Yamaha YZ250 Owner'S Service Manual Download Page 218

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3-41

IGNITION TIMING CHECK

INSP

ADJ

7. Adjust:

Ignition timing

Adjustment steps:

Loosen the screws (stator)

Align the punch mark on the rotor with
punch mark on the stator

by moving the

stator.

Tighten the screws (stator).

Screw (stator):

7 Nm (0.7 m•kg, 5.1 ft•lb)

1P8-9-32-3b 5/1/06 9:41 AM Page 50

Summary of Contents for YZ250

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 PAPER YZ250 W W1 1P8 9 32 hyoshi 4 29 06 2 17 PM Page 1 ...

Page 2: ...by Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 1P8 9 32 hyoshi 4 29 06 2 17 PM Page 2 ...

Page 3: ...Yamaha Motor Co Ltd 1 Ausgabe Mai 2006 Alle Rechte vorbehalten Nachdruck auch auszugsweise oder nicht autorisierte Verwendung sind ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan YZ250 W W1 MANUALE DI SERVIZIO DEL PROPRIETARIO 2006 by Yamaha Motor Co Ltd 1a Edizione Mei 2006 Tutti i diritti riservati Sono espressamente proibiti qualsiasi ristampa o uso non a...

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

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

Page 6: ...MACHINE 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 or a face shield Also wear heavy boots gloves and protective clothing Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTAI...

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

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

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

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

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

Page 12: ... be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tun ing 2 The table of contents is at the beginning of the manual Look over the general layout of the book b...

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

Page 14: ...2 M W2 M W2 0Y hf O 0M O 0Y O 0Y he O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W2 L V M W2 0Yhf O2 0Y O M O M hfO 1 V 0Y O Mhf W2 M W2 0Y W2 0YhfO2 V40M W2 0Y hfW 0Y O M O MhfW2 O M hf O M W2 0Y W2 0Y he O 5 O2 0Yhf W2 0Y O M O M he W2 0Y W2 M W M W2 0Y W2 0YhfO M O 0Y hf O 0Y O M ...

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

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

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

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

Page 19: ...2 INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7 ALLGEMEINE ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHNISCHE DATEN REGELMÄSSIGE PRÜFUNG UND EINSTELLUNGEN MOTEUR MOTOR PARTIE CYCLE FAHRGESTELL PARTIE ELECTRIQUE ELEKTRISCHE EINRICHTUNGEN MISE AU POINT TUNING INDEX INDEX RENSEIGNEMENTS GENERAUX IC090010 INDICE ANALITICO ...

Page 20: ...L 1 12 STARTING AND BREAK IN 1 13 TORQUE CHECK POINTS 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 13 DEFINITION OF UNITS 2 13 CABLE ROUTING DIAGRAM 2 14 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 ENGINE 3 5 CHASSIS 3 17 ELECT...

Page 21: ...ÖL 1 12 STARTEN UND EINFAHREN 1 13 ANZUGSMOMENTE PRÜFPUNKTE 1 16 REINIGEN UND LAGERUNG 1 17 KAPITEL 2 TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN 2 1 WARTUNGSDATEN 2 3 ALLGEMEINE ANZUGSDATEN 2 13 DEFINITION DER EINHEITEN 2 13 KABELFÜHRUNGSÜBERSICHTPLAN 2 14 KAPITEL 3 REGELMÄSSIGE PRÜFUNG UND EINSTELLUNGEN WARTUNGSINTERVALLE 3 1 PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME 3 4 MOTOR 3 5 FAHRGESTELL ...

Page 22: ...ARY DRIVEN GEAR 4 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 SHIFT FORK 4 72 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FORK 5 26 HANDLEBAR 5 42 STEERING 5 50 SWINGARM 5 55 REAR SHOCK ABSORBER 5 63 ...

Page 23: ... SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 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 FOURCHETTE 4 72 CHAPITRE 5 PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE 5 1 FREIN AVANT ET FREIN ARRIERE 5 10 FOURCHE AVANT 5 26 GUIDON 5 42 DIRECTION 5 50 BRAS OSCILLANT 5 55 AMORTISSEUR ARRIERE 5 63 CAPITOL...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 SOLENOID VALVE SYSTEM 6 7 TPS THROTTLE POSITION SENSOR SYSTEM 6 9 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 12 ...

Page 25: ...E 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 CAPITOLO 6 PARTE ELETTRICA COMPONENTI ELETTRICI E SCHEMA ELETTRICO 6 1 SISTEMA DI ACCENSIONE 6 2 SISTEMA ELETTROVALVOLA 6 7 SISTEMA TPS SENSORE DI POSI ZIONE DELL ACCELERATORE 6 9 CAPITOLO 7 MESSA A...

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

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

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

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

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 and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the o...

Page 31: ...èces sont correctement remon tées 5 Tenir éloigné du feu 4 Während der Demontage der Maschine sind alle Teile zu reini gen und in der Reihenfolge der Demontage in Ablagen abzule gen um die Montage zu beschleunigen und den richtigen Einbau aller Teile sicherzustellen 5 Offenes Feuer und Funken fern halten 4 Durante lo smontaggio del veico lo pulire tutte le parti e collocarle in vassoi nell ordine ...

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

Page 33: ...d Öldichtungen 2 so einbauen dass das Zeichen des Herstellers oder die Herstellungs nummer nach außen gerichtet ist die eingeschlagenen Buchsta ben müssen sichtbar sein Wenn Öldichtungen eingebaut werden sind die Öldichtlippen mit Lithi um Fett zu bestreichen Beim Einbau die Lager großzügig mit Öl schmieren dD Niemals die Lager mit Druckluft trocknen Dadurch könnte die Oberfläche der Lager beschäd...

Page 34: ...hould be inspected carefully 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 tioned opposite to the thrust 3 it receives See the sectional view 4 Shaft ...

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

Page 36: ... check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect 9Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE 9If there in no continuity clean the terminals 9Be sure to perform the steps 1 to 7 listed above when checking the wireharness 9For a field remedy use a contact revitalizer a...

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

Page 38: ...e 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 This tool is used when loosening or tightening the flywheel magneto securing nut YU 3097 90890 01252 Dial gauge and stand YU 3097 90890 01252 YU 1256 Spark plug hole dial stand YU 1256 These tools are u...

Page 39: ...the fork oil seal YU 3112 C 90890 03112 Yamaha pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 90890 03113 90890 03113 Engine tachometer This tool is needed for observing engine rpm YM 91042 90890 04086 Clutch holding tool YM 91042 90890 04086 This tool is used to hold the clutch when removing or ...

Page 40: ...uin de l une ou l autre de ses moitiés YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit être utilisé pour la dépose du volant magnétique YM 1189 90890 01189 YU 1235 90890 01235 Outil de poignée de rotor Cet outil est utilisé pour le desserrage ou le serrage du boulon de fixation de volant magnétique YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Comparateur et support...

Page 41: ...ie et l intensité YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 90890 85505 Outil de poignée débrrayage Cet outil est utilisé pour immobiliser l embrayage quand on déposé ou monte l écrou de fixation de la noix d embrayage Testeur d étincelle dynamique Contrôleur d allumage Ce testeur est nécessaire pour contrôler les composants du systém d allumage YAMAHA bond N 1215 ThreeBond N...

Page 42: ...M 1189 90890 01189 Schwungrad Abziehwerkzeug Dieses Werkzeug wird für den Ausbau des Schwung rad Magnetzünders benötigt YM 1189 90890 01189 YU 1235 90890 01235 Rotor Haltewerkzeug Dieses Werkzeug wird für das Lösen und Festziehen der Schwungmagnetzünder Befestigungsschraube verwendet YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Messuhr und Messuhrständer Skalenmessfuß für Zündkerzenöffnung Dies...

Page 43: ...nnung und der Strom stärke zu verwenden YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 90890 85505 Kupplung Halterwerkzeug Dieses Werkzeug wird für das Festhalten der Kupp lung verwendet wenn die Kupplungsnaben Befesti gungsmutter aus oder eingebaut wird Dynamischer Zündfunkenprüfer Zündungs Prüfgerät Dieses Prüfgerät wird für die Kontrolle der Bauteile der Zündanlage benötigt YAM...

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 Quepsile viene usato quando si allenta o si serra il dado di fissaggio del magnete del volano YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Comparatore e supporto Supporto del comparatore del foro dell...

Page 45: ...à 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 installa il dado di fissaggio del mozzo della frizione Tester a scintilla dinamico Controllore dell accensione Questo strumento è necessario per controllare i compo nenti del sistema di accensione YAMAHA ...

Page 46: ...DAL 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 starter 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and force fully to start the engine This model has a prima ry kick starter so th...

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

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

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

Page 50: ...STAND 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 This set pin 1 is used to remove and install the push rod of the engine cC Be sure to use the set pin If the set pin is not used the power valve constituent parts will result in damage EC15e000 NIPP...

Page 51: ...urante fuoriesca ed è 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 basso BEQUILLE LATERALE AMOVIBLE La béquille latérale 1 est utilisée pour soutenir la machine uniquement à l arrêt ou durant le transport XG 9Ne jamais la soumettre à une force supplémentaire 9Dégager la béq...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 68: ...angement 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 ZA Starting system Kick starter Lubrication system Premix 30 1 Yamalube 2 R Oil type or grade 2 Cycle Transmission oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Periodic oil change 0 75 L 0 ...

Page 69: ...hassis 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 pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front ...

Page 70: ...5 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 0 0012 0 0026 in 0 1 mm 0 004 in 2nd 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Crankshaft Crank width A 59 95 60 00 mm 2 360 2 362 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Connecti...

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 ø2 9 Cutaway C A 7 Pilot jet P J 50 52 50 Pilot air screw P A S 1 2 1 4 1 1 4 for reference only Valve seat size V S ø3 8 mm 0 15 in Starter jet G S 85 Power jet P W J 50 Float arm height F H 5 5 7 5 mm 0 22 030 in Reed valve Thicknes...

Page 72: ...amp 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 st...

Page 73: ...ch 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 guide M 6 1 0 2 10 1 0 7 2 Stopper lever M 6 1 0 1 10 1 0 7 2 Torsion spring shift shaft stopper bolt M 8 1 25 1 22 2 2 16 Segment M 8 1 25 1 30 3 0 22 Bearing plate cover shift cam right M 6 1 0 2 10 1...

Page 74: ...89 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 96 in 252 mm 9 92 in Two I D marks 259 mm 10 20 in 258 mm 10 16 in Three I D marks 250 5 mm 9 86 in 249 5 mm 9 82 in Min Max One I D mark 245 5 263 5 mm 9 67 10 37 in Two I D marks 251 5 269 5 mm 9 90...

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

Page 76: ...ake 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 caliper Front brake caliper and front fork Front brake caliper and brake hose holder Brake caliper front and rear and pad pin plug Brake caliper front and rear and pad pin Brake caliper front and rear an...

Page 77: ...ame 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 Fuel tank mounting Fuel tank and fuel cock Fuel tank and seat set bracket Fuel tank and hooking screw fitting band Fuel tank and fuel tank bracket Seat mounting Side cover mounting Air scoop and fuel ta...

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

Page 79: ... type Electrical CDI Magneto model stator Manufacturer 5CU 20 YAMAHA Source coil 1 resistance color 720 1 080 Ω at 20 C 68 F Black Black Red Source coil 2 resistance color 44 66 Ω at 20 C 68 F Green Blue Green White Pickup coil resistance color 248 372 Ω at 20 C 68 F White Blue White Red CDI unit model Manufacturer 1P8 00 YAMAHA Ignition coil Model Manufacturer 1P8 00 YAMAHA Minimum spark gap 6 mm...

Page 80: ...m temperature A Distance across flats B Outside thread diameter EC230000 DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS A B TORQUE SPECIFICATION Nut Bolt Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm milimeter 10 3 meter Length cm centimeter 10 2 meter Lengt...

Page 81: ...es Monocylindre incliné Cylindrée 249 cm3 8 76 lmp oz 8 42 US oz Alésage 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 Système de démarrage Démarreur au pied Système de graissage Mélange 30 1 Yamalube 2 R Type ou grade d huile 2 temps Huile de transmission Huile Yamalube 4 10W 30 ou huile moteur SAE 10W 30 type SE Vidange périod...

Page 82: ...UROPE CDN Type de cadre Simple berceau dé dédouble Angle de chasse 26 9 27 1 Chasse 115 mm 4 53 in 118 mm 4 65 in Pneu Type de pneu Avec chambre à air Taille de pneu avant 80 100 21 51M Taille de pneu arrière 110 90 19 62M Pression de pneu avant et arrière 100 kPa 1 0 kgf cm2 15 psi Freins Type de frein avant Frein à simple disque Commande Commande à la main droit Type de frein arrière Frein à sim...

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 monté 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Jeu latéral monté 1ére 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2e 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Vilebrequin Largeur du 59 95 60 00 mm vilebrequin A 2 360 2 362 in Lim...

Page 84: ...EIHIN 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 ø2 9 Echancrure C A 7 Gicleur de ralenti P J 50 52 50 Vis d air de ralenti P A S 1 2 1 4 1 1 4 référence uniquement Taille de siège de pointeau V S ø3 8 mm 0 15 in Gicleur de démarreur G S 85 Gicleur auxiliaire P W J 50 Hauteur 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 à air M 6 1 0 4 8 0 8 5 8 Bride de guidage de filtre à air M 5 0 8 1 1 0 1 0 7 Soupape flexible M 3 0 5 4 1 0 1 0 7 Boulon de réglage et contre écrou de câble d accélérateur M 8 1 25 1 7 0 7 5 1 Câble d accélérateur M 6 0 75 1 4 0 4 2 9 Tuyau d échappement avant M 6 1 0 1 14 1 4 10 Tuyau d échappement arrière M 6...

Page 86: ...sort d embrayage M 6 1 0 6 10 1 0 7 2 Boulon de réglage et contre écrou de câble d embrayage M 6 0 75 1 4 0 4 2 9 Axe de levier de poussé M 5 0 8 1 6 0 6 4 3 Pignon de chaîne M20 1 0 1 75 7 5 54 Guide de sélecteur M 6 1 0 2 10 1 0 7 2 Levier de butée M 6 1 0 1 10 1 0 7 2 Ressort de torsion arbre de sélecteur Boulon de butée M 8 1 25 1 22 2 2 16 Segment M 8 1 25 1 30 3 0 22 Couvercle de plateau de ...

Page 87: ... Zéro mm Zéro in Suspension arrière USA CDN ZA AUS NZ EUROPE Débattement d amortisseur 131 5 mm 5 18 in Longueur de ressort libre Approx 265 mm 10 43 in Longueur de raccord Une marque d identification 253 mm 9 96 in 252 mm 9 92 in Deux marques d identification 259 mm 10 20 in 258 mm 10 16 in Trois marques d identification 250 5 mm 9 86 in 249 5 mm 9 82 in min max Une marque d identification 245 5 ...

Page 88: ...10 in Epaisseur de plaquette 4 4 mm 0 17 in 1 0 mm 0 04 in Dia intérieur de maître cylindre 11 0 mm 0 433 in Dia intérieur de cylindre d etrier 27 0 mm 1 063 in 2 Type de liquide de frein DOT 4 Frein à disque arrière Dia extérieur épaisseur 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Limite de flèche 0 15 mm 0 006 in Epaisseur de plaquette 6 4 mm 0 25 in 1 0 mm 0 04 in Dia intérieur de maître ...

Page 89: ...uyau de frein Etrier de frein avant et arrière et bouchon de goupille de plaquette Etrier de frein avant et arrière et goupille de plaquette Etrier de frein avant et arrière et vis de purge Axe de roue avant et écrou Support d axe de roue avant Disque de frein avant et moyeu de roue Disque de frein arrière et moyeu de roue Support de repose pied et cadre Montage de pédale de frein Maître cylindre ...

Page 90: ... réservoir de carburant et cadre Montage de réservoir à essence Réservoir à essence et robinet à essence Réservoir à essence et patte de maintien Réservoir à essence et vis d accrochage bande de fixation Réservoir à essence et patte du réservoir à essence Montage de selle Montage de couvercle latéral Prise d air et réservoir de carburant Prise d air et panneau M 4 0 7 M10 1 25 M10 1 25 M20 1 5 M 8...

Page 91: ...e de pare boue arrière arrière Plaque d immatriculation M 6 1 0 M 6 1 0 M 6 1 0 M 6 1 0 Pièce à serrer Taille de filetage Q té 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 7 5 1 N B Le coupe de serrage des parties marquées doit être vérifié après le rodage ou avant chaque course ...

Page 92: ...rique CDI Magnéto modèle stator Fabricant 5CU 20 YAMAHA Résistance de bobinage de source 1 720 1 080 Ω à 20 C 68 F couleur noir noir rouge Résistance de bobinage de source 2 44 66 Ω à 20 C 68 F couleur vert bleu vert blanc Résistance de bobinage d excitation 248 372 Ω à 20 C 68 F couleur blanc bleu blanc rouge Bloc CDI Modèle Fabricant 1P8 00 YAMAHA Bobine d allumage Modèle Fabricant 1P8 00 YAMAHA...

Page 93: ...iletages propres et secs Les composants doivent être à température ambiante A Distance entre les plats B Diamètre extérieur du filetage DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE SPECIFICATION A B DE COUPLE Ecrou Vis Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unité Signification Défin...

Page 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 Verdichtungsverhältnis 9 2 10 6 1 Für USA und CDN 8 9 10 6 1 Für EUROPA AUS NZ und ZA Anlasssytem Kickstarter Schmiersystem Benzin Öl Gemisch 30 1 Yamalube 2 R Ölsorte oder Qualität Zweitakt Getriebeöl Yamalube 4 10W 30 oder Motoröl SAE 10W 30 SE Regelmäßige Ölwechsel 0 75 L ...

Page 95: ... 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 Reifengröße Bauart Mit Schlauch Reifengröße vorn 80 100 21 51M Reifengröße hinten 110 90 19 62M Reifendruck vorn und hinten 100 kPa 1 0 kgf cm2 15 psi Bremsen Vorderradbremse Einfach Scheibenbremse Betätigung Rechte Hand Hinterradbremse Einfach Scheiben...

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 Eingebaut 1 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Kurbelwelle Kurbelwangenbreite 59 95 60 00 mm A 2 360 2 362 in Kurbelwellenschlag C 0...

Page 97: ...PWK38S KEIHIN Identifikationsmarkierung 1P89 60 1P86 40 1P87 50 Hauptdüse M J 178 180 178 Hauptluftdüse M A J 200 Düsennadel Klemmposition J N N3EW 2 N3EW 3 N3EW 2 Hauptzerstäuber N J ø2 9 Abschrägung C A 7 Leerlaufdüse P J 50 52 50 Leerlauf Luftregulierschraube P A S 1 2 1 4 1 1 4 nur als Hinweis Ventilsitzgröße V S ø3 8 mm 0 15 in Starterdüse G S 85 Kraftdüse P W J 50 Schwimmerarmhöhe F H 5 5 7 ...

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 Luftfiltergehäuse M 6 1 0 4 8 0 8 5 8 Luftfilter Führungsschelle M 5 0 8 1 1 0 1 0 7 Zungenventil M 3 0 5 4 1 0 1 0 7 Gaszug Einstellschraube und Sicherungsmutter M 8 1 25 1 7 0 7 5 1 Gasseil M 6 0 75 1 4 0 4 2 9 Auspuffrohr vorn M 6 1 0 1 14 1 4 10 Auspuffrohr hinten M 6 1 0 1 12 1 2 8 7 Auspuffrohrstütze ...

Page 99: ...ungsfeder 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 Schaltführung M 6 1 0 2 10 1 0 7 2 Anschlaghebel M 6 1 0 1 10 1 0 7 2 Torsionsfeder Schaltwelle Entkupplungsgliedbolzen M 8 1 25 1 22 2 2 16 Segment M 8 1 25 1 30 3 0 22 Lagerplattendeckel Schaltnocken rechts M 6 1 0 2 10 1...

Page 100: ...gabelbeinrohre Hinterradaufhängung USA CDN ZA EUROPA AUS NZ Hub des Stoßdämpfers 131 5 mm 5 18 in Ungespannte Federlänge Etwa 265 mm 10 43 in Einbaulänge Eine ID Markierung 253 mm 9 96 in 252 mm 9 92 in Zwei ID Markierungen 259 mm 10 20 in 258 mm 10 16 in Drei ID Markierungen 250 5 mm 9 86 in 249 5 mm 9 82 in Min Max Eine ID Markierung 245 5 263 5 mm 9 67 10 37 in Zwei ID Markierungen 251 5 269 5 ...

Page 101: ... 0 12 in 9 84 0 10 in Bremsbelagstärke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder 11 0 mm 0 433 in Innendurchmesser Bremssattelzylinder 27 0 mm 1 063 in 2 Innendurchmesser Bremsflüssigkeit DOT 4 Hinterradscheibenbremse Außendurchmesser Dicke 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Ausweichungsgrenzwert 0 15 mm 0 006 in Bremsbelagstärke 6 4 mm 0 25 in 1 0 mm 0 04 in Hauptbremszylinder...

Page 102: ... ANMERKUNG Lenkerkrone und äußeres Rohr Untere Gabelbrücke und äußeres Rohr Lenkerkrone und Lenkerschaft Lenkerhalter oben Lenkerhalter Unten Lenkerringmutter Teleskopgabel und Dämpfer Baugruppe Teleskopgabel und Einsteller Dämpfer Baugruppe und Hauptventil Einsteller und Dämpfer Baugruppe Entlüftungsschraube Teleskopgabel und Hauptventil Vorderradgabel und Schutz Schutz und Bremsschlauchhalter Ga...

Page 103: ...ank Befestigungsklemmfaust und Rahmen Kraftstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstofftank und Hakenschraube Befestigungsband Kraftstoftank und Kraftstofftankhalterung Sitz Befestigung Seitendeckel Befestigung Luft Schrappergefäß und Kraftstofftank Luft Schrappergefäß und platte M 6 1 0 M 4 0 7 M10 1 25 M10 1 25 M20 1 5 M 8 1 25 M 6 1 ...

Page 104: ...u prüfen 2 11 WARTUNGSDATEN SPEC Vorderrad Kotflügel Befestigung Hinterrad Kotflügel Befestigung Vorderrad Hinterrad Kotflügel Befestigung Hinterrad Nummernschild M 6 1 0 M 6 1 0 M 6 1 0 M 6 1 0 Anzuziehendes Teil Gewindegröße Anzahl Anzugsmoment 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 7 5 1 ...

Page 105: ...Ausführung CDI Modell Stator Hersteller 5CU 20 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 Ω bei 20 C 68 F Schwarz Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 Ω bei 20 C 68 F Grün Blau Grün Weiß Widerstand der Aufnahmespule 248 372 Ω bei 20 C 68 F Farbe Weiß Blau Weiß Rot CDI Einheit Modell Hersteller 1P8 00 YAMAHA Zündspule Modell Hersteller 1P8 00 YAMAHA Mindestzündfunkenstrecke 6...

Page 106: ...t für trockene und saubere Gewinde Die anzuziehenden Bauteile sollten dabei Raumtemperatur aufweisen A Schlüsselweite B Gewindedurchmesser DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A B ANZUGSMOMENTE Mutter Schraube Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Einheit Bedeutung Defini...

Page 107: ...na 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 8 9 10 6 1 Per EUROPA AUS NZ e ZA Sistema di avviamento Pedivella della messa in moto Sistema di lubrificazione Miscela preparata 30 1 Yamalube 2 R Tipo o qualità di olio a 2 cicli Olio per trasmissioni...

