Yamaha YZ125(W)/W1, Owner'S Service Manual

Page 1: ...FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 W W1 1C3 28199 32 PRINTED IN JAPAN 2006 5 1 6 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED...

Page 2: ...y Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC01001...

Page 3: ...maha Motor Co Ltd 1 Ausgabe Mai 2006 Alle Rechte vorbehalten Nachdruck auch auszugsweise oder nicht autorisierte Verwendung sind ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet G...

Page 4: ...ign and quality Therefore while this manual contains the most current product infor mation available at the time of printing there may be minor discrepancies between your machine and this manual If yo...

Page 5: ...en permanence d am liorer la conception ainsi que la qualit de ses produits Par cons quent m me si ce manuel contient les toutes derni res informations sur les produits disponibles lors de l impressi...

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: ...UCTEUR 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 pr...

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

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

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

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

Page 14: ...2 M W2 M W2 0Y hf O 0M O 0Y O 0Y he O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W2...

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

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

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

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

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: ...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 DEFI...

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 13...

Page 25: ...FAHRGESTELL 7 13 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 13 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: ...contr 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...

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 dass das Zeichen des Herstellers oder die Herstellungs nummer nach aussen gerichtet ist die eingeschlagenen Buch staben m ssen sichtbar sein Wenn ldichtungen eingebaut werden sind die l...

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

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: ...890 01501 Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the damper assembly YM A0948 90890 01502 Fork seal driver YM A0948 90890 01502 This tool is used when install...

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: ...YM 34487 90890 06754 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 tincelle dyn...

Page 42: ...iehwerkzeug 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: ...upplung Halterwerkzeug Dieses Werkzeug wird f r das Festhalten der Kupp lung verwendet wenn die Kupplungsnaben Befesti gungsmutter aus oder eingebaut wird Dynamischer Z ndfunkenpr fer Z ndungs Pr fger...

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: ...487 90890 06754 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 Tester a sc...

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

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 dass der Pfeil auf den Kraftstofftank und nach unten weist IC15R001 CAVALLETTO STACCABILE Questo cavalletto 1 viene usato per supportare sol...

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: ...kr ftig durchtreten um den Motor zu starten 4 Den Motor bei Leerlauf Dreh zahl warmlaufen lassen f r das Warmlaufen werden normaler weise etwa eine bis zwei Minuten ben tigt 5 Der Motor ist warmgelauf...

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

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: ...nterradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradshcwinge Rad Einbau des Rades Vorn 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 bou...

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: ...donnez 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 f...

Page 68: ...roke 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 system Kick...

Page 69: ...1 1 095 Chassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 25 5 25 6 Trail 105 mm 4 13 in 107 mm 4 21 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M T...

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: ...ark 1C35 30 1C36 40 1C37 50 Main jet M J 410 430 Jet needle clip position J N 6BFY42 74 3 6BFY43 74 3 Cutaway C A 4 0 Pilot jet P J 40 45 40 Pilot air screw P A S 2 1 4 Valve seat size V S 3 8 mm 0 15...

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: ...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 Silencer and frame M 6 1 0 2 12 1 2 8 7 Fiber For USA and CDN M 6 1 0 2 10 1 0 7 2 Fiber Excep...

Page 74: ...89 in Front fork top end 5 mm 0 2 in Rear suspension USA CDN ZA EUROPE AUS NZ Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length One I D mark 256 mm 10 08...

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: ...tor and brake hose holder 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...

Page 77: ...8 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 1C3 10 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...

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: ...e 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 compression 8 6...

Page 81: ...A ZA AUS NZ EUROPE CDN Type de cadre Simple berceau d d double Angle de chasse 25 5 25 6 Chasse 105 mm 4 13 in 107 mm 4 21 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Tail...

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: ...Marque d identification 1C35 30 1C36 40 1C37 50 Gicleur principal M J 410 430 Aiguille J N 6BFY42 74 3 6BFY43 74 3 Echancrure C A 4 0 Gicleur de ralenti P J 40 45 40 Vis d air de ralenti P A S 2 1 4 T...

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: ...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 Silencieux et cadre M 6 1 0 2 12 1 2 8 7 Fibre pour USA et CDN M 6 1 0 2 10 1 0...

Page 86: ...5 mm 0 2 in Suspension arri re USA CDN ZA AUS NZ EUROPE D battement d amortisseur 131 5 mm 5 18 in Longueur de ressort libre Approx 265 mm 10 43 in Longueur de raccord Une marque d identification 256...

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: ...de levier d embrayage M 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...

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 2 0 2 1 4 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 1C3 10 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: ...tages propres et secs Les composants doivent tre temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filetage DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE SPECIFICATION...

Page 92: ...rgek hlter Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorn 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 Anlasssystem Kic...

Page 93: ...00 6 Gang 23 21 1 095 Fahrgestell USA ZA AUS NZ EUROPA CDN Rahmenbauart Semi Doppelscheibenrahmen Nachlauf 25 5 25 6 Nachlaufbetrag 105 mm 4 13 in 107 mm 4 21 in Reifengr e Bauart Mit Schlauch Reifeng...

Page 94: ...m 0 039 in T 2 35 mm 0 093 in Ringspalt 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: ...ikationsmarkierung 1C35 30 1C36 40 1C37 50 Hauptd se M J 410 430 D sennadel Klemmposition J N 6BFY42 74 3 6BFY43 74 3 Abschr gung C A 4 0 Leerlaufd se P J 40 45 40 Leerlauf Luftregulierschraube P A S...

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: ...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 Schalld mpfer und Rahmen M 6 1 0 2 12 1 2 8 7 Fasereinsatz F r USA und CDN M 6 1 0 2 10 1 0 7 2 Fasereinsatz Au er USA...

Page 98: ...beinrohre Hinterradaufh ngung USA CDN ZA EUROPA AUS NZ Hub des Sto d mpfers 131 5 mm 5 18 in Ungespannte Federl nge Etwa 265 mm 10 43 in Einbaul nge Eine ID Markierung 256 mm 10 08 in 254 mm 10 00 in...

