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1-7

SPECIAL TOOLS

GEN

INFO

EC140002

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and part number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.

NOTE:

9

For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC -”.

9

For others, use part number starting with “90890-”.

Part number

Tool name / How to use

IIIustration

YU-1135-A, 90890-01135

Crankcase separating tool

YU-1135-A

90890-01135

This tool is used to split the crankcase as well
as remove the crankshaft from either case.

YM-1189, 90890-01189

Flywheel puller

YM-1189

90890-01189

This tool is used to remove the flywheel magneto.

YU-1235, 90890-01235

Rotor holding tool

YU-1235

90890-01235

This tool is used when loosening or tightening the
flywheel magneto securing nut.

YU-3097, 90890-01252

Dial gauge and stand

YU-3097

90890-01252

YU-1256

Spark plug hole dial stand

YU-1256

These tools are used to set the ignition timing.

Crankcase installing tool

YU-90050

90890-01274

YU-90050, 90890-01274

Pot

YU-90063

90890-01275

YU-90050, 90890-01275

Bolt

90890-01278

YU-90063, 90890-01278

Adapter

These tools are used to install the crankshaft.

YU-1304, 90890-01304

Piston pin puller

YU-1304

90890-01304

This tool is used to remove the piston pin.

YU-24460-01,90890-01325

Radiator cap tester

YU-24460-01

90890-01325

YU-33984, 90890-01352

Adapter

YU-33984

90890-01352

These tools are used for checking the cooling
system.

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Содержание YZ250(V)

Страница 1: ...AHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 V 1P8 28199 31 PRINTED IN JAPAN 2005 5 2 0 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAP...

Страница 2: ...aha Motor Co Ltd 1st Edition May 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 1P8...

Страница 3: ...aha Motor Co Ltd 1 Ausgabe Mai 2005 Alle Rechte vorbehalten Nachdruck auch auszugsweise oder nicht autorisierte Verwendung sind ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Ge...

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

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

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

Страница 7: ...CTEUR 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 pro...

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: ...ourner 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 ga...

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

Страница 11: ...L 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 Si...

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 compre...

Страница 14: ...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 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W...

Страница 15: ...er 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 chiffr...

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: ...Serrage 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 lubrif...

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 ALLGEMEINE ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHNISCHE 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: ...SCH 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 13...

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: ...BRE DE 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...

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: ...tr 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...

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: ...um 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 fourch...

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 be...

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 dass 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 ld...

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: ...lbaums 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 Connect...

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: ...oil seal YU 3112 C 90890 03112 Yamaha pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 90890 03113...

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: ...tensit YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Outil de poign e d brrayage Cet outil est utilis pour immobiliser l embrayage quand on d pos ou monte...

Страница 42: ...M 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: ...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 Kupplung Halterwerkzeug Dieses Werkzeug wird f r das Festhalten der Kupp lung...

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: ...rrente YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Utensile per tenere la frizione Questo utensile viene usato per tenere la frizione quan do si toglie...

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

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: ...ine or higher octane 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...

Страница 53: ...RBURANTE E OLIO PER MISCELA PER MOTORI Miscelare l olio con la benzina nel rap porto specificato pi sotto Usare sem pre benzina fresca di marca e miscela re l olio e la benzina il giorno della gara No...

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: ...r 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 zwei Minuten ben tigt 5 Der Motor ist warmgela...

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: ...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 r...

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: ...nn eines der folgenden Teile erneuert wurde dann muss die Maschine wiederum eingefahren werden ZYLINDER UND KURBELWELLE Etwa eine Stunde Einfahrzeit ist erforderlich KOLBEN KOLBENRING UND ZAHNR DER Di...

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

Страница 61: ...adre De la timonerie l amortisseur De la timonerie au bras oscillant Arri re Installation de De l amortisseur au cadre l amortisseur Arri re Installation du bras oscillant Serrage de l arbre de pivot...

Страница 62: ...nterradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradschwinge Rad Einbau des Rades Vorn Festziehen der Vorderachse Festziehen...

Страница 63: ...Ammortizzatore telaio dell ammortizzatore Posteriore Installazione del Serraggio dell albero snodato forcellone oscillante Ruota Installazione della ruota Anteriore Serraggio dell asse anteriore Serra...

Страница 64: ...of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car...

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

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

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

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

Страница 69: ...ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 26 9 27 1 26 9 Trail 115 mm 4 53 in 118 mm 4 65 in 116 mm 4 57 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90 19 62M T...

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: ...urer PWK38S KEIHIN I D mark 1P85 30 1P86 40 1P87 50 Main jet M J 178 180 178 Main air jet M A J 200 Jet needle clip position J N N3EJ 2 N3EW 3 N3EW 2 Main nozzle N J 2 9 Cutaway C A 7 Pilot jet P J 50...

Страница 72: ...mp M 6 1 0 8 2 0 2 1 4 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 3 0 5 4...

Страница 73: ...h boss M20 1 0 1 75 7 5 54 Clutch spring M 6 1 0 6 10 1 0 7 2 Clutch cable adjust bolt and locknut M 6 0 75 1 4 0 4 2 9 Push lever axle M 5 0 8 1 6 0 6 4 3 Drive sprocket M20 1 0 1 75 7 5 54 Shift gui...

Страница 74: ...ension USA CDN ZA EUROPE AUS NZ Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length One I D paint mark One I D paint mark 255 mm 10 04 in 252 mm 9 92 in Two...

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: ...ke lever mounting bolt Brake lever mounting nut Brake lever position locknut Cable guide front brake hose and under bracket Front brake hose union bolt master cylinder Front brake hose union bolt cali...

Страница 77: ...me lower Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Cable guide and frame Fuel tank mounting boss and frame Fue...

Страница 78: ...2 11 MAINTENANCE SPECIFICATIONS SPEC MEMO...

Страница 79: ...ncer type Electrical CDI Magneto model stator Manufacturer 5CU 20 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 B...

Страница 80: ...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 81: ...t liquide Dispositions de cylindres Monocylindre inclin Cylindr e 249 cm3 8 76 lmp oz 8 42 US oz Al sage course 66 4 72 mm 2 614 2 835 in Taux de compression 9 2 10 9 1 Pour USA et CDN 8 9 10 6 1 Pour...

Страница 82: ...CDN Type de cadre Simple berceau d d double Angle de chasse 26 9 27 1 26 9 Chasse 115 mm 4 53 in 118 mm 4 65 in 116 mm 4 57 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Tai...

Страница 83: ...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 84: ...IHIN Marque d identification 1P85 30 1P86 40 1P87 50 Gicleur principal M J 178 180 178 Gicleur d air M A J 200 Aiguille J N N3EJ 2 N3EW 3 N3EW 2 Tubulure principal N J 2 9 Echancrure C A 7 Gicleur de...

Страница 85: ...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 1 0 1 0 7 Bou...

Страница 86: ...rt d embrayage M 6 1 0 6 10 1 0 7 2 Boulon de r glage et contre crou de c ble d embrayage M 6 0 75 1 4 0 4 2 9 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...

Страница 87: ...r 131 5 mm 5 18 in Longueur de ressort libre Approx 265 mm 10 43 in Longueur de raccord Une marque d iden Une marque d iden tification peinte tification peinte 255 mm 10 04 in 252 mm 9 92 in Deux marq...

Страница 88: ...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 89: ...e tuyau de frein 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 et arri re et vis de purge Axe de...

Страница 90: ...age du r servoir de carburant et cadre Montage de r servoir essence R servoir essence et robinet essence R servoir essence et patte de maintien R servoir essence et vis d accrochage bande de fixation...

Страница 91: ...ge de pare boue arri re arri re Plaque d immatriculation M 6 1 0 M 6 1 0 M 6 1 0 M 6 1 0 Pi ce serrer Taille de filetage Q t Couple de serrage Nm m kg ft lb 4 2 2 1 7 7 12 7 0 7 0 7 1 2 0 7 5 1 5 1 8...

Страница 92: ...ce Electrique CDI Magn to mod le stator Fabricant 5CU 20 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 couleu...

Страница 93: ...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 94: ...Wassergek hlter Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorn 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 2 10 6 1 F r USA un...

Страница 95: ...hrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 26 9 27 1 26 9 Nachlaufbetrag 115 mm 4 53 in 118 mm 4 65 in 116 mm 4 57 in Reifengr e Bauart Mit Schlauch Reifengr e...

Страница 96: ...m 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 Einge...