Page 108: ...olo 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 anteriore e posteriore 100 kPa 1 0 kgf cm2 15 psi Freno Tipo di freno anteriore Freno a disco singolo Azionamento Azionamento con la mano destra Tipo di freno posteriore Freno a disco singolo Azionamen...

Page 109: ... elastica Disegno in sezione Piano B 1 0 mm 0 039 in T 2 55 mm 0 100 in Distanza tra le estremità 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 0012 0 0026 in 0 1 mm 0 004 in 2 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Albero a gomiti Larghezza del gomito A 59 95 60 00 mm 2 360 2 362 in Limite di scentratura C 0 03 mm 0 0012 in 0 05 mm 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 principale N J ø2 9 Sezione C A No 7 Getto pilota P J No 50 No 52 No 50 Vite dell aria pilota P A S 1 2 1 4 1 1 4 solo riferimento Dimensioni della sede della valvola V S ø3 8 mm 0 15 in Getto avviamento G S N...

Page 111: ...iltro 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 3 0 5 4 1 0 1 0 7 Bullone di regolazione e controdado del cavo acceleratore M 8 1 25 1 7 0 7 5 1 Cavo dell acceleratore M 6 0 75 1 4 0 4 2 9 Tubo di scarico anteriore M 6 1 0 1 14 1 4 10 Tubo di sc...

Page 112: ...1 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 M20 1 0 1 75 7 5 54 Guida del cambio M 6 1 0 2 10 1 0 7 2 Leva di fermo M 6 1 0 1 10 1 0 7 2 Molla di torsione albero del cambio Bullone fermo M 8 1 25 1 22 2 2 16 Segmento M 8 1 25 1 30 3 0 22 Coper...

Page 113: ...OPA 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 Due contrassegni di marcatura di identificazione 259 mm 10 20 in 258 mm 10 16 in Tre contrassegni di marcatura di identificazione 250 5 mm 9 86 in 249 5 mm 9 82 in Min Max Un contrassegno di marcatur...

Page 114: ...4 in Diametro interno del cilindro principale 11 0 mm 0 433 in Diametro interno del cilindro delle pinze 27 0 mm 1 063 in 2 Tipo di liquido per freni DOT No 4 Freno a disco posteriore Diametro esterno del disco Spessore 245 4 0 mm 245 3 5 mm 9 65 0 16 in 9 65 0 14 in Limite di inflessione 0 15 mm 0 006 in Spessore della pastiglia 6 4 mm 0 25 in 1 0 mm 0 04 in Diametro interno del cilindro principa...

Page 115: ...l 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 anteriore M 6 1 0 1 4 0 4 2 9 e staffa inferiore Bullone di unione del tubo flessibile del freno M10 1 25 1 30 3 0 22 anteriore cilindro principale Bullone di unione del tubo flessibile del freno ant...

Page 116: ...0 58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio superiore M 8 1 25 1 32 3 2 23 Telaio posteriore e telaio inferiore M 8 1 25 2 29 2 9 21 Forcellone oscillante e supporto del tubo flessibile M 5 0 8 4 2 0 2 1 4 del freno Forcellone oscillante e superficie di contatto M 4 0 7 4 2 0 2 1 4 Suppor...

Page 117: ... Supporto 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 0 7 5 1 NOTA La parte marcata con deve essere controllata per il serraggio della coppia dopo il rodaggio o prima di ogni gara ...

Page 118: ...CDI Modello statore Costruttore del magnete 5CU 20 YAMAHA Resistenza 1 della bobina di origine 720 1 080 Ω à 20 C 68 F colore Nero Nero Rosso Resistenza 2 della bobina di origine 44 66 Ω à 20 C 68 F colore Verde Blu Verde Bianco Resistenza della bobina di accelerazione 248 372 Ω à 20 C 68 F colore Bianco Blu Bianco Rosso Modello Costruttore dell unità CDI 1P8 00 YAMAHA Bobina di accensione Modello...

Page 119: ...ti dovrebbero essere a temperatura ambiente A Distanza fra le parti piatte B Diametro esterno della filettatura IC230000 DEFINIZIONE DELLE UNITÀ IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA SPECIFICA RELATIVA A B ALLA COPPIA Dado Vite Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unità Lettura De...

Page 120: ...t 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 the frame F Clamp the throttle cable and wireharness to the frame G Pass the clutch cable in front of the center of the cylinder head tightening nut H Pass the air vent hose overflow hose and crankc...

Page 121: ...e vers la gauche et vers la droite E Brider le câble des gaz le câble d embrayage et le faisceau de fils au cadre F Brider le câble des gaz et le faisceau de fils au cadre G Faire passer le câble d embrayage devant le centre de l écrou de serrage de la culasse H Faire passer la durit de ventilation la durit de trop plein et la durit de mise à l air du carter moteur entre le cadre et la bielle I Pl...

Page 122: ...se 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 neutral switch lead except for USA and CDN to the frame G Clamp the radiator breather hose CDI magneto lead and neutral switch lead except for USA and CDN to the frame H Pass the CDI magneto lead radiator ...

Page 123: ...se à l air du radiateur à l intérieur du fil de magnéto CDI F Brider au cadre le fil de magnéto CDI la durit de mise à l air du radiateur la durit de mise à l air YPVS et le fil du contac teur de point mort excepté pour USA et CDN G Brider au cadre la durit de mise à l air du radiateur le fil de magnéto CDI et le fil du contacteur de point mort excepté pour USA et CDN H Faire passer le fil de magn...

Page 124: ...engine 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 radiator right and then above the radia tor fitting boss D Bring the connector cover into contact with the coupler E Pass the radiator breather hose behind the radiator hose F Insert the CDI unit band until...

Page 125: ...aire passer le fil haute tension à droite de la durit du radiateur de façon à ce que le fil haute tension ne soit pas en contact avec la durit du radiateur C Faire passer le fil du boîtier CDI entre le cadre et le radiateur droite et ensuite au dessus du bossage de montage du radiateur D Mettre le capuchon de connecteur en contact avec le coupleur E Faire passer la durit de mise à l air du radiate...

Page 126: ...ortion 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 twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder ...

Page 127: ... en contact avec la saillie de l étrier Faites ensuite passer le tuyau de frein dans les supports du tuyau de frein ç Si le tuyau de frein touche le ressort amortisseur arrière ajuster le coude Installer le tuyau de frein de manière que la partie avec le tuyau soit dirigée comme indiqué et touche légèrement la saillie sur le maître cylindre 1 Cilindro principale 2 Supporto del tubo flessibile del ...

Page 128: ...rake 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 STOP button lead to the han dlebar D Pass the brake hose in front of the number plate and through the cable guide E Pass the clutch cable through the cable guide on the number plate ...

Page 129: ...au de frein de manière que la partie avec le tuyau soit dirigée comme indipué et touche légèrement la saillie sur le maîtrecylindre Faire passer le fil de bouton d arrêt du moteur ENGINE STOP au centre du support d embrayage ç Fixer le fil du bouton ENGINE STOP sur le guidon Faire passer le tuyau de frein devant la plaque d immatriculation et à travers le guide de câble Faire passer le câble d emb...

Page 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 4 10W 30 or SAE 10W 30 SE motor oil Inspect wear Use chain lube Chain slack 48 58 mm 1 9 2 3 in PISTON Inspect and clean Replace PISTON RING Inspect Replace PISTON PIN SMALL END BEARING Inspect Repla...

Page 131: ...e fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER After Inspect and adjust rain ride Lube Molybdenum disulfide grease Replace spring seat Every one year Retighten CHAIN GUARD AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molyb...

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

Page 133: ...Changer 6 CULASSE Contrôler et nettoyer 6 6 Resserrer 6 6 CYLINDRE Contôler et nettoyer 6 6 Changer 6 YPVS Contrôler et nettoyer 6 6 EMBRAYAGE Contrôler et régler 6 6 Changer 6 BOITE DE VITESSE Changer l huile 6 6 Contrôler 6 Changer le roulement 6 FOURCHETTE BARILLET BARRE DE GUIDAGE Contrôler 6 ECROU DU ROTOR Resserrer 6 6 POT D ECHAPPEMENT Contrôler 6 6 Nettoyer 6 Resserrer 6 6 VILEBREQUIN Cont...

Page 134: ... 6 6 Contrôler la surface du frein à disque 6 6 Contrôler le niveau de fluide et les fuites 6 6 Resserrer les boulons du frein à disque les boulons d étier les boulons du maître cylindre et les boulons d union 6 6 Changer les plaquettes 6 Changer le liquide de frein 6 FOURCHE AVANT Contrôler et régler 6 6 Changer l huile 6 6 Changer la bague d étanchéité 6 BAGUE D ETANCHEITE ET JOINT ANTIPOUSSIERE...

Page 135: ...brifier 6 Changer le roulement 6 PNEU ROUES Contrôler la pression de gonflage le voile de roue et l usure des 6 6 pneus et voir s il n y a pas de rayon détendu Resserrer les boulons de la roue 6 6 dentée Contrôler les roulements 6 Changer les roulements 6 Graisser 6 ACCELERATEUR CABLES DE COMMANDE Contrôler le chaminement et le 6 6 branchement Graisser 6 6 Graisse au bisulfure de molybdène Graisse...

Page 136: ...neuern 6 ZYLINDERKOPF Prüfen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Prüfen und reinigen 6 6 Erneuern 6 YPVS Prüfen und reinigen 6 6 KUPPLUNG Prüfen und einstellen 6 6 Erneuern 6 GETRIEBE Öl wechseln 6 6 Prüfen 6 Lager erneuern 6 SCHALTGABEL SCHALTNOCKE FÜHRUNGSSTANGE Prüfen 6 ROTORMUTTER Nachziehen 6 6 SCHALLDÄMPFER Prüfen 6 6 Reinigen 6 Nachziehen 6 6 KURBELWELLE Prüfen und reinigen 6 6 VERGASE...

Page 137: ...RAHMEN Reinigen und prüfen 6 6 KRAFTSTOFFTANK KRAFT STOFFHAHN Reinigen und prüfen 6 6 BREMSEN Bremshebelposition und Bremspedalhöhe einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfläche prüfen 6 6 Flüssigkeitsstand prüfen und auf Undichtigkeit achten 6 6 Bremsscheiben und Bremssattel Befestigungsschrauben Haupt bremszylinder Befestigungs 6 6 schrauben und Hohlschrauben nachziehen Bremsbelagp...

Page 138: ...kerung prüfen Ketternrad Befestigungsschraube 6 6 nachziehen Lager prüfen 6 Lager erneuern 6 Schmieren 6 GASDREHGRIFF GASSEIL Seilzugführung und Anschlüsse 6 6 prüfen Schmieren 6 6 3 3 WARTUNGSINTERVALLE INSP ADJ Nach Nach Nach Benennung Nach dem jedem jedem jedem Wie Bemerkungen Einfahren Rennen dritten fünften erforderlich Rennen Rennen Molybdän Fett Lithium Fett Lithium Fett Yamaha Seilzug Schm...

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 CAMBIO CAMMA DEL CAMBIO GUIDA DI SCORRIMENTO Ispezione 6 DADO DEL ROTORE Riserraggio 6 6 MARMITTA Ispezione 6 6 Pulitura 6 Riserraggio 6 6 GOMITO Ispezione e pulitura 6 6 CARBURATORE Ispezione regolazion...

Page 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 DISPOSITIVO DI PROTEZIONE Sostituzione 6 AMMORTIZZATORE POSTERIORE Ispezione e regolazione 6 6 Lubrificazione 6 6 Sostituire la sede della molla 6 Riserraggio 6 6 COPRICATENA E RULLI PER CATENA Ispezione ...

Page 141: ...one gioco libero e riserraggio 6 6 Pulitura e lubrificazione 6 Sostituzione del cuscinetto 6 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneumatico e dell allentamento delle razze Riserraggio bullone del rocchetto 6 6 Ispezione dei cuscinetti 6 Sostituzione dei cuscinetti 6 Lubrificazione 6 VALVOLA A FARFALLA CAVO DI COMANDO Controllo del...

Page 142: ...ear brake P3 17 23 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 24 26 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P3 34 35 Steering Check that the handlebar can be turned smoothly and have no excessive play P3 35 37 Front forks and Check that they operate smoothly and there is no oil rear shock absorber...

Page 143: ...ne Contrôler la tension et l alignement de la chaîne S as surer que la chaîne est graissée correctement P3 24 26 Roues Contrôler s il n y a pas d usure excessive Contrôler s il n y a pas de rayons détendus et qu il n a pas de jeu ex P3 34 35 cessif Direction S assurer que le guidon peut être tourné en douceur et qu il n a pas de jeu excessif P3 35 37 Fourche avant et S assurer qu ils fonctionnent ...

Page 144: ...ung prü fen Auch sicherstellen dass die Kette richtig geschmiert P3 24 26 ist Räder Die Reifen auf übermäßige Abnutzung kontrollieren Speichen auf Lockerung und übermäßiges Spiel prü P3 34 35 fen Lenkung Darauf achten dass sich die Lenkstange glatt drehen lässt und kein übermäßiges Spiel aufweist P3 35 37 Vorderradgabel und Auf richtige Funktion achten und sicherstellen dass kein Hinterrad Stoßdäm...

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 Controllare che la marmitta sia montata saldamente e non presenti incrinature Controllare che il bullone di serraggio del rocchetto condotto non sia allentato Controllare il regolare funzionamento Lubr...

Page 146: ...ap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it cC Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright position ...

Page 147: ...teur et tourner lentement le bouchon à gauche jusqu au point de détente Cette procédure permet de faire tom ber toute pression résiduelle Quand le sifflement s est arrêté appuyer sur le bouchon tout en le tournant à droi te pour le déposer fF L eau calcaire et l eau salée sont nui sibles pour les pièces du moteur Si on ne dispose pas d eau douce on peut utiliser de l eau distillée 1 Placer la mach...

Page 148: ...Drain the coolant completely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Recommended coolant High quality ethylene glycol anti freeze containing anti corrosion for aluminum engine Coolant 1 and water soft water 2 mixing ratio 50 50 Coolant capacity 1 20 L 1 06 Imp qt 1 27 U...

Page 149: ...non schizzi sulle superfici ver niciate Se schizza toglierlo con acqua 1 Collocare un contenitore sotto il motore 2 Togliere 9 Bullone di scarico del liquido refrigerante 1 3 Togliere 9 Tappo del radiatore Scaricare completamente il liquido refrigerante 4 Pulire 9 Impianto di raffreddamento Lavare accuratamente l impian to di raffreddamento con acqua del rubinetto pulita 5 Installare 9 Rondella di...

Page 150: ...vel low Add coolant EC355000 RADIATOR CAP INSPECTION 1 Inspect 9Seal radiator cap 1 9Valve and valve seat 2 Crack Damage Replace Exist fur deposits 3 Clean or replace Handling notes of coolant The coolant is harmful so it should be handled with special care w 9When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor 9When coolant splashes to your clothes Quickly wa...

Page 151: ...it Wasser und danach mit Seife weg oder auswaschen 9Falls Kühlmittel eingenom men wird Die betroffene Person sofort zum Erbre chen bringen und zum näch sten Doktor begleiten Notes concernant la manipulation du liquide de refroidissement Le liquide de refroidissement étant dangereux il doit être manipulé avec une attention particuliére XG 9Quand vous vous mettez du liquide de refroidissement dans l...

Page 152: ...pres sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8 psi Standard pre...

Page 153: ...s sion spécifiée 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 sul dispositivo di tenu ta del tappo del radiatore 3 Tappo del radiatore 2 Applicare la pressione specificata 3 Ispezionare 9 Pressione Impossibile mantenere la pres sione specificata per 10 secondi So...

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 operation of clutch lever Clutch lever free play a a 8 13 mm 0 31 0 51 in Clutch lever free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until free play a is with in the specified limi...

Page 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 specifica Regolarlo 2 Regolare 9 Gioco libero della leva di comando della frizione NOTA 9Prima della regolazione mettere a nudo il dispositivo di regolazione spo stando il parapolvere 3 e il coperchio 4 9E...

Page 156: ...rottle 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 obtained 9Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted w After adjusting turn the handlebar to right and left and make sure that the ...

Page 157: ...avo dell acceleratore 2 Jeu à la poignée d accélé 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 Einstellschritte des Spiels des Gasseiles 9 Die Sicherungsmutter 1 lösen 9 Den Einsteller 2 drehen bis das Spiel innerhalb des vorgeschrie benen Bereiches liegt 9 Dis Sicherungsmutter festzie hen HINWEI...

Page 158: ...gine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove 9Seat 9Fitting bolt 1 9Washer 2 9Air filter element 3 9Filter guide 4 2 Clean 9Air filter element Clean them with solvent NOTE After cleaning remove the remaining solvent by squeezing the element cC Do not twist the element when squeezing the elem...

Page 159: ...assen anson sten können Staub und Schmutz in den Motor eindringen und schnel len Verschleiß sowie möglichen Motorschaden verursachen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelement 3 9 Luftfilterführung 4 2 Reinigen 9 Luftfilterelement Mit einer Waschlösung reini gen HINWEIS Nach dem Reinigen restliches Lösungsmittel aus dem Schaumgum mi ausdrücken dD Das Filterelement a...

Page 160: ...ole b in air filter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on filter guide with the hole b in air filter case EC35H002 TRANSMISSION OIL LEVEL CHECK 1 Start the engine warm it up for several min utes and wait for five minutes 2 Place the machine on a level place and ...

Page 161: ...to del filtro dell aria Danni Sostituirlo 4 Applicare 9 Olio per filtro dell aria in schiu ma oppure olio equivalente Sull elemento NOTA Comprimere per fare fuoriuscire l olio in eccesso L elemento dovrebbe essere umido ma non gocciolare 5 Installare 9 Guida del filtro 1 NOTA Allineare la sporgenza a sulla guida del filtro con il foro b nell elemento del filtro dell aria 2 Nm 0 2 m kg 1 4 ft lb 2 ...

Page 162: ...s 9Remove the oil check bolt 1 9Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level w Never attempt to remove the oil check bolt just after high speed operation The heat ed oil could spout out causing danger Wait until the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmission oil until oil flows ...

Page 163: ...nutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en plaçant le support convenable sous le moteur 3 Placer un récipient convenable sous le moteur 3 Controllare 9 Livello dell olio della trasmis sione Passi del controllo del livello dell olio della trasmissione 9Togliere il bullone di controllo dell olio 1 9Ispezionare il livello dell olio NOTA A...

Page 164: ...9Oil filler cap 2 EC35L021 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Adjusting steps 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw by the factory set number of turns NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before adjusting the pilot air screw turn it in ...

Page 165: ...é d huile change ments d huile pério 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 Capacità dell olio cambio dell olio periodico 0 75 L 0 66 Imp qt 0 79 US qt Passi della regolazione 9Girare la vite di disaerazione fino a quando non risulta ben fissata in sede 9Girare la vite di disaerazione dando il numero di giri indicato i...

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 å For USA and CDN Except for USA and CDN Adjustment steps Turn the throttle stop screw 1 until the engine runs at the lowest possible speed To increase idle speed Turn the throttle stop screw 1 1 in To decrease idle speed Tur...

Page 167: ...de butée d accélérateur 1 1 Passi della regolazione Ruotare la vite di arresto della val vola a farfalla 1 finché il motore non gira al numero di giri più basso possibile Per aumentare il numero di giri al minimo Ruotare in senso normale la vite di arresto della valvola a farfalla 1 1 Per diminuire il numero di giri al minimo Ruotare in senso inverso la vite di arresto della valvola a farfal la 1 ...

Page 168: ...right å 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 No 1215 or equivalent as shown Yamaha bond No 1215 ThreeBond No 1215 90890 85505 7 Nm 0 7 m kg 5 1 ft lb 12 Nm 1 2 m kg 8 7 ft lb A B ...

Page 169: ...1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 2 Déposer 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez généreusement de l agent d étanchéité Quick Gasket Yamaha Bond n 1215 ou équivalent comme illustré 2 Ausbauen 9 Innenrohr 1 3 Erneuern 9 Fasereinsatz 2 4 Einbauen 9 Innenrohr HINWEIS Quick Gasket Yamaha bond N...

Page 170: ...s a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end of the tube into a container e Slowly apply the brake lever or pedal sev eral times f Pull the lever in or push down on the ped al Hold the lever or pedal in position g ...

Page 171: ...lage Es kann zu einer gefährlichen Abnahme des Bremsvermögens kommen falls die Bremsanlage nicht richtig entlüftet ist 1 Ausbauen 9 Hauptbremszylinderkappe 9 Membrane 9 Schwimmer im Behälter vor dere Bremse 9 Schutz Hinterradbremse 2 Entlüften 9 Bremsflüssigkeit A Vorn B Hinten PARTIE CYCLE PURGE DE L AIR DU SYSTEME DE FREINAGE XG Purger le système de freinage si 9Le système a été démonté 9Un tuya...

Page 172: ...procedure when the tiny bubbles in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever position a a Standard position Extent of adjutment 95 mm 3 74 in 76 97 mm 2 99 3 82 in Brake lever position adjustment steps 9Loosen the locknut 1 9Turn the adjusting bolt 2 until the lever posi tion a is ...

Page 173: ...e circuit de freinage NOTA Se lo spurgo risulta difficoltoso può essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le bol licine nell impianto sono scompar se j Aggiungere liquido per frenio fino alla linea di livello sul ser batoio T Controllare il funzionamento del freno dopo avere spurgato l impianto frenante Posit...

Page 174: ...just NOTE The brake pedal height is the vertical distance from the inside top end of the footrest 2 Adjust 9Brake pedal height Brake pedal height a a Zero mm Zero in Pedal height adjustment steps 9Loosen the locknut 1 9Turn the adjusting nut 2 until the pedal height a is within specified height 9Tighten the locknut w 9Adjust the pedal height between the maximum Å Å and the minimum ı ı as shown In ...

Page 175: ...s die Pedalhöhe a innerhalb der vorgeschriebenen Höhe liegt 9 Die Sicherungsmutter festziehen W 9 Pedalhöhe gemäß Abbildung zwischen Maximum å å und Mini mum einstellen bei dieser Einstellung soll das Ende b b der Schraube 3 3 aus dem Gewinde teil überstehen 4 4 aber im Abstand von nicht weniger als 2 mm 0 08 in c c vom Bremspedal 5 5 9 Nachdem die Pedalhöhe einge stellt wurde darauf achten dass d...

Page 176: ...er its end 9Loosen the bleed screw and push the caliper piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 7 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper 8 and tighten the pad pin 9 Bleed screw 6 Nm 0 6 m kg 4 3 ft b Bolt caliper 23 Nm...

Page 177: ...ken dD Die abgelassene Bremsflüssig keit nicht wiederverwenden 9 Die Entlüftungsschraube festzie hein 9 Bremsbeläge 7 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbeläge mit deren Über ständen a in die Bremsschuh aussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 9 Den Sattel 8 einbauen und den Belagstift 9 festziehen 9Desserrer la goupille de plaquet...

Page 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 Brake pad thickness a a Standard 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Brake pad replacement steps 9Remove the protector 1 and pad pin plug 2 9Loosen the pad pin 3 9Remove the rear wheel 4 and caliper 5...

