Yamaha TTR90(M) Owner'S Service Manual Download

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INSP

ADJ

CHASSIS/FRONT BRAKE ADJUSTMENT/

REAR BRAKE ADJUSTMENT

T304002

CHASSIS

FRONT BRAKE ADJUSTMENT

1. Check:

●

Brake lever free play

Out of specification

→

Adjust.

Free play (brake lever):

10 ~ 20 mm (0.39 ~ 0.79 in)
(at brake lever end)

2. Adjust:

●

Brake lever free play

REAR BRAKE ADJUSTMENT

1. Check:

●

Brake pedal free play

Out of specification

→

Adjust.

2. Adjust:

●

Brake pedal free play

Adjustment steps:

●

Loosen the locknut

●

Turn the adjusters

in or out until the

specified free play is obtained.

Turning in:

Free play is increased.

Turning out:

Free play is decreased.

Free play:

10 ~ 20 mm (0.39 ~ 0.79 in)

Adjustment steps:

●

Turn the adjuster

in or out until the

specified free play is obtained.

Turning in:

Free play is decreased.

Turning out:

Free play is increased.

CAUTION:

Make sure that there is no brake drag
after adjusting the front brake lever free
play.

CAUTION:

Make sure that the brake does not drag
after adjusting it.

Summary of Contents for TTR90(M)

Page 1: ...5HN 28199 80 TTR90 M OWNER S SERVICE MANUAL MANUEL D ATELIER ET DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH...

Page 2: ...ER S SERVICE MANUAL 1999 by Yamaha Motor Co Ltd 1st Edition July 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibit...

Page 3: ...uch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TTR90 M MANUEL D ATELIER ET DU PROPRIETAIRE 1999 Yamaha Motor Co Ltd 1re dition juillet 199...

Page 4: ...out dated If you have any questions please con sult your Yamaha dealer WARNING READ THIS MANUAL CAREFULLY FOR INSTRUCTIONS ON HOW TO PROPERLY OPERATE THIS MACHINE ADULT INSTRUCTION AND SUPERVI SION A...

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

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 any...

Page 7: ...tergrund 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 sous...

Page 8: ...k out of the carburetor 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 withi...

Page 9: ...n Helm und spe zielle Motorradbekleidung Handschuhe Stiefel Hosen und Jacken tragen 4 Lors du transport de l engin dans un autre v hicule veiller le garder bien droit et ce que le robinet de carburant...

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

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

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

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

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

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

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

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

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

Page 19: ...LOCTITE K Erneuern SYMBOLES GRAPHIQUES Voir l illustration Les symboles graphiques 1 6 servent rep rer les diff rents chapitres et indiquer leur contenu 1 Renseignements g n raux 2 Caract ristiques 3...

Page 20: ...EB004000 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENT ENGINE CHASSIS ELECTRICAL...

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

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

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

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

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

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

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

Page 28: ...ine 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 ste...

Page 29: ...num ros afin de faciliter son identifica tion NUMERO D IDENTIFICATION DU VEHICULE Le num ro d identification du v hicule 1 est frapp au c t droit du tube de t te de fourche 1 2 MOTOR IDENTIFIZIERUNGS...

Page 30: ...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 31: ...gigen und korrekten Zusammenbau 5 Alle Teile von offenem Feuer fernhalten ERSATZTEILE 1 Nur Original Ersatzteile von Yamaha ver wenden Nur von Yamaha empfohlene Schmierstoffe verwenden Fremdfabrika te...

Page 32: ...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 33: ...ET BAGUES D ETANCHEITE 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...

Page 34: ...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 35: ...Taschen Multimeter auf Durchgang pr fen HINWEIS Ist der Durchgang nicht widerstandsfrei die Anschlu klemmen reinigen Bei der berpr fung von Kabelb umen stets die Schritte 1 bis 7 durchf hren Zur schne...

Page 36: ...sed when removing or installing the rocker arm shafts YU 1083 A 90890 01084 90890 01085 YU 01268 90890 01268 Ring nut wrench This tool is used when loosen the steering ring nut to specification YU 012...

Page 37: ...YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 90890 06754 YM 33975 90890 01403 Ring nut wrench This tool...

Page 38: ...8 SPECIAL TOOLS ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC QUICK GS KT 90890 85505 Part number Tool name How to use Il...

