the end 01 the brake arm INId lit i• ....:I the nut to the end .he brake rod ' or s,a'el<eepong. Remove the wlit pin whICh MCUres the torque arm retaining nut. then remove the nut ....:I1If)ring w
0'

OTmod,' S Remc:wo lhe 'wl"9ing .... m end KffIWS. Straoghten ....:I ... movllthe spill pon which relalns the whee!spondlll nul end llacken The apindle nut. ROlaTe bolh snaIl cam adl"slers SO lhat the wlMlol can be pushOO 'orw"d....:l the ckain di~ Irom its ,prockol. lIthei-II is Ins",'fi.

w_ _

F'g. 6.3 A..,wheel

"",• 5 6 7

8

9

Cham adJUs'. 2 off Lot:knuf 20ff AdjUs,er boo'! 2 on R.gh,·lwndSp«M BrM. bKkp/Irlll 8raI<.ClJmshafr W __ rndlCllror

10 fJraI;lIOpf1r11'lfIgtlml

'''''''' 12

8ra1ruh~

13 RellJf11 spn1I9 2011 14 fJunng 15 s,-er~ 16 HubSp«er

"18 ....", GrNsesui

TZR C2RK . nd 3PC1, moda'S

19

L.fr·hJmd~

22

Sprock.,

20 Cush dnvlI bush • on 21 NylonspllCflf 4 0n 23 T.tJwllSl>llr 2' Nul 'on

20n

Fig. 6.' R..rw ..... , T2R CJPC2.nd lPCl) mode,s

25 Ww-

WhHlspndill SpIi'pm

27 Nut

ChaIfIIfdius'~ 2 off I.«l
" "'"'"

28 Torque",",

"30 .."

SprIng wllShtH 31 Nut 32 Splilpm

33 .." 34 Spnng washer 35 Nul

36 SpIt'pm

"'"'"".... '"

10 Hub$plle« /I Boll 30n 12 8nJktJ diJe

" a.su.rsul

I ' ....",

/5 LlIfr·IMnd:spilar

/6 Cushdnvllbush 17 18 19 20

."If

NyIorlSl}«llr 'on Sprockel TlIbww- 20ff NUl

'"If

21 W9sher 22 Circkp 23 Nul

.......... ............ ",

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Chapter 6

Wheels, brakes and tyres

totque setting. Secure both nuts by fining lin A-pin through eac:h. Adjust tho rear brake and ,top !amp swtt(h as described in Aoutin8 main · tenance. 3 On laler models (3PC2 and 3PC31 tighten the wheel spindle nut to its recommended lorque setting and fil a new split pin. Aemove the wooden w edge from between Iha brake pads and refilthe caliper \0 its moonllng bracket. tightening all Ihe mounting boh. to the torque sellings given in Ihe Spe<:ifiClllions althe slart of thisChllpter. 4 On all models. Ihorooghly check lhe operation 01 the rear brake before taking lhe machineOUl on Ihe .0lId, makin.!! sure thallhe wheel alignmenl morks are facing outwDrds. Insen the spindln into the left· hand lotk of thl! swinging arm, lind remove the wooden wedge from between the brllke pads. Unles.s previously disconnected. in.lall the chain INer the rear sprocket whilst installing the wheel. complete wilh spacers, into lhe swinging erm end fnllnoetJvring il into pOsition. Make Sure that the brake disc is COffoclly PDSlUoned in the caliper and Ihen )J<Jsh Ihe spindle fully into position. Fitthe righI-hand snail cam adjuster and plain washer. Secure with the nUl, lightening il by hand only at Ihis S19g/l, Refilthe screws in the ends ol lhe swinging arm, securing their nuts linger-tight. 7 II previously disconnecled remake the final drive chain, noting Ihat the closed end of the spring clip join'ng link should fllCe Ihedir8Ction of normal whoe! rotation. Adjusl the chain and wheel aHgnmen! as described in Aoo" .... fnIIimenance. B Tighlen the wheel spindle nul and ,w'ng'ng arm end screws 10 lhe specified lorque sellings. and fil • new split pin to the spindJe nul.

9 Check the brake pedal height and StOP lamp swilch op8nuion IS described in AOUlinll mainlenance. 10 Thorooghly check the opanllion of the rea, brake before laking the mllChine oul on Ihe road.

6

Wheel burlngs: r~movDI , examination and relitting

I Befoto the wheel bearings can be examined. the wheel muSI be remINed as dllSCribed in Section 2 Or 4 of Ihi. Chapler. Front wheel 2 On the TZA model. the speedometer drive gearbo. muSt be witl\. drawn, followed by Ihe grease seal, the speedO<"nll!er drive ring re!alner, Bnd the speedomel~r drive ri~g , Heel Ihe end alan old flal·bladed screwdriver and bend the lip inlOa slighHyc,"rved shape with no sharp edges. This will give a useful !OOI for levering out Ihe oil seal wilhout damaging the sealing lip Or the spring benealh i1. The SplICer and dUSI seal on the disc side of Ihe hub can then be wl!hdrawn. if desired. In" similar manoor, or they can be driven OUI wilh Ihe bearings. For OT models lhe speedometerdrive gearbox mUSI be withdrawn. The grease seal. dust covar and spacer on lhe opposile side 01 the hub can be removed as dllSCribed above or driven OUI wrlh lhe bearings as desired , 3 Support the wheellirmly on IWO wooden blocks placed as close to the hub cenlre 8S possible 10 prevenl distortion, ensuring Ihal enough space is allowed 10 pe,mi! bearing romoval. Place Ihe end of 8 small fl.t-ended drift againsllhe upper face ol lhe lower bearing and tap the bearing downwards out ollhe wheel hub. The spacer located bet ween Ihe IWO bearings may ba moved sideways Slighlly in order 10 allow the drift 10 be positioned againSI Ihe lace of Ihe bearing. Move Ihe drift around lhe face of the bearing whilS! d,ifting il OUI 01 posilion, SO IhDt Ihe bearing leaves the hub SQuarely. 4 Wilh the one bearing removed, the wheel fnIIy be I~ted and lhe space.- withdrawn from the hub. Invert Ihe wheel and remove the secood bearing. using a similar procedure 10 that used for the first.

6.Bb ... and iiI second bearing ...

Ch.pter 6

Wheels, brakes .nd tyres

Wash the bearings thoroughly in a high flash-point IOIvi!nl to remove all traces of the old g.esse_Check the bearing lracks and balls for wear or pitting or damage to the ha,dened wrlaces_A small amount 01 sida movamenl in the bearing is normal but no ,edlal movement shoold be detectable . Chack the bearings for play end roughness when they a'e spun by hand. All used bearings will emile small amO<. alignlr>g too driva plate tangs con8Ctly. 10 Fit the Iront wheel assembly into the Ironl fo,h as described in Section3.

S

7.2d ... at>d lilt off sprockel

119

access to the rear wheel baarit>(lS. Due to the similarity in dalign and construction between lhe 1""'1 and rea. hubs of I18Ch 01 tOO machines described in this Manual. the procedures lew removal, eKamination. and relining ollha rear whofll baarings are eKiOCtty lhe same a8 those glvan above.

7

Rear.prochl: .emoval. nemln8lion and ,efitting

t Exami"" tllfl teelh 01 Ihe 'ear sprocket. II these aM hooklKl. chipped, Q( otherw'se dilmaged. the sprockel must be renewOld. NOle thaI it is considetl!d bad practice to renew juS! one sprocket Q( the chain alo",,; bolh I""'t and 'Oa' sprockets and the chain shout
7.3 TIghten nuts to .pecililKl torquo selling and ser;u •• with tab washer as shown

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Chapter6 Wheels, brakes and Ivres

,,, ,,,

Caliper Bleed niPple . Pad reurrmng pin

20ft

R'c/1f1 20" Boll 20fl Brakapads

remaining pislon !n D Simll~;a~I~;~~ ~~~ refil il ar.d absen<:e 0 •• Ihe P'SIOnS oul 0 . g linge.s trapped r. gradual'v gloa' ca,e 10 avoId Of ,emove the employed 1·:lons.. No,e; on nO acc.. of the caliper body; t emergIng pI h secu .... lhe IWO , . a. b.idge boilS whlc: ,aledduringovemaul. nis as descrIbed In pa., not need 10 be sepa n lhe cahpe< compone the piSlons. II both a e 11 hamine and cleabering nOI to dvisablc 10 clean raph 6 above •• r 81 Ihe same t,mo ,t IS a and R USing II 1'010 d tl'en to mark lhem L h one Reassembly with melhvlated OUto,.face Oft i;; based ma,ker pen 0 al sequence nollng tha I condition and luOOis a .eversal of .11'" re"",:,S 'egardless of a~,en '.. .mal. fluid a5 dDSCClbed In catethem WII y s ar.d shIms .10 machi"". 12 Relit the brnke an ~inst811IheC8hpe,onthe Routine maintenance

I!~~~~::~:~eair. !omP"f~~~.':e~~"wh~Cheve. me~~~~:

"pu~p

~emoved

~~::;'ken ou~es

em~ Ihec~l~pe SP~':h~n,ecessed

Alwa~ ~'h~7""~ie

fill .6.8 F'onl b.ake calipe. OTmodels 1

Caliper

9

2 3

Bleed nlPPW &11

11)

Pad sprmg {)IJstsfUll /I FlurdWilI 12 As/em

th?~

'1""'~~te'cleanhness

duri~ ;nslal~~JQn~lipe<

e~Ch All models . bolt using new coppe , sealing iliedwashers torque on selling. 13 Relillhe and tighten 10 t.he Ihe ,ecomm...,ded side of the hose utem will now reqUI .... 13 of thiS Chitpter. Remembe. the before use: tefe, 10 h k the brake OJ)e
u",o~ion ':;~"'ng

14

, ,,, ,

Inl~,change

~':;'o

s~h

fllll~tion

2 off

13 BoIr 20" 14 Oi5ccovf)f 15 Screw 20ft 16 C/IIipercovf)f

r de r. .emoval, Over haul.nd ,elitting

10

FtOnl b.ah masle, cy.n

..

ulie Huid re5e"'.oit

1 The mastOf cyli nde~forms. Unil with by a clamp the hv;t'~he 0 righi-hand SIde ar.d front br!Ike lever. a is mounted 01 the har.dlebars.

Chapter II Wheel l, brakes.nd ty,..

122

-"'-'-

F.1.10Rll
...

, 9

Bolt 2tJH Bt•• pMIs 10 PwdIpnnfJ 201f

"-

R_ _ R_ _

"

"""" W.."'"

8Jf«J mppIe 201f Mcxml.ng~

Bolt 20H

., --10 " 12 /3

Slum 20lf Ousl~ 20ff F/uld1/lHl 2tJH A8irll'! 20lf

Pwd ""..,.", /WI 2 tJH

2

T1'IIt unit .......t t.. draontod btl'" -'Y

~1W'og

'*' t.. ,"*-

Shom

12 OrntI/lHl

Pwd 1fISPK/1OII plug

" fluid .... I~

""'rII'!

MIf' rII'!'"

8 ~ e.rlfuly. '*"II hy(Qo.IIic fluid . . . luI;ono;tnt -.Id pislon. .-...g Ihllhm8nlW'og ~ MM. \he eon:Iip -.Id dull ....... lillld comICllv. -.Id IhIt .... unil ill damped MC:UrIIv 10 Ihi hIndIIbIra. Till ~ .. ITIIftIld 'UP' 10 .....1 corteeI refillong and iUl boIUI",...1 t.. Il(Ihlened 10 IhI ..-,liId IOfQ\HIle1long. UfII)If bolt lirsl. RtICOMICl lhe hydraulic hoM. ""ng nIIW .... ling wisherl NCh side 0I1h1 unIorI. Tighlen IhfI unoon boll 10 till ..eommer.dld lorQUI .. \ling lhe ,...voir temIfIlbIring '0 lOP up 1ft.. IhI ..... lenl hit been bIId bv loIIoWIng .... lI'ocedurI (IIVWI ., Section 13 01 IIliI

-.

Rei,.

lMiII\. PIIq • ItIiUtbll o;:(In1Iinf< btIow \he ~ unilllld
--

• R - . lhe locknut -.Id btIt. . . . . pivot 10 I ... \he ....... Aa 11 .. IihMl-.y noll \he...,.. SIlrinII wtIIch;. ""1Id into ChI -.Id dIr 5 R~ lhe two boQ who::h hcIId lh1 ","Ie< cyIin(Ie< cllmp hilt 10 lhe bcIdy IIId lhen ~ h lhe ......... o;yIln6Ir _ .... ' RImovI lhe cover If>(! d~1gm, lhen empty IlIIreMNOI,. lIllllIlill conneclid. ._.Ihe unkIn bc>It IfId '"" lhe ~Iic ' - from lhe ","I" cy\indIr body Tape . POIyt ....... blvClVtlflhe I
'*'

Inny CJf dirt IIId INkIge
II I'l.ol off \he dull .... from \he lAd
"*" ....

willII ....... E.oIminI 1111 piston and ..... lor ICOring or _

-.Id . . . - ~ ImPlnlMninlllld fIuod, and ~ lho... sulPfIClld, it i. probably worth ch«kong I'" eondl1ion 01 \he Cllipw _II lind pOlIOI'\. Nol. 1IIIIIhe mKl .. cyIonder ...... pillon lind IPrinu .. supplied ... MI IhIv <;InnOl t..obt...-dlndlviduallv. 7

Ag. ...11 fronl br.... mil' .. cylinder

7 SpnngWHhll 20ff

, ,

'0

~/OTonIot) ""tofI~/OT

IhowfI

TZR~

tkIIotIboir

II SHhngWNhttr

'2 eo ....

