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Yamaha YZ250F(R), Owner'S Service Manual


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INHALT

KAPITEL 1

ALLGEMEINE 

ANGABEN

FAHRZEUGBESCHREIBUNG 

... 1-1

FAHRZEUG-
IDENTIFIZIERUNG 

..................... 1-2

WICHTIGE 
INFORMATIONEN 

..................... 1-3

ANSCHLÜSSE PRÜFEN 

........... 1-6

SPEZIALWERKZEUGE 

............. 1-7

ARMATUREN 
UND DEREN FUNKTION 

......... 1-10

KRAFTSTOFF 

.......................... 1-13

ANLASSEN 
UND EINFAHREN 

.................... 1-14

ANZUGSMOMENTE 
KONTROLLIEREN 

................... 1-18

REINIGUNG 
UND STILLEGUNG 

.................. 1-19

KAPITEL 2

TECHNISCHE DATEN

ALLGEMEINE TECHNISCHE 
DATEN 

....................................... 2-1

WARTUNGSDATEN 

.................. 2-4

ALLGEMEINE 
ANZUGSMOMENTE 

................ 2-17

EINHEITEN 

............................... 2-17

KABELFÜHRUNG 

................... 2-18

KAPITEL 3

REGELMÄSSIGE 

INSPEKTION UND 

EINSTELLARBEITEN

WARTUNGSINTERVALLE UND 
SCHMIERDIENST 

...................... 3-1

WARTUNGS- 
UND EINSTELLARBEITEN 
VOR FAHRTBEGINN 

................. 3-4

MOTOR 

...................................... 3-5

FAHRWERK 

............................. 3-24

ELEKTRISCHE ANLAGE 

........ 3-45

TABLES DES 

MATIERES

CHAPITRE 1

RENSEIGNEMENTS 

GENERAUX

DESCRIPTION 

.............................. 1-1

IDENTIFICATION DE 
LA MACHINE 

................................ 1-2

INFORMATIONS 
IMPORTANTES 

............................ 1-3

VERIFICATION 
DES CONNEXIONS 

...................... 1-6

OUTILS SPECIAUX 

...................... 1-7

FONCTIONS 
DES COMMANDES 

.................... 1-10

ESSENCE 

...................................... 1-13

MISE EN MARCHE 
ET RODAGE 

................................ 1-14

POINTS DE VERIFICATION 
DE COUPLE DE SERRAGE 

...... 1-18

NETTOYAGE 
ET RANGEMENT 

....................... 1-19

CHAPITRE 2

CARACTERISTIQUES

CARACTERISTIQUES 
GENERALES 

.................................. 2-1

CARACTERISTIQUES 
D’ENTRETIEN 

.............................. 2-4

CARACTERISTIQUES 
GENERALES DE COUPLE 

....... 2-17

DEFINITION DES UNITES 

....... 2-17

CHEMINEMENT DES 
CABLES 

........................................ 2-18

CHAPITRE 3

CONTROLES ET 

REGLAGES 

COURANTS

PROGRAMME 
D’ENTRETIEN 

.............................. 3-1

CONTROLE ET ENTRETIEN 
AVANT UTILISATION 

................ 3-4

MOTEUR 

........................................ 3-5

PARTIE CYCLE 

.......................... 3-24

PARTIE ELECTRIQUE 

............. 3-45

INDICE

CAPITOLO 1

INFORMAZIONI 

GENERALI

DESCRIZIONE 

.............................. 1-1

IDENTIFICAZIONE 
DEL VEICOLO 

.............................. 1-2

INFORMAZIONI 
IMPORTANTI 

................................ 1-3

CONTROLLO 
DEI COLLEGAMENTI 

................. 1-6

UTENSILI SPECIALI 

................... 1-7

FUNZIONI DI COMANDO 

........ 1-10

CARBURANTE 

............................ 1-13

AVVIO E RODAGGIO 

................ 1-14

PUNTI PER IL CONTROLLO 
DEL SERRAGGIO 

....................... 1-18

PULIZIA ED 
IMMAGAZZINAGGIO 

............... 1-19

CAPITOLO 2
SPECIFICHE

SPECIFICHE GENERALI 

............ 2-1

SPECIFICHE 
DI MANUTENZIONE 

................... 2-4

SPECIFICHE RELATIVE ALLE 
COPPIE DI SERRAGGIO 
GENERALI 

................................... 2-17

DEFINIZIONE DELLE UNITÀ
DI MISURA 

................................... 2-17

SCHEMA DEL PERCORSO 
DEI CAVI 

...................................... 2-18

CAPITOLO 3
ISPEZIONI E 

REGISTRAZIONI 

REGOLARI

INTERVALLI 
DI MANUTENZIONE 

................... 3-1

CONTROLLI PRELIMINARI
E MANUTENZIONE 

..................... 3-4

MOTORE 

........................................ 3-5

PARTE CICLISTICA 

.................. 3-24

PARTE ELETTRICA 

.................. 3-45

Summary of Contents for YZ250F(R)

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

Page 2: ...NER S SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition July 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibi...

Page 3: ...R DU PROPRIETAIRE 2002 Yamaha Motor Co Ltd 1 re dition juillet 2002 Tous droits r serv s Toute reimpression ou utillisation sans la permission crite de la Yamaha Motor Co Ltd est formellement interdit...

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

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

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

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

Page 8: ...Carbon monoxide is a dangerous gas which can cause unconscious ness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine...

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

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

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

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

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

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

Page 15: ...ues 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 ra...

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: ...sit 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 n...

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

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

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

Page 21: ...RIFICATION DE COUPLE DE SERRAGE 1 18 NETTOYAGE ET RANGEMENT 1 19 CHAPITRE 2 CARACTERISTIQUES CARACTERISTIQUES GENERALES 2 1 CARACTERISTIQUES D ENTRETIEN 2 4 CARACTERISTIQUES GENERALES DE COUPLE 2 17 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 MAGNETIQUE CDI 4 78 DEPOSE DU MOTEUR 4 82 CARTER ET VILEBREQUIN 4 87 BOITE A VITESSES TAMBOUR ET FOURC...

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: ...cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 0 Radiator A Coolant drain bolt B Rear brake pedal C Valve joint D Fuel cock E Cold starter knob F Drive chain G Air filter H Shift pedal I Dip...

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

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 Drain hole on the cylinder head right side 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 gea...

Page 31: ...rrect 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 se so...

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: ...eins 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 correctement...

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: ...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 90...

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: ...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: ...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 125...

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

Page 48: ...Questo strumento utilizzato per controllare la velocit del motore YU 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: ...gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter cra...

Page 51: ...d mar rages doux le levier doit tre tir rapide ment et rel ch lentement PEDALE DE CHANGEMENT DE VITESSE Les 5 rapports de la bo te de vitesses prise constante sont id alement chelon n s Le changement...

Page 52: ...is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position COLD STARTER KNOB When cold the engine requires a richer air fuel m...

Page 53: ...ion BOUTON DE DEMARRAGE A FROID Quand il est froid le moteur a besoin d un m lange air essence plus riche pour le d marrage Un circuit de d marrage s par command par le bouton de de d marrage froid 1...

