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Yamaha YZ250F(R), Руководство по эксплуатации для владельца

Yamaha YZ250F(R) - это мощный мотоцикл для гонок, который требует регулярного обслуживания. Скачайте бесплатный руководство владельца и сервисное руководство с manualshive.com для правильного ухода за вашим мотоциклом. Не забудьте загрузить нужные инструкции для обслуживания вашего Yamaha YZ250F(R).

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6 - 4

–

+

ELEC

 

IGNITION SYSTEM

 

SPARK GAP TEST

 

1. Disconnect the spark plug cap from spark

plug.

2. Remove the ignition coil cap.
3. Connect the dynamic spark tester 

 

1

 

(ignition checker 

 

2

 

) as shown.

 

●

 

Ignition coil 

 

3

 

 

 

●

 

Spark plug 

 

4

 

 

 

Å

 

For USA and CDN

 

ı

 

Except for USA and CDN

 

4. Kick the kickstarter crank.
5. Check the ignition spark gap.
6. Start engine, and increase spark gap until

misfire occurs. (for USA and CDN only)

 

Minimum spark gap:

6.0 mm (0.24 in)

Å

ı

 

COUPLERS, LEADS AND IGNITION COIL 
CONNECTION INSPECTION

 

1. Check:

 

●

 

Couplers and leads connection
Rust/dust/looseness/short-circuit 

 

→

 

 

Repair or replace.

 

●

 

Ignition coil and spark plug as they are
fitted
Push in the ignition coil until it closely
contacts the spark plug hole in the cyl-
inder head cover.

 

ENGINE STOP SWITCH INSPECTION

 

1. Inspect:

 

●

 

Engine stop switch conduct

No continuous while being pushed 

 

→

 

 Replace.

Continuous while being freed 

 

→

 

 Replace.

 

Tester (+) lead 

 

→

 

 Black/White lead 

 

1

 

 

Tester (–) lead 

 

→

 

 Black lead 

 

2

 

 

 

B/W 

 

1

 

B

 

2

 

Tester selec-

tor position

PUSH IN

 

Ω

 

 

 

×

 

 1

FREE

B/W

B

1

1

2

2

Содержание YZ250F(R)

Страница 1: ...5UL 28199 30 YZ250F R OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO...

Страница 2: ...NER S SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition July 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibi...

Страница 3: ...R DU PROPRIETAIRE 2002 Yamaha Motor Co Ltd 1 re dition juillet 2002 Tous droits r serv s Toute reimpression ou utillisation sans la permission crite de la Yamaha Motor Co Ltd est formellement interdit...

Страница 4: ...lease contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING PLEASE R...

Страница 5: ...sion naire Yamaha N B Comme des am liorations sont faites sur ce mod le quelques donn es contenues dans ce manuel peuvent tre p rim es Si vous avez des questions poser pri re de consulter votre conces...

Страница 6: ...PROTECTIVE APPAREL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing...

Страница 7: ...e cette machine toujours porter un casque homologu avec des lunettes ou un prot ge visage Porter galement de grosses bottes des gants et des v te ments de protection Toujours porter des v tements de t...

Страница 8: ...Carbon monoxide is a dangerous gas which can cause unconscious ness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine...

Страница 9: ...si vous devez abandonner la machine Ne pas stationner en pente ou sur un sol mou ou elle pourrait se renverser 9 LE MOTEUR LE SYST ME D CHAPPEMENT ET LE R SERVOIR D HUILE SONT TR S CHAUDS LORSQUE LE...

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

Страница 11: ...e machine veuillez consulter votre concessionnaire Yamaha N B Ce manuel doit tre consid r comme partie permanente de la machine et doit rester avec celle ci si elle est revendue une tierce personne AV...

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

Страница 13: ...ten zu vereinfachen WARNUNG ACHTUNG INFORMATION AUFFINDEN 1 Diese Anleitung umfa t sieben Kapitel 1 Allgemeine Angaben 2 Technische Daten 3 Regelm ssige Inspektion und Einstellarbeiten 4 Motor 5 Fahrw...

Страница 14: ...start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A...

Страница 15: ...ues en clat les pi ces sont num rot es 2 dans l ordre des op rations effectuer Un chiffre entour d un cercle correspond une tape de d montage 3 Les vues en clat portent gale ment des symboles 3 qui ra...

Страница 16: ...Lubricant B Tightening C Specified value Service limit D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubri...

Страница 17: ...sit A Les symboles graphiques E H utilis s dans les vues en clat indiquent les endroit lubrifier et le type de lubrifiant E Appliquer de l huile moteur F Appliquer de l huile au bisulfure de moly bd n...

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

Страница 19: ...PIANTO ELETTRICO ELEC 6 MESSA A PUNTO TUN 7 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES COURANTS MOTEUR PARTIE CYCLE PARTIE ELECTRIQUE MISES AU POINT INDEX...

Страница 20: ...TING AND BREAK IN 1 14 TORQUE CHECK POINTS 1 18 CLEANING AND STORAGE 1 19 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITI...

Страница 21: ...RIFICATION DE COUPLE DE SERRAGE 1 18 NETTOYAGE ET RANGEMENT 1 19 CHAPITRE 2 CARACTERISTIQUES CARACTERISTIQUES GENERALES 2 1 CARACTERISTIQUES D ENTRETIEN 2 4 CARACTERISTIQUES GENERALES DE COUPLE 2 17 D...

Страница 22: ...CH 4 49 OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 4 56 BALANCER 4 63 OIL PUMP 4 66 KICK SHAFT AND SHIFT SHAFT 4 71 CDI MAGNETO 4 78 ENGINE REMOVAL 4 82 CRANKCASE AND CRANKSHAFT 4 87 TRAN...

Страница 23: ...RTER DROIT 4 56 BALANCIER 4 63 POMPE A HUILE 4 66 ARBRE DE KICK ET ARBRE DE SELECTEUR 4 71 VOLANT MAGNETIQUE CDI 4 78 DEPOSE DU MOTEUR 4 82 CARTER ET VILEBREQUIN 4 87 BOITE A VITESSES TAMBOUR ET FOURC...

Страница 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 MAP CONTROLLED CDI UNIT 6 2 IGNITION SYSTEM 6 3 THROTTLE POSITION SENSOR SYSTEM 6 7 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 11...

Страница 25: ...RIQUES ET SCHEMA DE CABLAGE 6 1 BLOC CDI CONTROLE PAR MICROPROCESSEUR 6 2 SYSTEME D ALLUMAGE 6 3 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ 6 7 CHAPITRE 7 MISES AU POINT MOTEUR 7 1 PARTIE CYCLE 7 11 CAPIT...

Страница 26: ...cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 0 Radiator A Coolant drain bolt B Rear brake pedal C Valve joint D Fuel cock E Cold starter knob F Drive chain G Air filter H Shift pedal I Dip...

Страница 27: ...idissement B P dale de frein arri re C Joint de robinet D Robinet de carburant E Bouton de d marrage froid F Cha ne de transmission G Filtre air H S lecteur I Jauge J Fourche avant N B Votre machine d...

Страница 28: ...hine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the st...

Страница 29: ...O D IDENTIFICATION DU VEHICULE Le num ro d identification du v hicule 1 est frapp du c t droit du tube de direction NUMERO DE SERIE DU MOTEUR Le num ro de s rie du moteur 1 est estamp sur un bossage s...

Страница 30: ...bottom Drain hole on the cylinder head right side 2 Use proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gea...

Страница 31: ...rrect Se reporter la section OUTILS SPECIAUX 3 Lors du d montage de la machine garder les pi ces conne xes ensemble Ils comprennent les engrenages cylindres pistons et autres pi ces connexes qui se so...

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

Страница 33: ...eins d crou 1 et goupilles fendues ne doivent jamais tre r utilis s Les onglets de blocage doivent tre dress s contre les faces de boulon ou d crou une fois que les boulons et crous ont t correctement...

Страница 34: ...uld be inspected carefully before reassembly Always replace pis ton pin clips after one use Replace dis torted circlips When installing a circlip 1 make sure that the sharp edged cor ner 2 is position...

Страница 35: ...circlips d axe de piston apr s une utilisa tion Changer tout circlip d form Lorsqu on monte un cir clip 1 s assurer que le c t non chanfrein 2 est positionn du c t oppos la pouss e 3 qu il re oit Voi...

Страница 36: ...check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for cont...

Страница 37: ...orne se d tache redresser la lame 1 de la broche et ins rer nouveau la borne dans le con necteur 6 Connecter Connecteur N B Les deux connecteurs s encliqu tent 7 V rifier la continuit avec un tes teur...

Страница 38: ...remove the flywheel magneto YM 1189 90890 01189 YU 1235 90890 01235 Rotor holding tool This tool is used when loosening or tightening the fly wheel magneto securing nut YU 1235 90890 01235 YU 3097 90...

Страница 39: ...tachometer Engine tachometer This tool is needed for observing engine rpm YU 8036 B 90890 03113 YM 33277 A 90890 03141 Timing light This tool is necessary for checking ignition timing YM 33277 A 90890...

Страница 40: ...ntake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in This tool is needed to rebore the new valve guide YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Dynamic spark tester Ignition checker This in...

Страница 41: ...doit tre utilis pour la d pose du volant magn ti que YM 1189 90890 01189 YU 1235 90890 01235 Outil de maintien de rotor Cet outil est utilis pour le desserrage ou le serrage du boulon de fixation de...

Страница 42: ...pour observer la vitesse de rotation du moteur YU 8036 B 90890 03113 YM 33277 A 90890 03141 Lampe stroboscopique induction Cet outil est n cessaire pour v rifier le r glage de l allu mage YM 33277 A 9...

Страница 43: ...in Echappement 4 5 mm 0 18 in Cet outil est n cessaire pour r al ser le nouveau guide de soupape YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d...

Страница 44: ...Ausbau des Schwungradmagnetz nder Rotors YM 1189 90890 01189 YU 1235 90890 01235 Rotorhalter Zum L sen und Befestigen des Schwungrad Magnetz nder Rotors YU 1235 90890 01235 YU 3097 90890 01252 YU 125...

Страница 45: ...8036 B 90890 03113 Induktivdrehzahlmesser Motor Drehzahlmesser Zur Ermittlung der Motordrehzahl YU 8036 B 90890 03113 YM 33277 A 90890 03141 Stroboskoplampe Zur Kontrolle des Z ndzeitpunktes YM 33277...

Страница 46: ...hrungs Reibahle Einla 4 0 mm Ausla 4 5 mm Zum Aufreiben der neuen Ventilf hrungen YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndpr fer Zur berpr fung der Z...

Страница 47: ...YM 1189 90890 01189 YU 1235 90890 01235 Utensile di sostegno per il rotore Questo attrezzo viene utilizzato quando si svita o si avvita la vite di fissaggio del magnete del volano YU 1235 90890 01235...

Страница 48: ...Questo strumento utilizzato per controllare la velocit del motore YU 8036 B 90890 03113 YM 33277 A 90890 03141 Lampada stroboscopica Questo strumento utilizzato per controllare la fasatura di accensi...

Страница 49: ...ttrezzo utilizzato per alesare il nuovo guidaval vola YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Tester della dinamicit della scintilla Tester dell accensione Questo attrezzo necessa...

Страница 50: ...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 KICKSTARTER CRANK Rotate the kickstarter cra...

Страница 51: ...d mar rages doux le levier doit tre tir rapide ment et rel ch lentement PEDALE DE CHANGEMENT DE VITESSE Les 5 rapports de la bo te de vitesses prise constante sont id alement chelon n s Le changement...

Страница 52: ...is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position COLD STARTER KNOB When cold the engine requires a richer air fuel m...

Страница 53: ...ion BOUTON DE DEMARRAGE A FROID Quand il est froid le moteur a besoin d un m lange air essence plus riche pour le d marrage Un circuit de d marrage s par command par le bouton de de d marrage froid 1...

Страница 54: ...Remove this sidestand before starting out EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose CAUTION In this installation make sure...

Страница 55: ...rale avant de rouler CLAPET DE DURIT DE MISE A LIAIR Ce clapet 1 vite que l essence ne s chappe et est mont sur la durit de mise l air du r servoir de carburant ATTENTION Lors de cet assemblage v rifi...

Страница 56: ...rings and exhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane grade WARNING For refueling be sure to stop the engine and use enough care not to sp...

Страница 57: ...ient utiliser une marque d essence dif f rente ou une classe d octane sup rieure AVERTISSEMENT Avant de faire le plein arr ter le moteur Faire attention de ne pas r pandre de carburant sur la machine...

Страница 58: ...like a two stroke engine this engine cannot be kick started when the throttle is open because the kick starter may kick back Also if the throttle is open the air fuel mixture may be too lean for the e...

Страница 59: ...actionner le kick sinon celui ci risque de se relever brutalement De plus l ouverture des gaz risque d appauvrir l exc s le m lange air carburant ce qui rendrait la mise en marche difficile Avant la m...

Страница 60: ...000 r min for 1 or 2 minutes NOTE Since this model is equipped with an accelera tor pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may...

Страница 61: ...ndant 1 2 minutes N B Puisque ce mod le est quip d une pompe d acc l ration le m lange air carburant devient trop riche et le moteur risque de caler lorsque l on emballe le moteur actionnement success...

Страница 62: ...kick the kickstarter crank 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an engine after a fall Operate the throttle grip before kick starting CAUTION Observe the fol...

Страница 63: ...actionner le kick ATTENTION Dans un premier temps observer la proc dure de rodage suivante afin d assurer le meilleur rendement et vi ter d endommager le moteur Gaz donn s Bouton de d mar rage froid...

Страница 64: ...1 2 open low to medium speed for about one hour 6 Restart the engine and check the opera tion of the machine throughout its entire operating range Restart the machine and operate it for about 10 to 15...

Страница 65: ...fier son fonctionnement tous les r gimes Relancer le moteur et piloter la machine pen dant 10 15 minutes suppl men taires Elle sera alors pr te pour la course ATTENTION Apr s le rodage ou avant chaque...

Страница 66: ...stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear shock absorbe...

Страница 67: ...tion au cadre De l arbre de direction la couronne de guidon De la couronne de guidon au guidon De la fourche avant la couronne de guidon De la fourche avant au dessous de bride Ensemble de timonerie T...

Страница 68: ...pf und obere Gabelbr cke obere Gabelbr cke und Lenker Teleskopgabel obere Gabelbr cke Teleskopgabel und untere Gabelbr kke bertragungs bis Umlenkhebel bertragungshebel und Rahmen Umlenkhebel und Sto d...

Страница 69: ...otore Dalla staffa motore al motore Dalla staffa motore al telaio Cannotto di sterzo al telaio Cannotto di sterzo alla trave superiore Trave superiore al manubrio Forcella anteriore alla trave superio...

Страница 70: ...n of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated ca...

Страница 71: ...ration on reuses ont r sult de l emploi abusif des vaporisateurs de d tergent haute pression tels que ceux qui quipent les laveries automa tiques de voitures 4 Apr s avoir chass la majeure partie de l...

Страница 72: ...witch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thor oughly with solvent and lubricate it Reinstall the chain or store it in a...

Страница 73: ...cha ne la nettoyer soi gneusement au dissolvant et lubrifier Remonter la cha ne ou la ranger dans un sachet plastique ferm fix au cadre 4 Lubrifier tous les c bles de com mande 5 Mettre le cadre sur p...

Страница 74: ...e type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 Imp oz 8 42 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 12 5 1 Star...

Страница 75: ...urer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chai...

Страница 76: ...Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber...

Страница 77: ...nside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 967 21 980 mm 0 8648 0 8654 in Shaft to cap clearance 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Cam dimensions Inta...

Страница 78: ...0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565...

Страница 79: ...mm 1 15 in Compressed force installed IN 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in EX 126 144 N at 29 30 mm 12 6 14 4 kg at 29 30 mm 28 44 32 41 lb at 1 15 in Tilt limit I...

Страница 80: ...0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022...

Страница 81: ...Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor USA CDN ZA AUS NZ EUROPE Type manufacturer FCR MX37 KEIHIN I D mark 5UL1...

