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Yamaha YZ250F(V), Owner'S Service Manual


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CHAS

BRAKE CALIPER DISASSEMBLY

È

Front

É

Rear

Extent of removal:

1

 Front brake caliper 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

Refer to “REMOVAL POINTS”.

5

 Dust 

seal

2

1

6

 Piston 

seal

2

1

2

1

FRONT BRAKE AND REAR BRAKE

Summary of Contents for YZ250F(V)

Page 1: ...MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO PRINTED IN JAPAN 2005 08 3 0 1 CR E F G H YZ250F V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO L...

Page 2: ...ER S SERVICE MANUAL 2005 by Yamaha Motor Co Ltd 1st Edition August 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohib...

Page 3: ...IER DU PROPRIETAIRE 2005 Yamaha Motor Co Ltd 1 re dition ao t 2005 Tous droits r serv s Toute reimpression ou utillisation sans la permission crite de la Yamaha Motor Co Ltd est formellement interdite...

Page 4: ...n and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual If you h...

Page 5: ...s informations sur les produits disponi bles lors de l impression de l g res dif f rences sont possibles entre votre machine et ce manuel Pour toute ques tion relative au pr sent manuel consulter un c...

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: ...ON 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...

Page 8: ...Carbon monoxide is a dan gerous gas which can cause uncon sciousness 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: ...r 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 umfasst sieben Kapitel 1 Allgemeine Angaben 2 Technische Daten 3 Regelm ssige Wartungs und Einstellarbeiten 4 Motor 5 Fahrwe...

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

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

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

Page 17: ...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 ne G...

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

Page 19: ...IMPIANTO ELETTRICO ELEC 6 MESSA A PUNTO TUN 7 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES PERIODIQUES MOTEUR CHASSIS PARTIE ELECTRIQUE MISE 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: ...DES COUPLES DE SERRAGE 1 18 NETTOYAGE ET REMISAGE 1 19 CHAPITRE 2 CARACTERISTIQUES CARACTERISTIQUES GENERALES 2 1 CARACTERISTIQUES D ENTRETIEN 2 4 CARACTERISTIQUES GENERALES DE COUPLE 2 17 DEFINITION...

Page 22: ...CH 4 50 OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 4 57 BALANCER 4 64 OIL PUMP 4 67 KICK SHAFT AND SHIFT SHAFT 4 73 CDI MAGNETO 4 80 ENGINE REMOVAL 4 84 CRANKCASE AND CRANKSHAFT 4 89 TRAN...

Page 23: ...VERCLE DE CARTER DROIT 4 57 BALANCIER 4 64 POMPE A HUILE 4 67 ARBRE DE KICK ET AXE DE SELECTEUR 4 73 VOLANT MAGNETIQUE CDI 4 80 DEPOSE DU MOTEUR 4 84 CARTER MOTEUR ET VILEBREQUIN 4 89 BOITE DE VITESSE...

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: ...CABLAGE 6 1 BOITIER CDI COMMANDE PAR PRESSION ABSOLUE DE LA TUBULURE D ADMISSION 6 2 SYSTEME D ALLUMAGE 6 3 SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ 6 7 CHAPITRE 7 MISE AU POINT MOTEUR 7 1...

Page 26: ...ngine 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 Oil level check window I...

Page 27: ...ein arri re C Joint de robinet D Robinet de carburant E Commande de d part froid F Cha ne de transmission G Filtre air H Hublot de contr le du niveau d huile I S lecteur J Fourche N B Votre moto diff...

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: ...son identification NUMERO D IDENTIFICATION DE LA MOTO Le num ro d identification de la moto 1 est estamp sur le c t droit du tube de direction NUMERO DE SERIE DU MOTEUR Le num ro de s rie du moteur 1...

Page 30: ...bottom Drain hole on the cylinder head right side 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears...

Page 31: ...3 Lors du d montage de la moto gar der ensemble les pi ces appari es Il s agit des engrenages cylindres pistons et autres pi ces qui ont t fa onn es l une l autre par l usure normale Ces pi ces doive...

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: ...les onglets de blocage contre la ou les faces du boulon ou de l crou apr s avoir correctement serr ces der niers ROULEMENTS ET BAGUES D ETANCHEITE 1 Monter les roulements 1 et les bagues d tanch it 2...

Page 34: ...ould be inspected carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip 1 make sure that the sharp edged corner 2 is posi tione...

Page 35: ...utilisation Rem placer tout circlip d form Lors du montage d un circlip 1 veiller ce que le c t non chanfrein 2 soit positionn du c t oppos la pous s e 3 qu il re oit Voir la vue en coupe 4 Arbre ANE...

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: ...pas 5 Si la borne se d tache redresser la lame 1 de la broche et r ins rer la borne dans le connecteur 6 Brancher Connecteur N B Les deux connecteurs s encliquettent 7 V rifier la continuit l aide d...

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: ...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...

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

Page 41: ...nt magn tique Cet outil sert extraire le volant magn tique YM 1189 90890 01189 YU 1235 90890 01235 Outil de maintien du rotor Cet outil permet de desserrer ou de serrer l crou de fixa tion du volant m...

Page 42: ...r sistance la tension de sortie et l intensit des bobines YU 3112 C 90890 03112 YM 33277 A 90890 03141 Lampe stroboscopique Cet outil permet de contr ler l avance l allumage YM 33277 A 90890 03141 YM...

Page 43: ...Echappement 4 5 mm 0 18 in Cet outil permet de r al ser les guides de soupape neufs YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Cet...

Page 44: ...5 A 90890 01135 YM 1189 90890 01189 Polrad Abzieher Zum Ausbau des Lichtmaschinenrotors YM 1189 90890 01189 YU 1235 90890 01235 Rotorhalter Zum L sen und Festziehen der Lichtmaschinenrotor Mutter YU 1...

Page 45: ...chen Multimeter Zur Pr fung von Widerst nden Spannungen und Stromst rken YU 3112 C 90890 03112 YM 33277 A 90890 03141 Stroboskoplampe Zur Pr fung des Z ndzeitpunktes YM 33277 A 90890 03141 YM 4019 908...

Page 46: ...s Reibahle Einlass 4 0 mm 0 16 in Auslass 4 5 mm 0 18 in Zum Ausbohren neuer Ventilf hrungen YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Z ndfunkenstrecken Tester Z ndungstester Zur P...

Page 47: ...890 01235 Attrezzo di bloccaggio rotore Questo attrezzo utilizzato quando si allenta o si serra il dado di sicurezza del magnete volano YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Comparatore e ca...

Page 48: ...zzato per controllare la resistenza della bobina la tensione in uscita e l amperaggio YU 3112 C 90890 03112 YM 33277 A 90890 03141 Stroboscopio Questo strumento utilizzato per controllare l anticipo m...

Page 49: ...mm 0 18 in Questo attrezzo utilizzato per alesare il nuovo guidaval vola YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Tester dinamico della scintilla Tester dell accensione Questo stru...

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: ...dale de kick 1 Appuyer l g rement sur la p dale pour mettre les pignons en prise puis l actionner vigou reusement mais en souplesse pour mettre le moteur en marche Ce mod le est quip d un d marreur a...

Page 52: ...s 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 mi...

Page 53: ...id le moteur a besoin d un m lange air carburant plus riche pour d marrer Un circuit de d marrage s par contr l par la commande de d part froid 1 fournit ce m lange Tirer la commande de d part froid a...

Page 54: ...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 the arrow faces the fuel tank and also downward SPARK PL...

Page 55: ...rburant ATTENTION Lors du montage veiller orienter la fl che vers le r servoir de carburant et vers le bas CLE A BOUGIE La cl bougie 1 permet de d poser et de reposer la bougie CLE A ECROUS DE RAYONS...

Page 56: ...ch as valves piston 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 en...

Page 57: ...d essence ou une essence d un indice d octane sup rieur AVERTISSEMENT Au moment de faire le plein ne pas oublier de couper le moteur Proc der avec soin pour ne pas renverser d essence Eviter de faire...

Page 58: ...ike 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 en...

Page 59: ...m lange air carburant risque d tre trop pauvre pour permettre le d marrage du moteur Avant de mettre le moteur en mar che effectuer les contr les repris dans la liste Contr les et entretiens avant ut...

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: ...papillon le m lange air carburant sera trop riche et le moteur risque de caler A la diff rence d un moteur deux temps par ailleurs ce mod le peut tourner au ralenti ATTENTION Ne pas faire chauffer le...

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: ...leur rende ment possible il convient de roder la moto de la mani re expliqu e ci apr s Utilisa tion de la poign e des gaz Com mandede d part froid Levierde d mar rage chaud D marrage d un moteur froid...

Page 64: ...2 open low to medium speed for about one hour 6 Restart the engine and check the operation of the machine throughout its entire operat ing range Restart the machine and oper ate it for about 10 to 15...

Page 65: ...ses Red mar rer la moto et rouler pendant 10 15 minutes environ La moto est main tenant pr te pour la course ATTENTION Apr s le rodage ou avant chaque course il est indispensable de con tr ler le bon...

Page 66: ...ket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear shock absorber to frame Tightening of pivot s...

Page 67: ...au cadre Colonne de direction au cadre Colonne de direction au t sup rieur T sup rieur au guidon Fourche au t sup rieur Fourche au t inf rieur Ensemble de timonerie Timonerie au cadre Timonerie l amor...

Page 68: ...belbr cke Obere Gabelbr cke und Lenker Gabelholme und obere Gabelbr cke Gabelholme und untere Gabelbr cke Umlenkhebel Hebel und Rahmen Hebel und Federbein Hebel und Schwinge Federbein und Rahmen Anzug...

Page 69: ...sterzo telaio Fusto dello sterzo staffa superiore Staffa superiore manubrio Forcella anteriore staffa superiore Forcella anteriore staffa inferiore Gruppo di articolazioni Articolazione telaio Articol...

Page 70: ...ion 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...

Page 71: ...dents convient parfaitement pour nettoyer les parties difficiles d acc s 5 Rincer imm diatement la moto l eau claire et s cher toutes les sur faces l aide d une peau de cha mois d une serviette ou d...

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 thoroughly with solvent and lubricate it Reinstall the chain or store it in a p...

Page 73: ...aisser Remettre en place la cha ne ou la conserver dans un sachet en plasti que attach au cadre pour viter de l garer 4 Lubrifier tous les c bles de com mande 5 Placer un support sous le cadre afin de...

Page 74: ...ght 1 292 mm 50 87 in 1 294 mm 50 94 in Seat height 983 mm 38 7 in 994 mm 39 13 in 993 mm 39 09 in Wheelbase 1 485 mm 58 46 in 1 473 mm 57 99 in Minimum ground clearance 369 mm 14 53 in 371 mm 14 61 i...

Page 75: ...qt With oil filter replacement 1 25 L 1 10 Imp qt 1 32 US qt Total amount 1 40 L 1 23 Imp qt 1 48 US qt Coolant capacity including all routes 0 99 L 0 87 Imp qt 1 05 US qt Air filter Wet type element...

Page 76: ...m 4 54 in Tire Type With tube Size front 80 100 21 51M For USA CDN ZA AUS NZ and F 80 100 21 51R For EUROPE except F Size rear 100 90 19 57M For USA CDN ZA AUS NZ and F 100 90 19 NHS For EUROPE except...

Page 77: ...1 mm 0 8661 0 8670 in Camshaft outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Cam dimensions Intake A 30 296 30 346 mm 1 192...

Page 78: ...n 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 0 1571 in 3 945 mm 0 1553 i...

Page 79: ...ce 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 IN 2 5 1 7mm 2 5 0 067 in...

Page 80: ...0 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 1 50 2 25 mm 0 06 0 09 in...

Page 81: ...rter Type Kick and ratchet type Carburetor USA CDN EUROPE ZA AUS NZ Type manufacturer FCR MX37 KEIHIN I D mark 5XC9 90 5XCA A0 Main jet M J 178 175 Main air jet M A J 2 0 Jet needle clip position J N...

Page 82: ...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 120 2 mm 4 7 in Height 240 mm 9 4 in Thickness 22 mm 0 9 in Radiator cap o...

Page 83: ...diator 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 element drain bolt M6 1 0 1 10...

Page 84: ...8 10 1 0 7 2 Right crankcase cover M6 1 0 8 10 1 0 7 2 Clutch cover M6 1 0 7 10 1 0 7 2 Crankcase oil drain bolt M10 1 25 1 20 2 0 14 Drive chain sprocket cover M6 1 0 2 8 0 8 5 8 Kick shaft ratchet...

Page 85: ...ront fork top end 5 mm 0 20 in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length One I D mark 257 mm 10 12 in One...

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: ...se holder M6 1 0 2 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 6 0 6 4 3 Brake lever mounting nut M6 1 0 1 6 0 6 4...

Page 88: ...lay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock abs...

Page 89: ...resistance color 248 372 at 20 C 68 F White Red CDI unit model manufacturer 5XC 90 YAMAHA For USA 5XC A0 YAMAHA Except for USA Ignition coil Model manufacturer 5UL 10 DENSO Minimum spark gap 6 mm 0 2...

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: ...4 in Hauteur de la selle 983 mm 38 7 in 994 mm 39 13 in 993 mm 39 09 in Empattement 1 485 mm 58 46 in 1 473 mm 57 99 in Garde au sol minimale 369 mm 14 53 in 371 mm 14 61 in Poids sec Sans huile ni ca...

Page 92: ...ent du filtre huile 1 25 L 1 10 Imp qt 1 32 US qt Quantit totale 1 40 L 1 23 Imp qt 1 48 US qt Quantit de liquide de refroidissement tout circuit compris 0 99 L 0 87 Imp qt 1 05 US qt Filtre air El me...

Page 93: ...Pneus Type A chambre air Taille avant 80 100 21 51M USA CDN ZA AUS NZ et F 80 100 21 51R EUROPE sauf F Taille arri re 100 90 19 57M USA CDN ZA AUS NZ et F 100 90 19 NHS EUROPE sauf F Pression de gonf...

Page 94: ...000 22 021 mm 0 8661 0 8670 in Diam tre ext rieur de l arbre cames 21 959 21 972 mm 0 8645 0 8650 in Jeu arbre chapeau 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Dimensions de la came Admission...

Page 95: ...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 Epaisseur de rebord D IN 0 8 mm 0 0315 in EX 0 7 mm 0 0276 in Diam tre ext rieur de la queue IN 3 975 3 990...

