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CARTER ET VILEBREQUIN

KURBELGEHÄUSE UND KURBELWELLE

CARTER E ALBERO A GOMITI

ENG

4-68

2. Ispezionare:

Cuscinetti

Ruotare l’anello interno con un
dito.
Ruvidità/Grippaggio

→

Sostituirli.

3. Ispezionare:

Paraolio

Danni

→

Sostituirlo.

IC4N4202

Albero a gomiti

1. Misurare:

Limite di scentratura

Limite di gioco dell’estremità
piccola

Gioco laterale dell’estremità
grande della biella

Larghezza del gomito

Fuori specifica

→

Sostituirlo.

Usare il comparatore e uno
spessimetro.

IC4N5000

MONTAGGIO E
INSTALLAZIONE

IC4N5300

Cuscinetto dell’albero a gomiti

1. Installare:

Cuscinetto

Sul carter (sinistro e destro).

NOTA:

Installare il cuscinetto premendone
parallelamente l’anello esterno.

Valore

<Limite>

normale

Limite di

0,03 mm

0,05 mm

scentratura: (0,0012 in)

(0,0020 in)

Gioco dell’es-

0,4~1,0 mm

2,0 mm

tremità
piccola:

(0,016~0,039 in) (0,08 in)

Gioco

0,25~0,75 mm

—

laterale:

(0,010~0,030 in)

Larghezza 59,95~60,00 mm

—

del gomito: (2,360~2,362 in)

2. Prüfen:

Lager

Den inneren Laufring mit
einem Finger drehen.
Rauhe Stellen/Freßspuren

→

Erneuern.

3. Prüfen:

Öldichtung

Beschädigung

→

Erneuern.

Kurbelwelle

1. Messen:

Schlaggrenze

Grenze des Spiels am Pleuel-
auge

Seitliches Spiel am Pleuelfuß

Kurbelwangenbreite

Abweichung von Spezifikation

→

Erneuern.

Die Meßuhr und die Fühlerleh-
re verwenden.

MONTAGE UND EINBAU

Kurbelwellenlager

1. Einbauen:

Lager

Am Kurbelgehäuse (Links und
Rechts).

HINWEIS:

Das Lager einbauen, indem der äuße-
re Laufring parallel eingepreßt wird.

2. Examiner:

Roulements

Faire tourner la bague intérieure
avec le doigt.
Point dur/grippage

→

Changer.

3. Examiner:

Bague d’étanchéité

Endommagement

→

Changer.

Vilebrequin

1. Mesurer:

Limite de faux-rond

Limite de déflexion de pied

Jeu latéral de tête de bielle

Largeur de vilebrequin

Hors spécification

→

Changer.

Utiliser un Comparateur à
Cadran et une jauge d’épaisseur.

REMONTAGE ET
MONTAGE

Roulement de vilebrequin

1. Monter:

Roulement

Vers le carter (gauche et droit).

N.B.:

Monter le roulement en appuyant paral-
lèlement sur la cage extérieure.

Comparateur:

YU-3097/90890-01252

Comparatore:

YU-3097/90890-01252

Meßuhr:

YU-3097/90890-01252

Normalwert

<Grenze>

Schlaggrenze:

0,03 mm

0,05 mm

(0,0012 in)

(0,0020 in)

Grenze des

0,4~1,0 mm

2,0 mm

Spiels am

Pleuelauge:

(0,016~0,039 in)

(0,08 in)

Seitliches

0,25~0,75 mm

—

Spiel:

(0,010~0,030 in)

Kurbelwan- 59,95~60,00 mm

—

genbreite:

(2,360~2,362 in)

Standard

<Limite>

Limite de

0,03 mm

0,05 mm

faux-rond:

(0,0012 in)

(0,0020 in)

Déflexion 0,4~1,0

2,0

de pied:

(0,016~0,039 in) (0,08 in)

Jeu latéral:

0,25~0,75 mm

—

(0,010~0,030 in)

Largeur de 59,95~60,00 mm

—

vilebrequin: (2,360~2,362 in)

5UP-9-30-4C 5/24/02 5:33 PM Page 39

Содержание YZ250(R)/LC

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

Страница 2: ...RVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition May 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Print...

Страница 3: ...maha Motor Co Ltd 1 Ausgabe Mai 2002 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet G...

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

Страница 5: ...pos 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 peuve...

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: ...QUATE 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 colorl...

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

Страница 11: ...ER 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 veicolo...

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: ...tre 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 compren...

Страница 14: ...I40M W2 M W2 0Y O2 M O M O2 0Y O 0Y O M W2 0Y W2 Y W2 M W2 M W2 0Y hf O 0M O 0Y O 0Y he O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0...

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 33 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 40 YPVS GOVERNOR 4 49 WATER PUMP 4 52 CDI MAGNETO 4 56 ENGINE REMOVAL 4 60 CRANKCASE AND CRANKSHAFT 4 65 TRANSMISSION SHIFT CAM AND S...

Страница 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 40 REGULATEUR YPVS 4 49 POMPE A EAU 4 52 MAGNETO CDI 4 56 DEPOSE DU MOTEUR 4 60 CARTER ET VILEBREQUIN 4 65 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 7 TPS THROTTLE POSITION SENSOR SYSTEM 6 9 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 7 SYSTEME TPS CAPTEUR DE POSITION DU PAPILLON 6 9 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 13...

Страница 26: ...k 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 ped...

Страница 27: ...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 9L...

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: ...pump housing 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...

Страница 31: ...ces sont correctement 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 bes...

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: ...ms 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 Connecteur...

Страница 38: ...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 01235 Rotor holding tool YU 1235 90890 01235 Thi...

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: ...uin de l une ou l autre de ses moiti s YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose du volant magn tique YM 1189 90890 01189 YU 1235 90890 01...

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: ...1189 90890 01189 Schwungrad Abziehwerkzeug Dieses Werkzeug wird f r den Ausbau des Schwung rad Magnetz nders ben tigt YM 1189 90890 01189 YU 1235 90890 01235 Rotor Haltewerkzeug Dieses Werkzeug wird...

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: ...1135 A 90890 01135 YM 1189 90890 01189 Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 01189 YU 1235 90890 01235 Utensile di supporto del rotore Quep...