Страница 97: ...PWK38S KEIHIN Identifikationsmarkierung 1P85 30 1P86 40 1P87 50 Hauptd se M J 178 180 178 Hauptluftd se M A J 200 D sennadel Klemmposition J N N3EJ 2 N3EW 3 N3EW 2 Hauptzerst uber N J 2 9 Abschr gung...

Страница 98: ...0 8 2 0 2 1 4 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 5 4...

Страница 99: ...ngsfeder M 6 1 0 6 10 1 0 7 2 Kupplungszug Einstellschraube und Sicherungsmutter M 6 0 75 1 4 0 4 2 9 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...

Страница 100: ...A AUS NZ Hub des Sto d mpfers 131 5 mm 5 18 in Ungespannte Federl nge Etwa 265 mm 10 43 in Einbaul nge Eine ID Farbmarkierung Eine ID Farbmarkierung 255 mm 10 04 in 252 mm 9 92 in Zwei ID Farbmarkieru...

Страница 101: ...0 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...

Страница 102: ...ANMERKUNG Lenkerkrone und u eres Rohr Untere Gabelbr cke und u eres Rohr Lenkerkrone und Lenkerschaft Lenkerhalter oben Lenkerhalter Unten Lenkerringmutter Teleskopgabel und D mpfer Baugruppe Teleskop...

Страница 103: ...ftank Befestigungsklemmfaust und Rahmen Kraftstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstofftank und Hakenschraube Befestigungsband Kraftstof...

Страница 104: ...pr fen 2 11 WARTUNGSDATEN SPEC Vorderrad Kotfl gel Befestigung Hinterrad Kotfl gel Befestigung Vorderrad Hinterrad Kotfl gel Befestigung Hinterrad Nummernschild M 6 1 0 M 6 1 0 M 6 1 0 M 6 1 0 Anzuzi...

Страница 105: ...sche Ausf hrung CDI Modell Stator Hersteller 5CU 20 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...

Страница 106: ...f r trockene und saubere Gewinde Die anzuziehenden Bauteile sollten dabei Raumtemperatur aufweisen A Schl sselweite B Gewindedurchmesser DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A B...

Страница 107: ...i raffreddato 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 compres...

Страница 108: ...denza 26 9 27 1 26 9 Avancorsa 115 mm 4 53 in 118 mm 4 65 in 116 mm 4 57 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 110 90 19 62M Pressione degli pne...

Страница 109: ...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 110: ...IHIN Marchio ID 1P85 30 1P86 40 1P87 50 Getto principale M J No 178 No 180 No 178 Ugello aria principale M A J No 200 Posizione della staffa dell ago di getto J N N3EJ 2 N3EW 3 N3EW 2 Ugello principal...

Страница 111: ...tro 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 M...

Страница 112: ...75 7 5 54 Molla della frizione M 6 1 0 6 10 1 0 7 2 Bullone di regolazione e controdado del cavo frizione M 6 0 75 1 4 0 4 2 9 Asse della leva di spinta M 5 0 8 1 6 0 6 4 3 Rocchetto di trasmissione M...

Страница 113: ...10 43 in Lunghezza di inserimento Uncontrassegnodipintodi Uncontrassegnodipintodi marcaturadiidentificazione marcaturadiidentificazione 255 mm 10 04 in 252 mm 9 92 in Duecontrassegnidipintidi Duecontr...

Страница 114: ...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 115: ...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 leva di comando del freno M 6 1 0 1 5 0 5 3 6 Guida per cavi tubo flessibile del freno a...

Страница 116: ...58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio superiore M 8 1 25 1 32 3 2 23 Telaio posterio...

Страница 117: ...upporto del parafango anteriore M 6 1 0 4 7 0 7 5 1 Supporto del parafango posteriore anteriore M 6 1 0 2 7 0 7 5 1 Supporto del parafango posteriore posteriore M 6 1 0 2 12 1 2 8 7 Targa M 6 1 0 1 7...

Страница 118: ...Elettrico CDI Modello statore Costruttore del magnete 5CU 20 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...

Страница 119: ...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 120: ...ton lead to the frame Tighten the clamp so that the ENGINE STOP button lead is not pulled when the handlebar is turned to the right and left E Clamp the throttle cable clutch cable and wireharness to...

Страница 121: ...la gauche et vers la droite E Brider le c ble des gaz le c ble d embrayage et le faisceau de fils au cadre F Brider le c ble des gaz et le faisceau de fils au cadre G Faire passer le c ble d embrayag...

Страница 122: ...e radiator breather hose outside the engine bracket and inside the down tube Then pass the radiator breather hose inside the CDI magneto lead F Clamp the CDI magneto lead radiator breather hose YPVS b...

Страница 123: ...e ensuite passer la durit de mise l air du radiateur l int rieur du fil de magn to CDI F Brider au cadre le fil de magn to CDI la durit de mise l air du radiateur la durit de mise l air YPVS et le fil...

Страница 124: ...ngine bracket B Pass the high tension cord to the right of the radiator hose so that the high tension cord does not contact the radiator hose C Pass the CDI unit lead between the frame and the radiato...

Страница 125: ...ur B Faire passer le fil haute tension droite de la durit du radiateur de fa on ce que le fil haute tension ne soit pas en contact avec la durit du radiateur C Faire passer le fil du bo tier CDI entre...

Страница 126: ...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 127: ...en 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...

Страница 128: ...se so that its pipe portion 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 Clamp the ENGINE STOP but...

Страница 129: ...frein de mani re que la partie avec le tuyau soit dirig 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 su...

Страница 130: ...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 Yamalube...

Страница 131: ...fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SH...

Страница 132: ...NTENANCE INTERVALS INSP ADJ Item Remarks THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or Lubricate SAE 10W 30 motor oil After break in Every race Every third Every fifth As re...

Страница 133: ...nger 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 Changer l...

Страница 134: ...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 cylindre et les boulo...

Страница 135: ...ubrifier 6 Changer 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 de...

Страница 136: ...euern 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 wechseln 6...

Страница 137: ...AHMEN Reinigen und pr fen 6 6 KRAFTSTOFFTANK KRAFT STOFFHAHN Reinigen und pr fen 6 6 BREMSEN Bremshebelposition und Bremspedalh he einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfl che pr fen 6...

Страница 138: ...erung pr fen Ketternrad Befestigungsschraube 6 6 nachziehen Lager pr fen 6 Lager erneuern 6 Schmieren 6 GASDREHGRIFF GASSEIL Seilzugf hrung und Anschl sse 6 6 pr fen Schmieren 6 6 3 3 WARTUNGSINTERVAL...

Страница 139: ...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 DEL CAMBI...

Страница 140: ...eni 6 FORCELLE ANTERIORI 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 GUIDA DEL DISP...

Страница 141: ...ne gioco libero e riserraggio 6 6 Pulitura e lubrificazione 6 Sostituzione del cuscinetto 6 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneu...

Страница 142: ...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 143: ...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 144: ...chtung pr fen Auch sicherstellen dass die Kette richtig geschmiert P3 24 26 ist R der Die Reifen auf berm ige Abnutzung kontrollieren Speichen auf Lockerung und berm iges Spiel pr P3 34 35 fen Lenkung...

Страница 145: ...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 146: ...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 147: ...iateur 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 en...

Страница 148: ...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 149: ...on 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 radia...

Страница 150: ...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 151: ...t 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 manipul...

Страница 152: ...res 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 specified pressure Radiator cap tester YU 24460 01...

Страница 153: ...res sion sp cifi e pendant 10 secondes Changer IC356002 ISPEZIONE DELLA PRESSIONE DI APERTURA DEL TAPPO DEL RADIATORE 1 Collegare 9 Tester del tappo del radiatore 1 e adattatore 2 NOTA Applicare acqua...

Страница 154: ...specification Adjust NOTE 9Before adjustment expose the adjuster by moving the boot 3 and cap 4 away 9Make minute adjustment on the lever side using the adjuster 5 9After adjustment check proper opera...

Страница 155: ...rarlo o sostituirlo 9 Manicotto flessibile del radiatore 3 Rigonfiamento Sostituirlo IC359020 REGOLAZIONE DELLA FRIZIONE 1 Controllare 9 Gioco libero della leva di comando della frizione a Fuori speci...

Страница 156: ...ottle 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 specified free play is o...

