Yamaha YZ450F(V) Owner'S Service Manual Download

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ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

EC4H3000

REMOVAL POINTS

EC4H3230

Transmission

1. Remove:

• Main axle

• Drive axle

• Shift cam
• Shift fork 3
• Shift fork 2
• Shift fork 1

NOTE:

• Remove assembly with the collar

installed

to the crankcase.

• Remove assembly carefully. Note the posi-

tion of each part. Pay particular 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-
mer.

EC4H4000

INSPECTION

EC4H4200

Gears

1. Inspect:

• Matching dog

• Gear teeth

• Shift fork groove

Wear/damage

→

Replace.

2. Inspect:

• O-ring

Damage

→

Replace.

3. Check:

• Gears movement

Unsmooth movement

→

Repair or

replace.

EC4H4600

Bearing

1. Inspect:

• Bearing

Rotate inner race with a finger.
Rough spot/seizure

→

Replace.

Summary of Contents for YZ450F(V)

Page 1: ...2005 09 2 0 1 CR E F G 2S2 28199 80 YZ450F V OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH YZ450F V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWA...

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

Page 3: ...auch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan YZ450F V MANUEL D ATELIER DU PROPRIETAIRE 2005 Yamaha Motor Co Ltd 1re dition septembre 2...

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: ...maha H nd ler gibt bei Fragen gerne Auskunft INTRODUCTION F licitations pour votre achat d une Yamaha s ries YZ Ce mod le est l aboutissement de la vaste exp rience de Yamaha dans la production de mac...

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: ...puffanlage versch ttet wird W hrend des Tankens offene Flam men und Funken fern halten und kei nesfalls rauchen SICHERHEITSINFORMATION NOTICE IMPORTANTE CETTE MACHINE EST STRICTEMENT DESTI NEE A LA CO...

Page 8: ...Carbon monoxide is a danger ous gas which can cause unconsciousness 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: ...des vapeurs d essence en exc s ou laissez de l essence p n trer dans vos yeux prendre imm diatement contact avec un m decin Si de l essence est renvers e sur votre peau ou vos v tements laver imm dia...

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: ...88 kg 194 lb f r 250 cc Klasse Mindest 98 kg 216 lb f r 500 cc Klasse Mindest 102 kg 225 lb Falls Sie Modifikationen an lhrer Maschine vornehmen z B zur Gewichtsverringerung unbedingt das oben angef h...

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: ...pitel zu erleichtern COMMENT UTILISER CE MANUEL INFORMATIONS PARTICULIE REMENT IMPORTANTES Le symbole d alerte de s curit signifie ATTENTION SOYEZ VIGILANT VOTRE SECURITE EST EN JEU Le non respect des...

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: ...F r Arbeiten f r die weitere Informationen ben tigt werden sind schrittweise Erg n zungen 6 zus tzlich zu dem Explosionsdi agramm und der Arbeitsanwei sungstabelle aufgef hrt FORMAT DU MANUEL Dans ce...

Page 16: ...ubricant 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 lubrica...

Page 17: ...erwenden SYMBOLES GRAPHIQUES Voir l illustration Les symboles graphiques 1 7 servent rep rer les diff rents chapitres et indiquer leur contenu 1 Renseignements g n raux 2 Caract ristiques 3 Contr les...

Page 18: ...EC090000 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...

Page 19: ...SSIGE WARTUNGS UND EINSTELLARBEITEN 3 MOTOR ENG 4 FAHRWERK CHAS 5 ELEKTRISCHE ANLAGE ELEC 6 ABSTIMMUNG TUN 7 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES PE...

Page 20: ...K 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 18 DEFINITION OF UNITS 2...

Page 21: ...VOR FAHRTBEGINN 3 4 MOTOR 3 5 FAHRWERK 3 24 ELEKTRISCHE ANLAGE 3 46 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS GENERAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MOTO 1 2 INFORMATIONS IMPORTANTES 1 3 VE...

Page 22: ...CLUTCH 4 49 OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT 4 56 BALANCER 4 63 OIL PUMP 4 66 KICK AXLE AND SHIFT SHAFT 4 70 CDI MAGNETO 4 78 ENGINE REMOVAL 4 81 CRANKCASE AND CRANKSHAFT 4 86 TRANSMISS...

Page 23: ...OPGABEL 5 26 LENKER 5 43 LENKUNG 5 49 SCHWINGE 5 54 FEDERBEIN 5 62 CHAPITRE 4 MOTEUR SELLE RESERVOIR DE CARBURANT ET CACHES LATERAUX 4 1 TUBE D ECHAPPEMENT ET SILENCIEUX 4 3 RADIATEUR 4 6 CARBURATEUR...

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

Page 25: ...NSOR 6 7 KAPITEL 7 ABSTIMMUNG MOTOR 7 1 FAHRWERK 7 11 CHAPITRE 6 PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 BOITIER CDI COMMANDE PAR PRESSION ABSOLUE DE LA TUBULURE D ADMISSION...

Page 26: ...cap 7 ENGINE STOP button 8 Kick starter 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 cleaner H Shift pedal I Oil dip...

Page 27: ...ezugnahme nderungen an Design und technischen Daten jederzeit vorbehalten DESCRIPTION FAHRZEUGBESCHREIBUNG RENSEIGNEMENTS GENERAUX DESCRIPTION 1 Levier d embrayage 2 Levier de d marrage chaud 3 Levier...

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: ...sitz angebracht Die Codenummer und das Info K rzel werden zur Ersatzteilbestel lung ben tigt IDENTIFICATION DE LA MOTO FAHRZEUG IDENTIFIZIERUNG IDENTIFICATION DE LA MOTO Il y a deux bonnes raisons de...

Page 30: ...e 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 gea...

Page 31: ...korrekten Zusammen bau 5 Feuer fern halten INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMATIONS IMPORTANTES PREPARATION A LA DEPOSE ET AU DEMONTAGE 1 Eliminer soigneusement salet s boue pous...

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: ...recommandons d utiliser des pi ces Yamaha d origine pour tous les remplacements Utiliser les graisses et ou huiles recommand es par Yamaha lors des remontages et r glages JOINTS BAGUES D ETANCHEITE ET...

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: ...antige Seite 2 den Ring gegen die Druckrichtung 3 abst tzt Siehe entsprechende Abbildung 4 Welle INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN CIRCLIPS 1 V rifier soigneusement tous les circlips ava...

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: ...tspray sollte nur als Notl sung verwendet werden Das Taschen Multimeter wie in der Abbil dung gezeigt anschlie en VERIFICATION DES CONNEXIONS KABELANSCHL SSE KONTROLLIEREN VERIFICATION DES CONNEXIONS...

Page 38: ...90 01274 YU 90050 90890 01275 YU 91044 90890 04081 YU 90063 90890 01278 Crankshaft installing tool Crankshaft installing pot Crankshaft installing bolt Spacer crankshaft installer Adapter M12 These to...

Page 39: ...assemblies YM 4019 90890 04019 YM 91042 90890 04086 Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut YM 91042 90890 04086 YM 4116 9089...

Page 40: ...90890 04152 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 90890 06754 90890 85505 YAMAHA Bond No 1215 Thr...

Page 41: ...ces YU 3097 YU 1256 90890 01252 YU 90050 90890 01274 YU 90050 90890 01275 YU 91044 90890 04081 YU 90063 90890 01278 Outil de montage du vilebrequin Pot de montage du vilebrequin Boulon de montage du v...

Page 42: ...M 4019 90890 04019 YM 91042 90890 04086 Outil de maintien de l embrayage Cet outil sert maintenir l embrayage lors de la d pose ou du remontage de l crou de fixation de la noix d embrayage YM 91042 90...

Page 43: ...YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Cet instrument sert contr ler les composants du syst me d allumage YM 34487 90890 06754 90890 85505 YAMAHA Bond N 1215 ThreeBon...

Page 44: ...teilen auf Schlag und Ver biegung YU 3097 YU 1256 90890 01252 YU 90050 90890 01274 YU 90050 90890 01275 YU 91044 90890 04081 YU 90063 90890 01278 Kurbelwellen Einbauwerkzeug Kurbelwellen Einbaufassung...

Page 45: ...pplungshalter Zum Festhalten der Kupplung beim L sen und Fest ziehen der Kupplungsnaben Mutter YM 91042 90890 04086 YM 4116 90890 04116 YM 4097 90890 04097 Ventilf hrungs Austreiber Einlass 4 5 mm 0 1...

Page 46: ...0890 06754 Z ndfunkenstrecken Tester Z ndungstester Zur Pr fung der Bauteile des Z ndsystems YM 34487 90890 06754 90890 85505 YAMAHA Dichtmasse Nr 1215 ThreeBond Nr 1215 Zum Abdichten von Kurbelgeh us...

Page 47: ...GEN INFO MEMO...

Page 48: ...DAL The 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 EC154000 KICK STARTER Rotate the kic...

Page 49: ...nehmen den Drehgriff schlie en FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION FONCTIONS DES COMMANDES BOUTON ENGINE STOP Le bouton ENGINE STOP 1 est situ sur la par tie gauche du guidon...

Page 50: ...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 51: ...Motors zu erleichtern FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION LEVIER DE FREIN AVANT Le levier de frein avant 1 est situ sur la partie droite du guidon Le tirer vers la poign e po...

Page 52: ...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 53: ...del Zieherwerkzeug 1 wird benutzt um die D sennadel aus dem Verga ser herauszuziehen FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION BEQUILLE LATERALE AMOVIBLE La b quille lat rale 1 ne...

Page 54: ...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 55: ...estoktanzahl von 95 ROZ CARBURANT KRAFTSTOFF CARBURANT Toujours utiliser le carburant recommand comme indiqu ci apr s Le jour de la course toujours utili ser de l essence fra che ATTENTION Utiliser ex...

Page 56: ...he spark plug will foul Unlike 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...

Page 57: ...tarterhebel r ckschlagen MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN MISE EN MARCHE ET RODAGE AVERTISSEMENT Ne jamais d marrer ou faire tourner le moteur dans un endroit clos Les gaz d chappement s...

Page 58: ...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 59: ...g lange im Leer lauf betreiben MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN 6 Repousser la commande de d part froid dans sa position d origine et faire tourner le moteur 3 000 5 000 tr min pendant 1...

Page 60: ...kick the kick starter 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 following...

Page 61: ...ON MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN MISE EN MARCHE A CHAUD Ne pas utiliser la commande de d part froid ni les gaz Tirer le levier de d marrage chaud 1 et d marrer le moteur en actionnan...

Page 62: ...peed 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 more minutes The machi...

Page 63: ...E ET RODAGE STARTEN UND EINFAHREN PROCEDURE DE RODAGE 1 Avant de d marrer le moteur faire le plein du r servoir de carburant 2 Effectuer les contr les avant utilisation 3 Mettre le moteur en marche et...

Page 64: ...axle Tightening of axle holder Tightening of rear axle Wheel to sprocket Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder Tigh...

Page 65: ...vant Serrage du support d axe Serrage de l axe arri re Roue au pignon Etrier la fourche avant Disque de frein la roue Serrage du boulon de raccord Ma tre cylindre au guidon Serrage du purgeur d air Se...

Page 66: ...moment der Hinterachse Rad und Kettenrad Bremssattel und Gabelbein Bremsscheibe und Rad Anzugsdrehmoment der Hohlschraube Hauptbremszylinder und Lenker Anzugsdrehmoment der Entl f tungsschraube Anzugs...

Page 67: ...GEN INFO MEMO...

Page 68: ...use only enough pressure to do the job CAUTION Excessive hose pressure may cause water seepage and contamination of wheel bear ings front forks brakes and transmission seals Many expensive repair bill...

Page 69: ...tiendra ses bonnes performances et augmentera la dur e de vie de nombre de ses com posants 1 Avant de nettoyer la moto couvrir la sortie du tuyau d chappement pour viter toute p n tra tion d eau Un sa...

Page 70: ...our a tablespoon of SAE 10W 30 motor oil in the spark plug hole and reinstall the plug With the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Re...

Page 71: ...eut tre utilis e pour toutes les surfaces peintes et chrom es Ne pas employer de cires d tergentes car elles contien nent souvent des abrasifs 9 Lorsque le nettoyage est termin mettre le moteur en mar...

Page 72: ...10 in 1 300 mm 51 18 in 1 301 mm 51 22 in Seat height 986 mm 38 82 in 998 mm 39 29 in Wheelbase 1 495 mm 58 86 in 1 494 mm 58 82 in Minimum ground clearance 370 mm 14 57 in 373 mm 14 69 in 374 mm 14 7...

Page 73: ...S qt With oil filter replacement 1 0 L 0 88 Imp qt 1 06 US qt Total amount 1 2 L 1 06 Imp qt 1 27 US qt Coolant capacity including all routes 0 99 L 0 87 Imp qt 1 05 US qt Air filter Wet type element...

Page 74: ...front 80 100 21 51M For USA CDN ZA AUS NZ and F 80 100 21 51R For EUROPE except F Size rear 110 90 19 62M For USA CDN ZA AUS NZ and F 110 90 19 NHS For EUROPE except F Tire pressure front and rear 10...

Page 75: ...m 0 8661 0 8670 in Camshaft journal 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 31 200 31 300 mm 1 2283 1...

Page 76: ...54 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 1 mm 0 0394 in 0 85 mm 0 033 in EX 1 mm 0 0394 in 0 85 mm 0 033 in Stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 1750 in EX 4...

Page 77: ...lb at 1 08 in Tilt limit IN 2 5 1 61mm 2 5 0 063 in EX 2 5 1 65mm 2 5 0 065 in Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026...

Page 78: ...ide clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 2 0 2 9 mm 0 08 0 11 in End gap installed 0 2 0 5 mm 0 01 0 02 in Crankshaft Crank width A 61 95 62 00 mm 2 439 2...

Page 79: ...Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kick starter Type Ratchet type Carburetor I D mark 2S21 00 Main jet M J 165 Main air jet M A J 2 0 Jet needle clip...

Page 80: ...nce 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 007 in Bypass valve setting pressure 40 80 kPa 0 4 0 8 kg cm2 5 69 11 38 psi Cooling Radiator core size Width 120 2 mm 4 73 in Height 240 mm 9 45 in Thickne...

Page 81: ...aft Valve lifter Cylinder head Piston cooler nozzle Piston Piston pin Crank pin Oil filter Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Transmission gears Main axle Drive axle Pressure fe...

Page 82: ...5 8 Air filter joint clamp M6 1 0 1 3 0 3 2 2 Air filter joint and air filter case M5 0 8 1 4 0 4 2 9 Throttle cable adjust bolt and locknut M6 0 75 1 4 0 4 2 9 Throttle cable pull M6 1 0 1 4 0 4 2 9...

Page 83: ...ck bolt crankcase M6 1 0 1 10 1 0 7 2 Oil strainer M6 1 0 1 10 1 0 7 2 Crankcase bearing stopper M6 1 0 4 14 1 4 10 Crankcase bearing stopper M6 1 0 8 10 1 0 7 2 Drive axle oil seal stopper M6 1 0 2 1...

Page 84: ...ter 48 mm 1 89 in Front fork top end Zero mm Zero in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 275 mm 10 83 in Fitting length One I D ma...

Page 85: ...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 86: ...Front brake master cylinder and bracket M6 1 0 2 9 0 9 6 5 Front brake master cylinder cap M4 0 7 2 2 0 2 1 4 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 3 B...