Page 39: ...s permettent de d poser et de remonter les axes de culbuteur YU 1083 A 90890 01084 90890 01085 YU 01268 90890 01268 Cl pour crou annulaire Cet outil est utilis pour desserrer l crou de bague de direct...

Page 40: ...eur d tincelle dynamique Contr leur d allumage Ce testeur est n cessaire pour contr ler les composants du syst me d allumage YM 34487 90890 06754 YM 33975 90890 01403 Cl pour crou annulaire Cet outil...

Page 41: ...X ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA bond No 1215 Cet agent d tanch it p te est utilis sur les plans de joint du carter etc ACC QUICK GS KT 90890 85505 Num ros de pi ce Nom et usage de l...

Page 42: ...reib Set Gewicht Kipphebelwellen Ausbauwerkzeug Zum Montieren oder Demontieren der Kipphebelwel len YU 1083 A 90890 01084 90890 01085 YU 01268 90890 01268 Hakenschl ssel Zum L sen der Lenkkopf Ringmut...

Page 43: ...m Einbau der Gabeldichtringe YM 33963 90890 01184 YM 34487 90890 06754 Z ndfunkenstreckentester Zur berpr fung der Z ndanlage YM 34487 90890 06754 YM 33975 90890 01403 Hakenschl ssel Zum Festziehen de...

Page 44: ...INFO SPEZIALWERKZEUGE ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Dichtmasse Nr 1215 Zum Abdichten der Kurbelgeh use Pa fl chen ACC QUICK GS KT 90890 85505 Teilenummer Werkzeug Anwendung Abbildung...

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

Page 46: ...e shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER WARNING Before starting the engine be sure to shift the transmission into neutral Rotate the kick starter 1 aw...

Page 47: ...das Getriebe in der Leerlauf stellung befindet Zum Anlassen des Motors den Kickstarter hebel 1 ausschwenken und langsam nieder treten bis deutlicher Widerstand sp rbar wird dann den Kickstarterhebel s...

Page 48: ...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 position RES This indicates reserve If you run out of fuel w...

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

Page 50: ...s use fresh name brand gasoline WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bottom of the filler tube 1 as shown in the illustration...

Page 51: ...IN Tankvolumen Gesamtinhalt 4 1 L Davon Reserve 0 5 L BOUCHON DE RESERVOIR DE CARBURANT Retirer le bouchon de r servoir de carburant 1 en le tournant dans le sens inverse des aiguilles d une montre AV...

Page 52: ...he engine is warm see if it responds to throttle normally with the stater choke turned off WARNING Before starting off be sure to turn up or remove the side stand Failure to retract the side stand com...

Page 53: ...le starter tant ferm AVERTISSEMENT Avant de d marrer bien veiller relever ou retirer la b quille lat rale Une b quille mal relev e risque d tre la cause d un accident grave dans les virages RODAGE 1...

Page 54: ...spricht WARNUNG Vor dem Losfahren sicherstellen da der Seitenst nder hochgeklappt ist Ein ausgeklappter Seitenst nder kann in Kurven schwere St rze verursachen EINFAHRVORSCHRIFTEN 1 Tank vor dem Start...

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

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

Page 57: ...uction system Chain drive Secondary reduction ratio 35 14 2 500 Transmission type Constant mesh 3 speed Operation Left foot operation Gear ratio 1st 37 13 2 846 2nd 33 19 1 736 3rd 28 23 1 217 Chassis...

Page 58: ...t shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 100 mm 4 33 in Rear wheel travel 93 mm 3 66 in Electrical Ignition system CDI mag...

Page 59: ...shaft Drive method Chain drive left Cam dimensions Intake A 25 428 25 528 mm 1 0011 1 0050 in 25 4 mm 1 00 in B 21 034 21 134 mm 0 8281 0 8320 in 21 0 mm 0 83 in C 4 328 4 628 mm 0 1704 0 1822 in Exha...

Page 60: ...0469 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 06 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 06 in D margin thickness IN 0 5 0 9 mm 0 0197 0 354 i...

Page 61: ...n 26 9 mm 1 06 in EX 28 32 mm 1 11 in 26 9 mm 1 06 in Set length valve closed IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Compressed pressure installed IN 90 4 104 1 N 9 2 10 6 kg 20 32 23 40 lb EX 90 4 104...

Page 62: ...mm 0 511 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 0 mm 0 04 0 08 in End gap installed 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Side clearance installed 0 030 0 065 mm 0 0012 0 002...