20ff

Chapter 6

Wheels. brakes and tyres

123

Fig. S.12 Rea.brake masterqlinder llR mod., I 2 3

Celleoe/am&' COlier ~mpl6,,:

o,aphmgm

,,-

R_w

Sprmg washer Washer

9 UnlOll 10 81)/' II ReslJrvl)ir 110se 12 HIJS8CIMlp 21)ff 13 C".,;;/ip

14 H<J5#1Uf1KN1

15 (}.tm9 ,6 Md:;l!l1 cyh,1<Jt>r

s.:.ew 20ft Plsronanemb/y Nut 21)// BrHe pedal hilI< Qmerpin Washer Spill pm SpOClll/ was/rur Umollball 26 Sealm9 waS/ler 2 off 17

18 19 20 21 22 23 24 25

Tho
9

11

Rur br.k. mas'.r cylinder: removal. overhaul and relining

Fig. 6.13 Rnr brake mao'er cylinder Cever mlamer Celler o,aplmtgm pia/fl o,aphragm ReservOir 6 Screw 7 Reservoir hose 8 Hose clamp 2ull 9 Union 10 eirelip 11 ()..nng I 2 3 4 5

OT model.

12 Master cylrnder 13 Screw 2011 14 PiStonassemb/y 15 Nut 20ff 16 Brakepedallrnk 17 COlier pin 18 Washer 19 Splitp1/J 20 Union bolt 21 Sea/ing washer 201/

methods 10 prevent lhe IPillaoe 01 brate fluid. The maSIa< cylit\dercan

now be dismanl!ed end overhauled using the procedure in Section 10. paragraphs 6 10 8.

1 The reDr brake master cylinder can be deall with in much lhe ume wav ItS he! been described in the previous Seclion. Ihe main dillerence-s arising in the procedure lor removing the assembly Irom lhe frame. Drain the hvdraulicfluid asdescribed prevlouslV.

ll" model 2 DiscOMOCI both the stop/amp and rear brake pedal ratum springs from the brake peUal. Remove the two screws which moum the master cvlinder to the fOOtreSl brackel and the rear brake pedal 'etaining boll. Puilihe brake pedal 011 its pivot on the fOOlresl brackal and remova the bracket from the Irama. Disconnect the rear brake pedal bV removing the aplil pin and withdrawing the cotter pIn and washer from the forked end 01 the maslercylind8f. J Remove lhe union bolt from the top of the master cylinder and disconnect tile hydraulic brake hose. Tape a poIythene bag 0II8f Ihe end 01 tile hose to pravem tile .. nlly of din and llIe leakB98 01 brake fluid. NOle tile posllion olille special washer before removing it Irom the top 01 the maS/8f cyliotlor 60 that it can be replaced correctlyon reassembly. Selore disconnecling ll1e reservoir hose from lho ma$ter ~y!inder find a small container to drain the brake fluid into. Allernallveiv ll1e hose can be plugl}6
DTmodei 4 Remove Ihe rear brake hose guides siluatad on Ihe swinging arm. Remove the unk>o boilirom the tOIl of tile mastercylinde, and discon. nectlhe braka hose. Tape a polVlhene bag over the end of the hose to prevent the entry 01 dirt and leakage of brake fluid. DiscOMeCt the lear brake pedal by 'emovlng tile split pin and withdrawing \ha COlier pin and washer from the lor ked end 01 the master cvlinder. Remove tile screw which ratalns the reservoir to Ihe frame tube and also the two master cylinder mounllng bolts. The maSler cylinde, and ralervo'r essemblvcan now be manoeuvred out of Ihe frame for inspeclion. 5 Unscrew the leservo" cap, remove Ihe iMer cap and diaphragm and empty the bra~e fluid inlO 8 suitable container. Then dlsconnecllhe brake hose Irom lhe master cVlinder. lhe ma$\er cylinder cen naN be dismantled and overhauled using lhe procedure in Seclion 10. para· graphs 6 10 8. All model. 6 The maSler cylinder is refilled to the frame bV a r8\lerse of the removal sequence. Use a new sptit pIn on the master cylinder COlier pin and renew bolh COppel 6I!ahng washers on Ihe union bolt. Make $U(e the union and all mounting bolls are tightened 10 their recommended

1000que Mltlllgl !Jiven ;., the Spoo;lfocatioM 1\ \hot 11.11 01 Ih'- Chlpu". 7 Remembe. I"'t the hydntulic I'(It ..... wiN now fi~jng with I.... __ Ifled bll'" fluid ....:I bleeding belor. 11M. by toIlDwing t.... QWC1iDn1 gi..... In Seclion 13. Check \hi brN' PIdII I*ght IS o..cribld In Ro\II,ne !'Nint.....-1II'Id tdjuIl II . - . - y. FlNlty check \hi ~Ion 01' lhe bfak.1II'Id Slop I8mp lhorough/V before lilting Ihi mIIChine on \hi road.

,IQUI',

, u.n-t00fl 01 \hi diIcs QfI be CIfriId out with lhe whMIII inlUiIId. Look lot .... 01 KOfIng. SO<... MgrM 01' ..xw;ng • lMv,t--.bulinl....., _ _ _ lIo1theditc mtv~~ 10 '"tort lui br,ting affecl. Check IhI disc lor warpa\JII. which CIIl ollen , ..... , from overheat,ng 01' impICt
,.ceaiII.

rna.,.

..

wrI_.

pipe from lhe bleed nipple 10 the' j.If. Not. lhill on lhe TZR model , -

.i.

br.t, .,.Iipe< h will be - - V 10 fUn. piOlf....., uch bIHd n,ppIe. II c.... piuloc lube IhouId be UHd so tllll bubbles CIfl be maN 1liiy IMO. PIIce MIIT'oI clNn hydfsvlic fIuOd WI t.... gIIu j.If so thllt \hi pipe It

ImmIrMd below \totlluid IUffIU Ihroughout \hot opei'.11on. 5 «parli 01' \tot Iyslem holY. bien ...-ed. -.nd I...... the .....1.... must be fkI. ",*"IM bIIId nippIe.tlotrlone lum snd pUmp lhe btaU '--" "",a ftuid ,,"'1 10 IMue from \hi c-. lube. Tlghlen lhe ~ nipple III'Id then conl,,- IMI'IOfmIi bIIIoding opeI'IUDn • 0IIcribId lit 1M IoIowong ~ KIIIP • cIoM cI*=k on lhe _ _ _ ...... wNkl the 1yII..-n • bIirI!I filIId. 6 ~. lhe I:nQ ......rplldll. '- • it d go III'Id hold It In \hi po.""o" ~I 1M fluid p"....... II IPOfIIIV btH, ~t.Ion "" oaaned It,...., b e - s r y 10 pUmp r.podIy the bfak,IwI<·'oe\W I ........oe. 01 1'"* until ptIPUftI ;. 1ChIeYed. With pnoUtn ~ IooIen lhe bleed nipple Ibout hili. Ium. TIghten thl nipple • IOOfI • lhe tev.,oecWt' hM _hod itl lui u.v.IlII'Id lhen ....... lhe \eY .. '~ dill. RepHl thisooer.11on unl~ no maN';' bubbIIs , ....oeIlid w,lh lilt fluid ;"10 lhe gll5l Is'. When Ihis condilion is....:hod the bleeding operallon thouId be «W'I'IIlIII •• 'HulII"II ;., • lirm IHI 10 lhe brlk. OOIfIl;on, II 1I>0"Il''-. lIi11lYidenl conu ...... 1"- blHding 00If,,1OO\ il may be th.Il an II' bubbIt u&pped 111M top 01 I hi l'(IUlfYI .... VII 10 work down Ihrough Ihi cIIiOIf

,i.

, The melhod of bINding. bfII<, .ysl..... a l ii. III'Id lhe procedure o..cribed below appI'f IQU/Iltv 10 either .Irom brit, 01' ,II< brII<, oIlhe hydreuliclltv SClulled tv.-· 2 If lhe brN,lCtlon beo;onws 'POI"IJV. or if....,. pIfI 01 the hyd..... ic ..... tern 116oIman1lld 11UCh. when. ' - I&.-wld! it II --...v 10 bINd Ihil'/'llern InOtder 1 0 ' _ " ~ 01'; •. The proc:ec:I...-.lOI' bIIIding lhe hydrItAie IVII,,", II belt c.erried aut bV twO ~ 3 ChecIt\hlIluid ....... 1n the....-.olrlll'ldlapup_th_fluidol the ~ ~ if .1CpIed. K..., IhI.-voir 11II1II hili lui during 1M ~ ptCOC«Iu.-; if lhe ....... is IIowed to ,.. too ,..... wilen'" the 1'(Slern requoring Ihlt !hi proc:edo.n bI llIrtId 191'" from 1CftIch. ~ lhe ClIP onlO the - . \0 IQYIICt •

13.4 Connect bleed Iubi dIYiaIlo nipple lllhown

12.

'4.2b Drum 1UI'f_ ,...., "- h ' from bteI<e dusl lll'ld ICOring

7

~

..

t._

of 8ir he ... been rerncMId from the .ylt..... top up

,t.. r--..oit III'Id refit the ~..-d ClIP 01 _ _• _1PCJfOPtiM .. o-lIlhe en' ... Ivstem lot ...... III'Id check -.0 \hilI the bo'aQ ~I"" in gtntraI ;. funo;Iiomng effociently before UIIt\Q the ....chine on the

.,.,Brat,

8 fluid draoned ITom !he • .,.,.... wit .n-I C8IUInIy be a)I'ttanww\ed.1Iithto' by ~ INtIIII' 01 rroor. ~ be !hi ~ . " fA _ lion Ih& • AI I¥*a*: IUdJ . . I) .om. __ t.,vo. KOPIc. IMt it, thtV'" t;IIP'b!e 01 drlow,"II WM .. !'om \he_~ and lheteby ~ading u..Ir ~ ... _ In view 01 and Ihe ...1..... ~oIlhlllluid.aldftuod IhouId w.v.boIdIIcanMd. 9
uw.

,,,

Rto ... d ... mbr...., ...mlnatlon..-d'_.11on

"'" .........

T2R2RKIII'Id

1 When the whNI 11M bMn ~... detcribed In Seo;lion 4, , ... tqk.bkk~.-..bIy ..... belitted--V.R~anvlCC ........... ltod ...., from the tw.I<, dn.om by wipong It _h • II1II ....."" In """-'t. Do not blow ,he dn.om out WIIh cornpr-.d .... Thedull c:ont...._ _ _ IOI ~which ............'uI if 1MMd. 2 ~ .. the 11<,,"11 thlck_ at '" point III'Id ...- Ihe ~ " they .... worn to or beyond \he ___ limit Ihown in ,he Spedfbt_ ktoon. The ~ IhouId .-0 be ...-eel if they """" ~oon""-Illd wilh oil or ~. The lining ,Nil"'" II bondtd 10 thllihoea end Ihill ........ Itwll lhe Ihoea IhouId be .-wed compie ••.

uu.v..t

10 Fold br,h ttIC* 10000ther In • V

10

I*lTliI rerroov ..

3 R_ _ 01 the brtoII, " - " ~ by foldong the " logMher 110 1"-1 they form. V . Wilh the q>nng I....a. ........td, both " - III'Id fPrinIp may be ,.....,.... from lh11 twak. bKkplatl .. an .nembIv. DeIKh the IOfinIII from 11'4 $hOoM; and ear.fully inapec:111lem fof tny ~ of Of ,~, ~ Ihtif free IiWIgIh wilh lhe givton in the ~1IOt'IL .. a.tor.lillong!he braU " - d.:II the! the braU operalongQll'lIl -'tinD smoolhly and II nol binding in III p/¥oL The cam c.n be •...-eel by withdrawing the pinch boll on lhe ~Iing ....., and pUlling !he....., off !he 111m. Beforto .-;ng Ihe..m.1t IIIdviubIe 10 .......to: iIs poMion in rWtion 10 lhe sMft ., 1'* It c.n be reIoc.\ed COfTKtIy. with 11'4 _IndicIIOf point ... 5 R~..,v cIepoIill 01 ha.dened g _ Of C()(t'WiOfI 'rom lhe burIng 1UI1_ of the brat, cam ... .no. by rubbong 1\ liuhtly .... th • .trIp of fir'III - V PIPW Of by ~ IOtIIenC wtth , piIu of rag. Llghtly ~ the IMgIh of lhe 111m and !he f_ of lhe operating cam prior to _ b l y . 0 - . and ...... v • _ _ 01 nIgn ..... llng·pOonl ~ 10 lhe piVOIllub wtlich II ... in the beckolill. 1I-.x.1I lhe -'>1ft. />wong IPPIIMI , _ of high ...... "'It1IOirI1 W - 10 iIs "**- Align and fit the opemong ....., wilh lhe _1nda10f POInl.. Tlghl ... lhe pinch bolt 10 lhe ~ lorq .... Mnlng. 6 fining \he Inl' ~ and Ip<\ng& 10 the Ink, bKkplall II I .......... of lhe .....ov.. ~ SomI ~ wiI be 1-*110 align lhe ~WJth the pivot and OpImIngcamwhltlllil ... lhe Ipting in Pl*lion; ora Ihty .., c:orrlClly .,igned. Ihty c.n be ~ bKk inlo poaitIon by pr-'ng downwardll 10 ...a(I m.n inlO

r.,......

,,,,;go...

-.nona

....... 7

u_

u.... the drum 1UI1_ fof . . . of IIQOnng. _

beyond the

....nc. limit Of oil COflI.lmIfll\Jon. AI of 1 ' - c:ondillOl\& will impao. twlk"""WII;...-.;y. 1 1 - . all

....,. bn.oth.

of dull. PNfetlbtv ""ng' brau UIIdng c.rI 1"101 10 ........ tny of it.. II it ill of .., ~IOI

Chapter 6

Wheels. brakes and tyres

natu.e and cons.equemly harmlul. Remove oil '" grease deposils. uSIng soIvem. II deep KOIlng is lIVident, due III lhe liningf haVIng worn Ihrough til Ihe shott al some lime. 100 drum must be skimmed on II laloo..... rer>ewed. Whilst lhere are firms who will undertake to .k,m a drum whilst II is lilted to lhe wheel il shoutd be borne in mind thaI a.tassive skimmIng will change the radius IIllha drum in relatioo IlIlhe brake shoes. IheMlore reducing the lriclion area umil extensive bedding in has taken pl&c:e. Also full adjuslmenl 01 the shOll'S may not be possible. 1/ in doubl aboullhis poinl, the advice 01 ooe ollhe speciaiisl engineoring fi.ms who undertake Ihis wor\; should be slIught 8 Relil the broke rn.ckplalo assembly to the wheeland .elit the wheel in the Irame. using the inlo.mation in Seolion 5.

