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Yamaha YZ 125, Owner'S Service Manual

The Yamaha YZ 125 is a high-performance motocross bike designed for adrenaline junkies. Its Parts Catalog provides comprehensive information on every component, ensuring easy repairs and maintenance. With our user-friendly manual available for free download on manualshive.com, you can maximize your riding experience without any hassle.

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2-9

SPEC

MAINTENANCE SPECIFICATIONS

NOTE:

1. First, tighten the ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the ring nut wrench,

then loosen the ring nut one turn.

2. Retighten the ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).

Part to be tightened

Thread size

Q'ty

T ightening torque

Nm

m•kg

ft•lb

Handle crown and outer tube

M  8 

×

1.25

4

21

2.1

15

Under bracket and outer tube

M  8 

×

1.25

4

21

2.1

15

Handle crown and steering shaft

M24 

×

1.0

1

145

14.5

105

Handlebar holder (upper)

M  8 

×

1.25

4

28

2.8

20

Handlebar holder (lower)

M12 

×

1.25

2

40

4.0

29

Steering ring nut

M28 

×

1.0

1

Refer to NOTE.

Front fork and damper assembly

M51 

×

1.5

2

30

3.0

22

Front fork and adjuster

M22 

×

1.25

2

55

5.5

40

Damper assembly and base valve

M42 

×

1.5

2

29

2.9

21

Adjuster and damper assembly

M12 

×

1.25

2

29

2.9

21

Bleed screw (front fork) and base valve

M  5 

×

0.8

2

1

0.1

0.7

Front fork and protector

M  6 

×

1.0

6

7

0.7

5.1

Cable guide (front brake hose) and under bracket

M  6 

×

1.0

1

4

0.4

2.9

Protector and brake hose holder

M  6 

×

1.0

2

7

0.7

5.1

Throttle cable cap

M  4 

×

0.7

2

1

0.1

0.7

Front brake master cylinder and bracket

M  6 

× 

1.0

2

9

0.9

6.5

Brake lever (bolt)

M  6 

×

1.0

1

6

0.6

4.3

(nut)

M  6 

×

1.0

1

6

0.6

4.3

Brake lever position locknut

M  6 

×

1.0

1

5

0.5

3.6

Clutch lever (nut)

M  6 

×

1.0

1

4

0.4

2.9

Clutch lever holder

M  5 

×

0.8

2

4

0.4

2.9

Front brake master cylinder cap

M  4 

×

0.7

2

2

0.2

1.4

Front brake hose union bolt (master cylinder)

M10 

×

1.25

1

30

3.0

22

Front brake hose union bolt (caliper)

M10 

×

1.25

1

30

3.0

22

Front brake caliper and front fork

M  8 

×

1.25

2

23

2.3

17

Front brake caliper and brake hose holder

M  6 

×

1.0

1

10

1.0

7.2

Grip cap upper and lower

M  6 

×

1.0

2

4

0.4

2.9

Brake caliper (front and rear) and pad pin plug

M10 

×

1.0

2

3

0.3

2.2

Brake caliper (front and rear) and pad pin

M10 

×

1.0

2

18

1.8

13

Brake caliper (front and rear) and bleed screw

M  8 

×

1.25

2

6

0.6

4.3

Front wheel axle and nut

M16 

×

1.5

1

105

10.5

75

Front wheel axle holder

M  8 

×

1.25

4

21

2.1

15

Front brake disc and wheel hub

M  6 

×

1.0

6

12

1.2

8.7

Rear brake disc and wheel hub

M  6 

×

1.0

6

14

1.4

10

Footrest bracket and frame

M10 

×

1.25

4

55

5.5

40

Brake pedal mounting

M  8 

×

1.25

1

26

2.6

19

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

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▲

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▲

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▲

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 1C3-9-32-2A  4/29/06 10:17 AM  Page 10

Summary of Contents for YZ 125

Page 1: ... FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 W W1 1C3 28199 32 PRINTED IN JAPAN 2006 5 1 6 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER YZ125 W W1 1C3 9 32 hyoshi 4 28 06 2 45 PM Page 1 ...

Page 2: ...by Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 1C3 9 32 hyoshi 4 28 06 2 45 PM Page 2 ...

Page 3: ...Yamaha Motor Co Ltd 1 Ausgabe Mai 2006 Alle Rechte vorbehalten Nachdruck auch auszugsweise oder nicht autorisierte Verwendung sind ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan YZ125 W W1 MANUALE DI SERVIZIO DEL PROPRIETARIO 2006 by Yamaha Motor Co Ltd 1a Edizione Mei 2006 Tutti i diritti riservati Sono espressamente proibiti qualsiasi ristampa o uso non a...

Page 4: ...sign and quality Therefore while this manual contains the most current product infor mation available at the time of printing there may be minor discrepancies between your machine and this manual If you have any ques tions concerning this manual please consult your Yamaha dealer w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OP ERATE THIS MACHINE...

Page 5: ... en permanence d améliorer la conception ainsi que la qualité de ses produits Par conséquent même si ce manuel contient les toutes dernières informations sur les produits disponibles lors de l impression de légères différences sont possibles entre votre machine et ce manuel Pour toute question relative au présent manuel consulter un concessionnaire Yamaha XG PRIERE DE LIRE ATTENTIVE MENT ET COMPLE...

Page 6: ...MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this ma chine 3 ALWAYS WEAR PROTECTIVE APPAR EL When operating this machine always wear an approved helmet with goggles or a face shield Also wear heavy boots gloves and protective clothing Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTA...

Page 7: ...EUR Ne pas prendre de passagers sur cette machine 3 TOUJOURS PORTER UN EQUIPEMENT DE PROTEC TION Lors de l utilisation de cette machine toujours porter un casque homologué avec des lunettes ou un protège visage Porter également de grosses bottes des gants et des vête ments de protection Toujours porter des vêtements de taille correcte qui ne seront pas pris dans une des pièces ou com mandes mobile...

Page 8: ...QUATE VENTILATION Never start the engine or let it run for any length of time in an enclosed area Exhaust fumes are poisonous These fumes contain carbon monoxide which by itself is odorless and colorless Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machin...

Page 9: ...r pendant un quelconque laps de temps dans un endroit clos Les fumées d échappement sont toxiques Ces fumées contiennent du monoxyde de carbone incolore et inodore Le monoxyde de carbone est un gaz toxique dangereux qui peut entraîner la perte de connaissance ou être mortel 8 STATIONNER AVEC SOIN LA MACHINE ET ARRE TER LE MOTEUR Toujours arrêter le moteur si vous devez abandonner la machine Ne pas...

Page 10: ...is machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha deal er Weights of machines without fuel The minimum weights for motocross ma chines are for the class 125 c...

Page 11: ...ER IL NUOVO PROPRIETARIO Questo manuale fornirà una buona comprensione di base delle caratteristi che del funzionamento e delle opera zioni fondamentali di manutenzione e di ispezione di questo veicolo Si prega di leggere attentamente e completamen te questo manuale prima di far funzio nare il veicolo nuovo Se vi sono domande riguardanti il funzionamento o la manutenzione del veicolo consul tare i...

Page 12: ...st be taken 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 seven chapters General Information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tuning 2 The table of contents is at the beginning of the manual Look over the general layout of the book ...

Page 13: ...être suivies pour éviter d endommager la machine N B Une N B fournit les renseignements nécessaires pour rendre les procédures plus faciles ou plus claires TROUVER LA PAGE RECHERCHEE 1 Ce manuel comprend 7 chapitres Renseignements généraux Caractéristiques Verification et réglages courants Moteur Partie cycle Partie électrique et Mise au point 2 La table des matières se trouve au d ebut du manuel ...

Page 14: ...M W2 M W2 0Y hf O 0M O 0Y O 0Y he O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W2 L V M W2 0Yhf O2 0Y O M O M hfO 1 V 0Y O Mhf W2 M W2 0Y W2 0YhfO2 V40M W2 0Y hfW 0Y O M O MhfW2 O M hf O M W2 0Y W2 0Y he O 5 O2 0Yhf W2 0Y O M O M he W2 0Y W2 M W M W2 0Y W2 0YhfO M O 0Y hf O 0Y O M O ...

Page 15: ...es opérations 1 Exemple de vue en éclaté 1 clari fiant les opérations de démontage et de remontage 2 Sur les vues en éclaté les pièces sont numérotées 2 dans l ordre des opérations à effectuer Un chiffre entouré d un cercle corres pond à une étape de démontage 3 Les vues en éclaté portent égale ment des symboles 3 qui rappel lent des points importants à ne pas oublier La signification de ces symbo...

Page 16: ...nt w Tightening e Specified value Service limit r Resistance Ω Voltage V Electric current A Illustrated symbols t to o in the exploded dia grams indicate grade of lubricant and location of lubrication point t Apply transmission oil y Apply engine mixing oil u Apply molybdenum disulfide oil i Apply lightweight lithium soap base grease o Apply molybdenum disulfide grease Illustrated symbols p to a i...

Page 17: ... Serrage e Valeur spécifiée limite de service r Résistance Ω tension V intensité A Les symboles graphiques t à o dans les vues éclatées indiquent le grade de lubrifiant et l emplacement des points de lubrification t Appliquer de l huile de transmission y Appliquer de l huile de mélange du moteur u Appliquer de l huile au bisulfure de molybdène i Appliquer de la graisse fluide à base de savon au li...

Page 18: ...EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING ...

Page 19: ...MEINE ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHNISCHE DATEN REGELMÄSSIGE PRÜFUNG UND EINSTELLUNGEN MOTORE MOTEUR MOTOR TELAIO PARTIE CYCLE FAHRGESTELL PARTE ELETTRICA PARTIE ELECTRIQUE ELEKTRISCHE EINRICHTUNGEN MESSA A PUNTO MISE AU POINT TUNING INDEX INDEX IC090010 INDICE ANALITICO RENSEIGNEMENTS GENERAUX ...

Page 20: ...L 1 12 STARTING AND BREAK IN 1 13 TORQUE CHECK POINTS 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 12 DEFINITION OF UNITS 2 12 CABLE ROUTING DIAGRAM 2 13 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 ENGINE 3 5 CHASSIS 3 17 ELECT...

Page 21: ...ÖL 1 12 STARTEN UND EINFAHREN 1 13 ANZUGSMOMENTE PRÜFPUNKTE 1 16 REINIGEN UND LAGERUNG 1 17 KAPITEL 2 TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN 2 1 WARTUNGSDATEN 2 3 ALLGEMEINE ANZUGSDATEN 2 12 DEFINITION DER EINHEITEN 2 12 KABELFÜHRUNGSÜBERSICHTPLAN 2 13 KAPITEL 3 REGELMÄSSIGE PRÜFUNG UND EINSTELLUNGEN WARTUNGSINTERVALLE 3 1 PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME 3 4 MOTOR 3 5 FAHRGESTELL ...

Page 22: ...ARY DRIVEN GEAR 4 30 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 37 YPVS GOVERNOR 4 45 WATER PUMP 4 48 CDI MAGNETO 4 52 ENGINE REMOVAL 4 56 CRANKCASE AND CRANKSHAFT 4 61 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 69 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FORK 5 26 HANDLEBAR 5 42 STEERING 5 50 SWINGARM 5 55 REAR SHOCK ABSORBER 5 63 ...

Page 23: ... SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 37 REGULATEUR YPVS 4 45 POMPE A EAU 4 48 MAGNETO CDI 4 52 DEPOSE DU MOTEUR 4 56 CARTER ET VILEBREQUIN 4 61 BOITE A VITESSES BARILLET DE SELECTEUR ET FOURCHETTE 4 69 CHAPITRE 5 PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE 5 1 FREIN AVANT ET FREIN ARRIERE 5 10 FOURCHE AVANT 5 26 GUIDON 5 42 DIRECTION 5 50 BRAS OSCILLANT 5 55 AMORTISSEUR ARRIERE 5 63 CAPITOL...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 13 ...

Page 25: ...1 FAHRGESTELL 7 13 CHAPITRE 6 PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 SYSTEME D ALLUMAGE 6 2 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 13 CAPITOLO 6 PARTE ELETTRICA COMPONENTI ELETTRICI E SCHEMA ELETTRICO 6 1 SISTEMA DI ACCENSIONE 6 2 CAPITOLO 7 MESSA A PUNTO MOTORE 7 1 TELAIO 7 13 ...

Page 26: ...nk cap 7 Kick starter 8 Fuel tank 9 Radiator 0 Coolant drain bolt q Check bolt Transmission oil level w Rear brake pedal e Valve joint r Fuel cock t Air cleaner y Drive chain u Shift pedal i Starter knob o Front fork NOTE 9The machine you have purchased may differ slightly from those shown in the following 9Designs and specifications are subject to change without notice ...

Page 27: ...contrôle niveau d huile de transmission w Pédale de frein arrière e Joint de robinet r Robinet à essence t Filtre à air y Chaîne de transmission u Pédale de sélecteur i Bouton de starter o Fourche avant N B 9La machine que vous avez achetée diffère peutêtre partiellement de celles montrées sur ces photos 9La conception et les caractéristiques peuvent êtres changées sans préavis IC100000 INFORMAZIO...

Page 28: ...ntify your machine EC121001 VEHICLE IDENTIFICATION NUMBER For USA CDN AUS NZ and E The vehicle identification number 1 is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER For F D GB I and ZA The frame serial number 1 is stamped on the right of the steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right si...

Page 29: ...our retrouver et identifier votre machine NUMERO D IDENTIFICATION DU VEHICULE Pour USA CDN AUS NZ et E Le numéro d identification du véhicule 1 est frappé du côté droit du tube de tête de fourche NUMERO DE SERIE DU CADRE Pour F D GB I et ZA Le numéro de série du cadre 1 est frappé du côté droit du tube de tête de fourche NUMERO DE SERIE DU MOTEUR Le numéro de série du moteur 1 est estampé sur un b...

Page 30: ...om 9Water pump housing hole at the bottom 9End of each hose 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an as sembly or replaced 4 During the machine disassembly clean all parts and ...

Page 31: ...ore 9 Apertura dell alloggiamento della pompa dell acqua dal lato inferiore 9 Estremità di ciascun tubo flessi bile 2 Usare utensili e apparecchiature di pulitura adeguati Consultare la sezione UTENSILI SPECIALI 4 Lors du démontage de la machine nettoyer toutes les pièces et les mettre dans des plateaux dans l ordre du démontage Ceci dimi nuera le temps de remontage et permettra d être sûr que tou...

Page 32: ...olt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward In other words the stamped letters must be on the side ex posed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bear ings libera...

Page 33: ...nd Öldichtungen 2 so einbauen dass das Zeichen des Herstellers oder die Herstellungs nummer nach aussen gerichtet ist die eingeschlagenen Buch staben müssen sichtbar sein Wenn Öldichtungen eingebaut werden sind die Öldichtlippen mit Lithiumfett zu bestreichen Beim Einbau die Lager großzügig mit Öl schmieren dD Niemals die Lager mit Druckluft trocknen Dadurch könnte die Oberfläche der Lager beschäd...

Page 34: ...hould be inspected carefully be fore reassembly Always replace piston pin clips after one use Replace distorted cir clips When installing a circlip 1 make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives See the sectional view 4 Shaft ...

Page 35: ...ips doivent être soigneusement véri fiés Toujours changer les circlips d axe de piston après une utilisa tion Changer tout circlip déformé Lorsqu on monte un circlip 1 s assurer que le côté non chanfrei né 2 est positionné du côté oppo sé à la poussée 3 qu il re coit Voir la vue en coupe 4 Arbre IC136000 ANELLI ELASTICI DI ARRESTO 1 Si dovrebbero ispezionare attenta mente tutti gli anelli elastici...

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 connector 6 Connect 9Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE 9If there in no continuity clean the terminals 9Be sure to perform the steps 1 to 7 listed above when checking the wireharness 9For a field remedy use a contact revitalizer a...

Page 37: ...baums unbedingt die Schritte 1 bis 7 befol gen 9 Handelsübliches Kontaktspray nur als Notlösung verwenden 9 Das Taschen Multimeter wie abge bildet am Steckverbinder ansch ließen 6 Connecter 9 Connecteur N B Les deux connecteurs s encliquètent 7 Vérifier la continuité avec un tes teur N B 9S il n y a pas continuité nettoyer les bornes 9S assurer d effectuer les opérations 1 à 7 ci dessus lors du co...

Page 38: ... 1189 90890 01189 Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto YU 1235 90890 01235 Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 3097 90890 01252 Dial gauge and stand YU 3097 90890 01252 YU 1256 Spark plug hole dial stand YU 1256 These tools are used to set the ignition timing Crank...

Page 39: ...0890 01501 Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the damper assembly YM A0948 90890 01502 Fork seal driver YM A0948 90890 01502 This tool is used when install the fork oil seal YU 3112 C 90890 03112 Yamaha pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YM 91042 90890 04086 Clutch holding tool Y...

Page 40: ...s YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit être utilisé pour la dépose du volant magnétique YM 1189 90890 01189 YU 1235 90890 01235 Outil de poignée de rotor Cet outil est utilisé pour le desserrage ou le serrage du boulon de fixation de volant magnétique YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Comparateur et support Support du comparateur d écartement ...

Page 41: ...34487 90890 06754 90890 85505 Outil de poignée débrrayage Cet outil est utilisé pour immobiliser l embrayage quand on déposé ou monte l écrou de fixation de la noix d embrayage Testeur d étincelle dynamique Contrôleur d allumage Ce testeur est nécessaire pour contrôler les composants du systém d allumage YAMAHA bond N 1215 ThreeBond N 1215 Ce mastic est utilisé sur les plans de joint du carter etc...

Page 42: ...ziehwerkzeug Dieses Werkzeug wird für den Ausbau des Schwung rad Magnetzünders benötigt YM 1189 90890 01189 YU 1235 90890 01235 Rotor Haltewerkzeug Dieses Werkzeug wird für das Lösen und Festziehen der Schwungmagnetzünder Befestigungsschraube verwendet YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Messuhr und Messuhrständer Skalenmessfuß für Zündkerzenöffnung Diese Werkzeuge werden für die Einst...

Page 43: ... Kupplung Halterwerkzeug Dieses Werkzeug wird für das Festhalten der Kupp lung verwendet wenn die Kupplungsnaben Befesti gungsmutter aus oder eingebaut wird Dynamischer Zündfunkenprüfer Zündungs Prüfgerät Dieses Prüfgerät wird für die Kontrolle der Bauteile der Zündanlage benötigt YAMAHA bond Nr 1215 ThreeBond Nr 1215 Dieses Dichmittel wird für die Passflächen der Kur belgehäusehälften usw verwend...

Page 44: ...89 Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 01189 YU 1235 90890 01235 Utensile di supporto del rotore Quepsile viene usato quando si allenta o si serra il dado di fissaggio del magnete del volano YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Comparatore e supporto Supporto del comparatore del foro della candela Questi utensili vengono usa...

Page 45: ...87 90890 06754 90890 85505 Utensile per tenere la frizione Questo utensile viene usato per tenere la frizione quan do si toglie o si installa il dado di fissaggio del mozzo della frizione Tester a scintilla dinamico Controllore dell accensione Questo strumento è necessario per controllare i compo nenti del sistema di accensione YAMAHA Bond No 1215 ThreeBond No 1215 Questo sigillante agglomerante v...

Page 46: ...DAL The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick starter 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and force fully to start the engine This model has a prima ry kick starter so th...

Page 47: ...el nen Gänge erfolgt mittels Fußschalt hebel 1 angebracht an der linken Seite des Motors KICKSTARTER Den Kickstarter 1 vom Motor weg schwenken Den Kickstarter langsam niedertreten bis die Zahnräder einra sten danach den Kickstarter schwungvoll durchtreten um den Motor anzulassen Dieses Modell ist mit einem Primärkickstarter ausgerü stet d h der Motor kann auch bei ein gelegtem Gang angelassen werd...

Page 48: ...iltering the fuel The fuel cock has the two positions OFF With the lever in this position fuel will not flow Always return the lever to this posi tion 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 EC159000 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A s...

Page 49: ...ezieller Starter kreislauf der über den Starterknof 1 kontrolliert wird liefert dieses Gemisch Den Starterknopf herauszie hen um den Kreislauf zum Anwerfen des Motors zu öffnen Wenn der Motor warmgelaufen ist den Knopf hineinstoßen um den Kreislauf zu schließen BOUTON DE DEMARREUR ESTRANGULEUR Quand il est froid le moteur a besoin d un mélange air essence plus riche pour le démarrage Un circuit de...

Page 50: ...C15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it w 9Never apply additional force to the side stand 9Remove this sidestand before starting out EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose cC In this installation make sure the arrow faces the fuel tank and also ...

Page 51: ...lauch eingebaut dD Bei diesem Einbau ist darauf zu achten dass der Pfeil auf den Kraftstofftank und nach unten weist IC15R001 CAVALLETTO STACCABILE Questo cavalletto 1 viene usato per supportare soltanto il veicolo quando è fermo o durante il trasporto T 9Non applicare mai forza supple mentare al cavalletto 9Togliere questo cavalletto prima di partire IC15F000 GIUNTO DELLA VALVOLA Questo giunto de...

Page 52: ...line or higher octane grade cC Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type Fuel tank capacity 8 0 L 1 76 Imp gal 2 11 US gal Mixing oil Recommended oil Yamalube 2 R Yamalube racing 2 cycle oil Mixing ratio 30 1 If unavailabl...

Page 53: ... CARBURANTE E OLIO PER MISCELA PER MOTORI Miscelare l olio con la benzina nel rap porto specificato più sotto Usare sem pre benzina fresca di marca e miscela re l olio e la benzina il giorno della gara Non usare una miscela già prepa rata che abbia più di qualche ora NOTA Se si verifica detonazione o battito in testa usare una marca di benzina diver sa o una qualità con un numero di ottani più alt...

Page 54: ... CHOKE 3 With the throttle completely closed start the engine by kicking the kick starter forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes about one or two minutes 5 The engine is warmed up when it responds normally to the throttle with the starter knob CHOKE turned off cC Do not warm up the engine for extended peri ods EC193001 STARTING ...

Page 55: ...rter kräftig durchtreten um den Motor zu starten 4 Den Motor bei Leerlauf Dreh zahl warmlaufen lassen für das Warmlaufen werden normaler weise etwa eine bis zwei Minuten benötigt 5 Der Motor ist warmgelaufen wenn er bei ausgeschaltetem Starterknopf CHOKE normal auf das Gasgeben anspricht dD Den Motor nicht für längere Zeit warmlaufen lassen STARTEN DES WARMEN MOTORS Den Starterknopf CHOKE nicht be...

Page 56: ...heck full throt tle response Stop and check the spark plug 6 After again allowing the engine to cool restart and run the machine for five more minutes Full throttle and the higher gears may be used but sustained full throttle op eration should be avoided Check the spark plug condition 7 Allow the engine to cool remove the top end and inspect the piston and cylinder Remove any high spots on the pis...

Page 57: ...éri fiez la réponse à pleine accéléra tion Arrêtez vous et revérifiez la bougie 6 A nouveau laissez le moteur se refroidir Redémarrez et pilotez pendant cinq nouvelles minutes Cette fois vous pouvez rouler à pleins gaz sur les rapports supé rieurs mais évitez une marche soutenue à pleine vitesse Vérifiez l état de la bougie 7 Laissez le moteur se refroidir déposez la culasse et le cylindre et exam...

Page 58: ...K POINTS Tighten all such fasteners as required 9When any of the following parts have been replaced they must be broken in CYLINDER AND CRANKSHAFT About one hour of break in operation is necessary PISTON RING AND GEARS These parts require about 30 minutes of break in operation at half throttle or less Observe the condition of the engine careful ly during operation ...

Page 59: ...9 Wenn eines der folgenden Teile erneuert wurde dann muss die Maschine wiederum eingefahren werden ZYLINDER UND KURBELWELLE Etwa eine Stunde Einfahrzeit ist erforderlich KOLBEN KOLBENRING UND ZAHNRÄDER Diese Teile erfordern eine Einfahr zeit von etwa 30 Minuten bei Halb gas oder weniger Bei laufendem Motor sorgfältig die Betriebsbe dingungen kontrollieren iI 9Dopo il rodaggio o prima di ciascu na ...

Page 60: ... Link to swingarm Rear Installation of shock Shock absorber to frame absorber Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Wheel to sprocket Brake Front Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder ...

Page 61: ...cillant Arrière Installation de De l amortisseur au cadre l amortisseur Arrière Installation du bras oscillant Serrage de l arbre de pivot Roue Installation de la roue Avant Serrage de l axe avant Serrage du support d axe Arrière Serrage de l axe arrière De la roue au pignon Frein Avant De l étrier à la fourche avant Du frein à disque à la roue Serrage du boulon d accouplement Du maître cylindre a...

Page 62: ...interradschwinge Hinten Einbau des Stoßdämpfer am Rahmen Stoßdämpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradshcwinge Rad Einbau des Rades Vorn Festziehen der Vorderachse Festziehen des Achshalters Hinten Festziehen der Hinterachse Rad am Kettenrad Bremse Vorn Bremssattel an Vorderradgabel Bremsscheibe am Rad Festziehen der Hohlschraube Hauptbremszylinder an Lenkstange Festziehe...

Page 63: ...Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione della ruota Anteriore Serraggio dell asse anteriore Serraggio del supporto dell asse Posteriore Serraggio dell asse posteriore Ruota rocchetto Freno Anteriore Pinza forcella anteriore Disco del freno ruota Serraggio del bullone di unione Cilindro principale...

Page 64: ... of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have re sulted from improper high pressure deter gent applications such as those available in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immedia...

Page 65: ...s ont résulté de l emploi abusif des vapori sateurs de détergent à haute pression tels que ceux qui équipent les laveries automatiques de voitures 4 Après avoir chassé la majeure par tie de la boue lavez toutes les sur faces avec de l eau chaude et un détergent neutre Utilisez une vieille brosse à dents pour atteindre les endroits difficiles d accès 5 Rincez immédiatement l engin avec de l eau pro...

Page 66: ... switch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise the wheels off the ground 6 Tie a plastic bag over the exhaust pipe out let to prevent moisture from enterin...

Page 67: ... donnez plusieurs coups de pédale pour enduire le cylindre d huile 3 Déposez la chaîne nettoyez la soi gneusement au dissolvant et lubri fiez Remontez la chaîne ou ran gez la dans un sachet plastique fermé fixé au cadre 4 Lubrifiez tous les câbles de com mande 5 Mettez le cadre sur plots pour sou lever les roues du sol 6 Fixez un sachet plastique sur la sortie du pot d échappement pour éviter l in...

Page 68: ...troke gasoline Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 4 36 lmp oz 4 19 US oz Bore Stroke 54 54 5 mm 2 126 2 146 in Compression ratio 8 6 10 7 1 Starting system Kick starter Lubrication system Premix 30 1 Yamalube 2 R Oil type or grade 2 Cycle Transmission oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Periodic oil change 0 66 L 0 58 Imp qt 0 69 US qt Tota...

Page 69: ...21 1 095 Chassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 25 5 25 6 Trail 105 mm 4 13 in 107 mm 4 21 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspens...

Page 70: ...m 0 093 in End gap installed 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Side clearance installed 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Crankshaft Crank width A 55 90 55 95 mm 2 201 2 203 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Connecting rod big end side clearance D 0 06 0 64 mm 0 002 0 025 in Small end free play F 0 8 1 0 mm 0 031 0 039 in 2 0 mm 0 08 in Clutch Friction pla...

Page 71: ...mark 1C35 30 1C36 40 1C37 50 Main jet M J 410 430 Jet needle clip position J N 6BFY42 74 3 6BFY43 74 3 Cutaway C A 4 0 Pilot jet P J 40 45 40 Pilot air screw P A S 2 1 4 Valve seat size V S ø3 8 mm 0 15 in Starter jet G S 80 Fuel level F L 9 5 10 5 mm 0 37 0 41 in Reed valve Thickness 0 47 mm 0 019 in Valve stopper height 8 2 8 6 mm 0 323 0 339 in Valve bending limit 0 2 mm 0 008 in Cooling Radiat...

