SERVICE MANUAL

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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 Zweiradwerk GmbH .. - - _ . _ - - -

YAMAHA MOTOR CO., LTD ..

_ _

~

-

-

SERViCE MANUAL660E.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. Nevertheless this manual will be helpful for you to maintain our MuZ SKORPION resp. MuZ S60E BAGHIRA and MASTIFF.

Partly reprint of microfiche Skorpion Motor MuZ660UK 06/1994 [SERVICE MANUAL YAMAHA XTZ 660 (91),Part engine] 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 of Yamaha Motor Co., Ltd, Motorrad- und Zweiradwerk GmbH, Zschopau, is expressly prohihibited.

2

SERVICE MANUAL660E.doc

NOTICE This manual was written by the Yamaha Motor Company 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 render it unfit to 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 of this manual.

PARTICULARLY IMPORTANT INFORMA1"ION This material is distinguished by the following notation. The Safety alert symbol means ATTENTIO! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNIG 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 damage to the motorcycle.

NOTE

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

3


CONTENTS

PAGE

ILLUSTRATED SYMBOLS

6

MAINTENANCE SPECIFICATIONS

YAMTD001

ENGINE CARBURETOR LUBRICATION SYSTEM COOLING SYSTEM CRANKCASE TIGHTENING SEQUENCE ELECTRICAL SYSTEM LUBRICATION POINTS

YAMTD001 YAMTD005 YAMTD005 YAMTD005 YAMTD006 YAMTD007 YAMTD009

ENGINE DISASSEMBLY

DE01

PIPE,STARTER MOTOR AND HOSES CYUN DER HEAD AND CYLINDER ROTOR AND STARTER DRIVES OIL FILTER AND WATER PUMP CLUTCH AND BALANCER GEAR SHIFT LEVER AND OIL PUMP CRANKCASE (RIGHT) OIL STRAINER BALANCER, TRANMISSION AND SHIFTER CRANKSHAFT ROCKER ARM VALVES

DE01 DE02 DE06

DE17 DE18 DE19

INSPECTION AND REPAIR

DE21

CYLINDER HEAD VALVE SEAT VALVE AND VALVE GUIDE VALVE SPRING CAMSHAFT DECOMPRESSION ROCKER ARM AND ROCKER ARM SHAFT TIMING CHAIN, SPROCKET AND CHAIN GUIDE CYLINDER AND PISTON CRANKSHAFT BALANCER GEARS ELECTRIC STARTER DRIVE PRIMARY DRIVE CLUTCH TRANSMISSION AND SHIFTER OIL PUMP, WATER PUMP AND STRAINER OIL DELIVERY PIPES CRANKCASE BEARING AND OIL SEAL CIRCLIP AND WASHER

DE21 DE22 DE25 DE27 DE28 DE30 DE30 DE31 DE32 DE3S DE37 DE3? DE38 DE38 DE40 DE42 DE44 DE44 DE44 DE44

ENGINE ASSEMBLY AND ADJUSTMENT VALVE AND ROCKER ARM VALVES ROCKER ARM CRANKSHAFT BALANCER AND TRANSMISSION

DEOa DE10 DE12 DE14 DE16

DE16

DE45 DE45 DE46 DE48 DE49 DE51

4


CONTENTS

PAGE

SHIFTER BALANCER. TRANSMISSION AND SHIFTER OIL STRAINER CRANKCASE SHIFT LEVER AND OIL PUMP OIL STRAINER CRANKCASE (RIGHT) SHIFT LEVER AND OIL PUMP BALANCER GEAR CLUTCH CLUTCH AND BALANCER GEAR OIL FILTER AND WATER PUMP ROTOR AND STARTER DRIVES CYLINDER CYLINDER HEAD CAMSHAFT AND TIMING CHAIN PIPES AND HOSES

