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Yamaha YZ250(W)/W1, Owner'S Service Manual


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2-5

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Thread size

Q’ty

T ightening torque

Nm

m•kg

ft•lb

Spark plug

M14S

×

1.25

1

20

2.0

14

Cylinder head

(nut)

M  8 

×

1.25

6

25

2.5

18

(stud)

M  8 

×

1.25

6

13

1.3

9.4

Cylinder

(nut)

M10 

×

1.25

4

42

4.2

30

(stud)

M10 

×

1.25

4

13

1.3

9.4

Power valve :

Holder

M  5 

×

0.8

2

6

0.6

4.3

Link rod

M  5 

×

0.8

2

6

0.6

4.3

Push rod

M  5 

×

0.8

1

5

0.5

3.6

Thrust plate

M  5 

×

0.8

1

6

0.6

4.3

Side holder

M  5 

×

0.8

4

4

0.4

2.9

Link lever

M  4 

×

0.7

1

4

0.4

2.9

Pulley

M  4 

×

0.7

2

4

0.4

2.9

Cover

M  5 

×

0.8

4

4

0.4

2.9

Governor fork

M  4 

×

0.7

2

5

0.5

3.6

Housing 

M  5 

×

0.8

4

5

0.5

3.6

Impeller

M  8 

×

1.25

1

14

1.4

10

Water pump housing cover

M  6 

×

1.0

4

10

1.0

7.2

Coolant drain bolt

M  6 

×

1.0

1

10

1.0

7.2

Radiator

M  6 

×

1.0

6

10

1.0

7.2

Radiator panel

M  6 

×

1.0

2

10

1.0

7.2

Radiator hose clamp

M  6 

×

1.0

8

2

0.2

1.4

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

4

8

0.8

5.8

Air filter guide clamp

M  5 

×

0.8

1

1

0.1

0.7

Reed valve

M  3 

×

0.5

4

1

0.1

0.7

Throttle cable adjust bolt and locknut

M  8 

×

1.25

1

7

0.7

5.1

Throttle cable

M  6 

×

0.75

1

4

0.4

2.9

Exhaust pipe (front)

M  6 

×

1.0

1

14

1.4

10

Exhaust pipe (rear)

M  6 

×

1.0

1

12

1.2

8.7

Exhaust pipe stay (front)

M  8 

×

1.25

1

25

2.5

18

Exhaust pipe stay (rear)

M  6 

×

1.0

1

12

1.2

8.7

Silencer:

Silencer and fram

M  6 

×

1.0

2

12

1.2

8.7

Fiber (For USA and CDN)

M  6 

×

1.0

2

10

1.0

7.2

Fiber (Except for USA and CDN)

M  6 

×

1.0

4

10

1.0

7.2

Crankcase

M  6 

×

1.0

11

14

1.4

10

Crankcase cover (left)

M  6 

×

1.0

5

5

0.5

3.6

Chain cover

M  6 

×

1.0

2

5

0.5

3.6

Crankcase cover (right)

M  6 

×

1.0

9

10

1.0

7.2

Bearing plate cover (drive axle left)

M  6 

×

1.0

2

10

1.0

7.2

Bearing plate cover (main axle right)

M  6 

×

1.0

2

10

1.0

7.2

Holder

M  6 

×

1.0

2

10

1.0

7.2

Oil drain bolt

M12 

×

1.5

1

23

2.3

17

Oil check bolt

M  6 

×

1.0

1

10

1.0

7.2

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

 1P8-9-32-2  4/29/06 11:45 AM  Page 6

Summary of Contents for YZ250(W)/W1

Page 1: ...FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 W W1 1P8 28199 32 PRINTED IN JAPAN 2006 5 1 3 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED...

Page 2: ...y Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC01001...

Page 3: ...maha Motor Co Ltd 1 Ausgabe Mai 2006 Alle Rechte vorbehalten Nachdruck auch auszugsweise oder nicht autorisierte Verwendung sind ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet G...

Page 4: ...ign and quality Therefore while this manual contains the most current product infor mation available at the time of printing there may be minor discrepancies between your machine and this manual If yo...

Page 5: ...en permanence d am liorer la conception ainsi que la qualit de ses produits Par cons quent m me si ce manuel contient les toutes derni res informations sur les produits disponibles lors de l impressi...

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: ...CTEUR 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 pro...

Page 8: ...QUATE VENTILATION Never start the engine or let it run for any length of time in an enclosed area Exhaust fumes are poisonous These fumes contain carbon monoxide which by itself is odorless and colorl...

Page 9: ...ourner 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 ga...

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: ...L 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 veicolo Si...

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: ...tre 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 compre...

Page 14: ...W2 M W2 M W2 0Y hf O 0M O 0Y O 0Y he O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W...

Page 15: ...er 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 chiffr...

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: ...Serrage 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 lubrifi...

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 ALLGEMEINE ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHNISCHE DATEN REGELM SSIGE PR FUNG UND EINSTELLUNGEN MOTEUR MOTOR PARTIE CYCLE FAHRGESTEL...

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: ...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 13 DEFI...

Page 22: ...RY DRIVEN GEAR 4 33 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 40 YPVS GOVERNOR 4 49 WATER PUMP 4 52 CDI MAGNETO 4 56 ENGINE REMOVAL 4 60 CRANKCASE AND CRANKSHAFT 4 65 TRANSMISSION SHIFT CAM AND S...

Page 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 40 REGULATEUR YPVS 4 49 POMPE A EAU 4 52 MAGNETO CDI 4 56 DEPOSE DU MOTEUR 4 60 CARTER ET VILEBREQUIN 4 65 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 7 TPS THROTTLE POSITION SENSOR SYSTEM 6 9 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 12...

Page 25: ...COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 SYSTEME D ALLUMAGE 6 2 SYSTEME D ELECTROVANNE 6 7 SYSTEME TPS CAPTEUR DE POSITION DU PAPILLON 6 9 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 12...

Page 26: ...k cap 7 Kick starter 8 Fuel tank 9 Radiator 0 Coolant drain bolt q Check bolt Transmission oil level w Rear brake pedal e Valve joint r Fuel cock t Starter knob y Drive chain u Air cleaner i Shift ped...

Page 27: ...tr 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...

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: ...um 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 fourch...

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

Page 31: ...ces sont correctement 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 be...

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 dass 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 ld...

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: ...lbaums 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 Connect...

Page 38: ...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 01235 Rotor holding tool YU 1235 90890 01235 Thi...

Page 39: ...he fork oil seal YU 3112 C 90890 03112 Yamaha pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 9089...

Page 40: ...uin de l une ou l autre de ses moiti s YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose du volant magn tique YM 1189 90890 01189 YU 1235 90890 01...

Page 41: ...e et l intensit YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 90890 85505 Outil de poign e d brrayage Cet outil est utilis pour immobiliser l embrayage quand on d pos ou monte l crou...

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

Page 43: ...nung und der Strom st rke zu verwenden YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 90890 85505 Kupplung Halterwerkzeug Dieses Werkzeug wird f r das Festhalten der Kupp lung verwend...

Page 44: ...1135 A 90890 01135 YM 1189 90890 01189 Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 01189 YU 1235 90890 01235 Utensile di supporto del rotore Quep...

Page 45: ...t di corrente YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 90890 85505 Utensile per tenere la frizione Questo utensile viene usato per tenere la frizione quan do si toglie o si inst...

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

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: ...TAND This sidestand 1 is used to support only the machine when standing or transporting it w 9Never apply additional force to the side stand 9Remove this sidestand before starting out EC15f000 SET PIN...

Page 51: ...carburante fuoriesca ed installato sullo sfiato del serbatoio del carburante iI In questa installazione assicurarsi che la freccia sia rivolta verso il ser batoio del carburante e anche verso il bass...

Page 52: ...ine or higher octane grade cC Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl...

Page 53: ...RBURANTE E OLIO PER MISCELA PER 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 No...

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: ...r 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 zwei Minuten ben tigt 5 Der Motor ist warmgela...

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: ...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 r...

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: ...nn eines der folgenden Teile erneuert wurde dann muss die Maschine wiederum eingefahren werden ZYLINDER UND KURBELWELLE Etwa eine Stunde Einfahrzeit ist erforderlich KOLBEN KOLBENRING UND ZAHNR DER Di...

Page 60: ...Link to swingarm Rear Installation of shock Shock absorber to frame absorber Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tighteni...

Page 61: ...adre 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 Serrage de l arbre de pivot...

Page 62: ...nterradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradschwinge Rad Einbau des Rades Vorn Festziehen der Vorderachse Festziehen...

Page 63: ...Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione della ruota Anteriore Serraggio dell asse anteriore Serra...

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: ...ngement 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 2 10 9 1 For USA and CDN 8 9 10 6 1 For EUROPE AUS NZ and...

Page 69: ...assis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 26 9 27 1 Trail 115 mm 4 53 in 118 mm 4 65 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90 19 62M Tire pressu...

Page 70: ...0 7087 in 0 7077 in Piston ring Sectional sketch Plain B 1 0 mm 0 039 in T 2 55 mm 0 100 in End gap installed 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...

Page 71: ...urer PWK38S KEIHIN I D mark 1P89 60 1P86 40 1P87 50 Main jet M J 178 180 178 Main air jet M A J 200 Jet needle clip position J N N3EW 2 N3EW 3 N3EW 2 Main nozzle N J 2 9 Cutaway C A 7 Pilot jet P J 50...

Page 72: ...mp M 6 1 0 8 2 0 2 1 4 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 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 1 0 1 0 7 Reed valve M 3 0 5 4...

Page 73: ...h boss M20 1 0 1 75 7 5 54 Clutch spring M 6 1 0 6 10 1 0 7 2 Clutch cable adjust bolt and locknut M 6 0 75 1 4 0 4 2 9 Push lever axle M 5 0 8 1 6 0 6 4 3 Drive sprocket M20 1 0 1 75 7 5 54 Shift gui...

Page 74: ...9 in Front fork top end Zero mm Zero in Rear suspension USA CDN ZA EUROPE AUS NZ Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length One I D mark 253 mm 9 9...

Page 75: ...0 12 in 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc...

Page 76: ...ke lever mounting bolt Brake lever mounting nut Brake lever position locknut Cable guide front brake hose and under bracket Front brake hose union bolt master cylinder Front brake hose union bolt cali...

