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o.8 Safety first!

Professional mechanics are trained in safe


working procedures. However enthusiastic you
may be about getting on with the job at hand,
take the time to ensure that your safety is not put
at risk. A moment's lack of attention can result in
an accident, as can failure to observe simple
precautions.
There will always be new ways of having
accidents, and the following is not a
comprehensive list of all dangers it is intended
rather to make you aware of the risks and to
encourage a safe approach to all work you carry
out on your bike.
Asbestos
! "ertain friction, insulating, sealing and
other products # such as brake pads, clutch
linings, gaskets, etc. # contain asbestos.
$%treme care must be taken to avoid
inhalation of dust from such products since it
is ha&ardous to health. 'f in doubt, assume
that they do contain asbestos.
Fire
! (emember at all times that petrol is highly
flammable. )ever smoke or have any kind of
naked flame around, when working on the
vehicle. *ut the risk does not end there # a
spark caused by an electrical short#circuit, by
two metal surfaces contacting each other, by
careless use of tools, or even by static
electricity built up in your body under certain
conditions, can ignite petrol vapour, which in
a confined space is highly e%plosive. )ever
use petrol as a cleaning solvent. +se an
approved safety solvent.
! Always disconnect the battery earth terminal
before working on any part of the fuel or electrical
system, and never risk spilling fuel on to a hot
engine or e%haust.
! 't is recommended that a fire e%tinguisher of
a type suitable for fuel and electrical fires is kept
handy in the garage or workplace at all times.
)ever try to e%tinguish a fuel or electrical fire with
water.
Fumes
! "ertain fumes are highly to%ic and can
,uickly cause unconsciousness and even death if
inhaled to any e%tent. Petrol vapour comes into
this category, as do the vapours from certain
solvents such as trichloro#ethylene. Any draining
or pouring of such volatile fluids should be done
in a well ventilated area.
! -hen using cleaning fluids and solvents,
read the instructions carefully. )ever use
materials from unmarked containers # they may
give off poisonous vapours.
! )ever run the engine of a motor vehicle in an
enclosed space such as a garage. $%haust
fumes contain carbon mono%ide which is
e%tremely poisonous if you need to run the
engine, always do so in the open air or at least
have the rear of the vehicle outside the
workplace.
The battery
! )ever cause a spark, or allow a naked
light near the vehicle's battery. 't will normally
be giving off a certain amount of hydrogen
gas, which is highly e%plosive.
! Always disconnect the battery ground .earth/
terminal before working on the fuel or electrical
systems .e%cept where noted/.
! 'f possible, loosen the filler plugs or cover
when charging the battery from an e%ternal
source. 0o not charge at an e%cessive rate or the
battery may burst.
! Take care when topping up, cleaning or
carrying the battery. The acid electrolyte,
evenwhen diluted, is very corrosive and should
not be allowed to contact the eyes or skin. Always
wear rubber gloves and goggles or a face shield.
'f you ever need to prepare electrolyte yourself,
always add the acid slowly to the water never
add the water to the acid.
Electricity
! -hen using an electric power tool, inspection
light etc., always ensure that the appliance is
correctly connected to its plug and that, where
necessary, it is properly grounded .earthed/. 0o
not use such appliances in damp conditions and,
again, beware of creating a spark or applying
e%cessive heat in the vicinity of fuel or fuel
vapour. Also ensure that the appliances meet
national safety standards.
! A severe electric shock can result from
touching certain parts of the electrical system,
such as the spark plug wires .HT leads/, when
the engine is running or being cranked,
particularly if components are damp or the
insulation is defective. -here an electronic
ignition system is used, the secondary .HT/
voltage is much higher and could prove fatal.
Remember...
.X Don't start the engine without first ascer#
taining that the transmission is in neutral. X
Don't suddenly remove the pressure cap from
a hot cooling system # cover it with a cloth and
release the pressure gradually first, or you may
get scalded by escaping coolant. X Don't
attempt to drain oil until you are sure it has
cooled sufficiently to avoid scalding you.
X Don't grasp any part of the engine or
e%haust system without first ascertaining that it
is cool enough not to burn you. X Don't allow
brake fluid or antifree&e to contact the
machine's paintwork or plastic components.
X Don't siphon to%ic li,uids such as fuel,
hydraulic fluid or antifree&e by mouth, or allow
them to remain on your skin. X Dont inhale
dust # it may be injurious to health .see
Asbestos heading/. X Dont allow any spilled oil
or grease to remain on the floor # wipe it up
right away, before someone slips on it. X Don't
use ill#fitting spanners or other tools which may
slip and cause injury. X Dont lift a heavy
component which may be beyond your
capability # get assistance.
X Don't rush to finish a job or take
unverified short cuts.
X Don't allow children or animals in or
around an unattended vehicle.
X Don't inflate a tyre above the
recommended pressure. Apart from
overstressing the carcass, in e%treme cases
the tyre may blow off forcibly.
! Do ensure that the machine is supported
securely at all times. This is especially
important when the machine is blocked up
to aid wheel or fork removal.
</ Do take care when attempting to loosen a
stubborn nut or bolt. 't is generally better to pull
on a spanner, rather than push, so that if you
slip, you fall away from the machine rather
than onto it.
! Do wear eye protection when using power
tools such as drill, sander, bench grinder etc.
! Do use a barrier cream on your hands prior
to undertaking dirty jobs # it will protect your
skin from infection as well as making the dirt
easier to remove afterwards but make sure
your hands aren't left slippery. )ote that long#
term contact with used engine oil can be a
health ha&ard.
! Do keep loose clothing .cuffs, ties etc. and
long hair/ well out of the way of moving
mechanical parts.
! Do remove rings, wristwatch etc., before
working on the vehicle # especially the
electrical system.
! Do keep your work area tidy # it is only too
easy to fall over articles left lying around.
! Do e%ercise caution when compressing
springs for removal or installation. $nsure that
the tension is applied and released in a
controlled manner, using suitable tools which
preclude the possibility of the spring escaping
violently.
! Do ensure that any lifting tackle used has a
safe working load rating ade,uate for the job.
! Do get someone to check periodically that
all is well, when working alone on the vehicle.
! Do carry out work in a logical se,uence and
check that everything is correctly assembled
and tightened afterwards.
! Do remember that your vehicle's safety
affects that of yourself and others. 'f in doubt
on any point, get professional advice. ! 'f in
spite of following these precautions, you are
unfortunate enough to injure yourself, seek
medical attention as soon as possible.
1caned by 1talker
+)($2'1T$($0 3'
'dentification numbers 09
4rame and engine numbers
The frame serial number is stamped into the
right side of the steering head. The engine
number is stamped into the top of the crankcase
on the right#hand side of the engine. *oth of
these numbers should be recorded and kept in a
safe place so they can be furnished to law
enforcement officials in the event of a theft. There
is also a carburettor identification number on the
intake side of each carburettor body, and a colour
code label on the top of the rear fender under the
passenger seat. The colour code label may also
contain the bike's production year and model
code.
The frame serial number, engine serial number,
carburettor identification number and colour code
should also be kept in a handy place .such as
with your driver's licence/ so they are always
available when purchasing or ordering parts for
your machine.
The procedures in this manual identify the
bikes by model type .eg T05/ and if necessary
by production year. )ote that the production year
does not necessarily correspond with the year of
sale or registration.
The model code number is very useful when
ordering parts for your bike and is linked to the
production year as shown in the accompanying
table. There should be a sticker on the bike's rear
frame section .usually visible once the seat is
lifted/ which gives the model code number .eg
6T76, meaning a 8999 T05/, the :amaha
production code number, and a letter indicating
the colour code. The frame and engine numbers
can also be used to establish the production year
and model code, although these are not available
for post#899; models. The accompanying table
gives model identification data for models
available in the +< market.
*uying spare parts
=nce you have found all the identification
numbers, record them for reference when buying
parts. 1ince the manufacturers change
specifications, parts and vendors .companies that
manufacture various components on the
machine/, providing the '0 numbers is the only
way to be reasonably sure that you are buying
the correct parts.
-henever possible, take the worn part to the
dealer so direct comparison with the new
component can be made. Along the trail from the
manufacturer to the parts shelf, there are
numerous places that the part can end up with
the wrong number or be listed incorrectly.
The two places to purchase new parts for your
motorcycle # the accessory store and the
franchised dealer # differ in the type of parts they
carry. -hile dealers can obtain virtually every
part for your motorcycle, the accessory dealer is
usually limited to normal high wear items such as
shock absorbers, tune#up parts, various engine
gaskets, cables, chains,
o!el ty"e #ro!$r o!el co!e Frame %o. En&ine %o.
T05>;? 8998 @308 ???8?8 on ???8?8 on
899A @306 ?AA8?8 on ?AA8?8 on
899@ @30; ?6?8?8 on ?6?8?8 on
8996 @30B ?C?8?8 on ?C?8?8 on
899; @309 ?B98?8 on ?B98?8 on
899C 6T78 not available
899B 6T7A not available
899> 6T7@ not available
8999 6T76 not available
T(7>;? 899C 6+)8 ???8?8 on ???8?8 on
899B 6+)@ not available
899>D9 6+)6 not available
7TEB;? 89>9 @F08 ???8?8 on ???8?8 on
899? @+0@ ?@A8?8 on ?@A8?8 on
8998 @F06 ?6>8?8 on ?6>8?8 on
899A @F0; ?C@8?8 on ?C@8?8 on
899@ @F0C ?B98?8 on ?B98?8 on
8996 @F0B ?9A8?8 on ?9A8?8 on
899; @F0> 8??8?8 on 8??8?8 on
your worn part to the breaker's yard for direct
comparison.
-hether buying new, used or rebuilt parts, the
best course is to deal directly with someone who
specialises in parts for your particular make.
Starte! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
The frame number is stam"e! on the ri&ht(
han! si!e of the steerin& hea!
The en&ine number is stam"e! into the to"
of the cran'case on the ri&ht(han! si!e of
the en&ine.
brake parts, etc. (arely will an accessory outlet have
major suspension components, cylinders,
transmission gears, or cases.
+sed parts can be obtained for roughly half the
price of new ones, but you can't always be sure of
what you're getting. =nce again, take
o.io 0aily .pre#ride/ checks
%ote) The daily (pre-ride) checks outlined in the owner's manual covers those items which should be inspected on a daily basis.
* En&ine+transmission oil le,el chec'
-e,el chec' "roce!ure
! Position the bike upright .not on its sidestand/
on a level surface.
! =n 8998 to 899; T05 models, remove the
seat .see "hapter >/. =n 7TE models, remove
the right#hand side cover .see "hapter >/.
! "heck the oil level as shown in the appropriate
photo se,uence and top up if necessary.
! )ow start the engine and warm it up to normal
operating temperature.
Caution: Do not run the engine in an
enclosed space such as a garage or
workshop.
! -ith the bike still in an upright position, let it
idle for a further 8? seconds then stop the
engine.
! Taking care to avoid scalding your hands,
recheck the oil level and top up if necessary.
The correct oil
! 5odern, high#rewing engines place great demands on their oil. 't is very important that the correct
oil for your bike is used.
! Always top up with a good ,uality oil of the specified type and viscosity and do not overfill the oil
tank.
Caution: Yamaha advise against using chemical oil additives, or oils with a grade of SH/CD
or higher, or oils labelled !"#Y C$!S"%&!# &&. Such additives or oils could cause
clutch slip.
.il ty"e AP' grade 1$, 14 or 12
.il ,iscosity 1A$8?-@?or8?-6?
/i'e care)
! 'f you have to add oil fre,uently, you should check whether you have any oil leaks. 'f there is no sign
of oil leakage from the joints and gaskets the engine could be burning oil .see Fault Finding).
TD800 1*99* to *9902 an! XT3400 mo!els
'=n T05 models, remove the seat .see "hapter >/ to access the oil filler cap .arrowed/.
=n 7TE models, remove the right#hand side cover .see "hapter >/ to access the oil filler cap .arrowed/.
nscrew the oil filler cap from the oil
tank. The dipstick is integral with the oil
filler cap, and is used to check the engine
oil level. "heck the condition of the cap =#ring
and renew it if damaged or deteriorated.
6 +sing a clean rag or paper towel, wipe all oil from the dipstick. 'nsert the clean dipstick back into the tank, but do not screw it in.
@+n tar
(emove the dipstick and observe the level of the oil, which should be somewhere in between the 4 .full/ and $ .empty/ level lines .arrowed/.
'f the level is below the $ line, top the oil tank up with the recommended grade and type of oil, to bring the level up to the 4 line on the dipstick. 0o not overfill.
Scane! by Stal'er
0aily .pre#ride/ checks o. **
TD800 1*995(on2 an! TRX mo!els
-ipe the oil level window .arrowed/ in the oil tank so that it is clean.
>
-ith the motorcycle held vertical, the oil level should lie between the upper and lower level lines marked on the oil tank .arrowed/.
r 'f the level is below the lower line, remove the filler cap .arrowed/
from the top of the oil tank.
10
Top the tank up with the recommended grade and type of oil,
to bring the level up to the upper line on the window.
Scane! by Stal'er
+)($2'1T$($03'
+)($2'1T$($03'
0.*6 Daily 1"re(ri!e2 chec's
6 /ra'e flui! le,el chec's
A
'arning: (rake h)draulic fluid can harm )our e)es and damage painted surfaces, so use e*treme caution when handling and
pouring it and cover surrounding surfaces with rag. Do not use fluid that has been standing open for some time, as it absorbs
moisture from the air which can cause a dangerous loss of braking effectiveness.
*efore you startG
! 1upport the motorcycle in an upright position,
using an au%iliary stand if re,uired.
! -hen checking the front brake fluid level turn
the handlebars until the top of the master cylinder
is as level as possible.
! =n 7TE models remove the right#hand side
cover to view the rear brake fluid level .see
"hapter >/.
! 5ake sure you have the correct hydraulic fluid.
0=T 6 is recommended.
! -rap a rag around the reservoir being worked
on to ensure that any spillage does not come into
contact with painted surfaces.
*ike careG
! The fluid in the front and rear brake master
cylinder reservoirs will drop slightly as the brake
pads wear down.
! 'f any fluid reservoir re,uires repeated topping#
up this is an indication of an hydraulic leak
somewhere in the system, which should be
investigated immediately.
! "heck for signs of fluid leakage from the
hydraulic hoses and components # if found,
rectify immediately.
! "heck the operation of both brakes before
taking the machine on the road if there is
evidence of air in the system .spongy feel to
lever or pedal/, it must be bled as described
in "hapter B.
Front bra'e flui! le,el
=n T(7 models, the front brake fluid level is
visible through the reservoir body # it must
be between the +PP$( and F=-$( level
lines .arrowed/.
=n T(7 models, if the level is below the
F=-$( level line, remove the reservoir cap
clamp screw .arrowed/, then
unscrew the cap and remove the diaphragm
plate and the diaphragm.
=n T05 and 7TE models, the front brake fluid
level is visible through the window in the
reservoir body # it must be above the F=-$(
level line .arrowed/.
=n T05 and 7TE models, if the level is
below the F=-$( level line, remove the
two reservoir cover screws and remove the
cover and the diaphragm.
; Top up with new clean hydraulic fluid of the recommended type, until the
level is above the F=-$( level line. Take care to avoid spills
.see 7arnin& above/.
Starte! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
$nsure that the diaphragm is correctly seated before installing the
plate .T(7 models/ and cover or cap.
0aily .pre#ride/ checks 013
Rear bra'e flui! le,el
=n T05 models, the rear brake fluid level is visible by looking up under the seat from the left#hand side of the rear wheel # it must be above F=-$( level
line .arrowed/.
B
> =n T(7 models, the rear brake fluid level is visible through the reservoir body # it must be above F=-$( level line .arrowed/.
=n 7TE models, remove the right#hand side cover .see "hapter >/ # the rear brake fluid level is visible through the reservoir body # it must be above F=-$(
level line .arrowed/.
9
! 'f topping up is re,uired, on T05 models remove the seat and " on T(7 models remove the side covers .see "hapter >/. =n T(7 and 7TE models, remove
the cap clamp, then on T(7 models support the reservoir or refit the screw. +nscrew the reservoir cap .arrowed/ and remove the plate and diaphragm. #
6 Top up with new clean hydraulic fluid of the recommended #6 = ' type, until the level is above the lower mark. Take care to avoid ' H spills .see
7arnin& above/.
8
$nsure that the diaphragm is correctly seated before installing the plate and cap. Tighten the cap securely. =n T(7 and 7TE models, fit the cap clamp.
tone! by Stal'er
0*14
0aily .pre#ride/
checks
8 9oolant le,el chec'
'arning: D$ !$+ remove the radiator
pressure cap to add coolant. +opping
up is done via the coolant reservoir tank
filler. D$ !$+ leave open containers of
coolant about, as it is poisonous.
$
*efore you startG
: 5ake sure you have a supply of coolant
available # a mi%ture of ;?I distilled water and
;?I corrosion inhibited ethylene glycol anti#
free&e is needed. %ote) %amaha speci!y that so!t
tap water can be used& but '(T hard
water. )! in doubt& boil the water !irst or use only
distilled water.
! Always check the coolant level when the
engine is cold.
! 1upport the motorcycle in an upright position,
using an au%iliary stand if re,uired, whilst
checking the level. 5ake sure the motorcycle is
on level ground.
*ike careG
! +se only the specified coolant mi%ture. 't is
important that anti#free&e is used in the system
all year round, and not just in the
winter. 0o not top the system up using only
water, as the system will become too diluted.
! 0o not overfill the reservoir tank. 'f the coolant
is significantly above the +PP$( level line at any
time, the surplus should be siphoned or drained
off to prevent the possibility of it being e%pelled
out of the breather hose.
! 'f the coolant level falls steadily, check the
system for leaks .see "hapter 8/. 'f no leaks are
found and the level continues to fall, it is
recommended that the machine is taken to a
:amaha dealer for a pressure test.
=n T05 models, the coolant reservoir 4+FF and F=- level lines are visible by looking up under the seat from the left#hand side of the rear wheel. The
coolant level lines .arrowed/ are marked on the reservoir.
'
=n T(7 models, remove the seat .see "hapter >/. The coolant 4+FF and F=- level lines .arrowed/ are marked on the inside of the reservoir.
=n 7TE models, the coolant reservoir 4+FF and F=- level lines are visible by looking up under the mudguard from the right#hand side of the rear wheel.
The coolant level lines .arrowed/ are marked on the reservoir.
@
'f the coolant level is not between the +PP$( and F=-$( markings, on T05 models remove the seat and on 7TE models the left#hand side cover .see
"hapter >/. (emove the reservoir filler cap. 6
Top the coolant level up with the recommended coolant mi%ture. 4it the cap securely, then install the seat, and on 7TE models the side cover .see
"hapter >/. ;
Scane! by Stal'er
0aily .pre#ride/ checks ?.8;
6 Tyre checks
The correct pressuresG
! The tyres, must be checked when col!; not
immediately after riding. )ote that low tyre
pressures may cause the tyre to slip on the rim or
come off. High tyre pressures will cause
abnormal tread wear and unsafe handling.
! +se an accurate pressure gauge.
! Proper air pressure will increase tyre life and
provide ma%imum stability and ride comfort.
Tyre careG
! "heck the tyres carefully for cuts, tears,
embedded nails or other sharp objects and
e%cessive wear. =peration of the motorcycle with
e%cessively worn tyres is e%tremely ha&ardous,
as traction and handling are directly affected.
! "heck the condition of the tyre valve and
ensure the dust cap is in place.
! Pick out any stones or nails which may have
become embedded in the tyre tread. 'f left, they
will eventually penetrate through the casing and
cause a puncture.
! 'f tyre damage is apparent, or une%plained
loss of pressure is e%perienced, seek the advice
of a tyre fitting specialist without delay.
-oa!in&+s"ee! Front Rear
*99* to *990 TD mo!els
(ider only
(ider and passenger, or high speed
68 psi 16.0 *ar/ 68
psi 16.0 *ar/
@@ psi .A.A; *ar/ @C
psi .A.;? *ar/
*995(on TD mo!els
All loadsDspeeds
6? psi .A.B; *ar/
88 psi .A.A; *ar/
TRX mo!els
(ider only
(ider and passenger, or high speed
88 psi .A.A; *ar/ 85
psi .A.;? *ar/
@C psi .A.;? *ar/ 68
psi .A.>? *ar/
XT3 mo!els
(ider only
(ider and passenger, or high speed
88 psi .A.A; *ar/ 88
psi .A.A; *ar/
@@ psi .A.A; *ar/ @C
psi .A.;? *ar/
Tyre tread depthG
! At the time of writing +< law re,uires that tread
depth must be at least 8 mm over @D6 of the tread
breadth all the way around the tyre, with no bald
patches. 5any riders, however, consider a
minimum of A mm tread depth to be a safer limit.
:amaha recommend a minimum of 8.; mm on
the front and A mm on the rear.
"heck the tyre pressures when the tyres
are cold and keep them properly inflated. 8
5easure tread depth at the centre of the
tyre using a tread depth gauge.
S
@ Tyre tread wear indicator bar location marking
.usually either an arrow, a triangle or the letters
T-'/ on the sidewall .arrowed/.
Scane! by Stal'er
! 5any tyres now incorporate wear indicators in
the tread. 'dentify the triangular pointer on the
tyre sidewall to locate the indicator bar and
replace the tyre if the tread has worn down to the
bar.
11
9ha"ter *
(outine maintenance and 1ervicing
9ontents
Air filter # cleaning and renewal ............................................................. ;
*attery # charging ................................................................ see "hapter 9
*attery # check........................................................................................ 88
*attery # removal, installation, inspection and
maintenance...................................................................... see "hapter 9
*rakes # fluid change and seal renewal .................................................AC
*rake hoses # renewal .......................................................................... A9
*rake pads # wear check ....................................................................... >
*rake system # check.............................................................................. 9
"arburettors # synchronisation................................................................. 6
"lutch # check and adjustment................................................................. 8?
"ooling system # check .......................................................................... 8C
"ooling system # draining, flushing and refilling.......................................AB
"ylinder compression # check ................................................................. @8
0rive chain and sprockets # check, adjustment and lubrication ... 8
$ngine oil pressure # check .................................................................. @A
$ngineDtransmission # oil change............................................................. B
$ngineDtransmission # oil change and filter renewal.................................AA
4ront forks # oil change............................................................................ @6
4uel hoses # renewal............................................................................... @@
4uel filter # renewal .8999 T05 models/..................................................A@
4uel system # check ................................................................................ C
Headlight aim # check and adjustment.....................................................@?
'dle speed # check and adjustment ........................................................ @
)uts and bolts # tightness check .............................................................8;
1idestand #check..................................................................................... 86
1idestand, lever pivots and cables # lubrication.......................................8>
1park plugs # gap check and adjustment................................................. A
1teering head bearings # freeplay check and adjustment ........................A8
1teering head bearings # lubrication........................................................ A;
1uspension # check ............................................................................... A?
1wingarm and suspension bearings .T05 and T(7 models/ #
lubrication .......................................................................................... A6
1wingarm and suspension bearings .7TE models/ # lubrication ... 89
Throttle and choke cables # check...........................................................8B
3alve clearances # check and adjustment ..............................................A>
-heels and tyres # general check .........................................................8A
-heel bearings # check ......................................................................... 8@
De&rees of !ifficulty
Easy; suitable for Jk
novice with little
e%penence <<=
Fairly easy; suitable Jjs, for
beginner with tH some
e%perience >S
Fairty !ifficult; Jk
suitable for competent H
0': mechanic ?<S
Difficult; suitable for H,
e%perienced 0': @K
mechanic H
3ery difficult,
suitable for e%pert 0': H
or professional 6S
Scane! by Stal'er
.@
8.A (outine maintenance
S"ecifications
En&ine
"ylinder identification.........................................................
1park plugs
Type .............................................................................
$lectrode gap ................................................................
$ngine idle speed
T05 8998 to 899; models.............................................
T05 899C#on models and all T(7 models.....................
7TE models...................................................................
"arburettor synchronisation # intake vacuum
T05 8998 to 899; models.............................................
T05 899C#on models.....................................................
T(7 and 7TE models ....................................................
"arburettor synchronisation # ma%. difference between
T05 8998 to 899; models and all 7TE models ....
T05 899C#on models and all T(7 models.....................
3alve clearances ."=F0 engine/
'nlet valves ...................................................................
$%haust valves .............................................................
"ylinder compression T05
8998 to 899; models
1tandard ...................................................................
5a%imum ................................................................
5inimum....................................................................
5a%. difference between cylinders.............................
T05 899C#on models and all T(7 models
1tandard ...................................................................
5a%imum ................................................................
5inimum....................................................................
5a%imum difference between cylinders.....................
7TE models
1tandard ...................................................................
5a%imum ................................................................
5inimum....................................................................
5a%imum difference between cylinders.....................
......................... )o. 8 .left#hand/, no. A .right#hand/
......................... )2< 0P(>$A#9 or )ippondenso 7A6$P(#+9
......................... ?.> to ?.9 mm
......................... 8??? to 8A?? rpm
......................... 8?;? to 8A;? rpm
......................... 88?? to 8A?? rpm
......................... A;? to AB? mm Hg
......................... AB? to A9? mm Hg
......................... A6? to AC? mm Hg
carburettors
......................... 8? mm Hg
......................... ; mm Hg
......................... ?.8; to ?.A? mm
......................... ?.A; to ?.@? mm
8;A psi .8?.; *ar/
8;> psi .8?.9 *ar/
86C psi .8?.8 *ar/
86.; psi .8.? *ar/
8B; psi .8A.? *ar/
8>A psi .8A.; *ar/
86; psi .8?.? *ar/
86.; psi .8.? *ar/
8@> psi .9.; *ar/
866 psi .9.9 *ar/
8@A psi .9.8 *ar/
86.; psi .8.? *ar/
9ycle "arts
0rive chain slack
T05 models .....................................................
T(7 models.......................................................
7TE models.......................................................
4ront brake lever freeplay .7TE models/...............
(ear brake pedal height .see te%t/
T05 8998 to 899; models.................................
T05 899C#on models........................................
T(7 models.......................................................
7TE models.......................................................
*rake pad friction material wear limit
T05 and T(7 models.......................................
7TE models.......................................................
"lutch cable freeplay
T05 8998 to 899; models.................................
All other models ................................................
Throttle cable freeplay
T(7 models.......................................................
All other models ...............................................
Tyre pressures .cold/ and minimum tread depth
1wingarm # 7TE models
1ide clearance ................................................
*earing spacer length .right#hand/....................
*earing spacer length .left#hand/......................
-asher thickness .............................................
6? to ;? mm
A? to @? mm
A; to @; mm
A to ; mm
8B to 68 mm A9
mm ;B mm ; to
A; mm
?.; mm 8.;
mm
> to 8A mm
8? to 8; mm
@ to B mm
@ to ; mm
see *aily (pre-ride) checks
?.6 to ?.B mm 9?.9; to
98.8?mm >?.9; to
>8.8? mm 8.9 to A.?
mm
TorAue settin&s
(ear a%le nut
T05 8998 to 899; models........................................................................ 8?; )m
T05 899C#on models................................................................................ 8?B )m
T(7 models............................................................................................... 88B )m
7TE models............................................................................................... 9? )m
(ear brake caliper bracket bolt .T05 models/.............................................. @; )m
"rankcase oil drain plug................................................................................ @; )m
=il filter housing drain plug............................................................................ @? )m
=il filter cover bolts........................................................................................ 8? )m
1teering head bearing adjuster nut .using service tool/ 8998 to
899; T05 models
'nitial setting ........................................................................................ ;A )m
4inal setting........................................................................................... @ )m
899C#on T05 models and all T(7 models
'nitial setting ........................................................................................ 6> )m
4inal setting........................................................................................... 8C )m
7TE models
'nitial setting ........................................................................................ @> )m
4inal setting........................................................................................... C )m
1teering stem nut
8998 to 899; T05 models........................................................................ 88? )m
899C#on T05 models................................................................................ 8?> )m
T(7 models............................................................................................... 88? )m
1teering stem bolt .7TE models/ ................................................................ >? )m
4ork clamp bolts .top yoke/ ......................................................................... A@ )m
"ooling system drain plugs ......................................................................... 8?)m
=il gallery bolt............................................................................................... 8? )m
+)($2'1T$($03'
(outine maintenance 8.@
Stane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
Recommen!e! lubricants an! flui!s
$ngineDtransmission oil type.......................................................................... AP' grade 1$, 14 or 12 motor oilL
$ngineDtransmission oil viscosity .................................................................. 1A$ 8?-@? or 8?-6?
$ngineDtransmission oil capacity T05 8998 to 899;
models and all 7TE models
=il change............................................................................................. @.> litres
=il and filter change .............................................................................. @.9 litres
4ollowing engine overhaul # dry engine, new filter................................. 6.A litres
T05 899C#on models and all T(7 models
=il change............................................................................................. @.; litres
=il and filter change .............................................................................. @.C litres
4ollowing engine overhaul # dry engine, new filter................................. 6.A litres
"oolant type.................................................................................................. ;?I distilled water, ;?I corrosion#inhibited ethylene glycol anti
free&e. %ote) %amaha speci!y that so!t tap water can be used& but
'(T hard water. )! in doubt& boil the water !irst or use only distilled
water.
"oolant capacity
(adiator and engine ................................................................................. 8.B litres
(eservoir
7TE models........................................................................................... ?.6; litre
All other models ................................................................................... ?.@ litre
*rakefluid...................................................................................................... 0=T6
4ront fork oil type, capacity and level............................................................ see "hapter C 1pecifications
0rive chain .................................................................................................. 1A$ @? to ;?- engine oil or chain lubricant suitable for =#ring
chains
1teering head bearings................................................................................. Fithium#based multi#purpose grease
1wingarm pivot bearings # T05 and T(7 models......................................... 5olybdenum disulphide grease
1wingarm pivot bearings # 7TE models......................................................... Fithium#based multi#purpose grease
1uspension linkage bearings # T(7 models ............................................... 5olybdenum disulphide grease
1uspension linkage bearings # 7TE models................................................... Fithium#based multi#purpose grease
-heel bearings and grease seal lips............................................................. Fithium#based multi#purpose grease
2earchange leverDclutch leverDfront brake leverDrear brake
pedalDsidestand pivots................................................................................... 8?-@? motor oil
"ables........................................................................................................... 8?-@? motor oil
Throttle grip ................................................................................................ 5ulti#purpose grease or dry film lubricant
'%amaha advise against using chemical oil additives& or oils with a grade o! +,/-* or higher& or oils labelled .'./0% -('+./1)'0 )). +uch
additives or oils could cause clutch slip.
8.6 "omponent locations
T05
# +teering head bearings
2 -lutch cable upper ad3uster
4 $ir !ilter
5 6attery (#77# to #778)
8 (il !iller cap/dipstick (#77# to #778)
9 -oolant reservoir
: *rive chain ad3uster
; )dle speed ad3uster
7 (il drain plug
T05
# /ear brake !luid reservoir
2 (il level window (#779-on)
4 (il !iller cap (#779-on)
5 Front brake !luid reservoir
; Throttle cable upper ad3uster
9 /adiator pressure cap
: -oolant drain plug on water
pump
-lutch cable lower ad3uster
(il !ilter and !ilter housing
drain plug
#< 6attery (#779-on)
1caned by 1talker
"omponent locations 8.;
TRX
# -oolant reservoir
2 /ear brake !luid reservoir
4 (il level window
5 (il !iller cap
8 Front brake !luid reservoir
9 Throttle cable upper ad3uster
: /adiator pressure cap
; -oolant drain plug on water
pump
7 -lutch cable lower ad3uster
#< (il !ilter and !ilter housing
drain plug
TRX
# -lutch cable upper ad3uster
2 +teering head bearing
ad3uster
4 $ir !ilter
5 )dle speed ad3uster
8 6attery
9 *rive chain ad3uster
: (il drain plug
Stane! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
.C "omponent locations
XT3
# /ear brake !luid reservoir
2 (il !iller cap/dipstick
4 Throttle cable upper ad3uster
5 Front brake !luid reservoir
8 +teering head bearing
ad3uster
9 -oolant drain plug on water
pump
: -lutch cable lower ad3uster
; (il !ilter and !ilter housing
drain plug
/adiator pressure cap
-lutch cable upper ad3uster
$ir !ilter
6attery
-oolant reservoir
*rive chain ad3uster
(il drain plug
Scane! by Stal'er
XT3
5aintenance schedule w
%ote) The daily (pre-ride) checks outlined in the owner's manual
covers those items which should be inspected on a daily basis. $lways
per!orm the pre-ride inspection at every maintenance interval (in
addition to the procedures listed). The intervals listed below are the
intervals recommended by the manu!acturer !or each particular
operation during the model years covered in this manual. %our owner's
manual may have di!!erent intervals !or your model.
0aily .pre#ride/
M 1ee '*aily (pre-ride) checks' at the beginning of this
$very 6??? miles .C??? km/ or
C months .whichever comes sooner/
.continued/
M (e#grease the swingarm and suspension linkage
bearings .7TE models/ .1ection 89/.
M "heck the suspension .1ection A?/
M "heck and adjust the steering head bearings
.1ection A8/
After the initial C?? miles .8??? km/
%ote) This check is usually per!ormed by a %amaha dealer a!ter the
!irst 9<< miles (#<<< km) !rom new. Therea!ter& maintenance is
carried out according to the !ollowing intervals o! the schedule.
$very @?? miles .;?? km/
M "heck, adjust and lubricate the drive chain
.1ection 8/
$very 6??? miles .C??? km/ or
C months .whichever comes sooner/
M "heck the spark plug gaps and plug condition
.1ection A/
M "heck and adjust the idle speed .1ection @/
0 "heckDadjust the carburettor synchronisation
.1ection 6/
M "lean and check the air filter element .1ection ;/
M "heck the fuel system and hoses .1ection C/ 0
"hange the engine oil .1ection B/
? "heck the brake pads .1ection >/
M "heck the brake system and brake light switch
operation .1ection 9/
M "heck and adjust the clutch .1ection 8?/
M "heck the battery .1ection 88/
0 "heck the condition of the wheels and tyres
.1ection 8A/
M "heck the wheel bearings .1ection 8@/
M "heck the sidestand .1ection 86/
M "heck the tightness of all nuts, bolts and
fasteners .1ection 8;/
M "heck the cooling system .1ection 8C/
M "heck and adjust the throttle and choke cables
.1ection 8B/
0 Fubricate the clutchDgearshiftDbrake leverDbrake
pedalDsidestand pivots and the throttleDchokeDclutch
cables .1ection 8>/
$very >??? miles .8A,??? km/ or 8A
months .whichever comes sooner/
-arry out all the items under the 5<<< mile (9<<< km) check& plus the
!ollowing=
M "hange the engine oil and filter .1ection AA/
M (enew the fuel filter .8999 T05 models/
.1ection A@/
$very 8C,??? miles .A6,??? km/ or
two years .whichever comes sooner/
-arry out all the items under the ;<<< mile (#2&<<< km) check& plus
the !ollowing=
M (e#grease the swingarm and suspension linkage
bearings .T05 and T(7 models/ .1ection A6/.
M (e#grease the steering head bearings .1ection A;/.
0 "hange the brake fluid and renew the brake master
cylinder and caliper seals .see 1ection AC/
M (enew the coolant .1ection AB/
$very A>,??? miles .6A,??? km/
-arry out all the items under the 5<<< mile (9<<< km) check& plus the
!ollowing=
M "heck and adjust the valve clearances .1ection A>/
very four years
M (enew the brake hoses .1ection A9/
)on#scheduled maintenance
M "heck and adjust the headlight aim .1ection @?/
M "heck the cylinder compression .1ection @8/
M "heck the engine oil pressure .see 1ection @A/
M (enew the fuel hoses .1ection @@/
M "hange the front fork oil .1ection @6/
Sta&e! by Stal'er
*.8 ?ntro!uction
* This "hapter is designed to help the home
mechanic maintain hisDher motorcycle for safety,
economy, long life and peak performance.
6 0eciding where to start or plug into the routine
maintenance schedule depends on several
factors. 'f the warranty period on your motorcycle
has just e%pired, and if it has been maintained
according to the warranty standards, you may
want to pick up routine maintenance as it
coincides with the ne%t mileage or calendar
interval. 'f you have owned the machine for some
time but have
never performed any maintenance on it, then you
may want to start at the nearest interval and
include some additional procedures to ensure
that nothing important is overlooked. 'f you have
just had a major engine overhaul, then you may
want to start the maintenance routine from the
beginning. 'f you have a used machine and have
no knowledge of its history or maintenance
record, you may desire to combine all the checks
into one large service initially and then settle into
the maintenance schedule prescribed. @ *efore
beginning any maintenance or
repair, the machine should be cleaned
thoroughly, especially around the oil filter, spark
plugs, valve cover, side panels, carburettors, etc.
"leaning will help ensure that dirt does not
contaminate the engine and will allow you to
detect wear and damage that could otherwise
easily go unnoticed.
6 "ertain maintenance information is sometimes
printed on decals attached to the motorcycle. 'f
the information on the decals differs from that
included here, use the information on the decal.
E,ery 800 miles 1000 'm2
* Dri,e chain an! s"roc'ets # 8JN
check, adjustment and ON
lubrication H
Check
8 A neglected drive chain won't last long and can
,uickly damage the sprockets. (outine chain
adjustment and lubrication isn't difficult and will
ensure ma%imum chain and sprocket life.
A To check the chain, place the bike on its
sidestand and shift the transmission into neutral.
@ Push up on the bottom run of the chain and
measure the slack midway between the two
sprockets, then compare your measurement
*.8 #ush u" on the chain an! measure the
slac'
to that listed in this "hapter's 1pecifications 1see
illustration2. As the chain stretches with wear,
adjustment will periodically be necessary .see
below/. 1ince the chain will rarely wear evenly,
roll the bike forwards so that another section of
chain can be checked do this several times to
check the entire length of chain and position the
tightest spot midway between the sprockets on
the bottom run of the chain.
6 'n some cases where lubrication has been
neglected, corrosion and galling may cause the
links to bind and kink, which effectively shortens
the chain's length. 1uch links should be
thoroughly cleaned and worked free. 'f the chain
is tight between the sprockets, rusty or kinked,
it's time to renew it. 'f you find a tight area, mark
it with felt pen or paint, and repeat
0'($"T'=) =4 (=TAT'=)
$)2')$ 1P(="<$T ($A( 1P(="<$T
-=()T==TH -=()T==TH
*.4 9hec' the s"roc'ets in the areas
in!icate! to see if they are Born
eCcessi,ely
the measurement after the bike has been ridden.
'f the chain's still tight in the same area, it may be
damaged or worn. *ecause a tight or kinked
chain can damage the transmission countershaft
bearing, it's a good idea to renew it.
0 "heck the entire length of the chain for
damaged rollers, loose links and pins, and
missing =#rings and renew it if damage is found.
%ote) 'ever install a new chain on old sprockets&
and never use the old chain i! you install new
sprockets - renew the chain and sprockets as a
set.
5 'f you suspect that the chain may be worn out,
you can measure a 8?#link length and compare it
with the wear limit. This re,uires the chain to be
removed from the bike and first cleaned .see
"hapter C/.
4 (emove the front sprocket cover .see "hapter
C/. "heck the teeth on the engine sprocket and
the rear wheel sprocket for wear 1see
illustration2.
8 'nspect the drive chain slider on the swingarm
for e%cessive wear and renew it if worn .see
"hapter C/.
,d-ustment
9 (otate the rear wheel until the chain is
positioned with the tightest point at the centre
of its bottom run, then place the machine on
its sidestand. =n T05 models, slacken the
brake caliper bracket bolt on the top of the
swingarm 1see illustration2.
*0 -here fitted, remove the split pin from the
rear a%le nut. 1lacken the nut 1see illustrations2.
*.9 .n TD mo!els; slac'en the bolt 1arroBe!2
*.*0a Rear aCle nut 1arroBe!2 (TD mo!els
*.*0b Rear aCle nut 1arroBe!2 (TRX mo!els
Scane! by Stal'er
$very @?? miles .;?? km/ 8.9
*.**a .n TD an! XT3 mo!els; slac'en the loc'nut 1arroBe!2...
*.**b ... an! turn the a!<uster as reAuire!
*.**c .n TRX mo!els; slac'en the loc'nut 1A2 an! turn the a!<uster 1/2 as reAuire!
** 1lacken the adjuster locknut on each side of
the swingarm, then turn the adjusters evenly until
the amount of freeplay specified at the beginning
of the "hapter is obtained at the centre of the
bottom run of the chain 1see illustrations/.
4ollowing chain adjustment, check that each
chain adjustment marker is in the same position
in relation to the marks on the swingarm 1see
illustrations2. 't is important each adjuster aligns
with the same notch if not, the rear wheel will be
out of alignment with the front. %ote) )! you need
to check wheel alignment re!er to -hapter :.
*6 'f there is a discrepancy in the chain adjuster
positions, adjust one of them so that its position
is e%actly the same as the other. "heck the chain
freeplay as described above and readjust if
necessary.
*8 Tighten the a%le nut to the tor,ue setting
specified at the beginning of the "hapter, then
tighten the adjuster locknuts securely 1see
?llustration2. -here removed, fit a new split pin
onto the a%le nut 1see illustration2. =n T05
models, tighten the brake caliper bracket bolt to
the specified tor,ue 1see illustration *.92.
Caution: $n models with a split pin securing
the a*le nut, if the groove in the nut does not
align with the hole in the a*le after the
specified tor.ue has been reached, tighten
the nut to align it / D$ !$+ loosen it.
0ubrication
*D 'f re,uired, wash the chain in paraffin
l.Hd .n TD an! XT3 mo!els; chec' the
relati,e "osition of the mar'er 1A2 an! the
notches 1/2 on each si!e
.kerosene/, then wipe it off and allow it to dry,
using compressed air if available. 'f the chain is
e%cessively dirty it should be removed from the
machine and allowed to soak in the paraffin .see
"hapter C/. Caution: Don1t use petrol, solvent
or other cleaning fluids which might damage
the internal sealing properties of the chain.
Don1t use high/pressure water. +he entire
process shouldn1t take longer than ten
minutes / if it does, the $/rings in the chain
rollers could be damaged. *0 4or routine
lubrication, the best time to lubricate the chain is
after the motorcycle has been ridden. -hen the
chain is warm, the lubricant will penetrate the
joints between the
*.**0 .n TRX mo!els; chec' the relati,e
"osition of the notches on the mar'er 1A2
an! the notches in the sBin&arm 1/2 on
each si!e
side plates better than when cold. %ote) %amaha
speci!ies +$. 4< to 8<> engine oil? you can use
an aerosol chain lube& but make sure that it is
suitable !or (-ring chains. Apply the oil to the
area where the side plates overlap # not the
middle of the rollers 1see illustration2.
centrifugal force will work the oil into
the chain when the bike is moving.
,fter appl)ing the lubricant, let it soak
in a few minutes before wiping off an)
eCcess.
*.*8a Ti&hten the aCle nut to the s"ecifie! torAue
>>.T>T8?
$
@@ly the oil to the top o!
Eh<?F? tne iower chain run& so
G?%T
*.*8b Ese a neB s"lit "in; Bhere a""ro"riate
*.*0 A""ly the oil to the o,erla" in the si!e "lates
Stane! by Stal'er
i.io $very 6??? miles .C??? km/ or C months
E,ery D000 miles 15000 'm2 or 5 months
6 S"ar' "lu&s #
check and adjustment P1j
8 5ake sure your spark plug socket is the
correct si&e .8> mm/ before attempting to remove
the plugs # a suitable one is supplied in the
motorcycle's tool kit which is stored under the
seat.
A =n 7TE models, remove the fuel tank and the
air filter housing .see "hapter 6/.
@ +sing compressed air if available, clean the
area around the base of the spark plugs to
prevent any dirt falling into the engine when the
plugs are removed.
6 "heck that the cylinder location is marked on
each plug lead, then pull the spark plug cap off
each spark plug 1see illustration2. +sing either
the plug tool supplied in the bike's toolkit or a
deep socket type wrench, unscrew the plugs from
the cylinder head 1see illustration2. Fay each
plug out in relation to its cylinder if either plug
shows up a problem it will then be easy to identify
the troublesome cylinder.
; 'nspect the electrodes for wear. *oth the
centre and side electrodes should have s,uare
edges and the side electrodes should be of
uniform thickness. Fook for e%cessive deposits
and evidence of a cracked or chipped insulator
around the centre electrode. "ompare your spark
plugs to the colour spark plug reading chart at
the end of this manual. "heck the threads, the
washer and the ceramic insulator body for cracks
and other damage.
C 'f the electrodes are not e%cessively worn, and
if the deposits can be easily removed with a wire
brush, the plugs can be re#gapped and re#used .if
no cracks or chips are visible in the insulator/. 'f in
doubt concerning the condition of the plugs,
renew them, as the e%pense is minimal. :amaha
do not specify a renewal interval, but leave it to
the discretion of the owner.
B "leaning spark plugs by sandblasting is
permitted, provided you clean the plugs with a
high flash#point solvent afterwards.
> *efore installing the plugs, make sure they are
the correct type and heat range and check the
gap between the electrodes 1see illustrations2.
"ompare the gap to that specified and adjust as
necessary. 'f the gap must be adjusted, bend the
side electrode only and be very careful not to chip
or crack the insulator nose 1see illustration2.
5ake sure the washer is in place on the plug
before installing it.
9 1ince the cylinder head is made of aluminium,
which is soft and easily damaged, thread the
plugs into the heads turning the tool by hand
1see illustration2. =nce the
plugs are finger#tight, the job can be finished with
a spanner on the tool supplied or a socket drive
1see illustration *.Db2. 'f a tor,ue wrench can be
applied, tighten the spark plugs to the specified
tor,ue setting. =therwise tighten them by 8D6 to
8DA turn after they have been fully hand#tightened
and have seated. 0o not over#tighten them.
HTflflH88
#As the
plugs are Auite
G?%T
short length of hose over the end of the
plug to use as a tool to thread it into place.
+he hose will grip the plug well enough to
turn it, but will start to slip if the plug begins
to cross/thread in the hole / this will prevent
damaged threads.
8? (econnect the spark plug caps, making sure
they are securely connected to the correct
cylinder. 'nstall all other components previously
removed. .
#?>G>GS +tripped plug threads in the GE?ES>
cylinder head can be
GiT
6.Da Remo,e the s"ar' "lu& ca"...
*
recesse!; )ou can slip a
repaired with a Heli/Coil ' insert /
see +ools and 'orkshop +ips1 in the
"eference section.
6.Db ... then unscreB the s"ar' "lu&
6.8a Esin& a Bire ty"e &au&e to measure the s"ar' "lu& electro!e &a"
6.8b Esin& a feeler &au&e to measure the s"ar' "lu& electro!e &a"
6.8c A!<ust the electro!e &a" by ben!in& the si!e electro!e only
6.9 Threa! the "lu& in as far as "ossible by turnin& the tool by han!
Scane! by Stal'er
$very 6??? miles .C??? km/ or C months 8.8.8
8.8a ?!le s"ee! a!<uster screB 1arroBe!2
(TD mo!els
@ 'dle speed # QH
check and adjustment
* The idle speed should be checked and
adjusted before and after the carburettors are
synchronised .balanced/ and when it is obviously
too high or too low. *efore adjusting the idle
speed, make sure the valve clearances and
spark plug gaps are correct. Also, turn the
handlebars back#and#forth and see if the idle
speed changes as this is done. 'f it does, the
throttle cable may not be adjusted or routed
correctly, or may be worn out. This is a
dangerous condition that can cause loss of
control of the bike. *e sure to correct this
problem before proceeding.
6 The engine should be at normal operating
temperature, which is usually reached after 8? to
8; minutes of stop#and#go riding. 5ake sure the
transmission is in neutral, and place the
motorcycle on its sidestand.
8 =n T05 and T(7 models, the idle speed
adjuster is located on the left#hand side 1see
illustrations2. =n 7TE models, the adjuster is
located at the back of the carburettors between
the float chambers. -ith the engine idling, adjust
the idle speed by turning the adjuster screw until
the idle speed listed in this "hapter's
1pecifications is obtained. Turn the screw
clockwise to increase idle speed, and anti#
clockwise to decrease it.
8.8b ?!le s"ee! a!<uster screB 1arroBe!2
(TRX mo!els
D 1nap the throttle open and shut a few times,
then recheck the idle speed. 'f necessary, repeat
the adjustment procedure.
0 'f a smooth, steady idle can't be achieved, the
fuelDair mi%ture may be incorrect .check the pilot
screw settings # see "hapter 6/ or the
carburettors may need synchronising .see
1ection 6/. Also check the inlet manifold rubbers
for cracks which will cause an air leak, resulting in
a weak mi%ture.
6 "arburettors # H
synchronisation H
'arning: 2etrol 3gasoline4 is
e*tremel) flammable, so take e*tra
precautions when )ou work on an)
part of the fuel s)stem. Don1t smoke or allow
open flames or bare light bulbs near the work
area, and don1t work in a garage where a
natural gas/t)pe appliance is present. &f )ou
spill an) fuel on )our skin, rinse it off
immediatel) with soap and water. 'hen )ou
perform an) kind of work on the fuel s)stem,
wear safet) glasses and have a fire
e*tinguisher suitable for a Class ( t)pe fire
3flammable li.uids4 on hand.
,
gauge take/off points on the intake
manifolds. Do not allow e*haust gases to
build up in the work area5 either perform the
check outside or use an e*haust gas
e*traction s)stem.
8 "arburettor synchronisation is simply the
process of adjusting the carburettors so they
pass the same amount of fuelDair mi%ture to each
cylinder. This is done by measuring the vacuum
produced in each cylinder. "arburettors that are
out of synchronisation will result in decreased
fuel mileage, increased engine temperature, less
than ideal throttle response and higher vibration
levels. *efore synchronising the carburettors,
make sure the valve clearances and idle speed
are properly set.
A To properly synchronise the carburettors you
will need a pair of vacuum gauges or a
manometer these instruments measure engine
vacuum and can be obtained from motorcycle
dealers or mail order parts suppliers. 'f you don't
have access to either of these instruments
entrust the work to a dealer.
@ 1tart the engine and let it run until it reaches
normal operating temperature, then shut it off.
6 (emove the fuel tank .see "hapter 6/.
; =n 8998 to 899> T05 models, release the
clamp securing the )o. 8 cylinder vacuum hose
to the fuel pump and detach the hose, then pull
the blanking plug out of the end of the )o. A
cylinder vacuum hose 1see illustrations2. 'f in
doubt, trace each hose from the take#off stub on
the top of each inlet manifold between the
carburettor and the cylinder head to make sure
you have the correct one. =n 8999 T05 models,
puil the blanking plug out of both vacuum hoses
situated down the right#hand side of the engine if
in doubt about their location, trace the hoses
from their take#off stubs on the inlet manifolds.
C =n T(7 models, release the clamp securing
the )o. A cylinder hose to the fuel pump and
detach the hose 1see illustration2. The )o. 8
cylinder vacuum hose has already been
detached from the fuel tap when removing the
fuel tank. 'f in doubt, trace each hose from the
take#off stub on the top of each intake
Stane! by Stal'er
D.0a .n TD mo!els; !etach the %o. *
,acuum hose 1arroBe!2 from the fuel
"um"...
D.0b ... an! remo,e the blan'in& "lu&
1arroBe!2 from the %o. 6 hose
D.5 .n TRX mo!els; !etach the %o. 6
,acuum hose 1arroBe!2 from the fuel
"um"
8.8A $very 6??? miles .C??? km/ or C months
D.4a .n XT3 mo!els; !etach the ,acuum hose 1arroBe!2.
D.4b ... an! remo,e the blan'in& "lu& 1arroBe!2
D.*6 9arburettor synchronisation screB
1arroBe!2 ( air filter housin& remo,e! for
clarity
manifold between the carburettor and the
cylinder head to make sure you have the correct
one. 'f access is not too restricted, the hoses can
be detached from the intake manifolds
themselves.
B =n 7TE models, release the clamps securing
the vacuum hose and the blanking plug to the
take#off stubs on the inlet manifolds between the
carburettor and the cylinder head and detach the
hose and plug 1see illustrations2.
> =n T05 and T(7 models, connect the gauges
to the vacuum hose ends. =n 7TE
models, connect the gauge hoses to the takeoff
stubs on the inlet manifolds. 5ake sure there are
no air leaks as false readings will result.
9 Arrange a temporary fuel supply, either by
using a small temporary tank or by using e%tra
long fuel pipes to the now remote fuel tank.
Alternatively, position the tank on a suitable
base on the motorcycle, taking care not to
scratch any paintwork, and making sure that
the tank is safely and securely supported. 'f
using the main tank, switch the tap to =) or
($1 on T05 and 7TE models, and to P(' on
T(7 models.
8? 1tart the engine and let it idle. 'f the gauges
are fitted with damping adjustment, set this so
that the needle flutter is just eliminated but so
that they can still respond to small changes in
pressure.
88 The vacuum readings for both cylinders
should be the same. 'f the vacuum readings
differ, proceed as follows.
8A The carburettors are adjusted by turning the
synchronising screw situated in#between the
carburettors, in the throttle linkage 1see
illustration2. %ote) *o not press down on the
screw whilst ad3usting it& otherwise a !alse
reading will be obtained. -hen the carburettors
are synchronised, open and close the throttle
,uickly a few times to settle
the linkage, and recheck the gauge readings,
readjusting if necessary.
8@ -hen the adjustment is complete, recheck
the vacuum readings, then adjust the idle speed
.see 1ection @/ until the speed listed in this
"hapter's 1pecifications is obtained. 0etach the
temporary fuel supply, then remove the gauges.
(efit the vacuum hoses andDor blanking plugs as
re,uired by your model .see 1teps 9, 8? and 88/.
86 'nstall the fuel tank .see "hapter 6/.
* (emove the fuel tank .see "hapter 6/. =n 7TE
models, also remove the air filter housing .see
"hapter 6/ it is possible to remove the covers
and elements with the housing in situ but access
to the screws is restricted and the screws are
easily dropped.
6 =n T05 and T(7 models remove the screws
securing the air filter cover to the filter housing,
then remove the cover and withdraw the filter
element from the housing 1see illustrations2.
8 =n 7TE models, there are two filter elements,
each fitted integral with its cover on the front of
the housing 1see illustrations2.
0.6a Remo,e the screBs 1arroBe!2 an! lift off
the co,er...
0.6b ..
then Bith!raB the element 1TD
shoBn2
0.8a Remo,e the screBs 1arroBe!2...
Scane! by Stal'er
$very 6??? miles .C??? km/ or C months *I*8
0.8b ... an! remo,e the co,er an! element to&ether
DTap the element on a hard surface to dislodge any large particles of dirt, then if compressed air is available, use it to clean the element, directing the air from the
inside out 1see illustration2.
0"heck the element for signs of damage. 'f the element is torn or cannot be cleaned, or is obviously beyond further use, renew it.
5'nstall the filter element, making sure it is properly seated, and install the fuel tank .see "hapter 6/.
Caution: &f the machine is ridden in dust) conditions, the filter should be cleaned more fre.uentl).
'arning: 2etrol 3gasoline4 is e*tremel) flammable, so take e*tra precautions when )ou work on an) part of the fuel s)stem. Don1t smoke or
allow open flames or bare light bulbs near the work area, and don1t work in a garage where a natural gas/t)pe appliance is present. &f )ou spill an)
fuel on )our skin, rinse it off immediatel) with soap and water. 'hen )ou perform an) kind of work on the fuel s)stem, wear safet) glasses and
have a fire e*tinguisher suitable for a Class ( t)pe fire 3flammable li.uids4 on hand.
,
4.Da EnscreB the cran'case oil !rain "lu&
1arroBe!2...
0.D 9lean the element usin& com"resse! air if a,ailable
Check
8 (emove the fuel tank .see "hapter 6/ and check the tank, the fuel tap, the fuel pump and the fuel and vacuum hoses for signs of leakage, deterioration or damage
in particular check that there is no leakage from the fuel hoses. (enew any hoses which are cracked or deteriorated.
A 'f the fuel tap is leaking, tighten the assembly screws .see "hapter 6/. 'f leakage persists remove the screws and disassemble the tap, noting how the components
fit. 'nspect all components and renew any that are worn or damaged. 1ome components are available individually, though it may be necessary to renew the whole
tap, depending on your model.
@ 'f the carburettor gaskets are leaking, the carburettors should be disassembled and rebuilt using new gaskets and seals .see "hapter 6/.
6ilter cleaning
D "leaning or renewal of the fuel filter is advised after a particularly high mileage has been covered. 't is also necessary if fuel starvation is suspected.
0 =n T(7, 7TE and 8998 to 899> T05 models, the fuel filters are mounted in the tank. =n T05 models, the filters are integral with the fuel outlet assembly from the
tank. =n T(7 and 7TE models, the filters are integral with the fuel tap. =n 7TE models, each fuel tap has its own filter. (emove the
' '
:
-^^^tafc.- *m
mjrl
>--
1
Wr*^- A
m
\\
4.Db ... an! alloB the oil to !rain
0.5 a'e sure the element is correctly seate!
fuel tank and the fuel tap.s/ .see "hapter 6/. "lean the gau&e filter to remove all traces of dirt and fuel sediment. "heck the gau&e for holes. 'f any are found, a
new filter should be fitted .check for availability # it may be necessary to renew the whole tap/. "heck the condition of the =#ring and renew it if it is in any way
damaged or deteriorated. C =n 8999 T05 models and in#line fuel filter is fitted between the fuel tap and fuel pump. (efer to 1ection A@ for details.
A 'arning: (e careful when draining the oil, as the e*haust pipes, the engine, and the oil itself can cause severe burns.
8 "onsistent routine oil and filter changes are
the single most important maintenance
procedure you can perform on a motorcycle.
The oil not only lubricates the internal parts of 6
the engine, transmission and clutch, but it
also acts as a coolant, a cleaner, a sealant,
and a protectant. *ecause of these demands,
the oil takes a terrific amount of abuse and should be changed often with new oil of the recommended grade and type. 1aving a little money on the difference in
cost between a good oil and a cheap oil won't pay off if the engine is damaged. The oil filter should be changed with every second oil change.
A *efore changing the oil, warm up the engine so the oil will drain easily.
@ Put the motorcycle on its sidestand, and position a clean drain tray below the engine. =n 8998 to 899; T05 models remove the seat, and on 7TE models
remove the right#hand side cover .see "hapter >/. +nscrew the oil filler cap from the oil tank to vent it and to act as a reminder that there is no oil in the en&ine
1see Dail) 3pre/ride4 checks4.
6 4irst unscrew the oil drain plug from the crankcase and allow the oil to flow into the drain tray 1see illustrations2. )e%t unscrew the oil drain plug from the oil
filter housing and
Scane! by Stal'er
8.86 $very 6??? miles .C??? km/ or C months
4.Dc EnscreB the oil filter housin& !rain 4.D!
"lu& 1arroBe!2...
allow the oil to flow into the drain tray 1see
illustrations2. "heck the condition of the sealing
washers on the drain plugs and discard them if
they are in any way damaged or worn. =n 899C#
on T05 and T(7 models, :amaha specify using
new ones as a matter of course.
; -hen the oil has completely drained, fit the
plugs to the crankcase and oil filter housing,
using new sealing washers if re,uired, and
tighten them to the tor,ue settings specified at
the beginning of the "hapter. Avoid
overtightening, as damage to the crankcase will
result.
C (efill the oil tank to the proper level using the recommended type and
amount of oil .see *aily (pre-ride) checks and this chapter's specifications/.
-ith the motorcycle vertical, the oil level should lie between the ma%imum
and minimum level lines on the dipstick or inspection window .according to
model/ .see *aily (pre-ride) checks). 'nstall the filler cap. 1tart the engine
and let it run for two or three minutes. 't is advisable to perform an oil
pressure check .see 1ection @A/. 1top the engine, wait a few minutes, then
check the oil level. 'f necessary, add more oil to bring the level up to the
ma%imum level line on the dipstick or window. "heck around the drain plugs
for leaks. RRRRRRRRR.#########R
B The old oil drained from the engine cannot ?>?? CC @@ CC
8 $ach brake pad has wear indicators that can
be viewed without removing the pads from the
caliper.
A =n T05 and T(7 models, the turned#in
corners of the brake pad backing material form
the wear indicators # when they are almost
contacting the disc itself the pads must be
renewed. The indicators are visible by looking at
the bottom corner of the pads 1see illustration2.
Caution: Do not allow the pads to wear to
the e*tent that the indicators contact the
disc itself as the disc will be damaged.
8 =n 7TE models, the indicators are in the form
of grooves in the brake pad friction material #
when the pads are worn so that the grooves are
only just visible the pads must be renewed 1see
illustration2.
D 'f the pads are worn to or beyond the
indicators, they must be renewed. 'f the pads are
dirty or if you are in doubt as to the amount of
friction material remaining, remove them and
measure the amount of friction material .see
"hapter B/. %ote) +ome a!ter-market pads may
use di!!erent indicators to those on the original
eAuipment as shown.
0 (efer to "hapter B for details of pad renewal.
5 *ikes used in the +< and anywhere where salt
is used on the roads are referred to "hapter B,
1ection A, 1tep 9 for details of brake pad and
caliper lubrication to prevent
8 A routine general check of the brake system will
ensure that any problems are discovered and
remedied before the rider's safety is jeopardised.
8.6 /ra'e "a! Bear in!icator 1arroBe!2 ( TD an! TRX mo!els 8.8 /ra'e "a! Bear in!icator &roo,e 1arroBe!2 ( XT3 mo!els
1TRX shoBn2
. an! alloB the oil to !rain
be re#used and should be disposed of properly.
"heck with your local refuse disposal company,
disposal facility or environmental agency to see
whether they will accept the used oil for
recycling. 0on't pour used oil into drains or onto
the ground.
?fl<flf<f<l&l -heck the old oil care!ully - i!
m7ttlSl ft -s ver) metaiiic coloured&
GiT
then the engine is e*periencing wear from
break/in 3new engine4 or from insufficient
lubrication. &f there are flakes or chips of
metal in the oil, then something is
drasticall) wrong internall) and the
engine will have to be disassembled for
inspection and repair. &f there are pieces
of fibre/like material in the oil, the clutch
&s e*periencing e*cessive wear and
should be checked.
!ote: &t is antisocial
and illegal to dump
oil down the drain. +o
find the location of
)our local oil
rec)cling bank, call
this number free.
Scane! by Stal'er
$very 6??? miles .C??? km/ or C months F'1
9.8 FleC the bra'e hoses an! chec' for crac's; bul&es an! lea'in& flui!
9.0a Rear bra'e li&ht sBitch J mo!els
TD
9.0b Rear bra'e li&ht sBitch ( TRX mo!els
6 "heck the brake lever and pedal for loose
connections, improper or rough action, e%cessive
play, bends, and other damage. (enew any
damaged parts .see "hapter B/. "lean and
lubricate the lever and pedal pivots if their action
is stiff or rough .see 1ection 8>/.
8 5ake sure all brake fasteners are tight. "heck
the brake pads for wear .see 1ection >/ and
make sure the fluid level in the reservoirs is
correct .see *aily (pre-ride) checks). Fook for
leaks at the hose and pipe connections and
check for cracks in the hoses and pipes
themselves 1see illustration2. 'f the lever or
pedal is spongy when applied, bleed the brakes
.see "hapter B/.
D 5ake sure the brake light operates when the
front brake lever is pulled in. The front brake light
switch, mounted on the underside of the master
cylinder, is not adjustable. 'f it fails to operate
properly, check it .see "hapter 9/.
0 5ake sure the brake light is activated just
before the rear brake takes effect. 'f adjustment
is necessary, hold the switch and turn the
adjuster ring on the switch body until the brake
light is activated when re,uired 1see
illustrations2. 'f the brake light comes on too
late, turn the ring clockwise. 'f the brake light
comes on too soon or is permanently on, turn the
ring anti#clockwise. 'f the switch doesn't operate
the brake light, check it .see "hapter 9/.
9.0c Rear bra'e li&ht sBitch ( XT3 mo!els
5 =n T05 and T(7 models, the front brake
lever has a span adjuster which alters the
distance of the lever from the handlebar 1see
illustrations2. $ach setting is identified by a
number on the adjuster which aligns with the
arrow on the lever bracket. Pull the lever away
from the handlebar and turn the adjuster ring
until the setting which best suits the rider is
obtained. There are four settings.
4 =n 7TE models, the front brake lever has a
freeplay adjuster which alters the amount of play
in the lever before the brake takes effect. "heck
the amount of freeplay by measuring the distance
the ball end of the
9.5a Front bra'e le,er s"an a!<uster (TD
mo!els
lever travels before the brake comes on and
compare it to the amount specified at the
beginning of the "hapter. To adjust the freeplay,
slacken the adjuster locknut and turn the adjuster
as re,uired until the specified amount of freeplay
is achieved 1see illustration2. Turn the adjuster
clockwise to decrease freeplay and anti#
clockwise to increase it.
Caution: 8ake sure that the correct amount
of freepla) is set. &nsufficient freepla) could
cause the brakes to bind and e*cessive
freepla) ma) not allow them to operate to
their full potential.
9.4 Front bra'e le,er free"lay a!<uster loc'nut 1A2 an! a!<uster 1/2
(
XT3 mo!els
Scane! by Stal'er
2.5b Front bra'e le,er s"an a!<uster ( TRX mo!els
Fie $very 6??? miles .C??? km/ or C months
9.8a Slac'en the loc'nut 1A2 an! turn the
"ushro! usin& the heC 1/2...
8 "heck the position of the brake pedal. :amaha
recommend the distance between the top of the
end of the brake pedal and the top of the rider's
footrest should be as specified at the beginning
of the "hapter. 'f the pedal height is incorrect, or
if the rider's preference is different, slacken the
clevis locknut on the master cylinder pushrod,
then turn the pushrod using a spanner on the he%
at the top of the rod until the pedal is at the
correct or desired height 1see illustration2. After
adjustment check that the pushrod end is visible
in the hole in the clevis .T05 and T(7 models/
1see illustration2 or below the clevis nut .7TE
models/. =n completion tighten the locknut
securely. Adjust the rear brake light switch after
adjusting the pedal height .see 1tep ;/.
9.8b ... ma'in& sure the ro! en! is still
,isible in the hole 1arroBe!2 1TD an! TRX
mo!els2
*0 9lutch #
check and adjustment
* "heck that the clutch cable operates smoothly
and easily.
6 'f the clutch lever operation is heavy or stiff,
remove the cable .see "hapter A/ and lubricate it
.see 1ection 8>/. 'f the cable is still stiff, renew it.
'nstall the lubricated or new cable .see "hapter
A/.
8 -ith the cable operating smoothly, check that
the clutch lever is correctly adjusted. Periodic
adjustment is necessary to compensate for wear
in the clutch plates and stretch of the cable.
"heck that the amount of
freeplay at the clutch lever end is within the
specifications listed at the beginning of the
"hapter 1see illustration2.
D 'f adjustment is re,uired, loosen the adjuster
lockring at the top of the cable and turn the
adjuster in or out until the re,uired amount of
freeplay is obtained 1see illustration2. To
increase freeplay, turn the adjuster clockwise. To
reduce freeplay, turn the adjuster anti#clockwise.
Tighten the locking ring securely.
0 =n T(7, 7TE and 899C#on T05 models, if all
the adjustment has been taken up at the lever,
reset the adjuster to give a large amount of
freeplay, then set the correct amount of freeplay
using the adjuster nuts on each end of the
threaded section in the cable bracket on the right#
hand side of the engine. =n T(7 models, first
remove the adjuster cover 1see iliustration2. To
reduce freeplay, slacken the rear nut and tighten
the front nut until the freeplay is as specified,
then tighten the rear nut 1see illustrations2.
1ubse,uent adjustments can now be made using
the lever adjuster only.
5 =n 8998 to 899; T05 models, if all the
adjustment has been taken up at the lever, set
the correct amount of freeplay using the adjuster
in the cable # the adjuster is positioned a short
way down the cable from the lever 1see
illustration2. 1lacken the locknut and turn the
adjuster as re,uired until the correct amount of
freeplay is obtained.
*0.8 easurin& clutch cable free"lay
*0.D Slac'en the loc'rin& 1A2 an! turn the
a!<uster 1/2 as reAuire!
* T05 and T(7 models are fitted with a sealed
.maintenance#free/ battery, and therefore re,uire
no maintenance. %ote) Do not attempt to remove
the battery caps to check the electrolyte level or
battery speci!ic gravity. /emoval will damage the
caps& resulting in electrolyte leakage and battery
damage. All that should be done is to check that
its terminals are clean and tight and that the
casing is not damaged or leaking. 1ee "hapter 9
for further details.
*0.0a .n TRX mo!els; remo,e the co,er
an! a!<ust the cable as !escribe! usin&
the nuts 1arroBe!2
?
*0.0b 9able a!<uster nuts 1arroBe!2 (mo!els
*0.5 Slac'en the loc'nut 1A2 an! turn the a!<uster 1/2 as reAuire!
Scane! by Stal'er
+)($2'1T$($0 3' +)($2'1T$($0 3'
$very 6??? miles .C??? km/ or C months 8.8B
**.6 9hec' that the electrolyte le,el is betBeen the E##ER an! -.7ER le,el lines 1arroBe!2
*8.6 9hec'in& for "lay in the Bheel bearin&s
6 7TE models are fitted with a standard
battery which re,uires regular checks of the
electrolyte level. (emove the left#hand side
cover for access to the battery .see "hapter
>/. The electrolyte level is visible through the
translucent battery case # it should be
between the +PP$( and F=-$( level marks
1see illustration2. 'f the electrolyte is low,
remove the battery .see "hapter 9/, then
remove the cell caps and fill each cell to the
upper level mark with distilled water. 0o not
use tap water .e%cept in an emergency/, and
do not overfill. The cell holes are ,uite small,
so it may help to use a clean plastic s,uee&e
bottle with a small spout to add the water.
'nstall the battery cell caps, tightening them
securely, then install the battery.
Caution: (e e*tremel) careful when handling
or working around the batter). +he electrol)te
is ver) caustic and an e*plosive gas
3h)drogen4 is given off when the batter) is
charging.
@ 'f the machine is not in regular use,
disconnect the battery and give it a refresher
charge every month to si% weeks .see "hap
ter 9/.
*6 7heels an! tyres #
general check
Cast allo) wheels
8 The cast alloy wheels fitted to T05 and T(7
models are virtually maintenance free, but they
should be kept clean and checked periodically for
cracks and other damage. Also check the wheel
runout and alignment .see "hapter B/. )ever
attempt to repair damaged cast wheels they
must be renewed. "heck the valve rubber for
signs of damage or deterioration and have it
renewed by a motorcycle tyre specialist if
necessary. Also, make sure the valve stem cap is
in place and tight.
Spoked wheels
A =n 7TE models, visually check the spokes for
damage, breakage or corrosion. A broken or bent
spoke must be renewed immediately because
the load taken by it will be transferred to adjacent
spokes which may in turn fail.
@ 'f you suspect that any of the spokes are
incorrectly tensioned, tap each one lightly with a
screwdriver and note the sound produced.
Properly tensioned spokes will make a sharp
pinging sound, loose ones will produce a lower
pitch and overtightened ones will be higher
pitched. A spoke wrench will be needed if any of
the spokes re,uire adjustment. +nevenly
tensioned spokes will promote rim misalignment #
check the wheel runout and alignment .see
"hapter B/ and seek the help of a wheel building
e%pert if this is suspected.
+)res
D "heck the tyre condition and tread depth
thoroughly # see *aily pre-ride) checks.
*8 7heel bearin&s # check
8 -heel bearings will wear over a period of time
and result in handling problems.
A 1upport the motorcycle upright using an
au%iliary stand so that the wheel being checked
is off the ground. "heck for any play in the
bearings by pushing and pulling the wheel
against the hub 1see illustration2. Also rotate the
wheel and check that it rotates smoothly.
@ 'f any play is detected in the hub, or if the
wheel does not rotate smoothly .and this is not
due to brake or transmission drag/, the wheel
must be removed for closer inspection of its
bearings .see "hapter B/.
*D Si!estan! an! cut(off
sBitches # check
Sidestand
8 The sidestand return spring must be capable
of retracting the stand fully and holding the stand
retracted when the motorcycle is in use. 'f the
spring is sagged or broken it must be renewed.
A Fubricate the sidestand pivot regularly .see
1ection 8>/.
Cut/off switches
@ The clutch and sidestand are fitted with
cut#off switches to prevent the bike being
started in gear unless the clutch lever is pulled
in, and to prevent the bike being ridden with
the sidestand down. #j
6 :our bike's owners handbook contains a
checking procedure for the sidestand and
clutch switches. To test, turn the ignition =)
and make sure the engine stop switch .kill
switch/ is in the (+) position. 1it on the bike
and retract the sidestand, then shift the
transmission into gear. Pull in the clutch lever
and press the starter button # the engine
should start, indicating that the clutch switch
is in good order. -ith the engine idling and
the clutch lever still held in, lower the
sidestand # the engine should stop if it
doesn't, the sidestand switch should be
checked out. (efer to "hapter 9 for clutch
switch and sidestand switch tests.
*0 %uts an! bolts #
tightness check
8 1ince vibration of the machine tends to loosen
fasteners, all nuts, bolts, screws, etc. should be
periodically checked for proper tightness.
+)($2'1T$($0 3'
Stane! by Stal'er
+)($2'1T$($0 3'
?
?
?
?
?
s
F
(1'=H =4 P'"T+($#0$1<SJ
8.8> $very 6??? miles .C??? km/ or C months
A Pay particular attention to the followingG
+parkplugs
.ngine oil drain plugs
0earchange lever& brake and clutch lever&
and brake pedal bolts
Footrest and stand bolts
.ngine mounting bolts
+hock absorber and suspension linkage
bolts and swingarm pivot bolts
,andlebar clamp bolts
Front aBle bolt and aBle clamp bolts
Front !ork clamp bolts (top and bottom
yoke)
/ear aBle nut
6rake caliper mounting bolts
6rake hose ban3o bolts and caliper bleed
valves
6rake disc bolts
.Bhaust system bolts/nuts
@ 'f a tor,ue wrench is available, use it along
with the tor,ue specifications at the beginning
of this and other "hapters.
8C "ooling system # check
QQN
iH
'arning: +he engine must be cool
before beginning this procedure. ,
* "heck the coolant level .see *aily (pre-ride)
checks).
6 The entire cooling system should be checked
for evidence of leakage. $%amine
each rubber coolant hose along its entire length.
Fook for cracks, abrasions and other damage.
1,uee&e each hose at various points. They
should feel firm, yet pliable, and return to their
original shape when released. 'f they are dried
out or hard, renew them.
@ "heck for evidence of leaks at each cooling
system joint. Tighten the hose clips carefully to
prevent future leaks.
6 "heck the radiator for leaks and other
damage. Feaks in the radiator leave tell#tale
scale deposits or coolant stains on the outside of
the core below the leak. 'f leaks are noted,
remove the radiator .see "hapter @/ and have it
repaired or renew it.
Caution: Do not use a li.uid leak stopping
compound to tr) to repair leaks.
; "heck the radiator fins for mud, dirt and
insects, which may impede the flow of air through
the radiator. 'f the fins are dirty, remove the
radiator .see "hapter @/ and clean it using water
or low pressure compressed air directed through
the fins from the rear side. 'f the fins are bent or
distorted, straighten them carefully with a
screwdriver. 'f the air flow is restricted by bent or
damaged fins over more than @?I of the
radiator's surface area, renew the radiator.
C To access the radiator pressure cap and filler,
on T05 models, remove the right#hand fairing
side panel, on T(7 models remove the fairing,
and on 7TE models remove the left#hand fairing
side panel .see "hapter >/. =n T(7 models,
remove the security bolt holding the radiator cap
1see illustration2. (emove
the pressure cap from the radiator filler neck by
turning it anti#clockwise until it reaches a stop
1see illustrations2. 'f you hear a hissing sound
.indicating there is still pressure in the system/,
wait until it stops. )ow press down on the cap
and continue turning the cap until it can be
removed. "heck the condition of the coolant in
the system. 'f it is rust#coloured or if
accumulations of scale are visible, drain, flush
and refill the system with new coolant .1ee
1ection AB/. "heck the cap seal for cracks and
other damage, if in doubt about the pressure
cap's condition, have it tested by a :amaha
dealer or renew it. 'nstall the cap by turning it
clockwise until it reaches the first stop then push
down on the cap and continue turning until it can
turn further.
B "heck the antifree&e content of the coolant
with an antifree&e hydrometer. 1ometimes
coolant looks like it's in good condition, but might
be too weak to offer ade,uate protection. 'f the
hydrometer indicates a weak mi%ture, drain, flush
and refill the system .see 1ection A@/.
> 1tart the engine and let it reach normal
operating temperature, then check for leaks
again. As the coolant temperature increases
beyond normal, the fan should come on
automatically and the temperature should begin
to drop. 'f it does not, refer to "hapter @ and
check the fan switch, fan motor and fan circuit
carefully.
9 'f the Tcoolant level is consistently low, and no
evidence of leaks can be found, have the entire
system pressure checked by a :amaha dealer.
8B Throttle and choke cables # QLN
check H
Throttle cables
8 5ake sure the throttle grip rotates easily from
fully closed to fully open with the front wheel
turned at various angles. The grip should return
automatically from fully open to fully closed when
released.
A 'f the throttle sticks, this is probably due to a
cable fault. (emove the cables .see "hapter 6/
and lubricate them .see 1ection 8>/. 'nstall the
cables, making sure they are correctly routed. 'f
this fails to improve the operation of the throttle,
the cables must be renewed. )ote that in very
rare cases the fault could lie in the carburettors
rather than the cables, necessitating the removal
of the carburettors and inspection of the throttle
linkage .see "hapter 6/.
@ -ith the throttle operating smoothly, check for
a small amount of freeplay in the cable assembly,
measured in terms of the amount of twistgrip
rotation before the throttle opens and the pull of
the cable is felt compare this amount to that
*5.5a .n TRX mo!els; remo,e the
"ressure ca" security bolt 1arroBe!2
*5.5c #ressure ca" 1arroBe!2
(XT3 mo!els
*5.5b #ressure ca" 1arroBe!2 (TD
mo!els
*4.8 easure the amount of free"lay at the
throttle &ri" flan&e
listed in this "hapter's 1pecifications 1see illustration2. 'f it's incorrect, adjust the cable assembly to correct it.
=4 P'"T+($#0$1<
Stane! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$
$very 6??? miles .C??? km/ or C months 8.89
6 4reeplay adjustments can be made at the
upper end of the accelerator cable. Foosen the
locknut on the adjuster 1see illustration2. Turn the
adjuster until the specified amount of freeplay is
obtained, then retighten the locknut. Turn the
adjuster clockwise to increase freeplay and anti#
clockwise to reduce it.
; 'f the adjuster has reached its limit of
adjustment, reset it so that the freeplay is at a
ma%imum, then remove the fuel tank and air filter
housing .see "hapter 6/ and adjust the accelerator
cable at the carburettor end. 1lacken the adjuster
locknut, then screw the adjuster in or out until the
specified amount of freeplay is obtained, then
tighten the locknut 1see illustration2. 4urther
adjustments can now be made at the cable's
upper end. 'f the cable cannot be adjusted as
specified, renew the accelerator and decelerator
cables .see "hapter 6/.