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: ...TAND This sidestand 1 is used to support only the machine when standing or transporting it w 9Never apply additional force to the side stand 9Remove this sidestand before starting out EC15f000 SET PIN...

Страница 51: ...carburante fuoriesca ed installato sullo sfiato del serbatoio del carburante iI In questa installazione assicurarsi che la freccia sia rivolta verso il ser batoio del carburante e anche verso il bass...

Страница 52: ...e grade 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 and the carburetor float bowl of old premix prio...

Страница 53: ...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 rata che abbia pi di qualc...

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 frame Link 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 T...

Страница 61: ...onerie timonerie 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 o...

Страница 62: ...st nge am Sto d 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 F...

Страница 63: ...ttino forcellone oscillante Posteriore Installazione Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione dell...

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: ...nnez 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 fer...

Страница 68: ...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 9 1 For USA CDN and ZA 9 0 10 6 1 For E...

Страница 69: ...5th 20 21 0 952 Chassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 27 0 26 8 Trail 118 mm 4 65 in 114 mm 4 49 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90...

Страница 70: ...0 7087 in 0 7077 in Piston ring Sectional sketch Plain B 1 0 mm 0 039 in T 2 55 mm 0 100 in End gap installed 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...

Страница 71: ...Z Type Manufacturer PWK38S KEIHIN I D mark 5NX1 00 5UP2 10 Main jet M J 178 180 Main air jet M A J 200 Jet needle clip position J N N3EJ 2 N3EW 3 Main nozzle N J 2 9 Cutaway C A 7 Pilot jet P J 50 52...

Страница 72: ...hose clamp M 6 1 0 8 1 0 1 0 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 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 1 0 1 0 7 Reed valve M...

Страница 73: ...1 75 7 5 54 Clutch spring M 6 1 0 6 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...

Страница 74: ...uter 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 suspen...

Страница 75: ...0 12 in 9 84 0 10 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: ...Rear frame and frame upper Rear frame and frame lower Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Fuel tank moun...

Страница 78: ...eto model stator Manufacturer 5CU 02 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 White Pickup coil r...

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: ...ispositions 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 9 1 Pour USA CDN et ZA 9 1 10 6 1 Pour EUROPE...

Страница 81: ...cycle USA ZA AUS NZ EUROPE CDN Type de cadre Simple berceau d d double Angle de chasse 27 0 26 8 Chasse 118 mm 4 65 in 114 mm 4 49 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21...

Страница 82: ...piston 17 995 18 000 mm 17 975 mm 0 7085 0 7087 in 0 7077 in Segment Forme du segment Plat en coupe B 1 0 mm 0 039 in 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...

Страница 83: ...icant PWK38S KEIHIN Marque d identification 5NX1 00 5UP2 10 Gicleur principal M J 178 180 Gicleur d air M A J 200 Aiguille J N N3EJ 2 N3EW 3 Tubulure principal N J 2 9 Echancrure C A 7 Gicleur de rale...

Страница 84: ...ent du filtre air M 6 1 0 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 4 8 0 8 5 8 Bride de guidage de filtre air M 5 0 8 1 1 0 1 0 7 Soupape flexible M 3 0 5 4...

Страница 85: ...M 6 1 0 6 10 1 0 7 2 Axe de levier de 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 arb...

Страница 86: ...yau 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 de fou...

Страница 87: ...in 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 di...

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: ...ervoir 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...

Страница 90: ...tator Fabricant 5CU 02 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 vert blanc R sistance...

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: ...t 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 F r USA CDN und ZA 9 0 10 6 1 F r...

Страница 93: ...091 5 Gang 20 21 0 952 Fahrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 27 0 26 8 Nachlaufbertrag 118 mm 4 65 in 114 mm 4 49 in Reifengr e Bauart Mit Schlauch Reife...

Страница 94: ...17 975 mm 0 7085 0 7087 in 0 7077 in Kolbenring Querschnitt Zylindrisch B 1 0 mm 0 039 in T 2 55 mm 0 100 in Ringenspalt Eingebaut 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Seitliches Spiel Eingeb...

Страница 95: ...ersteller Anzahl PWK38S KEIHIN Identifikationsmarkierung 5NX1 00 5UP2 10 Hauptd se M J 178 180 Hauptluftd se M A J 200 D sennadel Klemmposition J N N3EJ 2 N3EW 3 Hauptzerst uber N J 2 9 Abschr gung C...

Страница 96: ...6 1 0 8 1 0 1 0 7 Luftfilterelement 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 4 8 0 8 5 8 Luftfilter F hrungsschelle M 5 0 8 1 1 0 1 0 7 Zungenventil M 3 0...

Страница 97: ...plungsfeder M 6 1 0 6 10 1 0 7 2 Schubhebelachse 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 Schaltwel...

Страница 98: ...eren 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 Vorderradgabelbeinrohre H...

Страница 99: ...12 in 9 84 0 10 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 H...

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

Страница 101: ...tstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstof tank und Hakenschraube Befestigungsband Kraftstoftank und Kraftstofftankhalterung Sitz Betest...

Страница 102: ...staor Hersteller 5CU 02 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 Wai Widerstand der Auf...

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: ...o con liquido 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...

Страница 105: ...la semidoppia Angolo di incidenza 27 0 26 8 Avancorsa 118 mm 4 65 in 114 mm 4 49 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 110 90 19 62M Pressione d...

Страница 106: ...a elastica Disegno in sezione Piano B 1 0 mm 0 039 in T 2 55 mm 0 100 in Distanza tra le estremit installata 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Gioco laterale installata 1 0 030 0 065 mm 0 0...

Страница 107: ...truttore PWK38S KEIHIN Marchio ID 5NX1 00 5UP2 10 Getto principale M J No 178 No 180 Ugello aria principale M A J No 200 Posizione della staffa dell ago di getto J N N3EJ 2 N3EW 3 Ugello principale N...

Страница 108: ...iltro dell aria M 6 1 0 1 2 0 2 1 4 Giunto del carburatore M 6 1 0 5 10 1 0 7 2 Corpo del filtro dell aria M 6 1 0 4 8 0 8 5 8 Brida di guida del filtro dell aria M 5 0 8 1 1 0 1 0 7 Valvola a lamella...

Страница 109: ...della frizione M 6 1 0 6 10 1 0 7 2 Asse della 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...

