Yamaha YZ125(T)/T1, Owner'S Service Manual

Page 1: ...OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 T T1 1C3 28199 30...

Page 2: ...RVICE MANUAL 2004 by Yamaha Motor Co Ltd 1st Edition May 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Print...

Page 3: ...maha Motor Co Ltd 1 Ausgabe Mai 2004 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet G...

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4: ...please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yama ha dealer w PLEASE READ T...

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

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

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

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

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

Page 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...

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

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

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

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

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

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

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

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

Page 19: ...EIN ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHINSCHE DATEN REGELM SSIGE PR FUNG UND EINSTELLUNGEN MOTORE MOTEUR MOTOR TELAIO PARTIE CYCLE FAHRGESTELL PARTE ELETTRICA PARTIE ELECTR...

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

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

Page 22: ...RY DRIVEN GEAR 4 30 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 37 YPVS GOVERNOR 4 45 WATER PUMP 4 48 CDI MAGNETO 4 52 ENGINE REMOVAL 4 56 CRANKCASE AND CRANKSHAFT 4 61 TRANSMISSION SHIFT CAM AND S...

Page 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 37 REGULATEUR YPVS 4 45 POMPE A EAU 4 48 MAGNETO CDI 4 52 DEPOSE DU MOTEUR 4 56 CARTER ET VILEBREQUIN 4 61 BOITE A VITESSES BARILLET DE SELECTEUR ET FOUR...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 12...

Page 25: ...FAHRGESTELL 7 12 CHAPITRE 6 PARTIE ELECTRIQUE COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 SYSTEME D ALLUMAGE 6 2 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 12 CAPITOLO 6 PARTE ELETTRICA C...

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

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

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

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

Page 30: ...m 9Water pump housing hole at the bottom 9End of each hose 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They incl...

Page 31: ...re 9 Apertura dell alloggiamento della pompa dell acqua dal lato inferiore 9 Estremit di ciascun tubo flessi bile 2 Usare utensili e apparecchiature di pulitura adeguati Consultare la sezione UTENSILI...

Page 32: ...lt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward...

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

Page 34: ...ould be inspected carefully be fore reassembly Always replace piston pin clips after one use Replace distorted cir clips When installing a circlip 1 make sure that the sharp edged corner 2 is position...

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

Page 36: ...check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect 9Connector NOTE The two connectors click together 7 Check for conti...

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

Page 38: ...1189 90890 01189 Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto YU 1235 90890 01235 Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tig...

Page 39: ...p bolt wrench YM 01500 90890 01500 This tool is used to loosen or tighten the base valve YM 01501 90890 01501 Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the dampe...

Page 40: ...i s YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose du volant magn tique YM 1189 90890 01189 YU 1235 90890 01235 Outil de poign e de rotor Cet o...

Page 41: ...7 90890 06754 ACC QUICK GS KT 90890 85505 Outil de poign e d brrayage Cet outil est utilis pour immobiliser l embrayage quand on d pos ou monte l crou de fixation de la noix d embrayage Testeur d tinc...

Page 42: ...ehwerkzeug Dieses Werkzeug wird f r den Ausbau des Schwung rad Magnetz nders ben tigt YM 1189 90890 01189 YU 1235 90890 01235 Rotor Haltewerkzeug Dieses Werkzeug wird f r das L sen und Festziehen der...

Page 43: ...890 85505 Kupplung Haiterwerkzeug Dieses Werkzeug wird f r das Festhalten der Kupp lung verwendet wenn die Kupplungsnaben Befesti gungsmutter aus oder eingebaut wird Dynamischen Z ndfunkenpr fer Z ndu...

Page 44: ...Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 01189 YU 1235 90890 01235 Utensile di supporto del rotore Quepsile viene usato quando si allenta o s...

Page 45: ...90 06754 ACC QUICK GS KT 90890 85505 Utensile per tenere la frizione Questo utensile viene usato per tenere la frizione quan do si toglie o si installa il dado di fissaggio del mozzo della frizione Te...

Page 46: ...AL The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick...

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

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

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

Page 50: ...15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it w 9Never apply additional force to the side stand 9Remove this sidestand before starti...

Page 51: ...chlauch eingebaut dD Bei diesem Einbau ist darauf zu achten da der Pfeil auf den Kraft stofftank und nach unten weist IC15R001 CAVALLETTO STACCABILE Questo cavalletto 1 viene usato per supportare solt...

Page 52: ...ine or higher octane grade cC Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl...

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

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

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

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

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

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

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

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

Page 61: ...oscillant Arri re Installation de De l amortisseur au cadre l amortisseur Arri re Installation du bras oscillant Serrage de l arbre de pivot Roue Installation de la roue Avant Serrage de l axe avant...

Page 62: ...terradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradshcwinge Rad Einbau des Rades Vorne Festziehen der Vorderachse Festziehen...

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

Page 64: ...of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have re sulted from improper high pressure deter gent applications such as those available in coin operated car...

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

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

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

Page 68: ...ed 2 stroke gasoline Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 4 36 lmp oz 4 19 US oz Bore Stroke 54 54 5 mm 2 126 2 146 in Compression ratio 8 6 10 7 1 Starting syste...

Page 69: ...1 095 Chassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 25 5 25 6 Trail 104 mm 4 09 in 107 mm 4 21 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Ti...

Page 70: ...0 093 in End gap installed 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Side clearance installed 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Crankshaft Crank width A 55 90 55 95 mm 2 201 2 203 in Ru...

Page 71: ...S MIKUNI I D mark 1C31 00 1C32 10 Main jet M J 410 430 Jet needle clip position J N 6CHY5 80 4 Cutaway C A 4 0 Pilot jet P J 40 Pilot air screw P A S 2 1 4 Valve seat size V S 3 8 mm 0 15 in Starter j...

Page 72: ...1 2 0 2 1 4 Air filter joint clamp M 4 0 7 1 2 0 2 1 4 Air filter case M 6 1 0 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 4 0 4 2 9 Read valve M 3 0 5 6 1 0 1 0 7 Throttle cable adjust bolt and loc...

Page 73: ...m kg ft lb Exhaust pipe M 6 1 0 2 12 1 2 8 7 Exhaust pipe stay front M 6 1 0 1 12 1 2 8 7 Exhaust pipe stay rear M 6 1 0 1 12 1 2 8 7 Silencer M 6 1 0 2 12 1 2 8 7 Fiber silencer M 6 1 0 2 10 1 0 7 2...

Page 74: ...pacity 430 cm3 435 cm3 15 1 Imp oz 15 3 Imp oz 14 5 US oz 14 7 US oz Oil grade Suspension oil S1 Inner tube outer diameter 48 mm 1 89 in Front fork top end 5 mm 0 2 in Rear suspension USA CDN ZA EUROP...

Page 75: ...0 12 in 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc...

Page 76: ...lder M 6 1 0 2 7 0 7 5 1 Throttle cable cap M 4 0 7 2 1 0 1 0 7 Front brake master cylinder and bracket M 6 1 0 2 9 0 9 6 5 Brake lever bolt M 6 1 0 1 6 0 6 4 3 nut M 6 1 0 1 6 0 6 4 3 Brake lever pos...

Page 77: ...Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame and frame upper M 8 1 25 1 32 3 2 23 Rear frame and frame lower M 8 1 25 2 29 2 9...

Page 78: ...neto model stator Manufacturer 1C300 YAMAHA Source coil 1 resistance color 720 1 080 at 20 C 68 F Green White Black Red Source coil 2 resistance color 44 66 at 20 C 68 F Black Green Blue Pickup coil r...

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

Page 80: ...Type de moteur 2 temps essence refroidissement liquide Dispositions de cylindres Monocylindre inclin Cylindr e 124 cm3 4 36 lmp oz 4 19 US oz Al sage course 54 54 5 mm 2 126 2 146 in Taux de compress...

Page 81: ...ZA AUS NZ EUROPE CDN Type de cadre Simple berceau d d double Angle de chasse 25 5 25 6 Chasse 104 mm 4 09 in 107 mm 4 21 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Taill...

Page 82: ...en coupe B 1 0 mm 0 039 in T 2 35 mm 0 093 in Ecartement des becs mont 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Jeu lat ral mont 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Vilebrequin Largeur d...

Page 83: ...38SS MIKUNI Marque d identification 1C31 00 1C32 10 Gicleur principal M J 410 430 Aiguille J N 6CHY5 80 4 Echancrure C A 4 0 Gicleur de ralenti P J 40 Vis d air de ralenti P A S 2 1 4 Taille de si ge...

Page 84: ...tre air M 4 0 7 1 2 0 2 1 4 Carter de filtre air M 6 1 0 4 8 0 8 5 8 Bride de guidage de filtre air M 5 0 8 1 4 0 4 2 9 Clapets d admission M 3 0 5 6 1 0 1 0 7 Boulon de r glage et contre crou M 8 1 2...

Page 85: ...appement M 6 1 0 2 12 1 2 8 7 Support de tuyau d chappement avant M 6 1 0 1 12 1 2 8 7 Support de tuyau d chappement arri re M 6 1 0 1 12 1 2 8 7 Silencieux M 6 1 0 2 12 1 2 8 7 Fibre silencieux M 6 1...

Page 86: ...3 435 cm3 15 1 Imp oz 15 3 Imp oz 14 5 US oz 14 7 US oz Grade d huile Huile de suspension S1 Diam tre ext rieur de tube interne 48 mm 1 89 in Extr mite sup rieure de fourche avant 5 mm 0 2 in Suspensi...

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

Page 88: ...5 0 8 2 4 0 4 2 9 Capuchon de ma tre cylindre de frein avant M 4 0 7 2 2 0 2 1 4 Boulon d union de tuyau de frein avant M10 1 25 1 30 3 0 22 ma tre cylindre Boulon d union de tuyau de frein avant tri...

Page 89: ...23 Cadre arri re et cadre inf rieur M 8 1 25 2 29 2 9 21 Bras oscillant et support de tuyau de frein M 5 0 8 4 1 0 1 0 7 Bras oscillant et garniture M 4 0 7 4 2 0 2 1 4 Montage de tendeur de cha ne M...

Page 90: ...stator Fabricant 1C300 YAMAHA R sistance de bobinage de source 1 720 1 080 20 C 68 F couleur vert blanc noir rouge R sistance de bobinage de source 2 44 66 20 C 68 F couleur noir vert bleu R sistance...

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

Page 92: ...art Wassergek hlter Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorne geneigt Hubraum 124 cm3 4 36 lmp oz 4 19 US oz Bohrung Hub 54 54 5 mm 2 126 2 146 in Verdichtungsverh ltnis 8 6 10 7 1 Anla s...

Page 93: ...6 Gang 23 21 1 095 Fahrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheifenrahmen Nachlauf 25 5 25 6 Nachlaufbertrag 104 mm 4 09 in 107 mm 4 21 in Reifengr e Bauart Mit Schlauch Reifengr...

Page 94: ...0 039 in T 2 35 mm 0 093 in Ringenspalt Eingebaut 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Seitliches Spiel Eingebaut 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Kurbelwelle Kurbelwangenbreite 55...

Page 95: ...IKUNI Identifikationsmarkierung 1C31 00 1C32 10 Hauptd se M J 410 430 D sennadel Klemmposition J N 6CHY5 80 4 Abschr gung C A 4 0 Leerlaufd se P J 40 Leerlauf Luftregulierschraube P A S 2 1 4 Vertilsi...

Page 96: ...uftfilter Verbindungsklammer M 4 0 7 1 2 0 2 1 4 Luftfiltergeh use M 6 1 0 4 8 0 8 5 8 Luftfilter F hrungsschelle M 5 0 8 1 4 0 4 2 9 Zungenventil M 3 0 5 6 1 0 1 0 7 Gaszug Einstellschraube und Siche...

Page 97: ...1 0 2 12 1 2 8 7 Auspuffrohrst tze Vorne M 6 1 0 1 12 1 2 8 7 Auspuffrohrst tze Hinten M 6 1 0 1 12 1 2 8 7 Schalld mpfer M 6 1 0 2 12 1 2 8 7 Fasereinsatz Schalld mpfer M 6 1 0 2 10 1 0 7 2 HINWEIS...