Page 77: ...me lower Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Cable guide and frame Fuel tank mounting boss and frame Fue...

Page 78: ...2 11 MAINTENANCE SPECIFICATIONS SPEC MEMO...

Page 79: ...ncer type Electrical CDI Magneto model stator Manufacturer 5CU 20 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 B...

Page 80: ...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 81: ...res 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 2 10 9 1 Pour USA et CDN 8 9 10 6 1 Pour EUROPE AUS NZ et ZA Syst me de...

Page 82: ...NZ EUROPE CDN Type de cadre Simple berceau d d double Angle de chasse 26 9 27 1 Chasse 115 mm 4 53 in 118 mm 4 65 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Taille de pne...

Page 83: ...piston 17 995 18 000 mm 17 975 mm 0 7085 0 7087 in 0 7077 in Segment Forme du segment Plat en coupe B 1 0 mm 0 039 in 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...

Page 84: ...IHIN Marque d identification 1P89 60 1P86 40 1P87 50 Gicleur principal M J 178 180 178 Gicleur d air M A J 200 Aiguille J N N3EW 2 N3EW 3 N3EW 2 Tubulure principal N J 2 9 Echancrure C A 7 Gicleur de...

Page 85: ...air M 6 1 0 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 4 8 0 8 5 8 Bride de guidage de filtre air M 5 0 8 1 1 0 1 0 7 Soupape flexible M 3 0 5 4 1 0 1 0 7 Bou...

Page 86: ...rt d embrayage M 6 1 0 6 10 1 0 7 2 Boulon de r glage et contre crou de c ble d embrayage M 6 0 75 1 4 0 4 2 9 Axe de levier de 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...

Page 87: ...Z ro mm Z ro in Suspension arri re USA CDN ZA AUS NZ EUROPE D battement d amortisseur 131 5 mm 5 18 in Longueur de ressort libre Approx 265 mm 10 43 in Longueur de raccord Une marque d identification...

Page 88: ...in Epaisseur de plaquette 4 4 mm 0 17 in 1 0 mm 0 04 in Dia int rieur de ma tre cylindre 11 0 mm 0 433 in Dia int rieur de cylindre d etrier 27 0 mm 1 063 in 2 Type de liquide de frein DOT 4 Frein di...

Page 89: ...e tuyau de frein 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 et arri re et vis de purge Axe de...

Page 90: ...age du r servoir de carburant et cadre Montage de r servoir essence R servoir essence et robinet essence R servoir essence et patte de maintien R servoir essence et vis d accrochage bande de fixation...

Page 91: ...ge de pare boue arri re arri re Plaque d immatriculation M 6 1 0 M 6 1 0 M 6 1 0 M 6 1 0 Pi ce serrer Taille de filetage Q t Couple de serrage Nm m kg ft lb 4 2 2 1 7 7 12 7 0 7 0 7 1 2 0 7 5 1 5 1 8...

Page 92: ...ce Electrique CDI Magn to mod le stator Fabricant 5CU 20 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 couleu...

Page 93: ...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 94: ...Benzin Zylinder Ein Zylinder nach vorn 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 2 10 6 1 F r USA und CDN 8 9 10 6 1 F r EUROPA AUS...

Page 95: ...1 0 952 Fahrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 26 9 27 1 Nachlaufbetrag 115 mm 4 53 in 118 mm 4 65 in Reifengr e Bauart Mit Schlauch Reifengr e vorn 80 10...

Page 96: ...m 17 975 mm 0 7085 0 7087 in 0 7077 in Kolbenring Querschnitt Zylindrisch B 1 0 mm 0 039 in T 2 55 mm 0 100 in Ringenspalt Eingebaut 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Seitliches Spiel Einge...

Page 97: ...PWK38S KEIHIN Identifikationsmarkierung 1P89 60 1P86 40 1P87 50 Hauptd se M J 178 180 178 Hauptluftd se M A J 200 D sennadel Klemmposition J N N3EW 2 N3EW 3 N3EW 2 Hauptzerst uber N J 2 9 Abschr gung...

Page 98: ...0 8 2 0 2 1 4 Luftfilterelement 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 4 8 0 8 5 8 Luftfilter F hrungsschelle M 5 0 8 1 1 0 1 0 7 Zungenventil M 3 0 5 4...

Page 99: ...ngsfeder M 6 1 0 6 10 1 0 7 2 Kupplungszug Einstellschraube und Sicherungsmutter M 6 0 75 1 4 0 4 2 9 Schubhebelachse 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...

Page 100: ...belbeinrohre Hinterradaufh ngung USA CDN ZA EUROPA AUS NZ Hub des Sto d mpfers 131 5 mm 5 18 in Ungespannte Federl nge Etwa 265 mm 10 43 in Einbaul nge Eine ID Markierung 253 mm 9 96 in 252 mm 9 92 in...

Page 101: ...0 12 in 9 84 0 10 in Bremsbelagst rke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder 11 0 mm 0 433 in Innendurchmesser Bremssattelzylinder 27 0 mm 1 063 in 2 Innendurchmesser Bremsfl ssigkeit DOT 4...

Page 102: ...ANMERKUNG Lenkerkrone und u eres Rohr Untere Gabelbr cke und u eres Rohr Lenkerkrone und Lenkerschaft Lenkerhalter oben Lenkerhalter Unten Lenkerringmutter Teleskopgabel und D mpfer Baugruppe Teleskop...

Page 103: ...ftank Befestigungsklemmfaust und Rahmen Kraftstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstofftank und Hakenschraube Befestigungsband Kraftstof...

Page 104: ...pr fen 2 11 WARTUNGSDATEN SPEC Vorderrad Kotfl gel Befestigung Hinterrad Kotfl gel Befestigung Vorderrad Hinterrad Kotfl gel Befestigung Hinterrad Nummernschild M 6 1 0 M 6 1 0 M 6 1 0 M 6 1 0 Anzuzi...

Page 105: ...sche Ausf hrung CDI Modell Stator Hersteller 5CU 20 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...

Page 106: ...f r trockene und saubere Gewinde Die anzuziehenden Bauteile sollten dabei Raumtemperatur aufweisen A Schl sselweite B Gewindedurchmesser DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A B...

Page 107: ...zina 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 2 10 9 1 Per USA e CDN...

Page 108: ...lo di incidenza 26 9 27 1 Avancorsa 115 mm 4 53 in 118 mm 4 65 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 110 90 19 62M Pressione degli pneumatici an...

Page 109: ...a elastica Disegno in sezione Piano B 1 0 mm 0 039 in T 2 55 mm 0 100 in Distanza tra le estremit installata 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Gioco laterale installata 1 0 030 0 065 mm 0 0...

Page 110: ...IHIN Marchio ID 1P89 60 1P86 40 1P87 50 Getto principale M J No 178 No 180 No 178 Ugello aria principale M A J No 200 Posizione della staffa dell ago di getto J N N3EW 2 N3EW 3 N3EW 2 Ugello principal...

Page 111: ...tro dell aria M 6 1 0 1 2 0 2 1 4 Giunto del carburatore M 6 1 0 5 10 1 0 7 2 Corpo del filtro dell aria M 6 1 0 4 8 0 8 5 8 Brida di guida del filtro dell aria M 5 0 8 1 1 0 1 0 7 Valvola a lamella M...

Page 112: ...75 7 5 54 Molla della frizione M 6 1 0 6 10 1 0 7 2 Bullone di regolazione e controdado del cavo frizione M 6 0 75 1 4 0 4 2 9 Asse della leva di spinta M 5 0 8 1 6 0 6 4 3 Rocchetto di trasmissione M...

Page 113: ...A Corsa dell ammortizzatore 131 5 mm 5 18 in Lunghezza libera della molla 265 mm circa 10 43 in Lunghezza di inserimento Un contrassegno di marcatura di identificazione 253 mm 9 96 in 252 mm 9 92 in D...

Page 114: ...in Diametro interno del cilindro principale 11 0 mm 0 433 in Diametro interno del cilindro delle pinze 27 0 mm 1 063 in 2 Tipo di liquido per freni DOT No 4 Freno a disco posteriore Diametro esterno...

Page 115: ...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 4 3 Controdado di posizione della leva di comando del freno M 6 1 0 1 5 0 5 3 6 Guida per cavi tubo flessibile del freno a...

Page 116: ...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 superiore M 8 1 25 1 32 3 2 23 Telaio posterio...

Page 117: ...upporto del parafango anteriore M 6 1 0 4 7 0 7 5 1 Supporto del parafango posteriore anteriore M 6 1 0 2 7 0 7 5 1 Supporto del parafango posteriore posteriore M 6 1 0 2 12 1 2 8 7 Targa M 6 1 0 1 7...

Page 118: ...Elettrico CDI Modello statore Costruttore del magnete 5CU 20 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...

Page 119: ...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 120: ...ton lead to the frame Tighten the clamp so that the ENGINE STOP button lead is not pulled when the handlebar is turned to the right and left E Clamp the throttle cable clutch cable and wireharness to...

Page 121: ...la gauche et vers la droite E Brider le c ble des gaz le c ble d embrayage et le faisceau de fils au cadre F Brider le c ble des gaz et le faisceau de fils au cadre G Faire passer le c ble d embrayag...

Page 122: ...e outside the engine bracket and inside the down tube Then pass the radiator breather hose inside the CDI magneto lead F Clamp the CDI magneto lead radiator breather hose YPVS breather hose and neutra...

Page 123: ...mise l air du radiateur l int rieur du fil de magn to CDI F Brider au cadre le fil de magn to CDI la durit de mise l air du radiateur la durit de mise l air YPVS et le fil du contac teur de point mor...

Page 124: ...ngine bracket B Pass the high tension cord to the right of the radiator hose so that the high tension cord does not contact the radiator hose C Pass the CDI unit lead between the frame and the radiato...

Page 125: ...ur B Faire passer le fil haute tension droite de la durit du radiateur de fa on ce que le fil haute tension ne soit pas en contact avec la durit du radiateur C Faire passer le fil du bo tier CDI entre...

Page 126: ...rtion directs as shown and lightly touches the projec tion on the caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twis...

Page 127: ...en contact avec la saillie de l trier Faites ensuite passer le tuyau de frein dans les supports du tuyau de frein Si le tuyau de frein touche le ressort amortisseur arri re ajuster le coude Installer...