Страница 157: ...cavo dell acceleratore 2 Jeu la poign e d acc l ration a a 3 5 mm 0 12 0 20 in Gioco libero della mano pola dell acceleratore a a 3 5 mm 0 12 0 20 in Spiel am Gasdrehgriff a a 3 5 mm 0 12 0 20 in Eins...

Страница 158: ...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 159: ...nson sten k nnen Staub und Schmutz in den Motor eindringen und schnel len Verschlei sowie m glichen Motorschaden verursachen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelement...

Страница 160: ...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 161: ...ro 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 esse...

Страница 162: ...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 163: ...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 r cipient convenable sous le moteur 3 Controll...

Страница 164: ...Oil 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 by the factory se...

Страница 165: ...e 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 tipo SE Capacit dell olio cambio dell olio periodico 0 75 L...

Страница 166: ...place 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 For USA and CDN Except fo...

Страница 167: ...s 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 numero di giri pi basso possibile Per aumentare il numero di gi...

Страница 168: ...For USA and CDN Except for USA and CDN 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 12...

Страница 169: ...12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reusement de l agent d t...

Страница 170: ...Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed sc...

Страница 171: ...der Bremsanlage Es kann zu einer gef hrlichen Abnahme des Bremsverm gens kommen falls die Bremsanlage nicht richtig entl ftet ist 1 Ausbauen 9 Hauptbremszylinderkappe 9 Membrane 9 Schwimmer im Beh lte...

Страница 172: ...rocedure when 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 positi...

Страница 173: ...le circuit de freinage NOTA Se lo spurgo risulta difficoltoso pu essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le...

Страница 174: ...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 175: ...en bis die Pedalh he a innerhalb der vorgeschriebenen H he liegt 9 Die Sicherungsmutter festziehen W 9 Pedalh he gem Abbildung zwischen Maximum und Mini mum einstellen bei dieser Einstellung soll das...

Страница 176: ...r its end 9Loosen the bleed screw and push the caliper piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 7 and pad pin NOTE 9Install the brake pads wit...

Страница 177: ...r cken dD Die abgelassene Bremsfl ssig keit nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 7 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbel ge mit deren ber st nde...

Страница 178: ...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 0 Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb B...

Страница 179: ...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 180: ...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 181: ...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 9Se...

Страница 182: ...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 183: ...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 184: ...ease its tension 9Measure the length between drive chain roller 1 and y as shown 9Perform this measurement at two or three dif ferent places 2 Remove 9Master link clip 9Joint 1 9Drive chain 2 3 Clean...

Страница 185: ...ie L nge zwischen der Antriebsket tenrolle 1 und y wie dargestellt messen 9 Diese Messung an zwei oder drei verschiedenen Stellen durchf hren IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei...

Страница 186: ...lutions 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 Drive chain slack 48 58 mm 1 9 2 3 in Drive chain lubr...

Страница 187: ...ell anello principale nella direzione illustrata a Direzione di rotazione 6 Lubrificare 9 Catena di trasmissione 5 Monter 9 Cha ne de transmission 1 9 Raccord 2 9 Agrafe de l attache rapide 3 fF Veill...

Страница 188: ...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 189: ...aher innerhalb des spezifizier ten Bereiches 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 tr...

Страница 190: ...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 191: ...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 192: ...N DAMPING FORCE ADJUSTMENT 1 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 compression...

Страница 193: ...ota re il dispositivo di regolazione 1 1 in senso 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 L...

Страница 194: ...amaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smooth action Abn...

Страница 195: ...mager 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 VERIFICATION DE L AMOR TISSEUR ARRIERE 1 E...

Страница 196: ...STMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Remove 9Rear frame 3 Loosen 9Locknut 1 4 Adjust 9Spring preload By turning the adjuster 2 Stiffer Increase the spring...

Страница 197: ...e et toutes les salet s autour du contre crou et de l ajusteur avant de faire le r glage 9La longueur du ressort mont chan ge de 1 5 mm 0 06 in par tour com plet du dispositif de r glage 9La couleur b...

Страница 198: ...d juster with the punch mark b on the bracket cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the rebound damping force...

Страница 199: ...s Einstellers 1 IC36N020 REGOL ELLA FORZA DI SMOR ZAMENTO DELL ESTENSIONE D E L L A M M O R T I Z Z A T O R E POSTERIORE 1 Regolare 9 Forza di smorzamento dell estensione Ruotando il dispositivo di re...

Страница 200: ...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 minimum or maximum extent of adjustment The ad juster may...

Страница 201: ...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 202: ...tion Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged...

Страница 203: ...1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compressione Ruotando il dispositivo di rego laz...

Страница 204: ...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 205: ...che lo pneumatico scivola fuori dalla sua posizione sul cerchione 9Se si trova inclinato il gambo della valvola dello pneumatico si ritiene che lo pneumatico stia scivolando fuori dalla sua posizione...

Страница 206: ...st 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 nut adjustment steps 9Remove the num...

Страница 207: ...gola re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellschritte der Lenkring mutter 9 Das Nummernschild entfernen 9 Die Lenkstange und die Lenker krone entfernen 9 Die Ringmutter 1 mi...

Страница 208: ...The handlebar holder upper should be installed with the punched mark a forward 9Install the handlebar so that the marks b are in place on both sides 9Insert the end of the fuel breather hose e into th...

Страница 209: ...re dapprima i bulloni sul lato anteriore del supporto supe riore del manubrio e poi serrare quelli sul lato posteriore 9Desserrer l crou annulaire d un tour 9Resserrer l crou annulaire l aide de la cl...

Страница 210: ...to handlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding portion 0 Throttle cable end q Clutch cable end Use Yamaha cable lube or e...

Страница 211: ...la 8 Superficie di scorrimento del rullo della valvola a farfalla 9 Parte a spira del cavo di guida del tubo 0 Estremit del cavo dell acceleratore q Estremit del cavo della frizione A Usare lubrifican...

Страница 212: ...eds 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 Regap 4...

Страница 213: ...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 spessimetro Fuori specific...

Страница 214: ...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 215: ...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 216: ...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 217: ...hrauben Stator 1 l sen 9 Die K rnermarkierung am Rotor mit der K rnermarkierung am Sta tor 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allentar...

Страница 218: ...el tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 7 Side cover right 1 Refer to REMOVAL POINTS 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers r...

Страница 219: ...schild 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 220: ...inserted in the air cleaner case Number plate 1 Remove 9 Bolt number plate 9 Number plate 1 NOTE 9The projection a is inserted into the band of the number plate Pull the band off the projec tion befo...

Страница 221: ...d immatriculation 1 N B 9La saillie a est ins r e dans la bande de la plaque d immatriculation Reti rer la bande de la saillie avant la d pose 9D poser le c ble d embrayage 2 du guide de c ble b sur...

Страница 222: ...22 mm 0 87 in 1 Plain washer 26 mm 1 02 in 1 3 Silencer 1 4 Collar R 13 0 mm 0 51 in 1 Collar R 15 5 mm 0 61 in 1 5 Collar R 13 5 mm 0 53 in 1 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 B...

Страница 223: ...nt 2 10 Tuyau d chappement 1 Ausbauumfang Reihen Teilename St ck Bemerkungen folge zahl AUSBAU DES AUSPUFFROHRES UND SCHALLD MPFERS Seitendeckel rechts Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDE...

Страница 224: ...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 225: ...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 226: ...by the following procedure Place a thick rag like a towel over the radi ator cap slowly rotate the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the h...

Страница 227: ...radiateur 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 dur...

Страница 228: ...ction in the CHAPTER 2 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 3 Install 9Radiator left 1 9Plain washer 2 9Bolt radiator left 3 9Radiator hose 1 4 Refer to CABLE ROUTI...

Страница 229: ...Schraube K hler links 3 9 K hlerschlauch 1 4 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Festziehen 9 Klemme K hlerschlauch 2 5 5 Einbauen 9 Tafel 1 9 Schraube Tafel 2 HINWEIS Haken a...

Страница 230: ...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 231: ...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 232: ...p 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 Throttle sto...

Страница 233: ...immerstift 1 7 Schwimmer 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 234: ...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 235: ...ei 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 gu...

Страница 236: ...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 237: ...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 238: ...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 239: ...entilsitz 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 de...

Страница 240: ...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 241: ...st dD Die Schrauben allm hlich festzie hen um ein Verziehen des Ventils zu vermeiden REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 But e soupape flexible 2 9 Vis soupape flexib...

