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6-3

SYSTEME D’ALLUMAGE

ZÜNDANLAGE

SISTEMA DI ACCENSIONE

ELEC

TEST DER ZÜNDFUNKENSTRECKE

1. Den Zündkerzenstecker von der

Zündkerze abtrennen.

2. Den dynamischen Zündfunken-

prüfer

(Zündungs-Prüfgerät

) gemäß Abbildung ansch-

ließen.

Zündkerzenstecker

Zündkerze

Für USA und CDN

Außer USA und CDN

3. Den Motor mit Hilfe des Kickstar-

ters durchdrehen.

4. Die Zündfunkenstrecke kontrollie-

ren.

5. Den Motor anlassen und die

Zündfunkenstrecke vergrößern,
bis es zu Fehlzündungen kommt.
(nur für USA und CDN)

INSPEKTION DES ANSCHLUSSES
DER KUPPLUNGEN UND KABEL

1. Kontrollieren:

Anschluß deren Kupplungen
und Kabel
Rost/Staub/Lockerheit/Kurz-
schluß

→

Reparieren oder

erneuern.

INSPEKTION DES MOTORSTOPP-
KNOPFES „ENGINE STOP“

1. Prüfen:

Kontakt des Motorstoppknop-
fes „ENGINE STOP“

Kein Stromdurchgang, wenn gedrückt

→

Erneuern.

Stromdurchgang, wenn freigelassen

→

Erneuern.

ESSAI DE L’INTERVALLE
D’ETINCELLEMENT
D’ALLUMAGE

1. Déconnecter le capuchon de bou-

gie de la bougie.

2. Connecter le testeur dynamique

d’étincelle

(testeur d’allumage

) comme indiqué.

Capuchon de bougie

Bougie

Pour USA et CDN

Excepté pour USA et CDN

3. Actionner la pédale de kick.
4. Contrôler l’écartement d’étincelle

d’allumage.

5. Démarrer le moteur et augmenter

l’intervalle d’étincellement jusqu’à
ce qu’un raté se produise. (unique-
ment USA et CDN)

VERIFICATION DE CONNEXION
DES COUPLEURS ET FILS

1. Contrôler:

Connexion des coupleurs et fils
Rouille/poussière/desserré/court
-circuit

→

Réparer ou changer.

VERIFICATION DU BOUTON
D’ARRET DU MOTEUR “ENGINE
STOP”.

1. Examiner:

Conductibilité du bouton d’arrêt
du moteur “ENGINE STOP”

Pas de continuité lorsqu’enfoncé

→

Changer.
Continuité lorsque relâché

→

Changer.

IC622001

TEST DELLA DISTANZA TRA
GLI ELETTRODI

1. Scollegare la calotta della candela

dalla candela.

2. Collegare il tester dinamico delle

scintille

(apparecchio per il

controllo dell’accensione

) come

illustrato.

Calotta della candela

Candela

Per USA e CDN

Tranne che per USA e CDN

3. Azionare la pedivella della messa

in moto.

4. Controllare la distanza tra gli elet-

trodi dell’accensione.

5. Avviare il motore e aumentare la

distanza tra gli elettrodi finché non
si verifica uno scatto a vuoto. (sol-
tanto per USA e CDN)

IC624000

ISPEZIONE DEL
COLLEGAMENTO DI
ACCOPPIATORI E CONDUTTORI

1. Controllare:

Collegamento di accoppiatori e
conduttori
Ruggine/Polvere/Allentamen-
to/Cortocircuito

→

Ripararli o

sostituirli.

IC625002

ISPEZIONE DEL PULSANTE
“ARRESTO MOTORE”

1. Ispezionare:

Comportamento del pulsante
“ARRESTO MOTORE”

Assenza di continuità mentre è premuto

→

Sostituirlo.

Continuità mentre viene rilasciato

→

Sostituirlo.

B/W B

Posizione

del seletto

re del tester

PREM-

1 1

UTO

RILAS-

Ω ×

CIATO

Conduttore (+) del tester

→

Conduttore Nero/Bianco

Conduttore (–) del tester

→

Conduttore Nero

Distanza minima tra gli
elettrodi:

6,0 mm (0,24 in)

Ecartement d’étincelle
minimum:

6,0 mm (0,24 in)

Fil (+) de testeur

→

Fil noir/blanc

Fil (–) de testeur

→

Fil noir

B/W B

Position de

sélecteur du

testeur

ENFO-

1 1

NCE

RELA-

Ω ×

CHE

Min. Zündfunkenstrecke:

6,0 mm (0,24 in)

Positives (+) Kabel des Prüfgerätes

→

Schwarz/Weiß Kabel

Negatives (–) Kabel des Prüfgerätes

→

Schwarz Kabel

B/W

Position des

Wahlschalters

am Prüfgerät

GEDR

ÜCKT

FREIG

Ω ×

LASSEN

5MW-9-30-6 7/6/00 1:35 PM Page 9

Содержание YZ250(N)/LC

Страница 1: ...5MW 28199 30 OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 N LC...

Страница 2: ...RVICE MANUAL 2000 by Yamaha Motor Co Ltd 1st Edition July 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Prin...

Страница 3: ...maha Motor Co Ltd 1 Ausgabe Juli 2000 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet...

Страница 4: ...please contact your Yamaha deal er NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yamaha dealer w PLEASE READ T...

Страница 5: ...opos de ce manuel ou de votre machine pri re de prendre contact avec votre conces sionnaire Yamaha N B Comme des am liorations sont faites sur ce mod le quelques donn es conte nues dans ce manuel peuv...

Страница 6: ...ACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine 3 ALWAYS WEAR PROTECTIVE APPAR EL When operating this machine always wear an approved helmet with goggles o...

Страница 7: ...UR Ne pas prendre de passagers sur cette machine 3 TOUJOURS PORTER UN EQUIPEMENT DE PROTEC TION Lors de l utilisation de cette machine toujours porter un casque homologu avec des lunettes ou un prot g...

Страница 8: ...UATE VENTILATION Never start the engine or let it run for any length of time in an enclosed area Exhaust fumes are poisonous These fumes contain carbon monoxide which by itself is odorless and colorle...

Страница 9: ...rner pendant un quelconque laps de temps dans un endroit clos Les fum es d chappement sont toxiques Ces fum es contiennent du monoxyde de carbone incolore et inodore Le monoxyde de carbone est un gaz...

Страница 10: ...s machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there...

Страница 11: ...PER IL NUOVO PROPRIETARIO Questo manuale fornir una buona comprensione di base delle caratteristi che del funzionamento e delle opera zioni fondamentali di manutenzione e di ispezione di questo veico...

Страница 12: ...be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General I...

Страница 13: ...suivies pour viter d endommager la machine N B Une N B fournit les renseignements n cessaires pour rendre les proc dures plus faciles ou plus claires TROUVER LA PAGE RECHERCHEE 1 Ce manuel comprend 7...

Страница 14: ...s 6 are given in addition to the exploded diagram and job instruction chart 4 33 CLUTCH AND PRIMARY DRIVEN GEAR ENG Extent of removal Order Part name Q ty Remarks PRIMARY DRIVEN GEAR PUSH ROD AND PUSH...

Страница 15: ...ces op rations 1 Exemple de vue en clat 1 clari fiant les op rations de d montage et de remontage 2 Sur les vues en clat les pi ces sont num rot es 2 dans l ordre des op rations effectuer Un chiffre...

Страница 16: ...nt w Tightening e Specified value Service limit r Resistance Voltage V Electric current A Illustrated symbols t to o in the exploded dia grams indicate grade of lubricant and location of lubrication p...

Страница 17: ...age e Valeur sp cifi e limite de service r R sistance tension V intensit A Les symboles graphiques t o dans les vues clat es indiquent le grade de lubrifiant et l emplacement des points de lubrificati...

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

Страница 19: ...INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7 ALLGEMEIN ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHINSCHE DATEN REGELM SSIGE PR FUNG UND EINSTELLUNGEN MOTEUR MOTOR PARTIE CYCLE FAHRGESTELL...

Страница 20: ...1 12 STARTING AND BREAK IN 1 13 TORQUE CHECK POINTS 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 1...

Страница 21: ...CH L 1 12 STARTEN UND EINFAHREN 1 13 ANZUGSMOMENTE PR FPUNKTE 1 16 REINIGEN UND LAGERUNG 1 17 KAPITEL 2 TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN 2 1 WARTUNGSDATEN 2 3 ALLGEMEINE ANZUGSDATEN 2 12 D...

Страница 22: ...RY DRIVEN GEAR 4 32 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 39 YPVS GOVERNOR 4 48 WATER PUMP 4 50 CDI MAGNETO 4 55 ENGINE REMOVAL 4 59 CRANKCASE AND CRANKSHAFT 4 64 TRANSMISSION SHIFT CAM AND S...

Страница 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 39 REGULATEUR YPVS 4 48 POMPE A EAU 4 50 MAGNETO CDI 4 55 DEPOSE DU MOTEUR 4 59 CARTER ET VILEBREQUIN 4 64 BOITE A VITESSES BARILLET DE SELECTEUR ET FOUR...

Страница 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 SOLENOID VALVE SYSTEM 6 6 TPS THROTTLE POSITION SENSOR SYSTEM 6 8 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 13...

Страница 25: ...COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 SYSTEME D ALLUMAGE 6 2 SYSTEME D ELECTROVANNE 6 6 SYSTEME TPS CAPTEUR DE POSITION DU PAPILLON 6 8 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 13...

Страница 26: ...cap 7 Kick starter 8 Fuel tank 9 Radiator 0 Coolant drain bolt q Check bolt Transmission oil level w Rear brake pedal e Valve joint r Fuel cock t Starter knob y Drive chain u Air cleaner i Shift peda...

Страница 27: ...r le niveau d huile de transmission w P dale de frein arri re e Joint de robinet r Robinet essence t Bouton de starter y Cha ne de transmission u Filtre air i P dale de s lecteur o Fourche avant N B 9...

Страница 28: ...tify your machine EC121001 VEHICLE IDENTIFICATION NUMBER For USA CDN AUS NZ and E The vehicle identification number 1 is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER For...

Страница 29: ...m ros pour retrouver et identifier votre machine NUMERO D IDENTIFICATION DU VEHICULE Pour USA CDN AUS NZ et E Le num ro d identification du v hicule 1 est frapp du c t droit du tube de t te de fourche...

Страница 30: ...ousing hole at the bottom 2 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 o...

Страница 31: ...ment remon t es 5 Tenir loign du feu 4 W hrend der Demontage der Maschine sind alle Teile zu reini gen und in der Reihenfolge der Demontage in Ablagen abzule gen um die Montage zu beschleunigen und ri...

Страница 32: ...olt 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 numbers facing outward...

Страница 33: ...2 so einbauen da das Zeichen des Herstellers oder die Herstellungs nummer nach au en gerichtet ist die eingeschlagenen Buchsta ben m ssen sichtbar sein Wenn ldichtungen eingebaut werden sind die ldich...

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

Страница 35: ...rclips doivent tre soigneusement v ri fi s Toujours changer les circlips d axe de piston apr s une utilisa tion Changer tout circlip d form Lorsqu on monte un circlip 1 s assurer que le c t non chanfr...

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 connector 6 Connect 9Connector NOTE The two connectors click together 7 Check for conti...

Страница 37: ...aums unbedingt die Schritte 1 bis 7 befol gen 9 Handels bliches Kontaktspray nur als Notl sung verwenden 9 Das Taschen Multimeter wie abge bildet am Steckverbinder ansch lie en 6 Connecter 9 Connecteu...

Страница 38: ...sed to split the crankcase as well as remove the crankshaft from either case YM 1189 90890 01189 Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto YU 1235 90890 0123...

Страница 39: ...90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 90890 03113 90890 03113 Engine tachometer This tool is needed for observin...

Страница 40: ...ager le carter et extraire le vilebrequin de l une ou l autre de ses moiti s YU 1135 A YM 1305 90890 01135 90890 01305 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose...

Страница 41: ...et outil pour examiner la r sistance de bobine la tension de sortie et l intensit YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Outil de poign e d brrayag...

Страница 42: ...ieser Geh useh lften YU 1135 A YM 1305 90890 01135 90890 01305 YM 1189 90890 01189 Schwungrad Abziehwerkzeug Dieses Werkzeug wird f r den Ausbau des Schwung rad Magnetz nders ben tigt YM 1189 90890 01...

Страница 43: ...zeug ist f r das Pr fen des Spulenwie derstandes der Ausgangsspannung und der Strom st rke zu verwenden YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Kupp...

Страница 44: ...i da una delle due parti del carter YU 1135 A YM 1305 90890 01135 90890 01305 YM 1189 90890 01189 Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 011...

Страница 45: ...ispezionare la resistenza della bobina la tensione in uscita e l intensit di corrente YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Utensile per tenere l...

Страница 46: ...AL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick...

Страница 47: ...en G nge erfolgt mittels Fu schalt hebel 1 angebrancht an der linken Seite des Motors KICKSTARTER Den Kickstarter 1 vom Motor weg schwenken Den Kickstarter langsam niedertreten bis die Zahnr der einra...

Страница 48: ...ltering the fuel The fuel cock has the two positions OFF With the lever in this position fuel will not flow Always return the lever to this posi tion when the engine is not running ON With the lever i...

Страница 49: ...ieller Starter kreislauf der ber den Starterknof 1 kontrolliert wird liefert dieses Gemisch Den Starterknopf herauszie hen um den Kreislauf zum Anwerfen des Motors zu ffnen Wenn der Motor warmgelaufen...

Страница 50: ...o the fuel tank breather hose cC In this installation make sure the arrow faces the fuel tank and also downward EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when...

Страница 51: ...raftstofftank Bel ftungsschlauch eingebaut dD Bei diesem Einbau ist darauf zu achten da der Pfeil auf den Kraft stofftank und nach unten weist IC15R001 CAVALLETTO STACCABILE Questo cavalletto 1 viene...

Страница 52: ...oline is not available then leaded gasoline can be used cC Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank...

Страница 53: ...MOTORI Miscelare l olio con la benzina nel rap porto specificato pi sotto Usare sem pre benzina fresca di marca e miscela re l olio e la benzina il giorno della gara Non usare una miscela gi prepa ra...

Страница 54: ...CHOKE 3 With the throttle completely closed start the engine by kicking the kick starter forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes ab...

Страница 55: ...ftig durchtreten um den Motor zu starten 4 Den Motor bei Leerlaufter Dreh zahl warmlaufen lassen f r das Warmlaufen werden normaler weise etwa eine bis zwie Minuten ben tigt 5 Der Motor ist warmgelau...