Page 96: ...comprim pos IN 99 114 N 29 13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in EX 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 IN 2 5 1 7 mm 2 5 0 067 in EX 2 5 1...

Page 97: ...m 0 03 0 11 in Ecartement des becs segment 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 huile Dimensions B T 1 50 2...

Page 98: ...Carburateur USA CDN EUROPE ZA AUS NZ Type fabricant FCR MX37 KEIHIN Marque d identification 5XC9 90 5XCA A0 Gicleur principal MJ N 178 N 175 Gicleur principal M A J 2 0 Aiguille position clip J N OBE...

Page 99: ...in Jeu corps et rotor 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Refroidissement Taille du faisceau de radiateur Largeur 120 2 mm 4 7 in Hauteur 240 mm 9 4 in Epaisseur 22 mm 0 9 in Pression d o...

Page 100: ...7 2 Tuyau de radiateur M6 1 0 1 10 1 0 7 2 Couvercle de 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 de l l ment de filtre huile M6 1 0 1 10 1 0 7 2 Couvercle d l m...

Page 101: ...er droit M6 1 0 8 10 1 0 7 2 Couvercle d embrayage M6 1 0 7 10 1 0 7 2 Boulon de vidange d huile du carter moteur M10 1 25 1 20 2 0 14 Couvercle de pignon de cha ne de transmission M6 1 0 2 8 0 8 5 8...

Page 102: ...re USA CDN AUS NZ ZA EUROPE D battement d amortisseur 131 5 mm 5 18 in Longueur de ressort libre Approx 265 mm 10 43 in Longueur de raccord Un seul rep re d identification 257 mm 10 12 in Un seul rep...

Page 103: ...17 in 1 0 mm 0 04 in Diam tre int rieur du ma tre cylindre 11 0 mm 0 433 in Diam tre int rieur du cylindre d trier 27 0 mm 1 063 in 2 Type de liquide de frein DOT N 4 Frein disque arri re Diam tre ex...

Page 104: ...0 9 6 5 Boulon de montage du levier de frein M6 1 0 1 6 0 6 4 3 Ecrou de montage du levier de frein M6 1 0 1 6 0 6 4 3 Contre crou de r glage de position du levier de frein M6 1 0 1 5 0 5 3 6 Support...

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

Page 106: ...ine d excitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bo tier CDI 5XC 90 YAMAHA USA 5XC A0 YAMAHA Sauf USA Bobine d allumage Mod le fabricant 5UL 10 DENSO Longueur d tincelle mini...

Page 107: ...temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filet DEFINITION DES UNITES A Ecrou B Boulon SPECIFICATION DE COUPLE Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm...

Page 108: ...4 mm 50 94 in Sitzh he 983 mm 38 7 in 994 mm 39 13 in 993 mm 39 09 in Radstand 1 485 mm 58 46 in 1 473 mm 57 99 in Bodenfreiheit 369 mm 14 53 in 371 mm 14 61 in Trockengewicht Ohne l und Kraftstoff 93...

Page 109: ...8 US qt K hlsystem Fassungsverm gen 0 99 L 0 87 Imp qt 1 05 US qt Luftfilter Nassfiltereinsatz Kraftstoff Sorte Bleifreies Superbenzin mit einer Mindestoktan zahl von 95 ROZ Tankinhalt 7 0 L 1 54 Imp...

Page 110: ...cht F Dimension hinten 100 90 19 57M nur USA CDN ZA AUS NZ und F 100 90 19 NHS nur EUROPE nicht F Reifenluftdruck vorn und hinten 100 kPa 1 0 kgf cm2 15 psi Bremsen Vorderradbremse Einscheibenbremse B...

Page 111: ...1 mm 0 8661 0 8670 in Nockenwellen Lagerzapfen Durchmesser 21 959 21 972 mm 0 8645 0 8650 in Nockenwellen Lagerspiel 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Nocken Abmessungen Einlass A 30 29...

Page 112: ...Auslass 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Ventilteller St rke D Einlass 0 8 mm 0 0315 in Auslass 0 7 mm 0 0276 in Ventilschaft Durchmesser Einlass 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0...

Page 113: ...uck bei Einbaul nge Einlass 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 Auslass 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 Max Neigung Ei...

Page 114: ...nisch Abmessungen B T 0 80 2 75 mm 0 03 0 11 in Ringsto in Einbaulage 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 12 mm 0 005 in labstreifring Abmessung...

Page 115: ...CDN EUROPE ZA AUS NZ Typ Hersteller FCR MX37 KEIHIN Kennzeichnung 5XC9 90 5XCA A0 Hauptd se M J Nr 178 Nr 175 Hauptluftd se M A J 2 0 D sennadel D sennadel Clip Stellung J N OBELQ 3 OBEKP 3 Drosselkla...

Page 116: ...in 0 24 mm 0 009 in Innen und Au enrotor Axialspiel 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in K hlsystem K hlerabmessungen Breite 120 2 mm 4 7 in H he 240 mm 9 4 in Tiefe 22 mm 0 9 in K hlervers...

Page 117: ...serpumpengeh use M6 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 hlerrohr 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 lfilter Abla...

Page 118: ...7 2 Kurbelgeh usedeckel rechts M6 1 0 8 10 1 0 7 2 Kupplungsdeckel M6 1 0 7 10 1 0 7 2 lablassschraube am Kurbelgeh use M10 1 25 1 20 2 0 14 Antriebsritzel Abdeckung M6 1 0 2 8 0 8 5 8 Kickstarter Kl...

Page 119: ...mm 0 20 in Hinterradaufh ngung USA CDN AUS NZ ZA EUROPE Federweg 131 5 mm 5 18 in L nge der ungespannten Feder Ca 265 mm 10 43 in Einbaul nge Eine Kennmar kierung 257 mm 10 12 in Eine Kennmar kierung...

Page 120: ...4 0 12 in 250 2 5 mm 9 84 0 10 in Belagst rke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder Bohrung 11 0 mm 0 433 in Bremssattel Zylinderbohrung 27 0 mm 1 063 in 2 Bremsfl ssigkeit DOT Nr 4 Scheibe...

Page 121: ...auptbremszylinder vorn M6 1 0 2 9 0 9 6 5 Handbremshebel Schraube M6 1 0 1 6 0 6 4 3 Handbremshebel Mutter M6 1 0 1 6 0 6 4 3 Sicherungsmutter der Handbremshebel Einstell schraube M6 1 0 1 5 0 5 3 6 K...

Page 122: ...14 1 5 1 70 7 0 50 Umlenkhebel und bertragungshebel M14 1 5 1 80 8 0 58 bertragungshebel und Rahmen M14 1 5 1 80 8 0 58 Federbein und Rahmen M10 1 25 1 56 5 6 40 Federbein und Umlenkhebel M10 1 25 1 5...

Page 123: ...Schwarz Rosa Impulsgeber Widerstand Kabel farbe 248 372 bei 20 C 68 F Wei Rot Z ndbox Typ Hersteller 5XC 90 YAMAHA USA 5XC A0 YAMAHA Nicht USA Z ndspule Typ Hersteller 5UL 10 DENSO Min Z ndfunkenstre...

Page 124: ...und trockene Schraubverbindun gen bei Raumtemperatur A Schl sselweite B Gewindedurchmesser MASSEINHEITEN A Mut ter B Schrau be ANZUGSMOMENT Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm...

Page 125: ...a della sella 983 mm 38 7 in 994 mm 39 13 in 993 mm 39 09 in Interasse 1 485 mm 58 46 in 1 473 mm 57 99 in Altezza minima dal suolo 369 mm 14 53 in 371 mm 14 61 in Peso a secco Senza olio e carburante...

Page 126: ...S qt Con sostituzione del filtro dell olio 1 25 L 1 10 Imp qt 1 32 US qt Quantit totale 1 40 L 1 23 Imp qt 1 48 US qt Capacit refrigerante tutto il circuito compreso 0 99 L 0 87 Imp qt 1 05 US qt Filt...

Page 127: ...ni fronte 80 100 21 51M USA CDN ZA AUS NZ e F 80 100 21 51R EUROPE eccetto F Dimensioni retro 100 90 19 57M USA CDN ZA AUS NZ e F 100 90 19 NHS EUROPE eccetto F Pressione dei pneumatici anteriore e po...

Page 128: ...021 mm 0 8661 0 8670 in Diametro esterno dell albero a camme 21 959 21 972 mm 0 8645 0 8650 in Gioco tra albero e cappello 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Dimensioni delle camme Aspi...

Page 129: ...1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EST 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 EST 0 7 mm 0 0276 in Diametro esterno dello stelo INT 3 975 3 990 mm 0...

Page 130: ...ata 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 EST 126 144 N a 29 30 mm 12 6 14 4 kg a 29 30 mm 28 44 32 41 lb a 1 15 in Limite di inclinazione INT 2 5 1 7 mm 2 5 0 067 in...

Page 131: ...Luce fra le estremit fascia montata 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Gioco laterale 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Fascia raschiaolio Dimensioni B T 1 50 2 25 mm 0 06 0 0...

Page 132: ...cricchetto Carburatore USA CDN EUROPE ZA AUS NZ Tipo produttore FCR MX37 KEIHIN Contrassegno I D 5XC9 90 5XCA A0 Getto del massimo M J N 178 N 175 Getto dell aria del massimo M A J 2 0 Spillo del get...

Page 133: ...in Gioco tra alloggiamento e rotore 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Raffreddamento Dimensioni del nucleo del radiatore Larghezza 120 2 mm 4 7 in Altezza 240 mm 9 4 in Spessore 22 mm 0...

Page 134: ...6 10 1 0 7 2 Riparo radiatore M6 1 0 2 10 1 0 7 2 Tubo 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 M6 1 0 3 10 1 0 7 2 Tappo di scarico dell element...

Page 135: ...1 0 8 10 1 0 7 2 Carter frizione M6 1 0 7 10 1 0 7 2 Tappo di scarico olio carter M10 1 25 1 20 2 0 14 Coperchio ruota dentata della catena di trasmissione M6 1 0 2 8 0 8 5 8 Guida ruote cricchetto d...

Page 136: ...posteriore USA CDN AUS NZ ZA EUROPE Corsa ammortizzatore 131 5 mm 5 18 in Lunghezza libera della molla Approsimative 265 mm 10 43 in Lunghezza montaggio Un marchio iden tificativo I D 257 mm 10 12 in...

Page 137: ...4 0 12 in 250 2 5 mm 9 84 0 10 in Spessore pastiglia 4 4 mm 0 17 in 1 0 mm 0 04 in Diametro interno pompa 11 0 mm 0 433 in Diametro interno cilindro della pinza 27 0 mm 1 063 in 2 Tipo di liquido dei...

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

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

Page 140: ...obina pickup colore 248 372 a 20 C 68 F bianco rosso Modello produttore unit CDI 5XC 90 YAMAHA USA 5XC A0 YAMAHA Eccetto USA Bobina di accensione Modello produttore 5UL 10 DENSO Lunghezza minima della...

Page 141: ...ambiente A Apertura di chiave B Diametro esterno filettatura DEFINIZIONE DELLE UNIT DI MISURA A Dado B Bul lone SPECIFICA DI SER RAGGIO Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10...

Page 142: ...ring stem Pass the cylinder head breather hose on the outside of the radiator hose 1 and on the inside of the radiator pipe radi ator hose 4 Pass the clutch cable through the cable guides Pass the clu...

Page 143: ...le d embrayage dans les guide c bles Acheminer le c ble d embrayage devant la noix de montage du radiateur Acheminer la durit de carburant entre le c ble de starter chaud et le fil du capteur de posit...

Page 144: ...throttle cables throttle position sensor lead and ignition coil lead Fasten the throttle position sensor lead behind the hump of the frame Fasten the neutral switch lead on the oil hose Pass the neut...

Page 145: ...n de papillon des gaz et le fil de la bobine d allumage Attacher le fil du capteur de position de papillon des gaz derri re la bosse du cadre Attacher le fil du contacteur de point mort la durit d hui...

Page 146: ...harness and with the clamp ends facing downward Locate the clamp ends in the arrowed range Fasten the neutral switch lead and CDI magneto lead over the hump of the frame Fasten the hot starter cable...

Page 147: ...extr mit s du collier pince vers le bas Rechercher les extr mit s du collier pince dans la plage fl ch e Attacher le fil du contacteur de point mort et le fil du volant magn tique CDI la bosse du cad...

Page 148: ...Clamp 7 Rear arm bracket Pass the throttle cables over the radiator hose 2 Pass the cylinder head breather hose so that it does not contact the ignition coil Fasten the throttle cables with the clamp...

Page 149: ...la culasse de fa on ce qu elle ne soit pas en contact avec la bobine d allumage Fixer les c bles des gaz l aide du collier pince en vitant de couder les c bles puis les passer sous le support du bras...

Page 150: ...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 twist Ins...

Page 151: ...rein Si la durit de frein entre en contact avec le ressort amortisseur arri re en corriger la torsion Monter la durit de frein de mani re que sa partie tubulaire soit orient e comme sur l illustration...

Page 152: ...asten the engine stop switch lead to the handle bar Pass the clutch cable and hot starter cable through the cable guide Pass the brake hose in front of the number plate Pass the throttle cables throug...

Page 153: ...ble de starter chaud dans le guide c ble Acheminer la durit de frein devant la pla que d identification Acheminer les c bles des gaz dans le guide c ble Acheminer le c ble d embrayage et le c ble de...

Page 154: ...e cold Check the valve seats and valve stems for wear Check the valve clearances Inspect Replace VALVE SPRINGS Check the free length and the tilt Inspect Replace VALVE LIFTERS Check for scratches and...

Page 155: ...ct hoses OUTSIDE NUTS AND BOLTS Refer to STARTING AND BREAK IN section in the CHAPTER 1 Retighten AIR FILTER Clean and lubricate Use foam air filter oil or equivalent oil Replace OIL FILTER Replace OI...

Page 156: ...ube and retighten STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighte...

Page 157: ...ace d usure des si ges et des queues de soupapes Contr ler le jeu aux soupapes Contr ler Remplacer RESSORTS DE SOUPAPES Contr ler la longueur libre et l inclinaison Contr ler Remplacer POUSSOIRS DE SO...