Page 63: ...od Inner push cam push Push rod bending limit 0 5 mm 0 02 in Automatic centrifugal clutch Clutch in revolution 2 000 2 400 r min Clutch stall revolution 3 100 3 700 r min Shifter Shifter type Cam drum...

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

Page 65: ...etor joint cylinder head side M6 1 0 2 7 0 7 5 1 Carburetor joint carburetor side M6 1 0 2 7 0 7 5 1 Air filter case M6 1 0 2 7 0 7 5 1 Exhaust pipe M6 1 0 2 7 0 7 5 1 Exhaust pipe M5 0 8 2 4 0 4 2 9...

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

Page 67: ...1 5 mm 0 06 in Rear lining thickness 4 mm 0 16 in 1 5 mm 0 06 in Front shoe spring free length 32 7 mm 1 29 in Rear shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever fre...

Page 68: ...t fork cap bolt M20 1 0 2 40 4 0 29 Handle crown and handlebar holder lower M10 1 25 2 40 4 0 29 Handlebar holder upper M6 1 0 4 13 1 3 9 4 Front brake cable holder and front fork M6 1 0 2 7 0 7 5 1 S...

Page 69: ...color 688 1 032 at 20 C 68 F Brown Green Pickup coil resistance color 248 372 at 20 C 68 F Red White CDI unit model manufacturer 4GL YAMAHA Ignition coil Model manufacturer 2JN YAMAHA Minimum spark ga...

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

Page 71: ...teur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l avant Cylindr e 89 cm3 5 43 cu in Al sage course 47 0 51 8 mm 1 85 2 04 in Taux de c...

Page 72: ...722 Syst me de r duction secondaire Entra nement par cha ne Taux de r duction secondaire 35 14 2 500 Type de bo te de vitesses Prise constante 3 rapports Commande Pied gauche D multiplication 1re 37 1...

Page 73: ...essort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydraulique D battement de roue D battement de roue avant 100 mm 4 33 in D battement de roue ar...

Page 74: ...001 in Arbre cames M thode d entra nement Transmission par cha ne c t gauche Dimensions de came Admission A 25 428 25 528 mm 1 0011 1 0050 in 25 4 mm 1 00 in B 21 034 21 134 mm 0 8281 0 8320 in 21 0 m...

Page 75: ...835 0 7913 in B largeur de face AD 1 19 2 51 mm 0 0469 0 0989 in ECH 1 49 3 07 mm 0 0587 0 1209 in C largeur de si ge AD 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 06 in ECH 0 9 1 1 mm 0 0354 0 0433 in 1 6...

Page 76: ...6 9 mm 1 06 in ECH 28 32 mm 1 11 in 26 9 mm 1 06 in Longueur mont soupape ferm e AD 24 2 mm 0 95 in ECH 24 2 mm 0 95 in Pression la compression install AD 90 4 104 1 N 9 2 10 6 kg 20 32 23 40 lb ECH 9...

Page 77: ...8 mm 0 511 in Segments Segment de feu Type Cylindrique Dimensions B T 1 0 2 0 mm 0 04 0 08 in Ecartement des becs segment mont 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Jeu lat ral mont 0 030 0 065...

Page 78: ...came Limite de d formation de la tige de commande 0 5 mm 0 02 in Embrayage centrifuge automatique Vitesse d engagement de l embrayage 2 000 2 400 tr mn Vitesse de lib ration de l embrayage 3 100 3 70...

Page 79: ...lis m tallique Type de pompe huile Trocho dale Jeu en bout A ou B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Jeu de lubrification entre le logement...

Page 80: ...1 5 1 20 2 0 14 Raccord de carburateur c t culasse M6 1 0 2 7 0 7 5 1 Raccord de carburateur c t carburateur M6 1 0 2 7 0 7 5 1 Bo tier de filtre air M6 1 0 2 7 0 7 5 1 Tuyau d chappement M6 1 0 2 7 0...

Page 81: ...15W ou huile quiva lente Suspension arri re D battement d amortisseur 48 mm 1 89 in Longueur libre de ressort 169 mm 6 65 in Longueur mont 165 mm 6 5 in Constante standard de ressort K 45 6 N mm 4 6...

Page 82: ...ure frein avant 3 mm 0 12 in 1 5 mm 0 06 in Epaisseur de la garniture frein arri re 4 mm 0 16 in 1 5 mm 0 06 in Longueur libre de ressort de m choire de frein avant 32 7 mm 1 29 in Longueur libre de r...

