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Yamaha YZ250F(S), Owner'S Service Manual

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Yamaha YZ250F(S) Owner'S Service Manual Download Page 39

GEN

INFO

1 - 8

SPECIAL TOOLS

YU-33975, 90890-01403

Steering nut wrench

This tool is used when tighten the steering ring nut to 

specification.

YU-33975

90890-01403

YM-01442, 90890-01442

Fork seal driver

This tool is used when install the fork oil seal.

YM-01442

90890-01442

YM-01494, 90890-01494

Damper rod holder

Use this tool to remove and install the damper rod.

YM-01494

90890-01494

YU-3112-C, 90890-03112

Pocket tester

Use this tool to inspect the coil resistance, output 

voltage and amperage.

YU-3112-C

90890-03112

YM-33277-A, 90890-03141

Timing light

This tool is necessary for checking ignition timing.

YM-33277-A

90890-03141

YM-4019, 90890-04019

Valve spring compressor

This tool is needed to remove and install the valve 

assemblies.

YM-4019

90890-04019

YM-91042, 90890-04086

Clutch holding tool

This tool is used to hold the clutch when removing or 

installing the clutch boss securing nut.

YM-91042

90890-04086

YM-4111, 90890-04111

YM-4116, 90890-04116

Valve guide remover

Intake 4.0 mm (0.16 in)

Exhaust 4.5 mm (0.18 in)

This tool is needed to remove and install the valve 

guide.

YM-4111

YM-4116

90890-04111

90890-04116

YM-4112, 90890-04112

YM-4117, 90890-04117

Valve guide installer

Intake 4.0 mm (0.16 in)

Exhaust 4.5 mm (0.18 in)

This tool is needed to install the valve guide.

YM-4112

YM-4117

90890-04112

90890-04117

Part number

Tool name/How to use

Illustration

Summary of Contents for YZ250F(S)

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

Page 2: ...NER S SERVICE MANUAL 2003 by Yamaha Motor Co Ltd 1st Edition July 2003 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 2003 Yamaha Motor Co Ltd 1 re dition juillet 2003 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: ...Lors de l utilisation de 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 po...

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: ...ER 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 FOURCHE...

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: ...hecking ignition timing YM 33277 A 90890 03141 YM 4019 90890 04019 Valve spring compressor This tool is needed to remove and install the valve assemblies YM 4019 90890 04019 YM 91042 90890 04086 Clutc...

Page 40: ...4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 90890 06754 ACC QUICK...

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: ...3277 A 90890 03141 YM 4019 90890 04019 Compresseur de ressort de soupape Cet outil est n cessaire pour d poser et installer les soupa pes YM 4019 90890 04019 YM 91042 90890 04086 Outil de poign e d em...

Page 43: ...0890 04113 90890 04118 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Ce testeur est n cessaire pour contr ler les composants du syst me d allumage YM 34487 90890 06754 ACC QU...

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: ...ontrolle des Z ndzeitpunktes YM 33277 A 90890 03141 YM 4019 90890 04019 Ventilfederspanner Zum Aus und Einbau der Ventile YM 4019 90890 04019 YM 91042 90890 04086 Universal Kupplungshalter Zur Fixieru...

Page 46: ...gen YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndpr fer Zur berpr fung der Z ndanlage YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA...

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: ...ura di accensione YM 33277 A 90890 03141 YM 4019 90890 04019 Compressore delle molle delle valvole Questo attrezzo utilizzato per rimuovere e installare i gruppi valvole YM 4019 90890 04019 YM 91042 9...

Page 49: ...4 Tester della dinamicit della scintilla Tester dell accensione Questo attrezzo necessario per il controllo dei componenti del sistema di accensione YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Qu...

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: ...emove 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 t...

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: ...s gaz avant d actionner le kick ATTENTION Dans un premier temps observer la proc dure de rodage suivante afin d assurer le meilleur rendement et vi ter d endommager le moteur Gaz donn s Bouton de d ma...

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 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 Starting...

Page 75: ...nce 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 Chain drive Secondary red...

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...

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: ...h cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor Type manufacturer FCR MX37 KEIHIN I D mark 5XC1 00 Mai...

Page 82: ...9 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 Thickness...