Page 128: ...ake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Clamp the ENGINE ST...

Page 129: ...yau de frein de mani re que la partie avec le tuyau soit dirig e comme indipu et touche l g rement la saillie sur le ma trecylindre Faire passer le fil de bouton d arr t du moteur ENGINE STOP au centr...

Page 130: ...gap Inspect carbon deposits and eliminate them Check gasket Inspect score marks Inspect wear Inspect carbon deposits and eliminate them Inspect housing friction plate clutch plate and spring Yamalube...

Page 131: ...fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SH...

Page 132: ...NTENANCE INTERVALS INSP ADJ Item Remarks THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or Lubricate SAE 10W 30 motor oil After break in Every race Every third Every fifth As re...

Page 133: ...nger 6 CULASSE Contr ler et nettoyer 6 6 Resserrer 6 6 CYLINDRE Cont ler et nettoyer 6 6 Changer 6 YPVS Contr ler et nettoyer 6 6 EMBRAYAGE Contr ler et r gler 6 6 Changer 6 BOITE DE VITESSE Changer l...

Page 134: ...pivots 6 6 Contr ler la surface du frein disque 6 6 Contr ler le niveau de fluide et les fuites 6 6 Resserrer les boulons du frein disque les boulons d tier les boulons du ma tre cylindre et les boulo...

Page 135: ...ubrifier 6 Changer le roulement 6 PNEU ROUES Contr ler la pression de gonflage le voile de roue et l usure des 6 6 pneus et voir s il n y a pas de rayon d tendu Resserrer les boulons de la roue 6 6 de...

Page 136: ...euern 6 ZYLINDERKOPF Pr fen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Pr fen und reinigen 6 6 Erneuern 6 YPVS Pr fen und reinigen 6 6 KUPPLUNG Pr fen und einstellen 6 6 Erneuern 6 GETRIEBE l wechseln 6...

Page 137: ...AHMEN Reinigen und pr fen 6 6 KRAFTSTOFFTANK 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...

Page 138: ...erung pr fen Ketternrad Befestigungsschraube 6 6 nachziehen Lager pr fen 6 Lager erneuern 6 Schmieren 6 GASDREHGRIFF GASSEIL Seilzugf hrung und Anschl sse 6 6 pr fen Schmieren 6 6 3 3 WARTUNGSINTERVAL...

Page 139: ...6 6 Sostituzione 6 YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sostituzione dell olio 6 6 Ispezione 6 Sostituzione del cuscinetto 6 FORCELLA DEL CAMB...

Page 140: ...eni 6 FORCELLE ANTERIORI Ispezione e regolazione 6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pulitura e lubrificazione 6 6 GUIDA DEL DISP...

Page 141: ...ne gioco libero e riserraggio 6 6 Pulitura e lubrificazione 6 Sostituzione del cuscinetto 6 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneu...

Page 142: ...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 143: ...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 144: ...chtung pr fen Auch sicherstellen dass die Kette richtig geschmiert P3 24 26 ist R der Die Reifen auf berm ige Abnutzung kontrollieren Speichen auf Lockerung und berm iges Spiel pr P3 34 35 fen Lenkung...

Page 145: ...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 146: ...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 147: ...iateur 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 en...

Page 148: ...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 149: ...on 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 radia...

Page 150: ...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 151: ...t 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 manipul...

Page 152: ...res sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01...

Page 153: ...res sion sp cifi e pendant 10 secondes Changer IC356002 ISPEZIONE DELLA PRESSIONE DI APERTURA DEL TAPPO DEL RADIATORE 1 Collegare 9 Tester del tappo del radiatore 1 e adattatore 2 NOTA Applicare acqua...

Page 154: ...specification Adjust NOTE 9Before adjustment expose the adjuster by moving the boot 3 and cap 4 away 9Make minute adjustment on the lever side using the adjuster 5 9After adjustment check proper opera...

Page 155: ...rarlo o sostituirlo 9 Manicotto flessibile del radiatore 3 Rigonfiamento Sostituirlo IC359020 REGOLAZIONE DELLA FRIZIONE 1 Controllare 9 Gioco libero della leva di comando della frizione a Fuori speci...

Page 156: ...ottle 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 specified free play is o...

Page 157: ...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 in Spiel am Gasdrehgriff a a 3 5 mm 0 12 0 20 in Eins...

Page 158: ...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 159: ...nson sten k nnen Staub und Schmutz in den Motor eindringen und schnel len Verschlei sowie m glichen Motorschaden verursachen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelement...

Page 160: ...le b in air filter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on filte...

Page 161: ...ro dell aria Danni Sostituirlo 4 Applicare 9 Olio per filtro dell aria in schiu ma oppure olio equivalente Sull elemento NOTA Comprimere per fare fuoriuscire l olio in eccesso L elemento dovrebbe esse...

Page 162: ...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 163: ...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 r cipient convenable sous le moteur 3 Controll...

Page 164: ...Oil 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 by the factory se...

Page 165: ...e 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 tipo SE Capacit dell olio cambio dell olio periodico 0 75 L...

Page 166: ...place NOTE Install the O rings with their depressed a facing outward EC35R051 SILENCER FIBER REPLACEMENT 1 Remove 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 For USA and CDN Except fo...

Page 167: ...s de but e d acc l rateur 1 1 Passi della regolazione Ruotare la vite di arresto della val vola a farfalla 1 finch il motore non gira al numero di giri pi basso possibile Per aumentare il numero di gi...

Page 168: ...right For USA and CDN Except for USA and CDN 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond...

Page 169: ...0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reuseme...

Page 170: ...Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed sc...

Page 171: ...der Bremsanlage Es kann zu einer gef hrlichen Abnahme des Bremsverm gens kommen falls die Bremsanlage nicht richtig entl ftet ist 1 Ausbauen 9 Hauptbremszylinderkappe 9 Membrane 9 Schwimmer im Beh lte...

Page 172: ...rocedure when the tiny bubbles in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever positi...

Page 173: ...le circuit de freinage NOTA Se lo spurgo risulta difficoltoso pu essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le...

Page 174: ...Adjust NOTE The brake pedal height is the vertical distance from the inside top end of the footrest 2 Adjust 9Brake pedal height Brake pedal height a a Zero mm Zero in Pedal height adjustment steps 9...

Page 175: ...en bis die Pedalh he a innerhalb der vorgeschriebenen H he liegt 9 Die Sicherungsmutter festziehen W 9 Pedalh he gem Abbildung zwischen Maximum und Mini mum einstellen bei dieser Einstellung soll das...

Page 176: ...r its end 9Loosen the bleed screw and push the caliper piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 7 and pad pin NOTE 9Install the brake pads wit...

Page 177: ...r cken dD Die abgelassene Bremsfl ssig keit nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 7 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbel ge mit deren ber st nde...

Page 178: ...REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect 9Brake pad thickness a Out of specification Replace as a set 2 Replace 9Brake pad 9Install the pad pin plug 0 Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb B...

Page 179: ...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 180: ...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 181: ...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 9Se...

Page 182: ...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 183: ...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 184: ...ease its tension 9Measure the length between drive chain roller 1 and y as shown 9Perform this measurement at two or three dif ferent places 2 Remove 9Master link clip 9Joint 1 9Drive chain 2 3 Clean...

Page 185: ...ie L nge zwischen der Antriebsket tenrolle 1 und y wie dargestellt messen 9 Diese Messung an zwei oder drei verschiedenen Stellen durchf hren IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei...

Page 186: ...lutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 48 58 mm 1 9 2 3 in Drive chain lubr...

Page 187: ...ell anello principale nella direzione illustrata a Direzione di rotazione 6 Lubrificare 9 Catena di trasmissione 5 Monter 9 Cha ne de transmission 1 9 Raccord 2 9 Agrafe de l attache rapide 3 fF Veill...

Page 188: ...3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain...

Page 189: ...aher innerhalb des spezifizier ten Bereiches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sicherungsmuttern festziehen 3 R gler 9 Fl che de cha ne de tr...

Page 190: ...se on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1 Stiffer a a Increase the rebound damping force Turn the adjuster 1...

Page 191: ...eau de fourche interne et le cache poussi re 2 Nettoyer 9 Joint antipoussi re a 9 Bague d tanch it b N B 9Nettoyer le joint antipoussi re et la bague d tanch it apr s chaque cour se 9Appliquer la grai...

Page 192: ...N DAMPING FORCE ADJUSTMENT 1 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression...

Page 193: ...ota re il dispositivo di regolazione 1 1 in senso normale Pi morbido b b Diminuire la forza di smorza mento della com pressione Ruo tare il dispositivo di regolazione 1 1 in senso inverso REGLAGE DE L...

Page 194: ...ter may be damaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smoot...

Page 195: ...lateur au del du minimum ou du maximum au risque de l endommager XG Toujours r gler la m me position sur chaque bras de fourche avant Un r glage in gal peut entra ner une mauvaise maniabilit et une pe...

Page 196: ...tting EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Remove 9Rear frame 3 Loosen 9Locknut 1 4 Adjust 9Spring preload...

Page 197: ...250 5 mm 9 86 in 243 0 261 0 mm 249 5 mm 9 82 in 9 57 10 28 in Lunghezza della molla installata a a H rter Erh hung der Federvorspan nung Den Ein steller 2 2 hinein drehen Weicher Verminderung der Fed...

Page 198: ...d juster with the punch mark b on the bracket cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the rebound damping force...

Page 199: ...s Einstellers 1 IC36N020 REGOL ELLA FORZA DI SMOR ZAMENTO DELL ESTENSIONE D E L L A M M O R T I Z Z A T O R E POSTERIORE 1 Regolare 9 Forza di smorzamento dell estensione Ruotando il dispositivo di re...

Page 200: ...align the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may...

Page 201: ...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 202: ...tion Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damage...

Page 203: ...ller 1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compressione Ruotando il dispositivo di reg...

Page 204: ...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 205: ...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 206: ...st steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring nut adjustment steps 9Remove the num...

Page 207: ...gola re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellschritte der Lenkring mutter 9 Das Nummernschild entfernen 9 Die Lenkstange und die Lenker krone entfernen 9 Die Ringmutter 1 mi...

