Yamaha XVS1100 1999 User Manual [ru]

EB000000

XVS1100 (L)

SERVICE MANUAL

1998 by Yamaha Motor Co.,Ltd.

First edition, October 1998

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Y amaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Y amaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use.

Y amaha Motor Company , Ltd.is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Y amaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION:

NOTE: A NOTE provides key information to make procedures easier or clearer.

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 2nd title

: This is the title of the chapter with its symbol in the upper right corner of each page.

: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper right corner of the page. 3rd title

: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

T o 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

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

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

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

are given in addition to

the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.

General information

Specifications

Periodic inspections and adjustments

Engine

Cooling system

Carburetion

Chassis

Electrical

Troubleshooting

15 16 17

Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Ω, V, A

E004000

19 20

22 23

Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap base grease

Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply locking agent

and when to install new parts 25.

Apply locking agent (LOCTITE)

Replace

CHAPTER TITLES

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

GEN

INFO

SPEC

INSP

ADJ

ENG

CARB

1 2 3 4 5

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CHAS

ELEC

TRBL

SHTG

6 7 8

GEN

INFO

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTORCYCLE IDENTIFICATION

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number into the right side of the steering head.

MODEL LABEL

The model label information will be needed to order spare parts.

is affixed to the frame. This

GEN

INFO

is stamped

1-1

IMPORTANT INFORMATION

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

1. Remove all dirt, mud, dust and foreign material before removal and disassembly.

2. Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section.

3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4. During machine disassembly , clean all parts and place them in trays in the order of disassembly . This will speed up assembly and allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

GEN

INFO

EB101010

REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1-2

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1. Replace all lock washers/plates ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate.

Oil seal

GEN

INFO

and cot-

CAUTION:

Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.

Bearing

EB101050

CIRCLIPS

1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip edged corner thrust

Shaft

, make sure that the sharp-

is positioned opposite the

it receives. See sectional view.

1-3

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture, etc.

1. Disconnect:

 Connector

2. Check:

 Connector

Moisture  Dry each terminal with an air blower. Stains/rust  Connect and disconnect the terminals several times.

3. Check:

 Connector leads

Looseness  Bend up the pin nect the terminals.

GEN

INFO

and con-

4. Connect:

 Connector terminals

NOTE:

The two terminals “click” together.

5. Check:

 Continuity (using a pocket tester)

NOTE:

 If there is no continuity, clean the terminals.  When checking the wire harness be sure to

perform steps 1 to 3.

 As a quick remedy, use a contact revitalizer

available at most part stores.

 Check the connector with a pocket tester as

shown.

1-4

GEN

90890 01275

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly . Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country . In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes.

INFO

Tool No.

Weight

90890-01084

Bolt

90890-01085

90890-01135

90890-01229

Final gear

backlash band

90890-01230

Middle gear

backlash band

90890-01231

Tool name/How to use Illustration

Slide hammer bolt/weight

These tools are used to remove the rocker arm shaft.

Crankcase separating tool

This tool is used to remove the crankshaft. Coupling gear/Middle shaft tool

This tool is needed when removing or installing the final pinion shaft nut.

Final gear backlash band

This tool is needed when measuring final gear

/middle gear backlash.

Crankshaft installer pot/bolt/adapter/spacer

Installer pot

90890-01274

Bolt

90890-01275

Adaptor

90890-04130

Spacer

90890-04060

These tools are used to install the crankshaft. Piston pin puller

90890-01304

This tool is used to remove the piston pin. Fuel level gauge

90890-01312

This gauge is used to measure the fuel level in the float chamber.

1-5

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

T-handle

90890-01326

Holder

90890-01460

Puller

90890-01362

Adapter

90890-04131

Weight

90890-01367

Adapter

90890-01381

Ring nut wrench

90890-01403

Exhaust nut

wrench

90890-01268

T-handle/damper rod holder

These tools are needed to loosen and tighten the damper rod holding bolt.

