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Yamaha YZ250F(T), Owner'S Service Manual


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INSP

ADJ

HOT STARTER LEVER ADJUSTMENT/

AIR FILTER CLEANING

HOT STARTER LEVER ADJUSTMENT

1. Check:

• Hot starter lever free play 

a

Out of specification 

→

 Adjust.

2. Adjust:

• Hot starter lever free play

NOTE:

After adjustment, check proper operation of
hot starter.

Hot starter lever free play 

a

:

3 ~ 6 mm (0.12 ~ 0.24 in)

Hot starter lever free play adjustment 
steps:

• Loosen the locknut 

1

.

• Turn the adjuster 

2

 until free play 

a

 is

within the specified limits.

• Tighten the locknut.

AIR FILTER CLEANING

NOTE:

Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.

CAUTION:

Never run the engine 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:

• Seat
• Fitting bolt 

1

 

• Washer 

2

 

• Air filter element 

3

 

• Air filter guide 

4

 

Summary of Contents for YZ250F(T)

Page 1: ...5XC 28199 31 YZ250F T OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO...

Page 2: ...NER S SERVICE MANUAL 2004 by Yamaha Motor Co Ltd 1st Edition July 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibi...

Page 3: ...R DU PROPRIETAIRE 2004 Yamaha Motor Co Ltd 1 re dition juillet 2004 Tous droits r serv s Toute reimpression ou utillisation sans la permission crite de la Yamaha Motor Co Ltd est formellement interdit...

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

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

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

Page 7: ...ors de l utilisation de cette machine toujours porter un casque homologu avec des lunettes ou un prot ge visage Porter galement de grosses bottes des gants et des v te ments de protection Toujours por...

Page 8: ...Carbon monoxide is a dan gerous gas which can cause uncon sciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine...

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

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

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

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

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

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

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

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

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

Page 19: ...IMPIANTO ELETTRICO ELEC 6 MESSA A PUNTO TUN 7 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS GENERAUX CARACTERISTI QUES CONTROLES ET REGLAGES PERIODIQUES MOTEUR CHASSIS PARTIE ELECTRIQUE MISES AU POINT INDEX...

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

Page 21: ...DES COUPLES DE SERRAGE 1 18 NETTOYAGE ET REMISAGE 1 19 CHAPITRE 2 CARACTERISTIQUES CARACTERISTIQUES GENERALES 2 1 CARACTERISTIQUES D ENTRETIEN 2 4 CARACTERISTIQUES GENERALES DE COUPLE 2 17 DEFINITION...

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

Page 23: ...VERCLE DE CARTER DROIT 4 56 BALANCIER 4 63 POMPE A HUILE 4 66 ARBRE DE KICK ET AXE DE SELECTEUR 4 71 VOLANT MAGNETIQUE CDI 4 78 DEPOSE DU MOTEUR 4 82 CARTER MOTEUR ET VILEBREQUIN 4 87 BOITE DE VITESSE...

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

Page 25: ...CABLAGE 6 1 BOITIER CDI COMMANDE PAR PRESSION ABSOLUE DE LA TUBULURE D ADMISSION 6 2 SYSTEME D ALLUMAGE 6 3 SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ 6 7 CHAPITRE 7 MISE AU POINT MOTEUR 7 1...

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

Page 27: ...t B P dale de frein arri re C Joint de robinet D Robinet de carburant E Commande de d part froid F Cha ne de transmission G Filtre air H S lecteur I Jauge J Fourche N B Votre moto diff re peut tre par...

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

Page 29: ...son identification NUMERO D IDENTIFICATION DE LA MOTO Le num ro d identification de la moto 1 est estamp sur le c t droit du tube de direction NUMERO DE SERIE DU MOTEUR Le num ro de s rie du moteur 1...

Page 30: ...bottom Drain hole on the cylinder head right side 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears...

Page 31: ...Lors du d montage de la moto gar der ensemble les pi ces appari es Il s agit des engrenages cylindres pistons et autres pi ces qui ont t fa onn es l une l autre par l usure normale Ces pi ces doivent...

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

Page 33: ...s onglets de blocage contre la ou les faces du boulon ou de l crou apr s avoir correctement serr ces der niers ROULEMENTS ET BAGUES D ETANCHEITE 1 Monter les roulements 1 et les bagues d tanch it 2 en...

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: ...utilisation Rem placer tout circlip d form Lors du montage d un circlip 1 veiller ce que le c t non chanfrein 2 soit positionn du c t oppos la pous s e 3 qu il re oit Voir la vue en coupe 4 Arbre ANEL...

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 con nector 6 Connect Connector NOTE The two connectors click together 7 Check for cont...

Page 37: ...as 5 Si la borne se d tache redresser la lame 1 de la broche et r ins rer la borne dans le connecteur 6 Brancher Connecteur N B Les deux connecteurs s encliquettent 7 V rifier la continuit l aide d un...

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

Page 39: ...Use this tool to inspect the coil resistance output voltage and amperage YU 3112 C 90890 03112 YM 33277 A 90890 03141 Timing light This tool is necessary for checking ignition timing YM 33277 A 90890...

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

Page 41: ...nt magn tique Cet outil sert extraire le volant magn tique YM 1189 90890 01189 YU 1235 90890 01235 Outil de maintien du rotor Cet outil permet de desserrer ou de serrer l crou de fixa tion du volant m...

Page 42: ...r sistance la tension de sortie et l intensit des bobines YU 3112 C 90890 03112 YM 33277 A 90890 03141 Lampe stroboscopique Cet outil permet de contr ler l avance l allumage YM 33277 A 90890 03141 YM...

Page 43: ...ent 4 5 mm 0 18 in Cet outil permet de r al ser les guides de soupape neufs YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Testeur d tincelle dynamique Contr leur d allumage Cet instrume...

Page 44: ...5 A 90890 01135 YM 1189 90890 01189 Polrad Abzieher Zum Ausbau des Lichtmaschinenrotors YM 1189 90890 01189 YU 1235 90890 01235 Rotorhalter Zum L sen und Festziehen der Lichtmaschinenrotor Mutter YU 1...