Страница 110: ...n 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 forcel...

Страница 111: ...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 esterno...

Страница 112: ...hio 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 4 3 Controdado di posizione della...

Страница 113: ...eriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio superiore M 8 1 25 1 32 3 2 23 Telaio posteriore e telaio inferiore M 8 1 25 2 29 2 9 21 Forcellone oscillante e supporto del...

Страница 114: ...struttore del magnete 5CU 02 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 Verde Blu Verde Bianco R...

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: ...hrottle cable C Pass the throttle cable and ENGINE STOP button lead over the radiator hose D Clamp the throttle cable and ENGINE STOP button lead with the clamp ends downward E Pass the clutch cable a...

Страница 117: ...idez le c ble d acc l rateur et le fil du bouton d arr t du moteur ENGINE STOP en orientant les extr mit s de la bride vers le bas E Faites passer le c ble d embrayage en peu en avant de l crou de fix...

Страница 118: ...bracket and inside the down tube Pass the radiator breather hose inside the CDI magneto lead D Clamp the CDI magneto lead radiator breather hose and YPVS breather hose In so doing clamp the CDI magnet...

Страница 119: ...ur et le tuyau reniflard YPVS Ce faisant bridez le fil de magn to CDI l arri re du tube inf rieur avec les extr mit s de la bride orient es vers l extr rieur E Bridez le tuyau reniflard du radiateur e...

Страница 120: ...ts ends downward as shown C Position the CDI magneto lead coupler between the radiators D Clamp the wireharness to the right engine bracket E Clamp the high tension cord throttle cable and wireharness...

Страница 121: ...fils sur le support droit du moteur E Bridez le cordon de haute tension le c ble d acc l rateur et le faisceau de fils en orientant les extr mit s de la bride vers le bas de fa on ce que le cordon de...

Страница 122: ...rtion directs as shown and lightly touches the projec tion on the caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twis...

Страница 123: ...n contact avec la saillie de l trier Faites ensuite passer le tuyau de frein dans les supports du tuyau de frein Si le tuyau de frein touche le ressort amortisseur arri re ajuster le coude Installer l...

Страница 124: ...directs as shown 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...

Страница 125: ...e comme indipu et touche l g rement la saillie sur le ma trecylindre Faire passer le fil de bouton d arr t du moteur ENGINE STOP au centre du support d embrayage Faire passer le c ble d embrayage deva...

Страница 126: ...end gap Inspect carbon deposits and eliminate them Check gasket Inspect score marks Inspect wear Inspect carbon deposits and eliminate them Inspect housing friction plate clutch plate and spring Yama...

Страница 127: ...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 After Inspect and adjust rain rid...

Страница 128: ...3 3 INSP ADJ MEMO...

Страница 129: ...r 6 Changer 6 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 Ch...

Страница 130: ...6 6 Graisser les pivots 6 6 Contr ler la surface du frein disque 6 6 Contr ler le niveau de fluide et les fuites 6 6 Resserrer les boulons du frein disque les boulons d tier les boulons du ma tre cyl...

Страница 131: ...le roulement 6 PNEU ROUES Contr ler la pression de 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...

Страница 132: ...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 6 6 Erneuern 6 GETRIEBE l wech...

Страница 133: ...RAFT 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 Undichtigke...

Страница 134: ...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 135: ...litura 6 6 Sostituzione 6 YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sostituzione dell olio 6 6 Ispezione 6 Sostituzione del cuscinetto 6 FORCELLA D...

Страница 136: ...RI Ispezione e regolazione 6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pulitura e lubrificazione 6 6 AMMORTIZZATORE POSTERIORE Ispezione...

Страница 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...ppliquer 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 seconde...

Страница 150: ...adiator 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 side...

Страница 151: ...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 10 s...

Страница 152: ...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 153: ...A 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 2...

Страница 154: ...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 155: ...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 156: ...le 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 filte...

Страница 157: ...filtro dell aria Danni Sostituirlo 4 Applicare 9 Olio per filtro dell aria in schiu ma oppure olio equivalente Sull elemento NOTA Comprimere per fare fuoriuscire l olio in eccesso L elemento dovrebbe...

Страница 158: ...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 159: ...oteur 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 160: ...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 161: ...be 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...

Страница 162: ...ct 9O ring 1 Damage Replace NOTE Install the O rings with their depressed a facing outward EC35R051 SILENCER FIBER REPLACEMENT 1 Remove 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adj...

Страница 163: ...rateur 1 1 Pour diminuer le regime de ralenti D visser le vis de but e d acc l rateur 1 1 Passi della regolazione Ruotare la vite di arresto della val vola a farfalla 1 finch il motore non gira al num...

Страница 164: ...r 4 9Side cover right 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 11 Nm 1 1 m kg 8 0 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bo...

Страница 165: ...1 1 m kg 8 0 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 11 Nm 1 1 m kg 8 0 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reuse...

Страница 166: ...rake 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 167: ...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 168: ...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 169: ...o 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 liquido...

Страница 170: ...Adjust NOTE The brake pedal height is the vertical distance from the inside top end of the footrest 2 Adjust 9Brake pedal height Brake pedal height a a Zero mm Zero in Pedal height adjustment steps 9...

Страница 171: ...is die Pedalh he a innerhalb der vorgeschriebenen H he liegt 9 Die Sicherungsmutter festziehen W 9 Pedalh he gem ss Abbildung zwischen Maximum A A und Mini mum B B einstelle bei dieser Ein stellung so...

Страница 172: ...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 173: ...keit nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 8 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbel ge mit deren ber st nden a in die Bremsschuh aussparungen b an...

Страница 174: ...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 175: ...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 176: ...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 177: ...r 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 9S...

Страница 178: ...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 179: ...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 180: ...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 181: ...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 l...

Страница 182: ...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 183: ...me 3 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 principa...

Страница 184: ...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 each side of chain...

Страница 185: ...aher inner halb des spezifizierten Berei ches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sicherungsmuttern festziehen 3 R gler 9 Fl che de cha ne de t...

Страница 186: ...se on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1 Stiffer a a Increase the rebound damping force Turn the adjuster 1...

Страница 187: ...eau de fourche interne et le cache poussi re 2 Nettoyer 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 grai...