Страница 242: ...0 m kg 7 2 ft lb 3 Install 9Carburetor joint 1 9Bolt carburetor joint 2 EC4652F0 Carburetor 1 Install 9Power jet 1 To carburetor 2 2 Install 9O ring 1 9Solenoid valve 2 To carburetor cC 9Before instal...

Страница 243: ...ise de la soupape flexible avec sa face chanfrein e a orient e vers la droite 3 Monter 9 Raccord de carburateur 1 9 Boulon raccord de carburateur 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10...

Страница 244: ...out for reference only Note the following installation points 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw by the number of turns recorded before removing 5 In...

Страница 245: ...ungen ausdrehen Leerlauf Luftregulier schraube 1 Ausdrehung 2 1 4 Ausdrehungen 1 1 4 Ausdrehungen nur als Hinweis 3 Installare 9 Vite dell aria pilota 1 9 Vite di arresto della valvola a farfalla 2 Pe...

Страница 246: ...NG DIAGRAM section in the CHAPTER 2 NOTE Install the air vent hoses and overflow hose to the carburetor with their ends not having the cuts a toward the carburetor 9 Install 9Jet needle 1 9Collar 2 9S...

Страница 247: ...1 9 Tubo flessibile di sfiato dell aria 400 mm 15 7 in 2 9 Tubo flessibile di troppopieno 280 mm 11 0 in 3 9 Brida 4 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPITOLO 2 NOTA Install...

Страница 248: ...rottle grip for smooth movement EC465391 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor joint slots 10 Install 9Throttle cable 1 9Locknut 2 9Mixing...

Страница 249: ...lare 9 Parte superiore del diffusore 1 9 Vite parte superiore del diffu sore 2 Sul carburatore 3 NOTA 9Inserire la valvola a farfalla nel corpo del carburatore tirando contempora neamente la leva 4 ve...

Страница 250: ...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 251: ...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 252: ...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 253: ...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 254: ...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 255: ...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 256: ...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 257: ...des Kolbenbol zens 1 HINWEIS Vor dem Abnehmen des Stifts des Kol benbolzens ist das Kurbelgeh use mit einem sauberen Lappen abzudecken so dass der Stift nicht versehentlich in das Kurbelgeh use f llt...

Страница 258: ...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 259: ...egment en l ouvrant plus que n cessaire 3 Togliere 9 Fascia elastica 1 NOTA Attenzione a non graffiare il pistone o danneggiare la fascia elastica allargan dola pi di quanto sia necessario Proc dure d...

Страница 260: ...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 261: ...Die Zylinder Messlehre 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 Messw...

Страница 262: ...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 263: ...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 Co...

Страница 264: ...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 265: ...orona del pistone 2 Misurare 9 Distanza tra le estremit Usare uno spessimetro 1 Fuori limite Sostituirla Standard Grenze 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Kolbenring Endspalt eingebaut Stan...

Страница 266: ...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 267: ...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 268: ...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 269: ...n 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 270: ...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 271: ...ne 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 valv...

Страница 272: ...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 273: ...biscottino 2 9 Puleggia 3 9 Molla 2 4 9 Rosetta 5 9 Gambo della valvola 6 NOTA 9Installare la molla 1 sulla leva del biscottino e quindi sul cilindro 9Installare la molla 1 con la parte del fermo a ri...

Страница 274: ...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 275: ...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 276: ...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 277: ...t 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 kg...

Страница 278: ...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 279: ...e 1 9 Boulon bo tier de clapet de puissance 2 7 Monter 9 Culasse 1 9 Rondelle en cuivre 2 9 Ecrou culasse 3 N B Serrer les crous culasse par tapes en utilisant un mod le d entre croisement 6 Monter 9...

Страница 280: ...CYLINDER AND PISTON ENG 9 Install 9Spark plug 1 9Spark plug cap 2 8 Install 9Engine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 20 Nm 2 0 m kg 14 ft lb 34 Nm 3 4 m kg 24 ft lb 64 Nm...

Страница 281: ...ela 1 9 Calotta della candela 2 8 Einbauen 9 Motorhalterung 1 9 Schraube Motorhalterung 2 9 Motor Befestigungsschraube oben 3 8 Installare 9 Staffa del motore 1 9 Bullone staffa del motore 2 9 Bullone...

Страница 282: ...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 283: ...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 284: ...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 285: ...bhebelachse 1 14 Schubhebelachse 1 PRIM RABTRIEBSZAHNRAD SCHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Prim r...

Страница 286: ...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 287: ...lten F r USA und CDN Au er USA und CDN POINTS DE DEPOSE Noix d embrayage 1 D poser 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poign e d em...

Страница 288: ...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 289: ...quatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors sp cification Changer tous les disques d embrayage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Axe de levi...

Страница 290: ...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 291: ...pliquer 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 9...

Страница 292: ...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 293: ...tement 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 App...

Страница 294: ...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 295: ...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 ber K...

Страница 296: ...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 297: ...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 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...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 304: ...ft 2 Install 9Shift lever assembly 1 To shift guide 2 EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130...

Страница 305: ...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 306: ...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 307: ...rbre 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 Circ...

Страница 308: ...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 309: ...sur les surfaces de contact de la but e d axe du lanceur a et de la plaque de but e 3 9 Appliquer de l huile de bo te de vitesses sur l axe de d marreur au pied 9Faites coulisser l axe du lanceur dan...

Страница 310: ...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 311: ...t 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 en...

Страница 312: ...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 313: ...de montage du cou vercle d embrayage mais pas contre 8 Monter 9 P dale de s lecteur 1 9 Boulon p dale de s lecteur 2 N B Monter la p dale de s lecteur de sorte que le haut du diam tre ext rieur de la...

Страница 314: ...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 315: ...TEUR 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 Collerett...

Страница 316: ...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 317: ...ndelle 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 C...

Страница 318: ...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 319: ...le 3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9V rifier que le goujon d assemblage est bien ajust dans le gorge a du dispositif d arr t 4 Monter 9 Ensemble r gulateur 1 N...

Страница 320: ...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 321: ...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 322: ...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 323: ...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 de...

Страница 324: ...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 325: ...anch it 1 Usure endommagement Changer REMONTAGE ET MONTAGE Bague d tanch it 1 Monter 9 Bague d tanch it 1 N B 9Appliquer la graisse base de savon au lithium sur la l vre de la bague d tanch it 9Instal...

Страница 326: ...and impeller shaft And install the shaft while turn ing it 2 Install 9Plain washer 1 9Impeller 2 NOTE Hold the impeller shaft on its width across the flats a with spanners etc and install the impelle...

Страница 327: ...at 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 t...

Страница 328: ...emoval SIDE COVERS section Bolt radiator 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 1...

Страница 329: ...E RESERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur 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 cial...

Страница 330: ...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 331: ...age du vilebrequin et le coussinet vilebrequin Si n cessaire changer le stator et ou le magn to CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET MONTAG...

Страница 332: ...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 333: ...r 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 Inst...

Страница 334: ...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 335: ...rois 7 Connecter 9 Fil de magn to CDI 1 Se r f rer au paragraphe DIA GRAMME DE CHEMINE MENT DE CABLE au CHA PITRE 2 7 Anschlie en 9 Kabel des CDI Magnetz nders 1 Siehe Abschnitt KABEL F HRUNGS BERSICH...

Страница 336: ...section Exhaust pipe and silencer Refer to EXHAUST PIPE AND Exhaust pipe stay rear SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug Disconnect the...

Страница 337: ...r Siehe Abschnitt AUSPUFFROHR UND Auspuffrohrst tze hinten SCHALLD MPFER Kupplungskabel An der Motorseite abtrennen K hler Siehe Abschnitt K HLER Z ndkerze Das Kabel des CDI Magnetz nders abtrennen AU...

Страница 338: ...ke pedal 1 8 Brake pedal 1 9 Engine bracket 2 10 Engine mounting bolt 3 11 Pivot shaft 1 Remove completely 12 Engine 1 Refer to REMOVAL POINTS 4 61 ENGINE REMOVAL ENG Extent of removal 1 Engine remova...

Страница 339: ...ignon d entra nement 1 4 Rondelle frein 1 Se reporter POINTS DE DEPOSE 5 Pignon d entra nement 1 6 Agrafe 1 7 Boulon p dal de frein 1 8 P dale de frein 1 9 Support du moteur 2 10 Boulon de montage du...

Страница 340: ...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 341: ...1 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 si...

