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ENG

VALVES AND VALVE SPRINGS

Extent of removal:

Valves and valve springs removal

Extent of removal

Order

Part name

Q’ty

Remarks

VALVES AND VALVE SPRINGS
REMOVAL

Preparation for removal

Cylinder head

Refer to “CYLINDER HEAD” section.

Camshaft and rocker arms

Refer to “CAMSHAFT AND ROCKER
ARMS” section.

Valve cotter

Refer to “REMOVAL POINTS”.

Valve spring retainer

Valve spring

Intake valve

Exhaust valve

Valve stem seal

Valve spring seat

Содержание TT-R125E(R)

Страница 1: ...5HP 28199 8A OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH TT R125E R TT R125LWE R...

Страница 2: ...R OWNER S SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition November 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressl...

Страница 3: ...uch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R125E R TT R125LWE R MANUEL D ATELIER DU PROPRIETAIRE 2002 Yamaha Motor Co Ltd Premi re...

Страница 4: ...NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING READ THIS MANUAL CAREFULLY FOR INSTRUCTIO...

Страница 5: ...r den siehe Seite 3 3 Dieses Fahrzeug ist nur f r eine Person zugelassen Zweipersonen Betrieb ist nicht zul ssig Dieses Fahrzeug ist ausschlie lich f r den Einsatz abseits ffentlicher Stra en vorgeseh...

Страница 6: ...while smoking or in the vicinity of an open flame 2 If you should swallow some gasoline or inhale a lot of gasoline vapor or allow some gasoline to get in your eye s see your doctor immediately If an...

Страница 7: ...Untergrund abstellen damit es nicht umfallen kann SICHERHEITSINFORMATION REMARQUE IMPORTANTE Ce v hicule est con u uniquement pour une utilisa tion tout terrain par des pilotes tr s jeunes roulant sou...

Страница 8: ...k out of the car buretor or fuel tank 5 Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death with...

Страница 9: ...Helm und spezielle Motorradbekleidung Hand schuhe Stiefel Hosen und Jacken tragen 4 Lors du transport de l engin dans un autre v hicule veiller ce qu il soit bien droit et ce que le robinet de carbur...

Страница 10: ...one seater motorbike Do not give any person a ride 4 Let s learn how to ride properly Ask your parents for any question 5 When riding the machine be sure to wear the protective apparel as illustrated...

Страница 11: ...dschuhe 5 Motorradstiefel 6 Motocross Hose 7 Lang rmeliges Trainingshemd 8 Brustschutz INFORMATION DE SECURITE 1 Ne pas rouler sur la route 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il s ag...

Страница 12: ...ne 7 Before riding the machine ask your par ents to check the machine very carefully 8 Do not touch the areas shown or you will get burnt in the hand 9 Do not touch rotating or moving parts 10 Before...

Страница 13: ...er sich bewegen den Teile ber hren 10 Vor dem Starten des Motors sicherstellen da sich das Getriebe in der Leerlaufstel lung befindet 6 Ne jamais partir seul moto Toujours partir avec son instructeur...

Страница 14: ...any questions regarding the operation or maintenance of your machine please consult your Yamaha dealer NOTE This manual should be considered a perma nent part of this machine and should remain with it...

Страница 15: ...Aufgrund der konti nuierlichen Bem hungen von Yamaha um technischen Fortschritt und Qualit tsstei gerung k nnen einige Angaben jedoch f r Ihr Modell nicht mehr zutreffen Richten Sie Fragen zu dieser A...

Страница 16: ...taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer FINDING THE REQUIRED PAGE 1 This manual consists of six chapters General Information Spe...

Страница 17: ...un point particulier Arquer le manuel son bord comme illustr pour trouver le symbole du chapitre recher ch puis aller la page du th me recherch AVERTISSEMENT ATTENTION BENUTZERHINWEISE KENNZEICHNUNG...

Страница 18: ...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...

Страница 19: ...meiden 6 F r Arbeiten f r die weitere Informatio nen ben tigt werden sind schrittweise Erg nzungen 6 zus tzlich zu dem Explo sionsdiagramm und der Arbeitsanwei sungstabelle aufgef hrt FORMAT DU MANUE...

Страница 20: ...ightening B Specified value Service limit C Engine speed D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubr...

Страница 21: ...TE J Erneuern SYMBOLES GRAPHIQUES voir les illustrations Les symboles graphiques 1 6 servent rep rer les diff rents chapitres et indiquer leur contenu 1 Renseignements g n raux 2 Caract ristiques 3 Co...

Страница 22: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL...

Страница 23: ...DATEN SPEC 2 REGELM SSIGE WARTUNGS UND EINSTELLARBEITEN 3 MOTOR ENG 4 RAHMEN CHAS 5 ELEKTRIK ELEC 6 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS G N RAUX CARACT RISTI QUES CONTR LES ET R GLAGES P RIODIQUES...

Страница 24: ...R125LWE 1 17 CLEANING AND STORAGE 1 18 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 TT R125E 2 1 TT R125LWE 2 4 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 CHASSIS 2 15 TT R125E 2 15 TT R125LWE 2...

Страница 25: ...NG VOR INBETRIEBNAHME 3 3 MOTOR 3 4 FAHRWERK 3 15 ELEKTRISCHE ANLAGE 3 32 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS G N RAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MACHINE 1 2 INFORMATIONS IMPORTANT...

Страница 26: ...CLUTCH 4 58 ENGINE REMOVAL 4 63 CRANKCASE CRANKSHAFT AND BALANCER 4 67 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 75 CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE TT R125E 5 1 FRONT WHEEL TT R125LWE 5 8...

Страница 27: ...NLAGE 6 2 ELEKTROSTARTERSYSTEM 6 6 LADESYSTEM 6 16 CHAPITRE 4 MOTEUR SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX 4 1 POT D CHAPPEMENT 4 2 CARBURATEUR 4 3 CULASSE 4 12 ARBRE CAMES ET CULBUTEURS 4 2...

Страница 28: ...ottle grip 8 Fuel tank cap 9 Air filter 0 Kickstarter crank A Fuel tank B Dipstick C Rear brake pedal D Fuel cock E Drive chain F Shift pedal G Front fork The illustration shows the TT R125LWE NOTE Th...

Страница 29: ...a ten jederzeit vorbehalten Die Abbildung zeigt die TT R125LWE RENSEIGNEMENTS G N RAUX DESCRIPTION 1 Levier d embrayage 2 Coupe circuit du moteur 3 Commutateur principal 4 Bouton de starter 5 Commutat...

Страница 30: ...machine KEY IDENTIFICATION NUMBER The key identification number 1 is stamped on the key as shown in the following illustra tion This number can be used for ordering a new key EC121001 VEHICLE IDENTIFI...

Страница 31: ...em Rahmen angebracht Die Codenummer und das Info K rzel werden zur Ersatzteil Bestellung ben tigt IDENTIFICATION DE LA MACHINE Il y a deux bonnes raisons de conna tre le num ro de s rie de son v hicul...

Страница 32: ...per tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been m...

Страница 33: ...istet einen z gigen und korrekten Zusammenbau 5 Alle Teile von offenem Feuer fernhalten INFORMATIONS IMPORTANTES PR PARATION LA D POSE ET AU D MONTAGE 1 liminer soigneusement crasse boue pous si re et...

Страница 34: ...along the bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or num bers f...

Страница 35: ...DE RECHANGE 1 Il est recommand d utiliser des pi ces Yamaha d origine pour tous les remplace ments Utiliser les graisses et ou huiles recommand es par Yamaha lors des remonta ges et r glages JOINTS BA...

Страница 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...

Страница 37: ...Schritte 1 bis 7 durchf hren Zur schnellen Abhilfe kann ein handels bli ches Kontaktspray verwendet werden Die Steckverbinder wie abgebildet mit dem Me ger t pr fen V RIFICATION DES CONNEXIONS Traite...

Страница 38: ...se tools are used to split the crankcase as well as remove the crankshaft from either case YU 1135 A 90890 01135 YU 3097 90890 01252 YU 1256 Dial gauge stand set Stand These tools are used to check ea...

Страница 39: ...YU 33975 90890 01403 YS 1880 A 90890 01701 Sheave holder This tool is used for when loosening or tightening the flywheel magneto securing nut YS 1880 A 90890 01701 YU 3112 C 90890 03112 Pocket tester...

Страница 40: ...4097 YM 4098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 9...

Страница 41: ...r de demi carters Ces outils permettent de s parer le carter moteur ainsi que de retirer le vilebrequin d un demi carter YU 1135 A 90890 01135 YU 3097 90890 01252 YU 1256 Comparateur cadran et base Ba...

Страница 42: ...r n l s comme sp cifi YU 33975 90890 01403 YS 1880 A 90890 01701 Cl sangle Cet outil permet de desserrer et de resserrer l crou de fixation du volant magn tique YS 1880 A 90890 01701 YU 3112 C 90890 0...

Страница 43: ...YM 4097 YM 4098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Testeur d tincelle dynamique Contr ler d allumage Cet instrument sert contr ler les composants du syst me d allumage...

Страница 44: ...90890 01085 YU 1135 A 90890 01135 Kurbelgeh use Trennwerkzeug Zum Trennen der Kurbelgeh useh lften und Ausbau der Kurbelwelle YU 1135 A 90890 01135 YU 3097 90890 01252 YU 1256 Me uhr und Zubeh r St nd...

Страница 45: ...ziehen der Lenkkopf Ringmutter YU 33975 90890 01403 YS 1880 A 90890 01701 Kupplungskorb Halter Zum Halten des Kupplungskorbes YS 1880 A 90890 01701 YU 3112 C 90890 03112 Taschen Multimeter Zur Pr fung...

Страница 46: ...ben der neuen Ventilf hrungen YM 4097 YM 4098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndpr fer Zur berpr fung der Z ndanlage YM 34487 90890 06754 A...

Страница 47: ...GEN INFO MEMO...

Страница 48: ...to a stop START SWITCH The start switch 1 is located on the right han dlebar Push this switch to crank the engine with the starter 1 EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han...

Страница 49: ...da Anfahren Bergauffah ren und schnelles Beschleunigen m glich sind Die G nge dieses 5 Gang Getriebes werden ber den Fu schalthebel 1 linksseitig des Motors bei ausger ckter Kupplung ge schaltet FONC...

Страница 50: ...engine EC155001 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar it accelerates or decelerates the engine For acceleration turn the grip toward you for deceleration turn it away fr...

Страница 51: ...echten Seite des Lenkers FUSSBREMSHEBEL Der Fu bremshebel 1 zur Bet tigung der Hin terradbremse befindet sich auf der rechten Fahrzeugseite P DALE DE KICK AVERTISSEMENT Avant de mettre le moteur en ma...

Страница 52: ...AT THE FIRST OPPORTUNITY BE SURE TO SET THE LEVER TO ON AFTER REFUELING EC159000 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter circuit whi...

Страница 53: ...der Transportieren der Maschine ausgelegt WARNUNG Niemals den Seitenst nder mit zus tzli chem Gewicht belasten Vor dem Losfahren sicherstellen da der Seitenst nder hochgeklappt ist ROBINET DE CARBURAN...

Страница 54: ...r flow when the fuel heats up later and expands a Fuel level CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to the engine internal parts such as valves piston r...

Страница 55: ...Essence normale Capacit du r servoir de carburant Total 6 6 L 1 45 lmp gal 1 74 US gal R serve 1 9 L 0 42 lmp gal 0 5 US gal 1 12 KRAFTSTOFF Normalbenzin verwenden Immer frischen Markenkraftstoff eine...

Страница 56: ...ollowing conditions When the transmission is in neutral When the clutch is disengaged with the transmission in any position However it is recommended to shift into neutral before starting the engine 1...

Страница 57: ...f das Gasgeben anspricht 1 13 D MARRAGE ET RODAGE ATTENTION Avant de mettre le moteur en marche effectuer les contr les repris dans la liste Contr les et entretiens avant utilisation AVERTISSEMENT Ne...

Страница 58: ...fully with firm stroke CAUTION Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage BREAK IN Break in is important to better fit the...

Страница 59: ...Sitz pr fen und gegebenenfalls mit dem vorgeschriebenen Anzugsmoment festziehen D MARRAGE ET RODAGE STARTEN UND EINFAHREN N B Si le moteur ne d marre pas avec le commutateur de d marrage rel cher le c...

Страница 60: ...ne This is required especially when the following engine related parts are replaced Cylinder Piston Piston ring Valve Camshaft Crankshaft Clutch Transmission gear Shift fork For warming up and inspect...

Страница 61: ...UNGSARBEITEN in KAPITEL 3 aufgef hrt Tritt ein Problem auf ist der Motor sofort abzustellen und die Ursache herauszufinden D MARRAGE ET RODAGE STARTEN UND EINFAHREN RODAGE APR S REMPLACEMENT Il est to...

Страница 62: ...Muffler to cylinder head Muffler to rear fender bracket Muffler to seat pillar tube Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front f...

Страница 63: ...tem to frame Steering stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to shock absorber Link to swingarm S...

Страница 64: ...Pot d chappement culasse Pot d chappement support de garde bove arri re Pot d chappement sur tuyau de montant de selle Colonne de direction au cadre Colonne de direction au t sup rieur T sup rieur au...

Страница 65: ...tant de selle Colonne de direction au cadre Colonne de direction au t sup rieur T sup rieur au guidon Fourche avant au t sup rieur Fourche avant au t inf rieur Toutes les liaisons Liaison au cadre Lia...

Страница 66: ...er und Hinterradabdek kungs Halterung Schalld mpfer und Sitzstrebenr hre Lenkschaft und Rahmen Lenkschaft und obere Gabelbr cke Obere Gabelbr cke und Lenker Teleskopgabel und obere Gabelbr cke Telesko...

Страница 67: ...chaft und obere Gabelbr cke Obere Gabelbr cke und Lenker Teleskopgabel und obere Gabelbr cke Teleskopgabel und untere Gabelbr cke bertragungs und Umlenkhebel bertragungshebel und Rahmen Umlenkhebel un...

Страница 68: ...n of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated ca...

Страница 69: ...NETTOYAGE ET REMISAGE NETTOYAGE Il est conseill de nettoyer le v hicule fond aussi souvent que possible non seulement pour des raisons esth tiques mais aussi parce que ces nettoyages con tribuent am...

Страница 70: ...witch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thor oughly with solvent and lubricate it Rein stall the chain or store it in a...

Страница 71: ...UND STILLEGUNG REMISAGE Si la motocyclette doit tre remis e pendant 60 jours ou plus certaines pr cautions devront tre observ es pour la maintenir en parfait tat Apr s un nettoyage complet de la motoc...

Страница 72: ...in Minimum ground clearance 265 mm 10 4 in Basic weight With oil and full fuel tank 90 kg 198 4 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Di...

Страница 73: ...22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 68 19 3 579 Secondary reduction system Chain...

Страница 74: ...ic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel trave...

Страница 75: ...nce 295 mm 11 6 in Basic weight With oil and full fuel tank 90 kg 198 4 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 7 57 c...

Страница 76: ...22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 68 19 3 579 Secondary reduction system Chain...

Страница 77: ...scopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel t...

Страница 78: ...2 1260 2 1267 in Out of round limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295 mm 0 8344 0 8...

Страница 79: ...width IN 1 1 3 0 mm 0 0433 0 1181 in EX 1 7 2 8 mm 0 0669 0 1102 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0...

Страница 80: ...e length IN 32 55 mm 1 28 in 31 2 mm 1 23 in EX 32 55 mm 1 28 in 31 2 mm 1 23 in Set length valve closed IN 25 6 mm 1 01 in EX 25 6 mm 1 01 in Compressed pressure installed IN 137 5 158 1 N 14 0 16 1...

Страница 81: ...tside diameter 14 991 15 000 mm 0 5902 0 5906 in 14 971 mm 0 5894 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 1 mm 0 04 0 08 in End gap installed 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016...