DE53 DE55 DE56 DE57 DE58 DE58 DE59 DE62 DE63 DE64 DE6S DE70 DE74 DE75 DE7S DE83 DW1

WATER PUMP DC1

CARBURETOR

DC4

DISASSEMBLY PRIMARY CARBURETOR SECONDARY CARBURETOR INSPECTION ASSEMBLY MEASUREMENT AND ADJUSTMENT STEPS INSTALLATION FUELLEVELADJUSTMENT

DCS DC6 DC? DC9 DC13 DC15 DC16 DCn

FUEL PUMP DSTART1

ELECTRICAL STARTER SYSTEM

DSTART1

STARTER MOTOR DISASSEMBLY INSPECTION AND REPAIR ASSEMBLY

DSTART2 DSTART3 DSTART5 DCHARGO

CHARGING SYSTEM TROUBLE01

TROUBLE SHOOTING

TROUBLE01

STARTING FAILURE/HARD STARTING POOR IDLE SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE FAULTY GEAR SHI FTING CLUTCH SLIPPING/DRAGGING OVERHEATING OR OVERCOOLING FAULTY BRAKE FRONT FORK MALFUNCTION INSTABLE HANDLING FAULTY SIGNAL AND LIGHTING SYSTEM

TROUBLE03 TROUBLE03 TROUBLE04 TROUBLE04 TROUBLE05 TROUBLE06 TROUBLE06 TROUBLEO? TROUBLE08

5


ILLUSTRATED SYMBOLS (Refer to the illustration)

..

~ ~ ~ _

[1iJ

1

2

4

6

8

Illustrated symbols 1 to 16 are used to identify the specifications appearing in the text

..

3

~ ~

5

7

[g]

j 9

1

m 11

1 @)

12

~

~ ~ ~ 10

1

e

13

1;;Tj;;:

14

a I

YAMSYMB.COf

1 2 3 4 5 6 7

,

filling fluid Lubricant Special tooi Tightening Wear limit, clearance Engine speed n,V,A

lllustrated symbols 8 to 14 in the exploded diagram indicate grade of lubricant and location of lubrication point. 8 Apply engine oil 9 Apply gear oil 10 Apply molybdenium disulfide oil 11 Apply wheel bearing grease 12 Apply lightweight lithium soap base grease 13 Apply molybdenuim disulfide grease 14 Apply locking agent (Ioctite)

"


4NN MuZ 660

Model

Cylinder head: Warp limit. *

0,03 mm (0,0012 ii'll * Linos indicate straightedge measurement

, , ,*

t

T~v".

1

i

I

"

Cylinder: Bore size/Measuring point

100,1 mm 13,941 in) mmmmmmmcc

Camshaft: Drivemethod Camshaft outside diameter

_

Chain drive (left) 22,967 - 22,980 mm 10,9042 - 0,9047 In)

!

. Shaft to cap clearance Cam dimensions: Intake

~

1\1

"

sn

>

j~:Z'::f:: .

lJ

8

llmlng chain: Chain typel No. Of links Chain adjustment method Rocker arm! rocker arm shall: Rocker arm inside dla m. Shall outside dlam. Arm to shall clearance

75 RH 2015/126 Links Automatic 12,000-12,018 mm (0.472-0,473 in) 11,976-11,991 mm (0,471-0,472 ii'll 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): Valve dimensions:

!" , ~8' S'

AU "A

u

Head diameter

IN

EX

Seat width

"

"

Bu

IN EX IN EX IN EX IN

C"

Margin thickness ,,0" limit Stem outside diam.

EX IN

< Limit>

EX GUide inside diam.

IN

EX

< Limit >

IN EX

IN

Stem to guide clearance

EX

IN EX

Stem runout limit

~ ~!. . . . . II'

i

Valve seat width

Seat'width

Face width

Head alameter

Face width

0,10-0,15 mm 10,004-0,006 in) 0,15-0,20 mm (0,006-0,008 in)

IN

EX

1!

!

