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Yamaha YZ250F(N)/LC, Owner'S Service Manual


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4 - 1

ENG

 

EC400000

 

ENGINE

 

SEAT, FUEL TANK AND SIDE COVERS

 

Extent of removal:

 

1

 

 Seat removal

 

2

 

 Fuel tank removal

 

3

 

 Side covers removal

 

4

 

 Number plate removal

Extent of removal

Order

Part name

Q’ty

Remarks

Preparation for removal

 

SEAT, FUEL TANK AND SIDE 
COVERS REMOVAL

 

Turn the fuel cock to “OFF”.
Disconnect the fuel hose.

1

Seat

1

2

Air scoop (left and right)

2

3

Fitting band

1

Remove on fuel tank side.

4

Bolt (fuel tank)

2

5

Fuel tank

1

6

Left side cover

1

7

Right side cover

1

8

Number plate

1

1

3

4

2

3

 

SEAT, FUEL TANK AND SIDE COVERS

 

4

 

 

 

4 

Summary of Contents for YZ250F(N)/LC

Page 1: ...5NL 28199 30 YZ250F N LC OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO...

Page 2: ...ER S SERVICE MANUAL 2000 by Yamaha Motor Co Ltd 1st Edition September 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly pro...

Page 3: ...IER DU PROPRIETAIRE 2000 Yamaha Motor Co Ltd 1 re dition septembre 2000 Tous droits r serv s Toute reimpression ou utillisation sans la permission crite de la Yamaha Motor Co Ltd est formellement inte...

Page 4: ...lease contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING PLEASE R...

Page 5: ...sion naire Yamaha N B Comme des am liorations sont faites sur ce mod le quelques donn es contenues dans ce manuel peuvent tre p rim es Si vous avez des questions poser pri re de consulter votre conces...

Page 6: ...PROTECTIVE APPAREL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing...

Page 7: ...e cette machine toujours porter un casque homologu avec des lunettes ou un prot ge visage Porter galement de grosses bottes des gants et des v te ments de protection Toujours porter des v tements de t...

Page 8: ...Carbon monoxide is a dangerous gas which can cause unconscious ness 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 machine...

Page 9: ...si vous devez abandonner la machine Ne pas stationner en pente ou sur un sol mou ou elle pourrait se renverser 9 LE MOTEUR LE SYST ME D CHAPPEMENT ET LE R SERVOIR D HUILE SONT TR S CHAUDS LORSQUE LE...

Page 10: ...is machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If ther...

Page 11: ...e machine veuillez consulter votre concessionnaire Yamaha N B Ce manuel doit tre consid r comme partie permanente de la machine et doit rester avec celle ci si elle est revendue une tierce personne AV...

Page 12: ...avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer WARNING CAUTION EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters Gener...

Page 13: ...ten zu vereinfachen WARNUNG ACHTUNG INFORMATION AUFFINDEN 1 Diese Anleitung umfa t sieben Kapitel 1 Allgemeine Angaben 2 Technische Daten 3 Regelm ige Inspektionen und Einstellarbeiten 4 Motor 5 Fahrw...

Page 14: ...start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A...

Page 15: ...es en clat les pi ces sont num rot es 2 dans l ordre des op rations effectuer Un chiffre entour d un cercle correspond une tape de d montage 3 Les vues en clat portent gale ment des symboles 3 qui rap...

Page 16: ...Lubricant B Tightening C Specified value Service limit D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubri...

Page 17: ...nsit A Les symboles graphiques E H utilis s dans les vues en clat indiquent les endroit lubrifier et le type de lubrifiant E Appliquer de l huile moteur F Appliquer de l huile au bisulfure de moly bd...

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

Page 19: ...PIANTO ELETTRICO ELEC 6 MESSA A PUNTO TUN 7 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES COURANTS MOTEUR PARTIE CYCLE PARTIE ELECTRIQUE MISES AU POINT INDEX...

Page 20: ...TING AND BREAK IN 1 14 TORQUE CHECK POINTS 1 18 CLEANING AND STORAGE 1 19 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITI...

Page 21: ...ERIFICATION DE COUPLE DE SERRAGE 1 18 NETTOYAGE ET RANGEMENT 1 19 CHAPITRE 2 CARACTERISTIQUES CARACTERISTIQUES GENERALES 2 1 CARACTERISTIQUES D ENTRETIEN 2 4 CARACTERISTIQUES GENERALES DE COUPLE 2 17...

Page 22: ...CH 4 48 OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 4 55 BALANCER 4 62 OIL PUMP 4 65 KICK SHAFT AND SHIFT SHAFT 4 70 CDI MAGNETO 4 77 ENGINE REMOVAL 4 81 CRANKCASE AND CRANKSHAFT 4 86 TRAN...

Page 23: ...4 55 BALANCIER 4 62 POMPE A HUILE 4 65 AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR 4 70 MAGNETO CDI 4 77 DEPOSE DU MOTEUR 4 81 CARTER ET VILEBREQUIN 4 86 BOITE A VITESSES TAMBOUR ET FOURCHETTE DE...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 MAP CONTROLLED CDI UNIT 6 2 IGNITION SYSTEM 6 3 THROTTLE POSITION SENSOR SYSTEM 6 7 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 11...

Page 25: ...RIQUES ET SCHEMA DE CABLAGE 6 1 BLOC CDI CONTROLE PAR MICROPROCESSEUR 6 2 SYSTEME D ALLUMAGE 6 3 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ 6 7 CHAPITRE 7 MISES AU POINT MOTEUR 7 1 PARTIE CYCLE 7 11 CAPIT...

Page 26: ...k cap 8 Engine stop switch 9 Kickstarter crank 0 Fuel tank A Radiator B Coolant drain bolt C Rear brake pedal D Valve joint E Fuel cock F Cold starter knob G Hot starter knob red H Drive chain I Air f...

Page 27: ...nt C P dale de frein arri re D Joint de robinet E Robinet de carburant F Bouton de d marrage froid G Bouton de d marrage chaud rouge H Cha ne de transmission I Filtre air J S lecteur K Fourche avant N...

Page 28: ...hine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the st...

Page 29: ...O D IDENTIFICATION DU VEHICULE Le num ro d identification du v hicule 1 est frapp du c t droit du tube de direction NUMERO DE SERIE DU MOTEUR Le num ro de s rie du moteur 1 est estamp sur un bossage s...

Page 30: ...bottom Carburetor accelerator pump 2 Use proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders p...

Page 31: ...ge correct Se reporter la section OUTILS SPECIAUX 3 Lors du d montage de la machine garder les pi ces conne xes ensemble Ils comprennent les engrenages cylindres pistons et autres pi ces connexes qui...

Page 32: ...EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or...

Page 33: ...freins d crou 1 et goupilles fendues ne doivent jamais tre r utilis s Les onglets de blocage doivent tre dress s contre les faces de boulon ou d crou une fois que les boulons et crous ont t correcteme...

Page 34: ...uld be inspected carefully before reassembly Always replace pis ton pin clips after one use Replace dis torted circlips When installing a circlip 1 make sure that the sharp edged cor ner 2 is position...

Page 35: ...circlips d axe de piston apr s une utilisa tion Changer tout circlip d form Lorsqu on monte un cir clip 1 s assurer que le c t non chanfrein 2 est positionn du c t oppos la pouss e 3 qu il re oit Voi...

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 con nector 6 Connect Connector NOTE The two connectors click together 7 Check for cont...

Page 37: ...orne se d tache redresser la lame 1 de la broche et ins rer nouveau la borne dans le con necteur 6 Connecter Connecteur N B Les deux connecteurs s encliqu tent 7 V rifier la continuit avec un tes teur...

Page 38: ...to remove the flywheel magneto YM 1189 90890 01189 YU 1235 90890 01235 Rotor holding tool This tool is used when loosening or tightening the fly wheel magneto securing nut YU 1235 90890 01235 YU 3097...

Page 39: ...achometer Engine tachometer This tool is needed for observing engine rpm YU 08036 B 90890 03113 YM 33277 A 90890 03141 Timing light This tool is necessary for checking ignition timing YM 33277 A 90890...

Page 40: ...ntake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in This tool is needed to rebore the new valve guide YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Dynamic spark tester Ignition checker This in...

Page 41: ...doit tre utilis pour la d pose du volant magn ti que YM 1189 90890 01189 YU 1235 90890 01235 Outil de maintien de rotor Cet outil est utilis pour le desserrage ou le serrage du boulon de fixation de v...

Page 42: ...our observer la vitesse de rotation du moteur YU 08036 B 90890 03113 YM 33277 A 90890 03141 Lampe stroboscopique induction Cet outil est n cessaire pour v rifier le r glage de l allu mage YM 33277 A 9...

Page 43: ...in Echappement 4 5 mm 0 18 in Cet outil est n cessaire pour r al ser le nouveau guide de soupape YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d...

Page 44: ...Ausbau des Schwungradmagnetz nder Rotors YM 1189 90890 01189 YU 1235 90890 01235 Rotorhalter Zum L sen und Befestigen des Schwungrad Magnetz nder Rotors YU 1235 90890 01235 YU 3097 90890 01252 YU 1256...

Page 45: ...036 B 90890 03113 Induktivdrehzahlmesser Motor Drehzahlmesser Zur Ermittlung der Motordrehzahl YU 08036 B 90890 03113 YM 33277 A 90890 03141 Stroboskoplampe Zur Kontrolle des Z ndzeitpunktes YM 33277...

Page 46: ...hrungs Reibahle Einla 4 0 mm Ausla 4 5 mm Zum Aufreiben der neuen Ventilf hrungen YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndpr fer Zur berpr fung der Z...

Page 47: ...YM 1189 90890 01189 YU 1235 90890 01235 Utensile di sostegno per il rotore Questo attrezzo viene utilizzato quando si svita o si avvita la vite di fissaggio del magnete del volano YU 1235 90890 01235...

Page 48: ...Questo strumento utilizzato per controllare la velocit del motore YU 08036 B 90890 03113 YM 33277 A 90890 03141 Lampada stroboscopica Questo strumento utilizzato per controllare la fasatura di accensi...

Page 49: ...ttrezzo utilizzato per alesare il nuovo guidaval vola YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Tester della dinamicit della scintilla Tester dell accensione Questo attrezzo necessa...

Page 50: ...h The lever should be pulled rapidly and released slowly for smooth starts EC153000 SHIFT PEDAL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by...

Page 51: ...er le levier d embrayage vers le guidon pour d brayer et rel cher le levier pour embrayer Pour des d mar rages doux le levier doit tre tir rapide ment et rel ch lentement PEDALE DE CHANGEMENT DE VITES...

Page 52: ...he pressure in the cylinder head This enables the vehicle to be kickstarted more easily EC155001 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar it accelerates or decelerates the...

Page 53: ...de comprimer la soupape d chappement ce qui r duit la pression dans la culasse POIGNEE DES GAZ La poign e des gaz 1 est situ e la poi gn e droite elle permet d acc l rer ou de d c l rer le moteur Pou...

Page 54: ...air fuel mixture for starting A separate starter circuit which is controlled by the cold starter knob 1 supplies this mixture Pull the cold starter knob out to open the circuit for starting When the...

Page 55: ...d marrage froid 1 fournit ce m lange Tirer le bouton de d marrage froid pour ouvrir le circuit de d marrage Quand le moteur est chaud repousser le bouton pour fermer le circuit BOUTON DE DEMARRAGE A C...

Page 56: ...to prevent water from entering the car buretor while the motorcycle is operated in the rain attach the accessory flap 1 to the frame at the rear of the fuel tank NOTE Riding with the flap attached whe...

Page 57: ...onvient de monter la bavette 1 au cadre l arri re du r servoir de carburant N B Par temps sec la bavette permet de r duire la p n tration de poussi res crasses et sable dans le carburateur ESSENCE Tou...

Page 58: ...use the decompression lever after the engine is started The engine may be damaged if you use the decompression lever while it is running Before starting the machine perform the checks in the pre opera...

Page 59: ...vier de d compression lors que le moteur tourne risque d endommager ce dernier Avant la mise en marche effectuer les v rifications indiqu es dans la liste de contr le avant utilisation MISE EN MARCHE...

Page 60: ...while kicking the kickstarter crank Otherwise the kick starter may kick back 8 Return the cold starter knob to its original position and run the engine at 3 000 5 000 r min for 1 or 2 minutes NOTE Si...

Page 61: ...relever brutalement 8 Ramener le bouton de d marrage froid sa position d origine puis faire tourner le moteur 3 000 5 000 tr mn pendant 1 2 minutes N B Puisque ce mod le est quip d une pompe d acc l...

Page 62: ...while holding the lever kick the kickstarter crank 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an engine after a fall Operate the throttle grip before kick starting...

Page 63: ...apr s une chute Donner des gaz avant d actionner le kick ATTENTION Dans un premier temps observer la proc dure de rodage suivante afin d assurer le meilleur rendement et viter d endommager le moteur...

Page 64: ...speed for about one hour 6 Restart the engine and check the opera tion of the machine throughout its entire operating range Restart the machine and operate it for about 10 to 15 more minutes The mach...

Page 65: ...er son fonctionnement tous les r gimes Relancer le moteur et piloter la machine pen dant 10 15 minutes suppl men taires Elle sera alors pr te pour la course ATTENTION Apr s le rodage ou avant chaque c...

Page 66: ...pper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear shock absorber to fram...

Page 67: ...ction au cadre De l arbre de direction la couronne de guidon De la couronne de guidon au guidon De la fourche avant la couronne de guidon De la fourche avant au dessous de bride Ensemble de timonerie...

Page 68: ...Lenkkopf und obere Gabelbr cke obere Gabelbr cke und Lenker Teleskopgabel obere Gabelbr cke Teleskopgabel und untere Gabelbr kke bertragungs bis Umlenkhebel bertragungshebel und Rahmen Umlenkhebel un...

Page 69: ...sterzo alla trave superiore Trave superiore al manubrio Forcella anteriore alla trave superiore Forcella anteriore alla trave inferiore Gruppo bracci Braccio al telaio Braccio all ammortizzatore poste...

Page 70: ...n 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 ca...

Page 71: ...tion on reuses ont r sult de l emploi abusif des vaporisateurs de d tergent haute pression tels que ceux qui quipent les laveries automa tiques de voitures 4 Apr s avoir chass la majeure partie de la...

Page 72: ...witch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thor oughly with solvent and lubricate it Reinstall the chain or store it in a...

Page 73: ...cha ne la nettoyer soi gneusement au dissolvant et lubrifier Remonter la cha ne ou la ranger dans un sachet plastique ferm fix au cadre 4 Lubrifier tous les c bles de com mande 5 Mettre le cadre sur p...

Page 74: ...e type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 Imp oz 8 42 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 12 5 1 Star...

Page 75: ...r CR8E NGK U24ESR N DENSO Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chain dr...

Page 76: ...Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber...

Page 77: ...nside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 967 21 980 mm 0 8648 0 8654 in Shaft to cap clearance 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Cam dimensions Inta...

Page 78: ...0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 7 mm 0 0276 in EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565...

Page 79: ...sed IN 29 13 mm 1 15 in EX 29 30 mm 1 15 in Compressed pressure installed IN 99 114 N 10 1 11 6 kg 22 27 25 57 lb EX 126 144 N 12 9 14 7 kg 28 44 32 41 lb Tilt limit IN 2 5 1 7 mm 2 5 0 067 in EX 2 5...

Page 80: ...ring Type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimens...

Page 81: ...r push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor USA CDN ZA AUS NZ EUROPE Type manufacturer FCR MX...

Page 82: ...09 0 17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Cooling Radiator core size Width 107 8 mm 4 2 in Height 220 mm 8 7 in Thicknes...

Page 83: ...r hose clamp M6 1 0 8 2 0 2 1 4 Coolant drain bolt M6 1 0 1 10 1 0 7 2 Water pump housing M6 1 0 4 10 1 0 7 2 Radiator M6 1 0 6 10 1 0 7 2 Radiator guard M6 1 0 2 10 1 0 7 2 Radiator pipe M6 1 0 1 10...

Page 84: ...7 2 Clutch cover M6 1 0 7 10 1 0 7 2 Crankcase oil drain bolt M10 1 25 1 20 2 0 14 Drive chain sprocket cover M6 1 0 2 10 1 0 7 2 Kick shaft ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank...