Page 98: ...oz 14 5 US oz 14 7 US oz lsorte Teleskopgabel l S1 Au endurchmesser des inneren Rohres 48 mm 1 89 in Oberes Ende der 5 mm 0 2 in Vorderradgabelbeinrohre Hinterradaufh ngung USA CDN ZA EUROPA AUS NZ H...

Page 99: ...12 in 9 84 0 10 in Bremsbelagst rke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder 11 0 mm 0 433 in Innendurchmesser Bremssattelzylinder 27 0 mm 1 063 in 2 Innendurchmesser Bremsfl ssigkeit DOT 4 H...

Page 100: ...Vorderrad Hauptbremszylinderkappe M 4 0 7 2 2 0 2 1 4 Vorderrad Bremsschlauch Unionschraube M10 1 25 1 30 3 0 22 Hauptbremszylinder Vorderrad Bremsschlauch Unionschraube Bremssattel M10 1 25 1 30 3 0...

Page 101: ...errad Sto d mpfer und Relaisarm M10 1 25 1 53 5 3 38 Hintere Rahmen und Rahmen Ober M 8 1 25 1 32 3 2 23 Hintere Rahmen und Rahmen Unter M 8 1 25 2 29 2 9 21 Hinterradschwinge und Bremsschlauchhalter...

Page 102: ...Stator Hersteller 1C300 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 bei 20 C 68 F Gr n Wei Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 bei 20 C 68 F Schwarz Gr n Blau Widerstand der Au...

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

Page 104: ...pi raffreddato con liquido a benzina Disposizione dei cilindri Cilindro unico inclinato in avanti Cilindrata 124 cm3 4 36 lmp oz 4 19 US oz Alesaggio corsa 54 54 5 mm 2 126 2 146 in Rapporto di compre...

Page 105: ...pia Angolo di incidenza 25 5 25 6 Avancorsa 104 mm 4 09 in 107 mm 4 21 in Pneumatico Tipo Con camera d aria Dimensioni anteriore 80 100 21 51M Dimensioni posteriore 100 90 19 57M Pressione degli pneum...

Page 106: ...0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Gioco laterale installata 0 035 0 070 mm 0 1 mm 0 004 in 0 0014 0 0028 in Albero a gomiti Larghezza del gomito A 55 90 55 95 mm 2 201 2 203 in Limite di scen...

Page 107: ...KUNI Marchio ID 1C31 00 1C32 10 Getto principale M J No 410 No 430 Posizione della staffa dell ago di getto J N 6CHY5 80 4 Sezione C A 4 0 Getto pilota P J No 40 Vite dell aria pilota P A S 2 1 4 Dime...

Page 108: ...etto del giunto del filtro dell aria M 4 0 7 1 2 0 2 1 4 Corpo del filtro dell aria M 6 1 0 4 8 0 8 5 8 Brida di guida del filtro dell aria M 5 0 8 1 4 0 4 2 9 Valvola a lamella M 3 0 5 6 1 0 1 0 7 Bu...

Page 109: ...M 8 1 25 1 30 3 0 22 Tubo di scarico M 6 1 0 2 12 1 2 8 7 Puntello del tubo di scarico anteriore M 6 1 0 1 12 1 2 8 7 Puntello del tubo di scarico posteriore M 6 1 0 1 12 1 2 8 7 Silenziatore M 6 1 0...

Page 110: ...5 1 Imp oz 15 3 Imp oz 14 5 US oz 14 7 US oz Qualit di olio Olio per sospensioni S1 Diametro esterno del tubo interno 48 mm 1 89 in Estremit superiore della forcella anteriore 5 mm 0 2 in Sospensione...

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

Page 112: ...incipale del freno anteriore M 4 0 7 2 2 0 2 1 4 Bullone di unione del tubo flessibile del freno M10 1 25 1 30 3 0 22 anteriore cilindro principale Bullone di unione del tubo flessibile del freno ante...

Page 113: ...illante e supporto del tubo flessibile M 5 0 8 4 1 0 1 0 7 del freno Forcellone oscillante e superficie di contatto M 4 0 7 4 2 0 2 1 4 Supporto del tendicatena M 8 1 25 2 19 1 9 13 Supporto della cat...

Page 114: ...Costruttore del magnete 1C300 YAMAHA Resistenza 1 della bobina di origine 720 1 080 20 C 68 F colore Verde Bianco Nero Rosso Resistenza 2 della bobina di origine 44 66 20 C 68 F colore Nero Verde Blu...

Page 115: ...nti dovrebbero essere a temperatura am biente A Distanza fra le parti piatte B Diametro esterno della filettatura IC230000 DEFINIZIONE DELLE UNIT IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA SPEC...

Page 116: ...to the hole in the steering shaft cap C Align the throttle cable locating tape with the cable guide D Pass through the cable guide the throttle cable ENGINE STOP button lead and clutch cable E Pass th...

Page 117: ...des gaz sur le guide du c ble Faire passer dans guide de c ble le c ble des gaz le fil du bouton ENGINE STOP et le c ble d embrayage Faire passer le c ble des gaz et le c ble d embrayage au dessus de...

Page 118: ...engine bracket to the inside of the downtube K Clamp the C D I magneto lead radiator breather hose and Y P V S breather hose L Clamp to the frame the C D I magneto lead and radiator breather hose M Pa...

Page 119: ...vers l int rieur du tube descen dant Brider le fil du volant magn tique C D I la durit de mise l air du radiateur et la durit de mise l air Y P V S Brider sur le cadre le fil du volant magn tique C D...

Page 120: ...the frame the ENGINE STOP button lead and C D I magneto lead Clamp them in front of the radi ator fitting boss C Clamp to the frame the throttle cable clutch cable and ignition coil lead D Pass the C...

Page 121: ...E STOP et le fil du volant magn tique C D I Brider ces fils devant le bossage de montage du radiateur Brider au cadre le c ble des gaz le c ble d embrayage et le fil de la bobine d allu mage Faire pas...

Page 122: ...ec tion on the caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion...

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

Page 124: ...inder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Clamp the ENGINE STOP button lead to the handlebar to 3 clicks D Pass the brake hose in front of the number plate and thro...

Page 125: ...ide 8 Guide de c ble Istaller la tuyau de frein de mani re que la partie avec le tuyau soit dirig e comme indipu et touche l g rement la saillie sur le ma trecylindre Faire passer le fil de bouton d a...

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

Page 127: ...spect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER After Inspect and adjus...

Page 128: ...3 3 INSP ADJ MEMO...

Page 129: ...nger 6 CULASSE Contr ler et nettoyer 6 6 Resserrer 6 6 CYLINDRE Cont ler et nettoyer 6 6 Changer 6 YPVS Contr ler et nettoyer 6 6 EMBRAYAGE Contr ler et r gler 6 6 Changer 6 BOITE DE VITESSE Changer l...

Page 130: ...es pivots 6 6 Contr ler la surface du frein disque 6 6 Contr ler le niveau de fluide et les fuites 6 6 Resserrer les boulons du frein disque les boulons d tier les boulons du ma tre cylindre et les bo...

Page 131: ...le roulement 6 PNEU ROUES Contr ler la pression de gonflage le voile de roue et l usure des 6 6 pneus et voir s il n y a pas de rayon d tendu Resserrer les boulons de la roue 6 6 dent e Contr ler les...

Page 132: ...uern 6 ZYLINDERKOPF Pr fen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Pr fen und reinigen 6 6 Erneuern 6 YPVS Pr fen und reinigen 6 6 KUPPLUNG Pr fen und einstellen 6 6 Erneuern 6 GETRIEBE l wechseln 6...

Page 133: ...en 6 6 KRAFTSTOFFTANK KRAFT STOFFHAHN Reinigen und pr fen 6 6 BREMSEN Bremshebelposition und Bremspedalh he einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfl che pr fen 6 6 Fl ssigkeitsstand pr...

Page 134: ...iehen 6 6 Reinigen und schmieren 6 Lager erneuern 6 R DER REIFEN Reifendruck Felgenschlag Reifenverschlei und Speichen 6 6 auf Lockerung pr fen Ketternrad Befestigungsschraube 6 6 nachziehen Lager pr...

Page 135: ...6 Sostituzione 6 YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sostituzione dell olio 6 6 Ispezione 6 Sostituzione del cuscinetto 6 FORCELLA DEL CAMBI...

Page 136: ...6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pulitura e lubrificazione 6 6 GUIDA DEL DISPOSITIVO DI PROTEZIONE Sostituzione 6 AMMORTIZZAT...

Page 137: ...per motori SAE 10W 30 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneumatico e dell allentamento delle razze Riserraggio bullone del rocche...

Page 138: ...ar brake P3 17 23 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 24 26 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excess...

Page 139: ...ne Contr ler la tension et l alignement de la cha ne S as surer que la cha ne est graiss e correctement P3 24 26 Roues Contr ler s il n y a pas d usure excessive Contr ler s il n y a pas de rayons d t...

Page 140: ...usrichtung pr fen Auch sicherstellen da die Kette richtig geschmiert P3 24 26 ist R der Die Reifen auf berm ige Abnutzung kontrollieren Speichern auf Lockerung und berm iges Spiel pr P3 34 35 fen Lenk...

Page 141: ...della frizione e dell acceleratore si muovano senza problemi Controllare che non rimanga no impigliati quando viene girato il manubrio o quando le forcelle anteriori si alzano e si abbassano Controll...

Page 142: ...p slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise an...

Page 143: ...diateur et tourner lentement le bouchon gauche jusqu au point de d tente Cette proc dure permet de faire tom ber toute pression r siduelle Quand le sifflement s est arr t appuyer sur le bouchon tout e...

Page 144: ...ain the coolant completely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Rec...

Page 145: ...n schizzi sulle superfici ver niciate Se schizza toglierlo con acqua 1 Collocare un contenitore sotto il motore 2 Togliere 9 Bullone di scarico del liquido refrigerante 1 3 Togliere 9 Tappo del radiat...

Page 146: ...el low Add coolant EC355000 RADIATOR CAP INSPECTION 1 Inspect 9Seal radiator cap 1 9Valve and valve seat 2 Crack Damage Replace Exist fur deposits 3 Clean or replace Handling notes of coolant The cool...

Page 147: ...it Wasser und danach mit Seife weg oder auswaschen 9Falls K hlmittel eingenom men wird Die betroffene Person sofort zum Erbre chen bringen und zum n ch sten Doktor begleiten Notes concernant la manipu...

Page 148: ...res sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01...

Page 149: ...kunden gehalten werden Erneuern VERIFICATION DE LA PRESSION D OUVERTURE DU BOUCHON DU RADIATEUR 1 Attacher 9 Testeur du bouchon du radiateur 1 et adaptateur 2 N B Appliquer de l eau sur le joint du bo...

Page 150: ...specification Adjust NOTE 9Before adjustment expose the adjuster by moving the boot 3 and cap 4 away 9Make minute adjustment on the lever side using the adjuster 5 9After adjustment check proper opera...

Page 151: ...pararlo o sostituirlo 9 Manicotto flessibile del radiatore 3 Rigonfiamento Sostituirlo IC359020 REGOLAZIONE DELLA FRIZIONE 1 Controllare 9 Gioco libero della leva di comando della frizione a Fuori spe...

Page 152: ...en the locknut 1 9Turn the adjuster 2 until the specified free play is obtained 9Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted w After...

Page 153: ...9 Desserrer le contre crou 1 9 Tourner le dispositif de r glage 2 jusqu ce que le jeu soit compris dans les limites sp cifi es 9 Serrer le contre crou N B Avant de r gler le jeu de c ble de la command...

Page 154: ...ine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove 9Seat 9Fitting bolt 1 9Washer 2 9Air filter elem...

Page 155: ...ten w rden n mlich Staub und Schmutz in den Motor eindringen und schnellen Verschlei sowie m glichen Motorschaden verursa chen 1 Ausbauen 9 Sitz 9 Befestigungsschraube 1 9 Scheibe 2 9 Luftfilterelemen...

Page 156: ...le b in air filter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on filte...

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

Page 158: ...9Remove the oil check bolt 1 9Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level w Never attempt to remove the oil check bolt just after high speed...

Page 159: ...oteur le laisser chauffer quelques minutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en pla ant le support convenable sous le moteur 3 Placer un...