Страница 82: ...cam push Push rod bending limit 0 5 mm 0 020 in Shifter Shifter type Cam drum and guide bar Kick starter Type Kick and mesh type Kick clip friction force 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Carburetor...

Страница 83: ...ilter type Wire mesh type Oil pump type Trochoid type Tip clearance 0 15 mm 0 0059 in 0 2 mm 0 0079 in Side clearance 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Housing and rotor clearance 0 06 0...

Страница 84: ...her cover M4 0 7 2 2 0 2 1 4 Air filter case M6 1 0 3 7 0 7 5 1 Muffler M6 1 0 2 10 1 0 7 2 Muffler M10 1 25 1 60 6 0 43 Muffler M8 1 25 1 30 3 0 22 Muffler guard M6 1 0 7 10 1 0 7 2 Spark arrester M6...

Страница 85: ...portion shall be checked for torque tightening after break in or before each ride Cylinder head tightening sequence Segment M6 1 0 1 12 1 2 8 7 Stopper lever M6 1 0 1 10 1 0 7 2 Part to be tightened...

Страница 86: ...lent Inner tube outer diameter 30 mm 1 18 in Front fork top end Zero mm Zero in Rear suspension Shock absorber travel 65 mm 2 56 in Spring free length 178 mm 7 01 in Fitting length 165 mm 6 50 in Spri...

Страница 87: ...n 2 0 mm 0 08 in Rear lining thickness 4 0 mm 0 16 in 2 0 mm 0 08 in Front shoe spring free length 50 5 mm 1 99 in Rear shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever...

Страница 88: ...1 4 Brake lever mounting bolt M6 1 0 1 7 0 7 5 1 Brake lever mounting nut M6 1 0 1 7 0 7 5 1 Brake lever holder M5 0 8 2 4 0 4 2 9 Clutch lever mounting bolt M6 1 0 1 7 0 7 5 1 Clutch lever mounting...

Страница 89: ...2 4 2 30 Drive chain tensioner upper M8 1 25 1 23 2 3 17 Drive chain tensioner lower M6 1 0 1 7 0 7 5 1 Drive chain support and swingarm M6 1 0 2 7 0 7 5 1 Drive chain guide and swingarm M6 1 0 2 7 0...

Страница 90: ...170 5 mm 6 71 in Fitting length 160 5 mm 6 32 in Spring rate STD K 61 8 N mm 6 3 kg mm 352 lb in Optional spring No Enclosed gas pressure 1 200 kPa 12 kg cm2 171 psi Wheel Front wheel type Spoke whee...

Страница 91: ...2 0 mm 0 08 in Shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever free play lever end 2 5 mm 0 08 0 20 in Brake pedal position vertical height below footrest top 1 mm 0 0...

Страница 92: ...hrottle cable cap M4 0 7 2 2 0 2 1 4 Front brake master cylinder 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 7 0 7 5 1 Brake lever mounting...

Страница 93: ...connecting arm M10 1 25 1 35 3 5 25 Connecting arm and frame M10 1 25 1 35 3 5 25 Rear shock absorber assembly and frame M12 1 25 1 53 5 3 38 Rear shock absorber assembly and relay arm M10 1 25 1 35...

Страница 94: ...magneto Model manufacturer 5HP 10 YAMAHA Normal output 14 V 100 W at 5 000 r min Charging coil resistance color 0 64 0 96 at 20 C 68 F White Black Lighting coil resistance color 0 52 0 78 at 20 C 68 F...

Страница 95: ...M33221 MATSUSHITA Coil winding resistance 75 69 92 51 at 20 C 68 F Fuse amperage quantity Main fuse 10 A 1 Reserve fuse 10 A 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Pic...

Страница 96: ...threads Com ponents should be at room temperature 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 15 30 55 85 130 0 6 1 5 3 0 5...

Страница 97: ...Avec huile et r servoir de carburant rempli 90 kg 198 4 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l avant Cy...

Страница 98: ...m 0 02 0 03 in Type d embrayage Humide multidisque Bo te de vitesses Syst me de r duction primaire Pignon Taux de r duction primaire 68 19 3 579 Syst me de r duction secondaire Entra nement par cha ne...

Страница 99: ...rtisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydraulique D battement de roue D battement de roue avant 180 mm 7...

Страница 100: ...voir de carburant rempli 90 kg 198 4 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l avant Cylindr e 124 cm3 7 5...

Страница 101: ...0 02 0 03 in Type d embrayage Humide multidisque Bo te de vitesses Syst me de r duction primaire Pignon Taux de r duction primaire 68 19 3 579 Syst me de r duction secondaire Entra nement par cha ne T...

Страница 102: ...Amortisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydraulique D battement de roue D battement de roue avant 180 mm...

Страница 103: ...Arbre cames M thode d entra nement Transmission par cha ne c t gau che Dimensions de came Admission A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295 mm 0 8344 0 8384 in 21 165 m...

Страница 104: ...AD 1 1 3 0 mm 0 0433 0 1181 in CH 1 7 2 8 mm 0 0669 0 1102 in C largeur de si ge AD 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in CH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D paisseur de rebord A...

Страница 105: ...1 28 in 31 2 mm 1 23 in Longueur mont soupape ferm e AD 25 6 mm 1 01 in CH 25 6 mm 1 01 in Pression la compression install AD 137 5 158 1 N 14 0 16 1 kg 30 86 35 49 lb CH 137 5 158 1 N 14 0 16 1 kg 30...

Страница 106: ...4 971 mm 0 5894 in Segments Segment de feu Type Cylindrique Dimensions B T 1 0 2 1 mm 0 04 0 08 in cartement des becs segment mont 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016 in Jeu lat ral mont 0 035 0...

Страница 107: ...r Tambour de s lection et guide Kick Type Kick et mise en prise Force de friction du clip de kick 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Carburateur Marque d identification 5HP1 10 Gicleur principal M J N...

Страница 108: ...pe huile Trocho dale Jeu en bout 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Jeu de lubrification entre le logement et le rotor 0 06 0 10 mm 0 0024 0...

Страница 109: ...M6 1 0 3 7 0 7 5 1 Pot d chappement M6 1 0 2 10 1 0 7 2 Pot d chappement M10 1 25 1 60 6 0 43 Pot d chappement M8 1 25 1 30 3 0 22 Prot ge pot d chappement M6 1 0 7 10 1 0 7 2 Pare tincelles M6 1 0 3...

Страница 110: ...r s d un apr s le rodage et avant chaque d marrage Ordre de serrage de la culasse toile de verrouillage M6 1 0 1 12 1 2 8 7 Doigt de verrouillage M6 1 0 1 10 1 0 7 2 Pi ce serrer Diam tre de filet Qt...

Страница 111: ...tube plongeur 30 mm 1 18 in Sommet de fourche avant Z ro mm z ro in Suspension arri re D battement d amortisseur 65 mm 2 56 in Longueur libre de ressort 178 mm 7 01 in Longueur mont 165 mm 6 50 in Con...

Страница 112: ...n arri re 4 0 mm 0 16 in 2 0 mm 0 08 in Longueur libre de ressort de m choire de frein avant 50 5 mm 1 99 in Longueur libre de ressort de m choire de frein arri re 50 5 mm 1 99 in Levier de frein et p...

Страница 113: ...tage du levier de frein M6 1 0 1 7 0 7 5 1 crou de montage du levier de frein M6 1 0 1 7 0 7 5 1 Support de levier de frein M5 0 8 2 4 0 4 2 9 Boulon de montage du levier d embrayage M6 1 0 1 7 0 7 5...

Страница 114: ...7 0 7 5 1 Support de cha ne de transmission et bras oscillant M6 1 0 2 7 0 7 5 1 Patin de cha ne de transmission et bras oscillant M6 1 0 2 7 0 7 5 1 Fixation de patin de cha ne de transmission M6 1 0...

Страница 115: ...in Longueur mont 160 5 mm 6 32 in Constante standard de ressort K 61 8 N mm 6 3 kg mm 352 lb in Ressort optionnel Non Pression du gaz 1 200 kPa 12 kg cm2 171 psi Roue Type de roue avant Roue rayons Ty...

Страница 116: ...de m choire 50 5 mm 1 99 in Levier de frein et p dale de frein Jeu du levier de frein l extr mit 2 5 mm 0 08 0 20 in Position de la p dale de frein distance verticale sous le sommet du repose pied 1 m...

Страница 117: ...cylindre de frein avant 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 7 0 7 5 1 crou de montage du levier de frein M6...

Страница 118: ...sseur arri re et cadre M12 1 25 1 53 5 3 38 Amortisseur arri re et basculeur M10 1 25 1 35 3 5 25 Amortisseur arri re et contre crou pr contrainte M46 1 5 1 42 4 2 30 Tendeur de cha ne de transmission...

Страница 119: ...AMAHA Sortie normale 14 V 100 W 5 000 tr mn R sistance de la bobine de charge couleur 0 64 0 96 20 C 68 F blanc noir R sistance de la bobine d allumage couleur 0 52 0 78 20 C 68 F jaune noir Redresseu...

Страница 120: ...de la bobine 75 69 92 51 20 C 68 F Fusible amp res quantit Fusible principal 10 A 1 Fusible de r serve 10 A 1 Pi ce serrer Diam tre de filet Qt Couple de serrage Nm m kg ft lb Bobine d excitation M6 1...

Страница 121: ...ins que ce ne soit sp cifi autrement les sp cifications de couple s entendent pour des filetages propres et secs Les composants doivent tre temp rature ambiante A crou B vis CARACT RISTIQUES DE COUPLE...

Страница 122: ...odenfreiheit 265 mm 10 4 in Gewicht fahrfertig Mit l und vollgetankt 90 kg 198 4 lb Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hubraum 124 cm3...

Страница 123: ...U Hersteller NGK DENSO Elektrodenabstand 0 6 0 7 mm 0 02 0 03 in Kupplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 579 Sekund rantrieb Kettenantrieb Seku...

Страница 124: ...fh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydraulisch ged mpft Federelemente hinten Spiralfeder hydraulisch ged mpft ga...

Страница 125: ...11 6 in Gewicht fahrfertig Mit l und vollgetankt 90 kg 198 4 lb Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hubraum 124 cm3 7 57 cu in Bohrung H...

Страница 126: ...U Hersteller NGK DENSO Elektrodenabstand 0 6 0 7 mm 0 02 0 03 in Kupplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 579 Sekund rantrieb Kettenantrieb Sekun...

Страница 127: ...radaufh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydraulisch ged mpft Federelemente hinten Spiralfeder hydraulisch ged mp...

Страница 128: ...in Max Ovalit t 0 05 mm 0 0020 in Nockenwelle Antrieb Kettenantrieb links Nockenwellen Abmessungen Einla A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295 mm 0 8344 0 8384 in 21...

Страница 129: ...0 1181 in AUS 1 7 2 8 mm 0 0669 0 1102 in C Ventilsitz Breite EIN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in AUS 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D Ventilteller St rke EIN 0 4 0 8 mm 0 0...

Страница 130: ...n 31 2 mm 1 23 in AUS 32 55 mm 1 28 in 31 2 mm 1 23 in Einbaul nge Ventil geschlossen EIN 25 6 mm 1 01 in AUS 25 6 mm 1 01 in Federdruck bei Einbaul nge EIN 137 5 158 1 N 14 0 16 1 kg 30 86 35 49 lb A...

Страница 131: ...6 in 14 971 mm 0 5894 in Kolbenringe 1 Kompressionsring Topring Ausf hrung Abgerundet Abmessungen B T 1 0 2 1 mm 0 04 0 08 in Ringsto eingebaut 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016 in Ringnutspiel...

Страница 132: ...Schaltung Bauart Nockenwalze und Druckstange Kickstarter Kickstarter Bauart Kick und Eingriff Kickstarterclip Reibkraft 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Vergaser Kennzeichnung 5HP1 10 Hauptd se M J...

Страница 133: ...ilter Drahtgeflecht lpumpe Rotorpumpe Spalt 0 15 mm 0 0059 in 0 2 mm 0 0079 in Spiel 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Geh use und Rotor Laufspiel 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0...

Страница 134: ...Luftfiltergeh use M6 1 0 3 7 0 7 5 1 Kr mmer M6 1 0 2 10 1 0 7 2 Kr mmer M10 1 25 1 60 6 0 43 Kr mmer M8 1 25 1 30 3 0 22 Kr mmer Schutzabdeckung M6 1 0 7 10 1 0 7 2 Funkenf nger M6 1 0 3 10 1 0 7 2...

Страница 135: ...nach der Einfahrzeit oder vor jedem Rennen auf richtiges Anzugs moment gepr ft werden Anzugsreihenfolge Zylinderkopfschrauben Lamelle M6 1 0 1 12 1 2 8 7 Anschlaghebel M6 1 0 1 10 1 0 7 2 Festzuziehe...

Страница 136: ...mm 1 18 in Teleskopgabel Oberkante 0 mm 0 in Hinterradaufh ngung Sto d mpferhub 65 mm 2 56 in Ungespannte Federl nge 178 mm 7 01 in Einbaul nge 165 mm 6 50 in Standard Federrate K 50 5 N mm 5 1 kg mm...

Страница 137: ...in 2 0 mm 0 08 in Belagst rke hinten 4 0 mm 0 16 in 2 0 mm 0 08 in Bremsschuhfeder ungespannte L nge vorne 50 5 mm 1 99 in Bremsschuhfeder ungespannte L nge hinten 50 5 mm 1 99 in Bremshebel und Brems...

Страница 138: ...ng Schraube M6 1 0 1 7 0 7 5 1 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 5 1 Handbremshebel Halter M5 0 8 2 4 0 4 2 9 Kupplungshebel Befestigung Schraube M6 1 0 1 7 0 7 5 1 Kupplungshebel Befes...

Страница 139: ...spanner oben M8 1 25 1 23 2 3 17 Antriebskettenspanner unten M6 1 0 1 7 0 7 5 1 Antriebsketten Stiite und Schwinge M6 1 0 2 7 0 7 5 1 Kettenf hrung und Schwinge M6 1 0 2 7 0 7 5 1 Kettenschutz Befesti...

Страница 140: ...32 in Standard Federrate K 61 8 N mm 6 3 kg mm 352 lb in Umr stfeder Kein Gasd mpferdruck 1 200 kPa 12 kg cm2 171 psi R der Vorderrad Speichenrad Hinterrad Speichenrad Felgengr e Felgen Baustoff 19 1...

Страница 141: ...mm 0 08 in Bremsschuhfeder ungespannte L nge 50 5 mm 1 99 in Bremshebel und Bremspedal Handbremshebelspiel am Hebelende 2 5 mm 0 08 0 20 in Bremspedalh he Vertikale H he unterhalb Fu rasten Oberkante...

Страница 142: ...0 2 9 0 9 6 5 Hauptbremszylinder Verschlu deckel Vorder radbremse M4 0 7 2 2 0 2 1 4 Handbremshebel Befestigung Schraube M6 1 0 1 7 0 7 5 1 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 5 1 Handbr...

Страница 143: ...1 25 1 35 3 5 25 Verbindungsgelenk und Rahmen M10 1 25 1 35 3 5 25 Hinterradsto d mpfer und Rahmen M12 1 25 1 53 5 3 38 Hinterradsto d mpfer und Umlenkhebel M10 1 25 1 35 3 5 25 Hinterradsto d mpfer u...

Страница 144: ...p CDI Magnetz nder Modell Hersteller 5HP 10 YAMAHA Normalausgang 14 V 100 W bei 5 000 U min Ladespulenwiderstand Farbe 0 64 0 96 bei 20 C 68 F wei schwarz Lichtspulenwiderstand Farbe 0 52 0 78 bei 20...

Страница 145: ...ulenwicklungswiderstand 75 69 92 51 bei 20 C 68 F Sicherung St rke Anzahl Hauptsicherung 10 A 1 Reservesicherung 10 A 1 Festzuziehende Bauteile Gewinde gr e Anzahl Anzugsmoment Nm m kg ft lb Aufnahmes...