Страница 82: ...09 0 17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Cooling Radiator core size Width 107 8 mm 4 2 in Height 220 mm 8 7 in Thicknes...

Страница 83: ...ain bolt M6 1 0 1 10 1 0 7 2 Water pump housing M6 1 0 4 10 1 0 7 2 Radiator M6 1 0 6 10 1 0 7 2 Radiator guard M6 1 0 2 10 1 0 7 2 Radiator pipe M6 1 0 1 10 1 0 7 2 Oil pump cover M4 0 7 1 2 0 2 1 4...

Страница 84: ...er M6 1 0 7 10 1 0 7 2 Crankcase oil drain bolt M10 1 25 1 20 2 0 14 Drive chain sprocket cover M6 1 0 2 8 0 8 5 8 Kick shaft ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank M8 1 25 1 33 3 3...

Страница 85: ...2 in Min Max From top of outer tube with inner tube and damper rod fully com pressed without spring 80 150 mm 3 15 5 91 in Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front for...

Страница 86: ...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 outside dia Thickness...

Страница 87: ...7 2 Front fork and brake hose cover M8 M8 1 25 1 16 1 6 11 M6 M6 1 0 1 7 0 7 5 1 Throttle grip cap M5 0 8 2 4 0 4 2 2 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 1 0 1...

Страница 88: ...61 Relay arm and swingarm M14 1 5 1 80 8 0 58 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shoc...

Страница 89: ...olor 44 66 at 20 C 68 F Black Pink Pickup coil resistance color 248 372 at 20 C 68 F White Red CDI unit model manufacturer 5UL 00 YAMAHA Ignition coil Model manufacturer 5UL 00 DENSO Minimum spark gap...

Страница 90: ...A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6...

Страница 91: ...e double arbre cames en t te DOHC Dispositions du cylindre Monocylindre inclin vers l avant Cylindr e 249 cm3 8 76 Imp oz 8 42 US oz Al sage course 77 0 53 6 mm 3 03 2 11 in Taux de compression 12 5 1...

Страница 92: ...7 0 8 mm 0 028 0 031 in Type d embrayage Humide multi disques Transmission Syst me de r duction primaire Engrenage Taux de r duction primaire 57 17 3 353 Syst me de r duction secondaire Entra nement p...

Страница 93: ...lescopique Suspension arri re Bras oscillant monocross de type biellette Amortisseurs Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal amortisseur h...

Страница 94: ...1 mm 0 8661 0 8670 in Diam tre ext rieur d arbre cames 21 967 21 980 mm 0 8648 0 8654 in Jeu entre arbre cames et chapeau 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Dimensions de came Admission...

Страница 95: ...1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in ECH 0 9 1 1 mm 0 0354 0 0433in 1 6 mm 0 0630 in D paisseur de rebord AD 0 8 mm 0 0315 in ECH 0 7 mm 0 0276 in Diam tre ext rieur de queue AD 3 975 3 990 mm 0 1...

Страница 96: ...13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in ECH 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in Limite d inclinaison AD 2 5 1 7 mm 2 5 0 067 in ECH 2 5 1 6 mm 2 5 0 063 in Sens...

Страница 97: ...pe Fusel Dimensions B T 0 80 2 75 mm 0 03 0 11 in Ecartement des becs mont 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Jeu lat ral 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Segment racleur d h...

Страница 98: ...uidage 0 05 mm 0 002 in Kick Type Kick et m canisme rochet Carburateur USA CDN ZA AUS NZ EUROPE Type fabricant FCR MX37 KEIHIN Marque d identification 5UL1 00 5UL2 10 Gicleur principal M J N 178 Gicle...

Страница 99: ...009 in Jeu carter et rotor 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Refroidissement Taille du faisceau radiateur Largeur 107 8 mm 4 2 in Hauteur 220 mm 8 7 in Epaisseur 32 mm 1 26 in Pression...

Страница 100: ...Garde de radiateur M6 1 0 2 10 1 0 7 2 Tuyau de radiateur M6 1 0 1 10 1 0 7 2 Couvercle de la pompe huile M4 0 7 1 2 0 2 1 4 Pompe huile M6 1 0 3 10 1 0 7 2 Boulon de vidange d l ment du filtre huile...

Страница 101: ...1 20 2 0 14 Cache de pignon de cha ne de transmission M6 1 0 2 8 0 8 5 8 Guide de rochet d arbre de kick M6 1 0 2 12 1 2 8 7 P dale de kick M8 1 25 1 33 3 3 24 Pignon primaire M18 1 0 1 75 7 5 54 Ress...

Страница 102: ...eur et tige d amortisseur compl tement com prim es sans le ressort 80 150 mm 3 15 5 91 in Grade d huile Huile de suspen sion 01 Diam tre ext rieur de tube plongeur 46 mm 1 81 in Extr mit sup rieure de...

Страница 103: ...rieur de ma tre cylindre 11 0 mm 0 433 in Diam tre int rieur de cylindre d trier 27 0 mm 1 063 in 2 Type de liquide de frein DOT n 4 Frein disque arri re Diam tre ext rieur paisseur 245 4 0 mm 9 65 0...

Страница 104: ...avant M6 1 0 2 9 0 9 6 5 Boulon de montage de levier de frein M6 1 0 1 6 0 6 4 3 Ecrou de montage de levier de frein M6 1 0 1 6 0 6 4 3 Contre crou de r glage de position du levier de frein M6 1 0 1 5...

Страница 105: ...M14 1 5 1 80 8 0 58 Bielle et cadre M14 1 5 1 80 8 0 58 Amortisseur arri re et cadre M10 1 25 1 56 5 6 40 Amortisseur arri re et bras relais M10 1 25 1 53 5 3 38 Cadre arri re haut M8 1 25 1 32 3 2 23...

Страница 106: ...stance de bobine d excitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bloc CDI 5UL 00 YAMAHA Bobine d allumage Mod le fabricant 5UL 00 DENSO Longueur minimum d tincelle 6 mm 0 24 in...

Страница 107: ...s Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filetage DEFINITION DES UNITES A crou B vis CARACTERISTIQUES DE COUPLE Nm m kg ft lb 10mm 12mm 14mm...

Страница 108: ...249 cm3 Bohrung Hub 77 0 53 6 mm Verdichtungsverh ltnis 12 5 1 Startsystem Kickstarter Schmiersystem Trockensumpfschmierung Motor l lsorte und viskosit t Nur USA und CDN Empfohlene lsorte Viskosit t b...

Страница 109: ...ehrscheiben lbadkupplung Kraft bertragung Prim rantrieb Zahnrad Prim r bersetzung 57 17 3 353 Sekund rantrieb Kettenantrieb Sekund r bersetzung 48 13 3 692 Getriebe klauengeschaltetes 5 Gang Getriebe...

Страница 110: ...hebel rechts Radaufh ngung vorn Teleskopgabel hinten Monocross Schwinge Federelemente vorn Hydraulisch ged mpfte Teleskopgabel mit Spi ralfeder hinten Federbein mit gasdruckunterst tztem Sto d mpfer u...

Страница 111: ...mm Nockenwelle Antrieb Steuerkette links Nockenwellenlager Durchmesser 22 000 22 021 mm Nockenwellen Au endurchmesser 21 967 21 980 mm Lagerspiel 0 020 0 054 mm 0 08 mm Nockenabmessungen Einla A 30 2...

Страница 112: ...6 mm Ausla 0 9 1 1 mm 1 6 mm Ventiltellerst rke D Einla 0 8 mm Ausla 0 7 mm Ventilschaftdurchmesser Einla 3 975 3 990 mm 3 945 mm Ausla 4 460 4 475 mm 4 430 mm Ventilf hrungsdurchmesser Einla 4 000 4...

Страница 113: ...kkraft eingebaut Einla 99 114 N bei 29 13 mm 9 9 11 4 kg bei 29 13 mm Ausla 126 144 N bei 29 30 mm 12 6 14 4 kg bei 29 30 mm Rechtwinkligkeitsgrenze Einla 2 5 1 7 mm Ausla 2 5 1 6 mm Wicklungsrichtung...

Страница 114: ...gebaut 0 030 0 065 mm 0 12 mm 2 Kompressionsring Ausf hrung Minutenring Abmessungen B T 0 80 2 75 mm Sto spiel eingebaut 0 30 0 45 mm 0 80 mm Ringnutspiel 0 020 0 055 mm 0 12 mm labstreifring Abmessun...

Страница 115: ...m Kickstarter Bauart Rastenmechanismus Vergaser Modell Hersteller FCR MX37 KEIHIN Kennzeichnung 5UL2 10 Hauptd se M J Nr 178 Hauptluftd se M A J 2 0 D sennadel J N OBEKP 4 Konus C A 1 5 Leerlaufluftd...

Страница 116: ...mm 0 24 mm Geh use und Rotorabstand 0 03 0 10 mm 0 17 mm K hlsystem K hlerabmessungen Breite 107 8 mm H he 220 mm Tiefe 32 mm K hlerverschlu deckel ffnungsdruck 110 kPa 1 1 bar K hlsystem Fassungsverm...

Страница 117: ...h use M6 1 0 4 10 1 0 K hler M6 1 0 6 10 1 0 K hlerschutz M6 1 0 2 10 1 0 K hlerleitung M6 1 0 1 10 1 0 lpumpendeckel M4 0 7 1 2 0 2 lpumpe M6 1 0 3 10 1 0 lfiltereinsatz Ablaufstutzen M6 1 0 1 10 1 0...

Страница 118: ...10 1 0 Kurbelgeh use lablaufstutzen M10 1 25 1 20 2 0 Antriebsritzel Abdeckung M6 1 0 2 8 0 8 Kickstarter Rastenradf hrung M6 1 0 2 12 1 2 Kickstarterhebel M8 1 25 1 33 3 3 Prim rantriebszahnrad M18 1...

Страница 119: ...m Min Max gemessen von der Oberkante des Standrohres Gabel und D mpfer rohr vollst ndig eingefedert ohne Gabelfeder 80 150 mm lsorte Teleskopgabel l 01 Standrohr Durchmesser 46 mm Position der oberen...

Страница 120: ...rke 250 3 0 mm 250 2 5 mm Bremsbelagst rke 4 4 mm 1 0 mm Hauptbremszylinder Durchmesser 11 0 mm Bremszylinder Durchmesser 27 0 mm 2 Bremsfl ssigkeit DOT 4 Hinterradbremse Bremsscheibe Durchmesser St r...

Страница 121: ...8 1 25 1 16 1 6 M6 M6 1 0 1 7 0 7 Gasdrehgriffkappe M5 0 8 2 4 0 4 Frontbrems Hauptzylinder M6 1 0 2 9 0 9 Bremshebel Befestigungsschraube M6 1 0 1 6 0 6 Bremshebel Befestigungsmutter M6 1 0 1 6 0 6 B...

Страница 122: ...0 Relaisarm und Pleuelstange M14 1 5 1 80 8 0 Pleuelstange und Rahmen M14 1 5 1 80 8 0 Hinterer Sto d mpfer und Rahmen M10 1 25 1 56 5 6 Hinterer Sto d mpfer und Relaisarm M10 1 25 1 53 5 3 Hinterer...

Страница 123: ...nd Farbe der Erregerspule 2 44 66 bei 20 C schwarz rosa Impulsgeber Widerstand Farbe 248 372 bei 20 C wei rot CDI Z ndbox Typ Hersteller 5UL 00 YAMAHA Z ndspule Typ Hersteller 5UL 00 DENSO Min Z ndfun...

Страница 124: ...r saubere und trok kene Schraubverbindungen bei Raumtempera tur A Schl sselweite B Gewindedurchmesserer EINHEITEN A Mutter B Schrau be ALLGEMEINE ANZUGSMOMENTE Nm m kg 10 mm 12 mm 14 mm 17 mm 19 mm 2...

Страница 125: ...doppio albero a camme in testa DOHC Disposizione dei cilindri Monocilindrico inclinato in avanti Cilindrata 249 cm3 8 76 Imp oz 8 42 US oz Alesaggio corsa 77 0 53 6 mm 3 03 2 11 in Rapporto di compres...

Страница 126: ...elettrodi 0 7 0 8 mm 0 028 0 031 in Tipo di frizione Umida multidisco Trasmissione Sistema di riduzione primaria Ingranaggio Rapporto di riduzione primaria 57 17 3 353 Sistema di riduzione secondaria...

Страница 127: ...anteriore Forcella telescopica Sospensione posteriore Forcellone oscillante sospensione monocross di tipo a biscottino Ammortizzatore Ammortizzatore anteriore Molla elicoidale ammortizzatore a olio A...

Страница 128: ...interno del cappello dell albero a camme 22 000 22 021 mm 0 8661 0 8670 in Diametro esterno dell albero a camme 21 967 21 980 mm 0 8648 0 8654 in Gioco albero cappello 0 020 0 054 mm 0 0008 0 0021 in...

Страница 129: ...9 in Larghezza sede C INT 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EXT 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Spessore margine D INT 0 8 mm 0 0315 in EXT 0 7 mm 0 0276 in Diametro esterno st...

Страница 130: ...orza compressa installata INT 99 114 N a 29 13 mm 9 9 11 4 kg a 29 13 mm 22 27 25 57 lb a 1 15 in EXT 126 144 N a 29 30 mm 12 6 14 4 kg a 29 30 mm 28 44 32 41 lb a 1 15 in Limite di inclinazione INT 2...

Страница 131: ...005 in Seconda fascia Tipo Conica Dimensioni B T 0 80 2 75 mm 0 03 0 11 in Apertura del taglio fascia montata 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Gioco laterale 0 020 0 055 mm 0 0008 0 0022 i...

Страница 132: ...atura della barra guida 0 05 mm 0 002 in Avviamento a pedale Tipo Tipo a pedivella e ad arpionismo Carburatore USA CDN ZA AUS NZ EUROPE Tipo costruttore FCR MX37 KEIHIN Marcatura I D 5UL1 00 5UL2 10 G...

Страница 133: ...17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Gioco alloggiamento e rotore 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Raffreddamento Dimensioni massa radiante Larghezza 107 8 mm 4 2 in Altezza 220 mm 8...

Страница 134: ...dell acqua M6 1 0 4 10 1 0 7 2 Radiatore M6 1 0 6 10 1 0 7 2 Riparo del radiatore M6 1 0 2 10 1 0 7 2 Tubazione del radiatore M6 1 0 1 10 1 0 7 2 Coperchio pompa dell olio M4 0 7 1 2 0 2 1 4 Pompa del...

Страница 135: ...ino corona catena di trasmissione M6 1 0 2 8 0 8 5 8 Guida arpionismo albero a pedale M6 1 0 2 12 1 2 8 7 Avviamento a pedale M8 1 25 1 33 3 3 24 Ingranaggio conduttore della trasmissione primaria M18...

Страница 136: ...parte superiore del tubo esterno con il tubo interno e asta dell ammortizzatore completamente compressi senza molla 80 150 mm 3 15 5 91 in Tipo di olio Olio per sospensioni 01 Diametro esterno tubo in...

Страница 137: ...4 4 mm 0 17 in 1 0 mm 0 04 in Diametro interno cilindro principale 11 0 mm 0 433 in Diametro interno cilindretto pinza 27 0 mm 1 063 in 2 Tipo di liquido dei freni DOT n 4 Freno a disco posteriore Di...

Страница 138: ...iore e guaina tubo flessibile del freno M8 M8 1 25 1 16 1 6 11 M6 M6 1 0 1 7 0 7 5 1 Coperchio manopola acceleratore M5 0 8 2 4 0 4 2 2 Pompa freno anteriore M6 1 0 2 9 0 9 6 5 Bullone di montaggio le...

Страница 139: ...biella M14 1 5 1 80 8 0 58 Biella e telaio M14 1 5 1 80 8 0 58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e leva di rinvio M10 1 25 1 53 5 3 38 Telaio posterior...

Страница 140: ...0 C 68 F Nero Rosa Resistenza bobina pickup colore 248 372 a 20 C 68 F Bianco Rosso Modello costruttore unit CDI 5UL 00 YAMAHA Bobina di accensione Modello costruttore 5UL 00 DENSO Distanza minima sci...