Page 160: ...ansmission oil level 9 Install 9Oil filler cap 2 EC35L002 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Recommended oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Oil capacity periodic...

Page 161: ...e 2 Das Getriebe l ablassen 5 Einbauen 9 Aluminiumscheibe 9 labla schraube 1 Emphohlenes l Yamalube 4 10W 30 oder Motor l SAE 10W 30 SE l Fassungsverm gen Regelm iger lwech sel 0 66 L 0 58 Imp qt 0 69...

Page 162: ...lace NOTE Install the O rings with their depressed a facing outward EC35R050 SILENCER FIBER REPLACEMENT 1 Remove 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adjustment steps 9Loosen t...

Page 163: ...alld mpfer 1 9 Schalld mpfer 2 9 Schraube Fasereinsatz 3 IC35R050 SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE 1 Togliere 9 Copertura laterale destra 9 Bullone silenziatore 1 9 Silenziatore 2 9 Bullone f...

Page 164: ...3 9Side cover right 12 Nm 1 2 m kg 8 7 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 1215 or equivalent as shown Quick gasket ACC Q...

Page 165: ...rne N B Appliquez g n reusement de l agent d tanch it Quick Gasket Yamaha Bond n 1215 ou quivalent comme illustr 2 Ausbauen 9 Innenrohr 1 3 Erneuern 9 Fasereinsatz 2 4 Einbauen 9 Innenrohr HINWEIS Qui...

Page 166: ...a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed s...

Page 167: ...der Bremsanlage Es kann zu einer gef hrlichen Abnahme des Bremsverm gens kommen falls die Bremsanlage nicht richtig entl ftet ist 1 Ausbauen 9 Hauptbremszylinderkappe 9 Membrane 9 Schwimmer im Beh lte...

Page 168: ...rocedure when the tiny bubbles in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever positi...

Page 169: ...le circuit de freinage NOTA Se lo spurgo risulta difficoltoso pu essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le...

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

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

Page 172: ...r its end 9Loosen the bleed screw and push the caliper piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 7 and pad pin NOTE 9Install the brake pads wit...

Page 173: ...r cken dD Die abgelassene Bremsfl ssig keit nicht wiederverwenden 9 Die Entl ftungsschraube festzie hein 9 Bremsbel ge 7 und Bremsbelag plattenstift einbauen HINWEIS 9 Bremsbel ge mit deren ber st nde...

Page 174: ...REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect 9Brake pad thickness a Out of specification Replace as a set 2 Replace 9Brake pad 9Install the pad pin plug 0 Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb B...

Page 175: ...mando del freno Sensazione di morbidezza o spugnosit Spurgare impianto frenante Consultare la sezione SPURGO DELL ARIA DALL IMPIANTO FRENANTE IC366060 ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FREN...

Page 176: ...projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper w and rear wheel e Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 9Tighten...

Page 177: ...r le tuyau transparent 8 la vis de purge 9 et placer le r cipient appropri sous son extr mit 9Desserrer la vis de purge et y enfoncer le piston d trier fF Ne pas r utiliser le liquide de frein purg 9S...

Page 178: ...linder so that its top is in a horizontal position 2 Inspect 9Brake fluid level Fluid at lower level Fill up a Lower level Front Rear w 9Use only designated quality brake fluid to avoid poor brake per...

Page 179: ...LO DEL LIQUIDO PER FRENI 1 Collocare il cilindro principale in maniera tale che la sua parte supe riore si trovi in posizione orizzon tale 2 Ispezionare 9 Livello del liquido per freni Fluido a livell...

Page 180: ...ease its tension 9Measure the length between drive chain roller 1 and y as shown 9Perform this measurement at two or three dif ferent places 2 Remove 9Master link clip 9Joint 1 9Drive chain 2 3 Clean...

Page 181: ...e L nge zwischen der Antriebsket tenrolle 1 und y wie dargestellt messen 9 Diese Messung an zwei oder drei verschiedenen Stellen durchf hren IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei...

Page 182: ...lutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 48 58 mm 1 9 2 3 in Drive chain lubr...

Page 183: ...ell anello principale nella direzione illustrata a Direzione di rotazione 6 Lubrificare 9 Catena di trasmissione 5 Monter 9 Cha ne de transmission 1 9 Raccord 2 9 Agrafe de l attache rapide 3 fF Veill...

Page 184: ...3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain...

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

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

Page 187: ...eau de fourche interne et le cache poussi re 2 Nettoyer 9 Joint antipoussi re a 9 Bague d tanch it b N B 9Nettoyer le joint antipoussi re et la bague d tanch it apr s chaque cour se 9Appliquer la grai...

Page 188: ...DAMPING FORCE ADJUSTMENT 1 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression...

Page 189: ...re il dispositivo di regolazione 1 1 in senso normale Pi morbido b b Diminuire la forza di smorza mento della com pressione Ruo tare il dispositivo di regolazione 1 1 in senso inverso REGLAGE DE LA FO...

Page 190: ...damaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smooth action Ab...

Page 191: ...mmager XG Toujours r gler la m me position sur chaque bras de fourche avant Un r glage in gal peut entra ner une mauvaise maniabilit et une perte de stablilit VERIFICATION DE L AMOR TISSEUR ARRIERE 1...

Page 192: ...ster before adjustment 9The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster cC Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten 9Locknu...

Page 193: ...ore inferiore REGLAGE DE LA PRECON TRAINTE DE RESSORT DE L AMORTISSEUR ARRIERE 1 Sur lever la roue arri re en pla ant la cale appropri e sons le moteur 2 D poser 9 Cadre arri re 3 Desserrer 9 Contre c...

Page 194: ...turned in posi tion Which align the punch mark a on the ad juster with the punch mark b on the bracket cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may b...

Page 195: ...gler 9 Force d amortissement de rebond En tournant le dispositif de r glage 1 EINSTELLUNG DER EXPANSIONS D MPFUNGSKRAFT DES HINTER RAD STOSSD MPFERS 1 Einstellen 9 Expansions D mpfungskraft Durch Dre...

Page 196: ...align the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may...

Page 197: ...SD MPFERS 1 Einstellen 9 Niedrige Kompressions D mp fungskraft Den Einsteller 1 drehen IC36c000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare...

Page 198: ...ion Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged...

Page 199: ...rehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzamento ad alta compressione Ruotando il dispositivo di rego lazion...

Page 200: ...its position on the rim 9If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect 9S...

Page 201: ...lo pneumatico scivola fuori dalla sua posizione sul cerchione 9Se si trova inclinato il gambo della valvola dello pneumatico si ritiene che lo pneumatico stia scivolando fuori dalla sua posizione Corr...

Page 202: ...st steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring nut adjustment steps 9Remove the num...

Page 203: ...la re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellschritte der Lenkring mutter 9 Das Nummernschild entfernen 9 Die Lenkstange und die Lenker krone entfernen 9 Die Ringmutter 1 mit...

Page 204: ...The upper handlebar holder should be installed with the punched mark a forward 9Install the handlebar so that the marks b are in place on both sides 9Insert the end of the fuel breather hose e into th...

Page 205: ...o iI Serrare dapprima i bulloni sul lato anteriore del supporto del manubrio e poi serrare i bulloni sul lato posteriore 9Desserrer l crou annulaire d un tour 9Resserrer l crou annulaire l aide de la...

Page 206: ...ot 5 Throttle to handlebar contact 6 Drive chain 7 Throttle roller sliding surface 8 Tube guide cable winding portion 9 Throttle cable end 0 Clutch cable end Use Yamaha cable lube or equivalent on the...

Page 207: ...rimento del rullo della valvola a farfalla 8 Parte a spira del cavo di guida del tubo 9 Estremit del cavo dell acceleratore 0 Estremit del cavo della frizione A Usare lubrificante per cavi Yamaha o eq...

Page 208: ...eds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4...

Page 209: ...chiaro Colore nettamente diverso Controllare le condizioni del motore NOTA Quando il motore gira per molte ore a bassi regimi l isolatore della candela diventa fuligginoso anche se il motore e il carb...

Page 210: ...hen this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rot...

Page 211: ...sem Punkt stoppt die Anzeigenadel der Me uhr und ndert ihre Bewegungsrichtung wenn der Rotor in der gleichen Richtung weitergedreht wird 4 Im oberen Totpunkt ist die Me uhr auf Null zu stellen 5 Aus d...

Page 212: ...SP ADJ 7 Adjust 9Ignition timing Adjustment steps 9Loosen the screws stator 1 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator 9Tighten the screws stator Screw s...

Page 213: ...ben Stator 1 l sen 9 Die K rnermarkierung an dem Rotor mit der K rnermarkierung an dem Stator 2 ausrichten indem der Stator bewegt wird 9 Die Schrauben Stator festziehen Passi della regolazione 9Allen...

Page 214: ...el tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers r...

Page 215: ...schild 1 MOTOR SITZ KRAFTSTOFFTANK UND SEITENDECKEL Ausbauumfang 1 Ausbau des Sitzes 2 Ausbau des Kraftstofftanks 3 Ausbau der Seitendeckel 4 Ausbau des Nummernschildes IC400000 MOTORE IC4R0000 SELLA...

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

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

Page 218: ...AND removal SIDE COVERS section 1 Bolt silencer 2 2 Silencer 1 3 Collar D 10 5 mm 0 41 in 1 4 Collar D 10 0 mm 0 39 in 1 5 Grommet front 1 6 Grommet rear 1 7 Tension spring 2 8 Bolt exhaust pipe 2 9...

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

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

Page 221: ...LLA SERBATOIO DEL CARBURANTE E COPERTURE LATERALI 1 Pannello 2 2 Brida manicotto flessibile del radiatore 1 3 2 Soltanto allentamento 3 Manicotto flessibile del radiatore 2 1 4 Radiatore sinistro 1 5...

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

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

Page 224: ...CABLE ROUTING DIAGRAM section in the CHAPTER 2 3 Install 9Radiator left 1 9Plain washer 2 9Bolt radiator left 3 9Radiator hose 2 4 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Tighten 9Cl...

Page 225: ...la section CHE MINEMENT DES CABLES du CHAPITRE 2 4 Serrer 9 Bride tuyau du radiateur 1 3 5 5 Monter 9 Panneau 1 9 Boulon panneau 2 N B Ajustez d abord le crochet a sur la partie int rieure du radiateu...

Page 226: ...eparation for Fuel tank Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Clamp carburetor joint 2 Loosen the screws carburetor joint 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly...

Page 227: ...r 1 3 Vergaserverbindung 1 4 Zungenventil 1 5 Anschlag Zungenventil 2 6 Zungenventil 2 VERGASER UND ZUNGENVENTIL Ausbauumfang 1 Ausbau des Vergasers 2 Ausbau des Zungenventils IC460000 CARBURATORE E V...

Page 228: ...hamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Needle jet cover 1 7 Float pin 1 8 Float 1 9 Valve seat 1 0 Main jet 1 q Main jet holder 1...

Page 229: ...er 1 6 Nadeld sendeckel 1 7 Schwimmerstift 1 8 Schwimmer 1 9 Ventilsitz 1 0 Hauptd se 1 q Hauptd senhalter 1 w Leerlaufd se 1 e Starter Plungerkolben 1 r Drosselanschlagschraube 1 t Leerlauf Luftregul...

Page 230: ...able 5 NOTE While compressing the spring throttle valve disconnect the throttle cable EC464000 INSPECTION EC464140 Carburetor 1 Inspect 9Carburetor body Contamination Clean cC When cleaning the main a...

Page 231: ...N Carburateur 1 Examiner 9 Corps du carburateur Encrass Nettoyer fF Lors du nettoyage du conduit d air principal a a ne pas diriger le souffle d air comprim du c t du filtre car cela risque d obstruer...

Page 232: ...air or replace NOTE Insert the throttle valve 1 into the carburetor body and check for free movement EC464401 Jet needle 1 Inspect 9Jet needle 1 Bends Wear Replace 9Clip groove Free play exists Wear R...

Page 233: ...und auf freie Bewegung kontrollieren D sennadel 1 Pr fen 9 D sennadel 1 Biegung Verschlei Erneu ern 9 Klemmnut Spiel vorhanden Verschlei Erneuern 9 Klemmposition Pointeau 1 Examiner 9 Pointeau 1 9 Si...

