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Yamaha YZ250(N)/LC, Owner'S Service Manual


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4-67

CRANKCASE AND CRANKSHAFT

ENG

EC4N5000

ASSEMBLY AND INSTALLATION

EC4N5300

Crankshaft bearing

1. Install:

9

Bearing 

1

To crankcase (left and right).

NOTE:

Install the bearing by pressing its outer race
parallel.

Standard

<Limit>

Runout 

0.03 mm 

0.05 mm 

limit:

(0.0012 in)

(0.0020 in)

Small end 

0.4~1.0 mm 

2.0 mm 

free play:

(0.016~0.039 in)

(0.08 in)

Side 0.25~0.75 

mm 

—

clearance: (0.010~0.030in)

Crank 59.95~60.00 

mm 

—

width:

(2.360~2.362 in)

EC4N4202

Crankshaft

1. Measure:

9

Runout limit 

a

9

Small end free play limit 

b

9

Connecting rod big end side clearance 

c

9

Crank width 

d

Out of specification 

→

Replace.

Use the dial gauge and a thickness gauge.

2. Inspect:

9

Bearings 

1

Rotate inner race with a finger.
Rough spot/Seizure 

→

Replace.

3. Inspect:

9

Oil seal 

1

Damage 

→

Replace.

Dial gauge:

YU-3097/90890-01252

 5MW-9-30-4C  7/4/00 9:27 AM  Page 38

Summary of Contents for YZ250(N)/LC

Page 1: ...5MW 28199 30 OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 N LC...

Page 2: ...RVICE MANUAL 2000 by Yamaha Motor Co Ltd 1st Edition July 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Prin...

Page 3: ...maha Motor Co Ltd 1 Ausgabe Juli 2000 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet...

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...please contact your Yamaha deal er NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yamaha dealer w PLEASE READ T...

Page 5: ...opos 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 peuv...

Page 6: ...ACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine 3 ALWAYS WEAR PROTECTIVE APPAR EL When operating this machine always wear an approved helmet with goggles o...

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: ...s machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there...

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 veico...

Page 12: ...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 I...

Page 13: ...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 7...

Page 14: ...s 6 are given in addition to the exploded diagram and job instruction chart 4 33 CLUTCH AND PRIMARY DRIVEN GEAR ENG Extent of removal Order Part name Q ty Remarks PRIMARY DRIVEN GEAR PUSH ROD AND PUSH...

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: ...INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7 ALLGEMEIN ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHINSCHE DATEN REGELM SSIGE PR FUNG UND EINSTELLUNGEN MOTEUR MOTOR PARTIE CYCLE FAHRGESTELL...

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 32 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 39 YPVS GOVERNOR 4 48 WATER PUMP 4 50 CDI MAGNETO 4 55 ENGINE REMOVAL 4 59 CRANKCASE AND CRANKSHAFT 4 64 TRANSMISSION SHIFT CAM AND S...

Page 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 39 REGULATEUR YPVS 4 48 POMPE A EAU 4 50 MAGNETO CDI 4 55 DEPOSE DU MOTEUR 4 59 CARTER ET VILEBREQUIN 4 64 BOITE A VITESSES BARILLET DE SELECTEUR ET FOUR...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 SOLENOID VALVE SYSTEM 6 6 TPS THROTTLE POSITION SENSOR SYSTEM 6 8 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 13...

Page 25: ...COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 SYSTEME D ALLUMAGE 6 2 SYSTEME D ELECTROVANNE 6 6 SYSTEME TPS CAPTEUR DE POSITION DU PAPILLON 6 8 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 13...

Page 26: ...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 Starter knob y Drive chain u Air cleaner i Shift peda...

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

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: ...ousing 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 cylinders pistons and o...

Page 31: ...ment remon t es 5 Tenir loign du feu 4 W hrend der Demontage der Maschine sind alle Teile zu reini gen und in der Reihenfolge der Demontage in Ablagen abzule gen um die Montage zu beschleunigen und ri...

Page 32: ...olt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward...

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 before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip 1 make sure that the sharp edged corner 2 is posi tione...

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: ...aums 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 Connecteu...

Page 38: ...sed to split the crankcase as well as remove the crankshaft 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 0123...

Page 39: ...90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 90890 03113 90890 03113 Engine tachometer This tool is needed for observin...

Page 40: ...ager le carter et extraire le vilebrequin de l une ou l autre de ses moiti s YU 1135 A YM 1305 90890 01135 90890 01305 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose...

Page 41: ...et outil pour examiner la r 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 brrayag...

Page 42: ...ieser Geh useh lften YU 1135 A YM 1305 90890 01135 90890 01305 YM 1189 90890 01189 Schwungrad Abziehwerkzeug Dieses Werkzeug wird f r den Ausbau des Schwung rad Magnetz nders ben tigt YM 1189 90890 01...

Page 43: ...zeug ist f r das Pr fen des Spulenwie 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 Kupp...

Page 44: ...i da una delle due parti del carter YU 1135 A YM 1305 90890 01135 90890 01305 YM 1189 90890 01189 Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 011...

Page 45: ...ispezionare la resistenza della 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 l...

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: ...o the fuel tank breather hose cC In this installation make sure the arrow faces the fuel tank and also downward EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when...

Page 51: ...raftstofftank Bel ftungsschlauch 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...

Page 52: ...oline is not available then leaded gasoline can be used 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...

Page 53: ...MOTORI Miscelare l olio 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 ra...

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: ...heck full throt tle response Stop and check the spark plug 6 After again allowing the engine to cool restart and run the machine for five more minutes Full throttle and the higher gears may be used bu...

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 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 Tightening of f...

Page 61: ...e De la timonerie au cadre De la timonerie 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 Serrag...

Page 62: ...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 Festziehen der Vo...

Page 63: ...cellone oscillante Posteriore Installazione Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione della ruota A...

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

Page 65: ...ses 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 lavez...

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

Page 67: ...onnez 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 fe...

Page 68: ...2 stroke gasoline Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 lmp oz 8 42 US oz Bore Stroke 66 4 72 mm 2 614 2 835 in Compression ratio 9 1 10 6 1 Starting system K...

Page 69: ...SA CDN ZA AUS NZ EUROPE Frame type Semi double cradle Caster angle 27 2 26 9 Trail 118 mm 4 65 in 115 mm 4 53 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90 19 62M Tire pressure fron...

Page 70: ...0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Side clearance installed 1st 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2nd 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Crankshaft Crank width A 5...

Page 71: ...air jet M A J 200 Jet needle clip position J N N3EJ 2 N3CW 3 Main nozzle N J 2 9 Cutaway C A 7 Pilot jet P J 50 55 Pilot air screw P A S 1 1 3 4 for reference only Valve seat size V S 3 8 mm 0 15 in...

Page 72: ...7 Air filter element M 6 1 0 1 2 0 2 1 4 Carburetor joint M 6 1 0 5 10 1 0 7 2 Air filter case M 6 1 0 2 4 0 4 2 9 Air filter joint M 5 0 8 5 1 0 1 0 7 Reed valve M 3 0 5 4 1 0 1 0 7 Exhaust pipe M 6...

Page 73: ...10 1 0 7 2 Push lever axle M 5 0 8 1 6 0 6 4 3 Drive sprocket M20 1 0 1 75 7 5 54 Shift guide M 6 1 0 2 10 1 0 7 2 Stopper lever M 6 1 0 1 10 1 0 7 2 Torsion spring shift shaft stopper bolt M 8 1 25 1...

Page 74: ...p of outer 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 Zero mm Zero in Rear...

Page 75: ...3 0 mm 9 84 0 12 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: ...nt brake master cylinder cap Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Cable guide front brake hose and guide stay Front brake hose union bolt master cylinder Fro...

Page 77: ...r shock absorber and relay arm Rear frame and frame Swingarm and brake hose holder Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Fuel tank mounting Fuel tank and fu...

Page 78: ...r type Electrical CDI Magneto model Manufacturer F5CU10 YAMAHA Source coil 1 resistance color 720 1 080 at 20 C 68 F Black Black Red Source coil 2 resistance color 44 66 at 20 C 68 F Green Blue Green...

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: ...ment liquide Dispositions de cylindres Monocylindre inclin Cylindr e 249 cm3 8 76 lmp oz 8 42 US oz Al sage course 66 4 72 mm 2 614 2 835 in Taux de compression 9 1 10 6 1 Syst me de d marrage D marre...

Page 81: ...UROPE Type de cadre Simple berceau d d double Angle de chasse 27 2 26 9 Chasse 118 mm 4 65 in 115 mm 4 53 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Taille de pneu arri r...

Page 82: ...T 2 55 mm 0 100 in Ecartement des becs mont 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Jeu lat ral mont 1 re 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2e 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm...

