Yamaha YZF750R & YZF750SP 1993-1998 , YZF000R Thunderace 1996-2000 (Haynes Manual)

HAYNES SERVICE & REPAIR MANUAL

YAMAHA

YlF750R &YlF750SP '93 to '98 YlF1000R ThunderaCe '96 to

Yamaha YZF750R, YZF750SP and YZF1000R Thunderace Service and Repair Manual by Matthew Coombs (3720·288)

Models covered YZF750R. 1993 to 1997 (UK), 1994 to 1998 (US) YZF750SP. 1993 to 1997 (UK only) YZF1000R Thunderace. 1996 to 2000 (UK), 1997 only (US)

... _ " ' ... ...".. _ _ ""P* _ _

""""'_Ho,,"'I1'110 __... -...c.I,-......,. .......... "' __ .... "'.., ....... _ "'~ar_

~, ~

... oy

.~1

... , ....... , ......Iange or I......... _~In-""'llInlm .... oopyr\gIoI_.

!S8N , _ l 2 0 . _1.Ibr..,-~1n

~---.

l1li1

~o.t.e.

....

- . . , . "-Iruwy 195ti.rld W1'o rIamed 1hf1125 VA·' Red Dragonfly. Thl, machl.... a COllY 01 tne German OKW AT125 motorcycle.

'(If

"'a.

fe8\urlng. 'Ingle ~inder two-stroke engine wlln a lour-speed lI_bo .. . Due 10 the outstand,ng success of th,s model the moto>/cyc la operation was a&pa'aled from

Nippoo Gakki In July 1955 and tn. Yamat>o M,,!Of Company was formed. The VA·' a~ recei...cj accIaun by winning two of Japan'. biggflosl fQAd raoIlS, the Moun1 Fuji Cl imbing rBee and Ihe Asama Volcano ractI. The high ....,.. of putNil.., golf COIri. ~u'Ir1.1

robott, I.wnmower., swimmIng pooa. and areher'y equtprnenl

Two-strokes first

an 01 Yamaha', ~ was. whole string ollmovaUOM In ttlll two-.troke won,t Autolube eng ..... lubrication, torque WKluctlon. multH,otltd eng i...... ...cI

P

v. lv.. and power val..,.. kept Ih.I,

two·

.1rOkM at the !Of,1ron1 01 technology Many advanc. ... _ 1Ch~ with the UN 01 rICOI'IIiI .. a ~t I_ _tory, They ......,to!heUSA ... !he ... t~_ .. _· cooIoId 2500c \Won but didn't hrI!he ~ until the..ty t960s ~ FImklIto IIOOtIod a 11Mtrick 01 110111 _ _ in !he 1U&01 ManTT.!he Dutch TT..-.::tltle BeIgiIn GP, Thil.xper!mem ~ ... rt.. to !he ~ 01 the O'o' .. -the-(:ount .. _ ... _tI1at~.-btyin!heTDt. the I'nt 'on .. III'W'I'IIIIChe ..n.. 01 two-l1rokto r - . that ...... the ltandard i...... lor prtVIIt ..... '" ...tIoNII and int_toonaI _

IOf

~....,.

helped V..... he

-..op , _

roed "'gin..... While pI t... ln..

~ theFIMteg""'\>OI\a_~to

the IftIako GP cIaues 10 two cytn:jera. ~ "'otic biUoI dIIed but set !he ...,. lor an unparall.,ed cty"""y 01 ......·produced rteer"I baNd on the uma lechnology as Ihe road ~k .... In the 19605 and 70. the tVt'Q·"roIm, tIM InfonmItIorIlIfven.

0· 10

Safety first!

Prof9ssoonaI meci'>Anics ...... trained In sale working procedure". Howev .... entl!ut!astiC you may be about ge11i"ll on with the job al hand, I.. "" toe time to """"'" thaI yDflOO securely at al l tim .... Thi s i. espec ially Important _ the mach ....... IliOCk ad up to IlId _ or fork removal " De take care when attemJ>1.ing to Ioo$en a olubbom nut or boll. tt Is generally better to poll on a 5I>11n".. ratller than p~sI\. SO that il you slip. you fall away 'rom I he machine raltlar than onto it "Do wUr eye prolectlon when uSIng pow'" tOOl, .uCh .s dril l. send .... beng

• Always disconnect the battery ground (earth) t...." .....1 beIor1I worI<jng on the Iuet or IIIectricaI .y.~ (.><eepI1Io'tIIn notad). • "possit;Ma, Ioo$en the filial plugs or...whM charging the b.attery lrom an "",,,nal 1IOI.n:e. 00 oot charge at an excessive fIIle or

the battery may burst. • Taka ca" when lopplng up. cleaning or canying the battery. The acid electrolyta. "".nwhen di luted, I, very corr~v. and $hoI.J4d oot be allowed to OOfItoot the ~ or uoo. AI'ways _ ru_ giYa. _ gogo,""

-.

or • lace ohleld. II you ""'" nMd to prepar. alactrolyt" yourself. always add the acid oIowIy 10 the waifii'; .-.... ;odd the wa"" to the

Electricity • When u.ing an atectrie power tool. that th" Inspection light etc .• always apl'lianca i, correctly connected to Ita poIug and that. where nee ..saary. It III l>'opa!1y gro~nad). Do not usa such al'l'liancfll In daml' condit,on. and, agalfl, bewar.. 01 c,,"lng a spark or applying uces,lv" hftat In the "Icinfty 01 fuat or l uel

""!WrI!I

V8I>QIIf,AIso"""""lhlltltN!~""""

national ....fety standards. • A ""."r. electric shock can resu~ from toochlng CIIfI&in J)8I1s ot !hit electrical O)'SI""', such as the...,..... !>lUll _ (t-IT leedal. when the eng ine I. running or ~ng cranked. particularly 11 components a" daml' or lhe ;n""lal ion ;. defecli"... Wh_ an atectronic ignition "yolem i, usad. Ihe secondary (HTj vott""", Is much higher and could J>rBrIS " De remove rings. wns!watch etc .. before working on tn. vehicle - .sl>8Clally th • electrical system "" Da k... p YOU' work area lIdy _ It i. only too "".y to lall ov... arj iet.. ifill Iyi"ll

.-.

"0,, .~erclse cautlOf"l when Comp"tSSIr\g springs for removal or t"stDl laHon. Ensu" that the t""""", i. ~ and raIaaMd in ~ controlled manner. using sU itDblfl tools w!'Ik:h precIuOe the possibility of the Spr\r1g IIISCBJ>Ing -.1oIantly "De -,-""that any liltu.g tackle u~ has a ..afe Working toad ratlflQ adequale for the

..,

"Do get somllOM to check periodically that aU i1I welt, wher1 wor\e "" th& Vflhicle .