Страница 56: ...heck full throt tle response Stop and check the spark plug 6 After again allowing the engine to cool restart and run the machine for five more minutes Full throttle and the higher gears may be used bu...

Страница 57: ...et v ri fiez la r ponse pleine acc l ra tion Arr tez vous et rev rifiez la bougie 6 A nouveau laissez le moteur se refroidir Red marrez et pilotez pendant cinq nouvelles minutes Cette fois vous pouvez...

Страница 58: ...POINTS Tighten all such fasteners as required 9When any of the following parts have been replaced they must be broken in CYLINDER AND CRANKSHAFT About one hour of break in operation is necessary PIST...

Страница 59: ...enn eines der folgenden Teile erneuert wurde dann mu die Maschine wiederum eingefahren werden ZYLINDER UND KURBELWELLE Etwa eine Stunde Einfahrzeit ist erforderlich KOLBEN KOLBENRING UND ZAHNR DER Die...

Страница 60: ...to shock absorber Link to swingarm Rear Installation of shock Shock absorber to frame absorber Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of f...

Страница 61: ...e De la timonerie au cadre De la timonerie l amortisseur De la timonerie au bras oscillant Arri re Installation de De l amortisseur au cadre l amortisseur Arri re Installation du bras oscillant Serrag...

Страница 62: ...mpfer Gest nge an Hinterradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradshcwinge Rad Einbau des Rades Vorne Festziehen der Vo...

Страница 63: ...cellone oscillante Posteriore Installazione Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione della ruota A...

Страница 64: ...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 car...

Страница 65: ...ses ont r sult de l emploi abusif des vapori sateurs de d tergent haute pression tels que ceux qui quipent les laveries automatiques de voitures 4 Apr s avoir chass la majeure par tie de la boue lavez...

Страница 66: ...witch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a p...

Страница 67: ...onnez plusieurs coups de p dale pour enduire le cylindre d huile 3 D posez la cha ne nettoyez la soi gneusement au dissolvant et lubri fiez Remontez la cha ne ou ran gez la dans un sachet plastique fe...

Страница 68: ...2 stroke gasoline Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 lmp oz 8 42 US oz Bore Stroke 66 4 72 mm 2 614 2 835 in Compression ratio 9 1 10 6 1 Starting system K...

Страница 69: ...SA CDN ZA AUS NZ EUROPE Frame type Semi double cradle Caster angle 27 2 26 9 Trail 118 mm 4 65 in 115 mm 4 53 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90 19 62M Tire pressure fron...

Страница 70: ...0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Side clearance installed 1st 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2nd 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Crankshaft Crank width A 5...

Страница 71: ...air jet M A J 200 Jet needle clip position J N N3EJ 2 N3CW 3 Main nozzle N J 2 9 Cutaway C A 7 Pilot jet P J 50 55 Pilot air screw P A S 1 1 3 4 for reference only Valve seat size V S 3 8 mm 0 15 in...

Страница 72: ...7 Air filter element M 6 1 0 1 2 0 2 1 4 Carburetor joint M 6 1 0 5 10 1 0 7 2 Air filter case M 6 1 0 2 4 0 4 2 9 Air filter joint M 5 0 8 5 1 0 1 0 7 Reed valve M 3 0 5 4 1 0 1 0 7 Exhaust pipe M 6...

Страница 73: ...10 1 0 7 2 Push lever axle M 5 0 8 1 6 0 6 4 3 Drive sprocket M20 1 0 1 75 7 5 54 Shift guide M 6 1 0 2 10 1 0 7 2 Stopper lever M 6 1 0 1 10 1 0 7 2 Torsion spring shift shaft stopper bolt M 8 1 25 1...

Страница 74: ...p of outer tube with inner tube 3 15 5 91 in and damper rod fully compressed without spring Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end Zero mm Zero in Rear...

Страница 75: ...3 0 mm 9 84 0 12 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc...

Страница 76: ...nt brake master cylinder cap Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Cable guide front brake hose and guide stay Front brake hose union bolt master cylinder Fro...

Страница 77: ...r shock absorber and relay arm Rear frame and frame Swingarm and brake hose holder Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Fuel tank mounting Fuel tank and fu...

Страница 78: ...r type Electrical CDI Magneto model Manufacturer F5CU10 YAMAHA Source coil 1 resistance color 720 1 080 at 20 C 68 F Black Black Red Source coil 2 resistance color 44 66 at 20 C 68 F Green Blue Green...

Страница 79: ...temperature A Distance across flats B Outside thread diameter EC230000 DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS A B TORQUE SPECIFICATION Nut Bolt Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3...

Страница 80: ...ment liquide Dispositions de cylindres Monocylindre inclin Cylindr e 249 cm3 8 76 lmp oz 8 42 US oz Al sage course 66 4 72 mm 2 614 2 835 in Taux de compression 9 1 10 6 1 Syst me de d marrage D marre...

Страница 81: ...UROPE Type de cadre Simple berceau d d double Angle de chasse 27 2 26 9 Chasse 118 mm 4 65 in 115 mm 4 53 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Taille de pneu arri r...

Страница 82: ...T 2 55 mm 0 100 in Ecartement des becs mont 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Jeu lat ral mont 1 re 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2e 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm...

Страница 83: ...80 Gicleur d air M A J 200 Aiguille J N N3EJ 2 N3CW 3 Tubulure principal N J 2 9 Echancrure C A 7 Gicleur de ralenti P J 50 55 Vis d air de ralenti P A S 1 1 3 4 r f rence uniquement Taille de si ge d...

Страница 84: ...1 2 0 2 1 4 Raccord de carburateur M 6 1 0 5 10 1 0 7 2 Carter de filtre air M 6 1 0 2 4 0 4 2 9 Raccord du filtre air M 5 0 8 5 1 0 1 0 7 Soupape flexible M 3 0 5 4 1 0 1 0 7 Tuyau d chappement M 6 1...

Страница 85: ...pouss M 5 0 8 1 6 0 6 4 3 Pignon de cha ne M20 1 0 1 75 7 5 54 Guide de s lecteur M 6 1 0 2 10 1 0 7 2 Levier de but e M 6 1 0 1 10 1 0 7 2 Ressort de torsion arbre de s lecteur Boulon de but e M 8 1...

Страница 86: ...le tuyau 3 15 5 91 in int rieur et la tige d amortisseur compl tement appuy sans le ressort Grade d huile Huile de suspension 01 Diam tre ext rieur de tube interne 46 mm 1 81 in Extr mite sup rieure...

Страница 87: ...n Epaisseur de plaquette 4 4 mm 0 17 in 1 0 mm 0 04 in Dia int rieur de ma tre cylindre 11 0 mm 0 433 in Dia int rieur de cylindre d etrier 27 0 mm 1 063 in 2 Type de liquide de frein DOT 4 Frein disq...

Страница 88: ...vant trier Etrier de frein avant et fourche avant Etrier de frein avant et arri re et bouchon de goupille de plaquette Etrier de frein avant et arri re et goupille de plaquette Etrier de frein avant e...

Страница 89: ...voir essence et vis d accrochage bande de fixation R servoir essence et patte du r servoir essence Montage de selle Montage de couvercle lat ral Montage de buse d arriv e d air Montage de pare boue av...

Страница 90: ...rique CDI Magn to mod le Fabricant F5CU10 YAMAHA R sistance de bobinage de source 1 720 1 080 20 C 68 F couleur noir noir rouge R sistance de bobinage de source 2 44 66 20 C 68 F couleur vert bleu ver...

Страница 91: ...tages propres et secs Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filetage DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE SPECIFICATION...

Страница 92: ...er Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorne geneigt Hubraum 249 cm3 8 76 lmp oz 8 42 US oz Bohrung Hub 66 4 72 mm 2 614 2 835 in Verdichtungsverh ltnis 9 1 10 6 1 Anla system Kickstarter...

Страница 93: ...hrgestell USA CDN ZA AUS NZ EUROPA Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 27 2 26 9 Nachlaufbertrag 118 mm 4 65 in 115 mm 4 53 in Reifengr e Bauart Mit Schlauch Reifengr e Vorne 80 100 21 51M...

Страница 94: ...genspalt Eingebaut 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Seitliches Spiel Eingebaut 1 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in...

Страница 95: ...178 180 Hauptluftd se M A J 200 D sennadel Klemmposition J N N3EJ 2 N3CW 3 Hauptzerst uber N J 2 9 Abschr gung C A 7 Leerlaufd se P J 50 55 Leerlauf Luftregulierschraube P A S 1 1 3 4 nur als Hinweis...

Страница 96: ...element M 6 1 0 1 2 0 2 1 4 Vergaserverbindung M 6 1 0 5 10 1 0 7 2 Luftfiltergeh use M 6 1 0 2 4 0 4 2 9 Luftfilterverbindung M 5 0 8 5 1 0 1 0 7 Zungenventil M 3 0 5 4 1 0 1 0 7 Auspuffroht M 6 1 0...

Страница 97: ...ebelachse M 5 0 8 1 6 0 6 4 3 Antriebskettenrad M20 1 0 1 75 7 5 54 Schaltf hrung M 6 1 0 2 10 1 0 7 2 Anschlaghebel M 6 1 0 1 10 1 0 7 2 Torsionsfeder Schaltwelle Entkupplungsgliedbolzen M 8 1 25 1 2...

Страница 98: ...em inneren Rohr und der D mpfungsstange ohne Feder voll zusammengedr ckt lsorte Teleskopgabel l 01 Au endurchmesser des inneren Rohres 46 mm 1 81 in Oberes Ende der Null mm Null in Vorderradgabelbeinr...

Страница 99: ...4 0 12 in Bremsbelagst rke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder 11 0 mm 0 433 in Innendurchmesser Bremssattelzylinder 27 0 mm 1 063 in 2 Innendurchmesser Bremsfl ssigkeit DOT 4 Hinterradsc...

Страница 100: ...Belagplattenstift Bremssattel vorne und hinten und Entl ftungsschraube Vorderradachse und Mutter Vorderradachschalter Vorderrad Bremsscheibe und Radnabe Hinterrad Bremsscheibe und Radnabe Bremspedalb...

Страница 101: ...tz und Hinterradschwinge Kraftstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstof tank und Hakenschraube Befestigungsband Kraftstoftank und Krafts...

Страница 102: ...isch Ausf hrung CDI Modell Hersteller F5CU10 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 bei 20 C 68 F Schwarz Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 bei 20 C 68 F Gr n Blau Gr n W...

Страница 103: ...f r trockene und saubere Gewinde Die anzuziehenden Bauteile sollten dabei Raumtemperatur aufweisen A Schl sselweite B Gewindedurchmesserer DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A...

Страница 104: ...uido a benzina Disposizione dei cilindri Cilindro unico inclinato in avanti Cilindrata 249 cm3 8 76 lmp oz 8 42 US oz Alesaggio corsa 66 4 72 mm 2 614 2 835 in Rapporto di compressione 9 1 10 6 1 Sist...

Страница 105: ...idenza 27 2 26 9 Avancorsa 118 mm 4 65 in 115 mm 4 53 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 110 90 19 62M Pressione degli pneumatici anteriore e...

Страница 106: ...in 0 95 mm 0 037 in Gioco laterale installata 1 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Albero a gomiti Larghezza del gomito A 59 95 60 00 mm...

Страница 107: ...ale M A J No 200 Posizione della staffa dell ago di getto J N N3EJ 2 N3CW 3 Ugello principale N J 2 9 Sezione C A No 7 Getto pilota P J No 50 No 55 Vite dell aria pilota P A S 1 1 3 4 solo riferimento...

Страница 108: ...Giunto del carburatore M 6 1 0 5 10 1 0 7 2 Corpo del filtro dell aria M 6 1 0 2 4 0 4 2 9 Giunto del filtro dell aria M 5 0 8 5 1 0 1 0 7 Valvola a lamella M 3 0 5 4 1 0 1 0 7 Tubo di scarico M 6 1 0...

Страница 109: ...leva di spinta M 5 0 8 1 6 0 6 4 3 Rocchetto di trasmissione M20 1 0 1 75 7 5 54 Guida del cambio M 6 1 0 2 10 1 0 7 2 Leva di fermo M 6 1 0 1 10 1 0 7 2 Molla di torsione albero del cambio Bullone fe...

Страница 110: ...5 91 in il tubo interno e la barra dello smorzatore completamente compressi senza molla Qualit di olio Olio per sospensioni 01 Diametro esterno del tubo interno 46 mm 1 81 in Estremit superiore della...

Страница 111: ...04 in Diametro interno del cilindro principale 11 0 mm 0 433 in Diametro interno del cilindro delle pinze 27 0 mm 1 063 in 2 Tipo di liquido per freni DOT No 4 Freno a disco posteriore Diametro estern...

Страница 112: ...teriore M 6 1 0 2 9 0 9 6 5 Coperchio del cilindro principale del freno anteriore M 4 0 7 2 2 0 2 1 4 Leva di comando del freno vite M 6 1 0 1 6 0 6 4 3 Leva di comando del freno dado M 6 1 0 1 6 0 6...

Страница 113: ...telaio M14 1 5 1 80 8 0 58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio M 8 1 25 3 29 2 9 21 Fo...

Страница 114: ...ttrico CDI Modello Costruttore del magnete F5CU10 YAMAHA Resistenza 1 della bobina di origine 720 1 080 20 C 68 F colore Nero Nero Rosso Resistenza 2 della bobina di origine 44 66 20 C 68 F colore Ver...

Страница 115: ...ti dovrebbero essere a temperatura ambiente A Distanza fra le parti piatte B Diametro esterno della filettatura IC230000 DEFINIZIONE DELLE UNIT IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA SPECIF...

Страница 116: ...lead and solenoid valve lead with the clamp ends downward In so doing clamp the ENGINE STOP button lead at its protect ing tube E Clamp the clutch cable so that the clamp passes with its ends downwar...

Страница 117: ...ez le fil du bouton ENGINE STOP sur sa gaine de protection E Bridez le c ble d embrayage de fa on ce que la bride se pr sente avec les extr mit s vers le bas comme illustr F Faites passer le fil du ca...

Страница 118: ...ds for ward C Clamp the radiator breather hose and CDI magneto lead at the rear of the down tube with the clamp ends outward D Pass the clutch cable a little for ward of the extreme left nut that hold...

Страница 119: ...rieur avec les extr mit s de la bride vers l ext rieur D Faites passer le c ble d embrayage en peu en avant de l crou de fixation extr me gauche de la culasse E Faites passer le tuyau reniflard du rad...