Page 54: ...Remove this sidestand before starting out EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose CAUTION In this installation make sure...

Page 55: ...rale avant de rouler CLAPET DE DURIT DE MISE A LIAIR Ce clapet 1 vite que l essence ne s chappe et est mont sur la durit de mise l air du r servoir de carburant ATTENTION Lors de cet assemblage v rifi...

Page 56: ...rings and exhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane grade WARNING For refueling be sure to stop the engine and use enough care not to sp...

Page 57: ...ient utiliser une marque d essence dif f rente ou une classe d octane sup rieure AVERTISSEMENT Avant de faire le plein arr ter le moteur Faire attention de ne pas r pandre de carburant sur la machine...

Page 58: ...like a two stroke engine this engine cannot be kick started when the throttle is open because the kick starter may kick back Also if the throttle is open the air fuel mixture may be too lean for the e...

Page 59: ...actionner le kick sinon celui ci risque de se relever brutalement De plus l ouverture des gaz risque d appauvrir l exc s le m lange air carburant ce qui rendrait la mise en marche difficile Avant la m...

Page 60: ...000 r min for 1 or 2 minutes NOTE Since this model is equipped with an accelera tor pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may...

Page 61: ...ndant 1 2 minutes N B Puisque ce mod le est quip d une pompe d acc l ration le m lange air carburant devient trop riche et le moteur risque de caler lorsque l on emballe le moteur actionnement success...

Page 62: ...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 CAUTION Observe the fol...

Page 63: ...actionner le kick ATTENTION Dans un premier temps observer la proc dure de rodage suivante afin d assurer le meilleur rendement et vi ter d endommager le moteur Gaz donn s Bouton de d mar rage froid...

Page 64: ...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 65: ...fier 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 66: ...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 absorbe...

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

Page 68: ...pf und obere Gabelbr cke obere Gabelbr cke und Lenker Teleskopgabel obere Gabelbr cke Teleskopgabel und untere Gabelbr kke bertragungs bis Umlenkhebel bertragungshebel und Rahmen Umlenkhebel und Sto d...

Page 69: ...otore Dalla staffa motore al motore Dalla staffa motore al telaio Cannotto di sterzo al telaio Cannotto di sterzo alla trave superiore Trave superiore al manubrio Forcella anteriore alla trave superio...

Page 70: ...n of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated ca...

Page 71: ...ration 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 l...

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

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

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

Page 75: ...urer CR8E NGK resistance type 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 Chai...

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

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

Page 78: ...0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565...

Page 79: ...mm 1 15 in Compressed force installed IN 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in EX 126 144 N at 29 30 mm 12 6 14 4 kg at 29 30 mm 28 44 32 41 lb at 1 15 in Tilt limit I...

Page 80: ...0012 0 0026 in 0 12 mm 0 005 in 2nd 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...

Page 81: ...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 MX37 KEIHIN I D mark 5UL1...

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

Page 83: ...ain 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 1 0 7 2 Oil pump cover M4 0 7 1 2 0 2 1 4...

Page 84: ...er 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 M8 1 25 1 33 3 3...

Page 85: ...2 in Min Max From top of outer tube with inner tube and damper rod fully com pressed without spring 80 150 mm 3 15 5 91 in Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front for...

Page 86: ...Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness...

Page 87: ...7 2 Front fork and brake 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...

Page 88: ...61 Relay arm and swingarm M14 1 5 1 80 8 0 58 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shoc...

Page 89: ...olor 44 66 at 20 C 68 F Black Pink Pickup coil resistance color 248 372 at 20 C 68 F White Red CDI unit model manufacturer 5UL 00 YAMAHA Ignition coil Model manufacturer 5UL 00 DENSO Minimum spark gap...

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

Page 91: ...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 92: ...7 0 8 mm 0 028 0 031 in Type d embrayage Humide multi disques Transmission Syst me de r duction primaire Engrenage Taux de r duction primaire 57 17 3 353 Syst me de r duction secondaire Entra nement p...

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

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

Page 95: ...1 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 96: ...13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in ECH 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in Limite d inclinaison AD 2 5 1 7 mm 2 5 0 067 in ECH 2 5 1 6 mm 2 5 0 063 in Sens...

Page 97: ...pe Fusel Dimensions B T 0 80 2 75 mm 0 03 0 11 in Ecartement des becs mont 0 30 0 45 mm 0 012 0 018 in 0 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 98: ...uidage 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 5UL1 00 5UL2 10 Gicleur principal M J N 178 Gicle...

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

Page 100: ...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 2 0 2 1 4 Pompe huile M6 1 0 3 10 1 0 7 2 Boulon de vidange d l ment du filtre huile...

Page 101: ...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 33 3 3 24 Pignon primaire M18 1 0 1 75 7 5 54 Ress...

Page 102: ...eur et tige d amortisseur 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...

Page 103: ...rieur 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...

Page 104: ...avant M6 1 0 2 9 0 9 6 5 Boulon de 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...

Page 105: ...M14 1 5 1 80 8 0 58 Bielle et cadre M14 1 5 1 80 8 0 58 Amortisseur arri re et cadre M10 1 25 1 56 5 6 40 Amortisseur arri re et bras relais M10 1 25 1 53 5 3 38 Cadre arri re haut M8 1 25 1 32 3 2 23...

Page 106: ...stance de bobine d excitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bloc CDI 5UL 00 YAMAHA Bobine d allumage Mod le fabricant 5UL 00 DENSO Longueur minimum d tincelle 6 mm 0 24 in...

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

Page 108: ...249 cm3 Bohrung Hub 77 0 53 6 mm Verdichtungsverh ltnis 12 5 1 Startsystem Kickstarter Schmiersystem Trockensumpfschmierung Motor l lsorte und viskosit t Nur USA und CDN Empfohlene lsorte Viskosit t b...

Page 109: ...ehrscheiben 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...

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

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

Page 112: ...6 mm Ausla 0 9 1 1 mm 1 6 mm Ventiltellerst rke D Einla 0 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 113: ...kkraft eingebaut Einla 99 114 N bei 29 13 mm 9 9 11 4 kg bei 29 13 mm Ausla 126 144 N bei 29 30 mm 12 6 14 4 kg bei 29 30 mm Rechtwinkligkeitsgrenze Einla 2 5 1 7 mm Ausla 2 5 1 6 mm Wicklungsrichtung...

Page 114: ...gebaut 0 030 0 065 mm 0 12 mm 2 Kompressionsring 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 Abmessun...

Page 115: ...m Kickstarter Bauart Rastenmechanismus Vergaser Modell Hersteller FCR MX37 KEIHIN Kennzeichnung 5UL2 10 Hauptd se M J Nr 178 Hauptluftd se M A J 2 0 D sennadel J N OBEKP 4 Konus C A 1 5 Leerlaufluftd...

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

Page 117: ...h 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 M4 0 7 1 2 0 2 lpumpe M6 1 0 3 10 1 0 lfiltereinsatz Ablaufstutzen M6 1 0 1 10 1 0...

