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Yamaha Trx Tdm850 maintenance Manual that it's easy to use for all motorcycle fans that want to repair the small problems themselves and not to contact a mechanic. tips and tricks for all tdm and trx models owners.
Yamaha Trx Tdm850 maintenance Manual that it's easy to use for all motorcycle fans that want to repair the small problems themselves and not to contact a mechanic. tips and tricks for all tdm and trx models owners.
Yamaha Trx Tdm850 maintenance Manual that it's easy to use for all motorcycle fans that want to repair the small problems themselves and not to contact a mechanic. tips and tricks for all tdm and trx models owners.
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 toðer 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 $ngine, clutch and transmission A[A@ 98 Br CC/CD ; E/ % Fk / .&J _NG j & , =A X> H!g"HvT 1 tB/Gk + ! + fcQ
H@HrSS s............## NH*J ISf NN .CH-$mG1 "rr *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< ? 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 +)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< 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 +)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< +)($2'1T$($03' ALA> $ngine, clutch and transmission : =a@<iff< _ GcY s :V V>Z 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& #:& #;& 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 N r(((((((( h O rt g L # P
r L g
5 e a s u r e m e n t
T A T *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 Scane! by Stal'er *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 Scane! by Stal'er 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 Stane! by Stal'er +.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# Scane! by Stal'er 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 %.RTG AER?9A% 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 AG.**?>G&AHEA*? .> &D?ET&TI *AELFAGTL>?>- EA*? .> #>AED EA*? G.LET>I.F*AELFAGTL>? TI>? G.E-T>LGT&.E D?TA&H- fE8T >?8L&>?D &E LM" H.AD AED 6>?--L>? *A>M&EK>?8L&>?*?ET NE.T A66H&GA#H? &E LM" E.>T7 A*?>&GAE TI>? &D?ET&F&GAT&.E EL*#?> #&A- #?HT?D TI>? -&O? P TI>? -&O? D?-&KEAT&.E TI>?Q 6>.F&H? | RAD?A- 9.%STRE9T?.% T7? J.>D TL#?H?-- J7&*R A66H&GA#H? =*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 - S TS T^ H ^ ^ -^^^7tf!/ --^#4^*^gT 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! b2; then either remove the screw.s/ and detach the switch or withdraw the switch from the bracket, according to model 1see illustration2. 5 'nstallation is the reverse of removal. 6D Dio!e 1XT3 mo!els2 # H check and replacement H :(!!I Check * The diode is a small block that plugs into the main wiring harness .see >iring *iagrams at the end of the "hapter/. (emove the seat 68.6a 9lutch sBitch Birin& connector 1arroBe!2 # TD mo!els 68.6b 9lutch sBitch Birin& connector 1arroBe!2 ( XT3 mo!els 68.0 9lutch sBitch screB 1arroBe!2 (TD mo!els +)($2'1T$($0 3$(1'=) =4 P' "T+($#0$1<H Scane! by Stal'er 9L8> $lectrical system the transmission is in gear unless the sidestand is up and the clutch lever is pulled in. A 0isconnect the diode from the harness. The diode is situated on the left#hand side of the 60.6a Starter circuit cut(off relay 1arroBe!2 ( TD mo!els r+3U?+ /+$ E$ -+7 # /ed/black 2 6lack/yellow 4 6lue/white 5 6lue/white -+7-+7 /+$Sb-+$R+/ mm 60.8a Starter circuit cut(off relay test set(u" (*99* to *990 TD mo!els TT # /ed/black 2 6lack/yellow 4 6lue/white 5 6lue/white = = b 60.8b Starter circuit cut(off relay test set(u" (*995 to *998 TD mo!els an! T/X mo!els 60.8c Starter circuit cut(off relay test set(u" ( XT3 mo!els frame in the area where the fuel tank and side cover meet. @ +sing an ohmmeter or continuity tester, connect the positive .^ve/ probe to one terminal of the diode and the negative .#ve/ probe to the other terminal. )ow reverse the probes. The diode should show continuity in one direction and no continuity in the other direction. 'f it doesn't behave as stated, renew the diode. 6 'f the diode 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 0 The diode is a small block that plugs into the main wiring harness on the left#hand side of the frame in the area where the fuel tank and side cover meet. (emove the seat and fuel tank for access .see "hapters > and 6/. 