__ ~~ ~ ,~

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YAMAHA

,<;!
, [,
TT 600 R :97
4-
‘“*hi
.-

, . SERVICE
INFORMATION
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 "- - - ---~-
~ ~ ~ I - ~ ~~ ~~~~ . ___
1;

INTRODUCTION

This booklet has been created in order to provide further information aboutthe Yamaha l
T 600 R ('97) model.
For a full understanding of the information on the service procedures, use this booklet together with the mi-
crofiches of the Service Manual.

TT 600 R ('97) SERVICE MANUAL: 5CH-ME1

TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP
BELGARDA S.p.A.
f,,' .

-_4
'<*

lT 600 R '97
SERVICE INFORMATION
0 1997 BelgardaS.p.A.
1"'edition, September 1997
All rights reserved.
Any reprinting or unauthorised use
without the written permission of
Belgarda S.p.A. is expressly prohibited.
Printed in Italy
BCH-SEI
I -

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 ~

WARNING

This manual has been written by Belgarda S.p.A. mainly for use by Yamaha dealers and their skilled
mechanics. It is impossibleto provide a mechanic withall the information necessary in a single manual.
Presumably, though, the people who use this manual for the maintenance and repair of Yamaha motor-
cycles will already have elementary knowledge of the principles of mechanics and the procedures for
motorcycle repair techniques. Without this knowledge, repair or maintenance work on this model could
prove inefficient and/or dangerous.

Belgarda S.p.A. makes constant effortsto improve allits models. Important alteratlonsor changes to pro-
cedures characteristics will be communicated to all Yamaha dealers and published in future editions of
this manual.

NOTE:
Specifications and design are subject to change without notice.
\
v

PARTICULARLY IMPORTANT INFORMATION

The manual includes the following symbols and relative remarks:

~~ . safety
This alert symbol means: ATTENTION! BECOME
ALERT! YOUR SAFE-
TY IS INVOLVED!

v
m The WARNING symbolIndicatesspecialprocedures
severe
injury orrider
the
death
to orperson
the
Inspecting
to befollowed to avoid
or repairing
the
motorcycle.

'CAUTION:.,, CAUTIONindicates
special
precautions
to
be
taken to avoid
damage
to
the
motorcycle.

NOTE: NOTE
A provides
key
information
designed to make
procedures
easier
or
clear-
e r.

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 ~ ~ ~~~~~ ~

ILLUSTRATED SYMBOLS
IO IO I
I
I
~I
I
I
~
Illustratedsymbols (1) to (9) aredesigned as

I
thumb tabs to indicate the chapter's number and
content.
(1) General information
(2) Specifications
(3) Perlodic inspection and adjustment
(4) Engine
(5) Cooling system
P I
(6) Carburetion
IO IO I
COOL^ x I I y 1I
. I I , . I . (7) Chassis
(8) Electrical
~CARB~ (9) Troubleshooting

I
I

IO
IO

I
-
1- I
I Illustrated symbols(IO) to (17) are used to identi-
d

0 fy the specifications appearingIn the text.

1- @ Fl I
(1 0) Possible to maintain with engine mounted
(11) Fllling fluid
(12) Lubricant

@m
I
I
(1 3) Special tool

~1
(14) Tightening
(15) Wear limit, clearance
(16) Engine speed
I I I (1 7) 12, V, A
0 63

I
N I
L

@El@pl@pJ
' 1 4 '

I I
Illustrated symbols (18) to (23) in theexploded
0 8 @ diagrams indicate the types of lubricants and lubri-
I I I cation points.

I
El B GI I
(18 ) Apply englne oil
(19) Apply gear oil
(20) Apply molybdenum disulfide oil
0 0 0 (21) Apply wheel bearing grease
mi? &sz
L t
.
& ?szL
(22) Apply lightweight lithium-soap base grease
(23) Apply molybdenum disulfide grease

I@ IO 1 Illustrated symbols (24) to (25) in the exploded

I h I m I
I I I
diagramsindicatethewhere to applylocking
agent (24) and when to install new parts (25).
(24) Apply locking agent (LOCTITE@)
(25) Use new one

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 ~

INDEX

GENERAL INFORMATION
VEHICLE
IDENTIFICATION ..................................................................................... 1

SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................................................. 2
MAINTENANCE SPECIFICATIONS - ENGINE ........................................................ 5
LUBRICATION LAYOUT .......................................................................................... 10
ENGINE - TIGHTENING TORQUES ........................................................................ 14
MAINTENANCE SPECIFICATIONS - CHASSIS ...................................................... 17
CHASSIS - TIGHTENING TORQUES ...................................................................... 19
MAINTENANCE SPECIFICATIONS - ELECTRICAL ................................................ 21
GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES ........................ 23
LUBRICATION POINTS AND LUBRICANT TYPE ................................................. 24
Y
CABLEROUTING .................................................................................................... 26

PERIODIC INSPECTIONSAND ADJUSTMENTS

PERIODICMAINTENANCE/LUBRICATION INTERVALS ........................................ 30

EXPLODED DIAGRAM
CARBURETOR .................................................................................................. 33

ELECTRICAL
WIRING
DIAGRAM ............................................................................................... 35

‘W

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~- .

VEHICLE G E N l
INFO
IDENTIFICATION

GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (1) is stamped
into the right sideof the steering head pipe.

MODEL/COLOUR IDENTIFICATION LABEL

The modelkolour identification label (1) is affixed
to the rear frame. This information will be needed
to order spare parts.

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 GENERAL SPECIFICATIONS M
SPECIFICATIONS

GENERAL SPECIFICATIONS -
-
Item Standard
_- -

Model code TT 600 R: DJOI (5CH1) -

__
Dimensions:
Overall length 2,250 mm
Overall wldth 845 mm
Overall height 1,225 mm
Seat height 945 mm
Wheel base 1,480 mm
Minimum ground clearance 325 mm
Minimum turning radius 3,100 rnm (left)
3,300 mm (right)
I __ -

u I
I
Baslc weight:
Withoiland full fuel tank __
150 kg -

Engine:
Englne type Air cooled, 4-stroke, 4-valve, SOHC
Cylinder arrangement Forward-inched single cylinder
Displacement 595 cm3

+
Bore x stroke 95 x 84 mm
Compression ratio 851
Starting system Kick-starter
-_ -

Lubrication system Dry sump with separate oil tank -

I _.