IS

Tubed Iyru: remova~ repait and ... lilling

I To remove the Iy.e from eilhe. wheel. firsl detileh the wheellrom the milehine. Deflate Ihe Iy.e by .emovir>g lhe valve core. and when Ihe tyre is fully deflated. push lhe bead away from the wheel rim 00 bolh sides SO lhal Ihe beed enters lhe cenl.a well of lhe rim. Remove the locking ring and push the ty.e valve inlO Ihe IYM ilself. 2 Insert a tYM lever close 10 the valve and lever lhe edge of the Iy ... ove' lhe outside of Ihe ri"'- Very liltle lorce should be necessary; ~ re.islance is encountered it is probably due to Ihe lact Ihal lhe lyre beads have not enlerad Iha well ollhe rim. ell tho way round . On TZR models nOle Ihel damage to lhe solt alloy by ty.o levers cen be p.evenled by the use 01 plastic rim protectors. 3 Once the lyre hos been edged OVer the wheel rim, It is eesy 10 work rllund Ihe Wheel rirY), 10 Ih~llhe Iyr~ i$ completelv Iree f.om one side. AI Ihis stage Ihe inner·,ubecan be Mmoved. 4 Now wo
o.v

pOims. If the tyre is ur>evllnly located On the rim. try bouncIng the wheel when the tyre is at the recommended p.essu.e. II is probable lhal one of the beads has OOt pulled clea. of the cent.e well. 13 Always run the lyres 8t Ihe .ecommended p.essu.es and neve. unde.- or oVe<·inllate. The COf.ecl pressules a.e gIven in Routir>e ma.ntenance. 14 Ty.a .efining is aided by dusting the side wells. particula.ly in Ihe vicinity olthe beads. wilh a libe.al coating of french chalk. Washing'up liquid ean also be used 10 good effe
16 Tubelellly',,: .emov.t and .elitting

t It isstroogly recommended Ih8t should a repa;r loa tubeless Iyro ba necessary. the wheel il removed (rom the machine end ta~en III a tyre lining specialist whO is willing III do Iha iOb o. laken 10 en official dealer This is because tha lorce .equi.ed to break the seal belwean the whael rim and lyre bead is tonsidll.able and considered til be beyond Iha capabililies III an individual working with nllrmal tvre .emoving 101111. Any abort iva anemPI III braak the rim to bead seal mey also cause damaga 10 the wheel rim. resulting in an expensive wheel repl&<emenl. If. howeve,. a suitabfe bead releasing 10111 is availabfe. end e.patience has al.eady been gained in ilS use. Iy.e removel and refilling can be accomplished as 1001ows. 2 Remove lhe wheel f,om the machine by following Ihe InslfUCtions for wheel Mmoval as described in lhe relevanl Seclioo of Ihis Chapte<. Deflale Ihe lyre by .emoving lhe valve insert and when II is luliV dellated. push the bead 01 Ihe Iy.e away f.om the wheel rim on bolh sides so Ihatthe bead ente.s lhe cenl.e well of Ihe rim. As noted, Ihls opa.alion will almosl certain~ .equi.e Ihe use ola beed .eleasing tool , 3 Insert a Iy.e lever close 10 the valve and lever Ihe edllO of Ihe ty,e over Ihe oUlslde 01 Ihe wheel rim. Very linle foroe should be necessary; if resistance is encountered II Is probably due to the laCllhellhe lYre beads have nOI entered the well ollhe wheel rim 1111 the way round Ihe lyre. Should the Initial problem parsist, lubricalion 01 the tyre beed and Ihe inside edge and lip 01 the tim will facililale removal. Use a r
Tyre changing sequence· tubed tyrel

~ A

Deftat& tyre. After pushing tyre beads away from rim IIanges P'l&h tyr9 b&ad Into wen 01 rim at point oppos~e valve. Insert tyf& IflVE!< edjacent to valve and work bead over edge 01

'm.

UI!oII two IflVetS to work bead 0_ eclgtI of rim. NOI& us& of rim protectors

~ Removl:l innfl( tuba from tyre

When ftrst bead is ca. tyfe as shown

ren"IOVl:I

h

When fitting. partially inflale

~ InnE!< luba ar.d Insert in tyfe

Work first bead over rim er.d ,~ valvl:llhrougl> tIOI& In rim. Partially screw on retaining r.uI 10 hold valve in place.

~ G

Chock thatlnnE!< tube Is positioned COIT9Ctly sod work tleCond bead over rim using lyre levers . Start at a point opposi1e valve.

Work final area of bead over rim whilst P'lsNng valve InwiU"ds 10 ensure that inner lube Is not !nipped

Chapt.,6 Wheell, br,k . . .nd lyres

'"

HAND

/

lola of ..... 'KpIfIenOId. bKauM thlnr • no _ lube 10 IUIIttnr. In I'lOtIllII eondillO!'11 e IUtkItn bIow..out i& II¥OOded II 1 puneltnr of lhe tyre occ:un.. lhe tyre JhouId be r1ImO¥fId fo< lnepec:toon 100" da""", betore IIlV 111111\91 • made 1\ remedial aclion. The temporlry rtlPI''' of 1 punc:tured Ivre by ~'"'II 1 plug hom the OUI" thouId not be '\llmPlloII. AAhouIJh I..... type 01 lemporery ...,.... II UNd wrdeIv on cera, Ihe """""'lCIurfIrI Ilrong1y .--nend In" no su::h ....,... • .:erned out on I molorcyde 1yN. Not only don the tyrtc ...... I ~ eerc:MI, """"""" don not .... IUlfociolnl ItrfIpOr\ 10 lhe plug. bul "c:onHqUII"ICM of • ItrdcMn o.IIal00n _ oftlll lUfliellntly MnOtII IhIIl the !ilk 01 su::h III oc:cuoreroc:e JhouId be I¥Oided 1\ all toIIlI 2 The Ivre.hould beinspecled bothinlide .ndOUI fordamagor tOl~ UnfO<1Uf\1letv the in ...... lilllng of lhe Ivre wIlic:h taka t~ pIac. 01 the Innet tube ....... eMIly obIcu.. Illy ","""""lind _ IIC~ is <equo<ed In maI<"", I c:onec:! _ I 01 lhe IV'" oonditoon. 3 TheIl .... two ""'" tvPII of ty .. repeor which .... c:orIIoidefed uftr lor Idoploon in repIoIf'IAII tubliell motorc:yde fynIa. The firsl IVIM of reparr coneiI .. 01 ~ing I muahroom-heIded plug '"to 11"11 hole from the inside of the Ivre. The hole;' Prl"Pllred lor inHnoon 01 lhe plug by reaming lind the .pplatoon of In Id~ The MGOOd reparr is .,.med 01.11 by bulling Ihe irv>et lining in lhe damaged .... end Ipplying • ~ or ~ PI1th.1ItcIoAI both inspettion end '1IPIi<, WIhIy ... to III .:erned out MleIy, 1IqUIII1IC_1n thillVIM 01 WO
urc:...

FLOOR Hg. ' .14 Method 01 ..'tingl'" b. .d. on lube'... IV'" Iu.g... Here 8511'0. IhI 11M of I Iutwlc:wIl wiI IIMI fill,ng II it ~ ........oed strongly 1'* when refilling The ..,.. only . . . . . . . . . odoiod 1uI:Ir\gnt .. used bK.-1UCh IubrieIontl" howoIlUIing ~ DonollM_generowlnt.... ~lOfIotlubriQo1lorIyreC'...,may

9-~ fiUtng the uppet bud .. aimllar to fin,ng lhe low", bud SlIIn by _"1"11 the bHd OV8<,he nm end 1'110 the we.. III poilll diamenlc8lly QI)pOI5ile tho tvre vatve. Continue \¥O!1I:ing round !/'Ie tyfl, neh elde 01 , .... '\¥Iing point, .....unng tI>M the bud ~I. lhe WOflu"'g .... iI Mw~1n Ihe-'l. """"'~ _ - v . Avoid UIinQ..,.. ........ ........ 1ObPo.II~ _wi. 10 help ..ooc. ~ 10 the toft wtIMI nm. ThoI.- of ~ IhouId be -.quorMl only when the r... portiOn 01' bud isla be ~ 0Ye< the rim. , 0 Lubricatflthe tvtt bNdI togIIin prior 10 lhe tV", .,1(1 check IhIIl the wheel "m Is _Iv j)O$Itoonld In "11,,on 10 lhe tyftl bNd •. Inflation of the Iyrl may _I' PfOVI imf)OH,bIe Wllhoo." lhe UIe 01, high prMIUN .... !'10M. T .... lyre will ..n_ ... compielety ontv when the budI -firmly av--11he nm tdgR ~ -" pain"...cI ~ ....... be found

u..

""',;ng

"'*"'"

.-ury.w..

,",.,rded

....

5 In!he ......1 of lhe """'-.boI'IY 01 , ...... IV' .... 0Id01lllY lubed tV'1I "nloll wllh inne< lubes oIlhe ClOITeCt ..U'....., be filted. Refe<1O the manufaclure< or 1 IVre "IItng .pec;~'SI 10 ....... e Ih" onlv I r.,.. end lube oIlQ111velem type end IUII.bOIoIV "lil1ad, ,nd &Ito 10 ldvloa on the filtong o •• " ..... nUllO the nm hole

whIIn.-.g.lootpumpl"-t"~.llhe_ret ... It.pumped

Ill.

n. problem may Il1o be tncOUnl..-d when ..-.g .., ... ' - on •

_rvr-wl'lichn.....~~In"or .ndbywt.... ofl'profile /IoId the bNdt trNJy from the ,im ~ To _ ,hit.

drfficulty•• tourniquet may be placed around 1M cin:umlerenc. oIlh1 ty.e, over lhe ce.WlllfH of IM,re&l.,n initllllnllation it to pI"HI the ty .. into Ilwangle b e t _ 1 .... 11 .nd lhe floot W'lh lhe .irl..... Iurched 10 the"aIvir Idd,trorurl pr-... is then QlPliId to lhe Ivre by the hind lind Jhin, . . ahown In the _ par .'ng Whnl"hon. The apphcaloon 01 pr-..re ,t lour paintl I
..mo.e

"''''\JOn,

I' n.

n.

'rded

I primary ........c.ge of Ihe tubtrIeu IyN i& ill ...,., to IC:QoPI _1"!Jon by~obtIClllUCh ........ lHtwrlhoullolaof .... E....., if

Tubed",... 1 V"'" cor. MIdom ll'\/tliroubli. but do not 1111 Indelinol ..... Ow! under the ~ will.,.... \I p,Il.-ling ·Pow·punc:ltnr·. Chec:k IhIe tlIIt... not 1IIIt"", by Ipp/yong IPlltillo lhe lind 01 lhe" ..... end

"'''dq

""w __

2 A ........ ClIP • I Mllty dr.no:\I. end IhouId IIWIyI be fined ApIn from keep;f\(I dirt 01.11 oIlhe "aIvir, II p«widII 1 MCOnd MIl In .... III ......... I........ end ..... v prI¥"'t In eo:c:idem rltllJlHf\(I from IUddooI deflation. Tube.... tyreS 3 It will be lWrICiIted IYom the prKIIdir"rg Seaione m.t IhlIdopIlQI oIlublielltyfM hid made II .........-y 10 mod,fy the 'iaIve IfTIr"IOI" "-to .. thell II no IongIt IIlInnet tube whid> car> CIfJV 11"11""", __ The problem ' - been overcome by lilting I MIII"'e rubbet·bockI tvre which PIISSIIlhtough ,tloM·fitting hole in lhe rim. The ......... is fined Irom lhe n.m well.1nd Itlollow. lmot the ""'" can be ,....,.,.... end IIPIIc«I only when lhe tyfl ' - been removed from 1111 .... UrekI!II 01 ... lrom eround the " ..... bo<:tv is 'kely to oc:cur only ~ till

".w.

lUIong_t'. The"""'toreisof the _

tyfW,_

4 tvPIIlhlrl tiled Wllh tubed oc.....,. IntO the " ..... bo<:tv The COlI can be ~ WIth ....... $IOtled tool whio;h is Irw;otponrted in plunge< IVpe ~ IJIUII". Some "Ilve dolt ell» Inc:or"porate I prqe<:Iron fo< reIIIy. Ill ......... .tow..purw;ture c.IIl be UIC:ed 101 lell"r"" 'I11III_ end tlwrllhould be chrrcked beleq, goenuinor pure. M.is su.pe(:led.

norm.nv

·•••

" •••

"

no __ 01 11m

0eIIN tyra. All. ~ ~ pwh ~ '-:I .1 poW~ .......... 1..-1 ...... ~I to ........

...cI...,... --------".

II-' ov.r edge 01 11m.

-

OM two ....... 10

....

wort.

~ oYer

edge of rim

Not. use 01 rim

e.fort fitting . . . . . Itwt I)ft" IUitabIe lor wheel. r .. not. 01 W"f IIidew8II rTIII'kIngs 8UCh _ dIrwctIon 01 rocatlon ..rows.

". 5 T... " ...... dull~_ • .....,.....,tP'l'toflhetyre ........ ~ Not odIy do they preventl'- . . . . . of rOIIddin in lhe y ....... but aDo KI . . . ~..,.. whoc;h wiI ~ \he n5I< of audden ~"on il .

" ..... «nlhoukl'...

,

It ;. O;USlomwy 10 ~ , ... whee/$ c:ompIetl wllh Ihe I~ tnd.

wt.tr. fiu..s,1he 'lito.. Thoo Oo.lI-01'.to.Iance forces whoctI_t_ .....

na* and 'hi NndIing of the ........... ~ in ~,.

wi-' whidI .. t..dIv DUI of bIoIIorq produceo Itwouvh 'M II ......... ~I unpiuunl Nmtne<1I'I(I elleel I' hogh IfIII!ofIda. 2 Somto I y _ MY •• bNonce marit on 1M lidew'" -..IIy in the form 01. coIou<ed 'POI. Thil ........ mull be in line wl\lI ,he I~ .......... when ,,.,. ty\'1 ;'Iined 10 the Inner lube. Even then thewheel m.y requorto'M lKkIi\lon 01 balance ",etgh,1, 10 OHMlthe We.glll of the lyre ".rv.ltsel'

,vr.