Page 158: ...8 mm 1 9 2 3 in Lubrification jeu alignement Remplacer CIRCUIT DE REFROIDISSEMENT Contr ler le niveau de liquide de refroi dissement et l absence de fuites Contr ler le fonctionnement du bouchon de ra...

Page 159: ...MISSION Contr ler BRAS OSCILLANT Graisse au bisulfure de molybd ne Contr ler lubrifier et resserrer BRAS RELAIS BIELLE Graisse au bisulfure de molybd ne Contr ler lubrifier et resserrer TETE DE FOURCH...

Page 160: ...llieren Erneuern VENTILFEDERN Ungespannte L nge und Neigung kontrollieren Kontrollieren Erneuern TASSENST SSEL Auf Kratzer und Ver schlei kontrollieren Kontrollieren Erneuern NOCKENWELLEN Die Nockenwe...

Page 161: ...hmieren Durchhang und Ausrich tung einstellen Erneuern K HLSYSTEM K hlfl ssigkeitsstand kontrollieren und Anlage auf Undichtigkeit pr fen K hlerverschlussdeckel kontrollieren K hlfl ssigkeit wechseln...

Page 162: ...LLEN Kontrollieren SCHWINGE Molybd ndisulfidfett Kontrollieren schmieren und festziehen UMLENKHEBEL UND BERTRA GUNGSHEBEL Molybd ndisulfidfett Kontrollieren schmieren und festziehen LENKKOPF Spiel kon...

Page 163: ...ntrollare il gioco delle valvole Controllare Sostituire MOLLE DELLE VALVOLE Controllare la lunghezza libera e l inclinazione Controllare Sostituire ALZAVALVOLE Controllare graffi e usura Controllare S...

Page 164: ...48 58 mm 1 9 2 3 in Lubrificare gioco allineamento Sostituire SISTEMA DI RAFFREDDAMENTO Controllare il livello del refrigerante e la presenza di eventuali perdite Controllare il funzionamento del cope...

Page 165: ...ELLONE OSCILLANTE Grasso al disolfuro di molib deno Controllare lubrificare e serrare BRACCIO DI RINVIO BIELLA Grasso al disolfuro di molib deno Controllare lubrificare e serrare TESTA DELLO STERZO Co...

Page 166: ...drive chain slack and alignment Check that the drive chain is lubricated properly P 3 30 32 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 40...

Page 167: ...ent de la cha ne Contr ler que la cha ne est correctement lubrifi e P 3 30 32 Roues Contr ler l usure et la pression de gonflage des pneus Contr ler que les rayons sont bien tendus et ne pr sentent pa...

Page 168: ...rollieren Sicherstellen dass die Antriebskette gr ndlich geschmiert ist 3 30 32 R der Reifenluftdruck und auf starken Verschlei kontrollieren Auf lose Speichen und berm iges Spiel kontrollieren 3 40 4...

Page 169: ...n trollare che la catena di trasmissione sia correttamente lubrificata P 3 30 32 Ruote Verificare l eventuale eccesso di usura e pressione dei pneumatici Controllare l eventuale presenza di raggi alle...

Page 170: ...ly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remo...

Page 171: ...ent s arr te appuyer sur le bouchon tout en le faisant tourner dans le sens inverse des aiguilles d une montre puis l enlever ATTENTION L eau calcaire ou sal e est nuisible pour les pi ces du moteur E...

Page 172: ...oolant 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 10...

Page 173: ...Nettoyer Circuit de refroidissement Rincer soigneusement le circuit de refroidissement l eau claire 5 Monter Rondelle en cuivre Boulon de vidange du liquide de refroidissement T R 10 Nm 1 0 m kg 7 2 f...

Page 174: ...el 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 you...

Page 175: ...avec une attention particuli re AVERTISSEMENT En cas de projection de liquide de refroidissement dans les yeux Rincer soigneusement les yeux l eau et consulter un m decin En cas de projection de liqui...

Page 176: ...ible to maintain the specified pres sure 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 k...

Page 177: ...ture du bouchon de radiateur 110 kPa 1 1 kg cm2 15 6 psi CONTROLE DU CIRCUIT DE REFROIDISSEMENT 1 Contr ler Niveau du liquide de refroidisse ment 2 Fixer Testeur de bouchon de radiateur 1 et adaptateu...

Page 178: ...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 NOTE Before adjustment expose the adjuster by moving the boo...

Page 179: ...vant de proc der au r glage d cou vrir le dispositif de r glage en retirant le bouchon 3 et le manchon 4 Pour un r glage ponctuel utiliser le dispositif de r glage 5 du c t du levier Apr s le r glage...

Page 180: ...grip free play adjustment steps Slide the adjuster cover Loosen the locknut 1 Turn the adjuster 2 until the specified free play is obtained Tighten the locknut T R Locknut 4 Nm 0 4 m kg 2 9 ft lb NOTE...

Page 181: ...la poi gn e des gaz Glisser le cache du dispositif de r glage Desserrer le contre crou 1 Faire tourner le dispositif de r glage 2 jusqu obtention du jeu sp cifi Serrer le contre crou T R Contre crou 4...

Page 182: ...proper operation of hot starter AIR FILTER CLEANING NOTE Proper air filter maintenance is the biggest key to preventing premature engine wear and damage CAUTION Never run the engine without the air fi...

Page 183: ...aient p n trer dans le moteur et provoquer son usure pr matur e et d ventuels dommages 1 D poser Selle Boulon de fixation 1 Rondelle 2 El ment du bo tier de filtre air 3 Guide de filtre air 4 Jeu du l...

Page 184: ...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 185: ...agement Remplacer 4 Appliquer Huile pour filtre air mousse ou huile quivalente sur l l ment N B Comprimer pour liminer l exc s d huile L l ment doit tre humide mais sans exc s 5 Monter Guide de filtre...

Page 186: ...Start the engine warm it up for several minutes and 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 s...

Page 187: ...le couper et attendre cinq minutes 2 Placer la moto sur un sol plan et la maintenir la verticale en pla ant un support ad quat sous le moteur 3 Contr ler Niveau d huile Le niveau d huile doit corresp...

Page 188: ...the engine and let it warm up for sev eral minutes 6 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 189: ...fer pendant quelques minutes 6 Couper le moteur et v rifier nou veau le niveau d huile N B Attendre quelques minutes que l huile se stabilise avant d en contr ler le niveau Huile recommand e A 5 C 40...

Page 190: ...ight position by placing the suitable stand under the engine 3 Place a suitable container under the engine 4 Remove Lower engine guard 1 Bolt oil tank 2 Washer 3 Oil filler cap 4 Oil tank drain bolt 5...

Page 191: ...oir d huile 2 Rondelle 3 Capuchon de l orifice de remplis sage d huile 4 Boulon de vidange du r servoir d huile 5 Boulon de vidange d huile du carter moteur 6 Boulon de vidange de l l ment de filtre h...

Page 192: ...placement 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 filter ele...

Page 193: ...et l l ment de fil tre huile 2 Contr ler les joints toriques 3 s ils sont fissur s ou endommag s les remplacer Monter l l ment de filtre huile et son couvercle T R Couvercle d l ment de fil tre huile...

Page 194: ...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 Except for USA and CDN Adjustment steps NOTE To optimize the fuel flow at a smal...

Page 195: ...ulon de contr le de la pression d huile T R Boulon de contr le de la pression d huile 10 Nm 1 0 m kg 7 2 ft lb Etapes du r glage N B Pour optimiser le d bit de carburant plus faible r gime la vis de r...

Page 196: ...the engine tachometer close 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...

Page 197: ...inuer le r gime de ralenti Tourner la vis de but e de papillon des gaz 1 dans le sens b R gime de ralenti 1 900 2 100 tr mn INSPECTION ET REGLAGE DU JEU AUX SOUPAPES N B Le jeu aux soupapes doit tre r...

Page 198: ...ke valve 0 10 0 15 mm 0 0039 0 0059 in Exhaust valve 0 17 0 22 mm 0 0067 0 0087 in Checking steps Turn the crankshaft counterclockwise with a wrench Align the T D C mark a on the rotor with the align...

Page 199: ...inverse des aiguilles d une montre l aide d une cl Aligner le rep re du PMH a du rotor avec le rep re d alignement b du couvercle de carter lorsque le piston est au PMH de la course de compression N...

Page 200: ...fer to CAMSHAFTS section in the CHAPTER 4 Remove the valve lifters 1 and the pads 2 NOTE Place a rag in the timing chain space to prevent pads from falling into the crank case Identity each valve lift...

Page 201: ...stribution pour emp cher les plaquettes de tomber dans le carter Identifier soigneusement chaque poussoir de soupape et la position de chaque plaquette de mani re pouvoir les remonter leur empla cemen...

Page 202: ...rounded off value and the mea sured valve clearance in the chart PAD SELECTION TABLE The field where these two coordinates intersect shows the new pad number to use NOTE Use the new pad number only as...

Page 203: ...ique le nouveau num ro de plaquette utiliser N B N utiliser ce nouveau num ro de pla quette qu titre de guide pour le con tr le du r glage du jeu aux soupapes Monter les nouvelles plaquettes 3 et les...

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: ...26 1 30 235 240 1 31 1 35 240 ECHAPPEMENT JEU MESURE NUMERO DE PLAQUETTE MONTEE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 1...

Page 206: ...1 26 1 30 235 240 1 31 1 35 240 AUSLASS GEMESSE NES SPIEL NUMMER DES EINGEBAUTEN VENTILPL TTCHENS 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0...

Page 207: ...240 1 26 1 30 235 240 1 31 1 35 240 SCARICO GIOCO MISU RATO NUMERO SPESSORE INSTALLATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120...

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: ...et ne pas faire d border le r ser voir c Connecter herm tiquement le tuyau en plastique transparent 2 la vis de purge 1 de l trier d Placer l autre extr mit du tuyau dans un r cipient e Actionner lent...

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: ...e frei nage REGLAGE DU FREIN AVANT 1 Contr ler Position du levier de frein a 2 D poser Couvercle du levier de frein 3 R gler Position du levier de frein 4 Monter Couvercle du levier de frein Position...

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 2 mm 0 08 in c de la p dale de frein 5 Apr s le r glage de la hauteur de la p dale de frein contr ler que le frein arri re ne frotte pas CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN AVANT 1 Cont...

Page 214: ...n the bleed screw and push the brake caliper piston 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 7 and pad pin...

Page 215: ...ser le liquide de frein purg Resserrer la vis de purge T R Vis de purge 6 Nm 0 6 m kg 4 3 ft lb Monter les plaquettes de frein 7 et la goupille de plaquette N B Monter les plaquettes de frein en ins r...

Page 216: ...ing Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set Brake pad thickness 6...

Page 217: ...ins a Hors sp cifications Remplacer l ensemble 2 Remplacer Plaquette de frein Epaisseur de la plaquette de frein 6 4 mm 0 25 in Limite 1 0 mm 0 04 in Etapes du remplacement des pla quettes de frein D...

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 projections a into the brake caliper recesses b Temporarily tighten th...

Page 219: ...er les plaquettes de frein en ins rant leurs ergots a dans les gorges des triers de freins b A ce stade serrer provisoirement la goupille de plaquette Monter l trier de frein B et la roue arri re C Se...

Page 220: ...brake 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: ...eau a Niveau inf rieur Avant Arri re AVERTISSEMENT N utiliser que le liquide de frein recommand pour viter une perte d efficacit du freinage Toujours utiliser le m me type et la m me marque de liquide...

Page 222: ...cation Replace NOTE While measuring the drive chain length push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and F as shown Perform this measurement...

Page 223: ...ents Longueur de la cha ne de transmission 15 maillons Limite 242 9 mm 9 563 in 2 D poser Clip du maillon de fermeture Raccord 1 Cha ne de transmission 2 3 Nettoyer Cha ne de transmission La d poser d...

Page 224: ...lubricant SAE 10W 30 motor oil or suitable chain lubricants DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Check Drive chain slack a Above the...

Page 225: ...nt d entamer le contr le et ou le r glage faire tourner plusieurs fois la roue arri re pour d terminer le point de tension maximale Contr ler et ou r gler la tension de la cha ne lorsque la roue arri...

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: ...e que la cha ne soit align e avec le pignon vue de l arri re ATTENTION Une cha ne trop tendue impose un effort excessif au moteur et d autres organes vitaux Maintenir la tension dans les limites sp ci...

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: ...ent la d tente En tournant le dispositif de r glage 1 T R 1 Nm 0 1 m kg 0 7 ft lb Plus dur a Augmenter la force d amortissement la d tente Visser le dispositif de r glage 1 Plus mou b Diminuer la forc...

Page 230: ...G Always adjust 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 max...

Page 231: ...d clics d viss de 11 d clics REGLAGE DE LA FORCE D AMORTISSEMENT A LA COMPRESSION DE LA FOURCHE 1 R gler Force d amortissement la com pression En tournant le dispositif de r glage 1 Plus dur a Augmen...

Page 232: ...OPE CAUTION 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...

Page 233: ...i re chaque bras de la fourche Un r glage in gal risque de diminuer la maniabi lit et la stabilit Position standard d viss de 12 d clics d viss de 10 d clics CONTROLE DE L AMORTISSEUR ARRIERE 1 Contr...

Page 234: ...he adjuster The I D mark b is marked at the end of the spring The standard length and extent of adjust ment vary according to the quantity of I D marks CAUTION Never attempt to turn the adjuster beyon...

Page 235: ...Plus dur Augmenter la pr con trainte du ressort Visser le dis positif de r glage 2 Plus mou Diminuer la pr con trainte du ressort D visser le dispositif de r glage 2 Longueur du ressort mont a Longue...

Page 236: ...ease the rebound damp ing force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which i...

Page 237: ...ositif de r glage est d viss du nombre de d clics sp cifi par rapport la posi tion compl tement viss e Ce qui ali gne le rep re a du dispositif de r glage avec le rep re b du support EUROPE ATTENTION...

Page 238: ...damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position a b 1 STANDARD POSITION This is the position which is back by t...

Page 239: ...par rapport la posi tion compl tement viss e Ce qui ali gne le rep re a du dispositif de r glage avec le rep re b du dispositif de r glage de l amortissement la compression haute ATTENTION Ne pas for...

Page 240: ...adjustment Maximum Minimum Fully turned in position 2 turns out from maximum position a b 1 STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned...

