Yamaha YZ250(P)/LC, Owner'S Service Manual

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

Page 2: ......

Page 3: ...aha Motor Co Ltd 1 Ausgabe Juni 2001 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet G...

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4: ...please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yama ha dealer w PLEASE READ T...

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 19: ...INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7 ALLGEMEIN ANGABEN CARACTERISTIQUES VERIFICATION ET REGLAGES COURANTS TECHINSCHE DATEN REGELM SSIGE PR FUNG UND EINSTELLUNGEN MOTEUR MOTOR PARTIE CYCLE FAHRGESTELL...

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

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

Page 22: ...RY DRIVEN GEAR 4 33 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 40 YPVS GOVERNOR 4 49 WATER PUMP 4 52 CDI MAGNETO 4 56 ENGINE REMOVAL 4 60 CRANKCASE AND CRANKSHAFT 4 65 TRANSMISSION SHIFT CAM AND S...

Page 23: ...SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE 4 40 REGULATEUR YPVS 4 49 POMPE A EAU 4 52 MAGNETO CDI 4 56 DEPOSE DU MOTEUR 4 60 CARTER ET VILEBREQUIN 4 65 BOITE A VITESSES BARILLET DE SELECTEUR ET FOUR...

Page 24: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 SOLENOID VALVE SYSTEM 6 6 TPS THROTTLE POSITION SENSOR SYSTEM 6 8 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 13...

Page 25: ...COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE 6 1 SYSTEME D ALLUMAGE 6 2 SYSTEME D ELECTROVANNE 6 6 SYSTEME TPS CAPTEUR DE POSITION DU PAPILLON 6 8 CHAPITRE 7 MISE AU POINT MOTEUR 7 1 PARTIE CYCLE 7 13...

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

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

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: ...ousing hole at the bottom 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and o...

Page 31: ...ment remon t es 5 Tenir loign du feu 4 W hrend der Demontage der Maschine sind alle Teile zu reini gen und in der Reihenfolge der Demontage in Ablagen abzule gen um die Montage zu beschleunigen und ri...

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

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

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

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

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

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

Page 38: ...e the crankshaft from either case YM 1189 90890 01189 Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto YU 1235 90890 01235 Rotor holding tool YU 1235 90890 01235 Th...

Page 39: ...90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 90890 03113 90890 03113 Engine tachometer This tool is needed for observin...

Page 40: ...quin de l une ou l autre de ses moiti s YU 1135 A 90890 01135 YM 1189 90890 01189 Extracteur du volant Cet outil doit tre utilis pour la d pose du volant magn tique YM 1189 90890 01189 YU 1235 90890 0...

Page 41: ...et outil pour examiner la r sistance de bobine la tension de sortie et l intensit YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Outil de poign e d brrayag...

Page 42: ...M 1189 90890 01189 Schwungrad Abziehwerkzeug Dieses Werkzeug wird f r den Ausbau des Schwung rad Magnetz nders ben tigt YM 1189 90890 01189 YU 1235 90890 01235 Rotor Haltewerkzeug Dieses Werkzeug wird...

Page 43: ...zeug ist f r das Pr fen des Spulenwie derstandes der Ausgangsspannung und der Strom st rke zu verwenden YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Kupp...

Page 44: ...1135 A 90890 01135 YM 1189 90890 01189 Estrattore del volano Questo utensile viene usato per togliere il magnete del volano YM 1189 90890 01189 YU 1235 90890 01235 Utensile di supporto del rotore Que...

Page 45: ...ispezionare la resistenza della bobina la tensione in uscita e l intensit di corrente YU 3112 C 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Utensile per tenere l...

Page 46: ...AL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick...

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

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

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

Page 50: ...o the fuel tank breather hose cC In this installation make sure the arrow faces the fuel tank and also downward EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when...

Page 51: ...raftstofftank Bel ftungsschlauch eingebaut dD Bei diesem Einbau ist darauf zu achten da der Pfeil auf den Kraft stofftank und nach unten weist IC15R001 CAVALLETTO STACCABILE Questo cavalletto 1 viene...

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

Page 53: ...con la benzina nel rap porto specificato pi sotto Usare sem pre benzina fresca di marca e miscela re l olio e la benzina il giorno della gara Non usare una miscela gi prepa rata che abbia pi di qualc...

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

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

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

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

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

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

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

Page 61: ...onerie timonerie De la timonerie au cadre De la timonerie l amortisseur De la timonerie au bras oscillant Arri re Installation de De l amortisseur au cadre l amortisseur Arri re Installation du bras o...

Page 62: ...st nge am Sto d mpfer Gest nge an Hinterradschwinge Hinten Einbau des Sto d mpfer am Rahmen Sto d mpfers Hinten Einbau der Festziehen der Drehzapfenwelle Hinterradshcwinge Rad Einbau des Rades Vorne F...

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

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

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

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

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

Page 68: ...ooled 2 stroke gasoline Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 lmp oz 8 42 US oz Bore Stroke 66 4 72 mm 2 614 2 835 in Compression ratio 9 1 10 6 1 Starting sy...

Page 69: ...21 0 952 Chassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 27 0 26 8 Trail 118 mm 4 65 in 114 mm 4 49 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90 19 62M...

Page 70: ...0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Side clearance installed 1st 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2nd 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Crankshaft Crank width A 5...

Page 71: ...ain air jet M A J 200 Jet needle clip position J N N3EJ 2 N3CW 3 Main nozzle N J 2 9 Cutaway C A 7 Pilot jet P J 50 52 Pilot air screw P A S 1 1 3 8 for reference only Valve seat size V S 3 8 mm 0 15...

Page 72: ...hose clamp M 6 1 0 8 1 0 1 0 7 Air filter element M 6 1 0 1 2 0 2 1 4 Carburetor joint M 6 1 0 5 10 1 0 7 2 Air filter case M 6 1 0 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 1 0 1 0 7 Reed valve M...

Page 73: ...1 75 7 5 54 Clutch spring M 6 1 0 6 10 1 0 7 2 Push lever axle M 5 0 8 1 6 0 6 4 3 Drive sprocket M20 1 0 1 75 7 5 54 Shift guide M 6 1 0 2 10 1 0 7 2 Stopper lever M 6 1 0 1 10 1 0 7 2 Torsion spring...

Page 74: ...outer tube with inner tube 3 15 5 91 in and damper rod fully compressed without spring Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end Zero mm Zero in Rear susp...

Page 75: ...0 3 0 mm 9 84 0 12 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: ...nt brake master cylinder cap Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Cable guide front brake hose and guide stay Front brake hose union bolt master cylinder Fro...

Page 77: ...bsorber and relay arm Rear frame and frame Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Fuel tank mounting Fuel t...

Page 78: ...pe Electrical CDI Magneto model stator Manufacturer 5CU 01 YAMAHA Source coil 1 resistance color 720 1 080 at 20 C 68 F Black Black Red Source coil 2 resistance color 44 66 at 20 C 68 F Green Blue Gre...

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: ...refroidissement liquide Dispositions de cylindres Monocylindre inclin Cylindr e 249 cm3 8 76 lmp oz 8 42 US oz Al sage course 66 4 72 mm 2 614 2 835 in Taux de compression 9 1 10 6 1 Syst me de d mar...

Page 81: ...SA ZA AUS NZ EUROPE CDN Type de cadre Simple berceau d d double Angle de chasse 27 0 26 8 Chasse 118 mm 4 65 in 114 mm 4 49 in Pneu Type de pneu Avec chambre air Taille de pneu avant 80 100 21 51M Tai...

Page 82: ...T 2 55 mm 0 100 in Ecartement des becs mont 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Jeu lat ral mont 1 re 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2e 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm...

Page 83: ...175 Gicleur d air M A J 200 Aiguille J N N3EJ 2 N3CW 3 Tubulure principal N J 2 9 Echancrure C A 7 Gicleur de ralenti P J 50 52 Vis d air de ralenti P A S 1 1 3 8 r f rence uniquement Taille de si ge...

Page 84: ...ment du filtre air M 6 1 0 1 2 0 2 1 4 Raccord de carburateur M 6 1 0 5 10 1 0 7 2 Carter de filtre air M 6 1 0 4 8 0 8 5 8 Bride de guidage de filtre air M 5 0 8 1 1 0 1 0 7 Soupape flexible M 3 0 5...

Page 85: ...M 6 1 0 6 10 1 0 7 2 Axe de levier de pouss M 5 0 8 1 6 0 6 4 3 Pignon de cha ne M20 1 0 1 75 7 5 54 Guide de s lecteur M 6 1 0 2 10 1 0 7 2 Levier de but e M 6 1 0 1 10 1 0 7 2 Ressort de torsion arb...

Page 86: ...tuyau 3 15 5 91 in int rieur et la tige d amortisseur compl tement appuy sans le ressort Grade d huile Huile de suspension 01 Diam tre ext rieur de tube interne 46 mm 1 81 in Extr mite sup rieure de f...

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: ...vant trier Etrier de frein avant et fourche avant Etrier de frein avant et arri re et bouchon de goupille de plaquette Etrier de frein avant et arri re et goupille de plaquette Etrier de frein avant e...

Page 89: ...ervoir essence et vis d accrochage bande de fixation R servoir essence et patte du r servoir essence Montage de selle Montage de couvercle lat ral Montage de buse d arriv e d air Montage de pare boue...

Page 90: ...ue CDI Magn to mod le stator Fabricant 5CU 01 YAMAHA R sistance de bobinage de source 1 720 1 080 20 C 68 F couleur noir noir rouge R sistance de bobinage de source 2 44 66 20 C 68 F couleur vert bleu...

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: ...t Wassergek hlter Zweitakt Motor Benzin Zylinder Ein Zylinder nach vorne geneigt Hubraum 249 cm3 8 76 lmp oz 8 42 US oz Bohrung Hub 66 4 72 mm 2 614 2 835 in Verdichtungsverh ltnis 9 1 10 6 1 Anla sys...

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

Page 94: ...genspalt Eingebaut 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Seitliches Spiel Eingebaut 1 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 Gang 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in...

Page 95: ...M J 178 175 Hauptluftd se M A J 200 D sennadel Klemmposition J N N3EJ 2 N3CW 3 Hauptzerst uber N J 2 9 Abschr gung C A 7 Leerlaufd se P J 50 52 Leerlauf Luftregulierschraube P A S 1 1 3 8 nur als Hinw...

Page 96: ...6 1 0 8 1 0 1 0 7 Luftfilterelement M 6 1 0 1 2 0 2 1 4 Vergaserverbindung M 6 1 0 5 10 1 0 7 2 Luftfiltergeh use M 6 1 0 4 8 0 8 5 8 Luftfilter F hrungsschelle M 5 0 8 1 1 0 1 0 7 Zungenventil M 3 0...

Page 97: ...plungsfeder M 6 1 0 6 10 1 0 7 2 Schubhebelachse M 5 0 8 1 6 0 6 4 3 Antriebskettenrad M20 1 0 1 75 7 5 54 Schaltf hrung M 6 1 0 2 10 1 0 7 2 Anschlaghebel M 6 1 0 1 10 1 0 7 2 Torsionsfeder Schaltwel...

Page 98: ...nneren Rohr und der D mpfungsstange ohne Feder voll zusammengedr ckt lsorte Teleskopgabel l 01 Au endurchmesser des inneren Rohres 46 mm 1 81 in Oberes Ende der Null mm Null in Vorderradgabelbeinrohre...

