SERVICE MANUAL - Amazon Web Services

139 Pages·2009·4.02 MB·English

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SERVICE MANUAL
ENGINE
4NN I MuZ 660 E • YAMAHA
FOR MuZ
SKORPION TOUR, TRAVELLER, SPORT, REPLICA, CUP
AND
MuZ650 E
BAGHIRA, MASTIFF
Motorrad- und YAMAHA MOTOR CO., LTD
Zweiradwerk GmbH _ _
..--_._--- .. ~ - -
SERViCEMANUAL660E.doc
IMPORTANT REMARK
The repair manual you got is reprinted from the below mentioned mikroflche
because of that and the only possible method of repnnting the text is unfortunately
not in a very good quality.
Neverthelessthis manual will be helpful for you to maintain our MuZ SKORPION
resp. MuZ S60E BAGHIRAand MASTIFF.
Partly reprint ofmicrofiche
Skorpion Motor MuZ660UK 06/1994 [SERVICE MANUAL YAMAHA XTZ 660
(91),Partengine]
Equipped with new pictures, created by MuZ GmbH, Service Department
Deadline 1998-06-03
© 1991 by YAMAHA Motor Co, Ltd (Text and drawings)
© 1998 by Motorrad- und Zweiradwerk GmbH, Zschopau (pictures)
and KARLHEINZ MOLLER (photos as basis of all new pictures)
All rights reserved. Any unauthorised reprinting or use without the written permission
ofYamaha MotorCo., Ltd, Motorrad- und Zweiradwerk GmbH, Zschopau, is
expressly prohihibited.
2
SERVICEMANUAL660E.doc
NOTICE
This manual was written bythe Yamaha MotorCompany primarly for use by Yamaha
and MuZ dealers and their qualified mechanics. It is not possible to put an enlire
mechanic's education into one manual. so it is assumed that persons using this book
to perform maintenance and repairs on Yamaha resp. MuZ motorcycle have a basic
understanding of the mechanical concepts and procedures inherent in motorcycle
repair technology. Without such knowledge, attempted repairs or service to this
model may renderit unfitto use andl or unsafe.
Yamaha Motor Company, Ltd and MuZ GmbH are continually striving to improve all
models manufactured by Yamaha resp. MuZ.
Modifications and significant changes in specifications or procedures will be
forwarded to all authorized MuZ dealers and will, where applicable in future editions
ofthis manual.
PARTICULARLY IMPORTANT INFORMA1"ION
This material is distinguished bythe following notation.
The Safetyalert symbol means ATTENTIO! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
Failure to followWARNIG instruction could result in
severe injUry or death to the motorcycle operator, a
bystander or a person inspecting or repairing the
motorcycle.
CAUTION
A CAUTION indicates special precautions
that must be taken to avoid damageto the motorcycle.
NOTE A NOTE provides key information to make procedures
easier or clearer.
3
SERVICEMANUAL660E.doc
CONTENTS PAGE
ILLUSTRATED SYMBOLS 6
MAINTENANCE SPECIFICATIONS YAMTD001
ENGINE YAMTD001
CARBURETOR YAMTD005
LUBRICATION SYSTEM YAMTD005
COOLING SYSTEM YAMTD005
CRANKCASE TIGHTENING SEQUENCE YAMTD006
ELECTRICALSYSTEM YAMTD007
LUBRICATION POINTS YAMTD009
ENGINE DISASSEMBLY DE01
PIPE,STARTERMOTORAND HOSES DE01
CYUNDER HEADAND CYLINDER DE02
ROTORAND STARTER DRIVES DE06
OILFILTERANDWATERPUMP DEOa
CLUTCH AND BALANCERGEAR DE10
SHIFT LEVER AND OIL PUMP DE12
CRANKCASE(RIGHT) DE14
OILSTRAINER DE16
BALANCER, TRANMISSION AND SHIFTER DE16
CRANKSHAFT DE17
ROCKER ARM DE18
VALVES DE19
INSPECTION AND REPAIR DE21
CYLINDERHEAD DE21
VALVE SEAT DE22
VALVE ANDVALVE GUIDE DE25
VALVE SPRING DE27
CAMSHAFT DE28
DECOMPRESSION DE30
ROCKERARM AND ROCKERARM SHAFT DE30
TIMING CHAIN, SPROCKETAND CHAINGUIDE DE31
CYLINDER AND PISTON DE32
CRANKSHAFT DE3S
BALANCER GEARS DE37
ELECTRIC STARTER DRIVE DE3?
