Yamaha TZR125 &
DT125R Service and Repair Manual by Mark Coombs with an aclditlonal chapter on the 1997,00 DT125A mode...
185 downloads
1055 Views
23MB Size
Report
This content was uploaded by our users and we assume good faith they have the permission to share this book. If you own the copyright to this book and it is wrongfully on our website, we offer a simple DMCA procedure to remove your content from our site. Start by pressing the button below!
Report copyright / DMCA form
Yamaha TZR125 &
DT125R Service and Repair Manual by Mark Coombs with an aclditlonal chapter on the 1997,00 DT125A models by Phil Mather
Model. covered TZR125. 124«. M arch 1987 10 AugusI 1993
DT125 R. 124cc.April l 988on
M...,
Not..· rht/ TZR 125 R. IflltOducr!d in April 1993. IS nor
( 1655 - 11AB5)
Heyn" PYbl ishing Sparkford Nt Yeovil
Somerset BA22 7JJ England H.yn" Public'tion" Inc 861 Law rence Dfive Newbury Park California91320 USA
ctJ~tlnId
by this
AdlnowIedgem_ts Our IMnb _ due to APS MoIoteydeI; of w.... s-w.... n ~ MotooqodM of PoeM. 00rMI. wno IU!lPIied the ~ '-'nd in
1l1li Manuel ThIonI11 Yamaha TZ RI 2 S and
0T12S R mod.l, ModfIl dimensions and _'lIhts O,dllfing ' PI'" parll
Saletv ",.." ToolI and wOI'k,ng 1I,,;:"i,... Span,...,.
Ii., comPII"lOn
Standard 1000qutl letting. ChOOSIng Illd lott Ing accesso,,"
Faull diagnosis Roullne lnIIintenanc.
Ch I p", 1 Eng,ne, clutch and
gearbo~
Chlpte.2 Cooling system Chapter 3 FLIfI! Jy$tem and lubtiCition
"" "" " 39
" 78
Chapter 4
Ign,uon 1y$lem Chapt.r 5 F.ame am:! forks
"
..
Chapte r 8 Wheel., brakes Ind Iy\'M Chlpter 7 Elect!lcal system
Chapt.r 8 The 1997-on DT1 25 A models
",
""
Wiring diagram.
144
Convention factor.
151
Index
152
v....aII. TZR12SIlPC1! modIl
v......... DT125 A IlANZ) model
About this manual The purpose of this manuel is to Pee it rnede 'See Section 6.10' h meen, Section 6. ~.agraph 10 in the _ Chap' .... H I/IOt"" Chapter were Intended. the Allerenc. would ..-d. lor e x..... pie, 'See Chapu" 2, Section 6. 10'. All the photograp/ll ar, f;lptioned Ind right·1>and description, of the n"IIChTneI and their the ride< ", ... lIed nonn.lly. Motorcycle meno.AKIU ...... conl~".,.h cI\engeI to specIIicItlon •• nd racommendatlonl. and theM, wi*> notified. Ire incorporated into DUI' men ...... " the ee. clo.h and reINse the P',",ur'g,Mlu,11y ,,,... 01 you....., get scalded by esc'PI"" coolant CON 'T IttemPl to d"m oi' unll' you ,r, IUr' I' t.aa cooltod sullie ..""y 10 avf)Id scald'ng you . CON ' T grasp any JNlf1 01 ,he eno,ne, a.he"'t 01 a.olencer wlthou. hr., esc6r1a,n'ng 'h81 I' illlUll':l... d~ cool 10 ...00 bu,n,"II ~ou. DON ' T b convunlent wortlng hel;ht. ThB wotkbench Dr tabl, .hould be equipped with 8 vice whim the .pecIoli~ed category when he leeI,the e.~ Ie jullilled by the amount of UH theae toob; wiN be put to. II is obuious/y r>OI possible tri bits &llpeIn~ - 21b
H~wqun/olJ S8H~ pJitn Pf~
Mole {Jfip& or va {Jfip&
combinetKN!
Pf~
_
f1Hd,.1lO8I
1 Tools and working fa ci lities W,,,, brush (small) Safr·brisrledbrush
ShOp. An altsmativ8 is for a group of friend. or 8 motOfCYCle club to join in the purchsse.
Tyrepump FlvwhOf!I rotor pu/~r
Ty", preSSUffl gauge
TyffJ I"",d depth gauge
Clutch holding tool
Oi/elfn
Pis/on ring compressor Univf1fS8/ be/mng pu/~r Cylmder bore honing atriIChmtmt (for e/e\11 0< boil. Badly rustOO fasteners may have to bechiseled off 0' removad with a special nul breaker, available 811001 sllop$. Flat W8.hers and lock washers, when removad from an assembly should alway. be 'eplaced exactly a5 removed. Replace any damllged washers wilh new ones. Always u,," a lIal washer between a lock washer and any soft metal sur/aco 15""h aluminium), thin sheet metal Or plastic, Speciollocknuts can only be used once 0' twice b. I,bIe below.
Fu".... IVpe (11).ead d;'mele'eI In I'" ,.onl brlk......1... eylinder • ..,...... ....... 10 8\Ioid InV ttltnc. 01 .... entering lhe hydflUlIc: . .... tem. Alto c:hecII !hal IhI cebfoM; ... edjlA;.ed c:orr.o;Ity end 1"" .. hendIebar O(lnlfolll ".,....11 COITK.ty and CIrl be .-iIy ...,hed when
......
"""'''''''
CrMhbers. Il1o knowtt .. engone PfOlec:lOf bani. IngIne guerds, Of c..e ............ It>CINmIIy UMfulI! ...... 0I11QUipmem whido CIrl o;on.
lribule protect_lo the mec/'Iine'l .lfUCl.... it I CfHh OCt .... n..y. not. .. t>H been inl .... eeI in thl US. po ........1 IhI rider lrom crashing. 00 nee_'iIy preII ....1 ride. Injury should s ul6h occur. II Ie .ecommended Itltl only '''' ......... .,..ter. eng;"" protlCtor type 01 c.1Ihbef Is eor.ideJeeI. This type ¥oil off« proteclion while ... tncl"'llo"~lo. .. IsPOUible._lotheengoneendthelT\lc:h!ne·. ground deer...,;e. The~ should be deIIgned lor .-specH"1CIIy CII'I yoo..- mec:hint. end should be _lfUClMI of ........,~ tuboflg WIIh 1\lOng, 1m", mounlong brKbtI. Whetw PQI:IibIe. lhey should bolt 10. IlI'Ong lug CII'II ... , ...... ......-ltv It !he eng"" mounling bolts. The 111_...... type of aasnt.r iI the IIrVI' CIgI type.. This Iype Is not recommended in lPiIe 01 their ~ which promiIeI _ PfOllII:Uon '0 t ... fide< III well .. 10 the IT\Ic:h' .... The teroe' smounl 01 ......... lmpQlld bV Ihllire 0' thlltypeol c.I6h"-. Inc_lhe rl.k 0' ......... lrame dam&gfl in !he ........ 01 an ec:c:idenl. This Iype Il1o dec:_ IhllT\Ic:h!ne'. ground deer.nce....:l '.lncl.1CCISI 10 lhe engine T .... amounl 01 proteebon IftoI'dIId Ihi rider iI 10 _ doubt .. lhI dIIogo Ie bIIed on .... prIrTIIIIl .... IIIe rider wiIIltay in'he ~ _ed poIItlOf'l during anll::Ciclenl. end the cnsI'I bIr .INCI .... .... not iIMfllti. Neolhlt rMlAt can in InV w~ be "u...."'.... .... I e-nerel f\IIe. etways ~ the but. III ......-ltv the In»I I>H been cerried (IU~ and 1....1 particular mlk' should be l\fOIded . 01 .... fectotl to be borne In mind ere wtlethe. ,''' 1.1'IIuI1 .ysl..... slow. the .... 01 both cen!.. Ind .1de.\Inds. whll ....
ChOOIJlng .nd fitting .ee."
• tIIIows lUlf'oc_t _ _ 10 peg tlt>g- CIMock the b l herght. and mMe ...... nec-v edJUStmen!II.Aillltingllolt wiII_ an nco- on I........... and u...
...............
• CokIIIIect the choIr;. til..,. ~ lor correcl ~oon If the ~ jIms on !tie 'On' poI#\oon ...... quent IIl11ing 01 • hot . . . . . wiI bIo d,fI"ocutt • BIocted .... fit. A bIdIV rMlflCIed ... filter ... ClUMlfIooding. CIMock the filter end dun o r . -. . req";'ed. A coI8pMd onIet hoM wi ........ I .......... effecl. CIMoct lhellhe ... Iitt.. inlet hal 001 become blocked by • .eg or similar ;1....,
1 COmp'....1on low
• SsHrt plug 100M. T.... wiI be oeIf...-.nden1 on inlpe(:11OII, and n'III'f be ICCQmI)Inred by ...... ng noiM when the en.g;... ilr lurned 0\11". Rem<J\/'I the plug Ind check tM! the tlvNdl in the ~ held ... not dIn"IIgId. CIMock eIto tn.t the plug MIIing w ....... in IPJd condihon. • Cylinder held gIIket INking. T"" c:oncMion. otten.,.;omplAied bv , hogh pitched IqUMII; from IfOInI the cylinder hied and oIIloe1, - ' rmv be -.-d by ~tlV tighlened cylinder hied I..t _ I wwped cyIindrIt held 0< ~ I..... of Ihi gIIket mlierili.
Re-I~ the f'''_10 the oorrect specif\Cltoon rmv MIl the INI< in ..... i n I _ bul If dImIge .... oc:c:....-..IlhiI-..... of lC1ion wII
p~·~.l~'~"'3 §i!l-,_I.'~·3C'~1 ,~I ~. 1~'ll,' ~., . ",Hf"l,o§:q ~ ~ 23"'g-~ ~~3i"~j~~~~· :·ii~~ ! : "~ i ~~'H~ I. §HhHHI g'!1il3~i~S~i I riil!!~I~~~'i!ll~ ~ 'it j g ~ .. !f~l!~frll~~ir ~i~i ~ '" ;",2- 1 ,..i !!I ~ ~ • .~~·II I·tial··I· ~F!'i~'-!··!.h ~~h. ~ ~ ~l-~ i~S~ -t!;! ! ' " ,.
Fuel/air mlxt ..... Inc:Of'ect
• "It
be <eQUired.
rrh .. bIdIv litted Of omolled. O>eck tnII Ille fiI, ..........., ;. in pIKe and lilli, and ,he ...ur.!. lilter 110. cove< er.....rng OOIfeclly. Arrf _1 _ _it.WNltmi.I • Induc,ion 10.....a. O>eck lhe ..,;urirv 0 1 the t;erbure\IOf mounli. . and hoM COMICliona, and lor erae ... and IJI/ill in lhe '-n. ChICk &Ito IlIItlhe CII.bu.. nOf lOP it; ..,;ure. • Fuel level 100 low. See Section 3. • Fuel I..... k lillerCilp lit ""'" oborllUC,ed. C\eer bIoo;I!lg4I.
"
Clutch IIIlp
• No cknctllev.. play. Ad)"'1 clulCtl "",,,. end ~ KCQrd",O 10 lhe procedu.e In Rouu ... mainlenance. • Fnctlon pial" wom Of wa.ped. Oveffiltrl clulttl ..sembly ••e-piKing pial" OUI of epeelfallon. • PIa", pial" worn Of werped. 0vert\IuI clutttl -..b/y. ~ing pial" OUI of epeci!allOO. • Cluten spU$hood. nec.....-y • Outetl """ .. &rid out.. d""" worn. Severe IndenliliOn by lhe clulctl plale 'angII 01 tllecl\lnntl.1n lhecentg of .. WI, r-..II from .. mI$Md ge.rc...... or ,.... selection II hogh ~. • Selector fort end tnd pin _ Pronounced _ of , , - it..... rd
_"UIIIty. no MlKlion. A..-aI of the worn c:omponentl will be
.......