Page 179: ...omando del freno Sensazione di morbidezza o spugnosità Spurgare impianto frenante Consultare la sezione SPURGO DELL ARIA DALL IMPIANTO FRENANTE IC366060 ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 1 Ispezionare 9 Spessore delle pastiglie del freno a Fuori specifica Sostituirle come set 2 Sostituire 9 Pastiglia del freno Bouchon de goupille de plaquette 3 Nm 0 3 m kg 2 2 ft lb Tap...

Page 180: ...r projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper w and rear wheel e Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 9Tighten the pad pin r 9Install the pad pin plug t and protector y Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Bolt protector 7 Nm 0 7 m kg 5 1 ft ...

Page 181: ...uyau transparent 8 à la vis de purge 9 et placer le récipient approprié sous son extré mité 9Desserrer la vis de purge et y enfoncer le piston d étrier fF Ne pas réutiliser le liquide de frein purgé 9Serrer la vis de purge 9Installer les plaquettes de frein 0 et la goupille de plaquette q N B 9Installer les plaquettes de frein en ajustant leurs saillies a dans l encoche de l étrier b 9A ce stade s...

Page 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 ÅFront ıRear w 9Use only designated quality brake fluid to avoid poor brake performance 9Refill with same type and brand of brake flu id mixing fluids could result in poor brake performance 9Be sure that water or other contaminants do not enter master cylinder when refilling 9...

Page 183: ... LIQUIDO PER FRENI 1 Collocare il cilindro principale in maniera tale che la sua parte supe riore si trovi in posizione orizzon tale 2 Ispezionare 9 Livello del liquido per freni Fluido a livello più basso Rabboccarlo a Livello più basso A Anteriore B Posteriore T 9Per evitare uno scarso rendimento frenante usare soltanto liquido per freni della qualità indicata 9Rabboccare con lo stesso tipo e ma...

Page 184: ...rease its tension 9Measure the length between drive chain roller 1 and y as shown 9Perform this measurement at two or three dif ferent places 2 Remove 9Master link clip 9Joint 1 9Drive chain 2 3 Clean 9Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain EC369002 DRIVE CHAIN INSPECTION 1 Measure 9Drive chain length 15 lin...

Page 185: ...Die Länge zwischen der Antriebsket tenrolle 1 und y wie dargestellt messen 9 Diese Messung an zwei oder drei verschiedenen Stellen durchführen IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei rocchetti a Usura eccessiva Sostituirli NOTA Sostituire il rocchetto conduttore quel lo condotto e la catena di trasmissione come set IC369002 ISPEZIONE DELLA CATENA DI TRASMISSIONE 1 Misurare 9 Lun...

Page 186: ...olutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 48 58 mm 1 9 2 3 in Drive chain lubricant SAE 10W 30 motor oil or suitable chain lubricants 5 Install 9Drive chain 1 9Joint 2 9Master link clip 3 cC Be sure to install the master link clip to the direction as shown a Turning direction ...

Page 187: ... anello principale nella direzione illustrata a Direzione di rotazione 6 Lubrificare 9 Catena di trasmissione 5 Monter 9 Chaîne de transmission 1 9 Raccord 2 9 Agrafe de l attache rapide 3 fF Veiller à insérer l agrafe de l attache rapide dans le sens indiqué a Sens de la marche 6 Lubrifier 9 Chaîne de transmission Lubrifiant de chaîne de transmission Huile moteur SAE 10W 30 ou un lubrifiant pour ...

Page 188: ...3 3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain puller align ment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear cC Too small chain slack will overload the engine and other vital parts keep the slack...

Page 189: ... innerhalb des spezifizier ten Bereiches halten 9 Die Achsmuttern festziehen während die Antriebskette nach unten gedrückt wird 9 Die Sicherungsmuttern festziehen 3 Régler 9 Flèche de chaîne de transmis sion Procédure de réglage de flèche de chaîne de transmission 9Desserrer l écrou d axe 1 et les contre écrous 2 9Régler la flèche de chaîne en tor nant les dispositifs de réglage 3 Pour tendre Tour...

Page 190: ...ase on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1 Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the adjuster 1 1 out EC36f000 FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff during a run relieve t...

Page 191: ...au de fourche interne et le cache poussière 2 Nettoyer 9 Joint antipoussière a 9 Bague d étanchéité b N B 9Nettoyer le joint antipoussière et la bague d étanchéité après chaque cour se 9Appliquer la graisse à base de savon au lithium sur le tube interne Härter a a Die Expansions Dämpfungskraft erhöhen Den Einsteller 1 1 hin eindrehen Weicher b b Die Expansions Dämpfungskraft vermindern Den Einstel...

Page 192: ...ON DAMPING FORCE ADJUSTMENT 1 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 out Minimum 20 clicks out from maximum position 9STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in p...

Page 193: ... Ruota re il dispositivo di regolazione 1 1 in senso normale Più morbido b b Diminuire la forza di smorza mento della com pressione Ruo tare il dispositivo di regolazione 1 1 in senso inverso REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION DE LA FOURCHE AVANT 1 Régler 9 Force d amortissement de com pression En tournant le dispositif de réglage 1 EINSTELLUNG DER KOMPRESSI ONS DÄMPFUNGSKRAFT DER...

Page 194: ...ster 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 smooth action Abnormal noise Unsmooth action Grease the pivoting points or repair the piv oting points Damage Oil leakage Replace Minimum 20 clicks out from maximum position Extent of adjustment Maximum F...

Page 195: ...égulateur au delà du minimum ou du maximum au risque de l endommager XG Toujours régler à la même position sur chaque bras de fourche avant Un réglage inégal peut entraîner une mauvaise maniabilité et une perte de stablilité VERIFICATION DE L AMOR TISSEUR ARRIERE 1 Examiner 9 Action régulière du bras oscil lant Bruit anormal Action irrégulière Graisser les points de pivot ou les réparer Endommagem...

Page 196: ...etting EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Remove 9Rear frame 3 Loosen 9Locknut 1 4 Adjust 9Spring preload By turning the adjuster 2 Stiffer Increase the spring preload Turn the adjuster 2 2 in Softer Decrease the spring pre load Turn the adjuster 2 2 out Extent of adjustment 245 5 263 5 mm 9 67 10 37 in ...

Page 197: ...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 Härter Erhöhung der Federvorspan nung Den Ein steller 2 2 hinein drehen Weicher Verminderung der Federvor spannung Den Einsteller 2 2 her ausdrehen Plus dur Augmentation de la précontrainte de ressort Tourner le dispo sitif de réglage 2 2 a droit Plus mou Diminution de la précontrainte de ressort Tourner ...

Page 198: ...ad juster with the punch mark b on the bracket cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the ad juster 1 1 out Minimum 20 clicks out from maximum position Extent of adjustment Maximum Fully turned in position Sta...

Page 199: ... des Einstellers 1 IC36N020 REGOL ELLA FORZA DI SMOR ZAMENTO DELL ESTENSIONE D E L L A M M O R T I Z Z A T O R E POSTERIORE 1 Regolare 9 Forza di smorzamento dell estensione Ruotando il dispositivo di rego lazione 1 Maximum Minimum Position 20 le mettre hors complètement circuit à partir du rentrée réglage maximum Etendue de réglage Massima Minima 20 scatti in senso Posizione inverso avvitata comp...

Page 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 be damaged Stiffer a a Increase the low compression damping force Turn the ad juster 1 1 in Softer b b Decrease the low compres sion damping force Turn the adjuster 1 1 out Minimum 20 clicks out from...

Page 201: ...RADSTOS SDÄMPFERS 1 Einstellen 9 Niedrige Kompressions Dämp fungskraft Den Einsteller 1 drehen IC36c000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento a bassa compressione Ruotando il dispositivo di rego lazione 1 REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION BASSE DE L AMOR TISSEUR ARRIERE 1 Régler 9 Force d amor...

Page 202: ...i tion Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the high compression damping force Turn the ad juster 1 1 in Softer b b Decrease the high compres sion damping force Turn the adjuster 1 1 out Minimum 2 turns out from maximum ...

Page 203: ...teller 1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compressione Ruotando il dispositivo di rego lazione 1 REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION ELEVEE DE L AMOR TISSEUR ARRIERE 1 Régler 9 Force d amortissement de com pression élevée En tournant le dispositif de réglage 1 Maximu...

Page 204: ...f its position on the rim 9If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect 9Spokes 1 Bend Damage Replace Loose spoke Retighten 2 Tighten 9Spokes NOTE Be sure to retighten these spokes before and af ter break in After a practice or a race check spokes for looseness EC36T000 WH...

Page 205: ...ca che lo pneumatico scivola fuori dalla sua posizione sul cerchione 9Se si trova inclinato il gambo della valvola dello pneumatico si ritiene che lo pneumatico stia scivolando fuori dalla sua posizione Correggere la posizione dello pneumatico IC36S002 ISPEZIONE E SERRAGGIO DEI RAGGI 1 Ispezionare 9 Raggi 1 Curvatura Danni Sostituirli Raggio allentato Riserrarlo 2 Serrare 9 Raggi NOTA Assicurarsi ...

Page 206: ...ust steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring nut adjustment steps 9Remove the number plate 9Remove the handlebar and handle crown 9Loosen the ring nut 1 using the ring nut wrench 2 9Tighten the ring nut 3 using ring nut wrench 4 NOTE 9Apply the lithium soap base grease on the thr...

Page 207: ... re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellschritte der Lenkring mutter 9 Das Nummernschild entfernen 9 Die Lenkstange und die Lenker krone entfernen 9 Die Ringmutter 1 mit Hilfe des Ringmutterschlüssels 2 lösen 9 Die Ringmutter 3 mit Hilfe des Ringmutterschlüssels 4 festzie hen HINWEIS 9 Auf Seife basierendes Lithium fett auf das Gewinde der Lenk welle auftragen 9 Den Dre...

Page 208: ...r plate q NOTE 9The handlebar holder upper should be installed with the punched mark a forward 9Install the handlebar so that the marks b are in place on both sides 9Install the handlebar so that the projection c of the handlebar holder upper is posi tioned at the mark on the handlebar as shown 9Insert the end of the fuel breather hose w into the hole in the steering shaft cC First tighten the bol...

Page 209: ...rivolta in avanti 9Installare il manubrio in modo che i contrassegni b siano a posto da entrambi i lati 9Installare il manubrio in modo che la sporgenza c del suo supporto superiore sia posizionata sul segno sul manubrio come illustra to 9Inserire l estremità dello sfiato del carburante w nel foro dell albero dello sterzo iI Serrare dapprima i bulloni sul lato anteriore del supporto supe riore del...

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

Page 211: ...age couronne de guidon 21 Nm 2 1 m kg 15 ft lb Plaque d immatriculation 7 Nm 0 7 m kg 5 1 ft lb Dado dell albero dello sterzo 145 Nm 14 5 m kg 105 ft lb Supporto del manubrio superiore 28 Nm 2 8 m kg 20 ft lb Bullone serraggio corona del manubrio 21 Nm 2 1 m kg 15 ft lb Targa 7 Nm 0 7 m kg 5 1 ft lb Lenkerschaftmutter 145 Nm 14 5 m kg 105 ft lb Lenkerhalter oben 28 Nm 2 8 m kg 20 ft lb Klemmschrau...

Page 212: ... handlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding portion 0 Throttle cable end q Clutch cable end Å Use Yamaha cable lube or equivalent on these areas ı Use SAE10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quali ty lightweight lithium soap base grease cC Wipe off any excess grease an...

Page 213: ... Superficie di scorrimento del rullo della valvola a farfalla 9 Parte a spira del cavo di guida del tubo 0 Estremità del cavo dell acceleratore q Estremità del cavo della frizione A Usare lubrificante per cavi Yamaha o equivalente su queste zone B Usare olio per motori SAE 10W 30 o lubrificanti per catena adatti C Lubrificare le zone che seguono con grasso di alta qualità a base di sapone di litio...

Page 214: ...eeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten 9Spark plug NOTE 9Before installing a spark plug clean the gasket surface and plug surface 9Finger tighten a the spark plug before torq...

Page 215: ...gginoso anche se il motore e il carburatore sono in buone condizio ni di funzionamento 3 Misurare 9 Distanza tra le candele a Usare un calibro per fili metalli ci o uno spessimetro Fuori specifica Ridistanziar le 4 Pulire la candela con un pulitore per candela se necessario 5 Serrare 9 Candela NOTA 9Prima di installare una candela pulire la superficie della guarnizione e la superficie della candel...

Page 216: ...When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified distance from TDC 6 Check 9Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator Not aligne...

Page 217: ...cata da TDC 6 Contrôler 9 Avance à l allumage Le repère gravé a du rotor doit être aligné avec le repère gravé b du stator Ne pas aligné Ajuster 6 Kontrollieren 9 Zündzeitpunkt Die Körnermarkierung a auf dem Rotor sollte mit der Kör nermarkierung b auf dem Sta tor ausgerichtet sein Nicht übereinstimmend Ein stellen 6 Controllare 9 Messa in fase dell accensione La punzonatura a sul rotore dovrebbe ...

Page 218: ...NSP ADJ 7 Adjust 9Ignition timing Adjustment steps 9Loosen the screws stator 1 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator 9Tighten the screws stator Screw stator 7 Nm 0 7 m kg 5 1 ft lb ...

Page 219: ...Schrauben Stator 1 lösen 9 Die Körnermarkierung am Rotor mit der Körnermarkierung am Sta tor 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allentare le viti statore 1 9Allineare la punzonatura sul roto re con la punzonatura sullo statore 2 muovendo lo statore 9Serrare le viti statore 7 Einstellen 9 Zündzeitpunkt 7 Regolare 9 Messa in fase dell...

Page 220: ...e 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 7 Side cover right 1 Refer to REMOVAL POINTS 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal 2 3 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 6 Nm 0 6 m kg 4 3 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0...

Page 221: ...Nummernschild 1 MOTOR SITZ KRAFTSTOFFTANK UND SEITENDECKEL Ausbauumfang 1 Ausbau des Sitzes 2 Ausbau des Kraftstofftanks 3 Ausbau der Seitendeckel 4 Ausbau des Nummernschildes IC400000 MOTORE IC4R0000 SELLA SERBATOIO DEL CARBURANTE E COPERTURE LATERALI Ampiezza della rimozione 1 Rimozione della sella 2 Rimozione del serbatoio del carburante 3 Rimozione delle coperture laterali 4 Rimozione della ta...

Page 222: ...e inserted in the air cleaner case Number plate 1 Remove 9 Bolt number plate 9 Number plate 1 NOTE 9The projection a is inserted into the band of the number plate Pull the band off the projec tion before removal 9Remove the clutch cable 2 from the cable guide b on the number plate 9The projection c on the under bracket is inserted into the number plate Remove the number plate by pulling it off the...

Page 223: ... d immatriculation 1 N B 9La saillie a est insérée dans la bande de la plaque d immatriculation Reti rer la bande de la saillie avant la dépose 9Déposer le câble d embrayage 2 du guide de câble b sur la plaque d immatriculation 9La saillie c sur le support inférieur est insérée dans la plaque d immatri culation Déposer la plaque d imma triculation en la soulevant de la saillie Nummernschild 1 Ausb...

Page 224: ...2 mm 0 87 in 1 Plain washer ø 26 mm 1 02 in 1 3 Silencer 1 4 Collar R ø13 0 mm 0 51 in 1 Collar R ø15 5 mm 0 61 in 1 5 Collar R ø13 5 mm 0 53 in 1 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 Bolt exhaust pipe 2 10 Exhaust pipe 1 4 3 EXHAUST PIPE AND SILENCER ENG EC4S0000 EXHAUST PIPE AND SILENCER 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 25 Nm 2 5 m kg ...

Page 225: ...ent 2 10 Tuyau d échappement 1 Ausbauumfang Reihen Teilename Stück Bemerkungen folge zahl AUSBAU DES AUSPUFFROHRES UND SCHALLDÄMPFERS Seitendeckel rechts Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDECKEL 1 Schraube Schalldämpfer 2 2 Unterlegscheibe ø 22 mm 0 87 in 1 Unterlegscheibe ø 26 mm 1 02 in 1 3 Schalldämpfer 1 4 Hülse R ø13 0 mm 0 51 in 1 Hülse R ø15 5 mm 0 61 in 1 5 Hülse R ø13 5 mm 0 5...

Page 226: ...UEL 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 hose 1 EC450001 RADIATOR Extent of removal 1 Radiator removal 1 2 Nm 0 2 m kg 1 4 ft lb 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m ...

Page 227: ...sultare 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 Radiatore sinistro 1 5 Manicotto flessibile del radiatore 4 1 6 Radiatore destro 1 7 Manicotto flessibile del radiatore 2 2 8 Sfiato del radiatore 1 Preparazione per la rimozione Vorbereitung für den Ausb...

Page 228: ...p 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 hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect 9Radiator core 1 Obstruction Blow out with compressed air ...

Page 229: ...iateur en procédant comme suit Quand le moteur est froid mettre un chiffon épais tel qu une serviette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de détente Cette procédure permet d éliminer toute pression résiduelle Quand le sifflement s est arrêté appuyer sur le bouchon tout en le tournant vers la gauche puis l enle ver VERIFICATION Radiateur 1 Examiner 9 Carcasse 1 En...

Page 230: ...ection 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 ROUTING DIAGRAM section in the CHAPTER 2 4 Tighten 9Clamp radiator hose 2 5 5 Install 9Panel 1 9Bolt panel 2 NOTE Fit the hook a on the inner side first into the radiator 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2...

Page 231: ... 9 Schraube Kühler links 3 9 Kühlerschlauch 1 4 Siehe Abschnitt KABEL FÜHRUNGSÜBERSICHT PLAN im KAPITEL 2 4 Festziehen 9 Klemme Kühlerschlauch 2 5 5 Einbauen 9 Tafel 1 9 Schraube Tafel 2 HINWEIS Haken a an der Innenseite zuerst am Kühler befestigen 2 Installare 9 Radiatore destro 1 9 Rosetta 2 9 Bullone radiatore destro 3 9 Manicotto flessibile del radiato re 4 4 Consultare la sezione DIA GRAMMA D...

Page 232: ...olenoid 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 joint 4 Carburetor 1 5 Carburetor joint 1 6 Reed valve assembly 1 7 Stopper reed valve 2 8 Reed valve 2 9 Plate reed valve 1 1 Extent of removal 1 Carburetor removal 2 Reed valve removal 10 Nm 1 0 m kg...

Page 233: ...indung 2 Die Schrauben Vergaserverbindung lösen 4 Vergaser 1 5 Vergaserverbindung 1 6 Zungenventil 1 7 Anschlag Zungenventil 2 8 Zungenventil 2 9 Platte Zungenventil 1 VERGASER UND ZUNGENVENTIL Ausbauumfang 1 Ausbau des Vergasers 2 Ausbau des Zungenventils IC460000 CARBURATORE E VALVOLA A LAMELLA Ampiezza della rimozione 1 Rimozione del carburatore 2 Rimozione della valvola a lamella Ampiezza dell...

Page 234: ...op 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 stop screw 1 e Pilot air screw 1 Refer to REMOVAL POINTS r Power jet 1 t Solenoid valve 1 Extent of removal 1 Carburetor disassembly 1 4 Nm 0 4 m kg 2 9 ft lb ...

Page 235: ...chwimmerstift 1 7 Schwimmer 1 8 Nadelventil 1 9 Hauptdüse 1 0 Leerlaufdüse 1 q Starter Plungerkolben 1 w Drosselanschlagschraube 1 e Leerlauf Luftregulierschraube 1 Siehe unter AUSBAUPUNKTE r Kraftdüse 1 t Magnetventil 1 DEMONTAGE DES VERGASERS Ausbauumfang 1 Demontage des Vergasers IC468000 SMONTAGGIO DEL CARBURATORE Ampiezza della rimozione 1 Smontaggio del carburatore Ampiezza della rimozione O...

Page 236: ...hrottle 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 9Pilot air screw 1 NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before removing the pilot air screw turn it in...

Page 237: ... bei der Motorleistung bewirkt IC466020 NOTA PER IL MANEGGIO iI Non allentare le viti conduttore TPS sensore di posizione gas se non per cambiare il conduttore TPS sensore di posizione gas qualora si guasti per evitare di compromettere le presta zioni del motore Vis de richesse 1 Déposer 9 Vis de richesse 1 N B Pour optimiser l arrivée de carburant dans le cas d une plus petite ouverture du papill...

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 9Valve seat 2 Grooved wear a Replace Dust b Clean EC464000 INSPECTION EC464130 Carburetor 1 Inspect 9Carburetor body Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all ...

Page 239: ...u 1 Contrôler 9 Mouvement Coincement Réparer ou chan ger N B Insérer le boisseau 2 dans le corps du carburateur tout en maintenant le levier 1 relevé et contrôler s il coulisse en douceur Drosselventil 1 Kontrollieren 9 Freie Bewegung Klemmung Reparieren oder erneuern HINWEIS Drosselventil 2 bei hochgezogenem Hebel 1 in das Vergasergehäuse ein bringen und auf Bewegungsfreiheit prüfen IC464310 Valv...

Page 240: ...n 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 NOTE The float arm should be resting on the nee dle valve but not compressing the needle valve 9If the float height is not within specification inspect the valve seat and needle valve 9If either is wo...

Page 241: ...ntilsitz 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 Schwimmerhöhe durch Abbie gen der Schwimmerlasche b einzustellen 9 Die Schwimmerhöhe nochmals kontrollieren Altezza del galleggiante 5 5 7 5 mm 0 22 0 30 in Passi della misurazione e la rego lazione 9Tenere il carburatore in posizion...

Page 242: ...e 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 valve stopper Valve stopper height 10 3 10 7 mm 0 406 0 421 in EC464600 Float 1 Inspect 9Float 1 Damage Replace EC464701 Reed valve 1 Measure 9Reed valve bending a Out of specification Replace Reed val...

Page 243: ...ist dD Die Schrauben allmählich festzie hen um ein Verziehen des Ventils zu vermeiden REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 Butée soupape flexible 2 9 Vis soupape flexible 3 N B 9Mettre la lame soupape avec la cour bure de lame soupape de la manière indiquée 9Noter l entaille a dans le coin infé rieur de la soupape et de la plaque de butée fF Serrer les vis granduel...

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 installing the solenoid valve blow air on the solenoid valve and its installing loca tion on the carburetor in order to remove any foreign particles such as chips etc 9Apply the engine oil on the solenoid ...

Page 245: ...e de la soupape flexible avec sa face chanfreinée a orientée 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 Nm 1 0 m kg 7 2 ft lb Carburateur 1 Monter 9 Gicleur auxiliaire 1 Au carburateur 2 2 Monter 9 Joint torique 1 9 Electrovanne 2 Au carburateur fF 9Avant d installer l électrovanne nettoyez à l air compr...

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 Install 9Pilot jet 1 9Main jet 2 6 Install 9Needle valve 1 9Float 2 9Float pin 3 NOTE 9After installing the needle valve to the float install them to the carburetor 9Check the float for smooth movement...

Page 247: ...hungen 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 Per EUROPA Per AUS NZ e ZA 4 Installare 9 Stantuffo dell avviamento 1 Notare i seguenti punti di instal lazione 9Avvitare la vite dell aria pilota finché non è alloggiata legger mente 9Allentare la vit...

Page 248: ...ING 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 9Spring 3 9Needle holder 4 To throttle valve 5 NOTE Install the spring with its smaller dia a facing the collar 7 Install 9Float chamber 1 9Plate 2 9Screw float chamber 3 ...

