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Yamaha TTR125LM, Owner'S Service Manual


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CHAS

FRONT BRAKE

ASSEMBLY AND INSTALLATION

WARNING

●

All internal parts should be cleaned in
new brake fluid only.

●

Internal parts should be lubricated with
brake fluid when installed.

●

Replace the brake caliper piston seals
and brake caliper dust seals whenever a
brake caliper is disassembled.

Brake caliper piston

1. Clean:

●

Brake caliper

●

Brake caliper piston seal

●

Brake caliper dust seal

●

Brake caliper piston
Clean them with brake fluid.

2. Install:

●

Brake caliper piston seal 

1

 

●

Brake caliper dust seal 

2

 

WARNING

Always use new brake caliper piston seals
and brake caliper dust seals.

NOTE:
Fit the brake caliper piston seals and brake
caliper dust seals onto the slot on brake cali-
per correctly.

New

New

3. Install:

●

Brake caliper piston 

1

 

NOTE:
Apply the brake fluid on the brake caliper pis-
ton wall.

CAUTION:

●

Install the brake caliper piston with its
shallow depressed side 

a

 facing the

brake caliper.

●

Never force to insert.

Brake caliper

1. Install:

●

Sleeve boot 

1

.

On brake caliper bracket 

2

.

Summary of Contents for TTR125LM

Page 1: ...5HP 28199 81 TT R125LW M OWNER S SERVICE MANUAL MANUEL D ATELIER DU ET PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH...

Page 2: ...NER S SERVICE MANUAL 2000 by Yamaha Motor Co Ltd 1st Edition January 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly proh...

Page 3: ...h auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R125LW M MANUEL D ATELIER ET DU PROPRI TAIRE 2000 Yamaha Motor Co Ltd Premi re dition Janv...

Page 4: ...contact your Yamaha dealer 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 MANU...

Page 5: ...rden siehe Seite 3 3 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 vorgesehe...

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: ...Helm und spezielle Motorradbekleidung Hand schuhe Stiefel Hosen und Jacken tragen 4 Lors du transport de l engin dans un autre v hicule veiller ce qu il soit bien droit et ce que le robinet de carbur...

Page 10: ...one seater motorbike Do not 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 illustrated...

Page 11: ...dschuhe 5 Motorradstiefel 6 Motocross Hose 7 Lang rmeliges Trainingshemd 8 Brustschutz INFORMATION DE SECURITE 1 Ne pas rouler sur la route 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il s ag...

Page 12: ...ne 7 Before riding the machine ask your par ents to check the machine very carefully 8 Do not touch the areas shown or you will get burnt in the hand 9 Do not touch rotating or moving parts 10 Before...

Page 13: ...er sich bewegen 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...

Page 14: ...any questions regarding the operation or maintenance of your machine please consult your Yamaha dealer NOTE This manual should be considered a perma nent part of this machine and should remain with it...

Page 15: ...Aufgrund der konti nuierlichen Bem hungen von Yamaha um technischen Fortschritt und Qualit tsstei gerung k nnen einige Angaben jedoch f r Ihr Modell nicht mehr zutreffen Richten Sie Fragen zu dieser A...

Page 16: ...taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer FINDING THE REQUIRED PAGE 1 This manual consists of six chapters General Information Spe...

Page 17: ...particulier Arquer le manuel son bord comme illustr pour trouver le symbole du chapitre recher ch puis aller la page du th me recherch AVERTISSEMENT ATTENTION BENUTZERHINWEISE KENNZEICHNUNG WICHTIGER...

Page 18: ...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 19: ...meiden 6 F r Arbeiten f r die weitere Informatio nen ben tigt werden sind schrittweise Erg nzungen 6 zus tzlich zu dem Explo sionsdiagramm und der Arbeitsanwei sungstabelle aufgef hrt FORMAT DU MANUE...

Page 20: ...ightening B Specified value Service limit C Engine speed D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubr...

Page 21: ...tel LOCTITE J Erneuern SYMBOLES GRAPHIQUES voir les illustrations 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 22: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENT ENGINE CHASSIS ELECTRICAL...

Page 23: ...DATEN SPEC 2 REGELM SSIGE WARTUNGS UND EINSTELLARBEITEN 3 MOTOR ENG 4 RAHMEN CHAS 5 ELEKTRIK ELEC 6 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS G N RAUX CARACT RISTI QUES CONTR LES ET R GLAGES P RIODIQUES...

Page 24: ...ING AND BREAK IN 1 13 TORQUE CHECK POINTS 1 15 CLEANING AND STORAGE 1 16 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITIO...

Page 25: ...TUNG VOR INBETRIEBNAHME 3 3 MOTOR 3 4 FAHRWERK 3 15 ELEKTRISCHE ANLAGE 3 28 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS G N RAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MACHINE 1 2 INFORMATIONS IMPORTA...

Page 26: ...L PUMP 4 49 KICK AXLE AND SHIFT SHAFT 4 53 CDI MAGNETO 4 58 ENGINE REMOVAL 4 61 CRANKCASE CRANKSHAFT AND BALANCER 4 65 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 73 CHAPTER 5 CHASSIS FRONT WHEEL 5 1 FRON...

Page 27: ...ELEKTRIK ELEKTRISCHE ANLAGE UND SCHALTPLAN 6 1 Z NDANLAGE 6 2 CHAPITRE 4 MOTEUR SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX 4 1 POT D CHAPPEMENT 4 2 CARBURATEUR 4 3 CULASSE 4 12 ARBRE CAMES ET CUL...

Page 28: ...nt brake lever 5 Throttle grip 6 Fuel tank cap 7 Air filter 8 Kickstarter crank 9 Fuel tank 0 Dipstick A Rear brake pedal B Fuel cock C Drive chain D Shift pedal E Front fork NOTE The machine you have...

Page 29: ...n m glich nderungen an Design und technischen Da ten jederzeit vorbehalten RENSEIGNEMENTS G N RAUX DESCRIPTION 1 Levier d embrayage 2 Coupe circuit du moteur 3 Bouton de starter 4 Levier de frein avan...

Page 30: ...hine 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 the st...

Page 31: ...acht Die Codenummer und das Info K rzel werden zur Ersatzteil Bestellung ben tigt IDENTIFICATION DE LA MACHINE Il y a deux bonnes raisons de conna tre le num ro de s rie de son v hicule 1 Le num ro fa...

Page 32: ...ey include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts...

Page 33: ...en Fremdfabrika te erf llen h ufig nicht die gestellten Qualit tsanforderungen INFORMATIONS IMPORTANTES PR PARATION LA D POSE ET AU D MONTAGE 1 liminer soigneusement crasse boue pous si re et corps tr...

Page 34: ...5001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or num bers facing outward In other words the stamped letters must be on the side exposed to view...

Page 35: ...UES D TANCH IT 1 Monter les roulements 1 et les bagues d tanch it 2 avec leurs marques ou num ros de fabricant dirig s vers l ext rieur Autrement dit les lettres poin onn es doi vent tre sur le c t vi...

Page 36: ...check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for cont...

Page 37: ...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 V RIFICATION DES CONNEXIONS Traite...

Page 38: ...s are used to split the crankcase as well as remove the crankshaft from either case YU 01135 A 90890 01135 YU 03097 90890 01252 YU 01256 Dial gauge stand set Stand These tools are used to check each p...

Page 39: ...33975 90890 01403 YS 01880 A 90890 01701 Sheave holder This tool is used for when loosening or tightening the flywheel magneto securing nut YS 01880 A 90890 01701 YU 03112 C 90890 03112 Pocket tester...

Page 40: ...04097 YM 04098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487...

Page 41: ...mi carters Ces outils permettent de s parer le carter moteur ainsi que de retirer le vilebrequin d un demi carter YU 01135 A 90890 01135 YU 03097 90890 01252 YU 01256 Comparateur cadran et base Base C...

Page 42: ...s comme sp cifi YU 33975 90890 01403 YS 01880 A 90890 01701 Cl sangle Cet outil permet de desserrer et de resserrer l crou de fixation du volant magn tique YS 01880 A 90890 01701 YU 03112 C 90890 031...

Page 43: ...s YM 04097 YM 04098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Testeur d tincelle dynamique Testeur d allumage Cet instrument sert contr ler les composants du syst me d allumage...

Page 44: ...085 YU 01135 A 90890 01135 Kurbelgeh use Trennwerkzeug Zum Trennen der Kurbelgeh useh lften und Ausbau der Kurbelwelle YU 01135 A 90890 01135 YU 03097 90890 01252 YU 01256 Me uhr Verl ngerung St nder...

Page 45: ...sel Zum Festziehen der Lenkkopf Ringmutter YU 33975 90890 01403 YS 01880 A 90890 01701 Kupplungskorb Halter Zum Halten des Kupplungskorbes YS 01880 A 90890 01701 YU 03112 C 90890 03112 Taschen Multime...

Page 46: ...ufreiben der neuen Ventilf hrungen YM 04097 YM 04098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Z ndfunkenstreckentester Zur berpr fung der Z ndanlage YM 34487 90890 06754 ACC Q...

Page 47: ...GEN INFO MEMO...

Page 48: ...wly for smooth starts EC153000 SHIFT PEDAL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engi...

Page 49: ...l schwungvoll durchtreten GASDREHGRIFF Der Gasdrehgriff 1 befindet sich auf der rech ten Seite des Lenkers Zum Erh hen der Mo tordrehzahl Beschleunigung den Gasdreh griff in Gegenfahrtrichtung drehen...

Page 50: ...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 lever in this...

Page 51: ...startanreiche 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 LEVI...

Page 52: ...oun terclockwise WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it WARNING Nev...

Page 53: ...m Gewicht belasten Vor dem Losfahren sicherstellen da der Seitenst nder hochgeklappt ist BOUCHON DE R SERVOIR DE CARBURANT Retirer le bouchon de r servoir de carburant 1 en le tournant dans le sens in...

Page 54: ...k 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 Recommended fuel For USA Unleaded fuel For CDN and EUROPE...

Page 55: ...Essence sans plomb uniquement NZ Essence normale Capacit du r servoir de carburant Total 6 6 L 1 45 lmp gal 1 74 US gal R serve 1 9 L 0 42 lmp gal 0 5 US gal 1 12 KRAFTSTOFF Normalbenzin verwenden Imm...

Page 56: ...3 With the throttle completely closed start the engine by kicking the kickstarter crank forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes ab...

Page 57: ...otor darf w hrend der Einfahrzeit nicht zu stark beansprucht werden Darum sollten die nachfolgenden Anweisungen sorgf ltig gelesen und genau beachtet wer den 1 13 D MARRAGE ET RODAGE ATTENTION Avant d...

Page 58: ...okes CAUTION After the break in or before each ride you must check the entire machine for loose fit tings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as required BREAKING IN AF...

Page 59: ...t ein Problem auf ist der Motor sofort abzustellen und die Ursache heraus zufinden D MARRAGE ET RODAGE STARTEN UND EINFAHREN RODAGE Un rodage est important car les organes mobiles et immobiles du mote...

Page 60: ...stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to shock absorber Link to swingarm Shock absorber to frame...

Page 61: ...irection au cadre Colonne de direction au t sup rieur T sup rieur au guidon Fourche avant au t sup rieur Fourche avant au t inf rieur Toutes les liaisons Liaison au cadre Liaison l amortisseur Liaison...

Page 62: ...r cke Obere Gabelbr cke und Lenker Teleskopgabel und obere Gabelbr cke Teleskopgabel und untere Gabelbr cke bertragungs und Umlenkhebel bertragungshebel und Rahmen Umlenkhebel und Sto d mpfer Umlenkhe...

Page 63: ...GEN INFO MEMO...

Page 64: ...n of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated ca...

Page 65: ...NETTOYAGE ET REMISAGE NETTOYAGE Il est conseill de nettoyer le v hicule fond aussi souvent que possible non seulement pour des raisons esth tiques mais aussi parce que ces nettoyages con tribuent am...

Page 66: ...witch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thor oughly with solvent and lubricate it Rein stall the chain or store it in a...

Page 67: ...UND STILLEGUNG REMISAGE Si la motocyclette doit tre remis e pendant 60 jours ou plus certaines pr cautions devront tre observ es pour la maintenir en parfait tat Apr s un nettoyage complet de la motoc...

Page 68: ...n Wheelbase 1 270 mm 50 0 in Minimum ground clearance 295 mm 11 6 in Basic weight With oil and full fuel tank 84 kg 185 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylin...

Page 69: ...22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 68 19 3 578 Secondary reduction system Chain...

Page 70: ...ght foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Co...

Page 71: ...2 1260 2 1267 in Out of round limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295 mm 0 8344 0 8...

Page 72: ...width IN 1 1 3 0 mm 0 0433 0 1181 in EX 1 7 2 8 mm 0 0669 0 1102 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...

Page 73: ...e length IN 32 55 mm 1 28 in 31 2 mm 1 23 in EX 32 55 mm 1 28 in 31 2 mm 1 23 in Set length valve closed IN 25 6 mm 1 01 in EX 25 6 mm 1 01 in Compressed pressure installed IN 137 5 158 1 N 14 0 16 1...

Page 74: ...tside diameter 14 991 15 000 mm 0 5902 0 5906 in 14 971 mm 0 5894 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 1 mm 0 04 0 08 in End gap installed 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016...