Page 85: ...op of outer tube with inner tube and damper rod fully com pressed without spring 80 150 mm 3 15 5 91 in Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end 5 mm 0 20...

Page 86: ...thickness 4 4 mm 0 17 in 1 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 240...

Page 87: ...e hose cover M8 M8 1 25 1 16 1 6 11 M6 M6 1 0 1 7 0 7 5 1 Throttle grip cap M5 0 8 2 4 0 4 2 2 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 1 0 1 6 0 6 4 3 Brake lever m...

Page 88: ...0 7 2 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 80 8 0 58 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorb...

Page 89: ...F Black Pink Pickup coil resistance color 248 372 at 20 C 68 F White Red CDI unit model manufacturer 5NL 00 YAMAHA Ignition coil Model manufacturer 4SR 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primar...

Page 90: ...A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6...

Page 91: ...de double arbre cames en t te DOHC Dispositions du cylindre Monocylindre inclin vers l avant Cylindr e 249 cm3 8 76 Imp oz 8 42 US oz Al sage course 77 0 53 6 mm 3 03 2 11 in Taux de compression 12 5...

Page 92: ...odes 0 7 0 8 mm 0 028 0 031 in Type d embrayage Humide multi disques Transmission Syst me de r duction primaire Engrenage Taux de r duction primaire 57 17 3 353 Syst me de r duction secondaire Entra n...

Page 93: ...lescopique Suspension arri re Bras oscillant monocross de type biellette Amortisseurs Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal amortisseur h...

Page 94: ...1 mm 0 8661 0 8670 in Diam tre ext rieur d arbre cames 21 967 21 980 mm 0 8648 0 8654 in Jeu entre arbre cames et chapeau 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Dimensions de came Admission...

Page 95: ...1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in ECH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D paisseur de rebord AD 0 7 mm 0 0276 in ECH 0 7 mm 0 0276 in Diam tre ext rieur de queue AD 3 975 3 990 mm 0 1...

Page 96: ...mm 1 15 in Pression la compression install AD 99 114 N 10 1 11 6 kg 22 27 25 57 lb ECH 126 144 N 12 9 14 7 kg 28 44 32 41 lb Limite d inclinaison AD 2 5 1 7 mm 2 5 0 067 in ECH 2 5 1 6 mm 2 5 0 063 i...

Page 97: ...pe Fusel Dimensions B T 0 80 2 75 mm 0 03 0 11 in Ecartement des becs mont 0 30 0 45 mm 0 012 0 018 in 0 8 mm 0 031 in Jeu lat ral 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Segment racleur d hu...

Page 98: ...e de torsion de barre de guidage 0 05 mm 0 002 in Kick Type Kick et m canisme rochet Carburateur USA CDN ZA AUS NZ EUROPE Type fabricant FCR MX37 KEIHIN Marque d identification 5NL1 00 5NL2 10 Gicleur...

Page 99: ...009 in Jeu carter et rotor 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Refroidissement Taille du faisceau radiateur Largeur 107 8 mm 4 2 in Hauteur 220 mm 8 7 in Epaisseur 32 mm 1 26 in Pression...

Page 100: ...10 1 0 7 2 Carter de pompe eau M6 1 0 4 10 1 0 7 2 Radiateur M6 1 0 6 10 1 0 7 2 Garde de radiateur M6 1 0 2 10 1 0 7 2 Tuyau de radiateur M6 1 0 1 10 1 0 7 2 Couvercle de la pompe huile M4 0 7 1 3 0...

Page 101: ...on de vidange de l huile du carter moteur M10 1 25 1 20 2 0 14 Cache de pignon de cha ne de transmission M6 1 0 2 10 1 0 7 2 Guide de rochet d arbre de kick M6 1 0 2 12 1 2 8 7 P dale de kick M8 1 25...

Page 102: ...isseur compl tement com prim es sans le ressort 80 150 mm 3 15 5 91 in Grade d huile Huile de suspen sion 01 Diam tre ext rieur de tube plongeur 46 mm 1 81 in Extr mit sup rieure de fourche avant 5 mm...

Page 103: ...ur de ma tre cylindre 11 0 mm 0 433 in Diam tre int rieur de cylindre d trier 27 0 mm 1 063 in 2 Type de liquide de frein DOT n 4 Frein disque arri re Diam tre ext rieur paisseur 240 4 0 mm 9 45 0 16...

Page 104: ...e montage de levier de frein M6 1 0 1 6 0 6 4 3 Ecrou de montage de levier de frein M6 1 0 1 6 0 6 4 3 Contre crou de r glage de position du levier de frein M6 1 0 1 5 0 5 3 6 Demi palier de levier d...

Page 105: ...lant M14 1 5 1 80 8 0 58 Bras relais et bielle M14 1 5 1 80 8 0 58 Bielle et cadre M14 1 5 1 80 8 0 58 Amortisseur arri re et cadre M10 1 25 1 56 5 6 40 Amortisseur arri re et bras relais M10 1 25 1 5...

Page 106: ...tation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bloc CDI 5NL 00 YAMAHA Bobine d allumage Mod le fabricant 4SR 00 YAMAHA Longueur minimum d tincelle 6 mm 0 24 in R sistance de l enroul...

Page 107: ...s Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filetage DEFINITION DES UNITES A crou B vis CARACTERISTIQUES DE COUPLE Nm m kg ft lb 10mm 12mm 14mm...

Page 108: ...77 0 53 6 mm Verdichtungsverh ltnis 12 5 1 Startsystem Kickstarter Schmiersystem Trockensumpfschmierung Motor l lsorte und viskosit t Nur USA und CDN Empfohlene lsorte Viskosit t ber 5 C Yamalube 4 20...

Page 109: ...hrscheiben lbadkupplung Kraft bertragung Prim rantrieb Zahnrad Prim r bersetzung 57 17 3 353 Sekund rantrieb Kettenantrieb Sekund r bersetzung 48 13 3 692 Getriebe klauengeschaltetes 5 Gang Getriebe S...

Page 110: ...hebel rechts Radaufh ngung vorn Teleskopgabel hinten Monocross Schwinge Federelemente vorn hydraulisch ged mpfte Teleskopgabel mit Spi ralfeder hinten Federbein mit gasdruckunterst tztem Sto d mpfer u...

Page 111: ...mm Nockenwelle Antrieb Steuerkette links Nockenwellenlager Durchmesser 22 000 22 021 mm Nockenwellen Au endurchmesser 21 967 21 980 mm Lagerspiel 0 020 0 054 mm 0 08 mm Nockenabmessungen Einla A 30 2...

Page 112: ...6 mm Ausla 0 9 1 1 mm 1 6 mm Ventiltellerst rke D Einla 0 7 mm Ausla 0 7 mm Ventilschaftdurchmesser Einla 3 975 3 990 mm 3 945 mm Ausla 4 460 4 475 mm 4 430 mm Ventilf hrungsdurchmesser Einla 4 000 4...

Page 113: ...13 mm Ausla 29 30 mm Federdruck eingebaut Einla 99 114 N 10 1 11 6 kg Ausla 126 144 N 12 9 14 7 kg Rechtwinkligkeitsgrenze Einla 2 5 1 7 mm Ausla 2 5 1 6 mm Wicklungsrichtung Draufsicht Einla Im Uhrz...

Page 114: ...ompressionsring Ausf hrung Minutenring Abmessungen B T 0 80 2 75 mm Sto spiel eingebaut 0 30 0 45 mm 0 80 mm Ringnutspiel 0 020 0 055 mm 0 12 mm labstreifring Abmessungen B T 1 50 2 25 mm Sto spiel ei...

Page 115: ...ngenschlag 0 05 mm Kickstarter Bauart Rastenmechanismus Vergaser Modell Hersteller FCR MX37 KEIHIN Kennzeichnung 5NL2 10 Hauptd se M J Nr 175 Hauptluftd se M A J Nr 200 D sennadel J N OBEJP 4 Konus C...

Page 116: ...mm 0 24 mm Geh use und Rotorabstand 0 03 0 10 mm 0 17 mm K hlsystem K hlerabmessungen Breite 107 8 mm H he 220 mm Tiefe 32 mm K hlerverschlu deckel ffnungsdruck 110 kPa 1 1 bar K hlsystem Fassungsverm...

Page 117: ...lauchschelle M6 1 0 8 2 0 2 K hlmittel Abla schraube M6 1 0 1 10 1 0 Wasserpumpengeh use M6 1 0 4 10 1 0 K hler M6 1 0 6 10 1 0 K hlerschutz M6 1 0 2 10 1 0 K hlerleitung M6 1 0 1 10 1 0 lpumpendeckel...

Page 118: ...ckel rechts M6 1 0 8 10 1 0 Kupplungsdeckel M6 1 0 7 10 1 0 Kurbelgeh use lablaufstutzen M10 1 25 1 20 2 0 Antriebsritzel Abdeckung M6 1 0 2 10 1 0 Kickstarter Rastenradf hrung M6 1 0 2 12 1 2 Kicksta...

Page 119: ...mm Min Max gemessen von der Oberkante des Standrohres Gabel und D mpfer rohr vollst ndig eingefedert ohne Gabelfeder 80 150 mm lsorte Teleskopgabel l 01 Standrohr Durchmesser 46 mm Position der obere...

Page 120: ...50 3 0 mm 250 2 5 mm Bremsbelagst rke 4 4 mm 1 mm Hauptbremszylinder Durchmesser 11 0 mm Bremszylinder Durchmesser 27 0 mm 2 Bremsfl ssigkeit DOT 4 Hinterradbremse Bremsscheibe Durchmesser St rke 240...

Page 121: ...0 7 Gasdrehgriffkappe M5 0 8 2 4 0 4 Frontbrems Hauptzylinder M6 1 0 2 9 0 9 Bremshebel Befestigungsschraube M6 1 0 1 6 0 6 Bremshebel Befestigungsmutter M6 1 0 1 6 0 6 Bremshebel Positionierungssper...

Page 122: ...1 85 8 5 Relaisarm und Schwinge M14 1 5 1 80 8 0 Relaisarm und Pleuelstange M14 1 5 1 80 8 0 Pleuelstange und Rahmen M14 1 5 1 80 8 0 Hinterer Sto d mpfer und Rahmen M10 1 25 1 56 5 6 Hinterer Sto d...

Page 123: ...pule 2 44 66 bei 20 C schwarz rosa Impulsgeber Widerstand Farbe 248 372 bei 20 C wei rot CDI Z ndbox Typ Hersteller 5NL 00 YAMAHA Z ndspule Typ Hersteller 4SR 00 YAMAHA Min Z ndfunkenstrecke 6 mm Prim...

Page 124: ...f r saubere und trok kene Schraubverbindungen bei Raumtempera tur A Schl sselweite B Gewindedurchmesserer EINHEITEN A Mutter B Schrau be ALLGEMEINE ANZUGSMOMENTE Nm m kg 10 mm 12 mm 14 mm 17 mm 19 mm...

Page 125: ...doppio albero a camme in testa DOHC Disposizione dei cilindri Monocilindrico inclinato in avanti Cilindrata 249 cm3 8 76 Imp oz 8 42 US oz Alesaggio corsa 77 0 53 6 mm 3 03 2 11 in Rapporto di compre...

Page 126: ...ttrodi 0 7 0 8 mm 0 028 0 031 in Tipo di frizione Umida multidisco Trasmissione Sistema di riduzione primaria Ingranaggio Rapporto di riduzione primaria 57 17 3 353 Sistema di riduzione secondaria Tra...

Page 127: ...anteriore Forcella telescopica Sospensione posteriore Forcellone oscillante sospensione monocross di tipo a biscottino Ammortizzatore Ammortizzatore anteriore Molla elicoidale ammortizzatore a olio A...

Page 128: ...interno del cappello dell albero a camme 22 000 22 021 mm 0 8661 0 8670 in Diametro esterno dell albero a camme 21 967 21 980 mm 0 8648 0 8654 in Gioco albero cappello 0 020 0 054 mm 0 0008 0 0021 in...

Page 129: ...9 in Larghezza sede C INT 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EXT 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Spessore margine D INT 0 7 mm 0 0276 in EXT 0 7 mm 0 0276 in Diametro esterno st...

Page 130: ...vola chiusa INT 29 13 mm 1 15 in EXT 29 30 mm 1 15 in Pressione compressa installata INT 99 114 N 10 1 11 6 kg 22 27 25 57 lb EXT 126 144 N 12 9 14 7 kg 28 44 32 41 lb Limite di inclinazione INT 2 5 1...

Page 131: ...a fascia Tipo Conica Dimensioni B T 0 80 2 75 mm 0 03 0 11 in Apertura del taglio fascia montata 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Gioco laterale 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 0...

Page 132: ...ma e barra guida Limite di curvatura della barra guida 0 05 mm 0 002 in Avviamento a pedale Tipo Tipo a pedivella e ad arpionismo Carburatore USA CDN ZA AUS NZ EUROPE Tipo costruttore FCR MX37 KEIHIN...

Page 133: ...17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Gioco alloggiamento e rotore 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Raffreddamento Dimensioni massa radiante Larghezza 107 8 mm 4 2 in Altezza 220 mm 8...

Page 134: ...8 2 0 2 1 4 Bullone di scarico del refrigerante M6 1 0 1 10 1 0 7 2 Alloggiamento della pompa dell acqua M6 1 0 4 10 1 0 7 2 Radiatore M6 1 0 6 10 1 0 7 2 Riparo del radiatore M6 1 0 2 10 1 0 7 2 Tuba...

Page 135: ...Bullone di scarico olio dal carter M10 1 25 1 20 2 0 14 Carterino corona catena di trasmissione M6 1 0 2 10 1 0 7 2 Guida arpionismo albero a pedale M6 1 0 2 12 1 2 8 7 Avviamento a pedale M8 1 25 1...

Page 136: ...tubo esterno con il tubo interno e asta dell ammortizzatore completamente compressi senza molla 80 150 mm 3 15 5 91 in Tipo di olio Olio per sospensioni 01 Diametro esterno tubo interno 46 mm 1 81 in...

Page 137: ...4 4 mm 0 17 in 1 mm 0 04 in Diametro interno cilindro principale 11 0 mm 0 433 in Diametro interno cilindretto pinza 27 0 mm 1 063 in 2 Tipo di liquido dei freni DOT n 4 Freno a disco posteriore Diam...

Page 138: ...8 2 4 0 4 2 2 Pompa freno anteriore M6 1 0 2 9 0 9 6 5 Bullone di montaggio leva del freno M6 1 0 1 6 0 6 4 3 Dado di montaggio leva del freno M6 1 0 1 6 0 6 4 3 Controdado posizione leva del freno M...

Page 139: ...re M6 1 0 3 10 1 0 7 2 Riparo motore destro M8 1 25 2 10 1 0 7 2 Perno e dado M16 1 5 1 85 8 5 61 Leva di rinvio e forcellone oscillante M14 1 5 1 80 8 0 58 Leva di rinvio e biella M14 1 5 1 80 8 0 58...

Page 140: ...enza bobina pickup colore 248 372 a 20 C 68 F Bianco Rosso Modello costruttore unit CDI 5NL 00 YAMAHA Bobina di accensione Modello costruttore 4SR 00 YAMAHA Distanza minima scintilla 6 mm 0 24 in Resi...

Page 141: ...e A Distaza tra le aperture di chiave B Diametro filetto esterno DEFINIZIONE DELLE UNIT DI MISURA A Dado B Bullone SPECIFICHERELATIVE ALLECOPPIEDI SERRAGGIOGENERALI Nm m kg ft lb 10 mm 12 mm 14 mm 17...

Page 142: ...le of the number plate Fasten the engine stop switch lead and ignition coil lead of the sub wire harness Fasten the sub wire harness and engine stop switch lead Fasten the engine stop switch lead at i...

Page 143: ...ire et le fil du coupe circuit du moteur Attacher le fil de commutateur d arr t de moteur son tube de protection Attacher le faisceau de fils secondaires et les fils de commutateur d arr t de moteur F...

Page 144: ...nt of the radiator mounting boss Fit the brake hose into the guides on the protector Pass the carburetor breather hoses and overflow hose so that all there hoses do not con tact the rear shock absorbe...

