Yamaha SZR 660 User manual

YAMAHA
4SU-ME1
SERVICE
SZR660('95)
SERVICE MANUAL
©1996BELGARDAS.p.A.
R&D TECHNICAL DIVISION
V* edition February 1996
All rights reserved.
Any reprinting or unauthorised use
without the written permission ol
Belgarda S.p.A, is
expressly prohibited.
Although some of the drawings andphotographs used in this manual are taken from other manuals and do not refer directly to the mode?
in question, meprocedures described and the details illustrated are nonetheless relevant and suitable to the user's purposes.

WARNING HOW TO USE THIS MANUAL
This manual has been written by Belgarda S.pA mainiy for use by Yamaha dealers and their skilled
mechanics. It is impossible to provide amechanic with all the information necessary in asingle manual.
Presumably, though, the people who use this manual for the maintenance and repair of Yamaha motorcycles
will already have elementary knowledge of the principles of mechanics and the procedures for motorcycle
repair techniques. Without this knowledge, repair or maintenance work on this model could prove inefficient
and/or dangerous.
Yamaha makes constant efforts to improve all its models. Important alterations or changes to procedures
characteristics will be communicated to all Yamaha dealers and published in future editions of this manual.
Especially important information in this manual is highlighted by the graphics shown below.
TECHNICAL PUBLICATIONS
R&D TECHNICAL DIVISION
MOTORCYCLE GROUP
BELGARDA S.p.A.
PARTICULARLY IMPORTANT INFORMATION
The manual includes the following symbols and relative remarks:
AWARNING
CAUTION:
NOTE:
This safety alert symbol means: ATTENTION" BE CAREFUL! YOUR SAFETY IS
AT RISK!
The WARNING symbol indicates special procedures to be followed to avoid injury
to the rider or the person inspecting or repairing the cycle.
CAUTION indicates special precautions to be taken to avoid damage to the cycle.
ANOTE provides key information designed to make procedures easier or clearer.
LAYOUT
This manual consists of chapters on the principal cycle components (see "Symbol Legend").
(1)
(2)
(3)
This symbol, in the top right-hand corner of each page, identifies the chapter graphically.
This title appears at the top of each page to the left of the chapter symbol,
The final caption in the chapter "Periodic inspection and adjustment".
FORMAT
All the procedures suggested in this manual are arranged in asequential, step by step order. The information
is written in such away as to provide the mechanic with ahandy, easy to read reference containing
explanations on all disassembly, repair, assembly and inspection operations.
Particularly important procedure sequences (4) are shown between two rows of asterisks (*) and each
procedure is preceded by the symbol "•".
IMPORTANT SPECIFICATIONS
•All data and special tools are contained in insets preceded by the specific symbol (5).
•Anumber inscribed in round brackets indicates (6) the number of apart, whereas aletter of the alphabet
indicates alignment data or marks (7); further indications are signalled by aletter eclosed in an inset (8).
•The condition of afaulty component precedes Qn arrow followed by the procedure required and the symbol
(9).
ILLUSTRATED SEQUENCES
The simplest disassembly and reassembly sequences are shown in an exploded drawing of the parts and
atable in which the parts themselves are numbered in progressive order of disassembly. Follow the numbers
progressively to perform the disassembly sequence. Follow the numbered operations in the reverse order
to perform the reassembly sequence. The table also includes notes to facilitate operations.
EXPLODED DIAGRAMS
In some chapters the disassembly section is preceded by exploded diagrams. These are designed to aid
identification of components for proper assembly, as well as the assembly procedures themselves.
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SYMBOL LEGEND
(Refer to illustrations)
Symbols (1) to (9) are used to indicate chapter
number and content.
(1
)
General information
(2) Technical specifications
(3) Periodic inspection and adjustment
(4) Engine overhaul
(5) Cooling system
(6) Carburetor
(7) Chassis
(8) Electricals
(9) Troubleshooting
Symbols (10) to (16) serve to specify the following
elements:
(10) Fluid
(11) Lubricant
(12) Special tool
(13) Screw tightening
(14) Wear and tear limit, clearance
(15) Engine speed
(16) Resistance (fi), Voltage (V), Electric Current (A)
Symbols (17) to (23) in the exploded diagram
indicate type of lubricant and location of lubrication
point
(17) Appfy engine oil
(18) Apply gear oil
(19) Apply molybdenum disulfide oil
(20) Apply wheel bearing grease
(21) Apply lightweight lithium-soap grease
(22) Apply molybdenum disulfide grease
(23) Apply locking liquid (LOCTJTE®)
CONTENTS
GENERAL INFORMATION
TECHNICAL SPECIFICATIONS
PERIODIC INSPECTION
AND ADJUSTMENT
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETOR
CHASSIS
#^
GEN
INFO
PI
B
INSP
ADJ H
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ENG
X
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EARB
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CHAS

