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Yamaha TT-R90(R), Owner'S Service Manual

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Yamaha TT-R90(R) Owner'S Service Manual Download Page 23

INHALT

KAPITEL 1

ALLGEMEINE ANGABEN

FAHRZEUGBESCHREIBUNG 

................. 1-1

FAHRZEUG-IDENTIFIZIERUNG 

.............. 1-2

WICHTIGE INFORMATIONEN 

................. 1-3

ANSCHLÜSSE PRÜFEN 

.......................... 1-5

SPEZIALWERKZEUGE 

............................ 1-6

ARMATUREN UND DEREN 
FUNKTION

 ................................................ 1-9

KRAFTSTOFF 

......................................... 1-11

ANLASSEN UND INBETRIEBNAHME

 .. 1-12

KAPITEL 2

TECHNISCHE DATEN

ALLGEMEINE TECHNISCHE DATEN 

..... 2-1

WARTUNGSDATEN 

................................. 2-4

ALLGEMEINE ANZUGSMOMENTE 

...... 2-15

EINHEITEN 

............................................. 2-15

KABELFÜHRUNG 

.................................. 2-16

KAPITEL 3

REGELMÄSSIGE 

INSPEKTION UND 

EINSTELLARBEITEN

WARTUNGSINTERVALLE 

....................... 3-1

WARTUNGSINTERVALLE UND 
SCHMIERDIENST 

..................................... 3-1

WARTUNGS- UND EINSTELLARBEITEN 
VOR FAHRTBEGINN

 ................................ 3-2

MOTOR 

..................................................... 3-3

FAHRWERK 

............................................ 3-11

ELEKTRISCHE ANLAGE 

....................... 3-19

TABLES DES MATIERES

CHAPITRE 1

RENSEIGNEMENTS 

GENERAUX 

DESCRIPTION 

............................................... 1-1

IDENTIFICATION DE LA MACHINE 

....... 1-2

INFORMATIONS IMPORTANTES 

............ 1-3

VERIFICATION DES CONNEXIONS 

........ 1-5

OUTILS SPECIAUX 

...................................... 1-6

FONCTIONS DES COMMANDES 

.............. 1-9

CARBURANT 

............................................... 1-11

DEMARRAGE ET FONCTIONNEMENT 

1-12

CHAPITRE 2

CARACTERISTIQUES

CARACTERISTIQUES GENERALES 

........ 2-1

CARACTERISTIQUES D’ENTRETIEN 

..... 2-4

CARACTERISTIQUES GENERALES DE 
COUPLE 

........................................................ 2-15

DEFINITION DES UNITES 

........................ 2-15

CHEMINEMENT DES CABLES 

................ 2-16

CHAPITRE 3

CONTROLES ET REGLAGES 

COURANTS

PROGRAMME D’ENTRETIEN 

................... 3-1

ENTRETIENS PERIODIQUES ET GRAIS-
SAGES 

.............................................................. 3-1

CONTROLES ET ENTRETIENS AVANT 
UTILISATION 

................................................ 3-2

MOTEUR 

......................................................... 3-3

PARTIE CYCLE 

........................................... 3-11

PARTIE ELECTRIQUE 

.............................. 3-19

Summary of Contents for TT-R90(R)

Page 1: ...5HN 28199 83 TT R90 R OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH...

Page 2: ...ER S SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition April 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibi...

Page 3: ...g auch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R90 R MANUEL D ATELIER DU PROPRIETAIRE 2002 Yamaha Motor Co Ltd 1re dition avril 2002...

Page 4: ...NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING READ THIS MANUAL CAREFULLY FOR INSTRUCTI...

Page 5: ...Seite 15 Dieses Fahrzeug ist nur f r eine Person zugelassen Zweipersonen Betrieb ist nicht zul ssig Dieses Fahrzeug ist ausschlie lich f r den Einsatz abseits ffentlicher Stra en vorgesehen Der Gebrau...

Page 6: ...while smoking or in the vicinity of an open flame 2 If you should swallow some gasoline or inhale a lot of gasoline vapor or allow some gasoline to get in your eye s see your doctor immediately If an...

Page 7: ...Untergrund abstellen damit es nicht umfallen kann SICHERHEITSINFORMATION REMARQUE IMPORTANTE Ce v hicule est con u uniquement pour une utilisa tion tout terrain par des pilotes tr s jeunes roulant sou...

Page 8: ...k out of the car buretor or fuel tank 5 Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death with...

Page 9: ...en Helm und spezielle Motorradbekleidung Hand schuhe Stiefel Hosen und Jacken tragen 4 Lors du transport de l engin dans un autre v hicule veiller le garder bien droit et ce que le robinet de carburan...

Page 10: ...is a one seater motorbike Don t give any person a ride 4 Let s learn how to ride properly Ask your parents for any question 5 When riding the machine be sure to wear the protective apparel as illustr...

Page 11: ...hutz 4 Motorrad Handschuhe 5 Motorradstiefel 6 Motocross Hose 7 Lang rmeliges Trainingshemd INFORMATION DE SECURITE 1 Ne pas rouler sur la route 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il...

Page 12: ...lone 7 Before riding the machine ask your par ents to check the machine very carefully 8 Don t touch the areas shown or you ll get burnt in the hand 9 Don t touch rotating or moving parts 10 Before st...

Page 13: ...gen den Teile ber hren 10 Vor dem Starten des Motors sicherstellen da sich das Getriebe in der Leerlaufstel lung befindet 6 Ne jamais partir seul moto Toujours partir avec son instructeur 7 Avant de r...

Page 14: ...n to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of six chapters General Informatio...

Page 15: ...le d sir s Arquer le manuel son bord de la mani re indiqu e pour trouver le symbole de devant d sir et passer une page de la description et l article d sir s AVERTISSEMENT ATTENTION BENUTZERHINWEISE K...

Page 16: ...start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A...

Page 17: ...F r Arbeiten f r die weitere Informationen ben tigt werden sind schrittweise Erg n zungen 6 zus tzlich zu dem Explosions diagramm und der Arbeitsanweisungstabelle aufgef hrt FORMAT DU MANUEL Dans ce m...

Page 18: ...Tightening B Specified value Service limit C Engine speed D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagram indicate grade of lubricant and loca tion of lubr...

Page 19: ...mittel LOCTITE J Erneuern SYMBOLES GRAPHIQUES Voir l illustration Les symboles graphiques 1 6 servent rep rer les diff rents chapitres et indiquer leur contenu 1 Renseignements g n raux 2 Caract risti...

Page 20: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL...

Page 21: ...SPEC 2 REGELM SSIGE INSPEKTION UND EINSTELLARBEITEN 3 MOTOR ENG 4 FAHRWERK CHAS 5 ELEKTRISCHE ANLAGE ELEC 6 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES COU...

Page 22: ...ING AND OPERATION 1 12 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 15 DEFINITION OF UNITS 2 15 CABLE ROUTING DIAGRAM 2 16 CHAPTER...

Page 23: ...EN VOR FAHRTBEGINN 3 2 MOTOR 3 3 FAHRWERK 3 11 ELEKTRISCHE ANLAGE 3 19 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS GENERAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MACHINE 1 2 INFORMATIONS IMPORTANTES...

Page 24: ...IFT SHAFT 4 34 OIL PUMP 4 36 CDI MAGNETO 4 39 CRANKCASE AND CRANKSHAFT 4 41 SHIFT FORK SHIFT CAM AND TRANSMISSION 4 44 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT FORK 5 6 HANDLEBAR 5 9 STE...

Page 25: ...6 1 Z NDANLAGE 6 2 VERGASERBEHEIZUNGSSYSTEM 6 6 WARTUNGSPLAN 6 9 CHAPITRE 4 MOTEUR CARBURATEUR 4 1 CULASSE 4 8 ARBRE A CAMES ET CULBUTEURS 4 13 SOUPAPES ET RESSORTS DE SOUPAPE 4 16 CYLINDRE ET PISTON...

Page 26: ...hrottle grip 4 Fuel tank cap 5 Kick starter 6 Fuel tank 7 Air cleaner 8 Rear brake pedal 9 Fuel cock 0 Starter lever choke A Drive chain B Shift pedal C Front fork NOTE The machine you have purchased...