'arning: +urn the handlebars all the
wa) through their travel with the engine
idling. &dle speed should not change. &f
&t does, the cable ma) be routed incorrectl).
Correct this condition before riding the bike.
,
C "heck that the throttle twistgrip operates
smoothly and snaps shut ,uickly when
released.
Choke cable
B 'f the choke does not operate smoothly this
is probably due to a cable fault. (emove the
cable .see "hapter 6/ and lubricate it .see
1ection 8>/. 'nstall the cable, routing it so it
takes the smoothest route possible.
> 'f this fails to improve the operation of the
choke, the cable must be renewed. )ote that
in very rare cases the fault could lie in the
carburettors rather than the cable,
necessitating the removal of the carburettors
and inspection of the choke plungers .see
"hapter 6/. 5ake sure there is a small amount
of freeplay in the cable before the plungers
move. 'f there isn't, check that the cable is
seating correctly at the carburettor end. 'f it is,
then slacken the choke outer cable bracket
screw on the carburettor and slide the cable
further into the bracket, creating some
freeplay. =therwise, renew the cable.
*4.D Slac'en the loc'nut 1A2 an! turn the
a!<uster 1/2 as reAuire!
*8 Stan!; lever pivots and
cables # lubrication
2ivot points
* 1ince the controls, cables and various other
components of a motorcycle are e%posed to the
elements, they should be lubricated periodically
to ensure safe and trouble#free operation.
6 The footrests, clutch and brake levers, brake
pedal, gearshift lever linkage and sidestand
pivots should be lubricated fre,uently. 'n order for
the lubricant to be applied where it will do the
most good, the component should be
disassembled. However, if chain and cable
lubricant is being used, it can be applied to the
pivot joint gaps and will usually work its way into
the areas where friction occurs. 'f motor oil or
light grease is being used, apply it sparingly as it
A
# "able
lubricated when
oil drips from far
end
*8.8b -ubricatin& a cable Bith a ma'eshift
funnel an! motor oil
*4.0 Slac'en the loc'nut 1A2 an! turn the
a!<uster 1/2 as reAuire!
may attract dirt .which could cause the controls
to bind or wear at an accelerated rate/. %ote)
(ne o! the best lubricants !or the control lever
pivots is a dry-!ilm lubricant (available !rom many
sources by di!!erent names).
Cables
@ To lubricate the cables, disconnect the relevant
cable at its upper end, then lubricate the cable
with a cable oiler clamp, or if one is not available,
using the set#up shown 1see illustrations2. 1ee
"hapter 6 for the choke and throttle cable
removal procedures and "hapter A for the clutch
cable procedure.
6 The speedometer cable should be removed
.see "hapter 9/ and the inner cable withdrawn
from the outer cable and lubricated with motor oil
or cable lubricant. 0o not lubricate the upper few
inches of the cable as the lubricant may travel up
into the instrument head. )ote that the
speedometer on 8999 T05 models is
electronically operated, and thus does not have a
cable.
89 1wingarm and suspension UVJ
bearings .7TE models/ # H
re#greasing H
8 The swingarm and suspension linkage
components are e,uipped with grease nipples
1see illustration2. "lean off the nipples using a
rag, then apply some lithium#based grease to the
nipples using a grease gun.
*
Scane! by Stal'er
*8.8a -ubricatin& a cable Bith a cable
oiler clam"
?
)ipple
Plastic bag sealed
around outer cable
"able suspended
vertically
*9.* A""ly &rease to the ni""les on the
sus"ension lin'a&e 1arroBe!2 an! to the
ni""le on the sBin&arm "i,ot
8.A? $very 6??? miles .C??? km/ or C months
60.8 9hec' abo,e an! beloB the !ust seal for si&ns of flui! lea'a&e
60.4 9hec'in& for "lay in the rear shoc' mountin&s an! sus"ension lin'a&e bearin&s 1TRX an! XT3 mo!els2
* The suspension components must be
maintained in top operating condition to
ensure rider safety. Foose, worn or damaged
suspension parts decrease the motorcycle's
stability and control.
6ront suspension
A -hile standing alongside the motorcycle,
apply the front brake and push on the handlebars
to compress the forks several times. "heck that
they move up#and#down smoothly without
binding. 'f binding is felt, the forks should be
disassembled and inspected .see "hapter C/.
@ 'nspect the area around the dust seal for signs
of oil leakage, then carefully lever up the dust
seal using a flat#bladed screwdriver and inspect
the area around the fork seal 1see illustration2. 'f
leakage is evident, the seals must be renewed
.see "hapter C/. "heck the fork tubes for
scratches, corrosion and pitting as these will
cause premature seal failure. 'f the damage is
e%cessive the tubes should be renewed .see
"hapter C/.
6 "heck the tightness of all suspension nuts and
bolts to be sure none have worked loose,
referring to the tor,ue settings specified at the
beginning of "hapter C.
"ear suspension
; 'nspect the rear shock for fluid leakage and
tightness of its mountings. 'f leakage is found,
the shock should be renewed or taken to a
suspension specialist for overhaul .see "hapter
C/.
C -ith the aid of an assistant to support the
bike, compress the rear suspension several
times. 't should move up and down freely without
binding. 'f any binding is felt, the worn or faulty
component must be identified and renewed. The
problem could be due to either
the shock absorber, the suspension linkage
components .T(7 and 7TE models/ or the
swingarm components.
B 1upport the motorcycle using an au%iliary
stand so that the rear wheel is off the ground.
2rab the swingarm and rock it from side to side #
there should be no discernible movement at the
rear. 'f there's a little movement or a slight
clicking can be heard, inspect the tightness of all
the rear suspension mounting bolts and nuts,
referring to the tor,ue settings specified at the
beginning of "hapter C, and re#check for
movement. )e%t, grasp the top of the rear wheel
and pull it upwards # there should be no
discernible freeplay before the shock absorber
begins to compress 1see illustration2. Any
freeplay felt in either check indicates worn
bearings in the suspension linkage .T(7 and
7TE models/ or swingarm, or worn shock
absorber mountings. The worn components must
be renewed .see "hapter C/.
> To make an accurate assessment of the
swingarm bearings, remove the rear wheel .see
"hapter B/ and the bolt securing the shock
absorber .T05 models/ or suspension linkage
assembly .T(7 and 7TE models/ to the
swingarm .see "hapter C/. 2rasp the rear of the
swingarm with one hand and place your other
hand at the junction of the swingarm and the
frame. Try to move the rear of the swingarm from
side#to#side. Any wear .play/ in the bearings
should be felt as movement between the
swingarm and the frame at the front. 'f there is
any play the swingarm will be felt to move
forward and backward at the front .not from side#
to#side/. :amaha specify a ma%imum lateral
movement of 8 mm measured at the rear ends of
the swingarm. )e%t, move the swingarm up and
down through its full travel. 't should move freely,
without any binding or rough spots. 'f any play in
the swingarm is noted or if the swingarm does
not move freely, the bearings must be removed
for inspection or renewal .see "hapter C/.
9 =n 7TE models, the swingarm sideplay should
be measured. Push the swingarm to one side of
the frame, then slip a feeler gauge between the
frame and the swingarm cap on the side from
which the swingarm was pushed and measure
the clearance. 'f it is greater than specified,
remove the swingarm .see "hapter C/ and follow
the procedure in 1ection 86 of that "hapter to
calculate the shims re,uired to restore sideplay
to the correct amount.
6* Steerin& hea! bearin&s #
freeplay check and adjustment sJ
8 1teering head bearings can become
dented, rough or loose during normal use of
the machine. 'n e%treme cases, worn or loose
steering head bearings can cause steering
wobble # a condition that is potentially
dangerous.
Check
A 1upport the motorcycle on an au%iliary stand
so that the front wheel is off the ground.
@ Point the front wheel straight#ahead and slowly
move the handlebars from side#to#side. Any
dents or roughness in the bearing races will be
felt and the bars will not move smoothly and
freely.
6 )e%t, grasp the fork sliders and try to pull and
push them forward and backward. Any looseness
in the steering head bearings will be felt as front#
to#rear movement of the forks. 'f play is felt in the
bearings, adjust the steering head as follows.
HA:)$
1
TR4T
6reepla) in the fork due to
worn fork bushes can be
misinterpreted for steering
head bearing pla) / do not
confuse the two.
Scane! by Stal'er
@K
+)($2'1T$($0 3'
$very 6??? miles .C??? km/ or C months 8.A8
6*;5a Slac'en the for' clam" bolts 1arroBe!2...
6*.5b
. an! unscreB the steerin& stem nut
6*.4 Ease the to" yo'e u" off the steerin& stem an! for's
,d-ustment
TD an! TRX mo!els
0 0isplace the handlebars from the top yoke
.see "hapter C/. =n 899C#on T05 models,
unscrew the bolts securing the choke knob and
the cable guide to the top yoke.
5 1lacken the fork clamp bolts in the top yoke
1see illustration2. +nscrew the steering stem nut
and remove it along with its washer, where fitted
1see illustration2.
4 2ently ease the top yoke upwards off the fork
tubes and position it clear, using a rag to protect
the tank or other components 1see illustration2.
5ake sure no strain is placed on the ignition
switch wiring. =n T(7 models the yoke should
be supported so that the master cylinder
reservoir remains upright and so that no strain is
placed on the hydraulic hose.
8 (emove the tabbed lockwasher, noting how it
fits, then unscrew and remove the 'ocknut using
either a "#spanner, a peg spanner or a drift
located in one of the notches 1see illustrations2.
(emove the washer.
9 To adjust the bearings as specified by
:amaha, a special service tool .part )o. 9?>9?#
?86?@/ and a tor,ue wrench are re,uired. 'f the
tool is available, first slacken the adjuster nut,
then tighten it to the initial tor,ue setting
specified at the beginning of the "hapter, making
sure the tor,ue wrench handle is at right angles
.9?W/ to the centreline between the adjuster nut
and the wrench socket in the special tool 1see
illustration2. )ow slacken the nut one turn, then
tighten it to the final tor,ue setting specified.
"heck that the steering is still able to move freely
from side to side, but that all freeplay is
eliminated.
8? 'f the :amaha tool is not available, using
either a "#spanner, a peg spanner or a drift
located in one of the notches, slacken the
adjuster nut slightly until pressure is just
released, then tighten it until all freeplay is
removed, then tighten it a little more. This pre
loads the bearings. )ow slacken the nut, then
tighten it again, setting it so that all freeplay is
just removed yet the steering is able to move
freely from side to side. To do this tighten the nut
only a little at a time, and after each tightening
repeat the checks outlined above .1teps @ and 6/
until the bearings are correctly set. The object is
to set the adjuster nut so that the bearings are
under a very light loading, just enough to remove
any freeplay.
Caution: +ake great care not to appl)
e*cessive pressure because this will cause
premature failure of the bearings. ** -ith the
bearings correctly adjusted, install the washer
and the 'ocknut 1see illustration 66.8b2. =n
8998 to 899; T05 models the tapered side of
the 'ocknut must
6*.8b ... then unscreB the ?oc'nut 1A2;
remo,e the Basher 1/2; an! a!<ust the
bearin&s as !escribe! usin& the a!<uster
nut 192
6*.9 a'e sure the torAue Brench arm is at ri&ht an&les 190L2 to the tool
Stane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
face down. Tighten the 'ocknut finger#tight, then
tighten it further until its notches align with those
in the adjuster nut. 'f necessary, counter#hold the
adjuster nut and tighten the 'ocknut using a "#
spanner or drift until the notches align, but make
sure the adjuster nut does not turn as well. 'nstall
the tabbed lockwasher so that the tabs fit into the
notches in both the 'ocknut and adjuster nut 1see
illustration 66.8a2. *6 4it the top yoke onto the
steering stem 1see illustration 66.42; then install
the washer .where fitted/ and steering stem nut
tighten the nut to the tor,ue setting specified at
the beginning of the "hapter 1see
6*.8a Remo,e the tabbe!
loc'Basher...
1
AA $very 6??? miles .C??? km/ or C
months
illustration2. )ow tighten both the fork clamp
bolts to the specified tor,ue setting 1see
illustration2.
*8 (e#check the bearing adjustment as
described above and re#adjust if necessary.
*D 'nstall the handlebars .see "hapter C/. XT3
mo!els
*0 0isplace the handlebars from the top yoke
.see "hapter C/.
*5 1lacken the fork clamp bolts in the top yoke,
then slacken the steering stem bolt 1see
illustration2. There is no need to remove the top
yoke.
*4 To adjust the bearings as specified by
:amaha, a special service toot .part )o. 9?>9?#
?8AC>/ and a tor,ue wrench are re,uired. 'f the
tool is available, first slacken the adjuster nut
1see illustration 66.*82; then tighten it to the
initial tor,ue setting specified at the beginning of
the "hapter, making sure the tor,ue wrench
handle is at right angles .9?W/ to the line between
the adjuster nut and the wrench socket in the
special tool 1see illustration 66.92. )ow slacken
the nut one turn, then tighten it to the final tor,ue
setting specified. "heck that the steering is still
able to move freely from side to side, but that all
freeplay is eliminated.
*8 'f the :amaha tool is not available, using
either a "#spanner or drift located in one of the
notches, slacken the adjuster nut slightly until
pressure is just released, then tighten it until all
freeplay is removed, then tighten it a little more
1see illustration2. This pre#loads the bearings.
)ow slacken the nut, then tighten it again, setting
it so that all freeplay is just removed yet the
steering is able to move freely from side to side.
To do this tighten the nut only a little at a time,
and after each tightening repeat the checks
outlined above
6*.*5 Slac'en the for' clam" bolts 1A2 an!
the steerin& stem bolt 1/2
.1teps @ and 6/ until the bearings are correctly
set. The object is to set the adjuster nut so that
the bearings are under a very light loading, just
enough to remove any freeplay. Caution: +ake
great care not to appl) e*cessive pressure
because this will cause premature failure of
the bearings. *9 -ith the bearings correctly
adjusted,
an! the for' clam" bolts to the
s"ecifie! torAue
6*.*8 Steerin& hea! bearin& a!<uster nut
1arroBe!2
tighten the steering stem bolt and both the fork
clamp bolts to the tor,ue settings specified at the
beginning of the "hapter 1see illustration
66.*52.
60 (e#check the bearing adjustment as
described above and re#adjust if necessary.
6* 'nstall the handlebars .see "hapter C/.
E,ery 8000 miles 1*6;000 'm2 or *6 months
-arry out all the items under the 5<<< mile (9<<< km) check& plus the !ollowing=
>arning= 6e care!ul when draining the
oil, as the eBhaust pipes, the engine& and
the oil itsel! can cause severe burns. $
* "onsistent routine oil and filter changes are the
single most important maintenance procedure you
can perform on a motorcycle. The oil not only
lubricates the internal parts of the engine,
transmission and clutch, but it also acts as a
coolant, a cleaner, a sealant, and a protectant.
*ecause of these demands, the oil takes a terrific
amount of abuse and should be changed often
with new oil of the recommended grade and type.
1aving a little
money on the difference in cost between a good
oil and a cheap oil won't pay off if the engine is
damaged. The oil filter should be changed with
every second oil change.
A *efore changing the oil, warm up the engine
so the oil will drain easily. =n 8998 to 899; T05
models and 7TE models, remove the engine
bashplate .see "hapter >/.
@Put the motorcycle on its sidestand, and
position a clean drain tray below the engine. =n
8998 to 899; T05 models remove the seat, and
on 7TE models remove the right#hand side cover
.see "hapter >/. +nscrew the oil filler cap from
the oil tank to vent it and to act as a reminder
that there is no oil in the engine .see *aily (pre-
ride) checks).
64irst unscrew the oil drain plug from the
crankcase and allow the oil to flow into the drain
tray 1see illustrations 4.Da an! b2. )e%t
unscrew the oil drain plug from the oil filter
housing and allow the oil to flow into the drain
tray 1see illustrations 4.Dc an! !2. "heck the
condition of the sealing washers on the drain
plugs and discard them if they are in any way
damaged or worn. =n 899C#on T05 and T(7
models, :amaha specify using new ones as a
matter of course.
; -hen the oil has completely drained, fit the
plugs to the sump and oil filter housing, using
new sealing washers if re,uired, and tighten
them to the tor,ue settings specified at the
beginning of the "hapter. Avoid overtightening,
as damage to the crankcase will result.
C -ith the drain tray still under the engine to
catch any residue oil, unscrew the bolts securing
the oil filter cover to the crankcase and remove
the cover along with the filter,
SMane! by Stal'er
6*.*6a Ti&hten the steerin& stem nut.
$very >??? miles .8A,??? km/ or 8A months *.68
66.5a EnscreB the filter co,er bolts 1arroBe!2...
66.5b ... an! remo,e the co,er an! filter
66.4a Fit the neB .(rin&s 1arroBe!2...
66.4b ... then install the filter Bith the
"ro<ection fittin& into the co,er...
noting which way up it fits 1see illustrations2.
0iscard the filter. 0iscard the =#rings as new
ones must be used.
B 4it new =#rings into the cover, making sure
they fit properly in the groove and around the
collar 1see illustrations2. 4it the filter into the
cover with the projection on the filter facing into
the cover 1see illustration2. 4it the cover onto
the sump, then apply a suitable non#permanent
thread locking compound to the bolts and tighten
them to the tor,ue setting specified at the
beginning of the "hapter 1see illustration2.
66.4c ... an! fit the co,er onto the en&ine
8 (efill the oil tank to the proper level using the
recommended type and amount of oil .see *aily
(pre-ride) checks and this -hapter's
+peci!ications). -ith the motorcycle vertical, the
oil level should lie between the ma%imum and
minimum level lines on the dipstick or inspection
window .according to model/ .see *aily (pre-
ride) checks). 'nstall the filler cap. 1tart the
engine and let it run for two or three minutes. 't is
advisable to perform an oil pressure check .see
1ection @A/. 1top the engine, wait a few minutes,
then check the oil level. 'f necessary, add more
oil to bring the
level up to the ma%imum level line on the dipstick
or window. "heck around the drain plugs for
leaks.
9 The old oil drained from the engine cannot be
re#used and should be disposed of properly.
"heck with your local refuse disposal company,
disposal facility or environmental agency to see
whether they will accept the used oil for
recycling. 0on't pour used oil into drains or onto
the ground # see Haynes Hint and +<'s safe oil
disposal contact in 1ection B.
A@ Fuel filter # renewal .8999 fH
T05 models/ JJ
8 The fuel filter should be renewed periodically.
To do so, loosen the hose clamps and slide them
down the hoses, away from the filter. Pry the
hoses off each end of the filter and connect a
new filter in its place 1see illustration *0.*6 in
9ha"ter D2N fuel filters usually have an arrow on
their body indicating the direction of fuel flow.
A "heck that there is no sign of leakage from the
fuel pump. "heck that the fuel pump hose
connections are secure.
E,ery *5;000 miles 16D;000 'm2 or tBo years
-arry out all the items under the ;<<< mile (#2&<<< km) check=
6D SBin&arm an! sus"ension OI.
bearin&s 1TD an! TRX P
mo!els2 # re#greasing 1H
8 =ver a period of time the grease will harden or
dirt will penetrate the bearings due to failed dust
seals. +nlike the 7TE, these models are not
e,uipped with grease nipples
A (emove the swingarm as described in
"hapter C for greasing of the bearings.
@ =n T(7 models, the suspension linkage is
not e,uipped with grease models. (emove the
linkage as described in "hapter C for greasing of
the bearings.
A; Steerin& hea! bearin&s # 1J
lubrication fr
8 =ver a period of time the grease will harden or
may be washed out of the bearings by incorrect
use of jet washes.
A 0isassemble the steering head for re#greasing
of the bearings. (efer to "hapter C for details.
65 /ra'es # fluid change and XH
seal renewal 7
8 The brake fluid should be changed every two
years or whenever a master cylinder or caliper
overhaul is carried out. (efer to the
Siane! by Stal'er
8.A6 $very 8C,??? miles .A6,??? km/ or A years
64.6a EnscreB the Bater "um" !rain "lu& 1arroBe!2...
64.6b ... an! alloB the coolant to !rain
brake bleeding section in "hapter B, noting that
all old fluid must be pumped from the fluid
reservoir and hydraulic line before filling with new
fluid.
$ld brake fluid is invariabl)
much darker in colour than new
fluid, making it eas) to see
when all old fluid has been
e*pelled from the s)stem.
A *rake caliper and master cylinder seals will
deteriorate over a period of time and lose their
effectiveness, leading to sticking operation or
fluid loss, or allowing the ingress of air and dirt.
(efer to "hapter B and dismantle the
components for seal renewal every two years.
64 9oolin& system # draining,
flushing and refilling
'arning: ,llow the engine to cool
completel) before performing this
maintenance operation. ,lso, don1t
allow antifree9e to come into contact with )our
skin or the
,
painted surfaces of the motorc)cle. "inse off
spills immediatel) with plent) of water.
,ntifree9e is highl) to*ic if ingested. !ever
leave antifree9e l)ing around in an open
container or in puddles on the floor5 children
and pets are attracted b) its sweet smell and
ma) drink it. Check with local authorities
3councils4 about disposing of antifree9e.
8an) communities have collection centres
which will see that antifree9e is disposed of
safel). ,ntifree9e is also combustible, so
don1t store it near open flames.
Draining
* =n all models remove the seat, on T05
models the right#hand fairing side panel, on T(7
models the fairing, and on 7TE models the left#
hand fairing side panel .see "hapter >/. =n 8998
to 899; T05 models and 7TE models, remove
the engine bashplate .see "hapter >/. =n T(7
models, remove the security bolt holding the
radiator cap 1see illustration *5.5a2. (emove
the radiator pressure cap by turning it anti#
clockwise until it reaches a stop 1see
illustrations *5.5b an! c2. 'f you hear a hissing
sound .indicating there is still pressure in the
system/, wait until it stops. )ow press down on
the cap and continue turning the cap until it can
be removed.
A Position a suitable container beneath the
water pump. (emove the coolant drain plug from
the water pump and allow the coolant to drain
completely from the system 1see illustrations2.
(etain the old sealing washer for use during
flushing.
@ Position the container beneath the cylinders,
then remove the drain plug from the cylinder
block and allow the coolant to drain completely
from the engine 1see illustrations2. (etain the
old sealing washer for use during flushing.
6 Position the container beneath the coolant
reservoir and remove the filler cap. (elease the
clamp and detach the hose from the bottom of
the reservoir and allow the coolant to completely
drain 1see illustration2. 4it the hose back onto
the reservoir and secure it with the clamp.
6lushing
; 4lush the system with clean tap water by
inserting a garden hose in the radiator filler neck.
Allow the water to run through the system until it
is clear and flows cleanly out of the drain holes. 'f
the radiator is e%tremely corroded, remove it .see
"hapter @/ and have it cleaned professionally.
C "lean the drain holes then install the drain
plugs using the old sealing washers.
64.8a EnscreB the cylin!er !rain "lu& 1arroBe!2...
64.8b ... an! alloB the coolant to !rain
64.D Release the clam" an! !etach the hose 1arroBe!2 ( XT3 shoBn
Scane! by Stal'er
$very 8C,??? miles .A6,??? km/ or A years *.60
4 4ill the cooling system with clean water mi%ed
with a flushing compound. 5ake sure the flushing
compound is compatible with aluminium
components, and follow the manufacturer's
instructions carefully.
8 1tart the engine and allow it to reach normal
operating temperature. Fet it run for about ten
minutes.
9 1top the engine. Fet it cool for a while, then
cover the pressure cap with a heavy rag and turn
it anti#clockwise to the first stop, releasing any
pressure that may be present in the system.
=nce the hissing stops, push down on the cap
and remove it completely.
8? 0rain the system once again.
88 4ill the system with clean water and repeat
the procedure in 1teps B to 9.
/e!illing
*6 4it a new sealing washer to each drain plug
and tighten them to the tor,ue setting specified
at the beginning of the "hapter.
*84ill the system with the proper coolant
mi%ture .see this "hapter's 1pecifications/ 1see
illustration2. %ote) @our the coolant in slowly to
minimise the amount o! air entering the system.
-hen the radiator appears full, pull the bike
upright off its stand and shake it slightly to
dissipate the coolant, then place the bike back on
the stand and top the radiator up.
64.*8 Ese only the s"ecifie! coolant
miCture to fill the system ...
*D -hen the system is full .all the way up to the
top of the radiator filler neck/, install the pressure
cap 1see illustration2. )ow fill the coolant
reservoir to the +PP$( level mark .see *aily
(pre-ride) checks).
*0 1tart the engine and allow it to idle for A to @
minutes. 4lick the throttle twistgrip part open @ or
6 times, so that the engine speed rises to
appro%imately 6??? # ;??? rpm, then stop the
engine. Any air trapped in the system should
have bled back to the radiator filler neck.
*5 Fet the engine cool then remove the
pressure cap as described in 1tep 8. "heck that
the coolant level is still up to the radiator
64.*D ... then fit the "ressure ca"
filler neck. 'f it's low, add the specified mi%ture
until it reaches the top of the filler neck. (efit the
cap, then on T(7 models fit the security bolt.
8B "heck the coolant level in the reservoir and
top up if necessary.
8> "heck the system for leaks.
89 0o not dispose of the old coolant by pouring
it down the drain. 'nstead pour it into a heavy
plastic container, cap it tightly and take it into an
authorised disposal site or garage # see 7arnin&
at the beginning of this 1ection.
A? 'nstall the seat and body panels as re,uired
.see "hapter >/.
E,ery 68;000 miles 1D6;000 'm2
"any out all the items under the 5<<< mile (9<<< km) check& plus the !ollowing
m
A> 3alve clearances # JH
check and adjustment Y
8 The engine must be completely cool for this
maintenance procedure, so let the machine sit
overnight before beginning.
A (emove the fuel tank and the air filter housing
.see "hapter 6/, the radiator .see "hapter @/, the
spark plugs .see 1ection A/, and the valve cover
.see "hapter A/. $ach
cylinder is referred to by a numberG no. 8 cylinder
is the left cylinder and no. A cylinder is the right.
@ 5ake a chart or sketch of all valve positions so
that a note of each clearance can be made
against the relevant valve. There are two e%haust
valves and three inlet valves per cylinder.
6 +nscrew the timing inspection plug and the
centre plug from the alternator cover on the left#
hand side of the engine 1see illustration2.
0iscard the plug =#rings as new ones should
be used. The engine can be turned using a 89 mm
socket on the alternator rotor bolt and turning it in an
anti#clockwise direction only 1see illustration2.
Alternatively, place the motorcycle on an au%iliary
stand so that the H rear wheel is off the ground, select
a high gear and rotate the rear wheel by hand in its
normal direction of rotation.
; Turn the engine until the ''' mark on the rotor
aligns with the static timing mark on the
alternator cover .a notch in the timing inspection
hole/ 1see illustration2; and the
68.Da EnscreB the timin& ins"ection "lu& 1A2 an! the centre "lu& 1/2
68.Db Turn the en&ine usin& a soc'et on the alternator bolt
68.0a Turn the en&ine until the mar' on
the rotor 1A2 ali&ns Bith the static mar' on
the co,er 1/2
Scane! by Stal'er
+)($2'1T$($03$(1'=) =4 P'
.AC $very A>,??? miles .6A,??? km/
68.0b %ote the "osition of the cam lobes 1arroBe!2
>ith the cylinder at T*- on the compression stroke the lobes should
not be depressing the valves and should be !acing away !rom each
other
68.5 a'e sure the cam lobes 1arroBe!2 face aBay from each
other; then chec' the ,al,e clearances as shoBn
camshaft lobes for the )o. 8 .left#hand/ cylinder
are facing away from each other 1see
illustration2. %ote) *o not con!use the B' mark
on the rotor (which indicates T*-) with the ','
mark which will appear !irst and which indicates
the !iring point o! the ignition system. 'f the cam
lobes are facing towards each other, rotate the
engine anti#clockwise @C?W .one full turn/ so that
the T mark again aligns with the static timing
mark. The camshaft lobes will now be facing
away from each other and the )o. 8 cylinder is at
T0" .top dead centre/ on the compression
stroke. C -ith )o. 8 cylinder at T0" on the
compression stroke, check the clearances on
the )o. 8 cylinder inlet and e%haust valves. 'nsert
a feeler gauge of the same thickness as the
correct valve clearance .see 1pecifications/
between the camshaft lobe and follower of each
valve and check that it is a firm sliding fit # you
should feel a slight drag when the you pull the
gauge out 1see illustration2. 'f not, use the feeler
gauges to obtain the e%act clearance. (ecord the
measured clearance on the chart.
B =n 8998 to 899; T05 models and 7TE
models, now turn the engine anti#clockwise @C?W
.one full turn/ so that the ' mark on the timing
plate again once again aligns with the static
timing mark on the crankcase cover, and the
camshaft lobes for the )o. A .right#hand/ cylinder
are facing away from each other. =n 899C#on
T05 models and T(7 models, turn the engine
anti#clockwise AB?W .@D6 turn/ so that the
camshaft lobes for the )o. A .right#hand/ cylinder
are facing away from each other. The )o. A
cylinder is now at T0" on the compression
stroke. 5easure the clearances of the )o. A
cylinder valves using the method described in
1tep C.
> -hen all clearances have been measured and
charted, identify whether the clearance on any
valve falls outside that specified. 'f it does, the
shim between the cam follower and the valve
must be swapped with one of a
thickness which will restore the correct
clearance.
9 1him replacement re,uires removal of the
camshafts .see "hapter A/. There is no need
to remove both camshafts if shims from only
one side of the engine need replacing. Place
rags over the spark plug holes and the cam
chain tunnel to prevent a shim from dropping
into the engine on removal.
*0 -ith the camshaft removed, remove the cam
follower of the valve in ,uestion, then either
retrieve the shim from the inside of the follower or
pick it out of the top of the valve using either a
magnet, a small screwdriver with a dab of grease
on it .the shim will stick to the grease/, or a
screwdriver and a pair of pliers 1see
illustrations2. 0o not allow the shim to fall into
the engine.
** A si&e mark should be stamped on the upper
face oftheshim#ashim marked 8B; is 8.B; mm
thick. 'f the mark is not visible the shim thickness
will have to be measured. 't is recommended that
the shim is measured anyway to check that it has
not worn 1see illustration2.
*6 +sing the appropriate shim selection chart
.either inlet or e%haust/, find where the measured
valve clearance and e%isting shim thickness
values intersect and read off the shim si&e
re,uired 1see illustrations2. %ote) ++
ft
p
\
ft'-"- : -*3m^
"
*
*
c
W '.*r^ri wro^
A
I W^
<#* ^
68.*0b ... an! remo,e the shim either from
insi!e the folloBer ...
68.*0c ... or from the to" of the ,al,e
68.** easure the shim usin& a
micrometer
tone! by Stal'er
+)($2'1T$($03'
68.*0a -ift out the folloBer .
' +)($2'1T$($0 3'
$very A>,??? miles .6A,??? km/ 8.AB
MEASURED
CLEARANCE
INSTALLED SHIM SIZE
12
0
12
5
13
0
13
5
140 1145 15
0
15
5
16
0
16
5
17
0
17
5
18
0
18
5
19
0
19
5
20
0
20
5
21
0
21
5
22
0
22
5
230:235 240
0.00-0.04 12
0
125 130 13
5
14
0
14
5
15
0
15
5
16
0
16
5
17
0
17
5
18
0
18
5
19
0
19
5
20
0
20
5
21
0
2151220 225
0.05-0.09 12 12 130 135 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 220
1225
230
0.10-0.14 12 12 13 135 140 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 2251230 235
0.15-0.20 RECOMMENDED CLEARANCE
0.21-0.25 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.26-0.30 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.31-0.35 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.36-0.40 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.41-0.45 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.46-0.50 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.51-0.55 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.56-0.60 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.61-0.65 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.66-0.70 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.71-0.76 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.76-0.80 18 18 19 19 20 20 21 21 22 22 23 23 24
0.81-0.85 18 19 19 20 20 21 21 22 22 23 23 24
0.86-0.90 19 19 20 20 210
j
21 22 22 23 23 24
0.91-0.95 1951200 20
5
21
0
21
5
22
0
22
5
23
0
23
5
24
0 0.96-1.00 2001205 21 21 22 22 23 23 24
1.01-1.05 2051210 21
5
22
0
22
5
23
0
23
5
24
0 1.06-1.10 2101215 22 22 23 23 24
1.11-1.15 2151220 22 23 23 24
1.16-1.20 2201225 23 23 24
1.21 -1.25 2251230 23 24
1.26-1.30 2301235 24
1.31-1.35 2351240
1.36-1.40 240 i
68.*6a Shim selection chart ( inlet ,al,es
s
MEASURED
CLEARANCE
INSTALLED SHIM SIZE
12
0
125130 13
5
14
0
14
5
15
0
15
5
16
0
16
5
17
0
17
5
18
0
18
5
19
0
19
5
20
0
20
5
21
0
21
5
22
0
22
5
23
0
23
5
24
0 0.00-0.04 12
0
12
5
13
0
13
5
14
0
14
5
15
0
15
5
16
0
16
5
17
0
17
5
18
0
18
5
19
0
19
5
20
0
20
5
21
0
21
5 0.05-0.09 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22
0.10-0.14 12
0
12
5
13
0
13
5
14
0
14
5
15
0
15
5
16
0
16
5
17
0
17
5
18
0
18
5
19
0
19
5
20
0
20
5
21
0
21
5
22
0
22
5 0.15-0.19 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23
0.20-0.24 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23
0.25-0.30 RECOMMENDED CLEARANCE
0.31-0.36 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
: 0.36-0.40 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.41 -0.45 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.46-0.50 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.51-0.55 14 15 15 16 16 17 17 18 !8 19 19 20 20 21 21 22 22 23 23 24
0.56-0.60 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.61-0.65 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.66-0.70 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.71-0.75 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.76-0.80 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24
0.81-0.85 175
j
18 18 19 19 20 20 21 "1 22 22 23 23 24
0.86-0.90 #8
O1
18 19 19 20 20 21 21 22 22 23 23 24
0.91-0.95 18 19 19 20 20 21 21 22 22 23 23 24
0.96-1.00 19 19 20 20 21 21 22 22 23 23 24
1.01-1.05 19 20 20 21 21 22 22 23 23 24
1.06-1.10 20 20 21 21 22 22 23 23 24
1.11-1.15 20 21 21 22 $22
5
23 23 24
1.16-1.20 21 21 22 22 23 23 24
1.21-1.25 21 22 22 23 23 24
1.26-1.30 22 22 23 23 24
1.31-1.35 22 23 23 24
1.36-1.40 23 23 24
1.41-1.45 23 24
1.46-1.50 24
0
68.*6b Shim selection chart ( eChaust ,al,es
Stane! by Stal'er
+)($2'1T$($03'
*.68 $very A>,??? miles .6A,??? km/
68.*8 Fit the folloBer onto the ,al,e
the eBisting shim is marked with a number not
ending in < or 8& round it up or down as
appropriate to the nearest number ending in < or
8 so that the chart can be used. 1hims are
available in ?.?; mm increments from 8.A? mm to
A.6? mm. %ote) )! the reAuired
E,ery four years
68.*0 Ese neB .(rin&s on the "lu&s
replacement shim is greater than 2.5< mm (the
largest available)& the valve is probably not
seating correctly due to a build-up o! carbon
deposits and should be checked and cleaned or
resur!aced as reAuired (see -hapter 2).
*8 =btain the replacement shim, then lubricate
it with molybdenum disulphide oil .a ;?D;?
mi%ture of molybdenum disulphide grease and
engine oil/ and fit it into its recess in the top of
the valve, with the si&e marking on each shim
facing up 1see illustration 68.*0c2. "heck that
the shim is correctly seated, then lubricate the
follower with molybdenum disulphide oil and
install it onto the valve 1see illustration2. (epeat
the process for any other valves until the
clearances are correct, then install the camshafts
.see "hapter A/.
*D (otate the crankshaft several turns to seat
the new shim.s/, then check the clearances
again.
*0 'nstall all disturbed components in a reverse
of the removal se,uence. +se new =#rings on
the timing inspection plug and centre plug and
tighten the plugs securely 1see illustration2.
A (efer to "hapter B and disconnect the brake
hoses from the master cylinders and calipers.
Always renew the banjo union sealing washers.
%on(sche!ule! maintenance
80 Gea!li&ht aim # H
check and adjustment fg
%ote) $n improperly ad3usted headlight may
cause problems !or oncoming tra!!ic or provide
poor& unsa!e illumination o! the road ahead.
6e!ore ad3usting the headlight aim& be sure to
consult with local tra!!ic laws and regulations - !or
CD models re!er to E(T Test -hecks in the
/e!erence section. 8 The headlight beam can
adjusted both
80.6 Qertical a!<uster 1A2; horiRontal
a!<uster 1/2 (*99* to *990 TD mo!els
an! XT3 mo!els
hori&ontally and vertically. *efore making any
adjustment, check that the tyre pressures are
correct and the suspension is adjusted as
re,uired. 5ake any adjustments to the headlight
aim with the machine on level ground, with the
fuel tank half full and with an assistant sitting on
the seat. 'f the bike is usually ridden with a
passenger on the back, have a second assistant
to do this. A =n 8998 to 899; T05 models and
7TE models, vertical adjustment is made by
turning the adjuster screw on the top outer corner
of each headlight unit 1see illustration2. Turn it
clockwise to raise the beam, and anti#
clockwise to lower it.
Hori&ontal adjustment is made by turning the
adjuster screw on the bottom inner corner of
each headlight unit. 4or the left#hand beam, turn
it clockwise to move the beam to the right, and
anti#clockwise to move it to the left. 4or the right#
hand beam, turn it clockwise to move the beam
to the left, and anti#clockwise to move it to the
right.
@ =n 899C#on T05 models, vertical adjustment
is made by turning the adjuster screw on the
bottom outer corner of each headlight unit 1see
illustration2. Turn it anticlockwise to raise the
beam, and clockwise to lower it. Hori&ontal
adjustment is made by turning the adjuster screw
on the top outer
Stane! by Stal'er
* The hoses will in time deteriorate with age H
and should be renewed every four years PH
regardless of their apparent condition.
80.8 Qertical a!<usters 1*2; horiRontal a!<usters 162 ( *995(on TD mo!els
)on#scheduled maintenance 8.A9
80.D Qertical a!<uster 1A2; horiRontal
a!<uster 1/2 ( TRX mo!els
corner of each headlight unit. 4or the left#hand
beam, turn it clockwise to move the beam to the
left, and anti#clockwise to move it to the right. 4or
the right#hand beam, turn it clockwise to move
the beam to the right, and anti#clockwise to move
it to the left. 6 =n T(7 models, vertical
adjustment is made by turning the adjuster screw
on the bottom left corner of the headlight unit
1see illustration2. Turn it clockwise to raise the
beam, and anti #clockwise to lower it. Hori&ontal
adjustment is made by turning the adjuster screw
on the top right corner of the headlight unit. Turn
it clockwise to move the beam to the left, and
anti#clockwise to move it to the right.
@8 "ylinder compression
#check
8 Among other things, poor engine performance
may be caused by leaking valves, incorrect
valve clearances, a leaking head gasket, or
worn pistons, rings andDor cylinder walls. A
cylinder compression check will help pinpoint
these conditions and can also indicate the
presence of e%cessive carbon deposits in the
cylinder heads.
6 The only tools re,uired are a compression
gauge and a spark plug wrench. A compression
gauge with a threaded end for the spark plug 8A
mm diameter hole is preferable to the type which
re,uires hand pressure to maintain a tight seal.
0epending on the outcome of the initial test, a
s,uirt#type oil can may also be needed.
8 5ake sure the valve clearances are correctly
set .see 1ection A>/ and that the cylinder head
fasteners are tightened to the correct tor,ue
setting .see "hapter A/.
D Refer to 6ault 6inding .uipment in the
(eference section for details of the compression
test. (efer to the specifications at the beginning
of the "hapter for compression figures.
@A $ngine # oil pressure check
* )one of the models covered in this manual are
fitted with an oil pressure warning light. 'f a
lubrication problem is suspected, first check the
oil le,el 1see Dail) 3pre/ride4 checks4
6 'f the oil level is correct, an oil pressure check
must be carried out.
8 To check the oil pressure, slacken the oil
gallery bolt in the left#hand side of the cylinder
head # there is no need to remove it 1see
illustration2.
D 1tart the engine and allow it to idle. After a
short while oil should begin to seep out from the
oil gallery plug 1see illustration2. 'f no oil has
appeared after one minute, stop the engine
immediately.
0 'f the oil does not appear after one minute,
either the pressure regulator is stuck open, the
oil pump is faulty, the oil strainer or filter is
blocked, or there is other engine damage. *egin
diagnosis by checking the oil filter .1ection AA of
this "hapter/, strainer and regulator, then the oil
pump .see "hapter A/. 'f those items check out
okay, chances are the
bearing oil clearances are e%cessive and the
engine needs to be overhauled.
C'f the oil appears very ,uickly and spurts out,
the pressure may be too high, meaning either an
oil passage is clogged, the regulator is stuck
closed or the wrong grade of oil is being used.
B(efer to "hapter A and rectify any problems
before running the engine again.
>Tighten the oil gallery bolt to the tor,ue setting
specified at the beginning of the "hapter.
'arning: 2etrol 3gasoline4 is
e*tremel) flammable, so take e*tra
precautions when )ou work on an)
part of the fuel s)stem. Don1t smoke or
allow open flames or bare light bulbs near the
work area, and don1t work in a garage where a
natural gas/t)pe appliance is present. &f )ou
spill an) fuel on )our skin, rinse it off
immediatel) with soap and water. 'hen )ou
perform an) kind of work on the fuel s)stem,
wear safet) glasses and have a fire
e*tinguisher suitable for a Class ( t)pe fire
3flammable li.uids4 on hand.
,
8 The fuel delivery and vacuum hoses should be
renewed after a few years regardless of their
condition.
A (emove the fuel tank .see "hapter 6/.
0isconnect the fuel hoses from the fuel tap, fuel
pump and from the carburettors, noting the
routing of each hose and where it connects .see
"hapter 6 if re,uired/. 't is advisable to make a
sketch of the various hoses before removing them
to ensure they are correctly installed.
@ 1ecure each new hose to its unions using new
clamps. (un the engine and check that there are
no fuel leaks before taking the machine out on the
road.
86.8 Slac'en the &allery bolt 1arroBe!2...
t
=
=
86.D ... then start the en&ine an! chec' that the oil !ribbles out Bithin a minute
Scane! by Stal'er
i.@o )on#scheduled maintenance
8D Front for's ( oil chan&e
+D8, +":and ;<<= :+> models
8 4ork oil degrades over a period of time and
loses its damping ,ualities. The forks do not have
drain screws so it is necessary to remove them
from the fork yokes .see "hapter C, 1ection C/
and remove their top bolts, spacer and spring
assembly so that they can be turned upside
down and pumped to e%pel the fork oil.
A =nce the forks have been removed from the
yokes, refer to the appropriate part of 1ection B,
"hapter C, to unscrew the fork top bolt and
withdraw the spacer and spring assembly. )ote
that there is no need to slacken the damper rod
bolt as advised in the early part of this procedure
because this relates to fork overhaul. Turn the
fork upside down and pump the inner tube and
slider to e%pel as much oil as possible.
@ (efill each fork with the specified amount and
type of fork oil .see "hapter C 1pecifications/ and
install the fork spring, spacer and top bolt. Take
careful note of how the oil level is measured and
the importance of the level being identical in
each fork. (efer to the final part of the relevant
reassembly procedure in "hapter C, 1ection B for
details.
;<?< to ;<<@ :+> models
6 4ork oil degrades over a period of time and
loses its damping ,ualities. These models are
e,uipped with drain screws in the fork sliders
1see illustration 4.09 in 9ha"ter 52 and
therefore changing the fork oil is a relatively
straightforward task.
; Position the bike on an au%iliary stand and
support it under the engine so that the front
wheel is off the ground. +nscrew the fork top bolt
from the top of each fork tube.
'arning: +he fork spring is
pressing on the fork top bolt 3via the
spacer4 with considerable pressure.
7nscrew the bolt ver) carefull), keeping a
downward pressure on it and release it slowl)
as it is likel) to spring clear. &t is advisable to
wear some form of e)e and face protection
when carr)ing out this operation.
,
C Hold a piece of thick card to act as a chute
beneath the fork drain screw on one fork slider,
then remove the drain screw and allow the oil to
drain. Pump the fork to e%pel all of the oil. )ow do
the same on the other fork leg.
B 1lide the fork tube down into the slider and
withdraw the spacer, spring seat and the spring
from the tube. )ote which way up the spring is
fitted.
> "heck the condition of the sealing washers on
the drain screws and screw them back into the
fork sliders.
9 1lowly pour in the specified ,uantity of the
specified grade of fork oil .see "hapter C
1pecifications/ and pump the fork at least ten
times to distribute it evenly the oil level should
also be measured and adjustment made by
adding or subtracting oil. 4ully compress the fork
tube into the slider and measure the fork oil level
from the top of the tube 1see illustration 4.65b in
9ha"ter 52. Add or subtract fork oil until it is at the
level specified at the beginning of the "hapter.
)ote that bike must be upright when the oil level
is measured and the oil level must be the same in
each fork.
8? $%tend the fork tube and slider fully, then
install the spring, the spring seat, with its
shouldered side fitting down into the top of the
spring, and the spacer.
88 Apply a smear of grease to the top bolt =#
ring and thread the bolt into the top of the fork
tube.
'arning: &t will be necessar) to
compress the spring b) pressing it
down using the top bolt to engage the
threads of the top bolt with the fork tube. +his
is a potentiall) dangerous operation and
should be performed with care, using an
assistant &f necessar). 'ipe off an) e*cess oil
before starting to prevent the possibilit) of
slipping.
,
<eep the fork tube fully e%tended whilst pressing
on the spring. 1crew the top bolt carefully into the
fork tube making sure it is not cross#threaded and
tighten it to the specified tor,ue setting .see
"hapter C 1pecifications/.
Stane! by Stal'er
?
2*1
9ha"ter 6
$ngine, clutch and transmission
9ontents
Alternator rotor and stator # removal and installation .. .see "hapter 9
*alancer shafts # removal, inspection and installation..............................A@
"am chain and guides # removal, inspection and installation .................A6
"am chain tensioner# removal, inspection and installation....................... 9
"amshafts and followers # removal, inspection and installation ... >
"lutch cable # removal and installation .................................................8B
"lutch # check........................................................................ see "hapter 8
"lutch # removal, inspection and installation............................................8C
"onnecting rods # removal, inspection and installation............................A>
"rankcase halves # inspection and servicing...........................................AC
"rankcase halves # separation and reassembly......................................A;
"rankshaft and main bearings # removal, inspection
and installation ................................................................................. A9
"ylinder block # removal, inspection and installation................................8@
"ylinder head # removal and installation ...............................................8?
"ylinder head and valves # disassembly, inspection
and reassembly................................................................................... 8A
$ngine # compression check.................................................. see "hapter 8
$ngine # removal and installation ............................................................ ;
$ngine disassembly and reassembly # general information..................... C
2earchange mechanism e%ternal components #
removal, inspection and installation ................................................... 89
2eneral information................................................................................. 8
'dle speed # check and adjustment........................................see "hapter 8
'nitial start#up after overhaul.................................................................... @@
5ain and connecting rod bearings # general note....................................AB
5ajor engine repair # general note ......................................................... 6
)eutral switch # check, removal and installation....................see "hapter 9
=il and filter # change .........................................................see "hapter 8
=il level # check................................................see *aily (pre-ride) checks
=il pressure # check ........................................................... see "hapter 8
=il pumps # removal, inspection and installation......................................A?
=il sump, oil strainer and pressure relief valve #
removal, inspection and installation ................................................... AA
=il tank # removal and installation .899C#on T05 and T(7 models/ . A8
=perations possible with the engine in the frame.................................... A
=perations re,uiring engine removal .................................................... @
Pistons # removal, inspection and installation .......................................86
Piston rings # inspection and installation ................................................8;
Pick#up coil assembly # removal and installation......................................
see "hapter ;
(ecommended running#in procedure...................................................... @6
1elector drum and forks # removal, inspection and installation .... @A
1park plug gap # check and adjustment.................................see "hapter 8
1tarter clutch and idleDreduction gear # removal,
inspection and installation................................................................... 8>
1tarter motor # removal and installation ...............................see "hapter 9
Transmission shafts and bearings # removal and installation...................@?
Transmission shafts # disassembly, inspection and reassembly ... @8
3alve clearances # check and adjustment..............................see "hapter 8
3alve cover # removal and installation .................................................... B
3alvesDvalve seatsDvalve guides # servicing.............................................88
De&rees of !ifficulty
Easy; suitable for Pk
novice with little isZ
'n
e%perience H
Fairly easy; suitable Pk for
beginner with QH some
e%perience !<S
Fairly !ifficult;
suitable for competent H
0': mechanic =S
Difficult; suitable for H,
e%perienced 0': H
mechanic
Qery !ifficult;
suitable for e%pert 0': N1P
or professional ;1
S"ecifications
2eneral
Type.............................................................................................................. 4our#stroke parallel twin
"apacity
T05 and T(7 models............................................................................... >69 cc
7TE models............................................................................................... B69 cc
*ore
T05 and T(7 models............................................................................... >9.; mm
7TE models............................................................................................... >B.? mm
1troke
T05 and T(7 models............................................................................... CB.; mm
7TE models............................................................................................... C@ mm
"ompression ratio
*99* to 899; T05 models........................................................................ 9.A to 8
899C#on T05 models and T(7 models ................................................... *0.0 to 8
7TE models............................................................................................... 9.; to 8
"ylinder numbering .................................................................................... )o. 8 .left#hand/, )o. A .right#hand/
"ooling system............................................................................................. Fi,uid cooled
"lutch .......................................................................................................... -et multi#plate
Transmission................................................................................................. 4ive#speed constant mesh
4inal drive .................................................................................................... "hain
6
Sta&e! by Stal'er
.H
|5
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< J
A[A $ngine, clutch and transmission
9amshafts
'nlet lobe height 8998 to 899; T05 models and
7TE models
1tandard............................................................................................... @;.B to @;.> mm
1ervice limit .min/ ................................................................................ @;.C mm
899C#on T05 models and T(7 models
1tandard .............................................................................................. @;.9; to @C.?; mm
1ervice limit .min/ ............................................................................... @;.>; mm
$%haust lobe height # all models
1tandard................................................................................................... @;.9; to @C.?; mm
1ervice limit .min/ .................................................................................... @;.>; mm
Pournal diameter........................................................................................... A6.9CB to A6.9>? mm
Pournal holder diameter ................................................................................ A;.??? to A;.?A8 mm
Pournal oil clearance..................................................................................... ?.?A? to ?.?;6 mm
(unout .ma%/ ............................................................................................. ?.?@ mm
9ylin!er hea!
-arpage .ma%/ ............................................................................................. ?.?@ mm
Qal,es; &ui!es an! s"rin&s
3alve clearances........................................................................................... see "hapter 8
'nlet valve 1tem
diameter
1tandard .............................................................................................. ;.6B; to ;.69? mm
1ervice limit .min/ ............................................................................... ;.66; mm
2uide bore diameter
1tandard .............................................................................................. ;.;?? to ;.;8A mm
1ervice limit .ma%/................................................................................ ;.;; mm
1tem#to#guide clearance
1tandard .............................................................................................. ?.?8? to ?.?@B mm
1ervice limit .ma%/................................................................................. ?.?> mm
Head diameter ....................................................................................... A;.9 to AC.8 mm
4ace width ............................................................................................. A.?C to A.6C mm
1eat width................................................................................................. ?.9 to 8.8 mm
5argin thickness....................................................................................... ?.> to 8.A mm
$%haust valve 1tem
diameter
1tandard .............................................................................................. ;.6C? to ;.6B; mm
1ervice limit .min/ ............................................................................... ;.6@ mm
2uide bore diameter
1tandard............................................................................................... ;.;?? to ;.;8A mm
1ervice limit .ma%/................................................................................ ;.;; mm
1tem#to#guide clearance
1tandard .............................................................................................. ?.?A; to ?.?;A mm
1ervice limit .ma%/................................................................................. ?.8? mm
Head diameter ........................................................................................ AB.9 to A>.8 mm
4ace width ............................................................................................. A.?C to A.6C mm
1eat width................................................................................................. ?.9 to 8.8 mm
5argin thickness....................................................................................... ?.> to 8.A mm
3alve stem runout .ma%/............................................................................... ?.?8 mm
3alve springs free length .inlet and e%haust/
1tandard................................................................................................... @B.A9 mm
1ervice limit .min/ ................................................................................... @;.A mm
3alve spring bend .ma%/................................................................................ 8.B mm
9ylin!er bloc'
*ore T05 and T(7
models
1tandard .............................................................................................. >9.;?? to >9.;?; mm
1ervice limit .ma%/................................................................................ >9.C mm
7TE models
1tandard .............................................................................................. >B.??? to >B.??; mm
1ervice limit .ma%/................................................................................ >B.8 mm
-arpage .ma%/ ............................................................................................ ?.?@ mm
=vality .out#of#round/ .ma%/ ......................................................................... ?.?@ mm
Taper .ma%/................................................................................................... ?.?; mm
"ylinder compression.................................................................................... see "hapter 8
u.*i.ls,e,i0,i,s \\ Pl\ui,i,,is< .RRRRScane! by Stal'er
############################################################8 '')(4('1T4(40 34(1'''H fl4 PirT''(4#n4"
$ngine, clutch and transmission AL@
Pistons
Piston diameter .measured 6.; mm .T05 and T(7 models/ or 6.B
mm .7TE models/ up from skirt, at 9?W to piston pin a%is/
T05 and T(7 models............................................................................... >9.6A? to >9.6@; mm
7TE models............................................................................................... >C.9A? to >C.9@; mm
Stan!ar! Ser,ice -imit
Piston#to#bore clearance ............................................................................. ?.?C; to ?.?>; mm ?.8; mm
Piston pin diameter....................................................................................... 89.998 to A?.??? mm 89.9B; mm
Piston pin bore diameter in piston ................................................................ A?.??A to A?.?8@ mm A?.?6@ mm .ma%/
Piston pin#to#piston pin bore clearance......................................................... ?.??A to ?.?AA mm ?.?B mm
Piston rings
Top ring T05 and T(7
models
(ing width............................................................................................. @.; mm
(ing thickness....................................................................................... 8.? mm
(ing end gap .installed/
1tandard .......................................................................................... ?.@? to ?.6; mm
1ervice limit .ma%/............................................................................. ?.B? mm
Piston ring#to#groove clearance
1tandard .......................................................................................... ?.?@; to ?.?B? mm
1ervice limit .ma%/............................................................................. ?.8A mm
7TE models
(ing width............................................................................................. @.@ mm
(ing thickness....................................................................................... 8.? mm
(ing end gap .installed/
1tandard ........................................................................................... ?.@? to ?.;? mm
1ervice limit .ma%/............................................................................. ?.B? mm
Piston ring#to#groove clearance
1tandard ......................................................................................... ?.?@ to ?.?B mm
1ervice limit .ma%/............................................................................. ?.8A mm
A
nd
.middle/ ring 8998 to 899;
T05 models
(ing width............................................................................................. @.; mm
(ing thickness....................................................................................... 8.? mm
(ing end gap .installed/
1tandard ......................................................................................... ?.@? to ?.6; mm
1ervice limit .ma%/............................................................................. ?.B? mm
Piston ring#to#groove clearance
1tandard .......................................................................................... ?.?A to ?.?;; mm
1ervice limit .ma%/............................................................................. ?.8A mm
899C#on T05 models and T(7 models
(ing width............................................................................................. @.; mm
(ing thickness....................................................................................... 8.? mm
(ing end gap .installed/
1tandard .......................................................................................... ?.@? to ?.6; mm
1ervice limit .ma%/............................................................................. ?.B? mm
Piston ring#to#groove clearance
1tandard ........................................................................................... ?.?@; to ?.?B? mm
1ervice limit .ma%/............................................................................. ?.8A mm
7TE models
(ing width............................................................................................. @.@ mm
(ing thickness....................................................................................... 8.? mm
(ing end gap .installed/
1tandard .......................................................................................... ?.@? to ?.;? mm
1ervice limit .ma%/............................................................................. ?.B? mm
Piston ring#to#groove clearance
1tandard ......................................................................................... ?.?A to ?.?C mm
1ervice limit .ma%/............................................................................. ?.8A mm
=il ring T05 and T(7
models
(ing width............................................................................................. A.>; mm
(ing thickness....................................................................................... A.? mm
1ide#rail end gap .installed/................................................................... ?.A? to ?.B? mm
7TE models
(ing width............................................................................................. A.>? mm
(ing thickness....................................................................................... A.? mm
1ide#rail end gap .installed/................................................................... ?.A? to ?.B? mm
A[6 $ngine, clutch and transmission
9lutch
4riction plate thickness # all models
1tandard................................................................................................... A.9 to @.8 mm
1ervice limit .min/ ..................................................................................... A.> mm
Plain plates
8998 to 899; T05 models and all 7TE models
Thickness .special 'slick' plate/.............................................................. A.A to A.6 mm
Thickness .all other plates/ .................................................................. 8.9 to A.8 mm
-arpage .ma%/ .................................................................................... ?.8 mm
899C#on T05 models and all T(7 models
Thickness ............................................................................................ 8.9 to A.8 mm
-arpage .ma%/ ................................................................................... ?.8 mm
"lutch springs 1pring
free length
8998 to 899> T05 and all T(7 models
1tandard ......................................................................................... ;; mm
1ervice limit .min/ ........................................................................... ;@ mm
8999 T05 models
1tandard .......................................................................................... ;? mm
1ervice limit .min/ ............................................................................ 6> mm
7TE models
1tandard .......................................................................................... ;8.> mm
1ervice limit .min/ ........................................................................... ;? mm
.il "um"
'nner rotor tip#to#outer rotor clearance
1tandard................................................................................................... ?.? to ?.8A mm
1ervice limit .ma%/..................................................................................... ?.8B mm
=uter rotor#to#body clearance
1tandard................................................................................................... ?.?@ to ?.?> mm
1ervice limit .ma%/.................................................................................... ?.8; mm
(otor end#float.............................................................................................. ?.?@ to ?.?> mm
9onnectin& ro!s
*ig#end side clearance
1tandard................................................................................................... ?.8C? to ?.ABA mm
1ervice limit .ma%/..................................................................................... ?.; mm
*ig#end oil clearance
1tandard................................................................................................... ?.?AC to ?.?;? mm
1ervice limit .ma%/..................................................................................... ?.?9 mm
9ran'shaft an! bearin&s
5ain bearing oil clearance
1tandard................................................................................................... ?.?A? to ?.?@> mm
1ervice limit .ma%/..................................................................................... ?.8 mm
(unout .ma%/
8998 to 899; T05 models and all 7TE models........................................ ?.?A mm
899C#on T05 models and all T(7 models................................................ ?.?@; mm
Transmission
2ear ratios .no. of teeth/
8998 to 899; T05 models
Primary reduction ................................................................................ 8.B8> to 8 .CBD@9T/
4inal reduction ................................................................................... A.B;? to 8 .66D8CT/
8st gear................................................................................................. A.>6C to 8 .@BD8@T/
And gear .............................................................................................. 8.>;? to 8 .@BDA?T/
@rd gear................................................................................................ 8.@8> to 8 .A9DAAT/
6th gear................................................................................................. 8.?B6 to 8 .A9DABT/
;th gear................................................................................................. ?.9?? to 8 .ABD@?T/
899C to 899> T05 models
Primary reduction ................................................................................. 8.B8>to 8 .CBD@9T/
4inal reduction ................................................................................... A.6B8 to 8 .6AD8BT/
8st gear................................................................................................. A.>6C to 8 .@BD8@T/
And gear .............................................................................................. 8.>;? to 8 .@BDA?T/
@rd gear................................................................................................ 8.D69 to 8 .@?DA8T/
6th gear................................................................................................. 8.8B6 to 8 .ABDA@T/
;th gear................................................................................................. 8.?@B to 8 .A>DABT/
Siane! by Stal'er
$ngine, clutch and transmission AL;
8999 T05 models
Primary reduction ................................................................................. 8.B8> to 8
4inal reduction .................................................................................... A.C>> to 8
8st gear................................................................................................. A.C6@ to 8
And gear .............................................................................................. 8.96B to 8
@rd gear................................................................................................ 8.;?? to 8
6th gear................................................................................................. 8.8B6 to 8
;th &ear................................................................................................ ?.9C6 to 8
T(7 models
Primary reduction ................................................................................. 8.B8> to 8
4inal reduction ................................................................................... A.A96 to 8
8st gear................................................................................................. A.;B8 to 8
6n! gear .............................................................................................. 8.>;? to 8
@rd gear................................................................................................ 8.6A9 to 8
6th gear................................................................................................. 8.8B6 to 8
;th gear................................................................................................. 8.?@B to 8
7TE models
Primary reduction ................................................................................. 8.B8> to 8
4inal reduction .................................................................................... A.>B; to 8
8st gear................................................................................................. A.>6C to 8
And gear ............................................................................................... 8.>;? to 8
@rd gear................................................................................................. 8.6A9 to 8
6th gear................................................................................................. 8.8B6 to 8
;th gear................................................................................................. 8.?@B to 8
1haft runout .ma%/ ...................................................................................... ?.?> mm
1elector fork shaft runout .ma%/.................................................................... ?.?@ mm
Torque settings
$ngine mounting bolts T05
models
1mall triangular engine bracket bolts to engine..................................... @? )m
$ngine bracket bolts to underside of engine at back............................. @? )m
Fower rear mounting bolt ...................................................................... C6 )m
+pper rear mounting bolt nut ................................................................ >9 )m
$ngine bracket to engine bolts.............................................................. C? )m
$ngine bracket to frame bolts................................................................ @? )m
T(7 models
Fower rear mounting bolt nut ................................................................ B; )m
+pper rear mounting bolt nut ................................................................ B; )m
+pper front mounting bolts.................................................................... ;; )m
$ngine bracket to engine bolts .left#hand side/ .................................... @? )m
$ngine bracket to frame bolt .left#hand side/......................................... ;; )m
$ngine bracket to engine bolt .with collar/ .right#hand side/.................. ;; )m
$ngine bracket to frame bolts .right#hand side/..................................... @? )m
7TE models
1wingarm pivot bolt nut ....................................................................... 9? )m
Fower rear mounting bolt nut ................................................................ ;> )m
+pper rear mounting bolt nut ................................................................ ;> )m
4rame downtube boltsDnuts .................................................................. @A )m
Fower front mounting bolt nut ............................................................. ;> )m
3alve cover bolts ........................................................................................ 8? )m
"amshaft holder bolts ................................................................................. 8? )m
"amshaft sprocket bolts .............................................................................. A6 )m
"am chain tensioner mounting bolts ............................................................ 8? )m
"am chain tensioner cap bolt........................................................................ A? )m
"ylinder head nuts ....................................................................................... 6? )m
"ylinder head bolts....................................................................................... 8?)m
=il pipe banjo bolt to cylinder head ............................................................. A8 )m
"oolant hose union bolts .cylinder block/ ................................................... 8? )m
"lutch nut..................................................................................................... B? )m
"lutch spring bolts........................................................................................ > )m
"lutch cover bolts......................................................................................... 8? )m
1tarter clutch bolts........................................................................................ 8? )m
1elector drum retainer plate bolts ............................................................... 8A)m
1topper arm bolt
8998 to 899; T05 models and 7TE models ........................................... 8A )m
899C#on T05 models and T(7 models.................................................... 8? )m
2earchange linkage arm pinch bolt .............................................................. 8A )m
;
67/39T)
;
43/16T)
'37/14T)
'37/19T)
30/20T)
27/23T)
;27/28T)
CBD@9T/
@9D8BT/
@CD86T/
@BDA?T/
@?DA8T/
.ABDA@T/
GA>DABT/
67/39T)
'46/16T)
37/13T)
37/20T)
30/21T)
27/23T)
28/27T)
ALC $ngine, clutch and transmission
Tor,ue settings .continued/
=uter sprocket cover bolts............................................................................ ; )m
=il pump mounting screws............................................................................ C )m
=il pump assembly screw .......................................................................... C )m
=il pump cover bolts .................................................................................. 8?)m
=il pipe to oil pump cover bolts..................................................................... 8? )m
=il pipe banjo bolts to crankcase coverDoil tank and cylinder head .... A8 )m
=il pipe to oil tank bolts ................................................................................ 8? )m
=il pressure relief valve holder bolt ............................................................. 8?)m
=il strainer cover screws ............................................................................ B )m
=il sump bolts............................................................................................... 8? )m
=il hose union to crankcase bolts ............................................................... 8? )m
*alancer shaft holder bolts............................................................................ 8? )m
*alancer shaft retainer plate Tor% bolt........................................................... 8A )m
=il strainer holder bolts .............................................................................. 8? )m
"rankcase top cover bolts .8998 to 899; T05 models and
all 7TE models/......................................................................................... 8? )m
"rankcase C mm bolts ................................................................................. 8A )m
"rankcase > mm bolts ................................................................................. A6 )m
"rankcase 8? mm bolts ............................................................................... 6? )m
"onnecting rod cap nuts
'nitial setting
8998 to 899; T05 models and all 7TE models.................................... 6C )m
899C#on T05 models and all T(7 models............................................ @; )m
4inal setting .all models/........................................................................... 6> )m
Transmission output shaft retainer plate bolts ]left#hand side/ ..................... 8? )m
Transmission input shaft bearing retainer Tor% screws.................................. 8A )m
=il gallery bolt............................................................................................... 8? )m
8 2eneral information
the crankshaft. The transmission is a five#speed
constant#mesh unit. 4inal drive to the rear wheel
is by chain and sprockets.
=perations re,uiring engine
removal
The engineDtransmission unit is a li,uid#cooled
parallel twin with five valves per cylinder .three
inlet and two e%haust/. The valves are operated
by double overhead camshafts which are chain
driven off the crankshaft. The
engineDtransmission assembly is constructed
from aluminium alloy. The crankcase is divided
hori&ontally.
The crankcase incorporates a dry sump,
pressure#fed lubrication system which uses two
gear#driven oil pumps, one a feed pump to
lubricate the engine, the other a scavenge pump
to return oil to the tank, both driven off the
crankshaft. The sump houses the oil filter, by#
pass valve assembly and relief valve. The oil
tank is mounted behind the engine on 8998 to
899; T05 models and all 7TE models, and on
the engine behind the cylinders on later T05
models and all T(7 models. The oil pumps are
gear driven off the crankshaft.
The crankshaft also drives two balancer shafts
which eliminate the vibration inherent in parallel
twin engines
The alternator and starter clutch are on the
left#hand end of the crankshaft.
Power from the crankshaft is routed to the
transmission via the clutch. The clutch is of the
wet, multi#plate type and is gear#driven off
A =perations possible with the
engine in the frame
The components and assemblies listed below
can be removed without having to remove the
engineDtransmission assembly from the frame. 'f
however, a number of areas re,uire attention at
the same time, removal of the engine is
recommended.
1alve cover
-amsha!ts
-ylinder head
-ylinder block& pistons and piston rings
@ick-up coil assembly
-lutch
0earchange mechanism (eBternal
components)
$lternator
+tarter clutch
(il !ilter
(il pumps& oil strainer& oil pressure relie! valve
and by-pass valve
+tarter motor
>ater pump
6alancer sha!ts (#77# to #778 T*E and all
FTG models)
-am chain
't is necessary to remove the
engineDtransmission assembly from the frame to
gain access to the following components.
Transmission sha!ts
+elector drum and !orks
-onnecting rods and bearings
-ranksha!t and bearings
6alancer sha!ts (#779-on T*E models and all
T/F models)
6 5ajor engine repair #
general note
8 't is not always easy to determine when or if
an engine should be completely overhauled, as a
number of factors must be considered.
A High mileage is not necessarily an indication
that an overhaul is needed, while low mileage, on
the other hand, does not preclude the need for
an overhaul. 4re,uency of servicing is probably
the single most important consideration. An
engine that has regular and fre,uent oil and filter
changes, as well as other re,uired maintenance,
will most likely give many miles of reliable
service.
Scane! by Stal'er
$ngine, clutch and transmission A[B
"onversely, a neglected engine, or one which
has not been run in properly, may re,uire an
overhaul very early in its life.
@ $%haust smoke and e%cessive oil consumption
are both indications that piston rings andDor valve
guides are in need of attention, although make
sure that the fault is not due to oil leakage.
6 'f the engine is making obvious knocking or
rumbling noises, the connecting rods andDor main
bearings are probably at fault.
; Foss of power, rough running, e%cessive valve
train noise and high fuel consumption rates may
also point to the need for an overhaul, especially
if they are all present at the same time. 'f a
complete tune#up does not remedy the situation,
major mechanical work is the only solution.
C An engine overhaul generally involves
restoring the internal parts to the specifications of
a new engine. The piston rings and main and
connecting rod bearings are usually renewed and
the cylinder walls honed or, if necessary, re#
bored during a major overhaul. 2enerally the
valve seats are re#ground, since they are usually
in less than perfect condition at this point. The
end result should be a like new engine that will
give as many trouble#free miles as the original.
B *efore beginning the engine overhaul, read
through the related procedures to familiarise
yourself with the scope and re,uirements of the
job. =verhauling an engine is not all that difficult,
but it is time consuming. Plan on the motorcycle
being tied up for a minimum of two weeks. "heck
on the availability of parts and make sure that
any necessary special tools, e,uipment and
supplies are obtained in advance.
> 5ost work can be done with typical workshop
hand tools, although a number of precision
measuring tools are re,uired for inspecting parts
to determine if they must be renewed. =ften a
dealer will handle the inspection of parts and
offer advice concerning reconditioning and
renewal. As a
general rule, time is the primary cost of an
overhaul so it does not pay to 'nstall worn or
substandard parts.
9 As a final note, to ensure ma%imum life and
minimum trouble from a rebuilt engine,
everything must be assembled with care in a
spotlessly clean environment.
Caution: +he engine is ver) heav). ngine
removal and installation should be carried
out with the aid of at least one assistant5
personal in-ur) or damage could occur if the
engine falls or is dropped. ,n h)draulic or
mechanical floor -ack should be used to
support and lower or raise the engine if
possible.
"emoval
* 1upport the bike securely in an upright
position using an au%iliary stand. -ork can be
made easier by raising the machine to a suitable
working height on an hydraulic ramp or a suitable
platform. 5ake sure the motorcycle is secure and
will not topple over .see Tools and >orkshop
Tips in the (eference section/. -hen
disconnecting any wiring, cables and hoses, it is
advisable to mark or tag them as a reminder to
where they connect.
6 'f the engine is dirty, particularly around its
mountings, wash it thoroughly before starting any
major dismantling work. This will make work
much easier and rule out the possibility of caked
on lumps of dirt falling into some vital
component.
8 (emove the seat, side covers, fairing side
panels .T05 and 7TE models/, fairing, and
engine bashplate .8998 to 899; T05 models
and 7TE models/ .see "hapter >/. =n 899C#on
T05 models and 7TE models, the fairing can be
left in situ, though it is advisable to remove
it to avoid the possibility of damaging it while
removing the engine.
6 (emove the fuel tank .see "hapter 6/.
; 0rain the engine oil and the coolant .see
"hapter 8/.
C 0isconnect the negative .#ve/ lead from the
battery, then disconnect the positive .^ve/ lead
.see "hapter 9/. =n 8998 to 899; T05 models,
remove the battery and the battery bo% .see
"hapter 9/.
B (emove the radiator .see "hapter @/.
> (emove the e%haust system .see "hapter 6/.
9 (emove the carburettors .see "hapter 6/.
0etach the vacuum hose.s/ from the inlet
manifolds. =n 8998 to 899; T05 models,
unscrew the bolts securing the choke knob to the
left#hand engine mounting bracket and position it
clear. Plug the engine inlet manifolds with clean
rag. =n 8999 T05 remove the fuel pump and
fuel filter as a unit complete with their mounting
bracket .see "hapter 6/.
*0 =n T05 and T(7 models, remove the
thermostat housing .see "hapter @/. -hen
removing the housing, remove it along with the
pipe that bolts onto the valve cover, rather than
separating the hose from the pipe. The pipe is
secured by a bolt # make sure the pipe =#ring
does not fall into the engine when easing out the
pipe 1see illustration 4.62. 0iscard the =#ring as
a new one must be used.
** =n 7TE models, unscrew the bolt securing
the coolant pipe to the valve cover and ease the
pipe out, making sure the =#ring does not fall into
the engine. 0iscard the =#ring as a new one
must be used.
*6 Trace the alternator, ignition pick#up coil and
neutral switch wiring from the top of the
alternator cover and disconnect it at the
connectors 1see illustrations2. (elease the
wiring from any clips or ties, noting its routing,
and coil it so that it does not impede engine
removal.
*8 0isconnect the spark plug caps from the
spark plugs and secure them clear of the engine.
0.*6a Alternator+"ic'(u" coil+neutral
sBitch Birin& connectors 1arroBe!2 (
TD mo!els
0.*6b Alternator+"ic'(u" coil+neutral
sBitch Birin& connectors 1arroBe!2 (
TRX mo!els
0.*6c Alternator+"ic'(u" coil+neutral
sBitch Birin& connectors 1arroBe!2 (
XT3 mo!els
Stane! by Stal'er
A[> $ngine, clutch and transmission
0.*D EnscreB the nut an! !etach the starter motor lea! from the starter relay
0.*5 EnscreB the bolt 1arroBe!2 an! !etach the cable an! hose cli"
*D 0isconnect the starter motor lead from the
starter relay 1see illustration2.
*0 0isconnect the earth wiring connector from
the main wiring loom.
*5 =n 8998 to 899; T05 models and all 7TE
models, the battery's main earth cable can
remain attached to the engine. =n 899C#on T05
models and all T(7 models, unscrew the bolt
securing the cable to the back of the engine and
detach it along with the clip securing the hoses
1see illustration2.
0.*9a Release the clam" an! !etach the
breather hose 1arroBe!2
8B 0etach the clutch cable from the release
lever on the clutch cover .see 1ection 8B/.
8> (emove the front sprocket .see "hapter C/.
=n T05 and 7TE models, also remove the
gearchange lever .see "hapter C/.
89 =n 8998 to 899; T05 models and all 7TE
models, disconnect the crankcase breather hose
from the crankcase 1see illustration2. Also
slacken the clamp and detach the hose from its
union on the oil filter housing 1see illustration2.
)ow unscrew the bolts and detach the oil pipe
from the oil pump cover
>
Hpl. jjlih. HTHTTttirnvriiir iliiiffi-
II(((II
Sl
lHHHggwmHPLH# sf "H IJJJJKJ
0.*9b Slac'en the clam" screB 1arroBe!2 an!
!etach the hose
1see illustration2. 0iscard the =#ring as anew
one must be used.
A? At this point, position an hydraulic or
mechanical jack under the engine with a block of
wood between the jack head and crankcase 1see
illustration2. 5ake sure the jack is centrally
positioned so the engine will not topple in any
direction when the last mounting bolt is removed.
Take the weight of the engine on the jack. 't is
also advisable to place a block of wood between
the rear wheel and the ground, or under the
swingarm, to prevent the bike tilting back onto the
rear wheel when the engine is removed. "heck
around the engine and frame to make sure that
all wiring, cables and hoses that need to be
disconnected have been disconnected, and that
any remaining connected to the engine are not
retained by any clips, guides or brackets. "heck
that any protruding mounting brackets will not get
in the way and remove them if necessary.
A8 =n T05 models, unscrew the bolts securing
the engine bracket to the frame and the engine
on each side and remove the brackets 1see
illustrations2. )ote which bolt fits where as they
are of different lengths. 5ake sure the engine is
properly supported on the jack, and have an
assistant support it
0.*9c EnscreB the bolts 1arroBe!2 an! !etach the "i"e
0.60 #osition a <ac' un!er the en&ine
0.6*a EnscreB the bolts 1arroBe!2 an! remo,e the left(han! ...
Stane! by Stal'er
$ngine, clutch and transmission AL9
0.6*b ... an! ri&ht(han! en&ine brac'ets
0.6*c E""er rear en&ine mountin& bolt 0.6*! -oBer rear en&ine mountin& bolt
1arroBe!2 1arroBe!2
0.6* e Remo,e the trian&ular brac'et 1arroBe!2...
0.6*f ... an! the bottom brac'et 1arroBe!2
0.66a En&ine brac'et bolts 1A2 an! u""er front mountin& bolt 1/2 ( ri&ht(han! si!e
as well. (emove the cap from each end of the
upper rear mounting bolt, then unscrew the nut
and withdraw the bolt 1see illustration2. 4inally
unscrew and remove the lower rear mounting bolt
1see illustration2. 'f re,uired, after the engine
has been removed, unscrew the bolts securing
the small triangular mounting bracket to the left#
hand side of the engine and the bolts securing
the bracket to
the underside of the engine at the back and
remove the brackets 1see illustrations2. 66 =n
T(7 models, unscrew the bolts securing the
engine bracket to the frame and the engine on
each side and remove the brackets, along with
the collar fitted with the right#hand bracket 1see
illustrations2. )ote which bolt fits where as they
are of different lengths. (emove the caps from
the upper
front mounting bolts, then unscrew the bolts.
5ake sure the engine is properly supported on
the jack, and have an assistant support it as well.
+nscrew the nut from the upper rear mounting
bolt and withdraw the bolt 1see illustration2.
4inally unscrew the nut on the lower rear
mounting bolt and remove the bolt. A@ =n 7TE
models, unscrew the nut from the lower front
mounting bolt and remove the bolt
0.66b En&ine brac'et bolts 1A2 an! u""er front mountin& bolt 1/2 (left(han! si!e
0.66c E""er an! loBer rear mountin& bolts 1arroBe!2
Scane! by Stal'er
+.Hi.l1.iHi0.iH1in.n4P'"+Hi#0i1<
A[8? $ngine, clutch and transmission
0.68c DoBntube loBer bolts 1arroBe!2
1see illustration2. +nscrew the four bolts
securing each of the frame downtubes and
remove the downtubes 1see illustrations2.
(emove the cap from each end of the upper rear
mounting bolt, then unscrew the nut and
withdraw the bolt .see illustration2. +nscrew the
nut on the lower rear mounting bolt and remove
the bolt. (emove the cap from each end of the
swingarm pivot bolt, then unscrew the nut on its
right#hand end. The swingarm pivot bolt also acts
as the middle rear engine mounting bolt, so it
must be removed. To prevent the swingarmDrear
wheel assembly from becoming unstable,
partially withdraw the pivot bolt from the left#hand
side and slide into its place from the right#hand
side a suitable bolt that will support the
swingarm, making sure that it does not go into
the engine mount. -ithdraw the pivot bolt further
until the engine is free, but leave it partially
inserted so that it still supports the left#hand side
of the swingarm.
A6 The engine can now be removed from the
frame. "heck that all wiring, cables and hoses
are well clear, then carefully lower the engine
and manoeuvre it forward and out of the side
of the frame .see Caution above/.