1 II ,.... wtIIMI. r-.d dNr of lhe ground and if I5POfI. 01 Wit probIIbIy come 10 _ , WIth .... vl/w Of .... ,-,,*1 pwt downw.d and wiI always come 10 ..., in !he Arne IXI'&IlIon. BaIIonct we9lUI muM bt ..xIed 10' pOint ....... tncally ,hot hMvy ~ unlil' .... whMI will _ 10 ... , in My PQtIIIOn aft.. it ill &pm 4 Not" tMt ,\ .... V be neceua.v to •.....ov. It.. o;ool,pe< 10 thai the

_'I

wheel ill compIel&/y hee 10 rota'l Wllhoul bflke drag. Spec:ial w~" ltte ...aiLabie lor TZR w ....... f,om Vaornat..dea\efl in 1D, 20 and JO ",am sizes. IhHoi wtiQ/lti t...g conslfUCllld 10 clamp on to uch Iide of tilt rIa6d rib CM! on ,... wheel rim. WhiIIo ~ _gt>u ... not ~ c..ty listed by Y.....t..1or 1M or ITIOdIIl weoghUl 01 • suolabllo lyptI wiI be' ~ M ...... QCIOd motorcycle duIer follong~. The usual !ype II ~ 10 be c:IIompId 8found • spoke. MI<1 10 lhe rim. and wilt.. .......... in!l\lt'l'f diH_I ..,., FiNly. I'l0l1 ' ...."1 wiI be .¥ely ---v 10 bIIIInce the _ wheel bul llut the PrGC*Iure iI luctly the _ _ lor the front wheel. The only d1Ifereoce II tl>M the dn ... chajn muat be removed from the tpIOCht to allow the wheel to

Of..,...

.otltehee1v

Chapter 7 Electrical system For InrOfmation relating 10 the 1997-on DTJ25 R models, see Chapter 8

--

F.-locaIion.....t ...-we! Hom;

___ IocatIon.....tt.""11 _ _ _ _ _ _ _ _ _ _

Tum eIgnIII reI.y: Ioca1Ion tond 'Kling low oil level warning lamp drcuit: telling _ ____ CocHn\ t..... pe..-tu.. ~ cltt;ult: 8ulbl; _ e l H_. ____ HH' _____ " ___ H._... _H ___

'"ling ___

--_- --

GMJ..3B1FB3L.8

12N§..38

nv ......

_ _ _ _ _ _ __ 2SOOtpm _ _ _ _ .__

~.VlI"'"\IOIIIIgII~3000tpm.

Ug/lllng-V-II'"

~.\

H •• H . _ _ _ _ _

rc:.lt.o'9::':::::::::.~C=:fl~:-----,--'ON

II

.,.-

nA.-

G.n....tor

_N.

H.___

HH' _ _ _ _ _ _ _ _ 'H

• " 1t 12 13

nV3A><

,,,.

,,,.

....

0.3 OAohmI

13.3 U.lYOlt. 11.5 13.0Il0l11 0.3 O.5ohm1

No\~.bIe

0.24 0.36 o/VnI

10 15.JYOIII

,,.

". 12V,'510t0W 12V, ' W 12V,SI21W 12V.21W 12V, l AW 1N, m

...,." "

On TZII ITIOCItIt the pOWer for the compIet. Nc:tricaI .VI'.... " prD¥ided by • thrM-p/Iue ~Ior rnounltd on the (rriahatl left· Mnd WId. the output lrom wtIit:h II; ,.lIfiId and eomltlltd by • c:ombInMI ~1Jfi« uniI befono bein11 _ _ 10 \he ~I*V..-.d thenoI to the mIoIn ~ cin:uit. The OT modeII ~ • ..-..ch ~ . 1..... ~ by • ~ rnounilid on rhI c:.."b....tt left-hand ....t. The u.... coiII ~ on !he ~or ltatoo" pIec. independIonttv ~ IN dIatttiog,lighI.n; 8ndlgnrtion IyStem.. A combined I'fIQUIatOrlrloaifier iI fined. The -.gulI\or Iide of the unit con~ the ~ botIng ltd 10 tht bub IO~ them lromblowing Ihrough ~~ andlOlllr;'UPIM u _ current ~11d when ' .... Iioghu ... swile'*! off. Thill ~I

II diaperMd In the form 01 ....1. The teClifter convert. lhe _iode< 01 the IJ8IlIIr..Of output 10 dirK! currenl (del whietl ilthen UMd 10 chwge lhe ban....... wtlic:tI ~!he _iII
1

In lhIo_of .... ~ IY'tamfu..aIw..,..d.s!he phyIQII

00fIdiI;0n of Ihewirln!llO'ld ~ bef
Ir8ppIdOf bn;>k..,

~

. . . . 1O'Id""'*'Of~I'- . . _

.-y. ~ whidI hfvt broIr;.., in~""

not..av 1POI1ed. buI.....,

132

Ct"pt,r'

Ele c:trica l ays tt"":..._ _ _ _ _ __ _ _ _ _ _ _ __

.:.:~----"D,,----------:®",o--'..:::...----,....., ---'-"-'-WOth dill,lIed or !Iem'......liHd w.t.. only ..:!:.

-=.

wII..... subit,tutelnd do not Idd

,."""""..IIt, l

The

of

'.-It

Nev.r ....

lip

electrolyl. unItA foPiIIIIIe hili

cn.ov. of • bIIullfy can bII chec.ed .-.ng ... hyd.1;IfM-

• TlIII.-mIoIchlrge •• tefon bIIttltV "'';01 il' flledCII)Kily. lhus for • 5 II\'"oPItI hou< unrt cl'IIfgIng should ,,"e ~ II 0,5 In'IP bCMding t .... ~ c:oukI ~ lhe bllttllfy to ovlthNl. buctling lhe plllta II'Id fendering it ......... F_ ~ wol ~ ICI:IM 10 ... .,.~ WITeI'II conlrolling chetlJlt. MI if • .-mIoI dorNIlIC chetIJIt ill UMd checl thIIl.h ... poa;bIe"'\.III peek. the o;hwgI rill ''''10. IIf• ...... "Ihe bmltV~ hoto...",,~ "09. Futtlwchl!ll"'Q wi! ~ damIgL NotIINt the celc:.-shouId bllDoMned 1I'Id ........ ~uuetld cblngchwglng to IYOid I buiIcklP 01 ~ lI'Id ..k of

---

Fig. "

A

8

5 Ah.. d'II
51mp1oe clrc:uh I"t lng equ lpmenl

MuII_.. s.AJ

Cs."""

D Prwr_ pro/» E ~_probe

bII chec;ked UIiong I mull,mel" 01 • ~ bIIttOfY II'Id bulb ci<cu'l I •• conunuity I",... TI14 ....... rne
ell,,''' ' ' .

COf'* ,.pOIed ...,rf_

... nd......wo" ..... 2 The wmng h/ImIII II coIour-coOed Ind

will

~pOnd

wllh lhe

wiIi"" diIIgfam 1\ lhe end of I"" MII'IUII. W ..... "ocket COI'H'IICto. ..e

UNd. lhey ... det.igned 10 tlllli . _ t l o n can bII made only In !he comctpclllition.

3

V"IIUII inlpectoan wiI ......1y show whelher I......... eny lit_ita 01

'rav-I out.. CO¥tIf'inga which will w-. riM 10 Ihor1 eorcu,ta. 00cesi0nIIfy

• wife ....., bIIo:omII trepped bIIl_ IWO oomPOIMlln.. bteP.Ing the inner COfI but IMVII'IU 1l1li more ..... _t OUI.. ..over inllCt. Thill can give ... 10 myst.nou.lntermltt.,,1 011_ CIfWIt , . . . . . Ano!;het' IOUICe of lrouble n'Irf bII the ..-..p ~t
............

hili not lIMn pulhed,...... homein IheOUI.. hot-.g. 01 wheN c:orrt*on

•

1n'....... IIen! short_IIC11'1 oft .... btllrIICid to. chefed __ 'NI

4

Cha.gl!\8lysll m : chKkl!>glhe OU IPUI

1 ~ , .... righHI.nd atdepeoellOilin _ , 10 1110 !MII'ry, Note lhe ballllfy musl bII Mfy chl
eppropri,"

~ through 01 '" daM to • rntUII oomponent IUd> . . . , ...... .........tMr AvOO Ughl bends In It. Iud 01 _ _ wt.er. • Iud CII'1

bec:o _ '1tfI\PII1I'Id ...... ~ multmet.. 01 lhe IVPI sold by ,1Ic:t,oniu 01 motOl ecc:.IIOIY ~ 7 " you daubl your lbiI~y 10 chlc:k ,he IIIIctriClllIyslen'l. .... UUSI lhe wort to In MlIhoriIed YIITIIhe dIIIe<. 'n eny IV.,,' have your doubIoKhecked belOIt! c:onsigrII""'~~ eotnllOf'Mll1ltlO 1l1li aeflp.

....

lind.

I "Ihe light • ..,.,.. 10 bII dim 01 _tanl bulb blowing iI ... periencId. end IhI bulb fi'-"'"II IIPPN< 10 l1li .... melted. lhe lighlinll Iysl.." should bI chec;.ked to II'IMII'I tNl 1l1li .Ighl voItllQl '" being IUppIied. Notlthe bIInllfy ........1 blliuly (hergld end In good condrtlon' the 1_' illo bIIlCCUf.... 2 Remove the hlldllmp unI\, .. detcribId '"SecliOn II 3 Sel. voItmel ... 01 mutt, ....... on IhI 0 lOV ole . . . . Ind «II1I*I ill pOIIitiv.1ud 10 lhe QI"-' l"mtI'IIIlOd ~'I'IIQIII've Iud 10 m. bllc:k wi,. lermll"IIl 0 1 lhe COI'II"III:IOI. TUln lhe held""'" swilch on. check 11\111 lhe 11gh11ng d,p switch II III 10 ,he low beam pOIIitlon Ind .Ullt the lflii' .... Inc..... lhe engl.... PIed 10 2500 rpm II'Id no .. lhe .eedi"" obiMled. SI09 1l1li If this .Nd'!\8 d,lIen aignif"ICII'IUy from lhe IPI(iIlld limit.lhe !ight'",,'V-tam Is ' ....IIy. 4 II thllighh""'V-lem " 'ound lobi .. !IUII. further 11III1"", .houId tit CIfriId out to IlICIlhe ' .... lIy oomponlrll in the 0I'deI1hown below

WON heed""' "

eng....

1 Dellill of the ' egul.. chec;1ta needed to _inllln 1l1li ballllfy in good condition .., ghr.., in Roul"" _'nl~. IOQIIlher whh InItl'\.lCto. OIl f1H1'IOVll I0Il reliu'!\8 II'Id IJI"IfII bIIu.,., ell". Ball";' CII'1 bII dIngerouIlf .....1hIod1ed, fNd ClII'efuily lhe '$lIlly (nl' III:lion II lhe Ironl of lhill M........ beIoItI '111"1"'11 - " - .nd liwlyl _ 0VIf .... 01 old cIothl"" InCMI oIecckllntll.od 1(liIIIge. If ICId iI_1IowId 10 into your eve- 01 OIl 10 your iii... IIuIh it IWIy woth copious. quentit;" 01 f-" _I .. end - " ....... Idvic.e itnmec5IIety 2 wtMIII _ . lhe bell.,., II filltd with .... eleclrdyt.of diut, sulphuric: ICid hiving , specdic II'IV"Y 01 1.280 II woe (88"1'1. ~I IVIPOQIJOn. which oc:c\Q in nonnII ...... can bI ootnpII'IIIIld fOl by

"*""

Llghl"'ll f;OiI .....ltnCI. see Secllon S. Ibl Allw'IchII. wiring .nd conneclon., _ leI RI!IIJIIIIOII_tlfill""",1. _ SecIIOR 7

1111

Section 2.

If the rIIding II COffecl .nd lhe ' .... 11 PltMu. check 11\111 lhe bub filled _ oIlhe COIfec:t vo/uvI end w.lI. . ~ lhem ~_ 1Ify. If lhe bo.«lt ... of the COffecl rill""" IlIIIflllh mull iii In lhe wiring 01 buIbhoIder whid> IhouId bII checlld .. dIIcribed In Section 2 01 "" 5

""',.

"'H~~H

!l

,

I:;

~

" I!

N

'I R

!

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i~ill

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f g,i

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iii f 'lWi ~Il

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Pi tnHi iIi Il~l" o

.

"pi

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i

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€

Wli Hli! ~_ Itr ~_ II

:Br:Hlli

.~,~j!_t!i

11'j!"l h

;'l':;!'~

•• 1" -l~ ,EI li~!

"~-

iPi_h~j" i ...... "iH~!

lil~II!~I-j~ ltl~~111Ili~ ' . - '. ! j U - II,;

l~l~ll!~"i! f~1. liil'~lt i~11,;~Ii! ijJ'Zi!i!;li1

1'1 ."g' .11 lU~~! i I iJ! II!;!) IJI)I i!J11 't 1!' f'.;~{ j _It jH In !!' ~N Ifll~

ilI!t!~g! !jf]llllijti !'!]~" ~IZ "21,.-£

"i

E

I

I

IZ !~lr' ~!,

f'lf! -~ ·j'~.~ -!li'l iI d,· 11(1'21{t q!··f:i!~hll ..~.~~ ~l~ i"'Ih'" '·1 ;" !il

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€".t!

11·!~·lfhHI 11'1 " ;'P!tih~ IhWHH

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~ '"i!.>l I !l~~.!J!!iiI is h!\liII !!,. Ii" ';j.!

