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Yamaha YZ125(R)/LC, Owner'S Service Manual


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5-13

CHAS

FRONT BRAKE AND REAR BRAKE 

Extent of removal

Order

Part name

Q’ty

Remarks

MASTER CYLINDER DISASSEMBLY

1

Master cylinder cap

1

2

Diaphragm

1

3

Master cylinder boot

1

4

Circlip

1

Use a long nose circlip pliers.

5

Plain washer

1

6

Push rod

1

7

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

2 Nm (0.2 m•kg, 1.4 ft•lb)

2 Nm (0.2 m•kg, 1.4 ft•lb)

å

∫

Summary of Contents for YZ125(R)/LC

Page 1: ...OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SEVIZIO DEL PROPRIETARIO YZ125 R LC 5UN 28199 30...

Page 2: ...RVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition May 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Print...

Page 3: ...maha Motor Co Ltd 1 Ausgabe Mai 2002 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet G...

Page 4: ...please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yama ha dealer w PLEASE READ T...

Page 5: ...pos de ce manuel ou de votre machine pri re de prendre contact avec votre conces sionnaire Yamaha N B Comme des am liorations sont faites sur ce mod le quelques donn es conte nues dans ce manuel peuve...

Page 6: ...ACHINE 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...

Page 7: ...UR 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 homologu avec des lunettes ou un prot g...

Page 8: ...UATE 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 colorle...

Page 9: ...rner pendant un quelconque laps de temps dans un endroit clos Les fum es d chappement sont toxiques Ces fum es contiennent du monoxyde de carbone incolore et inodore Le monoxyde de carbone est un gaz...

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 ther...

Page 11: ...PER IL NUOVO PROPRIETARIO Questo manuale fornir una buona comprensione di base delle caratteristi che del funzionamento e delle opera zioni fondamentali di manutenzione e di ispezione di questo veicol...

Page 12: ...t 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...

Page 13: ...re suivies pour viter d endommager la machine N B Une N B fournit les renseignements n cessaires pour rendre les proc dures plus faciles ou plus claires TROUVER LA PAGE RECHERCHEE 1 Ce manuel comprend...

Page 14: ...W2 0Y O2 M O M O2 0Y O 0Y O M W2 0Y W2 Y W2 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 0...

Page 15: ...ces op rations 1 Exemple de vue en clat 1 clari fiant les op rations de d montage et de remontage 2 Sur les vues en clat les pi ces sont num rot es 2 dans l ordre des op rations effectuer Un chiffre...

Page 16: ...nt w Tightening e Specified value Service limit r Resistance Voltage V Electric current A Illustrated symbols t to o in the exploded dia grams indicate grade of lubricant and location of lubrication p...

Page 17: ...age e Valeur sp cifi e limite de service r R sistance tension V intensit A Les symboles graphiques t o dans les vues clat es indiquent le grade de lubrifiant et l emplacement des points de lubrificati...

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

Page 19: ...EIN ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHINSCHE DATEN REGELM SSIGE PR FUNG UND EINSTELLUNGEN MOTORE MOTEUR MOTOR TELAIO PARTIE CYCLE FAHRGESTELL PARTE ELETTRICA PARTIE ELECTR...

Page 20: ...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 1...

Page 21: ...CH L 1 12 STARTEN UND EINFAHREN 1 13 ANZUGSMOMENTE PR FPUNKTE 1 16 REINIGEN UND LAGERUNG 1 17 KAPITEL 2 TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN 2 1 WARTUNGSDATEN 2 3 ALLGEMEINE ANZUGSDATEN 2 12 D...

Page 22: ...RY DRIVEN GEAR 4 30 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 38 YPVS GOVERNOR 4 46 WATER PUMP 4 49 CDI MAGNETO 4 53 ENGINE REMOVAL 4 57 CRANKCASE AND CRANKSHAFT 4 62 TRANSMISSION SHIFT CAM AND S...

Page 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 38 REGULATEUR YPVS 4 46 POMPE A EAU 4 49 MAGNETO CDI 4 53 DEPOSE DU MOTEUR 4 57 CARTER ET VILEBREQUIN 4 62 BOITE A VITESSES BARILLET DE SELECTEUR ET FOUR...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 14...

Page 25: ...FAHRGESTELL 7 14 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 14 CAPITOLO 6 PARTE ELETTRICA C...

Page 26: ...k 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 kn...

Page 27: ...le niveau d huile de transmission w P dale de frein arri re e Joint de robinet r Robinet essence t Filtre air y Cha ne de transmission u P dale de s lecteur i Bouton de starter o Fourche avant N B 9L...

Page 28: ...tify 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...

Page 29: ...m ros pour retrouver et identifier votre machine NUMERO D IDENTIFICATION DU VEHICULE Pour USA CDN AUS NZ et E Le num ro d identification du v hicule 1 est frapp du c t droit du tube de t te de fourche...

Page 30: ...the bottom 9Water pump housing hole at the bottom 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears...

Page 31: ...tura dell alloggiamento della pompa dell acqua dal lato inferiore 2 Usare utensili e apparecchiature di pulitura adeguati Consultare la sezione UTENSILI SPECIALI 4 Lors du d montage de la machine nett...

Page 32: ...lt 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...

Page 33: ...2 so einbauen da das Zeichen des Herstellers oder die Herstellungs nummer nach au en gerichtet ist die eingeschlagenen Buchsta ben m ssen sichtbar sein Wenn ldichtungen eingebaut werden sind die ldich...

Page 34: ...ould 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 position...

Page 35: ...rclips doivent tre soigneusement v ri fi s Toujours changer les circlips d axe de piston apr s une utilisa tion Changer tout circlip d form Lorsqu on monte un circlip 1 s assurer que le c t non chanfr...

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 conti...

Page 37: ...ms unbedingt die Schritte 1 bis 7 befol gen 9 Handels bliches Kontaktspray nur als Notl sung verwenden 9 Das Taschen Multimeter wie abge bildet am Steckverbinder ansch lie en 6 Connecter 9 Connecteur...

Page 38: ...haft from either case YM 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 u...

Page 39: ...890 01442 Fork seal driver YM 01442 90890 01442 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 resi...

Page 40: ...une ou l autre de ses moiti s YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose du volant magn tique YM 1189 90890 01189 YU 1235 90890 01235 Outil...

Page 41: ...sistance de bobine la tension de sortie et l intensit YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Outil de poign e d brrayage Cet outil est utilis pour...

Page 42: ...890 01189 Schwungrad Abziehwerkzeug Dieses Werkzeug wird f r den Ausbau des Schwung rad Magnetz nders ben tigt YM 1189 90890 01189 YU 1235 90890 01235 Rotor Haltewerkzeug Dieses Werkzeug wird f r das...

Page 43: ...ie derstandes der Ausgangsspannung und der Strom st rke zu verwenden YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Kupplung Haiterwerkzeug Dieses Werkzeug...

Page 44: ...0 01135 YM 1189 90890 01189 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...

Page 45: ...lla bobina la tensione in uscita e l intensit di corrente YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Utensile per tenere la frizione Questo utensile vi...

Page 46: ...AL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick...

Page 47: ...en G nge erfolgt mittels Fu schalt hebel 1 angebrancht an der linken Seite des Motors KICKSTARTER Den Kickstarter 1 vom Motor weg schwenken Den Kickstarter langsam niedertreten bis die Zahnr der einra...

Page 48: ...ltering 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 i...

Page 49: ...ieller Starter kreislauf der ber den Starterknof 1 kontrolliert wird liefert dieses Gemisch Den Starterknopf herauszie hen um den Kreislauf zum Anwerfen des Motors zu ffnen Wenn der Motor warmgelaufen...

Page 50: ...15R001 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 starti...

Page 51: ...chlauch eingebaut dD Bei diesem Einbau ist darauf zu achten da der Pfeil auf den Kraft stofftank und nach unten weist IC15R001 CAVALLETTO STACCABILE Questo cavalletto 1 viene usato per supportare solt...

Page 52: ...e 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 prio...

Page 53: ...con la benzina nel rap porto specificato pi sotto Usare sem pre benzina fresca di marca e miscela re l olio e la benzina il giorno della gara Non usare una miscela gi prepa rata che abbia pi di qualc...

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 ab...

Page 55: ...ftig durchtreten um den Motor zu starten 4 Den Motor bei Leerlaufter Dreh zahl warmlaufen lassen f r das Warmlaufen werden normaler weise etwa eine bis zwie Minuten ben tigt 5 Der Motor ist warmgelau...

Page 56: ...eck 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...

Page 57: ...et v ri fiez la r ponse pleine acc l ra tion Arr tez vous et rev rifiez la bougie 6 A nouveau laissez le moteur se refroidir Red marrez et pilotez pendant cinq nouvelles minutes Cette fois vous pouvez...

Page 58: ...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 PIST...

Page 59: ...enn eines der folgenden Teile erneuert wurde dann mu die Maschine wiederum eingefahren werden ZYLINDER UND KURBELWELLE Etwa eine Stunde Einfahrzeit ist erforderlich KOLBEN KOLBENRING UND ZAHNR DER Die...

Page 60: ...to frame Link to shock absorber 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 T...

Page 61: ...l amortisseur De la timonerie au bras oscillant Arri re Installation de De l amortisseur au cadre l amortisseur Arri re Installation du bras oscillant Serrage de l arbre de pivot Roue Installation de...

Page 62: ...st nge am Sto d mpfer Gest nge an Hinterradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradshcwinge Rad Einbau des Rades Vorne F...

Page 63: ...ttino forcellone oscillante Posteriore Installazione Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione dell...

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...

Page 65: ...on reuses ont r sult de l emploi abusif des vapori sateurs de d tergent haute pression tels que ceux qui quipent les laveries automatiques de voitures 4 Apr s avoir chass la majeure par tie de la boue...

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...

Page 67: ...nnez plusieurs coups de p dale pour enduire le cylindre d huile 3 D posez la cha ne nettoyez la soi gneusement au dissolvant et lubri fiez Remontez la cha ne ou ran gez la dans un sachet plastique fer...

Page 68: ...stroke 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 7 11 0 1 Starting system Ki...

Page 69: ...hassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 25 6 25 4 Trail 108 mm 4 25 in 104 mm 4 09 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Tire press...

Page 70: ...3 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...

Page 71: ...UNI I D mark 5UN1 00 5UN2 10 Main jet M J 410 Jet needle clip position J N 6CHY6 82 3 6CHY6 82 4 Cutaway C A 4 0 Pilot jet P J 40 Pilot air screw P A S 2 1 1 2 Valve seat size V S 3 8 mm 0 15 in Start...

Page 72: ...1 0 1 0 7 Air filter element M 6 1 0 1 2 0 2 1 4 Carburetor joint M 6 1 0 4 10 1 0 7 2 Air filter case M 6 1 0 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 1 0 1 0 7 Read valve M 3 0 5 6 1 0 1 0 7 Cra...

Page 73: ...Q ty Tightening torque Nm m kg ft lb Exhaust pipe M 6 1 0 2 12 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 front M 6 1 0 1 12 1 2 8 7 Sil...

Page 74: ...er tube with inner tube 3 15 5 91 in and damper rod fully compressed without spring Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end 5 mm 0 20 in Rear suspension...

Page 75: ...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...