Page 208: ...plate q NOTE 9The handlebar holder upper should be installed with the punched mark a forward 9Install the handlebar so that the marks b are in place on both sides 9Install the handlebar so that the p...

Page 209: ...natura a rivolta in avanti 9Installare il manubrio in modo che i contrassegni b siano a posto da entrambi i lati 9Installare il manubrio in modo che la sporgenza c del suo supporto superiore sia posiz...

Page 210: ...EAD INSPECTION AND ADJUSTMENT INSP ADJ Steering shaft nut 145 Nm 14 5 m kg 105 t lb Handlebar holder upper 28 Nm 2 8 m kg 20 ft lb Pinch bolt handle crown 21 Nm 2 1 m kg 15 ft lb Number plate 7 Nm 0 7...

Page 211: ...ge couronne de guidon 21 Nm 2 1 m kg 15 ft lb Plaque d immatriculation 7 Nm 0 7 m kg 5 1 ft lb Dado dell albero dello sterzo 145 Nm 14 5 m kg 105 ft lb Supporto del manubrio superiore 28 Nm 2 8 m kg 2...

Page 212: ...to handlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding portion 0 Throttle cable end q Clutch cable end Use Yamaha cable lube or e...

Page 213: ...la 8 Superficie di scorrimento del rullo della valvola a farfalla 9 Parte a spira del cavo di guida del tubo 0 Estremit del cavo dell acceleratore q Estremit del cavo della frizione A Usare lubrifican...

Page 214: ...eds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4...

Page 215: ...fuligginoso anche se il motore e il carburatore sono in buone condizio ni di funzionamento 3 Misurare 9 Distanza tra le candele a Usare un calibro per fili metalli ci o uno spessimetro Fuori specific...

Page 216: ...hen this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rot...

Page 217: ...icata da TDC 6 Contr ler 9 Avance l allumage Le rep re grav a du rotor doit tre align avec le rep re grav b du stator Ne pas align Ajuster 6 Kontrollieren 9 Z ndzeitpunkt Die K rnermarkierung a auf de...

Page 218: ...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 219: ...hrauben Stator 1 l sen 9 Die K rnermarkierung am Rotor mit der K rnermarkierung am Sta tor 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allentar...

Page 220: ...4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 7 Side cover right 1 Refer to REMOVAL POINTS 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Num...

Page 221: ...schild 1 MOTOR SITZ KRAFTSTOFFTANK UND SEITENDECKEL Ausbauumfang 1 Ausbau des Sitzes 2 Ausbau des Kraftstofftanks 3 Ausbau der Seitendeckel 4 Ausbau des Nummernschildes IC400000 MOTORE IC4R0000 SELLA...

Page 222: ...inserted in the air cleaner case Number plate 1 Remove 9 Bolt number plate 9 Number plate 1 NOTE 9The projection a is inserted into the band of the number plate Pull the band off the projec tion befo...

Page 223: ...d immatriculation 1 N B 9La saillie a est ins r e dans la bande de la plaque d immatriculation Reti rer la bande de la saillie avant la d pose 9D poser le c ble d embrayage 2 du guide de c ble b sur...

Page 224: ...22 mm 0 87 in 1 Plain washer 26 mm 1 02 in 1 3 Silencer 1 4 Collar R 13 0 mm 0 51 in 1 Collar R 15 5 mm 0 61 in 1 5 Collar R 13 5 mm 0 53 in 1 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 B...

Page 225: ...nt 2 10 Tuyau d chappement 1 Ausbauumfang Reihen Teilename St ck Bemerkungen folge zahl AUSBAU DES AUSPUFFROHRES UND SCHALLD MPFERS Seitendeckel rechts Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDE...

Page 226: ...EL TANK AND SIDE COVERS section 1 Panel 2 2 Clamp radiator hose 2 2 Only loosening 3 Radiator hose 1 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator hose 2 2 8 Radiator breather...

Page 227: ...onsultare la sezione SELLA SERBATOIO DEL CARBURANTE E COPERTURE LATERALI 1 Pannello 2 2 Brida manicotto flessibile del radiatore 2 2 Soltanto allentamento 3 Manicotto flessibile del radiatore 1 1 4 Ra...

Page 228: ...by the following procedure Place a thick rag like a towel over the radi ator cap slowly rotate the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the h...

Page 229: ...radiateur en proc dant comme suit Quand le moteur est froid mettre un chiffon pais tel qu une serviette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de d tente Cette proc dur...

Page 230: ...ction in the CHAPTER 2 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 3 Install 9Radiator left 1 9Plain washer 2 9Bolt radiator left 3 9Radiator hose 1 4 Refer to CABLE ROUTI...

Page 231: ...Schraube K hler links 3 9 K hlerschlauch 1 4 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Festziehen 9 Klemme K hlerschlauch 2 5 5 Einbauen 9 Tafel 1 9 Schraube Tafel 2 HINWEIS Haken a...

Page 232: ...lenoid 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 carburetor jo...

Page 233: ...ng 2 Die Schrauben Vergaserverbindung l sen 4 Vergaser 1 5 Vergaserverbindung 1 6 Zungenventil 1 7 Anschlag Zungenventil 2 8 Zungenventil 2 9 Platte Zungenventil 1 VERGASER UND ZUNGENVENTIL Ausbauumfa...

Page 234: ...p 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 Throttle sto...

Page 235: ...immerstift 1 7 Schwimmer 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 236: ...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 237: ...ei 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 gu...

Page 238: ...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 239: ...u 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 240: ...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 241: ...entilsitz 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 de...

Page 242: ...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 243: ...st 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 flexib...

Page 244: ...0 m kg 7 2 ft lb 3 Install 9Carburetor joint 1 9Bolt carburetor joint 2 EC4652F0 Carburetor 1 Install 9Power jet 1 To carburetor 2 2 Install 9O ring 1 9Solenoid valve 2 To carburetor cC 9Before instal...

Page 245: ...ise de la soupape flexible avec sa face chanfrein e a orient e vers la droite 3 Monter 9 Raccord de carburateur 1 9 Boulon raccord de carburateur 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10...

Page 246: ...out for reference only Note the following installation 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 In...

Page 247: ...ungen ausdrehen Leerlauf Luftregulier schraube 1 Ausdrehung 2 1 4 Ausdrehungen 1 1 4 Ausdrehungen nur als Hinweis 3 Installare 9 Vite dell aria pilota 1 9 Vite di arresto della valvola a farfalla 2 Pe...

Page 248: ...NG DIAGRAM section in the CHAPTER 2 NOTE Install the air vent hoses and overflow hose to the carburetor with their ends not having the cuts a toward the carburetor 9 Install 9Jet needle 1 9Collar 2 9S...

Page 249: ...1 9 Tubo flessibile di sfiato dell aria 400 mm 15 7 in 2 9 Tubo flessibile di troppopieno 280 mm 11 0 in 3 9 Brida 4 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPITOLO 2 NOTA Install...

Page 250: ...rottle grip for smooth movement EC465391 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor joint slots 10 Install 9Throttle cable 1 9Locknut 2 9Mixing...

Page 251: ...lare 9 Parte superiore del diffusore 1 9 Vite parte superiore del diffu sore 2 Sul carburatore 3 NOTA 9Inserire la valvola a farfalla nel corpo del carburatore tirando contempora neamente la leva 4 ve...

Page 252: ...with its top as shown and secure the clamp in alignment with the hori zontal line b that passes the center of the car buretor bore 4 Connect 9TPS throttle position sensor lead 1 9Solenoid valve lead...

Page 253: ...ringen und Klemme in bereinstimmung mit der waagerechten Linie b ausrichten die durch die Mitte der Vergaserbohrung f hrt 4 Anschlie en 9 TPS Leitungskabel Drossel stellungssensor 1 9 Magnetventilleit...

Page 254: ...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 255: ...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 256: ...l 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 holder 1 1 11 Valve shaft 1 12 Link lever 1 13 Pulley 2 14 Link rod 1 15 Power valve 2 2 16 Val...

Page 257: ...9 Schraube 3 10 Ventilhalterung 1 1 11 Ventilwelle 1 12 Verbindungshebel 1 13 Riemenscheibe 2 14 Pleuelstange 1 15 Leistungsventil 2 2 16 Ventilhalterung 2 1 17 Leistungsventil 1 1 KOLBEN UND LEISTUNG...

Page 258: ...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 259: ...des Kolbenbol zens 1 HINWEIS Vor dem Abnehmen des Stifts des Kol benbolzens ist das Kurbelgeh use mit einem sauberen Lappen abzudecken so dass der Stift nicht versehentlich in das Kurbelgeh use f llt...

Page 260: ...arpage measurement and re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur face the cylinder...

Page 261: ...egment en l ouvrant plus que n cessaire 3 Togliere 9 Fascia elastica 1 NOTA Attenzione a non graffiare il pistone o danneggiare la fascia elastica allargan dola pi di quanto sia necessario Proc dure d...

Page 262: ...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 263: ...Die Zylinder Messlehre 1 ver wenden Au erhalb des Grenzwertes Erneuern HINWEIS Die Zylinderbohrung C parallel A B C und im rechten Winkel zur Kurbel welle a b messen Danach den Durchschnitt der Messw...

Page 264: ...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 265: ...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 Co...

Page 266: ...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 267: ...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 268: ...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 269: ...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 270: ...Spring 1 2 8 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 Combinati...

Page 271: ...n outil ac r viter de rayer l aluminium Leistungsventilbohrung im Zylinder 1 Ausbauen 9 Ru ablagerungen Aus der Leistungsventil Boh rung a HINWEIS Kein scharfkantiges Instrument ver wenden Kratzer auf...

Page 272: ...the 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 pi...

Page 273: ...e sur le clapet de puissance 1 IC475000 MONTAGGIO E INSTALLAZIONE IC475193 Valvola di potenza 1 Installare 9 Valvola di potenza 1 1 9 Portavalvola 2 2 9 Bullone portavalvola 2 3 NOTA 9Montare la valvo...

Page 274: ...ulfide 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 valve shaf...

Page 275: ...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 molla 1 con la parte del fermo a ri...

Page 276: ...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 277: ...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 278: ...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 279: ...t la surface de cylindre IC475383 Testa cilindro e cilindro 1 Applicare 9 Olio per motori Sul pistone 1 sulla fascia ela stica 2 e sulla superficie del cilindro 42 Nm 4 2 m kg 30 ft lb 42 Nm 4 2 m kg...