Page 45: ...aschen Multimeter Zur Pr fung von Widerst nden Spannungen und Stromst rken YU 3112 C 90890 03112 YM 33277 A 90890 03141 Stroboskoplampe Zur Pr fung des Z ndzeitpunktes YM 33277 A 90890 03141 YM 4019 9...

Page 46: ...hle Einla 4 0 mm 0 16 in Ausla 4 5 mm 0 18 in Zum Ausbohren neuer Ventilf hrungen YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Z ndfunkenstrecken Tester Z ndungstester Zur Pr fung des...

Page 47: ...890 01235 Attrezzo di bloccaggio rotore Questo attrezzo utilizzato quando si allenta o si serra il dado di sicurezza del magnete volano YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Comparatore e ca...

Page 48: ...zzato per controllare la resistenza della bobina la tensione in uscita e l amperaggio YU 3112 C 90890 03112 YM 33277 A 90890 03141 Stroboscopio Questo strumento utilizzato per controllare l anticipo m...

Page 49: ...in Questo attrezzo utilizzato per alesare il nuovo guidaval vola YM 4113 YM 4118 90890 04113 90890 04118 YM 34487 90890 06754 Tester dinamico della scintilla Tester dell accensione Questo strumento ut...

Page 50: ...gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter cra...

Page 51: ...dale de kick 1 Appuyer l g rement sur la p dale pour mettre les pignons en prise puis l actionner vigou reusement mais en souplesse pour mettre le moteur en marche Ce mod le est quip d un d marreur a...

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

Page 53: ...id le moteur a besoin d un m lange air carburant plus riche pour d marrer Un circuit de d marrage s par contr l par la commande de d part froid 1 fournit ce m lange Tirer la commande de d part froid a...

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

Page 55: ...rant de s chapper et est mont sur la durit de mise l air du r servoir de carburant ATTENTION Lors du montage veiller orienter la fl che vers le r servoir de carburant et vers le bas CLE A BOUGIE La cl...

Page 56: ...ch as valves piston rings and exhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane grade WARNING For refueling be sure to stop the engine and use en...

Page 57: ...essence ou une essence d un indice d octane sup rieur AVERTISSEMENT Au moment de faire le plein ne pas oublier de couper le moteur Proc der avec soin pour ne pas renverser d essence Eviter de faire l...

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

Page 59: ...m lange air carburant risque d tre trop pauvre pour permettre le d marrage du moteur Avant de mettre le moteur en mar che effectuer les contr les repris dans la liste Contr les et entretiens avant uti...

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

Page 61: ...papillon le m lange air carburant sera trop riche et le moteur risque de caler A la diff rence d un moteur deux temps par ailleurs ce mod le peut tourner au ralenti ATTENTION Ne pas faire chauffer le...

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

Page 63: ...eur rende ment possible il convient de roder la moto de la mani re expliqu e ci apr s Utilisa tion de la poign e des gaz Com mandede d part froid Levierde d mar rage chaud D marrage d un moteur froid...

Page 64: ...2 open low to medium speed for about one hour 6 Restart the engine and check the operation of the machine throughout its entire operat ing range Restart the machine and oper ate it for about 10 to 15...

Page 65: ...es Red mar rer la moto et rouler pendant 10 15 minutes environ La moto est main tenant pr te pour la course ATTENTION Apr s le rodage ou avant chaque course il est indispensable de con tr ler le bon s...

Page 66: ...ket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear shock absorber to frame Tightening of pivot s...

Page 67: ...au cadre Colonne de direction au cadre Colonne de direction au t sup rieur T sup rieur au guidon Fourche au t sup rieur Fourche au t inf rieur Ensemble de timonerie Timonerie au cadre Timonerie l amor...

Page 68: ...belbr cke Obere Gabelbr cke und Lenker Gabelholme und obere Gabelbr cke Gabelholme und untere Gabelbr cke Umlenkhebel Hebel und Rahmen Hebel und Federbein Hebel und Schwinge Federbein und Rahmen Anzug...

Page 69: ...sterzo telaio Fusto dello sterzo staffa superiore Staffa superiore manubrio Forcella anteriore staffa superiore Forcella anteriore staffa inferiore Gruppo di articolazioni Articolazione telaio Articol...

Page 70: ...ion 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...

Page 71: ...dents convient parfaitement pour nettoyer les parties difficiles d acc s 5 Rincer imm diatement la moto l eau claire et s cher toutes les sur faces l aide d une peau de cha mois d une serviette ou d...

Page 72: ...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 73: ...sser Remettre en place la cha ne ou la conserver dans un sachet en plasti que attach au cadre pour viter de l garer 4 Lubrifier tous les c bles de com mande 5 Placer un support sous le cadre afin de s...

Page 74: ...mm 50 91 in 1 295 mm 50 98 in Seat height 992 mm 39 06 in 994 mm 39 13 in 993 mm 39 09 in 994 mm 39 13 in Wheelbase 1 469 mm 57 83 in 1 465 mm 57 68 in 1 469 mm 57 83 in Minimum ground clearance 380 m...

Page 75: ...qt With oil filter replacement 1 1 L 0 97 Imp qt 1 16 US qt Total amount 1 2 L 1 06 Imp qt 1 27 US qt Coolant capacity including all routes 0 9 L 0 79 Imp qt 0 95 US qt Air filter Wet type element Fu...

Page 76: ...Tire Type With tube Size front 80 100 21 51M For USA CDN ZA AUS NZ and F 80 100 21 51R For EUROPE except F Size rear 100 90 19 57M For USA CDN ZA AUS NZ and F 100 90 19 NHS For EUROPE except F Tire p...

Page 77: ...1 mm 0 8661 0 8670 in Camshaft outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Cam dimensions Intake A 30 296 30 346 mm 1 192...

Page 78: ...n 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553 i...