Страница 141: ...e A Distaza tra le aperture di chiave B Diametro filetto esterno DEFINIZIONE DELLE UNIT DI MISURA A Dado B Bullone SPECIFICHERELATIVE ALLECOPPIEDI SERRAGGIOGENERALI Nm m kg ft lb 10 mm 12 mm 14 mm 17...

Страница 142: ...er plate Pass the hot starter cable between the cylinder head breather hose oil tank breather hose and ignition coil then on the outside of the left engine bracket Pass the clutch cable through the ca...

Страница 143: ...e puis sur l ext rieur du support de moteur gau che Faire passer le c ble d embrayage dans les guides de c ble Faire passer le c ble d embrayage devant la noix de montage du radiateur Ins rer le flexi...

Страница 144: ...switch lead on the oil hose with a plastic locking tie and cut off the tie end Fasten the neutral switch lead Fasten the neutral switch lead and CDI magneto lead Pass the neutral switch lead CDI magne...

Страница 145: ...l extr mit Attacher le fil du commutateur de point mort Attacher le fil du commutateur de point mort et le fil du magn to CDI Faire passer le fil du commutateur de point mort le fil de magn to CDI et...

Страница 146: ...throttle cables between the radiator and frame then under the radiator mounting boss Pass the throttle cables on the outside of the ignition coil Pass the radiator breather hose in front of the radiat...

Страница 147: ...les d acc l rateur entre le radiateur et le cadre puis sous la noix montage du radiateur Faire passer les c bles d acc l rateur l ext rieur de la bobine d allumage Faire passer le flexible de reniflar...

Страница 148: ...rtion directs as shown and lightly touches the projection on the brake caliper Pass the brake hose into the brake hose holders If the brake hose contacts the spring rear shock absorber correct its twi...

Страница 149: ...t la saillie sur l trier de frein Faire passer le flexible de frein dans les supports de flexible de frein Si le flexible de frein touche le ressort amortisseur arri re corriger sa cour bure Installer...

Страница 150: ...er cable 6 Engine stop switch lead 7 Brake hose 8 Hose guide Fasten the engine stop switch lead to the handlebar Pass the brake hose in front of the number plate Pass the clutch cable through the cabl...

Страница 151: ...teur d arr t de moteur au guidon Faire passer le flexible de frein devant la plaque d immatriculation Faire passer le c ble d embrayage dans le guide du c ble Faire passer les c bles d acc l rateur et...

Страница 152: ...learances Inspect Replace The engine must be cold Check the valve seats and valve stems for wear VALVE SPRINGS Inspect Replace Check the free length and the tilt VALVE LIFTERS Inspect Replace Check fo...

Страница 153: ...vel and leakage Check radiator cap operation Replace coolant Inspect hoses Every two years OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and...

Страница 154: ...Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing Lithium base grease TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke loosenes...

Страница 155: ...e soupape RESSORTS DE SOUPAPE Contr ler Remplacer Contr ler la longueur libre et l inclinaison POUSSOIRS DE SOUPAPE Contr ler Remplacer Contr ler s ils sont griff s ou us s ARBRES A CAMES Contr ler Re...

Страница 156: ...pour cha ne Jeu de la cha ne 40 50 mm 1 6 2 0 in CIRCUIT DE REFROIDISSEMENT Contr ler le niveau du liquide de refroi dissement et s il n y a pas de fuite Contr ler le fonctionnement du bouchon de rad...

Страница 157: ...A NE D ENTRA NEMENT Contr ler BRAS OSCILLANT Contr ler lubrifier et resserrer Graisse au bisulfure de molybd ne BRAS RELAIS BIELLE Contr ler lubrifier et resserrer Graisse au bisulfure de molybd ne TE...

Страница 158: ...gen VENTILE Ventilspiel kontrollieren Pr fen Erneuern Bei kaltem Motor Ventilsitze und schafte auf Verschlei pr fen VENTILFEDERN Pr fen Erneuern Ungespannte L nge und Rechtwinkligkeit pr fen TASSENST...

Страница 159: ...tung pr fen Erneuern Kettenschmiermittel ver wenden Durchhang 40 50 mm K HLSYSTEM K hlfl ssigkeitsstand auf Undichtig keit pr fen K hlerverschlu deckel pr fen K hlfl ssigkeit wechseln Schl uche pr fe...

Страница 160: ...schmieren und nachziehen Molybd ndisulfidfett ver wenden UMLENK UND BERTRAGUNGS HEBEL Pr fen schmieren und nachziehen Molybd ndisulfidfett ver wenden LENKKOPF Spiel pr fen und nachziehen Reinigen und...

Страница 161: ...lle delle valvole Ispezionare Sostituire Controllare la lunghezza libera e l inclinazione ALZAVALVOLA Ispezionare Sostituire Controllare eventuali graffi e il grado di usura ALBERI A CAMME Ispezionare...

Страница 162: ...ficare tendere allineare Sostituire Utilizzare un lubrificante per catene Allentamento della catena 40 50 mm 1 6 2 0 in SISTEMA DI RAFFREDDAMENTO Controllare il livello del refrigerante e la presenza...

Страница 163: ...LLANTE Ispezionare lubrificare e riserrare Grasso al disolfuro di molib deno LEVA DI RINVIO BIELLA Ispezionare lubrificare e riserrare Grasso al disolfuro di molib deno CANNOTTO DELLO STERZO Controlla...

Страница 164: ...k drive chain slack and alignment Check that the drive chain is lubricated properly P 3 31 33 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 41...

Страница 165: ...n et l alignement de la cha ne S assurer que la cha ne est graiss e correctement P 3 31 33 Roues Contr ler s il n y a pas d usure excessive Contr ler s il n y a pas de rayons d tendus et qu il n a pas...

Страница 166: ...skette Durchhang und Ausrichtung pr fen Kette nach Bedarf schmieren 3 31 33 R der Reifen auf berm igen Verschlei und Luftdruck pr fen Speichernspannung kontrollieren 3 41 42 Lenkung Auf Schwerg ngigke...

Страница 167: ...trasmissione Controllare che la catena di trasmissione sia lubrificata correttamente P 3 31 33 Ruote Verificarne l eventuale usura eccessiva e controllare la pressione dei pneumatici Verificare che no...

Страница 168: ...ly 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 and remo...

Страница 169: ...fon pais sur le bouchon du radiateur et tourner lente ment le bouchon gauche jusqu au point de d tente Cette proc dure per met de faire tomber toute pression r siduelle Quand le sifflement s est arr t...

Страница 170: ...Coolant drain bolt 1 3 Remove Radiator cap Drain the coolant completely 4 Clean Cooling system Thoroughly flush the cooling system with clean tap water 5 Install Copper washer Coolant drain bolt T R 1...

Страница 171: ...ment 1 3 D poser Bouchon du radiateur Vidanger compl tement le liquide de refroidissement 4 Nettoyer Circuit de refroidissement Bien rincer le circuit de refroi dissement avec de l eau du robinet 5 Mo...

Страница 172: ...l low Add coolant Handling notes of coolant The coolant is harmful so it should be han dled with special care WARNING When coolant splashes to your eye Thoroughly wash your eye with water and see your...

Страница 173: ...jouter le liquide de refroidissement Notes concernant la manipulation du liquide de refroidissement Le liquide de refroidissement tant dangereux il doit tre manipul avec une attention particuli re AVE...

Страница 174: ...ible to maintain the specified pressure for 10 seconds Replace Radiator cap tester YU 24460 01 90890 01325 Radiator cap tester adapter YU 33984 90890 01352 Radiator cap opening pressure 110 kPa 1 1 kg...

Страница 175: ...ible de maintenir la pression sp cifi e pendant 10 secondes Changer Testeur du bouchon de radiateur YU 24460 01 90890 01325 Embout d adaptation du testeur de bouchon de radiateur YU 33984 90890 01352...

Страница 176: ...replace Radiator hose 3 Swelling Replace CLUTCH ADJUSTMENT 1 Check Clutch lever free play a Out of specification Adjust Clutch lever free play a 8 13 mm 0 31 0 51 in 2 Adjust Clutch lever free play N...

Страница 177: ...teur 3 Gonflement Remplacer REGLAGE DE L EMBRAYAGE 1 Contr ler Jeu du levier d embrayage a Hors sp cification R gler Jeu du levier d embrayage a 8 13 mm 0 31 0 51 in 2 R gler Jeu de levier d embrayage...

Страница 178: ...e specified free play is obtained Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted WARNING After adjusting turn the handlebar to right an...

Страница 179: ...Apr s le r glage tourner le guidon vers la droite et vers la gauche et s assurer que le r gime de ralenti du moteur ne change pas GRAISSAGE DE L ACCELERA TEUR 1 D poser Cache capuchon du logement du...

Страница 180: ...ter lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut AIR FILTER CLEANING NOTE Proper air filter maintenanc...

Страница 181: ...contre crou 1 Tourner le r gulateur 2 jusqu ce que le jeu a soit dans les limites sp cifi es Serrer le contre crou NETTOYAGE DU FILTRE A AIR N B Un entretien convenable du filtre air est la cl pour vi...

Страница 182: ...much of solvent in the ele ment may result in poor starting 3 Inspect Air filter element Damage Replace 4 Apply Foam air filter oil or equivalent oil to the element NOTE Squeeze out the excess oil Ele...

Страница 183: ...us difficile 3 Contr ler El ment du filtre air Endommagement Rempla cer 4 Appliquer Huile de filtre air en mousse ou huile quivalente sur l l ment N B Eliminer l exc dent d huile L l ment doit tre hum...

Страница 184: ...then turn off the engine and wait for five minutes 2 Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine 3 Remove Oil tank cap 1 1 4 In...

Страница 185: ...e cinq minutes 2 Placer le v hicule sur un plan horizontal et le dresser la verti cale en pla ant un support ad quat sous le moteur 3 D poser Bouchon du r servoir d huile 1 4 Contr ler Niveau d huile...

Страница 186: ...the engine and let it warm up for several minutes 7 Turn off the engine and inspect the oil level once again NOTE Wait a few minutes until the oil settles before inspecting the oil level Recommended...

Страница 187: ...ie l embrayage et ces additifs pour raient le faire patiner Ne pas laisser entrer des corps trangers dans le carter 5 Monter Bouchon du r servoir d huile 6 Mettre le moteur en marche et le laisser cha...

Страница 188: ...upright position by placing the suitable stand under the engine 3 Place a suitable container under the engine 4 Remove Oil tank cap 1 Oil filler cap 2 Frame oil drain bolt 3 Crankcase oil drain bolt 4...

Страница 189: ...r servoir d huile 1 Capuchon de remplissage d huile 2 Boulon de vidange d huile au cadre 3 Boulon de vidange d huile de carter 4 Boulon de vidange d l ment de filtre huile 5 Vidanger l huile du carter...

Страница 190: ...oil level Replacement steps Remove the oil filter element cover 1 and oil filter element 2 Check the O rings 3 if cracked or dam aged replace them with a new one Install the oil filter element and oil...

Страница 191: ...u fil tre huile 2 Contr ler les joints toriques 3 et le remplacer s ils sont craquel s ou endommag s Remonter sont du filtre huile et son couvercle T R Couvercle d l ment du filtre huile 10 Nm 1 0 m k...

Страница 192: ...ure Tighten the oil pressure check bolt T R Oil pressure check bolt 10 Nm 1 0 m kg 7 2 ft lb PILOT SCREW ADJUSTMENT 1 Adjust Pilot screw 1 Adjustment steps NOTE To optimize the fuel flow at a smaller...

Страница 193: ...ttre le moteur en marche apr s avoir rem di au x probl me s et v rifier nouveau la pression d huile Serrer le boulon de contr le de la pression d huile au couple indiqu T R Boulon de contr le de la pr...

Страница 194: ...ease idle speed Turn the throt tle stop screw 1 out b Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Engine idling speed 1 900 2 100 r min VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE...

Страница 195: ...i ble Pour augmenter la r gime de ralenti Serrer a la vis de but e de l acc l rateur 1 Pour diminuer le r gime de ralenti Desserrer b la vis de but e de l acc l rateur 1 Compte tours inductif YU 8036...

Страница 196: ...tion in the CHAPTER 4 Spark plug Upper engine bracket Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 4 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 5 C...

Страница 197: ...Couvre culasse Se reporter la section ARBRES A CAMES au CHAPITRE 4 4 D poser Vis d acc s du rep re de distri bution 1 Vis d acc s de l extr mit de vilebrequin 2 Joint torique 5 Contr ler Jeu de soupa...

Страница 198: ...order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl inder head surface as shown in the...

Страница 199: ...N B Les pistons sont au PMH lorsque le rep re d alignement c de l arbre cames d chappement et le rep re d alignement d de l arbre cames d admission s alignent sur la surface de la culasse comme illus...

Страница 200: ...in 0 05 mm increments NOTE The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface Round off the last digit of the installed pad number to the nearest increment...

Страница 201: ...e millim tres sur la face de la cale Arrondir le dernier chiffre de la cale install e l paisseur de cale dispo nible la plus proche Dernier chiffre du num ro de cale Chiffre arrondi 0 1ou 2 0 4 5 ou 6...

Страница 202: ...ly the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pa...

Страница 203: ...poussoir de soupape doit tour ner en douceur Prendre soin de remettre les pous soirs de soupapes et les cales dans leur position d origine Remonter les arbres cames chappement et admission Se reporte...

Страница 204: ...16 1 20 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 2...

Страница 205: ...0 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 ECHAPPEMENT JEU MESURE NUMERO DE CALE INSTALLEE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215...

Страница 206: ...20 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 AUSLASS GEMESSE NES SPIEL NUMMER DES AUSGEBAUTEN VENTILPL TTCHENS 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190...

Страница 207: ...16 1 20 225 230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 SCARICO GIOCO MISURATO NUMERO SPESSORE INSTALLATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205...

Страница 208: ...fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the...

Страница 209: ...tre en place le diaphragme Prendre garde ne pas renverser ou faire d border le r servoir c Connecter herm tiquement le tuyau transparent en mati re plastique 2 la vis de purge 1 de l trier d Mettre l...

Страница 210: ...the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position 4 Install Brake lever cover Brake lev...

Страница 211: ...quand les bulles du syst me ont disparu j Remettre niveau le fluide de frein dans le r servoir AVERTISSEMENT V rifier le fonctionnement du frein apr s avoir purg le circuit de frei nage Position du le...

Страница 212: ...hten the locknut WARNING Adjust the pedal height between the maximum and the minimum as shown In this adjustment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 m...

Страница 213: ...ERTISSEMENT R gler la hauteur de la p dale entre le maximum et le mini mum de la mani re indiqu e Dans ce r glage l extr mit b du boulon 3 doit sortir de la partie filet e 4 mais pas de plus de 2 mm 0...

Страница 214: ...in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads 8 and pad pin NOTE Install the brake pads with their projec tions...

Страница 215: ...Vis de purge 6 Nm 0 6 m kg 4 3 ft lb Installer les plaquettes de frein 8 et la goupille de plaquette N B Installer les plaquettes de frein en ajustant leurs saillies a dans les encoches de l trier de...

Страница 216: ...ing Bleed brake system Refer to BRAKE SYSTEM AIR BLEEDING section REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Br...

Страница 217: ...CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE 1 V rifier Epaisseur a de plaquette de frein Hors sp cification Rempla cer la paire 2 Changer Plaquette de frein Epaisseur de plaquette de frein...

Страница 218: ...bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pad 0 and pad pin A NOTE Install the brake pads with their projec tions a into the brake caliper recesses b Temporarily tighten th...

Страница 219: ...e plaquette Monter l trier de frein B et la roue arri re C Se reporter la section ROUE AVANT ET ROUE ARRIERE du CHAPITRE 5 Serrer la goupille de plaquette D T R Goupille de plaquette 18 Nm 1 8 m kg 13...

Страница 220: ...rake pad insulator 1 Damage Replace BRAKE FLUID LEVEL INSPECTION 1 Place the brake master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level Fill up...

Страница 221: ...te de frein arri re 1 Endommagement Rempla cer CONTROLE DU NIVEAU DU LIQUIDE DE FREIN 1 Placer le ma tre cylindre pour que son extr mit soit en position horizontale 2 V rifier Niveau de liquide de fre...