Page 280: ...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 281: ...e 1 9 Boulon bo tier de clapet de puissance 2 7 Monter 9 Culasse 1 9 Rondelle en cuivre 2 9 Ecrou culasse 3 N B Serrer les crous culasse par tapes en utilisant un mod le d entre croisement 6 Monter 9...

Page 282: ...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 64 Nm...

Page 283: ...ela 1 9 Calotta della candela 2 8 Einbauen 9 Motorhalterung 1 9 Schraube Motorhalterung 2 9 Motor Befestigungsschraube oben 3 8 Installare 9 Staffa del motore 1 9 Bullone staffa del motore 2 9 Bullone...

Page 284: ...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 285: ...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 286: ...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 287: ...bhebelachse 1 14 Schubhebelachse 1 PRIM RABTRIEBSZAHNRAD SCHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Prim r...

Page 288: ...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 289: ...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 290: ...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 291: ...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 levi...

Page 292: ...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 293: ...pliquer 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 Monter 9...

Page 294: ...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 295: ...tement 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 App...

Page 296: ...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 297: ...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 HINWEIS Die Schrauben stufenweise ber K...

Page 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...arreur 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 de...

Page 304: ...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 305: ...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 306: ...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 307: ...ecteur 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 Ensembl...

Page 308: ...ke sure the stopper a of the torsion spring fits into the hole b on the kick axle EC4C5602 Kick axle assembly 1 Install 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer...

Page 309: ...rbre 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 Circ...

Page 310: ...e 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 NOTE 9Apply the molybdenum disulfide grease on the cont...

Page 311: ...sur les surfaces de contact de la but e d axe du lanceur a et de la plaque de but e 3 9 Appliquer de l huile de bo te de vitesses sur l axe de d marreur au pied 9Faites coulisser l axe du lanceur dan...

Page 312: ...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 313: ...t 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 en...

Page 314: ...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 315: ...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 la...

Page 316: ...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 317: ...TEUR 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 Collerett...

Page 318: ...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 319: ...ndelle 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 C...

Page 320: ...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 321: ...le 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 322: ...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 323: ...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 324: ...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 325: ...B S il n y a un d anomalie telle qu exces sif changement du niveau de liquide de refroidissement d coloration du liquide de refroidissement ou huile de bo te de vitesses blanch tre il est inutile de...

Page 326: ...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 327: ...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 328: ...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 329: ...at 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 t...

Page 330: ...emoval SIDE COVERS section Bolt radiator Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator 1...

Page 331: ...E RESERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur 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 cial...

Page 332: ...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 333: ...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 MONTAG...

Page 334: ...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 335: ...r 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 Inst...

Page 336: ...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 337: ...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 KABEL F HRUNGS BERSICH...

Page 338: ...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 Disconnect the...

Page 339: ...r Siehe Abschnitt AUSPUFFROHR UND Auspuffrohrst tze hinten SCHALLD MPFER Kupplungskabel An der Motorseite abtrennen K hler Siehe Abschnitt K HLER Z ndkerze Das Kabel des CDI Magnetz nders abtrennen AU...

Page 340: ...ke pedal 1 8 Brake pedal 1 9 Engine bracket 2 10 Engine mounting bolt 3 11 Pivot shaft 1 Remove completely 12 Engine 1 Refer to REMOVAL POINTS 4 61 ENGINE REMOVAL ENG Extent of removal 1 Engine remova...

Page 341: ...ignon d entra nement 1 4 Rondelle frein 1 Se reporter POINTS DE DEPOSE 5 Pignon d entra nement 1 6 Agrafe 1 7 Boulon p dal de frein 1 8 P dale de frein 1 9 Support du moteur 2 10 Boulon de montage du...

Page 342: ...e the engine 1 aslant and upward while inclining it toward the kick crank side so that the engine s mounting top does not contact the bracket on the frame EC4M3000 REMOVAL POINTS EC4F3100 Drive sprock...

Page 343: ...1 9 Catena di trasmissione 2 NOTA Togliere il rocchetto conduttore insieme alla catena di trasmissione IC4M3340 Rimozione del motore NOTA Assicurarsi che gli accoppiatori i tubi flessibili e i cavi si...

Page 344: ...EC4M5124 Engine installation 1 Install 9Engine 1 Install the engine from right side 9Pivot shaft 2 9Engine mounting bolt lower 3 9Engine mounting bolt front 4 9Engine bracket 5 9Bolt engine bracket 6...

Page 345: ...raisse base de savon au lithium sur le boulon les joints toriques et le support de p dale de frein IC4M5000 MONTAGGIO E INSTALLAZIONE IC4M5124 Installazione del motore 1 Installare 9 Motore 1 Installa...

Page 346: ...le applying the rear brake 3 Bend the lock washer tab to lock the nut 5 Nm 0 5 m kg 3 6 ft lb 75 Nm 7 5 m kg 54 ft lb EC4M5341 Drive sprocket 1 Install 9Drive sprocket 1 9Drive chain 2 NOTE Install th...

Page 347: ...ando il freno posteriore 75 Nm 7 5 m kg 54 ft lb 75 Nm 7 5 m kg 54 ft lb 75 Nm 7 5 m kg 54 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 Pignon d entra nement 1 Monter...

Page 348: ...Piston Refer to CYLINDER HEAD CYLINDER AND PISTON section Primary drive gear Kick idle gear Refer to KICK AXLE SHIFT SHAFT AND Stopper lever PRIMARY DRIVE GEAR section Rotor and stator Refer to CDI MA...

Page 349: ...6 in 1 6 Schraube L 70 mm 2 76 in 3 7 Halter 2 8 Kurbelgeh use rechts 1 Das Spezialwerkzeug verwenden 9 Kurbelgeh use links 1 Siehe unter AUSBAUPUNKTE 10 Kurbelwelle 1 Das Spezialwerkzeug verwenden Si...

Page 350: ...s cC Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end...

Page 351: ...tre l g rement d viss e pour mettre le corps de l outil de niveau 9Tout en serrant le boulon central taper alternativement sur le bossage de fixation du moteur et les arbres de transmission fF Utilis...

Page 352: ...kcase 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 bearing EC4...

Page 353: ...iere il cuscinetto dal carter pre mendone l anello interno come illu strato in 9Se il cuscinetto viene tolto insieme all albero a gomiti togliere il cusci netto usando un estrattore generico per cusci...

Page 354: ...30in Crank 59 95 60 00 mm width 2 360 2 362 in EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification R...

Page 355: ...9 Largeur de vilebrequin d Hors sp cification Changer Utiliser un Comparateur Cadran et une jauge d paisseur Comparateur YU 3097 90890 01252 Comparatore YU 3097 90890 01252 Messuhr YU 3097 90890 0125...

Page 356: ...ng tool until the crankshaft bottoms against the bear ing 9Before installing the crankshaft clean the con tacting surface of crankcase 9Apply the lithium soap base grease on the oil seal lip cC Do not...

Page 357: ...bero a gomiti 1 Installare 9 Albero a gomiti 1 Usare l utensile per installare l albero a gomiti 2 3 4 Per USA e CDN Tranne che per USA e CDN NOTA 9Reggere la biella nel punto morto superiore con una...

Page 358: ...ositioned at TDC top dead center cC In order to prevent the oil seal lip a a from being turned up or damaged wrap a vinyl tape or the like b b around the right end of the crankshaft and apply the lith...

Page 359: ...teur 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 au PMH point mort haut fF...

Page 360: ...n the bolt cC If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt 30 Nm 3 0 m kg 22 ft lb 7 Install 9Tension spring 1 9Holder 2 9Bol...

Page 361: ...saillie a du carter droit 8 Serrer 9 Segment 1 9 Boulon segment 2 N B 9Lors de l installation du segment sur l arbre came 3 aligner la marque imprim e a avec la broche de centra ge b 9Tourner le segme...

Page 362: ...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 363: ...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 364: ...ct 9Matching dog a 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 9Shif...

Page 365: ...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 Examiner 9 Crabot d accouplement a 9 D...

Page 366: ...ulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear then install 3 Check 9Shift fork movement Unsmooth operation Replace shift fork NOTE For a malfun...

Page 367: ...tionnement de la fourchette ne pas changer que la fourchette ellem me mais les deux pignons situ s de chaque c te de la fourchette REMONTAGE ET MONTAGE Bo te vitesses 1 Monter 9 Pignon de 5 21D 1 9 Pi...

Page 368: ...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 369: ...t rieure du pignon mobile puis les monter 9Appliquer de la graisse base de savon an lithium sur le joint torique 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9V rifier que le cot bord vif du cir cl...

Page 370: ...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 371: ...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 372: ...3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Exten...

Page 373: ...2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Collerette 2 6 Bague d tanch it 2 7 Roulement 2 Se reporter POINTS DE DEPOSE 8 Disque de frein 1 Pr paration pour la d pose XG Bien...

Page 374: ...e removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9...

Page 375: ...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 376: ...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 377: ...ure 9 Voile de roue Hors limite R parer Changer 2 Examiner 9 Roulement Faire tourner la bague int rieure avec le doigt Point dur grippage Changer N B Changer les roulements la bague d tanch it et la c...

Page 378: ...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 379: ...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 380: ...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 381: ...t 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 d...

Page 382: ...soap base grease on the wheel axle 6 Install 9Nut wheel axle 1 7 Tighten 9Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several ti...

Page 383: ...lare 9 Asse della ruota 1 NOTA Applicare sull asse della ruota il grasso a base di sapone di litio 6 Installare 9 Dado asse della ruota 1 7 Serrare 9 Bullone supporto dell asse 1 NOTA Prima di serrare...

Page 384: ...g 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made onl...

Page 385: ...le convenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ral droit doit monter premier 9Monter la bague d tanch it avec ses marques ou num ros de fabricant diri g s vers l ext r...

Page 386: ...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 387: ...ondotto 3 9 Dado rocchetto condotto 4 NOTA Serrare i dadi in sequenza usando uno schema incrociato 4 Installare 9 Bordino 1 NOTA Applicare sul labbro del paraolio il grasso a base di sapone di litio 5...

Page 388: ...heel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axle 1 9Locknut...