CHAPTER 1°
GENERAL INFORMATION
GEN
INFO
IGEN
INFO #^
IDENTIFICATION OF MOTORCYCLE A-6
IDENTIFICATION NUMBER A-6
ENGINE SERIAL NUMBER A-6
IMPORTANT INFORMATION A-6
PREPARATION FOR DISASSEMBLY AND REASSEMBLY A-6
SPARE PARTS A-7
GASKETS, OIL SEALS AND O-RINGS A-7
LOCK WASHERS, PLATES AND COTTER PINS A-7
BEARINGS AND OIL SEALS A-7
CIRCUPS A-7
SPECIAL TOOLS A-7

IDENTIFICATION OF MOTORCYCLE GEN
INFO <^N§
1. Motorcycle identification number
1. Engine serial number
IDENTIFICATION OF MOTORCYCLE
IDENTIFICATION NUMBER
The identification number is stamped on the right of
the steering head pipe.
Progressive serial number:
SZR 660
4SU-040101 (D) version
ZD04SU10000000101 (l-GR-P) version
ZD04SU1 00000201 01
[F-B-N-S-DK-NL-(A-CH)] version
ZD04SU10000060101 (E) version
ENGINE SERIAL NUMBER
The engine seriaf number is stamped on the right of
the engine-
Progressive engine serial number:
SZR 660
4SU-000101
NOTE:
The first three digits in these numbers identify the
model; the other digits form the progressive
production number of the unit.
Diagrams and specifications may be altered
without prior warning.
IMPORTANT INFORMATION GEN
INFO &%
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY AND
REASSEMBLY
1.Remove all dirt, mud, dust and foreign objects
prior to disassembly.
2. Use proper material and toots. Refer to sec-
tion 'SPECIAL TOOLS',
3. When disassembling the cycle, keep together
mated parts: gears, cylinders, pistons and
other parts 'mated' in the course of normal
wear and tear. Such parts must be either re-
used together or completely replaced.
4. During disassembly, clean all parts and place
them in trays in order of disassembfy. This
makes reassembly quicker and helps assure
that all parts are assembled properly.
5. Keep away from fire and sources of heat.
1-1 1-2

IMPORTANT INFORMATION GEN
INFO <^N§
SPARE PARTS
1. We recommend original Yamaha parts for all
replacements. Use the oil and grease recom-
mended by Yamaha for all assembly and
adjustment operations.
Products of other makes with the same func-
tion and appearance might be inferior in
quality.
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals and O-rings should be
replaced during engine overhauls. All gasket
surfaces, oil seal lips and O-rings must be
cleaned prior to assembly.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to oil seal
lips.
LOCK WASHERS, PLATES AND COTTER PINS
1.All lock washers, plates (1 )and cotter pins
must be replaced once removed. Lock tabs
must be bent along the bolt or nut surfaces
after the bolt or nut has been properly tight-
ened.
BEARINGS AND OIL SEALS
1.Fit bearings and oil seals with the manufactur-
er's mark or number facing outwards (ie, the
stamped letters must be visible). When install-
ing oil seals, apply alight coating of lightweight
lithium-based grease to the seal lips. Oil the
bearings liberally when installing.
(1) Oil seals
(£>
1f//J
I
CAUTION:
Do not use compressed air to dry the bearings.
This damages their outer surface.
(1) Bearing
IMPORTANT INFORMATION/
SPECIAL TOOLS GEN
INFO g!N*5
CIRCLIPS
1.All cirdips should be inspected carefully prior
to reassembly. Always replace piston ring
clips after one use.
Replace twisted cirdips. When installing a
circlip (1), make sure that the sharp-edged
corner (2) is positioned opposite the thrust (3)
it receives. See the illustration here.
(4) Shaft
SPECIAL TOOLS
Special tools are required to perform proper disas-
sembly and reassembly operations and for proper
tuning up. The use of such tools avoids damage
due to the use of unsuitable tools and/or makeshift
techniques.
The shape and part number used for the speciaf
tool differ by country, so two types are provided.
Refer to the list provided to avoid errors when
placing an order.
For USA, CDN
p/N. YM-nnnnn,
YS-QDDQD,
ACC-nODDD
Except for USA, CDN
P/N. 90890-aunon
YU-DDDDa
YK-OUDDD
Tool number Tool name Illustration
YM-08035 VALVE ADJUSTMENT TOOL
90890-01311 VALVE ADJUSTMENT TOOL
Cj* ji'
YU-08036-A INDUCTIVE ENGINE
SPEED INDICATOR M
1-3 1-4