&nstallation
A; 'nstallation is the reverse of removal,
noting the following pointsG
a) Eake sure no wires& cables or hoses
become trapped between the engine and the
!rame when installing the engine.
b) Eany o! the engine mounting bolts are o!
di!!erent siLe and length. Eake sure the
0.68! E""er an! loBer rear mountin& bolts
1arroBe!2
correct bolt is installed in its correct location&
with its washer i! !itted. )nstall all o! the bolts
and nuts !inger-tight until they are all located&
then tighten them in the order given in the
relevant +tep below to their torAue settings
as speci!ied at the beginning o! the -hapter.
c) (n T*E models& i! removed& and be!ore the
engine is mounted& !it the small triangular
mounting bracket onto the le!t-hand side o!
the engine and the bracket to the underside
o! the engine at the back and tighten their
bolts to the speci!ied torAue setting (see
illustration 8.2#e and !). Mocate all the
mounting bolts& not !orgetting the washers
with the engine bracket-to-engine mounting
bolts& and tighten them !inger-tight. 'ow
tighten the lower rear mounting bolt !irst&
then the upper rear mounting bolt nut& then
the engine bracket-to-engine bolts& and
!inally the engine bracket-to-!rame bolts&
tightening them all to their speci!ied torAue.
Fit the caps into each end o! the upper rear
bolt.
d) (n T/F models& locate all the mounting
bolts& not !orgetting the washers with the
upper and lower rear bolts (they locate under
the bolt head& not the nut)& and the collar
between the right-hand engine bracket and
the engine& and tighten them !inger-tight.
'ow tighten the lower rear mounting bolt nut
!irst& then the upper rear mounting bolt nut&
then the upper !ront mounting bolts (le!t-
hand side !irst)& then the engine bracket-to-
engine and
!rame bolts (le!t-hand side)& and !inally the
engine bracket-to-engine and !rame bolts
(right-hand side)& tightening them all to their
speci!ied torAue. Fit the caps into the upper
!ront bolts.
e)(n FTG models& locate the swingarm pivot
bolt !irst& !ollowed by the lower and upper and
rear mounting bolts& then !it the !rame
downtubes& and !inally locate the lower !ront
bolt& not !orgetting the washers with the
swingarm bolt nut and the lower rear bolt nut&
and tighten them !inger-tight. 'ow tighten
them in the same order to the speci!ied
torAue settings. Fit the caps into each end o!
the swingarm pivot and the upper rear bolt.
!) (n #77# to #778 T*E models and all FTG
models& use a new (-ring on the oil pipe to
oil pump cover union and tighten the bolts to
the speci!ied torAue setting.
g)Cse new gaskets on the eBhaust pipe
connections.
h) Eake sure all wires& cables and hoses are
correctly routed and connected& and
secured by any clips or ties& i) /e!ill the
engine with oil and coolant (see
-hapter #). i) $d3ust the throttle and
clutch cable
!reeplay and engine idle speed (see
-hapter #). k) $d3ust the drive chain slack
(see -hapter #). )) +tart the engine and check
that there are
no oil or coolant leaks be!ore installing the
body panels.
5 En&ine !isassembly an!
reassembly # general
information
Disassembl)
* *efore disassembling the engine, the
e%ternal surfaces of the unit should be
thoroughly cleaned and degreased. This will
prevent contamination of the engine internals,
and will also make working a lot easier and
cleaner. A high flash#point solvent, such as
paraffin .kerosene/ can be used, or better still,
a proprietary engine degreaser. +se old
paintbrushes and toothbrushes to work the
solvent into the various recesses of the engine
casings. Take care to e%clude solvent or water
from the electrical components and inlet and
e%haust ports.
'arning: +he use of petrol
3gasoline4 as a cleaning agent should
be avoided because of the risk of fire. $
A -hen clean and dry, arrange the unit on the
workbench, leaving suitable clear area for
working. 2ather a selection of small
containers and plastic bags so that parts can
be grouped together in an easily identifiable
manner. 1ome paper and a pen should be on
hand so that notes can be made and labels
attached where necessary. A supply of clean
rag is also re,uired.
Scane! by Stal'er
0.68a -oBer front mountin& bolt 1arroBe!2 0.68b DoBntube u""er bolts 1arroBe!2
r +)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
$ngine, clutch and transmission AL88
@ *efore commencing work, read through the
appropriate section so that some idea of the
necessary procedure can be gained. -hen
removing components it should be noted that
great force is seldom re,uired, unless specified.
'n many cases, a component's reluctance to be
removed is indicative of an incorrect approach or
removal method # if in any doubt, re#check with
the te%t.
6 An engine support stand made from short
lengths of A % 6 inch wood bolted together into a
rectangle will help support the engine 1see
illustration2. The perimeter of the mount should
be just big enough to accommodate the sump
within it so that the engine rests on its crankcase.
; -hen disassembling the engine, keep 'mated'
parts together .including gears, cylinders,
pistons, connecting rods, valves, etc. that have
been in contact with each other during engine
operation/. These 'mated' parts must be reused
or renewed as an assembly.
C A complete engineDtransmission
disassembly should be done in the following
general order with reference to the appropriate
1ections of this "hapter.
/emove the valve cover
/emove the camsha!ts
/emove the cylinder head
/emove the cylinder block
/emove the pistons
/emove the clutch
/emove the alternator/pick-up coil
assembly (see -hapter 7) /emove the
starter motor (see -hapter 7) /emove the
gearchange mechanism
eBternal components /emove the oil
pumps /emove the oil sump +eparate
the crankcase halves /emove the
cranksha!t /emove the transmission
sha!ts /emove the selector drum and
!orks /emove the balancer sha!ts
"eassembl)
B (eassembly is accomplished by reversing the
general disassembly se,uence.
5.D An en&ine su""ort ma!e from "ieces of 6
C D inch Boo!
4 Qal,e co,er # ON
removal and installation JQ
%ote) The valve covers can be removed with the
engine in the !rame. )! the engine has been
removed& ignore the steps which do not apply.
"emoval
* (emove the fuel tank, the air filter housing and
the carburettors .see "hapter 6/. 0rain the
coolant .see "hapter 8/.
6 =n T05 and T(7 models, remove the
thermostat housing .see "hapter @/. -hen
removing the housing, remove it along with the
pipe that bolts onto the valve cover, rather than
separating the hose from the pipe. The pipe is
secured by a bolt # make sure the pipe =#ring
does not fall into the engine when easing out the
pipe 1see illustration2. 0iscard the =#ring as a
new one must be used.
8 =n 7TE models, unscrew the bolt securing the
coolant pipe to the valve cover and ease the pipe
out, making sure the =#ring does not fall into the
engine 1see illustration 4.62. 0iscard the =#ring
as a new one must be used.
D 'f re,uired, release the clamp securing the
breather hose to the valve cover and detach the
hose 1see illustration2.
4.6 EnscreB the bolt 1arroBe!2 an! !etach the
"i"e from the co,er
; Pull the spark plug caps off the plugs and
secure them clear of the engine, noting which fits
where.
C +nscrew the bolts securing the valve cover
then lift the cover off the cylinder head 1see
illustration2. =n 899C#on T05 models and all
T(7 models, note which bolt fits where as some
are of different length. 'f the cover is stuck, do not
try to lever it off with a screwdriver. Tap it gently
around the sides with a rubber hammer or block
of wood to dislodge it. Also remove the gasket.
)ote the rubber spark plug hole gaskets fitted
inside the cover and remove them if they are
loose.
&nstallation
4 $%amine the valve cover gasket and the spark
plug hole gaskets for signs of damage or
deterioration and renew them if necessary.
1imilarly check the rubber grommets on the
cover bolts 1see illustration 4.*0b2.
8 "lean the mating surfaces of the cylinder head
and the valve cover with lac,uer thinner, acetone
or brake system cleaner.
9 'nstall the gasket onto the valve cover, making sure
it fits correctly into the groove 1see illustration2. Also
fit the spark plug hole o gaskets. +se a few dabs of
grease to keep the gaskets in place while the cover is
fitted.
4.D Release the clam" an! !etach the breather hose 1arroBe!2
4.5 EnscreB the ,al,e co,er bolts
1arroBe!2 an! remo,e the co,er ( early
TD an! XT3 ty"e co,er shoBn
4.9 Fit the main &as'et an! the s"ar' "lu& hole &as'ets 1arroBe!2 into their &roo,es
Scane! by Stal'er
AL8A $ngine, clutch and transmission
4.*0a ?nstall the ,al,e co,er...
4.*0b ... an! ti&hten the bolts
8.6a EnscreB the timin& ins"ection "lu& 1A2 an! the centre "lu& 1/2
8.6b Turn the en&ine usin& a soc'et on the alternator bolt
*0 Position the valve cover on the cylinder
head, making sure the gaskets stay in place 1see
illustration2. 'nstall the cover bolts and tighten
them to the tor,ue setting specified at the
beginning of the "hapter 1see illustration2.
** 'nstall the remaining components in the
reverse order of removal.
> "amshafts and followers #
removal, inspection and
installation
%ote) The camsha!ts can be removed with the
engine in the !rame. @lace rags over the spark
plug holes and the camchain tunnel to prevent
any component !rom dropping into the engine on
removal.
"emoval
* (emove the valve cover .see 1ection B/.
6 +nscrew the timing inspection plug and the
centre plug from the alternator cover on the left#
hand side of the engine 1see illustration2.
0iscard the plug =#rings as new ones should be
used. The engine can be turned using a 89 mm
socket on the alternator rotor bolt and turning it in
an anti#clockwise direction only 1see
illustration2. Alternatively, place the motorcycle
on an au%iliary stand so that the rear wheel is off
the ground, select a high gear and rotate the rear
wheel by hand in its normal direction of rotation.
@ Turn the engine until the T mark on the rotor
aligns with the static timing mark on the alternator
cover .a notch in the timing inspection hole/, and
the camshaft lobes for the )o. 8 .left#hand/
cylinder are facing away from each other 1see
illustration2. %ote) Do not con!use the T mark
on the rotor (which indicates T*-) with the ','
mark which will appear !irst and which indicates
the !iring point o! the ignition system. 'f the cam
lobes are facing towards each other, rotate the
engine anti#clockwise @C?W .one full turn/ so that
the ''' mark again aligns with the static timing
mark. The camshaft lobes will now be facing
away from each other and the )o. 8 cylinder is at
T0" .top dead centre/ on the
compression stroke. *efore disturbing the
camshafts, make a note of the timing markings
on the sprockets and how they align with the
cylinder head. -ith the )o. 8 cylinder at T0",
The '$' mark on the e%haust camshaft sprocket is
parallel with the cylinder head top
8.8a Turn the en&ine until the mar' on the
rotor 1A2 ali&ns Bith the static mar' on the
co,er1/2
Scane! by Stal'er
H
$ngine, clutch and transmission AL8@
8.8b %ote the ali&nment of the timin& mar' letters on the s"roc'ets Bith the cylin!er hea!...
8.8c ... an! of the "unch mar's 1A2 on the en!s of the camshafts Bith the lines 1/2 on the camshaft hol!ers
surface and faces back, while the ''' mark on the
inlet camshaft sprocket is parallel with the
cylinder head top surface and faces forward 1see
illustration2. Also the punch mark on each
camshaft sprocket holder faces up and aligns
with the mark on the top of the camshaft holder
1see illustration2. 'f you are in any doubt as to
the alignment of the markings, or if they are not
visible, make your own alignment marks between
all components, and also between a tooth on
each sprocket and its corresponding link on the
chain, before disturbing them. These markings
ensure that the valve timing can be correctly set
up on assembly without difficulty. As it is easy to
be a tooth out on installation, marking between a
tooth on each sprocket and its link in the chain is
especially useful.
6 +nscrew the bolts securing the cam chain top
guide and remove the guide, noting how it fits
1see illustration2.
; 1lacken, but do not remove, the camshaft
sprocket bolts 1see illustration2. 'f the sprockets
turn, counter#hold them by
inserting a screwdriver or bar through the hole in
the centre of the camshaft 1see illustration
8.69a2; or by counter#holding the alternator rotor.
C (emove the cam chain tensioner .see 1ection
9/.
B 5ake a mark on each sprocket to denote
whether it fits with the e%haust or inlet camshaft
.the appropriate e%isting letter can be
highlighted/. (emove the sprocket bolts, then
draw each sprocket off the end of its camshaft
and slip it out of the chain 1see illustration2. 'f
re,uired, also lift the cam chain front guide out of
the front of the cam chain tunnel, noting how and
which way round it fits .see 1ection A6/. -hile
the camshaft sprockets are off, don't allow the
cam chain to go slack and do not rotate the
crankshaft #the chain may drop down and bind
between the crankshaft and case, which could
damage these components. -ire the chain to
another component or secure it using a rod of
some sort to prevent it from dropping.
> *efore removing the camshaft holders, make
a note of which fits where. All the
holders are marked with a letter and number to
denote their location # ' 8 is the inlet camshaft
holder on the )o. 8 cylinder .left#hand/ side, $ 8
is the e%haust camshaft holder on the )o. 8
cylinder, and so on. Also each holder is marked
with an arrow which points towards the cam
chain. =therwise their
8.D EnscreB the bolts 1arroBe!2 an!
remo,e the &ui!e
8.0 Slac'en the camshaft s"roc'et bolts 1arroBe!2
8.4 Sli!e the s"roc'ets off the camshafts an! out of the chain
Scane! by Stal'er
+)($2'1T$($03'
AL86 $ngine, clutch and transmission
8.9 EnscreB an! remo,e the camshaft hol!er bolts 1arroBe!2
8.*0a -ift out the folloBer ...
8.*0b ... an! remo,e the shim either from insi!e the folloBer...
8.*0c ... or from the to" of the ,al,e
locations are readily identifiable by the differing
number or location of bolts which secures each
one.
9 *efore slackening the camshaft holder bolts,
check whether any of the cam lobes are directly
depressing the valves and if so, rotate the
camshaft slightly to release the pressure this will
prevent distortion or undue strain on the holders
as the bolts are slackened. +nscrew the
camshaft holder boits for the camshaft being
worked on, evenly and a little at a time in a criss#
cross
8.** 9hec' the <ournal surfaces of the
camshaft for scratches or Bear
pattern, until they are all loose .see
illustration2.
Caution: &f the bolts aren1t loosened
evenl), the camshaft ma) bind.
(emove the bolts, then lift off the camshaft
holders, noting how they fit, and remove the
camshafts 1see illustrations 8.65a an! 8.602.
(etrieve the dowels from either the holder or the
cylinder head if they are loose. <eep all mated
parts together.
*0 =btain a container which is divided into ten
compartments, and label each compartment
8.*6a 9hec' the lobes of the camshaft for
Bear ( here's an eCam"le of !ama&e
reAuirin& camshaft re"air or reneBal
with the location of its corresponding valve in the
cylinder head and whether it belongs with an inlet
or an e%haust valve. 'f a container is not
available, use labelled plastic bags. +sing a pair
of pliers or a magnet if necessary, lift each
follower out of the cylinder head and store it in its
corresponding compartment in the container 1see
illustration2. The shim is likely to stick to the
inside of the follower so take great care not to
lose it when removing the follower 1see
illustration2. (etrieve the shim from either the
inside of the follower or pick it out of the top of
the valve using a magnet, a small screwdriver
with a dab of grease on it .the shim will stick to
the grease/, or a screwdriver and a pair of pliers
1see illustration2. 0o not allow the shim to fall
into the engine.
&nspection
** 'nspect the bearing surfaces of the camshaft
holders and the corresponding journals on the
camshaft. Fook for score marks, deep scratches
and evidence of spailing .a pitted appearance/
1see illustration2.
*6 "heck the camshaft lobes for heat
discoloration .blue appearance/, score marks,
chipped areas, flat spots and spailing 1see
illustration2. 5easure the height of each lobe
Sta&e! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
$ngine, clutch and transmission AL8;
nft i
i
A
1
8.*6b easure the hei&ht of the camshaft
lobes Bith a micrometer
8.*8 easurin& camshaft runout 8.*0 -ay a stri" of #lasti&au&e across
each bearin& <ournal; "arallel Bith the
camshaft centreline
with a micrometer 1see illustration2 and
compare the results to the minimum lobe height
listed in this "hapter's 1pecifications. 'f damage
is noted or wear is e%cessive, the camshaft must
be renewed. Also, be sure to check the condition
of the followers. 8@ "heck the amount of
camshaft runout by supporting each end of the
camshaft on 3#blocks, and measuring any runout
using a dial gauge 1see illustration2. 'f the
runout e%ceeds the specified limit the camshaft
must be renewed.
"efer to +ools and 'orkshop
+ips in the "eference section for
details of how to read a
micrometer and dial gauge.
86 )e%t, check the camshaft bearing oil
clearances. "heck each camshaft in turn rather
than at the same time. "lean the camshaft, the
bearing surfaces in the cylinder head and
camshaft holders with a clean lint#free cloth, then
lay the camshaft in place in the cylinder head.
8;"ut some strips of Plastigauge and lay one
piece on each bearing journal, parallel with the
camshaft centreline 1see
illustration2. 5ake sure the camshaft holder
dowels are installed. Fay the holders in their
correct place in the cylinder head .see 1tep >/
1see illustration 8.65a2. 5ake sure the arrow on
each camshaft holder points towards the cam
chain. Tighten the bolts evenly and a little at a
time in a criss#cross pattern, working from the
centre of the camshaft outwards, to the tor,ue
setting specified at the beginning of the "hapter
1see illustration 8.65b2. -hilst tightening the
bolts, make sure the holders are being pulled
s,uarely down and are not binding on the
dowels. -hile doing this, don't let the camshafts
rotate.
*5 )ow unscrew the bolts a evenly and a little
at a time in a criss#cross pattern, and carefully lift
off the camshaft holders.
*4To determine the oil clearance, compare the
crushed Plastigauge .at its widest point/ on each
journal to the scale printed on the Plastigauge
container 1see illustration2. "ompare the results
to this "hapter's 1pecifications. 'f the oil
clearance is greater than specified, measure the
diameter of the cam bearing journal with a
micrometer 1see illustration2. 'f the journal
diameter is less than the specified limit, renew
the camshaft and recheck the clearance. 'f the
clearance is still too great, renew the cylinder
head and holders.
TflflflH&!H (efore renewing camshafts
or the holders because of
damage, check with local machine shops
specialising in motorc)cle engine work. &n
the case of the camshafts, it ma) be
possible for cam lobes to be welded,
reground and hardened, at a cost far lower
than that of a new camshaft. &f the bearing
surfaces in the holders are damaged, it ma)
be possible for them to be bored out to
accept bearing inserts. Due to the cost of
new components it is recommended that all
options be e*plored before condemning
them as trashA
*8 $%cept in cases of oil starvation, the cam
chain wears very little. 'f the chain has stretched
e%cessively, which makes it difficult to maintain
proper tension, or if it is stiff or the links are
binding or kinking, renew it. (efer to 1ection A6
for the procedure.
*9"heck the sprockets for wear, cracks and
other damage. 'f the sprockets are worn, the cam
chain is also worn, and so is the sprocket on the
crankshaft. 'f severe wear is apparent, the entire
engine should be disassembled for inspection.
S/
G?%T
GiA?T
8.*4a 9om"are the Bi!th of the crushe! #lasti&au&e to the scale "rinte! on the #lasti&au&e container
8.*4b easure the cam bearin& <ournals Bith a micrometer
Stane! by Stal'er
AL8C $ngine, clutch and transmission
8.66 Fit the folloBers onto the ,al,es
8.60 ?nstall the camshafts as shoBn; Bith the %o. * cylin!er
lobes 1A2 facin& aBay from each other an! the "unch mar' 1/2 on
each s"roc'et hol!er facin& u"
60 'nspect the cam chain guide blade .see
1ection A6/.
6* 'nspect the outer surfaces of the cam
followers for evidence of scoring or other
damage. 'f a follower is in poor condition, it is
probable that the bore in which it works is also
damaged. "heck for clearance between the
followers and their bores. -hilst no specifications
are given, if slack is e%cessive, renew the
followers. 'f the bores are seriously out#of#round
or tapered, the cylinder head and the followers
must be renewed.
&nstallation
AA Fubricate each shim and its follower with
molybdenum disulphide oil .a ;?D;? mi%ture of
molybdenum disulphide grease and engine
oil/ and fit each shim into its recess in the top
of the valve, with the si&e marking on each
shim facing up 1see illustration 8.*0c2. 5ake
sure each shim is correctly seated in the top
of the valve assembly, then install each
follower, making sure it fits s,uarely in its bore
1see illustration2. %ote) )t is most important
that the shims and !ollowers are returned to
their original valves otherwise the valve
clearances will be inaccurate.
68 'f removed, fit the cam chain front guide into
the front of the cam chain tunnel, making sure it
is the correct way round with the lugs properly
located in the cutouts in the top of the cylinder
head .see 1ection A6/.
6D 5ake sure the bearing surfaces on the
camshafts and in the holders are clean, then
apply molybdenum disulphide oil .a ;?D;?
mi%ture of molybdenum disulphide grease and
engine oil/ to each of them. Also apply it to the
camshaft lobes.
603erify that the T mark on the timing rotor is
still aligned with the notch .see 1tep @/ 1see
illustration 8.8a2. Fay the inlet camshaft .with si%
lobes/ onto the back of the head, making sure
the )o. 8 .left#hand/ cylinder lobes are facing
backwards and the punch mark on the sprocket
holder is facing up. )ow lay the e%haust
camshaft .with four lobes/ onto the front of the
head, making sure the )o. 8 cylinder lobes are
facing forward and the punch mark on the
sprocket holder is facing up 1see illustration2.
65 5ake sure the camshaft holder dowels are
installed. Fay the holders in their correct place in
the cylinder head .see 1tep >/ 1see
illustration2. 5ake sure the arrow on each
camshaft holder points towards the cam chain.
Tighten the bolts evenly and a little at a time in a
criss#cross pattern, working from the centre of the
camshaft outwards, to the tor,ue setting
specified at the beginning of the "hapter 1see
illustration2. -hilst tightening the bolts, make
sure the holders are being pulled s,uarely down
and are not binding on the dowels. Caution: +he
holders are likel) to break if the) are not
tightened down evenl) and s.uarel).
64 -hen installing the camshaft sprockets, align
the '$' marks .for the e%haust camshaft/ and the
''' marks .for the inlet camshaft/ on the camshaft
sprockets e%actly with the cylinder head surface,
with the letters that are the correct way up facing
each other 1see illustration 8.8b2. "heck that
the punch mark on each sprocket holder is
aligned with the mark on the camshaft holders
1see illustration 8.8c2. 'f the camshafts need to
be
8.65a Fit the hol!ers onto the !oBels..
8.65b ... an! ti&hten the bolts as !escribe! to the s"ecifie! torAue settin&
Scane! by Stal'er
$ngine, clutch and transmission AL8B
8.68a Fit the eChaust s"roc'et into the chain an! onto the camshaft...
8.68b ... then fit the inlet s"roc'et
8.69a ?nstall the s"roc'et bolts an! counter(hol! the camshafts as shoBn...
8.69b ... then ti&hten the bolts to the 8.80 ?nstall the cam chain to" &ui!e
s"ecifie! torAue
8.88 Ese neB .(rin&s on the "lu&s
turned slightly, use a screwdriver or bar through
the hole in the middle of the camshaft to turn
them.
A> 4it the cam chain around the e%haust
sprocket, aligning the marks between
sprocket tooth and link if made. -hen fitting
the chain, pull up on the front run to remove
all slack from it 1see illustration2. )ow fit the
sprocket onto the end of the camshaft,
aligning the bolt holes. )e%t fit the inlet
sprocket into the chain and onto the inlet
camshaft, making sure there is no slack in the
chain between the camshafts, and aligning
the bolt holes 1see illustration2. At this point
check that all the timing marks are still in
eCact alignment as described in 1tep @. )ote
that it is easy to be slightly out ]one tooth on
the sprocket/ without the marks appearing
drastically out of alignment. 'f all marks align
correctly, install the sprocket bolts and tighten
them finger#tight. 'f the marks are out, verify
which sprocket is misaligned and slide it off
the camshaft, then disengage it from the
chain and move it round as re,uired, then fit it
back into the chain and onto the sprocket,
and check the marks again.
Caution: &f the marks are not aligned e*actl)
as described, the valve timing will be
incorrect and the valves ma) strike the
pistons, causing e*tensive damage to the
engine.
A9 -ith everything correctly aligned, tighten
the sprocket bolts to the tor,ue setting
specified at the beginning of the "hapter,
using a screwdriver or bar inserted through the
hole in each camshaft to prevent them turning, or
by counter#holding the alternator rotor 1see
illustrations2.
80'nstall the cam chain top guide and tighten
the bolts to the same tor,ue setting as the other
camshaft holder bolts 1see illustration2.
8* 'nstall the cam chain tensioner .see 1ection
9/. Turn the engine anti#clockwise through two
full turns and check again that all the timing
marks still align .see 1tep @/.
86"heck the valve clearances and adjust them
if necessary .see "hapter 8/. %ote) $ valve
clearance check is essential i! you have installed
any new valve components or a new camsha!t.
88+se new =#rings on the timing inspection
plug and centre plug and tighten the plugs
securely 1see illustration2.
8D 'nstall the valve cover .see 1ection B/.
9 "am chain tensioner #
removal, inspection and
installation
%ote) This procedure can be per!ormed with the
engine in the !rame. Caution: $nce )ou start to
remove the tensioner bolts, )ou must remove
the tensioner all the wa) and reset it before
tightening the bolts. +he tensioner e*tends
itself and locks in place, so if )ou loosen the
bolts partwa) and then retighten them, the
tensioner or cam chain will be damaged.
"emoval
*+nscrew the tensioner spring cap bolt and
withdraw the springs from the tensioner body
1see illustration2.
6+nscrew the two tensioner mounting bolts and
withdraw the tensioner from the back of the
cylinder block, noting which way up it fits 1see
illustration 9.*2.
8 0iscard the tensioner body gasket as a new
one must be used.
&nspection
6 $%amine the tensioner components for
signs of wear or damage.
Stane! by Stal'er
?
9.* Tensioner ca" bolt 1A2; tensioner
mountin& bolts 1/2
AL8> $ngine, clutch an! transmission
9.0 Release the ratchet an! "ress the "lun&er ?n
9.8a ?nstall the tensioner usin& a neB &as'et...
9.8b ... an! ti&hten the mountin& bolts to the s"ecifie! torAue
9.9 ?nstall the s"rin&s an! ca" bolt
0(elease the ratchet mechanism from the
tensioner plunger and check that the plunger
moves freely in and out of the tensioner body
1see illustration2.
5 'f the tensioner or any of its components are
worn or damaged, or if the plunger is sei&ed in
the body, the tensioner must be renewed #
individual components are not available.
&nstallation
B(elease the ratchet mechanism and press the
tensioner plunger all the way into the tensioner
body 1see illustration 9.02.
> 4it a new gasket onto the tensioner body, then
install the tensioner in the engine and tighten
the bolts to the tor,ue setting
specified at the beginning of the "hapter 1see
illustrations2.
9 'nstall the springs and cap bolt, with its
washer, and tighten the bolt to the specified
tor,ue setting 1see illustration2.
*0 (emove the alternator cover centre plug and
turn the crankshaft anti#clockwise through two full
turns using a socket on the rotor bolt 1see
illustrations 8.6a an! b2. This will allow the
tensioner to set itself properly. +se a new =#ring
on the centre plug.
** 't is advisable to remove the valve cover
.see 1ection B/ and check that the cam chain is
tensioned and all the timing marks are in
alignment .see 1ection >/. 'f the chain is slack,
the tensioner plunger did not release when the
spring and cap bolt were installed. (emove the
tensioner again and re#check it. Again check the
timing marks .see 1ection >/, then install the
valve cover .see 1ection B/.
*0 9ylin!er hea! # fb
removal and installation gs
9aution) The engine must be completely cool
be!ore beginning this procedure or the
cylinder head may become warped.
%ote *) The cylinder head can be removed
with the engine in the !rame. )! the engine has
been removed& ignore the steps which don't
apply.
%ote 6) )! no work is being carried out on the
valves& the cylinder head can be removed with
the camsha!ts in place. ,oles in the camsha!ts
and in the right-hand camsha!t holders allow
access to the cylinder head nuts. The camsha!t
sprockets must be removed.
"emoval
* (emove the valve cover .see 1ection B/, the
camshaft sprockets .see 1ection >/, and if
re,uired the camshafts .see )ote A above/. 'f the
camshafts are being left in place, remove the
blanking cap from the top of each right#hand
camshaft holder, then turn the camshafts using a
screwdriver or rod through the hole in the middle
of the camshaft until the access holes in the
shafts align with the cylinder head nuts 1see
illustration2. 'f the camshafts are left in place,
the nuts and washers cannot be removed after
they have been loosened as the camshafts will
be in the way.
6 (emove the e%haust system .see "hapter 6/.
8 'f not already done, remove the cam chain
front guide .see 1ection A6/.
D 'f re,uired, release the clamp.s/ securing the
vacuum hose.s/ to the inlet manifold.s/ and
detach the hose.s/.
0 +nscrew the oil pipe banjo bolt from the
cylinder head and detach the pipe from the
cylinder head 1see illustration2. 0iscard the
banjo bolt sealing washers as new ones must be
used.
*0.* Remo,e the blan'in& ca"s 1A2 from
the holes in the hol!ers. Turn the shafts
usin& the centre holes 1/2 until the access
holes in each camshaft ali&n Bith the nuts
*0.0 EnscreB the ban<o bolt 1arroBe!2 an!
!etach the oil "i"e
*0.5a .n TD mo!els; remo,e the
cylin!er hea!(to(brac'et bolt 1arroBe!2 on
each si!e
Stane! by Stal'er
$ngine, clutch and transmission A[89
8?.Cb =n T(7 models, remove the blanking cap, then remove the frame#to#cylinder head bolt .arrowed/ on each side
8?.B "ylinder head bolts .A/ and nuts .*/
C =n T05 and T(7 models, unscrew the engine
mounting bolts which thread into the cylinder
head on each side .see illustrations/. =n T(7
models, first remove the caps.
B $ach cylinder head is secured by two bolts,
located in the cam chain tunnel, and si% nuts
.see illustration/. 4irst unscrew and remove the
bolts .see illustration 8?.8C/. )ow slacken the
nuts evenly and a little at a time in a criss#cross
pattern until they are all slack, then remove the
nuts and their washers .see illustration 8?.8;/.
> Pull the cylinder head up off the block .see
illustration/. 'f it is stuck, tap around the joint
faces of the cylinder head with a soft#faced
mallet to free the head. 0o not attempt to free the
head by inserting a screwdriver between the
head and cylinder block # you'll damage the
sealing surfaces. (emove the old cylinder head
gasket and discard it as a new one must be
used.
9 'f they are loose, remove the dowels from the
cylinder block. 'f they appear to be missing they
are probably stuck in the underside of the
cylinder head.
,8? "heck the cylinder head gasket and the
mating surfaces on the cylinder head and block
for signs of leakage, which could indicate
warpage. (efer to 1ection 8A and check the
flatness of the cylinder head.
&nstallation
88 "lean all traces of old gasket material from
the cylinder head and block. 'f a scraper is used,
take care not to scratch or gouge the soft
aluminium. *e careful not to let any of the gasket
material fall into the crankcase, the cylinder
bores or the oil passages.
?>TG>T88 (efer to Tools and
mil7Si workshop Tips in the
Gi7T
8A 'f removed, install the dowels into the
cylinder block .see illustration 8?.8@/. Fubricate
the cylinder bores with engine oil.
8@ $nsure both cylinder head and block mating
surfaces are clean, then lay the new head gasket
in place on the cylinder block, making sure all the
holes are correctly aligned .see illustration/.
)ever re#use the old gasket.
86 "arefully fit the cylinder head onto the block,
making sure it locates correctly onto the dowels
.see illustration 8?.>/.
8; Fubricate the threads of the cylinder head
nuts with clean engine oil .if the camshafts are in
place, one or two drops of oil can be s,uirted
around the nuts into the stud holes/. 'nstall the
nuts with their washers and tighten
them finger#tight .see illustration/. )ow tighten
the nuts evenly and a little at a time in a criss#
cross pattern to the tor,ue setting specified at
the beginning of the "hapter.
8C 'nstall the two cylinder head bolts and
tighten them to the specified tor,ue setting .see
illustration/.
8B =n T05 and T(7 models, install the engine
mounting bolts and tighten them to the specified
tor,ue setting .see illustrations 8?.Ca and b/. =n
T(7 models, fit the caps into the bolt heads.
8> 'nstall the oil pipe onto the cylinder head,
using new sealing washers on each side of
8?.8@ Fay a new head gasket over the dowels .arrowed/ and onto the head
/e!erence section !or details o!
gasket removal methods.
8?.> "arefully lift the head up off the block
8?.8; 'nstall the nuts with their washers
and tighten them as described to the
specified tor,ue
8?.8C 'nstall the bolts and tighten them to the specified tor,ue
1caned by Stal'er
A[A? $ngine, clutch and transmission
*0.*8a Ese neB sealin& Bashers on each
si!e of the union ...
the union, and tighten the banjo bolt to the
specified tor,ue 1see illustrations2.
*9 'f removed, fit the vacuum hose.s/ onto the
inlet manifold.s/ and fit the clamp.s/.
60 'nstall the remaining components in a
reverse of their removal se,uence, referring to
the relevant 1ections or "hapters .see 1teps 8, A
and @/.
** Qal,es+,al,e seats+,al,e
&ui!es # overhaul
* *ecause of the comple% nature of this job and
the special tools and e,uipment re,uired, most
owners leave servicing of the valves, valve seats
and valve guides to a professional.
6 The home mechanic can, however, remove the
valves from the cylinder head, clean and check
the components for wear and assess the e%tent
of the work needed, and, unless a valve overhaul
is re,uired, grind in the valves .see 1ection 8A/.
8 The engineer will renew the valves, guides
and springs, recut the valve seats, clean and
polish the valve ports and reassemble the valve
components.
D After the valve overhaul has been performed,
the head will be in like#new condition. -hen the
head is returned, be sure to clean it again very
thoroughly before installation on the engine to
remove any metal particles or abrasive grit that
may still be present from the valve service
operations.
*0.*8b ... an! ti&hten the ban<o bolt to the
s"ecifie! torAue
+se compressed air, if available, to blow out all
the holes and passages.
*6 9ylin!er hea! an! ,al,es #
disassembly, inspection and
reassembly
8 As mentioned in the previous section, valve
overhaul should be left to an engineer. However,
disassembly, cleaning and inspection of the
valves and related components can be done .if
the necessary special tools are available/ by the
home mechanic. This way no e%pense is
incurred if the inspection reveals that overhaul is
not re,uired at this time.
A To disassemble the valve components without
the risk of damaging them, a valve spring
compressor is absolutely essential. 5ake sure
that it is suitable for motorcycle work.
Disassembl)
8 *efore proceeding, arrange to label and store
the valves along with their related components
in such a way that they can be returned to their
original locations without getting mi%ed up 1see
illustration2. A good way to do this is to use the
same container as the shims are stored in .see
1ection >/, or to obtain a separate container
which is divided into ten compartments, and to
label each compartment with the identity of the
valve which will be stored in it .ie number of
cylinder, inlet or e%haust side, inner, middle or
outer valve/. Alternatively, labelled plastic bags
will do just as well.
*6.8 Qal,e com"onents
# -ollets 8 1alve stem oil
2 +pring retainer seal
4 1alve spring 9 1alve
5 +pring seat
6 "lean all traces of old gasket material from the
cylinder head. 'f a scraper is used, take care not
to scratch or gouge the soft aluminium.
"efer to +ools and 'orkshop
+ips in the "eference section for
details of gasket removal
methods.
; "ompress the valve spring on the first valve
with the spring compressor, making sure it is
correctly located onto each end of the valve
assembly 1see illustration2. 0o not compress
the spring any more than is absolutely necessary.
(emove the collets, using either needle#nose
pliers, twee&ers, a magnet or a screwdriver with
a dab of grease on it 1see illustration2. "arefully
release the valve spring compressor and remove
the spring retainer, noting which way up it fits, the
spring, the spring seat, and the valve, from the
head 1see illustration *6.82. 'f the valve binds in
the guide .won't pull through/, push it back into
the head and deburr the area around the collet
groove with a very fine file or whetstone 1see
illustration2.
*6.0a 9om"ressin& the ,al,e s"rin&s usin& a ,al,e s"rin& com"ressor
?
?
*6.0b Remo,e the collets Bith nee!le(nose "liers; tBeeRers; a ma&net or a screB!ri,er Bith a !ab of &rease on it
*6.0c ?f the ,al,e stem Bon't "ull throu&h
the &ui!e; !eburr the area abo,e the collet
&roo,e
Stane! by
Stal'er
$ngine, clutch and transmission AYA8
*6.*8 easure the ,al,e seat Bi!th Bith a
ruler Uor for &reater "recision use a ,ernier
cali"er2
5 (epeat the procedure for the remaining valves. (emember to keep the parts for each valve together and in order so they can be reinstalled in the same location.
4 =nce the valves have been removed and labelled, pull the valve stem seals off the top of the valve guides with pliers and discard them .the old seals should never
be reused/.
8 )e%t, clean the cylinder head with solvent and dry it thoroughly. "ompressed air will speed the drying process and ensure that all holes and recessed areas are
clean.
9 "lean all of the valve springs, collets, retainers and spring seats with solvent and dry them thoroughly. 0o the parts from one valve at a time so that no mi%ing of
parts between valves occurs.
8? 1crape off any deposits that may have
formed on the valve, then use a motorised
wire brush to remove deposits from the valve
heads and stems. Again, make sure the valves
do not get mi%ed up.
&nspection
** 'nspect the head very carefully for cracks
and other damage. 'f cracks are found, a new
head will be re,uired. "heck the cam bearing
surfaces for wear and evidence of sei&ure.
"heck the camshafts for wear as well .see
1ection >/.
*6.*Da easure the ,al,e stem !iameter Bith a micrometer
*6 +sing a precision straight#edge and a feeler gauge set to the warpage limit listed in the specifications at the beginning of the "hapter, check the head gasket
mating surface for warpage. (efer to Tools and >orkshop Tips in the (eference section for details of how to use the straight#edge.
*8 $%amine the valve seats in the combustion chamber. 'f they are pitted, cracked or burned, the head will re,uire work beyond the scope of the home mechanic.
5easure the valve seat width and compare it to this "hapter's 1pecifications 1see illustration2. 'f it e%ceeds the service limit, or if it varies around its circumference,
valve overhaul is re,uired. 'f available, use Prussian blue to determine the e%tent of valve seat wear. +niformly coat the seat with the Prussian blue, then install the
valve and rotate it back and forth using a lapping tool. (emove the valve and check whether the ring of blue on the valve is uniform and continuous around the valve,
and of the correct width as specified.
*D 5easure the valve stem diameter 1see illustration2. "lean the valve guides to remove any carbon build#up, then measure the inside diameters of the guides .at
both ends and the centre of the guide/ with a small#hole gauge and micrometer 1see
*6.*Db ?nsert a small(hole &au&e into the
,al,e &ui!e an! eC"an! it so there's a
sli&ht !ra& Bhen it's "ulle! out
illustrations2. The guides are measured at the ends and at the centre to determine if they are worn in a bell#mouth pattern .more wear at the ends/. 1ubtract the
stem diameter from the valve guide diameter to obtain the valve stem#to#guide clearance. 'f the stem#to#guide clearance is greater than listed in this "hapter's
1pecifications, the guides and valves will have to be renewed. 'f the valve stem or guide is worn beyond its limit, or if the guide is worn unevenly, it must be renewed.
*0 "arefully inspect each valve face for cracks, pits and burned spots. "heck the valve stem and the collet groove area for cracks 1see illustration2. (otate the
valve and check for any obvious indication that it is bent. +sing 3#blocks and a dial gauge if available, measure the valve stem runout and compare the results to the
specifications 1see illustration2. 'f the measurement e%ceeds the service limit specified, the valve must be renewed. "heck the end of the stem for pitting and
e%cessive wear. The presence of any of the above conditions indicates the need for valve servicing. The stem end can be ground down, provided that the amount of
stem above the collet groove after grinding is sufficient.
*5 5easure the valve margin thickness and compare it to the specifications 1see
*6.*Dc easure the small(hole &au&e Bith a micrometer
*6.*0a 9hec' the ,al,e face 1A2; stem 1/2
an! collet &roo,e 192 for si&ns of Bear an!
!ama&e
*6.*0b 9hec' the ,al,e stem for runout usin& Q(bloc's an! a !ial &au&e
Scane! by Stal'er
A[AA $ngine, clutch and transmission
E((((VAVWI>
=
/
'
$ ,ead diameter
6 Face width
- +eat width
* Eargin thickness
*6.*5 Qal,e hea! measurement "oints
illustration2. 'f it is thinner than specified, renew
the valve. The margin is the portion of the valve
head which is below the valve seat.
*4 "heck the end of each valve spring for wear
and pitting. 5easure the spring free length and
compare it to that listed in the specifications 1see
illustration2. 'f any spring is shorter than
specified it has sagged and must be renewed.
Also place the spring upright on a flat surface
and check it for bend by placing a ruler against it
1see illustration2. 'f the bend in any spring is
e%cessive, it must be renewed.
*8 "heck the spring retainers and collets for
obvious wear and cracks. Any ,uestionable parts
should not be reused, as e%tensive damage will
occur in the event of failure during engine
operation.
*9 'f the inspection indicates that no overhaul
work is re,uired, the valve components can be
reinstalled in the head.
"eassembl)
A? +nless a valve service has been performed,
before installing the valves in the head they
should be ground in .lapped/ to ensure a positive
seal between the valves and seats. This
procedure re,uires coarse and fine valve
grinding compound and a valve grinding tool. 'f a
grinding tool is not available, a piece of rubber or
plastic hose can be slipped over the valve stem
.after the valve has been installed in the guide/
and used to turn the valve.
A8 Apply a small amount of coarse grinding
compound to the valve face, then slip the valve
into the guide 1see illustration2. %ote) Eake
sure each valve is installed in its correct guide
and be care!ul not to get any grinding compound
on the valve stem.
AA Attach the grinding tool .or hose/ to the valve
and rotate the tool between the palms of
your hands. +se a back#and#forth motion .as
though rubbing your hands together/ rather than
a circular motion .ie so that the valve rotates
alternately clockwise and anticlockwise rather
than in one direction only/ 1see illustration2. Fift
the valve off the seat and turn it at regular
intervals to distribute the grinding compound
properly. "ontinue the grinding procedure until
the valve face and seat contact area is of uniform
width and unbroken around the entire
circumference of the valve face and seat 1see
illustrations2.
68 "arefully remove the valve from the guide
and wipe off all traces of grinding compound.
+se solvent to clean the valve and wipe the seat
area thoroughly with a solvent soaked cloth.
6D (epeat the procedure with fine valve
grinding compound, then repeat the entire
procedure for the remaining valves.
60 Fay the spring seat for each valve in place
*6.*4a easure the free len&th of the ,al,e s"rin&s
*6.*4b 9hec' the ,al,e s"rin&s for sAuareness
*6.6* A""ly the la""in& com"oun! ,ery
s"arin&ly; in small !abs; to the ,al,e face
only
*6.66a Rotate the ,al,e &rin!in& tool bac' an! forth betBeen the "alms of your han!s
*6.66b The ,al,e face an! seat shoul! shoB a uniform unbro'en rin& ...
*6.66c ... an! the seat 1arroBe!2 shoul! be the s"ecifie! Bi!th all the Bay roun!
Scane! by Stal'er
$ngine, clutch and transmission A[A@
98
Br CC/CD ;
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*6.60a Fit the s"rin& seat... *6.60b ... then "ress the ,al,e stem seal into "osition usin& a
suitable !ee" soc'et
*6.65a -ubricate the stem an! sli!e the ,al,e into its correct location
in the cylinder head, with its shouldered side up so that the spring fits into it, then install new valve stem seals on each of the guides 1see illustrations2. +se an
appropriate si&e deep socket to push the seals over the end of the valve guide until they are felt to clip into place. 0on't twist or cock them, or they will not seal
properly against the valve stems. Also, don't remove them again or they will be damaged.
AC "oat the valve stems with molybdenum disulphide grease, then install one of them into its guide, rotating it slowly to avoid damaging the seal 1see illustration2.
"heck
*6.64a A small !ab of &rease Bill hel" to
'ee" the collets in "lace on the ,al,e Bhile
the s"rin& is release!
*6.65b Fit the ,al,e s"rin& Bith its closer(Boun! coils facin& !oBn...
that the valve moves up and down freely in the guide. )e%t, install the spring, with its closer#wound coils facing down into the cylinder head, followed by the spring
retainer, with its shouldered side facing down so that it fits into the top of the spring 1see illustrations2.
64 Apply a small amount of grease to the collets to help hold them in place as the pressure is released from the springs 1see illustration2. "ompress the springs with
the valve spring compressor and install the collets 1see illustration2. -hen compressing the spring, depress them only as far as is
*6.64b 9om"ress the s"rin& an! install
the collets; ma'in& sure they locate in the
&roo,e
*D.65c ... then fit the s"rin& retainer
absolutely necessary to slip the collets into place. 5ake certain that the collets are securely locked in their retaining grooves. A> 1upport the cylinder head on blocks
so the valves can't contact the workbench top, then very gently tap each of the valve stems with a soft#faced hammer. This will help seat the collets in their grooves.
ffffffl&<l -heck !or proper sealing o! TTPTT the valves by pouring a GlR?T small amount o! solvent into
########### each of the valve ports. &f
the solvent leaks past an) valve into the combustion chamber area the valve grinding operation on that valve should be repeated.
*8 9ylin!er bloc'#removal,
inspection and installation
%ote) The cylinder block can be removed with the engine in the !rame.
"emoval
8 (emove the cylinder head .see 1ection 8?/.
A +nscrew the bolts securing the coolant hose union to the front of the block and
Stane! by Stal'er
*
A[A6 $ngine, clutch and transmission
*8.6 EnscreB the tBo bolts 1arroBe!2 an! remo,e the union
*8.8 -ift the bloc' u" off the crankcase
8@.6 Pick out the =#rings and discard them
remove the union 1see illustration2. The joint
pipe between the union and the water pump
housing may come with the union, otherwise
leave it in place in the housing. 0iscard the =#
rings as new ones must be used.
8 Hold the cam chain up and lift the cylinder
block up, then pass the cam chain down through
the tunnel 1see illustration2. 0o not let the chain
fall into the crankcase # secure it with a piece of
wire or metal bar to prevent it from doing so. 'f
the block is stuck, tap around the joint faces of
the block with a soft#faced mallet to free it from
the crankcase. 0on't attempt to free the block by
inserting a screwdriver between it and the
crankcase #you'll damage the sealing surfaces.
-hen the block is removed, stuff clean rags
around the pistons to prevent anything falling into
the crankcase. (emove the dowels from the
mating surface of the crankcase or the underside
of the block if they are loose. *e careful not to
drop them into the engine.
D (emove the =#ring from around each cylinder
liner and discard them as new ones must be
used 1see illustration2.
0 (emove the gasket and clean all traces of old
gasket material from the cylinder block and
crankcase mating surfaces. 'f a scraper is used,
take care not to scratch or gouge the soft
aluminium. *e careful not to let any of the gasket
material fall into the crankcase or the oil
passages.
&nspection
Caution: Do not attempt to separate the liners
from the cylinder block.
C "heck the cylinder walls carefully for
scratches and score marks. A rebore will be
necessary to remove any deep scores.
B +sing telescoping gauges and a micrometer
.see Tools and >orkshop Tips in the (eference
section/, check the dimensions of each cylinder
to assess the amount of wear, taper and ovality.
5easure near the top .but below the level of the
top piston ring at T0" # about 8? mm below the
top of the cylinder/, centre and bottom .but above
the level of the oil ring at *0" # about A? mm
above the bottom of the cylinder/ of the bore both
parallel to and across the crankshaft a%is 1see
illustration2. "alculate any differences
between the measurements taken to determine
any taper and ovality in the bore. "ompare the
results to the specifications at the beginning of
the "hapter. 'f the cylinders are tapered, oval, or
worn beyond the service limits, or badly
scratched, scuffed or scored, have them rebored
and honed by a :amaha dealer or engineer. 'f
the cylinders are rebored, they will re,uire
oversi&e pistons and rings.
> 'f the precision measuring tools are not
available, take the block and pistons to a
:amaha dealer or engineer for assessment and
advice.
9 'f the block and cylinders are in good condition
and the piston#to#bore clearance is within
specifications .see 1ection 86/, the cylinders
should be honed .de#gla&ed/. To perform this
operation you will need the proper si&e fle%ible
hone with fine stones .see Tools and >orkshop
Tips in the (eference section/, or a bottle#brush
type hone, plenty of light oil or honing oil, some
clean rags and an electric drill motor.
8? Hold the block sideways .so that the
bores are hori&ontal rather than vertical/ in a
vice with soft jaws or cushioned with wooden
blocks. 5ount the hone in the drill motor,
compress the stones and insert the hone into
the cylinder. Thoroughly lubricate the cylinder,
then turn on the drill and move the hone up
and down in the cylinder at a pace which
produces a fine cross#hatch pattern on the
cylinder wall with the lines intersecting at an
angle of appro%imately C?W. *e sure to use
*8.4 easure the cylin!er bore in the
!irections shoBn Bith a telesco"in&
&au&e; then measure the &au&e Bith a
micrometer
plenty of lubricant and do not take off any more
material than is necessary to produce the desired
effect. 0o not withdraw the hone from the
cylinder while it is still turning. 1witch off the drill
and continue to move it up and down in the
cylinder until it has stopped turning, then
compress the stones and withdraw the hone.
-ipe the oil from the cylinder and repeat the
procedure on the other cylinder. (emember, do
not take too much material from the cylinder wall.
** -ash the cylinders thoroughly with warm
soapy water to remove all traces of the abrasive
grit produced during the honing operation. *e
sure to run a brush through the bolt holes and
flush them with running water. After rinsing, dry
the cylinders thoroughly and apply a thin coat of
light, rust#preventative oil to all machined
surfaces.
*6 'f you do not have the e,uipment or desire to
perform the honing operation, take the block to a
:amaha dealer or engineer.
&nstallation
8@ "heck that the mating surfaces of the
cylinder block and crankcase are free from oil or
pieces of old gasket. 'f removed, fit the dowels
into the crankcase 1see illustration *8.*02.
86 4it a new =#ring into the groove around the
base of each cylinder liner and press it into the
groove between the liner and the cylinder block,
taking care not to damage it 1see illustration2.
8; (emove the rags from around the pistons.
Scane! by Stal'er
*8.*D Fit a neB .(rin& into the &roo,e
aroun! the liner base
' +)($2'1T$($0 3'
$ngine, clutch and transmission A[A;
*8.*0 -ay the neB &as'et o,er the !oBels 1arroBe!2 an! onto the cran'case
*8.*4 9arefully loBer the bloc' onto the "istons
*8.60a Fit a neB .(rin& onto the union .
*8.60b ... an! the <oint "i"e .
13.20c
. then install the union
Fay the new base gasket in place on the
crankcase, making sure all the holes are
correctly aligned 1see illustration2. )ever reuse
the old gasket.
8C 'f re,uired, install piston ring clamps onto the
pistons to ease their entry into the bores as the
block is lowered. This is not essential as each
cylinder has a good lead#in enabling the piston
rings to be hand#fed into the bore. 'f possible,
have an assistant to support the block while this
is done.
8B Fubricate the cylinder bores, pistons and
piston rings, and the connecting rod big# and
small#ends, with clean engine oil, then install the
block down over the studs until the piston crowns
fit into the bores 1see illustration2. At this stage
feed the cam chain up through the block and
secure it in place with a piece of wire to prevent it
from falling back down.
8> 2ently push down on the cylinder block,
making sure the pistons enter the bore s,uarely
and do not get cocked sideways. 'f piston ring
clamps are not being used, carefully compress
and feed each ring into the bore as the block is
lowered. 'f necessary, use a soft mallet to gently
tap the block down, but do not use force if the
block appears to be stuck as the pistons andDor
rings will be
damaged. 'f clamps are used, remove them once
the pistons are in the bore.
89 -hen the pistons are correctly installed in
the cylinders, press the block down onto the
base gasket, making sure it locates correctly
onto the dowels.
A? 4it a new =#ring into the groove in the
coolant union face and around the pipe joint 1see
illustrations2. 4it the coolant hose union onto
the front of the block and the joint pipe, or fit the
joint pipe into the water pump housing if it came
away with the union 1see illustration2. Tighten
the bolts to the tor,ue setting specified at the
beginning of the "hapter.
A8 'nstall the cylinder head .see 1ection 8?/.
*D #istons # removal, inspection
and installation
%ote) The pistons can be removed with the
engine in the !rame.
"emoval
8 (emove the cylinder block .see 1ection 8@/.
A *efore removing the piston from the
connecting rod, use a sharp scriber or felt
marker pen to write the cylinder identity on the
crown of each piston .or on the inside of the skirt
if the piston is dirty and going to be cleaned/ as it
must be installed in its original cylinder. $ach
piston should also have an arrow mark on its
crown which should face the e%haust side of the
bore .see illustration2. 'f this is not visible, mark
the piston accordingly so that it can be installed
the correct way round.
@ "arefully prise out the circlip on one side of the
piston using needle#nose pliers or a small
*D.6 %ote the arroB mar' on the "iston
Bhich must "oint forBar!s
Stane! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
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AYAC $ngine, clutch and transmission
*D.8a #rise out the circli" ...
*D.8b ... then "ush out the "in an!
remo,e the "iston
*D.0 Remo,in& the "iston rin&s usin& M
rin& remo,al an! installation tool
flat#bladed screwdriver inserted into the notch
1see illustration2. Push the piston pin out from
the other side to free the piston from the
connecting rod 1see illustration2. 'f re,uired,
remove the other circlip. 0iscard the removed
circlip.s/ as new ones must be used. -hen the
piston has been removed, install its pin back into
its bore so that related parts do not get mi%ed up.
1?><fl><f&&< To prevent the circlip !rom EE?/*
ping3ng a>ay& pass a rod or GlT screwdriver,
whose diameter
is greater than the gap between
the circlip ends, through the piston pin. +his
will trap the circlip if it springs out.
BBffiBflGl )! a piston pin is a tight !it in
l
SS
yaa

the piston bosses, soak a
GiT
rag in boiling water then , wnng N
out ancl wrgp n
around the piston ( this will e*pand the allo)
piston sufficientl) to release its grip on the
pin. &f the piston pin is particularl) stubborn,
e*tract it using a drawbolt tool, but be
careful to protect the piston1s working
surfaces.
&nspection
6 *efore the inspection process can be carried
out, the pistons must be cleaned and the old
piston rings removed. )ote that if the cylinders
are being rebored, piston inspection can be
overlooked as new ones will be fitted.
; +sing your thumbs or a piston ring removal
and installation tool, carefully remove the rings
from the pistons 1see illustration2. 0o not nick or
gouge the pistons in the process. "arefully note
which way up each ring fits and in which groove
as they must be installed in their original
positions if being re#used. The upper surface of
each ring has a manufacturer's mark or letter at
one end.
C 1crape all traces of carbon from the tops of
the pistons. A hand#held wire brush or a piece of
fine emery cloth can be used once most of
the deposits have been scraped away. 0o not,
under any circumstances, use a wire brush
mounted in a drill motor to remove deposits from
the pistons the piston material is soft and will be
eroded away by the wire brush.
B +se a piston ring groove cleaning tool to
remove any carbon deposits from the ring
grooves. 'f a tool is not available, a piece broken
off an old ring will do the job. *e very careful to
remove only the carbon deposits. 0o not remove
any metal and do not nick or gouge the sides of
the ring grooves.
> =nce the deposits have been removed, clean
the pistons with solvent and dry them thoroughly.
'f the identification previously marked on the
piston is cleaned off, be sure to re#mark it with
the correct identity. 5ake sure the oil return holes
below the oil ring groove are clear.
9 "arefully inspect each piston for cracks
around the skirt, at the pin bosses and at the ring
lands. )ormal piston wear appears as even,
vertical wear on the thrust surfaces of the piston
and slight looseness of the top ring in its groove.
'f the skirt is scored or scuffed, the engine may
have been suffering from overheating andDor
abnormal combustion, which caused e%cessively
high operating temperatures. The oil pump
should be checked thoroughly. Also check that
the circlip grooves are not damaged.
8? A hole in the piston crown, an e%treme to
be sure, is an indication that abnormal
combustion .pre#ignition/ was occurring. *urned
areas at the edge of the piston crown are usually
evidence of spark knock .detonation/. 'f any of
the above problems e%ist, the causes must be
corrected or the damage will occur again.
** 5easure the piston ring#to#groove clearance
by laying each piston ring in its groove and
slipping a feeler gauge in beside it 1see
illustration2. 5ake sure you have the correct ring
for the groove .see 1tep ;/. "heck the clearance
at three or four locations around the groove. 'f the
clearance is greater than specified, renew both
the piston and rings as a set. 'f new rings are
being used, measure the clearance using the
new rings. 'f the clearance is greater than that
specified, the piston is worn and must be
renewed.
*6 "heck the piston#to#bore clearance by
measuring the bore .see 1ection 8@/ and the
piston diameter. 5ake sure each piston is
matched to its correct cylinder. 5easure the
piston 6.; mm .8998 to 899; T05 models/, 6.B
mm .7TE models/, or ;.; mm .899C#on T05 and
all T(7 models/ up from the bottom of the skirt
and at 9?W to the piston pin a%is 1see
illustration2. 1ubtract the piston diameter from
the bore diameter to obtain the clearance. 'f it is
greater than the specified figure, the piston must
be renewed .assuming the bore itself is within
limits, otherwise a rebore is necessary/.
tone! by
Stal'er
*D.** easure the "iston rin&(to(&roo,e
clearance Bith a feeler &au&e
*D.*6 easure the "iston !iameter Bith a
micrometer at the s"ecifie! !istance from
the bottom of the s'irt
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line, clutch and transmission ALAB
1
!
A
t"
#
"
1
kl *D.*8a Sli" the "in 1A2 into the "iston 1/2
an! try to roc' it bac' an! forth. ?f it's
loose; reneB the "iston an! "in
*D.*8b easurin& the internal !iameter of
the bore in the "iston
*D.*5a Ali&n the "iston Bith the
connectin& ro! small(en! an! insert the
"in
*8 Apply clean engine oil to the piston pin,
insert it into the piston and check for any
freeplay between the two 1see illustration2.
5easure the pin e%ternal diameter 1see
illustration 68.5b2; and the pin bore in the
piston 1see illustration2. "alculate the
difference to obtain the piston pin#to#piston
pin bore clearance. "ompare the result to the
specifications at the beginning of the "hapter.
'f the clearance is greater than specified,
renew the components that are worn beyond
their specified limits.
&nstallation
86 'nspect and install the piston rings .see
1ection 8;/.
8; Fubricate the piston pin, the piston pin bore
and the connecting rod small#end bore with clean
engine oil.
8C-hen installing the pistons onto the
connecting rods, make sure that the arrow points
towards the e%haust side of the engine 1see
illustration *D.62. 'f both circlips were removed,
install a new circlip in one side of the piston .do
not re#use old circlips/. Fine up the piston on its
correct connecting rod, and insert the piston pin
from the other side 1see illustration2. 1ecure the
pin with the other new circlip. -hen installing the
circlips, compress them only just enough to fit
them in the piston, and make sure they are
properly seated in their grooves with the open
end
away from the removal notch 1see
illustration2.
*4 'nstall the cylinder block .see 1ection 8@/.
*0 #iston rin&s #
inspection and installation
* 't is good practice to renew the piston rings
when an engine is being overhauled. *efore
installing the new piston rings, the ring end gaps
must be checked with the rings installed in the
cylinder.
6 Fay out each piston with its new ring sets so
the rings will be matched with the same piston
and cylinder during the end gap measurement
procedure and engine assembly.
8To measure the installed ring end gap, insert
the top ring into the top of the first cylinder and
s,uare it up with the cylinder walls by pushing it
in with the top of the piston. The ring should be
about A? mm below the top edge of the cylinder.
To measure the end gap, slip a feeler gauge
between the ends of the ring and compare the
measurement to the specifications at the
beginning of the "hapter 1see illustration2.
D 'f the gap is larger or smaller than specified,
double check to make sure that you have the
correct rings before proceeding.
0'f the gap is too small, it must be enlarged or
the ring ends may come in contact with each
other during engine operation, which can cause
serious damage. The end gap can be increased
by filing the ring ends very carefully with a fine
file. -hen performing this operation, file only
from the outside in 1see illustration2.
5 $%cess end gap is not critical unless it
e%ceeds the service limit. Again, double#check to
make sure you have the correct rings for your
engine and check that the bore is not worn.
4 (epeat the procedure for each ring that will be
installed in the cylinders. -hen checking the oil
ring, only the side#rails can be checked as the
ends of the e%pander ring should contact each
other. (emember to keep the rings, pistons and
cylinders matched up.
8 =nce the ring end gaps have been
checkedDcorrected, the rings can be installed on
the pistons.
9 The oil control ring .lowest on the piston/ is
installed first. 't is composed of three separate
components, namely the e%pander and the upper
and lower side rails. 1lip the e%pander into the
groove, then install the upper side rail.
0o not use a piston ring installation tool on the A oil
ring side rails as they may be damaged. 'nstead, place
one end of the side rail into the groove between the
e%pander and the ring land. Hold it firmly in place and
slide a finger
*D.*5b Do not o,er(com"ress the circli" Bhen fittin& it into the "iston
*0.8 easurin& "iston rin& installe! en! &a"
*0.0 Rin& en! &a" can be enlar&e! by
clam"in& a file in a ,ice an! filin& the rin&
en!s
Stane! by Stal'er
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: =a@<iff<
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D
*0.9a ?nstall the oil rin& eC"an!er in its
&roo,e...
around the piston while pushing the rail into the
groove. )e%t, install the lower side rail in the
same manner 1see illustrations2. 5ake sure the
ends of the e%pander do not overlap.
*0 After the three oil ring components have
been installed, check to make sure that both the
upper and lower side rails can be turned
smoothly in the ring groove.
** The upper surface of each compression ring
is marked with a mark or letter at one end 1see
illustration2. 5ake sure that the identification
mark or letter near the end gap is facing up when
installed.
*6 4it the second ring into the middle groove in
the piston. 5ake sure the identification letter near
the end gap is facing up. 0o not e%pand the ring
any more than is necessary to slide it into place.
To avoid breaking the ring, use a piston ring
installation tool.
*8 4inally, install the top ring in the same
manner into the top groove in the piston. 5ake
sure the identification letter near the end gap is
facing up.
*D =nce the rings are correctly installed, check
they move freely without snagging and stagger
their end gaps as shown 1see illustration2.
*0.9b ... an! fit the si!e rails each si!e of it.
The oil rin& must be installe! by han!
*5 9lutch # removal, inspection
lfeN
and installation
%ote) The clutch can be removed with the
engine in the !rame. )! the engine has been
removed& ignore the steps which don't apply.
"emoval
* 0rain the engine oil .see "hapter 8/.
6 0etach the clutch cable from the operating
lever on the clutch cover .see 1ection 8B/.
8 -orking evenly in a criss#cross pattern,
unscrew the clutch cover bolts 1see illustration2.
Fift the cover away from the engine, being
prepared to catch any residual oil which may be
released as the cover is removed.
D (emove the gasket and discard it. )ote the
positions of the two locating dowels fitted to the
crankcase and remove them for safekeeping if
they are loose.
0 -orking in a criss#cross pattern, gradually
slacken the clutch pressure plate bolts
*0.** 9om"ression rin& to" surface is
mar'e! by a letter
/ 25 \
^$% /
25 \
& 25' J
%>
\
25
/
((\%
*0.*D Sta&&er the rin& en! &a"s as shoBn
# Top ring
2 (il ring lower rail
4 (il ring upper rail
5 +econd (middle) ring
until spring pressure is released 1see
illustration2. "ounter#hold the clutch housing to
prevent it turning. (emove the bolts and springs,
then lift out the clutch pressure plate complete
with its pull rod, thrust bearing and plate washer
1see illustrations *5.80b an! a2. 5 2rasp the
complete set of clutch plates and
*5.8 EnscreB the clutch co,er bolts 1arroBe!2 an! remo,e the co,er
*5.0 9lutch "ressure "late bolts 1arroBe!2
Scane! by Stal'er
$ngine, clutch and transmission A[A9
*5.5 Remo,e the clutch "lates as a "ac'
*5.4a /en! bac' the loc'Basher tabs
*5.4b Slac'enin& the clutch nut usin& the hol!in& tool !escribe!
lockwasher from the mainshaft, noting how it fits.
0iscard the lockwasher as a new one must be
used on installation.
8 (emove the clutch centre and the outer thrust
plate from the shaft 1see illustrations *5.65a
an! *5.602.
9 1upport the clutch housing and remove the
large sleeve from its centre 1see illustration2. To
get a grip on the sleeve, grasp the housing and
wiggle it out and in # it should draw the sleeve out
far enough to grip it. 'f difficulty is e%perienced,
screw a C mm bolt .a clutch cover bolt is the
correct si&e/ into one or both of the threaded
holes and pull the sleeve from the housing.
*0 (emove the caged needle roller bearing
from the housing if it didn't come away with
the sleeve, and then remove the housing
from the engine 1see illustrations *5. 6Da
an! *5.682.
** (emove the inner thrust plate 1see
illustration *5.66b2 and, Bith the
EEG>
TS#
WWI-
, clutch centre holding tool can easil) be made using two strips of steel with the ends
bent over, and bolted together in the middle
e%ception of 89>9 to 8998 7TE models, the
thrust washer from the shaft 1see illustration
*5.66a2.
*6 =n 89>9 7TE models, the clutch centre
anti#judder assembly can be left intact unless
the clutch has been chattering .juddering/
e%cessively. 'f it is necessary to remove it,
remove the wire retainer ring, plain plate, anti#
judder spring and spring seat.
&nspection
*8 After an e%tended period of service the
clutch friction plates will wear and promote
clutch slip. 5easure the thickness of each
friction plate using a vernier caliper .see
illustration2. 'f any plate has worn to or
beyond the service limit given in the
Stane! by Stal'er
remove them as a pack 1see illustration2.
+nless the plates are being renewed, keep them
in their original order. =n 8998 to 899; T05
models and 899?#on 7TE models, note the inner
plate fitted in the clutch centre # if you remove it,
keep it separate as it must be installed first 1see
illustration *5.642.
4 *end back the tabs on the clutch nut
lockwasher 1see illustration2. To remove the
clutch nut the transmission input shaft must be
locked. This can be done in several ways. 'f the
engine is in the frame, engage 8st gear and have
an assistant hold the rear brake on hard with the
rear tyre in firm contact with the ground.
Alternatively, the :amaha service tool .pt. no.
9?>9?#?6?>C/, or a similar homemade tool made
from two strips of steel bent at the ends and
bolted together in the middle .see Tool ti"2; can
be used to hold the clutch centre whilst the nut is
slackened 1see illustration2. +nscrew the nut
and remove the
>.0?% A##R.X.
.f 9-ET9G 9E%TRE S#-?%ES
*5.9 Remo,e the inner slee,e N
!escribe!
*5.*8 easurin& clutch friction "late
thic'ness
AL@? $ngine, clutch and transmission
*5.*D 9hec' the "lain "lates for Bar"a&e *5.*0 easure the free len&th of the
s"rin&s as shoBn
1pecifications at the beginning of the
"hapter, the friction plates must be renewed
as a set. Also, if any of the plates smell burnt
or are gla&ed, they must be renewed as a set.
*D The plain plates should not show any
signs of e%cess heating .bluing/. "heck for
warpage using a flat surface and feeler
gauges 1see illustration2. 'f any plate e%ceeds
the ma%imum permissible amount of
warpage, or shows signs of bluing, all plain
plates must be renewed as a set.
*0 5easure the free length of each clutch
spring using a vernier caliper 1see
illustration2. 'f any spring is below the service
limit specified, renew all the springs as a set.
*5 'nspect the clutch assembly for burrs and
# .-clip
2 >asher
4 (perating lever
5 (perating sha!t
8 /eturn spring
9 (il seal
: 6earings
; @inion
7 6olts
#
<
+prings
#
#
@ressure plate
#
2
>asher
#
4
Thrust bearing
#
5
@ullrod
B
;
Friction platesI
B
C
@lain plates'
#
:
'ut
B
>
Mock washer
B
9
>ire retainer ring -
#7;7 FTG
A
?
$nti-3udder spring -
#7;7 FTG
2
#
$nti-3udder spring seat -
#7;7 FTG
2
2
-lutch centre
2
4
(uter thrust plate
2
5
-lutch housing
2
8
-aged needle roller
bearing
2
9
+leeve
2
:
)nner thrust plate - FTG
2
;
)nner thrust plate-
T*E& T/F
2
7
Thrust washer -
T*E& T/F
're!er to clutch plate pack
guide table
*5.60 9lutch assembly
Scane! by Stal'er
$ngine, clutch and transmission A[@8
9lutch "late "ac' &ui!e
Eodel %o. of plates $rder of fitting to clutch centre
8998#9@ T05 > friction, > plain start with the special 'slick' plain plate, then alternate friction and plain plates until ending
with special friction plate which has a slot in one of its tabs.
8996#9; T05 > friction, > plain start with the special 'slick' plain plate, then alternate friction and plain plates.
899C#9> T05 and all T(7 9 friction, > plain start with friction plate, then alternate plates until ending with a friction plate.
8999 T05 9 friction, > plain start with a special friction plate .black/, then alternate plain and 5otion plates until
ending with a special friction plate .black/.
89>9 7TE > friction, > plain special plain plate fitted as part of anti#judder assembly, then alternate friction and plain
plates, until ending with special friction plate which has a slot in one of its tabs.
899?#96 7TE > friction, > plain start with the special 'slick' plain plate, then alternate friction and plain plates until ending
with special friction plate which has a slot in one of its tabs.
899; 7TE > friction, > plain start with the special 'slick' plain plate, then alternate friction and plain plates.
indentations on the edges of the protruding tangs
of the friction plates andDor slots in the edge of
the housing with which they engage. 1imilarly
check for wear between the inner tongues of the
plain plates and the slots in the clutch centre.
-ear of this nature will cause clutch drag and
slow disengagement during gear changes, since
the plates will snag when the pressure plate is
lifted. -ith care a small amount of wear can be
corrected by dressing with a fine file, but if this is
e%cessive the worn components should be
renewed.
*4 'nspect the sleeve and caged needle roller
bearing in conjunction with the clutch housing's
internal bearing surface. 'f there are any signs of
wear, pitting or other damage the affected parts
must be renewed.
*8 "heck the pressure plate, thrust bearing and
plate washer for signs of roughness, wear or
damage, and renew any parts as necessary.
*9 =n 89>9 7TE models, if removed, check the
clutch centre anti#judder assembly components
.consisting of the wire retainer ring, plain plate,
anti#judder spring and spring seat/ for wear or
damage, and renew any parts as necessary.
60 "heck the clutch operating mechanism in the
clutch cover for smooth operation. "heck the
pinion and pullrod teeth for signs of damage. 'f
necessary, prise off the $#clip securing the pinion
to the actuating shaft, and withdraw the shaft
from the cover 1see
illustration2. "heck the two needle roller
bearings for roughness, wear or damage. 'f they
need to be renewed, heat the cover in very hot
water to ease removal and drift them out. 'f the
shaft is removed, lever out the oil seal and renew
it. "lean all components and lubricate the seal
and bearings with grease.
&nstallation
A8 (emove all traces of old gasket from the
crankcase and clutch cover surfaces. =n 89>9
7TE models, if disassembled, reassemble the
clutch centre anti#judder assembly components,
fitting the spring seat, the anti#judder spring, the
plain plate and the wire retainer ring in that order.
66 =n all e%cept 89>9 to 8998 7TE models, fit
the thrust washer and the inner thrust plate onto
the shaft 1see illustrations2. =n 89>9 to 8998
7TE models, fit the inner thrust plate onto the
shaft with its shouldered side inwards.
68 Fubricate the needle roller bearing and
sleeve with clean engine oil. 'nstall the clutch
housing, without its needle roller bearing and
sleeve, and support it in position, making sure it
is engaged correctly with the primary drive gear
on the crankshaft 1see illustration2.
6D 'nstall the needle bearing and the sleeve into
the middle of the clutch housing 1see
illustrations2.
60 Fubricate the outer thrust plate with clean
*5.66b ... an! inner thrust "late onto the
shaft
*5.68 Sli!e the housin& into "lace so that it
en&a&es the "rimary !ri,e &ear...
*5.6Da ... then fit the nee!le bearin& ...
P'TY5U-
w
: (DDlifftDD. S I
T ' N
'P-H3P*
!Nr O , jit P5*P3
*5.6Db ... an! the slee,e into the mi!!le of
the housin&
Stane! by Stal'er
*5.66a Fit the thrust Basher.
+)($2'1T$($03'
AY@A $ngine, clutch and transmission
8C.A; 4it the outer thrust plate .
8C.ACa ... then slide the clutch centre 8C.ACb 'nstall the lockwasher, fitting the
onto the splines smaller bent tabs into the slots in the centre
8C.ACc 4it the nut.
8C.AB =n the stated models, fit the inner plate
8C.ACd ... and tighten it to the specified tor,ue, counter#holding the clutch centre
engine oil and fit it onto the shaft .see illustration/.
AC 'nstall the clutch centre onto the shaft splines, then install the new lockwasher, engaging its tabs with the slots .see illustrations/. 'nstall the clutch nut and, using the
method employed on dismantling to lock the input shaft, tighten the nut to the tor,ue setting specified at the beginning of the "hapter .see illustrations/. )oteG -heck that
the clutch centre rotates !reely a!ter tightening. *end up the tabs of the lockwasher to secure the nut .see illustration/.
AB =n 8998 to 899; T05 models and 899?#on 7TE models, fit the inner plain plate
8C.ACe *end up the lockwasher tabs to secure the nut
on the clutch centre # if it has become muddled with the rest, it is distinguishable by its slick surface .see illustration/. A> *uild up the clutch plates, starting with a friction
plate, then a plain plate and alternating friction and plain plates until all are installed .see illustrations/. "oat each plate with engine oil prior to installation. =n 8998 to 899@
T05 models and 89>9 to 8996 7TE models, make sure the friction plate with the slot in one of its tabs is fitted last, and align the slot with the embossed marks on the
outside of the clutch housing. )oteG /e!er to the table accompanying illustration #9.2< !or plate !itting details per model.
8C.A>a 1tart with a friction plate .
8C.A>b ... then fit a plain plate
+)($2'1T$($03'
1caned by 1talker
$ngine, clutch and transmission AL@@
*5.69 Fit the "ullro! assembly in the bac' of the "ressure "late
*5.80a ?nstall the "ressure "late; ali&nin& the "unch mar's 1arroBe!2...
69 Fubricate the thrust bearing and washer with
molybdenum disulphide oil .a ;?D;? mi%ture of
molybdenum disulphide grease and engine oil/.
'nstall the thrust bearing and plate washer onto
the pullrod, then install the pullrod assembly in
through the back of the clutch pressure plate
1see illustration2.
80 'nstall the pressure plate onto the clutch,
aligning the punch mark on the plate with that on
the clutch centre 1see illustration2. 'nstall the
springs and the bolts with their washers, and
tighten the bolts evenly in a criss#cross se,uence
to the specified tor,ue setting 1see illustration2.
"ounter#hold the clutch housing to prevent it
turning. "heck that the pullrod rotates freely.
8* 'f disassembled, install the clutch operating
mechanism in the clutch cover. Align the shaft so
that the operating lever is facing back but angled
out slightly.
86 'nsert the dowels in the crankcase, then set
the pullrod so that its teeth point towards the rear.
'nstall the clutch cover using a new
*5.80b ... then fit the s"rin&s; Bashers an!
bolts; an! ti&hten them as !escribe!
gasket and tighten its bolts evenly in a crisscross
se,uence to the specified tor,ue setting 1see
illustrations2. 88 Push the clutch operating lever
forward or in .according to model/ until all the
freeplay in the operating mechanism has been
taken up. At this point the mark on the lever
should align with the mark on the cover 1see
illustration2.
*5.86a Fit the &as'et onto the !oBels
1arroBe!2...
'f the marks do not align, remove the $#clip and
the lever, noting how the spring fits, and move
the lever around on the splines of the shaft until
they do. 5ake sure the spring is correctly set on
the lever and install the $#clip.
@6 'nstall the clutch cable onto the lever .see
1ection 8B/.
@; (efill the engine with oil .see "hapter 8/.
*5.86b ... then fit the co,er
*5.88 7ith the free"lay ta'en u" the mar's 1arroBe!2 shoul! ali&n ( TD shoBn
Scane! by Stal'er
AL@6 $ngine, clutch and transmission
*4.*a EnscreB the tBo bolts 1arroBe!2 an! !is"lace the ta"
8B "lutch cable#
removal and installation `Z
* =n T05 models, unscrew the two bolts securing the fuel tap and displace the tap 1see illustration2. )ow unscrew the two bolts securing the cable bracket to
the left#hand engine mounting bracket and detach the bracket, noting how the rear bolt also secures the idle speed adjuster 1see illustration2. *end back the
retaining tab securing the cable end in the clutch operating mechanism lever and disconnect the cable, noting how it
@
*4.*b EnscreB the tBo bolts 1A2 securin&
the cable brac'et; notin& the i!le s"ee!
a!<uster 1/2
fits 1see illustrations2.
6 =n T(7 and 7TE models, fully slacken the adjuster nuts on the threaded section in the cable bracket on the right#hand side of the engine and slip the adjuster
out of the bracket 1see illustration2. =n T(7 models, first remove the adjuster cover 1see illustration2. 0isconnect the cable end from the clutch operating
mechanism lever, noting how it fits 1see illustrations *4.*c an! !2.
8 =n all models fully slacken the lockring on the adjuster at the handlebar end of the cable then screw the adjuster fully in 1see illustration2. This resets it to the
beginning of its adjustment span.
D Align the slots in the adjuster and lockwheel
*4.*c /en! bac' the retainin& tab ..
with that in the lever bracket, then pull the outer cable end from the socket in the adjuster and release the inner cable from the lever 1see illustrations2. (emove
the cable from the machine, noting its routing and any guides or clips.
/Eflff/[! 6e!ore removing the cable
rfS>r<R
fr
L
m
C
he

bike
1
ta
2
e

tne

iomer
GllET end o! the new cable to the upper end of the old cable. Slowl) pull the lower end of the old cable out, guiding the new cable down into
position. 7sing this method will ensure the cable is routed correctl).
*4.id ... an! !etach the cable *4.6a Slac'en the nuts 1arroBe!2 an! sli" *4.6b .n TRX mo!els; first remo,e the
the cable out of the brac'et co,er
!"#$
1-)
-% & .'* 4(
1
I
*4.8 Slac'en the loc'rin& 1A2 an! threa! *4.Da Ali&n the slots an! sli" the cable out *4.Db ... an! the ni""le from the le,er
the a!<uster 1/2 in of the brac'et...
Scane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
line, clutch and transmission A[@;
*4.0 /en! the tab to secure the cable in the le,er
*8.6 The &ear shoul! rotate freely in the !irection shoBn
*8.D 9hec' the surface of the hub 1A2 an! the s"ra&s 1/2 as !escribe!
0 'nstallation is the reverse of removal. Apply
grease to the cable ends. 5ake sure the cable is
correctly routed. 1ecure the cable end in the
operating lever by bending the tab against it 1see
illustration2. Adjust the amount of clutch lever
freeplay .see "hapter 8/.
8> 1tarter clutch and UfeN
idleDreduction gear # removal, XO
inspection and installation @H
"emoval
8 (emove the alternator rotor .see "hapter
9/. The starter driven gear should come away
with the rotor. 'f it doesn't, remove it from the
crankshaft. The starter clutch is secured to
the back of the rotor by three Allen bolts on
the inside of the rotor.