Page 72: ...7 1 2 0 2 1 4 Air filter joint clamp M 4 0 7 1 2 0 2 1 4 Air filter case M 6 1 0 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 4 0 4 2 9 Read valve M 3 0 5 6 1 0 1 0 7 Throttle cable adjust bolt and locknut M 8 1 25 1 7 0 7 5 1 Throttle cable M 6 0 75 1 4 0 4 2 9 Crankcase M 6 1 0 12 14 1 4 10 Crankcase cover right M 6 1 0 8 10 1 0 7 2 Crankcase cover left M 6 1 0 4 5 0 5 3 6 Chain cover M 6 1 0 2 ...

Page 73: ... 1 2 8 7 Exhaust pipe stay front M 6 1 0 1 12 1 2 8 7 Exhaust pipe stay rear M 6 1 0 1 12 1 2 8 7 Silencer Silencer and frame M 6 1 0 2 12 1 2 8 7 Fiber For USA and CDN M 6 1 0 2 10 1 0 7 2 Fiber Except for USA and CDN M 6 1 0 4 10 1 0 7 2 NOTE marked portion shall be checked for torque tightening after break in or before each race ...

Page 74: ... 89 in Front fork top end 5 mm 0 2 in Rear suspension USA CDN ZA EUROPE AUS NZ Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length One I D mark 256 mm 10 08 in 254 mm 10 00 in Two I D marks 262 mm 10 31 in 260 mm 10 24 in Three I D marks 253 5 mm 9 98 in 251 5 mm 9 90 in Min Max One I D mark 245 5 263 5 mm 9 67 10 37 in Two I D marks 251 5 269 5 mm 9 90 ...

Page 75: ...4 0 12 in 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Deflection limit 0 15 mm 0 006 in Pad thickness 6 4 mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Calipe...

Page 76: ...ctor and brake hose holder M 6 1 0 2 7 0 7 5 1 Throttle cable cap M 4 0 7 2 1 0 1 0 7 Front brake master cylinder and bracket M 6 1 0 2 9 0 9 6 5 Brake lever bolt M 6 1 0 1 6 0 6 4 3 nut M 6 1 0 1 6 0 6 4 3 Brake lever position locknut M 6 1 0 1 5 0 5 3 6 Clutch lever nut M 6 1 0 1 4 0 4 2 9 Clutch lever holder M 5 0 8 2 4 0 4 2 9 Front brake master cylinder cap M 4 0 7 2 2 0 2 1 4 Front brake hos...

Page 77: ...58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame and frame upper M 8 1 25 1 32 3 2 23 Rear frame and frame lower M 8 1 25 2 29 2 9 21 Swingarm and brake hose holder M 5 0 8 4 2 0 2 1 4 Swingarm and patch M 4 0 7 4 2 0 2 1 4 Chain tensioner mounting M 8 1 25 2 16 1 6 11 Chain support and swingarm M 6 1 0 3 7 0 7 5 1 Seal guard a...

Page 78: ... model stator Manufacturer 1C3 10 YAMAHA Source coil 1 resistance color 720 1 080 Ω at 20 C 68 F Green White Black Red Source coil 2 resistance color 44 66 Ω at 20 C 68 F Black Green Blue Pickup coil resistance color 248 372 Ω at 20 C 68 F White Blue White Red CDI unit model Manufacturer 1C3 10 YAMAHA Ignition coil Model Manufacturer 1C3 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding res...

Page 79: ...m temperature A Distance across flats B Outside thread diameter EC230000 DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS A B TORQUE SPECIFICATION Nut Bolt Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm milimeter 10 3 meter Length cm centimeter 10 2 meter Lengt...

Page 80: ... moteur 2 temps essence refroidissement liquide Dispositions de cylindres Monocylindre incliné Cylindrée 124 cm3 4 36 lmp oz 4 19 US oz Alésage course 54 54 5 mm 2 126 2 146 in Taux de compression 8 6 10 7 1 Système de démarrage Démarreur au pied Système de graissage Mélange 30 1 Yamalube 2 R Type ou grade d huile 2 temps Huile de transmission Huile Yamalube 4 10W 30 ou huile moteur SAE 10W 30 typ...

Page 81: ... AUS NZ EUROPE CDN Type de cadre Simple berceau dé dédouble Angle de chasse 25 5 25 6 Chasse 105 mm 4 13 in 107 mm 4 21 in Pneu Type de pneu Avec chambre à air Taille de pneu avant 80 100 21 51M Taille de pneu arrière 100 90 19 57M Pression de pneu avant et arrière 100 kPa 1 0 kgf cm2 15 psi Freins Type de frein avant Frein à simple disque Commande Commande à la main droit Type de frein arrière Fr...

Page 82: ... en coupe B 1 0 mm 0 039 in T 2 35 mm 0 093 in Ecartement des becs monté 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Jeu latéral monté 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Vilebrequin Largeur du 55 90 55 95 mm vilebrequin A 2 201 2 203 in Limite de déflextion C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Jeu latéral de la tête de bielle D 0 06 0 64 mm 0 002 0 025 in Déflexion de pied de bielle F ...

Page 83: ...Marque d identification 1C35 30 1C36 40 1C37 50 Gicleur principal M J 410 430 Aiguille J N 6BFY42 74 3 6BFY43 74 3 Echancrure C A 4 0 Gicleur de ralenti P J 40 45 40 Vis d air de ralenti P A S 2 1 4 Taille de siège de pointeau V S ø3 8 mm 0 15 in Gicleur de démarreur G S 80 Niveau de carburant F L 9 5 10 5 mm 0 37 0 41 in Soupape flexible Epaisseur 0 47 mm 0 019 in Levèe de clapet 8 2 8 6 mm 0 323...

Page 84: ...iltre à air M 4 0 7 1 2 0 2 1 4 Carter de filtre à air M 6 1 0 4 8 0 8 5 8 Bride de guidage de filtre à air M 5 0 8 1 4 0 4 2 9 Clapets d admission M 3 0 5 6 1 0 1 0 7 Boulon de réglage et contre écrou M 8 1 25 1 7 0 7 5 1 Câble d accélérateur M 6 0 75 1 4 0 4 2 9 Carter M 6 1 0 12 14 1 4 10 Couvercle de carter droit M 6 1 0 8 10 1 0 7 2 Couvercle de carter gauche M 6 1 0 4 5 0 5 3 6 Couvercle de ...

Page 85: ... de tuyau d échappement avant M 6 1 0 1 12 1 2 8 7 Support de tuyau d échappement arrière M 6 1 0 1 12 1 2 8 7 Silencieux Silencieux et cadre M 6 1 0 2 12 1 2 8 7 Fibre pour USA et CDN M 6 1 0 2 10 1 0 7 2 Fibre excepté pour USA et CDN M 6 1 0 4 10 1 0 7 2 N B Le coupe de serrage des parties marquées doit être vérifié après le rodage ou avant chaque course ...

Page 86: ...t 5 mm 0 2 in Suspension arrière USA CDN ZA AUS NZ EUROPE Débattement d amortisseur 131 5 mm 5 18 in Longueur de ressort libre Approx 265 mm 10 43 in Longueur de raccord Une marque d identification 256 mm 10 08 in 254 mm 10 00 in Deux marques d identification 262 mm 10 31 in 260 mm 10 24 in Trois marques d identification 253 5 mm 9 98 in 251 5 mm 9 90 in min max Une marque d identification 245 5 2...

Page 87: ...10 in Epaisseur de plaquette 4 4 mm 0 17 in 1 0 mm 0 04 in Dia intérieur de maître cylindre 11 0 mm 0 433 in Dia intérieur de cylindre d etrier 27 0 mm 1 063 in 2 Type de liquide de frein DOT 4 Frein à disque arrière Dia extérieur épaisseur 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Limite de flèche 0 15 mm 0 006 in Epaisseur de plaquette 6 4 mm 0 25 in 1 0 mm 0 04 in Dia intérieur de maître ...

Page 88: ... de levier d embrayage M 5 0 8 2 4 0 4 2 9 Capuchon de maître cylindre de frein avant M 4 0 7 2 2 0 2 1 4 Boulon d union de tuyau de frein avant M10 1 25 1 30 3 0 22 maître cylindre Boulon d union de tuyau de frein avant étrier M10 1 25 1 30 3 0 22 Etrier de frein avant et fourche avant M 8 1 25 2 23 2 3 17 Etrier de frein avant et support de tuyau de frein M 6 1 0 1 10 1 0 7 2 Capuchon de poignée...

Page 89: ...Cadre arrière et cadre inférieur M 8 1 25 2 29 2 9 21 Bras oscillant et support de tuyau de frein M 5 0 8 4 2 0 2 1 4 Bras oscillant et garniture M 4 0 7 4 2 0 2 1 4 Montage de tendeur de chaîne M 8 1 25 2 16 1 6 11 Support de chaîne et bras oscillant M 6 1 0 3 7 0 7 5 1 Garde de joint et bras oscillant M 5 0 8 4 6 0 6 4 3 Guide de câble et cadre M 5 0 8 2 4 0 4 2 9 Bossage de montage du réservoir...

Page 90: ...bricant 1C3 10 YAMAHA Résistance de bobinage de source 1 720 1 080 Ω à 20 C 68 F couleur vert blanc noir rouge Résistance de bobinage de source 2 44 66 Ω à 20 C 68 F couleur noir vert bleu Résistance de bobinage d excitation 248 372 Ω à 20 C 68 F couleur blanc bleu blanc rouge Bloc CDI Modèle Fabricant 1C3 10 YAMAHA Bobine d allumage Modèle Fabricant 1C3 00 YAMAHA Etincellement minimale 6 mm 0 24 ...

Page 91: ...iletages propres et secs Les composants doivent être à température ambiante A Distance entre les plats B Diamètre extérieur du filetage DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE SPECIFICATION A B DE COUPLE Ecrou Vis Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unité Signification Défin...

Page 92: ...rgekühlter Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorn geneigt Hubraum 124 cm3 4 36 lmp oz 4 19 US oz Bohrung Hub 54 54 5 mm 2 126 2 146 in Verdichtungsverhältnis 8 6 10 7 1 Anlasssystem Kickstarter Schmiersystem Benzin Öl Gemisch 30 1 Yamalube 2 R Ölsorte oder Qualität Zweitakt Getriebeöl Yamalube 4 10W 30 oder Motoröl SAE 10W 30 SE Regelmäßige Ölwechsel 0 66 L 0 58 Imp qt 0 69 US qt Ge...

Page 93: ...0 6 Gang 23 21 1 095 Fahrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheibenrahmen Nachlauf 25 5 25 6 Nachlaufbetrag 105 mm 4 13 in 107 mm 4 21 in Reifengröße Bauart Mit Schlauch Reifengröße vorn 80 100 21 51M Reifengröße hinten 100 90 19 57M Reifendruck vorn und hinten 100 kPa 1 0 kgf cm2 15 psi Bremsen Vorderradbremse Einfach Scheibenbremse Betätigung Rechte Hand Hinterradbremse Ei...

Page 94: ...mm 0 039 in T 2 35 mm 0 093 in Ringspalt Eingebaut 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Seitliches Spiel Eingebaut 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Kurbelwelle Kurbelwangenbreite 55 90 55 95 mm A 2 201 2 203 in Kurbelwellenschlag C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Seitliches Spiel am Pleuelfluß D 0 06 0 64 mm 0 002 0 025 in Ausweichung des Pleuelauge F 0 8 1 0 mm 0 031 0 039...

Page 95: ...fikationsmarkierung 1C35 30 1C36 40 1C37 50 Hauptdüse M J 410 430 Düsennadel Klemmposition J N 6BFY42 74 3 6BFY43 74 3 Abschrägung C A 4 0 Leerlaufdüse P J 40 45 40 Leerlauf Luftregulierschraube P A S 2 1 4 Ventilsitzgröße V S ø3 8 mm 0 15 in Starterdüse G S 80 Kraftstoffstand F L 9 5 10 5 mm 0 37 0 41 in Zungenventil Dicke Groß 0 47 mm 0 019 in Ventilanschlaghöhe 8 2 8 6 mm 0 323 0 339 in Biegegr...

Page 96: ...uftfilter Verbindungsklammer M 4 0 7 1 2 0 2 1 4 Luftfiltergehäuse M 6 1 0 4 8 0 8 5 8 Luftfilter Führungsschelle M 5 0 8 1 4 0 4 2 9 Zungenventil M 3 0 5 6 1 0 1 0 7 Gaszug Einstellschraube und Sicherungsmutter M 8 1 25 1 7 0 7 5 1 Gasseil M 6 0 75 1 4 0 4 2 9 Kurbelgehäuse M 6 1 0 12 14 1 4 10 Kurbelgehäusedeckel rechts M 6 1 0 8 10 1 0 7 2 Kurbelgehäusedeckel links M 6 1 0 4 5 0 5 3 6 Kettendec...

Page 97: ... M 6 1 0 1 12 1 2 8 7 Auspuffrohrstütze hinten M 6 1 0 1 12 1 2 8 7 Schalldämpfer Schalldämpfer und Rahmen M 6 1 0 2 12 1 2 8 7 Fasereinsatz Für USA und CDN M 6 1 0 2 10 1 0 7 2 Fasereinsatz Außer USA und CDN M 6 1 0 4 10 1 0 7 2 HINWEIS Das mit markierte Teil ist nach dem Einfahren und vor jedem Rennen auf das richtige Anzugsmo ment zu prüfen ...

Page 98: ...elbeinrohre Hinterradaufhängung USA CDN ZA EUROPA AUS NZ Hub des Stoßdämpfers 131 5 mm 5 18 in Ungespannte Federlänge Etwa 265 mm 10 43 in Einbaulänge Eine ID Markierung 256 mm 10 08 in 254 mm 10 00 in Zwei ID Markierungen 262 mm 10 31 in 260 mm 10 24 in Drei ID Markierungen 253 5 mm 9 98 in 251 5 mm 9 90 in Min Max Eine ID Markierung 245 5 263 5 mm 9 67 10 37 in Zwei ID Markierungen 251 5 269 5 m...

Page 99: ... 0 12 in 9 84 0 10 in Bremsbelagstärke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder 11 0 mm 0 433 in Innendurchmesser Bremssattelzylinder 27 0 mm 1 063 in 2 Innendurchmesser Bremsflüssigkeit DOT 4 Hinterradscheibenbremse Außendurchmesser Dicke 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Ausweichungsgrenzwert 0 15 mm 0 006 in Bremsbelagstärke 6 4 mm 0 25 in 1 0 mm 0 04 in Hauptbremszylinder...

Page 100: ...alter M 5 0 8 2 4 0 4 2 9 Vorderrad Hauptbremszylinderkappe M 4 0 7 2 2 0 2 1 4 Vorderrad Bremsschlauch Unionschraube M10 1 25 1 30 3 0 22 Hauptbremszylinder Vorderrad Bremsschlauch Unionschraube Bremssattel M10 1 25 1 30 3 0 22 Vorderrad Bremssattel und Vorderradgabel M 8 1 25 2 23 2 3 17 Vorderbremssattel und Bremsschlauch Halterung M 6 1 0 1 10 1 0 7 2 Griffkappe oben und unten M 6 1 0 2 4 0 4 ...

Page 101: ...5 6 40 Hinterrad Stoßdämpfer und Relaisarm M10 1 25 1 53 5 3 38 Hintere Rahmen und Rahmen oben M 8 1 25 1 32 3 2 23 Hintere Rahmen und Rahmen unten M 8 1 25 2 29 2 9 21 Hinterradschwinge und Bremsschlauchhalter M 5 0 8 4 2 0 2 1 4 Hinterradschwinge und Schutz M 4 0 7 4 2 0 2 1 4 Kettenspanner Befestigung M 8 1 25 2 16 1 6 11 Kettenschutz und Hinterradschwinge M 6 1 0 3 7 0 7 5 1 Dichtungsschutz un...

Page 102: ...r Hersteller 1C3 10 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 Ω bei 20 C 68 F Grün Weiß Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 Ω bei 20 C 68 F Schwarz Grün Blau Widerstand der Aufnahmespule 248 372 Ω bei 20 C 68 F Farbe Weiß Blau Weiß Rot CDI Einheit Modell Hersteller 1C3 10 YAMAHA Zündspule Modell Hersteller 1C3 00 YAMAHA Mindestzündfunkenstrecke 6 mm 0 24 in Widerstand der ...

Page 103: ...nt für trockene und saubere Gewinde Die anzuziehenden Bauteile sollten dabei Raumtemperatur aufweisen A Schlüsselweite B Gewindedurchmesser DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A B ANZUGSMOMENTE Mutter Schraube Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Einheit Bedeutung Defin...

Page 104: ...ddato con liquido a benzina Disposizione dei cilindri Cilindro unico inclinato in avanti Cilindrata 124 cm3 4 36 lmp oz 4 19 US oz Alesaggio corsa 54 54 5 mm 2 126 2 146 in Rapporto di compressione 8 6 10 7 1 Sistema di avviamento Pedivella della messa in moto Sistema di lubrificazione Miscela preparata 30 1 Yamalube 2 R Tipo o qualità di olio a 2 cicli Olio per trasmissioni Olio per motori Yamalu...

Page 105: ...oppia Angolo di incidenza 25 5 25 6 Avancorsa 105 mm 4 13 in 107 mm 4 21 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 100 90 19 57M Pressione degli pneumatici anteriore e posteriore 100 kPa 1 0 kgf cm2 15 psi Freno Tipo di freno anteriore Freno a disco singolo Azionamento Azionamento con la mano destra Tipo di freno posteriore Freno a disco singolo ...

Page 106: ... 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Gioco laterale installata 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Albero a gomiti Larghezza del gomito A 55 90 55 95 mm 2 201 2 203 in Limite di scentratura C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Gioco laterale dell estremità grossa della leva di rinvio D 0 06 0 64 mm 0 002 0 025 in Gioco libero dell estremità piccola F 0 8 1 0 mm 0 031 0 039 in 2 ...

Page 107: ...1C35 30 1C36 40 1C37 50 Getto principale M J No 410 No 430 Posizione della staffa dell ago di getto J N 6BFY42 74 3 6BFY43 74 3 Sezione C A 4 0 Getto pilota P J No 40 No 45 No 40 Vite dell aria pilota P A S 2 1 4 Dimensioni della sede della valvola V S ø3 8 mm 0 15 in Getto avviamento G S No 80 Livello del carburante F L 9 5 10 5 mm 0 37 0 41 in Valvola a lamella Spessore 0 47 mm 0 019 in Altezza ...

Page 108: ...rsetto del giunto del filtro dell aria M 4 0 7 1 2 0 2 1 4 Corpo del filtro dell aria M 6 1 0 4 8 0 8 5 8 Brida di guida del filtro dell aria M 5 0 8 1 4 0 4 2 9 Valvola a lamella M 3 0 5 6 1 0 1 0 7 Bullone di regolazione e controdado del cavo acceleratore M 8 1 25 1 7 0 7 5 1 Cavo dell acceleratore M 6 0 75 1 4 0 4 2 9 Carter M 6 1 0 12 14 1 4 10 Copertura del carter destra M 6 1 0 8 10 1 0 7 2 ...

Page 109: ... M 6 1 0 2 12 1 2 8 7 Puntello del tubo di scarico anteriore M 6 1 0 1 12 1 2 8 7 Puntello del tubo di scarico posteriore M 6 1 0 1 12 1 2 8 7 Silenziatore Silenziatore e telaio M 6 1 0 2 12 1 2 8 7 Fibra Per USA e CDN M 6 1 0 2 10 1 0 7 2 Fibra Tranne che per USA e CDN M 6 1 0 4 10 1 0 7 2 NOTA La parte marcata con deve essere controllata per il serraggio della coppia dopo il rodaggio o prima di ...

Page 110: ... Corsa dell ammortizzatore 131 5 mm 5 18 in Lunghezza libera della molla 265 mm circa 10 43 in Lunghezza di inserimento Un contrassegno di marcatura 256 mm 10 08 in 254 mm 10 00 in di identificazione Due contrassegni di marcatura di 262 mm 10 31 in 260 mm 10 24 in identificazione Tre contrassegni di marcatura di 253 5 mm 9 98 in 251 5 mm 9 90 in identificazione Min Max Un contrassegno di marcatura...

Page 111: ...4 in Diametro interno del cilindro principale 11 0 mm 0 433 in Diametro interno del cilindro delle pinze 27 0 mm 1 063 in 2 Tipo di liquido per freni DOT No 4 Freno a disco posteriore Diametro esterno del disco Spessore 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Limite di inflessione 0 15 mm 0 006 in Spessore della pastiglia 6 4 mm 0 25 in 1 0 mm 0 04 in Diametro interno del cilindro principa...

Page 112: ... 9 Coperchio del cilindro principale del freno anteriore M 4 0 7 2 2 0 2 1 4 Bullone di unione del tubo flessibile del freno M10 1 25 1 30 3 0 22 anteriore cilindro principale Bullone di unione del tubo flessibile del freno anteriore pinza M10 1 25 1 30 3 0 22 Pinza del freno anteriore e forcella anteriore M 8 1 25 2 23 2 3 17 Pinza del freno anteriore e supporto del tubo flessibile del freno M 6 ...

Page 113: ...scillante e supporto del tubo flessibile M 5 0 8 4 2 0 2 1 4 del freno Forcellone oscillante e superficie di contatto M 4 0 7 4 2 0 2 1 4 Supporto del tendicatena M 8 1 25 2 16 1 6 11 Supporto della catena e forcellone oscillante M 6 1 0 3 7 0 7 5 1 Protezione del dispositivo di tenuta e forcellone oscillante M 5 0 8 4 6 0 6 4 3 Guida per cavi e telaio M 5 0 8 2 4 0 4 2 9 Sporgenza di supporto del...

Page 114: ... del magnete 1C3 10 YAMAHA Resistenza 1 della bobina di origine 720 1 080 Ω à 20 C 68 F colore Verde Bianco Nero Rosso Resistenza 2 della bobina di origine 44 66 Ω à 20 C 68 F colore Nero Verde Blu Resistenza della bobina di accelerazione 248 372 Ω à 20 C 68 F colore Bianco Blu Bianco Rosso Modello Costruttore dell unità CDI 1C3 10 YAMAHA Bobina di accensione Modello Costruttore 1C3 00 YAMAHA Dist...

Page 115: ...nti dovrebbero essere a temperatura am biente A Distanza fra le parti piatte B Diametro esterno della filettatura IC230000 DEFINIZIONE DELLE UNITÀ IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA SPECIFICA RELATIVA A B ALLA COPPIA Dado Vite Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unità Lettura ...

Page 116: ...lutch cable and ENGINE STOP button lead above the radiator hose D Install the ignition coil side core and ground lead together to the frame Take care to fas ten the ground lead so that its terminal is within the indicated range E Clamp the throttle cable and high tension cord to the frame F Clamp the clutch cable to the left engine bracket Clamp the clutch cable below the posi tioning grommet G Pa...

Page 117: ...ise à l air du radiateur Installer la bobine d allumage le fais ceau latéral et le fil de masse ensemble sur le cadre Fixer le fil de masse de façon à ce que sa borne se trouve dans la plage indiquée Brider le câble des gaz et le fil haute ten sion au cadre ƒ Brider le câble d embrayage sur le sup port gauche du moteur Brider le câble d embrayage sous l œillet de positionne ment Refaire passer la ...

Page 118: ... frame the CDI magneto lead and radiator breather hose Take care to clamp them above the projec tion on the frame L Locate the clamp ends in the arrowed range M Pass the air vent hose over flow hose and crankcase breather hose so that they do not contact the rear shock absorber N Bring the connector cover into contact with the coupler ...

Page 119: ... magnétique CDI et la durit de mise à l air du radiateur Veiller à les brider au dessus de la saillie du cadre Placer les extrémités du collier dans le sens de la flèche µ Faire passer la durit de ventilation la durit de trop plein et la durit de mise à l air du carter moteur de façon à ce qu elles ne soient pas en contact avec l amortisseur arrière Mettre le capuchon de connecteur en contact avec...

Page 120: ... In so doing clamp the ignition coil lead and ENGINE STOP button lead at their protecting tubes Tighten the clamp so that the ENGINE STOP button lead is not pulled when the handlebar is turned to the right and left D Pass the CDI magneto lead and radiator breather hose between the frame and the radiator right E Clamp the CDI magneto lead to the frame at its locating tape F Bring the connector cove...

Page 121: ...et le fil du bouton ENGINE STOP Serrer le collier à pince de façon à ce que le fil du bouton ENGINE STOP ne soit pas tiré lorsque le guidon tourne vers la gauche et vers la droite Faire passer le fil du volant magnétique CDI et la durit de mise à l air du radia teur entre le cadre et le radiateur droite Brider le fil de magnéto CDI au cadre sur sa bande adhésive de positionnement ƒ Mettre le capuc...

Page 122: ...ec tion on the caliper B Pass the brake hose into the brake hose hold ers C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projec tion on the master cylinder 1 Master cylinder 2 Brake hose holder 3 Brake hose ...

Page 123: ... en contact avec la saillie de l étrier Faites ensuite passer le tuyau de frein dans les supports du tuyau de frein ç Si le tuyau de frein touche le ressort amortisseur arrière ajuster le coude Installer le tuyau de frein de manière que la partie avec le tuyau soit dirigée comme indiqué et touche légèrement la saillie sur le maître cylindre 1 Cilindro principale 2 Support del tubo flessibile del f...

Page 124: ...P button lead in the middle of the clutch holder C Clamp the ENGINE STOP button lead to the handlebar D Pass the brake hose in front of the number plate and through the cable guide E Pass the clutch cable through the cable guide on the number plate 1 Brake hose 2 Master cylinder 3 ENGINE STOP button lead 4 ENGINE STOP button 5 Throttle cable 6 Clutch cable 7 Clamp 8 Cable guide ...

Page 125: ...au de frein de manière que la partie avec le tuyau soit dirigée comme indipué et touche légèrement la saillie sur le maîtrecylindre Faire passer le fil de bouton d arrêt du moteur ENGINE STOP au centre du support d embrayage ç Fixer le fil du bouton ENGINE STOP sur le guidon Faire passer le tuyau de frein devant la plaque d immatriculation et à travers le guide de câble Faire passer le câble d emb...

Page 126: ... gap Inspect carbon deposits and eliminate them Check gasket Inspect score marks Inspect wear Inspect carbon deposits and eliminate them Inspect housing friction plate clutch plate and spring Yamalube 4 10W 30 or SAE 10W 30 SE motor oil Inspect wear Use chain lube Chain slack 48 58 mm 1 9 2 3 in PISTON Inspect and clean Replace PISTON RING Inspect Replace PISTON PIN SMALL END BEARING Inspect Repla...

Page 127: ...fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER After Inspect and adjust rain ride Lube Molybdenum disulfide grease Replace spring seat Every one year Retighten CHAIN GUARD AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybde...

Page 128: ...INTENANCE INTERVALS INSP ADJ Item Remarks THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or Lubricate SAE 10W 30 motor oil After break in Every race Every third Every fifth As re quired ...

Page 129: ...Changer 6 CULASSE Contrôler et nettoyer 6 6 Resserrer 6 6 CYLINDRE Contôler et nettoyer 6 6 Changer 6 YPVS Contrôler et nettoyer 6 6 EMBRAYAGE Contrôler et régler 6 6 Changer 6 BOITE DE VITESSE Changer l huile 6 6 Contrôler 6 Changer le roulement 6 FOURCHETTE BARILLET BARRE DE GUIDAGE Contrôler 6 ECROU DU ROTOR Resserrer 6 6 POT D ECHAPPEMENT Contrôler 6 6 Nettoyer 6 Resserrer 6 6 VILEBREQUIN Cont...

Page 130: ... 6 6 Contrôler la surface du frein à disque 6 6 Contrôler le niveau de fluide et les fuites 6 6 Resserrer les boulons du frein à disque les boulons d étier les boulons du maître cylindre et les boulons d union 6 6 Changer les plaquettes 6 Changer le liquide de frein 6 FOURCHE AVANT Contrôler et régler 6 6 Changer l huile 6 6 Changer la bague d étanchéité 6 BAGUE D ETANCHEITE ET JOINT ANTIPOUSSIERE...

Page 131: ...brifier 6 Changer le roulement 6 PNEU ROUES Contrôler la pression de gonflage le voile de roue et l usure des 6 6 pneus et voir s il n y a pas de rayon détendu Resserrer les boulons de la roue 6 6 dentée Contrôler les roulements 6 Changer les roulements 6 Graisser 6 ACCELERATEUR CABLES DE COMMANDE Contrôler le chaminement et le 6 6 branchement Graisser 6 6 Graisse au bisulfure de molybdène Graisse...