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

Page 100: ...er M 5 0 8 2 4 0 4 2 9 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 Bremssa...

Page 101: ...5 6 40 Hinterrad Sto d mpfer und Relaisarm M10 1 25 1 53 5 3 38 Hintere Rahmen und Rahmen oben M 8 1 25 1 32 3 2 23 Hintere Rahmen und Rahmen unten M 8 1 25 2 29 2 9 21 Hinterradschwinge und Bremsschl...

Page 102: ...Stator Hersteller 1C3 10 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: ...t f r trockene und saubere Gewinde Die anzuziehenden Bauteile sollten dabei Raumtemperatur aufweisen A Schl sselweite B Gewindedurchmesser DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN ALLGEMEINE A...

Page 104: ...eddato 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 compressione 8...

Page 105: ...ppia Angolo di incidenza 25 5 25 6 Avancorsa 105 mm 4 13 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 pneu...

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: ...1C35 30 1C36 40 1C37 50 Getto principale M J No 410 No 430 Posizione della staffa dell ago di getto J N 6BFY42 74 3 6BFY43 74 3 Sezione C A 4 0 Getto pilota P J No 40 No 45 No 40 Vite dell aria pilota...

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: ...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 Silenziatore e telaio M 6 1 0 2 12 1 2 8 7 Fib...

Page 110: ...orsa dell ammortizzatore 131 5 mm 5 18 in Lunghezza libera della molla 265 mm circa 10 43 in Lunghezza di inserimento Un contrassegno di marcatura 256 mm 10 08 in 254 mm 10 00 in di identificazione Du...

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: ...Coperchio del cilindro principale 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...

Page 113: ...illante e supporto del tubo flessibile M 5 0 8 4 2 0 2 1 4 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 16 1 6 11 Supporto della cat...

Page 114: ...ostruttore del magnete 1C3 10 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: ...utch cable and ENGINE STOP button lead above the radiator hose D Install the ignition coil side core and ground lead together to the frame Take care to fas ten the ground lead so that its terminal is...

Page 117: ...it de mise l air du radiateur Installer la bobine d allumage le fais ceau lat ral et le fil de masse ensemble sur le cadre Fixer le fil de masse de fa on ce que sa borne se trouve dans la plage indiqu...

Page 118: ...frame the CDI magneto lead and radiator breather hose Take care to clamp them above the projec tion on the frame L Locate the clamp ends in the arrowed range M Pass the air vent hose over flow hose an...

Page 119: ...ant magn tique CDI et la durit de mise l air du radiateur Veiller les brider au dessus de la saillie du cadre Placer les extr mit s du collier dans le sens de la fl che Faire passer la durit de ventil...

Page 120: ...In so doing clamp the ignition coil lead and ENGINE STOP button lead at their protecting tubes Tighten the clamp so that the ENGINE STOP button lead is not pulled when the handlebar is turned to the r...

Page 121: ...e d allumage et le fil du bouton ENGINE STOP Serrer le collier pince de fa on ce que le fil du bouton ENGINE STOP ne soit pas tir lorsque le guidon tourne vers la gauche et vers la droite Faire passer...

Page 122: ...c tion on the caliper B Pass the brake hose into the brake hose hold ers 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: ...en contact avec la saillie de l trier Faites ensuite passer le tuyau de frein dans les supports du tuyau de frein Si le tuyau de frein touche le ressort amortisseur arri re ajuster le coude Installer...

Page 124: ...button lead in the middle of the clutch holder C Clamp the ENGINE STOP button lead to the handlebar D Pass the brake hose in front of the number plate and through the cable guide E Pass the clutch ca...

Page 125: ...yau 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 arr t du moteur ENGINE STOP au centr...

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

Page 128: ...NTENANCE INTERVALS INSP ADJ Item Remarks THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or Lubricate SAE 10W 30 motor oil After break in Every race Every third Every fifth As re...

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

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

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

Page 133: ...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 fen u...

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

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

Page 136: ...eni 6 FORCELLE ANTERIORI Ispezione e regolazione 6 6 Sostituzione dell olio 6 6 Sostituzione del paraolio 6 PARAOLIO E PARAPOLVERE DELLA FORCELLA ANTERIORE Pulitura e lubrificazione 6 6 GUIDA DEL DISP...

Page 137: ...ne gioco libero e riserraggio 6 6 Pulitura e lubrificazione 6 Sostituzione del cuscinetto 6 PNEUMATICO RUOTE Ispezione della pressione dell aria della scentratura della ruota 6 6 dell usura dello pneu...

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

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

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: ...non 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 radi...

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

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: ...lo 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 specific...

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 comman...

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: ...sten k nnen Staub und Schmutz in den Motor eindringen und schnel len Verschlei sowie einen m gli chen Motorschaden verursachen 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: ...moteur le laisser chauffer quelques minutes et attendre 2 Placer la machine sur une surface de niveau et la maintenir en posi tion verticale en pla ant le support convenable sous le moteur 3 Placer u...

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: ...2 Das Getriebe l ablassen 5 Einbauen 9 Aluminiumscheibe 9 lablassschraube 1 Empfohlenes 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: ...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 For USA and CDN Except for USA and CDN Adjustme...

Page 163: ...challd mpfer 2 9 Schraube Fasereinsatz 3 A F r USA und CDN B Au er USA und CDN IC35R050 SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE 1 Togliere 9 Copertura laterale destra 9 Bullone silenziatore 1 9 Sile...

Page 164: ...right For USA and CDN Except for USA and CDN 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...

Page 165: ...1 2 m kg 8 7 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reusement de l agent d tanch it Quick Gasket Yamaha Bond n 1215 ou quivalent com...

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

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

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

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

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 innerhalb des spezifizier ten Bereiches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sicherungsmuttern festziehen 3 R gler 9 Fl che de cha ne de tr...

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

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

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

Page 191: ...ommager 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: ...ADJ EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Remove 9Rear frame 3 Loosen 9Locknut 1 4 Adjust 9Spring preload B...