Page 241: ...du nombre de tours sp cifi par rapport la position com pl tement viss e Ce qui aligne le rep re a du dispositif de r glage avec le rep re b du corps du dispositif de r glage ATTENTION Ne pas forcer l...

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: ...Rayon desserr Resserrer 2 Serrer Rayons N B Veiller resserrer ces rayons avant et apr s le rodage Apr s tout entra nement ou toute course contr ler la tension des rayons T R 3 Nm 0 3 m kg 2 2 ft lb C...

Page 244: ...Grasp the bottom of the forks and gently 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 ste...

Page 245: ...de but e but e Fonctionnement irr gulier R gler l crou de blocage de la direction 4 R gler Ecrou de la colonne de direction Etapes de r glage de l crou de direction D poser la plaque d identification...

Page 246: ...5 1 ft lb Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings Install the washer 5 upper bracket 6 washer 7...

Page 247: ...tion Monter la rondelle 5 le t sup rieur 6 la rondelle 7 l crou de direction 8 le guidon 9 le sup port de guidon sup rieur 0 et la plaque d identification A N B Le support sup rieur du guidon doit tre...

Page 248: ...Steering stem nut 145 Nm 14 5 m kg 105 ft lb Handlebar upper holder 28 Nm 2 8 m kg 20 ft lb Pinch bolt upper bracket 23 Nm 2 3 m kg 17 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb STEERING HEAD INSPECTI...

Page 249: ...rieur 28 Nm 2 8 m kg 20 ft lb Boulon de pincement t sup rieur 23 Nm 2 3 m kg 17 ft lb Plaque d identification 7 Nm 0 7 m kg 5 1 ft lb T R Dado fusto dello sterzo 145 Nm 14 5 m kg 105 ft lb Supporto s...

Page 250: ...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 251: ...c ble de d marrage chaud Utiliser pour ces zones du lubrifiant Yamaha pour c bles ou un lubrifiant qui valent Utiliser de l huile moteur SAE 10W 30 ou un lubrifiant pour cha nes ad quat Lubrifier les...

Page 252: ...any 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 spe...

Page 253: ...pour fils ou un calibre d paisseur Hors sp cifications R gler 4 Si n cessaire nettoyer la bougie l aide d un nettoie bougies Ecartement des lectrodes 0 7 0 8 mm 0 028 0 031 in 5 Serrer Bougie N B Ava...

Page 254: ...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 255: ...ion REGLAGE DU REGIME DE RALENTI DU MOTEUR 4 Contr ler Avance l allumage Contr ler visuellement que l index fixe a se trouve dans la plage d allumage b indiqu e sur le rotor Plage d allumage incorrect...

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

Page 257: ...HES LATERAUX Pr paration la d pose Placer le robinet de carburant en position OFF D connecter la durit de carburant 1 Selle 1 2 Prise d air gauche et droite 2 3 Boulon r servoir de carburant 2 4 R ser...

Page 258: ...e number plate Pull the band off the pro jection before removal Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the num ber plate The projection c on the lower bracket is i...

Page 259: ...de la plaque d identification Retirer l ergot du collier avant la d pose D poser le c ble du starter chaud 2 et le c ble d embrayage 3 du guide c ble b sur la plaque d identification L ergot c du t i...

Page 260: ...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 silencer...

Page 261: ...rter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Boulon collier pince du silencieux 1 Desserrer uniquement 2 Boulon silencieux avant 1 3 Boulon silencieux arri re 1 4 Entretoise paul...

Page 262: ...tting holes 4 9 mm a in removal NOTE Pull out the inner pipe while lightly tapping the stay b on the silencer using a soft hammer 2 Replace Fiber 1 a 1 2 1 b 1 3 Install Inner pipe 1 Rivet front 2 NOT...

Page 263: ...Extraire le tuyau int rieur tout en frap pant l g rement sur le support b du silencieux l aide d un maillet en caout chouc 2 Remplacer Fibre 1 3 Monter Tuyau int rieur 1 Rivet avant 2 N B Appliquer la...

Page 264: ...aust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhaust pipe 24 Nm 2 4 m kg 17 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 24 Nm 2 4 m kg 17 ft lb 2 Install Silencer clamp 1 Gasket 2 Silencer 3 Washer...

Page 265: ...3 Nm 1 3 m kg 9 4 ft lb puis le boulon tube d chappement 24 Nm 2 4 m kg 17 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 24 Nm 2 4 m kg 17 ft lb 2 Monter Collier pince du silencieux 1 Joint 2 Silencieux 3 Ro...

Page 266: ...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 10 Only loosening 3 Radiator hose 1 1 4 Lef...

Page 267: ...BURANT ET CACHES LATERAUX 1 Plaque de protection du radiateur 2 2 Collier de durit de radiateur 10 Desserrer uniquement 3 Durit de radiateur 1 1 4 Radiateur gauche 1 5 Durit de radiateur 3 1 6 Tuyau d...

Page 268: ...ressure 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 Radiator core 1 Obstruction Blo...

Page 269: ...des aiguilles d une montre puis l enlever CONTROLE Radiateur 1 Contr ler Faisceau de radiateur 1 Obstruction Nettoyer l air comprim par l arri re du radia teur Ailette tordue R parer rempla cer ASSEMB...

Page 270: ...ll Left radiator 1 Bolt left radiator 2 Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Tighten Radiator hose clamp 4 6 Install Radiator guard 1 Bolt radiator guard 2 NOTE...

Page 271: ...la section DIA GRAMME D ACHEMINE MENT DES CABLES au CHAPITRE 2 5 Serrer Collier de durit du radiateur 4 6 Monter Plaque de protection de radiateur 1 Boulon protection du radiateur 2 N B Ins rer le cro...

Page 272: ...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 273: ...apide du fil du capteur de position de papillon des gaz 1 3 Couvercle du logement du c ble des gaz 1 4 C ble des gaz 2 5 Collier pince conduit d admission d air 1 Desserrer la vis raccord du filtre ai...

Page 274: ...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 275: ...u levier de soupape 1 3 Vis axe du papillon 1 4 Papillon des gaz 1 5 Support d aiguille 1 6 Aiguille 1 7 Couvercle de la pompe de reprise 1 8 Ressort 1 9 Diaphragme pompe de reprise 1 0 Cuve 1 A Gicle...

Page 276: ...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 277: ...lenti 1 J Gicleur de starter 1 K Tige de d brayage 1 Tirer la tige de d brayage L Axe du papillon complet 1 M Ensemble levier articul de la tige de d brayage 1 N Gicleur d air de ralenti 1 O Plongeur...

Page 278: ...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 279: ...B Pour optimiser le d bit de carburant faible ouverture du papillon la vis de ralenti de chaque moto a t r gl e indi viduellement en usine Avant de d poser la vis de ralenti la serrer fond en comptan...

Page 280: ...ir Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean EC464301 Throttle valve 1 Check Free movement Stick Repair or replace...

Page 281: ...Pointeau 1 Si ge de pointeau 2 Usure en creux a Remplacer Poussi re b Nettoyer Filtre c Bouch Nettoyer Papillon des gaz 1 Contr ler Mouvement Coincement R parer ou rem placer N B Ins rer le papillon d...

Page 282: ...the float will push in the needle valve resulting 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 283: ...ulisse mesurer la distance entre la surface de contact de la cuve et le haut du flotteur N B Le bras du flotteur doit reposer sur le pointeau mais sans le comprimer Si la hauteur du flotteur est hors...

Page 284: ...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 285: ...la pompe de reprise 3 Joint torique 4 Tige de d brayage 5 Craquelures diaphragme endommagement Remplacer Salet Nettoyer 2 Contr ler Axe du papillon 1 Ressort 2 Levier 1 3 Ressort 1 4 Levier 2 5 Ressor...

Page 286: ...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 287: ...levier articul de la tige de d brayage 1 N B Veiller engager la but e a du ressort 2 dans la gorge b du carburateur 6 Monter Rondelle 1 Circlip 2 7 Monter Ressort 1 Sur l axe du papillon 2 N B Monter...

Page 288: ...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 289: ...du carburateur Tourner l ensemble axe de papillon vers la gauche tout en maintenant le levier 1 5 abaiss et engager la pointe de la vis de but e de papillon des gaz d sur la but e e de la poulie de l...

Page 290: ...rew until it is lightly seated Turn out the pilot screw by the number of turns recorded before removing Pilot screw example 2 1 2 turns out 2 1 4 turns out 13 Install O ring Leak jet 1 Float chamber 2...

Page 291: ...du nom bre de tours enregistr avant la d pose Vis de ralenti exemple Desserr e de 2 1 2 tour Desserr e de 2 1 4 tour 13 Monter Joint torique Gicleur de fuite 1 Cuve 2 Boulon cuve 3 Support de c ble c...

Page 292: ...lve assembly 1 Screw throttle shaft 2 NOTE Install the valve lever rollers 3 into the slits a of the throttle valve 17 Install O ring 1 Valve lever housing cover 2 Bolt valve lever housing cover 3 18...

Page 293: ...on 17 Monter Joint torique 1 Couvercle du bo tier du levier de soupape 2 Boulon couvercle du bo tier du levier de soupape 3 18 Monter Durit de mise l air du carbura teur 1 N B Monter les durits de mis...

Page 294: ...0 031 in 0 7 mm 0 028 in Fully turn in the accelerator pump adjust ing screw 3 Check that the link lever 4 has free play b by pushing lightly on it Gradually turn out the adjusting screw while moving...

Page 295: ...de la pompe de reprise 3 Contr ler que le levier articul 4 a du jeu b en appuyant l g rement dessus D visser progressivement la vis de r glage tout en d pla ant le levier articul jusqu ce qu il n ait...

Page 296: ...le pull 1 Throttle cable return 2 6 Adjust Throttle grip free play Refer to THROTTLE CABLE 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 T...

Page 297: ...au CHAPITRE 3 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 Monter Couvercle du logement du c ble des gaz 1 Boulon couvercle du logement de c ble des gaz 2 T R 4 Nm 0 4 m kg 2 9 ft lb 8 M...

Page 298: ...Order Part name Q ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bo...

Page 299: ...et r servoir de carburant Se reporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Bougie 1 2 Durit de mise l air de la culasse 1 3 Boulon couvre culasse 2 4 Couvre culasse 1 5 Joint...

Page 300: ...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 301: ...E DEPOSE 2 Vis d acc s axiale du 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 arbre cames 2 6 Clip 2 7 Arbre cames d chappe...

Page 302: ...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 303: ...cames d chappement et le rep re poin onn d de l arbre cames d admission sont align s avec la sur face de la culasse comme le montre l illustration 3 D poser Boulon capuchon du tendeur de cha ne de dis...

Page 304: ...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 305: ...Longueur des bossages de cames Admission a 30 296 30 346 mm 1 1923 1 1947 in Limite 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limite 22 35 mm 0 8799 in Echappement a 30 399 30 499 mm 1 19...

Page 306: ...m 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 camshaf...

Page 307: ...internes vers les chapeaux ext rieurs Ne pas tourner l arbre cames pendant la mesure du jeu avec le Plastigauge D poser les chapeaux d arbres cames et mesurer la largeur du Plastigauge 1 5 Mesurer Dia...

Page 308: ...ALLATION Camshaft 1 Install Exhaust camshaft 1 Intake camshaft 2 Checking steps Check that the decompression mecha nism cam 1 moves smoothly Check that the decompression mecha nism cam lever pin 2 pro...

Page 309: ...i ce n est pas le cas remplacer le tendeur complet ASSEMBLAGE ET MONTAGE Arbre cames 1 Monter Arbre cames d chappement 1 Arbre cames d admission 2 Etapes du montage Tourner le vilebrequin dans le sens...

Page 310: ...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 311: ...lb N B Avant de d poser les clips couvrir la culasse avec un chiffon propre pour emp cher les clips de tomber dans la cavit de la culasse Appliquer de l huile au bisulfure de molybd ne sur les filets...

Page 312: ...the 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 3 Turn Crankshaft Counterc...

Page 313: ...serrer le joint 4 et le boulon capuchon 5 au couple sp cifi T R Boulon capuchon du ten deur 7 Nm 0 7 m kg 5 1 ft lb 3 Tourner Vilebrequin Plusieurs tours dans le sens inverse des aiguilles d une mont...

Page 314: ...head cover 3 Bolt cylinder head cover 4 NOTE Apply the sealant on the cylinder head cover gasket YAMAHA Bond No 1215 ThreeBond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 7 Install Oil tank breat...

Page 315: ...le produit d tanch it sur le joint de couvre culasse T R 10 Nm 1 0 m kg 7 2 ft lb YAMAHA Bond N 1215 ThreeBond N 1215 90890 85505 7 Monter Durit de mise l air du r servoir d huile Durit de mise l air...

Page 316: ...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 317: ...ateur 1 D connecter du c t de la culasse Carburateur Se reporter la section CARBURATEUR Arbre cames Se reporter la section ARBRES A CAMES Support de moteur sup rieur Se reporter la section DEPOSE DU M...

Page 318: ...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 319: ...tifier D formation de la culasse Inf rieure 0 05 mm 0 002 in Etapes de la mesure de la limite de d formation et de la rectification Placer un r glet et une jauge d paisseur lames sur la culasse Utilis...

Page 320: ...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 nu...

Page 321: ...u bisulfure de molybd ne sur les filets et les surfaces de contact des boulons Suivre l ordre num rique indiqu dans l illustration Serrer les boulons et les crous en deux tapes T R 38 Nm 3 8 m kg 27 f...

Page 322: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cot...

Page 323: ...pe 5 Utiliser l outil sp cial Se reporter POINTS DE DEPOSE 2 Cale de r glage 5 3 Clavette de soupape 10 4 Coupelle de ressort de soupape 5 5 Ressort de soupape 5 6 Joint de queue de soupape 5 7 Si ge...

Page 324: ...lve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly...

Page 325: ...largeur du si ge de soupape Etapes du contr le Verser du solvant de nettoyage 1 dans les lumi res d admission et d chappement Contr ler soigneusement les joints de soupapes Il ne peut y avoir aucune...

Page 326: ...3 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head i...

Page 327: ...ement N B Afin de faciliter la d pose et le mon tage du guide et afin de maintenir l ajustement correct chauffer la culasse dans un four une temp ra ture de 100 C 212 F D poser le guide de soupape l a...