Page 75: ...am push Push rod bending limit 0 5 mm 0 020 in Shifter Shifter type Cam drum and guide bar Kick starter Type Kick and mesh type Kick clip friction force 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Carburetor I...

Page 76: ...lter type Wire mesh type Oil pump type Trochoid type Tip clearance 0 15 mm 0 0059 in 0 2 mm 0 0079 in Side clearance 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Housing and rotor clearance 0 06 0...

Page 77: ...0 2 1 4 Coasting enricher cover M4 0 7 2 2 0 2 1 4 Air filter case M6 1 0 3 7 0 7 5 1 Muffler M6 1 0 2 10 1 0 7 2 Muffler M10 1 25 1 60 6 0 43 Muffler guard M6 1 0 7 10 1 0 7 2 Spark arrester M6 1 0 3...

Page 78: ...SPEC 2 11 MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence...

Page 79: ...h 178 mm 7 01 in Fitting length 165 mm 6 50 in Spring rate STD K 58 9 N mm 6 0 kg mm 336 lb in Optional spring No Enclosed gas pressure 1 500 kPa 15 kg cm2 213 psi Wheel Front wheel type Spoke wheel R...

Page 80: ...2 0 mm 0 08 in Shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever free play lever end 2 5 mm 0 08 0 20 in Brake pedal position vertical height below footrest top 1 mm 0 0...

Page 81: ...hrottle cable cap M4 0 7 2 2 0 2 1 4 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Front brake master cylinder cap M4 0 7 2 2 0 2 1 4 Brake lever mounting bolt M6 1 0 1 7 0 7 5 1 Brake lever mounting...

Page 82: ...25 1 53 5 3 38 Relay arm and connecting arm M10 1 25 1 35 3 5 25 Connecting arm and frame M10 1 25 1 35 3 5 25 Rear shock absorber assembly and frame M12 1 25 1 53 5 3 38 Rear shock absorber assembly...

Page 83: ...I unit model manufacturer 5HP 00 YAMAHA Ignition coil Model manufacturer 4KJ 10 YAMAHA Minimum spark gap 6 mm 0 24 in Primary coil resistance 0 18 0 28 at 20 C 68 F Secondary coil resistance 6 3 9 5 k...

Page 84: ...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 85: ...in Garde au sol minimale 295 mm 11 6 in Poids net Avec huile et r servoir de carburant rempli 84 kg 185 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition...

Page 86: ...NGK DENSO cartement 0 6 0 7 mm 0 02 0 03 in Type d embrayage Humide multidisque Bo te de vitesses Syst me de r duction primaire Pignon Taux de r duction primaire 68 19 3 578 Syst me de r duction secon...

Page 87: ...t Fourche t lescopique Suspension arri re Bras oscillant suspension monocross liaison Amortisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pn...

Page 88: ...valisation 0 05 mm 0 0020 in Arbre cames M thode d entra nement Transmission par cha ne c t gau che Dimensions de came Admission A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295...

Page 89: ...2 0 8701 in B largeur de face AD 1 1 3 0 mm 0 0433 0 1181 in CH 1 7 2 8 mm 0 0669 0 1102 in C largeur de si ge AD 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in CH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0...

Page 90: ...31 2 mm 1 23 in CH 32 55 mm 1 28 in 31 2 mm 1 23 in Longueur mont soupape ferm e AD 25 6 mm 1 01 in CH 25 6 mm 1 01 in Pression la compression install AD 137 5 158 1 N 14 0 16 1 kg 30 86 35 49 lb CH...

Page 91: ...15 000 mm 0 5902 0 5906 in 14 971 mm 0 5894 in Segments Segment de feu Type Cylindrique Dimensions B T 1 0 2 1 mm 0 04 0 08 in cartement des becs segment mont 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016...

Page 92: ...n S lecteur Type de s lecteur Tambour de s lection et guide Kick Type Kick et mise en prise Force de friction du clip de kick 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Carburateur Marque d identification 5HP...

Page 93: ...illis m tallique Type de pompe huile Trocho dale Jeu en bout 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Jeu de lubrification entre le logement et le...

Page 94: ...eur d inertie M4 0 7 2 2 0 2 1 4 Bo tier de filtre air M6 1 0 3 7 0 7 5 1 Pot d chappement M6 1 0 2 10 1 0 7 2 Pot d chappement M10 1 25 1 60 6 0 43 Prot ge pot d chappement M6 1 0 7 10 1 0 7 2 Pare t...

Page 95: ...SPEC 2 11 CARACT RISTIQUES D ENTRETIEN Ordre de serrage de la culasse...

Page 96: ...Diam tre ext rieur du tube plongeur 30 mm 1 18 in Sommet de fourche avant Z ro mm z ro in Suspension arri re D battement d amortisseur 65 mm 2 56 in Longueur libre de ressort 178 mm 7 01 in Longueur...

Page 97: ...e de frein tambour Double came simple came Diam tre interne du tambour 110 mm 4 33 in 111 mm 4 37 in paisseur de garniture 4 0 mm 0 16 in 2 0 mm 0 08 in Longueur libre maximale de ressort de m choire...

Page 98: ...ion M4 0 7 2 2 0 2 1 4 Ma tre cylindre de frein avant M6 1 0 2 9 0 9 6 5 Couvercle de ma tre cylindre de frein avant M4 0 7 2 2 0 2 1 4 Boulon de montage du levier de frein M6 1 0 1 7 0 7 5 1 crou de...

Page 99: ...25 Bras de raccordement et cadre M10 1 25 1 35 3 5 25 Amortisseur arri re et cadre M12 1 25 1 53 5 3 38 Amortisseur arri re et basculeur M10 1 25 1 35 3 5 25 Amortisseur arri re et contre crou pr cont...

Page 100: ...le fabricant 5HP 00 YAMAHA Bobine d allumage Mod le fabricant 4KJ 10 YAMAHA Longueur minimum d tincelle 6 mm 0 24 in R sistance de l enroulement primaire 0 18 0 28 20 C 68 F R sistance de l enroulemen...

Page 101: ...ins 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 CARACT RISTIQUES DE COUPLE...

Page 102: ...h he 805mm Radstand 1 270mm Bodenfreiheit 295mm Gewicht fahrfertig Mit l und vollgetankt 84 kg Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hubra...

Page 103: ...pplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 578 Sekund rantrieb Kettenantrieb Sekund r bersetzung 54 13 4 154 Getriebe Klauengeschaltetes 5 Gang Getri...

Page 104: ...Hinterradbremse Bet tigung Fu bremshebel rechts Radaufh ngung Vorderradaufh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydr...

Page 105: ...Max Verzug 0 03 mm Zylinder Bohrung 54 000 54 019 mm Max Ovalit t 0 05 mm Nockenwelle Antrieb Kettenantrieb links Nockenwellen Abmessungen Einla A 25 881 25 981 mm 25 851 mm B 21 195 21 295 mm 21 165...

Page 106: ...sser EIN 25 9 26 1 mm AUS 21 9 22 1 mm B Ventilkegel Breite EIN 1 1 3 0 mm AUS 1 7 2 8 mm C Ventilsitz Breite EIN 0 9 1 1 mm 1 6 mm AUS 0 9 1 1 mm 1 6 mm D Ventilteller St rke EIN 0 4 0 8 mm AUS 0 8 1...

Page 107: ...EIN 32 55 mm 31 2 mm AUS 32 55 mm 31 2 mm Einbaul nge Ventil geschlossen EIN 25 6 mm AUS 25 6 mm Federdruck bei Einbaul nge EIN 137 5 158 1 N 14 0 16 1 kg AUS 137 5 158 1 N 14 0 16 1 kg Federneigungsw...

Page 108: ...esser 14 991 15 000 mm 14 971 mm Kolbenringe 1 Kompressionsring Topring Ausf hrung Abgerundet Abmessungen B T 1 0 2 1 mm Ringsto eingebaut 0 15 0 30 mm 0 4 mm Ringnutspiel eingebaut 0 035 0 090 mm 0 1...

Page 109: ...starter Kickstarter Bauart Kick und Eingriff Kickstarterclip Reibkraft 6 4 13 2 N 0 65 1 35 kg Vergaser Kennzeichnung 5HP1 00 Hauptd se M J Nr 105 Hauptd senstock N J N 6M Hauptluftd se M A J 1 2 D se...

Page 110: ...C 2 9 WARTUNGSDATEN Schmiersystem lfilter Drahtgeflecht lpumpe Rotorpumpe Spalt 0 15 mm 0 2 mm Spiel 0 06 0 10 mm 0 15 mm Geh use und Rotor Laufspiel 0 06 0 10 mm 0 15 mm Bauteil Spezifikation Grenzwe...

Page 111: ...fgemischanreicherung M4 0 7 2 2 0 2 Luftfiltergeh use M6 1 0 3 7 0 7 Kr mmer M6 1 0 2 10 1 0 Kr mmer M8 1 25 1 40 4 0 Kr mmer Schutzabdeckung M6 1 0 7 10 1 0 Funkenf nger M6 1 0 3 10 1 0 Kurbelgeh use...

Page 112: ...SPEC 2 11 WARTUNGSDATEN Anzugsreihenfolge Zylinderkopfschrauben...

Page 113: ...urchmesser 30 mm Teleskopgabel Oberkante 0 mm Hinterradaufh ngung Sto d mpferhub 65 mm Ungespannte Federl nge 178 mm Einbaul nge 165 mm Standard Federrate K 58 9 N mm 6 0 kg mm 336 lb in Umr stfeder N...

Page 114: ...gkeit DOT 4 Hintere Trommelbremse Trommelbremse Bauart Simplex Trommelbremse Bremstrommel Innendurchmesser 110 mm 111 mm Belagst rke 4 0 mm 2 0 mm Bremsschuhfeder ungespannte L nge 50 5 mm Bremshebel...

Page 115: ...erradbremse M6 1 0 2 9 0 9 Hauptbremszylinder Verschlu deckel Vorder radbremse M4 0 7 2 2 0 2 Handbremshebel Befestigung Schraube M6 1 0 1 7 0 7 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 Handbr...

Page 116: ...5 3 Umlenkhebel und Verbindungsgelenk M10 1 25 1 35 3 5 Verbindungsgelenk und Rahmen M10 1 25 1 35 3 5 Hinterradsto d mpfer und Rahmen M12 1 25 1 53 5 3 Hinterradsto d mpfer und Umlenkhebel M10 1 25...

Page 117: ...rot C D I Einheit Modell Hersteller 5HP 00 YAMAHA Z ndspule Typ Hersteller 4KJ 10 YAMAHA Minimale Z ndfunkenstrecke 6 mm Prim rwicklungs Widerstand 0 18 0 28 bei 20 C Sekund rwicklungs Widerstand 6 3...

Page 118: ...ht anders angegeben gelten alle Anzugsmomente f r saubere trockene Gewin de Die Bauteile sollten Raumtemperatur auf weisen A Mutter B Schrau be ANZUGSMOMENTE Nm m kg 10 mm 12 mm 14 mm 17 mm 19 mm 22 m...

Page 119: ...SPEC MEMO...

Page 120: ...Fit the CDI unit band over the CDI unit bracket till it stops Clamp the ignition coil lead Clamp the wire harness coupler Clamp the CDI magneto lead throttle cable and starter cable Clamp the CDI mag...

Page 121: ...n farbigen Markie rungen befestigen Bremsschlauch durch die Kabelf hrungen f h ren CHEMINEMENT DES C BLES 1 Reniflard de r servoir de carburant 2 Bloc CDI 3 Sangle du bloc CDI 4 Bride 5 Fil de magn to...

Page 122: ...tall the primary coil terminal orange to the ignition coil Fasten the ground lead together with the ignition coil Pass the clutch cable on the inside of the throttle and starter cable Clamp the clutch...

Page 123: ...flard 2 Fil de bougie 3 C ble de starter 4 C ble des gaz 5 C ble d embrayage 6 Bride 7 Guide de c ble 8 Reniflard de carter 9 Flexible de trop plein Apr s avoir brid le c ble du starter le pousser con...

Page 124: ...iddle of the clutch holder Clamp the engine stop switch lead to the handlebar to 3 clicks Pass the brake hose in front of the number plate and through the cable guide Pass the clutch cable in back of...

Page 125: ...h unten weisen 1 Fil de coupe circuit du moteur 2 Coupe circuit du moteur 3 Reniflard de r servoir de carburant 4 Bride 5 Flexible de frein 6 C ble d embrayage 7 C ble des gaz Faire passer le fil de c...

Page 126: ...n if necessary Replace gasket if necessary Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining Clutch Check operation Adjust or replace cable...

Page 127: ...and for oil leakage Correct accordingly Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary Chassis fasteners Make sure that a...

Page 128: ...ur 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 ou remplacer le c ble Frein avant V ri...

Page 129: ...essaire Pare tincelles 1 Nettoyer Fourche avant Contr ler le fonctionnement et l tanch it Corriger si n cessaire Ensemble amortis seur arri re Contr ler le fonctionnements et l tanch it Remplacer le c...

Page 130: ...einstellen gegebe nenfalls erneuern Ventile Ventilspiel kontrollieren Gegebenenfalls einstellen Luftfilter Luftfiltereinsatz gegebenenfalls reinigen oder erneuern Vergaser Leerlaufdrehzahl und Choke F...

