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DEMONTAGE-EINZELHEITEN
Schaltgabeln, Schaltwalze und Getriebe

1. Demontieren:

• Schaltgabeln
• Schaltwalze
• Ausgangswelle komplett
• Eingangswelle komplett

HINWEIS:

• Zum Ausbau leicht mit einem Gummiham-

mer auf die Getriebe-Ausgangswelle und
Schaltwalze klopfen.

• Die Baugruppe vorsichtig demontieren. Die

entsprechende Einbaulage sämtlicher Teile
festhalten. Der Lage und Ausrichtung der
Schaltgabeln besondere Achtung schenken.

ZUSAMMENBAU UND MONTAGE
Getriebe, Schaltwalze und Schaltgabeln

1. Montieren:

• Eingangswelle komplett

• Ausgangswelle komplett

2. Montieren:

• Schaltgabel 1 “L”

• Schaltgabel 2 “R”

• Schaltwalze

• Führungsstange

HINWEIS:

Die Prägemarkierungen auf den Schaltgabeln
müssen in folgender Reihenfolge zur rechten
Motorseite gerichtet sein: “R”, “L”.

3. Kontrollieren:

• Funktion der Schaltung
• Funktion des Getriebes

Stockend

→

Erneuern.

FOURCHETTE DE SELECTION, TAMBOUR ET BOITE DE VITESSES

SCHALTGABELN, SCHALTWALZE UND GETRIEBE

POINTS DE DEPOSE
Fourchette de sélection, tambour et boîte de
vitesses

1. Déposer:

• Fourchettes de sélection
• Tambour
• Arbre secondaire complet
• Arbre primaire complet

N.B.:

• Tapoter légèrement l’arbre secondaire de trans-

mission et le tambour à l’aide d’un marteau en
caoutchouc pour les déposer.

• Déposer l’ensemble avec précaution. Prendre

note de la position de chaque pièce. Bien noter la
position et l’orientation des fourchettes de sélec-
tion.

ASSEMBLAGE ET MONTAGE
Boîte de vitesses, tambour et fourchette de sélec-
tion

1. Monter:

• Arbre primaire complet

• Arbre secondaire complet

2. Monter:

• Fourchette de sélection 1 “G”

• Fourchette de sélection 2 “D”

• Tambour

• Barre de guidage

N.B.:

Les repères poinçonnés des fourchettes de sélection
doivent être orientés vers la droite du moteur, et les
fourchettes être montées dans l’ordre suivant: “D”,
“G”.

3. Contrôler:

• Fonctionnement du sélecteur
• Fonctionnement de la boîte de vitesses

Fonctionnement irrégulier

→

Remplacer.

Содержание TT-R90(V)

Страница 1: ...0E V OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH PRINTED IN JAPAN 2005 04 0 3 1 CR E F G TT R90 V TT R90E V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 S...

Страница 2: ...V OWNER S SERVICE MANUAL 2005 by Yamaha Motor Co Ltd 1st Edition April 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly pr...

Страница 3: ...auch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R90 V TT R90E V MANUEL D ATELIER DU PROPRIETAIRE 2005 Yamaha Motor Co Ltd 1re dition a...

Страница 4: ...er 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 INSTRUC...

Страница 5: ...GESTATTET DIESES FAHRZEUG IST AUSSCHLIESS LICH F R DEN EINSATZ IM GEL NDE VORGESEHEN DER GEBRAUCH AUF FFENTLICHEN STRASSEN IST NICHT ZUL SSIG INTRODUCTION F licitations au propri taire de la TT R90 T...

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: ...k nnte umfallen SICHERHEITSINFORMATION NOTE IMPORTANTE Ce v hicule est con u uniquement pour une utilisa tion tout terrain par des pilotes tr s jeunes roulant sous la surveillance d un adulte apr s a...

Страница 8: ...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 poison ous and may cause loss of con sciousness and death wit...

Страница 9: ...Motorradbekleidung Hand schuhe Stiefel Hose und Jacke tra gen 4 Lors du transport de la moto dans un autre v hicule veiller le garder bien droit et ce que le robinet de carburant soit sur OFF Si le v...

Страница 10: ...is a one seater motorbike Don t 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 illustr...

Страница 11: ...tz 4 Handschuhe 5 Stiefel 6 Motocross Hose 7 Lang rmeliges Hemd 1 Ne pas rouler sur la route INFORMATION DE SECURITE 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il s agit d une moto une seule...

Страница 12: ...lone 7 Before riding the machine ask your par ents to check the machine very carefully 8 Don t touch the areas shown or you ll get burnt in the hand 9 Don t touch rotating or moving parts 10 Before st...

Страница 13: ...10 Vor dem Anlassen sicherstellen dass das Getriebe in der Leerlaufstellung ist 6 Toujours partir moto avec un parent ou ins tructeur Ne jamais partir seul 7 Avant de rouler demander ce qu un instruc...

Страница 14: ...to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer WARNING CAUTION EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of six chapters Gen...

Страница 15: ...rn COMMENT UTILISER CE MANUEL INFORMATIONS PARTICULIE REMENT IMPORTANTES Le symbole d alerte de s curit signifie ATTENTION SOYEZ VIGILANT VOTRE SECURITE EST EN JEU Le non respect des instructions AVER...

Страница 16: ...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 17: ...Informati onen ben tigen werden zus tzlich zur Explosionszeichnung und T tigkeits ber sicht erg nzende Schrittfolgen 6 aufge f hrt FORMAT DU MANUEL Dans ce manuel toutes les proc dures sont d crites p...

Страница 18: ...Tightening B Specified value Service limit C Engine speed D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagram indicate grade of lubricant and loca tion of lubr...

Страница 19: ...zu versehen sind I Klebemittel LOCTITE auftragen J Erneuern SYMBOLES GRAPHIQUES Voir l illustration Les symboles graphiques 1 6 servent a rep rer les diff rents chapitres et indiquer leur contenu 1 R...

Страница 20: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL...

Страница 21: ...PEC 2 REGELM SSIGE WARTUNGS UND EINSTELLARBEITEN 3 MOTOR ENG 4 FAHRWERK CHAS 5 ELEKTRISCHE ANLAGE ELEC 6 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES PERIODI...

Страница 22: ...12 STARTING AND OPERATION 1 13 CLEANING AND STORAGE 1 14 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITION OF UNITS 2 17...

Страница 23: ...TINEKONTROLLE VOR FAHRTBEGINN 3 3 MOTOR 3 4 FAHRWERK 3 12 ELEKTRISCHE ANLAGE 3 23 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS GENERAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MOTO 1 2 INFORMATIONS IMPO...

Страница 24: ...NETO AND STARTER CLUTCH TT R90E 4 41 CRANKCASE AND CRANKSHAFT 4 45 SHIFT FORK SHIFT CAM AND TRANSMISSION 4 48 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT FORK 5 10 HANDLEBAR 5 13 STEERING 5...

Страница 25: ...6 17 VERZEICHNIS DER WARTUNGSARBEITEN 6 21 CHAPITRE 4 MOTEUR CARBURATEUR 4 1 CULASSE 4 8 ARBRE A CAMES ET CULBUTEURS 4 13 SOUPAPES ET RESSORTS DE SOUPAPE 4 16 CYLINDRE ET PISTON 4 21 EMBRAYAGE 4 27 AR...

Страница 26: ...rottle grip 6 Fuel tank cap 7 Kick starter 8 Fuel tank 9 Air cleaner 0 Rear brake pedal A Fuel cock B Starter lever choke C Drive chain D Shift pedal E Front fork NOTE The machine you have purchased m...

Страница 27: ...und technischen Daten jederzeit vorbehalten Das abgebildete Modell ist TT R90E DESCRIPTION FAHRZEUGBESCHREIBUNG RENSEIGNEMENTS GENERAUX DESCRIPTION 1 Coupe circuit du moteur 2 Contacteur cl TT R90E 3...

Страница 28: ...achine KEY IDENTIFICATION NUMBER TT R90E 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 I...

Страница 29: ...t Die Codenummer und das Info K rzel werden zur Ersatzteilbestellung ben tigt IDENTIFICATION DE LA MOTO FAHRZEUG IDENTIFIZIERUNG IDENTIFICATION DE LA MOTO Il y a deux bonnes raisons de conna tre le nu...

Страница 30: ...Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have b...

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

Страница 32: ...EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or...

Страница 33: ...Nous recommandons d utiliser des pi ces Yamaha d origine pour tous les remplacements Utiliser les graisses et ou huiles recommand es par Yamaha lors des remontages et r glages JOINTS BAGUES D ETANCHEI...

Страница 34: ...etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air bower 3 Connect and disconnect the connector two or three times 4 Pull the lead to check that it will not come off 5 If the...

Страница 35: ...bliches Kontaktspray sollte nur als Notl sung verwendet werden Das Taschen Multimeter wie in der Abbil dung gezeigt anschlie en INFORMATIONS IMPORTANTES VERIFICATION DES CONNEXIONS WICHTIGE INFORMATI...

Страница 36: ...se tools are used when removing or installing the rocker arm shafts YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Ring nut wrench This tool is used when loosen the steering ring nut to specifi...

Страница 37: ...0890 01184 Fork seal driver weight This tool is used to installing the oil seal YM 33963 90890 01184 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checkin...

Страница 38: ...ller This tool is used to remove the rotor YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating sur face etc ACC QUICK GS...

Страница 39: ...extracteur inertie Cet outils sont utilis s pour la d pose ou la repose des axes de culbuteur YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Cl pour crou de direction Cet outil sert serrer l c...

Страница 40: ...184 Poids de montage de joint de fourche Cet outil permet de monter les bagues d tanch it YM 33963 90890 01184 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Cet instrument se...

Страница 41: ...t outil sert d poser le rotor YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 Cet agent d tanch it p te s utilise sur les plans de joint du carter moteur etc ACC QU...

Страница 42: ...ug Anwendung Abbildung YU 1083 A 90890 01084 90890 01085 Schlagabzieher Satz Gewicht Schlagabzieher Schraube Zum Ein und Ausbau der Kipphebelwellen YU 1083 A 90890 01084 90890 01085 YU 1268 90890 0126...

Страница 43: ...YM 33963 90890 01184 Gewicht des Gabeldichtring Treibers Zum Einbau des Gabeldichtrings YM 33963 90890 01184 YM 34487 90890 06754 Z ndfunkenstrecken Tester Z ndungstester Zur Pr fung des Z ndsystems...

Страница 44: ...bau des Rotors YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Dichtmasse Nr 1215 Zum Abdichten von Kurbelgeh use Passfl chen und dergleichen ACC QUICK GS KT 90890 85505 Teilenu...

