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


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INSP

ADJ

DRIVE CHAIN SLACK ADJUSTMENT

5. Install:

●

Drive chain 

1

 

●

Joint 

2

 

●

Master link clip 

3

 

CAUTION:

Be sure to install the master link clip to the
direction as shown.

a

Turning direction

6. Lubricate:

●

Drive chain

Drive chain lubricant:

SAE 10W-30 motor oil or suit-
able chain lubricants

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 specification 

→

 Adjust.

NOTE:

Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight-
est point. Check and/or adjust the drive chain
slack with the rear wheel in this “tight chain”
position.

Drive chain slack:

40 ~ 50 mm (1.6 ~ 2.0 in)

Summary of Contents for YZ250F(P)/LC

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

Page 2: ...NER S SERVICE MANUAL 2001 by Yamaha Motor Co Ltd 1st Edition August 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohi...

Page 3: ...ELIER DU PROPRIETAIRE 2001 Yamaha Motor Co Ltd 1 re dition ao t 2001 Tous droits r serv s Toute reimpression ou utillisation sans la permission crite de la Yamaha Motor Co Ltd est formellement interdi...

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: ...Arbeiten 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...

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 15 TORQUE CHECK POINTS 1 19 CLEANING AND STORAGE 1 20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITI...

Page 21: ...RIFICATION DE COUPLE DE SERRAGE 1 19 NETTOYAGE ET RANGEMENT 1 20 CHAPITRE 2 CARACTERISTIQUES CARACTERISTIQUES GENERALES 2 1 CARACTERISTIQUES D ENTRETIEN 2 4 CARACTERISTIQUES GENERALES DE COUPLE 2 17 D...

Page 22: ...CH 4 49 OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 4 56 BALANCER 4 63 OIL PUMP 4 66 KICK SHAFT AND SHIFT SHAFT 4 71 CDI MAGNETO 4 78 ENGINE REMOVAL 4 82 CRANKCASE AND CRANKSHAFT 4 87 TRAN...

Page 23: ...RTER DROIT 4 56 BALANCIER 4 63 POMPE A HUILE 4 66 ARBRE DE KICK ET ARBRE DE SELECTEUR 4 71 VOLANT MAGNETIQU CDI 4 78 DEPOSE DU MOTEUR 4 82 CARTER ET VILEBREQUIN 4 87 BOITE A VITESSES TAMBOUR ET FOURCH...

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: ...nk 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...

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: ...o 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 9...

Page 39: ...tachometer Engine tachometer This tool is needed for observing engine rpm YU 8036 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: ...l 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...

Page 42: ...pour observer la vitesse de rotation du moteur YU 8036 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: ...m 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 12...

Page 45: ...8036 B 90890 03113 Induktivdrehzahlmesser Motor Drehzahlmesser Zur Ermittlung der Motordrehzahl YU 8036 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: ...o 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 0123...

Page 48: ...Questo strumento utilizzato per controllare la velocit del motore YU 8036 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: ...IDESTAND This sidestand 1 is used to support only the machine when standing or transporting it WARNING Never apply additional force to the side stand Remove this sidestand before starting out FLAP In...

Page 57: ...s e pour soutenir la machine uniquement l arr t ou durant le transport AVERTISSEMENT Ne jamais la soumettre une force suppl mentaire D gager la b quille lat rale avant de rouler BAVETTE Pour viter tou...

Page 58: ...use of leaded gasoline will cause severe damage to the engine internal parts such as valves piston rings and exhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or...

Page 59: ...aux parties internes du moteur valves segments de piston syst me d chappement etc N B Si un cognement ou un cliquetis sur vient utiliser une marque d essence dif f rente ou une classe d octane sup ri...

Page 60: ...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 operation check list STARTI...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 G...

Page 66: ...1 2 open low to medium 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...

Page 67: ...ier 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...

Page 68: ...ring stem to upper 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 ab...

Page 69: ...direction 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 timon...

Page 70: ...abel 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 Umlenkhebe...