Page 83: ...ourche M20 1 0 2 40 4 0 29 T sup rieur et demi palier de guidon inf rieur M10 1 25 2 40 4 0 29 Demi palier de guidon sup rieur M6 1 0 4 13 1 3 9 4 Support de c ble de frein avant et fourche avant M6 1...

Page 84: ...e de la bobine d alimentation couleur 688 1 032 20 C 68 F brun vert R sistance de la bobine d excitation couleur 248 372 20 C 68 F rouge blanc Bloc CDI mod le fabricant 4GL YAMAHA Bobine d allumage Mo...

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

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

Page 87: ...rieb Sekund r bersetzung 35 14 2 500 Getriebe klauengeschaltetes 3 Gang Getriebe Schaltung Fu schalthebel links Untersetzungsverh ltnis 1 Gang 37 13 2 846 2 Gang 33 19 1 736 3 Gang 28 23 1 217 Fahrwer...

Page 88: ...C Federelemente vorn Hydraulisch ged mpfte Teleskopgabel mit Spi ralfeder hinten Federbein mit gasdruckunterst tztem Sto d mpfer und Spiralfeder Federweg vorn 100 mm hinten 93 mm Elektrische Anlage Z...

Page 89: ...r Bohrungsdurchmesser 47 000 47 005 mm 47 05 mm Max Ovalit t 0 03 mm Nockenwelle Antrieb Steuerkette links Nockenabmessungen Einla A 25 428 25 528 mm 25 4 mm B 21 034 21 134 mm 21 0 mm C 4 328 4 628 m...

Page 90: ...ite B Einla 1 19 2 51 mm Ausla 1 49 3 07 mm Ventilsitzbreite C Einla 0 9 1 1 mm 1 6 mm Ausla 0 9 1 1 mm 1 6 mm Ventiltellerst rke D Einla 0 5 0 9 mm Ausla 0 8 1 2 mm Ventilschaftdurchmesser Einla 4 47...

Page 91: ...a 28 32 mm 26 9 mm Ausla 28 32 mm 26 9 mm Einbaul nge Ventil geschlossen Einla 24 2 mm Ausla 24 2 mm Federdruck eingebaut Einla 90 4 104 1 N 9 2 10 6 kg Ausla 90 4 104 1 N 9 2 10 6 kg Rechtwinkligkeit...

Page 92: ...2 98 mm Kolbenringe 1 Kompressionsring Topring Ausf hrung abgerundet Abmessungen B T 1 0 2 0 mm Sto spiel eingebaut 0 10 0 25 mm 0 4 mm Ringnutspiel eingebaut 0 030 0 065 mm 0 12 mm 2 Kompressionsring...

Page 93: ...he Fliehkraftkupplung Kupplung greift bei 2 000 2 400 U min Bei bet tigter Bremse stirbt Motor bei 3 100 3 700 U min Schaltung Schaltmechanismus Schaltwalze F hrungsstange Kickstarter Bauart Rastenmec...

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

Page 95: ...20 2 0 Vergaseranschlu zylinderseitig M6 1 0 2 7 0 7 Vergaserverbindung vergaserseitig M6 1 0 2 7 0 7 Luftfiltergeh use M6 1 0 2 7 0 7 Kr mmer M6 1 0 2 7 0 7 Kr mmer M5 0 8 2 4 0 4 Kr mmerschutz M6 1...

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

Page 97: ...110 mm 111 mm Bremsbelagst rke vorn 3 mm 1 5 mm Bremsbelagst rke hinten 4 mm 1 5 mm Bremsbacken R ckholfeder vorn ungespannte L nge 32 7 mm Bremsbacken R ckholfeder hinten ungespannte L nge 50 5 mm H...

Page 98: ...Abdeckschraube M20 1 0 2 40 4 0 Obere Gabelbr cke und Lenkerhalterung unten M10 1 25 2 40 4 0 Lenkerhalterung oben M6 1 0 4 13 1 3 Vorderradbremszug Halter und Teleskopgabel M6 1 0 2 7 0 7 Ringmutter...

Page 99: ...er F5HN YAMAHA Widerstand Farbe der Erregerspule 688 1 032 bei 20 C braun gr n Impulsgeber Widerstand Farbe 248 372 bei 20 C rot wei CDI Z ndbox Typ Hersteller 4GL YAMAHA Z ndspule Typ Hersteller 2JN...

