Muz 660 e Yamaha

SERVICE MANUAL
r--'M \
~ - - - - - - - - - - - - - - - - - - - - ' / C J t "--
{f
ENGINE
4NN I MuZ 660 E YAMAHA
FOR MuZ
SKORPION TOUR, TRAVELLER, SPORT, REPLICA, CUP
AND
MuZ650 E
BAGHIRA, MASTIFF
Motorrad- und
Zweiradwerk GmbH
.. --_._---
YAMAHA MOTOR CO., LTD
.._ _ ~ - -
SERViCE MANUAL660E.doc
IMPORTANT REMARK
The repair manual you got is reprinted from the below mentioned mikroflche
because of that and the only possible method of repnnting the text is unfortunately
not in a very good quality.
Nevertheless this manual will be helpful for you to maintain our MuZ SKORPION
resp. MuZ S60E BAGHIRA and MASTIFF.
Partly reprint of microfiche
Skorpion Motor MuZ660UK 06/1994 [SERVICE MANUAL YAMAHA XTZ 660
(91),Part engine]
Equipped with new pictures, created by MuZ GmbH, Service Department
Deadline 1998-06-03
1991 by YAMAHA Motor Co, Ltd (Text and drawings)
1998 by Motorrad- und Zweiradwerk GmbH, Zschopau (pictures)
and KARLHEINZ MOLLER (photos as basis of all new pictures)
All rights reserved. Any unauthorised reprinting or use without the written permission
of Yamaha Motor Co., Ltd, Motorrad- und Zweiradwerk GmbH, Zschopau, is
expressly prohihibited.
2
SERVICE MANUAL660E.doc
NOTICE
This manual was written by the Yamaha Motor Company primarly for use by Yamaha
and MuZ dealers and their qualified mechanics. It is not possible to put an enlire
mechanic's education into one manual. so it is assumed that persons using this book
to perform maintenance and repairs on Yamaha resp. MuZ motorcycle have a basic
understanding of the mechanical concepts and procedures inherent in motorcycle
repair technology. Without such knowledge, attempted repairs or service to this
model may render it unfit to use andl or unsafe.
Yamaha Motor Company, Ltd and MuZ GmbH are continually striving to improve all
models manufactured by Yamaha resp. MuZ.
Modifications and significant changes in specifications or procedures will be
forwarded to all authorized MuZ dealers and will, where applicable in future editions
of this manual.
PARTICULARLY IMPORTANT INFORMA1"ION
This material is distinguished by the following notation.
The Safety alert symbol means ATTENTIO! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNIG instruction could result in
severe injUry or death to the motorcycle operator, a
bystander or a person inspecting or repairing the
motorcycle.
CAUTION
NOTE
A CAUTION indicates special precautions
that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures
easier or clearer.
3
CONTENTS
ILLUSTRATED SYMBOLS
MAINTENANCE SPECIFICATIONS
ENGINE
CARBURETOR
LUBRICATION SYSTEM
COOLING SYSTEM
CRANKCASE TIGHTENING SEQUENCE
ELECTRICAL SYSTEM
LUBRICATION POINTS
ENGINE DISASSEMBLY
PIPE,STARTER MOTOR AND HOSES
CYUNDER HEAD AND CYLINDER
ROTOR AND STARTER DRIVES
OIL FILTER AND WATER PUMP
CLUTCH AND BALANCER GEAR
SHIFT LEVER AND OIL PUMP
CRANKCASE (RIGHT)
OIL STRAINER
BALANCER, TRANMISSION AND SHIFTER
CRANKSHAFT
ROCKER ARM
VALVES
INSPECTION AND REPAIR
CYLINDER HEAD
VALVE SEAT
VALVE AND VALVE GUIDE
VALVE SPRING
CAMSHAFT
DECOMPRESSION
ROCKER ARM AND ROCKER ARM SHAFT
TIMING CHAIN, SPROCKET AND CHAIN GUIDE
CYLINDER AND PISTON
CRANKSHAFT
BALANCER GEARS
ELECTRIC STARTER DRIVE
PRIMARY DRIVE
CLUTCH
TRANSMISSION AND SHIFTER
OIL PUMP, WATER PUMP AND STRAINER
OIL DELIVERY PIPES
CRANKCASE
BEARING AND OIL SEAL
CIRCLIP AND WASHER
ENGINE ASSEMBLY AND ADJUSTMENT
VALVE AND ROCKER ARM
VALVES
ROCKER ARM
CRANKSHAFT
BALANCER AND TRANSMISSION
PAGE
6
YAMTD001
YAMTD001
YAMTD005
YAMTD005
YAMTD005
YAMTD006
YAMTD007
YAMTD009
DE01
DE01
DE02
DE06
DEOa
DE10
DE12
DE14
DE16
DE16
DE17
DE18
DE19
DE21
DE21
DE22
DE25
DE27
DE28
DE30
DE30
DE31
DE32
DE3S
DE37
DE3?
DE38
DE38
DE40
DE42
DE44
DE44
DE44
DE44
DE45
DE45
DE46
DE48
DE49
DE51
4
CONTENTS
SHIFTER
BALANCER. TRANSMISSION AND SHIFTER
OIL STRAINER
CRANKCASE
OIL STRAINER
CRANKCASE (RIGHT)
BALANCER GEAR
CLUTCH
CLUTCH AND BALANCER GEAR
OIL FILTER AND WATER PUMP
ROTOR AND STARTER DRIVES
CYLINDER
CYLINDER HEAD
CAMSHAFT AND TIMING CHAIN
PIPES AND HOSES
WATER PUMP
CARBURETOR
DISASSEMBLY
PRIMARY CARBURETOR
SECONDARY CARBURETOR
INSPECTION
ASSEMBLY
MEASUREMENT AND ADJUSTMENT STEPS
INSTALLATION
FUELLEVELADJUSTMENT
FUEL PUMP
ELECTRICAL STARTER SYSTEM
STARTER MOTOR
DISASSEMBLY
ASSEMBLY
CHARGING SYSTEM
TROUBLE SHOOTING
STARTING FAILURE/HARD STARTING
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FAULTY GEAR SHI FTING
CLUTCH SLIPPING/DRAGGING
OVERHEATING OR OVERCOOLING
FAULTY BRAKE
FRONT FORK MALFUNCTION
INSTABLE HANDLING
FAULTY SIGNAL AND LIGHTING SYSTEM
PAGE
DE53
DE55
DE56
DE57
DE58
DE58
DE59
DE62
DE63
DE64
DE6S
DE70
DE74
DE75
DE7S
DE83
DW1
DC1
DC4
DCS
DC6
DC?
DC9
DC13
DC15
DC16
DCn
DSTART1
DSTART1
DSTART2
DSTART3
DSTART5
DCHARGO
TROUBLE01
TROUBLE01
TROUBLE03
TROUBLE03
TROUBLE04
TROUBLE04
TROUBLE05
TROUBLE06
TROUBLE06
TROUBLEO?
TROUBLE08
5
ILLUSTRATED SYMBOLS
(Refer to the illustration)
..~ ~ ~ _ ..
1
[1iJ
2
~
3
~
4
~
5
~
6
[g]
7
~
j
8
1
9
1
10 1
,
m
@)
e
11
~
14
I
a
12
1;;Tj;;:
13
YAMSYMB.COf
Illustrated symbols 1 to 16 are used to
identify the specifications
appearing in the text
1 filling fluid
2 Lubricant
3 Special tooi
4 Tightening
5 Wear limit, clearance
6 Engine speed
7 n,V,A
lllustrated symbols 8 to 14 in the
exploded diagram indicate grade of
lubricant and location of lubrication
point.
8 Apply engine oil
9 Apply gear oil
10 Apply molybdenium disulfide oil
11 Apply wheel bearing grease
12 Apply lightweight lithium soap base
grease
13 Apply molybdenuim disulfide grease
14 Apply locking agent (Ioctite)
"
Model 4NN MuZ 660
Cylinder head:
Warp limit. *
0,03 mm (0,0012 ii'll
* Linos indicate straightedge measurement
t
,
, ,*
T ~ v
1 ".
I i
"
Cylinder:
Bore size/Measuring point
*
100,005-100,045 mm 13,9372-3,9388 inl
[]J*
50 mm 11,97 in)
< Wear limit
:>
100,1 mm 13,941 in)
mmmmmmmcc _
Camshaft:
Drivemethod Chain drive (left)
!
Camshaft outside diameter
22,967 - 22,980 mm 10,9042 - 0,9047 In)
.
Shaft to cap clearance O,020-0,ll54 mm 10,0008-0,0021 ii'll
Cam dimensions: Intake A" 35,69-35,79 mm 11,4051-1,4091 ii'll
"
~
< Umit >
35,54 mm 11,3992 ii'll
sn
30,06- 30,16 mm 11,1835-1,1874 ii'll
1\1
"
<'Limit
:> 29,91 mm 11,1776 In)
en
5,74 mm 10,2260 In)
~ '
"
Exhaust
A" 36,50-36,60 mm 11.4370-1,44C-9 In)
"
< Limit>
36,35 mm 11,4311 in)
6" 30,11-30,21 mm 1t,t854-1.1894 in)
"
,
<Limit
.> 29,96 mm 11,1795 in)
C" 6,55 mm 10,2579 in)
..
Camshaft runcut limit
0,03 mm 10,0012 in)
Jl
ff
-t>j~ : Z ' : : f : : .
lJ
8
llmlng chain:
Chain typel No. Of links
75 RH 2015/126 Links
Chain adjustment method
Automatic
Rocker arm! rocker arm shall:
Rocker arm inside dlam.
12,000-12,018 mm (0.472-0,473 in)
Shall outside dlam.
11,976-11,991 mm (0,471-0,472 ii'll
Arm to shall clearance
0,009-0,042 mm 10,0004-0,0020 in)
YAMTDOOl
MAINTFNANCE SPECIFICATIONS
Model
i
4NN MuZ.660
Valve, valve seat, valve guide:
IN 0,10-0,15 mm 10,004-0,006 in)
EX 0,15-0,20 mm (0,006-0,008 in)
Valve clearence (cold):
Valve dimensions:
AU
Head alameter

Face width
!" , C
S'
Seat'width
!\
D"
Margin
Stem runout limit
GUide inside diam.
<limit>
< Limit >
IN ! 29,9-30,1 mm (1,1772-1,1850 in)
EX 31,9-32,1 mm 11,2560-1,2638 in)
IN 2,25 mm (0,0886 in)
EX 2,26 mm (0,0890 in)
IN 0,9-1,1 mm 10,035-0,043 in)
EX 0,9-1,1 mm 10,035-0,043 in)
IN 0,85-1,15 mm 10,0335-0,0453 in)
EX 0,85-1,15 mm (0,0335-0,0453 In)
IN 5,975-5,990 mm (0,2352-0,2358 in)
EX 5,960-5,975 mm 10,2346-0,2352 in)
IN 5,95 mm (0,234 in)
EX 5,93 mm 10,233 in)
IN 6,000-6,012 mm (0,2362-0,2367 in)
EX 6,000-6,012 mm (0,2362-0,2367 in)
IN 6,05 mm (0,238 in)
EX 6,55 mm 10,258 in)
IN 0,010-0,037 mm (0,0004-0,0015 in)
EX 0,025-0,052 mm lO,0010-0,0020 in)
IN O,OB mm (0,003 in)
EX 0,1 mm (0,004 in)
0,01 mm (0,0004 il;l).
B
u
"
C"
"
Seat width

.......... 'lj
II' i 1!
Face width
A
u
Head diameter "
Stem to guide clearance
Margin thickness ,,0"
limit
Stem outside diam.
< Limit>
Valve seat width
IN
EX
0,9-1,1 mm (O,035-0,oi in)
0,9 -1,1 mm 10,035- 0,00 in)
YAMT0002
Model
Valve spring:
leng'ltl
Set lengtl> (valve closed)
Compressed pressure
(valve closed)
Tlltlimi!
." 4NN MuZ 850
--------1
IN 32,63 mm {1,285 in)
EX 36,46 mm n,435 in)
IN 27,50 mm {Ul63 in)
EX 31.00 mm 11 ,220 in)
IN 10,2-11,8 kg 122,49-26,01 Ib)
EX 12,3-14,1 kg 127,12-31,08 Ibl
IN 2,5
0
/1,4 mm 12.5"/0,055 inl
EX 2.5"/1.6 mm 12,5"/0,063 inl
Direction of winding
(top view)
IN
Clockwise 0
Clockwise 0
Piston:
Piston size "D"
Meclsuring point"H"
Piston off set
Piston off set direction
Piston to cylinder clearance
< Limit >
,+,-+H
99,945 - 99,985 mm {3,935 - 3,936 in)
2,5 mm (O,OOO in)
1 mm 10,04 in)
INSIDE
0,050 - 0,070 mm 10,0020 - 0,0028 in)
<0,15 mm (0,0059 inl>
Piston ring:
Top ring
Type
Dimensions laxT)
End gap (Installed)
Borell
1,2x3,8 mm lO,047xO,l50 in)
0,30-0,45 mm 10,012-0,018 Inl
Side clearance (Installed)
2nd ring:
Type
DimenSIOns (BxT)
End gap (installed)
T
0,04-0,08 mm 10,002-0,003 in)
Taper
1,2x4,0 mm (0,047xO,157 in!
0,30-0,45 mm (0,012 - 0,018 in)
0,03-0,07 mm 10,001-0,003 in)
Oil ring:
Dimensions (BxT) ~ C i 't8
End gap (installed) I. ~ - - - - ! .
clearance (installed] T
2,5 x3,4 mm {0,098 x0,134 in)
0,2-0,7 mm {0,008-0,028 in)
0,015-0,042 mm (0,0000-0,0017 inl
VAMTDCCl3
AU
"
Model
Crankshaft
Crank width
Runout limit" C"
Big end side clearance "D" ...f-
Big end radial clearance" E" t;.
Small end ~
free play "F" U E'
+Jf..+D
~ A - l
Balancer:
Drive method
Ciiiich:
Friklion plate
Thickness
Quatity
Wear limit
Frlktlon plate
Thickness
Quantity
wear JImit
Clutch plate
Thickness
Quantity
wear limit
Clutch spring.
Free length
Quantity
Minimum free length
Clutch release melhod
Transmission
Main axle n./frout limit
Drive axle runout limit
Shifter:
Type
4NN MuZ660
74,95 - 75,00 mm (2,951 - 2,953 inl
0,03 mm (0,0012 in)
0,35-0,65 mm (0,014-0,026 in)
0,01 - 0,025 mm (0,0004 - 0,0010 Inl
0,8-1,0 mm (0,0315-0,0394 in!
gear
2,74-2,86 mm 10,108-0,113 in)
6 pes
2,6 mm (0,102 inl
2,94-3,06 mmlO,116-0,120 in)
2 pCS
2,8 mm (0,110 inl
1,2 mm 10,047 in)
7 pes
0,2 mm (0,008 in)
42,8 mm (1,685 in)
5 pes
40,8 mm (1,606 in)
Ouler pUll, raCK and pinion pull
O,OB mm 10,003 in)
0,08 mm (0,003 in)
Cam drum and gUide bar
i
I
!
I
Decompression device
Type
Automatics:
YAMTD004
I
Carburetor:
ID mar"
Model
~ ~ ~ ~
4NN MuZ660
3YF 00, 4BW 00 (AHCH)
Primary
,
Secondary
Main jet
(M.J.1 #130
! #165
Main air jet (MAJJ </>1,0 <i> t ,0
Jet needle (J.N.! 5D963/5 5X7C315
5D973/5 iAHCHI
Needle jet
(N.J.) VOO 2,7
Pilot jet
IP.J.! #48
-
Pilot air jet
IPAJ.! 00,6
Bypass
(B.P.! <1>1,0 -
Pilot screw
(p.S.l 2 und 1/2 Turns open
-
Carburetor diameter
26 mm (0.97 In) 35 mm (137 in )
Valve seat
(v.S') 4>2,5 -
Starter et
(G.S.! #76
Pilot outlet
(P.O.1 00,8
Fuel level
IF.Ll 6,0-8,0 mm (0,24-0,31 inl
Float height
Below from the float chamber mating surface
(F.H.l 25-27 mm 10,98-1,06 in!
1.250-1.350 r/min
Vacuum pressure at Idllng speed
26,6- 34,6 kPa
1200-260 mmHg, 7,87-10,24 inHgl
Lubrication system
011 filter type
Paper type
011 pump type
Trochoid Pump type
Tip clearance
0,12 mm IO,D05 in!
Side clearance
0,03-0,08 mm 10,001-0,003 inl
Bypass valve setting pressure
80-120 kPa
(0,B-l,2 kg/em', 11,3B-17,07 psi)
Cooling system
Water
radiator Skorplon 1 pes
Baghiral Mastiff 2pcs
fan
Skorplon 2 pes
Baghlral Mastiff 1pes
Water pump
Type
Single suction centrifugal pump
Reduction ratio 33/34 10,971)
Thermostat
17LB1C (160.. 178F) Opening temperatur
YAMTOOOS
Model
4NN MuZ 660
Lubrication chart:
q Pressured feed
.. Splashed
II
Connecting rod
Rocker arm
1 j
i I
I I
II
! I
II
"
II
I I
,------JI
One way clutch _ I
"
i-Ji
i.._ f
'II
j I
-I
II
-II
,I
"