"'Iion
• Slrucnnl lltilufe. f ...... 01..., one component 011 .... oeIIctor rod ..-.d chIongIo mechanWro.vil tMUIt In Imptoptor Of 1"""'-'1 gNI'
• Del","...., -..bIy worn or~' W_ of IN Mm tnd !he ~ wolh which it 1Dc:Io,.. 1tnd twlllllegto of ,......,""' sprong c.n _ _ impnoc:. . gotar '-':110" I'MI>It.ong in iurnPonQ OUI 01 gMr. A _ "'"
• GMr p;n;on aog. worn Roo.ndIng oft the dog odgIIII.-.d --~ the mMlng . - In MlIK*'I pillion INd 10 .... , of gear 01 ~.
Ron
~
when under !oed. The ~ IhouId be intp«1ed ..-d ..--.cI. AItempting 10 .-prof.,he dogIiI no! , _ , • Selec:IOI lon. .. drum end pinion IIfOCI'Y'" worn. Exl...,... _ of t ' Inten:onoec:led It..... c.n 0CCUf .tl" hogh .......,.. ~ wI1ett lubrical;on .... bHn neglec;IMI. The _ n C()InpDniIflIl iTIUIt be . .
.,,,,oded
-". • -
pinion-. bv"- end an.tlli worn. R _ lhe wom component.. • Benl llN'Chenge ""'1. Ollen c:au..d by d,opp;ng the machineOouId be looIi:ecllor
Wi'"
:
;
Ii I
Abnormal trlJnsmission noise
" ""'''' ..... • Clutch outer drvnVfnctlOtl pille "'''' c:IMr...ce ... ~ • Clutch OUI. drumiItvuIl ......... clIIr..- e>.IIInce. E'ther COf\dition. paflicular1y In the lronl Iy ... win promota shakingof tho! fO
~~.
II
..
-· :Ea~
I·' I fj ~Ii i!~! iH ~ !; hl -!~J • it!" • • ~ h~ ?'
H, • ;g.i ~ &!t
- II
:! :;:
1:;d ~:;.
_ ..
a:~o h,
i.~
itit,
qiE :l§!i: at 3 ii"=
HI[ H Hi Iii §l ~~
i=:~. ~!f
i •• ~ .
111~~i O ~r~~' O !ii:l O lil!:lII O ['r~! O
•
f~r~!~ci:i~~~ti~§. ~ ~s~~fti~f~OI~:aa:
~ 3-
'hi' ' 1•~~H~h!~ IjIi.d, h,~jllul' -!.! ~ Ii:
~::i;"'J:
::!:
!\~[U
3
3· [~.
i
t ~. !.'"
i
~ c· a. i
1:.& _ ail" ~_
i;-m
~~~mi~?t:il~~!w·[fi'·h hi~[
i•
!ti"!;-~0i5~~
i ~ ,
;'1,. ,
!'
a '"
g
H~ ~ l
-~~
f
i -
~l
x
~
n ••
~
.
_~,-
~i l~~i Ie"~ •.~~~_ ~p.~~ a:i. E~~5" "· . [I' "~Iit~~ I~ il·•• _I III f:l'· _", .i i" -[ • !
~!
_~
,~jl:
'~~'[ &!t ~ ~~
~
~
2.~
. ", 'o!
~~
~
t~Esi'" .. ~i~
!~
-~ !~ ~
o~
it';'·· I ·
i"'is
" ."
J~i; ~ . I~~~l ~f ;~[~
ii
!!~.~ il ~~f; ~~! "I' '§ -.~~ {"I~! §i '§ .~, 1 3" _ !• !, ,3!a'l •·
;jl,
.. !
Ii,'IJ
~
.. ~o· ~ ·
t
-.. ,_..'1or' .. '. -
il~!'l~.
I'll
~ .
~
~ - &~,.
h
"!
ili~i
•
~F.\'i
..
~.l
. ..
'JI ~.
~.
~I
... ... ~
~
~
~
3
~ e '5i e
!
F"~" ;' g. -I ~. ~if• C:"'i~~
8 !![~
~. ; . !t
~lh
t ,i
§
lila
. i'
i, f
~n~Sl
00
(fl·.
~~.
j
'j'i' i
~'.o. ""-8 i ~
~
f. iii ~ ti.! 2 •[ -I
""rI'T ~'''-[' II- ' .' ~ it .. ~.
!l.
~~ ~ ?· is.~
." d, '\ { .;n ~..,
2' _
~
~l Q
§
.~
~. ~! l~
j :I
'l
h
i.
- I ' , •i. i[.f ![.[il .!-[~=- ~".~. R· ~ ~ ;i" ! iHi" I;. sl_1-
~ ii
-ldr
=i
~.
~ ~- ~.
h t [
! !. 1" ; ~ [ . ;;. i~
!{
0
.l!
I
dh~a ;ml~i! hUIH ~HF !i,.ii~ .itW~' .if, •• I,i •• i, •• ~
{, ~ for. Oll o!.r· OlO•• O'O•• O o '~-[' 1 -" ~' ~ t~!~fi ~i!~i~!~.;~&3[~ •• [.IJ·I '3' · • ~i[I!I:I. ' I If~ ' t :I~ l~"a~§~t - ~ ~3..IJiil l ·d~,e~i. ~l! ; * "W f ,.••• j'. • - I ' !'-'~ , ~f~! '
~i3..!;· i~S.,.
~!f~~!.J ~;~,tIH!b.!hIU -(!~I;~ j!g![tl:l!i~li~~~ ~~~~.t~ 1(II'i~el~;!'~!!11 H,ll.si ";:h'i"'~ § ' ~"'" '~IIII' ··~~I· I .l 1[11'CIpI.. 1Q.
Iound 10 bt
7 Check th8 controls o-k I.... Ihronll8nd dutcll cablel and Ieve<s. t .... gear liver and I.... fOOl...11 10 . . -.. lhet lhey .re Mljualed COfT1IClly. funclionlng correctly. 8nd 1.... l l hey ... _ety I.tllled II. bolt .. QOII'III IO won: 100M. 0< • CIbiIINj). it .. betl er 1....1 It ;. diIcovertd 111M ItIQII WIlh till whiJe purct\MIog. pocket gMIgII fof thos purpoH bK..-the ~
on gw-.ge fo,~ ~ ... nC)I(lfioul1y
pr-..... IhouId be chec:ted
w"h the
tyfe. cold.
INccunot. The mileI
Even • f_
1.......,_~upthetvr-IO.poinIwt>e<e~IrIc_8nd
"'~.~wilresuh
Allhe ....... time .. \hI Jyfe ~ _ chlcked. ex .......... lhe lyrIIl ............... o-k lhem 101 dIoInaQe. npeciIIIV for qJIiIMQ of the ~ .~ .tonw 01 othe< roed debri. c.ugM ~ lween the 1...0.. Th"" I*!OC:ut.rty Import.nt on lilt ' IUI' Iy ... whe il found to be worn out. Of il any bnb are klnkad Of It~1 t/wOlJ9h IItck of lubrication. Of If damage IUCh asaplit Of milling rollers Of ...:Ie plates is found. the chain muSt be ,_ad. This should be done .Iw~ys in COI»UflChon with both sprockets &lJ'ICe the rumling tOgEUI>er of new and pan·worn components g.eatly inc.eases the fata of wear of all three iterm, resulling In even goruter e~pend;tu.e than l'lllClluary. When pun;h ... ng • new chalI> .lways quote lhe lize. lhe I>"",be< of ~nk •• 0000001fed and the machine 10 wh.ich the chall> It to be finad. Standard chain I"es are given in the SpecifICatiOn. Seeliol> of Chapter I. bul note thltl the gearing may well heYe beer> aUe lubricanll can be .pphed. wh,~ the cha'I> is In ptace on lhe mlChine. II should be applied II lealt 0fICCI 8 week. aNI daoIy if the machine is used in wet _athe< condition •. Engine oil can be uted IOf this task, but remembe< that it il flung off the chain far more e_1y than grellSll. t""'- mak,ng the '88. end of the machine un_rily dirtv. and reqtJ"es mo<e freq .... nt app!lcahon If it it perfOfm itl t.... ltdeQuately. Also remembe< that sufplus oil wijl eventually find ill way on to the tyre. w,th qu,,, diSlltrouti CGnII'IqIItmCM. While thto will serve III estop-gill' meiKOre. it doel not reach the in"'" bear'ng surlaceo of the chain. These can be lubric.lltad correctly only by removing and clean,ng the chain .. described above and by imrn&rSing II in " motlen bIIth of spe the sprockel•. tHllng aIor>g the enti.e length of tha ehall>. When the lightHl1pol has beer> found. me8su.e the total up and down moveme... available; thil should be between the ~mill gi"",,1n the SpecifIClIIOnl if nQl tha chaln mult be IIdjusted as loIIowt. T2Jl modal Remove lhe splil pin and lIacIoen lhe .ea. wheellpindle nul by juSt eough to PII!I<mit the spindle 10 be moved. On late. models w ith a disc brake 81 lhe fear it will also be noceuarv to slacken the brah e.IiPl!< mounting bolt to allow the ealiPl!< bracket 10 move freely. Stackan tha chain adjusler IocknulS and tightel> both d.awbolll equally to draw the spindle back by the fequi. ed amount to Ulke up e~cetllchaUl slack. To preserve 1ICCU,.te wheelaligl>mel>lansure that lhe notches lIamped in lhe chain Idjulte<s line up with lhe same lines lIamped on each Iw'nging arm fort end. Whal> tha chain is COtflClly ten&iOfMtd. tightel> the whaellpindle rnn 10 the lpecifoad torque selling and fit . new split pin. Note thaI on modell with a drum braka II will be necHsary to apply lhe rea. brake flrmly tocentf.lise the brake thoeI whOlSt the nul is tightened. Addilion· any it might .Iso be necKUlY to adjust the .ear brake and Slop lamp , Wlld! ~ the chain has beer> IlI9nificanUy adjulled; lhese Ml1,ngolhould be checked befOfe taking the machine on tha foad. rtgt>len the lIdiu"., Iocknu, • ..-d brake callpe. rr:tOUf>t'ng b
Check the spark plug Thelpart plug ....ppliad II original equipment will prOIf8 utislactory In mosl opeIliloy closely. Tho J>Illiev Ihotrld stan 10 ,otate jusl as Ihe throttle cable lakfll up ilS free play and 118ns to lift lhe throllie valva. FuliV opIIn It.e Ihrollia. The pulley should rolala smoolhly to Ihe fully open posi· tion. Bnd should return equally smoothly to ils fullV closed position when the twistgrip is releaSffij end allowelW1 .... f;.....ot t..obtWled ...--U.. duu:h cable... It. problem lhe dutch ~ be dilrnantltd and e • ....-.ed .. ~ '" 1
_IS"
muI'
a..m..
and WPlied I I","' of cellfMIJ lI'e_ 10 ill IlIInk Tighten lhe rel8< ""'" ClSI 00 lhe IlIckINII. lhe shoes ... WOI'n out end .......1 be ....--ed II I perl. Tt. in¥ONes lhol .emovll of the wheel "om .he mIChone • deIaibIId in Chapl". 6 110 lhal the br.... componants CII'I
lhen be ditmenlled. dNned. a-ted lor _ . end
~
1'*
Iowrng lhe ".ItUC!tOJ'II grven in lhol ..... ChIpI., 1'1 II importenl 11\.01 moving PIfI' such _Ihe btalc. eamthlh "Ilubriceled WIth I . . . - of high meIi"'ll"POOnI W - on .....embIy (see lWO-yelfly hINI:IingI.