Page 234: ...retor and fuel level gauge ver tically when measuring the fuel level 9If the fuel level is not within specification in spect the valve seat and needle valve 9If either is worn replace them both 9If bo...

Page 235: ...ivello del car burante tenere verticali il carbura tore e l indicatore di livello del car burante 9Se il livello del carburante non rientra nella specifica ispezionare la sede della valvola e la valvo...

Page 236: ...alve 3 NOTE 9Install the reed valve with the reed valve bend ing as shown 9Note the cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping Valve stopp...

Page 237: ...auteur de la but e de soupape b Horssp cification R gler changer la but e de clapet REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 But e soupape flexible 2 9 Vis soupape flexibl...

Page 238: ...rburetor joint 2 EC4652C2 Carburetor 1 Install 9Throttle stop screw 1 9Locknut 2 9Pilot air screw 3 Pilot air screw 2 1 4 turns out Note the following installation points 9Screw in the pilot air screw...

Page 239: ...1 Installare 9 Vite di arresto della valvola a farfalla 1 9 Controdado 2 9 Vite dell aria pilota 3 10 Nm 1 0 m kg 7 2 ft lb Die folgeden Einbaupunkte beachten 9 Die Leerlauf Luftregulierschrau be ein...

Page 240: ...nstall 9Needle valve 1 9Float 2 9Float pin 3 9Screw float pin 4 9Needle jet cover 5 NOTE 9After installing the needle valve to the float in stall them to the carburetor 9Check the float for smooth mov...

Page 241: ...gicleur aiguilles 5 N B 9Apr s avoir install le pointeau sur le flotteur les installer sur le carbura teur 9V rifier que le flotteur bouge en dou ceur 3 Einbauen 9 Hauptd senhalter 1 9 Hauptd se 2 9...

Page 242: ...oove b in the needle holder 7 8 Install 9Mixing chamber top 1 9Screw mixing chamber top 2 To carburetor 3 NOTE After installing check the throttle grip for smooth movement 9 Install 9Air vent hose 1 9...

Page 243: ...e carburateur 3 N B Apr s avoir r alis le montage v rifier que l attache des gaz se d place sans coup 7 Installare 9 Cavo dell acceleratore 1 9 Controdado 2 9 Parte superiore del diffusore 3 9 Molla v...

Page 244: ...er joint 1 9Bolt carburetor joint 2 3 Clamp 9Air vent hose 1 9Overflow hose 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Adjust 9Idle speed Refer to IDLE SPEED ADJUSTMENT section in the...

Page 245: ...bo flessibile di sfiato dell aria 1 9 Tubo flessibile di troppopieno 2 Consultare la sezione DIA GRAMMA DEL PASSAGGIO DEI CAVI al CAPITOLO 2 4 Regolare 9 Numero di giri al minimo Consultare la sezione...

Page 246: ...AUST PIPE AND SILENCER section Radiator Refer to RADIATOR section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 5 Loosen each nut 1 4 turn and remove them after all nuts are loosened 4 Cylinde...

Page 247: ...bis alle Muttern locker sind 4 Zylinderkopf 1 5 Leistungsventilgeh use 1 6 Schubstange 1 Siehe unter AUSBAUPUNKTE 7 Mutter Zylinder 4 8 Zylinder 1 ZYLINDERKOPF ZYLINDER UND KOLBEN ZYLINDERKOPF UND ZYL...

Page 248: ...er to REMOVAL POINTS 4 Small end bearing 1 5 Piston ring 1 6 Power valve cover 1 7 Thrust plate 1 8 Bolt link lever 1 9 Valve holder 1 10 Valve shaft 1 11 Collar 2 12 Link lever 1 13 Spring 2 14 Power...

Page 249: ...ube Verbindungshebel 1 9 Ventilhalterung 1 10 Ventilwelle 1 11 H lse 2 12 Verbindungshebel 1 13 Feder 2 14 Leistungsventil 1 1 15 Leistungsventil 2 1 KOLBEN UND LEISTUNGSVENTIL Ausbauumfang 1 Ausbau d...

Page 250: ...n rag to prevent the pis ton pin clip from falling into the crankcase cav ity 2 Remove 9Piston pin 1 9Piston 2 9Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin h...

Page 251: ...et la r gion du trou de l axe Si l axe de piston est encore difficile enlever alors que sa gorge est d calami n e utiliser l extracteur d axe de piston 4 fF Ne pas utiliser de marteau pour chas ser l...

Page 252: ...ge measurement and re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur face the cylinder head...

Page 253: ...ineal 1 und Einstell Lehre 2 anbringen 9 Die Verwerfungsgrenze messen 9 Wenn die Verwerfung nicht den erforderlichen Ma en entspricht Zylinderkopffl che bearbeiten 9 Ein feuchtes Sandpapier 3 Feinheit...

Page 254: ...urface Score marks Repair or replace Use 400 600 grit wet sandpaper cC Do not rebore the cylinder 3 Measure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C...

Page 255: ...N B Mesurer l al sage de cylindre C en parall le A B C et angle droit du vilebrequin a b Ensuite faire la moyenne des mesures Piston 1 liminer 9 D p ts de calamine De la couronne de piston a et des ra...

Page 256: ...ston pin 1 is in place in the piston 2 There should be no noticeable for the play Free play exists Replace piston pin and or piston 4 Install 9Small end bearing 9Piston pin Into the small end of conne...

Page 257: ...de bielle 1 Examiner 9 Axe de piston 9 Coussinet de pied de bielle Signes de d coloration par la chaleur Changer 2 Mesurer 9 Diam tre ext rieur d axe de pis ton Utiliser le microm tre 1 Hors limite C...

Page 258: ...thickness gauge 1 Out of limit Replace piston and or ring NOTE Check at several points EC474602 Piston clearance 1 Calculate 9Piston clearance Out of limit Replace piston and piston ring and or cylin...

Page 259: ...r une jauge d paisseur 1 Hors limite Changer 3 Mesurer 9 Jeu lat ral Utiliser une jauge d paisseur 1 Hors limite Changer le piston et ou les segments N B V rifier en plusieurs points Jeu de piston 1 C...

Page 260: ...clearance Standard Limit 0 040 0 045 mm 0 1 mm 0 0016 0 0018 in 0 004 in Cylinder mark a a Cylinder size A 54 000 54 002 mm 2 1260 2 1261 in B 54 004 54 006 mm 2 1261 2 1262 in C 54 008 54 010 mm 2 1...

Page 261: ...0018 in 0 004 in Kolbenspiel Kolben markierung a a Kolbengr e farben A rot 53 957 53 960 mm 2 1243 2 1244 in B orange 53 961 53 964 mm 2 1244 2 1246 in C gr n 53 965 53 968 mm 2 1246 2 1247 in D viol...

Page 262: ...Replace 9Spring 6 Broken Replace EC474901 Power valve hole on cylinder 1 Remove 9Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratching the aluminum EC475...

Page 263: ...gsventilbohrung im Zylinder 1 Ausbauen 9 Ru ablagerungen Aus der Leistungsventil Boh rung a HINWEIS Kein scharfkantiges Instrument ver wenden Kratzer auf dem Aluminium vermeiden Clapet de puissance 1...

Page 264: ...se grease on the oil seal lip 3 Install 9Thrust plate 1 9Screw thrust plate 2 4 Check 9Power valve smooth movement Unsmooth movement Repair or replace 5 Install 9Gasket power valve cover 1 9Power valv...

Page 265: ...uen da das Anschlagteil a nach innen gerichtet ist 9 Lithiumseifen Schmierfett auf der ldichtungslippe auftragen 2 Monter 9 Ressort 1 9 Levier articul 2 9 Collerette 3 9 Arbre tiroirs 4 9 Support de s...

Page 266: ...l onto the bearing crank shaft and connecting rod and connecting rod big end washers 9Install the gasket with the seal print side toward the crankcase 3 Install 9Piston 1 9Piston pin 2 9Piston pin cli...

Page 267: ...fermaglio dello spinotto dello stantuffo per evitare di distorcerlo si devono usare le mani 9 9Non lasciare che le estremit aperte del fermaglio a graffa tocchino la fessura del pistone b b Kolbenring...

Page 268: ...t to install the bolt push rod 9Do not forget to remove the collar EC4753A2 Cylinder head and cylinder 1 Apply 9Engine oil To piston 1 piston ring 2 and cylinder surface 2 Install 9Cylinder 1 cC Make...

Page 269: ...einge baut wurde dieses auf glatte Bewe gung pr fen Culasse et cylindre 1 Appliquer 9 Huile du moteur Sur le piston 1 le segment 2 et la surface de cylindre 2 Monter 9 Cylindre 1 fF Veiller positionne...

Page 270: ...ngine bracket 1 9Nut engine bracket 2 9Engine mounting nut upper 3 9 Install 9Spark plug 1 9Spark plug cap 2 28 Nm 2 8 m kg 20 ft lb 34 Nm 3 4 m kg 24 ft lb 34 Nm 3 4 m kg 24 ft lb 20 Nm 2 0 m kg 14 f...

Page 271: ...stungsventil geh use 9 Leistungsventilgeh use 1 9 Schraube Leistungsventil geh use 2 5 Monter 9 Joint bo tier de clapet de puis sance 9 Bo tier de chapet de puissance 1 9 Boulon bo tier de clapet de p...

Page 272: ...Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Press...

Page 273: ...er 6 3 Kupplungsfeder 6 4 Druckscheibe 1 5 Reibscheibe 8 6 Kupplungsscheibe 7 KUPPLUNG UND PRIM RABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und Reibsch...

Page 274: ...7 Nut clutch boss 1 Use special tool 8 Lock washer 1 Refer to REMOVAL POINTS 9 Clutch boss 1 10 Plain washer D 34mm 1 34 in 1 11 Primary driven gear 1 12 Bearing 1 13 Plain washer D 34mm 1 34 in 1 14...

Page 275: ...e D 34 mm 1 34 in 1 14 Schbhebelachse 1 PRIM RABTRIEBSZAHNRAD SHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Pr...

Page 276: ...ON EC484100 Clutch housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free pl...

Page 277: ...ten F r USA und CDN Au er USA und CDN POINTS DE DEPOSE Noix d embrayage 1 D poser 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poign e d emb...

Page 278: ...plate 1 and thickness gauge 2 EC484700 Push lever axle 1 Inspect 9Push lever axle 1 Wear Damage Replace EC484810 Push rod 1 Inspect 9Push rod 1 1 9Bearing 2 9Plain washer 3 9Push rod 2 4 9Ball 5 Wear...

Page 279: ...r chaque disque en quatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors sp cification Changer tous les disques d embrayage Utiliser une plaque surfacer 1 et une jauge d pais...

Page 280: ...il on the bearing spacer and primary driven gear inner circumference 2 Install 9Plain washer D 34 mm 1 34 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding to...

Page 281: ...re 4 N B Appliquer de l huile de bo te de vitesses sur le roulement l entretoise et la circonf rence int rieure du pignon men primaire 2 Monter 9 Rondelle ordinaire D 34mm 1 34 in 1 9 Noix d embrayage...

Page 282: ...ion oil on the friction plates and clutch plates 6 Install 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4 NOTE Apply the lithium soap base grease on the bear ing and plain washer 7 Install 9Pus...

Page 283: ...t en terminant par une plaques de frottement 9Appliquer de l huile de bo te de vitesses sur les disques de friction et disque d embrayage 6 Monter 9 Roulement 1 9 Rondelle ordinaire 2 9 Circlip 3 sur...

Page 284: ...ewl pin 1 9Gasket cluch cover 2 11 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 12 Install 9O ring 1 9Clutch cable 2 NOTE Apply the lithium s...

Page 285: ...n lithium sur le joint torique 10 Installare 9 Grano di centraggio 1 9 Guarnizione coperchio della frizione 2 11 Einbauen 9 Kupplungsdeckel 1 9 Schraube Kupplungsdeckel 2 HINWEIS Die Schrauben stufenw...

Page 286: ...ward Radiator hose 4 Disconnect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosenin...