Page 132: ...neuern 6 ZYLINDERKOPF Prüfen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Prüfen und reinigen 6 6 Erneuern 6 YPVS Prüfen und reinigen 6 6 KUPPLUNG Prüfen und einstellen 6 6 Erneuern 6 GETRIEBE Öl wechseln 6 6 Prüfen 6 Lager erneuern 6 SCHALTGABEL SCHALTNOCKE FÜHRUNGSSTANGE Prüfen 6 ROTORMUTTER Nachziehen 6 6 SCHALLDÄMPFER Prüfen 6 6 Reinigen 6 Nachziehen 6 6 KURBELWELLE Prüfen und reinigen 6 6 VERGASE...

Page 133: ... 6 KRAFTSTOFFTANK KRAFT STOFFHAHN Reinigen und prüfen 6 6 BREMSEN Bremshebelposition und Bremspedalhöhe einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfläche prüfen 6 6 Flüssigkeitsstand prüfen und auf Undichtigkeit achten 6 6 Bremsscheiben und Bremssattel Befestigungsschrauben Haupt bremszylinder Befestigungs 6 6 schrauben und Hohlschrauben nachziehen Bremsbelagplatten erneuern 6 Bremsflüss...

Page 134: ...hziehen 6 6 Reinigen und schmieren 6 Lager erneuern 6 RÄDER REIFEN Reifendruck Felgenschlag Reifenverschleiß und Speichen 6 6 auf Lockerung prüfen Kettenrad Befestigungsschraube 6 6 nachziehen Lager prüfen 6 Lager erneuern 6 Schmieren 6 GASDREHGRIFF GASSEIL Seilzugführung und Anschlüsse 6 6 prüfen Schmieren 6 6 Lithium Fett Lithium Fett Yamaha Seilzug Schmiermittel oder Motoröl SAE 10W 30 ...

Page 135: ... 6 6 Sostituzione 6 YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sostituzione dell olio 6 6 Ispezione 6 Sostituzione del cuscinetto 6 FORCELLA DEL CAMBIO CAMMA DEL CAMBIO GUIDA DI SCORRIMENTO Ispezione 6 DADO DEL ROTORE Riserraggio 6 6 MARMITTA Ispezione 6 6 Pulitura 6 Riserraggio 6 6 GOMITO Ispezione e pulitura 6 6 CARBURATORE Ispezione regolazion...

Page 136: ...eni 6 FORCELLE ANTERIORI Ispezione e regolazione 6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pulitura e lubrificazione 6 6 GUIDA DEL DISPOSITIVO DI PROTEZIONE Sostituzione 6 AMMORTIZZATORE POSTERIORE Ispezione e regolazione 6 6 Lubrificazione 6 6 Sostituire la sede della molla 6 Riserraggio 6 6 COPRICATENA E RULLI PER CATENA Ispezione ...

Page 137: ...one gioco libero e riserraggio 6 6 Pulitura e lubrificazione 6 Sostituzione del cuscinetto 6 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneumatico e dell allentamento delle razze Riserraggio bullone del rocchetto 6 6 Ispezione dei cuscinetti 6 Sostituzione dei cuscinetti 6 Lubrificazione 6 VALVOLA A FARFALLA CAVO DI COMANDO Controllo del...

Page 138: ...ear brake P3 17 23 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 24 26 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P3 34 35 Steering Check that the handlebar can be turned smoothly and have no excessive play P3 35 37 Front forks and Check that they operate smoothly and there is no oil rear shock absorber...

Page 139: ...ne Contrôler la tension et l alignement de la chaîne S as surer que la chaîne est graissée correctement P3 24 26 Roues Contrôler s il n y a pas d usure excessive Contrôler s il n y a pas de rayons détendus et qu il n a pas de jeu ex P3 34 35 cessif Direction S assurer que le guidon peut être tourné en douceur et qu il n a pas de jeu excessif P3 35 37 Fourche avant et S assurer qu ils fonctionnent ...

Page 140: ...ung prü fen Auch sicherstellen dass die Kette richtig geschmiert P3 24 26 ist Räder Die Reifen auf übermäßige Abnutzung kontrollieren Speichen auf Lockerung und übermäßiges Spiel prü P3 34 35 fen Lenkung Darauf achten dass sich die Lenkstange glatt drehen lässt und kein übermässiges Spiel aufweist P3 35 37 Vorderradgabel und Auf richtige Funktion achten und sicherstellen dass kein Hinterrad Stoßdä...

Page 141: ... della frizione e dell acceleratore si muovano senza problemi Controllare che non rimanga no impigliati quando viene girato il manubrio o quando le forcelle anteriori si alzano e si abbassano Controllare che la marmitta sia montata saldamente e non presenti incrinature Controllare che il bullone di serraggio del rocchetto condotto non sia allentato Controllare il regolare funzionamento Lubrificare...

Page 142: ...ap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it cC Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright position ...

Page 143: ...t tourner lentement le bouchon à gauche jusqu au point de détente Cette procédure permet de faire tom ber toute pression résiduelle Quand le sifflement s est arrêté appuyer sur le bouchon tout en le tournant à droi te pour le déposer fF L eau calcaire et l eau salée sont nui sibles pour les pièces du moteur Si on ne dispose pas d eau douce on peut utiliser de l eau distillée 1 Placer la machine su...

Page 144: ...rain the coolant completely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Recommended coolant High quality ethylene glycol anti freeze containing anti corrosion for aluminum engine Coolant 1 1 and water soft water 2 2 mixing ratio 50 50 Coolant capacity 0 9 L 0 79 Imp qt 0 95...

Page 145: ... non schizzi sulle superfici ver niciate Se schizza toglierlo con acqua 1 Collocare un contenitore sotto il motore 2 Togliere 9 Bullone di scarico del liquido refrigerante 1 3 Togliere 9 Tappo del radiatore Scaricare completamente il liquido refrigerante 4 Pulire 9 Impianto di raffreddamento Lavare accuratamente l impian to di raffreddamento con acqua del rubinetto pulita 5 Installare 9 Rondella d...

Page 146: ...vel low Add coolant EC355000 RADIATOR CAP INSPECTION 1 Inspect 9Seal radiator cap 1 9Valve and valve seat 2 Crack Damage Replace Exist fur deposits 3 Clean or replace Handling notes of coolant The coolant is harmful so it should be handled with special care w 9When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor 9When coolant splashes to your clothes Quickly wa...

Page 147: ...t Wasser und danach mit Seife weg oder auswaschen 9Falls Kühlmittel eingenom men wird Die betroffene Person sofort zum Erbre chen bringen und zum näch sten Doktor begleiten Notes concernant la manipulation du liquide de refroidissement Le liquide de refroidissement étant dangereux il doit être manipulé avec une attention particuliére XG 9Quand vous vous mettez du liquide de refroidissement dans le...

Page 148: ...pres sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8 psi Standard pre...

Page 149: ... Sekunden gehalten werden Erneuern VERIFICATION DE LA PRESSION D OUVERTURE DU BOUCHON DU RADIATEUR 1 Attacher 9 Testeur du bouchon du radiateur 1 et adaptateur 2 N B Appliquer de l eau sur le joint du bou chon du radiateur 3 Bouchon du radiateur 2 Appliquer la pression spécifiée 3 Examiner 9 Pression Impossible de maintenir la pres sion spécifiée pendant 10 secondes Changer IC356002 ISPEZIONE DELL...

Page 150: ... specification Adjust NOTE 9Before adjustment expose the adjuster by moving the boot 3 and cap 4 away 9Make minute adjustment on the lever side using the adjuster 5 9After adjustment check proper operation of clutch lever Clutch lever free play a a 8 13 mm 0 31 0 51 in Clutch lever free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until free play a is with in the specified limi...

Page 151: ...lo o sostituirlo 9 Manicotto flessibile del radiatore 3 Rigonfiamento Sostituirlo IC359020 REGOLAZIONE DELLA FRIZIONE 1 Controllare 9 Gioco libero della leva di comando della frizione a Fuori specifica Regolarlo 2 Regolare 9 Gioco libero della leva di comando della frizione NOTA 9Prima della regolazione mettere a nudo il dispositivo di regolazione spo stando il parapolvere 3 e il coperchio 4 9Eseg...

Page 152: ...sen the locknut 1 9Turn the adjuster 2 until the specified free play is obtained 9Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted w After adjusting turn the handlebar to right and left and make sure that the en gine idling does not run faster Throttle grip free play a a 3 5 mm 0 12 0 20 in Locknut 7 Nm 0 7 m kg 5 1 ft lb 2 Apply 9Lith...

Page 153: ... Desserrer le contre écrou 1 9 Tourner le dispositif de réglage 2 jusqu à ce que le jeu soit compris dans les limites spécifiées 9 Serrer le contre écrou N B Avant de régler le jeu de câble de la commande des gaz il faut régler la vitesse de marche au ralenti du moteur XG Après le réglage tourner le gui don vers la droite et vers la gauche et s assurer que le régime de ralenti du moteur ne changer...

Page 154: ...gine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove 9Seat 9Fitting bolt 1 9Washer 2 9Air filter element 3 9Filter guide 4 2 Clean 9Air filter element Clean them with solvent NOTE After cleaning remove the remaining solvent by squeezing the element cC Do not twist the element when squeezing the elem...

Page 155: ... anson sten können Staub und Schmutz in den Motor eindringen und schnel len Verschleiß sowie einen mögli chen Motorschaden verursachen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelement 3 9 Luftfilterführung 4 2 Reinigen 9 Luftfilterelement Mit einer Waschlösung reini gen HINWEIS Nach dem Reinigen restliches Lösungsmittel aus dem Schaumgum mi ausdrücken dD Das Filterelement...

Page 156: ...ole b in air filter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on filter guide with the hole b in air filter case EC35H002 TRANSMISSION OIL LEVEL CHECK 1 Start the engine warm it up for several min utes and wait for five minutes 2 Place the machine on a level place and ...

Page 157: ...lemento del filtro dell aria Danni Sostituirlo 4 Applicare 9 Olio per filtro dell aria in schiu ma oppure olio equivalente Sull elemento NOTA Comprimere per fare fuoriuscire l olio in eccesso L elemento dovrebbe essere umido ma non gocciolare 5 Installare 9 Guida del filtro 1 NOTA Allineare la sporgenza a sulla guida del filtro con il foro b nell elemento del filtro dell aria 2 Nm 0 2 m kg 1 4 ft ...

Page 158: ...s 9Remove the oil check bolt 1 9Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level w Never attempt to remove the oil check bolt just after high speed operation The heat ed oil could spout out causing danger Wait until the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmission oil until oil flows ...

Page 159: ...marreur le moteur le laisser chauffer quelques minutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en plaçant le support convenable sous le moteur 3 Placer un récipient convenable sous le moteur 3 Controllare 9 Livello dell olio della trasmis sione Passi del controllo del livello dell olio della trasmissione 9Togliere il bullone di controllo del...

Page 160: ...ransmission oil level 9 Install 9Oil filler cap 2 EC35L002 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Recommended oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Oil capacity periodic oil change 0 66 L 0 58 Imp qt 0 69 US qt Adjustment steps 9Screw in the pilot air screw until it is lightly seated 9Back out by the specified number of turns Pilot air screw 2 1 4 turns out 20 Nm 2 ...

Page 161: ...2 Das Getriebeöl ablassen 5 Einbauen 9 Aluminiumscheibe 9 Ölablassschraube 1 Empfohlenes Öl Yamalube 4 10W 30 oder Motoröl SAE 10W 30 SE Öl Fassungsvermögen Regelmäßiger Ölwech sel 0 66 L 0 58 Imp qt 0 69 US qt 4 Togliere 9 Bullone di scarico dell olio 1 9 Tappo di riempimento dell olio 2 Scaricare l olio della trasmissione 5 Installare 9 Rondella d alluminio 9 Bullone di scarico dell olio 1 20 Nm...

Page 162: ...O rings with their depressed a facing outward EC35R050 SILENCER FIBER REPLACEMENT 1 Remove 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Å For USA and CDN ı Except for USA and CDN Adjustment steps 9Loosen the locknut 1 9Turn the throttle stop screw 2 until the en gine runs at the lowest possible speed 9Tighten the locknut To increase idle speed Turn the throttle stop screw 2 2 in To...

Page 163: ...alldämpfer 2 9 Schraube Fasereinsatz 3 A Für USA und CDN B Außer USA und CDN IC35R050 SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE 1 Togliere 9 Copertura laterale destra 9 Bullone silenziatore 1 9 Silenziatore 2 9 Bullone fibra 3 å Per USA e CDN Tranne che per USA e CDN IC35M010 REGOLAZIONE DEL NUMERO DI GIRI AL MINIMO 1 Avviare il motore e scaldarlo com pletamente 2 Regolare 9 Numero di giri al mini...

Page 164: ...ight Å For USA and CDN ı Except for USA and CDN 12 Nm 1 2 m kg 8 7 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 1215 or equivalent as shown Yamaha bond No 1215 ThreeBond No 1215 90890 85505 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb A B ...

Page 165: ...m 1 2 m kg 8 7 ft lb 2 Déposer 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez généreusement de l agent d étanchéité Quick Gasket Yamaha Bond n 1215 ou équivalent comme illustré 2 Ausbauen 9 Innenrohr 1 3 Erneuern 9 Fasereinsatz 2 4 Einbauen 9 Innenrohr HINWEIS Quick Gasket Yamaha bond Nr 1215 oder gleichwertiges Produkt voll auftragen wie dargestellt 2 Togli...

Page 166: ...s a Add proper brake fluid to 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 of the tube into a container e Slowly apply the brake lever or pedal sev eral times f Pull the lever in or push down on the ped al Hold the lever or pedal in position g ...

Page 167: ...lage Es kann zu einer gefährlichen Abnahme des Bremsvermögens kommen falls die Bremsanlage nicht richtig entlüftet ist 1 Ausbauen 9 Hauptbremszylinderkappe 9 Membrane 9 Schwimmer im Behälter vor dere Bremse 9 Schutz Hinterradbremse 2 Entlüften 9 Bremsflüssigkeit A Vorn B Hinten PARTIE CYCLE PURGE DE L AIR DU SYSTEME DE FREINAGE XG Purger le système de freinage si 9Le système a été démonté 9Un tuya...

Page 168: ...procedure when the tiny bubbles in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever position a a Standard position Extent of adjutment 95 mm 3 74 in 76 97 mm 2 99 3 82 in Brake lever position adjustment steps 9Loosen the locknut 1 9Turn the adjusting bolt 2 until the lever posi tion a is ...

Page 169: ...e circuit de freinage NOTA Se lo spurgo risulta difficoltoso può essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le bol licine nell impianto sono scompar se j Aggiungere liquido per frenio fino alla linea di livello sul ser batoio T Controllare il funzionamento del freno dopo avere spurgato l impianto frenante Posit...

Page 170: ...just NOTE The brake pedal height is the vertical distance from the inside top end of the footrest 2 Adjust 9Brake pedal height Brake pedal height a a Zero mm Zero in Pedal height adjustment steps 9Loosen the locknut 1 9Turn the adjusting nut 2 until the pedal height a is within specified height 9Tighten the locknut w 9Adjust the pedal height between the maximum Å Å and the minimum ı ı as shown In ...

Page 171: ...s die Pedalhöhe a innerhalb der vorgeschriebenen Höhe liegt 9 Die Sicherungsmutter festziehen W 9 Pedalhöhe gemäß Abbildung zwischen Maximum å å und Mini mum einstellen bei dieser Einstellung soll das Ende b b der Schraube 3 3 aus dem Gewinde teil überstehen 4 4 aber im Abstand von nicht weniger als 2 mm 0 08 in c c vom Bremspedal 5 5 9 Nachdem die Pedalhöhe einge stellt wurde darauf achten dass d...

Page 172: ...er its end 9Loosen the bleed screw and push the caliper piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 7 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper 8 and tighten the pad pin 9 Bleed screw 6 Nm 0 6 m kg 4 3 ft b Bolt caliper 23 Nm...

Page 173: ...ken dD Die abgelassene Bremsflüssig keit nicht wiederverwenden 9 Die Entlüftungsschraube festzie hein 9 Bremsbeläge 7 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbeläge mit deren Über ständen a in die Bremsschuh aussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 9 Den Sattel 8 einbauen und den Belagstift 9 festziehen 9Desserrer la goupille de plaquet...

Page 174: ... REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect 9Brake pad thickness a Out of specification Replace as a set 2 Replace 9Brake pad 9Install the pad pin plug 0 Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Brake pad thickness a a Standard 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Brake pad replacement steps 9Remove the protector 1 and pad pin plug 2 9Loosen the pad pin 3 9Remove the rear wheel 4 and caliper 5...

Page 175: ...omando del freno Sensazione di morbidezza o spugnosità Spurgare impianto frenante Consultare la sezione SPURGO DELL ARIA DALL IMPIANTO FRENANTE IC366060 ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 1 Ispezionare 9 Spessore delle pastiglie del freno a Fuori specifica Sostituirle come set 2 Sostituire 9 Pastiglia del freno Bouchon de goupille de plaquette 3 Nm 0 3 m kg 2 2 ft lb Tap...

Page 176: ...r projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper w and rear wheel e Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 9Tighten the pad pin r 9Install the pad pin plug t and protector y Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Bolt protector 7 Nm 0 7 m kg 5 1 ft ...

Page 177: ...uyau transparent 8 à la vis de purge 9 et placer le récipient approprié sous son extré mité 9Desserrer la vis de purge et y enfoncer le piston d étrier fF Ne pas réutiliser le liquide de frein purgé 9Serrer la vis de purge 9Installer les plaquettes de frein 0 et la goupille de plaquette q N B 9Installer les plaquettes de frein en ajustant leurs saillies a dans l encoche de l étrier b 9A ce stade s...

Page 178: ...linder so that its top is in a horizontal position 2 Inspect 9Brake fluid level Fluid at lower level Fill up a Lower level ÅFront ıRear w 9Use only designated quality brake fluid to avoid poor brake performance 9Refill with same type and brand of brake flu id mixing fluids could result in poor brake performance 9Be sure that water or other contaminants do not enter master cylinder when refilling 9...

Page 179: ... LIQUIDO PER FRENI 1 Collocare il cilindro principale in maniera tale che la sua parte supe riore si trovi in posizione orizzon tale 2 Ispezionare 9 Livello del liquido per freni Fluido a livello più basso Rabboccarlo a Livello più basso A Anteriore B Posteriore T 9Per evitare uno scarso rendimento frenante usare soltanto liquido per freni della qualità indicata 9Rabboccare con lo stesso tipo e ma...

Page 180: ...rease its tension 9Measure the length between drive chain roller 1 and y as shown 9Perform this measurement at two or three dif ferent places 2 Remove 9Master link clip 9Joint 1 9Drive chain 2 3 Clean 9Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain EC369002 DRIVE CHAIN INSPECTION 1 Measure 9Drive chain length 15 lin...

Page 181: ...Die Länge zwischen der Antriebsket tenrolle 1 und y wie dargestellt messen 9 Diese Messung an zwei oder drei verschiedenen Stellen durchführen IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei rocchetti a Usura eccessiva Sostituirli NOTA Sostituire il rocchetto conduttore quel lo condotto e la catena di trasmissione come set IC369002 ISPEZIONE DELLA CATENA DI TRASMISSIONE 1 Misurare 9 Lun...

Page 182: ...olutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 48 58 mm 1 9 2 3 in Drive chain lubricant SAE 10W 30 motor oil or suitable chain lubricants 5 Install 9Drive chain 1 9Joint 2 9Master link clip 3 cC Be sure to install the master link clip to the direction as shown a Turning direction ...

Page 183: ... anello principale nella direzione illustrata a Direzione di rotazione 6 Lubrificare 9 Catena di trasmissione 5 Monter 9 Chaîne de transmission 1 9 Raccord 2 9 Agrafe de l attache rapide 3 fF Veiller à insérer l agrafe de l attache rapide dans le sens indiqué a Sens de la marche 6 Lubrifier 9 Chaîne de transmission Lubrifiant de chaîne de transmission Huile moteur SAE 10W 30 ou un lubrifiant pour ...

Page 184: ...3 3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain puller align ment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear cC Too small chain slack will overload the engine and other vital parts keep the slack...

Page 185: ... innerhalb des spezifizier ten Bereiches halten 9 Die Achsmuttern festziehen während die Antriebskette nach unten gedrückt wird 9 Die Sicherungsmuttern festziehen 3 Régler 9 Flèche de chaîne de transmis sion Procédure de réglage de flèche de chaîne de transmission 9Desserrer l écrou d axe 1 et les contre écrous 2 9Régler la flèche de chaîne en tor nant les dispositifs de réglage 3 Pour tendre Tour...

Page 186: ...ase on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1 Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the adjuster 1 1 out EC36f000 FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff during a run relieve t...

Page 187: ...au de fourche interne et le cache poussière 2 Nettoyer 9 Joint antipoussière a 9 Bague d étanchéité b N B 9Nettoyer le joint antipoussière et la bague d étanchéité après chaque cour se 9Appliquer la graisse à base de savon au lithium sur le tube interne Härter a a Die Expansions Dämpfungskraft erhöhen Den Einsteller 1 1 hin eindrehen Weicher b b Die Expansions Dämpfungskraft vermindern Den Einstel...

Page 188: ...ON DAMPING FORCE ADJUSTMENT 1 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 out Minimum 20 clicks out from maximum position 9STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in p...

Page 189: ... Ruota re il dispositivo di regolazione 1 1 in senso normale Più morbido b b Diminuire la forza di smorza mento della com pressione Ruo tare il dispositivo di regolazione 1 1 in senso inverso REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION DE LA FOURCHE AVANT 1 Régler 9 Force d amortissement de com pression En tournant le dispositif de réglage 1 EINSTELLUNG DER KOMPRESSI ONS DÄMPFUNGSKRAFT DER...

Page 190: ...damaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smooth action Abnormal noise Unsmooth action Grease the pivoting points or repair the piv oting points Damage Oil leakage Replace Minimum 20 clicks out from maximum position Extent of adjustment Maximum Fully turned ...

Page 191: ...endommager XG Toujours régler à la même position sur chaque bras de fourche avant Un réglage inégal peut entraîner une mauvaise maniabilité et une perte de stablilité VERIFICATION DE L AMOR TISSEUR ARRIERE 1 Examiner 9 Action régulière du bras oscil lant Bruit anormal Action irrégulière Graisser les points de pivot ou les réparer Endommagement fuites d huile Changer INSPEKTION DES HINTERRAD STOSSD...

Page 192: ...P ADJ EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Remove 9Rear frame 3 Loosen 9Locknut 1 4 Adjust 9Spring preload By turning the adjuster 2 Stiffer Increase the spring preload Turn the adjuster 2 2 in Softer Decrease the spring pre load Turn the adjuster 2 2 out Extent of adjustment 245 5 263 5 mm 9 67 10 37 in 2...

Page 193: ...er 9 Précontrainte de ressort En tournant le dispositif de réglage 2 N B 9Bien enlever toute la boue et toutes les saletés autour du contre écrou et de l ajusteur avant de faire le réglage 9La longueur du ressort monté chan ge de 1 5 mm 0 06 in par tour com plet du dispositif de réglage 9La marque d identification b est apposée à l extrémité du ressort 9La longueur standard et la plage de réglage ...

Page 194: ...ad juster with the punch mark b on the bracket cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the ad juster 1 1 out Minimum 20 clicks out from maximum position Extent of adjustment Maximum Fully turned in position Sta...

Page 195: ... des Einstellers 1 IC36N020 REGOL ELLA FORZA DI SMOR ZAMENTO DELL ESTENSIONE D E L L A M M O R T I Z Z A T O R E POSTERIORE 1 Regolare 9 Forza di smorzamento dell estensione Ruotando il dispositivo di rego lazione 1 Maximum Minimum Position 20 le mettre hors complètement circuit à partir du rentrée réglage maximum Etendue de réglage Massima Minima 20 scatti in senso Posizione inverso avvitata comp...

Page 196: ... posi tion Which align the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the low compression damping force Turn the ad juster 1 1 in Softer b b Decrease the low compres sion damping force Turn the adjuster 1 1 out Minimum 20...

Page 197: ...SSIONS DÄMPFUNGS KRAFT DES HINTERRADSTOS SDÄMPFERS 1 Einstellen 9 Niedrige Kompressions Dämp fungskraft Den Einsteller 1 drehen IC36c000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento a bassa compressione Ruotando il dispositivo di rego lazione 1 REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION BASSE DE L AMOR TISSEU...

Page 198: ...tion Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the high compression damping force Turn the ad juster 1 1 in Softer b b Decrease the high compres sion damping force Turn the adjuster 1 1 out Minimum 2 turns out from maximum po...

Page 199: ...1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compressione Ruotando il dispositivo di rego lazione 1 REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION ELEVEE DE L AMOR TISSEUR ARRIERE 1 Régler 9 Force d amortissement de com pression élevée En tournant le dispositif de réglage 1 Maximum Minim...

Page 200: ...f its position on the rim 9If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect 9Spokes 1 Bend Damage Replace Loose spoke Retighten 2 Tighten 9Spokes NOTE Be sure to retighten these spokes before and af ter break in After a practice or a race check spokes for looseness EC36T000 WH...

Page 201: ...ca che lo pneumatico scivola fuori dalla sua posizione sul cerchione 9Se si trova inclinato il gambo della valvola dello pneumatico si ritiene che lo pneumatico stia scivolando fuori dalla sua posizione Correggere la posizione dello pneumatico IC36S002 ISPEZIONE E SERRAGGIO DEI RAGGI 1 Ispezionare 9 Raggi 1 Curvatura Danni Sostituirli Raggio allentato Riserrarlo 2 Serrare 9 Raggi NOTA Assicurarsi ...

Page 202: ...ust steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring nut adjustment steps 9Remove the number plate 9Remove the handlebar and handle crown 9Loosen the ring nut 1 using the ring nut wrench 2 9Tighten the ring nut 3 using ring nut wrench 4 NOTE 9Apply the lithium soap base grease on the thr...

Page 203: ... re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellschritte der Lenkring mutter 9 Das Nummernschild entfernen 9 Die Lenkstange und die Lenker krone entfernen 9 Die Ringmutter 1 mit Hilfe des Ringmutterschlüssels 2 lösen 9 Die Ringmutter 3 mit Hilfe des Ringmutterschlüssels 4 festzie hen HINWEIS 9 Auf Seife basierendes Lithium fett auf das Gewinde der Lenk welle auftragen 9 Den Dre...

Page 204: ...r plate q NOTE 9The handlebar holder upper should be installed with the punched mark a forward 9Install the handlebar so that the marks b are in place on both sides 9Install the handlebar so that the projection C of the handlebar holder upper is posi tioned at the mark on the handlebar as shown 9Insert the end of the fuel breather hose w into the hole in the steering shaft cC First tighten the bol...

Page 205: ...rivolta in avanti 9Installare il manubrio in modo che i contrassegni b siano a posto da entrambi i lati 9Installare il manubrio in modo che la sporgenza c del suo supporto superiore sia posizionata sul segno sul manubrio come illustra to 9Inserire l estremità dello sfiato del carburante w nel foro dell albero dello sterzo iI Serrare dapprima i bulloni sul lato anteriore del supporto supe riore del...

Page 206: ...HEAD INSPECTION AND ADJUSTMENT INSP ADJ Steering shaft nut 145 Nm 14 5 m kg 105 t lb Handlebar holder upper 28 Nm 2 8 m kg 20 ft lb Pinch bolt handle crown 21 Nm 2 1 m kg 15 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb ...

Page 207: ...age couronne de guidon 21 Nm 2 1 m kg 15 ft lb Plaque d immatriculation 7 Nm 0 7 m kg 5 1 ft lb Lenkerschaftmutter 145 Nm 14 5 m kg 105 ft lb Lenkerhalter oben 28 Nm 2 8 m kg 20 ft lb Klemmschraube Lenkerkrone 21 Nm 2 1 m kg 15 ft lb Nummernschild 7 Nm 0 7 m kg 5 1 ft lb Dado dell albero dello sterzo 145 Nm 14 5 m kg 105 ft lb Supporto del manubrio superiore 28 Nm 2 8 m kg 20 ft lb Bullone serragg...