Page 27: ...erungen an Design und technischen Da ten jederzeit vorbehalten RENSEIGNEMENTS GENERAUX DESCRIPTION 1 Coupe circuit du moteur 2 Levier de frein avant 3 Poign e d acc l rateur 4 Bouchon d orifice de rem...

Page 28: ...machine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of th...

Page 29: ...teil Bestellung ben tigt IDENTIFICATION DE LA MACHINE Il existe deux bonnes raisons de conna tre les num ros de s rie de sa machine 1 A la commande de pi ces de rechange ces num ros permettent au conc...

Page 30: ...Use proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have...

Page 31: ...gen Dies ge w hrleistet einen z gigen und korrekten Zusammenbau 5 Alle Teile von offenem Feuer fernhalten INFORMATIONS IMPORTANTES PREPARATION POUR LA DEPOSE ET DEMONTAGE 1 Eliminer soigneusement cras...

Page 32: ...EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or...

Page 33: ...ous recommandons d utiliser des pi ces Yamaha d origine pour tous les remplace ments Utiliser les huiles graisses recomman d es par Yamaha lors des remontages et r glages JOINTS BAGUES D ETANCHEITE ET...

Page 34: ...e etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air bower 3 Connect and disconnect the connector two or three times 4 Pull the lead to check that it will not come off 5 If th...

Page 35: ...g von Kabelb umen stets die Schritte 1 bis 7 durchf hren Zur schnellen Abhilfe kann ein handels bli ches Kontaktspray verwendet werden Die Steckverbinder wie abgebildet mit dem Me ger t pr fen CIRCLIP...

Page 36: ...se tools are used when removing or installing the rocker arm shafts YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Ring nut wrench This tool is used when loosen the steering ring nut to specifi...

Page 37: ...0890 01184 Fork seal driver weight This tool is used to installing the oil seal YM 33963 90890 01184 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checkin...

Page 38: ...uller This tool is used to remove the rotor YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC QUICK GS...

Page 39: ...tracteur inertie Ces outils permettent de d poser et de remonter les axes de culbuteur YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Cl pour crou annulaire Cet outil est utilis pour desserrer...

Page 40: ...de montage de joint de fourche Cet outil permet de monter les bagues d tanch it YM 33963 90890 01184 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Ce testeur est n cessaire...

Page 41: ...utilis pour la d pose du volant magn ti que YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond n 1215 Cet agent d tanch it p te est utilis sur les plans de joint du carter et...

Page 42: ...90 01084 90890 01085 Austreib Set Gewicht Kipphebelwellen Ausbauwerkzeug Zum Montieren oder Demontieren der Kipphebelwel len YU 01083 A 90890 01084 90890 01085 YU 1268 90890 01268 Hakenschl ssel Zum L...

Page 43: ...instellen der Ventile YM 8035 90890 01311 YM 33963 90890 01184 Gabeldichtring Treiber Zum Einbau der Gabeldichtringe YM 33963 90890 01184 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndpr fer Zur b...

Page 44: ...Polrad Abzieher Zum Demontieren des Rotors YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Dichtmasse Nr 1215 Zum Abdichten der Kurbelgeh use Pa fl chen ACC QUICK GS KT 90890 85...

Page 45: ...GEN INFO MEMO...

Page 46: ...ifted by using the shift pedal 1 on the left side of the engine WARNING When starting out on the machine shift the transmission into 1st after pulling in the front brake lever and closing the throttle...

Page 47: ...Zum Erh hen der Mo tordrehzahl Beschleunigung den Gasdreh griff in Gegenfahrtrichtung drehen zum Reduzieren der Motordrehzahl den Gasdreh griff in Fahrtrichtung drehen FONCTIONS DES COMMANDES COUPE CI...

Page 48: ...s position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lev...

Page 49: ...Kaltstartanreiche rung des Gemischs den Chokehebel 1 bis zum Anschlag herausziehen Zum Abschalten des Chokemechanismus normaler Fahrbe trieb mit warmem Motor den Hebel bis zum Anschlag zur ckschieben...

Page 50: ...tank above the bottom of the filler tube 1 as shown in the illustration or it may over flow when the fuel heats up later and expands a Fuel level CAUTION Use only unleaded gasoline The use of leaded...

Page 51: ...r ZA Bleifrei Normal Tankvolumen Gesamtinhalt 4 1 L Davon Reserve 0 5 L BOUCHON DE RESERVOIR DE CARBURANT Retirer le bouchon de r servoir de carburant 1 en le tournant dans le sens inverse des aiguill...

Page 52: ...ction The starter choke should not be used The throttle should be opened slightly CAUTION See Engine break in Section prior to operating engine for the first time WARMING UP To get maximum engine life...

Page 53: ...arter Ne pas acc l rer brutalement ATTENTION Se reporter la section Rodage avant la pre mi re mise en marche du moteur MISE EN TEMPERATURE Toujours r chauffer le moteur avant de d marrer afin de prolo...

Page 54: ...Choke jedoch nicht aktivieren Den Grasdrehgriff etwas ffnen ACHTUNG Vor dem ersten Fahrtantritt unbedingt die nachfolgenden Einfahrvorschriften durchlesen MOTOR WARMFAHREN Den Motor immer warmfahren u...

Page 55: ...GEN INFO MEMO...

Page 56: ...Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 89 cm3 5 43 cu in Bore stroke 47 0 51 8 mm 1 85 2 04 in Compression ratio 8 5 1 Compression pre...

Page 57: ...6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc and centrifugal automatic Transmission Primary reduction system Spur gear Primary reduction ratio 67 18 3 722 Secondary reduction system Chain driv...

Page 58: ...spension Front suspension Telescopic fork Rear suspension Swingarm monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel...

Page 59: ...und limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 428 25 528 mm 1 0011 1 0050 in 25 398 mm 0 9999 in B 21 034 21 134 mm 0 8281 0 8320 in 21 004 mm 0 8269 in...

Page 60: ...9 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 5 0 9 mm 0 0197 0 354...

Page 61: ...n 26 9 mm 1 06 in EX 28 32 mm 1 11 in 26 9 mm 1 06 in Set length valve closed IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Compressed pressure installed IN 90 4 104 1 N 9 22 10 62 kg 20 33 23 41 lb EX 90 4 1...

Page 62: ...000 mm 0 5117 0 5118 in 12 976 mm 0 5109 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 0 mm 0 04 0 08 in End gap installed 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Side clearance insta...

Page 63: ...od Inner push cam push Push rod bending limit 0 5 mm 0 02 in Automatic centrifugal clutch Clutch in revolution 2 160 2 560 r min Clutch stall revolution 3 300 3 800 r min Shifter Shifter type Cam drum...

Page 64: ...ump type Trochoid type Tip clearance A or B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Side clearance 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Housing and rotor clearance 0 06 0 10 mm 0 0024 0 0039 in...

Page 65: ...int cylinder head side M6 1 0 2 7 0 7 5 1 Carburetor joint carburetor side M6 1 0 2 7 0 7 5 1 Air filter case M6 1 0 2 7 0 7 5 1 Exhaust pipe M6 1 0 2 7 0 7 5 1 Exhaust pipe protector M6 1 0 7 7 0 7 5...

Page 66: ...r travel 48 mm 1 89 in Spring free length 169 mm 6 65 in Fitting length 165 mm 6 5 in Spring rate STD K 45 6 N mm 4 65 kg mm 260 lb in Optional spring No Enclosed gas pressure 2 000 kPa 20 kg cm2 290...

Page 67: ...n Front lining thickness 3 mm 0 12 in 2 mm 0 08 in Rear lining thickness 4 mm 0 16 in 2 mm 0 08 in Front shoe spring free length 32 7 mm 1 29 in Rear shoe spring free length 50 5 mm 1 99 in Brake leve...

Page 68: ...0 29 Under bracket and front fork M10 1 25 2 33 3 3 24 Damper rod bolt M8 1 25 2 20 2 0 14 Handle crown and handlebar holder lower M10 1 25 2 40 4 0 29 Handlebar holder upper M6 1 0 4 13 1 3 9 4 Fron...

Page 69: ...ckup coil resistance color 248 372 at 20 C 68 F Red White CDI unit model manufacturer 4GL 20 YAMAHA Ignition coil Model manufacturer 2JN 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding resist...

Page 70: ...threads Com ponents should be at room temperature A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 0 6 1 5 3 0 5...