Page 193: ...gler 9 Pr contrainte de ressort En tournant le dispositif de r glage 2 N B 9Bien enlever toute la boue et toutes les salet s autour du contre crou et de l ajusteur avant de faire le r glage 9La longue...

Page 194: ...d juster with the punch mark b on the bracket cC Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a a Increase the rebound damping force...

Page 195: ...s Einstellers 1 IC36N020 REGOL ELLA FORZA DI SMOR ZAMENTO DELL ESTENSIONE D E L L A M M O R T I Z Z A T O R E POSTERIORE 1 Regolare 9 Forza di smorzamento dell estensione Ruotando il dispositivo di re...

Page 196: ...posi tion Which align the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the minimum or maximum extent of adjustment Th...

Page 197: ...S D MPFUNGS KRAFT DES HINTERRADSTOS SD MPFERS 1 Einstellen 9 Niedrige Kompressions D mp fungskraft Den Einsteller 1 drehen IC36c000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL AMM...

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 minimum or maximum extent of adjustment The ad juster may be damaged...

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

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

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

Page 204: ...plate q NOTE 9The handlebar holder upper should be installed with the punched mark a forward 9Install the handlebar so that the marks b are in place on both sides 9Install the handlebar so that the p...

Page 205: ...natura a rivolta in avanti 9Installare il manubrio in modo che i contrassegni b siano a posto da entrambi i lati 9Installare il manubrio in modo che la sporgenza c del suo supporto superiore sia posiz...

Page 206: ...EAD INSPECTION AND ADJUSTMENT INSP ADJ Steering shaft nut 145 Nm 14 5 m kg 105 t lb Handlebar holder upper 28 Nm 2 8 m kg 20 ft lb Pinch bolt handle crown 21 Nm 2 1 m kg 15 ft lb Number plate 7 Nm 0 7...

Page 207: ...ge couronne de guidon 21 Nm 2 1 m kg 15 ft lb Plaque d immatriculation 7 Nm 0 7 m kg 5 1 ft lb Lenkerschaftmutter 145 Nm 14 5 m kg 105 ft lb Lenkerhalter oben 28 Nm 2 8 m kg 20 ft lb Klemmschraube Len...

Page 208: ...to handlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding portion 0 Throttle cable end q Clutch cable end Use Yamaha cable lube or e...

Page 209: ...la 8 Superficie di scorrimento del rullo della valvola a farfalla 9 Parte a spira del cavo di guida del tubo 0 Estremit del cavo dell acceleratore q Estremit del cavo della frizione A Usare lubrifican...

Page 210: ...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 211: ...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 212: ...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 213: ...em Punkt stoppt die Anzeigenadel der Messuhr und ndert ihre Bewegungsrichtung wenn der Rotor in der gleichen Richtung weitergedreht wird 4 Im oberen Totpunkt ist die Mes suhr auf Null zu stellen 5 Aus...

Page 214: ...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 215: ...uben 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 9Alle...

Page 216: ...4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 7 Side cover right 1 Refer to REMOVAL POINTS 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Num...

Page 217: ...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 218: ...r 9 Side cover left and right 1 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case Number plate 1 Remove 9 Bolt number plate 9 Number plate 1 NOTE...

Page 219: ...d immatriculation 1 N B 9La saillie a est ins r e dans la bande de la plaque d immatriculation Reti rer la bande de la saillie avant la d pose 9D poser le c ble d embrayage 2 du guide de c ble b sur...

Page 220: ...mm 0 51 in 1 Collar R 15 5 mm 0 61 in 1 5 Collar R 13 5 mm 0 53 in 1 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 Bolt exhaust pipe 2 10 Exhaust pipe 1 4 3 ENG EXHAUST PIPE AND SILENCER EC...

Page 221: ...1 6 Taukranz vorn 1 7 Taukranz hinten 1 8 Zugfeder 2 9 Schraube Auspuffrohr 2 10 Auspuffrohr 1 AUSPUFFROHR UND SCHALLD MPFER Au er USA und CDN Ausbauumfang 1 Ausbau des Schalld mpfers 2 Ausbau des Aus...

Page 222: ...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 223: ...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 224: ...p by the following procedure Place a thick rag like a towel over the radi ator cap slowly rotate the cap counter clockwise to the detent This procedure al lows any residual pressure to escape When the...

Page 225: ...radiateur en proc dant comme suit Quand le moteur est froid mettre un chiffon pais tel qu une serviette sur ce bouchon puis le tourner lentement vers la gauche jusqu au point de d tente Cette proc du...

Page 226: ...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 227: ...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 radiate...

Page 228: ...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 1 5 Stopper reed valve 2...

Page 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...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 235: ...ntrollieren 9 Freie Bewegung Klemmung Reparieren oder erneuern HINWEIS Das Drosselventil 1 in das Vergaser geh use einsetzen und auf freie Bewegung kontrollieren D sennadel 1 Pr fen 9 D sennadel 1 Bie...

Page 236: ...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 237: ...l car burante 9Se il livello del carburante non rientra nella specifica ispezionare la sede della valvola e la valvola ad ago 9Se una delle due usurata sosti tuirle entrambe 9Se entrambe vanno bene re...

Page 238: ...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 239: ...9 Hauteur 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 fle...

Page 240: ...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 241: ...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 242: ...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 243: ...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 244: ...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 245: ...le 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...

Page 246: ...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 247: ...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 248: ...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 249: ...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 250: ...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 251: ...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 252: ...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 253: ...icco la 3 NOTA Prima di togliere lo spinotto sbavare la zona della scanalatura del fermaglio a graffa e del foro dello spinotto Se la scanalatura dello spinotto sbavata e lo spinotto ancora difficile...

Page 254: ...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 255: ...neal 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 256: ...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 257: ...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 rainu...

Page 258: ...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 259: ...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 260: ...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 261: ...er 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...

Page 262: ...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 263: ...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 264: ...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 265: ...rn Leistungsventilbohrung 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 pu...

Page 266: ...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 267: ...uen dass 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...

Page 268: ...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 269: ...l 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 Kolbenri...