Page 249: ...in 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 Installare i tubi flessibili di sfiato dell aria e il tubo flessibile di troppo pieno sul carburatore con le estremità prive di tagli a rivolte verso il carbura tore 9 Monter 9 Aiguille 1 9 Collerette 2 9 ...

Page 250: ...hrottle 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 chamber top 3 9Spring throttle valve 4 9Ring 5 9Throttle valve 6 NOTE 9While compressing the spring connect the throttle cable 9Align the projection a on the ring with the groove b in the needle hold...

Page 251: ...allare 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 verso l alto 9Dopo l installazione controllare che la manopola dell acceleratore si muova senza difficoltà 10 Einbauen 9 Gasseil 1 9 Sicherungsmutter 2 9 Mischkammer Oberteil 3 9 Feder Drosselventil 4...

Page 252: ...a 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 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Adjust 9Idle speed Refer to IDLE SPEED ADJUSTMENT section in the CHAPTER 3 ...

Page 253: ...n anbringen und Klemme in Übereinstimmung mit der waagerechten Linie b ausrichten die durch die Mitte der Vergaserbohrung führt 4 Anschließen 9 TPS Leitungskabel Drossel stellungssensor 1 9 Magnetventilleitung 2 Siehe Abschnitt KABEL FÜHRUNGSÜBERSICHT PLAN im KAPITEL 2 5 Einstellen 9 Leerlaufdrehzahl Siehe Abschnitt EINSTEL LUNG DER LEERLAUFDREH ZAHL im KAPITEL 3 2 Serrare 9 Vite giunto del carbur...

Page 254: ...at 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 4 Cylinder head 1 5 Power valve housing 1 6 Push rod 1 Refer to REMOVAL POINTS 7 Nut cylinder 4 8 Cylinder 1 Extent of removal 1 Cylinder head removal 2 Cylinder removal 1 2 34 Nm 3 4 m kg 24 ft lb 6...

Page 255: ...er nur jeweils 1 4 Drehung lösen bis alle Muttern locker sind 4 Zylinderkopf 1 5 Leistungsventilgehäuse 1 6 Schubstange 1 Siehe unter AUSBAUPUNKTE 7 Mutter Zylinder 4 8 Zylinder 1 ZYLINDERKOPF ZYLINDER UND KOLBEN ZYLINDERKOPF UND ZYLINDER Ausbauumfang 1 Ausbau des Zylinderkopfes 2 Ausbau des Zylinders IC470000 TESTA CILINDRO CILINDRO E PISTONE IC478000 TESTA CILINDRO E CILINDRO Ampiezza della rimo...

Page 256: ...ll 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 Valve holder 2 1 17 Power valve 1 1 Extent of removal 1 Piston and piston ring removal 2 Power valve removal 2 1 6 Nm 0 6 m kg 4 3 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9...

Page 257: ... 1 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 LEISTUNGSVENTIL Ausbauumfang 1 Ausbau des Kolbens und Kolbenrings 2 Ausbau des Leistungsventiles IC478100 PISTONE E VALVOLA DI POTENZA Ampiezza della rimozione 1 Rimozione del pistone e della fascia elasti...

Page 258: ...Piston 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 2 Remove 9Piston pin 1 9Piston 2 9Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficu...

Page 259: ... des Kolbenbol zens 1 HINWEIS Vor dem Abnehmen des Stifts des Kol benbolzens ist das Kurbelgehäuse mit einem sauberen Lappen abzudecken so dass der Stift nicht versehentlich in das Kurbelgehäuse fällt 2 Ausbauen 9 Kolbenbolzen 1 9 Kolben 2 9 Pleuelfußlager 3 HINWEIS Vor dem Entfernen des Kolbenbol zens sind die Sicherungsringnut und Bolzenbohrung zu entgraten Wenn die Kolbenbolzennut entgratet ist...

Page 260: ...Warpage measurement and re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur face the cylinder head 9Place 400 600 grit wet sandpaper 3 on the surface plate and re surface the head 4 using a figure eight sanding pattern NOTE Rotate the cylinder head several times to avoid removing too much mat...

Page 261: ... segment en l ouvrant plus que nécessaire 3 Togliere 9 Fascia elastica 1 NOTA Attenzione a non graffiare il pistone o danneggiare la fascia elastica allargan dola più di quanto sia necessario Procédure de mesure de la défor mation et rectification 9Poser une règle 1 et un calibre d épaisseur 2 sur la culasse 9Mesurer la déformation 9Si la déformation est hors spécifi cation rectifier la culasse 9M...

Page 262: ...Measure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measurements EC474321 Piston 1 Eliminate 9Carbon deposits From the piston crown a and ring groove b 2 Inspect 9Piston wall Score marks Repair or replace Standard Wear limit Cylinder 66 400 66 414mm 66 5 mm bo...

Page 263: ... C Die Zylinder Messlehre 1 ver wenden Außerhalb 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 Messwerte bilden 3 Misurare 9 Alesaggio cilindro C Usare calibro per cilindri 1 Fuori limite Sostituirlo NOTA Misurare l alesaggio cilindro C paral lelamente A B C e perpendicolar mente all albero a gomi...

Page 264: ...coloration 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 the play Free play exists Replace piston pin and or piston 4 Install 9Small end bearing 9Piston pin Into the small end of connecting rod 17 5 mm 66 352 66 367 mm 0 69 in 2 6120 2 6129 in Distance b b P...

Page 265: ...re extérieur d axe de piston 3 Prüfen 9 Spiel Wenn der Kolbenbolzen 1 im Kolben 2 eingebaut ist Es sollte kein spürbares Spiel sein Spiel wird festgestellt Kolbenbolzen und oder Kolben erneuern 3 Contrôler 9 Jeu lorsque l axe 1 est en place dans le piston 2 Il ne doit pas y avoir de jeu remarquable Il y a du jeu Changer l axe de piston et ou le piston 4 Monter 9 Coussinets de pied de bielle 9 Axe ...

Page 266: ...earance 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 Standard Limit 0 030 0 065 mm 0 1 mm 0 0012 0 0026 in 0 004 in 5 Check 9Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con...

Page 267: ...rona del pistone 2 Misurare 9 Distanza tra le estremità 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 Standard Grenze 0 030 0 065 mm 0 1 mm 0 0012 0 0026 in 0 004 in Seitliches Spiel Valore normale Limite 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Distanza tra le estremità della fascia installata Valore...

Page 268: ...6 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 2 61244 2 61256 in C green 66 360 66 363 mm 2 61260 2 61272 in D purple 66 364 66 367 mm 2 61276 2 61287 in EC474602 Piston clearance 1 Calculate 9Piston clearance Out of limit Replace piston and pi...

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 66 363 mm 2 61260 2 61272 in D porpora 66 364 66 367 mm 2 61276 2 61287 in Marque de piston a a Taille de piston couleur A rouge 66 352 66 355mm 2 61228 2 61240 in B orange 66 356 66 359 mm 2 61244 2 6125...

Page 270: ...9Spring 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 Combination Combine the piston and cylinder by the fol lowing chart NOTE When you purchase a cylinder you cannot des ignate its size Choose the piston that matches the above chart Cylinder mark Piston mark co...

Page 271: ... outil acéré éviter de rayer l aluminium Leistungsventilbohrung im Zylinder 1 Ausbauen 9 Rußablagerungen Aus der Leistungsventil Boh rung a HINWEIS Kein scharfkantiges Instrument ver wenden Kratzer auf dem Aluminium vermeiden IC474901 Foro della valvola di potenza sul cilindro 1 Togliere 9 Depositi carboniosi Dalla superficie del foro della valvola di potenza a NOTA Non usare uno strumento appunti...

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 pins b on the power valves 2 3 Install 9Thrust plate 1 9Screw thrust plate 2 NOTE Be sure to install the thrust plate to the cylinder before installing the valve shaft 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 ...

Page 273: ...ne 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 valvola di potenza 1 con il taglio a rivolto verso l alto 9Applicare olio al bisolfuro di molib deno sulla valvola di potenza 1 MONTAGE UND EINBAU Leistungsventil 1 Einbauen 9 Leistungsventil 1 1 9 Ventil...

Page 274: ...sulfide 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 shaft so that its cut faces upward 5 Install 9Valve holder 1 1 9Bolt link lever 2 9Bolt pulley 3 NOTE First tighten the bolt link lever and then tighten the bolts pulleys 6 Check 9Power valve 1 smooth mo...

Page 275: ... del biscottino 2 9 Puleggia 3 9 Molla 2 4 9 Rosetta 5 9 Gambo della valvola 6 NOTA 9Installare la molla 1 sulla leva del biscottino e quindi sul cilindro 9Installare la molla 1 con la parte del fermo a rivolta verso l interno 9Applicare l olio al bisolfuro di molib deno sulle scanalature delle pulegge 9Applicare il grasso a base di sapone di litio sul bordo del paraolio e sulle sca nalature delle...

Page 276: ...d 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 the piston ring 9Align the piston ring gap with the pin 2 9After installing the piston ring check the smooth movement of it 2 Install 9Gasket cylinder 1 9Small end bearing 2 9Dowel pin 3 NOTE 9Apply...

Page 277: ... côté imprimé du joint vers le couvercle du clapet de puissance 9Installer le couvercle du clapet de puissance en orientant vers le haut la saillie b à l arrière 2 Installare 9 Guarnizione cilindro 1 9 Cuscinetto dell estremità picco la 2 9 Perno di riferimento 3 NOTA 9Applicare l olio per motore al cusci netto albero a gomiti biella e rondel le dell estremità grande della biella 9Installare la gu...

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 clip 3 NOTE 9The arrow a on the piston dome must point to exhaust side 9Before installing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the ...

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 30 ft lb 42 Nm 4 2 m kg 30 ft lb 3 Monter 9 Piston 1 9 Axe de piston 2 9 Agrafe de l axe de piston 3 N B 9La flèche a située sur la calotte du piston doit être dirigée vers le côté échappement 9Avant ...

Page 280: ...s 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 the lithium soap base grease on the O rings 7 Install 9Cylinder head 1 9Copper washer 2 9Nut cylinder head 3 NOTE Tighten the nuts cylinder head in stage using a crisscross pattern 5 Nm 0 5 m kg 3 6 f...

Page 281: ... 1 9 Boulon boîtier de clapet de puissance 2 7 Monter 9 Culasse 1 9 Rondelle en cuivre 2 9 Ecrou culasse 3 N B Serrer les écrous culasse par étapes en utilisant un modéle d entre croisement 6 Monter 9 Joint torique 1 9 Goujon 2 N B Appliquer de la graisse à base de savon au lithium sur le joint torique 5 Installare 9 Guarnizione corpo della valvo la di potenza 9 Corpo della valvola di potenza 1 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 6 4 m kg 46 ft lb ...

Page 283: ...dela 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 di montaggio del moto re superiore 3 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 m kg 46 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 m kg 46 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 m kg 46 ft lb 8 Monter 9 Suppor...

Page 284: ...3 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 Extent of removal 1 Clutch plate and friction plate removal EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 1 10 Nm 1 ...

Page 285: ...sfeder 6 3 Kupplungsfeder 6 4 Druckscheibe 1 5 Reibscheibe 8 6 Kupplungsscheibe 7 KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und Reibscheibe IC490000 FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC498000 DISCO DELLA FRIZIONE E DISCO DI INNESTO Ampiezza della rimozione 1 Rimozione del disco della frizione e del disco di innesto Ampiezz...

Page 286: ...al tool 7 Lock washer 1 Refer to REMOVAL POINTS 8 Clutch boss 1 9 Thrust plate D ø44mm 1 73 in 1 10 Primary driven gear 1 11 Bearing 1 12 Thrust plate D ø42mm 1 65 in 1 13 Bolt push lever axle 1 14 Push lever axle 1 EC498200 PRIMARY DRIVEN GEAR PUSH ROD AND PUSH LEVER AXLE Extent of removal 1 Push rod and push lever axle removal 2 Push rod 1 disassembly 3 Primary driven gear removal 2 3 1 1 1 3 75...

Page 287: ...chubhebelachse 1 14 Schubhebelachse 1 PRIMÄRABTRIEBSZAHNRAD SCHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Primärabtriebszahnrades IC498200 INGRANAGGIO CONDOTTO PRIMARIO ASTA DI SPINTA E ASSE DELLA LEVA DI SPINTA Ampiezza della rimozione 1 Rimozione della asta di spinta e asse della leva di spinta 2 Smontaggi...

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 play exists Replace 9Gear teeth a Wear Damage Replace EC484400 Clutch spring 1 Measure 9Clutch spring free length a Out of specification Replace springs as a set Clutch holding tool YM 91042 4 4 90890 0...

Page 289: ...en å Für USA und CDN Außer USA und CDN POINTS DE DEPOSE Noix d embrayage 1 Déposer 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poignée d embrayage 4 5 pour maintenir la noix d embrayage å Pour USA et CDN Excepté pour USA et CDN VERIFICATION Cloche et noix d embrayage 1 Examiner 9 Cloche d embrayage 1 Craquelures usure endommage ment Chan...

Page 290: ...e 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 ASSEMBLY AND INSTALLATION EC485120 Push lever axle 1 Install 9Push lever axle 1 9Copper washer 2 9Bolt push lever axle 3 NOTE Apply the lithium soap base grease on the oil seal lip and push lever axle Fric...

Page 291: ...uatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors spécification Changer tous les disques d embrayage Utiliser une plaque à surfacer 1 et une jauge d épaisseur 2 Axe de levier de poussée 1 Examiner 9 Axe de levier de poussée 1 Usure endommagement Chan ger Tige de poussée 1 Examiner 9 Tige de poussée 1 1 9 Roulement 2 9 Rondelle ordinaire 3 9 Tige de poussée 2 4 Usure en...

Page 292: ...l on the bearing spacer and primary driven gear inner circumference 2 Install 9Thrust plate D ø 44 mm 1 73 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding tool 3 4 to hold the clutch boss å For USA and CDN Except for USA and CDN 4 Bend the lock washer 1 tab 75 Nm 7 5 m kg 54 ft lb Clutch holding tool YM 91042 3 3 90890 04086 4 4 å ...

Page 293: ...Appliquer de l huile de boîte de vitesses sur le roulement l entretoise et la circonférence intérieure du pignon mené primaire 2 Monter 9 Plaque de botée D ø44 mm 1 73 in 1 9 Noix d embrayage 2 3 Monter 9 Rondelle frein 1 9 Ecrou Noix d embrayage 2 N B Utiliser l outil de poignée d embrayage 3 4 pour maintenir la noix d embrayage å Pour USA et CDN Excepté pour USA et CDN 4 Courber la languette de ...

Page 294: ...tes 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 9Apply the transmission oil on the ends of the push rod 2 9Install the push rod 2 with its smaller end a toward you 8 Install 9Pressure plate 1 9 Install 9Clutch spring 1 9Screw clutch spring 2 NOTE...

Page 295: ...ent 9Appliquer de l huile de boîte de vitesses sur les disques de friction et disque d embrayage 6 Monter 9 Roulement 1 9 Rondelle ordinaire 2 9 Circlip 3 sur le champignon de débrayage 1 4 N B Appliquer de la graisse à base de savon au lithium sur le roulement et la rondel le ordinaire 7 Monter 9 Champignon de débrayage 2 1 9 Champignon de débrayage 1 2 N B 9Appliquez de l huile de transmission s...

Page 296: ...l 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 base grease on the O ring 10 Nm 1 0 m kg 7 2 ft lb ...

Page 297: ...n 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 über Kreuz festziehen 11 Installare 9 Coperchio della frizione 1 9 Bullone coperchio della frizio ne 2 NOTA Serrare gradualmente i bulloni in croce 12 Einbauen 9 O Ring 1 9 Kupplungskabel 2 HINWEIS Den L...

Page 298: ...nect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4 Primary driven gear 1 Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 5 Primary drive gear 1 6 Thrust plate 1 EC4C0000 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 1 Exten...

Page 299: ... Pousser la pédale de frein vers le bas Tuyau de radiateur 4 Déconnecter du côté pompe à eau Boulon Se reporter à la section CULASSE champignon de débrayage CYLINDRE ET PISTON 1 Kick starter 1 2 Couvercle de carter droit 1 3 Boulon pignon de transmission primaire 1 Uniquement desserrage Se reporter à POINS DE DEPOSE 4 Pignon mené primaire 1 Se reporter à la section EMBRAYAGE ET PIGNON MENE PRIMAIR...

Page 300: ...axle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 9 Holder 1 10 Tension spring 1 1 Extent of removal 1 Kick axle and kick idle gear removal 2 Shift shaft and stopper lever removal 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 301: ... arbre de sélecteur et du levier de butée Etendue de dépose Ordre Nom de pièce Q té Remarques DEPOSE DE L AXE DE DEMAR REUR AU PIED ET DE L ARBRE DE SELECTEUR 1 Pignon de renvoi de démarreur au pied 1 2 Ensemble axe de démarreur au pied 1 Se reporter à POINTS DE DEPOSE 3 Pédale de sélecteur 1 4 Arbre de sélecteur 1 5 Roulement 1 6 Guide de sélecteur 1 Se reporter à POINTS DE DEPOSE 7 Ensemble levi...

Page 302: ...emove 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 assembly 2 NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4C4000 INSPECTION EC4C4200 Kick axle and ratchet wheel 1 Check 9Ratchet wheel 1 smooth movement Unsmooth movem...

Page 303: ...reur au pied 1 Déposer 9 Ensemble axe de démarreur au pied 1 N B Décrocher le ressort de torsion 2 de l orifice a sur le vilebrequin Ensemble guide de levier de sélecteur 1 Déposer 9 Boulon guide de sélecteur 9 Guide de sélecteur 1 9 Ensemble levier de sélecteur 2 N B L ensemble de levier de sélecteur est démonté en même temps que le guidage de sélecteur VERIFICATION Axe de kick et Roue à cliquet ...

Page 304: ...0 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 guide and shift lever assembly 1 Inspect 9Shift guide 1 9Shift lever 2 9Pawl 3 9Pawl pin 4 9Spring 5 Wear Damage Replace EC4C4300 Kick gear kick idle gear and ratchet wheel 1 Inspect 9Kick gear 1 9Kick...

Page 305: ...er Guide de sélecteur et ensemble levier de sélecteur 1 Examiner 9 Guide de sélecteur 1 9 Levier de sélecteur 2 9 Le cliquet 3 9 Le broche à cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de butée 1 Examiner 9 Levier de butée 1 Usure endommagement Changer 9 Roulement 2 Faites tourner la bague extérieu re avec le doigt Point dur grippage Remplacez le levier de butée 9 Ressort de tension 3...

Page 306: ...aft 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 Stopper lever 1 Install 9Tension spring 1 9Holder 2 9Bolt holder 3 9Plain washer 4 9Stopper lever 5 9Bolt stopper lever 6 NOTE Align the stopper lever roller with the slot on seg ment 10 Nm 1 0 m kg...

Page 307: ...ecteur et ensemble levier de sélecteur 1 Monter 9 Ressort 1 9 Broche à cliquet 2 9 Cliquet 3 Au levier de sélecteur 4 2 Monter 9 Ensemble levier de sélecteur 1 Au guide de sélecteur 2 3 Monter 9 Ensemble levier de sélecteur 1 9 Guide de sélecteur 2 N B 9L ensemble de levier de sélecteur est installé en même temps que le guida ge de sélecteur 9Enduire l axe de boulon segment d huile de transmission...

Page 308: ...ake 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 6 9Circlip 7 To kick axle 8 NOTE 9Apply the transmission oil on the kick gear inner circumference 9Align the punch mark a on the ratchet wheel with the punck mark b on the kick axle 4 Install 9Bolt ...

Page 309: ...re de sélecteur 3 N B Enduire l arbre de sélecteur et les roule ments d huile de transmission Ensemble axe de démarreur au pied 1 Monter 9 Pignon de démarreur au pied 1 9 Rondelle ordinaire 2 9 Circlip 3 9 Roue à cliquet 4 9 Resort 5 9 Rondelle ordinaire 6 9 Circlip 7 A l axe de démarreur au pied 8 N B 9Appliquez de l huile de transmission sur la circonférence intérieure du pignon du lanceur 9Alig...

Page 310: ...he 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 contacting surfaces of the kick axle stopper a and stopper plate 3 9Apply the transmission oil on the kick axle 9Slide the kick axle assembly into the crankcase and make sure the kick axle stopper fits i...

Page 311: ...ne sur les surfaces de contact de la butée d axe du lanceur a et de la plaque de butée 3 9 Appliquer de l huile de boîte de vitesses sur l axe de démarreur au pied 9Faites coulisser l axe du lanceur dans le carter et assurez vous que la butée d axe du lanceur s adapte sur la plaque de butée 5 Crocher 9 Ressort de torsion 1 N B Tourner le ressort de torsion à droite et l accrocher dans le bon orifi...

Page 312: ...Bolt 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 9Governor drive gear 3 9Plain washer 4 9Bolt primary drive gear 5 NOTE 9Install the plain washer with its chamfered side a toward you 9Temporarily tighten the bolt at this point 2 Install 9Primary driven...

Page 313: ...t le boulon à ce stade 2 Monter 9 Pignon mené primaire Se reporter à la section EMBRAYAGE ET PIGNON MENE PRIMAIRE 3 Serrer 9 Boulon pignon de transmission primaire 1 N B Mettre une plaque en aluminium a entre les dents du pignon de transmis sion primaire 2 et du pignon mené 3 4 Monter 9 Goujon 1 9 Joint capot darter moteur droit 2 5 Monter 9 Couvercle de carter droit 1 N B Engager le pignon de rég...

Page 314: ...b 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 contact ing the clutch cover mounting boss a 6 Install 9Bolt crankcase cover right 1 NOTE Tighten the bolts in stage using a crisscross pattern 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm...

Page 315: ... a de montage du cou vercle d embrayage mais pas contre 8 Monter 9 Pédale de sélecteur 1 9 Boulon pédale de sélecteur 2 N B Monter la pédale de sélecteur de sorte que le haut du diamètre extérieur de la pédale a soit le plus haut possible mais sans dépasser la ligne b reliant le centre de l arbre de sélecteur et le bas de la vis couvercle de carter gauche 3 6 Installare 9 Bullone copertura del car...

Page 316: ...D removal PRIMARY DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 EC4K0000 YPVS GOVERNOR 1 Extent of removal 1 YPVS governor removal and disassembly 5 Nm 0 5 m kg 3 6 ft lb ...

Page 317: ...CTEUR ET PIGNON DE TRANSMISSION 1 Ensemble régulateur 1 2 Goujon 1 Se reporter à POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de butée 2 8 Collerette 1 9 Plaque 1 10 Ressort de compression 1 11 Pignon de régulateur 1 12 Arbre de régulateur 1 IC4K0000 REGOLATORE YPVS Ampiezza della rimozione 1 Rimozione e smontaggio del regolatore YPVS Ampiezza...

Page 318: ...eight 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 dowel pin EC4K4000 INSPECTION EC4K4100 Governor groove 1 Inspect 9Plain washer 1 9Collar 2 Wear Damage Replace EC4K4200 Bearing 1 Inspect 9Thrust bearing 1 9Plain washer 2 Wear Damage Replace ...

Page 319: ...ondelle ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTAGE Régulateur 1 Monter 9 Pignon de régulateur 1 9 Ressort de compression 2 9 Plaque 3 9 Rondelle ordinaire 4 9 Roulement de butée 5 9 Collerette 6 9 Masselotte de retenue 7 sur l arbre du régulateur 8 N B Appliquer de la graisse de base de savon au lithium sur le roulement de butée IC4K3000 PUNTI DI RIMOZIONE IC4K3100 Regolatore 1 T...