Page 79: ...ce installed IN 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in EX 126 144 N at 29 30 mm 12 6 14 4 kg at 29 30 mm 28 44 32 41 lb at 1 15 in Tilt limit IN 2 5 1 7mm 2 5 0 067 in...

Page 80: ...0 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 1 50 2 25 mm 0 06 0 09 in...

Page 81: ...tarter Type Kick and ratchet type Carburetor USA EUROPE CDN ZA AUS NZ Type manufacturer FCR MX37 KEIHIN I D mark 5XC5 50 5XC6 60 Main jet M J 182 Main air jet M A J 2 0 Jet needle clip position J N OB...

Page 82: ...0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Cooling Radiator core size Width 107 8 mm 4 2 in Height 220 mm 8 7 in Thickness 32 mm 1 26 in Radiator cap...

Page 83: ...Radiator M6 1 0 6 10 1 0 7 2 Radiator guard M6 1 0 2 10 1 0 7 2 Radiator pipe M6 1 0 1 10 1 0 7 2 Oil pump cover M4 0 7 1 2 0 2 1 4 Oil pump M6 1 0 3 10 1 0 7 2 Oil filter element drain bolt M6 1 0 1...

Page 84: ...M10 1 25 1 20 2 0 14 Drive chain sprocket cover M6 1 0 2 8 0 8 5 8 Kick shaft ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank M8 1 25 1 33 3 3 24 Primary drive gear M18 1 0 1 75 7 5 54 Clutc...

Page 85: ...14 5 US oz Oil grade Suspension oil S1 Inner tube outer diameter 48 mm 1 89 in Front fork top end 5 mm 0 20 in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 132 mm 5 20 in Spring free...

Page 86: ...in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 2...

Page 87: ...7 5 1 Throttle grip cap M5 0 8 2 4 0 4 2 9 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 1 0 1 6 0 6 4 3 Brake lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever position...

Page 88: ...and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear fram...

Page 89: ...resistance color 248 372 at 20 C 68 F White Red CDI unit model manufacturer 5XC 50 YAMAHA For USA 5XC 60 YAMAHA Except for USA Ignition coil Model manufacturer 5UL 10 DENSO Minimum spark gap 6 mm 0 2...

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

Page 91: ...ur de la selle 992 mm 39 06 in 994 mm 39 13 in 993 mm 39 09 in 994 mm 39 13 in Empattement 1 469 mm 57 83 in 1 465 mm 57 68 in 1 469 mm 57 83 in Garde au sol minimale 380 mm 14 96 in 382 mm 15 04 in P...

Page 92: ...compris 0 9 L 0 79 Imp qt 0 95 US qt Filtre air El ment de type humide Carburant Type Essence super sans plomb uniquement avec indice d octane de recherche gal ou sup rieur 95 Capacit du r servoir 7 0...

Page 93: ...F 100 90 19 NHS EUROPE sauf F Pression de gonflage avant et arri re 100 kPa 1 0 kgf cm2 15 psi Freins Type de frein avant Frein monodisque Commande Main droite Type de frein arri re Frein monodisque C...

Page 94: ...000 22 021 mm 0 8661 0 8670 in Diam tre ext rieur de l arbre cames 21 959 21 972 mm 0 8645 0 8650 in Jeu arbre chapeau 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Dimensions de la came Admission...

Page 95: ...9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Epaisseur de rebord D IN 0 8 mm 0 0315 in EX 0 7 mm 0 0276 in Diam tre ext rieur de la queue IN 3 975 3 990...

Page 96: ...comprim pos IN 99 114 N 29 13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in EX 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in Limite d inclinaison IN 2 5 1 7 mm 2 5 0 067 in EX 2 5 1...

Page 97: ...m 0 03 0 11 in Ecartement des becs segment mont 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Jeu lat ral 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Segment racleur d huile Dimensions B T 1 50 2...

Page 98: ...het Carburateur USA EUROPE CDN ZA AUS NZ Type fabricant FCR MX37 KEIHIN Marque d identification 5XC5 50 5XC6 60 Gicleur principal MJ N 182 Gicleur principal M A J 2 0 Aiguille position clip J N OBELR...

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

Page 100: ...diateur M6 1 0 2 10 1 0 7 2 Tuyau de radiateur M6 1 0 1 10 1 0 7 2 Couvercle de pompe huile M4 0 7 1 2 0 2 1 4 Pompe huile M6 1 0 3 10 1 0 7 2 Boulon de vidange de l l ment de filtre huile M6 1 0 1 10...

Page 101: ...Couvercle de pignon de cha ne de transmission M6 1 0 2 8 0 8 5 8 Guide rochet de l arbre de kick M6 1 0 2 12 1 2 8 7 P dale de kick M8 1 25 1 33 3 3 24 Pignon menant de transmission primaire M18 1 0 1...

Page 102: ...Type d huile Huile de fourche S1 Diam tre ext rieur du tube plongeur 48 mm 1 89 in Extr mit sup rieure de la fourche 5 mm 0 20 in Suspension arri re USA CDN AUS NZ ZA EUROPE D battement d amortisseur...

Page 103: ...rieur du ma tre cylindre 11 0 mm 0 433 in Diam tre int rieur du cylindre d trier 27 0 mm 1 063 in 2 Type de liquide de frein DOT N 4 Frein disque arri re Diam tre ext rieur du disque Epais seur 245 4...

Page 104: ...ge du levier de frein M6 1 0 1 6 0 6 4 3 Ecrou de montage du levier de frein M6 1 0 1 6 0 6 4 3 Contre crou de r glage de position du levier de frein M6 1 0 1 5 0 5 3 6 Support de levier d embrayage M...

Page 105: ...seur arri re et cadre M10 1 25 1 56 5 6 40 Amortisseur arri re et bras relais M10 1 25 1 53 5 3 38 Cadre arri re sup rieur M8 1 25 1 32 3 2 23 Cadre arri re inf rieur M8 1 25 2 29 2 9 21 Bras oscillan...