Страница 45: ...GEN INFO MEMO...

Страница 46: ...an emer gency such when the machine is up set or trouble takes place in the throttle system The engine will not start or run when the engine stop switch is turned to START SWITCH TT R90E The start swi...

Страница 47: ...den ersten Gang schalten FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION FONCTIONS DES COMMANDES CONTACTEUR A CLE TT R90E Les fonctions correspondant aux diff rentes posi tions du conta...

Страница 48: ...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 from you...

Страница 49: ...die Hinterradbremse bet tigt FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION KICK AVERTISSEMENT Avant de mettre le moteur en marche ne pas oublier de mettre au point mort D ployer le ki...

Страница 50: ...position FILL THE TANK AT THE FIRST OPPORTUNITY BE SURE TO SET THE LEVER TO ON AFTER REFUEL ING STARTER LEVER CHOKE When cold the engine requires a richer air fuel mixture for starting A separate sta...

Страница 51: ...Ausf hrung ver schiedener Wartungs und Reparaturarbeiten FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION ROBINET DE CARBURANT Le robinet de carburant am ne le carburant du r servoir au c...

Страница 52: ...it may over 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 valve...

Страница 53: ...Imp gal 1 11 US gal Davon Reserve 0 5 L 0 11 lmp gal 0 13 US gal CARBURANT KRAFTSTOFF CARBURANT Utiliser de l essence normale Toujours utiliser de l essence fra che d une bonne marque AVERTISSEMENT N...

Страница 54: ...kstarter 1 Turn the fuel cock to ON 2 Turn the main switch to ON 3 Shift the transmission into neutral 4 Operate the starter choke and completely close the throttle grip 5 Slide the ENGINE STOP switch...

Страница 55: ...Placer le robinet de carburant en position ON 2 Placer le contacteur cl sur ON 3 Mettre au point mort 4 Tirer le starter et couper les gaz compl tement 5 Faire basculer le coupe circuit du moteur en...

Страница 56: ...ellen 2 Den Z ndschl ssel auf ON stellen 3 Das Getriebe in die Leerlaufstellung schalten 4 Den Choke bet tigen und den Gasdrehgriff ganz schlie en 5 Den Motorstoppschalter ENGINE STOP auf stellen 6 De...

Страница 57: ...and lubricate the chain to prevent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfaces Avoid c...

Страница 58: ...rouille 7 Nettoyer la selle l aide d un produit de net toyage pour similicuir afin de conserver intacts la souplesse et le lustre de la housse 8 De la cire pour automobile peut tre utilis e pour toute...

Страница 59: ...nd sofort schmieren um Korrosion zu verhindern 7 Die Sitzbank mit einem Reiniger f r Vinyl polster abwischen damit der Bezug geschmeidig und gl nzend bleibt 8 Lack und Chromfl chen k nnen mit Auto wac...

Страница 60: ...in Seat height 625 mm 24 6 in Wheelbase 1 040 mm 40 9 in Minimum ground clearance 160 mm 6 3 in Dry weight Without oil and fuel TT R90 60 0 kg 132 3 lb TT R90E 63 0 kg 138 9 lb Engine Engine type Air...

Страница 61: ...85 US qt Total amount 1 0 L 0 88 Imp qt 1 06 US qt Air filter Wet type element Fuel Type Unleaded gasoline only USA AUS and NZ Regular unleaded gasoline only CDN Europe and ZA Tank capacity 4 2 L 0 92...

Страница 62: ...N Type front and rear KNOBBY Tire pressure front and rear 100 kPa 1 00 kgf cm2 14 5 psi Brake Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Right foot...

Страница 63: ...und limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 034 21 134 mm 0 8281 0 8320 in 21 000 mm 0 8268 in...

Страница 64: ...9 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 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 5 0 9 mm 0 0197 0 354...

Страница 65: ...in 26 9 mm 1 06 in EX 32 45 mm 1 28 in 26 9 mm 1 06 in Set length valve closed IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Compressed pressure installed IN 138 158 N 14 07 16 11 kg 31 02 35 52 lb EX 138 15...

Страница 66: ...000 mm 0 5117 0 5118 in 12 980 mm 0 511 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 0 mm 0 04 0 08 in End gap installed 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Side clearance instal...

Страница 67: ...d Inner push cam push Push rod bending limit 0 5 mm 0 02 in Automatic centrifugal clutch Clutch in revolution 2 160 2 560 r min Clutch stall revolution 3 300 3 800 r min Shifter Shifter type Cam drum...

Страница 68: ...ump type Trochoid type Tip clearance A or B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Side clearance 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Housing and rotor clearance 0 06 0 10 mm 0 0024 0 0039 in...

Страница 69: ...0 2 7 0 7 5 1 Carburetor joint carburetor side M6 1 0 2 7 0 7 5 1 Air filter case M6 1 0 2 7 0 7 5 1 Exhaust pipe M6 1 0 2 7 0 7 5 1 Exhaust pipe protector M6 1 0 7 7 0 7 5 1 Silencer M8 1 25 1 24 2...

Страница 70: ...r travel 48 mm 1 89 in Spring free length 169 mm 6 65 in Fitting length 165 mm 6 5 in Spring rate STD K 45 6 N mm 4 65 kg mm 260 lb in Optional spring No Enclosed gas pressure 2 000 kPa 20 kg cm2 290...

Страница 71: ...n Front lining thickness 3 mm 0 12 in 2 mm 0 08 in Rear lining thickness 4 mm 0 16 in 2 mm 0 08 in Front shoe spring free length 32 7 mm 1 29 in Rear shoe spring free length 50 5 mm 1 99 in Brake leve...

Страница 72: ...20 2 0 14 Handle crown and handlebar holder lower M10 1 25 2 40 4 0 29 Handlebar holder upper TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Front brake cable holder and front fork M6 1 0 2 7...

Страница 73: ...n Pickup coil resistance color 248 372 at 20 C 68 F Red White CDI unit model manufacturer 4GL 20 YAMAHA Ignition coil Model manufacturer 2JN 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding re...

Страница 74: ...put 14 V 100 W at 5 000 r min Lighting coil 1 resistance color 0 64 0 96 at 20 C 68 F White Black Lighting coil 2 resistance color 0 52 0 78 at 20 C 68 F Yellow Black Rectifier regulator Regulator typ...

Страница 75: ...80 A Coil winding resistance 4 2 4 6 at 20 C 68 F Starting circuit cut off relay Model manufacturer ACM33221 MATSUSHITA Coil winding resistance 75 69 92 51 at 20 C 68 F Fuse amperage quantity Main fus...

Страница 76: ...A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6...

Страница 77: ...ur de la selle 625 mm 24 6 in Empattement 1 040 mm 40 9 in Garde au sol minimale 160 mm 6 3 in Poids sec Sans huile ni carburant TT R90 60 0 kg 132 3 lb TT R90E 63 0 kg 138 9 lb Moteur Type de moteur...

Страница 78: ...L 0 70 Imp qt 0 85 US qt Quantit totale 1 0 L 0 88 Imp qt 1 06 US qt Filtre air El ment de type humide Carburant Type Essence sans plomb uniquement USA AUS et NZ Essence normale sans plomb uniquement...

Страница 79: ...arri re CHENG SHIN Type avant et arri re KNOBBY Pression de gonflage avant et arri re 100 kPa 1 00 kgf cm2 14 5 psi Freins Type de frein avant Frein tambour Commande Main droite Type de frein arri re...

Страница 80: ...imite d ovalisation 0 05 mm 0 0020 in Arbre cames M thode de transmission Transmission par cha ne gauche Dimensions de came Admission A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 034 2...

Страница 81: ...in largeur de la port e B IN 1 19 2 51 mm 0 0469 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 in largeur du si ge C 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...

Страница 82: ...IN 32 45 mm 1 28 in 26 9 mm 1 06 in EX 32 45 mm 1 28 in 26 9 mm 1 06 in Longueur mont soupape ferm e IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Pression la compression mont IN 138 158 N 14 07 16 11 kg 31...

Страница 83: ...13 000 mm 0 5117 0 5118 in 12 980 mm 0 511 in Segments de piston Segment de feu Type Cylindrique Dimensions B T 1 0 2 0 mm 0 04 0 08 in Ecartement des becs segment mont 0 10 0 25 mm 0 004 0 010 in 0...

Страница 84: ...rmation de la tige de d brayage 0 5 mm 0 02 in Embrayage centrifuge automatique Vitesse d engagement de l embrayage 2 160 2 560 tr mn Vitesse de lib ration de l embrayage 3 300 3 800 tr mn S lecteur T...

Страница 85: ...huile Type de tamis Type de pompe huile Type trocho de Jeu entre rotors A ou B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Jeu entre le corps et le...

Страница 86: ...7 0 7 5 1 Raccord de carburateur c t carburateur M6 1 0 2 7 0 7 5 1 Bo tier de filtre air M6 1 0 2 7 0 7 5 1 Tube d chappement M6 1 0 2 7 0 7 5 1 Protection du tube d chappement M6 1 0 7 7 0 7 5 1 Si...

Страница 87: ...e D battement d amortisseur 48 mm 1 89 in Longueur de ressort libre 169 mm 6 65 in Longueur mont 165 mm 6 5 in Raideur de ressort standard K 45 6 N mm 4 65 kg mm 260 lb in Ressort en option Non Pressi...

Страница 88: ...110 mm 4 33 in 111 mm 4 37 in Epaisseur de la garniture frein avant 3 mm 0 12 in 2 mm 0 08 in Epaisseur de la garniture frein arri re 4 mm 0 16 in 2 mm 0 08 in Longueur libre de ressort de m choire de...

Страница 89: ...u guidon inf rieur M10 1 25 2 40 4 0 29 Support du guidon sup rieur TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Support de c ble de frein avant et fourche avant M6 1 0 2 7 0 7 5 1 Ecrou de...

Страница 90: ...0 C 68 F brun vert R sistance de la bobine d excitation couleur 248 372 20 C 68 F rouge blanc Bo tier CDI mod le fabricant 4GL 20 YAMAHA Bobine d allumage Mod le fabricant 2JN 00 YAMAHA Longueur d tin...

Страница 91: ...d le fabricant F5HN YAMAHA Puissance nominale 14 V 100 W 5 000 tr min R sistance de la bobine d clairage 1 couleur 0 64 0 96 20 C 68 F blanc noir R sistance de la bobine d clairage 2 couleur 0 52 0 78...

Страница 92: ...ECO Amp rage 180 A R sistance de l enroulement 4 2 4 6 20 C 68 F Relais de coupe circuit de d marrage Mod le fabricant ACM33221 MATSUSHITA R sistance de l enroulement 75 69 92 51 20 C 68 F Fusibles am...