Page 328: ...7 90890 04117 Valve guide reamer Intake 4 0 mm 0 16 in YM 4113 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 90890 04118 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pi...

Page 329: ...0 18 in YM 4118 90890 04118 N B Apr s avoir remplac le guide de soupape rectifier le si ge de soupape 3 Contr ler Port e de soupape Piq res usure Rectifier la por t e de soupape Embout de queue de so...

Page 330: ...a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps App...

Page 331: ...n 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Echappement 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Etapes de la mesure Appliquer du bleu de m canicien Dykem b sur la port e de sou p...

Page 332: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Page 333: ...ats de rodage tapoter l g rement le si ge de soupape tout en faisant tourner la soupape entre les mains avec un mouvement de va et vient Appliquer une p te roder fine sur la port e de soupape et r p t...

Page 334: ...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 335: ...com prim Admission 99 114 N 29 13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in Echappement 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in 3 Mesurer Inclinaison du ressort a Hors sp...

Page 336: ...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 337: ...essorts de soupape en pla ant les spires les plus grandes c vers le haut d Petites spires 3 Monter Clavette de soupape N B Monter les clavettes de soupape tout en comprimant le ressort de soupape l ai...

Page 338: ...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 339: ...uer de l huile moteur sur les poussoirs de soupapes Le poussoir de soupape doit tourner librement sous la pouss e du doigt Veiller remonter les poussoirs de soupapes et les cales leur emplace ment d o...

Page 340: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin cli...

Page 341: ...S 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 l outil sp cial Se reporter POINTS DE DEPO...

Page 342: ...se a hammer to drive the piston pin out 2 Remove Piston ring 1 NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustrati...

Page 343: ...n soulevant le segment de piston par des sus la calotte du piston comme illustr Kit extracteur d axe de pis ton YU 1304 90890 01304 CONTROLE Cylindre et piston 1 Contr ler Parois du cylindre et du pis...

Page 344: ...re the piston skirt diameter P with a micrometer a 8 mm 0 31 in from the piston bottom edge Piston size P Standard 76 955 76 970 mm 3 0297 3 0303 in If out of specification replace the piston and pist...

Page 345: ...u piston Taille du piston P Standard 76 955 76 970 mm 3 0297 3 0303 in Si hors sp cifications remplacer ensemble le piston et les segments de piston 3 me tape Calculer le jeu entre piston et cylindre...

Page 346: ...rown 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 00...

Page 347: ...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 Coupe de segment Hors sp cifications Rempla cer N B Il n est pas...

Page 348: ...piston and piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 15 991 16 000...

Page 349: ...piston a Si hors sp cifications remplacer l axe de piston Diam tre ext rieur axe de piston 15 991 16 000 mm 0 6296 0 6299 in Mesurer le diam tre int rieur pis ton b Diam tre int rieur pis ton 16 002 1...

Page 350: ...ton Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from...

Page 351: ...r sur l axe de piston et le piston Contr ler que la fl che a du piston pointe vers le c t chappement du moteur Avant de monter l agrafe d axe de pis ton couvrir le carter d un chiffon pro pre pour vit...

Page 352: ...h one hand while com pressing the piston rings with the other hand CAUTION Pass the timing chain 3 through the tim ing chain cavity Be careful not to damage the timing chain guide 4 during installatio...

Page 353: ...ON Acheminer la cha ne de distribu tion 3 dans la cavit de la cha ne de distribution Veiller ne pas endommager le patin de cha ne de distribution 4 pendant l installation 4 Monter Boulon cylindre 5 T...

Page 354: ...al Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOV...

Page 355: ...CHANGEMENT DE L HUILE MOTEUR au CHAPITRE 3 P dale de frein Se reporter la section DEPOSE DU MOTEUR C ble d embrayage D connecter du c t du moteur 1 Couvercle d embrayage 1 2 Ressort d appui du plateau...

Page 356: ...ty Remarks 10 Friction plate 9 11 Clutch plate 8 12 Cushion spring 1 13 Seat plate 1 14 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 15 Lock washer 1 16 Clutch boss 1 17 Thrust washer 1...

Page 357: ...si ge 1 14 Ecrou noix d embrayage 1 Utiliser l outil sp cial Se reporter POINTS DE DEPOSE 15 Rondelle frein 1 16 Noix d embrayage 1 17 Rondelle de but e 1 18 Pignon men de transmission primaire 1 19...

Page 358: ...YM 91042 90890 04086 EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1...

Page 359: ...t Remplacer Noix d embrayage 2 Formation de rayures usure endommagement Remplacer Pignon men de transmission primaire 1 Contr ler Jeu p riph rique Pr sence de jeu Remplacer Dents de pignon a Usure end...

Page 360: ...Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 7 mm 0 106 in Warp limit...

Page 361: ...rbre 1 et une jauge d paisseur 2 Epaisseur du disque garni 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 Arbre de tige de pouss e 1 Contr ler Arbre de tige de...

Page 362: ...the groove a of the push lever shaft and tighten the bolt seat plate T R 10 Nm 1 0 m kg 7 2 ft lb Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on the...

Page 363: ...onter Pignon men de transmission pri maire 1 Rondelle de but e 2 Noix d embrayage 3 N B Appliquer de l huile moteur sur la cir conf rence int rieure du pignon men de transmission primaire 2 Monter Ron...

Page 364: ...Install 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 pa...

Page 365: ...ni et en ter minant par un disque garni Utiliser les disques garnis 1 comme premier et dernier disques en tenant compte de la diff rence de motifs de la surface Appliquer de l huile moteur sur les dis...

Page 366: ...essure plate 1 9 Install Clutch spring 1 Bolt clutch spring 2 NOTE Tighten the bolts in stage using a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb 10 Install Dowel pin 1 Gasket clutch cover 2 11 In...

Page 367: ...r Ressort d embrayage 1 Boulon ressort d embrayage 2 N B Serrer les boulons par tapes et en proc dant en croix T R 10 Nm 1 0 m kg 7 2 ft lb 10 Monter Goujon 1 Joint couvercle d embrayage 2 11 Monter C...

Page 368: ...rks OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to CO...

Page 369: ...n CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT au CHAPITRE 3 Durit de radiateur 3 D connecter du c t de la pompe eau Tube d chappement Se reporter la section TUBE D ECHAPPEMENT ET SILENCIEUX P dale de fre...

Page 370: ...VER Extent of removal Order Part name Q ty Remarks 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to REMOVAL POINTS 9...

Page 371: ...vercle de carter droit 1 8 Rotor 1 Se reporter POINTS DE DEPOSE 9 Rondelle 1 10 Axe de pompe 1 11 Bague d tanch it 2 12 Roulement 1 3 2 Estensione della rimozione Ordine Denominazione Quantit Osservaz...

Page 372: ...oss the flats a with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant le...

Page 373: ...u niveau de liquide de refroidissement une d coloration du liquide de refroidisse ment ou un aspect laiteux de l huile de bo te de vitesses 1 D poser Roulement 1 2 D poser Bague d tanch it 1 CONTROLE...

Page 374: ...Gear teeth a Wear damage Replace EC4H4600 Bearing 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace EC444400 Oil seal 1 Inspect Oil seal 1 Wear damage Replace ASSEMBLY AND...

Page 375: ...tanch it 1 Contr ler Bague d tanch it 1 Usure endommagement Rem placer ASSEMBLAGE ET MONTAGE Bague d tanch it 1 Monter Bague d tanch it 1 N B Appliquer de la graisse savon de lithium sur la l vre de...

Page 376: ...dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning...

Page 377: ...entra nement Monter l axe tout en le faisant tourner Maintenir l axe de pompe en le saisis sant par les c t s plats a l aide d une cl etc et monter le rotor T R 14 Nm 1 4 m kg 10 ft lb Couvercle de ca...

Page 378: ...kg 7 2 ft lb Kickstarter crank 1 Install Kickstarter crank 1 Washer 2 Bolt kickstarter crank 3 NOTE Install the kickstarter crank with the kickstarter crank and frame 15 mm 0 59 in or more apart a an...

Page 379: ...s de 15 mm 0 59 in ou plus a et l axe et le carter droit loign s de 3 mm 0 12 in ou plus b 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 8 m kg 5 8 ft lb 3 Mo...

Page 380: ...he lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter element 1 Install Oil filter element 1 O ring 2 Oil filter el...

Page 381: ...nt de filtre huile 3 Boulon couvercle d l ment de filtre huile N B Appliquer de la graisse savon de lithium sur le joint torique T R 10 Nm 1 0 m kg 7 2 ft lb Alloggiamento della pompa dell acqua 1 Ins...

Page 382: ...r to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to REMOVAL POIN...

Page 383: ...menant de transmission pri maire 1 Se reporter POINTS DE DEPOSE 2 Ecrou pignon men de l arbre de balancier 1 3 Rondelle frein 1 4 Pignon menant de transmission primaire 1 5 Pignon menant de l arbre d...

Page 384: ...d driven gear 4 Balancer shaft 1 Remove Balancer shaft 1 NOTE When removing the balancer shaft align the center a of the balancer shaft weight along the line connecting the centers of the crank shaft...

Page 385: ...bre de balancier CONTROLE Pignon menant de transmission pri maire pignon menant et pignon men de l arbre de balancier 1 Contr ler Pignon menant de transmission primaire 1 Pignon menant de l arbre de b...

Page 386: ...r shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 NOTE Align the punched mark a on the balancer shaft drive gear with the punched mark b on th...

Page 387: ...le rep re poin onn c du pignon menant de l arbre du balancier avec la cannelure inf rieure d de l extr mit du vilebrequin 4 Monter Rondelle frein 1 Ecrou pignon men de l arbre de balancier 2 Pignon m...

Page 388: ...EMBLY Preparation for removal Primary driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section 1 Circlip 1 2 Washer 1 3 Oil p...

Page 389: ...POMPE A EAU ET COUVERCLE DE CAR TER DROIT 1 Circlip 1 2 Rondelle 1 3 Pignon menant de pompe huile 1 4 Pompe huile compl te 1 5 Rotor externe 2 1 6 Circlip 1 7 Rotor interne 2 1 8 Goujon 1 9 Couvercle...

Page 390: ...4 68 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 2...

Page 391: ...e la d pose Ordre Nom de la pi ce Qt Remarques 12 Goujon 1 13 Rondelle 1 14 Arbre d entra nement de pompe huile 1 15 Bo tier du rotor 1 2 Estensione della rimozione Ordine Denominazione Quantit Osserv...

Page 392: ...of removal Order Part name Q ty Remarks OIL TANK REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pi...

Page 393: ...paration la d pose Vidanger l huile moteur Se reporter la section CHANGEMENT DE L HUILE MOTEUR au CHAPITRE 3 1 Durit d huile 2 1 2 Durit d huile 1 1 3 Goujon 2 4 Durit de mise l air du r servoir d hui...

Page 394: ...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 395: ...tor 3 et les rotors 1 2 Hors sp cifications Remplacer la pompe huile compl te Jeu entre rotors a 0 12 mm ou moins 0 0047 in ou moins Limite 0 20 mm 0 008 in Jeu lat ral b 0 09 0 17 mm 0 0035 0 0067 in...

Page 396: ...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 397: ...1 1 N B Appliquer de l huile moteur sur le rotor externe 1 3 Monter Couvercle de pompe huile 1 Vis couvercle de pompe huile 2 Goujon 3 Rotor interne 2 4 Circlip 5 N B Appliquer de l huile moteur sur l...

Page 398: ...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 399: ...le rotor externe 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 Monter Pignon menant de pompe huile 1 Rondelle 2 Circlip 3 N B Appliquer de l huile moteur sur la cir conf rence int rie...

Page 400: ...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 401: ...uile Se reporter la section POMPE A HUILE 1 Pignon fou de kick 1 2 Arbre de kick complet 1 Se reporter POINTS DE DEPOSE 3 Guide de ressort 1 4 Ressort de torsion 1 5 Roue rochet 1 6 Pignon de kick 1 7...

Page 402: ...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 403: ...eur complet 1 16 Levier de s lecteur 1 17 Cliquet 2 18 Goupille de cliquet 2 19 Ressort 2 20 Boulon doigt de verrouillage 1 21 Doigt de verrouillage 1 22 Ressort de torsion 1 23 Segment 1 Se reporter...

Page 404: ...100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt CAUTION If the segment gets an impact it may be damaged Take care not to give an...

Page 405: ...a but e et desserrer le boulon ATTENTION Si le segment re oit un impact il ris que d tre endommag Veiller ne pas heurter le segment lors de la d pose du boulon CONTROLE Arbre de kick et roue rochet 1...

Page 406: ...4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace ASSEMBLY AND INSTALLATION Segment 1 Install Segment 1 Bolt segment N...

Page 407: ...verrouillage 1 Contr ler Doigt de verrouillage 1 Usure endommagement Rem placer Ressort de torsion 2 Cass Remplacer ASSEMBLAGE ET MONTAGE Segment 1 Monter Segment 1 Boulon segment N B Aligner l encoc...

Page 408: ...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 409: ...er de l huile moteur sur le res sort la goupille de cliquet et le cliquet 2 Monter Levier de s lecteur complet 1 Sur le guide de s lecteur 2 3 Monter Levier de s lecteur complet 1 Guide de s lecteur 2...

Page 410: ...1 4 mm 0 06 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 NOT...

Page 411: ...2 Circlip 3 Roue rochet 4 Ressort 5 Rondelle 6 Circlip 7 Sur l arbre de kick 8 N B Appliquer de l huile au bisulfure de molybd ne sur les circonf rences internes du pignon de kick et de la roue roche...

Page 412: ...top per a and kick shaft ratchet wheel guide 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 kick shaft...

Page 413: ...et v rifier que la but e d arbre de kick a s engage dans le guide de roue rochet de l arbre de kick 5 Accrocher Ressort de torsion 1 N B Faire tourner le ressort de torsion dans le sens des aiguilles...

Page 414: ...arks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT sect...

Page 415: ...a section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX D connecter le fil du volant magn tique CDI S lecteur Se reporter la section ARBRE DE KICK ET AXE DE SELECTEUR 1 Couvercle de carter gauche 1...

Page 416: ...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 417: ...s d une montre Extracteur de volant magn tique YM 1189 90890 01189 CONTROLE Volant magn tique CDI 1 Contr ler Surface int rieure du rotor a Surface ext rieure du stator b Endommagement Contr ler le fa...