Page 76: ...0 7 2 Front fork and hose cover M 8 1 25 1 16 1 6 11 Front fork and hose cover M 6 1 0 1 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 Br...

Page 77: ...ng rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 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 u...

Page 78: ...eto model stator Manufacturer 4SS 01 YAMAHA Source coil 1 resistance color 720 1 080 at 20 C 68 F Green White Black Red Source coil 2 resistance color 44 66 at 20 C 68 F Black Green Blue Pickup coil r...

Page 79: ...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...

Page 80: ...teur Type de moteur 2 temps essence refroidissement liquide Dispositions de cylindres Monocylindre inclin Cylindr e 124 cm3 4 36 lmp oz 4 19 US oz Al sage course 54 54 5 mm 2 126 2 146 in Taux de comp...

Page 81: ...NZ EUROPE CDN Type de cadre Simple berceau d d double Angle de chasse 25 6 25 4 Chasse 108 mm 4 25 in 104 mm 4 09 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Taille de pn...

Page 82: ...B 1 0 mm 0 039 in T 2 35 mm 0 093 in Ecartement des becs mont 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Jeu lat ral mont 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Vilebrequin Largeur du 55 90 5...

Page 83: ...S MIKUNI Marque d identification 5UN1 00 5UN2 10 Gicleur principal M J 410 Aiguille J N 6CHY6 82 3 6CHY6 82 4 Echancrure C A 4 0 Gicleur de ralenti P J 40 Vis d air de ralenti P A S 2 1 1 2 Taille de...

Page 84: ...1 2 0 2 1 4 Raccord de carburateur M 6 1 0 4 10 1 0 7 2 Carter de filtre air M 6 1 0 4 8 0 8 5 8 Bride de guidage de filtre air M 5 0 8 1 1 0 1 0 7 Clapets d admission M 3 0 5 6 1 0 1 0 7 Carter M 6...

Page 85: ...ge Nm m kg ft lb Tuyau d chappement M 6 1 0 2 12 1 2 8 7 Support de tuyau d chappement avant M 6 1 0 1 12 1 2 8 7 Support de tuyau d chappement arri re M 6 1 0 1 12 1 2 8 7 Silencieux avant M 6 1 0 1...

Page 86: ...au 3 15 5 91 in int rieur et la tige d amortisseur compl tement appuy sans le ressort Grade d huile Huile de suspension 01 Diam tre ext rieur de tube interne 46 mm 1 81 in Extr mite sup rieure de four...

Page 87: ...in Epaisseur de plaquette 4 4 mm 0 17 in 1 0 mm 0 04 in Dia int rieur de ma tre cylindre 11 0 mm 0 433 in Dia int rieur de cylindre d etrier 27 0 mm 1 063 in 2 Type de liquide de frein DOT 4 Frein di...

Page 88: ...de frein boulon M 6 1 0 1 6 0 6 4 3 crou M 6 1 0 1 6 0 6 4 3 Contre crou du r glage de position de levier de frein M 6 1 0 1 5 0 5 3 6 Levier d embrayage boulon M 6 1 0 1 2 0 2 1 4 Support de levier...

Page 89: ...e M14 1 5 1 80 8 0 58 Amortisseur arri re et cadre M10 1 25 1 56 5 6 40 Amortisseur arri re et bras de relais M10 1 25 1 53 5 3 38 Cadre arri re et cadre sup rieur M 8 1 25 1 32 3 2 23 Cadre arri re e...

Page 90: ...tator Fabricant 4SS 01 YAMAHA R sistance de bobinage de source 1 720 1 080 20 C 68 F couleur vert blanc noir rouge R sistance de bobinage de source 2 44 66 20 C 68 F couleur noir vert bleu R sistance...

Page 91: ...etages propres et secs Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filetage DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE SPECIFICATIO...

Page 92: ...gek hlter Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorne geneigt Hubraum 124 cm3 4 36 lmp oz 4 19 US oz Bohrung Hub 54 54 5 mm 2 126 2 146 in Verdichtungsverh ltnis 8 7 11 0 1 Anla system Kick...

Page 93: ...23 1 087 Fahrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 25 6 25 4 Nachlaufbertrag 108 mm 4 25 in 104 mm 4 09 in Reifengr e Bauart Mit Schlauch Reifengr e Vorne 80...

Page 94: ...39 in T 2 35 mm 0 093 in Ringenspalt 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...

Page 95: ...Identifikationsmarkierung 5UN1 00 5UN2 10 Hauptd se M J 410 D sennadel Klemmposition J N 6CHY6 82 3 6CHY6 82 4 Abschr gung C A 4 0 Leerlaufd se P J 40 Leerlauf Luftregulierschraube P A S 2 1 1 2 Vert...

Page 96: ...7 Luftfilterelement M 6 1 0 1 2 0 2 1 4 Vergaserverbindung M 6 1 0 4 10 1 0 7 2 Luftfiltergeh use M 6 1 0 4 8 0 8 5 8 Luftfilter F hrungsschelle M 5 0 8 1 1 0 1 0 7 Zungenventil M 3 0 5 6 1 0 1 0 7 K...

Page 97: ...nt Nm m kg ft lb Auspuffrohr M 6 1 0 2 12 1 2 8 7 Auspuffrohrst tze Vorne M 6 1 0 1 12 1 2 8 7 Auspuffrohrst tze Hinten M 6 1 0 1 12 1 2 8 7 Schalld mpfer Vorne M 6 1 0 1 12 1 2 8 7 Schalld mpfer Hint...

Page 98: ...der D mpfungsstange ohne Feder voll zusammengedr ckt lsorte Teleskopgabel l 01 Au endurchmesser des inneren Rohres 46 mm 1 81 in Oberes Ende der 5 mm 0 20 in Vorderradgabelbeinrohre Hinterradaufh ngun...

Page 99: ...12 in 9 84 0 10 in Bremsbelagst rke 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 Bremsfl ssigkeit DOT 4 H...

Page 100: ...be M 6 1 0 1 6 0 6 4 3 Mutter M 6 1 0 1 6 0 6 4 3 Bremshebelpositions Sicherungsmutter M 6 1 0 1 5 0 5 3 6 Kupplungshebel Schraube M 6 1 0 1 2 0 2 1 4 Kupplungshebelhalter M 5 0 8 2 4 0 4 2 9 Vorderra...

Page 101: ...interradschwinge M14 1 5 1 80 8 0 58 Relaisarm und Pleuelstange M14 1 5 1 80 8 0 58 Pleuelstange und Rahmen M14 1 5 1 80 8 0 58 Hinterrad Sto d mpfer und Rahmen M10 1 25 1 56 5 6 40 Hinterrad Sto d mp...

Page 102: ...Stator Hersteller 4SS 01 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 bei 20 C 68 F Gr n Wei Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 bei 20 C 68 F Schwarz Gr n Blau Widerstand der Au...

Page 103: ...f r trockene und saubere Gewinde Die anzuzie henden Bauteile sollten dabei Raumtemperatur aufweisen A Schl sselweite B Gewindedurchmesserer DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A...

Page 104: ...mpi raffreddato 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 compr...

Page 105: ...olo di incidenza 25 6 25 4 Avancorsa 108 mm 4 25 in 104 mm 4 09 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 100 90 19 57M Pressione degli pneumatici a...

Page 106: ...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...

Page 107: ...I Marchio ID 5UN1 00 5UN2 10 Getto principale M J No 410 Posizione della staffa dell ago di getto J N 6CHY6 82 3 6CHY6 82 4 Sezione C A 4 0 Getto pilota P J No 40 Vite dell aria pilota P A S 2 1 1 2 D...

Page 108: ...0 1 2 0 2 1 4 Giunto del carburatore M 6 1 0 4 10 1 0 7 2 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 1 0 1 0 7 Valvola a lamella M 3 0 5 6 1 0 1 0 7 C...

Page 109: ...tura Nm m kg ft lb Tubo di scarico 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 anteriore...

Page 110: ...il tubo interno e la barra dello smorzatore completamente compressi senza molla Qualit di olio Olio per sospensioni 01 Diametro esterno del tubo interno 46 mm 1 81 in Estremit superiore della forcell...

Page 111: ...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...

Page 112: ...i posizione della leva di comando del freno M 6 1 0 1 5 0 5 3 6 Leva di comando della frizione vite M 6 1 0 1 2 0 2 1 4 Supporto della leva di comando della frizione M 5 0 8 2 4 0 4 2 9 Coperchio del...

Page 113: ...teriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio superiore M 8 1 25 1 32 3 2 23 Telaio posteriore e telaio inferiore M 8 1 25 2 29 2 9 21 Forcellone oscillante e supporto de...

Page 114: ...ostruttore del magnete 4SS 01 YAMAHA Resistenza 1 della bobina di origine 720 1 080 20 C 68 F colore Verde Bianco Nero Rosso Resistenza 2 della bobina di origine 44 66 20 C 68 F colore Nero Verde Blu...

Page 115: ...nti dovrebbero essere a temperatura am biente A Distanza fra le parti piatte B Diametro esterno della filettatura IC230000 DEFINIZIONE DELLE UNIT IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA SPEC...

Page 116: ...reharness to the main pipe With the clamp ends downward tighten the throttle cable to the extent that it moves smoothly E Clamp the ENGINE STOP button lead where there is no protector wireharness and...

Page 117: ...c ble d acc l rateur de mani re ce qu il se d place ais ment Fixez le fil du bouton ENGINE STOP le faisceau de fils et le c bled acc l ra teur ensemble sur le tube principal avec les extr mit s de la...

Page 118: ...eck with the brake hose holder bottom N Pass the brake hose in front of the axle boss then fit it into the hose groove so that the brake hose does not contact the nut wheel axle O Fit the brake hose i...

Page 119: ...du tuyau de frein Faire passer le tuyau de frein l avant du bossage d essieu puis l ins rer dans la cannelure de sorte qu il ne touche pas l crou exe de roue Faire rentrer le tuyau de frein dans le g...

Page 120: ...pper part of the frame gusset at its protecting tube E Pass the ground lead between the ignition coil and bracket and fasten it together with the ignition coil Make sure that the ground lead does not...

Page 121: ...la bobine d allumage et le support et fixez le avec la bobine d allumage Assurez vous que le fil de masse n est pas en contact avec la bobine d allumage ni avec le support Faites passer le tuyau renif...

Page 122: ...ec tion on the caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion...

Page 123: ...n contact avec la saillie de l trier Faites ensuite passer le tuyau de frein dans les supports du tuyau de frein Si le tuyau de frein touche le ressort amortisseur arri re ajuster le coude Installer l...

Page 124: ...lutch holder C Pass the clutch cable in front of the throttle cable D Clamp the ENGINE STOP button lead to the handlebar to 3 clicks E Pass the brake hose in front of the number plate and through the...

Page 125: ...comme indipu et touche l g rement la saillie sur le ma trecylindre Faire passer le fil de bouton d arr t du moteur ENGINE STOP au centre du support d embrayage Faire passer le c ble d embrayage devan...

Page 126: ...end 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 Yama...

Page 127: ...ONT FORKS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease REAR SHOCK ABSORBER After Inspect and adjust rain ride...

Page 128: ...3 3 INSP ADJ MEMO...