Page 106: ...ine d excitation couleur 248 372 20 C 68 F blanc rouge Mod le fabricant du bo tier CDI 5XC 50 YAMAHA USA 5XC 60 YAMAHA Sauf USA Bobine d allumage Mod le fabricant 5UL 10 DENSO Longueur d tincelle mini...

Page 107: ...temp rature ambiante A Distance entre les plats B Diam tre ext rieur du filet DEFINITION DES UNITES A Ecrou B Boulon SPECIFICATION DE COUPLE Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm...

Page 108: ...in Sitzh he 992 mm 39 06 in 994 mm 39 13 in 993 mm 39 09 in 994 mm 39 13 in Radstand 1 469 mm 57 83 in 1 465 mm 57 68 in 1 469 mm 57 83 in Bodenfreiheit 380 mm 14 96 in 382 mm 15 04 in Trockengewicht...

Page 109: ...US qt K hlsystem Fassungsverm gen 0 9 L 0 79 Imp qt 0 95 US qt Luftfilter Na filtereinsatz Kraftstoff Sorte Bleifreies Superbenzin mit einer Mindestoktan zahl von 95 ROZ Tankinhalt 7 0 L 1 54 Imp gal...

Page 110: ...ension hinten 100 90 19 57M nur USA CDN ZA AUS NZ und F 100 90 19 NHS nur EUROPE nicht F Reifenluftdruck vorn und hinten 100 kPa 1 0 kgf cm2 15 psi Bremsen Vorderradbremse Einscheibenbremse Bet tigung...

Page 111: ...021 mm 0 8661 0 8670 in Nockenwellen Lagerzapfen Durchmesser 21 959 21 972 mm 0 8645 0 8650 in Nockenwellen Lagerspiel 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Nocken Abmessungen Einla A 30 29...

Page 112: ...n Ausla 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Ventilteller St rke D Einla 0 8 mm 0 0315 in Ausla 0 7 mm 0 0276 in Ventilschaft Durchmesser Einla 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553...

Page 113: ...druck bei Einbaul nge Einla 99 114 N bei 29 13 mm 9 9 11 4 kg bei 29 13 mm 22 27 25 57 lb bei 1 15 in Ausla 126 144 N bei 29 30 mm 12 6 14 4 kg bei 29 30 mm 28 44 32 41 lb bei 1 15 in Max Neigung Einl...

Page 114: ...nisch Abmessungen B T 0 80 2 75 mm 0 03 0 11 in Ringsto in Einbaulage 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Ringnutspiel 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in labstreifring Abmessung...

Page 115: ...SA EUROPE CDN ZA AUS NZ Typ Hersteller FCR MX37 KEIHIN Kennzeichnung 5XC5 50 5XC6 60 Hauptd se M J Nr 182 Hauptluftd se M A J 2 0 D sennadel D sennadel Clip Stellung J N OBELR 4 OBEKS 4 Drosselklappen...

Page 116: ...0 24 mm 0 009 in Innen und Au enrotor Axialspiel 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in K hlsystem K hlerabmessungen Breite 107 8 mm 4 2 in H he 220 mm 8 7 in Tiefe 32 mm 1 26 in K hlerversc...

Page 117: ...7 2 Wasserpumpengeh use M6 1 0 4 10 1 0 7 2 K hler M6 1 0 6 10 1 0 7 2 K hlerschutz M6 1 0 2 10 1 0 7 2 K hlerrohr M6 1 0 1 10 1 0 7 2 lpumpendeckel M4 0 7 1 2 0 2 1 4 lpumpe M6 1 0 3 10 1 0 7 2 lfilt...

Page 118: ...h use M10 1 25 1 20 2 0 14 Antriebsritzel Abdeckung M6 1 0 2 8 0 8 5 8 Kickstarter Klinkenradf hrung M6 1 0 2 12 1 2 8 7 Kickstarterhebel M8 1 25 1 33 3 3 24 Prim rantriebsritzel M18 1 0 1 75 7 5 54 K...

Page 119: ...0 cm3 15 1 Imp oz 14 5 US oz lsorte Gabel l S1 Gleitrohr Au endurchmesser 48 mm 1 89 in Gabelrohr berstand 5 mm 0 20 in Hinterradaufh ngung USA CDN AUS NZ ZA EUROPE Federweg 132 mm 5 20 in L nge der u...

Page 120: ...0 in Belagst rke 4 4 mm 0 17 in 1 0 mm 0 04 in Hauptbremszylinder Bohrung 11 0 mm 0 433 in Bremssattel Zylinderbohrung 27 0 mm 1 063 in 2 Bremsfl ssigkeit DOT Nr 4 Scheibenbremse hinten Scheibendurchm...

Page 121: ...mszylinder vorn M6 1 0 2 9 0 9 6 5 Handbremshebel Schraube M6 1 0 1 6 0 6 4 3 Handbremshebel Mutter M6 1 0 1 6 0 6 4 3 Sicherungsmutter der Handbremshebel Einstell schraube M6 1 0 1 5 0 5 3 6 Kupplung...

Page 122: ...5 1 80 8 0 58 bertragungshebel und Rahmen M14 1 5 1 80 8 0 58 Federbein und Rahmen M10 1 25 1 56 5 6 40 Federbein und Umlenkhebel M10 1 25 1 53 5 3 38 Rahmenheck oben M8 1 25 1 32 3 2 23 Rahmenheck un...

Page 123: ...F Schwarz Rosa Impulsgeber Widerstand Kabel farbe 248 372 bei 20 C 68 F Wei Rot Z ndbox Typ Hersteller 5XC 50 YAMAHA USA 5XC 60 YAMAHA Nicht USA Z ndspule Typ Hersteller 5UL 10 DENSO Min Z ndfunkenstr...

Page 124: ...und trockene Schraubverbindun gen bei Raumtemperatur A Schl sselweite B Gewindedurchmesser MASSEINHEITEN A Mut ter B Schrau be ANZUGSMOMENT Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm...