Page 270: ...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 271: ...l 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 position...

Page 272: ...gine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt 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...

Page 273: ...ung Leistungsventil 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 clap...

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

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

Page 276: ...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 277: ...e D 34 mm 1 34 in 1 14 Schubhebelachse 1 PRIM RABTRIEBSZAHNRAD SCHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des...

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

Page 279: ...alten 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 e...

Page 280: ...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 281: ...rer 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 pa...

Page 282: ...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 283: ...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 284: ...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 285: ...et 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 su...

Page 286: ...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 287: ...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 288: ...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 289: ...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 290: ...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 291: ...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 292: ...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 293: ...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 294: ...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 295: ...oche 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 du...

Page 296: ...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 297: ...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 298: ...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 299: ...e 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 a...

Page 300: ...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 301: ...marreur 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 a...

Page 302: ...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 303: ...ire 2 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 lecte...

Page 304: ...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 305: ...TEUR ET PIGNON DE TRANSMISSION 1 Ensemble r gulateur 1 2 Goujon 1 Se reporter POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de but e 2 8 Collerett...

Page 306: ...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 307: ...le 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 Coll...

Page 308: ...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 309: ...elle 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...

Page 310: ...SHIFT SHAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 4 Plain washer 1 5 Impeller shaft assembly 1 6 Bearing 1 Refer to REMOVAL POINTS 7...

Page 311: ...on AXE DE DEMARREUR 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 4 Rondelle plain 1 5 Ensemble d axe de rotor 1 6 R...

Page 312: ...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 313: ...ement 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 tanc...

Page 314: ...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 315: ...gement 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 bagu...

Page 316: ...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 317: ...9 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 Monte...

Page 318: ...emoval SIDE COVERS section Bolt Radiator Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator 1...

Page 319: ...E RESERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur Se reporter la section RADIATEUR D connecter le fil de magn to CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil sp cial...

Page 320: ...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 321: ...e 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 E...

Page 322: ...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 323: ...gler 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 I...

Page 324: ...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 325: ...MA 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 mo...

Page 326: ...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 327: ...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 328: ...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 329: ...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 330: ...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 331: ...zionando 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 To...

Page 332: ...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 333: ...n 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 Ins...

Page 334: ...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 335: ...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 336: ...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 337: ...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 338: ...shafts cC Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If on...

Page 339: ...e vis peut tre l g rement d viss e pour mettre le corps de l outil de niveau 9Tout en serrant le boulon central taper alternativement sur le bossage de fixation du moteur et les arbres de transmission...

Page 340: ...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 341: ...lebrequin 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 dan...

Page 342: ...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 343: ...c 9 Kurbelwangenbreite d Abweichung von Spezifikation Erneuern Die Messuhr und die F hler lehre verwenden MONTAGE UND EINBAU Kurbelwellenlager 1 Einbauen 9 Lager 1 Am Kurbelgeh use links und rechts HI...

Page 344: ...ng 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 bottoms against the bear ing 9Before installing the...

Page 345: ...uin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer de la graisse au bisulfure de molybd ne sur la surface de contact a entre le vilebreq...

Page 346: ...ransmission 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 Yamaha bond No 1215...

Page 347: ...onctionnement raide 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 t...

Page 348: ...r face a where the crankshaft and bearing come in contact 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 th...

Page 349: ...r gestellt au er f r die USA und Kanada 9 Die Unterlegscheiben so einbauen dass sie nicht von der Kurbelwellen mitte abweichen au er f r die USA und Kanada 9 Wenn das Kurbelgeh use eingebaut wird soll...

Page 350: ...to give an impact to the segment when tightening 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 ro...

Page 351: ...ne pas causer d impact sur le seg ment lors du serrage du 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 refoulem...

Page 352: ...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 353: ...LLET 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 peti...

Page 354: ...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 355: ...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 356: ...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 357: ...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 358: ...of the sliding gear then install 9Apply the molybdenum disulfide grease on the inner surface of the 4th wheel gear then install 3 Install 9Plain washer 1 9Circlip 2 NOTE 9Be sure the circlip sharp ed...

Page 359: ...e du pignon mobile puis les monter 9Appliquer de la graisse au bisulfure de molybd ne sur la surface int rieure du pignon de 4 me puis l installer 3 Monter 9 Rondelle ordinaire 1 9 Circlip 2 N B 9V ri...

Page 360: ...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 361: ...et 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 9...

Page 362: ...4 74 ENG TRANSMISSION SHIFT CAM AND SHIFT FORK 4 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair...

Page 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...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 369: ...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 370: ...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 371: ...te d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arri re 4 0 mm 0 16 in 3 5 mm 0 14 in IC594200 Disco del freno 1 Misurare 9 Inflessione del disco del freno soltanto il disco d...

Page 372: ...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 373: ...t diri g s vers l ext rieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment ext rieur 2 Monter 9 Disque de frein 1 9 Boulon disque d...

Page 374: ...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 375: ...lare 9 Asse della ruota 1 NOTA Applicare sull asse della ruota il grasso a base di sapone di litio 6 Installare 9 Dado asse della ruota 1 7 Serrare 9 Bullone supporto dell asse 1 NOTA Prima di serrare...

Page 376: ...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 377: ...le convenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ral droit doit monter premier 9Monter la bague d tanch it avec ses marques ou num ros de fabricant diri g s vers l ext r...

Page 378: ...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 379: ...ondotto 3 9 Dado rocchetto condotto 4 NOTA Serrare i dadi in sequenza usando uno schema incrociato 4 Installare 9 Bordino 1 NOTA Applicare sul labbro del paraolio il grasso a base di sapone di litio 5...

Page 380: ...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 381: ...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 382: ...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 383: ...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 384: ...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 385: ...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 386: ...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 387: ...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 388: ...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 389: ...ptbremszylindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorn B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE...

Page 390: ...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 391: ...E IC5A3101 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Coperchio del cilindro principa le 1 9 Dispositivo di protezione NOTA Non togliere il diaf...