Page 131: ...fen Entsprechend korrigieren Sp testens nach 120 Betriebsstunden mit Lithium fett schmieren Seitenst nder Funktion pr fen Gegebenenfalls schmieren oder reparieren Funkenl scher 1 Reinigen Teleskopgab...

Page 132: ...and rear brake Check fluid level and leakage P 3 15 19 Drive chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 20 21 Wheels Check for excessive wear and tire pres...

Page 133: ...ontr ler le niveau de fluide et les fuites P 3 15 19 Cha ne de transmission Contr ler la tension et l alignement de la cha ne Contr ler et si n ces saire lubrifier la cha ne P 3 20 21 Roues Contr ler...

Page 134: ...nd auf Undichtigkeit achten 3 15 19 Antriebskette Durchhang und Einstellung der Antriebskette pr fen Kontrollie ren ob die Kette ausreichend geschmiert ist 3 20 21 R der Auf berm igen Verschlei pr fen...

Page 135: ...INSP ADJ MEMO...

Page 136: ...k proper operation of clutch lever Clutch lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut EC35A001 THROTT...

Page 137: ...r 2 hinein oder herausdrehen bis das vorgeschriebene Spiel korrekt ein gestellt ist Kontermutter wieder festdrehen MOTEUR R GLAGE DE L EMBRAYAGE 1 Contr ler Garde du levier d embrayage a Hors sp cific...

Page 138: ...engine idling does not run faster 2 Apply Lithium soap base grease On the throttle cable end a and tube guide cable winding portion b 3 Install Throttle cable cap T R 2 Nm 0 2 m kg 1 4 ft lb AIR FILT...

Page 139: ...Andernfalls kann Schmutz und Staub in den Motor eindringen und raschen Ver schlei und m glicherweise Besch digun gen im Motor verursachen LUBRIFICATION DU C BLE DES GAZ 1 D poser Couvercle du logemen...

Page 140: ...case cover 2 3 Remove Air filter assembly 1 Wing nut 2 Washer 3 Air filter element 4 Air filter guide 5 4 Clean Air filter element Clean them with solvent NOTE After cleaning remove the remaining sol...

Page 141: ...em Luftfiltereinsatz ausdr cken ACHTUNG Den Luftfiltereinsatz beim Ausdr cken nicht verdrehen 5 Kontrollieren Luftfiltereinsatz Besch digung Erneuern 1 D poser Cache lat ral droit 1 N B Desserrer la v...

Page 142: ...nt 1 On air filter guide 2 8 Apply Lithium soap base grease On the matching surface a on air filter element 9 Install Air filter element 1 Washer 2 Wing nut 3 ENGINE OIL LEVEL INSPECTION 1 Start the e...

Page 143: ...uf einem ebenen Unter grund mit Hilfe eines geeigneten St n ders abstellen 3 Herausdrehen lme stab 1 6 Appliquer Huile pour filtre air en mousse ou huile de m lange Sur l l ment N B Comprimer pour lim...

Page 144: ...t 10 C 10 F or higher Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil At 5 C 40 F or higher Yamalube 4 20W 40 or SAE 20W 40 type SE motor oil Except for USA and CDN CAUTION Do not add any chemical a...

Page 145: ...swahl der richtigen lsorte die f r die entspre chenden Temperaturen geeig net ist Empfohlene Motor l Spezifikation API NORM API SE oder besser vorzugsweise Motorrad l 4 Contr ler Niveau d huile Le niv...

Page 146: ...warm it up for sev eral minutes and wait for five minute 2 Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine 3 Place a suitable containe...

Page 147: ...Hineinschrauben lme stab 2 F llmenge Regelm iger lwechsel 1 0 L 5 Installer Jauge 6 Mettre le moteur en marche et le laisser chauffer pendant quelques minutes 7 Couper le moteur et v rifier une nouve...

Page 148: ...l pressure check bolt T R Oil pressure check bolt 7 Nm 0 7 m kg 5 1 ft lb PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjustment steps Screw in the pilot air screw until it is lightly seated...

Page 149: ...or dem Einstellen leicht bis zum Anschlag hineindrehen und die Anzahl der Umdrehungen z hlen Diese Zahl als werk seitige Anzahl der Umdrehungen notieren CONTR LE DE LA PRESSION D HUILE DE MOTEUR 1 Con...

Page 150: ...ERS section in the CHAPTER 4 Adjustment steps Adjust the pilot air screw Refer to PILOT AIR SCREW ADJUST MENT section Turn the throttle stop screw 1 until the specified engine idling speed To increase...

Page 151: ...ehzahl 1 300 1 500 U min 3 Demontieren Z ndeinstell Verschlu schraube 1 Kurbelwellen Verschlu schraube 2 O Ring CONTR LE ET R GLAGE DU JEU DE SOUPAPES N B Le jeu de soupapes doit tre r gl quand le mot...

Page 152: ...he crankcase cover when piston is at T D C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance 5 Adjust Valve clearance Adjustment steps Loos...

Page 153: ...d Kontermutter festziehen T R Kontermutter 8 Nm 0 8 m kg CONTR LE ET R GLAGE DU JEU DE SOUPAPES VENTILSPIEL KONTROLLIEREN UND EINSTELLEN 4 Contr ler Jeu de soupapes Hors sp cifications R gler 5 R gler...

Page 154: ...lithium soap base grease on the O rings New T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 7 Install O ring 1 Exhaust tappet cover 2 Intake tappet cover 3 NOTE Apply the lithium soap base gr...

Page 155: ...Nm 1 8 m kg T R 13 Nm 1 3 m kg T R 10 Nm 1 0 m kg T R 7 Nm 0 7 m kg Mesurer le jeu de soupapes Si le jeu est incorrect r p ter les tapes ci des sus jusqu obtention du jeu correct 6 Installer Joint tor...

Page 156: ...gine when cleaning the exhaust system 1 Remove Bolt spark arrester 1 2 Remove Spark arrester 1 Pull the spark arrester out of the muf fler 3 Clean Spark arrester Tap the spark arrester lightly then us...

Page 157: ...challd mpfer hineinschieben und auf die Bohrungen f r die Schrauben ausrichten Schraube Funkenl scher T R 10 Nm 1 0 m kg NETTOYAGE DU PARE TINCELLES pour les USA AVERTISSEMENT S assurer que le tuyau e...

Page 158: ...the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end...

Page 159: ...m Kunst stoffschlauch befinden PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE FAHRWERK HYDRAULISCHE BREMSANLAGE ENTL FTEN PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE AVERTISSEMENT Purger le...

Page 160: ...oir WARNING Check the operation of the brake after bleeding the brake system FRONT BRAKE ADJUSTMENT 1 Check Brake lever free play a Out of specification Adjust 2 Adjust Brake lever free play CAUTION M...

Page 161: ...oder herausdrehen bis das vorgeschriebene Spiel a einge stellt ist Kontermuttern festziehen 3 Monter Diaphragme Couvercle du ma tre cylindre de frein N B Si la purge est difficile il peut tre n cessa...

Page 162: ...L HEIGHT ADJUSTMENT 1 Check Brake pedal height a Out of specification Adjust 2 Adjust Brake pedal height FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1 Remove Plug 2 Inspect Brake pad thickness a Out of...

Page 163: ...bene Pedal h he a eingestellt ist Kontermutter wieder festziehen Bremsbelagst rke a Standard Grenzwert 4 0 mm 0 8 mm R GLAGE DU FREIN ARRI RE 1 Contr ler Garde de la p dale de frein a Hors sp cificati...

Page 164: ...the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake caliper 6 and brake cali per support bolt 7 T R Brake caliper support bolt 22 Nm 2 2 m kg 16 ft lb CAUTION Do not reuse the d...

Page 165: ...GE ENTL FTEN CONTR LE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT VORDERRAD BREMSBEL GE KONTROLLIEREN UND ERNEUERN 3 Changer Plaquette de frein 4 Examiner Niveau du liquide de frein Se reporter CONTR...

Page 166: ...contaminants do not enter brake master cylinder when refilling Clean up spilled fluid immediately to avoid erosion of painted surfaces or plas tic parts Brake shoe lining wear limit checking steps Ful...

Page 167: ...Bereichs a befindet Grenzwert berschritten Bremsbelag erneuern Siehe unter HINTERRAD UND HINTER RADBREMSE in KAPITEL 5 Empfohlene Bremsfl ssigkeit DOT 4 CONTR LE DES M CHOIRES DE FREIN 1 Examiner Lim...

Page 168: ...ain from the kerosene and dry the chain 3 Measure Drive chain length 10 links a Out of specification Replace Drive chain length 10 links Limit 121 4 mm 4 78 in 4 Check Drive chain stiffness a Clean an...

Page 169: ...Clip unbedingt gem Abbil dung montieren a Antriebsketten Drehrichtung New CONTR LE DE LA CHA NE DE TRANSMISSION 1 D poser Agrafe de maillon d tachable Maillon d tachable 1 Cha ne de transmission 2 2...

Page 170: ...ns and check the slack several times to find the tight est point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 35 60 mm 1 4 2 4 in 3 Adjust Drive chain...

Page 171: ...en Durch hang belastet den Motor und andere wichtige Teile Deshalb den Antriebsket ten Durchhang laut Vorschrift einstellen 6 Lubrifier Cha ne de transmission R GLAGE DE LA TENSION DE LA CHA NE DE TRA...

Page 172: ...tion Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placin...

Page 173: ...g erh hen Einsteller 2 hin eindrehen Federung weicher Federvorspannung verringern Einsteller 2 her ausdrehen Federl nge Einbaul nge a Standardl nge Einstellbereich 165 mm 155 175 mm INSPECTION DE LA F...

Page 174: ...ver T R 42 Nm 4 2 m kg 30 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb EC36Q000 TIRE PRESSURE CHECK 1 Measure Tire pressure Out of specification Adjust NOTE Check the tire while it is cold Loose bead stoppers al...

Page 175: ...hat mu die Reifenstellung korrigiert werden Standard Reifendruck 100 kPa 1 0 bar CONTR LE DE LA PRESSION DE GONFLAGE DE PNEU REIFENDRUCK PR FEN N B Avant d effectuer le r glage bien veiller ce que le...

Page 176: ...ctice check spokes for looseness T R Front 2 Nm 0 2 m kg 1 4 ft lb Rear 3 Nm 0 3 m kg 2 2 ft lb EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2...

Page 177: ...unter dem Motor plazieren um Vorderrad anzuheben 2 Kontrollieren Lenkwelle Die Gleitrohre am unteren Ende umfas sen und die Teleskopgabel hin und her bewegen Spiel Lenkkopf einstellen INSPECTION ET S...

Page 178: ...g nut 2 and rubber washer 3 Loosen the lower ring nut 4 using the steering nut wrench 5 Steering nut wrench YU 33975 90890 01403 Tighten the lower ring nut 6 using steer ing nut wrench 7 and turn the...

Page 179: ...rehmomentschl ssel im rechten Win kel zum Hakenschl ssel ansetzen WARNUNG Ringmutter nicht berm ig festziehen 3 Contr ler Fonctionnement en douceur de la direction Tourner le guidon de but e but e Fon...

Page 180: ...bracket 25 Nm 2 5 m kg 18 ft lb Steering stem nut 110 Nm 11 0 m kg 80 ft lb Handlebar upper holder 23 Nm 2 3 m kg 17 ft lb Starter knob nut 1 Nm 0 1 m kg 0 7 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft l...

Page 181: ...r Vorder seite des Lenkerhalters festziehen und anschlie end die Schrauben auf der R ckseite festziehen T R crou annulaire serrage final 20 Nm 2 0 m kg 14 ft lb V rifier la colonne de direction en la...

Page 182: ...tch 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 Clutch cable end Use Yamaha cable lube or e...

Page 183: ...mit einem qualitativ hoch wertigen leichten Lithiumfett abschmieren 3 27 LUBRIFICATION Afin de garantir le bon fonctionnement de tous les l ments il convient de lubrifier la machine avant la premi re...

Page 184: ...s 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 Cle...

Page 185: ...t Z ndkerze per Hand hineindrehen a und anschlie end mit dem vorgeschriebe nen Drehmoment b festziehen T R 13 Nm 1 3 m kg PARTIE LECTRIQUE INSPECTION DE LA BOUGIE 1 D poser Bougie 2 Examiner lectrodes...

Page 186: ...xtent of removal Order Part name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF 1 Seat 1 2 Air scoop left and right 2 3 Fuel hose 1 Remove on fue...

Page 187: ...tartnummernblech 1 1 3 4 2 3 SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX SITZ KRAFTSTOFFTANK UND SEITENDECKEL MOTEUR SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX D poses effectuer 1 D pose de l...

Page 188: ...removal Extent of removal Order Part name Q ty Remarks MUFFLER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt spark arrester 3 2 Spark arreste...

Page 189: ...kenl scher 1 3 Mutter Schalld mpfer 2 4 Schraube Schalld mpfer 1 5 Schalld mpfer 1 1 POT D CHAPPEMENT D poses effectuer 1 D pose du pot d chappement D poses effectuer Ordre Nom de pi ce Qt Remarques D...