Page 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...rer 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...

Page 78: ...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 79: ...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 80: ...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 8 mm 0 0315 in EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565...

Page 81: ...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 82: ...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 83: ...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 MX3...

Page 84: ...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 85: ...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 86: ...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 8 0 8 5 8 Kick shaft ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank M...

Page 87: ...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 in R...

Page 88: ...ad 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 24...

Page 89: ...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 90: ...lay 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 absorber and frame M10 1 25 1 56 5 6 40 Rear shock abs...

Page 91: ...68 F Black Pink Pickup coil resistance color 248 372 at 20 C 68 F White Red CDI unit model manufacturer 5SG 00 YAMAHA Ignition coil Model manufacturer 4SR 00 YAMAHA Minimum spark gap 6 mm 0 24 in Pri...

Page 92: ...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 93: ...e 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 1...

Page 94: ...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 nement par...

Page 95: ...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 96: ...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 97: ...1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in ECH 0 9 1 1 mm 0 0354 0 0433in 1 6 mm 0 0630 in D paisseur de rebord AD 0 8 mm 0 0315 in ECH 0 7 mm 0 0276 in Diam tre ext rieur de queue AD 3 975 3 990 mm 0 1...

Page 98: ...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 99: ...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 80 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 h...

Page 100: ...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 5SG1 00 5SG2 10 Gicleur p...

Page 101: ...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 102: ...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 103: ...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 8 0 8 5 8 Guide de rochet d arbre de kick M6 1 0 2 12 1 2 8 7 P dale de kick M8 1 25 1...

Page 104: ...r 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 0 20...

Page 105: ...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 245 4 0 mm 9 65 0 16...

Page 106: ...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 107: ...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 53 5 3 38 Cadre arri re M8 1 25 3 29 2 9 21 Bras oscillant et...

Page 108: ...xcitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bloc CDI 5SG 00 YAMAHA Bobine d allumage Mod le fabricant 4SR 00 YAMAHA Longueur minimum d tincelle 6 mm 0 24 in R sistance de l enr...

Page 109: ...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 110: ...7 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 20W...

Page 111: ...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 112: ...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 113: ...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 114: ...6 mm Ausla 0 9 1 1 mm 1 6 mm Ventiltellerst rke D Einla 0 8 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 115: ...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 116: ...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 117: ...ngenschlag 0 05 mm Kickstarter Bauart Rastenmechanismus Vergaser Modell Hersteller FCR MX37 KEIHIN Kennzeichnung 5SG2 10 Hauptd se M J Nr 178 Hauptluftd se M A J Nr 200 D sennadel J N OBEKP 4 Konus C...

Page 118: ...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 119: ...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 120: ...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 8 0 8 Kickstarter Rastenradf hrung M6 1 0 2 12 1 2 Kickstar...

Page 121: ...m 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 oberen...

Page 122: ...ke 250 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...

Page 123: ...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 124: ...elaisarm 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 mpfer und Relaisarm M10 1 25 1 53 5 3 Hinterer Rahm...

Page 125: ...rregerspule 2 44 66 bei 20 C schwarz rosa Impulsgeber Widerstand Farbe 248 372 bei 20 C wei rot CDI Z ndbox Typ Hersteller 5SG 00 YAMAHA Z ndspule Typ Hersteller 4SR 00 YAMAHA Min Z ndfunkenstrecke 6...

Page 126: ...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 2...

Page 127: ...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 compres...

Page 128: ...ettrodi 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 Tr...

Page 129: ...anteriore Forcella telescopica Sospensione posteriore Forcellone oscillante sospensione monocross di tipo a biscottino Ammortizzatore Ammortizzatore anteriore Molla elicoidale ammortizzatore a olio A...

Page 130: ...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 131: ...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 8 mm 0 0315 in EXT 0 7 mm 0 0276 in Diametro esterno st...

Page 132: ...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 133: ...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 134: ...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 Ma...