SPECIAL TOOLS GEN
INFO #^
Tool number Tool name
90890-03113
YM-33277-A
90890-03141
YU-33223
90890-03081
YU-33223-3
90890-04082
YM-01312-A
90890-01312
YU-01304
INDUCTIVE ENGINE
SPEED INDICATOR
INDUCTIVE STROBOSCOPE LAMP
INDUCTIVE STROBOSCOPIC LAMP
PRESSURE GAUGE
PRESSURE GAUGE
ADAPTER FOR PRESSURE GAUGE
ADAPTER FOR PRESSURE GAUGE
FUEL LEVEL GAUGE
Illustration
FUEL LEVEL GAUGE
PISTON PIN CLIP PULLER
9
O
n
^\\ '
SPECIAL TOOLS GEN
INFO <?JN5
Tool number
90890-01304
YS-01880
90890-01 701
YU-33270
90890-01362
YM-04063-A
90890-04063
YM-91042
90890-04086
YU-01135-A
Tool name
PISTON PIN CUP PULLER
ROTOR HOLDER
ROTOR HOLDER
ROTOR SCREW PULLER
ROTOR SCREW PULLER
ADAPTER FOR ROTOR SCREW
PULLER
ADAPTER FOR ROTOR SCREW
PULLER
ALL-PURPOSE CLUTCH HOLDER
ALL-PURPOSE CLUTCH HOLDER
CRANKCASE SEPARATING TOOL
Illustration
.-^
©a
^
X
f^a
1-5 1-6

SPECIAL TOOLS GEN
INFO #^
Tool number
90890-01135
YU-01083-A
90890-01083
90890-01084
YM-04019
90890-04019
YM-91043
YM-04064
90890-04064
YM-04066
Tool name
CRANKCASE SEPARATING TOOL
SLIDING HAMMER UNIT
SLIDING HAMMER BOLT
Illustration
SLIDING HAMMER WEIGHT
VALVE SPRING COMPRESSION
CLAMP
VALVE SPRING COMPRESSION
CLAMP
VALVE HOUSJNG CUTTER
6mm (0.24 in) VALVE GUIDE PULLER
6mm (0.24 in) VALVE GUIDE PULLER
6mm (0.24 in) VALVE GUIDE REAMER
IV ri
jOn?
SPECIAL TOOLS GEN
INFO $^5
Tool number
90890-04066
YM-04065-A
90890-04065
YU-90050
90890-01274
90890-01275
YM-90069
90890-04059
YM-91044
90890-04081
Tool name
6mm (0-24 in) VALVE GUIDE REAMER
6mm (0.24 in) VALVE GUfDE
INSTALLER
6mm (0.24 in) VALVE GUIDE
INSTALLER
DRIVING SHAFT
INSTALLATION UNIT
DRIVING SHAFT
INSTALLATION HOSE
DRIVING SHAFT
INSTALLATION BOLT
#10 (M14) ADAPTER
(FOR DRIVING
SHAFT INSTALLATION)
#10 (M14) ADAPTER
(FOR DRIVING
SHAFT INSTALLATION)
CRANK SPACER
CRANK SPACER
Illustration
©
1-7 1-8

SPECIAL TOOLS
Tool number
90890-01288
Tool name
SPACER (FOR CRANK)
ACC-11001-01
90890-85505
YU-24460-01
90890-01325
YU-33984
SEALANT (QUICK GASKET)'
Yamaha Bond No. 1216®
SEALANT (QUICK GASKET)®
Yamaha Bond No- 1215®
Illustration
RADIATOR CAP TESTER
RADIATOR CAP TESTER
ADAPTER
(FOR RADIATOR CAP TESTER)
90890-01352 ADAPTER
(FOR RADIATOR CAP TESTER)
4SU-F8120-W0
YU-01268
90890-01268
FRONT FORK SERVICE KIT ASSY
RING NUT WRENCH
RING NUT WRENCH
Tool number
90890-01385
YM-34487
90890-03144
YU-031 1
2
90890-03112
Tool name
RING NUT WRENCH
D1NAM1C SPARK TESTER
IGNITION CHECKER
POCKET TESTER
POCKET TESTER
SPECIAL TOOLS GEN
INFO <^^5
Illustration
1-9 1-10

spec 0/
CHAPTER 2°
TECHNICAL SPECIFICATIONS
SPEC f>t
GENERAL SPECIFICATIONS A-13
MAINTENANCE SPECIFICATIONS A-14
ENGINE A-14
ELECTRIC SYSTEM A-16
CHASSIS B-2
TIGHTENING TORQUES B-3
GENERAL TORQUE SPECIFICATIONS B-6
DEFINITION OF MEASUREMENT UNITS B-6
LUBRICATION POINTS AND TYPE OF LUBRICANT B-7
ENGINE B-7
CHASSIS B-7
LUBRICATION LAYOUT B-8
COOLING LAYOUT B-10
CABLE ROUTING 8-11