"" De carry out work 111 a logical sequence and chack 1hat IWerything is corractly _bled and tighter1f!d alterw8fdS "De that your vehicle's ulmy affects th at of yourse~ and ot her •. It In doubt on any peOnt, I1"t profassionDlIKMcoo. • II in of IoIIowIrl{J thllso! precau\IO

"*'*

(UK)

YlF1000F1~

Yl:J'1000A Tlu:1der_ YZF1(l()()fl Thundetace YZF1000f1 Thundentce

1000 .......... (uSI YHllXlCiA(tQ - 49-$Ial1 VZFlOOOR(KC) - CIobIomoII

-. the price 01

.... 01 _

"" """ "., ,,.. ,- . '" ''''''' ..." ," .,,' "" ,," ",. "" "" .'" "" ,"" "" .'" "" ,"'" "" "., ."" '''''' "'" """ "'" ,.W. "" "" 4H51

150 rnodM (US) VZF75OA(Fj - 49-lIate VZl'7MlR(FC) - QII,!omIa YZF75OF11H) • 49-_ VZF7SOR(HC) - c./domoa VZf75OA(J\ - 4ktat. Y2f75OA(JC) - Cal!fcmIIo YZF7!SOfl(l(J - 49·s181. VZf75OA(KC) - cailfomla

you
e rod ...sc:osi\y and cIo 001 overfMI

• """"')'11

'*'" •to I'l!IIdI notmII opsratJng

c.uwn: Do not ..... ~ IIddItiI'M .". oIfII wtrII • ~ ot CD or 1Iighw. 01" ..... .,..

-.~

--

_

Calli/on: 00 nOI ... n Iha angln. In .n lHIeltnMl

Sp«II

. uth "

• ,11.~'

Of'

"'"'--

~N~ftOYCONSERVINO

,'-,....." _ . " . . , . . eou/de.....

API ~ SE, SF Of

" '_

&.IrE tOW3O Of IOWCO

U8modoo ..

"" ........ the motOfCVdl undl.turl>ed tor. lew ~ to .-ow the 01...,.. 10 ItJIbIoN

dutch....,.

so

&AE 10W30

Of:>ow.co

·~IOIhIJ~,.."'-""ctIhlJOlibest .... '-'dIO'IfJU#"oondI'IIIona.

Bike care • ~ 1'00 ~ 10 KId oil frwQuIntIy.\'OU shOukIdwc< whifdWyou IIawo any oiIlMQ. If lhln .. no Iigr1 01 oiIlIekage from IhejOOt. 8nd ~ IIMt ....... caAd to. tuning oil (1M FIIUIt Fhdingj.

-W-tO"

Q'>

10" 20"

~ 40"~

! ! ! ! ! ! ! ! ~ :'OW(Jo j

i SloE IOWl49

:

~~bl": "'.el the 011

but lull«l to

1 ::~~~~= =:': =~Ioc~-:: .. ~

W~h

........ .r-.ld I..

'emoveIow 11>00 mInimum 10M, t h. fight-hand I.... ng s.lde-I*"'I (_ et>apt_ 8). 1WncI"" the h..... cap from 1M top oIl1Mt cluldl _

------....

_w.... _ .................... the I'IIOIOfCyde

mnmo.m ..,....... on 1M

~.

window ~WTOWed).

!he oM

Daily or (pre-ride) checks

0" 3

2 Coolant level check ia lmponanl thlt atUl"'HU I, used In the ~t"'" .n yur round, and not just In \he WItIMr Do IlOI lOP till' system up usong _ , .. the ~""' wiI ~ too dilVled

ontv

Before you start II'

~ - . 1TI1loo*I bI .....lJga!ed..........edoat

FRONT BRAKE FLUID LEVEL (CONTlNUED OVERlEAF)

mi.,.,....

0" 4

Daily or (pre-ride) checks FRONT BRAKE FLUID LEVEL (CONTINUED)

REAR BRAKE FLUID LEVEL

Ylf750R SP 5 1Iw'o\.9I1he __ rrwI atxwe LOWER ..........., H II 1M LOWER ......... ......,..... cap On

...,;I models, Ihe ,.., t:nke fluid ....... 'Alible body - ~ be \he ....... DIllow !he ...voIr clamp ,..;r.,w (Irrowed) vod .....-oove the cla'np. Support the .--voIr uprIgI\l. UlIXAtW lhe cap _ .............. tt>oo dl~ pIaIe and the

--

"*'

8

!:,~~:t~h:~~~ !e,:.41~~d=~

01'1_

matk. Take car. 10 aWlid spik ( _ Warning prwyioua~.

9

Ens~r.

U,,' Ih' d iaphragm Is eOmtC:lly

_led bel",. Installlrlg ItHt plaIa and Tight ... the cap~, On YZFT50R ..m SP mocIM;, fit '1'4 c~ clamp. On 'YZFl000R models, light.., the mounting IICrew. Ins'" the side covwjl) CO' _I o;owIng ClIp.

(_Chap,. 8).

Daily or (pre-ride) checks

0' "

4 Clutch fluid level check

A •

w.,..;"g:

a,..P<Mri>SI - h_

dutcII

,...,.... _ tione, . . .

~ ~

_~".,...,

fluid

c.n"""" _.,... _

sumxmdIfnsII aurt.c.. wflh .-g.

__

Before you start: "" Support tile motorcycle in .., upright pet'e in the syst ...., wI\od1 IhooId t.. ""_tlgIted imrnMIIately

" -r "~ ...

~

• ChecII tOt ~ oIl1uld ~ from tI'le hyd .... lie hoM alld component. - II round rwctify....-tl!ly • ChK:Ir.Ihe CII*Eon ot the CIuId'I; I f _ • ~ or ... on Itw av-t_ t-Pngy !MIllO lh. lev..}. bletd the clutch U deacribed in

Chap'«:

~ '-'$\ '~

""~.'~"~

I' I" f"111 ......J..:...( 1..1{~, 1

_ SP model •. 'M cllllch IS visible . 1 Or> VZF750R n_ be_u..lOWER ...... !he"'" II the LOWER ...... n . .......,...1'" fluid

~

II'WOugtlIhe_body_ . If

,

....

~

~ ""P clllmp _ _ (.rrowed), then u~w the c.p .n.d .....,.... !he dillphregm plet. and II-. dl~

...... h.... Tak, c. ... to ."'lId SPiI' (_

w...-.g ~.

5 :.~:;cap.:~:-i:'I:;~-o;~S =~~'~ On SP

co_

Of

YZF1~.nd

.::.n !he c.p WIth itS c:IIImp

mocMola.

0" 6

Daily or (pre-ride) checks

5 Tyre checks The correct pressures •

noc

The tyr. ..... , t.. cl\eckMl _ cold ~ aft. riding. NoI,1tIat Iow~

Pf8SWreI II'IIY CIUH the ty .. to slop on ,"rim or comeofl. Hightvr ~ wlM cause ...,.""... __ and.. ..... 1. hIndIlog.