Page 118: ...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 Kickstarterhebel M8 1 25 1 33 3 3 Prim rantriebszahnrad M18 1...

Page 119: ...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 120: ...rke 250 3 0 mm 250 2 5 mm Bremsbelagst rke 4 4 mm 1 0 mm Hauptbremszylinder Durchmesser 11 0 mm Bremszylinder Durchmesser 27 0 mm 2 Bremsfl ssigkeit DOT 4 Hinterradbremse Bremsscheibe Durchmesser St r...

Page 121: ...8 1 25 1 16 1 6 M6 M6 1 0 1 7 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 B...

Page 122: ...0 Relaisarm und Pleuelstange M14 1 5 1 80 8 0 Pleuelstange und Rahmen M14 1 5 1 80 8 0 Hinterer Sto d mpfer und Rahmen M10 1 25 1 56 5 6 Hinterer Sto d mpfer und Relaisarm M10 1 25 1 53 5 3 Hinterer...

Page 123: ...nd Farbe der Erregerspule 2 44 66 bei 20 C schwarz rosa Impulsgeber Widerstand Farbe 248 372 bei 20 C wei rot CDI Z ndbox Typ Hersteller 5UL 00 YAMAHA Z ndspule Typ Hersteller 5UL 00 DENSO Min Z ndfun...

Page 124: ...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 125: ...doppio albero a camme in testa DOHC Disposizione dei cilindri Monocilindrico inclinato in avanti Cilindrata 249 cm3 8 76 Imp oz 8 42 US oz Alesaggio corsa 77 0 53 6 mm 3 03 2 11 in Rapporto di compres...

Page 126: ...elettrodi 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...

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

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

Page 129: ...9 in Larghezza sede C INT 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EXT 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Spessore margine D INT 0 8 mm 0 0315 in EXT 0 7 mm 0 0276 in Diametro esterno st...

Page 130: ...orza compressa installata INT 99 114 N a 29 13 mm 9 9 11 4 kg a 29 13 mm 22 27 25 57 lb a 1 15 in EXT 126 144 N a 29 30 mm 12 6 14 4 kg a 29 30 mm 28 44 32 41 lb a 1 15 in Limite di inclinazione INT 2...

Page 131: ...005 in Seconda 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 i...

Page 132: ...atura 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 Marcatura I D 5UL1 00 5UL2 10 G...

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

Page 134: ...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 Tubazione del radiatore M6 1 0 1 10 1 0 7 2 Coperchio pompa dell olio M4 0 7 1 2 0 2 1 4 Pompa del...

Page 135: ...ino 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 33 3 3 24 Ingranaggio conduttore della trasmissione primaria M18...

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

Page 137: ...4 4 mm 0 17 in 1 0 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 Di...

Page 138: ...iore e guaina tubo flessibile del freno M8 M8 1 25 1 16 1 6 11 M6 M6 1 0 1 7 0 7 5 1 Coperchio manopola acceleratore M5 0 8 2 4 0 4 2 2 Pompa freno anteriore M6 1 0 2 9 0 9 6 5 Bullone di montaggio le...

Page 139: ...biella M14 1 5 1 80 8 0 58 Biella e telaio M14 1 5 1 80 8 0 58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e leva di rinvio M10 1 25 1 53 5 3 38 Telaio posterior...

Page 140: ...0 C 68 F Nero Rosa Resistenza bobina pickup colore 248 372 a 20 C 68 F Bianco Rosso Modello costruttore unit CDI 5UL 00 YAMAHA Bobina di accensione Modello costruttore 5UL 00 DENSO Distanza minima sci...

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

Page 142: ...er plate Pass the hot starter cable between the cylinder head breather hose oil tank breather hose and ignition coil then on the outside of the left engine bracket Pass the clutch cable through the ca...

Page 143: ...e puis sur l ext rieur du support de moteur gau che Faire passer le c ble d embrayage dans les guides de c ble Faire passer le c ble d embrayage devant la noix de montage du radiateur Ins rer le flexi...

Page 144: ...switch lead on the oil hose with a plastic locking tie and cut off the tie end Fasten the neutral switch lead Fasten the neutral switch lead and CDI magneto lead Pass the neutral switch lead CDI magne...

Page 145: ...l extr mit Attacher le fil du commutateur de point mort Attacher le fil du commutateur de point mort et le fil du magn to CDI Faire passer le fil du commutateur de point mort le fil de magn to CDI et...

Page 146: ...throttle cables between the radiator and frame then under the radiator mounting boss Pass the throttle cables on the outside of the ignition coil Pass the radiator breather hose in front of the radiat...

Page 147: ...les d acc l rateur entre le radiateur et le cadre puis sous la noix montage du radiateur Faire passer les c bles d acc l rateur l ext rieur de la bobine d allumage Faire passer le flexible de reniflar...

Page 148: ...rtion directs as shown and lightly touches the projection on the brake caliper Pass the brake hose into the brake hose holders If the brake hose contacts the spring rear shock absorber correct its twi...

Page 149: ...t la saillie sur l trier de frein Faire passer le flexible de frein dans les supports de flexible de frein Si le flexible de frein touche le ressort amortisseur arri re corriger sa cour bure Installer...

Page 150: ...er cable 6 Engine stop switch lead 7 Brake hose 8 Hose guide Fasten the engine stop switch lead to the handlebar Pass the brake hose in front of the number plate Pass the clutch cable through the cabl...

Page 151: ...teur d arr t de moteur au guidon Faire passer le flexible de frein devant la plaque d immatriculation Faire passer le c ble d embrayage dans le guide du c ble Faire passer les c bles d acc l rateur et...

Page 152: ...learances 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 the tilt VALVE LIFTERS Inspect Replace Check fo...

Page 153: ...vel and 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...

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

Page 155: ...e soupape RESSORTS DE SOUPAPE Contr ler Remplacer Contr ler la longueur libre et l inclinaison POUSSOIRS DE SOUPAPE Contr ler Remplacer Contr ler s ils sont griff s ou us s ARBRES A CAMES Contr ler Re...

Page 156: ...pour cha ne Jeu de la cha ne 40 50 mm 1 6 2 0 in CIRCUIT DE REFROIDISSEMENT Contr ler le niveau du liquide de refroi dissement et s il n y a pas de fuite Contr ler le fonctionnement du bouchon de rad...

Page 157: ...A NE D ENTRA NEMENT Contr ler BRAS OSCILLANT Contr ler lubrifier et resserrer Graisse au bisulfure de molybd ne BRAS RELAIS BIELLE Contr ler lubrifier et resserrer Graisse au bisulfure de molybd ne TE...

Page 158: ...gen VENTILE Ventilspiel kontrollieren Pr fen Erneuern Bei kaltem Motor Ventilsitze und schafte auf Verschlei pr fen VENTILFEDERN Pr fen Erneuern Ungespannte L nge und Rechtwinkligkeit pr fen TASSENST...

Page 159: ...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 ssigkeit wechseln Schl uche pr fe...

Page 160: ...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 nachziehen Reinigen und...