Page 389: ...N B A ce stage resserrer provisoirement les crous axe de roue 8 Installare 9 Estrattore per catena destro 1 9 Rosetta 2 9 Dado asse della ruota 3 NOTA Serrare temporaneamente il dado asse della ruota...

Page 390: ...n when disassembling the caliper 7 Caliper 1 8 Brake lever 1 9 Master cylinder bracket 1 10 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose re...

Page 391: ...Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 6 Goupille de plaquette 1 Desserrer lors du d montage de l trier 7 Etrier 1 8 Levier de frein 1 9 Etrier de ma...

Page 392: ...3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Caliper 1 Extent of removal 1 Master cylinder...

Page 393: ...1 6 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du d montage de l trier 8 Etrier 1 Pr paration pour la d pose XG...

Page 394: ...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 395: ...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 396: ...gm 1 3 Reservoir float 1 4 Master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Plain washer 1 7 Push rod 1 8 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear E...

Page 397: ...ptbremszylindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorn B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE...

Page 398: ...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 399: ...E IC5A3101 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Coperchio del cilindro principa le 1 9 Dispositivo di protezione NOTA Non togliere il diaf...

Page 400: ...d dust seals w Replace the piston seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534120 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Sc...

Page 401: ...les joints de piston et antipoussi 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 n...

Page 402: ...B Rear 2 Inspect 9Caliper piston 1 Wear Score marks Replace caliper piston assembly w Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Bra...

Page 403: ...ilindro principale A Anteriore B Posteriore IC534214 Pinza 1 Ispezionare 9 Superficie interna del cilindro della pinza a Usura Rigature Sostituire il gruppo pinza A Anteriore B Posteriore 2 Ispezionar...

Page 404: ...and dust seals onto the slot on caliper correctly A Front B Rear 3 Install 9Caliper piston 1 NOTE Apply the brake fluid on the piston wall cC 9Install the piston with its shallow depressed side a a fa...

Page 405: ...on et antipoussi re dans la rainure situ e sur l trier A Avant B Arri re IC5A5801 Pistone della pinza 1 Pulire 9 Pinza 9 Guarnizione di tenuta del pisto ne 9 Parapolvere 9 Pistone della pinza Pulirli...

Page 406: ...d pin at this point 2 Install 9Disc cover 1 9Bolt disc cover 2 2 Install 9Caliper 1 9Bolt caliper 2 3 Tighten 9Pad pin 3 4 Install 9Pad pin plug 4 23 Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm...

Page 407: ...emsschuhaussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 2 Monter 9 Etrier 1 9 Boulon trier 2 3 Serrer 9 Goupille de plaquette 3 4 Monter 9 Bouchon de goupill...

Page 408: ...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 409: ...lle du ma tre cylindre doit tre pos e dans la direction indiqu e Une mauvaise intallation enta ne une performance incorrecte du freinage A Avant B Arri re IC5A5220 Kit del cilindro principale 1 Pulire...

Page 410: ...ose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mar...

Page 411: ...festziehen 4 Installare Anteriormente 9 Kit del cilindro principale 1 9 Rosetta 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 Posteriormente 9 Kit...

Page 412: ...t its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 2 Install 9Master cylinder 1 9Bolt master cylinder 2 10 Nm 1 0 m kg 7 2...

Page 413: ...der 1 9 Schraube Hauptbremszylin der 2 IC5A5401 Cilindro principale posteriore 1 Installare 9 Rondella in rame 1 9 Tubo flessibile del freno 2 9 Bullone di unione 3 T Usare sempre rondelle in rame nuo...

Page 414: ...ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Install 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT section in the CHAPTER 3 EC5A5911 Front...

Page 415: ...ie in der Abbildung gezeigt angeordnet ist und den berstand b b am Bremsbe lag leicht ber hrt 2 Einbauen 9 Bremsschlauchhalter 1 9 Schraube Bremsschlauchhal ter 2 3 Einbauen 9 Bremsschlauchhalter 1 9...

Page 416: ...so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb EC5A5502 Rear brake hose 1 Install 9Copper washer 1 9Brake hose 2...

Page 417: ...ibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro principale Tuyau de frein arri re 1 Monter 9 Rondelle en cuivre 1 9...

Page 418: ...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 419: ...et un mauvais fonctionnement du frein 9Toujours utiliser la m me marque de liquide de frein Le m lange de liquides de marques diff rentes risque de provoquer une r action chimique nuisible au fonctio...

Page 420: ...iaphragm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Master cylinder cap 1 9Bolt master cylinder cap 2 cC After installation while pulling the lever in or pushing down on the...

Page 421: ...iaframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale0 2 Posteriormente 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Bullone coperchio del cilindro principal...

Page 422: ...S section in the CHAPTER 4 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt u...

Page 423: ...die Vorderradgabel demontiert wird Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 4 Klemmschraube 2 Nur l sen Untere Gabelbr cke 5 Vorderradgabel 1 VORDERRADGABEL Ausbauumfang 1 Ausbau der Vorderr...

Page 424: ...tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 0 Oil seal 1 q Base valve 1 Drain the fork oil Use special tool w Damper assembly 1 Refer to REMOVAL POINTS 5 27 CHAS FRONT F...

Page 425: ...l outil sp cial Se reporter POINTS DE DEPOSE 2 Ressort de fourche 1 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...

Page 426: ...uction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled...

Page 427: ...ger compl tement les chambres air IC556000 NOTA PER IL MANEGGIO NOTA La forcella anteriore richiede grande at tenzione Si raccomanda pertanto di ef fettuare la manutenzione della forcella anteriore pr...

Page 428: ...not remove the locknut as the damper rod may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove 9Dust seal 1 9Stopper ring 2 Using...

Page 429: ...adere nel gruppo ammortizzatore senza che sia possibile estrarla Cl bague de boulon capuchon YM 01501 90890 01501 Chiave ad anello per vite mordente YM 01501 90890 01501 Schraubenschl ssel f r Nockenw...

Page 430: ...Inspect 9Damper assembly 1 Bend Damage Replace 9O ring 2 Wear Damage Replace cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive t...

Page 431: ...RIFICATION Amortisseur complet 1 V rifier 9 Amortisseur complet 1 Courbure endommagement Changer 9 Joint torique 2 Us endommag Changer fF La fourche avant ayant une tige de piston incorpor e a une con...

Page 432: ...Piston metal 3 Wear Damage Replace 9Spring 4 Damage Fatigue Replace base valve 9Air bleed screw 5 Wear Damage Replace EC554400 Fork spring 1 Measure 9Fork spring free length a Out of specification Rep...

Page 433: ...a 2 Usura Danni Sostituire 9 Metallo del pistone 3 Usura Danni Sostituire 9 Molla 4 Danni Affaticamento Sostitui re la valvola di base 9 Vite di spurgo dell aria 5 Usura Danni Sostituire Ressort de fo...

Page 434: ...of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the...

Page 435: ...den k nnen IC554502 Tubo interno 1 Ispezionare 9 Superficie del tubo interno a Rigature Ripararlo o sostituir lo Usare carta vetrata umida di grana no 1000 Pezzo di bloccaggio dell olio danneggiato So...

Page 436: ...have an ex cessively adverse effect on the front fork performance 9Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Oil capacity 195cm3 6 86 Imp oz 6 59 US oz 4...

Page 437: ...no avere un effetto ec cessivamente negativo sul rendi mento della forcella anteriore 9Non permettere mai la penetrazione di materiali estranei nella forcella anteriore Huile recommand e Huile de susp...

Page 438: ...Loosen 9Compression damping adjuster 1 NOTE 9Loosen the compression damping adjuster fin ger tight 9Record the set position of the adjuster the amount of turning out the fully turned in posi tion 8 In...

Page 439: ...d amener la pression de la tige d amortissement au maximum Ins taller ensuite la valve de base tout en rel chant la pression de la tige d amor tissement 9 V rifier que l amortisseur complet est totale...

Page 440: ...5 35 CHAS FRONT FORK 12 While protecting the damper assembly 1 with a rag and compressing fully allow excessive oil to overflow on the base valve side cC Take care not to damage the damper assembly 13...

Page 441: ...lassen w hrend die D mpfer Baugruppe 1 durch einen Lappen gesch tzt und vollst ndig zusammenge dr ckt wird dD Darauf achten dass die D mpfer Baugruppe nicht besch digt wird 13 Das bersch ssige l an d...

Page 442: ...installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 9Install the oil seal with its manufacture s marks or number facing the axle holder side 9Install the oil sea...

Page 443: ...ation de la bague d tanch it utiliser une feuille en vi nyle a avec de l huile de fourche ap pliqu e pour prot ger la l vre de la bague d tanch it 9Installer le joint huile dont les marques d usine ou...

Page 444: ...ver 3 19 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 20 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 21 Insta...

Page 445: ...S Den Gabelbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 20 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren R...

Page 446: ...o damper assembly 3 NOTE Install the collar with its larger dia end a facing the fork spring 25 Install 9Damper assembly 1 To inner tube 2 cC To install the damper assembly into the inner tube hold th...

Page 447: ...lta verso la molla della forcella 25 Monter 9 Amortisseur complet 1 Au tube interne 2 fF Pour installer l amortisseur complet dans le tube plongeur maintenir l tanch it du tube plongeur Si le tube plo...

Page 448: ...stalled out of specification proper damping force cannot be obtained 29 Tighten 9Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster with specified torque 30 Install 9Adjuster 1 To inn...

Page 449: ...si zionare la chiave ad anello per vite mordente 7 tra il tubo interno e il controdado 6 9Serrare a fondo con le dita il regolato re sul gruppo ammortizzatore 28 Ispezionare 9 Distanza a tra il regola...

Page 450: ...9Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque w Never fail to make the oil amount adjustment between the maximum and minimum amount and a...

Page 451: ...es sch dliche Einfl sse auf die Lei stung der Teleskopgabel mit sich bringen 9 Darauf achten dass keine Fremd k rper in die Vorderradgabel ein dringen T Non mancare mai di eseguire la rego lazione del...

Page 452: ...ront fork top end a Front fork top end standard a a Zero mm Zero in 4 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too muc...

Page 453: ...insteller 1 mit den Fin gern festziehen und danach in die urspr ngliche Einstellposition heraus drehen 5 Monter 9 Protecteur 1 9 Boulon protecteur 2 6 R gler 9 Force d amortisseur de rebond N B Tourne...