Page 129: ...r 6 Changer 6 CULASSE Contr ler et nettoyer 6 6 Resserrer 6 6 CYLINDRE Cont ler et nettoyer 6 6 Changer 6 YPVS Contr ler et nettoyer 6 6 EMBRAYAGE Contr ler et r gler 6 6 Changer 6 BOITE DE VITESSE Ch...

Page 130: ...6 6 Graisser les pivots 6 6 Contr ler la surface du frein disque 6 6 Contr ler le niveau de fluide et les fuites 6 6 Resserrer les boulons du frein disque les boulons d tier les boulons du ma tre cyl...

Page 131: ...le roulement 6 PNEU ROUES Contr ler 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 d tendu Resserrer les boulons de la roue 6 6 dent e Contr ler les...

Page 132: ...6 Erneuern 6 ZYLINDERKOPF Pr fen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Pr fen und reinigen 6 6 Erneuern 6 YPVS Pr fen und reinigen 6 6 KUPPLUNG Pr fen und einstellen 6 6 Erneuern 6 GETRIEBE l wech...

Page 133: ...RAFT STOFFHAHN Reinigen und pr fen 6 6 BREMSEN Bremshebelposition und Bremspedalh he einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfl che pr fen 6 6 Fl ssigkeitsstand pr fen und auf Undichtigke...

Page 134: ...ch Rennen Rennen R DER REIFEN Reifendruck Felgenschlag Reifenverschlei und Speichen 6 6 auf Lockerung pr fen Ketternrad Befestigungsschraube 6 6 nachziehen Lager pr fen 6 Lager erneuern 6 Schmieren 6...

Page 135: ...litura 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 D...

Page 136: ...RI 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 AMMORTIZZATORE POSTERIORE Ispezione...

Page 137: ...per motori SAE 10W 30 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 rocche...

Page 138: ...ar 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 excess...

Page 139: ...ne Contr ler la tension et l alignement de la cha ne S as surer que la cha ne est graiss e correctement P3 24 26 Roues Contr ler s il n y a pas d usure excessive Contr ler s il n y a pas de rayons d t...

Page 140: ...usrichtung pr fen Auch sicherstellen da die Kette richtig geschmiert P3 24 26 ist R der Die Reifen auf berm ige Abnutzung kontrollieren Speichern auf Lockerung und berm iges Spiel pr P3 34 35 fen Lenk...

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 Controll...

Page 142: ...p 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 an...

Page 143: ...diateur et tourner lentement le bouchon gauche jusqu au point de d tente Cette proc dure permet de faire tom ber toute pression r siduelle Quand le sifflement s est arr t appuyer sur le bouchon tout e...

Page 144: ...in 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 Reco...

Page 145: ...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 radiato...

Page 146: ...el 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 cool...

Page 147: ...it Wasser und danach mit Seife weg oder auswaschen 9Falls K hlmittel eingenom men wird Die betroffene Person sofort zum Erbre chen bringen und zum n ch sten Doktor begleiten Notes concernant la manipu...

Page 148: ...essure Impossible to maintain the specified 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 speci...

Page 149: ...ppliquer de l eau sur le joint du bou chon du radiateur 3 Bouchon du radiateur 2 Appliquer la pression sp cifi e 3 Examiner 9 Pression Impossible de maintenir la pres sion sp cifi e pendant 10 seconde...

Page 150: ...adiator hose 3 Swelling Replace 2 Adjust 9Clutch lever free play EC359020 CLUTCH ADJUSTMENT 1 Check 9Clutch lever free play a Out of specification Adjust NOTE 9Make minute adjustment on the lever side...

Page 151: ...NOTA 9Non applicare pressione superiore alla pressione specificata 9Il radiatore dovrebbe essere completa mente pieno 4 Ispezionare 9 Pressione Impossibile mantenere la pres sione specificata per 10...

Page 152: ...ase On the throttle cable end a tube guide ca ble winding portion b and roller sliding surface c Throttle grip free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until the specified...

Page 153: ...0 20 in Spiel am Gasdrehgriff a a 3 5 mm 0 12 0 20 in Einstellschritte des spiels des Gasseiles 9 Die Sicherungsmutter 1 l sen 9 Den Einsteller 2 drehen bis das Spiel innerhalb des vorgeschrie benen B...

Page 154: ...ine 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 elem...

Page 155: ...ten w rden n mlich Staub und Schmutz in den Motor eindringen und schnellen Verschlei sowie m glichen Motorschaden verursa chen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelemen...

Page 156: ...le 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 filte...

Page 157: ...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...

Page 158: ...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...

Page 159: ...oteur le laisser chauffer quelques minutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en pla ant le support convenable sous le moteur 3 Placer un...

Page 160: ...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...

Page 161: ...niumscheibe 9 labla schraube 1 Emphohlenes l Yamalube 4 10W 30 oder Motor l SAE 10W 30 SE l Fassungsverm gen Regelm iger lwech sel 0 65 L 0 57 Imp qt 0 69 US qt 4 Togliere 9 Bullone di scarico dell ol...

Page 162: ...lace NOTE Install the 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 Adjustment steps 9Loosen t...

Page 163: ...alld mpfer 1 9 Schalld mpfer 2 9 Schraube Fasereinsatz 3 IC35R050 SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE 1 Togliere 9 Copertura laterale destra 9 Bullone silenziatore 1 9 Silenziatore 2 9 Bullone f...

Page 164: ...r 4 9Side cover right 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 11 Nm 1 1 m kg 8 0 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bo...

Page 165: ...m 1 2 m kg 8 7 ft lb 11 Nm 1 1 m kg 8 0 ft lb 12 Nm 1 2 m kg 8 7 ft lb 11 Nm 1 1 m kg 8 0 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reu...

Page 166: ...rake 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...

Page 167: ...iedrigem Bremsfl ssig keitsstand 9 Bei fehlerhafter Funktion der Bremsanlage Falls die Bremsanlage nicht richtig entl ftet wird kann es zu einer gef hrlichen Abnahme des Brems verm gens kommen 1 Ausba...

Page 168: ...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 Standar...

Page 169: ...o pu 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...

Page 170: ...Adjust 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 9...

Page 171: ...is die Pedalh he a innerhalb der vorgeschriebenen H he liegt 9 Die Sicherungsmutter festziehen W 9 Pedalh he gem ss Abbildung zwischen Maximum A A und Mini mum B B einstelle bei dieser Ein stellung so...

Page 172: ...er piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 8 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9T...

Page 173: ...keit nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 8 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbel ge mit deren ber st nden a in die Bremsschuh aussparungen b an...

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 w Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb B...

Page 175: ...mando del freno Sensazione di morbidezza o spugnosit Spurgare impianto frenante Consultare la sezione SPURGO DELL ARIA DALL IMPIANTO FRENANTE IC366060 ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FREN...

Page 176: ...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...

Page 177: ...r le tuyau transparent 8 la vis de purge 9 et placer le r cipient appropri sous son extr mit 9Desserrer la vis de purge et y enfoncer le piston d trier fF Ne pas r utiliser le liquide de frein purg 9S...

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 Front Rear w 9Use only designated quality brake fluid to avoid poor brake per...

Page 179: ...LO DEL 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 livell...

Page 180: ...SPECTION 1 Remove 9Master link clip 9Joint 1 9Drive chain 2 2 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 3...

Page 181: ...9 Kettenschlo klemme 9 Verbindung 1 9 Antriebskette 2 IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei rocchetti a Usura eccessiva Sostituirli NOTA Sostituire il rocchetto conduttore quel l...

Page 182: ...adjusting rotate the rear wheel through several revolutions 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 D...

Page 183: ...3 dD Unbedingt die Kettenschlo klemme in der gezeigten Richtung einbau en a Drehrichtung 6 Schmieren 9 Antriebskette 5 Installare 9 Catena di trasmissione 1 9 Giunto 2 9 Graffa dell anello principale...

Page 184: ...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...

Page 185: ...aher inner halb des spezifizierten Berei ches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sicherungsmuttern festziehen 3 R gler 9 Fl che de cha ne de t...

Page 186: ...se 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...

Page 187: ...eau de fourche interne et le cache poussi re 2 Nettoyer 9 Joint antipoussi re a 9 Bague d tanch it b N B 9Nettoyer le joint antipoussi re et la bague d tanch it apr s chaque cour se 9Appliquer la grai...

Page 188: ...ORCE ADJUSTMENT 1 Remove 9Rubber cap 2 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 c...

Page 189: ...enso normale Pi 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...

Page 190: ...lways adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install 9Rubber cap EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smoot...

Page 191: ...e de l endommager XG Toujours r gler la m me position sur chaque bras de fourche avant Un r glage in gal peut entra ner une mauvaise maniabilit et une perte de stablilit 3 Monter 9 Capuchon en caoutch...

Page 192: ...stment 9The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster cC Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten 9Locknut 6 Install 9Rea...

Page 193: ...ESSORT DE L AMORTISSEUR ARRIERE 1 Sur lever la roue arri re en pla ant la cale appropri e sons le moteur 2 D poser 9 Cadre arri re 3 Desserrer 9 Contre crou 1 4 R gler 9 Pr contrainte de ressort En to...

Page 194: ...ion Which align the punch mark a on the ad juster with the punch mark b on the bracket For EUROPE cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be dam...

Page 195: ...rebond En tournant le dispositif de r glage 1 EINSTELLUNG DER EXPANSIONS D MPFUNGSKRAFT DES HINTER RAD STOSSD MPFERS 1 Einstellen 9 Expansions D mpfungskraft Durch Drehen des Einstellers 1 IC36N020 RE...

Page 196: ...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 mini mum or maximum extent of adjustment The adjuster may...

Page 197: ...SD MPFERS 1 Einstellen 9 Niedrige Kompressions D mp fungskraft Den Einsteller 1 drehen IC36c000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9...

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 mini mum or maximum extent of adjustment The adjuster may be damage...

Page 199: ...essions D mp fungskraft Den Einsteller 1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compressi...

Page 200: ...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 9S...

Page 201: ...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 Corr...

Page 202: ...sembly back and forth Free play Adjust 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...

Page 203: ...sta di sterzo 3 Controllare 9 Azione senza problemi dello sterzo Girare il manubrio da blocco a blocco Azione con problemi Regola re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellsch...

Page 204: ...number plate 9 NOTE 9The upper handlebar holder should be installed with the punched mark a forward 9Insert the end of fuel breather hose 0 into the hole of the number plate cC First tighten the bolts...

Page 205: ...i sul lato posteriore 9Desserrer l crou annulaire d un tour 9Resserrer l crou annulaire l aide de la cl pour crou annu laire XG Prendre garde de ne pas serrer excessivement 9V rifier l arbre de direct...

Page 206: ...ot 5 Throttle to handlebar contact 6 Drive chain 7 Throttle roller sliding surface 8 Tube guide cable winding portion 9 Throttle cable end 0 Clutch cable end Use Yamaha cable lube or equivalent on the...

Page 207: ...rimento del rullo della valvola a farfalla 8 Parte a spira del cavo di guida del tubo 9 Estremit del cavo dell acceleratore 0 Estremit del cavo della frizione A Usare lubrificante per cavi Yamaha o eq...

Page 208: ...eds 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...

Page 209: ...chiaro 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 carb...

Page 210: ...hen 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 rot...