GENERAL SPECIFICATIONS SPEC 09 GENERAL SPECIFICATIONS SPEC pf
TECHNICAL SPECIFICATIONS -GENERAL SPECIFICATIONS
Model code number
Initial engine stamp number
Initial frame stamp number
4SU1
4SU-000101
4SU-040101 (D) version
2D04SU10000000101 (l-GR-P) version
ZD04SU10000020101 (F-B-N-S-DK-NL-(A-CH)]
version
ZD04SU100000601 01 (E) version
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheel base
Minimum ground clearance
2,040 mm
740 mm
1.140 mm
770 mm
1,410 mm
145 mm
Basic weight 159 kg
Minimum turning radius 3,150 mm (left); 3,200 mm (right)
Engine:
Engine type
Model
Cylinder layout
Displacement
Bore xstroke
Compression ratio
Starting system
4-sUoke, SOHC, liquid cooled, 5-vafve
4SU1
Single cylinder, inclined forward
659 cc
100x84 mm
9.2:1
Electric starter
Lubrication:
Type
Recommended engine oil
Dry sump with separate oif tank
SHELL SUPER 4TX 20W/50
Capacity (engine oil):
Periodic oil change
With oil filter replacement
Total amount
2.6 liters
2.7 liters
3.0 liters
Cooling system:
Type
Water/cooiing liquid ratio
Circuit liquid total quantity
Expansion tank capacity
From "LOW to "FULL"
Liquid with forced circulation and electric fan
50% -50%
1.4 liters
0.55 (iters
0.210 liters
Air filter:
Type Dry filter element
_i i
Fuel (type):
Tank capacity:
Total
Reserve amount
Premium Grade Fuel. If Premium Grade gasoline
is not available, then unleaded gasoline with
octane grade (R.O-N.) of 91 or higher can be used
14 liters
2.5 liters
Carburetor;
Type/Manufacturer Y26PV-3J/TEIKEI
Spark plug:
Type/Manufacturer
Electrode gap DPR8EA-9 or DPR9EA-9/NGK
0-8^0.9 mm
Clutch:
Type Wet, multi-disc
Transmission:
Type Constant mesh 5-speed
Primary reduction system Straight-tooth gears
Primary reduction ratio 71/34(2-088)
Secondary reduction system Chain drive
Secondary reduction ratio 39/15(2.600)
Operation Left foot operation
Gearratio: 1st 30/13(2.308)
2nd 27/17(1.588)
3rd 24/20(1.200)
4th 21/22 (0.954)
5th 19/24(0.792)
Frame:
Frame type Deitabox aluminium frame
Caster angle/Trail 24°/102mm
Tires:
Type Tubeless
Size:
Front 110/70 2R17 TX15 (MICHELIN) -
110/70 ZR17TL(DUNLOP)
Rear 150/60 ZR17 TX25 (MICHELIN) -
150/60 ZR17 TL (DUNLOP)
Tire inflation pressure (cold tires) bar-kg/cm?(psi)
Rider only
With passenger
Front Rear
2(28) 2.2 (32)
2-2 (32) 2.5 (37)
Brakes:
Front brake type Single 320 mm disk brake
Operation Right hand operation
Rear brake type Single 210 mm disk brake
Operation Right foot operation
Front suspension: Adjustable upside-down telescopic fork,
dia. 41 mm, Upside Down
Rear suspension; Aluminium swinging fork with
adjustable shock absorber
Wheel travel:
Front 120 mm
Rear 121.5 mm
Electric system:
Ignition system T.C.I. (Digital)
Battery type/Voftage CTX9 BS YACHT MF/12V 8Ah
Fuses 20A (Main) *7.5A (Electric fan)
Generator A.C. 12V
Headlight type Provided with quartz lamp (halogen)
Bulb specifications;
Headlights (halogen) 12V-2x55W
Tai^Brake light 12V-21/5W
Turn lights 12V-10W
Front parking light 12V-5W
Numberplate light 12V-5W
Warning famps: "NT (neutral) -"High beam" 12V-4x1.2W
"Low fuel" -"Turn lights*
2-1 2-2