Страница 146: ...gegeben gelten alle Anzugsmomente f r saubere trockene Gewin de Die Bauteile sollten Raumtemperatur auf weisen A Mutter B Schrau be ANZUGSMOMENTE Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm...

Страница 147: ...SPEC MEMO...

Страница 148: ...rake cable for the TT R125E F Cable guide G Main switch lead H Engine stop switch lead I Clutch switch lead J Start switch lead K CDI unit band L CDI unit M Connector cover N Rubber cover O Starter ca...

Страница 149: ...utzr hre f r die CDI Ma gnetz nderleitung befestigen CHEMINEMENT DES C BLES 1 Fil de terre 2 Fil de bobine primaire 3 Bride 4 Faisceau de fils 5 Fil de relais de d marreur 6 Fil de redresseur r gulate...

Страница 150: ...t off relay lead under the frame and at the right of the chassis Fasten the rear shock absorber assembly sub tank TT R125LWE only Pass the CDI unit lead on the outside of the main switch lead engine s...

Страница 151: ...CDI Einheit B gel setzen Den Bremsseilzug befestigen Apr s avoir attach le fil de relais de d marreur faire passer le fil la gauche du ch ssis Attacher le fil de magn to CDI et le fil de relais de d...

Страница 152: ...engine stop switch lead clutch switch lead and start switch lead together Position the starter cable throt tle cable CDI magneto lead wire harness and rear shock absorber assembly sub tank hose TT R1...

Страница 153: ...rband Enden positionieren wie in der Abbildung gezeigt A A A B A C Apr s avoir raccord le raccord du commutateur prin cipal le raccord de coupe circuit du moteur le rac cord du commutateur d embrayage...

Страница 154: ...ather hose C Positive battery lead D Overflow hose E Air vent hose F Primary coil lead G Ground lead Pass the clutch cable on the inside of the throttle cable and starter cable Pass the fuel tank brea...

Страница 155: ...d den Starterseilzug durch die Seilzugf hrung verlegen 1 C ble d acc l rateur 2 C ble d embrayage 3 C ble de d marreur 4 Flexible de reniflard de r servoir essence 5 Guide de flexible 6 Bride 7 Guide...

Страница 156: ...frame as shown Fasten the engine oil breather hose overflow hose and air vent hoses to 2 clicks After fastening the starter cable push it against the starter plunger Put the tip of the air vent hose...

Страница 157: ...n an der Z ndspule anbringen Die Masseleitung zusammen mit der Z ndspule befestigen Attacher le fil du moteur de d marreur Faire passer le flexible du reniflard d huile moteur et le flexible de trop p...

Страница 158: ...umber plate Starting at the forepart pass the main switch lead clutch cable and start switch lead in that order Pass the start switch lead in back of the starter cable Pass the main switch lead on the...

Страница 159: ...chalters verlegen 1 Bride 2 Fil de commutateur d embrayage 3 Fil de coupe circuit du moteur 4 Flexible de frein c ble de frein pour le mod le TT R125E 5 C ble d embrayage 6 C ble d acc l rateur 7 Fil...

Страница 160: ...ssary Replace gasket if necessary Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining Clutch Check operation Adjust or replace cable Front br...

Страница 161: ...Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly ti...

Страница 162: ...r le niveau d huile et l tanch it Corriger si n cessaire Changer Faire chauffer le moteur avant la vidange Embrayage V rifier le fonctionnement R gler ou remplacer le c ble Frein avant V rifier le fon...

Страница 163: ...ontr ler le fonctionnement et l tanch it Corriger si n cessaire Ensemble amortis seur arri re Contr ler le fonctionnements et l tanch it Remplacer le combin ressort amortisseur si n cessaire Attaches...

Страница 164: ...len gegebe nenfalls erneuern Ventile Ventilspiel kontrollieren Gegebenenfalls einstellen Luftfilter Luftfiltereinsatz gegebenenfalls reinigen oder erneuern Vergaser Leerlaufdrehzahl und Choke Funktion...

Страница 165: ...ach 120 Betriebsstunden mit Lithium fett schmieren Seitenst nder Funktion pr fen Gegebenenfalls schmieren oder reparieren Funkenl scher 1 Reinigen Teleskopgabel Funktion und auf Undichtigkeit pr fen G...

Страница 166: ...r brake Check fluid level and leakage TT R125LWE only P 3 15 20 Drive chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 21 22 Wheels Check for excessive wear and t...

Страница 167: ...e niveau de fluide et les fuites TT R125LWE seulement P 3 15 20 Cha ne de transmission Contr ler la tension et l alignement de la cha ne Contr ler et si n cessaire lubrifier la cha ne P 3 21 22 Roues...

Страница 168: ...Undichtigkeit achten Nur TT R125LWE 3 15 20 Antriebskette Durchhang und Einstellung der Antriebskette pr fen Kontrollie ren ob die Kette ausreichend geschmiert ist 3 21 22 R der Auf berm igen Verschle...

Страница 169: ...INSP ADJ MEMO...

Страница 170: ...k proper operation of clutch lever Clutch lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut EC35A001 THROTT...

Страница 171: ...er 1 l sen Einsteller 2 hinein oder herausdrehen bis das vorgeschriebene Spiel korrekt ein gestellt ist Kontermutter wieder festdrehen MOTEUR R GLAGE DE L EMBRAYAGE 1 Contr ler Garde du levier d embra...

Страница 172: ...engine idling does not run faster 2 Apply Lithium soap base grease On the throttle cable end a and tube guide cable winding portion b 3 Install Throttle cable cap T R 2 Nm 0 2 m kg 1 4 ft lb AIR FILT...

Страница 173: ...montiert ist Andernfalls kann Schmutz und Staub in den Motor eindringen und raschen Ver schlei und m glicherweise Besch digun gen im Motor verursachen LUBRIFICATION DU C BLE DES GAZ 1 D poser Couverc...

Страница 174: ...case cover 2 3 Remove Air filter assembly 1 Wing nut 2 Washer 3 Air filter element 4 Air filter guide 5 4 Clean Air filter element Clean them with solvent NOTE After cleaning remove the remaining sol...

Страница 175: ...em Luftfiltereinsatz ausdr cken ACHTUNG Den Luftfiltereinsatz beim Ausdr cken nicht verdrehen 5 Kontrollieren Luftfiltereinsatz Besch digung Erneuern 1 D poser Cache lat ral droit 1 N B Desserrer la v...

Страница 176: ...nt 1 On air filter guide 2 8 Apply Lithium soap base grease On the matching surface a on air filter element 9 Install Air filter element 1 Washer 2 Wing nut 3 ENGINE OIL LEVEL INSPECTION 1 Start the e...

Страница 177: ...inem ebenen Unter grund mit Hilfe eines geeigneten St n ders abstellen 3 Demontieren lme stab 1 6 Appliquer Huile pour filtre air en mousse ou huile de m lange Sur l l ment N B Comprimer pour liminer...

Страница 178: ...t 10 C 10 F or higher Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil At 5 C 40 F or higher Yamalube 4 20W 40 or SAE 20W 40 type SE motor oil Except for USA and CDN CAUTION Do not add any chemical a...

Страница 179: ...e Auswahl der richtigen lsorte die f r die entspre chenden Temperaturen geeig net ist Empfohlene Motor l Spezifikation API NORM API SE oder besser vorzugsweise Motorrad l 4 Contr ler Niveau d huile Le...

Страница 180: ...warm it up for sev eral minutes and wait for five minute 2 Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine 3 Place a suitable containe...

Страница 181: ...Montieren lme stab 2 F llmenge Regelm iger lwechsel 1 0 L 0 88 Imp qt 1 06 US qt 5 Monter Jauge 6 Mettre le moteur en marche et le laisser chauffer pendant quelques minutes 7 Couper le moteur et v rif...

Страница 182: ...l pressure check bolt T R Oil pressure check bolt 7 Nm 0 7 m kg 5 1 ft lb PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjustment steps NOTE To optimize the fuel flow at a smaller throttle op...

Страница 183: ...ierschraube um die angegebene Anzahl von Umdrehungen herausdrehen Leerlaufluft Regulierschraube einstellen Um 2 1 2 3 1 2 Umdrehungen herausdrehen Beispiel CONTR LE DE LA PRESSION D HUILE DE MOTEUR 1...

Страница 184: ...ERS section in the CHAPTER 4 Adjustment steps Adjust the pilot air screw Refer to PILOT AIR SCREW ADJUST MENT section Turn the throttle stop screw 1 until the specified engine idling speed To increase...

Страница 185: ...zahl 1 300 1 500 U min 3 Demontieren Z ndeinstell Verschlu schraube 1 Kurbelwellen Verschlu schraube 2 O Ring CONTR LE ET R GLAGE DU JEU DE SOUPAPES N B Le jeu de soupapes doit tre r gl quand le moteu...

Страница 186: ...he crankcase cover when piston is at T D C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance 5 Adjust Valve clearance Adjustment steps Loos...

Страница 187: ...ehen kann und Kontermutter festziehen T R Kontermutter 8 Nm 0 8 m kg 5 8 ft lb CONTR LE ET R GLAGE DU JEU DE SOUPAPES VENTILSPIEL KONTROLLIEREN UND EINSTELLEN 4 Contr ler Jeu de soupapes Hors sp cific...

Страница 188: ...lithium soap base grease on the O rings New T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 7 Install O ring 1 Exhaust tappet cover 2 Intake tappet cover 3 NOTE Apply the lithium soap base gr...

Страница 189: ...m kg 13 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb Mesurer le jeu de soupapes Si le jeu est incorrect r p ter les tapes ci des sus jusqu obtention du...

Страница 190: ...gine when cleaning the exhaust system 1 Remove Bolt spark arrester 1 2 Remove Spark arrester 1 Pull the spark arrester out of the muf fler 3 Clean Spark arrester Tap the spark arrester lightly then us...

Страница 191: ...lld mpfer hineinschieben und auf die Bohrungen f r die Schrauben ausrichten Schraube Funkenl scher T R 10 Nm 1 0 m kg 7 2 ft lb NETTOYAGE DU PARE TINCELLES pour les USA AVERTISSEMENT S assurer que le...

Страница 192: ...the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end...

Страница 193: ...t stoffschlauch befinden PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE TT R125LWE FAHRWERK HYDRAULISCHE BREMSANLAGE ENTL FTEN TT R125LWE PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE TT R125...

Страница 194: ...ystem FRONT BRAKE ADJUSTMENT TT R125E 1 Check Brake lever free play a Out of specification Adjust 2 Adjust Brake lever free play NOTE For minute adjustment loosen the locknut 2 on the lever side and a...

Страница 195: ...ttern drehen bis sich das freie Spiel a innerhalb des vorgeschriebenen Wertes befindet Kontermuttern festziehen 3 Monter Diaphragme Couvercle du ma tre cylindre de frein N B Si la purge est difficile...

Страница 196: ...oosen the locknut 1 Turn the adjuster 2 until the free play a is within the specified limits Tighten the locknut REAR BRAKE ADJUSTMENT 1 Check Brake pedal free play a Out of specification Adjust 2 Adj...

Страница 197: ...1 hinein oder herausdrehen bis das vorgeschriebene Spiel a eingestellt ist TT R125LWE 1 Contr ler Garde du levier de frein a Hors sp cifications R gler 2 R gler Garde du levier de frein ATTENTION Apr...

Страница 198: ...height a 1 mm 0 04 in Pedal height adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 until the pedal height a is within specified height Tighten the locknut Brake pad thickness a Standar...

Страница 199: ...S PLAQUETTES DE FREIN AVANT TT R125LWE BREMSPEDAL H HE EINSTELLEN VORDERRAD BREMSBEL GE KONTROLLIEREN UND ERNEUERN TT R125LWE R GLAGE DE LA HAUTEUR DE LA P DALE DE FREIN 1 Contr ler Hauteur de p dale...

Страница 200: ...e caliper piston in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake caliper 6 and brake cali per support bolt 7 NOTE Appl...

Страница 201: ...ten Bremsbelag erneuern Siehe unter VORDERRAD UND VORDER RADBREMSE in KAPITEL 5 4 Contr ler Niveau du liquide de frein Se reporter la section CONTR LE DU NIVEAU DU LIQUIDE DE FREIN 5 Contr ler Fonctio...

Страница 202: ...contaminants do not enter brake master cylinder when refilling Clean up spilled fluid immediately to avoid erosion of painted surfaces or plas tic parts Brake shoe lining wear limit checking steps Ful...

Страница 203: ...enen Bereichs a befindet Grenzwert berschritten Bremsbelag erneuern Siehe unter HINTERRAD UND HINTER RADBREMSE in KAPITEL 5 Empfohlene Bremsfl ssigkeit DOT 4 CONTR LE DES M CHOIRES DE FREIN 1 Contr le...

Страница 204: ...ain from the kerosene and dry the chain 3 Measure Drive chain length 10 links a Out of specification Replace Drive chain length 10 links Limit 121 4 mm 4 78 in 4 Check Drive chain stiffness a Clean an...

Страница 205: ...Kettenschlo Clip unbedingt gem Abbil dung montieren a Antriebsketten Drehrichtung New CONTR LE DE LA CHA NE DE TRANSMISSION 1 D poser Agrafe de maillon d tachable Maillon d tachable 1 Cha ne de transm...

Страница 206: ...ns and check the slack several times to find the tight est point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 35 50 mm 1 4 2 0 in 3 Adjust Drive chain...

Страница 207: ...ang laut Vorschrift einstellen Achsmutter bei heruntergedr ckter Antriebs kette festziehen T R Achsmutter 60 Nm 6 0 m kg 43 ft lb 6 Lubrifier Cha ne de transmission R GLAGE DE LA TENSION DE LA CHA NE...

Страница 208: ...load By turning the adjuster 1 STANDARD POSITION CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions WARNING Always adjust eac...

Страница 209: ...PECTION DE LA FOURCHE AVANT AJUSTEMENT DE LA PR TENSION DU RESSORT DE FOURCHES AVANT TT R125LWE TELESKOPGABEL KONTROLLIEREN EINSTELLUNG DER TELEGABEL FEDERVORSPANNUNG TT R125LWE INSPECTION DE LA FOURC...

Страница 210: ...move all dirt and mud from around the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjust...

Страница 211: ...a Standardl nge Einstellbereich TT R125E 165 mm 6 50 in TT R125LWE 160 5 mm 6 32 in TT R125E 155 175 mm 6 10 6 89 in TT R125LWE 147 5 167 5 mm 5 81 6 59 in CONTR LE DE L AMORTISSEUR ARRI RE 1 Contr le...

Страница 212: ...is back by the spe cific number of clicks from the fully turned in position CAUTION Never go beyond the maximum or mini mum adjustment positions Stiffer a Increase the rebound damp ing force Turn the...

Страница 213: ...ellungen Maximal Minimal Vollst ndig hinein gedreht 20 Rasten gel st nach vollst ndi gem Hineindrehen Normaleinstellung Ungef hr 12 Rasten gel st 5 Serrer Contre crou 6 Monter Cache lat ral gauche T R...

Страница 214: ...ompression damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 12 clicks out from maximum position b a 1 STANDARD POSITION This is the position which is...

Страница 215: ...leinstellung Ungef hr 9 Rasten gel st REGLAGE DE LA FORCE D AMORTISSEMENT A COMPRESSION DE L AMORTISSEUR ARRIERE TT R125LWE EINSTELLUNG DER FEDERBEIN DRUCKSTUFEND MPFUNG TT R125LWE REGLAGE DE LA FORCE...

Страница 216: ...on 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 00 kgf cm2 15 psi SPOKES INSPECT...

Страница 217: ...rden Speichenspannung nach Probefahrt kontrollie ren T R Vorderrad 2 Nm 0 2 m kg 1 4 ft lb Hinterrad 3 Nm 0 3 m kg 2 2 ft lb R DER KONTROLLIEREN 1 Kontrollieren Schlag Rad anheben und drehen berm iger...