Page 161: ...lle delle valvole Ispezionare Sostituire Controllare la lunghezza libera e l inclinazione ALZAVALVOLA Ispezionare Sostituire Controllare eventuali graffi e il grado di usura ALBERI A CAMME Ispezionare...

Page 162: ...ficare tendere allineare Sostituire Utilizzare un lubrificante per catene Allentamento della catena 40 50 mm 1 6 2 0 in SISTEMA DI RAFFREDDAMENTO Controllare il livello del refrigerante e la presenza...

Page 163: ...LLANTE Ispezionare lubrificare e riserrare Grasso al disolfuro di molib deno LEVA DI RINVIO BIELLA Ispezionare lubrificare e riserrare Grasso al disolfuro di molib deno CANNOTTO DELLO STERZO Controlla...

Page 164: ...k drive chain slack and alignment Check that the drive chain is lubricated properly P 3 31 33 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 41...

Page 165: ...n et l alignement de la cha ne S assurer que la cha ne est graiss e correctement P 3 31 33 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 pas...

Page 166: ...skette Durchhang und Ausrichtung pr fen Kette nach Bedarf schmieren 3 31 33 R der Reifen auf berm igen Verschlei und Luftdruck pr fen Speichernspannung kontrollieren 3 41 42 Lenkung Auf Schwerg ngigke...

Page 167: ...trasmissione Controllare che la catena di trasmissione sia lubrificata correttamente P 3 31 33 Ruote Verificarne l eventuale usura eccessiva e controllare la pressione dei pneumatici Verificare che no...

Page 168: ...ly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remo...

Page 169: ...fon pais sur le bouchon du radiateur et tourner lente ment 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 t...

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

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

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

Page 173: ...jouter 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 AVE...

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

Page 175: ...ible 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 90890 01352...

Page 176: ...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 177: ...teur 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 embrayage...

Page 178: ...e specified free play is obtained Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted WARNING After adjusting turn the handlebar to right an...

Page 179: ...Apr s le r glage tourner le guidon vers la droite et vers la gauche et s assurer que le r gime de ralenti du moteur ne change pas GRAISSAGE DE L ACCELERA TEUR 1 D poser Cache capuchon du logement du...

Page 180: ...ter lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut AIR FILTER CLEANING NOTE Proper air filter maintenanc...

Page 181: ...contre crou 1 Tourner le r gulateur 2 jusqu ce que le jeu a soit dans les limites sp cifi es Serrer le contre crou NETTOYAGE DU FILTRE A AIR N B Un entretien convenable du filtre air est la cl pour vi...

Page 182: ...much of solvent in the ele ment may result in poor starting 3 Inspect Air filter element Damage Replace 4 Apply Foam air filter oil or equivalent oil to the element NOTE Squeeze out the excess oil Ele...

Page 183: ...us difficile 3 Contr ler El ment du filtre air Endommagement Rempla cer 4 Appliquer Huile de filtre air en mousse ou huile quivalente sur l l ment N B Eliminer l exc dent d huile L l ment doit tre hum...

Page 184: ...then turn off the engine and wait for five minutes 2 Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine 3 Remove Oil tank cap 1 1 4 In...

Page 185: ...e cinq minutes 2 Placer le v hicule sur un plan horizontal et le dresser la verti cale en pla ant un support ad quat sous le moteur 3 D poser Bouchon du r servoir d huile 1 4 Contr ler Niveau d huile...

Page 186: ...the engine and let it warm up for several minutes 7 Turn off the engine and inspect the oil level once again NOTE Wait a few minutes until the oil settles before inspecting the oil level Recommended...

Page 187: ...ie l embrayage et ces additifs pour raient le faire patiner Ne pas laisser entrer des corps trangers dans le carter 5 Monter Bouchon du r servoir d huile 6 Mettre le moteur en marche et le laisser cha...

Page 188: ...upright position by placing the suitable stand under the engine 3 Place a suitable container under the engine 4 Remove Oil tank cap 1 Oil filler cap 2 Frame oil drain bolt 3 Crankcase oil drain bolt 4...

Page 189: ...r servoir d huile 1 Capuchon de remplissage d huile 2 Boulon de vidange d huile au cadre 3 Boulon de vidange d huile de carter 4 Boulon de vidange d l ment de filtre huile 5 Vidanger l huile du carter...

Page 190: ...oil level Replacement steps Remove the oil filter element cover 1 and oil filter element 2 Check the O rings 3 if cracked or dam aged replace them with a new one Install the oil filter element and oil...

Page 191: ...u fil tre huile 2 Contr ler les joints toriques 3 et le remplacer s ils sont craquel s ou endommag s Remonter sont du filtre huile et son couvercle T R Couvercle d l ment du filtre huile 10 Nm 1 0 m k...

Page 192: ...ure Tighten the oil pressure check bolt T R Oil pressure check bolt 10 Nm 1 0 m kg 7 2 ft lb PILOT SCREW ADJUSTMENT 1 Adjust Pilot screw 1 Adjustment steps NOTE To optimize the fuel flow at a smaller...

Page 193: ...ttre le moteur en marche apr s avoir rem di au x probl me s et v rifier nouveau la pression d huile Serrer le boulon de contr le de la pression d huile au couple indiqu T R Boulon de contr le de la pr...

Page 194: ...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 195: ...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 196: ...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 197: ...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 soupa...

Page 198: ...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 the cyl inder head surface as shown in the...

Page 199: ...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 alignent sur la surface de la culasse comme illus...

Page 200: ...in 0 05 mm increments NOTE The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface Round off the last digit of the installed pad number to the nearest increment...

Page 201: ...e millim tres sur la face de la cale Arrondir le dernier chiffre de la cale install e l paisseur de cale dispo nible la plus proche Dernier chiffre du num ro de cale Chiffre arrondi 0 1ou 2 0 4 5 ou 6...

Page 202: ...ly the engine oil on the valve lifters Apply the molybdenum disulfide 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 203: ...poussoir de soupape doit tour ner en douceur Prendre soin de remettre les pous soirs de soupapes et les cales dans leur position d origine Remonter les arbres cames chappement et admission Se reporte...

Page 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...tre 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 210: ...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 211: ...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 212: ...hten 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 threaded portion 4 but not be less than 2 m...

Page 213: ...ERTISSEMENT 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 la partie filet e 4 mais pas de plus de 2 mm 0...

Page 214: ...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 215: ...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 216: ...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 217: ...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 plaquette de frein...

Page 218: ...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 219: ...e 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 m kg 13...

Page 220: ...rake pad insulator 1 Damage Replace BRAKE FLUID LEVEL INSPECTION 1 Place the brake master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level Fill up...

Page 221: ...te de frein arri re 1 Endommagement Rempla cer CONTROLE DU NIVEAU DU LIQUIDE DE FREIN 1 Placer le ma tre cylindre pour que son extr mit soit en position horizontale 2 V rifier Niveau de liquide de fre...

Page 222: ...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 223: ...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 224: ...ants 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...

Page 225: ...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 226: ...rks 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 chain slack will over...