Page 392: ...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 393: ...les joints de piston et antipoussi re lors d un d montage d trier A Avant B Arri re IC533402 Kit delle guarnizioni di tenuta del pistone 1 Togliere 9 Parapolvere 1 9 Guarnizione di tenuta del pisto n...

Page 394: ...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 395: ...ilindro principale A Anteriore B Posteriore IC534214 Pinza 1 Ispezionare 9 Superficie interna del cilindro della pinza a Usura Rigature Sostituire il gruppo pinza A Anteriore B Posteriore 2 Ispezionar...

Page 396: ...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 397: ...on et antipoussi re dans la rainure situ e sur l trier A Avant B Arri re IC5A5801 Pistone della pinza 1 Pulire 9 Pinza 9 Guarnizione di tenuta del pisto ne 9 Parapolvere 9 Pistone della pinza Pulirli...

Page 398: ...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 399: ...emsschuhaussparungen b anbringen 9 Bremsbelagplattenstifte an diesem Punkt provisorisch festziehen 2 Monter 9 Etrier 1 9 Boulon trier 2 3 Serrer 9 Goupille de plaquette 3 4 Monter 9 Bouchon de goupill...

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

Page 401: ...lle du ma tre cylindre doit tre pos e dans la direction indiqu e Une mauvaise intallation enta ne une performance incorrecte du freinage A Avant B Arri re IC5A5220 Kit del cilindro principale 1 Pulire...

Page 402: ...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 403: ...festziehen 4 Installare Anteriormente 9 Kit del cilindro principale 1 9 Rosetta 2 9 Anello elastico di arresto 3 9 Protezione del cilindro principa le 4 Sul cilindro principale 5 Posteriormente 9 Kit...

Page 404: ...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 405: ...der 1 9 Schraube Hauptbremszylin der 2 IC5A5401 Cilindro principale posteriore 1 Installare 9 Rondella in rame 1 9 Tubo flessibile del freno 2 9 Bullone di unione 3 T Usare sempre rondelle in rame nuo...

Page 406: ...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 407: ...ie in der Abbildung gezeigt angeordnet ist und den berstand b b am Bremsbe lag leicht ber hrt 2 Einbauen 9 Bremsschlauchhalter 1 9 Schraube Bremsschlauchhal ter 2 3 Einbauen 9 Bremsschlauchhalter 1 9...

Page 408: ...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 409: ...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 410: ...y brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction...

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

Page 412: ...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 413: ...iaframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale0 2 Posteriormente 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Bullone coperchio del cilindro principal...

Page 414: ...S section in the CHAPTER 4 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt u...

Page 415: ...die Vorderradgabel demontiert wird Spezialwerkzeug verwenden Siehe unter AUSBAUPUNKTE 4 Klemmschraube 2 Nur l sen Untere Gabelbr cke 5 Vorderradgabel 1 VORDERRADGABEL Ausbauumfang 1 Ausbau der Vorderr...

Page 416: ...tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 0 Oil seal 1 q Base valve 1 Drain the fork oil Use special tool w Damper assembly 1 Refer to REMOVAL POINTS 5 27 CHAS FRONT F...

Page 417: ...l outil sp cial Se reporter POINTS DE DEPOSE 2 Ressort de fourche 1 3 Joint antipoussi re 1 4 Bague d arr t 1 Se reporter POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 M tal de piston 1 8 Bague...

Page 418: ...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 419: ...ger compl tement les chambres air IC556000 NOTA PER IL MANEGGIO NOTA La forcella anteriore richiede grande at tenzione Si raccomanda pertanto di ef fettuare la manutenzione della forcella anteriore pr...

Page 420: ...not remove the locknut as the damper rod may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove 9Dust seal 1 9Stopper ring 2 Using...

Page 421: ...adere nel gruppo ammortizzatore senza che sia possibile estrarla Cl bague de boulon capuchon YM 01501 90890 01501 Chiave ad anello per vite mordente YM 01501 90890 01501 Schraubenschl ssel f r Nockenw...

Page 422: ...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 423: ...RIFICATION Amortisseur complet 1 V rifier 9 Amortisseur complet 1 Courbure endommagement Changer 9 Joint torique 2 Us endommag Changer fF La fourche avant ayant une tige de piston incorpor e a une con...

Page 424: ...Piston metal 3 Wear Damage Replace 9Spring 4 Damage Fatigue Replace base valve 9Air bleed screw 5 Wear Damage Replace EC554400 Fork spring 1 Measure 9Fork spring free length a Out of specification Rep...

Page 425: ...a 2 Usura Danni Sostituire 9 Metallo del pistone 3 Usura Danni Sostituire 9 Molla 4 Danni Affaticamento Sostitui re la valvola di base 9 Vite di spurgo dell aria 5 Usura Danni Sostituire Ressort de fo...

Page 426: ...of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the...

Page 427: ...den k nnen IC554502 Tubo interno 1 Ispezionare 9 Superficie del tubo interno a Rigature Ripararlo o sostituir lo Usare carta vetrata umida di grana no 1000 Pezzo di bloccaggio dell olio danneggiato So...

Page 428: ...have an ex cessively adverse effect on the front fork performance 9Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Oil capacity 195cm3 6 86 Imp oz 6 59 US oz 4...

Page 429: ...no avere un effetto ec cessivamente negativo sul rendi mento della forcella anteriore 9Non permettere mai la penetrazione di materiali estranei nella forcella anteriore Huile recommand e Huile de susp...

Page 430: ...Loosen 9Compression damping adjuster 1 NOTE 9Loosen the compression damping adjuster fin ger tight 9Record the set position of the adjuster the amount of turning out the fully turned in posi tion 8 In...

Page 431: ...d amener la pression de la tige d amortissement au maximum Ins taller ensuite la valve de base tout en rel chant la pression de la tige d amor tissement 9 V rifier que l amortisseur complet est totale...

Page 432: ...5 35 CHAS FRONT FORK 12 While protecting the damper assembly 1 with a rag and compressing fully allow excessive oil to overflow on the base valve side cC Take care not to damage the damper assembly 13...