0isconnect the diode from the harness and connect the new one. A; 1tarter circuit cut#off relay # H check and replacement Y Check * The starter circuit cut#off relay 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. 6 'f the starter circuit is faulty, first check the fuse .see 1ection ;/. The starter cut#off relay is located under the seat on all e%cept 899C#on T05 models, where it is behind the fairing. (emove the seat or fairing for access .see "hapter >/. 0isconnect the relay wiring connector and remove the relay 1see illustrations an! **.8b2. 8 1et a multimeter to the ohms % 8 scale and connect it across the relay's terminals as shown, according to your model 1see illustrations2. +sing a fully#charged 8A volt battery and two insulated jumper wires, connect the battery to the relay's terminals as shown, according to your model. At this point the multimeter should show &ero ohms .continuity/. 'f this is the case the relay is proved good. 'f the relay indicates no continuity .infinite resistance/ across its terminals, it is faulty and must be renewed. %ote) 'o test details are available !or the #777 T*E model # the relay can only be checked by the substitution o! a new relay. D 'f the relay 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/. Scane! by Stal'er and fuel tank for access .see "hapters > and 6/. The diode 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 60.6b Starter circuit cut(off relay 1arroBe!2 ( XT3 mo!els (X '6` R+/ Sb XI 7 R r @ +)($2'1T$($03' Electrical system 9`*9 "eplacement 0The starter cut#off relay is located under the seat on all e%cept 899C#on T05 models, where it is behind the fairing. (emove the seat or fairing for access .see "hapter >/. 0isconnect the relay wiring connector and remove the relay 1see ?llustrations 60.6a an! b; an! **.8b2. 5 'nstallation is the reverse of removal. 8. .. ,L 65 Gorn # QO check and replacement JJ 65.8a Gorn Birin& connectors 1A2 an! mountin& bolt 1/2 ( TD mo!els 65.8b Gorn Birin& connectors 1A2. Check 8 'f the horn, doesn't work, first check the fuse .see 1ection ;/ and the battery .see 1ection @/. A The horn is mounted behind the fairing side panels or the fairing, depending on model. =n T05 and T(7 models, remove the fairing, and on 7TE models remove the left#hand fairing side panel .see "hapter >/. @ +nplug the wiring connectors from the horn 1see ?llustrations2. +sing two jumper wires, apply battery voltage directly to the terminals on the horn. 'f the horn sounds, check the switch .see 1ection 89/ and the wiring between the switch and the horn .see the wiring diagrams at the end of this "hapter/. 6 'f the horn doesn't sound, renew it. "eplacement ; The horn is mounted behind the fairing side panels or the fairing, depending on model. =n T05 and T(7 models, remove the fairing, and on 7TE models remove the left#hand fairing side panel .see "hapter >/. C +nplug the wiring connectors from the horn, then unscrew the bolt.s/ securing the horn and remove it from the bike 1see ?llustrations 65.8a; b, c an! d/. B 'nstall the horn and securely tighten the bolt.s/. "onnect the wiring connectors to the horn. 64 Starter relay ( c02c; a#< 52"\ac2=29> ;)J[ KKK/K1 /KKK1K ))+)(J J Check 8 'f the starter circuit is faulty, first check the fuse .see 1ection ;/. A The starter relay is located under the seat. (emove the seat for access .see "hapter >/. Fift the rubber terminal cover and unscrew the bolt securing the starter motor lead 1see illustration2N position the lead away from the relay terminal. -ith the ignition switch =), the engine kill switch in the (+) position, the transmission in 65.8c ... an! mountin& bolt 1/2 ( TRX mo!els neutral and the clutch pulled in, press the starter switch. The relay should be heard to click. @ 'f the relay doesn't click, switch off the ignition and remove the relay as described below test it as follows. 6 This test is made with the relay removed from the bike and on the bench. 1et a multimeter to the ohms % 8 scale and connect it across the relay's starter motor and battery lead terminals. +sing a fully#charged 8A volt battery and two insulated jumper wires, connect the jumper leads as follows according to the model being worked onG 8998 to 9; T05 *attery positive lead to the red wire terminal of the relay, negative lead to the blueDwhite terminal *attery positive lead to the redDwhite wire terminal of the relay, negative lead to the blueDwhite terminal *attery positive lead to the blueDwhite wire terminal of the relay, negative lead to the red terminal *attery positive lead to the blueDwhite wire terminal of the relay, negative lead to the redDwhite terminal 1996-)# T?