Page 320: ...e 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 Install 9Ball 1 9Retainer 2 To governor shaft 3 NOTE Apply the transmission oil on the retainer and ball ...

Page 321: ...lle 3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9Vérifier que le goujon d assemblage est bien ajusté dans le gorge a du dispositif d arrêt 4 Monter 9 Ensemble régulateur 1 N B Aligner la rainure a du régulateur avec la fourchette b puis positionner le régulateur dans le couvercle de carter 2 Installare 9 Sfera 1 9 Fermo 2 Sull albero del regolatore 3 NOTA Applicare l ol...

Page 322: ...R 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 REMOVAL POINTS 4 Impeller shaft 1 5 Bearing 1 6 Oil seal 2 Refer to REMOVAL POINTS 1 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 14 Nm 1 4 m kg 10 ft lb ...

Page 323: ...ter à la section AXE DE DEMARREUR AU PIED ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSON 1 Couvercle de boîtier de pompe à eau 1 2 Turbine 1 3 Rondelle ordinaire 1 Se reporter à POINTS DE DEPOSE 4 Axe de turbine 1 5 Roulement 1 Se reporter à POINTS DE DEPOSE 6 Bague d étanchéité 2 IC4G0000 POMPA DELL ACQUA Ampiezza della rimozione 1 Rimozione dell albero del girante 2 Rimozione del paraolio Ampiezza ...

Page 324: ...spanners 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 coolant or milky transmission oil 1 Remove 9Bearing 1 2 Remove 9Oil seal 1 EC4G4000 INSPECTION EC444200 Impeller shaft 1 Inspect 9Impeller shaft 1 Bend Wear Damage Replace Fur deposits Clean ...

Page 325: ... N B S il n y a un d anomalie telle qu exces sif changement du niveau de liquide de refroidissement décoloration du liquide de refroidissement ou huile de boîte de vitesses blanchâtre il est inutile de démonter la pompe à eau 1 Déposer 9 Roulement 1 2 Déposer 9 Bague d étanchéité 1 VERIFICATION Axe de turbine 1 Examiner 9 Axe de turbine 1 Déformée usure endommagement Changer Dépôts de tartre Netto...

Page 326: ...Replace 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 lip 9Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 2 2 Install 9Bearing 1 NOTE Install the bearing by pressing its outer race par allel ...

Page 327: ...nchéité 1 Usure endommagement Changer REMONTAGE ET MONTAGE Bague d étanchéité 1 Monter 9 Bague d étanchéité 1 N B 9Appliquer la graisse à base de savon au lithium sur la lèvre de la bague d étanchéité 9Installez la bague d étanchéité avec les marques du fabricant ou les numé ros de référence vers le couvercle de carter droit 2 2 Monter 9 Roulement 1 N B Monter le roulement en appuyant paral lèleme...

Page 328: ...p 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 impeller 3 Install 9Dowel pin 1 9Gasket water pump housing cover 2 4 Install 9Water pump housing cover 1 9Bolt water pump housing cover 2 9Copper washer coolant drain bolt 3 9Coolant drain bolt 4 10 Nm 1 0 ...

Page 329: ...s latérales aplaties a au moyen d une clé etc et monter la turbine 3 Monter 9 Goujon 1 9 Joint couvercle de boîtier de pompe à eau 2 4 Monter 9 Couvercle de boîtier de pompe à eau 1 9 Boulon couvercle de boîtier de pompe à eau 2 9 Rondelle en cuivre boulon de vidange de refriodissement 3 9 Boulon de vidange de refroidis sement 4 IC4G5220 Albero del girante 1 Installare 9 Albero del girante 1 NOTA ...

Page 330: ...removal SIDE COVERS section Bolt radiator Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator 1 5 Woodruff key 1 EC4L0000 CDI MAGNETO 1 Extent of removal 1 CDI magneto removal 7 Nm 0 7 m kg 5 1 ft lb 5 Nm 0 5 m kg 3 6 ft lb 56 Nm 5 6 m kg 40 ft lb ...

Page 331: ...LE RESERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur Se reporter à la section RADIATEUR Déconnecter le fil de magnéto CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil spécial Se reporter à 3 Rotor 1 POINTS DE DEPOSE 4 Stator 1 5 Clavette de demi lune 1 IC4L0000 MAGNETE CDI Ampiezza della rimozione 1 Rimozione del magnete CDI Ampiezza della rimozione Ordine Particolare ...

Page 332: ...oun 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 9Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect 9Woodruff key 1 Damage Replace Rotor hol...

Page 333: ...age du vilebrequin et le coussinet vilebrequin Si nécessaire changer le stator et ou le magnéto CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET MONTAGE Magnéto CDI 1 Monter 9 Stator 1 9 Vis stator 2 N B Serrer provisoirement la vis stator à ce moment IC4L3000 PUNTI DI RIMOZIONE IC4L3102 Rotore 1 Togliere 9 Dado rotore 1 9 Rosetta 2 Usare l utensile...

Page 334: ...n 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 the crankshaft center line b 9When installing the rotor align the keyway c of the rotor with the woodruff key 7 Nm 0 7 m kg 5 1 ft lb Rotor holding tool YU 1235 90890 01235 Ignition timing B T D C 0 1...

Page 335: ...9 Avance à l allumage Se reporter à la section CONTROLE ET REGLAGE DE L AVANCE A L ALLU MAGE du CHAPITRE 3 5 Serrer 9 Vis stator 1 6 Contrôler 9 Avance à l allumage Recontrôler l avance à l alluma ge 2 Installare 9 Linguetta Woodruff 1 9 Rotore 2 NOTA 9Pulire le parti coniche dell albero a gomiti e del rotore 9Quando si installa la linguetta Woo druff assicurarsi che la sua superficie piana a sia ...

Page 336: ...to lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a crisscross pattern 5 Nm 0 5 m kg 3 6 ft lb ...

Page 337: ...croisé 7 Connecter 9 Fil de magnéto CDI 1 Se référer au paragraphe DIA GRAMME DE CHEMINE MENT DE CABLE au CHA PITRE 2 7 Anschließen 9 Kabel des CDI Magnetzünders 1 Siehe Abschnitt KABEL FÜHRUNGSÜBERSICHT im KAPITEL 2 7 Collegare 9 Conduttore del magnete CDI 1 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPITOLO 2 8 Installare 9 Guarnizione copertura del car ter sinistra 9 Copertura ...

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 CDI magneto lead 4 60 ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL w Support the machine securely so there is no dan ger of it falling over 26 Nm 2 6 m kg 19 ft lb 64 Nm 6 4 m kg 46 ft lb 75 Nm 7 5 m kg...

Page 339: ...dämpfer Siehe Abschnitt AUSPUFFROHR UND Auspuffrohrstütze hinten SCHALLDÄMPFER Kupplungskabel An der Motorseite abtrennen Kühler Siehe Abschnitt KÜHLER Zündkerze Das Kabel des CDI Magnetzünders abtrennen AUSBAU DES MOTORS DEPOSE DU MOTEUR IC4M0000 RIMOZIONE DEL MOTORE Ampiezza della rimozione Ordine Particolare Quantità Osservazioni RIMOZIONE DEL MOTORE Reggere il veicolo collocando sotto il motor...

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 removal 1 26 Nm 2 6 m kg 19 ft lb 64 Nm 6 4 m kg 46 ft lb 75 Nm 7 5 m kg 54 ft lb 5 Nm 0 5 m kg 3 6 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 m kg 46 ft lb 85 Nm 8 5 m kg 61 ft lb å Except for USA and CDN 4 N...

Page 341: ...n d entraînement 1 4 Rondelle frein 1 Se reporter à POINTS DE DEPOSE 5 Pignon d entraînement 1 6 Agrafe 1 7 Boulon pédal de frein 1 8 Pédale de frein 1 9 Support du moteur 2 10 Boulon de montage du moteur 3 11 Axe de pivot 1 Déposez complètement 12 Moteur 1 Se reporter à POINTS DE DEPOSE Ampiezza della rimozione 1 Rimozione del motore Ampiezza della rimozione Ordine Particolare Quantità Osservazio...

Page 342: ...ve 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 sprocket 1 Remove 9Nut drive sprocket 1 9Lock washer 2 NOTE 9Straighten the lock washer tab 9Loosen the nut while applying the rear brake 2 Remove 9Drive sprocket 1 9Drive chain 2 NOTE Remove the drive spr...

Page 343: ...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 siano scollegati 1 Sollevare il motore 1 fino a quan do la parte anteriore del supporto motore non tocca più la staffa sul telaio 2 Togliere il motore 1 con un movimento trasversale e verso l al to inclin...

Page 344: ...N 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 9Engine mounting bolt upper 7 NOTE Apply the molybdenum disulfide grease on the pivot shaft 85 Nm 8 5 m kg 61 ft lb 64 Nm 6 4 m kg 46 ft lb 64 Nm 6 4 m kg 46 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm 6 4 ...

Page 345: ...raisse à base de savon au lithium sur le boulon les joints toriques et le support de pédale de frein IC4M5000 MONTAGGIO E INSTALLAZIONE IC4M5124 Installazione del motore 1 Installare 9 Motore 1 Installare il motore dal lato destro 9 Albero snodato 2 9 Bullone di montaggio del moto re inferiore 3 9 Bullone di montaggio del moto re anteriore 4 9 Staffa del motore 5 9 Bullone staffa del motore 6 9 Bu...

Page 346: ...ile 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 the drive sprocket together with the drive chain 5 Connect except for USA and CDN 9Neutral switch lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 ...

Page 347: ...nando 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 entraînement 1 Monter 9 Pignon d entraînement 1 9 Chaîne de transmission 2 N B Monter le pignon d entraînement avec la chaîne de transmission Antriebskettenrad 1 Einbauen 9 Antriebskettenrad 1 9 Antriebskette 2 HINWEIS Da...

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 MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Holder 2 Except for USA and CDN 3 Bolt Neutral switch lead holder 1 4 Bolt L 50 mm 1 97 in 7 5 Bolt L 60 mm 2 36 in 1 6 Bolt L 70 mm 2 76 in 3 7 Ho...

Page 349: ... 60 mm 2 36 in 1 6 Schraube L 70 mm 2 76 in 3 7 Halter 2 8 Kurbelgehäuse rechts 1 Das Spezialwerkzeug verwenden 9 Kurbelgehäuse links 1 Siehe unter AUSBAUPUNKTE 10 Kurbelwelle 1 Das Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 11 Öldichtung 2 12 Lager 2 Siehe unter AUSBAUPUNKTE KURBELGEHÄUSE UND KURBELWELLE Ausbauumfang 1 Trennung des Kurbelgehäuses 2 Ausbau der Kurbelwelle 3 Ausbau des Kurb...

Page 350: ...ts cC Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case bolt or fitting Do not force EC4N3000 REMOVAL POINTS Segment 1 Remove 9Bolt se...

Page 351: ...ut être légèrement dévissée pour mettre le corps de l outil de niveau 9Tout en serrant le boulon central taper alternativement sur le bossage de fixation du moteur et les arbres de transmission fF Utiliser un maillet en plastique et ne taper que sur les portions renforcées du carter Ne pas taper sur les plans de joint Travailler lentement et avec précaution en s assurant que les deux moitiés du ca...

Page 352: ...kcase by pressing its inner race as shown in å 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed bearing EC4N3302 Crankshaft 1 Remove 9Crankshaft 1 Use the crankcase separating tool 2 NOTE Make appropriate bolts 3 as shown available by yourself and attach the tool with them cC Do not use a hammer to drive...

Page 353: ...9Togliere il cuscinetto dal carter pre mendone l anello interno come illu strato in å 9Se il cuscinetto viene tolto insieme all albero a gomiti togliere il cusci netto usando un estrattore generico per cuscinetti 2 come illustrato in 9Non utilizzare il cuscinetto smontato IC4N4000 ISPEZIONE IC4N4101 Carter 1 Ispezionare 9 Superficie di contatto a Graffi Sostituirlo 9 Mozzo di montaggio del motore ...

Page 354: ...030in 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 Replace Use the dial gauge and a thickness gauge Dial gauge YU 3097 90890 01252 2 Inspect 9Bearings 1 Rotate inner race with a finger Rough spot Seizure Replace 3 Inspect 9Oil seal 1 Damage Replace ...

Page 355: ... 9 Largeur de vilebrequin d Hors spécification Changer Utiliser un Comparateur à Cadran et une jauge d épaisseur Comparateur YU 3097 90890 01252 Comparatore YU 3097 90890 01252 Messuhr YU 3097 90890 01252 Normalwert Grenze Schlaggrenze 0 03 mm 0 05 mm 0 0012 in 0 0020 in Grenze des 0 4 1 0 mm 2 0 mm Spiels am Pleuelauge 0 016 0 039 in 0 08 in Seitliches 0 25 0 75 mm Spiel 0 010 0 030 in Kurbelwan ...

Page 356: ...alling 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 use a hammer to drive in the crank shaft EC4N5000 ASSEMBLY AND INSTALLATION EC4N5300 Crankshaft bearing 1 Install 9Bearing 1 To crankcase left and right NOTE Install the bearing by pressing its o...

Page 357: ... a gomiti 1 Installare 9 Albero a gomiti 1 Usare l utensile per installare l albero a gomiti 2 3 4 å Per USA e CDN Tranne che per USA e CDN NOTA 9Reggere la biella nel punto morto superiore con una mano ruotando il dado dell utensile di installazione con l altra Usare l utensile di installazio ne finché l albero a gomiti non scende contro il cuscinetto 9Prima di installare l albero a gomiti pulire...

Page 358: ...positioned 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 lithium soap base grease over the tape NOTE Clean the contacting surface of crankcase left and right before applying the sealant 4 Apply 9Sealant On the crankcase right 1 Yamaha bond No 1215 ThreeBond No...

Page 359: ...r gauche sur le cartermoteur droit Taper légère ment sur le cartrer à l aide d un mar teau souple 9Quand le carter est installé la bielle d accouplement doit être positionnée au PMH point mort haut fF Pour éviter de relever ou d endom mager la lèvre de la bague d étan chéité a a enroulez de bande vinyle ou autre b b l extrémité droite du vile brequin et appliquez de la graisse à base de savon au l...

Page 360: ...en 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 9Bolt holder 3 NOTE Install the holder so that it contacts the projec tion a on the crankcase right 10 Nm 1 0 m kg 7 2 ft lb 9 Remove 9Sealant Forced out on the cylinder mating surface 10 Apply 9Engine o...

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 à came 3 aligner la marque imprimée a avec la broche de centra ge b 9Tourner le segment dans le sens des aiguilles d une montre jusqu à ce qu il s arrête et resserrer le boulon fF Si le segment subit un impact il risque d être endommagé Veiller à ne pas causer d impact sur le seg me...

Page 362: ...ine 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 fork 2 1 6 Shift fork 1 1 7 Spacer 1 EC4H0000 TRANSMISSION SHIFT CAM AND SHIFT FORK Extent of removal 1 Main axle drive axle shift cam and shift fork removal 1 ...

Page 363: ...e Q té Remarques DEPOSE DE LA BOITE A VITESSES DU BARILLET DE SELECTEUR ET DE LA FOURCHETTE Moteur Se reporter à la section DEPOSE DU MOTEUR Séparer le carter Se reporter à la section CARTER ET VILEBRE QUIN 1 Axe principal 1 2 Axe moteur 1 3 Barillet de sélecteur 1 4 Fourchette 3 1 Se reporter à POINTS DE DEPOSE 5 Fourchette 2 1 6 Fourchette 1 1 7 Entretoise 1 IC4H0000 TRASMISSIONE CAMMA DEL CAMBI...

Page 364: ...ect 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 9Shift fork 1 NOTE 9Remove assembly carefully Note the position of each part Pay particular attention to the location and direction of shift forks 9Remove the main axle drive axle shift cam and shift fork...

Page 365: ... sélecteur et la fourchette du sélecteur ensemble en tapotant légèrement sur l arbre de transmission à l aide d un marteau à tête en caoutchouc VERIFICATION Pignons 1 Examiner 9 Crabot d accouplement a 9 Dent de pignon b 9 Gorge de fourchette c Usure endommagement Changer 2 Examiner 9 Joint torique 1 Endommagement Changer 3 Contrôler 9 Movement des pignons Pas de douceur Réparer ou changer Rouleme...

Page 366: ...sulfide 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 malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork 2 Inspect 9Shift cam 1 9Segment 2 Wear Damage Replace EC4H4810 Shift fork shift cam and s...

Page 367: ...nnement de la fourchette ne pas changer que la fourchette ellemême mais les deux pignons situés de chaque côte de la fourchette REMONTAGE ET MONTAGE Boîte à vitesses 1 Monter 9 Pignon de 5è 21D 1 9 Pignon de 3è 18D 2 9 Collerette 3 9 Pignon de 4è 22D 4 9 Pignon de 2è 15D 5 A l axe principal 6 N B Appliquer de l huile au bisulfure de molybdène sur la surface intérieure et d extrémité du pignon libr...

Page 368: ...rclip 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 gear 23 T 1 94th wheel gear 24 T 2 93rd wheel gear 23 T 3 95th wheel gear 20 T 4 91st wheel gear 27 T 5 9O ring 6 To drive axle 7 NOTE 9Apply the molybdenum disulfide oil on the inner and end surface ...

Page 369: ...e du pignon mobile puis les monter 9Appliquer de la graisse à base de savon an lithium sur le joint torique 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9Vérifier que le coté à bord vif du cir clip a soit opposé à la rondelle ordi naire située contre le pignon b 9Vérifier que l extrémité du circlip c est située dans une gorge de l axe d 4 Monter 9 Collerette 1 N B 9Appliquer la graisse à base d...

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 6 Install 9Transmission assembly 1 To crankcase left 2 NOTE Apply the transmission oil on the bearings and guide bars 7 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair ...

Page 371: ...cipal 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 bisolfuro di molibdeno sulle scanalature della for cella del cambio 9Ingranare la forcella del cambio No 1 L con l ingranaggio a ruota della 4a 5 e la No 3 R con l ingranaggio a ruota della 5a 7 sull asse m...

Page 372: ...1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of removal 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal w Support the machine securely so there is no dan ger of it falling over 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft l...

Page 373: ... 2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Collerette 2 6 Bague d étanchéité 2 7 Roulement 2 Se reporter à POINTS DE DEPOSE 8 Disque de frein 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser IC500000 TELAIO IC590000 RUOTA ANTERIORE E RUOTA POSTERIORE IC598000 RUOTA ANTERIORE Ampiezza della rimozione 1 Rimozione della ruota...

Page 374: ...he removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 2 1 3 3 w Support the machine securely so there is no dan ger of it falling over 125 Nm 12 5 m kg 90 ft lb 14 Nm 1 4 m kg 10 ft lb 19 Nm 1 9 m kg 13 ...

Page 375: ... arrière 1 Se reporter à POINTS DE DEPOSE 5 Collerette 2 6 Pignon mené 1 7 Bague d étanchéité 2 8 Circlip 1 9 Roulement 2 Se reporter à POINTS DE DEPOSE 10 Disque de frein 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser IC598100 RUOTA POSTERIORE Ampiezza della rimozione 1 Rimozione della ruota posteriore 2 Rimozione del cuscinetto della ruota 3 R...

Page 376: ...necessary 1 Remove 9Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure 9Wheel runout Out of limit Repair Replace 2 Inspect 9Bearing Rotate inner race with a finger Rough spot Seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 1 2 0mm 0 08 in Lateral 2 2 2 0mm 0 08 in ...

Page 377: ...ure 9 Voile de roue Hors limite Réparer Changer 2 Examiner 9 Roulement Faire tourner la bague intérieure avec le doigt Point dur grippage Changer N B Changer les roulements la bague d étanchéité et la collerette de roue comme un ensemble IC593000 PUNTI DI RIMOZIONE IC523101 Ruota posteriore 1 Togliere 9 Ruota 1 NOTA Spingere in avanti la ruota e togliere la catena di trasmissione 2 IC513201 Cuscin...

Page 378: ...94200 Brake disc 1 Measure 9Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition re place the brake disc 2 Measure 9Brake disc thickness a Out of limit Replace Wheel axle bending limit 0 5 mm 0 020 in Disc wear limit Standard Limit Front 3 0 mm 0 12 in 2 5 mm 0 10 in Rear 4 0 mm 0 16 in 3 5 mm 0 14 in Disc de...

Page 379: ...imite d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arrière 4 0 mm 0 16 in 3 5 mm 0 14 in IC594200 Disco del freno 1 Misurare 9 Inflessione del disco del freno soltanto il disco del freno posteriore Usare il comparatore 1 Fuori specifica Ispezionare la scentratura della ruota Se la scentratura della ruota è in buone condizioni sostituire il disco del freno 2 Misurare 9 Spes...

Page 380: ...all be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern 3 Install 9Collar 1 NOTE 9Apply the lithium soap base grease on the oil seal lip 9Install the collars ...

Page 381: ...ricant diri gés vers l extérieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment extérieur 2 Monter 9 Disque de frein 1 9 Boulon disque de frein 2 N B Serrer les boulons par étape en utilisant un modèle d entre croisement 3 Monter 9 Collerette 1 N B 9Appliquer de la graisse à base de savon au lithium sur les lèvres de bague d étan...

Page 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 times with the front brake applied 105 Nm 10 5 m kg 75 ft lb 21 Nm 2 1 m kg 15 ft lb ...

Page 383: ...llare 9 Asse della ruota 1 NOTA Applicare sull asse della ruota il grasso a base di sapone di litio 6 Installare 9 Dado asse della ruota 1 7 Serrare 9 Bullone supporto dell asse 1 NOTA Prima di serrare il bullone montare l asse della ruota sul supporto dell asse facendo scorrere più volte la forcella anteriore con il freno anteriore aziona to 6 Monter 9 Ecrou axe de roue 1 7 Serrer 9 Boulon suppor...

Page 384: ...ng 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern EC5251A1 Rear wheel 1 Install 9Bearing right 1 9Circlip 2 9Spacer 3 9Beari...

Page 385: ...douille convenant au dia mètre extérieure de la cage du roule ment 9Le roulement latéral droit doit monter premier 9Monter la bague d étanchéité avec ses marques ou numéros de fabricant diri gés vers l extérieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment extérieur 2 Monter 9 Disque de frein 1 9 Boulon disque de frein 2 N B Se...

Page 386: ...NOTE Apply the lithium soap base grease on the oil seal lip 5 Install 9Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install 9Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install 9Chain puller left 1 9Wheel axle 2 NOTE 9Install the chain puller left and insert the wheel axle from left side 9Apply the lithium soap base grease on the wheel axle...

Page 387: ...to condotto 3 9 Dado rocchetto condotto 4 NOTA Serrare i dadi in sequenza usando uno schema incrociato 4 Installare 9 Bordino 1 NOTA Applicare sul labbro del paraolio il grasso a base di sapone di litio 5 Installare 9 Ruota NOTA Installare correttamente il disco del freno 1 fra le pastiglie del freno 2 6 Monter 9 Chaîne de transmission 1 N B Pousser la roue 2 vers l avant et mon ter la chaîne de t...

Page 388: ...wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axle 1 9Locknut 2 125 Nm 12 5 m kg 90 ft lb Drive chain slack 48 58 mm 1 9 2 3 in 19 Nm 1 9 m kg 13 ft lb ...