Page 83: ...80 Gicleur d air M A J 200 Aiguille J N N3EJ 2 N3CW 3 Tubulure principal N J 2 9 Echancrure C A 7 Gicleur de ralenti P J 50 55 Vis d air de ralenti P A S 1 1 3 4 r f rence uniquement Taille de si ge d...

Page 84: ...1 2 0 2 1 4 Raccord de carburateur M 6 1 0 5 10 1 0 7 2 Carter de filtre air M 6 1 0 2 4 0 4 2 9 Raccord du filtre air M 5 0 8 5 1 0 1 0 7 Soupape flexible M 3 0 5 4 1 0 1 0 7 Tuyau d chappement M 6 1...

Page 85: ...pouss M 5 0 8 1 6 0 6 4 3 Pignon de cha ne M20 1 0 1 75 7 5 54 Guide de s lecteur M 6 1 0 2 10 1 0 7 2 Levier de but e M 6 1 0 1 10 1 0 7 2 Ressort de torsion arbre de s lecteur Boulon de but e M 8 1...

Page 86: ...le tuyau 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...

Page 87: ...n 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 disq...

Page 88: ...vant trier Etrier de frein avant et fourche avant Etrier de frein avant et arri re et bouchon de goupille de plaquette Etrier de frein avant et arri re et goupille de plaquette Etrier de frein avant e...

Page 89: ...voir essence et vis d accrochage bande de fixation R servoir essence et patte du r servoir essence Montage de selle Montage de couvercle lat ral Montage de buse d arriv e d air Montage de pare boue av...

Page 90: ...rique CDI Magn to mod le Fabricant F5CU10 YAMAHA R sistance de bobinage de source 1 720 1 080 20 C 68 F couleur noir noir rouge R sistance de bobinage de source 2 44 66 20 C 68 F couleur vert bleu ver...

Page 91: ...tages 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 SPECIFICATION...

Page 92: ...er Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorne geneigt Hubraum 249 cm3 8 76 lmp oz 8 42 US oz Bohrung Hub 66 4 72 mm 2 614 2 835 in Verdichtungsverh ltnis 9 1 10 6 1 Anla system Kickstarter...

Page 93: ...hrgestell USA CDN ZA AUS NZ EUROPA Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 27 2 26 9 Nachlaufbertrag 118 mm 4 65 in 115 mm 4 53 in Reifengr e Bauart Mit Schlauch Reifengr e Vorne 80 100 21 51M...

Page 94: ...genspalt Eingebaut 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Seitliches Spiel Eingebaut 1 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in...

Page 95: ...178 180 Hauptluftd se M A J 200 D sennadel Klemmposition J N N3EJ 2 N3CW 3 Hauptzerst uber N J 2 9 Abschr gung C A 7 Leerlaufd se P J 50 55 Leerlauf Luftregulierschraube P A S 1 1 3 4 nur als Hinweis...

Page 96: ...element M 6 1 0 1 2 0 2 1 4 Vergaserverbindung M 6 1 0 5 10 1 0 7 2 Luftfiltergeh use M 6 1 0 2 4 0 4 2 9 Luftfilterverbindung M 5 0 8 5 1 0 1 0 7 Zungenventil M 3 0 5 4 1 0 1 0 7 Auspuffroht M 6 1 0...

Page 97: ...ebelachse M 5 0 8 1 6 0 6 4 3 Antriebskettenrad M20 1 0 1 75 7 5 54 Schaltf hrung M 6 1 0 2 10 1 0 7 2 Anschlaghebel M 6 1 0 1 10 1 0 7 2 Torsionsfeder Schaltwelle Entkupplungsgliedbolzen M 8 1 25 1 2...

Page 98: ...em inneren Rohr und 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 Null mm Null in Vorderradgabelbeinr...

Page 99: ...4 0 12 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 Hinterradsc...

Page 100: ...Belagplattenstift Bremssattel vorne und hinten und Entl ftungsschraube Vorderradachse und Mutter Vorderradachschalter Vorderrad Bremsscheibe und Radnabe Hinterrad Bremsscheibe und Radnabe Bremspedalb...

Page 101: ...tz und Hinterradschwinge Kraftstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstof tank und Hakenschraube Befestigungsband Kraftstoftank und Krafts...

Page 102: ...isch Ausf hrung CDI Modell Hersteller F5CU10 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 bei 20 C 68 F Schwarz Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 bei 20 C 68 F Gr n Blau Gr n W...

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

Page 104: ...uido a benzina Disposizione dei cilindri Cilindro unico inclinato in avanti Cilindrata 249 cm3 8 76 lmp oz 8 42 US oz Alesaggio corsa 66 4 72 mm 2 614 2 835 in Rapporto di compressione 9 1 10 6 1 Sist...

Page 105: ...idenza 27 2 26 9 Avancorsa 118 mm 4 65 in 115 mm 4 53 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 110 90 19 62M Pressione degli pneumatici anteriore e...

Page 106: ...in 0 95 mm 0 037 in Gioco laterale installata 1 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Albero a gomiti Larghezza del gomito A 59 95 60 00 mm...

Page 107: ...ale M A J No 200 Posizione della staffa dell ago di getto J N N3EJ 2 N3CW 3 Ugello principale N J 2 9 Sezione C A No 7 Getto pilota P J No 50 No 55 Vite dell aria pilota P A S 1 1 3 4 solo riferimento...

Page 108: ...Giunto del carburatore M 6 1 0 5 10 1 0 7 2 Corpo del filtro dell aria M 6 1 0 2 4 0 4 2 9 Giunto del filtro dell aria M 5 0 8 5 1 0 1 0 7 Valvola a lamella M 3 0 5 4 1 0 1 0 7 Tubo di scarico M 6 1 0...

Page 109: ...leva di spinta M 5 0 8 1 6 0 6 4 3 Rocchetto di trasmissione M20 1 0 1 75 7 5 54 Guida del cambio M 6 1 0 2 10 1 0 7 2 Leva di fermo M 6 1 0 1 10 1 0 7 2 Molla di torsione albero del cambio Bullone fe...

Page 110: ...5 91 in 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...

Page 111: ...04 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 estern...

Page 112: ...teriore M 6 1 0 2 9 0 9 6 5 Coperchio del cilindro principale del freno anteriore M 4 0 7 2 2 0 2 1 4 Leva di comando del freno vite M 6 1 0 1 6 0 6 4 3 Leva di comando del freno dado M 6 1 0 1 6 0 6...

Page 113: ...telaio M14 1 5 1 80 8 0 58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio M 8 1 25 3 29 2 9 21 Fo...

Page 114: ...ttrico CDI Modello Costruttore del magnete F5CU10 YAMAHA Resistenza 1 della bobina di origine 720 1 080 20 C 68 F colore Nero Nero Rosso Resistenza 2 della bobina di origine 44 66 20 C 68 F colore Ver...

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

Page 116: ...lead and solenoid valve lead with the clamp ends downward In so doing clamp the ENGINE STOP button lead at its protect ing tube E Clamp the clutch cable so that the clamp passes with its ends downwar...

Page 117: ...ez le fil du bouton ENGINE STOP sur sa gaine de protection E Bridez le c ble d embrayage de fa on ce que la bride se pr sente avec les extr mit s vers le bas comme illustr F Faites passer le fil du ca...

Page 118: ...ds for ward C Clamp the radiator breather hose and CDI magneto lead at the rear of the down tube with the clamp ends outward D Pass the clutch cable a little for ward of the extreme left nut that hold...

Page 119: ...rieur avec les extr mit s de la bride vers l ext rieur D Faites passer le c ble d embrayage en peu en avant de l crou de fixation extr me gauche de la culasse E Faites passer le tuyau reniflard du rad...

Page 120: ...he brake hose and swingarm bracket E Pass the reservoir hose into the hose guide F Clamp the high tension cord throttle cable TPS throttle posi tion sensor and solenoid valve lead so that the high ten...

Page 121: ...ur de posi tion du papillon TPS et le fil d lectro vanne de fa on ce que le c ble haute tension ne soit pas en contact avec les crous de montage du support du moteur G Fixer le fil de masse avec la pa...

Page 122: ...cts as show and lightly touches the projection on the master cylinder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Pass the clutch cable in front of the throttle cable D Cla...

Page 123: ...diqu et touche l g rement la saillie sur le ma trecylindre B Faire passer le fil de bouton d arr t du moteur ENGINE STOP au centre du support d embrayage C Faire passer le c ble d embrayage devant le...

Page 124: ...Check ring end gap Replace PISTON PIN SMALL END BEARING Inspect Replace CYLINDER HEAD Inspect and clean Remove carbon Retighten Check gasket CYLINDER Inspect and clean Inspect score marks Replace Ins...

Page 125: ...luid Every one year FRONT 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 Inspect and a...

Page 126: ...3 3 INSP ADJ MEMO...

Page 127: ...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 Changer l huile...