( T(7 7TE 65.8! Gorn Birin& connectors 1A2 an! mountin& bolt 1/2 ( XT3 mo!els At this point the relay should be heard to click and the multimeter read ? ohms .continuity/. 'f this is the case the relay is proved good. 'f the relay does not click when battery voltage is applied and indicates no continuity .infinite resistance/ across its terminals, it is faulty and must be renewed. ; 'f the relay 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 C (emove the seat .see "hapter >/. B 0isconnect the relay wiring connector, and unscrew the two nuts securing the starter motor and battery leads to the relay and +)($2'1T$($03' Scane! by Stal'er 64.6 Detach the starter motor lea! from the relay 9I60 Electrical system 64.4 #ull bac' the co,ers to access the terminal nuts 68.Da EnscreB the bolts 1arroBe!2. detach the leads 1see illustration2. (emove the relay with its rubber sleeve from its mounting lug on the frame. > 'nstallation is the reverse of removal. 5ake sure the terminal nuts are securely tightened. "onnect the negative .#ve/ lead last when reconnecting the battery. 68.Db ... an! remo,e the starter motor 68 Starter motor # removal and installation "emoval 8 (emove the seat .see "hapter >/. 0isconnect the battery negative .#ve/ lead. A The starter motor is mounted underneath the engine. @ Peel back the rubber terminal cover and remove the nut securing the starter lead to the starter relay 1see illustration 64.62. 0etach the lead and feed it through to the starter motor. 6 +nscrew the two bolts securing the starter motor to the crankcase 1see illustration2. 1lide the starter motor out from the crankcase and remove it from the machine 1see illustration2. ; (emove the =#ring on the end of the starter motor and discard it as a new one must be used. &nstallation 5 'nstall a new =#ring on the end of the starter motor and ensure it is seated in its groove 1see illustration2. Apply a smear of engine oil to the =#ring to aid installation. 4 5anoeuvre the motor into position and slide it into the crankcase 1see illustration 68.Db2. $nsure that the starter motor teeth mesh correctly with those of the starter idleDreduction gear. 'nstall the mounting bolts and tighten them to the tor,ue setting specified at the beginning of the "hapter 1see illustration2. 8 "onnect the starter lead to the starter relay and secure it with the nut 1see illustration 64.62. 5ake sure the rubber cover is correctly seated over the terminal. 9 "onnect the battery negative .#ve/ lead and install the seat .see "hapter >/. 68.5 Fit a neB .(rin& into the &roo,e ? 68.4 ?nstall the bolts an! ti&hten them to the s"ecifie! torAue Scane! by Stal'er $lectrical system 9[A8 69.* EnscreB the terminal nut an! !etach the lea! 69.6 %ote the ali&nment mar's 1arroBe!2; or ma'e your oBn 69.8 EnscreB the lon& bolts 1arroBe!2 69.Da Remo,e the front co,er... 69.Db ... an! sli!e off the shims 69 Starter motor # disassembly, QH inspection and reassembly Pa Disassembl) 8(emove the starter motor .see 1ection A>/. Pull back the rubber terminal cover, then unscrew the nut and detach the lead from the terminal bolt 1see illustration2. A )ote the alignment marks between the main housing and the front and rear covers, or make your own if they aren't clear 1see illustration2. @+nscrew the two long bolts and withdraw them from the starter motor 1see illustration2. 6-rap some insulating tape around the teeth on the end of the starter motor shaft # this will protect the oil seal from damage as the front cover is removed. (emove the front cover from the motor 1see illustration2. (emove the cover =#ring from the main housing and discard it as a new one must be used. (emove the shims from the front end of the armature shaft or the inside of the front cover, noting their correct fitted locations 1see illustration2. Also remove the tabbed thrust washer from the front cover 1see illustration 69.60b2. 0 (emove the rear cover from the motor 1see illustration2. (emove the cover =#ring from the main housing and discard it as a new one must be used. (emove the shims from the rear end of the armature shaft or from inside the rear cover 1see illustration2. 