Crank
, Balancer
Shift fork shaft Gear f ,
:
Main axle ' Clutch I
'-------' >11
, Drive aXle ===========:;.:.
, __-...J
Bypass
valve
Check valve
II
II
II
I
....
IReUe! valve
II
j I
II
II I r t I
I J ; I
II "' ...
II
II
II
II
II
f I ; i
II '
I I r""'----.,
I ........1.'
11-
....
Feed pump
! Oil strainer
!
Crankcase tightening sequence:
Crankcase (left)
Crankcase (right)
YAMTOOO6
ELEKTRICAL
Model
Voltage
Ignition system:
Ignition timing (B.T.D.C.)
Advanced timing (B,T.D.C.)
Advancer type
4NN Mul 660
12V
12 at 1.300 U/min (Rpm)
38 at 6.500 U/min (Rpm)
Electrical type
rpm
I
I f
Engine speed (x 10' rpm )
Ignitor
Pickup coil resistance
(Colour)
Ignitor unit I Manufacturer
Ignition coil
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
Spark plug gap
Type
Resistance
Charging system
Type
1184-2760 at 20
0
e (68FI
(Blue/yellow GreenlwhitEl
TNDF13/NlPPONDENSO
J0268/NlPPONDENSO
6 mm 10,24 in)
3,4-4,60 at 20C (68F)
10,4-15,6kO bel 20
0
e {68FI
Resin type
10kO at 20
0
e {68FI
AC. Magneto generator
YAMTOOO7
!
4NN MuZ eoo
Model
AC. Generator
Modell manufacturer TLMZ551NIPPONDENSO
nominal output 14V 24,5A at 5.000
,
!
,
I
,
26
I
C
24,
,
I
_'I
22
<ll
20
-
,
-
18
::J ,
<..l
16 ,
' ,
]
14
I ,
,
12
C
10
,
,
S
I I
,
6
<I
2
, , ' i ,
o 1 2345578
Engine speed
\ x 10' rpm
)
Stator coil resistance (colour)
I 0,20 - O,JOP. At 2Qac !6l:l
c
F} t VI.'hite w h j ! " ~ m .
Rectifier /regulator
i
Model/manufacturer
SH569/SINOENGEN
Type
Semi conductor -short circuit ripe
Voltage regulator
No load regulated vottage
14,3-15,3V
Rectifier
Capacity 25A
Withstand voltage 240V
Battery
iIlI!I1.28kg/l (1,23 kgli for tropical countries specific gravity
Electrical starter system:
Type
Starter motor
Model/manufacturer
SM13iMlTSUBA
Output
0,8 kW
Brush- overall lenght
12,5 mm (0,49 inl
<Limit
:> <5 mm 10,20 inl>
Commutator diameter 28,0 mm (1,10 inl
Wear limit 27,0 mm (1,06 in)
Mica undercut
0,7 mm 10,028 in)
Starter relay
Model/manufacturer
MS5D1911HITACH)
Amperage rating
l00A
1-
ENGINE
LUBRICATION POINTS AND LUBRICANT TYPE
LUBRICATION POINTS (part name) LUBRICANT TYPE
Oil seal lips (all)
MM
-(!]
Bearing retainer
!
----------
-1m
Crank pin
-Ie!]
Connecting rod (big end)
"'""
j
-1m
Piston and piston ring
i
.. ....... -
Boss (balancer dove gear)
..
Piston pin
-1Ci]
r ..
Valve stem and valve gUIde
.....
-]
Oil seal (valve stem end)
-18
..
m ______
....
Rocker arm shaft and rocker arm
-1Ci]
__ ___
----- ._--._......-
Cam and bearing [camsr.aft)
I

Decamp cam and decamp shaft
!

Rotor and rotor housing (oil pump)
...n_..
-IG.]
.._ ...
---_...
Push rod
I

r--:-- ......._ ........
-IG.]
Primary driven gear and maIn axle
I
Sliding gear (transmission)
I
-G
Free movement gear (transmission)
-G
.......-
i
Driven gear and drive gear (tachometer gear unit)
I

Shift fork and guide bar
-IG.]
Shift cam and bearing (shift cam)
i
-1m
Shift shaft
-iCi]
- ...
Crankcase mating surfaces
Sealant
(Quick gasket)'"
I
Yamaha Bond Nr. 1215
Mating surfaces (cylinder head and
Sealant
[Quick gasketl$
cylinder head cover)
i
Yamaha Bond Nr. 1215
YAMTDOO9
DISASSEMBLY
ENGINE OIS,l,\SSEMBLY
PIPE. STARTER fI/IO:r:OR ANO HOSES
1 Remove'
--Oii pme
i: -Reruov-8:'
''OJ! Pine:
.,3 .
.*SuHier "fOt1,)f
4 Removft
-0,1 hose 1
-Breather hn$ 2 {crank.case'
"Breather -hoSe 3 I (ill tank.}
,5 Remove
-COOil;:ifH
DE 01(E17)
ENGINE DISASSEMBLY
C1'LINOER,'l;:iEAD, CYLINDER AND
PISTON
NOTE','_' _
With'. engine I1'lOunted the cyiHK)e
r
head
;ove'r:"camShati and cy1mder h-elHj Gan bfc malt,
.tained 'bY: removing HlP ports
!'"Seat '.,
" Side c'.overs '
-Air::' sccl'ops
oFuet .tanK.
, .; ..
.. gt.Jarri
Radlsior' .
PIp"S
.,gmti6.n:cOil, .
,-0,1 ,Ilmi<: breather 'h,,'se
" ,

- l' Re'11(}ve
.. Spark Jilun'-
2
- friapd(')lr:'!s
3 Rf'!lIO\:P
-1" HHol llfld
D02(E1Sj
ENGINE DISASSEMBLY
4, Remove:
;,. rIming ,plug
.{'Iug Icenter) 2
5. Tum:
C,ankshat!
tuntil 3: IS a'ilSFlea wl1hstatli.,ln
iH;Y po,nter 4)
6 Rem",,!,
"Tappet CDver (intake) 1
Tappet 'cove'
. '7 ..;Rernove.
COver ';
NOTE: __,.,,-_"'- _
WorkH'lg-ln a crisscross uansro. ioose-t1 the Oolts
1>4 each. Rel'?"ovn' tnem all aff;
loosened "
8 Loosen
BOllS l S;proc'kCll
9 -loos.en'
"Cap bOl1 J !chi'H11 1enStoner
10 RemQve
"fCnain tertsJoner 2
ENGINE DISASSEMBLY
"Remove"
Cl!m
2
NOn: _
fasten asafe1Y w.Fe 3 to trle timIng .:r{lP1 to
if from the <f.ankcase
-10 noHaii the !i!oPDe' plsle 101:; 111.
crankcase' 'When tne ool'\s 1cai'''

12 Remove
- Chain guide"1 (.illadSl).
13
'P4Ie, i
- Q'rlng'
,'Boll& ':I
-,an!ls 3
-,Solis
NOTe' '-- __
WOtkmg in Cfi$Woss pattern the fmlU;
1/4 tum ear.h Remnvf' lhcm aft{>t fltl
IQOsel;leo.
14
.CY,hndt,r. hetH;
004(20)
.ENGINE DlSASSEMBLY
.15. Remo....e
-Gasket 1 neadj
., DOwel pjns. 2
'ur, Ramovt7:'
'1
17,:
. 'Batts. 'I'
. , .
.B"""''''2. -
NOTE: --?l'.,-".....--------
\lvo;kmg on n,ct<ls-scrCSS pattern, loostiH1 the nalts
1M- a{ter al' 'aut
18 R-emov.e-

1$ Remo"t"
I
- Dowel Dlr;s 2
D05(E211
ENGINE DJSASSeMBLY
cAUTiON:
20 '!'lemove'
e!'-lstOtl pip C!H':!IP 1

;. PIStO!" .3
Piston pin putler:
908oo-0T304
"
NOTE: __
-Bctorf;ft"emoving the piston pln4.C;lfciJp. Gover Ine
c'rankc';se wnh a ciann rag ro-ptP..venLtI'le (:11 f
clip lrcm faUirw inw the cranKcaS!1 cavity
the p,siil" lJm. deb,,;,'toe ci,p
gre.oved and.'.;)jn, area If the pl?t""
groove IS debutr.ed and pisron pin'ls
,. '-
lo:.femove.. the p,ston pin puller
, -
. .
Do ;,ot'u1le a'hatnmer to drive the piston pin
:out.
ROTOR AND STARTER, DRI\(ERS
NOT!,: _
With'the engine mounted. fhe A( !"',aqnp!o allcJ
steHler oHves 'can he maint(olrned rJ'y "the'
following par.t
EnCl,,'e guard
1 Remove
"Cover 1
DE06(E22)
ENGINE DISASSEMBLV
CAUnON:
Do not allow .the. rotor "Qld", to touch the
prOlltctionsj 1)n the rotor
6' Remove
-Nui 1 Irotor;
NOTE _--- ""-__
Loosefllb-e mit irotOrJ While- hofGlnfl the rotOt With
the rOWf ho'der 2
l
Rotor hold.."
PIN. YS-0188D 9OS91M171
5 Remove:
,. ge.ar 2
Needle bearing 2
ShalT . 3
.. 4' tcrankcase
O,?wel pinS' '!l"
'Orings If
2 Remove;
s.tarter lote gear 1
"NeeC!<e bearmg 2
Shaft 3
"
"Dowel pm S'
3
sWitl;.h lead
,4'. ReQlove: '.
CIa'nkcase: ",Nt"r 1I&l1!
NOTE':;.'_""- .,-.
VVofk-ing in a Cfls?crdss' pattefn. loosen rhe bOltS
1;'4 turn' 'ein:h. Remove them alter all ari:
IOCH!el1l!(L
DE07(23)
ENGINE DISASSEMBLY
, "
7. Remove:
Rotor 1
.. '
W"oonl'H !<oy . :2
Use the H')tOf J adarHt" t. '

, ;Rritpr\ .; I"
?PJJ''t. Ytl'33271L 9089001362'
Adapt"r: j
. PIN, 9OOllO,0400:'1
'N0'r
E
:
Tighten the lOp; hokbn!j !mIll' lfl.'
the to?1 body 15 para"ltetwith,H1 fotOt' l!
one may- bejJaf'k-erj out to 1ft\'
;b.iY " , ...,
B
V,Jr.e-e1 'r:reor
Needle b",,''''g :2
Washer j
9. 'Mp.inove.
HUlrlB'
-Tml1ng dln,ln."2
OIL fi;l TER ANO.WArE R PUM P
NOn '_......,. _
VVnh the Cf',gtrlt' trw ","iHt, (HHt1lJ {.-1;;
he nlamtameo by rhf' ptill
"ErlgtTlP guard' .
"
1.. Ren,uve
-O:!l fOVPf
ENGtNE D1SASSEMBty
i .. RernQ"1i"::
>' .Oir rUte;
i.o.,"t!.-r,;j, .
3. R<lmo:V,,".
V;k't<;'fpumlS'.
" - .
4.
-0-0,
1
-
'5 Remove:
It Wate, pump nOU5loq 1
6 Rem(.ive
CHchp"
-Wattu pump" t.:tea, 2. '
-Pm 3'
'4
"lltUp housing. ;5
Impeller shaft 1\
ENGiNE OlSASSEMsLY
CLUTCH AND BALANCER'GE'AR
NOTE ,....:...__ _
Wllh the mountPod, The Ciutcri. can bf': malr
py'removmg the. followIng pa\"ts,
"Cklrcn cah!e
-Engine guard
-Water pur;.p
(flghtl
oBrake pMal ..
Remove:

2
- pull lever '3
,.RetlJrFj'jpn;ng '4
-Washer; 5
2. Remove:
, "Crankcase cover, 1 .lrlgh1L
NOTE: __ __'--
, a Crisscross 'pattN!" loascrUhe bolts
-, 1'/4 turn each Remove - fhem' all are
loosehed' .
!.,Remove.
-Gask'et 1''\c:rani<;casf: >Gover!'
-Oowel pins
4, Remove
oBol1 1
-Washer 2
do Pull ,i;ver axle' :1
. [from coven
DE10(E26j
ENGINE DISASSEMBLY
" 5, R"f"Ove
BoLes -i
Outen springs
.P,eSSU!" p1ale" '3

"6ea"ng':5
Pull rod' 6
-Fnc:tJon plate. 1,:
". auich p!a,e
,. CushiOnllPHrig,: 9':
NOTE, " ",,:, , ,;
CJ'1SS1:;"s., lhe ball:;,
1i II ,lhll':'1ill1,.' e( dr.

:'
.,L.i.>i:k,
'.- .... " . ..
'7,loosen:
NUl Jl.elUl.!:b DOS",
!'JOlt! _
IHeri>J.j rdJi", h61diti;1.tO<:
"'.. .. '..',., '.' . .. '.' ...' ..
, cpu:wilIi 'urllverllaLclu,lch flcldar .;l ,
'". ., . . .
Ul'li....l'$a
l
.
P/N;YM91042:
a Refl'\QVll'
,.r;wt
b,C>. 2
:'CIWICh
pl.,e 4' ,
.h<:rusi!il1S
BLY:
-----------
::9:"8i,(.,:tgfll"n:
,: rabs '
10;jl:.tioSl'!", "
"'NUt,:".02;: i'Grankshaltf
I

., .' . '. ,'.__ d,} " _. _ _.
ot'1he (jilve'gu<" anti ,balance"
:_" ?_ f' _
gef,
to dilroa!;l": thegeaf
",:" ",':: .H",--:,
,1'L:Req,pVll,
. ,', ;"1;
"'l"lare'2,,
-o.Salanc!i,"if'iWl'lleal- :3'
- ", "
,
iL,'
PfatfL ')': . '.

"j(ey1'!; ,
SHiFT.LEVEl'l AND GIL PUMP
NOTE: -
Wl,tn eflgme 1he 011 pump he
maiIHlllrlS'd -by femov"y the fOliowifllJ lJ'"i,
'Clutch,c,able
): - "
En9'inv g\,aH!
<,.' o'- ... '--f" '.' ,
pump ho
" - '
-Footrest \righll
,Btak.e pedal '
OE12(E28)
ENGINE DISASSEMBLY
1 Remove,
-Cltcl,p .!
Stull >eve' ;).
~ TonHon 5p1'tng 3
Washet 4:
1
2. Remove.
Stopper levei' 1,
-Co_ar '2
ill Rerum (pnn9 3
3. Remov<;,
Circlip 'f
'0,1 pump Ilea> 2
q Remove
-Oii pump assembly 1
5. Remove'
-Gasket
-Ofings .2
DE13tE:2f:lj
ENGINE. DISASSEMBLY
NOTE:
NOTE
A. CnanK'tase 11lghl!
B Cn:u"fktusc ll.P.ft!
Crankcase sepllrating tool
PIN, YU01135A, 90890.01135
---'
CIl,ANKl:;ASE IRIGHT)
1, Remove'
-Bni1s lr:rankcas.e:
" Remove'
CIClJp 1
Colla
t
-ClfClIP 3
'l.oosen 1he bon:; 1 4 tlJrn Biler] nod r?mOVe them
after all are looseoef:l
Loosen the bolts slanln5i w.1h me h!ghesi' rlvf"'l"\
bered one
.tThe embossed numbers In tlii; crankCfu.,e fles,.g
nct,';; s.equ$f\te
'2 An.til,
-Cnmkcasc separahng lO<)1
3
Cranke" lnghll 2
Turn the shift t:am tc; the PCSI!lot\ Shtfv,,,,: m tr-.e
'that It doos not rlj.m;.ca-s.e-
whe-n sepanUtt)ij. rhf: cr attkcasc:
ENGINE DISASSEMBLY
NOTE: _
.fully 11ghum the too! hold"'9 bolts, but make
sure the roo' body,s parallel ,,11M' the Case II
necessary. one screw m'ay oe backed OUI<llight'y
to level 1001 bodv,
Ai' pressure IS- aPl)lled. allerr;alely tap 0" me
,
front engine ",{)Unting boss, lransm...ion shatts,
MId shift ,cam,
CAUTION:'
Use. lOott to flip on the case half, Tap
o"ly on PQrtions of case" Do 1101
tap on gllSket mating su.rface, Work slowly
and carefully, Make !Iure'the cas'e hal""s
sepa,ate eV<l"'ly. If one end "hangs up:' take
. pressure off the !)llSh screw, and
start over. If the "-5 do 1'101 separate,
check for II remaming ser.,,,,,, dr fitting,
Do not force,
1
4 Remolle'
-Oowel DU,S- ,1
"'Dowel pIn 2
-Q'ring '3
ENGINE DISASSEMBLY
Oil.: .STRAINER
1.. Remove
- Oil t
'Oil COVel .2
'2: Remove'
f .\oil.
BALANCER. TRANSMISSION' AND
. -
SHIF.TI'R
J R'emove:
Shih sMa.!! f
, "
. ShlO shaft 2 '2
!
2, Remove
-Gulfflfbjl' Ishort)
Guide bar ;1 00119 i
-Sh'l' cam '3
-Sh,lt.lark 2 "C' 4
.Sh;!' lork 3R' 5
-Shilt lor." "'l" 6
3. Remove
*M,,;n axle assembly
DE1srE321
a
I
.
,<..:
ENGINE DISASSEMBLY
, ,Remo\le.
D7Ive axle 8sse1TIQlv 1
Coitar 2
3
,5 Rernpve'
shaft :1
EL 'Rt'fm9vf!'
'.,N""fral:swl'ch l'
CRANKSHAFl '