Страница 93: ...ndent pour des filets propres et secs Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filet DEFINITION DES UNITES A crou B boulon SPECIFICATION DE CO...

Страница 94: ...he 865 mm 34 1 in Sitzh he 625 mm 24 6 in Radstand 1 040 mm 40 9 in Bodenfreiheit 160 mm 6 3 in Trockengewicht Ohne l und Kraftstoff TT R90 60 0 kg 132 3 lb TT R90E 63 0 kg 138 9 lb Motor Bauart Luft...

Страница 95: ...0 70 Imp qt 0 85 US qt Gesamtmenge 1 0 L 0 88 Imp qt 1 06 US qt Luftfilter Nassfiltereinsatz Kraftstoff Sorte Ausschlie lich bleifreies Benzin USA AUS und NZ Ausschlie lich bleifreies Normalbenzin CD...

Страница 96: ...nd hinten CHENG SHIN Modell vorn und hinten KNOBBY Reifenluftdruck vorn und hinten 100 kPa 1 00 kgf cm2 14 5 psi Bremsen Vorderradbremse Trommelbremse Bet tigung Handbremshebel rechts Hinterradbremse...

Страница 97: ...1 8524 in Max Ovalit t 0 05 mm 0 0020 in Nockenwelle Antriebsart Kettenantrieb links Nocken Abmessungen Einlass A 25 428 25 528 mm 1 0011 1 0050 in 25 400 mm 1 0000 in B 21 034 21 134 mm 0 8281 0 832...

Страница 98: ...49 3 07 mm 0 0587 0 1209 in Ventilsitz Breite C Einlass 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Auslass 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Ventilteller St rke D Einlass 0 5 0 9 mm 0 019...

Страница 99: ...in 26 9 mm 1 06 in Auslass 32 45 mm 1 28 in 26 9 mm 1 06 in Einbaul nge Ventil geschlossen Einlass 24 2 mm 0 95 in Auslass 24 2 mm 0 95 in Federkraft bei Einbaul nge Einlass 138 158 N 14 07 16 11 kg...

Страница 100: ...2 980 mm 0 511 in Kolbenringe 1 Kompressionsring Topring Ausf hrung Abgerundet Abmessungen B T 1 0 2 0 mm 0 04 0 08 in Ringsto in Einbaulage 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Ringnutspiel in...

Страница 101: ...tangen Verbiegung 0 5 mm 0 02 in Automatische Fliehkraftkupplung Einr ckdrehzahl 2 160 2 560 U min Anfahrdrehzahl 3 300 3 800 U min Schaltung Schaltmechanismus Schaltwalze und F hrungsstange Kickstart...

Страница 102: ...Bauart Trochoidenpumpe Rotor Radialspiel A oder B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Innen und Au enrotor Radialspiel 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Innen und Au enrotor Axialspiel 0...

Страница 103: ...1 0 2 7 0 7 5 1 Vergasereinlass Anschluss M6 1 0 2 7 0 7 5 1 Luftfiltergeh use M6 1 0 2 7 0 7 5 1 Auspuffkr mmer M6 1 0 2 7 0 7 5 1 Auspuffkr mmer Blende M6 1 0 7 7 0 7 5 1 Schalld mpfer M8 1 25 1 24...

Страница 104: ...Federweg 48 mm 1 89 in L nge der ungespannten Feder 169 mm 6 65 in Einbaul nge 165 mm 6 5 in Standard Federrate K 45 6 N mm 4 65 kg mm 260 lb in Umr stm glichkeiten Keine D mpfergasdruck 2 000 kPa 20...

Страница 105: ...37 in Vorderrad Trommelbrems Belag st rke 3 mm 0 12 in 2 mm 0 08 in Hinterrad Trommelbrems Belag st rke 4 mm 0 16 in 2 mm 0 08 in L nge der ungespannten Vorder rad Trommelbremsbelag R ckhol feder 32...

Страница 106: ...8 1 25 2 20 2 0 14 Obere Gabelbr cke und Lenkerhalter unten M10 1 25 2 40 4 0 29 Lenkerhalter oben TT R90 M6 1 0 4 13 1 3 9 4 TT R90E M8 1 25 4 23 2 3 17 Vorderrad Bremszughalterung und Gabel holme M6...

Страница 107: ...2 bei 20 C 68 F Braun Gr n Impulsgeber Widerstand Kabelfarbe 248 372 bei 20 C 68 F Rot Wei Z ndbox Typ Hersteller 4GL 20 YAMAHA Z ndspule Typ Hersteller 2JN 00 YAMAHA Min Z ndfunkenstrecke 6 mm 0 24 i...

Страница 108: ...Typ Hersteller F5HN YAMAHA Nennleistung 14 V 100 W bei 5 000 U min Widerstand Kabelfarbe der Lichtspule 1 0 64 0 96 bei 20 C 68 F Wei Schwarz Widerstand Kabelfarbe der Lichtspule 2 0 52 0 78 bei 20 C...

Страница 109: ...DECO Nennstromst rke 180 A Wicklungs Widerstand 4 2 4 6 bei 20 C 68 F Anlasssperrrelais Typ Hersteller ACM33221 MATSUSHITA Wicklungs Widerstand 75 69 92 51 bei 20 C 68 F Sicherungs St rke Anzahl Siche...

Страница 110: ...ie genannten Anzugsmomente f r saubere und trockene Schraubverbindun gen bei Raumtemperatur A Schl sselweite B Gewindedurchmesser MASSEINHEITEN A Mutter B Schrau be ANZUGSMOMENT Nm m kg ft lb 10 mm 12...

Страница 111: ...2 18 SPEC MEMO...

Страница 112: ...ark plug lead 0 Throttle cable A Cable holder B Fuel tank breather hose C Brake cable After fastening the starter cable CDI magneto lead wire harness and thermo switch lead cut off any excess from the...

Страница 113: ...en CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME CHEMINEMENT DES CABLES TT R90 1 Durit de mise l air du carter moteur 2 Faisceau de fils 3 Fil du volant magn tique CDI 4 C ble de starter 5 Fil de chau...

Страница 114: ...oil 9 Cable guide 0 Wire harness A Damper B CDI unit lead C CDI unit D Rectifier regulator lead E Rectifier regulator F Crankcase breather hose G Carburetor breather hose H Spark plug lead I Fuel hose...

Страница 115: ...tmaschinen Kabel L Thermoschalter CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME 1 Guide c ble 2 C ble de frein 3 C ble des gaz 4 Durit de mise l air du r servoir de carburant 5 Fil du coupe circuit du...

Страница 116: ...Fasten the CDI unit lead and rectifier regulator lead with the plastic clamp Align the tape on the rectifier regulator lead with the plastic clamp After fastening the engine stop switch lead cut off a...

Страница 117: ...Das Lichtmaschinen Kabel durch die F hrung leiten CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Acheminer la durit de mise l air de r servoir de car burant dans le guide c ble Acheminer le c ble des...

Страница 118: ...e cable C Brake cable D Engine stop switch lead E Main switch lead F Start switch lead Pass the spark plug lead through the lead guide Make sure that the starter cable does not contact the engine brac...

Страница 119: ...befestigen CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME TT R90E 1 Durit de mise l air du carter moteur 2 Fil du volant magn tique CDI 3 Faisceau de fils 4 Contacteur thermique 5 Fil du contacteur th...

Страница 120: ...Fuel hose J Carburetor heater lead K Carburetor breather hose L Carburetor heater coupler M CDI magneto coupler N CDI unit coupler O CDI unit connector P CDI unit lead Q Thermo switch lead R Thermo sw...

Страница 121: ...LF HRUNGSDIAGRAMME 1 Collier pince 2 Fil du coupe circuit du moteur 3 Fil du contacteur cl 4 Fil du contacteur du d marreur 5 C ble de frein 6 C ble des gaz 7 Durit de mise l air du r servoir de carbu...

Страница 122: ...stic locking tie For fastening pass the plastic locking tie through the hole in the bracket After fastening the starter motor lead cut off any excess from the plastic locking tie end After fastening t...

Страница 123: ...GRAMME Acheminer le fil du contacteur du d marreur le fil du contacteur cl le fil du coupe circuit du moteur et le c ble des gaz par le guide c ble Acheminer la durit de mise l air de r servoir de car...

Страница 124: ...e start switch lead main switch lead and engine stop switch lead at the tape with the plastic locking tie Fasten the battery leads Fasten the wire harness and starting circuit cut off relay lead at th...

Страница 125: ...EMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Attacher le c ble de starter le fil du contacteur ther mique le fil du bo tier CDI le fil du contacteur cl et le fil du coupe circuit du moteur Attacher le...

Страница 126: ...t cut off relay lead does not contact the spring rear shock absorber Position the wire harness CDI magneto lead thermo switch lead and CDI unit lead as shown A A A C C D B B B B F F F E E D A A B B E...

Страница 127: ...ie Z ndbox Kabel wie abgebil det platzieren CHEMINEMENT DES CABLES KABELF HRUNGSDIAGRAMME Acheminer le fil du relais de d marreur dans le relais de d marreur Placer les extr mit s du ruban blanc dans...

Страница 128: ...nce Check and adjust valve clearance when engine is cold 4 Air filter element Clean with solvent Replace if necessary 5 Breather system Check ventilation hose for cracks or damage Replace if necessary...

Страница 129: ...m soap based grease lightly 21 Front fork Check operation and for oil leakage Replace if necessary 22 Shock absorber assembly Check operation and for oil leakage Replace if necessary 23 Control cables...

Страница 130: ...D MAINTENANCE Item Routine Page Brake Check operation adjustment P3 12 Engine oil Change oil as required P3 6 8 Drive chain Check alignment adjustment lubrication P3 13 15 Spark plug Check color condi...

Страница 131: ...at R gler l cartement et nettoyer 3 Jeu aux soupapes V rifier et ajuster le jeu aux soupapes lorsque le moteur est froid 4 El ment du bo tier de filtre air Nettoyer l aide d un solvant Remplacer si n...

Страница 132: ...ein Appliquer l g rement de la graisse base de savon au lithium 20 Pivot de b quille Contr ler le fonctionnement Appliquer l g rement de la graisse base de savon au lithium 21 Fourche Contr ler le fon...

Страница 133: ...ement et le r glage P3 12 Huile moteur Changer l huile comme sp cifi P3 6 8 Cha ne de transmission Contr ler l alignement le r glage et la lubrification P3 13 15 Bougie Contr ler la couleur et l tat P...

Страница 134: ...n 2 Z ndkerze Zustand pr fen Elektrodenabstand einstellen und reinigen 3 Ventilspiel Das Ventilspiel bei kaltem Motor kontrollieren und einstellen 4 Luftfiltereinsatz Mit L sungsmittel s ubern Gegeben...