69.0a Remo,e the rear co,er... 69.0b ... an! sli!e off the shims V Scane! by Stal'er 9LAA $lectrical system 69.5 7ith!raB the armature 69.4 EnscreB the terminal nut 1A2 an! remo,e the Bashers; then lift out the brush"late 1/2 5 -ithdraw the armature from the main housing 1see illustration2. 4 )oting the correct fitted location of each component, unscrew the terminal nut and remove it along with its washer and the insulating washers 1see illustration2. -ithdraw the brushplate assembly and 69.8 easure the len&th of each brush terminal bolt from the main housing. (emove the brushplate seat 1see illustration 69.*0a2. &nspection > The parts of the starter motor that are most likely to re,uire attention are the brushes. 5easure the length of the brushes and compare the results to the brush length listed in this "hapter's 1pecifications 1see illustration2. 'f any of the brushes are worn beyond the service limit, renew the brush assembly. 'f the brushes are not worn e%cessively, nor cracked, chipped, or otherwise damaged, they may be re#used. 9 'nspect the commutator bars on the armature for scoring, scratches and discoloration. The commutator can be cleaned and polished with crocus cloth, but do not use sandpaper or emery paper. After cleaning, wipe away any residue with a cloth soaked in electrical system cleaner or denatured alcohol. 5easure the diameter of the commutator and compare 't to the specifications. 'f it has worn below the wear limit, renew the starter motor. 5easure the depth of the insulating 5ica below the surface of the commutator bars. 'f the 5ica is less than the depth specified, scrape it away until the specified depth is reached. 8? +sing an ohmmeter or a continuity test light, check for continuity between the commutator bars 1see illustration2. "ontinuity should e%ist between each bar and all of the others. Also, check for continuity between the commutator bars and the armature shaft 1see illustration2. There should be no continuity .infinite resistance/ between the commutator and the shaft. 'f the checks indicate otherwise, the armature is defective. 88 "heck for continuity between the terminal bolt and the housing .when assembled/. There should be no continuity .infinite resistance/. 8A "heck the front end of the armature shaft for worn, cracked, chipped and broken teeth. 69.*0a 9ontinuity shoul! eCist betBeen the commutator bars 69.*0b There shoul! be no continuity betBeen the commutator bars an! the armature shaft Scane! by Stal'er +)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< +)($2'1T$($0 3' $lectrical system CSG" 69.*0a Fit the brush"late seat 69.*0b a'e sure the insulators are in "lace.. *0c ... then install the terminal bolt assembly into the housin& an! brush"late seat... 69.*0! . an! fit the washers an! nut 'f the shaft is damaged or worn, renew the armature. 8@ 'nspect the end covers for signs of cracks or wear. 'nspect the magnets in the main housing and the housing itself for cracks. 86 'nspect the insulating washers and front cover oil seal for signs of damage and renew them if necessary. 8B 4it each brush into its holder and press it back against the spring, then lock it in that position by inserting a strip of plastic .such as the cut#off end of a cable tie/ between the spring end and the holder, preventing the spring from pushing the brush back out 1see illustration2. This provides the clearance necessary for the armature to be installed without becoming entangled with the e%posed brush ends. 8> 'nsert the armature into the main housing, noting that it will be forcibly drawn in by the attraction of the magnets 1see illustration 69.52. (emove the strips securing the brushes. "heck that each brush is securely pressed against the commutator "eassembl) *0 4it the brushplate seat into the main housing 1see illustration2. $nsure that the inner rubber insulator and =#ring are in place on the terminal bolt, then insert the bolt through the main housing and locate the arms into the brushplate seat 1see illustrations2. 4it the insulating washers over the terminal, then fit the standard washer and the nut 1see illustration2. *5 4it the brushplate assembly onto the main housing, locating the terminal bolt brush wires in the cutouts and making sure the tab on the plate locates in the cutout in the housing 1see illustration2. 69.*5 Fit the brush"late; locatin& the tab in the notch 1A2 the brush Bires in the cutouts 1/2 69.*4 -oc' the brushes into their hol!ers as !escribe! an! shoBn Scane! by Stal'er +)($2'1T$($0 3$(1'=) =4 P'"T+($#0$1< 9[A6 $lectrical system +)($2'1T$($0 3' 69.