Page 190: ...REMOVAL Preparation for removal Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Fuel hose 1 2 Over flow hose 1 3 Air vent hose 2 4 Starter plunger 1 5 Carburetor top cover 1 6 Clamp air cl...

Page 191: ...eil 7 Klemme Vergaser Anschlu teil 1 Schrauben lockern Vergaser Anschlu teil 8 Vergaser 1 1 CARBURATEUR D poses effectuer 1 D pose du carburateur D poses effectuer Ordre Nom de pi ce Qt Remarques D PO...

Page 192: ...Refer to REMOVAL POINTS 3 Jet needle set 1 4 Carburetor top cover 1 5 Starter plunger 1 6 Float chamber 1 7 Float pivot pin 1 8 Float 1 9 Needle valve 1 0 Main jet washer 1 A Needle valve seat holder...

Page 193: ...UNKTE I Leerlaufeinstellschraube 1 J Leerlaufanreicherung 1 1 D MONTAGE DU CARBURATEUR D poses effectuer 1 D montage du carburateur D poses effectuer Ordre Nom de pi ce Qt Remarques D MONTAGE DU CARBU...

Page 194: ...MOVAL POINTS Throttle valve 1 Remove Throttle valve 1 Spring throttle valve 2 Carburetor top cover 3 Throttle cable 4 NOTE While compressing the spring throttle valve disconnect the throttle cable Pil...

Page 195: ...em Demontie ren leicht bis zum Anschlag hineindrehen und die Anzahl der Umdrehungen z hlen Diese Zahl als werkseitige Anzahl der Umdrehungen notieren REMARQUE altitude lev e la pression atmosph rique...

Page 196: ...ets with com pressed air Never use a wire 2 Inspect Main jet 1 Main jet nozzle 2 Pilot jet 3 NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never u...

Page 197: ...lenbildung a Erneuern Staub b Reinigen HINWEIS Nadelventil und Nadelventilsitz immer kom plett erneuern INSPECTION Carburateur 1 Examiner Corps de carburateur Encrassement Nettoyer N B Nettoyer avec d...

Page 198: ...Below the float chamber mat ing surface Measurement and adjustment steps Connect the fuel level gauge 1 to the float chamber Fuel level gauge YM 01312 A 90890 01312 Hold the fuel level gauge verticall...

Page 199: ...htes Bie gen des Schwimmerhabels b eingestellt werden Kraftstoffstand erneut messen Boisseau 1 Contr ler Souplesse du mouvement Calage R parer ou remplacer N B Introduire le boisseau 1 dans le carbura...

Page 200: ...retor 1 Install Diaphragm 1 Spring 2 Cover 3 Screw 4 T R 2 Nm 0 2 m kg 1 4 ft lb LT 2 Install Throttle stop screw 1 Pilot air screw 2 3 Install Pilot air jet 1 1 Pilot air jet 2 2 Note the following i...

Page 201: ...e um die Anzahl der Umdrehungen herausdrehen die vor dem Demontieren notiert wurde Leerlaufluft Regulierschraube 2 1 2 3 1 2 Beispiel Flotteur 1 Examiner Flotteur 1 Endommagement Remplacer Enrichisseu...

Page 202: ...installing the needle valve to the float install them to the carburetor Check the float for smooth movement 6 Install Gasket Float chamber 1 Screw float chamber 2 7 Install Spring 1 Starter plunger 2...

Page 203: ...Support d aiguille 2 Sur le boisseau 3 N B Aligner les saillies a sur le boisseau et les gorges b du support d aiguille 4 Montieren Leerlaufd se 1 Hauptd senstock 2 Hauptd se 3 Nadelventilsitz 4 Nadel...

Page 204: ...Throttle valve 3 On throttle cable 4 NOTE While compressing the spring connect the throttle cable Carburetor installation 1 Install Carburetor assembly 1 NOTE Install the projection between the carbur...

Page 205: ...2 Festziehen Schraube Vergaser Verbindungsteil 1 Schraube Luftfilter Anschlu teil 2 9 Installer Cache sup rieur du carburateur 1 Ressort boisseau 2 Boisseau 3 Sur le c ble d acc l ration 4 N B Connect...

Page 206: ...op cover 1 Starter plunger 2 Air vent hose 3 Over flow hose 4 Fuel hose 5 NOTE Align the slit a of the throttle valve with the tab b of the carburetor body 4 Adjust Idle speed Refer to ENGINE IDLING S...

Page 207: ...corps du carburateur 4 R gler R gime de ralenti Se reporter R GLAGE DU R GIME DE RALENTI au CHAPITRE 3 CARBURATEUR VERGASER 3 Montieren Vergaserdeckel 1 Chokeschieber 2 Bel ftungsschlauch 3 berlaufsc...

Page 208: ...s CYLINDER HEAD SIDE COVER AND TAPPET COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Muffler Refer to MUFFLER section Carburetor Refer to CARB...

Page 209: ...ckel 1 4 Ventildeckel 2 5 Kurbelwellen Verschlu schraube 1 6 Z ndeinstell Verschlu schraube 1 1 CULASSE CACHE LAT RAL DE CULASSE ET COUVRE POUSSOIRS D poses effectuer 1 D pose du cache lat ral de cula...

Page 210: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER HEAD REMOVAL 1 Bolt camshaft sprocket 1 Refer to REMOVAL POINTS 2 Bolt timing chain tensioner cap 1 3 Timing chain tensioner 1 4 Gasket...

Page 211: ...Deckel 1 3 Steuerkettenspanner 1 4 Dichtung 1 5 Nockenwellen Kettenrad 1 6 Zylinderkopf 1 7 Pa h lse 2 8 Dichtung 1 1 CULASSE D poses effectuer 1 D pose de la culasse D poses effectuer Ordre Nom de pi...

Page 212: ...ed with the stationary pointer the piston is at the Top Dead Center 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 s...

Page 213: ...mutter mit einem Schraubenschl ssel halten und Schraube demontieren 3 Demontieren Schraube Steuerkettenspanner Dek kel 1 Schraube Steuerkettenspanner 2 Steuerkettenspanner 3 PI CES D POSER Culasse 1 A...

Page 214: ...the bolts starting with the lowest number one INSPECTION Cylinder head 1 Eliminate Carbon deposits from the combustion chambers Use a rounded scraper NOTE Do not use a sharp instrument to avoid dam ag...

Page 215: ...t berschritten Planschlei fen Arbeitsschritte Lineal und F hlerlehre auf den Zylinder kopf legen Den Verzug messen 4 D poser Boulon pignon d arbre cames 1 Pignon d arbre cames 2 N B Attacher un fil m...

Page 216: ...side ASSEMBLY AND INSTALLATION Cylinder head 1 Install Dowel pin 1 Gasket 2 New 2 Install Cylinder head Copper washer Bolt cylinder head NOTE Apply Quick gasket Yamaha bond No 1215 on end of the cyli...

Page 217: ...Quick Gasket ACC QUICK GS KT Yamaha Dichtmasse Nr 1215 90890 85505 T R M8 22 Nm 2 2 m kg M6 10 Nm 1 0 m kg Limite de d formation 0 03 mm 0 0012 in Si la d formation est hors sp cifications surfa cer l...

Page 218: ...inter b on the crankcase cover Align the match mark c on the camshaft sprocket with the stationary pointer d on the cylinder head Fit the timing chain 1 onto camshaft sprocket 2 and install the camsha...

Page 219: ...dernfalls zu Motor sch den oder einer ungenauen Ventilsteuerung kommt Den Sicherungsdraht von der Steuerkette entfernen 3 Installer Cha ne de distribution Pignon d arbre cames 4 Installer Rondelle Bou...

Page 220: ...se a thin screwdriver and wind the tensioner rod up fully clockwise With the rod fully wound install the gasket 1 and the chain tensioner 2 and tighten the bolts 3 to the specified torque T R Bolt cha...

Page 221: ...estziehen Schraube 1 HINWEIS Rotormutter mit einem Schraubenschl ssel festhalten und Schraube festziehen T R 20 Nm 2 0 m kg 5 Installer Tendeur de la cha ne de distribution 6 Tourner Vilebrequin De qu...

Page 222: ...y Engine oil On camshaft 11 Install Tappet cover 1 Cylinder head side cover 2 T R 18 Nm 1 8 m kg 13 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 12 Install Timing mark accessing screw 1 Crankshaft end accessing...

Page 223: ...Montieren Z ndkerze Motorhalterung T R 13 Nm 1 3 m kg T R 40 Nm 4 0 m kg 9 Contr ler Jeu de soupapes Hors sp cifications R gler Se reporter la section CONTR LE ET R GLAGE DU JEU DE SOUPAPES au CHAPITR...

Page 224: ...oval Order Part name Q ty Remarks CAMSHAFT AND ROCKER ARMS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Camshaft bearing holder 1 2 Intake rocker arm shaft 1 Refer to...

Page 225: ...TE 3 Kipphebelwelle Ausla seite 1 4 Nockenwelle 1 Siehe unter DEMONTAGEPUNKTE 5 Kipphebel Einla seite 1 6 Kipphebel Ausla seite 1 1 2 ARBRE CAMES ET CULBUTEURS D poses effectuer 1 D pose de l arbre ca...

Page 226: ...0 01084 Camshaft 1 Remove Camshaft 1 Camshaft bearing 2 NOTE Screw in a suitable length of 8 mm bolt 3 into the threaded end of the camshaft and pull out the camshaft INSPECTION Camshaft 1 Inspect Cam...

Page 227: ...ht vorschriftsm ig Erneuern Nockenh he Grenzwert Einla a 25 851 mm b 21 165 mm Ausla a 25 811 mm b 21 020 mm PI CES D POSER Axes de culbuteur 1 D poser Axes de culbuteur N B Se servir d un boulon d ex...

Page 228: ...rocker arm 10 000 10 015 mm 0 3937 0 3943 in Limit 10 03 mm 0 3949 in Measure the outside diameter b of the rocker arm shafts Out of specification Replace Outside diameter rocker arm shaft 9 981 9 991...

Page 229: ...3 Auftragen Motor l auf die Kipphebelwelle 4 Montieren Kipphebelwelle Culbuteurs et axes de culbuteur 1 Examiner Surface de contact de bossage de came a Surface du dispositif de r glage 1 Usure piq r...

Page 230: ...4 23 ENG CAMSHAFT AND ROCKER ARMS 5 Install Camshaft bearing holder 1 Bolt 2 T R 10 Nm 1 0 m kg 7 2 ft lb LT...

Page 231: ...BRE CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL 5 Montieren Nockenwellenlager Halter 1 Schraube 2 T R 10 Nm 1 0 m kg LT 5 Installer Support de roulement d arbre cames 1 Boulon 2 T R 10 Nm 1 0 m kg 7...

Page 232: ...Q ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Camshaft and rocker arms Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4...

Page 233: ...Ventilfeder 2 4 Einla ventil 1 5 Ausla ventil 2 6 Ventilschaftdichtung 2 7 Ventilfedersitz 2 1 SOUPAPES ET RESSORTS DE SOUPAPE D poses effectuer 1 D poses des soupapes et des ressorts de soupape D po...

Page 234: ...ls properly There should be no leakage at the valve seat 2 2 Remove Valve cotters 1 NOTE Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve...

Page 235: ...upape 4 Si ge de ressort de soupape 5 N B Marquer la position de chaque pi ce avec soin afin de pouvoir les remonter dans leur position d origine DEMONTAGEPUNKTE Ventil 1 Kontrollieren Ventil Dichthei...

Page 236: ...ement steps Remove the valve guide using a valve guide remover 1 Install the new valve guide using a valve guide remover and valve guide installer After installing the valve guide bore the valve guide...

Page 237: ...INSPECTION Soupape 1 Mesurer Jeu de queue dans le guide Hors sp cifications Remplacer le guide de soupape Jeu de queue dans le guide de soupape diam tre int rieur de guide de soupape a diam tre de qu...

Page 238: ...ce 5 Measure Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal Margin thickness I...

Page 239: ...und Ventilsitz 7 Kontrollieren Ventilsitze Pitting Bildung Verschlei Ventilsitz neu fr sen 3 Examiner Face de soupape Piq res usure Surfacer la face de sou pape Embout de queue de soupape En forme de...

Page 240: ...o the valve seat to make a clear pattern Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed If the valve seat is too wide too narrow or the se...

Page 241: ...gelangen Molybd ndisulfid auf den Ventilschaft auf tragen 8 Mesurer Largeur de si ge de soupape a Hors sp cifications Surfacer le si ge de soupape Largeur du si ge de soupape Admission 0 9 1 1 mm 0 0...

Page 242: ...and onto the valve seat to make a clear pattern Measure the valve seat width again If the valve seat width is out of specification reface and re lap the valve seat NOTE For best lapping results light...

Page 243: ...Nicht vorschriftsm ig Erneuern Ungespannte L nge Ventilfeder Einla 32 55 mm Grenzwert 31 2 mm Ausla 32 55 mm Grenzwert 31 2 mm Installer la soupape dans la culasse Tourner la soupape jusqu ce que la...

Page 244: ...4 0 16 1 kg at 25 6 mm 30 86 35 49 lb at 1 01 in Spring tilt limit Intake 2 5 1 4 mm 0 06 in Exhaust 2 5 1 4 mm 0 06 in ASSEMBLY AND INSTALLATION Valve 1 Apply Engine oil onto the valve stem and valve...