Страница 135: ...bestreichen 20 Seitenst nder Drehpunkt Funktion kontrollieren Leicht mit Lithiumseifenfett bestreichen 21 Teleskopgabel Funktion pr fen und auf Undichtigkeit untersuchen Gegebenenfalls erneuern 22 Fed...

Страница 136: ...ollpunkt Ausf hrung Seite Bremsen Funktion und Einstellung kontrollieren S 3 12 Motor l Gegebenenfalls wechseln S 3 6 8 Antriebskette Ausrichtung Spannung und Schmierzustand kontrollieren S 3 13 15 Z...

Страница 137: ...INSP ADJ MEMO...

Страница 138: ...gine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage Throttle grip free play adjustment steps NOTE Before adj...

Страница 139: ...ISSEMENT Apr s le r glage tourner le guidon vers la droite et vers la gauche et contr ler que le r gime de ralenti du moteur ne change pas 3 4 MOTOR GASZUG EINSTELLEN 1 Kontrollieren Gaszugspiel a am...

Страница 140: ...n squeezing the element Leaving too much of solvent in the ele ment may result in poor starting 4 Inspect Air filter element Damage Replace 5 Apply Foam air filter oil or engine mixing oil To the elem...

Страница 141: ...filtre air et les trous b de l l ment du bo tier de filtre air 7 Monter Couvercle du bo tier de filtre air 8 Monter Prise d air droite 3 5 1 Montieren Lufthutze rechts 1 2 Montieren Luftfilter Geh use...

Страница 142: ...ow Add oil to proper level NOTE When inspecting the oil level do not screw the dipstick into the oil tank Insert the gauge lightly For USA and CDN CAUTION Do not add any chemical additives Engine oil...

Страница 143: ...huile moteur SAE 10W 30 de type SE SF SG A 5 C 40 F ou plus Yamalube 4 20W 40 ou huile moteur SAE 20W 40 de type SE SF SG 3 6 MOTOR LSTAND KONTROLLIEREN 1 Den Motor anlassen einige Minuten lang warm...

Страница 144: ...E Wait a few minutes until the oil settles before inspecting the oil level Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommend...

Страница 145: ...n des diff rentes temp ratures atmos ph riques Classification des huiles moteur recommand es NORME API API SE SF SG ou qualit sup rieure destin e essentiellement aux motos 3 7 Nicht USA und CDN ACHTUN...

Страница 146: ...oil change 0 8 L 0 70 Imp qt 0 85 US qt 7 Install Dipstick 8 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPEC TION PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjusti...

Страница 147: ...mais sans forcer D visser du nombre de tours sp cifi s Vis d air de ralenti D visser de 1 3 4 tour 3 8 5 Montieren Dichtung Ablassschraube New T R 20 Nm 2 0 m kg 14 ft lb 6 Bef llen Kurbelgeh use lle...

Страница 148: ...eck or adjust the valve clearance 1 Remove Air scoop right 1 Air filter case 2 2 Remove Spark plug Tappet cover intake side 1 Tappet cover exhaust side 2 Adjustment steps Adjust the pilot screw Refer...

Страница 149: ...s gaz 1 dans le sens a Pour diminuer le r gime de ralenti Tour ner la vis de but e de papillon des gaz 1 dans le sens b Compte tours inductif YU 8036 B 90890 03113 R gime de ralenti 1 400 1 600 tr mn...

Страница 150: ...C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance Adjustment steps Loosen the locknut 1 Turn the adjuster 3 in or out with the valve adju...

Страница 151: ...soupapes Si le jeu est incorrect r p ter les tapes ci des sus jusqu obtention du jeu sp cifi T R 7 Nm 0 7 m kg 5 1 ft lb 3 10 4 Kontrollieren Ventilspiel Nicht nach Vorgabe Korrigieren 5 Einstellen V...

Страница 152: ...not start the engine when cleaning the exhaust system 1 Remove Bolt tailpipe 1 2 Remove Tailpipe 2 Pull the tailpipe out of the muffler 3 Clean Spark arrester Use a wire brush to remove any carbon de...

Страница 153: ...ent et aligner le trou du boulon Boulon tuyau d chappement arri re T R 18 Nm 1 8 m kg 13 ft lb New T R 18 Nm 1 8 m kg 13 ft lb New T R 13 Nm 1 3 m kg 9 4 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7...

Страница 154: ...ee play Adjustment steps Loosen the locknuts 1 Turn the adjusters 2 in or out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the...

Страница 155: ...age 1 jusqu obtention du jeu sp cifi Visser Le jeu diminue D visser Le jeu augmente ATTENTION Apr s le r glage contr ler que le frein ne frotte pas 3 12 FAHRWERK VORDERRADBREMSE EINSTELLEN 1 Kontrolli...

Страница 156: ...ve chain 2 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain 3 Measure Drive chain length 15 links a Out of spec...

Страница 157: ...ONTR LE DES PIGNONS CONTR LE DE LA CHA NE DE TRANSMISSION KETTENR DER KONTROLLIEREN ANTRIEBSKETTE KONTROLLIEREN CONTR LE DES PIGNONS 1 Contr ler Dent de pignon a Usure excessive Changer N B Changer le...

Страница 158: ...nts DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Check Drive chain slack a In the center between the drive axle and rear wheel axle Out of sp...

Страница 159: ...LA CHAINE DE TRANSMISSION ANTRIEBSKETTEN DURCHHANG EINSTELLEN 5 Monter Cha ne de transmission 1 Maillon d tachable 2 Agrafe de maillon d tachable 3 ATTENTION Bien veiller reposer l agrafe de maillon...

Страница 160: ...s a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear CAUTION Too small chain slack will overload the engine and othe...

Страница 161: ...n douceur de la fourche avant Actionner le frein avant et enfoncer la four che Fonctionnement dur fuite d huile R parer ou remplacer 3 15 3 Einstellen Antriebsketten Durchhang Antriebsketten Durchhang...

Страница 162: ...levate the rear wheel by placing the suit able stand under the engine 2 Remove Rear shock absorber Refer to SWINGARM section in the CHAPTER 5 3 Remove Spring guide 1 NOTE While compressing the spring...

Страница 163: ...la pr contrainte du ressort monter le circlip dans la rainure b N B Ne pas trop carter le circlip Position de montage standard Rainure b 5 Monter Guide de ressort 1 N B Monter le guide du ressort en...

Страница 164: ...tes that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100...

Страница 165: ...ler retendre ces rayons avant et apr s le rodage Apr s un entra nement ou une course con tr ler le serrage des rayons T R 2 Nm 0 2 m kg 1 4 ft lb 3 17 6 Montieren Federbein Siehe unter SCHWINGE in KAP...

Страница 166: ...ront wheel by placing a suit able stand under the engine 2 Check Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check St...

Страница 167: ...ection Etapes de r glage de l crou de direction D poser le garde boue avant 1 D poser le guidon et le t sup rieur Desserrer l crou de direction 2 l aide de la cl pour crou de direction 3 3 18 R DER KO...

Страница 168: ...the ring nut using the ring nut wrench WARNING Avoid over tightening T R Ring nut final tightening 1 Nm 0 1 m kg 0 7 ft lb Check the steering shaft by turning it lock to lock If there is any binding r...

Страница 169: ...ni re que les espaces b soient gaux T R Boulon de colonne de direction 40 Nm 4 0 m kg 2 9 ft lb Bouchon de tube de fourche 40 Nm 4 0 m kg 2 9 ft lb Support de guidon sup rieur 13 Nm 1 3 m kg 9 4 ft lb...

Страница 170: ...wrench so that they form a right angle Ring nut wrench YM 33975 90890 01403 T R Ring nut initial tightening 38 Nm 3 8 m kg 27 ft lb Loosen the ring nut one turn Retighten the ring nut using the ring...

Страница 171: ...ournant d une but e l autre S il y a la moindre g ne d monter l arbre de direction complet et con tr ler les paliers de la direction Reposer le t sup rieur 6 le commutateur cl 7 le guidon 8 et le gard...

Страница 172: ...handlebar holder should be installed with the punched mark b for ward CAUTION First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side T R Steerin...

Страница 173: ...tion 40 Nm 4 0 m kg 2 9 ft lb Bouchon de tube de fourche 40 Nm 4 0 m kg 2 9 ft lb Support de guidon sup rieur 23 Nm 2 3 m kg 17 ft lb 3 21 HINWEIS Die Lenker Halterung so montieren dass deren Kerbe a...

Страница 174: ...ke lever pivot 3 Shift 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 cable end Use Yamaha cable lube or equ...

Страница 175: ...les ou d un produit quivalent Utiliser de l huile moteur SAE 10W 30 ou un lubri fiant pour cha nes ad quat Lubrifier les points suivants l aide de graisse fluide base de savon de lithium de haute qual...

Страница 176: ...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 177: ...ter une bougie nettoyer le plan de joint et la surface de la bougie Serrer la bougie la main a avant de la serrer au couple correct b T R 13 Nm 1 3 m kg 9 4 ft lb 3 23 ELEKTRISCHE ANLAGE Z NDKERZE KON...

Страница 178: ...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 179: ...rm ment la m thode de charge illustr e dans ce manuel Si l on surcharge la batterie son niveau d lectro lyte diminuera consid rablement Il convient donc de charger la batterie avec beaucoup de prudenc...

Страница 180: ...ead coupler 1 from the battery terminals NOTE Push down on the tab a and then remove the battery lead coupler 3 Remove Battery 1 a 4 Measure Battery charge Measurement steps Connect a pocket tester 1...

Страница 181: ...mesurant la tension entre ses bornes en circuit ouvert c est dire la ten son apr s d connexion de la borne positive Inutile de recharger tant que la tension en cir cuit ouvert est sup rieure ou gale 1...

Страница 182: ...0 30 5 Charge Battery refer to the appropriate 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 charge...

Страница 183: ...t tre char g e sur la moto d connecter le c ble n gatif de la borne de la batterie Afin de r duire le risque de production d tin celles ne pas brancher le chargeur de batterie avant d avoir connect le...

Страница 184: ...ct 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 reconnect...

Страница 185: ...en se stabilise environ 30 minutes apr s la fin de la charge Par cons quent attendre 30 minutes apr s la charge avant de mesurer la tension en circuit ouvert 3 27 Ebenso die Anschlussklemmen des Lade...

Страница 186: ...dard charging amperage exceeded NO YES If the amperage does not exceed the standard charg ing amperage after 5 min utes replace the battery If the required charging time exceeds 5 hours it is advisabl...

Страница 187: ...reaches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the batter...