Page 454: ...rn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer to REMOVAL POINTS 11 Handlebar holder upper 2 12 Ha...

Page 455: ...puchon 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 Couvercle de capuchon 1 9 Colleret...

Page 456: ...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 457: ...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 POI...

Page 458: ...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 459: ...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 Poig...

Page 460: ...er 1 9Plain washer 2 9Nut handlebar holder lower 3 NOTE 9Install the handlebar holder lower with its side having the greater distance a from the mount ing bolt center facing forward 9Apply the lithium...

Page 461: ...avant 9Appliquer de la graisse base de savon au lithium sur le filetage du support de guidon inf rieur 9L installation du support de guidon inf rieur en sens inverse permet de changer le d calage d av...

Page 462: ...the handlebar as shown 9First tighten the bolts on the front side of the handlebar holder upper and then tighten the bolts on the rear side 4 Install 9Grip left 1 Apply the adhesive to the handlebar 2...

Page 463: ...s 9Installer le guidon de fa on ce que la saillie c du support de guidon sup rieur soit positionn e sur la marque du guidon comme illustr 9Serrer d abord les boulons l avant du support de guidon sup r...

Page 464: ...2 9 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 10 Install 9Cap cover 1 1 Nm 0 1 m kg 0 7 ft lb 6 Install 9Throttle cable 1 To tube guide 2 NOTE Apply...

Page 465: ...capuchon de poi gn e provisoirement sans fixer l ac c l rateur sur le guidon 5 Einbauen 9 H lse 1 9 Kappenabdeckung 2 9 Gasdrehgriff 3 HINWEIS 9 Lithium Fett an der Gleitfl che des Gasdrehgriffs auft...

Page 466: ...grip cap and brake lever 2 2 are equal If you make a mistake in the grip cap installation position the brake lever may contact the grip cap resulting in poor brake performance 9After tightening the bo...

Page 467: ...s avoir serr les boulons v ri fier que la poign e d acc l rateur 3 3 tourne sans probl me Sinon res serrer les boulons pour la r gler 13 Monter 9 Bouton d arr t du moteur EN GINE STOP 1 9 Support de l...

Page 468: ...5 49 CHAS HANDLEBAR 14 Install 9Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch cable end 15 Adjust 9Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3...

Page 469: ...u CHAPITRE 3 14 Einbauen 9 Kupplungskabel 1 HINWEIS Lithium Fett am Kupplungskabelende auftragen 15 Einstellen 9 Spiel des Kupplungshebels Siehe Abschnitt EINSTEL LUNG DER KUPPLUNG im KAPITEL 3 14 Ins...

Page 470: ...rown 1 4 Ring nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Bearing race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Bearing race 2 Refer to REMOVAL POIN...

Page 471: ...geordnet wird Nummernschild Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDECKEL im KAPITEL 4 Lenkstange Siehe Abschnitt LENKSTANGE Vorderrad Kotfl gel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe...

Page 472: ...down EC563300 Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Bearing race 1 Remove 9Bearing race 1 Remove the bearing race...

Page 473: ...pas endommager le file tage de l arbre de direction Cage de roulement 1 D poser 9 Cage de roulement 1 D poser la cage de roulement l aide d une tige 2 et d un marteau VERIFICATION Arbre de direction...

Page 474: ...on in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION EC5651A0 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the...

Page 475: ...ulement et de cages de roulement REMONTAGE ET MONTAGE 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...

Page 476: ...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 9Tempora...

Page 477: ...l 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 bridage trier...

Page 478: ...e under bracket to specified torque If torqued too much it may cause the front fork to malfunction Front fork top end standard a a Zero mm Zero in 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 9 Aft...

Page 479: ...Serrare la staffa inferiore alla coppia specificata Se troppo serrata pu provocare il malfunzionamento della forcella anteriore Oberes Ende der Gabelbein rohre Standard a Null mm Null in Extr mit sup...

Page 480: ...e pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swinga...

Page 481: ...E 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 Hinterradschwi...

Page 482: ...Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 10 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and...

Page 483: ...und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename St ckzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 Siehe unter AUSBAUPUNKTE 2 Relaisarm 1 3 Pleuelstange 1 4 H lse 2 5 ld...

Page 484: ...ush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574211 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revol...

Page 485: ...ken auf den u eren Laufring ausbauen INSPEKTION Die Lager Buchsen und H lsen in L sungsmittel waschen Hinterradschwinge 1 Pr fen 9 Lager 1 9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost Lager un...

Page 486: ...nstalled depth of bearings Outer a a Zero mm Zero in Inner b b 6 5 mm 0 26 in EC574311 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and colla...

Page 487: ...mit den Herstellermarkierungen oder Herstellungsnummern eingepresst wird 9 Zuerst die u eren Lager und danach die inneren Lager bis zur vorgeschrie benen Tiefe von innen einbauen Profondit installata...

Page 488: ...er 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the be...

Page 489: ...der Drucklager auftragen 2 Einbauen 9 H lse 1 9 Unterlegscheibe 2 Zum Relaisarm 3 HINWEIS Das Molybd n Fett auf den H lsen und den ldichtungslippen auftragen Profondeur install e de roulement a a Z ro...

Page 490: ...lybdenum disulfide grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To...

Page 491: ...r l crou ce stade 6 Monter 9 Bras oscillant 1 9 Axe de pivot 2 N B 9Appliquer de la graisse de molybd ne sur l axe de pivot 9Introduire l arbre pivot par le c t droit 5 Einbauen 9 Relaisarm 1 9 Schrau...

Page 492: ...Plain washer 2 9Nut connecting rod 3 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay...

Page 493: ...2 9 Mutter Pleuelstange 3 HINWEIS 9 Das Molybd n Fett auf der Schraube auftragen 9 Die Mutter noch nicht festziehen 9 Einbauen 9 Schraube Hinterrad Sto d mpfer Relaisarm 1 9 Mutter Hinterrad Sto d mp...

Page 494: ...her 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover 10mm 0 39in 5 7...

Page 495: ...er unten 5 14 Einbauen 9 Kettenschutz 1 9 St tzenabdeckung 2 9 Schraube Kettenschutz 50 mm 1 97 in 3 9 Mutter Kettenschutz 4 9 Schraube St tzenabdeckung 10 mm 0 39 in 5 13 Installare 9 Bullone tendica...

Page 496: ...under the engine Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air cleaner joint 1 Loosen the bolt...

Page 497: ...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 Si ge de res...

Page 498: ...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 499: ...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 500: ...ON EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly 9Spring 3 Damag...

Page 501: ...plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet Fuite de gaz Remplacer l amortisseur complet 9 Ressort 3 Endommagement Changer le ressort Fatigue Changer le ressort Comprimer et d te...

Page 502: ...bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopper ring upper bearing 1 NOTE After installing the stopper ring push back t...

Page 503: ...sur c t o les rep res ou num rous du fa bricant sont inscrits Ressort amortisseur arri re 1 Monter 9 Ressort 1 9 Guide de ressort sup rieur 2 9 Guide de ressort inf rieur 3 IC585000 MONTAGGIO E INSTA...

Page 504: ...pply the lithium soap base grease on the O rings 2 Install 9Bush 1 9Collar 2 9Dust seal 3 NOTE 9Apply the molybdenum disulfide grease on the bearing and dust seal lips 9Install the dust seals with the...

Page 505: ...toriques 2 Monter 9 Bague 1 9 Collerette 2 9 Joint antipoussi re 3 N B 9Appliquer de la graisse au bisulfure de molybd ne sur le roulement et les l vres des joints antipoussi re 9Monter les joints an...

Page 506: ...um disulfide grease on the bolt 5 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 6 Install 9Rear frame 1 9Bol...

Page 507: ...2 N B Appliquer de la graisse de molybd ne sur le boulon 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re sup rieur 2 9 Boulon cadre arri re inf rieur 3 7 Serrer 9 Boulon raccord de filtre air 1 3 I...

Page 508: ...osition sensor 5 Solenoid valve 6 Neutral switch Except for USA and CDN 7 CDI magneto 8 Spark plug EC612000 WIRING DIAGRAM 6 1 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC COLOR CODE B Black L Blue O...

Page 509: ...moteur ENGINE STOP 3 Bobine d allumage 4 TPS capteur de position du papillon 5 Electrovanne 6 Contacteur de point mort Except pour USA et CDN 7 Magn to CDI 8 Bougie CODE DE COULEUR B Noir L Bleu O Or...

Page 510: ...ap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI magneto Replace Replace Replace Replace Replace marked...

Page 511: ...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 servoir essence 9Utiliser les outils sp ciaux suivants dans ce d pistage des pannes Te...

Page 512: ...as Z ndungspr fger t verwendet wird HINWEIS 9Die folgenden Teile vor Beginn der St rungsbeseitigung ausbauen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge f r die St rungsbeseitigung verwend...

Page 513: ...io per il controllo dell accensione NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9 In questa ispezione usare i seguenti utensili speciali Tester dinamico...

Page 514: ...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 515: ...ET 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 GLI...

Page 516: ...move the spark plug cap by turning it coun terclockwise and inspect 9Install the spark plug cap by turning it clock wise until it is tight Tester lead Yellow lead 1 Tester lead Black lead 2 Tester lea...

Page 517: ...appuccio della candela girandolo in senso antiorario e con trollarlo 9Rimontare il cappuccio della candela girandolo in senso orario finch non bene avvitato Resistenza Posizione del della bobina selet...

Page 518: ...oose connection Tighten Deteriorated Damaged Replace 9Spark plug cap resistance Out of specification Replace Tester lead Spark plug lead terminal 1 Tester lead Spark plug terminal 2 Spark plug cap Tes...

Page 519: ...uire 9 Resistenza del cappuccio della candela Non rientra nelle specifiche Sostituire R sistance Position de du capuchon s lecteur de de bougie testeur 4 6k k 1 20 C 68 F Fil de testeur Borne 1 du c b...

Page 520: ...66 at 10 20 C 68 F EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again NEUTRAL SWITCH INSPECTION 1 Inspect...

Page 521: ...ger t 1 2 W hl schalter LEER 1 1 LAUF GANG 1 EINGE LEGT VERIFICATION DE BLOC CDI V rifier tous les quipements lec triques Si aucun d faut n est trouv remplacer le bloc CDI puis v rifier nouveau les qu...