Page 100: ...ht sind Falls nicht an ders angegeben gelten die genannten Anzugsmomente f r saubere und trockene Schraubverbindungen bei Raumtemperatur A Mutter B Schrau be ALLGEMEINE ANZUGSMOMENTE Nm m kg 10 mm 12...

Page 101: ...SPEC MEMO...

Page 102: ...lead 8 Throttle cable 9 Fuel tank breather hose 0 Cable holder A Brake cable After fastening the starter cable CDI magneto lead and ignition coil lead cut off any excess from the plastic locking tie e...

Page 103: ...Kabelbindern befestigen Bremszug durch Kabelf hrungen leiten CHEMINEMENT DES CABLES 1 Reniflard de carter 2 Faisceau de fils 3 Fil de magn to CDI 4 C ble de starter 5 Fil de coupe circuit du moteur 6...

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

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

Page 106: ...se through the hose guide Fasten the CDI unit lead and rectifier regulator lead with the plastic clamp Fasten the engine stop switch lead with the plas tic locking tie Pass the CDI unit lead through t...

Page 107: ...oppschalter Kabel mit Kabelbinder befestigen Z ndbox Kabel durch Kabelf hrung leiten Faire passer le c ble des gaz et le fil de coupe circuit du moteur par le guide de c ble Faire passer le flexible d...

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

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

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

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

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

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

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

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

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

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

Page 118: ...evel 3 Remove Dipstick 1 4 Inspect Oil level Oil level should be between maximum a and minimum b marks Oil level is low Add oil to proper level NOTE When inspecting the oil level do not screw the oil...

Page 119: ...SF Unter 5 C Yamalube 4 20W40 oder Motor l SAE 20W40 Klasse SE SF CONTROLE DU NIVEAU D HUILE MOTEUR 1 Placer la motocyclette sur une surface de niveau N B S assurer de placer la motocyclette la verti...

Page 120: ...more than 10 seconds while keeping the motorcycle upright Then stop the engine and add the oil to the maximum level 7 Install Dipstick ENGINE OIL REPLACEMENT 1 Start the engine and let it warm up for...

Page 121: ...F CC Nach ACEA CCMC z B G4 oder G5 Motorrad Motor l Except les E U et le CDN ATTENTION Ne pas ajouter d additifs chimiques et ne pas uti liser d huiles de qualit s CD a ou sup rieures NeNe pas utilise...

Page 122: ...t 1 06 US qt Periodic oil change 0 8 L 0 70 Imp qt 0 85 US qt 6 Install Dipstick 7 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPEC TION PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilo...

Page 123: ...Leerlaufgemisch Regulierschraube um die angegebene Anzahl von Umdrehungen wieder herausdrehen Leerlaufgemisch Regulierschraube 1 3 4 Umdrehungen heraus 4 Installer Joint Boulon de vidange New T R 20 N...

Page 124: ...To increase idle speed Turn the throttle stop screw 1 in a To decrease idle speed Turn the throttle stop screw 1 out b Engine idling speed 1 450 1 550 r min VALVE CLEARANCE ADJUSTMENT NOTE The valve c...

Page 125: ...2 Demontieren Kipphebeldeckel Einla seite 1 Kipphebeldeckel Ausla seite 2 3 Demontieren Schwungrad Abdeckschraube 1 Rotorzapfen Abdeckschraube 2 O Ringe REGLAGE DU REGIME DE RALENTI 1 Mettre le moteur...

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

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

Page 128: ...ring 2 7 Install Tappet cover exhaust side O ring Spark plug Timing plug Straight plug 8 Install Air filter case Air scoop right T R 18 Nm 1 8 m kg 13 ft lb New T R 18 Nm 1 8 m kg 13 ft lb New T R 13...

Page 129: ...8 Nm 1 8 m kg New T R 18 Nm 1 8 m kg New T R 13 Nm 1 3 m kg T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg 6 Installer Cache de poussoir c t admission 1 Joint torque 2 7 Installer Cache de poussoir c t chappemen...

Page 130: ...Brake pedal free play Adjustment steps Loosen the locknut 1 Turn the adjusters 2 in or out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreas...

Page 131: ...ACHTUNG Nach Einstellung des Handbremshebel spiels darf die Bremse nicht schleifen ACHTUNG Nach Einstellung des Fu bremshebel spiels darf die Bremse nicht schleifen PARTIE CYCLE REGLAGE DU FREIN AVANT...