Страница 218: ...assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring...

Страница 219: ...gmutter 4 mit Hilfe des Haken schl ssels 5 lockern Hakenschl ssel YU 33975 90890 01403 3 28 2 Contr ler Jeu de roulement Jeu Remplacer CONTR LE ET R GLAGE DE LA T TE DE FOURCHE 1 Sur lever la roue ava...

Страница 220: ...assembly and inspect the steering bearings Install the rubber washer 8 upper ring nut 9 and special washer 0 NOTE Tighten the upper ring nut until it contacts the rubber washer Insert the special wash...

Страница 221: ...e Markierung a in Fahrtrich tung zeigen Schlauchende des Kraftstoff Entl ftungs schlauchs I in die Schlaucklammer f hren Resserrer l crou cr nel inf rieur 6 l aide de la cl ergots 7 puis tourner quelq...

Страница 222: ...t side of the handlebar holder and then tighten the bolts on the rear side T R Pinch bolt upper bracket 25 Nm 2 5 m kg 18 ft lb Steering stem nut 110 Nm 11 0 m kg 80 ft lb Handlebar upper holder 23 Nm...

Страница 223: ...kg 80 ft lb Oberer Lenkerhalter 23 Nm 2 3 m kg 17 ft lb Chokezug Befestigungsmutter 1 Nm 0 1 m kg 0 7 ft lb Startnummernblech 7 Nm 0 7 m kg 5 1 ft lb ATTENTION Serrer d abord les boulons situ s l ava...

Страница 224: ...ift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake and clutch cable ends Clutch cable end only for the TT R1...

Страница 225: ...inem qualitativ hoch wertigen leichten Lithiumfett abschmieren LUBRIFICATION Afin de garantir le bon fonctionnement de tous les l ments il convient de lubrifier la machine avant la premi re utilisatio...

Страница 226: ...s 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 specification Regap 4 Cle...

Страница 227: ...st Z ndkerze per Hand hineindrehen a und anschlie end mit dem vorgeschriebe nen Drehmoment b festziehen T R 13 Nm 1 3 m kg 9 4 ft lb PARTIE LECTRIQUE INSPECTION DE LA BOUGIE 1 D poser Bougie 2 Contr l...

Страница 228: ...bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get imm...

Страница 229: ...er wichtig da die Batterie vor schriftsm ig geladen wird CONTROLE ET RECHARGE DE LA BATTERIE AVERTISSEMENT Les batteries produisent de l hydrog ne qui est un gaz explosif et elles contiennent de l lec...

Страница 230: ...irst disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Battery 4 Measure Battery charge Measurement steps Connect a pocket tester 1 to the battery terminals Tester p...

Страница 231: ...erden Kein Laden ist erforderlich wenn die Ruhespannung mindestens 12 8 V betr gt N B Comme une batterie MF est scell e il est impossi ble de v rifier son tat de charge en mesurant la densit de l lect...

Страница 232: ...ppropriate charging method illustration WARNING Do not quick charge a battery CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage cu...

Страница 233: ...emmen des Ladeger ts an den Batteriepolen angeschlossen worden sind Relation entre la tension en circuit ouvert et le temps de charge 20 C 68 F Ces valeurs varient selon la temp rature l tat des plaqu...

Страница 234: ...ontact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before recon...

Страница 235: ...uhen lassen CONTROLE ET RECHARGE DE LA BATTERIE BATTERIE KONTROLLIEREN UND LADEN Ne pas oublier de couper l alimentation du chargeur avant de retirer les pinces du char geur des bornes de la batterie...

Страница 236: ...3 37 INSP ADJ Charging method using a variable voltage charger BATTERY INSPECTION AND CHARGING...

Страница 237: ...3 38 INSP ADJ Charging method using a constant voltage charger BATTERY INSPECTION AND CHARGING...

Страница 238: ...rage est il sup rieur l amp rage standard de charge indiqu sur la batte rie R gler la tension de charge 20 25 V Surveiller l amp rage pendant 3 5 minutes L amp rage de charge standard est il d pass Si...

Страница 239: ...eures Laisser reposer la batterie pendant 30 minutes avant de mesurer sa tension en circuit ouvert 12 8 V La charge est termin e 12 0 12 7 V Il est n cessaire de recharger Moins de 12 0 V Changer la b...

Страница 240: ...adestromst rke zu erhalten Ist die Amperezahl h her als die auf der Batterie abgegeben normalen Ladestromst rke Die Ladespannung auf 20 25 V stellen Die Stromst rke 3 5 Minuten lang berwachen Wird die...

Страница 241: ...Messen der Ruhespannung die Batterie ber 30 Minuten lang nicht benut zen 12 8 V Der Ladevorgang ist abgeschlos sen 12 0 12 7 V Die Batterie erneut laden Unter 12 0 V Die Batterie erneuern ACHTUNG Lade...

Страница 242: ...ttery cover FUSE INSPECTION CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Battery cover 2 Check Continuity 2 Reserve fuse Recommended lu...

Страница 243: ...Multime ters auf 1 stellen Taschen Multimeter YU 03112 C 90890 03112 Falls das Multimeter anzeigt die Sicherung erneuern 6 Monter Batterie 7 Contr ler Bornes de batterie Crasse Nettoyer avec une bros...

Страница 244: ...rical system cause the starting and ignition systems to malfunction and could possibly cause a fire 4 Install Battery cover Replacement steps Set the main switch to OFF Install a new fuse of the corre...

Страница 245: ...fen Brennt die Sicherung sofort wieder durch den entsprechenden Stromkreis kontrollie ren Sicherung Ampere Anzahl Hauptsicherung 10 A 1 3 Remplacer Fusible grill AVERTISSEMENT Ne jamais utiliser un fu...

Страница 246: ...Extent of removal Order Part name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF 1 Seat 1 2 Air scoop left and right 2 3 Fuel hose 1 Remove on fu...

Страница 247: ...ernblech 1 1 3 4 2 3 SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX SITZ KRAFTSTOFFTANK UND SEITENDECKEL MOTEUR SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX Organisation de la d pose 1 D pose de l...

Страница 248: ...removal Extent of removal Order Part name Q ty Remarks MUFFLER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt spark arrester 3 2 Spark arreste...

Страница 249: ...Mutter Schalld mpfer 2 4 Schraube Schalld mpfer 1 5 Schalld mpfer 1 1 POT D CHAPPEMENT Organisation de la d pose 1 D pose du pot d chappement Organisation de la d pose Ordre Nom de pi ce Qt Remarques...

Страница 250: ...ration for removal Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Number plate 1 Fuel hose 1 2 Over flow hose 1 3 Air vent hose 2 4 Starter plunger starter knob 1 5 Carburetor top cover 1 6...

Страница 251: ...Anschlu teil 1 Schrauben lockern Vergaser Anschlu teil 8 Vergaser 1 1 CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarques D POSE DU...

Страница 252: ...Refer to REMOVAL POINTS 3 Jet needle set 1 4 Carburetor top cover 1 5 Starter plunger 1 6 Float chamber 1 7 Float pivot pin 1 8 Float 1 9 Needle valve 1 0 Main jet washer 1 A Needle valve seat holder...

Страница 253: ...tellschraube 1 J Leerlaufanreicherung 1 1 D MONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarques D MONTAGE DU CARBURA T...

Страница 254: ...MOVAL POINTS Throttle valve 1 Remove Throttle valve 1 Spring throttle valve 2 Carburetor top cover 3 Throttle cable 4 NOTE While compressing the spring throttle valve disconnect the throttle cable Pil...

Страница 255: ...em Demontie ren leicht bis zum Anschlag hineindrehen und die Anzahl der Umdrehungen z hlen Diese Zahl als werkseitige Anzahl der Umdrehungen notieren REMARQUE altitude lev e la pression atmosph rique...

Страница 256: ...ets with com pressed air Never use a wire 2 Inspect Main jet 1 Main jet nozzle 2 Pilot jet 3 NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never u...

Страница 257: ...nbildung a Erneuern Staub b Reinigen HINWEIS Nadelventil und Nadelventilsitz immer kom plett erneuern INSPECTION Carburateur 1 Contr ler Corps de carburateur Encrassement Nettoyer N B Nettoyer avec du...

Страница 258: ...Below the float chamber mat ing surface Measurement and adjustment steps Connect the fuel level gauge 1 to the float chamber Fuel level gauge YM 1312 A 90890 01312 Hold the fuel level gauge vertically...

Страница 259: ...h leichtes Bie gen des Schwimmerhabels b eingestellt werden Kraftstoffstand erneut messen Boisseau 1 Contr ler Souplesse du mouvement Calage R parer ou remplacer N B Introduire le boisseau 1 dans le c...

Страница 260: ...retor 1 Install Diaphragm 1 Spring 2 Cover 3 Screw 4 T R 2 Nm 0 2 m kg 1 4 ft lb LT 2 Install Throttle stop screw 1 Pilot air screw 2 3 Install Pilot air jet 1 1 Pilot air jet 2 2 Note the following i...

Страница 261: ...rschraube um die Anzahl der Umdrehungen herausdrehen die vor dem Demontieren notiert wurde Leerlaufluft Regulierschraube 2 1 2 3 1 2 Beispiel Flotteur 1 Contr ler Flotteur 1 Endommagement Remplacer En...

Страница 262: ...installing the needle valve to the float install them to the carburetor Check the float for smooth movement 6 Install Gasket Float chamber 1 Screw float chamber 2 7 Install Spring 1 Starter plunger 2...

Страница 263: ...t d aiguille 2 Sur le boisseau 3 N B Aligner les saillies a sur le boisseau et les gorges b du support d aiguille 4 Montieren Leerlaufd se 1 Hauptd senstock 2 Hauptd se 3 Nadelventilsitz 4 Nadelventil...

Страница 264: ...Throttle valve 3 On throttle cable 4 NOTE While compressing the spring connect the throttle cable Carburetor installation 1 Install Carburetor assembly 1 NOTE Install the projection between the carbur...

Страница 265: ...en 2 Festziehen Schraube Vergaser Verbindungsteil 1 Schraube Luftfilter Anschlu teil 2 9 Monter Cache sup rieur du carburateur 1 Ressort boisseau 2 Boisseau 3 Sur le c ble d acc l ration 4 N B Connect...

Страница 266: ...ose 5 NOTE Align the slit a of the throttle valve with the tab b of the carburetor body CAUTION In order to release the starter cable from the twist install the starter knob after tight ening the nut...

Страница 267: ...marreur 4 R gler R gime de ralenti Se reporter la section R GLAGE DU R GIME DE RALENTI au CHAPITRE 3 CARBURATEUR VERGASER 3 Montieren Vergaserdeckel 1 Chokeschieber 2 Bel ftungsschlauch 3 berlaufschl...

Страница 268: ...s CYLINDER HEAD SIDE COVER AND TAPPET COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Muffler Refer to MUFFLER section Carburetor Refer to CARB...

Страница 269: ...Kurbelwellen Verschlu schraube 1 6 Z ndeinstell Verschlu schraube 1 1 CULASSE CACHE LAT RAL DE CULASSE ET COUVRE POUSSOIRS Organisation de la d pose 1 D pose du cache lat ral de culasse et des couvre...

Страница 270: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER HEAD REMOVAL 1 Bolt camshaft sprocket 1 Refer to REMOVAL POINTS 2 Bolt timing chain tensioner cap 1 3 Timing chain tensioner 1 4 Gasket...

Страница 271: ...Steuerkettenspanner 1 4 Dichtung 1 5 Nockenwellenrad 1 6 Zylinderkopf 1 7 Pa h lse 2 8 Dichtung 1 1 CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de pi...

Страница 272: ...ed with the stationary pointer the piston is at the Top Dead Center T D C NOTE In order to be sure that the piston is at Top Dead Center the match mark c on the camshaft sprocket must align with the s...

Страница 273: ...tter mit einem Schraubenschl ssel halten und Schraube demontieren 3 Demontieren Schraube Steuerkettenspanner Dek kel 1 Schraube Steuerkettenspanner 2 Steuerkettenspanner 3 PI CES D POSER Culasse 1 Ali...

Страница 274: ...the bolts starting with the lowest number one INSPECTION Cylinder head 1 Eliminate Carbon deposits from the combustion chambers Use a rounded scraper NOTE Do not use a sharp instrument to avoid dam ag...

Страница 275: ...ritten Planschlei fen Arbeitsschritte Lineal und F hlerlehre auf den Zylinder kopf legen Den Verzug messen 4 D poser Boulon pignon d arbre cames 1 Pignon d arbre cames 2 N B Attacher un fil m tallique...

Страница 276: ...side ASSEMBLY AND INSTALLATION Cylinder head 1 Install Dowel pin 1 Gasket 2 New 2 Install Cylinder head Copper washer Bolt cylinder head NOTE Apply Quick gasket YAMAHA Bond No 1215 on end of the cyli...

Страница 277: ...Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 T R M8 22 Nm 2 2 m kg 16 ft lb M6 10 Nm 1 0 m kg 7 2 ft lb Limite de d formation 0 03 mm 0 0012 in Si la d formation est hors sp cifi...

Страница 278: ...inter b on the crankcase cover Align the match mark c on the camshaft sprocket with the stationary pointer d on the cylinder head Fit the timing chain 1 onto camshaft sprocket 2 and install the camsha...

Страница 279: ...n oder einer ungenauen Ventilsteuerung kommt Den Sicherungsdraht von der Steuerkette entfernen 3 Monter Cha ne de distribution Pignon d arbre cames 4 Monter Rondelle Boulon pignon d arbre cames N B Se...

Страница 280: ...se a thin screwdriver and wind the tensioner rod up fully clockwise With the rod fully wound install the gasket 1 and the chain tensioner 2 and tighten the bolts 3 to the specified torque T R Bolt cha...

Страница 281: ...lb 8 Festziehen Schraube 1 HINWEIS Rotormutter mit einem Schraubenschl ssel festhalten und Schraube festziehen T R 20 Nm 2 0 m kg 14 ft lb 5 Monter Tendeur de la cha ne de distribution 6 Tourner Vile...

Страница 282: ...y Engine oil On camshaft 11 Install Tappet cover 1 Cylinder head side cover 2 T R 18 Nm 1 8 m kg 13 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 12 Install Timing mark accessing screw 1 Crankshaft end accessing...

Страница 283: ...g 5 1 ft lb 13 Montieren Z ndkerze Motorhalterung T R 13 Nm 1 3 m kg 9 4 ft lb T R 40 Nm 4 0 m kg 29 ft lb 9 Contr ler Jeu de soupapes Hors sp cifications R gler Se reporter la section CONTR LE ET R G...

Страница 284: ...xtent of removal Order Part name Q ty Remarks CAMSHAFT AND ROCKER ARMS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Camshaft bearing holder 1 2 Intake rocker arm shaf...

Страница 285: ...TAGEPUNKTE 3 Kipphebelwelle Ausla seite 1 4 Nockenwelle 1 5 Kipphebel Einla seite 1 6 Kipphebel Ausla seite 1 1 2 ARBRE CAMES ET CULBUTEURS Organisation de la d pose 1 D pose de l arbre cames 2 D pose...

Страница 286: ...890 01084 Camshaft 1 Remove Camshaft 1 Camshaft bearing 2 NOTE Screw in a suitable length of 8 mm bolt 3 into the threaded end of the camshaft and pull out the camshaft INSPECTION Camshaft 1 Inspect C...

Страница 287: ...uern Nockenh he Grenzwert Einla a 25 851 mm 1 0178 in b 21 165 mm 0 8333 in Ausla a 25 811 mm 1 0162 in b 21 020 mm 0 8276 in PI CES D POSER Axes de culbuteur 1 D poser Axes de culbuteur N B Se servir...

Страница 288: ...rocker arm 10 000 10 015 mm 0 3937 0 3943 in Limit 10 03 mm 0 3949 in Measure the outside diameter b of the rocker arm shafts Out of specification Replace Outside diameter rocker arm shaft 9 981 9 991...