&nspection
A 'nstall the starter driven gear into the starter
clutch .if removed/ and, with the rotor face down
on a workbench, check that the gear rotates
freely in an anti#clockwise direction and locks
against the rotor in a clockwise direction 1see
illustration2. 'f it doesn't, renew the starter clutch
# no replacement parts are available.
@ -ithdraw the starter driven gear from the
starter clutch 1see illustration *8.D2. 'f it appears
stuck, rotate it anti#clockwise as you withdraw it
to free it from the starter clutch. )ote the thrust
washer fitted inside the starter clutch and remove
it for safekeeping 1see illustration *8.42.
D "heck the bearing surface of the starter driven
gear hub and the condition of the sprags inside
the clutch body 1see illustration2. 'f the bearing
surface shows signs of e%cessive wear or the
sprags are damaged, marked or flattened at any
point, the starter clutch should be renewed.
0 $%amine the teeth of the starter idleDreduction
gear and the corresponding teeth of the starter
driven gear and starter motor shaft. (enew the
gears andDor starter motor if worn or chipped
teeth are discovered.
5 To renew the starter clutch sprag assembly,
hold the alternator rotor in a rotor holder then
undo the three bolts securing the clutch to the
rotor. (emove the clutch from the back of the
rotor and install the new one back onto the rotor.
Tighten the bolts to the tor,ue setting specified at
the beginning of the "hapter, using the rotor
holder to hold the rotor. Fubricate the starter
clutch sprags with new engine oil.
&nstallation
B 'nstall the thrust washer in the starter clutch
1see illustration2. Fubricate the hub of the
starter driven gear with clean engine oil, then
install it into the clutch, rotating it clockwise
as you do so to spread the rollers and allow
the hub of the gear to enter 1see illustration
*8.D2.
8 'nstall the alternator rotor .see "hapter 9/.
89 2earchange mechanism QJ
e%ternal components # removal, sX
inspection and installation H
%ote) The gearchange mechanism (eBternal
components) can be removed with the engine in
the !rame. )! the engine has been removed&
ignore the steps which don't apply.
"emoval
* 5ake sure the transmission is in neutral.
6 (emove the alternator cover .see "hapter 9/.
'f re,uired, disconnect the alternator and pick#up
coil wiring connectors, otherwise ignore those
1teps and lay the cover down so as not to strain
the wiring.
8 (emove the clutch .see 1ection 8C/.
D (emove the $#clip securing the left#hand end
of the gearchange shaft in the crankcase, and
slide the washer off the shaft 1see illustrations2.
0 )ote how the gearchange shaft centralising
spring ends fit on each side of the locating pin in
the casing, and how the pawls on the
*8.4 Do not omit the thrust Basher
*9.Da Remo,e the E(cli"...
*9.Db ... an! sli!e off the Basher
Stane! by Stal'er
A[@C $ngine, clutch and transmission
*9.0 DraB the &earchan&e shaft an! selector arm assembly off the
selector !rum an! out of the casin&
%ote hoB the roller locates in the neutral !etent 1arroB2;
then unscreB the bolt an! remo,e the sto""er arm
*9.5b ?f reAuire!; unscreB the bolts 1A2 an! remo,e the "late an! the s"rin& 1/2
*9.8 \earchan&e shaft centralisin& s"rin& can be remo,e! after releasin& circli" an! Basher from shaft
selector arm locate onto the pins on the end of
the selector drum 1see illustration *9.*62. 2rasp
the end of the shaft and withdraw the shaftDarm
assembly 1see illustration2.
5 )ote how the stopper arm spring ends
locate and how the roller on the arm locates in
the neutral detent on the selector drum
.gearbo% in neutral/, then unscrew the stopper
arm bolt and remove the arm, and on 899C#on
T05 models and all T(7 models, the spacer
1see illustration2. To remove the spring,
unscrew the two remaining bolts securing the
selector drum retainer plate and remove the
plate # the spring sits behind the plate 1see
illustration2.
&nspection
4 "heck the selector arm for cracks,
distortion and wear of its pawls, and check for
any corresponding wear on the selector pins
in the selector drum. Also check the stopper
arm roller and the detents in the selector drum
for any wear or damage, and make sure the
roller turns freely. (enew any components
that are worn or damaged.
> 'nspect the shaft centralising spring 1see
illustration2 and the stopper arm return spring
for fatigue, wear or damage renew them if
necessary. The centralising spring is retained on
the shaft by a circlip and washer # a new circlip
should be used if removed. The stopper arm
spring is secured by the retainer plate .see 1tep
C/. Also check that the centralising spring
locating pin in the crankcase is securely
tightened. 'f it is loose,
S"9tf> ?fI 7>
]2
Z
v
( it
Tm
=(S=y
:I
*9.9a 9hec' the shaft oil seal 1arroBe!2 *9.9b ?f reAuire!; le,er out the ol! seal...
Scane! by Stal'er
remove it and apply a non#permanent thread
locking compound to its threads, then tighten it
securely.
9 "heck the gearchange shaft for straightness
and damage to the splines. 'f the shaft is bent
you can attempt to straighten it, but if the splines
are damaged the shaft must be renewed. Also
check the condition of the shaft oil seal in the left#
hand side of the crankcase 1see illustration2. 'f it
is damaged,
$ngine, clutch and transmission AL@B
*9.9c ... an! "ress or !ri,e a neB one in
*9.*0a -ocate the sto""er arm s"rin& ...
*9.*0b ... then fit the retainer "late
j3
. . #_ w
^^^^^^^^ ! ^^^^^^^^^^^l^^^^^^^^^^^^^^
*9.**a A""ly threa! loc' to the bolt...
*9.** b ... then fit the sto""er arm into the
neutral !etent on the selector !rum an!
ma'e sure the s"rin& en!s locate correctly
*9.*6 The installe! assembly shoul! be as
shoBn
deteriorated or shows signs of leakage it must be
renewed. Fever out the old seal and drive the
new one s,uarely into place, with its lip facing
inward, using a seal driver or suitable socket 1see
illustrations2.
&nstallation
*0 'f removed, locate the stopper arm spring,
then install the selector drum retainer plate 1see
illustrations2. Apply a suitable non#permanent
thread locking compound to the two front bolts
and tighten them to the tor,ue setting specified at
the beginning of the "hapter 1see illustration
*9.5b2.
** Apply a suitable non#permanent thread
locking compound to the stopper arm bolt 1see
illustration2. 'nstall the stopper arm, and on
899C#on T05 models and all T(7 models, the
spacer, making sure the spring ends are
positioned correctly 1see illustration2. Focate the
arm onto the neutral detent on the selector drum,
then tighten the bolt to the specified tor,ue
setting 1see illustration *9.5a2.
*6 1lide the gearchange shaft into place and
push it all the way through the case until the
splined end comes out the other side 1see
illustration *9.02. Focate the selector arm pawls
onto the pins on the selector drum. 5ake sure the
centralising spring ends locate correctly on each
side of the locating pin 1see illustration2.
*8 1lide the washer onto the left#hand end of
the shaft, then fit the $#clip into its groove,
making sure it is secure 1see illustrations *9.Db
an! a2.
*D 'nstall the clutch .see 1ection 8C/.
*0 'nstall the alternator cover .see "hapter 9/.
"onnect the alternator and pick#up coil wiring
connectors, if disconnected.
60 .il "um"s # removal, H
inspection and installation a<
%ote) The oil pumps can be removed with the
engine in the !rame. )! the engine has been
removed& ignore the steps which don't apply.
"emoval
8 Two oil pumps are fitted, a feed pump to
60.8 EnscreB the tBo bolts 1arroBe!2 an!
!etach the "i"e
lubricate the engine and a scavenge pump to
return oil to the tank. As you look at the engine
from the right#hand side, the feed pump is the
left#hand pump and the scavenge pump is the
right#hand pump 1see illustration 60.52.
6 0rain the engine oil .see "hapter 8/. =n 7TE
models, remove the engine bashplate .see
"hapter >/ and the e%haust system .see "hapter
6/.
8 +nscrew the two bolts securing the oil pipe to
the oil pump cover on the right#hand side of
the engine 1see illustration2. 0etach the pipe A and
discard the =#ring as a new one must be used.
6 +nscrew the bolts securing the oil pump
cover and remove the cover, being prepared
to catch any residue oil 1see illustration2.
Stane! by Stal'er
60.D .il "um" co,er bolts 1arroBe!2
AL@> $ngine, clutch and transmission
60.0a Remo,e the circli".
60.0b ... an! sli!e off the &ear
60.5 Fee! "um" screBs 1A2; sca,en&e "um" screBs 1/2
60.4a Remo,e the screB 1arroBe!2.
0iscard the gasket as a new one must be used. (emove the dowels from either the cover or the crankcase if they are loose. Also note the oil passage collar
located in the orifice in the scavenge pump cover. 0iscard the =#ring as a new one must be used, and remove the collar if re,uired 1see illustration 60.*82.
0 (emove the circlip securing the oil pump driven gear to the feed pump shaft and remove the gear 1see illustrations2. 0iscard the circlip as a new one should be
used. 0o the same to free the driven gear from the scavenge pump.
60.4b ... an! se"arate the housin&
5 $ach pump is secured by three screws 1see
illustration2. (emove the screws and remove
the pump, noting how it fits. 0iscard the
gasket as a new one must be used. )ote the
dowel locating the scavenge pump and
remove it if it is loose.
&nspection
B 'f re,uired, the pumps can be disassembled
for cleaning. (emove the single assembly screw
and separate the pump housing, on the feed
pump noting how the cam chain guide fits 1see
illustrations2. (emove the housing locating pins
if they are loose. 0raw the inner rotor with the
60.4c DraB out the shaft an! remo,e the rotors
driveshaft out of the pump housing, then remove the outer rotor 1see illustration2. )ote which way round the rotors fit and how the driveshaft pin locates in the
slots in the inner rotor.
8 "lean all the components in solvent 1see illustration2.
9 'nspect the pump body and rotors for scoring and wear 1see illustration2. 'f any damage, scoring or uneven or e%cessive wear is evident, renew the pump
.individual components are not available/.
8? 4it the outer rotor into the pump body. 4it
the drive pin into the shaft, then slide the shaft
into the inner rotor, locating the drive pin ends
60.8 .il "um" com"onents
# ,ousing 2 (uter rotor 4 )nner rotor 5 +ha!t 8 *rive pin
60.9 -oo' for scorin& an! Bear; such as on this outer rotor
Scane! by Stal'er
$ngine, clutch and transmission AY@9
60.*0a Assemble! oil "um"
in the slots in the rotor, then fit the inner rotor into
the outer rotor 1see illustration2. 5easure the
clearance between the inner rotor tip and the
outer rotor with a feeler gauge and compare it to
the ma%imum clearance listed in the
specifications at the beginning of the "hapter
1see illustration2. 'f the clearance measured is
greater than the ma%imum listed, renew the
pump.
88 5easure the clearance between the outer
rotor and the pump body with a feeler gauge and
compare it to the ma%imum clearance listed in
the specifications at the beginning of the "hapter
1see illustration2. 'f the clearance measured is
greater than the ma%imum listed, renew the
pump.
8A =n 899C#on T05 models and all T(7
models, lay a straight#edge across the rotors and
60.*0b easurin& inner rotor ti"(to(outer
rotor ti" clearance
the pump body and, using a feeler gauge,
measure the rotor end#float .the gap between the
rotors and the straight#edge 1see illustration2. 'f
the clearance measured is greater than the
ma%imum listed, renew the pump. )o
specifications are given for other models.
8@ "heck the nylon pump driven gears for wear
or damage, and renew them if necessary.
0amage to the steel drive gear is unlikely, but if
found will necessitate crankshaft renewal.
86 'f the pump is good, make sure all the
components are clean, then lubricate them with
new engine oil. Assemble the housing, making
sure the pins locate correctly, and tighten the
assembly screw to the tor,ue setting specified at
the beginning of the "hapter, not forgetting the
cam chain guide on
60.** easurin& outer rotor(to(bo!y
clearance
the feed pump 1see illustration 60.4b an! a2.
*0 (otate the pump shaft by hand and check
that the rotors turn smoothly and freely. 'f not,
renew the pump.
&nstallation
*5 'nstall the pump using a new gasket, not
forgetting the locating dowel for the scavenge
pump, if removed, and tighten the screws to the
tor,ue setting specified at the beginning of the
"hapter 1see illustrations2.
*4 Focate the pump driven gear onto its shaft,
aligning the flat in the gear with that on the shaft,
and secure it using a new circlip 1see
illustrations 60.0b an! a2. Align the open end of
the circlip with the flat on the shaft 1see
illustration2.
*8 'f removed, install the oil passage collar
60.*6 easurin& rotor en!(float
60.*5a Fit the &as'et; on the sca,en&e
"um" locatin& it onto the !oBel 1arroBe!2
60.*5b ?nstall the "um" ...
60.*5c ... an! ti&hten its screBs to the s"ecifie! torAue
60.*4 Ali&n the o"en en!s of the circli"s Bith the flats on the shafts
Starte! by Stal'er
6ID0 En&ine; clutch an! transmission
60.*8 Fit a neB .(rin& aroun! the collar 60.*9a a'e sure the &as'et fits onto the
!oBels 1arroBe!2...
60.*9b ... then install the co,er
60.60a Ese a neB .(rin& on the oil "i"e
union...
60.60b
.. an! ti&hten its bolts to the
s"ecifie! torAue
into the orifice in the scavenge pump, then fit
a new =#ring 1see illustration2.
*9 'f removed, fit the oil pump cover dowels
into the crankcase, then install the cover
using a new gasket, making sure it locates
correctly onto the dowels 1see illustration2.
Tighten the cover bolts evenly in a criss#cross
se,uence to the specified tor,ue setting 1see
illustration2.
60 4it the oil pipe onto the cover using a new
=#ring and tighten the bolts to the specified
tor,ue setting 1see illustrations2.
6* =n 7TE models, install the e%haust
system .see "hapter 6/ and the engine
bashplate .see "hapter >/.
66 4ill the engine with the specified ,uantity
and type of new engine oil .see "hapter 8/.
6*.0 .il tan' 1*995(on TD an! all TRX mo!els2
6* .il tan' # removal and
installation .899C#on T05
models and all T(7 models/
%ote) To remove the oil tank& the engine must be
removed !rom the !rame.
"emoval
* (emove the engine from the frame .see
1ection ;/.
6 +nscrew the banjo bolts securing the oil pipe
to the left#hand side of the oil tank and to the
cylinder head, and the pipe bracket bolt, and
remove the pipe. 0iscard the banjo bolt sealing
washers as new ones must be used.
8 +nscrew the two bolts securing the oil pipe to
the right#hand side of the oil tank and detach the
pipe. 0iscard the =#ring as a new one must be
used.
D 1lacken the clamp securing the oil pipe .from
the rear of the oil tank/ in the oil hose and detach
the pipe from the hose. +nscrew the two bolts
securing the pipe to the oil tank and withdraw the
pipe. 0iscard the =#ring as a new one must be
used.
0 +nscrew the bolts securing the top of the oil
tank, noting which fits where as they are of
different lengths, and noting the clip secured by
the bolt on the right#hand side 1see illustration2.
Fift off the top of the tank, being prepared to
catch any residue oil. 0iscard the gasket as a
new one must be used. )ote the
Scane! by Stal'er
# (il tank top cover
2 0asket Top cover bolts
-#5 o!! Top cover dowel
-2 o!! 6ase 0asket
6ase dowels -2 o!! 6ase
bolts -: o!!
+)($2'1T$($0 3'
$ngine, clutch and transmission AL68
66.8 EnscreB the bolts 1arroBe!2 an! remo,e the sum"
66.Da Remo,e the screBs 1arroBe!2.
positions of the two dowels and remove them
if they are loose.
C +nscrew the bolts securing the base of the
oil tank to the crankcase and lift off the base.
0iscard the gasket as a new one must be
used. )ote the positions of the two dowels
and remove them if they are loose.
&nstallation
B 'nstallation is the reverse of removal, noting
the following pointsG
a) -lean the oil tank in solvent and dry it
using compressed air& i! available.
b) Eake sure the dowels are correctly
located.
c) Cse new gaskets.
d) Tighten the oil tank base and top bolts to
the torAue setting speci!ied at the
beginning o! the -hapter.
e) Cse new sealing washers on each side o!
the oil pipe ban3o unions and tighten the
ban3o bolts to the speci!ied torAue
setting.
!)Cse new (-rings on the oil pipe unions and
tighten the bolts to the speci!ied torAue
setting.
66 .il sum"; oil strainer an! =
"ressure relief ,al,e#removal, JQ
inspection and installation H
%ote) The oil sump& strainer and pressure
relie! valve can be removed with the engine in
the !rame. )! the engine has been removed&
ignore the steps which don't apply.
"emoval
8 =n 8998 to 899; T05 models and 7TE
models, remove the engine bashplate .see
"hapter >/. =n T05 and T(7 models remove
the e%haust system .see "hapter 6/.
A 0rain the engine oil and remove the oil filter
.see "hapter 8/.
@ +nscrew the sump bolts, slackening them
evenly in a criss#cross se,uence to prevent
distortion, and remove the sump 1see
illustration2. 0iscard the gasket as a new one
must be used. )ote the positions of the
dowels and remove them if they are loose.
6 (emove the screws securing the oil strainer
cover and remove the cover and the strainer
1see illustrations2.
; (emove the bolt securing the pressure
relief valve holder and remove the holder 1see
illustration2. -ithdraw the valve and discard
the =#ring as a new one must be used.
&nspection
C (emove all traces of gasket from the sump
and crankcase mating surfaces, and clean the
inside of the sump with solvent.
B "lean the oil strainer in solvent and remove
any debris caught in its mesh. 'nspect the
strainer for any signs of wear or damage and
renew it if necessary.
> Push the relief valve plunger into the valve
body and check that it moves smoothly and
freely against the spring pressure. 'f not,
renew the relief valve # individual components
are not available. 1imilarly check that the
bypass valve ball can be pushed into its bore
and is not stuck 1see illustration 66.S2. Also
check that the oil no&&le is securely screwed
into its bore and has not worked loose.
9 (enew the =#rings around the oil passage
collars in the crankcase 1see illustration2.
)ote their different si&es.
66.Dc ... an! the strainer 66.0 #ressure relief ,al,e 1A2; by"ass ,al,e
1/2; oil noRRle 192
66.9 The .(rin&s 1arroBe!2 shoul! be
reneBe!
Starte! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
+)($2'1T$($03'
AL6A $ngine, clutch and transmission
66.*6 Fit the neB &as'et; ma'in& sure the
!oBels 1arroBe!2 are in "lace ...
&nstallation
*0 4it a new =#ring onto the relief valve and
smear it with clean oil, then push the valve into
its socket in the crankcase. 4it the holder, then
apply a suitable non#permanent thread locking
compound to the bolt and tighten it to the tor,ue
setting specified at the beginning of the "hapter
1see illustration 66.02.
** 'nstall the oil strainer and its cover 1see
illustrations 66.Dc; b an! a2. Apply a suitable
non#permanent thread locking compound to the
cover screws and tighten them to the tor,ue
setting specified at the beginning of the "hapter.
*6 'f removed, fit the sump dowels into the
crankcase. Fay a new gasket onto the sump .if
the engine is in the frame/ or onto the
68.8 Remo,e the screBs 1arroBe!2 an! lift off
the co,er
66.*8 ... then fit the sum"
crankcase .if the engine has been removed and
is positioned upside down on the work surface/
1see illustration2. 5ake sure the holes in the
gasket align correctly with the bolt holes.
*8 Position the sump onto the crankcase, then
apply a suitable non#permanent thread locking
compound to the bolts and install them finger#
tight 1see illustration2. Tighten the bolts evenly
in a criss#cross pattern to the specified tor,ue
setting.
*D 'nstall the oil filter and cover and fill the
engine with the correct type and ,uantity of oil
.see "hapter 8/.
*0 =n T05 and T(7 models install the e%haust
system .see "hapter 6/. =n 8998 to 899; T05
models and 7TE models, install the
68.Da EnscreB the ban<o bolts 1A2 an! the
brac'et bolt 1/2 an! remo,e the "i"e
engine bashplate .see "hapter >/. 1tart the
engine and check that there are no oil leaks
around the sump and oil filter cover.
A@ *alancer shafts # removal,
inspection and installation
%ote) (n #77# to #778 T*E models and FTG
models& the balancer sha!ts can be removed with
the engine in the !rame. )! the engine has been
removed& ignore the steps which do not apply. (n
#779-on T*E models and all T/F models& the
engine must be removed !rom the !rame.
"emoval
* =n 8998 to 899; T05 models and 7TE
models, remove the seat, side covers and engine
bashplate .see "hapter >/, the fuel tank and
e%haust system .see "hapter 6/, the starter
clutch and idleDreduction gear .see 1ection 8>/,
and the oil sump .see 1ection AA/.
6 =n 899C#on T05 models and T(7 models,
remove the oil tank .see 1ection A8/, the starter
clutch and idleDreduction gear .see 1ection 8>/,
and the oil sump .see 1ection AA/.
8 =n 899A to 899; T05 models, unscrew the
bolts securing the mudflapDengine top cover and
remove the cover, feeding the earth cable
through as you do 1see illustration2.
D =n 8998 to 899; T05 models and 7TE
models, unscrew the oil pipe banjo bolts and the
bracket bolt securing the oil pipe to the cylinder
head and the crankcase top cover and remove
the pipe 1see illustration2. 0iscard the sealing
washers as new ones must be used. -orking
evenly in a criss#cross pattern, unscrew the bolts
securing the cover to the top of the crankcase
and remove the cover 1see illustration2. )ote
the position of the earth cable and cable guide.s/
and of the bolt with the copper sealing washer.
0iscard the gasket as a new one must be used.
)ote the positions of the dowels and remove
them if they are loose.
0 +nscrew the bolts securing the oil strainer
holder and remove the holder 1see illustration2.
(emove the =#ring from the oil passage collar in
the crankcase 1see illustration2N a new =#ring is
re,uired for reassembly.
68.Db EnscreB the bolts 1arroBe!2 an! remo,e the co,er; notin& the earth cable 1A2; cable &ui!e 1/2 an! co""er Basher 192
?
68.0a EnscreB the bolts 1arroBe!2 an! remo,e the hol!er
68.0b The .(rin& 1arroBe!2 shoul! be reneBe!
Stane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
+)($2'1T$($03$(1'=) =4 P'
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
$ngine, clutch and transmission A[6@
68.5 Each retainer "late is secure! by a TorC
screB 1arroBe!2
i
*+
,
if ^
^-^
m ./^/
68.4a EnscreB the bolts 1arroBe!2 an!
remo,e the hol!er...
68.4b
... then Bith!raB the shaft an!
lift out the rear Bei&ht
5 +nscrew the Tor% bolt securing each balancer
shaft retainer plate and remove the plates, noting
how they fit 1see illustration2.
4 +nscrew the bolts securing the rear balancer
shaft holder and remove the holder 1see
illustration2. (emove the dowels if they are
loose. 1upport the rear balancer shaft weight,
then withdraw the shaft from the left#hand side of
the crankcase and lift the weight out of the top
1see illustration2. 0iscard the shaft =#ring as a
new one must be used. <eep the weight and
shaft together as a matched pair, and do not
confuse them with the front weight and shaft.
8 +nscrew the bolts securing the front balancer
shaft holder and remove the holder 1see
illustration2. (emove the dowels if they are
loose. 1upport the front balancer shaft weight,
then withdraw the shaft from the left#hand side of
the crankcase and remove the weight from the
bottom 1see illustration2.
&nspection
9 "heck the weights for cracked, chipped
and worn teeth on the driven gears and renew
the weight if any are found. The drive gears on
the crankshaft should also be checked. "heck
the condition of the needle bearings in the
bore of the weight. 'f they are worn, the weight
must be renewed as the bearings are not
listed as being available separately, though it
is worth checking with a :amaha dealer or
bearing specialist.
8? "heck the shafts are straight by rolling
them on a flat surface such as a piece of
glass. Also check the bearing surfaces for
scuffing and wear.
&nstallation
** Turn the crankshaft until the -oodruff key
slot .for the alternator rotor/ on the left#hand
end aligns with the triangular mark on the
crankcase 1see illustration2. The best way to
turn the engine with the alternator rotor
removed is to engage a gear and use the front
sprocket nut. 'f the engine is still in the frame,
the rear wheel can be used. Turn the sprocket
in an anti#clockwise direction only and
remove the spark plugs .see "hapter 8/ to
release the compression in the engine,
68.8a EnscreB the bolts 1arroBe!2 an!
remo,e the hol!er...
making it much easier to turn and to prevent the
nut from undoing.
*6Apply clean engine oil to the front balancer
shaft. Position the front balancer weight in the
engine, aligning the punch mark on the larger
gear with the mark on the crankcase, then slide
the shaft in from the left#hand side until it is fully
home 1see illustration an! 68.8b2. "heck that
the marks on both the crankshaft and the
balancer shaft are still correctly aligned. 'f
removed, fit the balancer holder dowels, then
install the holder and tighten its bolts to the
tor,ue setting specified at the beginning of the
"hapter 1see illustration2.
*8 4it a new =#ring onto the rear balancer shaft
and smear it with lithium#based grease
68.8b ... then Bith!raB the shaft an! lift out
the front Bei&ht
68.** Ali&n the 7oo!ruff 'ey slot 1A2 Bith the trian&ular mar' 1/2
68.*6a Ali&n the "unch mar' on the &ear 1A2 Bith the mar' on the cran'case 1/2
68.*6b Fit the hol!er onto the !oBels
+)($2'1T$($0 3'
Stane! by Stal'er
+)($2'1T$($0 3'
AL66 $ngine, clutch and transmission
68.*8a Fit a neB .(rin& into the narroB
&roo,e
*
'Jft TsI
*
'
68.*8b Ali&n the "unch mar' on the &ear 1A2
Bith the mar' on the cran'case 1/2
68.*8c Fit the hol!er onto the !oBels
1see illustration2. Apply clean engine oil to the
shaft. Position the rear balancer weight in the
engine, aligning the punch mark on the larger
gear with the mark on the crankcase, then slide
the shaft in from the left#hand side until it is fully
home 1see illustration an! 68.4b2. "heck that
the marks on both the crankshaft and the
balancer shaft are still correctly aligned. 'f
removed, fit the balancer holder dowels, then
install the holder and tighten its bolts to the
tor,ue setting specified at the beginning of the
"hapter 1see illustration2. *D 4it the shaft
retainer plates with the
counter#sink for the screw heads on the outside,
then apply a suitable non#permanent thread
locking compound to the Tor% screw threads and
tighten them to the specified tor,ue setting 1see
illustration2.
*0 4it a new =#ring around the oil passage
collar 1see illustration 68.0b2; then fit the oil
strainer holder 1see illustration2. Apply a
suitable non#permanent thread locking
compound to the holder bolts and tighten them to
the specified tor,ue setting.
*5 =n 8998 to 899; T05 models and 7TE
models, if removed, install the crankcase top
cover dowels. 4it the cover using a new
gasket, then tighten the bolts evenly in a criss#
cross pattern to the specified tor,ue, not
forgetting the earth cable and cable guide.s/ and
making sure the bolt with the copper washer is
positioned at the rear on the right#hand side 1see
illustrations2. 'nstall the oil pipe using new
sealing washers on each side of the unions and
tighten the banjo bolts and the bracket bolt to the
specified tor,ue settings 1see illustration2.
*4 'nstall all remaining components or
assemblies in a reverse of the removal procedure
.see 1teps @, A and 8/.
68.*D Fit each retainer "late into its slot in the shaft en!
68.*0 ?nstall the strainer hol!er
68.*5a Fit the neB &as'et onto the !oBels 68.*5b ... then install the co,er
1arroBe!2...
ti^ff^M
0#&#/ >-.1
.
A
#1 1
2
1..-*/
68.*5c Ese neB sealin& Bashers on each si!e
of the union
Stane! by Stal'er
$ngine, clutch and transmission AL6;
6D.6 DraB the cam chain out of the en&ine
A6 "am chain and guides #
removal, inspection and installation
"emoval
9am chain
* (emove the valve cover .see 1ection B/, the cam chain tensioner .see 1ection 9/, the cam chain top guide and the camshaft sprockets .see 1ection >/, and the
oil pumps .see 1ection A?/.
6 4eed the cam chain down through the tunnel and draw it out of the oil pump housing 1see illustration2.
9hain &ui!es
8 The cam chain top guide can be unbolted from the cylinder head after the valve cover has been removed .see 1ection B/ 1see illustration >.6/.
D The cam chain front guide can be lifted from the cylinder head after the cam chain tensioner .see 1ection 9/ and the e%haust camshaft sprocket have been
removed .see 1ection >/ 1see illustrations2. )ote which way up and round the guide fits and how it locates.
0 The cam chain rear guide is secured by a pivot pin, which is located behind one of the C mm crankcase bolts. (emove the cam chain tensioner .see 1ection 9/,
the inlet camshaft sprocket .see 1ection >/ and the oil pump
6D.Da %ote hoB the front &ui!e locates in the cylin!er hea! 1arroB2...
cover .see 1ection A?/. +nscrew the bolt 1see illustration2. As the pivot pin is set deep, its centre is threaded to accept a ; mm bolt. Thread the bolt into the pin,
then draw out the bolt with the pin attached and lift the guide out of the top of the tunnel 1see illustrations2.
&nspection
9am chain
5 "heck the chain for binding, kinks and any
obvious damage and renew it if necessary.
"heck the camshaft sprocket teeth for wear
and renew the cam chain and sprockets as a
set if necessary .see "hapter >/.
9hain &ui!es
4 "heck the guides for e%cessive wear, deep
grooves, cracking and other obvious damage,
and renew them if necessary. "heck the
condition of the pivot hardware on the rear
guide and renew any components that are
damaged or deteriorated.
&nstallation
> 'nstallation of the chain and guides is the
reverse of removal, noting the followingG
a) $pply engine oil to the !aces o! the guides& to the rear guide pivot pin& and to the chain.
b) Cse a piece o! bent wire to hook up the cam chain and draw it up the tunnel.
c3 Tighten the 9 mm crankcase bolt !or the rear guide to the torAue setting speci!ied at the beginning o! the -hapter.
6D.Db ... an! lift it out
A; "rankcase halves #
separation and reassembly
%ote) To separate the crankcase halves& the engine must be removed !rom the !rame.
Separation
* To access the connecting rods, crankshaft, bearings, transmission shafts and the selector drum and forks, the crankcase must be split into two parts.
6 To enable the crankcases to be separated, the engine must be removed from the frame .see 1ection ;/. *efore the crankcases can be separated the following
components must be removedG
a) 1alve cover (+ection :).
b) -ylinder head (+ection #<).
c)-ylinder block (+ection #4).
d) @istons (+ection #5).
e) -lutch (+ection #9).
a) +tarter clutch and idle/reduction gear (+ection #;).
b) 0earchange mechanism eBternal components (+ection #7).
h) (il pumps (+ection 2<).
i) -am chain and guides (+ection 25).
3) (il tank (#779-on T*E models and all
T/F models) (+ection 2#). k) (il sump (+ection 22). )) 6alancer sha!ts (+ection 24). m) >ater pump (-hapter 4). n) +tarter motor (i! reAuired) (-hapter 7).
6
6D.0a EnscreB the cran'case bolt 1arroBe!2...
6D.0b ... then threa! a 0 mm bolt into the hea! of the "i,ot "in ...
.. then Bith!raB the "in an! lift out the &ui!e
Stane! by Stal'er
AL6C $ngine, clutch and transmission
60.8 EnscreB the bolts 1arroBe!2 an!
remo,e the "late
@ +nscrew the bolts securing the transmission
output shaft retainer plate to the left#hand side of
the crankcase and remove the plate 1see
illustration2.
6 +nscrew the C mm and > mm upper
crankcase bolts 1see illustrations2. +nscrew the
bolts evenly, a little at a time in a reverse of the
numerical se,uence until they are finger#tight,
then remove them. The number of each bolt is
cast into the crankcase. )ote the copper washers
fitted with some of the bolts. %ote) $s each bolt
is removed& store it in its relative position& with its
washer where applicable& in a cardboard
template o! the crankcase halves. This will
ensure all bolts are installed in the correct
location on reassembly.
; Turn the engine upside down so that it rests on
the cylinder head studs.
C+nscrew the C mm lower crankcase bolts, the
> mm bolts, and the 8? mm bolts 1see
illustrations 60.Da an! b2. +nscrew the bolts
evenly, a little at a time in a reverse of the
numerical se,uence until they are finger#tight,
then remove them. The number of each bolt is
cast into the crankcase. )ote the copper washers
fitted with some of the bolts, and also the cable
guide. %ote) $s each bolt is removed& store it in
its relative position& with its washer and cable
guide where applicable& in a cardboard template
o! the crankcase halves. This will ensure all bolts
are installed in the correct location on
reassembly.
Fower +pper
)& 2& 4& 5& 8& 9
# #< mm bolts
:& ;& 7& #<& #4& #8&
2#& 22& 24& 25& 28
# ; mm bolts
))& #2& #5& #9& #:&
#;& #7& 2<& 29& 2:
# 9 mm bolts
60.Da 9ran'case bolts ( *99* to *990 TD mo!els an! XT3 mo!els
Fower +pper
#& 2& 4& 5& 8& 9 4^^^^^^^
-#< mm bolts
:& ;& 7& #<& #4& #8& 2<&
2#& 22& 24& 25& 28& 29& 2:
# ; mm bolts 0((((((((((((
D(((((((((((
* ##& #2& #5& #9& #:&
#;&#7& A>, A9 *6((((((((((
# 9 mm bolts
*D((((((((((
S
*5 6* 60 *4 *9 66 *0
60.Db 9ran'case bolts ( *995(on TD mo!els an! TRX mo!els
Scane! by Stal'er
60 *4 *9 *0
65 6D 60
*8(
$ngine, clutch and transmission AL6B
60.8 Remo,e the !oBel 1arroBe!2 if it is loose
60.** Ese a neB out"ut shaft oil seal if reAuire!
4 "arefully lift the lower crankcase half off the
upper half, using a soft#faced hammer to tap
around the joint to initially separate the halves if
necessary 1see illustration 60.*02. %ote) )! the
halves do not separate easily& make sure all
!asteners have been removed. *o not try and
separate the halves by levering against the
crankcase mating sur!aces as they are easily
scored and will leak oil. Tap around the 3oint
!aces with a so!t-!aced mallet.
8 (emove the locating dowel from the crankcase
if it is loose .it could be in either crankcase half/
1see illustration2.
9 (efer to 1ections AC to @A for the removal and
installation of the components housed within the
crankcases.
"eassembl)
8? (emove all traces of sealant from the
crankcase mating surfaces.
88 $nsure that all components and their
bearings are in place in the upper and lower
crankcase halves. 'f the transmission shafts have
not been removed, check the condition of the
output shaft oil seal on the left#hand
end of the shaft and renew it if it is damaged or
deteriorated 1see illustration2.
*6 2enerously lubricate the crankshaft and
transmission shafts, particularly around the
bearings, with clean engine oil, then use a rag
soaked in high flash#point solvent to wipe over
the mating surfaces of both crankcase halves to
remove all traces of oil.
*8 'f removed, install the locating dowel in the
upper crankcase half 1see illustration 60.82.
*D Apply a small amount of suitable sealant
.such as :amaha *ond 8A8;/ to the outer mating
surface of one crankcase half 1see illustration2.
Caution: Do not appl) an e*cessive amount
of sealant as it will oo9e out when the case
halves are assembled and ma) obstruct oil
passages. Do not appl) the sealant on or too
close 3within F to I mm4 to an) of the bearing
inserts or surfaces.
*0 "heck again that all components are in
position, particularly that the bearing shells
are still correctly located in the lower
crankcase half. "arefully install the lower
crankcase half down onto the upper
crankcase half, making sure the dowel locates
correctly into the lower crankcase half 1see
illustration2.
*5 "heck that the lower crankcase half is
correctly seated. %ote) The crankcase halves
should !it together without being !orced. )! the
casings are not correctly seated& remove the
lower crankcase hal! and investigate the
problem. *o not attempt to pull them together
using the crankcase bolts as the casing will crack
and be ruined.
*4 "lean the threads of the 8? mm lower
crankcase bolts and apply molybdenum
disulphide oil .a ;?D;? mi%ture of molybdenum
disulphide grease and new engine oil/ to their
threads. 'nsert them with their washers in their
original locations. "lean the threads of the > mm
and C mm lower crankcase bolts and apply new
engine oil to their threads. 'nsert them .with their
washers where fitted, and not forgetting the cable
guide/ in their original locations. 1ecure all bolts
finger#tight at first, then tighten them evenly and
a little at a time in the correct numerical
se,uence to the tor,ue settings specified at the
beginning of the "hapter 1see illustrations
60.Da or b2.
bsLc####'jP
60.*D A""ly the sealant to the sha!e! areas 60.*0 Fit the loBer half onto the u""er half; ma'in& sure it locates
onto the !oBel 1arroBe!2
Scane! by Stal'er
l$$$0`
' &. )$*a*+,.:^-
A[6> $ngine, clutch and transmission
A;.A? 'nstall the retainer plate
8> Turn the engine over. "lean the threads of
the > and C mm upper crankcase bolts and apply
new engine oil to their threads. 'nsert them .with
their washers where fitted/ in their original
locations. 1ecure all bolts finger#tight at first, then
tighten them evenly and a little at a time in the
correct numerical se,uence to the tor,ue settings
specified at the beginning of the "hapter .see
illustrations A;.6a or b/.
89 -ith all crankcase fasteners tightened,
check that the crankshaft and transmission
shafts rotate smoothly and easily. "heck that the
transmission shafts rotate freely and
independently in neutral, then rotate the selector
drum by hand and select each gear in turn whilst
rotating the input shaft. "heck that all gears can
be selected and that the shafts rotate freely in
every gear. 'f there are any signs of undue
stiffness, tight or rough spots, or of any other
problem, the fault must be rectified before
proceeding further.
A? 'nstall the transmission output shaft retainer
plate onto the left#hand side of the crankcase
.see illustration/. Apply a suitable non#permanent
thread locking compound to the threads of the
bolts and tighten them to the specified tor,ue
setting.
A8 'nstall all other removed assemblies in the
reverse of the se,uence given in 1tep A.
AC "rankcase halves #
inspection and servicing
8 After the crankcases have been separated,
remove the crankshaft, connecting rods,
transmission shafts, selector drum and forks,
water pump drive gear, and neutral switch,
referring to the relevant 1ections of this "hapter,
and to "hapter @ for the water pump and "hapter
9 for the neutral switch. Also remove the oil
passage collars and their =#rings .see illustration
AA.9/. 0iscard the =#rings as new ones must be
used.
A The crankcases should be cleaned thoroughly
with new solvent and dried with compressed air.
All oil passages should be blown out with
compressed air. Also check that the oil no&&les
are securely screwed into their bores and have
not worked loose.
@ All traces of old gasket sealant should be
removed from the mating surfaces. 5inor
damage to the surfaces can be cleaned up with a
fine sharpening stone or grindstone. -aution= 6e
very care!ul not to nick or gouge the crankcase
mating sur!aces or oil leaks will result. -heck
both crankcase halves very care!ully !or cracks
and other damage.
6 1mall cracks or holes in aluminium castings
may be repaired with an epo%y resin adhesive as
a temporary measure. Permanent repairs can
only be effected by argon#arc welding, and only a
specialist in this process is in a position to advise
on the economy or practical aspect of such a
repair. 'f any damage is found that can't be
repaired, renew the crankcase halves as a set.
; 0amaged threads can be economically
reclaimed by using a diamond section wire insert,
of the Heli#"oil type, which is easily fitted after
drilling and re#tapping the affected thread.
C 1heared studs or screws can usually be
removed with screw e%tractors, which consist of
a tapered, left thread screw of very hard steel.
These are inserted into a pre#drilled hole in the
stud, and usually succeed in dislodging the most
stubborn stud or screw.
"efer to +ools and
G?%T
'orkshop +ips for details of
installing a thread insert and
using screw e*tractors.
B 'nstall all components and assemblies,
referring to the relevant 1ections of this "hapter
and to "hapters @ and 9, before reassembling
the crankcase halves. 0o not forget to install the
oil passage collars using new =#rings.
64 ain an! connectin& ro!
bearin&s # general information
8 $ven though main and connecting rod
bearings are generally renewed during the
engine overhaul, the old bearings should be
retained for close e%amination as they may
reveal valuable information about the condition of
the engine.
A *earing failure occurs mainly because of lack
of lubrication, the presence of dirt or other foreign
particles, overloading the engine andDor
corrosion. (egardless of the cause of bearing
failure, it must be corrected before the engine is
reassembled to prevent it from happening again.
@ -hen e%amining the connecting rod bearings,
remove them from the connecting rods and caps
and lay them out on a clean surface in the same
general position as their location on the
crankshaft journals. This will enable you to match
any noted bearing problems with the
corresponding crankshaft journal.
6 0irt and other foreign particles get into the
engine in a variety of ways. 't may be left in the
engine during assembly or it may pass through
filters or breathers. 't may get into the oil and
from there into the bearings. 5etal chips from
machining operations and normal engine wear
are often present. Abrasives are sometimes left in
engine components after reconditioning
operations, especially when parts are not
thoroughly cleaned using the proper cleaning
methods. -hatever the source, these foreign
objects often end up imbedded in the soft bearing
material and are easily recognised. Farge
particles will not imbed in the bearing and will
score or gouge the bearing and journal. The best
prevention for this cause of bearing failure is to
clean all parts thoroughly and keep everything
spotlessly clean during engine reassembly.
4re,uent and regular oil and filter changes are
also recommended.
; Fack of lubrication or lubrication breakdown
has a number of interrelated causes. $%cessive
heat .which thins the oil/, overloading .which
s,uee&es the oil from the bearing face/ and oil
leakage or throw off .from e%cessive bearing
clearances, worn oil pumps or high engine
speeds/ all contribute to lubrication breakdown.
*locked oil passages will also starve a bearing
and destroy it. -hen lack of lubrication is the
cause of bearing failure, the bearing material is
wiped or e%truded from the steel backing of the
bearing. Temperatures may increase to the point
where the steel backing and the journal turn blue
from overheating.
TI9T[/8? /e!er to Tools and T>>>>>T
>orkshop Tips !or bearing GlT
!ault!inding.
C (iding habits can have a definite effect on
bearing life. 4ull throttle low speed operation, or
labouring the engine, puts very high loads on
bearings, which tend to s,uee&e out the oil film.
These loads cause the bearings to fle%, which
produces fine cracks in the bearing face .fatigue
failure/. $ventually the bearing material will
loosen in pieces and tear away from the steel
backing. 1hort trip riding leads to corrosion of
bearings, as insufficient engine heat is produced
to drive off the condensed water and corrosive
gases produced. These products collect in the
engine oil, forming acid and sludge. As the oil is
carried to the engine bearings, the acid attacks
and corrodes the bearing material.
B 'ncorrect bearing installation during engine
assembly will lead to bearing failure as well. Tight
fitting bearings which leave insufficient bearing oil
clearances result in oil starvation. 0irt or foreign
particles trapped behind a bearing insert result in
high spots on the bearing which lead to failure.
> To avoid bearing problems, clean all parts
thoroughly before reassembly, double check all
bearing clearance measurements and lubricate
the new bearings with clean engine oil during
installation.
1caned by 1talker
*
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
+)($2'1T$($03'
$ngine, clutch and transmission AL69
68.6 easure the connectin& ro! si!e clearance usin& a feeler &au&e
68.D EnscreB the nuts 1arroBe!2 an! remo,e the connectin& ro!s
68 9onnectin& ro!s #
removal, inspection and
installation
%ote) To remove the connecting rods the engine
must be removed !rom the !rame and the
crankcases separated.
"emoval
8 (emove the engine from the frame .see
1ection ;/ and separate the crankcase halves
.see 1ection A;/.
A *efore removing the rods from the crankshaft,
measure the side clearance on each rod with a
feeler gauge 1see illustration2. 'f the clearance
between any rod is greater than the service limit
listed in this "hapter's 1pecifications, replace that
rod with a new one.
@ +sing paint or a felt marker pen, mark the
relevant cylinder identity on each connecting rod
and cap. 5ark across the cap#to#connecting rod
join and note the : mark on each connecting rod
which must face to the left#hand side of the
engine to ensure that the cap and rod are fitted
the correct way around on reassembly. )ote that
the number etched
across the rod and cap indicates rod si&e grade,
not cylinder number.
6 +nscrew the big#end cap nuts and separate
the cap from the crankpin 1see illustration2.
0o not remove the bolts from the connecting
rods. 'mmediately install the relevant bearing
shells .if removed/, bearing cap, and nuts on
each pistonDconnecting rod assembly so that
they are all kept together as a matched set to
ensure correct installation.
&nspection
; "heck the connecting rods for cracks and
other obvious damage.
C Apply clean engine oil to the piston pin, insert
it into the connecting rod small#end and check for
any freeplay between the two 1see illustration2.
5easure the pin e%ternal and compare the result
to the specifications at the beginning of the
"hapter 1see illustration2. 'f the piston pin is
worn below the service limit it should be
renewed.
B (efer to 1ection AB and e%amine the
connecting rod bearing shells. 'f they are scored,
badly scuffed or appear to have sei&ed, new
shells must be installed. Always renew the shells
in the connecting rods as a set. 'f they are badly
damaged, check the corresponding crankpin.
$vidence of e%treme
heat, such as discoloration, indicates that
lubrication failure has occurred. *e sure to
thoroughly check the oil pump and pressure relief
valve as well as all oil holes and passages before
reassembling the engine.
> Have the rods checked for twist and bend
by a :amaha dealer or engineer if you are in
doubt about their straightness.
$il clearance check
9 -hether new bearing shells are being fitted
or the original ones are being re#used, the
connecting rod bearing oil clearance should
be checked prior to reassembly.
*0 "lean the backs of the bearing shells and
the bearing locations in both the connecting rod
and cap.
** Press the bearing shells into their locations,
ensuring that the tab on each shell engages the
notch in the connecting rodDcap 1see
illustration2. 5ake sure the bearings are fitted in
the correct locations and take care not to touch
any shell's bearing surface with your fingers.
*6 "ut a length of the appropriate si&e
Plastigauge .it should be slightly shorter than the
width of the crankpin/. Place a strand of
Plastigauge on the .cleaned/ crankpin journal.
*8 Apply molybdenum disulphide grease to
68.5a Sli" the "iston "in into the ro!'s
small(en! an! roc' it bac' an! forth to
chec' for looseness
68.5b easure the eCternal !iameter of the "in
68.** a'e sure the tab 1A2 locates in the notch 1/2
Stane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< J +)($2'1T$($0 3'
AL;? $ngine, clutch and transmission
68.6*a /i&(en! <ournal siRe numbers 1A2; main <ournal siRe numbers 1/2
68.6*b 9onnectin& ro! siRe number is mar'e! across the ca" an! ro! <oin
68.66 /earin& shell colour co!e location
the bolt shanks and threads and to the seats
of the nuts. 'nstall the .clean/ connecting rod,
shells and cap. 5ake sure the cap is fitted the
correct way around so the previously made
markings align, and that the rod is facing the
right way .see 1tep @/. Tighten the nuts finger#
tight, making sure the connecting rod does
not rotate on the crankshaft.
86 Tighten the bearing cap nuts evenly, in
two or three stages, to the initial tor,ue
setting specified at the beginning of the
"hapter, making sure the connecting rod
does not rotate on the crankshaft. )ow
tighten each nut in turn and in one continuous
movement to the final tor,ue setting
specified. 'f the tightening is interrupted
between the initial and final tor,ue settings,
slacken the nuts and begin the procedure
again.
8; 1lacken the cap nuts and remove the
connecting rod, again taking great care not to
rotate the rod or crankshaft.
8C "ompare the width of the crushed
Plastigauge on the crankpin to the scale
printed on the Plastigauge envelope to obtain
the connecting rod bearing oil clearance 1see
illustration 69.602. "ompare the reading to
the specifications at the beginning of the
"hapter.
8B =n completion carefully scrape away all
traces of the Plastigauge material from the
crankpin and bearing shells using a fingernail
or other object which is unlikely to score the
shells.
8> 'f the clearance is within the range listed in
this "hapter's 1pecifications and the bearings
are in perfect condition, they can be reused. 'f
the clearance is beyond the service limit,
renew the shells .see 1teps A8 and AA/. "heck
the oil clearance once again .the new shells
may be thick enough to bring bearing
clearance within the specified range/. Always
renew the shells in both connecting rods at
the same time.
89 'f the clearance is still greater than the
service limit listed in this "hapter's
1pecifications, the crankpin is worn and the
crankshaft should be renewed.
A? (epeat the bearing selection procedure
for other connecting rod.
(earing shell selection
6* )ew bearing shells for the big#end
bearings are supplied on a selected fit basis.
"ode numbers stamped on various
components are used to identify the correct
parts. The crankshaft journal si&e numbers are
stamped on the outside of the crankshaft web
on the right#hand end 1see illustration2. The
block of two numbers are for the big#end
bearing journals .the block of three
numbers are for the main bearing journals/.
The left#hand number is for the left#hand
.)o. 8 cylinder/ journal. The connecting
rod numbers are marked in ink on the flat face
of the connecting rod and cap 1see
illustration2.
66 A range of bearing shells is available. To
select the correct bearing for a particular
connecting rod, subtract the big#end bearing
journal number .stamped on the crank
web/ from the connecting rod number
.marked on the rod/. "ompare the bearing
number calculated with the table below to
find the colour coding of the new bearing
re,uired. The bearing shell colour code is
marked on the side of the shell 1see
illustration2.
%umber 9olour
* *lue
6 *lack
8 *rown
D 2reen
&nstallation
A@ "lean the backs of the bearing shells and
the bearing locations in both the connecting
rod and cap.
A6 Press the bearing shells into their
locations, making sure the tab on each shell
locates in the notch in the connecting rodDcap
1see illustration 68.**2. 5ake sure the
bearings are fitted in their correct locations
and take care not to touch any shell's bearing
surface with your fingers. Fubricate the shells
with clean engine oil.
A; Apply molybdenum disulphide grease to
the bolt shanks and threads and to the seats
of the nuts. Assemble the connecting rod and
cap on the crankpin. 5ake sure the cap is
fitted the correct way around so the
previously made markings align, and that the
rod is facing the right way .see 1tep @/.
Tighten the nuts finger#tight, making sure the
connecting rod does not rotate on the
crankshaft. "heck again to make sure all
components have been returned to their
original locations using the marks made on
disassembly.
AC Tighten the bearing cap nuts evenly, in
two or three stages, to the initial tor,ue
setting specified at the beginning of the
"hapter, making sure the connecting rod
does not rotate on the crankshaft. )ow
tighten each nut in turn and in one continuous
movement to the final tor,ue setting
specified. 'f the tightening is interrupted
between the initial and final tor,ue settings,
slacken the nuts and begin the procedure
again.
AB "heck that the rods rotate smoothly and
freely on the crankpin. 'f there are any signs of
roughness or tightness, remove the rods and
re#check the bearing clearance. 1ometimes
tapping the bottom of the connecting rod cap
will relieve tightness, but if in doubt, recheck
the clearances.
A> (eassemble the crankcase halves .see
1ection A;/.
A9 "rankshaft and main
bearings # removal,
inspection and installation
%ote) To remove the cranksha!t the engine
must be removed !rom the !rame and the
crankcase halves separated.
"emoval
8 (emove the engine from the frame .see
1ection ;/ and separate the crankcase halves
.see 1ection A;/.
A 1eparate the connecting rods from the
crankshaft .see 1ection A>/. %ote) )! no work
is to be carried out on the cranksha!t or
connecting rod assemblies& there is no need
to separate them.
@ Fift the crankshaft out of the upper
Scane! by Stal'er
@
?
=
$ngine, clutch and transmission A[;8
A9.@ "arefully lift the crankshaft out of the
crankcase
crankcase half, taking care not to dislodge the
main bearing shells .see illustration/.
6 The main bearing shells can be removed
from the crankcase halves by pushing their
centres to the side, then lifting them out .see
illustration/. <eep the shells in order.
&nspection
; "lean the crankshaft with solvent, using a rifle#
cleaning brush to scrub out the oil passages. 'f
available, blow the crank dry with compressed
air, and also blow through the oil passages.
"heck the drive gears for wear or damage .see
illustration/. 'f any of the gear teeth are
e%cessively worn, chipped or broken, the
crankshaft must be renewed. 'f wear or damage
is found, check the driven gears on the balancer
shafts, oil pumps, water pump and clutch
housing.
C (efer to 1ection AB and e%amine the main
bearing shells. 'f they are scored, badly scuffed
or appear to have been sei&ed, new bearings
must be installed. Always renew the main
bearings as a set. 'f they are badly damaged,
check the corresponding crankshaft journals.
$vidence of e%treme heat, such as discoloration,
indicates that lubrication failure has occurred. *e
sure to thoroughly check the oil pump and
pressure relief valve as well as all oil holes and
passages before reassembling the engine.
B 2ive the crankshaft journals a close visual
e%amination, paying particular attention where
damaged bearings have been discovered. 'f the
journals are scored or pitted in any way a new
crankshaft will be re,uired. )ote that undersi&es
are not available, precluding the option of re#
grinding the crankshaft.
> Place the crankshaft on 3#blocks and check
the runout at the main bearing journals using a
dial gauge .see illustration/. "ompare the reading
to the ma%imum specified at the beginning of the
"hapter. 'f the runout e%ceeds the limit, the
crankshaft must be renewed.
$il clearance check
9 -hether new bearing shells are being fitted
or the original ones are being re#used, the
main bearing oil clearance should be checked
before the engine is reassembled. 5ain
A9.6 To remove a main bearing shell, push it
sideways and lift it out
bearing oil clearance is measured with a product
known as Plastigauge.
8? "lean the backs of the bearing shells and
the bearing housings in both crankcase halves.
88 Press the bearing shells into their cutouts,
ensuring that the tab on each shell engages in
the notch in the crankcase .see illustration/.
5ake sure the bearings are fitted in the correct
locations and take care not to touch any shell's
bearing surface with your fingers.
8A $nsure the shells and crankshaft are clean
and dry. Fay the crankshaft in position in the
upper crankcase.
8@ "ut several lengths of the appropriate si&e
Plastigauge .they should be slightly shorter than
the width of the crankshaft journals/.
A
1caned by Stal'er
A9.; "heck the condition of the gear and
sprocket teeth
Place a strand of Plastigauge on each .cleaned/
journal .see illustration/. 5ake sure the
crankshaft is not rotated.
86 'f removed, install the locating dowel in the
upper crankcase half .see illustration A;.>/.
"arefully install the lower crankcase half on to
the upper half, making sure the dowel locates
correctly into the lower crankcase half .see
illustration A;.8;/. "heck that the lower
crankcase half is correctly seated. %ote) *o not
tighten the crankcase bolts i! the casing is not
correctly seated.
8; "lean the threads of the 8? mm lower
crankcase bolts and apply molybdenum
disulphide oil .a ;?D;? mi%ture of molybdenum
disulphide grease and new engine oil/ to their
threads. 'nsert them with their washers in their
original locations. "lean the threads of the
A9.> 5easuring crankshaft runout
A9.8@ Fay a strip of Plastigauge on each journal
parallel to the crankshaft centreline
69.** a'e sure the tab on the shell locates
in the notch in the rod
A[;A $ngine, clutch and transmission
Tft111
69.60 easure the Bi!th of the crushe!
#lasti&au&e 1be sure to use the correct
scale ( metric an! im"erial are inclu!e!2
> and C mm lower crankcase bolts and apply
new engine oil to their threads. 'nsert them .with
their washers where fitted/ in their original
locations. 1ecure all bolts finger#tight at first, then
tighten them evenly and a little at a time in the
correct numerical se,uence to the tor,ue
settings specified at the beginning of the "hapter
1see illustrations 60.Da or b2. 5ake sure that
the crankshaft is not rotated as the bolts are
tightened.
8C Turn the engine over. "lean the threads of
the > and C mm upper crankcase bolts and apply
new engine oil to their threads. 'nsert them .with
their washers where fitted/ in their original
locations. 1ecure all bolts finger#tight at first, then
tighten them evenly and a little at a time in the
correct numerical se,uence to the tor,ue
settings specified at the beginning of the "hapter
1see illustrations 60.Da or b2. 5ake sure that
the crankshaft is not rotated as the bolts are
tightened.
8B +nscrew the C mm and > mm upper
crankcase bolts evenly, a little at a time in a
re,erse of the numerical se,uence until they are
finger#tight, then remove them 1see illustrations
60.Da or b2 The number of each bolt is cast into
the crankcase. )ote the copper washers fitted
with some of the bolts. %ote) $s each bolt is
removed& store it in its relative position& with its
washer where applicable& in a cardboard
template o! the
crankcase halves. This will ensure all bolts are
installed in the correct location on reassembly.
*8 Turn the engine upside down so that it rests
on the cylinder head studs.
*9 +nscrew the C mm lower crankcase bolts,
the > mm bolts, and the 8? mm bolts evenly, a
little at a time in a re,erse of the numerical
se,uence until they are finger#tight, then remove
them 1see illustrations 60.Da or b2. The number
of each bolt is cast into the crankcase. "arefully
lift off the lower crankcase half, making sure the
Plastigauge is not disturbed.
60 "ompare the width of the crushed
Plastigauge on each crankshaft journal to the
scale printed on the Plastigauge envelope to
obtain the main bearing oil clearance 1see
illustration2. "ompare the reading to the
specifications at the beginning of the "hapter.
6* =n completion carefully scrape away all
traces of the Plastigauge material from the
crankshaft journal and bearing shells use a
fingernail or other object which is unlikely to
score them.
66 'f the oil clearance falls into the specified
range, new bearing shells are not re,uired
.provided they are in good condition/. 'f the
clearance is beyond the service limit, refer to the
marks on the case and the marks on the
crankshaft and select new bearing shells .see
1teps A6 and A;/. 'nstall the new shells and
check the oil clearance once again .the new
shells may bring bearing clearance within the
specified range/. Always renew all of the main
bearing shells at the same time.
68 'f the clearance is still greater than the
ser,ice limit listed in this "hapter's
1pecifications .even with new shells/, the
crankshaft journal is worn and the crankshaft
should be renewed.
8ain bearing shell selection
A6 )ew bearing shells for the main bearings
are supplied on a selected fit basis. "ode
numbers stamped on various components are
used to identify the correct si&e bearings. The
crankshaft journai si&e numbers are stamped
on the outside of the crankshaft web on the
right#hand end 1see illustration 68.6*a2. The
block of three numbers are for the main bearing
journals .the block of two numbers are for the
big#end bearing journals/. The main bearing
housing numbers are stamped into the upper
crankcase half 1see illustration2. )ote that if
there is only one number stamped into the
crankcase, it means that all the journals are the
same number. 60 A range of bearing shells is
available. To select the correct bearing for a
particular journal, subtract the main bearing
journal number .stamped on the crank web/ from
the main bearing housing number .stamped on
the crankcase/. "ompare the bearing number
calculated with the table below to find the colour
coding of the new bearings re,uired. The bearing
shell colour code is marked on the side of the
shell 1see illustration 68.662.
%umber 9olour
8 *lue
6 *lack
@ *rown
D 2reen
; :ellow
C Pink
B (ed
&nstallation
AC "lean the backs of the bearing shells and the
bearing cut#outs in both crankcase halves. 'f new
shells are being fitted, ensure that all traces of
the protective grease are cleaned off using
paraffin .kerosene/. -ipe dry the shells and
crankcase halves with a lint#free cloth. 5ake sure
all the oil passages and holes are clear, and blow
them through with compressed air if it is
available.
ABPress the bearing shells into their locations.
5ake sure the tab on each shell engages in the
notch in the casing 1see illustration 69.**2.
5ake sure the bearings are fitted in the correct
locations and take care not to touch any shell's
bearing surface with your fingers. Fubricate each
shell with clean engine oil 1see illustration2.
A> Fower the crankshaft into position in the
69.6D ain bearin& housin& numbers 1arroBe!2
69.64 \enerously lubricate all the bearin& shells
tone! by Stal'er
$ngine, clutch and transmission AY;@
80.6 -ift out the out"ut shaft
80.Da DraB out the shaft once the retainer screBs ha,e been remo,e!
upper crankcase, making sure all bearings
remain in place 1see illustration 69.82.
69 Fit the connecting rods onto the
crankshaft .see 1ection A>/.
80 (eassemble the crankcase halves .see
1ection A;/.
@? Transmission shafts and
bearings # removal and
installation
%ote) To remove the transmission sha!ts the
engine must be removed !rom the !rame and the
crankcase halves separated.
"emoval
8 (emove the engine from the frame .see
1ection ;/ and separate the crankcase halves
.see 1ection A;/.
A Fift the output shaft out of the casing, noting
how the selector forks locate in the grooves 1see
illustration2. 'f it is stuck, use a soft#faced
hammer and gently tap on the ends of the shaft
to free it. (emove the bearing half#ring retainer
from the right#hand end of the output shaft and
note how the locating pin on each bearing fits into
the cutouts in the crankcase 1see illustration
80.**2. 'f the half#ring retainer is not in the slot in
the crankcase, remove it from the slot in the
bearing.
@ (emove the selector forks .see 1ection @A/.
6 (emove the three Tor% screws securing the
input shaft bearing retainer on the right#hand end
of the shaft 1see illustration 80.4c2. 0raw the
shaft out of the crankcase from the right#hand
side 1see illustration2. 'f it is stuck, thread a C
mm bolt into the centre of the blanking plug on
the left#hand end of the shaft and remove the
plug by pulling on the bolt 1see illustration2.
0iscard the plug = Ting as a new one must be
used. =nce the plug is removed, tap on the end
of the shaft using a soft#faced mallet to free it
from the crankcase.
; 'f necessary, the input shaft and output shaft
can be disassembled and inspected for wear or
damage .see 1ection @8/.
C (eferring to Tools and >orkshop Tips
.1ection ;/ in the (eference 1ection, check
the bearings on the transmission shafts or in
the bearing housings in the crankcase. (enew
the bearings if necessary. Also check the
condition of the output shaft oil seal and
renew it if it is worn or damaged 1see
illustration 60.**2.
&nstallation
J 1lide the input shaft into the crankcase,
aligning the four holes in the bearing retainer
with those in the crankcase 1see illustration
an! 80.Db2. +se the screws, a long bolt or a
VYQ
PH . 'P
J
(
_L #LP
D --"O '*PU /NI
J 'f
8
bH'
80.Db Threa! a suitable bolt into the "lu& an!
"ull it out
rod as a guide to align the holes, as once the
retainer is in the housing it will be difficult to turn.
+se a hammer and block of wood to drive the
shaft fully home 1see illustration2. Apply a
suitable non#permanent thread locking compound
to the Tor% screws and tighten them to the tor,ue
setting specified at the beginning of the "hapter.
%ote) )t is advisable to renew the TorB screws
because the originals are likely to have been
damaged by previous staking. +sing a suitable
punch, stake the screws against the retainer 1see
illustration2. 'f it was removed, fit the blanking
plug with a new =#ring and press it home 1see
illustrations2.
80.4a %ote hoB the holes must ali&n
1arroB2
80.4c ?nstall the TorC screBs 1arroBe!2 an!
sta'e them in "lace
Stane! by Stal'er
_
?
=
80.4b Ta" the shaft into "lace as shoBn
+)($2'1T$($03'
AL;6 $ngine, clutch and transmission
80.4! Fit a neB .(rin& onto the "lu& .
80.4e ... an! "ress it into "lace
80.9 Fit the half(rin& retainer into the slot
8 'nstall the selector forks .see 1ection @A/.
9 'nstall the bearing half#ring retainer for the
right#hand end of the output shaft into its slot in
the upper crankcase half 1see illustration2.
*0 'f it has not been removed, slide the output
shaft oil seal off the left#hand end of the shaft
1see illustration 60.**2N the seal must be
renewed. Fubricate the shaft and new seal with
clean oil and slide it onto the shaft. 1mear the
seal rim with oil.
** Fower the output shaft into position in the
crankcase half 1see illustration 80.62; making
sure the selector fork guide pins are engaged
with their selector drum groove and the forks
themselves fit into the grooves in the pinions, and
the slot in the right#hand bearing engages
correctly with the bearing half#ring retainer, the
circlip on the left#hand bearing fits into its slot,
and the bearing locating pins fit into the cutouts in
the crankcase 1see illustration2.
*6 5ake sure both transmission shafts are
correctly seated and their related pinions are
correctly engaged.
-aution= )! the bearing hal!-ring retainer& circlip
and locating pins are not correctly engaged& the
crankcase halves will not seat correctly.
8@ Position the gears in the neutral position and
check the shafts are free to rotate easily and
independently ]ie the input shaft can turn whilst
the output shaft is held stationary/ before
proceeding further.
86 (eassemble the crankcase halves .see
1ection A;/.
8* Transmission shafts#
disassembly, inspection and
reassembly
8 (emove the transmission shafts from the
casing .see 1ection @?/. Always disassemble the
transmission shafts separately to avoid mi%ing up
the components.
&nput shaft disassembl)
ffffB$ftH >hen disassembling the EEG?S?
transmission sha!ts& place GllET the parts on
a long rod or
thread a wire through them to keep
them in order and !acing the proper direction.
A (emove the And gear pinion from the left#hand
end of the shaft using a puller, referring to Tools
and >orkshop Tips .1ection ;/ in the (eference
1ection if re,uired 1see illustration2. 'f a legged
puller is being used, it will be easier to set it up
with the legs behind the ;th gear pinion, and
draw the And and ;th pinions off together. %ote)
)n our eBperience an hydraulic press was needed
to remove the 2nd gear pinion as it was so tight
on the sha!t. Take the sha!t to a properly
eAuipped workshop i! necessary.
@ 1lide the ;th gear pinion off the shaft 1see
illustration 8*.*Bd/.
6 To remove the ;th gear pinion bush, set up a
puller behind the @rd gear pinion and use
that to draw the bush off 1see illustration2.
(emove the thrust washer and the @rd gear
pinion 1see illustration 8*.*4a an! 8*.*52.
; (emove the circlip securing the 6th gear
pinion, then slide the splined washer and the
pinion off the shaft 1see illustrations 8*.*0c; b
an! a/. The 6th gear pinion bush is a press fit. 0o
not remove it unless it needs to be renewed.
(emove it using a puller.
C The 8st gear pinion is integral with the shaft.
&nput shaft inspection
: -ash all of the components in clean solvent
and dry them off.
; "heck the gear teeth for cracking, chipping,
pitting and other obvious wear or damage. Any
pinion that is damaged as such must be
renewed.
7 'nspect the dogs and the dog holes in the
gears for cracks, chips, and e%cessive wear
especially in the form of rounded edges. 5ake
sure mating gears engage properly. (enew the
paired gears as a set if necessary.
8? "heck for signs of scoring or bluing on the
pinions, bushes and shaft. This could be caused
by overheating due to inade,uate lubrication.
"heck that all the oil holes and passages are
clear. (enew any damaged pinions or bushes.
88 "heck that each mobile pinion moves freely
on the shaft or bush but without undue freeplay.
8A The shaft is unlikely to sustain damage
unless the engine has sei&ed, placing an
80.** a'e sure that each "in 1arroBe!2
locates in its cutout
8*.6 Ese a "uller or "ress to remo,e the
6n! &ear "inion
8*.D DraB off the bush usin& a "uller
behin! the 8r! &ear "inion
Scane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
$ngine, clutch and transmission A[;;S
8*.*0a Sli!e the Dth &ear "inion onto the bush...
unusually high loading on the transmission, or the machine has covered a very high mileage. "heck the surface of the shaft, especially where a pinion turns on it,
and renew the shaft if it has scored or picked up, or if there are any cracks. 0amage of any kind can only be cured by renewal. "heck the shaft runout using 3#
blocks and a dial gauge and renew the shaft if the runout e%ceeds the limit specified at the beginning of the "hapter.
*8 "heck the washers and circlips and renew
any that are bent or appear weakened or
worn. 't is a good policy to renew all circlips
and washers as a matter of course during a
gearshaft overhaul.
&nput shaft reassembl)
*D 0uring reassembly, apply engine oil to the
. then sli!e on the s"line! Basher....
mating surfaces of the shaft, pinions and bushes. -hen installing the circlips, do not e%pand their ends any further than is necessary. 'nstall the stamped circlips
so that their chamfered side faces the pinion it secures and the sharp edged sides faces the direction of thrust load .see 'correct fitting of a stamped circlip
illustration' in Tools and >orkshop Tips in the (eference section/.
8; 'f removed, drive or press the 6th gear pinion bush onto the shaft, aligning the oil hole in the bush with the hole in the shaft. 1lide the 6th gear pinion, with the
pinion dog holes facing away from the integral 8st gear onto the bush 1see illustration2. 1lide the splined washer onto the shaft, then fit the circlip, making sure
that it locates
8*.*0b
8*.*0c ... an! secure them Bith the circli"
correctly in the groove in the shaft 1see illustrations2.
*5 1lide the @rd gear pinion onto the shaft with the selector fork groove facing the 6th gear pinion 1see illustration2.
*4 1lide the thrust washer onto the shaft, then drive or press the ;th gear pinion bush into place, aligning the oil hole in the bush with the hole in the shaft 1see
illustrations2. 1lide the ;th gear pinion onto the bush 1see illustration2.
*8 Press the And gear pinion onto the left#hand end of the shaft using a press or tubular drift, referring to BboDs and >orkshop Tips .1ection ;/ in the (eference
1ection if re,uired 1see illustration2. 1et the pinion so that the distance between the outside edge of the And gear pinion and the outside edge of
8*.*5 Sli!e the 8r! &ear "inion onto the shaft; ma'in& sure it is the correct Bay roun!
8*.*4a Sli!e on the thrust Basher.
8*.*4b ... then fit the bush .
--
]=
. >
' QH
*
m 'F
9
8*.*4c ... ali&nin& the oil holes 1arroBe!2 8*.*4! ?nstall the 0th &ear "inion o,er the
bush
8*.*8a Fit the 6n! &ear "inion .
Scane! by Stal'er
6I05 En&ine; clutch an! transmission
8*.*8b ... an! set the !istance as s"ecifie! 8*.*9 The assemble! in"ut shaft shoul! be as shoBn
the 8st gear pinion .which is integral with the
shaft/ is 88C.C mm to 88C.> mm 1see
illustration2.
*9 "heck that all components have been
correctly installed 1see illustration2.
$utput shaft disassembl)
*99* to *99D TD mo!els an! all XT3
mo!els
60 (emove the caged ball bearing from the
right#hand end of the shaft 1see illustration
8*.D*2.
6* 1lide the 8st gear pinion and the 6th gear
pinion off the right#hand end of the shaft 1see
illustrations 8D.D0b an! a2.
66 (emove the circlip securing the @rd gear
pinion, then slide the splined washer, the @rd
gear pinion and its splined bush, followed by the
;th gear pinion off the shaft 1see illustrations
@8.@9d, c; b an! a; an! 8*.842.
68 This leaves the And gear pinion, its bush and
the bearing on the left#hand end of the shaft
these components are not available individually #
refer to a :amaha dealer if they need renewing.
*990(on TD mo!els an! all TRX
mo!els
A6(emove the caged ball bearing from the
right#hand end of the shaft 1see illustration
8*.D*2.
A;1lide the thrust washer, the 8st gear pinion
and the 6th gear pinion off the right#hand end of
the shaft 1see illustrations 8*.D0c; b an! a2.
AC(emove the circlip securing the @rd gear
pinion, then slide the splined washer, the @rd
gear pinion and its splined bush off the shaft 1see
illustrations 8*.89!; c; b an! a2
AB1lide the lockwasher and the splined washer
off the shaft, noting how they fit together, then
slide the ;th gear pinion off the shaft 1see
illustrations 8*.88c; b an! a; an! 8*.842.
A> This leaves the And gear pinion, its bush and
the bearing on the left#hand end of the shaft
these components are not available
individually # refer to a :amaha dealer if they
need renewing.
$utput shaft inspection
A9 (efer to 1teps B to 8@ above.
$utput shaft reassembl)
*99* to *99D TD mo!els an! XT3 mo!els
80 0uring reassembly, apply engine oil to the
mating surfaces of the shaft, pinions and bushes.
-hen installing the circlips, do not e%pand their
ends any further than is necessary. 'nstall the
stamped circlips so that their chamfered side
faces the pinion it secures and the sharp edged
sides faces the direction of thrust load .see
'correct fitting of a stamped circlip illustration' in
Tools and >orkshop Tips in the (eference
section/.
8* 1lide the ;th gear pinion onto the right#hand
end of the shaft, with its dogs facing the And gear
pinion .integral with the shaft/ 1see illustration
8*.842.
86 1lide the @rd gear pinion splined bush onto
the shaft, followed by the @rd gear pinion, and the
splined washer, and secure them with the circlip,
making sure it locates correctly in its groove in
the shaft 1see illustrations 8*.89a; b; c an! !2.
@@1lide the 6th gear pinion onto the shaft, with
its selector fork groove facing the @rd gear pinion,
followed by the 8st gear pinion 1see illustrations
8*.D0a an! b2.
@64it the caged ball bearing onto the right#hand
end of the shaft 1see illustration 8*.D*2.
@; "heck that all components have been
correctly installed.
*990(on TD mo!els an! TRX mo!els
85 0uring reassembly, apply engine oil to the
mating surfaces of the shaft, pinions and bushes.
-hen installing the circlips, do not e%pand their
ends any further than is necessary. 'nstall the
stamped circlips so that their chamfered side
faces the pinion it secures and the sharp edged
sides faces the direction of thrust load .see
'correct fitting of a stamped circlip illustration' in
Tools and >orkshop Tips in the (eference
section/.
84 1lide the ;th gear pinion onto the right#hand
end of the shaft, with its dogs facing the And gear
pinion .integral with the shaft/ 1see illustration2.
88 1lide the slotted splined washer onto the
shaft and locate it in its groove, then turn it in the
groove so that the splines on the washer locate
between the splines of the shaft and secure the
washer in the groove 1see illustrations2. 1lide
the lockwasher onto the
Scane! by Stal'er
8*.84 Sli!e the 0th &ear "inion onto the
shaft; ma'in& sure it is the correct Bay
roun!
8*.88a Sli!e the slotte! s"line! Basher on
...
$ngine, clutch and transmission AL;B
####==== J
_fULf. . ! <r
J
?fI
. _
8*.88b ... an! ali&n it as shoBn ... 8*.88c ... then sli!e the loc'Basher on;
fittin& the tabs into the slots
8*;89a Sli!e on the s"line! bush ..
shaft, so that the tabs on the lockwasher face the
left#hand end of the shaft and locate into the slots
in the outer rim of the splined washer 1see
illustration2.
89 1lide the @rd gear pinion splined bush onto
the shaft, followed by the @rd gear pinion, and the
splined washer, and secure them with the circlip,
making sure it locates correctly in its groove in
the shaft 1see illustrations2.
D0 1lide the 6th gear pinion onto the shaft, with
its selector fork groove facing the @rd gear pinion,
followed by the 8st gear pinion, and the thrust
washer 1see illustrations2.
D* 4it the caged ball bearing onto the right#hand
end of the shaft 1see illustration2.
D6 "heck that all components have been
correctly installed.
86 Selector !rum an! for's
removal, inspection and
installation
V
*
;... 8c
%ote) To remove the selector drum and !orks the
engine must be removed !rom the !rame and the
crankcase halves separated.
"emoval
8 (emove the engine .see 1ection ;/ and
separate the crankcase halves .see 1ection A;/.
The selector drum and forks are located in the
upper crankcase half.
8*.89b ... the 8r! &ear "inion .
8*.89! ... an! secure them Bith the
circli"
8*.89c ... an! the s"line! Basher .
8*.D0a Sli!e on the Dth &ear "inion;
ma'in& sure it is the correct Bay roun! .
. folloBe! by the *st &ear "inion...
8*.D0c ... the thrust Basher ..
8*.D* ... an! the bearin&
Scane! by Stal'er
AL;> $ngine, clutch and transmission
86.D %ote the letter on each for' !enotin& its "osition
86.*6 Sli!e the !rum into the casin&
6 (emove the transmission output shaft .see
1ection @?, 1tep A/.
8 'f not already done when removing the
gearchange mechanism .e%ternal
components/, remove the selector drum
retainer plate and the stopper arm return
spring, noting how the plate locates against
the flats on the selector fork shaft ends .see
1ection 89/.
D *efore removing the selector forks, note
that each fork is lettered for identification. The
right#hand fork has an '(', the centre fork a
'", and the left#hand fork an 'UR' 1see
illustration2. These letters face the right#hand
side of the engine. 'f no letters are visible,
mark them yourself using a felt pen.
0 1upport the selector forks and withdraw the
shafts from the casing, then remove the forks
1see illustrations 86.*8b an! a2. =nce
removed from the case, slide the forks back
onto their shafts in their correct order and way
round. =n 8998 to 899; T05 models and 7TE
models, note the spring fitted on the outside
of the left#hand fork.
5 -ithdraw the selector drum from the
right#hand side of the casing 1see illus(
tration 86.*62.
&nspection
4 'nspect the selector forks for any signs of
wear or damage, especially around the fork
ends where they engage with the groove in
the pinion. "heck that each fork fits correctly
in its pinion groove. "heck closely to see if the
forks are bent. 'f the forks are in any way
damaged they must be renewed.
8 "heck that the forks fit correctly on their
shaft. They should move freely with a light fit
but no appreciable freeplay. "heck that the
fork shaft holes in the casing are not worn or
damaged.
9 The selector fork shaft can be checked for
trueness by rolling it along a flat surface. A
bent shaft will cause difficulty in selecting
gears and make the gearchange action heavy.
(enew the shaft if it is bent.
8? 'nspect the selector drum grooves and
selector fork guide pins for signs of wear or
damage. 'f either component shows signs of
wear or damage the selector.s/ and drum
must be renewed.
88 "heck that the selector drum bearing
rotates freely and has no sign of freeplay
between it and the casing. (enew the bearing
if necessary .see Tools and >orkshop Tips
.1ection ;/ in the (eference 1ection/. Also
check that the neutral switch contact plunger
in the other end of the drum is free to move in
and out under spring pressure. 'f re,uired,
remove the screw securing the contact plate
and remove the plunger and spring for
inspection or renewal .see "hapter 9/.
&nstallation
*6 1lide the selector drum into position in the
crankcase and position it so that the neutral
contact is against the neutral switch 1see
illustration2.
*8 (efer to 1tep 6 for the correct location of
each fork 1see illustration 86.D2. Fubricate the
selector fork shafts with clean engine oil and
slide them into the crankcase, with the cut
end of the upper .single fork/ shaft facing the
right#hand side, and the spring .where fitted/
in the lower shaft end facing the left#hand
side. 1lide each shaft through its fork.s/ and
into its bore, locating the guide pin on the end
of each fork into its groove in the drum as you
do 1see illustrations2.
*D Focate the stopper arm spring, then install
the selector drum retainer plate, making sure
86.*8a Fit the centre for' 192 into the &roo,e in the in"ut shaft
"inion an! locate the &ui!e "in in its &roo,e in the !rum; then
sli!e in the shaft
86.*8b Sli!e the shaft into the casin& an! throu&h each for' in
turn ( note the s"rin& 1arroBe!2
Stane! by Stal'er
$ngine, clutch and transmission A[;9
it locates correctly against the flat in the end
of the fork shaft .see 1ection 89/.