Страница 222: ...ION 1 Remove Master link clip Joint 1 Drive chain 2 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the drive chain from the kerosene and dry the drive chai...

Страница 223: ...ansmission 2 2 Nettoyer Cha ne de transmission La mettre dans du k ros ne et brosser autant que possible la crasse Puis retirer la cha ne de transmission du k ros ne et la s cher 3 Mesurer Longueur de...

Страница 224: ...ants DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suitable stand under the engine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust...

Страница 225: ...moteur 2 Contr ler Fl che de la cha ne de trans mission a Au dessus du boulon de fixa tion de la garde de joint Hors sp cification R gler N B Avant de proc der la v rification ou au r glage faire tou...

Страница 226: ...rks a on each side of the drive chain puller alignment NOTE Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear CAUTION Too small drive chain slack will over...

Страница 227: ...roue Les rep res a figurent de chaque c t sur les ten deurs de cha ne de transmission N B Tourner le tendeur pour que la cha ne de transmission soit align e avec la couronne vue par l arri re ATTENTI...

Страница 228: ...rease on the inner tube FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff dur ing a run relieve the front fork internal pres sure 1 Elevate the front wheel by...

Страница 229: ...d tanch it b N B Nettoyer le joint antipoussi re et la bague d tanch it apr s chaque course Appliquer la graisse base de savon au lithium sur le tube interne PURGE DE L AIR DE LA FOUR CHE AVANT N B Si...

Страница 230: ...t each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum posi tion...

Страница 231: ...r glage in gal peut entra ner une mauvaise maniabilit et une perte de stabilit Plage de r glage Maximum Minimum Position compl tement viss e Desserrer de 20 d clics partir du r glage maxi mum Positio...

Страница 232: ...Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handli...

Страница 233: ...m au risque de l endommager AVERTISSEMENT Toujours r gler la m me position les dispositifs de chaque bras de fourche avant Un r glage in gal peut entra ner une mauvaise maniabilit et une perte de stab...

Страница 234: ...djustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten Locknut 6 Instal...

Страница 235: ...age La longueur du ressort mont change de 1 5 mm 0 06 in par tour complet du dispositif de r glage ATTENTION Ne jamais essayer de tourner le dispo sitif de r glage au del de la position maximale ou mi...

Страница 236: ...rn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of...

Страница 237: ...ent de d tente D visser le dispositif de r glage 1 Plage de r glage Maximum Minimum Position com pl tement vis s e D visser de 20 d clics par tir du r glage maximum POSITION STANDARD C est la position...

Страница 238: ...s sion damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by t...

Страница 239: ...lage 1 Plus doux b Diminuer la force d amortissement basse com pression D visser le dispositif de r glage 1 Plage de r glage Maximum Minimum Position com pl tement d viss e D visser de 20 d clics part...

Страница 240: ...Maximum Minimum Fully turned in position 2 turns out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned in position Which...

Страница 241: ...u r glage maximum POSITION STANDARD C est la position qui se trouve en arri re du nombre sp cifi de tours partir de la position enti rement vis s e Ce qui aligne le rep re grav a du dispositif de r gl...

Страница 242: ...ts position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi EC36S0...

Страница 243: ...ndique que le pneu se d tache de sa position sur la jante Si la tige de soupape de pneu est incli n e le pneu a tendance se d tacher de sa position Corriger la position du pneu Pression des pneus stan...

Страница 244: ...the bottom of the forks and gen tly rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering...

Страница 245: ...le en avant et en arri re Jeu R gler la t te de four che 3 Contr ler Action r guli re de la direction Tourner le guidon fond dans les deux sens Action irr guli re R gler l crou annulaire de direction...

Страница 246: ...ing 7 Nm 0 7 m kg 5 1 ft lb Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings Install the upper bracket 5 w...

Страница 247: ...S il y a une g ne quelconque retirer l ensemble colonne de direction et inspecter le support de direction Remettre en place le support sup rieur 5 la rondelle l crou d arbre direction 6 le guidon 7 le...

Страница 248: ...t 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end Use Yamaha cable lube or equivalent on these areas Us...

Страница 249: ...ment du c ble dans le guide de tube 8 Extr mit de c ble des gaz 9 Extr mit s des c bles d embrayage 0 Extr mit du c ble de d marreur chaud Mettre du lubrifiant Yamaha pour c bles ou quivalent sur ces...

Страница 250: ...many hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of sp...

Страница 251: ...se couvre de suie m me si le moteur et le carburateur sont en bon tat de marche 3 Mesurer Ecartement des lectrodes a Utiliser un calibre pour c ble ou un calibre d paisseur Hors sp cification R gler 4...

Страница 252: ...ng light YM 33277 A 90890 03141 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Checking steps Start the engine and let it warm up Let the engine run at the specified speed Engine speed 1...

Страница 253: ...plampe YM 33277 A 90890 03141 Induktivdrehzahlmesser YU 8036 B Motor Drehzahlmesser 90890 03113 Arbeitsschritte Motor anlassen einige Minuten warmlaufen lassen und dann mit der vorgeschriebenen Dreh z...

Страница 254: ...Part name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove...

Страница 255: ...t Remarques DEPOSE DE LA SELLE DU RESERVOIR DE CARBURANT ET DES CACHES LATERAUX Pr paration la d pose Tourner le robinet de carburant la position OFF D connecter la durit de carburant 1 Selle 1 2 Buse...

Страница 256: ...POINTS Side cover 1 Remove Bolt side cover Left side cover 1 Right side cover 2 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air fil ter case SEAT FUEL TANK...

Страница 257: ...ral droit 2 N B Tirer le cache lat ral vers le bas pour l enlever car les griffes a sont ins r es dans le carter de filtre air PUNTI DI RIMOZIONE Coperchio laterale 1 Rimuovere Bullone coperchio late...

Страница 258: ...l Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt...

Страница 259: ...UYAU D ECHAPPEMENT ET DU SILENCIEUX Pr paration la d pose Cache lat ral droit Se reporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Boulon bride de silencieux 1 Desserrer uniquemen...

Страница 260: ...OTE First temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20 Nm 2 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhau...

Страница 261: ...ement 20 Nm 2 0 m kg 14 ft lb Serrer ensuite une nouvelle fois l crou tuyau d chappement 13 Nm 1 3 m kg 9 4 ft lb puis le boulon tuyau d chap pement 24 Nm 2 4 m kg 17 ft lb T R 13 Nm 1 3 m kg 9 4 ft l...

Страница 262: ...rain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Ra...

Страница 263: ...rvoir de carburant Se reporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Protection de radiateur 2 2 Bride de durit de radiateur 8 Desserrer uniquement 3 Durit de radiateur 1 1 4 R...

Страница 264: ...procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect...

Страница 265: ...pression r siduelle Quand le sifflement s est arr t appuyer sur le bouchon tout en le tournant vers la gauche puis l enlever CONTROLE Radiateur 1 Contr ler Carcasse 1 Encrass Nettoyer en souf flant d...

Страница 266: ...stall Left radiator 1 Bolt left radiator 2 Radiator hose 1 3 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 Tighten Radiator hose clamp 4 6 Install Radiator guard 1 Bolt radiator guard 2 N...

Страница 267: ...au CHAPITRE 2 5 Serrer Bride de durit de radiateur 4 6 Monter Protection de radiateur 1 Boulon protection de radia teur 2 N B Accrocher le panneau d abord l int rieur a puis l ext rieur T R 10 Nm 1 0...

Страница 268: ...r Part name Q ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp 1 2 Throttle position sensor lead cou pler 1 3 Throttle c...

Страница 269: ...CHES LATERAUX 1 Bride 1 2 Fiche rapide de fil de capteur de position de papillon des gaz 1 3 Cache du logement des c bles de gaz 1 4 C ble de gaz 2 5 Bride raccord de filtre air 1 Desserrer la vis con...

Страница 270: ...CARBURETOR DISASSEMBLY 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 D...

Страница 271: ...rcle de logement de levier de soupape 1 3 Vis axe d acc l rateur 1 4 Boisseau 1 5 Support d aiguille 1 6 Aiguille 1 7 Couvercle de pompe d acc l ration 1 8 Ressort 1 9 Membrane pompe d acc l ration 1...

Страница 272: ...l Order Part name Q ty Remarks F Main jet 1 G Needle jet 1 H Spacer 1 I Pilot jet 1 J Starter jet 1 K Push rod 1 Pull the push rod L Throttle shaft assembly 1 M Push rod link lever assembly 1 N Pilot...

Страница 273: ...uptd se 1 G Leerlaufd se 1 H Distanzst ck 1 I Choke D se 1 J Nadeld se 1 K Druckstange 1 Ventilst el L Drosselwellenbaugruppe 1 M St elstangenverbindungshebel Baugruppe 1 N Leerlaufluftd se 1 O Kaltst...

Страница 274: ...crew 1 NOTE To optimize the fuel flow at a small throttle opening each machine s pilot screw has been individually set at the factory Before removing the pilot screw turn it in fully and count the num...

Страница 275: ...e ouverture des gaz la vis de richesse de chaque v hicule a t r gl individuellement l usine Avant de remonter la vis de richesse la visser compl tement en comptant le nombre de tours exact Retenir et...

Страница 276: ...om pressed air Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean EC464301 Throttle valve 1 Check Free movement Stick Repair or replace NOTE Insert...

Страница 277: ...delventil 1 Ventilsitz 2 Rillenf rmiger Verschlei a Erneuern Staub b Reinigen Gasschieber 1 Kontrollieren Leichtg ngigkeit Schwerg ngigkeit Instand setzen oder erneu ern HINWEIS Das Gasschieber 1 in d...

Страница 278: ...the float will push in the needle valve result ing in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE T...

Страница 279: ...plan de joint de la cuve niveau constant et le haut du flotteur N B Le bras du flotteur doit reposer sur le pointeau mais il ne doit pas le com primer Si la hauteur du flotteur est hors sp cifications...

Страница 280: ...celerator pump 1 Spring accelerator pump 2 Accelerator pump cover 3 O ring 4 Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spr...

Страница 281: ...d acc l ration 2 Couvercle de pompe d acc l ration 3 Joint torique 4 Tige de pouss e 5 D chirure diaphragme endommagement Rempla cer Encrassement Nettoyer 2 Inspecter Axe de papillon 1 Ressort 2 Levie...

Страница 282: ...Install Spring 2 1 To lever 2 2 1 2 5 Install Push rod link lever assembly 1 NOTE Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 1 a b 6 Install Washer 1 Circlip 2 2...

Страница 283: ...ier 2 2 5 Installer Ensemble de levier de timone rie de la tige de commande 1 N B S assurer que la but e a du ressort 2 rentre dans l encoche b du carburateur 6 Installer Rondelle 1 Circlip 2 7 Instal...

Страница 284: ...ensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throt tle stop screw tip d to the...

Страница 285: ...ourner l ensemble de l axe de papillon vers la gauche tout en appuyant sur le levier 1 5 et adapter l extr mit de la vis d arr t de papillon d la but e e de la poulie d ensem ble d axe de papillon 9 I...

Страница 286: ...until it is lightly seated Turn out the pilot screw by the number of turns recorded before removing Pilot screw 1 5 8 turns out example 13 Install O ring Leak jet 1 Float chamber 2 Screw float chamber...

Страница 287: ...ours en arri re example 13 Monter Joint torique Gicleur de fuite 1 Cuve niveau constant 2 Vis cuve niveau constant 3 Support de c ble c ble de vis d arr t de l acc l ration 4 Support de durit durit de...

Страница 288: ...Valve lever housing cover 2 Bolt valve lever housing cover 3 18 Install Carburetor breather hose 1 NOTE Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where...

Страница 289: ...18 Monter Durit de mide l air de carbu rateur 1 N B Installer la dorit de mise l air sur le car burateur de sorte qu il ne se plie pas l endroit o il est install R glage de l avance de la pompe d acc...

Страница 290: ...play Carburetor installation 1 Install Carburetor joint 1 NOTE Install the projection a on the cylinder between the carburetor joint slots b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Carburetor 1 NOTE In...

Страница 291: ...Raccord de carburateur 1 N B Monter la saillie a du cylindre entre les fentes du raccord de carburateur b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Monter Carburateur 1 N B Mettre la saillie a entre les fentes de...

Страница 292: ...o THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 1 7 Install Throttle cable cover 1 Screw throttle cable cover 2 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Install Throttle position sensor lead coupler 1...

Страница 293: ...logement des c bles des gaz 2 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Monter Fiche rapide de fil de capteur de position de papillon des gaz 1 Bride 2 Se reporter la section CHE MINEMENT DES CABLES au CHAPITRE 2...

Страница 294: ...INDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section 1 Spark plug 1 2 Cylinder head breather hose...

Страница 295: ...tion SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX Carburateur Se reporter la section CARBURATEUR 1 Bougie 1 2 Durit de mise l air de culasse 1 3 Reniflard de r servoir d huile 1 4 Boulon couvre cu...

Страница 296: ...emoval Order Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing mark accessing screw 1 Refer to REMOVAL POINTS 2 Crankshaft end accessing screw 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tens...

Страница 297: ...de distribution 1 Se reporter POINTS DE DEPOSE 2 Vis d acc s de l extr mit de vilebrequin 1 3 Boulon capuchon du tendeur de cha ne de dis tribution 1 4 Tendeur de cha ne de distribution 1 5 Chapeau d...

Страница 298: ...order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl inder head surface as shown in the...

Страница 299: ...ep re d alignement d de l arbr cames d admission s alignent sur la surface de la culasse comme illustr 3 D poser Boulon capuchon du tendeur de la cha ne de distribution 1 Tendeur de la cha ne de distr...

Страница 300: ...ce 2 Measure Cam lobe length a and b Out of specification Replace Cam lobes length Intake a 30 296 30 346 mm 1 1923 1 1947 in Limit 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm...

Страница 301: ...r de came Admission a 30 296 30 346 mm 1 1923 1 1947 in Limite 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limite 22 35 mm 0 8799 in Echappement a 30 399 30 499 mm 1 1968 1 2007 in Limite 30...

Страница 302: ...Nm 1 0 m kg 7 2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camsha...

Страница 303: ...es de la mesure Installer l arbre cames sur la culasse Placer une bande de Plastigauge 1 sur l arbre cames Installer le circlip les goujons et les chapeaux d arbre cames T R Boulon de chapeau d arbre...

Страница 304: ...screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner assembly ASSEMBLY AND INSTALLATION Camshaft 1 Install Exhaust camshaf...

Страница 305: ...rifier si la tige du ten deur sort sans probl me Si elle ne sort pas remplacer le tendeur ASSEMBLAGE ET MONTAGE Arbre cames 1 Monter Arbre camesd chappement1 Arbre cames d admission 2 Etapes de l ins...

Страница 306: ...he clips camshaft caps 4 and bolts camshaft cap 5 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Before removing the clips cover the cylin der head with a clean rag to prevent the clips from into...

Страница 307: ...2 ft lb N B Avant de retirer les clips couvrir la culasse d un chiffon propre pour emp cher qu ils ne tombent dans la cavit de la culasse Appliquer de l huile moteur sur toute la surface des boulons d...

Страница 308: ...e screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci fied torque T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft lb 5 4 New 3 Turn Crankshaft Counter...

Страница 309: ...Boulon capuchon de ten deur de cha ne de distribu tion 7 Nm 0 7 m kg 5 1 ft lb 3 Tourner Vilebrequin De quelques tours dans le sens inverse des aiguilles d une montre 4 V rifier Rep re de PMH du roto...

Страница 310: ...cover 3 Bolt cylinder head cover 4 NOTE Apply the sealant on the cylinder head cover gasket Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 7 Install Oil tank...

Страница 311: ...ck gasket ACC QUICK GS KT YAMAHA Bond n 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 7 Monter Durit de mise l air de r ser voir d huile Durit de mise l air de culasse Bougie T R 13 Nm 1 3 m kg 9 4 ft...

Страница 312: ...IDE COVERS section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHA...

Страница 313: ...ateur 1 D connecter du c t de la culasse Carburateur Se reporter la section CARBURATEUR Arbre cames Se reporter la section ARBRES A CAMES Support sup rieur de moteur Se reporter la section DEPOSE DU M...