Page 135: ...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 136: ...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 137: ...Bullone di scarico olio dal carter M10 1 25 1 20 2 0 14 Carterino corona catena di trasmissione M6 1 0 2 8 0 8 5 8 Guida arpionismo albero a pedale M6 1 0 2 12 1 2 8 7 Avviamento a pedale M8 1 25 1 3...

Page 138: ...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 Estr...

Page 139: ...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 140: ...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 141: ...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 Biella e telaio M14 1 5 1 80 8 0 58 Ammortizzatore posteriore e telai...

Page 142: ...sistenza bobina pickup colore 248 372 a 20 C 68 F Bianco Rosso Modello costruttore unit CDI 5SG 00 YAMAHA Bobina di accensione Modello costruttore 4SR 00 YAMAHA Distanza minima scintilla 6 mm 0 24 in...

Page 143: ...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 144: ...of the sub wire harness Fasten the sub wire harness and engine stop switch lead Fasten the engine stop switch lead at its protecting tube Fasten the sub wire harness Pass the sub wire harness between...

Page 145: ...e protection Attacher le faisceau de fils secondaire Faire passer le faisceau de fils secondaires entre les supports sup rieurs du moteur Attacher le faisceau de fils secondaires au ruban blanc Attach...

Page 146: ...oss 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 absorber Pass the neutral switch lea...

Page 147: ...ection 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 Faire passer le fil du commutateur de point mort et le fil d...

Page 148: ...ss the throttle cables through the cable guide Pass the throttle cables and CDI unit lead through the cable guide Pass the throttle cables under the radiator mounting boss Insert the CDI unit band ove...

Page 149: ...montage du radiateur Ins rer 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...

Page 150: ...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 151: ...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 152: ...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 153: ...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 154: ...NT 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 t...

Page 155: ...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 156: ...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 looseness Retighten sprocket...

Page 157: ...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 158: ...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 159: ...rrer 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 le voile de r...

Page 160: ...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 161: ...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 162: ...en SCHWINGE Pr fen schmieren und nachziehen Molybd ndisulfidfett ver wenden UMLENK UND BERTRAGUNGS HEBEL Pr fen schmieren und nachziehen Molybd ndisulfidfett ver wenden LENKKOPF Spiel pr fen und nachz...

Page 163: ...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 164: ...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 165: ...TO DELLO STERZO Controllarne il gioco libero e serrare Pulire e lubrificare Sostituire il cuscinetto Grasso a base di litio PNEUMATICI RUOTE Controllare la pressione dell aria il disassamento della ru...

Page 166: ...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 167: ...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 168: ...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 169: ...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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...replace Radiator hose 3 Swelling Replace CLUTCH ADJUSTMENT 1 Check Clutch lever free play a Out of specification Adjust Clutch lever free play a 8 13 mm 0 31 0 51 in 2 Adjust Clutch lever free play N...

Page 179: ...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 8 13 mm 0 31 0 51 in 2 R gler Jeu de levier d embrayag...

Page 180: ...ould be adjusted When the motorcycle is accelerating throttle cable 1 3 is pulled and throttle cable 2 4 is pushed 1st step Loosen the locknuts 5 on throttle cable 2 Adjust the free play by changing t...

Page 181: ...1 re tape Desserrer les contre crous 5 du c ble des gaz n 2 R gler le jeu en modifiant leur ser rage 2 me tape Desserrer les contre crous 6 du c ble des gaz n 1 R gler le jeu en modifiant leur ser rag...

Page 182: ...0 4 m kg 2 9 ft lb DECOMPRESSION 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 scr...

Page 183: ...T R 4 Nm 0 4 m kg 2 9 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 e...

Page 184: ...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 185: ...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 186: ...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 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...eur 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 Imp q...

Page 196: ...he 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 For EUROPE Adjustment steps NOTE To optimize the fuel flow at a smaller thr...

Page 197: ...e 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 pression...

Page 198: ...ease idle speed Turn the throt tle stop screw 1 out b Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Engine idling speed 1 900 2 100 r min VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE...