Oil type or grade:

Engine oil
-20°-100 0" 10" 20" 30" 40"50"C
I
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4
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$AEiOWj30
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II
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; ':SA220A/40:*
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API standard: Type API Service " S E , "SF" or equivalent -

I
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-.

Oil capacity:
Engine oil
Periodic oil change 2.7 L
With oil fllter replacement 2.8 L
Oil tank 2.6 L
Total amount -.
3.3 L -

Oiled filter element

I7~
Air filter - _
Fuel:
TY Pe Regular unleaded gasoline
Tank capaclty 10 L
Reserve 2.1 L
I I -

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 ~-~

GENERAL SPECIFICATIONS W l
~
Item I Standard
Carburetor:
Type Y30PV-2ATK
Manufacturer TElKEl
Spark plug:
Type DPR8EA-S/DPRSEA-9
Manufacturer NGK
Electrode gap -
0.8 0.9 mm
Clutch type Wet, multi-dlsc
...-

Transmission:
Primary reduction system Straight-tooth gears
Primary reduction ratio 74/31(2.387)
Secondary reductlon system Chain drive
Secondary reduction ratio 44/15 (2.933)
Transmission type Constant mesh 5-speed
Operation Left foot operation '4~
ratio Gear 1I' 30/13 (2.308)
2M 27/17 (1.588)
3 d 24/20 (1.200)
4'h 21/22 (0.954)
5'h 19/24 (0.792)
Frame,
Frame type Open-cradle backbone frame
and removable rear frame
Caster angle 26" 30'
Trail 114 mm
Tyres:
Type With tube
Size 90/90-21"-54R / 90190-21"-545
rear 130/90-18-69R / 130180-18-66R
140/80-18-70R / 130180-18-668
Manufacturer/model
front PlRELLl MT21 or MT70
MlCHELlN BAJA or T63
rear PlRELLl MT21 or MT70
d
MlCHELlN BAJA or T63
-
Maximum load* except motorcycle 180 kg
Tire pressure (cold tire):
only Rider 150 kPa (1.50 kg/cm', 1.50 bar)
rear 180 kPa (1.80 kg/cm2, 1.80 bar)
With
maximum
load*
front 200 kPa (2.00 kg/cm', 2.00 bar)
rear 220 kPa (2.20 kg/cm2, 2.20 bar)
Off-road 100 kPa (1.OO kg/cm2, 1.OO bar)
rear 100 kPa (1.OO kgicm', 1 .OO bar)
* Load is the total weight of cargo,
passenger, and accessories.
Brakes:
ype brake Front Single dla. 267 mm disk brake
operation Right hand operation
pe brake Rear Single dia. 220 mm disk brake
operation Right foot operation

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 GENERAL SPECIFICATIONS !Giq-q
Item Standard
Suspension:
Front suspension Adjustable telescopic fork (dia. 43 mm)
Rear suspension DELTA-BOX SWINGARM
Shock absorber:
Front shock absorber Adjustable /Coil spring /Oil damper
Rear shock absorber Adjustable / Coil spring / Oil-gas damper
with separated tank
Wheel travel:
Front wheel travel 280 mrn
Rear wheel travel 280 mm
Electric system:
Type Without battery
‘W Ignition system C.D.I. (digital)
Generator A.C. magneto 12V

Headlight type Quartz bulb (halogen)

Bulb wattage x quantity:
Headlight 12V6OWl55W
Headlight (only for Australian market) 12V35W135W
Tail /brake light 12V5Wl21w
Flasher light 12VlOWx4
Front marker light 12v5wx1
Meter light 12v3wx1
Neutral indicator light 12V1,2WXl
High beam indicatorlight 12v1,2wx1
Turn indicator light 12v1,2wx1
t

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MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS 1-
ENGINE

Itern Standard Limit

1*
I I I

1
Cylinder head:
Warp limit ---- 0.03 mm

* The lines show where you have

to site the
measuring
slide rule. I
Cylinder:
Bore size -
94.97 95.02 rnm 95.1 mm
u
Measurement point (a) (a) = 50 rnrn --_-

Camshaft:
TlEi I I I

Advance method Chain advance (left) ----

Camshaft outer diameter
Backlash between camshaft and cap
-
22.967 22.980 mrn
-
0.020 0.054 mrn
__--
_-__
Cam dimensions
1

I
w
t i l A

Intake "A" 36.47- 36.57 mm ----

- -_--

-*-
"B 30.06 30.1 6 mm
"C" 6.41 rnm ----
Exhaust 'A" 36.62-36.72 rnrn ___-
"8" 30.11 -30.21 mm ----
"C" 6.51 rnm _---
Camshaft
runout limit _I_
0.03 mm

----JL--

- I

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 ~~

MAINTENANCE SPECIFICATIONS W l
Itern Standard Llrnrt

Timing chain
Timing cham type/ 75-010
Llnk number 126 ---_
Timing chaln adjustment method Automatic ____
Rocker arm/ rocker armshaft,
Rocker arm inner diameter -
12.000 rnrn 12.018 rnm .___

Rocker shaft outer diameter -

11.976 rnrn 11.991 rnrn .___

-
Rocker arm-to-rocker armshaft clearance 0.009 rnm 0.042 rnrn ____
Valves, valve seat, valve guide:
clearance
Valve
(cold) IN 0.05 - 0.10 rnrn ____
EX 0.12 - 0.17 rnrn _-_-
Valve dlmensions

\u

nwidth Seat width Face

diameter
Head
[)() ”A”
I ( ) Y ::.;. I!\
,,
“C“

\It “D“

“ Adiameter
head IN -
36.9 37.1 rnm ____
____
EX -
31.9 32.1 rnrn
wldth
“B” face IN 2.26 rnrn ____
EX 2.26 mrn ____
width
“C” seat IN 1.0- 1.2 mrn 1.8 rnm
EX 1.0- 1.2 rnrn 1.8 rnm
I’D” margin
thickness IN -
1.O 1.4 rnrn 0.8 rnrn
EX -
0.8 1.2 rnrn 0.65 rnm
Stern
outside
diameter IN -
6.975 6.990 mrn 6.955 rnm
EX -
6.955 6.970 mm 6,925 rnrn
Guide
lnslde
diameter IN -
7 000 7.01 2 rnrn 7.042 rnrn
EX -
7.000 7.012 mm 7.042 rnrn
u Stem-to-gulde
clearance IN -
0.010 0.037 rnrn 0.08 rnrn
EX -
0.025 0.052 rnrn
____
0.10 rnrn
0.01 rnrn
Stem runout limit