Страница 120: ...he brake hose and swingarm bracket E Pass the reservoir hose into the hose guide F Clamp the high tension cord throttle cable TPS throttle posi tion sensor and solenoid valve lead so that the high ten...

Страница 121: ...ur de posi tion du papillon TPS et le fil d lectro vanne de fa on ce que le c ble haute tension ne soit pas en contact avec les crous de montage du support du moteur G Fixer le fil de masse avec la pa...

Страница 122: ...cts as show and lightly touches the projection on the master cylinder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Pass the clutch cable in front of the throttle cable D Cla...

Страница 123: ...diqu et touche l g rement la saillie sur le ma trecylindre B Faire passer le fil de bouton d arr t du moteur ENGINE STOP au centre du support d embrayage C Faire passer le c ble d embrayage devant le...

Страница 124: ...Check ring end gap Replace PISTON PIN SMALL END BEARING Inspect Replace CYLINDER HEAD Inspect and clean Remove carbon Retighten Check gasket CYLINDER Inspect and clean Inspect score marks Replace Ins...

Страница 125: ...luid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease REAR SHOCK ABSORBER Inspect and a...

Страница 126: ...3 3 INSP ADJ MEMO...

Страница 127: ...CULASSE Contr ler et nettoyer 6 6 Resserrer 6 6 CYLINDRE Cont ler et nettoyer 6 6 Changer 6 YPVS Contr ler et nettoyer 6 6 EMBRAYAGE Contr ler et r gler 6 6 Changer 6 BOITE DE VITESSE Changer l huile...

Страница 128: ...et les fuites 6 6 Resserrer les boulons du frein disque les boulons d tier les boulons du ma tre cylindre et les boulons d union 6 6 Changer les plaquettes 6 Changer le liquide de frein 6 FOURCHE AVAN...

Страница 129: ...gonflage le voile de roue et l usure des 6 6 pneus et voir s il n y a pas de rayon d tendu Resserrer les boulons de la roue 6 6 dent e Contr ler les roulements 6 Changer les roulements 6 Graisser 6 A...

Страница 130: ...BOLZEN PLEUELAUGEN LAGER Pr fen 6 Erneuern 6 ZYLINDERKOPF Pr fen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Pr fen und reinigen 6 6 Erneuern 6 YPVS Pr fen und reinigen 6 6 KUPPLUNG Pr fen und einstellen...

Страница 131: ...KRAFT STOFFHAHN Reinigen und pr fen 6 6 BREMSEN Bremshebelposition und Bremspedalh he einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfl che pr fen 6 6 Fl ssigkeitsstand pr fen und auf Undichtigk...

Страница 132: ...ch Rennen Rennen R DER REIFEN Reifendruck Felgenschlag Reifenverschlei und Speichen 6 6 auf Lockerung pr fen Ketternrad Befestigungsschraube 6 6 nachziehen Lager pr fen 6 Lager erneuern 6 Schmieren 6...

Страница 133: ...A CILINDRO Ispezione e pulitura 6 6 Riserraggio 6 6 CILINDRO Ispezione e pulitura 6 6 6 Sostituzione YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sost...

Страница 134: ...e pastiglie 6 Sostituzione liquido per freni 6 FORCELLE ANTERIORI Ispezione e regolazione 6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pul...

Страница 135: ...per motori SAE 10W 30 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneumatico e dell allentamento delle razze Riserraggio bullone del rocche...

Страница 136: ...ar brake P3 17 23 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 24 26 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excess...

Страница 137: ...ne Contr ler la tension et l alignement de la cha ne S as surer que la cha ne est graiss e correctement P3 24 26 Roues Contr ler s il n y a pas d usure excessive Contr ler s il n y a pas de rayons d t...

Страница 138: ...usrichtung pr fen Auch sicherstellen da die Kette richtig geschmiert P3 24 26 ist R der Die Reifen auf berm ige Abnutzung kontrollieren Speichern auf Lockerung und berm iges Spiel pr P3 34 35 fen Lenk...

Страница 139: ...i cavi della frizione e dell acceleratore si muovano senza problemi Controllare che non rimanga no impigliati quando viene girato il manubrio o quando le forcelle anteriori si alzano e si abbassano C...

Страница 140: ...p slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise an...

Страница 141: ...diateur et tourner lentement le bouchon gauche jusqu au point de d tente Cette proc dure permet de faire tom ber toute pression r siduelle Quand le sifflement s est arr t appuyer sur le bouchon tout e...

Страница 142: ...rain the coolant completely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Re...

Страница 143: ...schizzi sulle superfici ver niciate Se schizza toglierlo con acqua 1 Collocare un contenitore sotto il motore 2 Togliere 9 Bullone di scarico del liquido refrigerante 1 3 Togliere 9 Tappo del radiato...

Страница 144: ...el low Add coolant EC355000 RADIATOR CAP INSPECTION 1 Inspect 9Seal radiator cap 1 9Valve and valve seat 2 Crack Damage Replace Exist fur deposits 3 Clean or replace Handling notes of coolant The cool...

Страница 145: ...it Wasser und danach mit Seife weg oder auswaschen 9Falls K hlmittel eingenom men wird Die betroffene Person sofort zum Erbre chen bringen und zum n ch sten Doktor begleiten Notes concernant la manipu...

Страница 146: ...essure Impossible to maintain the specified pres sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the speci...

Страница 147: ...Appliquer de l eau sur le joint du bou chon du radiateur 3 Bouchon du radiateur 2 Appliquer la pression sp cifi e 3 Examiner 9 Pression Impossible de maintenir la pres sion sp cifi e pendant 10 second...

Страница 148: ...Radiator hose 3 Swelling Replace 2 Adjust 9Clutch lever free play EC359020 CLUTCH ADJUSTMENT 1 Check 9Clutch lever free play a Out of specification Adjust NOTE 9Make minute adjustment on the lever sid...

Страница 149: ...ge NOTA 9Non applicare pressione superiore alla pressione specificata 9Il radiatore dovrebbe essere completa mente pieno 4 Ispezionare 9 Pressione Impossibile mantenere la pres sione specificata per 1...

Страница 150: ...rease On the throttle cable end a tube guide cable winding portion b and roller sliding surface c Throttle grip free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until the specifie...

Страница 151: ...1 Togliere 9 Coperchio della calotta 1 9 Calotta del cavo dell acceleratore 2 Jeu la poign e d acc l ration a a 3 5 mm 0 12 0 20 in Gioco libero della mano pola dell acceleratore a a 3 5 mm 0 12 0 20...

Страница 152: ...ine 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 1 Remove 9Seat 9Fitting bolt 1 9Washer 2 9Air filter elem...

Страница 153: ...ten w rden n mlich Staub und Schmutz in den Motor eindringen und schnellen Verschlei sowie m glichen Motorschaden verursa chen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelemen...

Страница 154: ...hole b in air filter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on fil...

Страница 155: ...filtro dell aria Danni Sostituirlo 4 Applicare 9 Olio per filtro dell aria in schiu ma oppure olio per miscela per motori Sull elemento NOTA Comprimere per fare fuoriuscire l olio in eccesso L elemen...

Страница 156: ...9Remove the oil check bolt 1 9Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level w Never attempt to remove the oil check bolt just after high speed...

Страница 157: ...moteur le laisser chauffer quelques minutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en pla ant le support convenable sous le moteur 3 Placer un...

Страница 158: ...level 9 Install 9Oil filler cap 2 EC35L021 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Adjusting steps 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw...

Страница 159: ...4 10W 30 ou huile moteur SAE 10W 30 type SE Quantit d huile change ments d huile p rio diques 0 75 L 0 66 Imp qt 0 79 US qt Olio raccomandato Olio per motore Yamalube 4 10W 30 oppure SAE 10W 30 del t...

Страница 160: ...0 MUFFLER INSPECTION 1 Inspect 9O ring 1 Damage Replace EC35R041 SILENCER FIBER REPLACEMENT 1 Remove 9Seat 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adjustment steps Turn the thrott...

Страница 161: ...ne au r gime le plus bas pos sible Pour diminuer le regime de ralenti Visser le vis de but e d acc l rateur 1 1 Pour diminuer le regime de ralenti D visser le vis de but e d acc l rateur 1 1 Passi del...

Страница 162: ...right 9Seat 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 1215...

Страница 163: ...0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reusement de l agent d tanch it...

Страница 164: ...ake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place...

Страница 165: ...iedrigem Bremsfl ssig keitsstand 9 Bei fehlerhafter Funktion der Bremsanlage Falls die Bremsanlage nicht richtig entl ftet wird kann es zu einer gef hrlichen Abnahme des Brems verm gens kommen 1 Ausba...

Страница 166: ...the tiny bubbles in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever position a a Standar...

Страница 167: ...oso pu essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le bol licine nell impianto sono scompar se j Aggiungere liqui...

Страница 168: ...heck 9Brake pedal height a Out of specification Adjust 2 Adjust 9Brake pedal height Brake pedal height a a 5 mm 0 20 in Pedal height adjustment steps 9Loosen the locknut 1 9Turn the adjusting nut 2 un...

Страница 169: ...instellung soll te das Ende b b der Schraube 3 3 ander unteren Einstellmutter 4 4 berstehen aber um nicht mehr als 2 mm 0 08 in c c von dem Bremspedal 5 5 9 Nachdem die Pedalh he einge stellt wurde da...

Страница 170: ...er piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 8 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9T...

Страница 171: ...it nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 8 und Bremsbelag plattenstift einbauen ANMERKUNG 9 Bremsbel ge mit deren ber st nden a in die Bremsschuh aussparungen b an...

Страница 172: ...REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect 9Brake pad thickness a Out of specification Replace as a set 2 Replace 9Brake pad 9Install the pad pin plug w Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb B...

Страница 173: ...mando del freno Sensazione di morbidezza o spugnosit Spurgare impianto frenante Consultare la sezione SPURGO DELL ARIA DALL IMPIANTO FRENANTE IC366060 ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FREN...

Страница 174: ...projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper w and rear wheel e Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 9Tighten...

Страница 175: ...er le tuyau transparent 8 la vis de purge 9 et placer le r cipient appropri sous son extr mit 9Desserrer la vis de purge et y enfoncer le piston d trier fF Ne pas r utiliser le liquide de frein purg 9...

Страница 176: ...linder so that its top is in a horizontal position 2 Inspect 9Brake fluid level Fluid at lower level Fill up a Lower level Front Rear w 9Use only designated quality brake fluid to avoid poor brake per...

Страница 177: ...LO DEL LIQUIDO PER FRENI 1 Collocare il cilindro principale in maniera tale che la sua parte supe riore si trovi in posizione orizzon tale 2 Ispezionare 9 Livello del liquido per freni Fluido a livell...

Страница 178: ...SPECTION 1 Remove 9Master link clip 9Joint 1 9Drive chain 2 2 Clean 9Drive 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...

Страница 179: ...n 9 Kettenschlo klemme 9 Verbindung 1 9 Antriebskette 2 IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei rocchetti a Usura eccessiva Sostituirli NOTA Sostituire il rocchetto conduttore quel...

Страница 180: ...adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position D...

Страница 181: ...dD Unbedingt die Kettenschlo klemme in der gezeigten Richtung einbau en a Drehrichtung 6 Schmieren 9 Antriebskette 5 Installare 9 Catena di trasmissione 1 9 Giunto 2 9 Graffa dell anello principale 3...

Страница 182: ...Turn adjuster 3 3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on ea...

Страница 183: ...es Motors und anderer wichtiger Teile die Kettenspannung daher inner halb des spezifizierten Berei ches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sic...

Страница 184: ...seal and oil seal after every run 9Apply the lithium soap base grease on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1...

Страница 185: ...ettoyer 9 Joint antipoussi re a 9 Bague d tanch it b N B 9Nettoyer le joint antipoussi re et la bague d tanch it apr s chaque cour se 9Appliquer la graisse base de savon au lithium sur le tube interne...

Страница 186: ...t can cause poor handling and loss of stability EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Remove 9Rubber cap 2 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a...

Страница 187: ...so completamente inverso partendo avvitata dalla posizione massima Ampiezza della regolazione H rter a a Die Kompressi ons D mpfungs kraft erh hen Den Einsteller 1 1 hineindrehen Weicher a a Die Kompr...

Страница 188: ...aximum extent of adjustment The ad juster may be damaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install 9Rubber cap EC36K...

Страница 189: ...stabilit 3 Installare 9 Tappo di gomma 9 POSITION STANDARD C est la position qui se trouve en arri re du nombre sp cifi de d clics partir de la position enti rement vis s e fF Ne pas forcer le r gula...

Страница 190: ...nut and adjuster before adjustment 9The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster cC Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tig...

Страница 191: ...REGLAGE DE LA PRECON TRAINTE DE RESSORT DE L AMORTISSEUR ARRIERE 1 Sur lever la roue arri re en pla ant la cale appropri e sons le moteur 2 D poser 9 Cadre arri re 3 Desserrer 9 Contre crou 1 4 R gler...

Страница 192: ...ion Which align the punch mark a on the ad juster with the punch mark b on the bracket For EUROPE cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be dam...

Страница 193: ...ebond En tournant le dispositif de r glage 1 EINSTELLUNG DER EXPANSIONS D MPFUNGSKRAFT DES HINTER RAD STOSSD MPFERS 1 Einstellen 9 Expansions D mpfungskraft Durch Drehen des Einstellers 1 IC36N020 REG...

Страница 194: ...n the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be d...

Страница 195: ...OS SD MPFERS 1 Einstellen 9 Niedrige Kompressions D mp fungskraft Den Einsteller 1 drehen IC36c000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolar...

Страница 196: ...Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged q a...

Страница 197: ...sions D mp fungskraft Den Einsteller 1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compression...

Страница 198: ...its position on the rim 9If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect 9S...

Страница 199: ...che lo pneumatico scivola fuori dalla sua posizione sul cerchione 9Se si trova inclinato il gambo della valvola dello pneumatico si ritiene che lo pneumatico stia scivolando fuori dalla sua posizione...

Страница 200: ...sembly back and forth Free play Adjust steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring...

Страница 201: ...ta di sterzo 3 Controllare 9 Azione senza problemi dello sterzo Girare il manubrio da blocco a blocco Azione con problemi Regola re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellschr...

Страница 202: ...plate 9 NOTE 9The upper handlebar holder should be installed with the punched mark a forward 9Insert the end of fuel breather hose 0 into the hole of the number plate cC First tighten the bolts on the...