To ........ lhe , _ btl6.e, suppon .... mIChone 110 thel the'HI" wheel isclell' oItheground,lIQOtI the wheel end l""'len the adJIII!Jng nul unlill rubbrng .ound is hoIlItd _ lhe Ihoes begin 10 "",,1.1 lhe drum. then llec:ken the nUl by one Of tWO I ...... unl~ lhe IOUnd 0faMI. SPIn lhe wheel end applv the brel:;e t1Ifd 10 MIllie lhe componanlL Check 11\.01 the edjuslmotnl has not elle,ed end lighlen _etv an dlSlurbed fasl_ ... Thli IIhouId eppro.imall the lj)(lCIlied sailIng ot 1_ pIev be'OJe lhe brake begins to engage lhe drum (see $peI;1. iclotionll. Swilch on I'" ignition end check I..... lhol lIoplamp lighll juS11i III t... plav hal been '-"en up end lhe bJltU II beginning to 1If19IIIII. Tl'NI .adjusled by holding ste.ctv t... IIOp limp , _ IWllen body end tOt""'" I'" plHtlC sleeve nullO ...... OJ IoweJ the IWllen II f'MICIt&8ty; do not allow lhe body 10 rotl" OJ itllem'MnII will be ciIo'Noged. Check lhe _en ..""", the _ bJ"e is Idjusled. CompIe" breI. • ....,1 __ by r::hed.ng that the wheaIII ..e f_ 10 tOtlllllllily.end ItrenlubnClll lllioUoe pivog. To~t the . . of oil finding ill wrt on 10 the lyra OJ the btII<e Ihoe linings do not oiIlhe brake component • •..-vetv: I few dtOpl 01 oil It! uch poinl wII suffICe. LubnC/lle lhe IIOPIemp &wilen WIth I wal" ~I Hurd
wne.-
"""-..,.,
B.,k,leve. end ped.1 edju. , menu . 11 model. TO g)mpiete brake """;menance il w,1I be neceaury to c/lec~ thai the brak e lever and pedal Ire cor.ec.1y edjuIted The front brake lever i& ediuSted by a ICrew and locknut .. tuated on the handleba< lever. When propertv adjUSted thera ahould be 2 5 nvn W.08 0.20 in) h eeplay. meat.u<ed al the t,p of the br'ke leve. II nol _k8f1 the lockout and edlU5t the ICrCW untU the COllect amount of f_plav Ia obt.lned Once conecl'V Idjusleg 11>0 machine on the road On lhe rea. drum brake II wiU firsl be netISNty 10 cn.ck that tho pedalia Hlallhe conec. heighl. The tip of the brake pedal ahould be 41 mm (1 .6Inl below 11>0 lop of lhe fOOI ..., . •f nol. the POdaI height can be ,lle.ed by alackenlr>g illlocknUI and movir>glhe ..... te ... tUBted on tile foo"..t bnlckll. Once 11>0 ped,l height is known be coneclthe brake pedal f.ee plIoV 0 brake pedal can be adjusted using the IWO nuu on lhe bollom of lhe master c:vI,nde. openoling rod. On TZR model"he lop nut iI the locknut end the bollom nut 11>0 adjuster, wher.,. on OT model, the bottom nut i.,he locknut and the pedal is adjusted ,-",ng the lop nul. Sla0lo» wheel wiI produce. ~ elllC! Ihrough !he "1Ofing " high speed. Spin Ihi wheel _ I I I...... A well bIlanced wheel will come 10 resl in ...... posilron. en. Ihll ~ 10 ,..., in the .. me po&Ilion will hive it. helVieit pIIf\ dow ........ d and welghll mult btl Idded 10 I porrri diamelrically oppoe!te untH ~ iI echMIved Whe' 1 the ty'. hal I billarrce ....... k on IlIlkIIw!llliu_11y a coloured .pot!. check II " In ~ne wilh the vllve. Tocheck the wheel bnrings.II"ISP eech whlel li,mIy lithe lOP and botlom and Inampl 10 rock it from tide 10 IkII; II'IY I , " play indicat.. worn bNringi which ......, be _ e d .. detgh to WlNTTI the oil up to normal OPIIf'Iting temPllfllIlled regularly will not only 5t.>CCumb IesI s.peedily 10 lhe inevitable COfTOSion 01 exl""nat wrf-. and hence maintain its m&rlcel ~alue, but will be far more aJ>l)foach.ilble when lhe t,me comes lor maintenance or Mlmee work. furthermore. loose or lai~ng componan" are nwwe readily SPOl!ed when nol P&r1ially obscured by. mantla 01 ,oad grime and oil. Surface d,n should be removed us.ing • 1ponge and wann, soapy wateed Of eXlended as ne1_ wire blush. F;"ish the head and pillon worh melat polish,. polished surface will slow the subseQuem build-up 01 carbon. Clean out the barr~1 POff1 to ptevem !he r"tfICtion 0/ gas flow and clean the VPVS componenl1. Remove atl debril by washing each compon8fll in paraffin whilst observing lhe neceuary /i,e preeautoon ... Renew the pilton rings. if necassary, on <eassembly.
usa.
3 Grease wheel bearings, speedometer drive and brake camshaft To ptoiong their life lIS on..::h lIS POS$ObIII, the lront and reilt wheeII t.hoold be removed from the machine 110 that lhe .. be¥Ing$ can be driven oot cle&ned, checked for we ... and r~ if necessary. then repao::loed wilh the recommended 9 r _ and rellned. At the same time the ~Ie< drive s.houId be deaned and packed wolh grease. and on drum lII"ek8$ only, lhe blate camwh s.houId be removed. cleaned and lighlly greased. Refer 10 the rele~&rll Sections 01 Dlapter 6.
usa.
Exhaust • .,.I1em
Certain "u. do nol fall under lhe pteviot/$ mileageltime headings as they concern ,tems whICh deteriofate with "98, whether the machine is used • IIrH! deal. or hardly al all.
,
Cleaning the machine
Keep;ng the motOfq'CIe clean should be oon&idered "an impOrtanl pan ol lhe rooune mainlenance, to be C8f"ried oot whenever the need
first check thee lhe e xheust system is securely fastened and lhal ther. ara no axl\ilust leat ... Renew lhe ax!\aust pOrt 98lkel and, on DT models only, lhe rubber seal between lhe tWO P&r1' of the ..... tem. if leak...a found 11 either oIlhesa poinlS. Some idea of tn..condilion 01 tn.. .xhausl can be ga,ned by Iook'ng 81 the tlitp;pe. It the mixture and oil pump MIllings .... COff8CI, and the machine ;. ridden normally, the", 5hoo1d be • th'" film 01Il001.,. black CIe< 'hlft and gNI"boIc CQmpgnenll _ _ _ _ _ _ _ _ R_mblong !he engine/grIarbox unit: joining !he crankClIlfl
26 27 " " ., " 32
10
ItMOITlbly _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
35
FleMMtmbling lhe ~~ unit: rertlling the gerwalOr __ R........t>Iing lhe engi....~ unit: refilling lhe flXlemll gear lOIIIIe1orcomponen" _ _ _ _ _ _ _ _ _ _ _ _ _
J6
1\
()per unrt: remoY'ng the ""I*1Itor. _ DiImarltiing lhe engi .... unrt: .. mewing the reed vllve _ DiImarllling lhe engi .....gearbo.o unit: seprw.ting the c .. nkCMfl
ge.mo.c
""'"
-------Di ....... lling \he engi ....gearbox unit: remoYing the crllnkshaft
,nd goNrbox comPOflllllS _ _ _ _ _ _ _ _ _ _ _ _ _ . DiImarllling \he engi .....""atbox unit: removing oil ..... In
17 18
19 20 21
U 23
,..,..._------------------R....uembling lhe engi ....gearbox unit: rertlling the reed veIwI
RllasHmbllng !he enginIIIge.rbox reHlling Ihe tloChomelllr drivege _ _______ .. __ ._____ ... _..unit: _______ .. ____ .___
J9
R_mllling the ltOQI""'geatbox unit: relining ,he kicQt.art auemblv .nd idler gear .______________________
40
R....."."bIIng the enQi""'gearbox unit: refilling 'heclu,ch .. __ .__ RuuembIing the enQine/1JHfboJC ......It: refitting the righl·hInd crlnkcase OO\Ier •.. _ ... _ ... ___ ._______ ._._._.. ______ . __ .. __
42
RlIIoMIM"bIing lhe engine/ge_box unit: .....______ fin ing the._ VPVS componenll_. ___ ._____ ._____ ... _._____
43
bit""
RlINIIIMbIing the enQineigeatbo" ..,it; refilling the p;.lon, cyIInOot lind heed .. _ ... ___ .__ .. __ ._.. _ .. _._____ Refilllng'he~unil l n\hetramll _ _ _ _ _ _ _ $I.-IIng lAd running lhe rebuilt lingo"" .________ .___ .... _ Taiung lhe rebuilt machine on \he road .___________
Eng ine 124ccl7.6cu inl
La,erOT modell13RN1 onwlrdl. _ _ _ _ _ _ _ _ _ Siroke: TZR and IIWty OT modeI&(308 11_ _ _ _ _ _ _ _ LaterOT modell (JRN1 oowardl _ _ _ _ _ _ _ ._ _ _ _ ComPfanion .... tiD: TZR modeI. _ _ _ _ _ _ _ _ _ _ _ __ OTmodell. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
CylindClf helld Geske' f _
ma~i"",m
werpaQII ••• __ "_. __ •. _. ___________ ..
J7
38
SpKiflc:.n ion.
TZR IndIlWty OT modeII (3081 1_ _ _ _ _ _ _ _ _ _
"
"
ReaMltmbling lhe engi ....geartx;»r unil: refilling Ihe prirnIrv drive lind broIBrIott shaft geItI _ _ _ _ . _ _ _ _ _ _ _ _ _
24
'-" 11«11:
25
S6.A mm 12.22 inl 56.0 mm 12.20 inl
SO.O mmtl .91 ,nl SO.7 mm 12.00 inl 5.9;1 6.8:'
0.03 mm 10.0012 inl
41
44
45 46 47
.
Chapter'
Engine, dutc:h.net V"fbOli
S6AO 56A2mml2.2205 222ll;,,1 $6.00 56.02 mm 12.2G47 2.2051i Inl
"'I
56.SO mm (2.2244 56.10 mm (2.2087 inl 0.045 0.05Omm((l.0018 0.0020;"1 0.1 mm (0.004 inl 0.05 mm to.OO2O in! 0.01 mm fO.OOO4 in)
Piston S~OO:
~-:;i=~~=II_--_-_--_-----
DT modeIIlRN4 OflWIfdl______.____. 2nd~'= ----""ot.....DT rnodIIIlYI~~~-::.~.:::======== lit oversil l piston: lit...
lit...
~_
Pillon ,ingl
S6.14 5eAOmml2.2181
2.22051n1
&6.950 &S.956mm(2.202 7 2.2029;"1 56.25 mm (2.2 14610) 56.65 mm (2.230310) 56.50 mm 12..224410) S6.90mml2..2.0.2in) nRlrlClelrlyOT
lit.. OT model
modeI.130BI )
I3RNt onw..d)
Klyltoroe 1.2 mm (0.0472 In) 2.2 mm(0.08661n)
Klylloroe 1.2 mm (0.0472 in) 2.4 mm (0.0945 inl
...
"""
1.2 mm 100472 in) 1.2mm(0.0472inl 2.2 mm 1O.086e in) UmmlO.074Bin) O..JO 0.45 ...... 10-0118 o.olnin)
0.020 0.080 mm (0.0008 0.0024 in! 0.035 0.070 mm (0.001 4 0.002t inl
Cr.nklh.ft
Cank width
__ "
RVOCIO.lIIimII
1lIg-end •• 111 deIw..- (eno:IfIoIll ~ rod ........ defleclIOO
57.90 ~7.9Smm(2..2100 2..2815in) 0.02 mm ((l.0008 in! 0..20 0.70mmlO.oo79 0.0278in) 0.8 1.0 mm to.OllS 0.03!M in)
Prima", drive _ _ _ _ _ _ _ _ _ _ _ _ __ Rlduclionratio l.227;1 (71122T)
,,"" ......... •
, •,
OTrnodel.