MAINTENANCE SPECIFICATIONS SPEC 09
MAINTENANCE SPECIFICATIONS
ENGINE
Part Standard
Cylinder head:
Cylinder:
Sore
Measurement point (a)
Cam shaft:
Advance method
Cam shaft outer diameter
Backlash between cam shaft and cap
Cam size:
Suction: "A"
"C"
Exhaust: "A"
"B*
"C"
Cam shaft eccentricity limit
Timing chain:
Timing chain type
Link number
Timing chain adjustment
method
100.005- 100.07 mm
50 mm
Chain advance (left)
22.967 ~22,980 mm
0.020 -0.054 mm
35.69 -35.79 mm
30.06 -30-16 mm
5.74 mm
36.50 -36.60 mm
30.11 -30.21 mm
6.55 mm
75 RN 2015
126 links
Automatic
Rocker/rocker shaft:
Rocker outer diameter
Rocker shaft inner diameter
Rocker-shaft backlash
12.000- 12.018 mm
11.976- 11.991 mm
0.009 ~0.042 mm
Limit
003 mm
The lines show where
you have to site the
measuring slide rule
100.1 mm
35.54 mm
29.91 mm
36.35 mm
29.96 mm
0.03 mm
MAINTENANCE SPECIFICATIONS
Part Standard
Valves, valve seats,
valve guide:
Valve clearance (cold):
Suction
Exhaust
Valve sizes:
Suction:
"A ahead diameter
"B" face width
MC" seat width
MDMedge thickness
Exhaust:
"A" head diameter
"B" face width
"G" seat width
-D-edge thickness
0,10- 0.15 mm
0.15- 0.20 mm
29.9 -30.1 mm
2.25 mm
0.9- 1.1 mm
0.85 ~1.15 mm
31.9-32.1 mm
2.26 mm
0.9 -1.1 mm
0-85 -1.15 mm
Limit
£3
Head
diameter
"C" i(zi'*Dri
Face
width
Seat
width
Edge
thickness
Rod outer diameter:
Suction
Exhaust
Guide inner diameter:
Suction
Exhaust
Backlash between rod and guide:
Suction
Exhaust
Rod eccentricity limit
Valve seat standard width:
Suction and Exhaust
5,975 -5-990 mm
5.960 -5.975 mm
6.000 mm ~6.012 mm
6.000- 6.012 mm
0.010 mm -0.037 mm
0,025 -0.052 mm
0,9- 1.1 mm
5.95 mm
5.93 mm
6.05 mm
6.55 mm
008 mm
0.1 mm
0.01 mm
2-3 2-4

MAINTENANCE SPECIFICATIONS
Part
Valve springs:
Free length:
Suction
Exhaust
Position size
(with closed valve):
Suction
Exhaust
Winding sense (top view):
Suction and exhaust
Slope limit:
Suction
Exhaust
V\W
Compression force (with closed valve):
Suction
Exhaust
Piston:
"D" piston size
"H" measurement
point
<y
—D~J
Piston allowance
Piston pin off-centring
Piston-cylinder backlash
H
Standard
32.63 mm
36.46 mm
27.50 mm
31-00 mm
Clockwise
10.2-11.8 kg
12.3-14.1 kg
99.945 -99.985 mm
2.5 mm
1.0 mm
Suction side
0-050 -0.070 mm
Limit
2-571 .4 mm
2.571.6 mm
0.15 mm
Rings:
Type:
Upper ring
Lower ring
Sizes (BxT):
Upper ring
Lower ring
Scraper ring
J3
\i
ii= i
a
B
B
L-T—
Trapezoidal
Conic
B= 1.2 mm
Ts= 3.8 mm
B=1.2 mm
T=4.0mm
8=2.5 mm
T=3.4 mm
2-5
MAINTENANCE SPECIFICATIONS
Part Standard Limit
End clearance (with mounted ring):
Upper ring
Lower ring
Scraper ring
Side backlash (with installed ring):
Upper ring
Lower ring
Scraper ring
0.30 ~0.45 mm
0.30 -0.45 mm
0.20 -0.70 mm
0.04 -0.08 mm
0.03 ~0.07 mm
0.015-0.042 mm
—
Main shaft:
"A" shaft width JT
*C* off-centring ©nln
limit t_o |1
*Dhbacklash *£^ 1
T" small end -JJ
backlash K"1
74.95 -75.00 mm
0.35 ~0.65 mm
0.8 -1.0 mm
0.03 mm
Balancing weight;
Advance method Cylinder gear
Ciutch:
Friction plate:
Thickness
Quantity
Friction plate;
Thickness
Quantity
Clutch plate:
Thickness
Quantity
Distortion limit
Clutch spring:
Free length
Quantity
Clutch release method
2.74 ~2.86 mm
6parts
2.94 ~3.06 mm
2parts
1.2 mm
7parts
42.8 mm
5parts
Rack and pinion external
traction
2.6 mm
2.8 mm
0.2 mm
40.8 mm
Gear box:
Principal axis off-centring
limit
Intermediate shaft off-centring
limit
—0.08 mm
0.08 mm
Selector:
Type Drum with cam
and guide bar
2-6