Page 199: ...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 8036...

Page 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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 205: ...orrecte 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...

Page 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...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 214: ...the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position 4 Install Brake lever cover Brake lev...

Page 215: ...quand les bulles du syst me ont disparu j Remettre niveau le fluide de frein dans le r servoir AVERTISSEMENT V rifier le fonctionnement du frein apr s avoir purg le circuit de frei nage Position du le...

Page 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...ION 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 drive chain from the kerosene and dry the drive chai...

Page 227: ...ansmission 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 de transmission du k ros ne et la s cher 3 Mesurer Longueur de...

Page 228: ...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 specification A...

Page 229: ...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 au r glage faire tou...

Page 230: ...nment There are marks a on each side of the drive chain puller alignment NOTE Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear CAUTION Too small drive cha...

Page 231: ...alignement cor rect de la roue Les rep res a figurent de chaque c t sur les ten deurs de cha ne de transmission N B Tourner le tendeur pour que la cha ne de transmission soit align e avec la couronne...

Page 232: ...rease on the inner tube FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff dur ing a run relieve the front fork internal pres sure 1 Elevate the front wheel by...

Page 233: ...d tanch it b N B Nettoyer 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 PURGE DE L AIR DE LA FOUR CHE AVANT N B Si...

Page 234: ...each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum posi tion S...

Page 235: ...entra ner une mauvaise maniabilit et une perte de stabilit Plage de r glage Maximum Minimum Position compl tement viss e Desserrer de 20 d clics partir du r glage maxi mum Position standard Desserrer...

Page 236: ...Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handli...

Page 237: ...um au risque de l endommager AVERTISSEMENT Toujours 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 sta...

Page 238: ...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 setti...

Page 239: ...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 glage au...

Page 240: ...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 241: ...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 242: ...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 243: ...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 244: ...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 245: ...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 246: ...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 kgf cm2 15 psi EC36S0...

Page 247: ...ndique 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 stan...

Page 248: ...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 steering...

Page 249: ...vant 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 direction 4 R gle...

Page 250: ...eck 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 handlebar 7...

Page 251: ...que retirer l ensemble colonne de direction et inspecter le support de direction Remettre en place le support sup rieur 5 l crou d arbre direction 6 le guidon 7 le support sup rieur de guidon 8 et la...

Page 252: ...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 253: ...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 254: ...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 255: ...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 256: ...ng light YM 33277 A 90890 03141 Inductive tachometer YU 8036 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 257: ...ampe YM 33277 A 90890 03141 Induktivdrehzahlmes ser YU 8036 B Motor Drehzahlmesser 90890 03113 Arbeitsschritte Motor anlassen einige Minuten warmlaufen lassen und dann mit der vorgeschriebenen Dreh za...

Page 258: ...emoval 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 ba...

Page 259: ...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 260: ...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 261: ...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 262: ...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 263: ...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 264: ...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 265: ...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 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 Throttle cable cap 1 6 Clamp air...

Page 271: ...ride 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 Capuchon du logement du c ble des gaz 1 6 Bride raccord de filtre a...

Page 272: ...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 273: ...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 274: ...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 275: ...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 276: ...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 277: ...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 278: ...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 279: ...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 280: ...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 281: ...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 282: ...ccelerator 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 AND...

Page 283: ...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 MONTAGE Carbu...

Page 284: ...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 285: ...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 286: ...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 287: ...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 288: ...s 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 5 8 turns out 1 1 2 turns out example 13 Install O ring Leak...

Page 289: ...la d pose Vis de ralenti 1 5 8 tours en arri re 1 1 2 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 v...

Page 290: ...Valve lever housing cover 2 Bolt valve lever housing cover 3 18 Install Carburetor breather hose 1 NOTE Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where...

Page 291: ...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 ne se plie pas l endroit o il est install R glage de l avance de la pompe d acc...

Page 292: ...no more free play Carburetor installation 1 Install Carburetor joint 1 NOTE Install the projection a on the cylinder between the carburetor joint slots b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Carburet...