• Usoo . . ~. ~ gauge. • PtoI*'" ~ wII ncr- tyre III, and provide mulmum .t'bolrty and rIOe

-""'

.t...-

lYre care • Check tile 'Yr- c.refIAy t", - . t ..... IImtMdcSed naft or ott- sharp otIjoIets and u _ _ . Openollon ot tI1e motorqocle with

' ~C".I~.ly

wOrn ry.... I, ut... m~y

I'WIUrdoul, . . I,acllon Ind hlndhng .... dIr8c:tIy.tl~.

•

Check the condition 01 11-. tyre ....... ....:I

-..tMo..\ c.pialn~.

• PIck out any or Raila whld> m.-y ....... bec:ornI ~ In IhII lyre 1rMd. II WI. ttwv wII ~ ~ II'lwgh tI1e c.Ing and _ • punc\lA.

--. •

II tyra damage II apparent, or unexplained sa ot preslUta .. uptrleneclc 11111 1"- Ih,oW.

ct.:k that MIntand

gnp ,olalH

I1IWm IIfl'Ing holds

the "and eec...-e/y up when retrac!ed.

•

Tl'1I. may - . " obvOous. but chKI! th.1 """"g~ fuel \0 compll'. your If you notlOe.q,. o f fuellMk.ager..::dty !he _ _ inmedlaIeIy.

you h.ve

Ensure you I.e \"- correc:I grade fuel 0'I0Ipt.- • SpecII\cabara.

,.,

Chapter 1 Routine maintenance and Servicing Contents

,

Nt l1li.. _ cINnng IUId ...--.l All«rla10f brushes - . -..AI SIn...,. - charging a.n...,. - check

---=-

Ban...,. -.....,.."....

8nN _

~.

"

.._Chapt.,e

"

r.pectlcn_

clutch 1 - . - _ _

29 --et.pr.&

8nN WId dutch mut. c;:yIndIw ....::I caI!*"-- cyIIrIdw ..... -

...-...

..2tI

Stake IIuid le>tel check .

DeIly (pr8-ride) u-kI

. .. _

a

Bl'11cI~-w_c:twd
edeI*;

NGK CR9E or 0.710 O.S INn

'''' "',.,.,., gap . '''' ElectrOOe 0II!l '

......Ellctrode

N~

NGK 04'18£A Of

L127ESR·N

NI~

X24ESR-U

0.6100.1 mm

VZF15OF1 r
..""

16Nm 110Nnl

""" ''''.., """" m """ """

,

,.4Maintenance schedule Nol. :

n.. dally (pt-.-ndfI) chKkI oorHt>fld...

u...,...,..".--...t covers !110M ItetN whlch • dilly basIs............,.. P¥form ,IIe p,.tide iIllP'K'l(In .1 -->' should tt. 1Mpect.d on

....m~ Inr.rv~ (In ~I/OII 10 rile proc«/urIU HS led). inftlllleJ. /lfr.,. bM>w are III. intflf'l"/s teCOmmended by t~

n..

manulKrur... kx eecll ".,rJcuIM opInIlion

Daily (pre-ride) See Deily (pI&-ride) checks at the beginning of this

Every 8000 miles (12,000 km) or 12 months (whichever comes sooner)

.........

manual.

c.v.y aut l1li tIN iMmS """'"" rile 4000 mIM (I!lOOO 11m) checII. p/I4 tIN

After the initial 600 miles (1000 km) II USUiIify ptJtfomwKJ cr. YtmIhI dM/Ir fIIIw lIN

flak: 1hiI _ fim 600 _

r:II!ring rile ~ ""'" cOVMKt In 1hI. m.nl.llli. Y!XJr OWtltl,', ",-null mlY he .... rMfwen//nteM/s Irx 'JOUf model.

(I OOO 11m) from rHIW.

.,.mad out ~ 10 11M ~

~1Mf'.

Q

mall!_ Is

Change the eng.neltransmission Oil and filter (Section 21) Renew !he spark plugs (Section 2)

In,.,..,. 01 eM ldIeduie

Every 300 miles (600 km) YZF750R and SP Check, adjust, clean and lubricate the drive chain

(Section 1)

Every 600 miles (1000 km) YZF1000R

Every 16,000 miles (24,000 km) or two years (whichever comes sooner)

""-

ca..y aut II rile _ _ _ !he 8000 mIM (12.000 Icm) cMdQSP)

10 Englfle/lranSlT'lWioo oil fillet cap

Component locations on left-hand side - YZF750R and SP models I

CJtJtchffuld~

2

Stvering head bearings Idle speed /lCliU$ter

3

(YZRSOR)

.. , 8

AltttrrllalOf EXUP pulley COWW" Coolant drain plug in water

1

-,.,.

8

",mp

_ _ oiI

COoism cklJIn plug in

cytinder block II

Ertgine/rran~mJuJon

,""

oil

,

'.6 Maintenance - component location Component locations on right-hand side - YZF1 OOOR model r-------------------------~

1

Coo/aIItreservoir

2

RMr brake fluid res&voir In-line /vel fiitw Air filter Front bUId c:ornbInoo .u \tie check, 1m" one Wo-lniIisI ~ lWId th.., loto the malntenaOCfl achadule

2 o.cldlng wt.er. \0 11811 or plug into lhe routine maintenance achIocI .... dependI on - - ' lacIon.. " !hit -..nty period on )'
to II'IIIt listed In thll Ctlapter'a Speclfleatiool ( _ IIIus' riltlon) ..... 1M C/I!Iin '!reIet. wtrh W_. ..:Iiu.I",.,,1 will periodically 1M ~

t- beIowJ. Slnoe the chain will

. .ely wear.....nly, roIlM I)iq fc<warda ... IhM waocher MCtIon 01 chain can be ~;

do IN, _ _ I tlm.. 10 eheck lila IIItll' length 01 chain. .. II the challl h •• 'Helle
1 _ Illustration) II Iospect the drive chall! sWdar 0(1 the swingarm tor &l
to ehepter 7 fOl' /nformetlon on "h"'~lng

Refer

wheel e llgnmenl.

12 II Ihere Is a dls.crepal'l¢)l In the chain adluatllf positions, adjust one 011l'l9m so that ~s position fs e> Lubrication 14 II required, wa!lll Iha chain In paraffin then wipe ~ off and allow k 10 '*'I, using compressed air W available. N the chain Is excessively dirty ~ should be removad from the machln. and allowed to loak In Ihe paraffin (1M ChapI ... 6). CII"tion: Don~ UN petrol IgII8OIineJ, .."...", or Ofher cle"n/nl1 flu/ds "'hleh m/f1ht 1IMn1l~ the "'".mlll _IInl1 properties of tha "haln. Don~ "Ia hll1h-PBSs"re war .... (k~}.