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

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

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

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

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

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

Page 138: ...After a practice or a race check spokes for looseness T R 2 5 Nm 0 25 m kg 1 8 ft lb EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2 Inspect Be...

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

Page 140: ...ring nut 4 using ring nut wrench 5 Ring nut wrench YM 33975 90890 01403 T R Ring nut initial tightening 38 Nm 3 8 m kg 27 ft lb Loosen the ring nut one turn Retighten the ring nut using the ring nut...

Page 141: ...Hakenschl ssel ansetzen WARNUNG Nicht zu fest anziehen 3 Contr ler Fonctionnement en douceur de la direction Tourner le guidon de but e but e Fonctionnement dur R gler l crou annulaire de direction 4...

Page 142: ...R Steering stem bolt 40 Nm 4 0 m kg 2 9 ft lb Front fork cap bolt 40 Nm 4 0 m kg 2 9 ft lb Handlebar upper holder 13 Nm 1 3 m kg 9 4 ft lb CAUTION First tighten the bolts on the front side of the hand...

Page 143: ...TUNG Zuerst die vorderen Schrauben der Len kerhalterung danach die hinteren Schrauben anziehen T R Boulon de colonne de direction 40 Nm 4 0 m kg 2 9 ft lb Bouchon de tube de fourche 40 Nm 4 0 m kg 2 9...

Page 144: ...2 Brake lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake cable end Use Yamaha cable lube o...

Page 145: ...verwenden LUBRIFICATION Afin de garantir le bon fonctionnement de tous les l ments il convient de lubrifier la machine avant la premi re utilisation apr s le rodage ainsi qu apr s chaque course 1 Tou...

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

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

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

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

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

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

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

Page 153: ...selklappen Anschlag schraube 1 H Leerlaufgemisch Regulier schraube 1 I Vergaserbeheizung 1 1 Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarq...

Page 154: ...Pilot jet 2 Needle jet 3 Pilot air screw 4 Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire EC464...

Page 155: ...Leichtg ngigkeit Schwerg ngigkeit Instand setzen oder erneuern Das Gasschieber 1 in das Vergaser geh use einsetzen und auf Leichtg n gigkeit pr fen CONTROLE Carburateur 1 Contr ler Corps du carburateu...

Page 156: ...float using a vernier calipers If the float height is not within specifica tion inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by...

Page 157: ...s Nadelventil lediglich ber hren nicht niederdr cken Aiguille 1 Contr ler Aiguille 1 D form e usure Changer Position de clip Position standard de clip Rainure n 2 Hauteur du flotteur 1 Mesurer Hauteur...

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

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

Page 160: ...4 7 ENG CARBURETOR 1 Measure Fuel level a Out of specification Adjust Fuel level 2 3 mm 0 08 0 12 in below the float chamber line...

Page 161: ...tand a Unvorschriftsm ig Korrigieren Schwimmerstand 2 3 mm unterhalb der Schwim merkammer Pa fl che 1 Mesurer Niveau de carburant a Hors sp cification R gler Niveau de carburant 2 3 mm 0 08 0 12 in au...

Page 162: ...at and fuel tank Exhaust pipe Carburetor Refer to CARBURETOR section Air filter case 1 Plug cap spark plug 1 1 2 Crankshaft end cover O ring 1 1 3 Timing plug O ring 1 1 4 Camshaft sprocket cover O ri...

Page 163: ...nwellenrad Schraube Unterlegscheibe 1 1 1 CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE Pr para...

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

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

Page 166: ...e 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 sta tionary pointer d on the cylinder head as shown...

Page 167: ...das Kur belgeh use fallen kann Beim L sen der Schraube 1 die Lichtma schinenrotor Mutter mit einem Schrauben schl ssel festhalten POINTS DE DEPOSE Culasse 1 D poser Cache d extr mit de vilebrequin Bo...

Page 168: ...stages T R 22 Nm 2 2 m kg 16 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Camshaft sprocket 1 Installation steps Turn the crankshaft counterclockwise until the I mark a on the rotor is aligned with th...

Page 169: ...d chappement maintenir la cha ne de distribu tion aussi tendue que possible du c t chappe ment CULASSE ZYLINDERKOPF 5 Demontieren Zylinderkopf HINWEIS Die Schrauben und Muttern in der angege benen Re...

Page 170: ...sioner 6 Check Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Installation steps Remove the tensioner cap bolt 1 and spring 2 Release the timi...