Page 211: ...sem Punkt stoppt die Anzeigenadel der Me uhr und ndert ihre Bewegungsrichtung wenn der Rotor in der gleichen Richtung weitergedreht wird 4 Im oberen Totpunkt ist die Me uhr auf Null zu stellen 5 Aus d...

Page 212: ...SP 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 s...

Page 213: ...ben Stator 1 l sen 9 Die K rnermarkierung an dem Rotor mit der K rnermarkierung an dem Stator 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allen...

Page 214: ...ting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank...

Page 215: ...schild 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...

Page 216: ...AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413110 Side cover 1 Remove 9 Bolt side cover 9 Side cover left and right 1 NOTE Draw the side cover downward to remove it because its claws a are inserted in...

Page 217: ...ftfiltergeh use eingesetzt sind POINTS DE DEPOSE Couvercle lat ral 1 D poser 9 Boulon couvercle lat ral 9 Couvercle lat ral gauche et droit 1 N B Abaissez le couvercle lat ral vers le bas pour le d po...

Page 218: ...AND removal SIDE COVERS section 1 Bolt silencer 2 2 Silencer 1 3 Collar D 10 5 mm 0 41 in 1 4 Collar D 10 0 mm 0 39 in 1 5 Grommet front 1 6 Grommet rear 1 7 Tension spring 2 8 Bolt exhaust pipe 2 9...

Page 219: ...0 0 mm 0 39 in 1 5 Taukranz vorne 1 6 Taukranz hinten 1 7 Zugfeder 2 8 Schraube Auspuffrohr 2 9 Auspuffroht 1 AUSPUFFROHR UND SCHALLD MPFER Ausbauumfang 1 Ausbau des Schalld mpfers 2 Ausbau des Auspuf...

Page 220: ...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...

Page 221: ...LLA 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...

Page 222: ...p by the following procedure Place a thick rag like a towel over the radiator cap slowly rotate the cap counter clockwise to the detent This procedure al lows any residual pressure to escape When the...

Page 223: ...diateur en proc dant comme suit Quand le moteur est froid mettre un chiffon pais tel qu une serviette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de d tente Cette proc dure...

Page 224: ...ght 1 9Bolt radiator right 2 9Radiator hose 4 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 3 Install 9Radiator left 1 9Bolt radiator left 2 9Radiator hose 2 3 Refer to CABLE ROUTING DIAGR...

Page 225: ...E INSTALLAZIONE IC455343 Radiatore 1 Installare 9 Sfiato del radiatore 1 9 Manicotto flessibile del radiato re 3 2 9 Manicotto flessibile del radiato re 1 3 Sul radiatore destro 4 NOTA Agganciare il t...

Page 226: ...eparation for Fuel tank 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...

Page 227: ...r 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 V...

Page 228: ...Y 1 Mixing 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 j...

Page 229: ...er 1 6 Nadeld sendeckel 1 7 Schwimmerstift 1 8 Schwimmer 1 9 Ventilsitz 1 0 Hauptd se 1 q Hauptd senhalter 1 w Leerlaufd se 1 e Starter Plungerkolben 1 r Drosselanschlagschraube 1 t Leerlauf Luftregul...

Page 230: ...able 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 a...

Page 231: ...N Carburateur 1 Examiner 9 Corps du carburateur Encrass Nettoyer fF Lors du nettoyage du conduit d air principal a a ne pas diriger le souffle d air comprim du c t du filtre car cela risque d obstruer...

Page 232: ...ace 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 9Cli...

Page 233: ...und auf freie Bewegung kontrollieren D sennadel 1 Pr fen 9 D sennadel 1 Biegung Verschlei Erneu ern 9 Klemmnut Spiel vorhanden Verschlei Erneuern 9 Klemmposition Pointeau 1 Examiner 9 Pointeau 1 9 Si...

Page 234: ...retor 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 bo...

Page 235: ...ivello del car burante tenere verticali il carbura tore e l indicatore di livello del car burante 9Se il livello del carburante non rientra nella specifica ispezionare la sede della valvola e la valvo...

Page 236: ...alve 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 stopp...

Page 237: ...auteur de la but e de soupape b Horssp cification R gler changer la but e de clapet REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 But e soupape flexible 2 9 Vis soupape flexibl...

Page 238: ...all 9Carburetor joint 1 9Bolt carburetor joint 2 EC4652C2 Carburetor 1 Install 9Throttle stop screw 1 9Locknut 2 9Pilot air screw 3 For EUROPE Pilot air screw 2 turns out 1 1 2 turns out Note the foll...

Page 239: ...erschraube 3 F r EUROPA Carburateur 1 Monter 9 Vis but e d acc l rateur 1 9 Contre crou 2 9 Vis de richesse 3 Pour EUROPE IC4652C2 Carburatore 1 Installare 9 Vite di arresto della valvola a farfalla 1...

Page 240: ...nstall 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 mov...

Page 241: ...gicleur aiguilles 5 N B 9Apr s avoir install le pointeau sur le flotteur les installer sur le carbura teur 9V rifier que le flotteur bouge en dou ceur 3 Einbauen 9 Hauptd senhalter 1 9 Hauptd se 2 9...

Page 242: ...the groove b in the needle holder 6 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 ho...

Page 243: ...mbre de m lan ge 2 Vers le carburateur 3 N B Apr s avoir r alis le montage v rifier que l attache des gaz se d place sans coup 7 Installare 9 Cavo dell acceleratore 1 9 Parte superiore del diffusore 2...

Page 244: ...Tighten 9Screw air filter joint 1 9Screw 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...

Page 245: ...filtro dell aria 1 9 Vite giunto del carburatore 2 3 Bloccare 9 Tubo flessibile di sfiato dell aria 1 9 Tubo flessibile di troppopieno 2 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPI...

Page 246: ...head side Bolt radiator Refer to RADIATOR section Radiator hose 3 Disconnect at right side radiator then shift the radiators forward 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 5 Loosen eac...

Page 247: ...kopf 5 Dabei jede Mutter nur jeweils 1 4 Drehung l sen bis alle Muttern locker sind 4 Zylinderkopf 1 5 Leistungsventilgeh use 1 6 Schubstange 1 Siehe unter AUSBAUPUNKTE 7 Mutter Zylinder 4 8 Zylinder...

Page 248: ...er 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...

Page 249: ...ube Verbindungshebel 1 9 Ventilhalterung 1 10 Ventilwelle 1 11 H lse 2 12 Verbindungshebel 1 13 Feder 2 14 Leistungsventil 1 1 15 Leistungsventil 2 1 KOLBEN UND LEISTUNGSVENTIL Ausbauumfang 1 Ausbau d...

Page 250: ...n 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 h...

Page 251: ...et la r gion du trou de l axe Si l axe de piston est encore difficile enlever alors que sa gorge est d calami n e utiliser l extracteur d axe de piston 4 fF Ne pas utiliser de marteau pour chas ser l...

Page 252: ...ge 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...

Page 253: ...ineal 1 und Einstell Lehre 2 anbringen 9 Die Verwerfungsgrenze messen 9 Wenn die Verwerfung nicht den erforderlichen Ma en entspricht Zylinderkopffl che bearbeiten 9 Ein feuchtes Sandpapier 3 Feinheit...

Page 254: ...urface 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...

Page 255: ...N B Mesurer l al sage de cylindre C en parall le A B C et angle droit du vilebrequin a b Ensuite faire la moyenne des mesures Piston 1 liminer 9 D p ts de calamine De la couronne de piston a et des ra...

Page 256: ...ston 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 conne...

Page 257: ...de bielle 1 Examiner 9 Axe de piston 9 Coussinet de pied de bielle Signes de d coloration par la chaleur Changer 2 Mesurer 9 Diam tre ext rieur d axe de pis ton Utiliser le microm tre 1 Hors limite C...

Page 258: ...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 cylin...

Page 259: ...r une jauge d paisseur 1 Hors limite Changer 3 Mesurer 9 Jeu lat ral Utiliser une jauge d paisseur 1 Hors limite Changer le piston et ou les segments N B V rifier en plusieurs points Jeu de piston 1 C...

Page 260: ...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 1...

Page 261: ...0018 in 0 004 in Kolbenspiel Kolben markierung a a Kolbengr e 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 gr n 53 965 53 968 mm 2 1246 2 1247 in D viol...

Page 262: ...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 EC475...

Page 263: ...gsventilbohrung im Zylinder 1 Ausbauen 9 Ru ablagerungen Aus der Leistungsventil Boh rung a HINWEIS Kein scharfkantiges Instrument ver wenden Kratzer auf dem Aluminium vermeiden Clapet de puissance 1...

Page 264: ...se 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 valv...

Page 265: ...uen da das Anschlagteil a nach innen gerichtet ist 9 Lithiumseifen Schmierfett auf der ldichtungslippe auftragen 2 Monter 9 Ressort 1 9 Levier articul 2 9 Collerette 3 9 Arbre tiroirs 4 9 Support de s...

Page 266: ...l 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 cli...

Page 267: ...fermaglio dello spinotto dello stantuffo per evitare di distorcerlo si devono usare le mani 9 9Non lasciare che le estremit aperte del fermaglio a graffa tocchino la fessura del pistone b b Kolbenring...

Page 268: ...t 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...

Page 269: ...einge baut wurde dieses auf glatte Bewe gung pr fen 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 positionne...

Page 270: ...ket 2 9CDI unit bracket 3 9Engine mounting bolt upper 4 9 Install 9Spark plug 1 9Spark plug cap 2 9Radiator hose 2 3 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...

Page 271: ...gsventil geh use 9 Leistungsventilgeh use 1 9 Schraube Leistungsventil geh use 2 5 Monter 9 Joint bo tier de clapet de puis sance 9 Bo tier de chapet de puissance 1 9 Boulon bo tier de clapet de puiss...

Page 272: ...3 Bolt brake pedal Shift the brake pedal downward Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 5 3 Clutch spring 5 4 Pressure plate 1 5 Push rod 1 6 Plain washer 2 7...

Page 273: ...1 5 Schubstange 1 6 Beilegescheibe 2 7 Lager 1 8 Reibscheibe 8 9 Kupplungsscheibe 7 KUPPLUNG UND PRIM RABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und...

Page 274: ...REMOVAL 1 Nut clutch boss 1 Use special tool 2 Lock washer 1 Refer to REMOVAL POINTS 3 Clutch boss 1 4 Plain washer 34 mm 1 34 in 1 5 Primary driven gear 1 6 Bearing 1 7 Plain washer 34 mm 1 34 in 1...

Page 275: ...pplungsnabe 1 4 Beilegescheibe 34 mm 1 34 in 1 5 Prim rabtriebszahnrad 1 6 Lager 1 7 Beilegescheibe 34 mm 1 34 in 1 8 Schubhebel 1 PRIM RABTRIEBSZAHNRAD Ausbauumfang 1 Ausbau der Prim rabtriebszahnrad...

Page 276: ...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 pl...

Page 277: ...ten F r USA und CDN Au er USA und CDN POINTS DE DEPOSE Noix d embrayage 1 D poser 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poign e d emb...

Page 278: ...Measure 9Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 EC494100 Push lever and push rod 1 Inspect 9Push lever 1 9Push rod 2 Wear...