Page 227: ...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 vue par l arri re ATTENTI...

Page 228: ...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 229: ...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 230: ...t 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...

Page 231: ...r glage in gal peut 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 Positio...

Page 232: ...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 233: ...m 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 stab...

Page 234: ...djustment 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 setting 5 Tighten Locknut 6 Instal...

Page 235: ...age 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 del de la position maximale ou mi...

Page 236: ...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 237: ...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 238: ...s sion damping force 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 t...

Page 239: ...lage 1 Plus doux b Diminuer 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 part...

Page 240: ...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 in position Which...

Page 241: ...u 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 du dispositif de r gl...

Page 242: ...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 243: ...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 244: ...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 245: ...le en avant et en arri re Jeu R gler la t te de four che 3 Contr ler Action r guli re de la direction Tourner le guidon fond dans les deux sens Action irr guli re R gler l crou annulaire de direction...

Page 246: ...ing 7 Nm 0 7 m kg 5 1 ft lb Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings Install the upper bracket 5 w...

Page 247: ...S il y a une g ne quelconque retirer l ensemble colonne de direction et inspecter le support de direction Remettre en place le support sup rieur 5 la rondelle l crou d arbre direction 6 le guidon 7 le...

Page 248: ...t 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end Use Yamaha cable lube or equivalent on these areas Us...

Page 249: ...ment 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 marreur chaud Mettre du lubrifiant Yamaha pour c bles ou quivalent sur ces...

Page 250: ...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 251: ...se 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 252: ...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 253: ...plampe YM 33277 A 90890 03141 Induktivdrehzahlmesser YU 8036 B Motor Drehzahlmesser 90890 03113 Arbeitsschritte Motor anlassen einige Minuten warmlaufen lassen und dann mit der vorgeschriebenen Dreh z...

Page 254: ...Part name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove...

Page 255: ...t 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 carburant 1 Selle 1 2 Buse...

Page 256: ...POINTS Side cover 1 Remove Bolt side cover Left side cover 1 Right side cover 2 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air fil ter case SEAT FUEL TANK...

Page 257: ...ral droit 2 N B Tirer le cache lat ral vers le bas pour l enlever car les griffes a sont ins r es dans le carter de filtre air PUNTI DI RIMOZIONE Coperchio laterale 1 Rimuovere Bullone coperchio late...

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

Page 259: ...UYAU 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 uniquemen...

Page 260: ...OTE 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 bolt exhau...

Page 261: ...ement 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 l...

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

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

Page 264: ...procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect...

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

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

Page 267: ...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 R 10 Nm 1 0...

Page 268: ...r Part name Q ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp 1 2 Throttle position sensor lead cou pler 1 3 Throttle c...

Page 269: ...CHES LATERAUX 1 Bride 1 2 Fiche rapide de fil de capteur de position de papillon des gaz 1 3 Cache du logement des c bles de gaz 1 4 C ble de gaz 2 5 Bride raccord de filtre air 1 Desserrer la vis con...

Page 270: ...CARBURETOR 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 D...

Page 271: ...rcle de logement 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...

Page 272: ...l Order Part name Q ty Remarks F Main jet 1 G Needle jet 1 H Spacer 1 I Pilot jet 1 J Starter jet 1 K Push rod 1 Pull the push rod L Throttle shaft assembly 1 M Push rod link lever assembly 1 N Pilot...

Page 273: ...uptd se 1 G Leerlaufd se 1 H Distanzst ck 1 I Choke D se 1 J Nadeld se 1 K Druckstange 1 Ventilst el L Drosselwellenbaugruppe 1 M St elstangenverbindungshebel Baugruppe 1 N Leerlaufluftd se 1 O Kaltst...

Page 274: ...crew 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 num...

Page 275: ...e ouverture 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...

Page 276: ...om pressed air Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean EC464301 Throttle valve 1 Check Free movement Stick Repair or replace NOTE Insert...

Page 277: ...delventil 1 Ventilsitz 2 Rillenf rmiger Verschlei a Erneuern Staub b Reinigen Gasschieber 1 Kontrollieren Leichtg ngigkeit Schwerg ngigkeit Instand setzen oder erneu ern HINWEIS Das Gasschieber 1 in d...

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

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

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

Page 281: ...d acc l ration 2 Couvercle de pompe d acc l ration 3 Joint torique 4 Tige de pouss e 5 D chirure diaphragme endommagement Rempla cer Encrassement Nettoyer 2 Inspecter Axe de papillon 1 Ressort 2 Levie...

Page 282: ...Install 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...

Page 283: ...ier 2 2 5 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 Instal...

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

Page 285: ...ourner 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 ensem ble d axe de papillon 9 I...

Page 286: ...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 example 13 Install O ring Leak jet 1 Float chamber 2 Screw float chamber...

Page 287: ...ours en arri re example 13 Monter Joint torique Gicleur de fuite 1 Cuve niveau constant 2 Vis cuve niveau constant 3 Support de c ble c ble de vis d arr t de l acc l ration 4 Support de durit durit de...

Page 288: ...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 289: ...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 290: ...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 Carburetor 1 NOTE In...

Page 291: ...Raccord de 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 Mettre la saillie a entre les fentes de...

Page 292: ...o THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 1 7 Install Throttle cable cover 1 Screw throttle cable cover 2 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Install Throttle position sensor lead coupler 1...

Page 293: ...logement des c bles des gaz 2 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 section CHE MINEMENT DES CABLES au CHAPITRE 2...

Page 294: ...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 295: ...tion SELLE RESERVOIR DE CAR BURANT ET 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 cu...

Page 296: ...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 297: ...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 298: ...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 the cyl inder head surface as shown in the...

Page 299: ...ep 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 de distribution 1 Tendeur de la cha ne de distr...

Page 300: ...ce 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...

Page 301: ...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 302: ...Nm 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 camsha...

Page 303: ...es 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 304: ...screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner assembly ASSEMBLY AND INSTALLATION Camshaft 1 Install Exhaust camshaf...

Page 305: ...rifier si la tige du ten deur sort sans probl me Si elle ne sort pas remplacer le tendeur ASSEMBLAGE ET MONTAGE Arbre cames 1 Monter Arbre camesd chappement1 Arbre cames d admission 2 Etapes de l ins...

Page 306: ...he clips camshaft caps 4 and bolts camshaft cap 5 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Before removing the clips cover the cylin der head with a clean rag to prevent the clips from into...

Page 307: ...2 ft lb N B Avant de retirer les clips couvrir la culasse d un chiffon propre pour emp cher qu ils ne tombent dans la cavit de la culasse Appliquer de l huile moteur sur toute la surface des boulons d...

Page 308: ...e screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci fied torque T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft lb 5 4 New 3 Turn Crankshaft Counter...

Page 309: ...Boulon capuchon de ten deur de cha ne de distribu tion 7 Nm 0 7 m kg 5 1 ft lb 3 Tourner Vilebrequin De quelques tours dans le sens inverse des aiguilles d une montre 4 V rifier Rep re de PMH du roto...