Page 293: ...e carburateur 1 N B Monter la saillie a du cylindre entre les fentes du raccord de carburateur b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Monter Carburateur 1 N B Monter l extr mit du support de c ble d acc l ra...

Page 294: ...n the CHAPTER 3 7 Install Throttle cable cover 1 Screw throttle cable cover 2 NOTE Install the throttle cable cover with its pawl a hung on the carburetor 1 2 a T R 4 Nm 0 4 m kg 2 9 ft lb 8 Install T...

Page 295: ...les des gaz en veillant ce que son linguet a soit accroch au carburateur T R 4 Nm 0 4 m kg 2 9 ft lb 8 Monter Fiche rapide de fil de capteur de position de papillon des gaz 1 Bride 2 Se reporter la se...

Page 296: ...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 297: ...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 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...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 304: ...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 305: ...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 306: ...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 307: ...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 308: ...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 309: ...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 310: ...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 311: ...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 312: ...4 28 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 313: ...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 314: ...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 315: ...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 316: ...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 317: ...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 318: ...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 319: ...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 320: ...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 321: ...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 322: ...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 323: ...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 324: ...lve 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 325: ...e 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 r...

Page 326: ...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 327: ...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 328: ...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 329: ...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 330: ...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 331: ...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 332: ...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 333: ...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 334: ...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 335: ...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 336: ...a color Valve lifter mark b color Red Red Blue Blue Yellow Yellow Purple Black ASSEMBLY AND INSTALLATION Valve and valve spring 1 Apply Molybdenum disulfide oil Onto the valve stem and valve stem seal...

Page 337: ...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 338: ...alve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 4019 90890 04019 5 Install Adjusting pad 1 Valve lifter 2 NOTE Apply...

Page 339: ...mpresseur de ressort de soupape YM 4019 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 pouss...

Page 340: ...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 341: ...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 342: ...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 343: ...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 344: ...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 345: ...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 346: ...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 347: ...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 348: ...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 349: ...a 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 a...

Page 350: ...s ton 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 fro...

Page 351: ...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 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ...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 359: ...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 360: ...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 361: ...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 362: ...the groove a of the push lever shaft and tighten the bolt seat plate 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 the...

Page 363: ...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 364: ...ll the clutch plates and 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 a...

Page 365: ...noix d 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 Appliq...

Page 366: ...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 367: ...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 368: ...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 369: ...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 370: ...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 371: ...droit 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 Alloggiame...

Page 372: ...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 373: ...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 374: ...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 375: ...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 376: ...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 377: ...rotor tout en le tournant Maintenir l arbre de rotor par les zones lat rales aplaties a au moyen d une cl etc et monter la turbine de pompe T R 14 Nm 1 4 m kg 10 ft lb Demi carter droit 1 Monter Goup...

Page 378: ...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 379: ...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 380: ...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 381: ...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 382: ...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 383: ...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 384: ...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 385: ...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 386: ...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 387: ...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 388: ...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 389: ...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 390: ...4 67 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 391: ...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 392: ...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 393: ...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 394: ...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 395: ...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 396: ...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 397: ...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 398: ...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 399: ...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 400: ...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 401: ...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 402: ...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 403: ...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 404: ...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 405: ...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 406: ...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 1 To shift guide 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install...

Page 407: ...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 guide de s lecteur 2 3 Monter Levier...

Page 408: ...ift pedal is about 2 mm a above the top of the footrest Kick shaft assembly 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 NOTE Apply the molybden...

Page 409: ...dessus du sommet du repose pied Arbre de kick complet 1 Monter Pignon de kick 1 Rondelle 2 Circlip 3 Rochet 4 Ressort 5 Rondelle 6 Circlip 7 Sur l arbre de kick 8 N B Appliquer de l huile de disulfure...

Page 410: ...the kick shaft stop per a and stopper plate 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the stopper pla...