:H:ij mil 1:1

, 34

Chapter 7 Electrical system

8.6 Remove from StOp lamp switch as desc:ribed in text

8.7 Rearstop lampswitch location TZR125 shown

the fro~t StOP lamp switch and the remarks made abova can be Bpplied. Datails of switch height adjustment can be found in Routine main· tananca. S If occess to the wiring connectOrs is requirad nOte thBt it will be necessary to remOve the seat.

outside may lerve to free Ihe internal contacts. If this fBils. the horn must be renewed 05 repairs are nOI possible. 4 Different types of horn may be fitted; if a screw and locknut is provided on the oUIslde of the horn. Iha inlernal r;onlllClS may be adjusted to compensate fo' wesr end 10 cure a weak 0' inlermlttent hom nole . Slacken the locknut and rotate slowly tne screw unlll the clearesl and loudest note is oblained, then retighten the lock nUl . If no means of adlustment Is provided on Ihe hom fined, il must be renewed.

Nautral.nd .tduhnd switches 9 The nautral and sidestand switches are coverad in Chapter 4, Section 9,

9

Fusr.loc.tion .nd renewal

1 The electrical system is protecled by a single fuse wh;,;h is retained in II plast;,; CIIslng set In the battery positive« + f 18rmin'llead, and is clipped to a nolder next to the battery. if the spare fuse is eve' used, replace it with one of the correct rating as SOOfl8s possible. 2 Belore ren8wlng a fuse that has blown. check thot no Obvious short circuit haso<:currad, otherwise the replacement fuse will blow immedi· ately it I. infl(lrte<:L II is always wise to chack the eleclrical circuit thoroughly. 10 trlte-e the fault and eliminale it. 3 When a fuse blows whilelhe machine is running and no spar8 is available, a 'gel you home' remedy is to remove the blown fuse and wrap it in sll"", paOllr before replacing it in the fUie holde<. The silver pape' will rll$tore the eleclrical continuity by bridging the broken fuse wire. This e.pedi&l"ll should never be used if lhere ,. evideoce of short circuit or olher major electrical faults. otherwise more serious d~mage will be caused. Repface the 'doctored' fuse at the earliest possible opportun'ty. 10 restore full circuit protection.

10

H,,,,, , IOCMlnn and la$lin9

I The hom is mou~ted On the bollom yoka of the TZR modals. and is bollad 10 Iha frame. JUBI below the radi8tOr, on oT modals. No main. tenance is reQuired other than regular cleaning to remove road dirt and occasional sprayiflg with WD40 Or a similar water disper&&nl spray 10 minimise inlemal corrOilion. 2 If lhe horn feila to work, firsl check thallhe ballary is fully charged. If full powe< ill available, a simple test will reveal whether lhe current is reachi"ll the hom. Disconnect the hom wi .... and substitute a 12 Voll bulb. Swilch on the ignition and press the hom button. If the bulb fails to light check the horn billion and wiring as desc:ribed in Sac:tions 2 and 8 of Ih;' Chapler. If Ihe btolbdoes light, the hom circuit il proved good and the hom itself must be checked. 3 Wilh the ho,n wirll$ sliII disconnected, conr.ac:t a fully charged 12 volt banerydirectly 10 the horn. If it does not sound, a sharp lap on the

11

Turn sign.1 re',y: lonlion and testing

1 The tum 5ignal relay is a sealed unit black plastic unit, rubber. mounted to protecl it from vib,ation. On TZR models it is mounted 00 the rear mudguard, betwean the oil lank and expansion tank fiIlar eaps snd it will be necessary to remove Ihe seal to gain access to it. On DT models the turn 5ignal rlliay is located btlhind Ihe haadlemp uni~ necessitaling removal of the headlamp fairing and unit. as described in Section 14, before it can be reached. 2 If Ihe tum signal lamps cease 10 function correctly, Ihere may be any one of several POSalble faults responsible wh;,;h should be checked beforelhe relay is suspected. Firsl check thsl the lamps are correctly mounted and that all the earth conneclions are clean and tighl. Check that the bulbs are of Ihe correct wSllage and th8t corrosion has nol

~pte.

101 HomIoc:ll\JOn

7

EIeeme.I ,.,.tem

11 .1 b _ and behond heod\IImp o.rit 01\ or

TZR modII

"""" 6e¥eIoped 01\ the butt. or itll'- haIderL Any IIUCI'I ~ mull be thorougt'ly cIMroed of! to _ _ proper bulb conlX'l. AlIoo check tNl the turn IIgo:\lII Iwltch ill funo:tjonjng COrNctly and lhI1lhe wiring 110 in good ora.., Finelly ensure IMI the i>Mlery ill o;ht
"*'

.oov.

'"'11'1\1

checking the! .. OIher lilectncel cIn::uItI wort property. then cIiIconnKt its wire lrom the IMder uM and cMct t ....\ the ignition IIlWItched on. The temperll .... g.IIUgII MellIe II'IoIM poinl tO 'C. Earth the MOder unit wire on !he (ytinder hud, whereupon the needle II'IoIM immedIIt ..... awing ov..- to 'H., Do not unh 1111 wire lor more IhIn 5 ucondI or till

gauge may be demasled. Iflhe needle moves II dHcribed lbove. I laul\ in till t.mperlture tender "";t II Indicated and It thould be ",moved from till held for lurthef tesling II dHcribed below. Ho_er. if the needle ltill to mGIIIIt, lhe OIUIII' or wlnng II faulty Ind IhouId bIII...,.,;ned 1uI1her: prcxeed to

3

Pl'8ll<1I'tt 8. .. To _ the ' - ' " "";1 dIIconnect the WI" Ieeding to It. then tll<:1len It .-.ng.auot.lble spenner, Untctew the unit .. I..t .. ~ and withdraw It. .wlftly plugging the opening to .top 1111 oooIent eKaping. Refer 10 peragreph 5 for tMUng deIIiII. On retitling ~ the COFIdi._of_,...&ng ....

1 n.. COfCU1 conMlI ole ..-de< unit. _ t e d in the top 01 the oi \.IIIIk. and \tie bulb itMIf, which II mounted in the Nt/OO'Olrlt peneI (TZR mod-'! or in the c.o;homet. (OT modeoIt. 2 Wllh the Ign/Iion IW.tched on. and the t,.-nInIon in ..... trel. the oil level _!'ling '-"P IohouId light up . . . dlKk that u.. •.,.tem II

worong. n..'-"Pthoo.IIdgooutftllOOl'l" thet~1t put into

0tM. If not. lhere II Intufflclent oil in the tank; top up the t....... detcribed In Roullne mlint_ncllt and check ~In thet the Itmp IIOH out. It thelamp 'I~I doH not goout or doH not comeon ft lillhe 'VI'lem II faultv Ind fTIUIt bechecked. l If the bulb flillo to IIghI Il .tI. the mott liII ..... _ of filiure w1U be. blown bulb. buIlt II ~h~ing fi ..1thM lhe bftlery II "'tv c'*vell, ehKt lhI1 .. OIher ..,.'_l1l1I wo"""g normtIIv ... ep.oiek Itll oIlhiL n.. bulb 110 NITICIVed and refilled .. detcribed In Slttoon I. of 1M ChIpt. and Section 17 01 Cl\lc:lter 5. .. If the bulb ill in good CCII'IIIIitjon the leult mull III in !he lwitdI or in u.. wonng. a-. the ..........t wiring. .. dHcribed In SectIon 2 01 !hoi ChIpt., UIing the WIring ~ ft the end of IhiI ChIpt ... to traoIthe Orcurt. If the bulb end .....w;ng l1l1I in good condi\jon the leult fTIUIt iii in \tie t.....·_ted ..-de< "";1. 5 RlIfTIOIfIIttheolleYelw.nlnog..-de
1 _

The eioeuit oor-.tI 01 the..,.;ier .....t mounted In the cylinder hNd ... ,..::k-.1Ind the g.IIUgII ~ mounted in the Nt/OO'Olrll peneI rnocIeIl or tachometer (OT modIItII. To 'tlllhe ..,.,..... fQt """"" that the bellery It tuev cn.,ged by

(TZR

2

_-...Ingltif~,

_ _ I ...

a.>detunit into pIKe: donot 0YeOIInt t.... perllure Mnder Ipp$Ifl. 10 be faulty It can be 1"led by ~ III .. t1tPnclit II VIrioul'INTIperl' ...... To ICC()rI'IpIish this II will be necftIIrV '0 ~Iher together 1 healprOOf contllner 1n\0 which the tender t;IIn be placed, • bu",., of.orne clMcriptoon (I gN.powerwd GImPIng t.o.orr- would be 1duIl, I IhennomIllr ~of..-...tngbe'_«l·CIndI20·CI122·F 2"·F)andlfl otwnm.!.. or muItomet ... eapebIe of ..-.tng 0 200 ohmI wllh • ........t>Ie de?w of 1CCUrICy. 6 Fil the conI"'" WJth cold wal. and IrfI"III the . . . . unit 01\ ..",.,. __ 10 tNl lhe probe end IIInvnerMd in it. ~ _ 01 the

u..

......1

IeIocN to !he . . . . bocty and the OIher to the \IrlI'W\IIt SuIpend the tnermorneterlO ,.... \ the ~ It doH to the Hndet probe. 7 SIIrIIO ..... thewal .... and noteof the ....llnCereeding.,

met ...

mil,.

Chapte r 7 Elec:triullv. tem

'"

14.2. 1'181_ hNdlamp unit by 'em<)\/'ng

14.2b .~ Of screwt (TZA modeIl __

14.2~

._ ....:! ... nf)Iogging wiring conneclOt

the boilS IDT modell.,

14.2d P6t\lng "mp bulbhoIder~. bayonet fi. in headl,mp uM

14.3a Removerubber cover

the temperalure ahoWf'O in the table below. II the unit doH rIO! give readings which approximate quil' doHIv 10 thou ,!'!own i'I mull be

renewed. Coo!8(lII&mp&fltur.

sooCP22°fl 80 0C(17soFj

l00 ' C(212°F)

Sender reSIstance

153.9f1

262 2S.:m

47.5 56.8Il

'ppe'"

n.

14.lb _. then bulbholDe. nne ...

2 Remova both the headtarnp retaining bolts (OT models) Of Ie'a ..... (TZR models) end partially wilhd'lw the headlamp auembly until the w,ring can be reached. Unplug the headlamp bulb winne connectOf. then ,amove the pa
lithe gauge 10 be faultv. dismantle the 1... 'I\Imen\ PllneI. OS described In Section 11 of Chapter 5, end check !he ,"118(1\ wiring and 8

connect.". .. described in Sec1;oo 2 of this O>.ple<. If eIIeppu.. 10 be it will be necllSHfY \0 check the power I
IwitCh Iidoe of the wlrirl(J.11 the I Wlich ia in. good condition there ahould be cominuity between the termin.all when the switch is in the ON position and an Open eircuit r.,linile resislanefl} when il is in the OFF position. II the ' Hulls are not IS IIhown the igllilion switch must be

~". I 0 If the tlllts carried OUt on the sender unit. ignition s wilch and wi""O show that they are in \ICJOd condition. the f.ult must be in the 9II
14 Bulbs: ..... w .. H4IMllamp and INrI
14.3c •.. and withdraw he&diamp bulb

14.3<1 e....... re I&goI 0fI bulb loce1e Nulol in tleadlamp ref\ector

14.4 Insuumem and waming lamp bulbholdef'l .... a p<_ fit in panel

,-""

be lilted OUt of the unit. The Pl'rlcinCI lamp bulb should be preMed In and twilted .... ucloc~wise to relHse It from Itl hoIde<. On refilling make""re the tabe 00 tile tleadlamp bulb eot'eclly P05itOoned In the 'efllctor Check lhe tleadlamp bum I8llings. II det<;.ibed In Routine main-

If.

_ ... ".R=

'0 PlIIktngt.mpbulb

RellectrKutlSI

Retllirnng qx;ng

12 HeMllMnpIhell 13 ~ 20" 20"

14 ~

8 !l

RvbbMcolI.,.

15

BHmMijuSlmg_ >off Sprmg 20" Nut 20"

16 ()amp'ng~ 17 SpacIJr 20" 18 Nut 20"

o.mp.ng~

tenance. Inltrument llI"mlnl1lng and warning lamp' 4 An I'. filled inlO bulbhoIdef'I which _ prsssed into the ~ of the insuumenl Pl'nel. Ref •• 10o..pl8t S. Sec:\H:>n 17 for det.il. of the worlc .-ury to .alldlthem. 5 Unplug the buIbhoIder concerned. then 'emove the bulb. All the bulbe Ire of the ClIpieM type which simply pull out of the hoIde<. On .efining. taka cere 001 to dlfT\llge the fine wire "ilt; of the bulb. and 8I1IUr1t thaI they are pushed fullV into their contlCll. Tum IIgnal •• nd .topflai".mp 6 With lhe e~cePlion of lhe tan lamp 0fI TZR models. all1amp Ien_ I" .etained by screws. Remova the ,.tl,ning sc.aws whi<;h the lamp tens end withdraw lhe tellS. In the case of the TZR model t.illamp. carefully prill tile tenaout of its retaining lugs and Hit it c\ea,. Note that it ",;gIlt be.-sa", to first remove the small Pllnei from beneath the

ne",.

CNopter 7 grab rail 10 gain

Elec:triul lYltem

10 IMae lugs, On In lenin make AI" tklll It.. sui betw&efl the lenllfld body is not c\eITIIIoCd. ",newing it i11'1CCe$oary. The bulb lhould be preHed in.nd
,.

Fig.. 1.4 H••cH ....p

Refilling il lhe rlVefH of the ten"IO"O'll procedu .... Note !Not on It.. slop/IaiIlamp bulb the locating pins ere ofIMt IJO 111011110 bulb (;tn only be refilled I.... COI1"ecl ..,IV, Do no! O'IIert;ghu.n 1.... 1en• .,;rew. Of \tilhe<

1

I .... IeM will be CrICked Of I .... piHtic: bcdv

~

DT model.

R~

Refl«;lorunir 8oI/ · 20H Spiar · 20ff Gromtn.H - 2 off

-""" ,,-

wi. be demIged.