Страница 188: ...RCE ADJUSTMENT 1 Remove 9Rubber cap 2 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the co...

Страница 189: ...so normale Pi morbido b b Diminuire la forza di smorza mento della com pressione Ruo tare il dispositivo di regolazione 1 1 in senso inverso REGLAGE DE LA FORCE D AMORTISSEMENT DE COM PRESSION DE LA F...

Страница 190: ...lways adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install 9Rubber cap EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smoot...

Страница 191: ...e de l endommager XG Toujours r gler la m me position sur chaque bras de fourche avant Un r glage in gal peut entra ner une mauvaise maniabilit et une perte de stablilit 3 Monter 9 Capuchon en caoutch...

Страница 192: ...stment 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 Tighten 9Locknut 6 Install 9Rea...

Страница 193: ...ESSORT 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 9 Pr contrainte de ressort En to...

Страница 194: ...tion 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 mini mum or maximum extent of adjustment The adjuster may be da...

Страница 195: ...rebond 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 R...

Страница 196: ...align 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 mini mum or maximum extent of adjustment The adjuster may...

Страница 197: ...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 198: ...ion 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 mini mum or maximum extent of adjustment The adjuster may be damaged...

Страница 199: ...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 compressione Ruo...

Страница 200: ...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 201: ...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 Corr...

Страница 202: ...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 203: ...sta 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 Einstellsch...

Страница 204: ...number 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...

Страница 205: ...i sul 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 direct...

Страница 206: ...ot 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 the...

Страница 207: ...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 208: ...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 209: ...re 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 sp...

Страница 210: ...hen 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 rot...

Страница 211: ...icata da TDC 6 Contr ler 9 Avance l allumage Le rep re grav a du rotor doit tre align avec le rep re grav b du stator Ne pas align Ajuster 6 Kontrollieren 9 Z ndzeitpunkt Die K rnermarkierung a auf de...

Страница 212: ...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 213: ...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 214: ...ting 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 Extent of removal 1 Seat removal 2 Fuel tank...

Страница 215: ...lation 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...

Страница 216: ...AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413110 Side cover 1 Remove 9 Bolt side cover 9 Side cover left and right 1 NOTE Draw the side cover downward to remove it because its claws a are inserted in...

Страница 217: ...ftfiltergeh use eingesetzt sind POINTS DE DEPOSE Couvercle lat ral 1 D poser 9 Boulon couvercle lat ral 9 Couvercle lat ral gauche et droit 1 N B Abaissez le couvercle lat ral vers le bas pour le d po...

Страница 218: ...g 18 ft lb 12 Nm 1 2 m kg 8 7 ft lb 14 Nm 1 4 m kg 10 ft lb Extent of removal Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for Side cover right Refer to SEAT FUEL TANK AN...

Страница 219: ...0 0 mm 0 39 in 1 5 Taukranz vorne 1 6 Taukranz hinten 1 7 Zugfeder 2 8 Schraube Auspuffrohr 2 9 Auspuffroht 1 AUSPUFFROHR UND SCHALLD MPFER Ausbauumfang 1 Ausbau des Schalld mpfers 2 Ausbau des Auspuf...

Страница 220: ...EL TANK AND SIDE COVERS section 1 Panel 2 2 Clamp radiator hose 2 2 Only loosening 3 Radiator hose 1 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator hose 2 2 8 Radiator breather...

Страница 221: ...onsultare la sezione SELLA SERBATOIO DEL CARBURANTE E COPERTURE LATERALI 1 Pannello 2 2 Brida manicotto flessibile del radiatore 2 2 Soltanto allentamento 3 Manicotto flessibile del radiatore 1 1 4 Ra...

Страница 222: ...p by the following procedure Place a thick rag like a towel over the radiator cap slowly rotate the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the h...

Страница 223: ...adiateur en proc dant comme suit Quand le moteur est froid mettre un chiffon pais tel qu une serviette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de d tente Cette proc dure...

Страница 224: ...ction in the CHAPTER 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 secti...

Страница 225: ...rschlauch 1 3 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Festziehen 9 Klemme K hlerschlauch 2 4 5 Einbauen 9 Tafel 1 9 Schraube Tafel 1 HINWEIS Haken a an der Innenseite zuerst am K h...

Страница 226: ...lenoid 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 carburetor jo...

Страница 227: ...ng 2 Die Schrauben Vergaserverbindung l sen 4 Vergaser 1 5 Vergaserverbindung 1 6 Zungenventil 1 7 Anschlag Zungenventil 2 8 Zungenventil 2 9 Platte Zungenventil 1 VERGASER UND ZUNGENVENTIL Ausbauumfa...

Страница 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...u 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 234: ...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 235: ...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 236: ...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 237: ...D 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 3...

Страница 238: ...tall the gasket reed valve with its projection a to the left 9Install the reed valve spacer with its chamfered side b to the right 4 13 ENG CARBURETOR AND REED VALVE 10 Nm 1 0 m kg 7 2 ft lb 3 Install...

Страница 239: ...serverbindung 1 9 Schraube Vergaserverbin dung 2 2 Einbauen 9 Dichtung Zungenventil 1 9 Platte Zungenventil 2 9 Zungenventil 3 9 Zungenventil Abstandhalter 4 HINWEIS 9 Dichtung Zungenventil mit dem Vo...

Страница 240: ...crew 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 2 Install 9O ring 1 9Solenoid valve 2 9Clamp 3 9Screw c...

Страница 241: ...Per EUROPA 4 Installare 9 Stantuffo dell avviamento 1 Notare i seguenti punti di instal lazione 9Avvitare la vite dell aria pilota finch non alloggiata legger mente 9Allentare la vite dell aria pilota...

Страница 242: ...r ends 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 6 I...

Страница 243: ...Support de pointeau 4 Vers le boisseau 5 N B Installer le ressort avec son plus faible diam tre a face au collier 9 Einbauen 9 D sennadel 1 9 H lse 2 9 Feder 3 9 Nadelhalter 4 Zum Drosselventil 5 HINW...

Страница 244: ...er side of the air vent hose 9After installing check the throttle grip for smooth movement EC465391 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor j...