Страница 188: ...e charge standard est il d pass NON OUI Si le courant ne d passe pas le courant de charge standard apr s 5 minutes remplacer la batterie Si le temps de charge requis d passe 5 heures il est conseill d...

Страница 189: ...atterie pendant plus de 30 minutes avant de mesurer sa tension en circuit ouvert 12 8 V La charge est termin e 12 0 12 7 V Une nouvelle charge est n cessaire Moins de 12 0 V Remplacer la batterie Ce t...

Страница 190: ...omst rke berschritten NEIN JA bersteigt die Amperezahl nach f nf Minuten nicht die normale Ladestromst rke muss die Batterie ersetzt werden bersteigt die ben tigte Ladezeit f nf Stunden ist es ratsam...

Страница 191: ...essen der Ruhespannung die Batterie mindestens 30 Minuten lang nicht benutzen 12 8 V Der Ladevorgang ist abge schlossen 12 0 12 7 V Weiteres Laden ist erfor derlich Unter 12 0 V Die Batterie erneuern...

Страница 192: ...Recommended lubricant Lithium soap base grease FUSE INSPECTION TT R90E CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Seat Rear fender 2...

Страница 193: ...ircuit N B R gler le s lecteur du multim tre sur 1 Multim tre YU 03112 C 90890 03112 Si le multim tre indique remplacer le fusible 3 30 6 Montieren Batterie 7 Kontrollieren Batteriepole Verschmutzt Mi...

Страница 194: ...damage to the electrical system cause the starting and ignition systems to malfunction and could possibly cause a fire 4 Install Rear fender Seat Replacement steps Set the main switch to OFF Install a...

Страница 195: ...onctionne Si le fusible grille nouveau imm diatement contr ler le circuit lectrique El ments Amp rage Q t Fusible principal 10 A 1 3 31 3 Erneuern durchgebrannte Sicherung WARNUNG Eine Sicherung niema...

Страница 196: ...ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank 1 Clamp air filter joint 1 Loosen the screw air filter joint 2 Carburetor heater lead 1 3 Air vent hose 1 4 Fuel hose 1 5 Bolt 2 6 Carbu...

Страница 197: ...zst ck 1 9 Vergaserdeckel 1 10 Chokeschieber 1 1 CARBURATEUR VERGASER MOTEUR CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre Nom de la pi ce Q t Remarques...

Страница 198: ...disassembly Extent of removal Order Part name Q ty Remarks CARBURETOR DISASSEMBLY 1 Throttle valve 1 2 Throttle cable 1 3 Spring 1 4 Gasket 1 5 Carburetor top cover 1 6 Jet needle stopper 1 7 Jet nee...

Страница 199: ...hokeschieber 1 9 Chokezug 1 0 Schwimmerkammer 1 1 CARBURATEUR VERGASER DEMONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de la pi ce Q t...

Страница 200: ...R Extent of removal Order Part name Q ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1 G Throttle stop screw assembly 1 H Pilot air screw assembly 1 I Carb...

Страница 201: ...ube 1 H Leerlaufgemisch Regulier schraube 1 I Vergaserheizung 1 1 CARBURATEUR VERGASER Organisation de la d pose Ordre Nom de la pi ce Q t Remarques A Axe de flotteur 1 B Flotteur 1 C Pointeau 1 D Gic...

Страница 202: ...jet 1 Pilot jet 2 Needle jet 3 Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire Needle valve 1 I...

Страница 203: ...NWEIS Den Gasschieber 1 in das Vergasergeh use einsetzen und dessen Leichtg ngigkeit kon trollieren CARBURATEUR VERGASER CONTROLE Carburateur 1 Contr ler Corps du carburateur Encrass Nettoyer N B Nett...

Страница 204: ...the measurement when the needle valve aligns with the float arm If the carburetor is level the weight of the float will push in the needle valve resulting in an incorrect measurement Measure the dist...

Страница 205: ...sind den Schwimmerstand durch leichtes Biegen der Lasche 1 ein stellen Den Schwimmerstand erneut kontrollie ren CARBURATEUR VERGASER Aiguille 1 Contr ler Aiguille 1 D formation usure Remplacer Rainur...

Страница 206: ...rew until it is lightly seated Back out it by the specified number of turns Pilot air screw 1 3 4 turns out 2 Install Throttle valve 1 Starter plunger 2 NOTE Align the slit a of the throttle valve wit...

Страница 207: ...e sind leicht ent flammbar und explosiv Deshalb Funken offene Flammen brennende Zigaretten und andere Feuerquellen fernhalten CARBURATEUR VERGASER Flotteur 1 Contr ler Flotteur 1 Endommagement Remplac...

Страница 208: ...4 7 ENG CARBURETOR 1 Measure Fuel level a Use a fuel level gauge 1 Out of specification Adjust Fuel level gauge YM 1312 A 90890 01312 Fuel level 2 3 mm 0 08 0 12 in below the float chamber line...

Страница 209: ...A 90890 01312 Kraftstoffstand 2 3 mm 0 08 0 12 in unterhalb der Schwimmerkammer Markierung CARBURATEUR VERGASER 1 Mesurer Niveau de carburant a Utiliser une jauge de niveau de carburant 1 Hors sp cifi...

Страница 210: ...d rear fender Exhaust pipe Carburetor Refer to CARBURETOR section Air filter case and starter lever 1 Plug cap spark plug 1 1 2 Crankshaft end cover O ring 1 1 3 Timing plug O ring 1 1 4 Camshaft spro...

Страница 211: ...NZELHEITEN 8 Steuerkettenspanner 1 9 Dichtung 1 1 CULASSE ZYLINDERKOPF CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de la pi ce Q t Remarques DEPOSE DE...

Страница 212: ...4 9 ENG CYLINDER HEAD Extent of removal Order Part name Q ty Remarks 10 Camshaft sprocket 1 Refer to REMOVAL POINTS 11 Timing chain 1 12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2 1...

Страница 213: ...DEMON TAGE EINZELHEITEN 11 Steuerkette 1 12 Zylinderkopf 1 13 Dichtung 1 14 Passh lse 2 1 CULASSE ZYLINDERKOPF Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 10 Pignon d arbre cames 1 S...

Страница 214: ...enter 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 sta tionary pointer d on the cylinder head as shown in the illu...

Страница 215: ...urbelgeh use hinab f llt Beim Demontieren der Schraube 1 die Rotor Mutter mit einem Schraubenschl ssel gegenhalten CULASSE ZYLINDERKOPF POINTS DE DEPOSE Culasse 1 Aligner Rep re I avec index fixe Etap...

Страница 216: ...ration Tighten the bolts and nuts in two stages T R 22 Nm 2 2 m kg 16 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Camshaft sprocket 1 Installation steps Turn the crankshaft counterclockwise until the...

Страница 217: ...ge des Nockenwellenrads darauf achten dass die Steuerkette an der Auslassseite m glichst straff ist CULASSE ZYLINDERKOPF 4 D poser Culasse N B Desserrer les boulons et crous dans l ordre de desserrage...

Страница 218: ...rk Align with the crankcase stationary pointer Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Installation steps Remove the tensioner cap bolt...

Страница 219: ...rschrifts m ig festziehen T R Verschlussschraube 8 Nm 0 8 m kg 5 8 ft lb CULASSE ZYLINDERKOPF ATTENTION Veiller ce que le vilebrequin reste immobile pendant la repose de l arbre cames Cela risquerait...

Страница 220: ...name Q ty Remarks CAMSHAFT AND ROCKER ARMS Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Rocker arm shaft intake 1 Use special tool Refer to REMOVAL POINTS 2 Rocker arm shaft...

Страница 221: ...ntilspiel Einstellschraube 2 7 Ventilspiel Einstellschraube 2 2 1 ARBRE A CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL ARBRE A CAMES ET CULBUTEURS Organisation de la d pose 1 D pose du culbuteur 2 D...

Страница 222: ...ide hammer bolt 90890 01085 Weight 90890 01084 INSPECTION Camshaft 1 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 25 398 mm 0 9999 in b 21 004 mm 0 826...

Страница 223: ...r l auf das Nockenwellenlager 2 Montieren Nockenwelle 1 ARBRE A CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL POINTS DE DEPOSE Axe de culbuteur 1 D poser Axes de culbuteur N B Utiliser un extracteur i...

Страница 224: ...4 15 ENG CAMSHAFT AND ROCKER ARMS 3 Apply Molybdenum disulfide oil onto the rocker arm and rocker arm shaft 4 Install Rocker arm 1 Rocker arm shaft 2...

Страница 225: ...ipphebel und Kipphebelwelle 4 Montieren Kipphebel 1 Kipphebelwelle 2 ARBRE A CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL 3 Appliquer Huile au bisulfure de molybd ne sur le culbuteur et l axe de culb...

Страница 226: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Rocker arm and camshaft Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4 Use...

Страница 227: ...1 5 Auslassventil 1 6 Ventilschaft Dichtring 2 1 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la d pose 1 D pose des soupapes Organisation d...

Страница 228: ...sor YM 4019 90890 04019 INSPECTION Valve 1 Measure Stem to guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Clea...

Страница 229: ...Erneuern Max Schlag 0 02 mm 0 0008 in SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN POINTS DE DEPOSE D pose des soupapes 1 D poser Clavettes de soupape 1 N B Fixer un compresseur de ressor...

Страница 230: ...h a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps A...

Страница 231: ...uss der Ventilsitz nachbearbeitet werden SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN Ressort de soupape 1 Mesurer Longueur libre du ressort de soupape a Hors sp cifications Remplacer 2 Me...

Страница 232: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Страница 233: ...er Vorgabe entspricht Ventilkegel und sitz erneut einschleifen SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN 2 Roder Port e de soupape Si ge de soupape N B Apr s rectification du si ge de s...

Страница 234: ...the embossed mark as follows Intake G Exhaust L Install the valve springs with the larger pitch a facing upwards b Smaller pitch New 3 Install Valve cotters NOTE While compressing the valve spring wi...

Страница 235: ...n SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN ASSEMBLAGE ET MONTAGE 1 Appliquer Huile au bisulfure de molybd ne sur la queue de soupape et le joint de queue de soupape 2 Monter Joints de...

Страница 236: ...ks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Timing chain guide exhaust 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pin clip 2 Use special...

Страница 237: ...TAGE EINZELHEITEN 9 2 Kolbenring 1 10 labstreifring Expander 2 1 2 1 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Organis...

Страница 238: ...use the piston pin puller set 4 Piston pin puller set YU 1304 90890 01304 Piston ring 1 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top...

Страница 239: ...messen Anschlie end den Durchschnitt der gemessenen Werte ermitteln CYLINDRE ET PISTON ZYLINDER UND KOLBEN POINTS DE DEPOSE Piston 1 D poser Clips d axes de pistons 1 Axe de piston 2 Piston 3 N B Avan...