Page 411: ...e au bisul fure de molybd ne Appliquer l huile sur l arbre de kick Ins rer l arbre de kick dans le carter et s assurer que la but e d arbre de kick a repose bien sur l onglet de la pla que de but e 5...

Page 412: ...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 413: ...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 414: ...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 415: ...nt le tourner dans le sens inverse des aiguilles d une montre 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 416: ...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 417: ...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 418: ...TING 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 Bolt left crankcase cover 3 NOTE Tighten the bolt...

Page 419: ...r 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 Boulon demi carter gauch...

Page 420: ...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 421: ...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 422: ...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 423: ...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 424: ...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 425: ...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 426: ...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 427: ...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 428: ...uide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 T R 8 Nm 0 8 m kg 5 8 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 429: ...8 ft 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 Res...

Page 430: ...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 431: ...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 432: ...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 433: ...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 434: ...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 435: ...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 436: ...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 437: ...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 438: ...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 439: ...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 440: ...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 441: ...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 442: ...10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 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...

Page 443: ...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 main tout en tournant l crou de l outil de montage avec l autre...

Page 444: ...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 445: ...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 446: ...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 447: ...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 448: ...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 449: ...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 450: ...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 451: ...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 452: ...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 453: ...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 454: ...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 455: ...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 456: ...oil 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...

Page 457: ...e 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 r...

Page 458: ...marks 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...

Page 459: ...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 460: ...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 461: ...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 462: ...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 463: ...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 464: ...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 465: ...e 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 Epaisseur...

Page 466: ...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 467: ...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 468: ...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 469: ...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 470: ...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 471: ...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 472: ...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 473: ...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 474: ...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 475: ...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 476: ...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 477: ...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 478: ...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 479: ...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 480: ...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 481: ...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 482: ...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 483: ...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 484: ...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 485: ...n 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 486: ...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 487: ...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 488: ...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 489: ...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 490: ...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 491: ...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 492: ...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 493: ...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 494: ...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 495: ...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 496: ...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 497: ...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 498: ...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 499: ...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 500: ...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 501: ...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 502: ...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 503: ...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 504: ...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 505: ...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 506: ...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 507: ...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 508: ...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 509: ...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 510: ...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 511: ...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 512: ...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 513: ...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 514: ...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 515: ...vant 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 Bouch...

Page 516: ...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 517: ...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 518: ...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 519: ...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 520: ...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 521: ...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 522: ...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 523: ...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 524: ...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 525: ...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 526: ...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 527: ...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 528: ...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 529: ...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 530: ...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 531: ...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 532: ...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 533: ...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 534: ...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 535: ...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 536: ...older 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 2 pushed...

Page 537: ...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 tir 1 D connecter du c t acc...

Page 538: ...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 539: ...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 540: ...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 541: ...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 542: ...guide 2 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 6 Install Throttle cable cap 1 Screw throttle cable cap 2 WARNING After tightening the...

Page 543: ...dans le guide de tube 6 Monter Couvercle de logement de c ble des gaz 1 Vis couvercle de logement de c ble des gaz 2 AVERTISSEMENT Apr s avoir serr les vis v rifier que la poign e des gaz 3 tourne san...

Page 544: ...ine stop switch 1 Clutch lever holder 2 Bolt clutch lever holder 3 Decompression lever holder 4 Bolt decompression lever holder 5 Clamp 6 T R 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb NOTE T...

Page 545: ...du levier de d com presseur 4 Boulon support du levier de d compresseur 5 Bride 6 N B Le du moteur le support de levier d embrayage le support du levier de d compression et l attache en plasti que do...

Page 546: ...n in the CHAPTER 3 Decompression lever free play Refer to DECOMPRESSION LEVER ADJUSTMENT section in the CHAP TER 3 12 Clamp the clamp portion a of the num ber plate to the handlebar 13 Insert the end...

Page 547: ...compression Se reporter la section REGLAGE DU LEVIER DE DECOMPRESSION du CHAPITRE 3 12 Fixer la partie de fixation a de la plaque de num ro au guidon 13 Introduire l extr mit de la durit de mise l air...