Page 208: ... handlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding portion 0 Throttle cable end q Clutch cable end Å Use Yamaha cable lube or equivalent on these areas ı Use SAE10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quali ty lightweight lithium soap base grease cC Wipe off any excess grease an...

Page 209: ... Superficie di scorrimento del rullo della valvola a farfalla 9 Parte a spira del cavo di guida del tubo 0 Estremità del cavo dell acceleratore q Estremità del cavo della frizione A Usare lubrificante per cavi Yamaha o equivalente su queste zone B Usare olio per motori SAE 10W 30 o lubrificanti per catena adatti C Lubrificare le zone che seguono con grasso di alta qualità a base di sapone di litio...

Page 210: ...eeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten 9Spark plug NOTE 9Before installing a spark plug clean the gasket surface and plug surface 9Finger tighten a the spark plug before torq...

Page 211: ...aro Colore nettamente diverso Controllare le condizioni del motore NOTA Quando il motore gira per molte ore a bassi regimi l isolatore della candela diventa fuligginoso anche se il motore e il carburatore sono in buone condizio ni di funzionamento 3 Misurare 9 Distanza tra le candele a Usare un calibro per fili metalli ci o uno spessimetro Fuori specifica Ridistanziar le 4 Pulire la candela con un...

Page 212: ...When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified distance from TDC 6 Check 9Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator Not aligne...

Page 213: ...esem Punkt stoppt die Anzeigenadel der Messuhr und ändert ihre Bewegungsrichtung wenn der Rotor in der gleichen Richtung weitergedreht wird 4 Im oberen Totpunkt ist die Mes suhr auf Null zu stellen 5 Aus dem oberen Totpunkt ist der Rotor im Uhrzeigersinn zu dre hen bis die Messuhr den vorge schriebenen Abstand des Kol bens vom oberen Totpunkt anzeigt An dieser Stelle sollten die Markierungen am Ro...

Page 214: ...NSP ADJ 7 Adjust 9Ignition timing Adjustment steps 9Loosen the screws stator 1 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator 9Tighten the screws stator Screw stator 7 Nm 0 7 m kg 5 1 ft lb ...

Page 215: ...rauben Stator 1 lösen 9 Die Körnermarkierung an dem Rotor mit der Körnermarkierung an dem Stator 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allentare le viti statore 1 9Allineare la punzonatura sul roto re con la punzonatura sullo statore 2 muovendo lo statore 9Serrare le viti statore 7 Einstellen 9 Zündzeitpunkt 7 Regolare 9 Messa in fase ...

Page 216: ...e 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 7 Side cover right 1 Refer to REMOVAL POINTS 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal 2 3 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 6 Nm 0 6 m kg 4 3 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0...

Page 217: ...Nummernschild 1 MOTOR SITZ KRAFTSTOFFTANK UND SEITENDECKEL Ausbauumfang 1 Ausbau des Sitzes 2 Ausbau des Kraftstofftanks 3 Ausbau der Seitendeckel 4 Ausbau des Nummernschildes IC400000 MOTORE IC4R0000 SELLA SERBATOIO DEL CARBURANTE E COPERTURE LATERALI Ampiezza della rimozione 1 Rimozione della sella 2 Rimozione del serbatoio del carburante 3 Rimozione delle coperture laterali 4 Rimozione della ta...

Page 218: ...er 9 Side cover left and right 1 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case Number plate 1 Remove 9 Bolt number plate 9 Number plate 1 NOTE 9The projection a is inserted into the band of the number plate Pull the band off the projec tion before removal 9Remove the clutch cable 2 from the cable guide b on the number plate 9The projection ...

Page 219: ... d immatriculation 1 N B 9La saillie a est insérée dans la bande de la plaque d immatriculation Reti rer la bande de la saillie avant la dépose 9Déposer le câble d embrayage 2 du guide de câble b sur la plaque d immatriculation 9La saillie c sur le support inférieur est insérée dans la plaque d immatri culation Déposer la plaque d imma triculation en la soulevant de la saillie Nummernschild 1 Ausb...

Page 220: ...0 mm 0 51 in 1 Collar R ø15 5 mm 0 61 in 1 5 Collar R ø13 5 mm 0 53 in 1 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 Bolt exhaust pipe 2 10 Exhaust pipe 1 4 3 ENG EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 1 å Except for USA and CDN Extent of removal 1 Silencer removal 2 Exhaust pipe removal 2 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 221: ...n 1 6 Taukranz vorn 1 7 Taukranz hinten 1 8 Zugfeder 2 9 Schraube Auspuffrohr 2 10 Auspuffrohr 1 AUSPUFFROHR UND SCHALLDÄMPFER å Außer USA und CDN Ausbauumfang 1 Ausbau des Schalldämpfers 2 Ausbau des Auspuffrohres IC4S0000 TUBO DI SCARICO E SILENZIATORE å Tranne che per USA e CDN Ampiezza della rimozione 1 Rimozione del silenziatore 2 Rimozione del tubo di scarico Ampiezza della rimozione Ordine ...

Page 222: ... FUEL TANK AND SIDE COVERS section 1 Panel 2 2 Clamp radiator hose 1 3 2 Only loosening 3 Radiator hose 2 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator hose 1 1 8 Radiator hose 3 1 9 Radiator breather hose 1 EC450001 RADIATOR Extent of removal 1 Radiator removal 1 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m k...

Page 223: ...A SERBATOIO DEL CARBURANTE E COPERTURE LATERALI 1 Pannello 2 2 Brida manicotto flessibile del radiatore 1 3 2 Soltanto allentamento 3 Manicotto flessibile del radiatore 2 1 4 Radiatore sinistro 1 5 Manicotto flessibile del radiatore 4 1 6 Radiatore destro 1 7 Manicotto flessibile del radiatore 1 1 8 Manicotto flessibile del radiatore 3 1 9 Sfiato del radiatore 1 Preparazione per la rimozione Vorbe...

Page 224: ...ap by the following procedure Place a thick rag like a towel over the radi ator cap slowly rotate the cap counter clockwise to the detent This procedure al lows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect 9Radiator core 1 Obstruction Blow out with compressed ai...

Page 225: ...adiateur en procédant comme suit Quand le moteur est froid mettre un chiffon épais tel qu une serviette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de détente Cette procédure permet d éliminer toute pression résiduelle Quand le sifflement s est arrêté appuyer sur le bouchon tout en le tournant vers la gauche puis l enle ver VERIFICATION Radiateur 1 Examiner 9 Carcasse 1 ...

Page 226: ... CABLE ROUTING DIAGRAM section in the CHAPTER 2 3 Install 9Radiator left 1 9Plain washer 2 9Bolt radiator left 3 9Radiator hose 2 4 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Tighten 9Clamp radiator hose 1 3 5 5 Install 9Panel 1 9Bolt panel 2 NOTE Fit the hook a on the inner side first into the radiator 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2...

Page 227: ...r à la section CHE MINEMENT DES CABLES du CHAPITRE 2 4 Serrer 9 Bride tuyau du radiateur 1 3 5 5 Monter 9 Panneau 1 9 Boulon panneau 2 N B Ajustez d abord le crochet a sur la partie intérieure du radiateur 4 6 ENG RADIATEUR KÜHLER RADIATORE IC455000 MONTAGGIO E INSTALLAZIONE IC445344 Radiatore 1 Installare 9 Sfiato del radiatore 1 9 Manicotto flessibile del radiato re 3 2 9 Manicotto flessibile de...

Page 228: ... Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Clamp carburetor joint 2 Loosen the screws carburetor joint 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Stopper reed valve 2 6 Reed valve 2 1 Extent of removal 1 Carburetor removal 2 Reed valve removal 2 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 229: ...aser 1 3 Vergaserverbindung 1 4 Zungenventil 1 5 Anschlag Zungenventil 2 6 Zungenventil 2 VERGASER UND ZUNGENVENTIL Ausbauumfang 1 Ausbau des Vergasers 2 Ausbau des Zungenventils IC460000 CARBURATORE E VALVOLA A LAMELLA Ampiezza della rimozione 1 Rimozione del carburatore 2 Rimozione della valvola a lamella Ampiezza della rimozione Ordine Particolare Quantità Osservazioni RIMOZIONE DEL CARBURATORE...

Page 230: ...chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Needle jet cover 1 7 Float pin 1 8 Float 1 9 Valve seat 1 0 Main jet 1 q Main jet holder 1 w Pilot jet 1 e Starter plunger 1 r Throttle stop screw 1 t Pilot air screw 1 Extent of removal 1 Carburetor disassembly 1 4 Nm 0 4 m kg 2 9 ft lb ...

Page 231: ...ammer 1 6 Nadeldüsendeckel 1 7 Schwimmerstift 1 8 Schwimmer 1 9 Ventilsitz 1 0 Hauptdüse 1 q Hauptdüsenhalter 1 w Leerlaufdüse 1 e Starter Plungerkolben 1 r Drosselanschlagschraube 1 t Leerlauf Luftregulierschraube 1 DEMONTAGE DES VERGASERS Ausbauumfang 1 Demontage des Vergasers IC468000 SMONTAGGIO DEL CARBURATORE Ampiezza della rimozione 1 Smontaggio del carburatore Ampiezza della rimozione Ordin...

Page 232: ...cable 5 NOTE While compressing the spring throttle valve disconnect the throttle cable EC464000 INSPECTION EC464140 Carburetor 1 Inspect 9Carburetor body Contamination Clean cC When cleaning the main air passage a a do not blow air at the filter side because it will clog the passage with mud or sand NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed ai...

Page 233: ...urateur 1 Examiner 9 Corps du carburateur Encrassé Nettoyer fF Lors du nettoyage du conduit d air principal a a ne pas diriger le souffle d air comprimé du côté du filtre car cela risque d obstruer le conduit avec de la boue ou du sable N B 9Pour le nettoyage employer un dis solvant à base de pétrole Passer tous les conduits et gicleurs à l air compri mé 9Ne jamais utiliser de fil 9Lors du nettoya...

Page 234: ...pair or replace NOTE Insert the throttle valve 1 into the carburetor body and check for free movement EC464401 Jet needle 1 Inspect 9Jet needle 1 Bends Wear Replace 9Clip groove Free play exists Wear Replace 9Clip position Standard clip position No 3 Groove 2 Inspect 9Main jet 1 9Main jet holder 2 9Pilot jet 3 Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all passag...

Page 235: ...rollieren 9 Freie Bewegung Klemmung Reparieren oder erneuern HINWEIS Das Drosselventil 1 in das Vergaser gehäuse einsetzen und auf freie Bewegung kontrollieren Düsennadel 1 Prüfen 9 Düsennadel 1 Biegung Verschleiß Erneu ern 9 Klemmnut Spiel vorhanden Verschleiß Erneuern 9 Klemmposition Pointeau 1 Examiner 9 Pointeau 1 9 Siège de pointeau 2 Usure creusée a Changer Poussière b Nettoyer N B Toujours ...

Page 236: ...uretor and fuel level gauge ver tically when measuring the fuel level 9If the fuel level is not within specification in spect the valve seat and needle valve 9If either is worn replace them both 9If both are fine adjust the fuel level by bend ing the float tab b on the float 9Recheck the fuel level EC464802 Fuel level 1 Measure 9Fuel level a Out of specification Adjust Fuel level 9 5 10 5 mm 0 37 ...

Page 237: ... burante 9Se il livello del carburante non rientra nella specifica ispezionare la sede della valvola e la valvola ad ago 9Se una delle due è usurata sosti tuirle entrambe 9Se entrambe vanno bene regolare il livello del carburante piegando la linguetta del galleggiante b sul galleggiante 9Ricontrollare il livello del carbu rante Adattatore dell indicatore di livello del carburante YM 01470 90890 01...

Page 238: ...valve 3 NOTE 9Install the reed valve with the reed valve bend ing as shown 9Note the cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping Valve stopper height 8 2 8 6 mm 0 323 0 339 in 1 Nm 0 1 m kg 0 7 ft lb EC464600 Float 1 Inspect 9Float 1 Damage Replace EC464701 Reed valve 1 Measure 9Reed valve bending a Out of specification Replace Reed valv...

Page 239: ...n 9 Hauteur de la butée de soupape b Horsspécification Régler changer la butée de clapet REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 Butée soupape flexible 2 9 Vis soupape flexible 3 N B 9Mettre la lame soupape avec la cour bure de lame soupape de la manière indiquée 9Noter l entaille a dans le coin infé rieur de la soupape et de la plaque de butée fF Serrer les vis grand...

Page 240: ...arburetor joint 2 EC4652C2 Carburetor 1 Install 9Throttle stop screw 1 9Locknut 2 9Pilot air screw 3 Pilot air screw 2 1 4 turns out Note the following installation points 9Screw in the pilot air screw until it is lightly seated 9Back out it by the specified number of turns 10 Nm 1 0 m kg 7 2 ft lb 2 Install 9Starter plunger 1 ...

Page 241: ...1 Installare 9 Vite di arresto della valvola a farfalla 1 9 Controdado 2 9 Vite dell aria pilota 3 10 Nm 1 0 m kg 7 2 ft lb Die folgeden Einbaupunkte beachten 9 Die Leerlauf Luftregulierschrau be einschrauben bis diese leicht aufsitzt 9 Danach die Schraube um die vorgeschriebene Anzahl von Umdrehungen lösen Leerlauf Luftregulier schraube 2 1 4 Ausdrehungen 10 Nm 1 0 m kg 7 2 ft lb Prendere nota de...

Page 242: ...Install 9Needle valve 1 9Float 2 9Float pin 3 9Screw float pin 4 9Needle jet cover 5 NOTE 9After installing the needle valve to the float in stall them to the carburetor 9Check the float for smooth movement 5 Install 9Float chamber 1 9Plate 2 9Screw float chamber 3 6 Install 9Jet needle 1 9Needle holder 2 To throttle valve 3 ...

Page 243: ...gicleur à aiguilles 5 N B 9Aprés avoir installé le pointeau sur le flotteur les installer sur le carbura teur 9Vérifier que le flotteur bouge en dou ceur 3 Einbauen 9 Hauptdüsenhalter 1 9 Hauptdüse 2 9 Leerlaufdüse 3 9 Ventilsitz 4 9 Schraube Ventilsitz 5 4 Einbauen 9 Nadelventil 1 9 Schwimmer 2 9 Schwimmerstift 3 9 Schraube Schwimmerstift 4 9 Nadeldüsendeckel 5 HINWEIS 9 Nachdem das Nadelventil a...

Page 244: ...roove b in the needle holder 7 8 Install 9Mixing chamber top 1 9Screw mixing chamber top 2 To carburetor 3 NOTE After installing check the throttle grip for smooth movement 9 Install 9Air vent hose 1 9Overflow hose 2 9Clamp 3 NOTE Pass the air vent hose at the rear on the air cleaner side of the throttle cable 4 EC465352 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection b...

Page 245: ...carburateur 3 N B Après avoir réalisé le montage vérifier que l attache des gaz se déplace sans à coup 7 Installare 9 Cavo dell acceleratore 1 9 Controdado 2 9 Parte superiore del diffusore 3 9 Molla valvola regolatrice del flusso 4 9 Anello 5 9 Valvola regolatrice del flusso 6 NOTA 9Collegare il cavo dell acceleratore comprimendo la molla 9Allineare la sporgenza a sull anello con la scanalatura b...

Page 246: ...ter joint 1 9Bolt carburetor joint 2 3 Clamp 9Air vent hose 1 9Overflow hose 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Adjust 9Idle speed Refer to IDLE SPEED ADJUSTMENT section in the CHAPTER 3 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 247: ... Tubo flessibile di sfiato dell aria 1 9 Tubo flessibile di troppopieno 2 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPITOLO 2 4 Regolare 9 Numero di giri al minimo Consultare la sezione REGO LAZIONE DEL NUMERO DI GIRI AL MINIMO al CAPI TOLO 3 2 Festziehen 9 Schraube Luftfilterverbindung 1 9 Schraube Vergaserverbin dung 2 3 Klemmen 9 Belüftungsschlauch 1 9 Überlaufschlauch 2 Siehe...

Page 248: ...HAUST PIPE AND SILENCER section Radiator Refer to RADIATOR section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 5 Loosen each nut 1 4 turn and remove them after all nuts are loosened 4 Cylinder head 1 5 Power valve housing 1 6 Push rod 1 Refer to REMOVAL POINTS 7 Nut cylinder 4 8 Cylinder 1 Extent of removal 1 Cylinder head removal 2 Cylinder removal 1 2 34 Nm 3 4 m kg 24 ft lb 20 Nm 2 0 ...

Page 249: ...g lösen bis alle Muttern locker sind 4 Zylinderkopf 1 5 Leistungsventilgehäuse 1 6 Schubstange 1 Siehe unter AUSBAUPUNKTE 7 Mutter Zylinder 4 8 Zylinder 1 ZYLINDERKOPF ZYLINDER UND KOLBEN ZYLINDERKOPF UND ZYLINDER Ausbauumfang 1 Ausbau des Zylinderkopfes 2 Ausbau des Zylinders IC470000 TESTA CILINDRO CILINDRO E PISTONE IC478000 TESTA CILINDRO E CILINDRO Ampiezza della rimozione 1 Rimozione della t...

Page 250: ...fer to REMOVAL POINTS 4 Small end bearing 1 5 Piston ring 1 6 Power valve cover 1 7 Thrust plate 1 8 Bolt link lever 1 9 Valve holder 1 10 Valve shaft 1 11 Collar 2 12 Link lever 1 13 Spring 2 14 Power valve 1 1 15 Power valve 2 1 Extent of removal 1 Piston and piston ring removal 2 Power valve removal 2 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 5 Nm 0 5 m kg 3 6 ft lb 8 Nm 0 8 m kg 5 8 ft...

Page 251: ...chraube Verbindungshebel 1 9 Ventilhalterung 1 10 Ventilwelle 1 11 Hülse 2 12 Verbindungshebel 1 13 Feder 2 14 Leistungsventil 1 1 15 Leistungsventil 2 1 KOLBEN UND LEISTUNGSVENTIL Ausbauumfang 1 Ausbau des Kolbens und Kolbenrings 2 Ausbau des Leistungsventiles IC478100 PISTONE E VALVOLA DI POTENZA Ampiezza della rimozione 1 Rimozione del pistone e della fascia elastica 2 Rimozione della valvola d...

Page 252: ...an rag to prevent the pis ton pin clip from falling into the crankcase cav ity 2 Remove 9Piston pin 1 9Piston 2 9Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use the piston pin puller 4 cC Do not use a hammer to drive the piston pin out 3 Remove 9Piston ring 1 NOTE T...

Page 253: ...icco la 3 NOTA Prima di togliere lo spinotto sbavare la zona della scanalatura del fermaglio a graffa e del foro dello spinotto Se la scanalatura dello spinotto è sbavata e lo spinotto è ancora difficile da togliere usare l estrattore per spinotto 4 iI Non usare un martello per fare uscire lo spinotto Estrattore per spinotto YU 1304 90890 01304 3 Ausbauen 9 Kolbenring 1 HINWEIS Darauf achten den K...

Page 254: ...age measurement and re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur face the cylinder head 9Place 400 600 grit wet sandpaper 3 on the surface plate and re surface the head 4 using a figure eight sanding pattern NOTE Rotate the cylinder head several times to avoid removing too much materia...

Page 255: ...neal 1 und Einstell Lehre 2 anbringen 9 Die Verwerfungsgrenze messen 9 Wenn die Verwerfung nicht den erforderlichen Maßen entspricht Zylinderkopffläche bearbeiten 9 Ein feuchtes Sandpapier 3 Feinheit 400 600 auf die Ober flächenplatte legen und den Zylinderkopf 4 durch Aus führung einer Achterfigur abschleifen HINWEIS Um zu vermeiden dass an einer Seite zu viel abgeschliffen wird den Zylinderkopf ...

Page 256: ...surface Score marks Repair or replace Use 400 600 grit wet sandpaper cC Do not rebore the cylinder 3 Measure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measurements 17 5 mm 53 957 53 972 mm 0 69 in 2 1243 2 1249 in Standard Wear limit Cylinder 54 000 54 014mm...

Page 257: ...surer l alésage de cylindre C en parallèle A B C et à angle droit du vilebrequin a b Ensuite faire la moyenne des mesures Piston 1 Éliminer 9 Dépôts de calamine De la couronne de piston a et des rainures de segment b 2 Examiner 9 Paroi de cylindre Marques de rayures Réparer ou changer 3 Mesurer 9 Diamètre de la jupe de piston Utiliser le micromètre 1 Mesurer la distance spécifique a à partir du re...

Page 258: ...iston pin 1 is in place in the piston 2 There should be no noticeable for the play Free play exists Replace piston pin and or piston 4 Install 9Small end bearing 9Piston pin Into the small end of connecting rod 5 Check 9Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con necting rod as required Piston pin outside diamete...

Page 259: ...de bielle 1 Examiner 9 Axe de piston 9 Coussinet de pied de bielle Signes de décoloration par la chaleur Changer 2 Mesurer 9 Diamètre extérieur d axe de pis ton Utiliser le micromètre 1 Hors limite Changer 3 Contrôler 9 Jeu lorsque l axe 1 est en place dans le piston 2 Il ne doit pas y avoir de jeu remarquable Il y a du jeu Changer l axe de piston et ou le piston 4 Monter 9 Coussinets de pied de b...

Page 260: ...a thickness gauge 1 Out of limit Replace piston and or ring NOTE Check at several points EC474602 Piston clearance 1 Calculate 9Piston clearance Out of limit Replace piston and piston ring and or cylinder Refer to Cylinder and Piston Ring end gap installed Standard Limit 0 5 0 7 mm 1 2mm 0 020 0 028 in 0 047 in Side clearance Standard Limit 0 035 0 070 mm 0 1mm 0 0014 0 0028 in 0 004 in PISTON CLE...

Page 261: ...une jauge d épaisseur 1 Hors limite Changer 3 Mesurer 9 Jeu latéral Utiliser une jauge d épaisseur 1 Hors limite Changer le piston et ou les segments N B Vérifier en plusieurs points Jeu de piston 1 Calculer 9 Jeu de piston Hors limite Changer le piston les segments et ou le cylindre Se reporter à Cylindre et Pis ton IC474502 Fascia elastica 1 Installare 9 Fascia elastica Nel cilindro Spingere la ...

Page 262: ...n clearance Standard Limit 0 040 0 045 mm 0 1 mm 0 0016 0 0018 in 0 004 in Cylinder mark a a Cylinder size A 54 000 54 002 mm 2 1260 2 1261 in B 54 004 54 006 mm 2 1261 2 1262 in C 54 008 54 010 mm 2 1263 2 1264 in D 54 012 54 014 mm 2 1265 2 1265 in Piston mark a a color Piston size A red 53 957 53 960 mm 2 1243 2 1244 in B orange 53 961 53 964 mm 2 1244 2 1246 in C green 53 965 53 968 mm 2 1246 ...

Page 263: ...16 0 0018 in 0 004 in Kolbenspiel Kolben markierung a a Kolbengröße Farben A rot 53 957 53 960 mm 2 1243 2 1244 in B orange 53 961 53 964 mm 2 1244 2 1246 in C grün 53 965 53 968 mm 2 1246 2 1247 in D violett 53 969 53 972 mm 2 1248 2 1249 in Zylinder Kolbenmarkierung markierung Farben A A rot B B orange C C grün D D violett Valore normale Limite 0 040 0 045 mm 0 1 mm 0 0016 0 0018 in 0 004 in Gio...

Page 264: ...e Replace 9Spring 6 Broken Replace EC474901 Power valve hole on cylinder 1 Remove 9Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratching the aluminum EC475000 ASSEMBLY AND INSTALLATION EC4751A1 Power valve 1 Install 9Power valve 1 1 9Power valve 2 2 9Bolt power valve 3 NOTE Install the power valve at cut away faced a for down side 8 Nm 0 8 m kg 5 8 ft ...

Page 265: ... Leistungsventilbohrung im Zylinder 1 Ausbauen 9 Rußablagerungen Aus der Leistungsventil Boh rung a HINWEIS Kein scharfkantiges Instrument ver wenden Kratzer auf dem Aluminium vermeiden Clapet de puissance 1 Examiner 9 Clapet de puissance 1 2 1 Usure endommagement Rem placer Dépots de calamine Enlever 9 Support de soupape 2 9 Levier articulé 3 9 Arbre à tiroirs 4 9 Collerette 5 Usure endommagement...

Page 266: ...ase grease on the oil seal lip 3 Install 9Thrust plate 1 9Screw thrust plate 2 4 Check 9Power valve smooth movement Unsmooth movement Repair or replace 5 Install 9Gasket power valve cover 1 9Power valve cover 2 9Screw power valve cover 3 9YPVS breather hose 4 NOTE 9Install the power valve cover so that the arrow mark a faces upward 9Install the clamp of the YPVS breather hose with its opening port...

Page 267: ... dass das Anschlagteil a nach innen gerichtet ist 9 Lithiumseifen Schmierfett auf der Öldichtungslippe auftragen 2 Monter 9 Ressort 1 9 Levier articulé 2 9 Collerette 3 9 Arbre à tiroirs 4 9 Support de soupape 5 9 Boulon levier articulé 6 N B 9Installer le ressort sur le levier articulé puis sur le cylindre 9Installer le ressort avec les ergots a tournés vers l intérieur 9Appliquer la graisse à ba...

Page 268: ...il onto the bearing crank shaft and connecting rod and connecting rod big end washers 9Install the gasket with the seal print side toward the crankcase 3 Install 9Piston 1 9Piston pin 2 9Piston pin clip 3 NOTE 9The arrow a on the piston dome must point to exhaust side 9Before installing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the c...

Page 269: ...maglio dello spinotto dello stantuffo per evitare di distorcerlo si devono usare le mani 9 9Non lasciare che le estremità aperte del fermaglio a graffa tocchino la fessura del pistone b b Kolbenring und Kolben 1 Ausbauen 9 Kolbenring 1 HINWEIS 9 Darauf achten dass der Kolben nicht zerkratzt und der Kolbenring nicht beschädigt wird 9 Den Kolbenringspalt mit dem Stift 2 ausrichten 9 Nach dem Einbau ...

Page 270: ...it to install the bolt push rod 9Do not forget to remove the collar EC4753A2 Cylinder head and cylinder 1 Apply 9Engine oil To piston 1 piston ring 2 and cylinder surface 2 Install 9Cylinder 1 cC Make sure the piston ring is properly posi tioned Install the cylinder with one hand while compressing the piston ring with the other hand NOTE After installing check the smooth movement of the piston 30 ...

Page 271: ... einge baut wurde dieses auf glatte Bewe gung prüfen Culasse et cylindre 1 Appliquer 9 Huile du moteur Sur le piston 1 le segment 2 et la surface de cylindre 2 Monter 9 Cylindre 1 fF Veiller à positionner le segment cor rectement Mettre d une main le cylindre en place tout en comprimant le segment de l autre N B Après avoir monter contrôler si elle se déplace régulièrement 3 Monter 9 Ecrou cylindr...

Page 272: ...ngine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 9 Install 9Spark plug 1 9Spark plug cap 2 28 Nm 2 8 m kg 20 ft lb 34 Nm 3 4 m kg 24 ft lb 34 Nm 3 4 m kg 24 ft lb 20 Nm 2 0 m kg 14 ft lb 5 Install 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 6 Install 9O ring 1 NOTE Apply the lithium soap base grease on the O rings 4 Nm 0 4 m kg 2 9 ft lb ...

Page 273: ...ng Leistungsventil gehäuse 9 Leistungsventilgehäuse 1 9 Schraube Leistungsventil gehäuse 2 5 Monter 9 Joint boîtier de clapet de puis sance 9 Boîtier de chapet de puissance 1 9 Boulon boîtier de clapet de puissance 2 6 Monter 9 Joint torique 1 N B Appliquer de la graisse à base de savon au lithium sur le joint torique 7 Monter 9 Culasse 1 9 Rondelle en cuivre 2 9 Ecrou culasse 3 N B Serrer les écr...

Page 274: ...3 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 Extent of removal 1 Clutch plate and friction plate removal EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 1 10 Nm 1 ...

Page 275: ...sfeder 6 3 Kupplungsfeder 6 4 Druckscheibe 1 5 Reibscheibe 8 6 Kupplungsscheibe 7 KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und Reibscheibe IC490000 FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC498000 DISCO DELLA FRIZIONE E DISCO DI INNESTO Ampiezza della rimozione 1 Rimozione del disco della frizione e del disco di innesto Ampiezz...