C

!\ Margin thicknJs~'

29,9-30,1 mm (1,1772-1,1850 in) 31,9-32,1 mm 11,2560-1,2638 in) 2,25 mm (0,0886 in) 2,26 mm (0,0890 in) 0,9-1,1 mm 10,035-0,043 in) 0,9-1,1 mm 10,035-0,043 in) 0,85-1,15 mm 10,0335-0,0453 in) 0,85-1,15 mm (0,0335-0,0453 In) 5,975-5,990 mm (0,2352-0,2358 in) 5,960-5,975 mm 10,2346-0,2352 in) 5,95 mm (0,234 in) 5,93 mm 10,233 in) 6,000-6,012 mm (0,2362-0,2367 in) 6,000-6,012 mm (0,2362-0,2367 in) 6,05 mm (0,238 in) 6,55 mm 10,258 in) 0,010-0,037 mm (0,0004-0,0015 in) 0,025-0,052 mm lO,0010-0,0020 in) O,OB mm (0,003 in) 0,1 mm (0,004 in) 0,01 mm (0,0004 il;l).

'lj IN EX

0,9-1,1 mm (O,035-0,oi in) 0,9 -1,1 mm 10,035 - 0,00 in) YAMT0002

D"

MAINTENANCE SPECIFICATIONS ." 4NN MuZ 850

Model

--------1

Valve spring: leng'ltl

IN EX IN EX IN EX

Set lengtl> (valve closed) Compressed pressure (valve closed)

EX

32,63 mm {1,285 in) 36,46 mm n,435 in) 27,50 mm {Ul63 in) 31.00 mm 11 ,220 in) 10,2-11,8 kg 122,49-26,01 Ib) 12,3-14,1 kg 127,12-31,08 Ibl 2,5 0 /1,4 mm 12.5"/0,055 inl 2.5"/1.6 mm 12,5"/0,063 inl

IN

Clockwise

IN

Tlltlimi!

Direction of winding (top view)

Clockwise Piston: Piston size "D" Meclsuring point"H"

0 0

99,945 - 99,985 mm {3,935 - 3,936 in) 2,5 mm (O,OOO in) ,+,-+H

1 mm 10,04 in) INSIDE

Piston off set Piston off set direction

0,050 - 0,070 mm 10,0020 - 0,0028 in)

Piston to cylinder clearance < Limit >

Piston ring: Top ring

Type

Borell

Dimensions laxT) End gap (Installed)

1,2x3,8 mm lO,047xO,l50 in) 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 DimenSIOns (BxT) End gap (installed)

1,2x4,0 mm (0,047xO,157 in! 0,30-0,45 mm (0,012 - 0,018 in)

Taper T

0,03-0,07 mm 10,001-0,003 in)

Oil ring: Dimensions (BxT) ~C i 8 End gap (installed) I. ~----!. clearance (installed] T

't

2,5 x 3,4 mm {0,098 x 0,134 in) 0,2-0,7 mm {0,008-0,028 in) 0,015-0,042 mm (0,0000-0,0017 inl VAMTDCCl3


4NN MuZ660

Model Crankshaft Crank width

i "

AU

Runout limit" C" Big end side clearance

t;. U "D"

...f-

Big end radial clearance" E" © Small end ~ free play "F"

74,95 - 75,00 mm (2,951 - 2,953 inl 0,03 mm (0,0012 in) 0,35-0,65 mm (0,014-0,026 in) 0,01 - 0,025 mm (0,0004 - 0,0010 Inl 0,8-1,0 mm (0,0315-0,0394 in!