Page 145: ...e frein dans les guides de la protection Faire passer la durit de mise l air du car burateur et la durit de trop plein de sorte ce qu elles ne touchent l amortisseur arri re Attacher le fil de la mass...

Page 146: ...hose and radiator mounting boss Pass the throttle cables through cable guide Pass the throttle cables under the radiator mounting boss Insert the CDI unit band over the CDI unit stay frame as far as...

Page 147: ...le plus loin possible la sangle du bloc CDI par dessus le support du bloc CDI cadre Faire passer le flexible de reniflard de radiateur devant le bossage arri re de montage de radiateur et la gauche du...

Page 148: ...ipe facing the brake caliper and with the pipe contacting the brake caliper projection Pass the brake hose into the brake hose holders If the brake hose contacts the spring rear shock absorber correct...

Page 149: ...peint du tuyau vers l trier de frein et ce que le tuyau touche la saillie de l trier de frein Faire passer la durit de frein dans les sup ports de durit de frein Si la durit de frein touche le ressor...

Page 150: ...Throttle cable 2 Clamp 3 Decompression cable 4 Clutch cable 5 Brake hose 6 Hose guide 7 Engine stop switch lead Fasten the engine stop switch lead to the handlebar with the plastic band Pass the brake...

Page 151: ...durit 7 Fil de coupe circuit du moteur Attacher le fil du coupe circuit du moteur au guidon l aide d un lastique Faire passer la durit de frein par devant la plaque du num ro 1 Cavo acceleratore 2 Mor...

Page 152: ...T OIL STRAINER Clean VALVES Check the valve clearances Inspect Replace The engine must be cold Check the valve seats and valve stems for wear VALVE SPRINGS Inspect Replace Check the free length and th...

Page 153: ...leakage Check radiator cap operation Replace coolant Inspect hoses Every two years OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubrica...

Page 154: ...Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing Lithium base grease TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke loosenes...

Page 155: ...t tre froid Contr ler l usure des si ges et les queues de soupape RESSORTS DE SOUPAPE Contr ler Remplacer Contr ler la longueur libre et l inclinaison POUSSOIRS DE SOUPAPE Contr ler Remplacer Contr le...

Page 156: ...s il n y a pas de fuite Contr ler le fonctionnement du bouchon de radiateur Remplacer le liquide de refroidissement Contr ler les tuyaux Tous les deux ans BOULONS ET ECROUS EXTERIEURS Resserrer Se re...

Page 157: ...r ler et lubrifier Graisse au bisulfure de molybd ne TETE DE FOURCHE Contr ler le jeu Nettoyer et lubrifier Remplacer le roulement Graisse base de lithium PNEUS ROUES Contr ler la pression de gonflage...

Page 158: ...gen MOTOR L Erneuern Pr fen LFILTER EINSATZ ISIE Reinigen VENTILE Ventilspiel kontrollieren Pr fen Erneuern Bei kaltem Motor Ventilsitze und schafte auf Verschlei pr fen VENTILFEDERN Pr fen Erneuern U...

Page 159: ...hmieren Durchhang und Ausrich tung pr fen Erneuern Kettenschmiermittel ver wenden Durchhang 40 50 mm K HLSYSTEM K hlfl ssigkeitsstand auf Undichtig keit pr fen K hlerverschlu deckel pr fen K hlfl ssig...

Page 160: ...hziehen Molybd ndisulfidfett ver wenden KETTENSCHUTZ UND ROLLEN Pr fen SCHWINGE Pr fen und nachziehen UMLENK UND BERTRAGUNGS HEBEL Pr fen und schmieren Molybd ndisulfidfett ver wenden LENKKOPF Spiel p...

Page 161: ...i delle val vole Molle delle valvole Ispezionare Sostituire Controllare la lunghezza libera e l inclinazione ALZAVALVOLA Ispezionare Sostituire Controllare eventuali graffi e il grado di usura ALBERI...

Page 162: ...igerante e la presenza di eventuali perdite Controllare l azionamento del tappo del radiatore Sostituire il refrigerante Ispezionare i flessibili Ogni due anni DADI E BULLONI ESTERNI Serrare Fare rife...

Page 163: ...l disolfuro di molib deno CANNOTTO DELLO STERZO Controllarne il gioco libero e serrare Pulire e lubrificare Sostituire il cuscinetto Grasso a base di litio PNEUMATICI RUOTE Controllare la pressione de...

Page 164: ...ck drive chain slack and alignment Check that the drive chain is lubricated properly P 3 32 34 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 4...

Page 165: ...ion et l alignement de la cha ne S assurer que la cha ne est graiss e correctement P 3 32 34 Roues Contr ler s il n y a pas d usure excessive Contr ler s il n y a pas de rayons d tendus et qu il n a p...

Page 166: ...bskette Durchhang und Ausrichtung pr fen Kette nach Bedarf schmieren 3 32 34 R der Reifen auf berm igen Verschlei und Luftdruck pr fen Speichernspannung kontrollieren 3 42 43 Lenkung Auf Schwerg ngigk...

Page 167: ...i trasmissione Controllare che la catena di trasmissione sia lubrificata correttamente P 3 32 34 Ruote Verificarne l eventuale usura eccessiva e controllare la pressione dei pneumatici Verificare che...

Page 168: ...ly 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 remo...

Page 169: ...iffon pais sur le bouchon du radiateur et tourner len tement le bouchon gauche jusqu au point de d tente Cette proc dure per met de faire tomber toute pression r siduelle Quand le sifflement s est arr...

Page 170: ...Coolant drain bolt 1 3 Remove Radiator cap Drain the coolant completely 4 Clean Cooling system Thoroughly flush the cooling system with clean tap water 5 Install Copper washer Coolant drain bolt T R 1...

Page 171: ...ment 1 3 D poser Bouchon du radiateur Vidanger compl tement le liquide de refroidissement 4 Nettoyer Circuit de refroidissement Bien rincer le circuit de refroi dissement avec de l eau du robinet 5 Mo...

Page 172: ...l low Add coolant Handling notes of coolant The coolant is harmful so it should be han dled with special care WARNING When coolant splashes to your eye Thoroughly wash your eye with water and see your...

Page 173: ...Ajouter le liquide de refroidissement Notes concernant la manipulation du liquide de refroidissement Le liquide de refroidissement tant dangereux il doit tre manipul avec une attention particuli re AV...

Page 174: ...ible to maintain the specified pressure for 10 seconds Replace Radiator cap tester YU 24460 01 90890 01325 Radiator cap tester adapter YU 33984 90890 01352 Radiator cap opening pressure 110 kPa 1 1 kg...

Page 175: ...on Impossible de maintenir la pression sp cifi e pendant 10 secondes Changer Testeur du bouchon de radiateur YU 24460 01 90890 01325 Embout d adaptation du testeur de bouchon de radiateur YU 33984 908...

Page 176: ...r replace Radiator hose 3 Swelling Replace CLUTCH ADJUSTMENT 1 Check Clutch lever free play a Out of specification Adjust Clutch lever free play a 2 4 mm 0 08 0 16 in 2 Adjust Clutch lever free play N...

Page 177: ...ateur 3 Gonflement Remplacer REGLAGE DE L EMBRAYAGE 1 Contr ler Jeu du levier d embrayage a Hors sp cification R gler Jeu du levier d embrayage a 2 4 mm 0 08 0 16 in 2 R gler Jeu de levier d embrayage...

Page 178: ...hould be adjusted When the motorcycle is accelerating throttle cable 1 2 is pulled and throttle cable 2 3 is pushed 1st step Loosen the locknuts 4 on throttle cable 2 Adjust the free play by changing...

Page 179: ...t le c ble des gaz n 2 3 est pouss 1 re tape Desserrer les contre crous 4 du c ble des gaz n 2 R gler le jeu en modifiant leur ser rage 2 me tape Desserrer les contre crous 5 du c ble des gaz n 1 R gl...

Page 180: ...SION ADJUSTMENT 1 Check Decompression lever free play a Out of specification Adjust Checking steps Remove the timing mark accessing screw 1 and crankshaft end accessing screw 2 Turn the crankshaft cou...

Page 181: ...ft lb REGLAGE DE LA DECOMPRES SION 1 Contr ler Jeu au levier de d compres sion a Hors sp cification R gler Etapes du contr le D poser la vis d acc s du rep re de distribution 1 et la vis d acc s de l...

Page 182: ...Air filter guide 4 2 Clean Air filter element Clean them with solvent NOTE After cleaning remove the remaining solvent by squeezing the element CAUTION Do not twist the element when squeezing the elem...

Page 183: ...e nettoyer avec du dissolvant N B Une fois l entretien termin liminer ce qui reste de solvant en serrant l l ment ATTENTION Ne pas tordre l l ment en l esso rant Un exc s de dissolvant sur l l ment ri...

Page 184: ...air filter element 6 Apply Lithium soap base grease On the matching surface a on air filter element 7 Install Air filter element 1 Washer Fitting bolt NOTE Align the projection a on filter guide with...

Page 185: ...an lithium Sur la surface d accouplement a de l l ment de filtre air 7 Monter El ment de filtre air 1 Rondelle Boulon de fixation N B Aligner la saillie a sur le guide du filtre sur l orifice b situ s...

Page 186: ...USA and CDN CAUTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase Recommended...

Page 187: ...le r servoir en veillant ne pas la visser Pour les USA et le CDN ATTENTION Ne pas ajouter d additifs chimiques L huile moteur lubrifie galement l embrayage et des additifs risquent de provoquer le pa...

Page 188: ...a few minutes until the oil settles before inspecting the oil level Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommended eng...

Page 189: ...eur et v rifier une nouvelle fois le niveau d huile N B Attendre quelques minutes que l huile se soit stabilis e avant de v rifier son niveau Huile recommand e Se r f rer au tableau suivant pour chois...

Page 190: ...e 2 Oil hose 3 Oil strainer frame 4 6 Inspect Oil strainer frame Clogged Blow 7 If the oil filter is to be replaced during this oil change remove the following parts and reinstall them Replacement ste...

Page 191: ...adre Bouch Passer l air com prim 7 S il est n cessaire de remplacer le filtre huile lors de cette vidange d huile d poser les pi ces sui vantes et les r installer Etapes de remplacement Enlever le cou...

Page 192: ...10 Fill Engine oil 11 Check Oil leakage 12 Install Oil tank cap 13 Check Engine oil level Oil quantity Total amount 1 7 L 1 50 Imp qt 1 80 US qt Periodic oil change 1 5 L 1 32 Imp qt 1 59 US qt With o...

Page 193: ...moteur 13 Monter Bouchon du r servoir d huile Quantit d huile Quantit totale 1 7 L 1 50 Imp qt 1 80 US qt Vidange p riodique 1 5 L 1 32 Imp qt 1 59 US qt Avec changement du fil tre huile 1 6 L 1 41 Im...

Page 194: ...sure Tighten the oil pressure check bolt T R Oil pressure check bolt 18 Nm 1 8 m kg 13 ft lb PILOT SCREW ADJUSTMENT 1 Adjust Pilot screw 1 Adjustment steps NOTE To optimize the fuel flow at a smaller...

Page 195: ...ttre le moteur en marche apr s avoir rem di au x probl me s et v rifier nouveau la pression d huile Serrer le boulon de contr le de la pression d huile au couple indiqu T R Boulon de contr le de la pr...

Page 196: ...ease idle speed Turn the throttle stop screw 1 out b Inductive tachometer YU 08036 B Engine tachometer 90890 03113 Engine idling speed 1 700 1 900 r min VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE...

Page 197: ...i ble Pour augmenter la r gime de ralenti Serrer a la vis de but e de l acc l rateur 1 Pour diminuer le r gime de ralenti Desserrer b la vis de but e de l acc l rateur 1 Compte tours inductif YU 08036...

Page 198: ...tion in the CHAPTER 4 Spark plug Upper engine bracket Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 4 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 5 C...

Page 199: ...r Couvre culasse Se reporter la section ARBRES A CAMES au CHAPITRE 4 4 D poser Vis d acc s du rep re de distri bution 1 Vis d acc s de l extr mit de vilebrequin 2 Joint torique 5 Contr ler Jeu de soup...

Page 200: ...is at T D C on compression stroke NOTE In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with th...

Page 201: ...iston est au PMH sur sa course de compression N B Les pistons sont au PMH lorsque le rep re d alignement c de l arbre cames d chappement et le rep re d alignement d de l arbre cames d admission s alig...

Page 202: ...alled in their original place Select the proper pad using the pad selecting table Pad range Pad Availability 25 increments No 120 No 240 1 20 mm 2 40 mm Pads are available in 0 05 mm increments NOTE T...

Page 203: ...ecte l aide du tableau suivant Epaisseur de cale Nombre d pais seurs disponibles 25 N 120 N 240 1 20 mm 2 40 mm Les cales sont dis ponibles par incr ments de 0 05 mm N B L paisseur a de chaque cale es...

Page 204: ...ly the engine oil on the valve lifters Apply the molybdenum disulfied oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pa...

Page 205: ...ur ner en douceur Prendre soin de remettre les pous soirs de soupapes et les cales dans leur position d origine Monter l arbre de d compression 9 la rondelle de cuivre 0 le bou lon arbre de d compress...

Page 206: ...16 1 20 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 2...

Page 207: ...0 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 ECHAPPEMENT JEU MESURE NUMERO DE CALE INSTALLEE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215...

Page 208: ...20 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 AUSLASS GEMESSE NES SPIEL NUMMER DES AUSGEBAUTEN VENTILPL TTCHENS 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190...

Page 209: ...16 1 20 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 SCARICO GIOCO MISURATO NUMERO SPESSORE INSTALLATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205...

Page 210: ...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...

Page 211: ...ttre en place le diaphragme Prendre garde ne pas renverser ou faire d border le r servoir c Connecter herm tiquement le tuyau transparent en mati re plastique 2 la vis de purge 1 de l trier d Mettre l...

Page 212: ...ING Check the operation of the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a Brake lever position a Standard position Extent of adjustment 95 mm...

Page 213: ...ionnement du frein apr s avoir purg le circuit de frei nage REGLAGE DE FREIN AVANT 1 Contr ler Position du levier de frein a 2 R gler Position du levier de frein Position du levier de frein a Position...

Page 214: ...en the locknut WARNING Adjust the pedal height between the maximum and the minimum as shown In this adjustment the bolt 3 end b should protrude out of the lower adjusting nut 4 but not be less than 2...

Page 215: ...RTISSEMENT R gler la hauteur de la p dale entre le maximum et le mini mum de la mani re indiqu e Dans ce r glage l extr mit b du boulon 3 doit sortir de l crou de r glage inf rieur 4 mais pas de plus...

Page 216: ...in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads 8 and pad pin NOTE Install the brake pads with their projec tions...

Page 217: ...Vis de purge 6 Nm 0 6 m kg 4 3 ft lb Installer les plaquettes de frein 8 et la goupille de plaquette N B Installer les plaquettes de frein en ajustant leurs saillies a dans les encoches de l trier de...

Page 218: ...ing Bleed brake system Refer to BRAKE SYSTEM AIR BLEEDING section REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Br...

Page 219: ...DE FREINAGE CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE 1 V rifier Epaisseur a de plaquette de frein Hors sp cification Rempla cer la paire 2 Changer Plaquette de frein Epaisseur de plaquet...

Page 220: ...bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pad 0 and pad pin A NOTE Install the brake pads with their projec tions a into the brake caliper recesses b Temporarily tighten th...

Page 221: ...upille de plaquette Monter l trier de frein B et la roue arri re C Se reporter la section ROUE AVANT ET ROUE ARRIERE du CHAPITRE 5 Serrer la goupille de plaquette D T R Goupille de plaquette 18 Nm 1 8...

Page 222: ...insulator 1 Damage Replace BRAKE FLUID LEVEL INSPECTION 1 Place the brake master cylinder reser voir tank so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level...

Page 223: ...ette de frein arri re 1 Endommagement Rempla cer CONTROLE DU NIVEAU DU LIQUIDE DE FREIN 1 Placer le ma tre cylindre r ser voir pour que son extr mit soit en position horizontale 2 V rifier Niveau de l...

Page 224: ...N INSPECTION 1 Remove Master link clip Joint 1 Drive chain 2 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain 3...