Crani<shah a.sembl,
,
the 2" and-
aaaprel,3
'Crank",."" ,.""ratlng 1001:
"P/I'\I',YUOt135-A, 9Qll9O.0H3!5
. .
Al1l>ptl!r
PIN,'
NOTE,
r,gMel'l the lQol hOl<1tngl:li;)lllJ, bUt mlIke Iliat
Ule ,lnOlb,lK!y IS v";:i,cal wlil1 the If
naclltSSB!'V4- one :;t:rew rnay 1Hici(6ti
!y to ,,' , ..
.. .
ROCKER ,ARM
NO:rl;;'_' _
WIth mowltqd ,the ",cke<arf1" can oe
removing paft.::

<i:
u
';;{ '"
'. < '1:
-':E9
U
l'(gI,t;;rc!
"Fli'd"'tot' ,
Exl'laus1 'P'I>il5

'lOse
Cyltnde','head cove'
J Rerrtove
Plug 1
2. ,RetnOlte
'< ,
.Boli ,I. {rod,,,, ",o,',h.;;:
"
ENGINE DiSASSEMBLY
-:>.
'. AOC';;81 lllm shafl
Roder arm
_
'Remove tt1e rOCKer -arm shaft 0'1 the slide ham
mern"l:' J.' and weIgl'!! 2
Slide'hsmmllr set:
piN YU-ll1ll83-A
Slide hamme. boll'
P/N.90S90..01083
Weight,
P! N, 9OO1lO-!l1l:1B4
VALVES'
NOTE, .,,- _
8e{Qr.e Pilr1S lv-give. v;1t\te
spring, valvp. seat etc. j of the cyHnder J'H,:ad
The 'valve sealing snou'ld lae, checked
Check
valva sea! I ng
leakage al valve seat ;00
faca; valile .eat.al1ovalve sea! width,
Refe'1o lhe AND REPAIR
VALVE SEAT"
1::11",,1<1,n9
. Pour a clean . 1 inW Rnd ex
hauST pons,
.. [neck 100 valve sealing, ,
Jlle';; no I""".ge aHl>e ",..
ENGINE DISASSEMBLY
2. llemove:
. ;'Valve -Cotters
NOTE: .,..-
valve cotters whIte compresSlf)g the
;sPflnQ_ the. 5prioy
Valve SWil1lPlo.mpressol: .
f' YM-04019, !1089l)-04O,li
3 Re;nove.:
Valve reta'joers
't Valve- spong 2'
Vah/e 3
Oliseal .4
Spnng sea! 5
NOTE
idef"1,tify eqch part "Verv CBretully so thar
It can be -relnstafled In'I!S origInal place
AND- REPAIR
INspeCTION,AND REPAIR
CYLiNDER liEAQ.
,1. Eliminate:
Catb';n dl>pasi'
Itrom combustion oharnbe'l
uSe 'QW1ded ,scraper
NOTE' .. -
Do nQt vSl!a-sroarp lnS!lwnen; and avO;d aamag
:;"9 0' se,att:t1ing.:
'Spafil plugth,eao
I). 'VaNe _seat
"1
'I' Cy'-,hn der head
Darr-.age Replace
\rVater facke[
, of m4naraiS RuSl . ElJrnmiiHf?
3 Measure'_
1lWarpagt:
Ou: of specii'icat!on Re5"J!'-fa.ce
Cylinder head ""a,page
'Leas than 0,03 mm IlHI012 inl
4 Resurfate'
head
s ,
-,
'Steps
.. Piae>.> II 400 - 600 gm wet sandpaper on If>e SUI'
face plaIa, "ndresurtace Ihe heBe using a
ligure-e,gh1 sanding patte'"
INSPECnOJIIANOREPAIR
NOTE: _
Rotate the head. several times to 8yold mmo.vmg
roo much 'material from one SlelL'
VALVE SEAT
1 Eiimlnatt?',
-Carbon deoosrt
(from valve 1acI: and v,qlve'senff
2 lf1$peCI'
-Va'ive seat
. Pf!tin$JfYVear Rela.cc the valve seal
3. Measure
eValve.. sea1 width a
Out of specrflcatron Re-tace H1% vaive seal
Valve ."qt,width.
Intake
0,9 - 1.1 mm 10,035 0.043 Inl
Ehau.t
, "Q,g.- 1,1 mm JO,035 0043 inl
.. .. ... t ..
Measuremeot staps:
Apply the MechaniCS bhJlng oye IDY"em'
to the V.a\\I: face
the valve Into the heap
.. Press the valv.e through'1he, valve gUide and
onto the valve seal to make a cleat' pattern.
Measure the yalve sea! w;dth Wherever
valv.e'seat and -valve fac: rnaOf> contaCl 1l!tJ
HIll wiil have been relXl,o\f8d
.'lfthe \/!Jlve seat wtdth:s too Wide, too naf/OW.
or seat has not centereo. ffu: v.arve Seat mUSI
he
022!E38)
INSPECTIOIII AND.REPAtR
,,4 Remc,,"
*Valveseat
Usa 8 ;))Q,,4QV and SOC VafV$ seat cutter
When cutter k'$:ep an 8''''$''' dowfl,-
wtI,q'pr..""",,, (4 ".4kg) to prevefV( chatter
msrks,
--.
Cut Mctionas follows
I
,Section
I
CutU",
I
1
A 3ll"
.i
)
B
.;.-"
i . .
C
:
$0
1-
t
: > .l"
Refacing .teps:
A. Vaive $$a1. TS' -on faoe bul
.1 tOO
;8
valVe sea'! is 'n the 'Midie of Ihe lace hut
it i,s .1,00 narrow
..
\latve seat cutter ,et 'OiHitao ,reS'ult
Tn ftchkfve !t uniform
Us. 46" -t;utt1tr v.llw selr w'dth of
1 II mm 100000lni
@-
----
INSPECTiON AND REPAIR
c .$ too narrow and Ii IS
valve m8!gm
V.'ve ...t euytef lJet , O".'t'('l:d lesutt
fln,, To cenl., the :9.81:
U.e
30 c;:utter and tp .chi-eve its
Second' width ot 1 \l mm
,
cutter' fO.039 inl
o VaJve saar IS rqo 1l8rf6.... ann :.1 IS toclHen
"" near the- boHClm' e.dge ot lhe vah.... F<lU>
V.WIl seat cutter SfJ1, Desired r8t\ul\
: Ant:
U
i lOP To CflMler the SinH liU1C
I' increase its widt",
I
i cutter
, '..
5. Lap
Valve face
-Valve sea.t
, .
NOTE -,- _
Aher r-efacing the valve seal 01 replacing the valve
and \;6lve."'gwde, lne valve seat and val\re tacE:
shQuld 'be lapped
Lappin! .....pa:
Appty acoarse lappIng compounn to, rhp. valve
face.
cAuTlOI\h-
. ..
B:Q sure n'o compoynd ent$fS the gap be,
tween the valve stem and guide.
Apply a.molybdenum dJsulfied Ott to,the valw:
stem.'
!oSlatr thl? valve 'Into 1he noaa
Turn 1he- the val ....e ann valve seat
are '.eVt'!'1h,. polished then' c1ean uH all
compdund,
0E24{E40j
tNSPECTIQN' AND REPAIR
!'lOTe, --__,__
Tv obta'" the !:lest lapping rewlls, hghllY tao the.
valve SlIal while ,otallng Ih",,,alve back /l!OO lort;,'
be_n youl hand.,
.. Apply line lapping compound 10 tn" valve lace
and ree!ll Ihe !lbOve,Slws
NOTE.
8e s",e 10 clEia""H all,comoolJ",t!tom the valve,
lace and ""'ve seal, ane' every iaPP.ng """,Otlon','
"Appll',a'Ml;<:ha"'C:s dye lOykam. to,lhe
'valve IBce, ' , '
InsleI1.lnev.;l>l1e in1" the' cylinder ,
<IlP.tesstM lhtccgh'lhe ,vaive g....Jde and
,ontolhe,I111I"e sea! lo,mai<e ii cleal I:\atlem
.. Measure the Ital"'" seafWiolt\ again' '
Ii Ihe valve seal width ,,"1,01 specificalH.:m,
and tap the vatve seat.. ' '
VALVE AND VALliE GUIDE
Measl"e
ctearance
Stem-to,guide clearanc.. =
V"lvlt ,guide iMide dl,ametn, 8
V..lve litem diamat"r b',
Stem-Io-guide cl...rance'
In\6ke:.'
0;1)10 -1l.l137 mm
1ll,00ll4 - 0,0014 in)
<: limit>, Ollil mm (0,lm1 11'11

Exh,u,"t:
OJl2S - 0,052 mrn
tIl,Oll1 ":tUlll2 in)
.:' limit;. , lUll mm Ill,llOO9 in!
OE2S(!41j
lNSP,ECTIONAND REPAIR
2. Replace-
Vaiveguide
Rsp!aeemem nep..
NOTE '-- _
Heat the cyhnder head m an overt to jO()f'::
to ease- gu,de re:.rnovaf and installatIon and
ttl ma,ntain correct !flier'ere-nee fit,
.. Remove.the vaiv-e guiQe
remove" .1
-j'nstalJ the ",naive gutde tnewJ USlt19 t-he \islve
gutde'ln:rtal\et 2. and vaive rem"ove' 1
t\her IrtstaUing the valve guttie. bpre t he valve
gUide ueing the varve guide rellmier 3' I" "0
. proner.stemlo,guide
Velv$lIuid'e TBmOVel II mm
i"l:
PiN YM-04064-A. !lOO:9O.()4(l64
Valve guide tSlIme, (; mm
11).24 inl:
PIN. VM04066. i!!Oll9O-04066
Valve .golde-instaile, 6 'mm.
10.24 iI,1.
PIN YM04066, A !lll8!lll-ll4ll
NOTE - __" _
Aetace the .Sflin a-fte!. rep1acU1g the
.\I"
rd
" .
3 EI.m'nat"
-Carbon
11rom .alv"
4 Inspect
.Valve tac'
P"t;"9 Wear G",io the lace.
Valve "Iem end
MuSOtOQn"l shape 9' <harnet9t
of 'Rep,lace
INSPEctiON AND REPAIR
5 Measurll:
:>Margin
0,,' 01. $pe<:djcal,,,,,, . ""'plac",
, Margin tb!ekn_:'
LImit: ();II, rnm'IO:032 inl
. 6-
-FlU,nQVT 1\1lJ1Vl! slem,
ru;l oJ spllCil10lllIQn .. A11p1a(:e
Note: -:- _
leoJace gUldell the "' replaced.
""!",ays replace Ihe 0,1 seal il the va;.e is
remoVed,
, Runo!!t:,_
I.e than 0,01 m'm 1iP.OOO4 In]
'----....l
IIALve._SPRING
,I Measure
!FJ/,e''''''9Ih " ,,,alve springl
Out 01 specif,calion' Replace
..Fm.. '."gth 'l/slvlI Jlpringl:
Intak,,:
32,llJ mm 11.2llS in!
ExllllU1iI'
3llA6 mm 11435 inl
I"NSPECTION ANO REPAIR

.gorce waNe spnngl -1
. Out of spedficstlon r Reolace,
t fs installed
I
Compressed 10'C8(
imake: ,
102 -lUl kg 1,2?49 26.011b)
at VJill mm IUl83 in)
. .
Exhaust:,
12.3 - 141 kg \27.12 - 31.08 Ib I
al 31,00 rnm11.2:20 Ii'll
.
3. Measure
-Spring IiI: a
Oui ,of spe1:;ific3t10r. '. Replace'
Spring llit:
'1nt;,ke: .
mm tll..056 ii'll
.Exhaust, .
'.Le1l. t1)8n1.6 mm 10.063 In!.

CAMSHAF'r"
,i. "'soect:..
oCllr:l 'lobs
'PHiing-,S<;ralches Blue. 0Iscolor81,.oii .
.Rf\plac6.
2. MeaSure,.
111iiglh a anti h
..OUI olspeclflCalion -Replace.
,CiliTlJoblls length:
. iliiltke: .. ' . .
JiUl6 - in'tTl
11.1l13s"1.1874 in)
"b"3U9- 35:1ll rom .
. 14091 in)
. crt
INSPECTION ANO REPAIR
.Cam length:
rAl bheul!l'
.. 30.11 - 30.21 mm
11.1ll54 -1.1894.ln)
. b 3I!.5lJ-36.6lt rom
Il.4m-1.44O!I i,,1
3
-Ronoot lcamshaft!
- _OU1 of .. Ae.ptace;
lIu""'" Icam'haltl:
lit". I""n 0.03 mm 1Il.ll012 in;

-riut of ;Measure th
'ameter '-
. -
;,. "' ,. 4;,.0',,""" ,. ,..-
5t:ep3:
-llmoll 1M camshalt onlo Ihe p,ilinder head
.. PosHlon . 'I . pf f'laJiliglil.!Il" '<}fiIO !he
c,,""'ball ' .
"(fOW6! and cvlihdet head:covef
-1loll'!cyllnde, ""..d. eover',
10 Nm (1.0 m.kg: 7,2 ft;(bl
.NOTE ---:. _
. .
the oohs (cylinder nead'coverl", a cnS$-
cross 'pa;u"rn -from- mnermost 10 OUter_
it Dc nat tlJtrnhe when,measuri'ng dl,1ar
once with t"e' fHast>g3uge:'
.. Remove the cytind!3f -haaet COvel Bnd measure
w,dlh of. the Pllmigaugl!'
@
5. K'teasufE
:'.Baanng dtam(tl't:i" a ;cam:Hlatt
.Oul oJ st>eethcahon ccffishah
W,tnln specriIClltlOO -Rep",ce <,lind.., hea"
. a... diameter (camshaft)
22.961 - 22.!ll'll) tTl m
109042 0.9047 'n:
4

1 Inspect:
"Spnng 1
, Damage-Aep'"ce
DecomPressIon" 'pin .2
.. DecompresSIon fever .3
.; OecompresslLin cam 4
DalTlilge' 8enrls Wear
2 Check
play
Play ""SIS Repjat"e
ROCKER 411"", ANO ROCKER ARM SHAFi
Inspect'
III am} shaft
Blue OISCOIot illion Grooves: 'Replacelrnm
inspecT hJoricatton
2 InspeCi
-Bllckl.'r arm .shah I
Cam lobe contact Slirface ;>
Adjuster svrlace 3
Wear PittIng' 1'l1;".,. diS"O:O'"!tOP
. .
. RUoiace, l/'l$P&cf lUnr;CtlHorr{r,.vs1em
INSPECTION ANO REPAII'l
3. Measel,eo
Arm-to-shah cli;a,anc".
Ar-ml(HtJ".aft eiearance #:
Rocker 3rm msrde dlat't\fiu;,r<! -
Roek&r arm shah diameter 0
OUl of specificatlOfi -.. Reptace as a sel
Armto-s:haft clearance:
0.00!l;' n.OoI2 mm
IO:Q904 ,O.OO2IJ in;
T1MlNGCHAlN. SPROCKET AND CHAIN
GUIDE
1, lnspe<:1";
.-rimmg Chain
St!ff, Cracks" Replace tlm!flg chatn and
sprocket as a set
'2 mspec1
, .. Cam
Wear, ",,'Repiace cam sprocket and
hmll"'lg Cham,as a set
3 '''SDeCI
ehaln gutde 'l h?xhai)Sl side!
-,Cham gUide- :2 -(.make 51deJ
O31(&47)
P
UOl J
C =(X + Y)/2
If out of specifcatlon, rebore or replace
the cylinder and the piston and piston nngs as
a set
2nd steps
.. Measure the piston skirt diameter "P" with a
~ c r o m e t e r
2.5 mm (0.098 In) from the piston bottom edgE
Piston skirt diameter "P"
99.945 99.985 mm
(3.935 3.936 in)
'" If out of specification replace the piston
and piston rings as a set
3rd steps
.. Find the piston to cylinder clearance with for
lowing formula.
Piston to cylinder clearance ==
Cylinder bore "e" .
Piston skirt diameter "P"
Piston to cylinder clearance:
0.060 ...0.070 mm
(0.0020 ...0.0028 in)
Limit: 0.15 mm (0.00589 in)
If out of the specification, rebore or replace the
cylinder and replace the piston and piston ring
as a set
PISTON RING
1 Measure:
Side clearance
out of specificatlon-+ Replace piston and
piston rings as a set
NOTE:
Clean carbon from piston ring grooves and rings
before measuring side clearance.
CVLlNDER AND PISTON
l: Eliminate
'!f CaJ:bol'" deposus
11tc.m the plSH':m CH3Y..ff"} "ind tlny ytft(}\If:'. i
2 Insp'cr
. Piston waf!
We.tH Scratches Damaqe Replace
3 Ehm1-i\B1"
," Scorf.'! f'.T'U1fks- iHld, fHU1-W-er
rtrom the- side of t.ne J)Jston ;
Use II 600 - 800 gn! "'1'1 slInQP"Pl'!
--
Sand 1M' ku,:riSSC1QSS pattE-in 00 not sam; ex(;t1S