2.9 l .I ...... (0.1142 0.1220iol 2.7mmlO·106lin) 1.05 l.35mmlO.0413 0.0531 in) 0.05 mm (0.0020 in! l4.5mm(l.l583 in) 32.0mm (1.2598 in) 0.15 mm (O.OO5t in)
K(c:kl t.rt Spring dip tenaion
.......
Ind autputWft runClUllimII _ _ _ _ _ _ _ __
~
''''' >d ''''~~
""
""""
0.8
1.2kll(I.78 2.651b)
G.08mm IO.DOll in)
""-
2.8ll:11l4I12n 1.8ll:1 t29116T) 1.368:1 (2tI19T) 1.143:1 (24/2 1T) 1.000:1 (2312lT) 0.917" 122124T)
Df_ 2.8ll:1(l4112T)
1.875 1 1»1
en
1.4121 (24117T) 1.143:1 (2412 1T) 0.957; 1 (22123T) 0.818:1 (18122T)
Chepter 1
Engine. clutch .nd ge.rbo.
"
2.813:114$116n 2.23S:1Issrl7n 3.s63:1IS1f16n . 26U_""
,.,
'" ,,..
'~h
'~m >2
..
..•• ......••........,,
,."
,.• ,.•
..,
.,."
3.' U
,,.. ,.,
,
.."
,.,,.,.,
."
.3
0»
"...
.. .......,.,..,, ..,.
U
LA
"
•• ... .....,
".,"'2"
,n
'2 '2
" "" " "" "
'-'
U
32
'3 32
"" ""
3.3 3.3
,
0..-.. dncription
The V........ nRl2s.nd OTl2S R modeIII employ. W.'e<
,-r.
8 oIf
"13 c-. Splir.edf""~ 14 Our... """,, IS ThttnfW.w-
16 Dtshedw~ '1 afr-hMld pusNod '8 SrNIt»6
,."""".... "
RJf/IW-hMldpurlllOd
21 RtlfUmfPnt'lll
21 W.,. 13 OJSHI
"-" " MA UW"""'
21 Prttn.y6-rwtlN' A 40Hon TZRmotJ.Is
Chapter 1
48
Engine. clutch .nd gearbox
2 To fflmove the kicut." .ssemblv, use ..... itfble pair 01 piiel"l tO unilool< the OUtl. en.1.ncer thafl.. In separete conlaine.s 10.-.oid anv PQUibilitV 01 conlusion on "es.sembly.
,"-It
',om
IIhouId be pulktd out with. twiltOng motion. II ~ UnllefflwHIg it. 00 not .UempttO lever it OUt .. the plet;tic: moulding would only be da~
m.
13 Dllmantli"l! englne/g.e.rbox unit: .emoving g.e....leet ... componenU
m. . IR. mel
t The componenll of the geM Mlector mecklnism which can be removed wilhoutseparaHng the crankcase kllv" COfIIiIt of IhI gearchange thafl..lf"ICOfj)Of1Iting the aeleclor claw _mbly.• ndue difficulty II ....countered. IIIP 11M CIIM beck logIIhe< and 111temple if I lauh Ippeatl tO have been caused by a failure of tM OIl s upply. all components should be dismantled 10 IN! lhe oilw8ylc.ln btl checked and cleared of any POI$ibll obstructions. Raf... tOChaptM 3 for delails of the lubricalion fytllem. Alwaytl use clean. lim-I'ee rag for cleaning and drying companenlS to p<event t .... rill< of ,maft p.IIniclee obslructing ailways. 5 Exami .... ca,"fully each part to dallrml.... tlte a",ent of wear, checking with the tolentnco ftgureslisted in lhe Speclflc.ll
[
"\, ..
:I ii
t"'!illi~i,j -.'h . - ljmmHH~ UI,hPI; :
-. '''-1-'·
~~~§Ii~ I!i~
""'"'-'1·· .• -"''· .. ,•• "', ·-'1 .,,! !"-i'· .~ ," '·la··',o "11~I.'ILIP ;" ~U'. ; !~~i'lll~ ~!~~I!!!I!'it!II'I! 11 ! ~:I~!III. r!~l I h'~¥'~U .~ .i~ '.- i'-··-"". i '- · -- ·
;-
"l~~I'~!~;li :~f~;~i~~~~~.
.1~!~!li~!~II~!JII'~ I!~ ii~!~I!I.tl~!
iil~I~:[!i~lliilil!II!~1 l'I;!ii!i~li![ 1!~i;!~~l~Jl!!!~~~i!!!i~ !·fl.~.~ •. 1·1-·,··l •. !I'!.·i'~ • • • • • ".----n. Do not Iltllmpl to IIdJuII • worn dip by binding il. 1 Ex...... lhe kicksl ... pinion IOf Of ........ ~ ' O
w_
d_k II In eOtIj\HICllon Wlth the OUlpUt ..... 't-rnounle
_w
, Givl lhe gHK.ed 'or t.....-by ~""' .. !hI compOnIIfll.l lrom the....,., IS dllc:ribed in 3O.1f1d bHmg 8Hnng-.JaIt,.,Scntw 20ft
Inpurwh Inpur $I1.h 5rll (/Hr Thrust w.~ 2 off
Ctf;/ip 3011 Inputlhlft 3trI/41h fIN'" 9 InputWft6thgHr 10 fIIpuIlhlh2f1dgH' I 1 Input IhIh leh-hlnd bHnnfI 12 Outpurwhr>(Jhl·hMtd~
1 8
13~
14 Thnmw.m.r
15 16 11 18 19 20 21 22 23
Ol.lqwuh.ft ISfflN'" Outpurwh51hflN' ~ 40ff SpIin«IlhNslw~20ft
OuIPl.lflhlh3rdgHr Outpullhlh 41h gH' Outpur IhIh 6rh (}Hr ThruJr wMhlr 0u/pU1 IhIh 2f1d gt/"8f
U Ou/pufwh 25 Outputlhlhleh-hlndbHtiolg 26 0iI1HI 21 GHrl:>o.ot IPfOCA:ft .. 28 l.«bn(J pIM• . . 29 Belt 20" "
",_l> 31
Gwrl1o,,~
32 T.tow.m.r
"MAl> .. TZR n\OdfIII
6.
DTmDdtJIJ
6.
6
tr_'*"
2 Make "',. 1M of old gaPet. t..v. been removed and thttltht mating ",tI\ICeII .re de,n and und.~. Great thouId be leten when "rnovirIg old gI.ket f;Ompound nol 10 darTllOge lhe .... llng ",tlacl. MoIII g"ht comPQUndt can t>II soh M>ed utlng I willbla sokIent IoUCh I I melhyllttd lpiri' a. acetone ... "elluloH thinl\lf. Tht type 01 sokI .... ' leQUiftd won d.tpend on tht type 01 compound UMd.
f;IO,.
Ch.Iptell
58
Engine. clutch .nd gllrbo.:
Gaske~
compound 01 1M ,-,·N.deoing type ean be removed using I soh brau-wire bnJt.h of lhe type UIfId 10< cleaning ....oe JhoeI.. A considerable amoum 01 scrubbing CIIn take place without fear 01 hMming the ....1;"11 surface.. Some difficulty mey be encoume<ed when Inemptlng 10 .emova gasketl of the S&/f·vulanising type. the " " of which is becoming wiOeIp;fa"',,::.e caotl"91 should bel clean and dry with
lIfIY damJgCI, I.IICn II WOfn threeds. r"p&ired. II any belarings ... " to bel
relined. the c.ankcau CII.til'>Sl mlill1 bel heated li"t I I described in Sec:tion 18. 2 PIIce the heated wooden
,I\&t the bearing ;'
33.1 fit c.anbhalt and gric:tled ..,.;I ~ lhe~ ..... ft Inloi\..OIec:k thol the.n.tI~"""'..,.;1 l..-!y. Chec:t ""I ItIt gtIIrbo>c InPliI ..,.;I OUlpUt ..... ft Itft·hJnd btaringl .., 1~lod Ind lhililhe oil ""' ....1 10 lhe OUlput .... ft belring h8II plenty 01 g'..lIon itt 1I.ling lips. Tempgr.rily WQlP' ~ver 01 LlpeoY'" the OUlpUl .... ft .pli.... to PfOIec:1 the 011 IIHI IIPI on Inll.IlII!on. lhen mtIh both ahaft_ 1.1111< COITIp(ll"Mlflil. II • f)If1lculor IhIh '- Iliff to 101111.' ......, liP on each end using .1oIt-11C1d .... nel wifl contral'" lhe .... '1 In II, btaring. If 1l1li; does nol if eny Olher problem II; encountertld. ItIt uenkca .... fTIInl be MPI'"od ~n 10 find ..,.;I 'ec:liIy lhe IwIt. PlN;k ct.... "II into the c . ...... _ moulh 10 prevenl\he enuy of dirt. Ilion ,,' il lhe u..miMIon oil dr ... plug. if remo'4d. tighlening it 10 lhe '9Kified lorque ... t~
",1In,
w.-
won.. ....
fig. , .. Gear ... lIet.... .....,.......... 1
;
J 4
s-c,."Dhun s-c,." ton ftputwlt kdl4lh l1N'
,
Pivotbolf
9
0..,.,.".,
""-ton
I; R«""rptII"Ig 13 Gd!p /4 Oil ...
s./«,." ton ..." s./«,." ton tMPapter.
1 o.g._ the rolO< and c,lnkah81t lipefa Ind flfit the Wood.ulf kay IntO the cnonkWfI. 2 RaIoc&tl the ItltO< In its originel poalnon. tiling the wi""", . . . guodoI. and " ' _ tn. rubboIr winr MIllIng ~II intO their CUtOUll1n the crantCIM wal_ Relit and tJght .... the twO .t.tor rnc,..·,,"'9 screws to lhe speaf'1Iid IOng thlt i, rnaheI correctly WIth both the clutch outer d .... m and th6 venical driven gIIIf. Ind hold il in ~e while pushing the shah into place. The second tlwust washe< ..... V then be fllted oYfIf the lhah tnd to r6St '!I&ilti! 1116 drivt goNi". Tlke grNI care locheck lhat the _mbly illlill in place bel"... the crankcase righl·hand coYfIf is refilled. II it It only the "'n.r.....tlich reel!irl$ the drive gear assembly
CMptir 1 Engine. duto;h Ind geerbox
"
39.1 b Fit I pIWlllwull wMhor _
39.11 Fit drivItl gAf and pllstichousing. Avo;.;! oYtI'tiglnening tilt .. \.lining bolt
40 "--mbI1ng I"" englnLlgurbo_ unh:: "lInlno the kldlll¥1 ....... bIy...cl1d1e< v-r
I
UIing '1Uit1" pIir of Qrdip p/ieQ, refit the clrdip on I"" w..m-I 01 tilt tWO grOOVH IT\IctIined in lhe oulpU! "'-" rlght"'-d.-.d. " ' - . thnnl wither oYer lilt ~I on
_'t
""It
....