Страница 342: ...EC4M5124 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...

Страница 343: ...raisse base de savon au lithium sur le boulon les joints toriques et le support de p dale de frein IC4M5000 MONTAGGIO E INSTALLAZIONE IC4M5124 Installazione del motore 1 Installare 9 Motore 1 Installa...

Страница 344: ...le applying the rear brake 3 Bend the lock washer tab to lock the nut 5 Nm 0 5 m kg 3 6 ft lb 75 Nm 7 5 m kg 54 ft lb EC4M5341 Drive sprocket 1 Install 9Drive sprocket 1 9Drive chain 2 NOTE Install th...

Страница 345: ...ando il freno posteriore 75 Nm 7 5 m kg 54 ft lb 75 Nm 7 5 m kg 54 ft lb 75 Nm 7 5 m kg 54 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 Pignon d entra nement 1 Monter...

Страница 346: ...Piston Refer to CYLINDER HEAD CYLINDER AND PISTON section Primary drive gear Kick idle gear Refer to KICK AXLE SHIFT SHAFT AND Stopper lever PRIMARY DRIVE GEAR section Rotor and stator Refer to CDI MA...

Страница 347: ...6 in 1 6 Schraube L 70 mm 2 76 in 3 7 Halter 2 8 Kurbelgeh use rechts 1 Das Spezialwerkzeug verwenden 9 Kurbelgeh use links 1 Siehe unter AUSBAUPUNKTE 10 Kurbelwelle 1 Das Spezialwerkzeug verwenden Si...

Страница 348: ...fts cC Use soft hammer to tap 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 en...

Страница 349: ...l g rement d viss e pour mettre le corps de l outil de niveau 9Tout en serrant le boulon central taper alternativement sur le bossage de fixation avant du moteur et les arbres de transmission fF Util...

Страница 350: ...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 351: ...iere il cuscinetto dal carter pre mendone l anello interno come illu strato in 9Se il cuscinetto viene tolto insieme all albero a gomiti togliere il cusci netto usando un estrattore generico per cusci...

Страница 352: ...30in Crank 59 95 60 00 mm width 2 360 2 362 in EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification R...

Страница 353: ...9 Largeur de vilebrequin d Hors sp cification Changer Utiliser un Comparateur Cadran et une jauge d paisseur Comparateur YU 3097 90890 01252 Comparatore YU 3097 90890 01252 Messuhr YU 3097 90890 0125...

Страница 354: ...ng tool until the crankshaft bottoms against the bear ing 9Before installing the crankshaft clean the con tacting surface of crankcase 9Apply the lithium soap base grease on the oil seal lip cC Do not...

Страница 355: ...bero a gomiti 1 Installare 9 Albero a gomiti 1 Usare l utensile per installare l albero a gomiti 2 3 4 Per USA e CDN Tranne che per USA e CDN NOTA 9Reggere la biella nel punto morto superiore con una...

Страница 356: ...ned at TDC top dead center cC In order to prevent the oil seal lip a a from being turned up or damaged wrap a vinyl tape or the like b b around the right end of the crankshaft and apply the lithium so...

Страница 357: ...droit 2 Vers le carter gauche 3 N B 9Fixer le carter moteur gauche sur le cartermoteur droit Taper l g re ment sur le cartrer l aide d un mar teau souple 9Quand le carter est install la bielle d accou...

Страница 358: ...n the bolt cC If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt 30 Nm 3 0 m kg 22 ft lb 7 Install 9Tension spring 1 9Holder 2 9Bol...

Страница 359: ...saillie a du carter droit 8 Serrer 9 Segment 1 9 Boulon segment 2 N B 9Lors de l installation du segment sur l arbre came 3 aligner la marque imprim e a avec la broche de centra ge b 9Tourner le segme...

Страница 360: ...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 361: ...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 362: ...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 363: ...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 364: ...ulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear then install 3 Check 9Shift fork movement Unsmooth operation Replace shift fork NOTE For a malfun...

Страница 365: ...tionnement de la fourchette ne pas changer que la fourchette 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 Pi...

Страница 366: ...clip 2 NOTE 9Be sure the circlip sharp edged corner a is positioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 2 Install 92nd wheel g...

Страница 367: ...t rieure du pignon mobile puis les monter 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 cl...

Страница 368: ...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 369: ...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 370: ...3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Exten...

Страница 371: ...2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Collerette 2 6 Bague d tanch it 2 7 Roulement 2 Se reporter POINTS DE DEPOSE 8 Disque de frein 1 Pr paration pour la d pose XG Bien...

Страница 372: ...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 373: ...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 374: ...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 375: ...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 376: ...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 377: ...te d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arri re 4 0 mm 0 16 in 3 5 mm 0 14 in IC594200 Disco del freno 1 Misurare 9 Inflessione del disco del freno soltanto il disco d...

Страница 378: ...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 379: ...t 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 d...

Страница 380: ...soap base grease on the wheel axle 6 Install 9Nut wheel axle 1 7 Tighten 9Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several ti...

Страница 381: ...lare 9 Asse della ruota 1 NOTA Applicare sull asse della ruota il grasso a base di sapone di litio 6 Installare 9 Dado asse della ruota 1 7 Serrare 9 Bullone supporto dell asse 1 NOTA Prima di serrare...

Страница 382: ...g 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 bearing Contact should be made onl...

Страница 383: ...le convenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ral droit doit monter premier 9Monter la bague d tanch it avec ses marques ou num ros de fabricant diri g s vers l ext r...

Страница 384: ...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 385: ...ondotto 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 5...

Страница 386: ...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 387: ...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 388: ...n when disassembling the caliper 7 Caliper 1 8 Brake lever 1 9 Master cylinder bracket 1 10 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose re...

Страница 389: ...Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 6 Goupille de plaquette 1 Desserrer lors du d montage de l trier 7 Etrier 1 8 Levier de frein 1 9 Etrier de ma...

Страница 390: ...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 391: ...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 392: ...per piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 EC5A8200 CALIPER DISASSEMBLY A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear calipe...

Страница 393: ...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 394: ...gm 1 3 Reservoir float 1 4 Master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Plain washer 1 7 Push rod 1 8 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear E...

Страница 395: ...ptbremszylindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorn B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE...

Страница 396: ...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 397: ...E 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 diaf...

Страница 398: ...d dust seals w Replace the piston seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534120 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Sc...

Страница 399: ...les joints de piston et antipoussi 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 n...

Страница 400: ...B Rear 2 Inspect 9Caliper piston 1 Wear Score marks Replace caliper piston assembly w Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Bra...

Страница 401: ...ilindro principale A Anteriore B Posteriore IC534214 Pinza 1 Ispezionare 9 Superficie interna del cilindro della pinza a Usura Rigature Sostituire il gruppo pinza A Anteriore B Posteriore 2 Ispezionar...

Страница 402: ...and dust seals onto the slot on caliper correctly A Front 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 fa...

Страница 403: ...on et antipoussi re dans la rainure situ e sur l trier A Avant B Arri re IC5A5801 Pistone della pinza 1 Pulire 9 Pinza 9 Guarnizione di tenuta del pisto ne 9 Parapolvere 9 Pistone della pinza Pulirli...

Страница 404: ...d pin at this point 2 Install 9Disc cover 1 9Bolt disc cover 2 2 Install 9Caliper 1 9Bolt caliper 2 3 Tighten 9Pad pin 3 4 Install 9Pad pin plug 4 23 Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm...

Страница 405: ...emsschuhaussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 2 Monter 9 Etrier 1 9 Boulon trier 2 3 Serrer 9 Goupille de plaquette 3 4 Monter 9 Bouchon de goupill...

Страница 406: ...imary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong...

Страница 407: ...lle du ma tre cylindre doit tre pos e dans la direction indiqu e Une mauvaise intallation enta ne une performance incorrecte du freinage A Avant B Arri re IC5A5220 Kit del cilindro principale 1 Pulire...

Страница 408: ...ose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mar...

Страница 409: ...festziehen 4 Installare Anteriormente 9 Kit del cilindro principale 1 9 Rosetta 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 Posteriormente 9 Kit...

Страница 410: ...t 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 2 Install 9Master cylinder 1 9Bolt master cylinder 2 10 Nm 1 0 m kg 7 2...

Страница 411: ...der 1 9 Schraube Hauptbremszylin der 2 IC5A5401 Cilindro principale posteriore 1 Installare 9 Rondella in rame 1 9 Tubo flessibile del freno 2 9 Bullone di unione 3 T Usare sempre rondelle in rame nuo...