Page 276: ...7 Nut clutch boss 1 Use special tool 8 Lock washer 1 Refer to REMOVAL POINTS 9 Clutch boss 1 10 Plain washer D ø34mm 1 34 in 1 11 Primary driven gear 1 12 Bearing 1 13 Plain washer D ø34mm 1 34 in 1 14 Push lever axle 1 EC498200 PRIMARY DRIVEN GEAR PUSH ROD AND PUSH LEVER AXLE Extent of removal 1 Push rod and push lever axle removal 2 Push rod 1 disassembly 3 Primary driven gear removal 2 3 1 1 1 ...

Page 277: ...ibe D ø34 mm 1 34 in 1 14 Schubhebelachse 1 PRIMÄRABTRIEBSZAHNRAD SCHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Primärabtriebszahnrades IC498200 INGRANAGGIO CONDOTTO PRIMARIO ASTA DI SPINTA E ASSE DELLA LEVA DI SPINTA Ampiezza della rimozione 1 Rimozione della asta di spinta e asse della leva di spinta 2 Smo...

Page 278: ...ON EC484100 Clutch housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free play exists Replace 9Gear teeth a Wear Damage Replace EC484400 Clutch spring 1 Measure 9Clutch spring free length a Out of specification Replace springs as a set Clutch holding tool YM 91042 4 4 90890 0...

Page 279: ...ten å Für USA und CDN Außer USA und CDN POINTS DE DEPOSE Noix d embrayage 1 Déposer 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poignée d embrayage 4 5 pour maintenir la noix d embrayage å Pour USA et CDN Excepté pour USA et CDN VERIFICATION Cloche et noix d embrayage 1 Examiner 9 Cloche d embrayage 1 Craquelures usure endommage ment Cha...

Page 280: ...e plate 1 and thickness gauge 2 EC484700 Push lever axle 1 Inspect 9Push lever axle 1 Wear Damage Replace EC484810 Push rod 1 Inspect 9Push rod 1 1 9Bearing 2 9Plain washer 3 9Push rod 2 4 9Ball 5 Wear Damage Bend Replace EC495000 ASSEMBLY AND INSTALLATION EC485120 Push lever axle 1 Install 9Push lever axle 1 NOTE Apply the lithium soap base grease on the oil seal lip and push lever axle Friction ...

Page 281: ...r chaque disque en quatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors spécification Changer tous les disques d embrayage Utiliser une plaque à surfacer 1 et une jauge d épaisseur 2 Axe de levier de poussée 1 Examiner 9 Axe de levier de poussée 1 Usure endommagement Chan ger Tige de poussée 1 Examiner 9 Tige de poussée 1 1 9 Roulement 2 9 Rondelle ordinaire 3 9 Tige de ...

Page 282: ...l on the bearing spacer and primary driven gear inner circumference 2 Install 9Plain washer D ø 34 mm 1 34 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding tool 3 4 to hold the clutch boss å For USA and CDN Except for USA and CDN 4 Bend the lock washer 1 tab 80 Nm 8 0 m kg 58 ft lb Clutch holding tool YM 91042 3 3 90890 04086 4 4 å ...

Page 283: ...aire 4 N B Appliquer de l huile de boîte de vitesses sur le roulement l entretoise et la circonférence intérieure du pignon mené primaire 2 Monter 9 Rondelle ordinaire D ø34mm 1 34 in 1 9 Noix d embrayage 2 3 Monter 9 Rondelle frein 1 9 Ecrou Noix d embrayage 2 N B Utiliser l outil de poignée d embrayage 3 4 pour maintenir la noix d embrayage å Pour USA et CDN Excepté pour USA et CDN 4 Courber la ...

Page 284: ...sion oil on the friction plates and clutch plates 6 Install 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4 NOTE Apply the lithium soap base grease on the bear ing and plain washer 7 Install 9Push rod 2 1 9Ball 2 9Push rod 1 3 NOTE Apply the transmission oil the push rod 1 2 and ball 8 Install 9Pressure plate 1 9 Install 9Clutch spring 1 9Screw clutch spring 2 NOTE Tighten the screws in stag...

Page 285: ... et en terminant par une plaques de frottement 9Appliquer de l huile de boîte de vitesses sur les disques de friction et disque d embrayage 6 Monter 9 Roulement 1 9 Rondelle ordinaire 2 9 Circlip 3 sur le champignon de débrayage 1 4 N B Appliquer de la graisse à base de savon au lithium sur le roulement et la rondel le ordinaire 7 Monter 9 Champignon de débrayage 2 1 9 Bille 2 9 Champignon de débr...

Page 286: ...oewl pin 1 9Gasket cluch cover 2 11 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 12 Install 9O ring 1 9Clutch cable 2 NOTE Apply the lithium soap base grease on the O ring 10 Nm 1 0 m kg 7 2 ft lb ...

Page 287: ...n an lithium sur le joint torique 10 Installare 9 Grano di centraggio 1 9 Guarnizione coperchio della frizione 2 11 Einbauen 9 Kupplungsdeckel 1 9 Schraube Kupplungsdeckel 2 HINWEIS Die Schrauben stufenweise über Kreuz festziehen 11 Installare 9 Coperchio della frizione 1 9 Bullone coperchio della frizio ne 2 NOTA Serrare gradualmente i bulloni in croce 12 Einbauen 9 O Ring 1 9 Kupplungskabel 2 HI...

Page 288: ...nward Radiator hose 4 Disconnect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4 Primary driven gear 1 Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 5 Primary drive gear 1 EC4C0000 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE G...

Page 289: ...té du moteur Boulon pédal de frein Pousser la pédale de frein vers le bas Tuyau de radiateur 4 Déconnecter du côté pompe à eau Boulon Se reporter à la section CULASSE champignon de débrayage CYLINDRE ET PISTON 1 Kick starter 1 2 Couvercle de carter droit 1 3 Boulon pignon de transmission primaire 1 Uniquement desserrage Se reporter à POINS DE DEPOSE 4 Pignon mené primaire 1 Se reporter à la sectio...

Page 290: ...L 1 Kick idle gear 1 2 kick axle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 1 Extent of removal 1 Kick axle and kick idle gear removal 2 Shift shaft and stopper lever removal 2 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 291: ...r au pied 2 Dépose de l arbre de sélecteur et du levier de butée Etendue de dépose Ordre Nom de pièce Q té Remarques DEPOSE DE L AXE DE DEMAR REUR AU PIED ET DE L ARBRE DE SELECTEUR 1 Pignon de renvoi de démarreur au pied 1 2 Ensemble axe de démarreur au pied 1 Se reporter à POINTS DE DEPOSE 3 Pédale de sélecteur 1 4 Arbre de sélecteur 1 5 Roulement 1 6 Guide de sélecteur 1 Se reporter à POINTS DE...

Page 292: ...torsion spring 2 from the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assembly 2 NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4C4000 INSPECTION EC4B4100 Kick axle and kick gear 1 Check 9Kick gear smooth movement Unsmooth movement Replace 2 Inspect 9Kick axle 1 Wear Damage Replace...

Page 293: ...vilebrequin Ensemble guide de levier de sélecteur 1 Déposer 9 Boulon guide de sélecteur 9 Guide de sélecteur 1 9 Ensemble levier de sélecteur 2 N B L ensemble de levier de sélecteur est démonté en même temps que le guidage de sélecteur VERIFICATION Axe de kick et engrenage de kick 1 Contrôler 9 Mouvement régulier de pignon de démarreur au pied Mouvement irrégulier Changer 2 Examiner 9 Axe de démar...

Page 294: ...and shift lever assembly 1 Inspect 9Shift guide 1 9Shift lever 2 9Pawl 3 9Pawl pin 4 9Spring 5 Wear Damage Replace EC4E4100 Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Roller 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever 9Torsion spring 3 Broken Replace EC484300 Primary drive gear and primary driven gear 1 Inspect 9Primary drive gear 1 9Primary dr...

Page 295: ...he à cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de butée 1 Examiner 9 Levier de butée 1 Usure endommagement Changer 9 Rouleau 2 Faites tourner la bague extérieu re avec le doigt Point dur grippage Remplacez le levier de butée 9 Ressort de torsion 3 Cassé Changer Pignon de transmission primaire et pignon mené primaire 1 Examiner 9 Pignon de transmission primaire 1 9 Pignon mené primai...

Page 296: ...stalling the stopper lever make sure that the torsion spring is in the position as shown EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 2 Install 9Shift lever assembly 1 To shift guide 2 3 Install 9Shift lever assembly 1 9Shift guide 2 NOTE 9The shift lever assembly is installed at the same time as the shift guide 9Apply the transmission oil ...

Page 297: ...ressort de torsion soit positionné comme illustré Guide de sélecteur et ensemble levier de sélecteur 1 Monter 9 Ressort 1 9 Broche à cliquet 2 9 Cliquet 3 Au levier de sélecteur 4 2 Monter 9 Ensemble levier de sélecteur 1 Au guide de sélecteur 2 3 Monter 9 Ensemble levier de sélecteur 1 9 Guide de sélecteur 2 N B 9L ensemble de levier de sélecteur est installé en même temps que le guida ge de séle...

Page 298: ...ick axle 4 NOTE Make sure the stopper a of the torsion spring fits into the hole b on the kick axle 2 Install 9Spring 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 spring 3 Install 9Kick axle assembly 1 NOTE 9Apply the transmission oil on the kick axle 9Slide the kick axle assembly into the crankcase make sure t...

Page 299: ...e de démarreur au pied 4 N B S assurer que la butée a du ressort de torsion correspond au trou b sur l axe de démarreur au pied 2 Monter 9 Guide de ressort 1 N B Coulisser la guide de ressort dans l axe de démarreur au pied s assurer que la gorge a dans la guide de ressort soit engagée sur la butée du ressort de tor sion 3 Monter 9 Ensemble axe de démarreur au pied 1 N B 9 Appliquer de l huile de ...

Page 300: ...n the kick idle gear inner circumference EC4C5503 Primary drive gear 1 Install 9Spacer 1 9Primary drive gear 2 9Bolt 3 NOTE Install the primary drive gear with its depressed side toward you 2 Install 9Primary driven gear Refer to CLUTCH AND PRIMARY DRI VEN GEAR section 3 Tighten 9Bolt primary drive gear 1 NOTE Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear ...

Page 301: ...marreur au pied Pignon de transmission primaire 1 Monter 9 Entretoise 1 9 Pignon de transmission primaire 2 9 Boulon 3 N B Monter le pignon d attaque de trans mission primaire avec la face renfoncée avers vous 2 Monter 9 Pignon mené primaire Se reporter à la section EMBRAYAGE ET PIGNON MENE PRIMAIRE 3 Serrer 9 Boulon pignon de transmission primaire 1 N B Mettre une plaque en aluminium a entre les ...

Page 302: ...ss pattern 7 Install 9Kick starter 1 9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not contact ing the pillar tube 4 8 Install 9Shift pedal 1 9Bolt shift pedal 2 NOTE Align the upper line a of the shift pedal with the center b of the crankcase projection and rotate the shift pedal counterclockwise until it first engages Then install the shift pedal 12 Nm 1 2 m k...

Page 303: ...aire 2 9 Boulon kick starter 3 N B Installer le kick starter le plus près pos sible du tube de montant 4 mais de sorte qu il ne le touche pas 8 Monter 9 Pédale de sélecteur 1 9 Boulon pédale de sélecteur 2 N B Aligner la ligne supérieure a du sélec teur sur le centre b de la saillie du car ter moteur et faire tourner le sélecteur dans le sens antihoraire jusqu à ce qu il s engage Puis monter le sé...

Page 304: ...D removal PRIMARY DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 EC4K0000 YPVS GOVERNOR 1 Extent of removal 1 YPVS governor removal and disassembly 5 Nm 0 5 m kg 3 6 ft lb ...

Page 305: ...CTEUR ET PIGNON DE TRANSMISSION 1 Ensemble régulateur 1 2 Goujon 1 Se reporter à POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de butée 2 8 Collerette 1 9 Plaque 1 10 Ressort de compression 1 11 Pignon de régulateur 1 12 Arbre de régulateur 1 IC4K0000 REGOLATORE YPVS Ampiezza della rimozione 1 Rimozione e smontaggio del regolatore YPVS Ampiezza...

Page 306: ...Inspect 9Plain washer 1 9Collar 2 Wear Damage Replace EC4K4200 Bearing 1 Inspect 9Thrust bearing 1 9Plain washer 2 Wear Damage Replace EC4K5000 ASSEMBLY AND INSTALLATION EC4K5120 Governor 1 Install 9Governor gear 1 9Compression spring 2 9Plate 3 9Plain washer 4 9Thrust bearing 5 9Collar 6 9Retainer weight 7 To governor shaft 8 NOTE Apply the lithium soap base grease on the thrust bearing ...

Page 307: ...lle ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTA GE Régulateur 1 Monter 9 Pignon de régulateur 1 9 Ressort de compression 2 9 Plaque 3 9 Rondelle ordinaire 4 9 Roulement de butée 5 9 Collerette 6 9 Masselotte de retenue 7 Sur l arbre du régulateur 8 N B Appliquer de la graisse de base de savon au lithium sur le roulement de butée IC4K3000 PUNTI DI RIMOZIONE IC4K3100 Regolatore 1 Togl...

Page 308: ...oil on the retainer and ball 3 Install 9Dowel pin 1 NOTE 9While compressing the spring install the dowel pin 9Make sure the dowel pin fits into the groove a in the retainer 4 Install 9Governor assembly 1 NOTE Align the groove a in the governor with the fork b and set the governor in the crankcase cover ...

Page 309: ...elle 3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9Vérifier que le goujon d assemblage est bien ajusté dans le gorge a du dispositif d arrêt 4 Monter 9 Ensemble régulateur 1 N B Aligner la rainure a du régulateur avec la fourchette b puis positionner le régulateur dans le couvercle de carter 2 Installare 9 Sfera 1 9 Fermo 2 Sull albero del regolatore 3 NOTA Applicare l o...

Page 310: ... SHIFT SHAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 4 Plain washer 1 5 Impeller shaft assembly 1 6 Bearing 1 Refer to REMOVAL POINTS 7 Oil seal 2 EC4G0000 WATER PUMP 1 2 Extent of removal 1 Impeller shaft removal 2 Oil seal removal 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 311: ...ion AXE DE DEMARREUR AU PIED ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSON 1 Couvercle de boîtier de pompe à eau 1 2 Pignon de l axe de rotor 1 3 Goujon 1 4 Rondelle plain 1 5 Ensemble d axe de rotor 1 6 Roulement 1 Se reporter à POINTS DE DEPOSE 7 Bague d étanchéité 2 IC4G0000 POMPA DELL ACQUA Ampiezza della rimozione 1 Rimozione dell albero del girante 2 Rimozione del paraolio Ampiezza della rimoz...

Page 312: ...r coolant leaks out from the water pump housing hole at the bottom 9Do not reuse the removed bearing and oil seal 1 Remove 9Bearing 1 2 Remove 9Oil seal outside 1 9Oil seal inside 2 EC4G4000 INSPECTION EC444200 Impeller shaft assembly 1 Inspect 9Impeller shaft assembly1 Bend Wear Damage Replace Fur deposits Clean ...

Page 313: ...ement s écoule par l orifice dans le bas du logement de pompe à eau 9Ne pas réutiliser le roulement ni la bague d étanchéité 1 Déposer 9 Roulement 1 2 Déposer 9 Bague d étanchéité extérieure 1 9 Bague d étanchéité intérieure 2 VERIFICATION Ensemble d axe de rotor 1 Examiner 9 Ensemble d axe de rotor 1 Déformée usure endommagement Changer Dépôts de tartre Nettoyer IC4G3000 PUNTI DI RIMOZIONE IC4G32...

Page 314: ...400 Oil seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal inside 1 9Oil seal outside 2 NOTE 9Apply the lithium soap base grease on the oil seal lip 9Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 3 2 Install 9Bearing 1 NOTE Install the bearing by pressing its outer race par allel ...

Page 315: ...gement Changer REMONTAGE ET MONTAGE Bague d étanchéité 1 Monter 9 Bague d étanchéité intérieure 1 9 Bague d étanchéité extérieure 2 N B 9Appliquer la graisse à base de savon au lithium sur la lèvre de la bague d étanchéité 9Installez la bague d étanchéité avec les marques du fabricant ou les numé ros de référence vers le couvercle de carter droit 3 2 Monter 9 Roulement 1 N B Monter le roulement en...

Page 316: ... impeller shaft assembly And install the shaft while turning it 2 Install 9Plain washer 1 9Dowel pin 2 9Impeller shaft gear 3 9Collar 4 9Plain washer 5 9Circlip 6 NOTE Install the Impeller shaft gear with the dowel pin fitted in the groove a in the same gear 3 Install 9Dowel pin 1 9Gasket water pump housing cover 2 4 Install 9Water pump housing cover 1 9Bolt water pump housing cover 2 9Copper wash...

Page 317: ... 4 9 Rondelle ordinaire 5 9 Circlip 6 N B Monter le pignon de l axe de rotor avec le goujon inséré dans la rainure a du même pignon 3 Monter 9 Goujon 1 9 Joint couvercle de boîtier de pompe à eau 2 4 Monter 9 Couvercle de boîtier de pompe à eau 1 9 Boulon couvercle de boîtier de pompe à eau 2 9 Rondelle en cuivre boulon de vidange de refriodissement 3 9 Boulon de vidange de refroidis sement 4 IC4G...

Page 318: ...removal SIDE COVERS section Bolt Radiator Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator 1 5 Woodruff key 1 EC4L0000 CDI MAGNETO 1 Extent of removal 1 CDI magneto removal 7 Nm 0 7 m kg 5 1 ft lb 56 Nm 5 6 m kg 40 ft lb 5 Nm 0 5 m kg 3 6 ft lb ...

Page 319: ...LE RESERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur Se reporter à la section RADIATEUR Déconnecter le fil de magnéto CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil spécial Se reporter à 3 Rotor 1 POINTS DE DEPOSE 4 Stator 1 5 Clavette de demi lune 1 IC4L0000 MAGNETE CDI Ampiezza della rimozione 1 Rimozione del magnete CDI Ampiezza della rimozione Ordine Particolare ...

Page 320: ...101 CDI magneto 1 Inspect 9Rotor inner surface a 9Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect 9Woodruff key 1 Damage Replace EC4L5000 ASSEMBLY AND INSTALLATION EC4L5172 CDI magneto 1 Install 9Stator 1 9Screw stator 2 NOTE Temporarily tighten the screw stator at this point Rotor hol...

Page 321: ...le dépinçage du vilebrequin et le coussinet vilebrequin Si nécessaire changer le stator et ou le magnéto CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET MONTAGE Magnéto CDI 1 Monter 9 Stator 1 9 Vis stator 2 N B Serrer provisoirement la vis stator à ce moment IC4L3000 PUNTI DI RIMOZIONE IC4L3102 Rotore 1 Togliere 9 Dado rotore 1 9 Rosetta 2 Usare l...

Page 322: ...hen installing the rotor align the keyway c of the rotor with the woodruff key 3 Install 9Plain washer 1 9Nut rotor 2 Use the rotor holding tool 3 4 Adjust 9Ignition timing Refer to IGNITION TIMING CHECK sec tion in the CHAPTER 3 5 Tighten 9Screw stator 1 6 Check 9Ignition timing Re check the ignition timing 56 Nm 5 6 m kg 40 ft lb Rotor holding tool YU 1235 90890 01235 7 Nm 0 7 m kg 5 1 ft lb Ign...

Page 323: ...er 9 Avance à l allumage Se reporter à la section CONTROLE ET REGLAGE DE L AVANCE A L ALLU MAGE du CHAPITRE 3 5 Serrer 9 Vis stator 1 6 Contrôler 9 Avance à l allumage Recontrôler l avance à l alluma ge 2 Installare 9 Linguetta Woodruff 1 9 Rotore 2 NOTA 9Pulire le parti coniche dell albero a gomiti e del rotore 9Quando si installa la linguetta Woo druff assicurarsi che la sua superficie piana a s...

Page 324: ...to lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a crisscross pattern 5 Nm 0 5 m kg 3 6 ft lb ...

Page 325: ...E MA DE CHEMINEMENT DES CABLES du CHAPITRE 2 8 Monter 9 Joint couvercle de carter gauche 9 Couvercle de carter gauche 1 9 Vis couvercle de carter gauche 2 N B Serrer les vis par ètapes em utilisant un modèle d entre croisement 7 Collegare 9 Conduttore del magnete CDI 1 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPITOLO 2 8 Installare 9 Guarnizione copertura del car ter sinistra 9 ...

Page 326: ...D REED VALVE section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug cap Disconnect the CDI magneto lead EC4M0000 ENGINE REMOVAL w Support the machine securely so there is no dan ger of it falling over 26 Nm 2 6 m kg 19 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 m kg 46 ft lb 85 Nm 8 5 m kg 61 ft...

Page 327: ...ent et silencier Se reporter à la section TUYAU D ECHAPPE MENT ET SILENCIEUX Câble d embrayage Déconnecter du côté du moteur Radiateur Se reporter à la section RADIATEUR Capuchon de bougie Déconnecter le fil de la magnéto CDI IC4M0000 RIMOZIONE DEL MOTORE Ampiezza della rimozione Ordine Particolare Quantità Osservazioni RIMOZIONE DEL MOTORE Reggere il veicolo collocando sotto il motore l apposito ...

Page 328: ...r 1 Refer to REMOVAL POINTS 4 Drive sprocket 1 5 Clip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Engine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Refer to REMOVAL POINTS 11 Engine 1 1 26 Nm 2 6 m kg 19 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 m kg 46 ft lb 85 Nm 8 5 m kg 61 ft lb 75 Nm 7 5 m kg 54 ft lb 5 Nm 0 5 m kg 3 6 ft lb 64 Nm 6 4 m kg 46 ft lb ...

Page 329: ...1 2 Ecrou pignon d entraînement 1 3 Rondelle frein 1 Se reporter à POINTS DE DEPOSE 4 Pignon d entraînement 1 5 Agrafe 1 6 Boulon pédal de frein 1 7 Pédale de frein 1 8 Support du moteur 2 9 Boulon de montage du moteur 3 10 Axe de pivot 1 Se reporter à POINTS DE DEPOSE 11 Moteur 1 Ampiezza della rimozione 1 Rimozione del motore Ampiezza della rimozione Ordine Particolare Quantità Osservazioni 1 Co...

Page 330: ...ve sprocket 1 9Drive chain 2 NOTE Remove the drive sprocket together with the dri ve chain EC4M3301 Engine removal 1 Remove 9Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will come loose If possible insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove 9Engine 1 From right side NOTE Make sure that the couplers hoses and cables ...

Page 331: ...ionando il freno posteriore 2 Togliere 9 Rocchetto conduttore 1 9 Catena di trasmissione 2 NOTA Togliere il rocchetto conduttore insieme alla catena di trasmissione IC4M3301 Rimozione del motore 1 Togliere 9 Albero snodato 1 NOTA Se l albero snodato viene estratto com pletamente il forcellone oscillante si allenta Se possibile inserire un albero di diametro simile nell altro lato del forcellone os...

Page 332: ...the molybdenum disulfide grease on the pivot shaft EC4M5211 Brake pedal 1 Install 9Spring 1 9Brake pedal 2 9O ring 3 9Bolt brake pedal 4 9Clip 5 NOTE Apply the lithium soap base grease on the bolt O rings and brake pedal bracket EC4M5311 Drive sprocket 1 Install 9Drive sprocket 1 9Drive chain 2 NOTE Install the drive sprocket together with the drive chain 85 Nm 8 5 m kg 61 ft lb 64 Nm 6 4 m kg 46 ...

Page 333: ...rein Pignon d entraînement 1 Monter 9 Pignon d entraînement 1 9 Chaîne de transmission 2 N B Monter le pignon d entraînement avec la chaîne de transmission IC4M5000 MONTAGGIO E INSTALLAZIONE IC4M5171 Installazione del motore 1 Installare 9 Motore 1 Installare il motore dal lato destro 9 Albero snodato 2 9 Bullone di montaggio del moto re inferiore 3 9 Bullone di montaggio del moto re anteriore 4 9...

Page 334: ...ock washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 Install 9Chain guide 1 9Chain cover 2 9Screw chain cover 3 5 Nm 0 5 m kg 3 6 ft lb 75 Nm 7 5 m kg 54 ft lb ...

Page 335: ... 2 N B Serrer l écrou en actionnant le frein arrière 3 Courber la languette de la rendel le frein pour verrouiller l écrou 4 Monter 9 Guide chaîne 1 9 Couvercle de chaîne 2 9 Vis couvercle de chaîne 3 2 Installare 9 Rosetta di sicurezza 1 9 Dado rocchetto conduttore 2 NOTA Serrare il dado azionando il freno posteriore 3 Piegare la linguetta della rosetta di sicurezza per bloccare il dado 4 Install...

Page 336: ...MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 45 mm 1 77 in 6 3 Bolt L 55 mm 2 17 in 4 4 Bolt L 65 mm 2 56 in 1 5 Bolt L 75 mm 2 95 in 1 6 Holder 1 7 Crankcase right 1 Use special tool 8 Crankcase left 1 Refer to REMOVAL POINTS 9 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 10 Oil seal 2 11 Bearing 2 Refer to REMOVAL POINTS EC4N0000 CRANKCASE AND CRANKSHAFT 1 2 3 Extent of ...

Page 337: ...AU PIED ARBRE DE SELECTEUR ET PIGNON Levier de butée DE TRANSMISSION Rotor et stator Se reporter à la section MAGNETO CDI 1 Segment 1 Se reporter à POINTS DE DEPOSE 2 Boulon L 45 mm 1 77 in 6 3 Boulon L 55 mm 2 17 in 4 4 Boulon L 65 mm 2 56 in 1 5 Boulon L 75 mm 2 95 in 1 6 Support 1 7 Carter droit 1 Utiliser l outil spécial 8 Carter gauche 1 Se reporter à POINTS DE DEPOSE 9 Vilebrequin 1 Utiliser...

Page 338: ...n shafts cC Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw re align and start over If the cases do not separate check for a remaining case bolt or fitting Do not force Rotor puller YU 1362 A 90890 01362 EC4N300...

Page 339: ...une vis peut être légèrement dévissée pour mettre le corps de l outil de niveau 9Tout en serrant le boulon central taper alternativement sur le bossage de fixation du moteur et les arbres de transmission fF Utiliser un maillet en plastique et ne taper que sur les portions renforcées du carter Ne pas taper sur les plans de joint Travailler lentement et avec précaution en s assurant que les deux moi...

Page 340: ...rankshaft bearing 1 Remove 9Bearing 1 NOTE 9Remove the bearing from the crankcase by pressing its inner race as shown in å 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed bearing EC4N4000 INSPECTION EC4N4101 Crankcase 1 Inspect 9Contacting surface a Scratches Replace 9Engine mounting boss b crankcase Cr...

Page 341: ...ilebrequin en appuyant de carter intérieure comme indiqué dans å 9Si le roulement est enlevé en même temps que le vilebrequin déposer le roulement en utilisant un extracteur de roulement 2 comme indiqué dans 9N utilisez pas le roulement déposé VERIFICATION Carter 1 Examiner 9 Surface de contact a Rayures Changer 9 Bossage de montage du monteur b carter Craquelures endommagement Changer IC4N3302 Al...

Page 342: ...e with a finger Rough spot Seizure Replace 3 Inspect 9Oil seal 1 Damage Replace EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification Replace Use the dial gauge and a thickness gauge EC4N5000 ASSEMBLY AND INSTALLATION EC4N5300 Crankshaft bearing 1 Install 9Bearing 1 To crankcase left and right NOTE In...

Page 343: ... c 9 Kurbelwangenbreite d Abweichung von Spezifikation Erneuern Die Messuhr und die Fühler lehre verwenden MONTAGE UND EINBAU Kurbelwellenlager 1 Einbauen 9 Lager 1 Am Kurbelgehäuse links und rechts HINWEIS Das Lager einbauen indem der äuße re Laufring parallel eingepresst wird 2 Examiner 9 Roulements 1 Faire tourner la bague intérieure avec le doigt Point dur grippage Changer 3 Examiner 9 Bague d...