Valve
widthseat IN 1.1 rnrn 1.8 rnrn
EX 1.1rnrn 1.8 rnrn

Valve spring: Inner spring Outer spring

length Free IN 40.1mm 43.8 rnrn 38.1 rnm
EX 40.1mm 43.8 mrn 38.1mm
size Position IN 22.7 mm 34.2 rnm ____
EX closed) (valve 22.7 mm 34.2 rnrn ___-
A

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MAINTENANCE SPECIFICATIONS p-qq

Item Standard Limit
Compressed pressure Outer spring Inner spring
(spring Installed) IN 164.8 190.2 N - -
71.6 87.3 N _-__
16.80 19 39 kg- -
7.3 8.9 kg
EX 164.8 190.2 N - -
149.1 182.4 N ____
16.80-1939 kg -
15.2 18.6 kg
hmit* Tilt IN -___ ____ 2.5"/1.7 mm
EX ____ ____ 2.5"/1.9 mm

Winding sense
(top wew) IN
0 0 Counterclockwise ____
Counterclockwlse
'd
EX Counterclockwise Counterclockwise ____
Piston:
Piston to cylmder clearance -
0.045 0.065 mm 0 1 mm
Plston size "D" -
94.91 5 94.965 mm .___

B
Measuring point "H"

4" oversize
Piston allowance
--
-.

D
--- -c
-H
t
5 mm
95.5 mm 2" oversize
96.0 mm
2 mm
____
____
____
____
Piston pin off-centring Intake side W'
Piston pin bore lnslde diameter -
22.004 22.015 mm ____
Piston pin outslde diameter -
21.995 22.000 mm ____
Piston rings:
Top ring.

P?B
TY Pe Barrel -_--
Sizes (B x T) 1.2 x 3.2 mm __--
End gap (installed) -
0.15 0.30 mm 0.7 mm
Slde clearance (installed) -
0.03 0.07 mm 0.1 3 mm

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 Itern
MAINTENANCE SPECIFICATIONS

Standard
m Limit

2nd ring:

0
L-T-1
3
TY Pe Plat
Sizes (B x T) 1.2 x 3.8 mm __-_
End gap (installed) -
0.30 0.45 mm 0.8 rnm
Side clearance (Installed) -
0.03 0.07 mm 0.13 mm
Oil ring:

E
L
I
B T-l
W

Slzes (B x T) 2.5 x 3.4 mrn ____

End gap (installed) -
0.02 0.06 mm ____
Crankshaft:

- F

Crank width “ A 74.95 - 75 00 mm __-_

Runout limit “ C ’ 0.03 rnrn
0.35 - 0.65 mm ___-
‘u
Big end side clearance“D”
Small end backlash ‘IF’ 0.8 mrn ____
Balancing weight:
Advance method Straight-tooth gear __--
Clutch:
Friction plate:
Thickness 2.72 -2.88 mm ____
Quantity 6 parts ____
Wear limit __-- 2.6 mm
Frlctlon plate:
Thickness -
2.94 3.06 rnrn __--
__--
Quantity 2 parts
Wear hmit _--- 28mrn
Clutch plate:
Thickness 1.2 rnm ____
Quantity 7 parts ____
Wear limit ___- 0.2 mm

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 ~~~~~
~~ ._~ __. ~
~ ~~~
~

MAINTENANCE SPECIFICATIONS W l
Item Standard Llmlt

Clutch spring:
Clutch spring free length 34.9 mm ____
Quantlty 5 parts --__
Clutch houslng:
Thrust backlash 0.070 0.071 mm - ____
____
Inner cam pushtng Clutch release system
Transmission:
Main axle
off-centring limlt ____ 0.08 mm
Drive axle
off-centring limlt _-__ 0.08 mm

Shift cam:
TY Pe Drum with cam and guide bar
Carburetor: W“
I.D. mark 5CH, 00
Main jet (M.J.)
Primary carburetor # 150
Secondary carburetor # 130
Main air let (M.A.J.)
Primary carburetor 0 1.0
Secondary carburetor 0 0.9
needle Jet (J.N.)
Primary carburetor 5C5A - 315
Secondary carburetor 5Y 18 - 315
Needle let (M.N.)
Primary carburetor 0 2.60
Secondary carburetor 0 2.60
Cutaway (C.A.) 4.0
Pilot air jet (PA J ) 0 0.8
Pilot jet (P.J ) # 54
Pilot outlet (P.O.) 0 0.8
Bypass 1 (B.P.) 0 1 x2 u.<
Bypass (B.P.P.) 3.0/5.0
screw Pilot (P.S.) 3 1/2 + 112 revs approx., open
size seat Valve (V.S.) 0 2.5
Starter jet (G.S.) # 74
Fuel level (F.L.) -
6 8 mm
Float helght (F.H.) -
27 29 mm
Idle speed:
Englne idle speed 1,150 - 1:450 rimin _-_-
Lubrication system:
011 filter type Paper
011 pump type: Trochoid
“A” or “B” tip clearance 0.12 mm 0.2 mm
Side clearance -
0.03 0 08 mm 0.15 mm
Shunt valve calibration pressure -
80 120 kPa (0.82 122 kgflcm2) - ..._

Safety valve calibration pressure -

80 120 kPa (0.82 122 kgf/cmz) - ____
----
Oil pressure (hot) 13 kPa/1,300 r/mm (0.13 kgficmzi1,300 r/min)
Pressure checkpoint Oil filter chamber

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 ~~

LUBRICATION LAYOUT
LUBRICATION LAYOUT m
(1) Oil tank [A] DELIVERY
(2) Oilpump [B] RETRIEVAL
(3) Oil filter (oil tank)
(4) Oilstrainer(engine)
(5) Oil vapourretrievalhose
(6) Oil blow-by retrievalhose