9

-,,,,,,,,

Rel.ming spnng

9

8u1bho1c/e1

10 Rubbt/roov. II Padung '-'P bulb f3 /e 15 16 /]

8Nrnlldju&rlf>{JJ
20ff

W~ - 20H

Spring 20H NUf 20H CiIp _ 4 0ff

/' HeM1I8mpI,,"IfJ 19.sa- 20"

II

'!

"

•

,.

~"\W" 14.611 Tum signellemp IenseI are ,~ained by two IerlWi on TZR model _

14.Gb '" end I tingleKfll'N on DT model

14.6<1 T .... DT model limp IeM iI .."ined by tWO ICf$WI end use. " tingle bulb _.

",Imined by lugs (I"owed) _

14.68 _ wtoe._t .... TZR model ...... It

14.61 ._ end UWI • lwin bulb '''lIfI9EImenl. Note ol1set pins on bulb

Chapter 8 The 1997 -on 01125 R models Contents Oil

Introduetlon RoI.Ibne;

"*"'-.0.' Int ....... _ lQ99.on ~ __

~"",,",

~

- 1999-on models

~ WId ~ thoI YPVS c:ompoowItS - 1997-00

4

~ren-.I-lIK11-on~

AImcMng WId I'IIIittJng the generator - 1999-on c.rtuwnor: ckmImIong - 1999-«1 models

~

~II'4YPVS""'-1997-onmodels

;~~-1999-(11'1~

5

8

IgnrIIOn . . . " _ ll1111k1n modeII ~ whMI:""-- - 1998-on modeII ElectrIcIIsyst_ - 19S11k1n rnodItI

Specification, Model dimensions and weight - 3RME 1999'00 models o-.I~'"

2170nvn(85....) 127 kjjI (21fIb)

~-....gr.t

--_.......

Carbllrettor - 3RME 1999-on modeJs

..-

w_

-,. -,.

~

from top __

Ttvonle wIYe ~

.......

NI _ _

, ""'" •• ,., '" "" "' '"see

3RM02

......

NMdIe dip poertiOn -

....... ,..,...

.

",.

.

~out)

""'--..............

15.5 _ 18.5 mrn 10810 - 0.650 In) ChapI. 3, Mellon 7

F......... Ell{IIfWkIe Ipeed

--

,JOO-l"1Xlrpm

Engine lubrication - 3RME 1999-on models

"-

020 - 0.2. min 10,008 -0.008 in) 1.35 - ,.11 mm 10,053 -0.0581111

Ignition system - 3RME 1999-0.1 models a.n.raotor taurCI COil ~ -

...........

~.IO ~red

888 - 1032 ohm. 2O"C

....

,.S

'-'

Torque settings YPVS pulley ~ mounllflQ bolts .

YP\IS puIey ~ boll YPVS va/wo cap . . . YPVS va/w retaI'WIg AIIWI bolt

'-,

,.,,.,

" ""

• • 7 8

• models • •••• •• ••

e

10 11

12

Chapter 8 The 1997-on DT125 R models

140

.... 3 . 1.

Remove the oil pump COV8f (arI'Owed)

3.1b ... check thallhe reI--.ce marl<. W and Nne (B) align with the Ihroltle wide open

Introduction ThIs chapter c::owws the following OT125A 1TlOQe/$: 1997 3AM9, 1998 :IRMa. t 999 JRME. 200011 3RW and 2002 3RMM n'ICl
Introduced wIIh the 1999 JRME model, including I new design of oil

3.1t T...,!he o;abIe Idjust. (arrowed) 10 tho! setting if ~

(:()ITtICt

hold it In Ihb; position. The line on the end of the 011 hose lPon should align with the ret.ence marl<. on the pump puIev. If necessary. loosen Ihe locknut on the oil pump cable adjuster and tum the adjust • ..uN the pulley • In the correct position with the throttle IWislp 1liiy open. TOghten the locknut and check !he aetting. then refit the cover. 2 Nota tl\iU the 01 pump cabIeIIhroItIe cable junction boK it of '" diIIerenl design and cannot be dismanlled. If II'Ief* II '" raul! with the jooctIon bo., or If ther1I hllnsu1I\ck!Inl tM:I~tment In the cables to obta&ol Ihe <:On'fIet setting tor tho 011 po.mp, fit • __ ~ eSMmbty.

Pl)'TlP. generator. COl unit and regulatorfnlctJfief. When wcrtIng

on 1997 or later models, reler lira! 10 this Chapter lot

the Ini0000000tion ~. If no mention 18 made, the task IYII be the _ as for the DT125 models covered in the ~ Chapt... 01

""""""".

RoutIne maintenance: intllfVsl. - 1999-0n moOela

EngIne/gearbox removal- 1997-on modals 1 In MkItIon to the procedufe deIcribfId In s.ction 4 01 Chepter " JlOte that the oil delivery pipe 1$ now (:(IMO!oCted to the InIeI stub and not to the carburettor. and dOM not need to be disconnected at this Itage. 2 It will be necessary to disconnecl the YI"VS cables and ...-nove the ..-.omotor (SectIon 9).

SI .. monthly, or evIllY 4000 mlln (6000 knit ChecI< Ihe 011 pwnp cable adJ~1 (S«tlon 3) E't8Il' two

~

or 16 000 miles (24 000 kin) Change the tl'ansmisslon oil (Routine maintenance)

m_.

Routine maintenance: additional operations - 1999-0n

I Remove the 1ef1./wIfId crankcase _ and the CO'IfIII gasket and undo the rotor centre /lUI 88 described In Section 14 01 Chepter 1. Not. the Large pIaJn washer fitted behind the centre nul. An extnoc1or or puler be needed to draw the rotor 011 ~$ taper. A IhnIe-wev puller can be used II three bolts ... h i _ e d Into the three t/YeacIed hoIee In the rotor. -.ring the bolts ... not IICfewed In 10 th8I they contact and d/Imago!I the stator ooils. The rotor can be prevented from tumong by holding it with a strap ....-.ch. W~h the rolor removed. not. the WoodnJII key In the creoksh8ft and flIIllOYe it WIt Is loose.

wi.

Cheell the 0/1 pump c:able adJulu...n1 1 first ensure that 1here lathe 000'IICt IImOI,a"lt 01 free pIIIy In the ttvortIe cable {FIouIine mamlenancej. Remove the oil pump cov. on the right· hand side 01 the eogIne and t..m the throttle twl$tgrip hAy open and

5.18 A large washer is fitted behind the generator rotor centnI nut

Removing eod refitting the genemtor - 1999-on models

5.1 b TlwMded holes In the rotor (BrTOWed) fadlitate the ...... of •.

'I!(

5.1e ... allv$e-wev puller

'4'

Chapter 8 The 1997-on DT125 R models

2 Trace the generalor IIiirIng Irom the stator and diIconneet ~ at the connector. then remoYe the dip aec:u!Inog the wiring 10 the stalor backplate. UnOO the Une ~ secuMg the ltator IISSo8fI'ltlty and hit

Chapter 3. Note how the seat fits OYer the ~ retaining plale and _ It Is Iitled the correct way ro.n:j on 1'NSS8I1'IbIy.

~~' ~howo!:..~~b:at~ ~~'::"bIy

_'_ _

•

1 The IU11P covar and pump he .... been r8(IeaIgned, but the pnx:«Iure lor removing them Is stilt asdelcribed In SectIon 14 of Chapter 3. Note that the oil pump/aankcase joint II; now -*:I with an ()-ring which should be ....-ed if the pump 1I1'8I'I'IQYed. 2 The oil pump stroka Is noI adjultableo. 3 To bleed the pump. follow the procedtn doMCribKI In Soctlon 16 of Chapter 3. but noIe that a plastic cap and spring eIip .e now fitted to the bleed hole on the lower edge 01 the pump body In place 01 the bleed aaew. Eneure that the spMg clip II; comtCtty Installed on the cap after bleeding the pump.

on the backplate, ....urIng the IIiirIng grorrrnet Is correctly located In the casa. and tighten the !tow KteW8 to the" torque setting spedIIed al the botgming of Chapter I . SeCIn the wWr!g with the clip and IInSId It II correctly connected, Follow the prooedure deIIo1bed In SectIon 36 of ChIIpter 1 to insl. me rotor, 4 Cheek the eond~1on of me 00'0'er gasket: Wh II damaged. discard ~ and lit a __ onto Maq I l n the gasket II property dipped In place belen Installing the 00'0'er.

Carburettor. dismantling - 1999-on models

o_"Cpu_mC'_-_'_-__M_m_ode __'._________ 00_

1 In addition to the procedure desa1bed In SectIon 5 01 Chapter 3,

~.'~:an~~;:n~~=IIU:=':

8

In the C8Ibo.IretIor body and should be ..-wed if It tIaI become ~. 2 The tt.ottle cable Is I8C\.II'ed In the thronIe Y8Ive by a plastic eprtng _ , whic::h Is Allained by the carOOtettor retLnl eprtng. To detach the cable follow the pn:x::edo.n deectIbed In panograph 5. SectIon 4 of

1 Remove the power valYe puIey covar on the ktft'hand sIdIo of the ~ bam!II. SWItch the ignition ON. The power Y8Ive will 0JII'f1 and dose !INS II a self-cleaning function which 0CCUts ..a. !lme the

6.2a Note which way
Adjusting the YPVS cables -1997-0" models

142

Chapter 8 The 1997-on DT125 R models

V'J and power valve pulley (8)

8.2b .•• before aetllng tile cable Id/Wtment

11.1 S«vomotor pulley

ignition If; t.... ned on). With the valve . t ..,.1, check thet the notch In the pulley aligns wtthlhe hole In !tie rear 01 the housing. SwItch !tie ignition

~, If ~. disconneI:l the ...-.omoIOO' wItIog COMeCtOO' and unbolt the a.vomolOO' from ~. moonting br8cI\eI. 3 RemoYe the cylinder heed and barrel as deeaIbed 10 Section 6 01 Chapter t. 4 Undo the sentw...:umg the right-hand power v~ .,..;I cap and ..-nove the cap and O-ring. " - ' e ~ 01 wood inlO the tlffia\>$C port to pw«lt the valve turning. U- unscrew the long Allen bolt which HCIftIII the two ~ 01 the valve together. Withdraw the right·hand vatve half. then the oil seal. valve sleeve with O-ring and left-hand vlllwl hall from the cyIoder barrel. taking care not to lose the two doWfII pins wtIIch ~iO'11N v.IYe IIaNet. 5 Check that the power vatve compooents ... clean and fI'ee from carbon deposits. F'"~ the dowel pn. in one hall 01 the \l81li, and Install the two haIYes as shown In Section 43 01 Chapter t. Ensure the dowel pint Io(;at, c:orr.elty. then lubriellt' the ~ of the Allen bolt wiIh molybdenum ....lpIQ ~ and Install the bolt fInoer tlQl>t. II .-sary. fiI e new O-ring to the velve sleeve. thel'llubr\e.ale the sleeve wiIh e smear 01 graese and install ~. Prevent the 1I$Iv, from turning .., before and tl{jhten the Allen bolt 10 the specified torque Mltong. 6 If nec:essary, fill new O-ring to the righi-hand end cap and ~It ~ wiIh e ~ 01 grease. Install the end cap and l!{Ihlen the securing IICIWW 10 the specified lorque HIIing. Check !hat Ihe power valve lurns smooth/V In Ita bole. 1 fnsld the ~ barleI IWld r-l as described In SectIOl'l 44 01 Chapter I, 6 If nec:essary. tit e new 011 II1I8I to the Ieft·hand and 01 the power valve aod lubrlcat, It wiIh I smear of grease. theI'Ilnstali the pulley housing

"".

2 If the notch and hole do not align. loosen both pulley cable adjuster locknuts and turn the ~ters cIockwIsa until Ihefe • sufficient IIIecIc In !tie cables to align !tie notch and lhe hole by hand. "-" • 4 mm diameter pin (s dr'oI bit 00' Allen key can "-used) ttvough!tle notch and Into the hole 10 hold !tie pulley In position. then adjust !tie cables equally 1,J:lI~ . . play i$ rert'IOY«f. Back olf the adjusters by 'I. tum. thin tighten the locknuts !WId ..-nove the pin. Switch the ignition ON and check the atqvnenI again.

"fie

Removing a nd refitting the YPVS components -

1991-on model s t Puff the rubber boot ott the ...-.omoIOO' to IICCe8I the savo pulley and remove !tie power v~ puIey cover on the left-hand side 01 !tie cylinder bar!et. Loosen both puIey cable adjuster locknuts and tum !tie adjuslers dockwfs.e until Ihefe i$ aufllcient slack in !tie cables 10 dIsconnecI lhem !n)m the savo puIey. 2 Insert e 4 mm diameter pin (e dr1I bit 00' Allen key can be used) through !tie notch in tile valve pulley and i1tO the hole In the ~ of the houeing to lock the pulley. then undo !tie centre bolt !WId f8ITICMI !tie pulley. Dosconnect the cabIeII and..-nove the pin. Undo the two bolts securing the hoI.ISir>g to !tie cylinder barrel and 11IITIOYII!tIe housing and

Chapter 8 The 1997-00 OT125 R models lind ~ Iht -=urlngpotta to Iht ~ torque MItIng. ConnecI Iht c--. 10 Iht .... pulley lind IIIIht pulley. Align Iht noIch In the pulley wfth the hole In the houMIg lind lock the pulley WIth a • nwn ~ pin _ ~. tIwI tigtII.. the boll to the IC*:iIIIId

--

'*'"

.--.1Ind

9 II ~ ...... Iht c:otWIKt the...ww.g. tIwIlnMaII Iht elIbIM on the _ pulley. With the .... pulley ItilIoc:kMI by the

pin........ the '*"- ~ mtiI II IrM ~ II; .....-..d. tIwI bKk oft the ~ by !urn lind IlgtlWI the . . . - locknut&. AImcMt Iht !WI WId en.d< Iht c-... ....".".1SKtIon .1. tIwI ..... the pulley _lind _ _ boaC.

I,.

10 Ignitlon .yatem -1~ rI'IOde'-

................