Page 522: ...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 523: ...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 524: ...ule Erneuern CDI Magnetz nder kontrollieren CDI Einheit erneuern Nicht in Ordnung MAGNETVENTILSYSTEM PR FVORG NGE Falls das Magnetventil nicht funktioniert sind die folgenden berpr fungen durchzuf hre...

Page 525: ...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 526: ...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 527: ...ISPEZIONE DEL COLLEGAMENTO DI ACCOPPIATORI E CONDUTTORI 1 Controllare 9 Collegamento di accoppiatori e conduttori Ruggine Polvere Allentamen to Cortocircuito Ripararli o sostituirli IC652040 FUNZIONA...

Page 528: ...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 529: ...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 530: ...auen 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 In...

Page 531: ...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 532: ...ixing chamber top Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 2 Inspect 9TPS coil resistance Out of specification Replace Tester lead Blue lead 1 Tester lead Black lead 2 TPS coil Test...

Page 533: ...nd Abweichung von Spezifikation Erneuern 2 Ispezionare 9 Resistenza della bobina del TPS Fuori specifica Sostituirla Resistenza Posizione del della bobina selettore del del TPS tester 4 6k a k 1 20 C...

Page 534: ...of specification Replace Tester lead Yellow lead 2 Tester lead Black lead 3 Tester selector position Full closed Full opened Zero 2k at 4 6k at 20 C 68 F 20 C 68 F k 1 EC693001 TPS REPLACEMENT AND AD...

Page 535: ...Positives Kabel des Pr fger tes Gelbes Kabel 2 Negatives Kabel des Pr fger tes Schwarzes Kabel 3 Regelbarer Position des TPS Spulenwider W hlschalters stand am Pr fger t Vollst ndig Vollst ndig geschl...

Page 536: ...nt steps 9Set the inductive tachometer engine tachometer to the high tension cord 9Turn the throttle stop screw 1 until the specified idle speed Refer to IDLE SPEED ADJUSTMENT sec tion in the CHAPTER...

Page 537: ...auf den Abschnitt EINSTELLUNG DER LEER LAUFDREHZAHL im KAPITEL 3 Leerlaufdrehzahl f r TPS Einstellung 1 700 bis 1 900 U min Passi della regolazione 9Collegare il tachimetro induttivo tachimetro motore...

Page 538: ...1 NOTE Tighten the screws TPS using 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 i...

Page 539: ...indem die vor dem Ausbau angebrachten Markie rungen a zum Ausrichten benutzt werden 14 Einbauen 9 Vergaser Siehe Abschnitt VERGASER UND ZUNGENVENTIL 13 Serrare 9 Vite TPS 1 NOTA Serrare le viti usand...

Page 540: ...PS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect 9TPS input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2...

Page 541: ...Einheit erneuern IC694000 ISPEZIONE DELLA TENSIONE IN INGRESSO NEL TPS 1 Scollegare l accoppiatore del TPS 2 Avviare il motore 3 Ispezionare 9 Tensione in ingresso nel TPS Fuori specifica Sostituire u...

Page 542: ...t be properly suited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed r...

Page 543: ...a surface 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 glage...

Page 544: ...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 545: ...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 oss...

Page 546: ...calibrating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Standard main jet 178 180 EC71V000 Power jet adjustment Th...

Page 547: ...est trop chaude S 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 in...

Page 548: ...cceleration will result Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and therefore it should be judged from your feeling of actual engine op...

Page 549: ...re difficile far girare il motore senza problemi a regimi inter medi si deve regolare l ago a getto 1 Se la miscela troppo ricca o troppo povera durante il funzionamento a regi mi intermedi si avranno...

Page 550: ...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 551: ...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 mittleren Drehzah...

Page 552: ...ion 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 8 to...

Page 553: ...diam tre de 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 groove Riche N3EW 4e groove...

Page 554: ...le straight por tion diameter around 1 8 to 1 4 throttle 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 i...

Page 555: ...apillon il d pend de la position de d but de c ne et de la position 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...

Page 556: ...2 4MX 14943 90 Pilot jet 2 2 Rich 62 4MX 14948 12 60 4MX 14948 11 58 4MX 14948 10 55 4MX 14948 09 STD 52 4MX 14948 08 STD 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 40 4MX 14948 0...

Page 557: ...170 4MX 14943 41 No 168 4MX 14943 91 No 165 4MX 14943 40 Povera No 162 4MX 14943 90 Getto Ricca No 62 4MX 14948 12 pilota No 60 4MX 14948 11 2 2 No 58 4MX 14948 10 No 55 4MX 14948 09 STD No 52 4MX 149...

Page 558: ...e 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 smoke fitted Th...

Page 559: ...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 560: ...la condition est bonne Si la normalisation est impossible Si ge de pointeau bouch Tuyau de carburant bouch Robinet de carburant bouch D coloration de la bougie Si la couleur est fonc e la condition e...

Page 561: ...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 562: ...ochdrehens Ein etwas fetteres Gemisch reduziert die Motorst rung D sennadel Klemmenposition absenken 1 Nut niedriger D sennadel Klemmenposition erh hen 1 Nut h her D sennadel Klemmenposition absenken...

Page 563: ...nadel 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 N...

Page 564: ...o della candela Se color cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Scolorim...

Page 565: ...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 566: ...No of the main jet must be changed by 15 it is advisable to change the heat range of spark plugs and newly select the proper main jet NOTE 9When checking the discoloration of spark plugs be sure to st...

Page 567: ...and de changer la plage de chaleur des bougies et de s lection ner un autre gicleur principal correct N B 9Lors du contr le de la d coloration des bougies attention bien arr ter le moteur imm diatemen...

Page 568: ...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 569: ...et d 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...

Page 570: ...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 13216 STD 14T 9383E 14215 Driv...

Page 571: ...2T 1C3 25452 00 Pression des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kgf cm2 9 0 12 psi Reifendruck Der...

Page 572: ...final stroke can be changed by changing the fork oil amount cC Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a nois...

Page 573: ...uit une tendance au dur cissement de la fourche avec comme cons quence une d t rioration des performances et des caract ristiques Voil pourquoi il convient d ajuster la fourche dans la plage sp cifi e...

Page 574: ...ronger and the front fork may sink deeply over a series of gaps To set a soft spring 9Change the rebound damping Turn out one or two clicks 9Change the compression damping Turn in one or two clicks 2...

Page 575: ...ndern Um eine oder zwei Klickstel lungen herausdrehen 9 Die Einfederd mpfung ndern Um eine oder zwei Klickstel lungen hereindrehen 2 Verwendung einer harten Feder Normaleweise bewirkt eine harte Fede...

Page 576: ...h of the spring 9Change the spring 2 Setting of damping force 9Change the rebound damping 9Change the compression damping SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 398 1C3 23141 A0 I SOFT 0...

Page 577: ...IIIII 0 449 1C3 23141 F0 I I HART 0 459 1C3 23141 G0 I II 0 469 1C3 23141 H0 I III 0 479 1C3 23141 J0 I IIII IC72P010 Parti di regolazione della forcella anteriore 9Molla della forcella anteriore 1 N...

Page 578: ...e the standard figure from the subtraction of the length b from the length a Standard figure 90 100 mm 3 5 3 9 in NOTE 9If the machine is new and after it is broken in the same set length of the sprin...

Page 579: ...ottraen do la lunghezza b dalla lunghezza a Valeur standard 90 100 mm 3 5 3 9 in Standardwert 90 100 mm 3 5 3 9 in Cifra normale 90 100 mm 3 5 3 9 in HINWEIS 9 Wenn eine neue Maschine eingefah ren wor...

Page 580: ...ng for more rebound damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the...

Page 581: ...k tur den niedrigen Einfederd mp fungeinsteller zur weicheren Seite hin stellen IC72G020 Registrazione della molla dopo la sostituzione Dopo la sostituzione assicurarsi di regolare la molla alla lungh...

Page 582: ...I D marks SPRING SPRING I D SPRING TYPE RATE PART NUMBER MARK FREE Q TY LENGTH SOFT 4 3 5UN 22212 00 Brown 1 260 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 STIFF 5 7 5UN 22212 70 White...

Page 583: ...22212 60 Rose 1 260 DUR 5 7 5UN 22212 70 Blanc 1 260 FEDER FEDER TEILE ID Mar Ungespannte TYP KON NUMMER kierung Federl nge STANTE Quantit t WEICH 4 3 5UN 22212 00 Braun 1 260 5 3 5UN 22212 50 Gelb 1...

Page 584: ...OF LENGTH ADJUSTMENT b 260mm 10 24in 240 5 258 5mm 9 47 10 18in 275mm 10 83in 255 5 273 5mm 10 06 10 77in SPRING FREE EXTENT OF LENGTH ADJUSTMENT b One I D mark 245 5 263 5 mm 9 67 10 37 in Approx 26...

Page 585: ...18 in 275 mm 10 83 in 255 5 273 5 mm 10 06 10 77 in LONGUEUR DE ETENDUE DE RESSORT LIBRE REGLAGE b Une marque d identification 245 5 263 5 mm 9 67 10 37 in Deux marques Approx 265 mm d identification...

Page 586: ...ssion damping Turn adjuster clockwise about 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 out Imp oz 0 2 0 3 US oz Spring...

Page 587: ...nd Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decre...

Page 588: ...2 0 3 US oz Monter un ressort doux V rifier s il y a coudes coups ou tout autre endommagement visible Si tel est le cas rem placer les parties affect es Remplacer par un nouveau pour une utilisation p...

Page 589: ...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 590: ...cm3 0 2 0 4 Imp oz 0 2 0 3 US oz reduzieren Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtbare Sch den etc pr fen Falls vorhanden betroffene Teile ersetzen Durch ein neues mit verl ngerter...

Page 591: ...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 592: ...iorario circa 2 scatti per diminuire lo smor zamento Diminuire la quantit d olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Sostituirla con una molla dolce Controllare eventuali curvature ammaccat...

Page 593: ...re lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aumen...

Page 594: ...TUN MEMO...

Page 595: ...y Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC01001...

Page 596: ...FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 W W1 1P8 28199 32 PRINTED IN JAPAN 2006 5 1 3 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED...

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