Page 71: ...lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l avant Cylindr e 89 cm3 5 43 cu in Al sage course 47 0 51 8 mm 1...

Page 72: ...02 0 03 in Type d embrayage Humide multidisque et centrifuge automatique Bo te de vitesses Syst me de r duction primaire Engrenage denture droite Taux de r duction primaire 67 18 3 722 Syst me de r d...

Page 73: ...ant Fourche t lescopique Suspension arri re Bras oscillant suspension monocross Amortisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumati...

Page 74: ...imite d ovalisation 0 05 mm 0 0020 in Arbre cames M thode d entra nement Transmission par cha ne c t gauche Dimensions de came Admission A 25 428 25 528 mm 1 0011 1 0050 in 25 398 mm 0 9999 in B 21 03...

Page 75: ...0 7913 in B largeur de face AD 1 19 2 51 mm 0 0469 0 0989 in ECH 1 49 3 07 mm 0 0587 0 1209 in C largeur de si ge AD 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in ECH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm...

Page 76: ...6 9 mm 1 06 in ECH 28 32 mm 1 11 in 26 9 mm 1 06 in Longueur mont soupape ferm e AD 24 2 mm 0 95 in ECH 24 2 mm 0 95 in Pression la compression install AD 90 4 104 1 N 9 22 10 62 kg 20 33 23 41 lb ECH...

Page 77: ...6 13 000 mm 0 5117 0 5118 in 12 976 mm 0 5109 in Segments Segment de feu Type Cylindrique Dimensions B T 1 0 2 0 mm 0 04 0 08 in Ecartement des becs segment mont 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 0...

Page 78: ...came Limite de d formation de la tige de commande 0 5 mm 0 02 in Embrayage centrifuge automatique Vitesse d engagement de l embrayage 2 160 2 560 tr mn Vitesse de lib ration de l embrayage 3 300 3 80...

Page 79: ...lis m tallique Type de pompe huile Trocho dale Jeu en bout A ou B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Jeu de lubrification entre le logement...

Page 80: ...2 0 14 Raccord de carburateur c t culasse M6 1 0 2 7 0 7 5 1 Raccord de carburateur c t carburateur M6 1 0 2 7 0 7 5 1 Bo tier de filtre air M6 1 0 2 7 0 7 5 1 Tuyau d chappement M6 1 0 2 7 0 7 5 1 Pr...

Page 81: ...va lente Suspension arri re D battement d amortisseur 48 mm 1 89 in Longueur libre de ressort 169 mm 6 65 in Longueur mont 165 mm 6 5 in Constante standard de ressort K 45 6 N mm 4 65 kg mm 260 lb in...

Page 82: ...mm 4 33 in 111 mm 4 37 in Epaisseur de la garniture frein avant 3 mm 0 12 in 2 mm 0 08 in Epaisseur de la garniture frein arri re 4 mm 0 16 in 2 mm 0 08 in Longueur libre de ressort de m choire de fr...

Page 83: ...urche avant M10 1 25 2 33 3 3 24 Boulon de bielle d amortisseur M8 1 25 2 20 2 0 14 T sup rieur et demi palier de guidon inf rieur M10 1 25 2 40 4 0 29 Demi palier de guidon sup rieur M6 1 0 4 13 1 3...

Page 84: ...8 F brun vert R sistance de la bobine d excitation couleur 248 372 20 C 68 F rouge blanc Bloc CDI mod le fabricant 4GL 20 YAMAHA Bobine d allumage Mod le fabricant 2JN 00 YAMAHA Longueur minimum d tin...

Page 85: ...moins que ce ne soit sp cifi autrement les sp cifications de couple s entendent pour des filetages propres et secs Les composants doivent tre temp rature ambiante A crou B vis CARACTERISTIQUES DE COU...

Page 86: ...ek hlter 1 Zyl 4 Takt Ottomotor eine oben liegende Nockenwelle SOHC Zylinderanordnung 1 Zylinder nach vorn geneigt Hubraum 89 cm3 Bohrung Hub 47 0 51 8 mm Verdichtungsverh ltnis 8 5 1 Verdichtungsverh...

Page 87: ...uart Mehrscheiben lbadkupplung automatische Fliehkraftkupplung Kraft bertragung Prim rantrieb Stirnr der Prim r bersetzung 67 18 3 722 Sekund rantrieb Kettenantrieb Sekund r bersetzung 35 14 2 500 Get...

Page 88: ...remse Bet tigung Fu bremshebel rechts Radaufh ngung vorn Teleskopgabel hinten Monocross Schwinge Federelemente vorn Hydraulisch ged mpfte Teleskopgabel mit Spi ralfeder hinten Federbein mit gasdruckun...

Page 89: ...g 0 03 mm Zylinder Bohrungsdurchmesser 47 000 47 005 mm 47 05 mm Max Ovalit t 0 05 mm Nockenwelle Antrieb Steuerkette links Nockenabmessungen Einla A 25 428 25 528 mm 25 398 mm B 21 034 21 134 mm 21 0...

Page 90: ...B Einla 1 19 2 51 mm Ausla 1 49 3 07 mm Ventilsitzbreite C Einla 0 9 1 1 mm 1 6 mm Ausla 0 9 1 1 mm 1 6 mm Ventiltellerst rke D Einla 0 5 0 9 mm Ausla 0 8 1 2 mm Ventilschaftdurchmesser Einla 4 475 4...

Page 91: ...28 32 mm 26 9 mm Ausla 28 32 mm 26 9 mm Einbaul nge Ventil geschlossen Einla 24 2 mm Ausla 24 2 mm Federdruck eingebaut Einla 90 4 104 1 N 9 22 10 62 kg Ausla 90 4 104 1 N 9 22 10 62 kg Rechtwinkligke...

Page 92: ...ser 12 996 13 000 mm 12 976 mm Kolbenringe 1 Kompressionsring Topring Ausf hrung abgerundet Abmessungen B T 1 0 2 0 mm Sto spiel eingebaut 0 10 0 25 mm 0 4 mm Ringnutspiel eingebaut 0 030 0 065 mm 0 1...

Page 93: ...he Fliehkraftkupplung Kupplung greift bei 2 160 2 560 U min Bei bet tigter Bremse stirbt Motor bei 3 300 3 800 U min Schaltung Schaltmechanismus Schaltwalze F hrungsstange Kickstarter Bauart Rastenmec...

Page 94: ...ATEN SPEC Schmiersystem lfilter Drahtgeflecht Einsatz lpumpe Rotorpumpe Radialspiel A oder B 0 15 mm 0 2 mm Axialspiel 0 13 0 18 mm 0 23 mm Rotor Laufspiel 0 06 0 10 mm 0 15 mm Bezeichnung Spezifikati...

Page 95: ...anschlu zylinderseitig M6 1 0 2 7 0 7 Vergaserverbindung vergaserseitig M6 1 0 2 7 0 7 Luftfiltergeh use M6 1 0 2 7 0 7 Kr mmer M6 1 0 2 7 0 7 Kr mmerschutz M6 1 0 7 7 0 7 Schalld mpfer M8 1 25 1 24 2...

Page 96: ...derelement hinten Federweg 48 mm Feder ungespannte L nge 169 mm Einbaul nge 165 mm Standard Federrate K 45 6 N mm 4 65 kg mm Umr stm glichkeiten Keine Gasdruck 2 000 kPa 20 bar Schwinge Max Spiel Axia...

Page 97: ...strommel Innendurchmesser hinten 110 mm 111 mm Bremsbelagst rke vorn 3 mm 2 mm Bremsbelagst rke hinten 4 mm 2 mm Bremsbacken R ckholfeder vorn ungespannte L nge 32 7 mm Bremsbacken R ckholfeder hinten...

Page 98: ...skopgabel Abdeckschraube M20 1 0 2 40 4 0 Unterb gel und Frontkabel M10 1 25 2 33 3 3 D mpferstangenschraube M8 1 25 2 20 2 0 Obere Gabelbr cke und Lenkerhalterung unten M10 1 25 2 40 4 0 Lenkerhalter...

Page 99: ...rregerspule 688 1 032 bei 20 C braun gr n Impulsgeber Widerstand Farbe 248 372 bei 20 C rot wei CDI Z ndbox Typ Hersteller 4GL 20 YAMAHA Z ndspule Typ Hersteller 2JN 00 YAMAHA Min Z ndfunkenstrecke 6...