_-
40.1b _ foIowId
a.rge pIlOn wHhe< whldlloQtNIgIinsc!he """ thouIdIf. "'-\"" klculan return IIPri"II _ the """ with both IIPri"II .... flClng inwatdl. towatdIl'" Iarge~., 1IPIi-. and n.t the apMg Ihott innI< lind inlO i1elocating"" in I'" kic:kaan WIt. Refl\ \'- whit, nyton spring guide onlO I'" Wft. -.ring 1_ I'" CUl-oo.rt on _ lind III f8Cing inwardllnd ~ with the apring innI< and. 3 L~tI 811 blaring fUr/_ of I'" klckell" Hlftmbly and inN" lhe KIImbIy Inlo \'" crankCIII. N 1M end of I'" 1II,1t fi,. 1n10 it, hauling In I'" CtlMet.. WIlli, ensure 1"'1 IIIfge lIoppet .. m Iocat" COI'l'CI(:tly . ' MII'" 1I0Il CHI In the ~tln.ketM w .... tnd \h" lhe friction c!;p looped and 1111 1n10 the t " * , , prOYidood lor it. MIke, quk:lc check 10 ......... 1"'1 lhe klcu1.atl .uembIy ;. _ _ ling eotrIClly bv tOtet.ing lhe ""11 II lit II ~ 1Itltk:b::tcw;u. The ""t! thouId tOtell IITIOOtht'f' Ind MIlly unt~ the 1iq:Jper Inn ~ 1n10 _ with ill MCOnd 1I01l. end '''' klck"l" pinion &houIcI _ - " y up II, ""11 \0 Ifl(II9t with I'" \Mlh of !he Idler gAf. Rittum the """ 10 its notmII poIit;on bv rotMing II cIockwiM Ind ... ,1UitIbIe poW of pIiert 10 bring the ,,'um tpring long ~ end eround so IhIt II Clflbe
t""
"'*-
bv fint plain Ihrusl w ......
""It
Chapter 1
64
Engine, clutch and gearbox
4O.2d Slide nylon guide imo place ensu~ng
Ihal notch on9ll9~ with innvr .. ndol kic~slart spring engaged in illloc:a ling ~e in the aankcase wall. Take Care 811his poim 10 ensu,. lhallhe spring end is hooked firmly Imo the locating hole. as Iha spring will be under quite heavy Pf8Ssu.e.
41
Rnssembllng Ih, engin"llea.bo~ unit: refitting tile clutch
1 Commence reassembly bV fiuing Ihe dished washer and thruSt washer over the input shaft nght_hand end, noting that Iha dishe"ctivlI Slits of tellth on Ihe oute< drum. Refit tha second. splinad, thrust wash"r with its slightly chamfered surfacII facing outwards, then lit tha clutch canlre over the shah lind. fit II nllw teb wHsher with its small protruding tang located In tM cul·OUt in the clutch centre bo$., whereupon lhe retaining nut may be replaced On the &haft lind and lightllned down as far a5 possible by hand. 3 Lock the Clutch Centre using the melhod IImployed on dismantling and tighten lhe retaining nut to the recommended lotq .... oeuing. Secl-'ra the nut by bending a portion of the tab washer up against one 01 the flatS of the nut. Check thet the clutch OUtllr drum and the clutch centre can retata freely. easily, and indlll>"ndllntly 01 ona another Thoroughly grease the left·hand pushrod and insen il Into the input Shah. followed by the steel bell. 4 The clulch plain and friction plates should becoated with transmis· sion oil prior 10 insl8l1alion. II will be nOled Ihaillach olthll plain plalell
~~a~: :~~~I~~i:~I\~'o~~g;1 ~~~:i:~C~U~i:;:r:~~~!i~e~~ ~:~~~~~ Fig. 1.10 Kick"." mechanism K/CksrlYt/ever
7
Nm
8 9
OilstMI Spring guide Rerum spring
W"'"'
/(icilsum pinion FricrioncJip Kicks/an $haft /0 Csldip 20" II Thrust washer 2 oH
Ol-'Iwards under the centrifugallorce and Ihus reducing clutch noise. Tn preventtha whola clulch f,om glllling oul of I>oI"ncII il i. necessary In arrange Ihe plales so Ihal Ihe ma-chined araas ara spa-ced evenly areur.d ils circumference. This can be achieved by arranging each cutaway arN 10 be approximalely 60 0 lOT models) and 72 0 (TlR models) away from the previous one. (See fig. 1.1 I.) Sianing wilh a friclion p481e, and thana plain plate, insen lhe plat" in succession unlil all are fi\ted. NOle on DT modoelsthallke friclion plale w ith the larger intemel diameler, should be the second friction p1atelo be inSlalled inlO Ike clUlch oule. drum. along with theclulch damper ring.
12 IdJergN'
41 .1. fit dished wltSher to input shah righl·hand end ..
41 .1 b ... followed by -II thrust washer
41 .28 Refit clutch outer drum ..
5
When fitting IheclutclI preM.iJer.lly 0 ' _ lhe Ill*- ollhe kicqlln ....It itself. Ofler up lile COY .., IIItlng greet c:ere nol to damage I'" oil .... lips .. lhe kicqterl 1lii0i1 PIIIIS IhrougIIllIem.. E _ 8110 m.11'" WI' .. IU"P
'*-'
andoilpUmpdrive~~COOT«ttywitlllhecrenbhlft~
4 fig. , .,, CoeII bor., rerTlOlll 11>11 r-.g from the Cfankcasfl moulh and puah lhe blnal carefully down 10 rell on lhe
111'-1 port 1..1--. lirl!. thtn lhe remeining mountings. On OT 125 mocIeII. donol lorv-I to chick tI"IIt IUbuli..... between the .........1 pipe .nd Iitencor; Ihis .....1 be .-wed if damaged. aptil Of bfok .... Tlghlen .U •• hausl mounting bolts .nd null 10 lhe apecifled tOfqut HI1~ 9 Connect t1'4 bal1enI QIVIOI be .-....ed ICCUtIleIy use I.... light~ II dIIeribed in Rou\irIe Nlllnl~ bul noI. tllel the tev.I wiI drOQ eft.. the . . . . . " - ' - ' run for me r...1 lime II t .... oil if dislributed ..-ound the vlrioul oomponenll .,..;I wiI thereforto requ;,. carllul ~ Relit !hoi fkpll.og. 10 Aef. me radiIlOf.,..;l1Xplonlion!¥>ll1l deIeribed in ChIIpte< 2 but do noI ret refi! the ..... IOf C8P IS the ~ ...... wil l" ~ the engine II run for Ihe lifsltime. 11 Refit me I..... Iri II dnCfibed in Chapler 3. tum on Ihe luel tIP and cl'«k for InY IeeItI ~ musl be cu,ed lmmIdille1y.
45.7b Do noI omIl oil .... when refitting IIChomeler d ...... CIbIe 12 M I •• I r..... chICk 1"-1" components have been refilled end t"-I .D ani coneelly adlu.ted and HCL>I'eIy In toned; tile ••ce~tion .... 1111 componentS 01 lhe Inglne lubrication and cooling SVStem, whkll ... lIiU to rocaNe. final chick befOf. IIIe ..-.cNne is flidy IOf ,,".
1 AlIomp\ to .1111 the . . . . . UIing the usuet pnx:.ed\n idopted fot. cold . . . . .. Do noI be diIiIIuIioned if the<e if no IIign "" Iif. irOtlaltv. A cenIin -.nounl of ~ may PtoYII - - V 10 __ I....
engine InIO eclMty ....... if new parU; ...... not been rmld. Should the engine Pltllatln noI liMing. chICk that the span plug hn not become louted by I.... oil lINd during ...-..bIy. Failing lhill go Ihrough the flUlt ~ _ion .,..;I wutt OUI wt.1 the problem if mIlhodQ\ly. 2 When Ihe engine doH"ln, keep it running asllowty .. poaalbIe 10 eHow I.... 011 10 clrcula... ()pen IIIe clIott. II soon as !hot engine wi' run wilhout it. During lhe 1niI... running. 1 can.in .mounl of Imok. may be in evidence due 10 I .... oil uted in I .... rensembIv sequence being burnt aw.v. Till ' .... ltlng Imokl should gradually fUbside. 3 Check I.... engine fOf blowing gaShl1 end coolant Of oil It,k.. aelOfI \>lIng t1'4 mac:hine on Ille told. chICk 1"-, .. IIIe ge'rI IIIICI ~. and tllell .... controls lunction correclly. AI soon 1111'4 engine up 10 normal operating temperalure and if running ImODIlllyltopit.,..;lc'-l! lhe f~ a ThI ~ Ievet IhouId drop II the engine fUI'II. ~ II lOon IS the the<mofll1 opetII, . . lhecootantll dislribuled IfOInIt ....... pISUgI5 "" the system. TfIPped air wiI be expelled in Ihe form of bubbles Ind .....t be .-owed to 8ICIPfI bel.". the radillOf C8P II ,.,lItlld. As 1000 II the l""-
.
., ~
"'" '0
'"
'",'.
Chapter 2 Cooling system a......
_ _ _ _ _ _ _ _ _ _ _ _ _ __ CooIing .yst ....:drllining _ _ _ ._ _ _ _ _ _ _ _ _ _ _ Cooling *V$1....: nu.hing _ _ _ _ _ _ _ _ _ _ _ I~plion
..---.--..·-.-·...-_
~~~=I~I~:: ="'O,,=,;="'=.=.~·~------------
Radiator and cap: cleaning and e>
,'-,.. ,,... ,,... ,., ,..,..
....,...,, ...•
Ibllt
'-'
••• "
w"""
The hot coolant .. oIsa used 10 the c.rbu.enor. The cooI.nt flows through a small·bore pipe lrom t"- cytinde. hied. 10 lhe c.rbut"et· tor. circulates around the corburauor bo
5.2. ~t ' _PIInslon t."k hoM from 1Jdiat00neck ...
Fig. 2..1 RldiatOf TV! mo6el
, """ 2 .sa.w
4 0N
3 1M 40N 4 BoIr 20ff 5
1 8 9
W..",.,. 20" 20ff Moun/in(} I"IJbbM 2 off RMIi,/O' Moun/Ing tUbbtIr
10
c.,,~
6
~
1/ EqMIUIO(ItMlk~
12 0j:I 20" 13 lOp'-~ 14 HO$H'-'. 40ff 15 l"-'-1MhousIng
" '"""
/1 T"-'-IM
18 O-ring 19 BolfomhoM/outlel) 20 30N ~_
2 I 8Ie«J boll 22 SHImg WlshM 23 C¥tJur.tror wanner pipI - 2 o ff 24 Clip 4 0ff 25 boll 2 off 26 SNIing wlSIw 4 oN 2J Pipe uniotI 2 oN
u.-
5..2b .* follow«! by top ...
If.
74
Cnapter 2 Cooling system
--""'-
Fie. U RMlIMOf
8011 20" W.",.,. 20" Iobmlmg~ 201f Sp«et 201f Eltl»fUlOl'llllnllpipe
9 10
ToplloM/fiNed 2 oN
'** tMmp
"'-'-tM~
" ...... "
~ 30ff
13~M
"15 ",.,. IJotrom ' - (oudMJ Ht».~ 2011 17 MM.bomImhoMl
15
"
",.,. 19~ 20" 20 CMDunItfg the fIuIhitIg proctdurt dMcribfld in s.etion 3 01 IhiI et.p.... Additionll f\ushing c.n III canltd out by pIIocing the hoM in the liIItt ntek and aIowing the wlter.o flow Ihrough lor lbout Itn minut ... linder no drc ...... _ IhouId 'I'l0l hoM III «II'II'IfCled ' 0 the filler neck ~1Iy ........ IUdden bIocklgllln 1M rIdiIlor 0r\ure when the 'dlOko' is opetIIled. lIIler DT modell Ire filted wllh I flat o.Iide type OIIrbu.ettor of simiter design. UCflJlt for IOfM minor diffe.enc" in construcllon. Ai. ,,"Irtnng IheOllrbureltor PII_ through an oil-imp.egnaled foam .i. filter. Thill offllCti\frllv removel any airborne dust. which would otherwise enter the ""IIi'" and OIIuse premature w ...... Theai. cktlner .Iso helps IIilencfI induction noise .• r;ommon probIrtm inherenl with tWOo-ltroke engines. The induction I Vl lf:lm filted 10 the mlehines delcribed in Ihill Manual he$ IWO funhe. f.,.turet: lhe YEIS chembee Ilngle la"" ...... moundng boll. lhen litt IW.Y and pul 10 one &ida the boll. washe .. and damping rubbe •. Lilt 1M 11fl~ up llihe ra •• and _ I t backwards oft illlf1;lfll mounli"",. liking OIIre not 10 d'm1{18 the palnlwoO: as lhe mountings.re very light when new and have a naslV habit of .elealing lhei. grip 10 thai lhe ' .... k c _
.wav suddenly
3 Inspecllhe lank mounting rubbers for ligns of darna{18 or deterioralion and. ~ neceuary . •_ w them before lhe link iI rafitted_ 4 In the lvenl 11>11 II I. flrlCrIISIfY 10 remove the pelrollink for "'PIli.. lhe following poinll Ihould be noled. Petrol link repai •. whether necMSitlled by accidenl or by palrolleaks. is elas!< for lhe ptofaslional. Welding or bralirog II nol recommended unlesllhe tank II purged of ,II pelrol vapour: whic:h is I diffteull condilion 10 achieve. Resin_based lan.k
2.2a Check that luell&p is H\ to lhe OFF posillon _.