. .
sl\ie.ly
4 Inspect:
Cyltnder wlfle.t jl>"kel
C,rUSf Q( mlOera,ls Rus! - Remo\'e
Cyhnder waft
wfla., SCt.(jtChf.?'5 Rehofe Of replace-
5: MttesVT--
Pistor:- io-cvlltlOOI dea(orH.:e
..._.............
_ i.
Measuf.ement steps
Firat sleps
Measure bore' C with a Cllllnder
gauge_
a 50 mlTI' \ 1 97 fron, tbp to<)
Non: .
Measure the Dore .,(" !no par-ailf;"1 to and
at nght at>gies.1C the ctat>ksh"tt
Then find tne of' Hle
Cvlinde, bo'" "C;"
100.006.- 100:045 mm
13.9m- 3.!l38ll inl
<:: limit:l00.1 mm 13.941 in)
IN'SPECTION ANO'REPAiR
2,
Piston pin to-pist,pJi t,ie-arsnce
Mauur.8ment stepa:
.'MeaSure the plstonp", OI.l!s'de,dil!meter a,
If out specification, repiaee me PtstOrt pm,
Outside dlarrniter Ipi$tOfl pinl:
. 21 JI9t - 2i.l'lOO mrn
10.11658 - 0.11661 In.l
Measure the "'$\on, "',jde diameter b,
Calculate tne' piston pH'H,O""SIOfl clearance
with follow,,,g formula:
. Pillton pin-to-platon clearance
Bore $In lpi<rton pinl b
OutsIde diameter (piston pinl Ii
Piston "in-to-plston clearance:

10,0002 ... o.liIbII fn I
Limit: [1.07 "'mia.oro in)

Side clearance
Top ring:
0.04'H008 mm
(0.00LO.003 in)
2nd ring:
O,03'HO.07 mm)
(0.00LO.003 tn)
2. Position
Piston ring
(into the cylinder)
NOTE _
Push the ring with the piston crown so that the
ring will be at a right angle to cylinder bore
00mm (0.8 in)
3, Measure
End gap
out of specffication _ Replace
NOTE _
You cannot measure end gap on expander spacer
of oil control ring If oil control ring rails show ex-
cessive gap, replace all three rings.
End gap:
Top ring
0.30.,0.45 mm
(0.012...0.018 In)
2nd ring:
0.30,.0.45 mm
(0.012.,0.018 in)
Oil ring:
0.2...0.7 mm
(0.008'HOO18 in)
PISTON PIN
1. Inspect
Piston pin
Blue discoloration groove _ Replace, then
inspect lubrication system
INSPECTION A:ND REPAIR
CRANKSHAFT
1 Measu'e'
"rail1< width A
OLl! of . Replate n ankshan
Crank. width.
14.95-75.00 mm
12.951 - 2.95:\ inl
, .
C
Out 01 specificatIon" Replace crankshat!
andlOr bearing.
. . .
Runout Jmit;. .
[6J.. O.03mm 10.001 in)
Small'end free play 0
Out of Replace big end bear
Ing. crank pon and'or conneC.l'!'\g rod
Small end free piay;
. {LS mm 10.031 inl
1
-13lg end rad,al clearance
OtJl 01 specification. Replace connecting.
roo. big. end bearon" and'or crank pon
,
. Bill end radial "Iaarance
0.01 - 0.025 mm ,
, 10.0004 -'0.0010 in)
SIde c111arance j:'

Ol.ll of .spacificalion Replace conr>ectlnll
rOd.
. Big. end s'de clea'80tHl' .
0.35':"0.65 mm 10.014-0.026 in!
Crankshaft' reassembling point
the e'ankshaf1 1' end the CTllnx pon 2 '011
sages 'must b.e .p,operly mlerc'onneCled wiTh a
tolerance of less' ihm lmm ro.04 inl
OE36(E50)
INSPECTIONAND.REPAIR
BALANCER DRIVE GEAR AND BALANCER
GEAll
,I Inspect:
Bal9ncer drive gear Jeetb
Balancer gear leeth 2,
Wear IOamage : Replace both gears
1 2, Chec,
Match 1
'If Ihey are.nol aligned, -AI,gn mmen mar;,s
. ,
as shown
HECTfUC STAatER-OR1V.{
1 Inspect' _
Starter- gea' 1 leeth 1.
Starler 'die lIear 2teelh :I
StllMer wheel gear leeth J
Bu'rs 'enipS: Roughness ... ," Replace
2, inspect:
eStaf1:et 'wheat gear
(con,tactmg- $urfa,c.esi
P'rtlng Wear Damage Replace,
J, Check
-Starte' 1;lvlCh operat;on
. '.
Chetkmg step.:
.ln51all the 'Slaller Wheel gear to, the S1arte'
clutch. and hold lhe star1erclutch
-- When turning trle Starlf;l1 wheel gear CtOCfo; W'!se
.A', ,the starter imd the wheel gear should
Oe engaged,
it nol, tim statte,. dUICh is faolly It
OEJ7!E51)
.Wnen tUrn'ng wheel ge"r COU!"Jer-
dock'AliSe .'8' starter Cll;lcn gear shoy'C i\J;-f1
. .' -. .
_teel"
11 no!. the Slarter clutch 1$ tauHv It
,PRIMARY'I:HHV.':
" inspect; .:
, .Pumarv drIVe'gllllr teeth 1 ,
.Pnma,i d,wl"ri gea, 'teeth , 2
Weal ;Vamllge oolh ,gears'
Excess,iva,flb!$l1$ dunn\? operation ,Replace
gears
,
GIUTCH
I 'Inspect;
plate
, D<JmaQe: Wear Repiace j"clion "Iaie as a
":"" , ,
.w_
limit
"
.2.8 mm
10 1111 in;
fOm
Ilrlll2 'n'
'; , Thlckne",s
f--lI..
I
,. " t ; .,.,.-, ., t-
Typ.,; "A' ,U.. - 3.tJli -mm
.: 12, _ :JIUt6 0 120 '"I,
. "13" i.74" 2':ll6mm :
'Ill. lOS.' 0.113 \"1
:(;'Me"St.lfB
pl3/e rt,;ckness
: Replace Ir 'Clion pia te
:as '.' . / .
1"
MeasJrl! :n "lilt 100' po.nts
, . .- . .
,:,r.
DE311IE52)
'INSPECTION AND aEPAiR'
3 ,lllsp"e!:
-ClutCh -plate
Damage. :,ReDlace clurcWplate as B sel
.Warp limit:
la"" thanO,z mmlq.OO8 In}
4, Measur,,:
.Clilte"': pI.IIle '''Blpage
Out "f llPacilt.;ation;:RePlac-e efutch plate
as ,
B surface piateeand teeler gauge 1
" :() . .
S. In.pe<: I:
Clutch s""ng
Oarr18{15 Rep;.ace as "e set,
. .
"'---..... @
, 6. Measure: ,
.Clutch tprmg ,Iree lenl'/ffl "".
Oul "j sp&#icaOon . Rep:a.;e 'SIlTIng os a
set. - ,',:'
,Free length iCIOteh./lj:lringl
42.8 mm (1:. inl ,
... <limit: 4O.S mm 11.6D(l inl;>.
7 tnspec-t:
..CrOg$ 'cn H'" cr'uIe,," hollsrng _
or replace.
NOTE' '.:' .
the-cll.t'''''' el.
<, . . ' ' - >" -'
'pVC.. atlon
DE39(ES3)
Reolace
iNSPECTION A'ND REPAIR
'S,lnspect:
. boss" splines

.. "', .-
NOn",
I
Seoring on the clutch bO$S sPhnes et
"ratic operatfof). ' ;
9 Cru!ck
*Cm::umfarenhai play
.. Free' play J:.xi.slS ,Repfa'ce.'
, ,
10, 'l<1soeO! ,
, .. ' .. J. 1
-Oe;1f fee!h !'pul! lever fllde
1
J
G",.i; ie9tf"ipl.l1l 'odl :I
,Wea,! D<!malle ' "Replace '8S, a s,""
'iI,'fliiiecr
1 "pnll ."d'
'.W'; Dilmatl'
Transmission 'ANO:,SHIFTrn
Inspect.' " ,
Sl1iit:f(I,k'''an' iollOWlff f
. . .. - .
'.. ShIh tqdr pawl 2. ,
'8enos, _
lNSP,ECTIQN ANtLRE'PAIR
2
"Sh'ftt cam J:J'foove.
.: St"tt cam.
D"-Se",Rep'ocp.
'
S hitl ltlrk "",'leT"nl
Unsmooth' 'i!r>erahen 'Stil:: -fOtk;
'.illl\d 'or guide bar.'
.:i Inspect'
-rGLi-1de Oaf
ROIL the bar on 'a flat
lllillti:ts'fleptllCe '

.po ,,!<l!' att"mp! 10 straight"" a bent guid"
, blfT.
5 Measure
RunOUi maIn a:<:el
.' Replace
Runaut'
le th"" 0:08 mm 4OJlO3.in)
-,,-----"'--,
Do not attempt. to straighten a befit a,de
0, Inspect:
tooro'
p.nmg Wear
oogs
era,s::s jv1rsslng portion$. .-
Repl/lce
OE41(E55i
"INSPEc:nON AND. REPAIR
..,"."
'".- ..
ReSlSs.SmbJirig,,' paint:
the 2'('l<1'Plnlpn gear 1- 1M: the f),8Jr. a)i(l(i
;!.as ..
... 4"
.7.. .
'!Spring:T .
..
Shlft leve!".?:., :.'
.:Damagel'SendsLWear
.. , ""',
,S'!hspect
Shih 'shal1
Sends Weai Damage
9 lnS;1ect
."Stopper iev'er', l
.Boller ,?ughiy . ',R<lp!.i'c.
Ben<l!i[)amage'" "Ifpl;,ce.
ReMn:;'Po,mg ;:2 . ,
.Darriage' Ctacks Replace' .
OIL PIJMf'.WATER F'UMP'AND:STflAINER
. 1. Me1l\l(J'e: .'
'TIp cleari'l1r:ea- ".
f,betweerj'irmer rare!"' f"'and pvlr rOtor 2.. I
-Side <Iesiance .b
txJ!er,:ro!pf
";1'1
".b.ut 'OJ' p\!rr!p', i
DE42(E56)
INSPECTION ANOREPAI R

Tip clearance:
"0.12 mm 10.005 in) .
Sid.. cl.... ..: '
:O.03.,O:llll mm Ul.OO1 - 0.003 inf
1
2 rnspecf:.
' Qif pump -drive gear '1
Oil pump ClI.....en gea;' "{
Replace.
3, inspect
"-1
.vv:.ater .l?ump hou$Jng 2
!II Water pump gear4 3
CraC"s Wear Re;face,
4 Inspect
.Od strainer i
l;Jamage" Replace
DE43(E57)
INSPECTioN ANt> REPAIR
OIL 'OEUVERY PIPES
i. lnspect
Oil del ivery pipes
.Cracksl Damalles -. Reolace
Clog" Blowout with compressec aor
CRANKCi<SE
1. wash the case halves Hi mild
solvent.
2. Clean all th/! gas,et mating suriace and crank
.CPSe mating surtoce thoroughh
3. Inspect:
-Crankcase
Damage"Replace
Oil ifelrvery passages
Blowout wit.h compressed air
BEARING AND OIL SEAL
,1. Inspect:

Clean ar,d lubnr.ate, then rotate Hiner race
with fingef'.
RouQhness Replace
2. Inspect
-Oil seals
Damage/Weal
CIRCUP AIVO WASHER
1 Inspel:l
-e'n;llpS:
-W&v.ttrs
looseoe$ll," BM'lits Replat:t;
DE44(ES8)
i Valve (intake!
Hat ,
.,tnt Shatt lexbaU$tJ
Rtl'Ci:et,&(f'r\ #.;
HoCker at'm d3
ROCket arm shaft reJl:haust;
Vakie
ENGINE ASSEMBLY AND
ENGINE ASSEMBLY AND.ADJUSTMENT
IIll.tltE AND ROCKER ARM ,
;T, Rocker arm #. 2 .
Wave wesner "
arm shatt {tr.rake}
Roektll arm .. :. ..
t Vatve cotter
:4: ret'lf'l(N
o_1 sea! '"
\! yatve Sptlflg ,
!VALVE SPRING TILT LIMIT:
l
inn". spring:
B Ul" or 1.4 mm 10.055 inl
, Outer spring:
I 2.5" or 1.6 mm (lU163 inl
14 Nm 11.4 m-kg. 10 h-lbl
110 Nm 11.0 m-k", 7.2 ft-lbl I
C STEM RVNOUT UMIT:
0.01 mm (0.0004 inl
o VAl.VE SEAT WIDTH:
I 0.9-1.1 mm ro.03S-0.043lnl
VALVE CLEARANCE (COLDI:
A Intek.: 0.10-0.15 rom 10.llll4 - 0.006 in)
Exhaullt: 0.15-0.20 mm 10.006-0.008 inl
DE45(E60)
'ENGINE AS'SEM8Lv AND ADJUSTMENT
ENGINE ASSEMBLY AND
AO"U.JSTMENT

For"tmgine reassembly. nrplaclf lhe foUow
In\; parti; witnnew' <me$..

-Gasket.
-all >oeal
-c.opper:was"",
-lock llYn"....
-Cireiip
VALVES
l.:Deburr:
,;,Vahte: stem end,'
UilIl to smOoth the 5,em end
'" . .. .
2. "Apply:
- MolybdMum disuif;de Ol;
lonto 1Ialve .tern alld oii seat!
3: Install:
.. i"Sptlflg "ea'

-Valve
-V1ri,;esprlnll.4
-Valve reta'''er
, ',,' ,
1""0 cylllld<:?, flea'dl
ASSEMBlY'AN'O ADJUSTMENT
NOTE' _
-,Make sure that tnjeaeh valve IS >0 Its
. 'O!'I\tH,\al b to'H, iQen,
matk," as toflow,
100al$.e :I>/1'-
3VF
-Install the valve spru)Q \IV.t" larger pitch 6 lac-
. lnH upwaid
! Sri'ldlier pfH:h
4 Hlstafl
-VaJve cotter,? -1 .
NOTE: -'- _
Ins:'t,aU the v()lve cotters<wh.uR coropressmg ihE:
vaive With the vidvf; 50fmy 'Of'!'lPI8SS0t
Valve spring compressor
PiN. YM0401 9089004019
5: Sec\.He the valve (On!:' an to the valve stem
by Tt3PPH)9 if wnh a pt,:,ce of' wood
.NOT!' .,....
On not hd so much 11'5 to the \o\?lve
DE47(E62)
-ADJUSTMENt.. ' .
." ..
. ROCKER ARM
J l'Ubnc8te
.. Engme Drl
'HO t.he. rocker arm S1">.,ft;
2_ I"stall: .
riocker al"1"T'
, aJIT'>' sha
t
'\
BpI! 1 lroc'ker arm shahl
10 N.m no m'!<g. 7.2 fl.lbl
1 # 1
-2 .2

4 R4
:; .jnStall
'Plu;' 1
ENGINE ASSEMBLY AND ADJUSTMEN'
CRANKSHAFT
1 Crank pin
2 Crank (left)
3 Connecting
4 Bearing
5 Bearing
I
CRANK WIDTH:
A 14.95 - 75.00 mOl 12.Sl5O- 2.953 inl
B ' RUII/OUT LIMIT:
0.03 mOl 10.0012 in)
C SMAlJ. END FREE PLAY:
0.11 mOl 10.031 Inl
BIG END RADIAL CLEARANCE:
o 1),(11-0.025 mm 10.0004 -0.0010 inl
BIG END SIDE CLEARANCE:
E
0.35- 0.65 mOl 10.013 - 0.026 inl
1
CD
I11/37-45-221
\
\
1\
i
1
m
\ @ ~
~ I
!150 Nm 115.0 mkll. 110 tt.lbl I
DE49!E64)
ENGINE ASSEMBLY. AND ADJUSTMENT
CRANKSHAFT
Attach:
.. Crankshaft- l(iS1a1h<ig tOni
if\staller set
PIN. YU-!IOO5O
Crank POt spac", 1.
PIN. YM-91044
PIN, 9089ll.D4061
Adapt", .. 10 2
PIN YM90069
PIN !Illll9O-04059
C'anksllaf.t instaUe, pot 3
PIN. 90890-01274
Crank.hal't instill I.. , bolt 4
PIN, 9089ll-01275
Space, .5
PIN, 9089ll-012l18
NOTE: _'--- -:- ,-
H9ld the 'conne(:ttng rod a1 lOP dead (ante! with
one hand wfllie !Urr1lfitJ nut of tOe installing
tool wjth the the !nstalhng tool Untff
half of the 5;rankshaf'1:beanng $ IS Inserter! Il1tO
lhf+ as.. Thfm aod the s.pacer
5 ',6S;,5hown and tnSlarhflH too! \lntll
the against rhp.
CAlITlON:
TO'protect th" crllnkshafl against .cratch"s
0' -to facilitate the oper81io'n of the
httion.
Appfv the grease to 011 .",>1 lips. ana ap
.ply.t'tle,"engine oil to each be"a.ling
DE50(E65)
ENGJNE ASSEM9 YAND ADJUSTMENT
TRAI'tSMISSION
\
1
m
c I USE New ONE
A DRIVE AXl.E flUNOUT LIMIT:
0.118 mm 10.003 Inl
IB630SNRX1C31
IB6305SH2 I
B MAIN AXLE RUNOUT LIMIT:
0.118 mm 1ll.003 inl
SHIl'TER
1 Guide Oaf Ooogl
2. Shitl lor' *' 3 "if
:> SI'!i!1 10'0 .. I"L
4$;"111 ,om
5 Guide bar i shurt'
5 Sh"'l"'" # ziC
7 Snill shat<, 2
8 Shift snair
9 011 1;1;81
1
m
DES2(EGS)
. ~ . .. -
BALAN:CER: TRANSMISSION AND
SHIFT'ER
1. Install
"Neulral ;-.;wi,ch 1
2 Instal;'
"Sai,mcer !;hatt 1
'3 lr1stalL
.. Collar 1.
Or.ive al< ie assel1lt>'Y 2
"1. InSTall
"M.un a:.:le assemt)lv' 1
. .
5 Apply
.. Engine"oil
lonto gwde barsi
ENGINe ASSEMBLY AND ADJUSTMENT
S. inSlaH
., Shih torI< ""i.'
Shit! tOtk 3 .. R' ']
'Sh"l fork 2"C 3
-Shift cam
-Guloe bar HOflq I
ha: snort , 6
!IIOTE
f!1'S>tCftl shih h,rk.!> wHM1'hft or)
Hadl $hl,h foo tat."lfl1J figh1 !u'lc et' fhi:: -r:n-ginc_
7 1"5toll
-ShIh srl-at,l 2 .
"Shift sJi.lft 2
8 Check
.,;r Opp:r<tl;nn
f)en.<;p
DE54IE701
OIL STRAINER
_
ENGINE
_=:;-_... mmm
,
,
11 Nm 10.7 m.kg. .