Page 83: ...ousing 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 Oil pump M6 1 0 3 10 1 0 7 2 Oil filter e...

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: ...amper rod fully com pressed without spring 105 135 mm 4 13 5 31 in Oil grade Suspension oil 01 Inner tube outer diameter 48 mm 1 89 in Front fork top end 5 mm 0 20 in Rear suspension USA CDN AUS NZ ZA...

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 9 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 1 0 1...

Page 88: ...4 1 5 1 80 8 0 58 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10...

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 5XC 00 YAMAHA Ignition coil Model manufacturer 5UL 10 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: ...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 Syst me de d...

Page 92: ...in Type d embrayage Humide multi disques Transmission Syst me de r duction primaire Engrenage Taux de r duction primaire 57 17 3 353 Syst me de r duction secondaire Entra nement par cha ne Taux de r d...

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: ...9 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: ...torsion de barre de guidage 0 05 mm 0 002 in Kick Type Kick et m canisme rochet Carburateur Type fabricant FCR MX37 KEIHIN Marque d identification 5XC1 00 Gicleur principal M J N 180 Gicleur d air M A...

Page 99: ...n 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 d ouve...

Page 100: ...diateur 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 M6 1 0 1 10...

Page 101: ...e l huile du carter moteur M10 1 25 1 20 2 0 14 Cache de pignon de cha ne de transmission M6 1 0 2 8 0 8 5 8 Guide de rochet d arbre de kick M6 1 0 2 12 1 2 8 7 P dale de kick M8 1 25 1 33 3 3 24 Pign...

Page 102: ...e ressort 105 135 mm 4 13 5 31 in Grade d huile Huile de suspension 01 Diam tre ext rieur de tube plongeur 48 mm 1 89 in Extr mit sup rieure de fourche avant 5 mm 0 20 in Suspension arri re USA CDN AU...

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...

Page 105: ...rtisseur 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 sup rieur M8 1 25 1 32 3 2 23 Cadre arri re inf rieur M8 1 25 2 29 2 9 21 Bras osci...

Page 106: ...stance de bobine d excitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bloc CDI 5XC 00 YAMAHA Bobine d allumage Mod le fabricant 5UL 10 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: ...nung 1 Zylinder nach vorn geneigt Hubraum 249 cm3 8 76 Imp oz 8 42 US oz Bohrung Hub 77 0 53 6 mm 3 03 2 11 in Verdichtungsverh ltnis 12 5 1 Startsystem Kickstarter Schmiersystem Trockensumpfschmierun...

Page 109: ...rt Mehrscheiben lbadkupplung Kraft bertragung Prim rantrieb Zahnrad Prim r bersetzung 57 17 3 353 Sekund rantrieb Kettenantrieb Sekund r bersetzung 48 13 3 692 Nicht EUROPE 49 13 3 769 Nur EUROPE Getr...

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

Page 111: ...22 000 22 021 mm 0 8661 0 8670 in Nockenwellen Au endurchmesser 21 967 21 980 mm 0 8648 0 8654 in Lagerspiel 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Nockenabmessungen Einla A 30 296 30 346 mm...

Page 112: ...0630 in Ventiltellerst rke D Einla 0 8 mm 0 0315 in Ausla 0 7 mm 0 0276 in Ventilschaftdurchmesser Einla 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553 in Ausla 4 460 4 475 mm 0 1756 0 1762 in 4 430...

Page 113: ...aut Einla 99 114 N bei 29 13 mm 9 9 11 4 kg bei 29 13 mm 22 27 25 57 lb bei 1 15 in Ausla 126 144 N bei 29 30 mm 12 6 14 4 kg bei 29 30 mm 28 44 32 41 lb bei 1 15 in Rechtwinkligkeitsgrenze Einla 2 5...

Page 114: ...in 2 Kompressionsring Ausf hrung Minutenring Abmessungen B T 0 80 2 75 mm 0 03 0 11 in Sto spiel eingebaut 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Ringnutspiel 0 020 0 055 mm 0 0008 0 0022 in 0 1...

Page 115: ...hrungsstangenschlag 0 05 mm 0 002 in Kickstarter Bauart Rastenmechanismus Vergaser Modell Hersteller FCR MX37 KEIHIN Kennzeichnung 5XC1 00 Hauptd se M J Nr 180 Hauptluftd se M A J 2 0 D sennadel J N...