Страница 314: ...ad warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurface ment steps Place a straightedge and a feeler gauge across the cylinder head...

Страница 315: ...la culasse Moins de 0 05 mm 0 002 in Etapes de la mesure de la limite de d formation et du surfa age Placer une r gle et une jauge d paisseur sur la culasse Utiliser une jauge d paisseur pour mesurer...

Страница 316: ...3 Bolts L 135 mm 5 31 in 4 Nuts 5 NOTE Apply the molybdenum disulfide grease on the thread and contact surface of the bolts Follow the numerical order shown in the illus tration Tighten the bolts and...

Страница 317: ...des boulons Suivre l ordre num rique donn dans l illustration Serrer les boulons et crous en deux tapes T R 38 Nm 3 8 m kg 27 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Monter R...

Страница 318: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cot...

Страница 319: ...oir de soupape 5 Utiliser un outil sp cial Se reporter POINTS DE DEPOSE 2 Cale de r glage 5 3 Clavette de soupape 10 4 Retenue de ressort de soupape 5 5 Ressort de soupape 5 6 Joint de queue de soupap...

Страница 320: ...lve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly...

Страница 321: ...ge de soupape Examiner la face de soupape le si ge de soupape et la largeur du si ge de soupape Etapes de la v rification Verser du dissolvant propre 1 dans les lumi res d admission et d chappement V...

Страница 322: ...3 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head i...

Страница 323: ...Etapes de remplacement N B Pour faciliter l extraction et la remise en place du guide et maintenir un ajustage correct faire chauffer la culasse 100 C 212 F dans un four D poser le guide de soupape en...

Страница 324: ...7 90890 04117 Valve guide reamer Intake 4 0 mm 0 16 in YM 4113 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 90890 04118 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pi...

Страница 325: ...6 Outil d installation de guide de soupape Admission 4 0 mm 0 16 in YM 4112 90890 04112 Echappement 4 5 mm 0 18 in YM 4117 90890 04117 Al soir de guide de sou pape Admission 4 0 mm 0 16 in YM 4113 908...

Страница 326: ...a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps App...

Страница 327: ...mission 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Echappement 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Etapes de la mesure Appliquer du bleu de m canicien Dykem b sur la face de l...

Страница 328: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Страница 329: ...s puis liminer la p te roder N B Pour obtenir un bon rodage tapoter sur le si ge de soupape tout en faisant tourner la soupape dans la main Appliquer de la p te roder fine sur la face de soupape puis...

Страница 330: ...m 1 41 in Exhaust 37 54 mm 1 48 in Limit 35 7 mm 1 41 in Compressed spring force Intake 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in Exhaust 126 144 N at 29 30 mm 12 6 14 4 k...

Страница 331: ...ssort com prim Admission 99 114 N 29 13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in Echappement 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in 3 Mesurer Inclinaison de ressort a Ho...

Страница 332: ...color Valve lifter mark b color Red Red Blue Blue Yellow Yellow Purple Black a b ASSEMBLY AND INSTALLATION Valve and valve spring 1 Apply Molybdenum disulfide oil Onto the valve stem and valve stem se...

Страница 333: ...MONTAGE Soupape et ressort de soupape 1 Appliquer Huile au bisulfure de molyb d ne Sur la queue de soupape et la bague d tanch it de queue de soupape 2 Monter Soupapes 1 Si ges de ressort de soupape 2...

Страница 334: ...alve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 4019 90890 04019 5 Install Adjusting pad 1 Valve lifter 2 NOTE Apply...

Страница 335: ...mpresseur de ressort de soupape YM 4019 90890 04019 5 Monter Cales de r glage 1 Poussoir de soupape 2 N B Enduire l extr mit de la queue de soupape d huile au bisulfure de moly bd ne Enduire les pouss...

Страница 336: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin cli...

Страница 337: ...rdre Nom de pi ce Qt Remarques DEPOSE DES CYLINDRES ET DES PIS TONS Pr paration la d pose Culasse Se reporter la section CULASSE 1 Boulon cylindre 1 2 Cylindre 1 3 Agrafe d axe de piston 2 Utiliser un...

Страница 338: ...se a hammer to drive the piston pin out 2 Remove Piston ring 1 NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustrati...

Страница 339: ...our chasser l axe de piston 2 D poser Segment de piston 1 N B Ecarter largement les becs tout en soule vant en m me temps le segment de pis ton au dessus de la couronne de piston comme montr sur l ill...

Страница 340: ...re the piston skirt diameter P with a micrometer a 8 mm 0 31 in from the piston bottom edge Piston size P Standard 76 955 76 970 mm 3 0297 3 0303 in If out of specification replace the piston and pist...

Страница 341: ...rom tre a 8 mm 0 31 in du bord inf rieur de pis ton Taille de piston P Standard 76 955 76 970 mm 3 0297 3 0303 in Si hors sp cifications remplacer le piston et ses segments 3 me tape Calculer l cart e...

Страница 342: ...crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 0...

Страница 343: ...0012 0 0026 in 0 12 mm 0 005 in Segment d tan ch it 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in 3 Mesurer Ecartement des becs Hors sp cifications Rempla cer N B Il est impossible de mesurer l car...

Страница 344: ...piston and piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 15 991 16 000...

Страница 345: ...a S il n est pas conforme aux sp cifi cations remplacer l axe de piston Diam tre ext rieur axe de piston 15 991 16 000 mm 0 6296 0 6299 in Mesurer le diam tre int rieur pis ton b Diam tre int rieur ax...

Страница 346: ...on Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from f...

Страница 347: ...ton et le piston S assurer que la fl che a sur le piston soit orient e vers le c t chappement du moteur Avant d installer l agrafe d axe de pis ton couvrir le carter avec un chiffon propre pour viter...

Страница 348: ...h one hand while com pressing the piston rings with the other hand CAUTION Pass the timing chain 3 through the tim ing chain cavity Be careful not to damage the timing chain guide 4 during installatio...

Страница 349: ...asser la cha ne de distribu tion 3 par la cavit pr vue cet effet Veiller ne pas endommager l amortisseur de la cha ne de distri bution 4 lors de l installation 4 Monter Boulon cylindre 5 T R 10 Nm 1 0...

Страница 350: ...al Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOV...

Страница 351: ...folge Bauteil Anz Bemerkungen KUPPLUNG DEMONTIEREN Vorbereitung f r den Ausbau Motor l ablassen Siehe unter MOTOR L WECHSELN im KAPITEL 3 Fu bremshebel Siehe unter MOTOR DEMONTIEREN Kupplungszug Motor...

Страница 352: ...ty Remarks 10 Friction plate 9 11 Clutch plate 8 12 Cushion spring 1 13 Seat plate 1 14 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1...

Страница 353: ...ortisseur 1 13 Plaque d assise 1 14 Ecrou noix d embrayage 1 Utiliser un outil sp cial Se reporter POINTS DE DEPOSE 15 Rondelle d arr t 1 16 Noix d embrayage 1 17 Rondelle de but e 1 18 Pignon men pri...

Страница 354: ...YM 91042 90890 04086 EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1...

Страница 355: ...OLE Cloche et noix d embrayage 1 V rifier Cloche d embrayage 1 Craquelures usure endomma gement Ramplacer Noix d embrayage 2 Rayures usure endommage ment Ramplacer Pignon men primaire 1 V rifier Jeu c...

Страница 356: ...Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 7 mm 0 106 in Warp limit...

Страница 357: ...yage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Epaisseur de disque de friction 2 9 3 1 mm 0 114 0 122 in Limite 2 7 mm 0 106 in Limite de d formation 0 1 mm 0 004 in Levier de pouss e 1...

Страница 358: ...groove a of the push lever shaft and tighten the bolt seat plate 3 1 a 2 T R 10 Nm 1 0 m kg 7 2 ft lb Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on...

Страница 359: ...2 ft lb Embrayage 1 Monter Pignon men primaire 1 Rondelle de but e 2 Noix d embrayage 3 N B Enduire la circonf rence int rieure du pignon d huile de moteur 2 Monter Rondelle frein 1 Ecrou noix d embra...

Страница 360: ...l the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying at...

Страница 361: ...oix d embrayage en comen ant par un disque de friction et en terminant par un disque de friction Commencer et terminer par un disque de friction 1 et tre attentif la diff rence de leur surface Appliqu...

Страница 362: ...essure plate 1 9 Install Clutch spring 1 Bolt clutch spring 2 NOTE Tighten the bolts in stage using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 10 Install Dowel pin 1 Gasket clutch cover 2 11 Ins...

Страница 363: ...Boulon ressort d embrayage 2 N B Serrer les boulons par tapes dans un ordre entrecrois T R 8 Nm 0 8 m kg 5 8 ft lb 10 Monter Goujon 1 Joint couvercle d embrayage 2 11 Monter Couvercle d embrayage 1 Bo...

Страница 364: ...rks OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to CO...

Страница 365: ...ation la d pose Vidanger le moteur Se reporter la section CHANGEMENT DE L HUILE DE MOTEUR au chapitre 3 Vidanger le liquide de refroidissement Se reporter la section CHANGEMENT DU LIQUIDE DE REFROIDIS...

Страница 366: ...VER Extent of removal Order Part name Q ty Remarks 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to REMOVAL POINTS 9...

Страница 367: ...droit 1 8 Rotor 1 Se reporter POINTS DE DEPOSE 9 Rondelle 1 10 Arbre de rotor 1 11 Bague d tanch it 2 12 Roulement 1 3 2 Portata dello smontaggio Ordine Denominazione Quantit Osservazioni 3 Alloggiame...

Страница 368: ...oss the flats a with spanners 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 le...

Страница 369: ...e un changement excessif du niveau ou une d coloration du liquide de refroidissement ou une huile de bo te de vitesses laiteuse 1 D poser Roulement 1 2 D poser Bague d tanch it 1 CONTROLE Tuyau d arri...

Страница 370: ...Gear teeth a Wear damage Replace EC4H4600 Bearing 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace EC444400 Oil seal 1 Inspect Oil seal 1 Wear damage Replace ASSEMBLY AND...

Страница 371: ...ler Bague d tanch it 1 Usure endommagement Remplacer ASSEMBLAGE ET MONTAGE Bague d tanch it 1 Monter Bague d tanch it 1 N B Appliquer la graisse base de savon au lithium sur la l vre de la bague d ta...

Страница 372: ...dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning...

Страница 373: ...rotor tout en le tournant Maintenir l arbre de rotor par les zones lat rales aplaties a au moyen d une cl etc et monter la turbine de pompe T R 14 Nm 1 4 m kg 10 ft lb Demi carter droit 1 Monter Goup...

Страница 374: ...kg 7 2 ft lb Kickstarter crank 1 Install Kickstarter crank 1 Washer 2 Bolt kickstarter crank 3 NOTE Install the kickstarter crank so that the kick starter crank is as vertical as possible with the dis...

Страница 375: ...ble et ce que la distance a entre la p dale et le cadre soit de 8 mm 0 31 in minimum 2 Monter Durit d huile 1 Boulon durit d huile 2 T R 33 Nm 3 3 m kg 24 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Monter R...

Страница 376: ...he lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter element 1 Install Oil filter element 1 O ring 2 Oil filter el...

Страница 377: ...que 2 Couvercle d l ment de filtre huile 3 Boulon couvercle d l ment de filtre huile N B Enduire le joint torique de graisse base de savon au lithium T R 10 Nm 1 0 m kg 7 2 ft lb Alloggiamento della p...

Страница 378: ...r to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to REMOVAL POIN...

Страница 379: ...eporter la section VOLANT MAGNETIQUE CDI 1 Ecrou pignon menant primaire 1 Se reporter POINTS DE DEPOSE 2 Ecrou pignon men du balancier 1 3 Rondelle frein 1 4 Pignon menant primaire 1 5 Pignon menant d...

Страница 380: ...d driven gear 4 Balancer shaft 1 Remove Balancer shaft 1 NOTE When removing the balancer shaft align the center a of the balancer shaft weight along the line connecting the centers of the crank shaft...

Страница 381: ...tre du vilebrequin et le centre de l arbre de balancier CONTROLE Pignon menant primaire pignon menant et pignon men du balancier 1 Contr ler Pignon menant primaire 1 Pignon menant du balancier 2 Pign...

Страница 382: ...r shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 NOTE Align the punched mark a on the balancer shaft drive gear with the punched mark b on th...

Страница 383: ...re poin onn c sur le pignon menant de balancier et la saillie d sur l extr mit de vilebrequin 4 Monter Rondelle frein 1 Ecrou pignon men de balan cier 2 Pignon menant primaire 3 Ecrou pignon menant pr...

Страница 384: ...EMBLY Preparation for removal Primary driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section 1 Circlip 1 2 Washer 1 3 Oil p...

Страница 385: ...orter la section ELEMENT DE FILTRE A HUILE POMPE A EAU ET DEMI CARTER DROIT 1 Circlip 1 2 Rondelle 1 3 Pignon menant de la pompe huile 1 4 Ensemble pompe huile 1 5 Rotor ext rieur 2 1 6 Circlip 1 7 Ro...

Страница 386: ...4 67 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 2...

Страница 387: ...lle 1 15 Rotorgeh use 1 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 12 Goupille 1 13 Rondelle 1 14 Arbre de transmission de la pompe huile 1 15 Logement de rotor 1 2 Portata dello smon...

Страница 388: ...he outer rotor 2 and rotor housing 3 Housing and rotor clearance c between the rotor housing 3 and rotors 1 2 Out of specification Replace the oil pump assembly Tip clearance a 0 12 mm or less 0 0047...

Страница 389: ...re le logement de rotor 3 et les rotors 1 2 Hors sp cifications Rempla cer la pompe huile compl te Jeu en bout a 0 12 mm ou moins 0 0047 in ou moins Limite 0 20 mm 0 008 in Jeu lat ral b 0 09 0 17 mm...

Страница 390: ...shaft and inner rotor 1 Fit the dowel pin into the groove in the inner rotor 1 2 Install Outer rotor 1 1 NOTE Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover...

Страница 391: ...Monter Rotor ext rieur 1 1 N B Enduire le rotor ext rieur 1 d huile moteur 3 Monter Couvercle de pompe huile 1 Vis couvercle de pompe huile 2 Goupille 3 Rotor int rieur 2 4 Circlip 5 N B Enduire le r...

Страница 392: ...5 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 NOTE Apply the engine oil on the outer rotor 2 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install Oil pump drive gear 1 Washer...

Страница 393: ...huile moteur T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Monteur Pignon menant de la pompe huile 1 Rondelle 2 Circlip 3 N B Enduire la circonf rence int rieure du pignon menant d huil...

Страница 394: ...oval Extent of removal Order Part name Q ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to RE...

Страница 395: ...pi ce Qt Remarques DEPOSE DE L ARBRE DE KICK ET DE L ARBRE DE SELECTEUR Pr paration la d pose Pompe huile Se reporter la section POMPE A HUILE 1 Pignon de renvoi de kick 1 2 Arbre de kick complet 1 S...

Страница 396: ...Q ty Remarks 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to REMOVAL POINTS 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper...

Страница 397: ...ouleau 1 14 Guide de s lecteur 1 Se reporter POINTS DE DEPOSE 15 Ensemble levier de s lecteur 1 16 Levier de s lecteur 1 17 Cliquet 2 18 Goupille de cliquet 2 19 Ressort 2 20 Boulon levier de but e 1...

Страница 398: ...embly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION Kick s...

Страница 399: ...ecteur se d monte en m me temps que le guide de s lecteur Barillet 1 D poser Boulon barillet 1 Barillet 2 N B Tourner le barillet dans le sens antiho raire jusqu l arr t et desserrer le bou lon CONTRO...

Страница 400: ...assembly 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace ASSE...

Страница 401: ...1 Contr ler Guide de s lecteur 1 Levier de s lecteur 2 Cliquet 3 Goupille du cliquet 4 Ressort 5 Usure endommagement Remplacer Levier de but e 1 Contr ler Levier de but e 1 Usure endommagement Rempla...