8; 'nstall the transmission output shaft .see
1ection @?, 1tep 88/.
8C (eassemble the crankcase halves .see
1ection A;/.
@@ 'nitial start#up after overhaul
8 5ake sure the engine oil level and coolant
level are correct .see *aily (pre-ride) checks).
A 5ake sure there is fuel in the tank, then turn
the fuel tap to the =) or ($1 position as
re,uired, and set the choke on.
@ As there isn't an oil pressure warning light
fitted, an oil pressure check must be carried
out. 4ollow the procedure in "hapter 8,
1ection @A.
6 'f the oil pressure test is satisfactory, allow
the engine to run at a moderately fast idle until
it reaches operating temperature and check
that there are no oil and coolant leaks. 1top
the engine.
; "heck carefully that the transmission and
controls, especially the brakes, function
properly before road testing the machine.
(efer to 1ection @6 for the recommended
running#in procedure.
C +pon completion of the road test, and after
the engine has cooled down completely,
recheck the valve clearances .see "hapter 8/
and check the engine oil and coolant levels
.see 0aDBy (pre-ride) checks).
@6 (ecommended running#in
"roce!ure
8 Treat the machine gently for the first few
miles to make sure oil has circulated
throughout the engine and any new parts
installed have started to seat.
A$ven greater care is necessary if the engine
has been rebored or a new crankshaft has
been installed. 'n the case of a rebore, the
bike will have to be run in as when new. This
means greater use of the transmission and a
restraining hand on the throttle until at least
C?? miles .8??? km/ have been covered.
There's no point in keeping to any set speed
limit # the main idea is to keep from labouring
the engine and to gradually increase
performance up to the C?? mile .8??? km/
mark. These recommendations can be
lessened to an e%tent when only a new
crankshaft is installed. $%perience is the best
guide, since it's easy to tell when an engine is
running freely. The accompanying table
indicates ma%imum engine speed limitations,
which :amaha provide for new motorcycles,
can be used as a guide.
@'f a lubrication failure is suspected, stop the
engine immediately and try to find the cause.
'f an engine is run without oil, even for a short
period of time, severe damage will occur.
*99* to *990 TD mo!els an! all XT3 mo!els
+p to 8?? miles .8;? km/ 6??? rpm ma% 3ary throttle positionDspeed. 0o not use full throttle. 1top the engine and let it cool for
; to 8? minutes after every hour of operation.
8?? to @?? miles .8;? to ;?? km/ ;??? rpm ma% 3ary throttle positionDspeed. 0o not use full throttle
@?? to C?? miles .;?? to 8??? km/ C??? rpm ma% 3ary throttle positionDspeed. +se full throttle for short bursts
=ver C?? miles .8??? km/ >??? rpm ma% 0o not e%ceed tachometer red line
*995(on TD mo!els an! all TRX mo!els
+p to 8?? miles .8;? km/ ;??? rpm ma% 3ary throttle positionDspeed. 0o not use full throttle. 1top the engine and let it cool for
; to 8? minutes after every hour of operation.
8?? to @?? miles .8;? to ;?? km/ C??? rpm ma% 3ary throttle positionDspeed. 0o not use full throttle
@?? to C?? miles .;?? to 8??? km/ B??? rpm ma% 3ary throttle positionDspeed. +se full throttle for short bursts
=ver C?? miles .8??? km/ >??? rpm ma% 0o not e%ceed tachometer red line
1tarted by 1talker
+)($2'1T$($03'
+)($2'1T$($03'
3*1
9ha"ter 8
"ooling system
9ontents
"oolant hoses # removal and installation ................................................ 9
"oolant level check...........................................see 0aily .pre#ride/ checks
"oolant reservoir # removal and installation............................................. @
"oolant temperature gauge and sender # check and renewal.................. ;
"ooling fan and thermostatic switch # check and renewal ..................... 6
"ooling system checks ........................................................ see "hapter 8
"ooling system draining, flushing and refilling ....................see "hapter 8
De&rees of !ifficulty
2eneral information................................................................................. 8
(adiator # removal and installation.......................................................... B
(adiator pressure cap # check................................................................. A
Thermostat housing and thermostat # removal,
check and installation ......................................................................... C
-ater pump # check, removal and installation......................................... >
Easy; suitable for
novice with little
e%perience
=
Fairly easy; suitable Jk for
beginner with JQ
some e%perience
Fairly !ifficult; g%,
suitable for competent >=
Difficult; suitable for H
e%perienced 0': ;j
mechanic
Qery !ifficult;
suitable for e%pert
0': H
or professional
UU1
S"ecifications
9oolant
5i%ture type and capacity ............................................................................. see "hapter 8
Ra!iator
"ap valve opening pressure.......................................................................... 88 to 8; psi .?.B; to 8.?; *ar/
Fan sBitch
"ooling fan cut#in temperature...................................................................... 8?A to 8?>W"
"ooling fan cut#out temperature .................................................................. 9>W"
9oolant tem"erature sensor
(esistance # 8998 to 899; T05 models and all 7TE models
P ;?W" ................................................................................................... 8;6 ohms
d >?W" ................................................................................................... 6B to ;@ ohms
d 8??W" ................................................................................................. AC to A9 ohms
d 8A?W" ................................................................................................. 8C ohms
(esistance # 899C#on T05 models and all T(7 models
b >?W" ................................................................................................... 6B to ;@ ohms
d 8??W" .................................................................................................. AC to @? ohms
Thermostat
=pening temperature ................................................................................... >? to >6W"
3alve lift ...................................................................................................... > mm .min/ d 9;W"
TorAue settin&s
"ooling fan switch ....................................................................................... A> )m
"oolant temperature sensor
8998 to 899; T05 models and all 7TE models......................................... 8@ )m
899C#on T05 models and all T(7 models................................................ 8; )m
Thermostat cover bolts.................................................................................. 8? )m
Thermostat mounting bolt ............................................................................ 8?)m
-ater pump bolts.......................................................................................... 8?)m
4rame downtube boltsDnuts .7TE models/.................................................... @A )m
8
+)($2'1T$($0 3'
Scane! by Stal'er
+)($2'1T$($0 3'
|5
@LA 9oolin& system
* \eneral information
The cooling system uses a waterDantifree&e
coolant to carry away e%cess energy in the form
of heat. The cylinders are surrounded by a water
jacket from which the heated coolant is circulated
by thermo#syphonic action in conjunction with a
water pump, driven by the front balancer shaft.
The hot coolant passes upwards to the
thermostat and through to the radiator. The
coolant then flows across the radiator core,
where it is cooled by the passing air, to the water
pump and back to the engine where the cycle is
repeated.
A thermostat is fitted in the system to prevent
the coolant flowing through the radiator when the
engine is cold, therefore accelerating the speed
at which the engine reaches normal operating
temperature. A coolant temperature sensor
mounted in the thermostat housing transmits to
the temperature gauge on the instrument panel.
A thermostatically#controlled cooling fan is also
fitted to aid cooling in e%treme conditions. The
fan switch is mounted in the thermostat housing.
The complete cooling system is partially sealed
and pressurised, the pressure being controlled by
a valve contained in the spring#loaded radiator
cap. *y pressurising the coolant the boiling point
is raised, preventing premature boiling in adverse
conditions. The overflow pipe from the system is
connected to a reservoir into which e%cess
coolant is e%pelled under pressure. The
discharged coolant automatically returns to the
radiator when the engine cools.
'arning: Do not remove the
pressure cap from the radiator when
the engine is hot. Scalding hot coolant
and steam ma) be blown out underpressure,
which could cause serious in-ur). 'hen the
engine has cooled, place a thick rag, like a
towel over the pressure cap5 slowl) rotate the
cap anti/clockwise to the first stop. +his
procedure allows an) residual pressure to
escape. 'hen the steam has stopped
escaping, press down on the cap while turning
it anti/clockwise and remove it. Do not allow
antifree9e to come in contact with )our skin or
painted surfaces of the motorc)cle. "inse off
an) spills immediatel) with plent) of water.
,ntifree9e is highl) to*ic if ingested. !ever
leave antifree9e t)ing around in an open
container or in puddles on the floor5 children
and pets are attracted b) its sweet smell and
ma) drink it. Check with the local authorities
about disposing of used antifree9e. 8an)
communities will have collection centres
which will see that antifree9e is disposed of
safel). Caution: ,t all times use the specified
t)pe of antifree9e, and alwa)s mi* it with
distilled water in the correct proportion. +he
antifree9e contains corrosion inhibitors which
are essential to avoid damage to the cooling
s)stem. , lack of these inhibitors could lead to
a build/up of corrosion which would block the
coolant passages,
,
resulting in overheating and severe engine
damage. Distilled water must be used as
opposed to tap water to avoid a build/up of
scale which would also block the passages.
* 'f problems such as overheating or loss of
coolant occur, check the entire system as
described in "hapter 8. The radiator cap opening
pressure should be checked by a :amaha dealer
with the special tester re,uired to do the job. 'f
the cap is defective, renew it.
9oolant reser,oir #
removal and installation
"emoval
* =n T05 models, remove the seat ]see
"hapter >/. =n T(7 models, remove the seat
and the side covers .see "hapter >/. =n 7TE
models remove the left#hand side cover .see
"hapter >/.
6 (elease the clamp securing the breather hose
.coming out of the top of the reservoir/ and
detach the hose 1see illustrations2.
8 Place a suitable container underneath the
reservoir, then release the clamp securing the
radiator overflow hose to the base of the
reservoir. 0etach the hose and allow the coolant
to drain into the container.
D +nscrew the reservoir mounting bolts or
screws and remove the reservoir, noting how it
fits 1see illustrations 8.6a; b an! c2.
&nstallation
0 'nstallation is the reverse of removal. 5ake
sure the hoses are correctly installed and
secured with their clamps. =n completion
refill the reservoir as described in "hapter 8.
8.6b /reather hose 1A2; ra!iator o,erfloB hose 1/2; mountin& screBs 192 ( TRX mo!els
8.6a /reather hose 1A2; mountin& bolts 1/2 #
TD mo!els
?
8.6c /reather hose 1A2; ra!iator o,erfloB hose 1/2; mountin& screBs 192 ( XT3 mo!els
Scane! by Stal'er
"ooling system @L@
D.8a Fan motor Birin& connector 1arroBe!2 ( TD mo!els
D.8b Fan motor Birin& connector 1arroBe!2 ( XT3 mo!els
D 9oolin& fan an! coolin& fan OH
sBitch # check and renewal 1<
Cooling fan
9hec'
* 'f the engine is overheating and the cooling fan
isn't coming on, first check the fan circuit fuse
.see "hapter 9/ and then the fan switch as
described in 1teps 9 to 8@ below.
D.0 Fan assembly mountin& bolts
1arroBe!2
D.9b Fan sBitch Birin& connector 1A2;
tem"erature sen!er Birin& connector 1/2 (
TRX mo!els
A 'f the fan does not come on, .and the fan
switch is good/, the fault lies in either the cooling
fan motor or the relevant wiring. Test all the
wiring and connections as described in "hapter
9.
@To test the cooling fan motor, trace the fan
motor wiring and disconnect it at the connector
1see illustrations2. (emove the fuel tank and on
T05 and T(7 the air filter housing for best
access. +sing a 8A volt battery and two jumper
wires, connect the battery leads to the fan wiring
connector. =nce connected the fan should
operate. 'f it
D.9a Fan sBitch Birin& connector 1A2;
tem"erature sen!er Birin& connector 1/2 (
TD mo!els
8
b
*
0
PeA
c
iS tN =*
D.9c Fan sBitch Birin& connector 1A2;
tem"erature sen!er Birin& connector 1/2 (
XT3 mo!els
does not, and the wiring is all good, then the
fan is faulty.
ReneBal
'arning: +he engine must be
completel) cool before carr)ing out this
procedure.
,
D (emove the radiator .see 1ection B/.
; +nscrew the three bolts securing the fan
shroud and fan assembly to the radiator 1see
illustration2. =n T05 and T(7 models,
unscrew the bolts on the front of the fan
securing it to the shroud and remove the
shroud. 1eparate the fan blade from the
motor and renew the motor. =n 7TE models,
individual components are not available and
the entire fan assembly must be renewed.
C 'nstallation is the reverse of removal.
B 'nstall the radiator .see 1ection B/.
Cooling fan switch
9hec'
8 'f the engine is overheating and the cooling
fan isn't coming on, first check the fan circuit
fuse .see "hapter 9/. 'f the fuse is blown,
check the fan circuit for a short to earth .see
the wiring diagrams at the end of this book/.
9 'f the fuse is good, on T05 and T(7
models, remove the fuel tank and air filter
housing .see "hapter 6/. =n 7TE models,
remove the left#hand fairing side panel .see
"hapter >/. 0isconnect the wiring connectorfs/
from the fan switch, mounted in the thermostat
housing 1see illustrations2. +sing a jumper
wire, connect between the terminals in the
wiring connectorfs/. The fan should come on. 'f
it does, the fan switch is defective and must be
renewed. 'f it does not come on, the fan
should be tested .see 1tep @/.
8? 'f the fan is on the whole time, disconnect
the wiring connector. The fan should stop. 'f it
does, the fan switch is defective and must be
renewed. 'f it doesn't, check the wiring
between the fan switch and the fan motor,
and the fan itself.
88 'f the fan works but is suspected of
Starte! by Stal'er
@L6 "ooling system
cutting in at the wrong temperature, a more
comprehensive test of the switch can be made as
follows.
8A (emove the switch .see 1teps 86 to 8B/. 4ill
a small heatproof container with coolant and
place it on a stove. "onnect the probes of an
ohmmeter to the terminals of the switch, and
using some wire or other support suspend the
switch in the coolant so that just the sensing
portion and switch body are submerged 1see
illustration2. Also place a thermometer capable
of reading temperatures up to 88?L? in the
coolant so that its bulb is close to the switch.
%ote) 'one o! the components should be allowed
to directly touch the container.
8@ 'nitially the ohmmeter reading should be very
high indicating that the switch is open .=44/.
Heat the coolant, stirring it gently.
'arning: +his must be done ver)
carefull) to avoid the risk of personal
in-ur). -hen the temperature reaches
around 8?A to 8?>W" the meter reading should
drop to around &ero ohms, indicating that the
switch has closed .=)/. )ow turn the heat off. As
the temperature falls below 9>W" the meter
reading should show infinite .very high/
resistance, indicating that the switch has opened
.=44/. 'f the meter readings obtained are
different, or they are obtained at different
temperatures, then the switch is faulty and must
be renewed.
$
Remo,al an! installation
'arning: +he engine must be
completel) cool before carr)ing out
this procedure. ,
*D 0rain the cooling system .see "hapter 8/.
%ote) The !an switch is positioned near the top o!
the cooling system so coolant draining can be
avoided i! care is taken to catch any coolant
which escapes as the switch is removed.
*0 =n T05 and T(7 models, remove the fuel
tank and air filter housing .see "hapter 6/. =n
7TE models, remove the left#hand fairing side
panel .see "hapter >/. 0isconnect the wiring
connector.s/ from the fan switch, mounted in the
thermostat housing 1see illustrations D.9a; b
an! c2. +nscrew the switch and withdraw it from
the housing.
8C Apply a suitable thread locking and sealing
compound to the switch threads, then install the
switch and tighten it to the tor,ue setting
specified at the beginning of the "hapter. Take
care not to overtighten the switch as the housing
could be damaged.
8B (econnect the switch wiring and refill or top
up the cooling system .see "hapter 8/.
; "oolant temperature
gaugeDwarning light and
sender # check and renewal H
'arning: +he engine must be
completel) cool before carr)ing
out work on the temperature
sender.
Coolant temperature gauge
3:+>, +": and ;<<;/<? +D8
models4
"heck
8 The circuit consists of the sender mounted in
the thermostat housing and the gauge assembly
mounted in the instrument panel. 'f the system
malfunctions check first that the battery is fully
charged and that the fuses are all good. 'f they
are, on T05 and T(7 models, remove the fuel
tank and air filter housing .see "hapter 6/. =n
7TE models, remove the left#hand fairing side
panel .see "hapter >/.
A 0isconnect the wire from the sender and turn
the ignition switch =) 1see illustrations D.9a; b
an! c2. The temperature gauge needle should be
on the " on the gauge. )ow earth the sender
wire on the engine. The needle should swing
immediately over to the H on the gauge.
Caution: Do not earth the wire for an) longer
than is necessar) to take the reading, or the
gauge ma) be damaged.
'f the needle moves as described above, the
sender is proven defective and must be renewed.
8 'f the needle movement is still faulty, or if it
does not move at all, the fault lies in the wiring
or the gauge itself. "heck all the relevant
wiring and wiring connectors .see "hapter 9/.
'f all appears to be well, the gauge is defective
and must be renewed.
Remo,al an! installation
D 1ee "hapter 9, 1ection 8C.
Coolant temperature warning light
3;<<< +D8 models4
; The circuit consists of the sender mounted in
the thermostat housing and the coolant
temperature warning light in the instrument panel.
The warning light should illuminate briefly when
the ignition is first turned on as a check of the
warning light bulb the light should then
e%tinguish. 'f the bulb doesn't li&ht; it is probably
blown and should be renewed as described in
"hapter 9. -ess likely is a wiring fault, but
referring to the wiring diagram at the end of this
manual, check the coolant temperature warning
light circuit wiring for continuity.
C The bulb should illuminate if the engine coolant
ever reaches too high a temperature. 'f you
suspect that the bulb is failing to come on check
the sender as described below.
Sender check 3all models4
4 The sender is mounted in the thermostat
housing. =n T05 and T(7 models, remove the
fuel tank and air filter housing .see "hapter 6/.
=n 7TE models, remove the left#hand fairing side
panel .see "hapter >/. 0rain the cooling system
.see "hapter 8/. %ote) The sender is positioned
near the top o! the cooling system so coolant
draining can be avoided i! care is taken to catch
any coolant which escapes as the sender is
removed.
8 0isconnect the sender wiring connector 1see
illustrations D.9a; b an! c2. +sing a continuity
tester, check for continuity between the sender
body and earth on the motorcycle's frame. There
should be continuity. 'f there is no continuity,
check that the thermostat mounting is secure,
and where fitted, that the thermostat housing
earth wire is securely connected.
9 +nscrew the sender and remove it from the
thermostat housing .see below/. Test the sender
according to the appropriate subsection.
*99* to *990 TD mo!els an! all XT3
models
*0 4ill a small heatproof container with
coolant mi%ture and place it on a stove. +sing
an ohmmeter, connect the positive .^ve/
probe of the meter to the terminal on the
sender, and the negative .#ve/ probe to the tip
of the sender. +sing some wire or other
support suspend the sender in the coolant so
that it is submerged. Also place a
thermometer capable of reading temperatures
up to 8A?W" in the coolant so that its bulb is
close to the sender 1see illustration2. %ote)
'one o! the components should be allowed to
directly touch the container.
Scane! by Stal'er
D.*6 Fan sBitch testin& set(u"
?
A
0.*0 Tem"erature sen!er testin& set(u" (
*99* to *990 TD mo!els an! all XT3
mo!els
+)($2'1T$($0 3'
9oolin& system 8P0
** Heat the coolant, stirring it gently. -hen
the temperature reaches around ;?W" the
meter should read 8;6 ohms. -hen the
temperature reaches around >?W" the meter
should read between 6B and ;@ ohms. -hen
the temperature reaches around 8??W" the
meter should read between AC and A9 ohms.
-hen the temperature reaches around 8A?W"
the meter should read 8C ohms. 'f the meter
readings obtained are different, or they are
obtained at different temperatures, then the
sender is faulty and must be renewed. *995(
on TD mo!els an! all TRX mo!els
*6 4ill a small heatproof container with water
and place it on a stove. +sing an ohmmeter,
connect the positive .^ve/ probe of the meter
to the terminal on the sender, and the
negative .#ve/ probe to the body of the
sender. +sing some wire or other support
suspend the sender in the water so that just the
sensing portion and the threads are submerged.
Also place a thermometer capable of reading
temperatures up to 88?W" in the water so that its
bulb is close to the sender 1see illustration2.
%ote) )one o! the components should be
allowed to directly touch the container.
*8 Heat the water, stirring it gently. -hen the
temperature reaches around >?W" the meter
should read 6B to ;@ ohms. -hen the
temperature reaches around 8??W" the meter
should read AC to @? ohms. 'f the meter readings
obtained are different, or they are obtained at
different temperatures, then the sender is faulty
and must be renewed.
Sender removal and installation
3all models4
*D 0rain the cooling system .see "hapter 8/.
=n T05 and T(7 models, remove the fuel tank
and air filter housing .see "hapter 6/. =n 7TE
models, remove the left#hand fairing side panel
.see "hapter >/.
*0 0isconnect the sender wiring connector
0.*6 Tem"erature sen!er testin& set(u"
(*995(on TD mo!els an! all TRX mo!els
1see illustrations D.9a; b an! c2. +nscrew the
sender and remove it from the thermostat
housing.
*5 Apply a suitable thread locking and sealing
compound to the sender threads, then install the
sender and tighten it to the tor,ue setting
specified at the beginning of the "hapter. Take
care not to overtighten the sender as the housing
could be damaged.
*4 (econnect the sender wiring and top up the
cooling system .see "hapter 8/.
Thermostat housin& an! =
thermostat # removal, check J>
and installation H
"emoval
'arning: +he engine must be completel) cool
before carr)ing out this procedure.
8 The thermostat is automatic in operation and
should give many years of service without
re,uiring attention. 'n the event of a failure, the
valve will probably jam open, in which
5.8
Slac'en the clam" screBs
an! "ull off the hoses
case the engine will take much longer than
normal to warm up. "onversely, if the valve jams
shut, the coolant will be unable to circulate and
the engine will overheat. )either condition is
acceptable, and the fault must be investigated
promptly.
A 0rain the cooling system .see "hapter 8/.
@ The thermostat is located in the thermostat
housing. =n T05 and T(7 models, remove the
fuel tank and air filter housing .see "hapter 6/.
=n 7TE models, remove the left#hand fairing side
panel .see "hapter >/. 1lacken the clamps
securing the hoses to the housing and detach the
hoses, noting which fits where 1see illustration
an! D.9b an! c/. =n 7TE models, release the
clamp securing the overflow hose to the filler
neck and detach the hose.
6 0isconnect the fan switch and temperature
sensor wiring connectors 1see illustrations D.9a;
b an! c/. -here fitted, also slacken the screw
securing the earth lead and detach the lead.
; +nscrew the bolt securing the thermostat
housing and remove the housing, noting how it
fits 1see illustration an! D.9b an! c/.
C +nscrew the two bolts securing the cover and
separate it from the housing 1see illustration2.
-ithdraw the thermostat, noting
8
5.0 Thermostat housin& mountin& bolt 1arroBe!2 ( TD mo!els 5.5a EnscreB the bolts an! remo,e the co,er ...
+)($2'1T$($0 3'
Scane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($0 +)($2'1T$($0 3$(1'=) =4 P'"T+($0
@[C "ooling system
TH$(5=5$T$(
5.5b ... an! Bith!raB the thermostat
5.8 Thermostat testin& set(u"
how it fits 1see illustration2. 0iscard the cover
=#ring as a new one must be used.
-heck
4 $%amine the thermostat visually before
carrying out the test. 'f it remains in the open
position at room temperature, it should be
renewed.
8 1uspend the thermostat by a piece of wire in a
container of cold water. Place a thermometer in
the water so that the bulb is close to the
thermostat 1see illustration2. Heat the water,
noting the temperature when the thermostat
opens, and compare the result
with the specifications given at the beginning of
the "hapter. Also check the amount the valve
opens after it has been heated at 9;W" for a few
minutes and compare the measurement to the
specifications. 'f the readings obtained differ from
those given, the thermostat is faulty and must be
renewed.
9 'n the event of thermostat failure, as an
emergency measure only, it can be removed
and the machine used without it. %ote) Take
care when starting the engine !rom cold as it
will take much longer than usual to warm up.
$nsure that a new unit is installed as soon as
possible.
)nstallation
*0 4it the thermostat into the housing, making
sure that it seats correctly and that the hole is at
the top 1see illustration 5.5b2.
** 4it a new =#ring onto the cover, using a dab
of grease to keep it in place if re,uired 1see
illustration2. 4it the cover onto the housing, then
install the two bolts and tighten them to the
tor,ue setting specified at the beginning of the
"hapter 1see illustrations 5.5a2.
*6 'nstall the thermostat housing and tighten the
bolt to the specified tor,ue setting 1see
illustrations D.9b an! c2. "onnect the hoses
and tighten the clamps securely. Also connect the
wiring connectors, not forgetting the earth lead,
where fitted. 8@ (efill the cooling system .see
"hapter 8/.
B (adiator #
removal and installation
/emoval
'arning: +he engine must be
completel) cool before carr)ing out this
procedure. $
8 (emove the fairing side panels on T05 and
7TE models, and the fairing on T(7 models .see
"hapter >/. (emove the fuel tank, and on T05
and T(7 models, the air filter housing .see
"hapter 6/. 0rain the cooling system .see "hapter
8/.
A Trace the fan motor wiring and disconnect it at
the connector 1see illustrations D.8a an! b2.
@ 1lacken the clamps securing the radiator
hoses and detach them from the radiator 1see
illustrations2.
6 +nscrew the bolts securing the radiator, noting
the arrangement of the collars and rubber
grommets, and carefully manoeuvre
4.8a Detach the u""er.
TH$(5=1TAT
5.** Fit the co,er usin& a neB .(rin&
4.8b ... an! loBer ra!iator hoses 1early TD shoBn2...
4.8c ... an! on TD an! TRX mo!els the o,erfloB hose 1arroBe!2
+)($2'1T$($03$(1'=) =4 P'"T+($#0
Scane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0'
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<8
eT+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
"ooling system @LB
4.Da Ra!iator mountin& bolts 1arroBe!2 (*99* to *990 TD mo!els
4.Db Ra!iator mountin& bolts 1arroBe!2 (
*995(on TD mo!els an! all TRX mo!els
1TRX shoBn2
4.Dc Ra!iator mountin& bolts 1arroBe!2 (
XT3 mo!els. %ote hoB the rubber !am"er
locates in the brac'et 1A2
the radiator away from the machine, noting
how it fits 1see illustrations2.
0 =n T05 models, if re,uired, unscrew the
bolts securing the radiator stay to the frame
and remove the stay.
5 'f necessary, remove the cooling fan .see
1ection 6/ from the radiator.
4 'f re,uired, remove the stone guard from
the radiator. "heck the stone guard and the
radiator for signs of damage and clear any dirt
or debris that might obstruct air flow and
inhibit cooling. 'f the radiator fins are badly
damaged or broken the radiator must be
renewed. Also check the rubber mounting
grommets, and renew them if necessary.
&nstallation
> 'nstallation is the reverse of removal, noting
the following.
a) Eake sure the various collars and
grommets are correctly installed with the
mounting bolts.
b) Eake sure that the !an wiring is correctly
connected.
c) .nsure the coolant hoses are in good
condition (see -hapter #)& and are
securely retained by their clamps& using
new ones i! necessary.
d) (n completion re!ill the cooling system as
described in -hapter #.
8 7ater "um" # check, QJ
removal, and installation JJ
Check
* The water pump is located on the right#
hand side of the engine. 3isually check the
area around the pump for signs of leakage.
6 To prevent leakage of water from the
cooling system into the lubrication system
and vice versa, two seals are fitted on the
pump shaft. =n the underside of the pump
body there is a drainage hole 1see illustration
8.*6a2. 'f either seal fails, this hole should
allow the coolant or oil to escape and prevent
the oil and coolant mi%ing.
8 'f there is any leakage from the drainage
hole, remove the pump and renew it
#individual components .e%cept =#rings and
bolts/ are not available.
"emoval
60rain the coolant .see "hapter 8/. Place a
suitable container below the water pump to
catch any residue as the water pump is
removed. =n 7TE models, remove the
e%haust system .see "hapter 6/. Also unscrew
the bolts securing the right#hand frame
downtube section and remove it.
;1lacken the clamp securing the coolant
hose to the pump cover and detach the hose
1see illustration2.
5 +nscrew the bolts securing the pump to the
crankcase 1see illustration2. "arefully draw
the pump from the crankcase, noting how it
fits. 't may be necessary to lever it out to
overcome the =#rings on the pump body and
on the joint pipe between the top of the pump
housing and the union on the cylinder block.
Caution: , shim is fitted on the pump shaft
between the circlip and the drive gear. +he
shim will probabl) stick to the gear,
however great care must be taken as it is
possible for the shim to slip down into the
engine as the shaft is withdrawn from the
gear.
(emove the =#ring from the rear of the pump
body and from the joint pipe and discard them
as new ones must be used. )ote the position
of each bolt as their lengths differ.
B+nscrew the remaining bolts securing the
pump cover and remove the cover 1see
illustration 8.52. 0iscard the cover =#ring as a
new one must be used.
>-iggle the water pump impeller back#and#
forth and in#and#out. 'f there is e%cessive
movement the pump must be renewed.
(otate the impeller and check that it turns
smoothly and freely. Also check for corrosion
or a build#up of scale in the pump body and
clean or renew the pump as necessary.
9To remove the pump drive gear, first
remove the front balancer shaft .see "hapter
A/. 1lide the gear out of its bore in the @
crankcase and lift it out, noting how it fits 1see
illustration2.
8.0 Slac'en the clam" 1arroBe!2 an! !etach the hose
8.5 7ater "um" mountin& bolts 1A2; co,er bolts 1A2 an! 1/2
8.9 7ater "um" !ri,e &ear 1arroBe!2
=)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< 8
Stane! by Stal'er
+)($2'1T$($0 3$(1'0)+4 P'"T+($#0$1<
@[> "ooling system
8.**a Fit the .(rin& into the &roo,e in the
co,er...
8.**b ..
then fit the co,er an! its tBo
bolts
1^^^.344i5
-
miMU
67
7
8.*6a Fit a neB .(rin& onto the bo!y...
&nstallation
*0 'f removed, slide the shouldered side of the
pump drive gear into its bore in the crankcase
1see illustration 8.92. 'nstall the front balancer
shaft .see "hapter A/.
** 'nstall the new cover =#ring into its groove in
the pump 1see illustration2. 4it the cover and
secure it with the two bolts 1see illustration2.
*6 4it the new pump body =#ring and joint pipe
=#ring 1see illustration2. Apply some grease to
the shim to stick it in place, then slide it onto the
pump shaft 1see illustrations2. 'nstall the pump
into the crankcase, making sure it locates
correctly into the driven gear 1see illustration2.
'nstall the bolts and tighten them to the tor,ue
setting specified at the beginning of the "hapter
1see illustration 8.52. 5ake sure the different
length bolts are in their correct locations.
*8 Attach the coolant hose to the pump cover
and secure it with its clamp 1see illustration
8.02.
*D =n 7TE models, install the frame downtube
and tighten its bolts to the specified tor,ue
setting .see "hapter A/.
Also install the e%haust system .see "hapter 6/.
8; (efill the cooling system .see "hapter 8/.
9 .))/a#t 0)121 -
removal and installation
'&'&- &&3:; :;:;;.'.&*4 T 5/'6#--
:
"emoval
* *efore removing a hose, drain the coolant
.see "hapter 8/.
6 +se a screwdriver to slacken the larger#bore
hose clamps, then slide them back along the
hose and clear of the union spigot 1see
illustrations 5.8; 4.8a an! b2. The smaller#bore
hoses are secured by spring clamps which can
be e%panded by s,uee&ing their ears together
with pliers 1see illustration 4.8c2.
Caution: +he radiator unions are fragile. Do
not use e*cessive force when attempting to
remove the hoses.
8 'f a hose proves stubborn, release it by
rotating it on its union before working it off. 'f
all else fails, cut the hose with a sharp knife
then slit it at each union so that it can be peeled
off in two pieces. -hilst this means replacing the
hose, it is preferable to buying a new radiator.
6 The water pipe union on the front of the
cylinder block can be removed by unscrewing
the retaining bolts .see "hapter A, 1ection 8@/.
'f it is removed, the =#rings must be renewed.
&nstallation
; 1lide the clamp onto the hose and then
work it on to its respective union.
&f the hose is difficult to . H
push on its union, it can be <Gllt?T! so!tened
by soaking it in
ver) hot water, or alternativel) a
little soap) water can be used as a
lubricant.
5 (otate the hose on its union to settle it in
position before sliding the clamp into place and
tightening it securely.
4 'f the water pipe union on the engine has been
removed, fit new =#rings, then install the union
and tighten the mounting bolts to the specified
tor,ue setting .see "hapter A, 1ection 8@/.
8.*6b ... then &rease the shim ..
=
8.*6c ... an! sli!e it onto the shaft
8.*6! ?nstall the "um"; ma'in& sure it locates correctly into the !ri,e &ear
Stane! by Stal'er
)*1
9ha"ter D
4uel and e%haust systems
9ontents
Air filter # cleaning and renewal..............................................see "hapter 8
Air filter housing # removal and installation............................................... 6
"arburettor overhaul # general information ............................................ C
"arburettor synchronisation ................................................see "hapter 8
"arburettor warmer system # 899C#on T05 and T(7 models..................8C
"arburettors # disassembly, cleaning and inspection ............................. >
"arburettors # reassembly, and fuel level check .....................................8?
"arburettors # removal and installation ................................................. B
"arburettors # separation and joining....................................................... 9
"hoke cable # removal and installation .................................................8A
$%haust system # removal and installation...............................................8@
4uel hoses # renewal ............................................................see "hapter 8
4uel level sender and gauge ................................................ see "hapter 9
De&rees of !ifficulty
4uel pump # check and renewal
.T(7, 7TE and 8998 to 899> T05 models/........................................86
4uelpump#checkand renewal .8999T05models/....................................8;
4uel system # check ........................................................... see "hapter 8
4uel tank # cleaning and repair................................................................ @
4uel tank and fuel tap.s/ # removal and installation ............................... A
2eneral information and precautions ...................................................... 8
'dle fuelDair mi%ture adjustment # general information ............................ ;
'dle speed # check................................................................. see "hapter 8
Throttle and choke cables # check and adjustment ... .see "hapter 8
Throttle cables # removal and installation................................................. 88
Throttle position sensor .899C#on T05 models
and all T(7 models/ # check and adjustment ....................see "hapter ;
Easy; suitable for
novice with little
#G Z
%&'%(i%)*%
4airly easy, suitable Jk for
beginner with NQJ some
e%perience =S
Fairly !ifficult; Jk
suitable for competent PH
0': mechanic H
Difficult; suitable for H
e%perienced 0': Aj
mechanic =S
Qery !ifficult;
suitable for e%pert 0': LP
or professional Nj1
S"ecifications
Fuel
2rade ........................................................................................................... +nleaded, minimum 98 (=) .(esearch =ctane )umber/
4uel tank capacity .including reserve/
8998 to 899; T05 models........................................................................ 8>.? litres
899C#on T05 models................................................................................ A?.? litres
T(7 models............................................................................................... 8>.? litres
7TE models............................................................................................... AC.? litres
(eserve
8998 to 899; T05 models........................................................................ @.; litres
899C#on T05 models................................................................................ @.8 litres
T(7 models.............................................................................................. @.; litres
7TE models............................................................................................... ;.? litres
fcane! by Stal'er
@
6LA 4uel and e%haust systems
9arburettors
Type
8998 to 899> T05 models, all T(7 and 7TE models............................... 5ikuni *01T@>
8999 T05 models.................................................................................... 5ikuni *01(@>
'0 mark
8998 to 899; T05 models........................................................................ @30 ??
899C to 899> T05 models........................................................................ 6T7 ??
8999 T05 models.................................................................................... 6T76
T(7 models.............................................................................................. 6+) ??
7TE models............................................................................................... @F0 ??
Pilot screw setting .turns out/
8998 to 899; T05 models........................................................................ @
899C#on T05 models............................................................................... A
T(7 models........................... ............................................................... A 8DA
7TE models............................................................................................... A
4uel level .see te%t/
8998 to 899; T05 models........................................................................ B.6 to >.6 mm above float chamber line
899C to 899> T05 models and T(7 models ........................................... 8;.>to8C.>mm below 5'<+)' mark
8999 T05 models.................................................................................... @.6 to 6.6 mm below line
7TE models............................................................................................... ;.8 to C.8 mm above float chamber line
'dle speed..................................................................................................... see "hapter 8
9arburettor <et siRes
5ain jet
8998 to 899; T05 models........................................................................ 86?
8999 T05 models..................................................................................... 86B.;
All other models ...................................................................................... 86A.;
5ain air jet
8998 to 899; T05 models........................................................................ ;?
8999 T05 models..................................................................................... C;
All other models ...................................................................................... C?
Pet needle
8998 to 899; T05 models........................................................................ ;2;A#@
899C to 899> T05 models and all T(7 models............................................;$8>;#AD;
8999 T05 models..................................................................................... 8 # C0PP8B A # C"F8
7TE models.............................................................................................. ;"89#@
)eedle jet
8998 to 899; T05 models and all 7TE models........................................ :#6
899C to 899> T05 models and all T(7 models........................................ :#A
8999 T05 models..................................................................................... P#?
Pilot air jet
7TE models.............................................................................................. C?
8999 T05 models.................................................................................... >B.;
All other models ...................................................................................... B?
Pilot jet
8998 to 899; T05 models........................................................................ @B.;
899C to 899> T05 models and all T(7 models........................................ 6;
8999 T05 models.................................................................................... 8B.;
7TE models.............................................................................................. 6A.;
1tarter jet
7TE models.............................................................................................. B?
8999 T05 models..................................................................................... @A.;
All other models ...................................................................................... B;
Fuel le,el sen!er
(esistance
4uel tank full ............................................................................................ 6 to 8? ohms P A?W"
4uel tank empty ...................................................................................... 9? to 8?? ohms d A?W"
TorAue settin&s
$%haust downpipe flange nuts...................................................................... A? )m
$%haust clamp bolts...................................................................................... A? )m
1ilencer and collector bo% mounting bolts..................................................... A6 )m
4ootrest bracket mounting bolts .7TE models/ .......................................... A? )m
Scane! by Stal'er
4uel an! e%haust systems DI8
* \eneral ?nformation an!
"recautions
#eneral information
The fuel system consists of the fuel tank with
internal filter, fuel tap, fuel pump, carburettors, fuel
hoses and control cables.
=n T05 models, a remote fuel tap is fitted for
normal operation, while the filter is integral with the
fuel outlet assembly from the tank. =n T(7
models, a vacuum#operated fuel tap with integral
filter is mounted on the left#hand side of the fuel
tank. =n 7TE models, a fuel tap with integral filter
is mounted on each side of the fuel tank.
4uel is pumped to the carburettors by a
vacuum#operated fuel pump on all T(7 and 7TE
models and 8998 to 899> T05 models. The 8999
T05 model has an electrically#operated fuel
pump.
The carburettors used on all models are "3
types. There is a carburettor for each cylinder. 4or
cold starting, a choke knob is connected to the
carburettors by a cable. =n 8998 to 899; T05
models, the choke knob is mounted above the
front sprocket cover on 899C#on T05 models and
7TE models it is mounted on the handlebars on
T(7 models it is mounted on the frame between
the fuel tank and the fairing. =n 899C#on T05 and
T(7 models the carburettors are warmed by the
engine's coolant.
Air is drawn into the carburettors via an air filter
which is housed under the fuel tank.
The e%haust system is a two#into#two design.
5any of the fuel system service procedures are
considered routine maintenance items and for that
reason are included in "hapter 8.
2recautions
A 'arning: 2etrol 3gasoline4 is
an) fuel on )our skin, rinse it off immediatel)
with soap and water. 'hen )ou perform an)
kind of work on the fuel s)stem, wear safet)
glasses and have a fire e*tinguisher suitable
for a class ( t)pe fire 3flammable li.uids4 on
hand.
Always perform service procedures in a well#
ventilated area to prevent a build#up of fumes.
)ever work in a building containing a gas
appliance with a pilot light, or any other form of
naked flame. $nsure that there are no naked
light bulbs or any sources of flame or sparks
nearby.
0o not smoke .or allow anyone else to smoke/
while in the vicinity of petrol .gasoline/ or of
components containing it. (emember the
possible presence of vapour from these sources
and move well clear before smoking.
"heck all electrical e,uipment belonging to the
house, garage or workshop where work is being
undertaken .see the 1afety firstU section of this
manual/. (emember that certain electrical
appliances such as drills, cutters etc. create
sparks in the normal course of operation and
must not be used near petrol .gasoline/ or any
component containing it. Again, remember the
possible presence of fumes before using
electrical e,uipment.
Always mop up any spilt fuel and safety
dispose of the rag used.
Any stored fuel that is drained off during
servicing work must be kept in sealed containers
that are suitable for holding petrol .gasoline/, and
clearly marked as such the containers
themselves should be kept in a safe place. )ote
that this last point applies e,ually to the fuel tank
if it is removed from the machine also remember
to keep its filler cap closed at all times.
(ead the 1afety firstU section of this manual
carefully before starting work.
6 Fuel tan' an! fuel tap.s/
#removal and installation
A
6.6 Detach the loBer hose 1A2; then
unscreB the bolts 1/2 an! !is"lace
the ta"
6uel tank / +D8 models
Remo,al
* 5ake sure the fuel cap is secure and the fuel
tap is in the =44 position. =n 8998 to 899;
models, remove the seat, the fairing side panels
and the fairing .see "hapter >/. =n 899C#on
models, remove the seat, the fairing side panels
and the side trim panels .see "hapter >/.
6 =n 8998 to 899; models, release the clamp
securing the lower hose .to the fuel pump/ on the
remote fuel tap and detach the hose, then
unscrew the bolts securing the tap and displace
it 1see illustration2.
8 =n 899C to 899> models, either proceed as
described for the earlier models in 1tep A, or
close the tap on the fuel outlet assembly under
the tank and detach the fuel hoses from the
outlet, noting which fits where. )ote that access
may be restricted until the tank bolts have been
removed and the tank can be raised at the rear.
D =n 8999 models, turn the fuel tap lever to the
=44 position. (elease the clamp securing the
hose to the side of the fuel tap and detach the
hose.
0 +nscrew the bolt securing the rear of the tank,
then unscrew the bolt on each side at the front
and release the trim panel from the lug 1see
illustrations2. (aise the tank at the rear and
release the clamp securing the breather hose to
its union and detach the hose 1see illustration2.
=n 8998 to 899>
6.0a EnscreB the rear bolt 1arroBe!2...
e*tremel) flammable, so take e*tra
precautions when )ou work on an) part of
the fuel s)stem. Don1t smoke or allow open
flames or bare light bulbs near the work area,
and don1t work in a garage where a natural
gas/t)pe appliance is present. &f )ou spill
'arning: "efer to the precautions
given in Section ; before starting
work.
6.0b ... an! the bolt on each si!e 1A2; an! release the trim from the lu& 1/2
6.0c Detach the hose from the union 1arroBe!2 an! remo,e the tan'
Scane! by Stal'er
6[6 4uel and e%haust systems
6.9a Detach the fuel hose 1A2; the ,acuum hose 1/2...
6.9b ... an! the breather hose 1arroBe!2
6.*0a Remo,e the rear mountin& bolt 1arroBe!2...
models, carefully lift the tank off the frame and
remove it, bringing the remote fuel tap and hoses
with it .where still attached/, making sure the tap
does not get snagged. =n 8999 models, carefully
lift the tank up to access the fuel level sender
wiring disconnect the wiring and remove the
tank, making sure the tap does not get snagged.
C 'nspect the tank mounting rubbers for signs
of damage or deterioration and renew them if
necessary.
?nstallation
4 'nstallation is the reverse of removal, noting
the followingG
a) Eake sure the hoses are properly attached
and secured by their clamps.
b3 (n #779 to #77; models& i! the tap on the
!uel outlet !rom the tank was turned (FF& do
not !orget to turn it back ('.
c) *on't !orget to reconnect the !uel level
sender wiring on #777 T*E models.
d) +tart the engine and check that there is no
sign o! !uel leakage& then shut i! o!!.
6uel tank / +": models
Remo,al
8 5ake sure the fuel filler cap is secure and the
fuel tap is in the =) or ($1 position. (emove
the seat .see "hapter >/.
9 (elease the clamps securing the fuel hose to
the fuel pump and the vacuum hose to the fuel
tap and detach the hoses 1see illustration2. Also
release the clamp securing
the breather hose to its union and detach the
hose 1see illustration2.
*0 +nscrew the nut and withdraw bolt securing
the rear of the tank, then unscrew the bolt on
each side at the front 1see illustrations2.
** "arefully lift the tank off the frame and
remove it.
*6 'nspect the tank mounting rubbers for signs
of damage or deterioration and renew them if
necessary.
?nstallation
*8 'nstallation is the reverse of removal,
noting the followingG
a) Eake sure the hoses are properly attached
and secured by their clamps.
b) +tart the engine and check that there is no
sign o! !uel leakage& then shut i! o!!.
6uel tank / :+> models
Remo,al
*D 5ake sure the fuel filler cap is secure and
both fuel taps are in the =44 position. (emove
the seat and the fairing side panels .see "hapter
>/.
*0 (elease the clamp securing the fuel hose to
each fuel tap and detach the hoses.
*5+nscrew the bolts securing the rear of the
tank, then unscrew the bolt on each side at the
front, and the top bracket#to#frame bolt 1see
illustrations2.
*4 "arefully lift the tank off the frame and
remove it.
*8 'nspect the tank mounting rubbers for
signs of damage or deterioration and renew
them if necessary.
?nstallation
*9 'nstallation is the reverse of removal,
noting the followingG
a) Eake sure the hoses are properly attached
and secured by their damps.
b) +tart the engine and check that there is no
sign o! !uel leakage& then shut i! o!!.
6uel tap3s4
Remo,al
%ote) The tap should not be removed
unnecessarily !rom the tank to prevent the
possibility o! damaging the (-ring or the !ilter.
60 (emove the fuel tank as described above.
6* =n 8998 to 899; T05 models, connect a
drain hose to the fuel outlet union on the remote
tap and insert its end in a container suitable and
large enough for storing the petrol. Turn the fuel
tap to the ($1 position and allow the tank to
drain. -hen the tank has drained, turn the tap to
the =44 position.
66 =n 899C to 899> T05 models, if the remote
tap is still attached, connect a drain hose to the
fuel outlet union on the remote tap and insert its
end in a container suitable and large enough for
storing the petrol. Turn the fuel tap to the ($1
position and allow the tank to drain. 'f the remote
tap was left in situ, connect a drain hose to each
union on the fuel outlet on the tank and insert
their ends in a container suitable and
6.*0b ... an! the front mountin& bolt 1arroBe!2 on each si!e
6.*5a Remo,e the rear mountin& bolts 1arroBe!2...
6.*5b ... an! the front mountin& bolt 1arroBe!2 on each si!e
Stane! by Stal'er
4uel and e%haust systems 6L;
6.65 %ote Bhich hose fits Bhere before !etachin& them
6.64a Fuel outlet screBs 1arroBe!2 ( *99* to *990 TD mo!els
large enough for storing the petrol. Turn the
outlet tap to the =) position and allow the tank to
drain. -hen the tank has drained, turn the tap to
the =44 position.
A@ =n 8999 T05 models, connect a drain hose
to the union on the fuel tap and insert its end in a
container suitable and large enough for storing
the petrol. Turn the tap =) and allow the tank to
drain. -hen the tank has drained, turn the tap to
the =44 position.
A6 =n T(7 models, connect a drain hose to the
fuel outlet union on the tap and insert its end in a
container suitable and large enough for storing
the petrol. Turn the fuel tap to the P(' position
and allow the tank to drain. -hen the tank has
drained, turn the tap back to the =) or ($1
position.
A; =n 7TE models, connect a drain hose to the
fuel outlet union on each tap and insert their ends
in a container suitable and large enough for
storing the petrol. Turn the fuel taps to the ($1
position and allow the tank to drain. -hen the
tank has drained, turn the taps to the =44
position.
AC 'f the fuel tap has been leaking, tightening
the assembly screws may help. 1lacken all the
screws a little first, then tighten them evenly a
little at a time to ensure the cover seats properly
on the tap body. 'f leakage persists, the tap
should be renewed, however nothing is lost by
dismantling the tap for further inspection.
+nscrew the screws and disassemble the tap,
noting how the components fit. 'nspect all
components for wear or damage, and renew
them as necessary, if available. 'f any of the
components are worn or damaged beyond repair
and are not available individually, a new tap must
be fitted. =n 8998 to 899> T05 models, note
which hose fits where on the remote tap 1see
illustration2.
64 (emove the screws securing the tap to the
tank and withdraw the tap assembly 1see
illustrations2. "heck the condition of the =#ring.
'f it is in good condition it can be reused, though
it is better to use a new one. 'f it is in any way
deteriorated or damaged it must be renewed.
68 "lean the gau&e filters to remove all traces
of dirt and fuel sediment. "heck the gau&e for
holes. 'f any are found, a new tap should be fitted
as the filters are not available individually.
69 =n T(7 models, the fuel tap is automatic,
operated by a vacuum created when the
engine is turned over. 'f it is faulty, it can be
disassembled and inspected. The most likely
problem is a hole or split in the diaphragm.
*efore removing and dismantling the tap,
check that the vacuum hose is securely
attached at both ends, and that there are no
splits or cracks in the hose. 'f in doubt, attach
a spare hose to the vacuum union on the tap
and apply a vacuum to the hose. 'f fuel does
not flow through the tap .make sure it is
turned to =) or ($1/, remove it and
disassemble it to check the diaphragm .the
best way is to hold it up to the light, which will
show through any splits or holes/. 1ome
individual components are available for the
tap, but if the diaphragm is split the whole tap
will probably have to be renewed # check with
your dealer.
?nstallation
80 'nstallation is the reverse of removal. +se a
new =#ring on the tap if re,uired, and tighten the
bolts securely.
8* 'nstall the fuel tank .see above/.
6.64b Fuel ta" screBs 1arroBe!2 ( TRX mo!els
6.64c Fuel ta" screBs 1arroBe!2 ( XT3 mo!els
Sorte! by Stal'er
6LC 4uel and e%haust systems
8 Fuel tan' #
cleaning and repair
* All repairs to the fuel tank should be carried
out by a professional who has e%perience in this
critical and potentially dangerous work. $ven
after cleaning and flushing of the fuel system,
e%plosive fumes can remain and ignite during
repair of the tank.
6 'f the fuel tank is removed from the bike, it
should not be placed in an area where sparks or
open flames could ignite the fumes coming out of
the tank. *e especially careful inside garages
where a natural gas#type appliance is located,
because the pilot light could cause an e%plosion.
D Air filter housing #
removal and installation
"emoval
8 (emove the fuel tank .see 1ection A/.
A (elease the clamps securing the breather
hose and the drain hose to the air filter housing
and detach the hoses 1see illustration2.
0epending on your model, it may be easier to
detach the drain hose once the housing has been
lifted off the carburettors.
@ =n T05 and 7TE models, unscrew the bolt
securing the front of the housing to the frame
1see illustrations2. =n all models, slacken the
clamp screws securing the housing to the
carburettor intakes 1see illustration2.
6 Fift the housing up off the carburettors and
remove it, on T(7 models noting how the peg at
the front on the right locates in the grommet on
the frame 1see illustration2. =n 7TE models,
draw the intake ducts apart so that they clear the
frame tube 1see illustration2.
&nstallation
; 'nstallation is the reverse of removal. "heck
the condition of the various hoses and their
clamps and renew them if necessary.
D.8b Air filter housin& bolt 1arroBe!2 J XT3
mo!els
; ?!le fuel+air miCture
a!<ustment #
general information
* 0ue to the increased emphasis on controlling
e%haust emissions, certain governmental
regulations ha,e been formulated which directly
affect the carburation of this machine. The pilot
screws can be adjusted, but the use of an
e%haust gas analyser and an au%iliary
tachometer capable of accurately displaying
changes of ;? rpm is the only certain way to
adjust the idle fuelDair mi%ture and be sure the
machine doesn't e%ceed the emissions
regulations.
6 The pilot screws are set to their correct
position by the manufacturer and should not
D.8c Slac'en the clam" screBs
1arroBe!2...
be adjusted or removed unless it is necessary to
do so during a carburettor overhaul. 'f the screws
are to be removed, record the pilot screw's
current setting by turning the screw it in until it
seats lightly, counting the number of turns
necessary to achieve this, then fully unscrew it.
=n installation, the screw is simply backed out
the number of turns you've recorded. )ote that
for some markets, the pilot screws are sealed
with a plug to prevent tampering.
@ 'f the engine runs e%tremely rough at idle or
continually stalls, and if a carburettor overhaul
does not cure the problem, take the motorcycle
to a :amaha dealer e,uipped with an e%haust
gas analyser. They will be able to properly adjust
the idle fuelDair mi%ture to achieve a smooth idle
and restore low speed performance.
D.8! ... Bhich on XT3 mo!els are accesse! from each si!e 1arroB2
D.8a Air filter housin& bolt 1arroBe!2
(TD mo!els
D.6 Drain hose 1arroBe!2 ( XT3 mo!els
i
D.Da .n TRX mo!els; note hoB the "e& 6.6b .n XT3 mo!els; !raB the !ucts a"art
locates in the &rommet to clear the frame
Scane! by Stal'er
Fuel an! eChaust systems D`4
5 9arburettor o,erhaul (
&eneral information
* Poor engine performance, hesitation, hard
starting, stalling, flooding and backfiring are all
signs that major carburettor maintenance may be
re,uired.
6 <eep in mind that many so#called carburettor
problems are really not carburettor problems at
all, but mechanical problems within the engine or
ignition system malfunctions. Try to establish for
certain that the carburettors are in need of
maintenance before beginning a major overhaul.
8 "heck the fuel tap and filter, the fuel and
vacuum hoses, the intake manifold joint clamps,
the air filter, the ignition system, the spark plugs,
valve clearances and carburettor synchronisation
before assuming that a carburettor overhaul is
re,uired.
D 5ost carburettor problems are caused by dirt
particles, varnish and other deposits which build
up in and block the fuel and air passages,
especially if the motorcycle has been laid up for a
time. Also, in time, gaskets and =#rings shrink or
deteriorate and cause fuel and air leaks which
lead to poor performance.
0 -hen overhauling the carburettors,
disassemble them completely and clean the parts
thoroughly with a carburettor cleaning solvent
and dry them with filtered, unlubricated
compressed air. *low through the fuel and air
passages with compressed air to force out any
dirt that may have been loosened but not
removed by the solvent. =nce the cleaning
process is complete, reassemble the carburettor
using new gaskets and =#rings.
5 *efore disassembling the carburettors, make
sure you have all necessary =#rings and other
parts, some carburettor cleaner, a supply of clean
rags, some means of blowing out the carburettor
passages and a clean place to work. 't is
recommended that only one carburettor be
overhauled at a time to avoid mi%ing up parts.
4.Da ?!le s"ee! a!<uster bolt 1arroBe!2 (TD
mo!els
4 9arburettors # H
removal and installation YJ
'arning: "efer to the precautions
given in Section ; before starting
work. ,
"emoval
* (emove the fuel tank and the air filter housing
.see 1ections A and 6/.
6 1lacken the choke outer cable bracket screw
and free the cable from the bracket on the front of
the carburettors, then detach the inner cable
nipple from the choke linkage lever 1see
illustrations2.
8 0etach the throttle cables from the
carburettors .see 1ection 88, 1teps A and @/.
4.Db ?!le s"ee! a!<uster bolt 1arroBe!2 #TRX
mo!els
'f access is too restricted, detach them after the
carburettors have been lifted off the cylinder
head intakes.
D =n T05 and T(7 models, unscrew the bolt
securing the idle speed adjuster and feed it
through to the base of the carburettors 1see
illustrations2.
0 (elease the clamp securing the drain hose to
the bottom of each float chamber and detach the
hoses 1see illustration2. Also release the clamp
securing the fuel supply hose to the carburettors
and detach the hose 1see illustration2N be
careful to catch the small gau&e filter fitted in the
fuel supply hose union as the hose is detached
.e%cept 8999 T05 models/.
5 =n 899C#on T05 models and T(7 models,
disconnect the wiring connector from the throttle
position sensor on the left#hand end of the
carburettors 1see illustration2. Also
4.6b ... an! !etach the cable en! from the
le,er
4.6a Slac'en the clam" screB 1arroBe!2...
4.0a Detach the !rain hoses 1arroBe!2...
4.0b ... an! the fuel hose
4.5 Disconnect the throttle "osition sensor Birin& connector 1arroBe!2
Stane! by Stal'er
6L> 4uel and e%haust systems
4.4a Slac'en the u""er or loBer clam" screBs as reAuire! 1arroBs2...
4.4b
. an! remo,e the carburettors
clamp the two warmer system coolant hoses to
prevent loss of coolant and disconnect the hose
from the side of each carburettor.
B 4ully slacken the clamps on the cylinder
head intake rubbers, then ease the
carburettors off the intakes and remove them
1see illustrations2. To remove the
carburettors with the rubbers, slacken the
lower clamp bolts .which are more
accessible/. To leave the rubbers on the
cylinder head, slacken the upper clamp bolts.
%ote) Deep the carburettors level to prevent
!uel spillage !rom the !loat chambers and the
possibility o! the piston diaphragms being
damaged.
Caution: Stuff clean rag into each c)linder
head intake after removing the carburettors
to prevent an)thing from falling in.
> Place a suitable container below the float
chambers, then slacken the drain screw on
each chamber in turn and drain all the fuel
from the carburettors 1see illustration2.
Tighten the drain screws securely once all the
fuel has been drained.
9 'f necessary, slacken the clamps securing
the intake rubbers and remove them, noting
which way up and round they fit.
)nstallation
*0 'nstallation is the reverse of removal,
noting the following.
a) -heck !or cracks or splits in the cylinder
head intake rubbers& and renew them i!
necessary.
b) Eake sure the carburettors are !ully
engaged with the intake rubbers and the
clamps are securely tightened.
c) Eake sure all hoses are correctly routed
and secured and not trapped or kinked.
d) /e!er to +ection ## !or installation o! the
throttle cables. -heck the operation o! the
cables and ad3ust them as necessary (see
-hapter #).
e) /e!er to +ection #2 !or details o! choke
cable reconnection.
!) -heck idle speed and carburettor
synchronisation and ad3ust as necessary
(see -hapter #).
"arburettors
cleaning and inspection
'arning: "efer to the precautions
given in Section ; before starting
work.
#77# to #77; T*E models& all T/F
and FTG models
0isassembly
8 (emove the carburettors from the machine as
described in the previous 1ection. %ote) *o not
separate the carburettors unless absolutely
necessary? each carburettor can be dismantled
su!!iciently !or all normal cleaning and
ad3ustments while in place on the mounting
brackets. *ismantle the carburettors separately
to avoid interchanging parts.
A +nscrew and remove the top cover retaining
screws 1see illustration2. Fift off the cover and
remove the spring from inside the piston, noting
the spring seat fitted in the
I
> K K , = ST'.. /y
HrHfc #
G
4.8 Float chamber !rain screB 1arroBe!2 8.6 Remo,e the screBs 1arroBe!2 an! lift off the co,er
Stane! by Stal'er
A
disassembly, HsN
*
4uel and e%haust systems 6L9
8.8 Remo,e the air "assa&e .(rin&
8.D -ift out the !ia"hra&m+"iston assembly
bottom of the spring 1see illustrations *0.*6b
an! a2.
@(emove the air passage =#ring and discard it
as a new one should be used 1see illustration2.
6"arefully peel the diaphragm away from its
sealing groove in the carburettor and withdraw
the diaphragm and piston assembly 1see
illustration2.
Caution: Do not use a sharp instrument to
displace the diaphragm as it is easil)
damaged.
; Push the jet needle up from the bottom of
the piston and withdraw it from the top, along
with the washer 1see illustration2. 'f the $#clip is
removed from the needle, note which notch it is
fitted into.
C (emove the screws securing the float
chamber to the base of the carburettor and
remove the float chamber, noting how it fits 1see
illustration2. (emove the rubber gasket and
discard it as a new one must be used.
B "arefully prise the float assembly out of the
carburettor body, noting how it fits 1see
illustration2. (emove the =#ring and discard it
as a new one must be used. 'f re,uired, withdraw
the float pivot pin and remove the float and
needle valve, then unhook the
needle valve from the tab on the float, noting
how it fits 1see illustration2.
8 +nscrew and remove the starter jet, then
remove the main jet holder, noting how it fits 1see
illustration2. (emove the main jet # it is a push
fit. 0iscard the =#ring as a new one should be
used.
9 +nscrew and remove the pilot jet 1see
illustration 8.82.
*0 +nscrew the bolt securing the jet housing
and remove the collar 1see illustration2.
(emove the jet housing and discard its rubber
gasket as a new one should be used. Push on
the needle jet and withdraw the piston guide
yffiiH
Hns HD
"NiNtoiti&
F
<
wmm
8.0 Remo,e the <et nee!le an! its Basher 8.5 Remo,e the screBs 1arroBe!2 an! lift off
the float chamber
8.4a 9arefully "rise out the float assembly
8.4b 7ith!raB the "i,ot "in an! se"arate
the float; nee!le ,al,e an! seat
8.8 Starter <et 1A2; main <et hol!er 1/2; main <et
192; "ilot <et 1D2
8.*0a EnscreB the bolt 1A2; remo,e the
collar 1/2; an! lift off the <et housin& 192
Scane! by Stal'er
51
"hapter ;
'gnition system
9ontents
2eneral information................................................................................. 8
'gnitor unit # check, removal and installation .......................................... ;
'gnition .main/ switch # check, removal and
installation ...................................................................... see "hapter 9
'gnition HT coils # check, removal and installation................................... @
'gnition system # check............................................................................ A
'gnition timing # general information and check........................................ C
)eutral switch # check and replacement................................see "hapter 9
Pick#up coil # check and replacement ..................................................... 6
1idestand switch # check and replacement ..........................see "hapter 9
1park plugs # gap check and replacement.............................see "hapter 8
Throttle position sensor .899C#on T05 and T(7/ #
check, adjustment and replacement.................................................... B
De&rees of !ifficulty
Easy; suitable for
novice with little
e%perience
Fairly easy; suitable JH for
beginner with lQ some
e%perience >S
Fairly !ifficult; Jk
suitable for competent ;H
0': mechanic ?<S
Difficult; suitable for QI,
e%perienced 0': NK
mechanic
Qery !ifficult;
H
suitable for e%pert
0': Aj
or professional
AH
S"ecifications
\eneral information
"ylinder numbering
Feft ........................................................................................................... 8
(ight ........................................................................................................ A
1park plugs................................................................................................... see "hapter 8
?&nition timin&
At idle ........................................................................................................... 8?W *T0"
4ull advance
8998 to 899; T05 models........................................................................ 6AW *T0" d ;??? rpm
7TE models............................................................................................... 6@W *T0" d C??? rpm
899C#on T05 models and T(7 models.................................................... not available
#ic'(u" coil
(esistance
8998 to 899; T05 models and 7TE models ........................................... 8>6 to ABC ohms d A?W"
899C#on T05 models and T(7 models.................................................... 89A to A>> ohms d A?W"
?&nition GT coils
Primary winding resistance
8998 to 899; T05 models and all 7TE models........................................ A.@> to @.AA ohms P A?W"
899C#on T05 models and all T(7 models................................................ @.8? to 6.C? ohms P A?W"
1econdary winding resistance .without plug cap/
8998 to 899; T05 models and all 7TE models........................................ 8A.? to 8>.? <#ohms d A?W"
899C#on T05 models and all T(7 models................................................ 8?.6 to 8;.C <#ohms d A?W"
1park plug cap resistance ............................................................................ 8? <#ohms d A?W"
5inimum spark gap .see 1ection A/............................................................. C mm
tone! by Stal'er
;LA 'gnition system
All models are fitted with a fully transistorised
electronic ignition system, which due to its lack of
mechanical parts is totally maintenance free. The
system comprises a rotor, pick#up coil, ignitor unit
and ignition HT coil.s/ .refer to the wiring
diagrams at the end of "hapter 9 for details/. All
T(7 models and 899C#on T05 models are fitted
with two HT coils, while all other models have
one coil supplying both cylinders. The T(7
models and 899C#on T05 models are also fitted
with a throttle position sensor.
The ignition triggers, which are on the
alternator rotor on the left#hand end of the
crankshaft, magnetically operate the pick#up coil
as the crankshaft rotates. The pick#up coil sends
a signal to the ignitor unit which then supplies the
ignition HT coil.s/ with the power necessary to
produce a spark at the plugs. The ignitor
incorporates an electronic advance system
controlled by signals generated by the ignition
triggers and the pick#up coil.
The ignitor is linked to the clutch and sidestand
cut#off switches. This safety circuit prevents the
bike being started in gear unless the clutch lever
is pulled in, and prevents the bike being ridden
with the sidestand down.
*ecause of their nature, the individual ignition
system components can be checked but not
repaired. 'f ignition system troubles occur, and
the faulty component can be isolated, the only
cure for the problem is to renew the part. <eep in
mind that most electrical parts, once purchased,
cannot be returned. To avoid unnecessary
e%pense, make very sure the faulty component
has been positively identified before buying a
new part.
)ote that there is no provision for adjusting
the ignition timing on these models.
A 'gnition system # check
'arning: +he energ) levels in
electronic s)stems can be ver) high.
$n no account should the ignition be
switched on whilst the plugs or plug caps are
being held. Shocks from the H+ circuit can be
most unpleasant. Secondl), it is vital that the
engine is not turned over or run with either of
the plug caps removed, and that the plugs are
soundl) earthed 3grounded4 when the s)stem
is checked for sparking. +he ignition s)stem
components can be seriousl) damaged if the
H+ circuit becomes isolated.
,
8 As no means of adjustment is available, any
failure of the system can be traced to failure of
a system component or a simple wiring fault.
=f the two possibilities, the latter is by far the
most likely. 'n the event of failure, check the
system in a logical fashion, as described
below.
A 0isconnect the HT leads from the spark
plugs. "onnect each lead to a spare spark
plug and lay each plug on the engine with the
threads contacting the engine 1see
illustration2. 'f necessary, hold each spark
plug with an insulated tool.
'arning: Do not remove the
sparkplugs from the engine to perform
this check / atomised fuel being
pumped out of an open spark plug hole could
ignite, causing severe in-ur)A
,
8 Having observed the above precautions,
check that the kill switch is in the (+)
position and the transmission is in neutral,
then turn the ignition switch =) and turn the
engine over on the starter motor. 'f the system
is in good condition a regular, fat blue spark
should be evident at each plug electrode. 'f
the spark appears thin or yellowish, or is non#
e%istent, further investigation Bill be necessary.
*efore proceeding further, turn the ignition =44.
6 The ignition system must be able to produce a
spark which is capable of jumping a particular
si&e gap. A healthy system should produce a
spark capable of jumping at least C mm. A simple
testing tool can be made to test the minimum gap
across which the spark will jump .see Tool Ti"2
or alternatively it is possible to buy an ignition
spark gap tester tool and some of these tools are
adjustable to alter the spark gap.
rem
TS#
, simple spark gap testing tool can be
made from a block of wood, a large alligator
clip and two nails, one of which is
fashioned so that a spark plug cap or bare
H+ lead end can be connected to its end.
8ake sure the gap between the two nail
ends is the same as specified.
; "onnect one of the spark plug HT leads to the
protruding electrode on the test tool, and clip the
tool to a good earth .ground/ on the engine or
frame 1see illustration2. "heck that the kill
switch is in the (+) position, turn the ignition
switch =) and turn the engine over on the starter
motor. 'f the system is in good condition a
regular, fat blue spark should be seen to jump the
gap between the nail ends. =n 899C#on T05
models and T(7 models,
6.6 Earth the s"ar' "lu& an! o"erate the starter ( bri&ht blue 6.0 9onnect the tester as shoBn ( Bhen the starter is o"erate!
s"ar's shoul! be ,isible s"ar's shoul! <um" betBeen the nails
Stane! by Stal'er
+)($2'1T$($03'
+)($2'1T$($03'
'gnition system ;[@
8.Da ?&nition coil ( *99* to *990 TD mo!els
8.Db ?&nition coil ( TRX mo!els
8.Dc ?&nition coil ( XT3 mo!els
repeat the test for the other coil. 'f the test results
are good the entire ignition system can be
considered good. 'f the spark appears thin or
yellowish, or is non#e%istent, further investigation
will be necessary. C 'gnition faults can be divided
into two categories, namely those where the
ignition system has failed completely, and those
which are due to a partial failure. The likely faults
are listed below, starting with the most probable
source of failure. -ork through the list
systematically, referring to the subse,uent
sections for full details of the necessary checks
and tests. %ote) 6e!ore checking the !ollowing
items ensure that the battery is !ully charged and
that all !uses are in good condition.
a) Moose& corroded or damaged wiring
connections& broken or shorted wiring
between any o! the component parts o! the
ignition system (see -hapter 7).
b) Faulty ,T lead or spark plug cap& !aulty
sparkplug& dirty& worn or corroded plug
electrodes& or incorrect gap between
electrodes.
c) Faulty ignition (main) switch or engine kill
switch (see -hapter 7).
d) Faulty neutral& clutch or sidestand switch&
and on FTG models& diode (see -hapter 7).
e) Faulty pick-up coil or damaged rotor triggers.
b) Faulty ignition ,T coil!s).
c) Faulty ignitor unit.
B 'f the above checks don't reveal the cause of
the problem, have the ignition system tested by a
:amaha dealer e,uipped with diagnostic testing
e,uipment.
8 ?&nition GT coils # check,
removal and installation
Check
* The ignition HT coil.s/ can be checked visually
.for cracks and other damage/ and the primary
and secondary coil resistance can be measured
with a multimeter. 'f the coil is undamaged, and if
the resistance readings are as specified at the
beginning of the "hapter, it is probably capable of
proper operation, although note that sometimes a
fault is only evident when the coil is under load
and the engine running at high speed.
6 (emove the left#hand side cover .7TE models/
or the seat .all other models/ .see "hapter >/.
8 0isconnect the battery negative .#ve/ lead.
D =n T05 and T(7 models, the coil.s/ isDare
mounted on the inside of the frame behind the
steering head # remove the fuel tank and the air
filter housing for access .see "hapter 6/ 1see
illustrations2. =n 7TE models, the coil is
mounted underneath the rear of the fuel tank
#remove the tank for access .see "hapter 6/ 1see
illustration2.
0 0isconnect the primary circuit electrical
connectors from the coil and the HT leads from
the spark plugs. 5ark the locations of all wires
and leads before disconnecting them.
5 1et the meter to the ohms % 8 scale and
measure the resistance between the primary
circuit terminals on the coil 1see illustration2.
This will give a resistance reading of the primary
windings of the coil and should be consistent with
the value given in the 1pecifications at the
beginning of the "hapter.
4 To check the condition of the secondary
windings, unscrew the spark plug caps from the
HT leads and set the meter to the < ohm scale.
=n 8998 to 899; T05 models and 7TE models,
connect one meter probe to one HT lead end and
the other probe to the other HT lead end 1see
illustration2. =n 899C#on T05 models and T(7
models, connect the positive .^ve/ meter probe
to the HT lead end and the negative .#ve/ probe
to the redDblack wire
+)($2'1T$($0 3'
Sta&e! by Stal'er
+)($2'1T$($0 3'
/
K78
?
?
8.5 To test the coil "rimary resistance; connect the multimeter lea!s betBeen the
"rimary circuit terminals on the coil
8.4a 9oil secon!ary resistance test (*99* to *990 TD an! all XT3 mo!els
?
;L6 'gnition system
89+5
-
:;
3
8.4b 9oil secon!ary resistance test ( *995(on TD an! all TRX mo!els 8.8 easure the resistance of the s"ar'
"lu& ca"
primary circuit terminal 1see illustration2. 'f the
reading obtained is not within the range shown in
the 1pecifications, it is likely that the coil is
defective.
> 'f the reading is as specified, measure the
resistance of the spark plug cap by connecting
the meter probes between the HT lead socket in
the cap and the spark plug contact in the cap
1see illustration2. 'f the reading obtained is not
as specified, renew the spark plug caps.
9 1hould any of the above checks not produce
the e%pected result, have your findings confirmed
by a :amaha dealer. 'f the coil is confirmed to be
faulty, it must be renewed the coil is a sealed
unit and cannot therefore be repaired.
"emoval
*0 (emove the left#hand side cover .7TA
models/ or the seat .all other models/ .see
"hapter >/. 0isconnect the battery negative .#ve/
lead.
** =n T05 and T(7 models, the coilDs isDare
mounted on the inside of the frame behind the
steering head # remove the fuel tank and the air
filter housing for access .see "hapter 6/ 1see
illustrations 8.Da an! b2. =n 7TE models, the
coil is mounted underneath the rear of the fuel
tank # remove the tank for access .see "hapter
6/ 1see illustration 8.Dc2.
*6 0isconnect the primary circuit electrical
connectors from the coil and disconnect the HT
lead.s/ from the spark plug.s/. 5ark the
locations of all wires and leads before
disconnecting them.
*8 +nscrew the two bolts or screws securing
each coil, noting any spacers, and on T(7
models the earth wire secured by one of the
screws, and remove the coils 1see
illustrations 8.Da; b an! c2. )ote the routing
of the HT leads.
&nstallation
86 'nstallation is the reverse of removal.
5ake sure the wiring connectors and HT
leads are securely connected.
#ic'(u" coil #
check and replacement
Check
8 =n T05 and T(7 models remove the seat,
and on 7TE models remove the left#hand side
cover .see "hapter >/. 0isconnect the battery
negative .#ve/ lead.
A =n T(7 models, remove the side covers .see
"hapter >/.
@ Trace the pick#up coilDalternator wiring from
the top of the alternator cover and disconnect it
at the connector with the whiteDgreen and
whiteDred .early T05 models/ or greenDwhite and
blueDyellow .all other models/ wires 1see
illustrations2. +sing a multimeter set to the
ohms % 8?? scale, measure the resistance
between the terminals on the pick#up coil side of
the connector.
6 "ompare the reading obtained with that given
in the 1pecifications at the beginning of this
"hapter. The pick#up coil must be renewed if the
reading obtained differs greatly from that given,
particularly if the meter indicates a short circuit
.no measurable resistance/ or an open circuit
.infinite, or very high resistance/.
; 'f the pick#up coil is thought to be faulty, first
check that this is not due to a damaged or broken
wire from the coil to the connector pinched or
broken wires can usually be repaired.
"eplacement
C The pick#up coil is wired integrally with the
alternator stator, which means that the stator
must be removed and renewed along with the
coil if the coil is faulty. However it is worth
checking with a :amaha dealer to see if the coil
can be obtained separately and wired into the
loom to avoid the e%tra e%pense of paying for a
stator as well.
B (efer to "hapter 9 for details of alternator
statorDpick#up coil assembly removal.
0 ?&nitor unit # check,
removal and installation
Check
8 'f the tests shown in the preceding or following
1ections have failed to isolate the
D.8a #ic'(u" coil Birin& connector
1arroBe!2 ( T. mo!els
D.8b #ic'(u" coil Birin& connector
1arroBe!2 ( TRX mo!els
D.8c #ic'(u" coil Birin& connector
1arroBe!2 ( XT3 mo!els
Scane! by Stal'er
?
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
+)($2'1T$($03'
?&nition system 0`0
0.8a ?&nitor unit ( TD an! TRX mo!els
0.8b ?&nitor unit ( XT3 mo!els
0.D Disconnect the Birin& connectors 1arroBe!2
cause of an ignition fault, it is possible that the
ignitor unit itself is faulty. )o test details are
available with which the unit can be tested on
home workshop e,uipment. Take the machine to
a :amaha dealer for testing.
"emoval
6 =n T05 and T(7 models remove the seat,
and on 7TE models remove the left#hand side
cover and right#hand fairing side panel .see
"hapter >/. 0isconnect the battery negative .#ve/
lead.
8=n T05 and T(7 models the ignitor is
mounted under the seat, and on 7TE models it is
mounted in the fairing 1see illustrations2.
D0isconnect the wiring connectors from the
ignitor unit 1see illustration2.
0 (emove the screws securing the ignitor unit
and remove the unit.
&nstallation
C 'nstallation is the reverse of removal. 5ake
sure the wiring connectors are correctly and
securely connected.
5 ?&nition timin& # general
information and check
#eneral information
* 1ince no provision e%ists for adjusting the
ignition timing and since no component is subject
to mechanical wear, there is no need for regular
checks only if investigating a fault such as a loss
of power or a misfire, should the ignition timing
be checked.
6The ignition timing is checked dynamically
.engine running/ using a stroboscopic lamp. The
ine%pensive neon lamps should be ade,uate in
theory, but in practice may produce a pulse of
such low intensity that the timing mark remains
indistinct. 'f possible, one of the more precise
%enon tube lamps should be used, powered by
an e%ternal source of the appropriate voltage.
%ote) *o not use the machine's own battery as
an incorrect reading may result !rom stray
impulses within the machine's electrical system.
Check
8 -arm the engine up to normal operating
temperature then stop it.
D +nscrew the timing inspection plug from the
alternator cover 1see illustration2. 0iscard the
cover =#ring as a new one must be used.
0 The timing mark on the alternator rotor which
indicates the firing point at idle speed for the no.
8 cylinder is a '' 'T mark. The static timing mark
with which this should align is the notch in the
threads for the inspection plug on the alternator
cover 1see illustration2.
5 "onnect the timing light to the no. 8 cylinder
HT lead as described in the manufacturer's
instructions.
T>f>>>t The timing marks can be
T highlighted with white paint
GllET to make them more visible under the
stroboscope light.
4 1tart the engine and aim the light at the static
timing mark.
8 -ith the machine idling at the specified speed,
the static timing mark should lie between the two
vertical lines '' ''.
9 1lowly increase the engine speed whilst
observing the '' '' mark. The mark should move
clockwise, increasing in relation to the engine
speed until it reaches full advance .no
identification mark/.
8? As already stated, there is no means of
adjustment of the ignition timing on these
machines. 'f the ignition timing is incorrect, or
suspected of being incorrect, one of the
ignition system components is at fault, and the
system must be tested as described in the
preceding 1ections of this "hapter. 88 -hen the
check is complete, install the timing inspection
plug using a new =#ring and tighten it securely.
4 Throttle "osition sensor 1*995( I
on TD an! TRX2( check, Y
adjustment and replacement 1L
8 The throttle position sensor is located on the
side of the left#hand carburettor and is keyed to
the end of the throttle operating shaft. The sensor
provides the ignitor unit with information relating
to throttle opening and the ignitor is thus able to
set the ignition timing accordingly to produce the
best running conditions and cleaner e%haust
emissions. )ot surprisingly it is essential that the
throttle position sensor should be set up
correctly. 0o not tamper with the sensor's
position unless it has been disturbed during
carburettor overhaul or poor running problems
have been e%perienced.
A -hen the engine is running, the throttle
position sensor performs its own self#diagnosis in
the event of failure or faulty wiring. -hen this
diagnosis occurs, the tachometer will be seen to
display &ero rpm for @ seconds, then @??? rpm
for A.; seconds, then the actual engine speed for
@ seconds, whereupon it will repeat the cycle
until the engine is switched off.
Sta&e! by Stal'er
?
5.D EnscreB the timin& ins"ection "lu&
1arroBe!2
5.0 ?&nition timin& mar's at i!le s"ee!