PRIMARYDRIVE DE38
CLUTCH DE38
TRANSMISSION AND SHIFTER DE40
OILPUMP, WATER PUMP AND STRAINER DE42
OILDELIVERYPIPES DE44
CRANKCASE DE44
BEARINGAND OIL SEAL DE44
CIRCLIPANDWASHER DE44
ENGINE ASSEMBLY AND ADJUSTMENT DE45
VALVEAND ROCKERARM DE45
VALVES DE46
ROCKERARM DE48
CRANKSHAFT DE49
BALANCER ANDTRANSMISSION DE51
4
SERVICEMANUAL660E.doc
PAGE
CONTENTS
SHIFTER DE53
BALANCER. TRANSMISSION AND SHIFTER DE55
OILSTRAINER DE56
CRANKCASE DE57
SHIFTLEVER AND OIL PUMP DE58
OIL STRAINER DE58
CRANKCASE(RIGHT) DE59
SHIFTLEVERANDOIL PUMP DE62
BALANCERGEAR DE63
CLUTCH DE64
CLUTCH AND BALANCERGEAR DE6S
OIL FILTERANDWATER PUMP DE70
ROTORAND STARTERDRIVES DE74
CYLINDER DE75
CYLINDER HEAD DE7S
CAMSHAFTANDTIMING CHAIN DE83
PIPESAND HOSES
DW1
WATER PUMP
DC1
CARBURETOR DC4
DISASSEMBLY DCS
PRIMARYCARBURETOR DC6
SECONDARYCARBURETOR DC?
INSPECTION DC9
ASSEMBLY DC13
MEASUREMENT AND ADJUSTMENTSTEPS DC15
INSTALLATION DC16
FUELLEVELADJUSTMENT
DCn
FUEL PUMP
DSTART1
ELECTRICAL STARTER SYSTEM DSTART1
STARTER MOTOR DSTART2
DISASSEMBLY DSTART3
INSPECTIONAND REPAIR DSTART5
ASSEMBLY
DCHARGO
CHARGING SYSTEM
TROUBLE01
TROUBLE SHOOTING TROUBLE01
STARTINGFAILURE/HARDSTARTING TROUBLE03
POOR IDLE SPEEDPERFORMANCE TROUBLE03
POORMEDIUM AND HIGH SPEEDPERFORMANCE TROUBLE04
FAULTYGEARSHIFTING TROUBLE04
CLUTCH SLIPPING/DRAGGING TROUBLE05
OVERHEATING OR OVERCOOLING TROUBLE06
FAULTYBRAKE TROUBLE06
FRONTFORKMALFUNCTION TROUBLEO?
INSTABLE HANDLING TROUBLE08
FAULTYSIGNALAND LIGHTING SYSTEM
5
SERVICEMANUAL660E.doc
ILLUSTRATED SYMBOLS
(Refer to the illustration)
.. .. Illustrated symbols 1 to 16 are used to
~~~_ [1iJ
1 identifythe specifications
appearing in the text
1 filling fluid
2 Lubricant
2 ~ 3 ~
3 Special tooi
4 Tightening
5 Wearlimit, clearance
6 Engine speed
4 5
~ ~ 7 n,V,A
6 [g] 7 ~
j
8 1 9 1 10 1 , lllustrated symbols 8 to 14 in the
m e
exploded diagram indicate grade of
@)
lubricant and location of lubrication
point.