Page 225: ...1 Cha ne de transmission 2 2 Nettoyer Cha ne de transmission La mettre dans du k ros ne et brosser autant que possible la crasse Puis retirer la cha ne du k ros ne et la s cher 3 Mesurer Longueur de...

Page 226: ...ricants EC36A060 DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suitable stand under the engine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specific...

Page 227: ...appropri e sous le moteur 2 Contr ler Fl che de la cha ne de trans mission a Au dessus du boulon de fixa tion de la garde de joint Hors sp cification R gler N B Avant de proc der la v rification ou a...

Page 228: ...gnment There are marks a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear CAUTION Too small chain slack will overloa...

Page 229: ...re de tours pour conserver l alignement cor rect de la roue Les rep res a figurent de chaque c t sur les ten deurs de cha ne N B Tourner le tendeur pour que la cha ne soit align e avec la couronne vue...

Page 230: ...e lithium soap base grease on the inner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust Rebound damping force By turning the adjuster 1 STANDARD POSITION This is the position which...

Page 231: ...yer le joint antipoussi re et la bague d tanch it apr s chaque course Appliquer la graisse base de savon au lithium sur le tube interne REGLAGE DE LA FORCE D AMOR TISSEMENT DE DETENTE DE LA FOURCHE AV...

Page 232: ...adjustment can cause poor handling and loss of stability EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Remove Rubber cap 2 Adjust Compression damping force By turning the adjuster 1 Stif...

Page 233: ...ilit et une perte de stabilit REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION DE LA FOURCHE AVANT 1 D poser Capuchon en caoutchouc 2 R gler Force d amortissement de compression En tournant le disp...

Page 234: ...imum extent of adjustment The adjuster may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install Rubber cap T R...

Page 235: ...rs r gler la m me position les dispositifs de chaque bras de fourche avant Un r glage in gal peut entra ner une mauvaise maniabilit et une perte de stabilit 3 Monter Capuchon en caoutchouc T R Positio...

Page 236: ...the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum...

Page 237: ...itif de r glage avant de faire le r glage La longueur du ressort mont change de 1 5 mm 0 06 in par tour complet du dispositif de r glage ATTENTION Ne jamais essayer de tourner le dispo sitif de r glag...

Page 238: ...rn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of...

Page 239: ...ent de d tente D visser le dispositif de r glage 1 Plage de r glage Maximum Minimum Position com pl tement vis s e D visser de 20 d clics par tir du r glage maximum POSITION STANDARD C est la position...

Page 240: ...orce Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by the spe cific num...

Page 241: ...uer la force d amortissement basse com pression D visser le dispositif de r glage 1 Plage de r glage Maximum Minimum Position com pl tement d viss e D visser de 20 d clics partir du r glage maxi mum P...

Page 242: ...t of adjustment Maximum Minimum Fully turned in position 2 turns out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned i...

Page 243: ...de 2 tours par tir du r glage maximum POSITION STANDARD C est la position qui se trouve en arri re du nombre sp cifi de tours partir de la position enti rement vis s e Ce qui aligne le rep re grav a d...

Page 244: ...ts position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100 kPa 1 0 kg cm2 15 psi EC36S00...

Page 245: ...indique que le pneu se d tache de sa position sur la jante Si la tige de soupape de pneu est incli n e le pneu a tendance se d tacher de sa position Corriger la position du pneu Pression des pneus sta...

Page 246: ...Grasp the bottom of the forks and gen tly rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust st...

Page 247: ...semble en avant et en arri re Jeu R gler la t te de four che 3 Contr ler Action r guli re de la direction Tourner le guidon fond dans les deux sens Action irr guli re R gler l crou annulaire de direct...

Page 248: ...Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings Install the upper bracket 5 steering stem nut 6 handleba...

Page 249: ...une g ne quelcon que retirer l ensemble colonne de direction et inspecter le support de direction Remettre en place le t sup rieur 5 l crou de colonne de direction 6 le guidon 7 le demi palier de gui...

Page 250: ...5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Decompression cable end Use Yamaha cable lube or equivalent on these areas U...

Page 251: ...nroulement du c ble dans le guide de tube 8 Extr mit de c ble des gaz 9 Extr mit s des c bles d embrayage 0 Extr mit du c ble de d compresseur Mettre du lubrifiant Yamaha pour c bles ou quivalent sur...

Page 252: ...many hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of sp...

Page 253: ...e couvre de suie m me si le moteur et le carburateur sont en bon tat de marche 3 Mesurer Ecartement des lectrodes a Utiliser un calibre pour c ble ou un calibre d paisseur Hors sp cification R gler 4...

Page 254: ...g light YM 33277 A 90890 03141 Inductive tachometer YU 08036 B Engine tachometer 90890 03113 Checking steps Start the engine and let it warm up Let the engine run at the specified speed Engine speed 1...

Page 255: ...mpe YM 33277 A 90890 03141 Induktivdrehzahlmes ser YU 08036 B Motor Drehzahlmesser 90890 03113 Arbeitsschritte Motor anlassen einige Minuten warmlaufen lassen und dann mit der vorgeschriebenen Dreh za...

Page 256: ...moval Order Part name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting ban...

Page 257: ...ose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA SELLE DU RESERVOIR DE CARBURANT ET DES CACHES LATERAUX Pr paration la d pose Tourner le robinet de carburant la position OFF D connecter la durit de ca...

Page 258: ...l Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt...

Page 259: ...AU D ECHAPPEMENT ET DU SILENCIEUX Pr paration la d pose Cache lat ral droit Se reporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Boulon bride de silencieux 1 Desserrer uniquement...

Page 260: ...ipe 3 NOTE First temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20 Nm 2 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bol...

Page 261: ...pement 20 Nm 2 0 m kg 14 ft lb Serrer ensuite une nouvelle fois l crou tuyau d chappement 13 Nm 1 3 m kg 9 4 ft lb puis le boulon tuyau d chap pement 24 Nm 2 4 m kg 17 ft lb T R 13 Nm 1 3 m kg 9 4 ft...

Page 262: ...rain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Ra...

Page 263: ...rvoir de carburant Se reporter la section SELLE RESERVOIR A ESSENCE ET CACHES LATERAUX 1 Protection de radiateur 2 2 Bride de durit de radiateur 8 Desserrer uniquement 3 Durit de radiateur 1 1 4 Radia...

Page 264: ...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...

Page 265: ...pression r siduelle Quand le sifflement s est arr t appuyer sur le bouchon tout en le tournant vers la gauche puis l enlever CONTROLE Radiateur 1 Contr ler Carcasse 1 Encrass Nettoyer en souf flant d...

Page 266: ...stall Left radiator 1 Bolt left radiator 2 Radiator hose 1 3 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 Tighten Radiator hose clamp 4 6 Install Radiator guard 1 Bolt radiator guard 2 N...

Page 267: ...DES C BLES au CHAPITRE 2 5 Serrer Bride de durit de radiateur 4 6 Monter Protection de radiateur 1 Boulon protection de radia teur 2 N B Accrocher le panneau d abord l int rieur a puis l ext rieur T...

Page 268: ...for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp 1 2 Throttle position sensor lead cou pler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter join...

Page 269: ...R A ESSENCE ET CACHES LATERAUX 1 Bride 1 2 Fiche rapide de fil de capteur de position de papillon des gaz 1 3 Cache du logement des c bles de gaz 1 4 C ble de gaz 2 5 Bride raccord de filtre air 1 Des...

Page 270: ...OR DISASSEMBLY 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm...

Page 271: ...t de levier de soupape 1 3 Vis axe d acc l rateur 1 4 Boisseau 1 5 Support d aiguille 1 6 Aiguille 1 7 Couvercle de pompe d acc l ration 1 8 Ressort 1 9 Membrane pompe d acc l ration 1 0 Cuve 1 A Gicl...

Page 272: ...Main jet 1 H Needle jet 1 I Spacer 1 J Pilot jet 1 K Starter jet 1 L Push rod 1 Pull the push rod M Throttle shaft assembly 1 N Push rod link lever assembly 1 O Intake joint 1 P Pilot air jet 1 Q Mai...

Page 273: ...t ck 1 J Choke D se 1 K Nadeld se 1 L Druckstange 1 Ventilst el M Drosselwellenbaugruppe 1 N St elstangenverbindungshebel Baugruppe 1 O Ansauggummi 1 P Leerlaufluftd se 1 Q Hauptluftd se 1 R Kaltstart...

Page 274: ...rew 1 NOTE To optimize the fuel flow at a small throttle opening each machine s pilot screw has been individually set at the factory Before removing the pilot screw turn it in fully and count the numb...

Page 275: ...verture des gaz la vis de richesse de chaque v hicule a t r gl individuellement l usine Avant de remonter la vis de richesse la visser compl tement en comptant le nombre de tours exact Retenir et note...

Page 276: ...e a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b and c Clean NOTE Replace the needle valve and valve seat as a set EC464301 Throttle valve 1 Check Free movemen...

Page 277: ...rmiger Verschlei a Erneuern Staub b und C Reini gen HINWEIS Nadelventil und Ventilsitz als ganzen Satz austauschen Gasschieber 1 Kontrollieren Leichtg ngigkeit Schwerg ngigkeit Instand setzen oder er...

Page 278: ...the float will push in the needle valve result ing in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE T...

Page 279: ...plan de joint de la cuve niveau constant et le haut du flotteur N B Le bras du flotteur doit reposer sur le pointeau mais il ne doit pas le com primer Si la hauteur du flotteur est hors sp cification...

Page 280: ...p 2 Accelerator pump cover 3 O ring 4 Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clean 1 2 3 4 5 6 ASSEMBLY...

Page 281: ...de pouss e 5 D chirure diaphragme endommagement Rempla cer Encrassement Nettoyer 2 Inspecter Axe de papillon 1 Ressort 2 Levier 1 3 Ressort 1 4 Levier 2 5 Ressort 2 6 Sale Nettoyer ASSEMBLAGE ET MONTA...

Page 282: ...l Spring 2 1 To lever 2 2 1 2 5 Install Push rod link lever assembly 1 NOTE Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 1 a b 6 Install Washer 1 Circlip 2 2 1 7 In...

Page 283: ...Installer Ensemble de levier de timone rie de la tige de commande 1 N B S assurer que la but e a du ressort 2 rentre dans l encoche b du carburateur 6 Installer Rondelle 1 Circlip 2 7 Installer Ressor...

Page 284: ...ensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throt tle stop screw tip d to the...

Page 285: ...Tourner l ensemble de l axe de papillon vers la gauche tout en appuyant sur le levier 1 5 et adapter l extr mit de la vis d arr t de papillon d la but e e de la poulie d ensemble d axe de papillon 9 I...

Page 286: ...ints Turn in the pilot screw until it is lightly seated Turn out the pilot screw by the number of turns recorded before removing Pilot screw 1 3 4 turns out example 13 Install O ring Leak jet 1 Float...

Page 287: ...avant la d pose Vis de ralenti 1 3 4 tours en arri re example 13 Monter Joint torique Gicleur de fuite 1 Cuve niveau constant 2 Vis cuve niveau constant 3 Support de c ble c ble de vis d arr t de l ac...

Page 288: ...the slits a of the throttle valve 17 Install O ring 1 Valve lever housing cover 2 Bolt valve lever housing cover 3 18 Install Carburetor breather hose 1 NOTE Install the carburetor breather hoses to t...

Page 289: ...ent de levier de boisseau 2 Boulon couvercle du logement de levier de boisseau 3 18 Monter Durit de mide l air de carbu rateur 1 N B Installer la dorit de mise l air sur le car burateur de sorte qu il...

Page 290: ...kg 2 2 ft lb 4 Install Throttle cable 1 5 Adjust Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 6 Install Throttle cable cover 1 Screw throttle cable cover 2 NOTE...

Page 291: ...au CHAPITRE 3 6 Monter Cache du logement des c bles des gaz 1 Vis cache du logement des c bles des gaz 2 N B Monter le cache du logement des c bles des gaz en veillant ce que son linguet a soit accroc...

Page 292: ...INDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section 1 Spark plug 1 2 Cylinder head breather hose...

Page 293: ...ion SELLE RESERVOIR DE CAR BURANT CACHES LATERAUX Carburateur Se reporter la section CARBURATEUR 1 Bougie 1 2 Durit de mise l air de culasse 1 3 Reniflard de r servoir d huile 1 4 Boulon couvre culass...

Page 294: ...emoval Order Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing mark accessing screw 1 Refer to REMOVAL POINTS 2 Crankshaft end accessing screw 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tens...

Page 295: ...de distribution 1 Se reporter POINTS DE DEPOSE 2 Vis d acc s de l extr mit de vilebrequin 1 3 Boulon capuchon du tendeur de cha ne de dis tribution 1 4 Tendeur de cha ne de distribution 1 5 Chapeau d...

Page 296: ...n is at T D C on compression stroke NOTE In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with...

Page 297: ...nement c de l arbre cames d chappement et le rep re d alignement d de l arbr cames d admission s alignent sur la surface de la culasse comme illustr 3 D poser Boulon capuchon du tendeur de la cha ne d...

Page 298: ...2 Measure Cam lobe length a and b Out of specification Replace Cam lobes length Intake a 30 296 30 346 mm 1 1923 1 1947 in Limit 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm 0...

Page 299: ...r de came Admission a 30 296 30 346 mm 1 1923 1 1947 in Limite 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limite 22 35 mm 0 8799 in Echappement a 30 399 30 499 mm 1 1968 1 2007 in Limite 30...

Page 300: ...1 0 m kg 7 2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camshaft...

Page 301: ...pes de la mesure Installer l arbre cames sur la culasse Placer une bande de Plastigauge 1 sur l arbre cames Installer le circlip les goujons et les chapeaux d arbre cames T R Boulon de chapeau d arbre...

Page 302: ...aft 2 Installation steps Turn the crankshaft counterclockwise with a wrench NOTE Squeezing the decompression lever allows the crankshaft to be turned easily Align the T D C mark a on the rotor with th...

Page 303: ...Tourner le vilebrequin l aide d une cl dans le sens inverse des aiguilles d une montre N B Actionner le levier de d compres sion a fin de faciliter la rotation du rilebrequin Aligner le rep re de PMH...

Page 304: ...ce of the bolts camshaft cap Tighten the bolts camshaft cap 5 in a crisscross pattern CAUTION The bolts camshaft cap must be tight ened evenly or damage to the cylinder head camshaft caps and camshaft...

Page 305: ...porte de serrer les boulons de chapeau d arbre cames uniform ment pour viter d endommager la culasse les chapeaux d arbre cames et l arbre cames 2 Monter Tendeur de la cha ne de distri bution Etapes d...

Page 306: ...gn with the crankcase align mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing mark accessing screw 1 Crankshaft end accessing screw 2 6 Install Ti...

Page 307: ...de l arbre cames la sur face de la culasse Non align s R gler 5 Monter Vis d acc s du rep re de distri bution 1 Vis d acc s de l extr mit de vilebrequin 2 6 Monter Guide de cha ne de distribution c t...

Page 308: ...4 27 ENG 7 Install Oil tank breather hose Cylinder head breather hose Spark plug T R 13 Nm 1 3 m kg 9 4 ft lb CAMSHAFTS...

Page 309: ...Nm 1 3 m kg 7 Monter Durit de mise l air de r ser voir d huile Durit de mise l air de culasse Bougie T R 13 Nm 1 3 m kg 9 4 ft lb 7 Installare Sfiatatoio serbatoio dell olio Sfiatatoio testata del cil...

Page 310: ...T PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section Upper engine bracket Refer to ENGINE REMOVAL sec...

Page 311: ...RBURATEUR Arbre cames Se reporter la section ARBRES A CAMES Support sup rieur de moteur Se reporter la section DEPOSE DU MOTEUR 1 Tuyau de radiateur 1 2 Guide de c ble de d compression 1 3 Tuyau d arr...

Page 312: ...ad warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurface ment steps Place a straightedge and a feeler gauge across the cylinder head...

Page 313: ...la culasse Moins de 0 05 mm 0 002 in Etapes de la mesure de la limite de d formation et du surfa age Placer une r gle et une jauge d paisseur sur la culasse Utiliser une jauge d paisseur pour mesurer...