Page 344: ...ing rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bear ing 9Before installing the crankshaft clean the con tacting surface of crankcase 9Apply molybdenum disulfide grease to the sur face a where the crankshaft and bearing come in contact 9Apply the lithium soap base grease on the...

Page 345: ...vilebrequin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer de la graisse au bisulfure de molybdène sur la surface de contact a entre le vilebrequin et le roulement 9Appliquer une graisse à base de savon au lithium sur la lèvre de la bague d étanchéité fF Ne pas utiliser de marteau pour insé rer le vilebrequin IC4N5102 Paraolio 1 Insta...

Page 346: ...Transmission operation Unsmooth operation Repair 3 Apply 9Sealant On the crankcase right 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Yamaha bond No 1215 ThreeBond No 1215 90890 85505 4 Install 9Dowel pin 1 9O ring 2 ...

Page 347: ...nctionnement raide Réparation 3 Mettre 9 Etanchéité Sur le carter droit 1 N B Nettoyer la surface de contact des demi carters gauche et droit avant d appliquer l étanchéité 4 Monter 9 Goujon 1 9 Joint torique 2 2 Controllare 9 Funzionamento del cambio 9 Funzionamento della trasmissione Difficoltà di funzionamento Ripararli 3 Applicare 9 Sigillante Sul carter destro 1 NOTA Pulire la superficie di c...

Page 348: ...ur face a where the crankshaft and bearing come in contact 9Use two plain washers Yamaha genuine 90201 243K3 5 or the ones of a size as shown one on the other Except for USA and CDN 9Install so that the plain washers do not deviate from the crankshaft center Except for USA and CDN 9When installing the crankcase the connecting rod should be positioned at TDC top dead center 9Install while checking ...

Page 349: ...gend dar gestellt außer für die USA und Kanada 9 Die Unterlegscheiben so einbauen dass sie nicht von der Kurbelwellen mitte abweichen außer für die USA und Kanada 9 Wenn das Kurbelgehäuse eingebaut wird sollte die Pleuelstange am OT oberen Totpunkt positioniert sein 9 Beim Einbau überprüfen ob sich die Passhülse in ihrer Position befindet 5 Installare 9 Carter destro 1 Usare l utensile per install...

Page 350: ...t to give an impact to the segment when tightening the bolt 9 Remove 9Sealant Forced out on the cylinder mating surface 10 Apply 9Engine oil To the crank pin bearing oil delivery hole and connecting rod big end washer 11 Check 9Crankshaft and transmission operation Unsmooth operation Repair NOTE If the crankshaft will not turn smoothly make an adjustment by gently tapping its right end with a soft...

Page 351: ... ne pas causer d impact sur le seg ment lors du serrage du boulon 9 Déposer 9 Etanchéité Chassée sur le plan de joint du cylindre 10 Mettre 9 Huile moteur Sur le maneton le roulement le trou de refoulement et les ron delles de tête de bielle 11 Contrôler 9 Fonctionnement de vilebrequin et de boîte à vitesses Pas de douceur Réparer N B Si le vilebrequin ne tourne pas réguliè rement l ajuster en tap...

Page 352: ...the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Guide bar long 1 2 Guide bar short 1 3 Shift cam 1 4 Shift fork 3 1 5 Shift fork 1 1 6 Shift fork 2 1 7 Main axle 1 8 Drive axle 1 Refer to REMOVAL POINTS 9 Spacer 1 EC4H0000 TRANSMISSION SHIFT CAM AND SHIFT FORK Extent of removal 1 Shift cam and shift fork removal 2 Main axle and drive axle removal 1 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m...

Page 353: ...ET DE SELECTEUR ET DE LA FOURCHETTE Moteur Se reporter à la section DEPOSE DU MOTEUR Séparer le carter Se reporter à la section CARTER ET VILEBRE QUIN 1 Barre de guidage longue 1 2 Barre de guidage petite 1 3 Barillet de sélecteur 1 4 Fourchette 3 1 5 Fourchette 1 1 6 Fourchette 2 1 7 Axe principal 1 Se reporter à POINTS DE DEPOSE 8 Axe moteur 1 9 Entretoise 1 IC4H0000 TRASMISSIONE CAMMA DEL CAMBI...

Page 354: ...ove 9Remove assembly carefully Note the position of each part Pay particular attention to the lo cation and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect 9Matching dog a 9Gear teeth b 9Shift fork groove c Wear Damage Replace 2 Check 9Gears movement Unsmooth movement Repair or replace EC4H4600 Bearing 1 Inspect 9Bearing 1 Rotate inner race with a finger Rough spot Seizure Re...

Page 355: ...igneusement Noter la position de chaque pièce Bien faire attention à l emplacement et à l orientation des fourchettes VERIFICATION Pignons 1 Examiner 9 Crabot d accouplement a 9 Dent de pignon b 9 Gorge de fourchette c Usure endommagement Changer 2 Contrôler 9 Movement des pignons Pas de douceur Réparer ou changer Roulement 1 Examiner 9 Roulement 1 Faire tourner la bague intérieure avec le doigt P...

Page 356: ...ace shift fork and or guide bar NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION EC4H5213 Transmission 1 Install 96th pinion gear 21T 1 93rd 4th pinion gear 17T 17T 2 95th pinion gear 20T 3 92nd pinion gear 15T 4 To main axle 5 NOTE Apply the molybdenum disulfide oil on the inner and en...

Page 357: ...gui dage N B En cas de mauvais fonctionnement de la fourchette ne pas changer que la fourchette ellemême mais les deux pignons situés de chaque côte de la fourchette REMONTAGE ET MONTAGE Boîte à vitesses 1 Monter 9 Pignon de 6è 21D 1 9 Pignon de 3è 4è 17D 17D 2 9 Pignon de 5è 20D 3 9 Pignon de 2è 15D 4 A l axe principal 5 N B Appliquer de l huile au bisulfure de molybdène sur la surface intérieure...

Page 358: ...e of the sliding gear then install 9Apply the molybdenum disulfide grease on the inner surface of the 4th wheel gear then install 3 Install 9Plain washer 1 9Circlip 2 NOTE 9Be sure the circlip sharp edged corner a is po sitioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 4 Install 9Spacer 1 NOTE 9Apply the lithium soap base grease ...

Page 359: ...u pignon mobile puis les monter 9Appliquer de la graisse au bisulfure de molybdène sur la surface intérieure du pignon de 4ème puis l installer 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9Vérifier que le coté à bord vif du cir clip a soit opposé à la rondelle ordi naire située contre le pignon b 9Vérifier que l extrémité du circlip c est située dans une gorge de l axe d 4 Monter 9 Entretoise ...

Page 360: ...gear 5 on the main axle 2 Install 9Shift cam 1 NOTE 9Apply the transmission oil on the shift cam 9Install the shift cam while holding up the 5th wheel gear 2 and keeping the shift fork 1 3 moved in the direction of the arrow 3 Install 9Guide bar short 1 9Guide bar long 2 NOTE 9Apply the transmission oil on the guide bars 9Be sure the long bar is inserted into the shift forks 1 and 3 and the short ...

Page 361: ...let 9Installez la came d inverseur tout en maintenant le 5e pignon 2 et la four chette d inverseur n 1 3 dans le sens de la flèche 3 Monter 9 Barre de guidage petite 1 9 Barre de guidage longue 2 N B 9Appliquer de l huile de boîte de vitesses sur les barres guidages 9Vérifier que la barre longue est situé dans les fourchettes N 1 et 3 et la petite dans le numéro 2 IC4H5312 Camma del cambio e force...

Page 362: ...4 74 ENG TRANSMISSION SHIFT CAM AND SHIFT FORK 4 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair ...

Page 363: ...A DEL CAMBIO 4 Kontrollieren 9 Funktion der Gangschaltung 9 Funktion des Getriebes Ungleichmäßiger Betrieb Reparieren 4 Contrôler 9 Fonctionnement de sélecteur 9 Fonctionnement de boîte à vitesse Fonctionnement raide Réparer 4 Controllare 9 Funzionamento del cambio 9 Funzionamento della trasmissio ne Difficoltà di funzionamento Ripararli ...

Page 364: ...1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of removal 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal w Support the machine securely so there is no dan ger of it falling over 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft l...

Page 365: ... 2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Collerette 2 6 Bague d étanchéité 2 7 Roulement 2 Se reporter à POINTS DE DEPOSE 8 Disque de frein 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser IC500000 TELAIO IC590000 RUOTA ANTERIORE E RUOTA POSTERIORE IC598000 RUOTA ANTERIORE Ampiezza della rimozione 1 Rimozione della ruota...

Page 366: ...he removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 2 1 3 3 w Support the machine securely so there is no dan ger of it falling over 125 Nm 12 5 m kg 90 ft lb 14 Nm 1 4 m kg 10 ft lb 19 Nm 1 9 m kg 13 ...

Page 367: ... arrière 1 Se reporter à POINTS DE DEPOSE 5 Collerette 2 6 Pignon mené 1 7 Bague d étanchéité 2 8 Circlip 1 9 Roulement 2 Se reporter à POINTS DE DEPOSE 10 Disque de frein 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser IC598100 RUOTA POSTERIORE Ampiezza della rimozione 1 Rimozione della ruota posteriore 2 Rimozione del cuscinetto della ruota 3 R...

Page 368: ...necessary 1 Remove 9Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure 9Wheel runout Out of limit Repair Replace 2 Inspect 9Bearing Rotate 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 1 2 0mm 0 08 in Lateral 2 2 2 0mm 0 08 in ...

Page 369: ...ure 9 Voile de roue Hors limite Réparer Changer 2 Examiner 9 Roulement Faire tourner la bague intérieure avec le doigt Point dur grippage Changer N B Changer les roulements la bague d étanchéité et la collerette de roue comme un ensemble IC593000 PUNTI DI RIMOZIONE IC523101 Ruota posteriore 1 Togliere 9 Ruota 1 NOTA Spingere in avanti la ruota e togliere la catena di trasmissione 2 IC513201 Cuscin...

Page 370: ...94200 Brake disc 1 Measure 9Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition re place the brake disc 2 Measure 9Brake disc thickness a Out of limit Replace Wheel axle bending limit 0 5 mm 0 020 in Disc wear limit Standard Limit Front 3 0 mm 0 12 in 2 5 mm 0 10 in Rear 4 0 mm 0 16 in 3 5 mm 0 14 in Disc de...

Page 371: ...imite d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arrière 4 0 mm 0 16 in 3 5 mm 0 14 in IC594200 Disco del freno 1 Misurare 9 Inflessione del disco del freno soltanto il disco del freno posteriore Usare il comparatore 1 Fuori specifica Ispezionare la scentratura della ruota Se la scentratura della ruota è in buone condizioni sostituire il disco del freno 2 Misurare 9 Spes...

Page 372: ...all be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern 3 Install 9Collar 1 NOTE 9Apply the lithium soap base grease on the oil seal lip 9Install the collars ...

Page 373: ...ricant diri gés vers l extérieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment extérieur 2 Monter 9 Disque de frein 1 9 Boulon disque de frein 2 N B Serrer les boulons par étape en utilisant un modèle d entre croisement 3 Monter 9 Collerette 1 N B 9Appliquer de la graisse à base de savon au lithium sur les lèvres de bague d étan...

Page 374: ... soap base grease on the wheel axle 6 Install 9Nut wheel axle 1 7 Tighten 9Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied 105 Nm 10 5 m kg 75 ft lb 21 Nm 2 1 m kg 15 ft lb ...

Page 375: ...llare 9 Asse della ruota 1 NOTA Applicare sull asse della ruota il grasso a base di sapone di litio 6 Installare 9 Dado asse della ruota 1 7 Serrare 9 Bullone supporto dell asse 1 NOTA Prima di serrare il bullone montare l asse della ruota sul supporto dell asse facendo scorrere più volte la forcella anteriore con il freno anteriore aziona to 6 Monter 9 Ecrou axe de roue 1 7 Serrer 9 Boulon suppor...

Page 376: ...ng 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern EC5251A1 Rear wheel 1 Install 9Bearing right 1 9Circlip 2 9Spacer 3 9Beari...

Page 377: ...douille convenant au dia mètre extérieure de la cage du roule ment 9Le roulement latéral droit doit monter premier 9Monter la bague d étanchéité avec ses marques ou numéros de fabricant diri gés vers l extérieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment extérieur 2 Monter 9 Disque de frein 1 9 Boulon disque de frein 2 N B Se...

Page 378: ...NOTE Apply the lithium soap base grease on the oil seal lip 5 Install 9Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install 9Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install 9Chain puller left 1 9Wheel axle 2 NOTE 9Install the chain puller left and insert the wheel axle from left side 9Apply the lithium soap base grease on the wheel axle...

Page 379: ...tto condotto 3 9 Dado rocchetto condotto 4 NOTA Serrare i dadi in sequenza usando uno schema incrociato 4 Installare 9 Bordino 1 NOTA Applicare sul labbro del paraolio il grasso a base di sapone di litio 5 Installare 9 Ruota NOTA Installare correttamente il disco del freno 1 fra le pastiglie del freno 2 6 Monter 9 Chaîne de transmission 1 N B Pousser la roue 2 vers l avant et mon ter la chaîne de ...

Page 380: ...wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axle 1 9Locknut 2 125 Nm 12 5 m kg 90 ft lb Drive chain slack 48 58 mm 1 9 2 3 in 19 Nm 1 9 m kg 13 ft lb ...

Page 381: ... N B A ce stage resserrer provisoirement les écrous axe de roue 8 Installare 9 Estrattore per catena destro 1 9 Rosetta 2 9 Dado asse della ruota 3 NOTA Serrare temporaneamente il dado asse della ruota a questo punto 9 Régler 9 Flèche de chaîne de transmis sion a Se reporter à la section REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION du CHAPITRE 3 Flèche de chaîne de trans mission 48 58 mm 1 9 2 3...

Page 382: ...en when disassembling the caliper 7 Caliper 1 8 Brake lever 1 9 Master cylinder bracket 1 10 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose removal 2 Caliper removal 3 Master cyilinder removal w Support the machine securely so there is no dan ger of it falling over 2 1 3 3 9 Nm 0 9 m kg 6 5 ft lb 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 f...

Page 383: ... Bouchon de goupille de plaquette 1 Déposer lors du desserrage de la goupille de plaquette 6 Goupille de plaquette 1 Desserrer lors du démontage de l étrier 7 Etrier 1 8 Levier de frein 1 9 Etrier de maître cylindre 1 10 Maître cylindre 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser Se reporter à POINTS DE DEPOSE IC5A0000 FRENO ANTERIORE E FRENO...

Page 384: ... 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Caliper 1 Extent of removal 1 Master cylinder removal 2 Brake hose removal 3 Caliper removal w Support the machine securely so there is no dan ger of it falling over 2 3 3 1 1 2 Nm 0 2 m kg 1 4 ft lb 30 Nm 3 0 m kg 22 ft lb 30 Nm 3 0 m kg 22 ft...

Page 385: ...1 6 Bouchon de goupille de plaquette 1 Déposer lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du démontage de l étrier 8 Etrier 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser Se reporter à la section ROUE AVANT ET ROUE ARRIERE Se reporter à POINTS DE DEPOSE IC5A8100 FRENO POSTERIORE Ampiezza della rimozio...

Page 386: ...iper piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 EC5A8200 CALIPER DISASSEMBLY A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear caliper disassembly 2 1 6 Nm 0 6 m kg 4 3 ft lb 3 Nm 0 3 m kg 2 2 ft lb 18 Nm 1 8 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb ...

Page 387: ...er avant 2 Démontage de l étrier arrière Etendue de dépose Ordre Nom de pièce Q té Remarques DEMONTAGE DE L ETRIER A B 1 Goupille de plaquette 1 1 2 Palquette de frein 2 2 3 Support de plaquette 1 1 4 Piston d étrier 2 1 Se reporter à POINTS DE DEPOSE 5 Joint antipoussière 2 1 Se reporter à POINTS DE DEPOSE 6 Joint de piston 2 1 IC5A8200 SMONTAGGIO DELLA PINZA A Anteriore B Posteriore Ampiezza del...

Page 388: ...agm 1 3 Reservoir float 1 4 Master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Plain washer 1 7 Push rod 1 8 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear Extent of removal 1 Front master cylinder disassembly 2 Rear master cylinder disassembly 1 1 2 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 2 ...

Page 389: ...auptbremszylindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorn B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE CYLINDRE A Avant B Arrière Etendue de dépose 1 Démontage du maître cylindre avant 2 Démontage du maître cylindre arrière IC5A8300 SMONTAGGIO DEL CILINDRO PRINCIPALE A Anteriore B Posteriore Ampiezza...

Page 390: ... pulling the lever in or pushing down on the pedal cC 9Do not reuse the drained brake fluid 9Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 Caliper piston 1 Remove 9Caliper piston Use compressed air and proceed carefully w 9Cover piston with rag and use extreme cau tion when expelling piston from cylinder 9Never attempt to pry out piston ...

Page 391: ...IC5A3101 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Coperchio del cilindro principa le 1 9 Dispositivo di protezione NOTA Non togliere il diaframma A Anteriore B Posteriore 2 Collegare il tubo flessibile traspa rente 2 alla vite di spurgo 1 e collocare sotto la sua estremità un contenitore adatto A Anteriore B Posteriore 3 Allentare la vite d...

Page 392: ...nd dust seals w Replace the piston seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534120 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder assembly Stains Clean w Use only new brake fluid A Front B Rear 2 Inspect 9Diaphragm 1 Crack Damage Replace A Front B Rear 3 Inspect front brake only 9Reservoir float ...

Page 393: ... les joints de piston et antipoussière lors d un démontage d étrier A Avant B Arrière IC533402 Kit delle guarnizioni di tenuta del pistone 1 Togliere 9 Parapolvere 1 9 Guarnizione di tenuta del pisto ne 2 NOTA Togliere le guarnizioni di tenuta del pistone e i parapolvere spingendoli con un dito iI Non tentare mai di fare leva sulle guarnizioni di tenuta del pistone e sui parapolvere per estrarli T...

Page 394: ...t B Rear 2 Inspect 9Caliper piston 1 Wear Score marks Replace caliper piston assembly w Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Brake hose 1 Crack Damage Replace EC5A5000 ASSEMBLY AND INSTALLATION w 9All internal parts should be cleaned in new brake fluid only 9Internal parts should be lubricated with brake fluid when installed ...

Page 395: ...lindro principale A Anteriore B Posteriore IC534214 Pinza 1 Ispezionare 9 Superficie interna del cilindro della pinza a Usura Rigature Sostituire il gruppo pinza A Anteriore B Posteriore 2 Ispezionare 9 Pistone della pinza 1 Usura Rigature Sostituire gruppo pistone della pinza T Sostituire le guarnizioni di tenuta del pistone e i parapolvere 2 2 ogni volta che si smonta una pinza IC534301 Tubo fle...

Page 396: ... and dust seals onto the slot on caliper correctly A Front B Rear 3 Install 9Caliper piston 1 NOTE Apply the brake fluid on the piston wall cC 9Install the piston with its shallow depressed side a a facing the caliper 9Never force to insert A Front B Rear EC5A5700 Front caliper 1 Install 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper r...

Page 397: ... et antipoussière dans la rainure située sur l étrier A Avant B Arrière IC5A5801 Pistone della pinza 1 Pulire 9 Pinza 9 Guarnizione di tenuta del pisto ne 9 Parapolvere 9 Pistone della pinza Pulirli con liquido per freni 2 Installare 9 Guarnizione di tenuta del pisto ne 1 9 Parapolvere 2 T Usare sempre guarnizioni di tenuta del pistone e parapolvere nuovi NOTA Inserire le guarnizioni di tenuta del...

Page 398: ...ad pin at this point 2 Install 9Disc cover 1 9Bolt disc cover 2 2 Install 9Caliper 1 9Bolt caliper 2 3 Tighten 9Pad pin 3 4 Install 9Pad pin plug 4 23 Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Install 9Caliper 1 9Rear wheel 2 Refer to FRONT WHEEL AND REAR WHEEL section 4 Tighten 9Pad pin 3 5 Insta...

Page 399: ...remsschuhaussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 2 Monter 9 Etrier 1 9 Boulon étrier 2 3 Serrer 9 Goupille de plaquette 3 4 Monter 9 Bouchon de goupille de plaquet te 4 Etrier arrière 1 Monter 9 Support de plaquette 1 9 Plaquette de frein 2 9 Goupille de plaquette 3 N B 9Installer les plaquettes de frein en ajustant leurs saillies a dans l encoche...

Page 400: ...rimary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance A Front B Rear 3 Install 9Spring 1 To master cylinder piston 2 NOTE Install the spring at the smaller dia side A Front B Rear ...

Page 401: ...lle du maître cylindre doit être posée dans la direction indiquée Une mauvaise intallation entaîne une performance incorrecte du freinage A Avant B Arrière IC5A5220 Kit del cilindro principale 1 Pulire 9 Cilindro principale 9 Kit del cilindro principale Pulirli con liquido per freni 2 Installare 9 Anello conico del cilindro prin cipale primario 1 9 Anello conico del cilindro prin cipale secondario...

Page 402: ...nose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mark a face upward 9First tighten the bolts on the upper side of the master cylinder bracket and then tighten the bolts on the lower side 9 Nm 0 9 m kg 6 5 ft lb 2 Install 9Brake lever 1 9Bolt brake lev...

Page 403: ...te festziehen 4 Installare Anteriormente 9 Kit del cilindro principale 1 9 Rosetta 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 Posteriormente 9 Kit del cilindro principale 1 9 Asta di comando 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 NOTA 9Applicare il liquido per freni sul kit del cilin...

Page 404: ...at its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 2 Install 9Master cylinder 1 9Bolt master cylinder 2 10 Nm 1 0 m kg 7 2 ft lb 3 Install 9Spring 1 9Brake pedal 2 9O ring 3 9Bolt brake pedal 4 9Clip 5 NOTE Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 26 Nm 2 6 m kg 19 ft lb ...

Page 405: ...inder 1 9 Schraube Hauptbremszylin der 2 IC5A5401 Cilindro principale posteriore 1 Installare 9 Rondella in rame 1 9 Tubo flessibile del freno 2 9 Bullone di unione 3 T Usare sempre rondelle in rame nuove iI Installare il tubo flessibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro principale 2 Installare 9 Cilindro ...

Page 406: ...2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Install 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT section in the CHAPTER 3 EC5A5911 Front brake hose 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the pro...

Page 407: ...a wie in der Abbildung gezeigt angeordnet ist und den Überstand b b am Bremsbe lag leicht berührt 2 Einbauen 9 Bremsschlauchhalter 1 9 Schraube Bremsschlauchhal ter 2 3 Einbauen 9 Bremsschlauchhalter 1 9 Mutter Bremsschlauchhalter 2 HINWEIS Die Oberseite a der Bremsschlauch Halterung am Anstrich b des Brems schlauches ausrichten 4 Installare 9 Spina 1 9 Rosetta 2 9 Coppiglia 3 NOTA Dopo l installa...

Page 408: ... so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb EC5A5502 Rear brake hose 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the caliper 30 Nm 3 0 m kg 22 ft lb ...

Page 409: ...sibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro principale Tuyau de frein arrière 1 Monter 9 Rondelle en cuivre 1 9 Tuyau de frein 2 9 Boulon d union 3 XG Toujour utiliser les rondelles en cuivre neuves fF Installer la tuyau de frein de manière que la partie avec le tuyau soit a a dirigée comme indiqué et touche ...

Page 410: ...ty brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction and lead to poor performance 9Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock cC Br...

Page 411: ... et un mauvais fonctionnement du frein 9Toujours utiliser la même marque de liquide de frein Le mélange de liquides de marques différentes risque de provoquer une réaction chimique nuisible au fonctionne ment du frein 9Lorsqu on ajoute du liquide faire attention de ne pas laisser pénétrer de l eau dans le maître cylindre L eau risque d abaisser fortement le point d ébullition et de provoquer le ph...

Page 412: ...Diaphragm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Master cylinder cap 1 9Bolt master cylinder cap 2 cC After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper A Front B Rear 5 Install rear brake only 9Protector 1 9Bolt p...

Page 413: ...aframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale0 2 Posteriormente 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Bullone coperchio del cilindro principale 2 iI Dopo l installazione tirando verso l interno la leva o premendo il peda le controllare se vi sono perdite di liquido per freni dove sono installati i bulloni di unione rispettivamente sul cilind...

Page 414: ...RS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt under bracket 2 Only loosening 5 Front fork 1 5 26 CHAS FRONT FORK 1 w Support the machine securely so there is no dan ger of it falling over Extent of removal 1 Front fork removal 7 Nm 0 7 m kg 5 1 f...

Page 415: ... wenn die Vorderradgabel demontiert wird Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 4 Klemmschraube 2 Nur lösen Untere Gabelbrücke 5 Vorderradgabel 1 VORDERRADGABEL Ausbauumfang 1 Ausbau der Vorderradgabel FOURCHE AVANT Etendue de dépose 1 Dépose de la fourche avant Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser IC550000 FORCELLA ANTERIORE...

Page 416: ... tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 0 Oil seal 1 q Base valve 1 Drain the fork oil Use special tool w Damper assembly 1 Refer to REMOVAL POINTS 5 27 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 1 Extent of removal 1 Oil seal removal 2 Damper assembly removal 2 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 30 Nm 3 0 m kg 22 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 417: ... outil spécial Se reporter à POINTS DE DEPOSE 2 Ressort de fourche 1 3 Joint antipoussière 1 4 Bague d arrêt 1 Se reporter à POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 Métal de piston 1 8 Bague antifriction 1 9 Rondelle de bague d étanchéité 1 0 Bague d étanchéité 1 q Soupape de base 1 Vidanger d huile de fourche Utiliser l outil spécial w Amortisseur complet 1 Se reporter à POINTS DE DE...

Page 418: ...ruction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled 9Before removing the base valves or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS EC553311 Damper assembly 1 Loosen 9Damper assembly 1 NOTE Before rem...

Page 419: ...ger complètement les chambres à air IC556000 NOTA PER IL MANEGGIO NOTA La forcella anteriore richiede grande at tenzione Si raccomanda pertanto di ef fettuare la manutenzione della forcella anteriore presso il concessionario iI Per evitare un esplosione accidentale di aria si dovrebbero osservare le se guenti istruzioni 9La forcella anteriore con una biella incorporata ha una costruzione in terna ...

Page 420: ...o not remove the locknut as the damper rod may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove 9Dust seal 1 9Stopper ring 2 Using slotted head screwdriver cC Take care not to scratch the inner tube 2 Remove 9Inner tube 1 Oil seal removal steps 9Push in slowly a the inner tube just be fore it bottoms out and then pull it back q...

Page 421: ...nel gruppo ammortizzatore senza che sia possibile estrarla Clé à bague de boulon capuchon YM 01501 90890 01501 Chiave ad anello per vite mordente YM 01501 90890 01501 Schraubenschlüssel für Nockenwellenlagerdeckel Schraubenringe YM 01501 90890 01501 Inneres Rohr 1 Ausbauen 9 Staubdichtung 1 9 Anschlagring 2 Einen Schlitzschraubendreher verwenden dD Darauf achten dass der Schlauch nicht verkratzt w...

Page 422: ... Inspect 9Damper assembly 1 Bend Damage Replace 9O ring 2 Wear Damage Replace cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign ma terial Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled Cap bolt wrench YM 01500 90890 01500...

Page 423: ...VERIFICATION Amortisseur complet 1 Vérifier 9 Amortisseur complet 1 Courbure endommagement Changer 9 Joint torique 2 Usé endommagé Changer fF La fourche avant ayant une tige de piston incorporée a une construction interne très sophistiquée et est parti culièrement sensible aux substances étrangères Faire suffisamment attention à ne pas laisser pénétrer de substances étrangères lorsque l huile est ...

Page 424: ...9Piston metal 3 Wear Damage Replace 9Spring 4 Damage Fatigue Replace base valve 9Air bleed screw 5 Wear Damage Replace EC554400 Fork spring 1 Measure 9Fork spring free length a Out of specification Replace Standard Limit 454 mm 449 mm 17 9 in 17 7 in Fork spring free length Collar 1 Inspect 9Piston metal 1 Wear Damage Replace ...