Page 171: ...ung mit dem vorge schriebenen Drehmoment festziehen T R Steuerkettenspanner Verschlu schraube 8 Nm 0 8 m kg D tacher le fil m tallique de la cha ne de dis tribution ATTENTION Veiller ce que le vilebre...

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

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

Page 174: ...83 A Slide hammer bolt 90890 01085 Weight 90890 01084 INSPECTION Camshaft 1 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 25 4 mm 1 00 in b 21 0 mm 0 83...

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

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

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

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

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

Page 180: ...or YM 01253 90890 01253 INSPECTION Valve 1 Measure Stem to guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Clea...

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

Page 182: ...dth a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Measurement steps App...

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

Page 184: ...g compound to the valve face and repeat the above steps Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto t...

Page 185: ...wird HINWEIS Nach jedem L ppen sicherstellen da die Schleifpaste vollst ndig von Ventilkegel und Ventilsitz entfernt wird 2 Roder Face de soupape Si ge de soupape N B Apr s le surfa age du si ge de so...

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

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

Page 188: ...Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Timing chain guide exhaust 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pi...

Page 189: ...bolzen 1 7 Kolben 1 8 1 Kompressionsring Topring 1 9 2 Kompressionsring 1 10 labstreifring mit Expander 2 1 2 1 CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Org...

Page 190: ...e piston ring over the top of the piston crown as shown in the illustration INSPECTION Cylinder and piston 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure...

Page 191: ...hten Winkel zur Kurbelwelle messen Danach den Durchschnitt der Messung bestimmen POINTS DE DEPOSE Piston 1 D poser Circlip d axe de piston 1 Axe de piston 2 Piston 3 N B Avant de retirer le circlip d...

Page 192: ...16 in from the piston bottom edge Piston size P Standard 46 960 46 975 mm 1 8488 1 8494 in If out of specification replace the piston and piston rings as a set 3rd step Calculate the piston to cylind...

Page 193: ...lls unvorschriftsm ig den Zylinder erneuern und Kolben sowie Kolbenringe im Satz erneuern C maximum D T maximum D1 ou D2 maximum D5 ou D6 R maximum D1 D3 ou D5 minimum D2 D4 ou D6 Si hors sp cificatio...

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

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

Page 196: ...de diameter b Calculate the piston pin to piston clear ance with the following formula Piston pin to piston clearance Bore size piston pin b Outside diameter piston pin a If out of specification repla...

Page 197: ...xe de piston D coloration bleue gorges Remplacer puis examiner le syst me de graissage 2 Mesurer Jeu entre axe de piston et piston ASSEMBLAGE ET MONTAGE Piston 1 Monter Segments de piston sur le pisto...

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

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

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

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

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

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

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

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

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

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

Page 208: ...length a Out of specification Replace springs as a set Warp limit 0 05 mm 0 002 in Clutch spring free length Standard Limit 26 2 mm 1 03 in 24 2 mm 0 95 in Push rod 1 Measure Push rod 2 bend Out of sp...

Page 209: ...kupplungsgeh use Innen durchmesser 105 mm Grenzwert 106 mm Disques d embrayage 1 Mesurer Voile de disque d embrayage Hors sp cification Changer tous les dis ques d embrayage Utiliser une plaque surfac...

Page 210: ...Nut primary clutch 2 NOTE Tighten the nut while holding the magneto rotor with the sheave holder 3 Sheave holder YS 01880 90890 01701 T R 50 Nm 5 0 m kg 36 ft lb EC495221 Clutch 1 Install Lock washer...

Page 211: ...he Universal Kupplungshalter YM 91042 90890 04086 New T R 60 Nm 6 0 m kg 2 Mesurer Profondeur de gorge de garniture d embra yage a Hors sp cifications Remplacer Profondeur de gorge de garniture d embr...

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

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

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

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

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

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

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

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

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

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

Page 222: ...n Replace the oil pump assembly Tip clearance a 0 15 mm 0 0059 in Limit 0 2 mm 0 0079 in Side clearance b 0 06 0 10 mm 0 0024 0 0039 in Limit 0 15 mm 0 006 in Rotor housing and rotor clear ance c 0 13...

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

Page 224: ...ent of removal 1 Pickup coil stator assembly removal 2 Rotor removal Extent of removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover lef...

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

Page 226: ...01701 2 Remove Rotor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel puller...

Page 227: ...dabziehers anzupassen ACHTUNG Kurbelwellenzapfen zum Schutz mit dem Steckschl ssel abdecken Schwungradabzieher YU 33270 90890 01362 POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Rondelle 2 N B Des...