Page 279: ...cation Changer tous les disques d embrayage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Levier de pouss e et champignon de d brayage 1 Examiner 9 Levier de pouss e 1 9 Champignon de d bra...

Page 280: ...he transmission oil on the spacer bearing and primary driven gear inner circumference 2 Install 9Plain washer 34 mm 1 34 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the cl...

Page 281: ...de l huile de bo te de vitesses sur l entretoise le roulement et la circonf rence int rieur du pignon men primaire 2 Monter 9 Rondelle ordinaire 34 mm 1 34 in 1 9 Noix d embrayage 2 3 Monter 9 Rondel...

Page 282: ...ates 1 for the first and final while paying attention to the difference in sur face pattern 9Apply the transmission oil on the friction plates and clutch plates 10 Nm 1 0 m kg 7 2 ft lb 8 Install 9Clu...

Page 283: ...men cant par une disque de fric tion et en terminant par une disque de friction 9Utiliser les plaques de friction 1 pour le premier et le dernier tout en tant attentif aux diff rentes surfaces 9Appliq...

Page 284: ...sitioned between area a If not reinstall the push lever 3 Adjust 9Push lever position 10 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 10 Nm 1...

Page 285: ...spinta NOTA Quando si spinge in avanti la leva di spinta la tacca di allineamento b dovrebbe essere situata nella zona a In caso contrario reinstallare la leva di spinta 3 Einstellen 9 Position des S...

Page 286: ...4 37 ENG CLUTCH AND PRIMARY DRIVEN GEAR 4 Install 9Plain washer 1 9Circlip 2...

Page 287: ...E PRIMAIRE KUPPLUNG UND PRIM RABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 4 Monter 9 Rondelle ordinaire 1 9 Circlip 2 4 Einbauen 9 Beilegescheibe 1 9 Sprengring 2 4 Installare 9 Rossetta...

Page 288: ...ward 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 loosenin...

Page 289: ...c t du moteur Boulon p dal de frein Pousser la p dale de frein vers le bas Tuyau de radiateur 4 D connecter du c t pompe eau Boulon Se reporter la section CULASSE champignon de d brayage CYLINDRE ET...

Page 290: ...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 Exten...

Page 291: ...eur au pied 2 D pose de l arbre de s lecteur et du levier de but e Etendue de d pose Ordre Nom de pi ce Q t Remarques DEPOSE DE L AXE DE DEMAR REUR AU PIED ET DE L ARBRE DE SELECTEUR 1 Pignon de renvo...

Page 292: ...orsion 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 disass...

Page 293: ...vilebrequin Ensemble guide de levier de s lecteur 1 D poser 9 Boulon guide de s lecteur 9 Guide de s lecteur 1 9 Ensemble levier de s lecteur 2 N B L ensemble de levier de s lecteur est d mont en m me...

Page 294: ...d 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 9Bearing 2 Rotate...

Page 295: ...e cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de but e 1 Examiner 9 Levier de but e 1 Usure endommagement Changer 9 Roulement 2 Faites tourner la bague ext rieu re avec le doigt Point dur...

Page 296: ...n installing 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 In...

Page 297: ...e que le ressort de torsion soit positionn comme illustr Guide de s lecteur et ensemble levier de s lecteur 1 Monter 9 Ressort 1 9 Broche cliquet 2 9 Cliquet 3 Au levier de s lecteur 4 2 Monter 9 Ense...

Page 298: ...ck 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 th...

Page 299: ...de d marreur au pied 4 N B S assurer que la but e a du ressort de torsion correspond au trou b sur l axe de d marreur au pied 2 Monter 9 Guide de ressort 1 N B Coulisser la guide de ressort dans l axe...

Page 300: ...inner circumference 9Install the kick idle gear with its depressed side a toward you EC4C5503 Primary drive gear 1 Install 9Spacer 1 9Primary drive gear 2 9Bolt 3 NOTE Temporarily tighten the bolt at...

Page 301: ...pignon de renvoi de d mar reur au pied le c t abaiss a orient vers soi Pignon de transmission primaire 1 Monter 9 Entretoise 1 9 Pignon de transmission primaire 2 9 Boulon 3 N B Serrer provisoirement...

Page 302: ...arter 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 Install the shift pedal so...

Page 303: ...pr s pos sible du tube de montant 4 mais de sorte qu il ne le touche pas 8 Monter 9 P dale de s lecteur 1 9 Boulon p dale de s lecteur 2 N B Monter la p dale de s lecteur de sorte que le haut du diam...

Page 304: ...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 Co...

Page 305: ...EUR ET PIGNON DE TRANSMISSION 1 Ensemble r gulateur 1 2 Goujon 1 Se reporter POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de but e 2 8 Collerette...

Page 306: ...nspect 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 9Go...

Page 307: ...ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTA GE R gulateur 1 Monter 9 Pignon de r gulateur 1 9 Ressort de compression 2 9 Plaque 3 9 Rondelle ordinaire 4 9 Roulement de but e 5 9 Collere...

Page 308: ...il 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...

Page 309: ...e 3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9V rifier que le goujon d assemblage est bien ajust dans le gorge a du dispositif d arr t 4 Monter 9 Ensemble r gulateur 1 N B...

Page 310: ...HAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller 1 3 Plain washer 1 Refer to REMOVAL POINTS 4 Impeller shaft 1 5 Bearing 1 6 Oil seal 2 Refer to REMOVAL POINTS EC4G0...

Page 311: ...orter la section AXE DE DEMARREUR AU PIED ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSON 1 Couvercle de bo tier de pompe eau 1 2 Turbine 1 3 Rondelle ordinaire 1 Se reporter POINTS DE DEPOSE 4 Axe de tur...

Page 312: ...panners etc and remove the im peller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discoloration of...

Page 313: ...N B S il n y a un d anomalie telle qu exces sif changement du niveau de liquide de refroidissement d coloration du liquide de refroidissement ou huile de bo te de vitesses blanch tre il est inutile de...

Page 314: ...eplace EC444400 Oil seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal 1 NOTE 9Apply the lithium soap base grease on the oil seal l...

Page 315: ...ch it 1 Usure endommagement Changer REMONTAGE ET MONTAGE Bague d tanch it 1 Monter 9 Bague d tanch it 1 N B 9Appliquer la graisse base de savon au lithium sur la l vre de la bague d tanch it 9Installe...

Page 316: ...and impeller shaft And install the shaft while turn ing it 2 Install 9Plain washer 1 9Impeller 2 NOTE Hold the impeller shaft on its width across the flats a with spanners etc and install the im pell...

Page 317: ...rales aplaties a au moyen d une cl etc et monter la turbine 3 Monter 9 Goujon 1 9 Joint couvercle de bo tier de pompe eau 2 4 Monter 9 Couvercle de bo tier de pompe eau 1 9 Boulon couvercle de bo tier...

Page 318: ...oval SIDE COVERS section Bolt Radiator left 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...

Page 319: ...ERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil de magn to CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil sp ci...

Page 320: ...01 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...

Page 321: ...d pin age du vilebrequin et le coussinet vilebrequin Si n cessaire changer le stator et ou le magn to CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET...

Page 322: ...en 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 CHE...

Page 323: ...er 9 Avance l allumage Se reporter la section CONTROLE ET REGLAGE DE L AVANCE A L ALLU MAGE du CHAPITRE 3 5 Serrer 9 Vis stator 1 6 Contr ler 9 Avance l allumage Recontr ler l avance l alluma ge 2 Ins...

Page 324: ...o 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 c...

Page 325: ...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 tapes em utilisant un mod...

Page 326: ...utch cable Disconnect at engine side Radiator hose 2 Disconnect at cylinder head side Radiator hose 4 Disconnect at water pump side Bolt radiator Refer to RADIATOR section Radiator hose 3 Disconnect a...

Page 327: ...2 D brancher du c t de la culasse Tuyau de radiateur 4 D connecter du c t pompe eau Boulon radiateur Se reporter la section RADIATEUR Tuyau de radiateur 3 D connecter du c t droit des radiateurs et t...

Page 328: ...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...

Page 329: ...1 2 Ecrou pignon d entra nement 1 3 Rondelle frein 1 Se reporter POINTS DE DEPOSE 4 Pignon d entra nement 1 5 Agrafe 1 6 Boulon p dal de frein 1 7 P dale de frein 1 8 Support du moteur 2 9 Boulon de...

Page 330: ...e 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...

Page 331: ...nando 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 Togli...

Page 332: ...ide 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 9Apply the lithium soap base grease on the bolt O rings and brake pedal...

Page 333: ...ec la but e a tourn e vers l int rieur Pignon d entra nement 1 Monter 9 Pignon d entra nement 1 9 Cha ne de transmission 2 N B Monter le pignon d entra nement avec la cha ne de transmission IC4M5000 M...

Page 334: ...tall 9Lock 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 cover 1 9Screw chain cover 2 5 Nm 0 5 m kg 3 6...

Page 335: ...nement 2 N B Serrer l crou en actionnant le frein arri re 3 Courber la languette de la rendel le frein pour verrouiller l crou 4 Monter 9 Couvercle de cha ne 1 9 Vis couvercle de cha ne 2 2 Installar...

Page 336: ...efer to CDI MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 50 mm 1 97 in 4 3 Bolt L 60 mm 2 36 in 6 4 Bolt L 70 mm 2 76 in 2 5 Holder 1 6 Crankcase right 1 Use special tool 7 Crankcase l...

Page 337: ...arreur au pied AU PIED ARBRE DE SELECTEUR ET PIGNON Levier de but e DE TRANSMISSION Rotor et stator Se reporter la section MAGNETO CDI 1 Segment 1 Se reporter POINTS DE DEPOSE 2 Boulon L 50 mm 1 97 in...

Page 338: ...ure the tool body is parallel with the case If necessary one screw may be backed out slightly to level tool body 9As pressure is applied alternately tap on the front engine mounting boss and transmiss...

Page 339: ...ntral taper alternativement sur le bossage de fixation avant du moteur et les arbres de transmission fF Utiliser un maillet en plastique et ne taper que sur les portions renforc es du carter Ne pas ta...

Page 340: ...rankshaft bearing 1 Remove 9Bearing 1 NOTE 9Remove the bearing from the crankcase by pressing its inner race as shown in 9If the bearing is removed together with the crankshaft remove the bearing usin...

Page 341: ...ebrequin en appuyant de carter int rieure comme indiqu dans 9Si le roulement est enlev en m me temps que le vilebrequin d poser le roulement en utilisant un extracteur de roulement 2 comme indiqu dans...

Page 342: ...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...

Page 343: ...c 9 Kurbelwangenbreite d Abweichung von Spezifikation Erneuern Die Me uhr und die F hlerleh re verwenden MONTAGE UND EINBAU Kurbelwellenlager 1 Einbauen 9 Lager 1 Am Kurbelgeh use Links und Rechts HI...

Page 344: ...CDN Except for USA and CDN NOTE 9Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft...

Page 345: ...ontage avec l autre Actionner l outil de montage jusqu a ce que le vilebrequin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer une graiss...

Page 346: ...9Dowel pin 1 9O ring 2 9Crankcase right 3 To crankcase left 4 NOTE 9Fit the crankcase right onto the crankcase left Tap lightly on the case with soft hammer 9When installing the crankcase the connecti...