'-'
I
I
5 1 ftlbl I
.
DE55iE72i
ENGfNE ASSEMBLy. ANd.a.OJUSTMENT
CRANKCASI'
1 piaU)
2 locli plate
:3 CtaNi.case hOse.
4 -cab;e
5 CranKuse
6 Coiia
t
7 DQ:w6r pin
e O'Owei pin
9 Of'tl"'IIii
jA ITIGHTENING SEQUENCE: I
4}
DE56!E73\
ENGINE ASSEMalY AND ADJUSTMENT
SHIFT U5VE9 AND OIL f'lIMP
f
(!"HUt. .
, '!r.41f'\\'g
4 Cc1l.af
t.
6
,-' ..
.!
.' . D,
9., m:)
ra-
.
A
/:
:
j
ENGJN..ASSEM8l V
Gil STRAINER
1 '''''!'<ill:
'-G",*e/. 1
-0::1 suatt'ffiJ 2
,. Oil t-o<vel . 3
Boltla" sUll;ns" ' J
7 Nm'jO.1m.kg.5.1 !t.lb)
BQl:noil pa!is:-ge Ctlv"d, .
,1 Nm 10.7 mkg.:!W!:t.lb, .
.- _"0 ... , _.
CRANKCASE IRIGHTI
I Apply
Sealant
lome ma1t:,g (11 halves i
'NOTI'. .-"c....:--_-'--_-'-- _
DO' -Al:LOVV any seai;'HH W If! CmHtlt:!
WIlh ,he ",I.gaU"IV.
..
S"ah.nll'luiCk 1l".I<e'VI ,
..PIN.ACC-nOOH)1
Vama'h. Bond No,
pI N 9llll9O-85505.
Quick Gasket
IM!all
'0 ""ll I
-OGwal ",n 2'
-D{)wel.pms 3
l Fit fhe 1t!11 unto lfw nttl;! (;16(' Tap
,un 'th+- "'.IIth rl SOfr ..
OE58(E75)
ENGINE ASSEMBLVAND ADJUSTMENT
NOTE- --,. ---
Twirl' the shift cam to' the POSHll',;:H1 shown in tbe
figure"Sd' that it does nor contact The cf.arikc.as'e
!r1sta'lling. try"e '

Bet.,..., "'''tailing ,end torquing the crankc""e
-tlOldinll'Sc'llWlt, 'be stire to check whether
H\:'lO\!'jf 'rIle transmission Is fu...:tion"'g properly by
manually faUlting the mi'!!, ""m,'a'ther wey,
4 Tighten
1 ... 14
5 Apply
64 SHOkl; engme oil
. Ito-..t,he mank ytn, oil de'tvery
, Bolts'./.crankCMlel
10'Nml',O'm:kg,1,2,ft.ibl
6Chec,
-Crankshaft transmlsSlon operatIon
Unsmooth opefiltion -Repalr,
SHIFTLEVHl AND OIL PUMP
1. Instali
Cirt;lip '.1 ito dnvp. aXle!')
-Collar '2
ClI'"hp J
NOTE: -'-
Sf.af.!ing fha InweSl
ber-ec one
the cable on "the boll N;J 4
DE59(E781
AND ADJUSTMENT
2. App;.,
t4, StrOKe !mgtnc ct!
Ho me .oIl passa}}t::'s lH o,.t" as';
,

Apply "/lb"ral lImol.ll'1t.of 4 ."ok" ,,"g'''. oil
to the"oil pump PS!UUfyeS in the
Q/the eng';n& may be damaged
3 Apply .
+4,-sHoke eng-m,e Oli
ito th@ oil jl.aSSitgBS l!"'l tnr: 0,1 r.vmfJ)
, 4 In'Slall
1
0 'dn9 ,-2
-O!I pU'T1p 3
.. ali p:ump gevf, 4
-C"ClIP .5
Bolt loll pump! "---"]
'--'L-_1_O_N_",_, !1_0_rn__k.:;\l_._7_2_,_1'_, ._lb_'__.1.
:) instal!
50J';II'9
-Coil.' ,2
Slnppt'l 3
NOTE
Ser rh' Spt!(H
f
fHul "'1onnt-'! !s:vw dl pr-ilp.;; fl-{;
SltH)fl
DE60(E79)
6 lnstall
ePJatfi washer 1
T spnog 2
Shltf leye! :1
-CtrChp' 4
NOTE: -.,.. _
rnslaHmg the S'll+t lever dllgn the puncnert
OIl ,the 'Shift levPl wl1h tMe pu.l1f:Oed fl\sh
on the,_sflif! 'shaff
DE61(E80)
BALANCER GEAA
1 Key
2 Balancer gear
3 Plate
4 Lock washer
5 NUl
6 Plate washer
7 Key
8 Plate
9 Balancer d r i v ~ gear
10 Plate
11 Primal)' drive gear
12 lock washer
13 Nul
ji>.! USE NEW ONE I
6iJ Nm (11.0 m-kg, 43 h .Ibl
F'I USE NEW ONE I
r
/
i
Oe2fE81I
m_ _
ENGINE ASSEMBLY AND ADJI.!STMENT
CLUTCH
1 Clutch Sft
lH1
iJ
2 Pressure piaH:l
3 Pull B"';o
4 Pull, "lSio'er -
5 PUll kt...e:1 ade
6 fn{'"!lon pia.te : .Ai
7 Wavtt "plate
8 .c-'iftch rJJw
9 IIYfiE' 1:$:
10 Ciutc-h hos!J
11 throst wastltH
, 2 OHler-. I"lCUS'n<J
13 Pmnary
A 1 FRICTION PLATE:
Type ! Thickneu
Wear Limit
A
2.94-:U16 mm
2.8 mm 10.110 in)
2 pes.. 10.116-0.120 inl
B 2.74 - 2.86 mm
i 2.6 mm 11l.1ll2 inl
6 pes.. 10.108- 0.113 inl
I
Is Nm 11l.8 mkg. 5.8 tt.lbl I
\
<D
,
I
I
1120 111m 112.0 mokll. 85 ttlb) I
10 IUSE NEW ONE I
CLUTCH SPRING MINIMUM
S FREE LENGTH:
40.8 mm 11.606 in)
CLUTCH PLATE
C WARPAGE LIMIT:
C.l mm 10.008 inl
]6.5 Nm 10.&5 rookg. 4.7 ttlbl I

/

e lui USE NEW ONEI
3 AOP'Y
0.;
"Onto hearrtlg and taft'h)
4 Instal:
CiutCh housing
! Thws1' :2
-CI"tch "U55 3
-lock waSher .;
-tJl.u1 eli' Idutc); bossl
NOTE
..'
fifthe laos Oflh tOCk washer to'The Q'oove of
tne: Clutch bOSE.
5
--Nut bos.si,
'2
Universal clutch holder'
, F:/N YM,91042. 90890-04086
III "t.( clutch boss!:
90 111m. (9,0 m.kg, OS 1tjbl
6 Ben?, :"
-Lock washer fab 0
(along nl!t fraU
7 Apply
M(llvtHjenul'r: q'HI1${'
{<1109HH ieCl'h of mill tmil
Ef\gJ!ie Otl
!ontQ bearing iPtltl
DE5S(E83;
-CLUTCH AND BALANCER GEAR
'1 lns",II'
-Key 1
Batancer gear .?,
-Plale 3,
"'Lock washer 4
-Nut 5 Ibalancer 'gear;
Plate washer 6
-Key ,7
-Plate '.6
drive 'geer 9
- Plate it}
., Primary dnve gear -I!
- Lock washer '12
".- .'
. Nut .1 primary drlye gear)
Nut lbalancer lle.,rl
60 Nm [6,0 m-kg. 4.3 fHbl
Nut jprimarydrive gea'l:
120 Nm [12.0m-kll, 85 /tlbl
NOTE: . '
-When Instalitng the dnve gear. align the puncher:!
mark "iff on the dnve gear. ..Mfh the punched mark
1} on the tlalancer ,
Place a tag or alummum plate biWeen
ihe teeth of the MIMce, dnve gear and balance!
.gea"
-Take cale no! 10 damage the 'gear teelh.
,
c Bend the lock washer. tab along th'f nut liaTS'
iii . .
DE64(E84;
ENGINE,a.SSMBlY AND AD:.JUSTMfNT
NOTE' _
. Align punches mark 12 on .me C;.Jtcn DOSS
with the arrow mark oh -the dutch pJate
13
.91)1t
8 Nm <08 m.kg.. 5.8 fHbi
I-....::L.__....,.:..-.:..-_..=.c'-- -'-_J
g A,pply_
-L1thft.!m greas.e
(onto Oil seal lips in cranx;taSf: cOvetl
Englf:uB;'011 .
tontO Hl covet \
2-_....:

1{) InsleH
Rulllevcr Ie
-' Imto .crankcase covetl
-2,'
f> 3
Bl)lt 'pull Jever
6.5 Nm 1065 li1.kg; 47 fHbl

11 Gasket." (crankcase- cnVp.1 j
-D)j\l\flil Pi"S 2
12 If'lslal!.
Crankcase Cover 1 i.
. .
NOTE
Tighten the bOlts U:rankcase in d'cnsscro?-!>-
pattern
Bolt (crankcase cover I
10 Nm (10 m.kg. 7.2 It Ibl
DE67(E861
ENGINE ASSEMBly AND ADJUSTMENT
1II0TE: _
Install the clutch plates and friction plales ailer
natefy on IHe,2hitcn bOss. startrng \Allth d- irlc..tlon
plate a"nd ending wuh a tllC:1l0n' plate
The friction pilltes Itype Ai 1/1'. with the lerg
er of tlie insllJediemeler must.oe installed
in the second ann last
oThe clJ!'hion.spriog it must be placed on
Ille inside of second I'Lelion plate
8 I'nstall.
-.Foctlon
Clutch pla,es 2
ClJtShlon sJ:!ring '3
PlJII rQ<l 4
';;; {null rodl
. "
-WaSh'lr 6,
- Pressure plale 7
surmg 8
oSollS 9:
.CAUTION:
.

Friction 'Pjate
.
Typ. "A"
.
TYl1o"S"
...
Quantity
..
2
.. 6 pC'S
.
InsidEr' '," , - <
"116 mm 113 mm
DfS1!'eter "0" 1457 inl " (4,45 in;
, ...
OE66rE85]
ENGINE ASSeMBLY AND ADJUSTMENT
13 'rlstall
.Wasner 1
Return Spnng 2
Pull lever 3
.4
-C"chpo
NOTE _
,t\Make- sure tt;at me.ma',lI:'6 on tt)e puillevF:f is
cHigned WIlh' lhe emb<?'sseQ mark 7 on 'The
pvshm.g the pull lever t{ not
change t.tte. pull lever POsition
Install 1he pullleve'wIlh lhe UP rna" 8 lac
'flg upward.
Oft. FilTER AIIIO WATER PUMP
J Instali-
Impeller shaft 1
pump housmg 2
"Circhp- -3
.PTn.A.-
Water pump gea' 5
:oCrn::lip $
;,.
NOTE: _
Install the w-!tfE;T pump gear wnh embossed sAd'
:.,,7,. faCing to rnslde .
2 Apply'
Molybrlenum dISulfide
(\)fIIO IrTJpeller .shaft endl
.,... .
DE68(E87)
,ENGINE ASSEMBlY,AND ADJUSTME,NT
L>.-_--1
3: In'tall
-0 f1t19 1
iwater. pump)'
10 lIfm i1.0 m.kg-J.?,lt.lbl
4 'Inslal(
, h6ustng 1
"'!Water' pumo cO\,,:;[ '2
,,;
': .
.Install
4011 liller, r
-0'
1
-, ,. .
,
CAUnON:. _
the oil as shown
6"jnstall
, .. co'"e'( ,
Bolt (oil lilter 'cD""rl
10 Nm n.o ",..kg, 7,2 ft-I!:>I-
DE69(E88)
, EN,GIN!:', ,o.:SSEMBlY
ROTOR,AND STAR1"ERiQRlVES,
1 Starter Gear
2 Start"r 'dl" gear 1
3 Starter ,d'e gear 2
4 Starter wheel gear
5 Starter clutch
6 Rotor (A, C G,)
DE701E89)
EII.IG.INE:"'ASSEMBl;YAND MJJUSTMENT
< gull
" :llHlm (i;Om,l<g, ],2 fllh'
-,
the il,!,,-l"ng 10 .
.'"
<l'l()TOR AND SO,TARTER DRIVES.
1< InS1811.
. TIm,ng cha,,, 1
Cha,n gwde 2
2
'E";g,ne oll
on
j ",stali
WashtJl ,,1":':'
'2-
e.\J\!heel"geaf '3 .'
, "
4,),OSlall
";W?odrvtf key
,HOIOf 2
N'O;TE::,,_--------:-__
In&l8jliogti'ie tnagnctu rotor ",taKe :sura that
lhe woo:dfUlf ktW 'IS properly sedlen In Ihe kBl"
,
. . .
5 InSlal1
aN4t 1
TtghtfID the nut f'-otdmq !he rOIOf wit'ti
the rotor ,holder. -2, . , "' . .' <
'. -
ENGINE ASSEMBLY AND
,
Rotor holder. .
lJ'""J PIN. YS'01,880, 90890-01701
CAuTION:.
00 not aUow the rotor h()lder'to touch the
projection!t 3 on the rotor.
6. Install
- Starter idle gea, 2
-Needle oearlng 2'
-Shaf, 3
-Gasket 4' '"CrankC<JSI:'
Oowel pIns 5
-0 "ngs 6
NOTE
7 lnstail:
-Crankcase COver 1 Ileft]
Tighten the boHs Icrankcase COv8t.11f\ a Crisscross.
parrern
Boh tcrankcase tover)
10 Nm 1'.0 m.kg. 72 !tJbl
8 Connect
.S'!h"Hch 2
9 Instail
Shah ! 1Si(U1er loie qean
Needle bearing 2
., Starter "'tHe gear j
-Gasket 4
Dowel pm 5
DE72lE91)
,
10. Instal!.
-Cover 1
Bolt lcover)..
10 Nrn.ll0 m.kg. 7.2 ftlbl '
DE73(E92)
ENGINE ASS!;M8lY AND AB;>JU5TMENT-
. .
/
,
)
10 Nm 11.0 mkg. 7.2 ft.lbl
BORE SIZE:
8 10IUXl5-11lO.045 mm 13.9372-3.9388 in}
<LIMIT>:
<: 100.1 mm 13.941 Inb
PISTON-YO-CYLINDER CLEARANCE:
C 0.050-0.070 mm 10.1lO2ll-0.0ll28 inl
<:L1MIT>:
<11.16 mm 10.0059 inl>
/0 I USE NEW ONE , - - ~
)0 i USE NEW OlliE
138 Nm 13.8 m.kg. 'Z1 ft.lbl 11-----
A I TIGHTENING SEQUENCE;
(j)
@
j
;
!) ~ ~ L!)
1_.,
,
~ ~ Q
~ C ~ ~ ~
~ , I ~
~ ~ / ~
e Varve tmtake valve)
9 Va-ive' gliH:Wt valve I
1(). Spa,,, plvg
11 Oqwef p.ir,
CYLINDER MEAD
1 Cyiindef nead cowr
2 l.,.ppet c:o\ler Hntil}el
3 o."'ng
4 (;ovef
5 Q.nng.
6 Tachomet", gea' umr (not for MuZ app;ieabon)
7 Cytmdet head
SPARK PLUG TYPE:
II>. DPAlIEII>..9 DPR9EA-9 INGKI
SPARK PLUG GAP:
B 0.8-0.9 mm (0.031-0.036 Inl
CYLINDER HEAD WARPAGE
C LIMIT:
1l.1l3 mm lO.llO12 Inl
112 Nm 11.2 m-kg. 8.7 tt.lbl!
111lllm
11.0 m.kg. 7.2 ftlbl
1
M
38 111m
(J.S m-k;g. 27 ft.lbl
D SEALANT !QUICK GASKET)"':
YAMAHA BOND NO. 1215"
DE75(E94)
ENGINE 4SSEMBLY AND
. . "
l::1ltMSl-lAFf AlIID TIMING CHAI!'!
'l'; Ca(11""iIf>. (8. Sh.1lt
SpflflQ . tj. 510P<>ef,;lbi<le pta,,,
pm, iftt ChaIn guidEr
(4"; OecompresSitl'f'l Kf"e- TimlP\gch8't(l ,
$ Cam '"Sptocke'L _ ijUlOe
'll' O."''''",....oQ.oarn 1}
:'" '!iR"ng . eN,,, CI.nlilOMr,
StlAFT-To-CAP CLEARANCE:
A 0.020-0.054 mm
10.0008 - 0.0021 inl
a CAMSHAFT RUNOUT LIMIT:
0.03 mm 10.00'l2 inl
20 Nm 12.0 ",kg. 14 itlbl
j 20 Nm (2.0 ",-kg. 14 it.lbO