Page 99: ...3 0 mm 9 84 0 12 in Bremsbelagst rke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder 11 0 mm 0 433 in Innendurchmesser Bremssattelzylinder 27 0 mm 1 063 in 2 Innendurchmesser Bremsfl ssigkeit DOT 4 H...

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

Page 101: ...utz und Hinterradschwinge Kraftstofftank Befestigung Kraftstofftank und Kraftstoffhahn Kraftstoftank und Sitzeinstellhalterung Kraftstof tank und Hakenschraube Befestigungsband Kraftstoftank und Kraft...

Page 102: ...h Ausf hrung CDI Modell staor Hersteller 5CU 01 YAMAHA Widerstand der Stromspule 1 Farbe 720 1 080 bei 20 C 68 F Schwarz Schwarz Rot Widerstand der Stromspule 2 Farbe 44 66 bei 20 C 68 F Gr n Blau Gr...

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

Page 104: ...re a 2 tempi raffreddato con liquido a benzina Disposizione dei cilindri Cilindro unico inclinato in avanti Cilindrata 249 cm3 8 76 lmp oz 8 42 US oz Alesaggio corsa 66 4 72 mm 2 614 2 835 in Rapporto...

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

Page 106: ...in 0 95 mm 0 037 in Gioco laterale installata 1 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Albero a gomiti Larghezza del gomito A 59 95 60 00 mm...

Page 107: ...ncipale M A J No 200 Posizione della staffa dell ago di getto J N N3EJ 2 N3CW 3 Ugello principale N J 2 9 Sezione C A No 7 Getto pilota P J No 50 No 52 Vite dell aria pilota P A S 1 1 3 8 solo riferim...

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

Page 109: ...della frizione M 6 1 0 6 10 1 0 7 2 Asse della leva di spinta M 5 0 8 1 6 0 6 4 3 Rocchetto di trasmissione M20 1 0 1 75 7 5 54 Guida del cambio M 6 1 0 2 10 1 0 7 2 Leva di fermo M 6 1 0 1 10 1 0 7 2...

Page 110: ...in il tubo interno e la barra dello smorzatore completamente compressi senza molla Qualit di olio Olio per sospensioni 01 Diametro esterno del tubo interno 46 mm 1 81 in Estremit superiore della forc...

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: ...teriore M 6 1 0 2 9 0 9 6 5 Coperchio del cilindro principale del freno anteriore M 4 0 7 2 2 0 2 1 4 Leva di comando del freno vite M 6 1 0 1 6 0 6 4 3 Leva di comando del freno dado M 6 1 0 1 6 0 6...

Page 113: ...atore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore e telaio M 8 1 25 3 29 2 9 21 Forcellone oscillante e supporto del t...

Page 114: ...co CDI Modello statore Costruttore del magnete 5CU 01 YAMAHA Resistenza 1 della bobina di origine 720 1 080 20 C 68 F colore Nero Nero Rosso Resistenza 2 della bobina di origine 44 66 20 C 68 F colore...

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

Page 116: ...hrottle cable C Pass the throttle cable and ENGINE STOP button lead over the radiator hose D Clamp the throttle cable and ENGINE STOP button lead with the clamp ends downward E Pass the clutch cable a...

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

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

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

Page 120: ...e clamp passes with its ends downward as shown C Position the CDI magneto lead coupler between the radiators D Clamp the wireharness to the right engine bracket E Clamp the high tension cord throttle...

Page 121: ...adiateurs D Bridez le faisceau de fils sur le support droit du moteur E Bridez le cordon de haute tension le c ble d acc l rateur et le faisceau de fils en orientant les extr mit s de la bride vers le...

Page 122: ...e brake hose to the caliper with the paint on the pipe facing the caliper and with the pipe contacting the caliper projection C Pass the brake hose into the brake hose holders D If the brake hose cont...

Page 123: ...peine sur le conduit soit orient e vers l trier et que le conduit soin et 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...

Page 124: ...directs as show and lightly touches the projection on the master cylinder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Pass the clutch cable in front of the throttle cable D...

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

Page 126: ...Check ring end gap Replace PISTON PIN SMALL END BEARING Inspect Replace CYLINDER HEAD Inspect and clean Remove carbon Retighten Check gasket CYLINDER Inspect and clean Inspect score marks Replace Ins...

Page 127: ...KS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease REAR SHOCK ABSORBER After Inspect and adjust rain ride Lube Mo...

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

Page 129: ...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 huile...

Page 130: ...frein disque les boulons d tier les boulons du ma tre cylindre et les boulons d union 6 6 Changer les plaquettes 6 Changer le liquide de frein 6 FOURCHE AVANT Contr ler et r gler 6 6 Changer l huile 6...

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

Page 132: ...BOLZEN PLEUELAUGEN LAGER Pr fen 6 Erneuern 6 ZYLINDERKOPF Pr fen und reinigen 6 6 Nachziehen 6 6 ZYLINDER Pr fen und reinigen 6 6 Erneuern 6 YPVS Pr fen und reinigen 6 6 KUPPLUNG Pr fen und einstellen...

Page 133: ...AHN Reinigen und pr fen 6 6 BREMSEN Bremshebelposition und Bremspedalh he einstellen 6 6 Drehzapfen schmieren 6 6 Bremsscheibenfl che pr fen 6 6 Fl ssigkeitsstand pr fen und auf Undichtigkeit achten 6...

Page 134: ...ch Rennen Rennen R DER REIFEN Reifendruck Felgenschlag Reifenverschlei und Speichen 6 6 auf Lockerung pr fen Ketternrad Befestigungsschraube 6 6 nachziehen Lager pr fen 6 Lager erneuern 6 Schmieren 6...

Page 135: ...A CILINDRO Ispezione e pulitura 6 6 Riserraggio 6 6 CILINDRO Ispezione e pulitura 6 6 6 Sostituzione YPVS Ispezione e pulitura 6 6 FRIZIONE Ispezione e regolazione 6 6 Sostituzione 6 TRASMISSIONE Sost...

Page 136: ...ELLE 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 AMMORTIZZATORE POSTERIOR...

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

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

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

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

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

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

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

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

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

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

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

Page 148: ...essure Impossible to maintain the specified pres sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the speci...

Page 149: ...ppliquer de l eau sur le joint du bou chon du radiateur 3 Bouchon du radiateur 2 Appliquer la pression sp cifi e 3 Examiner 9 Pression Impossible de maintenir la pres sion sp cifi e pendant 10 seconde...

Page 150: ...Radiator hose 3 Swelling Replace 2 Adjust 9Clutch lever free play EC359020 CLUTCH ADJUSTMENT 1 Check 9Clutch lever free play a Out of specification Adjust NOTE 9Make minute adjustment on the lever sid...

Page 151: ...NOTA 9Non applicare pressione superiore alla pressione specificata 9Il radiatore dovrebbe essere completa mente pieno 4 Ispezionare 9 Pressione Impossibile mantenere la pres sione specificata per 10 s...

Page 152: ...rease On the throttle cable end a tube guide cable winding portion b and roller sliding surface c Throttle grip free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until the specifie...

Page 153: ...A 1 Togliere 9 Coperchio della calotta 1 9 Calotta del cavo dell acceleratore 2 Jeu la poign e d acc l ration a a 3 5 mm 0 12 0 20 in Gioco libero della mano pola dell acceleratore a a 3 5 mm 0 12 0 2...

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

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

Page 156: ...hole 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 fil...

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

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

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

Page 160: ...level 9 Install 9Oil filler cap 2 EC35L021 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Adjusting steps 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw...

Page 161: ...4 10W 30 ou huile moteur SAE 10W 30 type SE Quantit d huile change ments d huile p rio diques 0 75 L 0 66 Imp qt 0 79 US qt Olio raccomandato Olio per motore Yamalube 4 10W 30 oppure SAE 10W 30 del ti...

Page 162: ...ct 9O ring 1 Damage Replace NOTE Install the O rings with their depressed a facing outward EC35R050 SILENCER FIBER REPLACEMENT 1 Remove 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adj...

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

Page 164: ...r 4 9Side cover right 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9 Inner pipe NOTE Fully apply Quick gasket Yamaha bo...

Page 165: ...0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 D poser 9 Silencieux interne 1 3 Changer 9 Fibre 2 4 Monter 9 Silencieux interne N B Appliquez g n reusem...

Page 166: ...rake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place...

Page 167: ...iedrigem Bremsfl ssig keitsstand 9 Bei fehlerhafter Funktion der Bremsanlage Falls die Bremsanlage nicht richtig entl ftet wird kann es zu einer gef hrlichen Abnahme des Brems verm gens kommen 1 Ausba...

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

Page 169: ...o pu essere necessario lasciare stabi lizzare il liquido dell impianto fre nante per qualche ora Ripetere la procedura di spurgo quando le bol licine nell impianto sono scompar se j Aggiungere liquido...

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 9L...

Page 171: ...nnerhalb der vorgeschriebenen H he liegt 9 Die Sicherungsmutter festziehen W 9 Die Pedalh he gem Abbil dung zwischen dem Maximum A A und dem Minimum B B einstel len Bei dieser Einstellung soll te das...

Page 172: ...er piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 8 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9T...

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

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 w Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb B...

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

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

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

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

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

Page 180: ...SPECTION 1 Remove 9Master link clip 9Joint 1 9Drive chain 2 2 Clean 9Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain 3...

Page 181: ...9 Kettenschlo klemme 9 Verbindung 1 9 Antriebskette 2 IC368000 ISPEZIONE DEI ROCCHETTI 1 Ispezionare 9 Denti dei rocchetti a Usura eccessiva Sostituirli NOTA Sostituire il rocchetto conduttore quel l...

Page 182: ...adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position D...

Page 183: ...me 3 dD Unbedingt die Kettenschlo klemme in der gezeigten Richtung einbau en a Drehrichtung 6 Schmieren 9 Antriebskette 5 Installare 9 Catena di trasmissione 1 9 Giunto 2 9 Graffa dell anello principa...

Page 184: ...Turn adjuster 3 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 ea...

Page 185: ...s Motors und anderer wichtiger Teile die Kettenspannung daher inner halb des spezifizierten Berei ches halten 9 Die Achsmuttern festziehen w hrend die Antriebskette nach unten gedr ckt wird 9 Die Sich...

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: ...er 1 1 her ausdrehen Plus dur a a Augmenter la force d amortisse ment de rebond Rentrer le dispo sitif de r glage 1 1 Plus mou b b Diminuer la force d amortissement de rebond Sortir le dispositif de r...

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

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

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

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

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

Page 193: ...PRECON TRAINTE DE RESSORT DE L AMORTISSEUR ARRIERE 1 Sur lever la roue arri re en pla ant la cale appropri e sons le moteur 2 D poser 9 Cadre arri re 3 Desserrer 9 Contre crou 1 4 R gler 9 Pr contrai...

Page 194: ...ion Which align the punch mark a on the ad juster with the punch mark b on the bracket For EUROPE cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be dam...

Page 195: ...ebond En tournant le dispositif de r glage 1 EINSTELLUNG DER EXPANSIONS D MPFUNGSKRAFT DES HINTER RAD STOSSD MPFERS 1 Einstellen 9 Expansions D mpfungskraft Durch Drehen des Einstellers 1 IC36N020 REG...