Page 128: ...et les fuites 6 6 Resserrer les boulons du frein disque les boulons d tier les boulons du ma tre cylindre et les boulons d union 6 6 Changer les plaquettes 6 Changer le liquide de frein 6 FOURCHE AVAN...

Page 129: ...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 roulements 6 Changer les roulements 6 Graisser 6 A...

Page 130: ...BOLZEN PLEUELAUGEN LAGER Pr fen 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...

Page 131: ...KRAFT 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 Undichtigk...

Page 132: ...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 133: ...A CILINDRO Ispezione e pulitura 6 6 Riserraggio 6 6 CILINDRO Ispezione e pulitura 6 6 6 Sostituzione YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sost...

Page 134: ...e pastiglie 6 Sostituzione liquido per freni 6 FORCELLE ANTERIORI Ispezione e regolazione 6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pul...

Page 135: ...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 136: ...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 137: ...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 138: ...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 139: ...i cavi 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 C...

Page 140: ...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 141: ...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 142: ...rain the coolant completely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Re...

Page 143: ...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 144: ...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 145: ...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 146: ...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 147: ...Appliquer 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 second...

Page 148: ...Radiator 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 sid...

Page 149: ...ge 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 1...

Page 150: ...rease On the throttle cable end a tube guide cable winding portion b and roller sliding surface c Throttle grip free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until the specifie...

Page 151: ...1 Togliere 9 Coperchio della calotta 1 9 Calotta del cavo dell acceleratore 2 Jeu la poign e d acc l ration a a 3 5 mm 0 12 0 20 in Gioco libero della mano pola dell acceleratore a a 3 5 mm 0 12 0 20...

Page 152: ...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 153: ...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 154: ...hole 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 fil...

Page 155: ...filtro dell aria Danni Sostituirlo 4 Applicare 9 Olio per filtro dell aria in schiu ma oppure olio per miscela per motori Sull elemento NOTA Comprimere per fare fuoriuscire l olio in eccesso L elemen...

Page 156: ...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 157: ...moteur le laisser chauffer quelques minutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en pla ant le support convenable sous le moteur 3 Placer un...

Page 158: ...level 9 Install 9Oil filler cap 2 EC35L021 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Adjusting steps 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw...

Page 159: ...4 10W 30 ou huile moteur SAE 10W 30 type SE Quantit d huile change ments d huile p rio diques 0 75 L 0 66 Imp qt 0 79 US qt Olio raccomandato Olio per motore Yamalube 4 10W 30 oppure SAE 10W 30 del t...

Page 160: ...0 MUFFLER INSPECTION 1 Inspect 9O ring 1 Damage Replace EC35R041 SILENCER FIBER REPLACEMENT 1 Remove 9Seat 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adjustment steps Turn the thrott...

Page 161: ...ne au r gime le plus bas pos sible Pour diminuer le regime de ralenti Visser le vis de but e d acc l rateur 1 1 Pour diminuer le regime de ralenti D visser le vis de but e d acc l rateur 1 1 Passi del...

Page 162: ...right 9Seat 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 1215...

Page 163: ...0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reusement de l agent d tanch it...

Page 164: ...ake 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 165: ...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 166: ...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 167: ...oso 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 liqui...

Page 168: ...heck 9Brake pedal height a Out of specification Adjust 2 Adjust 9Brake pedal height Brake pedal height a a 5 mm 0 20 in Pedal height adjustment steps 9Loosen the locknut 1 9Turn the adjusting nut 2 un...

Page 169: ...instellung soll te das Ende b b der Schraube 3 3 ander unteren Einstellmutter 4 4 berstehen aber um nicht mehr als 2 mm 0 08 in c c von dem Bremspedal 5 5 9 Nachdem die Pedalh he einge stellt wurde da...

Page 170: ...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 171: ...it nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 8 und Bremsbelag plattenstift einbauen ANMERKUNG 9 Bremsbel ge mit deren ber st nden a in die Bremsschuh aussparungen b an...

Page 172: ...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 173: ...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 174: ...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 175: ...er 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 9...

Page 176: ...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 177: ...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 178: ...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 179: ...n 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...

Page 180: ...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 181: ...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 3...

Page 182: ...Turn adjuster 3 3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on ea...

Page 183: ...es Motors und anderer wichtiger Teile die Kettenspannung daher inner halb des spezifizierten Berei ches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sic...

Page 184: ...seal and oil seal after every run 9Apply the lithium soap base grease on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1...

Page 185: ...ettoyer 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 graisse base de savon au lithium sur le tube interne...

Page 186: ...t can cause poor handling and loss of stability EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Remove 9Rubber cap 2 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a...

Page 187: ...so completamente inverso partendo avvitata dalla posizione massima Ampiezza della regolazione H rter a a Die Kompressi ons D mpfungs kraft erh hen Den Einsteller 1 1 hineindrehen Weicher a a Die Kompr...

Page 188: ...aximum extent of adjustment The ad juster may be damaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install 9Rubber cap EC36K...

Page 189: ...stabilit 3 Installare 9 Tappo di gomma 9 POSITION STANDARD C est la position qui se trouve en arri re du nombre sp cifi de d clics partir de la position enti rement vis s e fF Ne pas forcer le r gula...

Page 190: ...nut and adjuster before adjustment 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 Tig...

Page 191: ...REGLAGE DE LA PRECON TRAINTE DE RESSORT 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...

Page 192: ...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 minimum or maximum extent of adjustment The ad juster may be dam...

Page 193: ...ebond 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 REG...

Page 194: ...n the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be d...

Page 195: ...OS 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 Regolar...

Page 196: ...Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged q a...

Page 197: ...sions 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 compression...

Page 198: ...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 199: ...che lo pneumatico scivola fuori dalla sua posizione sul cerchione 9Se si trova inclinato il gambo della valvola dello pneumatico si ritiene che lo pneumatico stia scivolando fuori dalla sua posizione...

Page 200: ...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 201: ...ta 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 Einstellschr...

Page 202: ...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 on the...

Page 203: ...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 direction e...

Page 204: ...vot 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 th...

Page 205: ...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 206: ...low speeds 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...

Page 207: ...tore della candela diventa fuligginoso anche se il motore e il carburatore sono in buone condizio ni di funzionamento 3 Misurare 9 Distanza tra le candele a Usare un calibro per fili metalli ci o uno...

Page 208: ...C When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the...

Page 209: ...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 dem oberen Totpunkt ist der Rotor i...

Page 210: ...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 211: ...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 212: ...ht 2 3 Fitting 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 3 Extent of removal 1 Seat removal...

Page 213: ...ion 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 SER...

Page 214: ...TS EC413101 Side cover 1 Remove 9Side cover left and right 1 cC Be sure to remove the seat before remov ing the side cover If you remove the side cover with force without removing the seat the panel 2...

Page 215: ...POINTS DE DEPOSE Couvercle lat ral 1 D poser 9 Couvercle lat ral gauche et droit 1 fF Veiller enlever d abord la selle avant de retirer le couvercle lat ral Si le couvercle lat ral est enlev e en for...

Page 216: ...cover right Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Bolt silencer 2 2 Silencer 1 3 Tension spring 2 4 Bolt exhaust pipe 2 5 Exhaust pipe 1 1 Extent of removal 1 Silencer removal 2 E...

Page 217: ...lld mpfer 1 3 Zugfeder 2 4 Schraube Auspuffrohr 2 5 Auspuffroht 1 AUSPUFFROHR UND SCHALLD MPFER Ausbauumfang 1 Ausbau des Schalld mpfers 2 Ausbau des Auspuffrohres IC4S0000 TUBO DI SCARICO E SILENZIAT...

Page 218: ...FUEL TANK AND SIDE COVERS section 1 Panel 2 Refer to REMOVAL POINTS 2 Clamp radiator hose 2 3 2 Only loosening 3 Radiator hose 1 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator h...

Page 219: ...CARBURANTE E COPERTURE LATERALI 1 Pannello 2 Consultare PUNTI DI RIMOZIONE 2 Brida manicotto flessibile del radiatore 2 3 2 Soltanto allentamento 3 Manicotto flessibile del radiatore 1 1 4 Radiatore...

Page 220: ...te the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it...

Page 221: ...viette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de d tente Cette proc dure permet d liminer toute pression r siduelle Quand le sifflement s est arr t appuyer sur le bouch...

Page 222: ...TER 2 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb 3 Install 9Radiator left 1 9Bolt radiator left 2 9Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER...

Page 223: ...chlauch 1 3 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Festziehen 9 Klemme K hlerschlauch 2 3 4 5 Einbauen 9 Tafel 1 ANMERKUNG 9 Darauf achten da das Blech nicht mehr als erforderlich...

Page 224: ...ection 1 Solenoid valve lead 1 Disconnect the solenoid valve lead 2 TPS throttle position sensor 1 Disconnect the TPS lead throttle position sensor lead 3 Clamp carburetor joint 2 Loosen the screws ca...