Page 389: ... N B A ce stage resserrer provisoirement les écrous axe de roue 8 Installare 9 Estrattore per catena destro 1 9 Rosetta 2 9 Dado asse della ruota 3 NOTA Serrare temporaneamente il dado asse della ruota a questo punto 9 Régler 9 Flèche de chaîne de transmis sion a Se reporter à la section REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION du CHAPITRE 3 Flèche de chaîne de trans mission 48 58 mm 1 9 2 3...

Page 390: ...en when disassembling the caliper 7 Caliper 1 8 Brake lever 1 9 Master cylinder bracket 1 10 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose removal 2 Caliper removal 3 Master cyilinder removal w Support the machine securely so there is no dan ger of it falling over 2 1 3 3 9 Nm 0 9 m kg 6 5 ft lb 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 f...

Page 391: ... Bouchon de goupille de plaquette 1 Déposer lors du desserrage de la goupille de plaquette 6 Goupille de plaquette 1 Desserrer lors du démontage de l étrier 7 Etrier 1 8 Levier de frein 1 9 Etrier de maître cylindre 1 10 Maître cylindre 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser Se reporter à POINTS DE DEPOSE IC5A0000 FRENO ANTERIORE E FRENO...

Page 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 removal 2 Brake hose removal 3 Caliper removal w Support the machine securely so there is no dan ger of it falling over 2 3 3 1 1 2 Nm 0 2 m kg 1 4 ft lb 30 Nm 3 0 m kg 22 ft lb 30 Nm 3 0 m kg 22 ft...

Page 393: ...1 6 Bouchon de goupille de plaquette 1 Déposer lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du démontage de l étrier 8 Etrier 1 Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser Se reporter à la section ROUE AVANT ET ROUE ARRIERE Se reporter à POINTS DE DEPOSE IC5A8100 FRENO POSTERIORE Ampiezza della rimozio...

Page 394: ...iper piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 EC5A8200 CALIPER DISASSEMBLY A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear caliper disassembly 2 1 6 Nm 0 6 m kg 4 3 ft lb 3 Nm 0 3 m kg 2 2 ft lb 18 Nm 1 8 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb ...

Page 395: ...er avant 2 Démontage de l étrier arrière Etendue de dépose Ordre Nom de pièce Q té Remarques DEMONTAGE DE L ETRIER A B 1 Goupille de plaquette 1 1 2 Palquette de frein 2 2 3 Support de plaquette 1 1 4 Piston d étrier 2 1 Se reporter à POINTS DE DEPOSE 5 Joint antipoussière 2 1 Se reporter à POINTS DE DEPOSE 6 Joint de piston 2 1 IC5A8200 SMONTAGGIO DELLA PINZA A Anteriore B Posteriore Ampiezza del...

Page 396: ...agm 1 3 Reservoir float 1 4 Master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Plain washer 1 7 Push rod 1 8 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear Extent of removal 1 Front master cylinder disassembly 2 Rear master cylinder disassembly 1 1 2 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 2 ...

Page 397: ...auptbremszylindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorn B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE CYLINDRE A Avant B Arrière Etendue de dépose 1 Démontage du maître cylindre avant 2 Démontage du maître cylindre arrière IC5A8300 SMONTAGGIO DEL CILINDRO PRINCIPALE A Anteriore B Posteriore Ampiezza...

Page 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 Caliper piston 1 Remove 9Caliper piston Use compressed air and proceed carefully w 9Cover piston with rag and use extreme cau tion when expelling piston from cylinder 9Never attempt to pry out piston ...

Page 399: ...IC5A3101 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Coperchio del cilindro principa le 1 9 Dispositivo di protezione NOTA Non togliere il diaframma A Anteriore B Posteriore 2 Collegare il tubo flessibile traspa rente 2 alla vite di spurgo 1 e collocare sotto la sua estremità un contenitore adatto A Anteriore B Posteriore 3 Allentare la vite d...

Page 400: ...nd dust seals w Replace the piston seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534120 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder assembly Stains Clean w Use only new brake fluid A Front B Rear 2 Inspect 9Diaphragm 1 Crack Damage Replace A Front B Rear 3 Inspect front brake only 9Reservoir float ...

Page 401: ... les joints de piston et antipoussière lors d un démontage d étrier A Avant B Arrière IC533402 Kit delle guarnizioni di tenuta del pistone 1 Togliere 9 Parapolvere 1 9 Guarnizione di tenuta del pisto ne 2 NOTA Togliere le guarnizioni di tenuta del pistone e i parapolvere spingendoli con un dito iI Non tentare mai di fare leva sulle guarnizioni di tenuta del pistone e sui parapolvere per estrarli T...

Page 402: ...t B Rear 2 Inspect 9Caliper piston 1 Wear Score marks Replace caliper piston assembly w Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Brake hose 1 Crack Damage Replace EC5A5000 ASSEMBLY AND INSTALLATION w 9All internal parts should be cleaned in new brake fluid only 9Internal parts should be lubricated with brake fluid when installed ...

Page 403: ...lindro principale A Anteriore B Posteriore IC534214 Pinza 1 Ispezionare 9 Superficie interna del cilindro della pinza a Usura Rigature Sostituire il gruppo pinza A Anteriore B Posteriore 2 Ispezionare 9 Pistone della pinza 1 Usura Rigature Sostituire gruppo pistone della pinza T Sostituire le guarnizioni di tenuta del pistone e i parapolvere 2 2 ogni volta che si smonta una pinza IC534301 Tubo fle...

Page 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 facing the caliper 9Never force to insert A Front B Rear EC5A5700 Front caliper 1 Install 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper r...

Page 405: ... et antipoussière dans la rainure située sur l étrier A Avant B Arrière IC5A5801 Pistone della pinza 1 Pulire 9 Pinza 9 Guarnizione di tenuta del pisto ne 9 Parapolvere 9 Pistone della pinza Pulirli con liquido per freni 2 Installare 9 Guarnizione di tenuta del pisto ne 1 9 Parapolvere 2 T Usare sempre guarnizioni di tenuta del pistone e parapolvere nuovi NOTA Inserire le guarnizioni di tenuta del...

Page 406: ...ad pin at this point 2 Install 9Disc cover 1 9Bolt disc cover 2 2 Install 9Caliper 1 9Bolt caliper 2 3 Tighten 9Pad pin 3 4 Install 9Pad pin plug 4 23 Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Install 9Caliper 1 9Rear wheel 2 Refer to FRONT WHEEL AND REAR WHEEL section 4 Tighten 9Pad pin 3 5 Insta...

Page 407: ...remsschuhaussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 2 Monter 9 Etrier 1 9 Boulon étrier 2 3 Serrer 9 Goupille de plaquette 3 4 Monter 9 Bouchon de goupille de plaquet te 4 Etrier arrière 1 Monter 9 Support de plaquette 1 9 Plaquette de frein 2 9 Goupille de plaquette 3 N B 9Installer les plaquettes de frein en ajustant leurs saillies a dans l encoche...

Page 408: ...rimary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance A Front B Rear 3 Install 9Spring 1 To master cylinder piston 2 NOTE Install the spring at the smaller dia side A Front B Rear ...

Page 409: ...lle du maître cylindre doit être posée dans la direction indiquée Une mauvaise intallation entaîne une performance incorrecte du freinage A Avant B Arrière IC5A5220 Kit del cilindro principale 1 Pulire 9 Cilindro principale 9 Kit del cilindro principale Pulirli con liquido per freni 2 Installare 9 Anello conico del cilindro prin cipale primario 1 9 Anello conico del cilindro prin cipale secondario...

Page 410: ...nose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mark a face upward 9First tighten the bolts on the upper side of the master cylinder bracket and then tighten the bolts on the lower side 9 Nm 0 9 m kg 6 5 ft lb 2 Install 9Brake lever 1 9Bolt brake lev...

Page 411: ...te festziehen 4 Installare Anteriormente 9 Kit del cilindro principale 1 9 Rosetta 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 Posteriormente 9 Kit del cilindro principale 1 9 Asta di comando 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 NOTA 9Applicare il liquido per freni sul kit del cilin...

Page 412: ...at its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 2 Install 9Master cylinder 1 9Bolt master cylinder 2 10 Nm 1 0 m kg 7 2 ft lb 3 Install 9Spring 1 9Brake pedal 2 9O ring 3 9Bolt brake pedal 4 9Clip 5 NOTE Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 26 Nm 2 6 m kg 19 ft lb ...

Page 413: ...inder 1 9 Schraube Hauptbremszylin der 2 IC5A5401 Cilindro principale posteriore 1 Installare 9 Rondella in rame 1 9 Tubo flessibile del freno 2 9 Bullone di unione 3 T Usare sempre rondelle in rame nuove iI Installare il tubo flessibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro principale 2 Installare 9 Cilindro ...

Page 414: ...2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Install 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT section in the CHAPTER 3 EC5A5911 Front brake hose 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the pro...

Page 415: ...a wie in der Abbildung gezeigt angeordnet ist und den Überstand b b am Bremsbe lag leicht berührt 2 Einbauen 9 Bremsschlauchhalter 1 9 Schraube Bremsschlauchhal ter 2 3 Einbauen 9 Bremsschlauchhalter 1 9 Mutter Bremsschlauchhalter 2 HINWEIS Die Oberseite a der Bremsschlauch Halterung am Anstrich b des Brems schlauches ausrichten 4 Installare 9 Spina 1 9 Rosetta 2 9 Coppiglia 3 NOTA Dopo l installa...

Page 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 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the caliper 30 Nm 3 0 m kg 22 ft lb ...

Page 417: ...sibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro principale Tuyau de frein arrière 1 Monter 9 Rondelle en cuivre 1 9 Tuyau de frein 2 9 Boulon d union 3 XG Toujour utiliser les rondelles en cuivre neuves fF Installer la tuyau de frein de manière que la partie avec le tuyau soit a a dirigée comme indiqué et touche ...

Page 418: ...ty brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction and lead to poor performance 9Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock cC Br...

Page 419: ... et un mauvais fonctionnement du frein 9Toujours utiliser la même marque de liquide de frein Le mélange de liquides de marques différentes risque de provoquer une réaction chimique nuisible au fonctionne ment du frein 9Lorsqu on ajoute du liquide faire attention de ne pas laisser pénétrer de l eau dans le maître cylindre L eau risque d abaisser fortement le point d ébullition et de provoquer le ph...

Page 420: ...Diaphragm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Master cylinder cap 1 9Bolt master cylinder cap 2 cC After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper A Front B Rear 5 Install rear brake only 9Protector 1 9Bolt p...

Page 421: ...aframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale0 2 Posteriormente 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Bullone coperchio del cilindro principale 2 iI Dopo l installazione tirando verso l interno la leva o premendo il peda le controllare se vi sono perdite di liquido per freni dove sono installati i bulloni di unione rispettivamente sul cilind...

Page 422: ...RS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt under bracket 2 Only loosening 5 Front fork 1 5 26 CHAS FRONT FORK 1 w Support the machine securely so there is no dan ger of it falling over Extent of removal 1 Front fork removal 7 Nm 0 7 m kg 5 1 f...

Page 423: ... wenn die Vorderradgabel demontiert wird Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 4 Klemmschraube 2 Nur lösen Untere Gabelbrücke 5 Vorderradgabel 1 VORDERRADGABEL Ausbauumfang 1 Ausbau der Vorderradgabel FOURCHE AVANT Etendue de dépose 1 Dépose de la fourche avant Préparation pour la dépose XG Bien soutenir la machine afin qu elle ne risque pas de se renverser IC550000 FORCELLA ANTERIORE...

Page 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 FORK EC558000 FRONT FORK DISASSEMBLY 1 Extent of removal 1 Oil seal removal 2 Damper assembly removal 2 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 30 Nm 3 0 m kg 22 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 425: ... outil spécial Se reporter à POINTS DE DEPOSE 2 Ressort de fourche 1 3 Joint antipoussière 1 4 Bague d arrêt 1 Se reporter à POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 Métal de piston 1 8 Bague antifriction 1 9 Rondelle de bague d étanchéité 1 0 Bague d étanchéité 1 q Soupape de base 1 Vidanger d huile de fourche Utiliser l outil spécial w Amortisseur complet 1 Se reporter à POINTS DE DE...

Page 426: ...ruction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled 9Before removing the base valves or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS EC553311 Damper assembly 1 Loosen 9Damper assembly 1 NOTE Before rem...

Page 427: ...ger complètement les chambres à air IC556000 NOTA PER IL MANEGGIO NOTA La forcella anteriore richiede grande at tenzione Si raccomanda pertanto di ef fettuare la manutenzione della forcella anteriore presso il concessionario iI Per evitare un esplosione accidentale di aria si dovrebbero osservare le se guenti istruzioni 9La forcella anteriore con una biella incorporata ha una costruzione in terna ...

Page 428: ...o not remove the locknut as the damper rod may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove 9Dust seal 1 9Stopper ring 2 Using slotted head screwdriver cC Take care not to scratch the inner tube 2 Remove 9Inner tube 1 Oil seal removal steps 9Push in slowly a the inner tube just be fore it bottoms out and then pull it back q...

Page 429: ...nel gruppo ammortizzatore senza che sia possibile estrarla Clé à bague de boulon capuchon YM 01501 90890 01501 Chiave ad anello per vite mordente YM 01501 90890 01501 Schraubenschlüssel für Nockenwellenlagerdeckel Schraubenringe YM 01501 90890 01501 Inneres Rohr 1 Ausbauen 9 Staubdichtung 1 9 Anschlagring 2 Einen Schlitzschraubendreher verwenden dD Darauf achten dass der Schlauch nicht verkratzt w...

Page 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 to foreign ma terial Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled Cap bolt wrench YM 01500 90890 01500...

Page 431: ...VERIFICATION Amortisseur complet 1 Vérifier 9 Amortisseur complet 1 Courbure endommagement Changer 9 Joint torique 2 Usé endommagé Changer fF La fourche avant ayant une tige de piston incorporée a une construction interne très sophistiquée et est parti culièrement sensible aux substances étrangères Faire suffisamment attention à ne pas laisser pénétrer de substances étrangères lorsque l huile est ...

Page 432: ...9Piston metal 3 Wear Damage Replace 9Spring 4 Damage Fatigue Replace base valve 9Air bleed screw 5 Wear Damage Replace EC554400 Fork spring 1 Measure 9Fork spring free length a Out of specification Replace Standard Limit 454 mm 449 mm 17 9 in 17 7 in Fork spring free length Collar 1 Inspect 9Piston metal 1 Wear Damage Replace ...

Page 433: ...nuta 2 Usura Danni Sostituire 9 Metallo del pistone 3 Usura Danni Sostituire 9 Molla 4 Danni Affaticamento Sostitui re la valvola di base 9 Vite di spurgo dell aria 5 Usura Danni Sostituire Ressort de fourche 1 Mesurer 9 Longueur libre de ressort de fourche a Hors spécification Changer Stantard Limite 454 mm 449 mm 17 9 in 17 7 in Longueur libre de ressort de fourche Gabelbeinfeder 1 Messen 9 Unge...

Page 434: ...t of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube Inner tube bending limit 0 2 mm 0 008 in EC554600 Outer tube 1 Inspect 9Outer tube 1 Score marks Wear Damage Replace Adjuster 1 Inspect 9Adjuster 1 9O ring 2 Wear Damage Replace ...

Page 435: ...erden können IC554502 Tubo interno 1 Ispezionare 9 Superficie del tubo interno a Rigature Ripararlo o sostituir lo Usare carta vetrata umida di grana no 1000 Pezzo di bloccaggio dell olio danneggiato Sostituirlo 9 Curvature del tubo interno Fuori specifica Sostituirlo Usare il comparatore 1 NOTA Il valore di curvatura corrisponde alla metà del valore letto dal comparatore T Non tentare di raddrizz...

Page 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 After filling pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper assembly of air NOTE Be careful not to excessive full stroke A stroke of 200 m...

Page 437: ...ere un effetto ec cessivamente negativo sul rendi mento della forcella anteriore 9Non permettere mai la penetrazione di materiali estranei nella forcella anteriore Huile recommandée Huile de suspension S1 Capacité d huile 195 cm3 6 86 Imp oz 6 59 US oz Olio consigliato Olio per sospensioni S1 Capacità olio 195 cm3 6 86 Imp oz 6 59 US oz Empfohlenes Öl Teleskopgabelöl S1 Öl Fassungsvermögen 195 cm3...

Page 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 Install 9Base valve 1 To damper assembly 2 NOTE First bring the damper rod pressure to a maxi mum Then install the base valve while releas ing the damper rod pressure 9 Check that the damper assembly i...

Page 439: ...bord amener la pression de la tige d amortissement au maximum Ins taller ensuite la valve de base tout en relâchant la pression de la tige d amor tissement 9 Vérifier que l amortisseur complet est totalement déployé Pas totalement déployé Répéter les étapes 2 à 8 7 Lösen 9 Verdichtungsdämpfer Einsteller 1 HINWEIS 9 Den Verdichtungsdämpfer Einsteller mit der Hand lösen 9 Die Einstellposition des An...

Page 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 Allow the overflowing oil to escape at the hole a in the damper assembly 14 Check 9Damper assembly smooth movement Tightness Binding Rough spots Repeat the steps 2 to 13 29 Nm 2 9 m kg 21 ft lb Cap ...

Page 441: ...hrend die Dämpfer Baugruppe 1 durch einen Lappen geschützt und vollständig zusammenge drückt wird dD Darauf achten dass die Dämpfer Baugruppe nicht beschädigt wird 13 Das überschüssige Öl an der Öff nung a in der Dämpfer Baugrup pe ablaufen lassen 14 Kontrollieren 9 Gleitbewegung der Dämpfer Baugruppe Auzug Bindung rauhe Stellen Die Schritte 2 bis 13 wieder holen 10 Serrer 9 Soupape de base 1 N B ...

Page 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 seal washer with its projections b facing upward 16 Install 9Piston metal 1 NOTE Install the piston metal onto the slot on inner tube 17 Install 9Outer tube 1 To inner tube 2 ...

Page 443: ...lation de la bague d étanchéité utiliser une feuille en vi nyle a avec de l huile de fourche ap pliquée pour protéger la lèvre de la bague d étanchéité 9Installer le joint à huile dont les marques d usine ou les numéros font face au côté du support d axe 9Installer la rondelle de bague d étan chéité avec les saillies b orientées vers le haut 16 Monter 9 Métal de piston 1 N B Installer le métal de ...

Page 444: ...iver 3 19 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 20 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 21 Install 9Dust seal 1 NOTE Apply the lithium soap base grease on the inner tube Fork seal driver YM A0948 90890 01502 Fork seal driver YM A0948 90890 01502 ...

Page 445: ...n Gabelbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das äußere Gabelbeinrohr ein pressen 20 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des äußeren Rohres einsetzen 21 Einbauen 9 Staubdichtung 1 HINWEIS Lithium Fett auf dem inneren Rohr auftragen 18 Monter 9 Bague antifriction 1 9 Rondelle de bague d étanchéité 2 Vers la fente de tube externe N B En...

Page 446: ...To damper assembly 3 NOTE Install the collar with its larger dia end a facing the fork spring 25 Install 9Damper assembly 1 To inner tube 2 cC To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper assembly may fall into it damaging the valve inside 26 Loosen 9Rebound damping adjuster 1 NOTE 9Loosen the rebound damping adjuster...

Page 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 étanchéité du tube plongeur Si le tube plongeur est maintenu verticale ment l amortisseur risque de tomber dedans et d endommager la valve à l intérieur 25 Einbauen 9 Dämpfer Baugruppe 1 Zum inneren Rohr 2 dD Das Standrohr schräg halten um ...

Page 448: ...nstalled out of specification proper damping force cannot be obtained 29 Tighten 9Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster with specified torque 30 Install 9Adjuster 1 To inner tube 31 Fill 9Front fork oil 1 From outer tube top For EUROPE 29 Nm 2 9 m kg 21 ft lb 55 Nm 5 5 m kg 40 ft lb Gap a a between adjuster and locknut 0 5 1 0mm 0 02 0 04 in Recommended oil Suspension...

Page 449: ...osi zionare la chiave ad anello per vite mordente 7 tra il tubo interno e il controdado 6 9Serrare a fondo con le dita il regolato re sul gruppo ammortizzatore 28 Ispezionare 9 Distanza a tra il regolatore 1 e il controdado 2 Fuori specifica Riavvitare e regolare di nuovo il controdado NOTA Se il regolatore non è installato secondo le specifiche sarà impossibile ottenere la corretta forza di smorz...

Page 450: ...n 9Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque w Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability cC 9Be sure to use recommended fork oil If other oils are used they may have an ex ces...

Page 451: ...es schädliche Einflüsse auf die Lei stung der Teleskopgabel mit sich bringen 9 Darauf achten dass keine Fremd körper in die Vorderradgabel ein dringen T Non mancare mai di eseguire la rego lazione della quantità d olio tra la quantità massima e minima con la stessa regolazione per ciascuna for cella anteriore Una regolazione dif ferente rischia di provocare scarsa maneggevolezza e perdita di stabi...

Page 452: ...Front 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 much it may cause the front fork to malfunction 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 7 Adjust 9Compression damping force NOTE Turn in the damping adjuster 1 finger tight and then turn out to ...

Page 453: ...eller 1 mit den Fin gern festziehen und danach in die ursprüngliche Einstellposition heraus drehen 5 Monter 9 Protecteur 1 9 Boulon protecteur 2 6 Régler 9 Force d amortisseur de rebond N B Tourner en serrant à la main le régleur 1 d amortisseur puis régler à la posi tion de réglage d origine 7 Régler 9 Force de compression d amor tissement N B Tourner en serrant à la main le régleur 1 d amortisse...

Page 454: ...urn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer to REMOVAL POINTS 11 Handlebar holder upper 2 12 Handlebar 1 13 Handlebar holder lower 2 5 42 CHAS HANDLEBAR EC5B0000 HANDLEBAR 1 Extent of removal 1 Handlebar removal 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb 28 Nm 2 8 ...

Page 455: ...apuchon du câble d accélérateur 1 Retourner le couvercle de capuchon 6 Câble d accélérateur 1 Déconnecter du côté accélérateur 7 Accélérateur 1 Desserrer les boulons 8 Couvercle de capuchon 1 9 Collerette 1 10 Poignée gauche 1 Se reporter à POINTS DE DEPOSE 11 Support de guidon supérieur 2 12 Guidon 1 13 Support de guidon inférieur 2 Préparation pour la dépose IC5B0000 MANUBRIO Ampiezza della rimo...

Page 456: ...le disassembly Extent of removal Order Part name Q ty Remarks THROTTLE DISASSEMBLY 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to REMOVAL POINTS 5 Tube guide 1 1 EC5B8000 THROTTLE DISASSEMBLY 4 Nm 0 4 m kg 2 9 ft lb ...

Page 457: ...de dépose Ordre Nom de pièce Q té Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poigée inférieur 1 2 Capuchon de poigée supérieur 1 3 Ensemble de la poignée 1 4 Poignée droite 1 Se reporter à POINTS DE DEPOSE 5 Guide de tube 1 IC5B8000 SMONTAGGIO DELL ACCELERATORE Ampiezza della rimozione 1 Smontaggio dell acceleratore Ampiezza della rimozione Ordine Particolare Quantità Osservazione SMONTA...