-
-
m :,,..~..;;,:.:;..,<<.,
.: -- .<--,.,., ,. ,,.,,.~.
,,.,,/,,A% ,
, <.,, 9, ..I X'd'
I

-;:;;;;>.,:;::.:
5
Dl
\
W

3
,u

/
/
/

2
I I

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(1) Oil pump

LUBRICATION LAYOUT
[A] DELIVERY
ppq
(2) Oil filter [B] RETRIEVAL
(3) Camshaft
(4) Oildeliveryhose
(5) Maindrivingshaft
(6) Driveshaft

,;.$g;z,... ,,..<,,.
\X%...< -
-
ji;z;
a
ipi

\I

, I

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 (1) Oil filter
LUBRICATION LAYOUT
[A] DELIVERY
M
(2) Camshaft [B] RETRIEVAL
(3) Connectingrodpin
(4) Maindrivingshaft
(5) Secondarydrive shaft
(6) Drain plug

;;:j ;:::,i; .<I :..I i

L.:,;>;:;;~~:;~
~

i;

El

u
4

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 ~~ - . . _ ~ ~~

pump (1) Oil

LUBRICATION LAYOUT
[A] DELIVERY
m
(2) Oil filter [e] RETRIEVAL
(3) Oil delivery hose
(4) Transmission
(5) Oil stramer

rn """;y:yp"""4
& X,f % q g . S.W.?<*.
.*<.x:*Y.v+ U&//>,f*
-

2 L.4'

LJ

I I

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 ENGINE
MAINTENANCE SPECIFICATIONS /SPEC1
Cylinder head tightening steps:

L’

Crankcase tightening steps:

Left crankcase Right crankcase

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Tightening torques
MAINTENANCE SPECIFICATIONS 1-
- ILiJ
I Tlghtenlng
Part Thread torque
Part to be tightened ~

name size
Remarks
I
Cylinder head Washer based

Cylinder head
bolt
Stud bolt
M8 x 1.25
M10 x 1.25
1
~ 29
20
2.9
2.0
Cylinder head Hexagon socket
head screw M6 x 1.0 10 1.0
Cylinder head Stud bolt M6 x 1.0 7 0.7
Cylinder head:
Cap (oil check) Union bolt M6 x 1.0 7 0.7
Spark plug - M12x 1.25 18 1.8
Cylinder head cover Hexagon socket
head screw M6 x 1.0 10 1.0 W.
Tappet cover (Intake) Hexagon socket
head screw M6 x 1.0 10 1.0
Tappet cover (exhaust) - M32 x 1.5 12 1.2
Cylinder Crown nut M8 x 1.25 22 2.2
Cylinder Nut M I 0 x 1.25 42 4.2
Cyllnder Hexagon socket
head screw M6 x 1.0 10 1.0
Weight drive gear Hexagon nut M16 x 1 .O 60 60
Rotor (A.C. magneto) Hexagon nut M14 x 1.5 120 12.0
Lock nut (valve adjusting screw) Hexagon nut M6 x 1 .O 14 1.4
Cam chain sprocket Washer based
bolt M7 x 1.O 20 2.0
Cam chain stopper guide Hexagon socket
head screw M6 x 1 .O 10 1.0
Cam chain stopper guide Washer based
screw M16 x 1 0 20 2.0
Rocker shaft Hexagon socket W
head screw M6 x 1.O 10 1.0
Oil pump Hexagon socket
head screw M6 x 1.O 10 1.0
Oil deliveryhetrieval pipe Pan screw M6 x 1.O 7 0.7
Oil drainlng pipe Washer based
screw M14 x 1 5 30 3.0
Oil filter cover Hexagon socket
head screw M6 x 1.0 10 1.o
Bleed screw (oil filter cover) Hexagon screw M5 x 0.8 5 0.5
Push lever (clutch) Pan screw M8 x 1.0 12 1.2
Push rod (clutch) Hexagon nut M6 x 1 .O 8 0.8
Sprocket Hexagon nut M18x 1.0 110 11.0
Lock washer (oil seal) Hexagon screw M6 x 1.0 10 1.o
Stop lever Bolt M6 x 1.0 10 1.o
Shift cam Hexagon screw M6 x 1.O 10 1.o
Stator Pan head
(+) screw M5 x 0.8 5 0.5
- A

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 ~

MAINTENANCE SPECIFICATIONS pl-+l -

I Part to be tightened
Part Thread
Tightening
torque
- Remarks
name size
Nrn
-I
I rnkg
-

Stator (pick-up coil) Hexagon socket I

head screw M6 x 1.0 7 0.7 fi

Engine oil pipe 1 Hexagon socket

Engine oil pipe 2

Oil delivery pipe
head screw
Union screw
Union bolt
M6x10
M12 x 1 25
M8 x 1.25
lo 3.5
35
18
1.0II 1.8
Carburetor joints Hexagon socket
head screw M6 x 1.0 10 1.0
Air filter case (frame) Hexagon screw M6 x 1.O 10 1.0
Air filter case (frame) Washer based
screw M6 x 1.0 10 1.0
u Exhaust pipe Washer based
nut M6 x 1.0 10 1.0 1

Exhaust pipe protector Pan head M6 x 1.0 7 0.7 &

(+) screw
Muffler Hexagon socket
head screw M8 x 1.25 23 2.3 t
&
. Gz
L

Muffler (band)
Muffler
I Nut,
nylon
Washer based
I M8 x 1.25 23 2.3

screw M8 x 1.25 23 2.3

Crankcase Hexagon socket
head screw M6 x 1.O 10 1.0
Crankcase Stud bolt M10 x 1.25 20 2.0
Crankcase cover (rlght) Hexagon socket
head screw M6 x 1.O 10 1.0
Crankcase cover (left) Hexagon socket
head screw M6 x 1.O 10 1.0
L Sprocket cover Hexagon socket
head screw M6 x 1 .O 10 1.0
a1

Flat I
Stop washer (bearing)
headscrew M6 x 1.O 7 0.7
&
Pressure plate Washer based
screw M6 x 1.O 8 08
Clutch housing Hexagon nut M20 x 1.O 90 9.0
Prlrnary drive gear Hexagon nut M20 x 1.O 120 12.0
d