The en"... process shouldn't ,"ke lon_

Every 300 miles (yZF750), every 600 miles (YZF1000)

1. 9

"""""ut ..

llYn -Wltdon, tIM O-rfnSroo In !tie cit';" ron.r. could be dtnn~ 15 Fa< routi". iubrieation. the best tim. '0 ...t.-lo;'''1 the chaolll.tl.h ~ 11M ~ tIddetl. WMn the chain .. warm, the 1..obrIcwoI .... ~.IM~~1he IIde plat" belt.. !han wilen cold N ot.: y........ spIICh'iM SAE 30 m 50 W ~ oil: do nor us. eNj" ru~, wllieh m.¥ co""jn ~ts 11>11 cOUld _goo /he O·ring•. ....... It is ~ Tor O-mg chehs. ~ U. Iubrican! 10 II-. _ """"' the Iidto pIa\tI8 - ' a p - not t .... mldd.. 01 ,..... on .... 1_

-.

Every 4000 miles (6000 km) or 6 months pt...,.m any din tailing Into the q i n e _ UM~""...........:I.

1 ~.k. su"

you •• park plug IIQC:k-' fIi the

.nempUng to _ . "'" Is ....pplied In ttle rnotort:yo:Ie', tool kit whictlls ~ UI"IO:Nr \he

COINCt sIZII !)eIcq ~

_.

- • sort,tIIe ooe

~

"""". 2 UsIng

U.. '"lIng side

~

~

t_

IIIr WiMIiIabIe.~"" IhII

I.M around the b. . . 01 , .... spark ph.>g' to

ma/k.,

3 et.dc IIIal UM "'fIind sflul s 1,,,-, t'-1 rechKl< 1M idle 1PMd. II

'ew

-V,,,,-#III~~.

c.n'

5 II. ImOOIh, _ y Idle boo_, '''' , ....... alI' mi>ctu......y be incot'rect (chick the pllOIocraw Mltmg. - ..... ChIjltar 4) or tha ~ may ~ sync:hroniP>g ( _ Section 4), AJao dleCk the Inllka manifold nJ _ _

I,,~""'k:llwiM_"''''

leak. rw.IIing In ......... 1YD:!I.n.

~"~I.lfroul{Jlll""Yfuelor!

~"""""""oII""""'-'~IO'ifh_ .ttd _ _ WI'Ien rou P«f«m ..." kind at

_m . . . .

worl< on I"a f"si syslam, WI.' uf.ty gill.... .nd ".... • II,. ax/;"I1"I."., .,,/table fOI' • Cia.. B typII ".. (fmnmlIbJa

WMnJng: T.k.

~,

...... "ot to

bum~_or!_""'''''''''''

unll w"en • .,.,..aI"l1 ,Ita g.~ tak...," point. or! Iha Milk. rnanIfokIs. Do nol allow f1ISII 10 build up IrI Ilta _ - - " _petfomIlhad-" ~ •

.xIIII",,'

W 1!\41 ..:urIng Ih1 .... M..- _ 10 "" r.tt.

ICf1WS

12 When tIM adJUltment I. completl, -'** IIw ya;o.o,m ~ IIw Idle apeed Section 3) unlil 1M apeed

g, ......aYe IIw CO\f1I" IMId withdraw 1M M. element /rom 1M housing t_

Every 4000 miles or 6 months

3 On YZFl000R modeII. ~ u... ~~ MCUring tile ai. fitter coyer 10 tile lin... hoed Ihe mounting plat" gaskfll In Ihe bottom of the tank lor IeIIb.

"*

2 II lhe lu.I lap II; leaking. lighten lIMo .......bIy IICI'ew. ....:I mounting bolls ( _ Chapter .~ IIIMkaQe persiIa ....,.,. the Up and diM_bIe It, notong how the c:ornpc:on.nt. fit. 1nspM:t . . comporwJlS lind

replacto any that era "'om or dam~ed with ' - ~ H.... allat"-. oo...wIIoI fit • ..w tap. 3 II tMe carburettor gukal. I," INking, the

sapanlle!y. "" In-line fuel litter. Iit\MI In lho hose from the toe! lap to the ..... pump ( _ IIhJstratlon) . R«nOVtI In. IueI tank fOf acceu lsee~ .. 4). If 1ha d~ Of cIoQgad,

lilt.,.. up....,dlaoDnnect

ottwwIIe rwedI ...--aI. haw I rag hIIld>' to IOIik 11IIiduIoIIueI, then ....... Ina

0
QN', Of

while the IfI!jine II "'""'*'II. 1ha EXUP '¥It.... on 1995-on VZF750A and SP 1T"OOdfIM..-.d all YZF1000R model. performs lis own ..,, -

4. 10 Unscr_ thto boIll (..,.owed) IfId

"'*

--

........

11.12.- ChacI< .... ~In_ 1t1t Is Inooonoct. adjuIt It .. 6a801beJ.1r>IaI1Ing \hoi Into \hoi ..... 1-owedI.., It IockI

'*'

,.......

4.12b EXUP cable

~

MlJustaR

Every 4000 miles or 6 months

"'5

""_"tt.r.c.-.g. tt.I::_:~.:.~~:",,:~;::';~:~~:::;~;;~:~;::~;~:::: into

I~

hole 1_

illustration I , ,:la) Tum

""'~""QU[umiliI_1Igtrt.

tt.'I tum" In by '''~ tum on YlF75OR....:I SP 1/2 tum on VZfl000R modeII., u..n loghl.,. tile Iockrings. Remove Ille POll !rom tIM _ ....:I ctw:k ItIaIIhll frMpIay ~ as I!)eCHI«I ..-d ~ lor IMICh cable. 13 Install the cOlIer and Ugh'.., !tie bolls to tIM ~ HIring specified at IhII beoglnnlng of Ihe lI ...tnot!on &,101.

_.1Ind

ChapI_,_

Englneltr8nsmiAion -

'" """" A

Wa rning;

Sa

e. ,..flJl

...,.."

I

dra lnl"fi Ihe 011, s. rI, • •• "a"sl p/JMo., tIN 611Q'lrN, IiI>d th. 01/11,-'1 c... .,.use _ _ tNlm .. 1 c:or...tent fOI,I\lne .... ....,. fill., c:NIf'I(jeoI fIII1I 1M au>gle molt Important malnt_nc:. Pf'IC*'UN you c.1 piIt10nn on • ~. TIle 01 noll f1I't1ltJbric:ata. the lnIwMI f*\IC of the engImI , t.anatTllUICfl and clutch. buI ~

.... _

7.4c To...-the old IMIIIng w . ....,

Check the condition 01 tt. MaIing washer on the drain pUg ...., dIacard ~ If ~ is da'naged or worn _ ~ wit ~ t. necessary to CUI 1M old one off ~ pIWI , _ nlustrallonl. 5 When 1M oil h9I completely drained. lit the plug Into the e or ItnII ........ Stop till ang/ne, WIllI • lew ~. then ctMock II'1e oil level. H ~. ao:Id lflOAloiltotmg 1M level up to 1M ma>:.mum level .... on \he window. Check .-cunei \he drain pUg thallIwto . . no-'

~ ,

•

. . . coolant,. _

•• _

•.

n-._.