Page 458: ...the grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect 9Handlebar 1 Bends Cracks Damage Replace w Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5100 Throttle assembly 1 Install 9Grip right 1 Apply the adhesive on the tube guide 2 NOTE 9Before applying the adhesive wipe...

Page 459: ... 9 Guidon 1 Deformée craquelures endom magement Changer XG Ne pas tenter de redresser un guidon déformé car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble accélérateur 1 Monter 9 Poignée droite 1 Appriquer l adhésif sur le guide de tube 2 N B 9 Avant d appliquer l adhésif essuyer la graisse ou l huile sur la surface du guide de tube a avec du diluant de peinture 9 Aligner l indi...

Page 460: ...wer 1 9Plain washer 2 9Nut handlebar holder lower 3 NOTE 9Install the handlebar holder lower with its side having the greater distance a from the mount ing bolt center facing forward 9Apply the lithium soap base grease on the thread of the handlebar holder lower 9Installing the handlebar holder lower in the reverse direction allows the front to rear offset amount of the handlebar position to be ch...

Page 461: ...avant 9Appliquer de la graisse à base de savon au lithium sur le filetage du support de guidon inférieur 9L installation du support de guidon inférieur en sens inverse permet de changer le décalage d avant en arrière de la position du guidon 9Ne pas serrer l écrou à ce stade Lenkstange 1 Einbauen 9 Lenkerhalter unten 1 9 Unterlegscheibe 2 9 Mutter Lenkerhalter unten 3 HINWEIS 9 Die Lenkerhalterung...

Page 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 NOTE 9Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner 9Install the grip left to the handlebar so that the line b between the two arrow marks fa...

Page 463: ...s 9Installer le guidon de façon à ce que la saillie c du support de guidon supé rieur soit positionnée sur la marque du guidon comme illustré 9Serrer d abord les boulons à l avant du support de guidon supérieur et ensuite les boulons du côté arrière du guidon HINWEIS 9 Der Lenkerhalter oben sollte so angebracht werden dass die einge stanzte Markierung a nach vorn zeigt 9 Den Lenker so einbauen das...

Page 464: ...p 2 9 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 10 Install 9Cap cover 1 1 Nm 0 1 m kg 0 7 ft lb 6 Install 9Throttle cable 1 To tube guide 2 NOTE Apply the lithium soap base grease on the throt tle cable end and tube guide cable winding por tion 5 Install 9Collar 1 9Cap cover 2 9Throttle 3 NOTE 9Apply the lithium soap base grease on the throttle gr...

Page 465: ...s capuchon de poi gnée provisoirement sans fixer l ac célérateur sur le guidon 5 Einbauen 9 Hülse 1 9 Kappenabdeckung 2 9 Gasdrehgriff 3 HINWEIS 9 Lithium Fett an der Gleitfläche des Gasdrehgriffs auftragen 9 Die Schrauben Griffkappe vorläufig festziehen ohne den Gasdrehgriff an der Lenkstange anzubringen 5 Installare 9 Collare 1 9 Coperchio della calotta 2 9 Acceleratore 3 NOTA 9Applicare il gras...

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 bolts check that the throttle grip 3 3 moves smoothly If it does not retighten the bolts for adjustment 4 Nm 0 4 m kg 2 9 ft lb 11 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cyl...

Page 467: ...rès avoir serré les boulons véri fier que la poignée d accélérateur 3 3 tourne sans problème Sinon res serrer les boulons pour la régler 13 Monter 9 Bouton d arrêt du moteur EN GINE STOP 1 9 Support de levier d embrayage 2 9 Boulon support de levier d em brayage 3 9 Bride 4 N B 9Le bouton d arrêt du moteur ENGI NE STOP le support et la bride de levier d embrayage doivent être ins tallés selon les ...

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

Page 470: ...crown 1 4 Ring nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Bearing race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Bearing race 2 Refer to REMOVAL POINTS Extent of removal 1 Under bracket removal 2 Bearing removal 2 1 w Support the machine securely so there is no dan ger of it falling over EC560000 STEERING 145 Nm 14 5 m kg 105 ft lb 21 Nm 2 1 m kg...

Page 471: ...Motor angeordnet wird Nummernschild Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDECKEL im KAPITEL 4 Lenkstange Siehe Abschnitt LENKSTANGE Vorderrad Kotflügel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe Abschnitt VORDERRADGABEL 3 Lenkerkrone 1 4 Ringmutter 1 Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 5 Untere Gabelbrücke 1 6 Lagerlaufring Abdeckung 1 7 Lager oben 1 8 Lager unten 1 Sie...

Page 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 using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect 9Steering shaft 1 Bend Damage Replace Ring nut wrench YU 33975 90890 01403 ...

Page 473: ...e pas endommager le file tage de l arbre de direction Cage de roulement 1 Déposer 9 Cage de roulement 1 Déposer la cage de roulement à l aide d une tige 2 et d un marteau VERIFICATION Arbre de direction 1 Examiner 9 Arbre de direction 1 Déformations endommagement Changer IC563000 PUNTI DI RIMOZIONE IC563202 Ghiera 1 Togilere 9 Ghiera 1 Usare la chiave per ghiera 2 T Sostenere l albero dello sterzo...

Page 474: ...ion in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION EC5651A0 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install 9Bearing race 9Bearing upper 1 9Bearing race cover 2 NOTE Apply the lithium soap base grease on the bear ing and bearing race cover lip 3 Insta...

Page 475: ...ement et de cages de roulement REMONTAGE ET MONTAGE Etrier inférieur 1 Monter 9 Roulement inférieur 1 N B Appliquer de la graisse à base de savon au lithium sur la lèvre du joint anti poussière et sur la cironférence interne du roulement 2 Monter 9 Cage de roulement 9 Roulement supérieur 1 9 Couvercle de cage de roulement 2 N B Appliquer de la graisse à base de savon au lithium sur le roulement et...

Page 476: ...t by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE 9Temporarily tighten the pinch bolts under bracket 9Do not tighten the pinch bolts handle crown yet 8 Install 9Plain washer 1 9Steering shaft nut 2 7 Nm 0 7 m kg 5 1 ft lb 145 Nm 14 5 m kg 105 ft lb ...

Page 477: ...quel conque retirer l ensemble axe de direction et inspecter le support de direction 6 Monter 9 Rondelle ordinaire 1 7 Monter 9 Fourche avant 1 9 Etrier supérieur 2 N B 9Serrer le boulon de bridage étrier in férieur provisoirement 9Ne pas encore serrer le boulon de bri dage couronne de guidon 8 Monter 9 Rondelle ordinaire 1 9 Ecrou de colonne de direction 2 4 Installare 9 Ghiera 1 Serrare la ghier...

Page 478: ...he 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 After tightening the nut check the steering for smooth movement If not adjust the steering by loosening the ring nut little by little ...

Page 479: ... Serrare la staffa inferiore alla coppia specificata Se troppo serrata può provocare il malfunzionamento della forcella anteriore Oberes Ende der Gabelbein rohre Standard a Null mm Null in Extrémité supérieure de fourche avant Standard a a Zéro mm Zéro in Estremità superiore della forcella anteriore valore normale a a Zero mm Zero in 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 1...

Page 480: ...ke pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 Extent of removal 1 Swingarm removal 1 w Support the machine securely so there is no dan ger of it falling over EC570000 SWINGARM 53 Nm 5 3 m kg 38 ft lb 80 Nm 8 0 m kg 58 ft lb 16 Nm 1 6 m kg 1...

Page 481: ...EMSE UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdrücken Antriebskette 1 Kettenschutz 1 2 Kettenspanner unten 1 3 Schraube Hinterad Stoßdämpfer 1 Die Hinterradschwinge festhalten Relaisarm 4 Schraube Pleuelstange 1 5 Drehzapfenwelle 1 6 Hinterradschwinge 1 Vorbereitung für den Aus bau W Die Maschine richtig abstützen damit sie nicht umfallen kann IC570000 FOR...

Page 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 disassembly 3 Relay arm removal and disassembly 1 2 3 2 3 70 Nm 7 0 m kg 50 ft lb 6 Nm 0 6 m kg 4 3 ft lb 80 Nm 8 0 m kg 58 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 483: ...sbau und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename Stückzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 Siehe unter AUSBAUPUNKTE 2 Relaisarm 1 3 Pleuelstange 1 4 Hülse 2 5 Öldichtung 2 6 Drucklager 2 7 Buchse 2 8 Öldichtung 8 9 Lager 10 Siehe unter AUSBAUPUNKTE IC578000 SMONTAGGIO DEL FORCELLONE OSCILLANTE Ampiezza della rimozione 1 Smontaggio del forcellone oscillant...

Page 484: ...Bush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574211 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Oil seal 3 Damage Replace EC573000 REMOVAL POINTS Cap 1 Remove 9Cap left 1 NOTE Remove with a slotted head screwdriver inserted under the mar...

Page 485: ...Drücken auf den äußeren Laufring ausbauen INSPEKTION Die Lager Buchsen und Hülsen in Lösungsmittel waschen Hinterradschwinge 1 Prüfen 9 Lager 1 9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und Buchse als Satz erneuern 2 Prüfen 9 Öldichtung 3 Beschädigung Erneuern Relaisarm 1 Prüfen 9 Lager 1 9 Hülse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und Hülse als Satz erneuern 2 Prüfe...

Page 486: ...Installed depth of bearings Outer a a Zero mm Zero in Inner b b 6 5 mm 0 26 in EC574311 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Oil seal 3 Damage Replace 2 Install 9Bearing 1 9Plain washer 2 9Oil seal 3 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the b...

Page 487: ...te mit den Herstellermarkierungen oder Herstellungsnummern eingepresst wird 9 Zuerst die äußeren Lager und danach die inneren Lager bis zur vorgeschrie benen Tiefe von innen einbauen Profondità installata dei cuscinetti Esterno a a Zero mm Zero in Interno b b 6 5 mm 0 26 in Einbautiefe der Lager Außen a a Null mm Null in Innen b b 6 5 mm 0 26 in Bielle 1 Examiner 9 Roulement 1 9 Collerette 2 Il y ...

Page 488: ...her 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numbers Installed depth of bearings a a Zero mm Zero in 3 Install 9Collar 1 To connecting rod ...

Page 489: ...er Drucklager auftragen 2 Einbauen 9 Hülse 1 9 Unterlegscheibe 2 Zum Relaisarm 3 HINWEIS Das Molybdän Fett auf den Hülsen und den Öldichtungslippen auftragen Profondeur installée de roulement a a Zéro mm Zéro in 3 Monter 9 Roulement 1 9 Bague d étanchéité 2 Au bielle N B 9Appliquer une graisse de molybdéne sur le roulement lors de la repose 9Installer le roulement en l insérant sur côté où les rep...

Page 490: ...olybdenum disulfide grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To relay arm 5 NOTE Apply the molybdenum disulfide grease on the bolt 80 Nm 8 0 m kg 58 ft lb 7 Check 9Swingarm side play a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsm...

Page 491: ... écrou à ce stade 6 Monter 9 Bras oscillant 1 9 Axe de pivot 2 N B 9Appliquer de la graisse de molybdéne sur l axe de pivot 9Introduire l arbre pivot par le côté droit 5 Einbauen 9 Relaisarm 1 9 Schraube Relaisarm 2 9 Unterlegscheibe 3 9 Mutter Relaisarm 4 Zur Hinterradschwinge HINWEIS 9 Molybdän Fett auf dem Schraubenum fang und auf dem Gewinde auftragen 9 Die Mutter noch nicht festziehen 6 Einba...

Page 492: ...9Plain washer 2 9Nut connecting rod 3 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 53 Nm 5 3 m kg 38 ft lb 12 Install 9Cap 1 NOTE Install the cap right with its mark a facing for ward ...

Page 493: ...ibe 2 9 Mutter Pleuelstange 3 HINWEIS 9 Das Molybdän Fett auf der Schraube auftragen 9 Die Mutter noch nicht festziehen 9 Einbauen 9 Schraube Hinterrad Stoßdämpfer Relaisarm 1 9 Mutter Hinterrad Stoßdämp fer Relaisarm 2 HINWEIS Das Molybdän Fett auf der Schraube auftragen 8 Installare 9 Bullone leva di rinvio 1 9 Rosetta 2 9 Dado leva di rinvio 3 NOTA 9Applicare sul bullone il grasso a base di bis...

Page 494: ...sher 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover 10mm 0 39in 5 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 16 Nm 1 6 m kg 11 ft lb ...

Page 495: ...nner unten 5 14 Einbauen 9 Kettenschutz 1 9 Stützenabdeckung 2 9 Schraube Kettenschutz 50 mm 1 97 in 3 9 Mutter Kettenschutz 4 9 Schraube Stützenabdeckung 10 mm 0 39 in 5 13 Installare 9 Bullone tendicatena inferiore 1 9 Rosetta 2 9 Bordino 3 9 Tendicatena 4 9 Dado tendicatena inferiore 5 14 Installare 9 Supporto della catena 1 9 Copertura del supporto 2 9 Bullone supporto della catena 50 mm 1 97 ...

Page 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 air cleaner joint 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 7 Adjuster 1 8 Spring seat 2 9 Spring ...

Page 497: ... Cadre arrière 1 3 Boulon amortisseur arrière bras de relais 1 Tenir le bras oscillant 4 Boulon amortisseur arrière cadre 1 5 Amortisseur arrière 1 6 Contre écrou 1 7 Dispositif de réglage 1 8 Siège de ressort 2 9 Guide de ressort inférieur 1 10 Guide de ressort supérieur 1 11 Ressort amortisseur arrière 1 12 Roulement 2 Se reporter à POINTS DE DEPOSE Préparation pour la dépose XG Bien soutenir la...

Page 498: ...gas expansion and or damage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scr...

Page 499: ...dom mager toute partie du réservoir à gaz Un réservoir à gaz endom magé affectera la capacité d amortissement ou entraînera un mauvais fonctionnement 4 Prendre garde à ne pas rayer la surface de contact de la tige du piston avec le cylindre l huile pourrait fuir 5 Ne jamais essayer d enlever le plot situé au bas du réservoir à azotè Il est très dangereux d en lever le plot 6 Pour la mise au rebut ...

Page 500: ...ION EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly 9Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down 9Spring guide 4 Wear Damage Replace spring guide 9Spring seat 5 Cracks Damage Replace 9Bearing 6 Free play exists Unsmooth revolution R...

Page 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 détendre le res sort 9 Guide de ressort 4 Usure Endommagement Changer le guide de ressort 9 Siège de ressort 5 Fissuré endommagé Rempla cer 9 Roulement 6 Il y a jeu fonctionnel tour irré gulier rouille C...

Page 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 the bearing until it contacts the stopper ring 3 Install 9Lower bearing 1 NOTE Install the bearing by pressing it on the side hav ing the manufacture s marks or numbers Installed depth of the bearing ...

Page 503: ... sur côté où les repères ou numérous du fa bricant sont inscrits Ressort amortisseur arrière 1 Monter 9 Ressort 1 9 Guide de ressort supérieur 2 9 Guide de ressort inférieur 3 IC585000 MONTAGGIO E INSTAL LAZIONE IC585320 Cuscinetto 1 Installare 9 Cuscinetto superiore 1 NOTA Installare il cuscinetto parallelo finché premendone l anello esterno non com pare la scanalatura dell anello di fermo iI Non...

Page 504: ...Apply the lithium soap base grease on the O rings 2 Install 9Bush 1 9Collar 2 9Dust seal 3 NOTE 9Apply the molybdenum disulfide grease on the bearing and dust seal lips 9Install the dust seals with their lips facing out ward 4 Adjust 9Spring length installed Refer to REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT sec tion in the CHAPTER 3 5 Tighten 9Locknut 1 3 Tighten 9Adjuster 1 ...

Page 505: ...nts toriques 2 Monter 9 Bague 1 9 Collerette 2 9 Joint antipoussière 3 N B 9Appliquer de la graisse au bisulfure de molybdène sur le roulement et les lèvres des joints antipoussière 9Monter les joints antipoussière avec les lèvres orientées vers l extérieur Hinterrad Stoßdämpfer 1 Einbauen 9 Staubdichtung 1 9 O Ring 2 9 Hülse 3 HINWEIS 9Das Molybdän Fett auf den Staub dichtungen und den Hülsen auf...

Page 506: ...num 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 9Bolt rear frame upper 2 9Bolt rear frame lower 3 7 Tighten 9Bolt air cleaner joint 1 56 Nm 5 6 m kg 40 ft lb 53 Nm 5 3 m kg 38 ft lb 29 Nm 2 9 m kg 21 ft lb 32 Nm 3 2 m kg 23 ft lb ...

Page 507: ... 2 N B Appliquer de la graisse de molybdène sur le boulon 6 Monter 9 Cadre arrière 1 9 Boulon cadre arrière supé rieur 2 9 Boulon cadre arrière infé rieur 3 7 Serrer 9 Boulon raccord de filtre à air 1 3 Installare 9 Ammortizzatore posteriore 4 Installare 9 Bullone ammortizzatore poste riore telaio 1 9 Rosetta 2 9 Dado ammortizzatore posterio re telaio 3 NOTA Applicare sul bullone il grasso a base ...

Page 508: ...position 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 Orange R Red Sb Sky blue Y Yellow B L Black Blue B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red 1 Except for USA and CDN ...

Page 509: ...du moteur ENGINE STOP 3 Bobine d allumage 4 TPS capteur de position du papillon 5 Electrovanne 6 Contacteur de point mort Excepté pour USA et CDN 7 Magnéto CDI 8 Bougie CODE DE COULEUR B Noir L Bleu O Orange R Rouge Sb Bleu ciel Y Jaune B L Noir Bleu B R Noir Rouge B W Noir Blanc G L Vert Bleu G W Vert Blanc W L Blanc Bleu W R Blanc Rouge SCHEMA DE CABLAGE 1 Excepté pour USA et CDN IC600000 PARTE ...

Page 510: ...gap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI magneto Replace Replace Replace Replace Replace marked Only when the ignition checker is used NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition...

Page 511: ...ur d allumage et utilisé N B 9Déposer les pièces suivantes avant de procéder au dépistage des pannes 1 Selle 2 Réservoir à essence 9Utiliser les outils spéciaux suivants dans ce dépistage des pannes Testeur d étincelle dynamique YM 34487 Contrôleur d allumage 90890 06754 Tester de poche YU 3112 C 90890 03112 O K O K O K O K SYSTEME D ALLUMAGE ETAPES DE VERIFICATION Utiliser les étapes suivantes po...

Page 512: ...as Zündungsprüfgerät verwendet wird HINWEIS 9Die folgenden Teile vor Beginn der Störungsbeseitigung ausbauen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge für die Störungsbeseitigung verwenden Dynamischer Zündfunkenprüfer YM 34487 Zündungsprüfgerät 90890 06754 Taschenprüfgerät YU 3112 C 90890 03112 In Ordnung In Ordnung In Ordnung In Ordnung ZÜNDANLAGE PRÜFVORGÄNGE Durch folgende Schritt...

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 delle scintille YM 34487 Apparecchio per il controllo dell accensione 90890 06754 Tester tascabile YU 3112 C 90890 03112 OK OK OK OK IC620000 SISTEMA DI ACCENSIONE IC621003 OPERAZIONI DI ISPEZIONE Us...

Page 514: ...and increase spark gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or replace EC625002 ENGINE STOP BUTTON INSPECTION 1 Inspect 9 ENGINE STOP button conduct Not continuous while being pushed Replace Continuous while being freed Replace Minimum spark gap 6 0 mm 0 24 in Test...

Page 515: ... DU MOTEUR ENGINE STOP 1 Examiner 9 Conductibilité du bouton d arrêt du moteur ENGINE STOP Pas de continuité lorsqu enfoncé Changer Continuité lorsque relâché Changer IC622001 TEST DELLA DISTANZA TRA GLI ELETTRODI 1 Scollegare la calotta della candela dalla candela 2 Collegare il tester dinamico delle scintille 1 apparecchio per il controllo dell accensione 2 come illustrato 9 Calotta della candel...

Page 516: ...ve the spark plug cap by turning it coun terclockwise and inspect 9Install the spark plug cap by turning it clock wise until it is tight Tester lead Yellow lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Yellow lead 2 Primary coil Tester selector resistance position 0 20 0 30Ω at Ω 1 20 C 68 F Secondary coil Tester selector resistance position 9 5 14 3kΩ at kΩ 1 20 C 68 F...

Page 517: ...della candela girandolo in senso antiorario e con trollarlo 9Rimontare il cappuccio della candela girandolo in senso orario finché non è bene avvitato Resistenza Posizione del della bobina selettore del primaria tester 0 20 0 30Ω a Ω 1 20 C 68 F Conduttore del tester Conduttore giallo 1 Conduttore del tester Conduttore nero 2 Resistenza Posizione della bobina del selettore secondaria del tester 9 ...

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 Tester selector resistance position 4 6kΩ at kΩ 1 20 C 68 F EC627011 CDI MAGNETO INSPECTION 1 Inspect 9Pick up coil resistance Out of specification Replace Tester lead White Red lead 1 Tester lead White ...

Page 519: ...re 9 Resistenza del cappuccio della candela Non rientra nelle specifiche Sostituire Résistance Position de du capuchon sélecteur de de bougie testeur 4 6kΩ à kΩ 1 20 C 68 F Fil de testeur Borne 1 du câble de bougie Fil de testeur Borne 2 de la bougie Positives Kabel des Prüfgerätes Zündkerzenkabelpol 1 Negatives Kabel des Prüfgerätes Zündkerzenpol 2 4 6kΩ bei kΩ 1 20 C 68 F Resistenza Posizione de...

Page 520: ...6Ω at Ω 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 9Neutral switch conduct No continuous while in neutral Replace Continuous while in gear Replace Tester lead Sky blue lead 1 Tester lead Ground 2 Sb Ground 1 2 NEUTRAL IN GEAR Tester selec tor posit...

Page 521: ...sgerät 1 2 Wähl schalter LEER 1 1 LAUF GANG Ω 1 EINGE LEGT VERIFICATION DE BLOC CDI Vérifier tous les équipements élec triques Si aucun défaut n est trouvé remplacer le bloc CDI puis vérifier à nouveau les équipements électriques INSPEKTION DER CDI EINHEIT Die gesamte elektrische Ausrüstung prüfen Wenn kein Fehler festgestellt wird die CDI Einheit erneuern Danach die elektrische Ausrüstung nochmal...

Page 522: ...ood 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 IGNITION SYSTEM section NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use l2V battery in this inspection 9Use the following special tools in this inspection Pocket tester YU...

Page 523: ...magnéto CDI Changer le bloc CDI Mauvais SYSTEME D ELECTROVANNE ETAPES DE VERIFICATION Si l électrovanne ne fonctionne pas applicuez la proqédure d inspection suivante Indication Se reporter à la section SYSTEME D ALLUMAGE N B 9Déposer les pièces suivantes avant de procéder au dépistage des pannes 1 Selle 2 Réservoir à essence 9Pour cette inspection utilisez une batterie de 12 V 9Utiliser les outil...

Page 524: ...pule Erneuern CDI Magnetzünder kontrollieren CDI Einheit erneuern Nicht in Ordnung MAGNETVENTILSYSTEM PRÜFVORGÄNGE Falls das Magnetventil nicht funktioniert sind die folgenden Überprüfungen durchzuführen Markierung Siehe Abschnitt ZÜNDANLAGE HINWEIS 9Die folgenden Teile vor Beginn der Störungsbeseitigung ausbauen 1 Sitz 2 Kraftstofftank 912V Batterie für diese Überprüfung benutzen 9Die folgenden S...