Page 418: ...05 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 in pa...

Page 419: ...Rotor 2 N B Nettoyer les parties coniques du vile brequin et du rotor En montant la clavette demi lune veiller ce que sa surface plane a soit parall le la ligne de centrage du vilebrequin b En montan...

Page 420: ...ING DIAGRAM 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 NOTE Tighten the bolts in...

Page 421: ...2 5 Monter Goujon Joint couvercle de carter gau che Couvercle de carter gauche 1 Guide de durit durit de mise l air de la culasse 2 Boulon couvercle de carter gau che N B Serrer les boulons par tapes...

Page 422: ...l 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 Disconnect at engine sid...

Page 423: ...r du c t du moteur Radiateur Se reporter la section RADIATEUR S lecteur Se reporter la section ARBRE DE KICK ET AXE DE SELECTEUR Durits de mise l air de la culasse Se reporter la section ARBRES A CAME...

Page 424: ...Right engine guard 1 Lower engine guard 1 2 Neutral switch 1 3 Drive chain sprocket cover 1 4 Nut drive sprocket 1 Refer to REMOVAL POINTS 5 Lock washer 1 6 Drive sprocket 1 7 Clip 1 8 Bolt brake peda...

Page 425: ...ouronne arri re 1 Se reporter POINTS DE DEPOSE 5 Rondelle frein 1 6 Couronne arri re 1 7 Clip 1 8 Boulon p dale de frein 1 9 P dale de frein 1 10 Support de moteur sup rieur 2 11 Support de moteur inf...

Page 426: ...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 427: ...D pose du moteur 1 D poser Boulon pivot 1 N B Si l on extrait enti rement le boulon pivot le bras oscillant n est plus sup port Si possible ins rer un axe de dia m tre quivalent dans l autre extr mit...

Page 428: ...denum disulfide grease on the pivot shaft Install the patch with the claw a facing out side the chassis T R 85 Nm 8 5 m kg 61 ft lb T R 53 Nm 5 3 m kg 38 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 53 Nm 5...

Page 429: ...8 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 53 Nm 5 3 m kg 38 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb P dale de frein 1 Monter Ressort 1 P dale de frein...

Page 430: ...ive chain sprocket guide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 T R 8 Nm 0 8 m kg 5 8 ft lb Neutral switch and hose guide 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4...

Page 431: ...ft lb Contacteur point mort et durit de frein 1 Monter Ressort 1 Goupille 2 Joint torique 3 Contacteur de point mort 4 Vis contacteur de point mort 5 N B Appliquer de la graisse savon de lithium sur l...

Page 432: ...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 433: ...e de kick complet Se reporter la section ARBRE DE KICK ET AXE DE SELECTEUR Segment Stator Se reporter la section VOLANT MAGNETIQUE CDI Arbre de balancier Se reporter la section BALANCIER 1 Patin de ch...

Page 434: ...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 435: ...55 mm 2 17 in 1 6 Boulon L 70 mm 2 76 in 4 7 Guide de durit 1 8 Support du c ble d embrayage 1 9 Carter moteur droit 1 10 Carter moteur gauche 1 11 Cr pine huile 1 12 Vilebrequin 1 Utiliser l outil sp...

Page 436: ...1 Crankcase bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift c...

Page 437: ...UR Pr paration la d pose Bo te de vitesses Se reporter la section BOITE DE VITESSES TAM BOUR ET FOURCHETTES DE SELECTION Tambour et fourchette de s lection 1 Bague d tanch it 2 2 Roulement 10 Se repor...

Page 438: ...right half apart while lift ing it horizontally by lightly tapping the projection a on it using a soft hammer When splitting it leave the crankshaft and transmission with the left half CAUTION Use so...

Page 439: ...s paration laisser le car ter et la bo te de vitesses avec la moiti gauche ATTENTION Taper sur le demi carter l aide d un maillet en plastique Ne taper que sur portions renforc es du car ter Ne pas t...

Page 440: ...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 441: ...Contr ler Cha ne de distribution Fissures rigidit Remplacer ensemble la cha ne de distribu tion et le pignon d arbre cames 2 Contr ler Patin de cha ne de distribution Usure endommagement Rem placer Ca...

Page 442: ...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 443: ...pied de bielle 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Jeu lat ral 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Largeur de volant 55 95 56 00 mm 2 203 2 205 in Cr pine huile 1 Contr ler Cr pine hui...

Page 444: ...shaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 For USA and CDN Except for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut o...

Page 445: ...rt haut d une main tout en tournant l crou de l outil de montage de l autre main Actionner l outil de montage jusqu ce que le vilebrequin bute contre le roulement Avant de monter le vilebrequin net to...

Page 446: ...ht crankcase 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 o...

Page 447: ...tact des carters moteur droit et gauche avant d appliquer la p te d tanch it 5 Monter Goujon 1 Joint torique 2 Carter moteur droit Sur le carter moteur gauche N B Adapter le carter moteur droit sur le...

Page 448: ...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 449: ...tin de cha ne de distribution c t admission 2 Boulon patin de cha ne de distri bution 3 9 D poser P te d tanch it R pandue sur la surface de con tact du cylindre 10 Appliquer Huile moteur Sur le manet...

Page 450: ...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 451: ...n DEPOSE DU MOTEUR S parer le carter moteur Se reporter la section CARTER MOTEUR ET VILE BREQUIN 1 Arbre primaire 1 Se reporter POINTS DE DEPOSE 2 Arbre secondaire 1 3 Tambour 1 4 Fourchette de s lect...

Page 452: ...rticular 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 453: ...g rement sur l arbre secondaire de la transmission l aide d un marteau en plastique CONTROLE Pignons 1 Contr ler Crabot d accouplement a Dents du pignon b Gorge de fourchette de s lection c Usure end...

Page 454: ...hift fork NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION Transmission 1 Install 5th p...

Page 455: ...les deux pignons adjacents ASSEMBLAGE ET MONTAGE Bo te de vitesses 1 Monter Pignon de 5 me 24T 1 Pignon de 3 me 20T 2 Entretoise paul e 3 Pignon de 4 me 22T 4 Pignon de 2 me 16T 5 Sur l arbre primaire...

Page 456: ...the inner surface of the sliding gear then install Apply the lithium soap base grease on the O ring 3 Install Washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite s...

Page 457: ...l oppos de la rondelle et du pignon b Monter le circlip en asseyant unifor m ment ses extr mit s c sur les cr tes des cannelures 4 Monter Entretoise paul e 1 N B Appliquer de la graisse savon de lith...

Page 458: ...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 459: ...hette n 3 D avec le pignon de 5 me 7 de l arbre secondaire Engrener la fourchette n 2 C avec le pignon de 3 me 6 de l arbre princi pal 6 Monter Bo te de vitesses compl te 1 Sur le carter moteur gauche...

Page 460: ...removal Order Part name Q ty Remarks FRONT WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable...

Page 461: ...paration la d pose Caler la moto en pla ant un support ad quat sous le moteur 1 Boulon support d axe 4 Desserrer uniquement 2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Entretois...

Page 462: ...machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive ch...

Page 463: ...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 DEPOSE 5 Entretoise paul e 2 6 Pignon de roue arri re 1 7 Bagu...

Page 464: ...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 465: ...Mesurer Voile de roue Hors sp cifications R parer remplacer Limite de voile de roue Radial 1 2 0 mm 0 08 in Lat ral 2 2 0 mm 0 08 in 2 Contr ler Roulement Faire tourner la cage interne avec le doigt...

Page 466: ...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 467: ...arri re seulement Utiliser le comparateur cadran 1 Hors sp cifications Contr ler le voile de roue Si le voile de roue est normal remplacer le disque de frein 2 Mesurer Epaisseur du disque de frein a H...

Page 468: ...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 469: ...ENTION Ne pas frapper sur la cage interne du roulement Le contact ne peut avoir lieu qu avec la cage externe 2 Monter Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tapes et en...

Page 470: ...base grease on the wheel axle 6 Install Nut wheel axle 1 T R 105 Nm 10 5 m kg 75 ft lb 7 Tighten Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking t...

Page 471: ...105 Nm 10 5 m kg 75 ft lb 7 Serrer Boulon support d axe 1 N B Avant de serrer le boulon engager l axe de roue dans le support d axe en pous sant plusieurs fois sur la fourche tout en serrant le frein...

Page 472: ...f bearing shall be installed 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...

Page 473: ...ricant ATTENTION Ne pas frapper sur la cage interne du roulement Le contact ne peut avoir lieu qu avec la cage externe 2 Monter Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par ta...

Page 474: ...ctly 6 Install Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 NOTE Install the left drive chain puller and insert the wheel ax...

Page 475: ...transmission 1 Axe de roue 2 N B Monter le tendeur gauche de la cha ne de transmission et ins rer l axe de roue du c t gauche Appliquer de la graisse savon de lithium sur l axe de roue 8 Monter Tende...

Page 476: ...HEEL 9 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 Drive chain slack 48 58 mm 1 9 2 3 in 10 Tighten Nut wheel axle 1 Locknut 2 T R 125 Nm 12 5 m kg 90 ft...

Page 477: ...TRANS MISSION au CHAPITRE 3 Tension de la cha ne de transmission 48 58 mm 1 9 2 3 in 10 Serrer Ecrou axe de roue 1 Contre crou 2 T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb 9 Regolare Gi...

Page 478: ...ely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Drain the brake fluid Refer to REMOVAL POINTS 1 Brake hose holder p...

Page 479: ...liquide de frein Se reporter POINTS DE DEPOSE 1 Support de durit de frein protection 2 2 Support de durit de frein etrier de frein 1 3 Boulon de raccord 2 4 Durit de frein 1 5 Bouchon de goupille de p...

Page 480: ...alling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOVAL POINTS...

Page 481: ...orter 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 frein 2 4 Boulon de raccord...

Page 482: ...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 483: ...DEMONTAGE DE L ETRIER DE FREIN A B 1 Goupille de plaquette 1 1 2 Plaquette de frein 2 2 3 Support de plaquette 1 1 4 Piston d trier de frein 2 1 Se reporter POINTS DE DEPOSE 5 Joint antipoussi re 2 1...

Page 484: ...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 485: ...RE DE FREIN 1 Couvercle de ma tre cylindre de frein 1 2 Diaphragme 1 3 Flotteur du r servoir 1 4 Soufflet de ma tre cylindre de frein 1 5 Circlip 1 Utiliser une pince circlip bec long 6 Rondelle 1 7 T...

Page 486: ...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 487: ...te trace de liquide renvers Piston d trier de frein 1 D poser Piston d trier de frein Utiliser de l air comprim et pro c der prudemment AVERTISSEMENT Recouvrir le piston d un chiffon et faire tr s att...

Page 488: ...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 489: ...Avant Arri re CONTROLE Ma tre cylindre de frein 1 Contr ler Surface interne du ma tre cylin dre de frein a Usure rayures Remplacer le ma tre cylindre complet Taches Nettoyer AVERTISSEMENT Utiliser uni...

Page 490: ...per piston 1 Wear score marks Replace brake cali per piston assembly WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Cra...

Page 491: ...ts de pis ton et antipoussi re 2 lors du d mon tage d un trier Durit de frein 1 Contr ler Durit de frein 1 Craquelures endommagement Remplacer ASSEMBLAGE ET MONTAGE AVERTISSEMENT Toutes les pi ces int...

Page 492: ...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 493: ...1 N B Appliquer du liquide de frein sur la paroi du piston ATTENTION Monter le piston en orientant sa face l g rement surbaiss e a vers l trier de frein Ne jamais forcer pour ins rer Avant Arri re Et...

Page 494: ...g 17 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb Rear brake caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the brake...

Page 495: ...2 ft lb Etrier de frein arri re 1 Monter Support de plaquette 1 Plaquette de frein 2 Goupille de plaquette 3 N B Monter les plaquettes de frein en ins rant leurs ergots a dans les gorges des triers d...

Page 496: ...e 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 piston 3 NOTE Apply the brake fluid on th...

Page 497: ...u ma tre cylindre secondaire 2 Sur le piston du ma tre cylindre de frein 3 N B Appliquer le liquide de frein sur la cou pelle du ma tre cylindre de frein AVERTISSEMENT Apr s la repose la coupelle du c...

Page 498: ...ake master cyl inder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers Front Rear Front brake master cylinder 1 Install Brake...

Page 499: ...hium sur l extr mit de la tige de commande Monter le circlip l aide d une pince circlip Avant Arri re Ma tre cylindre de frein avant 1 Monter Ma tre cylindre de frein 1 Support de ma tre cylindre de f...

Page 500: ...lways use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T...

Page 501: ...on et touche l g rement la saillie b du ma tre cylindre de frein T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb T R 30 Nm 3 0 m kg 22 ft lb 2 Monter Ma tre cylindre de frein 1 Boulon ma tre c...

Page 502: ...3 WARNING Always use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake cali per T R 30 Nm 3 0 m kg 22 ft...

Page 503: ...ur l illustration et touche l g rement la saillie b de l trier de frein T R 30 Nm 3 0 m kg 22 ft lb 2 Monter Support de durit de frein 1 Boulon support de durit de frein 2 T R 10 Nm 1 0 m kg 7 2 ft lb...

Page 504: ...o that its pipe por tion 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 b...

Page 505: ...in arri re 1 Monter Rondelle en cuivre 1 Durit de frein 2 Boulon de raccord3 AVERTISSEMENT Toujours utiliser des rondelles en cui vre neuves ATTENTION Monter la durit de frein de mani re que sa partie...

Page 506: ...rake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and...

Page 507: ...m me marque de liquide de frein le m lange de liquides de marques diff rentes risque de provoquer une r action chimique nuisible au fonc tionnement des freins Veiller ce que lors du remplis sage de l...

Page 508: ...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 509: ...capuchon du ma tre cylindre de frein 2 ATTENTION Apr s le montage rechercher en actionnant le levier ou la p dale de frein les fuites ventuelles de liquide de frein au niveau des boulons de rac cord s...

Page 510: ...urely 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 plate Refer to SEAT FUEL T...

Page 511: ...EIN ARRIERE Plaque d identification Se reporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX au CHAPITRE 4 1 Protection 1 2 Boulon de pincement t sup rieur 2 Desserrer uniquement 3 Amor...