Page 116: ...und Rotorabstand 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in K hlsystem K hlerabmessungen Breite 107 8 mm 4 2 in H he 220 mm 8 7 in Tiefe 32 mm 1 26 in K hlerverschlu deckel ffnungsdruck 110 kPa 1...

Page 117: ...1 0 4 10 1 0 7 2 K hler M6 1 0 6 10 1 0 7 2 K hlerschutz M6 1 0 2 10 1 0 7 2 K hlerleitung M6 1 0 1 10 1 0 7 2 lpumpendeckel M4 0 7 1 2 0 2 1 4 lpumpe M6 1 0 3 10 1 0 7 2 lfiltereinsatz Ablaufstutzen...

Page 118: ...plungsdeckel M6 1 0 7 10 1 0 7 2 Kurbelgeh use lablaufstutzen M10 1 25 1 20 2 0 14 Antriebsritzel Abdeckung M6 1 0 2 8 0 8 5 8 Kickstarter Rastenradf hrung M6 1 0 2 12 1 2 8 7 Kickstarterhebel M8 1 25...

Page 119: ...ndig eingefedert ohne Gabelfeder 105 135 mm 4 13 5 31 in lsorte Teleskopgabel l 01 Standrohr Durchmesser 48 mm 1 89 in Position der oberen Gabelbr cke 5 mm 0 20 in Federelement hinten USA CDN AUS NZ...

Page 120: ...4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder Durchmesser 11 0 mm 0 433 in Bremszylinder Durchmesser 27 0 mm 1 063 in 2 Bremsfl ssigkeit DOT 4 Hinterradbremse Bremsscheibe Durchmesser St rke 245 4...

Page 121: ...6 11 M6 M6 1 0 1 7 0 7 5 1 Gasdrehgriffkappe M5 0 8 2 4 0 4 2 9 Frontbrems Hauptzylinder M6 1 0 2 9 0 9 6 5 Bremshebel Befestigungsschraube M6 1 0 1 6 0 6 4 3 Bremshebel Befestigungsmutter M6 1 0 1 6...

Page 122: ...Pleuelstange und Rahmen M14 1 5 1 80 8 0 58 Hinterer Sto d mpfer und Rahmen M10 1 25 1 56 5 6 40 Hinterer Sto d mpfer und Relaisarm M10 1 25 1 53 5 3 38 Hinterer Rahmen oben M8 1 25 1 32 3 2 23 Hinte...

Page 123: ...spule 2 44 66 bei 20 C 68 F schwarz rosa Impulsgeber Widerstand Farbe 248 372 bei 20 C 68 F wei rot CDI Z ndbox Typ Hersteller 5XC 00 YAMAHA Z ndspule Typ Hersteller 5UL 10 DENSO Min Z ndfunkenstrecke...

Page 124: ...d trok kene Schraubverbindungen bei Raumtempera tur A Schl sselweite B Gewindedurchmesserer EINHEITEN A Mutter B Schrau be ALLGEMEINE ANZUGSMOMENTE Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6...

Page 125: ...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 compressione 1...

Page 126: ...m 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 Trasmissione a cate...

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: ...Forza 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...

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: ...guida Limite di curvatura della barra guida 0 05 mm 0 002 in Avviamento a pedale Tipo Tipo a pedivella e ad arpionismo Carburatore Tipo costruttore FCR MX37 KEIHIN Marcatura I D 5XC1 00 Getto del mas...

Page 133: ...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 7 in...

Page 134: ...qua 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 dell olio...

Page 135: ...olio dal carter M10 1 25 1 20 2 0 14 Carterino corona catena di trasmissione M6 1 0 2 8 0 8 5 8 Guida arpionismo albero a pedale M6 1 0 2 12 1 2 8 7 Avviamento a pedale M8 1 25 1 33 3 3 24 Ingranaggi...

Page 136: ...ta dell ammortizzatore completamente compressi senza molla 105 135 mm 4 13 5 31 in Tipo di olio Olio per sospensioni 01 Diametro esterno tubo interno 48 mm 1 89 in Estremit superiore forcella anterior...