+)($2'1T$($0 3' +)($2'1T$($0 3'
;LC 'gnition system
4.8
Throttle "osition sensor Birin&
connector 1A2 an! mountin& screBs
1/2
4.D Throttle "osition sensor Birin& connector terminals
6it 6lack and blue M 6lue
% %ellow
Check
8 (emove the fuel tank and the air filter housing
.see "hapter 6/. The throttle sensor is mounted
on the outside of the left#hand carburettor 1see
illustration2.
D 5ake sure that the ignition is =44, then
disconnect the throttle sensor's wire connector.
+sing a multimeter set on the <#ohms range,
measure the resistance between the blue and
blackDblue wire terminals on the throttle sensor
half of the connector @.; to C.; <#ohms should
be shown 1see illustration2. )ow measure the
resistance between the yellow and blackDblue
wire terminals on the same half of the connector
whilst rotating the throttle grip slowly the
resistance should vary between ? to ; <#ohms f
8.; <#ohm. 'f either test does not produce the
correct readings the throttle sensor should be
renewed.
0 'f the fault cannot be traced to the throttle
sensor, check all three wires between the ignitor
and throttle sensor for continuity. "heck for
continuity between one end to the
other on each wire. 'f no continuity is indicated,
this is probably due to a damaged or broken wire
between the connectors pinched or broken wires
can usually be repaired. 'f the wiring and
connectors are good, check the adjustment of
the sensor as described below.
C 'f the sensor is suspected of being faulty,
take it to a :amaha dealer for further testing. 'f
it is confirmed to be faulty, it must be
renewed the sensor is a sealed unit and
cannot therefore be repaired. 'f the sensor is
good, have the ignitor checked by the dealer.
,d-ustment
B *efore adjusting the sensor, check the idle
speed and carburettor synchronisation .see
"hapter 8/.
> Turn the ignition switch =), then disconnect
and reconnect the sensor wiring connector. This
sets the ignitor unit to sensor adjustment mode.
9 1lacken the sensor mounting screws and
rotate the sensor until the tachometer needle
reads 6??? rpm. 'f the tachometer reads either
8??? rpm or >??? rpm, the angle of the sensor is
either too narrow or too wide. Adjust it as
re,uired until the reading is 6??? rpm, then
tighten the screws.
8? To come out of the adjustment mode,
start the engine or simply turn the ignition
switch =44.
"eplacement
88 (emove the carburettors .see "hapter 6/.
8A The throttle sensor is mounted on the outside
of the left#hand carburettor 1see illustration 4.82.
0isconnect the wiring connector, then unscrew
the sensor mounting screws and remove the
sensor, noting how it fits. (etrieve the seal from
behind the sensor as it is withdrawn. =n T(7
models and 8998 to 899> T05 models the
sensor mounts on a plate which is itself secured
to the carburettor body by two screws.
8@ 'nstall the sensor and lightly tighten the
screws. After installing the carburettors follow the
adjustment procedure above to set the correct
sensor position.
+)($2'1T$($03'
Scane! by Stal'er
<*1
9ha"ter 5
4rame, suspension and final drive
9ontents
0rive chain # removal, cleaning and installation.......................................8;
0rive chain and sprockets # check, adjustment
and lubrication .................................................................. see "hapter 8
4ootrests, brake pedal and gearchange lever #
removal and installation....................................................................... @
4orks # disassembly, inspection and reassembly..................................... B
4orks # oil change ................................................................ see "hapter 8
4orks # removal and installation .............................................................. C
4rame # inspection and repair.................................................................. A
2eneral information................................................................................. 8
Handlebars and levers # removal and installation.................................... ;
Handlebar switches # check .................................................see "hapter 9
Handlebar switches # removal and installation.......................see "hapter 9
(ear shock absorber # removal, inspection and installation ..................8?
(ear suspension linkage .T(7 and 7TA models/ #
removal, inspection and installation ..................................................88
(ear sprocket couplingDrubber damper ..................................................8B
De&rees of !ifficulty
1prockets # check and replacement........................................................ 8C
1idestand # check ................................................................. see "hapter 8
1idestand # lubrication ........................................................see "hapter 8
1idestand # removal and installation ..................................................... 6
1idestand switch # check and replacement .........................see "hapter 9
1teering head bearings # freeplay check and
adjustment ........................................................................ see "hapter 8
1teering head bearings # inspection and replacement............................. 9
1teering head bearings # lubrication .....................................see "hapter 8
1teering stem # removal and installation ............................................... >
1uspension # adjustments ..................................................................... 8A
1uspension # check............................................................... see "hapter 8
1wingarm # inspection and bearing replacement.....................................86
1wingarm # removal and installation ..................................................... 8@
1wingarm and suspension linkage bearings #
lubrication.......................................................................... see "hapter 8
Easy; suitable for
novice with little
e%perience
fe I
Fairly easy; suitable Jk for
beginner with H some
e%perience &S
Fairly !ifficult;
suitable for competent H
0': mechanic ><S
Difficult; suitable for Q;,
e%perienced 0': H
mechanic
Qery !ifficult;
suitable for e%pert
0': LP
or professional
AH
S"ecifications
Front for's
4ork oil type
899C#on T05 models............................................................................... 1uspension oil ?8
All other models ...................................................................................... 8?- fork oil
4ork oil capacity
8998 to 899; T05 models........................................................................ @9; cc
899C#on T05 models............................................................................... ;8; cc
T(7 models.............................................................................................. 6>@ cc
7TA models.............................................................................................. CC9 cc
4ork oil levelL
8998 to 899; T05 models........................................................................ 8;8 mm
899C#on T05 models, T(7 models and 7TE models ............................. 8@? mm
4ork spring free length 8998
to 899; T05 models
1tandard .............................................................................................. 6AB mm
1ervice limit.......................................................................................... 6?C mm
899C#on T05 models
1tandard .............................................................................................. ;?; mm
1ervice limit.......................................................................................... ;?? mm
T(7 models
1tandard .............................................................................................. @>; mm
1ervice limit.......................................................................................... @>8 mm
7TE models
1tandard .............................................................................................. ;66.; mm
1ervice limit.......................................................................................... ;8Bmm
4ork tube runout limit .................................................................................. ?.A mm
I(il level is measured !rom the top o! the tube with the !ork spring removed and the leg !ully compressed.
<
Scane! by Stal'er
J? |5
CLA 4rame, suspension and final drive
Rear sus"ension
1hock absorber spring free length T05
models
5ain spring .......................................................................................... 866 mm
1ub spring............................................................................................. C9 mm
T(7 models.............................................................................................. AA?.; mm
7TE models............................................................................................... A6? mm
1wingarm # 7TE models
1ide clearance ....................................................................................... ?.6 to ?.B mm
*earing spacer length .right#hand/............................................................ 9?.9; to 98.8? mm
*earing spacer length .left#hand/ ............................................................. >?.9; to >8.8? mm
-asher thickness ..................................................................................... 8.9 to A.? mm
Final !ri,e chain
"hain si&e
T05 and T(7 models............................................................................... ;A;
7TE model ............................................................................................. ;A?
)o. of links
T05 model............................................................................................... 886
T(7 model ............................................................................................. 88?
7TE model................................................................................................ 88A
"hain freeplay and lubricant......................................................................... see "hapter 8
"hain stretch limit .8?#link length/
8998 to 899; T05 models........................................................................ 8;? mm
899C#on T05 models............................................................................... 8;9 mm
T(7 models.............................................................................................. 8;; mm
7TE models............................................................................................... 8;? mm
TorAue settin&s
4ootrest bracket bolts # T05 and T(7 models............................................. @? )m
4ootrest bracket bolts # 7TE models
4ront ........................................................................................................ 6; )m
(ear.......................................................................................................... A? )m
*rake pedal pivot bolt # T(7 models............................................................. @; )m
Handlebar holder clamp bolts # T05 models .............................................. A@ )m
Handlebar holder clamp bolts # 7TE models................................................. A? )m
Handlebar retaining bolt # T(7 models ....................................................... A@ )m
Handlebar holder positioning bolt # T(7 models........................................... 8? )m
Handlebar holder clamp bolt # T(7 models................................................... 8B )m
4ork clamp bolts
T05 and 7TE models............................................................................... A@ )m
T(7 models
Top yoke............................................................................................... A@ )m
*ottom yoke ......................................................................................... @? )m
4ork top bolt
T05 models ............................................................................................. A6 )m
T(7 and 7TE models ............................................................................... A@ )m
4ork damper rod bolt # T05 and T(7 models............................................... @? )m
4ork damper rod bolt # 7TE models.............................................................. CA )m
1teering stem nut
8998 to 899; T05 models........................................................................ 88? )m
899C#on T05 models............................................................................... 8?> )m
T(7 models.............................................................................................. 88? )m
1teering stem bolt .7TE models/ ................................................................ >? )m
(ear shock absorber mounting bolt nuts # T05 models................................ C6 )m
(ear shock absorber mounting bolt nuts # T(7 models .............................. 6? )m
(ear shock absorber mounting bolt nuts # 7TE models ............................... @; )m
1uspension linkage bolt nuts # T(7 models ............................................... 6> )m
1uspension linkage bolt nuts # 7TE models ............................................... ;9 )m
1wingarm pivot bolt nut
T05 and 7TE models............................................................................... 9? )m
T(7 models.............................................................................................. 8A; )m
(ear brake tor,ue arm nuts # T(7 models ................................................. @? )m
4ront sprocket nut ....................................................................................... B? )m
(ear sprocket nuts
T05 and T(7 models............................................................................... C? )m
7TE models.............................................................................................. ;; )m
2earchange linkage arm pinch bolt .............................................................. 8A )m
=uter sprocket cover bolts............................................................................ ; )m
+)($2'1T$($0 3'
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
Frame; sus"ension an! final !ri,e 5`8
8.*a %ote hoB the s"rin& en! 1arroBe!2 locates
8.*b Footrest brac'et bolts 1A2; footrest rubber screBs 1/2
* \eneral information
T05 models use a twin spar bo%#section
aluminium frame which uses the engine as a
stressed member.
T(7 models use a trellis#type steel tube frame
which uses the engine as a stressed member.
7TE models use a cradle#type steel frame.
4ront suspension is by a pair of oil#damped
telescopic forks. =n 7TE models, the forks have
a conventional damper system, while T05 and
T(7 models have a cartridge damper. =n T05
and T(7 models the forks are adjustable for pre#
load and rebound damping.
At the rear, an aluminium swingarm acts on a
single shock absorber, on T(7 and 7TE models
via a three#way linkage. The shock absorber is
adjustable for spring pre#load on all models, for
rebound damping on T05 models, and for both
rebound and compression damping on T(7
models. =n T(7 models, the shock absorber has
a remote reservoir.
The drive to the rear wheel is by chain.
for signs of cracking or splitting at the welded
joints. Foose engine mount bolts can cause
ovaling or fracturing of the mounting tabs. 5inor
damage can often be repaired by welding,
depending on the e%tent and nature of the
damage. This is, however, a job for a frame
specialist, especially where an aluminium frame
is concerned. @ (emember that a frame which is
out of alignment will cause handling problems. 'f
misalignment is suspected as the result of an
accident, it will be necessary to strip the machine
completely so the frame can be thoroughly
checked.
Footrests; bra'e "e!al an!
&earchan&e le,er #
removal and installation
6ootrests
Remo,al ( front footrests
* =n T05 models, remove the rubber cap from
the back of the footrest bracket, then unscrew
the nut and separate the footrest from the
bracket, noting how the return spring end locates
in the bracket 1see illustration2. 4or easier
access to the nut, first unscrew the
two bolts securing the bracket and remove it
1see illustration2. The footrest rubber can be
renewed by removing the two screws that secure
it to the footrest.
A =n T(7 models, unscrew the nut from the
back of the footrest bracket and separate the peg
from the bracket. The footrest rubber can be
renewed by removing the two screws that secure
it to the footrest. 4or easier access to the nut,
first remove the brake pedal or gearchange lever
]see below/, then unscrew the bolts securing the
footrest bracket and displace it.
@=n 7TE models, remove the split pin and
washer .where fitted/ from the bottom of the
footrest pivot pin, then withdraw the pivot pin and
remove the footrest 1see illustration2. )ote the
fitting of the return spring. The footrest rubber
can be renewed by removing the two bolts that
secure it to the peg. Remo,al ( rear footrests
6=n 8998 to 899; T05 models, remove the
split pin from the bottom of the footrest pivot pin,
then withdraw the pivot pin and remove the
footrest 1see illustration2. )ote the fitting of the
detent plate, ball and spring, and take care that
they do not spring out when removing the
footrest. Also note the collar for the pivot pin. The
footrest rubber can be
6 Frame # inspection and repair
8 The frame should not re,uire attention unless
accident damage has occurred. 'n most cases,
frame renewal is the only satisfactory remedy for
such damage. A few frame specialists have the
jigs and other e,uipment necessary for
straightening the frame to the re,uired standard
of accuracy, but even then there is no simple way
of assessing to what e%tent the frame may have
been over stressed.
A After the machine has accumulated a lot of
miles, the frame should be e%amined closely
8.8 Remo,e the s"lit "in 1A2 an! Bith!raB
the "i,ot "in; notin& noB the s"rin& en!s
locate 1/2
8.D Remo,e the s"lit "in 1A2 an! Bith!raB
the "i,ot "in; notin& hoB the !etent "late
an! ball fit 1/2
<
+)($2'1T$($0 3'
Stane! by Stal'er
+)($2'1T$($0 3'
CL6 4rame, suspension and final drive
8.5 EnscreB the nut 1A2 an! Bith!raB the bolt 1/2
8.4 Remo,e the s"lit "in 1arroBe!2 an! Bith!raB the "i,ot "in
8.9a Remo,e the "inch bolt 1A2 an! sli!e
the "e!al off the shaft. %ote the ali&nment
of the "unch mar' 1/2 Bith the notch 192
renewed by removing the two screws that secure
it to the footrest.
; =n 899C#on T05 models, unscrew the nut
from the bottom of the footrest pivot bolt, then
withdraw the bolt and remove the footrest. )ote
the fitting of the detent plates, ball and spring,
and take care that they do not spring out when
removing the footrest. Also note the collar for the
pivot bolt. The footrest rubber can be renewed by
removing the two screws that secure it to the
footrest.
C =n T(7 models, unscrew the nut from the
bottom of the footrest pivot bolt, then withdraw
the bolt and remove the footrest. )ote the fitting
of the detent plates, ball and spring, and take
care that they do not spring out when removing
the footrest 1see illustration2. Also note the
collar for the pivot bolt.
B =n 7TE models, remove the split pin and
washer .where fitted/ from the bottom of the
footrest pivot pin, then withdraw the pivot pin and
remove the footrest .see illustration2. The
footrest rubber can be renewed by removing the
washer and drawing the rubber off the footrest. 'f
it is stuck fast, slit it with a sharp knife.
?nstallation
8 'nstallation is the reverse of removal. =n
T05 and T(7 models, if removed, tighten the
front footrest bracket bolts to the tor,ue
setting specified at the beginning of the
chapter.
(rake pedal
Remo,al
9 =n T05 models, note the alignment of the
notch in the top of the pedal with the punch
mark on the shaft, then unscrew and remove
the pinchbolt and slide the arm off the shaft
1see illustration2. 'f re,uired, unhook the
brake pedal return spring and the brake
light switch spring from the bracket on the inside
of the pedal shaft, then remove the split pin from
the clevis pin securing the master cylinder
pushrod to the bracket 1see illustration2.
(emove the clevis pin and separate the pushrod
from the bracket, then draw the shaft assembly
out of the frame.
*0 =n T(7 models, unhook the brake pedal
return spring and the brake light switch spring
from the bracket on the pedal. (emove the split
pin from the clevis pin securing the brake pedal
to the master cylinder pushrod 1see illustration2.
(emove the clevis pin and separate the pushrod
from the pedal. +nscrew the pedal pivot bolt and
remove the pedal. 'f re,uired, remove the screw
securing the spring bracket to the inside of the
pedal and remove the bracket.
** =n 7TE models, unhook the brake pedal
return spring and the brake light switch spring
from the bracket on the pedal. (emove the split
pin from the clevis pin securing the brake
pedal to the master cylinder pushrod. (emove
the clevis pin and separate the pushrod from the
pedal. (emove the split pin holding the pedal
pivot in the frame and remove the pedal. 0iscard
the split pin as a new one must be used.
?nstallation
*6 'nstallation is the reverse of removal,
noting the followingG
a) $pply molybdenum disulphide grease to the
brake pedal pivot& or on T*E models& the
unsplined section o! the sha!t.
b) (n T/F models& tighten the pedal pivot bolt
securely.
c) Cse a new split pin on the clevis pin securing
the brake pedal to the master cylinder
pushrod& and on FTG models on the brake
pedal pivot.
d) -heck the operation o! the rear brake light
switch (see -hapter #).
#earchange lever
Remo,al
8@=n T05 and 7TE models, unscrew the bolts
securing the outer front sprocket cover and
remove the cover 1see illustration2.
86 To remove the lever on its own, slacken the
gearchange lever linkage rod locknuts, then
unscrew the rod and separate it from the
8.9b Enhoo' the s"rin&s an! se"arate the
"ushro! from the brac'et 1arroBe!2
8.*0 Enhoo' the s"rin&s at the bac'; then
remo,e the cle,is "in 1A2 an! unscreB the
"i,ot bolt 1/2
8.*8 S"roc'et co,er bolts 1arroBe!2
Stane! by Stal'er
Frame; sus"ension an! final !ri,e 5I0
8.*Da Slac'en the loc'nuts 1arroBe!2 an!
threa! the ro! out of the le,er an! arm
8.*Db EnscreB the "i,ot bolt. 3.1)c . an! remo,e the le,er; notin&
the Bashers
lever and the arm .the rod is reverse#threaded on
one end and so will simultaneously unscrew from
both lever and arm when turned in the one
direction/ 1see illustration2. )ote the how far the
rod is threaded into the lever and arm as this
determines the height of the lever relative to the
footrest. +nscrew the pivot bolt and remove the
lever, noting the arrangement of the washers
1see illustrations2.
*0 To remove the lever with the linkage rod
and arm as an assembly, first note the
alignment of the punch mark on the
gearchange shaft with the slit in the linkage
arm, then unscrew the linkage arm pinchbolt
and slide the arm off the shaft 1see
illustrations2. )ow unscrew the lever pivot
bolt and remove the lever and linkage
assembly, noting how it fits 1see illustrations
8.*Db an! c2.
?nstallation
*5 'nstallation is the reverse of removal,
noting the followingG
a) $pply molybdenum disulphide oil to the gear
lever pivot
b) $lign the punch mark on the sha!t with the
slit in the clamp as noted on removal 3see
illustrations I.; Sa and b-.
c) Tighten the gearchange lever pivot bolt
securely.
d) $d3ust the gear lever height as reAuired by
screwing the rod in or out o! the lever and
arm. Tighten the locknuts securely 3see
illustration I.;@a4.
8.*0a -in'a&e arm+shaft ali&nment #TD
mo!els
D Si!estan! (
remo,al an! installation
* 1upport the bike using an au%iliary stand.
6 =n T05 and 7TE models, unhook the stand
springs, then counter#hold the pivot bolt and
unscrew the nut on the inside of the bracket 1see
illustration2. -ithdraw the pivot bolt and remove
the stand, noting how it locates against the
sidestand switch plunger.
8 =n T(7 models, unhook the stand springs,
then unscrew the retaining bolt 1see
illustration2. 1lide the stand off its pivot, noting
how it fits. 'f re,uired, counter#hold the pivot
piece and unscrew the nut
D.8 Si!estan! retainin& bolt 1arroBe!2 J
TRX mo!els
8.*0b -in'a&e arm+shaft ali&nment #TRX
mo!els
securing it in the bracket, then withdraw the
pivot.
6 =n installation apply grease to the pivot and a
suitable non#permanent thread locking
compound to the bolt threads. Tighten the
nutDbolt securely. (econnect the sidestand spring
and check that it holds the stand securely up
when not in use # an accident is almost certain to
occur if the stand e%tends while the machine is in
motion.
; "heck the operation of the sidestand switch
.see "hapter 8/.
Gan!lebars an! le,ers #
removal and installation
Handlebars
Remo,al
%ote) The handlebars can be displaced !rom the
top yoke without having to remove any o! the
lever or switch assemblies. (n T/F models& the
handlebars can be removed !rom the handlebar
holders which clamp around the top o! the !orks&
leaving the holders in place.
* 0isplace the front brake master cylinder and
reservoir .see "hapter B/. There is no need to
disconnect the hydraulic hose. <eep the reservoir
upright to prevent possible fluid leakage and
make sure no strain is placed on the hydraulic
hose.s/.
6 0isplace the throttle cable housing from the
handlebars .see "hapter 6/. There is no need
D.6 Si!estan! "i,ot bolt 1arroBe!2 ( TD
mo!els
*
?
Sta&e! by Stal'er
CLC 4rame, suspension and final drive
0.8 9lutch sBitch Birin& connector 1arroBe!2 ( TD mo!els
0.0a .n TD mo!els; remo,e the blan'in& ca"s
0.0b Gan!lebar clam" bolts 1arroBe!2 (TD mo!els
to detach the cables from the carburettors.
8$ither remove the clutch lever .see below/, or
detach the clutch cable from the lever .see
"hapter A/. 0isconnect the clutch switch wiring
connector .see "hapter 9/ 1see illustration2.
D 0isplace the handlebar switches .see "hapter
9/. There is no need to disconnect the wiring
connectors.
0=n T05 models, lever out the handlebar
holder clamp bolt blanking caps 1see
illustration2. =n T05 and 7TE models, unscrew
the handlebar holder clamp bolts and remove the
handlebars, noting how the choke knob fits,
where appropriate 1see illustrations2.
5 =n T(7 models, to remove the handlebar
and leave the holder in place, remove the
blanking cap from the inner end of the handlebar,
then unscrew the retaining bolt and slide the bar
out of the holder, noting how it locates 1see
illustration2. 4 =n T(7 models, to remove the
handlebar and holder together, remove the
blanking cap from the holder positioning bolt,
then unscrew the bolt 1see illustration2. 1lacken
the handlebar holder clamp bolt, then ease the
handlebar holder up and off the fork. ?nstallation
8 'nstallation is the reverse of removal, noting the
following.
a) (n T*E models& align the mark on the !ront
o! the handlebars with the mating
sur!aces o! the holder 3see illustration4.
Eake sure the handlebars are centrally
positioned. )nstall the holder clamp with the
arrow pointing up& then tighten the !ront
clamp bolt !irst& !ollowed by the rear bolt& to
the torAue setting speci!ied at the beginning
o! the -hapter 3see illustrations4.
b) (n FTG models& make sure the handlebars
are centrally positioned. )nstall the holder
clamp with the punch mark pointing !orward&
then tighten the !ront clamp bolt !irst&
!ollowed by the rear bolt& to the torAue
setting speci!ied at the beginning o! the
-hapter.
c) (n T/F models& i! separated& make sure the
!lat on the inner end o! the handlebar
0.0c Gan!lebar clam" bolts ( XT3 mo!els
0.5 Remo,e the ca" to access the bolt
0.4 Remo,e the ca" an! unscreB the
"ositionin& bolt 1A2; then slac'en the
clam" bolt 1/2
0.8a Ali&n the mar' 1arroBe!2 Bith the
clam" matin& surfaces
"ointin& u"...
0.8c ... an! ti&hten the bolts as !escribe! to
the s"ecifie! torAue
Starte! by Stal'er
4rame, suspension and final drive CLB
0.8! Ensure that the flat 1A2 ali&ns Bith the cut(out 1/2
0.9 Gan!&uar! retainin& screB #XT3 mo!els
aligns correctly with the corresponding cut-
out in the holder 3see illustration4. Tighten
the retaining bolts& positioning bolts and
clamp bolts to the torAue settings speci!ied
at the beginning o! the -hapter. Tighten the
positioning bolt be!ore the clamp bolt.
d) /e!er to the relevant -hapters as directed
!or the installation o! the handlebar mounted
assemblies
e) *o not !orget to reconnect the !ront brake
light switch and clutch switch wiring
connectors.
Clutch lever
9 =n 7TE models, remove the hand guard
1see illustration2.
*0 1lacken the clutch cable adjuster lockring
and thread the adjuster fully into the bracket
to provide ma%imum freeplay in the cable 1see
illustration2. +nscrew the lever pivot bolt
locknut, then withdraw the pivot bolt and
remove the lever, detaching the cable nipple
via the slots in the adjuster and lockring. =n
T(7 models, note the collar for the pivot bolt.
# @ivot bolt
2 -ollar
4 'ut
5 -ap
8 .-clip
9 'ut
: +pring
; @late
88 'nstallation is the reverse of removal.
Apply grease to the pivot bolt shaft, or on T(7
models to the collar, and the contact areas
between the lever and its bracket, and to the
clutch cable nipple. Adjust the clutch cable
freeplay .see "hapter 8/.
6ront brake lever
*6 =n 7TE models, remove the hand guard
1see illustration 0.92.
*8 =n T05 models, remove the cap from the
end of the master cylinder pushrod in the lever,
then remove the $#clip, the nut, the spring and
the plate 1see illustration2.
*D +nscrew the lever pivot bolt locknut, then
withdraw the pivot bolt and remove the lever 1see
illustration2.
*0 'nstallation is the reverse of removal. Apply
grease to the pivot bolt shaft and the contact
areas between the lever and its bracket. =n T05
models, locate the master cylinder pushrod
through the pivot in the lever, and install the
plate, the spring, the nut, the $#clip and the cap.
0.*0 Slac'en the loc'rin& 1A2 an! turn the
a!<uster 1/2 fully in; then unscreB the nut
192 an! Bith!raB the "i,ot bolt 1D2 to free
the le,er
4orks #
removal and installation
"emoval
Caution: ,lthough not strictl) necessar),
before removing the forks it is recommended
that the fairing panels and/or fairing are
removed 3see Chapter ?4. +his will prevent
accidental damage to the paintwork.
8 (emove the front wheel .see "hapter B/.
A (emove the front mudguard .see "hapter >/.
C
0.*8 /ra'e le,er com"onents ( TD mo!els 0.*D EnscreB the nut 1A2 an! Bith!raB the
bolt 1/2
Stane! by Stal'er
?
+)($2'1T$($03'
CL> 4rame, suspension and final drive
5.8 /ra'e hose clam" bolt 1arroBe!2
5.D Gan!lebar hol!er clam" bolt 1A2; for' clam" bolt 1/2; for' to" bolt 192
5.0 Slac'en the for' clam" bolt 1A2; an! ?f reAuire! the for' to" bolt 1/2
8 +nscrew the brake hose clamp bolt from each
fork slider 1see illustration2. 'f not already done,
displace the front brake calipers .see "hapter B/.
There is no need to disconnect the hydraulic
hoses. (elease the speedometer cable from any
guides, and loosen any cable ties around the top
of the fork tubes.
D =n T(7 models, slacken the handlebar holder
clamp bolts 1see illustration2.
0 1lacken the fork clamp bolts in the top yoke
5.5a Slac'en the bottom yo'e for' clam"
bolts 1arroBe!2...
1see illustration2. 'f the forks are to be
disassembled, or if the fork oil is being changed,
it is advisable to slacken the fork top bolts at this
stage.
C )ote the alignment or amount of protrusion of
the tops of the fork tubes with the top yoke.
1lacken but do not remove the fork clamp bolts
in the bottom yoke, and remove the forks by
twisting them and pulling them downwards 1see
illustrations2.
&f the fork legs are sei9ed in the
)okes, spra) the area with
penetrating oil and allow time
for it to soak in before tr)ing
again.
&nstallation
4 (emove all traces of corrosion from the fork
tubes and the yokes. 1lide the forks up through
the bottom yoke, then install the wiring ties where
appropriate onto the forks 1see illustration
5.5b2. 1lide the forks up into the top yoke. "heck
that the amount of protrusion of the fork tube
above the top yoke is as noted on removal and
e,ual on both
sides. =n T05 and 7TE models, the tops of the
tubes should be flush with the top of the top
yoke. =n T(7 models, the top of the fork tube
should protrude 8>.; mm above the top of the
handlebar holder.
8 Tighten the fork clamp bolts in the bottom yoke
to the tor,ue setting specified at the beginning of
the "hapter 1see illustration 5.5a2. 'f the fork
legs have been dismantled or if the fork oil has
been changed, the fork top bolts should now be
tightened to the specified tor,ue setting. )ow
tighten the fork clamp bolts in the top yoke, and
on T(7 models the handlebar holder clamp bolts,
to the specified tor,ue settings 1see illustration
an! 5.D2.
9 'nstall the front wheel .see "hapter B/, the
front mudguard .see "hapter >/, and the brake
calipers .see "hapter B/. 4it the brake hose
clamps onto the mudguard 1see illustration 5.82.
=n all models e%cept the 8999 T05, make sure
the speedometer cable is routed through its
guide.s/. =n 8999 T05 models make sure that
the speedometer sensor lead is well secured by
its ties.
8? "heck the operation of the front forks and
brakes before taking the machine out on the
road.
C.Cb ... an! remo,e the for's
5.8 Ti&hten the ,arious clam" bolts to their s"ecifie! torAue settin&s
Stane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
4rame, suspension and final drive C[9
B Top bolt
A (-ring
@ @re-load ad3uster
5 *amping ad3uster rod
8 +pring seat
C Mocknut
B +pring
; *amper
7 Fork tube
#
<
6ottom bush
#
#
*amper rod seat
#
2
*ust seal
#
4
/etaining clip
#
5
(il seal
B
;
>asher
B
C
Top bush i
#
:
Fork slider #
#
;
+ealing washer
#
7
*amper rod bolt "NQ
4 For's # disassembly, jH
inspection and reassembly 7
;<<; to ;<<S +D8 models
Disassembly
* Always dismantle the fork legs separately to
avoid interchanging parts and thus causing an
accelerated rate of wear. 1tore all
components in separate, clearly marked
containers 1see illustration2.
6 *efore dismantling the fork, it is advised
that the damper rod bolt be slackened at this
stage. "ompress the fork tube in the slider so
that the spring e%erts ma%imum pressure on
the damper rod head, then have an assistant
slacken the damper rod bolt in the base of the
fork slider 1see illustration2.
8 'f the fork top bolt was not slackened with
the fork in situ, carefully clamp the fork tube in
a vice e,uipped with soft jaws, taking care not
to overtighten or score its surface, and
slacken the top bolt.
D +nscrew the fork top bolt from the top of
the fork tube 1see illustration2. The bolt can
remain threaded on the pre#load adjuster, but
remove it by holding the adjuster and
unscrewing it if re,uired 1see illustration2.
0 "arefully clamp the fork slider in a vice and
slide the fork tube down into the slider a little
way .wrap a rag around the top of the tube to
minimise oil spillage/ while, with the aid of an
assistant if necessary, keeping the damper
rod fully e%tended. "ounter#hold the pre#load
adjuster and thread the locknut to the base of
its threads 1see illustration2. )ow counter#
4.* Front for' com"onents (*99* to *990 TD mo!els 4.6 Slac'en the !am"er ro! Allen bolt
,
0f.
=VVSSSSSS&<
?f
Ff1P$s
Hil CGf 0F
4.Da EnscreB the to" bolt from the for' 4.Db ... an! threa! it off the a!<uster if 4.0 Remo,e the "re(loa! a!<uster as
tube... reAuire! !escribe!
Stane! by Stal'er
C[8? 4rame, suspension and final drive
4.5 7ith!raB the !am"in& a!<uster ro!
1A2; then remo,e the s"rin& seat 1/2 an!
Bith!raB the s"rin& 192
4.*0 #rise out the !ust seal usin& a flat(bla!e! screB!ri,er
4.** #rise out the retainin& cli" usin& a flat(bla!e! screB!ri,er
hold the locknut and thread the pre#load adjuster
.with the top bolt if not removed/ off the damper
rod.
5 (emove the damping adjuster rod from the
centre of the damper rod, then remove the spring
seat and withdraw the spring from the tube,
noting which way up it fits 1see illustration2.
4 'nvert the fork leg over a suitable container
and pump the fork and the damper rod vigorously
to e%pel as much fork oil as possible.
8 (emove the previously slackened damper rod
bolt and its copper sealing washer from the
bottom of the slider. 0iscard the sealing washer
as a new one must be used on
4.*6 To se"arate the inner an! outer for'
tubes; "ull them a"art firmly se,eral times
( the sli!e(hammer effect Bill "ull the
tubes a"art
reassembly. 'f the damper rod bolt was not
slackened before dismantling the fork, use the
:amaha service tool .9?>9?#?866B/ to prevent
the damper rod from turning. This tool is passed
down through the fork tube and engages the
damper rod head a similar tool can be easily
made in the home workshop.
9 'nvert the fork and withdraw the damper rod
from inside the fork tube 1see illustration
4.60a2.
*0 "arefully prise out the dust seal from the top
of the slider to gain access to the oil seal
retaining clip 1see illustration2. 0iscard the dust
seal as a new one must be used.
** "arefully remove the retaining clip, taking
care not to scratch the surface of the tube 1see
illustration2.
*6 To separate the tube from the slider it is
necessary to displace the top bush and oil seal.
The bottom bush should not pass through the top
bush, and this can be used to good effect. Push
the tube gently inwards until it stops against the
damper rod seat. Take care not to do this forcibly
or the seat may be damaged. Then pull the tube
sharply outwards until the bottom bush strikes
the top bush. (epeat this operation until the top
bush and seal are tapped out of the slider 1see
illustration2.
*8 -ith the tube removed, slide off the oil seal,
washer and top bush, noting which way up they
fit 1see illustration2. 0iscard the oil seal as a
new one must be used. Caution: Do not
remove the bottom bush from the tube unless
it is to be renewed.
*D Tip the damper rod seat out of the slider,
noting which way up it fits.
?ns"ection
*0 "lean all parts in solvent and blow them dry
with compressed air, if available. "heck the fork
tube for score marks, scratches, flaking of the
chrome finish and e%cessive or abnormal wear.
Fook for dents in the tube and renew the tube in
both forks if any are found. "heck the fork seal
seat for nicks, gouges and scratches. 'f damage
is evident, leaks will occur. Also check the oil seal
washer for damage or distortion and renew it if
necessary.
*5 "heck the fork tube for runout .bending/
using 3#blocks and a dial gauge, or have it done
by a dealer 1see illustration2. :amaha do not
specify a runout limit, but if the tube is bent it
should be renewed.
*4 "heck the spring for cracks and other
damage. 5easure the spring free length and
compare the measurement to the specifications
at the beginning of the "hapter. 'f it is defective
or sagged below the service limit, renew the
springs in both forks. )ever renew only one
spring. Also check the rebound spring on the
damper.
*8 $%amine the working surfaces of the two
bushes if worn or scuffed they must be renewed.
To remove the bottom bush from the fork tube,
prise it apart at the slit using a flat#bladed
screwdriver and slide it off 1see illustration2.
5ake sure the new one seats properly.
$/$71$
**^#=
&****
>
ml"'
-
4.*8 The oil seal 1*2; Basher 162; to" bush
182 an! bottom bush 1D2 Bill come out Bith
the for' tube
4.*5 9hec' the for' tube for runout usin& Q(
bloc's an! a !ial &au&e
4.*8 #rise off the bottom bush usin& a flat(
bla!e! screB!ri,er
Scane! by Stal'er
4rame, suspension and final drive C[88
4.60a Sli!e the !am"er into the tube..
4.60b
. an! fit the seat onto its bottom en!
4.6* A""ly a threa! loc'in& com"oun! to
the !am"er ro! bolt an! use a neB sealin&
Basher
*9 "heck the damper rod assembly for
damage and wear, and renew it if necessary.
Holding the outside of the damper, pump the
rod in and out of the damper. 'f the rod does
not move smoothly in the damper it must be
renewed.
Reassembly
60 'nsert the damper rod into the fork tube and
slide it into place so that it projects fully from the
bottom of the tube, then install the seat on the
bottom of the damper rod, making sure the
projection in the base of the seat locates with the
flat on the bottom of the damper 1see
illustrations2.
6* =il the fork tube and bottom bush with the
specified fork oil and insert the assembly into the
slider. 4it a new copper sealing washer to the
damper rod bolt and apply a few drops of a
suitable non#permanent thread locking
compound, then install the bolt into the bottom of
the slider 1see illustration2. Tighten the bolt to
the specified tor,ue setting. 'f the damper rod
rotates inside the tube, wait until the fork is fully
reassembled before tightening the bolt.
66 Push the fork tube fully into the slider, then
oil the top bush and slide it down over the tube
1see illustration2. Press the bush s,uarely into
its recess in the slider as far as possible, then
install the oil seal washer with its flat side facing
up 1see illustration2. $ither use the :amaha
service tool or a
suitable piece of tubing to tap the bush fully into
place the tubing must be slightly larger in
diameter than the fork tube and slightly smaller in
diameter than the bush recess in the slider. Take
care not to scratch the fork tube during this
operation it is best to make sure that the fork
tube is pushed fully into the slider so that any
accidental scratching is confined to the area
above the oil seal.
A@ -hen the bush is seated fully and s,uarely in
its recess in the slider, .remove the washer to
check, wipe the recess clean, then reinstall the
washer/, install the new oil seal. 1mear the seal's
lips with fork oil and slide it over the tube so that
its markings face upwards and drive the seal into
place as
rc<flfll&<l @lace the old oil seal on top llGillG=
Lf fne new one tL protect &t
when driving the seal &nto
place.
described above until the retaining clip groove is
visible above the seal 1see illustration2.
A6=nce the seal is correctly seated, fit the
retaining clip, making sure it is correctly located
in its groove 1see illustration2.
A;Fubricate the lips of the new dust seal then
slide it down the fork tube and press it into
position 1see illustration2.
AC 1lowly pour in the specified ,uantity of the
specified grade of fork oil and pump the fork and
damper rod at least ten times each to
A6
s *
^^^rf^*
m
W. ..'
C
4.68 a'e sure the oil seal is the correct
Bay u"
4.6D ?nstall the retainin& cli"... 4.60 ... folloBe! by the !ust seal
Stane! by Stal'er
4.66a ?nstall the to" bush ...
Gi%T
4.66b ... folloBe! by the Basher
C[8A 4rame, suspension and final drive
4.65a #our the oil into the to" of the tube 4.65b easure the oil le,el Bith the for'
hel! ,ertical
4.64a ?nsert the !am"in& a!<uster ro!
4.64b Tie a "iece of Bire aroun! the base
of the loc'nut to 'ee" the !am"er ro!
eCten!e!...
!istribute it evenly 1see illustration2N wait ten
minutes then measure the oil level and adjust as
necessary by adding or subtracting oil. 4ully
compress the fork tube and damper rod into the
slider and measure the fork oil level from the top
of the tube 1see illustration2. Add or subtract
fork oil until it is at the level specified at the
beginning of the "hapter. 64 4it the damping
adjuster rod into the damper rod 1see
illustration2. 't is advisable to tie a piece of wire
around the locknut so that it can be used to hold
the damper rod out when installing the spring #
otherwise the rod
4.64c ... an! install the s"rin&
will settle down into the fork and will be
inaccessible with the spring installed 1see
illustration2. "lamp the slider in a vice via the
brake caliper mounting lugs, taking care not to
overtighten and damage them. Pull the fork tube
and damper rod out of the slider as far as
possible then install the spring with its closer#
wound coils at the top 1see illustration2. 4it the
spring seat, with its shouldered side fitting down
into the top of the spring 1see illustration 4.52.
68 4it a new =#ring onto the fork top bolt. Thread
the pre#load adjuster .with the top bolt
if it wasn't removed/ onto the damper rod as far
as it will go, then counter#hold it and tighten the
locknut securely against it 1see illustration an!
4.02. ?f it was removed, thread the top bolt onto
the pre#load adjuster 1see illustration 4.Db2.
69 -ithdraw the tube fully from the slider and
carefully screw the top bolt into the fork tube
making sure it is not cross#threaded 1see
illustration2. %ote) The top bolt can be tightened
to the speci!ied torAue setting at this stage i! the
tube is held between the padded 3aws o! a vice&
but do not risk distorting the tube by doing so. $
better method is to tighten the top bolt when the
!ork leg has been installed and is securely held in
the triple clamps.
+his makes it unnecessar) to remove the
tool from the bolt whilst threading &t in
making it easier to maintain a downward
pressure on the spring.
'f the damper rod Allen bolt re,uires tightening,
clamp the fork slider between the padded jaws of
a vice and have an assistant compress the tube
into the slider so that
4.68 Threa! the "re(loa! a!<uster onto the !am"er ro! an! ti&hten the loc'nut a&ainst it
t+ P ?` G 7se a ratchet/t)pe tool when Vi=>
installing the !ork top bolt.
Ti#
4.69 Threa! the to" bolt into the for' tube
Scane! by Stal'er
+)($2'1T$($03'
4rame, suspension and final drive CL8@
ma%imum spring pressure is placed on the
damper rod head # tighten the damper Allen bolt
to the specified tor,ue setting 1see illustration
4.62.
80 'nstall the forks .see 1ection C/. 1et the
spring pre#load adjuster as re,uired .see
1ection 8A/.
;<<M/on +D8 models and +":
models
0isassembly
8* Always dismantle the fork legs separately to
avoid interchanging parts and thus causing an
accelerated rate of wear. 1tore all components in
separate, clearly marked containers 1see
illustration2.
86 *efore dismantling the fork, it is advised that
the damper rod bolt be slackened at this stage.
"ompress the fork tube in the slider so that the
spring e%erts ma%imum pressure on the damper
rod head, then have an assistant slacken the
damper rod bolt in the base of the fork slider 1see
illustration B.A/.
88 'f the fork top bolt was not slackened with the
fork in situ, carefully clamp the fork tube in a vice
e,uipped with soft jaws, taking care not to
overtighten or score its surface, and slacken the
top bolt 1see illustration 4.D2.
8D The fork top bolt comes as an assembly with
the pre#load adjuster and damping adjuster rod.
+nscrew the fork top bolt from the top of the fork
tube and lift it out until the damping adjuster rod
is clear.
80 1lide the fork tube down into the slider. =n
T05 models withdraw the spring seat and spring
from the tube. =n T(7 models withdraw the
washer, spacer, spring seat and the spring from
the tube. )ote which way up the spring is fitted.
85 'nvert the fork leg over a suitable container
and pump the fork vigorously to e%pel as much
fork oil as possible.
84 (emove the previously slackened damper
rod bolt and its copper sealing washer from the
bottom of the slider. 0iscard the sealing washer
as a new one must be used on reassembly. 'f the
damper rod bolt was not slackened before
dismantling the fork, use the :amaha service tool
.T05 models # pt. nos. 9?>9?#?86C; and 9?>9?#
?8@AC, T(7 models # pt. nos. 9?>9?#?8@>> and
9?>9?#?8@AC/ to prevent the damper rod from
turning. This tool is passed down through the fork
tube and engages the damper rod head a similar
tool can be easily made in the home workshop.
88 'nvert the fork and withdraw the damper rod
from inside the fork tube 1see illustration2. 'f
re,uired, slide the rebound spring off the damper
rod.
89 "arefully prise out the dust seal from the top
of the slider to gain access to the oil seal
retaining clip 1see illustration 4.*02. 0iscard the
dust seal as a new one must be used.
D0 "arefully remove the retaining clip, taking
care not to scratch the surface of the tube 1see
illustration 4.**2.
D* To separate the tube from the slider it is
4.8* Front for' com"onents ( *995(on TD mo!els an! TRX mo!els
necessary to displace the top bush and oil seal.
The bottom bush should not pass through the top
bush, and this can be used to good effect. Push
the tube gently inwards until it stops against the
damper rod seat. Take care not to do this forcibly
or the seat may be damaged. Then pull the tube
sharply outwards until the bottom bush strikes
the top bush. (epeat this operation until the top
bush and seal are tapped out of the slider 1see
illustration 4.*62.
D6 -ith the tube removed, slide off the oil seal,
washer and top bush, noting which way up they fit
1see illustration 4.*82. 0iscard the oil seal as a
new one must be used. Caution: Do not remove
the bottom bush from the tube unless it is to be
renewed.
D8 Tip the damper rod seat out of the slider,
noting which way up it fits.
?ns"ection
DD "lean all parts in solvent and blow them
dry with compressed air, if available. "heck
the fork tube for score marks, scratches,
flaking of the chrome finish and e%cessive or
abnormal wear. Fook for dents in the tube and
renew the tube in both forks if any are found.
Top bolt and preload
ad3uster (-ring
>asher # T/F only
+pacer - T/F only
+pring seat +pring
*amper rod and
rebound spring
; Fork tube and
bottom bush
7 *amper rod seat
#< *ust seal
## /etaining clip
#2 (il seal
#4 >asher
#5 Top bush
#8 +lider
#9 *amper rod bolt and
sealing washer
#
"heck the fork seal seat for nicks, gouges and
scratches. 'f damage is evident, leaks will occur.
Also check the oil seal washer for damage or
distortion and renew it if necessary.
6; "heck the fork tube for runout .bending/ using
3#blocks and a dial gauge, or have it done by a
dealer 1see illustration 4.*52. :amaha do not
specify a runout limit, but if the tube is bent it
should be renewed.
4.88 7ith!raB the !am"er ro! an!
reboun! s"rin& from the tube
+)($2'1T$($0 3'
Stane! by Stal'er
C[86 4rame, suspension and final drive
D5 "heck the spring for cracks and other
damage. 5easure the spring free length and
compare the measurement to the specifications
at the beginning of the "hapter. 'f it is defective
or sagged below the service limit, renew the
springs in both forks. )ever renew only one
spring. Also check the rebound spring on the
damper.
D4 $%amine the working surfaces of the two
bushes if worn or scuffed they must be renewed.
To remove the bottom bush from the fork tube,
prise it apart at the slit using a flat#bladed
screwdriver and slide it off 1see illustration
4.*82. 5ake sure the new one seats properly.
D8 "heck the damper rod for damage and wear,
and renew it if necessary. Reassembly
D9 'f removed, slide the rebound spring onto the
damper rod. 'nsert the damper rod into the fork
tube and slide it into place so that it projects fully
from the bottom of the tube, then fit the seat onto
the bottom of the damper rod 1see illustrations
4.88 an! 4.60b2.
00 =il the fork tube and bottom bush with the
specified fork oil and insert the assembly into the
slider. 4it a new copper sealing washer to the
damper rod bolt and apply a few drops of a
suitable non#permanent thread locking
compound, then install the bolt into the bottom of
the slider 1see illustration 4.6*2. Tighten the bolt
to the specified tor,ue setting. 'f the damper rod
rotates inside the tube, use the tool described in
1tep @B to hold the damper rod.
0* Push the fork tube fully into the slider, then
oil the top bush and slide it down over the tube
1see illustration 4.66a2. Press the bush s,uarely
into its recess in the slider as far as possible,
then install the oil seal washer 1see illustration
4.66b2. $ither use the :amaha service tool or a
suitable piece of tubing to tap the bush fully into
place the tubing must be slightly larger in
diameter than the fork tube and slightly smaller in
diameter than the bush recess in the slider. Take
care not to scratch the fork tube during this
operation it is best to make sure that the fork
tube is pushed fully into the slider so that any
accidental scratching is confined to the area
above the oil seal.
06 -hen the bush is seated fully and s,uarely
in its recess in the slider, .remove the washer to
check, wipe the recess clean, then reinstall the
washer/, install the new oil seal. 1mear the seal's
lips with lithium#based grease and slide it over
the tube so that its markings face upwards and
drive the seal into place as described above until
the retaining clip groove is visible above the seal
1see illustration 4.682.
nBrcra
2lace the old oil seal on top
GilET
of the new one to protect &t
when driving the seal into
place.
08 =nce the seal is correctly seated, fit the
retaining ciip, making sure it is correctly located in
its groove 1see illustration 4.6D2.
0D Fubricate the lips of the new dust seal then
slide it down the fork tube and press it into
position 1see illustration 4.602.
00 1lowly pour in the specified ,uantity of the
specified grade of fork oil and pump the fork at
least ten times to distribute it evenly 1see
illustration 4.65a2N the oil level should also be
measured and adjustment made by adding or
subtracting oil. 4ully compress the fork tube into
the slider and measure the fork oil level from the
top of the tube 1see illustration 4.65b2. Add or
subtract fork oil until it is at the level specified at
the beginning of the "hapter.
05 "lamp the slider upright in a soft#jawed vice
using the brake caliper mounting lugs, taking care
not to overtighten and damage them. Pull the fork
tube out of the slider as far as possible then install
the spring and the spring seat. =n T(7 models fit
the spacer and the washer.
04 Apply a smear of fork oil or grease to the
new top bolt =#ring. 'nstall the top bolt assembly,
making sure the bottom of the damping adjuster
rod locates correctly into the hole in the top of the
damper rod, and thread the bolt into the top of the
fork tube 1see illustration 4.692.
'arning: &t will be necessar) to compress
the spring b) pressing it down using
the top bolt to engage the threads of
the top bolt with the fork tube. +his is a
potentiall) dangerous operation and should be
performed with care, using an assistant if
necessar). 'ipe off an) eCcess oil before
starting to prevent the possibilit) of slipping.
,
<eep the fork tube fully e%tended whilst pressing
on the spring. 1crew the top bolt carefully into the
fork tube making sure it is not cross#threaded.
%ote) The top bolt can be tightened to the
speci!ied torAue setting at this stage i! the tube is
held between the padded 3aws o! a vice& but do
not risk distorting the tube by doing so. $ better
method is to tighten the top bolt when the !ork has
been installed in the bike and is securely held in
the bottom yoke.
;> 'nstall the forks .see 1ection C/.
:+> models
Disassembly
09 Always dismantle the fork legs separately to
avoid interchanging parts and thus causing an
accelerated rate of wear. 1tore all components in
separate, clearly marked containers 1see
illustration2.
50 1lacken the clamps securing the fork gaiter
and slide the gaiter off the top of the fork.
5* *efore dismantling the fork, it is advised that
the damper rod bolt be slackened at this stage.
"ompress the fork tube in the slider so that the
spring e%erts ma%imum pressure on the damper
rod head, then have an assistant slacken the
damper rod bolt in the base of the fork slider 1see
illustration 4.62. 'f an assistant is not available,
clamp the brake caliper mounting lugs in a soft#
jawed vice to support the fork.
56 'f the fork top bolt was not slackened with the
fork in situ, carefully clamp the fork tube in a vice
e,uipped with soft jaws, taking care not to
overtighten or score its surface, and slacken the
top bolt.
58 +nscrew the fork top bolt from the top of the
fork tube.
'arning: +he fork spring is
pressing on the fork top bolt 3via the
spacer4 with considerable pressure.
7nscrew the bolt ver) carefull), keeping a
downward pressure on it and release it slowl)
as it is likel) to spring clear. &t is advisable to
wear some form of e)e and face protection
when carr)ing out this operation.
,
5D 1lide the fork tube down into the slider and
withdraw the spacer, spring seat and the spring
from the tube. )ote which way up the spring is
fitted.
50 'nvert the fork leg over a suitable container
and pump the fork vigorously to e%pel as much
fork oil as possible.
55 (emove the previously slackened damper
rod bolt and its copper sealing washer from the
bottom of the slider. 0iscard the sealing washer as
a new one must be used on reassembly. 'f the
damper rod bolt was not slackened before
dismantling the fork, use the :amaha service tool
.pt. nos. 9?>9?#?8@AC and 9?>9?#?8@AB/ to
prevent the damper rod from turning. This tool
is passed down
7se a ratchet/t)pe tool when &nstalling the
fork top bolt. +his makes it unnecessar) to
remove the tool from the bolt whilst
threading it in making it easier to maintain a
downward pressure on the spring.
Stane! by Stal'er
+)($2'1T$($0 3'
3$(1'=) =4 P'"T+($#0
4rame, suspension and final drive CL8;
C
# Top bolt
2 (-ring
4 +pacer
5 +pring seat
8 +pring
9 Fork tube and bottom bush
4.09 Front for' com"onents ( XT3 mo!els
: *amper rod and rebound spring
; *amper rod seat
7 *ust seal
#< /etaining clip
## (il seal
#2 >asher
#4 Top bush
#5 +lider
#8 (il drain screw and sealing washer
-#7;7-75 models
#9 *amper rod bolt and sealing washer
+)($2'1T$($03'
Scane! by Stal'er
3$(1'=) =4 P'"T+($#0
+)($2'1T$($03'
C[8C 4rame, suspension and final drive
through the fork tube and engages the damper
rod head a similar tool can be easily made in the
home workshop..
54 'nvert the fork and withdraw the damper rod
from inside the fork tube 1see illustration 4.882.
'f re,uired, slide the rebound spring off the
damper rod.
58 "arefully prise out the dust seal from the top
of the slider to gain access to the oil seal
retaining clip 1see illustration 4.*02. 0iscard the
dust seal as a new one must be used.
59 "arefully remove the retaining clip, taking
care not to scratch the surface of the tube 1see
illustration 4.**2.
40 To separate the tube from the slider it is
necessary to displace the top bush and oil seal.
The bottom bush should not pass through the top
bush, and this can be used to good effect. Push
the tube gently inwards until it stops against the
damper rod seat. Take care not to do this forcibly
or the seat may be damaged. Then pull the tube
sharply outwards until the bottom bush strikes the
top bush. (epeat this operation until the top bush
and seal are tapped out of the slider 1see
illustration 4.*62.
4* -ith the tube removed, slide off the oil seal,
washer and top bush, noting which way up they
fit 1see illustration 4.*82. 0iscard the oil seal as
a new one must be used. Caution: Do not
remove the bottom bush from the tube unless
it is to be renewed.
46 Tip the damper rod seat out of the slider,
noting which way up it fits.
?ns"ection
48 "lean all parts in solvent and blow them dry
with compressed air, if available. "heck the fork
tube for score marks, scratches, flaking of the
chrome finish and e%cessive or abnormal wear.
Fook for dents in the tube and renew the tube in
both forks if any are found. "heck the fork seal
seat for nicks, gouges and scratches. 'f damage
is evident, leaks will occur. Also check the oil seal
washer for damage or distortion and renew it if
necessary.
4D "heck the fork tube for runout .bending/
using 3#blocks and a dial gauge, or have it done
by a dealer 1see illustration 4.*52. :amaha do
not specify a runout limit, but if the tube is bent it
should be renewed.
40 "heck the spring for cracks and other
damage. 5easure the spring free length and
compare the measurement to the specifications
at the beginning of the "hapter. 'f it is defective
or sagged below the service limit, renew the
springs in both forks. )ever renew only one
spring. Also check the rebound spring.
45 $%amine the working surfaces of the two
bushes if worn or scuffed they must be renewed.
To remove the bottom bush from the fork tube,
prise it apart at the slit using a flat#bladed
screwdriver and slide it off 1see illustration
4.*82. 5ake sure the new one seats properly.
44 "heck the damper rod for damage and wear,
and renew it if necessary.
Reassembly
48 'f removed, slide the rebound spring onto the
rod. 'nsert the damper rod into the fork tube and
slide it into place so that it projects fully from the
bottom of the tube, then fit the seat onto the
bottom of the damper rod 1see illustration 4.88
an! 4.60b2.
49 =il the fork tube and bottom bush with the
specified fork oil and insert the assembly into the
slider. 4it a new copper sealing washer to the
damper rod bolt and apply a few drops of a
suitable non#permanent thread locking
compound, then install the bolt into the bottom of
the slider 1see illustration 4.6*2. Tighten the bolt
to the specified tor,ue setting. 'f the damper rod
rotates inside the tube, use the tool described in
1tep CC to hold the damper rod.
80 Push the fork tube fully into the slider, then oil
the top bush and slide it down over the tube 1see
illustration 4.66a2. Press the bush s,uarely into
its recess in the slider as far as possible, then
install the oil seal washer 1see illustration
4.66b2. $ither use the :amaha service tool or a
suitable piece of tubing to tap the bush fully into
place the tubing must be slightly larger in
diameter than the fork tube and slightly smaller in
diameter than the bush recess in the slider. Take
care not to scratch the fork tube during this
operation it is best to make sure that the fork
tube is pushed fully into the slider so that any
accidental scratching is confined to the area
above the oil seal.
8* -hen the bush is seated fully and s,uarely
in its recess in the slider, .remove the washer to
check, wipe the recess clean, then reinstall the
washer/, install the new oil seal. 1mear the sealis
lips with lithium#base grease and slide it over the
tube so that its markings face upwards and drive
the seal into place as described above until the
retaining clip groove is visible above the seal
1see illustration 4.682.
2lace the old oil seal on top
G?%T
of the new one to protect &t
when driving the seal into
place.
>A=nce the seal is correctly seated, fit the
retaining clip, making sure it is correctly located
in its groove 1see illustration 4.6D2.
>@Fubricate the lips of the new dust seal then
slide it down the fork tube and press it into
position 1see illustration 4.602.
>61lowly pour in the specified ,uantity of the
specified grade of fork oil and pump the fork at
least ten times to distribute it evenly 1see
illustration 4.65a2N the oil level should also be
measured and adjustment made by adding or
subtracting oil. 4ully compress the fork tube into
the slider and measure the fork oil level from the
top of the tube 1see illustration 4.65b2. Add or
subtract fork oil until it is at the level specified at
the beginning of the "hapter.
>; "lamp the slider in a soft#jawed vice using
the brake caliper mounting lugs, taking care not to
overtighten and damage them. Pull the fork tube
out of the slider as far as possible then install the
spring, the spring seat, with its shouldered side
fitting down into the top of the spring, and the
spacer.
>C Apply a smear of grease to the new top bolt
=#ring and thread the bolt into the top of the fork
tube.
'arning: &t will be necessar) to
compress the spring b) pressing it
down using the top bolt to engage the
threads of the top bolt with the fork tube. +his
is a potentiall) dangerous operation and
should be performed with care, using an
assistant if necessar). 'ipe off an) e*cess oil
before starting to prevent the possibilit) of
slipping. <eep the fork tube fully e%tended whilst
pressing on the spring. 1crew the top bolt carefully
into the fork tube making sure it is not cross#
threaded. %ote) The top bolt can be tightened to
the speci!ied torAue setting at this stage i! the tube
is held between the padded 3aws o! a vice& but do
not risk distorting the tube by doing so (see +ool
+ip4. $ better method is to tighten the top bolt
when the !ork has been installed in the bike and is
securely held in the bottom yoke.
,
84 'nstall the forks .see 1ection C/.
> 1teering stem #
removal and installation
"emoval
8 (emove the front forks .see 1ection C/.
A =n T05 models, displace the handlebars from
the top yoke .see 1ection ;/, then disconnect the
horn wiring connectors and unscrew the bolts
securing the front brake hoseDhorn bracket to the
bottom yoke 1see illustration2. =n 899C#on
models, unscrew the bolts securing the choke
knob and the cable guide to the top yoke.
Stane! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
H
8.6 Disconnect the horn Birin& connectors
1A2; then unscreB the bolts 1/2 an!
!is"lace the bra'e hose union+horn
assembly
+)($2'1T$($0 3$(1'=) ?
+)($2'1T$($03'
4rame, suspension and final drive CL8B
8.8 Disconnect the horn Birin& connectors; then unscreB the bolts 1arroBe!2 an! !is"lace the bra'e hose+horn assembly
8.Da Free the cable an! Birin& from the &ui!es 1arroBe!2 on the to" yo'e ...
8 =n T(7 models, disconnect the horn wiring
connectors and unscrew the bolts securing the
front brake hoseDhorn bracket to the bottom yoke
1see illustration2.
D =n 7TE models, displace the handlebars from
the top yoke .see 1ection ;/. 1lip the cables and
wiring out of the guides on the top yoke, and
unscrew the bolts securing the front brake hose
and the cable guide to the bottom yoke 1see
illustrations2.
0 +nscrew the steering stem nut or bolt and
remove it along with its washer, where fitted 1see
illustration2. Fift the top yoke off the steering
stem and place it aside, making sure no strain is
placed on the ignition switch wiring 1see
illustration2. =n T(7 models the yoke should be
supported so that the master cylinder reservoir
remains upright and so that no strain is placed on
the hydraulic hoses.
5 =n T05 and T(7 models, remove the tabbed
lockwasher, noting how it fits, then unscrew and
remove the locknut using either a "#spanner, a
peg spanner or a drift located in one of the
notches 1see illustration2. (emove the washer.
B 1upporting the bottom yoke, unscrew the
adjuster nut using either a "#spanner, a peg#
spanner or a drift located in one of the notches,
then remove the adjuster nut and the bearing
cover from the steering stem.
> 2ently lower the bottom yoke and steering
stem out of the frame.
8.Db ... an! !is"lace the bra'e hose
union 1A2 an! &ui!e 1/2 from the bottom
yo'e by unscreBin& the bolts
9 (emove the upper bearing from the top of the
steering head. (emove all traces of old grease
from the bearings and races and check them for
wear or damage as described in 1ection 9. %ote)
*o not attempt to remove the outer races !rom
the !rame or the lower bearing !rom the steering
stem unless they are to be renewed.
8.0a EnscreB the steerin& stem nut or
bolt...
C
8.0b ... an! lift off the to" yo'e 8.5 Remo,e the loc'Basher; then unscreB the loc'nut 1arroBe!2
+)($2'1T$($0 3$(1'=) ?
Scane! by Stal'er
+)($2'1T$($0 3'
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< J +)($2'1T$($0 3$(1'=) =4 P'"T+($0
CL8> 4rame, suspension and final drive
8.*6 Ali&n the a!<uster nut an! loc'nut so that the loc'Basher tabs fit into the notches in both
8.*8 Ti&hten the steerin& stem nut or bolt to the s"ecifie! torAue
&nstallation
*0 1mear a liberal ,uantity of lithium#based
grease on the bearing races in the frame. Also
work some grease well into both the upper and
lower bearings.
** "arefully lift the steering stemDbottom yoke
up through the steering head. 4it the upper
bearing into the top of the steering head, then
install the bearing cover. Thread the adjuster nut
onto the steering stem and adjust the bearings
as described in "hapter 8.
*6 =n T05 and T(7 models, install the washer
and the locknut. =n 8998 to 899; T05 models
the tapered side of the locknut must face down.
Tighten the locknut finger#tight, then tighten it
further until its notches align with those in the
adjuster nut. 'f necessary, counter#hold the
adjuster nut and tighten the locknut using a "#
spanner or drift until the notches align, but make
sure the adjuster nut does not turn as well. 'nstall
the tabbed lockwasher so that the tabs fit into the
notches in both the locknut and adjuster nut 1see
illustration2.
*8 4it the top yoke onto the steering stem 1see
illustration 8.0b2; then install the washer .where
fitted/ and steering stem nut or bolt and tighten it
finger#tight 1see illustration 8.0a2. Temporarily
install one of the forks to
align the top and bottom yokes, and secure it by
tightening the bottom yoke clamp bolt only. )ow
tighten the steering stem nut or bolt to the tor,ue
settings specified at the beginning of the "hapter
1see illustration2.
86 'nstall the remaining components in a
reverse of the removal procedure.
8; "arry out a check of the steering head
bearing freeplay as described in "hapter 8, and
if necessary re#adjust.
9 Steerin& hea! bearin&s # H
inspection and replacement LX
&nspection
* (emove the steering stem .see 1ection >/.
9.5 DraBbolt arran&ement for fittin&
steerin& stem bearin& outer races
# Mong bolt or threaded bar
2 Thick washer
4 0uide !or lower race
A (emove all traces of old grease from the
bearings and races and check them for wear or
damage.
@ The outer races should be polished and free
from indentations. 'nspect the bearing rollers for
signs of wear, damage or discoloration, and
e%amine the bearing roller retainer cage for signs
of cracks or splits. 1pin the bearings by hand.
They should spin freely and smoothly. 'f there are
any signs of wear on any of the above
components both upper and lower bearing
assemblies must be renewed as a set. =nly
remove the races if they need to be renewed # do
not re#use them once they have been removed.
"eplacement
6 The outer races are an interference fit in the
steering head and can be tapped from position
with a suitable drift 1see illustration2. Tap firmly
and evenly around each race to ensure that it is
driven out s,uarely. 't may prove advantageous
to curve the end of the drift slightly to improve
access.
; Alternatively, the races can be removed using
a slide#hammer type bearing e%tractor these can
often be hired from tool shops.
C The new outer races can be pressed into the
head using a drawbolt arrangement 1see
illustration2; or by using a large diameter tubular
drift which bears only on the outer edge of the
race. $nsure that the drawbolt washer or drift .as
applicable/ bears only on the outer edge of the
race and does not contact the working surface.
Alternatively, have the races installed by a
:amaha dealer e,uipped with the bearing race
installing tools.
Htflflf&&H )nstallation o! new bearing
E7ilifii outer races is made much
Gi%T
easier if the races are left overnight in the
free9er. +his causes them to contract
slightl) making them a looser fit.
,lternativel), use a free9e spra).
+)($2'1T$($0 3$(1'=) ?
Scane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0'
9.D Dri,e the bearin& outer races out Bith a
!rift as shoBn
4rame, suspension and final drive C[89
9.4a Remo,e the loBer bearin& an! &rease
seal only if they are bein& reneBe!
J The lower bearing should only be removed f a
new one is being fitted 1see illustration2. To
remove the lower bearing from the steering stem,
use two screwdrivers placed sn opposite sides of
the race to work it free. 'f ehe bearing is firmly in
place it will oe necessary to use a bearing puller
Tsee illustration2; or in e%treme circumstances to
split the bearing's inner section using an angle
grinder. Take the steering stem to a :amaha
dealer if re,uired. "heck the condition of the dust
seal that fits under the lower bearing and renew it
if it is worn, damaged or deteriorated. * 4it the
new lower bearing onto the steering stem. A
length of tubing with an internal diameter slightly
larger than the steering stem will be needed to
tap the new bearing into position 1see
illustration2. $nsure that the drift bears only on
the inner edge of the bearing and does not
contact the rollers. 9 'nstall the steering stem
.see 1ection >/.
8? (ear shock absorber
#removal, inspection
and installation
'arning: Do not attempt to
disassemble this shock absorber. &t is
nitrogen/charged under high pressure.
&mproper disassembl) could result in serious
in-ur). &nstead, take the shock to a Yamaha
dealer or suspension specialist with the
proper e.uipment to do the -ob.
,
"emoval
TD mo!els
* Place the machine on an au%iliary stand.
Position a support under the rear wheel so that it
does not drop when the shock absorber is
removed, but also making sure that the weight of
the machine is off the rear suspension so that the
shock is not compressed.
6 (emove the seat .see "hapter >/.
8 +nscrew the nut and withdraw the bolt
9.4b ?t is best to remo,e the loBer bearin&
usin& a "uller
securing the bottom of the shock absorber to the
swingarm 1see illustrations2.
D +nscrew the nut on the shock absorber
upper mounting bolt 1see illustration2.
1upport the shock absorber and withdraw the
upper mounting bolt, then manoeuvre the
shock down and out of the bottom of the
machine 1see illustration2.
TRX an! XT3 mo!els
0 Place the machine on an au%iliary stand.
Position a support under the rear wheel so
9.8 Dri,e the neB bearin& on usin& a
suitable bearin& !ri,er or a len&th of "i"e
that bears only a&ainst the inner race an!
not a&ainst the rollers or ca&e
that it does not drop when the shock absorber is
removed, but also making sure that the weight of
the machine is off the rear suspension so that the
shock is not compressed.
C (emove the seat .see "hapter >/. 'f re,uired
for improved clearance, also remove the e%haust
system .see "hapter 6/. =n 7TE models, remove
the fuel tank .see "hapter 6/, and where fitted,
remove the rubber boot from around the shock
absorber lower mounting.
B +nscrew the nut and withdraw the bolt
*0.Db ... then su""ort the shoc' an!
Bith!raB the bolt
Scane! by Stal'er
+)($2'1T$($0 3'
*0.8a EnscreB the nut 1arroBe!2.
*0.Da EnscreB the nut 1arroBe!2.
. an! Bith!raB the bolt
CLA? 4rame, suspension and final drive
*0.4a -in'a&e ro! to lin'a&e arm bolt 1A2; shoc' absorber loBer mountin& bolt 1/2 ( TRX mo!els
*0.4b -in'a&e ro! to lin'a&e arm bolt 1A2; shoc' absorber loBer mountin& bolt 1/2 ( XT3 mo!els
securing the linkage rods to the linkage arm 1see
illustrations2. +nscrew the nut and withdraw the
bolt securing the bottom of the shock absorber to
the suspension linkage arm. 1wing the linkage
rods rearwards and the linkage arm down.
> =n T(7 models, slacken the clamp screw
securing the reservoir to its holder and free the
hose from its clip on the frame 1see
illustrations2. 1lip the reservoir out and feed it
through to the shock absorber.
9 +nscrew the nut on the shock absorber upper
mounting bolt 1see illustrations2.
*0 1upport the shock absorber and withdraw
*0.8a Slac'en the clam" screB 1arroBe!2 an!
free the reser,oir...
the upper mounting bolt, then manoeuvre the
shock down and out of the bottom of the
machine, on T(7 models feeding the reservoir
through as you do.
&nspection
** 'nspect the shock absorber for obvious
physical damage and the coil spring for
looseness, cracks or signs of fatigue.
*6 'nspect the damper rod for signs of bending,
pitting and oil leakage 1see illustration2.
*8 'nspect the pivot hardware at the top and
bottom of the shock for wear or damage.
.. an! release the hose from its cli"
1arroBe!2
&nstallation
*D 'nstallation is the reverse of removal. Apply
molybdenum disulphide grease to the shock
absorber and linkage rod pivot points. 'nstall the
bolts and nuts finger#tight only until all
components are in position, then tighten the nuts
to the tor,ue settings specified at the beginning
of the "hapter.
88 (ear suspension linkage 1TRX
Q[
and 7TE models/ # removal,
inspection and installation
"emoval
8 Place the machine on an au%iliary stand.
Position a support under the rear wheel so that it
does not drop when the shock absorber lower
mounting bolt is removed, but also making sure
that the weight of the machine is off the rear
suspension so that the shock is not compressed.
A (emove the seat .see "hapter >/. 'f re,uired
for improved clearance, also remove the e%haust
system .see "hapter 6/. =n 7TE models, where
fitted, remove the rubber boot from around the
shock absorber lower mounting.
*0.8b
*
*0.9a Shoc' absorber u""er mountin& bolt 1arroBe!2 ( TRX mo!els
*0.9b Shoc' absorber u""er mountin& bolt 1arroBe!2 ( XT3 mo!els
*0.*6 -oo' for crac's; "ittin& an! oil lea'a&e on the !am"er ro! 1arroBe!2
Scane! by Stal'er
4rame, suspension and final drive C[A8
8 +nscrew the nuts and withdraw the bolts
securing the shock absorber and the linkage rods
to the linkage arm 1see illustrations2. )ote
which bolts fit where.
D +nscrew the nut and withdraw the bolt
securing the linkage rods to the swingarm and
remove the rods.
0 +nscrew the nut and withdraw bolt securing
the linkage arm to the frame and remove the
linkage arm, noting which way round it fits.
&nspection
C -ithdraw the inner sleeves and lever out
the grease seals from the linkage arm and
swingarm, noting their different si&es 1see
?llustrations2. Thoroughly clean all
**.8a Shoc' absorber to lin'a&e arm bolt
1A2; lin'a&e ro! to lin'a&e arm bolt 1/2;
lin'a&e ro! to sBin&arm bolt 192; lin'a&e
arm to frame bolt 1D2 ( TRX mo!els
**.8b Shoc' absorber to lin'a&e arm bolt
1A2; lin'a&e ro! to lin'a&e arm bolt 1/2;
lin'a&e ro! to sBin&arm bolt 192; lin'a&e
arm to frame bolt 1D2 ( XT3 mo!els
**;5a Sus"ension lin'a&e an! sBin&arm assembly ( TRX mo!els
Stane! by Stal'er
CLAA 4rame, suspension and final drive
**.5b Sus"ension lin'a&e an! sBin&arm assembly # XT3 mo!els
components, removing all traces of dirt, corrosion
and grease. =n 7TE models make sure that the
grease nipple passages in the linkage arm and
pivot bolts are clear.
B 'nspect all components closely, looking for
obvious signs of wear such as heavy scoring, or
for damage such as cracks or distortion.
> "heck the condition of the needle roller
bearings in the linkage arm and swingarm.
9 -orn bearings can be drifted out of their
bores, but note that removal will destroy them
new components should be obtained before work
commences. The new ones should be pressed or
drawn into their bores rather than driven into
position. 'n the absence of a press, a suitable
drawbolt arrangement can be made up as
described below.
8? =btain a long bolt or a length of threaded
rod from a local engineering works or some
other supplier. The bolt or rod should be
86 Fubricate the needle roller bearings and the
spacers with molybdenum disulphide grease
.T(7 models/ or lithium#based grease .7TE
models/ and install the inner sleeves.
8; "heck the condition of the grease seals and
renew them if they are damaged or deteriorated.
Press the seals s,uarely into place.
&nstallation
8C 'nstallation is the reverse of removal.
Apply molybdenum disulphide grease .T(7
models/ or lithium#based grease .7TE models/
to the pivot points. 'nstall the bolts and nuts
finger#tight only until all components are in
position, then tighten the nuts to the tor,ue
settings specified at the beginning of the
"hapter.
8A 1uspension # adjustments I
6ront forks
8 =n 7TE models, the front forks are not
adjustable.
A =n T05 and T(7 models, spring pre#load is
adjusted using a suitable spanner on the adjuster
flats on the top of the forks .see illustration/. The
amount of pre#load is indicated by lines on the
adjuster. There are five lines on T05 models and
eight on T(7 models. The standard position is
with the fifth .8998 to 899; T05 models/, third
.899C#on T05 models/ or si%th .T(7 models/
line just visible above the top bolt he%. Turn the
adjuster clockwise to increase pre#load and anti#
clockwise to decrease it. Always make sure both
adjusters are set e,ually.
@ =n T05 models, rebound damping is adjusted
using a screwdriver in the slot in the adjuster
protruding from the pre#load adjuster .see
illustration 8A.A/. The amount of damping is
indicated by the number of clicks when turned
anti#clockwise from the fully screwed#in position.
There are si% positions on 8998 to 899; T05
models, and five on 899C#on T05 models. The
standard position is four clicks out. Turn the
adjuster clockwise
1caned by Stal'er
about one inch longer than the combined width of
the linkage piece and one bearing. Also re,uired are
suitable nuts and two large and robust washers
having a larger outside diameter than the bearing
housing. 'n the case of the threaded rod, fit one nut
to one end of the rod and stake it in place for
convenience.
88 4it one of the washers over the bolt or rod so
that it rests against the head or staked nut, then pass
the assembly through the relevant bore. =ver the
projecting end place the bearing, which should be
greased to ease installation, followed by the
remaining washer and nut.
8A Holding the bearing to ensure that it is kept
s,uare, slowly tighten the nut so that the bearing is
drawn into its bore.
8@ =nce it is fully home, remove the drawbolt
arrangement and, if necessary, repeat the procedure
to fit the other bearings.
8A.A 1pring pre#load adjuster .A/, rebound
damping adjuster .*/ # T05 and
TRX models
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
CLA6 4rame, suspension and final drive
*6.9 9om"ression !am"in& a!<uster(TRX
mo!els
the shock absorber reservoir Usee illustration2.
Turn the adjuster clockwise to increase damping
and anti#clockwise to decrease it. To establish
the current setting, turn the adjuster in
.clockwise/ until it stops, counting the number of
clicks, then reset it as re,uired by turning it out.
There are twenty positions. The standard position
is ten clicks out.
*0 =n 7TE models, pre#load adjustment is made
by slackening the locknut on the base of the
shock absorber, then turning the adjuster nut
clockwise .as you look up at it from the bottom/
to increase pre#load and anti#clockwise to
decrease it 1see illustration2. (efer to the
diagram for the standard, ma%imum and
minimum settings 1see illustration2. Tighten the
locknut securely after adjustment.
*6.*0a Slac'en the loc'nut 1A2 an! turn the
a!<uster 1/2 as reAuire! ...
*8 SBin&arm( QH
removal and installation 1
"emoval
* (emove the rear wheel .see "hapter B/.
6 =n 7TE models, the swingarm side clearance
should be measured prior to removal. Push the
swingarm to one side of the frame, then slip a
feeler gauge between the frame and the
swingarm on the side from which the swingarm
was pushed and measure the clearance. 'f it is
greater than specified, refer to 1ection 86.
8 =n T05 models, unscrew the bolt which
secures the caliper bracket to the swingarm and
remove the bracket .see "hapter B,
f
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*6.*0b ... an! accor!in& to the s"ecifie!
settin&s
+tandard length& $ R 8.5 mm
Einimum length& $ R 8.5 mm
EaBimum length& $ R #8.5 mm
1ection 8A, 1tep A/. +nscrew the bolts securing
the hose guide to the swingarm, noting how they
also secure the rear mudguard 1see illustration2.
D =n T(7 models, unscrew the bolt securing
each brake hose guide to the swingarm 1see
illustration2. (emove the split pin from the bolt
securing the brake tor,ue arm to the swingarm,
then unscrew the nut, withdraw the bolt and
detach the arm 1see illustration2.
0 =n 7TE models, unscrew the bolt securing
each brake hose guide to the underside of the
swingarm 1see illustration2. 0isconnect the
brake hose from the rear caliper .see "hapter B/
and remove the caliper. 4eed the hose through
its guide on the inside of the swingarm and
support it with its end upright.
5 +nscrew the bolts securing the chain guard to
the swingarm and remove the guard, on T05
models along with the rear mudguard, noting how
they fit 1see illustration2.
*8.Db Detach the torAue arm by remo,in& the
bolt 1arroBe!2
*8.0 EnscreB the bolts 1arroBe!2 an!
!etach the hose
*8.5 9hain&uar!+rear mu!&uar! bolts
1arroBe!2 ( TD shoBn
Stane! by Stal'er
=)($2'1T$($0 3$(1'=) =4 P'"T=($#0$1<
*8.8 EnscreB the bolts 1arroBe!2 an!
!etach the hose &ui!e
*8.Da EnscreB the bolts 1arroBe!2 an!
!etach the hose &ui!es
r+H($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
i, suspension and final drive CLA;
*8.9a Remo,e the blan'in& ca"s if fitte! ...
*8.9b ... then unscreB the sBin&arm nut 1arroBe!2 ( TD shoBn
*8.*0 7ith!raB the "i,ot bolt an! remo,e the sBin&arm # TD shoBn
4 =n T05 models, unscrew the nut and
withdraw the bolt securing the bottom of the
shock absorber to the swingarm 1see
illustrations *0.8a an! b2.
8 =n T(7 and 7TE models, remove the rear
shock absorber .see 1ection 8?/. 'f re,uired,
remove the linkage rods from the swingarm .see
1ection 88/.
9 -here fitted, remove the blanking cap from
each end of the swingarm pivot 1see
illustration2. +nscrew the nut on the end of the
swingarm pivot bolt and remove the washer,
where fitted 1see illustration2.
*0 1upport the swingarm, then withdraw the
pivot bolt and remove the swingarm 1see
illustration2. <nock the pivot bolt through using
a drift if re,uired.
88 (emove the chain slider from the front of the
swingarm if necessary, noting how it fits 1see
illustration2. 'f it is badly worn or damaged, it
should be renewed.
8A 'nspect all components for wear or damage
as described in 1ection 86.