Page 287: ...c t du moteur Boulon p dal de frein Pousser la p dale de frein vers le bas Tuyau de radiateur 4 D connecter du c t pompe eau Boulon Se reporter la section CULASSE champignon de d brayage CYLINDRE ET...

Page 288: ...1 Kick idle gear 1 2 kick axle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 1 Exten...

Page 289: ...eur au pied 2 D pose de l arbre de s lecteur et du levier de but e Etendue de d pose Ordre Nom de pi ce Q t Remarques DEPOSE DE L AXE DE DEMAR REUR AU PIED ET DE L ARBRE DE SELECTEUR 1 Pignon de renvo...

Page 290: ...orsion spring 2 from the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assembly 2 NOTE The shift lever assembly is disass...

Page 291: ...vilebrequin Ensemble guide de levier de s lecteur 1 D poser 9 Boulon guide de s lecteur 9 Guide de s lecteur 1 9 Ensemble levier de s lecteur 2 N B L ensemble de levier de s lecteur est d mont en m me...

Page 292: ...nd shift lever assembly 1 Inspect 9Shift guide 1 9Shift lever 2 9Pawl 3 9Pawl pin 4 9Spring 5 Wear Damage Replace EC4E4100 Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Roller 2 Rotate...

Page 293: ...che cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de but e 1 Examiner 9 Levier de but e 1 Usure endommagement Changer 9 Rouleau 2 Faites tourner la bague ext rieu re avec le doigt Point dur...

Page 294: ...talling the stopper lever make sure that the torsion spring is in the position as shown EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 2 Install...

Page 295: ...ressort de torsion soit positionn comme illustr Guide de s lecteur et ensemble levier de s lecteur 1 Monter 9 Ressort 1 9 Broche cliquet 2 9 Cliquet 3 Au levier de s lecteur 4 2 Monter 9 Ensemble lev...

Page 296: ...ck axle 4 NOTE Make sure the stopper a of the torsion spring fits into the hole b on the kick axle 2 Install 9Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a in th...

Page 297: ...de d marreur au pied 4 N B S assurer que la but e a du ressort de torsion correspond au trou b sur l axe de d marreur au pied 2 Monter 9 Guide de ressort 1 N B Coulisser la guide de ressort dans l axe...

Page 298: ...the kick idle gear inner circumference EC4C5503 Primary drive gear 1 Install 9Spacer 1 9Primary drive gear 2 9Bolt 3 NOTE Install the primary drive gear with its depressed side toward you 2 Install 9...

Page 299: ...eur au pied Pignon de transmission primaire 1 Monter 9 Entretoise 1 9 Pignon de transmission primaire 2 9 Boulon 3 N B Monter le pignon d attaque de trans mission primaire avec la face renfonc e avers...

Page 300: ...s pattern 7 Install 9Kick starter 1 9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not contact ing the pillar tube 4 8 Install 9Shift pedal 1 9Bolt shift pedal 2 NOT...

Page 301: ...9 Boulon kick starter 3 N B Installer le kick starter le plus pr s pos sible du tube de montant 4 mais de sorte qu il ne le touche pas 8 Monter 9 P dale de s lecteur 1 9 Boulon p dale de s lecteur 2...

Page 302: ...removal PRIMARY DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Co...

Page 303: ...EUR ET PIGNON DE TRANSMISSION 1 Ensemble r gulateur 1 2 Goujon 1 Se reporter POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de but e 2 8 Collerette...

Page 304: ...nspect 9Plain washer 1 9Collar 2 Wear Damage Replace EC4K4200 Bearing 1 Inspect 9Thrust bearing 1 9Plain washer 2 Wear Damage Replace EC4K5000 ASSEMBLY AND INSTALLATION EC4K5120 Governor 1 Install 9Go...

Page 305: ...ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTA GE R gulateur 1 Monter 9 Pignon de r gulateur 1 9 Ressort de compression 2 9 Plaque 3 9 Rondelle ordinaire 4 9 Roulement de but e 5 9 Collere...

Page 306: ...il on the retainer and ball 3 Install 9Dowel pin 1 NOTE 9While compressing the spring install the dowel pin 9Make sure the dowel pin fits into the groove a in the retainer 4 Install 9Governor assembly...

Page 307: ...e 3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9V rifier que le goujon d assemblage est bien ajust dans le gorge a du dispositif d arr t 4 Monter 9 Ensemble r gulateur 1 N B...

Page 308: ...AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 Refer to REMOVAL POINTS 4 Plain washer 1 5 Impeller shaft assembly 1 6 Bearing 1 Refer to REMO...

Page 309: ...UR AU PIED ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSON 1 Couvercle de bo tier de pompe eau 1 2 Pignon de l axe de rotor 1 3 Goujon 1 Se reporter POINTS DE DEPOSE 4 Rondelle plain 1 5 Ensemble d axe de...

Page 310: ...coolant leaks out from the water pump housing hole at the bottom 9Do not reuse the removed bearing and oil seal 1 Remove 9Bearing 1 2 Remove 9Oil seal outside 1 9Oil seal inside 2 EC4G4000 INSPECTION...

Page 311: ...ent s coule par l orifice dans le bas du logement de pompe eau 9Ne pas r utiliser le roulement ni la bague d tanch it 1 D poser 9 Roulement 1 2 D poser 9 Bague d tanch it ext rieure 1 9 Bague d tanch...

Page 312: ...00 Oil seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal inside 1 9Oil seal outside 2 NOTE 9Apply the lithium soap base grease on...

Page 313: ...ment Changer REMONTAGE ET MONTAGE Bague d tanch it 1 Monter 9 Bague d tanch it int rieure 1 9 Bague d tanch it ext rieure 2 N B 9Appliquer la graisse base de savon au lithium sur la l vre de la bague...

Page 314: ...impeller shaft assembly And install the shaft while turning it 2 Install 9Plain washer 1 9Dowel pin 2 9Impeller shaft gear 3 9Collar 4 9Plain washer 5 9Circlip 6 NOTE Install the Impeller shaft gear w...

Page 315: ...Rondelle ordinaire 5 9 Circlip 6 N B Monter le pignon de l axe de rotor avec le goujon ins r dans la rainure a du m me pignon 3 Monter 9 Goujon 1 9 Joint couvercle de bo tier de pompe eau 2 4 Monter 9...

Page 316: ...oval SIDE COVERS section Bolt Radiator left Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator...

Page 317: ...ERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil de magn to CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil sp ci...

Page 318: ...01 CDI magneto 1 Inspect 9Rotor inner surface a 9Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key...

Page 319: ...d pin age du vilebrequin et le coussinet vilebrequin Si n cessaire changer le stator et ou le magn to CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET...

Page 320: ...en installing the rotor align the keyway c of the rotor with the woodruff key 3 Install 9Plain washer 1 9Nut rotor 2 Use the rotor holding tool 3 4 Adjust 9Ignition timing Refer to IGNITION TIMING CHE...

Page 321: ...er 9 Avance l allumage Se reporter la section CONTROLE ET REGLAGE DE L AVANCE A L ALLU MAGE du CHAPITRE 3 5 Serrer 9 Vis stator 1 6 Contr ler 9 Avance l allumage Recontr ler l avance l alluma ge 2 Ins...

Page 322: ...o lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a c...

Page 323: ...DE CHEMINEMENT DES CABLES du CHAPITRE 2 8 Monter 9 Joint couvercle de carter gauche 9 Couvercle de carter gauche 1 9 Vis couvercle de carter gauche 2 N B Serrer les vis par tapes em utilisant un mod...

Page 324: ...REED VALVE section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug cap Disconnect the CDI mag...

Page 325: ...et silencier Se reporter la section TUYAU D ECHAPPE MENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR Capuchon de bougie D connecter le fil...

Page 326: ...1 Refer to REMOVAL POINTS 4 Drive sprocket 1 5 Clip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Engine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Refer to REMOVAL POINTS 11 Engine 1 1 26 Nm 2 6...

Page 327: ...1 2 Ecrou pignon d entra nement 1 3 Rondelle frein 1 Se reporter POINTS DE DEPOSE 4 Pignon d entra nement 1 5 Agrafe 1 6 Boulon p dal de frein 1 7 P dale de frein 1 8 Support du moteur 2 9 Boulon de...

Page 328: ...e sprocket 1 9Drive chain 2 NOTE Remove the drive sprocket together with the dri ve chain EC4M3301 Engine removal 1 Remove 9Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm...

Page 329: ...nando il freno posteriore 2 Togliere 9 Rocchetto conduttore 1 9 Catena di trasmissione 2 NOTA Togliere il rocchetto conduttore insieme alla catena di trasmissione IC4M3301 Rimozione del motore 1 Togli...

Page 330: ...he molybdenum disulfide grease on the pivot shaft EC4M5211 Brake pedal 1 Install 9Spring 1 9Brake pedal 2 9O ring 3 9Bolt brake pedal 4 9Clip 5 NOTE Apply the lithium soap base grease on the bolt O ri...

Page 331: ...ein Pignon d entra nement 1 Monter 9 Pignon d entra nement 1 9 Cha ne de transmission 2 N B Monter le pignon d entra nement avec la cha ne de transmission IC4M5000 MONTAGGIO E INSTALLAZIONE IC4M5171 I...

Page 332: ...ck washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 Install 9Chain guide 1 9Chain cover 2 9Screw chain cover 3 5 Nm 0 5 m...

Page 333: ...2 N B Serrer l crou en actionnant le frein arri re 3 Courber la languette de la rendel le frein pour verrouiller l crou 4 Monter 9 Guide cha ne 1 9 Couvercle de cha ne 2 9 Vis couvercle de cha ne 3 2...

Page 334: ...AGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 45 mm 1 77 in 6 3 Bolt L 55 mm 2 17 in 4 4 Bolt L 65 mm 2 56 in 1 5 Bolt L 75 mm 2 95 in 1 6 Holder 1 7 Crankcase right 1 Use special tool 8...

Page 335: ...d AU PIED ARBRE DE SELECTEUR ET PIGNON Levier de but e DE TRANSMISSION Rotor et stator Se reporter la section MAGNETO CDI 1 Segment 1 Se reporter POINTS DE DEPOSE 2 Boulon L 45 mm 1 77 in 6 3 Boulon L...

Page 336: ...one screw may be backed out slightly to level tool body 9As pressure is applied alternately tap on the front engine mounting boss and transmission shafts cC Use soft hammer to tap on the case half Tap...

Page 337: ...oteur et les arbres de transmission fF Utiliser un maillet en plastique et ne taper que sur les portions renforc es du carter Ne pas taper sur les plans de joint Travailler lentement et avec pr cautio...

Page 338: ...rankshaft bearing 1 Remove 9Bearing 1 NOTE 9Remove the bearing from the crankcase by pressing its inner race as shown in 9If the bearing is removed together with the crankshaft remove the bearing usin...

Page 339: ...ebrequin en appuyant de carter int rieure comme indiqu dans 9Si le roulement est enlev en m me temps que le vilebrequin d poser le roulement en utilisant un extracteur de roulement 2 comme indiqu dans...

Page 340: ...with a finger Rough spot Seizure Replace 3 Inspect 9Oil seal 1 Damage Replace EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Cran...

Page 341: ...c 9 Kurbelwangenbreite d Abweichung von Spezifikation Erneuern Die Me uhr und die F hlerleh re verwenden MONTAGE UND EINBAU Kurbelwellenlager 1 Einbauen 9 Lager 1 Am Kurbelgeh use Links und Rechts HI...

Page 342: ...CDN Except for USA and CDN NOTE 9Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft...

Page 343: ...ontage avec l autre Actionner l outil de montage jusqu a ce que le vilebrequin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer une graiss...

Page 344: ...ission operation Unsmooth operation Repair 3 Apply 9Sealant On the crankcase right 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Quick gasket ACC QUICK GS...

Page 345: ...e R paration 3 Mettre 9 Etanch it Sur le carter droit 1 N B Nettoyer la surface de contact des demi carters gauche et droit avant d appliquer l tanch it 4 Monter 9 Goujon 1 9 Joint torique 2 2 Control...

Page 346: ...N NOTE 9Use two plain washers Yamaha genuine 90201 243K3 5 or the ones of a size as shown one on the other Except for USA and CDN 9Install so that the plain washers do not deviate from the crankshaft...