E'

+Jf..+D ~A-l

Balancer: Drive method

I

gear

Ciiiich: Friklion plate Thickness Quatity Wear limit

2,74-2,86 mm 10,108-0,113 in) 6 pes 2,6 mm (0,102 inl

Frlktlon plate

Thickness Quantity wear JImit

2,94-3,06 mmlO,116-0,120 in) 2 pCS 2,8 mm (0,110 inl

Clutch plate Quantity wear limit

1,2 mm 10,047 in) 7 pes 0,2 mm (0,008 in)

Clutch spring. Free length Quantity Minimum free length

42,8 mm (1,685 in) 5 pes 40,8 mm (1,606 in)

Thickness

Clutch release melhod

Ouler pUll, raCK and pinion pull

Transmission

Main axle n./frout limit Drive axle runout limit

O,OB mm 10,003 in) 0,08 mm (0,003 in)

!

I

Shifter: Type

Cam drum and gUide bar

•

I

Decompression device Type

Automatics: YAMTD004

MAINTENANCE SPECIFICATIONS Model

4NN MuZ660

~~~~

Carburetor:

ID

mar"

3YF 00, 4BW 00 (AHCH)

Primary

, Secondary ! #165

Main jet Main air jet Jet needle

(M.J.1 (MAJJ

#130 1,0

(J.N.!

5D96·3/5 5D97·3/5 iAHCHI

5X7C·315

Needle jet Pilot jet Pilot air jet Bypass Pilot screw

(N.J.)

VOO

¢2,7

IP.J.! IPAJ.! (B.P.! (p.S.l

00,6 1,0

Carburetor diameter

#48

2 und 1/2 Turns open 26 mm (0.97 In)

(v.S') (G.S.!

4>2,5

t ,0

-

-

35 mm (137 in )

-

Valve seat Starter et Pilot outlet Fuel level

(P.O.1

00,8

IF.Ll

Float height

(F.H.l

6,0-8,0 mm (0,24-0,31 inl Below from the float chamber mating surface 25-27 mm 10,98-1,06 in! 1.250-1.350 r/min 26,6- 34,6 kPa 1200-260 mmHg, 7,87-10,24 inHgl

Vacuum pressure at Idllng speed Lubrication system 011 filter type 011 pump type Tip clearance Side clearance Bypass valve setting pressure

Cooling system radiator fan

Water pump Type Reduction ratio

#76

Paper type Trochoid· Pump type 0,12 mm IO,D05 in! 0,03-0,08 mm 10,001-0,003 inl 80-120 kPa (0,B-l,2 kg/em', 11,3B-17,07 psi) Water Skorplon 1 pes Baghiral Mastiff 2pcs Skorplon 2 pes Baghlral Mastiff 1pes

Single suction centrifugal pump 33/34 10,971)

Thermostat

Opening temperatur

17LB1°C (160.. 178°F)

YAMTOOOS

MAINTENANCE SPECIFICATIONS 4NN MuZ 660

Model

q

Lubrication chart:

Pressured feed

. . Splashed Shift fork shaft ~ Gear Feed pump

Main axle

Check valve

f,

~======~I"i ' Clutch

_ _-...J ,, Drive aXle

===========:;.:.

....

II

1j i I

• I

I I

IReUe! valve

II ! I

II

II

I

II r-:===~ II I r t I I J

;

II II II II II II f

I ;

" II I I

I

,------·JI

"' ...

Bypass valve i

II ' I I r""'----.,

One way clutch

Crank Connecting rod

, Balancer

I 11'-'~":;;:~:.:.J---........1.'.:C::a::.:.m:..:s~h:::aft~.-J 11-

.... !

!

_I

"

i-Ji i.._ f 'II j I

-I II

Rocker arm

,I -II

"

..~