Page 425: ...nuta 2 Usura Danni Sostituire 9 Metallo del pistone 3 Usura Danni Sostituire 9 Molla 4 Danni Affaticamento Sostitui re la valvola di base 9 Vite di spurgo dell aria 5 Usura Danni Sostituire Ressort de fourche 1 Mesurer 9 Longueur libre de ressort de fourche a Hors spécification Changer Stantard Limite 454 mm 449 mm 17 9 in 17 7 in Longueur libre de ressort de fourche Gabelbeinfeder 1 Messen 9 Unge...

Page 426: ...t of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube Inner tube bending limit 0 2 mm 0 008 in EC554600 Outer tube 1 Inspect 9Outer tube 1 Score marks Wear Damage Replace Adjuster 1 Inspect 9Adjuster 1 9O ring 2 Wear Damage Replace ...

Page 427: ...erden können IC554502 Tubo interno 1 Ispezionare 9 Superficie del tubo interno a Rigature Ripararlo o sostituir lo Usare carta vetrata umida di grana no 1000 Pezzo di bloccaggio dell olio danneggiato Sostituirlo 9 Curvature del tubo interno Fuori specifica Sostituirlo Usare il comparatore 1 NOTA Il valore di curvatura corrisponde alla metà del valore letto dal comparatore T Non tentare di raddrizz...

Page 428: ... have an ex cessively adverse effect on the front fork performance 9Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Oil capacity 195cm3 6 86 Imp oz 6 59 US oz 4 After filling pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper assembly of air NOTE Be careful not to excessive full stroke A stroke of 200 m...

Page 429: ...ere un effetto ec cessivamente negativo sul rendi mento della forcella anteriore 9Non permettere mai la penetrazione di materiali estranei nella forcella anteriore Huile recommandée Huile de suspension S1 Capacité d huile 195 cm3 6 86 Imp oz 6 59 US oz Olio consigliato Olio per sospensioni S1 Capacità olio 195 cm3 6 86 Imp oz 6 59 US oz Empfohlenes Öl Teleskopgabelöl S1 Öl Fassungsvermögen 195 cm3...

Page 430: ... Loosen 9Compression damping adjuster 1 NOTE 9Loosen the compression damping adjuster fin ger tight 9Record the set position of the adjuster the amount of turning out the fully turned in posi tion 8 Install 9Base valve 1 To damper assembly 2 NOTE First bring the damper rod pressure to a maxi mum Then install the base valve while releas ing the damper rod pressure 9 Check that the damper assembly i...

Page 431: ...bord amener la pression de la tige d amortissement au maximum Ins taller ensuite la valve de base tout en relâchant la pression de la tige d amor tissement 9 Vérifier que l amortisseur complet est totalement déployé Pas totalement déployé Répéter les étapes 2 à 8 7 Lösen 9 Verdichtungsdämpfer Einsteller 1 HINWEIS 9 Den Verdichtungsdämpfer Einsteller mit der Hand lösen 9 Die Einstellposition des An...

Page 432: ... 5 35 CHAS FRONT FORK 12 While protecting the damper assembly 1 with a rag and compressing fully allow excessive oil to overflow on the base valve side cC Take care not to damage the damper assembly 13 Allow the overflowing oil to escape at the hole a in the damper assembly 14 Check 9Damper assembly smooth movement Tightness Binding Rough spots Repeat the steps 2 to 13 29 Nm 2 9 m kg 21 ft lb Cap ...

Page 433: ...hrend die Dämpfer Baugruppe 1 durch einen Lappen geschützt und vollständig zusammenge drückt wird dD Darauf achten dass die Dämpfer Baugruppe nicht beschädigt wird 13 Das überschüssige Öl an der Öff nung a in der Dämpfer Baugrup pe ablaufen lassen 14 Kontrollieren 9 Gleitbewegung der Dämpfer Baugruppe Auzug Bindung rauhe Stellen Die Schritte 2 bis 13 wieder holen 10 Serrer 9 Soupape de base 1 N B ...

Page 434: ... installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 9Install the oil seal with its manufacture s marks or number facing the axle holder side 9Install the oil seal washer with its projections b facing upward 16 Install 9Piston metal 1 NOTE Install the piston metal onto the slot on inner tube 17 Install 9Outer tube 1 To inner tube 2 ...

Page 435: ...lation de la bague d étanchéité utiliser une feuille en vi nyle a avec de l huile de fourche ap pliquée pour protéger la lèvre de la bague d étanchéité 9Installer le joint à huile dont les marques d usine ou les numéros font face au côté du support d axe 9Installer la rondelle de bague d étan chéité avec les saillies b orientées vers le haut 16 Monter 9 Métal de piston 1 N B Installer le métal de ...

Page 436: ...iver 3 19 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 20 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 21 Install 9Dust seal 1 NOTE Apply the lithium soap base grease on the inner tube Fork seal driver YM A0948 90890 01502 Fork seal driver YM A0948 90890 01502 ...

Page 437: ...n Gabelbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das äußere Gabelbeinrohr ein pressen 20 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des äußeren Rohres einsetzen 21 Einbauen 9 Staubdichtung 1 HINWEIS Lithium Fett auf dem inneren Rohr auftragen 18 Monter 9 Bague antifriction 1 9 Rondelle de bague d étanchéité 2 Vers la fente de tube externe N B En...

Page 438: ...To damper assembly 3 NOTE Install the collar with its larger dia end a facing the fork spring 25 Install 9Damper assembly 1 To inner tube 2 cC To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper assembly may fall into it damaging the valve inside 26 Loosen 9Rebound damping adjuster 1 NOTE 9Loosen the rebound damping adjuster...

Page 439: ...lta verso la molla della forcella 25 Monter 9 Amortisseur complet 1 Au tube interne 2 fF Pour installer l amortisseur complet dans le tube plongeur maintenir l étanchéité du tube plongeur Si le tube plongeur est maintenu verticale ment l amortisseur risque de tomber dedans et d endommager la valve à l intérieur 25 Einbauen 9 Dämpfer Baugruppe 1 Zum inneren Rohr 2 dD Das Standrohr schräg halten um ...

Page 440: ...nstalled out of specification proper damping force cannot be obtained 29 Tighten 9Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster with specified torque 30 Install 9Adjuster 1 To inner tube 31 Fill 9Front fork oil 1 From outer tube top For EUROPE 29 Nm 2 9 m kg 21 ft lb 55 Nm 5 5 m kg 40 ft lb Gap a a between adjuster and locknut 0 5 1 0mm 0 02 0 04 in Recommended oil Suspension...

Page 441: ...osi zionare la chiave ad anello per vite mordente 7 tra il tubo interno e il controdado 6 9Serrare a fondo con le dita il regolato re sul gruppo ammortizzatore 28 Ispezionare 9 Distanza a tra il regolatore 1 e il controdado 2 Fuori specifica Riavvitare e regolare di nuovo il controdado NOTA Se il regolatore non è installato secondo le specifiche sarà impossibile ottenere la corretta forza di smorz...

Page 442: ...n 9Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque w Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability cC 9Be sure to use recommended fork oil If other oils are used they may have an ex ces...

Page 443: ...es schädliche Einflüsse auf die Lei stung der Teleskopgabel mit sich bringen 9 Darauf achten dass keine Fremd körper in die Vorderradgabel ein dringen T Non mancare mai di eseguire la rego lazione della quantità d olio tra la quantità massima e minima con la stessa regolazione per ciascuna for cella anteriore Una regolazione dif ferente rischia di provocare scarsa maneggevolezza e perdita di stabi...

Page 444: ... 9Front fork top end a Front fork top end standard a a 5 mm 0 20 in 4 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 7 Adjust 9Compression damping force NOTE Turn in the damping adjuster 1 finger tight and then turn out to t...

Page 445: ...rigine 7 Régler 9 Force de compression d amor tissement N B Tourner en serrant à la main le régleur 1 d amortisseur puis régler à la posi tion de réglage d origine 5 Installare 9 Dispositivo di protezione 1 9 Bullone dispositivo di protezi ne 2 6 Regolare 9 Forza di smorzamento dell es tensione NOTA Avvitare il regolatore di smorzamento 1 finché è possibile farlo con le dita e quindi ruotarlo in s...

Page 446: ...urn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer to REMOVAL POINTS 11 Handlebar holder upper 2 12 Handlebar 1 13 Handlebar holder lower 2 5 42 CHAS HANDLEBAR EC5B0000 HANDLEBAR 1 Extent of removal 1 Handlebar removal 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb 28 Nm 2 8 ...

Page 447: ...apuchon du câble d accélérateur 1 Retourner le couvercle de capuchon 6 Câble d accélérateur 1 Déconnecter du côté accélérateur 7 Accélérateur 1 Desserrer les boulons 8 Couvercle de capuchon 1 9 Collerette 1 10 Poignée gauche 1 Se reporter à POINTS DE DEPOSE 11 Support de guidon supérieur 2 12 Guidon 1 13 Support de guidon inférieur 2 Préparation pour la dépose IC5B0000 MANUBRIO Ampiezza della rimo...

Page 448: ...le disassembly Extent of removal Order Part name Q ty Remarks THROTTLE DISASSEMBLY 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to REMOVAL POINTS 5 Tube guide 1 1 EC5B8000 THROTTLE DISASSEMBLY 4 Nm 0 4 m kg 2 9 ft lb ...

Page 449: ...de dépose Ordre Nom de pièce Q té Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poigée inférieur 1 2 Capuchon de poigée supérieur 1 3 Ensemble de la poignée 1 4 Poignée droite 1 Se reporter à POINTS DE DEPOSE 5 Guide de tube 1 IC5B8000 SMONTAGGIO DELL ACCELERATORE Ampiezza della rimozione 1 Smontaggio dell acceleratore Ampiezza della rimozione Ordine Particolare Quantità Osservazione SMONTA...

Page 450: ...the grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect 9Handlebar 1 Bends Cracks Damage Replace w Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5100 Throttle assembly 1 Install 9Grip right 1 Apply the adhesive on the tube guide 2 NOTE 9Before applying the adhesive wipe...

Page 451: ... 9 Guidon 1 Deformée craquelures endom magement Changer XG Ne pas tenter de redresser un guidon déformé car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble accélérateur 1 Monter 9 Poignée droite 1 Appriquer l adhésif sur le guide de tube 2 N B 9 Avant d appliquer l adhésif essuyer la graisse ou l huile sur la surface du guide de tube a avec du diluant de peinture 9 Aligner l indi...

Page 452: ...all 9Handlebar holder lower 1 9Plain washer 2 9Nut handlebar holder lower 3 NOTE 9Install the handlebar holder lower with its side having the greater distance a from the mount ing bolt center facing forward 9Apply the lithium soap base grease on the thread of the handlebar holder lower 9Installing the handlebar holder lower in the reverse direction allows the front to rear offset amount of the han...

Page 453: ...avant 9Appliquer de la graisse à base de savon au lithium sur le filetage du support de guidon inférieur 9L installation du support de guidon inférieur en sens inverse permet de changer le décalage d avant en arrière de la position du guidon 9Ne pas serrer l écrou à ce stade Lenkstange 1 Einbauen 9 Lenkerhalter unten 1 9 Unterlegscheibe 2 9 Mutter Lenkerhalter unten 3 HINWEIS 9 Die Lenkerhalterung...

Page 454: ... the handlebar as shown 9First tighten the bolts on the front side of the handlebar holder upper and then tighten the bolts on the rear side 4 Install 9Grip left 1 Apply the adhesive to the handlebar 2 NOTE 9Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner 9Install the grip left to the handlebar so that the line b between the two arrow marks fa...

Page 455: ...és 9Installer le guidon de façon à ce que la saillie c du support de guidon supé rieur soit positionnée sur la marque du guidon comme illustré 9Serrer d abord les boulons à l avant du support de guidon supérieur et ensuite les boulons du côté arrière du guidon HINWEIS 9 Der Lenkerhalter oben sollte so angebracht werden dass die einge stanzte Markierung a nach vorn zeigt 9 Den Lenker so einbauen da...

Page 456: ...p 2 9 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 10 Install 9Cap cover 1 1 Nm 0 1 m kg 0 7 ft lb 6 Install 9Throttle cable 1 To tube guide 2 NOTE Apply the lithium soap base grease on the throt tle cable end and tube guide cable winding por tion 5 Install 9Collar 1 9Cap cover 2 9Throttle 3 NOTE 9Apply the lithium soap base grease on the throttle gr...

Page 457: ...del tubo 2 NOTA Applicare sull estremità del cavo dell acceleratore e sulla parte a spira del cavo di guida del tubo il grasso a base di sapone di litio 7 Installare 9 Rullo 1 9 Collare 2 NOTA 9Applicare il grasso a base di sapone di litio sulla superficie di scorrimento del rullo e sulla guida per cavi 9Installare il rullo in modo che la mar catura UPPER a sia rivolta verso l alto 9Far passare il...

Page 458: ... grip cap and brake lever 2 2 are equal If you make a mistake in the grip cap installation position the brake lever may contact the grip cap resulting in poor brake performance 9After tightening the bolts check that the throttle grip 3 3 moves smoothly If it does not retighten the bolts for adjustment 4 Nm 0 4 m kg 2 9 ft lb 11 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cyl...

Page 459: ...rès avoir serré les boulons véri fier que la poignée d accélérateur 3 3 tourne sans problème Sinon res serrer les boulons pour la régler 13 Monter 9 Bouton d arrêt du moteur EN GINE STOP 1 9 Support de levier d embrayage 2 9 Boulon support de levier d em brayage 3 9 Bride 4 N B 9Le bouton d arrêt du moteur ENGI NE STOP le support et la bride de levier d embrayage doivent être ins tallés selon les ...

Page 460: ...5 49 CHAS HANDLEBAR 14 Install 9Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch cable end 15 Adjust 9Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 ...

Page 461: ...E du CHAPITRE 3 14 Einbauen 9 Kupplungskabel 1 HINWEIS Lithium Fett am Kupplungskabelende auftragen 15 Einstellen 9 Spiel des Kupplungshebels Siehe Abschnitt EINSTEL LUNG DER KUPPLUNG im KAPITEL 3 14 Installare 9 Cavo della frizione 1 NOTA Applicare sull estremità del cavo della frizione il grasso a base di sapone di li tio 15 Regolare 9 Gioco della leva di comando della frizione Consultare la sez...

Page 462: ...crown 1 4 Ring nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Bearing race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Bearing race 2 Refer to REMOVAL POINTS Extent of removal 1 Under bracket removal 2 Bearing removal 2 1 w Support the machine securely so there is no dan ger of it falling over EC560000 STEERING 145 Nm 14 5 m kg 105 ft lb 21 Nm 2 1 m kg...

Page 463: ...Motor angeordnet wird Nummernschild Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDECKEL im KAPITEL 4 Lenkstange Siehe Abschnitt LENKSTANGE Vorderrad Kotflügel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe Abschnitt VORDERRADGABEL 3 Lenkerkrone 1 4 Ringmutter 1 Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 5 Untere Gabelbrücke 1 6 Lagerlaufring Abdeckung 1 7 Lager oben 1 8 Lager unten 1 Sie...

Page 464: ... down EC563300 Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Bearing race 1 Remove 9Bearing race 1 Remove the bearing race using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect 9Steering shaft 1 Bend Damage Replace Ring nut wrench YU 33975 90890 01403 ...

Page 465: ...e pas endommager le file tage de l arbre de direction Cage de roulement 1 Déposer 9 Cage de roulement 1 Déposer la cage de roulement à l aide d une tige 2 et d un marteau VERIFICATION Arbre de direction 1 Examiner 9 Arbre de direction 1 Déformations endommagement Changer IC563000 PUNTI DI RIMOZIONE IC563202 Ghiera 1 Togilere 9 Ghiera 1 Usare la chiave per ghiera 2 T Sostenere l albero dello sterzo...

Page 466: ...ion in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION EC5651A0 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install 9Bearing race 9Bearing upper 1 9Bearing race cover 2 NOTE Apply the lithium soap base grease on the bear ing and bearing race cover lip 3 Insta...

Page 467: ...ement et de cages de roulement REMONTAGE ET MONTAGE Etrier inférieur 1 Monter 9 Roulement inférieur 1 N B Appliquer de la graisse à base de savon au lithium sur la lèvre du joint anti poussière et sur la cironférence interne du roulement 2 Monter 9 Cage de roulement 9 Roulement supérieur 1 9 Couvercle de cage de roulement 2 N B Appliquer de la graisse à base de savon au lithium sur le roulement et...

Page 468: ...t by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE 9Temporarily tighten the pinch bolts under bracket 9Do not tighten the pinch bolts handle crown yet 8 Install 9Plain washer 1 9Steering shaft nut 2 7 Nm 0 7 m kg 5 1 ft lb 145 Nm 14 5 m kg 105 ft lb ...

Page 469: ...quel conque retirer l ensemble axe de direction et inspecter le support de direction 6 Monter 9 Rondelle ordinaire 1 7 Monter 9 Fourche avant 1 9 Etrier supérieur 2 N B 9Serrer le boulon de bridage étrier in férieur provisoirement 9Ne pas encore serrer le boulon de bri dage couronne de guidon 8 Monter 9 Rondelle ordinaire 1 9 Ecrou de colonne de direction 2 4 Installare 9 Ghiera 1 Serrare la ghier...

Page 470: ...the under bracket to specified torque If torqued too much it may cause the front fork to malfunction Front fork top end standard a a 5 mm 0 20 in 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 9 After tightening the nut check the steering for smooth movement If not adjust the steering by loosening the ring nut little by little ...

Page 471: ... 2 iI Serrare la staffa inferiore alla coppia specificata Se troppo serrata può provocare il malfunzionamento della forcella anteriore Oberes Ende der Gabelbein rohre Standard a 5 mm 0 20 in Extrémité supérieure de fourche avant Standard a a 5 mm 0 20 in Estremità superiore della forcella anteriore valore normale a a 5 mm 0 20 in 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft...

Page 472: ...ke pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 Extent of removal 1 Swingarm removal 1 w Support the machine securely so there is no dan ger of it falling over EC570000 SWINGARM 53 Nm 5 3 m kg 38 ft lb 80 Nm 8 0 m kg 58 ft lb 16 Nm 1 6 m kg 1...

Page 473: ...EMSE UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdrücken Antriebskette 1 Kettenschutz 1 2 Kettenspanner unten 1 3 Schraube Hinterad Stoßdämpfer 1 Die Hinterradschwinge festhalten Relaisarm 4 Schraube Pleuelstange 1 5 Drehzapfenwelle 1 6 Hinterradschwinge 1 Vorbereitung für den Aus bau W Die Maschine richtig abstützen damit sie nicht umfallen kann IC570000 FOR...

Page 474: ... Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 10 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly 1 2 3 2 3 70 Nm 7 0 m kg 50 ft lb 6 Nm 0 6 m kg 4 3 ft lb 80 Nm 8 0 m kg 58 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 475: ...sbau und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename Stückzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 Siehe unter AUSBAUPUNKTE 2 Relaisarm 1 3 Pleuelstange 1 4 Hülse 2 5 Öldichtung 2 6 Drucklager 2 7 Buchse 2 8 Öldichtung 8 9 Lager 10 Siehe unter AUSBAUPUNKTE IC578000 SMONTAGGIO DEL FORCELLONE OSCILLANTE Ampiezza della rimozione 1 Smontaggio del forcellone oscillant...

Page 476: ...Bush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574211 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Oil seal 3 Damage Replace EC573000 REMOVAL POINTS Cap 1 Remove 9Cap left 1 NOTE Remove with a slotted head screwdriver inserted under the mar...

Page 477: ...Drücken auf den äußeren Laufring ausbauen INSPEKTION Die Lager Buchsen und Hülsen in Lösungsmittel waschen Hinterradschwinge 1 Prüfen 9 Lager 1 9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und Buchse als Satz erneuern 2 Prüfen 9 Öldichtung 3 Beschädigung Erneuern Relaisarm 1 Prüfen 9 Lager 1 9 Hülse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und Hülse als Satz erneuern 2 Prüfe...

Page 478: ...Installed depth of bearings Outer a a Zero mm Zero in Inner b b 6 5 mm 0 26 in EC574311 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Oil seal 3 Damage Replace 2 Install 9Bearing 1 9Plain washer 2 9Oil seal 3 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the b...

Page 479: ...te mit den Herstellermarkierungen oder Herstellungsnummern eingepresst wird 9 Zuerst die äußeren Lager und danach die inneren Lager bis zur vorgeschrie benen Tiefe von innen einbauen Profondità installata dei cuscinetti Esterno a a Zero mm Zero in Interno b b 6 5 mm 0 26 in Einbautiefe der Lager Außen a a Null mm Null in Innen b b 6 5 mm 0 26 in Bielle 1 Examiner 9 Roulement 1 9 Collerette 2 Il y ...

Page 480: ...her 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numbers Installed depth of bearings a a Zero mm Zero in 3 Install 9Collar 1 To connecting rod ...

Page 481: ...er Drucklager auftragen 2 Einbauen 9 Hülse 1 9 Unterlegscheibe 2 Zum Relaisarm 3 HINWEIS Das Molybdän Fett auf den Hülsen und den Öldichtungslippen auftragen Profondeur installée de roulement a a Zéro mm Zéro in 3 Monter 9 Roulement 1 9 Bague d étanchéité 2 Au bielle N B 9Appliquer une graisse de molybdéne sur le roulement lors de la repose 9Installer le roulement en l insérant sur côté où les rep...

Page 482: ...olybdenum disulfide grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To relay arm 5 NOTE Apply the molybdenum disulfide grease on the bolt 80 Nm 8 0 m kg 58 ft lb 7 Check 9Swingarm side play a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsm...

Page 483: ... écrou à ce stade 6 Monter 9 Bras oscillant 1 9 Axe de pivot 2 N B 9Appliquer de la graisse de molybdéne sur l axe de pivot 9Introduire l arbre pivot par le côté droit 5 Einbauen 9 Relaisarm 1 9 Schraube Relaisarm 2 9 Unterlegscheibe 3 9 Mutter Relaisarm 4 Zur Hinterradschwinge HINWEIS 9 Molybdän Fett auf dem Schraubenum fang und auf dem Gewinde auftragen 9 Die Mutter noch nicht festziehen 6 Einba...

Page 484: ...9Plain washer 2 9Nut connecting rod 3 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 53 Nm 5 3 m kg 38 ft lb 12 Install 9Cap 1 NOTE Install the cap right with its mark a facing for ward ...

Page 485: ...ibe 2 9 Mutter Pleuelstange 3 HINWEIS 9 Das Molybdän Fett auf der Schraube auftragen 9 Die Mutter noch nicht festziehen 9 Einbauen 9 Schraube Hinterrad Stoßdämpfer Relaisarm 1 9 Mutter Hinterrad Stoßdämp fer Relaisarm 2 HINWEIS Das Molybdän Fett auf der Schraube auftragen 8 Installare 9 Bullone leva di rinvio 1 9 Rosetta 2 9 Dado leva di rinvio 3 NOTA 9Applicare sul bullone il grasso a base di bis...

Page 486: ...sher 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover 10mm 0 39in 5 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 16 Nm 1 6 m kg 11 ft lb ...

Page 487: ...nner unten 5 14 Einbauen 9 Kettenschutz 1 9 Stützenabdeckung 2 9 Schraube Kettenschutz 50 mm 1 97 in 3 9 Mutter Kettenschutz 4 9 Schraube Stützenabdeckung 10 mm 0 39 in 5 13 Installare 9 Bullone tendicatena inferiore 1 9 Rosetta 2 9 Bordino 3 9 Tendicatena 4 9 Dado tendicatena inferiore 5 14 Installare 9 Supporto della catena 1 9 Copertura del supporto 2 9 Bullone supporto della catena 50 mm 1 97 ...

Page 488: ...itable stand under the engine Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air cleaner joint 1 Loosen the bolt air cleaner joint 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 7 Adjuster 1 8 Spring seat...

Page 489: ... Cadre arrière 1 3 Boulon amortisseur arrière bras de relais 1 Tenir le bras oscillant 4 Boulon amortisseur arrière cadre 1 5 Amortisseur arrière 1 6 Contre écrou 1 7 Dispositif de réglage 1 8 Siège de ressort 2 9 Guide de ressort inférieur 1 10 Guide de ressort supérieur 1 11 Ressort amortisseur arrière 1 12 Roulement 2 Se reporter à POINTS DE DEPOSE Préparation pour la dépose XG Bien soutenir la...

Page 490: ...gas expansion and or damage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scr...

Page 491: ...dom mager toute partie du réservoir à gaz Un réservoir à gaz endom magé affectera la capacité d amortissement ou entraînera un mauvais fonctionnement 4 Prendre garde à ne pas rayer la surface de contact de la tige du piston avec le cylindre l huile pourrait fuir 5 Ne jamais essayer d enlever le plot situé au bas du réservoir à azotè Il est très dangereux d en lever le plot 6 Pour la mise au rebut ...

Page 492: ...ION EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly 9Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down 9Spring guide 4 Wear Damage Replace spring guide 9Spring seat 5 Cracks Damage Replace 9Bearing 6 Free play exists Unsmooth revolution R...

Page 493: ... plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet Fuite de gaz Remplacer l amortisseur complet 9 Ressort 3 Endommagement Changer le ressort Fatigue Changer le ressort Comprimer et détendre le res sort 9 Guide de ressort 4 Usure Endommagement Changer le guide de ressort 9 Siège de ressort 5 Fissuré endommagé Rempla cer 9 Roulement 6 Il y a jeu fonctionnel tour irré gulier rouille C...

Page 494: ... bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contacts the stopper ring 3 Install 9Lower bearing 1 NOTE Install the bearing by pressing it on the side hav ing the manufacture s marks or numbers Installed depth of the bearing ...

Page 495: ... sur côté où les repères ou numérous du fa bricant sont inscrits Ressort amortisseur arrière 1 Monter 9 Ressort 1 9 Guide de ressort supérieur 2 9 Guide de ressort inférieur 3 IC585000 MONTAGGIO E INSTAL LAZIONE IC585320 Cuscinetto 1 Installare 9 Cuscinetto superiore 1 NOTA Installare il cuscinetto parallelo finché premendone l anello esterno non com pare la scanalatura dell anello di fermo iI Non...

Page 496: ...Apply the lithium soap base grease on the O rings 2 Install 9Bush 1 9Collar 2 9Dust seal 3 NOTE 9Apply the molybdenum disulfide grease on the bearing and dust seal lips 9Install the dust seals with their lips facing out ward 4 Adjust 9Spring length installed Refer to REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT sec tion in the CHAPTER 3 5 Tighten 9Locknut 1 3 Tighten 9Adjuster 1 ...

Page 497: ...nts toriques 2 Monter 9 Bague 1 9 Collerette 2 9 Joint antipoussière 3 N B 9Appliquer de la graisse au bisulfure de molybdène sur le roulement et les lèvres des joints antipoussière 9Monter les joints antipoussière avec les lèvres orientées vers l extérieur Hinterrad Stoßdämpfer 1 Einbauen 9 Staubdichtung 1 9 O Ring 2 9 Hülse 3 HINWEIS 9Das Molybdän Fett auf den Staub dichtungen und den Hülsen auf...

Page 498: ...e grease on the bolt 5 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 6 Install 9Rear frame 1 9Bolt rear frame upper 2 9Bolt rear frame lower 3 7 Tighten 9Bolt air cleaner joint 1 56 Nm 5 6 m kg 40 ft lb 53 Nm 5 3 m kg 38 ft lb 29 Nm 2 9 m kg 21 ft lb 32 Nm 3 2 m kg 23 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 499: ...lybdène sur le boulon 6 Monter 9 Cadre arrière 1 9 Boulon cadre arrière supé rieur 2 9 Boulon cadre arrière infé rieur 3 7 Serrer 9 Boulon raccord de filtre à air 1 3 Installare 9 Ammortizzatore posteriore 4 Installare 9 Bullone ammortizzatore poste riore telaio 1 9 Rosetta 2 9 Dado ammortizzatore posterio re telaio 3 NOTA Applicare sul bullone il grasso a base di bisolfuro di molibdeno 5 Installa...

Page 500: ...AL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 ENGINE STOP button 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black O Orange Y Yellow B R Brack Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red ...

Page 501: ...MPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE COMPOSANTS ELECTRIQUES 1 Bouton d arrêt du moteur ENGINE STOP 2 Bloc CDI 3 Bobine d allumage 4 Magnéto CDI 5 Bougie CODE DE COULEUR B Noir O Orange Y Jaune B R Noir Rouge B W Noir Blanc G L Vert Bleu G W Vert Blanc W L Blanc Bleu W R Blanc Rouge SCHEMA DE CABLAGE IC600000 PARTE ELETTRICA IC610000 COMPONENTI ELETTRICI E SCHEMA ELETTRICO IC611000 COMPONENTI ...