*9 Fit a neB .(rin& onto the rear of the housin& 69.60a Fit a neB .(rin& onto the front of the housin& . by its spring and is free to move easily in its holder. *9 1lide the shims onto the end of the armature 1see illustration 69.0b2; then fit a new rear cover =#ring 1see illustration2. 4it the rear cover onto the housing, aligning the marks noted or made earlier 1see illustration 69.0a2. 60 1lide the shims onto the front of the armature 1see illustration 69.Db2; then fit a new front cover =#ring 1see illustration2. Apply a smear of grease to the lips of the front cover oil seal. 4it the tabbed washer onto the cover 1see illustration2; making sure the tabs locate correctly, then install the cover, aligning the marks made on removal 1see illustration 69.Da2. (emove the protective tape from the shaft end. 6* "heck the alignment marks made on removal are correctly aligned, then install the long bolts and tighten them securely 1see illustration2. 66 4it the starter motor lead onto the terminal bolt, then secure it with the nut and cover it with the rubber boot 1see illustration A9.8/. 68 'nstall the starter motor .see 1ection A>/. 80 9har&in& system testin& # general information and precautions 8 'f the performance of the charging system is suspect, the system as a whole should be checked first, followed by testing of the individual components. %ote) 6e!ore beginning the checks& make sure the battery is !ully charged and that all system connections are clean and tight. A "hecking the output of the charging system and the performance of the various components within the charging system re,uires the use of a multimeter ]with voltage, current and resistance checking facilities/. @ -hen making the checks, follow the procedures carefully to prevent incorrect connections or short circuits, as irreparable damage to electrical system components may result if short circuits occur. 6 'f a multimeter is not available, the job of checking the charging system should be left to a :amaha dealer. @8 "harging system #leakage and output test 8 'f the charging system of the machine is thought to be faulty, remove the seat .see "hapter >/ and perform the following checks. 0eakage test Caution: ,lwa)s connect an ammeter in series, never in parallel with the batter), otherwise it will be damaged. Do not turn the ignition $! or operate the starter motor when the ammeter is connected / a sudden surge in current will blow the meter1s fuse. A Turn the ignition switch =44 and disconnect the lead from the battery negative .#ve/ terminal. @1et the multimeter to the Amps function and connect its negative .#ve/ probe to the battery negative .#ve/ terminal, and positive .^ve/ probe to the disconnected negative .#ve/ lead 1see 69.60b ... and fit the tabbe! Basher into the co,er i 69.6* ?nstall an! ti&hten the lon& bolts Scane! by Stal'er +)($2'1T$($03$(1'=) =4 P'"T+($#0$1< $lectrical sysiefr4fH&f @8.@ "hecking the charging system leakage rate # connect the ammeter as shown @A.Aa Alternator wiring connector .A/, pickup coil wiring connector .*/ # T05 models @A.Ab Alternator wiring connector .A/, pickup coil wiring connector .*/ # T(7 models illustration/. Always set the meter to a high amps range initially and then bring it down to the mA .milli Amps/ range if there is a high current flow in the circuit it may blow the meter's fuse. 6 'f the current leakage indicated e%ceeds the amount specified at the beginning of the "hapter, there is probably a short circuit in the wiring. 0isconnect the meter and connect the negative .#ve/ lead to the battery, tightening it securely, ; 'f leakage is indicated, use the wiring diagrams at the end of this book to systematically disconnect individual electrical components and repeat the test until the source is identified. $utput test C 1tart the engine and warm it up to normal operating temperature. (emove the seat .see "hapter >/. B To check the regulated voltage output, allow the engine to idle and connect a multimeter set to the ? to A? volts 0" scale .voltmeter/ between the terminals of the battery .meter positive .^ve/ lead to battery positive terminal, meter negative .#ve/ lead to battery negative terminal/. 1lowly increase the engine speed to ;??? rpm and note the reading obtained. The regulated voltage should be as specified at the beginning of the "hapter. 