Page 100: ...t sind Falls nicht anders angegeben gel ten die genannten Anzugsmomente f r saube re und trokkene Schraubverbindungen bei Raumtemperatur A Mutter B Schrau be ALLGEMEINE ANZUGSMOMENTE Nm m kg 10 mm 12...

Page 101: ...SPEC MEMO...

Page 102: ...ug lead 0 Throttle cable A Cable holder B Fuel tank breather hose C Brake cable After fastening the starter cable CDI magneto lead wire harness and thermo switch lead cut off any excess from the plast...

Page 103: ...mit Kabelbindern befestigen Bremszug durch Kabelf hrungen leiten CHEMINEMENT DES CABLES 1 Reniflard de carter 2 Faisceau de fils 3 Fil de magn to CDI 4 C ble de starter 5 Fil de chauffage de carburate...

Page 104: ...coil 9 Cable guide 0 Wire harness A Damper B CDI unit lead C CDI unit D Rectifier regulator lead E Rectifier regulator F Crankcase breather hose G Carburetor breather hose H Spark plug lead I Fuel hos...

Page 105: ...ftungsschlauch H Z ndkabel I Kraftstoffschlauch J Chokezug K Lichtmaschinen Kabel L Thermoschalter 1 Guide de c ble 2 C ble de frein 3 C ble des gaz 4 Reniflard de r servoir de carburant 5 Fil de cou...

Page 106: ...Fasten the CDI unit lead and rectifier regulator lead with the plastic clamp Align the tape on the rectifier regulator lead with the plastic clamp After fastening the engine stop switch lead cut off...

Page 107: ...en vom Plastikschlauchband abschneiden Z ndbox Kabel durch Kabelf hrung leiten Faire passer le reniflard du r servoir de carburant dans le guide de c ble Faire passer le c ble des gaz et le fil de cou...

Page 108: ...ust if necessary Exhaust systems Check for leakage Retighten if necessary Replace gasket if necessary Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine bef...

Page 109: ...ake sure that all nuts bolts and screws are properly tightened Tighten if necessary Sidestand Check operation Lubricate and repair if necessary Spark arrester 1 Clean Front fork Check operation and fo...

Page 110: ...r le joint si n cessaire Huile de moteur Contr ler le niveau d huile et l tanch it Corriger si n cessaire Changer Faire chauffer le moteur avant la vidange Embrayage V rifier le fonctionnement R gler...

Page 111: ...rer que tous les crous boulons et vis sont correctement serr s Resserrer si n cessaire B quille lat rale V rifier le fonctionnement Lubrifier et r parer si n cessaire Pare tincelles 1 Nettoyer Fourche...

Page 112: ...ufdrehzahl und Starterfunktion pr fen Gegebenenfalls einstellen Auspuffanlage Auf Undichtigkeit pr fen Gegebenenfalls nachziehen Gegebenenfalls Dichtung erneuern Motor l lstand kontrollieren und Fahrz...

Page 113: ...f Schwerg ngigkeit pr fen Entsprechend korrigieren Nach jeweils 120 Betriebsstunden mit Lithiumfett schmieren Schraubverbindun gen am Fahrwerk Alle Schrauben und Muttern auf festen Sitz pr fen Gegeben...

Page 114: ...gine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage Throttle grip free play adjustment steps NOTE Before adj...

Page 115: ...LES D ACCELERATION NETTOYAGE DU FILTRE A AIR MOTOR GASZUGSPIEL EINSTELLEN LUFTFILTER REINIGEN MOTEUR REGLAGE DES CABLES D ACCELERATION 1 V rifier Jeu la poign e des gaz a Hors sp cification R gler 2 R...

Page 116: ...n squeezing the element Leaving too much of solvent in the ele ment may result in poor starting 4 Inspect Air filter element Damage Replace 5 Apply Foam air filter oil or engine mixing oil To the elem...

Page 117: ...uf die Boh rung b am Luftfiltereinsatz ausrichten 7 Montieren Luftfilter Geh usedeckel 8 Montieren Lufthutze rechts 1 Installer Car nage de prise d air droit 1 2 Installer Couvercle du bo tier du filt...

Page 118: ...to proper level NOTE When inspecting the oil level do not screw the dipstick into the oil tank Insert the gauge lightly For USA and CDN CAUTION Do not add any chemical additives Engine oil also lubric...

Page 119: ...pfohlene lsorte Bei 10 C oder h her Yamalube 4 10W 30 oder SAE 10W 30 SE SF Motor l Bei 5 C oder h her Yamalube 4 20W 40 oder SAE 20W 40 SE SF Motor CONTR LE DU NIVEAU D HUILE DE MOTEUR 1 Mettre le mo...

Page 120: ...ce again NOTE Wait a few minutes until the oil settles before inspecting the oil level ENGINE OIL REPLACEMENT 1 Start the engine and warm it up for sev eral minutes and wait for five minutes 2 Place t...

Page 121: ...turen geeig net ist Empfohlene Motor l Spezifikation API NORM API SE odr besser vorzugsweise Motorrad l Except les USA et le CDN ATTENTION Ne pas ajouter d additifs chimiques et ne pas uti liser d hui...

Page 122: ...oil change 0 8 L 0 70 Imp qt 0 85 US qt 7 Install Dipstick 8 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPEC TION PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjusti...

Page 123: ...ag eindrehen Leerlaufgemisch Regulierschraube um die angegebene Anzahl von Umdrehungen wieder herausdrehen Leerlaufgemisch Regulierschraube 1 3 4 Umdrehungen heraus 5 Installer Joint Boulon de vidange...

Page 124: ...heck or adjust the valve clearance 1 Remove Air scoop right 1 Air filter case 2 2 Remove Spark plug Tappet cover intake side 1 Tappet cover exhaust side 2 Adjustment steps Adjust the pilot screw Refer...

Page 125: ...hraube 1 nach b dre hen um die Leerlaufdrehzahl zu reduzieren Induktivdrehzahlmesser YU 8036 B 90890 03113 Leerlaufdrehzahl 1 400 1 600 U min REGLAGE DU REGIME DE RALENTI 1 Mettre le moteur en marche...

Page 126: ...C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance Adjustment steps Loosen the locknut 1 Turn the adjuster 3 in or out with the valve adju...

Page 127: ...schriftsmig die obige Schritte wiederholen bis das vorgeschriebene Spiel eingestellt ist T R 7 Nm 0 7 m kg 4 Contr ler Jeu de soupapes Hors sp cifications R gler 5 R gler Jeu de soupapes Jeu de soupap...

Page 128: ...not start the engine when cleaning the exhaust system 1 Remove Bolt tailpipe 1 2 Remove Tailpipe 2 Pull the tailpipe out of the muffler 3 Clean Spark arrester Use a wire brush to remove any carbon dep...

Page 129: ...1 3 m kg T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg 6 Installer Cache de poussoir c t admission 1 Joint torque 2 N B Enduire le joint torique de graisse base de savon au lithium 7 Installer...

Page 130: ...ee play Adjustment steps Loosen the locknuts 1 Turn the adjusters 2 in or out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the...

Page 131: ...geschriebene Spiel erreicht ist Hineindrehen Spiel kleiner Herausdrehen Spiel gr er ACHTUNG Nach Einstellung des Fu bremshebel spiels darf die Bremse nicht schleifen PARTIE CYCLE REGLAGE DU FREIN AVAN...

Page 132: ...this tight chain position Drive chain slack 40 53 mm 1 6 2 1 in 3 Adjust Drive chain slack Drive chain slack adjustment steps Loosen the wheel axle nut 1 Adjust chain slack by turning the adjusters 2...

Page 133: ...LAGEDELATENSIONDELACHAINEDETRANSMISSION ANTRIEBSKETTEN DURCHHANG EINSTELLEN REGLAGE DE LA TENSION DE LA CHAINE DE TRANSMISSION 1 Sur lever la roue arri re en pla ant un sup port ad quat sous le moteur...

Page 134: ...front fork Unsmooth action oil leakage Repair or replace EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair th...

Page 135: ...om Boden abzuheben 2 Demontieren Siehe unter SCHWINGE im KAPITEL 5 3 Demontieren Federsitz 1 HINWEIS Den Federsitz bei zusammengedr ckter Feder demontieren Serrer l crou d axe de roue tout en appuyant...