13
11 12
8 Apply engine oil
~ 1;;Tj;;:
9 Apply gearoil
10Apply molybdenium disulfide oil
11 Applywheel bearing grease
14
a 12 Apply lightweight lithium soap base
I
grease
YAMSYMB.COf 13 Apply molybdenuim disulfide grease
14Apply locking agent(Ioctite)
"
MAINTENANCE SPECIFICATIONS
Model 4NN MuZ 660
Cylinderhead:
Warp limit.* 0,03 mm (0,0012 ii'll
*
, Linos indicate straightedge measurement
, ,*
t
T~v
1 ".
I i "
Cylinder:
Bore size/Measuring point * 100,005-100,045 mm 13,9372-3,9388 inl
[]J* 50 mm 11,97 in)
< Wear limit :> 100,1 mm 13,941 in)
mmmmmmmcc _
Camshaft:
Drivemethod Chain drive (left)
!
Camshaft outside diameter 22,967- 22,980 mm 10,9042- 0,9047 In)
.
Shaftto cap clearance O,020-0,ll54 mm 10,0008-0,0021 ii'll
Cam dimensions: Intake A" 35,69-35,79 mm 11,4051-1,4091 ii'll
"
~ < Umit > 35,54 mm 11,3992 ii'll
sn
1\1 30,06-30,16 mm 11,1835-1,1874 ii'll
"
<'Limit :> 29,91 mm 11,1776 In)
en
~' 5,74mm 10,2260 In)
"
Exhaust "A" 36,50-36,60 mm 11.4370-1,44C-9 In)
< Limit> 36,35 mm 11,4311 in)
6" 30,11-30,21 mm 1t,t854-1.1894 in) ,
"
.<.Limit .> 29,96 mm 11,1795 in)
C" 6,55 mm 10,2579 in)
Camshaft runcut limit 0,03 mm 10,0012 in)
ff¢
Jl
-t>j~:Z'::f:: .
lJ 8
llmlngchain:
ChaintypelNo.Oflinks 75 RH 2015/126 Links
Chain adjustmentmethod Automatic
Rockerarm!rockerarm shall:
Rockerarminsidedlam. 12,000-12,018 mm (0.472-0,473 in)
Shalloutsidedlam.
11,976-11,991 mm (0,471-0,472 ii'll
Armto shallclearance
0,009-0,042 mm 10,0004-0,0020 in)
YAMTDOOl
MAINTFNANCE SPECIFICATIONS
i
Model 4NN MuZ.660
Valve, valve seat, valve guide:
Valve clearence (cold): IN 0,10-0,15 mm 10,004-0,006 in)
EX 0,15-0,20 mm (0,006-0,008 in)
Valve dimensions:
~8' !" , !\
S 'C
D"
AU thicknJs~'
Head alameter Face width Seat'width Margin
Head diameter "Au IN ! 29,9-30,1 mm (1,1772-1,1850 in)
EX 31,9-32,1 mm 11,2560-1,2638 in)
Face width Bu IN 2,25 mm (0,0886 in)
"
EX 2,26 mm (0,0890 in)
C"
Seat width IN 0,9-1,1 mm 10,035-0,043 in)
"
EX 0,9-1,1 mm 10,035-0,043 in)
Margin thickness,,0" IN 0,85-1,15 mm 10,0335-0,0453 in)
limit EX 0,85-1,15 mm (0,0335-0,0453 In)
Stem outside diam.
IN 5,975-5,990 mm (0,2352-0,2358 in)
EX 5,960-5,975 mm 10,2346-0,2352 in)
< Limit> IN 5,95 mm (0,234 in)
EX 5,93 mm 10,233 in)
GUide insidediam. IN 6,000-6,012 mm (0,2362-0,2367 in)
EX 6,000-6,012 mm (0,2362-0,2367 in)
< Limit > IN 6,05 mm (0,238 in)
EX 6,55 mm 10,258 in)
Stem to guide clearance IN 0,010-0,037 mm (0,0004-0,0015 in)
EX 0,025-0,052 mm lO,0010-0,0020 in)
<limit> IN O,OB mm (0,003 in)
EX 0,1 mm (0,004 in)
Stem runout limit
0,01 mm (0,0004 il;l).