Page 125: ...lla 992 mm 39 06 in 994 mm 39 13 in 993 mm 39 09 in 994 mm 39 13 in Interasse 1 469 mm 57 83 in 1 465 mm 57 68 in 1 469 mm 57 83 in Altezza minima dal suolo 380 mm 14 96 in 382 mm 15 04 in Peso a secc...

Page 126: ...to compreso 0 9 L 0 79 Imp qt 0 95 US qt Filtro aria Elemento tipo a umido Carburante Tipo Benzina super senza piombo solo con numero di ottano RON uguale o superiore a 95 Capacit serbatoio 7 0 L 1 54...

Page 127: ...Pressione dei pneumatici anteriore e posteriore 100 kPa 1 0 kgf cm2 15 psi Freno Tipo di freno anteriore Freno a disco singolo Comando Con la mano destra Tipo di freno posteriore Freno a disco singol...

Page 128: ...021 mm 0 8661 0 8670 in Diametro esterno dell albero a camme 21 959 21 972 mm 0 8645 0 8650 in Gioco tra albero e cappello 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Dimensioni delle camme Aspi...

Page 129: ...1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EST 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Spessore margine D INT 0 8 mm 0 0315 in EST 0 7 mm 0 0276 in Diametro esterno dello stelo INT 3 975 3 990 mm 0...

Page 130: ...ata INT 99 114 N a 29 13 mm 9 9 11 4 kg a 29 13 mm 22 27 25 57 lb a 1 15 in EST 126 144 N a 29 30 mm 12 6 14 4 kg a 29 30 mm 28 44 32 41 lb a 1 15 in Limite di inclinazione INT 2 5 1 7 mm 2 5 0 067 in...

Page 131: ...Luce fra le estremit fascia montata 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Gioco laterale 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Fascia raschiaolio Dimensioni B T 1 50 2 25 mm 0 06 0 0...

Page 132: ...con cricchetto Carburatore USA EUROPE CDN ZA AUS NZ Tipo produttore FCR MX37 KEIHIN Contrassegno I D 5XC5 50 5XC6 60 Getto del massimo M J N 182 Getto dell aria del massimo M A J 2 0 Spillo del getto...

Page 133: ...n Gioco tra alloggiamento e rotore 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Raffreddamento Dimensioni del nucleo del radiatore Larghezza 107 8 mm 4 2 in Altezza 220 mm 8 7 in Spessore 32 mm 1 2...

Page 134: ...1 0 7 2 Radiatore M6 1 0 6 10 1 0 7 2 Riparo radiatore M6 1 0 2 10 1 0 7 2 Tubo del radiatore M6 1 0 1 10 1 0 7 2 Coperchio pompa dell olio M4 0 7 1 2 0 2 1 4 Pompa dell olio M6 1 0 3 10 1 0 7 2 Tapp...

Page 135: ...della catena di trasmissione M6 1 0 2 8 0 8 5 8 Guida ruote cricchetto dell albero di avviamento M6 1 0 2 12 1 2 8 7 Leva avviamento a pedale M8 1 25 1 33 3 3 24 Ingranaggio conduttore della trasmissi...

Page 136: ...e dell olio Olio sospensione S1 Diametro esterno del tubo di forza 48 mm 1 89 in Estremit superiore della forcella ante riore 5 mm 0 20 in Sospensione posteriore USA CDN AUS NZ ZA EUROPE Corsa ammorti...

Page 137: ...e pastiglia 4 4 mm 0 17 in 1 0 mm 0 04 in Diametro interno pompa 11 0 mm 0 433 in Diametro interno cilindro della pinza 27 0 mm 1 063 in 2 Tipo di liquido dei freni DOT N 4 Freno a disco posteriore Di...

Page 138: ...l freno anteriore M6 1 0 2 9 0 9 6 5 Bullone di fissaggio leva del freno M6 1 0 1 6 0 6 4 3 Dado di fissaggio leva del freno M6 1 0 1 6 0 6 4 3 Controdado posizione leva del freno M6 1 0 1 5 0 5 3 6 S...

Page 139: ...80 8 0 58 Ammortizzatore posteriore e telaio M10 1 25 1 56 5 6 40 Ammortizzatore posteriore e braccio di rinvio M10 1 25 1 53 5 3 38 Telaio posteriore superiore M8 1 25 1 32 3 2 23 Telaio posteriore...

Page 140: ...obina pickup colore 248 372 a 20 C 68 F bianco rosso Modello produttore unit CDI 5XC 50 YAMAHA USA 5XC 60 YAMAHA Eccetto USA Bobina di accensione Modello produttore 5UL 10 DENSO Lunghezza minima della...

Page 141: ...ambiente A Apertura di chiave B Diametro esterno filettatura DEFINIZIONE DELLE UNIT DI MISURA A Dado B Bul lone SPECIFICA DI SER RAGGIO Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10...

Page 142: ...breather hose oil tank breather hose and ignition coil then on the outside of the left engine bracket Pass the clutch cable through the cable guides Pass the clutch cable in front of the radiator moun...

Page 143: ...r gauche Acheminer le c ble d embrayage dans les guide c bles Acheminer le c ble d embrayage devant la noix de montage du radiateur Fixer le fil du contacteur de point mort et le fil du volant magn ti...

Page 144: ...and cut off the tie end Fasten the neutral switch lead Fasten the neutral switch lead CDI magneto lead and radiator breather hose Pass the neutral switch lead CDI magneto lead and radiator breather h...

Page 145: ...e fil du volant magn tique CDI et la durit de mise l air du radiateur Acheminer le fil du contacteur de point mort le fil du volant magn tique CDI et la durit de mise l air du radiateur entre le radia...

Page 146: ...throttle cables between the radiator and frame then over the radiator mounting boss Pass the throttle cables on the outside of the ignition coil Pass the radiator breather hose in front of the radiato...

Page 147: ...rieur de la bobine d allumage Acheminer la durit de mise l air du radiateur devant la durit de radiateur 2 la gauche du ch ssis puis entre le cadre et la durit de radiateur 4 Ins rer la sangle du bo...