Page 310: ...cover 3 Bolt cylinder head cover 4 NOTE Apply the sealant on the cylinder head cover gasket Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 7 Install Oil tank...

Page 311: ...ck gasket ACC QUICK GS KT YAMAHA Bond n 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 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...

Page 312: ...IDE COVERS section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHA...

Page 313: ...ateur 1 D connecter du c t de la culasse Carburateur Se reporter la section CARBURATEUR Arbre cames Se reporter la section ARBRES A CAMES Support sup rieur de moteur Se reporter la section DEPOSE DU M...

Page 314: ...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 315: ...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 316: ...3 Bolts L 135 mm 5 31 in 4 Nuts 5 NOTE Apply the molybdenum disulfide grease on the thread and contact surface of the bolts Follow the numerical order shown in the illus tration Tighten the bolts and...

Page 317: ...des boulons Suivre l ordre num rique donn dans l illustration Serrer les boulons et crous en deux tapes 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 3 Monter R...

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

Page 319: ...oir 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 soupap...

Page 320: ...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 321: ...ge de soupape Examiner la face de soupape le si ge de soupape et la largeur du si ge de soupape Etapes de la v rification Verser du dissolvant propre 1 dans les lumi res d admission et d chappement V...

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

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

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

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

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

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

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

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

Page 330: ...m 1 41 in Exhaust 37 54 mm 1 48 in Limit 35 7 mm 1 41 in Compressed spring force Intake 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in Exhaust 126 144 N at 29 30 mm 12 6 14 4 k...

Page 331: ...ssort com prim Admission 99 114 N 29 13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in Echappement 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in 3 Mesurer Inclinaison de ressort a Ho...

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

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

Page 334: ...alve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 4019 90890 04019 5 Install Adjusting pad 1 Valve lifter 2 NOTE Apply...

Page 335: ...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 336: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin cli...

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

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

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

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

Page 341: ...rom 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 e...

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

Page 343: ...0012 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 car...

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

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

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

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

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

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

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

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

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

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

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

Page 355: ...OLE 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 c...

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

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

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

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

Page 360: ...l 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 at...

Page 361: ...oix 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 Appliqu...

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

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

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

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

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

Page 367: ...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 368: ...oss the flats a with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant le...

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

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

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

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

Page 373: ...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 374: ...kg 7 2 ft lb Kickstarter crank 1 Install Kickstarter crank 1 Washer 2 Bolt kickstarter crank 3 NOTE Install the kickstarter crank so that the kick starter crank is as vertical as possible with the dis...

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

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

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

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

Page 379: ...eporter la section VOLANT MAGNETIQUE 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 d...

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

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

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

Page 383: ...re 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 pr...

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

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

Page 386: ...4 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 387: ...lle 1 15 Rotorgeh use 1 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 12 Goupille 1 13 Rondelle 1 14 Arbre de transmission de la pompe huile 1 15 Logement de rotor 1 2 Portata dello smon...

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

Page 389: ...re le 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...

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

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

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

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

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

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

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

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

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

Page 399: ...ecteur 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 barillet dans le sens antiho raire jusqu l arr t et desserrer le bou lon CONTRO...

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

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

Page 402: ...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 403: ...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 d...

Page 404: ...1 mm 0 04 in a above the top of the footrest T R 12 Nm 1 2 m kg 8 7 ft lb 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...

Page 405: ...repose pied T R 12 Nm 1 2 m kg 8 7 ft lb 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...

Page 406: ...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 407: ...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 408: ...AL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt left radiator Refer to RADIATOR section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHA...

Page 409: ...ence Se reporter la section SELLE RESERVOIR DE CAR BURANT ET 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...

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

Page 411: ...lant 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...

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

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

Page 414: ...G 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 bolts i...

Page 415: ...r au paragraphe DIA GRAMME DE CHEMINE MENT DES 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 gauc...

Page 416: ...over Seat and fuel tank Refer 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 Disconn...

Page 417: ...a section TUYAU D ECHAPPEMENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR P dale de s lecteur Se reporter la section ARBRE DE KICK ET ARBRE...

Page 418: ...ne guard 1 Lower engine guard 1 2 Neutral switch 1 3 Bolt oil hose 2 4 Drive chain sprocket cover 1 5 Nut drive sprocket 1 Refer to REMOVAL POINTS 6 Lock washer 1 7 Drive sprocket 1 8 Clip 1 9 Bolt br...

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

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

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

Page 422: ...lfide grease on the pivot shaft EC4M5211 Brake pedal 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 NOTE Apply the lithium soap base grease on the bolt O rings and brake pedal bra...

Page 423: ...e la graisse base de savon au lithium sur le boulon les joints toriques et le support de p dale de frein Monter l agrafe avec la but e a tour n e vers l int rieur T R 85 Nm 8 5 m kg 61 ft lb T R 69 Nm...

Page 424: ...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 425: ...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 426: ...RANKCASE AND CRANK SHAFT REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT sec...

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

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

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

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

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

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

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

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

Page 435: ...n 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 Remplacer...

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

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

Page 438: ...shaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 For USA and CDN Except for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut o...

Page 439: ...ntage de vilebrequin 2 3 4 et 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 440: ...nkcase 1 NOTE Clean the contacting surface of left and right crankcase before applying the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase NOTE Fit the right crankcase onto th...

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

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

Page 443: ...ide 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 c...

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

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

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

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

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

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

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

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

Page 452: ...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 453: ...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 454: ...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 455: ...tenir la machine en pla ant un support appropri sous le moteur 1 Logement de durit de frein 1 2 Boulon support de durit de frein 2 Desserrer uniquement 3 Boulon support d axe 4 Desserrer uniquement 4...

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

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

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

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

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

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

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

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

Page 464: ...e 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 bolt brake hose holder align the top a of...

Page 465: ...ant 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 flexible de frein aligner le haut a du collet de flexible de fr...

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

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

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

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

Page 470: ...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 6 2 0 in 10 T...

Page 471: ...t 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 mission 40 50 mm 1 6 2...

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

Page 473: ...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 frein...

Page 474: ...uitable stand under the engine 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 REMOV...

Page 475: ...e ne risque pas de se renverser Roue arri re Se reporter la section ROUE AVANT ET ROUE ARRIERE Vidanger le liquide de frein Se reporter POINTS DE DEPOSE 1 P dale de frein 1 2 Ma tre cylindre 1 3 Suppo...

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

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

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

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

Page 480: ...n 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 caliper pist...

Page 481: ...quide 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 comprim en...

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

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

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

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

Page 486: ...er piston 1 NOTE Apply the brake fluid on the piston wall ACHTUNG CAUTION Install the piston with its shallow depressed side a facing the brake cali per Never force to insert Front Rear Front brake ca...

Page 487: ...frein sur la paroi du piston ATTENTION Installer le piston avec le c t ren fonc a face l trier de frein Ne jamais forcer pour ins rer Avant Arri re Etrier de frein avant 1 Monter Support de plaquette...

Page 488: ...all 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 pi...

Page 489: ...pport 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...