Page 225: ...gaserverbindung 2 Die Schrauben Vergaserverbindung l sen 4 Vergaser 1 5 Vergaserverbindung 1 6 Zungenventil 1 7 Anschlag Zungenventil 2 8 Zungenventil 2 VERGASER UND ZUNGENVENTIL Ausbauumfang 1 Ausbau...

Page 226: ...g chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Float pin 1 7 Float 1 8 Needle valve 1 9 Main jet 1 0 Pilot jet 1 q Starter plunger 1 w...

Page 227: ...mmerstift 1 7 Schiwimmer 1 8 Nadelventil 1 9 Hauptd se 1 0 Leerlaufd se 1 q Starter Plungerkolben 1 w Drosselanschlagschraube 1 e Leerlauf Luftregulierschraube 1 Siehe unter AUSBAUPUNKTE r Kraftd se 1...

Page 228: ...rottle valve 1 9Ring 2 9Spring throttle valve 3 9Mixing chamber top 4 9Throttle cable 5 NOTE While compressing the spring throttle valve disconnect the throttle cable EC463401 Pilot air screw 1 Remove...

Page 229: ...bei der Motorleistung bewirkt IC466020 NOTA PER IL MANEGGIO iI Non allentare le viti conduttore TPS sensore di posizione gas se non per cambiare il conduttore TPS sensore di posizione gas qualora si g...

Page 230: ...9Power jet 3 Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air 9Never use a wire EC464210 Needle valve 1 Inspect 9Needle valve 1...

Page 231: ...1 Contr ler 9 Mouvement Coincement R parer ou chan ger N B Ins rer le boisseau 2 dans le corps du carburateur tout en maintenant le levier 1 relev et contr ler s il coulisse en douceur Drosselventil...

Page 232: ...Measurement and adjustment steps 9Hold the carburetor in an upside down posi tion 9Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers N...

Page 233: ...tilsitz und das Nadelventil kontrollieren 9 Wenn eines der beiden Teile abgenutzt ist beide Teile erneu ern 9 Befinden sich beide Teile in gutem Zustand dann ist die Schwimmerh he durch Abbie gen der...

Page 234: ...cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping 1 Nm 0 1 m kg 0 7 ft lb 9Valve stopper height b Out of specification Adjust stopper Replace va...

Page 235: ...dD Die Schrauben allm hlich festzie hen um ein Verziehen des Ventils zu vermeiden REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 But e soupape flexible 2 9 Vis soupape flexible...

Page 236: ...ND REED VALVE 10 Nm 1 0 m kg 7 2 ft lb EC4652F0 Carburetor 1 Install 9Power jet 1 To carburetor 2 2 Install 9O ring 1 9Solenoid valve 2 9Clamp 3 9Screw clamp 4 To carburetor 5 cC 9Before installing th...

Page 237: ...ur 2 2 Monter 9 Joint torique 1 9 Electrovanne 2 9 Bride 3 9 Vis bride 4 Au carburateur 5 fF 9Avant d installer l lectrovanne nettoyez l air comprim l lectro vanne et sa position de montage sur le car...

Page 238: ...allation points 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw by the number of turns recorded before removing 5 Install 9Pilot jet 1 9Main jet 2 6 Install 9Need...

Page 239: ...tto pilota 1 9 Getto principale 2 3 Monter 9 Vis de richesse 1 9 Vis but e d acc l rateur 2 Pour EUROPE 4 Monter 9 Plongeur de d marreur 1 Noter les points de montage sui vants 9Visser la vis de riche...

Page 240: ...nds not having the cuts a toward the carburetor 9 Install 9Jet needle 1 9Collar 2 9Spring 3 9Needle holder 4 To throttle valve 5 NOTE Install the spring with its smaller dia a facing the collar 10 Ins...

Page 241: ...ventilation et le tuyau de trop plein au carburateur avec les extr mit s sans chancrures a orient es vers le carburateur 8 Einbauen 9 Bel ftungsschlauch 580mm 22 8 in 1 9 Bel ftungsschlauch 400mm 15 7...

Page 242: ...e air vent hose 9After installing check the throttle grip for smooth movement EC465390 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor joint slots 2...

Page 243: ...AL MINIMO al CAPI TOLO 3 3 Anschlie en 9 TPS Leitungskabel Drossel stellungssensor 1 9 Magnetventilleitung 2 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Einstellen 9 Leerlaufdrehzahl S...

Page 244: ...t cylinder head side Carburetor Refer to CARBURETOR AND REED VALVE section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 6 Loosen each nut 1 4 turn and remove them after all nuts are loosened...

Page 245: ...weils 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 1 ZYLINDERKOPF ZYLINDER UND KOL...

Page 246: ...INTS 4 Small end bearing 1 5 Piston ring 2 6 Power valve cover 1 7 Side holder 2 8 Thrust plate 1 9 Bolt 3 10 Valve shaft 1 11 Link lever 1 12 Pulley 2 13 Link rod 1 14 Power valve 2 2 15 Valve holder...

Page 247: ...cheibe 1 9 Schraube 3 10 Ventilwelle 1 11 Verbindungshebel 1 12 Riemenscheibe 2 13 Pleuelstange 1 14 Leistungsventil 2 2 15 Ventilhalterung 1 16 Leistungsventil 1 1 KOLBEN UND LEISTUNGSVENTIL Ausbauum...

Page 248: ...iston and piston ring 1 Remove 9Piston pin clip 1 NOTE Before removing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the crankcase cav ity...

Page 249: ...des Kolbenbol zens 1 ANMERKUNG Vor dem Abnehmen des Stifts des Kol benbolzens ist das Kurbelgeh use mit einem sauberen Lappen abzudecken so da der Stift nicht versehentlich in das Kurbelgeh use f llt...

Page 250: ...tion Re surface Warpage 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 f...

Page 251: ...se 4 en lui faisant faire des huit N B Tourner la culasse plusieurs fois pour viter d enlever trop de mati re d un c t Limite de d formation 0 03 mm 0 0012 in Schritte f r Messung der Ver werfung und...

Page 252: ...easure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measureme...

Page 253: ...ung C Die Zylinder Me lehre 1 ver wenden Au erhalb des Grenzwertes Erneuern ANMERKUNG Die Zylinderbohrung C parallel A B C und im rechten Winkel zur Kurbel welle a b messen Danach den Durchschnitt der...

Page 254: ...oloration Replace 2 Measure 9Piston pin outside diameter Use micrometer 1 Out of limit Replace 3 Check 9Free play when the piston pin 1 is in place in the piston 2 There should be no noticeable for th...

Page 255: ...tre ext rieur d axe de piston 3 Pr fen 9 Spiel Wenn der Kolbenbolzen 1 im Kolben 2 eingebaut ist Es sollte kein sp rbares Spiel sein Spiel wird festgestellt Kolbenbolzen und oder Kolben erneuern 3 Con...

Page 256: ...arance Use a thickness gauge 1 Out of limit Replace piston and or ring NOTE Check at several points Ring end gap installed Standard Limit 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Side clearance St...

Page 257: ...orona del pistone 2 Misurare 9 Distanza tra le estremit Usare uno spessimetro 1 Fuori limite Sostituirla Standard Grenze 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Kolbenring Endspalt Eingebaut Stan...

Page 258: ...mm 2 61433 2 61441 in C 66 408 66 410 mm 2 61449 2 61457 in D 66 412 66 414 mm 2 61465 2 61472 in Piston mark a a color Piston size A red 66 352 66 355 mm 2 61228 2 61240 in B orange 66 356 66 359 mm...

Page 259: ...66 412 66 414 mm 2 61465 2 61472 in Tacca del Dimensioni pistone a a del pistone colore A rossa 66 352 66 355 mm 2 61228 2 61240 in B arancione 66 356 66 359 mm 2 61244 2 61256 in C verde 66 360 66 36...

Page 260: ...2 7 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 3 Combination Combin...

Page 261: ...ium Leistungsventilbohrung im Zylinder 1 Ausbauen 9 Ru ablagerungen Aus der Leistungsventil Boh rung a ANMERKUNG Kein scharfkantiges Instrument ver wenden Kratzer auf dem Aluminium vermeiden IC474901...

Page 262: ...e molybdenum disulfide oil on the power valve 1 2 Install 9Power valve 2 1 9Link rod 2 9Plain washer 3 9Screw link rod 4 NOTE Install the link rod with the cuts a in its arm ends fitting over the pins...

Page 263: ...ne sur le clapet de puissance 1 IC475000 MONTAGGIO E INSTALLAZIONE IC475192 Valvola di potenza 1 Installare 9 Valvola di potenza 1 1 9 Portavalvola 2 9 Bullone portavalvola 3 NOTA 9Montare la valvola...

Page 264: ...bdnum disulfide oil on the grooves in the pulleys 9Apply the lithium soap base grease on the oil seal lip 9Install the valve shaft with its cut b aligning with the thrust plate 7 and then rotate the v...