Page 548: ...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 549: ...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 550: ...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 551: ...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 billes 1 D...

Page 552: ...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 553: ...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 554: ...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 555: ...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 556: ...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 557: ...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 558: ...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 559: ...sbau 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 Antriebsk...

Page 560: ...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 561: ...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 562: ...ee 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 ru...

Page 563: ...oule 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 co...

Page 564: ...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 565: ...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 566: ...lar 1 To relay arm 2 NOTE Apply the molybdenum disulfide grease on the collars bearings and oil seal lips 3 Install Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the colla...

Page 567: ...e la graisse au bisulfure de molybd ne sur les collerettes les roule ments et les l vres de bague d tan ch it 3 Monter Collerette 1 Sur la bielle 2 N B Appliquer de la graisse au bisulfure de molybd n...

Page 568: ...Nm 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 an...

Page 569: ...bras oscillant 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 8...

Page 570: ...ts mark a facing for ward 13 Install Bolt lower chain tensioner 1 Washer 2 Collar 3 Lower chain tensioner 4 Nut lower chain tensioner 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Drive chain case 1 Drive...

Page 571: ...deur inf rieur de cha ne 4 Ecrou tendeur inf rieur de cha ne 5 14 Monter Carter de cha ne de transmis sion 1 Couvercle de carter de cha ne de transmission 2 Boulon carter de cha ne de transmission r 5...

Page 572: ...ine WARNING Support the machine securely so there is no danger of it falling over Seat and fitting band Refer to SEAT FUEL TANK AND SIDE COVERS section Silencer Refer to EXHAUST PIPE AND SILENCER sect...

Page 573: ...NCE 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 Bo...

Page 574: ...5 59 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 575: ...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 576: ...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 577: ...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 578: ...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 579: ...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 580: ...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 581: ...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 582: ...rn 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 Apply th...

Page 583: ...rou 1 Longueur de ressort mont a Longueur stan dard Etendue de r glage 246 5 mm 9 70 in 262 mm 10 31 in 240 5 258 5 mm 9 47 10 18 in 255 5 273 5 mm 10 06 10 77 in Amortisseur arri re 1 Monter Joint an...

Page 584: ...olt rear shock absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm...

Page 585: ...sse de molybd ne sur le boulon T R 56 Nm 5 6 m kg 40 ft lb 5 Monter Boulon amortisseur arri re bras de relais 1 Ecrou amortisseur arri re bras de relais 2 N B Appliquer de la graisse de molybd ne sur...

Page 586: ...plug 6 Ignition coil 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue 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 Y R P Br W G R B Br...

Page 587: ...ES 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 Orange P Ros...

Page 588: ...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 589: ...ns 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 capteur d...

Page 590: ...tion 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 Mikroprozessor CDI...

Page 591: ...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 592: ...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 593: ...carburant 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 cir...

Page 594: ...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 595: ...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 596: ...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 597: ...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 598: ...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 599: ...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 600: ...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 601: ...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 602: ...e the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Check entire ignition system for connection Repair or...

Page 603: ...ans 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 du cap teur de papillon des gaz Remplacer V rifier l...

Page 604: ...berpr fen Erneuern oder instand setzen Den Drosselklappen Positi onssensor pr fen Drosselklap pen Positions sensor Spule Erneuern Den CDI Schwungrad Magnetz nder pr fen Prim rspule Erneuern Die CDI Ei...

Page 605: ...n questa ispezione Tester tascabile YU 3112 C 90890 03112 Contagiri induttivo YU 8036 B Contagiri motore 90890 03113 Controllare il collegamento dell intero sistema di accensione Riparare o sostituire...

Page 606: ...ION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace THROTTLE POSITION SENSOR COIL INSPECTION 1 Inspect Throttle position sensor coil resistance Out of specifi...

Page 607: ...z Hors sp cifications Rempla cer Fil de multin tre Fil bleu 1 Fil de multin tre Fil noir 2 Fiche rapide de fil de capteur de position de papillon des gaz Position du s lecteur de l appareil de contr l...