Page 314: ...oil on the decompression shaft T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Decompression cable 4 Cylinder head 5 NOTE Install the decom...

Page 315: ...2 Guide de cha ne de distribution c t chappement 3 C ble de d compresseur 4 Culasse 5 N B Monter le c ble de d compression la culasse puis au cylindre Monter le guide de la cha ne de distri bution c...

Page 316: ...ten the bolts and nuts in two stages T R 38 Nm 3 8 m kg 27 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4...

Page 317: ...Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Monter Rondelle en cuivre 1 Tuyau d arriv e d huile 2 Boulon raccord M8 3 Boulon raccord M10 4 T R 18 Nm 1 8 m kg 13 ft lb T R 20 Nm 2 0 m kg 14 ft...

Page 318: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cot...

Page 319: ...r de soupape 5 Utiliser un outil sp cial Se reporter POINTS DE DEPOSE 2 Cale de r glage 5 3 Clavette de soupape 10 4 Retenue de ressort de soupape 5 5 Ressort de soupape 5 6 Joint de queue de soupape...

Page 320: ...ve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly...

Page 321: ...ge de soupape Examiner la face de soupape le si ge de soupape et la largeur du si ge de soupape Etapes de la v rification Verser du dissolvant propre 1 dans les lumi res d admission et d chappement V...

Page 322: ...3 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head i...

Page 323: ...Etapes de remplacement N B Pour faciliter l extraction et la remise en place du guide et maintenir un ajustage correct faire chauffer la culasse 100 C 212 F dans un four D poser le guide de soupape en...

Page 324: ...7 90890 04117 Valve guide reamer Intake 4 0 mm 0 16 in YM 4113 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 90890 04118 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pi...

Page 325: ...6 Outil d installation de guide de soupape Admission 4 0 mm 0 16 in YM 4112 90890 04112 Echappement 4 5 mm 0 18 in YM 4117 90890 04117 Al soir de guide de sou pape Admission 4 0 mm 0 16 in YM 4113 908...

Page 326: ...a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps App...

Page 327: ...mission 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Echappement 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Etapes de la mesure Appliquer du bleu de m canicien Dykem b sur la face de l...

Page 328: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Page 329: ...s puis liminer la p te roder N B Pour obtenir un bon rodage tapoter sur le si ge de soupape tout en faisant tourner la soupape dans la main Appliquer de la p te roder fine sur la face de soupape puis...

Page 330: ...1 49 in Limit 35 9 mm 1 41 in Exhaust 37 54 mm 1 48 in Limit 35 7 mm 1 41 in Compressed spring force Intake 10 1 11 6 kg at 29 13 mm 22 27 25 57 lb at 1 15 in Exhaust 12 9 14 7 kg at 29 30 mm 28 44 3...

Page 331: ...1 in Force du ressort com prim Admission 10 1 11 6 kg 29 13 mm 22 27 25 57 lb 1 15 in Echappement 12 9 14 7 kg 29 30 mm 28 44 32 41 lb 1 15 in 3 Mesurer Inclinaison de ressort a Hors sp cifications Re...

Page 332: ...color Valve lifter mark b color Red Red Blue Blue Yellow Yellow Purple Black a b ASSEMBLY AND INSTALLATION Valve and valve spring 1 Apply Molybdenum disulfide oil Onto the valve stem and valve stem se...

Page 333: ...MONTAGE Soupape et ressort de soupape 1 Appliquer Huile au bisulfure de molyb d ne Sur la queue de soupape et la bague d tanch it de queue de soupape 2 Monter Soupapes 1 Si ges de ressort de soupape 2...

Page 334: ...alve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 04019 90890 04019 5 Install Adjusting pad 1 Valve lifter 2 NOTE Apply...

Page 335: ...mpresseur de ressort de soupape YM 04019 90890 04019 5 Monter Cales de r glage 1 Poussoir de soupape 2 N B Enduire l extr mit de la queue de soupape d huile au bisulfure de moly bd ne Enduire les pous...

Page 336: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin cli...

Page 337: ...rdre Nom de pi ce Qt Remarques DEPOSE DES CYLINDRES ET DES PIS TONS Pr paration la d pose Culasse Se reporter la section CULASSE 1 Boulon cylindre 1 2 Cylindre 1 3 Agrafe d axe de piston 2 Utiliser un...

Page 338: ...se a hammer to drive the piston pin out 2 Remove Piston ring 1 NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustrati...

Page 339: ...our chasser l axe de piston 2 D poser Segment de piston 1 N B Ecarter largement les becs tout en soule vant en m me temps le segment de pis ton au dessus de la couronne de piston comme montr sur l ill...

Page 340: ...re the piston skirt diameter P with a micrometer a 8 mm 0 31 in from the piston bottom edge Piston size P Standard 76 955 76 970 mm 3 0297 3 0303 in If out of specification replace the piston and pist...

Page 341: ...om tre a 8 mm 0 31 in du bord inf rieur de pis ton Taille de piston P Standard 76 955 76 970 mm 3 0297 3 0303 in Si hors sp cifications remplacer le piston et ses segments 3 me tape Calculer l cart en...

Page 342: ...crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 0...

Page 343: ...012 0 0026 in 0 12 mm 0 005 in Segment d tan ch it 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in 3 Mesurer Ecartement des becs Hors sp cifications Rempla cer N B Il est impossible de mesurer l cart...

Page 344: ...piston and piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 15 991 16 000...

Page 345: ...S il n est pas conforme aux sp ci fications remplacer l axe de pis ton Diam tre ext rieur axe de piston 15 991 16 000 mm 0 6296 0 6299 in Mesurer le diam tre int rieur pis ton b Diam tre int rieur ax...

Page 346: ...on Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from f...

Page 347: ...ston et le piston S assurer que la fl che a sur le piston soit orient e vers le c t chappement du moteur Avant d installer l agrafe d axe de pis ton couvrir le carter avec un chiffon propre pour viter...

Page 348: ...h one hand while com pressing the piston rings with the other hand CAUTION Pass the timing chain 3 through the tim ing chain cavity Be careful not to damage the timing chain guide 4 during installatio...

Page 349: ...asser la cha ne de distribu tion 3 par la cavit pr vue cet effet Veiller ne pas endommager l amortisseur de la cha ne de distri bution 4 lors de l installation 4 Monter Boulon cylindre 5 T R 10 Nm 1 0...

Page 350: ...al Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOV...

Page 351: ...folge Bauteil Anz Bemerkungen KUPPLUNG DEMONTIEREN Vorbereitung f r den Ausbau Motor l ablassen Siehe unter MOTOR L WECHSELN im KAPITEL 3 Fu bremshebel Siehe unter MOTOR DEMONTIEREN Kupplungszug Moto...

Page 352: ...ty Remarks 10 Friction plate 9 11 Clutch plate 8 12 Cushion spring 1 13 Seat plate 1 14 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1...

Page 353: ...ortisseur 1 13 Plaque d assise 1 14 Ecrou noix d embrayage 1 Utiliser un outil sp cial Se reporter POINTS DE DEPOSE 15 Rondelle d arr t 1 16 Noix d embrayage 1 17 Rondelle de but e 1 18 Pignon men pri...

Page 354: ...YM 91042 90890 04086 EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1...

Page 355: ...LE Cloche et noix d embrayage 1 V rifier Cloche d embrayage 1 Craquelures usure endomma gement Ramplacer Noix d embrayage 2 Rayures usure endommage ment Ramplacer Pignon men primaire 1 V rifier Jeu ci...

Page 356: ...Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 7 mm 0 106 in Warp limit...

Page 357: ...yage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Epaisseur de disque de friction 2 9 3 1 mm 0 114 0 122 in Limite 2 7 mm 0 106 in Limite de d formation 0 1 mm 0 004 in Levier de pouss e 1...

Page 358: ...groove a of the push lever shaft and tighten the bolt seat plate 3 1 a 2 T R 10 Nm 1 0 m kg 7 2 ft lb Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on...

Page 359: ...2 ft lb Embrayage 1 Monter Pignon men primaire 1 Rondelle de but e 2 Noix d embrayage 3 N B Enduire la circonf rence int rieure du pignon d huile de moteur 2 Monter Rondelle frein 1 Ecrou noix d embra...

Page 360: ...friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying attention to the differenc...

Page 361: ...embrayage en comen ant par un disque de friction et en terminant par un disque de friction Commencer et terminer par un disque de friction 1 et tre attentif la diff rence de leur surface Appliquer de...

Page 362: ...essure plate 1 9 Install Clutch spring 1 Bolt clutch spring 2 NOTE Tighten the bolts in stage using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 10 Install Dowel pin 1 Gasket clutch cover 2 11 Ins...

Page 363: ...Boulon ressort d embrayage 2 N B Serrer les boulons par tapes dans un ordre entrecrois T R 8 Nm 0 8 m kg 5 8 ft lb 10 Monter Goujon 1 Joint couvercle d embrayage 2 11 Monter Couvercle d embrayage 1 Bo...

Page 364: ...rks OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to CO...

Page 365: ...ation la d pose Vidanger le moteur Se reporter la section REMPLACEMENT DE L HUILE MOTEUR au chapitre 3 Vidanger le liquide de refroidissement Se reporter la section REMPLACEMENT DU LIQUIDE DE REFROIDI...

Page 366: ...VER Extent of removal Order Part name Q ty Remarks 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to REMOVAL POINTS 9...

Page 367: ...oit 1 8 Rotor 1 Se reporter POINTS DE DEPOSE 9 Rondelle 1 10 Arbre de rotor 1 11 Bague d tanch it 2 12 Roulement 1 3 2 Portata dello smontaggio Ordine Denominazione Quantit Osservazioni 3 Alloggiament...

Page 368: ...oss the flats a with 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 le...

Page 369: ...e un changement excessif du niveau ou une d coloration du liquide de refroidissement ou une huile de bo te de vitesses laiteuse 1 D poser Roulement 1 2 D poser Bague d tanch it 1 CONTROLE Tuyau d arri...

Page 370: ...Gear teeth a Wear damage Replace EC4H4600 Bearing 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace EC444400 Oil seal 1 Inspect Oil seal 1 Wear damage Replace ASSEMBLY AND...

Page 371: ...ler Bague d tanch it 1 Usure endommagement Remplacer ASSEMBLAGE ET MONTAGE Bague d tanch it 1 Monter Bague d tanch it 1 N B Appliquer la graisse base de savon au lithium sur la l vre de la bague d ta...

Page 372: ...dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning...

Page 373: ...arbre de rotor tout en le tournant Maintenir l arbre de rotor par les zones lat rales aplaties a au moyen d une cl etc et d poser le rotor T R 14 Nm 1 4 m kg 10 ft lb Demi carter droit 1 Monter Goupil...

Page 374: ...kg 7 2 ft lb Kickstarter crank 1 Install Kickstarter crank 1 Washer 2 Bolt kickstarter crank 3 NOTE Install the kickstarter crank so that the kick starter crank is as vertical as possible with the dis...

Page 375: ...ble et ce que la distance a entre la p dale et le cadre soit de 8 mm 0 31 in minimum 2 Monter Durit d huile 1 Boulon durit d huile 2 T R 33 Nm 3 3 m kg 24 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Monter R...

Page 376: ...he lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter element 1 Install Oil filter element 1 O ring 2 Oil filter el...

Page 377: ...que 2 Couvercle d l ment de filtre huile 3 Boulon couvercle d l ment de filtre huile N B Enduire le joint torique de graisse base de savon au lithium T R 10 Nm 1 0 m kg 7 2 ft lb Alloggiamento della p...

Page 378: ...r to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to REMOVAL POIN...

Page 379: ...e reporter la section ALTERNATEUR CDI 1 Ecrou pignon menant primaire 1 Se reporter POINTS DE DEPOSE 2 Ecrou pignon men du balancier 1 3 Rondelle frein 1 4 Pignon menant primaire 1 5 Pignon menant du b...

Page 380: ...d driven gear 4 Balancer shaft 1 Remove Balancer shaft 1 NOTE When removing the balancer shaft align the center a of the balancer shaft weight along the line connecting the centers of the crank shaft...

Page 381: ...tre du vilebrequin et le centre de l arbre de balancier CONTROLE Pignon menant primaire pignon menant et pignon men du balancier 1 Contr ler Pignon menant primaire 1 Pignon menant du balancier 2 Pign...

Page 382: ...r shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 NOTE Align the punched mark a on the balancer shaft drive gear with the punched mark b on th...

Page 383: ...e poin onn c sur le pignon menant de balancier et la saillie d sur l extr mit de vilebrequin 4 Monter Rondelle frein 1 Ecrou pignon men de balan cier 2 Pignon menant primaire 3 Ecrou pignon menant pri...

Page 384: ...EMBLY Preparation for removal Primary driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section 1 Circlip 1 2 Washer 1 3 Oil p...

Page 385: ...orter la section ELEMENT DE FILTRE A HUILE POMPE A EAU ET DEMI CARTER DROIT 1 Circlip 1 2 Rondelle 1 3 Pignon menant de la pompe huile 1 4 Ensemble pompe huile 1 5 Rotor ext rieur 2 1 6 Circlip 1 7 Ro...

Page 386: ...4 66 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 2...

Page 387: ...lle 1 15 Rotorgeh use 1 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 12 Goupille 1 13 Rondelle 1 14 Arbre de transmission de la pompe huile 1 15 Logement de rotor 1 2 Portata dello smon...

Page 388: ...he outer rotor 2 and rotor housing 3 Housing and rotor clearance c between the rotor housing 3 and rotors 1 2 Out of specification Replace the oil pump assembly Tip clearance a 0 12 mm or less 0 0047...

Page 389: ...logement de rotor 3 et les rotors 1 2 Hors sp cifications Rempla cer la pompe huile compl te Jeu en bout a 0 12 mm ou moins 0 0047 in ou moins Limite 0 20 mm 0 008 in Jeu lat ral b 0 09 0 17 mm 0 003...

Page 390: ...shaft and inner rotor 1 Fit the dowel pin into the groove in the inner rotor 1 2 Install Outer rotor 1 1 NOTE Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover...

Page 391: ...Monter Rotor ext rieur 1 1 N B Enduire le rotor ext rieur 1 d huile moteur 3 Monter Couvercle de pompe huile 1 Vis couvercle de pompe huile 2 Goupille 3 Rotor int rieur 2 4 Circlip 5 N B Enduire le r...

Page 392: ...5 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 NOTE Apply the engine oil on the outer rotor 2 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install Oil pump drive gear 1 Washer...

Page 393: ...huile moteur T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Monteur Pignon menant de la pompe huile 1 Rondelle 2 Circlip 3 N B Enduire la circonf rence int rieure du pignon menant d huil...

Page 394: ...oval Extent of removal Order Part name Q ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to RE...

Page 395: ...pi ce Qt Remarques DEPOSE DE L ARBRE DE KICK ET DE L ARBRE DE SELECTEUR Pr paration la d pose Pompe huile Se reporter la section POMPE A HUILE 1 Pignon de renvoi de kick 1 2 Arbre de kick complet 1 Se...

Page 396: ...Q ty Remarks 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to REMOVAL POINTS 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper...

Page 397: ...ouleau 1 14 Guide de s lecteur 1 Se reporter POINTS DE DEPOSE 15 Ensemble levier de s lecteur 1 16 Levier de s lecteur 1 17 Cliquet 2 18 Goupille de cliquet 2 19 Ressort 2 20 Boulon levier de but e 1...

Page 398: ...embly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION Kick s...

Page 399: ...s lecteur se d monte en m me temps que le guide de s lecteur Barillet 1 D poser Boulon barillet 1 Barillet 2 N B Tourner le segment dans le sens antiho raire jusqu l arr t et desserrer le bou lon CONT...

Page 400: ...assembly 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace ASSE...

Page 401: ...1 Contr ler Guide de s lecteur 1 Levier de s lecteur 2 Cliquet 3 Goupille du cliquet 4 Ressort 5 Usure endommagement Rmplacer Levier de but e 1 Contr ler Levier de but e 1 Usure endommagement Remplac...

Page 402: ...m 1 0 m kg 7 2 ft lb Shift guide and shift lever assembly 1 Install Spring 1 Pawl pin 2 Pawl 3 To shift lever 4 NOTE Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly...