Страница 289: ...tieren Kipphebel Nockenwelle 1 3 Auftragen Motor l auf die Kipphebelwelle 4 Montieren Kipphebelwelle Culbuteurs et axes de culbuteur 1 Contr ler Surface de contact de bossage de came a Surface du disp...

Страница 290: ...4 23 ENG CAMSHAFT AND ROCKER ARMS 5 Install Camshaft bearing holder 1 Bolt 2 T R 10 Nm 1 0 m kg 7 2 ft lb LT...

Страница 291: ...CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL 5 Montieren Nockenwellenlager Halter 1 Schraube 2 T R 10 Nm 1 0 m kg 7 2 ft lb LT 5 Monter Support de roulement d arbre cames 1 Boulon 2 T R 10 Nm 1 0 m k...

Страница 292: ...Q ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Camshaft and rocker arms Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4...

Страница 293: ...nla ventil 1 5 Ausla ventil 2 6 Ventilschaftdichtung 2 7 Ventilfedersitz 2 1 SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la d pose 1 D poses des soupapes et des ressorts de soupape Organisation de...

Страница 294: ...als properly There should be no leakage at the valve seat 2 2 Remove Valve cotters 1 NOTE Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve...

Страница 295: ...upape 4 Si ge de ressort de soupape 5 N B Marquer la position de chaque pi ce avec soin afin de pouvoir les remonter dans leur position d origine DEMONTAGEPUNKTE Ventil 1 Kontrollieren Ventil Dichthei...

Страница 296: ...e Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head in an over to 100 C 212 F Remove the valve guide using a valve guide remover 1 Install th...

Страница 297: ...Ventilf hrung den Ventilsitz nachschleifen INSPECTION Soupape 1 Mesurer Jeu de queue dans le guide Hors sp cifications Remplacer le guide de soupape Jeu de queue dans le guide diam tre int rieur de g...

Страница 298: ...ce 5 Measure Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal Margin thickness I...

Страница 299: ...ungen von Ventilkegel und Ventilsitz 7 Kontrollieren Ventilsitze Pitting Bildung Verschlei Ventilsitz neu fr sen 3 Contr ler Face de soupape Piq res usure Surfacer la face de sou pape Embout de queue...

Страница 300: ...o the valve seat to make a clear pattern Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed If the valve seat is too wide too narrow or the se...

Страница 301: ...chaft und Ventilf hrung gelangen Molybd ndisulfid auf den Ventilschaft auf tragen 8 Mesurer Largeur de si ge de soupape a Hors sp cifications Surfacer le si ge de soupape Largeur du si ge de soupape A...

Страница 302: ...lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head Press the va...

Страница 303: ...tsm ig Erneuern Ungespannte L nge Ventilfeder Einla 32 55 mm 1 28 in Grenzwert 31 2 mm 1 23 in Ausla 32 55 mm 1 28 in Grenzwert 31 2 mm 1 23 in Installer la soupape dans la culasse Tourner la soupape...

Страница 304: ...1 kg at 25 6 mm 30 86 35 49 lb at 1 01 in Spring tilt limit Intake 2 5 1 4 mm 0 06 in Exhaust 2 5 1 4 mm 0 06 in ASSEMBLY AND INSTALLATION Valve 1 Apply Molybdenum disulfide oil onto the valve stem an...

Страница 305: ...telle montiert wird Ventilfedern mit der gr eren Federteilung a nach oben montieren b Kleinere Federteilung New 2 Mesurer Force de ressort comprim a Hors sp cifications Remplacer b Longueur mont 3 Mes...

Страница 306: ...valve spring with a valve spring compressor 2 install the valve cotters Valve spring compressor YM 4019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a p...

Страница 307: ...Klopfen auf die Ventil schaftenden k nnten die Ventile besch digt werden Ventilfederspanner YM 4019 90890 04019 3 Monter Clavettes de soupape 1 N B Installer les clavettes de soupape en comprimant le...

Страница 308: ...of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Exhaust timing chain guide 1 2 Cylinder O ring 1 1 3 Dowel p...

Страница 309: ...1 5 Kolbenbolzensicherung 2 Siehe unter DEMONTAGEPUNKTE 6 Kolbenbolzen 1 7 Kolben 1 8 Kolbenring Satz 1 1 2 CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Organi...

Страница 310: ...pin hole area If the piston pin groove is deburred and the piston pin is still difficult to remove use the piston pin puller 4 CAUTION Do not use a hammer to drive the piston pin out Piston ring 1 Re...

Страница 311: ...nbolzen Austreiber YU 1304 90890 01304 PR FEN Zylinder und Kolben 1 Kontrollieren Zylinder und Kolbenhemd Senkrechte Kratzer Zylinder und Kolben erneuern PI CES D POSER Piston 1 D poser Circlips d axe...

Страница 312: ...T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 If out of specification replace the cylinder and replace the piston and piston rings as set 2nd step Measure t...

Страница 313: ...olbenlaufspiel 0 020 0 026 mm 0 0008 0 0010 in Grenzwert 0 15 mm 0 006 in 2 Mesurer Jeu entre piston et cylindre tapes de la mesure du jeu piston cylindre 1re tape Mesurer l al sage de cylindre C au m...

Страница 314: ...cation system 2 Measure Piston pin to piston clearance Measurement steps Measure the piston pin outside diameter a If out of specification replace the piston pin Outside diameter piston pin 14 991 15...

Страница 315: ...Kolbenbol zenauge 15 002 15 013 mm 0 5906 0 5911 in Grenzwert 15 043 mm 0 5922 in Si la valeur obtenue ne correspond pas aux sp cifications remplacer le cylindre et rempla cer la fois le piston et se...

Страница 316: ...ton ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 40 mm 1 57 in into the cylin der Push the ring with the piston crown so that the ring will be at a right angle to th...

Страница 317: ...4 mm 0 016 in 2 Kom pressi onsring 0 30 0 45 mm 0 012 0 018 in 0 55 mm 0 022 in lab streifring 0 20 0 70 mm 0 01 0 03 in Segment de piston 1 Mesurer Jeu lat ral de segment Utiliser une cale d paisseur...

Страница 318: ...er size A 54 000 54 003 mm 2 1260 2 1261 in B 54 004 54 007 mm 2 1261 2 1263 in C 54 008 54 011 mm 2 1263 2 1264 in D 54 012 54 015 mm 2 1265 2 1266 in E 54 016 54 019 mm 2 1266 2 1267 in Cylinder mar...

Страница 319: ...1257 2 1258 in Zylinder Markierung Kolbenmarkierung Farbe A A rot B B orange C C gr n D D violett E E blau Combinaisons de piston et cylindre 1 Contr ler Rep re sur le cylindre a 2 Contr ler Rep re su...

Страница 320: ...own a Top ring end b 2nd ring end c Oil ring end upper d Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clips 3 NOTE Apply engine oil onto the piston pin piston rings and piston Be sure...

Страница 321: ...hmieren Kolben Kolbenringe Zylinderlauffl che HINWEIS Reichlich Motor l auftragen New ASSEMBLAGE ET REPOSE Segments et piston 1 Monter Segments de piston sur le piston N B S assurer d installer le seg...

Страница 322: ...t timing chain guide CAUTION Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain through the cylin der timing chain cavity Be careful not to...

Страница 323: ...darf bei der Montage nicht besch digt werden HINWEIS Nach der Montage die Leichtg ngigkeit des Kolbens pr fen New Cylindre 1 Monter Goujons 1 Joint cylindre 2 New 2 Monter Joint torique Cylindre 1 Pa...

Страница 324: ...ION PLATE REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine skidplate Refer to ENGINE REMOVAL section Starter motor 1 Refer to ELECTR...

Страница 325: ...5 9 Kupplungsscheibe 4 10 Mutter Unterlegscheibe 1 1 11 Druckstange 1 1 12 Druckplatte 1 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE DISQUES D EMBRAYAGE ET DE FRICTION Organisation de la d pose 1 D pose des di...

Страница 326: ...xtent of removal Order Part name Q ty Remarks PRIMARY DRIVEN GEAR REMOVAL 1 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 2 Lock washer 1 3 Clutch boss 1 4 Thrust plate 1 5 Primary driven...

Страница 327: ...1 Se reporter la section PI CES D PO SER 9 Pignon menant primaire 1 10 Clavette droite 1 2 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE KUPPLUNG UND PRIM RABTRIEBSZAHNRAD PRIM RABTRIEBSZAHNRAD Demontage Arbeit...

Страница 328: ...CH AND PRIMARY DRIVEN GEAR PUSH LEVER Extent of removal 1 Push lever removal Extent of removal Order Part name Q ty Remarks PUSH LEVER REMOVAL 1 Clutch cable 1 2 Push lever 1 3 Spring 1 4 Circlip 1 5...

Страница 329: ...l Anz Bemerkungen AUSR CKHEBEL DEMONTIE REN 1 Kupplungszug 1 2 Ausr ckhebel 1 3 Feder 1 4 Sicherungsring 1 5 Dichtring 1 1 LEVIER DE POUSS E Organisation de la d pose 1 D pose du levier de pouss e Org...

Страница 330: ...6 Primary drive gear 1 Remove Nut primary drive gear 1 Primary drive gear 2 NOTE Place a folded rag or aluminum plate between the teeth of the primary drive gear and primary driven gear Take care not...

Страница 331: ...Verschlei Besch digung Erneuern Prim rabtriebszahnrad 1 Kontrollieren Umfangsspiel Spiel vorhanden Erneuern Zandrad Z hne a Verschlei Besch digung Erneuern PI CES D POSER Noix d embrayage 1 D poser c...

Страница 332: ...plate 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points EC484600 Clutch plate 1 Measure Clutch plate warpage Out of specification Repla...

Страница 333: ...21 in Grenzwert 2 8 mm 0 110 in Verzugsgrenze 0 2 mm 0 008 in Ressort d embrayage 1 Mesurer Longueur libre de ressort d embrayage a Hors sp cifications Remplacer tous les ressorts Longueur libre de re...

Страница 334: ...ush lever 1 NOTE Apply the lithium soap base grease on the oil seal lip Apply the engine oil on the push lever Primary drive gear 1 Install Straight key Primary drive gear 1 Washer 2 Nut primary drive...

Страница 335: ...platte 5 zwischen die Z hne des Prim rantriebszahnrades und des Pri m rabtriebszahnrades stecken T R 70 Nm 7 0 m kg 50 ft lb Tige de commande 1 Contr ler Tige de commande 1 1 Bille 2 Usure endommageme...

Страница 336: ...holding tool YM 91042 90890 04086 New T R 60 Nm 6 0 m kg 43 ft lb 4 Install Friction plate 1 Clutch plate 2 NOTE Install the clutch plates and friction plates alternately on the clutch boss starting...

Страница 337: ...m Ver satz von etwa 90 zur Nase der vorhergehen den Scheibe montieren Im Uhrzeigersinn vorgehen bis alle Kupplungsscheiben mon tiert sind Embrayage 1 Monter Rondelle lastique conique 1 Plaque de pouss...

Страница 338: ...Bolt clutch spring 3 NOTE Align the arrow mark a on the pressure plate with the punched mark b on the clutch boss Tighten the bolts in stage using a crisscross pattern T R 6 Nm 0 6 m kg 4 3 ft lb 8 Ch...

Страница 339: ...sgerichtet sind Einstellen a Markierung auf dem Ausr ckhebel b Markierung auf dem Kurbelgeh use 5 Monter Bille N B Enduire la bille d huile de moteur 6 Monter Tige de commande 1 1 Plaque de pouss e 2...

Страница 340: ...crankcase cover Right crankcase cover Battery negative lead 1 Lead holder 2 Bolts right crankcase cover NOTE Apply Quick gasket YAMAHA Bond No 1215 to end of the right crankcase cover bolts as shown...

Страница 341: ...sedeckel besteht Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 New T R 10 Nm 1 0 m kg 7 2 ft lb T R 50 Nm 5 0 m kg 36 ft lb 9 R gler Position du levier de pouss e tapes du r glage...

Страница 342: ...l Extent of removal Order Part name Q ty Remarks OIL PUMP REMOVAL Preparation for removal Clutch and primary drive gear Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 1 Rotary filter 1 2 Oil pump dri...

Страница 343: ...1 2 lpumpe Antriebsrad 1 3 lpumpe komplett 1 4 Dichtung 1 5 lpumpensieb 1 1 POMPE HUILE Organisation de la d pose 1 D pose de la pompe huile Organisation de la d pose Ordre Nom de pi ce Qt Remarques D...

Страница 344: ...assembly Extent of removal Order Part name Q ty Remarks OIL PUMP DISASSEMBLY 1 Circlip 1 2 Oil pump driven gear 1 3 Conical spring washer 1 4 Circlip 1 5 Washer 1 6 Oil pump cover 1 7 Pin 2 8 Oil pump...

Страница 345: ...tift 1 0 Innenrotor 1 A Au enrotor 1 B lpumpengeh use 1 1 D MONTAGE DE LA POMPE HUILE Organisation de la d pose 1 D montage de la pompe huile Organisation de la d pose Ordre Nom de pi ce Qt Remarques...

Страница 346: ...the oil pump housing 3 Out of specification Replace the oil pump assembly Housing and rotor clearance between the pump housing 3 and the rotors 1 2 Out of specification Replace the oil pump assembly T...

Страница 347: ...5 mm 0 0059 in Zentrifugalfilter 1 Kontrollieren Zentrifugalfilter Risse Besch digung Erneuern INSPECTION Pompe huile 1 Contr ler Pignon menant de pompe huile Pignon men de pompe huile Logement de la...

Страница 348: ...o the outer rotor inner rotor and oil pump shaft Install the conical spring washer in the direc tion as shown 2 Install Oil strainer Gasket Oil pump assembly Screws oil pump assembly NOTE Apply engine...

Страница 349: ...3 6 ft lb New T R 7 Nm 0 7 m kg 5 1 ft lb Cr pine huile 1 Contr ler Cr pine huile Craquelures endommagement Rempla cer Crasses obstructions Nettoyer ASSEMBLAGE ET REPOSE Pompe huile 1 Monter Logement...

Страница 350: ...ND SHIFT SHAFT REMOVAL Preparation for removal Shift pedal link Refer to ENGINE REMOVAL section Clutch Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 1 Kick axle assembly 1 Refer to REMOVAL POINTS 2...

Страница 351: ...ckstarter Anschlag 1 11 Kickstarter Anschlag 1 12 Feder 1 13 Kickstarter Zahnsegment 1 Siehe unter DEMONTAGEPUNKTE 1 2 AXE DE KICK ET ARBRE DE S LECTEUR AXE DE KICK ET ARBRE DE S LECTEUR Organisation...

Страница 352: ...le and kickstarter segment gear 1 Check Kickstarter segment gear smooth movement Unsmooth movement Replace 2 Inspect Kick axle 1 Wear damage Replace Kickstarter segment gear and kick idle gear 1 Inspe...

Страница 353: ...rritzel Clip 1 Messen Kickstarterritzel Clip Friktionskraft R ckholfeder Nicht vorschriftsm ig Erneuern Dynamometer 1 verwenden Kickstarterritzel Clip Friktionskraft 0 65 1 35 kg 1 4 3 0 lb PI CES D P...

Страница 354: ...g 2 Broken Replace EC4C5000 ASSEMBLY AND INSTALLATION Segment 1 Install Segment 1 Screw segment 2 NOTE Align the notch a on the segment with the pin b on the shift cam Tighten the screw using the T30...

Страница 355: ...INWEIS Kickstarter Anschlag Rolle auf den Schlitz im Kickstarter Zahnsegment ausrichten T R 12 Nm 1 2 m kg 8 7 ft lb LT T R 10 Nm 1 0 m kg 7 2 ft lb LT Arbre de s lecteur 1 Contr ler Arbre de s lecteu...

Страница 356: ...of the torsion spring fits into the hole b on the kick axle 2 Install Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a in the spring guide fits on the stopper of th...