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: ...eriore 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 9 Pompa freno anteriore M6 1 0 2 9 0 9 6 5 Bullone di montaggio...

Page 139: ...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 posteriore superiore M8 1 25 1 32 3 2 23 Telaio posteriore inferiore...

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 5XC 00 YAMAHA Bobina di accensione Modello costruttore 5UL 10 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: ...ather hose and ignition coil then on the outside of the left engine bracket Pass the clutch cable through the cable guides Pass the clutch cable in front of the radiator mounting boss Fit the brake ho...

Page 143: ...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 flexible de frein dans les guides sur la protection Attacher le...

Page 144: ...and cut off the tie end Fasten the neutral switch lead Fasten the neutral switch lead CDI magneto lead and radiator breather hose Pass the neutral switch lead CDI magneto lead and radiator breather h...

Page 145: ...commutateur de point mort Attacher le fil du commutateur de point mort le fil du magn to CDI et le flexible de reniflard de radiateur Faire passer le fil du commutateur de point mort le fil de magn t...

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

Page 147: ...acc l rateur entre le radiateur et le cadre puis au dessus de la noix de 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 ren...

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: ...e 2 Fuel tank breather hose 3 Clamp 4 Clutch cable 5 Hot starter 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 fr...

Page 151: ...ur d arr t de moteur 7 Flexible de frein 8 Guide de flexible Attacher le fil de commutateur d arr t de moteur au guidon Faire passer le flexible de frein devant la plaque d immatriculation 1 Cavo dell...

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: ...ars OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Replace Use foam air filter oil or equivalent oil OIL FILTER Replace OIL STR...

Page 154: ...AD Inspect free play and retighten Clean and lube Replace bearing Lithium base grease TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect beari...

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: ...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 radiateur Remplacer le liquide de refroidissement Contr ler...

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: ...el ver wenden Durchhang 40 50 mm 1 6 2 0 in K HLSYSTEM K hlfl ssigkeitsstand auf Undichtig keit pr fen K hlerverschlu deckel pr fen K hlfl ssigkeit wechseln Schl uche pr fen Alle zwei Jahre SCHRAUBVER...

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: ...er catene Allentamento della catena 40 50 mm 1 6 2 0 in SISTEMA DI RAFFREDDAMENTO Controllare il livello del refrigerante e la presenza di eventuali perdite Controllare l azionamento del tappo del rad...

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: ...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: ...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: ...kette 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 ngigkei...

Page 167: ...rasmissione 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 non...

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: ...e de refroidis sement 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 ea...

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: ...manipulation du liquide de refroidissement Le liquide de refroidissement tant dangereux il doit tre manipul avec une attention particuli re AVERTISSEMENT En cas d claboussures de liquide de refroidis...

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

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: ...u radiateur 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 em...

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: ...ERTISSEMENT 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 l...

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: ...er le 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 p...

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: ...en dre 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 h...

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: ...ubrifie 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 laisse...

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: ...remplacement Enlever le couvercle d l ment du filtre huile 1 et l l ment du 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 h...

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: ...ts Mettre 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...

Page 194: ...to the ignition coil 2 To increase idle speed Turn the throt tle stop screw 1 in a To decrease idle speed Turn the throt tle stop screw 1 out b Engine idling speed 1 900 2 100 r min c 2 VALVE CLEARAN...

Page 195: ...gime de ralenti Pour d tecter le r gime du ralenti approcher le capteur du tachy m tre c pr s de la bobine d allu mage 2 Pour augmenter la r gime de ralenti Serrer a la vis de but e de l acc l rateur...

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: ...p rieur de moteur 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...

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

Page 209: ...n cor rect dans le r servoir b Mettre 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...

Page 210: ...eck the operation of 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 l...

Page 211: ...o c dure de purge 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 n...

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: ...e contre crou AVERTISSEMENT 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 d...

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: ...de purge T R 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...

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

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: ...ment la goupille de plaquette Monter l trier de frein B et la roue arri re C Se reporter la section ROUE AVANT ET ROUE ARRIERE du CHAPITRE 5 Serrer la goupille de plaquette D T R Goupille de plaquette...