Page 525: ...funziona Sostituirlo Controllare magnete CDI Sostituire unità CDI Non funziona IC650001 SISTEMA ELETTROVALVOLA IC651032 OPERAZIONI DI ISPEZIONE Se l elettrovalvola non funziona effettuare i seguenti controlli contrassegnato consultare la sezione SISTEMA DI ACCENSIONE NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9Per questo controllo utilizzare una bat...

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 9Solenoid valve coil resistance Out of specification Replace Tester lead Red lead 1 Tester lead Red lead 2 22 8 27 8Ω at 20 C 68 F Solenoid resistance Tester selector position Ω 10 Battery lead Red lead...

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 FUNZIONAMENTO DELL ELETTROVALVOLA 1 Scollegare l accoppiatore dell elet trovalvola 2 Collegare la batteria 12V all accoppiatore dell elettrovalvo la 3 Ispezionare 9 Elettrovalvola 1 Nessun clic quando si colle...

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 section NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use the following special tools in this inspection Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Pocket test...

Page 529: ...au dépistage des pannes 1 Selle 2 Réservoir à essence 9Utiliser les outils spéciaux suivants dans ce dépistage des pannes Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 Tester de poche YU 3112 C 90890 03112 O K O K Bobine primaire Mauvais Contrôler la magnéto CDI Changer O K Tension d entrée du TPS Mauvais Contrôler le bloc CDI Changer SYSTEME TPS CAPTEUR DE POSITION DU PAPILLON E...

Page 530: ...auen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge für die Störungsbeseitigung verwenden Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 Taschenprüfgerät YU 3112 C 90890 03112 In Ordnung In Ordnung Stromspule Nicht in Ordnung CDI Magnetzünder kontrollieren Erneuern In Ordnung TPS Eingangs spannung Nicht in Ordnung CDI Einheit kontrollieren Erneuern TPS SYSTEM TPS DROSSELSTELL...

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 03113 Tester tascabile YU 3112 C 90890 03112 OK OK Bobina primaria Controllare magnete CDI Sostituirla OK Tensione in ingresso nel TPS Controllare unità CDI Sostituirla IC690000 SISTEMA TPS SENSORE DI PO...

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 Tester selector resistance position 4 6kΩ at kΩ 1 20 C 68 F EC69A000 HANDLING NOTE cC Do not loosen the screws TPS throttle position sensor except when changing the TPS throttle position sensor due to fai...

Page 533: ... 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 6kΩ a kΩ 1 20 C 68 F Conduttore del tester Conduttore Blu 1 Conduttore del tester Conduttore nero 2 Résistance Position de de la bobine sélecteur de du TPS testeur 4 6kΩ à kΩ 1 20 C 68 F Fil de testeur Fil bleu 1 Fil...

Page 534: ...of specification Replace Tester lead Yellow lead 2 Tester lead Black lead 3 Tester selector position Full closed Full opened Zero 2kΩ at 4 6kΩ at 20 C 68 F 20 C 68 F kΩ 1 EC693001 TPS REPLACEMENT AND ADJUSTMENT 1 Remove 9Carburetor 9Mixing chamber top Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 2 Remove 9Screw TPS 1 9TPS 2 NOTE Loosen the screws using the T25 bit 3 Replace 9TPS TPS...

Page 535: ... Positives Kabel des Prüfgerätes Gelbes Kabel 2 Negatives Kabel des Prüfgerätes Schwarzes Kabel 3 Regelbarer Position des TPS Spulenwider Wählschalters stand am Prüfgerät Vollständig Vollständig geschlossen geöffnet Null 2kΩ bei 4 6kΩ bei kΩ 1 20 C 68 F 20 C 68 F Resistenza variabile Posizione della bobina del selettore del TPS del tester Completa Completa mente chiuso mente aperto Zero 2kΩ a 4 6k...

Page 536: ...ent 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 3 7 Insert the thin electric conductors 2 lead wire into the TPS coupler 1 as shown and connect the tester to them cC 9Do not insert the electric conductors more than required because it may reduce t...

Page 537: ...en auf den Abschnitt EINSTELLUNG DER LEER LAUFDREHZAHL im KAPITEL 3 Leerlaufdrehzahl für TPS Einstellung 1 700 bis 1 900 U min Passi della regolazione 9Collegare il tachimetro induttivo tachimetro motore al terminale scollegato alta tensione 9Girare la vite d arresto dell acce leratore 1 fino al minimo specifi cato Vedi la parte REGOLAZIONE DEL MINIMO nel capitolo 3 Minimo per la regolazio ne del ...

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 in the CHAPTER 4 8 Start the engine 9 Adjust 9TPS output voltage Adjustment steps Adjust the installation angle of the TPS 1 to obtain the specified output volt age TPS output Tester selector voltage ...

Page 539: ...typ 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 usando la punta T20 tipo di dispositivo di fissaggio resistente alla manomissione e allineando le indica zioni a di posizione segnate prima dello smontaggio 14 Installare 9 Carburatore Consultare la sez...

Page 540: ...TPS 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 TPS input Tester selector voltage position 4 6V DCV 20 ...

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 unità CDI Tensione in Posizione del ingresso selettore del nel TPS tester 4 6V DCV 20 Conduttore del tester Conduttore Blu 1 Conduttore del tester Conduttore Nero Blu 2 Tension Position de d entrée sél...

Page 542: ...st be properly suited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed road surface conditions and for the discoloration of the spark plug s After tak ing these into consideration he must select the best possible carburetor settings It is advisable to make a note of sett...

Page 543: ... de la route et la décoloration de bougie s Prenant ces facteurs en considération il sélectionnera les meilleurs réglages de carburateur possibles Il est recommandé de prendre note des réglages des conditions atmos phériques de la surface de la route le temps au tour etc afin que ce mémorandum puisse être utilisé ultérieurement comme référence Conditions atmosphériques et régla ge de carburateur L...

Page 544: ...ity of the air EC713001 Test run After warming up the engine equipped with the standard type carburetor s and spark plug s run two or three laps of the circuit and check the smooth operation of the engine and discoloration of spark plug s å Normal Over burned too lean ç Oil fouled too rich Discoloration Condition of spark plug Normal Insulator is dry and burnt brown Over burned Insulator is whitis...

Page 545: ...ugie s A Normale B Surbrûlée trop pauvre C Encrassée d huile trop riche Cioè 9 Una temperatura più alta fa dilatare l aria ne risulta una densità ridotta 9 Un umidità più elevata riduce la quantità di ossigeno nell aria in misura proporzionale al vapore acqueo contenuto nella stessa aria 9 Una pressione atmosferica più bassa a un altitudine elevata riduce la densità dell aria IC713001 Corsa di pro...

Page 546: ...r 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 The richness of air fuel mixture under 8 500 rpm to the extent of 1 2 to full opened throttle can be set by changing the power jet 1 A larger size jet results in a richer mixture and a smaller size in ...

Page 547: ... est trop chaude Sélectionner un gicleur principal avec un numéro de calibrage supé rieur à la norme Pour enrichir 2 La bougie est mouillée Sélectionner un gicleur principal avec un numéro de calibrage infé rieur à la norme Pour appauvrir Standard Hauptdüse 178 180 Gicleur principal standard 178 180 Getto principale normale No 178 No 180 Einstellung der Kraftdüse Die Fettheit des Luft Kraftstoffge...

Page 548: ...acceleration will result Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and therefore it should be judged from your feeling of actual engine operation For EUROPE Standard pilot jet 50 52 EC716001 Pilot air screw adjustment The richness of air fuel mixture with full closed to 1 8 throttle can be set by turning the pilot air screw 1 Turning i...

Page 549: ...e essere difficile far girare il motore senza problemi a regimi inter medi si deve regolare l ago a getto 1 Se la miscela è troppo ricca o troppo povera durante il funzionamento a regi mi intermedi si avranno un funziona mento irregolare del motore e una scar sa accelerazione E difficile determina re in base alla candela se la ricchezza della miscela sia adeguata oppure no questo dovrebbe pertanto...

Page 550: ...ick 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 pick up speed quickly Step up the jet needle clip by one groove and move up the needle to enrich the mix ture ...

Page 551: ...icht glatt beschleunigt werden In diesem Fall die Düsennadelklam mer um eine Nut höher positionie ren und die Düsennadel absenken um ein magereres Gemisch zu erhalten 2 Zu mager bei mittleren Drehzah len Der Motor wird nur hart bearbei tet und kann nicht schnell beschleunigt werden Die Düsen nadelklammer um eine Nut nied riger positionieren und die Nadel anheben um ein fetteres Gemisch zu erhalten...

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 1 4 open 9 Taper starting position Difference of 0 5 groove Rich N3EW 4th groove N3CW 4th groove N3EW 3rd groove N3CW 3rd groove Lean N3EW 2nd groove Changing the taper starting position pro duces the...

Page 553: ...re de la partie droite ajuste le mélan ge air carburant lorsque l ouver ture des gaz est comprise entre 1 8 et 1 4 9 Position de départ de cône Différence d une demi groove Riche N3EW 4e groove N3CW 4e groove N3EW 3e groove N3CW 3e groove Pauvre N3EW 2e groove Le changement de la position de départ de cône produit le même effet que le changement de posi tion du circlip d une demi groove Exemple Si...

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 is balanced at each stage of throttle opening by the combination of the jet needle straight portion diameter taper starting position and clip position Example N3EW 3rd groove N3EW 4th groove N3EJ 3rd g...

Page 555: ...llon il dépend de la position de début de cône et de la position de l agrafe Par conséquent l écoulement du carbu rant est équilibré à chaque étape de l ouverture du papillon par la combinai son du diamètre de la portion droite du papillon et de sa position de départ de cône ainsi que de la position de l agrafe Exemple N3EW 3e groove N3EW 4e groove N3EJ 3e groove N8RW 3e groove A Pauvre Diamètre p...

Page 556: ...62 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 03 Lean 38 4MX 14948 02 Jet needle 3 3 Rich N8RH 4SR 14916 RH N3EH 4SR 14916 EH N8RW 4SR 14916 RW STD N3EW 4SR 14916 EW N3CW 4SR 14916 CW N3EJ 4SR 14916 EJ Lean N3CJ 4SR 14916 CJ Power jet 4 4 Rich 65...

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 14948 08 STD No 50 4MX 14948 07 No 48 4MX 14948 06 No 45 4MX 14948 05 No 42 4MX 14948 04 No 40 4MX 14948 03 Povera No 38 4MX 14948 02 Ago a Ricca N8RH 4SR 14916 RH getto 3 3 N3EH 4SR 14916 EH N8RW 4SR 14...

Page 558: ...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 The position is numbered from Poor acceleration the top Leaner Standard Richer EC71C030 Road condition and examples of carburetor setting å For USA and CDN For EUROPE ç For AUS NZ and ZA NOTE Optimum pilot air...

Page 559: ...t 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 Use main jet having lower calibration No Raise jet needle clip position 1 groove up If no effect reverse the above procedures Poor engine operation Turn in pilot air screw Check throttle valve operati...

Page 560: ...bonne Si la normalisation est impossible Siège de pointeau bouché Tuyau de carburant bouché Robinet de carburant bouché Décoloration de la bougie Si la couleur est foncée la condition est bonne Si aucum effet Vis du filtre a air Fuite de carburant depuis le carburateur La position de fixation indique la posi tion de la groove de l aiguille de gicleur dans laquelle la fixation est enclenchée Les po...

Page 561: ...inverser les procédures mentionnées ci dessus Contrôler tous les réglages d ensemble Utiliser un gicleur principal avec un n de calibrage inférieur Elever la position de fixation de l aiguille de gicleur 1 groove plus haut Si l effet est nul inverser les procédures mentionnées ci dessus Visser la vis de richesse Contrôler Nombre de tours de dévissage Corriger correctement Fuite en provenance du ca...

Page 562: ...ehens Ein etwas fetteres Gemisch reduziert die Motorstörung Düsennadel Klemmenposition absenken 1 Nut niedriger Düsennadel Klemmenposition erhöhen 1 Nut höher Düsennadel Klemmenposition absenken 1 Nut niedriger Düsennadel Klemmenposition erhöhen 1 Nut höher Prüfung Verfärbung der Zündkerze Bei hellbrauner Farbe ist sie in gutem Zustand Falls nicht normalisiert werden kann Verstopfter Schwimmervent...

Page 563: ...adel Klemmenposition erhöhen Falls keine Wirkung die obigen Vorgänge umkehren Gesamteinstellungen überprüfen Hauptdüse mit niedrigerer Kalibrierungs Nr verwenden Düsennadel Klemmenposition erhöhen 1 Nut höher Falls keine Wirkung die obigen Vorgänge umkehren Leerlaufluftschraube hineinschrauben Prüfung Anzahl der Ausdrehungen Richtig korrigieren Überlauf am Vergaser Bremse schleift Überlauf am Verg...

Page 564: ...la Se color cuoio è in buone condizioni Se non può essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Scolorimento della candela Se color cuoio è in buone condizioni Se non vi è effetto Filtro dell aria otturato Traboccamento di carburante dal carburatore La posizione del fermaglio a graffa indica la posizione della sc...

Page 565: ...ire al contrario le procedure sopra descritte Controllare le registrazioni generali Usare un getto principale che abbia un No di taratura più basso Alzare la posizione del fermaglio a graffa dell ago a getto su di 1 scanalatura Se non vi è effetto eseguire al contrario le procedure sopra descritte Avvitare la vite dell aria pilota Controllo Numero di giri in senso contrario Correggere adeguatament...

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 stop the engine immediately after a run and check 9Avoid racing 9When changing the heat range of spark plugs never attempt to change it more than 1 rank 9When using a spark plug other than standard che...

Page 567: ...é de changer la plage de chaleur des bougies et de sélection ner un autre gicleur principal correct N B 9Lors du contrôle de la décoloration des bougies attention à bien arrêter le moteur immédiatement après un tour et vérifier 9Eviter de faire la course 9En changeant la plage de chaleur des bougies ne jamais essayer de la chan ger de 1 degré 9Dans le cas de l utilisation d une bou gie autre que s...

Page 568: ...ntire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while mak ing notes of lap times to find the best balance then determine the secondary reduction ratio 9If a course has a long straight portion where a machine can run at maximum speed the mach...

Page 569: ... déterminer le taux de réduction secon daire 9Quand il y a de grandes lignes droites régler la machine de sorte à ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en évitant que la vitesse de rotation du moteur soit excessive N B Chaque motocycliste a sa propre tech nique de conduite et les performances varient aussi d une machine à l autre Eviter donc de copier ...

Page 570: ...h 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 Driven sprocket 2 2 47T 1C3 25447 00 48T 1C3 25448 00 49T 1C3 25449 00 STD 50T 1C3 25450 00 51T 1C3 25451 00 52T 1C3 25452 00 Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi Extent of adjustment 60 80 ...

Page 571: ... 52T 1C3 25452 00 Pression des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de réglage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de réglage 60 80 kPa 0 6 0 8 kgf cm2 9 0 12 psi Reifendruck Der Reifendruck soll so gewählt wer den dass er dem Zustand der Streckenoberfläche am Tag des Ren nens entspricht 9 Unter regnerischen schlammigen oder rutschigen Bedingungen sollte der Reifendruck nied...

Page 572: ...inal stroke can be changed by changing the fork oil amount cC Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body Alternatively too large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the con sequ...

Page 573: ...une tendance au dur cissement de la fourche avec comme conséquence une détérioration des performances et des caractéristiques Voilà pourquoi il convient d ajuster la fourche dans la plage spécifiée IC722011 Registrazione della forcella anteriore La registrazione della forcella anteriore dovrebbe essere effettuata in base alla sen sazione che il guidatore ha di una corsa effettiva e alle condizioni...

Page 574: ...tronger and the front fork may sink deeply over a series of gaps To set a soft spring 9Change the rebound damping Turn out one or two clicks 9Change the compression damping Turn in one or two clicks 2 Use of stiff spring Generally a stiff spring gives a stiff riding feeling Rebound damping tends to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handl...

Page 575: ...ändern Um eine oder zwei Klickstel lungen herausdrehen 9 Die Einfederdämpfung ändern Um eine oder zwei Klickstel lungen hereindrehen 2 Verwendung einer harten Feder Normaleweise bewirkt eine harte Feder ein hartes Fahrgefühl Die Ausfederdämpfung wird geringer und ein Gefühl mangelnden Fahrbahnkontaktes kann entste hen ebenso wie Vibrationen im Lenker Zum Einstellen einer harten Feder 9 Die Ausfede...

Page 576: ...th 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 0 408 1C3 23141 B0 II 0 418 1C3 23141 C0 III STD 0 428 1P8 23141 M0 0 438 1C3 23141 E0 IIIII 0 449 1C3 23141 F0 I I STIFF 0 459 1C3 23141 G0 I II 0 469 1C3 23141 H0 I III 0 479 1C3 23141 J0 I IIII EC7...

Page 577: ... E0 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 NOTA La marcatura di identificazione fendi ture a viene provata all estremità della molla IC72B000 Registrazione della sospensione posteriore La registrazione della sospensione posteriore dovrebbe e...

Page 578: ...ve the standard figure from the subtraction of the length b from the length a Standard figure 90 100 mm 3 5 3 9 in NOTE 9If the machine is new and after it is broken in the same set length of the spring may change because of the initial fatigue etc of the spring Therefore be sure to make re evaluation 9If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spri...

Page 579: ...raen do la lunghezza b dalla lunghezza a Valeur standard 90 100 mm 3 5 3 9 in Standardwert 90 100 mm 3 5 3 9 in Cifra normale 90 100 mm 3 5 3 9 in HINWEIS 9 Wenn eine neue Maschine eingefah ren worden ist kann es sein dass die Einstellänge der Feder sich ändert aufgrund von Faktoren wie Ermüdung der Feder etc Es wird darum empfohlen nach dem Einfah ren die Einstellung zu überprüfen 9 Wenn der Stan...

Page 580: ...ing for more rebound damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed more or less by a change in the com pression damping For correction turn the low compression damping adjuster on the softer side cC When using a rear cushion other ...

Page 581: ...orrek tur den niedrigen Einfederdämp fungeinsteller zur weicheren Seite hin stellen IC72G020 Registrazione della molla dopo la sostituzione Dopo la sostituzione assicurarsi di regolare la molla alla lunghezza regi strata lunghezza abbassata 90 100 mm 3 5 3 9 in e registrarla 1 Uso di una molla dolce 9 Registrare la molla dolce per un minore smorzamento dell esten sione per compensarne il minore ca...

Page 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 1 260 SPRING SPRING I D SPRING TYPE RATE PART NUMBER MARK FREE approx Q TY LENGTH SOFT 4 5 5UN 22212 A0 Green 2 275 4 7 5UN 22212 B0 Red 2 275 4 9 5UN 22212 C0 Black 2 275 5 1 5UN 22212 D0 Blue 2 275...

Page 583: ...60 5 5 5UN 22212 60 Rose 1 260 DUR 5 7 5UN 22212 70 Blanc 1 260 FEDER FEDER TEILE ID Mar Ungespannte TYP KON NUMMER kierung Federlänge STANTE Quantität WEICH 4 3 5UN 22212 00 Braun 1 260 5 3 5UN 22212 50 Gelb 1 260 5 5 5UN 22212 60 Rosa 1 260 HART 5 7 5UN 22212 70 Eeiß 1 260 FLESSI NUMERO TIPO BILITÀ CATEGORICO DELLA MOLLA DOLCE 4 3 5UN 22212 00 Marrone 1 260 5 3 5UN 22212 50 Gialla 1 260 5 5 5UN ...

Page 584: ...T OF LENGTH ADJUSTMENT b 260mm 10 24in 240 5 258 5mm 9 47 10 18in 275mm 10 83in 255 5 273 5mm 10 06 10 77in SPRING FREE EXTENT OF LENGTH ADJUSTMENT b One I D mark 245 5 263 5 mm 9 67 10 37 in Approx 265mm Two I D marks 10 43 in 251 5 269 5 mm 9 90 10 61 in Three I D marks 243 0 261 0 mm 9 57 10 28 in ...

Page 585: ...0 18 in 275 mm 10 83 in 255 5 273 5 mm 10 06 10 77 in LONGUEUR DE ETENDUE DE RESSORT LIBRE REGLAGE b Une marque d identification 245 5 263 5 mm 9 67 10 37 in Deux marques Approx 265 mm d identification 10 43 in 251 5 269 5 mm 9 90 10 61 in Trois marques d identification 243 0 261 0 mm 9 57 10 28 in UNGESPANNTE EINSTELLUMFANG FEDERLÄNGE b Eine ID Markierung 245 5 263 5 mm 9 67 10 37 in Zwei ID Mark...

Page 586: ...ession damping Turn adjuster clockwise about 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 out Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke 1 Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz end 0 2 US oz Soft toward stroke 1 Oil amount Increase oil amount by about 5 cm3 0 2 Imp oz en...

Page 587: ...and Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression Turn adjuster clockwise about 1 click to in damping crease damping Poor road gripping 1 High compression Turn adjuster clockwise about 1 6 turn to damping increase damping...

Page 588: ...0 2 0 3 US oz Monter un ressort doux Vérifier s il y a coudes coups ou tout autre endommagement visible Si tel est le cas rem placer les parties affectées Remplacer par un nouveau pour une utilisation prolongée Remplacer par un nouveau pour une utilisation prolongée Resserrer au couple spécifié Tourner le dispositif de réglage vers la gauche de 2 déclics pour réduire l amortissement Enduire la bag...

Page 589: ...sement Régler la longueur sur 90 100 mm 3 5 3 9 in avec une personne assise correctement sur la selle Tourner le dispositif de réglage vers la droite de 2 déclics pour augmenter l amortissement Tourner le dispositif de réglage dans le sens horaire env 1 déclic pour augmenter la force d amortissement Monter un ressort dur Tourner le dispositif de réglage vers la gauche de 2 déclics pour réduire l a...

Page 590: ... 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz reduzieren Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtbare Schäden etc prüfen Falls vorhanden betroffene Teile ersetzen Durch ein neues mit verlängerter Lebensdauer austauschen Durch ein neues mit verlängerter Lebensdauer austauschen Auf Soll Anzugsdrehmoment festziehen Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die Däm...

Page 591: ... Dämpfung zu ver ringern Eingetauchte Länge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die Dämpfung zu steigern Einsteller im Uhrzeigersinn drehen etwa 1 Klick stellung um die Dämpfung zu steigern Durch härtere Feder ersetzen Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die Dämpfun...

Page 592: ...ntiorario circa 2 scatti per diminuire lo smor zamento Diminuire la quantità d olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Sostituirla con una molla dolce Controllare eventuali curvature ammaccature e altri segni rilevabili ecc Nel caso sostituire le parti interessate Sostituire con uno nuovo per uso prolungato Sostituire con uno nuovo per uso prolungato Riserrarla alla coppia specificata ...

Page 593: ...ire lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aumentare lo smorzamento Ruotare il dispositivo di regolazione in senso ora rio 1 scatto circa per aumentare lo smorzamen to Sostituirla con una molla rigida Ruotare il dispositivo di regolazione in senso...

Page 594: ...TUN MEMO ...

Page 595: ...by Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 1P8 9 32 hyoshi 4 29 06 2 17 PM Page 2 ...

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 PAPER YZ250 W W1 1P8 9 32 hyoshi 4 29 06 2 17 PM Page 1 ...

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Yamaha YZ250, Owner'S Service Manual, Page: 218 / 596

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