Page 403: ...1 Monter Ressort 1 Goupille de cliquet 2 Cliquet 3 Au levier de s lecteur 4 N B Enduire les ressorts les goupilles de cli quets et les cliquets d huile moteur 2 Monter Levier de s lecteur complet 1 Au...

Page 404: ...olt shift pedal 2 NOTE When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 2 mm a above the top of the footrest Kick shaft assembly 1 Install Kick...

Page 405: ...re de s lecteur 2 N B Au moment de monter la p dale de s lecteur sur l arbre de s lecteur veiller ce que le centre de la p dale de s lec tion soit environ 2 mm a au dessus du sommet du repose pied Arb...

Page 406: ...ion spring 4 Install Kick shaft assembly 1 Washer 2 NOTE Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case make sure the kick shaft stopper a fit into their home...

Page 407: ...e torsion 4 Monter Arbre de kick complet 1 Rondelle 2 N B Appliquer l huile sur l arbre de kick Coulisser l arbre de kick dans le car ter s assurer que la but e l arbre de kick a s engage dans la posi...

Page 408: ...AL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt left radiator Refer to RADIATOR section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHA...

Page 409: ...ce Se reporter la section SELLE RESERVOIR DE CAR BURANT CACHES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil de volant magn tique CDI P dale de s lecteur Se repo...

Page 410: ...lywheel puller turn it counterclockwise Rotor holding tool YU 1235 90890 01235 Flywheel puller YM 1189 90890 01189 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer...

Page 411: ...s d une montre Outil de maintien de rotor YU 1235 90890 01235 Extracteur de volant YM 1189 90890 01189 CONTROLE Volant magn tique CDI 1 Contr ler Surface interne de rotor a Surface externe de stator b...

Page 412: ...90 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Woodruff key 1 Rotor 2 NOTE Clean the tapered portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is...

Page 413: ...kg 7 2 ft lb 2 Monter Clavette de demi lune 1 Rotor 2 N B Nettoyer la partie conique du vilebre quin et du demi lune rotor Lors du montage de la clavette s assu rer que sa surface plane a est paral l...

Page 414: ...ING DIA GRAM section in the CHAPTER 2 5 Install Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Screw left crankcase cover 3 NOTE Tighten the scre...

Page 415: ...rer au paragraphe DIA GRAMME DE CHEMINE MENT DE CABLE au CHAPITRE 2 5 Monter Goujon Joint demi carter gauche Demi carter gauche 1 Guide de durit durit de mise l air de culasse 2 Vis demi carter gauch...

Page 416: ...r to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at engine side Decompres...

Page 417: ...ET SILENCIEUX C ble d embrayage D connecter du c t du moteur C ble et guide de d compresseur D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR P dale de s lecteur Se reporter la...

Page 418: ...ad Right engine guard 1 Neutral switch 1 2 Bolt oil hose 2 3 Drive chain sprocket cover 1 4 Nut drive sprocket 1 Refer to REMOVAL POINTS 5 Lock washer 1 6 Drive sprocket 1 7 Clip 1 8 Bolt brake pedal...

Page 419: ...on de cha ne de transmission 1 4 Ecrou pignon d entra nement 1 Se reporter POINTS DE DEPOSE 5 Rondelle frein 1 6 Pignon d entra nement 1 7 Agrafe 1 8 Boulon p dale de frein 1 9 P dale de frein 1 10 Su...

Page 420: ...sprocket 1 Drive chain 2 NOTE Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm wil...

Page 421: ...de transmission 2 N B D poser le pignon d entra nement avec la cha ne de transmission D pose du moteur 1 D poser Axe de pivot 1 N B Si l on sort compl tement l axe de pivot le bras oscillant va tombe...

Page 422: ...m 8 5 m kg 61 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 34 Nm 3 4 m kg 24 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 55 Nm 5 5 m kg 40 ft lb EC4M5211 Brake pedal 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt...

Page 423: ...onter Ressort 1 P dale de frein 2 Joint torique 3 Boulon p dale de frein 4 Agrafe 5 N B Appliquer de la graisse base de savon au lithium sur le boulon les joints toriques et le support de p dale de fr...

Page 424: ...uide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 T R 10 Nm 1 0 m kg 7 2 ft lb Oil hose and neutral switch 1 Install O ring 1 Dowel pin 2 Oil hose 3 Bolt oil hose 4 NOTE Apply the...

Page 425: ...t lb Durit d huile et contacteur de point mort 1 Monter Joint torique 1 Goujon 2 Durit d huile 3 Boulon durit d huile 4 N B Enduire le joint torique de graisse base de savon au lithium 2 Monter Ressor...

Page 426: ...RANKCASE AND CRANK SHAFT REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT sec...

Page 427: ...porter la section DEPOSE DU MOTEUR Piston Se reporter la section CYLINDRE ET PISTON Arbre de kick complet Se reporter la section ARBRE DE KICK ET ARBRE DE SELECTEUR Barillet Stator Se reporter la sect...

Page 428: ...ty Remarks 4 Bolt L 45 mm 1 77 in 6 Refer to REMOVAL POINTS 5 Bolt L 55 mm 2 17 in 1 6 Bolt L 70 mm 2 76 in 4 7 Hose guide 1 8 Clutch cable holder 1 9 Right crankcase 1 10 Left crankcase 1 11 Oil str...

Page 429: ...7 in 6 Se reporter POINTS DE DEPOSE 5 Boulon L 55 mm 2 17 in 1 6 Boulon L 70 mm 2 76 in 4 7 Guide de durit 1 8 Support de c ble d embrayage 1 9 Demi carter droit 1 10 Demi carter gauche 1 11 Carter d...

Page 430: ...1 Crankcase bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND S...

Page 431: ...de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DES ROULEMENTS DE CAR TER Pr paration la d pose Bo te vitesses Tambour et fourchettes de s lection Se reporter la section BOITE A VITESSES ET TAM B...

Page 432: ...litting slit a in the crankcase Lift the right crankcase horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mis...

Page 433: ...g re ment la fente de s paration ainsi que la noix de montage du moteur l aide d un maillet en plastique Le carter et la bo te vitesses res tent attach s au demi carter gau che ATTENTION Utiliser un...

Page 434: ...e removed bearing Crankcase separating tool YU 1135 A 90890 01135 INSPECTION Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a...

Page 435: ...ion 1 Contr ler Cha ne de distribution Craquelures raideur Rem placer l ensemble cha ne de distribution et pignon d arbre cames 2 Contr ler Guide de cha ne de distribution Usure endommagement Remplace...

Page 436: ...auge Dial gauge and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clearance 0 15 0 45 mm 0...

Page 437: ...in 0 05 mm 0 002 in D flexion de pied de bielle 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Jeu lat ral 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Largeur de volant 55 95 56 00 mm 2 203 2 205 in Cr p...

Page 438: ...R 10 Nm 1 0 m kg 7 2 ft lb 1 a b T R 10 Nm 1 0 m kg 7 2 ft lb Crankshaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 5 For USA and CDN Except for USA and CDN NOTE Hold the connecti...

Page 439: ...7 2 ft lb Vilebrequin 1 Monter Vilebrequin 1 Utiliser l outil de montage de vilebrequin 2 3 4 5 Pour les USA et le CDN Except pour les USA et le CDN N B Tenir la bielle au PMH point mort haut avec une...

Page 440: ...nkcase 1 NOTE Clean the contacting surface of left and right crankcase before applying the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase NOTE Fit the right crankcase onto th...

Page 441: ...emi carters gauche et droit avant d appliquer l agent d tanch it 5 Monter Goujon 1 Joint torique 2 Demi carter droit Vers le demi carter gauche N B Fixer le demi carter droit sur le demi carter gauche...

Page 442: ...1 O ring 2 Bolt oil delivery pipe 2 3 NOTE Apply the lithium soap base grease on the O rings T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain gu...

Page 443: ...uide de cha ne de distribution c t admission 2 Boulon guide de cha ne de distribution 3 9 D poser Agent d tanch it Sorti sur la surface usin e du cylindre 10 Appliquer Huile moteur Sur la goupille de...

Page 444: ...removal Extent of removal Order Part name Q ty Remarks TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRAN...

Page 445: ...n de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA BOITE A VITESSES DU TAMBOUR ET DE LA FOURCHETTE DE SELECTION Pr paration la d pose Moteur Se reporter la section DEPOSE DU MOTEUR S parer le...

Page 446: ...articular attention to the location and direction of shift forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham...

Page 447: ...l arbre secondaire l aide d un mar teau doux CONTROLE Pignons 1 Contr ler Crabot d accouplement a Dent de pignon b Gorge de fourchette c Usure endommagement Remplacer 2 Contr ler Joint torique 1 Endo...

Page 448: ...oning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION Transmission 1 Install 5th pinion gear 24T 1 3rd pinion ge...

Page 449: ...e 3 me 20D 2 Collerette 3 Pignon de 4 me 22D 4 Pignon de 2 me 16D 5 Sur l arbre primaire 6 N B Appliquer de l huile au bisulfure de molybd ne sur la circonf rence int rieure des 4e et 5e pignons et su...

Page 450: ...Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumfer ence Apply the lithium soap base grease on the O ring 3 Install Washer 1 Circlip 2 NOTE Be sure the circlip sharp edg...

Page 451: ...ier que le c t bord vif du cir clip a soit oppos la rondelle situ e contre le pignon b V rifier que l extr mit du circlip c est situ e dans une gorge de l axe d 4 Monter Collerette 1 N B Appliquer la...

Page 452: ...il on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle 6...

Page 453: ...l arbre secondaire Engrener la fourchette n 2 C avec le pignon de 3 me 6 de l arbre pri maire 6 Monter Ensemble bo te vitesse 1 Vers le demi carter gauche 2 N B Appliquer de l huile moteur sur les ro...

Page 454: ...arks Preparation for removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Brake h...

Page 455: ...tenir la machine en pla ant un support appropri sous le moteur 1 Logement de durit de frein 1 2 Boulon support de durit de frein 2 Desserrer uniquement 3 Boulon support d axe 4 Desserrer uniquement 4...

Page 456: ...VAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive ch...

Page 457: ...ntenir la machine en pla ant un support appropri sous le moteur 1 Ecrou axe de roue arri re 1 2 Axe de roue arri re 1 3 Tendeur de cha ne de transmission 2 4 Roue arri re 1 Se reporter POINTS DE DEPOS...

Page 458: ...necessary 1 Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate in...

Page 459: ...roulement en utilisant un arrache roulement courant 2 CONTROLE Roue 1 Mesure Voile de roue Hors limite R parer rempla cer Limite de voile de la roue Radial 1 2 0 mm 0 08 in Lat ral 2 2 0 mm 0 08 in 2...

Page 460: ...Wheel axle bending limit 0 5 mm 0 020 in EC594200 Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in...

Page 461: ...ue de frein disque de frein arri re unique ment Utiliser le comparateur 1 Hors sp cification Exami ner le voile de roue Si le voile de la roue est nor mal changer le disque de frein 2 Mesurer Epaisseu...

Page 462: ...ed first Install the oil seal with its manufacture s marks or numbers facing outward ACHTUNG CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Insta...

Page 463: ...s de fabricant diri g s vers l ext rieur ATTENTION Ne pas frapper sur la cage de roule ment interne Le contact ne doit avoir lieu qu avec la cage de roulement externe 2 Monter Disque de frein 1 Boulon...

Page 464: ...tening the bolt fit the wheel axle to the axle holder by stroking the front fork sev eral times with the front brake applied 8 Install Brake hose 1 To brake hose holder 2 NOTE Before tightening the bo...

Page 465: ...n nant plusieurs coups sur la fourche avant tout en serrant le frein avant 8 Monter Durit de frein 1 Sur le support de durit de frein 2 N B Avant de serrer le boulon support de durit de frein faire pa...

Page 466: ...ring and oil seal lip when installing Install the bearing with seal facing outward Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed f...

Page 467: ...ors de la repose Monter le roulement avec son joint dirig vers l ext rieur Utiliser une douille convenant au dia m tre ext rieur de la cage du roule ment Monter d abord le roulement droit Monter la ba...

Page 468: ...HEEL 4 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip 5 Install Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install Drive chain 1 NOTE Push t...

Page 469: ...B Reposer correctement le disque de frein 1 entre les plaquettes de frein 2 6 Monter Cha ne de transmission 1 N B Pousser la roue 2 vers l avant et monter la cha ne de transmission 7 Monter Tendeur g...

Page 470: ...r 2 Nut wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 40 50 mm 1...

Page 471: ...errer provisoirement l crou axe de roue 9 R gler Fl che de cha ne de transmis sion a Se reporter la section REGLAGE DE LA FLECHE DE CHAINE DE TRANSMIS SION au CHAPITRE 3 Fl che de cha ne de trans miss...

Page 472: ...e by placing the suitable stand under the engine Drain the brake fluid WARNING Support the machine securely so there is no danger of it falling over Refer to REMOVAL POINTS 1 Brake hose cover 1 2 Brak...

Page 473: ...le liquide de frein Se reporter POINTS DE DEPOSE 1 Logement de durit de frein 1 2 Support de durit de frein 1 3 Boulon support de durit de frein 2 Desserrer uniquement 4 Boulon raccord 2 5 Durit de fr...

Page 474: ...ngine WARNING Support the machine securely so there is no danger of it falling over Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOVAL POINTS 1 Pad pin plug...

Page 475: ...er Roue arri re Se reporter la section ROUE AVANT ET ROUE ARRIERE Vidanger le liquide de frein Se reporter POINTS DE DEPOSE 1 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupil...

Page 476: ...2 Rear brake caliper disassembly Extent of removal Order Part name Q ty Remarks BRAKE CALIPER DISASSEM BLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to REMOV...

Page 477: ...la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DE L ETRIER A B 1 Goupille de plaquette 1 1 2 Plaquette de frein 2 2 3 Support de plaquette 1 1 4 Piston d trier de frein 2 1 Se reporter POINTS DE...

Page 478: ...ylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Brake master...

Page 479: ...re Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DU MAITRE CYLINDRE DE FREIN 1 Couvercle de ma tre cylindre de frein 1 2 Diaphragme 1 3 Soufflet de ma tre cylindre de frein 1 4...

Page 480: ...lever in or pushing down on the pedal ACHTUNG CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Brake calip...

Page 481: ...purg Le liquide de frein attaque les surfa ces peintes et le plastique Si on en renverse il faut l essuyer imm dia tement Piston d trier de frein 1 D poser Piston d trier de frein Appliquer de l air...

Page 482: ...e piston seals and dust seals whenever a caliper is disassembled Front Rear EC5A4000 INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cyl...

Page 483: ...e d trier Avant Arri re CONTROLE Ma tre cylindre de frein 1 Contr ler Surface interne du ma tre cylindre de frein a Usure rayures Ramplacer l ensemble ma tre cylindre Taches Nettoyer AVERTISSEMENT Uti...

Page 484: ...a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crack damage Replace EC5A5000 ASSEMBLY AND INSTALLATION WARNING All internal parts should be cleaned in new brake fluid only Inter...

Page 485: ...it de frein 1 Contr ler Durit de frein 1 Craquelure endommagement Remplacer REMONTAGE ET MONTAGE AVERTISSEMENT Toutes les pi ces internes doivent tre nettoy es en utilisant unique ment du liquide de f...

Page 486: ...HTUNG CAUTION For the front brake caliper install the pis ton with its depressed side a facing the brake caliper For the rear brake caliper install the piston with its shallow depressed side b facing...

Page 487: ...installer le pis ton avec le c t creux a face l trier de frein Pour l trier de frein arri re installer le piston avec le c t renfonc b face l trier Ne jamais forcer pour ins rer Avant Arri re Etrier...

Page 488: ...ll Brake hose holder 1 Brake caliper 2 Bolt brake caliper 3 NOTE Fit the brake hose holder cut a over the pro jection b on the front fork and clamp the brake hose 4 Tighten Pad pin 4 5 Install Pad pin...

Page 489: ...rt de durit de frein a sur la saillie b de la fourche avant et fixer la durit de frein 4 Serrer Goupille de plaquette 4 5 Monter Bouchon de goupille de pla quette 5 T R 23 Nm 2 3 m kg 17 ft lb T R 18...