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 ~~~~~~ ~~ ~~ ~
~~ -

MAINTENANCE SPECIFICATIONS 1-
CHASSIS

Item Standard Limit

Steering:
Bearing type Taper rolllng bearmg ____
Front suspension:
Front fork travel 277 - 283 mm ____
____
Fork spring free length 530 mm
Spring rate (K) 4.6 Nimm (0.46 kgimm) ____
Stroke 330 mm ____
Oil amount x inner tube 615 cc ____
011level 160 mm ____
-
cl min max > -
150 170 mm (from upper edge
of inner tube, fully compressed
without spring) Ld
Oil type "01" SUSPENSION OIL --__
Rear suspension:
Shock absorber stroke 105 mm 107 mm
Spring free length 250 mm -___
Fitting-length 231.5 mm ____
rate Spring (K) 65 Nlmm (6.5 kgimm) ____
Optional spring None
Gas pressure 1.400 kPa (14.0 kg/cm2, 14.0bar) ----
Rear arm.
Clearancerear
hmrt end
arm ____ 1 mm
side to side 0.4 - 0.7 mm ____
Front wheel:
Type Spoke wheel -___
Rim size 1.85 x 21" -___
Rim material Aluminium -_-_ V'

Rim runout
limit radial 1 .O mm 2 mm
lateral 0.5 mm 2 mm
~

Rear wheel:
TY Pe Spoke wheel _--_
Rim size 250x18 _-__
Rim material Aluminium _-_-
Rim runout
limit radial 1.O mm 2 rnm
lateral 0.5 mm 2 mm

Drive chain:
Type/manufacturer 520/135 ORHIXRING-REGINA CHAIN --_-
Number of links 112 ---_
Chain slack -
30 40 mm ____

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 MAINTENANCE SPECIFICATIONS W l
Item Standard Limit

Front brake:
TY Pe Single disc ____
Disc outside
diameter x thickness 267 x 4 mm ___-
Pad thickness 7.5 mm ____
Wear hmit ____ * = 1 mm

r
F If. ' If II I
I 1,

Master cylinder lnslde diameter 13 mm __--

Caliper cylinder outside diameter 28 mm x 2 (elastic fastener) ____
Brake fluid type DOT 4 ___-
u Rear brake,
Type Single disc _-__
Disc outside
diameter x thickness 220 x 5 mm ___-
Pad thickness 9 mm _-__
Wear limit --__ * = 1.2 mm
I
L I 1 %

Master cylinder inside diameter 12.7 mm ____

Caliper cylinder outside diameter 34 mm -_--
Brake fluid type DOT 4 -___
Front brake lever Adjustable __--

Brake pedal lever

L Brake pedal posltlon 10 rnm (below
the footrest plane) ___-
Clutch lever:
Clutch lever free play 2.0 - 3.0 mm --__
Throttle grip:
Throttle cable free play 3.0 - 5.0 mm ____
(at the grip flange)