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

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: ...us le moteur 2 Contr ler Fl che de la cha ne de trans mission a Au dessus du boulon de fixa tion de la garde de joint Hors sp cification R gler N B Avant de proc der la v rification ou au r glage fair...

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: ...ect de la roue Les rep res a figurent de chaque c t sur les ten deurs de cha ne de transmission N B Tourner le tendeur pour que la cha ne de transmission soit align e avec la couronne vue par l arri r...

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: ...ague 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...

Page 230: ...each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum posi tion S...

Page 231: ...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 Position standa...

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: ...justment 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 Install...

Page 235: ...de r glage avant de faire le r glage La longueur du ressort mont change de 1 5 mm 0 06 in par tour complet du dispositif de r glage ATTENTION Ne jamais essayer de tourner le dispo sitif de r glage au...

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

Page 239: ...uer la force d amortissement basse com pression D visser le dispositif de r glage 1 Plage de r glage Maximum Minimum Position com pl tement d viss e D visser de 20 d clics partir du r glage maxi mum P...

Page 240: ...t of adjustment Maximum Minimum Fully turned in position 2 turns out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned i...

Page 241: ...de 2 tours par tir du r glage maximum POSITION STANDARD C est la position qui se trouve en arri re du nombre sp cifi de tours partir de la position enti rement vis s e Ce qui aligne le rep re grav a d...

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

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: ...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 washer 5 upper bracket 6 washer 7 steerin...

Page 247: ...ne g ne quelconque retirer l ensemble colonne de direction et inspecter le support de direction Remettre en place la rondelle 5 le support sup rieur 6 la rondelle 7 l crou d arbre de direction 8 le ch...

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: ...d allumage 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 cificat...

Page 252: ...ignition coil lead orange lead 1 Timing light YM 33277 A 90890 03141 1 3 Adjust Engine idling speed Refer to ENGINE IDLING SPEED ADJUSTMENT section 4 Check Ignition timing Visually check the stationar...

Page 253: ...ndspulenleitung orangefarbene Leitung 1 Stroboskoplampe YM 33277 A 90890 03141 3 Einstellen Leerlaufdrehzahl Siehe unter LEERLAUF DREHZAHL EINSTELEN 4 Kontrollieren Z ndzeitpunkt Kontrollieren ob sich...

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: ...is ser rer le boulon tuyau d chappement 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...

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: ...toute 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 fl...

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: ...r CHEMINE MENT DES CABLES au CHAPITRE 2 5 Serrer Bride de durit de radiateur 4 T R 10 Nm 1 0 m kg 7 2 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb 6 Monter Protection de radiateur 1 B...

Page 268: ...moval Extent of removal Order 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...

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: ...le 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 cificat...

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: ...u 3 18 Monter Durit de mide l air de carbu rateur 1 N B Installer la dorit de mise l air sur le car burateur de sorte qu il ne se plie pas l endroit o il est install R glage de l avance de la pompe d...

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: ...arburateur 1 Monter 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...

Page 292: ...E ADJUST MENT section in the CHAPTER 3 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 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 Inst...

Page 293: ...c bles des gaz 2 T R 4 Nm 0 4 m kg 2 9 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 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...

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: ...ame a et b Hors sp cifications Rempla cer Limite de longueur 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 i...

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: ...ant par ceux situ s au centre Ne pas faire tourner l arbre cames pendant la mesure du jeu avec le Plastigauge Enlever les chapeaux d arbre cames et mesurer la largeur 1 du Plastigauge 5 Mesurer Diam t...

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: ...kg 7 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 boul...

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: ...p cifi T R 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 P...

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: ...nch it Quick 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...

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: ...de radiateur 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 DEP...

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: ...n de 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 mes...

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: ...molybd ne sur le filet et la surface 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...

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: ...2 Remplacer Guide de soupape 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...

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: ...4 5 mm 0 18 in YM 4116 90890 04116 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 Adm...

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: ...Largeur du si ge de sou pape Admission 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 c...

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 45 in Exhaust 37 54 mm 1 48 in Limit 36 54 mm 1 44 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...

Page 331: ...37 54 mm 1 48 in Limite 36 54 mm 1 44 in Force du ressort 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 3...

Page 332: ...e also referring to the painted color as follows Intake middle a yellow Intake right left b white Exhaust no paint Install the valve springs with the larger pitch c facing upward d Smaller pitch 3 Ins...