&nstallation
*8 'f removed, install the chain slider and
tighten its bolt.s/ securely 1see illustration
*8.**2.
*D (emove the cap and washer .where fitted/
from each side of the swingarm, and withdraw
the bearing spacer.s/ 1see illustrations2.
Fubricate the seals .7TE models/ and bearings
with molybdenum disulphide grease .T(7
models/ or lithium#based grease .7TE models/.
Also grease the collar.s/ and swingarm pivot.
(e#install the washers and caps.
*0 =ffer up the swingarm, and have an assistant
hold it in place 1see illustration2. 5ake sure the
drive chain is looped over the front of the
swingarm. 1lide the pivot bolt through the
swingarm 1see illustration *8.*02; on T05
models making sure the flats on the head of the
pivot bolt locate correctly with the flats in the
frame 1see illustration2. 'nstall the
*8.** Remo,e the chain sli!er if reAuire!
*8.*Da Remo,e the ca" an! Basher 1Bhere fitte!2...
*8.*Db ... then Bith!raB the collar...
*8.*Dc ... an! &rease the bearin&s an! other com"onents as !escribe!
*8.*0a Do not for&et to loo" the chain o,er the sBin&arm
*8.*0b .n TD mo!els; ma'e sure the bolt hea! flats locate correctly
Stane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T=($#0$1<
C[AC 4rame, suspension and final drive
*8.*0c Fit the nut 1Bith its Basher; Bhere
fitte!2...
nut with its washer, where fitted and tighten the
nut to the tor,ue setting specified at the
beginning of the "hapter 1see illustrations2. =n
T(7 and 7TE models it may be necessary to
counter#hold the bolt head to prevent it from
turning. -here removed, fit the blanking caps
1see illustration *8.9a2.
*5 'nstall the rear shock absorber .see 1ection
8?/ and on T(7 and 7TE models the suspension
linkage rods, if removed .see 1ection 88/.
*4 'nstall the chainguard, along with the rear
fender on T05 models, making sure it locates
correctly over the lugs on the swingarm 1see
illustrations2.
*8 =n T05 models, fit the caliper bracket onto
the swingarm and loosely install the bolt 1see
illustration2. 4it the brake hose guide onto the
swingarm 1see illustration *8.82.
*9 =n T(7 models, fit the brake tor,ue arm
onto the swingarm, then install the bolt and
tighten the nut to the specified tor,ue setting
1see illustration *8.Db2. 4it a new split pin onto
the bolt. 4it the brake hose guides onto the
swingarm 1see illustration *8.Da2.
60 =n 7TE models, feed the brake hose
through its guide on the inside of the swingarm
and install it onto the caliper .see "hapter B/
note that the rear brake hydraulic system will
re,uire topping up and bleeding of air. 4it the
brake hose guides onto the underside of the
swingarm 1see illustration *8.02.
6* 'nstall the rear wheel .see "hapter B/, not
*8.*0! ... an! ti&hten it to the s"ecifie!
torAue
forgetting to tighten the caliper bracket bolt on
T05 models.
AA "heck and adjust the drive chain slack .see
"hapter 8/. "heck the operation of the rear
suspension before taking the machine on the
road.
86 SBin&arm # inspection and
bearing replacement
&nspection
*Thoroughly clean all components, removing all
traces of dirt, corrosion and grease 1see
illustrations **.5a an! b2.
6 'nspect all components closely, looking for
obvious signs of wear such as heavy scoring,
and cracks or distortion due to accident damage.
Any damaged or worn component must be
renewed.
8 "heck the swingarm pivot bolt for straightness
by rolling it on a flat surface such as a piece of
plate glass .first wipe off all old grease and
remove any corrosion using fine emery cloth/. 'f
the e,uipment is available, place the a%le in 3#
blocks and measure the runout using a dial
gauge. :amaha do not specify a ma%imum
runout limit but if it is obviously bent it must be
renewed.
(earing replacement / T*E and
+": models
6 (emove the cap and washer .where fitted/
^^^
i
Mmutmm
m
=^ 1
|?7
%
#7p61tf
@
+ufiA+ ^/* 7
*8.*4a .n TD mo!els; locate the
chain&uar! as shoBn ...
from each side of the swingarm 1see illustration
*8.*Da2.
0 -ithdraw the bearing spacer 1see illustration
*8.*Db2 and clean all old grease off the spacer
and the two needle roller bearings in the
swingarm. 'f the bearings do not run smoothly
and freely they must be renewed 1see
illustration *8.*Dc2. (efer to Tools and
>orkshop Tips (+ection 8) in the (eference
section for details of using a drawbolt tool or
bearing e%tractor with slide#hammer attachment
to remove the bearings and install new ones.
5 Fubricate the bearings and the spacer with
molybdenum disulphide grease. 'nstall the caps
and washers .where fitted/ on the swingarm ends
(earing replacement / :+>
models
4 (emove the cap and washer .and any shims,
where fitted/ from each side of the swingarm
1see illustration *8.*Da2. Fever out the grease
seal on each side of each swingarm pivot.
8 -ithdraw the bearing spacers, noting their
different length 1see illustration *8.*Db2. "lean
all old grease off the spacers, the two needle
roller bearings and the two plain bushes in the
swingarm. $%amine the bearings and the bushes
if the bearings do not run smoothly and freely
and the bushes are scored or worn they must all
be renewed. (efer to Tools and >orkshop Tips
(+ection 8)
*8.*4b ... then fit the mu!&uar!...
_
?
=
*8.*4c ... not for&ettin& the collars
*8.*8 -ocate the cali"er brac'et an! loosely install the bolt
Stane! by Stal'er
Frame; sus"ension an! final !ri,e 5I64
*D.8 SBin&arm bearin& 1*2 an! bush 162 installe! !e"th
$ 5 mm 6 ; mm
in the (eference section for details of using a
drawbolt tool or bearing e%tractor with slide#
hammer attachment to remove the bearings and
bushes and install new ones. -hen installing the
new components note that they must be
positioned to a specific depth in the swingarm
housings 1see illustration2.
9 5easure the length of each bearing spacer
and the thickness of each washer and
compare them to the specifications, renewing
any component that is worn. %ote) -orn
components will increase swingarm sidepiay.
*0 Although it is possible to measure the
swingarm sidepiay with all components
assembled on the bike it is preferably to
calculate sidepiay by direct measurement of
the individual components. 0one this way,
you will be able to install any shims re,uired
as the swingarm is refitted. :ou will need a
vernier gauge to do this accurately. 5easure
the width of the swingarm mounting boss on
the engine and call this dimension A. (ecord
the lengths of the two spacers measured in
1tep 9 as dimensions * and ". )ow measure
the overall length of the swingarm .from the
outside of one bearing housing to the outside
of the other/ and record this as dimension 0.
(ecord the thicknesses of the two washers
.added together/ measured in 1tep 9 and
record this as dimension $. "ompute
swingarm sidepiay by subtracting the
swingarm width and washer thicknesses from
the boss width and spacer lengths, thusG
1idepiay h .A ^ * ^ "/ # .0 ^ $/
'f the sidepiay is within the limit of ?.6 to ?.B mm
no shims are re,uired. 'f sidepiay e%ceeds ?.B
mm, fit one or two shims as re,uired to bring
sidepiay within the specified limit. 1hims are
available in ?.@ mm thicknesses. The shims
should be fitted between the cap and washer if
two shims are re,uired fit one on each side,
whereas if only one shim is re,uired fit this on
the right#hand side.
88 Press the grease seals into their locations
in each side of the swingarm bearing
housings, renewing them if they are damaged or
deteriorated.
*6 Fubricate the bearings, bushes and spacers
with lithium#based grease. 0o not forget to install
the bearing spacer between the bearings in the
swingarm. 'nstall the washers, shims .where
fitted/ and caps on the outer ends of the
swingarm.
*0 Dri,e chain # removal,
cleaning and installation
ndless t)pe chain
%ote) $n endless chain has no riveted (so!t) link -
all links and pins are the same. The chain !itted
as original eAuipment and supplied as a spare
part !rom %amaha dealers is o! the endless type.
'arning: !%" install a drive
chain which uses a clip/t)pe master
3split4 link. $
Remo,al
* (emove the swingarm .see 1ection 8@/. )ote
that if the front sprocket is being removed, the
sprocket nut should be slackened before
removing the swingarm, so that the rear brake
can be used so stop the sprocket turning .see
1ection 8C/.
6=n T05 and 7TE models, unscrew the bolts
securing the outer front sprocket cover and
remove the cover 1see illustration2. +nscrew the
gearchange lever linkage arm pinchbolt and
remove the arm from the shaft, noting the
alignment of the punch mark with the slit in the
clamp 1see illustration2. 'f no mark is visible,
make your own before removing the arm so that
it can be correctly aligned with the shaft on
installation. +nscrew the bolts securing the inner
sprocket cover, on T05 models noting the clip
secured by the top rear bolt, and remove the
cover 1see illustration2.
8 =n T(7 models, unscrew the gearchange
*0.6a EnscreB the bolts 1arroBe!2 an!
remo,e the co,er
*0.6c EnscreB the bolts 1arroBe!2 an!
remo,e the inner co,er
<
Stane! by Stal'er
?
*0.6b -in'a&e arm+shaft ali&nment (TD
mo!els
CLA> 4rame, suspension and final drive
*0.8 -in'a&e arm+shaft ali&nment (TRX
mo!els
lever linkage arm pinchbolt and remove the arm
from the shaft, noting the alignment of the punch
mark with the slit in the clamp 1see illustration2.
'f no mark is visible, make your own before
removing the arm so that it can be correctly
aligned with the shaft on installation. +nscrew the
bolts securing the outer front sprocket cover and
remove the cover, then unscrew the bolts
securing the inner sprocket cover, noting the clip
secured by the top rear bolt, and remove the
cover.
6 1lip the chain off the front sprocket and
remove it from the bike.
9leanin& an! Bear chec'
0 1oak the chain in paraffin .kerosene/ for
appro%imately five or si% minutes. Caution: Don1t
use gasoline 3petrol4, solvent or other
cleaning fluids. Don1t use high/pressure
water. "emove the chain, wipe it off, then
blow dr) it with compressed air immediatel).
+he entire process shouldn1t take longer than
ten minutes / if it does, the $/rings in the
chain rollers could be damaged.
5 =nce the chain has been cleaned and dried,
check it for wear by measuring a 8?#link length
with the chain taught anchor one end of the
chain and hold the other end tensioned whilst the
measurement is taken 1see illustration2.
"ompare the result the wear limits at the
beginning of this "hapter. )ote that chains do
not wear evenly, so take measurements at
various points in the chain's run.
?nstallation
B 'nstallation is the reverse of removal. =n
completion adjust and lubricate the chain
following the procedures described in "hapter 8.
"iveted link t)pe chain
(emoval
%ote) The riveted (so!t) link can be identi!ied by
its identi!ication markings on the side plate and
usually slightly di!!erent colour. $lso the staked
ends o! the link's two pins look as i! they have
been deeply centre-punched& instead o! peened
over as with all other pins.
> Focate the joining link in a suitable position to
work on by rotating the back wheel midway
between the sprockets is ideal.
9 1lacken the drive chain as described in
"hapter 8.
*0 1plit the chain at the joining link using an
approved chain breaker tool intended for
motorcycle use. There are a number of types
available for motorcycle use and it is important to
follow carefully the instructions supplied with the
tool # see BboDs and >orkshop Tips in the
(eference section for a typical e%ample. (emove
the chain from the bike, noting its routing through
the swingarm. 9leanin& an! Bear chec'
** 1ee 1teps ; and C.
?nstallation
'arning: !%" install a drive
chain which uses a clip/t)pe master
3split4 link. &f )ou do not have access to
a chain riveting tool, have the chain fitted b) a
Yamaha dealer.
$
8A (emove the engine sprocket cover as
described in 1teps A or @, as applicable.
8@ Thread the chain into position, making sure
that it takes the correct route around the
swingarm and sprockets and leave the two ends
in a convenient place to work on. =btain a new
soft link # never attempt to reuse an old link.
86 'nstall the new soft link complete with an =#
ring on each of its pins through the chain ends
from the inside of the chain. 'nstall an =#ring over
the pin ends and fit the side plate with its
identification marks facing out use the chain tool
to press the side plate into position.
8;1take the new link pins using the chain
riveting tool, following carefully the instructions of
both the chain manufacturer and the tool
manufacturer. (efer to Tools and >orkshop Tips
in the (eference section for
chain riveting details using a typical commercially
available tool.
*5 After riveting, check the soft link pin ends for
any signs of cracking. 'f there is any evidence of
cracking, the soft link, =#rings and side plate
must be removed and the procedure repeated
with a new soft link.
*4 'nstall the sprocket cover in a reverse of the
removal procedure. Adjust and lubricate the chain
following the procedures described in "hapter 8.
1< -proc5ets- |5
check and replacement Js
Check
* =n T05 and 7TE models, unscrew the bolts
securing the outer front sprocket cover and
remove the cover 1see illustration *0.6a2.
+nscrew the gearchange lever linkage arm
pinchbolt and remove the arm from the shaft,
noting the alignment of the punch mark with the
slit in the clamp 1see illustration *0.6b2. 'f no
mark is visible, make your own before removing
the arm so that it can be correctly aligned with the
shaft on installation. +nscrew the bolts securing
the inner sprocket cover, on T05 models noting
the clip secured by the top rear bolt, and remove
the cover 1see illustration *0.6c2.
6 =n T(7 models, unscrew the gearchange
lever linkage arm pinchbolt and remove the arm
from the shaft, noting the alignment of the punch
mark with the slit in the clamp 1see illustration
*0.82. 'f no mark is visible, make your own before
removing the arm so that it can be correctly
aligned with the shaft on installation. +nscrew the
bolts securing the outer front sprocket cover and
remove the cover, then unscrew the bolts
securing the inner sprocket cover, noting the clip
secured by the top rear bolt, and remove the
cover.
8 "heck the wear pattern on both sprockets 1see
illustration *.4 in 9ha"ter *2. 'f the sprocket
teeth are worn e%cessively, renew the chain and
both sprockets as a set. -henever the sprockets
are inspected, the drive chain should be
inspected also .see "hapter 8/. 'f you are
renewing the chain, renew the sprockets as well.
D Adjust and lubricate the chain following the
procedures described in "hapter 8. Caution: 7se
onl) the recommended lubricant.
"eplacement
Front s"roc'et
0 =n T05 and 7TE models, unscrew the
bolts securing the outer front sprocket cover
and remove the cover 1see illustration *0.6a2.
+nscrew the gearchange lever linkage arm
pinchbolt and remove the arm from the shaft,
noting the alignment of the punch mark with
the slit in the clamp 1see illustration *0.6b2. ?f
Scane! by Stal'er
''' llT5llTll ll'tT ll'l ' 5Tl ' FF'FF#+.
.AH@1rAHW@1;<XHH
S88
*0.5 9hec' the amount of stretch by measurin& a *0(lin' len&th as shoBn
+)($2'1T$($0 3'
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
4rame, suspension and final drive CLA9
*5.4 /en! bac' the loc'Basher tab1s2 1arroBe!2; then unscreB the nut
*5.8 Sli!e the s"roc'et off the shaft an! remo,e it
*5.*0a Fit a neB loc'Basher.
*5.*0b ... ma'e sure the nut is the correct Bay roun! ...
*5.*0c ... an! ti&hten it to the s"ecifie! torAue
*5.*0! /en! the tabs u" a&ainst the nut
no mark is visible, make your own before
removing the arm so that it can be correctly
aligned with the shaft on installation. +nscrew
the bolts securing the inner sprocket cover, on
T05 models noting the clip secured by the top
rear bolt, and remove the cover 1see illustration
*0.6c2.
5 =n T(7 models, unscrew the gearchange
lever linkage arm pinchbolt and remove the arm
from the shaft, noting the alignment of the punch
mark with the slit in the clamp 1see illustration
*0.82. 'f no mark is visible, make your own before
removing the arm so that it can be correctly
aligned with the shaft on installation. +nscrew
the bolts securing the outer front sprocket cover
and remove the cover, then unscrew the bolts
securing the inner sprocket cover, noting the clip
secured by the top rear bolt, and remove the
cover.
4 *end down the tab.s/ on the sprocket nut
lockwasher 1see illustration2. Have an assistant
apply the rear brake, then unscrew the nut and
remove the washer. (efer to "hapter 8 and
adjust the chain so that it is fully slack.
8 1lide the sprocket and chain off the shaft and
slip the sprocket out of the chain 1see
illustration2. 'f there is not enough slack on the
chain to remove the sprocket, disengage the
chain from the rear wheel.
9 $ngage the new sprocket with the chain and
slide it on the shaft 1see illustration *5.82. Take
up the slack in the chain ]see "hapter 8/.
*0 1lide on a new lockwasher, then fit the nut
with its recessed side facing in and tighten it to
the tor,ue setting specified at the beginning of
the "hapter, using the method employed on
removal to prevent the sprocket from turning 1see
illustrations2. *end up one of the pre#formed
tabs of the lockwasher against the nut flats 1see
illustration2.
** =n T05 and 7TE models, install the inner
sprocket cover, on T05 models not forgetting the
clip secured by the top rear bolt, and tighten the
bolts securely 1see illustration *0.6c2. Align the
split in the gearchange linkage arm clamp with
the punch mark on the shaft, then fit the arm on
the shaft and tighten the pinchbolt to the
specified tor,ue setting 1see illustration *0.6b2.
'nstall the outer sprocket cover and tighten its
bolts to the specified tor,ue 1see illustration
*0.6a2.
*6 =n T(7 models, install the inner sprocket
cover, not forgetting the clip secured by the top
rear bolt, and tighten the bolts securely. 'nstall
the outer sprocket cover and tighten its bolts to
the specified tor,ue. Align the split in the
gearchange linkage arm clamp with the punch
mark on the shaft, then fit the arm on the shaft
and tighten the pinchbolt to the specified tor,ue
setting 1see illustration *0.82.
Rear s"roc'et
*8 (emove the rear wheel .see "hapter B/.
*D =n 7TE models, bend back the locking tabs
on the sprocket nut lockplates.
*0 +nscrew the nuts securing the sprocket to
the hub assembly 1see illustration2. (emove the
sprocket, noting which way round it fits.
*5 'nstall the sprocket onto the hub with the
stamped mark facing out. =n 7TE models, install
the lockplates, noting that new ones should be
used. Tighten the nuts evenly and in a criss#
cross se,uence to the tor,ue setting specified at
the beginning of the "hapter. =n 7TE models,
bend the tabs of the lockplates up against the nut
flats.
*4 'nstall the rear wheel .see "hapter B/.
*5.*0 EnscreB the nuts 1arroBe!2 an!
remo,e the s"roc'et
<
+)($2'1T$($0 3'
Scane! by Stal'er
+)($2'1T$($0 3'
CL@? 4rame, suspension and final drive
*4.6 -ift the s"roc'et cou"lin& out of the Bheel...
*4.8 ... an! remo,e the rubber !am"ers
*4.0 Fit the s"acer into the bearin& if it Bas remo,e!
*4 Rear s"roc'et f=
cou"lin&+rubber !am"ers # LX
check and replacement H
* (emove the rear wheel .see "hapter B/.
Caution: Do not la) the wheel down on the
disc as it could become warped. 0a) the
wheel on wooden blocks so that the disc is
off the ground.
A Fift the sprocket coupling out of the wheel
leaving the rubber dampers in position in the
wheel 1see illustration2. )ote the spacer inside
the coupling # it should be a tight fit but remove it
if it is likely to drop out. "heck the coupling for
cracks or any obvious signs of damage. Also
check the sprocket studs for wear or damage.
@ Fift the rubber damper segments from the
wheel and check them for cracks, hardening and
general deterioration 1see illustration2. (enew
the rubber dampers as a set if necessary.
6 "hecking and replacement procedures for the
sprocket coupling bearing are described in
"hapter B.
;'nstallation is the reverse of removal. 5ake
sure the spacer is still correctly installed in the
coupling, or install it if it was removed 1see
illustration2.
C 'nstall the rear wheel .see "hapter B/.
Stane! by Stal'er
4`*
9ha"ter 4
*rakes, wheels and tyres
9ontents
*rake calipers # removal, overhaul and installation ................................. @
*rake discs # inspection, removal and installation.................................... 6
*rake fluid level check.......................................see *aily (pre-ride) checks
*rake light switches # check and replacement.......................see "hapter 9
*rake pads # replacement ...................................................................... A
*rake pad wear check...........................................................see "hapter 8
*rake hoses, pipes and unions # inspection and replacement .... B
*rake system bleeding ........................................................................... >
*rake system check.............................................................. see "hapter 8
4ront brake master cylinder # removal, overhaul and installation ... ;
4ront wheel # removal and installation ................................................... 88
2eneral information................................................................................. 8
(ear brake master cylinder # removal, overhaul and installation ... C
(ear wheel # removal and installation...................................................... 8A
Tyres # general information and fitting ..................................................... 86
Tyres # pressure, tread depth and
condition....................................................... see *aily (pre-ride) checks
-heels # general check......................................................... see "hapter 8
-heel bearings # check......................................................... see "hapter 8
-heel bearings # removal, inspection and installation.............................8@
-heels # alignment check ..................................................................... 8?
-heels # inspection and repair................................................................ 9
De&rees of !ifficulty
$asy, suitable for Jk
novice with little
Y(
N
e%penence gjg
4airly easy, suitable Jk for
beginner with QQ some
e%perience H
Fairly !ifficult; Jk
suitable for competent ;H
0': mechanic <S
Difficult; suitable for Jk
e%perienced 0T3 ;j
mechanic a1
Qery!7ficult; I'
suitable for e%pert 0': YP
or professional Nj1
S"ecifications
*rakes
*rake fluid type............................................................................................. D.T 6
*rake pad friction material wear limit
T05 and T(7 models............................................................................... ?.; mm
7TE models............................................................................................... 8.; mm
4ront caliper bore '0
8998 to 899; T05 models........................................................................ 6;.6? mm
899C#on T05 models
+pper bore ........................................................................................... @@.9C mm
Fower bore .......................................................................................... @?.A@ mm
T(7 models.............................................................................................. @A.8? mm
7TE models............................................................................................... AB.?? mm
4ront disc thickness
1tandard................................................................................................... 6.? mm
1ervice limit............................................................................................... @.; mm
4ront disc ma%imum runout .......................................................................... ?.A mm
4ront master cylinder bore '0
T05 and T(7 models............................................................................... 8;.> mm
7TE models............................................................................................... 86.? mm
(ear caliper bore '0
T05 and T(7 models............................................................................... 6A.> mm
7TE models............................................................................................... AB.? mm
(ear disc minimum thickness
1tandard................................................................................................... ;.? mm
1ervice limit............................................................................................... 6.; mm
(ear disc ma%imum runout ......................................................................... ?.8; mm
(ear master cylinder bore '0 ........................................................................ 86.? mm
1caned by 1talker
+)($2'1T$($0 3'
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
B[A *rakes, wheels and tyres
7heels
-heel runout .ma%/
A%ial .side#to#side/
T05 and 7TE models........................................................................... ?.; mm
T(7 models.......................................................................................... A.? mm
(adial .out#of#round/
T05 and 7TE models........................................................................... 8.? mm
T(7 models.......................................................................................... A.? mm
Tyres
Tyre pressures ............................................................................................ see *aily (pre-ride) checks
Tyre si&esL
8998 to 899; T05 models
4ront .................................................................................................... 88?D>?#8> ;>H, tubeless
(ear...................................................................................................... 8;?DB?#8B C9H, tubeless
899C#on T05 models
4ront .................................................................................................... 88?D>?#E(8>, tubeless
(ear...................................................................................................... 8;?DB?#E(8B, tubeless
T(7 models
4ront ................................................................................................... 8A?DC?#E(8B, tubeless
(ear...................................................................................................... 8C?DC?#E(8B, tubeless
7TE models
4ront ................................................................................................... 9?D9?#A8 ;6H, tubed
(ear...................................................................................................... 86?D>?#8B C9H, tubed
D"efer to the owners handbook or the t)re information label on the swingarm for approved t)re brands.
TorAue settin&s
*rake pad retaining pins # 7TE models ........................................................ 8> )m
*rake caliper mounting bolts
8998 to 899; T05 models........................................................................ @; )m
899C#on T05 models and T(7 models.................................................... 6? )m
7TE models.............................................................................................. @; )m
*rake hose banjo bolts
8998 to 899; T05 models........................................................................ AC )m
899C#on T05 models and T(7 models ................................................... @? )m
7TE models............................................................................................... A; )m
*rake disc bolts
T05 models and 7TE models ................................................................ A? )m
T(7 models.............................................................................................. A@ )m
4ront brake master cylinder clamp bolts
T05 models ............................................................................................. 9 )m
T(7 and 7TE models .............................................................................. 8?)m
(ear brake master cylinder bolts
T05 and T(7 models............................................................................... A@ )m
7TE models............................................................................................... A? )m
*rake caliper bleed valves .......................................................................... C )m
4ront wheel a%le
T05 models............................................................................................. ;> )m
T(7 models.............................................................................................. C; )m
4ront wheel a%le clamp bolt
T05 models ............................................................................................ 89)m
T(7 models.............................................................................................. A? )m
4ront wheel a%le nut # 7TE models ............................................................ 88? )m
* \eneral information
T05 and T(7 models are fitted with cast alloy
wheels designed for tubeless tyres only. 7TE
models are fitted with spoked wheels designed
for tubed tyres only. *oth front and rear brakes
are hydraulically operated disc brakes.
=n T05 and T(7 models, the front brakes are
twin opposed#piston calipers, and the rear brake is
a single opposed piston caliper. =n 7TE models,
both front and rear brakes are twin piston sliding
calipers.
'arning: Disc brake components
rarel) re.uire disassembl). Do not
disassemble components unless
absolutel) necessar). &f a h)draulic brake
,
line is loosened, the entire s)stem must be
disassembled, drained, cleaned and then
properl) filled and bled upon reassembl). Do
not use solvents on internal brake
components. Solvents will cause the seals to
swell and distort. 7se onl) clean brake fluid
or denatured alcohol for cleaning. 7se care
when working with brake fluid as it can in-ure
)our e)es and it will damage painted
surfaces and plastic parts.
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
1taged by Stal'er
+)($2'1T$($0 3'
*rakes, wheels and tyres B[@
6.*a Remo,e the "a! co,er...
6.*b ... then remo,e the retainin& cli"s .
6.*c ... an! Bith!raB the "a! "ins
6.* ! Remo,e the "a! s"rin& ...
6.* e ... an! lift out the "a!s
A *rake pads # replacement H
'arning: +he dust created b)
the brake s)stem ma) contain
asbestos, which is harmful to
)our health. !ever blow it out with
compressed air and don1t inhale an) of it. ,n
approved filtering mask should be worn when
working on the brakes.
* =n T05 and T(7 models, where fitted,
remove the pad cover from the top of the caliper
1see illustration2. (emove the pad pin retaining
clips, then withdraw the pad pins from the caliper,
noting how they locate
against the pad spring 1see illustrations2.
(emove the spring, noting how it fits, then lift out
the pads 1see illustrations2. -here fitted,
remove the shims from the back of the pads,
noting how they fit.
A =n 7TE models, slacken the pad retaining
pins, then unscrew the caliper mounting bolts
and slide the caliper off the disc 1see
illustrations2. +nscrew the pad retaining pins
6.6a Slac'en the "a! retainin& "ins 1A2; then unscreB the cali"er mountin& bolts 1/2...
A
6.6b ... an! sli!e the cali"er off the !isc
Scane! by Stal'er
B[6 *rakes, wheels and tyres
6.6c Remo,e the "a! "ins...
6.6!
.. an! lift out the "a!s; notin& hoB they fit
6.6e Sli!e the brac'et out of the cali"er
and withdraw them 1see illustration2. (emove
the inner pad, noting how it locates against the
guide pin on the caliper bracket, then remove the
outer pad, noting how it sits in the caliper bracket
1see illustration2. -here fitted, remove the
shims from the back of the pads, noting how they
fit. 1eparate the bracket from the caliper, noting
how it fits 1see illustration2. (emove the pad
spring if re,uired, noting how it fits 1see
illustration 6.**a2.
8 'nspect the surface of each pad for
contamination and check that the friction material
has not worn level with or beyond the wear
indicator tangs or groove .see "hapter 8/ 1see
illustrations2. :amaha also specify a minimum
friction material thickness .see
TD
1pecifications/ which should correspond with the
tang height or groove depth on genuine :amaha
pads. 't is strongly advised that the pads are
renewed well before the wear indicators or
minimum amount of friction material is reached.
The pads should also be renewed if they are
fouled with oil or grease, or heavily scored or
damaged by dirt and debris it is not possible to
degrease the friction material. Always renew both
pads in the caliper and renew the pads in each
front caliper at the same time. 6 'f the pads are in
good condition clean them carefully, using a fine
wire brush which is completely free of oil and
grease to remove all traces of road dirt and
corrosion. +sing a pointed instrument, clean out
the grooves in
the friction material and dig out any embedded
particles of foreign matter. Any areas of gia&ing
may be removed using emery cloth.
; "heck the condition of the brake disc]s/ .see
1ection 6/.
C (emove all traces of corrosion from the pad
pins. 'nspect the pins for signs of damage and
renew them if necessary.
B =n 7TE models, clean the old grease off the
caliper slider pins on the bracket and check the
rubber boots in the caliper 1see illustration
6.6e2. 'f they are damaged or deteriorated, they
should be renewed.
> Push the pistons as far back into the caliper as
possible using hand pressure or a piece of wood
as leverage. 0ue to the increased friction
material thickness of new pads, it may be
necessary to remove the master cylinder
reservoir cover and diaphragm and siphon out
some fluid.
9 -here removed, fit the shims onto the back of
the pads, making sure the arrow points in the
direction of normal disc rotation 1see
illustration2. The following step is necessary on
+< models, and anywhere else where salt is
used on the roads, to ensure that the pads move
freely in the calipers. Apply a thin film of
0uckhams "opper 8? or e,uivalent to the
6.8b #a! friction material shoBin& Bear limit &roo,e ( XT3 mo!els
6.8a #a! Bear in!icator tan&s 1a2 an! minimum friction material limit 1arroBe!2 _
an! TRX
6.9a Fit the shim onto the bac' of the "a!; ma'in& sure the arroB "oints in the !irection of normal !isc rotation
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*rakes, wheels and tyres BL;
$ $pply *uckhams
-opper #< or
eAuivalent to the
shaded areas 6 $pply
+hin-.tsu 0-5<E
or eAuivalent silicone
grease to the shaded
areas
6.9b S"ecial lubricants are reAuire! in the EF 1an! recommen!e! anyBhere salt is use! on the
roa!s2 to "re,ent corrosion
g) The areas o! the pad backing
plates that contact the pistons.
*0 =n T05 and T(7 models, insert the pads
into the caliper so that the friction material faces
the disc 1see illustration 6.*e2. 4it the pad
spring onto the pads, making sure the arrow
.where present/ or the longer outer tabs point in
the direction of normal disc rotation 1see
illustration 6.*!2. 'nstall the pad pins, making
sure they pass through the hole in each pad and
locate correctly onto the pad spring, then fit the
retaining clips 1see illustrations 6.*c an! b2.
-here fitted, install the caliper cover 1see
illustration2.
** =n 7TE models, if removed, fit the pad
spring into the caliper, making sure the larger
tabs point to the outside of the caliper 1see
illustration2. Apply the specified grease .see
1tep 9/ to the slider pins on the bracket and slide
the bracket into the caliper 1see
8 A fcjiJ
6.9c A""ly the recommen!e! lubricants to
the "a! friction areas insi!e the cali"er
an! to the eC"ose! "ortion of the cali"er
"istons
$ *uckhams -opper #< 6 +hin-.tsu 0-5<E
or eAuivalent silicone grease
6.*0 9li" the co,er onto the cali"er;
ma'in& sure it is secure
illustration 6.6e2. 4it the outer pad, making sure
it locates correctly 1see illustration2;
following areas before installing the pads 1see
illustrations2)
a) To the edges o! the metal backing on
the brake pads.
b) To the pad retaining pins.
c) To the areas o! the caliper where the
pads rub.
d) To the threads o! the caliper
mounting bolts.
e) To the sur!aces o! the slider pins on
:+> models.
Caution: Don1t use too much Copper ;L
and make sure it doesn1t contact the
brake discs or the pad friction surfaces.
Apply a thin film of 1hin#$tsu 2#6?5 or
e,uivalent silicone grease to the
followingG
!3 .Bposed areas o! the caliper
pistons
6.**a ?nstall the "a! s"rin& as shoBn
6.** b -ocate the outer "a! into the cali"er as shoBn
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BLC *rakes, wheels and tyres
6.**c Sli!e the cali"er onto the !isc .
6.**! ..
an! ti&hten the mountin& bolts ...
6.**e ... an! the "a! "ins to the s"ecifie! torAue
then fit the inner pad, locating the cutout against
the guide 1see illustration A.Ad/. 'nstall the pad
pins, making sure they pass through the hole in
each pad, and tighten them finger#tight 1see
illustration 6.6c2. 'nstall the brake caliper and
tighten its bolts to the tor,ue setting specified at
the beginning of the "hapter, then tighten the
pad retaining pins to the specified tor,ue 1see
illustrations2.
*6 Top up the master cylinder reservoir if
necessary .see *aily (pre-ride) checks)& and refit
the reservoir cover and diaphragm.
8.* EnscreB the bolts 1arroBe!2 an!
remo,e the shiel!
8@ =perate the brake lever several times to bring
the pads into contact with the disc. "heck the
operation of the brake before riding the
motorcycle.
/ra'e cali"ers # removal,
overhaul and installation
'arning: &f a caliper indicates the
need for an overhaul 3usuall) due to
leaking fluid or stick) operation4, all old
brake fluid should be flushed from the s)stem.
,lso, the dust created b) the brake s)stem
ma) contain asbestos, which is harmful to
)our health. !ever blow it out with
compressed air and don1t inhale an) of it. ,n
approved filtering mask should be worn when
working on the brakes. Do not, under an)
circumstances, use petroleum/based solvents
to clean brake parts. 7se clean brake fluid onl)
on the internal parts. (rake cleaner or
denatured alcohol can be used on e*ternal
parts.
,
"emoval
* =n 7TE models, if removing the rear brake
caliper, unscrew the bolts securing the rear
caliper shield and remove the shield 1see
illustration2. 'f the brake pads are being
removed from the calipers, slacken the pad
retaining pins now 1see illustration 6.6a2.
6 'f the calipers are just being displaced and not
completely removed or overhauled, do not
disconnect the brake hose. 'f the calipers are
being overhauled, unscrew the brake hose banjo
bolt 1see illustration2. )ote the alignment of the
hose on the caliper and separate the hose from
the caliper. =n the rear caliper on T05 models,
counter#hold the hose nut and unscrew the
locknut and separate the hose from the hose joint
in the caliper 1see illustration2. Plug the hose
end or wrap a plastic bag tightly around it to
minimise fluid loss and prevent dirt entering the
system. 0iscard the banjo bolt sealing washers
as new ones must be used on installation. %ote)
)! you are planning to overhaul the caliper and
don't have a source o! compressed air to blow
out the pistons& 3ust loosen the ban3o bolt at this
stage and retighten it lightly. The bike's hydraulic
system can then be used to !orce the pistons out
o! the body once the pads have been removed.
*isconnect the hose once the pistons have been
su!!iciently displaced.
8 +nscrew the caliper mounting bolts, and
8.6a EnscreB the bra'e hose ban<o bolt 1arroBe!2; notin& its ali&nment
?
8.6b 9ounter(hol! the hose nut 1A2 an! unscreB the loc'nut 1/2 from the hose <oint 192
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+.Hi.l1.iHi0.iH1in.n4P'"+Hi#0i1<
*rakes, wheels and tyres BLB
slide the caliper off the disc 1see illustrations2.
D 'f the calipers are being overhauled, remove
the brake pads .see 1ection A/. 'f the calipers
are just being displaced, the pads can be left
in place.
$verhaul
;"lean the e%terior of the caliper with brake system cleaner or denatured alcohol. =n 7TE models, if not already done, separate the caliper bracket from the
caliper, noting how it fits 1see illustration 6.6e2.
C 0isplace the pistons as far as possible from the caliper body, either by pumping them out by operating the front brake lever or rear brake pedal .as applicable/, or
by forcing them out using compressed air. 'f the compressed air method is used, place a wad of rag between the pistons and the caliper to act as a cushion, then
use compressed air directed into the fluid inlet to force the pistons out of the body. +se only low pressure to ease the pistons out and make sure the pistons are
displaced at the same time. 'f the air pressure is too high and the pistons are forced out, the caliper andDor pistons may be damaged. =n opposed piston calipers
there is not enough room to remove the pistons from both sides at the same time, so block one side in their
8.4 Ese a "lastic or Boo!en tool 1such as a
"encil2 to remo,e the seals
bores using a piece of wood and displace the opposite side first, then remove the seals .see below/, reinstall the removed pistons and block them using the wood
while removing the other side. )ow remove the wood and the first pistons, which can now be easily removed. 5ark each piston head and caliper body with a felt
marker to ensure that the pistons can be matched to their original bores on reassembly.
'arning: !ever place )our fingers in front of the pistons in an attempt to catch or protect them when appl)ing compressed air, as serious in-ur)
could result. ,
Caution: $n +D8 and +": models, do not attempt to remove the caliper bod) bolts and separate the caliper halves.
B +sing a wooden or plastic tool, remove the dust seals from the caliper bores 1see illustration2. 0iscard them as new ones must be used on installation. 'f a
metal tool is being used, take great care not to damage the caliper bores.
> (emove and discard the piston seals in the same way.
9 "lean the pistons and bores with clean brake fluid. 'f compressed air is available, use it to dry the parts thoroughly .make sure it's filtered and unlubricated/.
8.*5 Ti&hten the cali"er mountin& bolts to the
s"ecifie! torAue
Caution: Do not, under an) circumstances, use a petroleum/based solvent to clean brake parts.
*0 'nspect the caliper bores and pistons for signs of corrosion, nicks and burrs and loss of plating. 'f surface defects are present, the caliper assembly must
be renewed. 'f the caliper is in bad shape the master cylinder should also be checked.
** Fubricate the new piston seals with clean brake fluid and install them in their grooves in the caliper bores. )ote that on some models different si&es of bore
and piston are used .see 1pecifications/, and care must therefore be taken to ensure that the correct si&e seals are fitted to the correct bores. The same
applies when fitting the new dust seals and pistons.
*6 Fubricate the new dust seals with clean brake fluid and install them in their grooves in the caliper bores.
*8 Fubricate the pistons with clean brake fluid and install them closed#end first into the caliper bores. +sing your thumbs, push the pistons all the way in,
making sure they enter the bore s,uarely.
&nstallation
*D 'nstall the brake pads .see 1ection A/.
*0 'nstall the caliper on the brake disc making sure the pads sit s,uarely either side of the disc 1see illustration 8.8b2.
*5 'nstall the caliper mounting bolts, and tighten them to the tor,ue setting specified at the beginning of the "hapter 1see illustration2. =n 7TE models, if the
pads were removed, now tighten the pad retaining pins to the specified tor,ue 1see illustration 6.6a2.
*4 'f removed, connect the brake hose to the caliper, using new sealing washers on each T side of the banjo fittings 1see illustration 4.D2. Align the hose as noted
on removal 1see illustration 8.6a2. Tighten the banjo bolt to the tor,ue setting specified at the beginning of the "hapter. =n the rear caliper on T05 models, fit the
hose against the hose joint and tighten the locknut onto the hose, counter#
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B[> *rakes, wheels and tyres
D.6 Set u" a !ial &au&e Bith the "robe
contactin& the bra'e !isc; then rotate the
Bheel to chec' for runout
D.8 Esin& a micrometer to measure !isc thic'ness
D.0 EnscreB the bolts 1arroBe!2 an! remo,e the !isc ( TD rear !isc shoBn
holding the hose nut to prevent the hose twisting
1see illustration 8.6b2. 0o not overtighten the
locknut. Top up the master cylinder reservoir with
0=T 6 brake fluid .see *aily (pre-ride) checks)
and bleed the hydraulic system as described in
1ection >.
8> =n 7TE models, install the rear brake caliper
shield.
89 "heck for leaks and thoroughly test the
operation of the brake before riding the
motorcycle.
6 /ra'e discs # inspection, H
removal and installation iL
&nspection
8 3isually inspect the surface of the disc for
score marks and other damage. Fight scratches
are normal after use and won't affect brake
operation, but deep grooves and heavy score
marks will reduce braking efficiency and
accelerate pad wear. 'f a disc is badly grooved it
must be machined or renewed.
A To check disc runout, position the bike on an
au%iliary stand and support it so that the wheel is
raised off the ground. =n 7TE models, remove
the front disc covers 1see illustration **.02.
5ount a dial gauge on a fork slider or on the
swingarm, with the plunger on the gauge
touching the surface of the disc about 8? mm
.8DA in/ from the outer edge 1see illustration2.
(otate the wheel and watch the gauge needle,
comparing the reading with the limit listed in the
1pecifications at the beginning of the "hapter. 'f
the runout is greater than the service limit, check
the wheel bearings for play .see "hapter 8/. 'f
the bearings are worn, renew them .see 1ection
8@/ and repeat this check. 'f the disc runout is still
e%cessive, it will have to be renewed, although
machining by an engineer may be possible.
@ The disc must not be machined or allowed to
wear down to a thickness less than the service
limit as listed in this "hapter's 1pecifications.
The thickness of the disc can be checked with
a micrometer 1see
illustration2. 'f the thickness of the disc is less
than the service limit, it must be renewed.
"emoval
6 (emove the wheel .see 1ection 88 .front/
or 8A .rear//.
Caution: Do not la) the wheel down and allow
it to rest on the disc or sprocket /the) could
become warped. Set the wheel on wood
blocks so the disc doesn1t support the weight
of the wheel.
; 5ark the relationship of the disc to the wheel,
so it can be installed in the same position.
+nscrew the disc retaining bolts, loosening
them a little at a time in a criss#cross pattern to
avoid distorting the disc, then remove the disc
from the wheel 1see illustration2.
&nstallation
5 'nstall the disc on the wheel, making sure the
marked side is on the outside. Align the
previously applied matchmarks .if you're
reinstalling the original disc/.
4 Apply a suitable non#permanent thread locking
compound to the disc bolts, then install the bolts
and tighten them in a criss#cross pattern evenly
and progressively to the tor,ue setting specified
at the beginning of the "hapter. "lean off all
grease from the brake disc.s/ using acetone or
brake system cleaner. 'f a new brake disc has
been installed, remove any protective coating
from its working surfaces.
8 'nstall the wheel .see 1ection 88 or 8A/.
9 =perate the brake lever or pedal several times
to bring the pads into contact with the
disc. "heck the operation of the brakes carefully
before riding the bike.
0 Front bra'e master cylin!er ON
# removal, overhaul and 1
installation HK
8 'f the master cylinder is leaking fluid, or if the
lever does not produce a firm feel when the brake
is applied, and bleeding the brakes does not help
.see 1ection >/, and the hydraulic hoses are all in
good condition, then master cylinder overhaul is
recommended.
A *efore disassembling the master cylinder, read
through the entire procedure and make sure that
you obtain a new pistonDseal kit. Also, you will
need some new 0=T 6 brake fluid, some clean
rags and internal circlip pliers. %ote) To prevent
damage to the paint !rom spilled brake !luid&
always cover the !uel tank when working on the
master cylinder. Caution: Disassembl),
overhaul and reassembl) of the brake master
c)linder must be done in a spotlessl) clean
work area to avoid contamination and
possible failure of the brake h)draulic s)stem
components.
"emoval
@ =n 7TE models, remove the hand guard.
=n T05 and 7TE models, loosen, but do not
remove, the screws holding the reservoir
cover in place 1see illustration2. =n TRX
models, remove the reservoir cap clamp and
partially unscrew the cap 1see illustration2.
Scane! by Stal'er
0.8a .n TD an! XT3 mo!els; slac'en the
reser,oir co,er screBs 1arroBe!2
0.8b .n TRX mo!els; remo,e the clam"
1arroBe!2 an! "artially unscreB the ca"
+.Hi.l1.iHi0.iH1in.n4P'"+Hi#0i1<
*rakes, wheels and tyres BL9
0.Da /ra'e sBitch Birin& connector 1arroBe!2 ( TD mo!els
0.Db /ra'e sBitch Birin& connectors 1arroBe!2 ( TRX mo!els
0.5a /ra'e hose ban<o bolt 1arroBe!2 (TD mo!els
0.5b /ra'e hose ban<o bolt 1arroBe!2 (TRX mo!els
0.4a Reser,oir mountin& bolt...
0.4b ... an! hose clam" ( TRX mo!els
D =n T05 and T(7 models, disconnect the
brake light switch wiring connector.s/ 1see
illustrations2. =n 7TE models, remove the
switch from the brake lever bracket.
0 (emove the front brake lever .see "hapter C/.
=n T05 and 7TE models, remove the rear view
mirror.
5 +nscrew the brake hose banjo bolt and
separate the hose.s/ from the master cylinder,
noting the alignment 1see illustrations2. 0iscard
the sealing washers as they must be renewed.
-rap the end.s/ of the hose.s/ in a clean rag and
suspend in an upright position or bend down
carefully and place the open end.s/ in a clean
container. The objective is to prevent e%cessive
loss of
brake fluid, fluid spills and system contamination.
B =n T(7 models, unscrew the bolt securing the
reservoir to the bracket, then release the clamp
securing the reservoir hose to the union on the
master cylinder 1see illustrations2. (emove the
reservoir cap and lift off the diaphragm plate and
the rubber diaphragm. 0rain the brake fluid from
the reservoir into a suitable container, then
detach the reservoir hose from its union on the
master cylinder. -ipe any remaining fluid out of
the reservoir with a clean rag.
> +nscrew the master cylinder clamp bolts, then
lift the master cylinder away from the handlebar
1see illustrations2.
9 =n T05 and 7TE models, remove the
reservoir cover retaining screws and lift off the
cover, the diaphragm plate and the rubber
diaphragm. 0rain the brake fluid from the
reservoir into a suitable container. -ipe any
remaining fluid out of the reservoir with a
clean rag.
8? 'f re,uired, on T05 and T(7 models,
remove the brake light switch .see "hapter 9/.
$verhaul
88 =n T05 models, thread the adjuster off the
pushrod and remove the spring .where fitted/,
the nut and the plate.
8A"arefully remove the dust boot from the
master cylinder 1see illustration2.
0.8a aster cylin!er clam" bolts
1arroBe!2 ( TRX mo!els
0.8b aster cylin!er clam" bolts
1arroBe!2 ( XT3 mo!els
0.*6 Remo,e the rubber boot from the en! of
the master cylin!er "iston ...
Scane! by Stal'er
0.iH1in.n4P'"+Hi#0P1in
BL8? *rakes, wheels and tyres
0.*8a ... then !e"ress the "iston an!
remo,e the circli" usin& a "air of internal
circli" "liers
*8+sing circlip pliers, remove the circlip and slide out the washer and pushrod .T05 models/, the piston assembly and the spring, noting how they fit 1see
illustration2. Fay the parts out in the proper order to prevent confusion during reassembly 1see illustration2.
*D =n T(7 models, remove the fluid reservoir hose union rubber cap, then remove the circlip and detach the union from the master cylinder. 0iscard the =#ring
as a new one must be used. 'nspect the reservoir hose for cracks or splits and renew if necessary.
*0 "lean all parts with clean brake fluid. 'f compressed air is available, use it to dry the parts thoroughly .make sure it's filtered and unlubricated/.
Caution: Do not, under an) circumstances, use a petroleum/based solvent to clean brake parts.
*5 "heck the master cylinder bore for corrosion, scratches, nicks and score marks. 'f damage or wear is evident, the master cylinder must be renewed. 'f the
master cylinder is in poor condition, then the calipers should be checked as well. "heck that the fluid inlet and outlet ports in the master cylinder are clear.
*4 The dust boot, circlip, piston, seal, primary cup and spring are only available as a kit. +se all of the new parts, regardless of the apparent condition of the old
ones. 'f the seal and cup are not already on the piston, fit them according to the layout of the old piston assembly.
*8 'nstall the spring in the master cylinder. =n T05 models the spring's tapered end faces in, and on T(7 and 7TE models its tapered end faces out.
*9 Fubricate the piston, seal and cup with clean brake fluid. 'nstall the assembly into the master cylinder, making sure it is the correct way round 1see
illustration 0.*8b2. 5ake sure the lips on the cup do not turn inside out when they are slipped into the bore. =n T05 models slide in the pushrod with its washer.
0epress the piston and install the new circlip, making sure that it locates in the master cylinder groove 1see illustration 0.*8a2.
60 'nstall the rubber dust boot, making sure
0.*8b -ay out the internal "arts as shoBn;
e,en if neB "arts are bein& use!; to a,oi!
confusion on reassembly
the lip is seated correctly in the groove 1see illustration 0.*62.
6* =n T(7 models, fit a new =#ring onto the reservoir hose union, then press the union into the master cylinder and secure it with the circlip. 4it the rubber cap
over the circlip.
66 'nspect the reservoir cover rubber diaphragm and renew it if it is damaged or deteriorated.
&nstallation
68 'f removed, on T05 and T(7 models, install the brake light switch .see "hapter 9/.
6D Attach the master cylinder to the handlebar and, where marked, fit the clamp with its +P mark facing up, aligning the top mating surfaces of the clamp with
the punch mark on the handlebar 1see illustration2. Tighten first the upper bolt, then the lower bolt to the tor,ue setting specified at the beginning of the "hapter
1see illustrations 0.8a an! b2.
60 "onnect the brake hose.s/ to the master cylinder, using new sealing washers on each side of the union.s/, and aligning the hose.s/ as noted on removal
1see illustrations 0.5a an! b2. Tighten the banjo bolt to the tor,ue setting specified at the beginning of this "hapter.
65 'nstall the brake lever .see "hapter C/, and on T05 and 7TE models the rear view mirror.
64 =n T(7 models, mount the reservoir onto its bracket and tighten the bolt securely 1see illustration 0.4a2. "onnect the reservoir hose to the union and
secure it with the clamp 1see illustration 0.4b2.
68 =n T05 and T(7 models, connect the brake light switch wiring 1see illustrations 0.Da an! b2. =n 7TE models, fit the switch into the lever bracket.
69 4ill the fluid reservoir with new 0=T 6 brake fluid as described in *aily (pre-ride) checks. (efer to 1ection > of this "hapter and bleed the air from the
system.
80 4it the rubber diaphragm, making sure it is correctly seated, the diaphragm plate and the cover or cap onto the master cylinder reservoir 1see illustration
0.8a2. =n T(7 models, fit the cap clamp 1see illustration 0.8b2.
8* "heck the operation of the front brake before riding the motorcycle.
0.6D Ali&n the clam" matin& surfaces Bith
the "unch mar' on the han!lebar
1arroBe!2
C (ear brake master cylinder # H
removal, overhaul and 1
installation PH
* 'f the master cylinder is leaking fluid, or if the lever does not produce a firm feel when the brake is applied, and bleeding the brakes does not help .see 1ection
>/, and the hydraulic hoses are all in good condition, then master cylinder overhaul is recommended.
6 *efore disassembling the master cylinder, read through the entire procedure and make sure that you obtain a new pistonDseal kit. Also, you will need some
new 0=T 6 brake fluid, some clean rags and internal circlip "liers. %ote) To prevent damage to the paint !rom spilled brake !luid& always cover the surrounding
components when working on the master cylinder.
Caution: Disassembl), overhaul and reassembl) of the brake master c)linder must be done in a spotlessl) clean work area to avoid contamination
and possible failure of the brake h)draulic s)stem components.
"emoval
@ =n T05 models, remove the seat, and on 7TE models remove the right#hand side cover .see "hapter >/.
6 +nscrew the bolt securing the master cylinder fluid reservoir to the frame, then remove the reservoir cap and pour the fluid into a container 1see illustrations2.
(elease
Stane! by Stal'er
5.Da aster cylin!er reser,oir screB
1arroBe!2 ( TD mo!els
*rakes, wheels and tyres BL88
C.6b 5aster cylinder reservoir screw .arrowed/ # T(7 models
C.6c 5aster cylinder reservoir boa .arrowed/ # 7TE models
teser voir hose clamp .A/, brake banjo bolt .*/ # T05 models
C.;b (eservoir hose clamp .A/, brake hose
banjo bolt .*/, master cylinder mounting
bolts ."/# T(7 models
_rn
C.C
(emove the split pin .A/ and
withdraw the clevis pin .*/
'!!_''..
;<<; ; .D
? c
?
f
i
r
> C /
;. X ; H
i
f
SftG/r' iN(
f,
_
^ 1/DD
=G-ilt-<
C.B 5aster cylinder mounting bolts
.arrowed/ # T05 shown
the clamp securing the reservoir hose to the
union on the master cylinder and detach the
hose .see illustrations C.;a and b/. ;
+nscrew the brake hose banjo bolt and
separate the brake hose from the master
cylinder, noting its alignment .see
illustrations/. 0iscard the two sealing
washers as they must be renewed. -rap the
nd of the hose in a clean rag and suspend
Ghe hose in an upright position or bend it
town carefully and place the open end in
a lean container. The objective is to
prevent wcessive loss of brake fluid, fluid
spills and lystem contamination.
8 (emove the split pin and washer from the
ilevis pin securing the brake pedal to the
naster cylinder pushrod .see illustration/.
3ithdraw the clevis pin and separate the
ledal from the pushrod. 0iscard the split pin
s a new one must be used. ' +nscrew the
two bolts securing the master ylinder to the
bracket and remove the master ylindor .see
illustration and C.;b/.
$verhaul
> 'f re,uired, mark the position of the clevis
locknut on the pushrod, then slacken the
locknut and thread the clevis and its base nut
off the pushrod .see illustration/.
9 0islodge the rubber dust boot from the
base of the master cylinder to reveal the
pushrod retaining circlip .see illustrations/.
8? 0epress the pushrod and, using
C.9a 5aster cylinder components
/ubber boot
Circlip
@iston/seal assembly
+pring
Easter cylinder
C.> Hold the clevis and slacken the
locknut
C.9b (emove the dust boot from .he
pushrod
1caned by 1talker
BY8A *rakes, wheels and tyres
5.*0 De"ress the "iston an! remo,e the
circli" from the cylin!er
circlip pliers, remove the circlip 1see
illustration2. 1lide out the piston assembly and
spring. 'f they are difficult to remove, apply low
pressure compressed air to the fluid outlet. Fay
the parts out in the proper order to prevent
confusion during reassembly.
** "lean all of the parts with clean brake
fluid.
Caution: Do not, under an) circumstances,
use a petroleum/based solvent to clean brake
parts. &f compressed air is available, use it to
dr) the parts thoroughl) 3make sure it1s
filtered and unlubricated4.
8A "heck the master cylinder bore for corrosion,
scratches, nicks and score marks. 'f damage is
evident, the master cylinder must be renewed. 'f
the master cylinder is in poor condition, then the
caliper should be checked as well.
8@ 'nspect the reservoir hose for cracks or splits
and renew if necessary. 'f re,uired, on T05
models remove the screw and on 7TE models
the circlip securing the hose union to the master
cylinder. =n T(7 models the union is a push fit.
Pull the union from the master cylinder. 0iscard
the =#ring or bush .T(7 models/ as a new one
must be used.
86 The dust boot, circlip, piston, seal, primary
cup and spring are only available as a kit. +se all
of the new parts, regardless of the apparent
condition of the old ones. 'f the seal and cup are
not already on the piston, fit them according to
the layout of the old piston assembly.
*0 'nstall the spring in the master cylinder so
that its tapered end faces the piston.
*5 Fubricate the piston, seal and cup with clean
brake fluid. 'nstall the assembly into the master
cylinder, making sure it is the correct way round.
5ake sure the lips on the cup do not turn inside
out when they are slipped into the bore.
*4 'nstall and depress the pushrod, then fit a
new circlip, making sure it is properly seated in
the groove.
*8 'nstall the rubber dust boot, making sure the
lip is seated properly in the groove.
*9 'f removed, fit a new =#ring or bush .T(7
models/ to the fluid reservoir hose union, then
push the union into the master cylinder and on
T05 and 7TE models secure it with its screw or
circlip.
&nstallation
60 'f removed, install the clevis locknut, the
clevis and the base nut onto the master cylinder
pushrod end. Position the clevis as noted on
removal, then tighten the clevis locknut securely
1see illustration 5.82.
6* 'nstall the master cylinder onto the footrest
bracket and tighten its mounting bolts to the
tor,ue setting specified at the beginning of the
"hapter 1see illustration 5.0b an! 5.42.
66 Align the brake pedal with the master
cylinder pushrod clevis, then slide in the clevis
pin and secure it using a new split pin, not
forgetting the washer 1see illustration 5.52.
68 "onnect the brake hose banjo bolt to the
master cylinder, using a new sealing washer on
each side of the banjo union. $nsure that the
hose is positioned so that it butts against the lug
and tighten the banjo bolt to the specified tor,ue
setting 1see illustrations 5.0a an! b2.
6D 1ecure the fluid reservoir to the frame with
its retaining bolt 1see illustrations 5.Da; b an!
c2. $nsure that the hose is correctly routed, then
connect it to the union on the master cylinder and
secure it with the clamp 1see illustration 5.0a
an! b2. "heck that the hose is secure and
clamped at the reservoir end as well. 'f the
clamps have weakened, use new ones.
60 4ill the fluid reservoir with new 0=T 6
_T'I*1F#'
G

U
'
4.D Remo,e the ban<o bolt an! se"arate
the hose from the cali"erN there is a
sealin& Basher on each si!e of the fittin&
brake fluid .see *aily (pre-ride3 checks) and
bleed the system following the procedure in
1ection >.
65 =n T05 models, install the seat, and on 7TE
models install the right#hand side cover .see
"hapter >/.
64 "heck the operation of the brake carefully
before riding the motorcycle.
;
4 /ra'e hoses; "i"es an!
unions # inspection and
replacement
&nspection
* *rake hose and pipe condition should be
checked regularly and the hoses renewed at the
specified interval .see "hapter 8/.
6 Twist and fle% the rubber hoses while looking
for cracks, bulges and seeping fluid 1see
illustration2. "heck e%tra carefully around the
areas where the hoses connect with the banjo
fittings, as these are common areas for hose
failure.
8 'nspect the metal brake pipe .899C#on models/
and the banjo union fittings connected to the
brake hoses. 'f the fittings are rusted, scratched
or cracked, renew them.
"eplacement
6The brake hoses have banjo union fittings on
each end, with the e%ception of the rear caliper
hose on T05 models which has a joint piece. =n
899C#on T05 models, the brake pipe splitting the
front brake hose has flare nuts. "over the
surrounding area with plenty of rags and unscrew
the banjo bolt or flare nut at each end of the hose
or pipe, noting its alignment. =n the rear caliper
on T05 models, counter#hold the hose nut and
unscrew the locknut and separate the hose from
the hose joint in the caliper 1see illustration
8.6b2. 'f re,uired, unscrew the joint from the
caliper. 4ree the hose or pipe from any clips or
guides and remove it. 0iscard the sealing
washers on the hose unions 1see illustration2.
;Position the new hose or pipe, making sure it
isn't twisted or otherwise strained, and abut the
tab on the hose union with the lug on the
component casting, where present. =therwise
align the hose or pipe as noted on removal.
'nstall the hose banjo bolts using new sealing
washers on both sides of the unions. Tighten the
banjo bolts to the tor,ue settings specified at the
beginning of this "hapter. 0o not overtighten the
brake pipe flare nuts. =n the rear caliper on T05
models, if removed, thread the joint piece into the
caliper using a new sealing washer and tighten
securely 1see illustration 8.6b2. 4it the hose
against the hose joint and tighten the locknut
onto the hose, counter#holding the hose nut to
prevent the hose twisting. 0o not overtighten the
locknut. 5ake sure the hoses and pipes are
correctly aligned and routed clear of all moving
components.
Scane! by Stal'er
4.6 FleC the bra'e hoses an! chec' for
crac's; bul&es an! lea'in& flui!
*
*rakes, wheels and tyres BL8@
8.5a /ra'e cali"er blee! ,al,e
8.5b To blee! the bra'es; you nee! a s"anner; a short section of clear tubin&; an! a clear container half(fille! Bith bra'e flui!
5 4lush the old brake fluid from the system, refill
with new 0=T 6 brake fluid .see 0aDDy (pre-ride)
checks) and bleed the air from the system .see
1ection >/. "heck the operation of the brakes
carefully before riding the motorcycle.
> *rake system # bleeding
* *leeding the brakes is simply the process of
removing all the air bubbles from the brake fluid
reservoirs, the hoses and the brake calipers.
*leeding is necessary whenever a brake system
hydraulic connection is loosened, when a
component or hose is renewed, or when the
master cylinder or caliper is overhauled. Feaks in
the system may also allow air to enter, but
leaking brake fluid will reveal their presence and
warn you of the need for repair.
6 To bleed the brakes, you will need some new
0=T 6 brake fluid, a length of clear vinyl or
plastic tubing, a small container partially filled
with clean brake fluid, some rags and a spanner
to fit the brake caliper bleed valves.
8 "over the fuel tank and other painted
components to prevent damage in the event that
brake fluid is spilled.
D -hen bleeding the rear brake, on T05
models, remove the seat, and on 7TE models
remove the right#hand side cover .see "hapter
>/ for access to the fluid reservoir.
0 (emove the reservoir cover or cap, diaphragm
plate .where fitted/ and diaphragm and slowly
pump the brake lever or pedal a few times, until
no air bubbles can be seen floating up from the
holes in the bottom of the reservoir. 0oing this
bleeds the air from the master cylinder end of the
line. Foosely refit the reservoir cover.
5 Pull the dust cap off the bleed valve 1see
illustration2. Attach one end of the clear vinyl or
plastic tubing to the bleed valve and
submerge the other end in the brake fluid in the
container 1see illustration2.
4 (emove the reservoir cover and check the
fluid level. 0o not allow the fluid level to drop
below the lower mark during the bleeding
process.
8 "arefully pump the brake lever or pedal three
or four times and hold it in .front/ or down .rear/
while opening the caliper bleed valve. -hen the
valve is opened, brake fluid will flow out of the
caliper into the clear tubing and the lever will
move toward the handlebar or the pedal will
move down.
9 (etighten the bleed valve, then release the
brake lever or pedal gradually. (epeat the
process until no air bubbles are visible in the
brake fluid leaving the caliper and the lever or
pedal is firm when applied. =n completion,
disconnect the bleeding e,uipment, then tighten
the bleed valve to the tor,ue setting specified at
the beginning of the chapter and install the dust
cap.
B =n T05 and T(7 models front brakes, go
on to bleed air from the other brake caliper. =n
the rear brake of T05 and T(7 models, go on to
bleed air from the other side of the caliper .two
bleed valves are fitted/.
> 'nstall the diaphragm and cover assembly,
wipe up any spilled brake fluid and check the
entire system for leaks.
/7><r#? )! it's not possible to
. produce a !irm !eel to the
GllET lever or pedal the !luid my be
aerated. 0et the brake fluid in the
s)stem stabilise for a few hours and
then repeat the procedure when the
tin) bubbles in the s)stem have settled
out.
-heels #
inspection and repair
* 'n order to carry out a proper inspection of the
wheels, it is necessary to support the bike upright
so that the wheel being inspected is raised off the
ground. Position the motorcycle on an au%iliary
stand. "lean the wheels thoroughly to remove
mud and dirt that may interfere with the
inspection procedure or mask defects. 5ake a
general check of the wheels .see "hapter 8/ and
tyres .see *aily (pre-ride) checks).
6 Attach a dial gauge to the fork slider or the
swingarm and position its stem against the side
of the rim. 1pin the wheel slowly and check the
a%ial .side#to#side/ runout of the rim. 'n order to
accurately check radial .out of round/ runout with
the dial gauge, the wheel would have to be
removed from the machine, and the tyre from the
wheel. -ith the a%le clamped in a vice and the
dial gauge positioned on the top of the rim, the
wheel can be rotated to check the runout 1see
illustration2.
8 An easier, though slightly less accurate,
method is to attach a stiff wire pointer to the fork
slider or the swingarm and position the end a
fraction of an inch from the wheel .where the
wheel and tyre join/. 'f the wheel is true, the
distance from the pointer to the rim will be
constant as the wheel is rotated. %ote) )! wheel
runout is eBcessive& check the wheel or hub
bearings very care!ully be!ore replacing the
wheel.
Scane! by Stal'er
?
9.6 9hec' the Bheel for ra!ial 1out(of(
roun!2 runout 1A2 an! aCial 1si!e(to(si!e2
runout 1/2
*
B[86 *rakes, wheels and tyres
6 The wheels should also be visually inspected
for cracks, flat spots on the rim and other
damage, =n cast alloy wheels, look very closely
for dents in the area where the tyre bead
contacts the rim. 0ents in this area may prevent
complete sealing of the tyre against the rim,
which leads to deflation of the tyre over a period
of time. 'f damage is evident, or if runout in either
direction is e%cessive, the wheel will have to be
renewed. )ever attempt to repair a damaged
cast alloy wheel.
; =n 7TE models, check for loose or broken
spokes. Tapping the spokes with a screwdriver is
the best guide to their tension. A loose spoke will
make a dull flat note compared to a tight one.
Foose spokes must be tightened by turning the
nipple at the spoke end 'n an anti#clockwise
direction. Always check for runout after altering
the tension in any of the spokes. 1mall
irregularities can be corrected by adjusting the
spokes in the affected area, although a certain
amount of practice is necessary to prevent over#
correction. 'f the wheel runout continues to be
e%cessive, take the wheel to a professional
wheel builder for inspection and adjustment.
8? -hee1s # alignment check
?
# 5isalignment of the wheels, which may be due
to a cocked rear wheel or a bent frame or fork
yokes, can cause strange and possibly serious
handling problems. 'f the frame or yokes are at
fault, repair by a frame specialist or replacement
with new parts are the only alternatives.
2 To check the alignment you will need an
assistant, a length of string or a perfectly straight
piece of wood and a ruler. A plumb bob or other
suitable weight will also be re,uired.
4 'n order to make a proper check of the wheels
it is necessary to support the bike in an upright
position, using an au%iliary stand. 5easure the
width of both tyres at their widest points. 1ubtract
the smaller measurement from the larger
measurement, then divide the difference by two.
The result is the amount of offset that should
e%ist between the front and rear tyres on both
sides.
6 'f a string is used, have your assistant hold
one end of it about halfway between the floor and
the rear a%le, touching the rear sidewall of the
tyre.
; (un the other end of the string forward and
pull it tight so that it is roughly parallel to the floor.
1lowly bring the string into contact with the front
sidewall of the rear tyre, then turn the front wheel
until it is parallel with the string. 5easure the
distance from the front tyre sidewall to the string
.see illustration2.
C (epeat the procedure on the other side of the
motorcycle. The distance from the front tyre
sidewall to the string should be e,ual on both
sides.
B As was previously pointed out, a perfectly
straight length of wood may be substituted for the
string .see illustration/. The procedure is the
same.
> 'f the distance between the string and tyre is
greater on one side, or if the rear wheel appears
to be cocked, refer to "hapter 8, 1ection 8 and
check that the chain adjuster markings coincide
on each side of the swingarm.
9 'f the front#to#back alignment is correct, the
wheels still may be out of alignment vertically.
8? +sing the plumb bob, or other suitable
weight, and a length of string, check the rear
wheel to make sure it is vertical. To do this, hold
the string against the tyre upper sidewall and
allow the weight to settle just off the floor. -hen
the string touches both the upper and lower tyre
sidewalls and is perfectly straight, the wheel is
vertical. '' it is not, place thin spacers under one
leg of the au%iliary stand.
88 =nce the rear wheel is vertical, check the
front wheel in the same manner. 'f both wheels
are not perfectly vertical, the frame andDor major
suspension components are bent.
88 4ront wheel#removal
and installation
3t
/emoval
8 Position the motorcycle on an au%iliary stand
and support it under the crankcase so that the
front wheel is off the ground. Always make sure
the motorcycle is properly supported.
A (emove the brake caliper mounting bolts
*0.4 7heel ali&nment chec' usin& a
strai&ht(e!&e
and slide the calipers off the discs .see 1ection
@/. 1upport the calipers with a piece of wire or a
bungee cord so that no strain is placed on the
hydraulic hoses. There is no need to disconnect
the hoses from the calipers. %ote) *o not
operate the !ront brake lever with the calipers
removed. @ =n T(7, 7TE and 8998 to 899> T05
models, unscrew the knurled ring securing the
speedometer cable to the drive gear and detach
the cable 1see illustration an! **.02.
**.8 EnscreB the rin& 1arroBe!2 i
!etach the cable
1taned by 1talker
FiC atrtn& here
^^^^0
Strin& heB taut
9hec' for contact here
8?.; -heel alignment check using string
*rakes, wheels and tyres BY8;
**.D Slac'en the clam" bolt 1A2 an! unscreB the aCle 1/2
**.0 S"ee!ometer cable 1A2; !isc co,er screBs 1/2; s"lit "in 192; aCle nut 1D2
=n 8999 T05 models, trace the wiring from the
speedometer drive gear up to its @#pin connector
and disconnect it, then free the wiring from the
clips which retain it to the brake hose
alternatively, leave the wiring attached so that as
the wheel is removed the drive gear is left joined
to its lead.
D =n T05 and T(7 models, slacken the a%le
clamp bolt on the bottom of the right#hand fork,
then unscrew the a%le 1see illustration2.
0 =n 7TE models, first remove the screws
securing the disc covers and remove the covers
1see illustration2. (emove the split pin from the
end of the a%le, then unscrew the a%le nut and
remove the washer. "ounter#hold the a%le head
to prevent it turning if necessary. 0iscard the split
pin as a new one should be used.
5 1upport the wheel, then withdraw the a%le
from the right#hand side and carefully lower the
wheel. +se a drift to drive out the a%le if re,uired.
4 (emove the spacer from the right#hand side of
the wheel and the speedometer drive gear from
the left#hand side, noting how they fit 1see
illustrations2.
Caution: Don1t la) the wheel down and allow
it to rest on a disc ( the disc could become
warped. Set the wheel on wood blocks so the
disc doesn1t support the weight of the wheel,
or keep it upright
8 "heck the a%le for straightness by rolling it on
a flat surface such as a piece of plate glass .first
wipe off all old grease and remove any corrosion
using fine emery cloth/. 'f the a%le is bent, renew
it.
9 "heck the condition of the wheel bearings
.see 1ection 8@/.
&nstallation
*0 Apply lithium#based grease to the wheel
spacer, the lips of the grease seals and to the
to the speedometer drive gear. 4it the spacer
into the right#hand side of the wheel and the
drive gear into the left#hand side, making sure
the tabs locate in the slots 1see illustrations
**.4a an! b2.
** 5anoeuvre the wheel into position. Apply a
thin coat of grease to the a%le.
*6 Fift the wheel into place between the fork
sliders, making sure the spacer and drive gear
remain in position, and that the slot in the drive
gear locates over the tab on the inside of the fork
1see illustration2. 1lide the a%le in from the right#
hand side 1see illustration2.
*8 =n T05 and T(7 models, tighten the a%le
to the tor,ue setting specified at the beginning of
the "hapter 1see illustration2.
**.4b ... an! the s"ee!ometer !ri,e &ear
housin&
**.*6a -ocate the tab on the insi!e of the for' in the slot in the to" of the housin& ...
**.4a Remo,e the s"acer...
**.*6b ... an! insert the aCle
**.*8 Ti&hten the aCle to the s"ecifie! torAue
Starte! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
BL8C *rakes, wheels and tyres
)ow tighten the a%le clamp bolt on the bottom of
the right#hand fork to 'he specified tor,ue setting
1see illustration **.D2.
*D =n 7TE models, fit the washer and a%le nut,
then counter#hold the head of the a%le and
tighten the nut to the tor,ue setting specified at
the beginning of the "hapter. 4it a new split
through the end of the a%le 1see illustration
**.02. 'nstall the disc covers.
*0 'nstall the brake calipers, making sure the
pads sit s,uarely on either side of the discs .see
1ection @/. Tighten the caliper mounting bolts to
the specified tor,ue setting.
*5 4it the speedometer cable into the drive
housing and tighten the knurled ring securely
1see illustrations **.8 an! **.02. =n 8998 T05
models if the speedometer wiring was
disconnected, remake the @#pin connector and
secure the wiring to the brake hose and the guide
provided on the brake caliper lower mounting
bolt use the proper clips to the secure the wire to
the brake hose and don't fasten them too tight
otherwise the hose will be distorted.
*4 Apply the front brake a few times to bring the
pads back into contact with the discs. 5ove the
motorcycle off the stand, apply the front brake
and pump the front forks a few times to settle all
components in position.
*8 "heck for correct operation of the front brake
before riding the motorcycle.
*6 Rear Bheel # fH
removal and installation JQ
"emoval
8Position the motorcycle on an au%iliary stand
so that the wheel is off the ground. =n 7TE
models, unscrew the bolts securing the rear
brake caliper shield and remove the cover 1see
illustration 8.*2.
A(emove the brake caliper mounting bolts and
slide the caliper off the disc .see 1ection @/.
1upport the caliper with a piece of wire or a
bungee cord so that no strain is placed on the
hydraulic hose. There is no need to disconnect
the hose from the caliper. %ote) *o not operate
the brake pedal with the calipers removed. =n
T05 models, slacken the caliper bracket bolt on
the swingarm 1see illustration2.
@-here fitted, remove the split pin from the a%le
nut on the end of the a%le 1see illustration2.
+nscrew the a%le nut and remove the washer,
and on T(7 models the adjuster position marker
1see illustration2.
61upport the wheel then withdraw the a%le and
lower the wheel to the ground 1see illustration2.
=n T(7 models, retrieve the adjustment position
marker. )ote how the caliper bracket locates
between the wheel and the swingarm.
0 0isengage the chain from the sprocket and
remove the wheel from the swingarm 1see
illustration *6.*02.
Caution: Do not la) the wheel down and allow
it to rest on the disc or the sprocket ( the)
could become warped. Set the wheel on
wood blocks so the disc or the sprocket
doesn1t support the weight of the wheel. Do
not operate the brake pedal with the wheel
removed.
5 "heck the a%le for straightness by rolling it on
a flat surface such as a piece of plate glass .first
wipe off all old grease and remove any corrosion
using fine emery cloth/. 'f the a%le is bent, renew
it.
4(emove the collar from each side of the
wheel, noting which fits where 1see
illustrations2. "heck the condition of the grease
seals and wheel bearings .see 1ection 8@/.
&nstallation
> Apply a thin coat of lithium#based grease to
the lips of each grease seal, and also to the
collars and the a%le. =n T(7 models, slide the
right#hand adjustment position marker onto the
a%le, making sure it is the correct way round.
9 'nstall the short collar into the left#hand side of
the wheel and the long shouldered collar into the
right#hand side 1see illustrations *6.4b an! a2.
5anoeuvre the wheel so that it is in between the
ends of the swingarm. Align
*6.6 .n TD mo!els; slac'en the cali"er brac'et bolt 1arroBe!2
*6.8a Rear aCle nut an! s"lit "in (*99* to *990 TD mo!els
*6.8b Rear aCle nut 1A2 an! "osition mar'er 1/2 ( TRX mo!els
*6.D 7ith!raB the aCle an! remo,e the Bheel
*6.4a Remo,e the collar from each si!e...
*6.4b ... notin& Bhich Bay roun! they fit
Sta&e! by Stal'er
=)($2'1T$($03$(1'=) =4 P'"T=($#0$1<
*rakes, wheels and tyres B[8B
*6.*0 anoeu,re the Bheel into "osition
an! fit the chain onto the s"roc'et
*6.** .n TRX mo!els; ma'e sure the aCle
hea! locates correctly in the a!<ustment
mar'er
*6.*6 7here fitte!; use a neB s"lit "in
the brake caliper bracket, on 7TE models
locating it against the swingarm so that the lug
on the swingarm fits into the slot in the bracket.
8? $ngage the drive chain with the sprocket and
lift the wheel into position 1see illustration2.
5ake sure the collars and caliper bracket remain
correctly in place.
88 'nstall the a%le with its washer, or on T(7
models with the adjustment marker 1see
illustration *6.D2. =n 8998 to 899; T05
models, the a%le goes in from the left, while on
all other models it goes in from the right. 5ake
sure it passes through the chain adjusters and
the caliper bracket. =n T(7 models, align the
flats on the a%le head with the adjustment marker
1see illustration2. "heck that
everything is correctly aligned, then fit the left#
hand adjustment position marker .T(7 models/,
the washer and the a%le nut 1see illustration
*6.8b2. Tighten the nut lightly at this stage, on
T05 and 7TE models counter#holding the a%le
head on the other side of the wheel.
*6Adjust the chain slack as described in
"hapter 8. )ow tighten the a%le nut to the
specified tor,ue setting. =n 8998 to 899; T05
models and 7TE models, secure the nut using a
new split pin 1see illustration2. =n T05 models,
tighten the caliper bracket bolt to the specified
tor,ue setting 1see illustration *6.62.
*8 'nstall the brake caliper, making sure the
pads sit s,uarely on either side of the disc
*8.8b ... then le,er out the retainer "late an!
remo,e the !ri,e "late 1arroBe!2
.see 1ection @/. Tighten the caliper mounting
bolts to the specified tor,ue setting. =n 7TE
models, install the caliper shield 1see illustration
8.*2.
*D =perate the brake pedal several times to
bring the pads into contact with the disc. "heck
the operation of the rear brake carefully before
riding the bike.
8@ 7heel bearings # removal,
inspection and installation
6ront wheel bearings
%ote) $lways renew the wheel bearings in pairs.
'ever renew the bearings individually. $void
using a high pressure cleaner on the wheel
bearing area.
* (emove the wheel .see 1ection 88/.
6 1et the wheel on blocks so as not to allow the
weight of the wheel to rest on the brake disc.
8=n 8998 to 899> T05 and all T(7 models,
lever out the grease seal on each side of the
wheel using a flat#bladed screwdriver, taking
care not to damage the rim of the hub 1see
illustration2. 0iscard the seals if they are
damaged or deteriorated. Fever out the retainer
plate on the left#hand side of the wheel and
remove the speedometer drive plate, noting how
it fits 1see illustrations2.
*8.0a Fnoc' out the bearin&s usin& a
!rift...
r V*
>< P;
*8.0b ... locatin& it as shoBn
H>Efflf&[H @osition a piece o! wood TTLLTL_
against the wheel to prevent
GilET
6=n 7TE models, lever out the grease seal on
the right#hand side of the wheel using a flat#
bladed screwdriver, taking care not to damage
the rim 1see illustration *8.82.
;+sing a metal rod .preferably a brass drift
punch/ inserted through the centre of the one
bearing, tap evenly around the inner race of the
other bearing to drive it from the hub 1see
illustrations2. The bearing spacer will also come
out.
Stane! by Stal'er
*8.8a -e,er out the &rease seal...
?
the screwdriver shaft
damaging it when levering
the grease seals out.
BL8> *rakes, wheels and tyres
*8.*0 A soc'et can be use! to !ri,e in the bearin&
*8.*6a Fit the !ri,e "late as !escribe! .
*8.*6b ... then fit the retainer "late
5 Fay the wheel on its other side so that the
remaining bearing faces down. 0rive the bearing
out of the wheel using the same techni,ue as
above.