Page 136: ...ber Refer to SWINGARM section in the CHAPTER 5 EC36Q000 TIRE PRESSURE CHECK 1 Measure Tire pressure Out of specification Adjust NOTE Check the tire while it is cold Loose bead stoppers allow the tire...

Page 137: ...a der Reifen verrutscht ist Bei geneigtem Reifenventilschaft mu die Reifenposition berichtigt werden Standard Reifenluftdruck 100 kPa 1 00 bar 4 Pour durcir la pr contrainte de ressort mon ter le circ...

Page 138: ...After a practice or a race check spokes for looseness T R 2 Nm 0 2 m kg 1 4 ft lb EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2 Inspect Bear...

Page 139: ...en um das Vorderrad vom Boden abzuheben 2 Kontrollieren Lenkkopf Die Gleitrohre am unteren Ende umfas sen und die Teleskopgabel wie gezeigt hin und her bewegen Spiel Einstellen INSPECTION ET SERRAGE D...

Page 140: ...t wrench 5 and turn the steering right and left a few times NOTE Set the torque wrench to the ring nut wrench so that they form a right angle Ring nut wrench YM 33975 90890 01403 T R Ring nut initial...

Page 141: ...belbr cke 6 Lenker 7 und Vorderrad Abdeckung montieren 3 Contr ler Fonctionnement en douceur de la direction Tourner le guidon de but e but e Fonctionnement dur R gler l crou annulaire de direction 4...

Page 142: ...Install the handlebar holder with its groove a facing outward and tighten the bolts so that the gaps b are equal T R Steering stem bolt 40 Nm 4 0 m kg 2 9 ft lb Front fork cap bolt 40 Nm 4 0 m kg 2 9...

Page 143: ...nd T R Lenkkopfmutter 40 Nm 4 0 m kg Lenkerhalterung 40 Nm 4 0 m kg Abdeckschraube 13 Nm 1 3 m kg ATTENTION Installer le demi palier de guidon avec son encoche a tourn e vers l ext rieur et serrer les...

Page 144: ...ke lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake cable end Use Yamaha cable lube or equ...

Page 145: ...Lithiumfett verwenden LUBRIFICATION Afin de garantir le bon fonctionnement de tous les l ments il convient de lubrifier la machine avant la premi re utilisation apr s le rodage ainsi qu apr s chaque c...

Page 146: ...ds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Cl...

Page 147: ...ndfest anziehen a und dann erst vorschriftsm ig festziehen b T R 13 Nm 1 3 m kg PARTIE ELECTRIQUE INSPECTION DE BOUGIE 1 D poser Bougie 2 Examiner Electrode 1 Usure endommagement Remplacer Couleur de...

Page 148: ...ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank 1 Clamp air filter joint 1 Loosen the screw air filter joint 2 Carburetor heater lead 1 3 Air vent hose 1 4 Fuel hose 1 5 Bolt 2 6 Carbu...

Page 149: ...aser 1 7 O Ring 1 8 Distanzst ck 1 9 Vergaserdeckel 1 10 Choke Einrichtung 1 1 CARBURATEUR VERGASER MOTEUR CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre...

Page 150: ...disassembly Extent of removal Order Part name Q ty Remarks CARBURETOR DISASSEMBLY 1 Throttle valve 1 2 Throttle cable 1 3 Spring 1 4 Gasket 1 5 Carburetor top cover 1 6 Jet needle stopper 1 7 Jet nee...

Page 151: ...l 1 8 Choke 1 9 Chokezug 1 0 Schwimmerkammer 1 1 DEMONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DU CA...

Page 152: ...R Extent of removal Order Part name Q ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1 G Throttle stop screw assembly 1 H Pilot air screw assembly 1 I Carb...

Page 153: ...G Drosselklappen Anschlag schraube 1 H Leerlaufgemisch Regulier schraube 1 I Vergaserbeheizung 1 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques A Axe de flotteur 1 B Flotteur 1 C Pointea...

Page 154: ...jet 1 Pilot jet 2 Needle jet 3 Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire Needle valve 1 I...

Page 155: ...gigkeit Schwerg ngigkeit Instand setzen oder erneuern HINWEIS Das Gasschieber 1 in das Vergasergeh use einsetzen und auf Leichtg ngigkeit pr fen CONTROLE Carburateur 1 Contr ler Corps du carburateur E...

Page 156: ...the measurement when the needle valve aligns with the float arm If the carburetor is level the weight of the float will push in the needle valve result ing in an incorrect measurement Measure the dist...

Page 157: ...ls 1 einstellen Schwimmerh he erneut kontrollieren Aiguille 1 Contr ler Aiguille 1 D form e usure Changer Gorge de l agrafe Jeu usure Remplacer Position de clip Position standard de clip Rainure n 2 H...

Page 158: ...rew until it is lightly seated Back out it by the specified number of turns Pilot air screw 1 3 4 turns out 2 Install Throttle valve 1 Starter plunger 2 NOTE Align the slit a of the throttle valve wit...

Page 159: ...toff Benzin und Kraftstoffdampf sind leicht entz ndlich und explosiv und m ssen deshalb von allen Feuerquellen wie Z ndfunken Zigaretten offenen Flam men etc ferngehalten werden Flotteur 1 Contr ler F...

Page 160: ...4 7 ENG CARBURETOR 1 Measure Fuel level a Use a fuel level gauge 1 Out of specification Adjust Fuel level gauge YM 1312 A 90890 01312 Fuel level 2 3 mm 0 08 0 12 in below the float chamber line...

Page 161: ...messer YM 1312 A 90890 01312 Schwimmerstand 2 3 mm unterhalb der Schwim merkammer Pa fl che 1 Mesurer Niveau de carburant a Utiliser une jauge de niveau de carburant 1 Hors sp cification R gler Jauge...

Page 162: ...d rear fender Exhaust pipe Carburetor Refer to CARBURETOR section Air filter case and starter lever 1 Plug cap spark plug 1 1 2 Crankshaft end cover O ring 1 1 3 Timing plug O ring 1 1 4 Camshaft spro...

Page 163: ...Steuerkettenspanner 1 9 Dichtung 1 1 CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE Pr paration...

Page 164: ...4 9 ENG CYLINDER HEAD Extent of removal Order Part name Q ty Remarks 10 Camshaft sprocket 1 Refer to REMOVAL POINTS 11 Timing chain 1 12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2 1...

Page 165: ...cames 1 Se reporter POINTS DE DEPOSE 11 Cha ne de distribution 1 12 Culasse 1 13 Joint 1 14 Goujon 2 1 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 10 Nockenwellenrad 1 Siehe unter AUSBAU 1...

Page 166: ...enter T D C NOTE In order to be sure that the piston is at Top Dead Center the match mark c on the camshaft sprocket must align with the sta tionary pointer d on the cylinder head as shown in the illu...

Page 167: ...Kur belgeh use fallen kann Beim L sen der Schraube 1 die Lichtma schinenrotor Mutter mit einem Schrauben schl ssel festhalten POINTS DE DEPOSE Culasse 1 Aligner Rep re I avec l index fixe Etapes de la...

Page 168: ...ration Tighten the bolts and nuts in two stages T R 22 Nm 2 2 m kg 16 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Camshaft sprocket 1 Installation steps Turn the crankshaft counterclockwise until the...

Page 169: ...re cames d chappement maintenir la cha ne de distribu tion aussi tendue que possible du c t chappe ment CULASSE ZYLINDERKOPF 4 Demontieren Zylinderkopf HINWEIS Die Schrauben und Muttern in der angege...

Page 170: ...rk Align with the crankcase stationary pointer Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Installation steps Remove the tensioner cap bolt...

Page 171: ...aube samt Dichtung mit dem vorge schriebenen Drehmoment festziehen T R Steuerkettenspanner Verschlu schraube 8 Nm 0 8 m kg ATTENTION Veiller ce que le vilebrequin reste immobile pendant la mise en pla...

Page 172: ...Q ty Remarks CAMSHAFT AND ROCKER ARMS Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Rocker arm shaft intake 1 Use special tool 2 Rocker arm shaft exhaust 1 Refer to REMOVAL P...