Page 490: ...r kit 1 Clean Brake master cylinder Brake master cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder p...

Page 491: ...re cylindre de frein Les nettoyer avec du liquide de frein 2 Monter Couvercle de ma tre cylindre de frein primaire 1 Couvercle de ma tre cylindre de frein secondaire 2 Au piston d trier de frein 3 N B...

Page 492: ...ke master cylinder 5 NOTE Apply the brake fluid on the brake 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 plier...

Page 493: ...e frein sur le kit ma tre cylindre de frein Appliquer de la graisse 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...

Page 494: ...NG CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb...

Page 495: ...dirig e comme indiqu et touche la projection du ma tre cylindre de frein b 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 30 Nm 3 0 m kg 22 ft lb 2 Monter Ma tre cylindre de frein 1 Boul...

Page 496: ...er align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not con...

Page 497: ...as ser ensuite le flexible de frein devant la noix d arbre c et l ins rer dans la rai nure de flexible d de sorte que le flexi ble de frein ne touche pas l crou arbre de roue T R 10 Nm 1 0 m kg 7 2 ft...

Page 498: ...a directs as shown and lightly touches the projection b on the brake master cylinder T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING Always use...

Page 499: ...ndiqu et touche la projection du ma tre cylindre de frein b T R 30 Nm 3 0 m kg 22 ft lb Durit de frein arri re 1 Monter Rondelle en cuivre 1 Tuyau de frein 2 Boulon raccord 3 AVERTISSEMENT Toujours ut...

Page 500: ...nly the designated quality brake 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 ha...

Page 501: ...ra 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 nuisi...

Page 502: ...w brake master cylinder cap 2 Rear Diaphragm Brake master cylinder cap 1 Bolt brake master cylinder cap 2 ACHTUNG CAUTION After installation while pulling the brake lever in or pushing down on the bra...

Page 503: ...phragme Couvercle de ma tre cylindre de frein 1 Boulon couvercle de ma tre cylindre de frein 2 ATTENTION Apr s le montage rechercher les fui tes ventuelles de liquide de frein au niveau des boulons ra...

Page 504: ...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 505: ...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 506: ...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 507: ...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 508: ...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 509: ...nt 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 Bouchon...

Page 510: ...from the outer 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 dam...

Page 511: ...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 inter...

Page 512: ...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 513: ...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 514: ...HTUNG 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 Install Copper w...

Page 515: ...ne 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 interne 4 4 Se...

Page 516: ...pper 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 protect the oil...

Page 517: ...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 bague...

Page 518: ...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 519: ...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 014...

Page 520: ...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 521: ...plissage pomper lentement plus de 10 fois vers le haut et le bas la tige d amortisseur 1 pour distribuer l huile du four che 17 Remplir Huile de fourche avant Une nouvelle fois jusqu au sommet du four...

Page 522: ...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 For EUROPE NOTE Be sure to install the spring guide 2 when checking the...

Page 523: ...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 niveau d h...

Page 524: ...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 525: ...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 526: ...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 527: ...hon 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 Ser...

Page 528: ...holder 1 Bolt brake hose holder 2 Protector 3 Bolt protector 4 NOTE When installing the brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brak...

Page 529: ...le haut a du collet de flexible de frein et le bas du support de flexible de frein b Faire passer ensuite le flexible de frein 5 devant la noix d arbre c et l ins rer dans la rai nure de flexible d de...

Page 530: ...lever holder 1 3 Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to REMOVAL POINTS 7 Throttle cable cap 1 8 Throttle cable 2...

Page 531: ...lindre 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 l rat...

Page 532: ...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 533: ...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 a...

Page 534: ...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 the two ar...

Page 535: ...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 536: ...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 537: ...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 sa...

Page 538: ...hot starter lever holder 5 Clamp 6 NOTE The engine stop switch clutch lever holder and clamp should be installed according to the dimensions shown Pass the engine stop switch lead in the mid dle of t...

Page 539: ...tall s en respectant les dimensions indiqu es Faire passer le fil du commutateur d arr t du moteur au centre du support d embrayage T R 9 Nm 0 9 m kg 6 5 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0...

Page 540: ...5 44 CHAS HANDLEBAR 12 Clamp the clamp portion a of the num ber plate to the handlebar 13 Insert the end of the fuel tank breather hose 1 into the hole of the number plate...

Page 541: ...f hren 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 du r servoir de car burant 1 dans le trou de la pla que de num ro 12 Bloccar...

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

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

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

Page 545: ...75 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 poser Cage billes 1 Enle...

Page 546: ...on 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 dust seal lip an...

Page 547: ...nter 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 sup rie...

Page 548: ...ve the steering stem assembly and inspect the steering bearings 6 Install Front fork 1 Upper bracket 2 NOTE Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper brack...

Page 549: ...ter les roulements de direction 6 Monter Fourche avant 1 T sup rieur 2 N B Serrer les boulons de bridage t inf rieur provisoirement Ne pas encore serrer les boulons de bridage t sup rieur 7 Monter Ron...

Page 550: ...upper bracket 1 Pinch bolt lower bracket 2 ACHTUNG CAUTION Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction T R 23 Nm 2 3 m kg 17 ft lb T R...

Page 551: ...idage 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 avant pourrait mal fonctionner T R 23 Nm 2 3 m kg 17 ft lb T R 20...

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

Page 553: ...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 Antriebsketten...

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

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

Page 556: ...ce EC574210 Relay arm 1 Inspect Bearing polylube bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Bearing polylube bearing 1 Loss of solid lub...

Page 557: ...llerette 2 Jeu rotation irr guli re rouille Remplacer la fois le roule ment et la collerette 2 Contr ler Roulement roulement poly lube 1 Perte de lubrification solide Remplacer Bague d tanch it 3 Endo...

Page 558: ...free With polylube bearings no grease nipple and regular lubrication is necessary However grease should be applied to all oil seals and collars when removed or installed EC575000 ASSEMBLY AND INSTALL...

Page 559: ...les colliers et joints huile doi vent n anmoins tre graiss s lorsqu ils sont retir s ou install s REMONTAGE ET MONTAGE Roulement et bague d tanch it 1 Monter Roulement 1 Bague d tanch it 2 Sur le bra...

Page 560: ...sulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings a 5 mm 0 20 in Installed depth of bea...

Page 561: ...ndeur d installation des roulements a 5 mm 0 20 in Profondeur d installation des roulements a 5 mm 0 20 in Bras oscillant 1 Monter Bague 1 Roulement de but e 2 Bague d tanch it 3 Collerette 4 Sur le b...

Page 562: ...elay arm 2 Washer 3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the molybdenum disulfide...

Page 563: ...Ecrou bras relais 4 Sur le bras oscillant N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon Ne pas resserrer l crou ce stade 6 Monter Bras oscillant 1 Arbre de pivot 2 N B Appliquer...

Page 564: ...et 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 53 Nm 5 3 m kg 38 ft lb 10 Tighten Nut connecting rod 1...

Page 565: ...ade 9 Monter Boulon amortisseur arri re bras de relais 1 Ecrou amortisseur arri re bras de relais 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon T R 53 Nm 5 3 m kg 38 ft lb 10 S...