Страница 412: ...ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Install 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT section in the CHAPTER 3 EC5A5911 Front...

Страница 413: ...ie in der Abbildung gezeigt angeordnet ist und den berstand b b am Bremsbe lag leicht ber hrt 2 Einbauen 9 Bremsschlauchhalter 1 9 Schraube Bremsschlauchhal ter 2 3 Einbauen 9 Bremsschlauchhalter 1 9...

Страница 414: ...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 washer 1 9Brake hose 2...

Страница 415: ...ibile 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 dro principale Tuyau de frein arri re 1 Monter 9 Rondelle en cuivre 1 9...

Страница 416: ...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 417: ...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 418: ...iaphragm 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...

Страница 419: ...iaframma 9 Coperchio 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 principal...

Страница 420: ...S section in the CHAPTER 4 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt u...

Страница 421: ...die Vorderradgabel demontiert wird Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 4 Klemmschraube 2 Nur l sen Untere Gabelbr cke 5 Vorderradgabel 1 VORDERRADGABEL Ausbauumfang 1 Ausbau der Vorderr...

Страница 422: ...tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 0 Oil seal 1 q Base valve 1 Drain the fork oil Use special tool w Damper assembly 1 Refer to REMOVAL POINTS 5 27 CHAS FRONT F...

Страница 423: ...l outil sp cial Se reporter POINTS DE DEPOSE 2 Ressort de fourche 1 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...

Страница 424: ...uction and is particularly sensitive to foreign material 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...

Страница 425: ...ger compl tement les chambres air IC556000 NOTA PER IL MANEGGIO NOTA La forcella anteriore richiede grande at tenzione Si raccomanda pertanto di ef fettuare la manutenzione della forcella anteriore pr...

Страница 426: ...not remove the locknut as the damper rod may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove 9Dust seal 1 9Stopper ring 2 Using...

Страница 427: ...adere nel gruppo ammortizzatore senza che sia possibile estrarla Cl bague de boulon capuchon YM 01501 90890 01501 Chiave ad anello per vite mordente YM 01501 90890 01501 Schraubenschl ssel f r Nockenw...

Страница 428: ...Inspect 9Damper assembly 1 Bend Damage Replace 9O ring 2 Wear Damage Replace cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive t...

Страница 429: ...RIFICATION Amortisseur complet 1 V rifier 9 Amortisseur complet 1 Courbure endommagement Changer 9 Joint torique 2 Us endommag Changer fF La fourche avant ayant une tige de piston incorpor e a une con...

Страница 430: ...Piston metal 3 Wear Damage Replace 9Spring 4 Damage Fatigue Replace base valve 9Air bleed screw 5 Wear Damage Replace EC554400 Fork spring 1 Measure 9Fork spring free length a Out of specification Rep...

Страница 431: ...a 2 Usura Danni Sostituire 9 Metallo del pistone 3 Usura Danni Sostituire 9 Molla 4 Danni Affaticamento Sostitui re la valvola di base 9 Vite di spurgo dell aria 5 Usura Danni Sostituire Ressort de fo...

Страница 432: ...of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the...

Страница 433: ...den k nnen IC554502 Tubo interno 1 Ispezionare 9 Superficie del tubo interno a Rigature Ripararlo o sostituir lo Usare carta vetrata umida di grana no 1000 Pezzo di bloccaggio dell olio danneggiato So...

Страница 434: ...have an ex cessively adverse effect on the front fork performance 9Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Oil capacity 195cm3 6 86 Imp oz 6 59 US oz 4...

Страница 435: ...no avere un effetto ec cessivamente negativo sul rendi mento della forcella anteriore 9Non permettere mai la penetrazione di materiali estranei nella forcella anteriore Huile recommand e Huile de susp...

Страница 436: ...Loosen 9Compression damping adjuster 1 NOTE 9Loosen the compression damping adjuster fin ger tight 9Record the set position of the adjuster the amount of turning out the fully turned in posi tion 8 In...

Страница 437: ...d amener la pression de la tige d amortissement au maximum Ins taller ensuite la valve de base tout en rel chant la pression de la tige d amor tissement 9 V rifier que l amortisseur complet est totale...

Страница 438: ...5 35 CHAS FRONT FORK 12 While protecting the damper assembly 1 with a rag and compressing fully allow excessive oil to overflow on the base valve side cC Take care not to damage the damper assembly 13...

Страница 439: ...lassen w hrend die D mpfer Baugruppe 1 durch einen Lappen gesch tzt und vollst ndig zusammenge dr ckt wird dD Darauf achten dass die D mpfer Baugruppe nicht besch digt wird 13 Das bersch ssige l an d...

Страница 440: ...installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 9Install the oil seal with its manufacture s marks or number facing the axle holder side 9Install the oil sea...

Страница 441: ...ation de la bague d tanch it utiliser une feuille en vi nyle a avec de l huile de fourche ap pliqu e pour prot ger la l vre de la bague d tanch it 9Installer le joint huile dont les marques d usine ou...

Страница 442: ...ver 3 19 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 20 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 21 Insta...

Страница 443: ...S Den Gabelbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 20 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren R...

Страница 444: ...o damper assembly 3 NOTE Install the collar with its larger dia end a facing the fork spring 25 Install 9Damper assembly 1 To inner tube 2 cC To install the damper assembly into the inner tube hold th...

Страница 445: ...lta verso la molla della forcella 25 Monter 9 Amortisseur complet 1 Au tube interne 2 fF Pour installer l amortisseur complet dans le tube plongeur maintenir l tanch it du tube plongeur Si le tube plo...

Страница 446: ...stalled out of specification proper damping force cannot be obtained 29 Tighten 9Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster with specified torque 30 Install 9Adjuster 1 To inn...

Страница 447: ...si zionare la chiave ad anello per vite mordente 7 tra il tubo interno e il controdado 6 9Serrare a fondo con le dita il regolato re sul gruppo ammortizzatore 28 Ispezionare 9 Distanza a tra il regola...

Страница 448: ...9Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque w Never fail to make the oil amount adjustment between the maximum and minimum amount and a...

Страница 449: ...es sch dliche Einfl sse auf die Lei stung der Teleskopgabel mit sich bringen 9 Darauf achten dass keine Fremd k rper in die Vorderradgabel ein dringen T Non mancare mai di eseguire la rego lazione del...

Страница 450: ...ront fork top end a Front fork top end standard a a Zero mm Zero in 4 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too muc...

Страница 451: ...insteller 1 mit den Fin gern festziehen und danach in die urspr ngliche Einstellposition heraus drehen 5 Monter 9 Protecteur 1 9 Boulon protecteur 2 6 R gler 9 Force d amortisseur de rebond N B Tourne...

Страница 452: ...rn 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 to REMOVAL POINTS 11 Handlebar holder upper 2 12 Ha...

Страница 453: ...puchon 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 Couvercle de capuchon 1 9 Colleret...

Страница 454: ...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 455: ...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 POI...

Страница 456: ...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 457: ...9 Guidon 1 Deform e craquelures endom magement Changer XG Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble acc l rateur 1 Monter 9 Poig...

Страница 458: ...ll 9Handlebar holder lower 1 9Plain washer 2 9Nut handlebar holder lower 3 NOTE 9Install the handlebar holder lower with its side having the greater distance a from the mount ing bolt center facing fo...

Страница 459: ...avant 9Appliquer de la graisse base de savon au lithium sur le filetage du support de guidon inf rieur 9L installation du support de guidon inf rieur en sens inverse permet de changer le d calage d av...

Страница 460: ...ll the handlebar so that the marks b are in place on both sides 9First tighten the bolts on the front side of the handlebar holder upper and then tighten the bolts on the rear side 4 Install 9Grip lef...

Страница 461: ...e per vernice 9Installare la manopola sinistra sul manubrio in modo che la linea b tra le due frecce sia rivolta direttamente verso l alto 5 Installare 9 Collare 1 9 Coperchio della calotta 2 9 Accele...

Страница 462: ...the throttle cable in the groove b in the roller 8 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 9 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTE...

Страница 463: ...tion UPPER a soit dirig e vers le haut 9Faire passer le c ble d acc l rateur dans la rainure b du rouleau 8 Monter 9 Capuchon du c ble d acc l ra teur 1 9 Vis capuchon du c ble d acc l rateur 2 9 R gl...