Page 333: ...re a jaune Admission droite gauche b blanc Echappement sans peinture Installer le ressort de soupape en tour nant le pas le plus grand c vers le haut d Pas le plus petit 3 Monter Clavette de soupape N...

Page 334: ...pad 1 Valve lifter 2 NOTE Apply the molybdenum disulfide oil on the valve stem end Apply the engine oil on the valve lifters Valve lifter must turn smoothly when rotated with a finger Be careful to re...

Page 335: ...poussoirs de soupape d huile moteur Quand on le fait tourner du doigt un poussoir de soupape doit tourner en douceur Prendre soin de remettre les poussoirs de soupapes et les cales dans leur posi tion...

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: ...tre P de la jupe de piston l aide d un microm 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...

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: ...in Jeu lat ral Standard Limite Segment de feu 0 030 0 065 mm 0 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...

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: ...m tre ext rieur axe de piston 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 p...

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: ...ire passer 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 N...

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: ...86 CONTROLE 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 rifi...

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: ...s disques d embrayage 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 Le...

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: ...0 m kg 7 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 noi...

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: ...brayage 1 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 embr...

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

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: ...plus la verticale que possible 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 8 Nm 0...

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: ...Joint torique 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 Alloggiamen...

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: ...r le rep 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...

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: ...rotor 3 Jeu c entre logement et rotors entre 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...

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: ...r 1 2 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...

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: ...otor ext rieur 2 d 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 pi...

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: ...mplet 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 R...

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

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: ...sommet du 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...

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: ...Nm 1 0 m 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 es...

Page 414: ...NG 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...

Page 415: ...f rer 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...

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: ...isulfide 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...

Page 423: ...p dale de frein 4 Agrafe 5 N B Appliquer de la graisse base de savon au lithium sur le boulon les joints toriques et le support de p dale de frein Monter l agrafe avec la but e a tour n e vers l int r...

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: ...T R 8 Nm 0 8 m kg 5 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...

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: ...L 45 mm 1 77 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...

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: ...Limite Limite de faux rond 0 03 mm 0 0012 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...

Page 438: ...ft 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 of t...

Page 439: ...r l outil de montage 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 monta...

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: ...des demi 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 g...

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: ...stribution 1 Guide 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 l...

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: ...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 edged cor...

Page 451: ...c t bord vif du cir clip a soit oppos la rondelle situ e contre le pignon b Installer le circlip en positionnant ses extr mit s c bien assises sur la cr te des cannelures 4 Monter Collerette 1 N B App...

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: ...oser le 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...

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: ...Mesurer D flexion de disque 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...

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

Page 463: ...um ros 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 B...

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: ...la fourche avant tout en serrant le frein avant 8 Monter Durit de frein 1 Sur le support de durit de frein 2 N B Avant de serrer le boulon support de flexible de frein aligner le haut a du collet de...

Page 466: ...bearing 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 install...

Page 467: ...e d tanch it lors 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 droi...

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: ...oue N 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 Tend...

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

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

Page 473: ...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 1 6 Bouch...

Page 474: ...tand 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 REMOVAL POINTS...

Page 475: ...ser 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 de frein 1 3 Support de durit de frei...

Page 476: ...disassembly 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 Re...

Page 477: ...arri re Organisation de 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...

Page 478: ...assembly 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 Reservoir float 1 4 Bra...

Page 479: ...ion 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 Flotteur de r servoir 1 4 Soufflet de ma tre cylindre...

Page 480: ...er in or pushing down on the pedal 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 piston 1...

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: ...s and dust seals WARNING Replace the 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...

Page 483: ...les joints de piston et antipoussi re lors d un d montage 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 e...

Page 484: ...per piston 1 Wear score marks Replace brake caliper piston assembly WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crac...

Page 485: ...ier de frein 1 Usure rayures Remplacer le piston d trier de frein complet AVERTISSEMENT Toujours remplacer les joints de pis ton et les joints antipoussi re 2 lors d un d montage d trier Durit de frei...

Page 486: ...t on brake caliper correctly Front Rear 3 Install Brake caliper piston 1 NOTE Apply the brake fluid on the piston wall CAUTION Install the piston with its shallow depressed side a facing the brake cal...