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

Page 149: ...in Si la durit de frein entre en contact avec le ressort amortisseur arri re en corriger la torsion Monter la durit de frein de mani re que sa partie tubulaire soit orient e comme sur l illustration e...

Page 150: ...Fuel tank breather hose 3 Clamp 4 Clutch cable 5 Hot starter cable 6 Engine stop switch lead 7 Brake hose 8 Hose guide Fasten the engine stop switch lead to the handlebar Pass the brake hose in front...

Page 151: ...Fil du coupe circuit du moteur 7 Durit de frein 8 Guide de durit Attacher le fil du coupe circuit du moteur au guidon Acheminer la durit de frein devant la pla que d identification 1 Cavo accelerator...

Page 152: ...e cold Check the valve seats and valve stems for wear Check the valve clearances Inspect Replace VALVE SPRINGS Check the free length and the tilt Inspect Replace VALVE LIFTERS Check for scratches and...

Page 153: ...hoses OUTSIDE NUTS AND BOLTS Refer to STARTING AND BREAK IN section in the CHAPTER 1 Retighten AIR FILTER Clean and lubricate Use foam air filter oil or equivalent oil Replace OIL FILTER Replace OIL S...

Page 154: ...STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt I...

Page 155: ...ace d usure des si ges et des queues de soupapes Contr ler le jeu aux soupapes Contr ler Remplacer RESSORTS DE SOUPAPES Contr ler la longueur libre et l inclinaison Contr ler Remplacer POUSSOIRS DE SO...

Page 156: ...m 1 9 2 3 in Lubrification jeu alignement Remplacer CIRCUIT DE REFROIDISSEMENT Contr ler le niveau de liquide de refroi dissement et l absence de fuites Contr ler le fonctionnement du bouchon de radia...

Page 157: ...OSCILLANT Graisse au bisulfure de molybd ne Contr ler lubrifier et resserrer BRAS RELAIS BIELLE Graisse au bisulfure de molybd ne Contr ler lubrifier et resserrer TETE DE FOURCHE Contr ler le jeu et r...

Page 158: ...lieren Erneuern VENTILFEDERN Ungespannte L nge und Neigung kontrollieren Kontrollieren Erneuern TASSENST SSEL Auf Kratzer und Ver schlei kontrollieren Kontrollieren Erneuern NOCKENWELLEN Die Nockenwel...

Page 159: ...eren Durchhang und Ausrich tung einstellen Erneuern K HLSYSTEM K hlfl ssigkeitsstand kontrollieren und Anlage auf Undichtigkeit pr fen K hlerverschlu deckel kontrollieren K hlfl ssigkeit wechseln Alle...

Page 160: ...ren SCHWINGE Molybd ndisulfidfett Kontrollieren schmieren und festziehen UMLENKHEBEL UND BERTRA GUNGSHEBEL Molybd ndisulfidfett Kontrollieren schmieren und festziehen LENKKOPF Spiel kontrollieren und...

Page 161: ...ntrollare il gioco delle valvole Controllare Sostituire MOLLE DELLE VALVOLE Controllare la lunghezza libera e l inclinazione Controllare Sostituire ALZAVALVOLE Controllare graffi e usura Controllare S...

Page 162: ...8 mm 1 9 2 3 in Lubrificare gioco allineamento Sostituire SISTEMA DI RAFFREDDAMENTO Controllare il livello del refrigerante e la presenza di eventuali perdite Controllare il funzionamento del coper ch...

Page 163: ...sso al disolfuro di molib deno Controllare lubrificare e serrare BRACCIO DI RINVIO BIELLA Grasso al disolfuro di molib deno Controllare lubrificare e serrare TESTA DELLO STERZO Controllare il gioco e...

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

Page 165: ...de la cha ne Contr ler que la cha ne est correctement lubrifi e P 3 31 33 Roues Contr ler l usure et la pression de gonflage des pneus Contr ler que les rayons sont bien tendus et ne pr sentent pas d...

Page 166: ...ntrollieren Sicherstellen da die Antriebskette gr ndlich geschmiert ist 3 31 33 R der Reifenluftdruck und auf starken Verschlei kontrollieren Auf lose Speichen und berm iges Spiel kontrollieren 3 41 4...

Page 167: ...Con trollare che la catena di trasmissione sia correttamente lubrificata P 3 31 33 Ruote Verificare l eventuale eccesso di usura e pressione dei pneumatici Controllare l eventuale presenza di raggi a...

Page 168: ...ly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remo...

Page 169: ...t s arr te appuyer sur le bouchon tout en le faisant tourner dans le sens inverse des aiguilles d une montre puis l enlever ATTENTION L eau calcaire ou sal e est nuisible pour les pi ces du moteur En...

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

Page 171: ...toyer Circuit de refroidissement Rincer soigneusement le circuit de refroidissement l eau claire 5 Monter Rondelle en cuivre Boulon de vidange du liquide de refroidissement T R 10 Nm 1 0 m kg 7 2 ft l...

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

Page 173: ...vec une attention particuli re AVERTISSEMENT En cas de projection de liquide de refroidissement dans les yeux Rincer soigneusement les yeux l eau et consulter un m decin En cas de projection de liquid...

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

Page 175: ...du bouchon de radiateur 110 kPa 1 1 kg cm2 15 6 psi CONTROLE DU CIRCUIT DE REFROIDISSEMENT 1 Contr ler Niveau du liquide de refroidisse ment 2 Fixer Testeur de bouchon de radiateur 1 et adaptateur 2 3...

Page 176: ...hose 3 Swelling Replace CLUTCH ADJUSTMENT 1 Check Clutch lever free play a Out of specification Adjust Clutch lever free play a 8 13 mm 0 31 0 51 in 2 Adjust Clutch lever free play NOTE Make minute ad...