Page 490: ...er washers ACHTUNG CAUTION Install the brake hose to the brake caliper with the paint a on the pipe facing the brake caliper and with the pipe contacting the brake caliper projection b T R 30 Nm 3 0 m...

Page 491: ...Installer la durit de frein sur l trier de frein en veillant ce que la marque a peinte sur le tuyau soit orient e vers l trier de frein et que le tuyau soit en contact avec la saillie b de l trier de...

Page 492: ...y 1 Brake master cylinder cup secondary 2 To brake master cylinder piston 3 NOTE Apply the brake fluid on the brake master cyl inder cup WARNING After installing cylinder cup should be installed as sh...

Page 493: ...re de frein secondaire 2 Au piston d trier de frein 3 N B Appliquer le liquide de frein sur la cou pelle du ma tre cylindre de frein AVERTISSEMENT Apr s la repose la coupelle du ma tre cylindre doit t...

Page 494: ...rake master cylinder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers Front Rear Front brake master cylinder 1 Install Brake...

Page 495: ...e au lithium sur l extr mit de la tige de commande Pour mettre le circlip en place utiliser une pince de circlip longs becs Avant Arri re Ma tre cylindre de frein avant 1 Monter Ma tre cylindre de fre...

Page 496: ...l Reservoir hose 1 Reservoir tank 2 Bolt reservoir tank 3 T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Brake master cylinder 1 Bolt brake master cylin...

Page 497: ...t de r servoir 1 R servoir 2 Boulon r servoir 3 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Monter Ma tre cylindre de frein 1 Boulon ma tre cylindre de frein 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Monter Ressort 1 P dal...

Page 498: ...fore tightening the bolt brake hose holder pass the brake hose in front of the axle boss a then fit it into the hose groove b so that the brake hose does not contact the nut wheel axle T R 10 Nm 1 0 m...

Page 499: ...sieu a puis l ins rer dans la cannelure de la durit b pour que la durit de frein ne tou che pas l crou axe de roue T R 10 Nm 1 0 m kg 7 2 ft lb 2 Monter Logement de durit de frein 1 Rondelle 2 Boulon...

Page 500: ...ter cylin der T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Copper washer 3 Union bolt 4 WARNING Always use new copper washers ACHTUNG CAUTION When installing the...

Page 501: ...Durit de frein arri re 1 Monter Rondelle en cuivre 1 Durit de frein 2 Rondelle en cuivre 3 Boulon raccord 4 AVERTISSEMENT Toujours utiliser des rondelles en cui vre neuves ATTENTION Monter la durit de...

Page 502: ...rake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and...

Page 503: ...era des fuites et un mauvais fonctionnement du frein Toujours utiliser la m me marque de liquide de frein Le m lange de liquides de marques diff rentes ris que de provoquer une r action chi mique nuis...

Page 504: ...r cap 2 Rear Diaphragm Reservoir tank cap 1 Screw reservoir tank cap 2 Brake master cylinder guard ACHTUNG CAUTION After installation while pulling the brake lever in or pushing down on the brake peda...

Page 505: ...r servoir 1 Vis couvercle du r servoir 2 Couvercle du r servoir ATTENTION Apr s le montage rechercher les fui tes ventuelles de liquide de frein au niveau des boulons raccords sur le ma tre cylindre d...

Page 506: ...ING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number...

Page 507: ...mfallen sichern Vorderrad Siehe unter VORDER UND HINTERRAD Bremssattel vorn Siehe unter VORDER UND HINTERRAD BREMSE Nummernschild Lenker Siehe unter LENKER 1 Protektor 1 2 Bremsschlauch Halterung 2 3...

Page 508: ...arks FRONT FORK DISASSEMBLY 1 Front fork cap bolt 1 Refer to REMOVAL POINTS 2 Fork spring 1 Drain the fork oil 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7 Pi...

Page 509: ...E 2 Ressort de fourche 1 Vidanger d huile de fourche 3 Joint antipoussi re 1 Se reporter POINTS DE DEPOSE 4 Bague d arr t 1 5 Tube plongeur 1 6 Fourreau 1 7 Bague coulissante de piston 1 8 Bague antif...

Page 510: ...ough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disas sembled and reassembled Before removing the cap bolts or front forks be sure to extract...

Page 511: ...ant est d mont e ou remont e Avant de d visser les bouchons de tube de fourche ou d enlever les bras de fourche avant tre s r d avoir compl tement purg l air du r servoir d air POINTS DE DEPOSE Boucho...

Page 512: ...ter tube EC553311 Damper rod 1 Remove Base valve 1 Damper rod 2 NOTE Use a damper rod holder 3 to lock the damper rod EC554000 INSPECTION EC554100 Damper rod 1 Inspect Damper rod 1 Bend damage Replace...

Page 513: ...tige d amortisseur 3 pour bloquer la tige d amortisseur CONTROLE Tige d amortisseur 1 Contr ler Tige d amortisseur 1 Courbure endommagement Remplacer la tige d amortis seur ATTENTION La construction i...

Page 514: ...000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING...

Page 515: ...Remplacer D formations de tube plongeur Hors sp cification Rempla cer Utiliser le comparateur 1 N B La valeur de courbure est indiqu e par la moiti de la valeur du comparateur cadran AVERTISSEMENT Ne...

Page 516: ...r tube 2 ACHTUNG CAUTION To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Insta...

Page 517: ...ube interne de biais Si le tube plongeur est tenu verticalement la tige d amortisseur peut y tomber endommageant le clapet 3 Monter Rondelle en cuivre 1 Joint torique 2 Soupape de base 3 Au tube inter...

Page 518: ...seal 1 Stopper ring 2 Oil seal 3 Oil seal washer 4 Slide metal 5 To inner tube 6 NOTE Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to prote...

Page 519: ...6 N B Appliquer de l huile de fourche sur le tube plongeur Lors de l installation de la bague d tanch it utiliser une feuille plasti que a enduite d huile de fourche pour prot ger la l vre de la bagu...

Page 520: ...ver 3 Fork seal driver YM 01442 90890 01442 10 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 11 Install Stopper ring 1 NO...

Page 521: ...90890 01442 10 Monter Bague d tanch it 1 N B Enfoncer la bague d tanch it dans le fourreau l aide de l outil d insertion de joint de fourche 2 Outil d insertion de joint de fourche YM 01442 90890 0144...

Page 522: ...rk performance Never allow foreign materials to enter the front fork Recommended oil Suspension oil 01 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distribute the fo...

Page 523: ...per lentement plus de 10 fois vers le haut et le bas la tige d amortis seur 1 pour distribuer l huile du fourche 17 Remplir Huile de fourche avant Une nouvelle fois jusqu au sommet du fourreau avec l...

Page 524: ...ith the fork oil up to the top of the outer tube and bleed the front forks 20 Measure Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking th...

Page 525: ...aller le guide 2 de ressort lors de la v rification du niveau d huile AVERTISSEMENT Toujours veiller ce que le niveau d huile se situe entre les rep res de niveau maximum et minimum et ce que le nivea...

Page 526: ...e amount of turning out the fully turned in posi tion 23 Install Cushion rubber 1 Washer 2 Spacer 3 To front fork cap bolt 4 NOTE Install the cushion rubber with its smaller dia end a facing the front...

Page 527: ...niture en caoutchouc 1 Rondelle 2 Entretoise 3 Au bouchon de tube de fourche 4 N B Installer la garniture en caoutchouc avec le c t de plus faible diam tre a face au bouchon de tube de fourche 24 Mont...

Page 528: ...pecified torque 27 Install Front fork cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt T R 29 Nm 2 9 m kg 21 ft lb 28 Install Protector guide 1 Installation 1 Install Front fork 1 NOTE T...

Page 529: ...chon de tube de fourche 1 Sur le fourreau N B Serrer le bouchon de tube de fourche de quelques tours T R 29 Nm 2 9 m kg 21 ft lb 28 Monter Guide de protection 1 Montage 1 Monter Fourche avant 1 N B Se...

Page 530: ...amp the brake hose 6 Install Brake hose holder 1 Bolt brake hose holder 2 Protector 3 Bolt protector 4 NOTE When installing the brake hose holder pass the brake hose 5 in front of the axle boss a then...

Page 531: ...e l installation du support de durit de frein faire passer la durit de frein 5 l avant du bossage d essieu a puis l ins rer dans la cannelure de durit b afin que la durit de frein ne touche pas l crou...

Page 532: ...on lever holder 1 3 Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to REMOVAL POINTS 7 Throttle cable cap 1 8 Throttle cable...

Page 533: ...pe circuit du moteur 1 6 Ma tre cylindre de frein 1 Se reporter POINTS DE DEPOSE 7 Couvercle du logement de c ble des gaz 1 8 C ble des gaz 2 pouss 1 D connecter du c t acc l rateur 9 C ble des gaz 1...

Page 534: ...ake master cylinder cap side horizontal to prevent air from coming in EC5B3200 Grip 1 Remove Grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has bec...

Page 535: ...e frein l horizon tale pour emp cher toute p n tra tion d air Poign e 1 D poser Poign e 1 N B Souffler de l air entre le guidon ou le guide de tube et la poign e Enlever ensuite la poign e quand elle...

Page 536: ...dhesive to the handlebar 2 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the left grip to the handlebar so that the line b between...

Page 537: ...sur la surface du guidon a avec du diluant de peinture Fixer la poign e gauche sur le guidon de sorte que la ligne b entre les deux fl ches soit dirig e vers le haut 3 Monter Poign e droite 1 Colleret...

Page 538: ...After tightening the screws check that the throttle grip 4 moves smoothly If it does not retighten the bolts for adjustment T R 4 Nm 0 4 m kg 2 9 ft lb 6 Install Brake master cylinder 1 Brake master...

Page 539: ...serr les vis v rifier que la poign e des gaz 4 tourne sans pro bl me Sinon resserrer les boulons pour la r gler T R 4 Nm 0 4 m kg 2 9 ft lb 6 Monter Ma tre cylindre de frein 1 Demi palier de ma tre cy...

Page 540: ...ions shown Pass the engine stop switch lead in the mid dle of the clutch holder 8 Install Clutch cable 1 Decompression cable 2 NOTE Apply the lithium soap base grease on the clutch cable end and decom...

Page 541: ...b 8 Monter C ble d embrayage 1 C ble de d compression 2 N B Enduire de graisse base de savon au lithium l extr mit du c ble d embrayage et l extr mit du c ble de d compression 9 R gler Jeu du levier d...

Page 542: ...r removal Hold the machine by placing the suitable stand under the engine Number plate Handlebar Cable guide Front fender Refer to HANDLEBAR section 1 Steering stem nut 1 2 Front fork 2 Refer to FRONT...

Page 543: ...pla ant un support appropri sous le moteur Plaque de num ro Guidon Guide de c ble Garde boue avant Se reporter la section GUIDON 1 Ecrou de colonne de direction 1 2 Fourche avant 2 Se reporter la sect...

Page 544: ...t fall down Steering nut wrench YU 33975 90890 01403 Lower bearing 1 Remove Lower bearing 1 Use the floor chisel 2 ACHTUNG CAUTION Take care not to damage the steering shaft thread EC563400 Ball race...

Page 545: ...rou cr nel de directione YU 33975 90890 01403 Roulement inf rieur 1 D poser Roulement inf rieur 1 Utiliser un burin 2 ATTENTION Veiller ne pas endommager le file tage de l arbre de direction Cage bill...

Page 546: ...their operation in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Lower bearing 1 NOTE Apply the lithium soap base grease on the dus...

Page 547: ...ur 1 Monter Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint antipous si re et sur la circonf rence interne du roulement 2 Monter Cage billes Roulement...

Page 548: ...kg 5 1 ft lb 5 Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 Install Washer 1 7 Install Front fork 1...

Page 549: ...er la colonne de direction en la tournant d une but e l autre S il y a un point dur reti rer l ensemble colonne de direc tion et inspecter les roulements de direction 6 Monter Rondelle 1 7 Monter Four...

Page 550: ...g nut little by little 10 Adjust Front fork top end a Front fork top end standard a 5 mm 0 20 in 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 ACHTUNG CAUTION Tighten the lower brac...

Page 551: ...Extr mit sup rieure de four che avant a 11 Serrer Boulon de bridage t sup rieur 1 Boulon de bridage t inf rieur 2 ATTENTION Resserrer le t inf rieur au couple sp cifi S il est trop serr la fourche ava...

Page 552: ...falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Rear brake caliper Bolt brake pedal Drive chain Refer to FRONT BRAKE AND REAR BR...

Page 553: ...den Ausbau Das Motorrad am Motor aufbocken Bremsschlauch Halterung Bremssattel hinten Schraube Fu bremshebel Antriebskette Siehe unter VORDER UND HINTERRAD BREMSE Den Fu bremshebel zur ckklappen 1 Ant...

Page 554: ...necting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil se...

Page 555: ...age du bras de relais Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DU BRAS OSCILLANT 1 Capuchon 2 2 Bras relais 1 3 Bielle 1 4 Collerette 2 5 Bague d tanch it 2 6 Roulement de b...

Page 556: ...ree play exists unsmooth revolution rust Replace bearing and bushing as a set 2 Inspect Oil seal 3 Damage Replace EC574210 Relay arm 1 Inspect Bearing 1 Collar 2 Free play exists unsmooth revolution r...

Page 557: ...ule ment et la bague 2 Contr ler Bague d tanch it 3 Endommagement Changer Bras de relais 1 Contr ler Roulement 1 Collerette 2 Jeu rotation irr guli re rouille Remplacer la fois le roule ment et la col...

Page 558: ...stalled depth of bearings Outer a Zero mm Zero in Inner b 8 5 mm 0 33 in 2 Install Bearing 1 Oil seal 2 To relay arm NOTE Apply the molybdenum disulfide grease on the bearing when installing Install t...

Page 559: ...ppliquer une graisse au bisulfure de molybd ne sur le roulement lors de la repose Installer le roulement en appuyant sur le c t o figurent les rep res ou num ros du fabricant 3 Monter Roulement 1 Bagu...

Page 560: ...oil seal lips 3 Install Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the collar bearings and oil seal lips 4 Install Connecting rod 1 Bolt connecting rod 2 Washer 3 Nut c...

Page 561: ...e 1 Sur la bielle 2 N B Appliquer de la graisse au bisulfure de molybd ne sur la collerette les roule ments et les l vres de bague d tan ch it 4 Monter Bielle 1 Boulon bielle 2 Rondelle 3 Ecrou bielle...

Page 562: ...8 5 m kg 61 ft lb 7 Check Swingarm side play a Free play exists Replace thrust bear ing Swingarm up and down movement b Unsmooth movement binding rough spots Grease or replace bearings bushings and c...

Page 563: ...t a Jeu Remplacer le roulement de but e Mouvement de bas en haut du bras oscillant b Mouvement irr gulier coince ment point dur Graisser ou changer les roulements bagues et collerettes T R 85 Nm 8 5 m...

Page 564: ...mark a facing forward 13 Install Bolt lower chain tensioner 1 Washer 2 Collar 3 Lower chain tensioner 4 Nut lower chain tensioner 5 T R 19 Nm 1 9 m kg 13 ft lb 14 Install Drive chain case 1 Drive cha...

Page 565: ...ur inf rieur de cha ne 4 Ecrou tendeur inf rieur de cha ne 5 T R 19 Nm 1 9 m kg 13 ft lb 14 Monter Carter de cha ne de transmis sion 1 Couvercle de carter de cha ne de transmission 2 Boulon carter de...

Page 566: ...the engine WARNING Support the machine securely so there is no danger of it falling over Seat Refer to SEAT FUEL TANK AND SIDE COVERS section Silencer Refer to EXHAUST PIPE AND SILENCER section in th...

Page 567: ...ET CACHES LATERAUX Silencieux Se r f rer la section TUYAU D ECHAPPEMENT ET SILENCIEUX du CHAPITRE 4 1 Boulon r servoir 1 2 Bride raccord de filtre air 1 Desserrer uniquement 3 Cadre arri re 1 4 Boulo...

Page 568: ...5 58 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 10 Upper spring guide 1 11 Spring rear shock absorber 1 12 Bearing 2 Refer to REMOVAL POINTS 2...