Страница 357: ...den 4 Einhaken R ckholfeder 1 HINWEIS R ckholfeder im Uhrzeigersinn drehen und in die entsprechende Bohrung a im Kurbelge h use einh ngen Arbre de s lecteur 1 Monter Arbre de s lecteur 1 N B Enduire l...

Страница 358: ...FT SHAFT Kick idle gear 1 Install Circlip 1 Washer 2 Kick idle gear 3 Washer 4 Circlip 5 NOTE Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its depress...

Страница 359: ...S Motor l auf das gesamte Kickstarterritzel auftragen Kickstarterritzel mit der flachen Seite nach au en montieren New New Pignon libre de kick 1 Monter Circlip 1 Rondelle 2 Pignon libre de kick 3 Ron...

Страница 360: ...Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank 1 CDI magneto lead 1 2 Neutral switch lead 1 3 Left crankcase cover 1 4 Nut rotor 1 Use special tool Refer to REMOVAL POINTS 5...

Страница 361: ...terleerlaufrad 1 11 Starterleerlaufrad 1 12 Kabelf hrung 1 13 Aufnehmerspule St nder Bau gruppe 1 2 1 1 MAGNETO CDI ET ROCHET DE DEMARRAGE Organisation de la d pose 1 D pose de la bobine d excitation...

Страница 362: ...0 01362 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and...

Страница 363: ...keit Ver schlei Die defekten Teile erneuern MAGNETO CDI ET ROCHET DE DEMARRAGE CDI MAGNETZ NDER UND STARTERKUPPLUNG PI CES D POSER Rotor 1 D poser crou rotor 1 Rondelle plate 2 Se servir d une cl sang...

Страница 364: ...ust be replaced When turning the starter clutch drive gear clockwise it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced 1 2 E...

Страница 365: ...ad 1 Scheibe 2 Schraube 3 Unterlegscheibe 4 HINWEIS Das Motor l auf den Innenumfang des Starter leerlaufrads und auf den Au enumfang der Welle auftragen T R 7 Nm 0 7 m kg 5 1 ft lb 3 Contr ler Fonctio...

Страница 366: ...serve as a stop per a T R 30 Nm 3 0 m kg 22 ft lb 5 Install Starter wheel gear 1 Woodruff key 2 Rotor 3 NOTE Clean the tapered portion of the crankshaft and the magneto hub When installing the magneto...

Страница 367: ...gehalten wird Kupplungskorb Halter YS 1880 A 90890 01701 T R 80 Nm 8 0 m kg 58 ft lb MAGNETO CDI ET ROCHET DE DEMARRAGE CDI MAGNETZ NDER UND STARTERKUPPLUNG 3 Installer l embrayage de d marreur 1 sur...

Страница 368: ...ver left 8 Connect Neutral switch lead 1 NOTE Pass the neutral switch lead into the crank case cover groove as shown 9 Connect CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2...

Страница 369: ...rotor Kabel Siehe unter KABELF HRUNG in KAPITEL 2 MAGNETO CDI ET ROCHET DE DEMARRAGE CDI MAGNETZ NDER UND STARTERKUPPLUNG 7 Monter Couvercle de carter gauche 8 Connecter Fil de contacteur de point mor...

Страница 370: ...Seat fuel tank and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Muffler Refer to MUFFLER section Clutch cable Disconnect at engine side Spark plug...

Страница 371: ...M in KAPITEL 6 Motor l ablassen Siehe unter MOTOR L WECHSELN in KAPITEL 3 D POSE DU MOTEUR Organisation de la d pose 1 D pose du moteur Organisation de la d pose Ordre Nom de pi ce Qt Remarques D POSE...

Страница 372: ...over 1 2 Bolt drive sprocket 2 Refer to REMOVAL POINTS 3 Drive sprocket holder 1 4 Drive sprocket 1 5 Shift pedal link 1 6 Crankcase breather hose 1 7 Engine bracket upper 1 8 Engine skidplate 1 9 Eng...

Страница 373: ...orhalterung vorne 1 10 Motorbefestigungsschraube hinten 2 11 Motor 1 Siehe unter DEMONTAGEPUNKTE 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 1 Cache de pignon menant 1 2 Boulon pignon...

Страница 374: ...les are disconnected ASSEMBLY AND INSTALLATION Engine installation 1 Install Engine 1 Install the engine from left side Engine mounting bolt rear 2 Engine bracket front 3 Bolt engine bracket 4 Engine...

Страница 375: ...29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb PI CES D POSER Pignon menant 1 D poser Boulon pignon menant Support de pignon m...

Страница 376: ...olt shift pedal link 2 NOTE Adjust the center a of the front end of the shift pedal to match the highest point of the foot rest T R 10 Nm 1 0 m kg 7 2 ft lb Drive sprocket 1 Install Drive sprocket 1 D...

Страница 377: ...bsritzel Deckel 1 Schraube Antriebsritzel Deckel 2 T R 12 Nm 1 2 m kg 8 7 ft lb N B Enduire le filet des boulons de montage du moteur 2 de graisse base de savon au lithium Serrer le boulon de montage...

Страница 378: ...der Part name Q ty Remarks CRANKCASE CRANKSHAFT AND BALANCER REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Primary drive gear Refe...

Страница 379: ...he unter KICKSTARTERWELLE UND SCHALTWELLE Kickstarter Zahnsegment Rotor und Stator Siehe unter CDI MAGNETZ NDER UND STARTERKUPPLUNG CARTER MOTEUR VILEBREQUIN ET BALANCIER Organisation de la d pose 1 S...

Страница 380: ...1 2 Timing chain 1 3 Bolt 45 mm 1 8 in 7 4 Bolt 55 mm 2 2 in 1 5 Bolt 30 mm 1 2 in 2 6 Lead guide 1 7 Clutch cable holder 1 8 Right crankcase 1 Use special tool Refer to REMOVAL POINTS 9 Left crankcas...

Страница 381: ...1 11 Kurbelwelle 1 Spezialwerkzeug verwenden Siehe unter DEMONTAGEPUNKTE 12 Lager 3 Siehe unter DEMONTAGEPUNKTE 3 2 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 1 Patin de cha ne de dis...

Страница 382: ...case If necessary one screw may be backed out slightly to level tool body As pressure is applied alternately tap on the front engine mounting boss and transmission shafts CAUTION Use soft hammer to t...

Страница 383: ...lften nicht trennen lassen mu gepr ft werden ob eine Geh u seschraube oder befestigung vergessen wurde Keinesfalls rohe Kraft anwenden Kurbelgeh use Trennwerkzeug YU 1135 A 90890 01135 PI CES D POSER...

Страница 384: ...kcase separating tool YU 1135 A 90890 01135 Bearing 1 Remove Bearing 1 NOTE Remove the bearing from the crankcase by pressing its inner race as shown in Do not use the removed bearing INSPECTION Timin...

Страница 385: ...ifheit Steuerkette und Nok kenwellen Kettenrad komplett erneu ern 2 Kontrollieren Steuerkettenf hrung Verschlei Besch digung Erneuern Vilebrequin 1 D poser Vilebrequin 1 Se servir d un s parateur de d...

Страница 386: ...with a finger Rough spot seizure Replace Crankshaft 1 Measure Runout limit a Connecting rod big end side clearance b Crank width c Out of specification Replace Use the dial gauge and a thickness gaug...

Страница 387: ...Axial spiel 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Kurbel breite 46 95 47 00 mm 1 848 1 850 in Carter moteur 1 Contr ler Plan de joint a Rayures Remplacer Noix de montage du moteur b carter mo...

Страница 388: ...cept for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms...

Страница 389: ...g 3 YU 90050 90890 01275 Adapter 4 YU 90063 90890 01278 Distanzh lse 5 YM 91044 90890 04081 Balancier 1 Contr ler Balancier Craquelures endommagement Rempla cer ASSEMBLAGE ET REPOSE Roulement 1 Monter...

Страница 390: ...crankcase 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 2 Install Dowel pin 1 Right crankcas...

Страница 391: ...fte aufsetzen Vorsichtig mit einem weichen Hammer auf die Geh u seh lfte klopfen Bei der Montage des Kurbelgeh uses sollte sich die Pleuelstange im oberen Totpunkt TDC befinden 2 Monter Balancier N B...

Страница 392: ...ankcase bolts 45 mm 1 8 in 3 as shown Tighten the crankcase bolts in stage using a crisscross pattern Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 N...

Страница 393: ...rkettenf hrung Einla seite 2 Schraube Steuerkettenf hrung Ein la seite T R 10 Nm 1 0 m kg 7 2 ft lb LT 3 Serrer Guide de fil 1 Support de c ble d embrayage 2 Boulon carter moteur 45 mm 1 8 in 3 Boulon...

Страница 394: ...Remarks TRANSMISSION SHIFTCAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE CRANKSHAFT AND BALANCER section 1 Shift f...

Страница 395: ...NTAGEPUNKTE 8 Ausgangswelle 1 9 Druckstange 2 1 10 Anlaufscheibe 1 1 2 BO TE DE VITESSES TAMBOUR ET FOURCHETTES DE S LECTION Organisation de la d pose 1 D pose du tambour et des fourchettes de s lecti...

Страница 396: ...mmer to remove Remove assembly carefully Note the posi tion of each part Pay particular attention to the location and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect Matching dog...

Страница 397: ...e 2 1 Verschlei Besch digung Verbiegung Erneuern PI CES D POSER Bo te de vitesses 1 D poser Arbre primaire 1 Arbre secondaire 2 N B D poser l arbre secondaire de la bo te de vitesse en le tapotant l g...

Страница 398: ...hift cam 1 Inspect Shift fork 1 Wear damage scratches Replace 2 Inspect Shift cam 1 Shift fork guide bar 2 Bend wear damage Replace 3 Check Shift fork movement On its guide bar Unsmooth operation Repl...

Страница 399: ...e sich neben der Schaltgabel befinden Roulement 1 Contr ler Roulement 1 Faire tourner la cage interne avec un doigt Duret grippage Remplacer Fourchette de s lection et tambour 1 Contr ler Fourchette d...

Страница 400: ...xle 5 NOTE Apply the molybdenum disulfide oil on the gears inner circumference Install the 5th pinion gear so that measure ment a is 83 25 83 45 mm 3 278 3 285 in 2 Install 2nd wheel gear 32T 1 5th wh...

Страница 401: ...auf den Innenring der Zahn r der auftragen Bo te de vitesses 1 Monter 4e pignon menant 22T 1 3e pignon menant 19T 2 2e pignon menant 18T 3 5e pignon menant 24T 4 Sur l arbre primaire 5 N B Enduire la...

Страница 402: ...end c is positioned at axle spline groove d New 4 Install Push rod 2 On main axle NOTE Apply the engine oil on the push rod 2 5 Install Washer 1 On drive axle 6 Install Main axle Drive axle Install t...

Страница 403: ...geachtet werden da die Dichtlippe des Kurbelge h use Dichtrings nicht besch digt wird 3 Monter Rondelle plate 1 Circlip 2 N B S assurer de diriger le c t ouvert a du circlip du c t oppos de la rondell...

Страница 404: ...he drive axle Mesh the shift fork 2 C with the 3rd pinion gear on the main axle 2 Install Shift cam 1 NOTE Apply the engine oil on the shift cam 3 Install Shift fork guide bar 1 short 1 Shift fork gui...

Страница 405: ...parieren Tambour et fourchette de s lection 1 Monter Fourchette de s lection 1 L 1 Fourchette de s lection 2 C 2 Fourchette de s lection 3 R 3 N B Engrener la fourchette de s lection n 1 L avec le 2e...

Страница 406: ...ame Q ty Remarks Preparation for removal FRONT WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it fal...

Страница 407: ...Distanzst ck 1 2 3 1 ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E PARTIE CYCLE ROUE AVANT ET FREIN AVANT TT R125E Organisation de la d pose 1 D pose de la roue avant 2 D p...

Страница 408: ...FRONT WHEEL AND FRONT BRAKE TT R125E Extent of removal Order Part name Q ty Remarks 11 Brake shoe 2 12 Spring 2 13 Brake camshaft lever 1 14 Wear indicator plate 1 15 Brake camshaft 1 16 Brake shoe p...

Страница 409: ...1 14 Verschlei anzeige 1 15 Bremsnocken 1 16 Bremsankerplatte 1 3 ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11...

Страница 410: ...runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set...

Страница 411: ...biegung 0 5 mm 0 020 in ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E PI CES D POSER Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement l aide d...

Страница 412: ...ce NOTE Replace the brake shoes and springs as a set if either is worn to the limit Brake shoe lining thickness Standard Limit 40 mm 0 16 in 2 0 mm 0 08 in 3 Measure Brake drum inside diameter a Out o...

Страница 413: ...chtig und gleichm ig polieren ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E Frein tambour 1 Contr ler Surface de garniture de m choire de frein Zones brillantes Poncer Util...

Страница 414: ...tor plate 1 NOTE When installing the wear indicator plate to the brake camshaft align the projection a on the wear indicator plate with the slots b on the brake camshaft 4 Install Brake camshaft lever...

Страница 415: ...emsbel ge auftra gen T R 10 Nm 1 0 m kg 7 2 ft lb New ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E REMONTAGE ET INSTALLATION Flasque de frein complet 1 Monter Came de frei...

Страница 416: ...am eter of the race of the bearing Left side of wheel 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...

Страница 417: ...NT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E Roue avant 1 Monter Roulement de roue 1 Entretoise 2 Roulement de roue 3 Bague d tanch it 4 N B Enduire le roulement de roue et la l vre de la bague...

Страница 418: ...R 45 Nm 4 5 m kg 32 ft lb 6 Install Brake cable NOTE Brake camshaft lever side of brake cable shall be installed first 7 Install Brake cable holder 1 T R 7 Nm 0 7 m kg 5 1 ft lb 8 Adjust Brake lever...

Страница 419: ...Siehe unter VORDERRADBREMSE EINSTELLEN IN KAPITEL 3 ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E 5 Monter crou d axe 1 T R 45 Nm 4 5 m kg 32 ft lb 6 Monter C ble de frein...

Страница 420: ...Preparation for removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Axle nut 1 2...

Страница 421: ...ter DEMONTAGEPUNKTE 8 Distanzst ck 1 9 Bremsscheibe 1 2 3 1 3 ROUE AVANT TT R125LWE VORDERRAD TT R125LWE ROUE AVANT TT R125LWE Organisation de la d pose 1 D pose de la roue avant 2 D pose des roulemen...

Страница 422: ...ring Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in EC51420...

Страница 423: ...in Max Seitenschlag 2 2 0 mm 0 08 in Maximal zul ssige Achsbiegung 0 5 mm 0 020 in PI CES D POSER Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement l aide d un extracteur...

Страница 424: ...AND INSTALLATION Front wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 NOTE Apply the lithium soap base grease on the wheel bearing and oil seal lip when installing Install the whe...

Страница 425: ...0 in New Disque de frein 1 Mesurer D formation du disque de frein Utiliser un comparateur cadran 1 Hors sp cifications V rifier la d forma tion de la roue Si la d formation de la roue est dans les lim...

Страница 426: ...T R 12 Nm 1 2 m kg 8 7 ft lb LT 3 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lips Install the longer collar on the brake disc 2 side 4 Install Front wheel NOTE Install t...

Страница 427: ...l ge 2 f hren 5 Montieren Radachse 1 6 Montieren Unterlegscheibe 1 Achsmutter 2 T R 45 Nm 4 5 m kg 32 ft lb 2 Monter Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tapes et dan...

Страница 428: ...he machine by placing the suitable stand under the engine Drain the brake fluid WARNING Support the machine securely so there is no danger of it falling over Refer to REMOVAL POINTS 1 Brake hose holde...

Страница 429: ...USBAU 7 Handbremshebel 1 8 Hauptbremszylinder Halterung 1 9 Hauptbremszylinder 1 2 3 1 3 2 FREIN AVANT TT R125LWE Organisation de la d pose 1 D pose du flexible de frein 2 D pose de l trier de frein 3...