Page 177: ...Jeu du levier d embrayage a 8 13 mm 0 31 0 51 in 2 R gler Jeu du levier d embrayage N B Pour un r glage ponctuel utiliser le dispositif de r glage 2 du c t du levier Apr s le r glage contr ler le fon...

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

Page 179: ...a gauche et con tr ler que le r gime de ralenti du moteur ne s acc l re pas GRAISSAGE DE L ACCELERATEUR 1 D poser Couvercle du logement de c ble des gaz 1 Cache capuchon de la poign e 2 Capuchon de la...

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

Page 181: ...t l endommagement pr matur s du moteur ATTENTION Ne jamais faire tourner un moteur lorsque l l ment du bo tier du filtre air n est pas en place Des crasses et des poussi res pourraient p n trer dans l...

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

Page 183: ...ment Remplacer 4 Appliquer Huile pour filtre air mousse ou huile quivalente sur l l ment N B Comprimer pour liminer l exc s d huile L l ment doit tre humide mais sans exc s 5 Monter Guide de filtre ai...

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

Page 185: ...intenir la verticale en pla ant un support ad quat sous le moteur 3 D poser Bouchon du r servoir d huile 1 4 Contr ler Niveau d huile Le niveau d huile doit se situer entre les rep res de niveau maxi...

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

Page 187: ...pendant quelques minutes 7 Couper le moteur et v rifier nou veau le niveau d huile N B Attendre quelques minutes que l huile se stabilise avant d en contr ler le niveau Huile recommand e A 5 C 40 F o...

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

Page 189: ...l orifice de remplis sage d huile 2 Boulon de vidange d huile du cadre 3 Boulon de vidange d huile du carter moteur 4 Boulon de vidange de l l ment de filtre huile 5 Vidanger le carter moteur et le r...

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

Page 191: ...uile 1 et l l ment de fil tre huile 2 Contr ler les joints toriques 3 s ils sont fissur s ou endommag s les remplacer Monter l l ment de filtre huile et son couvercle T R Couvercle d l ment de fil tre...

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

Page 193: ...de contr le de la pression d huile T R Boulon de contr le de la pression d huile 10 Nm 1 0 m kg 7 2 ft lb Etapes du r glage N B Pour optimiser le d bit de carburant plus faible r gime la vis de ralent...

Page 194: ...to the ignition coil 2 To increase idle speed Turn the throt tle stop screw 1 in a To decrease idle speed Turn the throt tle stop screw 1 out b Engine idling speed 1 900 2 100 r min c 2 VALVE CLEARAN...

Page 195: ...es gaz 1 dans le sens b R gime de ralenti 1 900 2 100 tr mn INSPECTION ET REGLAGE DU JEU AUX SOUPAPES N B Le jeu aux soupapes doit tre r gl quand le moteur est froid au toucher Le piston doit tre au p...

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

Page 197: ...ale du vilebrequin 2 Joint torique 5 Contr ler Jeu aux soupapes Hors sp cifications R gler Jeu aux soupapes froid Soupape d admission 0 10 0 15 mm 0 0039 0 0059 in Soupape d chappement 0 17 0 22 mm 0...

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

Page 199: ...c de l arbre cames d chappement et le rep re poin onn d de l arbre cames d admission sont align s avec la sur face de la culasse comme le montre l illustration Mesurer le jeu aux soupapes e l aide d...

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

Page 201: ...de millim tres sur la surface sup rieure de la plaquette Arrondir le dernier chiffre du num ro de la rondelle mont e la gradation la plus proche Dernier chiffre du num ro de plaquette Valeur d arrond...

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

Page 203: ...tour ner librement sous la pouss e du doigt Veiller remonter les poussoirs de soupapes et les cales leur empla cement d origine Monter les arbres cames d admission et d chappement Se reporter la secti...

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

Page 205: ...26 1 30 235 240 1 31 1 35 240 ECHAPPEMENT JEU MESURE NUMERO DE PLAQUETTE MONTEE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 1...

Page 206: ...1 26 1 30 235 240 1 31 1 35 240 AUSLASS GEMESSE NES SPIEL NUMMER DES EINGEBAUTEN VENTILPL TTCHENS 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0...

Page 207: ...240 1 26 1 30 235 240 1 31 1 35 240 SCARICO GIOCO MISU RATO NUMERO SPESSORE INSTALLATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120...

Page 208: ...a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed...

Page 209: ...ne pas faire d border le r ser voir c Connecter herm tiquement le tuyau en plastique transparent 2 la vis de purge 1 de l trier d Placer l autre extr mit du tuyau dans un r cipient e Actionner lentem...

Page 210: ...eck the operation of the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position 4 Install Brake l...

Page 211: ...rei nage REGLAGE DU FREIN AVANT 1 Contr ler Position du levier de frein a 2 D poser Couvercle du levier de frein 3 R gler Position du levier de frein 4 Monter Couvercle du levier de frein Position du...

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

Page 213: ...mm 0 08 in c de la p dale de frein 5 Apr s le r glage de la hauteur de la p dale de frein contr ler que le frein arri re ne frotte pas CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN AVANT 1 Contr l...

Page 214: ...n the bleed screw and push the brake caliper piston in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads 7 and pad pin...

Page 215: ...r le liquide de frein purg Resserrer la vis de purge T R Vis de purge 6 Nm 0 6 m kg 4 3 ft lb Monter les plaquettes de frein 7 et la goupille de plaquette N B Monter les plaquettes de frein en ins ran...

Page 216: ...ing Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set Brake pad thickness 6...

Page 217: ...ins a Hors sp cifications Remplacer l ensemble 2 Remplacer Plaquette de frein Epaisseur de la plaquette de frein 6 4 mm 0 25 in Limite 1 0 mm 0 04 in Etapes du remplacement des pla quettes de frein D...

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

Page 219: ...r les plaquettes de frein en ins rant leurs ergots a dans les gorges des triers de freins b A ce stade serrer provisoirement la goupille de plaquette Monter l trier de frein B et la roue arri re C Se...