Page 512: ...FRONT FORK DISASSEMBLY 1 Adjuster 1 Drain the fork oil Use special tool Refer to REMOVAL POINTS 2 Fork spring 1 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7...

Page 513: ...che 1 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 antifriction 1 9 Rondelle de bague d tanch it 1 0 Ba...

Page 514: ...con struction and is particularly 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 reasse...

Page 515: ...trer de corps trangers lors du changement de l huile ou du d montage et remontage de la fourche Avant de retirer les soupapes de base ou les bras de fourche veiller laisser s chapper tout l air du r...

Page 516: ...o not remove the locknut as the damper rod may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove Dust seal 1 Stopper ring 2 Using...

Page 517: ...ans l amortisseur et de ne plus pou voir en tre retir e Cl annulaire pour boulon capuchon YM 01501 90890 01501 Tube plongeur 1 D poser Joint antipoussi re 1 Bague d arr t 2 A l aide d un tournevis lam...

Page 518: ...nch YM 01501 90890 01501 EC554000 INSPECTION Damper assembly 1 Inspect Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace CAUTION The front fork with a built in piston rod has a very s...

Page 519: ...eur complet 1 D formation endommagement Remplacer Joint torique 2 Usure endommagement Rem placer ATTENTION La construction interne d une four che tige de piston incorpor e est tr s sophistiqu e et par...

Page 520: ...metal 3 Wear damage Replace Spring 4 Damage fatigue Replace base valve Air bleed screw 5 Wear damage Replace Collar 1 Inspect Piston metal 1 Wear damage Replace EC554400 Fork spring 1 Measure Fork sp...

Page 521: ...r Ressort 4 Endommagement fatigue Remplacer la soupape de base Vis de purge d air 5 Usure endommagement Rem placer Entretoise paul e 1 Contr ler Bague coulissante de piston 1 Usure endommagement Rem p...

Page 522: ...tion Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube I...

Page 523: ...r cadran 1 N B La valeur de flexion est gale la moiti de la valeur affich e sur le comparateur cadran AVERTISSEMENT Ne pas tenter de redresser un tube plongeur tordu car cela pourrait l affaiblir dang...

Page 524: ...ve an excessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Oil capacity 195 cm3 6 86 Imp oz 6 59 US oz 4 Aft...

Page 525: ...trer de corps trangers dans la fourche Huile recommand e Huile de fourche S1 Capacit d huile 195 cm3 6 86 Imp oz 6 59 US oz 4 Apr s le remplissage pomper lente ment l amortisseur 1 de haut en bas cour...

Page 526: ...r tighten the locknut onto the damper assembly 7 Loosen Compression damping adjuster 1 NOTE Loosen the compression damping adjuster finger tight Record the set position of the adjuster the amount of t...

Page 527: ...ain le dispositif de r glage de l amortissement la com pression Noter le r glage du dispositif de r glage de l amortissement la d tente le nombre de tours partir de la position viss e fond 8 Monter So...

Page 528: ...t wrench YM 01500 90890 01500 Cap bolt ring wrench YM 01501 90890 01501 T R 29 Nm 2 9 m kg 21 ft lb 11 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the...

Page 529: ...annulaire pour boulon capuchon YM 01501 90890 01501 11 Apr s le remplissage effectuer plus de 10 pompages lents de l amortis seur 1 vers le haut et vers le bas pour distribuer l huile de fourche 12 P...

Page 530: ...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 seal with its manufacture s marks or number fa...

Page 531: ...feuille plasti que a enduite d huile de fourche pour prot ger la l vre de la bague d tan ch it Monter la bague d tanch it en veillant placer les marques d usine ou les num ros du c t du support d axe...

Page 532: ...iver 3 Fork seal driver YM A0948 90890 01502 19 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM A0948 90890 01502 20 Install Stopper ring 1 N...

Page 533: ...nfoncer la bague d tanch it dans le fourreau l aide de l outil de montage de joint de fourche 2 Outil de montage de joint de fourche YM A0948 90890 01502 20 Monter Bague d arr t 1 N B Loger correcteme...

Page 534: ...amper assembly 3 NOTE Install the collar with its larger dia end a fac ing the fork spring 25 Install Damper assembly 1 To inner tube 2 CAUTION To install the damper assembly into the inner tube hold...

Page 535: ...r complet 1 Sur le tube plongeur 2 ATTENTION Incliner le tube plongeur avant d y introduire l amortisseur complet Si le tube plongeur est tenu verticalement l amortisseur risque de glisser jusqu au fo...

Page 536: ...assembly Cap bolt ring wrench YM 01501 90890 01501 28 Inspect Gap a between the adjuster 1 and lock nut 2 Out of specification Retighten and readjust the locknut NOTE If the adjuster is installed out...

Page 537: ...tr ler Jeu a entre le dispositif de r glage 1 et le contre crou 2 Hors sp cifications Resserrer le contre crou et le r gler nou veau N B Un mauvais montage du dispositif de r glage emp che d obtenir l...

Page 538: ...handling and loss of stabil ity CAUTION Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow foreign materi...

Page 539: ...urche recommand e L utilisation d autres huiles peut compromettre le bon fonctionnement de la fourche Ne laisser en aucun cas p n trer de corps trangers dans la fourche Huile recommand e Huile de four...

Page 540: ...ly tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet 2 Tighten Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified...

Page 541: ...incement t sup rieur 2 Serrer Amortisseur complet 1 N B Utiliser la cl annulaire pour boulon capuchon 2 pour serrer l amortisseur au couple sp cifi T R 30 Nm 3 0 m kg 22 ft lb Cl annulaire pour boulon...

Page 542: ...R 23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb 5 Install Protector 1 Bolt protector 2 T R 7 Nm 0 7 m kg 5 1 ft lb 6 Adjust Rebound damping force NOTE Turn in the damping adjuster 1 finger tight...

Page 543: ...kg 5 1 ft lb 6 R gler Force d amortissement la d tente N B Serrer la main le dispositif de r glage d amortissement 1 puis desserrer gra duellement jusqu la position de r glage d origine 7 R gler Forc...

Page 544: ...lder 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 1 pulled 1...

Page 545: ...ein 1 Se reporter POINTS DE DEPOSE 7 Couvercle du logement de c ble des gaz 1 8 C ble des gaz n 1 tir 1 D connecter du c t acc l rateur 9 C ble des gaz n 2 enfonc 1 D connecter du c t acc l rateur 10...

Page 546: ...nspect Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1 Instal...

Page 547: ...magement Remplacer AVERTISSEMENT Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement ASSEMBLAGE ET MONTAGE Guidon 1 Monter Support inf rieur du guidon 1 Rondelle 2 cro...

Page 548: ...that the marks b are in place on both sides Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown First tighten the bolts on...

Page 549: ...des deux c t s Monter le guidon de mani re ce que l ergot c du support du guidon sup rieur soit positionn selon le rep re d alignement situ sur le guidon comme indiqu Serrer d abord les boulons situ s...

Page 550: ...ow marks faces straight upward 5 Install Right grip 1 Collar 2 Apply the adhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lacque...

Page 551: ...2 Appliquer un agent adh sif sur le guide de tube 3 N B Avant d appliquer l adh sif essuyer toute trace de graisse ou d huile de la surface du guide de tube a avec du diluant peinture laque Monter la...

Page 552: ...hrottle grip 3 moves smoothly If it does not retighten the bolts for adjustment T R 4 Nm 0 4 m kg 2 9 ft lb 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Brake master cylinder 1 Bra...

Page 553: ...ons pour la r gler T R 4 Nm 0 4 m kg 2 9 ft lb 9 Monter Cache du capuchon de la poign e 1 Couvercle du logement de c ble des gaz 2 10 Monter Ma tre cylindre de frein 1 Support de ma tre cylindre de fr...

Page 554: ...dimensions shown Pass the engine stop switch lead in the mid dle of the clutch lever holder T R 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb 12 Install Clutch cable 1 Hot starter cable 2 NOTE...

Page 555: ...m 0 4 m kg 2 9 ft lb 12 Monter C ble d embrayage 1 C ble de d marrage chaud 2 N B Appliquer de la graisse savon de lithium sur les extr mit s du c ble d embrayage et du c ble de d marrage chaud 13 R g...

Page 556: ...tion in the CHAPTER 4 Preparation for removal Hold the machine by placing the suitable stand under the engine Number plate Handlebar Front fender Refer to HANDLEBAR section 1 Steering stem nut 1 2 Fro...

Page 557: ...porter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX au CHAPITRE 4 Guidon Garde boue avant Se reporter la section GUIDON 1 Ecrou de la colonne de direction 1 2 Fourche 2 Se reporter la s...

Page 558: ...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 Bearing race 1 Remove B...

Page 559: ...t inf rieur 1 D poser Roulement inf rieur 1 Utiliser le burin 2 ATTENTION Veiller ne pas endommager les filets de l arbre de direction Cage de roulement 1 D poser Cage de roulement 1 D poser la cage d...

Page 560: ...the bearing races replace bear ings and bearing 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...

Page 561: ...SEMBLAGE ET MONTAGE T inf rieur 1 Monter Roulement inf rieur 1 N B Appliquer de la graisse savon de lithium sur la l vre de la bague d tan ch it et la circonf rence interne du rou lement 2 Monter Cage...

Page 562: ...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 563: ...nne de direction en la tournant d une but e l autre S il y a la moindre g ne d monter la colonne de direction et contr ler les paliers de la direction 6 Monter Rondelle 1 7 Monter Fourche 1 T sup rieu...

Page 564: ...little by little 10 Adjust Front fork top end a Front fork top end standard a 5 mm 0 20 in 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 CAUTION Tighten the lower bracket to specifi...

Page 565: ...tandard a 5 mm 0 20 in 11 Serrer Boulon de pincement t sup rieur 1 Boulon de pincement t inf rieur 2 ATTENTION Serrer le t inf rieur au couple sp ci fi Un serrage excessif peut compro mettre le bon fo...

Page 566: ...falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Shift the brake pedal backward Rear b...

Page 567: ...AVANT ET FREIN ARRIERE Glisser la p dale de frein vers l arri re Etrier de frein arri re Boulon p dale de frein Cha ne de transmission 1 Support de cha ne de transmission 1 2 Tendeur de cha ne inf rie...

Page 568: ...removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 Refer to REMOVAL POINTS 2 Relay arm 1 3 Connecting rod 1 4 Colla...

Page 569: ...Qt Remarques DEMONTAGE DU BRAS OSCILLANT 1 Capuchon 2 Se reporter POINTS DE DEPOSE 2 Bras relais 1 3 Bielle 1 4 Entretoise paul e 2 5 Bague d tanch it 2 6 Roulement de but e 2 7 Bague 2 8 Bague d tan...

Page 570: ...bearing by pressing its outer race INSPECTION Wash the bearings bushings and collars in a solvent Swingarm 1 Inspect Bearing 1 Bushing 2 Free play exists unsmooth revolution rust Replace bearing and b...

Page 571: ...u solvant Bras oscillant 1 Contr ler Roulement 1 Bague 2 Jeu rotation irr guli re rouille Remplacer ensemble le roulement et la bague 2 Contr ler Bague d tanch it 3 Endommagement Remplacer Bras relais...

Page 572: ...the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bear ings to a specified depth from inside Installed depth of bearings Oute...

Page 573: ...ent int rieur la profon deur sp cifi e partir de l int rieur Profondeur d installation des roulements Ext rieur a Z ro mm z ro in Int rieur b 6 5 mm 0 26 in 2 Monter Roulement 1 Rondelle 2 Bague d tan...

Page 574: ...e s marks or numbers Installed depth of bearings a Zero mm Zero in Swingarm 1 Install Bushing 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5 NOTE Apply the molybdenum disulfide grease on the bus...

Page 575: ...r le bras oscillant 5 N B Appliquer de la graisse au bisulfure de molybd ne sur les bagues les roule ments de but e les l vres des bagues d tanch it et les surfaces de contact de l entretoise paul e e...

Page 576: ...3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the mo...

Page 577: ...conf rence du boulon et la partie filet e Ne pas encore serrer l crou 6 Monter Bras oscillant 1 Boulon pivot 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon pivot Ins rer le boul...

Page 578: ...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 579: ...re bras relais 1 Ecrou amortisseur arri re bras relais 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon T R 53 Nm 5 3 m kg 38 ft lb 10 Serrer Ecrou bielle 1 T R 80 Nm 8 0 m kg 58...

Page 580: ...oner 4 Nut lower chain tensioner 5 T R 16 Nm 1 6 m kg 11 ft lb 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support 50 mm 1 97 in 3 Nut drive chain support 4 Bolt driv...

Page 581: ...de cha ne de transmis sion 1 Couvercle du support de cha ne de transmission 2 Boulon support de cha ne de transmis sion 50 mm 1 97 in 3 Ecrou support de cha ne de trans mission 4 Boulon couvercle du...

Page 582: ...eparation for removal Hold the machine by placing the suitable stand under the engine Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER...

Page 583: ...ction TUBE D ECHAPPEMENT ET SILENCIEUX au CHAPITRE 4 1 Collier pince conduit d admission d air 1 Desserrer uniquement 2 Cadre arri re 1 3 Boulon amortisseur arri re bras relais 1 Maintenir le bras osc...

Page 584: ...5 63 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 10 Upper spring guide 1 11 Spring rear shock absorber 1 12 Bearing 2 Refer to REMOVAL POINTS 2...

Page 585: ...Nom de la pi ce Qt Remarques 10 Guide de ressort sup rieur 1 11 Ressort amortisseur arri re 1 12 Roulement 2 Se reporter POINTS DE DEPOSE 2 Estensione della rimozione Ordine Denominazione Quantit Osse...

Page 586: ...amage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of t...

Page 587: ...d amortissement ou entra nera un mauvais fonctionne ment 4 Veiller ne pas rayer la surface de contact de la tige de piston avec le cylindre afin d viter tout risque de fuite d huile 5 Ne jamais essaye...

Page 588: ...ng 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 shock absorber as...

Page 589: ...r l amortisseur arri re complet Amortisseur 2 Fuite d huile Remplacer l amortisseur arri re complet Fuite de gaz Remplacer l amortisseur arri re complet Ressort 3 Endommagement Remplacer le ressort Fa...

Page 590: ...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 591: ...r 1 N B Apr s avoir install la bague d arr t repousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter Roulement inf rieur 1 N B Monter le roulement en pressant sur le c t o sont imprim s...