Page 433: ...lassen w hrend die D mpfer Baugruppe 1 durch einen Lappen gesch tzt und vollst ndig zusammenge dr ckt wird dD Darauf achten dass die D mpfer Baugruppe nicht besch digt wird 13 Das bersch ssige l an d...

Page 434: ...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 435: ...ation de la bague d tanch it utiliser une feuille en vi nyle a avec de l huile de fourche ap pliqu e pour prot ger la l vre de la bague d tanch it 9Installer le joint huile dont les marques d usine ou...

Page 436: ...ver 3 19 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 20 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 21 Insta...

Page 437: ...S Den Gabelbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 20 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren R...

Page 438: ...o damper assembly 3 NOTE Install the collar with its larger dia end a facing the fork spring 25 Install 9Damper assembly 1 To inner tube 2 cC To install the damper assembly into the inner tube hold th...

Page 439: ...lta verso la molla della forcella 25 Monter 9 Amortisseur complet 1 Au tube interne 2 fF Pour installer l amortisseur complet dans le tube plongeur maintenir l tanch it du tube plongeur Si le tube plo...

Page 440: ...stalled out of specification proper damping force cannot be obtained 29 Tighten 9Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster with specified torque 30 Install 9Adjuster 1 To inn...

Page 441: ...si zionare la chiave ad anello per vite mordente 7 tra il tubo interno e il controdado 6 9Serrare a fondo con le dita il regolato re sul gruppo ammortizzatore 28 Ispezionare 9 Distanza a tra il regola...

Page 442: ...9Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque w Never fail to make the oil amount adjustment between the maximum and minimum amount and a...

Page 443: ...es sch dliche Einfl sse auf die Lei stung der Teleskopgabel mit sich bringen 9 Darauf achten dass keine Fremd k rper in die Vorderradgabel ein dringen T Non mancare mai di eseguire la rego lazione del...

Page 444: ...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 445: ...origine 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 protezio...

Page 446: ...rn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer to REMOVAL POINTS 11 Handlebar holder upper 2 12 Ha...

Page 447: ...puchon du c ble d acc l rateur 1 Retourner le couvercle de capuchon 6 C ble d acc l rateur 1 D connecter du c t acc l rateur 7 Acc l rateur 1 Desserrer les boulons 8 Couvercle de capuchon 1 9 Colleret...

Page 448: ...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 449: ...de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poig e inf rieur 1 2 Capuchon de poig e sup rieur 1 3 Ensemble de la poign e 1 4 Poign e droite 1 Se reporter POI...

Page 450: ...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 451: ...9 Guidon 1 Deform e craquelures endom magement Changer XG Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble acc l rateur 1 Monter 9 Poig...

Page 452: ...ll 9Handlebar holder lower 1 9Plain washer 2 9Nut handlebar holder lower 3 NOTE 9Install the handlebar holder lower with its side having the greater distance a from the mount ing bolt center facing fo...

Page 453: ...avant 9Appliquer de la graisse base de savon au lithium sur le filetage du support de guidon inf rieur 9L installation du support de guidon inf rieur en sens inverse permet de changer le d calage d av...

Page 454: ...the handlebar as shown 9First tighten the bolts on the front side of the handlebar holder upper and then tighten the bolts on the rear side 4 Install 9Grip left 1 Apply the adhesive to the handlebar 2...

Page 455: ...s 9Installer le guidon de fa on ce que la saillie c du support de guidon sup rieur soit positionn e sur la marque du guidon comme illustr 9Serrer d abord les boulons l avant du support de guidon sup...

Page 456: ...2 9 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 10 Install 9Cap cover 1 1 Nm 0 1 m kg 0 7 ft lb 6 Install 9Throttle cable 1 To tube guide 2 NOTE Apply...

Page 457: ...tubo 2 NOTA Applicare 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 7 Installare 9 Rullo 1 9 Collare 2 NOTA 9Applicare i...

Page 458: ...grip cap and brake lever 2 2 are equal If you make a mistake in the grip cap installation position the brake lever may contact the grip cap resulting in poor brake performance 9After tightening the bo...

Page 459: ...s avoir serr les boulons v ri fier que la poign e d acc l rateur 3 3 tourne sans probl me Sinon res serrer les boulons pour la r gler 13 Monter 9 Bouton d arr t du moteur EN GINE STOP 1 9 Support de l...

Page 460: ...5 49 CHAS HANDLEBAR 14 Install 9Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch cable end 15 Adjust 9Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3...

Page 461: ...u CHAPITRE 3 14 Einbauen 9 Kupplungskabel 1 HINWEIS Lithium Fett am Kupplungskabelende auftragen 15 Einstellen 9 Spiel des Kupplungshebels Siehe Abschnitt EINSTEL LUNG DER KUPPLUNG im KAPITEL 3 14 Ins...

Page 462: ...rown 1 4 Ring nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Bearing race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Bearing race 2 Refer to REMOVAL POIN...

Page 463: ...geordnet wird Nummernschild Siehe Abschnitt SITZ KRAFTSTOFFTANK UND SEITENDECKEL im KAPITEL 4 Lenkstange Siehe Abschnitt LENKSTANGE Vorderrad Kotfl gel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe...

Page 464: ...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 465: ...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...

Page 466: ...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 467: ...ulement et de cages de roulement REMONTAGE ET MONTAGE Etrier inf rieur 1 Monter 9 Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint anti poussi re et sur...

Page 468: ...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 469: ...l conque retirer l ensemble axe de direction et inspecter le support de direction 6 Monter 9 Rondelle ordinaire 1 7 Monter 9 Fourche avant 1 9 Etrier sup rieur 2 N B 9Serrer le boulon de bridage trier...

Page 470: ...he under bracket 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 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 9 After...

Page 471: ...2 iI Serrare la staffa inferiore alla coppia specificata Se troppo serrata pu provocare il malfunzionamento della forcella anteriore Oberes Ende der Gabelbein rohre Standard a 5 mm 0 20 in Extr mit su...