\
110 Nm 11.0 m .kg. 7.2 it-Ibl I
.@ 18 Nm 10.1l m-kg. 5.8 ito/bl I
OE76{E95i
CYClNOER HEAD. CYLINDER AND PISTON
.Apply <"
.f1gltle Oli
. !onto PiSton flnS-i aHd lJlSttllt ;')1(1&'
2. Install
ling!>
NOTE __-'--__-,-. _
til irst8}1 nng So
Of",gumbers an; or< I"t" rOD !itt"!", of rhp
lings
. 3.If1Slal
.'Plston
...PISton pm
>CHChPS . 3:
NO'l't
"The ,arlow 4 01"1 the 015iO(1 muSt ilO.1ll141 flit:'
Irom at. engme
. the COVe! H\fl crankcal,W
\wtth a clean towel or fag So you Wlij nOi d1Z'Ctden
ti:;Hy drop the pin chp am"! materral trllo tht-'
eran;kcase
4' Instate
-Casket
"powel OinS ", 2
DE77(E96)
ENGINE ASSEMBty AIIlOADJUSTMEIIIT
.. 5' POSI'hOl\ '
*Tim rill;
11l<l ""'9
Offset the prst,OD nl\9 9GPS as s.now""
1 r90 HnQ .,nd
2. '0<1 .",1 (Lower)
3,Od ri"ll oM (IIpper)
4" 2nd f!Mq
6.' hr,St.a4t'
.CYlmoet
NOTE' _
cyhhder while cornoressH'lY tl"w" piston
by 'ho """d
7 lrrstan
--Bolts
-SOilS t
.. ,
"42"Nrn 14.1 ",,-k1l, 30 .It-illi
Bolts :I.
iO Nm tl0 rn-kg, 72 hlbl

['I/hlen Ine halts
lpipel'
10 Nm (1,0 m-kg. 1.2 h-llli
DE78(E97}
ENGINE ASSfMBLY AND ADJUSTMENT
"9 1nS1afi
-Gaskt 1 1 l.vJJ(lrye;' heao
-Dowe1 pms-2
10 hl$laH
-Cyii,nrb;.
II
'SOllS
-Bol' ';1
-Bolts "3-
0 ""9 (Pipe 4}
-PIpe 4
Bolts 1 J"
311 Nm l31l m .kg, :n lHbi
Iloh .2
10 Nm 11.0 m.kg, 7.2 fl.lbl
NOTE
,AOpIV the englt"li? oli unfo lhe 0
.Tt$hter! the botts 1 'm a p-iHl,fn
12
Charn i It''::a:.hci'f!-ti
ENGINE ASSEM,BlV-AND AOJUSTMENT
1
'1 J lns!a!l.
-Cam sprocket 1
.C8"",ha!; 2
InstlliHng SU!J1S
Turn the crankst)af't untli the
TOC mar' 3 IS wi1h the SUltllll'>ll"f
pomtar ,4 ,
.. Alig,.. the match mar. 5 .on tt..
the, puncne(f mal"k 6' OM the deC'ornpresStuM
lever
.. Fit the. cham onto cam sprocket al7l(1lo
tbe uam,sprock(H on the ,arnshaH
HOTE: _
-when ;r,stlilling lneC/imwrodet. io.eeo the tim
'119 enemllS teflS'!. as. pouitlh;' O"li/1e ",Nus,
Side.
-AhSn-, to& p,ml 7 On decompresSion iev-r
wlUi tt:!e !tots a if'l the decomp
r
el1s
1
0r; cam
,-Set the matcf:."'nit'rks 9 to be plJ:raliet
wtln the Case, surtac:e thE' correspcndmg
Sides, and aligh ...ce ma'n:h 1'narks'1\1
'10 vert)Cai, , .
CAUTION:
00 not ILlrn cranllShah during the cam
sl'llrsm lnuallation. Oa mage' or imp,.,!>.".
va,lve timing wlll ,'''SUli. .
hokitog the camshaft, temporary.ught
err botts
14 1nstall'
'Chalr tenSl('mef
.... *., ..... .. _... >-.

Instaffing steps
me cap oqlt 2 washer a am) spnng
4
.. ReieasR t!1 far01i?1 5 and push.the tf.:'r'!sl.on.
ro-r1 6
ENGINE ASSEMBLY-AND ADJUSTMENT
.Instan t,he cham l.eflSJ;oner with tne ratr.ner en'.:)
tactng downward
T thtt nons"
'"Bolt Ichain tension'srL .
10 111m (10 m.kg. 7,2 h.jbl
Cap bolt {timing "hi\.in,tensloner4
20 111m (2:0 ",.kg. 14 ftdb)
lS' i,gh\ur..
4Soits '1 i:,am
,8olt leam sprocke'tl
.20 111m 120 m.kg. 14 It.lbl'
16 C"",.,
Vaht- 'tIH+lnSi
OUi, of : A<}lllSl
- R;f.el to anovp, h! 1J _" 15
n ...
-:Yalvt'! ,
Out Of -Mjll,)!
R"I"'>fnVAlVE CLEARANce ADJUST
ME,NT -.!\ertlO!1 if' tho CHAPTER\}
In$taU valve Icold)
0.10 . 015 mm 10004 . 0006 in'
valve lcold'!. .
0.15, 0.20 m"'; 10006 . 0.006 m)
DE81(E100:
EN.GINE ASSEMBLY AND ADJUSTMENT
42 '",nail,
-Tachomets! gear
Bolt hlylloo8' nead): .
11.G m;'k,: H ftlbl
S8,81ant Iqulcl< gaskell'
" PIN
Yamaha Bo"ti No. IllS"
f' f.1\l. '9089O-llS505
18, Apply:
-Sealant. 1
jontO lhe cyunaer ncaa ",aung surfaces'
, .
19 tristall
Do-Ael '1'" '2
20, InstalL
"Cvlrnae' head cover
NOTE, _'_' '_'_-,-'--__-,-'-__
Tignteti -tne 'boas in 'usmg n Cflss(;rOS'S
pal1l!rfl
r'-,.----'-C------.:......--,
Boh Ivylinder haad (;Dved_
tll IUJ m'ki. 7.2 Ittbl
::n
Til'Tll"Q pit/II
.Plug :2
23lrislall.
imake. manrloh:ls 1
'. Bolt (intak" manifoldl
10Nm n.o m'1<!!, 7.2 11-Ibl
DE82fE1Q1\
EN6JNrASSEMBLv AND ADJUSTMENT
24. 1""tolL
.... Scark "1
Sparl< .plog:
17.5 111m 1175 m.kg. 1.2.5 ftolbl
f!if'S.ANO HOSES
.' '" .
soap base gHit15-e
.1<Jrl,IO O"ng an,p,i p,pe'S!
.2 Install
.1
;$ lnStali
'l3,e8lhef .MOO!! 1 1,,,1 !dm I
Breather hose 2" Irt.(jIlkc.aS-1
"011 hO!lll j
Soil loll h"""I:
10 111m 11 0 m.kg. 7.2 fHbl
4 Appiy
L,rnlllm soap b'aSE \I'ease [OHm 0 flOg on
, starter mOlor J
O!!B31!!1021
.Ul1lon bQlt ,,,i1 pipel
';liHlm (2<0 mkg.< 14 ft.lb)
Boh tst80-t.tr motoj'i
<' 1,0 Nm 11'.0 mkg. 72 ltolb!
UnIon bolt:
20 111m ILO m:kl/. 14 ft.lbl
Bolt: .,
11) !11m 110 m 'kg 7<2 ft.lb)
5 InSlal1
-SUther mO!Or 1
6 Instilll
'0,1' pIpe 1
7< Install:
-Od pipe j
REMOUNTING E.l\lGfNE
\<Vhen t(fl1100fltlr19 rhe engIne, reverse the removal
prOCedure:, No,(e tnt' f n n o w j n ~ pun),:;;;
OE84(E103)
WATER PUMP
DISASSEMBl Y
- 1
'Sl*l!'

-AH'SCOmis
"fUElI 13(lk
gvard
Referto COOtANT R!'PlACEMENT
SBeIlO" tr1 'l
NOTE: _
BaS,ute to nralfl 'C90lao1 OIi,iiS.semtHy
of n'le COOil.l':19 system cQtnpcmems
2 D,scc>n,,'ect
RadllllOr',tlOse '1, ilf0r;' ra(!laID:
*Fled'a'lprhose 2 '10
lilt water drain screw 3
DW1(Elllj
WAIERPUMP
:I 6""'0';;' ,
.c.ove
t
pump) 1
1
Rerno"'e
. oO,,,,,g 1
5 Remove
pVt"C;p
6 A"move:
'-elrel,,, :1
pump "gear "2
"Prn 3,
C:rC'fp 4
"Water pump h0951r'lQ 5
1l1rnpeli1 6
7
iii DepoSlt'S.
Frotti the tf")uei1+>.r and Wn,fer Dvrnp I ng
DV>J2(E112j
YAM4-1D-.6
WATERPUMP
JNSPECTioN
1. Inspect
-OrinQ 1
-Water pump hOlJsmg 2
pump gear 3
We-a! t;lBrnaye Repii::;Cf; ,
ASSeMBLY
Reve"e 'he' DISASSEMBlY; procedu,e
1 ApPly
<Molybdenum disulfide grease
lon,o ,mpeller shaft ;>nOI,
,2 Fill:
,It Cooling syste.m
Reier to the ':COOLANT Rf-PLACEMENT
sec,;'b""n 'he CHr.-PlER 3 '
DW3(E113)
CARBURETOR
_ _
CARBURETIOIV
CARBURETOR
1 Cqnnectlf\Q arm
2 .i4t _Ie "'"
3 "thrQttfe va;..re
4 Coasting enocher
5 v.iw selll _mb!y
6 N..ecliljel
7 0''';''9
8 1.1.", jel
9 !'ilol I.lt
10 PifO. !!C'.'" "".
11 rhrtmle stop-sere'"
12 Floal .'
13 Srane. Plunger set.-
14 -Drein screw .
15 Main
16 NeOOle.ji1'
17 Pi5!Qn,valve
18 Jet "".<ile ... '
,
. SPECIFICATlONS
10 MARK
.
9'1'1'-00. 4liWlllJ IAI ICHI
"
.
PRIMARY
, SECONOMIY
MAIN JET IM,J,I
.
. '" 1lI0
)II 1.
JET IP..J.l ....
,JET NEEOl. IJ,NJ ' '60!J6..3/li SX7C3f5
.'
6D97!l11i ICHI
.
NEEDLE,JET IIll.J,1
,
V!lO . 2.7
PILOT SCREW IP.Sj
2. .....d, 112 lur"" ""I -
RQAT .IF.H! 11l-V mm',q.1l8-1.D8ir'l1 .
FVEL LEVEL .11'.1;.,1' 'lllla.O mm 10.34":0.31 inl
,
a"low fro", th" flo"t :'Jilting
. .vnllc. "- p
IDlING'SI!fEO, 12!1ll-1.81 '1m,,, ,
@--
2Nm
(0.2 mokS. 1.4 ft.lb)
I
1
9
Nm (U rookS. 11.5 ftlbl I

I
13 Nm 10.3 ro.kS. 2.2 ft.!b) I
3.5 Nm
10.35 mokS. 2.5 ft.lbl
3Nm
;;;z:; 10.3 mokg. 2.2 tt-lbl
II Nm Ill.S mke. 4.3 ftlbJ
..,.-- ,
CARBURETOR
A. POl'Nt'Y carbule!ot
[!f SecMOary~ carburetor'
CARBURETOR
B. OlSCCmn1K'!:
.Vacuun} hose
,DelivE>'Y hose 2
Carbv<etor 'lissemO'y
, I from intake In?f\llolrll
DISASS"MBlY
NOTE _
:n",,'!oUowing pans can be allli "",soect
edwllhour drsasSlilmbly,
Diaph'au.rrl,lCoasHhg ennch"ri
p'unger
-TtlrOlfl" SlOp screw .
1. Disconrie;:t
'Air ver\t hnse ."
2
Alf. pipe :3
flow 1\""" 4
2, ,AemQlfe:
,<Stay plate ,5 (rear;
,-Slay plale '6 Bronll
3. 'Dl:;con,.,ect
.. .
<P,pe t
-Pipe 2
-tir\k rod :3
4: SllParale:
'. Pt,mary carUvrel<;ft, 4
Secondary 5
DC4(E120)
CARBURETOR.
Primary c:arbUrS1'Of
1. 'Remove:
.. Float chamber ,i .
ni
n
' 'i"
p' ..
Float 3
NOTE: _
2,
#Needle valve/Valve
-. Main le11 "je:
'Pilot jet.3'
pact Screw 4
O:rino ;
3 DiSconneot
.. Throttle stop $Crtl""
4, ,Remove:
;-siii;i;;; pl.;,;g;;, 2.'
. {fromlhe'starte, cableI
5 Remoye:
-Cover.. i {coasting
-Spring .., '
Oiaphrl!gm . ,3
.. .
DCS{Et21 )
CARBURETOR
6. Remove.
-Too cover 1
GasKe1 2.
"Sctew 3 (connecting arm)
7 Remoye.
Thr01tle
-Colla, 2
Cable holde' 3
8 Remove'
aT;,roltle shall
-Spring 2.
valve IWHh -t;onnectrnQ arm)
g..Remove:.
CCinnectln\l"arrrr 1
".lel freed!e 2
-Throttle ",ilve" ,3
Secondary carburetor
1, .Remove
Plug", r
"Gaskel "2
aMain jel 3
.-Nee'!'e jel 4
DC6(E1221
v
CARBURETOR
2, "emo",,:
Top cover . 1
2
3 Remove:,
Piston ''''aive J
JeI needie 2
INSPECTION
, InsPect: ' '
-Ca'Ov'elof DO,dy
.. Float .chamhef"
,C,a.cksf Replace
, Fue' passage, ,
"Crean
IIIOTE: ,..- ---__
Use a pei,olel.\ih based soiven!'!"r 'c,eanlng (Do
nofuse. any c,*,mng sOlUlicui.l.
Blowout'all passages'ano let,s"wm; compressed
air .
t
2 1
J. &t-4
IPl
3
2' ll1$peC1 ,
Val"" seal' 1
Needle "alve 2
-0-"n9 ..
DamagelWellr 1C,lntamlf'atlon :.Replace"s
a'sel
t' .
NOTE: -;---- -,-
A1wai's',,,place,,if,e needle valve and valve seat.,
as a,set
The luel strainer 4 has 10 be always clean!
CARBURETOR
-----"' ..
:3.
Stljl1er plunge, 1
WllarJOamage -RePlaCe
"Ttn'fltlle ';loP screw i
0a.mage Replace .
2
b
4. In.p*lel.
'RIJl)btJr diap!"lr.agm 1 Ip1S10,", valve;
diaphragm 2 \coasling enrich.rI
Tears i Oamage '. Replace
" - :, ' _" t

.. J,n needle ,. (pwTlaryl.
J!H needte {secondary;
. Bends :Wear . ."lepiace
1-
1
6:- lospec!"-
. Throttle valve 1 tptlmary j
, .
-',P1SlOh valve '2 (sf:!condaryl
Scratches!Ww: Damage Repiace.
'7. Check'
mov-ernerir '
... . .
. Slick Replace. .
In'lm!h" throttle valve and pISIOr, valli" ,nt"
the. carbure.lD' body, a""o cr;eck lor I,e'"
r.n'overnent,
,
SeGcndaty carbUretor
DC8{E124)
CARBURETOR
8 Ins>!ect;
-Float 1
Damage ..... Repi.acf:l:
9. Inspect
oMain jet '1 (primary)
-Main let 2 (secondaryl
-Needle jet' j (pr,ma/yl
- Needle jet lsecondarvl
-O-flOg' 5 tprlmary)
- Pilot ,et 6
Wear/D-amag,;: Replace
ContamtrlatloD'- Biow QUi ,ets Wlm cpm
0" 'pressed ,airI
ASSEMBLY
Reverse thl:: "OISASSEMBLy" procedUles Nole
tha following points
CAU110N:
-Belore reassembling, wash the all parts In
clean petroleum based solvent.
Always use a new !lasket.
"" '" ' ,
Secondarycarburator
j. 'nstan; r.
-Jet '1
-Piston. valve 2
NOTE' __....:.-'-- _
tab 011 the rubber diaphragm to
matching recess In. the Secondary carburetor i
SCrew hop cover};
2 N 10.2 m-kg, 1.4 It-II;I .
. .
2_ Install;
-SPMi! :1.
.
-Top cover .;2'
DC9(E125)
CARBURETOR
3.ln"Sllail:
- Needle let 1
- Ma.lf> je: :I.
-Plug 3
Ma,,, jet:
Nm IQ2 mkg. VI fl-lb,