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

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

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

Page 199: ...tellen 9 Hohe Kompressions D mp fungskraft Den Einsteller 1 drehen IC36d000 REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL AMMOR TIZZATORE POSTERIORE 1 Regolare 9 Forza di smorzament...

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

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

Page 202: ...sembly back and forth Free play Adjust steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring...

Page 203: ...sta di sterzo 3 Controllare 9 Azione senza problemi dello sterzo Girare il manubrio da blocco a blocco Azione con problemi Regola re la ghiera dello sterzo 4 Regolare 9 Ghiera dello sterzo Einstellsch...

Page 204: ...plate 9 NOTE 9The upper handlebar holder should be installed with the punched mark a forward 9Insert the end of fuel breather hose 0 into the hole of the number plate cC First tighten the bolts on the...

Page 205: ...lato posteriore 9Desserrer l crou annulaire d un tour 9Resserrer l crou annulaire l aide de la cl pour crou annu laire XG Prendre garde de ne pas serrer excessivement 9V rifier l arbre de direction en...

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

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

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

Page 209: ...re della candela diventa fuligginoso anche se il motore e il carburatore sono in buone condizio ni di funzionamento 3 Misurare 9 Distanza tra le candele a Usare un calibro per fili metalli ci o uno sp...

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

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

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

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

Page 214: ...tting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tan...

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

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

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

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

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

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

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

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

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

Page 224: ...ction in the CHAPTER 2 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb 3 Install 9Radiator left 1 9Bolt radiator left 2 9Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM secti...

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

Page 226: ...lead 1 Disconnect the solenoid valve lead 2 TPS throttle position sensor 1 Disconnect the TPS lead throttle position sensor lead 3 Clamp carburetor joint 2 Loosen the screws carburetor joint 4 Carbure...

Page 227: ...l sen 4 Vergaser 1 5 Vergaserverbindung 1 6 Zungenventil 1 7 Anschlag Zungenventil 2 8 Zungenventil 2 9 Platte Zungenventil 1 VERGASER UND ZUNGENVENTIL F r USA CDN ZA AUS und NZ Ausbauumfang 1 Ausbau...

Page 228: ...g chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Float pin 1 7 Float 1 8 Needle valve 1 9 Main jet 1 0 Pilot jet 1 q Starter plunger 1 w...

Page 229: ...mmerstift 1 7 Schiwimmer 1 8 Nadelventil 1 9 Hauptd se 1 0 Leerlaufd se 1 q Starter Plungerkolben 1 w Drosselanschlagschraube 1 e Leerlauf Luftregulierschraube 1 Siehe unter AUSBAUPUNKTE r Kraftd se 1...

Page 230: ...rottle valve 1 9Ring 2 9Spring throttle valve 3 9Mixing chamber top 4 9Throttle cable 5 NOTE While compressing the spring throttle valve disconnect the throttle cable EC463401 Pilot air screw 1 Remove...

Page 231: ...bei der Motorleistung bewirkt IC466020 NOTA PER IL MANEGGIO iI Non allentare le viti conduttore TPS sensore di posizione gas se non per cambiare il conduttore TPS sensore di posizione gas qualora si g...

Page 232: ...9Power jet 3 Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air 9Never use a wire EC464210 Needle valve 1 Inspect 9Needle valve 1...

Page 233: ...u 1 Contr ler 9 Mouvement Coincement R parer ou chan ger N B Ins rer le boisseau 2 dans le corps du carburateur tout en maintenant le levier 1 relev et contr ler s il coulisse en douceur Drosselventil...

Page 234: ...Measurement and adjustment steps 9Hold the carburetor in an upside down posi tion 9Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NO...

Page 235: ...ilsitz und das Nadelventil kontrollieren 9 Wenn eines der beiden Teile abgenutzt ist beide Teile erneu ern 9 Befinden sich beide Teile in gutem Zustand dann ist die Schwimmerh he durch Abbie gen der S...

Page 236: ...cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping 1 Nm 0 1 m kg 0 7 ft lb 9Valve stopper height b Out of specification Adjust stopper Replace va...

Page 237: ...D Die Schrauben allm hlich festzie hen um ein Verziehen des Ventils zu vermeiden REMONTAGE ET MONTAGE Soupape flexible 1 Monter 9 Soupape flexible 1 9 But e soupape flexible 2 9 Vis soupape flexible 3...

Page 238: ...4 NOTE 9Install the gasket reed valve with its projec tion a to the left 9Install the reed valve spacer with its chamfered side b to the right 4 13 ENG CARBURETOR AND REED VALVE 10 Nm 1 0 m kg 7 2 ft...

Page 239: ...1 9 Schraube Vergaserverbin dung 2 2 Einbauen 9 Dichtung Zungenventil 1 9 Platte Zungenventil 2 F r USA CDN ZA AUS und NZ 9 Zungenventil 3 9 Zungenventil Abstandhalter 4 HINWEIS 9 Dichtung Zungenventi...

Page 240: ...it is lightly seated 9Turn out the pilot air screw by the number of turns recorded before removing 5 Install 9Pilot jet 1 9Main jet 2 2 Install 9O ring 1 9Solenoid valve 2 9Clamp 3 9Screw clamp 4 To...

Page 241: ...fo dell avviamento 1 Notare i seguenti punti di instal lazione 9Avvitare la vite dell aria pilota finch non alloggiata legger mente 9Allentare la vite dell aria pilota del numero di giri registrato pr...

Page 242: ...r ends not having the cuts a toward the carburetor 9 Install 9Jet needle 1 9Collar 2 9Spring 3 9Needle holder 4 To throttle valve 5 NOTE Install the spring with its smaller dia a facing the collar 6 I...

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

Page 244: ...er side of the air vent hose 9After installing check the throttle grip for smooth movement EC465390 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor j...

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

Page 246: ...w air cleaner joint 1 9Screw carburetor joint 2 3 Connect 9TPS throttle position sensor lead 1 9Solenoid valve lead 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Adjust 9Idle speed Refer...

Page 247: ...erverbindung 1 9 Schraube Vergaserverbin dung 2 3 Anschlie en 9 TPS Leitungskabel Drossel stellungssensor 1 9 Magnetventilleitung 2 Siehe Abschnitt KABEL F HRUNGS BERSICHT PLAN im KAPITEL 2 4 Einstell...

Page 248: ...t cylinder head side Carburetor Refer to CARBURETOR AND REED VALVE section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 6 Loosen each nut 1 4 turn and remove them after all nuts are loosened...

Page 249: ...weils 1 4 Drehung l sen bis alle Muttern locker sind 4 Zylinderkopf 1 5 Leistungsventilgeh use 1 6 Schubstange 1 Siehe unter AUSBAUPUNKTE 7 Mutter Zylinder 4 8 Zylinder 1 ZYLINDERKOPF ZYLINDER UND KOL...

Page 250: ...l end bearing 1 5 Piston ring 2 6 Power valve cover 1 7 Side holder 2 8 Thrust plate 1 9 Bolt 3 10 Valve holder 1 1 11 Valve shaft 1 12 Link lever 1 13 Pulley 2 14 Link rod 1 15 Power valve 2 2 16 Val...

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

Page 252: ...iston and piston ring 1 Remove 9Piston pin clip 1 NOTE Before removing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the crankcase cav ity...

Page 253: ...g des Kolbenbol zens 1 HINWEIS Vor dem Abnehmen des Stifts des Kol benbolzens ist das Kurbelgeh use mit einem sauberen Lappen abzudecken so da der Stift nicht versehentlich in das Kurbelgeh use f llt...

Page 254: ...rpage 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 h...

Page 255: ...e de N 400 600 3 sur un marbre et rectifier la culasse 4 en lui faisant faire des huit N B Tourner la culasse plusieurs fois pour viter d enlever trop de mati re d un c t Limite de d formation 0 03 mm...

Page 256: ...easure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measureme...

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

Page 258: ...oloration Replace 2 Measure 9Piston pin outside diameter Use micrometer 1 Out of limit Replace 3 Check 9Free play when the piston pin 1 is in place in the piston 2 There should be no noticeable for th...

Page 259: ...tre ext rieur d axe de piston 3 Pr fen 9 Spiel Wenn der Kolbenbolzen 1 im Kolben 2 eingebaut ist Es sollte kein sp rbares Spiel sein Spiel wird festgestellt Kolbenbolzen und oder Kolben erneuern 3 Con...

Page 260: ...arance Use a thickness gauge 1 Out of limit Replace piston and or ring NOTE Check at several points Ring end gap installed Standard Limit 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Side clearance St...

Page 261: ...rona del pistone 2 Misurare 9 Distanza tra le estremit Usare uno spessimetro 1 Fuori limite Sostituirla Standard Grenze 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Kolbenring Endspalt Eingebaut Stand...

Page 262: ...mm 2 61433 2 61441 in C 66 408 66 410 mm 2 61449 2 61457 in D 66 412 66 414 mm 2 61465 2 61472 in Piston mark a a color Piston size A red 66 352 66 355 mm 2 61228 2 61240 in B orange 66 356 66 359 mm...

Page 263: ...66 412 66 414 mm 2 61465 2 61472 in Tacca del Dimensioni pistone a a del pistone colore A rossa 66 352 66 355 mm 2 61228 2 61240 in B arancione 66 356 66 359 mm 2 61244 2 61256 in C verde 66 360 66 36...

Page 264: ...Spring 1 2 8 Broken Replace EC474901 Power valve hole on cylinder 1 Remove 9Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratching the aluminum 3 Combinati...

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

Page 266: ...the molybdenum disulfide oil on the power valve 1 2 Install 9Power valve 2 1 9Link rod 2 9Plain washer 3 9Screw link rod 4 NOTE Install the link rod with the cuts a in its arm ends fitting over the pi...

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

Page 268: ...ulfide oil on the grooves in the pulleys 9Apply the lithium soap base grease on the oil seal lip 9Install the valve shaft with its cut b aligning with the thrust plate 7 and then rotate the valve shaf...

Page 269: ...cottino 2 9 Puleggia 3 9 Molla 2 4 9 Rosetta 5 9 Gambo della valvola 6 NOTA 9Installare la molla 1 sulla leva del biscottino e quindi sul cilindro 9Installare la molla 1 con la parte del fermo a rivol...

Page 270: ...the power valve cover 9Install the power valve cover so that the arrow mark b faces upward EC475233 Piston ring and piston 1 Install 9Piston ring 1 NOTE 9Take care not to scratch the piston or damage...

Page 271: ...le c t imprim du joint vers le couvercle du clapet de puissance 9Installer le couvercle du clapet de puissance en orientant vers le haut la saillie b l arri re 2 Installare 9 Guarnizione cilindro 1 9...

Page 272: ...hand NOTE After installing check the smooth movement of the piston 3 Install 9Nut cylinder 1 NOTE Tighten the nuts in stage using a crisscross pat tern 3 Install 9Piston 1 9Piston pin 2 9Piston pin cl...

Page 273: ...et la surface de cylindre IC475382 Testa cilindro e cilindro 1 Applicare 9 Olio per motori Sul pistone 1 sulla fascia ela stica 2 e sulla superficie del cilindro 35 Nm 3 5 m kg 25 ft lb 35 Nm 3 5 m k...

Page 274: ...not used the power valve constituent parts will result in damage 5 Install 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 6 Install 9O ring 1 9Dowel pin 2 NOTE Apply t...

Page 275: ...lla valvola di potenza 1 9 Bullone corpo della valvola di potenza 2 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5 Nm 0 5 m kg 3 6 ft lb 25 Nm 2 5 m kg 18 ft lb 25 Nm 2 5 m...