Страница 464: ...grip cap and brake lever 2 2 are equal If you make a mistake in the grip cap installation position the brake lever may contact the grip cap resulting in poor brake performance 9After tightening the bo...

Страница 465: ...s avoir serr les boulons v ri fier que la poign e d acc l rateur 3 3 tourne sans probl me Sinon res serrer les boulons pour la r gler 13 Monter 9 Bouton d arr t du moteur EN GINE STOP 1 9 Support de l...

Страница 466: ...5 49 CHAS HANDLEBAR 14 Install 9Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch cable end 15 Adjust 9Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3...

Страница 467: ...u CHAPITRE 3 14 Einbauen 9 Kupplungskabel 1 HINWEIS Lithium Fett am Kupplungskabelende auftragen 15 Einstellen 9 Spiel des Kupplungshebels Siehe Abschnitt EINSTEL LUNG DER KUPPLUNG im KAPITEL 3 14 Ins...

Страница 468: ...4 Handle crown 1 5 Ring nut 1 Use special tool Refer to REMOVAL POINTS 6 Under bracket 1 7 Bearing race cover 1 8 Bearing upper 1 9 Bearing lower 1 Refer to REMOVAL POINTS 10 Bearing race 2 Refer to...

Страница 469: ...mmernschild Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDECKEL im KAPITEL 4 Lenkstange Siehe Abschnitt LENKSTANGE Vorderrad Kotfl gel 1 Lenkerschaftdeckel 1 2 Lenkerschaftmutter 1 3 Vorderradgabel 2...

Страница 470: ...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 Bearing race 1 Remove 9Bearing race 1 Remove the bearing race...

Страница 471: ...pas endommager le file tage de l arbre de direction Cage de roulement 1 D poser 9 Cage de roulement 1 D poser la cage de roulement l aide d une tige 2 et d un marteau VERIFICATION Arbre de direction...

Страница 472: ...on in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION EC5651A0 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the...

Страница 473: ...ulement et de cages de roulement REMONTAGE ET MONTAGE Etrier inf rieur 1 Monter 9 Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint anti poussi re et sur...

Страница 474: ...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 9Tempora...

Страница 475: ...l 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 bridage trier...

Страница 476: ...o specified torque If torqued too much it may cause the front fork to malfunction Front fork top end standard a a Zero mm Zero in 23 Nm 2 3 m kg 17 ft lb 20 Nm 2 0 m kg 14 ft lb 9 Install 9Steering sh...

Страница 477: ...rata pu provocare il malfunzionamento della forcella anteriore Oberes Ende der Gabelbein rohre Standard a Null mm Null in Extr mit sup rieure de fourche avant Standard a a Z ro mm Z ro in Estremit sup...

Страница 478: ...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 479: ...E 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 Hinterradschwi...

Страница 480: ...Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 10 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and...

Страница 481: ...und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename St ckzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 Siehe unter AUSBAUPUNKTE 2 Relaisarm 1 3 Pleuelstange 1 4 H lse 2 5 ld...

Страница 482: ...ush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574211 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revol...

Страница 483: ...ken auf den u eren Laufring ausbauen INSPEKTION Die Lager Buchsen und H lsen in L sungsmittel waschen Hinterradschwinge 1 Pr fen 9 Lager 1 9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost Lager un...

Страница 484: ...nstalled depth of bearings Outer a a Zero mm Zero in Inner b b 6 5 mm 0 26 in EC574311 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and colla...

Страница 485: ...mit den Herstellermarkierungen oder Herstellungsnummern eingepresst wird 9 Zuerst die u eren Lager und danach die inneren Lager bis zur vorgeschrie benen Tiefe von innen einbauen Profondit installata...

Страница 486: ...er 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the be...

Страница 487: ...der Drucklager auftragen 2 Einbauen 9 H lse 1 9 Unterlegscheibe 2 Zum Relaisarm 3 HINWEIS Das Molybd n Fett auf den H lsen und den ldichtungslippen auftragen Profondeur install e de roulement a a Z ro...

Страница 488: ...lybdenum 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 connecting rod 4 To...

Страница 489: ...r l crou ce stade 6 Monter 9 Bras oscillant 1 9 Axe de pivot 2 N B 9Appliquer de la graisse de molybd ne sur l axe de pivot 9Introduire l arbre pivot par le c t droit 5 Einbauen 9 Relaisarm 1 9 Schrau...

Страница 490: ...Plain washer 2 9Nut connecting rod 3 NOTE 9Apply the molybdenum 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...

Страница 491: ...2 9 Mutter Pleuelstange 3 HINWEIS 9 Das Molybd n Fett auf der Schraube auftragen 9 Die Mutter noch nicht festziehen 9 Einbauen 9 Schraube Hinterrad Sto d mpfer Relaisarm 1 9 Mutter Hinterrad Sto d mp...

Страница 492: ...her 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover 10mm 0 39in 5 7...

Страница 493: ...er unten 5 14 Einbauen 9 Kettenschutz 1 9 St tzenabdeckung 2 9 Schraube Kettenschutz 50 mm 1 97 in 3 9 Mutter Kettenschutz 4 9 Schraube St tzenabdeckung 10 mm 0 39 in 5 13 Installare 9 Bullone tendica...

Страница 494: ...under the engine Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air cleaner joint 1 Loosen the bolt...

Страница 495: ...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 Si ge de res...

Страница 496: ...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 497: ...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 498: ...ON 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 assembly 9Spring 3 Damag...

Страница 499: ...plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet Fuite de gaz Remplacer l amortisseur complet 9 Ressort 3 Endommagement Changer le ressort Fatigue Changer le ressort Comprimer et d te...

Страница 500: ...bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopper ring upper bearing 1 NOTE After installing the stopper ring push back t...

Страница 501: ...sur c t o les rep res ou num rous du fa bricant sont inscrits Ressort amortisseur arri re 1 Monter 9 Ressort 1 9 Guide de ressort sup rieur 2 9 Guide de ressort inf rieur 3 IC585000 MONTAGGIO E INSTA...

Страница 502: ...pply the lithium soap base grease on the O rings 2 Install 9Bush 1 9Collar 2 9Dust seal 3 NOTE 9Apply the molybdenum disulfide grease on the bearing and dust seal lips 9Install the dust seals with the...

Страница 503: ...toriques 2 Monter 9 Bague 1 9 Collerette 2 9 Joint antipoussi re 3 N B 9Appliquer de la graisse au bisulfure de molybd ne sur le roulement et les l vres des joints antipoussi re 9Monter les joints an...

Страница 504: ...um disulfide 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 9Bol...

Страница 505: ...2 N B Appliquer 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 Boulon raccord de filtre air 1 3 I...

Страница 506: ...osition sensor 5 Solenoid valve 6 Neutral switch Except for USA and CDN 7 CDI magneto 8 Spark plug EC612000 WIRING DIAGRAM 6 1 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC COLOR CODE B Black L Blue O...

Страница 507: ...moteur ENGINE STOP 3 Bobine d allumage 4 TPS capteur de position du papillon 5 Electrovanne 6 Contacteur de point mort Except pour USA et CDN 7 Magn to CDI 8 Bougie CODE DE COULEUR B Noir L Bleu O Or...

Страница 508: ...ap 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 Replace Replace Replace Replace marked...

Страница 509: ...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 les outils sp ciaux suivants dans ce d pistage des pannes Te...

Страница 510: ...as Z ndungspr fger t verwendet wird HINWEIS 9Die folgenden Teile vor Beginn der St rungsbeseitigung ausbauen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge f r die St rungsbeseitigung verwend...

Страница 511: ...io per il controllo dell accensione NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9 In questa ispezione usare i seguenti utensili speciali Tester dinamico...

Страница 512: ...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 513: ...ET 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 GLI...

Страница 514: ...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 Yellow lead 1 Tester lead Black lead 2 Tester lea...

Страница 515: ...appuccio 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 selet...

Страница 516: ...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 517: ...uire 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 Borne 1 du c b...

Страница 518: ...66 at 10 20 C 68 F EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again NEUTRAL SWITCH INSPECTION 1 Inspect...

Страница 519: ...ger t 1 2 W hl schalter LEER 1 1 LAUF GANG 1 EINGE LEGT VERIFICATION DE BLOC CDI V rifier tous les quipements lec triques Si aucun d faut n est trouv remplacer le bloc CDI puis v rifier nouveau les qu...