'f the voltage is outside these limits, check the alternator and the regulator .see 1ections @A and @@/. GT.f/[! -lues to a !aulty regulator VZSZIZ are constantly blowing G?%T 86 Alternator # check, removal and installation Check 8 To access the wiring connectors, 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 >/. A Trace the wiring back from the top of the alternator cover on the left#hand side of the engine and disconnect it at the white connector containing the three white wires .see illustrations/. @ +sing a multimeter set to the ohms % 8 .ohmmeter/ scale measure the resistance between each of the white wires on the alternator side of the connector, taking a total of three readings, then check for continuity between each terminal and earth. 'f the stator coil windings are in good condition the three readings should be within the range shown in the 1pecifications at the start of this "hapter and there should be no continuity .infinite resistance/ between any of the terminals and earth. 'f not, the alternator stator coil assembly is at fault and should be renewed. )oteG 6e!ore condemning the stator coils& check the !ault is not due to damaged wiring between the connector and coils. "emoval 6 To access the wiring connectors, 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 alternatorDpick#up coil wiring back from the top of the alternator cover on the left# hand side of the engine and disconnect it at the two white connectors .see illustrations @A.Aa, b and c/. 4ree the wiring from any clips or guides and feed it through to the alternator cover. C =n T05 and 7TE models, unscrew the bolts securing the outer front sprocket cover and remove the cover .see illustration/. +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 .see illustration/. '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 @A.Ac Alternator wiring connector .A/, pickup coil wiring connector .*/ # 7TE models bulbs& with brightness varying considerably with engine speed& and battery overheating. ? @A.Ca +nscrew the bolts .arrowed/ and remove the cover @A.Cb 2earchange armDshaft alignment #T05 models V 1caned by Stal'er 9[AC $lectrical system 86.5c EnscreB the tBo bolts an! remo,e the inner co,er 86.4 \earchan&e arm+shaft ali&nment ( TRX mo!els top rear bolt, and remove the cover 1see illustration2. 4 =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 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. 86.8 EnscreB the bolts 1arroBe!2 an! remo,e the co,er +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. > -orking in a criss#cross pattern, unscrew the bolts securing the alternator cover and remove the cover 1see illustration2. 0iscard the gasket as a new one must be used. )ote 86.9 7ith!raB the shaft 1arroBe!2 an! remo,e the &ear the position of the dowels and remove them if loose. 9 -ithdraw the shaft from the starter idleDreduction gear and remove the gear, noting how it fits 1see illustration2. *0 To remove the rotor bolt it is necessary to stop the rotor from turning. 'f a rotor holding strap or tool is not available, and if the engine is still in the fame, place the transmission in gear and have an assistant apply the rear brake, then unscrew the bolt 1see illustration2. ** To remove the rotor from the shaft it is necessary to use a rotor puller. :amaha provide a special tool .Pt. )os. 9?>9?#?8@CA and 9?>9?# ?8@>A, or alternatively a similar tool can be set up as shown, using the threaded holes in the rotor 1see illustration2. After the rotor has been removed, remove the -oodruff key from the slot in the crankshaft for safekeeping if loose 1see illustration 86.*Da2. *6 To remove the stator from the cover, remove the three screws securing the stator, and the two screws securing the pick#up coil, 86.*0 EnscreB the rotor bolt 1arroBe!2 86.** DraBin& the rotor off the shaft usin& a "uller Sta&e! by Stal'er +)($2'1T$($0 3' $lectrical system 9LAB 86.*6a Remo,e the rotor screBs 1A2. 86.*6b ... an! the "ic'(u" coil screBs 1/2; an! free the Birin& &rommets 192 86.*Da ?f remo,e!; fit the 7oo!ruff 'ey into its slot... then remove the assembly, noting how the rubber wiring grommets fit 1see illustrations2. &nstallation *8 'nstall the stator and the pick#up coil in the cover, aligning the rubber wiring grommets with the grooves 1see illustrations 86.