Страница 240: ...re the piston skirt diameter P with a micrometer a 4 mm 0 16 in from the piston bottom edge Piston size P Standard 46 960 46 975 mm 1 8488 1 8494 in If out of specification replace the piston and pist...

Страница 241: ...olbenringe erneuern CYLINDRE ET PISTON ZYLINDER UND KOLBEN Al sage de cylindre C 47 000 47 005 mm 1 8504 1 8506 in Limite de conicit T 0 05 mm 0 002 in Ovalisation R 0 05 mm 0 002 in C maximum D T max...

Страница 242: ...crown so that the ring will be at a right angle to the cylinder bore a 5 mm 0 20 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of t...

Страница 243: ...fring 0 2 0 7 mm 0 01 0 03 in CYLINDRE ET PISTON ZYLINDER UND KOLBEN Segment de piston 1 Mesurer Jeu lat ral du segment Utiliser une jauge d paisseur lames Hors sp cifications Remplacer ensemble le pi...

Страница 244: ...ngs so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Measurement steps Measure the piston pin outs...

Страница 245: ...zwert 13 045 mm 0 5136 in CYLINDRE ET PISTON ZYLINDER UND KOLBEN Axe de piston 1 Contr ler Axe de piston D coloration bleue rainures Remplacer puis contr ler le syst me de lubri fication 2 Mesurer Dia...

Страница 246: ...nts to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate Piston Pisto...

Страница 247: ...schiene nicht besch digt wird Die Steuerkette durch den Steuerketten schacht f hren New CYLINDRE ET PISTON ZYLINDER UND KOLBEN 2 Position Segment de feu Segment d tanch it Segment racleur d huile D c...

Страница 248: ...er Part name Q ty Remarks CRANKCASE COVER LEFT AND RIGHT REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Shift pedal 1 2 Drive sprocket...

Страница 249: ...starterhebel 1 8 Kurbelgeh usedeckel rechts 1 9 Dichtung 1 10 Passh lse 2 2 1 EMBRAYAGE KUPPLUNG EMBRAYAGE COUVERCLE DE CARTER GAUCHE ET DROIT Organisation de la d pose 1 D pose du couvercle de carter...

Страница 250: ...removal Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL 1 Bolt clutch spring 4 4 2 Pressure plate 1 3 Washer 1 4 Push rod 1 1 5 Friction plate 5 6 Clutch plate 4 7 Push rod 2 1 8 Clutch...

Страница 251: ...0 Kupplungsnabe 1 11 Beilagscheibe 1 12 Kupplungskorb 1 2 1 3 EMBRAYAGE KUPPLUNG EMBRAYAGE Organisation de la d pose 1 D pose du disque garni et du plateau de pression 2 D pose de la cloche d embrayag...

Страница 252: ...me Q ty Remarks 13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool Refer to REMOVAL POINTS 16 Washer 1 17 Spacer 1 18 Primary clutch housing 1 19 Primary clutch boss 1 20 Clutch carrier...

Страница 253: ...Anfahrkupplungsnabe 1 20 Antriebstr ger 1 21 Freilauf 1 22 Beilagscheibe 1 3 2 EMBRAYAGE KUPPLUNG Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 13 Entretoise 1 14 Entretoise 1 15 Ecro...

Страница 254: ...lutch holding tool YM 91042 90890 04086 Primary clutch 1 Remove Primary clutch nut 1 NOTE Loosen the nut while holding the magneto rotor with the sheave holder 2 INSPECTION EC484500 Friction plate 1 M...

Страница 255: ...rke Standard Grenzwert 2 7 2 9 mm 0 106 0 114 in 2 6 mm 0 102 in EMBRAYAGE KUPPLUNG POINTS DE DEPOSE Noix d embrayage 1 D poser Ecrou de noix d embrayage 1 Rondelle frein 2 Noix d embrayage N B Redre...

Страница 256: ...sure Push rod 2 bend Out of specification Replace Warp limit 0 2 mm 0 008 in Clutch spring free length Standard Limit 26 2 mm 1 03 in 24 2 mm 0 95 in Bending limit 0 5 mm 0 02 in Primary clutch 1 Meas...

Страница 257: ...4 in EMBRAYAGE KUPPLUNG Plateau de pression 1 Mesurer D formation du plateau de pression Hors sp cifications Remplacer le plateau de pression complet Utiliser une plaque surfacer 1 et une jauge d pais...

Страница 258: ...ing tool 3 to hold the clutch boss For USA and CDN Except for USA and CDN 2 Bend Lock washer tab Sheave holder YS 1880 A 90890 01701 Clutch holding tool YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft l...

Страница 259: ...n Um 1 8 Umdrehung herausdrehen Die Sicherungsmutter festziehen T R Sicherungsmutter 8 Nm 0 8 m kg 5 8 ft lb EMBRAYAGE KUPPLUNG ASSEMBLAGE ET MONTAGE Embrayage primaire 1 Monter Rondelle 1 Ecrou embra...

Страница 260: ...name Q ty Remarks KICK AXLE REMOVAL AND DISASSEMBLY Preparation for removal Crankcase cover right Refer to CLUTCH section 1 Kick axle assembly 1 2 Circlip 2 3 Spring cover 1 4 Torsion spring 1 5 Sprin...

Страница 261: ...ng 1 10 Beilagscheibe Federscheibe 1 1 11 Kickstarter Ritzel 1 12 Kickhebelwelle 1 2 1 ARBRE DE KICK KICKHEBELWELLE ARBRE DE KICK Organisation de la d pose 1 D pose de l arbre de kick 2 D montage de l...

Страница 262: ...HAFT REMOVAL Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section 1 Shift fork guide bar 1 2 Shift arm 3 1 3 Plate washer 1 4 Compression spring 1 5 Shift guide 1 6 Ball h...

Страница 263: ...haltklinke komplett 1 13 Schaltwelle 1 1 AXE DE SELECTEUR SCHALTWELLE AXE DE SELECTEUR Organisation de la d pose 1 D pose de l axe de s lecteur Organisation de la d pose Ordre Nom de la pi ce Q t Rema...

Страница 264: ...4 35 ENG SHIFT SHAFT Extent of removal Order Part name Q ty Remarks 14 Stopper lever 1 15 Torsion spring 1 16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1 1...

Страница 265: ...cherungsring 1 17 Unterlegscheibe 1 18 Torsionsfeder 1 19 Schaltklinke 1 1 AXE DE SELECTEUR SCHALTWELLE Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 14 Doigt de verrouillage 1 15 Ress...

Страница 266: ...ty Remarks OIL PUMP REMOVAL AND DIS ASSEMBLY Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section Shift shaft Refer to SHIFT SHAFT section 1 Rotary filter 1 2 Oil pump as...

Страница 267: ...9 Sicherungsring 1 10 Beilagscheibe 1 2 1 3 POMPE A HUILE LPUMPE POMPE A HUILE Organisation de la d pose 1 D pose de la pompe huile 2 D pose de la cr pine huile 3 D montage de la pompe huile Organisat...

Страница 268: ...4 37 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 11 Oil pump cover 1 12 Dowel pin 2 13 Oil pump drive shaft 1 14 Pin 1 15 Inner rotor 1 16 Outer rotor 1 17 Rotor housing 1 3...

Страница 269: ...lle 1 14 Stift 1 15 Innenrotor 1 16 Au enrotor 1 17 Rotorgeh use 1 3 POMPE A HUILE LPUMPE Organisation de la d pose Ordre Nom de la pi ce Q t Remarques 11 Couvercle de pompe huile 1 12 Goujon 2 13 Arb...

Страница 270: ...ce the oil pump assembly Tip clearance a 0 15 mm 0 0059 in Limit 0 2 mm 0 0079 in Side clearance b 0 13 0 18 mm 0 0051 0 0071 in Limit 0 23 mm 0 0091 in Rotor housing and rotor clear ance c 0 06 0 10...

Страница 271: ...ung b in der Kur belwelle ausrichten POMPE A HUILE LPUMPE CONTROLE Pompe huile 1 Mesurer Jeu entre rotors a entre le rotor interne 1 et le rotor externe 2 Jeu lat ral b entre le rotor externe 2 et le...

Страница 272: ...removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover left Refer to CLUTCH section 1 CDI magneto coupler 1 2 Pickup coil stator assembl...

Страница 273: ...EITEN 4 Rotor 1 5 Scheibenfeder 1 2 1 VOLANT MAGNETIQUE CDI TT R90 LICHTMASCHINE TT R90 VOLANT MAGNETIQUE CDI TT R90 Organisation de la d pose 1 D pose de l ensemble bobine d excitation stator 2 D pos...

Страница 274: ...otor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel puller and the rotor i...

Страница 275: ...tzen Polrad Abzieher YU 33270 B 90890 01362 VOLANT MAGNETIQUE CDI TT R90 LICHTMASCHINE TT R90 POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Rondelle 2 N B Desserrer l crou de rotor tout en immobil...

Страница 276: ...gear removal Extent of removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover left Refer to CLUTCH section 1 CDI magneto coupler 1 2 Pic...

Страница 277: ...OLANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E VOLANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E Organisation de la d pose 1 D pose de l ensembl...

Страница 278: ...1880 A 90890 01701 2 Remove Rotor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the fl...

Страница 279: ...33270 B 90890 01362 VOLANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E POINTS DE DEPOSE Rotor 1 D poser Ecrou de rotor 1 Rondelle 2 N B Desserrer l crou...

Страница 280: ...er clutch When turning the starter wheel gear clock wise the starter clutch and the starter wheel gear should be engaged If not the starter clutch is faulty Replace it When turning the starter wheel g...

Страница 281: ...UE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E CONTROLE Embrayage du d marreur 1 Contr ler Dents du pignon fou du d marreur a Dents du pignon d entra nement du d ma...

Страница 282: ...Woodruff key 1 Rotor 2 NOTE Clean the tapered portion of the crankshaft and the magneto hub When installing the magneto rotor make sure the woodruff key is properly seated in the key way of the cranks...

Страница 283: ...LANT MAGNETIQUE CDI ET EMBRAYAGE DU DEMARREUR TT R90E LICHTMASCHINE UND STARTERKUPPLUNG TT R90E 3 Monter Ressort 1 Capuchon de ressort 2 Goupille 3 4 Monter Cale 1 Engrenage roue du d marreur 2 Pignon...

Страница 284: ...t pipe Air filter case Carburetor Refer to CARBURETOR section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine guard and drive sprocket Engine assembly From the cha...

Страница 285: ...khebelwelle komplett Siehe dazu den Abschnitt KICKHEBEL WELLE CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE CARTER MOTEUR ET VILEBREQUIN Organisation de la d pose Ordre Nom de la pi ce Q...