.-.d. proIectant. S - - 01 ,he 011 taltM , Ulfrlr", amount 01 _buM and II'IOIikI De chaooed ott.., wllh ' - 011 of \he f'ICOIm1eI\ded grlKle and type. SaYIng • lillie ~ on Ih' diffMence In COil DeIWMIl. 000d oil Md • c'*'t> oil won" ~ oft" lhot tong .... II damao-d. The 011 fin .. s _ be

..

l Ab ..• IIId IIIIow the 011 10 linin

u-.o

ma-imum and minimum ,,,,,81 II... on the inspecIioo window 1_ CWy~) CI'I8Cb,I.

~ •

I

s.a..;"g.lItfMmonoeyontN

.-

r1iff_ be,"""",, good

_

cfIoNp'"

-.1,.., otf

"tN~II~

..

.

7 Every so otten, and ~11y u Yamahe 00 not lit '" 011 praaiU switch and warning light (the system lilled ullH "" 011 "'vIII

~-..iIh....,seoond oI~

2 a.tON changIng ItIe oil, w ...... up the ........ Ihe ...... chin MSitt- Remove II-. ~ fulng and !hoi nghl-haI'Id !airing side

PI'lII i_ ChtIpI.- 8). 3 Pul the motorcycle on ~s iJkIHtanCl, and potlllon. clIog - Ihe m~ Is 0.5 mm, • Rill. 10 Chapl.

7 lor delalls 01 pad

-.

1 A rouIlo& genera l chack 0I1IIe brake aysI ....

will ....... lllal IIOy probIamI ... ~

2

lhe brake Ia_ and pedal fur Improper o. .ough acllon. pl ay. bandl. and Olh. damage. RepIaao any damaged ~ wi1h ..... OI'M t - c:r..pt. 1). CIs-. ..., Iubricale the _ CIlIc~

~en....

e . ~assi ....

badlng ma, .. iallOfm the wear Indlcators-

..., padIII pivots If !heir action " ,1If1 ..-1QUgh ( _ SactIon 161

when they ... alrnoM cantactil'lg the; disc ~sel t the ~ Jn4I be..--.d. The Indir;ators . . visibII by looking .t the bottom corner of the pad. ( _ Illu s trational . Nol.: a n.,-

3 Make lura au brlke fas' ........ Ire 'Ighl. Check the tnIut ~ lor _ ~ Saction 81 ...,,,...... . . . thellliid,...,..,\tIe--.o .. Is COfTICt ( _ Dally (pre·ride) cII«:,b). Look

.scm.

9 .3 Flea .... ~k. ho. . ...cI ~k lOt crllIf81.. w,*, IhI fronl brake I...,.,. I, pulled In. The lront brake light Iwllch. mw:lIed on !he underside oIlha mBll.~. II not adJuIIab/a If ~ Ilill to 0f>If811 propwty. chac;k 11 (1M before thl .ea. brake ta k.. Iflact II

and .1In\IId1ad belore 1M ridar'1 ""ety II

I Each bfake pad hIS wear 11Id1c.tors that can be vlewMl without removing tIM !>lid. fram the c.Iper. 2 The lu,,"oed In com.t1I of the brat" ~

..-.-y,.,..

5 Make ..... the brake light II activated just

""'"

."'.-

lor leaks at Iha t-. ~ ...cI chack lor crlClIiQI'rt ( _ Step 5).

1.7b Sieck... the IoeIllclced lor p"oI*

----_....

tigh~.

--

13.2 Checking 101' pWy In

If.,.,

Engne(l/l_~

!he_

~_.taIce_dJtcII_.

end M/ot ptKJeI bOI/$

Foolrest

3 pIrf II det..:ted In !he r..r., or Wu-.. whHI _ no! rotate smoothly (and !his Is not _ to tnb or I.............. drag). _ whHI 'oMtIngs inapected lor

P..,~. !t _to_ l oIow'i-Ig·

mus' be; rlII\"IOV'td and _ or darrnIge ( _

"'-".

_"...:1

bOI/$

dIrecI.,;! tIvoug/I tIM h from the b8c:bide. " the h ... bent 01 distorted. ~ !hem

FrMt aodeboltendadlo~_ FIOIIIib't dImp bolls p::tp find bottom

1IWl:J01ol. 01 tIM radiator'a " " " - . . . "-tal

--~

. - - - by

--

disc _

~st 'l"Mm boII.sI""r. 3 II • 10OIanI ltaina 001 !he CIUISidIo 01 tIM CON I>oIow tIM ...... Hleeks ... not.,;!. 'eefon ...." ,he bi.Ir&

A , •

8 Chtoclt that the Ihfottle twlsigrip opera", ....aothly and ut qtJickly when

.-

lin..,. ....

Choice cable 1 II the c;:I\(>Q doll not or:-ata ~ this II probably due 10 , cable faI/I. "*'- If-. cable (see Chapt. 4) and lubrical' h (SM $action '8). I~ the cable, •.,ut,,"iI h 10 H takes the ..-nool*1 _II po<SSibIe 8 II It'Iis tails to imPg eond~lon to

.......... riW "'-'V.~. worn or ~ '"'~ partl dec ..... IIIto motorcycle', IllabiIit)'...-.dCOl'IfOl.

Front auspens lon

Rear suspett810fl 5 I"'I*'! the __ -'IOd< for IIuid leakage and IighIMss ~ its mounl'''OI. If leakage 1ll1ound. • n...... shoc~ .ho~kj be Instan.d (aM ChapI.6j.

e

2 While a\.lOdlog alonOtlde the mot~, apply \he Iroot tnlce and puIh on 11>10 I'l.and~ 10 tomP""'" lhe forb _ ..

WrIh the aid 01 . . -..IIItanI 10 support the Dilla. comprest 1M __ ~ IMI¥WaI

IllnM, See II tt.y ~ up.ancHlown ~ without bnIing. "l:WIdrog .. !WI. "'" foo'k8 thouId be dtsassembIIod ..-.;I qp.cted (sH ChapI.. 0)

wIIhouI t.IdIng. " WI)' birdng" felt. the """'" 00' laulty componenl mUll be iderlt,/Ied and ...--ed. n. ptobIwn could be .... 10 IIi!hw

3 Inspect tile area around the ous, _I lor sig'" of oIIleakaQe. carefully __ ott tM duat seal UIInQ a IW·DIaded ~ and lnapect the .... around the Iori< _ I (He ftlustfatlonll W-...., .. ....-s.rrt. _ ..... must to. fitt.,;l I.- CMpt.- &). DIede !hot kIfI< ~1or~ •• ~_PlIIlno;J ..

components 00' the IwIrIgarm compon,,,,•. 7 Support lhe rnoiOO'cy.:fe uting an .u ~ 1I1ary stand so that the __ ""*M '" ott the ground. Grab the ...... ngarm end rocl< It from 111M to 111M - u-e Ihould be no discernible rnavement at the .... (Y....- specify •

"*'

hmM. It aIIoukj

.no... up

and down ""'Y

lhe shock abeort>w. thoI .... spwlSion Ilnkagil

_I.-et.pwe).

rnaunum of t rnml (He muatratlon}. " tt...·1 • little moYWTWIt 01' • sight dicIdng CW1 be _ . It\IfIeCI the tight..-. 01 .. the rear suapoonalon mounllng _ and nut ..