Page 276: ...CYLINDER AND PISTON ENG 9 Install 9Spark plug 1 9Spark plug cap 2 8 Install 9Engine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 20 Nm 2 0 m kg 14 ft lb 34 Nm 3 4 m kg 24 ft lb 69 Nm...

Page 277: ...ela 1 9 Calotta della candela 2 8 Einbauen 9 Motorhalterung 1 9 Schraube Motorhalterung 2 9 Motor Befestigungsschraube Ober 3 8 Installare 9 Staffa del motore 1 9 Bullone staffa del motore 2 9 Bullone...

Page 278: ...Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Press...

Page 279: ...er 6 3 Kupplungsfeder 6 4 Druckscheibe 1 5 Reibscheibe 8 6 Kupplungsscheibe 7 KUPPLUNG UND PRIM RABTRIEBSZAHNRAD KUPPLUNGSSCHEIBE UND REIBSCHEIBE Ausbauumfang 1 Ausbau der Kupplungsscheibe und Reibsch...

Page 280: ...al tool 7 Lock washer 1 Refer to REMOVAL POINTS 8 Clutch boss 1 9 Thrust plate D 44mm 1 73 in 1 10 Primary driven gear 1 11 Bearing 1 12 Thrust plate D 42mm 1 65 in 1 13 Bolt push lever axle 1 14 Push...

Page 281: ...bhebelachse 1 14 Schbhebelachse 1 PRIM RABTRIEBSZAHNRAD SHUBSTANGE UND SCHUBHEBELACHSE Ausbauumfang 1 Ausbau der Schubstange und der Schubhebelachse 2 Demontage der Schubstange 1 3 Ausbau des Prim rab...

Page 282: ...ON EC484100 Clutch housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free pl...

Page 283: ...ten F r USA und CDN Au er USA und CDN POINTS DE DEPOSE Noix d embrayage 1 D poser 9 Ecrou 1 9 Rondelle frein 2 9 Noix d embrayage 3 N B Redresser la rondelle frein et utiliser l outil de poign e d emb...

Page 284: ...2 EC484700 Push lever axle 1 Inspect 9Push lever axle 1 Wear Damage Replace EC484810 Push rod 1 Inspect 9Push rod 1 1 9Bearing 2 9Plain washer 3 9 Push rod 2 4 Wear Damage Bend Replace EC495000 ASSEMB...

Page 285: ...uatre endroits Disque d embrayage 1 Mesurer 9 Voile de disque d embrayage Hors sp cification Changer tous les disques d embrayage Utiliser une plaque surfacer 1 et une jauge d paisseur 2 Axe de levier...

Page 286: ...il on the bearing spacer and primary driven gear inner circumference 2 Install 9Thrust plate D 44 mm 1 73 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding to...

Page 287: ...ppliquer de l huile de bo te de vitesses sur le roulement l entretoise et la circonf rence int rieure du pignon men primaire 2 Monter 9 Plaque de bot e D 44 mm 1 73 in 1 9 Noix d embrayage 2 3 Monter...

Page 288: ...es and clutch plates 6 Install 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4 NOTE Apply the lithium soap base grease on the bear ing and plain washer 7 Install 9Push rod 2 1 9Push rod 1 2 NOTE...

Page 289: ...ment 9Appliquer de l huile de bo te de vitesses sur les disques de friction et disque d embrayage 6 Monter 9 Roulement 1 9 Rondelle ordinaire 2 9 Circlip 3 sur le champignon de d brayage 1 4 N B Appli...

Page 290: ...9O ring 1 To clucth cover 11 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 12 Install 9O ring 1 9Clutch cable 2 NOTE Apply the lithium soap b...

Page 291: ...an lithium sur le joint torique 10 Installare 9 Anello di tenuta 1 Verso la protezione della frizio ne 11 Einbauen 9 Kupplungsdeckel 1 9 Schraube Kupplungsdeckel 2 HINWEIS Die Schrauben stufenweise be...

Page 292: ...ect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4...

Page 293: ...ein Pousser la p dale de frein vers le bas Tuyau de radiateur 4 D connecter du c t pompe eau Boulon Se reporter la section CULASSE champignon de d brayage CYLINDRE ET PISTON 1 Kick starter 1 2 Couverc...

Page 294: ...xle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 9 Holder 1 10 Tension spring 1 1 Ex...

Page 295: ...l arbre de s lecteur et du levier de but e Etendue de d pose Ordre Nom de pi ce Q t Remarques DEPOSE DE L AXE DE DEMAR REUR AU PIED ET DE L ARBRE DE SELECTEUR 1 Pignon de renvoi de d marreur au pied...

Page 296: ...move 9Kick axle assembly 1 NOTE Unhook the torsion spring 2 from the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assemb...

Page 297: ...arreur au pied 1 D poser 9 Ensemble axe de d marreur au pied 1 N B D crocher le ressort de torsion 2 de l orifice a sur le vilebrequin Ensemble guide de levier de s lecteur 1 D poser 9 Boulon guide de...

Page 298: ...Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Bearing 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever 9Tension spring 3 Broken Replace EC4C4100 Shift gu...

Page 299: ...r Guide de s lecteur et ensemble levier de s lecteur 1 Examiner 9 Guide de s lecteur 1 9 Levier de s lecteur 2 9 Le cliquet 3 9 Le broche cliquet 4 9 Ressort 5 Usure endommagement Changer Levier de bu...

Page 300: ...aft 2 Install 9Shift lever assembly 1 To shift guide 2 EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 EC4C5000 ASSEMBLY AND INSTALLATION EC4C513...

Page 301: ...ecteur et ensemble levier de s lecteur 1 Monter 9 Ressort 1 9 Broche cliquet 2 9 Cliquet 3 Au levier de s lecteur 4 2 Monter 9 Ensemble levier de s lecteur 1 Au guide de s lecteur 2 3 Monter 9 Ensembl...

Page 302: ...ke sure the stopper a of the torsion spring fits into the hole b on the kick axle EC4C5601 Kick axle assembly 1 Install 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer...

Page 303: ...re de s lecteur 3 N B Enduire l arbre de s lecteur et les roule ments d huile de transmission Ensemble axe de d marreur au pied 1 Monter 9 Pignon de d marreur au pied 1 9 Rondelle ordinaire 2 9 Circli...

Page 304: ...he kick axle make sure the groove a in the spring guide fits on the stopper of the torsion spring 4 Install 9Plain washer 1 9Kick axle assembly 2 NOTE 9Apply the molybdenum disulfide oil on the con ta...

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

Page 306: ...olt primary drive gear 1 NOTE Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3 EC4C5531 Primary drive gear 1 Install 9Thrust plate 1 9Primary drive gear 2 9Gov...

Page 307: ...le boulon ce stade 2 Monter 9 Pignon men primaire Se reporter la section EMBRAYAGE ET PIGNON MENE PRIMAIRE 3 Serrer 9 Boulon pignon de transmission primaire 1 N B Mettre une plaque en aluminium a ent...

Page 308: ...connecting the center of the shift shaft and bottom of the screw crankcase cover left 3 7 Install 9Kick starter 1 9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not...

Page 309: ...e montage du cou vercle d embrayage mais pas contre 8 Monter 9 P dale de s lecteur 1 9 Boulon p dale de s lecteur 2 N B Monter la p dale de s lecteur de sorte que le haut du diam tre ext rieur de la p...

Page 310: ...removal PRIMARY DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Co...

Page 311: ...EUR ET PIGNON DE TRANSMISSION 1 Ensemble r gulateur 1 2 Goujon 1 Se reporter POINTS DE DEPOSE 3 Retenue 1 4 Bille 4 5 Masselotte de retenue 1 6 Rondelle ordinaire 4 7 Roulement de but e 2 8 Collerette...

Page 312: ...ight 7 To governor shaft 8 NOTE Apply the lithium soap base grease on the thrust bearing EC4K3000 REMOVAL POINTS EC4K3100 Governor 1 Remove 9Dowel pin 1 NOTE While compressing the spring remove the do...

Page 313: ...lle ordinaire 2 Usure endommagement Changer REMONTAGE ET MONTAGE R gulateur 1 Monter 9 Pignon de r gulateur 1 9 Ressort de compression 2 9 Plaque 3 9 Rondelle ordinaire 4 9 Roulement de but e 5 9 Coll...

Page 314: ...fork b and set the governor in the crankcase cover 3 Install 9Dowel pin 1 NOTE 9While compressing the spring install the dowel pin 9Make sure the dowel pin fits into the groove a in the retainer 2 In...

Page 315: ...3 Monter 9 Goujon 1 N B 9Monter le goujon tout en comprimant le ressort 9V rifier que le goujon d assemblage est bien ajust dans le gorge a du dispositif d arr t 4 Monter 9 Ensemble r gulateur 1 N B...

Page 316: ...PUMP DISASSEMBLY Preparation for Crankcase cover right Refer to KICK AXLE SHIFT SHAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller 1 3 Plain washer 1 Refer to REMOVA...

Page 317: ...orter la section AXE DE DEMARREUR AU PIED ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSON 1 Couvercle de bo tier de pompe eau 1 2 Turbine 1 3 Rondelle ordinaire 1 Se reporter POINTS DE DEPOSE 4 Axe de tur...

Page 318: ...panners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discoloration of c...

Page 319: ...N B S il n y a un d anomalie telle qu exces sif changement du niveau de liquide de refroidissement d coloration du liquide de refroidissement ou huile de bo te de vitesses blanch tre il est inutile d...

Page 320: ...eplace EC444400 Oil seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal 1 NOTE 9Apply the lithium soap base grease on the oil seal l...

Page 321: ...ch it 1 Usure endommagement Changer REMONTAGE ET MONTAGE Bague d tanch it 1 Monter 9 Bague d tanch it 1 N B 9Appliquer la graisse base de savon au lithium sur la l vre de la bague d tanch it 9Installe...

Page 322: ...p and impeller shaft And install the shaft while turn ing it 2 Install 9Plain washer 1 9Impeller 2 NOTE Hold the impeller shaft on its width across the flats a with spanners etc and install the impell...

Page 323: ...rales aplaties a au moyen d une cl etc et monter la turbine 3 Monter 9 Goujon 1 9 Joint couvercle de bo tier de pompe eau 2 4 Monter 9 Couvercle de bo tier de pompe eau 1 9 Boulon couvercle de bo tier...

Page 324: ...oval SIDE COVERS section Bolt radiator left Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator...

Page 325: ...ERVOIR A ESSENCE ET COUVERCLES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil de magn to CDI 1 Couvercle de carter gauche 1 2 Ecrou rotor 1 Utiliser l outil sp ci...

Page 326: ...un terclockwise EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1 Remove 9Nut rotor 1 9Plain washer 2 Use the rotor holding tool 3 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect 9Rotor inner surface a 9Sta...

Page 327: ...ge du vilebrequin et le coussinet vilebrequin Si n cessaire changer le stator et ou le magn to CDI Clavette de demi lune 1 Examiner 9 Clavette de demi lune 1 Endommagement Changer REMONTAGE ET MONTAGE...

Page 328: ...n the CHAPTER 3 2 Install 9Woodruff key 1 9Rotor 2 NOTE 9Clean the tapered portions of the crankshaft and rotor 9When installing the woodruff key make sure that its flat surface a is in parallel with...