Страница 245: ...rseite durchf hren 9 Nach dem Einbau ist der Gasdreh griff auf glatte Bewegung zu pr fen 11 Installare 9 Parte superiore del diffusore 1 9 Vite parte superiore del diffu sore 2 Sul carburatore 3 NOTA...

Страница 246: ...with its top as shown and secure the clamp in alignment with the hori zontal line b that passes the center of the car buretor bore 4 Connect 9TPS throttle position sensor lead 1 9Solenoid valve lead...

Страница 247: ...ringen und Klemme in bereinstimmung mit der waagerechten Linie b ausrichten die durch die Mitte der Vergaserbohrung f hrt 4 Anschlie en 9 TPS Leitungskabel Drossel stellungssensor 1 9 Magnetventilleit...

Страница 248: ...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 249: ...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 250: ...l 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 holder 1 1 11 Valve shaft 1 12 Link lever 1 13 Pulley 2 14 Link rod 1 15 Power valve 2 2 16 Val...

Страница 251: ...9 Schraube 3 10 Ventilhalterung 1 1 11 Ventilwelle 1 12 Verbindungshebel 1 13 Riemenscheibe 2 14 Pleuelstange 1 15 Leistungsventil 2 2 16 Ventilhalterung 2 1 17 Leistungsventil 1 1 KOLBEN UND LEISTUNG...

Страница 252: ...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 253: ...g des Kolbenbol zens 1 HINWEIS 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 254: ...arpage 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 face the cylinder...

Страница 255: ...e de N 400 600 3 sur un marbre et rectifier la culasse 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...

Страница 256: ...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 257: ...ung C Die Zylinder Me lehre 1 ver wenden Au erhalb des Grenzwertes Erneuern HINWEIS Die Zylinderbohrung C parallel A B C und im rechten Winkel zur Kurbel welle a b messen Danach den Durchschnitt der M...

Страница 258: ...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 259: ...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 260: ...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 261: ...rona 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 Stand...

Страница 262: ...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 263: ...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 264: ...Spring 1 2 8 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 Combinati...

Страница 265: ...outil ac r viter de rayer l aluminium Leistungsventilbohrung im Zylinder 1 Ausbauen 9 Ru ablagerungen Aus der Leistungsventil Boh rung a HINWEIS Kein scharfkantiges Instrument ver wenden Kratzer auf...

Страница 266: ...the 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 pi...

Страница 267: ...e sur le clapet de puissance 1 IC475000 MONTAGGIO E INSTALLAZIONE IC475193 Valvola di potenza 1 Installare 9 Valvola di potenza 1 1 9 Portavalvola 2 2 9 Bullone portavalvola 2 3 NOTA 9Montare la valvo...

Страница 268: ...ulfide 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 valve shaf...

Страница 269: ...cottino 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 molla 1 con la parte del fermo a rivol...

Страница 270: ...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 271: ...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 272: ...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 273: ...et la surface de cylindre IC475383 Testa cilindro e cilindro 1 Applicare 9 Olio per motori Sul pistone 1 sulla fascia ela stica 2 e sulla superficie del cilindro 42 Nm 4 2 m kg 30 ft lb 42 Nm 4 2 m k...

Страница 274: ...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 275: ...lla 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 276: ...plug 1 9Spark plug cap 2 8 Install 9Engine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 NOTE Install the engine bracket with its damper a on the right side of the body 20 Nm 2 0 m k...

Страница 277: ...EIS Motorhalterung mit ihrem D mpfer a an der rechten Seite der Karosserie einbauen 8 Installare 9 Staffa del motore 1 9 Bullone staffa del motore 2 9 Bullone di montaggio del moto re superiore 3 NOTA...

Страница 278: ...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 279: ...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 280: ...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 281: ...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 282: ...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 283: ...ten 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 emb...

Страница 284: ...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 285: ...uatre 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 levier...

Страница 286: ...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 287: ...ppliquer 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 Monter...

Страница 288: ...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 289: ...ment 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 Appli...

Страница 290: ...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 291: ...an 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 HINWEIS Die Schrauben stufenweise be...

Страница 292: ...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 293: ...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 294: ...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 295: ...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 296: ...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 297: ...arreur 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 de...

Страница 298: ...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 299: ...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 300: ...aft 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 EC4C513...

Страница 301: ...ecteur 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 Ensembl...

Страница 302: ...ke sure the stopper a of the torsion spring fits into the hole b on the kick axle EC4C5602 Kick axle assembly 1 Install 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer...

Страница 303: ...re 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 Circli...

Страница 304: ...e 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 NOTE 9Apply the molybdenum disulfide grease on the cont...

Страница 305: ...la guida della molla nella pedivella assicurarsi che la scanalatura a nella guida della molla si inserisca sul fermo della molla di torsione 4 Monter 9 Rondelle ordinaire 1 9 Ensemble axe de d marreu...

Страница 306: ...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 307: ...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 ent...

Страница 308: ...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 309: ...e 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 la p...

Страница 310: ...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 311: ...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 312: ...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 313: ...lle 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 Coll...

Страница 314: ...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 315: ...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 B...

Страница 316: ...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 317: ...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 318: ...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 319: ...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 d...

Страница 320: ...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 321: ...ch 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 9Installe...

Страница 322: ...p 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 impell...

Страница 323: ...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 tier...

Страница 324: ...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 325: ...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 326: ...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 327: ...ge 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 MONTAGE...

Страница 328: ...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 329: ...er 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 Ins...

Страница 330: ...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 331: ...ois 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 BERSICHT...

Страница 332: ...efer to EXHAUST PIPE AND Exhaust pipe stay rear SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug Disconnect the CDI magneto lead CDI unit Reservoir...

Страница 333: ...rt 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 Bougie D connecter le fil de la magn to CDI Bloc CDI R ser...

Страница 334: ...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 Remove completely 11 Engine 1 Refer to REMOVAL POINTS 1...

Страница 335: ...ignon 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 montage du m...

Страница 336: ...e the engine 1 aslant and upward while inclining it toward the kick crank side so that the engine s mounting top does not contact the bracket on the frame EC4M3000 REMOVAL POINTS EC4F3100 Drive sprock...

Страница 337: ...9 Catena di trasmissione 2 NOTA Togliere il rocchetto conduttore insieme alla catena di trasmissione IC4M3340 Rimozione del motore NOTA Assicurarsi che gli accoppiatori i tubi flessibili e i cavi sia...