Page 347: ...roit 3 Vers le carter gauche 4 N B 9Fixer le carter moteur gauche sur le cartermoteur droit Taper l g re ment sur le cartrer l aide d un mar teau souple 9Quand le carter est install la bielle d accoup...

Page 348: ...ch mark a with the dowel pin b 9Turn the segment clockwise until it stops and tighten the bolt 8 Remove 9Sealant Forced out on the cylinder mating surface 9 Apply 9Engine oil To the crank pin bearing...

Page 349: ...ontre jusqu ce qu il s arr te et resserrer le boulon 8 D poser 9 Etanch it Chass e sur le plan de joint du cylindre 9 Mettre 9 Huile moteur Sur le maneton le roulement le trou de refoulement et les ro...

Page 350: ...he 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 RE...

Page 351: ...ILLET DE SELECTEUR ET DE LA FOURCHETTE Moteur Se reporter la section DEPOSE DU MOTEUR S parer le carter Se reporter la section CARTER ET VILEBRE QUIN 1 Barre de guidage longue 1 2 Barre de guidage pet...

Page 352: ...ve 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 t...

Page 353: ...oigneusement Noter la position de chaque pi ce Bien faire attention l emplacement et l orientation des fourchettes VERIFICATION Pignons 1 Examiner 9 Crabot d accouplement a 9 Dent de pignon b 9 Gorge...

Page 354: ...e 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...

Page 355: ...a fourchette ne pas changer que la fourchette ellem me mais les deux pignons situ s de chaque c te de la fourchette REMONTAGE ET MONTAGE Bo te vitesses 1 Monter 9 Pignon de 5 23D 1 9 Pignon de 3 19D 2...

Page 356: ...end surface 9Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumference 3 Install 9Plain washer 1 9Circlip 2 NOTE 9Be sure the circlip sharp edged corner a is po sitioned o...

Page 357: ...e l huile au bisulfure de molybd ne sur la circonf rence inter ne des 4e et 5e engrenages 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9V rifier que le cot bord vif du cir clip a soit oppos la rond...

Page 358: ...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 4th wheel gear 2 and keeping the shift fork 1 3 moved in the di...

Page 359: ...d inverseur tout en maintenant le 4e pignon 2 et la four chette d inverseur n 1 3 dans le sens de la fl che 3 Monter 9 Barre de guidage petite 1 9 Barre de guidage longue 2 N B 9Appliquer de l huile d...

Page 360: ...4 74 ENG TRANSMISSION SHIFT CAM AND SHIFT FORK 4 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair...

Page 361: ...LA DEL CAMBIO 4 Kontrollieren 9 Funktion der Gangschaltung 9 Funktion des Getriebes Ungleichm iger Betrieb Reparieren 4 Contr ler 9 Fonctionnement de s lecteur 9 Fonctionnement de bo te vitesse Foncti...

Page 362: ...wheel axle 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of rem...

Page 363: ...iquement desserrage 4 Ecrou axe de roue avant 1 5 Axe de roue avant 1 6 Roue avant 1 7 Collerette 2 8 Bague d tanch it 2 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 Pr paration pou...

Page 364: ...e 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...

Page 365: ...ue arri re 1 Se reporter POINTS DE DEPOSE 5 Collerette 2 6 Pignon men 1 7 Bague d tanch it 2 8 Circlip 1 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 Pr paration pour la d pose XG B...

Page 366: ...ecessary 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 i...

Page 367: ...ure 9 Voile de roue Hors limite R parer Changer 2 Examiner 9 Roulement Faire tourner la bague int rieure avec le doigt Point dur grippage Changer N B Changer les roulements la bague d tanch it et la c...

Page 368: ...4200 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 Meas...

Page 369: ...e d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arri re 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 de...

Page 370: ...ll 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 Ins...

Page 371: ...diri g s vers l ext rieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment ext rieur 2 Monter 9 Disque de frein 1 9 Boulon disque de...

Page 372: ...ing the front fork several times with the front brake applied 8 Install 9Brake hose 1 To brake hose holder 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck wi...

Page 373: ...ans la gorge du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 7 Serrer 9 Boulon support d axe 1 N B Avant de serrer le boulon embo ter l axe de la roue da...

Page 374: ...eter of the race of the bearing 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 bear...

Page 375: ...la bague d tauch it lors de la repose 9Monter le roulement avec se joint dirig vers l ext rieur 9Utiliser une douille convenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ral...

Page 376: ...OTE 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...

Page 377: ...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...

Page 378: ...heel 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...

Page 379: ...N B A ce stage resserrer provisoirement les crous 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...

Page 380: ...en disassembling the caliper 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose remov...

Page 381: ...ein 1 6 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du d montage de l trier 8 Etrier 1 9 Levier de frein 1 10 Etr...

Page 382: ...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...

Page 383: ...1 6 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du d montage de l trier 8 Etrier 1 Pr paration pour la d pose XG...

Page 384: ...per 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 calipe...

Page 385: ...trier avant 2 D montage de l trier arri re Etendue de d pose Ordre Nom de pi ce Q t 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...

Page 386: ...1 2 Diaphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long nose circlip pliers 5 Plain washer 1 6 Push rod 1 7 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear Extent of...

Page 387: ...lindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorne B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE CYLINDRE...

Page 388: ...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 C...

Page 389: ...IONE 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 d...

Page 390: ...n seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder...

Page 391: ...re lors d un d montage d trier A Avant B Arri re 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...

Page 392: ...st 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...

Page 393: ...tone 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 flessibil...

Page 394: ...nt 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...

Page 395: ...Arri re 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 pistone e i...

Page 396: ...stall 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 2 Install 9Copper washer 1...

Page 397: ...fourche avant et fixer le tuyau de frein 4 Serrer 9 Goupille de plaquette 4 5 Monter 9 Bouchon de goupille de plaquet te 5 Etrier arri re 1 Monter 9 Support de plaquette 1 9 Plaquette de frein 2 9 Gou...

Page 398: ...Master cylinder kit 1 Clean 9Master cylinder 9Master cylinder kit Clean them with brake fluid 2 Install 9Master cylinder cup primary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOT...

Page 399: ...re cylindre primaire 1 9 Coupelle du ma tre cylindre secondaire 2 Au piston de ma tre cylindre 3 N B Appliquer le liquide de frein sur la cou pelle du ma tre cylindre XG Apr s la repose la coupelle du...

Page 400: ...master cylinder 5 NOTE 9Apply the brake fluid on the master cylinder kit 9Apply the lithium soap base grease on the tip of the push rod 9When installing the circlip use a long nose circlip pliers A F...

Page 401: ...z 1 9 Schubstange 2 9 Sprengring 3 9 Manschette des Hauptbrems zylinders 4 Zum Hauptbremszylinder 5 HINWEIS 9 Bremsfl ssigkeit auf dem Haupt bremszylindersatz auftragen 9 Lithiumseifen Fett am Ende de...

Page 402: ...cylinder piston 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb EC5A5401 Rear master cylinder 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brak...

Page 403: ...onter 9 Rondelle en cuivre 1 9 Tuyau de frein 2 9 Boulon d union 3 XG Toujours utiliser les rondelles en cuivre neuves fF Installer la tuyau de frein de mani re que la partie avec le tuyau soit a a di...

Page 404: ...htening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so...

Page 405: ...uvercle de tuyau 1 9 Rondelle ordinaire 2 9 Boulon couvercle de tuyau M8 3 9 Boulon couvercle de tuyau M6 4 4 Einbauen 9 Stift 1 9 Beilegescheibe 2 9 Splint 3 HINWEIS Nach den Einbau die H he des Brem...

Page 406: ...nstall the brake hose 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 w...

Page 407: ...ione 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...

Page 408: ...y 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...

Page 409: ...et un mauvais fonctionnement du frein 9Toujours utiliser la m me marque de liquide de frein Le m lange de liquides de marques diff rentes risque de provoquer une r action chimique nuisible au fonctio...

Page 410: ...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 che...

Page 411: ...perchio 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...

Page 412: ...n Number plate 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt handle crown 2 Only loosening 4 Cap bolt 1 Loosen when disassembling the front fork 5 Pinch bolt under bracket 2 Only loosening 6 Front...

Page 413: ...ein 2 3 Boulon de bridage couronne de guidon 2 Uniquement desserrage 4 Boulon capuchon 1 Desserrer lors du d montage de la fourche avant 5 Boulon de bridage trier inf rieur 2 Uniquement desserrage 6 F...

Page 414: ...Refer to REMOVAL POINTS 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 q Spring guide 1 w Base valve 1 Use special tool e Damper rod 1 Refer to REMOVAL PO...

Page 415: ...E DEPOSE 2 Ressort de fourche 1 Vidanger d huile de fourche 3 Joint antipoussi re 1 4 Bague d arr t 1 Se reporter POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 M tal de piston 1 8 Bague antifri...

Page 416: ...aterial 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 cap bolts or front forks be...

Page 417: ...g res Faire suffisamment attention ne pas laisser p n trer de substances trang res lorsque l huile est rem plac e ou lorsque la fourche avant est d mont e ou remont e 9Avant d enlever la fourche avant...

Page 418: ...1 Bend Damage Replace damper rod 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 a...

Page 419: ...nge weist eine komplizierte interne Konstruktion auf und ist besonders gegen ber Fremdmaterialien empfindlich Darauf achten da keine Fremdmaterialien eintreten wenn das l erneuert oder die Vorderradga...

Page 420: ...lace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace 9Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge readi...

Page 421: ...eur de courbure est indiqu e par la moiti de la valeur du comparateur cadran XG Ne pas tenter de redresser un tube interne tordu car cela risquerait de l affaiblir dangereusement Tube externe 1 Examin...

Page 422: ...o inner tube 2 cC To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install 9Cop...

Page 423: ...ement l en semble de tige peut y tomber endom mageant l int rieur de la soupape 3 Monter 9 Rondelle en cuivre 1 9 Joint torique 2 9 Soupape de base 3 Au tube interne 4 4 Serrer 9 Soupape de base 1 N B...

Page 424: ...seal 1 9Stopper ring 2 9Oil seal 3 9Plain washer 4 9Slide metal 5 To inner tube 6 NOTE 9Apply the fork oil on the inner tube 9When installing the oil seal use vinyl seat a with fork oil applied to pr...

Page 425: ...3 9 Rondelle ordinaire 4 9 Bague antifriction 5 Au tube interne 6 N B 9Appliquer de l huile de fourche sur le tube interne 9Lors de l installation de la bague d tanch it utiliser une feuille en vi nyl...

Page 426: ...r 3 10 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 11 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 12 Install...

Page 427: ...belbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 11 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren Rohres ei...

Page 428: ...formance 9Never allow foreign materials to enter the front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil 17 Fill 9Front fork oil Until o...

Page 429: ...achten da keine Fremd k rper in die Vorderradgabel ein dringen 16 Nach dem Einf len die Kolbenstange 1 mehr als 10 mal langsam auf und ab pumpen um das Gabel l zu verteilen 17 F llen 9 Vorderradgabel...

Page 430: ...with the fork oil up to the top of the outer tube and bleed the front forks 20 Measure 9Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking...

Page 431: ...XG Ne jamais oublier de faire le r glage de niveau d huile entre les niveaux maximum et minimum et toujours r gler chaque fourche avant au m me r glage Un r glage in gal peut entra ner une mauvaise ma...