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 ~~~ ~ ~ ~ ~~~
~~~~~ -

Tightening torques
MAINTENANCE SPECIFICATIONS m
Part to be tightened
Part
name
~ T!y:d gr:“:~ torque

Front forWhandlebar:
Handle crown and inner tube Washer based
screw M8 x 1.25 28 2.8
Handle crown and
handle lower holder Nut, nylon M l O x 1.5 40 4.0
Under bracket and inner tube Washer based
screw M8 x 1.25 22 2.2
Handle lower holder Washer based
screw M8 x 1.25 20 2.0
Upper steering ring nut and
handle upper holder Nut M36 x 1.O 115 11.5 kJ
Upper steering ring nut
and steerlng axle - M28 x 1.5
Lower steering ring nut
and steerlng axle - M28 x 1.5
Front fork:
Cap bolt (inner tube) Nut M43 x 1.O 20 2.0
Lower compression valve (cap) Screw M24x 1.0 , 32 3.2
Wheel axle protector Hexagon socket
head screw M6 x 1 .O 9 0.9
Front brake master cylinder:
Master cylinder bracket Hexagon socket
head screw M6 x 1 .O 9 0.9
Reservoir cap Pan screw M4 x 0.7 1.5 0.1 5
Front master cylinderibrake hose Unlon bolt M I 0 x 1.0 20 20
Front brake caliper:
Caliper holder Hexagon socket
head screw M8 x 1.25 25 2.5 w’
Oil bleed screw Screw M10 x 1.0 14 1.4
Brake caliper and front fork Washer based
screw M8 x 1.25 25 2.5
Front brake calipedbrake hose Union bolt M l O x 1.0 20 2.0
Front & rear brake discihub Hexagon socket
head pan screw M6 x 1.0 12 1.2
Front wheel axle - M16x 1.5 59 5.9
Rear brake pedal Washer based
screw MlOx 125 45 45
Footrest brackevframe Washer based
screw M10 x 1.25 45 4.5
Rear master cylinder/frame Hexagon socket
head screw
(barrel) M6 x 1.O 10 1.o
Rear master cylindedbrake hose Screw M10 x 1.0 20 2.0
Rear caliper (oil bleed) Screw M10 x 1.0 14 1.4
Rear brake calipedbrake hose Screw M10 x 1.0 20 2.0

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 MAINTENANCE SPECIFICATIONS (SPECII
Tightenmg
Part Thread torque
Part to be tightened size name Remarks
Nm mkg
Driven sprockethear hub Hexagon socket
head pan screw M8 x 1.25 30 3.0
M18 x 1.5 Nut Rear
115wheel axle
11.5
Rear shock absorber.
Shock absorber (upper)/frame Hexagon socket
head screw M12 x 1.75 65 6.5
Shock absorber (lower) Bolt M l O x 1.25 50 50
Rear arm:
Pivot shaft Nut M I 6 x 1.5 85 8.5
Articulation,
Connecting rodlrear arm Bolt M12 x 1.25 65 6.5
Relay arm/frame Bolt M l O x 1.25 50 5.0
Connectmg rodhelay arm Bolt M10 x 1.25 50 50
L
Screw Cham sealM6
gardhear
x 1 .O arm 5 05
Chain support:
Chaln supporVrear arm Washer based
screw M6 x 1.0 9 0.9
Chain protectorichain support Pan screw M6 x 1.0 3 0.3
Chain casehear arm Screw M6xlO 9 0.9
Engine stay
Front stay and frame Washer based
screw M10 x 1.25 64 6.4
Front stay and engine Washer based
screw M10 x 1 25 64 6.4
Upper stay and frame Washer based
screw M10 x 1.25 64 6.4
Upper stay and engine Washer based
screw M10 x 1.25 64 6.4
Rear lower stay/frame Washer based
screw M10 x 1.25 64 64
Englne protectoriframe Screw M6 x 1 .O 10 1.0
‘W Framehear frame Nut, nylon M8 x 1.25 23 23
Rear footredframe Screw M8 x 1.25 20 2.0
Fuel tank:
Fuel tanklframe Screw M6 x 1.0 7 0.7
Fuel cock Pan head
(+) screw M6 x 1.O 7 07
Seat.
Seat and frame Washer based
screw M6 x 1.0 10 1.0
Clutch cableicrankcase cover Hexagon socket
head screw M6 x 1 .O 10 1.0
Voltage regulator Button head
screw M6 x 1.O 7 0.7
Meter:
Upper stay/handle crown Hexagon screw M6 x 1.0 10 1.0
Horn Hexagon screw M6 x 1.0 7 0.7
NOTE:
1 . Flrst tighten the ring nut approximately
38 Nm (3.8 mkg) by using the torque wrench, then loosen the ring
nut one turn.
2 Final tighten the ring nut at the torqueof 4 Nm (0 4 mkg).
I I

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 ~~~~~~ ~ . .. ~ ~~ ~~~~~~ - - ~~ ~~~~~~~~ ~ ~ ~~~~~~~~~

MAINTENANCE SPECIFICATIONS ~

ELECTRICAL

Item Standard Limit

I I
Ignition system:
lgnltlon timing (B.T.D.C.) 11O at 1,300 r h i n -___
Advanced timing (B.T.D.C.) 34" at 4,750 r/min _--_
Advanced type Electrical type ____

50

40
h
v)
W'
a,
g 30
m
=a,

m
=
._ 20
E
.-
c

-I:
.-
0
.-
-
c
U-J
lo

-10
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000
Engine speed (r/min)
14'

Ignition unit:
Magneto model / Manufacturer TLMZ89 / NIPPONDENSO _-_-
Pickup coil resistance / -
192 288 52 at 20°C (68" F) ----
____
GreenhVhite - Blue/Black Colour
CDI unit:
Model/Manufacturer
Ignition coil.
I QCB21/NIPPONDENSO

Model / Manufacturer J0144 (TJ0371) / NIPPONDENSO ___-

Primary winding resistance -
1.04 1.495 i2 at 20°C (68°F) ----
Secondary winding resistance -
14.88 22.32 kQ at 20°C (68°F) ----
Spark plug cap: I
____
Type / Manufacturer
Resistance
T-137 / TOKAI DENS0
10 kR at 20°C (68°F) 1 ____

1 Charglng system:
Type magneto A.C. 1 ____

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 MAINTENANCE SPECIFICATIONS F l
Item Standard Limlt
A.C. generator:
Model / Manufacturer LMZ89 I NIPPONDENSO _---
Normal output 14 V, 13 A at 5.000 rlmin _---
Stator coil resistance I -
0.608 0.912 R at 20°C (68°F) _-__
Colour (White - White) _-__
Regulator / Rectifier:
Model I Manufacturer SH629/A-12 / SHINDENGEN ____
Regulator:
Short-circuit semiconductors __--
Type
No load regulated voltage -
14.1 14 9 V ____
Rectifier:
Capacity 25 A .___

Withstand voltage 240 V ____

Smooth condenser:
W Model / Manufacturer ADP-26 / SHINDENGEN ____
Capacity / Voltage -
5,440 8,160 VF 1 5 0 V ____
Horn:
Type / Manufacturer Plat / LEONELLI ____
Voltage -
10 14 V C.C. ____
____
Maximum amperage 1.5 A
Flasher relay:
Type Semi-translstors
Model / Manufacturer FB222M / NIPPONDENSO _---
Automatic stop device None .___

Flasher frequency -
75 95 cycle/mln ____
____
Power lOWX2+3.4W

‘W

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 ~ ~ ~ ~ ~-~
~. ~ ...__. ~
~~ _ _
~~ . ~ ~ ...~~~- ~~~ ~~~~

GENERAL SPECIFICATIONS ABOUT TIGHTENING TORQUES

GENERAL SPECIFICATIONS
m
General specification