Страница 203: ...lato posteriore 9Desserrer l crou annulaire d un tour 9Resserrer l crou annulaire l aide de la cl pour crou annu laire XG Prendre garde de ne pas serrer excessivement 9V rifier l arbre de direction e...

Страница 204: ...vot 5 Throttle to handlebar contact 6 Drive chain 7 Throttle roller sliding surface 8 Tube guide cable winding portion 9 Throttle cable end 0 Clutch cable end Use Yamaha cable lube or equivalent on th...

Страница 205: ...rimento del rullo della valvola a farfalla 8 Parte a spira del cavo di guida del tubo 9 Estremit del cavo dell acceleratore 0 Estremit del cavo della frizione A Usare lubrificante per cavi Yamaha o eq...

Страница 206: ...low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification...

Страница 207: ...tore della candela diventa fuligginoso anche se il motore e il carburatore sono in buone condizio ni di funzionamento 3 Misurare 9 Distanza tra le candele a Usare un calibro per fili metalli ci o uno...

Страница 208: ...C When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the...

Страница 209: ...der Me uhr und ndert ihre Bewegungsrichtung wenn der Rotor in der gleichen Richtung weitergedreht wird 4 Im oberen Totpunkt ist die Me uhr auf Null zu stellen 5 Aus dem oberen Totpunkt ist der Rotor i...

Страница 210: ...SP ADJ 7 Adjust 9Ignition timing Adjustment steps 9Loosen the screws stator 1 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator 9Tighten the screws stator Screw s...

Страница 211: ...ben Stator 1 l sen 9 Die K rnermarkierung an dem Rotor mit der K rnermarkierung an dem Stator 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allen...

Страница 212: ...ht 2 3 Fitting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 4 3 Extent of removal 1 Seat removal...

Страница 213: ...ion 1 MOTOR SITZ KRAFTSTOFFTANK UND SEITENDECKEL Ausbauumfang 1 Ausbau des Sitzes 2 Ausbau des Kraftstofftanks 3 Ausbau der Seitendeckel 4 Ausbau des Nummernschildes IC400000 MOTORE IC4R0000 SELLA SER...

Страница 214: ...TS EC413101 Side cover 1 Remove 9Side cover left and right 1 cC Be sure to remove the seat before remov ing the side cover If you remove the side cover with force without removing the seat the panel 2...

Страница 215: ...POINTS DE DEPOSE Couvercle lat ral 1 D poser 9 Couvercle lat ral gauche et droit 1 fF Veiller enlever d abord la selle avant de retirer le couvercle lat ral Si le couvercle lat ral est enlev e en for...

Страница 216: ...cover right Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Bolt silencer 2 2 Silencer 1 3 Tension spring 2 4 Bolt exhaust pipe 2 5 Exhaust pipe 1 1 Extent of removal 1 Silencer removal 2 E...

Страница 217: ...lld mpfer 1 3 Zugfeder 2 4 Schraube Auspuffrohr 2 5 Auspuffroht 1 AUSPUFFROHR UND SCHALLD MPFER Ausbauumfang 1 Ausbau des Schalld mpfers 2 Ausbau des Auspuffrohres IC4S0000 TUBO DI SCARICO E SILENZIAT...

Страница 218: ...FUEL TANK AND SIDE COVERS section 1 Panel 2 Refer to REMOVAL POINTS 2 Clamp radiator hose 2 3 2 Only loosening 3 Radiator hose 1 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator h...

Страница 219: ...CARBURANTE E COPERTURE LATERALI 1 Pannello 2 Consultare PUNTI DI RIMOZIONE 2 Brida manicotto flessibile del radiatore 2 3 2 Soltanto allentamento 3 Manicotto flessibile del radiatore 1 1 4 Radiatore...

Страница 220: ...te the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it...

Страница 221: ...viette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de d tente Cette proc dure permet d liminer toute pression r siduelle Quand le sifflement s est arr t appuyer sur le bouch...

Страница 222: ...TER 2 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb 3 Install 9Radiator left 1 9Bolt radiator left 2 9Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER...

Страница 223: ...chlauch 1 3 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Festziehen 9 Klemme K hlerschlauch 2 3 4 5 Einbauen 9 Tafel 1 ANMERKUNG 9 Darauf achten da das Blech nicht mehr als erforderlich...

Страница 224: ...ection 1 Solenoid valve lead 1 Disconnect the solenoid valve lead 2 TPS throttle position sensor 1 Disconnect the TPS lead throttle position sensor lead 3 Clamp carburetor joint 2 Loosen the screws ca...

Страница 225: ...gaserverbindung 2 Die Schrauben Vergaserverbindung l sen 4 Vergaser 1 5 Vergaserverbindung 1 6 Zungenventil 1 7 Anschlag Zungenventil 2 8 Zungenventil 2 VERGASER UND ZUNGENVENTIL Ausbauumfang 1 Ausbau...

Страница 226: ...g chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Float pin 1 7 Float 1 8 Needle valve 1 9 Main jet 1 0 Pilot jet 1 q Starter plunger 1 w...

Страница 227: ...mmerstift 1 7 Schiwimmer 1 8 Nadelventil 1 9 Hauptd se 1 0 Leerlaufd se 1 q Starter Plungerkolben 1 w Drosselanschlagschraube 1 e Leerlauf Luftregulierschraube 1 Siehe unter AUSBAUPUNKTE r Kraftd se 1...

Страница 228: ...rottle valve 1 9Ring 2 9Spring throttle valve 3 9Mixing chamber top 4 9Throttle cable 5 NOTE While compressing the spring throttle valve disconnect the throttle cable EC463401 Pilot air screw 1 Remove...

Страница 229: ...bei der Motorleistung bewirkt IC466020 NOTA PER IL MANEGGIO iI Non allentare le viti conduttore TPS sensore di posizione gas se non per cambiare il conduttore TPS sensore di posizione gas qualora si g...

Страница 230: ...9Power jet 3 Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air 9Never use a wire EC464210 Needle valve 1 Inspect 9Needle valve 1...

Страница 231: ...1 Contr ler 9 Mouvement Coincement R parer ou chan ger N B Ins rer le boisseau 2 dans le corps du carburateur tout en maintenant le levier 1 relev et contr ler s il coulisse en douceur Drosselventil...

Страница 232: ...Measurement and adjustment steps 9Hold the carburetor in an upside down posi tion 9Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers N...

Страница 233: ...tilsitz und das Nadelventil kontrollieren 9 Wenn eines der beiden Teile abgenutzt ist beide Teile erneu ern 9 Befinden sich beide Teile in gutem Zustand dann ist die Schwimmerh he durch Abbie gen der...

Страница 234: ...cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping 1 Nm 0 1 m kg 0 7 ft lb 9Valve stopper height b Out of specification Adjust stopper Replace va...

Страница 235: ...dD Die Schrauben allm hlich festzie hen um ein Verziehen des Ventils zu vermeiden REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 But e soupape flexible 2 9 Vis soupape flexible...

Страница 236: ...ND REED VALVE 10 Nm 1 0 m kg 7 2 ft lb EC4652F0 Carburetor 1 Install 9Power jet 1 To carburetor 2 2 Install 9O ring 1 9Solenoid valve 2 9Clamp 3 9Screw clamp 4 To carburetor 5 cC 9Before installing th...

Страница 237: ...ur 2 2 Monter 9 Joint torique 1 9 Electrovanne 2 9 Bride 3 9 Vis bride 4 Au carburateur 5 fF 9Avant d installer l lectrovanne nettoyez l air comprim l lectro vanne et sa position de montage sur le car...

Страница 238: ...allation points 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw by the number of turns recorded before removing 5 Install 9Pilot jet 1 9Main jet 2 6 Install 9Need...

Страница 239: ...tto pilota 1 9 Getto principale 2 3 Monter 9 Vis de richesse 1 9 Vis but e d acc l rateur 2 Pour EUROPE 4 Monter 9 Plongeur de d marreur 1 Noter les points de montage sui vants 9Visser la vis de riche...

Страница 240: ...nds not having the cuts a toward the carburetor 9 Install 9Jet needle 1 9Collar 2 9Spring 3 9Needle holder 4 To throttle valve 5 NOTE Install the spring with its smaller dia a facing the collar 10 Ins...

Страница 241: ...ventilation et le tuyau de trop plein au carburateur avec les extr mit s sans chancrures a orient es vers le carburateur 8 Einbauen 9 Bel ftungsschlauch 580mm 22 8 in 1 9 Bel ftungsschlauch 400mm 15 7...

Страница 242: ...e air vent hose 9After installing check the throttle grip for smooth movement EC465390 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor joint slots 2...

Страница 243: ...AL MINIMO al CAPI TOLO 3 3 Anschlie en 9 TPS Leitungskabel Drossel stellungssensor 1 9 Magnetventilleitung 2 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Einstellen 9 Leerlaufdrehzahl S...

Страница 244: ...t cylinder head side Carburetor Refer to CARBURETOR AND REED VALVE section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 6 Loosen each nut 1 4 turn and remove them after all nuts are loosened...

Страница 245: ...weils 1 4 Drehung l sen bis alle Muttern locker sind 4 Zylinderkopf 1 5 Leistungsventilgeh use 1 6 Schubstange 1 Siehe unter AUSBAUPUNKTE 7 Mutter Zylinder 4 8 Zylinder 1 ZYLINDERKOPF ZYLINDER UND KOL...

Страница 246: ...INTS 4 Small end bearing 1 5 Piston ring 2 6 Power valve cover 1 7 Side holder 2 8 Thrust plate 1 9 Bolt 3 10 Valve shaft 1 11 Link lever 1 12 Pulley 2 13 Link rod 1 14 Power valve 2 2 15 Valve holder...

Страница 247: ...cheibe 1 9 Schraube 3 10 Ventilwelle 1 11 Verbindungshebel 1 12 Riemenscheibe 2 13 Pleuelstange 1 14 Leistungsventil 2 2 15 Ventilhalterung 1 16 Leistungsventil 1 1 KOLBEN UND LEISTUNGSVENTIL Ausbauum...

Страница 248: ...iston and piston ring 1 Remove 9Piston pin clip 1 NOTE Before removing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the crankcase cav ity...

Страница 249: ...des Kolbenbol zens 1 ANMERKUNG Vor dem Abnehmen des Stifts des Kol benbolzens ist das Kurbelgeh use mit einem sauberen Lappen abzudecken so da der Stift nicht versehentlich in das Kurbelgeh use f llt...

Страница 250: ...tion Re surface Warpage measurement and re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur f...

Страница 251: ...se 4 en lui faisant faire des huit N B Tourner la culasse plusieurs fois pour viter d enlever trop de mati re d un c t Limite de d formation 0 03 mm 0 0012 in Schritte f r Messung der Ver werfung und...

Страница 252: ...easure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measureme...

Страница 253: ...ung C Die Zylinder Me lehre 1 ver wenden Au erhalb des Grenzwertes Erneuern ANMERKUNG Die Zylinderbohrung C parallel A B C und im rechten Winkel zur Kurbel welle a b messen Danach den Durchschnitt der...

Страница 254: ...oloration Replace 2 Measure 9Piston pin outside diameter Use micrometer 1 Out of limit Replace 3 Check 9Free play when the piston pin 1 is in place in the piston 2 There should be no noticeable for th...

Страница 255: ...tre ext rieur d axe de piston 3 Pr fen 9 Spiel Wenn der Kolbenbolzen 1 im Kolben 2 eingebaut ist Es sollte kein sp rbares Spiel sein Spiel wird festgestellt Kolbenbolzen und oder Kolben erneuern 3 Con...

Страница 256: ...arance Use a thickness gauge 1 Out of limit Replace piston and or ring NOTE Check at several points Ring end gap installed Standard Limit 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Side clearance St...

Страница 257: ...orona del pistone 2 Misurare 9 Distanza tra le estremit Usare uno spessimetro 1 Fuori limite Sostituirla Standard Grenze 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Kolbenring Endspalt Eingebaut Stan...

Страница 258: ...mm 2 61433 2 61441 in C 66 408 66 410 mm 2 61449 2 61457 in D 66 412 66 414 mm 2 61465 2 61472 in Piston mark a a color Piston size A red 66 352 66 355 mm 2 61228 2 61240 in B orange 66 356 66 359 mm...

Страница 259: ...66 412 66 414 mm 2 61465 2 61472 in Tacca del Dimensioni pistone a a del pistone colore A rossa 66 352 66 355 mm 2 61228 2 61240 in B arancione 66 356 66 359 mm 2 61244 2 61256 in C verde 66 360 66 36...

Страница 260: ...2 7 Broken Replace EC474901 Power valve hole on cylinder 1 Remove 9Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratching the aluminum 3 Combination Combin...

Страница 261: ...ium Leistungsventilbohrung im Zylinder 1 Ausbauen 9 Ru ablagerungen Aus der Leistungsventil Boh rung a ANMERKUNG Kein scharfkantiges Instrument ver wenden Kratzer auf dem Aluminium vermeiden IC474901...

Страница 262: ...e molybdenum disulfide oil on the power valve 1 2 Install 9Power valve 2 1 9Link rod 2 9Plain washer 3 9Screw link rod 4 NOTE Install the link rod with the cuts a in its arm ends fitting over the pins...

Страница 263: ...ne sur le clapet de puissance 1 IC475000 MONTAGGIO E INSTALLAZIONE IC475192 Valvola di potenza 1 Installare 9 Valvola di potenza 1 1 9 Portavalvola 2 9 Bullone portavalvola 3 NOTA 9Montare la valvola...

Страница 264: ...bdnum disulfide oil on the grooves in the pulleys 9Apply the lithium soap base grease on the oil seal lip 9Install the valve shaft with its cut b aligning with the thrust plate 7 and then rotate the v...

Страница 265: ...tallare 9 Molla 1 1 9 Leva del biscottino 2 9 Puleggia 3 9 Molla 2 4 9 Rosetta 5 9 Gambo della valvola 6 NOTA 9Installare la molla 1 sulla leva del biscottino e quindi sul cilindro 9Installare la moll...

Страница 266: ...the power valve cover 9Install the power valve cover so that the arrow mark b faces upward EC475233 Piston ring and piston 1 Install 9Piston ring 1 NOTE 9Take care not to scratch the piston or damage...

Страница 267: ...le c t imprim du joint vers le couvercle du clapet de puissance 9Installer le couvercle du clapet de puissance en orientant vers le haut la saillie b l arri re 2 Installare 9 Guarnizione cilindro 1 9...