I The IICUW coil II; now ., lrQgraIl*I 01 the ~or -.or. The ~ tor Iwtng tNo IICUW coil ....~ II; _ ~ In SectIon 501 ChI!fIt_ 4.1'IOIi!IQ Iht.I themet_1hOuId bit MIlO theol'mt K 1000 ...... eomp.. the ~ with the IIp<<:IbIion g;...., -' tNo ~ 01 IhII; et.pt.-. II tNo -..w coil II; •....tty. a ' - .onor ~bIy .......1 bit Iitled (Seet1Ol'l 5). Hto .... tNo eompontfIl 1_1«1 by . .

10.2 Loca\Ion 01 tNo COl 11M I~

aulhof'tHd Vamah. dNl.- or aulO eI.elrlcal .poclallsl belore putChMIng. ' - eotnpOf*ll.

-

CD'unIt~

2 The COl un/! II; ~Ied eIde 01 the InIOCIn.

......

on

the IronI 01 the 01 '-'" on the rIght.!>and

3 The neutrIII NIey II; p.-1 01 the 9lIIion COf"IWI ~.... _ 0McrIbed In SectIon 9 01 ChepI.- 4. The NIey 1I;1oceI«I on the 1eII.fIend lOde 01 the Irame to the _ 01 the cooa...t ~ lank. II It-. II; a '-A In lhe syat... end the IIIdMIand end neutrN 1wII~ _ good. dIKonnM;t the '*Y wWYIg cornM:tof lind en.d< Ihet the ........ _ clllMllInd trw from corrwIon. a-k the ~ 01 the NIey by u.. IUbItJMIon oIa ~ -.nI c:omponIfIt.

1 The _

11M

~

",.,.. ...... nut II; 01 the .....1ockIng IyPe. Aft.- u.. ",.,.. _ _ _ the Ioeklng ... no longer bit

~

~

III'tt!c:tI¥e WId a ' - nut IhOuId bit 1i11«1. NwayI tigtII., the nut to the Ij:NlCillMltorq.Ie MIting IChePt« 8)

o-..~

1 The generalor chJIIVIng lind light,"" colli; _ now ., inteor-l pM 01 geneqlor "'Ior. The ~ lor I_tnu coil ~ " .. 0McrIb«I1n S«:IIon II of ChItpler 1. II eI\her 01 tNo 1WIstenc"4' obIaIned dif! ... grwelly lrom thaI apecIt\ed, a ' - .ttllor ess.rnbIy musI be litted (SectIon 5), H..... the eompontfIll_ted by ., euthOItMd VemIhII dealer or .no eIectrIcIiI ~ beI
u..

component

fNd"""

I 1.1

~

whMI .pndIe nut II; of the .... -Iocking type

143

144

,,

,,,

, ,,• ,, , '"'''' " TaW'top 'eI' ""

,,• ,, ,

F~

" """,.

Flight-hand tN.tUM eIgnIol

",.

" ""

"" " """ """" "" '" ,.""" ""

---'"

Component key - OT 3081 , 3RNI to 3RN9 models Lighting ,witch Engine kill lwileh Front brat. la'm.-witch 19nitlDn .wileh COlunil Flywheel gene
!empe tum a;gn..I Left·hand Ignition control uni1

SideI\.Ind switch

Oil level sende< unit

"

"" "" " ""

TumaigNl~

Ru. brah '-"'P .wileh ReguietorlrllClifler unit Elrth pelnl

.... _'"

-

I9nltoon HT c:oil

CocNn\ tempenuu .. M
"

H omlwilch

""" "

Turn 191.1 tWItch Dip ,witch left·hand lront tum tignol P.rI
"" ""'" ",. ""

Heedl,mp Oil ~ w ..ning IIImp High bNm ,,",p I...' ........n l l _ Tum aigNI warning ",",p Neut..ll...,p CooIiont temperal"'" ~ Rlght-n.nd front wm aigl\lll

-," ....

WI,. eolOUt Itt'l

, "

Ol

Og

...

0.'" brown o.rI
, ,o """" "'" ..... , G

Sb W

Gr""

,-

__

wtllte

19o1tion HT coil u.rth pelnt

COIunil

F/vWheeI ~"""'lor

R~lorlreclif.... unil Neutral ,witch Ignition contro!..."iI

BIlliOt'(

F_ Right-Nnd .ear tum lignal Left·hand .Nr rum 1iog....1 Tail/slopllmp SidMttnd lJWiteh 1'1,.. bral lamp IWilCh Tum IligNI rally CooIenllenlp&fII.... 1 Hndet unit

Oil level lel'lderunit Oip lwitch Tum IigNllwitch Hom switch Lighting ,witch Ignition ,wilch Left-hand front tum IigNI Plrtinglamp Headlllmp High beam limp Dillev.. w arning LImp Tum aigNI WII'I'IirIg lamp N&utrallamp InauumentlaJ'nl» CooIIm temperature gauge Engine kill Iwl!ch FlOnt brake lamp switch Right· .... nd ffonttum lignal

145

@ @

1~ --------------------------------------~

.,•

r------------------

®

@

®

147

1~ ------------------------------------~

e

.. . >-<>=-

@

.::ffi!J@ ~@

1 t

@

~ .

s-

@)

~!

. ,.

.

. ..

e

-~

,,

€:I

~t

..

P

· @f

·'" • ! ·

®

1-------------

" 9

150

COfTIponeI11 key - DT 3RM 9 models onward

1 2 3 4

COl magne10 Neu\fal switch Rectifier/regulator Fuse

5 Battery 6 M91n switch 7 EnGine kill switch

8 Servomotor

9 COl unit 10 Ignition coli 11 Read switch 12 MO!Ier light 13 M(lter light 14 NvutraI indic;ator light 15 ~ Iftvellndicator light

16 High bftam indic:ato.-light 17

engine lempenitUffl gauge

18 Thermo unit 19 Turn IndOcalor light 20 NOOlral relay 21 Sldesland switch

22 Oil level switch 23 Rear brake switch 24 Front brake switch

25 TalVbrak& IIgl11 26 Flasher relay

27 Hom 28 Tum sigoallamp 29 Tum signal swi1ch 30 Hom SWItch 31 DIp SWItch

32 Lighting switch 33 Handlebat SWllchBs Oeft) 34 Parking lamp 35 Headlamp

Wlrs colour key

B B,

"'"

8M aN

B,'"

Blac k Brown Blaci
Brow"","'.

e,

Chocolate

G/R

'"

G_ G_"

ON< ON

Greenl'Whita GreenfVellow

G

L

"' ,,'" "

0

W

W~

,W/R

'"

"""gB'oo Blue/Red 81ueNeliow

Orange Pink

'"

-". ,-

Sky blue WhitaIBlue

WhltaIRed YellowlRed

--

Conversion Factors

..... ..,

Length (distance)

. · -""

..... .... -'"'"

....

.. 25 .•

Cubic Ir'oc:n.t (a.I in~ In') IrnperSaI plnl$ Q""" pi)

1I 0.061 1I 1.76

COOle

In'IpWII qua-tI (Imp qt)

II 16.381 a Cubic ~(cc; aTl'I 1I 0.568 _ Utr.. (II 1I ,'31 • l..itreIIlII II 1.201 • US QUWta (US qt)

.. 0.88 II 0.833

IrnpwIaI ~ (Imp
US~(USqI)

"Ot46·l..itreIIlI

II 1.1)57

US~(USqt)

• 02>

~ - - (Imp gil) ..,..,.. -(U$gII) - (Imp gil) US _ _

F~'"

II 0,03$4 •

.0305 • _1mI lIle08

Volume (capacity) ~quno(lmpqt)

~--(lmpglll)

Imptr\III gIIIgr-. (Imp gil) US~(USfi114

... ,s.6 • l..itreIIII II 1.201 • US (IIIont (US gil) .. 3.185 II

26.31\

II

0"54

......., ._..,

o..nc..-/an:ltfo;d;~ PolRh-~(Ibf;1bl _~1Nl

In,

Omp pi)

1I O.27fJ '" NfrfrItDNINI

1I 3.6

.«8

o..--/oI'CIe !OZt. 0Z3

1I

.0=

f>ol.nca.ton:. (lit; III

1I

0.1

1I 11.81

-~1Nl

II

...........

--- _.... ---

• KiograI'M-1oroe (kgI: kg)

.. 0.070 • ~Ioroe,*~

....

~

II

D.OM

.. 0.0&8

.

(koI/c:m';

.. 14.m.

~Ioroe 1* ....... Inch

!t*: IbUIn"; M'I')

kO'cm')

II 14._ •

x 14.5

1I 8.895 .~(kP~

1I 0.1"5

• ~lotcIper~ ~ (kgIIcm': 1IWcm') • PMcaI(p~ II 001"5. Pounds-IoroeI* ....... 1rlctI (pel: Won'; b'In') II 0.75 • ~oImen:uy(mmHg) II O.~l • Irw;ha 01 wet .. (InHp) .. 01 __ (inH:p)

1I 98.1

'* .......

Pounct.Icwct Inch (pi/; IbUW; b"on') ~Iorw 1* ~ Inch pI;lbIJ\+.b"on') Pounds-Ioroe per ....... Inch

(pII:Ibllln':IB'In'l

~(kP~

1I 0.01

M''''~

"00

I~

J<

0.535 0.036 • ~Ioroe

-_ ..... --.....

" 0.138 ..

PouD-Ioroe 1M! (IbI II; Ib ftI Newlon ",..... (Nm)

"

J<

'* ~ Inch

.. 0.01

.. 68.1N7.o MiIIiba- (mbIr)

".."

II 2.• 91 I< 1.868 I< 27.68

II*: tlIIIn': bW)

Torque (moment of force) .0....

J<

1.152 ..

J<

0.113 .. Newlon mttrM (Nm)

I<

J<

0.083 ..

'"

~Iorcot~

(\!QIcm;lrOcm)

(IIlI'in;blnj

M"'~ M~~~

Mil~ 1nehM0I _01_~ (nYnHg) ~

-_ ..... --Pounca.·1orcot InehM (IbI In; bin)

8.85

Obi In; Ib In)

Obi In; Ib In)

~IorcotIMl(lblIt;IbIl)

Ibtln: bin)

PouD-torc.lMI (IbI It; Ib It)

feu In;

0..."", .........

Pressure

MIIImetrw 01 ~ (mmHgj InehM 01 _ _ ~HaOI

~

~ pinta

.. 0.035 2.205

Force

---_.....

.. 0.833 .. D.2&'

• ""'0

Mass (weight) """"' ,.., -,.,

Pounds-fo«:e 1* .,..,. Inch (pel; tltIW; b"on') f'ol.nc».lorce 1* ~ Inch (pII; 1bUIn'; b'In') PoI.ndHorce 1* ....... Inch (pel; ibIJIn'; b1n') I'ounctt-Ioroe 1* ~ Inch (pei,l,JIIIn';lbIIn')

.. 3.281 .. 0.621

...

~-toro.

........

• 1.033

(\!QIm;IrO~

.. Newlon mttrM lNm) " 0.H12 .. KIogrwTIa-toro. .....

\bt In: bin) PouD-foroIo 1M! (IIlI' It; II ft) Poo..ma-Ioroe!eM (Ill II; II ft) Newlon ........ (Nml

I< I<

0.138 9.1104

I<

0.0013. 1iorMpoww(hpj

(lIQI'm: kg m)

Power ~(hpI

,,7.5.7 .. Watts(Wj

Velocity (speed) ~,*hcu(rnllWhr.mph)

~,*no..(kr'n!tr,~.

I<

1.8011 •

J<

0.35-( .. I
Fuel consumption'" M....

'*

~

(nwJ

Temperature o.gr.. f......,... .. rc I< 1.8).32

'*

~ (krrVI)

0.621

• 2.825

~,*no..(rnIIWhr.mph)

M_

'* II*'" (mpg)

e.g... c.t.Iue (OegreM~:"C)oo ('f" - 32). 0.!i6 • " is ccwnmon txae_ 10 ~ fh:m,......". QIIIlbn ~ 10 IItrMIfoo ~ IIfOObn), ...-. n.,o xll loo.tm .. m

Index

...... ...,,,,-

A Accn-* 11 Adjultment:-

1nke3l,34 _«30 dulCIl31,32

--

1auII~20.21

b leeding 124, 125 ~ 38, 120. 121 <*c 124

_...-36

fNI~~26·2a

_38

01 pump 30, $1, $2, 140 _ -..penIIon..nt lOll, 110 .".,to; plug (IICl28 _ _ 30 tIOp '-'"P twIICh 33

...... c:yIinOw38.121-12. _ check..-.d _ _ 32, 33 drI.m Inke; ~~,35 ~...cj_bonI25,126

AIr ttn.r 28. 30, 88

openIttnu ctIITIIhatt lubric8toon 37 speclfIc:I.llons 113 -'oP '-lIP twItCh 33. 133

B BIon.ry._ <;he(;k24,25 ~...c:I~'32 ~ 130

BaIIIndno -

BaIIIoow 8hIIrt: . r.fftI,ng 58, 59 NIfI'lCMII.t9.50

e.a.nc.r an.n ~­ ....."....Ilon lind rM'ICMItICIn S3

......... rwftttng

eo - 62

BNmg..:engnI50. 51. 58 _ IlJSI*'OIWOO 35, 106 - 108 tlMI1n9 head 37, HM, 105 ...m..I 34. 35. 37, 11 8.119 BIHdIng:·

braIt. 124, 125

'" """""

c CIIbIn;cIuIch 31, 32

......""'''

01 pump 30, 140

_30

VPVS '41 Caliper _ dite Inke 120 - 121 ~~30.ee,81 ~....-bOn.nd~IS3-88.1.'