Page 173: ...llenlager Halter 1 5 Nockenwelle 1 6 Kontermutter Ventileinstell schraube 2 7 Ventileinstellschraube 2 1 2 ARBRE A CAMES ET CULBUTEURS Organisation de la d pose 1 Culbuteur 2 D pose de l arbre cames O...

Page 174: ...ide hammer bolt 90890 01085 Weight 90890 01084 INSPECTION Camshaft 1 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 25 398 mm 0 9999 in b 21 004 mm 0 826...

Page 175: ...d ndisulfid l auf die Nocken Motor l auf die Nockenwellenlager 2 Montieren Nockenwelle 1 POINTS DE DEPOSE Axe de culbuteur 1 D poser Axes de culbuteur N B Se servir d un boulon d extracteur inertie 1...

Page 176: ...4 15 ENG CAMSHAFT AND ROCKER ARMS 3 Apply Molybdenum disulfide oil onto the rocker arm and rocker arm shaft 4 Install Rocker arm 1 Rocker arm shaft 2...

Page 177: ...LLE UND KIPPHEBEL 3 Auftragen Molybd ndisulfid l auf Kipphebel und Kipphebelwelle 4 Montieren Kipphebel 1 Kipphebelwelle 2 3 Appliquer Huile au bisulfure de molybd ne sur le culbuteur et l axe de culb...

Page 178: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Rocker arm and camshaft Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4 Use...

Page 179: ...ederteller 2 3 Ventilfeder 2 4 Ausla ventil 1 5 Einla ventil 1 6 Ventilschaftdichtung 2 1 SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la d pose 1 D pose des soupapes Organisation de la d pose Ordr...

Page 180: ...sor YM 4019 90890 04019 INSPECTION Valve 1 Measure Stem to guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Clea...

Page 181: ...ern Max zul ssiger Schlag 0 02 mm POINTS DE DEPOSE D pose des soupapes 1 D poser Clavettes de soupape 1 N B Fixer un compresseur de ressort de soupape 2 entre la retenue de ressort de soupape et la cu...

Page 182: ...h a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps A...

Page 183: ...n Ressort de soupape 1 Mesurer Longueur libre du ressort de soupape a Hors sp cifications Remplacer 2 Mesurer Inclinaison du ressort a Hors sp cifications Remplacer Longueur libre ressort de soupape A...

Page 184: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Page 185: ...ssen Entspricht die Ventilsitzbreite noch immer nicht dem Sollma den Ventilsitz nochmals nachbe arbeiten und einschleifen 2 Roder Face de soupape Si ge de soupape N B Apr s le surfa age du si ge de so...

Page 186: ...the embossed mark as follows Intake G Exhaust L Install the valve springs with the larger pitch a facing upwards b Smaller pitch New 3 Install Valve cotters NOTE While compressing the valve spring wi...

Page 187: ...as Ventilschaftende k nnen das Ventil besch digen ASSEMBLAGE ET MONTAGE 1 Appliquer Huile au bisulfure de molybd ne sur la queue de soupape et la bague d tan ch it de queue de soupape 2 Monter Bagues...

Page 188: ...ks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Timing chain guide exhaust 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pin clip 2 Use special...

Page 189: ...1 Kompressionsring Topring 1 Siehe unter AUSBAU 9 2 Kompressionsring 1 10 labstreifring Expander 2 1 2 1 CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Organisati...

Page 190: ...use the piston pin puller set 4 Piston pin puller set YU 1304 90890 01304 Piston ring 1 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top...

Page 191: ...ng C parallel zum und im rechten Winkel zur Kurbelwelle messen Danach den Durchschnitt der Messung bestimmen POINTS DE DEPOSE Piston 1 D poser Circlip d axe de piston 1 Axe de piston 2 Piston 3 N B Av...

Page 192: ...re the piston skirt diameter P with a micrometer a 4 mm 0 16 in from the piston bottom edge Piston size P Standard 46 960 46 975 mm 1 8488 1 8494 in If out of specification replace the piston and pist...

Page 193: ...Zylinder erneuern und Kolben sowie Kolbenringe im Satz erneuern Al sage de cylindre C 47 000 47 005 mm 1 8504 1 8506 in Limite de conicit T 0 05 mm 0 002 in Ovalisation R 0 05 mm 0 002 in C maximum D...

Page 194: ...crown so that the ring will be at a right angle to the cylinder bore a 5 mm 0 20 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of t...

Page 195: ...e piston 1 Mesurer Jeu lat ral du segment Utiliser une jauge d paisseur Hors sp cifications Remplacer la fois le piston et ses segments N B Eliminer les d p ts de calamine des gorges de seg ment et de...

Page 196: ...gs so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Measurement steps Measure the piston pin outsi...

Page 197: ...renzwert 13 045 mm Axe de piston 1 Contr ler Axe de piston D coloration bleue gorges Remplacer puis examiner le syst me de graissage 2 Mesurer Diam tre ext rieur d axe de piston Diam tre int rieur d a...

Page 198: ...nts to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate Piston Pisto...

Page 199: ...ger l amor tisseur de cha ne de distribution pendant l ins tallation Faire passer la cha ne de distribution travers la cavit de cha ne de distribution New 2 Montieren 1 Kompressionsring Topring 2 Komp...

Page 200: ...er Part name Q ty Remarks CRANKCASE COVER LEFT AND RIGHT REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Shift pedal 1 2 Drive sprocket...

Page 201: ...5 Pa stift 2 6 Kupplungseinstellschraube 1 7 Kickstarterhebel 1 8 Kurbelgeh usedeckel rechts 1 9 Dichtung 1 10 Pa stift 2 2 1 EMBRAYAGE DEMI CARTERS GAUCHE ET DROIT Organisation de la d pose 1 D pose...

Page 202: ...removal Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL 1 Bolt clutch spring 4 4 2 Pressure plate 1 3 Washer 1 4 Push rod 1 1 5 Friction plate 5 6 Clutch plate 4 7 Push rod 2 1 8 Clutch...

Page 203: ...SBAU 10 Kupplungsnabe 1 11 Unterlegscheibe 1 12 Kupplungskorb 1 3 1 2 EMBRAYAGE Organisation de la d pose 1 D pose des disques de friction et des disques d embrayage 2 D pose du carter d embrayage 3 D...

Page 204: ...me Q ty Remarks 13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool Refer to REMOVAL POINTS 16 Washer 1 17 Spacer 1 18 Primary clutch housing 1 19 Primary clutch boss 1 20 Clutch carrier...

Page 205: ...19 Prim rkupplungsnabe 1 20 Kupplungskorb 1 21 Ausr cklager 1 22 Unterlegscheibe 1 3 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 13 Entretoise 1 14 Entretoise 1 15 Ecrou d embrayage pr...

Page 206: ...Clutch holding tool YM 91042 90890 04086 Primary clutch 1 Remove Primary clutch nut 1 NOTE Loosen the nut while holding the magnet rotor with the sheave holder 2 INSPECTION EC484500 Friction plate 1 M...

Page 207: ...sen Reibscheibenst rke Standard Grenzwert 2 7 2 9 mm 2 6 mm POINTS DE DEPOSE Noix d embrayage 1 D poser Ecrou 1 Rondelle frein 2 Noix d embrayage N B Redresser la rondelle frein et utiliser l outil de...

Page 208: ...sure Push rod 2 bend Out of specification Replace Warp limit 0 2 mm 0 008 in Clutch spring free length Standard Limit 26 2 mm 1 03 in 24 2 mm 0 95 in Bending limit 0 5 mm 0 02 in Primary clutch 1 Meas...

Page 209: ...t 1 0 1 3 mm Grenzwert 0 1 mm Disques d embrayage 1 Mesurer Voile de disque d embrayage Hors sp cification Changer tous les dis ques d embrayage Utiliser une plaque surfacer 1 et une jauge d paisseur...

Page 210: ...ing tool 3 to hold the clutch boss For USA and CDN Except for USA and CDN 2 Bend Lock washer tab Sheave holder YS 1880 A 90890 01701 Clutch holding tool YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft l...

Page 211: ...icht fest sitzt Um 1 8 Drehung ausdrehen Die Kontermutter festziehen T R Kontermutter 8 Nm 0 8 m kg ASSEMBLAGE ET MONTAGE Embrayage primaire 1 Installer Rondelle 1 Ecrou embrayage primaire 2 N B Serre...