MAINTENANCE SPECIFICATIONS
Pari Standard Limit
Lubrication system;
Oil filter:
Type Paper
Oil pump:
Type Trochoidal
Extremity clearance 0.12 mm —
Lateral clearance 0.03 -0.08 mm —
Derivation valve adjustment pressure 80-120 kPa (0.8 ~1.2 kg/cm2)—
Cooling system:
Radiator Width 431 mm —
Height 133 mm —
Thickness 32 mm —
Valve adjustment pressure 95 -125 kPa (0.95 -1.25 kg/cm2)—
Expansion tank capacity 0,55 litri —
From "LOW" to "FULL" 0.210 iitri —
Liquid pump:
Type Single suction centrifugal pump
Reduction ratio 33/34(0.971) —
Thermostat;
Opening temperature 80~84°C(176- 183VF) —
Carburetor:
Identification initials 4SU-00 —
Main jet (MJO
Primary carburetor #140 —
Secondary carburetor #165 —
Main air jet (M.A.J.)
Primary carburetor 01.0 —
Secondary carburetor 01.0 —
Jet needle (J.N.)
Primary carburetor 5D96-3/5 —
Secondary carburetor 5X7C-4/5 —
Nozzle jet (NJ.)
Primary carburetor V-00 —
Secondary carburetor 02.7 —
Pilot air jet (P.A.JO 0.6 —
Pilot jet (P.J.) #50 —
Pilot output (P.O.) 0,8 —
By pass <B.P.) 01.0 —
Pilot screw (P.S.) ca. 3turns open —
Valve seat (V.S.) 2.5 —
Starter jet (G.S.) #76 —
Fuel level (F.L) 6.0-8.0 mm under float chamber
matching surface
^"
Float height (F-H.) 25.0-27.0 mm —
Engine idle speed 1,300 +50 rpm -
Suction pressure at engine idie speed 26.6-34.6 kPa {200-260 mmHg)
MAINTENANCE SPECIFICATIONS SPEC 09
ELECTRIC SYSTEM
Part
Voltage:
Standard
12V
Limit
Ignition system:
Minimum spark advance {B.T.D.C.)
Maximum spark advance (B.T.D.C.)
Spark advance device
50 -i
12° at 11300 rpm
38° at 6,500 rpm
Electric type
12.9°/700rpm
o
c
>
cd
ex
40
30 -
20 -
10 •=
iX38°/6,50Q rpm
24°/3t000+20Q rpm
14°/2,555±200 rpm
12 3 4 5 67 8
Engine speed (x 1,000 rpm)
-i r~
910
Spark unit:
Model/Manufacturer
Pick-up coil resistance
(colour)
Ignition coil:
Model/Manufacturer
Primary coil resistance
Secondary coil resistance
TMDF19/NIPPONDENSO
184-276 at 20°C (68°F)
(Biue/Yelfow -Green/White)
J0268/NIPPONDENSO
3.4-4.6 Qat 20°C (68°F)
10.4-15.6 kQ at 20°C {68°F)
Spark plug cap:
Type
Spark plug cap resistance
Charge system:
Type
Resin
10ktlat20°C(68F)
CA magnet generator
2-7 2-8

MAINTENANCE SPECIFICATIONS
Pari
AC Alternator:
Model/Manufacturer
Recharge output
Armature resistance {winding)
(colour)
Standard
TLMZ55/N1PPONDENSO
14V,24.5A at 5,000 rpm
0.20-0.30 Qat 20°C (68°F)
(White -White)
3
a
o
a>
o
a:
26
24
22
20
IS
16
14
12
10
8
6
4
2
1Ml! |
_L _LLLi
_-_-.
i [
_, -ill ———-.-.
frm
——/- _.. --.
—"Li
4- r
Tl "l~l
Limit
Battery:
Electrolyte density
Electric smarter system:
Type
Starter motor:
Model/Manufacturer
Capacity
Brush length
Commutator diameter
Mica cut (depth)
Ignition relay:
Model/Manufacturer
Nominal amperage
Horn:
Type
Model/Manufacturer
Max, intensity
o18
Engine speed {x1,000 rpm)
Voltage regulator/Rectifier:
Model/Manufacturer
Voltage regulator:
Type
Not charged adjusted voltage
Rectifier:
Capacity
Resistance voltage
SH650A/SHINDENGEN
Short circuit semiconductor
14.2-15.2V
25A
240V
1.320
Constant mesh gear
SM-13/MITSU8A
0.8 kW
12.5 mm
28 mm
0.7 mm
MS5D-191/HITACHI
100A
Flat
220/CEV-PAGAN!
2.5A
5mm
27 mm
MAINTENANCE SPECIFICATIONS SPEC 0Y
Pari Standard Limit
Turn light relay:
Type
Model/Manufacturer
Automatic stop device
Flashing frequency
Power
Warm-wire type
301877102/CEV-PAGANI
None
60-120 cycles/min
10Wx2+2W —
Electric fan:
Model/Manufacturer VA27-A37/C-46A 12V/SPAL
Thermostatic switch:
Model/Manufacturer
Operating temperature
VF105A/N. THERMOSTAT
102~108°C <215.6~226.4°C): ON
98°C (208.4°F): OFF —
Thermo unit:
Model/Manufacturer
Coil resistance
KIAL 41/NIPPONDENSO
226 £2 at 50°C(122°F)
26.4 Qat 11 5°C
—
Electric circuit switch device:
Type
Individual amperage Fuse
20A (main)
7.5A (electric fan}
2-9 2-10