Page 608: ...losed Full opened k 1 Zero 3 k at 20 C 68 F 4 6 k at 20 C 68 F THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1 Remove Throttle position sensor coupler Screw throttle position sensor 1 Washer 2 T...

Page 609: ...a pratiqu e dans le capteur de papillon des gaz sur la saillie b du carburateur Serrer provisoirement les vis capteur de papillon des gaz Fil de multin tre Fil jaune 1 Fil de multin tre Fil noir 2 R s...

Page 610: ...erproof function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical com ponents 7 Start the engine Tester lead Yellow lead 3...

Page 611: ...7 D marrer le moteur Fil de l appareil de contr le Fil jaune 3 Fil de l appareil de contr le Fil noir 4 8 R gler la tension de sortie du TPS tapes de r glage R gler l angle de montage du TPS 1 pour ob...

Page 612: ...ROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input voltage Out of specification Replace the C...

Page 613: ...ntr e du capteur de papillon des gaz Hors sp cifications Rempla cer le bloc CDI Fil de multin tre Fil bleu 1 Fil de multin tre Fil noir 2 Tensiond entr e du capteur de papillon des gaz Position du s l...

Page 614: ...best 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 fut...

Page 615: ...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 616: ...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 617: ...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 618: ...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 619: ...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 620: ...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 621: ...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 622: ...fuel 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...

Page 623: ...en usine 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...

Page 624: ...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 625: ...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 626: ...ble with different straight portion diameters Standard jet needle OBEKP Example OBEKP 4 Clip position Diameter a of straight portion Effects of changing the jet needle refer ence Diameter of the strai...

Page 627: ...la partie droite diff rent selon les aiguilles Aiguille standard OBEKP Exemple OBEKP 4 Position du clip Diam tre a de la par tie droite Effets du changement d aiguille r f rence Diam tre de la partie...

Page 628: ...ple 100 90 2 Rough engine operation is felt in quick throttle opening Select a leak jet having higher calibrating No than standard to lean out the mixture Example 100 110 For EUROPE Standard leak jet...

Page 629: ...rapide du papillon S lectionner un gicleur de fuite ayant un plus petit N de calibre que le gicleur standard pour r duire le m lange Exemple N 100 N 110 Pour l EUROPE Gicleur de fuite standard N 100 N...

Page 630: ...40 38 35 4MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Jet needle Rich STD Lean OBEKL OBEKM OBEKN OBEKP OBEKQ OBEKR OBEKS 5JG 14916 EL 5JG 14916 EM 5JG 149...

Page 631: ...4948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Aiguille Riche Standard Pauvre OBEKL OBEKM OBEKN OBEKP OBEKQ OBEKR OBEKS 5JG 14916 EL 5JG 14916 EM 5JG 14916 EN 5JG 14916 EP 5JG 14916 E1 5J...

Page 632: ...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 633: ...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 634: ...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 635: ...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 636: ...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 637: ...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 638: ...re 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 639: ...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 les...

Page 640: ...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 641: ...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 642: ...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 643: ...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 644: ...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 645: ...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 646: ...PE 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 4...

Page 647: ...TYPE 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 2...

Page 648: ...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 649: ...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 650: ...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 651: ...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 652: ...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 653: ...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 654: ...12 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 5NG 22212 60 5DH 22212 40 5SF 22212 00 5DH 22212 60 Black 1 Blue 1 Yellow 1 Pink 1 260 260 265 265 TYPE SPRING RATE a...

Page 655: ...DH 22212 20 Rouge 1 260 DUR 5 0 5 2 5 4 5 6 5NG 22212 60 5DH 22212 40 5SF 22212 00 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 de res...

Page 656: ...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 657: ...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 658: ...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 659: ...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 660: ...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 661: ...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 662: ...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 663: ...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 664: ......

Page 665: ......

Page 666: ...PRINTED IN JAPAN 2001 8 1 7 1 CR E F G H PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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