7

ABOUT TIGHTENING TORQUES A B

about tightening torques
(Nut) (Bolt) -
ThistableIndicatesthetighteningtorquesfor
Nm mkg -
standard attachments with ISO-pitch thread.
Torque specifications for special components or 10 m m 6 mm 6 0.6
-
units are indicated In the related sections of this 12 mm 8 mm 15 1.5
manual. In order to avoidanydamage,tighten 14 mm 10 mm 30 3.0
those units with many fastenings by following a
progressive cross sequence, until the final tight- 17 mm 12 mm 55 5.5
ening torque is obtained. Unless otherwise speci- 19 mm 14 mm 85 8.5
fied, the tightening torques given are meant for 22 mm 16 rnm 130 13.0
clean and dry threads. All components must be at I I I I -
ambient temperature.

A L-
p tia’

I I
A: Distance between flat parts
B: External thread dlameter

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 LUBRICATION POINTS AND LUBRICANT TYPE l=l
I I
PI
t I

LUBRICATION POINTS AND LUBRICANT TYPE

ENGINE
-
Lubrication points (part name) Lubricant type
Oil seal edges (completely) 5
Bearlng retainer -la
Rod pins -la
Rod (big end) -
1 4
-

Plston and piston rings -la -

Hub (werght drive sprocket) -1Q
-

Plston ain I
-la -
Valve stem and gulde +la -
i/
Oil seal (valve stem end) -la -
Rocker shaft and rocker arm -la -

Cam and bearing (camshaft) --I@ ~

I
Rotor and rotor housing
_ (oil
. pump)
. . . -la I

Push rod (clutch) -5

Primary driven gear and main shaft -1Q

Sliding gear (transmlssion) -la

Idle gear (transmission) +la
Shift forks and bar -la
Shift cam and bearing (gearshift cam) -1Q

Shift shaft -la

Rod housing coupled surfaces Bonding agent (rapld seal adheave)@
L/ Yamaha bond No. 1215@
Coupled surfaces (cylinder head and cyllnder head cover) Bonding agent (rapid seal adhesive)@
Yamaha bond No. 1215@

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

CHASSIS
LUBRICATION POINTS AND LUBRICANT TYPE ISPECI p 1
Lubrication points (part name) Lubrlcant type
..
I I

W'

Ir'

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 ~~

CABLE ROUTING F l
CABLE ROUTING
Clutch
(1)
cable (8) Tachometer/ (14) Right turn
light [A] clutch
the
Lay
odometerconnector
cable
cable in front of the
(2) Brakehoseholder throttle cables.
(9) Complete wire (15) Meter wire harness
connector
harness
(3)hose
Brake hosebrake the
[B] Lay
(4) Throttle
cables (10) Socket
cover (16) Main switch wire throught the holder
on the handle
(1( 5 ) Bands 1) Engine stop switch
crown. harness connector

(6) Lighting
wire connector
harness (12) Headlight wire
harness connector
(7) Brakeandengine
stop switch wire (13) Left turn light
harness connector

I I

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

(1) Front
brake
hose (IO)Throtte
cables
CABLE ROUTING 1-
(17) Engine oil breather [A] Lay the
brake
hose
holder
pipe (to air cleaner
behind
the left tube
(2) Brakehoseholder
it fastenandguard
case)
(11) Wire harness band
own guard
(3) Left tube of
(4)
(12) Fuel pipe from fuel (18) Oil hose (oil tank to
Plastic plate engine)
the plate 4.
cock [B] Attachthrottle
(5) Throttie cables (1 3) Flasher
relay (19) Oil hose
(engine to cables 5 .
tank)
oil [C] Fasten
the fuel
(6) Tachometer/
odometer cable
(14) Sidestand
switch (20) Condenser pipe 12tank.
the
to

(7) Clutchcable
(15)A.C. generator wire (21)Diode
harness (engine)
(8) Clutch cabie hoider (16) Engineoilbreather
(9) Clutch
cable
holder
pipe
(to
engine 011
tank) engine) (on
1

td

13

-4'

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 ~

~ ~
CABLE ROUTING p-pl
(1) Tachometer/ (8) Decompressor (1 4) Rear brake hose [AI Insert the
odometer cable cable holders tachometer/
odometer cable
(2) Tachometer/ (9) Decompressor (1 5 ) Pipe into the band 3 and
odometer cable cable band the holder 2
holder (16) Air breather pipe
(10) Main wire
(3) Tachometer/ harness band (17) Spark plug ignltlon
odometer cable coil
band (11) Rear brake switch
wire harness (18 ) Rear shock
Right tube guard absorber oil tank
(4)
(12) Rear brake fluid
(5) Spark plug cable tank hose (19) Shock absorber
tank.bands
(6) Horn
. . Hose from rear
(13)
(7) Carburetorsuction master cylinder
Pipe caliper to

11

i/

14

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 ~
~~ ~

(1) Rectifler (5) Bracket (8)

CABLE ROUTING
Tail light wire
p-pq
[A] the
Insert tail
(2) CDI unit (6) wire
turn
Left harness damper the4 into
frame then fasten
(3) Tail
harness
wire
light (9) Air breather
plpe the bracket 5.
(carburetor)
harness bands (7) Rlght turn
wire
(4) Tail
harness
damper

‘.us:

k d

v
3 3

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 ~~~

PERIODIC MAINTENANCE/
LUBRICATION INTERVALS IlNSP
ADJ
PERIODIC INSPECTIONSAND ADJUSTMENTS

=
PERIODIC MAINTENANCWLUBRICATION INTERVALS
- -
EVERY
-
ROUTINE BREAK-IN 6,000 km 12,000 kmI
ITEM
11,000km
6 months 12monthsi
- -
I Fuelline Check fuel hose for

*I cracks or damage. 0 0

r=
*I
Spark plug

Valve clearance
Adjust
-

-
Replace if necessary.
Check condition.
Clean or replace if necessary.
Check valve clearance.
if necessary.
0

0
0

0
0

0
-

L
9
- -
Air filter Wash with water and biodegradable
u
liquid soap, smear with SAE 20Wi50
engine oil or specialfilter oil. 3 0
-
Replace if necessary. -
Air filter case Check condition.
0 0
Clean.
I - -

I
IClutch -
Check for proper operation.
Adjust or replace the cable.
0 0
-

*I
I
Decompression
device
Check for proper operation.
Adjust
~
if necessary.
0 0
-

-1Front
brake system
Adjust lever free play.
Check and replace pads
if necessary. 0 0

*I Replace brake fluid every 24,000 km

- or 24 months. -

Real
brake system
Adjust pedal free play.
Check and replace pads
if necessary.

*I
0 0
u
Replace brake fluid every 24,000 km
I -
or 24 months.
Drive chain Check and adjust chain slack
and alignment.