Page 592: ...shown 3 Tighten Adjuster 1 4 Adjust Spring length installed Refer to REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT sec tion in the CHAPTER 3 5 Tighten Locknut 1 Rear shock absorber 1 Install Dust sea...

Page 593: ...errer Contre crou 1 Amortisseur arri re 1 Monter Joint antipoussi re 1 Joint torique 2 Entretoise paul e 3 N B Appliquer de la graisse au bisulfure de molybd ne sur les l vres de joint anti poussi re...

Page 594: ...shock absorber frame 1 Washer 2 Nut rear shock absorber frame 3 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm...

Page 595: ...raisse au bisulfure de molybd ne sur le boulon 5 Monter Boulon amortisseur arri re bras relais 1 Ecrou amortisseur arri re bras relais 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le bo...

Page 596: ...rk plug 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 597: ...allumage 6 Bougie 7 Bo tier CDI CODES DE COULEUR B Noir Br Brun G Vert L Bleu O Orange P Rose R Rouge Sb Bleu ciel W Blanc Y Jaune B L Noir bleu B W Noir blanc B Y Noir jaune G B Vert noir L W Bleu b...

Page 598: ...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 599: ...nt galement en compte l ouverture du papillon commande tridimensionnelle Repr sentation en 3D de l avance l allumage diff rente des caract ristiques actuelles Composant Fonction Capteur de position de...

Page 600: ...Ein pr ziseres dreidi mensionales Z ndsystem bezieht also die Drosselklappen Position mit ein Dreidimensionales Z ndzeitpunkt Kennfeld gilt nicht zur Bezugnahme Bauteil Funktion Drosselklappensensor E...

Page 601: ...ratezza l anticipo minimo tenendo in considerazione anche l apertura dell acceleratore controllo tridimensionale Mappa dell immagine tridimensionale dell anticipo minimo diverso dalle reali caratteris...

Page 602: ...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 603: ...age 90890 06754 Multim tre YU 3112 C 90890 03112 Test de la longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions de l ensemble du syst me d allumage fiches rapides fils et bobi...

Page 604: ...trol lieren Z ndkerze reinigen ggf erneuern Kabelanschl sse des gesamten Z ndsystems kontrollieren Steckverbinder Kabel Z ndspule Instand setzen ggf erneuern Motorstoppschalter kontrol lieren Erneuern...

Page 605: ...06754 Tester tascabile YU 3112 C 90890 03112 Test lunghezza della scintilla Pulire o sostituire la candela di accensione Controllare tutti i collegamenti dell impianto di accensione accoppiatori cavi...

Page 606: ...y 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 sp...

Page 607: ...ALLUMAGE 1 Contr ler Connexion des fiches rapides et des fils Rouille poussi re jeu court cir cuit R parer ou remplacer Bobine d allumage et bougie en place Appuyer sur la bobine d allu mage jusqu ce...

Page 608: ...ification 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 spe...

Page 609: ...e Remplacer CONTROLE DU VOLANT MAGNETIQUE CDI 1 Contr ler R sistance de la bobine d excita tion Hors sp cifications Rempla cer Fil du multim tre fil orange 1 Fil du multim tre borne de bougie 2 R sist...

Page 610: ...ead 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 W R Br G P B NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No continuous wh...

Page 611: ...20 C 68 F 10 CONTROLE DU CONTACTEUR DE POINT MORT 1 Contr ler Continuit du contacteur de point mort Pas de continuit au point mort Rem placer Continuit en vitesse Remplacer CONTROLE DU BOITIER CDI V...

Page 612: ...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 613: ...le Multim tre YU 3112 C 90890 03112 Contr ler les connexions de l ensemble du syst me d allu mage R parer ou remplacer Capteur de position de papillon des gaz Bobineducapteur de position de papillon d...

Page 614: ...ultimeter YU 3112 C 90890 03112 Kabelanschl sse des gesamten Z ndsystems kontrollieren Instand setzen ggf erneuern Drosselklappensensor kontrollieren Drosselklap pensensor Spule Erneuern Lichtmaschine...

Page 615: ...attrezzi seguenti Tester tascabile YU 3112 C 90890 03112 Controllare tutti i collegamenti dell impianto di accensione Riparare o sostituire Controllare il sensore posi zione farfalla Bobina sensore po...

Page 616: ...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 617: ...1 Contr ler R sistance de la bobine du cap teur de position de papillon des gaz Hors sp cifications Rempla cer Fil du multim tre fil bleu 1 Fil du multim tre fil noir 2 R sistancedelabobine du capteu...

Page 618: ...n 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 Carburetor 2 Remove Screw throttle...

Page 619: ...n de papillon des gaz Carburateur 2 Deposer Vis capteur de position de papillon des gaz 1 Capteur de position de papillon des gaz 2 N B Desserrer les vis capteur de position de papillon des gaz l aide...

Page 620: ...e waterproof 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 8 Start the engine Tester lead Yellow l...

Page 621: ...8 Mettre le moteur en marche Fil du multim tre fil jaune 3 Fil du multim tre fil noir 4 9 R gler Tension de sortie du capteur de position de papillon des gaz Etapes du r glage R gler l angle de montag...

Page 622: ...T25 bit 14 Install the carburetor 1 THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Inspect Throttle position sensor input vo...

Page 623: ...E PAPILLON DES GAZ 1 D brancher la fiche rapide du cap teur de position de papillon des gaz 2 Mettre le moteur en marche 3 Contr ler Tension d entr e du capteur de position de papillon des gaz Hors sp...

Page 624: ...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 625: ...iques conditions de la piste de la surface temps interm diaire pour faciliter les r glages ult rieurs du carburateur AVERTISSEMENT Le carburateur fait partie du circuit d alimentation Par cons quent v...

Page 626: ...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 627: ...ation d oxyg ne dans l air d ter mine la richesse ou la pauvret du m lange air carburant Il convient d s lors de se conformer au tableau ci des sus pour la composition du m lange Tenir compte des troi...

Page 628: ...2 3 4 Main system The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing machines since it supplies an even flow of fuel even at full load Use the main jet and the j...

Page 629: ...incipal primaire Ce type de gicleur principal est parfait pour les motos de course car il garantit un d bit de carburant r gulier m me pleine charge Utiliser le gicleur principal et l aiguille pour r...

Page 630: ...s of the air fuel mixture at full throt tle can be set by changing the main jet 1 Except for USA and CDN If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor ac...

Page 631: ...le m lange air carburant est trop riche ou trop pauvre la puissance du moteur diminue et les acc l rations sont moins efficaces Gicleur principal stan dard N 178 N 175 Effets de la modification du gi...

Page 632: ...mize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Rec...

Page 633: ...iduelle ment en usine Avant de r gler la vis de ralenti la serrer fond en comptant le nombre de tours Enregistrer ce nombre comme tant le nombre de tours de desserrage r gl en usine Effets du r glage...

Page 634: ...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 635: ...chage de l aiguille et d abaisser cette derni re 2 M lange trop pauvre aux r gimes interm diaires Le moteur crachote et acc l re trop lentement Il faut enrichir le m lange en abais sant d un cran le c...

Page 636: ...e available with different straight portion diameters Example OBELQ 3 Clip position Diameter a of straight portion Standard jet needle OBELQ OBEKP Effects of changing the jet needle refer ence Diamete...

Page 637: ...p Diam tre a de la par tie droite Aiguille standard OBELQ OBEKP Effets du remplacement de l aiguille r f rence Diam tre de la partie droite La modification du diam tre de la partie droite permet de r...

Page 638: ...0 70 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 80 90 Except for USA and CDN Standard leak...

Page 639: ...d N 80 N 85 Relation avec l ouverture du papillon Le d bit du carburant dans le syst me de carburateur principal est contr l par le gicleur principal puis une nouvelle r gu lation s effectue dans la z...

Page 640: ...48 02 Jet needle Rich STD Lean OBELM OBELN OBELP OBELQ OBELR OBELS OBELT 5NL 14916 EM 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1 5NL 14916 ER 5NL 14916 ES 5NL 14916 ET Jet needle Rich STD Lean OBEKL OBEKM...

Page 641: ...BELN OBELP OBELQ OBELR OBELS OBELT 5NL 14916 EM 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1 5NL 14916 ER 5NL 14916 ES 5NL 14916 ET Aiguille Riche STD Pauvre OBEKL OBEKM OBEKN OBEKP OBEKQ OBEKR OBEKS 5JG 14...

Page 642: ...p 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 nee...

Page 643: ...ne correctement sauf si le sympt me indique un m lange riche M lange riche Remonter la position du clip d aiguille 1 cran plus haut Ouverture 1 4 3 4 Crachotements Vitesse r duite Abaisser la position...

Page 644: ...frei funktioniert Ausnahme fettes Gemisch Fettes Gemisch D sennadel Clipposition anheben 1 Nut nach oben Bei 1 4 3 4 ge ffneter Drosselklappe Schweres Saugen Drehzahl niedrig D sennadel Clipposition s...

Page 645: ...etto su di 1 scanalatura Manopola dell acceleratore ruotata di 1 4 3 4 di giro Problemi di sfiato Perdita di velocit Posizione bassa del fermo spillo del getto gi di 1 scanalatura Manopola dell accele...

Page 646: ...he 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 the secondary reduction r...

Page 647: ...diff ren tes parties du circuit afin de calculer la moyenne et d terminer le taux de r duction secondaire Si le parcours comprend de longues lignes droites r gler la machine de mani re qu elle fournis...

Page 648: ...ressure Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact...

Page 649: ...ain boueux sablonneux ou glis sant r duire la pression des pneus pour une meilleure adh rence Sur route pav e ou sur surface dure augmenter la pression des pneus afin d viter les crevaisons Pression d...

Page 650: ...can be changed by changing the fork oil amount CAUTION Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a noise at ful...

Page 651: ...st trop bas il se produit un bruit lorsque la fourche est enti re ment comprim e ou le pilote ressent une certaine pression dans les mains ou le corps Au contraire quand le niveau d huile est trop lev...

Page 652: ...ink deeply over a series of gaps To set a soft spring Change the rebound damping Turn out one or two clicks Change the compression damping Turn in one or two clicks 2 Use of stiff spring Generally a s...

Page 653: ...ssement la com pression Visser d un ou deux d clics 2 Ressort dur En principe un ressort dur offre une sensation de conduite dure L amor tissement la d tente a tendance s affaiblir entra nant une pert...

Page 654: ...0 449 0 459 0 469 0 479 1C3 23141 F0 1C3 23141 G0 1C3 23141 H0 1C3 23141 J0 I I I II I III I IIII EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider s f...

Page 655: ...age de la suspension arri re Effectuer le r glage de la suspension arri re en fonction de l exp rience du pilote lors de la conduite ainsi que des conditions du terrain Les deux r glages de la suspens...

Page 656: ...ing bolt 3 Loosen the locknut 1 and make adjust ment by turning the spring adjuster 2 to achieve the standard figure from the sub traction of the length b from the length a NOTE If the machine is new...

Page 657: ...ndre la valeur standard obte nue en soustrayant la longueur b de la longueur a N B Si la moto est neuve et apr s qu elle a t rod e la longueur du ressort peut changer en raison de la fatigue initiale...

Page 658: ...r its greater spring load Run with the rebound damp ing adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed more or l...

Page 659: ...r glage en fonction des pr f rences person nelles Un r glage de l amortissement la d tente entra ne un changement de l amortissement la compression Pour corriger d visser le dispositif de r glage de l...

Page 660: ...of I D marks TYPE SPRING RATE SPRING PART NUMBER I D MARK SPRING FREE LENGTH approx SOFT 4 5 4 7 4 9 1C3 22212 00 1C3 22212 10 1C3 22212 20 Green Red Black 265 265 265 STD 5 1 1C3 22212 30 Blue 265 S...

Page 661: ...E DU RES SORT approx MOU 4 5 4 7 4 9 1C3 22212 00 1C3 22212 10 1C3 22212 20 Vert Rouge Noir 265 265 265 STD 5 1 1C3 22212 30 Bleu 265 DUR 5 3 5 5 5 7 1C3 22212 40 1C3 22212 50 1C3 22212 60 Jaune Rose...

Page 662: ...o I D marks 251 5 269 5 mm 9 90 10 61 in Three I D marks 243 0 261 0 mm 9 57 10 28 in Approx 275 mm 10 83 in One I D mark 255 5 273 5 mm 10 06 10 77 in Two I D marks 261 5 279 5 mm 10 30 11 00 in Thre...

Page 663: ...0 mm 9 57 10 28 in Environ 275 mm 10 83 in Un seul rep re d identification 255 5 273 5 mm 10 06 10 77 in Deux rep res d identification 261 5 279 5 mm 10 30 11 00 in Trois rep res d identification 253...

Page 664: ...over entire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to increase damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Repl...

Page 665: ...dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 cl...

Page 666: ...des aiguilles d une montre de 2 d clics pour augmenter l amortisse ment Quantit d huile Augmenter la quantit d huile d environ 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Ressort Monter un ressort dur Dur...

Page 667: ...d clics pour r duire l amor tissement Ressort Monter un ressort mou Mauvaise tenue de route Amortissement la d tente Tourner le dispositif de r glage dans le sens inverse des aiguilles d une montre de...

Page 668: ...ngs kraft Den Einsteller ca 2 Raststellungen im Uhrzeiger sinn drehen um die D mpfungskraft zu erh hen lmenge Die lmenge in 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Schritten erh hen Feder H rtere Feder...

Page 669: ...en im Gegenuhr zeigersinn drehen um die D mpfungskraft zu verrin gern Feder Weichere Feder einbauen Schlechte Bodenhaf tung Zugstufen D mpfungs kraft Den Einsteller ca 2 Raststellungen im Gegenuhr zei...

Page 670: ...l dispositivo di regolazione in senso orario circa 2 scatti per aumentare lo smorzamento Quantit di olio Aumentare la quantit dell olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Molla Sostituire...

Page 671: ...circa 2 scatti per diminuire lo smorzamento Molla Sostituire con una molla morbida Scarsa tenuta di strada Smorzamento in estensione Ruotare il dispositivo di regolazione in senso antiorario circa 2 s...

Page 672: ......

Page 673: ......

Page 674: ...MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO PRINTED IN JAPAN 2005 08 3 0 1 CR E F G H YZ250F V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO L...

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