Ro· • .1 F... II....
T2R model,
ChI>ptet' 3
Fig 3.2 F... II.... I
Fuelsvstem and lubriutlon
81
DT modal
F In the fonn 01 oapout"_ 7• pt"«4VIIOIWIOPf8VlMllhe rtSko( fnMldrNd the s.fMy finlf ~"'" of IhIs",.,.../»fote .Mf/llf1 wort;
.n
1
n.. fuel tap ill fllliMd by twoc_hIId _ t o the ~
3.1 F.... tapiol.--roed by twoC1OAhud1CflWa
F.... I . y.t.....nd lubriuotlon
Chapl ... J
82
tap.
it wit tot - V to ...,..,... the fuel tank. WId to Ihin 1M lull Into • ~ IhQtAd bt ~ during ___10;)0'\. BeIonI the
~
oonuo..lIUi:UobIetorholdingpeuol bt~alOI9. ~thII twO......,;ng crews MllIih!he 1IIP -.y, ~ QI1I not to o.m.g. the fihtrI whdI prtIfIICt into !he twok..
mo .........
2 ReItMe the . . . _ _ whM:h ret8Ww IhI! tap ODIltroi knob...cl PIA it off tIM 1fJind". ReIIeM the two _ _ whdl hold lhe tap poIition indiclolClr dIIC WId ,1IITIOVtI it. The tap rotor can !hen bt wh~n !rom ;1:1 body, complete with a-ring and 1Pring.1f the lap .... been 1nIIing, the rl'K»lli ...... _ I a I worn or damaged O-ring between lhe 1"1l rotor MIl the body. Till. CM\ be purchased N9M.tety from the tap MMtl'lbiv • • can the oval O-ring betw_ the lap body and the fu.l tank. l)ut l _ 0It>e< "~I 1MIt....
..,.1*.
,,-
3 The toe! tap ~ on OT ~ ..... be ll'M1od • • -.Ied unit. the oNv ~ pert ........... *'II the bel_ the tap body WId the fuel W*. If the tap i t _ be ...-..1
"'Utv ov" ....
........... •
The fuel I...:!
po","
........, -
WId
lap
filt-.1IhouId bt ~ f'II(jUUrty lor In ~ n'\IIinl _ _ 8nd
Pgntol_orNltrlonolion.~
5 8elor. refining the fuel lap. ~ m.t .. the PI!1' ... c:tean. ~ tilt fuel filt_1Ind main WId _ intalc... II Do not _Igh."'...., oIlhe lap component. during re~. Tt... .,.In. ,i_baNd alloy. wtuch wiN IrK'.... eMily ~ oYefMo.! OO;O;U. _ the """It of deltctive . . .
ca",,,,,, ."esMd.
INIPI1I'H
Ihe tlwoUIl ""um Ipring
'II'i....I it and hold it in ~ I91M .... I the top. !""en the tltronll va/wl
and thtk_ 0IIt the ptn.Mld "eel IIIJring II1II1. ThiI t:OmPOfllflt MrYItI to ~t the CIIbfI from '-"ing detlChld wt-.n In PO$ilion and once oulol Ihe the e.bfI be pushed down 1M IIIid 0IIt of itsloc8!ing ",DOVe. The ~ 1*" now be removed Ind IhouId be pfIIC8d with theClllbtnltOf
'*' '*'
w.-v
Early DT modIIl3DtI1J 6 the~tlOf, it. firet - - v 10 . . tad! the _ TOgllfl-. tnt _ _ _tofrom ill I ..... mountlng Ind 10 diIconnId the ~. ~ RImo;tow the bolt w1W;h ....... the _ InkI .-voir to Ihi "...... ..... ~ it .-.. of the o::awtlu'InOf wtoikl keIIJMnO It upr\ghI; if - V, Tie t h e . . - - 10 the""'" 10 I\IOId llraming the t.ydraIIiI: ....... II"'- ill knurted ring IfId pull the tao:hometer ~ its drfv" on the f ; f r i _ ~ t~1y
"om
1IIcfc", Qernpe whidI MCUfe ettrburettor 10 InIIIt stub Ind .... l iIt. ~ _
1.21 TlR modi!
Chlpter 3
Fuel5V1tlm and lubrica tion
OJ
., ••"-
.-•
•"
•
"
11 II requil'9d the 1/Wonle v.tv. Cln be MPI'aied from the ClbIe II ~ribed In J»f-waph S of Ih~ SectlOlL II not, it CIoII be lett anlChed 10 lhe ClbIe .nd I.pad clell. 01 the engi .....
•
All modals 12 The CIe!y fI~ ~ when in r". form of T.,.aJ/~lOlISfOpre"",rt"'nskofm..,)(fflMir"'S.f«y
fir$fl soctlOfl of (hIS man<MII belore SIMmp wort.
I Remove the cel'burellor from lhe machine as described in the pre'
iI"
a::
.llilii:!i=r: ~~.~'t.3
11!'I;lljill"~i~ li~!ii1i..f!l:· arlrerne/ot Ilammabie. eSpecially when in lhe form 01 lIaptJw. TtJte till pt"KIJUllOm ro prevenl lhens/< 01 liM Imd rtUId lhe S8lefy firstl sect.icm of this marwlJi before stiNting wort. 5.12 Ensure cutaway on needle jet al igns with peg inC8.bureno. body
1 The first &Iap In CIIrbu<e\lor adjustment ts 10:> ensu.e Ih~t the jet 5iles. needle posilion and 110111 height are correct. which will requi.e the removal and dismantling of Iha carburanor as described in S\lt.1\and ai. ICOOP to the fuel tank and .emove the Ii. $iCOOp. Disconnect the Mnesendo. unit 158 push iii in the lOP of the oil lank. To remove/he sen.der uni\, proceed as follows. T2Jl model Remove the Mat and IoII1·hand &ide~fIEIl aM 1&1&_ 1M oil IBM from lIS mounlings esdescribed in lho previous Secuon. NOle Ihal il is nol necesNry 10 disconnect Ihe oillaed pipe. Unplug tlla oil level sender unit from the mein wiring loom and pull Ihe unil OUI of lila oil tank.
:}
14 1
Oil pump' ,emov.l.nd refitting II is rarely naceassry 10 retnOl/e the oil PLJmp unless specific
attention to i\ is r8<juired.1I Should be noled Ihallhe pump Should be considered a Haled unit pans are n01 al/ailable and Ihus II Is nOI praClicable 10 repal, It. The pump ilself can be remOlled quile easily leal/ing Ihe drilleshah and pinion In piece in Iha right·hand out8r casing. If Ihese lauer components require Buention il will be necessary to drain lila cooling syStem and transmission oil 50 that Ihe righl·hend Ouler casing can be ramolled. Refer 10 Chllpte, 1 forfunher del ails. 2 To gain eccesllO tlla oil pump. remolle the sc,e-wo which secure the pump COlIer 10 lhe right·hand OUler casing. 3 Displace lhe s .... lI.pring Steel clip. which secures tho oil deliver-., pipe to tho pump OUllet, Ihen"se lho pipe off the OUllel slub using I small screwdriver. The "'roe faed pipe I.om lila oil lank is remol!ed in I similar fashion. OOt before ramoving il hal/e some sort of plug handy (such as a dean $Crew of wit able silello push intO the end 01 lhe pipe. This will p.evenllhB oillrpm the lank bEii~g Jo!it. Pull Or"l lh& puMI'l uble inner to rOl818 lho pump pulley. Holding tho pulley in il. lully open position relea&elhe cable and disengage il I.om the pulley 'ee must be confined 10 keeping lhe pump clear of air, and con-ectly adjusted. II described in Seclion 16 and Routine maintenance respectively. 6 Refillhe oil pump 10 the crankCilSB COll8r. using galkel., tho oil PllmplcrankellSl! colier joint. Replace af\d tighten Ilia IWO cro!lsllalld mounling screws 10 the specified lorque. TIla remainda.- ollhe rgs. sembty is IICcompliShed by f8\/ersing the dismantling procedure. bUI do not replace lhe pump COIle. al Ihis slage because Ihe oil pump must be
pe."
a",,,,,
"~Ii··"···!fi-·!rf
I~I I' " h~H, -· II~rlll". . 'U'[ n _•• ,., .- ,0 •• ,
r!
HHjma:UH jn !'ji -""'I"'! -f
3i'i·~~=l
. g
~
l!·i~· !~~ !~ i[ ,. "1"1' [i~~A ~
"O~"~3t· h= [~P ! .. 'J P ! i[}
~.
~
ila;
n·
!!:::
5-2,
~""'1-! i"[W:,Il -'2 •
:>
0-
tl~' l[~ ~~i
1
i
; l.
un i! ,0 0,
~i
'-j
;f ~~
5!l~
~!~: ~. ~ i ~s ..
--.
!~~~"fii"!~~~~~~3f ~"i~3
J •~
"
•
~
• .p
"-
I
28~'!ai· r!~~~i&~~~fl
~gwf&
~?i m_~
"~·~0 .~e~~
mi~. ~i~~{r~~~=.3g ~ .. _ ~"'5~ • • ~". ~s
l"i3~o~~~n"~ ~c" ~~ " ~l~~
00 ,
~. ~ [
§o~ii"
.g': :~.~. ~ i"'~ii~.
~!g' .llif:2:;i· ~
,,,,·0."< •i-
ll!~!o':~;;S3 '!
6..ii§:;~ ~g->l
~~t
g f§ ~i
i~~ 8~3~g!~!rr~( 2. =' _
~~~S'c
~i~ itit~~f'~QW; [3: 31 j~i
2.~~~iiJ5· g.g!!l::5
§~;"~~~3~fl~
!!:
~
~'~61 ~'B c ~:l~;:n;·1E ;:: ~".i~
:ilil n~~2~
!~~ i;til~~~!~fi
~ i'[
~,:i ¥-.=. ~~ ";-~:: 3. ,&';;:;' .
~~ ..
c~3~~
s.
r ,;
~
n
~. ~g iiJ~~· ~ ~ i"'~-
~
g:
8i~~;;:;§.!i-
52
n g.S''''
-~il!::~31S. ~ 2~n_"~;;iD. n 6..~,..-2"g!!'3~
c
3 i~[~. §· S:&'" ~. 2· fZ:j"~. ~· ~*,~ ~
i~l ~'~i&g~ij *,n;;~i!~' ~i ~' ~~lI .. i~lif~ ~~.~~
.6=-i~.ll"~i5'"
ii'
i~~ ~i ~~~~ll:~ . li~!1 ~=-f S~ ,,33''!' ' ~ii6.. ilgfilii
fi' ~' iI~~~~:
[
i-t
~i~ g
"'*'"
• SI.c~ .... "" lOP and DOllom yolo. p;ncn DOlts "'" . . . . - IhlIorI IMo UMd to obtM> IlUtfICiolnI ....... 8fId pr---. Once the ..a.oning bolt ' - t.wI ~ wfthdraw Ihe ~-..aIy rrom Ihe lower leg. 7 The loR oil .... eM> be levered out ot.-llion ...""'" large filii· bIIded ICreWdrIY .... whIIlt tlkiJ1fl CMfI not to .......... IIIe lUrfacl 01 the loR leg. The guide bush eM> &110 be rernoyed in • IimIIk W'Y. &gIin I~ lII..t CMfI. FiNltv.llp lhe tt MCtion...-nbIy eM! COI"I"I/"nII"O E _ Ilvt .. 00",.,0'*11"1 . . dMn 8fId thM \tilly . . 1iI111d 10 the fort II"Om wtKh they _ _ '1IfI'OWId. Alw8y"l fit. new oil .... The bush ~ eM> bot ~ only if ill perlKt oondition II'though it ............ odIId thM it bot .........c:I • • prllCallioNry - . 9 "" thI t.oo...d ..,Mg _ thI dImper rod 8fId Mp it In IhI .\Inl;hIon. p_ .1&ngIh 01 dowel d&ICribIId IboY&J up through thI.\IIIdIIon to hold !hi ~ rod in ~, thin lit !hi cIemper rod Oil the.1MlChIon 8fId support It ~caIy whh Ihe dlrnper rod 8
c-
_ I.