Oil strainer

Crankcase tightening sequence:

Crankcase (left)

I

' - - - - - - - ' >11

II II II

j

:

Crankcase (right)

YAMTOOO6

MAINTENANCE SPECIFICATIONS ELEKTRICAL

4NN Mul 660

Model Voltage Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B,T.D.C.) Advancer type

12V 12° at 1.300 U/min (Rpm) 38° at 6.500 U/min (Rpm) Electrical type

rpm

I •

I

f

Engine speed Ignitor Pickup coil resistance (Colour) Ignitor unit I Manufacturer

Ignition coil Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug gap Type Resistance Charging system Type

(x 10'

rpm )

1184-2760 at 20 0 e (68°FI (Blue/yellow ·GreenlwhitEl TNDF13/NlPPONDENSO J0268/NlPPONDENSO 6 mm 10,24 in) 3,4-4,60 at 20°C (68°F) 10,4-15,6kO bel 20 0 e {68°FI Resin type

10kO at 20 0 e {68°FI

AC. Magneto generator YAMTOOO7

MAINTENANCE SPECIFICATIONS !

Model

4NN MuZ eoo

AC. Generator Modell manufacturer nominal output

TLMZ551NIPPONDENSO 14V 24,5A at 5.000 ,

,

C

' .Oir rUte; i.o.,"t!.-r»,;j, .

3. Rj5 ,

,·pja!~: wasj)"'~

·PfatfL·· ')':

iL,' . '.

'B~an;::~ :ge~f~:;,

"j(ey1'!;

,

SHiFT.LEVEl'l AND GIL PUMP NOTE:

-

Wl,tn th~' eflgme mount~~.t 1he 011 pump :;~n maiIHlllrlS'd -by femov"y the fOliowifllJ lJ'"i, 'Clutch,c,able • En9'inv g\,aH! • ~

):

il5 .tgnlt~9ncoil

,,~.oil lan~,:fu.eati'l~r

'lOse

·Cyltnde','head cove'

J Rerrtove • Plug 1

2. ,RetnOlte '
.> II 400 - 600 gm wet sandpaper on If>e SUI' face plaIa, "ndresurtace Ihe heBe using a ligure-e,gh1 sanding patte'"

INSPECnOJIIANOREPAIR NOTE:

_

Rotate the head. several times to 8yold mmo.vmg

roo much 'material from one SlelL'

VALVE SEAT 1 Eiimlnatt?',

-Carbon deoosrt (·from valve 1acI: and v,qlve'senff

2 lf1$peCI' -Va'ive seat

. Pf!tin$JfYVea r •Rela.cc the valve seal

3. Measure eValve.. sea1 width a

Out of specrflcatron • Re-tace H1% vaive seal

Valve ."qt,width. Intake 0,9 - 1.1

mm 10,035· 0.043 Inl

E¥hau.t , "Q,g.- 1,1 mm JO,035 ~ 0043 inl

• .. • • .. • • • • • • •... t ..

~f

•••

Measuremeot staps: • Apply the MechaniCS bhJlng oye IDY"em' to the V.a\\I€: face • ~S!ah the valve Into the ~yltnder heap .. Press the valv.e through'1he, valve gUide and onto the valve seal to make a cleat' pattern .

• Measure the yalve sea! w;dth Wherever

t~e

valv.e'seat and -valve fac€: rnaOf> contaCl 1l!tJ

HIll wiil have been relXl,o\f8d .'lfthe \/!Jlve seat wtdth:s too Wide, too naf/OW. seat has not centereo. ffu: v.arve Seat mUSI

or

he

f~faced.

0£22!E38)

INSPECTIOIII AND.REPAtR ,,4 Remc,,"

*Valve·seat Usa 8 ;))Q,,4QV and SOC VafV$ seat cutter

When .tWt.S~fl9 cutter