Page 472: ...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 473: ...E UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdr cken Antriebskette 1 Kettenschutz 1 2 Kettenspanner unten 1 3 Schraube Hinterad Sto d mpfer 1 Die Hinterradschwi...

Page 474: ...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 475: ...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 476: ...ush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574211 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revol...

Page 477: ...ken auf den u eren Laufring ausbauen INSPEKTION Die Lager Buchsen und H lsen in L sungsmittel waschen Hinterradschwinge 1 Pr fen 9 Lager 1 9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost Lager un...

Page 478: ...nstalled depth of bearings Outer a a Zero mm Zero in Inner b b 6 5 mm 0 26 in EC574311 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and colla...

Page 479: ...mit den Herstellermarkierungen oder Herstellungsnummern eingepresst wird 9 Zuerst die u eren Lager und danach die inneren Lager bis zur vorgeschrie benen Tiefe von innen einbauen Profondit installata...

Page 480: ...er 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the be...

Page 481: ...der Drucklager auftragen 2 Einbauen 9 H lse 1 9 Unterlegscheibe 2 Zum Relaisarm 3 HINWEIS Das Molybd n Fett auf den H lsen und den ldichtungslippen auftragen Profondeur install e de roulement a a Z ro...

Page 482: ...lybdenum disulfide grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To...

Page 483: ...r l crou ce stade 6 Monter 9 Bras oscillant 1 9 Axe de pivot 2 N B 9Appliquer de la graisse de molybd ne sur l axe de pivot 9Introduire l arbre pivot par le c t droit 5 Einbauen 9 Relaisarm 1 9 Schrau...

Page 484: ...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 485: ...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 486: ...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 487: ...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 488: ...table stand under the engine Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air cleaner joint 1 Loos...

Page 489: ...re arri re 1 3 Boulon amortisseur arri re bras de relais 1 Tenir le bras oscillant 4 Boulon amortisseur arri re cadre 1 5 Amortisseur arri re 1 6 Contre crou 1 7 Dispositif de r glage 1 8 Si ge de res...

Page 490: ...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 491: ...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 492: ...ON EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly 9Spring 3 Damag...

Page 493: ...plet 9 Amortisseur 2 Fuite d huile Changer l amor tisseur complet Fuite de gaz Remplacer l amortisseur complet 9 Ressort 3 Endommagement Changer le ressort Fatigue Changer le ressort Comprimer et d te...

Page 494: ...bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopper ring upper bearing 1 NOTE After installing the stopper ring push back t...

Page 495: ...sur c t o les rep res ou num rous du fa bricant sont inscrits Ressort amortisseur arri re 1 Monter 9 Ressort 1 9 Guide de ressort sup rieur 2 9 Guide de ressort inf rieur 3 IC585000 MONTAGGIO E INSTA...

Page 496: ...pply the lithium soap base grease on the O rings 2 Install 9Bush 1 9Collar 2 9Dust seal 3 NOTE 9Apply the molybdenum disulfide grease on the bearing and dust seal lips 9Install the dust seals with the...

Page 497: ...toriques 2 Monter 9 Bague 1 9 Collerette 2 9 Joint antipoussi re 3 N B 9Appliquer de la graisse au bisulfure de molybd ne sur le roulement et les l vres des joints antipoussi re 9Monter les joints an...

Page 498: ...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 499: ...lybd 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 posterior...

Page 500: ...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 501: ...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 502: ...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 503: ...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 504: ...uern 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 ndsyst...

Page 505: ...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 506: ...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 507: ...ET DU MOTEUR ENGINE STOP 1 Examiner 9 Conductibilit du bouton d arr t du moteur ENGINE STOP Pas de continuit lorsqu enfonc Changer Continuit lorsque rel ch Changer IC622001 TEST DELLA DISTANZA TRA GLI...

Page 508: ...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 509: ...cio della candela girandolo in senso antiorario e con trollarlo 9Rimontare il cappuccio della candela girandolo in senso orario finch non bene avvitato Resistenza Posizione del della bobina selettore...

Page 510: ...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 511: ...ives Kabel des Pr fger tes Wei Rotes Kabel 1 Negatives Kabel des Pr fger tes Wei Blaues Kabel 2 Widerstand Position des der W hlschalters Aufnahmespule am Pr fger t 248 372 bei 100 20 C 68 F Positives...

Page 512: ...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 513: ...onare 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 Qu...

Page 514: ...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 515: ...urface de la route et la d coloration de bougie s Prenant ces facteurs en consid ration il s lectionnera les meilleurs r glages de carburateur possibles Il est recommand de prendre note des r glages d...

Page 516: ...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 517: ...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 518: ...ging the main jet 1 Except for USA and CDN 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 calibr...

Page 519: ...e 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 Tranne che per USA e CDN 1 La candela troppo calda Sele...

Page 520: ...ew 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 can be...

Page 521: ...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 peut tre eff...

Page 522: ...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 523: ...ebs 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 um e...

Page 524: ...om 6BFY42 74 to 6BFY44 74 has the same effect as a rising of 1 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 richer c 1 richer 7 6 TUN SETTI...

Page 525: ...positions de clip le changement de 6BFY42 74 6BFY44 74 pro duit le m me effet qu un rel vement de 1 posi tions de clip A Diff rence de diam tre de portion droite B Diff rence de position de rainure a...

Page 526: ...ip Position glei ch nummeriert ist hat die Ver nderung von 6BFY42 74 zu 6BFY44 74 die gleiche Wir kung wie das Anheben der 1 Clip Position A Unterschied beim Durchmesser des geraden Teils B Unterschie...

Page 527: ...mo lo stesso passare da 6BFY42 74 a 6BFY44 74 ha lo stesso effetto che alzare di 1 la posizione del fermo A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a graffa...

Page 528: ...position changing from 6BFY43 74 to 6BFY44 74 has the same effect as a rising of 0 5 clip position A Difference in straight portion dia B Difference in clip position a Reference needle b 0 5 richer c...