Page 87: ...rm 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 absorber and relay ar...

Page 88: ...olor 248 372 at 20 C 68 F White Red CDI unit model manufacturer 2S2 00 YAMAHA For USA and CDN 2S2 10 YAMAHA Except for USA and CDN Ignition coil Model manufacturer 5TA 10 DENSO Minimum spark gap 6 mm...

Page 89: ...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 90: ...n 1 300 mm 51 18 in 1 301 mm 51 22 in Hauteur de la selle 986 mm 38 82 in 998 mm 39 29 in Empattement 1 495 mm 58 86 in 1 494 mm 58 82 in Garde au sol minimale 370 mm 14 57 in 373 mm 14 69 in 374 mm 1...

Page 91: ...0 84 Imp qt 1 00 US qt Avec remplacement du filtre huile 1 0 L 0 88 Imp qt 1 06 US qt Quantit totale 1 2 L 1 06 Imp qt 1 27 US qt Quantit de liquide de refroidissement tout circuit compris 0 99 L 0 87...

Page 92: ...ype 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 110 90 19 62M USA CDN ZA AUS NZ et F 110 90 19 NHS EUROPE sauf F Pression de gonflage ava...

Page 93: ...chapeau d arbre cames 22 000 22 021 mm 0 8661 0 8670 in Diam tre des tourillons d 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 Dime...

Page 94: ...1 6 mm 0 0630 in ECH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Epaisseur de rebord D AD 1 mm 0 0394 in 0 85 mm 0 033 in ECH 1 mm 0 0394 in 0 85 mm 0 033 in Diam tre ext rieur de la queue AD 4 475 4...

Page 95: ...d inclinaison AD 2 5 1 61 mm 2 5 0 063 in ECH 2 5 1 65 mm 2 5 0 065 in Sens d enroulement vu d en haut AD Sens des aiguilles d une montre ECH Sens des aiguilles d une montre Piston Jeu du piston dans...

Page 96: ...n 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 2 0 2 9 mm 0 08 0 11 in Ecartement des becs segment mont 0 2 0 5 mm 0 01 0 02 in Vilebrequin Large...

Page 97: ...e came et barre de gui dage Limite de flexion de barre de guidage 0 05 mm 0 002 in Kick Type A rochet Carburateur Marque d identification 2S21 00 Gicleur principal M J N 165 Gicleur principal M A J 2...

Page 98: ...lat ral 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 007 in Pression de r glage du clapet de d rivation 40 80 kPa 0 4 0 8 kg cm2 5 69 11 38 psi Refroidissement Taille du faisceau de radiateur Largeur 120 2...

Page 99: ...Arbre cames Poussoirdesoupape Culasse Buseder frig rationdupiston Piston Axe de piston Maneton de bielle Filtre huile Bille d arr t Rotor de pompe huile 1 Rotor de pompe huile 2 Cr pine huile Engrenag...

Page 100: ...air M6 1 0 1 3 0 3 2 2 Conduit d admission d air et bo tier de filtre air M5 0 8 1 4 0 4 2 9 Boulon de r glage du c ble des gaz et contre crou M6 0 75 1 4 0 4 2 9 C ble des gaz tir M6 1 0 1 4 0 4 2 9...

Page 101: ...arter M6 1 0 1 10 1 0 7 2 Cr pine huile M6 1 0 1 10 1 0 7 2 Butoir de roulement de carter moteur M6 1 0 4 14 1 4 10 Butoir de roulement de carter moteur M6 1 0 8 10 1 0 7 2 Retenue de joint d tanch it...

Page 102: ...e de la fourche Z ro mm z ro in Suspension arri re USA CDN AUS NZ ZA EUROPE D battement d amortisseur 131 5 mm 5 18 in Longueur de ressort libre Approx 275 mm 10 83 in Longueur de raccord Un seul rep...

Page 103: ...in Epaisseur de plaquette 4 4 mm 0 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...

Page 104: ...t et support M6 1 0 2 9 0 9 6 5 Couvercle de ma tre cylindre de frein avant M4 0 7 2 2 0 2 1 4 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...

Page 105: ...s et bielle M14 1 5 1 80 8 0 58 Bielle et cadre M14 1 5 1 80 8 0 58 Amortisseur arri re et cadre M10 1 25 1 56 5 6 40 Amortisseur arri re et bras relais M10 1 25 1 53 5 3 38 Cadre arri re et cadre sup...

Page 106: ...66 20 C 68 F noir rose R sistance de la bobine d excitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bo tier CDI 2S2 00 YAMAHA USA et CDN 2S2 10 YAMAHA sauf USA et CDN Bobine d allum...

Page 107: ...nt pour des filets propres et secs Les l ments doivent tre 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...

Page 108: ...51 10 in 1 300 mm 51 18 in 1 301 mm 51 22 in Sitzh he 986 mm 38 82 in 998 mm 39 29 in Radstand 1 495 mm 58 86 in 1 494 mm 58 82 in Bodenfreiheit 370 mm 14 57 in 373 mm 14 69 in 374 mm 14 72 in Trocken...

Page 109: ...sel ohne Filterwechsel 0 95 L 0 84 Imp qt 1 00 US qt lwechsel mit Filterwechsel 1 0 L 0 88 Imp qt 1 06 US qt Gesamtmenge 1 2 L 1 06 Imp qt 1 27 US qt K hlsystem Fassungsverm gen 0 99 L 0 87 Imp qt 1 0...

Page 110: ...mm 4 64 in Reifen Ausf hrung Schlauch Reifen Dimension vorn 80 100 21 51M USA CDN ZA AUS NZ F 80 100 21 51R EUROPE nicht F Dimension hinten 110 90 19 62M USA CDN ZA AUS NZ F 110 90 19 NHS EUROPE nich...

Page 111: ...r 22 000 22 021 mm 0 8661 0 8670 in Nockenwellenzapfen 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...

Page 112: ...354 0 0433 in 1 6 mm 0 0630 in Ventilteller St rke D Einlass 1 mm 0 0394 in 0 85 mm 0 033 in Auslass 1 mm 0 0394 in 0 85 mm 0 033 in Ventilschaft Durchmesser Einlass 4 475 4 490 mm 0 1762 0 1768 in 4...

Page 113: ...14 9 kg bei 27 38 mm 28 66 32 85 lb bei 1 08 in Max Neigung Einlass 2 5 1 61mm 2 5 0 063 in Auslass 2 5 1 65mm 2 5 0 065 in Windungsrichtung Draufsicht Einlass Uhrzeigersinn Auslass Uhrzeigersinn Kol...

Page 114: ...age 0 35 0 50 mm 0 014 0 020 in 0 85 mm 0 033 in Ringnutspiel 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in labstreifring Abmessungen B T 2 0 2 9 mm 0 08 0 11 in Ringsto in Einbaulage 0 2 0 5 mm 0...

Page 115: ...nd F hrungs stange Max F hrungsstangen Verzug 0 05 mm 0 002 in Kickstarter Bauart Sperrklinke Vergaser Kennzeichnung 2S21 00 Hauptd se M J Nr 165 Hauptluftd se M A J 2 0 D sennadel Clipposition J N NF...

Page 116: ...n und Au enrotor Axialspiel 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 007 in Bypass Ventil Einstelldruck 40 80 kPa 0 4 0 8 kg cm2 5 69 11 38 psi K hlsystem K hlerabmessungen Breite 120 2 mm 4 73 in H he...

Page 117: ...ystem Schaubild ltank Nockenwelle Tassenst el Zylinderkopf Kolbenk hlerd se Kolben Kolbenbolzen Kurbelzapfen lfilter R ckschlagventil lpumpenrotor 1 lpumpenrotor 2 lsieb Getriebezahnr der Einhangswell...

Page 118: ...0 7 1 3 0 3 2 2 Luftfiltergeh use M6 1 0 2 8 0 8 5 8 Vergasereinlass Anschluss M6 1 0 1 3 0 3 2 2 Vergasereinlass Anschluss und Luftfilterge h use M5 0 8 1 4 0 4 2 9 Einstellschraube und Sicherungsmu...

Page 119: ...chraube Kurbelgeh use M6 1 0 1 10 1 0 7 2 lsieb M6 1 0 1 10 1 0 7 2 Kurbelgeh use Lagerdeckel M6 1 0 4 14 1 4 10 Kurbelgeh use Lagerdeckel M6 1 0 8 10 1 0 7 2 Ausgangswellen Dichtringanschlag M6 1 0 2...

Page 120: ...1 89 in Gabelrohr berstand Null mm null in Hinterradaufh ngung USA CDN AUS NZ ZA EUROPE Federweg 131 5 mm 5 18 in L nge der ungespannten Feder Ca 275 mm 10 83 in Einbaul nge Eine Kennmar kierung 264...

Page 121: ...250 3 0 mm 9 84 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 DO...

Page 122: ...d Halterung M6 1 0 2 9 0 9 6 5 Bremsfl ssigkeits Vorratsbeh lterdeckel vorn M4 0 7 2 2 0 2 1 4 Handbremshebel Schraube M6 1 0 1 6 0 6 4 3 Handbremshebel Mutter M6 1 0 1 6 0 6 4 3 Sicherungsmutter der...

Page 123: ...M14 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...

Page 124: ...F Schwarz Rosa Impulsgeber Widerstand Kabelfarbe 248 372 bei 20 C 68 F Wei Rot Z ndbox Typ Hersteller 2S2 00 YAMAHA USA und CDN 2S2 10 YAMAHA nicht USA und CDN Z ndspule Typ Hersteller 5TA 10 DENSO M...

Page 125: ...ie genannten Anzugsmomente f r saubere und trockene Schraubverbindun gen bei Raumtemperatur A Schl sselweite B Gewindedurchmesser MASSEINHEITEN A Mutter B Schrau be ANZUGSMOMENT Nm m kg ft lb 10 mm 12...

Page 126: ...2 19 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Crankshaft 6 Connecting rod From cylinder To oil tank...

Page 127: ...angswelle 5 Kurbelwelle 6 bertragungshebel Vom Zylinder Zum ltank DIAGRAMMES DE LUBRIFICATION SCHMIERSYSTEM SCHAUBILDER DIAGRAMMES DE LUBRIFICATION 1 El ment de filtre huile 2 Pompe huile 3 Arbre seco...

Page 128: ...2 20 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft To main axle From oil pump...

Page 129: ...ockenwelle 2 Auslass Nockenwelle Zur Getriebe Eingangswelle Von der lpumpe DIAGRAMMES DE LUBRIFICATION SCHMIERSYSTEM SCHAUBILDER 1 Arbre cames d admission 2 Arbre cames d chappement Vers l arbre prima...

Page 130: ...cylinder head breather hose on the outside of the radia tor hose 1 and between the radi ator hose 4 and frame Align the paint on the cylinder head breather hose with the front edge of the hose holder...

Page 131: ...CABLES KABELF HRUNGSDIAGRAMME DIAGRAMME D ACHEMINEMENT DES CABLES 1 Durit de mise l air du r servoir de carburant 2 Durit de radiateur 1 3 Durit de mise l air de la culasse 4 Support de durit 5 Durit...

Page 132: ...rottle cable Fasten the hot starter cable and throttle cables onto the frame Locate the clamp ends under the hot starter cable Fasten the hot starter cable throttle cables TPS lead and ignition coil l...

Page 133: ...de starter chaud 2 Collier pince 3 Fil du capteur de position de papillon des gaz 4 Bosse cadre 5 Fil du contacteur de point mort 6 Support de moteur 7 Support de la plaque de protection du moteur 8 F...

Page 134: ...ft of the chassis and then between the frame and radiator hose 4 Fasten the sub wire harness and ENGINE STOP button lead to the CDI unit bracket with the clamp ends facing downward behind the location...

Page 135: ...chinen Kabel am Rahmen oberhalb dessen W lbung befestigen DIAGRAMME D ACHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Attacher le fil du contacteur de point mort et la durit de mise l air du radiateur...

Page 136: ...breather hose Pass the throttle cables over the radiator hose 2 Pass the throttle cables on the outside of the igni tion coil Fasten the throttle cables with the clamp so that the cables are not bent...

Page 137: ...ie Z ndspule ber hrt DIAGRAMME D ACHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME 1 C ble des gaz tir 2 C ble des gaz retour 3 Durit de radiateur 2 4 Bobine d allumage 5 Support du bras arri re 6 Durit...

Page 138: ...n directs as shown and lightly touches the projec tion on the caliper Pass the brake hose into the brake hose holders If the brake hose contacts the spring rear shock absorber correct its twist Instal...

Page 139: ...bildet an der Nase des Hauptbremszylinders anliegt DIAGRAMME D ACHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME 1 Ma tre cylindre 2 Support de durit de frein 3 Durit de frein Monter la durit de frein de...

Page 140: ...asten the ENGINE STOP button lead to the handlebar 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 through...

Page 141: ...armstartzug durch die Kabelf hrung am Nummernschild f h ren DIAGRAMME D ACHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME 1 C ble des gaz 2 Collier pince 3 C ble de starter chaud 4 C ble d embrayage 5 Fi...

Page 142: ...he 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 wear Inspect R...

Page 143: ...hoses OUTSIDE NUTS AND BOLTS Refer to STARTING AND BREAK IN section in the CHAPTER 1 Retighten AIR FILTER Use foam air filter oil or equivalent oil Clean and lubricate Replace OIL FILTER Replace FRAME...

Page 144: ...CTING ROD Molybdenum disulfide grease Inspect lube and retighten STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel...

Page 145: ...es Contr ler Remplacer RESSORTS DE SOUPAPES Contr ler la longueur libre et l inclinaison Contr ler Remplacer POUSSOIRS DE SOUPAPES Rechercher toute trace de rayures et d usure Contr ler Remplacer ARBR...

Page 146: ...us les deux ans Contr ler les durits ECROUS ET BOULONS EXTERIEURS Se reporter la section MISE EN MARCHE ET RODAGE au CHAPITRE 1 Resserrer FILTRE A AIR Utiliser de l huile pour filtre air mousse ou une...

Page 147: ...IS BIELLE Graisse au bisulfure de molybd ne Contr ler lubrifier et resserrer TETE DE FOURCHE Contr ler le jeu et resserrer Nettoyer et lubrifier Graisse base de lithium Remplacer le roulement PNEUS RO...

Page 148: ...euern VENTILFEDERN Ungespannte L nge und Neigung kontrollieren Kontrollieren Erneuern TASSENST SSEL Auf Kratzer und Ver schlei kontrollieren Kontrollieren Erneuern NOCKENWELLEN Die Nockenwellen Ober f...

Page 149: ...n K hlfl ssigkeit wechseln Alle zwei Jahre Schl uche kontrollieren EXTERNE SCHRAUBVERBINDUNGEN Siehe unter STARTEN UND EINFAHREN in KAPITEL 1 Festziehen LUFTFILTER Schaumfilter l o ver wenden Reinigen...

Page 150: ...ND BERTRA GUNGSHEBEL Molybd ndisulfidfett Kontrollieren schmieren und festzie hen LENKKOPF Spiel kontrollieren und festziehen Reinigen und schmieren Lithiumseifenfett Lager erneuern R DER UND REIFEN L...

Page 151: ...P 3 24 30 Chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 31 33 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive p...

Page 152: ...ri re P 3 24 30 Cha ne Contr ler le jeu et l alignement de la cha ne Contr ler que la cha ne est correctement lubrifi e P 3 31 33 Roues Contr ler l usure et la pression de gonflage des pneus Contr ler...

Page 153: ...n Durchhang und Ausrichtung kontrollieren Sicherstellen dass die Antriebskette gr ndlich geschmiert ist S 3 31 33 R der Reifenluftdruck und auf starken Verschlei kontrollieren Auf lose Speichen und be...

Page 154: ...ap slowly 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 a...

Page 155: ...K hlerverschlussdeckel 3 Kontrollieren K hlfl ssigkeitsstand a Niedrig Korrigieren 1 K hler MOTEUR CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT AVERTISSEMENT Ne pas d poser le bouchon de radiateur...

Page 156: ...3 Remove Radiator cap Drain the coolant completely 4 Clean Cooling system Thoroughly flush the cooling system with clean tap water 5 Install Plain washer Coolant drain bolt Engine guard Bolt engine g...

Page 157: ...t New T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT AVERTISSEMENT Ne jamais enlever le bouchon de radiateur quand le moteur est chaud ATTENTION Vei...

Page 158: ...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 159: ...ENTION Ne pas m langer diff rents types d antigel l thyl ne glycol contenant un agent anticorro sion pour moteurs en aluminium Ne pas utiliser de l eau contenant des impure t s ou de l huile 7 Monter...

Page 160: ...pect Pressure Impossible to maintain the specified pres sure for 10 seconds Replace Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap opening pressure 110 kPa 1 1 k...

Page 161: ...Adapter 2 3 Mit dem vorgeschriebenen Druck beauf schlagen K hlerverschlussdeckel Pr fge r t YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Standard Druck 180 kPa 1 8 kg cm2 25 6 psi CONTROLE DE...

Page 162: ...NT 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 b...

Page 163: ...tziehen T R Sicherungsmutter 4 Nm 0 4 m kg 2 9 ft lb N B Ne pas appliquer de pression sup rieure la pres sion sp cifi e Le radiateur doit tre enti rement rempli 4 Contr ler Pression Impossible de main...

Page 164: ...tle 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...

Page 165: ...estellt ist WARNUNG Nach der Einstellung sollte der Lenker bei laufendem Motor beidseitig bis zum Anschlag gedreht und dabei sicherge stellt werden dass die Leerlaufdrehzahl sich nicht ver ndert 3 Mon...

Page 166: ...LTER 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 filter element in place this would allow...

Page 167: ...r 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb 2 Appliquer graisse savon de lithium A l extr mit du c ble des gaz a 3 Monter Couvercle du logement de c ble des gaz Vis couvercle du logement de...

Page 168: ...too 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...

Page 169: ...ltenase a am Filterrahmen in die ent sprechende Bohrung b im Luftfiltereinsatz einsetzen 6 Auftragen Lithiumseifenfett auf die Passfl che a des Filtereinsat zes 2 Nettoyer El ment de filtre air Nettoy...

Page 170: ...en checking the oil level make sure that the machine is upright Place the machine on a suitable stand WARNING Never remove the oil tank cap just after high speed operation The heated oil could spurt o...

Page 171: ...in aufrechter Stellung sein Anschlie end den Motor aus schalten und den lstand kontrollieren 3 Demontieren ltankverschluss 1 7 Monter El ment de filtre air 1 Rondelle Boulon de fixation N B Aligner la...

Page 172: ...and additives could cause clutch slippage Do not allow foreign material to enter the crankcase Except for USA and CDN Recommended oil At 5 C 40 F or higher Yamalube 4 20W 40 or SAE 20W 40 type SG mot...

Page 173: ...ach API API Klasse SG oder h herwertig Einsatzbereich Motorr der 4 Contr ler Niveau d huile D poser le bouchon du r servoir d huile et v rifier que le niveau d huile se situe au des sus du rep re a So...

Page 174: ...arm up for sev eral minutes CAUTION When the oil tank is empty never start the engine 6 Idle the engine more than 10 seconds while keeping the machine upright Then stop the engine and add the oil to t...

Page 175: ...us dem Kurbelgeh use und ltank ablassen ATTENTION Ne pas ajouter d additifs chimiques ni utiliser d huiles de qualit CD a ou sup rieure Ne pas utiliser d huiles portant l indication ENERGY CONSERVING...

Page 176: ...with a new one Install the oil filter element and oil filter cover T R Oil filter cover 10 Nm 1 0 m kg 7 2 ft lb 5 Install Gaskets Oil filter drain bolt Drain bolt crankcase right Drain bolt crankcase...

Page 177: ...84 Imp qt 1 00 US qt lwechsel mit Filterwechsel 1 0 L 0 88 Imp qt 1 06 US qt Gesamtmenge 1 2 L 1 06 Imp qt 1 27 US qt 4 Si le filtre huile doit tre remplac l occa sion du changement d huile d poser et...

Page 178: ...Start the engine after solving the prob lem s and recheck the oil pressure Tighten the oil gallery bolt to specification T R Oil gallery bolt 10 Nm 1 0 m kg 7 2 ft lb PILOT SCREW ADJUSTMENT 1 Adjust...

Page 179: ...um die vorgeschriebene Anzahl von Umdrehungen herausdrehen Leerlaufgemisch Regulierschraube Beispiel 2 1 8 Umdrehungen heraus 7 Monter Capuchon de l orifice de remplissage d huile 8 Contr ler Moteur f...

Page 180: ...Remove Spark plug Engine upper bracket Hot starter plunger Refer to CARBURETOR section in the CHAPTER 4 Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 Adjustment steps Adjust the pilo...

Page 181: ...ch a drehen Leerlaufdrehzahl niedriger Leerlaufeinstellschraube 1 nach b drehen Leerlaufdrehzahl 1 900 2 100 U min REGLAGE DU REGIME DE RALENTI 1 Mettre le moteur en marche et bien le laisser chauffer...

Page 182: ...clockwise with a wrench Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke NOTE In order to be sure that the piston is at To...

Page 183: ...Ventilspiel e mit einer F hlerlehre 1 messen HINWEIS Entspricht das gemessene Ventilspiel nicht der Vorgabe muss das Messergebnis f r sp tere Zwecke notiert werden 3 D poser Bouchon de calage 1 Clave...

Page 184: ...vent it from falling into the crankcase Remove the valve lifters 4 and the pads 5 NOTE Place a rag in the timing chain space to prevent pads from falling into the crank case Identity each valve lifte...

Page 185: ...S Die St rke a des Ventilpl ttchens ist in Hundertsteln von Millimetern auf dessen Oberseite angegeben 5 R gler Jeu aux soupapes Etapes du r glage Desserrer le boulon capuchon du tendeur de cha ne de...

Page 186: ...these two coordinates intersect shows the new pad number to use NOTE Use the new pad number only as a guide when verifying the valve clearance adjust ment Install the new pads 6 and the valve lift er...

Page 187: ...kel montieren Siehe unter NOCKENWELLEN in KAPI TEL 4 T R Schraube Nockenwellen Lager deckel 10 Nm 1 0 m kg 7 2 ft lb Arrondir le dernier chiffre du num ro de la rondelle mont e la gradation la plus p...

Page 188: ...ner Refer to CAMSHAFTS section in the CHAPTER 4 NOTE Turn the crankshaft counterclockwise sev eral turns so that the installed parts settle into the right position Recheck the valve clearance If the c...

Page 189: ...essung nicht dem Soll wert muss die Einstellung wiederholt wer den bis das vorgeschriebene Ventilspiel erreicht ist 6 Monter Toutes les pi ces d pos es N B Monter toutes les pi ces d pos es dans l ord...

Page 190: ...0 235 240 1 31 1 35 240 EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 14...

Page 191: ...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 192: ...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 193: ...INSP ADJ MEMO...

Page 194: ...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 scr...

Page 195: ...n T R Entl ftungsschraube 6 Nm 0 6 m kg 4 3 ft lb i Die Schritte e bis h so lange wiederho len bis keine Luftbl schen mehr im Kunststoffschlauch zu sehen sind CH SSIS PURGE D AIR DU CIRCUIT DE FREINAG...

Page 196: ...Check the operation of the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a Brake lever position a Standard position Extent of adjustment 95 mm 3 7...

Page 197: ...smutter 5 Nm 0 5 m kg 3 6 ft lb ACHTUNG Die Sicherungsmutter muss vorschriftsm ig festgezogen werden um eine Beeintr ch tigung der Bremsfunktion zu vermeiden 3 Monter Protection frein arri re Flotteur...

Page 198: ...ocknut 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 mm 0 08 in...

Page 199: ...emsbelag St rke a Standard Grenzwert 4 4 mm 0 17 in 1 0 mm 0 04 in Scheibenbremsbelag erneuern Die Scheibenbremsbelag Haltestift Abdek kung 1 demontieren REGLAGE DU FREIN ARRIERE 1 Contr ler Hauteur d...

Page 200: ...nd Loosen the bleed screw and push the cali per 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...

Page 201: ...i sorisch anziehen Den Bremssattel 8 montieren und den Scheibenbremsbelag Haltestift 9 festzie hen T R Bremssattel Schraube 23 Nm 2 3 m kg 17 ft lb Scheibenbremsbelag Haltestift 18 Nm 1 8 m kg 13 ft l...

Page 202: ...the pad pin plug 0 T R Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb EC366060 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad...

Page 203: ...en Haltestift 3 lockern Das Hinterrad 4 und den Bremssattel 5 demontieren Siehe unter VORDER UND HINTER RAD in KAPITEL 5 3 Contr ler Niveau du liquide de frein Se reporter la section CONTROLE DU NIVEA...

Page 204: ...the 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 caliper recesses b Temporarily tighten the p...

Page 205: ...m kg 13 ft lb Die Scheibenbremsbelag Haltestift Abdek kung E und den Protektor F montieren T R Scheibenbremsbelag Haltestift Abdeckung 3 Nm 0 3 m kg 2 2 ft lb Protektor Schraube 7 Nm 0 7 m kg 5 1 ft l...

Page 206: ...rake pad insulator 1 Damage Replace EC367001 BRAKE FLUID LEVEL INSPECTION 1 Place the master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level Fill...

Page 207: ...gelangt Bremsfl ssigkeit greift Lack und Kunst stoff an Deshalb vorsichtig handhaben und versch ttete Fl ssigkeit sofort abwi schen Empfohlene Bremsfl ssigkeit DOT Nr 4 3 Contr ler Niveau du liquide d...

Page 208: ...cification 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 measure...

Page 209: ...Schmutz so gut wie m g lich abb rsten Anschlie end die Kette aus dem Petroleumbad herausnehmen und trocknen CONTROLE DES PIGNONS 1 Contr ler Dents de pignon a Usure excessive Remplacer N B Remplacer e...

Page 210: ...chain 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 Abo...

Page 211: ...ng an dieser Stelle messen bzw einstellen Antriebsketten Durchhang 48 58 mm 1 9 2 3 in 4 Contr ler Raideur de la cha ne de transmission a Nettoyer et lubrifier la cha ne et la tenir comme illustr Raid...

Page 212: ...arks a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear CAUTION Too small chain slack will overload the engine and o...

Page 213: ...leskopgabel bei gezogenem Hand bremshebel mehrmals ein und ausfe dern Stockend undicht Instand setzen ggf erneuern 3 R gler Tension de la cha ne de transmission Etapes du r glage de la tension de la c...

Page 214: ...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 215: ...Einstellschraube 1 H rterr a Zugstufen D mpfungskraft erh hen Einstellschraube 1 hineindrehen Weicher b Zugstufen D mpfungskraft reduzieren Einstell schraube 1 herausdre hen T R 1 Nm 0 1 m kg 0 7 ft...

Page 216: ...ways 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 maximum...

Page 217: ...Einstell schraube 1 hineindrehen Weicher b Druckstufen D mpfungs kraft reduzieren Einstell schraube 1 herausdrehen POSITION STANDARD Position laquelle le dispositif de r glage est d viss du nombre de...

Page 218: ...er may be damaged WARNING 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 positio...

Page 219: ...r uschvoll stockend Drehpunkte schmieren ggf instand setzen Besch digt undicht Erneuern POSITION STANDARD Position laquelle le dispositif de r glage est d viss du nombre de d clics sp cifi par rapport...

Page 220: ...e 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 beyond...

Page 221: ...0 77 in 261 5 279 5 mm 10 30 11 00 in 253 0 271 0 mm 9 96 10 67 in REGLAGE DE LA PRECONTRAINTE DU RESSORT DE L AMORTISSEUR ARRIERE 1 Sur lever la roue arri re en pla ant un support ad quat sous le mot...

Page 222: ...rce Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position T R 32 Nm 3 2 m kg 23 ft lb STANDARD POSITION This is the position which i...

Page 223: ...inimal oder Maximaleinstellung hinaus drehen um diesen nicht zu besch digen Normaleinstellung Ca 8 Raststellung Ca 12 Raststellung 5 Serrer Contre crou 6 Monter Cadre arri re REGLAGE DE LA FORCE D AMO...

Page 224: ...n 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...

Page 225: ...inimal oder Maximaleinstellung hinaus drehen um diesen nicht zu besch digen Normaleinstellung Ca 8 Raststellung REGLAGE DE LA FORCE D AMORTISSEMENT A LA COMPRESSION BASSE DE L AMORTISSEUR ARRIERE 1 R...

Page 226: ...um Minimum Fully turned in position 2 turns out from maximum position 1 a b STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned in position Whic...

Page 227: ...einstellung hinaus drehen um diesen nicht zu besch digen Normaleinstellung Ca 1 1 2 Umdrehungen heraus Ca 1 1 4 Umdrehungen heraus REGLAGE DE LA FORCE D AMORTISSEMENT A LA COMPRESSION HAUTE DE L AMORT...

Page 228: ...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 229: ...m ssen vor und nach dem Ein fahren gespannt und nach jeder Fahrt kontrol liert werden T R 3 Nm 0 3 m kg 2 2 ft lb R DER KONTROLLIEREN 1 Kontrollieren Felgenschlag Das Rad anheben und drehen Anormaler...

Page 230: ...shaft 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 Adjus...

Page 231: ...utter 1 mit dem Hakenschl s sel 2 lockern Hakenschl ssel YU 33975 90890 01403 2 Contr ler Jeu des roulements Il y a du jeu Remplacer CONTROLE ET REGLAGE DE LA TETE DE FOURCHE 1 Sur lever la roue avant...

Page 232: ...y turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings Install the plain washer 5 handle crown 6 plain washer 7 steering shaft nut 8 han...

Page 233: ...kerhalterung festziehen danach die Schrauben an der Hinterseite vorschriftsm ig festziehen Serrer l crou de direction 3 l aide de la cl pour crou de direction 4 N B Appliquer de la graisse savon de li...

Page 234: ...Steering shaft nut 145 Nm 14 5 m kg 105 ft lb Handlebar holder upper 28 Nm 2 8 m kg 20 ft lb Pinch bolt handle crown 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 235: ...lb Nummernschild 7 Nm 0 7 m kg 5 1 ft lb CONTROLE ET REGLAGE DE LA TETE DE FOURCHE LENKKOPFLAGER KONTROLLIEREN UND EINSTELLEN T R Ecrou de l arbre de direction 145 Nm 14 5 m kg 105 ft lb Support du gu...

Page 236: ...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 237: ...ben fern halten LUBRIFICATION Pour assurer le bon fonctionnement de tous les organes lubrifier la moto avant la premi re utilisa tion apr s le rodage ainsi qu apr s chaque course 1 Tous les c bles de...

Page 238: ...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 239: ...en Die Z ndkerze zuerst handfest a und dann mit dem vorgeschriebenen Anzugsmoment b festziehen T R 13 Nm 1 3 m kg 9 4 ft lb PARTIE ELECTRIQUE CONTROLE DE LA BOUGIE 1 D poser Bougie 2 Contr ler Electro...

Page 240: ...er To the ignition coil lead orange lead 1 Timing light YM 33277 A 90890 03141 3 Adjust Engine idling speed Refer to IDLE SPEED ADJUSTMENT 4 Check Ignition timing Visually check the stationary pointer...

Page 241: ...Rotor befindet Z ndbereich falsch Rotor und Impuls geber kontrollieren 5 Montieren Rotor Abdeckschraube CONTROLE DE L AVANCE A L ALLUMAGE 1 D poser Bouchon de calage 1 2 Fixer Lampe stroboscopique Com...

Page 242: ...val Extent 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...

Page 243: ...schild 1 1 3 4 2 3 SELLE RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK KRAFTSTOFFTANK UND SEITENABDECKUNGEN MOTEUR SELLE RESERVOIR DE CARBURANT ET CACHES LATERAUX Organisation de la d pose 1 D po...

Page 244: ...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 under bracket is i...

Page 245: ...fthutze platzieren T R 7 Nm 0 7 m kg 5 1 ft lb SELLE RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK KRAFTSTOFFTANK UND SEITENABDECKUNGEN POINTS DE DEPOSE Cache lat ral 1 D poser Boulon cache lat r...

Page 246: ...ent of removal Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Side cover right Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt clamp 1 Only loosening 2 B...

Page 247: ...uffkr mmer Schraube 1 9 Auspuffkr mmer 1 10 Dichtung 2 2 1 2 TUBE D ECHAPPEMENT ET SILENCIEUX AUSPUFFKR MMER UND SCHALLD MPFER TUBE D ECHAPPEMENT ET SILENCIEUX Sauf USA et CDN Organisation de la d pos...

Page 248: ...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 249: ...f achten dass sich bei der Montage des inneren Rohrs der Faserstoff nicht ver zieht TUBE D ECHAPPEMENT ET SILENCIEUX AUSPUFFKR MMER UND SCHALLD MPFER CONTROLE Tube d chappement et silencieux 1 Contr l...

Page 250: ...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 3 1 2 New 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 Clamp 1 Gasket 2 Silencer 3 Plain washer 4...

Page 251: ...t werden wie in der Abbil dung gezeigt T R 16 Nm 1 6 m kg 11 ft lb New T R 35 Nm 3 5 m kg 25 ft lb TUBE D ECHAPPEMENT ET SILENCIEUX AUSPUFFKR MMER UND SCHALLD MPFER ASSEMBLAGE ET MONTAGE Tube d chappe...

Page 252: ...in the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section 1 Panel...

Page 253: ...Schlauch 1 1 11 Rohr 1 O Ring 1 1 1 RADIATEUR K HLER RADIATEUR Organisation de la d pose 1 D pose du radiateur Organisation de la d pose Ordre Nom de la pi ce Qt Remarques DEPOSE DU RADIATEUR Pr parat...

Page 254: ...residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect Radiator core 1 Obstr...

Page 255: ...0 2 m kg 1 4 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb RADIATEUR K HLER REMARQUES CONCERNANT LA MANIPULATION AVERTISSEMENT Ne pas enlever le bouchon du radiateur quand le moteur et le radiateur sont chauds D...

Page 256: ...e 1 Radiator right 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Panel 1 Bolt radiator panel upper 2 NOTE Fit the hook a on the inner side first into...

Page 257: ...en a an der Innenseite des K hlers einhaken T R 10 Nm 1 0 m kg 7 2 ft lb RADIATEUR K HLER 3 Monter Durit de mise l air du carburateur 1 Radiateur droit 2 Se reporter la section DIAGRAMME D ACHEMINEMEN...

Page 258: ...r to SEAT FUEL TANK AND SIDE COVERS section Rear shock absorber Refer to REAR SHOCK ABSORBER section in the CHAPTER 5 1 Band 1 2 TPS coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air c...

Page 259: ...rmstartkolben 1 8 Vergaser 1 9 Vergaserauslass Anschluss 1 1 CARBURATEUR VERGASER CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre Nom de la pi ce Qt Remar...

Page 260: ...y Remarks CARBURETOR DISASSEMBLY 1 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 Cover 1 8 Spring 1 9 Diaphragm accelerat...

Page 261: ...e unter DEMONTAGE EINZELHEI TEN C Schwimmerachse 1 D Schwimmer 1 E Nadelventil 1 1 CARBURATEUR VERGASER DEMONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la...

Page 262: ...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 263: ...ebel 1 N Leerlauf Luftd se 1 O Chokeschieber 1 1 CARBURATEUR VERGASER Organisation de la d pose Ordre Nom de la pi ce Qt Remarques F Gicleur principal 1 G Gicleur d aiguille 1 H Entretoise 1 I Gicleur...

Page 264: ...Pilot screw 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...

Page 265: ...o leumbasis verwenden S mtliche Kan le und D sen mit Druckluft ausblasen Niemals einen Draht verwenden CARBURATEUR VERGASER REMARQUES CONCERNANT LA MANIPULATION ATTENTION Ne pas desserrer les vis TPS...

Page 266: ...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 EC464300 Throttle valve 1 Check Free movement Stick Repair or replace...

Page 267: ...Clip Nut Spiel vorhanden verschlissen Erneu ern Clipposition Standard Clipposition 4 Nut CARBURATEUR VERGASER 2 Contr ler Gicleur principal 1 Gicleur de ralenti 2 Gicleur d aiguille 3 Gicleur de star...

Page 268: ...t of 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 NO...

Page 269: ...chwimmerstand erneut kontrollie ren Schwimmer 1 Kontrollieren Schwimmer 1 Besch digt Erneuern CARBURATEUR VERGASER Hauteur du flotteur 1 Mesurer Hauteur du flotteur a Hors sp cifications R gler Hauteu...

Page 270: ...pect Diaphragm accelerator pump 1 Spring 2 Cover 3 O ring 4 Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clea...

Page 271: ...GE Vergaser 1 Montieren Chokeschieber 1 2 Montieren Leerlauf Luftd se 1 CARBURATEUR VERGASER Plongeur de starter 1 Contr ler Plongeur de d marrage froid 1 Plongeur de d marrage chaud 2 Usure endommage...

Page 272: ...stall 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 Plain washer 1 Circlip...

Page 273: ...2 HINWEIS Das l ngere Ende a der Feder muss sich am Anschlag b der Drosselklappenwellen Scheibe befinden CARBURATEUR VERGASER 3 Monter Ressort 1 1 Levier 1 2 Sur le levier 2 3 N B Veiller engager le...

Page 274: ...ition sensor 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...

Page 275: ...hoked se 1 Leerlaufd se 2 Distanzst ck 3 Nadeld se 4 Hauptd se 5 CARBURATEUR VERGASER 8 Monter Axe du papillon complet 1 Rondelle pleine m tallique 2 Rondelle pleine r sine 3 Levier de soupape 4 N B A...

Page 276: ...tall Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points Turn in the pilot screw until it is lightly seated Turn out the pilot screw by the number of turns recorded before...

Page 277: ...hwimmerkammer 2 Schwimmerkammer Schraube 3 Seilzughalterung Leerlaufgemisch Regulierschraube 4 Schlauchhalterung Vergaser Bel ftungs schlauch 5 CARBURATEUR VERGASER 11 Monter Pointeau 1 Flotteur 2 Axe...

Page 278: ...Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6 5 6 1 2 3 4 16 Install Throttle valve assembly 1 Screw throttle shaft 2 NOTE Install the valve lever rollers 3...

Page 279: ...ren Vergaser Entl ftungsschlauch 1 Siehe unter KABELF HRUNGSDIA GRAMME in KAPITEL 2 CARBURATEUR VERGASER 14 Monter Diaphragme pompe de reprise 1 Ressort 2 Joint torique 3 Couvercle 4 Support de durit...

Page 280: ...ht 1 25 mm 0 049 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 the l...

Page 281: ...ase a muss im entsprechendem Spalt im Vergaser Auslassanschluss sitzen 3 Montieren Warmstartkolben 1 T R 2 Nm 0 2 m kg 1 4 ft lb CARBURATEUR VERGASER R glage du calage de la pompe de reprise Etapes du...

Page 282: ...n 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 Throttle cable cover 1 Screw th...

Page 283: ...he unter KABELF HRUNGSDIA GRAMME in KAPITEL 2 CARBURATEUR VERGASER 4 Serrer Boulon raccord du filtre air 1 Boulon raccord du carburateur 2 T R 3 Nm 0 3 m kg 2 2 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb 5 Mon...

Page 284: ...CYLINDER HEAD COVER REMOVAL Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Hot starter plunger Refer to CARBURETOR section Engine upper bracket right Refer to ENGINE REMOVAL sectio...

Page 285: ...ckel 1 5 Dichtung 1 6 Obere Steuerkettenschiene 1 1 ARBRES A CAMES NOCKENWELLEN ARBRES A CAMES COUVRE CULASSE Organisation de la d pose 1 D pose du couvre culasse Organisation de la d pose Ordre Nom d...

Page 286: ...t of removal Order Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing plug 1 Refer to REMOVAL POINTS 2 Straight plug 1 3 Tensioner cap bolt 1 4 Timing chain tensioner 1 5 Gasket 1 6 Bolt camshaft cap 1...

Page 287: ...0 7 Nockenwellen Lagerdeckel 2 8 Clip 2 9 Auslass Nockenwelle 1 10 Einlass Nockenwelle 1 1 ARBRES A CAMES NOCKENWELLEN ARBRES A CAMES Organisation de la d pose 1 D pose des arbres cames Organisation d...

Page 288: ...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 cylinder head surface as shown in the illustration If th...

Page 289: ...n an Zylinderkopf Nockenwel len und Nockenwellen Lagerdeckeln zu vermeiden m ssen die Lagerdeckel Schrauben gleichm ig gel st werden ARBRES A CAMES NOCKENWELLEN POINTS DE DEPOSE Arbre cames 1 D poser...

Page 290: ...ce 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length Intake a 31 200 31 300 mm 1 2283 1 2323 in Limit 31 100 mm 1 2244 in b 22 550 22 650 mm 0 8878 0 8917 in Limit 22 45...

Page 291: ...Nicht nach Vorgabe Erneuern Nockenwellen Schlag Max 0 03 mm 0 0012 in ARBRES A CAMES NOCKENWELLEN 6 D poser Clips Arbre cames d chappement 1 Arbre cames d admission 2 N B Attacher un fil 3 la cha ne d...

Page 292: ...Nm 1 0 m kg 7 2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camsh...

Page 293: ...chlissen Nockenwel lenr der und Steuerkette gemeinsam erneuern Nockenwellenzapfen Durchmes ser 21 959 21 972 mm 0 8645 0 8650 in ARBRES A CAMES NOCKENWELLEN 4 Mesurer Jeu arbre cames chapeau Hors sp c...

Page 294: ...tensioner rod up fully clock wise When releasing the screwdriver by press ing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner assembly ASSEMBL...

Page 295: ...das Dekompressionssystem auftragen ARBRES A CAMES NOCKENWELLEN D compresseur 1 Contr ler D compresseur Etapes du contr le Contr ler que la came du d compresseur 1 se d place correctement Contr ler que...

Page 296: ...alve timing will result Install the clips and camshaft caps 4 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Apply the molybdenum disulfide oil on the thread of the bolts camshaft cap 5 Tighten t...

Page 297: ...zum Anschlag im Uhrzeigersinn drehen und dabei leicht niederdr cken ARBRES A CAMES NOCKENWELLEN Monter la cha ne de distribution 3 sur les deux pignons d arbre cames et monter les arbres cames sur la...

Page 298: ...er 10 Nm 1 0 m kg 7 2 ft lb Release the screwdriver check the ten sioner rod to come out and tighten the gasket 5 and the cap bolt 6 to the speci fied torque T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 f...

Page 299: ...am Kurbelge h use ausrichten Nockenwellen Markierungen Auf die Zylinderkopf Passfl che ausrich ten Nicht nach Vorgabe Einstellen ARBRES A CAMES NOCKENWELLEN La tige tant compl tement enroul e et le re...

Page 300: ...ad bolts further to reach the specified angle 180 in the proper tightening sequence Extent of removal Order Part name Q ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refe...

Page 301: ...f 1 4 Dichtung 1 5 Passh lse 2 6 Steuerkettenschiene vorn 1 1 CULASSE ZYLINDERKOPF CULASSE CULASSE Organisation de la d pose 1 D pose de la culasse N B Serrer les boulons de culasse 30 Nm 3 0 m kg 22...

Page 302: ...d warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and re surface ment steps Place a straightedge and a feeler gauge across the cylinder head...

Page 303: ...bschleifen HINWEIS Den Zylinderkopf mehrmals drehen um einen gleichm igen Abschliff zu gew hr leisten CULASSE ZYLINDERKOPF CONTROLE Culasse 1 Eliminer D p ts de calamine de la chambre de com bustion U...

Page 304: ...procedure to obtain uniform tightening torque Wash the threads and contact surfaces of the bolts the contact surfaces of the plain washers the contact surface of the cylin der head and the threads of...

Page 305: ...iehen T R Zylinderkopf Schrauben 1 Schritt 30 Nm 3 0 m kg 22 ft lb New CULASSE ZYLINDERKOPF ASSEMBLAGE ET MONTAGE 1 Monter Patin de cha ne de distribution avant 1 Goujon 2 Joint de culasse 3 Culasse 4...

Page 306: ...ee steps in the proper tightening sequence as shown T R Bolts cylinder head 2nd 20 Nm 2 0 m kg 14 ft lb Put a mark on the corner 1 of the bolt cylinder head and the cylinder head 2 as shown NOTE Tight...

Page 307: ...Schrauben Letzter Schritt Vorgeschriebener Winkel von 180 3 Montieren Zylinderkopf Schrauben 1 T R 10 Nm 1 0 m kg 7 2 ft lb CULASSE ZYLINDERKOPF D poser les boulons Appliquer une nouvelle fois de la...

Page 308: ...Order Part name Q 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 Adjustin...

Page 309: ...entil 2 9 Einlassventil 3 1 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN SOUPAPES ET RESSORTS DE SOUPAPES SOUPAPES ET RESSORTS DE SOUPAPES Organisation de la d pose 1 D pose de la soupape...

Page 310: ...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 311: ...spanner YM 4019 90890 04019 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN POINTS DE DEPOSE Poussoir de soupape et clavette de soupape 1 D poser Poussoirs de soupape 1 Cales 2 N B Identifie...

Page 312: ...3 in Exhaust 0 020 0 047 mm 0 0008 0 0019 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 313: ...das korrekte Ventil schaft Spiel erreicht ist SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN CONTROLE Soupape 1 Mesurer Jeu queue guide Hors caract ristiques Remplacer le guide de soupape...

Page 314: ...ke 4 5 mm 0 18 in YM 4118 90890 04118 Exhaust 5 0 mm 0 20 in YM 4099 90890 04099 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem...