Страница 338: ...Engine installation 1 Install 9Engine 1 Install the engine from right side 9Pivot shaft 2 9Engine mounting bolt lower 3 9Engine mounting bolt front 4 9Engine bracket 5 9Bolt engine bracket 6 9Engine...

Страница 339: ...sse base de savon au lithium sur le boulon les joints toriques et le support de p dale de frein 9Mettre le collier de fixation avec la but e a tourn e vers l int rieur IC4M5000 MONTAGGIO E INSTALLAZIO...

Страница 340: ...washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 8 Nm 0 8 m kg 5 8 ft lb 75 Nm 7 5 m kg 54 ft lb EC4M5341 Drive sprocket 1 I...

Страница 341: ...g 54 ft lb 8 Nm 0 8 m kg 5 8 ft lb 8 Nm 0 8 m kg 5 8 ft lb 8 Nm 0 8 m kg 5 8 ft lb 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...

Страница 342: ...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 343: ...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 344: ...ap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure of...

Страница 345: ...entral taper alternativement sur le bossage de fixation avant du moteur et les arbres de transmission fF Utiliser un maillet en plastique et ne taper que sur les portions renforc es du carter Ne pas t...

Страница 346: ...kcase 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 bearing EC4...

Страница 347: ...ebrequin en appuyant de carter int rieure comme indiqu dans 9Si le roulement est enlev en m me temps que le vilebrequin d poser le roulement en utilisant un extracteur de roulement 2 comme indiqu dans...

Страница 348: ...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 349: ...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 HI...

Страница 350: ...01274 Bolt 3 YU 90050 90890 01275 Adapter 4 YU 90063 90890 01278 2 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair B For USA and CDN Except for USA and CDN NOTE 9Hold the co...

Страница 351: ...e 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 it...

Страница 352: ...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 353: ...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 au...

Страница 354: ...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 355: ...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 monteu...

Страница 356: ...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 357: ...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 358: ...ct 9Matching dog a 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 9Shif...

Страница 359: ...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 Examiner 9 Crabot d accouplement a 9 D...

Страница 360: ...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 361: ...tte 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 Pign...

Страница 362: ...ip 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 gear 23 T 1 94th wheel gear 24...

Страница 363: ...rconf rence inter ne des 4e et 5e engrenages 9Appliquer de la graisse base de savon an lithium sur le joint torique 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9V rifier que le cot bord vif du cir...

Страница 364: ...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 365: ...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 366: ...wheel axle 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of rem...

Страница 367: ...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 368: ...e 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 Oil seal 2 8 Circlip 1 9...

Страница 369: ...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 370: ...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 371: ...ure 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 la c...

Страница 372: ...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 373: ...e 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 de...

Страница 374: ...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 375: ...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 de...

Страница 376: ...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 377: ...ans 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 da...

Страница 378: ...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 379: ...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 ral...

Страница 380: ...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 381: ...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 litio...

Страница 382: ...heel 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 axle 1 9Locknut...

Страница 383: ...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 temporaneamente il dado asse della ruota...

Страница 384: ...en disassembling the caliper 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1 Extent of removal 1 Brake hose removal 2 Caliper removal 3 Master cyilinder removal w Support...

Страница 385: ...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 386: ...3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Caliper 1 Extent of removal 1 Master cylinder...

Страница 387: ...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 Pr paration pour la d pose XG...

Страница 388: ...per piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear caliper disassembly 2 1 EC5A8200 CA...

Страница 389: ...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 390: ...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 A Front B Rear Extent of removal 1 Front master cylinder disas...

Страница 391: ...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 392: ...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 393: ...IONE IC5A3101 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Coperchio del cilindro principa le 1 9 Dispositivo di protezione NOTA Non togliere il d...

Страница 394: ...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 395: ...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 396: ...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 397: ...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 398: ...nt B Rear 3 Install 9Caliper piston 1 NOTE Apply the brake fluid on the piston wall cC 9Install the piston with its shallow depressed side a a facing the caliper 9Never force to insert A Front B Rear...

Страница 399: ...Arri re 2 Installare 9 Guarnizione di tenuta 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...

Страница 400: ...stall 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 1...

Страница 401: ...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 Gou...

Страница 402: ...Master cylinder kit 1 Clean 9Master cylinder 9Master cylinder kit Clean them with brake fluid 2 Install 9Master cylinder cup primary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOT...

Страница 403: ...re cylindre primaire 1 9 Coupelle du ma tre cylindre secondaire 2 Au piston de ma tre cylindre 3 N B Appliquer le liquide de frein sur la cou pelle du ma tre cylindre XG Apr s la repose la coupelle du...

Страница 404: ...master cylinder 5 NOTE 9Apply the brake fluid on the master 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 F...

Страница 405: ...z 1 9 Schubstange 2 9 Sprengring 3 9 Manschette des Hauptbrems zylinders 4 Zum Hauptbremszylinder 5 HINWEIS 9 Bremsfl ssigkeit auf dem Haupt bremszylindersatz auftragen 9 Lithiumseifen Fett am Ende de...

Страница 406: ...cylinder piston 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb EC5A5401 Rear master cylinder 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brak...

Страница 407: ...onter 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 que la partie avec le tuyau soit a a di...

Страница 408: ...htening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so...

Страница 409: ...uvercle de tuyau 1 9 Rondelle ordinaire 2 9 Boulon couvercle de tuyau M8 3 9 Boulon couvercle de tuyau M6 4 4 Einbauen 9 Stift 1 9 Beilegescheibe 2 9 Splint 3 HINWEIS Nach den Einbau die H he des Brem...

Страница 410: ...nstall the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb EC5A5502 Rear brake hose 1 Install 9Copper w...

Страница 411: ...ione 3 T Usare sempre rondelle in rame nuove iI Installare il tubo flessibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin...

Страница 412: ...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 413: ...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 fonctio...

Страница 414: ...9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Master cylinder cap 1 9Bolt master cylinder cap 2 cC After installation while pulling the lever in or pushing down on the pedal che...

Страница 415: ...perchio del cilindro principa le 1 9 Vite coperchio del cilindro principale0 2 Posteriormente 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Bullone coperchio del cilindro principale 2 iI Dopo l...