Страница 268: ...hand NOTE After installing check the smooth movement of the piston 3 Install 9Nut cylinder 1 NOTE Tighten the nuts in stage using a crisscross pat tern 3 Install 9Piston 1 9Piston pin 2 9Piston pin cl...

Страница 269: ...2 et la surface de cylindre IC475382 Testa cilindro e cilindro 1 Applicare 9 Olio per motori Sul pistone 1 sulla fascia ela stica 2 e sulla superficie del cilindro 35 Nm 3 5 m kg 25 ft lb 35 Nm 3 5 m...

Страница 270: ...not used the power valve constituent parts will result in damage 5 Install 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 6 Install 9O ring 1 9Dowel pin 2 NOTE Apply t...

Страница 271: ...ella valvola di potenza 1 9 Bullone corpo della valvola di potenza 2 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 25 Nm 2 5 m kg 18 ft lb 25 Nm 2 5 m...

Страница 272: ...CYLINDER AND PISTON ENG 9 Install 9Spark plug 1 9Spark plug cap 2 8 Install 9Engine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 20 Nm 2 0 m kg 14 ft lb 34 Nm 3 4 m kg 24 ft lb 69 Nm...

Страница 273: ...ela 1 9 Calotta della candela 2 8 Einbauen 9 Motorhalterung 1 9 Schraube Motorhalterung 2 9 Motor Befestigungsschraube Ober 3 8 Installare 9 Staffa del motore 1 9 Bullone staffa del motore 2 9 Bullone...

Страница 274: ...Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Press...

Страница 275: ...er 6 3 Kupplungsfeder 6 4 Druckscheibe 1 5 Reibscheibe 8 6 Kupplungsscheibe 7 KUPPLUNG UND PRIM RABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und Reibsch...

Страница 276: ...al tool 7 Lock washer 1 Refer to REMOVAL POINTS 8 Clutch boss 1 9 Thrust plate D 44mm 1 73 in 1 10 Primary driven gear 1 11 Bearing 1 12 Thrust plate D 42mm 1 65 in 1 13 Bolt push lever axle 1 14 Push...

Страница 277: ...bhebelachse 1 14 Schbhebelachse 1 PRIM RABTRIEBSZAHNRAD SHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Prim rab...

Страница 278: ...ON EC484100 Clutch housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free pl...

Страница 279: ...lten F r USA und CDN Au er USA und CDN POINTS DE DEPOSE Noix d embrayage 1 D poser 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poign e d em...

Страница 280: ...2 EC484700 Push lever axle 1 Inspect 9Push lever axle 1 Wear Damage Replace EC484810 Push rod 1 Inspect 9Push rod 1 1 9Bearing 2 9Plain washer 3 9Push rod 2 4 Wear Damage Bend Replace EC495000 ASSEMB...

Страница 281: ...quatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors sp cification Changer tous les disques d embrayage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Axe de levie...

Страница 282: ...il on the bearing spacer and primary driven gear inner circumference 2 Install 9Thrust plate D 44 mm 1 73 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding to...

Страница 283: ...Appliquer de l huile de bo te de vitesses sur le roulement l entretoise et la circonf rence int rieure du pignon men primaire 2 Monter 9 Plaque de bot e D 44 mm 1 73 in 1 9 Noix d embrayage 2 3 Monte...

Страница 284: ...es and clutch plates 6 Install 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4 NOTE Apply the lithium soap base grease on the bear ing and plain washer 7 Install 9Push rod 2 1 9Push rod 1 2 NOTE...

Страница 285: ...ottement 9Appliquer de l huile de bo te de vitesses sur les disques de friction et disque d embrayage 6 Monter 9 Roulement 1 9 Rondelle ordinaire 2 9 Circlip 3 sur le champignon de d brayage 1 4 N B A...

Страница 286: ...9O ring 1 To clucth cover 11 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 12 Install 9O ring 1 9Clutch cable 2 NOTE Apply the lithium soap b...

Страница 287: ...lithium sur le joint torique 10 Installare 9 Anello di tenuta 1 Verso la protezione della frizio ne 11 Einbauen 9 Kupplungsdeckel 1 9 Schraube Kupplungsdeckel 2 ANMERKUNG Die Schrauben stufenweise be...

Страница 288: ...ect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4...

Страница 289: ...ein Pousser la p dale de frein vers le bas Tuyau de radiateur 4 D connecter du c t pompe eau Boulon Se reporter la section CULASSE champignon de d brayage CYLINDRE ET PISTON 1 Kick starter 1 2 Couverc...

Страница 290: ...xle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 9 Holder 1 10 Tension spring 1 1 Ex...

Страница 291: ...l arbre de s lecteur et du levier de but e Etendue de d pose Ordre Nom de pi ce Q t Remarques DEPOSE DE L AXE DE DEMAR REUR AU PIED ET DE L ARBRE DE SELECTEUR 1 Pignon de renvoi de d marreur au pied...

Страница 292: ...move 9Kick axle assembly 1 NOTE Unhook the torsion spring 2 from the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assemb...

Страница 293: ...d marreur au pied 1 D poser 9 Ensemble axe de d marreur au pied 1 N B D crocher le ressort de torsion 2 de l orifice a sur le vilebrequin Ensemble guide de levier de s lecteur 1 D poser 9 Boulon guide...

Страница 294: ...Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Bearing 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever 9Tension spring 3 Broken Replace EC4C4100 Shift gu...

Страница 295: ...r Guide de s lecteur et ensemble levier de s lecteur 1 Examiner 9 Guide de s lecteur 1 9 Levier de s lecteur 2 9 Le cliquet 3 9 Le broche cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de bu...

Страница 296: ...ft 2 Install 9Shift lever assembly 1 To shift guide 2 EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130...

Страница 297: ...lecteur et ensemble levier de s lecteur 1 Monter 9 Ressort 1 9 Broche cliquet 2 9 Cliquet 3 Au levier de s lecteur 4 2 Monter 9 Ensemble levier de s lecteur 1 Au guide de s lecteur 2 3 Monter 9 Ensem...

Страница 298: ...ke sure the stopper a of the torsion spring fits into the hole b on the kick axle EC4C5601 Kick axle assembly 1 Install 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer...

Страница 299: ...Arbre de s lecteur 3 N B Enduire l arbre de s lecteur et les roule ments d huile de transmission Ensemble axe de d marreur au pied 1 Monter 9 Pignon de d marreur au pied 1 9 Rondelle ordinaire 2 9 Cir...

Страница 300: ...all 9Spring 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 the torsion spring 4 Install 9Plain washer 1 9Kick axle assembly 2...

Страница 301: ...passen mu 3 Monter 9 Guide de ressort 1 N B Coulisser la guide de ressort dans l axe de d marreur au pied s assurer que la gorge a dans la guide de ressort soit engag e sur la but e du ressort de tor...

Страница 302: ...olt primary drive gear 1 NOTE Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3 EC4C5531 Primary drive gear 1 Install 9Thrust plate 1 9Primary drive gear 2 9Gov...

Страница 303: ...ent le boulon ce stade 2 Monter 9 Pignon men primaire Se reporter la section EMBRAYAGE ET PIGNON MENE PRIMAIRE 3 Serrer 9 Boulon pignon de transmission primaire 1 N B Mettre une plaque en aluminium a...

Страница 304: ...connecting the center of the shift shaft and bottom of the screw crankcase cover left 3 7 Install 9Kick starter 1 9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not...

Страница 305: ...a de montage du cou vercle d embrayage mais pas contre 8 Monter 9 P dale de s lecteur 1 9 Boulon p dale de s lecteur 2 N B Monter la p dale de s lecteur de sorte que le haut du diam tre ext rieur de l...

Страница 306: ...removal PRIMARY DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Co...

Страница 307: ...EUR ET PIGNON DE TRANSMISSION 1 Ensemble r gulateur 1 2 Goujon 1 Se reporter POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de but e 2 8 Collerette...

Страница 308: ...ight 7 To governor shaft 8 NOTE Apply the lithium soap base grease on the thrust bearing EC4K3000 REMOVAL POINTS EC4K3100 Governor 1 Remove 9Dowel pin 1 NOTE While compressing the spring remove the do...

Страница 309: ...delle ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTAGE R gulateur 1 Monter 9 Pignon de r gulateur 1 9 Ressort de compression 2 9 Plaque 3 9 Rondelle ordinaire 4 9 Roulement de but e 5 9 Co...

Страница 310: ...fork b and set the governor in the crankcase cover 3 Install 9Dowel pin 1 NOTE 9While compressing the spring install the dowel pin 9Make sure the dowel pin fits into the groove a in the retainer 2 In...

Страница 311: ...lle 3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9V rifier que le goujon d assemblage est bien ajust dans le gorge a du dispositif d arr t 4 Monter 9 Ensemble r gulateur 1 N...

Страница 312: ...PUMP DISASSEMBLY Preparation for Crankcase cover right Refer to KICK AXLE SHIFT SHAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller 1 3 Plain washer 1 Refer to REMOVA...

Страница 313: ...orter la section AXE DE DEMARREUR AU PIED ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSON 1 Couvercle de bo tier de pompe eau 1 2 Turbine 1 3 Rondelle ordinaire 1 Se reporter POINTS DE DEPOSE 4 Axe de tur...

Страница 314: ...panners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discoloration of c...

Страница 315: ...it N B S il n y a un d anomalie telle qu exces sif changement du niveau de liquide de refroidissement d coloration du liquide de refroidissement ou huile de bo te de vitesses blanch tre il est inutile...

Страница 316: ...eplace EC444400 Oil seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal 1 NOTE 9Apply the lithium soap base grease on the oil seal l...

Страница 317: ...anch it 1 Usure endommagement Changer REMONTAGE ET MONTAGE Bague d tanch it 1 Monter 9 Bague d tanch it 1 N B 9Appliquer la graisse base de savon au lithium sur la l vre de la bague d tanch it 9Instal...

Страница 318: ...and impeller shaft And install the shaft while turn ing it 2 Install 9Plain washer 1 9Impeller 2 NOTE Hold the impeller shaft on its width across the flats a with spanners etc and install the impelle...

Страница 319: ...t rales aplaties a au moyen d une cl etc et monter la turbine 3 Monter 9 Goujon 1 9 Joint couvercle de bo tier de pompe eau 2 4 Monter 9 Couvercle de bo tier de pompe eau 1 9 Boulon couvercle de bo ti...

Страница 320: ...oval SIDE COVERS section Bolt radiator left Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator...

Страница 321: ...ERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil de magn to CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil sp ci...

Страница 322: ...un terclockwise EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1 Remove 9Nut rotor 1 9Plain washer 2 Use the rotor holding tool 3 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect 9Rotor inner surface a 9Sta...

Страница 323: ...age du vilebrequin et le coussinet vilebrequin Si n cessaire changer le stator et ou le magn to CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET MONTA...

Страница 324: ...the CHAPTER 3 2 Install 9Woodruff key 1 9Rotor 2 NOTE 9Clean the tapered portions of the crankshaft and rotor 9When installing the woodruff key make sure that its flat surface a is in parallel with t...

Страница 325: ...ler 9 Avance l allumage Se reporter la section CONTROLE ET REGLAGE DE L AVANCE A L ALLU MAGE du CHAPITRE 3 5 Serrer 9 Vis stator 1 6 Contr ler 9 Avance l allumage Recontr ler l avance l alluma ge 2 In...

Страница 326: ...o lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a c...

Страница 327: ...rois 7 Connecter 9 Fil de magn to CDI 1 Se r f rer au paragraphe DIA GRAMME DE CHEMINE MENT DE CABLE au CHA PITRE 2 7 Anschlie en 9 Kabel des CDI Magnetz nders 1 Siehe Abschnitt KABELF H RUNGS BERSICH...

Страница 328: ...D REED VALVE section Exhaust pipe and silencer Refer to EXHAUST PIPE AND Exhaust pipe stay rear SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug Di...

Страница 329: ...ilencier Se reporter la section TUYAU D ECHAPPE Support de tuyau d chappement arri re MENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR Bougi...

Страница 330: ...1 Refer to REMOVAL POINTS 4 Drive sprocket 1 5 Clip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Engine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Refer to REMOVAL POINTS 11 Engine 1 1 26 Nm 2 6...

Страница 331: ...1 2 Ecrou pignon d entra nement 1 3 Rondelle frein 1 Se reporter POINTS DE DEPOSE 4 Pignon d entra nement 1 5 Agrafe 1 6 Boulon p dal de frein 1 7 P dale de frein 1 8 Support du moteur 2 9 Boulon de...

Страница 332: ...de of the swingarm to support it 2 Remove 9Engine 1 From right side NOTE Make sure that the couplers hoses and cables are disconnected EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1 Remove 9Nut dri...

Страница 333: ...azionando il freno posteriore 2 Togliere 9 Rocchetto conduttore 1 9 Catena di trasmissione 2 NOTA Togliere il rocchetto conduttore insieme alla catena di trasmissione IC4M3301 Rimozione del motore 1 T...

Страница 334: ...9Install the clip with its stopper portion a facing inward EC4M5000 ASSEMBLY AND INSTALLATION EC4M5123 Engine installation 1 Install 9Engine 1 Install the engine from right side 9Pivot shaft 2 9Engin...

Страница 335: ...a but e a tourn e vers l int rieur Pignon d entra nement 1 Monter 9 Pignon d entra nement 1 9 Cha ne de transmission 2 N B Monter le pignon d entra nement avec la cha ne de transmission IC4M5000 MONTA...

Страница 336: ...ck washer tab to lock the nut 4 Install 9Chain guide 1 9Chain cover 2 9Screw chain cover 3 2 Install 9Lock washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 8 Nm 0 8 m...

Страница 337: ...t 2 N B Serrer l crou en actionnant le frein arri re 3 Courber la languette de la rendel le frein pour verrouiller l crou 4 Monter 9 Guide cha ne 1 9 Couvercle de cha ne 2 9 Vis couvercle de cha ne 3...

Страница 338: ...fer to CDI MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 50 mm 1 97 in 7 3 Bolt L 60 mm 2 36 in 1 4 Bolt L 70 mm 2 76 in 3 5 Holder 2 6 Crankcase right 1 Use special tool 7 Crankcase le...

Страница 339: ...arreur au pied AU PIED ARBRE DE SELECTEUR ET PIGNON Levier de but e DE TRANSMISSION Rotor et stator Se reporter la section MAGNETO CDI 1 Segment 1 Se reporter POINTS DE DEPOSE 2 Boulon L 50 mm 1 97 in...