Page 315: ...ss 1 0 mm 0 039 in Grenzwert 0 85 mm 0 033 in SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN Outil de d pose de guide de soupape Admission 4 5 mm 0 18 in YM 4116 90890 04116 Echappement 5 0...

Page 316: ...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 Ap...

Page 317: ...u er mittig muss der Ventilsitz nachbearbeitet werden SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN 5 Mesurer Faux rond queue de soupape Hors sp cifications Remplacer N B En cas de pose d...

Page 318: ...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 319: ...Vorgabe entspricht Ventilkegel und sitz erneut einschleifen SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN 9 Roder Port e de soupape Si ge de soupape N B Apr s rectification du si ge de so...

Page 320: ...in Exhaust 37 68 mm 1 48 in Limit 36 68 mm 1 44 in Compressed spring force Intake 111 3 127 9 N at 27 87 mm 11 3 13 0 kg at 27 87 mm 24 91 28 66 lb at 1 10 in Exhaust 127 4 146 4 N at 27 38 mm 13 0 1...

Page 321: ...enst el Verkratzt besch digt Tassenst el und Zylinderkopf erneuern SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN Ressort de soupape 1 Mesurer Longueur libre du ressort de soupape a Hors sp...

Page 322: ...the painted color as follows Intake middle a blue Intake right left b gray Exhaust not paint Install the valve springs with the larger pitch c facing upward d Smaller pitch New 3 Install Valve cotter...

Page 323: ...OUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN ASSEMBLAGE ET MONTAGE 1 Appliquer Huile au bisulfure de molybd ne Sur la queue de soupape et le joint de queue de soupape 2 Monter Soupapes 1 S...

Page 324: ...pad 1 Valve lifter 2 NOTE Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem end Valve lifter must turn smoothly when rotated with a finger Be careful to re...

Page 325: ...sen in der urspr nglichen Lage montiert wer den SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN 5 Monter Cale de r glage 1 Poussoir de soupape 2 N B Appliquer de l huile moteur sur les pouss...

Page 326: ...moval 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 Gasket 1 4 Dowel...

Page 327: ...e unter DEMONTAGE EINZEL HEITEN 6 Kolbenbolzen 1 7 Kolben 1 8 Kolbenringsatz 1 2 1 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CYLINDRE ET PISTON CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cy...

Page 328: ...o drive the piston pin out Piston ring 1 Remove Piston rings 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 illustration...

Page 329: ...rchschnitt der gemessenen Werte ermitteln CYLINDRE ET PISTON ZYLINDER UND KOLBEN POINTS DE DEPOSE Piston 1 D poser Agrafes d axes de pistons 1 Axe de piston 2 Piston 3 N B Placer des rep res d identif...

Page 330: ...re the piston skirt diameter P with a micrometer a 8 mm 0 315 in from the piston bottom edge Piston size P Standard 94 945 94 960 mm 3 738 3 739 in If out of specification replace the piston and pisto...

Page 331: ...enringe erneuern CYLINDRE ET PISTON ZYLINDER UND KOLBEN Al sage de cylindre C 95 00 95 01 mm 3 7402 3 7406 in Limite de conicit T 0 05 mm 0 002 in Ovalisation R 0 05 mm 0 002 in C D maximum T D1 ou D2...

Page 332: ...crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 0...

Page 333: ...85 mm 0 033 in labstreif ring 0 20 0 50 mm 0 01 0 02 in CYLINDRE ET PISTON ZYLINDER UND KOLBEN Segment de piston 1 Mesurer Jeu lat ral du segment Utiliser une jauge d paisseur lames 1 Hors sp cificati...

Page 334: ...nd 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 17 991 18 000 mm 0 7083...

Page 335: ...nzwert 0 07 mm 0 003 in CYLINDRE ET PISTON ZYLINDER UND KOLBEN Axe de piston 1 Contr ler Axe de piston D coloration bleue rainures Remplacer puis contr ler le syst me de lubrification 2 Mesurer Jeu en...

Page 336: ...er the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase Install the piston pin clips with their ends fac ing downward 4 Lubricate Piston Piston rings Cylinder...

Page 337: ...besch digt wird 2 Montieren Zylinder Schraube New New New T R 10 Nm 1 0 m kg 7 2 ft lb CYLINDRE ET PISTON ZYLINDER UND KOLBEN 2 Position Segment de feu Segment d tanch it Segment racleur d huile Excen...

Page 338: ...r 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 REMOVAL section Clutch cable D...

Page 339: ...ckstange 2 1 4 1 2 3 1 EMBRAYAGE KUPPLUNG EMBRAYAGE EMBRAYAGE Organisation de la d pose 1 D pose de la tige de d brayage et de la tige de pouss e 2 D montage de la tige de d brayage 1 3 D pose du disq...

Page 340: ...of removal Order Part name Q ty Remarks 12 Clutch plate 8 13 Friction plate 9 14 Nut 1 Use special tool Refer to REMOVAL POINTS 15 Lock washer 1 16 Clutch boss 1 17 Thrust washer 1 18 Clutch housing 1...

Page 341: ...16 Kupplungsnabe 1 17 Anlaufscheibe 1 18 Kupplungskorb 1 19 Kupplungsausr cker 1 4 1 3 EMBRAYAGE KUPPLUNG Organisation de la d pose Ordre Nom de la pi ce Qt Remarques 12 Plateau de pression 8 13 Disq...

Page 342: ...1042 90890 04086 EC494000 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 Che...

Page 343: ...der Standard Grenzwert 47 8 mm 1 88 in 46 8 mm 1 84 in EMBRAYAGE KUPPLUNG POINTS DE DEPOSE Noix d embrayage 1 D poser Ecrou 1 Rondelle frein 2 Noix d embrayage 3 N B Redresser la languette de la ronde...

Page 344: ...e 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 92 3 08 mm 0 115 0 121 in Limit 2 8 mm 0 110 in Warp li...

Page 345: ...Druckstange 2 4 Kugel 5 Verschlissen besch digt verbogen Erneuern EMBRAYAGE KUPPLUNG Disque garni 1 Mesurer Epaisseur du disque garni Hors sp cifications Remplacer le disque garni complet Mesurer aux...

Page 346: ...st washer 2 Clutch boss 3 NOTE Apply the engine oil on the primary driven gear inner circumference 2 Install Lock washer 1 Nut clutch boss 2 NOTE Install the lock washer with its concaves fit ted over...

Page 347: ...5 m kg 54 ft lb 3 Die Lasche 1 der Sicherungsscheibe umbiegen EMBRAYAGE KUPPLUNG ASSEMBLAGE ET MONTAGE Tige de pouss e 1 Monter Tige de pouss e 1 N B Appliquer de la graisse savon de lithium sur la l...

Page 348: ...riction plate and ending with a friction plate Apply the engine oil on the friction plates and clutch plates 5 Install Bearing 1 Plain washer 2 Circlip 3 To push rod 1 4 NOTE Apply the engine oil on t...

Page 349: ...tragen New 7 Montieren Druckplatte 1 EMBRAYAGE KUPPLUNG 4 Monter Disque garni 1 Plateau de pression 2 N B Monter les plateaux de pression et les disques garnis dans la noix d embrayage en les alternan...

Page 350: ...Tighten the bolts in stage using a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb 9 Install Gasket clutch cover 1 Dowel pin 2 New 10 Install Clutch cover 1 Bolt clutch cover NOTE Tighten the bolts i...

Page 351: ...ube HINWEIS Die Schrauben schrittweise ber Kreuz fest ziehen T R 10 Nm 1 0 m kg 7 2 ft lb EMBRAYAGE KUPPLUNG 8 Monter Ressort d embrayage Boulon ressort d embrayage N B Serrer les boulons par tapes et...

Page 352: ...R WATER PUMP AND CRANKCASE COVER RIGHT REMOVAL Preparation for removal Engine guard right Refer to ENGINE REMOVAL section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3...

Page 353: ...STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT Organisation de la d...

Page 354: ...emoval Order Part name Q ty Remarks 6 Oil tank breather hose 1 7 Kick starter 1 8 Crankcase cover right 1 9 Gasket 1 10 Dowel pin O ring 3 1 11 Impeller 1 Refer to REMOVAL POINTS 12 Plain washer 1 13...

Page 355: ...ichtring 2 1 16 Lager 1 2 3 2 FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS Organisation de la d pose Ordre Nom de la pi ce Qt Remarques 6...

Page 356: ...ross 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 l...

Page 357: ...TRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS POINTS DE DEPOSE Axe de pompe 1 D poser Rotor 1 Rondelle pleine 2 Axe de pompe 3 N B Maintenir...

Page 358: ...EC444400 Oil seal 1 Inspect Oil seal Wear damage Replace ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1 Install Oil seal 1 NOTE Apply the lithium soap base grease on the oil seal lip Install the oil s...

Page 359: ...n Au enlaufring dr cken New FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS Roulement 1 Contr ler Roulement Faire tourner la cage interne av...

Page 360: ...while turning it Hold the impeller shaft on its width across the flats a with spanners etc and install the impeller T R 14 Nm 1 4 m kg 10 ft lb Crankcase cover right 1 Install Dowel pin 1 O ring 2 Col...

Page 361: ...R 10 Nm 1 0 m kg 7 2 ft lb FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS Axe de pompe 1 Monter Axe de pompe 1 Rondelle pleine 2 Rotor 3 N...

Page 362: ...n or more apart a and the kickstarter crank and right crank case 3 mm 0 12 in or more apart b b a 1 T R 33 Nm 3 3 m kg 24 ft lb 2 Install Oil tank breather hose 1 Clamp 2 T R 2 Nm 0 2 m kg 1 4 ft lb W...

Page 363: ...keits Ablassschraube 4 T R 10 Nm 1 0 m kg 7 2 ft lb New T R 10 Nm 1 0 m kg 7 2 ft lb FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS Lanceur...

Page 364: ...UMP AND CRANKCASE COVER RIGHT 3 Install O ring Coolant pipe 1 Bolt coolant pipe 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter 1 Install Oil filter 1 O ring 2 Oil filter cover 3 Bolt oil filter cover New T...

Page 365: ...R 10 Nm 1 0 m kg 7 2 ft lb FILTRE A HUILE POMPE A EAU ET COUVERCLE DE STARTER DROIT LFILTER WASSERPUMPE UND KURBELGEH USEDECKEL RECHTS 3 Monter Joint torique Tuyau de liquide de refroidissement 1 Bou...

Page 366: ...CLUTCH section Crankcase cover right Refer to OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT section Stator Refer to CDI MAGNETO section 1 Nut balancer 1 Refer to REMOVAL POINTS 2 Nut primary drive...

Page 367: ...itzel 1 10 Sicherungsscheibe 1 11 Ausgleichswellen Antriebsrad 1 2 1 2 1 BALANCIER AUSGLEICHSWELLE BALANCIER BALANCIER Organisation de la d pose 1 Pignon menant de balancier 2 Balancier Organisation d...

Page 368: ...gear 2 Nut balancer driven gear 3 NOTE Place an aluminum plate a between the teeth of the balancer drive gear 4 and balancer driven gear 5 INSPECTION Primary drive gear balancer drive gear and balanc...

Page 369: ...igt Erneuern Ausgleichswelle 1 Kontrollieren Ausgleichswelle Rissig besch digt Erneuern BALANCIER AUSGLEICHSWELLE POINTS DE DEPOSE Balancier pignon menant et pignon men du balancier 1 Redresser l ongl...

Page 370: ...th each other 3 Install Lock washer 1 Nut balancer driven gear 2 Primary drive gear 3 Conical washer 4 Nut primary drive gear 5 Straight key 6 Balancer 7 Lock washer 8 Nut balancer 9 NOTE Apply engine...

Page 371: ...0 m kg 36 ft lb T R 110 Nm 11 0 m kg 80 ft lb T R 45 Nm 4 5 m kg 33 ft lb BALANCIER AUSGLEICHSWELLE ASSEMBLAGE ET MONTAGE Balancier pignon menant et pignon men du balancier 1 Monter Pignon men du bal...

Page 372: ...ASSEMBLY Preparation for removal Clutch housing Refer to CLUTCH section Crankcase cover right Refer to OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT section 1 Circlip 1 2 Plate washer 1 3 Oil pump...

Page 373: ...nrotor 1 1 12 Innenrotor 1 1 2 1 POMPE A HUILE LPUMPE POMPE A HUILE POMPE A HUILE Organisation de la d pose 1 D pose de la pompe huile 2 D montage de la pompe huile Organisation de la d pose Ordre Nom...

Page 374: ...4 67 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 13 Pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 2...

Page 375: ...gen 13 Stift 1 14 Beilagscheibe 1 15 lpumpen Antriebswelle 1 16 Rotorgeh use 1 2 POMPE A HUILE LPUMPE Organisation de la d pose Ordre Nom de la pi ce Qt Remarques 13 Goupille 1 14 Rondelle 1 15 Arbre...

Page 376: ...the oil pump Tip clearance a 0 12 mm or less 0 0047 in or less Limit 0 20 mm 0 008 in Tip clearance b 0 09 0 17 mm 0 0035 0 0067 in Limit 0 24 mm 0 009 in Side clearance c 0 03 0 10 mm 0 0012 0 0039 i...

Page 377: ...im Innenrotor 1 sit zen POMPE A HUILE LPUMPE CONTROLE Pompe huile 1 Contr ler Pignon menant de pompe huile Pignon men de pompe huile Bo tier du rotor Couvercle de pompe huile Craquelures usure endomm...

Page 378: ...ump drive shaft end and inner rotor 2 Fit the pin into the groove in the inner rotor 2 T R 2 Nm 0 2 m kg 1 4 ft lb New 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly...

Page 379: ...bsritzels auftragen T R 10 Nm 1 0 m kg 7 2 ft lb New POMPE A HUILE LPUMPE 2 Monter Rotor externe 1 1 N B Appliquer de l huile moteur sur le rotor externe 1 3 Monter Couvercle de pompe huile 1 Vis couv...

Page 380: ...oval Extent of removal Order Part name Q ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick axle assembly 1 Refer to REMO...

Page 381: ...nzh lse 1 12 Torsionsfeder 1 3 2 1 4 1 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ARBRE DE KICK ET AXE DE SELECTEUR ARBRE DE KICK ET AXE DE SELECTEUR Organisation de la d pose 1...

Page 382: ...Part name Q ty Remarks 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 lever 1 2...

Page 383: ...latte 1 Siehe unter DEMONTAGE EINZELHEI TEN 4 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE Organisation de la d pose Ordre Nom de la pi ce Qt Remarques 13 Rouleau 1 14 Guide de s l...

Page 384: ...hift lever assembly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt CAU...

Page 385: ...welle 2 Verschlissen besch digt Erneuern Feder 3 Gebrochen Erneuern ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE POINTS DE DEPOSE Arbre de kick complet 1 D poser Arbre de kick comp...

Page 386: ...atchet teeth b Wear damage Replace EC4B4400 Shift shaft 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace EC4C4100 Shift guide and shift lever assembly 1 Inspect Shift guide 1 Shift...

Page 387: ...digt Erneuern Torsionsfeder 2 Gebrochen Erneuern ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE Pignon de kick pignon fou de kick et roue rochet 1 Contr ler Pignon de kick 1 Pignon f...