4 Chtdt the light.- ~ all ~ nul. _ bolts to to. __ non. have WOfktod 100M. retemng 10 the torque senlrlgS specified lIIlM ~ 01 CIIapI. 6.

relerring 10 the t~ M!tingI ~ at the beginning 01 ChaPI. e. and ,,·cheIts in IhII lop yok_

-....-

!_

20.7b .•• than 1.II'ISC<ew tha I\andIaOIr" positioning bolt to'J. tha hllndlebar clllfTlp bah (8) a nd tha IorI< clam9 bolt (e) on each llde

1. 22

Every 4000 miles or 6 months

. ~tt..~

.... nuI_"""""

It Illong ",i1h Its w",,*. ,..,.,... fitted , _

iIIuWatIonl. , Gently •• se tile tOIl yoQ IIPW",o. off

I~

10!1< tuDei and posIIlor\ It~. vsng. "III 10 Ptoteet the tank Of olh.. compoMllta ,_

"'........

10 Raomove the tlbbtd Iockwast., noting hOw It rotl, U- ~ and ........... the Iocktlut using .m.... • C'''I*\ner, • peg apanf* or • dtfft Iocellid in one 01 \he

r\OlchH ,.... lIIustratlona). Remove tile rubbef washe< '1M Illu• ....uonJ.

..:Ijualer nul and 1M wr....::h IOCI<et in \he e.pecial tool (_ IllustrHlon) . Now aIaekton Ihe nut "" !hal It It ~. then tIghIen It 10 II'W final IOt'l"" Mltlng tpeCH~. Check that thoI II-ng is .un able to move freely from IkM 10 lido, but _ .. 1rwpj8y .. eliminated. 12 II the V....... t ..... is noI • ...-..-. ueIng t/tIIer.c.~,.peg-..-or. CIrlfI. Iocurlng.. 13 With tile bearings eomoetly adjusted. install the and the lDc:l IhM tile IQ lit nto the In boIh the locknut and adjoAt. nut t - _tratIon 20.10.}. 1.. r~ tile tOIl yoU ontO the "-""U 11....

not"'"

(see iIustrItIon 20 .... IhIJl tosIIIIlht WISI'lIr rwn.r. m tedj and 5t~r>g 51em nut and tight"" ~ to tIw IDg ~Iad alltNt

Every 4000 miles or 6 months

'·'3

begIir'oniI>g 01 the CMpIIlr , _ M....htion.j Now l~hl1ln both lhol tone clllITIP boll. 10 the 'l*'d~ t~ Mtling 1_ MI .......Ilon) . 15 lnaIaIIlt1e MndIebIr po./tJoning bolts rod light.., them to the specifIMIlorque settJng, ~ t9Mn the ~ $/TIp boItIlO the II!*'1I1aod torqu. , _ 1II"'trlllo"I), RIttle ~anklno caps Into lhol positioning DOlts 1_ Ilut ...MIon 20.7-1 . la ntoI the from brtoke ...... c:yIIndet,...:I on VZF150R .rod SP !'IlCJd* II'1II dutch . . eyHndow, onto the top yok. and t;gllien the boft(" IKUlIIy 1_ llustratlonl 2O.S. and b). 17 AI-check \h' beRt'lng Idjuetment .. dMcrIbed &bow and r&-adjust " ~

Every 8000 miles (12,000 km) or 12 months CaI7)' out ,II tile It~5 undfJ, the 4000 mile (6000 !em) cI>«JI. plus u.. foIowtIg:

21~ oil and lilter change

&. I

Wlm/ng,

S,

~

~

r:_,. '" 1

...hM

min/nil the oil, •• the ... h ....t • pIpN, Ihe ~ ~ the oil /fNIf un c............ bum .. 1 Drain the 'r>gl"t oil &I dl",rlbed In SIoetIon 7. St_ 1 10 5.

2 Now plaoe the drain tnly below It1e 011 fin .... wl\k:h if, . t the Iront 01 lhol eng,ne. UI'I8CI'_ the oi .... uaong _titer...-lng su.p, cot... Of -wdllnd tip any rMIOue 01 into the draWl tray lIIu,tr,tIona). WIpe any oR ottIlie IKhaus! plPM to Pf ..... nt 100 much amok,

,t"

when)'Ol'tUlrlIl.

3 s..- dMn engine 01 onto th& nbbIr MIll on the new fill.,., !hen manoeuvre It Into pOMion rod _ ~ onto !hit .-.gine until the Hal jus' lINts ISH iIIut t'ltlons) . If lh' correct 100II •• Iv";labIe. 19h1eo the till. 10 the lorq .... Nttlng speclIIed ,I the ~

1

1· 24

Every 8000 miles or 12 months

of In. Chllpl.. I _ 1II"ltr.llon). OtI*Wl ....

I9tten the till.- as tlgIII .. pSSibIoI by hand, or Oy !". nurnDW 01 I....... ~"iog

rna

Z1 va/vto clearances check and adjustment 1 The 80\1l1li mull be compIelely coo/lor "'it. maint-.ce ~ .... tat the machinoo lit baIore bagooning. 2 RamoYil lhe valva cov .... ( _ Ckepter 2). Eltch cy\iflderll referred to by. number. They . . runberad 1 10 4 from tanto rIjtII. 3 MMII II ChWt or IkIII;:h 01 .. _ poeItIOnI ~ht

eo IhM a nota of 8Idl cIMrsnce can be made ~ Ihe '"""'-" ........

4 Ramovto tile leh-hand crankshaft end-

co_, secured by Ihree ",.ews, and !he umong ~ plug ( _ lIIu11l"alion). The C-rlngs call be .eused 1/ lhey .. a In 000d conown

!he ........ ~ • the ball . . . to. . _ 1ns\8lld of a collar - tighten the """ IIQIIinSIIhe end 01 the crankaha!! 10 lock tha boll (... UI"ltritlon) The qiM CIII'I I'>OW be Iurned

usang the boll ,"x. l..-ning it In an ....11clockwl.. direction only (.... lIIultratlonl

A.ltem"r .... ly. pl _ Ih' motorcycle on an It.10' 1_ ....tmIonl. The No. 2 eyIinder ill now.t roc on IN COmprMSlon Itrok.. MNlUr. IN ~anc:ee 01 In. No. 2 cyIInUer ....... ....-og the m.thod descrlt;,..;Iln $11p 8.