Page 329: ...er 9 Avance l allumage Se reporter la section CONTROLE ET REGLAGE DE L AVANCE A L ALLU MAGE du CHAPITRE 3 5 Serrer 9 Vis stator 1 6 Contr ler 9 Avance l allumage Recontr ler l avance l alluma ge 2 Ins...

Page 330: ...o lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a c...

Page 331: ...ois 7 Connecter 9 Fil de magn to CDI 1 Se r f rer au paragraphe DIA GRAMME DE CHEMINE MENT DE CABLE au CHA PITRE 2 7 Anschlie en 9 Kabel des CDI Magnetz nders 1 Siehe Abschnitt KABELF H RUNGS BERSICHT...

Page 332: ...aust pipe and silencer Refer to EXHAUST PIPE AND Exhaust pipe stay rear SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug Disconnect the CDI magneto...

Page 333: ...rt de tuyau d chappement arri re MENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR Bougie D connecter le fil de la magn to CDI Bloc CDI R ser...

Page 334: ...to REMOVAL POINTS 4 Drive sprocket 1 5 Clip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Engine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Remove completely 11 Engine 1 Refer to REMOVAL POINTS 1...

Page 335: ...ignon d entra nement 1 3 Rondelle frein 1 Se reporter POINTS DE DEPOSE 4 Pignon d entra nement 1 5 Agrafe 1 6 Boulon p dal de frein 1 7 P dale de frein 1 8 Support du moteur 2 9 Boulon de montage du m...

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

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

Page 338: ...t 9Install the clip with its stopper portion a facing inward EC4M5000 ASSEMBLY AND INSTALLATION EC4M5123 Engine installation 1 Install 9Engine 1 Install the engine from right side 9Pivot shaft 2 9Engi...

Page 339: ...ut e a tourn e vers l int rieur 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 MONTAGGI...

Page 340: ...ain guide 1 9Chain cover 2 9Screw chain cover 3 2 Install 9Lock washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 8 Nm 0 8 m...

Page 341: ...B Serrer l crou en actionnant le frein arri re 2 Installare 9 Rosetta di sicurezza 1 9 Dado rocchetto conduttore 2 NOTA Serrare il dado azionando il freno posteriore 75 Nm 7 5 m kg 54 ft lb 75 Nm 7 5...

Page 342: ...and stator Refer to CDI MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 50 mm 1 97 in 7 3 Bolt L 60 mm 2 36 in 1 4 Bolt L 70 mm 2 76 in 3 5 Holder 2 6 Crankcase right 1 Use special tool 7...

Page 343: ...arreur au pied AU PIED ARBRE DE SELECTEUR ET PIGNON Levier de but e DE TRANSMISSION Rotor et stator Se reporter la section MAGNETO CDI 1 Segment 1 Se reporter POINTS DE DEPOSE 2 Boulon L 50 mm 1 97 in...

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

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

Page 346: ...kcase by pressing its inner race as shown in 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed bearing EC4...

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

Page 348: ...4 1 0 mm 2 0 mm free play 0 016 0 039 in 0 08 in Side 0 25 0 75 mm clearance 0 010 0 030in Crank 59 95 60 00 mm width 2 360 2 362 in EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play...

Page 349: ...c 9 Kurbelwangenbreite d Abweichung von Spezifikation Erneuern Die Me uhr und die F hlerleh re verwenden MONTAGE UND EINBAU Kurbelwellenlager 1 Einbauen 9 Lager 1 Am Kurbelgeh use Links und Rechts HI...

Page 350: ...01274 Bolt 3 YU 90050 90890 01275 Adapter 4 YM 1277 90890 01277 2 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair B For USA and CDN Except for USA and CDN NOTE 9Hold the co...

Page 351: ...ue le vilebrequin bute contre le roulement 9Avant de reposer le vilebrequin net toyer la surface de contact du carter 9Appliquer une graisse base de savon au lithium sur la l vre de la bague d tanch i...

Page 352: ...hammer 9When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Install 9Bolt crankcase 1 NOTE Tighten the crankcase tightening bolts in stage using a crisscross...

Page 353: ...N B 9Fixer le carter moteur gauche sur le cartermoteur droit Taper l g re ment sur le cartrer l aide d un mar teau souple 9Quand le carter est install la bielle d accouplement doit tre positionn e au...

Page 354: ...he bolt 30 Nm 3 0 m kg 22 ft lb 7 Install 9Tension spring 1 9Holder 2 9Bolt holder 3 NOTE Install the holder so that it contacts the projec tion a on the crankcase right 10 Nm 1 0 m kg 7 2 ft lb 9 Rem...

Page 355: ...ge b 9Tourner le segment dans le sens des aiguilles d une montre jusqu ce qu il s arr te et resserrer le boulon 9 D poser 9 Etanch it Chass e sur le plan de joint du cylindre 10 Mettre 9 Huile monteu...

Page 356: ...reparation for Engine Refer to ENGINE REMOVAL section removal Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 2 Drive axle 1 3 Shift cam 1 4 Shift fork 3 1 Refer to REM...

Page 357: ...i ce Q t Remarques DEPOSE DE LA BOITE A VITESSES DU BARILLET DE SELECTEUR ET DE LA FOURCHETTE Moteur Se reporter la section DEPOSE DU MOTEUR S parer le carter Se reporter la section CARTER ET VILEBRE...

Page 358: ...ct 9Matching dog a 9Gear teeth b 9Shift fork groove c Wear Damage Replace EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1 Remove 9Main axle 1 9Drive axle 2 9Shift cam 9Shift fork 3 9Shift fork 2 9Shif...

Page 359: ...s lecteur et la fourchette du s lecteur ensemble en tapotant l g rement sur l arbre de transmission l aide d un marteau t te en caoutchouc VERIFICATION Pignons 1 Examiner 9 Crabot d accouplement a 9 D...

Page 360: ...h pinion gears inner circumference and on the end surface 9Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumference 3 Check 9Shift fork movement Unsmooth operation Replac...

Page 361: ...tte ellem me mais les deux pignons situ s de chaque c te de la fourchette REMONTAGE ET MONTAGE Bo te vitesses 1 Monter 9 Pignon de 5 21D 1 9 Pignon de 3 18D 2 9 Collerette 3 9 Pignon de 4 22D 4 9 Pign...

Page 362: ...ip sharp edged corner a is positioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 2 Install 92nd wheel gear 25 T 1 94th wheel gear 24...

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

Page 364: ...on the shift fork grooves 9Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle 9Mesh the shift fork 2 C10 with the 3rd pinion gear 6 on the main axle...

Page 365: ...incipal 5 Installare 9 Forcella del cambio 1 L 1 9 Forcella del cambio 2 C10 2 9 Forcella del cambio 3 R 3 9 Camma del cambio 4 Sull asse principale e l asse motore NOTA 9Applicare olio a base di biso...

Page 366: ...heel axle 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disk 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of remo...

Page 367: ...iquement desserrage 4 Ecrou axe de roue avant 1 5 Axe de roue avant 1 6 Roue avant 1 7 Collerette 2 8 Bague d tanch it 2 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 Pr paration pou...

Page 368: ...he machine by placing the 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 O...

Page 369: ...ue arri re 1 Se reporter POINTS DE DEPOSE 5 Collerette 2 6 Pignon men 1 7 Bague d tanch it 2 8 Circlip 1 9 Roulement 2 Se reporter POINTS DE DEPOSE 10 Disque de frein 1 Pr paration pour la d pose XG B...

Page 370: ...ecessary 1 Remove 9Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure 9Wheel runout Out of limit Repair Replace 2 Inspect 9Bearing Rotate i...

Page 371: ...ure 9 Voile de roue Hors limite R parer Changer 2 Examiner 9 Roulement Faire tourner la bague int rieure avec le doigt Point dur grippage Changer N B Changer les roulements la bague d tanch it et la c...

Page 372: ...4200 Brake disc 1 Measure 9Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition re place the brake disc 2 Meas...

Page 373: ...e d usure de disque Standard Limite Avant 3 0 mm 0 12 in 2 5 mm 0 10 in Arri re 4 0 mm 0 16 in 3 5 mm 0 14 in IC594200 Disco del freno 1 Misurare 9 Inflessione del disco del freno soltanto il disco de...

Page 374: ...l 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 Inst...

Page 375: ...diri g s vers l ext rieur fF Ne pas frapper sur le chemin de rou lement interne Le contact ne doit avoir lieu qu avec le chemin de roule ment ext rieur 2 Monter 9 Disque de frein 1 9 Boulon disque de...

Page 376: ...ing the front fork several times with the front brake applied 8 Install 9Brake hose 1 To brake hose holder 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck wi...

Page 377: ...ans la gorge du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 7 Serrer 9 Boulon support d axe 1 N B Avant de serrer le boulon embo ter l axe de la roue da...

Page 378: ...eter of the race of the bearing 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bear...

Page 379: ...la bague d tauch it lors de la repose 9Monter le roulement avec se joint dirig vers l ext rieur 9Utiliser une douille convenant au dia m tre ext rieure de la cage du roule ment 9Le roulement lat ral...

Page 380: ...OTE Apply the lithium soap base grease on the oil seal lip 5 Install 9Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install 9Drive chain 1 NOTE Push the wheel 2 forward and...

Page 381: ...condotto 3 9 Dado rocchetto condotto 4 NOTA Serrare i dadi in sequenza usando uno schema incrociato 4 Installare 9 Bordino 1 NOTA Applicare sul labbro del paraolio il grasso a base di sapone di litio...

Page 382: ...her 2 9Nut wheel 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 axl...

Page 383: ...le ordinaire 2 9 Ecrou axe de roue 3 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 temp...

Page 384: ...en disassembling the caliper 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose remov...

Page 385: ...ein 1 6 Bouchon de goupille de plaquette 1 D poser lors du desserrage de la goupille de plaquette 7 Goupille de plaquette 1 Desserrer lors du d montage de l trier 8 Etrier 1 9 Levier de frein 1 10 Etr...

Page 386: ...pad pin 2 Pad pin 1 Loosen when disassembling the caliper 3 Caliper 1 4 Brake hose holder 2 5 Union bolt 2 6 Brake hose 1 7 Brake pedal 1 8 Reservoir tank 1 9 Reservoir hose 1 10 Master cylinder 1 Ext...

Page 387: ...rs du d montage de l trier 3 Etrier 1 4 Support de tuyau de frein 2 5 Boulon d union 2 6 Tuyau de frein 1 7 P dale de frein 1 8 R servoir de r serve 1 9 Tuyau de r serve 1 10 Ma tre cylindre 1 Pr para...

Page 388: ...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 389: ...trier avant 2 D montage de l trier arri re Etendue de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ETRIER A B 1 Goupille de plaquette 1 1 2 Palquette de frein 2 2 3 Support de plaquette 1 1...

Page 390: ...ylinder cap 1 2 Diaphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long nose circlip pliers 5 Plain washer 1 6 Push rod 1 7 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rea...

Page 391: ...lindereinsatz 1 DEMONTAGE DES HAUPTBREMSZYLINDERS A Vorne B Hinten Ausbauumfang 1 Demontage des Vorderrad Hauptbremszylinders 2 Demontage des Hinterrad Hauptbremszylinders DEMONTAGE DU MAITRE CYLINDRE...

Page 392: ...pulling the lever in or pushing down on the pedal cC 9Do not reuse the drained brake fluid 9Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 C...