'oR,
~
13 OiISHI
"n ""'"
Fig. $.2 Front
T""",
lmo.-.
14 W. v . 15 TopbuU! 16 LlIhllM!dlowtw~ 17 A ..... bolt 18
s-IwIII""""
190.-_' 20 ~tIIIMIw·
,,-
21 RI(Iht./wttlIot/lIef 22 Sp.rtdtdwnp 23 NtA
40H
'N« fifr«J to 3RNN9 """""" " NoflittedlO lRN9/I"IIIdM
~ . SiItIIhe lower leg _ the .!IIdMon ....,bIv and . . thI d&mper rod bolt uWIu • new II8Iing w ...... InI&r III hAd. \.III Loctill "" lhe bolt Ih ...... 8fId light.... to thI.".afIed lorque MII"'II 10 Oi' Ihlguide bu$h.nd'-- ;I down_lhe I itnehion. To fit .... bush in ;1. _ _ it will IMo - - V to devi"", .., ..1..... live to IN iubul&rdrfft loo! uaIId by Y.meN deIIen. The _ I ....Ihoc! it 10 ...... length 01 t u bing IIigohtlv bIpf in dillmel... tlwlthe 'lInChion. IIrgI plain"". . . . ~t the bush 8fId tIW1 tIop it I"Iom4o """'" lhe MIt ... forme4 ~hIrnrne< T. . e... not 101Cf1lIon Ind buIh. II1d IUPPM It ver11c11y wrth the dImpef rod uPI*TT'OI\.. Slide IhilowIr leg _ lhe l!lnChion .......bIy Ind refit the damper rod boll ...sing. _ SHIIng wan... unde< ill heed.1JaIng 1.oo;tJt, on lhe boIIlhrudlll1d light ... 10 lhe IoPIdfied tOfQUl lIt'\ing. 22 Oil I'" lOP IJw.h Ind IIide It do:Mrn 0\1. . lhe l!lnChoon. To fill'" buill In iu . - II be nocNIIHY 10 deYi.. In .11......1.... 10 I'" luIIt.Q below''''
AII~' .
26 When 'eastemb\y ;'complete refjtthe lor1Ilega into tile for1( yokes as described in Section 5.
3.25b ._ followed by
~
II F,onllork e: eomln.tiof! and ,.novatlon 1 II the Iorir., lIIIye been damaged In an lOCCident. it is essential \0 m.peo;l both fort VOIce.. the Il&I1Chioniand the Iowa. legs. for dillOfloon and halrtine crackl. OisIOfted compone
Front IGrtoI: ,.fining
6
StH,1nfj held: dl,mlntJlng
1 BelOdhMdlMnp
6 TOP~ 1 Top bHring!HI 19 oH 8 Top bHnng cup 9 Lower bHnttg cup 5.2 TZR model 'tanchionl1hould protrude 10 mm above hendleblr casti"{lll
10 LowerfNNlmlgl»ll
TZJl modtol,
If w....erbNring(;O(lfl 12 Lower~~$t"'"
190H
""'.
IS &,.... 40H 16 R.ghI.h4nd~
'-'0'
11 BoIt - 30H
"19 Bolt a.mploH
-,.
=8~o~ii
O~~~n~ ~. ~ ~' & §·ii
~~.i!· ~!~i ~~[i-!fg !,;:;; l:l: .. _
~1fc~g!ig
;~' ~3 fli'3 lI::ts~ -I" g·et is, &og
;" lia~a ~
~t;' 5:i.~
•~ ~,,~~~. 'I"':>':> h~!g
o
l i~ ~a:;
l i[
mov"
,
Remove the duelseat and boIh IiOepenel&.
TlAmod.'
Should ~ become _ r y 10 dispoM of ,he cylinder do not juI, tl\row it away. It if lirlt necessary to release lhe 11M prnsUrl! end the manufect"' .... recommend thaI the loIIowing procedu •• II followed, 3 Rei ... 10 the accompanving fi(lu.e and martc 1 poinl 15 20 mm lbo\'e the boItom of the cyIIndet. Place the unit securely In • 'lice. eecaping 11M .-.dIor .... t.&I Wearing proper eye protection particln. drill. 2 3 mm hole through,he pre'o'lously martced point on the C'(IIndeging arm and relay Irm.
'Ga'
I.
, The rwr .uspansion unit II .efiued by ........."'9 lhe removal IIquance. Apply • li\hium·blSed grease 10 all oil ....... buIheI end to the Inside aurf_ 01 .. washe[H 1j ! g~H' ~~~~>ch rea. wtIe&I. designed to accept tubeleu tvrea. 80th f.ont and 'N< brakes arl hyd'aulically oper81ed d,scs. The OT modeillf. ,illed with w'-il 01 COIW.nhonal w,rtt·spoked construcllOn. uaing ch.omed IIMI rims 01 21 inch diamete< I1lhe lront, and 18 inch dlllmfllflf 81 the 'N0115 which '"a,n the bral<e calipe' to lhe lorI< leg. Uft lhe cehPl' clear of lhe w'-\ and IOfh. IV'ng it to the I,ame to .... OK! pl8c:ing undue it ...... on the hyd.aulic hoM. Before proceed"", !urthe,. i ...." I wooden wedge betweeft lhe brakl pads; th~ W>l1 prevent lhe pistons being expelled ~ lhe brald~
""""'...,
-"....
8Nnng 20"
OTmodel 4 Remove the tWO bolts which cl¥np the dose cover to the fork teo and the lront hall 01 the coYfIf. Pull the speeOomete< cable from
retnOY.
'-"'''''
7 8
9
~tttrdnvepUl.
RtltBIrItIf"
"""'...,
IO~tttrdmltl
..-'
II BnIJr. dtsc 12 8011 60ft
Chapte, 6 Wheel$, b,ake$ and tyres
'"
,I. g.earbox afte< releasol'l9 I'" knuried relalOlI'l9 ring. T... cable ~ be ralHsed ' ,om il' holder on lhe righl·hand lork leg iI W bliowarod 10 11M grOUnd and lilled eln' 01 11M fork •. Before proo;eed;ng funher, I....., • wooden wedge belween lhe brake pads. This will prevenl lhe pistons beil'l9 •• perlacl illhe brak.lever;" opIfllacl accrdenUIIIy.
'rom
All model. Refer 10 Rouline m.'nl'~ for !Ielalls of wlleol ..amIOlllion.
6
3
Front w ..... l: refittinll
The wheel ill ..finacl boo' .....",il'l9 In., 'emoval ~. Befofining lhe speedom..'" dnvtlll"llrbox to Ihe wheel. lhe drivtr "'-Ie lings iogrll o;orreclly in lhei. IIoIs in lhe hub. Refil lhe wheel in lheir COITacl PQaitiontr and, .emov. lhe woodIIn wedge 'rom lhe bnrIllr 2' Nul 'on
20n
Fig. 6.' R..rw ..... , T2R CJPC2.nd lPCl) mode,s
25 Ww-
WhHlspndill SpIi'pm
27 Nut
ChaIfIIfdius'~ 2 off I.«l
s' ~ !"ll~~ ~. ' ,. ",,1.~ .5. c
J
: !
i" js., ~lil
:l
I
i
~
I~ •;, ..
~~HI~ .!9. 1 ji"gn
0..
&i.iH~ :E 8. 1\ _
0
!l"" "l"'~ .1 ~ >:, ,:i.Ji
I.. i'fum :>3.~ i ,
S1-' -
.
lii~!!: [--' g too driva plate tangs con8Ctly. 10 Fit the Iront wheel assembly into the Ironl fo,h as described in Section3.
S
7.2d ... at>d lilt off sprockel
119
access to the rear wheel baarit>(lS. Due to the similarity in dalign and construction between lhe 1""'1 and rea. hubs of I18Ch 01 tOO machines described in this Manual. the procedures lew removal, eKamination. and relining ollha rear whofll baarings are eKiOCtty lhe same a8 those glvan above.
7
Rear.prochl: .emoval. nemln8lion and ,efitting
t Exami"" tllfl teelh 01 Ihe 'ear sprocket. II these aM hooklKl. chipped, Q( otherw'se dilmaged. the sprockel must be renewOld. NOle thaI it is considetl!d bad practice to renew juS! one sprocket Q( the chain alo",,; bolh I""'t and 'Oa' sprockets and the chain shout
~ &~~ ~iEt=i~~~~ ~ ~a~ ~~ ~15~' ~~:r~~ .. 3 .. 0Sa. "i:."g,, ~
~~~§[~~~~~~~13~1~~;Wi~~"~I~
i
t,
5.::f~~ a.~. ~ ~ii:! ::::'''3!3.''~ ;;i' ~ .. ~ ,l ~.~.g~ ~~~. [~~l~; ! ~ ~ 1'i·~IIQ.--r
s.:.ew 20ft Plsronanemb/y Nut 21)// BrHe pedal hilI< Qmerpin Washer Spill pm SpOClll/ was/rur Umollball 26 Sealm9 waS/ler 2 off 17
18 19 20 21 22 23 24 25
Thog lhe valve core. and when Ihe tyre is fully deflated. push lhe bead away from the wheel rim 00 bolh sides SO lhal Ihe beed enters lhe cenl.a well of lhe rim. Remove the locking ring and push the ty.e valve inlO Ihe IYM ilself. 2 Insert a tYM lever close 10 the valve and lever lhe edge of the Iy ... ove' lhe outside of Ihe ri"'- Very liltle lorce should be necessary; ~ re.islance is encountered it is probably due to Ihe lact Ihal lhe lyre beads have not enlerad Iha well ollhe rim. ell tho way round . On TZR models nOle Ihel damage to lhe solt alloy by ty.o levers cen be p.evenled by the use 01 plastic rim protectors. 3 Once the lyre hos been edged OVer the wheel rim, It is eesy 10 work rllund Ihe Wheel rirY), 10 Ih~llhe Iyr~ i$ completelv Iree f.om one side. AI Ihis stage Ihe inner·,ubecan be Mmoved. 4 Now wo tIOI& In rim. Partially screw on retaining r.uI 10 hold valve in place.
~ G
Chock thatlnnE!< tube Is positioned COIT9Ctly sod work tleCond bead over rim using lyre levers . Start at a point opposi1e valve.