4 'f the bearings are of the unsealed type or are
only sealed on one side, clean them with a high
flash#point solvent .one which won't leave any
residue/ and blow them dry with compressed air
.don't let the bearings spin as you dry them/.
Apply a few drops of oil to the bearing. %ote) )!
the bearing is sealed on both sides don't attempt
to clean it.
/7>>GS /e!er to Tools and llfilhlT?
workshop Tips (+ection 8)
GilET
> Hold the outer race of the bearing and rotate
the inner race # if the bearing doesn't turn
smoothly, has rough spots or is noisy, renew it.
9 'f the bearing is good and can be re#used,
wash it in solvent once again and dry it, then
pack the bearing with lithium#based grease.
8? Thoroughly clean the hub area of the
wheel. 'nstall the right#hand bearing into its
recess in the hub, with the marked or
sealed side facing outwards. +sing the old
bearing .if new ones are being fitted/, a
bearing driver or a socket large enough to
contact the outer race of the bearing, drive it in
until it's completely seated 1see illustration2.
** Turn the wheel over and install the bearing
spacer. 0rive the left#hand bearing into place as
described above.
*6 =n 8998 to 899> T05 and all T(7 models,
fit the speedometer drive plate into the left#hand
side of the wheel, with the drive tabs facing out
and aligning the flat tabs with the cutouts in the
hub 1see illustration2. Press the retainer plate
onto the drive plate 1see illustration2.
*8 Apply a smear of lithium#based grease to the
lips of the seal.s/, then press them into the
wheel, using a seal or bearing driver or a suitable
socket to drive it into place if necessary 1see
illustration2.
*D "lean off all grease from the brake discs
using acetone or brake system cleaner then
install the wheel .see 1ection 88/.
"ear wheel bearings
*0 (emove the rear wheel .see 1ection 8A/. Fift
the sprocket coupling out of the wheel, noting
how it fits 1see illustration2.
*5 1et the wheel on blocks so as not to allow
the weight of the wheel to rest on the brake disc.
*4 Fever out the grease seal on the right#hand
side of the wheel using a flat#bladed screwdriver,
taking care not to damage the
rim of the hub 1see illustration2. 0iscard the
seal as a new one should be used.
*8 +sing a metal rod .preferably a brass drift
punch/ inserted through the centre of one
bearing, tap evenly around the inner race of the
other bearing to drive it from the hub 1see
illustrations *8.0a an! b2. The bearing spacer
will also come out.
*9 Fay the wheel on its other side so that the
remaining bearing faces down. 0rive the bearing
out of the wheel using the same techni,ue as
above.
60 (efer to 1teps B to 9 above and check the
bearings.
6* Thoroughly clean the hub area of the wheel.
4irst install the right#hand bearing into its recess
in the hub, with the marked or sealed side facing
outwards. +sing the old bearing .if new ones are
being fitted/, a bearing driver or a socket large
enough to contact the outer race of the bearing,
drive it in s,uarely until it's completely seated
1see illustration *8.*02.
66 Turn the wheel over and install the bearing
spacer. 0rive the left#hand side bearing into
place as described above.
68 Apply a smear of grease to the lips of the
new grease seal, and press it into the right#hand
side of the wheel, using a seal or bearing driver,
a suitable socket or a flat piece of wood to drive it
into place if necessary 1see illustration2.
6D "lean off all grease from the brake disc
*8.*8 #ress the &rease seal into "lace *8.*0 -ift the s"roc'et cou"lin& out of the
Bheel
for more information about
bearings.
*8.*4 -e,er out the &rease seal
Stane! by Stal'er
*rakes, wheels and tyres BL89
*8.68 7here the seal sits flush Bith the
rim; a "iece of Boo! can be use! as
shoBn
using acetone or brake system cleaner. 'nstall the sprocket coupling assembly onto the wheel, then install the wheel .see 1ection 8A/.
Sprocket coupling bearing
60 (emove the rear wheel .see 1ection 8A/. Fift the sprocket coupling out of the wheel, noting how it fits 1see illustration *8.*02.
65 (emove the spacer from the inside of the coupling bearing, using a suitable socket to drive it out if it is tight, noting which way round it fits 1see illustrations2.
+sing a flat#bladed screwdriver, lever out the grease seal from the outside of the coupling 1see illustration2.
64 1upport the coupling on blocks of wood and drive the bearing out from the inside using a bearing driver or socket 1see illustration2.
68 (efer to 1teps B to 9 above and check the bearings.
69 Thoroughly clean the bearing recess then install the bearing into the recess in the coupling, with the marked or sealed side facing out. +sing the old bearing .if
new ones are being fitted/, a bearing driver or a socket large enough to contact the outer race of the bearing, drive it in until it is completely seated 1see illustration
*8.*02.
80 Apply a smear of grease to the lips of the new seal, and press it into the coupling, using
*8.65b ... notin& hoB it fits
*8.65a Ese a soc'et to !ri,e out the s"acer...
*8.65c -e,er out the &rease seal
a seal or bearing driver, a suitable socket or a flat piece of wood to drive it into place if necessary 1see illustration2. 'nstall the spacer into the inside of the coupling,
making sure it is the correct way round 1see illustration *8.65b2; and drive it into place if it is tight 1see illustration2.
8* "heck the sprocket couplingDrubber damper .see "hapter C/.
86"lean off all grease from the brake disc using acetone or brake system cleaner. 4it the sprocket coupling into the wheel 1see illustration *8.*02; then install the
wheel .see 1ection 8A/.
*8.64 Dri,e the bearin& out from the insi!e
N E
86 Tyres # general information and fitting
#eneral information
8 The wheels fitted on T05 and T(7 models are designed to take tubeless tyres only. The wheels fitted on 7TE models are designed to take tubed tyres only. Tyre
si&es are given in the 1pecifications at the beginning of this chapter.
A (efer to the 0aily .pre#ride/ checks listed at
B?C
C
$
*8.80a Fit the &rease seal... *8.80b ... an! the s"acer
Scane! by Stal'er
BLA? *rakes, wheels and tyres
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D?6A>T*?ET .FT>AE-6.>T
G.*6H&AEG? -I*#.H
A>>.J D?E.T&EK
T7? D&>?GT&.E .F
J7??H>.TAT&.E
*D.8 9ommon tyre si!eBall mar'in&s
the beginning of this manual for tyre
maintenance.
6itting new t)res
@-hen selecting new tyres, refer to the tyre
information label on the swingarm and the tyre
options listed in the owners handbook. $nsure
that front and rear tyre types are compatible, the
correct si&e and correct speed rating if
necessary seek advice from a :amaha dealer or
tyre fitting specialist 1see illustration2.
6 it is recommended that tyres are fitted by a
motorcycle tyre specialist rather than attempted
in the home workshop. This is particularly
relevant in the case of tubeless tyres because
the force re,uired to break the seal between the
wheel rim and tyre bead is substantial, and is
usually beyond the capabilities of an individual
working with normal tyre levers. Additionally, the
specialist will be able to balance the wheels after
tyre fitting. ; )ote that punctured tubeless tyres
can in
some cases be repaired. Any such repairs must
be carried out professionally by a motorcycle tyre
fitting specialist and advice sought on reduced
speed limits for repaired tyres.
C A punctured tubed tyre is best repaired by
fitting a new inner tube and of course removing
the item which caused the puncture from the tyre
tread. 'nner tubes can be repaired using a kit, but
the safest option is to renew the inner tube.
Scane! by Stal'er
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#&A- #?HT?D TI>? -&O? P
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=*1
9ha"ter 8
/o!yBor'
9ontents
$ngine bashplate # removal and installation................................... B 2eneral information........................................................................ 8
4airing # removal and installation ................................................. ; 1eat # removal and installation....................................................... A
4airing side panels # removal and installation.................................. 6 1ide covers # removal and installation ............................................ @
4ront mudguard # removal and installation..................................... C
De&rees of !ifficulty
$asy, suitable for 4airly easy, suitable
novice with little for beginner with
e%penence some e%penence
4airly !ifficult; fk
suitable for competent PH
0': mechanic iiS
Difficult; suitable for
e%perienced 0':
mechanic 3ery difficult,
suitable for e%pert 0': YP
or professional H
This "hapter covers the procedures
necessary to remove and install the body
parts. 1ince many service and repair
operations on these motorcycles re,uire the
removal of the body parts, the procedures are
grouped here and referred to from other
"hapters.
'n the case of damage to the body parts, it
is usually necessary to remove the broken
component and renew it .or replace it with a
used one from a breaker/. )ote that there are
however some companies that specialise in
'plastic welding' and there are a number of
bodywork repair kits now available for
motorcycles.
-hen attempting to remove any body
panel, first study it closely, noting any
fasteners and associated fittings, to be sure of
returning everything to its correct place on
installation. 'n some cases the aid of an
assistant will be re,uired when removing
panels, to help avoid the risk of damage to
paintwork. =nce the evident fasteners have
been removed, try to withdraw the panel as
described but 0= )=T 4=("$ 'T # if it will not
release, check that all fasteners have been
removed and try again. -here a panel
engages another by means of tabs, be careful
not to break the tab or its mating slot or to
damage the paintwork. (emember that a few
moments of patience at this stage will save
you a lot of money in renewing broken fairing
panelsU
-hen installing a body panel, first study it
closely, noting any fasteners and associated
fittings removed with it, to be sure of returning
everything to its correct place. "heck that all
fasteners are in good condition, including all
trim nuts or clips and dampingDrubber mounts
any of these must be renewed if faulty before
the panel is reassembled. "heck also that all
mounting brackets are straight and repair or
renew them if necessary before attempting to
install the panel. -here assistance was
re,uired to remove a panel, make sure your
assistant is on hand to install it.
Tighten the fasteners securely, but be
careful not to overtighten any of them or the
panel may break .not always immediately/ due
to the uneven stress. -here ,uick#release
fasteners are fitted, turn them 9?W anti#
clockwise to release them, and 9?W clockwise
to secure them.
/ERTGS
!ote

,hat

a

sma
D P
m
Q
un
R
ot
/h<?S? lubricant (liAuid soap or
7i+LT
8
1caned by 1talker
15
similar) applied to mounting
rubber grommets will assist
pegs to engage without the need !or
undue pressure.
8I6 /o!yBor'
6.6 Turn the 'ey to release the latch
6.8 a'e sure the seat locates correctly a&ainst the tan' J ty"e 1arroBe!2
"e&(
6 Seat(
remo,al an! installation
;<<; to ;<<= +D8 models
8 Pull the sides of the seat away from the fuel
tank to release the 3elcro fastener or the pegs
from the grommets.
A 'nsert the ignition key into the seat lock
located behind the rider's seat, and turn it
clockwise to unlock the seat 1see illustration2.
(emove the seat, noting how it fits.
@ 'nstallation is the reverse of removal. 5ake
sure the tab at the front of the seat locates
correctly under the tank bracket. 5ake sure the
3elcro fastens or the pegs locate correctly in their
rubber grommets 1see illustration2. Push down
on the rear of the seat to engage the latch.
;<<M/on +D8 models
6 'nsert the ignition key into the seat lock
located behind the rider's seat, and turn it
clockwise to unlock the seat. (emove the seat,
noting how it fits.
; 'nstallation is the reverse of removal. 5ake
sure the tabs at the front of the seat locate
correctly under and on the back of the tank.
Push down on the rear of the seat to engage
the latch.
+": models
C 'nsert the ignition key into the seat lock
located below the side cover on the left#hand
side, and turn it clockwise to unlock the
passenger seat 1see illustration2. (emove the
seat, noting how it fits.
B Pull back the latch at the back of the rider's
seat and remove the seat, noting how it fits 1see
illustration2.
> 'nstallation is the reverse of removal. 5ake
sure the tabs at the front of the rider's seat locate
correctly under the tank bracket, then push down
on the back of the seat to engage the latch.
5ake sure the hooks on the front of the
passenger seat locate correctly under the
hooks, then push down on the rear of the seat to
engage the latch.
:+> models
9 (emove the side covers .see 1ection @/.
8? +nscrew the bolt securing each side of
the seat and remove the seat, noting how it
fits 1see illustration2.
6.5 Turn the 'ey in the loc' 1arroBe!2 an!
remo,e the "assen&er seat
6.4 #ull bac' the latch to release the ri!er's seat
6.*0 EnscreB the bolt on each si!e 1arroB2 an! remo,e the seat
Stane! by Stal'er
+)($2'1T$($0 3' +)($2'1T$($0 3'
*odywork >Y@
S
f+ 4
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6.** -ocate the tab 1A2 un!er the brac'et 1/2
8.* Disconnect the tail li&ht Birin& connector 1arroBe!2
** 'nstallation is the reverse of removal.
5ake sure the tab at the front of the seat
locates correctly under the tank bracket, then
tighten the bolts securely 1see illustration2.
1ide covers #
removal and installation
+D8 models
* (emove the seat .see 1ection A/. 0isconnect
the tall light wiring connector 1see illustration2.
6+nscrew the four bolts securing the side
cover assembly to the frame 1see illustration2.
"arefully pull each side away from the frame at
the front to release the clips from the
grommets 1see illustration2. "arefully lift one
side up to clear the frame then remove the
assembly along with the tail light 1see
illustration2.
8 'nstallation is the reverse of removal.
+": models
D (emove the seats .see 1ection A/.
0 (emove the si% screws securing the side
cover assembly 1see illustration2. "arefully lift
one side up to clear the frame then remove
the assembly 1see illustration2.
5 'nstallation is the reverse of removal.
:+> models
B(emove the screw securing the side cover
1see illustration2. "arefully pull the cover
away from the frame to release the pegs from
the grommets, one at each end of the cover
1see illustration2.
> 'nstallation is the reverse of removal.
8.0a Remo,e the three screBs 1arroBe!2
on each si!e ...
8.6b ... then release each cli" from its
&rommet 1arroB2...
1
- i\^|
&**
8.0b ... an! remo,e the si!e co,er
assembly
8.6c ... an! remo,e the si!e co,er
assembly
8.4a Remo,e the screB 1arroBe!2...
8
+)($2'1T$($03'
Scane! by Stal'er
+)($2'1T$($03'
H
8ID /o!yBor'
8.4b ... then !raB the co,er aBay to
release the "e&s from the &rommets
1arroBe!2
D.* a Remo,e the four screBs 1arroBe!2...
D.*b ... an! remo,e the "anel
;<<; to ;<<= +D8 models
* (emove the four screws securing the
side panel and carefully manoeuvre the
panel away, noting how it fits 1see illustrations2.
6 'nstallation is the reverse of removal.
;<<M/on +D8 models
@(emove the three screws securing the side
panel, then carefully draw the panel away to
release the peg from the grommet 1see
illustration2.
6'f re,uired, remove the single screw
securing the side trim panel and remove the
panel, noting how it locates onto the lug on
the frame.
; 'nstallation is the reverse of removal.
:+> models
C (emove the seven screws securing the side
cover 1see illustration2. "arefully release the
slot at the bottom from the tab, then release
the tabs at the top from the fairing and
remove the panel 1see illustrations2.
B 'nstallation is the reverse of removal.
D.8 Fairin& si!e "anel screBs 1A2; "e& location 1/2 an! trim "anel screB 192
lirin& si!e "anels
remo,al an! installation
D.5a Remo,e the screBs 1arroBe!2...
D.5b ... then release the slot 1A2 from the tab 1/2 on the frame... D.5c ... an! the tabs 1arroBe!2 from the slots in the fairin&
Scane! by Stal'er
*odywork >L;
0.6a Remo,e the screBs an! bolts 1arroBe!2...
0.6b ... then !raB the fairin& forBar! an! remo,e the auCiliary li&ht bulbhol!er...
*
=
;<<; to ;<<= +D8 models
Remo,al
* (emove the fairing side panels .see 1ection 6/.
6(emove the two screws and two bolts
securing the fairing 1see illustration2 on each
side. "arefully draw the fairing up and forward
until the au%iliary light bulbholder becomes
accessible, then remove it from the au%iliary light
and remove the fairing 1see illustrations2.
?nstallation
8 'nstallation is the reverse of removal. 5ake
sure the wiring connector is correctly and
securely connected.
;<<M/on +D8 models Remo,al
6(emove the fairing side panels ]see 1ection
6/. (emove the three screws securing the
instrument cluster cover and remove the cover
and the foam damper 1see illustration2.
; (emove the screws securing the windshield
and remove the windshield. $ase the rubber
e%panders out of the windshield mounting points
in the fairing.
0.D Fairin& mountin&s
# )nstrument cluster cover ; -ockpit trim 7 Turn signal connectors
2 Foam clamper panel #< Turn signal retaining nuts
4 >indshield screw -9 o!! 9 +crew -5 o!! ## Fairing mounting screw #
5 /ubber eBpander - : ,eadlight connector 2 o!!
9 o!! ; $uBiliary light connector #2 Fairing mounting nut -5 o!!
8
Starte! by Stal'er
; 4ainng #
removal and installation
fr(
0.6c ... an! remo,e the fairin&
>LC *odywork
0.*0a EnscreB the nuts 1arroBe!2.
0.*0b ... Bith!raB the screBs an! remo,e the mirrors...
0.*0c ... an! the rubber "a!
0.**a Disconnect the hea!li&ht Birin& connector 1arroBe!2...
0.**b ... the auCiliary li&ht Birin& connector 1arroBe!2...
0.**c
.. an! the turn si&nal Birin& connectors
turn signal to the fairing. Thread the nut off the
wires and remove each turn signal assembly >
(emove the two screws and the four nuts
securing the fairing and headlight to the bracket.
"arefully draw the fairing forward and
0.*6 Fairin& mountin& screBs 1A2 an! nuts 1/2
remove it along with the headlight. 'f re,uired, lift
the headlight out of the fairing. ?nstallation
9 'nstallation is the reverse of removal. 5ake
sure the wiring connectors are correctly and
securely connected. "heck that the headlight,
au%iliary light and turn signals are all working.
+": models
Remo,al
*0 +nscrew the nuts securing the rear view
mirrors to the fairing bracket and remove the
mirrors along with the rubber pads 1see
illustrations2.
** 0isconnect the headlight, au%iliary light and
turn signal wiring connectors 1see illustrations2.
*6 (emove the screw securing each side of the
fairing and the four nuts securing the fairing and
headlight to the bracket 1see illustration2.
"arefully draw the fairing forward and remove it
along with the headlight. 'f re,uired, lift the
headlight out of the fairing.
?nstallation
*8 'nstallation is the reverse of removal.
5ake sure the arrow on each rubber pad for
the mirror is on the outside and pointing
forward 1see illustration 0.*0c2. 5ake
sure the wiring connectors are correctly
and securely connected. "heck that the
headlight, au%iliary light and turn signals are
all working.
Scane! by Stal'er
5 (emove the remaining screws securing the
cockpit trim panel and remove the panel.
4 (each inside the fairing and disconnect the
headlight, au%iliary light and turn signal wiring
connectors. +nscrew the nut which retains each
+)($2'1T$($03'
/o!yBor' 8I4
0.*0 Disconnect the hea!li&ht Birin&
connector 1A2 an! the auCiliary li&ht Birin&
connector 1/2 for each li&ht
:+> models
Remo,al
*D (emove the fairing side panels .see
1ection 6/.
*0 0isconnect the headlight wiring
connectors and the au%iliary light wiring
connectors 1see illustration2.
*5 (emove the three nuts securing the fairing
and headlight to the bracket. "arefully draw
the fairing forward and remove it along with
the headlight 1see illustration2. 'f re,uired, lift
the headlight out of the fairing.
?nstallation
*4 'nstallation is the reverse of removal.
^m 8(9
. M
I . 5
t
0.*5 The hea!li&ht comes aBay Bith the
fairin&
5ake sure the wiring connectors are correctly the cable and draw it up through the guide on
the mudguard.
A +nscrew the four bolts securing the
mudguard to the holder on each fork slider
and remove the mudguard, noting how it fits
1see illustrations2.
&nstallation
8 'nstallation is the reverse of removal.
is
?s
"emoval
8 =n 8998 to 899; T05 models, unscrew the
knurled ring securing the speedometer to the
drive housing on the front wheel, then detach
8.6b u!&uar! mountin& bolts 1arroBe!2
TRX mo!els
5.6c .n
are
XT3 mo!els; the bolts 1arroBe!2
on the insi!e of the for' le&
"emoval
8 =n T05 models, remove the cap from
the end of the through#bolt, then remove
the split pin and washer and withdraw
the bolt 1see illustration2. +nscrew the
two bolts on the bottom of the plate and
remove the bashplate, noting how it fits.
A =n 7TE models unscrew the four
bolts securing the bashplate to the
frame and engine and remove the plate,
noting how it fits 1see illustrations2.
&nstallation
8 'nstallation is the reverse of removal.
4.* En&ine bash"late mountin&s ( TD
mo!els
4.6a The bash"late is secure! by a
bolt 1arroBe!2 on each si!e at the
front...
4.6b .. an! on each side underneath
8
Scane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1<
5.6a .n TD mo!els; note hoB the
mountin& brac'ets fit
and securely connected. "heck that the
headlights and au%iliary lights are all
working.
5 Front mu!&uar! (
removal an! installation
i
4 En&ine bash"late
1*99*(90 TD an! all XT32( JQ
removal and installation jH
+)($2'1T$($03'
9I*
9ha"ter 9
$lectrical system
9ontents
Alternator rotor and stator # removal, inspection and installation . . @A
*attery # charging.................................................................................... 6
*attery # removal, installation, inspection and maintenance.................... @
*rake light switches # check and replacement.........................................86
*rakeDtail light bulb # renewal.................................................................. 9
"harging system # leakage and output test.............................................@8
"harging system testing # general information and precautions ... @?
"lutch switch # check and replacement...................................................A@
0iode .7TE models/ # check and replacement........................................A6
$lectrical system # fault finding................................................................ A
4uel gauge and sender unit # check and replacement.............................8B
4uses # check and renewal..................................................................... ;
2eneral information................................................................................. 8
Handlebar switches # check.................................................................... 89
Handlebar switches # removal and installation........................................A?
Headlight aim # check and adjustment..................................see "hapter 8
Headlight bulb and au%iliary light bulb # renewal..................................... B
Headlight assembly # removal and installation........................................ >
Horn # check and replacement................................................................ AC
'gnition .main/ switch # check, removal and installation...........................8>
'gnition system components .................................................see "hapter ;
'nstrument cluster and speedometer cable #
removal and installation....................................................................... 8;
'nstruments # check, replacement and bulbs...........................................8C
Fighting system # check .......................................................................... C
)eutral switch # check, removal and installation ....................................A8
(egulatorDrectifier # check and replacement ..........................................@@
1idestand switch # check and replacement..............................................AA
1tarter circuit cut#off relay # check and replacement................................A;
1tarter motor # disassembly, inspection and reassembly .......................A9
1tarter motor # removal and installation................................................... A>
1tarter relay # check and replacement.....................................................AB
Tail light assembly # removal and installation...........................................8?
Turn signal bulbs # renewal...................................................................... 8A
Turn signal assemblies # removal and installation ..................................8@
Turn signal circuit # check........................................................................ 88
De&rees of !ifficulty
Easy; suitable for
novice with little
e%perience
_
:=
Fairly easy; suitable Hjs,
for beginner with QQ
some e%perience
Fairly !ifficult; Jk
suitable for competent H
0': mechanic H
Difficult; suitable for H
e%perienced 0': @H
mechanic KH
S
Qery !ifficult;
=S
suitable for e%pert
0': LP
or professional
H
S"ecifications
*attery
"apacity
T05 and T(7 models............................................................................... 8A3, 8?Ah
7TE models.............................................................................................. 8A3, 86Ah
3oltage # T05 and T(7 models
4ully charged ......................................................................................... 8A.>3
(e,uires charging..................................................................................... below 8A.;3
1pecific gravity # 7TE models
4ully charged ......................................................................................... 8.A>?
(e,uires charging..................................................................................... below 8.A>?
"harging time # T05 and T(7 models ....................................................... until fully charged .8A.>3/ .ma% C.; hrs for a flat battery/
"harging rate # 7TE models......................................................................... ?.6A for 8? hrs
"harging system
"urrent leakage limit.................................................................................... 8 mA .ma%/
(egulated voltage output .no load/ ........................................................... 86.@ to 8;.@3 d ;??? rpm
Alternator nominal output
T05 and 7TE models............................................................................... 863, A;A d ;??? rpm
T(7 models.............................................................................................. 863, A@.;A d ;??? rpm
Alternator stator coil resistance
8998 to 899; T05 models and 7TE models ........................................... ?.A? to ?.@? ohms d A?W"
899C#on T05 models............................................................................... ?.A@ to ?.@; ohms d A?W"
T(7 models.............................................................................................. ?.AA to ?.@A ohms P A?W"
Scane! by Stal'er
UNRE+ISTERED ,I
UNRE+ISTERED ,- I
9LA $lectrical system
Starter motor
*rush length
1tandard................................................................................................... 8A.; mm
1ervice limit .min/ .................................................................................... ; mm
"ommutator diameter
1tandard................................................................................................... A> mm
1ervice limit .min/ .................................................................................... AB mm
5ica depth .................................................................................................. ?.B mm
Armature coil resistance................................................................................ ?.?8 ohms d A?W"
Fuses
8998 to 899; T05 models
5ain ....................................................................................................... 80A
Headlight.................................................................................................. A?A
1ignals ................................................................................................... 8?A
'gnition ................................................................................................... 8?A
4an ......................................................................................................... 8?A
899C to 899> T05 models
5ain ....................................................................................................... 80A
Headlight.................................................................................................. *0A
1ignals ................................................................................................... *0A
'gnition ................................................................................................... B.;A
4an .......................................................................................................... B.;A
8999 T05 models
5ain ....................................................................................................... 80A
Headlight.................................................................................................. *0A
1ignals ................................................................................................... *0A
'gnition ................................................................................................... *0A
Au%iliary light and ha&ard ........................................................................ 80A
4an ......................................................................................................... 4.0A
*ack#up ................................................................................................. ;A
T(7 models
ain ........................................................................................................ 80A
Headlight.................................................................................................. 8;A
1ignals ................................................................................................... *0A
'gnition .................................................................................................... B.;A
4an .......................................................................................................... B.;A
7TE models
5ain ........................................................................................................ 80A
4an .......................................................................................................... 8?A
/ulbs
Headlight
8998 to 899; T05 models........................................................................ @;D@;- halogen % A
899C#on T05 models............................................................................... ;;- halogen H@ % A
T(7 models.............................................................................................. C?D;;- halogen % 8
7TE models............................................................................................... @;D@;- halogen % A
Au%iliary light
TD models ............................................................................................ ;.?- % 8
T(7 models.............................................................................................. @.6- % 8
7TE models............................................................................................... @.6- % A
*rakeDtail light............................................................................................... A8D;-
Turn signal lights........................................................................................... A8-
'nstrument and warning lights#T(7, 7TE and 8998 to 899> T05 models
'nstrument lights....................................................................................... @.6-, 8.B-
Turn signal indicator light ......................................................................... @.6-
)eutral indicator light ............................................................................... @.6-
High beam indicator light .......................................................................... 8.D7
'nstrument and warning lights # 8999 T05 models
'nstrument lights....................................................................................... A.?-
Turn signal indicator light .......................................................................... *.D7
)eutral indicator light ............................................................................... 8.6-
High beam indicator light ......................................................................... 8,6-
"oolant warning light ............................................................................... 8.6-
4uel level warning light............................................................................. 6.07
+)($2'1T$($0 3'
Scane! by Stal'er
+)($2'1T$($0 3'
+)($2'1T$($0 3$(1'=) ? +)($2'1T$($0 3$(1'=) =4 P'"T+($0
$lectrical system 9L@
TorAue settin&s
Transmission output shaft retainer plate bolts............................................... 8?)m
1tarter motor mounting bolts......................................................................... 8? )m
Alternator rotor screws.................................................................................. B )m
Pick#up coil screws .................................................................................... 6 )m
Alternator rotor bolt .................................................................................... 8@? )m
* \eneral information
All models have a 8A#volt electrical system
charged by a three#phase alternator with a
separate regulatorDrectifier.
The regulator maintains the charging system
output within the specified range to prevent
overcharging, and the rectifier converts the ac
.alternating current/ output of the alternator to dc
.direct current/ to power the lights and other
components and to charge the battery. The
alternator rotor is mounted on the left#hand end
of the crankshaft.
The starter motor is mounted on the bottom of
the engine. The starting system includes the
motor, the battery, the relay and the various
wires and switches. A safety cut#out circuit
prevents the starter motor operating unless the
transmission is in neutral or the clutch lever is
pulled in and the sidestand is up
%ote) Deep in mind that electrical parts& once
purchased& cannot be returned. To avoid
unnecessary eBpense& make very sure the !aulty
component has been positively identi!ied be!ore
buying a new part.
Electrical system #
fault finding
'arning: +o prevent the risk of fmO
short circuits, the ignition 3main4
GGGG switch must alwa)s be $66 and
the batter) negative 3/ve4 terminal
should be disconnected before an) of the
bike1s other electrical components are
disturbed. Don1t forget to reconnect the
terminal securel) once work is finished or if
batter) power is needed for circuit testing.
8A typical electrical circuit consists of an
electrical component, the switches, relays, etc.
related to that component and the wiring and
connectors that hook the component to both the
battery and the frame. To aid in locating a
problem in any electrical circuit, refer to the
wiring diagrams at the end of this "hapter.
A*efore tackling any troublesome electrical
circuit, first study the wiring diagram .see end of
"hapter/ thoroughly to get a complete picture of
what makes up that individual circuit. Trouble
spots, for instance, can often
be narrowed down by noting if other components
related to that circuit are operating properly or
not. 'f several components or circuits fail at one
time, chances are the fault lies in the fuse or
earth connection, as several circuits often are
routed through the same fuse and earth
connections.
@ $lectrical problems often stem from simple
causes, such as loose or corroded connections
or a blown fuse. Prior to any electrical fault
finding, always visually check the condition of the
fuse, wires and connections in the problem
circuit. 'ntermittent failures can be especially
frustrating, since you can't always duplicate the
failure when it's convenient to test. 'n such
situations, a good practice is to clean all
connections in the affected circuit, whether or not
they appear to be good. All of the connections
and wires should also be wiggled to check for
looseness which can cause intermittent failure.
6 'f testing instruments are going to be utilised,
use the wiring diagram to plan where you will
make the necessary connections in order to
accurately pinpoint the trouble spot.
; The basic tools needed for electrical fault
finding include a battery and bulb test circuit, a
continuity tester, a test light, and a jumper wire. A
multimeter capable of reading volts, ohms and
amps is also very useful as an alternative to the
above, and is necessary for performing more
e%tensive tests and checks.
"efer to fault 6inding
G?%T
.uipment in the /e!erence
section !or details of how to
use electrical test
e.uipment.
8 /attery#removal, installation, JH
inspection and maintenance O,
Caution: (e e*tremel) careful when handling
or working around the batter). +he electrol)te
is ver) caustic and an e*plosive gas
3h)drogen4 is given off when the batter) is
charging.
"emoval and installation
* (emove the seat.s/ .see "hapter >/.
6=n 8998 to 899; T05 models, T(7 and 7TE
models, unscrew the negative .#ve/ terminal bolt
first and disconnect the lead from the battery
1see illustration2. Fift up the insulating cover to
access the positive .^ve/ terminal, then unscrew
the bolt and disconnect the lead. (elease the
battery strap or holder, where fitted, and remove
the battery from the bike 1see illustration2.
8 =n 899C#on T05 models, lift the insulating
cover from the battery negative .#ve/ lead
terminal on the frame, then remove the terminal
screw and detach the lead. Fift the insulating
cover from the battery positive .^ve/ lead
terminal on the starter relay, then remove the
terminal screw and detach the lead. 4it the
insulating covers back over the lead ends and
tape them in place to prevent the lead ends
contacting each other and shorting the battery
when it is being manoeuvred out of the frame.
(emove the two screws securing the battery bo%,
then manoeuvre the bo% around the right#hand
side of the shock absorber and draw it out of the
bike. 'f re,uired, disconnect the leads from the
battery, noting which fits where, and lift the
battery out of its bo%.
D =n 8998 to 899; T05 models, if re,uired,
+)($2'1T$($0 3$(1'=) ?8
Siane! by Stal'er
+)($2'1T$($0 3$(1'=) =4 P'"T+($0
6
8.6a Detach the ne&ati,e lea! first; then the
"ositi,e 1arroBe!2...
8.6b ... an! remo,e the battery
+)($2'1T$($0 3'
9L6 $lectrical system
8.Da EnscreB the bolt 1arroBe!2 on each si!e.
8.Db ... an! lift out the boC
unscrew the two bolts securing the battery bo%
and lift out the bo% 1see illustrations2. 0 =n
installation, clean the battery terminals and lead
ends with a wire brush or knife and emery paper.
(econnect the leads, connecting the positive
.^ve/ terminal first.
?>faflfl(l (atter) corrosion can be
ll7iilSl jcgpf to g minimum oy
Gi A?T appl)ing a la)er of
petroleum -ell) to the
terminals after the cables have been
connected.
5 'nstall the seat.s/ .see "hapter >/.
&nspection and maintenance
B The battery fitted to 7TE models is of the
conventional leadDacid type, re,uiring regular
checks of the electrolyte level, as described in
"hapter 8, in addition to those detailed below.
> The battery fitted to T05 and T(7 models is
of the maintenance free .sealed/ type, therefore
re,uiring no specific maintenance. However, the
following checks should still be regularly
performed.
9 "heck the battery terminals and leads for
tightness and corrosion. 'f corrosion is evident,
unscrew the terminal screws and disconnect the
leads from the battery, disconnecting the
negative .#ve/ terminal first, and clean the
terminals and lead ends with a wire brush or
knife and emery paper. (econnect the leads,
connecting the negative .#ve/ terminal last, and
apply a thin coat of petroleum jelly to the
connections to slow further corrosion.
8? The battery case should be kept clean to
prevent current leakage, which can discharge the
battery over a period of time .especially when it
sits unused/. -ash the outside of the case with a
solution of baking soda and water. (inse the
battery thoroughly, then dry it.
88 Fook for cracks in the case and renew the
battery if any are found. 'f acid has been spilled
on the frame or battery bo%, neutralise it with a
baking soda and water solution, dry it
thoroughly, then touch up any damaged paint.
8A 'f the motorcycle sits unused for long periods
of time, disconnect the cables from the battery
terminals, negative .#ve/ terminal first. (efer to
1ection 6 and charge the battery once every
month to si% weeks.
8@ The condition of the battery can be assessed
by measuring the voltage present at the battery
terminals. "onnect the voltmeter positive .^ve/
probe to the battery positive .^ve/ terminal, and
the negative .#ve/ probe to the battery negative .#
ve/ terminal. -hen fully charged there should be
more than 8A.; volts present. 'f the voltage falls
below 8A.; volts the battery must be removed,
disconnecting the negative .#ve/ terminal first,
and recharged as described in 1ection 6.
86 =n 7TE models, if available, an hydrometer
should be used to measure the specific gravity of
the electrolyte. (emove the battery and its cell
caps, then measure each cell in turn. 'f the
reading is below the level specified, the battery
should be recharged.
T?fyflf&!< /e!er to 'Fault Finding
'I L .uipment1in the
"eference
section for more &nformation on
batter) voltage and specific
gravit) checks.
Caution: (e e*tremel) careful when handling
or working around the batter). +he electrol)te
is ver) caustic and an e*plosive gas
3h)drogen4 is given off when the batter) is
charging. 8 (emove the battery .see
1ection @/. "onnect the charger to the battery,
making sure that the positive .^ve/ lead on the
charger is connected to the positive .^ve/
terminal on the battery, and the negative .#ve/
lead is connected to the negative .#ve/ terminal.
A'f the battery is fully discharged, :amaha
recommend that the battery should be charged
for a ma%imum of C.; hours .T05 and T(7
models/ or at a ma%imum rate of ?.6 amps for 8?
hours .7TE models/. 'f the battery was partially
charged, the battery should be charged until the
voltage across the terminals reaches 8A.> 3, or
on 7TE models until the specific gravity is at its
correct reading .see above/. $%ceeding this can
cause the battery to overheat, buckling the plates
and rendering it useless. 4ew owners will have
access to an e%pensive current controlled
charger, so if a normal domestic charger is used
check that after a possible initial peak, the charge
rate falls to a safe level 1see illustration2. 'f the
battery becomes hot during charging sto".
4urther charging will cause damage. %ote) &n
emergencies the battery can be charged at a
higher rate o! around 4.< amps !or a period o! #
hour. ,owever& this is not recommended and the
low amp charge is by !ar the sa!er method o!
charging the battery.
@ 'f the recharged battery discharges rapidly if
left disconnected it is likely that an internal short
caused by physical damage or sulphation has
occurred. A new battery will be re,uired. A sound
item will tend to lose its charge at about 8 I per
day.
D.6 ?f the char&er !oesn't ha,e ammeter
built in; connect one in series as shoBn.
D. %.T connect the ammeter betBeen the
battery terminals or it Bill be ruine!
Sta&e! by Stal'er
+)($2'1T$($03$(1'=) =4 P'"T+($#0$1<
G?%T
$lectrical system y[jN
;.8a 4usebo% # TD models
0.* b FuseboC ( TRX mo!els
0.*c 9oolin& fan fuse # XT3 mo!els
D 'nstall the battery .see 1ection @/.
0 'f the motorcycle sits unused for long periods
of time, charge the battery once every month to
si% weeks and leave it disconnected.
* The electrical system is protected by fuses of
different ratings. =n T05 and T(7 models, the
fuses are housed in the fusebo%, which is
located under the seat 1see illustrations2;
although on 899C#on T05 and all T(7 models
the main fuse is located on the starter relay .see
1ection AB/. =n 7TE models, the main fuse is
housed in the battery bracket on the front of the
battery, while the cooling fan fuse is fitted in line
with the wiring for the fan 1see illustration2.
6 To access the fuses on T05 and T(7 models,
remove the seat .see "hapter >/ and unclip the
fusebo% lid 1see illustration2. =n 7TE models,
remove the left#hand side cover to access the
main fuse .see "hapter >/, and the fuel tank to
access the cooling fan fuse .see "hapter 6/.
8 The fuses can be removed and checked
visually. 'f you can't pull the fuse out with your
fingertips, use a pair of suitable pliers. T05 and
T(7 models use flat#blade type fuses and the
7TE model uses glass cartridge type fuses. A
blown fuse is easily identified by a break in the
element 1see illustration2. $ach
fuse is clearly marked with its rating and must
only be replaced by a fuse of the correct rating. A
spare fuse of each rating is housed in the fusebo%
on T05 and T(7 models, and a spare main fuse
in the battery bracket on 7TE models. 'f a spare
fuse is used, always renew it so that a spare of
each rating is carried on the bike at all times.
'arning: !ever put in a fuse of a
higher rating or bridge the terminals
with an) other substitute, however
temporar) it ma) be. Serious damage ma) be
done to the circuit, or a fire ma) start.
,
6 'f a fuse blows, be sure to check the wiring
circuit very carefully for evidence of a short#circuit.
Fook for bare wires and chafed, melted or burned
insulation. 'f the fuse is renewed before the cause
is located, the new fuse will blow immediately.
; =ccasionally a fuse will blow or cause an
open#circuit for no obvious reason. "orrosion of
the fuse ends and fusebo% terminals may occur
and cause poor fuse contact. 'f this happens,
remove the corrosion with a wire brush or emery
paper, then spray the fuse end and terminals with
electrical contact cleaner.
C Fighting system # check
* The battery provides power for operation of the
headlight, tail light, brake light, turn
signals and instrument cluster lights. 'f none of
the lights operate, always check battery voltage
before proceeding. Fow battery voltage indicates
either a faulty battery or a defective charging
system. (efer to 1ection @ for battery checks and
1ections @? and @8 for charging system tests.
Also, check the condition of the fuses. -hen
checking for a blown filament in a bulb, it is
advisable to back up a visual check with a
continuity test of the filament as it is not always
apparent that a bulb has blown. -hen testing for
continuity, remember that on tail light and turn
signal bulbs it is often the metal body of the bulb
which is the earth.
Headlight
6 'f the headlight fails to work, first check the
fuse with the key =) .see 1ection ;/, and then
the bulb .see 1ection B/. 'f they are both good,
use jumper wires to connect the bulb directly to
the battery terminals. 'f the light comes on, the
problem lies in the wiring or one of the switches
in the circuit. (efer to 1ection 89 for the switch
testing procedures, and also the wiring diagrams
at the end of this "hapter.
8=n 899C to 899> T05 models, a diode is fitted
in the headlight circuit .see >iring *iagrams at
the end of the "hapter/. To test the diode,
disconnect it from the harness. +sing an
ohmmeter or continuity tester, connect the
positive .^ve/ probe to the female terminal of the
diode and the negative .#ve/ probe to the male
terminal. The diode should show continuity. )ow
reverse the probes. The diode should show no
continuity. 'f it doesn't behave as stated, renew
the diode. The diode is located on the left#hand
side of the headlight assembly.
+ail light
6 'f the tail light fails to work, check the bulbs
and the bulb terminals first .see 1ection 9/, then
the fuse, then check for battery voltage at the
blueDred .T05 and 7TE models/, or blue .T(7
models/ terminal on the supply side of the tail
light wiring connector. 'f voltage is present, check
the earth circuit for an open or poor connection.
; 'f no voltage is indicated, check the wiring
between the tail light and the ignition switch,
Scane! by Stal'er
0.6 .n TD an! TRX mo!els; uncli" the
fuseboC li! to access the fuses
?
0.8 A bloBn fuse can be i!entifie! by a brea' in
its element ( flat(bla!e ty"e fuse
9LC $lectrical system
4.6a Disconnect the Birin& connector...
then check the switch. Also check the lighting
switch.
(rake light
C 'f the brake light fails to work, check the bulbs
and the bulb terminals first .see 1ection 9/, then
the fuse, then check for battery voltage at the
yellow .T05 and T(7 models/ or greenDyellow
.7TE models/ terminal on the supply side of the
tail light wiring connector, with the brake lever
pulled in or the pedal depressed. 'f voltage is
present, check the earth circuit for an open or
poor connection.
B 'f no voltage is indicated, check the brake light
switches, then the wiring between the tail light
and the switches.
> 1ee 1ection 86 for brake switch check and
1ection 9 for tail light bulb renewal.
4.6b ... an! remo,e the !ust co,er
&nstrument and warning lights
9 1ee 1ection 8B for instrument and warning
light bulb renewal.
+urn signal lights
*0 1ee 1ection 88 for turn signal circuit
check.
4 Gea!li&ht bulb an! auCiliary =
li&ht bulb # renewal Jt
%ote) The headlight bulb is o! the AuartL-halogen
type. *o not touch the bulb glass as skin acids
will shorten the bulb's service li!e. )! the bulb is
accidentally touched& it
should be wiped care!ully when cold with a rag
soaked in methylated spirit and dried be!ore
!itting.
$ 'arning: ,llow the bulb time to cool
before removing it if the headlight
has -ust been on.
Headlight
* 4or best access to the headlight bulb.s/,
remove the fairing on T05 models and the
relevant fairing side panel on 7TE models .see
"hapter >/.
6 0isconnect the relevant wiring connector from
the back of the headlight assembly and remove
the rubber dust cover, noting how it fits 1see
illustrations2.
8 (elease the bulb retaining ring or clip, noting
how it fits, then remove the bulb 1see
illustrations2.
D 4it the new bulb, bearing in mind the
information in the %ote above. 5ake sure the
tabs on the bulb fit correctly in the slots in the bulb
housing, and secure it in position with the
retaining ring or clip.
0 'nstall the dust cover, making sure it is
correctly seated and with the T=P mark at the
top, and connect the wiring connector.
5 "heck the operation of the headlight.
lfG>f>!O $lways use a paper towel or
ll
'
,
A
,
'
'Ti

dry cloth when handling new
GiT
bulbs to prevent in-ur) if the
bulb should break and to
increase bulb life.
4.8a Remo,e the rin& . 4.8b ... or release the cli".
,u*iliar) light
B =n T05 models, remove the screws securing
the au%iliary light lens and remove the lens 1see
illustration2. "arefully pull the bulb out of its
holder and install the new one, then refit the lens
1see illustration2. 0o not overtighten the screws
as the lens could crack.
> =n 7TE models, for best access remove the
relevant fairing side panel .see "hapter >/. =n
T(7 and 7TE models, release the bulbholder
from its socket in the base of the headlight, then
press the bulb in and twist it anti#
4.8c ... an! remo,e the bulb
4.4a Remo,e the screBs 1arroBe!2 an! the lens...
4.4b ... an! "ull out the bulb
Stane! by Stal'er
$lectrical system'Tw
4.8 #ull the bulbhol!er out of the base of the hea!li&ht
8.6a Remo,in& the hea!li&ht (TRX mo!els
8.6b Remo,in& the hea!li&ht (XT3 mo!els
clockwise to release it from the holder 1see
illustration/. 'nstall the new bulb in the
bulbholder, then install the bulbholder in the
headlight. 5ake sure the rubber cover is
correctly seated. 9 "heck the operation of the
au%iliary light.
8 Gea!li&ht assembly # H
_ removal and installation JQ
"emoval
* (emove the fairing .see "hapter >/.
6=n 899C#on T05 models, T(7 and 7TE
models, lift the headlight out of the fairing 1see
illustration2.
8=n 8998 to 899; T05 models, disconnect the
headlight wiring connectors 1see illustration
4.6a2; then unscrew the three nuts securing the
headlight assembly to the bracket and draw the
assembly forward and off the bracket 1see
illustrations2.
D =n 8998 to 899; T05 models and 7TE
models, the headlight can be disassembled and
the lights renewed individually if re,uired.
&nstallation
; 'nstallation is the reverse of removal. 5ake
sure all the wiring is correctly connected and
secured. "heck the operation of the headlight
8.8a EnscreB the nut on each si!e 1A2; an!
the central nut on the bottom 1/2...
and au%iliary light. "heck the headlight aim .see
"hapter 8/.
9 /ra'e+tail li&ht bulb( fH
renewal JJ
8=n T05 models, remove the seat .see
"hapter >/. =n T(7 models, remove the
passenger seat, though best access is obtained
by removing the side covers as well .see "hapter
>/. =n 7TE models open the storage
compartment cover behind the seat and remove
the cover 1see illustration2.
A Turn the bulbholder anti#clockwise and
8.8b ... an! remo,e the hea!li&ht
assembly
withdraw it from the tail light 1see illustration2.
8 Push the bulb into the holder and twist it anti#
clockwise to remove it 1see illustration2. "heck
the socket terminals for corrosion and clean them
if necessary. Fine up the pins of the new bulb
with the slots in the socket, then push the bulb in
and turn it clockwise until it locks into place.
%ote) The pins on the bulb are o!!set so it can
only be installed one way. )t is a good idea to use
a paper towel or dry cloth when handling the new
bulb to prevent in3ury i! the bulb should break
and to increase bulb li!e.
D 'nstall the bulbholder into the tail light and turn
it clockwise to secure it.
9.* .n XT3 mo!els; remo,e the stora&e
co,er to access the bulbs
9.6 Release the bulbhol!er ...
9.8 ... an! remo,e the bulb
Stane! by Stal'er
9L> $lectrical system
*0.6a Tail li&ht Birin& connector 1arroBe!2 #
TRX mo!els
*0 Tail li&ht assembly #
removal and installation
"emoval
8=n T05 and T(7 models remove the side
covers .see "hapter >/. =n 7TE models open
the storage compartment cover behind the seat
and remove the cover 1see illustration 9.*2.
A=n T(7 and 7TE models, disconnect the tail
light wiring connector 1see illustrations2.
@ +nscrew the nuts securing the tail light
assembly to either the side cover assembly
.T05 models/ or the frame .T(7 and 7TE
models/ and carefully remove it noting how it
*0.8a Tail li&ht assembly nuts 1arroBe!2
(TD mo!els
*0.6b Tail li&ht Birin& connector 1arroBe!2 (
XT3 mo!els
fits 1see illustrations2. 'f re,uired, turn the
bulbholders anti#clockwise and withdraw them
from the tail light.
&nstallation
6 'nstallation is the reverse of removal. "heck
the operation of the tail light and the brake light.
** Turn si&nal circuit # check IN
6lasher rela)
8 The battery provides power for operation of the
turn signal lights, so if they do not operate,
*0.8b Tail li&ht assembly nuts 1arroBe!2 #XT3
mo!els
always check the battery voltage first. Fow
battery voltage indicates either a faulty battery
or a defective charging system. (efer to 1ection
@ for battery checks and 1ections @? and @8 for
charging system tests. Also, check the fuse
.e%cept 7TE models/ .see 1ection ;/ and the
switch .see 1ection 89/.
A 5ost turn signal problems are the result of a
burned out bulb or corroded socket. This is
especially true when the turn signals function
properly in one direction, but fail to flash in the
other direction. "heck the bulbs and the sockets
.see 1ection 8A/.
@ The relay is mounted under the seat on T05
and T(7 models, and behind the fairing on 7TE
models 1see illustrations2. (emove the seat or
fairing for access .see "hapter >/. 'f the bulbs
and sockets are good, check for voltage at the
turn signal relay brown wire .brownDred on 899B#
on +< models/ with the ignition =). 'f no voltage
is present, using the appropriate wiring diagram
at the end of this "hapter check the wiring
between the relay and the ignition .main/ switch.
=n 8999 T05 models, if there's no voltage
check the ha&ard relay as described below.
6 'f voltage was present, check for voltage at the
relay brownDwhite wire with the ignition =). 'f no
voltage is present, renew the relay. 'f voltage is
present, check the wiring between the relay, turn
signal switch and turn signal lights for continuity.
Turn the ignition =44 when the check is
complete.
Ha9ard rela) 3;<<< +D8
models4
0 'f there's no voltage at the flasher relay
brownDred wire .see 1tep @/ check for voltage at
the ha&ard relay brown wires with the ignition
=). 'f no voltage is shown check the signal fuse
and the wiring between the fuse and ha&ard
relay for a break or bad connection.
5 Also check for voltage at the ha&ard relay
blueDred wire with the ignition =) if no voltage is
shown check the ha&ard fuse and the wiring
between the ha&ard fuse and ha&ard relay.
4inally check the brownDred wire from the ha&ard
relay to the flasher relay for a break or bad
connection. 'f the fault still e%ists, renew the
ha&ard relay.
**.8a Turn si&nal relay 1arroBe!2 ( TD
mo!els
**.8b Turn si&nal relay 1A2; starter circuit
cut(off relay 1/2 ( TRX mo!els
J
,
J
*
6=t i=ioi
**.8c Turn si&nal relay 1arroBe!2
(mo!els
Scane! by Stal'er
?
XT3
*6.*a Turn si&nal lens screB 1arroBe!2
(TD mo!els
*6.*b Turn si&nal lens screB 1arroBe!2
(TRX mo!els
*6.*c Turn si&nal lens screB 1arroBe!2
(XT3 mo!els
*6 Turn si&nal bulbs # renewal QVN
?
* (emove the screw securing the turn signal
lens and remove the lens, noting how it fits
1see illustrations2.
6 Push the bulb into the holder and twist it
anti#clockwise to remove it 1see illustration2.
"heck the socket terminals for corrosion and
clean them if necessary. Fine up the pins of
the new bulb with the slots in the socket, then
push the bulb in and turn it clockwise until it
locks into place.
8 4it the lens onto the holder. 0o not
overtighten the screw as the lens or threads
could be damaged.
*8 Turn si&nal assemblies # H
removal and installation Jk
"emoval
* 0isconnect the turn signal wiring
connectors. =n the front turn signals, they are
on the inside of the fairing 1see illustrations2.
=n T05 models remove the fairing, and on
7TE models the fairing side panel.s/ for best
access .see "hapter >/. =n the rear turn
signals, remove the seat .see "hapter >/ 1see
illustrations2.
*6.*! Remo,e the screB an! !etach the
lens...
*8.*a Front turn si&nal Birin& connectors
( TD mo!els
*6.6 ... an! remo,e the
bulb
*8.*b Rear turn si&nal Birin& connectors
1arroBe!2 ( TD mo!els
*8.*c Front turn si&nal Birin& connectors (
TRX mo!els
*8.*! Rear turn si&nal Birin& connectors
(TRX mo!els
*8.le Front turn si&nal Birin& connectors (
XT3 mo!els
Scane! by Stal'er
9L8? $lectrical system
*8.*f Rear turn si&nal Birin& connectors (XT3 mo!els
*8.6a Front turn si&nal mountin& nut 1arroBe!2 ( TD mo!els
*8.6b Rear turn si&nal mountin& nut 1arroBe!2 ( XT3 mo!els
6 =n T05 and 7TE models, pull back the
rubber boot and unscrew the nut securing the
turn signal 1see illustration2. (emove the
assembly, taking care not to snag the wiring.
8 =n T(7 models, remove the screw or nut
securing the assembly to either the inside of the
fairing or rear mudguard 1see illustration2.
(emove the mounting plate, noting how it fits,
and withdraw the turn signal, taking care not to
snag the wiring.
&nstallation
6 'nstallation is the reverse of removal. "heck
the operation of the turn signals.
86 *rake light switches #
check and replacement
Circuit check
* *efore checking any electrical circuit, check
the bulbs .see 1ection 9/ and fuses .see 1ection
;/.
6 =n 7TE models, remove the fuel tank to
access the front brake switch wiring connector
.see "hapter 6/. =n all models, remove the seat
to access the rear brake switch connector .see
"hapter >/.
8 +sing a multimeter or test light connected to a
good earth, check for voltage at the brake light
switch brown or blackDred
*8.8 Front turn si&nal mountin& screB an!
"late ( TRX mo!els
wire .as applicable/ connector with the ignition
=) .connector halves remain joined/. 'f there's
no voltage present, check the wire between the
switch and the ignition switch .see the wiring
diagrams at the end of this "hapter/.
6 'f voltage is available, touch the probe of the
test light to the other terminal of the switch, then
pull the brake lever in or depress the brake
pedal. 'f no reading is obtained or the test light
doesn't light up, renew the switch.
; 'f a reading is obtained or the test light does
light up, check the wiring between the switch and
the brake light bulb .see the wiring diagrams at
the end of this "hapter/.
*D.4a Front bra'e sBitch Birin& connector
1arroBe!2 ( TD mo!els
Switch replacement
4ront brake lever switch
C The switch is mounted on the underside of the
brake lever bracket on T05 and T(7 models,
and is a push#fit into the bracket on 7TE models.
=n 7TE models remove the fuel tank to access
the wiring connector.
B 0isconnect the wiring connector.s/, then either
remove the screws and detach the switch or
withdraw the switch from the bracket, according
to model 1see illustrations2. =n 7TE models,
free the wiring from any clips or ties.
> 'nstallation is the reverse of removal. The
switch isn't adjustable.
i
m
J J JJ. .
T9]
?
1H$ r
1/>
>
I
D
# TpfH
*D.4b Front bra'e sBitch Birin&
connectors 1A2; mountin& screB 1/2 (
TRX mo!els
*D.4c Front bra'e sBitch Birin& connector
1arroBe!2 ( XT3 mo!els
*D.4! Front bra'e sBitch screBs
1arroBe!2 ( TD mo!els
Scane! by Stal'er
?
$lectrical system 9Y88
*D.9a Rear bra'e li&ht sBitch 1arroBe!2 (TD mo!els
*D.9b Rear bra'e li&ht sBitch 1arroBe!2 (TRX mo!els
*D.9c Rear bra'e sBitch Birin& connector 1arroBe!2 ( TD mo!els
Rear bra'e "e!al sBitch
9 The switch is mounted on the inside of the
right#hand footrest bracket 1see
illustrations2. (emove the seat for access to
the connector .see "hapter >/. Trace the
wiring from the switch and disconnect it at the
connector 1see illustration2. 4ree the wiring
from any clips or ties.
8? 0etach the lower end of the switch spring
from the brake pedal, then unscrew and remove
the switch.
88 'nstallation is the reverse of removal. 5ake
sure the brake light is activated just before the
rear brake pedal takes effect. 'f adjustment is
necessary, hold the switch and
turn the adjusting ring on the switch body until
the brake light is activated when re,uired.
8; 'nstrument cluster and H
speedometer cable # QQ
removal and installation H
&nstrument cluster
Remo,al
* (emove the fairing .see "hapter >/. =n T(7
models, remove the fuel tank and air filter
housing for best access to the wiring connectors
.see "hapter 6/. =n 7TE models,
release the clips on the instrument cluster
surround from the grommets on the cluster and
remove the surround 1see illustration2. =n T(7
models, remove the screws securing the trim
cover to free the wiring loom 1see illustration2.
6 =n all e%cept 8999 T05 models, unscrew the
knurled ring securing the speedometer cable to
the back of the speedometer and detach the
cable 1see illustration 8;.Ca/.
8 0isconnect the instrument cluster wiring
connector.s/ 1see illustrations2.
D +nscrew the nuts securing the instrument
cluster to the bracket and lift the cluster off,
noting how it fits 1see illustrations2.
*0.*a Release the cli"s from the &rommets an! remo,e the surroun!
*0.*b .n TRX mo!els; remo,e the trim that houses the Birin& loom
*0.8a ?nstrument cluster Birin& connectors ( TD mo!els
*0.8b .n TRX mo!els; the Birin&
connectors are locate! behin! the steerin&
hea!
*0.8c ?nstrument cluster Birin& connector
1arroBe!2 ( XT3 mo!els
*0.Da EnscreB the nuts 1arroBe!2...
Starte! by Stal'er
9[8A $lectrical system
*0.Db
. an! remo,e the cluster
1TRX shoBn2
*0.5a EnscreB the rin& 1arroBe!2
1XT3 shoBn2...
*0.5b ... an! !etach the cable
1TD shoBn2
?nstallation
0 'nstallation is the reverse of removal. 5ake
sure that the speedometer cable and wiring
connectors are correctly routed and secured.
+peedometer cable (T/F& FTG and
#77# to #77; T*E models)
(emoval
C(emove the fairing .see "hapter >/. +nscrew
the knurled ring securing the speedometer cable
to the back of the speedometer and detach the
cable 1see illustration2. =n T(7 models, access
is restricted due to the surround, so if re,uired,
displace the instrument cluster 1see illustrations
*0.Da an! b2; then remove the screw securing
the surround and remove the surround 1see
illustration *5.62.
B+nscrew the knurled ring securing the lower
end of the cable to the drive housing on the front
wheel and detach the cable 1see illustrations2.
> -ithdraw the cable, releasing it from its
guides, and remove it from the bike, noting its
correct routing.
?nstallation
9 (oute the cable up through its guides to the
back of the instrument cluster.
*0 "onnect the cable upper end to the
speedometer and tighten the retaining ring
securely 1see illustrations *0.5b an! a2.
** "onnect the cable lower end to the drive
housing and tighten the retaining ring securely
1see illustrations *0.4b an! a2.
*6 "heck that the cable doesn't restrict steering
movement or interfere with any other
components.
8C 'nstruments # check,
replacement and bulbs
Speedometer
9hec' 1TRX; XT3 an! *99* to *998 TD
mo!els2
81pecial instruments are re,uired to properly
check the operation of this meter. 'f it is believed
to be faulty, take the motorcycle to a :amaha
dealer for assessment. "heck that the fault is not
due to a broken cable. 9hec' 1*999 TD
mo!els2
A The electronic speedometer is supplied with
wheel speed information by a sensor on
the front wheel. To test the sensor, disconnect its
@#pin connector and make the following test on
the sensor side of the connector. 1et a
multimeter to the ? to A? volts 0" scale and
connect its positive .^ve/ probe to the white wire
terminal and its negative .#ve/ probe to the black
wire terminal. )ow connect a fully charged 8A3
batteryG positive lead to the red wire terminal and
negative lead to the black wire terminal. Position
the bike on an au%iliary stand and support it
under the crankcase so that the front wheel is off
the ground. 1lowly rotate the front wheel and
note the reading on the meter. 'f the sensor is
operating correctly, it should read ;3 four times
per wheel revolution.
@ 'f the speed sensor doesn't produce the
correct reading it must be renewed. 'f the reading
is correct, the fault must lie in the speedometer
or the wiring between the sensor and
speedometer.
6 'f the electronic clockDodometer is faulty note
that it is only available as part of the
speedometer and tachometer assembly.
Re"lacement ( all mo!els
0 (emove the instrument cluster .see 1ec
tion 8;/. =n T(7 models, remove the screw
*0.4a EnscreB the rin& 1arroBe!2.
?
*0.4b ... an! !etach the cable
Stane! by Stal'er
Electrical system 9I*8
*5.0 Remo,e the screB an! !etach the surroun!
*5.5a 9asin& screBs 1A2; s"ee!ometer screBs 1/2; tachometer screBs 192; tem"erature &au&e screBs 1D2 (*99* to *998 TD mo!els
securing the surround and remove the surround
1see illustration2.
5 =n T(7, 7TE and 8998 to 899> T05 models,
remove the casing screws from the back of the
cluster and lift off the front cover assembly 1see
illustrations2. =n 8999 T05 models, remove the
seven screws from the base of the cluster and
separate the upper and lower covers from the
instrument assembly note that the speedometer
and tachometer are only available as a unit with
their housing # remove the fuel gauge and
transfer it to the new assembly.
4 =n 8998 to 899> T05 and all T(7 models,
remove the two screws securing the
speedometer gearbo% and lift off the bo%.
8 (emove the two screws securing the
speedometer to the casing. "arefully withdraw
the speedometer from the front.
9 'nstallation is the reverse of removal.
+achometer
9hec'
8? 1pecial instruments are re,uired to
properly check the operation of this meter. 'f it
is believed to be faulty, take the motorcycle to a
:amaha dealer for assessment. Re"lacement
** (emove the instrument cluster .see 1ection
8;/. =n T(7 models, remove the screw securing
the surround and remove the surround 1see
illustration *5.02.
*6 =n T(7, 7TE and 8998 to 899> T05
models, remove the casing screws from the back
of the cluster and lift off the front cover assembly
1see illustrations *5.5a; b or c2. =n 8999 T05
models, remove the seven screws from the base
of the cluster and separate the upper and lower
covers from the instrument assembly note that
the speedometer and tachometer are only
available as a unit with their housing # remove
the fuel gauge and transfer it to the new
assembly.
*8 (emove the screws securing the three
tachometer wires and detach the wires, noting
which fits where.
*D (emove the two screws securing the
tachometer to the casing. "arefully withdraw the
tachometer from the front.
*0 'nstallation is the reverse of removal.
5ake sure the wiring is correctly connected. As
you look at the back of the cluster, the brown
wire is for the left#hand terminal, the black for the
middle terminal, and the grey for the right#hand
terminal.
Coolant temperature gauge
3+":, :+> and ;<<; to ;<<?
+D8 models4
9hec'
*5 1ee "hapter @.
Re"lacement
*4 (emove the instrument cluster .see 1ection
8;/. =n T(7 models, remove the screw securing
the surround and remove the surround 1see
illustration *5.02.
*8 (emove the casing screws from the back of
the cluster and lift off the front cover assembly
1see illustrations *5.5a; b or c2.
*9 (emove the screws securing the three
temperature gauge wires and detach the wires,
noting which fits where.
60 "arefully withdraw the temperature gauge
from the front.
*5.5b 9asin& screBs 1A2; s"ee!ometer screBs 1/2; tachometer screBs 192; tem"erature &au&e screBs 1D2 ( TRX mo!els
*5.5c 9asin& screBs 1A2; s"ee!ometer screBs 1/2; tachometer screBs 192; tem"erature &au&e screBs 1D2 ( XT3 mo!els
Stane! by Stal'er
9[86 $lectrical system
8C.ACa Pull out the bulbholder...
A8 'nstallation is the reverse of removal.
5ake sure the wiring is correctly connected.
As you look at the back of the cluster, the
greenDred wire is for the left#hand terminal, the
black for the middle terminal, and the brown
for the right#hand terminal.
6uel gauge 3;<<< +D8 models4
9hec'
661ee 1ection 8B.
Re"lacement
68 (emove the instrument cluster .see 1ection
8;/. (emove the seven screws from the base of
the cluster and separate the upper and lower
covers from the instrument assembly. The fuel
gauge is retained by three screws.
6D 'nstallation is the reverse of removal.
(ulb renewal
60 (emove the fairing .see "hapter >/. The
bulbs are accessible with the instrument cluster
in place, but access is ,uite restricted. 'f it is too
restricted, unscrew the nuts securing the
instrument cluster and displace it as re,uired to
improve access .see 1ection 8;/.
65 2ently pull the bulbholder out of the
instrument casing, then pull the bulb out of the
bulbholder 1see illustrations2. 'f the socket
contacts are dirty or corroded, scrape them clean
and spray with electrical contact cleaner before a
new bulb is installed. "arefully push the new bulb
into the holder and push the holder into the
casing.
64 'nstall the fairing .see "hapter >/.
*5.65b ... an! remo,e the bulb
*4 Fuel &au&e an! sen!er unit #
check and replacement .8999
T05 models/
Check
8 'f the fuel gauge fails to operate or the warning
light doesn't come on when the fuel level falls to
a low level, the fuel sender unit in the tank may
be at fault. (emove the fuel sender unit from the
tank as described below.
A (econnect the sender wiring, then turn the
ignition =) and manually raise its float. -ith the
float fully raised the gauge needle should swing
over to the 4 on the gauge. )ow lower the float
and check that the needle swings over to the $
on the gauge. Turn the ignition =44 when the
check is complete. 'f the gauge does not operate
as described it should be renewed.
@ 5ake the following test with the sender unit
disconnected from the bike and on the bench.
+sing a multimeter set to the ohms % 8 range,
connect the meter's positive probe to the
greenDred wire terminal of the wire connector and
its negative probe to the black wire terminal of
the connector. -ith the float in the down position,
9? to 8?? ohms should be indicated on the meter.
(aise the float up to its highest position and
check the meter reading # 6 to 8? ohms should
now be indicated. 'f the sender unit does not
produce the correct readings it must be renewed.
6 *efore renewing the fuel gauge or the sender
unit, check that the fault is not due to a
poor wire connection or break in any of the circuit
wiring. "heck that the fuel level warning light bulb
has not blown.
"eplacement
; (efer to 1ection 8C for renewal of the fuel
gauge and warning light bulb.
C To access the sender unit, first remove the fuel
tank as described in "hapter 6 and drain ail fuel
from the tank into a suitable container.
B (emove the four bolts which retain the sender
unit to the base of the tank. -ithdraw the sender
unit very carefully so that its float and arm and
not bent. "heck that the float is not punctured
and that the arm moves smoothly.
> -hen installing the sender unit, always use a
new gasket between the sender and tank and
make sure that the washers are in place on the
four retaining bolts.
>arning= @etrol is eBtremely
!lammable& so take eBtra precautions
when you work on any part o! the !uel
system. *on't smoke or allow open !lames or
bare light bulbs near the work area& and don't
work in a garage where a natural gas-type
appliance is present. )! you spill any !uel on your
skin& rinse it o!! immediately with soap and water.
>hen you per!orm any kind o! work on the !uel
system& wear sa!ety glasses and have a !ire
eBtinguisher suitable !or a class 6 type !ire
(!lammable liAuids) on hand.
$
*8 ?&nition 1main2 sBitch # fe
check, removal and installation S=
>arning= To prevent the risk o! short
circuits& disconnect the battery negative (-
ve) lead be!ore making any ignition (main)
switch checks.
$
Check
8 =n T05 models, remove the fairing. =n T(7
models remove the air filter housing, and on 7TE
models remove the fuel tank .see "hapter 6/.
Trace the ignition .main/ switch wiring back from
the base of the switch and disconnect it at the
connector .see illustrations an! *0.8b2.
A +sing an ohmmeter or a continuity tester,
check the continuity of the connector terminal
pairs .see the wiring diagrams at the end of this
"hapter/. "ontinuity should e%ist between the
terminals connected by a solid line on the
diagram when the switch is in the indicated
position.
@ 'f the switch fails any of the tests, renew it.
"emoval
6 =n T05 models, remove the fairing. =n
T(7 models remove the air filter housing, and
on 7TE models remove the fuel tank .see
"hapter 6/. Trace the ignition .main/ switch
Scane! by Stal'er
*8.*a ?&nition sBitch Birin& connector(
TD mo!els
*8.*b 'gnition switch Birin& connector
1arroBe!2 ( XT3 mo!els
$lectrical system 9L8;
*8.8 ?&nition sBitch bolts 1arroBe!2
wiring back from the base of the switch and
disconnect it at the connector 1see
illustrations *8.*a an! b an! *0.8b2. 0raw
the wiring through to the switch, freeing it
from any clips or ties and noting its routing.
;=n 899C#on T05 models, unscrew the
bolts securing the choke knob and the cable
guide to the top yoke. =n T(7 models,
unscrew the bolt securing the master cylinder
reservoir to the top yoke. =n 7TE models,
unscrew the bolt securing the cable guide to
the top yoke.
C0isplace the handlebars from the top yoke
.see "hapter C/.
B1lacken the fork clamp bolts in the top
yoke. +nscrew the steering stem nut or bolt
and remove it along with its washer, where
fitted. Fift the top yoke off the steering stem
and remove it.
>Two shear#head bolts mount the ignition
switch to the underside of the top yoke 1see
illustration2. The heads of the bolts must be
drilled off before the switch can be removed.
5ount the yoke in a vice e,uipped with soft
jaws and padded out with rags and drill off the
heads. (emove the bolts and withdraw the
switch from the top yoke.
&nstallation
9 'nstallation is the reverse of removal.
Tighten the new bolts until the heads shear
*9.8 Gan!lebar sBitch Birin& connectors
(TD mo!els
off. 5ake sure the wiring connector is
securely connected and correctly routed.
*9 Gan!lebar sBitches
#chec'
* 2enerally speaking, the switches are reliable
and trouble#free. 5ost troubles, when they do
occur, are caused by dirty or corroded contacts,
but wear and breakage of internal parts is a
possibility that should not be overlooked. 'f
breakage does occur, the entire switch and
related wiring harness will have to be renewed,
as individual parts are not available.
6 The switches can be checked for continuity
using an ohmmeter or a continuity test light.
Always disconnect the battery negative .#ve/
cable, which will prevent the possibility of a
short circuit, before making the checks.
8 =n T05 models, remove the fairing .see
"hapter >/. =n T(7 models remove the air
filter housing, and on 7TE models remove the
fuel tank .see "hapter 6/. Trace the wiring
harness of the switch in ,uestion back to its
connector and disconnect it 1see illustration
an! *8.*b an! *0.8b2.
D "heck for continuity between the terminals
of the switch harness with the switch in the
various positions .ie switch off # no continuity,
switch on # continuity/ # see the wiring
diagrams at the end of this "hapter. ; 'f the
continuity check indicates a problem e%ists,
refer to 1ection A?, remove the switch and
spray the switch contacts with electrical
contact cleaner. 'f they are accessible, the
contacts can be scraped clean with a knife or
polished with crocus cloth. 'f switch
components are damaged or broken, it will be
obvious when the switch is disassembled.
60 Gan!lebar sBitches
#removal and installation
"emoval
* 'f the switch is to be removed from the bike,
rather than just displaced from the handlebar,
trace the wiring harness of the switch in
,uestion back to its connector.s/ and
disconnect itDthem. =n T05 models, remove
the fairing .see "hapter >/. =n T(7 models
remove the air filter housing, and on 7TE
models remove the fuel tank .see "hapter 6/.
Trace the wiring harness of the switch in
,uestion back to its connector and
disconnect it 1see illustrations *9.8; *8.*b
an! *0.8b2. -ork back along the harness,
freeing it from all the relevant clips and ties,
whilst noting its correct routing.
6 =n T05 and T(7 models, disconnect the
wiring connectorfs/ from the brake light switch
.if removing the right#hand switch/ or the
clutch switch .if removing the left#hand switch/
1see illustrations *D.4a an! b; or 68.6a2.
8 +nscrew the handlebar switch screws and
free the switch from the handlebar by
separating the halves 1see illustrations2.
&nstallation
D 'nstallation is the reverse of removal. 5ake
sure the locating pin in the switch housing
locates in the hole in the handlebar and on
8999 T05 models ensure that the choke lever
locates correctly.
Stane! by Stal'er
*
60.8a Ri&ht(han! sBitch housin& screBs 1arroBe!2 ( TD mo!els 60.8b -eft(han! sBitch housin& screBs 1arroBe!2 ( TD mo!els
9L8C $lectrical system
6*.6a %eutral sBitch Birin& connector 1A2;
si!estan! sBitch Birin& connector 1/2 (
TD mo!els
6*.6b %eutral sBitch Birin& connector 1A2;
si!estan! sBitch Birin& connector 1/2 (
TRX mo!els
6*.6c %eutral sBitch Birin& connector 1arroBe!2 # XT3 mo!els
6* %eutral sBitch # check, H
removal and installation a<
Chock
* *efore checking the electrical circuit, check
the bulb .see 1ection 8C/ and fuse .see 1ection
;/.
6 The switch is located in the left#hand side of
the transmission casing above the front sprocket.
To access the wiring connector, on T05 models
remove the seat, on T(7 models remove the
side covers, and on 7TE models remove the left#
hand side cover .see "hapter >/. Trace the
single light blue wire from the top of the
alternator cover and disconnect it at
6*.8 EnscreB the bolts 1arroBe!2 an!
remo,e the "late
the connector 1see illustrations2. 5ake sure the
transmission is in neutral.
@ -ith the connector disconnected and the
ignition switched =), the neutral light should be
out. 'f not, the wire between the connector and
instrument cluster must be earthed at some point.
6 "heck for continuity between the wire terminal
on the switch side of the wiring connector and the
crankcase. -ith the transmission in neutral, there
should be continuity. -ith the transmission in
gear, there should be no continuity. 'f the tests
prove otherwise, then the switch is faulty.
; 'f the continuity tests prove the switch is good,
check for voltage at the terminal on the wiring
loom side of the wiring connector using a test
light with the ignition =). 'f there's no voltage
present, check the wire between the connector,
the instrument cluster and fusebo% .see the
wiring diagrams at the end of this "hapter/. Turn
the ignition =44.
"emoval
C 5ake sure the transmission is in neutral. The
switch is located in the left#hand side of the
transmission casing above the front sprocket.
To access the wiring connector, on T05 models
remove the seat, on T(7 models remove the
side covers, and on 7TE models remove the left#
hand side cover .see "hapter >/. Trace the
single light blue wire from the top of the
alternator cover and disconnect it at the
connector 1see illustrations 6*.6a; b an! c2.
4 (emove the alternator cover .see 1ection @A/.
8+nscrew the bolts securing the transmission
output shaft retainer plate to the left#hand side of
the crankcase and remove the plate 1see
illustration2.
9Pull the wiring grommet from its cutout in the
crankcase 1see illustration2.
*0 (emove the screws securing the switch
and detach it from the casing 1see
illustration2. 0iscard the =#ring as a new one
must be used.
&nstallation
** 4it a new =#ring onto the switch 1see
illustration2; then install the switch and tighten
its screws securely 1see illustration 6*.92.
*6 Press the wiring grommet into its cutout in
the crankcase 1see illustration 6*.92.
*8 'nstall the transmission output shaft retainer
plate onto the left#hand side of the crankcase
1see illustration 6*.82. Apply a suitable non#
permanent thread locking compound to the
threads of the bolts and tighten them to the
specified tor,ue setting.
*D "onnect the wiring connector 1see
illustrations 6*.6a; b an! c2. "heck the
operation of the neutral light.
*0 'nstall the alternator cover .see 1ection >/.
*5 =n T05 models install the seat, on T(7
models install the side covers, and on 7TE
models install the left#hand side cover .see
"hapter >/.
6*.9 Detach the Birin& &rommet an! remo,e the screBs 1arroBe!2...
6*.*0 ... an! remo,e the sBitch
6*.** Fit a neB .(rin& onto the sBitch
Stane! by Stal'er
=.($.'1$$(iP 3$(1'=) =f ('"$=(iTiii1r
$lectrical system 9[8B
AA 1idestand sBitch # H
check and replacement H
Check
* The sidestand switch is mounted on the
sidestand. The switch is part of the safety cutout
circuit which only allows the starter motor to
operate if the transmission is in neutral or the
clutch lever is pulled in and the sidestand is up.
*efore checking the electrical circuit, check the
fuse .see 1ection ;/.
6To access the wiring connector, on T05
models remove the seat, on T(7 models remove
the side covers, and on 7TE models remove the
left#hand side cover .see "hapter >/. Trace the
wiring back from the switch and disconnect it at
the connector 1see illustration an! 6*.6a an!
b2.
8 "heck the operation of the switch using an
ohmmeter or continuity test light. "onnect the
meter probes to the terminals on the switch side
of the connector. -ith the sidestand up there
should be continuity .&ero resistance/ between
the terminals, and with the stand down there
should be no continuity .infinite resistance/.
D 'f the switch does not perform as e%pected, it
is defective and must be renewed.
0'f the switch is good, check the wiring between
the various components in the starter safety
circuit .see the wiring diagrams at the end of this
book/.
"eplacement
C The sidestand switch is mounted on the
sidestand. To access the wiring connector, on
T05 models remove the seat, on T(7 models
remove the side covers, and on 7TE models
remove the left#hand side cover .see "hapter
>/. Trace the wiring back from the switch to its
connector and disconnect it 1see illustrations
6*.6a an! b an! 66.62. -ork back along the
switch wiring, freeing it from any relevant
retaining clips and ties, noting its correct
routing.
B +nscrew the switch bolts or screws and
remove the switch from the stand, noting how
it fits 1see illustration2.
66.6 Si!estan! sBitch Birin& connector (XT3
mo!els
8 4it the new switch onto the sidestand, making
sure the plunger locates correctly, and tighten
the bolts or screws securely.
9 5ake sure the wiring is correctly routed up to
the connector and retained by all the necessary
clips and ties.
*0 (econnect the wiring connector and check
the operation of the sidestand switch.
** =n T05 models install the seat, on T(7
models install the side covers, and on 7TE
models install the left#hand side cover .see
"hapter >/.
68 9lutch sBitch # H
check and replacement JJ
Check
* The clutch switch is mounted on the underside
of the clutch lever bracket on T05 and T(7
models, and is a push#fit into the bracket on the
7TE models. The switch is part of the safety
circuit which prevents or stops the engine
running if the transmission is in gear whilst the
sidestand is down, and prevents the engine from
starting if the transmission is in gear unless the
sidestand is up and the clutch lever is pulled in.
The switch isn't adjustable.
6 =n 7TE models, to access the switch wiring
connector, remove the fuel tank .see "hapter 6/.
To check the switch, disconnect the wiring
connector.s/ 1see illustrations2. "onnect the
probes of an ohmmeter or a continuity test
66.4 Si!estan! sBitch screBs 1arroBe!2
(TD shoBn
light to the two switch terminals. -ith the clutch
lever pulled in, continuity should be indicated.
-ith the clutch lever out, no continuity .infinite
resistance/ should be indicated.
@ 'f the switch is good, check the other
components in the starter circuit as described
in the relevant sections of this "hapter. 'f all
components are good, check the wiring
between the various components .see the
wiring diagrams at the end of this book/.
"eplacement
D The clutch switch is mounted on the underside
of the clutch lever bracket on T05 and T(7
models, and is a push#fit into the bracket on 7TE
models. =n 7TE models, to access the switch
wiring connector, remove the fuel tank .see
"hapter 6/.
00isconnect the wiring connector.s/ 1see
illustrations 68.6a an!