~ ~!
.......... 'lj
1!
II' i
Valve seat width
IN 0,9-1,1 mm (O,035-0,oi in)
EX 0,9-1,1 mm 10,035- 0,00 in)
YAMT0002
MAINTENANCE SPECIFICATIONS
Model ." 4NN MuZ 850
--------1
Valve spring:
leng'ltl IN 32,63 mm {1,285 in)
EX 36,46 mm n,435 in)
IN 27,50 mm {Ul63 in)
Setlengtl> (valve closed)
EX 31.00 mm 11,220 in)
Compressed pressure IN 10,2-11,8 kg 122,49-26,01 Ib)
(valve closed) EX 12,3-14,1 kg 127,12-31,08 Ibl
IN 2,50/1,4 mm 12.5"/0,055 inl
Tlltlimi!
EX 2.5"/1.6 mm 12,5"/0,063 inl
0
Directionofwinding IN Clockwise
(top view)
0
Clockwise
Piston:
Piston size "D" 99,945- 99,985 mm {3,935- 3,936 in)
Meclsuring point"H" 2,5 mm (O,OOO in)
,+,-+H
Piston offset 1 mm 10,04 in)
Piston offsetdirection INSIDE
Piston to cylinder clearance 0,050- 0,070 mm 10,0020- 0,0028 in)
< Limit > <0,15 mm (0,0059 inl>
Piston ring:
Top ring
Type Borell
Dimensions laxT) 1,2x3,8 mm lO,047xO,l50 in)
End gap (Installed) 0,30-0,45 mm 10,012-0,018 Inl
Side clearance (Installed) 0,04-0,08 mm 10,002-0,003 in)
2nd ring:
Type Taper
DimenSIOns(BxT) 1,2x4,0 mm (0,047xO,157 in!
End gap (installed) 0,30-0,45 mm (0,012- 0,018 in)
T
0,03-0,07 mm 10,001-0,003 in)
Oil ring:
't
~
Dimensions (BxT) C i 8 2,5x3,4 mm {0,098x0,134 in)
End gap (installed) I. ~----!.
0,2-0,7 mm {0,008-0,028 in)
clearance (installed] T 0,015-0,042 mm (0,0000-0,0017 inl
VAMTDCCl3
MAINTENANCE SPECIFICATIONS
Model 4NN MuZ660
i
Crankshaft
AU
Crank width 74,95- 75,00 mm (2,951 - 2,953 inl
" t;.
Runout limit"C" 0,03 mm (0,0012 in)
Big end side clearance "D" ...f- 0,35-0,65 mm (0,014-0,026 in)
© 0,01 - 0,025 mm (0,0004- 0,0010 Inl
Big end radial clearance"E"
Small end ~ 0,8-1,0 mm (0,0315-0,0394 in!
U
free play "F" E'
+Jf..+D
~A-l
I
Balancer:
Drivemethod gear
Ciiiich:
Friklion plate
Thickness
2,74-2,86 mm 10,108-0,113 in)
Quatity
6 pes
Wear limit
2,6 mm (0,102 inl
Frlktlon plate
Thickness 2,94-3,06 mmlO,116-0,120 in)
Quantity 2 pCS
wear JImit
2,8 mm (0,110 inl
Clutch plate
Thickness 1,2 mm 10,047 in)
Quantity 7 pes
wear limit 0,2 mm (0,008 in)
Clutch spring.
Free length 42,8 mm (1,685 in)
Quantity 5 pes
Minimum free length
40,8 mm (1,606 in)
Clutchrelease melhod OulerpUll, raCK and pinionpull
Transmission
Main axle n./frout limit O,OB mm 10,003 in)
Drive axlerunout limit
0,08 mm (0,003 in)
!
Shifter: I
Type
Cam drum and gUide bar
•
I
Decompression device
Type Automatics:
YAMTD004