Страница 416: ...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 417: ...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 418: ...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 419: ...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 420: ...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 421: ...g 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 avant...

Страница 422: ...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 423: ...nge 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 Vorderradga...

Страница 424: ...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 425: ...eur 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 Examin...

Страница 426: ...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 427: ...ement 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 B...

Страница 428: ...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 429: ...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 nyl...

Страница 430: ...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 431: ...belbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 11 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren Rohres ei...

Страница 432: ...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 433: ...achten 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...

Страница 434: ...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 435: ...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 ma...

Страница 436: ...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 437: ...e 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 fourche m...

Страница 438: ...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 439: ...tage 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 9...

Страница 440: ...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 441: ...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 To...

Страница 442: ...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 443: ...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 444: ...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 445: ...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 446: ...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 447: ...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 Poign...

Страница 448: ...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 449: ...ant 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 ches so...

Страница 450: ...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 451: ...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 2...

Страница 452: ...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 453: ...yage 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 t...

Страница 454: ...5 45 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 455: ...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 456: ...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 Extent of remov...

Страница 457: ...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 458: ...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 459: ...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 460: ...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 461: ...trier 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 Cage b...

Страница 462: ...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 463: ...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 464: ...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 465: ...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 466: ...e 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 Swinga...

Страница 467: ...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 468: ...Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disass...

Страница 469: ...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 470: ...eplace EC574211 Relay arm 1 Inspect 9Bearing polylube bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Bearing polylube bearing 1 Loss of so...

Страница 471: ...n 9 ldichtung 3 Besch digung Erneuern Relaisarm 1 Pr fen 9 Lager Polylube Lager 1 9 H lse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und H lse als Satz erneuern 2 Pr fen 9 Lager Polylube Lager...

Страница 472: ...Outer a a Zero mm Zero in Inner b b 8 5 mm 0 33 in EC574311 Connecting rod 1 Inspect 9Bearing polylube bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set...

Страница 473: ...jeu fonctionnel tour irr gulier rouille Changer roule ment et collerette comme un en semble 2 Examiner 9 Roulement roulement Polylu be 1 Pertes de lubrifiant solide Changer 9 Bague d tanch it 3 Endom...

Страница 474: ...stall 9Bearing 1 9Oil seal 2 To connecting rod 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 mark...

Страница 475: ...htung 2 Zum Relaisarm HINWEIS 9 Molybd n Fett auf dem Lager Wenn diese eingebaut werden 9 Das Lager einbauen indem es an der Seite mit den Herstellermarkierungen oder Herstellungsnummern eingepre t wi...

Страница 476: ...NOTE 9Apply the molybdenum disulfide grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut...

Страница 477: ...ras de relais 2 9 Rondelle ordinaire 3 9 Ecrou bras de relais 4 Au bras oscillant N B 9Appliquer de la graisse de molybd ne sur le boulon 9Ne pas resserrer l crou ce stade 6 Monter 9 Bras oscillant 1...

Страница 478: ...lybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the...

Страница 479: ...Schraube auftragen 8 Installare 9 Bullone leva di rinvio 1 9 Rosetta 2 9 Dado leva di rinvio 3 NOTA 9Applicare sul bullone il grasso a base di bisolfuro di molibdeno 9Non serrare ancora il dado 9 Inst...

Страница 480: ...chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support R 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover R 10mm 0 39in 5 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg...

Страница 481: ...t tzenabdeckung 10 mm 0 39 in 5 13 Installare 9 Bullone tendicatena inferiore 1 9 Rosetta 2 9 Bordino 3 9 Tendicatena 4 9 Dado tendicatena inferiore 5 14 Installare 9 Supporto della catena 1 9 Copertu...

Страница 482: ...nt 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 8 Spring guide lower 1 9 Spring guide upp...

Страница 483: ...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 484: ...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 485: ...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 486: ...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 487: ...ge 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 Fuit...

Страница 488: ...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 489: ...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 rep r...

Страница 490: ...he 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 length...

Страница 491: ...e 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 joints antipoussi r...

Страница 492: ...ide grease on the bolt 5 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 6 Install 9Rear frame 1 9Bolt rear fr...

Страница 493: ...er de la graisse de molybd ne sur le boulon 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re sup rieur 2 9 Boulon cadre arri re inf rieur 3 7 Serrer 9 Vis raccord de filtre air 1 3 Installare 9 Ammor...

Страница 494: ...r 5 Solenoid valve 6 CDI magneto 7 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black L Blue O Orange R Red Y Yellow B L Black Blue B R Black Red B W Black White G L Green Blue G W Green White W L...

Страница 495: ...MPOSANTS 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 Bleu O O...

Страница 496: ...on 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 magneto Replace CDI uni...

Страница 497: ...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 servoir essence 9Utiliser...

Страница 498: ...euern Erneuern Erneuern Erneuern Erneuern Markierung Nur wenn das Z ndungspr fger t verwendet wird HINWEIS 9Die folgenden Teile vor Beginn der St rungsbeseitigung ausbauen 1 Sitz 2 Kraftstofftank 9Die...

Страница 499: ...tituirla contrassegnato Soltanto quando viene usato l apparecchio per il controllo dell accensione NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9 In ques...

Страница 500: ...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 501: ...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 502: ...move the spark plug cap by turning it coun terclockwise and inspect 9Install the spark plug cap by turning it clock wise until it is tight Tester lead Orange lead 1 Tester lead Black lead 2 Tester lea...

Страница 503: ...ccio della candela girandolo in senso antiorario e con trollarlo 9Rimontare il cappuccio della candela girandolo in senso orario finch non bene avvitato Resistenza Posizione del della bobina selettore...

Страница 504: ...oose connection Tighten Deteriorated Damaged Replace 9Spark plug cap resistance Out of specification Replace Tester lead Spark plug lead terminal 1 Tester lead Spark plug terminal 2 Spark plug cap Tes...

Страница 505: ...sumato Sosti tuire 9 Resistenza del cappuccio della candela Non rientra nelle specifiche Sostituire R sistance Position de du capuchon s lecteur de de bougie testeur 4 6k k 1 20 C 68 F Fil de testeur...

Страница 506: ...place EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Green Blue lead 1 Tester lead Green...