Страница 520: ...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 521: ...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 522: ...ule Erneuern CDI Magnetz nder kontrollieren CDI Einheit erneuern Nicht in Ordnung MAGNETVENTILSYSTEM PR FVORG NGE Falls das Magnetventil nicht funktioniert sind die folgenden berpr fungen durchzuf hre...

Страница 523: ...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 524: ...olenoid valve coupler 2 Connect 12V battery to the solenoid valve coupler 3 Inspectt 9Solenoid valve 1 No click when connecting the battery Replace EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect 9S...

Страница 525: ...ISPEZIONE DEL COLLEGAMENTO DI ACCOPPIATORI E CONDUTTORI 1 Controllare 9 Collegamento di accoppiatori e conduttori Ruggine Polvere Allentamen to Cortocircuito Ripararli o sostituirli IC652040 FUNZIONA...

Страница 526: ...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 527: ...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 528: ...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 529: ...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 530: ...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 531: ...nd 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 C...

Страница 532: ...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 533: ...Positives Kabel des Pr fger tes Gelbes Kabel 2 Negatives Kabel des Pr fger tes Schwarzes Kabel 3 Regelbarer Position des TPS Spulenwider W hlschalters stand am Pr fger t Vollst ndig Vollst ndig geschl...

Страница 534: ...nt 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 CHAPTER...

Страница 535: ...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 motore...

Страница 536: ...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 537: ...indem die vor dem Ausbau angebrachten Markie rungen a zum Ausrichten benutzt werden 14 Einbauen 9 Vergaser Siehe Abschnitt VERGASER UND ZUNGENVENTIL 13 Serrare 9 Vite TPS 1 NOTA Serrare le viti usand...

Страница 538: ...PS 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 Blue lead 2...

Страница 539: ...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 u...

Страница 540: ...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 541: ...a surface 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 glage...

Страница 542: ...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 543: ...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 oss...

Страница 544: ...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 545: ...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 calibrage in...

Страница 546: ...cceleration 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 of actual engine op...

Страница 547: ...re 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 povera durante il funzionamento a regi mi intermedi si avranno...

Страница 548: ...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 549: ...icht glatt beschleunigt werden In diesem Fall die D sennadelklam mer um eine Nut h her positionie ren und die D sennadel absenken um ein magereres Gemisch zu erhalten 2 Zu mager bei mittleren Drehzah...

Страница 550: ...ing 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 i...

Страница 551: ...ment du 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...

Страница 552: ...tarting 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 thrott...

Страница 553: ...changement du diam 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...

Страница 554: ...tle 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 c...

Страница 555: ...la 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 d...

Страница 556: ...4948 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 EW N8RJ 4SR 14...

Страница 557: ...2 4MX 14943 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...

Страница 558: ...1 4 1 2 throttle Raise jet needle clip position Clip position indicates the position of Slow speed pick up 1 groove up jet needle groove to which the clip is White smoke fitted The position is numbere...

Страница 559: ...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 560: ...nne Si la normalisation est impossible Si ge de pointeau bouch Tuyau de carburant bouch Robinet de carburant bouch D coloration de la bougie Si la couleur est fonc e la condition est bonne Si aucum ef...

Страница 561: ...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 562: ...fetteres Gemisch reduziert die Motorst rung D sennadel Klemmenposition absenken 1 Nut niedriger D sennadel Klemmenposition erh hen 1 Nut h her D sennadel Klemmenposition absenken 1 Nut niedriger D sen...

Страница 563: ...nadel 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 N...

Страница 564: ...olor cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Scolorimento della candela S...

Страница 565: ...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 566: ...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 567: ...and 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 diatemen...

Страница 568: ...tire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire c...

Страница 569: ...et d terminer le taux de r duction secon daire 9Quand il y a de grandes lignes droites r gler la machine de sorte ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en...

Страница 570: ...the road surface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 13T 9383E 13216 STD 14T 9383E 14215 Driv...

Страница 571: ...2T 1C3 25452 00 Pression 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...

Страница 572: ...final stroke can be changed by changing the fork oil amount cC Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a nois...

Страница 573: ...uit une tendance au dur cissement de la fourche avec comme cons quence une d t rioration des performances et des caract ristiques Voil pourquoi il convient d ajuster la fourche dans la plage sp cifi e...

Страница 574: ...deeply over a series of gaps To set a soft spring 9Change the rebound damping Turn out one or two clicks 9Change the compression damping Turn in one or two clicks 2 Use of stiff spring Generally a st...

Страница 575: ...herausdrehen 9 Die Einfederd mpfung ndern Um eine oder zwei Klickstel lungen hereindrehen 2 Verwendung einer harten Feder Normaleweise bewirkt eine harte Feder ein hartes Fahrgef hl Die Ausfederd mpf...

Страница 576: ...h of the spring 9Change the spring 2 Setting of damping force 9Change the rebound damping 9Change the compression damping SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 398 1C3 23141 A0 I SOFT 0...

Страница 577: ...IIIII 0 449 1C3 23141 F0 I I HART 0 459 1C3 23141 G0 I II 0 469 1C3 23141 H0 I III 0 479 1C3 23141 J0 I IIII IC72P010 Parti di regolazione della forcella anteriore 9Molla della forcella anteriore 1 N...

Страница 578: ...e the standard figure from the subtraction of the length b from the length a Standard figure 90 100 mm 3 5 3 9 in NOTE 9If the machine is new and after it is broken in the same set length of the sprin...

Страница 579: ...ottraen do la lunghezza b dalla lunghezza a Valeur standard 90 100 mm 3 5 3 9 in Standardwert 90 100 mm 3 5 3 9 in Cifra normale 90 100 mm 3 5 3 9 in HINWEIS 9 Wenn eine neue Maschine eingefah ren wor...

Страница 580: ...mpensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed...

Страница 581: ...uzione Dopo la sostituzione assicurarsi di regolare la molla alla lunghezza regi strata lunghezza abbassata 90 100 mm 3 5 3 9 in e registrarla 1 Uso di una molla dolce 9 Registrare la molla dolce per...

Страница 582: ...ATE PART NUMBER COLOR FREE POINT LENGTH SOFT 4 3 5UN 22212 00 Brown 1 260 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 STIFF 5 7 5UN 22212 70 White 1 260 SPRING SPRING I D SPRING TYPE RAT...

Страница 583: ...derl nge STANTE PUNKT WEICH 4 3 5UN 22212 00 Braun 1 260 5 3 5UN 22212 50 Gelb 1 260 5 5 5UN 22212 60 Rosa 1 260 HART 5 7 5UN 22212 70 Eei 1 260 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4...

Страница 584: ...H ADJUSTMENT b 260mm 10 24in 240 5 258 5mm 9 47 10 18in 275mm 10 83in 255 5 273 5mm 10 06 10 77in SPRING FREE EXTENT OF LENGTH ADJUSTMENT b One I D paint mark 245 5 263 5 mm 9 67 10 37 in Approx 265mm...

Страница 585: ...273 5 mm 10 06 10 77 in LONGUEUR DE ETENDUE DE RESSORT LIBRE REGLAGE b Une marque d identi fication peinte 245 5 263 5 mm 9 67 10 37 in Deux marques Approx 265 mm d identification peintes 10 43 in 251...

Страница 586: ...ssion damping Turn adjuster clockwise about 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 out Imp oz 0 2 0 3 US oz Spring...

Страница 587: ...nd 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 decre...

Страница 588: ...2 0 3 US oz Monter un ressort doux V rifier s il y a coudes coups ou tout autre endommagement visible Si tel est le cas rem placer les parties affect es Remplacer par un nouveau pour une utilisation p...

Страница 589: ...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 590: ...cm3 0 2 0 4 Imp oz 0 2 0 3 US oz reduzieren Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtbare Sch den etc pr fen Falls vorhanden betroffene Teile ersetzen Durch ein neues mit verl ngerter...

Страница 591: ...D mpfung zu ver ringern Eingetauchte L nge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu steige...

Страница 592: ...iorario circa 2 scatti per diminuire lo smor zamento Diminuire la quantit d olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Sostituirla con una molla dolce Controllare eventuali curvature ammaccat...

Страница 593: ...re 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 aumen...

Страница 594: ...TUN MEMO...

Страница 595: ...aha Motor Co Ltd 1st Edition May 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 1P8...

Страница 596: ...AHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250 V 1P8 28199 31 PRINTED IN JAPAN 2005 5 2 0 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAP...

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