Page 566: ...er 4 Nut lower chain tensioner 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support r 50 mm 1 97 in 3 Nut drive chain support 4 Bolt driv...

Page 567: ...cle de support de cha ne de transmission 2 Boulon support de cha ne de transmission r 50 mm 1 97 in 3 Ecrou support de cha ne de transmission 4 Boulon couvercle de support de cha ne de transmission r...

Page 568: ...engine 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 in the CHAPTER 4 Silencer Refer to EXHAUST P...

Page 569: ...T ET CACHES LATERAUX du CHAPITRE 4 Silencieux Se r f rer la section TUYAU D ECHAPPEMENT ET SILENCIEUX du CHAPITRE 4 1 Bride raccord de filtre air 1 Desserrer uniquement 2 Cadre arri re 1 3 Boulon amor...

Page 570: ...5 59 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 9 Upper spring guide 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to REMOVAL POINTS 2...

Page 571: ...2 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 9 Oberer Federsitz 1 10 Feder Federbein 1 11 Lager 2 Siehe unter AUSBAU 2 AMORTISSEUR ARRIERE FEDERBEIN AMMORTIZZATORE POSTERIORE Portata del...

Page 572: ...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 573: ...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 574: ...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 575: ...ROLE Amortisseur 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 ga...

Page 576: ...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 577: ...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 578: ...urn 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 t...

Page 579: ...crou 1 Longueur de ressort mont a Longueur stan dard Etendue de r glage 248 mm 9 76 in 260 mm 10 24 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 ant...

Page 580: ...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 2 N...

Page 581: ...r 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 le boulon T R 53 Nm...

Page 582: ...on 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 5 6 2 3 4 B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P P B...

Page 583: ...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 584: ...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 585: ...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 586: ...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 587: ...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 588: ...ollowing 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 Check entire ignitio...

Page 589: ...r 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 raccords fils et bobine d allu mage R parer ou remplacer Cont...

Page 590: ...chtanlage auf einwandfreie Verbin dungen berpr fen Steckverbinder Kabel und Z ndspule Erneuern oder instand setzen Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuer...

Page 591: ...la 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 collegamento dell intero siste...

Page 592: ...Minimum spark gap 6 0 mm 0 24 in COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spar...

Page 593: ...FILS ET BOBINE D ALLUMAGE 1 Contr ler Connexion de coupleurs et fils Rouille poussi re jeu court cir cuit R parer ou remplacer Bobine d allumage et bougie telles quelles Ins rer la bobine d allumage j...

Page 594: ...ication Replace 3 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of speci...

Page 595: ...de la bougie c Us Remplacer CONTROLE DU VOLANT MAGNE TIQUE 1 V rifier R sistance de bobine d excita tion Hors sp cification Rempla cer Fil de multim tre Borne de bougie 1 Fil de multim tre Fil orange...

Page 596: ...ad Black lead 2 Charging coil 2 resistance Tester selector position 44 66 at 20 C 68 F 10 W R Br G P B 2 1 2 1 2 1 W R Br G P B 2 1 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No contin...

Page 597: ...e 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 C...

Page 598: ...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 599: ...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 600: ...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 601: ...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 602: ...TION 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 specif...

Page 603: ...p 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 le 4 6 k...

Page 604: ...or position Full closed 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 s...

Page 605: ...B Desserrer les vis capteur de papillon des gaz l aide d un embout T25 2 Remplacer Capteur de papillon des gaz 3 Installer Capteur de papillon des gaz 1 Vis capteur de papillon des gaz 2 N B Aligner l...

Page 606: ...erproof function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 7 Start the engine Tester lead Yellow lead 3...

Page 607: ...er 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 obtenir la...

Page 608: ...N 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 CDI unit Tester...

Page 609: ...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 bleu 2 Tensiond entr e du capteur de papillon des gaz Position du s lecte...

Page 610: ...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 611: ...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 612: ...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 613: ...e des gaz fonctionne correctement Conditions atmosph riques et r glages 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 a...

Page 614: ...3 4 Main system The 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 Use the main jet and the...

Page 615: ...p d un gicleur principal primaire Ce type de gicleur principal convient parfaitement au motos de course dans la mesure o il uniformise le d bit d essence m me plein rendement R gler le carburateur en...

Page 616: ...t 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 accel eratio...

Page 617: ...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 618: ...l flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num...

Page 619: ...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 du...

Page 620: ...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 621: ...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 622: ...lable with different straight portion diameters Standard jet needle OBELP OBEKP Example OBELP 4 Clip position Diameter a of straight portion Effects of changing the jet needle refer ence Diameter of t...

Page 623: ...de la partie droite diff rent selon les aiguilles Aiguille standard OBELP OBEKP Exemple OBELP 4 Position du clip Diam tre a de la par tie droite Effets du changement d aiguille r f rence Diam tre de...

Page 624: ...re Example 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 Standard leak jet 100...

Page 625: ...ouverture 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 Gicleur de fuite standard N 100 Rappo...

Page 626: ...MX 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 OBELL OBELM OBELN OBELP OBELQ OBELR OBELS 5NL 14916 EL 5NL 14916 EM 5NL 14916 EN 5NL...

Page 627: ...14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Aiguille Riche Standard Pauvre OBELL OBELM OBELN OBELP OBELQ OBELR OBELS 5NL 14916 EL 5NL 14916 EM 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1...

Page 628: ...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 629: ...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 630: ...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 631: ...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 632: ...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 633: ...onn 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 634: ...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 635: ...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 636: ...ear 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 produce a noise at...

Page 637: ...sent 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 et une d t rioratio...

Page 638: ...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 639: ...emplace 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 640: ...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 641: ...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 642: ...proved on the end of the spring TYPE 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 4SS 23141 10 4SS 23141 20...

Page 643: ...se trouve l extr mit du ressort 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 fentes MOU 0 380 0 390 0 400 0 410 0 420 4SS 2...

Page 644: ...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 645: ...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 646: ...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 647: ...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 648: ...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 649: ...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 650: ...22212 00 5UN 22212 10 Brown 1 Green 1 260 260 STD 4 7 5UN 22212 20 Red 1 260 STIFF 4 9 5 1 5 3 5 5 5 7 5UN 22212 30 5UN 22212 40 5UN 22212 50 5UN 22212 60 5UN 22212 70 Black 1 Blue 1 Yellow 1 Pink 1...

Page 651: ...22212 20 Rouge 1 260 DUR 4 9 5 1 5 3 5 5 5 7 5UN 22212 30 5UN 22212 40 5UN 22212 50 5UN 22212 60 5UN 22212 70 Noir 1 Bleu 1 Jaune 1 Rose 1 Blanc 1 260 260 260 260 260 Type Cons tante du res sort appr...

Page 652: ...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 653: ...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 654: ...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 655: ...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 656: ...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 657: ...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 658: ...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 659: ...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 660: ......

Page 661: ......

Page 662: ...PRINTED IN JAPAN 2002 07 1 5 1 CR E F G H PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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