Page 432: ...d up 9Install the fork spring with its smaller pitch end facing the cap bolt For EUROPE 9After installing the fork spring hold the damper rod end so that it will not go down 25 Install 9Cap bolt 1 Ful...

Page 433: ...e fourche avec la tige d amortisseur 3 d ploy e 9Installer le ressort de fourche avec l extr mit filet e la plus troite vers le boulon capuchon Pour EUROPE 9Apr s avoir install le ressort de fourche m...

Page 434: ...et the thin type spanners 2 between the spacer 3 and spring guide 4 9Hold the locknut 5 and tighten the cap bolt with specified torque 27 Install 9Cap bolt 1 To outer tube NOTE Temporarily tighten the...

Page 435: ...1 Montage 1 Monter 9 Fourche avant 1 N B 9Serrer le boulon de bridage trier in f rieur provisoirement 9Ne pas encore serrer le boulon de bri dage couronne de guidon 2 Serrer 9 Boulon capuchon 1 3 R gl...

Page 436: ...r 3 NOTE Fit the brake hose holder cut a over the projec tion b on the front fork and clamp the brake hose 6 Install 9Brake hose holder 1 9Bolt brake hose holder 2 9Protector 3 9Bolt protector 4 NOTE...

Page 437: ...5 devant le bossage de l axe c et l ajuster dans la gorge du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 7 R gler 9 Force d amortisseur de rebond N B To...

Page 438: ...1 Refer to REMOVAL POINTS 5 Throttle cable cap 1 Turn 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...

Page 439: ...rter POINTS DE DEPOSE 5 Capuchon du c ble d acc l rateur 1 Retourner le couvercle de capuchon 6 C ble d acc l rateur 1 D connecter du c t acc l rateur 7 Acc l rateur 1 Desserrer les boulons 8 Couvercl...

Page 440: ...e 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 EC5B80...

Page 441: ...de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poig e inf rieur 1 2 Capuchon de poig e sup rieur 1 3 Ensemble de la poign e 1 4 Poign e droite 1 Se reporter POIN...

Page 442: ...he 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 ma...

Page 443: ...Guidon 1 Deform e craquelures endom magement Changer XG Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble acc l rateur 1 Monter 9 Poign...

Page 444: ...er and then tighten the bolts on the rear side 2 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...

Page 445: ...ant d appliquer l adh sif essuyer la graisse ou l huile sur la surface du guidon a avec du diluant de peinture 9Fixer la poign e gauche sur le gui don de sorte que la ligne b entre les deux fl ches so...

Page 446: ...hrottle cable in the groove b in the roller 6 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 7 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 8...

Page 447: ...gler 9 Jeu du c ble d acc l ration Se reporter la section RE GLAGE DU CABLE D ACCE LERATEUR du CHAPITRE 3 8 Monter 9 Couvercle de capuchon 1 9 Monter 9 Ma tre cylindre 1 9 Etrier de ma tre cylindre 2...

Page 448: ...smoothly If it does not retighten the bolts for adjustment 11 Install 9 ENGINE STOP button 1 9Clutch lever holder 2 9Bolt clutch lever holder 3 9Clamp 4 NOTE 9The ENGINE STOP button clutch lever hold...

Page 449: ...yage 3 9 Bride 4 N B 9Le bouton d arr t du moteur ENGI NE STOP le support et la bride de levier d embrayage doivent tre ins tall s selon les dimensions indiqu es 9Faire passer le fil de bouton d arr t...

Page 450: ...5 45 CHAS HANDLEBAR 14 Clamp the clamp portion a of the number plate to the handlebar 15 Insert the end of the fuel breather hose 1 into the hole of the number plate...

Page 451: ...ie Bohrung des Nummernschil des einf hren 14 Fixer la partie de fixation a de la plaque d immatriculation au gui don 15 Introduire l extr mit du conduit d a ration de carburant 1 dans les trous de la...

Page 452: ...g nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Ball race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Ball race 2 Refer to REMOVAL POINTS Extent of remov...

Page 453: ...e ter St nder unter dem Motor angeordnet wird Nummernschild Lenkstange Siehe Abschnitt LENKSTANGE Kabelf hrung Vorderrad Kotfl gel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe Abschnitt VORDERRADGA...

Page 454: ...all 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 Ball race 1 Remove 9Ball race 1 Remove the ball race usin...

Page 455: ...ur 2 fF Veiller ne pas endommager le file tage de l arbre de direction Cage billes 1 D poser 9 Cage billes 1 Enlever la cage billes en utili sant une longue tige 2 et un marteau VERIFICATION Arbre de...

Page 456: ...ration in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION EC565113 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the du...

Page 457: ...trier inf rieur 1 Monter 9 Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint anti poussi re et sur la cironf rence interne du roulement 2 Monter 9 Cage b...

Page 458: ...ng shaft 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...

Page 459: ...une g ne 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 sup rieur 2 N B 9Serrer le boulon de...

Page 460: ...ring nut little by little 10 Adjust 9Front fork top end a 11 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...

Page 461: ...1 9 Boulon de bridage trier inf rieur 2 fF Resserrer le support auxiliaire au couple sp cifi S il est trop serr la fourche avant pourrait mal fonction ner 9 Dopo avere serrato il dado con trollare che...

Page 462: ...e 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 Swinga...

Page 463: ...SE UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdr cken Antriebskette 1 Kettenschutz 1 2 Kettenspanner Unten 1 3 Schraube Hinterad Sto d mpfer 1 Die Hinterradschw...

Page 464: ...Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and disassembly...

Page 465: ...tange 3 Ausbau und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename St ckzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 2 Relaisarm 1 3 Pleuelstange 1 4 H lse 2 5 ldichtung 2 6...

Page 466: ...eplace EC574211 Relay arm 1 Inspect 9Bearing polylube bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Bearing polylube bearing 1 Loss of so...

Page 467: ...n 9 ldichtung 3 Besch digung Erneuern Relaisarm 1 Pr fen 9 Lager Polylube Lager 1 9 H lse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und H lse als Satz erneuern 2 Pr fen 9 Lager Polylube Lager...

Page 468: ...Outer a a Zero mm Zero in Inner b b 8 5 mm 0 33 in EC574311 Connecting rod 1 Inspect 9Bearing polylube bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set...

Page 469: ...jeu fonctionnel tour irr gulier rouille Changer roule ment et collerette comme un en semble 2 Examiner 9 Roulement roulement Polylu be 1 Pertes de lubrifiant solide Changer 9 Bague d tanch it 3 Endom...

Page 470: ...stall 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 mark...

Page 471: ...ement en l ins rant sur c t o les rep res ou num ros du fa bricant sont inscrits 3 Einbauen 9 Lager 1 9 ldichtung 2 Zum Pleuelstange HINWEIS 9 Molybd n Fett auf dem Lager Wenn diese eingebaut werden 9...

Page 472: ...NOTE 9Apply the molybdenum 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...

Page 473: ...ras de relais 2 9 Rondelle ordinaire 3 9 Ecrou bras de relais 4 Au bras oscillant N B 9Appliquer de la graisse de molybd ne sur le boulon 9Ne pas resserrer l crou ce stade 6 Monter 9 Bras oscillant 1...

Page 474: ...lybdenum 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...

Page 475: ...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 bisolfuro di molibdeno 9Non serrare ancora il dado 9 Inst...

Page 476: ...t 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...

Page 477: ...t tzenabdeckung 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 Copertu...

Page 478: ...nt 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 guide lower 1 9 Spring guide upp...

Page 479: ...re arri re 1 3 Boulon amortisseur arri re bras de relais 1 Tenir le bras oscillant 4 Boulon amortisseur arri re cadre 1 5 Amortisseur arri re 1 6 Contre crou 1 7 Dispositif de r glage 1 8 Guide de res...

Page 480: ...as 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...

Page 481: ...endom mager toute partie du r servoir gaz Un r servoir gaz endom mag affectera la capacit d amortissement ou entra nera un mauvais fonctionnement 4 Prendre garde ne pas rayer la surface de contact de...

Page 482: ...e EC584000 INSPECTION 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 assem...

Page 483: ...ge ext rieure VERIFICATION Amortisseur arri re 1 Examiner 9 Tige d amortisseur 1 D form e Endommagement Changer l amortisseur com plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet Fuit...

Page 484: ...oove appears by pressing its outer race cC Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopp...

Page 485: ...1 N B Apr s avoir install la bague d arr t re pousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter 9 Roulement inf rieur 1 N B Installer le roulement en l ins rant sur c t o les rep r...

Page 486: ...he bearing 9Apply the lithium soap base grease on the bush collars and dust seals 9Install the dust seals with their lips facing out ward 3 Adjust 9Spring length installed a For EUROPE NOTE The length...

Page 487: ...e 3 N B 9Appliquer de la graisse de molybd ne sur le roulement 9Appliquer de la graisse base de sa von au lithium sur la bague les col liers et les joints antipoussi re 9Monter les joints antipoussi r...

Page 488: ...ide 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 fr...

Page 489: ...er de la graisse de molybd ne sur le boulon 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re sup rieur 2 9 Boulon cadre arri re inf rieur 3 7 Serrer 9 Vis raccord de filtre air 1 3 Installare 9 Ammor...

Page 490: ...ENGINE STOP button 2 Ignition coil 3 CDI unit 4 CDI magneto 5 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black O Orange B R Brack Red B W Black White G L Green Blue G W Green White W L White Blue...

Page 491: ...COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE COMPOSANTS ELECTRIQUES 1 Bouton d arr t du moteur ENGINE STOP 2 Bobine d allumage 3 Bloc CDI 4 Magn to CDI 5 Bougie CODE DE COULEUR B Noir O Orange B R Noir...

Page 492: ...on 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 uni...

Page 493: ...Changer Changer Changer O K O K O K O K SYSTEME D ALLUMAGE ETAPES DE VERIFICATION Utiliser les tapes suivantes pour v rifier la possibilit d attribution du mauvais fonctionnement du moteur une panne d...

Page 494: ...euern Erneuern Erneuern Erneuern Erneuern In Ordnung In Ordnung In Ordnung In Ordnung Z NDANLAGE PR FVORG NGE Durch folgende Schritte auf eine m gliche St rung des Motors durch einen Defekt im Z ndsys...

Page 495: ...tituirla 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...

Page 496: ...ne 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...

Page 497: ...RET DU MOTEUR ENGINE STOP 1 Examiner 9 Conductibilit du bouton d arr t du moteur ENGINE STOP Pas de continuit lorsqu enfonc Changer Continuit lorsque rel ch Changer IC622001 TEST DELLA DISTANZA TRA GL...

Page 498: ...move 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 Orange lead 1 Tester lead Black lead 2 Tester lea...

Page 499: ...ccio della candela girandolo in senso antiorario e con trollarlo 9Rimontare il cappuccio della candela girandolo in senso orario finch non bene avvitato Resistenza Posizione del della bobina selettore...

Page 500: ...osition 248 372 at 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 1 080 at 100 20 C 68 F EC62B000 SPARK PLUG CAP INSPEC...