Work final area of bead over rim whilst P'lsNng valve InwiU"ds 10 ensure that inner lube Is not !nipped
Chapt.,6 Wheell, br,k . . .nd lyres
'"
HAND
/
lola of ..... 'KpIfIenOId. bKauM thlnr • no _ lube 10 IUIIttnr. In I'lOtIllII eondillO!'11 e IUtkItn bIow..out i& II¥OOded II 1 puneltnr of lhe tyre occ:un.. lhe tyre JhouId be r1ImO¥fId fo< lnepec:toon 100" da""", betore IIlV 111111\91 • made 1\ remedial aclion. The temporlry rtlPI''' of 1 punc:tured Ivre by ~'"'II 1 plug hom the OUI" thouId not be '\llmPlloII. AAhouIJh I..... type 01 lemporery ...,.... II UNd wrdeIv on cera, Ihe """""'lCIurfIrI Ilrong1y .--nend In" no su::h ....,... • .:erned out on I molorcyde 1yN. Not only don the tyrtc ...... I ~ eerc:MI, """"""" don not .... IUlfociolnl ItrfIpOr\ 10 lhe plug. bul "c:onHqUII"ICM of • ItrdcMn o.IIal00n _ oftlll lUfliellntly MnOtII IhIIl the !ilk 01 su::h III oc:cuoreroc:e JhouId be I¥Oided 1\ all toIIlI 2 The Ivre.hould beinspecled bothinlide .ndOUI fordamagor tOl~ UnfOl.,n initllllnllation it to pI"HI the ty .. into Ilwangle b e t _ 1 .... 11 .nd lhe floot W'lh lhe .irl..... Iurched 10 the"aIvir Idd,trorurl pr-... is then QlPliId to lhe Ivre by the hind lind Jhin, . . ahown In the _ par .'ng Whnl"hon. The apphcaloon 01 pr-..re ,t lour paintl IM the dn ... chajn muat be removed from the tpIOCht to allow the wheel to
Of..,...
.otltehee1v
Chapter 7 Electrical system For InrOfmation relating 10 the 1997-on DTJ25 R models, see Chapter 8
--
F.-locaIion.....t ...-we! Hom;
___ IocatIon.....tt.""11 _ _ _ _ _ _ _ _ _ _
Tum eIgnIII reI.y: Ioca1Ion tond 'Kling low oil level warning lamp drcuit: telling _ ____ CocHn\ t..... pe..-tu.. ~ cltt;ult: 8ulbl; _ e l H_. ____ HH' _____ " ___ H._... _H ___
'"ling ___
--_- --
GMJ..3B1FB3L.8
12N§..38
nv ......
_ _ _ _ _ _ __ 2SOOtpm _ _ _ _ .__
~.VlI"'"\IOIIIIgII~3000tpm.
Ug/lllng-V-II'"
~.\
H •• H . _ _ _ _ _
rc:.lt.o'9::':::::::::.~C=:fl~:-----,--'ON
II
.,.-
nA.-
G.n....tor
_N.
H.___
HH' _ _ _ _ _ _ _ _ 'H
• " 1t 12 13
nV3A>
Mlery ill o;htdetunit into pIKe: donot 0YeOIInt t.... perllure Mnder Ipp$Ifl. 10 be faulty It can be 1"led by ~ III .. t1tPnclit II VIrioul'INTIperl' ...... To ICC()rI'IpIish this II will be necftIIrV '0 ~Iher together 1 healprOOf contllner 1n\0 which the tender t;IIn be placed, • bu",., of.orne clMcriptoon (I gN.powerwd GImPIng t.o.orr- would be 1duIl, I IhennomIllr ~of..-...tngbe'_«l·CIndI20·CI122·F 2"·F)andlfl otwnm.!.. or muItomet ... eapebIe of ..-.tng 0 200 ohmI wllh • ........t>Ie de?w of 1CCUrICy. 6 Fil the conI"'" WJth cold wal. and IrfI"III the . . . . unit 01\ ..",.,. __ 10 tNl lhe probe end IIInvnerMd in it. ~ _ 01 the
u..
......1
IeIocN to !he . . . . bocty and the OIher to the \IrlI'W\IIt SuIpend the tnermorneterlO ,.... \ the ~ It doH to the Hndet probe. 7 SIIrIIO ..... thewal .... and noteof the ....llnCereeding.,
met ...
mil,.
Chapte r 7 Elec:triullv. tem
'"
14.2. 1'181_ hNdlamp unit by 'em$C port to pw«lt the valve turning. U- unscrew the long Allen bolt which HCIftIII the two ~ 01 the valve together. Withdraw the right·hand vatve half. then the oil seal. valve sleeve with O-ring and left-hand vlllwl hall from the cyIoder barrel. taking care not to lose the two doWfII pins wtIIch ~iO'11N v.IYe IIaNet. 5 Check that the power vatve compooents ... clean and fI'ee from carbon deposits. F'"~ the dowel pn. in one hall 01 the \l81li, and Install the two haIYes as shown In Section 43 01 Chapter t. Ensure the dowel pint Io(;at, c:orr.elty. then lubriellt' the ~ of the Allen bolt wiIh molybdenum ....lpIQ ~ and Install the bolt fInoer tlQl>t. II .-sary. fiI e new O-ring to the velve sleeve. thel'llubr\e.ale the sleeve wiIh e smear 01 graese and install ~. Prevent the 1I$Iv, from turning .., before and tl{jhten the Allen bolt 10 the specified torque Mltong. 6 If nec:essary, fill new O-ring to the righi-hand end cap and ~It ~ wiIh e ~ 01 grease. Install the end cap and l!{Ihlen the securing IICIWW 10 the specified lorque HIIing. Check !hat Ihe power valve lurns smooth/V In Ita bole. 1 fnsld the ~ barleI IWld r-l as described In SectIOl'l 44 01 Chapter I, 6 If nec:essary. tit e new 011 II1I8I to the Ieft·hand and 01 the power valve aod lubrlcat, It wiIh I smear of grease. theI'Ilnstali the pulley housing
"".
2 If the notch and hole do not align. loosen both pulley cable adjuster locknuts and turn the ~ters cIockwIsa until Ihefe • sufficient IIIecIc In !tie cables to align !tie notch and lhe hole by hand. "-" • 4 mm diameter pin (s dr'oI bit 00' Allen key can "-used) ttvough!tle notch and Into the hole 10 hold !tie pulley In position. then adjust !tie cables equally 1,J:lI~ . . play i$ rert'IOY«f. Back olf the adjusters by 'I. tum. thin tighten the locknuts !WId ..-nove the pin. Switch the ignition ON and check the atqvnenI again.
"fie
Removing a nd refitting the YPVS components -
1991-on model s t Puff the rubber boot ott the ...-.omoIOO' to IICCe8I the savo pulley and remove !tie power v~ puIey cover on the left-hand side 01 !tie cylinder bar!et. Loosen both puIey cable adjuster locknuts and tum !tie adjuslers dockwfs.e until Ihefe i$ aufllcient slack in !tie cables 10 dIsconnecI lhem !n)m the savo puIey. 2 Insert e 4 mm diameter pin (e dr1I bit 00' Allen key can be used) through !tie notch in tile valve pulley and i1tO the hole In the ~ of the houeing to lock the pulley. then undo !tie centre bolt !WId f8ITICMI !tie pulley. Dosconnect the cabIeII and..-nove the pin. Undo the two bolts securing the hoI.ISir>g to !tie cylinder barrel and 11IITIOYII!tIe housing and
Chapter 8 The 1997-00 OT125 R models lind ~ Iht -=urlngpotta to Iht ~ torque MItIng. ConnecI Iht c--. 10 Iht .... pulley lind IIIIht pulley. Align Iht noIch In the pulley wfth the hole In the houMIg lind lock the pulley WIth a • nwn ~ pin _ ~. tIwI tigtII.. the boll to the IC*:iIIIId
--
'*'"
.--.1Ind
9 II ~ ...... Iht c:otWIKt the...ww.g. tIwIlnMaII Iht elIbIM on the _ pulley. With the .... pulley ItilIoc:kMI by the
pin........ the '*"- ~ mtiI II IrM ~ II; .....-..d. tIwI bKk oft the ~ by !urn lind IlgtlWI the . . . - locknut&. AImcMt Iht !WI WId en.d< Iht c-... ....".".1SKtIon .1. tIwI ..... the pulley _lind _ _ boaC.
I,.
10 Ignitlon .yatem -1~ rI'IOde'-
................
I The IICUW coil II; now ., lrQgraIl*I 01 the ~or -.or. The ~ tor Iwtng tNo IICUW coil ....~ II; _ ~ In SectIon 501 ChI!fIt_ 4.1'IOIi!IQ Iht.I themet_1hOuId bit MIlO theol'mt K 1000 ...... eomp.. the ~ with the IIp-=-
@
.::ffi!J@ ~@
1 t
@
~ .
s-
@)
~!
. ,.
.
. ..
e
-~
,,
€:I
~t
..
P
· @f
·'" • ! ·
®
1-------------
" 9
150
COfTIponeI11 key - DT 3RM 9 models onward
1 2 3 4
COl magne10 Neu\fal switch Rectifier/regulator Fuse
5 Battery 6 M91n switch 7 EnGine kill switch
8 Servomotor
9 COl unit 10 Ignition coli 11 Read switch 12 MO!Ier light 13 M(lter light 14 NvutraI indic;ator light 15 ~ Iftvellndicator light
16 High bftam indic:ato.-light 17
engine lempenitUffl gauge
18 Thermo unit 19 Turn IndOcalor light 20 NOOlral relay 21 Sldesland switch
22 Oil level switch 23 Rear brake switch 24 Front brake switch
25 TalVbrak& IIgl11 26 Flasher relay
27 Hom 28 Tum sigoallamp 29 Tum signal swi1ch 30 Hom SWItch 31 DIp SWItch
32 Lighting switch 33 Handlebat SWllchBs Oeft) 34 Parking lamp 35 Headlamp
Wlrs colour key
B B,
"'"
8M aN
B,'"
Blac k Brown Blaci
~ - - (Imp gil) ..,..,.. -(U$gII) - (Imp gil) US _ _
F~'"
II 0,03$4 •
.0305 • _1mI lIle08
Volume (capacity) ~quno(lmpqt)
~--(lmpglll)
Imptr\III gIIIgr-. (Imp gil) US~(USfi114
... ,s.6 • l..itreIIII II 1.201 • US (IIIont (US gil) .. 3.185 II
26.31\
II
0"54
......., ._..,
o..nc..-/an:ltfo;d;~ PolRh-~(Ibf;1bl _~1Nl
In,
Omp pi)
1I O.27fJ '" NfrfrItDNINI
1I 3.6
.«8
o..--/oI'CIe !OZt. 0Z3
1I
.0=
f>ol.nca.ton:. (lit; III
1I
0.1
1I 11.81
-~1Nl
II
...........
--- _.... ---
• KiograI'M-1oroe (kgI: kg)
.. 0.070 • ~Ioroe,*~
....
~
II
D.OM
.. 0.0&8
.
(koI/c:m';
.. 14.m.
~Ioroe 1* ....... Inch
!t*: IbUIn"; M'I')
kO'cm')
II 14._ •
x 14.5
1I 8.895 .~(kP~
1I 0.1"5
• ~lotcIper~ ~ (kgIIcm': 1IWcm') • PMcaI(p~ II 001"5. Pounds-IoroeI* ....... 1rlctI (pel: Won'; b'In') II 0.75 • ~oImen:uy(mmHg) II O.~l • Irw;ha 01 wet .. (InHp) .. 01 __ (inH:p)
1I 98.1
'* .......
Pounct.Icwct Inch (pi/; IbUW; b"on') ~Iorw 1* ~ Inch pI;lbIJ\+.b"on') Pounds-Ioroe per ....... Inch
(pII:Ibllln':IB'In'l
~(kP~
1I 0.01
M''''~
"00
I~
J
ge 36. 1:2 oI ...... dledt31.11'2
50'
L ~·'31,'3IS-138
~ Ind -..bIy56-57 rwfittJng 58, 59
~ 49.50
-" -"
~.tO •• ,
~
-."
.. _"
"''',,'' 011 ..... chect< 24
""""'"
o-cn.ng........,. -"
""""""
o..-.Ior.· refitmg 64, 140 ~48.1-40
l..cing 110', 95, 132, 133. 1"3
01 pump 30, eo - 92, 140, ,.\ 01 . . . . . 80 31
(hm t;nq~ ~ ~~chMl26-28
..- aurperoIion Inkage 35 ~.drIYt;37
--" .. .
~tIon5l3.
78. 139
.t~"-I~37
...".
H
oII .....