Страница 286: ...to SHIFT SHAFT section Oil pump and oil strainer Refer to OIL PUMP section Rotor for the TT R90 Refer to CDI MAGNETO section for the TT R90 Rotor and starter clutch for the TT R90E Refer to CDI MAGNET...

Страница 287: ...h useteil links 1 2 1 3 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE Organisation de la d pose 1 D pose de la cha ne de distribution 2 S paration du carter 3 D pose du vilebrequin Organi...

Страница 288: ...limit 0 03 mm 0 0012 in Side clearance 0 10 0 40 mm 0 0039 0 0157 in Radial clearance 0 010 0 025 mm 0 0004 0 0010 in 0 05 mm 0 002 in Crack width 42 95 43 00 mm 1 691 1 693 in ASSEMBLY AND INSTALLATI...

Страница 289: ...et ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 CARTER MOTEUR ET VILEBREQUIN KURBELGEH USE UND KURBELWELLE CONTROLE Vilebrequin 1 Mesurer Limite de faux rond a Jeu lat ral de t te de bielle b...

Страница 290: ...le disassembly Extent of removal Order Part name Q ty Remarks SHIFT FORK SHIFT CAM TRANSMISSION REMOVAL Preparation for removal Engine assembly Separate the crankcase Refer to CRANKCASE AND CRANK SHAF...

Страница 291: ...ibe 1 2 1 FOURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES SCHALTGABELN SCHALTWALZE UND GETRIEBE FOURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES Organisation de la d pose 1 D pose des fourche...

Страница 292: ...ANSMISSION Extent of removal Order Part name Q ty Remarks 10 3rd pinion gear 1 11 Main axle 1 12 Circlip 1 13 Washer 1 14 Collar 1 15 1st wheel gear 1 16 3rd wheel gear 1 17 Circlip 1 18 Washer 1 19 2...

Страница 293: ...ibe 1 19 Zahnrad 2 Gang 1 20 Ausgangswelle 1 3 2 FOURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES SCHALTGABELN SCHALTWALZE UND GETRIEBE Organisation de la d pose Ordre Nom de la pi ce Q t Remarque...

Страница 294: ...ully Note the posi tion of each part Pay particular attention to the location and direction of shift forks ASSEMBLY AND INSTALLATION Transmission shift cam shift fork 1 Install Main axle assembly 1 Dr...

Страница 295: ...OURCHETTE DE SELECTION TAMBOUR ET BOITE DE VITESSES SCHALTGABELN SCHALTWALZE UND GETRIEBE POINTS DE DEPOSE Fourchette de s lection tambour et bo te de vitesses 1 D poser Fourchettes de s lection Tambo...

Страница 296: ...HEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Bolt brake cable ho...

Страница 297: ...aul e 1 7 Flasque de frein complet 1 8 Bague d tanch it 1 9 Roulement 2 Se reporter la section POINTS DE DEPOSE 2 1 3 3 FAHRWERK VORDER UND HINTERRAD VORDER UND HINTERRADBREMSE Arbeitsumfang 1 Vorderr...

Страница 298: ...5 2 CHAS Extent of removal Order Part name Q ty Remarks 10 Brake shoe 2 11 Brake camshaft lever 1 12 Brake camshaft 1 3 FRONT WHEEL AND REAR WHEEL...

Страница 299: ...pi ce Q t Remarques 10 M choire de frein 2 11 Biellette de frein 1 12 Came de frein 1 3 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 10 Trommelbremsbelag 2 11 Bremswellenhebel 1 12 Bremswelle 1...

Страница 300: ...name Q ty Remarks REAR WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the eng...

Страница 301: ...arri re 1 7 Tendeur de cha ne de transmission 2 8 Roue arri re 1 9 Entretoise paul e droite 1 10 Flasque de frein complet 1 2 1 3 HINTERRAD UND HINTERRADBREMSE Arbeitsumfang 1 Hinterrad demontieren 2...

Страница 302: ...HEEL AND REAR WHEEL Extent of removal Order Part name Q ty Remarks 11 Collar left 1 12 Wheel drive hub assembly 1 13 Bearing 2 Refer to REMOVAL POINTS 14 Brake shoe 2 15 Brake camshaft lever 1 16 Brak...

Страница 303: ...ection POINTS DE DEPOSE 14 M choire de frein 2 15 Biellette de frein 1 16 Came de frein 1 2 3 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 11 Distanzh lse links 1 12 Mitnehmernabe komplett 1 13...

Страница 304: ...ake lining 1 Inspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper NOTE After polishing wipe the polished particles with a cloth Wheel runout limit Radial 1 2 0 mm 0 08 in Latera...

Страница 305: ...e de m choire de frein a Standard Avant 3 0 mm 0 12 in Arri re 4 0 mm 0 16 in Limite 2 0 mm 0 08 in DEMONTAGE EINZELHEITEN Radlager nach Bedarf 1 Demontieren Lager 1 HINWEIS Das Lager mit einem Lagera...

Страница 306: ...ke camshaft lever in relation to the punch mark a as shown Front Rear 1 1 a a 1 1 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Springs 1 Brake shoes 2 NOTE Apply the lithium soap base grease on the pivot pi...

Страница 307: ...Hebelachse auftragen WARNUNG Niemals Fett auf die Bremsbel ge auftra gen New ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD REMONTAGE ET INSTALLATION 1 Monter Biellette de frein 1 N B Installer le l...

Страница 308: ...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 of the bearing Contact should be made on...

Страница 309: ...T ROUE ARRIERE VORDER UND HINTERRAD 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 d tanch it de g...

Страница 310: ...ENT section in the CHAPTER 3 Wheel drive hub assembly 1 Install Bearing 1 Oil seal 2 Collar 3 Sprocket shaft 4 Driven sprocket 5 Lock washers 6 Nuts 7 Bolts 8 NOTE Install the oil seal with its manufa...

Страница 311: ...nach oben biegen New New T R 25 Nm 2 5 m kg 18 ft lb ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD 5 Monter Bride de fil de c ble de frein 1 T R 7 Nm 0 7 m kg 5 1 ft lb 6 R gler Garde du levier de...

Страница 312: ...race of the bearing Right side of bearing shall be installed first CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Drive chain 1 NOTE Push...

Страница 313: ...6 m kg 19 ft lb New ROUE AVANT ET ROUE ARRIERE VORDER UND HINTERRAD Roue arri re 1 Monter Roulement de roue 1 Entretoise 2 Roulement de roue 3 N B Avant de monter le roulement et la bague d tan ch it...

Страница 314: ...ne securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Han...

Страница 315: ...e r glage 1 Desserrer uniquement 4 Boulon de pincement t inf rieur 1 Desserrer uniquement 5 Fourche 1 1 TELESKOPGABEL Arbeitsumfang 1 Teleskopgabel demontieren Arbeitsumfang Reihen folge Bauteil Anz B...

Страница 316: ...oval Extent of removal Order Part name Q ty Remarks FRONT FORK DISASSEMBLY Preparation for disas sembly Drain the fork oil 1 Adjuster 1 2 Fork spring 1 3 Dust cover 1 4 Stopper ring 1 5 Bolt damper ro...

Страница 317: ...outil sp cial Se reporter la section POINTS DE DEPOSE 6 Tube plongeur 1 7 Tige d amortissement 1 8 Bague d tanch it 1 9 Fourreau 1 2 1 TELESKOPGABEL ZERLEGEN Arbeitsumfang 1 Dichtring demontieren 2 D...

Страница 318: ...55000 ASSEMBLY AND INSTALLATION Front fork assembly 1 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver weight 2 and fork seal driver attachment 3 2 Fill Fork oil 3...

Страница 319: ...0 01184 Accessoire de l outil de montage de joint de fourche 90890 01186 Quantit d huile 64 cm3 2 26 Imp oz 2 16 US oz Huile recommand e Huile de fourche 15W ou quivalente DEMONTAGE EINZELHEITEN Stand...

Страница 320: ...AL 1 ENGINE STOP switch 1 2 Brake lever cable 1 Disconnect at the lever side 3 Brake lever 1 4 Grip cap lower 1 5 Grip cap upper 1 6 Throttle cable 1 Disconnect at the throttle side 7 Grip right 1 Ref...

Страница 321: ...reporter la section POINTS DE DEPOSE 10 Support du guidon sup rieur 2 11 Guidon 1 12 Support du guidon inf rieur 2 1 LENKER TT R90 Arbeitsumfang 1 Lenker demontieren Arbeitsumfang Reihen folge Bautei...

Страница 322: ...switch 1 3 ENGINE STOP switch 1 4 Brake lever cable 1 Disconnect at the lever side 5 Brake lever 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle cable 1 Disconnect at the throttle side 9 Grip right...

Страница 323: ...1 Se reporter la section POINTS DE DEPOSE 12 Support du guidon sup rieur 2 13 Guidon 1 14 Support du guidon inf rieur 2 1 TT R90E Arbeitsumfang 1 Lenker demontieren Arbeitsumfang Reihen folge Bauteil...

Страница 324: ...come loose INSPECTION Handlebar 1 Inspect Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar ASSEMBLY AND INSTA...

Страница 325: ...Klebemittels Fett oder l mit Verd nner von der Oberfl che a des Drehgriffs entfernen GUIDON LENKER POINTS DE DEPOSE Poign e de guidon 1 D poser Poign e de guidon 1 N B Insuffler de l air entre le guid...

Страница 326: ...arrow marks faces straight upward 3 Install Grip right 1 Collar 2 Apply the adhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface a with a la...

Страница 327: ...n kon trollieren dass sich der Gasdrehgriff 1 rei bungslos dreht Falls dies nicht der Fall ist die Schrauben nochmals festziehen GUIDON LENKER 2 Monter Poign e gauche 1 Appliquer un agent adh sif sur...

Страница 328: ...grease on the front brake cable end The brake lever holder should be installed according to the dimensions as shown TT R90 TT R90E 1 2 LS 5mm 0 2 in LS Zero mm Zero in 1 2 6 Install Engine stop switc...

Страница 329: ...r 1 HINWEIS Die Nase a an der Motorstoppschalter Halte rung auf die Bohrung b im Lenker ausrichten GUIDON LENKER 5 Monter Support de levier de frein 1 C ble de frein 2 N B Appliquer de la graisse savo...

Страница 330: ...s STEERING REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front fork Refe...

Страница 331: ...7 Billes du roulement sup rieur 19 8 Billes du roulement inf rieur 16 9 Joint antipoussi re 1 10 Cage externe de roulement 2 2 1 LENKUNG Arbeitsumfang 1 Untere Gabelbr cke demontieren 2 Lager demonti...