Page 245: ...it der gr eren Federteilung a nach oben montieren b Kleinere Federteilung New 2 Mesurer Force de ressort comprim a Hors sp cifications Remplacer b Longueur mont 3 Mesurer Inclinaison de ressort a Hors...

Page 246: ...valve spring with a valve spring compressor 2 install the valve cotters Valve spring compressor YM 04019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a...

Page 247: ...lopfen auf die Ventil schaftenden k nnten die Ventile besch digt werden Ventilfederspanner YM 04019 90890 04019 3 Installer Clavettes de soupape 1 N B Installer les clavettes de soupape en comprimant...

Page 248: ...Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Exhaust timing chain guide 1 2 Cylinder O ring 1 1 3 Dowel pin 2 4 Gaske...

Page 249: ...benbolzensicherung 2 Siehe unter DEMONTAGEPUNKTE 6 Kolbenbolzen 1 7 Kolben 1 8 Kolbenring Satz 1 Siehe unter DEMONTAGEPUNKTE 1 2 CYLINDRE ET PISTON D poses effectuer 1 D pose du cylindre 2 D pose du p...

Page 250: ...nd pin hole area If the piston pin groove is deburred and the piston pin is still difficult to remove use the piston pin puller 4 CAUTION Do not use a hammer to drive the piston pin out Piston ring 1...

Page 251: ...nbolzen Ausbauwerkzeug YU 01304 90890 01304 PR FEN Zylinder und Kolben 1 Kontrollieren Zylinder und Kolbenhemd Senkrechte Kratzer Zylinder und Kol ben erneuern PI CES D POSER Piston 1 D poser Circlips...

Page 252: ...linder and replace the piston and piston rings as set 2nd step Measure the piston skirt diameter P with a micrometer a 5 mm 0 20 in from the piston bottom edge Piston size P Standard 53 977 53 996 mm...

Page 253: ...el 0 020 0 026 mm Grenzwert 0 15 mm 2 Mesurer Jeu entre piston et cylindre tapes de la mesure du jeu piston cylindre 1re tape Mesurer l al sage de cylindre C au moyen d un comparateur d al sage N B Me...

Page 254: ...cation system 2 Measure Piston pin to piston clearance Measurement steps Measure the piston pin outside diameter a If out of specification replace the piston pin Outside diameter piston pin 14 991 15...

Page 255: ...Kolbenbol zenauge 15 002 15 013 mm Grenzwert 15 043 mm Si la valeur obtenue ne correspond pas aux sp cifications remplacer le cylindre et rempla cer la fois le piston et ses segments Axe de piston 1...

Page 256: ...ton ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 40 mm 1 57 in into the cylin der Push the ring with the piston crown so that the ring will be at a right angle to th...

Page 257: ...onsring 0 30 0 45 mm 0 55 mm lab streifring 0 20 0 70 mm Segment de piston 1 Mesurer Jeu lat ral de segment Utiliser une cale d paisseur Hors sp cifications Remplacer la fois le piston et les segments...

Page 258: ...er size A 54 000 54 003 mm 2 1260 2 1261 in B 54 004 54 007 mm 2 1261 2 1263 in C 54 008 54 011 mm 2 1263 2 1264 in D 54 012 54 015 mm 2 1265 2 1266 in E 54 016 54 019 mm 2 1266 2 1267 in Cylinder mar...

Page 259: ...D D violett E E blau Combinaisons de piston et cylindre 1 Contr ler Rep re sur le cylindre a 2 Contr ler Rep re sur le piston a 3 Combiner Combiner un piston et un cylindre en sui vant le tableau ci...

Page 260: ...own a Top ring end b 2nd ring end c Oil ring end upper d Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clips 3 NOTE Apply engine oil onto the piston pin piston rings and piston Be sure...

Page 261: ...ren Kolben Kolbenringe Zylinderlauffl che HINWEIS Reichlich Motor l auftragen New ASSEMBLAGE ET REPOSE Segments et piston 1 Installer Segments de piston sur le piston N B S assurer d installer le segm...

Page 262: ...t timing chain guide CAUTION Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain through the cylin der timing chain cavity Be careful not to...

Page 263: ...rf bei der Montage nicht besch digt werden HINWEIS Nach der Montage die Leichtg ngigkeit des Kolbens pr fen New Cylindre 1 Installer Goujons 1 Joint cylindre 2 New 2 Installer Joint torique Cylindre 1...

Page 264: ...e Q ty Remarks CLUCTH PLATE AND FRIC TION PLATE REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine skidplate Refer to ENGINE REMOVAL s...

Page 265: ...te 1 7 Kugel 1 8 Reibscheibe 5 9 Kupplungsscheibe 4 10 Mutter Unterlegscheibe 1 1 11 Druckstange 1 1 12 Druckplatte 1 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE DISQUES D EMBRAYAGE ET DE FRICTION D poses effe...

Page 266: ...xtent of removal Order Part name Q ty Remarks PRIMARY DRIVEN GEAR REMOVAL 1 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 2 Lock washer 1 3 Clutch boss 1 4 Thrust plate 1 5 Primary driven...

Page 267: ...porter PI CES D POSER 9 Pignon menant primaire 1 10 Clavette droite 1 2 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE KUPPLUNG UND PRIM RABTRIEBSZAHNRAD PRIM RABTRIEBSZAHNRAD Demontage Arbeiten 1 Prim rabtriebsz...

Page 268: ...CH AND PRIMARY DRIVEN GEAR PUSH LEVER Extent of removal 1 Push lever removal Extent of removal Order Part name Q ty Remarks PUSH LEVER REMOVAL 1 Clutch cable 1 2 Push lever 1 3 Spring 1 4 Circlip 1 5...

Page 269: ...e Bauteil Anz Bemerkungen AUSR CKHEBEL DEMONTIE REN 1 Kupplungszug 1 2 Ausr ckhebel 1 3 Feder 1 4 Sicherungsring 1 5 Dichtring 1 1 LEVIER DE POUSS E D poses effectuer 1 D pose du levier de pouss e D p...

Page 270: ...6 Primary drive gear 1 Remove Nut primary drive gear 1 Primary drive gear 2 NOTE Place a folded rag or aluminum plate between the teeth of the primary drive gear and primary driven gear Take care not...

Page 271: ...schlei Besch digung Erneuern Prim rabtriebszahnrad 1 Kontrollieren Umfangsspiel Spiel vorhanden Erneuern Zandrad Z hne a Verschlei Besch digung Erneuern PI CES D POSER Noix d embrayage 1 D poser crou...

Page 272: ...plate 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points EC484600 Clutch plate 1 Measure Clutch plate warpage Out of specification Repla...

Page 273: ...Grenzwert 2 8 mm Verzugsgrenze 0 2 mm Ressort d embrayage 1 Mesurer Longueur libre de ressort d embrayage a Hors sp cifications Remplacer tous les ressorts Longueur libre de ressort d embrayage 33 mm...

Page 274: ...ush lever 1 NOTE Apply the lithium soap base grease on the oil seal lip Apply the engine oil on the push lever Primary drive gear 1 Install Straight key Primary drive gear 1 Washer 2 Nut primary drive...

Page 275: ...umplatte 5 zwischen die Z hne des Prim rantriebszahnrades und des Pri m rabtriebszahnrades stecken T R 70 Nm 7 0 m kg Tige de commande 1 Examiner Tige de commande 1 1 Bille 2 Usure endommagement d for...

Page 276: ...holding tool YM 91042 90890 04086 New T R 60 Nm 6 0 m kg 43 ft lb 4 Install Friction plate 1 Clutch plate 2 NOTE Install the clutch plates and friction plates alternately on the clutch boss starting...

Page 277: ...etwa 90 zur Nase der vorherge henden Scheibe montieren Im Uhrzeigersinn vorgehen bis alle Kupplungs scheiben montiert sind Embrayage 1 Installer Rondelle lastique conique 1 Plaque de pouss e 2 Pignon...

Page 278: ...Bolt clutch spring 3 NOTE Align the arrow mark a on the pressure plate with the punched mark b on the clutch boss Tighten the bolts in stage using a crisscross pattern T R 6 Nm 0 6 m kg 4 3 ft lb 8 Ch...

Page 279: ...ichtet sind Einstellen a Markierung auf dem Ausr ckhebel b Markierung auf dem Kurbelgeh use 5 Installer Bille N B Enduire la bille d huile de moteur 6 Installer Tige de commande 1 1 Plaque de pouss e...

Page 280: ...l pins Gasket right crankcase cover Right crankcase cover Bolts right crankcase cover NOTE Apply Quick gasket Yamaha bond No 1215 to end of the right crankcase cover bolts as shown Tighten the bolts i...

Page 281: ...n da ein Abstand von 5 10 mm a zwischen der Kick starterkurbel und dem rechten Kurbelgeh use deckel besteht T R 50 Nm 5 0 m kg 9 R gler Position du levier de pouss e tapes du r glage Desserrer le cont...

Page 282: ...l Extent of removal Order Part name Q ty Remarks OIL PUMP REMOVAL Preparation for removal Clutch and primary drive gear Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 1 Rotary filter 1 2 Oil pump dri...

Page 283: ...ifugalfilter 1 2 lpumpen Antriebsrad 1 3 lpumpe komplett 1 4 Dichtung 1 5 lpumpensieb 1 1 POMPE HUILE D poses effectuer 1 D pose de la pompe huile D poses effectuer Ordre Nom de pi ce Qt Remarques D P...

Page 284: ...assembly Extent of removal Order Part name Q ty Remarks OIL PUMP DISASSEMBLY 1 Circlip 1 2 Oil pump driven gear 1 3 Conical spring washer 1 4 Circlip 1 5 Washer 1 6 Oil pump cover 1 7 Pin 2 8 Oil pump...

Page 285: ...lle 1 9 Stift 1 0 Innenrotor 1 A Au enrotor 1 B lpumpengeh use 1 1 D MONTAGE DE LA POMPE HUILE D poses effectuer 1 D montage de la pompe huile D poses effectuer Ordre Nom de pi ce Qt Remarques D MONTA...

Page 286: ...the oil pump housing 3 Out of specification Replace the oil pump assembly Housing and rotor clearance between the pump housing 3 and the rotors 1 2 Out of specification Replace the oil pump assembly T...

Page 287: ...trollieren Zentrifugalfilter Risse Besch digung Erneuern INSPECTION Pompe huile 1 Examiner Pignon menant de pompe huile Pignon men de pompe huile Logement de la pompe huile Couvercle de pompe huile Cr...

Page 288: ...o the outer rotor inner rotor and oil pump shaft Install the conical spring washer in the direc tion as shown 2 Install Oil strainer Gasket Oil pump assembly Screws oil pump assembly NOTE Apply engine...

Page 289: ...0 5 m kg New T R 7 Nm 0 7 m kg Cr pine huile 1 Examiner Cr pine huile Craquelures endommagement Rempla cer Crasses obstructions Nettoyer ASSEMBLAGE ET REPOSE Pompe huile 1 Installer Logement de la po...

Page 290: ...ND SHIFT SHAFT REMOVAL Preparation for removal Shift pedal link Refer to ENGINE REMOVAL section Clutch Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 1 Kick axle assembly 1 Refer to REMOVAL POINTS 2...

Page 291: ...9 R ckholfeder 1 10 Schraube Kickstarter Anschlag 1 11 Kickstarter Anschlag 1 12 Feder 1 13 Kickstarter Zahnsegment 1 Siehe unter DEMONTAGEPUNKTE 1 2 AXE DE KICK ET ARBRE DE S LECTEUR AXE DE KICK ET...

Page 292: ...le and kickstarter segment gear 1 Check Kickstarter segment gear smooth movement Unsmooth movement Replace 2 Inspect Kick axle 1 Wear damage Replace Kickstarter segment gear and kick idle gear 1 Inspe...

Page 293: ...starterritzel Clip 1 Messen Kickstarterritzel Clip Friktionskraft R ckholfeder Nicht vorschriftsm ig Erneuern Dynamometer 1 verwenden Kickstarterritzel Clip Friktionskraft 0 65 1 35 kg PI CES D POSER...

Page 294: ...g 2 Broken Replace EC4C5000 ASSEMBLY AND INSTALLATION Segment 1 Install Segment 1 Screw segment 2 NOTE Align the notch a on the segment with the pin b on the shift cam Tighten the screw using the T30...

Page 295: ...eder 3 HINWEIS Kickstarter Anschlag Rolle auf den Schlitz im Kickstarter Zahnsegment ausrichten T R 12 Nm 1 2 m kg LT T R 10 Nm 1 0 m kg LT Arbre de s lecteur 1 Examiner Arbre de s lecteur 1 D formati...

Page 296: ...n spring fits into the hole b on the kick axle 2 Install Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a in the spring guide fits on the stopper of the torsion spr...

Page 297: ...h ngen R ckholfeder 1 HINWEIS R ckholfeder im Uhrzeigersinn drehen und in die entsprechende Bohrung a im Kurbelge h use einh ngen Arbre de s lecteur 1 Installer Arbre de s lecteur 1 N B Enduire les l...

Page 298: ...FT SHAFT Kick idle gear 1 Install Circlip 1 Washer 2 Kick idle gear 3 Washer 4 Circlip 5 NOTE Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its depress...