Page 347: ...ingebaut wird sollte die Pleuelstange am OT oberen Totpunkt positioniert sein 9 Beim Einbau berpr fen ob sich die Passh lse in ihrer Position befindet 5 Installare 9 Carter destro 1 Usare l utensile p...

Page 348: ...segment clockwise until it stops and tighten the bolt 9 Remove 9Sealant Forced out on the cylinder mating surface 10 Apply 9Engine oil To the crank pin bearing oil delivery hole and connecting rod bi...

Page 349: ...s aiguilles d une montre jusqu ce qu il s arr te et resserrer le boulon 9 D poser 9 Etanch it Chass e sur le plan de joint du cylindre 10 Mettre 9 Huile moteur Sur le maneton le roulement le trou de r...

Page 350: ...he crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Guide bar long 1 2 Guide bar short 1 3 Shift cam 1 4 Shift fork 3 1 5 Shift fork 1 1 6 Shift fork 2 1 7 Main axle 1 8 Drive axle 1 Refer to RE...

Page 351: ...ILLET DE SELECTEUR ET DE LA FOURCHETTE Moteur Se reporter la section DEPOSE DU MOTEUR S parer le carter Se reporter la section CARTER ET VILEBRE QUIN 1 Barre de guidage longue 1 2 Barre de guidage pet...

Page 352: ...ve 9Remove assembly carefully Note the position of each part Pay particular attention to the lo cation and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect 9Matching dog a 9Gear t...

Page 353: ...oigneusement Noter la position de chaque pi ce Bien faire attention l emplacement et l orientation des fourchettes VERIFICATION Pignons 1 Examiner 9 Crabot d accouplement a 9 Dent de pignon b 9 Gorge...

Page 354: ...ce shift fork and or guide bar NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION EC4H521...

Page 355: ...de gui dage N B En cas de mauvais fonctionnement de la fourchette ne pas changer que la fourchette ellem me mais les deux pignons situ s de chaque c te de la fourchette REMONTAGE ET MONTAGE Bo te vite...

Page 356: ...face of the idler gear and on the inner surface of the sliding gear then install 3 Install 9Plain washer 1 9Circlip 2 NOTE 9Be sure the circlip sharp edged corner a is po sitioned opposite side to the...

Page 357: ...extr mit du pignon libre et sur la surface int rieure du pignon mobile puis les monter 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9V rifier que le cot bord vif du cir clip a soit oppos la rondell...

Page 358: ...ear 5 on the main axle 2 Install 9Shift cam 1 NOTE 9Apply the transmission oil on the shift cam 9Install the shift cam while holding up the 5th wheel gear 2 and keeping the shift fork 1 3 moved in the...

Page 359: ...9Installez la came d inverseur tout en maintenant le 5e pignon 2 et la four chette d inverseur n 1 3 dans le sens de la fl che 3 Monter 9 Barre de guidage petite 1 9 Barre de guidage longue 2 N B 9Ap...

Page 360: ...4 74 ENG TRANSMISSION SHIFT CAM AND SHIFT FORK 4 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair...

Page 361: ...LA DEL CAMBIO 4 Kontrollieren 9 Funktion der Gangschaltung 9 Funktion des Getriebes Ungleichm iger Betrieb Reparieren 4 Contr ler 9 Fonctionnement de s lecteur 9 Fonctionnement de bo te vitesse Foncti...

Page 362: ...3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Exten...

Page 363: ...e 2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Collerette 2 6 Bague d tanch it 2 7 Roulement 2 Se reporter POINTS DE DEPOSE 8 Disque de frein 1 Pr paration pour la d pose XG Bien...

Page 364: ...e removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9...

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

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

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

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

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

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

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

Page 372: ...soap base grease on the wheel axle 6 Install 9Nut wheel axle 1 7 Tighten 9Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several ti...

Page 373: ...re 9 Asse della ruota 1 NOTA Applicare sull asse della ruota il grasso a base di sapone di litio 6 Installare 9 Dado asse della ruota 1 7 Serrare 9 Bullone supporto dell asse 1 NOTA Prima di serrare i...

Page 374: ...g 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made onl...

Page 375: ...onvenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ral droit doit monter premier 9Monter la bague d tanch it avec ses marques ou num ros de fabricant diri g s vers l ext rieur...

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

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

Page 378: ...heel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axle 1 9Locknut...

Page 379: ...N B A ce stage resserrer provisoirement les crous axe de roue 8 Installare 9 Estrattore per catena destro 1 9 Rosetta 2 9 Dado asse della ruota 3 NOTA Serrare temporaneamente il dado asse della ruota...

Page 380: ...n when disassembling the caliper 7 Caliper 1 8 Brake lever 1 9 Master cylinder bracket 1 10 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose re...

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

Page 382: ...3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Caliper 1 Extent of removal 1 Master cylinder...

Page 383: ...1 6 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du d montage de l trier 8 Etrier 1 Pr paration pour la d pose XG...

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

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

Page 386: ...gm 1 3 Reservoir float 1 4 Master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Plain washer 1 7 Push rod 1 8 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear E...

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

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

Page 389: ...IONE IC5A3101 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Coperchio del cilindro principa le 1 9 Dispositivo di protezione NOTA Non togliere il d...

Page 390: ...d dust seals w Replace the piston seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534120 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Sc...

Page 391: ...r les joints de piston et antipoussi re lors d un d montage d trier A Avant B Arri re IC533402 Kit delle guarnizioni di tenuta del pistone 1 Togliere 9 Parapolvere 1 9 Guarnizione di tenuta del pisto...

Page 392: ...B Rear 2 Inspect 9Caliper piston 1 Wear Score marks Replace caliper piston assembly w Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Bra...

Page 393: ...principale A Anteriore B Posteriore IC534214 Pinza 1 Ispezionare 9 Superficie interna del cilindro della pinza a Usura Rigature Sostituire il gruppo pinza A Anteriore B Posteriore 2 Ispezionare 9 Pist...

Page 394: ...and dust seals onto the slot on caliper correctly A Front B Rear 3 Install 9Caliper piston 1 NOTE Apply the brake fluid on the piston wall cC 9Install the piston with its shallow depressed side a a fa...

Page 395: ...oussi re dans la rainure situ e sur l trier A Avant B Arri re IC5A5801 Pistone della pinza 1 Pulire 9 Pinza 9 Guarnizione di tenuta del pisto ne 9 Parapolvere 9 Pistone della pinza Pulirli con liquido...

Page 396: ...d pin at this point 2 Install 9Disc cover 1 9Bolt disc cover 2 2 Install 9Caliper 1 9Bolt caliper 2 3 Tighten 9Pad pin 3 4 Install 9Pad pin plug 4 23 Nm 2 3 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm...

Page 397: ...Bremsschuhaussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 2 Monter 9 Etrier 1 9 Boulon trier 2 3 Serrer 9 Goupille de plaquette 3 4 Monter 9 Bouchon de goupi...

Page 398: ...imary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong...

Page 399: ...du ma tre cylindre doit tre pos e dans la direction indiqu e Une mauvaise intallation enta ne une performance incorrecte du freinage A Avant B Arri re IC5A5220 Kit del cilindro principale 1 Pulire 9...

Page 400: ...ose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mar...

Page 401: ...estziehen 4 Installare Anteriormente 9 Kit del cilindro principale 1 9 Rosetta 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 Posteriormente 9 Kit d...

Page 402: ...t its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 2 Install 9Master cylinder 1 9Bolt master cylinder 2 10 Nm 1 0 m kg 7 2...

Page 403: ...re sempre rondelle in rame nuove iI Installare il tubo flessibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro princip...

Page 404: ...ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Install 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT section in the CHAPTER 3 EC5A5911 Front...

Page 405: ...a wie in der Abbildung gezeigt ange ordnet ist und den berstand b b am Bremsbelag leicht ber hrt 2 Einbauen 9 Bremsschlauchhalter 1 9 Schraube Bremsschlauchhal ter 2 3 Einbauen 9 Bremsschlauchhalter...

Page 406: ...so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb EC5A5502 Rear brake hose 1 Install 9Copper washer 1 9Brake hose 2...

Page 407: ...ibile del freno in modo che la sua parte di tubo a a sia rivolta come illustrato e tocchi leggermente la sporgenza b b sul cilin dro principale Tuyau de frein arri re 1 Monter 9 Rondelle en cuivre 1 9...

Page 408: ...y brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction...

Page 409: ...et un mauvais fonctionnement du frein 9Toujours utiliser la m me marque de liquide de frein Le m lange de liquides de marques diff rentes risque de provoquer une r action chimique nuisible au fonctio...

Page 410: ...iaphragm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Master cylinder cap 1 9Bolt master cylinder cap 2 cC After installation while pulling the lever in or pushing down on the...

Page 411: ...Diaframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale0 2 Posteriormente 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Bullone coperchio del cilindro principa...

Page 412: ...Number plate 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt under bracket...

Page 413: ...guidon 2 Uniquement desserrage 3 Amortisseur complet 1 Desserrer lors du d montage de la fourche avant Utiliser l outil sp cial Se reporter POINTS DE DEPOSE 4 Boulon de bridage trier inf rieur 2 Uniqu...

Page 414: ...REMOVAL POINTS 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 0 Oil seal 1 q Base valve 1 Drain the fork oil Use special tool w Damper assembly 1 Refer to REMOVAL P...

Page 415: ...l sp cial Se reporter POINTS DE DEPOSE 2 Ressort de fourche 1 3 Joint antipoussi re 1 4 Bague d arr t 1 Se reporter POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 M tal de piston 1 8 Bague antif...

Page 416: ...uction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled...

Page 417: ...compl tement les chambres air IC556000 NOTA PER IL MANEGGIO NOTA La forcella anteriore richiede grande at tenzione Si raccomanda pertanto di ef fettuare la manutenzione della forcella anteriore press...

Page 418: ...cC Do not remove the locknut as it may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove 9Dust seal 1 9Stopper ring 2 Using slott...

Page 419: ...atore senza che sia possibile estrarlo Cl bague de boulon capuchon YM 01501 90890 01501 Chiave ad anello per vite mordente YM 01501 90890 01501 Schraubenschl ssel f r Nockenwellenlagerdeckel Schrauben...

Page 420: ...Inspect 9Damper assembly 1 Bend Damage Replace 9O ring 2 Wear Damage Replace cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive t...

Page 421: ...ERIFICATION Amortisseur complet 1 V rifier 9 Amortisseur complet 1 Courbure endommagement Changer 9 Joint torique 2 Us endommag Changer fF La fourche avant ayant une tige de piston incorpor e a une co...

Page 422: ...th a Out of specification Replace EC554502 Inner tube 1 Inspect 9Inner tube surface a Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace 9Inner tube bends Out of...

Page 423: ...mals das innere Gabelbeinrohr ge radebiegen da dadurch die Festigkeit reduziert werden und gef hrliche Situationen hervorrufen k nnte Ressort de fourche 1 Mesurer 9 Longueur libre de ressort de fourch...

Page 424: ...t fork assembly 1 Wash the all parts in a clean solvent 2 Stretch the damper assembly fully 3 Fill 9Front fork oil 1 To damper assembly cC 9Be sure to use recommended fork oil If other oils are used t...

Page 425: ...tizzatore 3 Remplir 9 Huile de fourche 1 Sur l amortisseur complet fF 9Toujours utiliser l huile de fourche recommand Si d autres huiles sont utilis es elles peuvent avoir un effet nuisible sur le ren...

Page 426: ...ched check that the oil is above the step a on the damper assembly Below the step Replenish fork oil above the step 6 Tighten 9Locknut 1 NOTE Fully finger tighten the locknut onto the damper assembly...

Page 427: ...D mpfer Baugruppe berpr fen ob sich das l ber der Stufe a an der D mpfer Bau gruppe befindet Unter der Stufe Gabel l ber die Stufe nachf llen 6 Festziehen 9 Sicherungsmutter 1 HINWEIS Die Sicherungsmu...

Page 428: ...5 34 CHAS FRONT FORK 11 While protecting the damper assembly 1 with a rag and compressing fully allow excessive oil to overflow on the base valve side cC Take care not to damage the damper assembly 12...