Flywheel puller/adapter

These tools are needed to remove the rotor. Fork seal driver weight/adapter

These tools are needed when installing the slide metal, oil seal and dust seal into the fork.

Ring nut wrench/ehaust and steering nut wrench

This tool is needed to loosen and tighten the steering stem ring nut.

90890-01701

90890-03081

90890-03094

90890-031 12

Sheave holder

This tool is needed to hold the rotor when removing or installing the rotor bolt.

Compression gauge set

These tools are needed to measure engine compression.

Vacuum gauge

This gauge is needed for carburetor synchronization.

Pocket tester

This instrument is needed for checking the electrical system.

Engine tachometer

90890-03113

This tool is needed for observing engine r/min.

1-6

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Timing light

90890-03141

This tool is necessary for checking ignition timing.

Valve guide remover & installer

90890-04014

This tool is needed to remove and install the valve guide.

Valve spring compressor

90890-04019

This tool is needed to remove and install the valve assemblies.

INFO

Adapter

90890-01277

Shock puller

90890-01290

Weight

90890-01291

90890-04137

Wrench

90890-04138

Holder

90890-04055

90890-04062

Crankshaft installer bolt adapter/armature shock puller/weight

These tools are needed when removing the final pinion shaft.

Bearing retainer wrench

This tool is needed when removing or installing the middle drive shaft assembly.

Middle drive shaft nut wrench/Middle drive shaft holder

These tools are needed when removing or installing the middle drive shaft bearing.

Universal joint holder

This tool is needed when removing or installing the driven pinion gear nut.

Bearing retainer wrench

90890-04077

90890-04086

This tool is needed when removing or installing the final drive pinion gear assembly.

Clutch holding tool

This tool is needed to hold the clutch when removing or installing the clutch boss nut.

1-7

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Damper spring compressor

90890-04090

This tool is needed when removing or installing the damper spring.

Dynamic spark tester Ignition checker

90890-06754

This instrument is necessary for checking the ignition system components.

Yamaha bond No.1215

90890-85505

This sealant (bond) is used on crankcase mating surfaces, etc.

INFO

1-8

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-21. . . . . . . . . . . . . . . .

ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS

SPECIFICATIONS

SPEC

Item

Model code: XVS1100: 5EL1 (For Europe)

5EL2 (For D, A, FIN) 5EL3 (For Australia)

Dimensions:

Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius

Basic weight:

With oil and a full fuel tank

Engine:

Engine type Cylinder arrangement Displacement Bore  stroke Compression ratio Compression pressure (STD) Starting system

2,405 mm 895 mm 1,095 mm 690 mm 1,640 mm 145 mm 3,200 mm

274 kg (5EL2 : 275kg)

Air cooled 4-stroke, SOHC V-type 2-cylinder

1.063 L 95  75mm

8.3 : 1 1,000 kPa (10 kg/cm Electric starter

Standard

, 10 bar) at 400 r/min

Lubrication system: Wet sump Oil type or grade:

Engine oil

Final gear oil: SAE80API “GL-4” Hypoid Gear Oil Oil quantity:

Engine oil

Periodic oil change With oil filter replacement Total amount

Final gear case oil

Total amount

Air filter: Dry type element

Temp. C

API standard:

“SE” or higher grade

ACEA standard:

G4 or G5

3.0 L

3.1 L

3.6 L

0.2 L

Fuel:

Type Fuel tank capacity Fuel reserve amount

Regular unleaded gasoline 17 L

4.5 L

2-1

GENERAL SPECIFICATIONS

Item Standard

Carburetor:

Type/quantity Manufacturer

Spark plug:

Type Manufacturer

Spark plug gap Clutch type: Wet, multiple-disc Transmission:

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Transmission type

Operation

Gear ratio 1st

2nd 3rd 4th 5th

Chassis:

Frame type

Caster angle

Trail Tire:

Type

Size front

rear

Manufacturer front

rear

Type front

rear

Maximum load-except motorcycle: 201 kg (5EL2 : 200kg)