Page 487: ...ton d trier de frein 1 N B Appliquer du liquide de 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 E...

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

Page 489: ...ner l encoche du support 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...

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: ...ein Kit de ma tre 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...

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: ...ide de 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...

Page 494: ...AUTION 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 T R...

Page 495: ...tie avec le tuyau a soit 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...

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: ...frein b Faire pas 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...

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: ...e comme indiqu 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 To...

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: ...causera 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...

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

Page 503: ...dre de frein 2 Arri re Diaphragme 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 fre...

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: ...articularly sensitive to foreign material Use enough 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...

Page 509: ...lorsque l huile est rem plac e ou lorsque la fourche avant 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 teme...

Page 510: ...rom 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 dama...

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 intern...

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: ...e endomma g e 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 AVE...

Page 514: ...2 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 washe...

Page 515: ...nterne 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...

Page 516: ...l 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 seal lip Install the oil...

Page 517: ...he 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 d tan ch it Installer la bague d t...

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: ...erformance 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 fork o...

Page 521: ...s le remplissage 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...

Page 522: ...th the fork oil up to the top of the outer tube and bleed the front forks 20 Measure Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking the...

Page 523: ...ujours installer 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 q...

Page 524: ...ount of turning out the fully turned in posi tion 23 Install Push rod 1 Fork spring 2 NOTE Install the fork spring with the damper rod 3 pulled up After installing the fork spring hold the damper rod...

Page 525: ...viss e fond 23 Monter Tige de pouss e 1 Ressort de fourche 2 N B Installer le ressort de fourche tout en tirant sus la tige d amortisseur 3 Apr s avoir install le ressort de four che maintenir la tig...

Page 526: ...ket Do not tighten the pinch bolts upper bracket yet 2 Tighten Front fork cap bolt 1 3 Adjust Front fork top end a Front fork top end standard a 5 mm 0 20 in T R 30 Nm 3 0 m kg 22 ft lb 4 Tighten Pinc...

Page 527: ...rrer les boulons de bridage t sup rieur 2 Serrer Bouchon de tube de fourche 1 3 R gler Sommet de bras de fourche avant a 4 Serrer Boulon de bridage t sup rieur 1 Boulon de bridage t inf rieur 2 ATTENT...

Page 528: ...ector 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 brake hose 5 in front of the axle boss c an...

Page 529: ...ollet 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 sorte que le...

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: ...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 become...

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: ...ant 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 Coll...

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: ...c ble 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 tour...

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: ...doivent tre ins 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...

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 in the steering stem cap 2 2 1 a...

Page 541: ...a 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 du carburant 1 dans le trou du cha peau de colonne de direction 2 12 Bloccare la...

Page 542: ...oval Hold the machine by placing the suitable stand under the engine Number plate Handlebar Front fender Refer to HANDLEBAR section 1 Steering stem cap 1 2 Steering stem nut 1 3 Front fork 2 Refer to...

Page 543: ...support appropri sous le moteur Plaque de num ro Guidon Garde boue avant Se reporter la section GUIDON 1 Chapeau de colonne de direction 1 2 Ecrou de colonne de direction 1 3 Fourche avant 2 Se repor...

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

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: ...0 7 m kg 5 1 ft lb 5 Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 Install Washer 1 7 Install Front f...

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

Page 550: ...eering ring nut little by little 11 Adjust Front fork top end a Front fork top end standard a 5 mm 0 20 in 12 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 CAUTION Tighten the lower br...

Page 551: ...petit l crou cr nel 11 R gler Extr mit sup rieure de four che avant a 12 Serrer Boulon de bridage t sup rieur 1 Boulon de bridage t inf rieur 2 ATTENTION Resserrer le t inf rieur au couple sp cifi S i...

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: ...es Tous 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...

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: ...nt Profondeur 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...

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: ...ndelle 3 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 A...

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: ...r l crou ce stade 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...

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: ...transmis sion 1 Couvercle 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 ch...

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: ...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 contact...

Page 577: ...roulement 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...

Page 578: ...he adjuster beyond the maximum or minimum setting Spring length installed a Standard length Extent of adjustment 249 mm 9 80 in 264 5 mm 10 41 in 240 5 258 5 mm 9 47 10 18 in 255 5 273 5 mm 10 06 10 7...