Page 429: ...lassen w hrend die D mpfer Baugruppe 1 durch einen Lappen gesch tzt und vollst ndig zusammenge dr ckt wird dD Darauf achten dass die D mpfer Baugruppe nicht besch digt wird 12 Das bersch ssige l an de...

Page 430: ...installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 9Install the oil seal with its manufacture s marks or number facing the axle holder side 9Install the oil sea...

Page 431: ...on de la bague d tanch it utiliser une feuille en vi nyle a avec de l huile de fourche ap pliqu e pour prot ger la l vre de la bague d tanch it 9Installer le joint huile dont les marques d usine ou le...

Page 432: ...ver 3 18 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 19 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 20 Insta...

Page 433: ...Den Gebelbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 19 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren Ro...

Page 434: ...Spacer resin 3 To damper assembly 4 NOTE Install the spacer with the plate a facing the fork spring 24 Install 9Damper assembly 1 To inner tube 2 cC To install the damper assembly into the inner tube...

Page 435: ...stanziatore con la piastri na a rivolta alla molla della forcella 24 Monter 9 Amortisseur complet 1 Au tube interne 2 fF Pour installer l amortisseur complet dans le tube plongeur maintenir l tanch it...

Page 436: ...stalled out of specification proper damping force cannot be obtained 28 Tighten 9Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster with specified torque 29 Install 9Adjuster 1 To inn...

Page 437: ...si zionare la chiave ad anello per vite mordente 7 tra il tubo interno e il controdado 6 9Serrare a fondo con le dita il regolato re sul gruppo ammortizzatore 27 Ispezionare 9 Distanza a tra il regola...

Page 438: ...bolt ring wrench 2 to tighten the damper assembly with specified torque w Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the...

Page 439: ...m kg 22 ft lb 30 Nm 3 0 m kg 22 ft lb XG Ne jamais omettre d ajuster la quan tit d huile entre les rep res de quan tit maximale et minimale et toujours ajuster chaque fourche au m me r glage Un r glag...

Page 440: ...9Front fork top end a Front fork top end standard a a 5 mm 0 20 in 4 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too much...

Page 441: ...rigine 7 R gler 9 Force de compression d amor tissement N B Tourner en serrant la main le r gleur 1 d amortisseur puis r gler la posi tion de r glage d origine 5 Installare 9 Dispositivo di protezione...

Page 442: ...1 Refer to REMOVAL POINTS 5 Throttle cable cap 1 Turn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer...

Page 443: ...rter POINTS DE DEPOSE 5 Capuchon du c ble d acc l rateur 1 Retourner le couvercle de capuchon 6 C ble d acc l rateur 1 D connecter du c t acc l rateur 7 Acc l rateur 1 Desserrer les boulons 8 Couvercl...

Page 444: ...e disassembly Extent of removal Order Part name Q ty Remarks THROTTLE DISASSEMBLY 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to REMOVAL POINTS 5 Tube guide 1 1 EC5B80...

Page 445: ...de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poig e inf rieur 1 2 Capuchon de poig e sup rieur 1 3 Ensemble de la poign e 1 4 Poign e droite 1 Se reporter POIN...

Page 446: ...he grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect 9Handlebar 1 Bends Cracks Damage Replace w Do not attempt to straighten a bent handlebar as this ma...

Page 447: ...Guidon 1 Deform e craquelures endom magement Changer XG Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble acc l rateur 1 Monter 9 Poign...

Page 448: ...forward 9Install the handlebar so that the marks b are in place on both sides 9First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side 2 Install 9...

Page 449: ...res b soient en place des deux c t s 9Serrer d abord les boulons du c t avant du support de guidon puis serrer les boulons du c t arri re 2 Monter 9 Poign e gauche 1 Appliquer l adh sif sur le gui do...

Page 450: ...he UPPER mark a faces upward 9Pass the throttle cable in the groove b in the roller 6 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 7 Adjust 9Throttle grip free play Refer to THROTTLE CABL...

Page 451: ...pplicare sull estremit del cavo dell acceleratore e sulla parte a spira del cavo di guida del tubo il grasso a base di sapone di litio 5 Installare 9 Rullo 1 9 Collare 2 NOTA 9Applicare sulla superfic...

Page 452: ...11 Install 9 ENGINE STOP button 1 9Clutch lever holder 2 9Bolt clutch lever holder 3 9Clamp 4 NOTE 9The ENGINE STOP button clutch lever hold er and clamp should be installed according to the dimensio...

Page 453: ...voir serr les boulons v ri fier que la poign e d acc l rateur 3 3 tourne sans probl me Sinon res serrer les boulons pour la r gler 11 Monter 9 Bouton d arr t du moteur EN GINE STOP 1 9 Support de levi...

Page 454: ...handlebar 15 Insert the end of the fuel breather hose 1 into the hole in the steering shaft cap 2 12 Install 9Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch cable end 13 Adjust...

Page 455: ...1 nel foro del coper chio dell albero dello sterzo 2 12 Monter 9 C ble d embrayage 1 N B Appliquer de la graisse base de savon au lithium sur l extr mit du c ble d embrayage 13 R gler 9 Jeu du levier...

Page 456: ...e special tool Refer to REMOVAL POINTS 6 Under bracket 1 7 Bearing race cover 1 8 Bearing upper 1 9 Bearing lower 1 Refer to REMOVAL POINTS 10 Bearing race 2 Refer to REMOVAL POINTS Extent of removal...

Page 457: ...unter dem Motor angeordnet wird Nummernschild Lenkstange Siehe Abschnitt LENKSTANGE Vorderrad Kotfl gel 1 Lenkerschaftdeckel 1 2 Lenkerschaftmutter 1 3 Vorderradgabel 2 Siehe Abschnitt VORDERRADGABEL...

Page 458: ...down EC563300 Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Bearing race 1 Remove 9Bearing race 1 Remove the bearing race...

Page 459: ...pas endommager le file tage de l arbre de direction Cage de roulement 1 D poser 9 Cage de roulement 1 D poser la cage de roulement l aide d une tige 2 et d un marteau VERIFICATION Arbre de direction 1...

Page 460: ...on in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION EC5651A0 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the...

Page 461: ...ement et de cages de roulement REMONTAGE ET MONTAGE Etrier inf rieur 1 Monter 9 Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint anti poussi re et sur l...

Page 462: ...by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE 9Tempora...

Page 463: ...conque retirer l ensemble axe de direction et inspecter le support de direction 6 Monter 9 Rondelle ordinaire 1 7 Monter 9 Fourche avant 1 9 Etrier sup rieur 2 N B 9Serrer le boulon de bridage trier i...

Page 464: ...to specified torque If torqued too much it may cause the front fork to malfunction Front fork top end standard a a 5 mm 0 20 in 23 Nm 2 3 m kg 17 ft lb 20 Nm 2 0 m kg 14 ft lb 9 Install 9Steering sha...

Page 465: ...serrata pu provocare il malfunzionamento della forcella anteriore Oberes Ende der Gabelbein rohre Standard a 5 mm 0 20 in Extr mit sup rieure de fourche avant Standard a a 5 mm 0 20 in Estremit super...

Page 466: ...e pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swinga...

Page 467: ...SE UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdr cken Antriebskette 1 Kettenschutz 1 2 Kettenspanner Unten 1 3 Schraube Hinterad Sto d mpfer 1 Die Hinterradschw...

Page 468: ...Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 10 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and...

Page 469: ...und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename St ckzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 Siehe unter AUSBAUPUNKTE 2 Relaisarm 1 3 Pleuelstange 1 4 H lse 2 5 ld...

Page 470: ...9Bush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574211 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth re...

Page 471: ...en auf den usse ren Laufring ausbauen INSPEKTION Die Lager Buchsen H lsen und Deckel in L sungsmittel waschen Hinterradschwinge 1 Pr fen 9 Lager 1 9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost...

Page 472: ...nstalled depth of bearings Outer a a Zero mm Zero in Inner b b 8 5 mm 0 33 in EC574311 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and colla...

Page 473: ...ll in Innen b b 8 5 mm 0 33 in Bielle 1 Examiner 9 Roulement 1 9 Collerette 2 Il y a jeu fonctionnel tour irr gulier rouille Changer roule ment et collerette comme un en semble 2 Examiner 9 Bague d ta...

Page 474: ...her 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the b...

Page 475: ...e und der Drucklager auftragen 2 Einbauen 9 H lse 1 9 Beilagscheibe 2 Zum Relaisarm 3 HINWEIS Das Molybd n Fett auf den H lsen und den ldichtungslippen auftragen Profondeur install e de roulement a a...

Page 476: ...e grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To relay arm 5 NOTE...

Page 477: ...llant 1 9 Axe de pivot 2 N B 9Appliquer de la graisse de molybd ne sur l axe de pivot 9Introduire l arbre pivot par le c t droit 5 Einbauen 9 Relaisarm 1 9 Schraube Relaisarm 2 9 Beilegescheibe 3 9 Mu...

Page 478: ...Plain washer 2 9Nut connecting rod 3 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay...

Page 479: ...2 9 Mutter Pleuelstange 3 HINWEIS 9 Das Molybd n Fett auf der Schraube auftragen 9 Die Mutter noch nicht festziehen 9 Einbauen 9 Schraube Hinterrad Sto d mpfer Relaisarm 1 9 Mutter Hinterrad Sto d mp...

Page 480: ...her 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover 10mm 0 39in 5 7...

Page 481: ...er Unten 5 14 Einbauen 9 Kettenschutz 1 9 St tzenabdeckung 2 9 Schraube Kettenschutz 50 mm 1 97 in 3 9 Mutter Kettenschutz 4 9 Schraube St tzenabdeckung 10 mm 0 39 in 5 13 Installare 9 Bullone tendica...

Page 482: ...ame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 7 Adjuster 1 8 Spring guide lower 1 9 Spring guide upper 1 10 Spri...

Page 483: ...dre arri re 1 3 Boulon amortisseur arri re bras de relais 1 Tenir le bras oscillant 4 Boulon amortisseur arri re cadre 1 5 Amortisseur arri re 1 6 Contre crou 1 7 Dispositif de r glage 1 8 Guide de re...

Page 484: ...as expansion and or damage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the...

Page 485: ...endom mager toute partie du r servoir gaz Un r servoir gaz endom mag affectera la capacit d amortissement ou entra nera un mauvais fonctionnement 4 Prendre garde ne pas rayer la surface de contact de...

Page 486: ...e EC584000 INSPECTION EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assem...

Page 487: ...ge ext rieure VERIFICATION Amortisseur arri re 1 Examiner 9 Tige d amortisseur 1 D form e Endommagement Changer l amortisseur com plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet Fuit...

Page 488: ...oove appears by pressing its outer race cC Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopp...

Page 489: ...1 N B Apr s avoir install la bague d arr t re pousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter 9 Roulement inf rieur 1 N B Installer le roulement en l ins rant sur c t o les rep r...

Page 490: ...ide grease on the bearing 9Apply the lithium soap base grease on the bush collars and dust seals 9Install the dust seals with their lips facing out ward 3 Adjust 9Spring length installed a For EUROPE...

Page 491: ...9 Bague 1 9 Collerette 2 9 Joint antipoussi re 3 N B 9Appliquer de la graisse de molybd ne sur le roulement 9Appliquer de la graisse base de sa von au lithium sur la bague les col liers et les joints...

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

Page 493: ...bd ne sur le boulon 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re sup rieur 2 9 Boulon cadre arri re inf rieur 3 7 Serrer 9 Boulon raccord de filtre air 1 3 Installare 9 Ammortizzatore posteriore...

Page 494: ...L COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 ENGINE STOP button 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black O Orange Y Yellow B...

Page 495: ...SANTS ELECTRIQUES ET SCHEMA DE CABLAGE COMPOSANTS ELECTRIQUES 1 Bouton d arr t du moteur ENGINE STOP 2 Bloc CDI 3 Bobine d allumage 4 Magn to CDI 5 Bougie CODE DE COULEUR B Noir O Orange Y Jaune B R N...

Page 496: ...on system for connection Spark gap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI magneto Replace CDI uni...