Страница 332: ...he steering shaft so that it may not fall 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 lo...

Страница 333: ...l 2 benutzen ACHTUNG Darauf achten das Lenkwellengewinde nicht zu besch digen 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...

Страница 334: ...chine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section R...

Страница 335: ...tenir le bras oscillant 5 Bras oscillant 1 6 Patin de cha ne de transmission 1 7 Protection de cha ne de transmission 1 8 Support de cha ne de transmission 1 2 1 SCHWINGE Arbeitsumfang 1 Schwinge demo...

Страница 336: ...5 21 CHAS SWINGARM Extent of removal Order Part name Q ty Remarks 9 Cotter pin 1 10 Nut tension bar 1 11 Bolt tension bar 1 12 Tension bar 1 1...

Страница 337: ...Remarques 9 Goupille fendue 1 10 Ecrou barre de tension 1 11 Boulon barre de tension 1 12 Barre de tension 1 1 Arbeitsumfang Reihen folge Bauteil Anz Bemerkungen 9 Splint 1 10 Zugstangen Mutter 1 11 Z...

Страница 338: ...plug 5 ENGINE STOP switch 6 Thermo switch 7 Carburetor heater 8 Rectifier regulator COLOR CODE B Black Br Brown G Green O Orange R Red W White EC612000 WIRING DIAGRAM G W B R W L W R Br G R W W B Y R...

Страница 339: ...L Wei Blau W R Wei Rot SCHALTPLAN COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE TT R90 COMPOSANTS ELECTR...

Страница 340: ...ting circuit cut off relay COLOR CODE B Black Br Brown G Green O Orange R Red Sb Sky blue W White Y Yellow EC612000 WIRING DIAGRAM G W B R W L W R Br G R W B W Br B R B W B Br R B W B W B B B R W Br B...

Страница 341: ...b Rot SCHALTPLAN COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN TT R90E COMPOSANTS ELECTRIQUES 1 Contacteur cl 2 Coupe circuit du moteur 3 Contacteur thermique 4 Bobin...

Страница 342: ...ng special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark plug Check entire ignition syst...

Страница 343: ...Testeur d allumage 90890 06754 Multim tre YU 3112 C 90890 03112 Test de la longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions de l ensemble du syst me d allu mage R parer ou...

Страница 344: ...l lieren Z ndkerze reinigen ggf erneuern Kabelanschl sse des gesamten Z ndsystems kontrollieren Instand setzen ggf erneuern Z ndschloss kontrollieren Nur TT R90E Erneuern Motorstoppschalter ENGINE STO...

Страница 345: ...ELEC MEMO...

Страница 346: ...ap 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 circuit...

Страница 347: ...R 1 Br 2 B W 3 B 4 Messger t Wahlschalter ON 1 OFF SYSTEME D ALLUMAGE Z NDSYSTEM TEST DE LA LONGUEUR D ETINCELLE 1 D connecter le capuchon de bougie de la bou gie 2 Connecter le testeur d tincelle dyn...

Страница 348: ...002 IGNITION 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 res...

Страница 349: ...er 6 3 9 5 k bei 20 C 68 F k 1 SYSTEME D ALLUMAGE Z NDSYSTEM CONTROLE DU COUPE CIRCUIT DU MOTEUR 1 Contr ler Continuit du coupe circuit du moteur Pas de continuit la position Remplacer Continuit la po...

Страница 350: ...Tester lead Red lead 1 Tester lead White lead 2 Pickup coil resistance Tester selector position 248 372 at 20 C 68 F 100 2 Inspect Source coil resistance Out of specification Replace Tester lead Brow...

Страница 351: ...20 C 68 F 100 SYSTEME D ALLUMAGE Z NDSYSTEM CONTROLE DU VOLANT MAGNETIQUE CDI 1 Contr ler R sistance de la bobine d excitation Hors sp cifications Remplacer Fil du multim tre fil rouge 1 Fil du multim...

Страница 352: ...operating when this condi tion has not been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When the above condition has been met the starting...

Страница 353: ...RAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E FONCTIONNEMENT DU SYSTEME DE COUPE CIRCUIT DE DEMARRAGE Si le contacteur cl est plac sur ON le d mar reur ne peut fo...

Страница 354: ...in this inspection 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 ea...

Страница 355: ...outils sp ciaux suivants pendant ce contr le Multim tre YU 3112 C 90890 03112 1 Contr ler le fusible Remplacer le fusible et contr ler le faisceau de fils 2 Contr ler la batterie Recharger ou remplace...

Страница 356: ...ung kontrollieren Sicherung erneuern und Kabelbaum kon trollieren 2 Batterie kontrollieren Laden ggf erneuern S mtliche Steckverbinder und Kabelanschl sse kontrollieren Instand setzen ggf erneuern 3 Z...

Страница 357: ...ELEC MEMO...

Страница 358: ...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 CIRCUIT...

Страница 359: ...atterie angeschlos sen SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS 1 Contr ler Connexion des fiches rapides et des fils Rouille p...

Страница 360: ...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 SW...

Страница 361: ...er LEERLAUF 1 GANG EIN GELEGT SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE DU RELAIS DE DEMARREUR 1 D poser Relais de d marreur 2 Contr ler Continuit du relais de d marreur Uti...

Страница 362: ...Start switch continuity Not continuous while being pushed Replace Continuous while being freed Replace Tester lead Black lead 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PUSH IN 1 FR...

Страница 363: ...2 Messger t Wahlschalter EINDR CKEN 1 FREI GEBEN SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE DU CONTACTEUR DU DEMARREUR 1 Contr ler Continuit du contacteur du d marreur Pas de...

Страница 364: ...e 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 Front bracket...

Страница 365: ...Ring 1 3 Kohleb rsten Satz 1 4 Anker 1 5 Stator 1 1 SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E DEMARREUR Organisation de la d pose 1 D montage du d marreur Organisation de la d pose...

Страница 366: ...ensure proper operation of com mutator Commutator wear limit 16 6 mm 0 65 in Mica undercut 1 35 mm 0 05 in 4 Measure Armature assembly resistance commu tator and insulation Out of specification Repla...

Страница 367: ...68 F Entspricht einer der Widerst nde nicht der Vorgabe den Startermotor erneuern SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E CONTROLE ET REPARATION 1 Contr ler Collecteur Salet Nettoy...

Страница 368: ...n Replace as a set Brush spring force 3 92 5 88 N 400 600 g 14 1 21 2 oz ASSEMBLY 1 Install Brush holder 2 Install Armature coil 1 3 Install Ring 1 Stator assembly 2 Front bracket 3 NOTE Apply molybde...

Страница 369: ...er auftragen Die Markierungen an Polgeh use und Lager schild m ssen fluchten SYSTEME DE DEMARRAGE ELECTRIQUE TT R90E STARTSYSTEM TT R90E 5 Mesurer Longueur des balais a Hors sp cifications Remplacer L...

Страница 370: ...g parts 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...

Страница 371: ...iliser l outil sp cial suivant pour effectuer ce 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 e...

Страница 372: ...e Taschen Multimeter YU 3112 C 90890 03112 Induktions Drehzahlmesser YU 8036 B Diagnose Drehzahlmesser 90890 03113 1 Sicherung kontrollieren Sicherung erneuern und Kabelbaum kon trollieren 2 Batterie...

Страница 373: ...ELEC MEMO...

Страница 374: ...of 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 positio...

Страница 375: ...1 SYSTEME DE CHARGE TT R90E LADESYSTEM TT R90E CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS 1 Contr ler Connexion des fiches rapides et des fils Rouille poussi re jeu court circuit R parer o...

Страница 376: ...e the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Check entire carburetor heating system for connec tion...

Страница 377: ...1 Selle 2 R servoir de carburant Utiliser les outils sp ciaux suivants pendant ce contr le Multim tre YU 3112 C 90890 03112 Contr ler les connexions de l ensemble du syst me de r chauffage du carburat...

Страница 378: ...e verwenden Taschen Multimeter YU 3112 C 90890 03112 Kabelanschl sse der gesamten Vergaserheizan alge kontrollieren Instand setzen ggf erneuern Starterschalter kontrollieren Erneuern Vergaser Heizelem...

Страница 379: ...ELEC MEMO...

Страница 380: ...ion Replace Inspection steps Remove the thermo switch Connect the pocket tester to the thermo switch coupler as shown Tester lead Black 1 Tester lead Black 2 Immerse the thermo switch in a container f...

Страница 381: ...n Temperaturen auf Durchgang pr fen TT R90 TT R90E SYSTEME DE RECHAUFFAGE DU CARBURATEUR VERGASERHEIZUNG CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS 1 Contr ler Connexion des fiches rapides...

Страница 382: ...re than 16 3 C 60 8 5 4 F NO 3 TT R90 More than 12 4 C 53 6 7 2 F TT R90E More than 11 3 C 51 8 5 4 F NO 4 TT R90 Less than 12 4 C 53 6 7 2 F TT R90E Less than 11 3 C 51 8 5 4 F YES Test steps 1 2 Hea...

Страница 383: ...Thermoschalters kontrol lieren SYSTEME DE RECHAUFFAGE DU CARBURATEUR VERGASERHEIZUNG Le circuit du contacteur thermique est ouvert Le circuit du contacteur thermique est ferm Etape du test Temp rature...

Страница 384: ...Carburetor heater body 2 Carburetor heater resistance Tester selector position 6 10 at 20 C 68 F 1 CDI MAGNETO INSPECTION 1 Inspect Lighting coil resistance Out of specification Replace TT R90 TT R90E...

Страница 385: ...52 0 78 bei 20 C 68 F 1 SYSTEME DE RECHAUFFAGE DU CARBURATEUR VERGASERHEIZUNG CONTROLE DU RECHAUFFEUR DE CARBURATEUR 1 Contr ler R sistance du r chauffeur de carburateur Hors sp cifications Remplacer...

Страница 386: ...dance with the emission warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of mainte nance work MAINTE NANCE INTERVAL DATE O...

Страница 387: ...li s la garantie du syst me antipollution Le seul but du tableau ci dessous est de rappeler l utilisateur que l entretien doit tre effectu Il ne constitue pas une preuve que l entretien a t r alis PR...

Страница 388: ...leistung zu dokumentieren Folgende Tabelle dient lediglich als Wartungsplan stellt an sich aber keinen Beleg f r die Durchf h rung der Arbeiten dar INTERVALL DATUM DER WARTUNGS ARBEIT KILOMETER STAND...

Страница 389: ......

Страница 390: ...0E V OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGSHANDBUCH PRINTED IN JAPAN 2005 04 0 3 1 CR E F G TT R90 V TT R90E V PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 S...

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