Page 265: ...tallare 9 Molla 1 1 9 Leva del biscottino 2 9 Puleggia 3 9 Molla 2 4 9 Rosetta 5 9 Gambo della valvola 6 NOTA 9Installare la molla 1 sulla leva del biscottino e quindi sul cilindro 9Installare la moll...

Page 266: ...the power valve cover 9Install the power valve cover so that the arrow mark b faces upward EC475233 Piston ring and piston 1 Install 9Piston ring 1 NOTE 9Take care not to scratch the piston or damage...

Page 267: ...le c t imprim du joint vers le couvercle du clapet de puissance 9Installer le couvercle du clapet de puissance en orientant vers le haut la saillie b l arri re 2 Installare 9 Guarnizione cilindro 1 9...

Page 268: ...hand NOTE After installing check the smooth movement of the piston 3 Install 9Nut cylinder 1 NOTE Tighten the nuts in stage using a crisscross pat tern 3 Install 9Piston 1 9Piston pin 2 9Piston pin cl...

Page 269: ...2 et la surface de cylindre IC475382 Testa cilindro e cilindro 1 Applicare 9 Olio per motori Sul pistone 1 sulla fascia ela stica 2 e sulla superficie del cilindro 35 Nm 3 5 m kg 25 ft lb 35 Nm 3 5 m...

Page 270: ...not used the power valve constituent parts will result in damage 5 Install 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 6 Install 9O ring 1 9Dowel pin 2 NOTE Apply t...

Page 271: ...ella valvola di potenza 1 9 Bullone corpo della valvola di potenza 2 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 25 Nm 2 5 m kg 18 ft lb 25 Nm 2 5 m...

Page 272: ...CYLINDER AND PISTON ENG 9 Install 9Spark plug 1 9Spark plug cap 2 8 Install 9Engine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 20 Nm 2 0 m kg 14 ft lb 34 Nm 3 4 m kg 24 ft lb 69 Nm...

Page 273: ...ela 1 9 Calotta della candela 2 8 Einbauen 9 Motorhalterung 1 9 Schraube Motorhalterung 2 9 Motor Befestigungsschraube Ober 3 8 Installare 9 Staffa del motore 1 9 Bullone staffa del motore 2 9 Bullone...

Page 274: ...Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Press...

Page 275: ...er 6 3 Kupplungsfeder 6 4 Druckscheibe 1 5 Reibscheibe 8 6 Kupplungsscheibe 7 KUPPLUNG UND PRIM RABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und Reibsch...

Page 276: ...al tool 7 Lock washer 1 Refer to REMOVAL POINTS 8 Clutch boss 1 9 Thrust plate D 44mm 1 73 in 1 10 Primary driven gear 1 11 Bearing 1 12 Thrust plate D 42mm 1 65 in 1 13 Bolt push lever axle 1 14 Push...

Page 277: ...bhebelachse 1 14 Schbhebelachse 1 PRIM RABTRIEBSZAHNRAD SHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Prim rab...

Page 278: ...ON EC484100 Clutch housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free pl...

Page 279: ...lten 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 em...

Page 280: ...2 EC484700 Push lever axle 1 Inspect 9Push lever axle 1 Wear Damage Replace EC484810 Push rod 1 Inspect 9Push rod 1 1 9Bearing 2 9Plain washer 3 9Push rod 2 4 Wear Damage Bend Replace EC495000 ASSEMB...

Page 281: ...quatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors sp cification Changer tous les disques d embrayage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Axe de levie...

Page 282: ...il on the bearing spacer and primary driven gear inner circumference 2 Install 9Thrust plate D 44 mm 1 73 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding to...

Page 283: ...Appliquer de l huile de bo te de vitesses sur le roulement l entretoise et la circonf rence int rieure du pignon men primaire 2 Monter 9 Plaque de bot e D 44 mm 1 73 in 1 9 Noix d embrayage 2 3 Monte...

Page 284: ...es and clutch plates 6 Install 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4 NOTE Apply the lithium soap base grease on the bear ing and plain washer 7 Install 9Push rod 2 1 9Push rod 1 2 NOTE...

Page 285: ...ottement 9Appliquer de l huile de bo te de vitesses sur les disques de friction et disque d embrayage 6 Monter 9 Roulement 1 9 Rondelle ordinaire 2 9 Circlip 3 sur le champignon de d brayage 1 4 N B A...

Page 286: ...9O ring 1 To clucth cover 11 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 12 Install 9O ring 1 9Clutch cable 2 NOTE Apply the lithium soap b...

Page 287: ...lithium sur le joint torique 10 Installare 9 Anello di tenuta 1 Verso la protezione della frizio ne 11 Einbauen 9 Kupplungsdeckel 1 9 Schraube Kupplungsdeckel 2 ANMERKUNG Die Schrauben stufenweise be...

Page 288: ...ect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4...

Page 289: ...ein 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 PISTON 1 Kick starter 1 2 Couverc...

Page 290: ...xle 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 9 Holder 1 10 Tension spring 1 1 Ex...

Page 291: ...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 renvoi de d marreur au pied...

Page 292: ...move 9Kick axle assembly 1 NOTE Unhook the torsion spring 2 from the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assemb...

Page 293: ...d marreur au pied 1 D poser 9 Ensemble axe de d marreur au pied 1 N B D crocher le ressort de torsion 2 de l orifice a sur le vilebrequin Ensemble guide de levier de s lecteur 1 D poser 9 Boulon guide...

Page 294: ...Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Bearing 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever 9Tension spring 3 Broken Replace EC4C4100 Shift gu...

Page 295: ...r Guide de s lecteur et ensemble levier de s lecteur 1 Examiner 9 Guide de s lecteur 1 9 Levier de s lecteur 2 9 Le cliquet 3 9 Le broche cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de bu...

Page 296: ...ft 2 Install 9Shift lever assembly 1 To shift guide 2 EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130...

Page 297: ...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 Ensemble levier de s lecteur 1 Au guide de s lecteur 2 3 Monter 9 Ensem...

Page 298: ...ke sure the stopper a of the torsion spring fits into the hole b on the kick axle EC4C5601 Kick axle assembly 1 Install 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer...

Page 299: ...Arbre de s lecteur 3 N B Enduire l arbre de s lecteur et les roule ments d huile de transmission Ensemble axe de d marreur au pied 1 Monter 9 Pignon de d marreur au pied 1 9 Rondelle ordinaire 2 9 Cir...

Page 300: ...all 9Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a in the spring guide fits on the stopper of the torsion spring 4 Install 9Plain washer 1 9Kick axle assembly 2...

Page 301: ...passen mu 3 Monter 9 Guide de ressort 1 N B Coulisser la guide de ressort dans l axe de d marreur au pied s assurer que la gorge a dans la guide de ressort soit engag e sur la but e du ressort de tor...

Page 302: ...olt primary drive gear 1 NOTE Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3 EC4C5531 Primary drive gear 1 Install 9Thrust plate 1 9Primary drive gear 2 9Gov...

Page 303: ...ent le boulon ce stade 2 Monter 9 Pignon men primaire Se reporter la section EMBRAYAGE ET PIGNON MENE PRIMAIRE 3 Serrer 9 Boulon pignon de transmission primaire 1 N B Mettre une plaque en aluminium a...

Page 304: ...connecting the center of the shift shaft and bottom of the screw crankcase cover left 3 7 Install 9Kick starter 1 9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not...

Page 305: ...a de montage du cou vercle d embrayage mais pas contre 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 tre ext rieur de l...

Page 306: ...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 307: ...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 308: ...ight 7 To governor shaft 8 NOTE Apply the lithium soap base grease on the thrust bearing EC4K3000 REMOVAL POINTS EC4K3100 Governor 1 Remove 9Dowel pin 1 NOTE While compressing the spring remove the do...

Page 309: ...delle ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTAGE 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 Co...

Page 310: ...fork b and set the governor in the crankcase cover 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 2 In...

Page 311: ...lle 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...

Page 312: ...PUMP DISASSEMBLY Preparation for Crankcase cover right Refer to KICK AXLE SHIFT SHAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller 1 3 Plain washer 1 Refer to REMOVA...

Page 313: ...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 314: ...panners etc and remove the impeller 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 c...

Page 315: ...it 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...

Page 316: ...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 317: ...anch 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 9Instal...

Page 318: ...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 impelle...

Page 319: ...t 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 ti...

Page 320: ...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 321: ...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 322: ...un terclockwise EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1 Remove 9Nut rotor 1 9Plain washer 2 Use the rotor holding tool 3 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect 9Rotor inner surface a 9Sta...

Page 323: ...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 MONTA...

Page 324: ...the CHAPTER 3 2 Install 9Woodruff key 1 9Rotor 2 NOTE 9Clean the tapered portions of the crankshaft and rotor 9When installing the woodruff key make sure that its flat surface a is in parallel with t...