*6a an! b2. Apply a suitable non#permanent thread locking compound to the stator and pick#up coil screw threads, then install the screws and tighten them to the tor,ue settings specified at the beginning of the "hapter. Apply a suitable sealant to the wiring grommets, then press them into the cut# outs in the cover. *D "lean the tapered end of the crankshaft and the corresponding mating surface on the inside of the rotor with a suitable solvent. 4it the -oodruff key into its slot in the crankshaft 1see illustration2. 5ake sure that no metal objects have attached themselves to the magnet on the inside of the rotor, then install the rotor onto the shaft, making sure the slot is correctly aligned with the key 1see illustration2. *0 'nstall the rotor bolt with its washer and tighten it to the tor,ue setting specified at the beginning of the "hapter, using the method employed on removal to prevent the rotor from turning 1see illustrations2. *5 Fubricate the starter idleDreduction gear shaft with clean engine oil. 'nstall the 86.*Db ... then sli!e on the rotor; ali&nin& the slot 1arroBe!2 Bith the 'ey idleDreduction gear, making sure it engages correctly with both the starter motor pinion and the starter clutch pinion, and insert the shaft 1see illustration 86.92. *4 'nstall the alternator cover using a new gasket, making sure it locates onto the dowels, and tighten the cover bolts evenly in a criss#cross pattern to the specified tor,ue setting 1see illustrations2. "onnect the alternator and pick# up coil wiring connectors, making sure they are correctly routed and secured by any clips or ties 1see illustrations 86.6a; b an! c2. *8 =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 86.*0a ?nstall the bolt... 86.5c2. 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 86.5b2. 'nstall the outer sprocket cover and tighten its bolts to the specified tor,ue 1see illustration 86.5a2. *9 =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 86.42. 86.*0b ... an! ti&hten it to the s"ecifie! torAue )3 - "**%?+ MM ~~ W ^ (* 1 ^Kk "^ 86.*4a -ocate the &as'et onto the !oBels 1arroBe!2... 86.*4b ... then install the co,er V Starte! by Stal'er +)($2'1T$($03$(1'=) =4 P'"T+($#0$1< +.Hi.l1.iHi0.iH1in.n4P'"+Hi#0i1< 9[A> $lectrical system @@ (egulatorDrectifier# QJ check and replacement H Check 8 :amaha provide no test specifications for the regulatorDrectifier. 'f it is suspected of being faulty, first check all other components and wiring in the charging circuit, referring to the relevant 1ections in this "hapter and to the wiring diagrams at the end. A 'f all other components and the wiring are good, then the regulatorDrectifier could be faulty. (emove the unit .see below/ and take it to a :amaha dealer for testing. Alternatively, substitute the suspect unit with a known good one and see if the fault is cured. "eplacement @ =n 8998 to 899; T05 models, the regulatorDrectifier is mounted on the outside of the left#hand frame beam 1see illustration2. =n 899C#on T05 models, it is mounted behind the fairing. (emove the fairing for access .see "hapter >/. =n 8998 to 899; 88.8a Re&ulator+rectifier (*99* to *990 TD mo!els models, remove the air filter housing for access to the wiring connector .see "hapter 6/ 1see illustration2. D =n T(7 models, the regulatorDrectifier is mounted to the underside of the rear mudguard near the top of the shock absorber 1see illustration2. (emove the rider's seat to access its wiring connector .see "hapter >/ 1see illustration2. 88.8b Re&ulator+rectifier Birin& connector ( *99* to *990 TD mo!els 0 =n 7TE models, the regulatorDrectifier is mounted behind the left#hand side cover 1see illustration2. (emove the cover for access .see "hapter >/. 5 0isconnect the wiring connector. 4 +nscrew the two bolts or nuts securing the regulatorDrectifier and remove it. 8 'nstall the new unit and tighten its bolts or nuts securely. "onnect the wiring connector. 88.Da Re&ulator+rectifier ( TRX mo!els 88.Db Re&ulator+rectifier Birin& connector ( TRX mo!els 88.0 Re&ulator+rectifier ( XT3 mo!els Stane! by Stal'er -iring diagrams 9LA9 0'l CMo 9C<Wb`=fi ? =>?9) ^^^^^^Scane! by Stal'er +)($2'1T$($03' 9[@? -iring diagrams J +)($2'1T$($03$(1'=) ?8 =)($2'1T$($03' Scane! by Stal'er J =)($2'1T$($0 3$(1'=) ? ' +)($2'1T$($03' -iring diagrams 9[@8 ^^^^^^Scane! by Stal'er J +)($2'1T$($03$(1'=) =4 P'"T+($#0$1< 9[@A -iring diagrams Scane! by Stal'er XT3400 gauge +tarter circuit 'eutral +tarter cut-o!! relay switch rnotor
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