Страница 402: ...1 Install Spring 1 Pawl pin 2 Pawl 3 To shift lever 4 NOTE Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly 1 To shift guide 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install...

Страница 403: ...2 Cliquet 3 Au levier de s lecteur 4 N B Enduire les ressorts les goupilles de cli quets et les cliquets d huile moteur 2 Monter Levier de s lecteur complet 1 Au guide de s lecteur 2 3 Monter Levier d...

Страница 404: ...1 mm 0 04 in a above the top of the footrest T R 12 Nm 1 2 m kg 8 7 ft lb Kick shaft assembly 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 NOTE...

Страница 405: ...repose pied T R 12 Nm 1 2 m kg 8 7 ft lb Arbre de kick complet 1 Monter Pignon de kick 1 Rondelle 2 Circlip 3 Rochet 4 Ressort 5 Rondelle 6 Circlip 7 Sur l arbre de kick 8 N B Appliquer de l huile de...

Страница 406: ...the kick shaft stop per a and stopper plate 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the stopper pla...

Страница 407: ...e au bisul fure de molybd ne Appliquer l huile sur l arbre de kick Ins rer l arbre de kick dans le carter et s assurer que la but e d arbre de kick a repose bien sur l onglet de la pla que de but e 5...

Страница 408: ...AL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt left radiator Refer to RADIATOR section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHA...

Страница 409: ...ence Se reporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil de volant magn tique CDI P dale de s lecteur Se...

Страница 410: ...lywheel puller turn it counterclockwise Rotor holding tool YU 1235 90890 01235 Flywheel puller YM 1189 90890 01189 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer...

Страница 411: ...lant le tourner dans le sens inverse des aiguilles d une montre Extracteur de volant YM 1189 90890 01189 CONTROLE Volant magn tique CDI 1 Contr ler Surface interne de rotor a Surface externe de stator...

Страница 412: ...90 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Woodruff key 1 Rotor 2 NOTE Clean the tapered portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is...

Страница 413: ...kg 7 2 ft lb 2 Monter Clavette de demi lune 1 Rotor 2 N B Nettoyer la partie conique du vilebre quin et du demi lune rotor Lors du montage de la clavette s assu rer que sa surface plane a est paral l...

Страница 414: ...G DIA GRAM section in the CHAPTER 2 5 Install Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Bolt left crankcase cover 3 NOTE Tighten the bolts i...

Страница 415: ...r au paragraphe DIA GRAMME DE CHEMINE MENT DES CABLE au CHAPITRE 2 5 Monter Goujon Joint demi carter gauche Demi carter gauche 1 Guide de durit durit de mise l air de culasse 2 Boulon demi carter gauc...

Страница 416: ...over Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconn...

Страница 417: ...a section TUYAU D ECHAPPEMENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR P dale de s lecteur Se reporter la section ARBRE DE KICK ET ARBRE...

Страница 418: ...ne guard 1 Lower engine guard 1 2 Neutral switch 1 3 Bolt oil hose 2 4 Drive chain sprocket cover 1 5 Nut drive sprocket 1 Refer to REMOVAL POINTS 6 Lock washer 1 7 Drive sprocket 1 8 Clip 1 9 Bolt br...

Страница 419: ...rcle de pignon de cha ne de transmission 1 5 Ecrou pignon d entra nement 1 Se reporter POINTS DE DEPOSE 6 Rondelle frein 1 7 Pignon d entra nement 1 8 Agrafe 1 9 Boulon p dale de frein 1 10 P dale de...

Страница 420: ...sprocket 1 Drive chain 2 NOTE Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will...

Страница 421: ...de transmission 2 N B D poser le pignon d entra nement avec la cha ne de transmission D pose du moteur 1 D poser Axe de pivot 1 N B Si l on sort compl tement l axe de pivot le bras oscillant va tombe...

Страница 422: ...lfide grease on the pivot shaft EC4M5211 Brake pedal 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 NOTE Apply the lithium soap base grease on the bolt O rings and brake pedal bra...

Страница 423: ...e la graisse base de savon au lithium sur le boulon les joints toriques et le support de p dale de frein Monter l agrafe avec la but e a tour n e vers l int rieur T R 85 Nm 8 5 m kg 61 ft lb T R 69 Nm...

Страница 424: ...uide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 T R 8 Nm 0 8 m kg 5 8 ft lb Oil hose and neutral switch 1 Install O ring 1 Dowel pin 2 Oil hose 3 Bolt oil hose 4 NOTE Apply the...

Страница 425: ...8 ft lb Durit d huile et contacteur de point mort 1 Monter Joint torique 1 Goujon 2 Durit d huile 3 Boulon durit d huile 4 N B Enduire le joint torique de graisse base de savon au lithium 2 Monter Res...

Страница 426: ...RANKCASE AND CRANK SHAFT REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT sec...

Страница 427: ...porter la section DEPOSE DU MOTEUR Piston Se reporter la section CYLINDRE ET PISTON Arbre de kick complet Se reporter la section ARBRE DE KICK ET ARBRE DE SELECTEUR Barillet Stator Se reporter la sect...

Страница 428: ...ty Remarks 4 Bolt L 45 mm 1 77 in 6 Refer to REMOVAL POINTS 5 Bolt L 55 mm 2 17 in 1 6 Bolt L 70 mm 2 76 in 4 7 Hose guide 1 8 Clutch cable holder 1 9 Right crankcase 1 10 Left crankcase 1 11 Oil str...

Страница 429: ...7 in 6 Se reporter POINTS DE DEPOSE 5 Boulon L 55 mm 2 17 in 1 6 Boulon L 70 mm 2 76 in 4 7 Guide de durit 1 8 Support de c ble d embrayage 1 9 Demi carter droit 1 10 Demi carter gauche 1 11 Carter d...

Страница 430: ...1 Crankcase bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND S...

Страница 431: ...de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DES ROULEMENTS DE CAR TER Pr paration la d pose Bo te vitesses Tambour et fourchettes de s lection Se reporter la section BOITE A VITESSES TAM BOUR...

Страница 432: ...litting slit a in the crankcase Lift the right crankcase horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mis...

Страница 433: ...g re ment la fente de s paration ainsi que la noix de montage du moteur l aide d un maillet en plastique Le carter et la bo te vitesses res tent attach s au demi carter gau che ATTENTION Utiliser un m...

Страница 434: ...e removed bearing Crankcase separating tool YU 1135 A 90890 01135 INSPECTION Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a...

Страница 435: ...n 1 Contr ler Cha ne de distribution Craquelures raideur Rem placer l ensemble cha ne de distribution et pignon d arbre cames 2 Contr ler Guide de cha ne de distribution Usure endommagement Remplacer...

Страница 436: ...auge Dial gauge and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clearance 0 15 0 45 mm 0...

Страница 437: ...in 0 05 mm 0 002 in D flexion de pied de bielle 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Jeu lat ral 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Largeur de volant 55 95 56 00 mm 2 203 2 205 in Cr p...

Страница 438: ...shaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 For USA and CDN Except for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut o...

Страница 439: ...ntage de vilebrequin 2 3 4 et 5 Pour les USA et le CDN Except pour les USA et le CDN N B Tenir la bielle au PMH point mort haut avec une main tout en tournant l crou de l outil de montage avec l autre...

Страница 440: ...nkcase 1 NOTE Clean the contacting surface of left and right crankcase before applying the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase NOTE Fit the right crankcase onto th...

Страница 441: ...emi carters gauche et droit avant d appliquer l agent d tanch it 5 Monter Goujon 1 Joint torique 2 Demi carter droit Vers le demi carter gauche N B Fixer le demi carter droit sur le demi carter gauche...

Страница 442: ...1 O ring 2 Bolt oil delivery pipe 2 3 NOTE Apply the lithium soap base grease on the O rings T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain gu...

Страница 443: ...ide de cha ne de distribution c t admission 2 Boulon guide de cha ne de distribution 3 9 D poser Agent d tanch it Sorti sur la surface usin e du cylindre 10 Appliquer Huile moteur Sur la goupille de c...

Страница 444: ...removal Extent of removal Order Part name Q ty Remarks TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRAN...

Страница 445: ...n de la d pose Ordre Nom de pi ce Qt Remarques DEPOSE DE LA BOITE A VITESSES DU TAMBOUR ET DE LA FOURCHETTE DE SELECTION Pr paration la d pose Moteur Se reporter la section DEPOSE DU MOTEUR S parer le...

Страница 446: ...articular attention to the location and direction of shift forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham...

Страница 447: ...l arbre secondaire l aide d un mar teau doux CONTROLE Pignons 1 Contr ler Crabot d accouplement a Dent de pignon b Gorge de fourchette c Usure endommagement Remplacer 2 Contr ler Joint torique 1 Endo...

Страница 448: ...oning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION Transmission 1 Install 5th pinion gear 24T 1 3rd pinion ge...

Страница 449: ...e 3 me 20D 2 Collerette 3 Pignon de 4 me 22D 4 Pignon de 2 me 16D 5 Sur l arbre primaire 6 N B Appliquer de l huile au bisulfure de molybd ne sur la circonf rence int rieure des 4e et 5e pignons et su...

Страница 450: ...Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumfer ence Apply the lithium soap base grease on the O ring 3 Install Washer 1 Circlip 2 NOTE Be sure the circlip sharp edg...

Страница 451: ...ier que le c t bord vif du cir clip a soit oppos la rondelle situ e contre le pignon b V rifier que l extr mit du circlip c est situ e dans une gorge de l axe d 4 Monter Collerette 1 N B Appliquer la...

Страница 452: ...oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle...

Страница 453: ...e l arbre secondaire Engrener la fourchette n 2 C avec le pignon de 3 me 6 de l arbre pri maire 6 Monter Ensemble bo te vitesse 1 Vers le demi carter gauche 2 N B Appliquer de l huile moteur sur les r...

Страница 454: ...marks Preparation for removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Brake...

Страница 455: ...tenir la machine en pla ant un support appropri sous le moteur 1 Logement de durit de frein 1 2 Boulon support de durit de frein 2 Desserrer uniquement 3 Boulon support d axe 4 Desserrer uniquement 4...

Страница 456: ...VAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive ch...

Страница 457: ...ntenir la machine en pla ant un support appropri sous le moteur 1 Ecrou axe de roue arri re 1 2 Axe de roue arri re 1 3 Tendeur de cha ne de transmission 2 4 Roue arri re 1 Se reporter POINTS DE DEPOS...

Страница 458: ...necessary 1 Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate in...

Страница 459: ...roulement en utilisant un arrache roulement courant 2 CONTROLE Roue 1 Mesure Voile de roue Hors limite R parer rempla cer Limite de voile de la roue Radial 1 2 0 mm 0 08 in Lat ral 2 2 0 mm 0 08 in 2...

Страница 460: ...Wheel axle bending limit 0 5 mm 0 020 in EC594200 Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in...

Страница 461: ...ue de frein disque de frein arri re unique ment Utiliser le comparateur 1 Hors sp cification Examiner le voile de roue Si le voile de la roue est nor mal changer le disque de frein 2 Mesurer Epaisseur...

Страница 462: ...ed first Install the oil seal with its manufacture s marks or numbers facing outward ACHTUNG CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Insta...

Страница 463: ...s de fabricant diri g s vers l ext rieur ATTENTION Ne pas frapper sur la cage de roule ment interne Le contact ne doit avoir lieu qu avec la cage de roulement externe 2 Monter Disque de frein 1 Boulon...

Страница 464: ...e axle holder by stroking the front fork sev eral times with the front brake applied 8 Install Brake hose 1 To brake hose holder 2 NOTE Before tightening the bolt brake hose holder align the top a of...

Страница 465: ...ant tout en serrant le frein avant 8 Monter Durit de frein 1 Sur le support de durit de frein 2 N B Avant de serrer le boulon support de flexible de frein aligner le haut a du collet de flexible de fr...

Страница 466: ...ring and oil seal lip when installing Install the bearing with seal facing outward Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed f...

Страница 467: ...ors de la repose Monter le roulement avec son joint dirig vers l ext rieur Utiliser une douille convenant au dia m tre ext rieur de la cage du roule ment Monter d abord le roulement droit Monter la ba...

Страница 468: ...HEEL 4 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip 5 Install Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install Drive chain 1 NOTE Push t...

Страница 469: ...B Reposer correctement le disque de frein 1 entre les plaquettes de frein 2 6 Monter Cha ne de transmission 1 N B Pousser la roue 2 vers l avant et monter la cha ne de transmission 7 Monter Tendeur g...

Страница 470: ...axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 40 50 mm 1 6 2 0 in 10 T...

Страница 471: ...t l crou axe de roue 9 R gler Fl che de cha ne de transmis sion a Se reporter la section REGLAGE DE LA FLECHE DE CHAINE DE TRANSMIS SION au CHAPITRE 3 Fl che de cha ne de trans mission 40 50 mm 1 6 2...

Страница 472: ...e by placing the suitable stand under the engine Drain the brake fluid WARNING Support the machine securely so there is no danger of it falling over Refer to REMOVAL POINTS 1 Brake hose cover 1 2 Brak...

Страница 473: ...liquide de frein Se reporter POINTS DE DEPOSE 1 Logement de durit de frein 1 2 Support de durit de frein 1 3 Boulon support de durit de frein 2 Desserrer uniquement 4 Boulon raccord 2 5 Durit de frein...

Страница 474: ...uitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOV...

Страница 475: ...e ne risque pas de se renverser Roue arri re Se reporter la section ROUE AVANT ET ROUE ARRIERE Vidanger le liquide de frein Se reporter POINTS DE DEPOSE 1 P dale de frein 1 2 Ma tre cylindre 1 3 Suppo...

Страница 476: ...2 Rear brake caliper disassembly Extent of removal Order Part name Q ty Remarks BRAKE CALIPER DISASSEM BLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to REMOV...

Страница 477: ...la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DE L ETRIER A B 1 Goupille de plaquette 1 1 2 Plaquette de frein 2 2 3 Support de plaquette 1 1 4 Piston d trier de frein 2 1 Se reporter POINTS DE...

Страница 478: ...ylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Brake master...

Страница 479: ...re Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DU MAITRE CYLINDRE DE FREIN 1 Couvercle de ma tre cylindre de frein 1 2 Diaphragme 1 3 Soufflet de ma tre cylindre de frein 1 4...

Страница 480: ...n or pushing down on the pedal ACHTUNG CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Brake caliper pist...

Страница 481: ...quide de frein attaque les surfa ces peintes et le plastique Si on en renverse il faut l essuyer imm dia tement Piston d trier de frein 1 D poser Piston d trier de frein Appliquer de l air comprim en...

Страница 482: ...e piston seals and dust seals whenever a caliper is disassembled Front Rear EC5A4000 INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cyl...

Страница 483: ...e d trier Avant Arri re CONTROLE Ma tre cylindre de frein 1 Contr ler Surface interne du ma tre cylindre de frein a Usure rayures Ramplacer l ensemble ma tre cylindre Taches Nettoyer AVERTISSEMENT Uti...

Страница 484: ...a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crack damage Replace EC5A5000 ASSEMBLY AND INSTALLATION WARNING All internal parts should be cleaned in new brake fluid only Inter...

Страница 485: ...it de frein 1 Contr ler Durit de frein 1 Craquelure endommagement Remplacer REMONTAGE ET MONTAGE AVERTISSEMENT Toutes les pi ces internes doivent tre nettoy es en utilisant unique ment du liquide de f...

Страница 486: ...er piston 1 NOTE Apply the brake fluid on the piston wall ACHTUNG CAUTION Install the piston with its shallow depressed side a facing the brake cali per Never force to insert Front Rear Front brake ca...

Страница 487: ...frein sur la paroi du piston ATTENTION Installer le piston avec le c t ren fonc a face l trier de frein Ne jamais forcer pour ins rer Avant Arri re Etrier de frein avant 1 Monter Support de plaquette...

Страница 488: ...all Brake hose holder 1 Brake caliper 2 Bolt brake caliper 3 NOTE Fit the brake hose holder cut a over the pro jection b on the front fork and clamp the brake hose 4 Tighten Pad pin 4 5 Install Pad pi...