Page 325: ...ler 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 In...

Page 326: ...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 327: ...rois 7 Connecter 9 Fil de magn to CDI 1 Se r f rer au paragraphe DIA GRAMME DE CHEMINE MENT DE CABLE au CHA PITRE 2 7 Anschlie en 9 Kabel des CDI Magnetz nders 1 Siehe Abschnitt KABELF H RUNGS BERSICH...

Page 328: ...D REED VALVE section Exhaust pipe and silencer Refer to EXHAUST PIPE AND Exhaust pipe stay rear SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug Di...

Page 329: ...ilencier Se reporter la section TUYAU D ECHAPPE Support de tuyau d chappement arri re MENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR Bougi...

Page 330: ...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 331: ...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 332: ...de of the swingarm to support it 2 Remove 9Engine 1 From right side NOTE Make sure that the couplers hoses and cables are disconnected EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1 Remove 9Nut dri...

Page 333: ...azionando 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 T...

Page 334: ...9Install the clip with its stopper portion a facing inward EC4M5000 ASSEMBLY AND INSTALLATION EC4M5123 Engine installation 1 Install 9Engine 1 Install the engine from right side 9Pivot shaft 2 9Engin...

Page 335: ...a 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 MONTA...

Page 336: ...ck washer tab to lock the nut 4 Install 9Chain guide 1 9Chain cover 2 9Screw chain cover 3 2 Install 9Lock washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 8 Nm 0 8 m...

Page 337: ...t 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 Guide cha ne 1 9 Couvercle de cha ne 2 9 Vis couvercle de cha ne 3...

Page 338: ...fer to CDI MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 50 mm 1 97 in 7 3 Bolt L 60 mm 2 36 in 1 4 Bolt L 70 mm 2 76 in 3 5 Holder 2 6 Crankcase right 1 Use special tool 7 Crankcase le...

Page 339: ...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 340: ...ating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a r...

Page 341: ...on fF Utiliser un maillet en plastique et ne taper que sur les portions renforc es du carter Ne pas taper sur les plans de joint Travailler lentement et avec pr caution en s assurant que les deux moit...

Page 342: ...e crankcase by pressing its inner race as shown in 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed beari...

Page 343: ...que le vilebrequin d poser le roulement en utilisant un extracteur de roulement 2 comme indiqu dans 9N utilisez pas le roulement d pos VERIFICATION Carter 1 Examiner 9 Surface de contact a Rayures Ch...

Page 344: ...4 1 0 mm 2 0 mm free play 0 016 0 039 in 0 08 in Side 0 25 0 75 mm clearance 0 010 0 030in Crank 59 95 60 00 mm width 2 360 2 362 in EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play...

Page 345: ...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 ANM...

Page 346: ...01274 Bolt 3 YU 90050 90890 01275 Adapter 4 YM 1277 90890 01277 2 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair B For USA and CDN Except for USA and CDN NOTE 9Hold the co...

Page 347: ...que le vilebrequin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer une graisse base de savon au lithium sur la l vre de la bague d tanch...

Page 348: ...hammer 9When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Install 9Bolt crankcase 1 NOTE Tighten the crankcase tightening bolts in stage using a crisscross...

Page 349: ...e 3 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 accouplement doit tre positionn e...

Page 350: ...he bolt 30 Nm 3 0 m kg 22 ft lb 7 Install 9Tension spring 1 9Holder 2 9Bolt holder 3 NOTE Install the holder so that it contacts the projec tion a on the crankcase right 10 Nm 1 0 m kg 7 2 ft lb 9 Rem...

Page 351: ...ra ge b 9Tourner le segment dans le sens des aiguilles d une montre jusqu ce qu il s arr te et resserrer le boulon 9 D poser 9 Etanch it Chass e sur le plan de joint du cylindre 10 Mettre 9 Huile mont...

Page 352: ...ne Refer to ENGINE REMOVAL section removal Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 2 Drive axle 1 3 Shift cam 1 4 Shift fork 3 1 Refer to REMOVAL POINTS 5 Shift...

Page 353: ...i ce Q t Remarques DEPOSE DE LA BOITE A VITESSES DU BARILLET 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...

Page 354: ...9Gear teeth b 9Shift fork groove c Wear Damage Replace EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1 Remove 9Main axle 1 9Drive axle 2 9Shift cam 9Shift fork 3 9Shift fork 2 9Shift fork 1 NOTE 9Rem...

Page 355: ...pal l axe moteur le barillet du s lecteur et la fourchette du s lecteur ensemble en tapotant l g rement sur l arbre de transmission l aide d un marteau t te en caoutchouc VERIFICATION Pignons 1 Examin...

Page 356: ...h pinion gears inner circumference and on the end surface 9Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumference 3 Check 9Shift fork movement Unsmooth operation Replac...

Page 357: ...hette 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 21D 1 9 Pignon de 3 18D 2 9 Collerette 3 9 Pignon de 4 22D 4 9 Pi...

Page 358: ...clip 2 NOTE 9Be sure the circlip sharp edged corner a is positioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 2 Install 92nd wheel g...

Page 359: ...uer de 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...

Page 360: ...on the shift fork grooves 9Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle 9Mesh the shift fork 2 C10 with the 3rd pinion gear 6 on the main axle...

Page 361: ...incipal 5 Installare 9 Forcella del cambio 1 L 1 9 Forcella del cambio 2 C10 2 9 Forcella del cambio 3 R 3 9 Camma del cambio 4 Sull asse principale e l asse motore NOTA 9Applicare olio a base di biso...

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

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: ...he machine by placing the 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 O...

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: ...Mesure 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 l...

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: ...te 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 d...

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: ...ant 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...

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: ...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 Serrer 9 Boulon support d axe 1 N B Avant de serrer le boulon embo ter l axe de la roue d...

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: ...de 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 ra...

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: ...to 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 lit...

Page 378: ...her 2 9Nut wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axl...

Page 379: ...lle ordinaire 2 9 Ecrou axe de roue 3 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 tem...

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: ...pad pin 2 Pad pin 1 Loosen when disassembling the caliper 3 Caliper 1 4 Brake hose holder 2 5 Union bolt 2 6 Brake hose 1 7 Brake pedal 1 8 Reservoir tank 1 9 Reservoir hose 1 10 Master cylinder 1 Ext...

Page 383: ...rs du d montage de l trier 3 Etrier 1 4 Support de tuyau de frein 2 5 Boulon d union 2 6 Tuyau de frein 1 7 P dale de frein 1 8 R servoir de r serve 1 9 Tuyau de r serve 1 10 Ma tre cylindre 1 Pr para...

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: ...ylinder 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 Rea...

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: ...DI RIMOZIONE IC5A3100 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Tappo del serbatoio 1 9 Dispositivo di protezione NOTA Non togliere il diafram...

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: ...fluid on the piston wall cC 9For the front caliper install the piston with its depressed side a a facing the caliper For the rear caliper install the pis ton with its shallow depressed side b b fac in...

Page 395: ...enuta 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 parapolvere sulla fessura sulla pinza i...

Page 396: ...nstall 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...

Page 397: ...a 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 G...

Page 398: ...C Install the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper projection b b 7 Nm 0 7 m kg 5 1 ft lb 30 Nm 3 0 m kg 22 ft lb 4 Inst...

Page 399: ...soit orient e vers l trier et que le conduit soit en contact avec la saillie b b de l trier 4 Monter 9 Etrier 1 9 Roue arri re 2 Se reporter la section ROUE AVANT ET ROUE ARRIE RE 5 Serrer 9 Goupille...

Page 400: ...imary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong...

Page 401: ...t au c t du diam tre plus petit A Avant B Arri re 2 Einbauen 9 Hauptbremszylinderkoppe Prim r 1 9 Hauptbremszylinderkoppe Sekund r 2 Zum Hauptbremszylinderkol ben 3 ANMERKUNG Bremsfl ssigkeit auf der...

Page 402: ...ster 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 Front B Rear EC5A5310 Front master cylinder 1 Install 9Ma...

Page 403: ...e au lithium sur l extr mit du champignon de d brayage 9Pour mettre le circlip en place utiliser des pinces de circlip long nez A Avant B Arri re Ma tre cylindre avant 1 Monter 9 Ma tre cylindre 1 9 E...

Page 404: ...master cylinder piston EC5A5400 Rear master cylinder 1 Install 9Reservoir hose 1 9Reservoir tank 2 NOTE Pass the reservoir hose into the hose guide 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb 10...

Page 405: ...e frein 2 9 Joint torique 3 9 Boulon p dale de frein 4 9 Agrafe 5 N B 9Appliquer de la graisse base de savon au lithium sur le boulon le joint torique et le support de p dale de frein 9Mettre le colli...