Page 228: ...aust pipe Air filter case Carburetor Refer to CARBURETOR section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine guard Engine assembly From the chassis Cylinder he...

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

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

Page 231: ...ne de distribution 1 3 Pignon menant 1 4 Carter droit 1 5 Goujon 2 6 Vilebrequin 1 7 Carter gauche 1 1 2 3 4 CARTER ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Demontage Arbeiten 1 Steuerkette demont...

Page 232: ...ndard Limit Runout limit 0 03 mm 0 0012 in Side clearance 0 1 0 4 mm 0 0039 0 0157 in Radial clearance 0 010 0 025 mm 0 0004 0 0010 in 0 05 mm 0 002 in Crack width 42 95 43 00 mm 1 691 1 693 in Crankc...

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

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

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

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

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

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

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

Page 240: ...Part name Q ty Remarks FRONT WHEEL REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Bolt brake cable holder 1 Only loosening 2 Brake cable 1 Disconnect...

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

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

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

Page 244: ...Part name Q ty Remarks REAR WHEEL REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Brake rod 1 2 Cotter pin 1 3 Nut tension bar 1 4 Bolt tension bar 1...

Page 245: ...Motorrad gegen Umfallen sichern 2 3 1 ROUE ET FREIN ARRIERE Organisation de la d pose 1 D pose de la roue arri re 2 D pose du roulement de roue 3 D pose et d montage du flasque et des m choires de fr...

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

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

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

Page 249: ...Verschlei grenze erreicht hat Trommelbremsbelag St rke a Standard 3 mm Grenzwert 2 mm POINTS DE DEPOSE Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement en utilisant un ar...

Page 250: ...ld the machine by placing the suitable stand under the engine Front wheel Refer to FRONT WHEEL AND FRONT BRAKE section Handlebar Refer to HANDLEBAR section Front fender 1 Brake cable holder 1 2 Cap bo...

Page 251: ...WARNUNG Das Motorrad gegen Umfallen sichern 1 FOURCHE AVANT Organisation de la d pose 1 D pose de la fourche avant Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration pour la d pose...

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

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

Page 254: ...C555000 ASSEMBLY AND INSTALLATION 1 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver weight 2 and fork seal driver attachment 3 2 Fill Fork oil Fork seal driver wei...

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

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

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

Page 258: ...STEERING REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the engine Front fork Refer to FRONT FORK section 1 Steering stem bolt 1 2 Handle crown 1 3 Ring nut 1 Us...

Page 259: ...otorrad gegen Umfallen sichern 2 1 DIRECTION Organisation de la d pose 1 D pose du t de fourche inf rieur 2 D pose du roulement Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA D...

Page 260: ...removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to REAR WHEEL AND REAR BRAKE section Rear fender Drive chain 1 Cotter pin 2 2 Pin 2 3 Rear shock absorber 1 4 P...

Page 261: ...orrad gegen Umfallen sichern 1 2 BRAS OSCILLANT Organisation de la d pose 1 D pose du bras oscillant 2 D pose de l amortisseur arri re Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE...

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

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

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

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

Page 266: ...at 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 STOP switch Repl...

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

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

Page 269: ...ELEC MEMO...

Page 270: ...ngine 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 dus...

Page 271: ...ie de la bougie 2 Connecter le testeur dynamique d tincelle 1 testeur d allumage 2 comme indiqu Capuchon de bougie 3 Bougie 4 Pour les E U et le CDN Except pour les E U et le CDN 3 Actionner le kick 4...

Page 272: ...il resistance Out of specification Replace NOTE When inspecting the secondary coil resis tance remove the spark plug cap EC627011 CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specifi...

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

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

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

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

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

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

Page 279: ...ELEC MEMO...

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

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

Page 282: ...7 2 F YES Test steps 1 2 Heating phase Test steps 3 4 Cooling phase Check the thermo switch operation WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shock...

Page 283: ...0 bei 20 C SYSTEME DE RECHAUFFEMENT DU CARBURATEUR VERGASERBEHEIZUNGSSYSTEM Le circuit du thermocontact est ouvert Le circuit du thermocontact est ferm Etapes du test Temp rature de l eau Conti nuit 1...

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

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

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

Page 287: ...PRINTED IN JAPAN 99 7 3 6 1 CR PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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Yamaha TTR90(M), Owner'S Service Manual

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