Page 299: ...Motor l auf das gesamte Kickstarterritzel auftragen Kickstarterritzel mit der flachen Seite nach au en montieren New New Pignon libre de kick 1 Installer Circlip 1 Rondelle 2 Pignon libre de kick 3 Ro...

Page 300: ...l Seat and fuel tank Refer to SAET FUEL TANK AND SIDE COVERS section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drive sprocket cover Refer to ENGINE REMOVAL section...

Page 301: ...verwenden Siehe unter DEMONTAGEPUNKTE 4 Rotor 1 5 Scheibenfeder 1 6 Aufnahmespule 1 7 Kabelf hrung 1 8 Stator 1 1 MAGN TO CDI D poses effectuer 1 D pose de la magn to CDI D poses effectuer Ordre Nom d...

Page 302: ...o 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Wood...

Page 303: ...Nm 1 0 m kg LT T R 7 Nm 0 7 m kg LT T R 10 Nm 1 0 m kg LT MAGN TO CDI LICHTMASCHINENROTOR PI CES D POSER Rotor 1 D poser crou rotor 1 Rondelle plate 2 Se servir d une cl sangle 3 Cl sangle YS 01880 A...

Page 304: ...ing the rotor align the keyway of the rotor with the woodruff key 3 Install Plain washer 1 Nut rotor 2 Use the sheave holder 3 Sheave holder YS 01880 A 90890 01701 T R 80 Nm 8 0 m kg 58 ft lb 4 Instal...

Page 305: ...r Kreuz festziehen New T R 10 Nm 1 0 m kg 5 Anschlie en Lichtmaschinenrotor Kabel Siehe unter KABELF HRUNG in KAPITEL 2 2 Installer Clavette demi lune 1 Rotor 2 N B Nettoyer la partie conique du vileb...

Page 306: ...machine by placing the suitable stand under the frame Seat fuel tank and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Muffler Refer to MUFFLER sec...

Page 307: ...enstecker Lichtmaschinenrotor Kabel abtrennen Motor l ablassen Siehe unter MOTOR L WECHSELN in KAPITEL 3 D POSE DU MOTEUR D poses effectuer 1 D pose du moteur D poses effectuer Ordre Nom de pi ce Qt R...

Page 308: ...over 1 2 Bolt drive sprocket 2 Refer to REMOVAL POINTS 3 Drive sprocket holder 1 4 Drive sprocket 1 5 Shift pedal link 1 6 Crankcase breather hose 1 7 Engine bracket upper 1 8 Engine skidplate 1 9 Eng...

Page 309: ...wannenschutz 1 9 Motorhalterung vorne 1 10 Motorbefestigungsschraube hinten 2 11 Motor 1 Siehe unter DEMONTAGEPUNKTE 1 D poses effectuer Ordre Nom de pi ce Qt Remarques 1 Cache de pignon menant 1 2 Bo...

Page 310: ...les are disconnected ASSEMBLY AND INSTALLATION Engine installation 1 Install Engine 1 Install the engine from left side Engine mounting bolt rear 2 Engine bracket front 3 Bolt engine bracket 4 Engine...

Page 311: ...40 Nm 4 0 m kg T R 40 Nm 4 0 m kg T R 40 Nm 4 0 m kg T R 40 Nm 4 0 m kg T R 40 Nm 4 0 m kg PI CES D POSER Pignon menant 1 D poser Boulon pignon menant Support de pignon menant 1 Pignon menant 2 Cha ne...

Page 312: ...ter a of the front end of the shift pedal to match the highest point of the foot rest T R 10 Nm 1 0 m kg 7 2 ft lb Drive sprocket 1 Install Drive sprocket 1 Drive chain 2 NOTE Install the drive sprock...

Page 313: ...itzel Deckel 1 Schraube Antriebsritzel Deckel T R 12 Nm 1 2 m kg N B Enduire le filet des boulons de montage du moteur 2 de graisse base de savon au lithium Tige de p dale de s lecteur 1 Installer Tig...

Page 314: ...emoval Order Part name Q ty Remarks CRANKCASE CRANKSHAFT AND BALANCER REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Primary drive...

Page 315: ...ND PRI M RABTRIEBSZAHNRAD Kickstarterwelle komplett Siehe unter KICKSTARTERWELLE UND SCHALTWELLE Kickstarter Zahnsegment Rotor und Stator Siehe unter LICHTMASCHINENRO TOR CARTER MOTEUR VILEBREQUIN ET...

Page 316: ...1 2 Timing chain 1 3 Bolt 45 mm 1 8 in 7 4 Bolt 55 mm 2 2 in 1 5 Bolt 30 mm 1 2 in 2 6 Lead guide 1 7 Clutch cable holder 1 8 Right crankcase 1 Use special tool Refer to REMOVAL POINTS 9 Left crankcas...

Page 317: ...gleichswelle 1 11 Kurbelwelle 1 Spezialwerkzeug verwenden Siehe unter DEMONTAGEPUNKTE 12 Lager 3 Siehe unter DEMONTAGEPUNKTE 3 2 1 D poses effectuer Ordre Nom de pi ce Qt Remarques 1 Patin de cha ne d...

Page 318: ...case If necessary one screw may be backed out slightly to level tool body As pressure is applied alternately tap on the front engine mounting boss and transmission shafts CAUTION Use soft hammer to t...

Page 319: ...lften nicht trennen lassen mu gepr ft werden ob eine Geh u seschraube oder befestigung vergessen wurde Keinesfalls rohe Kraft anwenden Kurbelgeh use Trennwerkzeug YU 01135 A 90890 01135 PI CES D POSER...

Page 320: ...kcase separating tool YU 01135 A 90890 01135 Bearing 1 Remove Bearing 1 NOTE Remove the bearing from the crankcase by pressing its inner race as shown in Do not use the removed bearing INSPECTION Timi...

Page 321: ...ifheit Steuerkette und Nok kenwellen Kettenrad komplett erneu ern 2 Kontrollieren Steuerkettenf hrung Verschlei Besch digung Erneuern Vilebrequin 1 D poser Vilebrequin 1 Se servir d un s parateur de d...

Page 322: ...with a finger Rough spot seizure Replace Crankshaft 1 Measure Runout limit a Connecting rod big end side clearance b Crank width c Out of specification Replace Use the dial gauge and a thickness gauge...

Page 323: ...Max Schlag 0 03 mm Axial spiel 0 15 0 45 mm 0 50 mm Kurbel breite 46 95 47 00 mm Carter moteur 1 Examiner Plan de joint a Rayures Remplacer Noix de montage du moteur b Craquelures endommagement Rempl...

Page 324: ...5 For USA and CDN Except for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until th...

Page 325: ...llen Montagebolzen 3 YU 90050 90890 01275 Adapter 4 YU 90063 90890 01278 Distanzst ck 5 YM 91044 90890 04081 Balancier 1 Examiner Balancier Craquelures endommagement Rempla cer ASSEMBLAGE ET REPOSE Ro...

Page 326: ...crankcase 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Quick gasket ACC QUICK GS KT Yamaha bond No 1215 90890 85505 2 Install Dowel pin 1 Right crankcas...

Page 327: ...seh lfte aufsetzen Vorsichtig mit einem weichen Hammer auf die Geh u seh lfte klopfen Bei der Montage des Kurbelgeh uses sollte sich die Pleuelstange im oberen Totpunkt TDC befinden 2 Installer Balanc...

Page 328: ...ankcase bolts 45 mm 1 8 in 3 as shown Tighten the crankcase bolts in stage using a crisscross pattern Quick gasket ACC QUICK GS KT Yamaha bond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 N...

Page 329: ...Einla seite 2 Schraube Steuerkettenf hrung Ein la seite T R 10 Nm 1 0 m kg LT 3 Serrer Guide de fil 1 Support de c ble d embrayage 2 Boulon carter moteur 45 mm 1 8 in 3 Boulon carter moteur 55 mm 2 2...

Page 330: ...Remarks TRANSMISSION SHIFTCAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE CRANKSHAFT AND BALANCER section 1 Shift f...

Page 331: ...swelle 1 Siehe unter DEMONTAGEPUNKTE 8 Ausgangswelle 1 9 Druckstange 2 1 10 Anlaufscheibe 1 1 2 BO TE DE VITESSES TAMBOUR ET FOURCHETTES DE S LECTION D poses effectuer 1 D pose du tambour et des fourc...

Page 332: ...mmer to remove Remove assembly carefully Note the posi tion of each part Pay particular attention to the location and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect Matching dog...

Page 333: ...ge 2 1 Verschlei Besch digung Verbiegung Erneuern PI CES D POSER Bo te de vitesses 1 D poser Arbre primaire 1 Arbre secondaire 2 N B D poser l arbre secondaire de la bo te de vitesse en le tapotant l...

Page 334: ...hift cam 1 Inspect Shift fork 1 Wear damage scratches Replace 2 Inspect Shift cam 1 Shift fork guide bar 2 Bend wear damage Replace 3 Check Shift fork movement On its guide bar Unsmooth operation Repl...

Page 335: ...die sich neben der Schaltgabel befinden Roulement 1 Examiner Roulement 1 Faire tourner la cage interne avec un doigt Duret grippage Remplacer Fourchette de s lection et tambour 1 Examiner Fourchette d...

Page 336: ...xle 5 NOTE Apply the molybdenum disulfide oil on the gears inner circumference Install the 5th pinion gear so that measure ment a is 83 25 83 45 mm 3 278 3 285 in 2 Install 2nd wheel gear 32T 1 5th wh...

Page 337: ...f den Innenring der Zahn r der auftragen Bo te de vitesses 1 Installer 4e pignon menant 22T 1 3e pignon menant 19T 2 2e pignon menant 18T 3 5e pignon menant 24T 4 Sur l arbre primaire 5 N B Enduire la...

Page 338: ...end c is positioned at axle spline groove d New 4 Install Push rod 2 On main axle NOTE Apply the engine oil on the push rod 2 5 Install Washer 1 On drive axle 6 Install Main axle Drive axle Install t...

Page 339: ...tet werden da die Dichtlippe des Kurbelge h use Dichtrings nicht besch digt wird 3 Installer Rondelle plate 1 Circlip 2 N B S assurer de diriger le c t ouvert a du circlip du c t oppos de la rondelle...

Page 340: ...he drive axle Mesh the shift fork 2 C with the 3rd pinion gear on the main axle 2 Install Shift cam 1 NOTE Apply the engine oil on the shift cam 3 Install Shift fork guide bar 1 short 1 Shift fork gui...

Page 341: ...eren Tambour et fourchette de s lection 1 Installer Fourchette de s lection 1 L 1 Fourchette de s lection 2 C 2 Fourchette de s lection 3 R 3 N B Engrener la fourchette de s lection n 1 L avec le 2e p...

Page 342: ...Remarks Preparation for removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine 1 Axle nut 1 2 Washer 1 3 Wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Whe...

Page 343: ...7 Radlager 2 Siehe unter DEMONTAGEPUNKTE 8 Distanzst ck 1 9 Bremsscheibe 1 2 3 1 3 ROUE AVANT VORDERRAD PARTIE CYCLE ROUE AVANT D poses effectuer 1 D pose de la roue avant 2 D pose des roulements de r...

Page 344: ...otate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in EC514200 Whee...

Page 345: ...ne Achse zu richten Maximal zul ssige Achsbiegung 0 5 mm PI CES D POSER Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement l aide d un extracteur de roulements universel 2...

Page 346: ...STALLATION Front wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 NOTE Apply the lithium soap base grease on the wheel bearing and oil seal lip when installing Install the wheel bea...

Page 347: ...1 Mesurer D formation du disque de frein Utiliser un comparateur cadran 1 Hors sp cifications V rifier la d forma tion de la roue Si la d formation de la roue est dans les limites remplacer le disque...

Page 348: ...2 Nm 1 2 m kg 8 7 ft lb LT 3 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lips Install the longer collar on the brake disc 2 side 4 Install Front wheel NOTE Install the bra...

Page 349: ...tieren Radachse 1 6 Montieren Unterlegscheibe 1 Achsmutter 2 T R 45 Nm 4 5 m kg 2 Installer Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tapes et dans un ordre entre crois T R...

Page 350: ...e machine by placing the suitable stand under the engine Drain the brake fluid Refer to REMOVAL POINTS 1 Brake hose holder 2 2 Union bolt 1 3 Brake hose 1 4 Joint 1 5 Brake caliper support bolt 1 6 Br...

Page 351: ...unter AUSBAU 7 Handbremshebel 1 8 Hauptbremszylinder Halterung 1 9 Hauptbremszylinder 1 2 3 1 3 2 FREIN AVANT D poses effectuer 1 D pose du flexible de frein 2 D pose de l trier de frein 3 D pose du m...

Page 352: ...LY Hold the machine by placing the suitable stand under the engine 1 Brake pad 2 2 Brake caliper bracket 1 3 Brake caliper piston 2 Refer to REMOVAL POINTS 4 Brake caliper dust seal 2 Refer to REMOVAL...

Page 353: ...0 Staubschutzkappe 1 A Sicherungsring 1 B Unterlegscheibe 1 C Hauptbremszylinder Bauteile 1 2 1 D MONTAGE DE L TRIER ET DU MA TRE CYLINDRE DE FREIN D poses effectuer 1 D montage de l trier de frein 2...