Page 406: ...fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 2 Install 9Hose cover 1 9Plain washer 2 9Bolt hose cover M8 3 9Bolt hose cover M6 4 10 Nm 1 0 m kg 7 2 ft lb 16...

Page 407: ...e du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 2 Monter 9 Couvercle de tuyau 1 9 Rondelle ordinaire 2 9 Boulon couvercle de tuyau M8 3 9 Boulon couver...

Page 408: ...o that its pipe por tion a a directs as show and lightly touches the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 4 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use n...

Page 409: ...tre cylindre Tuyau de frein arri re 1 Monter 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...

Page 410: ...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 411: ...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 fonction...

Page 412: ...gm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Reservoir tank cap 1 9Bolt reservoir tank 2 cC After installation while pulling the lever in or pushing down on the pedal check...

Page 413: ...te 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale 2 Posteriormente 9 Diaframma 9 Tappo del serbatoio 1 9 Bullone serbatoio 2 iI Dopo l installazione tirand...

Page 414: ...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 415: ...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 416: ...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 417: ...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 418: ...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 419: ...rang 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 av...

Page 420: ...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 421: ...ange 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 Vorderradg...

Page 422: ...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 423: ...leur 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 Exami...

Page 424: ...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 425: ...lement 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...

Page 426: ...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 427: ...it 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...

Page 428: ...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 429: ...belbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 11 Ausbauen 9 Anschlagring 1 ANMERKUNG Den Anschlagring richtig in die Nut des u eren Rohres...

Page 430: ...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 431: ...chten 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 l...

Page 432: ...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 433: ...e 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...

Page 434: ...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 435: ...t de 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 fourch...

Page 436: ...set 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 t...

Page 437: ...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 gler...

Page 438: ...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 439: ...in 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...

Page 440: ...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 441: ...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 442: ...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 443: ...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 444: ...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 445: ...9 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 Poi...

Page 446: ...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 447: ...9Avant 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 che...

Page 448: ...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 449: ...R 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...

Page 450: ...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 451: ...rayage 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...

Page 452: ...5 46 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 453: ...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 454: ...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 EC560000 STEERI...

Page 455: ...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 456: ...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 457: ...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 458: ...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 459: ...E Etrier 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 Cag...

Page 460: ...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 461: ...a 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 462: ...ing 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 c...

Page 463: ...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 lo...

Page 464: ...ke pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swing...

Page 465: ...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 466: ...Collar 2 5 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...

Page 467: ...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 468: ...h 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574210 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolut...

Page 469: ...2 Freies Spiel besteht Unrunde Drehung Rost Lager und Buchse als Satz erneuern 2 Pr fen 9 ldichtung 3 Besch digung Erneuern Relaisarm 1 Pr fen 9 Lager 1 9 H lse 2 Freies Spiel besteht Unrunde Drehung...

Page 470: ...l 9Bearing 1 9Oil seal 2 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numb...

Page 471: ...o 1 9 Paraolio 2 Sul braccio di rinvio NOTA 9Applicare il grasso a base di bisolfuro di molibdeno sul cuscinetto durante l installazione 9Installare il cuscinetto premendolo sul lato che riporta le ma...

Page 472: ...gs and oil seal lips 3 Install 9Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the collar bearings and oil seal lips 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Pla...

Page 473: ...olfuro di molibdeno sui bordini sui cuscinetti e sui labbri del paraolio 3 Installare 9 Bordino 1 Sulla leva di rinvio 2 NOTA Applicare il grasso a base di bisolfuro di molibdeno sul bordino sui cusci...

Page 474: ...9Swingarm side play a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars 8 Install 9Bolt conn...

Page 475: ...ntr ler 9 Jeu lat ral du bras oscillant a Il y a jeu fonctionnel Remplacer le roulement de bu t e 9 Mont e et descente du bras os cillant b Mouvement irr gulier coince ment point dure Graisser ou chan...

Page 476: ...9Bolt chain tensioner lower 1 9Plain washer 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support R 50mm 1 97in 3 9Nut chain supp...

Page 477: ...eriore 5 14 Installare 9 Supporto della catena 1 9 Copertura del supporto 2 9 Bullone supporto della catena 50 mm 1 97 in 3 9 Dado supporto della catena 4 9 Bullone copertura del supporto 10 mm 0 39 i...

Page 478: ...joint 1 Loosen the screw air cleaner joint 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 7 Adjuster 1...

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: ...cage 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 F...

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: ...eur 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 re...

Page 486: ...on the 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 le...

Page 487: ...nt antipoussi re 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 join...

Page 488: ...the molybdenum disulfide grease on the bolt 5 Install 9Plain washer 1 9Bolt rear shock absorber relay arm 2 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Insert the bolt from right side 6 I...

Page 489: ...n amortisseur arri re bras de relais 2 N B 9Appliquer de la graisse de molybd ne sur le boulon 9Ins rer le boulon partir de la droite 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re 2 7 Serrer 9 Vis...

Page 490: ...EC611000 ELECTRICAL COMPONENTS 1 CDI unit 2 ENGINE STOP button 3 Ignition coil 4 TPS throttle position sensor 5 Solenoid valve 6 CDI magneto 7 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black L B...

Page 491: ...GE COMPOSANTS ELECTRIQUES 1 Bloc CDI 2 Bouton d arr t du moteur ENGINE STOP 3 Bobine d allumage 4 TPS capteur de position du papillon 5 Electrovanne 6 Magn to CDI 7 Bougie CODE DE COULEUR B Noir L Ble...

Page 492: ...Check entire ignition 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 mag...

Page 493: ...bloc CDI Changer Changer Changer Changer Changer Indication Seulement quand le contr leur d allumage et utilis N B 9D poser les pi ces suivantes avant de proc der au d pistage des pannes 1 Selle 2 R...

Page 494: ...rollieren CDI Einheit erneuern Erneuern Erneuern Erneuern Erneuern Erneuern Markierung Nur wenn das Z ndungspr fger t verwendet wird ANMERKUNG 9Die folgenden Teile vor Beginn der St rungsbeseitigung a...

Page 495: ...uirla Sostituirla Sostituirla Sostituirla contrassegnato Soltanto quando viene usato l apparecchio per il controllo dell accensione NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 S...

Page 496: ...e and increase spark gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or...

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: ...I MAGNETO INSPECTION 1 Inspect 9Pick up coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Orange lead 2 Primary...

Page 499: ...bobine d excita tion Hors sp cification Changer IC626002 ISPEZIONE DELLA BOBINA DI ACCENSIONE 1 Ispezionare 9 Resistenza della bobina prima ria Fuori specifica Sostituirla 2 Ispezionare 9 Resistenza d...

Page 500: ...N Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Black Red lead 1 Tester lead Black lead 2 Source coil 1 Tester select...

Page 501: ...non si rileva alcun guasto sostituire l unit CDI Quindi ricontrollare i com ponenti elettrici Resistenza Posizione della bobina del selettore sorgente 1 del tester 720 1 080 a 100 20 C 68 F Conduttor...

Page 502: ...od Replace Check CDI magneto Replace CDI unit No good EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate use the following inspection steps marked Refer to...

Page 503: ...magn to CDI Changer le bloc CDI Mauvais SYSTEME D ELECTROVANNE ETAPES DE VERIFICATION Si l lectrovanne ne fonctionne pas applicuez la proq dure d inspection suivante Indication Se reporter la section...

Page 504: ...le Erneuern CDI Magnetz nder kontrollieren CDI Einbeit erneuern Nicht in Ordnung MAGNETVENTILSYSTEM PR FVORG NGE Falls das Magnetventil nicht funktioniert sind die folgenden berpr fungen durchzuf hren...

Page 505: ...unziona Sostituirlo Controllare magnete CDI Sostituire unit CDI Non funziona IC650001 SISTEMA ELETTROVALVOLA IC651032 OPERAZIONI DI ISPEZIONE Se l elettrovalvola non funziona effettuare i seguenti con...

Page 506: ...olenoid valve coupler 2 Connect 12V battery to the solenoid valve coupler 3 Inspectt 9Solenoid valve 1 No click when connecting the battery Replace EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect 9S...

Page 507: ...4000 ISPEZIONE DEL COLLEGAMENTO DI ACCOPPIATORI E CONDUTTORI 1 Controllare 9 Collegamento di accoppiatori e conduttori Ruggine Polvere Allentamen to Cortocircuito Ripararli o sostituirli IC652040 FUNZ...

Page 508: ...Replace Check CDI unit No good EC690000 TPS THROTTLE POSITION SENSOR SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate use the following inspection steps marked Refer to IGNITION SYSTEM sec...

Page 509: ...u d pistage des pannes 1 Selle 2 R servoir essence 9Utiliser les outils sp ciaux suivants dans ce d pistage des pannes Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 Tester de poche Y...

Page 510: ...bauen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge f r die St rungsbeseitigung verwenden Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 Taschenpr fger t YU 3112 C 90890 03112 I...