Страница 489: ...pport de durit de frein a sur la saillie b de la fourche avant et fixer la durit de frein 4 Serrer Goupille de plaquette 4 5 Monter Bouchon de goupille de pla quette 5 T R 23 Nm 2 3 m kg 17 ft lb T R...

Страница 490: ...r kit 1 Clean Brake master cylinder Brake master cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder p...

Страница 491: ...re cylindre de frein Les nettoyer avec du liquide de frein 2 Monter Couvercle de ma tre cylindre de frein primaire 1 Couvercle de ma tre cylindre de frein secondaire 2 Au piston d trier de frein 3 N B...

Страница 492: ...ke master cylinder 5 NOTE Apply the brake fluid on the brake master cylinder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip plier...

Страница 493: ...e frein sur le kit ma tre cylindre de frein Appliquer de la graisse au lithium sur l extr mit de la tige de commande Pour mettre le circlip en place utiliser une pince de circlip longs becs Avant Arri...

Страница 494: ...NG CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb...

Страница 495: ...dirig e comme indiqu et touche la projection du ma tre cylindre de frein b T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb T R 30 Nm 3 0 m kg 22 ft lb 2 Monter Ma tre cylindre de frein 1 Boul...

Страница 496: ...er align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not con...

Страница 497: ...as ser ensuite le flexible de frein devant la noix d arbre c et l ins rer dans la rai nure de flexible d de sorte que le flexi ble de frein ne touche pas l crou arbre de roue T R 10 Nm 1 0 m kg 7 2 ft...

Страница 498: ...a directs as shown and lightly touches the projection b on the brake master cylinder T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING Always use...

Страница 499: ...ndiqu et touche la projection du ma tre cylindre de frein b T R 30 Nm 3 0 m kg 22 ft lb Durit de frein arri re 1 Monter Rondelle en cuivre 1 Tuyau de frein 2 Boulon raccord 3 AVERTISSEMENT Toujours ut...

Страница 500: ...nly the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a ha...

Страница 501: ...ra des fuites et un mauvais fonctionnement du frein Toujours utiliser la m me marque de liquide de frein Le m lange de liquides de marques diff rentes ris que de provoquer une r action chi mique nuisi...

Страница 502: ...w brake master cylinder cap 2 Rear Diaphragm Brake master cylinder cap 1 Bolt brake master cylinder cap 2 ACHTUNG CAUTION After installation while pulling the brake lever in or pushing down on the bra...

Страница 503: ...phragme Couvercle de ma tre cylindre de frein 1 Boulon couvercle de ma tre cylindre de frein 2 ATTENTION Apr s le montage rechercher les fui tes ventuelles de liquide de frein au niveau des boulons ra...

Страница 504: ...ING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number...

Страница 505: ...mfallen sichern Vorderrad Siehe unter VORDER UND HINTERRAD Bremssattel vorn Siehe unter VORDER UND HINTERRAD BREMSE Nummernschild Lenker Siehe unter LENKER 1 Protektor 1 2 Bremsschlauch Halterung 2 3...

Страница 506: ...arks FRONT FORK DISASSEMBLY 1 Front fork cap bolt 1 Refer to REMOVAL POINTS 2 Fork spring 1 Drain the fork oil 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7 Pi...

Страница 507: ...E 2 Ressort de fourche 1 Vidanger d huile de fourche 3 Joint antipoussi re 1 Se reporter POINTS DE DEPOSE 4 Bague d arr t 1 5 Tube plongeur 1 6 Fourreau 1 7 Bague coulissante de piston 1 8 Bague antif...

Страница 508: ...ough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disas sembled and reassembled Before removing the cap bolts or front forks be sure to extract...

Страница 509: ...nt est d mont e ou remont e Avant de d visser les bouchons de tube de fourche ou d enlever les bras de fourche avant tre s r d avoir compl tement purg l air du r servoir d air POINTS DE DEPOSE Bouchon...

Страница 510: ...from the outer tube EC553311 Damper rod 1 Remove Base valve 1 Damper rod 2 NOTE Use a damper rod holder 3 to lock the damper rod EC554000 INSPECTION EC554100 Damper rod 1 Inspect Damper rod 1 Bend dam...

Страница 511: ...d amortisseur 3 pour bloquer la tige d amortisseur CONTROLE Tige d amortisseur 1 Contr ler Tige d amortisseur 1 Courbure endommagement Remplacer la tige d amortis seur ATTENTION La construction inter...

Страница 512: ...000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING...

Страница 513: ...Remplacer D formations de tube plongeur Hors sp cification Rempla cer Utiliser le comparateur 1 N B La valeur de courbure est indiqu e par la moiti de la valeur du comparateur cadran AVERTISSEMENT Ne...

Страница 514: ...HTUNG CAUTION To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install Copper w...

Страница 515: ...ne de biais Si le tube plongeur est tenu verticalement la tige d amortisseur peut y tomber endommageant le clapet 3 Monter Rondelle en cuivre 1 Joint torique 2 Soupape de base 3 Au tube interne 4 4 Se...

Страница 516: ...pper ring 2 Oil seal 3 Oil seal washer 4 Slide metal 5 To inner tube 6 NOTE Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil...

Страница 517: ...6 N B Appliquer de l huile de fourche sur le tube plongeur Lors de l installation de la bague d tanch it utiliser une feuille plasti que a enduite d huile de fourche pour prot ger la l vre de la bague...

Страница 518: ...ver 3 Fork seal driver YM 01442 90890 01442 10 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 11 Install Stopper ring 1 NO...

Страница 519: ...90890 01442 10 Monter Bague d tanch it 1 N B Enfoncer la bague d tanch it dans le fourreau l aide de l outil d insertion de joint de fourche 2 Outil d insertion de joint de fourche YM 01442 90890 014...

Страница 520: ...rk performance Never allow foreign materials to enter the front fork Recommended oil Suspension oil 01 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distribute the fo...

Страница 521: ...plissage pomper lentement plus de 10 fois vers le haut et le bas la tige d amortisseur 1 pour distribuer l huile du four che 17 Remplir Huile de fourche avant Une nouvelle fois jusqu au sommet du four...

Страница 522: ...oil up to the top of the outer tube and bleed the front forks 20 Measure Oil level left and right a Out of specification Adjust For EUROPE NOTE Be sure to install the spring guide 2 when checking the...

Страница 523: ...le guide 2 de ressort lors de la v rification du niveau d huile AVERTISSEMENT Toujours veiller ce que le niveau d huile se situe entre les rep res de niveau maximum et minimum et ce que le niveau d h...

Страница 524: ...e amount of turning out the fully turned in posi tion 23 Install Cushion rubber 1 Washer 2 Spacer 3 To front fork cap bolt 4 NOTE Install the cushion rubber with its smaller dia end a facing the front...

Страница 525: ...niture en caoutchouc 1 Rondelle 2 Entretoise 3 Au bouchon de tube de fourche 4 N B Installer la garniture en caoutchouc avec le c t de plus faible diam tre a face au bouchon de tube de fourche 24 Mont...

Страница 526: ...pecified torque 27 Install Front fork cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt T R 29 Nm 2 9 m kg 21 ft lb 28 Install Protector guide 1 Installation 1 Install Front fork 1 NOTE T...

Страница 527: ...hon de tube de fourche 1 Sur le fourreau N B Serrer le bouchon de tube de fourche de quelques tours T R 29 Nm 2 9 m kg 21 ft lb 28 Monter Guide de protection 1 Montage 1 Monter Fourche avant 1 N B Ser...

Страница 528: ...holder 1 Bolt brake hose holder 2 Protector 3 Bolt protector 4 NOTE When installing the brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brak...

Страница 529: ...le haut a du collet de flexible de frein et le bas du support de flexible de frein b Faire passer ensuite le flexible de frein 5 devant la noix d arbre c et l ins rer dans la rai nure de flexible d de...

Страница 530: ...lever holder 1 3 Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to REMOVAL POINTS 7 Throttle cable cap 1 8 Throttle cable 2...

Страница 531: ...lindre de frein 1 Se reporter POINTS DE DEPOSE 7 Couvercle du logement de c ble des gaz 1 8 C ble des gaz 2 pouss 1 D connecter du c t acc l rateur 9 C ble des gaz 1 tir 1 D connecter du c t acc l rat...

Страница 532: ...ake master cylinder cap side horizontal to prevent air from coming in EC5B3200 Grip 1 Remove Grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has bec...

Страница 533: ...frein l horizon tale pour emp cher toute p n tra tion d air Poign e 1 D poser Poign e 1 N B Souffler de l air entre le guidon ou le guide de tube et la poign e Enlever ensuite la poign e quand elle a...

Страница 534: ...the handlebar 2 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the left grip to the handlebar so that the line b between the two ar...

Страница 535: ...sur la surface du guidon a avec du diluant de peinture Fixer la poign e gauche sur le guidon de sorte que la ligne b entre les deux fl ches soit dirig e vers le haut 3 Monter Poign e droite 1 Colleret...

Страница 536: ...guide 2 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 6 Install Throttle cable cap 1 Screw throttle cable cap 2 WARNING After tightening the...

Страница 537: ...dans le guide de tube 6 Monter Couvercle de logement de c ble des gaz 1 Vis couvercle de logement de c ble des gaz 2 AVERTISSEMENT Apr s avoir serr les vis v rifier que la poign e des gaz 3 tourne sa...

Страница 538: ...hot starter lever holder 5 Clamp 6 NOTE The engine stop switch clutch lever holder and clamp should be installed according to the dimensions shown Pass the engine stop switch lead in the mid dle of t...

Страница 539: ...tall s en respectant les dimensions indiqu es Faire passer le fil du commutateur d arr t du moteur au centre du support d embrayage T R 9 Nm 0 9 m kg 6 5 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0...

Страница 540: ...5 44 CHAS HANDLEBAR 12 Clamp the clamp portion a of the num ber plate to the handlebar 13 Insert the end of the fuel tank breather hose 1 into the hole of the number plate...

Страница 541: ...f hren 12 Fixer la partie de fixation a de la plaque de num ro au guidon 13 Introduire l extr mit de la durit de mise l air du r servoir de car burant 1 dans le trou de la pla que de num ro 12 Bloccar...

Страница 542: ...r removal Hold the machine by placing the suitable stand under the engine Number plate Handlebar Cable guide Front fender Refer to HANDLEBAR section 1 Steering stem nut 1 2 Front fork 2 Refer to FRONT...

Страница 543: ...pla ant un support appropri sous le moteur Plaque de num ro Guidon Guide de c ble Garde boue avant Se reporter la section GUIDON 1 Ecrou de colonne de direction 1 2 Fourche avant 2 Se reporter la sect...

Страница 544: ...t fall down Steering nut wrench YU 33975 90890 01403 Lower bearing 1 Remove Lower bearing 1 Use the floor chisel 2 ACHTUNG CAUTION Take care not to damage the steering shaft thread EC563400 Ball race...

Страница 545: ...75 90890 01403 Roulement inf rieur 1 D poser Roulement inf rieur 1 Utiliser un burin 2 ATTENTION Veiller ne pas endommager le file tage de l arbre de direction Cage billes 1 D poser Cage billes 1 Enle...

Страница 546: ...on in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Lower bearing 1 NOTE Apply the lithium soap base grease on the dust seal lip an...

Страница 547: ...nter Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint antipous si re et sur la circonf rence interne du roulement 2 Monter Cage billes Roulement sup rie...

Страница 548: ...ve the steering stem assembly and inspect the steering bearings 6 Install Front fork 1 Upper bracket 2 NOTE Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper brack...

Страница 549: ...ter les roulements de direction 6 Monter Fourche avant 1 T sup rieur 2 N B Serrer les boulons de bridage t inf rieur provisoirement Ne pas encore serrer les boulons de bridage t sup rieur 7 Monter Ron...

Страница 550: ...upper bracket 1 Pinch bolt lower bracket 2 ACHTUNG CAUTION Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction T R 23 Nm 2 3 m kg 17 ft lb T R...

Страница 551: ...idage t sup rieur 1 Boulon de bridage t inf rieur 2 ATTENTION Resserrer le t inf rieur au couple sp cifi S il est trop serr la fourche avant pourrait mal fonctionner T R 23 Nm 2 3 m kg 17 ft lb T R 20...

Страница 552: ...falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Rear brake caliper Bolt brake pedal Drive chain Refer to FRONT BRAKE AND REAR BRA...

Страница 553: ...Das Motorrad am Motor aufbocken Bremsschlauch Halterung Bremssattel hinten Schraube Fu bremshebel Antriebskette Siehe unter VORDER UND HINTERRAD BREMSE Den Fu bremshebel zur ckklappen 1 Antriebsketten...

Страница 554: ...necting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil se...

Страница 555: ...age du bras de relais Organisation de la d pose Ordre Nom de pi ce Qt Remarques DEMONTAGE DU BRAS OSCILLANT 1 Capuchon 2 2 Bras relais 1 3 Bielle 1 4 Collerette 2 5 Bague d tanch it 2 6 Roulement de b...

Страница 556: ...ce EC574210 Relay arm 1 Inspect Bearing polylube bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Bearing polylube bearing 1 Loss of solid lub...

Страница 557: ...llerette 2 Jeu rotation irr guli re rouille Remplacer la fois le roule ment et la collerette 2 Contr ler Roulement roulement poly lube 1 Perte de lubrification solide Remplacer Bague d tanch it 3 Endo...

Страница 558: ...free With polylube bearings no grease nipple and regular lubrication is necessary However grease should be applied to all oil seals and collars when removed or installed EC575000 ASSEMBLY AND INSTALL...

Страница 559: ...les colliers et joints huile doi vent n anmoins tre graiss s lorsqu ils sont retir s ou install s REMONTAGE ET MONTAGE Roulement et bague d tanch it 1 Monter Roulement 1 Bague d tanch it 2 Sur le bra...

Страница 560: ...sulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings a 5 mm 0 20 in Installed depth of bea...

Страница 561: ...ndeur d installation des roulements a 5 mm 0 20 in Profondeur d installation des roulements a 5 mm 0 20 in Bras oscillant 1 Monter Bague 1 Roulement de but e 2 Bague d tanch it 3 Collerette 4 Sur le b...

Страница 562: ...elay arm 2 Washer 3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the molybdenum disulfide...

Страница 563: ...Ecrou bras relais 4 Sur le bras oscillant N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon Ne pas resserrer l crou ce stade 6 Monter Bras oscillant 1 Arbre de pivot 2 N B Appliquer...

Страница 564: ...et 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 53 Nm 5 3 m kg 38 ft lb 10 Tighten Nut connecting rod 1...

Страница 565: ...ade 9 Monter Boulon amortisseur arri re bras de relais 1 Ecrou amortisseur arri re bras de relais 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon T R 53 Nm 5 3 m kg 38 ft lb 10 S...

Страница 566: ...er 4 Nut lower chain tensioner 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support r 50 mm 1 97 in 3 Nut drive chain support 4 Bolt driv...

Страница 567: ...cle de support de cha ne de transmission 2 Boulon support de cha ne de transmission r 50 mm 1 97 in 3 Ecrou support de cha ne de transmission 4 Boulon couvercle de support de cha ne de transmission r...

Страница 568: ...engine WARNING Support the machine securely so there is no danger of it falling over Seat and fitting band Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST P...

Страница 569: ...T ET CACHES LATERAUX du CHAPITRE 4 Silencieux Se r f rer la section TUYAU D ECHAPPEMENT ET SILENCIEUX du CHAPITRE 4 1 Bride raccord de filtre air 1 Desserrer uniquement 2 Cadre arri re 1 3 Boulon amor...

Страница 570: ...5 59 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 9 Upper spring guide 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to REMOVAL POINTS 2...

Страница 571: ...2 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 9 Oberer Federsitz 1 10 Feder Federbein 1 11 Lager 2 Siehe unter AUSBAU 2 AMORTISSEUR ARRIERE FEDERBEIN AMMORTIZZATORE POSTERIORE Portata del...

Страница 572: ...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 contact surface of t...

Страница 573: ...fonctionnement 4 Prendre garde ne pas rayer la surface de contact de la tige du piston avec le cylindre l huile pourrait fuir 5 Ne jamais essayer d enlever le plot situ au bas du r servoir azote Il es...

Страница 574: ...E Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear...