Page 502: ...ion system for connection Spark gap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI magneto Replace CDI unit Replace Replace Replace Replace Replace marked Only when the ignition checker is used NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use the following special tools in this ...

Page 503: ...anger Changer Changer O K O K O K O K SYSTEME D ALLUMAGE ETAPES DE VERIFICATION Utiliser les étapes suivantes pour vérifier la possibilité d attribution du mauvais fonctionnement du moteur à une panne du circuit d allumage et pour vérifier la bougie d allumage qui n allume pas Indication Seulement quand le contrôleur d allumage et utilisé N B 9Déposer les pièces suivantes avant de procéder au dépi...

Page 504: ...uern Erneuern Erneuern Erneuern Erneuern In Ordnung In Ordnung In Ordnung In Ordnung ZÜNDANLAGE PRÜFVORGÄNGE Durch folgende Schritte auf eine mögliche Störung des Motors durch einen Defekt im Zündsystem prü fen und Ausfindigmachen einer aussetzenden Zündkerze Markierung Nur wenn das Zündungsprüfgerät verwendet wird HINWEIS 9Die folgenden Teile vor Beginn der Störungsbeseitigung ausbauen 1 Sitz 2 K...

Page 505: ...stituirla OK Sostituirla Controllare la calotta della candela Non funziona OK OK OK OK IC620000 SISTEMA DI ACCENSIONE IC621002 OPERAZIONI DI ISPEZIONE Usare le operazioni che seguono per controllare la possibilità che il malfunzionamento del motore sia attribuibile a un guasto del sistema di accensione e per controllare la candela che non emette scintille contrassegnato Soltanto quando viene usato...

Page 506: ...e and increase spark gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or replace EC625002 ENGINE STOP BUTTON INSPECTION 1 Inspect 9 ENGINE STOP button conduct Not continuous while being pushed Replace Continuous while being freed Replace Minimum spark gap 6 0 mm 0 24 in Te...

Page 507: ... DU MOTEUR ENGINE STOP 1 Examiner 9 Conductibilité du bouton d arrêt du moteur ENGINE STOP Pas de continuité lorsqu enfoncé Changer Continuité lorsque relâché Changer IC622001 TEST DELLA DISTANZA TRA GLI ELETTRODI 1 Scollegare la calotta della candela dalla candela 2 Collegare il tester dinamico delle scintille 1 apparecchio per il controllo dell accensione 2 come illustrato 9 Calotta della candel...

Page 508: ...ove the spark plug cap by turning it coun terclockwise and inspect 9Install the spark plug cap by turning it clock wise until it is tight Tester lead Yellow lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Yellow lead 2 Primary coil Tester selector resistance position 0 24 0 36Ω at Ω 1 20 C 68 F Secondary coil Tester selector resistance position 5 7 8 5kΩ at kΩ 1 20 C 68 F...

Page 509: ...a candela girandolo in senso antiorario e con trollarlo 9Rimontare il cappuccio della candela girandolo in senso orario finché non è bene avvitato Resistenza Posizione del della bobina selettore del primaria tester 0 24 0 36Ω a Ω 1 20 C 68 F Conduttore del tester Conduttore giallo 1 Conduttore del tester Conduttore nero 2 Resistenza Posizione della bobina del selettore secondaria del tester 5 7 8 ...

Page 510: ...tion 248 372Ω at Ω 100 20 C 68 F Tester lead Black Red lead 1 Tester lead Green White lead 2 Source coil 1 Tester selector resistance position 720 1 080Ω at Ω 100 20 C 68 F EC62B000 SPARK PLUG CAP INSPECTION 1 Inspect 9Spark plug cap Loose connection Tighten Deteriorated damaged Replace 9Spark plug cap resistance Out of specification Replace Tester lead Spark plug lead terminal 1 Tester lead Spark...

Page 511: ...ves Kabel des Prüfgerätes Weiß Rotes Kabel 1 Negatives Kabel des Prüfgerätes Weiß Blaues Kabel 2 Widerstand Position des der Wählschalters Aufnahmespule am Prüfgerät 248 372Ω bei Ω 100 20 C 68 F Positives Kabel des Prüfgerätes Schwarz Rotes Kabel 1 Negatives Kabel des Prüfgerätes Grün Weißes Kabel 2 Widerstand Position des der Wählschalters Stromspule 1 am Prüfgerät 720 1 080Ω bei Ω 100 20 C 68 F ...

Page 512: ...Replace EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Green Blue lead 1 Tester lead Black lead 2 Source coil 2 Tester selector resistance position 44 66Ω at Ω 10 20 C 68 F ...

Page 513: ...are 9 Resistenza della bobina sorgen te 2 Fuori specifica Sostituirla IC628000 ISPEZIONE DELL UNITÀ CDI Controllare tutti i componenti elettrici Se non si rileva alcun guasto sostituire l unità CDI Quindi ricontrollare i com ponenti elettrici Resistenza Posizione della bobina del selettore sorgente 2 del tester 44 66Ω a Ω 10 20 C 68 F Conduttore del tester Conduttore Verde Blu 1 1 Conduttore del t...

Page 514: ...st be properly suited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed road surface conditions and for the discoloration of the spark plug s After tak ing these into consideration he must select the best possible carburetor settings It is advisable to make a note of sett...

Page 515: ...e la route et la décoloration de bougie s Prenant ces facteurs en considération il sélectionnera les meilleurs réglages de carburateur possibles Il est recommandé de prendre note des réglages des conditions atmo sphériques de la surface de la route le temps au tour etc afin que ce mémorandum puisse être utilisé ultérieurement comme référence Conditions atmosphériques et régla ge de carburateur Les...

Page 516: ...ity of the air EC713001 Test run After warming up the engine equipped with the standard type carburetor s and spark plug s run two or three laps of the circuit and check the smooth operation of the engine and discoloration of spark plug s å Normal Over burned too lean ç Oil fouled too rich Discoloration Condition of spark plug Normal Insulator is dry and burnt brown Over burned Insulator is whitis...

Page 517: ...ugie s A Normale B Surbrûlé trop pauvre C Encrassée d huile trop riche Cioè 9 Una temperatura più alta fa dilatare l aria ne risulta una densità ridotta 9 Un umidità più elevata riduce la quantità di ossigeno nell aria in misura proporzionale al vapore acqueo contenuto nella stessa aria 9 Una pressione atmosferica più bassa a un altitudine elevata riduce la densità dell aria IC713001 Corsa di prov...

Page 518: ...nging the main jet 1 Except for USA and CDN 1 Spark plug is too hot Select a main jet having higher calibrating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Setting part Throttle valve opening Full closed 1 4 1 2 3 4 Full open Pilot air screw Pilot jet Diameter of straight portion Clip position Throttle valve Main ...

Page 519: ... La ricchezza della miscela aria carbu rante con valvola regolatrice del flusso a 1 2 4 4 può essere registrata cam biando il getto principale 1 Tranne che per USA e CDN 1 La candela è troppo calda Selezionare un getto principale che abbia un No di taratura più alto di quello normale Da arricchire 2 La candela è bagnata Selezionare un getto principale che abbia un No di taratura più basso di quell...

Page 520: ...rew will enrich the mix ture at low speeds and turning out it will lean out the mixture EC71R010 Pilot jet adjustment The richness of air fuel mixture with the throttle fully closed to 1 2 open can be set by turning the pilot jet 1 It is changed when adjustment cannot be made by the pilot air screw alone Standard pilot air 2 1 4 turns out screw position Standard pilot jet 40 45 For EUROPE ...

Page 521: ... mélange air essence avec l accélérateur entre la position de fermeture complète et la mi puissance peut être réglée en tournant le gicleur de ralenti 1 Le réglage est changé lorsqu il ne peut être effectué unique ment au moyen de la vis de richesse Pour EUROPE IC716001 Regolazione della vite dell aria pilota La ricchezza della miscela aria carbu rante con la valvola regolatrice del flus so comple...

Page 522: ...eans of the spark plug and therefore it should be judged from your feeling of actual engine operation 1 Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly In this case step up the jet needle clip by one groove or 0 5 groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will ...

Page 523: ...etriebs beurteilen müssen 1 Zu fett bei mittleren Drehzahlen Rauher Motorbetrieb kann festge stellt werden und der Motor kann nicht glatt beschleunigt werden In diesem Fall ist die Düsennadel klammer um eine Nut oder um eine halbe Nut höher einzustellen und die Düsennadel abzusenken um das Gemisch magerer zu gestalten 2 Zu mager bei mitteleren Dreh zahlen Der Motor wird nur hart bearbei tet und ka...

Page 524: ... 6BFY42 74 to 6BFY44 74 has the same effect as a rising of 1 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 richer c 1 richer 7 6 TUN SETTING Standard jet needle 6BFY42 74 Diameter of straight Rich Lean Clip position portion ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 mm 0 1079 in ø2 75 mm 0 1083 in ø2 76 mm 0 1087 in Rich 1 richer 6BFY44 ...

Page 525: ...positions de clip le changement de 6BFY42 74 à 6BFY44 74 pro duit le même effet qu un relèvement de 1 posi tions de clip A Différence de diamètre de portion droite B Différence de position de rainure a Aiguille de référence b 0 5 plus riche c 1 plus riche Aiguille standard 6BFY42 74 Diamètre de la partie Riche Pauvre Position du circlip droite ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 mm 0 1079 ...

Page 526: ... Position glei ch nummeriert ist hat die Veränderung von 6BFY42 74 zu 6BFY44 74 die gleiche Wir kung wie das Anheben der 1 Clip Position A Unterschied beim Durchmesser des geraden Teils B Unterschied bei der Klemmposition a Bezugsnadel b 0 5 fetter c 1 fetter Standard Düsennadel 6BFY42 74 Durchmesser des gera Fett Mager Klemmposition den Teils ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 mm 0 1079 ...

Page 527: ... è lo stesso passare da 6BFY42 74 a 6BFY44 74 ha lo stesso effetto che alzare di 1 la posizione del fermo A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a graffa a Ago di riferimento b 0 5 più ricca c 1 più ricca Ago a getto normale 6BFY42 74 Posizione Diametro della parte Ricca Povera del fermaglio a araffa diritta ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 ...

Page 528: ...sition changing from 6BFY43 74 to 6BFY44 74 has the same effect as a rising of 0 5 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 richer c 0 5 leaner Standard jet needle 6BFY43 74 Diameter of straight Rich Lean Clip position portion ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 mm 0 1079 in ø2 75 mm 0 1083 in ø2 76 mm 0 1087 in Rich 1 richer...

Page 529: ...de positions de clip le changement de 6BFY43 74 à 6BFY44 74 pro duit le même effet qu un relèvement de 0 5 position de clip A Différence de diamètre de portion droite B Différence de position de rainure a Aiguille de référence b 0 5 plus riche c 0 5 plus pauvre Aiguille standard 6BFY43 74 Diamètre de la partie Riche Pauvre Position du circlip droite ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 mm 0...

Page 530: ...Clip Position gleich nummeriert ist hat die Veränderung von 6BFY43 74 zu 6BFY44 74 die gleiche Wirkung wie das Anheben der 0 5 Clip Posi tion A Unterschied beim Durchmesser des geraden Teils B Unterschied bei der Klemmposition a Bezugsnadel b 0 5 fetter c 0 5 magerer Standard Düsennadel 6BFY43 74 Durchmesser des gera Fett Mager Klemmposition den Teils ø2 72 mm 0 1071 in ø2 73 mm 0 1075 in ø2 74 mm...

Page 531: ...rmo è lo stesso passare da 6BFY43 74 a 6BFY44 74 ha lo stesso effetto che alzare di 0 5 la posi zione del fermo A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a graffa a Ago di riferimento b 0 5 più ricca c 0 5 più povera Ago a getto normale 6BFY43 74 Posizione Diametro della parte Ricca Povera del fermaglio a araffa diritta ø2 72 mm 0 1071 in ø2 73 mm 0 1075 ...

Page 532: ...ottle to the second tapered portion at 1 2 throttle to the third tapered portion at 3 4 throttle and to the fourth tapered portion at full open Therefore the fuel flow is balanced at each stage of throttle opening by a combination of the jet needle diameter and clip position Example For USA and CDN 6BFY42 74 3rd groove 6BFY42 74 2nd groove 6BFY42 75 3rd groove For EUROPE AUS NZ and ZA 6BFY43 74 3r...

Page 533: ... à la 4e par tie conique à l ouverture complète du papillon Par conséquent l arrivée de carburant est équilibrée à chaque niveau de l ouverture du papillon dans une com binaison de diamètre de l aiguille de gicleur et de position de rainure Exemple Pour USA et CDN 6BFY42 74 3e groove 6BFY42 74 2e groove 6BFY42 75 3e groove Pour EUROPE AUS NZ et ZA 6BFY43 74 3e groove 6BFY43 74 2e groove 6BFY43 75 ...

Page 534: ... STD 45 4KM 14142 45 47 5 4KM 14142 47 Rich 50 4KM 14142 50 Throttle Rich valve 3 3 STD 4 0 1C3 14112 40 4 25 1C3 14112 42 Lean Jet needle 4 4 Rich 6BFY44 72 284 14116 K2 6BFY44 73 284 14116 K3 6BFY44 74 284 14116 K4 6BFY44 75 284 14116 K5 Lean 6BFY44 76 284 14116 K6 Rich 6BFY43 72 284 14116 J2 6BFY43 73 284 14116 J3 STD 6BFY43 74 284 14116 J4 6BFY43 75 284 14116 J5 Lean 6BFY43 76 284 14116 J6 Ric...

Page 535: ... 14142 40 No 42 5 4KM 14142 42 STD No 45 4KM 14142 45 No 47 5 4KM 14142 47 Ricca No 50 4KM 14142 50 Valvola Ricca regolatrice del STD 4 0 1C3 14112 40 flusso 4 25 1C3 14112 42 3 3 Povera Ago a Ricca 6BFY44 72 284 14116 K2 getto 4 4 6BFY44 73 284 14116 K3 6BFY44 74 284 14116 K4 6BFY44 75 284 14116 K5 Povera 6BFY44 76 284 14116 K6 Ricca 6BFY43 72 284 14116 J2 6BFY43 73 284 14116 J3 STD 6BFY43 74 284...

Page 536: ...et needle clip position 1 groove up 1 4 3 4 throttle Lower jet needle clip position Hard breathing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Slow speed pick up 1 groove up White smoke Poor acceleration Conditions General condition Sandy condition Under 10 C 15 25 C Over 30 C Under 10 C 15 25 C Over 30 C 50 F 59 77 F 86 F 50 F 59 77 F 86 F Parts Winter Spring Autum...

Page 537: ...e above intermediate speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly Use main jet having lower calibration No Raise jet needle clip position 1 groove up If no effect reverse the above procedures Poor engine operation Turn in pilot air screw Check throttle valve operation This should be taken simply for an example It is necessary ...

Page 538: ... foncée la condition est bonne Si la normalisation est impossible Siège de pointeau bouché Tuyau de carburant bouché Robinet de carburant bouché Décoloration de la bougie Si la couleur est foncée la condition est bonne Si aucum effet Vis du filtre a air Fuite de carburant depuis le carburateur Passage d air principal obstrué ou filtre obstrué La position de fixation indique la position de la rainu...

Page 539: ...les réglages d ensemble Utiliser un gicleur principal avec un n de calibrage inférieur Elever la position de fixation de l aiguille de gicleur 1 rainure plus haut Si l effet est nul inverser les procédures mentionnées ci dessus Visser la vis de richesse Contrôler Nombre de tours de dévissage Corriger correctement Fuite en provenance du carburateur Fein d entraînement Fuite en provenance du carbura...

Page 540: ... nicht normalisiert werden kann Verstopfter Schwimmerventilsitz Verstopfter Kraftstoffschlauch Verstopfter Kraftstoffhahn Verfärbung der Zündkerze Bei hellbrauner Farbe ist sie in gutem Zustand Wenn keine Wirkung Luftfilter verstopft Kraftstoff läuft am Vergaser über Hauptluftdurchgang verstopft oder Filter verstopft Die Klemmenposition gibt die Position der Düsennadelnut an an welcher die Klemme ...

Page 541: ...g die obigen Vorgänge umkehren Gesamteinstellungen überprüfen Hauptdüse mit niedrigerer Kalibrierungs Nr verwenden Düsennadel Klemmenposition erhöhen 1 Nut höher Falls keine Wirkung die obigen Vorgänge umkehren Die Leerlauf Luftregulierschraube hineinschrauben Prüfung Anzahl der Ausdrehungen Richtig korrigieren Überlauf am Vergaser Bremse schleift Überlauf am Vergaser Luftfilter auf Verschmutzung ...

Page 542: ...llo Scolorimento della candela Se color cuoio è in buone condizioni Se non può essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Scolorimento della candela Se color cuoio è in buone condizioni Se non vi è effetto Filtro dell aria otturato Traboccamento di carburante dal carburatore Passaggio principale dell aria o fil...

Page 543: ... generali Usare un getto principale che abbia un No di taratura più basso Alzare la posizione del fermaglio a graffa dell ago a getto su di 1 scanalatura Se non vi è effetto eseguire al contrario le procedure sopra descritte Avvitare la vite dell aria pilota Controllo Numero di giri in senso contrario Correggere adeguatamente Traboccamento dal carburatore Strisciamento dei freni Traboccamento dal ...

Page 544: ...No of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet NOTE 9When checking the discoloration of spark plugs be sure to stop the engine immediately after a run and check 9Avoid racing 9When changing the heat range of spark plugs never attempt to change it more than 1 rank 9When using a spark plug other than standard chec...

Page 545: ...de changer la plage de chaleur des bougies et de sélection ner un autre gicleur principal correct N B 9Lors du contrôle de la décoloration des bougies attention à bien arrêter le moteur immédiatement après un tour et vérifier 9Eviter de faire la course 9En changeant la plage de chaleur des bougies ne jamais essayer de la chan ger de 1 degré 9Dans le cas de l utilisation d une bou gie autre que sta...

Page 546: ...ntire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while mak ing notes of lap times to find the best balance then determine the secondary reduction ratio 9If a course has a long straight portion where a machine can run at maximum speed the mach...

Page 547: ... déterminer le taux de réduction secon daire 9Quand il y a de grandes lignes droites régler la machine de sorte à ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en évitant que la vitesse de rotation du moteur soit excessive N B Chaque motocycliste a sa propre tech nique de conduite et les performances varient aussi d une machine à l autre Eviter donc de copier ...

Page 548: ...tact with the road surface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 STD 13T 9383B 13218 Driven sprocket 2 2 47T 1C3 25447 00 STD 48T 1C3 25448 00 49T 1C3 25449 00 50T 1C3 25450 00 51T 1C3 25451 00 52T 1C3 25452 00 Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi Extent of adjustment 60 80 kPa 0 6 ...

Page 549: ...on des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de réglage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de réglage 60 80 kPa 0 6 0 8 kgf cm2 9 0 12 psi Reifendruck Der Reifendruck soll so gewählt wer den dass er dem Zustand der Streckenoberfläche am Tag des Ren nens entspricht 9 Unter regnerischen schlammigen oder rutschigen Bedingungen sollte der Reifendruck niedriger sein um eine größe...

Page 550: ...inal stroke can be changed by changing the fork oil amount cC Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body Alternatively too large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the con sequ...

Page 551: ...une tendance au dur cissement de la fourche avec comme conséquence une détérioration des performances et des caractéristiques Voilà pourquoi il convient d ajuster la fourche dans la plage spécifiée IC722011 Registrazione della forcella anteriore La registrazione della forcella anteriore dovrebbe essere effettuata in base alla sen sazione che il guidatore ha di una corsa effettiva e alle condizioni...

Page 552: ...tronger and the front fork may sink deeply over a series of gaps To set a soft spring 9Change the rebound damping Turn out one or two clicks 9Change the compression damping Turn in one or two clicks 2 Use of stiff spring Generally a stiff spring gives a stiff riding feeling Rebound damping tends to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handl...

Page 553: ...ändern Um eine oder zwei Klickstel lungen herausdrehen 9 Die Einfederdämpfung ändern Um eine oder zwei Klickstel lungen hereindrehen 2 Verwendung einer harten Feder Normaleweise bewirkt eine harte Feder ein hartes Fahrgefühl Die Ausfederdämpfung wird geringer und ein Gefühl mangelnden Fahrbahnkontaktes kann entste hen ebenso wie Vibrationen im Lenker Zum Einstellen einer harten Feder 9 Die Ausfede...

Page 554: ...Change the spring 2 Setting of damping force 9Change the rebound damping 9Change the compression damping SPRING SPRING I D TYPE RATE PART NUMBER MARK slits SOFT 0 398 1C3 23141 A0 I STD 0 408 1C3 23141 N0 0 418 1C3 23141 C0 III 0 428 1C3 23141 D0 IIII 0 438 1C3 23141 E0 IIIII STIFF 0 449 1C3 23141 F0 I I 0 459 1C3 23141 G0 I II 0 469 1C3 23141 H0 I III 0 479 1C3 23141 J0 I IIII 7 17 TUN SETTING EC...

Page 555: ...1 E0 IIIII HART 0 449 1C3 23141 F0 I I 0 459 1C3 23141 G0 I II 0 469 1C3 23141 H0 I III 0 479 1C3 23141 J0 I IIII IC72P010 Parti di regolazione della forcella anteriore 9Molla della forcella anteriore 1 NOTA La marcatura di identificazione fendi ture a viene provata all estremità della molla IC72B000 Registrazione della sospensione posteriore La registrazione della sospensione posteriore dovrebbe ...

Page 556: ...ve the standard figure from the subtraction of the length b from the length a Standard figure 90 100 mm 3 5 3 9 in NOTE 9If the machine is new and after it is broken in the same set length of the spring may change because of the initial fatigue etc of the spring Therefore be sure to make re evaluation 9If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spri...

Page 557: ...raen do la lunghezza b dalla lunghezza a Valeur standard 90 100 mm 3 5 3 9 in Standardwert 90 100 mm 3 5 3 9 in Cifra normale 90 100 mm 3 5 3 9 in HINWEIS 9 Wenn eine neue Maschine eingefah ren worden ist kann es sein dass die Einstellänge der Feder sich ändert aufgrund von Faktoren wie Ermüdung der Feder etc Es wird darum empfohlen nach dem Einfah ren die Einstellung zu überprüfen 9 Wenn der Stan...

Page 558: ...ing for more rebound damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed more or less by a change in the com pression damping For correction turn the low compression damping adjuster on the softer side cC When using a rear cushion other ...

Page 559: ...orrek tur den niedrigen Einfederdämp fungeinsteller zur weicheren Seite hin stellen IC72G020 Registrazione della molla dopo la sostituzione Dopo la sostituzione assicurarsi di regolare la molla alla lunghezza regi strata lunghezza abbassata 90 100 mm 3 5 3 9 in e registrarla 1 Uso di una molla dolce 9 Registrare la molla dolce per un minore smorzamento dell esten sione per compensarne il minore ca...

Page 560: ... I D marks SPRING SPRING I D SPRING TYPE RATE PART NUMBER MARK FREE Q TY LENGTH SOFT 4 3 5UN 22212 00 Brown 1 260 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 STIFF 5 7 5UN 22212 70 White 1 260 SPRING SPRING I D SPRING TYPE RATE PART NUMBER MARK FREE approx Q TY LENGTH SOFT 4 5 5UN 22212 A0 Green 2 275 4 7 5UN 22212 B0 Red 2 275 4 9 5UN 22212 C0 Black 2 275 5 1 5UN 22212 D0 Blue 2 275...

Page 561: ...n trassegni di marcatura di identifica zione FEDER FEDER TEILE ID Markie Ungespannte TYP KON NUMMER rung Federlänge STANTE Quantität WEICH 4 3 5UN 22212 00 Braun 1 260 5 3 5UN 22212 50 Gelb 1 260 5 5 5UN 22212 60 Rosa 1 260 HART 5 7 5UN 22212 70 Eeiß 1 260 NUMERO Lunghezza TIPO FLESSI CATEGORICO libera BILITÀ DELLA MOLLA della molla DOLCE 4 3 5UN 22212 00 Marrone 1 260 5 3 5UN 22212 50 Gialla 1 26...

Page 562: ...T OF LENGTH ADJUSTMENT b 260mm 10 24in 240 5 258 5mm 9 47 10 18in 275mm 10 83in 255 5 273 5mm 10 06 10 77in SPRING FREE EXTENT OF LENGTH ADJUSTMENT b One I D mark 245 5 263 5 mm 9 67 10 37 in Approx 265mm Two I D marks 10 43 in 251 5 269 5 mm 9 90 10 61 in Three I D marks 243 0 261 0 mm 9 57 10 28 in ...

Page 563: ...0 18 in 275 mm 10 83 in 255 5 273 5 mm 10 06 10 77 in LONGUEUR DE ETENDUE DE RESSORT LIBRE REGLAGE b Une marque d identification 245 5 263 5 mm 9 67 10 37 in Deux marques Approx 265 mm d identification 10 43 in 251 5 269 5 mm 9 90 10 61 in Trois marques d identification 243 0 261 0 mm 9 57 10 28 in UNGESPANNTE EINSTELLUMFANG FEDERLÄNGE b Eine ID Markierung 245 5 263 5 mm 9 67 10 37 in Zwei ID Mark...

Page 564: ...ession damping Turn adjuster clockwise about 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 out Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke 1 Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz end 0 2 US oz Soft toward stroke 1 Oil amount Increase oil amount by about 5 cm3 0 2 Imp oz en...

Page 565: ...and Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression Turn adjuster clockwise about 1 click to in damping crease damping Poor road gripping 1 High compression Turn adjuster clockwise about 1 6 turn to damping increase damping...

Page 566: ...0 2 0 3 US oz Monter un ressort doux Vérifier s il y a coudes coups ou tout autre endommagement visible Si tel est le cas rem placer les parties affectées Remplacer par un nouveau pour une utilisation prolongée Remplacer par un nouveau pour une utilisation prolongée Resserrer au couple spécifié Tourner le dispositif de réglage vers la gauche de 2 déclics pour réduire l amortissement Enduire la bag...

Page 567: ...sement Régler la longueur sur 90 100 mm 3 5 3 9 in avec une personne assise correctement sur la selle Tourner le dispositif de réglage vers la droite de 2 déclics pour augmenter l amortissement Tourner le dispositif de réglage dans le sens horaire env 1 déclic pour augmenter la force d amortissement Monter un ressort dur Tourner le dispositif de réglage vers la gauche de 2 déclics pour réduire l a...

Page 568: ... 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz reduzieren Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtbare Schäden etc prüfen Falls vorhanden betroffene Teile ersetzen Durch ein neues mit verlängerter Lebensdauer austauschen Durch ein neues mit verlängerter Lebensdauer austauschen Auf Soll Anzugsdrehmoment festziehen Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die Däm...

Page 569: ... Dämpfung zu ver ringern Eingetauchte Länge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die Dämpfung zu steigern Einsteller im Uhrzeigersinn drehen etwa 1 Klick stellung um die Dämpfung zu steigern Durch härtere Feder ersetzen Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die Dämpfun...

Page 570: ...ntiorario circa 2 scatti per diminuire lo smor zamento Diminuire la quantità d olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Sostituirla con una molla dolce Controllare eventuali curvature ammaccature e altri segni rilevabili ecc Nel caso sostituire le parti interessate Sostituire con uno nuovo per uso prolungato Sostituire con uno nuovo per uso prolungato Riserrarla alla coppia specificata ...

Page 571: ...ire lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aumentare lo smorzamento Ruotare il dispositivo di regolazione in senso ora rio 1 scatto circa per aumentare lo smorzamen to Sostituirla con una molla rigida Ruotare il dispositivo di regolazione in senso...

Page 572: ...TUN MEMO ...

Page 573: ...TUN MEMO ...

Page 574: ...TUN MEMO ...

Page 575: ...by Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 1C3 9 32 hyoshi 4 28 06 2 45 PM Page 2 ...

Page 576: ... FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 W W1 1C3 28199 32 PRINTED IN JAPAN 2006 5 1 6 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER YZ125 W W1 1C3 9 32 hyoshi 4 28 06 2 45 PM Page 1 ...

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