Страница 430: ...YLINDER DISAS SEMBLY Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Brake pad 2 2 Brake caliper bracket...

Страница 431: ...1 0 Staubschutzkappe 1 A Sicherungsring 1 B Unterlegscheibe 1 C Hauptbremszylinder Bauteile 1 2 1 D MONTAGE DE L TRIER ET DU MA TRE CYLINDRE DE FREIN Organisation de la d pose 1 D montage de l trier...

Страница 432: ...parts Always clean up spilled fluid immediately Brake caliper 1 Remove Brake caliper 1 NOTE Turn the brake caliper counterclockwise and pull out it from the guide pin 2 on the brake caliper bracket B...

Страница 433: ...Bremssattelkolben vorsichtig mit Druckluft aus dem Bremssattel heraus pressen FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE PI CES D POSER Liquide de frein 1 D poser Couvercle de ma tre cylindre d...

Страница 434: ...s WARNING Replace the brake caliper piston seals and brake caliper dust seals whenever a brake caliper is disassembled INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a...

Страница 435: ...tbremszylinder Bauteile erneuern Joints de piston d trier de frein 1 D poser Joint antipoussi re d trier de frein 1 Joint de piston d trier de frein 2 N B Retirer les joints de piston d trier et les j...

Страница 436: ...ake caliper piston seals and brake caliper dust seals 2 whenever a brake caliper is disassembled 3 Inspect Brake caliper bracket 1 Cracks damage Replace the brake caliper assembly Guide pin 2 Rust dam...

Страница 437: ...EIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE trier de frein 1 Contr ler Surface int rieure du cylindre d trier de frein a Endommagement striation par usage Remplacer l trier de frein complet 2 Cont...

Страница 438: ...al Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper dust seal 2 WARNING Always use new brake caliper piston seals and brake caliper dust seals NOTE...

Страница 439: ...Auf Bremssattel Halterung 2 aufset zen New New FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE REMONTAGE ET INSTALLATION AVERTISSEMENT Nettoyer les pi ces internes exclusivement avec du liquide de f...

Страница 440: ...Nm 3 0 m kg 22 ft lb 4 Install Brake caliper 1 NOTE Apply the lithium soap base grease on the guide pin 2 Install the brake caliper into the guide pin and turn it clockwise 5 Install Brake caliper su...

Страница 441: ...ile Mit Bremsfl ssigkeit reinigen FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 2 Monter Manchon sup rieur 1 sur l trier de frein 2 N B Enduire la surface interne du manchon sup rieur de graisse b...

Страница 442: ...inder cup should be installed as shown direction Wrong instal lation cause improper brake performance 3 Install Spring 1 On brake master cylinder piston 2 NOTE Install the spring at the smaller diamet...

Страница 443: ...Montage des Sicherungsrings eine Zange mit langen Backen verwenden FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 2 Monter Coupelle primaire de ma tre cylindre de frein 1 Coupelle secondaire de ma...

Страница 444: ...olt brake lever 3 Nut brake lever 4 NOTE Apply the lithium soap base grease on the bolt and brake lever sliding surface Apply the molybdenum disulfide grease on the tip of the adjuster bolt T R 9 Nm 0...

Страница 445: ...ft lb FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE Ma tre cylindre de frein 1 Monter Ma tre cylindre de frein 1 Demi palier de fixation de ma tre cylindre de frein 2 Boulon demi palier de fixati...

Страница 446: ...WARNING Always use a new copper washer NOTE When turning the joint over the brake hose hold the brake hose so that it may not be twisted New T R 26 Nm 2 6 m kg 19 ft lb T R 14 Nm 1 4 m kg 10 ft lb 4...

Страница 447: ...rung 1 Schrauben Bremsschlauch Halterung 2 T R 7 Nm 0 7 m kg 5 1 ft lb FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 2 Faire passer le flexible de frein par le guide de c ble 1 3 Monter Rondelle e...

Страница 448: ...performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock CAUTION Brake fluid...

Страница 449: ...I TEL 3 FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE Liquide de frein 1 Remplir Liquide de frein jusqu ce que le niveau du liquide atteigne la ligne LOWER a AVERTISSEMENT Utiliser exclusivement l...

Страница 450: ...master cylinder cap 2 CAUTION After installation while pulling in the lever check whether there is any brake fluid leak ing where the union bolts are installed respectively at the brake master cylinde...

Страница 451: ...Bremssattel Bremsfl ssigkeit austritt T R 2 Nm 0 2 m kg 1 4 ft lb FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 4 Monter Diaphragme Couvercle de ma tre cylindre de frein 1 Vis couvercle de ma tre...

Страница 452: ...l REAR WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Brake rod 1 2 Axle nut 1 3 D...

Страница 453: ...e 1 10 Distanzh lse links 1 2 3 1 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE ROUE ARRI RE ET FREIN ARRI RE Organisation de la d pose 1 D pose de la roue arri re 2 D pose des roulement...

Страница 454: ...ut wheel sprocket 4 12 Wheel sprocket 1 13 Oil seal 1 14 Wheel bearing 2 Refer to REMOVAL POINTS 15 Spacer 1 16 Brake shoe 2 17 Spring 2 18 Brake camshaft lever 1 19 Wear indicator plate 1 20 Brake ca...

Страница 455: ...Feder 2 18 Bremsnocken Bet tigungshebel 1 19 Verschlei anzeiger 1 20 Bremsnocken 1 21 Bremsankerplatte 1 3 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11 crou pignon de roue arri re 4...

Страница 456: ...uller 2 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and...

Страница 457: ...m 0 08 in Max Seitenschlag 2 2 0 mm 0 08 in Maximal zul ssige Achsbiegung 0 5 mm 0 020 in PI CES D POSER Roue arri re 1 D poser Roue 1 N B Pousser la roue vers l avant et d poser la cha ne de transmis...

Страница 458: ...and paper NOTE After polishing wipe the polished particles with a cloth 2 Measure Brake shoe lining thickness a Out of specification Replace NOTE Replace the brake shoes and springs as a set if either...

Страница 459: ...ftsm ig Erneuern Bremstrommel Innendurchmes ser Standard Grenzwert 110 mm 4 33 in 111 mm 4 37 in N B Pour obtenir la d formation il faut diviser en deux la valeur affich e sur le comparateur cadran AV...

Страница 460: ...ake camshaft 1 NOTE Apply the lithium soap base grease on the brake camshaft 2 Check Brake camshaft operation Unsmooth operation Repair 3 Install Wear indicator plate 1 NOTE When installing the wear i...

Страница 461: ...ung a montieren wie in der Abbildung gezeigt T R 10 Nm 1 0 m kg 7 2 ft lb ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 4 Contr ler Surface int rieure du tambour de frein Taches d huile...

Страница 462: ...e brake shoe lin ings New Rear wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 NOTE Apply the lithium soap base grease on the oil seal lip when installing Install the bearing with...

Страница 463: ...ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 5 Monter Ressorts 1 M choires de frein 2 sur le flasque de frein 3 N B Enduire la goupille pivot de graisse base de savon au lithium Bien veiller ne pas...

Страница 464: ...hoe plate assembly Collar right NOTE Apply the lithium soap base grease on the oil seal lip 4 Install Rear wheel NOTE Make sure that the slot a on the brake shoe plate with the stopper b on the swinga...

Страница 465: ...er linken Seite aus montie ren ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 2 Monter Pignon de roue arri re 1 Rondelles d arr t 2 crou pignon de roue arri re 3 N B Serrer les crous par...

Страница 466: ...int 8 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 35 50 mm 1 4 2 0 in 9 Tighten Axle nut 1 T R 60 Nm 6 0 m kg 43 ft lb 10 Install Sprin...

Страница 467: ...ter HINTERRADBREMSE EINSTELLEN in KAPITEL 3 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 7 Monter Tendeur de cha ne de transmission droit 1 Rondelle plate 2 crou d axe 3 N B Serrer l cr...

Страница 468: ...able stand under the engine WARNING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND FRONT BRAKE section Refer to FRONT WHEEL section for the...

Страница 469: ...Klemmschraube untere Gabelbr cke 1 1 Nur lockern 5 Teleskopgabel 1 1 1 FOURCHE AVANT TELESKOPGABEL FOURCHE AVANT TT R125E TT R125LWE Organisation de la d pose 1 D pose de la fourche avant Organisatio...

Страница 470: ...Q ty Remarks FRONT FORK DISASSEMBLY A B 1 Dust boot 1 1 2 Cap bolt 1 1 Refer to REMOVAL POINTS 3 Spacer 1 4 Washer 1 1 5 Fork spring 1 1 Drain the fork oil 6 Dust seal 1 1 Use special tool Refer to RE...

Страница 471: ...htring 1 1 D Tauchrohr 1 1 2 1 FOURCHE AVANT TELESKOPGABEL D MONTAGE DE LA FOURCHE AVANT TT R125E TT R125LWE Organisation de la d pose 1 D pose de la bague d tanch it 2 D pose de la tige d amortisseur...

Страница 472: ...Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled EC553000 REMOVAL POINTS Cap bolt 1 Remove Cap bolt 1 From t...

Страница 473: ...ferrohrbuchse Metallh lse HINWEIS Den D mpferrohr Halter 1 und den T Hand griff 2 zum L sen der D mpferrohr Schraube verwenden FOURCHE AVANT TELESKOPGABEL REMARQUE CONCERNANT LA MANIPULATION N B Les t...

Страница 474: ...ith a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is...

Страница 475: ...6 mm 17 66 in FOURCHE AVANT TELESKOPGABEL Support de tige d amortisseur YM 1300 90890 01294 Poign e en T YM 1326 90890 01326 3 D poser Bague d tanch it 1 Se servir d un tournevis t te plate ATTENTION...

Страница 476: ...ge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube 2 Inspect Piston metal 1 Wear...

Страница 477: ...O Ring 2 Verschlei Besch digung Erneuern FOURCHE AVANT TELESKOPGABEL Tube plongeur 1 Contr ler Surface du tube plongeur a Striation par usage R parer ou rempla cer Utiliser du papier de verre humide...

Страница 478: ...per rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it and be damaged 3 Install Inner tube On outer tube 4 Install Copper washer Bo...

Страница 479: ...90 01294 T Griff YM 01326 90890 01326 New T R 23 Nm 2 3 m kg 17 ft lb LT FOURCHE AVANT TELESKOPGABEL REMONTAGE ET INSTALLATION Fourche avant 1 Nettoyer toutes les pi ces dans du dissolvant propre 2 Mo...

Страница 480: ...the oil seal into the outer tube with fork seal driver attachment 30 2 and fork seal driver weight 3 Fork seal driver weight YM 33963 90890 01367 Fork seal driver attachment YM 33281 90890 01400 New 6...

Страница 481: ...AVANT TELESKOPGABEL 5 Monter Bague d tanch it 1 N B Enduire le tube plongeur d huile de fourche Pour installer la bague d tanch it sans ab mer les l vres de la bague d tanch it se servir d une toile e...

Страница 482: ...ork leg TT R125E 159 cm3 5 60 Imp oz 5 38 US oz TT R125LWE 158 cm3 5 56 Imp oz 5 34 US oz 11 After filling pump the inner tube slowly up and down more than 10 times to dis tribute the fork oil 12 Meas...

Страница 483: ...ante des Standrohrs bei vollst ndig eingetauchtem Standrohr und ohne Gabelfeder FOURCHE AVANT TELESKOPGABEL 9 Comprimer fond la fourche avant 10 Remplir Huile de fourche avant 1 ATTENTION Utiliser san...

Страница 484: ...R125E TT R125LWE Front fork top end standard a Zero mm Zero in a 1 T R 23 Nm 2 3 m kg 17 ft lb 4 Tighten Pinch bolt lower bracket 1 Pinch bolt upper bracket 2 Screw dust boot 3 NOTE Make sure that the...

Страница 485: ...m 6 0 m kg 43 ft lb T R 25 Nm 2 5 m kg 18 ft lb 5 Montieren TT R125E Schutzkappe 1 FOURCHE AVANT TELESKOPGABEL Installation 1 Monter Fourche avant N B Serrer le boulon de pincement du t inf rieur de q...

Страница 486: ...al HANDLEBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Front brake cable 1 5 Start switch 1 6 Front brake lever 1 7 Grip cap lower 1 8 Grip cap upper 1 9 Throttle...

Страница 487: ...schalter 1 14 Lenkerhalter 2 15 Lenker 1 1 GUIDON LENKER GUIDON TT R125E Organisation de la d pose 1 D pose du guidon Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration la d pose D...

Страница 488: ...EBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Brake master cylinder 1 Refer to REMOVAL POINTS 5 Start switch 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle c...

Страница 489: ...er 1 12 Lenkerhalter 2 13 Lenker 1 1 GUIDON LENKER TT R125LWE Organisation de la d pose 1 D pose du guidon Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration la d pose D POSE DU GUI...

Страница 490: ...ASSEMBLY DISASSEMBLY Extent of removal 1 Throttle grip assembly disassembly Extent of removal Order Part name Q ty Remarks THROTTLE GRIP ASSEMBLY DISASSEMBLY 1 Handlebar grip right 1 Refer to REMOVAL...

Страница 491: ...I GN E DES GAZ 1 Poign e de guidon droite 1 Se reporter la section L MENTS D POSER 2 Entretoise paul e 2 3 Tube de commande des gaz 1 1 GASDREHGRIFF ZERLEGEN Demontage Arbeiten 1 Gasdrehgriff zerlegen...

Страница 492: ...master cylinder cap side horizontal to prevent air from coming in U P 1 2 Handlebar grip 1 Remove Handlebar grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the gri...

Страница 493: ...en ker zu richten weil dadurch seine Stabilit t verloren geht GUIDON LENKER PI CES D POSER Ma tre cylindre de frein TT R125LWE 1 D poser Demi palier de fixation de ma tre cylindre de frein 1 Ma tre cy...

Страница 494: ...dlebar 1 Install Handlebar 1 Handlebar holder 2 Main switch 3 Main switch holder 4 Bolt handlebar holder 5 NOTE Align the punched mark a on the handlebar with the upper surface of the handlebar holder...

Страница 495: ...e hinteren Schrauben festziehen T R 23 Nm 2 3 m kg 17 ft lb GUIDON LENKER REMONTAGE ET INSTALLATION Poign e des gaz compl te 1 Monter Entretoise paul e 1 Poign e de guidon droite 2 Enduire le tube de...

Страница 496: ...cap upper 2 Throttle cable 3 On tube guide 4 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 5 Install Throttle cable cap 1 Screw throttle cable...

Страница 497: ...g 2 9 ft lb GUIDON LENKER 2 Monter Poign e de guidon gauche 1 Enduire le guidon 2 d adh sif N B Avant d enduire le guidon a d adh sif nettoyer tout r sidu de graisse ou d huile avec du diluant pour pe...

Страница 498: ...er side 7 Install Engine stop switch 1 Clutch lever holder 2 Screws clutch lever holder 3 NOTE The engine stop switch and clutch lever holder should be installed according to the dimensions shown Pass...

Страница 499: ...ntacteur de d marrage 1 Boulons contacteur de d marrage 2 C ble de frein avant 3 Bride N B Enduire de graisse base de savon au lithium l extr mit du c ble de frein TT R125LWE Contacteur de d marrage 1...

Страница 500: ...lacing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Front forks Refer to FRONT FORK section Handlebar Refer to HANDLEBAR section Fr...

Страница 501: ...mutter unten 1 7 Untere Gabelbr cke 1 8 Lager Schutzkappe 1 1 2 DIRECTION LENKUNG DIRECTION Organisation de la d pose 1 D pose du t inf rieur 2 D pose de la tige d amortisseur ETAPES DE SERRAGE Serrer...