Page 393: ...DI RIMOZIONE IC5A3100 Liquido per freni 1 Togliere Anteriormente 9 Coperchio del cilindro principa le 1 Posteriormente 9 Tappo del serbatoio 1 9 Dispositivo di protezione NOTA Non togliere il diaframm...

Page 394: ...n seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder...

Page 395: ...re lors d un d montage d trier A Avant B Arri re IC533402 Kit delle guarnizioni di tenuta del pistone 1 Togliere 9 Parapolvere 1 9 Guarnizione di tenuta del pisto ne 2 NOTA Togliere le guarnizioni di...

Page 396: ...st seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Brake hose 1 Crack Damage Replace EC5A5000 ASSEMBLY AND INSTALLATION w 9All internal parts should be cleaned in new brake...

Page 397: ...tone della pinza 1 Usura Rigature Sostituire gruppo pistone della pinza T Sostituire le guarnizioni di tenuta del pistone e i parapolvere 2 2 ogni volta che si smonta una pinza IC534301 Tubo flessibil...

Page 398: ...fluid on the piston wall cC 9For the front caliper install the piston with its depressed side a a facing the caliper For the rear caliper install the pis ton with its shallow depressed side b b facing...

Page 399: ...ta del pisto ne 1 9 Parapolvere 2 T Usare sempre guarnizioni di tenuta del pistone e parapolvere nuovi NOTA Inserire le guarnizioni di tenuta del pistone e i parapolvere sulla fessura sulla pinza in m...

Page 400: ...nstall 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 2 Install 9Copper washer...

Page 401: ...fourche avant et fixer le tuyau de frein 4 Serrer 9 Goupille de plaquette 4 5 Monter 9 Bouchon de goupille de plaquet te 5 Etrier arri re 1 Monter 9 Support de plaquette 1 9 Plaquette de frein 2 9 Gou...

Page 402: ...C Install the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper projection b b 7 Nm 0 7 m kg 5 1 ft lb 30 Nm 3 0 m kg 22 ft lb 4 Inst...

Page 403: ...soit orient e vers l trier et que le conduit soit en contact avec la saillie b b de l trier 4 Monter 9 Etrier 1 9 Roue arri re 2 Se reporter la section ROUE AVANT ET ROUE ARRIE RE 5 Serrer 9 Goupille...

Page 404: ...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 405: ...ort au c t du diam tre plus petit A Avant B Arri re 2 Einbauen 9 Hauptbremszylinderkoppe Prim r 1 9 Hauptbremszylinderkoppe Sekund r 2 Zum Hauptbremszylinderkol ben 3 HINWEIS Bremsfl ssigkeit auf der...

Page 406: ...ster cylinder kit 9Apply the lithium soap base grease on the tip of the push rod 9When installing the circlip use a long nose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Ma...

Page 407: ...au lithium sur l extr mit du champignon de d brayage 9Pour mettre le circlip en place utiliser des pinces de circlip long nez A Avant B Arri re Ma tre cylindre avant 1 Monter 9 Ma tre cylindre 1 9 Etr...

Page 408: ...master cylinder piston EC5A5400 Rear master cylinder 1 Install 9Reservoir hose 1 9Reservoir tank 2 NOTE Pass the reservoir hose into the hose guide 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb 10...

Page 409: ...rein 2 9 Joint torique 3 9 Boulon p dale de frein 4 9 Agrafe 5 N B 9Appliquer de la graisse base de savon au lithium sur le boulon le joint torique et le support de p dale de frein 9Mettre le collier...

Page 410: ...fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 2 Install 9Hose cover 1 9Plain washer 2 9Bolt hose cover M8 3 9Bolt hose cover M6 4 10 Nm 1 0 m kg 7 2 ft lb 16...

Page 411: ...du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 2 Monter 9 Couvercle de tuyau 1 9 Rondelle ordinaire 2 9 Boulon couvercle de tuyau M8 3 9 Boulon couvercl...

Page 412: ...o that its pipe por tion a a directs as show and lightly touches the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 4 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use n...

Page 413: ...tre cylindre Tuyau de frein arri re 1 Monter 9 Rondelle en cuivre 1 9 Tuyau de frein 2 9 Boulon d union 3 XG Toujours utiliser les rondelles en cuivre neuves fF Installer la tuyau de frein de mani re...

Page 414: ...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 415: ...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 fonction...

Page 416: ...gm 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Reservoir tank cap 1 9Bolt reservoir tank 2 cC After installation while pulling the lever in or pushing down on the pedal check...

Page 417: ...te 9 Diaframma 9 Coperchio del cilindro principa le 1 9 Vite coperchio del cilindro principale 2 Posteriormente 9 Diaframma 9 Tappo del serbatoio 1 9 Bullone serbatoio 2 iI Dopo l installazione tirand...

Page 418: ...n Number plate 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt handle crown 2 Only loosening 4 Cap bolt 1 Loosen when disassembling the front fork 5 Pinch bolt under bracket 2 Only loosening 6 Front...

Page 419: ...ein 2 3 Boulon de bridage couronne de guidon 2 Uniquement desserrage 4 Boulon capuchon 1 Desserrer lors du d montage de la fourche avant 5 Boulon de bridage trier inf rieur 2 Uniquement desserrage 6 F...

Page 420: ...Refer to REMOVAL POINTS 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 q Spring guide 1 w Base valve 1 Use special tool e Damper rod 1 Refer to REMOVAL PO...

Page 421: ...E DEPOSE 2 Ressort de fourche 1 Vidanger d huile de fourche 3 Joint antipoussi re 1 4 Bague d arr t 1 Se reporter POINTS DE DEPOSE 5 Tube interne 1 6 Tube externe 1 7 M tal de piston 1 8 Bague antifri...

Page 422: ...aterial Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled 9Before removing the cap bolts or front forks be...

Page 423: ...g res Faire suffisamment attention ne pas laisser p n trer de substances trang res lorsque l huile est rem plac e ou lorsque la fourche avant est d mont e ou remont e 9Avant d enlever la fourche avant...

Page 424: ...1 Bend Damage Replace damper rod cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign ma terial Use enough care not to a...

Page 425: ...nge weist eine komplizierte interne Konstruktion auf und ist besonders gegen ber Fremdmaterialien empfindlich Darauf achten da keine Fremdmaterialien eintreten wenn das l erneuert oder die Vorderradga...

Page 426: ...lace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace 9Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge readi...

Page 427: ...eur de courbure est indiqu e par la moiti de la valeur du comparateur cadran XG Ne pas tenter de redresser un tube interne tordu car cela risquerait de l affaiblir dangereusement Tube externe 1 Examin...

Page 428: ...o inner tube 2 cC To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install 9Cop...

Page 429: ...ement l en semble de tige peut y tomber endom mageant l int rieur de la soupape 3 Monter 9 Rondelle en cuivre 1 9 Joint torique 2 9 Soupape de base 3 Au tube interne 4 4 Serrer 9 Soupape de base 1 N B...

Page 430: ...seal 1 9Stopper ring 2 9Oil seal 3 9Plain washer 4 9Slide metal 5 To inner tube 6 NOTE 9Apply the fork oil on the inner tube 9When installing the oil seal use vinyl seat a with fork oil applied to pr...

Page 431: ...3 9 Rondelle ordinaire 4 9 Bague antifriction 5 Au tube interne 6 N B 9Appliquer de l huile de fourche sur le tube interne 9Lors de l installation de la bague d tanch it utiliser une feuille en vi nyl...

Page 432: ...r 3 10 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 11 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 12 Install...

Page 433: ...belbein Dichtring mit Hife des Vorderradgabel Dichtungstreibdorns 2 in das u ere Gabelbeinrohr ein pressen 11 Ausbauen 9 Anschlagring 1 HINWEIS Den Anschlagring richtig in die Nut des u eren Rohres ei...

Page 434: ...formance 9Never allow foreign materials to enter the front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil 17 Fill 9Front fork oil Until o...

Page 435: ...achten da keine Fremd k rper in die Vorderradgabel ein dringen 16 Nach dem Einf len die Kolbenstange 1 mehr als 10 mal langsam auf und ab pumpen um das Gabel l zu verteilen 17 F llen 9 Vorderradgabel...

Page 436: ...with the fork oil up to the top of the outer tube and bleed the front forks 20 Measure 9Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking...

Page 437: ...XG Ne jamais oublier de faire le r glage de niveau d huile entre les niveaux maximum et minimum et toujours r gler chaque fourche avant au m me r glage Un r glage in gal peut entra ner une mauvaise ma...

Page 438: ...d up 9Install the fork spring with its smaller pitch end facing the cap bolt For EUROPE 9After installing the fork spring hold the damper rod end so that it will not go down 25 Install 9Cap bolt 1 Ful...

Page 439: ...e fourche avec la tige d amortisseur 3 d ploy e 9Installer le ressort de fourche avec l extr mit filet e la plus troite vers le boulon capuchon Pour EUROPE 9Apr s avoir install le ressort de fourche m...

Page 440: ...set the thin type spanners 2 between the spacer 3 and spring guide 4 9Hold the locknut 5 and tighten the cap bolt with specified torque 27 Install 9Cap bolt 1 To outer tube NOTE Temporarily tighten t...

Page 441: ...tage 1 Monter 9 Fourche avant 1 N B 9Serrer le boulon de bridage trier in f rieur provisoirement 9Ne pas encore serrer le boulon de bri dage couronne de guidon 2 Serrer 9 Boulon capuchon 1 3 R gler 9...

Page 442: ...r 3 NOTE Fit the brake hose holder cut a over the projec tion b on the front fork and clamp the brake hose 6 Install 9Brake hose holder 1 9Bolt brake hose holder 2 9Protector 3 9Bolt protector 4 NOTE...

Page 443: ...5 devant le bossage de l axe c et l ajuster dans la gorge du tuyau d de fa on ce que le tuyau de frein ne soit pas en contact avec l crou axe de la roue 7 R gler 9 Force d amortisseur de rebond N B To...

Page 444: ...1 Refer to REMOVAL POINTS 5 Throttle cable cap 1 Turn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer...

Page 445: ...rter POINTS DE DEPOSE 5 Capuchon du c ble d acc l rateur 1 Retourner le couvercle de capuchon 6 C ble d acc l rateur 1 D connecter du c t acc l rateur 7 Acc l rateur 1 Desserrer les boulons 8 Couvercl...

Page 446: ...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 447: ...de d pose Ordre Nom de pi ce Q t Remarques DEMONTAGE DE L ACCELERA TEUR 1 Capuchon de poig e inf rieur 1 2 Capuchon de poig e sup rieur 1 3 Ensemble de la poign e 1 4 Poign e droite 1 Se reporter POIN...

Page 448: ...the 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 m...

Page 449: ...Guidon 1 Deform e craquelures endom magement Changer XG Ne pas tenter de redresser un guidon d form car cela l affaiblirait dange reusement REMONTAGE ET MONTAGE Ensemble acc l rateur 1 Monter 9 Poign...

Page 450: ...er and then tighten the bolts on the rear side 2 Install 9Grip left 1 Apply the adhesive to the handlebar 2 NOTE 9Before applying the adhesive wipe off grease or oil on the handlebar surface a with a...

Page 451: ...ant d appliquer l adh sif essuyer la graisse ou l huile sur la surface du guidon a avec du diluant de peinture 9Fixer la poign e gauche sur le gui don de sorte que la ligne b entre les deux fl ches so...