Page 212: ...name Q ty Remarks KICK AXLE REMOVAL AND DISASSEMBLY Preparation for removal Crankcase cover right Refer to CLUTCH section 1 Kick axle assembly 1 2 Circlip 2 3 Spring cover 1 4 Torsion spring 1 5 Sprin...

Page 213: ...erungsring 1 9 Sicherungsring 1 10 Unterlegscheibe Spezialscheibe 1 1 11 Kickstarterzahnrad 1 12 Kickstarterwelle 1 2 1 ARBRE DE KICK Organisation de la d pose 1 D pose de l arbre de kick pied 2 D mon...

Page 214: ...HAFT REMOVAL Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section 1 Shift fork guide bar 1 2 Shift arm 3 1 3 Plate washer 1 4 Compression spring 1 5 Shift guide 1 6 Ball h...

Page 215: ...ger 1 11 Sicherungsring 1 12 Schaltarm komplett 1 13 Schaltwelle 1 1 ARBRE DE SELECTION Organisation de la d pose 1 Depose de l arbre de selection Organisation de la d pose Ordre Nom de pi ce Qt Remar...

Page 216: ...4 35 ENG SHIFT SHAFT Extent of removal Order Part name Q ty Remarks 14 Stopper lever 1 15 Torsion spring 1 16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1 1...

Page 217: ...4 Rastenhebel 1 15 Torsionsfeder 1 16 Sicherungsring 1 17 Tellerscheibe 1 18 Torsionsfeder 1 19 Schaltarm 1 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 14 Levier de but e 1 15 Ressort...

Page 218: ...ty Remarks OIL PUMP REMOVAL AND DIS ASSEMBLY Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section Shift shaft Refer to SHIFT SHAFT section 1 Rotary filter 1 2 Oil pump as...

Page 219: ...rad 1 8 Federring 1 9 Sicherungsring 1 10 Beilagscheibe 1 2 1 3 POMPE A HUILE Organisation de la d pose 1 D pose de la pompe huile 2 D pose de la cr pine huile 3 D montage de la pompe huile Organisati...

Page 220: ...4 37 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 11 Oil pump cover 1 12 Dowel pin 2 13 Oil pump drive shaft 1 14 Pin 1 15 Inner rotor 1 16 Outer rotor 1 17 Rotor housing 1 3...

Page 221: ...ift 2 13 lpumpen Antriebswelle 1 14 Stift 1 15 Innenrotor 1 16 Au enrotor 1 17 Rotorgeh use 1 3 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11 Couvercle de pompe huile 1 12 Goujon 2 13 A...

Page 222: ...ce the oil pump assembly Tip clearance a 0 15 mm 0 0059 in Limit 0 2 mm 0 0079 in Side clearance b 0 13 0 18 mm 0 0051 0 0071 in Limit 0 23 mm 0 0091 in Rotor housing and rotor clear ance c 0 06 0 10...

Page 223: ...auf die Bohrung b in der Kurbelwelle ausrichten CONTROLE Pompe a huile 1 Mesurer Jeu en bout a entre rotors int rieur 1 et ext rieur 2 Jeu lat ral b entre le rotor ext rieur 2 et le logement de rotor...

Page 224: ...al Extent of removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover left Refer to CLUTCH section 1 CDI magneto coupler 1 2 Pickup coil st...

Page 225: ...klung Statorwicklung 1 3 Rotor Mutter 1 Spezialwerkzeug verwenden Siehe unter AUSBAU 4 Rotor 1 5 Scheibenfeder 1 1 2 MAGNETO CDI Organisation de la d pose 1 D pose du bloc bobine d excitation stator 2...

Page 226: ...1701 2 Remove Rotor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel puller...

Page 227: ...Schwungradabziehers anzupassen ACHTUNG Kurbelwellenzapfen zum Schutz mit dem Steckschl ssel abdecken Polrad Abzieher YU 33270 B 90890 01362 POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Rondelle...

Page 228: ...t pipe Air filter case Carburetor Refer to CARBURETOR section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine guard and drive sprocket Engine assembly From the cha...

Page 229: ...p lungskorb Siehe unter KUPPLUNG Kickstarter Siehe unter KICKSTARTERWELLE CARTER ET VILEBREQUIN Organisation de la d pose Ordre Nom de pi ce Qt Remarques SEPARATION DES DEMI CAR TERS ET DEPOSE DU VILE...

Page 230: ...aft removal Extent of removal Order Part name Q ty Remarks Shift shaft Refer to SHIFT SHAFT section Oil pump and oil strainer Refer to OIL PUMP section Rotor Refer to CDI MAGNETO section 1 Timing chai...

Page 231: ...ion admission 1 2 Cha ne de distribution 1 3 Carter droit 1 4 Goujon 2 5 Vilebrequin 1 6 Carter gauche 1 1 2 3 CARTER ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Demontage Arbeiten 1 Steuerkette demo...

Page 232: ...limit 0 03 mm 0 0012 in Side clearance 0 10 0 40 mm 0 0039 0 0157 in Radial clearance 0 010 0 025 mm 0 0004 0 0010 in 0 05 mm 0 002 in Crack width 42 95 43 00 mm 1 691 1 693 in ASSEMBLY AND INSTALLAT...

Page 233: ...htmittel in den lkanal a gelangt Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 CONTROLE Vilebrequin 1 Mesurer Limite de faux rond a Jeu lat ral de t te de bielle b Jeu radial de t...

Page 234: ...le disassembly Extent of removal Order Part name Q ty Remarks SHIFT FORK SHIFT CAM TRANSMISSION REMOVAL Preparation for removal Engine assembly Separate the crankcase Refer to CRANKCASE AND CRANK SHAF...

Page 235: ...le zerlegen 1 6 Ausgangswelle zerlegen 1 7 Ritzel 2 Gang 1 8 Sicherungsring 1 9 Unterlegscheibe 1 1 2 FOURCHETTES DE SELECTION TAMBOUR ET BOITE DE VITESSES Organisation de la d pose 1 D pose des fourc...

Page 236: ...ANSMISSION Extent of removal Order Part name Q ty Remarks 10 3th pinion gear 1 11 Main axle 1 12 Circlip 1 13 Washer 1 14 Collar 1 15 1st wheel gear 1 16 3rd wheel gear 1 17 Circlip 1 18 Washer 1 19 2...

Page 237: ...nterlegscheibe 1 14 Distanzh lse 1 15 Zahnrad 1 Gang 1 16 Zahnrad 3 Gang 1 17 Sicherungsring 1 18 Unterlegscheibe 1 19 Zahnrad 2 Gang 1 20 Ausgangswelle 1 2 3 Organisation de la d pose Ordre Nom de pi...

Page 238: ...ully Note the posi tion of each part Pay particular attention to the location and direction of shift forks ASSEMBLY AND INSTALLATION Transmission shift cam shift fork 1 Install Main axle assembly 1 Dr...

Page 239: ...gschaltung Funktion des Getriebes Ungleichm iger Betrieb Reparie ren POINTS DE DEPOSE Fourchettes de s lection tambour et bo te vitesses 1 D poser Fourchettes Tambour Arbre secondaire complet Arbre pr...

Page 240: ...t name Q ty Remarks FRONT WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the e...

Page 241: ...RIERE VORDER UND HINTERRAD PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT ET FREIN AVANT Organisation de la d pose 1 D pose de la roue avant 2 D pose du roulement de roue 3 D pose et d montage du...

Page 242: ...5 2 CHAS Extent of removal Order Part name Q ty Remarks 10 Brake shoe 2 11 Brake camshaft lever 1 12 Brake camshaft 1 3 FRONT WHEEL AND REAR WHEEL...

Page 243: ...Anz Bemerkungen 10 Bremsbacken 2 11 Bremswellenhebel 1 12 Bremswelle 1 3 ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD Organisation de la d pose Ordre Nom de pi ce Qt Remarques 10 M choire de frein...

Page 244: ...name Q ty Remarks REAR WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the eng...

Page 245: ...e rechts 1 10 Bremsankerplatte 1 2 3 1 ROUE ET FREIN ARRIERE Organisation de la d pose 1 D pose de la roue arri re 2 D pose du roulement de roue 3 D pose et d montage du flasque et des m choires de fr...

Page 246: ...HEEL AND REAR WHEEL Extent of removal Order Part name Q ty Remarks 11 Collar left 1 12 Wheel drive hub assembly 1 13 Bearing 2 Refer to REMOVAL POINTS 14 Brake shoe 2 15 Brake camshaft lever 1 16 Brak...

Page 247: ...hmernabe komplett 1 13 Lager 2 Siehe unter AUSBAU 14 Bremsbacke 2 15 Bremswellenhebel 1 16 Bremswelle 1 3 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11 Collerette gauche 1 12 Moyeu d...

Page 248: ...eel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in Brake lining 1 Inspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper NOTE After polishing wipe the polished part...

Page 249: ...rommelbremsbelag St rke a Standard vorne 3 0 mm hinten 4 0 mm Grenzwert 2 0 mm POINTS DE DEPOSE Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement en utilisant un arrache r...

Page 250: ...e securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Hand...

Page 251: ...lbr cke 1 Nur lockern 5 Teleskopgabel 1 1 FOURCHE AVANT Organisation de la d pose 1 D pose de la fourche avant Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration pour la d pose DEPO...

Page 252: ...val Extent of removal Order Part name Q ty Remarks FRONT FORK DISASSEMBLY Preparation for disas sembly Drain the fork oil 1 Adjuster 1 2 Fork spring 1 3 Dust cover 1 4 Stopper ring 1 5 Bolt damper rod...

Page 253: ...unter AUSBAU 6 Gleitrohr 1 7 D mpferrohr 1 8 Dichtring 1 9 Standrohr 1 1 2 DEMONTAGE DE LA FOURCHE AVANT Organisation de la d pose 1 D pose de la bague d tanch it 2 D pose de la tige d amortisseur Or...

Page 254: ...5000 ASSEMBLY AND INSTALLATION Front fork assembly 1 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver weight 2 and fork seal driver attachment 3 2 Fill Fork oil 3 A...

Page 255: ...FOURCHE AVANT TELESKOPGABEL POINTS DE DEPOSE Tube plongeur 1 D poser Boulon tige d amortisseur N B Desserrer le boulon de la tige d amortisseur tout en maintenant la tige d amortisseur l aide de l out...

Page 256: ...arks HANDLEBAR REMOVAL 1 ENGINE STOP switch 1 2 Brake lever cable 1 Disconnect at the lever side 3 Brake lever 1 4 Grip cap lower 1 5 Grip cap upper 1 6 Throttle cable 1 Disconnect at the throttle sid...

Page 257: ...rgriff links 1 10 Lenkerhalterung oben 2 11 Lenker 1 12 Lenkerhalterung unten 2 1 GUIDON Organisation de la d pose 1 D pose du guidon Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE D...

Page 258: ...s STEERING REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front fork Refe...

Page 259: ...1 DIRECTION Organisation de la d pose 1 D pose du t de fourche inf rieur 2 D pose du roulement ETAPES DE SERRAGE Serrer l crou cr nel un couple d environ 38 Nm 3 8 m kg 27 ft lb Le desserrer complete...

Page 260: ...chine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section R...

Page 261: ...tenschutztr ger 1 1 2 BRAS OSCILLANT Organisation de la d pose 1 D pose du bras oscillant 2 D pose de l amortisseur arri re Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DU BRAS OSC...

Page 262: ...5 12 CHAS SWINGARM Extent of removal Order Part name Q ty Remarks 9 Cotter pin 1 10 Nut tension bar 1 11 Bolt tension bar 1 12 Tension bar 1 1...

Page 263: ...nt 1 10 Mutter Bremsankerstrebe 1 11 Schraube Bremsankerstrebe 1 12 Bremsankerstrebe 1 1 BRAS OSCILLANT SCHWINGE Organisation de la d pose Ordre Nom de pi ce Qt Remarques 9 Goupille fendue 1 10 Ecrou...

Page 264: ...5 ENGINE STOP switch 6 Thermo switch 7 Carburetor heater 8 Rectifier regulator COLOR CODE B Black Br Brown G Green O Orange R Red W White EC612000 WIRING DIAGRAM G W B R W L W R Br G R W W B Y R O B...

Page 265: ...B schwarz Br braun G gr n O orange R rot W wei B R schwarz rot B W schwarz wei G W gr n wei W L wei blau W R wei rot SCHALTPLAN PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE COMPOSANTS...

Page 266: ...Fuel tank Use the following special tools in this inspection Spark gap test Clean or replace spark plug Check entire ignition system for connection Repair or replace Check ENGINE STOP switch Replace C...

Page 267: ...dans ce d pistage des pannes Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions du sys t me entier d allumage R parer ou remplacer Contr ler le coupe circuit du moteu...

Page 268: ...ten Z ndenlage kon trollieren Erneuern oder instand setzen Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuern Sekund r spule Erneuern CDI Schwungradmagnet z nder ko...

Page 269: ...ELEC MEMO...

Page 270: ...rt engine and increase spark gap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust...

Page 271: ...chon de bougie de la bougie 2 Connecter le testeur dynamique d tincelle 1 testeur d allumage 2 comme indiqu Capuchon de bougie 3 Bougie 4 Pour les USA et le CDN Except pour les USA et le CDN 3 Actionn...

Page 272: ...y coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis tance remove the spark plug cap CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specificatio...

Page 273: ...1 V rifier R sistance de bobine d excitation Hors sp cification Changer Fil de multim tre Fil de bougie 1 Fil de multim tre Fil orange 2 R sistance de bobine secondaire Position de s lec teur de mult...

Page 274: ...EC IGNITION SYSTEM 2 Inspect Source coil resistance Out of specification Replace Tester lead Brown lead 1 Tester lead Green lead 2 Source coil resistance Tester selector position 688 1 032 at 20 C 68...

Page 275: ...raun 1 Me kabel Kabel gr n 2 Erregerspule Widerstand Me ger t Einstellung 688 1 032 bei 20 C 100 2 V rifier R sistance de bobine de source Hors sp cification Changer Fil de multim tre Fil brun 1 Fil d...

Page 276: ...ve the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Check entire carburetor heating system for connec tion Repair or replace Check thermo swi...

Page 277: ...es pannes 1 Selle 2 R servoir de carburant Utiliser les outils sp ciaux suivants dans ce d pistage des pannes Contr ler les connexions de l int gralit du syst me de r chauffement du carburateur R pare...

Page 278: ...es Spezialwerkzeug verwenden Kabelanschl sse des gesamten Vergaserbehei zungssystems kontrollieren Erneuern oder instand setzen Thermoschalter kontrollieren Erneuern Vergaserbeheizung kontrollieren Er...

Page 279: ...ELEC MEMO...

Page 280: ...ION 1 Inspect Thermo switch operation Faulty operation Replace Inspection steps Remove the thermo switch Connect the pocket tester to the thermo switch coupler as shown Tester lead Black 1 Tester lead...

Page 281: ...sen Thermoschalter auf Durchgang laut Tabelle kontrollieren SYSTEME DE RECHAUFFEMENT DU CARBURATEUR VERGASERBEHEIZUNGSSYSTEM CONTROLE DES CONNEXIONS DE COUPLEURS ET FILS 1 Contr ler Connexion de coupl...

Page 282: ...steps 1 2 Heating phase Test steps 3 4 Cooling phase WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it Che...

Page 283: ...1 SYSTEME DE RECHAUFFEMENT DU CARBURATEUR VERGASERBEHEIZUNGSSYSTEM Le circuit du thermocontact est ouvert Le circuit du thermocontact est ferm Etapes du test Temp rature de l eau Conti nuit 1 Moins d...

Page 284: ...dance with the emission warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of mainte nance work MAINTE NANCE INTERVAL DATE O...

Page 285: ...a garantie du syst me antipollution Le seul but du tableau ci dessous est de rappeler l utilisateur que l entretien doit tre effectu Il ne constitue pas une preuve que l entretien a t effectu PROGRAMM...

Page 286: ...u doku mentieren Die untenstehende Tabelle dient nur als Erinnerung daran da die Wartungsarbeiten durchgef hrt werden m ssen Sie ist kein anerkannter Beleg f r die Durchf hrung der Wartungsar beiten W...

Page 287: ......

Page 288: ...PRINTED IN JAPAN 2002 05 0 5 1 CR E F G PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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