9. !'1m 109 "'-kg. lUi !Hbl
carbutetor
1 In.,all,
- Jet noodle 1
'arITj 2
tto val",,fl;
SClew h::onnecttng afm;: J
G.l!Nm 1(l0ll m'Kg, 0.6 fHbl .
-
NOTE: -'- _
Make corole.cung arm assertil:'1v '3
1$ ai the mustrinf?O pas-Won
" '
2: InslaH.
va!ve 1
J
-Spr"'\ll
,-Throttle shait::!
NOTE: ....,.,-.:. _
Set 'the sonng Shovv,l.
DC101E125)
CARBVRETOR
Screw {conntH;::ting srm)
2 111m 10.2 mkg. 1'1 ft.lt;\
,L instllll:

1II0TE,, ,..---- _
Turn 1he l2turn <::lockwlse to giVe
preload t9 the sorln,g hold 11
Then. instan the tconnectiog afm"
4
5 Insta!1
!\) Cabie hOldel 1
-Colla' 2
'It T:;ronle ie'\ier J
NOTE; --' _
6 E!e sure throttle shatt .4 and adjusting boit
5 I CIre Iil!igned when tightening thwttie shaft nu1
. '
Sc,,,w Icable holde,J:
3 'Nm 10..3 m.kg. 2.2 ftlbl
'Nut lthtQ1'thi leve'l:
3.5 Nm 10.35 mkg. 2.5 ftlbl
......._--- ---------'
. ';>"n,w Itoll CO"!,'I:
2 Nm ICl:2m.!ill. 1.4 Itlal
6. in.s1all:
.-Gasket
.rT00 'Cover 2
DCllIEl:!?)
CARBURETOR
7. Install'
.l1:ubbtH dicph!agm
Non
MalCh Ihe Illb <>n Ihe fubbef dlaphregm to Ihe
matching fe_cess to the coasling -e,uict1e
t
a. 'Cannect;
.Starter pivnger {to me Slaner caDle)
B. InslaH:
Tlrro!tle stop screw
10,
01'1101 Sc'flW I
PHol iel 2 <
'NeeCle lei 3
Maln fe: .(
.>, 'S'1at 5
> Noo(lle' v.,:ve' 6.
!wiih 1loaO --
Ne",dl. jor;
2 "11)1 .10,2 m.kg, lkRlbl
.Main jet! : ,<
'.6 IIfrnle..16-m:kQ. "'2fHbl
Screw' tvalye seat'.
Z Nm 102 m.kg" 1.4 h
11 lruitall
Pin 1
NOTE: __ _
install the U,put Jo the -tifr-OW.
DC12(E128)
CARBURETOR
Measure:
/'lelght a
0141 o! sP<>cdl<;llliQn - AdjuSl
Mllaliu,emel'lt and ..djustmerlt steps:
HOld the in an ull..sii:le down oosillon.
111 Measure the dlslllnl:e from !be mating sunace
olthjil'f!oat 'cHamber' 19asket ,em';"'ed) to
toil'l:ll the flOlill. -
Nmi; -
. " .
The fIol.arm tie rest"'9 on the "p,e.'1le
v"lve. ,!:>vI no! cOr;l"PleSslng.!he needle ""lve
, '''', . .
,I'loetf'leight IF. H.}:
25.0 - 27.0 mm 10. - in)
eu the iioa(height is with,;speciiicariqn.n
. specl ttle valve sea! a'1d needle valve
II eltllar is worn: lePlace lhemboth,
ilIlI homa;e fine. adjust the float hfOiglH bv
Ing ihe .1. on .
.. Aecheck the: float he.g'h,
13 Install
'g Float chamber
Screw IfloBt, cham!,e;I:,
.2 Nrn to.2IT\kg. 14. ft .Ibl
14, :AajuSl.
-ElIOt '1
Pilot s.crew (turn .oull;
.2 snd..l1-2 tllms out
Adjustment'steps-:
.. Tum pilol SC'!!\'V unlil Illsligl1Uy lieated
.. !lack out speciffe<lnbmber of tjJ!'ns.
. . -. -. . . .
DC13{E129)
...............-(.J...f----, 6.0 mm
10.24 in)
.CARBU.RETOR
15 Install'
Primary caroureto.
-Secondary carburetor ;{
16. 10SI,,1I
plate fl;anti 1
"Stav plale {rearl ?
Screw lstay pla,al
3 Nt'" Ill.3 m.kg. 2.2 hlbl
1II0TE ,;;;.-.
Ahef the 1hronte lOver al1d
throWe va.]v: tm smooth action
17 Connect
.. Over l'o.Vv hose ...
Au veni ptpe 4
;;oVacuum hose '5
Au vetlt t:0S 6
18. Adjus!
-SCco!}dary..catbvfetor
,+ ,. , " .. \
'Adjustment steps,
Raise the primary ''!fottie: vcil,te 1 to helgm
-"I 61l mm 1024 inl as ,,"kala"
e. Tum me sVfichromz;ng 1, if1 or.out so
'hal' secondary Ihrotlle valve iii. "l)l!!l\ln. to
open
DC14t130
CARBURETOR
S'iHt: that the sp.condarv VaNe- IS opened
hon.lonti:!'l1y \ a -t,! '; when pnrnar'Y cart:.H.,i
tetOr -1i.!jVtt 1$ tullY oPened
INSTALLATION
Reverse thf!" >'REMOVAL' prOCCH'1v;es Notp HI'":'
follOWing pomlS
Inslall
*Carbure10r.
Screw Iloir1t bend'le/ti
2 Nm 10,'2 m.kg, 1,4 It ,fbi
Screw (joiO! b"nd-ri9h H
5 Nm 105 m.kg. 36 fl.lbl
,
Instali
-Carburetor /O,m to UHthHtOl by m(htlng
forward
3 Inslall,
ThrOlll cabie 1
-Srarter plunge! 2
Starter plunger,
6 Nm lUi m'''g. 4,3 11.fbJ
DCl5{E131)
CARBURETOR
4 Ad,u>l
.ihtQttie pia"
Reiet to 'THROTTLE ,H'Ef
PlAY ADJUS- TMENT l:n t;-l,,::
CHANER 3
Ttlrott.., cable"Ir"" play
;I . 5 mm 10 1:l . (l.2(L!n'
5 AdJIJSI
.I<lle speed'
Rete< SPEtD AOJUS"rMEN1
secttOl'1 ;n'the Ct1APffR 3
.
Eng"'" idle spe..d
1.25O1.J5lllhn",
FUEL LEVEl AOJUS'hV1ENT
. . ,
I Place on a 4eve-; ...
2' U&e}he 3U1tabk? s:faJ';{flJ.t}de, 'the
e:ngtfH? tD ensvre rhV'.! mit' " IS
tloned .v:r!H.:a:;fv
:1 C(,lnnecr the Fuel Lt""v'l Gauy,p rn'lht,' float
,-chamber P1PP..:,
Ftie' lever
PiN. YM01312A.
P/N 908900131.
. ..
4. Loosen lhe.m'Hfi 2. ,H1M ,Jp ih("
Q.ng!ile !or sevef.ii.njJ!}!ll-f'.!;i,
5 H01Q 1ht' nexi kl >tne fk)il1
tl){Hmg ..
6 MeasLJrEL
t ;J
Uui of Ad,t'Sl
Fuel level:
, 10.24,031 inl
B"low !,om' th" float chambe'
malting suri aCe
1 Adj".,
levtll
Adjustm&nt 3181""
f Rl;!mcr\lf' c.ar04JtelOl
seat ;1(\0 needle 'I.f!fvf!
H m 1.:01\"1
elf bo-ttl at'. fmc:. atijJst tN> float t:elghrhYl,,pri
iflgJhe Hom u,ng 1 .on t"he.f!lai
., 'hie: 'level I
DC16(E132)
FUEL PUMP
FUEL PUMP
PUMP OP,EAATION INSPECTION
1 Inspec1
PUn'll: operatIon
Op..,atiO" inspection
.. '.tl'w'!",,1 cod< to "ON
.O'$:COhl1cct the dehvery from 1M$';' c.d'
. ' ,
. bur.etor (fvel p'u.m.p,
lI.Ji?lace. receP.tacle under thfi delivery hOSt:
end
lhe m,Wl SWitch .10' - 'ON
PuStr 'the starter swltr:t"t
.. Check tuP.J flu}N jron, the h(J5i? "
end'.
U. rwr'lollv -oui. taplace ti"lff
asse.':"bly or .ref.er to'tNSRECTlOt'/'usecr,on
REMOVAL
'[).,.l;col1l:-eC1 '
"::Vac\!.um 'lOse'. tmi'" Intake nftm'if,.oid
:O-etivt!ry husf7 if,om' {;tirbJ.IH.Hor
. .. . -
Rem""",
,Fue/'plimp as"Olbly
INSPECTIQN
,.

VatuLrn 'nose
,Dellvery 'llOse
Crack Wear R'Cplace
2
.. Fu!j f,h!'t1Q It!%SB!?lbl't' 1
erfle'; ."ReDIac.f!
"SSfMlllY
q'everse the "REMOVAL Note
.'.
l.... ConMer:

-;'Th:tlive,y
t\o!ii
Note,
8e-sure 10 t.'urmect ttle hO'$e Q.'lu-et't'Y.'wh(ln ':on

2' IriSlillJ
Fue! tank
Ait scoops
SH1e coven.
-Seal
DC17(Et34)
STARTER MOTOR
1 0- Rng
2 Armalure
3 O-Ring
4 Yoke
5 O-RIng
6 Brush
ELECTRICAL STARTING SYSTEM
A BRUSH WEAR LIMIT:
5.0 mm 10.20 inl
B COMMUTATOR WEAR LIMIT:
1:1 mm 11.06 In)
C MICA UNDERCUT:
0.7 mm 10.027 inl
D ARMATURE COil RESISTANCE:
00 at 2O"C l611
o
F)
5 Nm 10,5 m.kg. 3.6 tt.lbl
El,ECJBtCAL STARTfNG:SYSTEM
Removal
1,::fremove:'
Sta.:ter:motor
. Refer to , fhe. "HiGH\lE OVEI'lHAUi:-
ENGINE DISASSEMBi,. Y" . section in tha
CHAPTER 4.
1 Oi9assern0.11'
l. P"t identifying marks .,. on the bracketsiii!
reassemoly as shown,
2
1
2. R e m O ~ ! l : ..
Cirelip !.l..
.Starlerdrl"egear :,:?
1
3, Remove,
'801::s :1
. '. . .
DSTART2(E16'i
ELECTRICAL. STARTING SYSTEM
4,
.B,acklll .(
*Washers(t,
Shn'!ls,j3
. B,acket:(!.

"_.'_
',aArmature ([,
'O-rings ,'t::"
Yoki (ij)'
: 5. Rem.ove:
Brush holder sel 1
Il'lsp.ection and ulpair
-1.1nspecr
-Commutator
Dkly-Cleanti witn "'600 g"l sandpape,
2.lVleaiure:
diamatet
ou, m -Replace starter
'Commutator wear. timIt;
TI mmf1.06inJ
DSTART3(E162)
ELECTRICAL STARTING SYSTEM
1 MO or more 00
I , I
ts=zj
nx1 0
@X1tdl
x10 +
2,
oM,ca'und"'cw'.
Oul of sp.edflcat:on ,', Scrape- ihe rruC-a ,to'
'proper use Jf olad-e car: be
19 fIt..
NOT: _
.T,ht: rraca:-in$lJlation ot'the COs-Timutalo1 mus1 be
, ' ,
vndetcut. to' ensure proper operatIOn of com
mu'@zor
4: 'nspect:
col'i
i. ,;. " starter motoL
",
e,COOOeCl. tester fOf conhnultV'ciWc:k
- -. .. '.,' "te'",:!"" _", - -
,::.t::and: insula/Jon, c,he,k
., the:aTrnature resIstances
rasistance:
check 1. '
: 'Oil at '2O"CI611"F,I' ., " "'
" . 'Insulation check 2':
1MU at 2{I;C .
,,,'""IM""I ':' ,", ,
- ,. _.- '.
lil,i the incorrilCt, the start
,,, motOr,""'''"' ,"" ' , '
S, Measure: ' :
Brush 1""Ilth
Oot <:>f"ilp'ci!icallon -. Rilplace..
I.enllth limit:
"'5:0',,;m IO.ZO inl
OSTART4(E.163)
ELECTRlCAl STARTU\lG SYSTEM
S'Measu!e
Q';.Jsb- lll'ring for.ce
of .specificalion "'leplace'as a
Q!-
1 2
-Spring fOl"ee>
680-!l2!J g 124.0-32.4 oZ'.
7, lnspeC\:
'Bearm>l .1'
OiI.sear.2 .
8",sh' [:1'. '.
_ ihe
00 r'.n/,.s4.
Wear/O.magl\l
A$'$emblv
Reserve "RemQviH"
Note'the follo""in9,pomls..
1
. I" . procedure
. _ InSlll.. .
-S'"." holiler set
NOTE,
llAiign the Pla're 1 v.rnn t!'e siat 2 em the
yoke as shown
Ii!lgo the projection .3' on tM otush seat wIth
the slOl .4 9" the housirig
2
.2. IAstall:
-Yoke I
-l'lrackets 2,'
- Stanmg drtve, gear '3,
NOTE; _---'-_'--_
" on Ihe yoke with Ihe
]
Bolt ..rt"r motOr),
, 10 Nm il,QjT"'kg, 7.Z'fflbl
Align the match "'''''s
Installation
J.
'. Siarter ,/notor
1II0T!?: .
Apply a bghfly to the
OSTART5(EI641
1 AC, Magneto
2 Regtifierl regulator
3 Battery
4 Fuse box
5 Main switch
CHARGING SYSTEM
MUZ 660 Skorpion
MuZ 660 E Baghira
CHARGIll,iG SYSTE:'I\II
TRDUBLESHOOTllllG
1
THE BATTERY IS NOTCHARGED.
tJ.
Procedure
Ched<.
1. Fuse !mainl
2. Barrery
3. ChargIng voltage
4. Stator coil resrstance'
5. Wirin.9 connection
IEntire chargmg system'
NOTE: _
-Remove Ihe following pans palore ttoublllShoo!i119
11 Seat
21 Side lIoftl
-Use the 101l0w,n9 sol!I::iai loolls' Ifl rh.s troubleshooting
Inductive tachometer:
PIN YU-ll8Q:i6-A, !lllflllO.0311J
Pocket tester:
PIN VU:0:3112. 9Oll9O03112
NOCONTINUITY
... I:'e:tTH).... e< tl'Uit use, ,
!
.1
*Connect the: pocke\ 1) t'3 {he fuse, :
-Check .:,
Reeler loThe --FUSE INpPECrlON" section In
J fuse i. faulty: replaCe il.
I
the CrtAPTEF! 3.
,JJ CONTIN\Jl"rY
t ,
.
2. Ballery
.. ,
iNCORRECT
- Check the battery eO"';'llOn,
-So
.Refe' to tho "8.<1. rTERY INS PECTioN sec
.
ta:m In the CHAPTER J
"
-Clean 'baltl1fY terminalS
'.
,.
-Recharge or '''J)!.ace battery.
Volt""", -Refe' to rhe :'SATTEBY INSPECTION'
l>fH:
12.8 V a' high", III 2O"C 'llllQl'l
. lIOn on the CHAPTER 3:.
. .
CORRECT
DC;-tARG1{El5111
CHARGING SYSTEM
3. voltage
.. COfl,oeit thEt inductive tachomen:tr to
sparl< plug toocL
'Connect the pocket tester lOC20V) .to tt1e
,
Denary.
/
,
Testar 14 I.hiad -Battery! + I terminal
Tetlter I -I lilad'-"Sattery I - Harmlna.l
,'Stan the eog"111 accelerate .to a.oout,
5,000 timin. '
-Check charginlJ 1IoitilQs.
E::S' Charging volta\111>:
<i'\' 1<1.0 V at 5,000 rI min
MEETS SPECIFICATiON
NOTE: _
1 OIJ.'r OF ..
SPECIFICATION
! s fuHcratge:d
i
4 Starot .coll rftSt-Stanc:e
"* i Ihe state; coil CQUpfe. from The
wh'eharness.
Connec! the pOCket tester "H .. T" to fhe siB
tor coils.
the
Slato' CO!l resiStances
1
.
. Teliter ( +1
lead -Whiti! lead
1
TeSler 1. )
lead .4Whlt" lead
'2
-
T"sta, 1 I llllad-W/li,a
l"..d 1"
Tast.., 1
I I"ad -'Whlte. lead
3
OCHAAG2(E169)
Stator coil resistance:
0.2-0.30 lOGe 168
G
Fl
. BOTH MEET
SPECIFICAnONS
> 5. Winng connectioh ;
CHARGING SYSTEM
OUT OF SPECIFICATIOl\
, 1
i,s faulty, replace it.
,POOR CONNECTION
Check' the igriitiOh system -fnT
'ne-ctlons.."
Reier 10 I"" "WIRING DIAGRAM' section, '
" .
Replace rGc'titier.-! regulator
:J
DCHARG3(E170j
TROUBLESHOOTI NG
,STARTiNG FAlLURElHARD STARTIN,G
NOTE:. 1 ,
The,loil(lw,ng Iroubl"""ootin\1 ;ioas not cover thil posslb!ll,causes'ot 1foubl": It shnuldbe"e'lllui.
Mowever,as a guide to tfoubtesttootin,g Refer to the re,lativeproced'UN3 -,n this mantJ.:!1 10.; lnSpeC1!On
t.djustmant afld reptacerrnm! 'ot parts:
,
STARTINGFAILUREJHARD STARTiNG
FUEL SV;;TEM , ' !:;P!9S!'
j-'Fuel lanK -EmpIV.,
,1 ' "CIOllgedfue\ hlter
! "'Clogg<!d fuel wlt,joe'
I CIQ9lled IU81b,eDther
1 flJE::i Qf h,H;J W<'\-lPf
k f(}N!'ll." mater,al
. I
t r ;:UO' CoCk---------r-Oogged hosO'
1 <Clog.pad 1",,1 liltfl!
L.. Oe1etlOlated .hte\ wM-i", OJ:

Cloggfl(1 0"01 ie!
.. Cloggun Pilot Sif
Si.H;;ked-l0 ;:Uf-
- Ol!fom''''l flbal
Groove, wofn, nflmHc val\H+
-lrnprontnJy seal.ed lI,tivn
Impfor;erly adlU,l\htd fuel l-eve';
-Improperly set !>f1t,1 1[11
-Clogged
- Star1e; plunger
Improperly Jl<1iusted SiRtl!H
'.
..-.Clogged
' ,_eFaully hJel purnp
V,'h':WHl!
TROUBLE01 (E198)
TROUBLESHOOTING
STARTING FAILUREfHARO .STARTING.
I
19011' lIoh
, FaUltv pici< ,loiD COli
'l' !lBrOken W01:>OruH
. 'Switct;"s ami -FaUlty J'nl3l!1 s\"vllt"h
i
i Faulty f<Et.GiNE SlOP' ,wllel;
I '.... 8rox\'n or shmted ''''ionq
'1' -ratdtv lHJ\ltNl'l
-FO'lvHv "STAR1" !lWlh.,:h
-r.f\uHy siop.stant1 .swlh'h
L "'FnuHv dUle.:l:
--__-,.f-ai.l11\t !'1Zlrtm I1M)l",
"h'lJ!tY mlH\
-Fml!1\,>' 01\',\.11.1 '(\It (H! IPl;l\-
.Fm'lty 1"H!rwr cfmdl ;
SYSTEM. !!ROBABI.E CAUSE
r
Spark
piug--'---------,i-lrnp;ope' p1ug ..!tllP
. 'WOfP elecnode:&
l
Wtre between letmmais ofk.en
I '''',mproper 'neat range
' . '- plug cap
,: Ignit:o" otiil---.----.----,,' *Sroxerfor 'Shoncd.. Sf.!corH,1;v)'
.i '1 Faulty soarli I1lu9. 1".<1
L--Brokenhoov
PROllABLE CAUSE
T cl,Jntc\:u:s\;
'I Oil
r f- t, vn/vi.'!
-lmprnoer1v i..:On1fldud VnlV{i .ann \,',11\1'1'
, "*lm})mjml tlnHti\1
I .
l -BmklJtl l,.'aJvc i:>D,Jl)(.)
L-t;!!'(1(1 rtttnhsf;"H

. lnfiHlile\j PIFlnf) nnl;l
-WUnt, ti1
i .Slilum1
L -St111Pt1 tlf jll:l".l;'lI1
l . ami
,
SYSTEM'
(Vlind(1'! cVtlnoer ,bead Luose spi;f"i\ piuq

-LoOSit cylindtH tH;,f(j (t4 \;yluitlPI
I .BrOIH_'f1- c:yknd'ttr hflnn
1 "\>VOfli, dH!na(fHf1 Of
lPH, .
TROUBLE02(E199j
TROUBLESHOOTING
POORrDLE SPEED PERFORMAfijCEI
POOR MED.UM AND HIGH SPEED PERFORMANCE
f>.OORIDLESPEEDPERFORMANCE,
f?OOB IOl.E, SPEED, PERfORMANCE PR.OjUl.,B.U
f.- Garb<>!elQf ----,...,.----r,'ImpropS,ly,'retumeo, stane, piuf'\J'"
I
LCIi>Se pilOl J<tt
'C1ll"lIl'd ,PilOI ai"jet
I
,'i .ynchran'red eart>4,elOis
J .improper.yadjustoo Idl1l speed '
, I
I : f:'fhrotfle StoP.
, L
i
.a:!mpr:oper play
\ 'Fl<X1(led carbureto,
Eleclrical SYSlem-.,.-----,...,., FauiTy ballary
5.t'J&l'k' plug.
'l-FaHJty UOil
lIFauhy pickup coil
:.- .. fAulty ,gnitlt;;" ::Ol(
LValve tr.m---- '----"}mprooerly vmve cfC(,}'.:mce
PRO!lAflLE CAUSE
fet chp POS!t\\1fi
'. '
-Jmp,operly ,adjtlsted levu'
"Of loose rn8nl jf'!i
Oeteflofill efi fHP! r.ofHaimfiU WMP'
rn-ate-nal
POOR MEDIUM AND HIGH SPEED PERFQRMANCE
POOR MEOlUMANO fllGH SPEED 'PfRFORMANCE
I
Ref'" to thl', "STARTINQ FAILURE!HARD STARTING'" "",1
PERFORMANCE "aM\ train '''eMn
i
[
Alf c!tntOW----... -CiO}Jgffd 'W fjltP.1 eloment
Fuel pumi) -----.-.;"oul(y fllel pldnp
TROU8LE03(E200i
TROUBLESHOOTING
FAULTY GEAR SHIFTING!
CLUTCH SLIPPING/DRAGGING
fAULTY GEAR SHIFTING
.HAf.\O SHQ'TlNG
R.f,,, to,l". "CLt,iTCH SL:IPPINGIDRAGGINGCLUTCH DRAGGING" se,'M,'
SHIFT'PEDAL DOE1H"CIT MOVE PROBABLE. CAUSE
". tShih ""Bent shih
'." earn. $tutt fork ----''''1-Groove l"mr;ll!O ""'til 'm;"moe,.
I
.StHz(U1 fork
i -Sent Shtft tork gutde bitr
LTrlmsmis"on -S"ized If."sm,SS"'" 9".'
ni:1ntfUlles
''a'![)f;mr.,ctl'r asserllhip.r1 ttansnj:t!i";li l1!
JUMPOUT GEAR pRO!lAelE CAUSE
Shih Shith .lnmmpe:rly .HillH'IHd il'Vl11
. /:;IOi)I'I;1 ll'\'t't
[
I StutT fork ------ , "Wmll kui<
- Sru/t f"nn,,,-, .. O'ltHpt,J(Hi! pia\,
LI ran"",,,,,m, __"" _,_", ," ::::::: ::::' \111)('",
CLUTCH SUPPING/DRAGGING
ClUTCH SUPPING
PROBABLE CAUSE
r ClliN:h ---7_'.,__............!-.__,"I' .loose $IHli\!j
, , "f;'Utpqed rI\Jtt'!l
[ --WOfl1 frklkm pJ.IW
t -Worn pf.'ltl'
,lRl":t:I'nbied \',!utt'i\
L oil .t,......... \1.1 i"Hl'1
-Irnp
t
tlpm 11 '\)\. 1
n...tlIl\1l.111'1I1
TROUBLE04(E201 )
TROUBLESHOOTING
OVERH.EATING'OR OVER"C.OOLING
f
CLUT.CH DIlAClClING
'r' C1Y'Sh-' preriure pi.:llV
l' '.Uneven1y"'tensioned CiVHJh sprIngs
t: -Ma1C". ma'ks, .
! 1 -loose dutch boss, nut"
Buint prim,nYdrtve<> goa' tl<Jshlng
r --Bant'du.tch .
1 -SWOlien iriChooojat6
-j '. "",,-
'- .Sro,ken clur<;t1 bass
L 0,1 r'ilgli' Of!
-Improper \ll1;),tJ"t {High, VJscosttvl
De'tfl:r1ora1Hj.fl
-----.,.i--lnwroper nillln 1m
. w"prOfjrH !lftHmn)
l !lII{Jnp!operly adJusterl
:- "'C19flQfff1 iiU fmm
.., [<F"',lhY It:mpp.fAl-.>Il' Hil\H)l'
'-Fall'ty lhf"llH!} l.-lnH
i lncorrflcl Cl:)Olt"nt tevp!
-'f.UHtly Ihern'Klst.H
t:;luHy th;;tnw
or darm10rHl fOOIZJtn
f:irtiainr",::np
.. .1IrJPfllkJ
I, 1m1 rnl)tOt
I
rF\Hd :;y'{tCJi1
I
J
':
H\ .------.- *HtM,t:';! .(Al'fi1<'l'\ hwtd.up
't !''';'''''' '''l,,--- .. _... - .....'T -11l""''''C' Of' :"".,1
n;l VlS.Cf)1-11lv
. oil qUili!tv
OVERHEATING OROVERCOOLING
OVERHEATING Pl\09ASllE CAliSE
rhp
1
tluln T :spn;k pluQ Hap
.spark nh'lq heAl l"lt111!"'
",t::nuttv t!ll'irOf Hf\t'
OVERCOOUNG
L. .. ... t('lIi
PROBABlf CAliSE
WfJtnf'
IPhtllHv iharmo ulHl
.. tnuhv
fIlllity SWJtcl)
q ;{toppriHi.... ftm
TRQUaLE05(E202)
TROUBLESHOOTING
FAULTY BRAKE/FRONT FORK OIL LEAKAGE
, AND FRONT FGRK MALFUNCTION
FAULTY 'BRAKE
P,OOR BRAlQlllG EFFECT CAUSE
. -WIl,n Otak" pari
" dISC-
'.,A", ',n fh,,ud
,', .'Leaktng:btake'
1;vbnder .klt CtlP
;:;aulty ,cahper kit sea]
-loose union bdk' -
BtOken brake hO$.J
Olly, or greasy brake 01$(
-Qih':-Qr greasy brake pm.J
"ImpropEr' fillllt It''vP!
FRONT FORK all: lEAKAGE ANO FRONT FORK MALFUNCTION
OIL PROBAi'!lLI' CAUSE
,,,.--..---- -"'--"""------r- 'St!nt Of ft/St\ 1(Hl{'1 hJt11'
{'H ,'!;11'"ft1 llihr
.. sri;l! lljl
-jl)iprmitf.ly tl)::-11alll'li PIt 'd!.H
.1mprOl;t'! Hil 'tN.>! !1d('l lHill llJ
1..\0'$0 H;'!n;i t1tJld,l'l\1 htlli
.. ('ill> huh 0
LUti!\{' riauj', hnlt
'--
MALFUNCTION
L .....
PROBABLE CAUSE
.. _- St.m. Of Hlt}{ll lq-hf'
r .B,>f\t' 0'
I Oarnat.lntt SPUf,'J\l
I .. thlsh
; -Sttm!\t OAlfHl{lttff n:trnptl1 Wtl
OhnpttJpfll oil Vl's.emufv
L uil "",\'Vl
TROUBLE06iE203)
TROUBLESHOOTI NG
IIItSTA8LEHANDlING
.. 1TWl5IOd
Dilfllilgect head ptpe
"lmpfO(lltrly inSHtltcrj
r tire dn boO; SH1HS
tH'O
Unevenlv ,worn
..l balillll'C
I -Dufmmed wtreel
I -Loose 1}e8fln\.f
; .. Bent" or whoel
L "Excessive 'WhetM nm out
ilh:.;mlJ(:)! F<1ft9UOO stmnH
.. SPflflO prp.ioad
l.. It 0,1 and gaR leak'age' .
INSTABLE eAliSE'
I- ImproOarly ';nslall"", Or nen,
, .. - , .lmproPerly haqdlebar CfOWI'"
I .. steerine-stem
L
'',' .tmprapefiy' instaiJea steetlng stem
l
.,flmpfOJ)erlY; bghteneq nUl!
.Damaged bearing
'I.: Frnnt oil .levels Ofl'.bort1. sides
i rBroken spring
L .Twlsted front forks
rTj'CS
I
rWhf:e,--
I

I
'f'. -----,------.,--Worn he,rfrln!J 0'
$' Rem O! tiRP1Rj.JOO'
L- Ri1ill
[
: - dhi,n Olm;)fOnefIY
Cnwflr'H -"---.. .Oam<tgorl
.. ""-01 lBt;tly H1J'HilJmd
TROUBLE07(E204)
TROUBLESHOOTING
FAULTY SIGNAL AND l.IGHTING SY$TEM
HEAOUGHTOARK. PROBABLE CAUSE
LI-..,..------_-,:""'__ ..
"\1 ;,.Too. many-tele,etti::
-Haro Charging tfr(o,lo:,erl sratol co'l! .ann or faulty
1,
1. re.ctlfief/reg...
(I'lncorrect COOfliiCt!on
frOOroperly
"Poor contacts -imSH":.(If SW;ft,hi
. L "life 8(t)tr-ed
SUlB BURNT OUT CAUSE
.:.- <I"'f)'ope, b,ilh
" auII vballl!':;r.
I
-FihihY"1?Cfrber regumtof
. hl1propeHy
, (NW'; iimt f1t
L-Bulb lift> tJi,piffhf
FLASHER DOES I\IOT LIGHT
FLASHER KEEPS 01\1
PJ'IOBABLE C"'USE
......_-_. Hf\)lil1dttd
DiSl:tvuyp.d b;u
\'JF3-\..HIf "lunrf-
-Fa-utfy rcJ;lY
8Jolo.l!!ltl
'" Loo5f'llv \'t)Uplt'l1
Pillh butnf'
f'R06ABlE CAUSf
__ __,_ -t:!iUifr- 'fjashe,
. hnt1ftr\t
,tl'ieaHy
-A\jlh,twml OUt
TROU6LE08(E205,
TROUBLESHOOTING
FAULT'( SIGNALAND lIGHTINGSYST.M
WINKS SLOWEIl - tl:.tI,l,.ISE
> FilUltv flasher rela\l.
1, -insuffteient
linearly diSChargedl
t .'mproOet 'bulb .
L:-' :rnain ,'andto; "XURN" $Wrtch
WINKS QUiCKER PROSA,S!;E CA.U.Sf
------------[>Improp.r bulb
-F."lty flasher 'llilly
HORN IS II\lOPEI'tATlVe PROBABLE CAuse
! .
---:- >.faultv bart;',,\,
!!'Faulty mnl;'; arH'f ,m "ryOi1N"
*'mnropet,!y, adjusted fl0fh
t IP!7aulty Morn
:.... --fhuken
TR0116kE09(E2D6)
TECHNISCHE DATEN UND FOLLMENGEN
TECHNICAL DATA AND FILLING VOLUMES
SKORPION:Tour I Traveller. Sport, Replica
MOTORAAD- UNOZWEIRAOWERK GMBH

PoriUach/POB 70
D-09401 bcbopau.Hohndod STAND f OEAOUNE 05196
BLAn /PAGE 1
'VERGASER
CAR8URETTOR
Haupldu.elinkslrecht. 1301165

Ouse!\lllldfllpoSldorHlx;
jer,needle
NadeldOselLr1auldus. Prim,:YOO
mm

Synchronisation( point of throttle valv. opening
secondal)' carburellor)
UBERSETZUNGEN
TRANSMrSSION
, .,.... 1,'''''' ., 'j"!'tl'!iV"
..
Kene, Anz.hl der GIIeder 110 his (up fo) Mod, '94: 108,518"><114", Q.Rlng endIos (endleS1S)
chain, boo 108, 5/8".114",
"

SKORPION:Tour !Traveller, Sport, Raplica
BLAn / PAGE 2
TECHNISCHE DATEN UND FOLLMENGEN
TECHNICAL DATA AND FILLING VOLUMES
MOTORRAD- UNOZWEIRAOWEAK GMBH
KLndendienst/seMce depilttmenllt 03725149918
P051Sactl1 POB 70
0-09401 Z8cb0paLHiohndol1 STAND JDEADLINE 05196
20ndzeitpunkl
ignition time
v.OT bei Ulmin
V.D.C. at rpm
Hinten (Bel. 1 ader 2 Pers. zu je 75kg)
rear (1 or 2 persons at 75 kg each!
Hinten (bei maX: zul. Achslast) '<;' .
rear ral max. load). , .
kPaibar 240/2,4 23012,3
ICW
SKORPION: Tour I Traveller, Sport, Replica
ANZUGSMOMENTE
SCREWTIGHTENING TORQUES
MOTOAAAo- UNO ZWEIRAOWERK GMBH
Kundemiemt I SelVk:edepaftment 2 03725149918
P<1slfach /poe 70
D4401 l:::hop$u4tc.mW1 $1ANDJOEAOUNEl)5J'9(l

Muz 660 e Yamaha

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Muz 660 e Yamaha

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SERVICE MANUAL

<: limit>, Ollil mm (0,lm1 11'11

Sand 1M' ku,:riSSC1QSS pattE-in 00 not sam; ex(;t1S

SIde c111arance j:'

.... *., ..... .. _... >-.

(Vlind(1'! cVtlnoer ,bead Luose spi;f"i\ piuq

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