Clean and grease with SAE 80Wi90 engine
I Every 500 km.

L011 or special lubricant for O-ring chains.

I
Wheels
~

Check damage, balanclng, run-out,

+
spoke tighteness.

*Inecessary. if
Tight spokes and balance/
reDlace I
0 0

*
_. -

7 Tires

-
Check damage and minimum
tire tread depth.
Replace if necessary.
Check bearing assembly
0 0
-

clearanceldamage. 0 0
*I
I - Replace if damaged.
-

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 ~~~ ~
~ ~ . __ ~.~~
- ~ ~ ~~~~ ~ - ~~ ~ ~ ~ ._.

PERIODIC MAINTENANCE/
LUBRICATION INTERVALS Em lNSP
ADJ
0

~T EVERY

:
ITEM ROUTINE BREAK-IN 6,000 km 12,000 km
1,000km
6 months 12months
I , I

I
-
Grease nipple Check rear arm system
bushes (rear for looseness.
0
arm pivot Grease moderately
-
shaft) -
(Ilthium soap-based grease). - O I 0
Arm relay/ Check for proper operation.
connecting Adjust if necessary. 0 1 0 '3
rod pivots
I !
(rear
.
arm) I I
I
I I I

Steering Check bearing for smooth

bearings rotation/looseness.
Repair if necessary. Ld
* '3 0
Grease every 24,000 km
or 24 months (lithium
~ ~
soap-based grease). -
Frame fastened Check all nuts, bolts and screws
* fittings for tightening. 0 0 0
- -.
Tight if necessary. ~

Front Check operation

fork and for oil
* 0 0
leakage.
Repair If necessary.
I ! I -1- ! I I

!
f
Rear shock Check operation and for
oil leakage. 0 0
Replace if necessary.
Sidestand Check for proper operation.
0 0 0
Repair if necessary.
I ! L e
I
*I 1
Sidestand
switch I
Check for proper operation.
ReDlace If necessarv.
Check for proper operation.
I
I
0
I
0
I
0
I

* Lights
0 0
and switches Repair or replace if necessary.
Carburetor Check engine Idle speed,
*
~ synchronization and starter
0 0 0

1 1
~

1
EZinnecessarv. I I I ~~ I
Engine oil Replace
0 0 0
(warm engine before draining).
w Engine
- oil filter Replace. 0 3 I
'3 I
I !

I*l
I 1
Engine oil
tank filter
I
Clean with solvent.
l 0 I - l c I
I 1 I I

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 PERIODIC MAINTENANCE/
LUBRICATION INTERVALS EmlNSP
ADJ
Items marked with an asterisk(*) requlre speclal tools, data and technical skills for servicing. Take the motor-
cycle to a Yamaha dealer or refer to Servlce Manual for the servicing of these parts.

NOTES:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Should the motorcycle be frequently used off-track,it is advised to replace engine oil every3,000 km.
~~ ~

NOTE:
Brake fluid replacement:
1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. Check the brake
fluid level and add fluid as required.
2. Replace the master cylinder and caliper cylinder oil seals everytwo years.
3. Replace the brake hoses every four years, orif cracked or damaged.

L’

I W

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 ~~ ~~~ ~~~~~~~~~~~~ ~~ ~~ ~~ ~ ~ .~ ~ ~~~ ~~~~ ~

CARBURETOR pqq
CARBURETOR
TYPE: YSOPV-2ATK
MANUFACTURER: TElKEl

0'

1 -

I I

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 CARBURETOR pq-q
(1) Carburetor
Throttle
(13)valve
Drain
(28)
valve
Stop
(43) screw set
spring assembly (29) Pipe Throttle (44)
washer
Spring(2)
(14) Cover (30) Pipe screw set
(15) gasket Nut
(31)Screw (45)Diaphragm
(3) Gasket, (1 6) Gasket (46) Needle set 1
nozzle (32) Screw
(17) Screw (33) Pipe (47) Needle set 2
Float
(4)
(18) Stop screw (48) Starter set
(5) Float
pin (34)Clip
(19)Nut (35) Main jet 1 (49) Way 3
(6) Floatchamber
gasket (20)Screw (36) Main nozzle 1 (50) Hose
(7) Screw (21) Hose (37) Throttle (51)Hose
(22)Diaphragm valve (52)Hose
(8)Floatchamber
fastening screw (23) Cover (38) Pilot jet (53)Clip
(9)Springwasher (24)Bracket (39)Main jet 2 (54)Breather
(10 ) Collar (25) O-ring (40) Main nozzle 2 Pipe
W (11) Spring
Screw
(26) washer screw
Pilot
(41) set O-ring
(55)
(12) Gasket (27) Spring Needle
set
valve
(42) (56) Pipe

SPECIFICATIONS

Main jet #150 FIRST

#130 SEC
W

Starter let #74

Needle jet 5C5A-3/5 (FIRST)

5Y 18-3/5(SEC)

nozzleMain 0 2.6

jet Pilot

Pilot air screw 3.5 -+ 0.5 revs

approx., open

Float height 27-29 mm

Fuel level 6-8 mm

Engine idle speed 1,150-1,450 r/min

Throttle valve housing 0 2.5 mm

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 ELECTRICAL
ELECTRICAL m*(
RAM WIRING COLOURS
1. CDI unit B - Black
2. Mainswitch Br - Brown
3. Frontbrakeswitch Ch - Chocolate
4. Emergency stop engine switch Dg - Deep green
5. lgnrtioncoil G - Green
6. Earth
GY - Grey
7 . Rear brake switch
L - Blue
8. Sidestandswitch
Or - Orange
9. AC generator
10.
Adjuster/Rectifier P - Pink
11. Smoothcondenser R - Red
12. Rear stop tailllight Sb - Sky-blue
13. Rear direction indicator lights w - White w'
14.
Diode Y - Yellow
15.Neutralswitch B/R - BlackfRed
16.Hornswitch BAN - BlacWhlte
17. Direction indicator light switch BN - Black/Yellow
18. Driving beam/dimmer light switch
Br/B - BrowniBlack
19. Lightsswitch
BrAN - BrowniWhite
20. Horn
21. Direction indicator lamp relay GB - Green/Black
22. Front direction indicator llghts G/R - Green/Red
23. Controllight G/W - Greenmhlte
24. Parking indicator light GN - Green/Yellow
25. Highbeamlight L'R -
Blue/Red
26. Direction indicator light w - BluelWhlte
27. " N neutral light I N - BlueIYellow
28. Runnlng light R/B - Red/Black
29. Drivingbeam/dimmer light
RNV - RedWhite
30. Resistor 'W'
RN - RedNellow
W/L - White/Blue
Y/R - Yellow/Red

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 0m
4J
7

@I9

1-
m nn ??
cu

2 >0 m m 0

a
m
m

“E

m
w
7

I
I
I

----

-i
co m-
- z

r- ---
(D

In

m
>
‘J

cu

T-

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 W

?~ELGARDA
dlstrlbutrice escluswa per I’ltalia
20050 Gerno di Lesmo(MI) - Via Tinelli, 67/69
Telefono (039)60961 Ricerca autornatica

Realizzazione PGS - Torm

Stampa TipolrtografiaSAlNl - Tnuggro

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