k'$:ep an 8''''$''' dowfl,-

wtI,q'pr..""",,, (4 ".4kg) to prevefV( chatter msrks,

--.

I

Cut Mctionas follows

I

,Section )

A

3ll"

B

~~

: :

C

I 1

CutU",

$0

.

.

.i

.;.-"

1-

i

t

> .l"

Refacing .teps: A. Vaive $$a1.

TS' ~;antered

-on

\ta~ve

faoe

bul

.1 .~s. tOO wi~~.

'n

;8 valVe sea'! is the 'Midie of Ihe lace hut it i,s .1,00 narrow \latve seat cutter ,et Us.

'OiHitao ,reS'ult

Tn ftchkfve !t uniform 46" -t;utt1tr v.llw selr w'dth

1 II mm 100000lni

..

~

of

INSPECTiON AND REPAIR

·c

'Va~~seg3uge:'

.. Remove the cytind!3f -haaet COvel Bnd measure

w,dlh of. the Pllmigaugl!'

INSPECTION AND REPAIR 5. K'teasufE :'.Baanng dtam(tl't:i" a ;cam:Hlatt

.Oul oJ st>eethcahon ·~Rep;aLe ccffishah W,tnln specriIClltlOO -Rep",ce

• Adjuster svrlace 3 Wear PittIng' SCI&I~t>e5 . 1'l1;".,. diS"O:O'"!tOP

.

.• RUoiace, t~n l/'l$P&cf lUnr;CtlHorr{r,.vs1em

INSPECTION ANO REPAII'l 3. Measel,eo • Arm-to-shah cli;a,anc". Ar-m·l(HtJ".aft eiearance

#:

Rocker 3rm msrde dlat't\fiu;,r
Roek&r arm shah

OUU.ll~

diameter 0

OUl of specificatlOfi -.. Reptace as a sel

Arm·to-s:haft clearance: • 0.00!l;' n.OoI2 mm IO:Q904 ,O.OO2IJ in;

T1MlNGCHAlN. SPROCKET AND CHAIN

GUIDE 1, lnspe"kel C,rUSf Q( mlOera,ls

Rus! - Remo\'e

• Cyhnder waft

wfla.,

SCt.(jtChf.?'5 • Rehofe Of

replace-

5: MttesVT€--

·Pistor:- io-cvlltlOOI dea(orH.:e

... _.........•..•.••. _

i.

•

•

Measuf.ement steps Firat sleps • Measure ~he_cyllnder bore' C with a Cllllnder bm~

gauge_

a 50 mlTI' \ 1 97 ~hl fron, tbp ~nde!" togies.1C the ctat>ksh"tt Then find

tne· pV~f~~9~

of' Hle

rr:~astJrem~n(?,

Cvlinde, bo'" "C;" 100.006.- 100:045 mm 13.9m - 3.!l38ll inl • 'iI,'fliiiecr ·g~'f\1i 1 "pnll ."d' '.W«'; Dilmatl€'~.f\""tace

Transmission 'ANO:,SHIFTrn Inspect.' " , •.Sl1iit:f(I,k'''an' iollO Wlff .f '.. ShIh tqdr pawl· 2. , Scarin~ '8enos, Wt~r, ·.R~f)~C:~". _

.

..

lNSP,ECTIQN ANtLRE'PAIR Ir.Sll~t,

2

"Sh'ftt

cam J:J'foove.•

.: St"tt cam. $eSm~m W~.r, D"-Se",Rep'ocp.

J~'Check: '

• S hitl ltlrk "",'leT"nl Unsmooth' 'i!r>erahen ~Repj~e 'Stil:: -fOtk; '.illl\d 'or guide bar·.'

.:i Inspect' -rGLi-1de Oaf ROIL the "'9~de: bar on 'a flat SlH1ac::~

lllillti:ts·' fleptllCe '

,~----~--.po

,,!/1'-

t~na"$t 3VF -Install the valve spru)Q

. lnH upwaid

!

\IV.t" larger pitch

6 lac-

•

Sri'ldlier pfH:h

4 Hlstafl -VaJve cotter,?

-1 .

NOTE:

-'-

_

Ins:'t,aU the v()lve cotters' sha t '\

."

BpI! 1 lroc'ker arm shahl 10 N.m no m'!

*' 3 "if

SI'!i!1 10'0 .. I"L

4$;"111 ,om 5 Guide bar i shurt'

5 Sh"'l"'"

ziC·

#

7 Snill shat