Page 569: ...2 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 10 Oberer Federsitz 1 11 Feder Federbein 1 12 Lager 2 Siehe unter AUSBAU 2 AMORTISSEUR ARRIERE FEDERBEIN AMMORTIZZATORE POSTERIORE Portata de...

Page 570: ...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 surface of t...

Page 571: ...fonctionnement 4 Prendre garde 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 situ au bas du r servoir azote Il es...

Page 572: ...E Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear...

Page 573: ...ortisseur arri re 1 Contr ler Tige d amortisseur 1 D form e endommagement Remplacer le combin ressort amortisseur Amortisseur 2 Fuite d huile Remplacer le combin ressort amortisseur Fuite de gaz Rempl...

Page 574: ...ause it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it con...

Page 575: ...lement 2 Monter Bague d arr t roulement sup rieur 1 N B Apr s avoir install la bague d arr t repousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter Roulement inf rieur 1 N B Monter le...

Page 576: ...to turn the adjuster beyond the maximum or minimum setting 4 Tighten Locknut 1 Rear shock absorber 1 Install Dust seal 1 O ring 2 Collar 3 NOTE Apply the molybdenum disulfide grease on the bearing App...

Page 577: ...tre crou 1 Longueur de ressort mont a Longueur stan dard Etendue de r glage 248 mm 9 76 in 262 mm 10 31 in 242 260 mm 9 53 10 24 in 257 275 mm 10 12 10 83 in Amortisseur arri re 1 Monter Joint antipou...

Page 578: ...rear shock absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Washer 1 Bolt rear shock absorber relay arm 2 NOTE Apply the molybdenum di...

Page 579: ...uer de la graisse de molybd ne sur le boulon 5 Monter Rondelle 1 Boulon amortisseur arri re bras de relais 2 N B Appliquer de la graisse de molybd ne sur le boulon Ins rer le boulon partir de la droit...

Page 580: ...ch 4 CDI magneto 5 Spark plug 6 Ignition coil 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red EC612000 WIRING DIAGRAM 7 1 6 5 2 3 4 L Y B Y L B L L G P W R Y B G B R P Br W...

Page 581: ...NTS ELECTRIQUES 1 Couper circuit du moteur 2 Capteur de papillon des gaz 3 Contacteur de point mort 4 Magn to CDI 5 Bougie 6 Bobine d allumage 7 Bloc CDI CODE DE COULEUR B Noir Br Brun G Vert L Bleu O...

Page 582: ...CDI unit as a throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the throttle p...

Page 583: ...aleurs dans le microprocesseur du bloc CDI Bobine d excitation Rep re le nombre de tours effectu s par le rotor et entre la valeur dans le microprocesseur du bloc CDI Bloc CDI Les valeurs obtenues du...

Page 584: ...nposition und sendet ein Drosselklap pen ffnungssignal an den CDI Z ndbox Mikroprozessor Impulsgeber berwacht den Impulsgeber Rotor und sendet ein Motordrehzahlsi gnal an den CDI Z ndbox Mikroprozesso...

Page 585: ...pertura della valvola a farfalla Bobina pickup Rileva i giri del rotore ed invia al computer nell unit CDI i segnali dei giri del motore Unit CDI I segnali del sensore di posizione della valvola a far...

Page 586: ...l tank Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark plug Chec...

Page 587: ...ant Se servir de l outil sp cial suivant Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler toutes connexions du syst me d allumage R parer ou remplacer Contr ler le coupe circuit d...

Page 588: ...ern Die gesamte Lichtanlage auf einwandfreie Verbin dungen berpr fen Erneuern oder instand setzen Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuern Sekund r spule...

Page 589: ...amicit della scintilla YM 34487 Tester dell accensione 90890 06754 Tester tascabile YU 3112 C 90890 03112 Test della distanza tra gli elettrodi Pulire o sostituire la candela Controllare il collegamen...

Page 590: ...ine and increase spark gap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust...

Page 591: ...uise unique ment USA et CDN Longueur d tincelle mini mum 6 0 mm 0 24 in CONTROLE DES CONNEXIONS DE COUPLEURS ET FILS 1 Contr ler Connexion de coupleurs et fils Rouille poussi re jeu court cir cuit R p...

Page 592: ...y coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis tance remove the spark plug cap CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specificatio...

Page 593: ...e capuchon de bou gie CONTROLE DU VOLANT MAGNE TIQUE 1 V rifier R sistance de bobine d excita tion Hors sp cification Rempla cer Fil de multim tre Fil de bougie 1 Fil de multim tre Fil orange 2 R sist...

Page 594: ...d Pink lead 1 Tester lead Black lead 2 Charging coil 2 resistance Tester selector position 44 66 at 20 C 68 F 10 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No continuous while in neutr...

Page 595: ...charge 2 Position de s lecteur de multim tre 44 66 20 C 68 F 10 CONTROLE DU CONTACTEUR DE POINT MORT 1 V rifier Continuit du contacteur de point mort Pas de continuit quand au point mort Remplacer Co...

Page 596: ...inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 08036 B Engine tachometer 90890 03113 Check entire ignition...

Page 597: ...de carburant Utiliser les outils sp ciaux suivants dans ce d pistage des pannes V rifier la connexion de tout le syst me d allumage R parer ou remplacer V rifier le capteur de papillon des gaz Bobine...

Page 598: ...erwenden Die gesamte Z ndanlage auf Anschlu berpr fen Erneuern oder instand setzen Den Drosselklappen Positi onssensor pr fen Drosselklap pen Positions sensor Spule Erneuern Den CDI Schwungrad Magnetz...

Page 599: ...Utilizzare i seguenti utensili speciali in questa ispezione Tester tascabile YU 3112 C 90890 03112 Contagiri induttivo YU 08036 B Contagiri motore 90890 03113 Controllare il collegamento dell intero s...

Page 600: ...le shaft is in the full close position Tester lead Blue lead 1 Tester lead Black lead 2 Throttle posi tion sensor coil resistance Tester selector position 4 6 k at 20 C 68 F k 1 3 Inspect Throttle pos...

Page 601: ...variable de la bobine du capteur de papillon des gaz S assurer que la r sistance aug mente lorsque la poign e des gaz est tourn e de la position de fermeture compl te la position d ouverture compl te...

Page 602: ...ttle position sen sor with the projection b on the carburetor Temporarily tighten the screws throttle posi tion sensor 4 Adjust Engine idling speed Refer to ENGINE IDLE SPEED ADJUSTMENT section in the...

Page 603: ...ne du capteur de papillon des gaz est de 5 k la r sis tance de la bobine du capteur de papillon des gaz au ralenti sera 5 k 0 13 0 15 650 750 Voir la section CONTR LE DE LA BOBINE DU CAPTEUR DE PAPILL...

Page 604: ...position sensor 1 NOTE Tighten the screws throttle position sensor using the T20 bit tamper resistant fastener type 8 Install Throttle position sensor coupler THROTTLE POSITION SENSOR INPUT VOLTAGE I...

Page 605: ...D brancher la fiche rapide du capteur de papillon des gaz 2 D marrer le moteur 3 Contr ler Tension d entr e du capteur de papillon des gaz Hors sp cifications Rempla cer le bloc CDI Fil de multin tre...

Page 606: ...est possi ble carburetor setting NOTE It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to make futu...

Page 607: ...r glages de carbura teur ult rieurs il est utile de conserver toutes les donn es c d les r glages correspondant aux diverses conditions atmosph riques conditions du terrain les temps etc AVERTISSEMENT...

Page 608: ...ed starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carb...

Page 609: ...e des gaz fonctionne correctement Conditions atmosph riques et r gla ges de carburateur La densit de l air c d la concen tration d oxyg ne dans l air d ter mine la richesse ou la pauvret de l mulsion...

Page 610: ...FLATCR carburetor has a primary main jet This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel even at full load The main air jet has almost no effect on the...

Page 611: ...de gicleur principal convient parfaitement au motos de course dans la mesure o il uniformise le d bit d essence m me plein rendement Le gicleur d air princi pal n a presqu aucun effet sur l mulsion a...

Page 612: ...djustment The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor acce...

Page 613: ...mulsion air essence pleine ouverture des gaz Une mulsion air essence trop riche ou trop pauvre provoquera une perte de puissance du moteur et par cons quent une mauvaise acc l ration Effets du change...

Page 614: ...flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num...

Page 615: ...sine afin de maximiser le flux de carburant petite ouverture des gaz Avant de r gler la vis de ralenti la visser tout fait et compter le nombre de tours n cessaires Noter ce chiffre car il s agit du r...

Page 616: ...the engine will not pick 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...

Page 617: ...uille redescende 2 Trop pauvre des vitesses inter m diaires Le moteur crachote et acc l re trop lentement Il faut enrichir l mulsion en abaissant d un cran le clip d accrochage de l aiguille afin de r...

Page 618: ...arged by the accelerator pump Since the accelerator pump operates only when throttle is open the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different f...

Page 619: ...gler le m lange du carburant lors d une ouverture rapide du papillon et diff re en ceci des autres pi ces servant r gler le m lange de car burant chaque ouverture du papillon pour chaque vitesse du mo...

Page 620: ...ain system is controlled by the main jet and then it is further regulated by the area between the main nozzle and the jet needle The fuel flow relates to the diameter of the straight portion of the je...

Page 621: ...tr l par le gicleur principal ainsi que par la distance entre le diffuseur et l aiguille Le d bit d pend du diam tre de la portion droite de l aiguille une ouverture des gaz de 1 8 1 4 et d pend de la...

Page 622: ...07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Jet needle Rich STD Lean OBELL OBELM OBELN OBELP OBELQ OBELR OBELS 5NL 14916 EL 5NL 14916 EM 5NL 14916 EN 5NL 14916 EP...

Page 623: ...8 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Aiguille Riche Standard Pauvre OBELL OBELM OBELN OBELP OBELQ OBELR OBELS 5NL 14916 EL 5NL 14916 EM 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1 5NL 1...

Page 624: ...op Check that the accelerator pump oper ates smoothly except for rich mixture symptom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet ne...

Page 625: ...pe d acc l ration sauf sympt me d un m lange trop riche Emulsion riche Remonter la position du clip d aiguille 1 cran plus haut Ouverture de 1 4 3 4 Crachotements Pas de puissance Abaisser la position...

Page 626: ...an numeriert Pr fen ob die Beschleunigungspumpe korrekt arbeitet au er bei fettem Gemisch Fettes Gemisch D sennadel Clip Position erh hen 1 Nut h her 1 4 3 4 Gas Schweres Atmen Drehzahl unzureichend D...

Page 627: ...a agevolmente tranne in caso di sintomi di miscela ricca Miscela ricca Alzare la posizione del fermaglio a graffa del getto di 1 scanalatura Valvola a farfalla a 1 4 3 4 Respirazione difficoltosa Manc...

Page 628: ...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 making notes of lap times to find the best balance then determin...

Page 629: ...donn et il faudra en sacrifier quelques uns Il convient de r gler la machine en fonction de la partie la plus importante du circuit Effectuer des essais et noter les temps pour les diff rentes parties...

Page 630: ...ure Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact with...

Page 631: ...ur surface boueuse sablonneuse ou glis sante r duire la pression des pneus pour une meilleure adh sion sur le ter rain Sur route pav e ou sur surface dure augmenter la pression des pneus afin d viter...

Page 632: ...racteristic near the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produc...

Page 633: ...le con ducteur ressent une certaine pression dans ses mains ou son corps De m me un niveau d huile trop lev produira rapidement un bouchon d huile entra nant une r duction de la course de la fourche...

Page 634: ...3 2 adjustment washers Standard washer quantity Zero adjustment washers Extent of adjustment Zero 2 adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be eas...

Page 635: ...mplace ment La suspension arri re influence les r gla ges de la fourche avant il convient donc d quilibrer l arri re et l avant de la machine la position etc avant d effec tuer les r glages 1 Ressort...

Page 636: ...ecome weaker resulting in lack of a sense of contact with the road surface or in a vibrating handlebar To set a stiff spring Change the rebound damping Turn in one or two clicks Change the compression...

Page 637: ...on de contact avec la sur face de la route ou un guidon nage R glage d un ressort dur R gler la force de rebond Visser d un ou deux d clics R gler la force de compression D visser d un ou deux d clics...

Page 638: ...thickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 380 0 390 0 400 0 410 0 420 0 430 4SS 23141 10 4SS 23141 20 4SS 23141 30 4SS 23141 40 4SS...

Page 639: ...PE paisseur Num ro de pi ce T 2 3 mm 0 09 in 4SS 23364 L0 Type Cons tante du ressort Num ro de pi ce de ressort Rep re fen tes MOU 0 380 0 390 0 400 0 410 0 420 0 430 4SS 23141 10 4SS 23141 20 4SS 231...

Page 640: ...ing EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender holding...

Page 641: ...ntre le centre de l axe de roue arri re et le boulon de fixation du garde boue arri re 2 Retirer le support ou le bloc et mesurer avec une personne assise correctement sur la selle la longueur b entre...

Page 642: ...ength sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Set the soft spring for less rebound damping to compensate for its less spring load Run with the rebound damping adjuster one o...

Page 643: ...ensuite selon ses pr f rences 2 Ressort dur R gler le ressort dur de sorte ce que la force de rebond soit plus lev e afin de compenser la charge du ressort plus grande Rouler apr s avoir viss le dispo...

Page 644: ...e the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider wei...

Page 645: ...er un amortisseur dont la longueur totale est sup rieure la longueur standard Ressort recommand en fonction du poids Poids du motocycliste 1 Mou 2 Standard 3 Dur Longueur standard a d amatisseur arri...

Page 646: ...5DH 22212 10 Brown 1 Green 1 260 260 STD 4 8 5DH 22212 20 Red 1 260 STIFF 5 0 5 2 5 4 5 6 5DH 22212 30 5DH 22212 40 5DH 22212 50 5DH 22212 60 Black 1 Blue 1 Yellow 1 Pink 1 260 260 265 265 TYPE SPRIN...

Page 647: ...TD 4 8 5DH 22212 20 Rouge 1 260 DUR 5 0 5 2 5 4 5 6 5DH 22212 30 5DH 22212 40 5DH 22212 50 5DH 22212 60 Noir 1 Bleu 1 Jaune 1 Rose 1 260 260 265 265 Type Cons tante du res sort appro x Num ro de pi ce...

Page 648: ...ssion damping Oil level oil amount Spring Turn adjuster clockwise about 2 clicks to increase damping Increase oil level by about 5 10 mm 0 2 0 4 in Replace with stiff spring Stiff toward stroke end Oi...

Page 649: ...dragging Rebound damping Spring Turn adjuster counterclockwise about 2 clicks to decrease damping Replace with soft spring Poor road gripping Rebound damping Low compression damping High compression...

Page 650: ...uilles d une montre de 2 d clics pour augmenter l amortissement Augmenter le niveau d huile d environ 5 10 mm 0 2 0 4 in Monter un ressort dur Dur en fin de course Niveau d huile quantit d huile R dui...

Page 651: ...d clics pour r duire l amortissement Monter un ressort doux Mauvaise tenue de route Force de rebond Amortissement basse com pression Amortissement haute com pression Longueur de ressort Ressort Tourn...

Page 652: ...d lmenge Feder Einsteller um etwa 2 Rasten im Uhrzeigersinn dre hen um die D mpfungskraft zu erh hen lstand um etwa 5 10 mm erh hen H rtere Feder einbauen Hart gegen Ende des Federwegs lstand lmenge l...

Page 653: ...teller um etwa 2 Rasten gegen den Uhrzeiger sinn drehen um die D mpfungskraft zu verringern Weichere Feder einbauen Schlechte Fahrbahn haftung Zugstufend mpfung Tiefdruckd mpfung Hochdruckd mpfung Fed...

Page 654: ...so orario circa 2 scatti per aumentare lo smorzamento Aumentare il livello dell olio di circa 5 10 mm 0 2 0 4 in Sostituire con una molla rigida Rigida verso la fine della corsa Livello dell olio quan...

Page 655: ...registro in senso antiorario circa 2 scatti per ridurre lo smorzamento Sostituire con una molla morbida Scarsa presa sulla strada Smorzamento di espansione Smorzamento di compressione bassa Smorzamen...

Page 656: ...PRINTED IN JAPAN 2000 9 3 5 1 CR PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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