--"

~""'~8:2.a3

IIf'*!nc.1lont 78, 1311

COl 1IyS1.... and unIIlW - 96, '''3 Chain - fine! ~ 26 - 28 Chargln.g .,.~: coil I . ! 133. ,.., 0UlpuI , . 132

Index Cleaning the machine 37 Clutch:_ adjustment 31, J2 examination and """",alion 53, 54 fau ll diagnosis 17, 19 refiHing 64, 65 rfII'T'lOYing 46, 47 specifications 40 Conversion I!'CIOt'S 151 Cooling system:check 35 coolanl l!lVel check 24 coo""l renewal 37 draining 71, 72 filling 72 flushing 72 hoses and connections 75 radiator 73 - 75 specifications 71 temperatu..., gauge 77,135 thormostat 75, 76 waI ... pump 76, 77 Crankca$
to... ,.

separation 49 Crankshaft_ examination and renovation 52, 53 refitting 58, 59 ","",val 49, 50 Cush drive - rear wheel 120 Cylinder head and balT1ll:egmlnalion and renovation 51, 52 ...,fill ing 66 - 66 remova l 44, 45

D

bIllancer shaft 49, SO, 58, 59 balance< shall gears 48, 53, 60 - 62 bearings SO, 51, 58 cran kcase cover -left-hand 43, 51, 59 crankcase CoYer- righi-hand 46, 51, 65 crankC3S8 halves 49, 51 , 59 crankshaft 49, SO, 52, 53, 58, 59 cylinder head and ba1Te144, 45, 51,52,66 - 66 decarbonlsing 37 dismantling - Pl'9llmlnaries 44 examination and renovation - general SO, 51 lault dlagoosis 15 - 19 011 level chock 24 0IIpump30.90-92,141,142 011 seals SO, 51, 56 piston and piston rings 44, 45, 52, 66 - 68 primary drive gear 46, 47, 53, 60 - 62 reassembly - general 57, 58 reed valve 49, 59, 50, 67 ",rltting In frame 68, 69 removal from frame 42 - 44. 140 specllioatlons 39 _ 41 9tl1011ng and running the rebUilt engine 69 laking Ihe rebuilt machlna on the road 69, 70 Yf'VS components 46, 66, 141, .42 Exhaust:deearbonislng 37

ganeml 68, 99 refitting 69 ramoval 42

F Fairing 112 Faull diagnosis 14 - 22 Fllter:- ,

air 28. 30, 88

Deearbonlslng:engine 37 e ~ haust 37, 36 Dimensions - model 6, 139 Disc brake see Front brake or reer brake - disc Drum brake see Rear brake _ drum

E Electrical system:batt
""'" '"

Instrument and warning lamps 137 neutral relay 143 neutral switch 49, 60 regulator/rectifier unit 133 specifications 131 stopltalilamp 137, 138 sw~ches

Englne:-

133, 134

lum signa ls 134, 137, 138 wiring dlagrarns 144 _ ISO

luel 37, 82 Final drlvfl chain 26 - 28 Footrests 110 Frame 105 Front brake:caliper 38, 120 - 121

fluid renewal 36 lever adjustment 34 master cylinder 36, 121 - 123 pad check and renewal 32, 33 Front lorks:011 chang.e 36 dismantling and massambly 99 - 102 examination and renovation 102, 103 refilling 103 removal 99 specifications 98 Front wtleel:bearings 34, 35. 37, 118, 119 refiltlng 115. 116 removall14,115 Fool system:carburettor 30, 82 - 87, 14 1 fault diagnosis 15 ·17 lvel fikers 37, 82 tuei pipes 30,81,82 fuel tank 79 - 81 luel tap 81, 82 specifications 78, 79, 139 FU!KI 134

153

Indo,

'54

G

_

_eo..

K

o...NlKtor~~· ~.,..;I-.tlon

50', 55

,............

-"

-.",...,...

Kkbtwt - ' o..-nbIy.. n and _

Irrt.."..~

1'IIfitting63, Sot

refitting 58, 59 removal 4", 50

r8'1'1CW11147,48

........-

1. . ~18.19

.....

011 cI\a'>ge 36. 1:2 oI ...... dledt31.11'2

50'

L ~·'31,'3IS-138

~ Ind -..bIy56-57 rwfittJng 58, 59

~ 49.50

-" -"

~.tO •• ,

~­

-."

.. _"

"''',,'' 011 ..... chect< 24

""""'"

o-cn.ng........,. -"

""""""

o..-.Ior.· refitmg 64, 140 ~48.1-40

l..cing 110', 95, 132, 133. 1"3

01 pump 30, eo - 92, 140, ,.\ 01 . . . . . 80 31

(hm t;nq~ ~ ~~chMl26-28

..- aurperoIion Inkage 35 ~.drIYt;37

--" .. .

~tIon5l3.

78. 139

.t~"-I~37

...".

H

oII ..... <:h«:k3'

... -..... H~

- .....ow.. .net ..rtttIng:-

whMI~31

DT model IG(, lOS

TZR model ag, 103

~.wtt~ 133

~ -~ buIb.-.lI36,137

Hom 130' I'IoeM - cooIWIt 75 IioeM - tI)odnuIIo 38

"'KT IMd 117

M MaInt..- - routine 23 - 38, 1.tO Mast"" cyIInder:front 38,121 -123 ..- 38,123,124

_eo

N

Neutnl IndleatOl' 1rWItch:.

ignition "Ptem:.

COO_"

..........

lest"'lllID.I3<1 143

NeutnI ~

COl I,WI/I 116, 143 ,..~15-'1,'"

HTccillW HT ' - I and ~ cap 97 IgnIIIon conttoI un/! 96

ignition llmk>g 97 pulMrcoil95 .o\.WtlIQoU4,iS.l43 ~ pk1!j128. 251, 31. 97

_-

..-" -,

~83,I3e

..,..oomet.- 37, 112 tacnomet. 48, 82

o OIt - englne:-

---" lew! cn.ck 24

......

~~90,'35

" ' •• 110

OI-~·

en.ng. 315, t2 lew! check 31, t2 011 pump:_ bIIIdlng 112. \.\

dr!woc--.35,112

cabIIo .:IjuatmetrI 30, 140

"-iIl1D

...,..,....1tld~90.91,

~137

sIrOQ~IiII.1I2

141

Index

p Parking lamp 136, 137 Parts - ordering 6 PiSlon and rings:examination and renovalion 5" refi1llng 66-66 removing 44, 45 Primary drive gea ...:examlnalion and renovation 53 refitting GO - 62: remo,,;ng 48, 41 Pow", vIII"" see YPVS components Pulser coli 95 Pump - Wilt", 76, 17 Pump _ oil 90 - 92, 140, 141

R Rlldiat .... 73 - 15 Rear broke - disc: caliper 38, 1.. 0, , .. , Huld renewal 36 master cylinder 38, '<'3, 124 pad check and renewal 32, 33 pedal adjustment 34 Rear brake - drum:adjustment 33, 34 cemshafllubrication 37 eKllrllination and renovation 125, 126 pedal adjustment 34 ReBr suspenslon: _ specifications 98 suspension un~ log. 110 swinging ann and suspension linkage 35, 105 - 109 Rear wh&eI:_ bearings 34, 35, 31, 119 refilling' 17. 118 removal 116, 117. 143 sprocket and CU8h drtve I 19. 120 RNd valve:el(8mlnalloo87,88 remllng 59, GO, 97. 88 removal 49, 87, 88 Regulator/rectifier unit 133 Routine maintenance 23 - 38, 140

5

,

Safaty precautions 7 Seat and sldapanela 112 SIde stand 35. 110.134 Side stand switch 96 SooJrce coil - ignition 94, 95, 143 Spare paris - ordering 6 Spark plug:check and adjuslmenl 28, 97 """,wal31 5pe<;lflcetlons:brakes 113 clutch 40 cooling syslem 71 electrical systems 131 engine 39 - 41. 139

fue! system lS. 79. 139 gtIBrl>ox 40. 41 Ignition system 93 lubrication system 23. 79, 139 maintenance 23, 24

-"

lyreS 114 wheels 113 Speedometer:drive37,112 drive cable 35, 11" head III Sprocket:gearbox 43 rear wheel 119. '20 Steering:-

""''''

f8U~ dia9nosls 19 head: bearings 37.104.105 d~n~ing 103, 104 f88SS8n1bty 105 Stop lamp switch 33, 133 StopJtalilamp 137. 138 Suppressor cap 97 SUspenslon :-

_35 lauH diagnosis 20 lront 36, 99 - 103 rear 105-110 Swlngln9 arm/sub-frame:-

_35 examInation and renovatiOn 106 - 108 mfilling 108, 109 removal lOS - 107 Swltches:handlebar 133 Ignttion and engine kiU 95, 133 neutral 49, GO, 110. 134 side stand 35, 110, 134 slop lamp 33. 133

T Tachometer._ drive 48, 62:. II" drive cable 35, 1 12 heed 110 Tank - fuel 79 - 81 Tap Sl -82 Temperature gauge - coolant: send ... U1lil 77 gauge circuit 135 Thermostat 75. 76 Throttle cable 9djustment 30, 140 TImlng:balancer shaft {IIIW5 GO - 62 Ignklon 97 Tools 6- 10 Torque settings 10. 24, 41. 71. 79, 98, 114. 131, 139 Transmission:_ lalllt diagnosts 18, 19 011 chang" 36. 92 ~I level change 31, 92 Tum slgnal:~ps 137. 138 relay 134

155

156

"....

-"

~,~.-.cI,..,;tbng.

tuIled 12$, 121 tubeleu 126. 128. 129 IPKfflcationl114 YWiee 128. 130

v V81Ye-~~66.141. IQ v.IM - 1'...:1 49, 59, 50, 87, 88 v.tv. - tyn 128. 130

Voltage ~or 133

w W.wr pump 78, n w.Ighq - moWII; 8, 138

-.-"

Index

baI.- 35, 130

~34.

36, 31, 118. 118

check 3001. 35

remcJ\llII MId refining: front 114_118 _1111-118,1~

~113

&prOCkM lind eu.hdlt.-.-_ ...... IIi. 120 wtmg~ I"-l50

Wo<1dng ~.m I~ 8. 9

y YEI5 88 YPVS componentS:. ~141

refining 88, 142 NfTlOVIIIoI.6,142

Notes

157

158

Notes

•

I l

•

rlaynes Motorcycle Manuals - The Complete List

"-11;1 AEl4R

!III" 80 (11 • Iifi!

IIamiIKC. KE .. 1OI100{1S .!!! ~KMXl2:5'200(.·IIII! ~250.350&400fI!'o'(12·1!J ~Gl ' 44111'w101(n,,,!

I(a..aId

1W1'

11'11 0. tiM 1m

UUOO& SSOfourl!7! ·il)

f\IwIIIId~&500"-!\WII!Ic!I)!85·t3)

tWIll'

D.V I DSD~

_EJ&_1GfZ!IIIII E1141"'"

17...11 IIiIndIHlro&HlIlOSSoIc!!II(!CI·!2)

IIOodI C&'COt25T" CM'~ 1WN{!7 . II!

...... oms!7!·OO! 1l000iii115125 (!I·G! _ M8XiMlXt25 .. MTX200 (113 • i3) _CDoQoIII5 ZIQT .. CM250C 2..... , . .

IOOIOR("!! 1!CHeOOIS ~""lf(IIIIooII!2roIE1ICi:In)

.1Ii

l.IoIIDItydo~r_!3rtIldiIIon)

Mtt

IoIc!IfC)ICIIFuII"..,.fIc:t6IoI;

IoI!I!n7d!Wo!!'!P ~ TteIIIIaat; {2nd~' TAIUMI'H

',lSO&soou...l_(5I·n! T!I!!'f/I~r_(47·~

r""""", I5CI .. 150 2..... UnI MIt !G. &3j Ttl!!!pllTI'donI I 8$AIIDIMI3 !!!. 1$1 'bI!¥ """(17 -. ,_J r__ lFIll .......... & FooIIII __ (il-.)

.••, .n

•• ''''

""

.'4 MlI

_""" .~

(I . . . . . . . . . . . "'US4

ThernlllWlsonllllSlUCII ............. 1IItougII 1)OOd~......,n~J/IopI

InClSeoldlllocully,COIItId . .............. (UK) " " . ' - (USA) .' _ _ _

(fR) .D 1 fl ,. .. II

(SV) . . 1. 1. . .

(AI,r$I'1IIiiINIw lNYncI) .., J

1711".

Preserving Our Motoring Heritage

Th. Mo"," J 1)"
Onryclg'''oi'l>cK ""'S"!/it"" ra.. W
on!r"""",pktakfaund ""uiJ< ,h~ Unl'nl S,u"" ofAmm{(J

It,

Alm"", "''1:1)' atr },ou','I: ",'cr kwcd. loalhed or dt:Sired is gmhc,-;:d u,,TIt( magnift<:cn\ 'R£d CoII«tion' is a spectacle of classic spons cars illdudins,\C. Alfa Romeo. ,\u:;nn Healer. l'eTT"dri, l.amborghini. Maserd\i. MG. Riler. Pon;che and Triumph.

A

Pc ,feci Day Our

Each und 1:''(;1)' .-chidc III the Ilu)'nes MOlor Muscum has pla)'(;d its purl In the hisloT}" "uti cuhure of MOlOring. Tod:!)', the) make a "'Onderful sl"'Ctade and a day oul for all the famlly. Bring thf kids. bring Mum "nd D~d. but abo>" all bring )'Ourcmn~ra 10 caplO'" ,h06C golden menlOrics for ':wr. You will also r.nd an Impress"..: array of mOlOring memorabilia. a romronable 70 Stat "deo cinema and one of the mOSl alens;..., trnJ15pof1 book shops in Britain. The Ph StOp Cafe scrl.'t'S C\'C1)1hing from a CliP oftu to wholesome. homemade mtab or. if )'Ou prefer. )Vll.;an enjoy the large pknic area nesded in the hcautlful nml1 surroundings of Somerset.

g"'"'

The 19J6 ~9Ik' wir<-<"8'Mro

0.1] 1'" """"tkrnnd

J
In,,,,,,,,,,,,,,,1

ali:""""" of!hr

N"",,"_,,-d/JDw,..'1I

"'.....,.'" aI 'hr .. /wi oiutluy.... Ugl"ll

/<win ""'ng....-.n>

Opcn q.)O.m .

.-1.,

Sporkford.just offlh<: A]{Il in Som
Tht Mu5<'Um" ."u.oltd on 1h< A}'>9 Y_11 10 Fmm< ~.JOpm