Страница 507: ...nare 9 Resistenza della bobina sorgen te 2 Fuori specifica Sostituirla IC628000 ISPEZIONE DELL UNIT CDI Controllare tutti i componenti elettrici Se non si rileva alcun guasto sostituire l unit CDI Qui...

Страница 508: ...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 509: ...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 510: ...ule 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 hre...

Страница 511: ...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 512: ...e 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 9Solenoid valv...

Страница 513: ...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 514: ...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 515: ...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 516: ...auen 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 In...

Страница 517: ...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 518: ...ixing chamber top Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 2 Inspect 9TPS coil resistance Out of specification Replace Tester lead Blue lead 1 Tester lead Black lead 2 TPS coil Test...

Страница 519: ...tand Abweichung von Spezifikation Erneuern 2 Ispezionare 9 Resistenza della bobina del TPS Fuori specifica Sostituirla Resistenza Posizione del della bobina selettore del del TPS tester 4 6k a k 1 20...

Страница 520: ...of specification Replace Tester lead Yellow lead 2 Tester lead Black lead 3 Tester selector position Full closed Full opened Zero 2k at 4 6k at 20 C 68 F 20 C 68 F k 1 EC693001 TPS REPLACEMENT AND AD...

Страница 521: ...F Positives Kabel des Pr fger tes Gelb Kabel 2 Negatives Kabel des Pr fger te Schwarz Kabel 3 Regelbarer Position des TPS Spulenwider Wahlschalters stand am Pr fger t Vollst ndig Vollst ndig geschloss...

Страница 522: ...Adjustment steps 9Set the inductive tachometer engine tachometer to the high tension cord 9Turn the throttle stop screw 1 until the specified idle speed Refer to IDLE SPEED ADJUSTMENT sec tion in the...

Страница 523: ...n auf den Abschnitt EINSTELLUNG DER LEER LAUFDREHZAHL im KAPITEL 3 Leerlaufdrehzahl f r TPS Einstellung 1 700 bis 1 900 U min Passi della regolazione 9Collegare il tachimetro induttivo tachimetro moto...

Страница 524: ...1 NOTE Tighten the screws TPS using 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 i...

Страница 525: ...em die vor dem Ausbau angebrachten Markierungen a zum Ausrichten benutzt werden 14 Einbauen 9 Vergaser Siehe Abschnitt VERGASER UND ZUNGENVENTIL 13 Serrare 9 Vite TPS 1 NOTA Serrare le viti usando la...

Страница 526: ...694000 TPS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect 9TPS input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blu...

Страница 527: ...I Einheit erneuern IC694000 ISPEZIONE DELLA TENSIONE IN INGRESSO NEL TPS 1 Scollegare l accoppiatore del TPS 2 Avviare il motore 3 Ispezionare 9 Tensione in ingresso nel TPS Fuori specifica Sostituire...

Страница 528: ...t 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 r...

Страница 529: ...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 530: ...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 531: ...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 532: ...calibrating 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 Power jet adjustment Th...

Страница 533: ...ugie est trop chaude S 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 calibra...

Страница 534: ...eration 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 therefore it should be judged from your feeling o...

Страница 535: ...posizione della sca nalatura sull ago a getto Se dovesse essere difficile far girare il motore senza problemi a regimi inter medi si deve regolare l ago a getto 1 Se la miscela troppo ricca o troppo p...

Страница 536: ...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 537: ...cht 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 zah...

Страница 538: ...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 539: ...u diam 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 groove Riche N3EJ 3e groov...

Страница 540: ...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 541: ...tre de 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 groove Riche N3EW 4e groove N3CW...

Страница 542: ...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 543: ...position 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...

Страница 544: ...8 10 55 4MX 14948 09 STD 52 4MX 14948 08 STD 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 40 4MX 14948 03 Lean 38 4MX 14948 02 Jet needle 3 3 Rich N8RW 4SR 14916 RW N3EW 4SR 14916 E...

Страница 545: ...90 Getto Ricca No 62 4MX 14948 12 pilota No 60 4MX 14948 11 2 2 No 58 4MX 14948 10 No 55 4MX 14948 09 STD No 52 4MX 14948 08 STD No 50 4MX 14948 07 No 48 4MX 14948 06 No 45 4MX 14948 05 No 42 4MX 149...

Страница 546: ...e clip position Hard breathing 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 w...

Страница 547: ...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 548: ...ve plus bas Elever la position de fixation de l aiguille de gicleur 1 groove plus haut Abaisser la position de fixation de l aiguille de gicleur 1 groove plus bas Elever la position de fixation de l a...

Страница 549: ...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 550: ...ageres 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 4 3 4 Gas Hartes Beatmen...

Страница 551: ...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 552: ...imento della candela Se color cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Sco...

Страница 553: ...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 554: ...No of the main jet must be changed by 15 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 sure to st...

Страница 555: ...d 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 ter le moteur imm diatement...

Страница 556: ...e entire 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 enti...

Страница 557: ...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 vitant que l...

Страница 558: ...urface 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 Driven sprocket...

Страница 559: ...on des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kgf cm2 9 0 12 psi Reifendruck Der Reifendruck soll soll...

Страница 560: ...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 561: ...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 562: ...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 563: ...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 564: ...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 565: ...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 566: ...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 567: ...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 568: ...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 569: ...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 570: ...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 571: ...er 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 weicher...

Страница 572: ...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 573: ...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 574: ...n 1 260 SOFT 4 5 5UN 22212 10 Green 1 260 4 7 5UN 22212 20 Red 1 260 STD 4 9 5UN 22212 30 Black 1 260 5 1 5UN 22212 40 Blue 1 260 STIFF 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 5 7 5U...

Страница 575: ...2 50 Gelb 1 260 5 5 5UN 22212 60 Rosa 1 260 5 7 5UN 22212 70 Wei 1 260 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4 3 5UN 22212 00 Marrone 1 260 4 5 5UN 22212 10 Verde 1 260 4 7 5UN 22212 2...

Страница 576: ...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 577: ...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 578: ...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 579: ...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 580: ...e 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 sichtb...

Страница 581: ...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 steiger...

Страница 582: ...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 583: ...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 584: ...TUN MEMO...

Страница 585: ......

Страница 586: ...PRINTED IN JAPAN 2002 5 1 7 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER YZ250 R LC...

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