Page 388: ...the segment when tightening the bolt T R 30 Nm 3 0 m kg 22 ft lb EC4B5111 Stopper lever 1 Install Torsion spring 1 Plain washer 2 Stopper lever 3 Bolt stopper lever 4 NOTE Align the stopper lever rol...

Page 389: ...2 Montieren Schaltklinke komplett 1 an der Schaltf hrung 2 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ASSEMBLAGE ET MONTAGE Segment 1 Monter Segment 1 Boulon segment N B Aligner...

Page 390: ...shift guide 1 T R 10 Nm 1 0 m kg 7 2 ft lb EC4C5301 Shift shaft 1 Install Roller 1 Collar 2 Torsion spring 3 Plain washer 4 Shift shaft 5 NOTE Apply the engine oil on the roller and shift shaft 2 Ins...

Page 391: ...a oberhalb der Fu rastenauflage ist T R 12 Nm 1 2 m kg 8 7 ft lb ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE 3 Monter Levier de s lecteur complet 1 Guide de s lecteur 2 N B Le le...

Page 392: ...To kick axle 2 NOTE Make sure the stopper a of the torsion spring fits into the hole b on the kick axle 3 Install Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a i...

Page 393: ...Kickhe belwellen Anschlag in der Klinkenrad F hrung sitzt ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE Arbre de kick complet 1 Monter Pignon de kick 1 Rondelle pleine 2 Circlip 3 R...

Page 394: ...hook into the proper hole a in the crankcase Kick idle gear 1 Install Kick idle gear 1 Plain washer 2 Circlip 3 NOTE Install the kick idle gear with its depressed side a toward you Apply the engine o...

Page 395: ...chtet ist Motor l auf die Innenfl che des Kickstarter Zwischenrads auftragen New ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE 5 Accrocher Ressort de torsion 1 N B Faire tourner le...

Page 396: ...rt name Q ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Gasket 1...

Page 397: ...EINZEL HEITEN 5 Rotor 1 6 Stator 1 7 Scheibenfeder 1 1 VOLANT MAGNETIQUE CDI LICHTMASCHINE VOLANT MAGNETIQUE CDI Organisation de la d pose 1 D pose du volant magn tique CDI Organisation de la d pose O...

Page 398: ...r outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace EC4L5000 ASSE...

Page 399: ...reeBond Nr 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb VOLANT MAGNETIQUE CDI LICHTMASCHINE POINTS DE DEPOSE Rotor 1 D poser Ecrou rotor 1 Rondelle pleine 2 D poser Rotor 1 Utiliser l extracteur de r...

Page 400: ...the rotor align the keyway c of the rotor with the woodruff key 3 Install Plain washer Nut rotor 1T R 56 Nm 5 6 m kg 40 ft lb 4 Connect CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the C...

Page 401: ...Schrauben schrittweise ber Kreuz fest ziehen New T R 10 Nm 1 0 m kg 7 2 ft lb VOLANT MAGNETIQUE CDI LICHTMASCHINE 2 Monter Clavette demi lune 1 Rotor 2 N B Nettoyer les parties coniques du vilebrequi...

Page 402: ...SIDE COVERS section Rear shock absorber Refer to REAR SHOCK ABSORBER section in the CHAPTER 5 Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER sectio...

Page 403: ...UR MOTOR DEMONTIEREN DEPOSE DU MOTEUR Organisation de la d pose Ordre Nom de la pi ce Qt Remarques DEPOSE DU MOTEUR Pr paration la d pose Caler la moto en pla ant un support ad quat sous le cadre AVER...

Page 404: ...tch 1 2 Chain cover 1 3 Nut drive sprocket 1 Refer to REMOVAL POINTS 4 Lock washer 1 5 Drive sprocket 1 6 Clip 1 7 Bolt brake pedal 1 8 Brake pedal 1 9 Engine upper bracket right 1 10 Engine upper bra...

Page 405: ...Schwingenachse 1 Siehe unter DEMONTAGE EINZEL HEITEN 14 Motor 1 1 DEPOSE DU MOTEUR MOTOR DEMONTIEREN Organisation de la d pose 1 D pose du moteur Organisation de la d pose Ordre Nom de la pi ce Qt Rem...

Page 406: ...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 407: ...or 1 von der rechten Seite HINWEIS Sicherstellen dass alle Kabel Schl uche und Seilz ge gel st sind DEPOSE DU MOTEUR MOTOR DEMONTIEREN POINTS DE DEPOSE Couronne arri re 1 D poser Ecrou couronne arri r...

Page 408: ...molybdenum disulfide grease on the pivot shaft Install the patch with the claw a facing out side the chassis Brake pedal 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 NOTE Apply...

Page 409: ...nd kette gemeinsam montie ren DEPOSE DU MOTEUR MOTOR DEMONTIEREN ASSEMBLAGE ET MONTAGE Montage du moteur 1 Monter Moteur 1 Monter le moteur par le c t droit Boulon pivot 2 Boulon d ancrage du moteur i...

Page 410: ...ew T R 75 Nm 7 5 m kg 54 ft lb 3 Bend the lock washer tab to lock the nut 4 Install Chain guide Chain cover 1 Screw chain cover 2 2 1 T R 8 Nm 0 8 m kg 5 8 ft lb 5 Install Spring 1 Pin 2 O ring 3 Neut...

Page 411: ...5 HINWEIS Den O Ring mit Lithiumseifenfett bestreichen New T R 4 Nm 0 4 m kg 2 9 ft lb DEPOSE DU MOTEUR MOTOR DEMONTIEREN 2 Monter Rondelle frein 1 Ecrou couronne arri re 2 N B Serrer l crou tout en a...

Page 412: ...CASE SEPARATION Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Balancer Refer to BALANCER section Kick axle assembly Refer to KICK AXLE AND...

Page 413: ...80 mm 3 6 Schlauchf hrung 1 2 1 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE CARTER MOTEUR ET VILEBREQUIN CARTER MOTEUR ET VILEBREQUIN Organisation de la d pose 1 S paration du carter mo...

Page 414: ...Extent of removal Order Part name Q ty Remarks 7 Crankcase right 1 Refer to REMOVAL POINTS 8 Crankcase left 1 9 Oil strainer 1 10 Balancer shaft 1 Refer to REMOVAL POINTS 11 Crankshaft 1 Use special...

Page 415: ...TEN 11 Kurbelwelle 1 Spezialwerkzeug verwenden Siehe unter DEMONTAGE EINZELHEI TEN 2 1 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Organisation de la d pose Ordre Nom de la pi ce Qt Rem...

Page 416: ...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 417: ...r 10 Siehe unter DEMONTAGE EINZELHEI TEN 1 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE ROULEMENT DE CARTER Organisation de la d pose 1 D pose du roulement de carter Organisation de la d...

Page 418: ...zontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mission with the crankcase left CAUTION Use soft hammer to tap o...

Page 419: ...bindungen u berpr fen Nicht forcieren Die Passh lsen und O Ringe erneuern CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE POINTS DE DEPOSE Carter 1 S parer Carter droit Carter gauche Etapes...

Page 420: ...152 Crankshaft bearing 1 Remove Bearing 1 NOTE Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing INSPECTION Timing chain and timing chain guide 1 Inspect...

Page 421: ...n Motorbefestigung b Kurbelgeh use Rissig besch digt Erneuern CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Vilebrequin 1 D poser Vilebrequin 1 Utiliser l outil de s paration de carter 2...

Page 422: ...rod big end side clearance c Crank width d Out of specification Replace Use the dial gauge and a thickness gauge Dial gauge and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in...

Page 423: ...lsieb Besch digt Erneuern CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE 2 Contr ler Roulement Faire tourner la cage interne avec le doigt Rugosit grippage Remplacer 3 Contr ler Bague d t...

Page 424: ...ose crush the screw head periphery a into the concave b using a punch etc In so doing take care not to damage the screwdriver receiving hole in the screw head New T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 N...

Page 425: ...Einbauh lse 5 YM 91044 90890 04081 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE ASSEMBLAGE ET MONTAGE Roulement de vilebrequin 1 Monter Roulement Butoir de roulement Boulon butoir de ro...

Page 426: ...ling the crankshaft clean the contacting surface of crankcase CAUTION Do not use a hammer to drive in the crank shaft 2 Check Shifter operation Transmission operation Unsmooth operation Repair 3 Insta...

Page 427: ...t werden YAMAHA Dichtmasse Nr 1215 ThreeBond Nr 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE N B Maintenir la bielle au point mort haut d un...

Page 428: ...top dead center New 6 Tighten Bolt hose guide 1 Bolt crankcase NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern 7 Install Timing chain Timing chain guide rear Bolt timi...

Page 429: ...nd setzen T R 12 Nm 1 2 m kg 8 7 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE 5 Monter Goujon 1 Joint torique 2 Carter droit Sur le carter gauche N B A...

Page 430: ...nd drive axle 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...

Page 431: ...TESSES TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE SCHALTWALZE UND SCHALTGABELN BOITE DE VITESSES TAMBOUR ET FOURCHETTES DE SELECTION BOITE DE VITESSES TAMBOUR ET FOURCHETTES DE SELECTION Organisatio...

Page 432: ...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 433: ...fest Erneuern BOITE DE VITESSES TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE SCHALTWALZE UND SCHALTGABELN POINTS DE DEPOSE Bo te de vitesses 1 D poser Arbre primaire 1 Arbre secondaire 2 Tambour Fourc...

Page 434: ...lace shift 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 ASSEMBLY AND INSTALLATION Transmission 1 Install 5th pini...

Page 435: ...lybd ndisulfid l bestreichen BOITE DE VITESSES TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE SCHALTWALZE UND SCHALTGABELN Fourchette de s lection tambour et segment 1 Contr ler Fourchette de s lection...

Page 436: ...the inner surface of the sliding gear then install Apply the lithium soap base grease on the O ring 3 Install Plain washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned oppo...

Page 437: ...htringlippe nicht zu besch digen BOITE DE VITESSES TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE SCHALTWALZE UND SCHALTGABELN 2 Monter Entretoise paul e 1 Pignon de 2 me 23T 2 Pignon de 4 me 24T 3 Pign...

Page 438: ...il on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle 6...

Page 439: ...ontrollieren Funktion der Schaltung Funktion des Getriebes Stockend Instand setzen BOITE DE VITESSES TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE SCHALTWALZE UND SCHALTGABELN 5 Monter Fourchette de s...

Page 440: ...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 441: ...Entretoise paul e 2 6 Bague d tanch it 2 7 Roulement 2 Se reporter POINTS DE DEPOSE 8 Disque de frein 1 2 3 1 3 FAHRWERK VORDER UND HINTERRAD VORDERRAD Arbeitsumfang 1 Vorderrad demontieren 2 Radlager...

Page 442: ...the 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 Cha...

Page 443: ...tie de bo te 1 7 Bague d tanch it 2 8 Circlip 1 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 2 3 1 3 HINTERRAD Arbeitsumfang 1 Hinterrad demontieren 2 Radlager demontieren 3 Bremssc...

Page 444: ...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 445: ...Remplacer N B Remplacer ensemble les roulements la bague d tanch it et l entretoise paul e de roue DEMONTAGE EINZELHEITEN Hinterrad 1 Demontieren Rad 1 HINWEIS Das Hinterrad nach vorn dr cken und die...

Page 446: ...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 g...

Page 447: ...d usure du disque de frein Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arri re 4 0 mm 0 16 in 3 5 mm 0 14 in Radachse 1 Messen Radachs Verbiegung Nicht nach Vorgabe Erneuern Eine Messuhr 1 ve...

Page 448: ...lled 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 Bra...

Page 449: ...vers la roue 4 Monter Roue N B Monter correctement le disque de frein 1 entre les plaquettes de frein 2 ZUSAMMENBAU UND MONTAGE Vorderrad 1 Montieren Lager links 1 Distanzst ck 2 Lager rechts 3 Dicht...

Page 450: ...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 451: ...rche tout en serrant le frein avant T R 23 Nm 2 3 m kg 17 ft lb 5 Montieren Radachse 1 HINWEIS Die Radachse mit Lithiumseifenfett bestrei chen 6 Montieren Achsmutter 1 T R 105 Nm 10 5 m kg 75 ft lb 7...

Page 452: ...of 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 453: ...e de bo te 4 N B Serrer les crous par tapes et en proc dant en croix T R 14 Nm 1 4 m kg 10 ft lb T R 42 Nm 4 2 m kg 30 ft lb Hinterrad 1 Montieren Lager rechts 1 Sicherungsring 2 Distanzst ck 3 Lager...

Page 454: ...chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install Chain puller left 1 Wheel axle 2 NOTE Install the chain puller left and insert the wheel axle from left side Apply the lithi...

Page 455: ...cha ne droit 1 Rondelle pleine 2 Ecrou axe de roue 3 N B A ce stade resserrer provisoirement l crou axe de roue 4 Montieren Distanzh lse 1 HINWEIS Die Dichtringlippen mit Lithiumseifenfett bestreichen...

Page 456: ...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 457: ...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 Einstellen Antriebsketten Durchhang a Siehe unter ANTRIEBSKETTEN DURCHHANG EINSTELLEN in KAPI T...

Page 458: ...ine securely 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...

Page 459: ...de frein 1 9 Support du ma tre cylindre 1 10 Ma tre cylindre 1 2 3 1 3 2 VORDER UND HINTERRADBREMSEN VORDERRADBREMSE Arbeitsumfang 1 Bremsschlauch demontieren 2 Bremssattel demontieren 3 Hauptbremszy...

Page 460: ...t falling 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 POI...

Page 461: ...ette 7 Goupille de plaquette 1 Desserrer pour d monter l trier 8 Etrier 1 3 1 3 2 1 HINTERRADBREMSE Arbeitsumfang 1 Hauptbremszylinder demontieren 2 Bremsschlauch demontieren 3 Bremssattel demontieren...

Page 462: ...caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q ty Remarks CALIPER DISASSEMBLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Caliper piston 2 1 Refer to REMO...

Page 463: ...de l trier de frein 2 1 Se reporter POINTS DE DEPOSE 5 Joint antipoussi re 2 1 6 Joint de piston 2 1 1 2 BREMSSATTEL ZERLEGEN Vorn Hinten Arbeitsumfang 1 Vorderrad Bremssattel zerlegen 2 Hinterrad Bre...

Page 464: ...linder disassembly 2 Rear master cylinder disassembly Extent of removal Order Part name Q ty Remarks MASTER CYLINDER DISAS SEMBLY 1 Master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Master cyl...

Page 465: ...une pince circlip bec long 6 Rondelle pleine 1 7 Tige de d brayage 1 8 Kit de ma tre cylindre 1 1 2 1 2 2 HAUPTBREMSZYLINDER ZERLEGEN Vorn Hinten Arbeitsumfang 1 Vorderrad Hauptbremszylinder zerlegen...

Page 466: ...e lever 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 EC533301 Caliper...

Page 467: ...ssu dans l trier de frein pour bloquer le piston Lib rer prudemment le piston du cylindre d trier de frein en insufflant de l air comprim DEMONTAGE EINZELHEITEN Bremsfl ssigkeit 1 Demontieren Vorn Bre...

Page 468: ...and dust seals WARNING Replace the piston seals and dust seals whenever a caliper is disassembled Front Rear EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect Master cylinder inner surface a Wea...