Страница 502: ...STEERING Extent of removal Order Part name Q ty Remarks 9 Bearing inner race upper 1 10 Bearing upper 1 11 Bearing outer race upper 1 Refer to REMOVAL POINTS 12 Bearing outer race lower 1 13 Bearing...

Страница 503: ...he unter DEMONTAGEPUNKTE 12 u erer Lager Laufring unten 1 13 Lager unten 1 2 DIRECTION LENKUNG Organisation de la d pose Ordre Nom de pi ce Qt Remarques 9 Cage interne haut de roulement 1 10 Roulement...

Страница 504: ...l down Steering nut wrench YU 33975 90890 01403 Bearing race 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer EC563300 Bearing lower 1 Remove Bearing lower 1 Use the flo...

Страница 505: ...en Lenkschaft 1 Verbiegung Besch digung Erneu ern DIRECTION LENKUNG PI CES D POSER crou cr nel 1 D poser crou cr nel 1 Utiliser la cl pour crou de direction 2 AVERTISSEMENT Soutenir la colonne de dire...

Страница 506: ...are not smooth in their operation in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Bearing lower 1 NOTE Apply the lithium soa...

Страница 507: ...ger und Dichtlippe der Lager Schutzkappe auftragen DIRECTION LENKUNG Billes et cages du roulement 1 Nettoyer les billes et les cages du roulement dans du dissolvant 2 Contr ler Billes de roulement Cag...

Страница 508: ...G HEAD INSPEC TION AND ADJUSTMENT section in the CHAPTER 3 6 Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bea...

Страница 509: ...Die Klemmschrauben der oberen Gabel br cke noch nicht festziehen DIRECTION LENKUNG 4 Monter T inf rieur 1 N B Enduire le roulement de graisse base de savon au lithium 5 Monter crou cr nel inf rieur 1...

Страница 510: ...not adjust the steering by loosening the ring nut little by little T R 110 Nm 11 0 m kg 80 ft lb 12 Adjust Front fork top end a TT R125E TT R125LWE Front fork top end standard a Zero mm Zero in a 13 T...

Страница 511: ...abelbr cke 1 Klemmschrauben obere Gabelbr cke 2 T R 60 Nm 6 0 m kg 43 ft lb T R 25 Nm 2 5 m kg 18 ft lb DIRECTION LENKUNG 9 Serrer crou de colonne de direction 1 10 Monter Capuchon 2 11 Apr s avoir se...

Страница 512: ...machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Rear wheel Refer to REAR WHEEL AND REAR BRAKE section 1 Drive chai...

Страница 513: ...dre 1 4 Boulon amortisseur arri re bascu leur 1 Maintenir le bras oscillant 5 Axe 1 6 Bras oscillant 1 1 SCHWINGE Demontage Arbeiten 1 Schwinge demontieren Demontage Arbeiten Reihen folge Bauteil Anz...

Страница 514: ...y 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Drive chain guard 1 2 Drive chain support 1 3 Drive chain guide 1 4 Dust cover 4 5 Collar 1...

Страница 515: ...Buchse 1 D Schwinge 1 3 1 2 BRAS OSCILLANT SCHWINGE D MONTAGE DU BRAS OSCILLANT Organisation de la d pose 1 D montage du bras oscillant 2 D pose et d montage du bras de raccordement 3 D pose et d mon...

Страница 516: ...gs as a set 2 Inspect Dust cover Damage Replace 3 Inspect Swingarm Damage bends cracks Replace Relay arm 1 Inspect Collar 1 Bushing 2 Damage pitting Replace collar and bushing as a set Bushing 3 Bushi...

Страница 517: ...bschutz 9 Besch digung Erneuern 3 Kontrollieren Umlenkhebel 0 Besch digung Verbiegung Kratzer Erneuern BRAS OSCILLANT SCHWINGE PI CES D POSER Bague 1 D poser Bague 1 N B Retirer la bague en la poussan...

Страница 518: ...ng arm 4 Damage bends cracks Replace EC575000 ASSEMBLY AND INSTALLATION Bushing 1 Install Bushing NOTE Make sure to press in the bushing so that they are flush with the surface of the connecting arm a...

Страница 519: ...hwinge HINWEIS Lagerbuchsen und Dichtlippen der Staub schutzabdeckungen mit Molybd ndisulfid bestreichen BRAS OSCILLANT SCHWINGE Bras de raccordement 1 Contr ler Entretoise paul e 1 Bague 2 Endommagem...

Страница 520: ...al lip and dust cover lip 3 Install Collar 1 Dust covers 2 On connecting arm NOTE Apply the molybdenum disulfide grease on the collar and dust cover lip 4 Install Relay arm 1 Bolt relay arm Plain wash...

Страница 521: ...streichen T R 70 Nm 7 0 m kg 50 ft lb T R 53 Nm 5 3 m kg 38 ft lb BRAS OSCILLANT SCHWINGE 2 Monter Bagues d tanch it 1 Entretoises paul es 2 Bague 3 Caches antipoussi re 4 Caches antipoussi re 5 Manch...

Страница 522: ...lb 7 Install Drive chain support 1 Collars Bolts drive chain support 2 Drive chain guard 3 Bolts drive chain guide 4 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb LT Installation 1 Install S...

Страница 523: ...en oder erneu ern T R 53 Nm 5 3 m kg 38 ft lb BRAS OSCILLANT SCHWINGE 5 Monter Bras de raccordement 1 Boulon bras de raccordement Rondelle plate crou bras de raccordement sur le bras relais N B Enduir...

Страница 524: ...Plain washer Nut connecting arm frame NOTE Apply the molybdenum disulfide grease on the bolt connecting arm frame T R 35 Nm 3 5 m kg 25 ft lb 5 Install Drive chain tensioner lower 1 Collar Bolt drive...

Страница 525: ...erbuchse mit Lithiumfett bestreichen T R 23 Nm 2 3 m kg 17 ft lb BRAS OSCILLANT SCHWINGE 3 Monter Boulon amortisseur arri re basculeur 1 Rondelle plate crou amortisseur arri re bras relais N B Enduire...

Страница 526: ...SSEMBLY REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Seat and side covers Refer to SEAT FUEL TA...

Страница 527: ...E 4 Hinterrad Sto d mpfer 1 1 COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER COMBIN RESSORT AMORTISSEUR ARRI RE Organisation de la d pose 1 D pose du combin ressort amortisseur arri re Orga...

Страница 528: ...ever tamper or attempt to open the rear shock absorber 2 Never throw the rear shock absorber into an open flame or other high heat The rear shock absorber may explode as a result of nitrogen gas expan...

Страница 529: ...en 5 Beim Entsorgen des Hinterradsto d mpfers m ssen die Anweisungen f r die Entsorgung befolgt werden COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMARQUE CONCERNANT LA MANIPULATION AVE...

Страница 530: ...the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped TT R125E TT R125LWE EC583000 REMOVAL POINTS Bushing 1 Remove Bushing 1 NOTE Remove the bushi...

Страница 531: ...eder auf und ab bewegen COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMARQUES SUR LA MISE AU REBUT CONCESSIONNAIRES YAMAHA UNIQUEMENT Il est indispensable d liminer la pression du gaz av...

Страница 532: ...Install Bolt rear shock absorber assembly frame Plain washer 1 Nut rear shock absorber assembly frame 2 NOTE Apply the molybdenum disulfide grease on the bolt rear shock absorber assembly frame T R 5...

Страница 533: ...g 25 ft lb COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMONTAGE ET INSTALLATION Bague 1 Monter Bague 1 N B Remettre la bague en place en la poussant Installation 1 Monter Combin ressort...

Страница 534: ...ottom portion directs as shown and lightly touches the projection a on the frame Install the rear shock absorber assembly sub tank with a clearance b between the sub tank and frame Fasten the sub tank...

Страница 535: ...TEL 2 T R 4 Nm 0 4 m kg 2 9 ft lb COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER 4 Monter TT R125LWE Sous r servoir de l ensemble de l amortis seur arri re 1 Crampon de vis 2 Attache 3 N B...

Страница 536: ...y 9 Starter relay 0 Fuse A Rectifier regulator B Neutral switch C CDI magneto D Starter motor E Spark plug COLOR CODE B Black Br Brown G Green O Orange R Red Sb Sky blue W White Y Yellow B W Black Whi...

Страница 537: ...u W wei Y gelb B W schwarz wei L Y blau gelb R W rot wei Die Abbildung zeigt die TT R125LWE SCHALTPLAN PARTIE LECTRIQUE QUIPEMENT LECTRIQUE ET SCH MA DE C BLAGE COMPOSANTS LECTRIQUES 1 Bloc CDI 2 Coup...

Страница 538: ...at 2 Fuel tank Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark p...

Страница 539: ...dans ce d pistage des pannes Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions du sys t me entier d allumage R parer ou remplacer Contr ler le coupe circuit principa...

Страница 540: ...Z ndenlage kon trollieren Erneuern oder instand setzen Z ndschalter kontrollieren Erneuern Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuern Sekund r spule Erneue...

Страница 541: ...ELEC MEMO...

Страница 542: ...rk gap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circ...

Страница 543: ...wei 3 Me kabel Kabel schwarz 4 Durchgang R 1 Br 2 B W 3 B 4 Me ger t Einstellung ON 1 OFF TEST DE LONGUEUR D ETINCELLE D ALLUMAGE 1 D connecter le capuchon de bougie de la bougie 2 Connecter le teste...

Страница 544: ...GNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace 2 Inspect Secondary coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis ta...

Страница 545: ...re Hors sp cification Remplacer N B Pour contr ler la r sistance de la bobine secon daire enlever le capuchon de bougie Fil de multim tre Fil orange 1 Fil de multim tre Fil noir 2 R sistance de bobine...

Страница 546: ...Red lead 1 Tester lead White lead 2 Pickup coil resistance Tester selector position 248 372 at 20 C 68 F 100 Br G R W 1 2 2 Inspect Source coil resistance Out of specification Replace Tester lead Brow...

Страница 547: ...gr n 2 Erregerspule Widerstand Me ger t Einstellung 688 1 032 bei 20 C 68 F 100 CONTROLE DE LA MAGNETO CDI 1 Contr ler R sistance de bobine d excitation Hors sp cification Remplacer Fil de multim tre...

Страница 548: ...erating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions h...

Страница 549: ...artermotor SYSTEM DE DEMARRAGE ELECTRIQUE FONCTIONNEMENT DU SYSTEME DE COUPURE DU CIRCUIT DE DEMARRAGE Lorsque le contacteur cl est sur ON le d mar reur ne fonctionne que si au moins une des deux cond...

Страница 550: ...ion Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check each coupler and w...

Страница 551: ...re YU 3112 C 90890 03112 1 Contr ler le fusible Remplacer le fusible et v rifier le faisceau de fils 2 Contr ler la batterie Recharger ou remplacer Contr ler la connexion de chaque raccord et fil R pa...

Страница 552: ...herung erneuern und Kabelbaum pr fen 2 Batterie kontrollieren Neu aufladen oder erneuern Alle Leitungsstecker und Kabelverbindungen kontrollieren Erneuern order instand setzen 3 Z ndschalter kontrolli...

Страница 553: ...ELEC MEMO...

Страница 554: ...the same capacity or more as that of the a battery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity STARTING CIR...

Страница 555: ...rot wei 3 Me kabel Kabel rot wei 4 R W 3 R W 4 Me ger t Einstellung An Batterie angeschlos sen 1 Nicht an Batterie angeschlos sen INSPECTION DE LA CONNEXION DES RACCORDS ET DES FILS 1 Contr ler Connex...

Страница 556: ...ter relay terminal 2 Tester lead Starter relay terminal 3 Tester lead Starter relay terminal 4 Ter minal 3 Ter minal 4 Tester selec tor position Connected to battery 1 Not connected to battery NEUTRAL...

Страница 557: ...Sb 1 B 2 Me ger t Einstellung LEERLAUF 1 GANG EIN GELEGT INSPECTION DU RELAIS DE DEMARREUR 1 D poser Relais de d marreur 2 Contr ler Conducteur de relais de d marreur Utiliser une batterie de 12 V Co...

Страница 558: ...Black lead 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PULL 1 FREE B B 1 2 START SWITCH INSPECTION 1 Inspect Start switch continuity No continuous while being pushed Replace Continuou...

Страница 559: ...Kabel schwarz 1 Me kabel Kabel schwarz 2 B 1 B 2 Me ger t Einstellung GE DR CKT 1 FREI INSPECTION DU CONTACTEUR D EMBRAYAGE 1 Contr ler Continuit du contacteur d embrayage Discontinuit quand tir Remp...

Страница 560: ...rder Part name Q ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Starter motor 1 STARTER MOTOR DISASSEM BLY 1 S...

Страница 561: ...t de d marreur 1 2 Rondelle couvercle avant de d mar reur 1 3 Rondelle bomb e 1 4 Circlip 1 5 Joint torique 3 1 STARTERMOTOR Demontage Arbeiten 1 Startermotor zerlegen Demontage Arbeiten Reihen folge...

Страница 562: ...CTRIC STARTING SYSTEM 7 4 3 5 2 1 5 8 0 9 0 9 5 6 1 New New New Extent of removal Order Part name Q ty Remarks 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rear cover 1 9 Brush 2 0 Bru...

Страница 563: ...e l armature 1 8 Couvercle arri re de d marreur 1 9 Balais 2 0 Ressort de balais 2 1 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 6 Startermotorjoch 1 7 Anker Baugruppe 1 8 Starterrotor R c...

Страница 564: ...ut to ensure proper operation of com mutator Commutator wear limit 21 0 mm 0 83 in Mica undercut 1 5 mm 0 06 in 4 Measure Armature assembly resistance com mutator and insulation Out of specification R...

Страница 565: ...nktion des Kommutators sicherzustellen Kommutatorverschlei grenze 21 0 mm 0 83 in Glimmerunterschneidung 1 5 mm 0 06 in INSPECTION ET REPARATION 1 Contr ler Commutateur Sale Nettoyer avec du papier de...

Страница 566: ...e Fatigue out of specification Replace as a set Brush spring force 5 52 8 28 N 560 840 g 19 8 29 7 oz ASSEMBLY 1 Install Brush spring 1 Brush 2 2 1 2 2 Install Armature assembly 1 Install while holdin...

Страница 567: ...e mit einem d nnen Schraubenzieher einge dr ckt wird ACHTUNG Darauf achten nicht die B rste beim Ein bau zu besch digen 5 Mesurer Longueur des balais a Hors sp cification Remplacer Limite d usure des...

Страница 568: ...washer 2 Washer starter motor front cover 3 Starter motor front cover 4 NOTE For installation align the projections on the washer with the slots in the front cover Align the match mark a on the starte...

Страница 569: ...5 Montieren Schraube 1 O Ring 2 HINWEIS Lithiumfett auf den O Rinmg auftragen New SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM 3 Monter Joint torique 1 Stator de d marreur 2 N B Faire co ncider...

Страница 570: ...before inspection 1 Seat 2 Rear fender 3 Fuel tank Use the following special tool in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 1...

Страница 571: ...outil sp cial suivant pour le contr le Multim tre YU 3112 C 90890 03112 Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 1 Contr ler le fusible Remplacer le fusible et contr ler le fais...

Страница 572: ...nden Taschen Multimeter YU 3112 C 90890 03112 Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 1 Sicherung kontrollieren Sicherung erneuern und Kabelbaum pr fen 2 Batterie kontrollieren Neu...

Страница 573: ...ELEC MEMO...

Страница 574: ...specification If no failure is found in checking the source coil resis tance replace the rectifier regulator Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester selector position 1...

Страница 575: ...rz 2 Ladespulen Widerstand Me ger t Einstellung 0 64 0 96 bei 20 C 68 F 1 INSPECTION DE LA CONNEXION DES RACCORDS ET DES FILS 1 Contr ler Connexion des raccords et des fils Rouille poussi re desserrag...

Страница 576: ......

Страница 577: ......

Страница 578: ...PRINTED IN JAPAN 2002 11 0 7 1 CR E F G PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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