Page 501: ...Positives Kabel des Pr fger tes Wei Rot Kabel 1 Negatives Kabel des Pr fger te Wei Blau Kabel 2 Widerstand Position des der Wahlschalters Aufnahmespule am Pr fger t 248 372 bei 100 20 C 68 F Positives...

Page 502: ...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 Bla...

Page 503: ...ezionare 9 Resistenza della bobina sorgen te 2 Fuori specifica Sostituirla IC628000 ISPEZIONE DELL UNIT CDI Controllare tutti i componenti elettrici Se non si rileva alcun guasto sostituire l unit CDI...

Page 504: ...t 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 r...

Page 505: ...e la route et la d coloration de bougie s Prenant ces facteurs en consid ration il s lectionnera les meilleurs r glages de carburateur possibles Il est recommand de prendre note des r glages des condi...

Page 506: ...sity 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 e...

Page 507: ...bougie s A Normale B Surbr l trop pauvre C Encrass e d huile trop riche Cio 9 Una temperatura pi alta fa dilatare l aria ne risulta una densit ridotta 9 Un umidit pi elevata riduce la quantit di ossi...

Page 508: ...be set by changing the main jet 1 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...

Page 509: ...C715002 Regolazione del getto principale La ricchezza della miscela aria carbu rante con valvola regolatrice del flusso a 1 2 4 4 pu essere registrata cam biando il getto principale 1 1 La candela tro...

Page 510: ...ll 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 b...

Page 511: ...essence avec l acc l rateur entre la position de fermeture compl te et la mi puissance peut tre r gl e en tournant le gicleur de ralenti 1 Le r glage est chang lorsqu il ne peut tre effectu unique me...

Page 512: ...spark plug and therefore it should be judged from your feeling of actual engine operation For EUROPE 1 Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up sp...

Page 513: ...en F r EUROPA 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 D sennadel klammer um eine Nut...

Page 514: ...effect as a lowering of 0 5 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 leaner 7 6 TUN SETTING 6CHY6 81 6CHY6 82 6CHY6 83 6CHY6 82 6CHY5...

Page 515: ...par une 6CHY5 82 produit le m me effet qu un abais sement d une demi position de la fixation A Diff rence de diam tre de portion droite B Diff rence de position de rainure a Aiguille de r f rence b 0...

Page 516: ...6 82 auf 6CHY5 82 hat die gleiche Auswirkung wie das Senken um eine halbe Klemmposition A Unterschied beim Durchmesser des geraden Teils B Unterschied bei der Klemmposition a Bezugsnadel b 0 5 magerer...

Page 517: ...bbe diminuendo di mezzo giro di posizione del fermaglio a graffa A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a graffa a Ago di riferimento b 0 5 pi povera Ago...

Page 518: ...has the same effect as a lowering of 0 5 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 leaner 6CHY6 81 6CHY6 82 6CHY6 83 6CHY5 82 6CHY6 82...

Page 519: ...une 6CHY5 82 produit le m me effet qu un abais sement d une demi position de la fixation A Diff rence de diam tre de portion droite B Diff rence de position de rainure a Aiguille de r f rence b 0 5 p...

Page 520: ...2 auf 6CHY5 82 hat die gleiche Auswirkung wie das Senken um eine halbe Klemmposition A Unterschied beim Durchmesser des geraden Teils B Unterschied bei der Klemmposition a Bezugsnadel b 0 5 magerer St...

Page 521: ...diminuendo di mezzo giro di posizione del fermaglio a graffa A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a graffa a Ago di riferimento b 0 5 pi povera Ago a g...

Page 522: ...ed 1 8 throttle to the 1st tapered portion at 1 4 throttle 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 The...

Page 523: ...3e partie conique une ouverture 3 4 du papillon et la 4e par tie conique l ouverture compl te du papillon Par cons quent l arriv e de carburant est quilibr e chaque niveau de l ouverture du papillon...

Page 524: ...2 35 4KM 14142 35 37 5 4KM 14142 37 STD 40 4KM 14142 40 42 5 4KM 14142 42 45 4KM 14142 45 47 5 4KM 14142 47 Rich 50 4KM 14142 50 Throttle Rich valve 3 3 3 75 5NY 14112 37 STD 4 0 5NY 14112 40 4 25 5NY...

Page 525: ...etto Povera No 30 4KM 14142 30 pilota No 32 5 4KM 14142 32 2 2 No 35 4KM 14142 35 No 37 5 4KM 14142 37 STD No 40 4KM 14142 40 No 42 5 4KM 14142 42 No 45 4KM 14142 45 No 47 5 4KM 14142 47 Ricca No 50 4...

Page 526: ...ower jet needle clip position 1 groove down Rich mixture Raise jet 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 t...

Page 527: ...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...

Page 528: ...lus haut Contr ler D coloration de la bougie d allumage Si la couleur est fonc e la condition est bonne Si la normalisation est impossible Si ge de pointeau bouch Tuyau de carburant bouch Robinet de c...

Page 529: ...es r glages d ensemble Utiliser un gicleur principal avec un n de calibrage inf rieur Elever la position de fixation de l aiguille de gicleur 1 rainure plus haut Si l effet est nul inverser les proc d...

Page 530: ...hzahl Wei er Rauch Schlechte Beschleunigung Einstellung Hauptd sen Kalibrierungs Nr erh hen schrittweise Hauptd sen Kalibrierungs Nr vermindern schrittweise Im Falle eines Hochdrehens Ein etwas fetter...

Page 531: ...kung die obigen Vorg nge umkehren Gesamteinstellungen berpr fen Hauptd se mit niedrigerer Kalibrierungs Nr verwenden D sennadel Klemmenposition erh hen 1 Nut h her Falls keine Wirkung die obigen Vorg...

Page 532: ...graffa dell ago a getto su di 1 scanalatura Controllo Scolorimento della candela Se color cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile...

Page 533: ...generali Usare un getto principale che abbia un No di taratura pi basso Alzare la posizione del fermaglio a graffa dell ago a getto su di 1 scanalatura Se non vi effetto eseguire al contrario le proc...

Page 534: ...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 st...

Page 535: ...d de changer la plage de chaleur des bougies et de s lection ner un autre gicleur principal correct N B 9Lors du contr le de la d coloration des bougies attention bien arr ter le moteur imm diatement...

Page 536: ...resistance Engine characteristics are shown below in rela tion to each rotor 9Standard rotor Engine pickup is faster in the entire engine speed range Pickup is fast at an extremely low engine speed 9O...

Page 537: ...r Drehzahl rasch auf Touren 9 Option Rotor Bei hoher Motordrehzahl wird ein Drehmomentgef hl erzielt Sp rbar gr ssere Leistungsband breite von der mittleren Drehzahl bis zu H chst drehzahlen HINWEIS 9...

Page 538: ...tire 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 c...

Page 539: ...erminer le taux de r duction secon daire 9Quand il y a de grandes lignes droites r gler la machine de sorte ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en vitan...

Page 540: ...d 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 12T 9383A 12017 STD 13T 9383A 13031 14T 9383A 14...

Page 541: ...50 00 51T 5NY 25451 00 52T 5NY 25452 00 Pression des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kgf cm2 9 0...

Page 542: ...g characteristic near the final stroke can be changed by changing the fork oil amount cC Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produc...

Page 543: ...tant de r gler le niveau d huile dans la fourche conform ment aux sp cifi cations donn es IC722011 Registrazione della forcella anteriore La registrazione della forcella anteriore dovrebbe essere eff...

Page 544: ...justment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in position...

Page 545: ...regolazione Ampiezza della regolazione zero 2 rondelle di regolazione R glage du ressort apr s remplace ment Les r glages de la fourche avant peu vent tre affect es par la suspension arri re il convi...

Page 546: ...s to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handlebar To set a stiff spring 9Change the rebound damping Turn in one or two clicks 9Change the co...

Page 547: ...entste hen ebenso wie Vibrationen im Lenker Zum Einstellen einer harten Feder 9 Die Ausfederd mpfung ndern Um eine oder zwei Klickstel lungen herausdrehen 9 Die Einfederd mpfung ndern Um eine oder zw...

Page 548: ...oved on the end of the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 380 4SS 23141 10 I I SOFT 0 390 4SS 23141 20 I II 0 400 4SS 23141 30 I III STD 0 410 4XM 23141 L0 0 420 4SS 23141 50...

Page 549: ...4SS 23141 30 I III STD 0 410 4XM 23141 L0 0 420 4SS 23141 50 II HART 0 430 4SS 23141 60 III 0 440 4SS 23141 70 IIII IC72P010 Parti di regolazione della forcella anteriore 9Rondella di regolazione 1 9M...

Page 550: ...ession damping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fe...

Page 551: ...en um das Hinter rad anzuheben und den Abstand a zwischen der Hinterradachs mitte und der Hinterradkotfl gel Halteschraube messen 2 Den St nder oder Block vom Motor entfernen und bei aufsit zendem Fah...

Page 552: ...t length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring 9Set the soft spring for less rebound damp ing to compensate for its less spring load Run with the rebound damping adjuster...

Page 553: ...er weichen Feder 9 Die weiche Feder auf weniger Ausfederd mpfung einstellen um die geringere Federspan nung auszugleichen Mit dem Ausfederd mpfung Einsteller um eine oder zwei Klickstellen zur weicher...

Page 554: ...se the one whose overall length a a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider w...

Page 555: ...ssort dont la longueur totale est sup rieure la longueur standard A Ressort recommand en fonction du poids B Poids du motocycliste 1 Mou 2 Standard 3 Dur iI Quando si usa un ammortizzatore posteriore...

Page 556: ...Brown 1 260 STD 4 5 5UN 22212 10 Green 1 260 4 7 5UN 22212 20 Red 1 260 4 9 5UN 22212 30 Black 1 260 STIFF 5 1 5UN 22212 40 Blue 1 260 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 5 7 5U...

Page 557: ...2 50 Gelb 1 260 5 5 5UN 22212 60 Rosa 1 260 5 7 5UN 22212 70 Eei 1 260 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4 3 5UN 22212 00 Marrone 1 260 NORMALE 4 5 5UN 22212 10 Verde 1 260 4 7 5UN...

Page 558: ...bout 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 out in Spring Replace with stiff spring Stiff toward stroke 1 O...

Page 559: ...nd 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 decre...

Page 560: ...positif de r glage vers la gauche de 2 d clics pour r duire l amortissement R duire le niveau d huile d environ 5 10 mm 0 2 0 4 in Monter un ressort doux V rifier s il y a coudes coups ou tout autre e...

Page 561: ...nt R gler la longueur sur 90 100 mm 3 5 3 9 in avec une personne assise correctement sur la selle Tourner le dispositif de r glage vers la droite de 2 d clics pour augmenter l amortissement Tourner le...

Page 562: ...Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu ver ringern lstand um etwa 5 10 mm 0 2 0 4 in senken Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtba...

Page 563: ...mpfung zu ver ringern Eingetauchte L nge 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 D mpfung zu steiger...

Page 564: ...to con l estremit posteriore Molla Livello dell olio quantit di olio Ruotare il dispositivo di regolazione in senso antiorario circa 2 scatti per diminuire lo smor zamento Diminuire il livello dell ol...

Page 565: ...re 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 aumen...

Page 566: ...TUN MEMO...

Page 567: ......

Page 568: ...PRINTED IN JAPAN 2002 5 2 0 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER YZ125 R LC...

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