IlIutlrlllonl' II lIMo cam 10_ ar. facing ~ ..::h other 80d the dati do not ~.

e

Nowlunh ..... ~t8O'(NII Ium) .., that tt. 'T' ..-.k 00 tt. roIOr IgIIin

rctaI.the . . . . . i~ 'ww36O"fgneU U'!\I.a Ih8I the T nwI< ~ _ _ with the p..-nl. in the Inspection window The carrlahaft IcbM win now be lacing away from

-.._tt.~~ tt.~...n:Iow

No.1

(Ieft.~~I_.waylrom.::h

Nell other aoo \ha dot. will be . 'Igntod. m.."lng the No 1 cylinder Is .1 TOC (top d.:I 0WItr-l on 11M CCIn'IpN5SIOn IJIrd
."""abl.,). tile

v.~

Is probably nor sealing

com!CtIy _ to .. build..", ofc.vl>on deposits lind should b$ chM;~~ and c,",,&d or IMUrfaced as requited Chapter 2).

r-

15 Obtain the ,aplaCflmeot shim. then luMeal" It wllh molybd""um disulphldfl and iii ~ Into Its recess In the top of !he ""IV8, with the size markir>g on each shim locing down 1_ illust ration) . Check ItIat the shim Is corMd disconnect the hose" from the

~.

Non-scheduled maintenance 30 Headlight aim check and adjustment

~ ~I

'"

Not,; An improperly edjusled r-1IigM mil)' c.",." probl!tfrn for orn::omlng traffIC or provide poor. ""safe illumination of the rOMI M»M. 8etOIfI ad;usllng !he '-dIigIl1 aim, be

Sulll 10 consult with Ioclll/raffrc laws and regvllJtions - f<x UK models reler to MOT Tes! et.d<s In !he 1lfIfftn!nce Merion. 1 The head!iQh! beam cao be adjusted both norizontally and EIeIor1o rnakrog ""Y

"""""'fly.

Bdjustment. chock thAt 111.. tyr..

~

.....

correct aod th .. suspenslOf' 11 adjusted as ''''lulred. Mak.. a ny ad justments to Ihe hiladl ighl aim with th .. machine on lev," ground , with the fuel tank half lull and with .. as.lslanl sittinll on tl14l .... al. ~ the blk .. 15 us.uaJIy ridden with a pas.aeoger on thil bao:;k. have a secood assistant to do this. 2

On

YZF750R aOO $P mod .. ls. venfcaJ

adjustmMlt I. made by turn ing Ihe adju.ter screw Of' tll8 top irIner comer of the headlight uoil C.... illustration) Turn It ckx:kwi.e to .aiM \he beam. and . . \i·CIOCkwise 10 lower ~. HortzonlaJ adjustmeM Is made by wmirIg the adjust... !!CNIW on the botlom out ... """"" of tt>e heedlight ....1. Fort"" riQht.hMd light uoit.

master cyllr.:Iers end caliperN$Ia"9 cylloder.

Always raplace the banjO unkJrl .eallng wasllenl wilh . - ones.

'·30 Non-scheduled maintenance

turn it ~ 10 mow. lhe DUm 10 the 1Igm, Ind ~ 10 " - h 10 the WI.. For 1M left·t.Id light unil. 1U'II1I cIockw1se to """'. ttle bum 10 In. rIg~t. ami antidockwlte to move 11 to the left. 3 00 YZ~'OOOR~, vertlt;al .cIJlI$tment S _ by turning the adjust.- kootJ on bottom outer CorIIW 01 Nell _'~t unit 1_ 'II.. SI. anon). Tum It ..,ti-dodc_ 10 ...... 1M beam. and clock_ to 10.... 11. HIlrtzonUII ~ • ....,. by Iurning !hi 1Id;.oII _ _ en !he bonom ...... "."... d

tne

"",t.

INCh headlight I.....,~

right-hand beam. tum It clock", ... 10 move the bNm 10 the let!, and Inll·"lockwlselo

_.::eMS

It 10 the f\oIlI. Remo'4 the tor to the

~

I~

~

....

(_

"-" 31 Cylinder compression ,hod
USIl\II I .c.-.wd,....,.

lrom below '''''' M6cIlight ( _ 111"I"allon) For tIM t.\t-1'Iand bMm. tum 11 clockwise 10 move \he ~ to the right. anc:I Inti-clock'oYlM 10 move II to the Itofl. For the

meMo

COI'I'ltCtly Nt 1_ s.ction 21) ..,.;I rn.t the cyIindIr ' - I nuts . . tig/lt«Ied to the corNCt t~"""'11 (Me CNpt_ 2). 4 Re! ... to F.."I Finding Eq*>w tile rrIIIin ~ plug. whictt 1It>*>w the ClDIIIuhaft end·cover on tlul rlghl.hand lid, 01 In. 1fIIIitw, 10 ClItch lIlY 0111_ lI\o4lr1ttion) 11 Unscrew tl>e plug and IwI!1ly screw tl>e ..s.pI_ Into the ~ Connect the gauge 10 tile II oil .. lost, r.pIInbh II to 1M COtfICt ........ befOtI

011

ttor_

ad""....

~(.-£Wy""""~).

Non-scheduled maintenance 12 Star! the engine and 1r.crea5e t~ engine speed to 4000 rpm whilst watching !he gauge reading. The 011 P'fiSIK9 should be ,.mUar 10 that given In !he Spocifocations at the start 01 thisChapt.... 13 Slop tile engIne and II"""~W Ihe gauge aod adapt .... Imm the crankcase. Instailihe main oil gallery plug using a new .... allng

washer. and tighten

~

Cl>ec~

the 011 l.. v,,1 (SH o.Uy (pre-ride) CMc/rs). If the pressure 15 signifICantly lower Ihan the standard, ellh .... the pressure regulator Is S!I>eI< open. the oil pump is faulty, the 011 strainer Of filt. is bIocklld. 01 !here Is other engin8 d"""'llO. 15 Begln diagnosis by chocking the oiIlilter. strainer and regulator. then the oil pump (_ pro~ .. ms are found wilh may waU be that the bearing oil

Chapter 2). II no those ~errt!I.

~

33 Fuel hoses renewal

to Ihe torque seiling

specified at the beginning of the Chaplet.

14

1.31

light may be laully. Check Ih"'" and the circuit and repla~ wilh a new one if necessary (see Chapt.... 9).

clearances are axc"".iv8 and the engine .--;Js to be overIIauIod. II the pressure is too

high. ellh .... an 011 passage I. c logged, Ih .. regulator Is SUlck closed or the wrong grade

01 oil is bw open flam es or bare lig!>1 bulbs neal' the work a"",. lInd don't work In a fI/JI'/JfIII where a tlaWrai gn.!ype -w/iance Is pnJSenl. " you spill any fuel on your sJcln, rin se II off Immedl.tely wllh soap and ....,.... WII_ you perform any kind 01 work on the fuel system. _ ..fely gJassulUld h.". e nr. extinguisher sult.bIe for • CI.ss B!ype'-"" (rIamm.b/e liquids) on hllrrd.