Page 469: ...t Arri re 3 Contr ler frein avant seulement Flotteur du r servoir 1 Endommagement Remplacer Staubschutz und Dichtringe 1 Demontieren Staubschutzring 1 Bremskolben Dichtring 2 HINWEIS Die Staubschutz u...

Page 470: ...ear score marks Replace caliper pis ton assembly WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crack damage Replace EC...

Page 471: ...internes avec du liquide de frein En cas de d montage d un trier toujours remplacer les joints de piston et antipoussi re 4 Kontrollieren Bremskolben 1 Hauptbremszylinder Manschette 2 Besch digt versc...

Page 472: ...lot on caliper correctly Front Rear 3 Install Caliper piston 1 NOTE Apply the brake fluid on the piston wall CAUTION Install the piston with its shallow depressed side a facing the caliper Never force...

Page 473: ...s les gorges des triers de freins b A ce stade serrer provisoirement la goupille de plaquette New New Bremskolben 1 Reinigen Bremssattel Bremskolben Dichtring Staubschutzring Bremskolben mit Bremsfl s...

Page 474: ...kg 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 EC5A5100 Rear caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the ca...

Page 475: ...e de frein 2 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Montieren Bremssattel 1 Bremssattel Schraube 2 3 Festziehen Scheibenbremsbelag Haltestift 3 4 Montieren Scheibenbremsbelag Haltestift Abdek kung 4 T R 23 Nm...

Page 476: ...18 Nm 1 8 m kg 13 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Master cylinder cup primary 1 Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylind...

Page 477: ...re cylindre 2 N B Reposer le ressort du c t du diam tre inf rieur Avant Arri re 3 Montieren Bremssattel 1 Hinterrad 2 Siehe unter VORDER UND HINTER RAD 4 Festziehen Scheibenbremsbelag Haltestift 3 5 M...

Page 478: ...ter cylinder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers Front Rear EC5A5310 Front master cylinder 1 Install Master cyl...

Page 479: ...er les boulons inf rieurs T R 9 Nm 0 9 m kg 6 5 ft lb 4 Montieren Vorn Hauptbremszylinder Bauteile 1 Beilagscheibe 2 Sicherungsring 3 Staubschutzkappe 4 am Hauptbremszylinder 5 Hinten Hauptbremszylind...

Page 480: ...ways 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 master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm...

Page 481: ...le joint torique et le support de p dale de frein T R 10 Nm 1 0 m kg 7 2 ft lb New T R 26 Nm 2 6 m kg 19 ft lb 2 Montieren Handbremshebel 1 Handbremshebel Schraube 2 Handbremshebel Mutter 3 HINWEIS Di...

Page 482: ...n bolt 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 caliper New T R 30 Nm 3 0 m kg 22...

Page 483: ...du support de durit de frein avec la peinture b de la durit de frein T R 7 Nm 0 7 m kg 5 1 ft lb 4 Montieren Stift 1 Beilagscheibe 2 Splint 3 HINWEIS Nach der Montage die Fu bremshebel Posi tion kontr...

Page 484: ...e so that its pipe por tion a directs as shown and lightly touches the projection b on the master cylinder New T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union...

Page 485: ...laire a soit orient e comme sur l illus tration et touche l g rement la saillie b de l trier de frein New T R 30 Nm 3 0 m kg 22 ft lb 4 Den Bremsschlauch durch die F hrung 1 leiten 5 Montieren Kupfers...

Page 486: ...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 487: ...ment toute trace de liquide renvers Avant Arri re Liquide de frein recommand DOT n 4 T R 2 Nm 0 2 m kg 1 4 ft lb 2 Montieren Bremsschlauch Halterung 1 Schraube Bremsschlauch Halterung 2 ACHTUNG Nach d...

Page 488: ...agm Master cylinder cap 1 Screw master cylinder cap 2 Rear Diaphragm Master cylinder cap 1 Bolt master cylinder cap 2 CAUTION After installation while pulling the lever in or pushing down on the pedal...

Page 489: ...1 Boulon protection 2 T R 2 Nm 0 2 m kg 1 4 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 2 Entl ften Bremshydraulik Siehe unter HYDRAULISCHE BREMS ANLAGE ENTL FTEN in KAPITEL 3 3 Kon...

Page 490: ...securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK...

Page 491: ...che Utiliser l outil sp cial Se reporter POINTS DE DEPOSE 4 Boulon de pincement t inf rieur 2 Desserrer uniquement 5 Fourche 1 1 TELESKOPGABEL Arbeitsumfang 1 Teleskopgabel demontieren Arbeitsumfang R...

Page 492: ...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 493: ...anch it 1 A Soupape de base 1 Vidanger l huile de fourche Utiliser l outil sp cial Se reporter POINTS DE DEPOSE B Amortisseur complet 1 1 2 TELESKOPGABEL ZERLEGEN Arbeitsumfang 1 Dichtring demontieren...

Page 494: ...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 495: ...e de la moto desserrer l amortisseur l aide de la cl annulaire pour bou lon capuchon 2 Cl annulaire pour boulon capuchon YM 01501 90890 01501 HANDHABUNGSHINWEISE HINWEIS Die Teleskopgabel muss mit gro...

Page 496: ...e 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 slotted hea...

Page 497: ...retirer rapidement b R p ter cette op ration jusqu ce que le tube plongeur puisse tre retir du fourreau Einstellmechanismus 1 Das l aus dem Standrohr ausgie en 2 Lockern Einstellmechanismus 1 3 Demon...

Page 498: ...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 499: ...gers Veiller ne pas laisser p n trer de corps tran gers lors du changement de l huile ou du d mon tage et remontage de la fourche Gabelventil 1 Demontieren Gabelventil 1 vom D mpferrohr 2 HINWEIS Das...

Page 500: ...al 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 spring...

Page 501: ...a Hors sp cifications Remplacer Longueur libre de ressort de fourche Standard Limite 454 mm 17 9 in 449 mm 17 7 in Gabelventil 1 Kontrollieren Gabelventil 1 Verschlissen besch digt Erneuern Verunreini...

Page 502: ...f specification 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...

Page 503: ...a cer Dispositif de r glage 1 Contr ler Dispositif de r glage 1 Joint torique 2 Usure endommagement Remplacer Gleitrohr 1 Kontrollieren Gleitrohr Oberfl che a Riefig Instand setzen ggf erneuern Schlei...

Page 504: ...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 505: ...e course de 200 mm 7 9 in ou plus fera entrer de l air Dans ce cas r p ter les tapes 2 4 ZUSAMMENBAU UND MONTAGE Teleskopgabel 1 S mtliche Bauteile mit frischem L sungs mittel reinigen 2 Das D mpferro...

Page 506: ...he 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 turning out...

Page 507: ...araufhin das Gabelventil montieren und dabei das D mpferrohr freigeben FOURCHE TELESKOPGABEL 5 Mesurer Niveau d huile gauche et droit a Hors sp cifications R gler Niveau d huile standard 145 148 mm 5...

Page 508: ...que Cap bolt 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 dist...

Page 509: ...pas endommager l amortisseur 13 Laisser l huile s couler par le trou a de l amortisseur 9 Kontrollieren dass die D mpfer Bau gruppe vollst ndig ausgezogen ist Nicht vollst ndig ausgezogen Die Schritt...

Page 510: ...pply 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 facing t...

Page 511: ...n 1 N B Installer la bague coulissante de piston sur la fente du tube plongeur New 17 Monter Fourreau 1 Sur le tube plongeur 2 14 Kontrollieren Leichtg ngigkeit des D mpferrohrs Schwerg ngig fest stoc...

Page 512: ...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 513: ...arr t dans la rainure du fourreau 21 Monter Joint antipoussi re 1 N B Appliquer de la graisse savon de lithium sur le tube plongeur 18 Montieren Gleitbuchse 1 Dichtring Beilagscheibe 2 an der Standroh...

Page 514: ...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 515: ...e 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 22 Kontrollieren Leichtg ngigkeit des Gleitrohrs Schwerg ngig fest stocke...

Page 516: ...sembly Cap bolt ring wrench YM 01501 90890 01501 New 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 ou...

Page 517: ...dispositif de r glage au couple sp cifi T R 29 Nm 2 9 m kg 21 ft lb 27 Montieren Druckstange1 Kupferscheibe 2 Einstellmechanismus 3 am D mpferrohr 4 HINWEIS Bei eingedr cktem Gleitrohr 5 den Abdeck s...

Page 518: ...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 519: ...WEIS Das D mpferrohr provisorisch festziehen FOURCHE TELESKOPGABEL 30 Monter Dispositif de r glage 1 Sur le tube plongeur T R 55 Nm 5 5 m kg 40 ft lb 31 Remplir Huile de fourche 1 Par le haut du fourr...

Page 520: ...y tighten the pinch bolts under bracket Do not tighten the pinch bolts handle crown yet 2 Tighten Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified to...

Page 521: ...instellen Gabelrohr berstand a Standard Gabelrohr berstand a Null mm null in FOURCHE TELESKOPGABEL 33 Monter Guide de protection 1 N B Monter le guide du dispositif de protection en orientant son c t...

Page 522: ...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 523: ...andfest anziehen und dann in die urspr ngliche Stel lung bringen FOURCHE TELESKOPGABEL 4 Serrer Boulon de pincement couronne de poign e 1 Boulon de pincement t inf rieur 2 ATTENTION Serrer le t inf ri...

Page 524: ...3 Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 ENGINE STOP button 1 6 Master cylinder 1 Refer to REMOVAL POINTS 7 Throttle cable cap 1 8 Throttle cable 1 pulled 1 Disconnect a...

Page 525: ...de tube 1 12 Entretoise paul e 1 13 Poign e gauche 1 Se reporter POINTS DE DEPOSE 14 Support du guidon sup rieur 2 15 Guidon 1 16 Support du guidon inf rieur 2 1 LENKER Arbeitsumfang 1 Lenker demonti...

Page 526: ...bar 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 Install Handlebar h...

Page 527: ...ier l ampleur de la d viation avant arri re de la position du guidon Ne pas encore serrer l crou DEMONTAGE EINZELHEITEN Hauptbremszylinder 1 Demontieren Hauptbremszylinder Halterung 1 Hauptbremszylind...

Page 528: ...ndlebar so that the marks b are in place on both sides Install the handlebar so that the projection c of the handlebar holder upper is positioned at the mark on the handlebar as shown First tighten th...

Page 529: ...Serrer Ecrou support inf rieur du guidon 1 T R 40 Nm 4 0 m kg 29 ft lb 2 Montieren Lenker 1 obere Lenker Halterung 2 Schraube obere Lenker Halterung 3 HINWEIS Die obere Lenker Halterung muss so mon t...

Page 530: ...dhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lacquer thinner Install the grip to the tube guide so that the grip match mark b...

Page 531: ...1 Sur le guide de tube 2 N B Appliquer de la graisse savon de lithium sur l extr mit du c ble des gaz et sur la partie d enrou lement du c ble dans le guide de tube 4 Montieren Lenkergriff links 1 Den...

Page 532: ...ts for adjustment T R 4 Nm 0 4 m kg 2 9 ft lb 9 Install Cover grip cap 1 Cover throttle cable cap 2 10 Install Master cylinder 1 Master cylinder bracket 2 Bolt master cylinder bracket 3 NOTE Install t...

Page 533: ...eur du support de ma tre cylindre puis serrer le boulon du c t inf rieur T R 9 Nm 0 9 m kg 6 5 ft lb 8 Montieren Gaszug Abdeckung 1 Schraube Gaszug Abdeckung 2 WARNUNG Nach dem Festziehen der Schraube...

Page 534: ...e dimensions shown Pass the ENGINE STOP button lead in the middle 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 535: ...reporter la section REGLAGE DE L EMBRAYAGE au CHAPITRE 3 Jeu du levier de d marrage chaud Se reporter la section REGLAGE DU LEVIER DE DEMARRAGE A CHAUD au CHAPITRE 3 11 Montieren Motorstoppschalter EN...

Page 536: ...d the machine by placing the suitable stand under the engine Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section Front fender 1 Steering...

Page 537: ...1 6 Couvercle de cage de roulement 1 7 Roulement sup rieur 1 8 Roulement inf rieur 1 Se reporter POINTS DE DEPOSE 9 Cage de roulement 2 2 1 LENKUNG Arbeitsumfang 1 Untere Gabelbr cke demontieren 2 La...

Page 538: ...n Ring nut wrench YU 33975 90890 01403 EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor chisel 2 CAUTION Take care not to damage the steering shaft thread Bearing race 1 Remove Bearing ra...

Page 539: ...aide d une longue tige 2 et d un marteau CONTROLE Arbre de direction 1 Contr ler Arbre de direction 1 D formation endommagement Remplacer DEMONTAGE EINZELHEITEN Ringmutter 1 Demontieren Ringmutter 1...

Page 540: ...a tion in the bearing races replace bear ings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION Under bracket 1 Install Bearing lower 1 NOTE Apply the lithium soap base grease on the dust...

Page 541: ...e roulement et la l vre du couvercle de cage de roule ment 3 Monter T inf rieur 1 N B Appliquer de la graisse savon de lithium sur le roulement la partie a et les filets de l arbre de direction Lager...

Page 542: ...the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install Plain washer 1 7 Install Front fork 1 Handle crown...

Page 543: ...incement couronne de poign e 8 Monter Rondelle pleine 1 Ecrou d arbre de direction 2 T R 145 Nm 14 5 m kg 105 ft lb 4 Montieren Ringmutter 1 Die Ringmutter mit dem Hakenschl ssel 2 festziehen Siehe un...

Page 544: ...nut little by little 10 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in 11 Tighten Pinch bolt handle crown 1 Pinch bolt under bracket 2 CAUTION Tighten the under bracket to s...

Page 545: ...ssif peut compromettre le bon fonction nement de la fourche T R 23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb 9 Nach dem festziehen der Mutter die Len kung auf Schwerg ngigkeit kontrollieren Bei...

Page 546: ...of it 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 Rear caliper Bolt brake pedal S...

Page 547: ...3 Boulon amortisseur arri re bras relais 1 Maintenir le bras oscillant 4 Boulon bielle 1 5 Boulon pivot 1 6 Bras oscillant 1 1 SCHWINGE Arbeitsumfang 1 Schwinge demontieren Arbeitsumfang Reihen folge...

Page 548: ...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 Coll...

Page 549: ...ch it 2 6 Roulement de but e 2 7 Bague 2 8 Bague d tanch it 8 9 Roulement 10 Se reporter POINTS DE DEPOSE 1 2 3 2 3 SCHWINGE ZERLEGEN Arbeitsumfang 1 Schwinge zerlegen 2 bertragungshebel demontieren u...

Page 550: ...ng by pressing its outer race EC574010 INSPECTION Wash the bearings bushes and collars in a solvent EC574111 Swingarm 1 Inspect Bearing 1 Bush 2 Free play exists unsmooth revolution rust Replace beari...

Page 551: ...Remplacer ensemble le roulement et l entretoise paul e 2 Contr ler Bague d tanch it 3 Endommagement Remplacer DEMONTAGE EINZELHEITEN Abdeckung 1 Demontieren Abdeckung links 1 HINWEIS Einen Schlitz Sc...

Page 552: ...earing 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 Outer a Ze...

Page 553: ...o sont imprim s la marque ou le num ro du fabri cant Appliquer de la graisse au bisulfure de molyb d ne sur la rondelle pleine Profondeur d installation des roule ments a Z ro mm z ro in bertragungshe...

Page 554: ...ture s marks or numbers Installed depth of bearings a Zero mm Zero in Swingarm 1 Install Bush 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5 NOTE Apply the molybdenum disulfide grease on the bus...

Page 555: ...ut e 2 Monter Entretoise paul e 1 Rondelle 2 Sur le bras relais 3 N B Appliquer de la graisse au bisulfure de molybd ne sur les entretoises paul es et les l vres des bagues d tanch it 3 Montieren Lage...

Page 556: ...arm 1 Bolt relay arm 2 Plain washer 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 Swingar...

Page 557: ...Mouvement irr gulier coincement rugosit s Graisser ou remplacer les roulements les bagues et les entretoises paul es T R 85 Nm 8 5 m kg 61 ft lb 3 Montieren Distanzh lse 1 am bertragungshebel 2 HINWEI...

Page 558: ...ut yet 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 r...

Page 559: ...hon 1 N B Installer le capuchon droit avec son rep re a vers l avant 8 Montieren bertragungshebel Schraube 1 Beilagscheibe 2 bertragungshebel Mutter 3 HINWEIS Molybd ndisulfidfett auf die Schraube auf...

Page 560: ...ain tensioner lower 4 Nut chain tensioner lower 5 T R 16 Nm 1 6 m kg 11 ft lb 14 Install Chain support 1 Support cover 2 Bolt chain support 50 mm 1 97 in 3 Nut chain support 4 Bolt support cover 10 mm...

Page 561: ...le du support 10 mm 0 39 in 5 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 13 Montieren Schraube unterer Kettenspanner 1 Beilagscheibe 2 Distanzh lse 3 Kettenspanner unten 4 Mutter unterer...

Page 562: ...ling over Preparation 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 A...

Page 563: ...ri re cadre 1 5 Amortisseur arri re 1 6 Contre crou 1 Desserrer uniquement 7 Dispositif de r glage 1 Desserrer uniquement 8 Si ge de ressort 2 1 2 FEDERBEIN Arbeitsumfang 1 Federbein demontieren 2 Fed...

Page 564: ...5 63 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 9 Spring guide lower 1 10 Spring guide upper 1 11 Spring rear shock absorber 1 12 Bearing 2 Refer to REMOVAL POINTS 2...

Page 565: ...1 10 Guide de ressort sup rieur 1 11 Ressort amortisseur arri re 1 12 Roulement 2 Se reporter POINTS DE DEPOSE 2 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 9 Federf hrung unten 1 10 Federf hru...

Page 566: ...m age 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 567: ...s chapper AVERTISSEMENT Confier la mise au rebut d un amortisseur endommag ou us un concessionnaire Yamaha HANDHABUNGSHINWEISE WARNUNG Der Sto d mpfer und Ausgleichsbeh lter enthalten Stickstoff unter...

Page 568: ...Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace absorber assembly Shock absorber 2 Oil leaks Replace absorber assembly...

Page 569: ...t Remplacer le guide de ressort Si ge de ressort 5 Craquelures endommagement Remplacer Roulement 6 Jeu mouvement irr gulier rouille Remplacer DEMONTAGE EINZELHEITEN Lager 1 Demontieren Sicherungsring...

Page 570: ...l 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 contacts the s...

Page 571: ...sort amortisseur arri re 1 Monter Ressort 1 Guide de ressort sup rieur 2 Guide de ressort inf rieur 3 Profondeur d installation du roule ment a 4 mm 0 16 in ZUSAMMENBAU UND MONTAGE Lager 1 Montieren o...

Page 572: ...hown 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 seal...

Page 573: ...d ne sur les l vres de joint antipoussi re et les entretoises paul es Appliquer de la graisse base de savon au lithium sur les joints toriques New 2 Montieren Federsitz 1 HINWEIS Den Federsitz so mont...

Page 574: ...absorber frame 1 Plain 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 575: ...1 Boulon cadre arri re 2 T R 32 Nm 3 2 m kg 23 ft lb 7 Serrer Boulon raccord du filtre air 1 T R 3 Nm 0 3 m kg 2 2 ft lb 2 Montieren Buchse 1 Distanzh lse 2 Staubschutzring 3 HINWEIS Molybd ndisulfidf...

Page 576: ...park 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...

Page 577: ...W Blau Wei R W Rot Wei SCHALTPLAN COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE COMPOSANTS ELECTRIQUES...

Page 578: ...uter in the 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 th...

Page 579: ...ar la charge du moteur Par cons quent on obtien dra une avance l allumage pr cise en prenant galement en compte l ouverture du papillon com mande tridimensionnelle Repr sentation en 3D de l avance l a...

Page 580: ...d Ein pr ziseres dreidimensionales Z nd system bezieht also die Drosselklappen Position mit ein Dreidimensionales Z ndzeitpunkt Kennfeld gilt nicht zur Bezugnahme Bauteil Funktion Drosselklappensensor...

Page 581: ...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 582: ...Contr leur d allumage 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 allu mage fiches r...

Page 583: ...ren Z ndkerze reinigen ggf erneuern Kabelanschl sse des gesamten Z ndsystems kontrollieren Steckverbinder Kabel Z ndspule Instand setzen ggf erneuern Motorstoppschalter ENGINE STOP kontrollieren Erneu...

Page 584: ...um 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 spark plu...

Page 585: ...Schwarz 2 B W 1 B 2 Messger t Wahlschalter EINDR K KEN 1 FREIGE BEN SYSTEME D ALLUMAGE Z NDSYSTEM TEST DE LA LONGUEUR D ETINCELLE 1 D connecter la bobine d allumage de la bougie 2 D poser le capuchon...

Page 586: ...ut of specification Replace 4 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace EC627011 CDI MAGNETO INSPECTION 1 Inspect Pick up coil r...

Page 587: ...EME D ALLUMAGE Z NDSYSTEM CONTROLE DE LA BOBINE D ALLUMAGE 1 D poser le capuchon de la bobine d allumage 2 Contr ler R sistance de l enroulement primaire Hors sp cifications Remplacer Fil du multim tr...

Page 588: ...d Black lead 2 Source 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 continuity while...

Page 589: ...ALLUMAGE Z NDSYSTEM 2 Contr ler R sistance de la bobine d alimentation 1 Hors sp cifications Remplacer 3 Contr ler R sistance de la bobine d alimentation 2 Hors sp cifications Remplacer Fil du multim...

Page 590: ...spection steps marked Refer to 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...

Page 591: ...YSTEME D ALLUMAGE N B Utiliser les outils sp ciaux suivants pendant le contr 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 Cont...

Page 592: ...timeter YU 3112 C 90890 03112 Kabelanschl sse des gesamten Z ndsystems kontrollieren Instand setzen ggf erneuern Drosselklappensensor kon trollieren Drosselklap pensensor Spule Erneuern Lichtmaschine...

Page 593: ...ELEC MEMO...

Page 594: ...COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace TPS COIL INSPECTION 1 Inspect TPS coil resistance Out of specificati...

Page 595: ...ME TPS CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR REMARQUES CONCERNANT LA MANIPULATION ATTENTION Ne pas desserrer les vis TPS capteur de position de papillon des gaz 1 sauf en cas de...

Page 596: ...lead Black lead 2 TPS coil variable resistance Tester selec tor position Full closed Full opened k 1 0 2 k at 20 C 68 F 4 6 k at 20 C 68 F TPS REPLACEMENT AND ADJUSTMENT 1 Remove TPS coupler Carbureto...

Page 597: ...r sitzen Die Drosselklappensensor Schrauben provi sorisch festziehen 5 Montieren Vergaser Drosselklappensensor Steckverbinder SYSTEME TPS CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR 3...

Page 598: ...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 9 Adjust TPS output voltage Test...

Page 599: ...spannung Messger t Wahlschalter 0 58 0 78 V DCV SYSTEME TPS CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR 6 R gler Ralenti Se reporter la section REGLAGE DU REGIME DE RALENTI au CHAPIT...

Page 600: ...en Screw TPS 1 NOTE Tighten the screws TPS using the T25 bit 14 Install the carburetor 1 EC694000 TPS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect TPS input volta...

Page 601: ...kabel Schwarz Blau 2 Drosselklappen sensor Eingangs spannung Messger t Wahlschalter 4 6 V DCV 20 SYSTEME TPS CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR 10 Placer les rep res d aligne...

Page 602: ...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 603: ...UNG MISE AU POINT MOTEUR R glage du carburateur Le m lange air carburant varie en fonction des conditions atmosph riques Il est donc n cessaire de tenir compte de la pression de l air de la tem p ratu...

Page 604: ...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 605: ...sensible aux corps trangers poussi re sable eau etc Pendant le montage veiller ce qu aucun corps tranger ne puisse p n trer dans le car burateur Toujours manipuler le carburateur et ses com posants av...

Page 606: ...Closed Fully open 1 2 3 4 1 4 1 8 1 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...

Page 607: ...Leerlauf Luftd se 3 Nadeld se 4 Hauptd se 5 Leerlaufd se 6 Leerlaufgemisch Regulierschraube REGLAGE EINSTELLUNG Effet des r glages sur l ouverture du papillon des gaz Ferm Compl tement ouvert 1 Vis d...

Page 608: ...1 4 open throttle Main jet adjustment The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 If the air fuel mixture is too rich or too lean the engine power wil...

Page 609: ...ge ffnet Standard Hauptd se Nr 165 1 4 1 2 3 4 10 Nr 165 10 Nr 168 Nr 162 REGLAGE EINSTELLUNG Syst me de ralenti Le carburateur FLATCR est muni d une vis de ralenti La plage de r glage de la vis de ra...

Page 610: ...the pilot screw only 1 2 of a turn in either direction To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the...

Page 611: ...eraus 2 1 5 8 Umdrehungen heraus 3 2 1 8Umdrehungen heraus Standard Einstellung der Leerlaufgemisch Regulierschraube Beispiel 2 1 8 1 4 1 2 3 4 5 5 1 2 3 REGLAGE EINSTELLUNG R glage de la vis de ralen...

Page 612: ...h engine operation is felt and 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 intermed...

Page 613: ...1 2 3 4 5 5 Nr 45 Nr 40 Nr 42 1 4 1 2 3 4 10 10 1 2 3 REGLAGE EINSTELLUNG R glage du gicleur de ralenti La richesse du m lange air carburant une ouver ture des gaz de 1 4 ou moins peut se r gler l ai...

Page 614: ...PR c b NFPR 4 NFLR 4 Diameter of straight portion Clip position Rich Lean N P Q R S T U Rich Lean 1 richer NFPN 5 NFPP 5 NFPQ 5 NFPR 5 NFPS 5 NFPT 5 NFPU 5 0 5 richer NFLN 5 NFLP 5 NFLQ 5 NFLR 5 NFLS...

Page 615: ...droite et du point de d part du c ne Exemple NFPR 4 Position du clip Diam tre a de la partie droite b Aiguille de r f rence c 0 5 fois plus pauvre Le remplacement d une aiguille NFPR 4 par une aiguil...

Page 616: ...Leak jet adjustment accelerator pump adjustment The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump Since the accelerator pump operates only when throttl...

Page 617: ...lon Le d bit du carburant dans le syst me de carbura teur principal est contr l par le gicleur principal puis une nouvelle r gulation s effectue dans la zone entre le gicleur principal et l aiguille L...

Page 618: ...50 48 45 42 40 38 35 4MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Jet needle Rich STD Lean NFPN NFPP NFPQ NFPR NFPS NFPT NFPU 5TA 14916 PN 5TA 14916 PP 5T...

Page 619: ...55 Nr 60 Nr 65 4JT 1494F 05 4JT 1494F 07 4JT 1494F 09 4JT 1494F 11 4JT 1494F 13 REGLAGE EINSTELLUNG Pi ces de r glage du carburateur Nom de la pi ce Taille Num ro de pi ce Gicleur principal Riche STD...

Page 620: ...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 621: ...nctionne correctement sauf dans le cas du symp t me de 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...

Page 622: ...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 623: ...TUN MEMO...

Page 624: ...on of the course that has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determine the secondary redu...

Page 625: ...on du rapport secon daire Il est g n ralement admis que le rapport de d multiplication de la transmission secondaire doit tre r duit pour une course de vitesse com prenant de longues portions en ligne...

Page 626: ...Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact with th...

Page 627: ...stellbereich 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi REGLAGE EINSTELLUNG Pi ces de r glage du pignon de sortie de bo te et de la couronne arri re Nom de la pi ce Taille Num ro de pi ce Couronnearri re1...

Page 628: ...l stroke 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 noi...

Page 629: ...urche en fonction de l exp rience de conduite du pilote sur le terrain ainsi que des condi tions du terrain Les trois r glages de la fourche sont les suivants 1 R glage de l amortissement pneumatique...

Page 630: ...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 631: ...edener Federn Fahrergewicht 1 Weich 2 Standard 3 Hart REGLAGE EINSTELLUNG R glage du ressort apr s remplacement La suspension arri re pouvant influencer le r glage de la fourche il convient donc d qui...

Page 632: ...41 F0 I II III IIII IIIII I I STD 0 459 2S2 23141 M0 STD 0 469 2S2 23141 L0 STIFF 0 479 1C3 23141 J0 I IIII EC72B000 Rear suspension setting The rear suspension setting should be made depending on the...

Page 633: ...skraft ndern Die Druckstufen D mpfungskraft ndern REGLAGE EINSTELLUNG Pi ces de r glage de la fourche Ressort de fourche 1 EUROPE N B Le rep re d identification fentes a se trouve l extr mit du ressor...

Page 634: ...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 635: ...5 3 9 in REGLAGE EINSTELLUNG Choix de la longueur de ressort 1 Placer un support ou un bloc sous le moteur pour sur lever la roue arri re et mesurer la lon gueur a entre le centre de l axe de roue ar...

Page 636: ...nsate for 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 m...

Page 637: ...s remplacement Apr s avoir remplac le ressort veiller l ajuster la longueur recommand e profondeur 90 100 mm 3 5 3 9 in et le r gler 1 Ressort mou R gler le ressort mou de mani re que la force d amort...

Page 638: ...of I D marks TYPE SPRING RATE SPRING PART NUMBER I D MARK SPRING FREE LENGTH approx SOFT 4 5 4 7 4 9 5 1 5 3 1C3 22212 00 1C3 22212 10 1C3 22212 20 1C3 22212 30 1C3 22212 40 Green Red Black Blue Yell...

Page 639: ...arz 2 Blau 2 Gelb 2 Rosa 2 Wei 2 275 275 275 275 275 275 275 REGLAGE EINSTELLUNG Pi ces de r glage de l amortisseur arri re Ressort d amortisseur arri re 1 Ressort en titane spires gales Ressort acier...

Page 640: ...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 641: ...0 83 in 255 5 273 5 mm 10 06 10 77 in REGLAGE EINSTELLUNG Plage de r glage longueur du ressort Ressort en titane Ressort acier LONGUEUR LIBRE DU RESSORT PLAGE DE REGLAGE b Approx 265 mm 10 43 in Un se...

Page 642: ...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 Rep...

Page 643: ...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 644: ...le sens 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...

Page 645: ...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 2...

Page 646: ...kstufen D mpfungs 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...

Page 647: ...Raststellungen 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...

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Page 650: ...2005 09 2 0 1 CR E F G 2S2 28199 80 YZ450F V OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH YZ450F V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWA...

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