Page 579: ...minimale Longueur de ressort mont a Longueur stan dard Etendue de r glage 249 mm 9 80 in 264 5 mm 10 41 in 240 5 258 5 mm 9 47 10 18 in 255 5 273 5 mm 10 06 10 77 in 4 Serrer Contre crou 1 Amortisseur...

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

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: ...RDS 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 alluma...

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: ...iletage 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 Fil orange 1 Fil de multim tre Borne de...

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: ...de 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...

Page 598: ...IGNITION SYSTEM section NOTE Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Check entire ignition system for connection Repair or replace Check throttle positio...

Page 599: ...r les outils sp ciaux suivants dans ce d pistage des pannes V rifier la connexion de tout le syst me d allumage R parer ou remplacer V rifier le capteur de papillon des gaz Bobine du cap teur de papil...

Page 600: ...esamte Z ndanlage auf Anschlu berpr fen Erneuern oder instand setzen Den Drosselklappen Positi onssensor pr fen Drosselklap pen Positions sensor Spule Erneuern Den CDI Schwungrad Magnetz nder pr fen P...

Page 601: ...i seguenti utensili speciali in questa ispezione Tester tascabile YU 3112 C 90890 03112 Controllare il collegamento dell intero sistema di accensione Riparare o sostituire Controllare il sensore di po...

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: ...s sp cifications Rempla cer Fil de multin tre Fil bleu 1 Fil de multin tre Fil noir 2 Fiche rapide de fil de capteur de position de papillon des gaz Position du s lecteur de l appareil de contr le 4 6...

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: ...2 N 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 Alig...

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: ...l 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 chan...

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

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

Page 624: ...ure Example 90 80 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 90 100 Standard leak jet 90 1...

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 90 N 100 Gicleur de fuite standard N 90 Rappor...

Page 626: ...4MX 14943 92 4MX 14943 41 Pilot jet Rich STD Lean 48 45 42 40 38 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 Jet needle Rich STD Lean OBEKN OBEKP OBEKQ OBEKR OBEKS OBEKT OBEKU 5J...

Page 627: ...dard Pauvre N 48 N 45 N 42 N 40 N 38 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 Aiguille Riche Standard Pauvre OBEKN OBEKP OBEKQ OBEKR OBEKS OBEKT OBEKU 5JG 14916 EN 5JG 14916 EP...

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: ...atched 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 determine...

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: ...pressure 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 contac...

Page 635: ...e conduite sous la pluie sur 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 pressi...

Page 636: ...racteristic near the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produc...

Page 637: ...t comprim e ou le con ducteur ressent une certaine pression dans ses mains ou son corps De m me un niveau d huile trop lev produira rapidement un bouchon d huile entra nant une r duction de la course...

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 ea...

Page 639: ...place 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 m...

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: ...TYPE thickness PART NUMBER T 2 3 mm 0 09 in 5XE 23364 00 TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 398 0 408 0 418 5XE 23141 00 5XE 23141 10 5XE 23141 20 I II III STD 0 428 5XC 23141...

Page 643: ...sort TYPE paisseur Num ro de pi ce T 2 3 mm 0 09 in 5XE 23364 00 Type Cons tante du ressort Num ro de pi ce de ressort Rep re fentes MOU 0 398 0 408 0 418 5XE 23141 00 5XE 23141 10 5XE 23141 20 I II I...

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: ...r a entre 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...

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: ...uster 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...

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: ...monter 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 a...

Page 650: ...n 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 White 1 260 260 260 260 260 TYPE SP...

Page 651: ...t 1 260 260 STD 4 7 5UN 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...

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: ...ler um etwa 2 Rasten im Uhrzeigersinn dre hen um die D mpfungskraft zu erh hen lstand um etwa 5 10 mm 0 2 0 4 in erh hen H rtere Feder einbauen Hart gegen Ende des Federwegs lstand lmenge lstand um et...

Page 657: ...twa 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 Federeinbaul n...

Page 658: ...nso 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 qua...

Page 659: ...l 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 Smorzame...

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Page 662: ...PRINTED IN JAPAN 2003 07 2 0 1 CR E F G H PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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