Page 529: ...de positions de clip le changement de 6BFY43 74 6BFY44 74 pro duit le m me effet qu un rel vement de 0 5 position de clip A Diff rence de diam tre de portion droite B Diff rence de position de rainur...

Page 530: ...Clip Position gleich nummeriert ist hat die Ver nderung von 6BFY43 74 zu 6BFY44 74 die gleiche Wirkung wie das Anheben der 0 5 Clip Posi tion A Unterschied beim Durchmesser des geraden Teils B Unters...

Page 531: ...fermo lo stesso passare da 6BFY43 74 a 6BFY44 74 ha lo stesso effetto che alzare di 0 5 la posi zione del fermo A Differenza di diametro della parte diritta B Differenza di posizione del fermaglio a g...

Page 532: ...ottle 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 Therefore the fuel flow is balanced at each stage of thr...

Page 533: ...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 dans une com binaison de diam tre de l aiguille de...

Page 534: ...STD 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 6BFY44 72 284 14116 K2 6BFY44 73 284 14116 K3 6BFY44...

Page 535: ...14142 40 No 42 5 4KM 14142 42 STD 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 4 25 1C3 14112 42 3 3 Povera Ago a Ricca 6B...

Page 536: ...Raise jet needle clip position 1 groove up 1 4 3 4 throttle Lower jet needle clip position Hard breathing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Slow speed pick up...

Page 537: ...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 538: ...i la couleur est fonc e la condition est bonne Si la normalisation est impossible Si ge de pointeau bouch Tuyau de carburant bouch Robinet de carburant bouch D coloration de la bougie Si la couleur es...

Page 539: ...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 540: ...and Falls nicht normalisiert werden kann Verstopfter Schwimmerventilsitz Verstopfter Kraftstoffschlauch Verstopfter Kraftstoffhahn Verf rbung der Z ndkerze Bei hellbrauner Farbe ist sie in gutem Zusta...

Page 541: ...ung 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 n...

Page 542: ...tura Controllo Scolorimento della candela Se color cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del ca...

Page 543: ...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 544: ...o 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 sto...

Page 545: ...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 546: ...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 547: ...et d terminer le taux de r duction secon daire 9Quand il y a de grandes lignes droites r gler la machine de sorte ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en...

Page 548: ...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 549: ...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 so gew...

Page 550: ...final stroke can be changed by changing the fork oil amount cC Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a nois...

Page 551: ...uit une tendance au dur cissement de la fourche avec comme cons quence une d t rioration des performances et des caract ristiques Voil pourquoi il convient d ajuster la fourche dans la plage sp cifi e...

Page 552: ...ronger and the front fork may sink deeply over a series of gaps To set a soft spring 9Change the rebound damping Turn out one or two clicks 9Change the compression damping Turn in one or two clicks 2...

Page 553: ...ndern Um eine oder zwei Klickstel lungen herausdrehen 9 Die Einfederd mpfung ndern Um eine oder zwei Klickstel lungen hereindrehen 2 Verwendung einer harten Feder Normaleweise bewirkt eine harte Fede...

Page 554: ...hange the spring 2 Setting of damping force 9Change the rebound damping 9Change the compression damping SPRING SPRING I D TYPE RATE PART NUMBER MARK slits SOFT 0 398 1C3 23141 A0 I STD 0 408 1C3 23141...

Page 555: ...0 IIIII HART 0 449 1C3 23141 F0 I I 0 459 1C3 23141 G0 I II 0 469 1C3 23141 H0 I III 0 479 1C3 23141 J0 I IIII IC72P010 Parti di regolazione della forcella anteriore 9Molla della forcella anteriore 1...

Page 556: ...e the standard figure from the subtraction of the length b from the length a Standard figure 90 100 mm 3 5 3 9 in NOTE 9If the machine is new and after it is broken in the same set length of the sprin...

Page 557: ...ottraen do la lunghezza b dalla lunghezza a Valeur standard 90 100 mm 3 5 3 9 in Standardwert 90 100 mm 3 5 3 9 in Cifra normale 90 100 mm 3 5 3 9 in HINWEIS 9 Wenn eine neue Maschine eingefah ren wor...

Page 558: ...ng for more rebound damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the...

Page 559: ...k tur den niedrigen Einfederd mp fungeinsteller zur weicheren Seite hin stellen IC72G020 Registrazione della molla dopo la sostituzione Dopo la sostituzione assicurarsi di regolare la molla alla lungh...

Page 560: ...I D marks SPRING SPRING I D SPRING TYPE RATE PART NUMBER MARK FREE Q TY LENGTH SOFT 4 3 5UN 22212 00 Brown 1 260 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 STIFF 5 7 5UN 22212 70 White...

Page 561: ...di marcatura di identifica zione FEDER FEDER TEILE ID Markie Ungespannte TYP KON NUMMER rung Federl nge STANTE Quantit t WEICH 4 3 5UN 22212 00 Braun 1 260 5 3 5UN 22212 50 Gelb 1 260 5 5 5UN 22212 6...

Page 562: ...OF LENGTH ADJUSTMENT b 260mm 10 24in 240 5 258 5mm 9 47 10 18in 275mm 10 83in 255 5 273 5mm 10 06 10 77in SPRING FREE EXTENT OF LENGTH ADJUSTMENT b One I D mark 245 5 263 5 mm 9 67 10 37 in Approx 26...

Page 563: ...18 in 275 mm 10 83 in 255 5 273 5 mm 10 06 10 77 in LONGUEUR DE ETENDUE DE RESSORT LIBRE REGLAGE b Une marque d identification 245 5 263 5 mm 9 67 10 37 in Deux marques Approx 265 mm d identification...

Page 564: ...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 565: ...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 566: ...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 567: ...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 568: ...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 569: ...D mpfung zu ver ringern Eingetauchte L nge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu steige...

Page 570: ...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 571: ...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...

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Page 575: ...y Yamaha Motor Co Ltd 1st Edition May 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC01001...

Page 576: ...FAHRER UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ125 W W1 1C3 28199 32 PRINTED IN JAPAN 2006 5 1 6 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED...