EB000000
TDM850 '96
SERVICE MANUAL1996 by Yamaha Motor Co., Ltd.
First edition, March 1996
All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render if unfit to use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
PARTICULARY IMPORTANT INFORMATION
This material is distinguished by the following notation.
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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR |
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SAFETY IS INVOLVED! |
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WARNING |
Failure to follow WARNING instructions could result in severe injury or |
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death to the motorcycle operator, a bystander, or a person inspecting or |
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repairing the motorcycle. |
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CAUTION: |
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A CAUTION indicates special precautions that must be taken to avoid |
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NOTE: |
damage to the motorcycle. |
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A NOTE provides key information to make procedures easier or clearer. |
EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See ªIllustrated symbolsº)
1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
1.An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2.Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page.
4.A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5.For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.
2 |
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4 |
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6
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7
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2 |
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SPEC |
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INFO |
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4 |
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INSP |
ENG |
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ADJ |
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5 |
6 |
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COOL |
CARB |
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7 |
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CHAS |
ELEC |
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9 |
10 |
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TRBL |
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SHTG |
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24 |
25 |
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on top right of each page and indicate the subject of each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Cooling system
6Carburetion
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
10Can be serviced with engine mounted
11Filling fluid
12Lubricant
13Special tool
14Torque
15Wear limit, clearance
16Engine speed
17Ω, V, A
Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18Apply engine oil
19Apply gear oil
20Apply molybdenum disulfide oil
21Apply wheel bearing grease
22Apply lightweight lithium soap base grease
23Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply a locking agent 24 and when to install new parts 25 .
24Apply locking agent (LOCTITE )
25Replace
INDEX
GENERAL INFORMATION |
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GEN |
1 |
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INFO |
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SPECIFICATIONS |
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SPEC |
2 |
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PERIODIC INSPECTION AND |
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INSP |
3 |
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ADJUSTMENT |
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ADJ |
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ENGINE OVERHAUL |
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ENG |
4 |
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COOLING SYSTEM |
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COOL |
5 |
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CARBURETION |
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CARB |
6 |
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CHASSIS |
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CHAS |
7 |
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ELECTRICAL |
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ELEC |
8 |
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TROUBLESHOOTING |
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TRBL |
9 |
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SHTG |
GEN
INFO
CHAPTER 1.
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . . . 1-3 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1-4 |
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
GEN INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped into the right side of the steering head.
NOTE:
The vehicle identification number is used to identify the motorcycle and may be used to register the motorcycle with a licensing authority.
EB100030
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into the crankcase.
NOTE:
The first three digits of the engine serial number indicate the model type; the remaining digits are the unit production number.
MODEL LABEL
The model label 1 is affixed to the frame. This information will be needed to order spare parts.
1-1
GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
1.Remove all dirt, mud dust, and foreign material before removal and disassembly.
2.Use proper tools and cleaning equipment. Refer to ªSPECIAL TOOLSº.
3.When disassembling the motorcycle keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been ªmatedº through normal wear. Mated parts must be reused as an assembly or replaced.
4.During the motorcycle disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.
5.Keep away from fire.
ALL REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS
1.All gaskets, seals and O-rings should be replaced when an engine is overhauled.
All gaskets surfaces, oil seal lips and O-rings must be cleaned.
2.Properly oil all mating parts and bearing during reassembly. Apply grease to the oil seal lips.
1-2
GEN
IMPORTANT INFORMATION INFO
LOCK WASHERS/PLATES AND COTTER PINS
1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) and oil seal(s) with their manufacturer's marks or numbers facing outward. (In other word, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.
2 Bearing
CIRCLIPS
1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlips 1 , make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.
4 Shaft
1-3
GEN
CHECKING OF CONNECTIONS INFO
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the connector.
1.Disconnect:
Connector
2.Dry each terminal with an air blower.
3.Connect and disconnect the connector two or three times.
4.Pull the lead to check that it will not come off.
5.If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector.
6.Connect:
Connector
NOTE:
The two connectors ªclickº together.
7. Check for continuity with a tester.
NOTE:
If there is no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed above when checking the wireharness.
For a field remedy, use a contact revitalizer available on the market.
Use the tester on the connector as shown.
1-4
GEN
HOW TO USE THE CONVERSION TABLE INFO
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex. |
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METRIC |
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MULTIPLIER |
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IMPERIAL |
**mm |
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0.03937 |
= |
**in |
2 mm |
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0.03937 |
= |
0.08 in |
CONVERSION TABLE
METRIC TO IMPERIAL
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Metric unit |
Multiplier |
Imperial unit |
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m kg |
7.233 |
ft lb |
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Torque |
m kg |
86.794 |
in lb |
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cm kg |
0.0723 |
ft lb |
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cm kg |
0.8679 |
in lb |
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Weight |
kg |
2.205 |
lb |
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g |
0.03527 |
oz |
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Speed |
km/hr |
0.6214 |
mph |
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km |
0.6214 |
mi |
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Dis- |
m |
3.281 |
ft |
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m |
1.094 |
yd |
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tance |
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cm |
0.3937 |
in |
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mm |
0.03937 |
in |
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cc (cm3) |
0.03527 |
oz (IMP liq.) |
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Volume/ |
cc (cm3) |
0.06102 |
cu in |
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Capacity |
lit (liter) |
0.8799 |
qt (IMP liq.) |
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lit (liter) |
0.2199 |
gal (IMP liq.) |
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kg/mm |
55.997 |
lb/in |
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Miscel- |
kg/cm2 |
14.2234 |
psi (lb/in2) |
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laneous |
Centigrade |
9/5+32 |
Fahrenheit |
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(_C) |
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(_F) |
1-5
GEN
SPECIAL TOOLS INFO
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly.
Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.
Tool No. |
Tool name/How to use |
Illustration |
90890-01083 Slide hammer bolt
90890-01084 Weight
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These tools are used to remove the |
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main axle assembly cover. |
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90890-01304 |
Piston pin puller |
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This tool is used to remove the piston |
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pin. |
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90890-01312 |
Fuel level gauge |
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This gauge is used to measure the fuel |
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level in the float chamber. |
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90890-01325 Radiator cap tester |
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90890-01352 |
Adapter |
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This tester is needed for checking the |
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cooling system. |
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90890-01362 |
Flywheel puller |
90890-01382 |
Crankshaft protector |
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These tools are used to remove the A.C. |
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magneto. |
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90890-01367 Fork seal driver weight |
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90890-01374 |
Adapter |
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These tools are used when installing the |
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fork seal. |
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90890-01326 T-handle |
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90890-01465 Damper rod holder |
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These tools are used to loosen and |
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tighten the front fork damper rod |
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holding bolt. |
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90890-01403 |
Ring nut wrench |
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This tool is used to loosen and tighten |
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the steering ring nut. |
1-6
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SPECIAL TOOLS |
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INFO |
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Tool No. |
Tool name/How to use |
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Illustration |
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90890-01701 |
Sheave holder |
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This tool is used to hold the rotor when |
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loosening and tightening the rotor bolt. |
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90890-03081 |
Compression gauge |
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This gauge is used to measure the |
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engine compression. |
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90890-03094 |
Vacuum gauge |
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This gauge is needed for carburetor |
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synchronization. |
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90890-03112 |
Pocket tester |
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This instrument is invaluable for |
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checking the electrical system. |
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90890-03113 |
Engine tachometer |
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This tool is needed for detecting |
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engine rpm. |
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90890-03141 |
Timing light |
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This tool is necessary for checking |
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ignition timing. |
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90890-04016 |
Valve guide remover, installer and |
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reamer (5.5 mm) |
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These tools are used to remove, install |
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and rebore the valve guide. |
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90890-04019 |
Valve spring compressor |
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90890-04108 |
Attachment |
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These tools are needed to remove and |
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install the valve assemblies. |
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90890-04086 |
Universal clutch holder |
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This tool is used to hold the clutch when |
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removing or installing the clutch boss |
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nut. |
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90890-06754 |
Ignition checker |
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This instrument is necessary for |
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checking the ignition system components. |
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1-7
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SPECIAL TOOLS |
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GEN |
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INFO |
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Tool No. |
Tool name/How to use |
Illustration |
90890-85505 Yamaha bond No. 1215
This sealant (bond) is used on crankcase mating surfaces, etc.
1-8
SPEC
CHAPTER 2.
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-1 |
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . . . . 2-18 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-20 |
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-25 |
SPEC
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GENERAL SPECIFICATIONS |
SPEC |
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SPECIFICATIONS |
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GENERAL SPECIFICATIONS |
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Item |
Standard |
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Model: |
TDM850 |
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Model code: |
4TX1 |
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Dimensions: |
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Overall length |
2,165 mm, 2,200 mm (D, DK, SF, N, S) |
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Overall width |
790 mm |
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Overall height |
1,285 mm |
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Seat height |
805 mm |
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Wheelbase |
1,475 mm |
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Minimum ground clearance |
165 mm |
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Minimum turning radius |
2,900 mm |
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Basic weight (With oil and full fuel tank): 229 kg |
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Engine: |
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Engine type |
Liquid-cooled 4-stroke, DOHC, 5 valve |
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Cylinder arrangement |
Forward-inclined parallel 2-cylinder |
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Displacement |
0.849 L |
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Bore stroke |
89.5 67.5 mm |
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Compression ratio |
10.5 : 1 |
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Compression pressure (STD) |
1,200 kPa (12 kg/cm2, 12 bar) at 300 r/min |
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Starting system |
Electric starter |
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Lubrication system: |
Dry sump |
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Oil type or grade: |
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Engine oil |
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API Standard: |
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API SE or higher grade |
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Oil capacity: |
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Engine oil |
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Periodic oil change |
3.5 L |
With oil filter replacement |
3.6 L |
Total amount |
4.2 L |
2-1
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GENERAL SPECIFICATIONS |
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SPEC |
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Item |
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Standard |
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Air filter: |
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Dry type element |
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Fuel: |
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Type |
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Regular unleaded gasoline |
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Fuel tank capacity |
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20 L |
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Fuel reserve amount |
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3.1 L |
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Carburetor: |
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Type/quantity |
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BDST38/2 |
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Manufacturer |
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MIKUNI |
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Spark plug: |
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Type |
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DPR8EA-9/X24EPR-U9 |
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Manufacturer |
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NGK/NIPPONDENSO |
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Spark plug gap |
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0.8 X 0.9 mm |
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Clutch type: |
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Wet, multiple-disc |
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Transmission: |
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Primary reduction system |
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Spur gear |
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Primary reduction ratio |
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67/39 (1.718) |
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Secondary reduction system |
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Chain drive |
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Secondary reduction ratio |
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42/17 (2.471) |
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Transmission type |
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Constant mesh 5-speed |
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Operation |
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Left foot operation |
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Gear ratio |
1st |
37/13 (2.846) |
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2nd |
37/20 (1.850) |
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3rd |
30/21 (1.429) |
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4th |
27/23 (1.174) |
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5th |
28/27 (1.037) |
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Chassis: |
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Frame type |
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Diamond |
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Caster angle |
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24.5 |
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Trail |
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103 mm |
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Tire: |
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Type |
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Tubeless |
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Size |
front |
110/80 ZR18 |
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rear |
150/70 ZR17 |
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Manufacturer |
front |
BRIDGESTONE/PIRELLI/MICHELIN |
|||
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rear |
BRIDGESTONE/PIRELLI/MICHELIN |
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Type |
front |
BT54F/MTR03/MACADAM90X |
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rear |
BT54R/MTR04/MACADAM90X |
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2-2
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GENERAL SPECIFICATIONS |
SPEC |
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Item |
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Standard |
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Tire pressure (cold tire): |
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Maximum load-except motorcycle |
180 kg |
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Loading condition A* |
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0 90 kg |
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front |
225 kPa (2.25 kg/cm2, 2.25 bar) |
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rear |
275 kPa (2.75 kg/cm2, 2.75 bar) |
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Loading condition B* |
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90 180 kg |
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front |
225 kPa (2.25 kg/cm2, 2.25 bar) |
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rear |
275 kPa (2.75 kg/cm2, 2.75 bar) |
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High speed riding |
|
225 kPa (2.25 kg/cm2, 2.25 bar) |
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front |
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||
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rear |
275 kPa (2.75 kg/cm2, 2.75 kg/cm2) |
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Brake: |
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Front brake |
type |
Dual disc brake |
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operation |
Right hand operation |
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Rear brake |
type |
Single disc brake |
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operation |
Right foot operation |
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Suspension: |
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Front suspension |
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Telescopic fork |
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Rear suspension |
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Swingarm (monocross) |
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Shock absorber: |
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Front shock absorber |
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Coil spring/Oil damper |
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Rear shock absorber |
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Coil spring/Gas-oil damper |
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Wheel travel: |
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Front wheel travel |
|
149 mm |
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Rear wheel travel |
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144 mm |
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Electrical: |
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Ignition system |
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T.C.I. (digital) |
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Generator system |
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A.C. magneto |
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Battery type |
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GT12B-4 |
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Battery capacity |
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12 V 10 AH |
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Headlight type: |
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Quartz bulb (halogen) |
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Bulb wattage quantity: |
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Headlight |
|
12 V 55 W 2 |
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Auxiliary light |
|
12 V 5 W 1 |
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Tail/brake light |
|
12 V 5/21 W 2 |
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Flasher light |
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12 V 21 W 4 |
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Meter light |
|
12 V 3.4 W 1 |
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12 V 1.7 W 2 |
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12 V 3.0 W 1 |
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Indicator lights |
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Neutral |
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12 V 3.4 W 1 |
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Turn |
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12 V 3.4 W 1 |
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High beam |
|
12 V 3.4 W 1 |
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* Load is total weight of cargo, rider, passenger and accessories
2-3
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item |
Standard |
Limit |
Cylinder head: |
|
0.03 mm |
Warp limit |
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Cylinder: |
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Bore size |
89.500 X 89.505 mm |
89.6 mm |
Taper limit |
|
0.05 mm |
Out of round limit |
|
0.03 mm |
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|
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Camshaft: |
Timing chain (right) |
|
Drive method |
|
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Camshaft cap inside diameter |
25.000 X 25.021 mm |
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Camshaft outside diameter |
24.967 X 24.980 mm |
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Camshaft-to-cap clearance |
0.020 X 0.054 mm |
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Cam dimensions |
|
|
Intake |
ªAº |
35.95 X 36.05 mm |
35.85mm |
|
ªBº |
27.95 X 28.05 mm |
27.85mm |
|
ªCº |
7.9 X 8.1 mm |
|
Exhaust |
ªAº |
35.95 X 36.05 mm |
35.85 mm |
|
ªBº |
27.95 X 28.05 mm |
27.85 mm |
|
ªCº |
7.9 X 8.1 mm |
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Camshaft runout limit |
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|
0.03 mm |
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Cam chain: |
|
82RH2015/138 |
|
Cam chain type/No. of links |
|
||
Cam chain adjustment method |
Automatic |
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Valve, valve seat, valve guide: |
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Valve clearance (cold) |
IN |
0.15 X 0.20 mm |
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Valve dimensions: |
EX |
0.25 X 0.30 mm |
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Head Dia Face Width Seat Width Margin Thickness
ªAº head diameter |
IN |
25.9 X 26.1 mm |
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EX |
27.9 X 28.1 mm |
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2-4 |
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MAINTENANCE SPECIFICATIONS |
|
SPEC |
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Item |
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Standard |
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Limit |
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ªBº face width |
IN |
2.06 X 2.46 mm |
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EX |
2.06 X 2.46 mm |
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ªCº seat width |
IN |
0.9 X 1.1 mm |
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EX |
0.9 X 1.1 mm |
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ªDº margin thickness |
IN |
0.8 X 1.2 mm |
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EX |
0.8 X 1.2 mm |
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Stem outside diameter |
IN |
5.475 X 5.490 mm |
|
5.445 mm |
|
|
EX |
5.460 X 5.475 mm |
|
5.43 mm |
|
Guide inside diameter |
IN |
5.500 X 5.512 mm |
|
5.55 mm |
|
|
EX |
5.500 X 5.512 mm |
|
5.55 mm |
|
Stem-to-guide clearance |
IN |
0.010 X 0.037 mm |
|
0.08 mm |
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|
EX |
0.025 X 0.052 mm |
|
0.10 mm |
|
Stem runout limit |
|
|
|
0.01 mm |
Valve seat width |
IN |
0.9 X 1.1 mm |
1.6 mm |
|
EX |
0.9 X 1.1 mm |
1.6 mm |
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Valve spring: |
|
|
|
Free length |
IN |
37.29 mm |
35.2 mm |
|
EX |
37.29 mm |
35.2 mm |
Set length (valve closed) |
IN |
30.39 mm |
|
|
EX |
30.39 mm |
|
Compressed pressure |
|
|
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(installed) |
IN |
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|
|
EX |
10.0 X 11.6 kg |
|
Tilt limit |
IN |
10.0 X 11.6 kg |
|
|
EX |
|
2.5_/1.7 mm |
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|
|
2.5_/1.7 mm |
Direction of winding |
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|
|
(top view) |
IN |
Clockwise |
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EX |
Clockwise |
|
2-5
MAINTENANCE SPECIFICATIONS |
|
SPEC |
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Item |
Standard |
|
Limit |
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Piston: |
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|
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Piston to cylinder clearance |
0.065 0.085 mm |
|
0.15 mm |
|
Piston size ªDº |
89.420 89.435 mm |
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Measuring point ªHº |
4.5 mm |
|
Piston off-set |
1 mm |
|
Piston off-set direction |
IN side |
|
Piston pin bore inside diameter |
20.002 20.013 mm |
20.043 mm |
Piston pin outside diameter |
19.991 20.000 mm |
19.975 mm |
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|
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Piston rings: |
|
|
Top ring: |
|
|
Type |
Barrel |
|
Dimensions (B T) |
1.0 3.5 mm |
|
End gap (installed) |
0.30 0.45 mm |
0.7 mm |
Side clearance (installed) |
0.035 0.070 mm |
0.12 mm |
2nd ring:
Type |
Taper |
|
Dimensions (B T) |
1.0 3.5 mm |
|
End gap (installed) |
0.30 0.45 mm |
0.8 mm |
Side clearance (installed) |
0.035 0.070 mm |
0.12 mm |
Oil ring:
Dimensions (B T) |
2.00 2.85 mm |
|
End gap (installed) |
0.2 0.7 mm |
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Connecting rod: |
|
|
Oil clearance |
0.026 0.050 mm |
0.09 mm |
2-6
|
MAINTENANCE SPECIFICATIONS |
|
SPEC |
|
|
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Item |
Standard |
|
Limit |
Crankshaft:
Assembly width ªAº |
|
153.6 X 154.4 mm |
|
Crank width ªBº |
|
64.75 X 65.25 mm |
|
Runout limit ªCº |
|
|
0.035 mm |
Big end side clearance ªDº |
0.160 X 0.272 mm |
0.5 mm |
|
Small end free play ªFº |
|
0.8 X 1.0 mm |
|
Journal oil clearance |
|
0.020 X 0.038 mm |
0.1 mm |
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Balancer: |
|
|
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Balancer drive method |
|
Gear |
|
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Clutch: |
|
|
|
Friction plate thickness |
|
2.9 X 3.1 mm |
2.8 mm |
Quantity |
|
9 |
|
Clutch plate thickness |
|
1.9 X 2.1 mm |
|
Quantity |
|
8 |
|
Warp limit |
|
|
0.1 mm |
Clutch spring free length |
|
55 mm |
53 mm |
Quantity |
|
6 |
|
Clutch release method |
|
Outer pull, rack & pinion pull |
|
|
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|
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Transmission: |
|
|
|
Main axle deflection limit |
|
|
0.08 mm |
Drive axle deflection limit |
|
|
0.08 mm |
|
|
|
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Shifter: |
|
|
|
Shifter type |
|
Guide bar |
|
Guide bar bending limit |
|
|
0.1 mm |
|
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|
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Carburetor: |
|
|
|
I.D.mark |
|
4TX 00 |
|
Main jet |
(M.J) |
#142.5 |
|
Main air jet |
(M.A.J) |
#60 |
|
Jet needle |
(J.N) |
5EI85-2/3 |
|
Needle jet |
(N.J) |
Y-2 |
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Pilot air jet 1 |
(P.A.J.1) |
#70 |
|
Pilot air jet 2 |
(P.A.J.2) |
1.4 |
|
Pilot outlet |
(P.O) |
0.9 |
|
Pilot jet |
(P.J) |
#45 |
|
Bypass 1 |
(B.P.1) |
0.8 |
|
Bypass 2 |
(B.P.2) |
0.9 |
|
Bypass 3 |
(B.P.3) |
0.8 |
|
Pilot screw |
(P.S) |
2.0 |
|
2-7
|
MAINTENANCE SPECIFICATIONS |
|
SPEC |
|
|||
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|||
Item |
|
Standard |
|
Limit |
|||
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|
|
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|
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Valve seat size |
(V.S) |
1.7 |
|
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Starter jet 1 |
(G.S.1) |
#75 |
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Starter jet 2 |
(G.S.2) |
0.8 |
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Throttle valve size |
(Th. V) |
#130 |
|
|
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|
|
Fuel level |
(F.L) |
15.8 16.8 mm |
|
|
|||
Engine idle speed |
|
1,050 1,250 r/min |
|
|
|||
Intake vacuum |
|
36.0 38.7 kPa (270 290 mmHg) |
|
|
|||
|
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Fuel pump: |
|
|
|
|
|
|
|
Type |
|
Vacuum type |
|
|
|||
Model/manufacturer |
|
4NX/MIKUNI |
|
|
|||
Output pressure |
|
10 kPa (0.1 kg/cm2, 0.1 bar) |
|
|
|||
Lubrication system: |
|
|
|
|
|
|
|
Oil filter type |
|
Paper type |
|
|
|||
Oil pump type |
|
Trochoid type |
|
|
|||
Tip clearance |
|
0 0.12 mm |
|
0.17 mm |
|||
Side clearance |
|
0.03 0.08 mm |
|
0.15 mm |
|||
Bypass valve setting pressure |
39 78 kPa (0.4 0.8 kg/cm2, |
|
|
||||
|
|
0.4 0.8 bar) |
|
|
|
||
Relief valve operating pressure |
343 441 kPa (3.5 4.5 kg/cm2, |
|
|
||||
|
|
3.5 4.5 bar) |
|
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Cooling system: |
|
|
|
|
|
|
|
Radiator core size |
|
|
|
|
|
|
|
Width/height/thickness |
|
300/180.6/27 mm |
|
|
|||
Radiator cap opening pressure |
75 105 kPa (0.75 1.05 kg/cm2, |
|
|
||||
|
|
0.75 1.05 bar) |
|
|
|
||
Reservoir tank capacity |
|
0.3 L |
|
|
|||
<From low to full level> |
|
0.2 L |
|
|
|||
Water pump |
|
|
|
|
|
|
|
Type |
|
Single suction centrifugal pump |
|
|
|||
Reduction ratio |
|
44/44 38/27 (1.407) |
|
|
|||
|
|
|
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|
|
2-8
MAINTENANCE SPECIFICATIONS |
|
|
SPEC |
|
||||||
Tightening torques |
|
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|
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Thread |
|
Tightening |
|
|
||||
Part to be tightened |
Part name |
Q'ty |
torque |
Remarks |
||||||
size |
||||||||||
|
|
|
Nm |
mSkg |
|
|
||||
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|
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|
|||||
Camshaft cap |
Flange bolt |
M6 |
16 |
10 |
1.0 |
|
|
|||
Cylinder head |
Nut |
M10 |
6 |
40 |
4.0 |
|
|
|||
|
Bolt |
M6 |
2 |
10 |
1.0 |
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Cylinder head cover |
Bolt |
M6 |
8 |
10 |
1.0 |
|
|
|||
Coolant drain bolt (cylinder body) |
Bolt |
M6 |
1 |
10 |
1.0 |
|
|
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Spark plug |
Ð |
M12 |
2 |
18 |
1.8 |
|
|
|||
Connecting rod |
Nut |
M9 |
4 |
48 |
4.8 |
|
|
|||
Rotor |
Flange bolt |
M12 |
1 |
130 |
13.0 |
|
|
|||
Camshaft sprocket |
Flange bolt |
M7 |
4 |
24 |
2.4 |
|
|
|||
Timing chain tensioner |
Bolt |
M6 |
2 |
10 |
1.0 |
|
|
|||
Radiator |
Flange bolt |
M6 |
4 |
7 |
0.7 |
|
|
|||
Delivery hose (crankcase-cylinder) |
Bolt |
M10 |
2 |
21 |
2.1 |
|
|
|||
|
Bolt |
M6 |
2 |
10 |
1.0 |
|
|
|||
Oil pump assembly |
Screw |
M6 |
6 |
6 |
0.6 |
|
|
|||
Oil baffle plate |
Flange bolt |
M6 |
2 |
10 |
1.0 |
|
|
|||
Drain bolt (oil pan) |
Bolt |
M14 |
1 |
35 |
3.5 |
|
|
|||
Oil strainer |
Screw |
M6 |
4 |
7 |
0.7 |
Stake |
||||
Stay (relief valve) |
Flange bolt |
M6 |
1 |
10 |
1.0 |
|
|
|||
Oil filter cover |
Flange bolt |
M10 |
1 |
30 |
3.0 |
|
|
|||
|
Flange bolt |
M6 |
1 |
10 |
1.0 |
|
|
|||
Ring nut (exhaust pipe) |
Nut |
M8 |
4 |
20 |
2.0 |
|
|
|||
Exhaust pipe (CO test) |
Bolt |
M6 |
2 |
10 |
1.0 |
|
|
|||
Exhaust pipe and frame |
Flange bolt |
M8 |
1 |
24 |
2.4 |
|
|
|||
Exhaust pipe and muffler |
Screw |
M8 |
1 |
20 |
2.0 |
|
|
|||
Muffler |
Bolt |
M10 |
2 |
24 |
2.4 |
|
|
|||
Crankcase |
Flange bolt |
M10 |
6 |
40 |
4.0 |
|
|
|||
|
Flange bolt |
M6 |
12 |
12 |
1.2 |
|
|
|||
|
Flange bolt |
M8 |
11 |
24 |
2.4 |
|
|
|||
Balancer shaft |
Screw |
M6 |
2 |
12 |
1.2 |
|
|
|||
Balancer holder |
Flange bolt |
M6 |
4 |
10 |
1.0 |
|
|
|||
Chain cover |
Flange bolt |
M6 |
2 |
5 |
0.5 |
|
|
|||
Drive sprocket cover |
Flange bolt |
M6 |
5 |
5 |
0.5 |
|
|
|||
Oil tank case 2 |
Flange bolt |
M6 |
2 |
10 |
1.0 |
|
|
|||
Engine bracket |
Flange bolt |
M8 |
2 |
24 |
2.4 |
|
|
|||
Crankcase cover (left) |
Flange bolt |
M6 |
1 |
10 |
1.0 |
|
|
|||
Starter clutch |
Bolt |
M6 |
3 |
10 |
1.0 |
|
|
|||
Clutch spring |
Screw |
M6 |
6 |
8 |
0.8 |
|
|
|||
Clutch boss |
Nut |
M20 |
1 |
70 |
7.0 |
Use lock washer |
||||
Main axle bearing housing |
Screw |
M6 |
3 |
12 |
1.2 |
|
|
|||
Drive sprocket |
Nut |
M18 |
1 |
70 |
7.0 |
Use lock washer |
||||
Drive axle cover plate |
Bolt |
M6 |
5 |
10 |
1.0 |
|
|
|||
Shift cam stopper lever |
Bolt |
M6 |
1 |
10 |
1.0 |
|
|
|||
Shift fork guide |
Flange bolt |
M6 |
2 |
12 |
1.2 |
|
|
|||
Shift arm |
Flange bolt |
M6 |
1 |
12 |
1.2 |
|
|
|||
Shift rod |
Nut |
M6 |
2 |
8 |
0.8 |
|
|
|||
Shift pedal |
Bolt |
M8 |
1 |
22 |
2.2 |
|
|
|||
Stopper bolt |
Bolt |
M8 |
1 |
22 |
2.2 |
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2-9
MAINTENANCE SPECIFICATIONS |
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SPEC |
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Thread |
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Tightening |
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Part to be tightened |
Part name |
Q'ty |
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torque |
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Remarks |
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size |
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Nm |
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mSkg |
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Stator coil |
Screw |
M6 |
3 |
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7 |
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0.7 |
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Starter motor |
Flange bolt |
M6 |
2 |
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10 |
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1.0 |
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Thermo switch |
Ð |
M6 |
1 |
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28 |
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2.8 |
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Thermo switch housing |
Ð |
PT1/8 |
1 |
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15 |
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1.5 |
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Crankcase tightening sequence:
2-10