A , •

1 The ruer deliwry hosea !Ihould be ~

alt.... a few Y""'" "'!II'rdless 01 their cood~ion. 2 Aemove the fuel tank (...... Chapter 4). Disconnect I~ fuel hoses lrom t~ luel tap. fiker. ruer pump and from the cart>urettors as required by your rnodtN. noting !he routiOlg 01 each h08e and where it connects (see Chapter 4 II required). k is IKMsabie to make a sketch 01 the various hose$ before removing

32.10 Main 011 gellery plug (am>wed)-

YZF1000R models lhem to ensure they we correctty Installed. 3 s..cura Bach new hose to lIS unions using new ctsmps. Aun the en"ine and check for leaks before taking the m achine out on t~

""".

34 Front forks oil change 1 Fork oH degrades over a period 01 timtt and loses ilS damp;ng <jUII1~1es. ReIer to Chapter 6 lor front fori< removal. 011draining and refilling. IQlk)wing the relevant SI&pa. The lorks do not ne«I to be completely d~.

1

2"

Chapter 2 Engine, clutch and transmission Contents AiI.".lor drive shaft. starter ckl!ch lOcI kllelr.cfuclion gear - .......,.,.aI, ~ and InsUillation . ..32 AII .....,Of~frecIifW·....-.IIOd....- .. _ CNpt.- 9 c....
."'~ -"-'

.,.. ,.

VIM ~ bend (mu)

1.r""" 1.9 ......

Cylinder block

W~(mu)

. IMIity taut-ol""""'""l (mu)

'--

."'~

Engine, clutch and transmission 2- 3 Pistons Pilton dIImet. ~ 3.5 rrwn up !rum skirt. .t 90" 10 I*IOt'I

... """.

11.90 10 11.94 rrwn

Plston·to-DOnI c:Iearance

""""".

~"""(ma>C) .. PislOO pin di""""• . PistOl' pin bani in pialoo PistOl' pin.lo--plstoo pin DOnI ~

eli"""".

..s.vto.lmt.

...... --. ""'.... -. ... ...-

0.07 10 0.09 rrwn 0.11 ...., 18.9911019.000 rrwn 19.004 10 19.015 rrwn 0.004 10 0.024 ....,

O.oro .....

Piston ring s

'®"

,,",100 rlng-Io-groove cIeet,rICfI •

2.8 ..... 0.8mm 0.2100.4""" 0.03100.01 ....,

Ring ...cIgoop fir-->

0.2 100.4 mm

-

RIng ...cI gap (nslalled)

Piston mg-\O-9"'I)OIIe~

CO . .

SlcM-I'lIiI...cI gap (hstaIIotd)

2.8 llYn ,.~

0.0210.06...., ,,~

1.5mm 0.2 I 0.1 rrwn

Clutch

--... --. """"". _.........Fi1cItOO plat..

""""",.

""""". tn** . s.vQ h i

2.9103.1...., 2.8....,

""""",.

WIIrJ)e(I8(mul .

",,"'

S""'""'.

s.Mc. limit \min) . Puahrod runaul (mul •

..... ....

1.&102.1 ...., 0.1 rrwn

,,~ ,,~

O.S"""

Lubrication system

"'R-.. ........ "'

CIJ**Ig pr1IQIQ •

........ ""orl~to-OUI. rotor ~. .

o.rt. rotor·to-body ~ Connecting rods B9-«'od tide .) •

O.03mm 0,05 rrm

Taper (max) . OytOndor compression .

0 05 rrm

nvn

_ChaIlter l

Pistons PIsIon diameter (measured 3.0 mrn up !rom skirt. at 90" to piston 75.425 10 1S.440 mm

pklaxisj.

Piston-to-bore cIeanIncleI va .... ft oparWng pressur1I • Oil pafl II rout..! 10 the vii the clu1ch. The clutch II of the _.1TUtI-pIaI1 typa .-.d II ge«~ of! the cranQheh. The lranamlssion i• • aj •• ~ (750 modals) or Itv.speed (1000 models) ~tanI·"""'....ot. FlneI """"to the rear wheal II by cham and oprockels.

t.......-..on

The englneltr.nsml""ion un~ '- • IlQuldcooIad In-linol four cyt_ wilh flVfl per cyll,.,.,.,.. The valves are opereted by doubj. ov.maad cemahafts which .... chain drlva1Nioo -m:.Iy II oonstruct«Ifrom ~ ..ay. Tha~ II dMded horizontaI1'f The ct.,kcaM ircorpof"al" a _ aump.

va""

~t.d

IutJrIc:alo::o: system wI\och _ .

~-driYen.

duaI·rotor oil pump. an 011 fill. _by·pau ..... -..bIy •• rIIIiaI ....... .->If aro 011 laval switch. The pump I. d ......... by I 0 - on the back of the clulch houIIing. The 01 " cooled by I cooler wtllch I. led 011 Ihl engine oooIng syslam. A Hy-Vo ch.ln .... nning olllha crlnkahaft

drIvw • tnaft which has the lltemator on Its t.ft·1Iand Iout hiving 10 '-OVfl lhe anglMlt,.nsmI5sIon ',,-"Illy Irom the Ira'na. H~ .• rKIrTIbo.- o! ......

,-"""""'"

requore anenuon at the lime time. !he englroe II racommanded.

removar 01

d piston rw"I\:II

""'"

........

~ .. necessary 10 IWTIOYI the IfIgIIW11ansm, •• ,on assembly "om lila I........ to _ . to !he torlowing c:omponent8. T~d>aftr

S_ _

s-:ror '*"'" and Iot1a

c-... _ _

~""'and-'"

Ifi''''

2- 8 Engine, clutch and transmission can bIo . . - ..... by ..-.g \he tnIIdwIoe to I _SbIa ""DI'kIog IMoghI on WI hyd,lUIl!; rlmp or. su~abIa platform. Maka ..... the n'ICIIOfI;:yCIt it ..,.... _ will not toppIa O'W.-

(.- SacIIOn 10fT".. and WorlmtJop 1pI W'I I"- Ratwance a.acto:InI. When d.-corv>ac""" ..-.y Wiring, cabIaa lind " ' - . II .. . , . . . . . to

1 ~ iI not -.y. eMy to del ....... _ or W ." .-.g.... -"ouId bIo c:ompIeIlily ......nauIed.

-

• • ........,.0I 111C1Otsm.lSlt.COI"IIidered. 2 High mileage la not .necessarlly .n N\dlcatlon trial an o-moul IS .-.:led. wtllie low mll. .~, on Ilia Oilier hand, don nOi precluo. 1"-1"4«1 lor an 0V