Страница 340: ...ating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a r...

Страница 341: ...on fF Utiliser un maillet en plastique et ne taper que sur les portions renforc es du carter Ne pas taper sur les plans de joint Travailler lentement et avec pr caution en s assurant que les deux moit...

Страница 342: ...e crankcase by pressing its inner race as shown in 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed beari...

Страница 343: ...que le vilebrequin d poser le roulement en utilisant un extracteur de roulement 2 comme indiqu dans 9N utilisez pas le roulement d pos VERIFICATION Carter 1 Examiner 9 Surface de contact a Rayures Ch...

Страница 344: ...4 1 0 mm 2 0 mm free play 0 016 0 039 in 0 08 in Side 0 25 0 75 mm clearance 0 010 0 030in Crank 59 95 60 00 mm width 2 360 2 362 in EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play...

Страница 345: ...c 9 Kurbelwangenbreite d Abweichung von Spezifikation Erneuern Die Me uhr und die F hlerleh re verwenden MONTAGE UND EINBAU Kurbelwellenlager 1 Einbauen 9 Lager 1 Am Kurbelgeh use Links und Rechts ANM...

Страница 346: ...01274 Bolt 3 YU 90050 90890 01275 Adapter 4 YM 1277 90890 01277 2 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair B For USA and CDN Except for USA and CDN NOTE 9Hold the co...

Страница 347: ...que le vilebrequin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer une graisse base de savon au lithium sur la l vre de la bague d tanch...

Страница 348: ...hammer 9When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Install 9Bolt crankcase 1 NOTE Tighten the crankcase tightening bolts in stage using a crisscross...

Страница 349: ...e 3 N B 9Fixer le carter moteur gauche sur le cartermoteur droit Taper l g re ment sur le cartrer l aide d un mar teau souple 9Quand le carter est install la bielle d accouplement doit tre positionn e...

Страница 350: ...he bolt 30 Nm 3 0 m kg 22 ft lb 7 Install 9Tension spring 1 9Holder 2 9Bolt holder 3 NOTE Install the holder so that it contacts the projec tion a on the crankcase right 10 Nm 1 0 m kg 7 2 ft lb 9 Rem...

Страница 351: ...ra ge b 9Tourner le segment dans le sens des aiguilles d une montre jusqu ce qu il s arr te et resserrer le boulon 9 D poser 9 Etanch it Chass e sur le plan de joint du cylindre 10 Mettre 9 Huile mont...

Страница 352: ...ne Refer to ENGINE REMOVAL section removal Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 2 Drive axle 1 3 Shift cam 1 4 Shift fork 3 1 Refer to REMOVAL POINTS 5 Shift...

Страница 353: ...i ce Q t Remarques DEPOSE DE LA BOITE A VITESSES DU BARILLET DE SELECTEUR ET DE LA FOURCHETTE Moteur Se reporter la section DEPOSE DU MOTEUR S parer le carter Se reporter la section CARTER ET VILEBRE...

Страница 354: ...9Gear teeth b 9Shift fork groove c Wear Damage Replace EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1 Remove 9Main axle 1 9Drive axle 2 9Shift cam 9Shift fork 3 9Shift fork 2 9Shift fork 1 NOTE 9Rem...

Страница 355: ...pal l axe moteur le barillet du s lecteur et la fourchette du s lecteur ensemble en tapotant l g rement sur l arbre de transmission l aide d un marteau t te en caoutchouc VERIFICATION Pignons 1 Examin...

Страница 356: ...h pinion gears inner circumference and on the end surface 9Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumference 3 Check 9Shift fork movement Unsmooth operation Replac...

Страница 357: ...hette ellem me mais les deux pignons situ s de chaque c te de la fourchette REMONTAGE ET MONTAGE Bo te vitesses 1 Monter 9 Pignon de 5 21D 1 9 Pignon de 3 18D 2 9 Collerette 3 9 Pignon de 4 22D 4 9 Pi...

Страница 358: ...clip 2 NOTE 9Be sure the circlip sharp edged corner a is positioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 2 Install 92nd wheel g...

Страница 359: ...uer de l huile au bisulfure de molybd ne sur la circonf rence inter ne des 4e et 5e engrenages 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9V rifier que le cot bord vif du cir clip a soit oppos la...

Страница 360: ...on the shift fork grooves 9Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle 9Mesh the shift fork 2 C10 with the 3rd pinion gear 6 on the main axle...

Страница 361: ...incipal 5 Installare 9 Forcella del cambio 1 L 1 9 Forcella del cambio 2 C10 2 9 Forcella del cambio 3 R 3 9 Camma del cambio 4 Sull asse principale e l asse motore NOTA 9Applicare olio a base di biso...

Страница 362: ...heel axle 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disk 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of remo...

Страница 363: ...iquement desserrage 4 Ecrou axe de roue avant 1 5 Axe de roue avant 1 6 Roue avant 1 7 Collerette 2 8 Bague d tanch it 2 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 Pr paration pou...

Страница 364: ...he machine by placing the removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 O...

Страница 365: ...ue arri re 1 Se reporter POINTS DE DEPOSE 5 Collerette 2 6 Pignon men 1 7 Bague d tanch it 2 8 Circlip 1 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 Pr paration pour la d pose XG B...

Страница 366: ...ecessary 1 Remove 9Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure 9Wheel runout Out of limit Repair Replace 2 Inspect 9Bearing Rotate i...

Страница 367: ...Mesure 9 Voile de roue Hors limite R parer Changer 2 Examiner 9 Roulement Faire tourner la bague int rieure avec le doigt Point dur grippage Changer N B Changer les roulements la bague d tanch it et l...

Страница 368: ...4200 Brake disc 1 Measure 9Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition re place the brake disc 2 Meas...

Страница 369: ...te d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arri re 4 0 mm 0 16 in 3 5 mm 0 14 in IC594200 Disco del freno 1 Misurare 9 Inflessione del disco del freno soltanto il disco d...

Страница 370: ...ll be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Ins...

Страница 371: ...ant diri g s vers l ext rieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment ext rieur 2 Monter 9 Disque de frein 1 9 Boulon disque...

Страница 372: ...ing the front fork several times with the front brake applied 8 Install 9Brake hose 1 To brake hose holder 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck wi...

Страница 373: ...dans la gorge du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 7 Serrer 9 Boulon support d axe 1 N B Avant de serrer le boulon embo ter l axe de la roue d...

Страница 374: ...eter of the race of the bearing 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bear...

Страница 375: ...de la bague d tauch it lors de la repose 9Monter le roulement avec se joint dirig vers l ext rieur 9Utiliser une douille convenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ra...

Страница 376: ...OTE Apply the lithium soap base grease on the oil seal lip 5 Install 9Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install 9Drive chain 1 NOTE Push the wheel 2 forward and...

Страница 377: ...to condotto 3 9 Dado rocchetto condotto 4 NOTA Serrare i dadi in sequenza usando uno schema incrociato 4 Installare 9 Bordino 1 NOTA Applicare sul labbro del paraolio il grasso a base di sapone di lit...

Страница 378: ...her 2 9Nut wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axl...

Страница 379: ...lle ordinaire 2 9 Ecrou axe de roue 3 N B A ce stage resserrer provisoirement les crous axe de roue 8 Installare 9 Estrattore per catena destro 1 9 Rosetta 2 9 Dado asse della ruota 3 NOTA Serrare tem...

Страница 380: ...en disassembling the caliper 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose remov...

Страница 381: ...ein 1 6 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du d montage de l trier 8 Etrier 1 9 Levier de frein 1 10 Etr...

Страница 382: ...pad pin 2 Pad pin 1 Loosen when disassembling the caliper 3 Caliper 1 4 Brake hose holder 2 5 Union bolt 2 6 Brake hose 1 7 Brake pedal 1 8 Reservoir tank 1 9 Reservoir hose 1 10 Master cylinder 1 Ext...

Страница 383: ...rs du d montage de l trier 3 Etrier 1 4 Support de tuyau de frein 2 5 Boulon d union 2 6 Tuyau de frein 1 7 P dale de frein 1 8 R servoir de r serve 1 9 Tuyau de r serve 1 10 Ma tre cylindre 1 Pr para...

Страница 384: ...per piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 EC5A8200 CALIPER DISASSEMBLY A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear calipe...

Страница 385: ...trier avant 2 D montage de l trier arri re Etendue de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ETRIER A B 1 Goupille de plaquette 1 1 2 Palquette de frein 2 2 3 Support de plaquette 1 1...

Страница 386: ...ylinder cap 1 2 Diaphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long nose circlip pliers 5 Plain washer 1 6 Push rod 1 7 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rea...

Страница 387: ...lindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorne B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE CYLINDRE...

Страница 388: ...pulling the lever in or pushing down on the pedal cC 9Do not reuse the drained brake fluid 9Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 C...

Страница 389: ...DI RIMOZIONE IC5A3100 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Tappo del serbatoio 1 9 Dispositivo di protezione NOTA Non togliere il diafram...

Страница 390: ...n seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder...

Страница 391: ...re lors d un d montage d trier A Avant B Arri re IC533402 Kit delle guarnizioni di tenuta del pistone 1 Togliere 9 Parapolvere 1 9 Guarnizione di tenuta del pisto ne 2 NOTA Togliere le guarnizioni di...

Страница 392: ...st seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Brake hose 1 Crack Damage Replace EC5A5000 ASSEMBLY AND INSTALLATION w 9All internal parts should be cleaned in new brake...

Страница 393: ...tone della pinza 1 Usura Rigature Sostituire gruppo pistone della pinza T Sostituire le guarnizioni di tenuta del pistone e i parapolvere 2 2 ogni volta che si smonta una pinza IC534301 Tubo flessibil...

Страница 394: ...fluid on the piston wall cC 9For the front caliper install the piston with its depressed side a a facing the caliper For the rear caliper install the pis ton with its shallow depressed side b b fac in...

Страница 395: ...enuta del pisto ne 1 9 Parapolvere 2 T Usare sempre guarnizioni di tenuta del pistone e parapolvere nuovi NOTA Inserire le guarnizioni di tenuta del pistone e i parapolvere sulla fessura sulla pinza i...

Страница 396: ...nstall 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 2 Install 9Copper washer...

Страница 397: ...a fourche avant et fixer le tuyau de frein 4 Serrer 9 Goupille de plaquette 4 5 Monter 9 Bouchon de goupille de plaquet te 5 Etrier arri re 1 Monter 9 Support de plaquette 1 9 Plaquette de frein 2 9 G...

Страница 398: ...C Install the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper projection b b 7 Nm 0 7 m kg 5 1 ft lb 30 Nm 3 0 m kg 22 ft lb 4 Inst...

Страница 399: ...soit orient e vers l trier et que le conduit soit en contact avec la saillie b b de l trier 4 Monter 9 Etrier 1 9 Roue arri re 2 Se reporter la section ROUE AVANT ET ROUE ARRIE RE 5 Serrer 9 Goupille...

Страница 400: ...imary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong...

Страница 401: ...t au c t du diam tre plus petit A Avant B Arri re 2 Einbauen 9 Hauptbremszylinderkoppe Prim r 1 9 Hauptbremszylinderkoppe Sekund r 2 Zum Hauptbremszylinderkol ben 3 ANMERKUNG Bremsfl ssigkeit auf der...

Страница 402: ...ster cylinder kit 9Apply the lithium soap base grease on the tip of the push rod 9When installing the circlip use a long nose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Ma...

Страница 403: ...e au lithium sur l extr mit du champignon de d brayage 9Pour mettre le circlip en place utiliser des pinces de circlip long nez A Avant B Arri re Ma tre cylindre avant 1 Monter 9 Ma tre cylindre 1 9 E...

Страница 404: ...master cylinder piston EC5A5400 Rear master cylinder 1 Install 9Reservoir hose 1 9Reservoir tank 2 NOTE Pass the reservoir hose into the hose guide 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb 10...

Страница 405: ...e frein 2 9 Joint torique 3 9 Boulon p dale de frein 4 9 Agrafe 5 N B 9Appliquer de la graisse base de savon au lithium sur le boulon le joint torique et le support de p dale de frein 9Mettre le colli...

Страница 406: ...fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 2 Install 9Hose cover 1 9Plain washer 2 9Bolt hose cover M8 3 9Bolt hose cover M6 4 10 Nm 1 0 m kg 7 2 ft lb 16...

Страница 407: ...e du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 2 Monter 9 Couvercle de tuyau 1 9 Rondelle ordinaire 2 9 Boulon couvercle de tuyau M8 3 9 Boulon couver...

Страница 408: ...o that its pipe por tion a a directs as show and lightly touches the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 4 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use n...

Страница 409: ...tre cylindre Tuyau de frein arri re 1 Monter 9 Rondelle en cuivre 1 9 Tuyau de frein 2 9 Boulon d union 3 XG Toujours utiliser les rondelles en cuivre neuves fF Installer la tuyau de frein de mani re...

Страница 410: ...y brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction...

Страница 411: ...et un mauvais fonctionnement du frein 9Toujours utiliser la m me marque de liquide de frein Le m lange de liquides de marques diff rentes risque de provoquer une r action chimique nuisible au fonction...

Страница 412: ...gm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Reservoir tank cap 1 9Bolt reservoir tank 2 cC After installation while pulling the lever in or pushing down on the pedal check...

Страница 413: ...te 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale 2 Posteriormente 9 Diaframma 9 Tappo del serbatoio 1 9 Bullone serbatoio 2 iI Dopo l installazione tirand...

Страница 414: ...n Number plate 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt handle crown 2 Only loosening 4 Cap bolt 1 Loosen when disassembling the front fork 5 Pinch bolt under bracket 2 Only loosening 6 Front...

Страница 415: ...ein 2 3 Boulon de bridage couronne de guidon 2 Uniquement desserrage 4 Boulon capuchon 1 Desserrer lors du d montage de la fourche avant 5 Boulon de bridage trier inf rieur 2 Uniquement desserrage 6 F...

Страница 416: ...Refer to REMOVAL POINTS 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 q Spring guide 1 w Base valve 1 Use special tool e Damper rod 1 Refer to REMOVAL PO...

Страница 417: ...E DEPOSE 2 Ressort de fourche 1 Vidanger d huile de fourche 3 Joint antipoussi re 1 4 Bague d arr t 1 Se reporter POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 M tal de piston 1 8 Bague antifri...

Страница 418: ...aterial Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled 9Before removing the cap bolts or front forks be...