Page 354: ...Always clean up spilled fluid immediately Brake caliper 1 Remove Brake caliper 1 NOTE Turn the brake caliper counterclockwise and pull out it from the guide pin 2 on the brake caliper bracket Brake c...

Page 355: ...ecken Den Bremssattelkolben vorsichtig mit Druckluft aus dem Bremssattel heraus pressen FREIN AVANT VORDERRADBREMSE PI CES D POSER Liquide de frein 1 D poser Couvercle de ma tre cylindre de frein 1 N...

Page 356: ...seals WARNING Replace the brake caliper piston seals and brake caliper dust seals whenever a brake caliper is disassembled INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surfa...

Page 357: ...der Bauteile erneuern Joints de piston d trier de frein 1 D poser Joint antipoussi re d trier de frein 1 Joint de piston d trier de frein 2 N B Retirer les joints de piston d trier et les joints anti...

Page 358: ...he brake caliper piston seals and brake caliper dust seals 2 whenever a brake caliper is disassembled 3 Inspect Brake caliper bracket 1 Cracks damage Replace the brake caliper assembly Guide pin 2 Rus...

Page 359: ...g Erneuern FREIN AVANT VORDERRADBREMSE trier de frein 1 Examiner Surface int rieure du cylindre d trier de frein a Endommagement striation par usage Remplacer l trier de frein complet 2 Examiner Pisto...

Page 360: ...ake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper dust seal 2 WARNING Always use new brake caliper piston seals and brake caliper dust seals NOTE Fit t...

Page 361: ...sattel Halteschraube 1 Auf Bremssattel Halterung 2 aufset zen FREIN AVANT VORDERRADBREMSE REMONTAGE ET INSTALLATION AVERTISSEMENT Nettoyer les pi ces internes exclusivement avec du liquide de frein pr...

Page 362: ...0 m kg 22 ft lb 4 Install Brake caliper 1 NOTE Apply the lithium soap base grease on the guide pin 2 Install the brake caliper into the guide pin and turn it clockwise 5 Install Brake caliper support...

Page 363: ...Mit Bremsfl ssigkeit reinigen FREIN AVANT VORDERRADBREMSE 2 Installer Manchon sup rieur 1 sur l trier de frein 2 N B Enduire la surface interne du manchon sup rieur de graisse base de savon au lithium...

Page 364: ...cup should be installed as shown direction Wrong instal lation cause improper brake performance 3 Install Spring 1 On brake master cylinder piston 2 NOTE Install the spring at the smaller diameter si...

Page 365: ...i der Montage des Sicherungsrings eine Zange mit langen Backen verwenden FREIN AVANT VORDERRADBREMSE 2 Installer Coupelle primaire de ma tre cylindre de frein 1 Coupelle secondaire de ma tre cylindre...

Page 366: ...pring 2 Bolt brake lever 3 Nut brake lever 4 NOTE Apply the lithium soap base grease on the spring bolt and brake lever sliding surface Apply the molybdenum disulfide grease on the tip of the adjuster...

Page 367: ...AVANT VORDERRADBREMSE Ma tre cylindre de frein 1 Installer Ma tre cylindre de frein 1 Demi palier de fixation de ma tre cylindre de frein 2 Boulon demi palier de fixation de ma tre cylindre de frein 3...

Page 368: ...hose 3 WARNING Always use a new copper washer NOTE When turning the joint over the brake hose hold the brake hose so that it may not be twisted New T R 26 Nm 2 6 m kg 19 ft lb T R 14 Nm 1 4 m kg 10 ft...

Page 369: ...alterung 1 Schrauben Bremsschlauch Halterung 2 T R 7 Nm 0 7 m kg FREIN AVANT VORDERRADBREMSE 2 Faire passer le flexible de frein par le guide de c ble 1 3 Installer Rondelle en cuivre 1 Raccord 2 Flex...

Page 370: ...poor performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock CAUTION Brake...

Page 371: ...ROLLIEREN in KAPI TEL 3 FREIN AVANT VORDERRADBREMSE Liquide de frein 1 Verser Liquide de frein jusqu ce que le niveau du liquide atteigne la ligne LOWER a AVERTISSEMENT Utiliser exclusivement le type...

Page 372: ...rake master cylinder cap 2 CAUTION After installation while pulling in the lever check whether there is any brake fluid leak ing where the union bolts are installed respectively at the brake master cy...

Page 373: ...ssattel Bremsfl ssigkeit austritt T R 2 Nm 0 2 m kg FREIN AVANT VORDERRADBREMSE 4 Installer Diaphragme Couvercle de ma tre cylindre de frein 1 Vis couvercle de ma tre cylindre de frein 2 ATTENTION Apr...

Page 374: ...l REAR WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine 1 Brake rod 1 2 Axle nut 1 3 Drive chain puller right 1 4 Wheel axle 1 5 Drive chain puller left 1 6 Drive c...

Page 375: ...emsankerplatte 1 10 Distanzh lse links 1 2 3 1 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE ROUE ARRI RE ET FREIN ARRI RE D poses effectuer 1 D pose de la roue arri re 2 D pose des roul...

Page 376: ...11 Lock washer 2 12 Wheel sprocket 1 13 Oil seal 1 14 Wheel bearing 2 Refer to REMOVAL POINTS 15 Spacer 1 16 Brake shoe 2 17 Spring 2 18 Brake camshaft lever 1 19 Wear indicator plate 1 20 Brake camsh...

Page 377: ...remsbelag 2 17 Feder 2 18 Bremsnocken Bet tigungshebel 1 19 Verschlei anzeiger 1 20 Bremsnocken 1 21 Bremsankerplatte 1 3 2 D poses effectuer Ordre Nom de pi ce Qt Remarques 11 Rondelle d arr t 2 12 P...

Page 378: ...bearing puller 2 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oi...

Page 379: ...schriftsm ig Erneuern Me uhr 1 verwenden Maximal zul ssige Achsbiegung 0 5 mm PI CES D POSER Roue arri re 1 D poser Roue 1 N B Pousser la roue vers l avant et d poser la cha ne de transmission 2 Roule...

Page 380: ...and paper NOTE After polishing wipe the polished particles with a cloth 2 Measure Brake shoe lining thickness a Out of specification Replace NOTE Replace the brake shoes and springs as a set if either...

Page 381: ...ftsm ig Erneuern Bremstrommel Innendurchmes ser Standard Grenzwert 110 mm 111 mm N B Pour obtenir la d formation il faut diviser en deux la valeur affich e sur le comparateur cadran AVERTISSEMENT Ne p...

Page 382: ...the brake camshaft 2 Check Brake camshaft operation Unsmooth operation Repair 3 Install Wear indicator plate 1 NOTE When installing the wear indicator plate to the brake camshaft align the projection...

Page 383: ...kenwelle und Punkt a 46 5 betr gt T R 10 Nm 1 0 m kg ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 4 Examiner Surface int rieure du tambour de frein Taches d huile rayures liminer REMONT...

Page 384: ...e brake shoe lin ings New Rear wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 NOTE Apply the lithium soap base grease on the oil seal lip when installing Install the bearing with...

Page 385: ...FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 5 Installer Ressorts 1 M choires de frein 2 sur le flasque de frein 3 N B Enduire la goupille pivot de graisse base de savon au lithium Bien veiller ne pas...

Page 386: ...ssembly Collar right NOTE Apply the lithium soap base grease on the oil seal lip 4 Install Rear wheel NOTE Make sure that the slot a on the brake shoe plate with the stopper b on the swingarm 5 Instal...

Page 387: ...en Seite aus montie ren ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 2 Installer Pignon de roue arri re 1 Rondelles d arr t 2 N B Serrer les crous par tapes et dans un ordre entrecrois...

Page 388: ...int 8 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 35 60 mm 1 4 2 4 in 9 Tighten Axle nut 1 T R 60 Nm 6 0 m kg 43 ft lb 10 Install Sprin...

Page 389: ...HINTERRADBREMSE EINSTELLEN in KAPITEL 3 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 7 Installer Tendeur de cha ne de transmission droit 1 Rondelle plate 2 crou d axe 3 N B Serrer l cr...

Page 390: ...machine by placing the suitable stand under the engine Front wheel Refer to FRONT WHEEL section Handlebar Refer to HANDLEBAR section 1 Cap 1 2 Pinch bolt upper bracket 1 Only loosening 3 Cap bolt 1 L...

Page 391: ...kopgabel zerlegt wird 4 Klemmschraube untere Gabelbr cke 1 Nur lockern 5 Teleskopgabel 1 1 FOURCHE AVANT TELESKOPGABEL FOURCHE AVANT D poses effectuer 1 D pose de la fourche avant D poses effectuer Or...

Page 392: ...name Q ty Remarks FRONT FORK DISASSEMBLY 1 Dust boot 1 2 Cap bolt 1 Refer to REMOVAL POINTS 3 Spacer 1 4 Washer 1 5 Fork spring 1 Drain the fork oil 6 Dust seal 1 Use special tool Refer to REMOVAL POI...

Page 393: ...1 B Metallh lse 1 C Dichtring 1 D Tauchrohr 1 2 1 FOURCHE AVANT TELESKOPGABEL D MONTAGE DE LA FOURCHE AVANT D poses effectuer 1 D pose de la bague d tanch it 2 D pose de la tige d amortisseur D poses...

Page 394: ...n material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled EC553000 REMOVAL POINTS Cap bolt 1 Remove Cap bo...

Page 395: ...mpferrohrbuchse Dichtring HINWEIS Den D mpferrohr Halter 1 und den T Hand griff 2 zum L sen der D mpferrohr Schraube verwenden FOURCHE AVANT TELESKOPGABEL REMARQUE CONCERNANT LA MANIPULATION N B Les t...

Page 396: ...ace damper rod CAUTION The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any forei...

Page 397: ...FOURCHE AVANT TELESKOPGABEL Outil de maintien de tige d amortis seur YM 01300 90890 01294 Manche en T YM 01326 90890 01326 3 D poser Bague d tanch it 1 Se servir d un tournevis t te plate ATTENTION Ve...

Page 398: ...ge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube 2 Inspect Piston metal 1 Wear...

Page 399: ...lei Besch digung Erneuern FOURCHE AVANT TELESKOPGABEL Tube plongeur 1 Examiner Surface du tube plongeur a Striation par usage R parer ou rempla cer Utiliser du papier de verre humide d un grain de 1 0...

Page 400: ...per rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it and be damaged 3 Install Inner tube On outer tube 4 Install Copper washer Bo...

Page 401: ...Handgriff YM 01326 90890 01326 New T R 23 Nm 2 3 m kg LT FOURCHE AVANT TELESKOPGABEL REMONTAGE ET INSTALLATION Fourche avant 1 Nettoyer toutes les pi ces dans du dissolvant propre 2 Installer Bague co...

Page 402: ...he oil seal into the outer tube with fork seal driver attachment 30 2 and fork seal driver weight 3 Fork seal driver weight YM 33963 90890 01367 Fork seal driver attachment 30 YM 33281 90890 01400 New...

Page 403: ...ESKOPGABEL 5 Installer Bague d tanch it 1 N B Enduire le tube plongeur d huile de fourche Pour installer la bague d tanch it sans ab mer les l vres de la bague d tanch it se servir d une toile en plas...

Page 404: ...mended oil Fork oil 10W or equivalent Quantity each front fork leg 156 cm3 5 49 Imp oz 5 27 US oz 11 After filling pump the inner tube slowly up and down more than 10 times to dis tribute the fork oil...

Page 405: ...Staubmanschette HINWEIS Verschlu schraube vorl ufig festziehen FOURCHE AVANT TELESKOPGABEL 9 Comprimer fond la fourche avant 10 Verser Huile de fourche avant 1 ATTENTION Utiliser sans faute le type d...

Page 406: ...rk top end a Front fork top end standard a Zero mm Zero in T R 23 Nm 2 3 m kg 17 ft lb 4 Tighten Pinch bolt lower bracket 1 Pinch bolt upper bracket 2 Screw dust boot 3 NOTE Make sure that the dust bo...

Page 407: ...R 60 Nm 6 0 m kg T R 25 Nm 2 5 m kg 5 Montieren Schutzkappe 1 FOURCHE AVANT TELESKOPGABEL Installation 1 Installer Fourche avant N B Serrer le boulon de pincement du t inf rieur de quelques tours Ne...

Page 408: ...oval Order Part name Q ty Remarks Preparation for removal HANDLEBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Brake master cylinder 1 Refer to REMOVAL POINTS 5 Gr...

Page 409: ...halterung Unterteil 1 6 Griffhalterung Oberteil 1 7 Gaszug 1 8 Gasdrehgriff 1 1 GUIDON LENKER GUIDON D poses effectuer 1 D pose du guidon D poses effectuer Ordre Nom de pi ce Qt Remarques Pr paration...

Page 410: ...5 35 CHAS HANDLEBAR Extent of removal Order Part name Q ty Remarks 9 Collar 1 10 Handlebar grip left 1 Refer to REMOVAL POINTS 11 Upper handlebar holder 2 12 Handlebar 1 1...