Page 511: ...ma dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9 In questa ispezione usare i seguenti utensili speciali Contagiri induttivo YU 8036 B Contagiri del motore 90890 031...

Page 512: ...9TPS coil resistance Out of specification Replace 3 Inspect 9TPS coil variable resistance Check that the resistance in increased as the lever 1 is moved from the full close position to the full open...

Page 513: ...stand Pr fen ob der Widerstand sich erh ht wenn der Hebel 1 vom vollst ndig geschlossenen Stand in den vollst ndig ge ff neten Stand bewegt wird Abweichung von Spezifikation Erneuern 2 Ispezionare 9...

Page 514: ...lain washer 2 9TPS 3 NOTE Loosen the screws using the T20 bit tamper resistant fastener type 3 Replace 9TPS 4 Install 9TPS 1 9Plain washer 2 9Screw TPS 3 NOTE 9Align the slot a in the TPS with the pro...

Page 515: ...ti usando la punta T20 tipo di dispositivo di fissaggio resi stente alla manomissione 3 Changer 9 TPS 3 Erneuern 9 TPS 3 Sostituire 9 TPS 4 Monter 9 TPS 1 9 Rondelle ordinaire 2 9 Vis TPS 3 N B 9Align...

Page 516: ...resistance 10 Adjust 9TPS coil resistance at idle speed Idle speed for TPS adjustment 1 700 1 900 rpm Adjustment steps 9Set the inductive tachometer engine tachometer to the high tension cord 9Turn th...

Page 517: ...tours induction compte tours du moteur sur le c ble haute tension 9Tourner la vis de but e d acc l rateur 1 jusqu obtention du r gime de ralenti sp cifi Se reporter la section REGLA GE DU RALENTI dans...

Page 518: ...the T20 bit tam per resistant fastener type by aligning the marks a that were put before removal 14 Install 9Carburetor Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 EC694000 TPS INPUT V...

Page 519: ...e 9 Vite TPS 1 NOTA Serrare le viti usando la punta T20 tipo di dispositivo di fissaggio resistente alla manomissione e allineando le indica zioni a di posizione segnate prima dello smontaggio 14 Inst...

Page 520: ...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 ro...

Page 521: ...de 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 cond...

Page 522: ...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 523: ...bougie s A Normale B Surbr l e 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 os...

Page 524: ...ating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Standard main jet 178 180 EC71V000 Powet jet adjustment The richn...

Page 525: ...lectionner un gicleur principal avec un num ro de calibrage sup rieur la norme Pour enrichir 2 La bougie est mouill e S lectionner un gicleur principal avec un num ro de calibrage inf rieur la norme...

Page 526: ...intermediate speed operation irregular engine operation and poor acceleration will result Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and...

Page 527: ...regolazione si cam bia il getto pilota 1 Un getto di dimensioni maggiori d una miscela pi ricca a bassi regimi e uno di dimensioni pi piccole d una miscela pi povera IC718001 Regolazione della posizio...

Page 528: ...ck up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pic...

Page 529: ...icht glatt beschleunigt werden In diesem Fall die D sennadelklam mer um eine Nut h her positionie ren und die D sennadel absenken um ein magereres Gemisch zu erhalten 2 Zu mager bei mitteleren Dreh za...

Page 530: ...starting position c Rich d Lean 2 Effects of changing the jet needle reference 9 Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throt...

Page 531: ...tre de la partie droite ajuste le m lan ge air carburant lorsque l ouverture des gaz est compri se entre 1 8 et 1 4 9 Position de d part de c ne Diff rence d une demi rainure Riche N3EJ 3e rainure N3C...

Page 532: ...position c Rich d Lean 2 Effects of changing the jet needle reference 9 Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throttle is 1...

Page 533: ...e la partie droite ajuste le m lan ge air carburant lorsque l ouver ture des gaz est comprise entre 1 8 et 1 4 9 Position de d part de c ne Diff rence d une demi rainure Riche N3CW 4e rainure N3EW 3e...

Page 534: ...ottle opening whereas around 1 4 to 1 1 throttle opening it relates to the taper starting position and to the clip position Therefore the fuel flow is balanced at each stage of throttle opening by the...

Page 535: ...tion de l agrafe Par cons quent l coulement du carbu rant est quilibr chaque tape de l ouverture du papillon par la combinai son du diam tre de la portion droite du papillon et de sa position de d par...

Page 536: ...4MX 14948 12 60 4MX 14948 11 58 4MX 14948 10 STD 55 4MX 14948 09 52 4MX 14948 08 STD 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 Lean 40 4SR 14948 03 Jet needle 3 3 Rich N3EW 4SR 1...

Page 537: ...o 165 4MX 14943 40 Povera No 162 4SR 14943 90 Getto Ricca No 62 4MX 14948 12 pilota No 60 4MX 14948 11 2 2 No 58 4MX 14948 10 STD No 55 4MX 14948 09 No 52 4MX 14948 08 STD No 50 4MX 14948 07 No 48 4MX...

Page 538: ...athing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Clip position indicates the position of Slow speed pick up 1 groove up jet needle groove to which the clip is White s...

Page 539: ...needle clip position range of low to If no effect reverse the above intermediate speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly U...

Page 540: ...tion de fixation de l aiguille de gicleur 1 rainure plus haut Abaisser la position de fixation de l aiguille de gicleur 1 rainure plus bas Elever la position de fixation de l aiguille de gicleur 1 rai...

Page 541: ...nverser les proc dures mentionn es ci dessus Contr ler tous les r glages d ensemble Utiliser un gicleur principal avec un n de calibrage inf rieur Elever la position de fixation de l aiguille de gicle...

Page 542: ...sch Wei liche Z ndkerze Mageres gemisch Bei Vollgas Drehzahl wird nicht erh ht Drehzahl wird nur langsam erh ht Langsames Ansprechen Verru te Z ndkerze Fettes Gemisch Mageres Gemisch Fettes Gemisch 1...

Page 543: ...Klemmenposition erh hen Falls keine Wirkung die obigen Vorg nge umkehren Gesamteinstellungen berpr fen Hauptd se mit niedrigerer Kalibrierungs Nr verwenden D sennadel Klemmenposition erh hen 1 Nut h...

Page 544: ...ndizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Scolorimento della candela Se color cuoio in buone...

Page 545: ...re al contrario le procedure sopra descritte Controllare le registrazioni generali Usare un getto principale che abbia un No di taratura pi basso Alzare la posizione del fermaglio a graffa dell ago a...

Page 546: ...bration 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 su...

Page 547: ...chang par 30 il est recommand 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...

Page 548: ...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 549: ...terminer 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 vita...

Page 550: ...th the road surface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 13T 9383E 13144 STD 14T 9383E 14215 Dr...

Page 551: ...00 52T 5ET 25452 00 Pression des pneus standard 100 kPa 1 0 kg cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kg cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kg cm2 9 0 12 psi Reifendruck Der...

Page 552: ...ing 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 prod...

Page 553: ...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 554: ...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 555: ...egolazione 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 convien...

Page 556: ...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 557: ...nt une perte de sensation de contact avec la surfa ce de la route ou un guidonnage R glage d un ressort dur 9 R gler la force de rebond Visser d un ou deux d clics 9 R gler la force de compression D v...

Page 558: ...proved on the end of the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 380 4SS 23141 10 I I 0 390 4SS 23141 20 I II SOFT 0 400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50...

Page 559: ...400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50 II STD 0 430 4XL 23141 L0 HART 0 440 4SS 23141 70 IIII IC72P010 Parti di regolazione della forcella anteriore 9Rondella di regolazione 1...

Page 560: ...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 561: ...llen 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 F...

Page 562: ...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 563: ...ner 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 weiche...

Page 564: ...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 565: ...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 566: ...LENGTH SOFT 4 4 5DH 22212 70 Brown 1 260 4 6 5DH 22212 10 Green 1 260 STD 4 8 5DH 22212 20 Red 1 260 5 0 5DH 22212 30 Black 1 260 STIFF 5 2 5DH 22212 40 Blue 1 260 5 4 5DH 22212 50 Yellow 1 265 5 6 5...

Page 567: ...1 260 HART 5 2 5DH 22212 40 Blau 1 260 5 4 5DH 22212 50 Gelb 1 265 5 6 5DH 22212 60 Rosa 1 265 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4 4 5DH 22212 70 Marrone 1 260 4 6 5DH 22212 10 Ver...

Page 568: ...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 569: ...d 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 decrea...

Page 570: ...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 571: ...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 572: ...ge 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 sicht...

Page 573: ...D 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 steige...

Page 574: ...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 575: ...ire lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aume...

Page 576: ...TUN MEMO...

Page 577: ......

Page 578: ...PRINTED IN JAPAN 2000 7 1 2 1 E F G I PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YZ250 N LC...

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