Страница 419: ...rang res Faire suffisamment attention ne pas laisser p n trer de substances trang res lorsque l huile est rem plac e ou lorsque la fourche avant est d mont e ou remont e 9Avant d enlever la fourche av...

Страница 420: ...1 Bend Damage Replace damper rod cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign ma terial Use enough care not to a...

Страница 421: ...ange weist eine komplizierte interne Konstruktion auf und ist besonders gegen ber Fremdmaterialien empfindlich Darauf achten da keine Fremdmaterialien eintreten wenn das l erneuert oder die Vorderradg...

Страница 422: ...lace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace 9Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge readi...

Страница 423: ...leur de courbure est indiqu e par la moiti de la valeur du comparateur cadran XG Ne pas tenter de redresser un tube interne tordu car cela risquerait de l affaiblir dangereusement Tube externe 1 Exami...

Страница 424: ...o inner tube 2 cC To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install 9Cop...

Страница 425: ...lement l en semble de tige peut y tomber endom mageant l int rieur de la soupape 3 Monter 9 Rondelle en cuivre 1 9 Joint torique 2 9 Soupape de base 3 Au tube interne 4 4 Serrer 9 Soupape de base 1 N...

Страница 426: ...seal 1 9Stopper ring 2 9Oil seal 3 9Plain washer 4 9Slide metal 5 To inner tube 6 NOTE 9Apply the fork oil on the inner tube 9When installing the oil seal use vinyl seat a with fork oil applied to pr...

Страница 427: ...it 3 9 Rondelle ordinaire 4 9 Bague antifriction 5 Au tube interne 6 N B 9Appliquer de l huile de fourche sur le tube interne 9Lors de l installation de la bague d tanch it utiliser une feuille en vi...

Страница 428: ...r 3 10 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 11 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 12 Install...

Страница 429: ...belbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 11 Ausbauen 9 Anschlagring 1 ANMERKUNG Den Anschlagring richtig in die Nut des u eren Rohres...

Страница 430: ...formance 9Never allow foreign materials to enter the front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil 17 Fill 9Front fork oil Until o...

Страница 431: ...chten da keine Fremd k rper in die Vorderradgabel ein dringen 16 Nach dem Einf len die Kolbenstange 1 mehr als 10 mal langsam auf und ab pumpen um das Gabel l zu verteilen 17 F llen 9 Vorderradgabel l...

Страница 432: ...with the fork oil up to the top of the outer tube and bleed the front forks 20 Measure 9Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking...

Страница 433: ...e XG Ne jamais oublier de faire le r glage de niveau d huile entre les niveaux maximum et minimum et toujours r gler chaque fourche avant au m me r glage Un r glage in gal peut entra ner une mauvaise...

Страница 434: ...d up 9Install the fork spring with its smaller pitch end facing the cap bolt For EUROPE 9After installing the fork spring hold the damper rod end so that it will not go down 25 Install 9Cap bolt 1 Ful...

Страница 435: ...t de fourche avec la tige d amortisseur 3 d ploy e 9Installer le ressort de fourche avec l extr mit filet e la plus troite vers le boulon capuchon Pour EUROPE 9Apr s avoir install le ressort de fourch...

Страница 436: ...set the thin type spanners 2 between the spacer 3 and spring guide 4 9Hold the locknut 5 and tighten the cap bolt with specified torque 27 Install 9Cap bolt 1 To outer tube NOTE Temporarily tighten t...

Страница 437: ...Montage 1 Monter 9 Fourche avant 1 N B 9Serrer le boulon de bridage trier in f rieur provisoirement 9Ne pas encore serrer le boulon de bri dage couronne de guidon 2 Serrer 9 Boulon capuchon 1 3 R gler...

Страница 438: ...r 3 NOTE Fit the brake hose holder cut a over the projec tion b on the front fork and clamp the brake hose 6 Install 9Brake hose holder 1 9Bolt brake hose holder 2 9Protector 3 9Bolt protector 4 NOTE...

Страница 439: ...in 5 devant le bossage de l axe c et l ajuster dans la gorge du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 7 R gler 9 Force d amortisseur de rebond N B...

Страница 440: ...1 Refer to REMOVAL POINTS 5 Throttle cable cap 1 Turn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer...

Страница 441: ...rter POINTS DE DEPOSE 5 Capuchon du c ble d acc l rateur 1 Retourner le couvercle de capuchon 6 C ble d acc l rateur 1 D connecter du c t acc l rateur 7 Acc l rateur 1 Desserrer les boulons 8 Couvercl...

Страница 442: ...e disassembly Extent of removal Order Part name Q ty Remarks THROTTLE DISASSEMBLY 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to REMOVAL POINTS 5 Tube guide 1 1 EC5B80...

Страница 443: ...de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poig e inf rieur 1 2 Capuchon de poig e sup rieur 1 3 Ensemble de la poign e 1 4 Poign e droite 1 Se reporter POIN...

Страница 444: ...he grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect 9Handlebar 1 Bends Cracks Damage Replace w Do not attempt to straighten a bent handlebar as this ma...

Страница 445: ...9 Guidon 1 Deform e craquelures endom magement Changer XG Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble acc l rateur 1 Monter 9 Poi...

Страница 446: ...er and then tighten the bolts on the rear side 2 Install 9Grip left 1 Apply the adhesive to the handlebar 2 NOTE 9Before applying the adhesive wipe off grease or oil on the handlebar surface a with a...

Страница 447: ...9Avant d appliquer l adh sif essuyer la graisse ou l huile sur la surface du guidon a avec du diluant de peinture 9Fixer la poign e gauche sur le gui don de sorte que la ligne b entre les deux fl che...

Страница 448: ...hrottle cable in the groove b in the roller 6 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 7 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 8...

Страница 449: ...R gler 9 Jeu du c ble d acc l ration Se reporter la section RE GLAGE DU CABLE D ACCE LERATEUR du CHAPITRE 3 8 Monter 9 Couvercle de capuchon 1 9 Monter 9 Ma tre cylindre 1 9 Etrier de ma tre cylindre...

Страница 450: ...smoothly If it does not retighten the bolts for adjustment 11 Install 9 ENGINE STOP button 1 9Clutch lever holder 2 9Bolt clutch lever holder 3 9Clamp 4 NOTE 9The ENGINE STOP button clutch lever hold...

Страница 451: ...rayage 3 9 Bride 4 N B 9Le bouton d arr t du moteur ENGI NE STOP le support et la bride de levier d embrayage doivent tre ins tall s selon les dimensions indiqu es 9Faire passer le fil de bouton d arr...

Страница 452: ...5 46 CHAS HANDLEBAR 14 Clamp the clamp portion a of the number plate to the handlebar 15 Insert the end of the fuel breather hose 1 into the hole of the number plate...

Страница 453: ...ie Bohrung des Nummernschil des einf hren 14 Fixer la partie de fixation a de la plaque d immatriculation au gui don 15 Introduire l extr mit du conduit d a ration de carburant 1 dans les trous de la...

Страница 454: ...g nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Ball race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Ball race 2 Refer to REMOVAL POINTS EC560000 STEERI...

Страница 455: ...e ter St nder unter dem Motor angeordnet wird Nummernschild Lenkstange Siehe Abschnitt LENKSTANGE Kabelf hrung Vorderrad Kotfl gel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe Abschnitt VORDERRADGA...

Страница 456: ...all down EC563300 Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove 9Ball race 1 Remove the ball race usin...

Страница 457: ...ur 2 fF Veiller ne pas endommager le file tage de l arbre de direction Cage billes 1 D poser 9 Cage billes 1 Enlever la cage billes en utili sant une longue tige 2 et un marteau VERIFICATION Arbre de...

Страница 458: ...ration in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION EC565113 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the du...

Страница 459: ...E Etrier inf rieur 1 Monter 9 Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint anti poussi re et sur la cironf rence interne du roulement 2 Monter 9 Cag...

Страница 460: ...ng shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE...

Страница 461: ...a une g ne quel conque retirer l ensemble axe de direction et inspecter le support de direction 6 Monter 9 Rondelle ordinaire 1 7 Monter 9 Fourche avant 1 9 Etrier sup rieur 2 N B 9Serrer le boulon de...

Страница 462: ...ing nut little by little 10 Adjust 9Front fork top end a 11 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too much it may c...

Страница 463: ...Boulon de bridage trier inf rieur 2 fF Resserrer le support auxiliaire au couple sp cifi S il est trop serr la fourche avant pourrait mal fonction ner 9 Dopo avere serrato il dado con trollare che lo...

Страница 464: ...ke pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swing...

Страница 465: ...SE UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdr cken Antriebskette 1 Kettenschutz 1 2 Kettenspanner Unten 1 3 Schraube Hinterad Sto d mpfer 1 Die Hinterradschw...

Страница 466: ...Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and...

Страница 467: ...tange 3 Ausbau und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename St ckzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 2 Relaisarm 1 3 Pleuelstange 1 4 H lse 2 5 ldichtung 2 6...

Страница 468: ...h 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574210 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolut...

Страница 469: ...2 Freies Spiel besteht Unrunde Drehung Rost Lager und Buchse als Satz erneuern 2 Pr fen 9 ldichtung 3 Besch digung Erneuern Relaisarm 1 Pr fen 9 Lager 1 9 H lse 2 Freies Spiel besteht Unrunde Drehung...

Страница 470: ...l 9Bearing 1 9Oil seal 2 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numb...

Страница 471: ...o 1 9 Paraolio 2 Sul braccio di rinvio NOTA 9Applicare il grasso a base di bisolfuro di molibdeno sul cuscinetto durante l installazione 9Installare il cuscinetto premendolo sul lato che riporta le ma...

Страница 472: ...gs and oil seal lips 3 Install 9Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the collar bearings and oil seal lips 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Pla...

Страница 473: ...olfuro di molibdeno sui bordini sui cuscinetti e sui labbri del paraolio 3 Installare 9 Bordino 1 Sulla leva di rinvio 2 NOTA Applicare il grasso a base di bisolfuro di molibdeno sul bordino sui cusci...

Страница 474: ...9Swingarm side play a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars 8 Install 9Bolt conn...

Страница 475: ...ntr ler 9 Jeu lat ral du bras oscillant a Il y a jeu fonctionnel Remplacer le roulement de bu t e 9 Mont e et descente du bras os cillant b Mouvement irr gulier coince ment point dure Graisser ou chan...

Страница 476: ...9Bolt chain tensioner lower 1 9Plain washer 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support R 50mm 1 97in 3 9Nut chain supp...

Страница 477: ...eriore 5 14 Installare 9 Supporto della catena 1 9 Copertura del supporto 2 9 Bullone supporto della catena 50 mm 1 97 in 3 9 Dado supporto della catena 4 9 Bullone copertura del supporto 10 mm 0 39 i...

Страница 478: ...joint 1 Loosen the screw air cleaner joint 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 7 Adjuster 1...

Страница 479: ...re arri re 1 3 Boulon amortisseur arri re bras de relais 1 Tenir le bras oscillant 4 Boulon amortisseur arri re cadre 1 5 Amortisseur arri re 1 6 Contre crou 1 7 Dispositif de r glage 1 8 Guide de res...

Страница 480: ...as expansion and or damage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the...

Страница 481: ...endom mager toute partie du r servoir gaz Un r servoir gaz endom mag affectera la capacit d amortissement ou entra nera un mauvais fonctionnement 4 Prendre garde ne pas rayer la surface de contact de...

Страница 482: ...e EC584000 INSPECTION EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assem...

Страница 483: ...cage ext rieure VERIFICATION Amortisseur arri re 1 Examiner 9 Tige d amortisseur 1 D form e Endommagement Changer l amortisseur com plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet F...

Страница 484: ...oove appears by pressing its outer race cC Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopp...

Страница 485: ...eur 1 N B Apr s avoir install la bague d arr t re pousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter 9 Roulement inf rieur 1 N B Installer le roulement en l ins rant sur c t o les re...

Страница 486: ...on the bearing 9Apply the lithium soap base grease on the bush collars and dust seals 9Install the dust seals with their lips facing out ward 3 Adjust 9Spring length installed a For EUROPE NOTE The le...

Страница 487: ...nt antipoussi re 3 N B 9Appliquer de la graisse de molybd ne sur le roulement 9Appliquer de la graisse base de sa von au lithium sur la bague les col liers et les joints antipoussi re 9Monter les join...

Страница 488: ...the molybdenum disulfide grease on the bolt 5 Install 9Plain washer 1 9Bolt rear shock absorber relay arm 2 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Insert the bolt from right side 6 I...

Страница 489: ...n amortisseur arri re bras de relais 2 N B 9Appliquer de la graisse de molybd ne sur le boulon 9Ins rer le boulon partir de la droite 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re 2 7 Serrer 9 Vis...

Страница 490: ...EC611000 ELECTRICAL COMPONENTS 1 CDI unit 2 ENGINE STOP button 3 Ignition coil 4 TPS throttle position sensor 5 Solenoid valve 6 CDI magneto 7 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black L B...

Страница 491: ...GE COMPOSANTS ELECTRIQUES 1 Bloc CDI 2 Bouton d arr t du moteur ENGINE STOP 3 Bobine d allumage 4 TPS capteur de position du papillon 5 Electrovanne 6 Magn to CDI 7 Bougie CODE DE COULEUR B Noir L Ble...

Страница 492: ...Check entire ignition system for connection Spark gap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI mag...

Страница 493: ...bloc CDI Changer Changer Changer Changer Changer Indication Seulement quand le contr leur d allumage et utilis N B 9D poser les pi ces suivantes avant de proc der au d pistage des pannes 1 Selle 2 R...

Страница 494: ...rollieren CDI Einheit erneuern Erneuern Erneuern Erneuern Erneuern Erneuern Markierung Nur wenn das Z ndungspr fger t verwendet wird ANMERKUNG 9Die folgenden Teile vor Beginn der St rungsbeseitigung a...

Страница 495: ...uirla Sostituirla Sostituirla Sostituirla contrassegnato Soltanto quando viene usato l apparecchio per il controllo dell accensione NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 S...

Страница 496: ...e and increase spark gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or...

Страница 497: ...RET DU MOTEUR ENGINE STOP 1 Examiner 9 Conductibilit du bouton d arr t du moteur ENGINE STOP Pas de continuit lorsqu enfonc Changer Continuit lorsque rel ch Changer IC622001 TEST DELLA DISTANZA TRA GL...

Страница 498: ...I MAGNETO INSPECTION 1 Inspect 9Pick up coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Orange lead 2 Primary...