Page 452: ...hrottle cable in the groove b in the roller 6 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 7 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 8...

Page 453: ...gler 9 Jeu du c ble d acc l ration Se reporter la section RE GLAGE DU CABLE D ACCE LERATEUR du CHAPITRE 3 8 Monter 9 Couvercle de capuchon 1 9 Monter 9 Ma tre cylindre 1 9 Etrier de ma tre cylindre 2...

Page 454: ...smoothly If it does not retighten the bolts for adjustment 11 Install 9 ENGINE STOP button 1 9Clutch lever holder 2 9Bolt clutch lever holder 3 9 Clamp 4 NOTE 9The ENGINE STOP button clutch lever hold...

Page 455: ...yage 3 9 Bride 4 N B 9Le bouton d arr t du moteur ENGI NE STOP le support et la bride de levier d embrayage doivent tre ins tall s selon les dimensions indiqu es 9Faire passer le fil de bouton d arr t...

Page 456: ...5 46 CHAS HANDLEBAR 14 Clamp the clamp portion a of the number plate to the handlebar 15 Insert the end of the fuel breather hose 1 into the hole of the number plate...

Page 457: ...ie Bohrung des Nummernschil des einf hren 14 Fixer la partie de fixation a de la plaque d immatriculation au gui don 15 Introduire l extr mit du conduit d a ration de carburant 1 dans les trous de la...

Page 458: ...g nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Ball race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Ball race 2 Refer to REMOVAL POINTS Extent of remov...

Page 459: ...e ter St nder unter dem Motor angeordnet wird Nummernschild Lenkstange Siehe Abschnitt LENKSTANGE Kabelf hrung Vorderrad Kotfl gel 1 Lenkerschaftmutter 1 2 Vorderradgabel 2 Siehe Abschnitt VORDERRADGA...

Page 460: ...all down EC563300 Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove 9Ball race 1 Remove the ball race usin...

Page 461: ...ur 2 fF Veiller ne pas endommager le file tage de l arbre de direction Cage billes 1 D poser 9 Cage billes 1 Enlever la cage billes en utili sant une longue tige 2 et un marteau VERIFICATION Arbre de...

Page 462: ...ration in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION EC565113 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the du...

Page 463: ...trier inf rieur 1 Monter 9 Roulement inf rieur 1 N B Appliquer de la graisse base de savon au lithium sur la l vre du joint anti poussi re et sur la cironf rence interne du roulement 2 Monter 9 Cage b...

Page 464: ...ng shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE...

Page 465: ...une g ne quel conque retirer l ensemble axe de direction et inspecter le support de direction 6 Monter 9 Rondelle ordinaire 1 7 Monter 9 Fourche avant 1 9 Etrier sup rieur 2 N B 9Serrer le boulon de...

Page 466: ...ng nut little by little 10 Adjust 9 Front fork top end a 11 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too much it may c...

Page 467: ...Boulon de bridage trier inf rieur 2 fF Resserrer le support auxiliaire au couple sp cifi S il est trop serr la fourche avant pourrait mal fonction ner 9 Dopo avere serrato il dado con trollare che lo...

Page 468: ...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 469: ...SE UND Hinterrad Bremssattel HINTERRADBREMSE Schraube Bremspedal Das Bremspedal niederdr cken Antriebskette 1 Kettenschutz 1 2 Kettenspanner Unten 1 3 Schraube Hinterad Sto d mpfer 1 Die Hinterradschw...

Page 470: ...Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and disassembly...

Page 471: ...tange 3 Ausbau und Demontage des Relaisarms Ausbauumfang Reihenfolge Teilename St ckzahl Bemerkungen DEMONTAGE DER HINTERRADSCH WINGE 1 Kappe 2 2 Relaisarm 1 3 Pleuelstange 1 4 H lse 2 5 ldichtung 2 6...

Page 472: ...h 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574210 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolut...

Page 473: ...9 Buchse 2 Freies Spiel besteht Unrunde Drehung Rost Lager und Buchse als Satz erneuern 2 Pr fen 9 ldichtung 3 Besch digung Erneuern Relaisarm 1 Pr fen 9 Lager 1 9 H lse 2 Freies Spiel besteht Unrunde...

Page 474: ...ll 9Bearing 1 9Oil seal 2 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side having the manufacture s marks or numb...

Page 475: ...etto 1 9 Paraolio 2 Sul braccio di rinvio NOTA 9Applicare il grasso a base di bisolfuro di molibdeno sul cuscinetto durante l installazione 9Installare il cuscinetto premendolo sul lato che riporta le...

Page 476: ...llar 1 To relay arm 2 NOTE Apply the molybdenum disulfide grease on the collars bearings and oil seal lips 3 Install 9Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the col...

Page 477: ...ui labbri del parao lio 2 Installare 9 Bordino 1 Sul braccio di rinvio 2 NOTA Applicare il grasso a base di bisolfuro di molibdeno sui bordini sui cuscinetti e sui labbri del paraolio 3 Installare 9 B...

Page 478: ...7 Check 9Swingarm side play a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars 8 Install 9Bo...

Page 479: ...ivot par le c t droit 7 Contr ler 9 Jeu lat ral du bras oscillant a Il y a jeu fonctionnel Remplacer le roulement de bu t e 9 Mont e et descente du bras os cillant b Mouvement irr gulier coince ment p...

Page 480: ...ll 9Bolt chain tensioner lower 1 9Plain washer 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support R 50mm 1 97in 3 9Nut chain s...

Page 481: ...inferiore 5 14 Installare 9 Supporto della catena 1 9 Copertura del supporto 2 9 Bullone supporto della catena 50 mm 1 97 in 3 9 Dado supporto della catena 4 9 Bullone copertura del supporto 10 mm 0 3...

Page 482: ...cleaner joint 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 7 Adjuster 1 8 Spring guide lower 1 9 Spri...

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

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

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

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

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

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

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

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

Page 491: ...e 3 N B 9Appliquer de la graisse de molybd ne sur le roulement 9Appliquer de la graisse base de sa von au lithium sur la bague les col liers et les joints antipoussi re 9Monter les joints antipoussi r...

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

Page 493: ...relais 1 9 Ecrou amortisseur arri re bras de relais 2 N B Appliquer de la graisse de molybd ne sur le boulon 6 Monter 9 Cadre arri re 1 9 Boulon cadre arri re 2 7 Serrer 9 Vis raccord de filtre air 1...

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

Page 495: ...MPOSANTS ELECTRIQUES 1 Bloc CDI 2 Bouton d arr t du moteur ENGINE STOP 3 Bobine d allumage 4 TPS capteur de position du papillon 5 Electrovanne 6 Magn to CDI 7 Bougie CODE DE COULEUR B Noir L Bleu O O...

Page 496: ...Check entire ignition 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 mag...

Page 497: ...bloc CDI Changer Changer Changer Changer Changer Indication Seulement quand le contr leur d allumage et utilis N B 9D poser les pi ces suivantes avant de proc der au d pistage des pannes 1 Selle 2 R...

Page 498: ...trollieren CDI Einheit erneuern Erneuern Erneuern Erneuern Erneuern Erneuern Markierung Nur wenn das Z ndungspr fger t verwendet wird HINWEIS 9Die folgenden Teile vor Beginn der St rungsbeseitigung au...

Page 499: ...uirla Sostituirla Sostituirla Sostituirla contrassegnato Soltanto quando viene usato l apparecchio per il controllo dell accensione NOTA 9Prima dell ispezione togliere le parti che seguono 1 Sella 2 S...

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

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

Page 502: ...I MAGNETO INSPECTION 1 Inspect 9Pick up coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Orange lead 2 Primary...

Page 503: ...obine d excita tion Hors sp cification Changer IC626002 ISPEZIONE DELLA BOBINA DI ACCENSIONE 1 Ispezionare 9 Resistenza della bobina prima ria Fuori specifica Sostituirla 2 Ispezionare 9 Resistenza de...

Page 504: ...N Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Black Red lead 1 Tester lead Black lead 2 Source coil 1 Tester select...

Page 505: ...non si rileva alcun guasto sostituire l unit CDI Quindi ricontrollare i com ponenti elettrici Resistenza Posizione della bobina del selettore sorgente 1 del tester 720 1 080 a 100 20 C 68 F Conduttor...

Page 506: ...od Replace Check CDI magneto Replace CDI unit No good EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate use the following inspection steps marked Refer to...

Page 507: ...magn to CDI Changer le bloc CDI Mauvais SYSTEME D ELECTROVANNE ETAPES DE VERIFICATION Si l lectrovanne ne fonctionne pas applicuez la proq dure d inspection suivante Indication Se reporter la section...

Page 508: ...ule Erneuern CDI Magnetz nder kontrollieren CDI Einbeit erneuern Nicht in Ordnung MAGNETVENTILSYSTEM PR FVORG NGE Falls das Magnetventil nicht funktioniert sind die folgenden berpr fungen durchzuf hre...

Page 509: ...unziona Sostituirlo Controllare magnete CDI Sostituire unit CDI Non funziona IC650001 SISTEMA ELETTROVALVOLA IC651032 OPERAZIONI DI ISPEZIONE Se l elettrovalvola non funziona effettuare i seguenti con...

Page 510: ...e coupler 2 Connect 12V battery to the solenoid valve coupler 3 Inspectt 9Solenoid valve 1 No click when connecting the battery Replace EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect 9Solenoid valv...

Page 511: ...4000 ISPEZIONE DEL COLLEGAMENTO DI ACCOPPIATORI E CONDUTTORI 1 Controllare 9 Collegamento di accoppiatori e conduttori Ruggine Polvere Allentamen to Cortocircuito Ripararli o sostituirli IC652040 FUNZ...

Page 512: ...Replace Check CDI unit No good EC690000 TPS THROTTLE POSITION SENSOR SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate use the following inspection steps marked Refer to IGNITION SYSTEM sec...

Page 513: ...u d pistage des pannes 1 Selle 2 R servoir essence 9Utiliser les outils sp ciaux suivants dans ce d pistage des pannes Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 Tester de poche Y...

Page 514: ...auen 1 Sitz 2 Kraftstofftank 9Die folgenden Spezialwerkzeuge f r die St rungsbeseitigung verwenden Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 Taschenpr fger t YU 3112 C 90890 03112 In...

Page 515: ...ma dell ispezione togliere le parti che seguono 1 Sella 2 Serbatoio del carburante 9 In questa ispezione usare i seguenti utensili speciali Contagiri induttivo YU 8036 B Contagiri del motore 90890 031...

Page 516: ...xing chamber top Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 2 Inspect 9TPS coil resistance Out of specification Replace Tester lead Blue lead 1 Tester lead Black lead 2 TPS coil Teste...

Page 517: ...tand Abweichung von Spezifikation Erneuern 2 Ispezionare 9 Resistenza della bobina del TPS Fuori specifica Sostituirla Resistenza Posizione del della bobina selettore del del TPS tester 4 6k a k 1 20...

Page 518: ...of specification Replace Tester lead Yellow lead 2 Tester lead Black lead 3 Tester selector position Full closed Full opened Zero 2k at 4 6k at 20 C 68 F 20 C 68 F k 1 EC693001 TPS REPLACEMENT AND AD...

Page 519: ...F Positives Kabel des Pr fger tes Gelb Kabel 2 Negatives Kabel des Pr fger te Schwarz Kabel 3 Regelbarer Position des TPS Spulenwider Wahlschalters stand am Pr fger t Vollst ndig Vollst ndig geschloss...