Страница 575: ...ROLE Amortisseur arri re 1 Contr ler Tige d amortisseur 1 D form e endommagement Remplacer le combin ressort amortisseur Amortisseur 2 Fuite d huile Remplacer le combin ressort amortisseur Fuite de ga...

Страница 576: ...ause it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it con...

Страница 577: ...lement 2 Monter Bague d arr t roulement sup rieur 1 N B Apr s avoir install la bague d arr t repousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter Roulement inf rieur 1 N B Monter le...

Страница 578: ...urn the adjuster beyond the maximum or minimum setting 4 Tighten Locknut 1 Rear shock absorber 1 Install Dust seal 1 O ring 2 Collar 3 NOTE Apply the molybdenum disulfide grease on the bearing Apply t...

Страница 579: ...crou 1 Longueur de ressort mont a Longueur stan dard Etendue de r glage 248 mm 9 76 in 260 mm 10 24 in 240 5 258 5 mm 9 47 10 18 in 255 5 273 5 mm 10 06 10 77 in Amortisseur arri re 1 Monter Joint ant...

Страница 580: ...rear shock absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 N...

Страница 581: ...r le boulon T R 56 Nm 5 6 m kg 40 ft lb 5 Monter Boulon amortisseur arri re bras de relais 1 Ecrou amortisseur arri re bras de relais 2 N B Appliquer de la graisse de molybd ne sur le boulon T R 53 Nm...

Страница 582: ...on coil 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue EC612000 WIRING DIAGRAM 7 1 5 6 2 3 4 B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P P B...

Страница 583: ...ES 1 Couper circuit du moteur 2 Capteur de papillon des gaz 3 Contacteur de point mort 4 Magn to CDI 5 Bougie 6 Bobine d allumage 7 Bloc CDI CODE DE COULEUR B Noir Br Brun G Vert L Bleu O Orange P Ros...

Страница 584: ...CDI unit as a throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the throttle p...

Страница 585: ...ns le microprocesseur du bloc CDI Bobine d excitation Rep re le nombre de tours effectu s par le rotor et entre la valeur dans le microprocesseur du bloc CDI Bloc CDI Les valeurs obtenues du capteur d...

Страница 586: ...tion und sendet ein Drosselklap pen ffnungssignal an den CDI Z ndbox Mikroprozessor Impulsgeber berwacht den Impulsgeber Rotor und sendet ein Motordrehzahlsi gnal an den CDI Z ndbox Mikroprozessor CDI...

Страница 587: ...pertura della valvola a farfalla Bobina pickup Rileva i giri del rotore ed invia al computer nell unit CDI i segnali dei giri del motore Unit CDI I segnali del sensore di posizione della valvola a far...

Страница 588: ...ollowing special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark plug Check entire ignitio...

Страница 589: ...r de l outil sp cial suivant Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler toutes connexions du syst me d allumage raccords fils et bobine d allu mage R parer ou remplacer Cont...

Страница 590: ...chtanlage auf einwandfreie Verbin dungen berpr fen Steckverbinder Kabel und Z ndspule Erneuern oder instand setzen Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuer...

Страница 591: ...la YM 34487 Tester dell accensione 90890 06754 Tester tascabile YU 3112 C 90890 03112 Test della distanza tra gli elettrodi Pulire o sostituire la candela Controllare il collegamento dell intero siste...

Страница 592: ...Minimum spark gap 6 0 mm 0 24 in COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spar...

Страница 593: ...FILS ET BOBINE D ALLUMAGE 1 Contr ler Connexion de coupleurs et fils Rouille poussi re jeu court cir cuit R parer ou remplacer Bobine d allumage et bougie telles quelles Ins rer la bobine d allumage j...

Страница 594: ...ication Replace 3 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of speci...

Страница 595: ...de la bougie c Us Remplacer CONTROLE DU VOLANT MAGNE TIQUE 1 V rifier R sistance de bobine d excita tion Hors sp cification Rempla cer Fil de multim tre Borne de bougie 1 Fil de multim tre Fil orange...

Страница 596: ...ad Black lead 2 Charging coil 2 resistance Tester selector position 44 66 at 20 C 68 F 10 W R Br G P B 2 1 2 1 2 1 W R Br G P B 2 1 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No contin...

Страница 597: ...e charge 2 Position de s lecteur de multim tre 44 66 20 C 68 F 10 CONTROLE DU CONTACTEUR DE POINT MORT 1 V rifier Continuit du contacteur de point mort Pas de continuit quand au point mort Remplacer C...

Страница 598: ...e the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Check entire ignition system for connection Repair or...

Страница 599: ...ans ce d pistage des pannes V rifier la connexion de tout le syst me d allumage R parer ou remplacer V rifier le capteur de papillon des gaz Bobine du cap teur de papillon des gaz Remplacer V rifier l...

Страница 600: ...berpr fen Erneuern oder instand setzen Den Drosselklappen Positi onssensor pr fen Drosselklap pen Positions sensor Spule Erneuern Den CDI Schwungrad Magnetz nder pr fen Prim rspule Erneuern Die CDI Ei...

Страница 601: ...n questa ispezione Tester tascabile YU 3112 C 90890 03112 Contagiri induttivo YU 8036 B Contagiri motore 90890 03113 Controllare il collegamento dell intero sistema di accensione Riparare o sostituire...

Страница 602: ...TION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace THROTTLE POSITION SENSOR COIL INSPECTION 1 Inspect Throttle position sensor coil resistance Out of specif...

Страница 603: ...p cifications Rempla cer Fil de multin tre Fil bleu 1 Fil de multin tre Fil noir 2 Fiche rapide de fil de capteur de position de papillon des gaz Position du s lecteur de l appareil de contr le 4 6 k...

Страница 604: ...or position Full closed Full opened k 1 Zero 3 k at 20 C 68 F 4 6 k at 20 C 68 F THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1 Remove Throttle position sensor coupler Screw throttle position s...

Страница 605: ...B Desserrer les vis capteur de papillon des gaz l aide d un embout T25 2 Remplacer Capteur de papillon des gaz 3 Installer Capteur de papillon des gaz 1 Vis capteur de papillon des gaz 2 N B Aligner l...

Страница 606: ...erproof function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 7 Start the engine Tester lead Yellow lead 3...

Страница 607: ...er le moteur Fil de l appareil de contr le Fil jaune 3 Fil de l appareil de contr le Fil noir 4 8 R gler la tension de sortie du TPS tapes de r glage R gler l angle de montage du TPS 1 pour obtenir la...

Страница 608: ...N SENSOR INPUT VOLTAGE INSPECTION 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input voltage Out of specification Replace the CDI unit Tester...

Страница 609: ...capteur de papillon des gaz Hors sp cifications Rempla cer le bloc CDI Fil de multin tre Fil bleu 1 Fil de multin tre Fil noir bleu 2 Tensiond entr e du capteur de papillon des gaz Position du s lecte...

Страница 610: ...best possi ble carburetor setting NOTE It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to make fut...

Страница 611: ...r glages de carbura teur ult rieurs il est utile de conserver toutes les donn es c d les r glages correspondant aux diverses conditions atmosph riques conditions du terrain les temps etc AVERTISSEMENT...

Страница 612: ...ed starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carb...

Страница 613: ...e des gaz fonctionne correctement Conditions atmosph riques et r glages de carburateur La densit de l air c d la concen tration d oxyg ne dans l air d ter mine la richesse ou la pauvret de l mulsion a...

Страница 614: ...3 4 Main system The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel even at full load Use the main jet and the...

Страница 615: ...p d un gicleur principal primaire Ce type de gicleur principal convient parfaitement au motos de course dans la mesure o il uniformise le d bit d essence m me plein rendement R gler le carburateur en...

Страница 616: ...t The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eratio...

Страница 617: ...mulsion air essence pleine ouverture des gaz Une mulsion air essence trop riche ou trop pauvre provoquera une perte de puissance du moteur et par cons quent une mauvaise acc l ration Effets du change...

Страница 618: ...l flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num...

Страница 619: ...usine afin de maximiser le flux de carburant petite ouverture des gaz Avant de r gler la vis de ralenti la visser tout fait et compter le nombre de tours n cessaires Noter ce chiffre car il s agit du...

Страница 620: ...the engine will not pick 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...

Страница 621: ...uille redescende 2 Trop pauvre des vitesses inter m diaires Le moteur crachote et acc l re trop lentement Il faut enrichir l mulsion en abaissant d un cran le clip d accrochage de l aiguille afin de r...

Страница 622: ...lable with different straight portion diameters Standard jet needle OBELP OBEKP Example OBELP 4 Clip position Diameter a of straight portion Effects of changing the jet needle refer ence Diameter of t...

Страница 623: ...de la partie droite diff rent selon les aiguilles Aiguille standard OBELP OBEKP Exemple OBELP 4 Position du clip Diam tre a de la par tie droite Effets du changement d aiguille r f rence Diam tre de...

Страница 624: ...re Example 100 90 2 Rough engine operation is felt in quick throttle opening Select a leak jet having higher calibrating No than standard to lean out the mixture Example 100 110 Standard leak jet 100...

Страница 625: ...ouverture rapide du papillon S lectionner un gicleur de fuite ayant un plus petit N de calibre que le gicleur standard pour r duire le m lange Exemple N 100 N 110 Gicleur de fuite standard N 100 Rappo...

Страница 626: ...MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Jet needle Rich STD Lean OBELL OBELM OBELN OBELP OBELQ OBELR OBELS 5NL 14916 EL 5NL 14916 EM 5NL 14916 EN 5NL...

Страница 627: ...14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Aiguille Riche Standard Pauvre OBELL OBELM OBELN OBELP OBELQ OBELR OBELS 5NL 14916 EL 5NL 14916 EM 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1...

Страница 628: ...op Check that the accelerator pump oper ates smoothly except for rich mixture symptom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet ne...

Страница 629: ...pe d acc l ration sauf sympt me d un m lange trop riche Emulsion riche Remonter la position du clip d aiguille 1 cran plus haut Ouverture de 1 4 3 4 Crachotements Pas de puissance Abaisser la position...

Страница 630: ...an numeriert Pr fen ob die Beschleunigungspumpe korrekt arbeitet au er bei fettem Gemisch Fettes Gemisch D sennadel Clip Position erh hen 1 Nut h her 1 4 3 4 Gas Schweres Atmen Drehzahl unzureichend D...

Страница 631: ...a agevolmente tranne in caso di sintomi di miscela ricca Miscela ricca Alzare la posizione del fermaglio a graffa del getto di 1 scanalatura Valvola a farfalla a 1 4 3 4 Respirazione difficoltosa Manc...

Страница 632: ...matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determin...

Страница 633: ...onn et il faudra en sacrifier quelques uns Il convient de r gler la machine en fonction de la partie la plus importante du circuit Effectuer des essais et noter les temps pour les diff rentes parties...

Страница 634: ...re Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact with...

Страница 635: ...surface boueuse sablonneuse ou glis sante r duire la pression des pneus pour une meilleure adh sion sur le ter rain Sur route pav e ou sur surface dure augmenter la pression des pneus afin d viter les...

Страница 636: ...ear the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produce a noise at...

Страница 637: ...sent une certaine pression dans ses mains ou son corps De m me un niveau d huile trop lev produira rapidement un bouchon d huile entra nant une r duction de la course de la fourche et une d t rioratio...

Страница 638: ...3 2 adjustment washers Standard washer quantity Zero adjustment washers Extent of adjustment Zero 2 adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be eas...

Страница 639: ...emplace ment La suspension arri re influence les r gla ges de la fourche avant il convient donc d quilibrer l arri re et l avant de la machine la position etc avant d effec tuer les r glages 1 Ressort...

Страница 640: ...ecome weaker resulting in lack of a sense of contact with the road surface or in a vibrating handlebar To set a stiff spring Change the rebound damping Turn in one or two clicks Change the compression...

Страница 641: ...on de contact avec la sur face de la route ou un guidon nage R glage d un ressort dur R gler la force de rebond Visser d un ou deux d clics R gler la force de compression D visser d un ou deux d clics...

Страница 642: ...proved on the end of the spring TYPE thickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 380 0 390 0 400 0 410 0 420 4SS 23141 10 4SS 23141 20...

Страница 643: ...se trouve l extr mit du ressort TYPE paisseur Num ro de pi ce T 2 3 mm 0 09 in 4SS 23364 L0 Type Cons tante du ressort Num ro de pi ce de ressort Rep re fentes MOU 0 380 0 390 0 400 0 410 0 420 4SS 2...

Страница 644: ...ing EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender holding...

Страница 645: ...ntre le centre de l axe de roue arri re et le boulon de fixation du garde boue arri re 2 Retirer le support ou le bloc et mesurer avec une personne assise correctement sur la selle la longueur b entre...

Страница 646: ...ength sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Set the soft spring for less rebound damping to compensate for its less spring load Run with the rebound damping adjuster one o...

Страница 647: ...ensuite selon ses pr f rences 2 Ressort dur R gler le ressort dur de sorte ce que la force de rebond soit plus lev e afin de compenser la charge du ressort plus grande Rouler apr s avoir viss le dispo...

Страница 648: ...e the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider wei...

Страница 649: ...er un amortisseur dont la longueur totale est sup rieure la longueur standard Ressort recommand en fonction du poids Poids du motocycliste 1 Mou 2 Standard 3 Dur Longueur standard a d amatisseur arri...

Страница 650: ...22212 00 5UN 22212 10 Brown 1 Green 1 260 260 STD 4 7 5UN 22212 20 Red 1 260 STIFF 4 9 5 1 5 3 5 5 5 7 5UN 22212 30 5UN 22212 40 5UN 22212 50 5UN 22212 60 5UN 22212 70 Black 1 Blue 1 Yellow 1 Pink 1...

Страница 651: ...22212 20 Rouge 1 260 DUR 4 9 5 1 5 3 5 5 5 7 5UN 22212 30 5UN 22212 40 5UN 22212 50 5UN 22212 60 5UN 22212 70 Noir 1 Bleu 1 Jaune 1 Rose 1 Blanc 1 260 260 260 260 260 Type Cons tante du res sort appr...

Страница 652: ...ssion damping Oil level oil amount Spring Turn adjuster clockwise about 2 clicks to increase damping Increase oil level by about 5 10 mm 0 2 0 4 in Replace with stiff spring Stiff toward stroke end Oi...

Страница 653: ...dragging Rebound damping Spring Turn adjuster counterclockwise about 2 clicks to decrease damping Replace with soft spring Poor road gripping Rebound damping Low compression damping High compression...

Страница 654: ...uilles d une montre de 2 d clics pour augmenter l amortissement Augmenter le niveau d huile d environ 5 10 mm 0 2 0 4 in Monter un ressort dur Dur en fin de course Niveau d huile quantit d huile R dui...

Страница 655: ...d clics pour r duire l amortissement Monter un ressort doux Mauvaise tenue de route Force de rebond Amortissement basse com pression Amortissement haute com pression Longueur de ressort Ressort Tourn...

Страница 656: ...d lmenge Feder Einsteller um etwa 2 Rasten im Uhrzeigersinn dre hen um die D mpfungskraft zu erh hen lstand um etwa 5 10 mm erh hen H rtere Feder einbauen Hart gegen Ende des Federwegs lstand lmenge l...

Страница 657: ...teller um etwa 2 Rasten gegen den Uhrzeiger sinn drehen um die D mpfungskraft zu verringern Weichere Feder einbauen Schlechte Fahrbahn haftung Zugstufend mpfung Tiefdruckd mpfung Hochdruckd mpfung Fed...

Страница 658: ...so orario circa 2 scatti per aumentare lo smorzamento Aumentare il livello dell olio di circa 5 10 mm 0 2 0 4 in Sostituire con una molla rigida Rigida verso la fine della corsa Livello dell olio quan...

Страница 659: ...registro in senso antiorario circa 2 scatti per ridurre lo smorzamento Sostituire con una molla morbida Scarsa presa sulla strada Smorzamento di espansione Smorzamento di compressione bassa Smorzamen...

Страница 660: ......

Страница 661: ......

Страница 662: ...PRINTED IN JAPAN 2002 07 1 5 1 CR E F G H PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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