BSR37/2 MIKUNI

BPR7ES/W22EPR–U NGK/DENSO

0.7 X 0.8 mm

Spur gear 78/47 (1.660) Shaft drive 44/47 19/18 32/11 (2.875) Constant mesh 5-speed Left foot operation 40/17 (2.353) 40/24 (1.667) 36/28 (1.286) 32/31 (1.032) 29/34 (0.853)

Double cradle 33 136 mm

With tube 110/90-18 61S 170/80-15M/C 77S BRIDGESTONE/DUNLOP BRIDGESTONE/DUNLOP EXEDRA L309/K555F EXEDRA G546/K555

SPEC

Tire pressure (cold tire):

0 X 90 kg (0 X 198 lb) load *

front rear

90 kg (198 lb) X Maximum load *

front rear

Brake:

Front brake type

operation

Rear brake type

operation

200 kPa (2.00 kg/cm2)

225 kPa (2.25 kg/cm

225 kPa (2.25 kg/cm 250 kPa (2.50 kg/cm2) * Load is the total weight of the cargo, rider, passenger and accessories.

Dual disc brake Right hand operation Single disc brake Right foot operation

2-2

)

GENERAL SPECIFICATIONS

Item Standard

Suspension:

Front suspension

Rear suspension Shock absorber:

Front shock absorber

Rear shock absorber Wheel travel:

Front wheel travel

Rear wheel travel Electrical:

Ignition system

Generator system

Battery type

Battery capacity Headlight type: Quartz bulb (halogen) Bulb wattage  quantity:

Headlight

Auxiliary light

Tail/brake light

Turn signal

Licence light

Meter light

Neutral indicator light

High beam indicator light

Turn indicator light

Oil level caution light

Engine warning light

Telescopic fork Swingarm (link suspension)

Coil spring/Oil damper Coil spring/Gas-oil damper

140 mm 113 mm

T.C.I. (digital) A.C. magneto GT14B-4 12 V 12 AH

12 V 60 W/55 W  1 12 V 4 W  1 12 V 5 W/21 W  1 12 V 21 W  4 12 V 5 W  1 14 V 1.4 W  2 12 V 1.7 W  1 12 V 1.7 W  1 12 V 1.7 W  1 12 V 1.7 W  1 12 V 1.7 W  1

SPEC

2-3

MAINTENANCE SPECIFICATIONS

ENGINE

SPEC

Item

Cylinder head:

Warp limit

Cylinder:

Bore size

Measuring point

Camshaft:

Drive method

Cam cap inside diameter

Camshaft outside diameter

Shaft-to-cap clearance

Cam dimensions

Standard Limit

SSS 0.03 mm

95.00 X 95.01 mm 40 mm

Chain drive (left & right)

25.000 X 25.021 mm

24.96 X 24.98 mm

0.020 X 0.061 mm

95.1 mm

SSS

SSS SSS SSS SSS

Intake “A”

“B”

“C”

Exhaust “A”

“B” “C”

Camshaft runout limit

39.112 X 39.212 mm #1: 32.093 X 32.193 mm #2: 32.127 X 32.227 mm

7.162 mm

39.145 X 39.245 mm

32.200 X 32.300 mm

7.195 mm

SSS

2-4

39.012 mm #1: 31.993 mm #2: 32.027 mm

7.012 mm

39.045 mm

32.100 mm

7.045 mm

0.03 mm

Item Standard Limit

Timing chain:

Timing chain type/No. of links

Timing chain adjustment method Rocker arm/rocker arm shaft:

Bearing inside diameter

Shaft outside diameter

Arm-to-shaft clearance Valve, valve seat, valve guide:

Valve clearance (cold) IN

Valve dimensions:

MAINTENANCE SPECIFICATIONS

SILENT CHAIN/98L Automatic

14.000 mm X 14.018 mm

13.985 mm X 13.991 mm

0.009 mm X 0.033 mm

0.07 X 0.12 mm

0.12 X 0.17 mm

SPEC

SSS SSS

14.036 mm

13.95 mm

0.086 mm

SSS SSS

Head Dia Face width Seat Width

“A” head diameter IN

“B” face width IN

“C” seat width IN

“D” margin thickness IN

Stem outside diameter IN

Guide inside diameter IN

Stem-to-guide clearance IN

47.0 X 47.2 mm

39.0 X 39.2 mm

2.1 mm

1.2 X 1.4 mm

1.1 X 1.5 mm

7.975 X 7.990 mm

7.960 X 7.975 mm

8.000 X 8.012 mm

0.010 X 0.037 mm

0.025 X 0.052 mm

Margin Thickness

SSS SSS SSS SSS

1.8 mm

0.8 mm

SSS SSS SSS SSS

0.08 mm

0.10 mm

2-5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

SPEC

Stem runout limit

Valve seat width IN

Valve spring:

Free length IN

Set length (valve closed) IN

Compressed pressure IN (installed) EX Tilt limit IN

SSS

1.2 X 1.4 mm

44.6 mm

44.6 mm 40 mm 40 mm

160.7 N (16.4 kg)

SSS SSS

0.03 mm

2.0 mm

43.5 mm

SSS SSS SSS SSS

2.5_ /1.9mm

Direction of winding (top view) IN

Piston:

Piston to cylinder clearance

Piston size “D”

Measuring point “H”

Piston off-set

Clockwise Clockwise

0.025 X 0.050 mm

94.960 X 94.975 mm

5 mm 0 mm

SSS SSS

0.15 mm

SSS

SSS SSS

2-6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

SPEC

Piston pin bore inside diameter

Piston pin outside diameter Piston rings:

Top ring:

Type Dimensions (B T) End gap (installed) Side clearance (installed)

2nd ring:

Type Dimensions (B T) End gap (installed) Side clearance

Oil ring:

22.004 X 22.015 mm

21.991 X 22.000 mm

Plain

1.5 3.8 mm

0.3 X 0.5 mm

0.04 X 0.08 mm

Taper

1.2 3.8 mm

0.30 X 0.45 mm

0.03 X 0.07 mm

SSS SSS

0.8 mm

0.1 mm

SSS SSS

0.8 mm

0.1 mm

Dimensions (B T) End gap (installed)

Connecting rod:

Oil clearance Color code (corresponding size)

Crankshaft:

Crank width “A”

Runout limit “C”

Big end side clearance “D”

2.5 3.4 mm

0.2 X 0.7 mm

0.044 X 0.073 mm Blue Black Brown Green Yellow

1 2 3 4 5

101.95 X 102.00 mm

SSS

0.320 X 0.474 mm

SSS SSS

SSS

0.02 mm

SSS

2-7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Clutch:

Friction plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch spring free length

Quantity Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit

Transmission:

Main axle deflection limit Drive axle deflection limit

Shifter:

Shifter type

Carburetor:

I. D. mark Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Needle jet (N.J) Pilot air jet (P.A.J.1)

(P.A.J.2) Pilot outlet (P.O) Pilot jet (P.J) Bypass 1 (B.P.1) Bypass 2 (B.P.2) Bypass 3 (B.P.3) Pilot screw (P.S) Valve seat size (V.S) Starter jet (G.S.1) Starter jet (G.S.2) Throttle valve size (Th.V) Fuel level (F.L)

Engine idle speed Intake vacuum Engine oil temperature

SPEC

2.9 X 3.1 mm 8

2.5 X 2.7 mm 1

1.9 X 2.1 mm 7

7.2 mm 1

0.05 X 0.40 mm

0.010 X 0.044 mm Inner push, screw push

SSS

SSS SSS

Guide bar SSS

5EL1 00 #1: #110, #2: #112.5 #55 #1: 5DL39-53-3/5, #2: 5DL40-53-3/5 P-0M #63.8 #145

1.0 #17.5

0.8

0.8 3

1.2 #42.5

0.8 #125 4X5 mm 950 X 1,050 r/min

34.7 X 37.3 kPa (260 X 280 mmHg) 75 X 85_C

2.8 mm

SSS

0.1 mm

SSS

0.1 mm

6.5 mm

SSS SSS SSS SSS

0.5 mm

0.08 mm

SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

Fuel pump:

Type Model/manufacturer Consumption amperage <max> Output pressure

Electrical type UC-Z6M/MITSUBISHI

0.8 A 12 kPa (0.12 kg/cm

2-8

SSS SSS SSS

)

SSS

Item Standard Limit

Lubrication system:

Oil filter type Oil pump type Tip clearance “A” or “B” Side clearance Relief valve operating pressure

Shaft drive:

Middle gear backlash Final gear backlash

MAINTENANCE SPECIFICATIONS

Paper type Trochoid type

0.03 X 0.09 mm

0.03 X 0.08 mm 450 X 550 kPa (4.5 X 5.5 kg/cm

0.1 X 0.2 mm

)

SPEC

SSS SSS

0.15 mm

SSS

SSS SSS

2-9

Lubrication chart:

MAINTENANCE SPECIFICATIONS

Item Standard

SPEC

2-10

MAINTENANCE SPECIFICATIONS

Cylinder head tightening sequence:

SPEC

Crankcase tightening sequence:

Left crankcase Right crankcase

2-11

Tightening torques

size

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Cylinder head Cylinder head Plate Cylinder head cover Cylinder head (exhaust pipe) Rocker arm shaft Camshaft sprocket cover Tappet cover Rocker arm shaft (oil passage) Stopper plate (camshaft) Spark plug Cylinder Lower cylinder head cover Upper cylinder head cover Connecting rod Rotor Valve adjusting locknut Camshaft sprocket Timing chain tensioner Timing chain tentioner cap Timing chain guide Oil pump Oil strainer cover Oil filter cover Oil pump gear Oil pump cap Oil deliuery pipe (cylinder head)

(crankcase) Drain bolt Carburetor cover Air filter case stay Air filter case assembly Exhaust pipe joint and cylinder head Exhaust pipe joint and muffler assembly Muffler Crankcase (cylinder) Crankcase (cylinder) Crankcase Crankcase Bearing retainer (middle drive pinion gear) Crankcase cover (left) Crankcase cover (right) Clamp One-way clutch Primary drive gear

Part name

Nut Nut

Bolt

Screw

Stud bolt

Union bolt

Bolt Bolt Bolt Bolt

— Bolt Bolt

Screw

Nut Nut

Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt

Union bolt Union bolt

— Bolt Bolt Bolt

Nut

Bolt Bolt

Stud bolt Stud bolt

Bolt Bolt Bolt

Bolt Bolt Bolt Bolt

Nut

Thread

M12 M10

M8 M6 M8

M16

M6 M6

M16

M14

M6 M6 M6 M9

M16

M10

M6 M6 M6 M6 M6 M6 M6

M6 M16 M10 M14

M8 M10

M12 M10 M10

M6 M20

Q’ty

8 2 2 4 4 2 4 8 4 4 2 2 6 8 4 1 4 2 4 2 4 3 3 5 1 1 2 1 1 2 2 3 4 2

2 8 2 3

13 11

1 8 1

Tightening

torque

Nm mSkg

50 35 20

12.5

37.5 10 10 38 20 20 10 10

175

27 55 10

10 10 10 10 12 10 20 20 43

10 20

20 25

24 20

38.5 10 25

10 10 10 12

110

5.0

3.5

2.0

0.4

1.25

3.75

1.0

3.8

2.0

1.0

0.5

4.8

17.5

2.7

5.5

1.0

0.8

1.0

1.2

1.0

2.0

4.3

0.7

1.0

0.2

2.0

2.5

2.4

2.0

3.85

1.0

2.5

1.0

1.2

11.0

Remarks

Use lock washer

2-12

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