Page 520: ...Adjustment steps 9Set the inductive tachometer engine tachometer to the high tension cord 9Turn the throttle stop screw 1 until the specified idle speed Refer to IDLE SPEED ADJUSTMENT sec tion in the...

Page 521: ...n auf den Abschnitt EINSTELLUNG DER LEER LAUFDREHZAHL im KAPITEL 3 Leerlaufdrehzahl f r TPS Einstellung 1 700 bis 1 900 U min Passi della regolazione 9Collegare il tachimetro induttivo tachimetro moto...

Page 522: ...1 NOTE Tighten the screws TPS using the T20 bit tam per resistant fastener type by aligning the marks a that were put before removal 14 Install 9Carburetor Refer to CARBURETOR AND REED VALVE section i...

Page 523: ...em die vor dem Ausbau angebrachten Markierungen a zum Ausrichten benutzt werden 14 Einbauen 9 Vergaser Siehe Abschnitt VERGASER UND ZUNGENVENTIL 13 Serrare 9 Vite TPS 1 NOTA Serrare le viti usando la...

Page 524: ...694000 TPS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect 9TPS input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blu...

Page 525: ...I Einheit erneuern IC694000 ISPEZIONE DELLA TENSIONE IN INGRESSO NEL TPS 1 Scollegare l accoppiatore del TPS 2 Avviare il motore 3 Ispezionare 9 Tensione in ingresso nel TPS Fuori specifica Sostituire...

Page 526: ...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 ro...

Page 527: ...de la route et la d coloration de bougie s Prenant ces facteurs en consid ration il s lectionnera les meilleurs r glages de carburateur possibles Il est recommand de prendre note des r glages des cond...

Page 528: ...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 529: ...bougie s A Normale B Surbr l e trop pauvre C Encrass e d huile trop riche Cio 9 Una temperatura pi alta fa dilatare l aria ne risulta una densit ridotta 9 Un umidit pi elevata riduce la quantit di os...

Page 530: ...calibrating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Standard main jet 178 175 EC71V000 Powet jet adjustment Th...

Page 531: ...ugie est trop chaude S lectionner un gicleur principal avec un num ro de calibrage sup rieur la norme Pour enrichir 2 La bougie est mouill e S lectionner un gicleur principal avec un num ro de calibra...

Page 532: ...intermediate speed operation irregular engine operation and poor acceleration will result Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and...

Page 533: ...golazione si cam bia il getto pilota 1 Un getto di dimensioni maggiori d una miscela pi ricca a bassi regimi e uno di dimensioni pi piccole d una miscela pi povera IC718001 Regolazione della posizione...

Page 534: ...ck up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pic...

Page 535: ...icht glatt beschleunigt werden In diesem Fall die D sennadelklam mer um eine Nut h her positionie ren und die D sennadel absenken um ein magereres Gemisch zu erhalten 2 Zu mager bei mitteleren Dreh za...

Page 536: ...starting position c Rich d Lean 2 Effects of changing the jet needle reference 9Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throt...

Page 537: ...tre de la partie droite ajuste le m lan ge air carburant lorsque l ouverture des gaz est compri se entre 1 8 et 1 4 9 Position de d part de c ne Diff rence d une demi rainure Riche N3EJ 3e rainure N3C...

Page 538: ...g position c Rich d Lean 2 Effects of changing the jet needle reference 9Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throttle is 1...

Page 539: ...e la partie droite ajuste le m lan ge air carburant lorsque l ouver ture des gaz est comprise entre 1 8 et 1 4 9 Position de d part de c ne Diff rence d une demi rainure Riche N3CW 4e rainure N3EW 3e...

Page 540: ...ottle opening whereas around 1 4 to 1 1 throttle opening it relates to the taper starting position and to the clip position Therefore the fuel flow is balanced at each stage of throttle opening by the...

Page 541: ...tion de l agrafe Par cons quent l coulement du carbu rant est quilibr chaque tape de l ouverture du papillon par la combinai son du diam tre de la portion droite du papillon et de sa position de d par...

Page 542: ...8 10 55 4MX 14948 09 STD 52 4MX 14948 08 STD 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 40 4MX 14948 03 Lean 38 4MX 14948 02 Jet needle 3 3 Rich N8RW 4SR 14916 RW N3EW 4SR 14916 E...

Page 543: ...90 Getto Ricca No 62 4MX 14948 12 pilota No 60 4MX 14948 11 2 2 No 58 4MX 14948 10 No 55 4MX 14948 09 STD No 52 4MX 14948 08 STD No 50 4MX 14948 07 No 48 4MX 14948 06 No 45 4MX 14948 05 No 42 4MX 149...

Page 544: ...edle clip position Hard breathing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Clip position indicates the position of Slow speed pick up 1 groove up jet needle groove t...

Page 545: ...needle clip position range of low to If no effect reverse the above intermediate speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly U...

Page 546: ...ure plus bas Elever la position de fixation de l aiguille de gicleur 1 rainure plus haut Abaisser la position de fixation de l aiguille de gicleur 1 rainure plus bas Elever la position de fixation de...

Page 547: ...nverser les proc dures mentionn es ci dessus Contr ler tous les r glages d ensemble Utiliser un gicleur principal avec un n de calibrage inf rieur Elever la position de fixation de l aiguille de gicle...

Page 548: ...res gemisch Bei Vollgas Drehzahl wird nicht erh ht Drehzahl wird nur langsam erh ht Langsames Ansprechen Verru te Z ndkerze Fettes Gemisch Mageres Gemisch Fettes Gemisch 1 4 3 4 Gas Hartes Beatmen unz...

Page 549: ...Klemmenposition erh hen Falls keine Wirkung die obigen Vorg nge umkehren Gesamteinstellungen berpr fen Hauptd se mit niedrigerer Kalibrierungs Nr verwenden D sennadel Klemmenposition erh hen 1 Nut h...

Page 550: ...rimento della candela Se color cuoio in buone condizioni Se non pu essere normalizzata Sede valvola a galleggiante otturata Tubo flessibile del carburante otturato Rubinetto del carburante otturato Sc...

Page 551: ...re al contrario le procedure sopra descritte Controllare le registrazioni generali Usare un getto principale che abbia un No di taratura pi basso Alzare la posizione del fermaglio a graffa dell ago a...

Page 552: ...bration No of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet NOTE 9When checking the discoloration of spark plugs be su...

Page 553: ...chang par 30 il est recommand 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...

Page 554: ...e entire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the enti...

Page 555: ...le taux de r duction secon daire 9Quand il y a de grandes lignes droites r gler la machine de sorte ce qu elle soit au maximum de ses per formances vers la fin des lignes droites tout en vitant que l...

Page 556: ...urface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 13T 9383E 13144 STD 14T 9383E 14215 Driven sprocket...

Page 557: ...on des pneus standard 100 kPa 1 0 kgf cm2 15 psi Etendue de r glage 100 120 kPa 1 0 1 2 kgf cm2 15 18 psi Etendue de r glage 60 80 kPa 0 6 0 8 kgf cm2 9 0 12 psi Reifendruck Der Reifendruck soll soll...

Page 558: ...ing characteristic near the final stroke can be changed by changing the fork oil amount cC Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to prod...

Page 559: ...tant de r gler le niveau d huile dans la fourche conform ment aux sp cifi cations donn es IC722011 Registrazione della forcella anteriore La registrazione della forcella anteriore dovrebbe essere eff...

Page 560: ...justment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in position...

Page 561: ...egolazione Ampiezza della regolazione zero 2 rondelle di regolazione R glage du ressort apr s remplace ment Les r glages de la fourche avant peu vent tre affect es par la suspension arri re il convien...

Page 562: ...s to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handlebar To set a stiff spring 9Change the rebound damping Turn in one or two clicks 9Change the co...

Page 563: ...nt une perte de sensation de contact avec la surfa ce de la route ou un guidonnage R glage d un ressort dur 9 R gler la force de rebond Visser d un ou deux d clics 9 R gler la force de compression D v...

Page 564: ...proved on the end of the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 380 4SS 23141 10 I I 0 390 4SS 23141 20 I II SOFT 0 400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50...

Page 565: ...400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50 II STD 0 430 4XL 23141 L0 HART 0 440 4SS 23141 70 IIII IC72P010 Parti di regolazione della forcella anteriore 9Rondella di regolazione 1...

Page 566: ...ession damping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fe...

Page 567: ...llen um das Hinter rad anzuheben und den Abstand a zwischen der Hinterradachs mitte und der Hinterradkotfl gel Halteschraube messen 2 Den St nder oder Block vom Motor entfernen und bei aufsit zendem F...

Page 568: ...t length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring 9Set the soft spring for less rebound damp ing to compensate for its less spring load Run with the rebound damping adjuster...

Page 569: ...er weichen Feder 9 Die weiche Feder auf weniger Ausfederd mpfung einstellen um die geringere Federspan nung auszugleichen Mit dem Ausfederd mpfung Einsteller um eine oder zwei Klickstellen zur weicher...

Page 570: ...se the one whose overall length a a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider w...

Page 571: ...ssort dont la longueur totale est sup rieure la longueur standard A Ressort recommand en fonction du poids B Poids du motocycliste 1 Mou 2 Standard 3 Dur iI Quando si usa un ammortizzatore posteriore...

Page 572: ...H SOFT 4 4 5DH 22212 70 Brown 1 260 4 6 5DH 22212 10 Green 1 260 STD 4 8 5DH 22212 20 Red 1 260 5 0 5DH 22212 30 Black 1 260 STIFF 5 2 5DH 22212 40 Blue 1 260 5 4 5DH 22212 50 Yellow 1 265 5 6 5DH 222...

Page 573: ...22212 40 Blau 1 260 5 4 5DH 22212 50 Gelb 1 265 5 6 5DH 22212 60 Rosa 1 265 FLESSI NUMERO TIPO BILIT CATEGORICO DELLA MOLLA DOLCE 4 4 5DH 22212 70 Marrone 1 260 4 6 5DH 22212 10 Verde 1 260 NORMALE 4...

Page 574: ...bout 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 out in Spring Replace with stiff spring Stiff toward stroke 1 O...

Page 575: ...d Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decrea...

Page 576: ...positif de r glage vers la gauche de 2 d clics pour r duire l amortissement R duire le niveau d huile d environ 5 10 mm 0 2 0 4 in Monter un ressort doux V rifier s il y a coudes coups ou tout autre e...

Page 577: ...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 578: ...e Einsteller gegen den Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu ver ringern lstand um etwa 5 10 mm 0 2 0 4 in senken Durch weiche Feder ersetzen Auf Verbiegungen Dellen sichtb...

Page 579: ...mpfung zu ver ringern Eingetauchte L nge auf 90 100 mm 3 5 3 9 in einstellen wenn ein Fahrer auf dem Sitz sitzt Einsteller im Uhrzeigersinn drehen um etwa 2 Klickstellungen um die D mpfung zu steiger...

Page 580: ...to con l estremit posteriore Molla Livello dell olio quantit di olio Ruotare il dispositivo di regolazione in senso antiorario circa 2 scatti per diminuire lo smor zamento Diminuire il livello dell ol...

Page 581: ...ire lo smor zamento Registrare la lunghezza abbassata su 90 100 mm 3 5 3 9 in con un passeggero a cavalcio ni della sella Ruotare il dispositivo di regolazione in senso ora rio circa 2 scatti per aume...

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