MAINTENANCE SPECIFICATIONS spec pf MAINTENANCE SPECIFICATIONS SPEC 9f
CHASSIS
Part Standard Limit
Steering:
Bearing type Taper roller bearing
Front suspension:
Fork travel
Fork spring: free length
Spring constant (K)
Optional spring
Oil amount
Oil level
Oil type:
Inner tube external diameter
120 mm
402 mm
7.95 N/mm (0.795 kg/mm)
None
300 cu.cm
130 mm
from upper edge
of inner tube {fully
compressed, without spring)
BELRAYMC10SAE5
41 mm
Rear suspension:
Shock absorber travel
Free spring length
Spring-loaded length:
Standard
Minimum
Maximum
Spring constant (K)
Travel
Optional spring
Gas pressure
48 mm
175 mm
166 mm
161 mm
170 mm
125 N/mm (12.5 kg/mm)
Zero-65 mm
None
12kg/sqcm(170psi)
^™1
Rear arm:
Clearance limit
Side clearance 0.4-0.7 mm
at the rear arm axle
1.0 mm at the rear
arm end (move rear
arm from side to side)
Front wheel:
Type
Rim size
Wheel material
Wheel eccentricity limit:
Vertical
Lateral
Light alloy
3.00x17"
Aluminium
0.5 mm
0.5 mm
Part Standard Limit
Rear wheel:
Type Light alloy
Rim size 4.00x17"
Wheel material Aluminium
Wheel eccentricity limit
Vertical —0-5 mm
Lateral —0-5 mm
Drive chain:
Type/Manufacturer 135 ORS-A REGINA CHAIN
Number of finks 110
Chain slack 25-40 mm —
Front disk brake:
Type Single
External disk diameter 320 mm
Disk thickness 4mm 3.5 mm
Pad thickness 5.0 mm 0-8 mm
Internal master cylinder diameter 13 mm
Interna! caliper cylinder diameter 30/34 mm
Quantity 2parts
Brake fluid type DOT #4
Rear disk brake:
Type Singfe
External disk diameter 210 mm
Disk thickness 5mm 4mm
Pad thickness 4.0 mm 0.8 mm
Internal master cylinder diameter 11 mm
Internal caliper cylinder diameter 32 mm
Brake fluid type DOT #4
Brake pedal lever:
Brake lever free play (travel) 2-5 mm
at the lever end
•**
Brake pedal position 50 mm
below the footrest
plane
Clutch lever and throttle grip:
Clutch lever free play 10-15 mm
at the lever end
^~
Throttle cable free play 3.0-5.0 mm
at the grip flange
2*11 2-12

MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUES
SPEC 09 MAINTENANCE SPECIFICATIONS
Part to be tightened Thread
size Q.ty Tightening torque Note
Nm mkg
Head
Flange bolt M9 438 3.8
Flange bolt M9 238 3.8
Socket head bolt M6 110 1.0
Stud bolt (exhaust pipe) M6 470.7
Screw plug M18 —55 5.5 ,0
Spark plug M12 118 1.8
Cylinder head cover
Socket head bolt M6 16 10 1.0
Cylinder head cover
Socket head bolt W6 110 1.0
Cylinder head lateral cover M32 212 1.2
Socket head bolt M6 410 1.0
Gear unit assembling
Socket head bolt M€ 110 1.0
Engine speed indicator stop cap
Flat head screw M6 170.7
Cylinder
Flange bolt M10 242 4.2
Flange bolt M10 242 4.2
Socket head bolt M6 210 1.0
1Support
Socket head bolt M6 110 1.0
Balancer shaft gear
Hexagonal nut M16 160 6.0 Use a
Rotor (AC magnet) lock
Hexagonal nut M14 1150 15.0 washer
Lock nut (valve clearance adjustment)
Hexagonal nut M6 414 1.4
2retainer guide
Hexagonal bolt M6 280.8
Timing sprocket
Flange bolt M7 220 2.0
Timing chain tensioner
Hexagonal head bolt M6 210 1.0
Rocker shaft stop
Socket head bolt M6 :210 1.0
Cooling liquid pump
Socket head bolt M6 310 1.0
1tube
Socket head bolt M6 110 1.0
2tube
Flange bolt M6 110 1.0
Thermostat assembly
Flange bolt M6 210 1.0
Part to be tightened Thread Q.ty Tightening torque Note
size Nm mkg
Filler (coolant)
Cylindrical socked head bolt M6 110 1.0
Oil pump
Socket head bolt M6 210 1.0
Oil delivery/return hose
Truncated cone head screw M6 270.7
Draining plug (oil sump) M14 130 30
Oil filter cover
Socket head bolt M6 310 1.0
Drainage screw M5 150.5
Radiator
Flange boit M6 410 1.0
Oil pump assembly
Flange bolt M6 310 1.0
2cover
Truncated cone head screw M6 170.7
Oil suction net filter
Truncated cone head screw M6 2 7 0.7
Drainage hote
Plug screw M14 130 3.0
Filter cover
Socket head bolt M6 110 1.0
Socket head bolt M6 2 10 1.0
Fitter cover drainage
Screw M5 150.5
1 oil tube
Socket head bolt M6 410 1.0
Drilled joint M12 135 3.5
2oil tube
Socket head bolt M6 210 1.0
Drilled joint M12 135 3.5
Connecting oil hose
Bolt M10 220 20
Socket head bolt M6 110 1.0
Carburetor joint
Socket head bolt M6 410 1.0
Left carburetor joint
Clamp M4 120.2
Right carburetor joint
Clamp M5 150.5
Carburetor joint (left, air filter)
Clamp M4 120.2
Carburetor joint (right, air filter)
Clamp W5 150.5
2-13 2-14

MAINTENANCE SPECIFICATIONS SPEC 09 MAINTENANCE SPECIFICATIONS spec p9
Part to be tightened Thread Q.ty Tightening torque Note
4
^r size Nm mkg
Air cleaner case
SeJf-tapping screw M9 750.5
Air cleaner cover
Crosshead screw M5 350.5
Exhaust pipe
Nut M6 410 1.0
1*2 exhaust pipes
Socket head bolt M6 110 1.0
Silent-Block to frame
Range nut M8 123 2.3
Silent-Block to bracket
Flange nut M8 123 2.3
1exhaust pipe to bracket
Flange screw M8 123 2.3
Muffler and exhaust pipe
Socket head bolt M6 110 1.0
Muffler assembling
Flange bolt M10 140 4.0
1-2oil sump
Socket head bolt M6 910 1.0
Socket head bolt M6 410 1.0
Socket head bolt M6 110 1.0 |
Holdfast (cable)
Truncated cone head screw M6 170.7
1crankcase cover
Socket head bolt M6 6 10 1.0 i
Socket head bolt M6 110 1.0 I
Socket head bolt M6 110 1.0
Socket head bolt M6 110 1.0
Plug screw M8 110 1.0 |
2crankcase cover
Socket head bolt M6 '210 1.0
3crankcase cover
Socket head bolt M6 510 1.0
Socket head bolt M6 310 1.0
Socket head bolt M6 210 1.0
Bearing cover plate
Flat head screw M6 370.7 -*3
Locking plate
Socket head bolt M6 210 1.0
Clutch spring
Screw with washer M6 580.8
Clutch hub
Nut M20 190 9.0 Use a
lock
Primary transmission gear washer
Nut M20 1120 12.0 ,Use a
lock
Thrust lever assembly (stop) washer
Bolt M6 16.5 0.65
Thrust lever assembly
Screw M8 112 1.2
Thrpari Tightening torque
Part to be tightened • • It ^Q\J Q.ty Note
size Nm mkg
Guide sprocket Use a
Nut M18 1110 11.0 lock
Oil seal cover washer
Socket head bolt M6 210 1.0
Stop lever
Screw with washer M6 110 1.0
Gearbox arm
Bolt M6 110 1,0
Stator coil
Truncated cone head screw M6 370.7 o
Neutral switch M10 120 2.0
1lateral cylinder head cover M32 212 1.2
Spring tensioner
Hole M16 120 2.0
Starter
Flange bolt M6 210 1.0
1cover
Socket head bolt M6 110 1.0
Socket head bolt M6 310 1.0
Starter unidirectional clutch
Stop -i{3 Socket head bolt we 330 3.0
Pick-up coif -0
Truncated cone head screw M5 250.5
Ignition coil
Socket head bolt M5 250,5
Voltage regulator
Hexagonal head bolt M6 2 5 0.5
Ignition unit
Hexagonal head screw M6 250.5
Thermo switch
Truncated cone head screw M16 128 2.8
Thermo unit
Truncated cone head screw PT1/8 115 1.5
2-15 2-16