Page 411: ...e 1 10 Lenkergriff links 1 Siehe unter DEMONTAGEPUNKTE 11 Lenkerhalter 2 12 Lenker 1 1 GUIDON LENKER D poses effectuer Ordre Nom de pi ce Qt Remarques 9 Entretoise paul e 1 10 Poign e de guidon gauche...

Page 412: ...ASSEMBLY DISASSEMBLY Extent of removal 1 Throttle grip assembly disassembly Extent of removal Order Part name Q ty Remarks THROTTLE GRIP ASSEMBLY DISASSEMBLY 1 Handlebar grip right 1 Refer to REMOVAL...

Page 413: ...N E DES GAZ 1 Poign e de guidon droite 1 Se reporter L MENTS D POSER 2 Entretoise paul e 2 3 Tube de commande des gaz 1 1 GASDREHGRIFF ZERLEGEN Demontage Arbeiten 1 Gasdrehgriff zerlegen Demontage Arb...

Page 414: ...aster cylinder cap side horizontal to prevent air from coming in Handlebar grip 1 Remove Handlebar grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which h...

Page 415: ...ker zu richten weil dadurch seine Stabilit t verloren geht GUIDON LENKER PI CES D POSER Ma tre cylindre de frein 1 D poser Demi palier de fixation de ma tre cylindre de frein 1 Ma tre cylindre de frei...

Page 416: ...a lac quer thinner Handlebar 1 Install Handlebar 1 Handlebar holder 2 Bolt handlebar holder 3 NOTE Align the punched mark a on the handlebar with the upper surface of the handlebar holder on the upper...

Page 417: ...en und dann die hinteren Schrauben festziehen T R 23 Nm 2 3 m kg GUIDON LENKER REMONTAGE ET INSTALLATION Poign e des gaz compl te 1 Installer Entretoise paul e 1 Poign e de guidon droite 2 Enduire le...

Page 418: ...pper 2 Throttle cables 3 On tube guide 4 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 5 Install Throttle cable cap 1 Screw throttle cable cap...

Page 419: ...kg T R 4 Nm 0 4 m kg GUIDON LENKER 2 Installer Poign e de guidon gauche 1 Enduire le guidon 2 d adh sif N B Avant d enduire le guidon a d adh sif nettoyer tout r sidu de graisse ou d huile avec du dil...

Page 420: ...9 Nm 0 9 m kg 6 5 ft lb 7 Install Engine stop switch 1 Clutch lever holder 2 Bolts clutch lever holder 3 NOTE The engine stop switch and clutch lever holder should be installed according to the dimens...

Page 421: ...LENKER 6 Installer Ma tre cylindre de frein 1 Demi palier de fixation de ma tre cylindre de frein 2 Boulon demi palier de fixation de ma tre cylindre de frein 3 N B Monter le support de sorte que la f...

Page 422: ...lacing the suitable stand under the engine Front forks Refer to FRONT FORK section Handlebar Refer to HANDLEBAR section Front fender 1 Steering stem nut 1 2 Upper bracket 1 3 Special washer 1 4 Upper...

Page 423: ...Ringmutter unten 1 7 Untere Gabelbr cke 1 8 Lager Schutzkappe 1 1 2 DIRECTION LENKUNG DIRECTION D poses effectuer 1 D pose du t inf rieur 2 D pose de la tige d amortisseur ETAPES DE SERRAGE Serrer l...

Page 424: ...tent of removal Order Part name Q ty Remarks 9 Bearing inner race upper 1 10 Bearing upper 1 11 Bearing outer race upper 1 Refer to REMOVAL POINTS 12 Bearing outer race lower 1 13 Bearing lower 1 Refe...

Page 425: ...UNKTE 12 u erer Lager Laufring unten 1 13 Lager unten 1 Siehe unter DEMONTAGEPUNKTE 2 DIRECTION LENKUNG D poses effectuer Ordre Nom de pi ce Qt Remarques 9 Cage interne haut de roulement 1 10 Roulemen...

Page 426: ...l down Ring nut wrench YU 33975 90890 01403 Bearing race 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor c...

Page 427: ...Lenkschaft 1 Verbiegung Besch digung Erneu ern DIRECTION LENKUNG PI CES D POSER crou cr nel 1 D poser crou cr nel 1 Utiliser la cl pour crous cr nel s 2 AVERTISSEMENT Soutenir la colonne de direction...

Page 428: ...are not smooth in their operation in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Bearing lower 1 NOTE Apply the lithium soa...

Page 429: ...Dichtlippe der Lager Schutzkappe auftragen DIRECTION LENKUNG Billes et cages du roulement 1 Nettoyer les billes et les cages du roulement dans du dissolvant 2 Examiner Billes de roulement Cages de rou...

Page 430: ...HEAD INSPEC TION AND ADJUSTMENT section in the CHAPTER 3 6 Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering beari...

Page 431: ...der oberen Gabel br cke noch nicht festziehen DIRECTION LENKUNG 4 Installer T inf rieur 1 N B Enduire le roulement de graisse base de savon au lithium 5 Installer crou cr nel inf rieur 1 Rondelle en c...

Page 432: ...ovement If not adjust the steering by loosening the ring nut little by little T R 110 Nm 11 0 m kg 80 ft lb 12 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in 13 Tighten Pinc...

Page 433: ...elbr cke 1 Klemmschrauben obere Gabelbr cke 2 T R 60 Nm 6 0 m kg T R 25 Nm 2 5 m kg DIRECTION LENKUNG 9 Serrer crou de colonne de direction 1 10 Installer Capuchon 2 11 Apr s avoir serr l crou contr l...

Page 434: ...machine by placing the suitable stand under the engine Rear wheel Refer to REAR WHEEL AND REAR BRAKE section 1 Drive chain tensioner upper 1 2 Drive chain tensioner lower 1 3 Bolt connecting arm fram...

Page 435: ...tisseur arri re bascu leur 1 Maintenir le bras oscillant 5 Axe 1 6 Bras oscillant 1 1 SCHWINGE Demontage Arbeiten 1 Schwinge demontieren Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen Vorbere...

Page 436: ...y 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Drive chain guard 1 2 Drive chain support 1 3 Drive chain guide 1 4 Dust cover 4 5 Collar 1...

Page 437: ...z 2 C Gleitbuchse 1 D Schwinge 1 3 1 2 BRAS OSCILLANT SCHWINGE D MONTAGE DU BRAS OSCILLANT D poses effectuer 1 D montage du bras oscillant 2 D pose et d montage du bras de raccordement 3 D pose et d m...

Page 438: ...gs as a set 2 Inspect Dust cover Damage Replace 3 Inspect Swingarm Damage bends cracks Replace Relay arm 1 Inspect Collar 1 Bushing 2 Damage pitting Replace collar and bushing as a set Bushing 3 Bushi...

Page 439: ...fen Dichtring 8 Staubschutz 9 Besch digung Erneuern 3 Pr fen Umlenkhebel 0 Besch digung Verbiegung Kratzer Erneuern BRAS OSCILLANT SCHWINGE PI CES D POSER Bague 1 D poser Bague 1 N B Retirer la bague...

Page 440: ...ng arm 4 Damage bends cracks Replace EC575000 ASSEMBLY AND INSTALLATION Bushing 1 Install Bushing NOTE Make sure to press in the bushing so that they are flush with the surface of the connecting arm a...

Page 441: ...Schwinge HINWEIS Lagerbuchsen und Dichtlippen der Staub schutzabdeckungen mit Molybd ndisulfid bestreichen BRAS OSCILLANT SCHWINGE Bras de raccordement 1 Examiner Entretoise paul e 1 Bague 2 Endommage...

Page 442: ...g arm NOTE Apply the molybdenum disulfide grease on the collar and dust cover lip 4 Install Relay arm 1 Bolt relay arm Plain washer Nut relay arm On swingarm NOTE Apply the molybdenum disulfide grease...

Page 443: ...estreichen T R 53 Nm 5 3 m kg T R 35 Nm 3 5 m kg BRAS OSCILLANT SCHWINGE 2 Installer Bagues d tanch it 1 Entretoises paul es 2 Bague 3 Caches antipoussi re 4 Caches antipoussi re 5 Manchon en caoutcho...

Page 444: ...Swingarm Pivot shaft 1 Plain washer Nut pivot shaft NOTE Apply the molybdenum disulfide grease on the pivot shaft 2 Check Swingarm side play a Free play exists Replace bushing Swingarm up and down mov...

Page 445: ...auftragen T R 35 Nm 3 5 m kg BRAS OSCILLANT SCHWINGE 6 Installer Patin de cha ne de transmission 1 Entretoises paul es Boulons patin de cha ne de transmission 2 T R 7 Nm 0 7 m kg 5 1 ft lb 7 Installe...

Page 446: ...arm frame T R 35 Nm 3 5 m kg 25 ft lb 5 Install Drive chain tensioner lower 1 Collar Bolt drive chain tensioner lower T R 7 Nm 0 7 m kg 5 1 ft lb 6 Install Bushing 1 Drive chain tensioner upper 2 Pla...

Page 447: ...Lithiumfett bestreichen T R 23 Nm 2 3 m kg BRAS OSCILLANT SCHWINGE 4 Installer Boulon bras de raccordement cadre 1 Rondelle plate crou bras de raccordement cadre N B Enduire le boulon bras de raccord...

Page 448: ...SORBER ASSEMBLY REMOVAL Hold the machine by placing the suitable stand under the engine Seat and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt rear shock absorber assem bly relay...

Page 449: ...unten DEMONTAGEPUNKTE 4 Hinterrad Sto d mpfer 1 1 COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER COMBIN RESSORT AMORTISSEUR ARRI RE D poses effectuer 1 D pose du combin ressort amortisseur...

Page 450: ...result of nitrogen gas expansion and or damage to the hose 3 Be careful not to damage any part of the rear shock absorber A damaged rear shock absorber will impair the damping performance or cause a m...

Page 451: ...schutz tragen um Augensch den durch austretendes Gas oder Metallsp ne zu vermeiden COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMARQUE CONCERNANT LA MANIPULATION AVERTISSEMENT Cet amort...

Page 452: ...rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear shock absorber assembly Gas leaks Replace rear shock absorber assembly Spring 3 Damage Replace rear shock absorber assembly Fatigue...

Page 453: ...IS Lagerbuchse hineinpressen COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER PI CES D POSER Bague 1 D poser Bague 1 N B Retirer la bague en la poussant CONTR LE Combin ressort amortisseur ar...

Page 454: ...asher 1 Nut rear shock absorber assembly frame 2 NOTE Apply the molybdenum disulfide grease on the bolt rear shock absorber assembly frame T R 53 Nm 5 3 m kg 38 ft lb 3 Install Bolt rear shock absorbe...

Page 455: ...kg COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER Installation 1 Installer Combin ressort amortisseur arri re sur le cadre N B Monter le combin ressort amortisseur arri re en veillant ce qu...

Page 456: ...AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 CDI unit 2 Engine stop switch 3 Ignition coil 4 CDI magneto 5 Spark plug COLOR CODE B Black Br Brown G Green O Orange R Red W White B R Black Red B...

Page 457: ...G gr n O orange R rot W wei B R schwarz rot B W schwarz wei G L gr n blau G W gr n wei W L wei blau W R wei rot SCHALTPLAN PARTIE LECTRIQUE QUIPEMENT LECTRIQUE ET SCH MA DE C BLAGE COMPOSANTS LECTRIQU...

Page 458: ...e inspection 1 Seat 2 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...

Page 459: ...ffectuer le contr le l aide des outils sp ciaux Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler toutes connexions du syst me d allumage R parer ou remplacer Contr ler coupe circu...

Page 460: ...e Pr fung verwenden Z ndfunke testen Z ndkerze reinigen oder erneuern Gesamte Z ndanlage auf Durchgang pr fen Reparieren oder Erneuern Motorstoppschalter pr fen Erneuern Z ndspule pr fen Prim rwick lu...

Page 461: ...ELEC MEMO...

Page 462: ...ne 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 dust l...

Page 463: ...bel schwarz 2 B W 1 B 2 Pr fger t Position HINEIN DR C KEN 1 LOS LASSEN TEST DE LA LONGUEUR D TINCELLE 1 D connecter le capuchon de bougie 2 Brancher un testeur d tincelle dynamique 1 testeur d alluma...

Page 464: ...ack lead 2 Primary coil resistance Tester selector position 0 18 0 28 at 20 C 68 F 1 2 Inspect Secondary coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis tanc...

Page 465: ...lec teur du multim tre 0 18 0 28 20 C 68 F 1 6 4 2 Examiner R sistance de l enroulement secondaire Hors sp cifications Remplacer N B D poser le capuchon de bougie avant de mesurer la r sistance de l...

Page 466: ...ter selector position 248 372 at 20 C 68 F 100 2 Inspect Charging coil resistance Out of specification Replace Tester lead Brown lead 1 Tester lead Green lead 2 Charging coil resistance Tester selecto...

Page 467: ...ie end elektrische Bauteile erneut pr fen CONTR LE DE LA MAGN TO CDI 1 Examiner R sistance de la bobine d excitation Hors sp cifications Remplacer Fil de multim tre fil rouge 1 Fil du multim tre fil b...

Page 468: ...PRINTED IN JAPAN 00 1 2 1 1 CR PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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