Страница 499: ...bobine d excita tion Hors sp cification Changer IC626002 ISPEZIONE DELLA BOBINA DI ACCENSIONE 1 Ispezionare 9 Resistenza della bobina prima ria Fuori specifica Sostituirla 2 Ispezionare 9 Resistenza d...

Страница 500: ...N Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Black Red lead 1 Tester lead Black lead 2 Source coil 1 Tester select...

Страница 501: ...non si rileva alcun guasto sostituire l unit CDI Quindi ricontrollare i com ponenti elettrici Resistenza Posizione della bobina del selettore sorgente 1 del tester 720 1 080 a 100 20 C 68 F Conduttor...

Страница 502: ...od Replace Check CDI magneto Replace CDI unit No good EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate use the following inspection steps marked Refer to...

Страница 503: ...magn to CDI Changer le bloc CDI Mauvais SYSTEME D ELECTROVANNE ETAPES DE VERIFICATION Si l lectrovanne ne fonctionne pas applicuez la proq dure d inspection suivante Indication Se reporter la section...

Страница 504: ...le Erneuern CDI Magnetz nder kontrollieren CDI Einbeit erneuern Nicht in Ordnung MAGNETVENTILSYSTEM PR FVORG NGE Falls das Magnetventil nicht funktioniert sind die folgenden berpr fungen durchzuf hren...

Страница 505: ...unziona Sostituirlo Controllare magnete CDI Sostituire unit CDI Non funziona IC650001 SISTEMA ELETTROVALVOLA IC651032 OPERAZIONI DI ISPEZIONE Se l elettrovalvola non funziona effettuare i seguenti con...

Страница 506: ...olenoid valve coupler 2 Connect 12V battery to the solenoid valve coupler 3 Inspectt 9Solenoid valve 1 No click when connecting the battery Replace EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect 9S...

Страница 507: ...4000 ISPEZIONE DEL COLLEGAMENTO DI ACCOPPIATORI E CONDUTTORI 1 Controllare 9 Collegamento di accoppiatori e conduttori Ruggine Polvere Allentamen to Cortocircuito Ripararli o sostituirli IC652040 FUNZ...

Страница 508: ...Replace Check CDI unit No good EC690000 TPS THROTTLE POSITION SENSOR SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate use the following inspection steps marked Refer to IGNITION SYSTEM sec...

Страница 509: ...u d pistage des pannes 1 Selle 2 R servoir essence 9Utiliser les outils sp ciaux suivants dans ce d pistage des pannes Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 Tester de poche Y...

Страница 510: ...bauen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge f r die St rungsbeseitigung verwenden Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 Taschenpr fger t YU 3112 C 90890 03112 I...

Страница 511: ...ma dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9 In questa ispezione usare i seguenti utensili speciali Contagiri induttivo YU 8036 B Contagiri del motore 90890 031...

Страница 512: ...9TPS coil resistance Out of specification Replace 3 Inspect 9TPS coil variable resistance Check that the resistance in increased as the lever 1 is moved from the full close position to the full open...

Страница 513: ...stand Pr fen ob der Widerstand sich erh ht wenn der Hebel 1 vom vollst ndig geschlossenen Stand in den vollst ndig ge ff neten Stand bewegt wird Abweichung von Spezifikation Erneuern 2 Ispezionare 9...

Страница 514: ...lain washer 2 9TPS 3 NOTE Loosen the screws using the T20 bit tamper resistant fastener type 3 Replace 9TPS 4 Install 9TPS 1 9Plain washer 2 9Screw TPS 3 NOTE 9Align the slot a in the TPS with the pro...

Страница 515: ...ti usando la punta T20 tipo di dispositivo di fissaggio resi stente alla manomissione 3 Changer 9 TPS 3 Erneuern 9 TPS 3 Sostituire 9 TPS 4 Monter 9 TPS 1 9 Rondelle ordinaire 2 9 Vis TPS 3 N B 9Align...

Страница 516: ...resistance 10 Adjust 9TPS coil resistance at idle speed Idle speed for TPS adjustment 1 700 1 900 rpm Adjustment steps 9Set the inductive tachometer engine tachometer to the high tension cord 9Turn th...

Страница 517: ...tours induction compte tours du moteur sur le c ble haute tension 9Tourner la vis de but e d acc l rateur 1 jusqu obtention du r gime de ralenti sp cifi Se reporter la section REGLA GE DU RALENTI dans...

Страница 518: ...the T20 bit tam per resistant fastener type by aligning the marks a that were put before removal 14 Install 9Carburetor Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 EC694000 TPS INPUT V...

Страница 519: ...e 9 Vite TPS 1 NOTA Serrare le viti usando la punta T20 tipo di dispositivo di fissaggio resistente alla manomissione e allineando le indica zioni a di posizione segnate prima dello smontaggio 14 Inst...

Страница 520: ...be properly suited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed ro...

Страница 521: ...de la route et la d coloration de bougie s Prenant ces facteurs en consid ration il s lectionnera les meilleurs r glages de carburateur possibles Il est recommand de prendre note des r glages des cond...

Страница 522: ...sity of the air EC713001 Test run After warming up the engine equipped with the standard type carburetor s and spark plug s run two or three laps of the circuit and check the smooth operation of the e...

Страница 523: ...bougie s A Normale B Surbr l e trop pauvre C Encrass e d huile trop riche Cio 9 Una temperatura pi alta fa dilatare l aria ne risulta una densit ridotta 9 Un umidit pi elevata riduce la quantit di os...

Страница 524: ...ating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Standard main jet 178 180 EC71V000 Powet jet adjustment The richn...

Страница 525: ...lectionner un gicleur principal avec un num ro de calibrage sup rieur la norme Pour enrichir 2 La bougie est mouill e S lectionner un gicleur principal avec un num ro de calibrage inf rieur la norme...

Страница 526: ...intermediate speed operation irregular engine operation and poor acceleration will result Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and...

Страница 527: ...regolazione si cam bia il getto pilota 1 Un getto di dimensioni maggiori d una miscela pi ricca a bassi regimi e uno di dimensioni pi piccole d una miscela pi povera IC718001 Regolazione della posizio...

Страница 528: ...ck up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pic...

Страница 529: ...icht glatt beschleunigt werden In diesem Fall die D sennadelklam mer um eine Nut h her positionie ren und die D sennadel absenken um ein magereres Gemisch zu erhalten 2 Zu mager bei mitteleren Dreh za...

Страница 530: ...starting position c Rich d Lean 2 Effects of changing the jet needle reference 9 Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throt...

Страница 531: ...tre de la partie droite ajuste le m lan ge air carburant lorsque l ouverture des gaz est compri se entre 1 8 et 1 4 9 Position de d part de c ne Diff rence d une demi rainure Riche N3EJ 3e rainure N3C...

Страница 532: ...position c Rich d Lean 2 Effects of changing the jet needle reference 9 Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throttle is 1...

Страница 533: ...e la partie droite ajuste le m lan ge air carburant lorsque l ouver ture des gaz est comprise entre 1 8 et 1 4 9 Position de d part de c ne Diff rence d une demi rainure Riche N3CW 4e rainure N3EW 3e...

Страница 534: ...ottle opening whereas around 1 4 to 1 1 throttle opening it relates to the taper starting position and to the clip position Therefore the fuel flow is balanced at each stage of throttle opening by the...

Страница 535: ...tion de l agrafe Par cons quent l coulement du carbu rant est quilibr chaque tape de l ouverture du papillon par la combinai son du diam tre de la portion droite du papillon et de sa position de d par...

Страница 536: ...4MX 14948 12 60 4MX 14948 11 58 4MX 14948 10 STD 55 4MX 14948 09 52 4MX 14948 08 STD 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 Lean 40 4SR 14948 03 Jet needle 3 3 Rich N3EW 4SR 1...

Страница 537: ...o 165 4MX 14943 40 Povera No 162 4SR 14943 90 Getto Ricca No 62 4MX 14948 12 pilota No 60 4MX 14948 11 2 2 No 58 4MX 14948 10 STD No 55 4MX 14948 09 No 52 4MX 14948 08 STD No 50 4MX 14948 07 No 48 4MX...

Страница 538: ...athing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Clip position indicates the position of Slow speed pick up 1 groove up jet needle groove to which the clip is White s...

Страница 539: ...needle clip position range of low to If no effect reverse the above intermediate speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly U...

Страница 540: ...tion de fixation de l aiguille de gicleur 1 rainure plus haut Abaisser la position de fixation de l aiguille de gicleur 1 rainure plus bas Elever la position de fixation de l aiguille de gicleur 1 rai...

Страница 541: ...nverser les proc dures mentionn es ci dessus Contr ler tous les r glages d ensemble Utiliser un gicleur principal avec un n de calibrage inf rieur Elever la position de fixation de l aiguille de gicle...

Страница 542: ...sch Wei liche Z ndkerze Mageres gemisch Bei Vollgas Drehzahl wird nicht erh ht Drehzahl wird nur langsam erh ht Langsames Ansprechen Verru te Z ndkerze Fettes Gemisch Mageres Gemisch Fettes Gemisch 1...

Страница 543: ...Klemmenposition erh hen Falls keine Wirkung die obigen Vorg nge umkehren Gesamteinstellungen berpr fen Hauptd se mit niedrigerer Kalibrierungs Nr verwenden D sennadel Klemmenposition erh hen 1 Nut h...

Страница 544: ...ndizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Scolorimento della candela Se color cuoio in buone...

Страница 545: ...re al contrario le procedure sopra descritte Controllare le registrazioni generali Usare un getto principale che abbia un No di taratura pi basso Alzare la posizione del fermaglio a graffa dell ago a...

Страница 546: ...bration No of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet NOTE 9When checking the discoloration of spark plugs be su...

Страница 547: ...chang par 30 il est recommand de changer la plage de chaleur des bougies et de s lection ner un autre gicleur principal correct N B 9Lors du contr le de la d coloration des bougies attention bien arr...

Страница 548: ...tire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire c...

Страница 549: ...terminer le taux de r duction secon daire 9Quand il y a de grandes lignes droites r gler la machine de sorte ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en vita...

Страница 550: ...th the road surface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 13T 9383E 13144 STD 14T 9383E 14215 Dr...

Страница 551: ...00 52T 5ET 25452 00 Pression des pneus standard 100 kPa 1 0 kg cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kg cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kg cm2 9 0 12 psi Reifendruck Der...

Страница 552: ...ing characteristic near the final stroke can be changed by changing the fork oil amount cC Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to prod...

Страница 553: ...tant de r gler le niveau d huile dans la fourche conform ment aux sp cifi cations donn es IC722011 Registrazione della forcella anteriore La registrazione della forcella anteriore dovrebbe essere eff...

Страница 554: ...justment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in position...

Страница 555: ...egolazione Ampiezza della regolazione zero 2 rondelle di regolazione R glage du ressort apr s remplace ment Les r glages de la fourche avant peu vent tre affect es par la suspension arri re il convien...

Страница 556: ...s to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handlebar To set a stiff spring 9Change the rebound damping Turn in one or two clicks 9Change the co...

Страница 557: ...nt une perte de sensation de contact avec la surfa ce de la route ou un guidonnage R glage d un ressort dur 9 R gler la force de rebond Visser d un ou deux d clics 9 R gler la force de compression D v...

Страница 558: ...proved on the end of the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 380 4SS 23141 10 I I 0 390 4SS 23141 20 I II SOFT 0 400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50...

Страница 559: ...400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50 II STD 0 430 4XL 23141 L0 HART 0 440 4SS 23141 70 IIII IC72P010 Parti di regolazione della forcella anteriore 9Rondella di regolazione 1...

Страница 560: ...ession damping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fe...

Страница 561: ...llen um das Hinter rad anzuheben und den Abstand a zwischen der Hinterradachs mitte und der Hinterradkotfl gel Halteschraube messen 2 Den St nder oder Block vom Motor entfernen und bei aufsit zendem F...

Страница 562: ...t length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring 9Set the soft spring for less rebound damp ing to compensate for its less spring load Run with the rebound damping adjuster...

Страница 563: ...ner weichen Feder 9 Die weiche Feder auf weniger Ausfederd mpfung einstellen um die geringere Federspan nung auszugleichen Mit dem Ausfederd mpfung Einsteller um eine oder zwei Klickstellen zur weiche...

Страница 564: ...se the one whose overall length a a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider w...

Страница 565: ...ssort dont la longueur totale est sup rieure la longueur standard A Ressort recommand en fonction du poids B Poids du motocycliste 1 Mou 2 Standard 3 Dur iI Quando si usa un ammortizzatore posteriore...

Страница 566: ...LENGTH SOFT 4 4 5DH 22212 70 Brown 1 260 4 6 5DH 22212 10 Green 1 260 STD 4 8 5DH 22212 20 Red 1 260 5 0 5DH 22212 30 Black 1 260 STIFF 5 2 5DH 22212 40 Blue 1 260 5 4 5DH 22212 50 Yellow 1 265 5 6 5...

Страница 567: ...1 260 HART 5 2 5DH 22212 40 Blau 1 260 5 4 5DH 22212 50 Gelb 1 265 5 6 5DH 22212 60 Rosa 1 265 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4 4 5DH 22212 70 Marrone 1 260 4 6 5DH 22212 10 Ver...

Страница 568: ...bout 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 out in Spring Replace with stiff spring Stiff toward stroke 1 O...

Страница 569: ...d Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decrea...

Страница 570: ...positif de r glage vers la gauche de 2 d clics pour r duire l amortissement R duire le niveau d huile d environ 5 10 mm 0 2 0 4 in Monter un ressort doux V rifier s il y a coudes coups ou tout autre e...

Страница 571: ...nt R gler la longueur sur 90 100 mm 3 5 3 9 in avec une personne assise correctement sur la selle Tourner le dispositif de r glage vers la droite de 2 d clics pour augmenter l amortissement Tourner le...

Страница 572: ...ge Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu ver ringern lstand um etwa 5 10 mm 0 2 0 4 in senken Durch weiche Feder ersetzen Auf Verbiegungen Dellen sicht...

Страница 573: ...D mpfung zu ver ringern Eingetauchte L nge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu steige...

Страница 574: ...to con l estremit posteriore Molla Livello dell olio quantit di olio Ruotare il dispositivo di regolazione in senso antiorario circa 2 scatti per diminuire lo smor zamento Diminuire il livello dell ol...

Страница 575: ...ire lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aume...

Страница 576: ...TUN MEMO...

Страница 577: ......

Страница 578: ...PRINTED IN JAPAN 2000 7 1 2 1 E F G I PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YZ250 N LC...

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