Page 497: ...Changer Changer Changer O K O K O K O K SYSTEME D ALLUMAGE ETAPES DE VERIFICATION Utiliser les tapes suivantes pour v rifier la possibilit d attribution du mauvais fonctionnement du moteur une panne d...

Page 498: ...euern Erneuern Erneuern Erneuern Erneuern In Ordnung In Ordnung In Ordnung In Ordnung Z NDANLAGE PR FVORG NGE Durch folgende Schritte auf eine m gliche St rung des Motors durch einen Defekt im Z ndsys...

Page 499: ...tituirla OK Sostituirla Controllare la calotta della candela Non funziona OK OK OK OK IC620000 SISTEMA DI ACCENSIONE IC621002 OPERAZIONI DI ISPEZIONE Usare le operazioni che seguono per controllare la...

Page 500: ...ne and increase spark gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or...

Page 501: ...RET DU MOTEUR ENGINE STOP 1 Examiner 9 Conductibilit du bouton d arr t du moteur ENGINE STOP Pas de continuit lorsqu enfonc Changer Continuit lorsque rel ch Changer IC622001 TEST DELLA DISTANZA TRA GL...

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

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

Page 504: ...osition 248 372 at 100 20 C 68 F Tester lead Black Red lead 1 Tester lead Green White lead 2 Source coil 1 Tester selector resistance position 720 1 080 at 100 20 C 68 F EC62B000 SPARK PLUG CAP INSPEC...

Page 505: ...Positives Kabel des Pr fger tes Wei Rot Kabel 1 Negatives Kabel des Pr fger te Wei Blau Kabel 2 Widerstand Position des der Wahlschalters Aufnahmespule am Pr fger t 248 372 bei 100 20 C 68 F Positives...

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

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

Page 508: ...t be properly suited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed r...

Page 509: ...e la route et la d coloration de bougie s Prenant ces facteurs en consid ration il s lectionnera les meilleurs r glages de carburateur possibles Il est recommand de prendre note des r glages des condi...

Page 510: ...sity of the air EC713001 Test run After warming up the engine equipped with the standard type carburetor s and spark plug s run two or three laps of the circuit and check the smooth operation of the e...

Page 511: ...bougie s A Normale B Surbr l trop pauvre C Encrass e d huile trop riche Cio 9 Una temperatura pi alta fa dilatare l aria ne risulta una densit ridotta 9 Un umidit pi elevata riduce la quantit di ossi...

Page 512: ...y changing the main jet 1 For EUROPE 1 Spark plug is too hot Select a main jet having higher calibrating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating...

Page 513: ...etto principale La ricchezza della miscela aria carbu rante con valvola regolatrice del flusso a 1 2 4 4 pu essere registrata cam biando il getto principale 1 Per EUROPA 1 La candela troppo calda Sele...

Page 514: ...air screw will enrich the mix ture at low speeds and turning out it will lean out the mixture EC71R010 Pilot jet adjustment The richness of air fuel mixture with the throttle fully closed to 1 2 open...

Page 515: ...richesse du m lange air essence avec l acc l rateur entre la position de fermeture compl te et la mi puissance peut tre r gl e en tournant le gicleur de ralenti 1 Le r glage est chang lorsqu il ne peu...

Page 516: ...ans of the spark plug and therefore it should be judged from your feeling of actual engine operation 1 Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up sp...

Page 517: ...betriebs beurteilen m ssen 1 Zu fett bei mittleren Drehzahlen Rauher Motorbetrieb kann festge stellt werden und der Motor kann nicht glatt beschleunigt werden In diesem Fall ist die D sennadel klammer...

Page 518: ...2 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 richer c 2 richer 7 6 TUN SETTING 6CHY5 79 6CHY5 80 6CHY5 81 6CHY5 80 6CHY6 80 b a B A c 6CH...

Page 519: ...le m me effet qu un rel vement de 2 posi tions de clip A Diff rence de diam tre de portion droite B Diff rence de position de rainure a Aiguille de r f rence b 0 5 plus riche c 2 plus riche Aiguille s...

Page 520: ...Y5 80 zu 6CHY18 80 die gleiche Wir kung wie das Anheben der 2 Clip Position A Unterschied beim Durchmesser des geraden Teils B Unterschied bei der Klemmposition a Bezugsnadel b 0 5 fetter c 2 fetter S...

Page 521: ...etto che alzare di 2 la posizione del fermo A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a graffa a Ago di riferimento b 0 5 pi ricca c 2 pi ricca Ago a getto n...

Page 522: ...ed 1 8 throttle to the 1st tapered portion at 1 4 throttle to the second tapered portion at 1 2 throttle to the third tapered portion at 3 4 throttle and to the fourth tapered portion at full open The...

Page 523: ...3e partie conique une ouverture 3 4 du papillon et la 4e par tie conique l ouverture compl te du papillon Par cons quent l arriv e de carburant est quilibr e chaque niveau de l ouverture du papillon...

Page 524: ...2 5 4KM 14142 42 45 4KM 14142 45 47 5 4KM 14142 47 Rich 50 4KM 14142 50 Throttle Rich valve 3 3 STD 4 0 1C3 14112 40 4 25 1C3 14112 42 Lean Jet needle 4 4 Rich 6CHY18 78 284 14116 G3 6CHY18 79 284 141...

Page 525: ...4KM 14142 35 No 37 5 4KM 14142 37 STD No 40 4KM 14142 40 No 42 5 4KM 14142 42 No 45 4KM 14142 45 No 47 5 4KM 14142 47 Ricca No 50 4KM 14142 50 Valvola Ricca regolatrice del STD 4 0 1C3 14112 40 flusso...

Page 526: ...ture Lean mixture Lower jet needle clip position 1 groove down Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Lower jet needle clip position Hard breathing 1 groove down Lack...

Page 527: ...above intermediate speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly Use main jet having lower calibration No Raise jet needle clip...

Page 528: ...icleur 1 rainure plus haut Contr ler D coloration de la bougie d allumage Si la couleur est fonc e la condition est bonne Si la normalisation est impossible Si ge de pointeau bouch Tuyau de carburant...

Page 529: ...es r glages d ensemble Utiliser un gicleur principal avec un n de calibrage inf rieur Elever la position de fixation de l aiguille de gicleur 1 rainure plus haut Si l effet est nul inverser les proc d...

Page 530: ...Schlechte Beschleunigung Einstellung Hauptd sen Kalibrierungs Nr erh hen schrittweise Hauptd sen Kalibrierungs Nr vermindern schrittweise Im Falle eines Hochdrehens Ein etwas fetteres Gemisch reduzier...

Page 531: ...kung die obigen Vorg nge umkehren Gesamteinstellungen berpr fen Hauptd se mit niedrigerer Kalibrierungs Nr verwenden D sennadel Klemmenposition erh hen 1 Nut h her Falls keine Wirkung die obigen Vorg...

Page 532: ...rmaglio a graffa dell ago a getto su di 1 scanalatura Controllo Scolorimento della candela Se color cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo fl...

Page 533: ...generali Usare un getto principale che abbia un No di taratura pi basso Alzare la posizione del fermaglio a graffa dell ago a getto su di 1 scanalatura Se non vi effetto eseguire al contrario le proc...

Page 534: ...No of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet NOTE 9When checking the discoloration of spark plugs be sure to st...

Page 535: ...d de changer la plage de chaleur des bougies et de s lection ner un autre gicleur principal correct N B 9Lors du contr le de la d coloration des bougies attention bien arr ter le moteur imm diatement...

Page 536: ...tire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire c...

Page 537: ...erminer le taux de r duction secon daire 9Quand il y a de grandes lignes droites r gler la machine de sorte ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en vitan...

Page 538: ...act with the road surface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 STD 13T 9383B 13218 Driven sproc...

Page 539: ...des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kgf cm2 9 0 12 psi Reifendruck Der Reifendruck soll soll ge...

Page 540: ...eristic near the final stroke can be changed by changing the fork oil amount cC Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork...

Page 541: ...mpr visible et une course de fourche plus courte en cons quen ce et une d t rioration des perfor mances et des caract ristiques Voil pourquoi il convient d ajuster la fourche dans la plage sp cifi e I...

Page 542: ...stment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in position et...

Page 543: ...Ampiezza della regolazione zero 2 rondelle di regolazione R glage du ressort apr s remplace ment Les r glages de la fourche avant peu vent tre affect es par la suspension arri re il convient donc d q...

Page 544: ...s to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handlebar To set a stiff spring 9Change the rebound damping Turn in one or two clicks 9Change the co...

Page 545: ...entste hen ebenso wie Vibrationen im Lenker Zum Einstellen einer harten Feder 9 Die Ausfederd mpfung ndern Um eine oder zwei Klickstel lungen herausdrehen 9 Die Einfederd mpfung ndern Um eine oder zw...

Page 546: ...d of the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits SOFT 0 398 1C3 23141 00 I STD 0 408 1C3 23141 M0 STD 0 418 1C3 23141 L0 0 428 1C3 23141 30 IIII 0 438 1C3 23141 40 IIIII STIFF 0 449...

Page 547: ...408 1C3 23141 M0 STD 0 418 1C3 23141 L0 0 428 1C3 23141 30 IIII 0 438 1C3 23141 40 IIIII HART 0 449 1C3 23141 50 I I 0 459 1C3 23141 60 I II 0 469 1C3 23141 70 I III 0 479 1C3 23141 80 I IIII TYPE epa...

Page 548: ...ession damping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fe...

Page 549: ...en um das Hinter rad anzuheben und den Abstand a zwischen der Hinterradachs mitte und der Hinterradkotfl gel Halteschraube messen 2 Den St nder oder Block vom Motor entfernen und bei aufsit zendem Fah...

Page 550: ...t length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring 9Set the soft spring for less rebound damp ing to compensate for its less spring load Run with the rebound damping adjuster...

Page 551: ...er weichen Feder 9 Die weiche Feder auf weniger Ausfederd mpfung einstellen um die geringere Federspan nung auszugleichen Mit dem Ausfederd mpfung Einsteller um eine oder zwei Klickstellen zur weicher...

Page 552: ...se the one whose overall length a a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider w...

Page 553: ...ssort dont la longueur totale est sup rieure la longueur standard A Ressort recommand en fonction du poids B Poids du motocycliste 1 Mou 2 Standard 3 Dur iI Quando si usa un ammortizzatore posteriore...

Page 554: ...22212 00 Brown 1 260 4 5 5UN 22212 10 Green 1 260 STD 4 7 5UN 22212 20 Red 1 260 4 9 5UN 22212 30 Black 1 260 5 1 5UN 22212 40 Blue 1 260 STIFF 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 26...

Page 555: ...u 1 260 HART 5 3 5UN 22212 50 Gelb 1 260 5 5 5UN 22212 60 Rosa 1 260 5 7 5UN 22212 70 Eei 1 260 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4 3 5UN 22212 00 Marrone 1 260 4 5 5UN 22212 10 Ve...

Page 556: ...ssion damping Turn adjuster clockwise about 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 out Imp oz 0 2 0 3 US oz Spring...

Page 557: ...nd Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decre...

Page 558: ...2 0 3 US oz Monter un ressort doux V rifier s il y a coudes coups ou tout autre endommagement visible Si tel est le cas rem placer les parties affect es Remplacer par un nouveau pour une utilisation p...

Page 559: ...nt R gler la longueur sur 90 100 mm 3 5 3 9 in avec une personne assise correctement sur la selle Tourner le dispositif de r glage vers la droite de 2 d clics pour augmenter l amortissement Tourner le...

Page 560: ...cm3 0 2 0 4 Imp oz 0 2 0 3 US oz reduzieren Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtbare Sch den etc pr fen Falls vorhanden betroffene Teile ersetzen Durch ein neues mit verl ngerter...

Page 561: ...mpfung zu ver ringern Eingetauchte L nge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu steiger...

Page 562: ...iorario circa 2 scatti per diminuire lo smor zamento Diminuire la quantit d olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Sostituirla con una molla dolce Controllare eventuali curvature ammaccat...

Page 563: ...re lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aumen...

Page 564: ...TUN MEMO...

Page 565: ...TUN MEMO...

Page 566: ...TUN MEMO...

Page 567: ......

Page 568: ...PRINTED IN JAPAN 2004 5 2 5 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER YZ125 T T1...