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

Page 221: ...u a Niveau inf rieur Avant Arri re AVERTISSEMENT N utiliser que le liquide de frein recommand pour viter une perte d efficacit du freinage Toujours utiliser le m me type et la m me marque de liquide d...

Page 222: ...cation Replace NOTE While measuring the drive chain length push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and F as shown Perform this measurement...

Page 223: ...nts Longueur de la cha ne de transmission 15 maillons Limite 242 9 mm 9 563 in 2 D poser Clip du maillon de fermeture Raccord 1 Cha ne de transmission 2 3 Nettoyer Cha ne de transmission La d poser da...

Page 224: ...lubricant SAE 10W 30 motor oil or suitable chain lubricants DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Check Drive chain slack a Above the...

Page 225: ...entamer le contr le et ou le r glage faire tourner plusieurs fois la roue arri re pour d terminer le point de tension maximale Contr ler et ou r gler la tension de la cha ne lorsque la roue arri re s...

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

Page 227: ...que la cha ne soit align e avec le pignon vue de l arri re ATTENTION Une cha ne trop tendue impose un effort excessif au moteur et d autres organes vitaux Maintenir la tension dans les limites sp cifi...

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

Page 229: ...t la d tente En tournant le dispositif de r glage 1 T R 1 Nm 0 1 m kg 0 7 ft lb Plus dur a Augmenter la force d amortissement la d tente Visser le dispositif de r glage 1 Plus mou b Diminuer la force...

Page 230: ...Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maxi...

Page 231: ...d clics d viss de 13 d clics REGLAGE DE LA FORCE D AMORTISSEMENT A LA COMPRESSION DE LA FOURCHE 1 R gler Force d amortissement la com pression En tournant le dispositif de r glage 1 Plus dur a Augmen...

Page 232: ...ition CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cau...

Page 233: ...la m me mani re chaque bras de la fourche Un r glage in gal risque de diminuer la maniabi lit et la stabilit Position standard d viss de 11 d clics CONTROLE DE L AMORTISSEUR ARRIERE 1 Contr ler Foncti...

Page 234: ...uster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten Lo...

Page 235: ...crou 6 Monter Cadre arri re sup rieur Cadre arri re inf rieur Plus dur Augmenter la pr con trainte du ressort Visser le dis positif de r glage 2 Plus mou Diminuer la pr con trainte du ressort D visser...

Page 236: ...mp ing force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by the spe c...

Page 237: ...lage est d viss du nombre de d clics sp cifi par rapport la posi tion compl tement viss e Ce qui ali gne le rep re a du dispositif de r glage avec le rep re b du support ATTENTION Ne pas forcer le dis...

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

Page 239: ...par rapport la posi tion compl tement viss e Ce qui ali gne le rep re a du dispositif de r glage avec le rep re b du dispositif de r glage de l amortissement la compression haute ATTENTION Ne pas forc...

Page 240: ...adjustment Maximum Minimum Fully turned in position 2 turns out from maximum position a b 1 STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned...

Page 241: ...du nombre de tours sp cifi par rapport la position com pl tement viss e Ce qui aligne le rep re a du dispositif de r glage avec le rep re b du corps du dispositif de r glage ATTENTION Ne pas forcer l...

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

Page 243: ...ayon desserr Resserrer 2 Serrer Rayons N B Veiller resserrer ces rayons avant et apr s le rodage Apr s tout entra nement ou toute course contr ler la tension des rayons T R 3 Nm 0 3 m kg 2 2 ft lb CON...

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

Page 245: ...but e Fonctionnement irr gulier R gler l crou de blocage de la direction 4 R gler Ecrou de la colonne de direction Etapes de r glage de l crou de direction D poser la plaque d identification D poser l...

Page 246: ...ning T R Steering ring nut final tightening 7 Nm 0 7 m kg 5 1 ft lb Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steerin...

Page 247: ...ne d monter la colonne de direction et contr ler les paliers de la direction Monter la rondelle 5 le t sup rieur 6 la rondelle 7 l crou de direction 8 le capuchon de la colonne de direction 9 le guido...

Page 248: ...Steering stem nut 145 Nm 14 5 m kg 105 ft lb Handlebar upper holder 28 Nm 2 8 m kg 20 ft lb Pinch bolt upper bracket 23 Nm 2 3 m kg 17 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb STEERING HEAD INSPECTI...

Page 249: ...rieur 28 Nm 2 8 m kg 20 ft lb Boulon de pincement t sup rieur 23 Nm 2 3 m kg 17 ft lb Plaque d identification 7 Nm 0 7 m kg 5 1 ft lb T R Dado fusto dello sterzo 145 Nm 14 5 m kg 105 ft lb Supporto s...

Page 250: ...t 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end Use Yamaha cable lube or equivalent on these areas Us...

Page 251: ...c ble de d marrage chaud Utiliser pour ces zones du lubrifiant Yamaha pour c bles ou un lubrifiant qui valent Utiliser de l huile moteur SAE 10W 30 ou un lubrifiant pour cha nes ad quat Lubrifier les...

Page 252: ...any hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of spe...

Page 253: ...e pour fils ou un calibre d paisseur Hors sp cifications R gler 4 Si n cessaire nettoyer la bougie l aide d un nettoie bougies Ecartement des lectrodes 0 7 0 8 mm 0 028 0 031 in 5 Serrer Bougie N B Av...

Page 254: ...ignition coil lead orange lead 1 Timing light YM 33277 A 90890 03141 1 3 Adjust Engine idling speed Refer to ENGINE IDLING SPEED ADJUSTMENT section 4 Check Ignition timing Visually check the stationar...

Page 255: ...ion REGLAGE DU REGIME DE RALENTI DU MOTEUR 4 Contr ler Avance l allumage Contr ler visuellement que l index fixe a se trouve dans la plage d allumage b indiqu e sur le rotor Plage d allumage incorrect...

Page 256: ...Part name Q ty Remarks SEAT FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove...

Page 257: ...Placer le robinet de carburant en position OFF D connecter la durit de carburant 1 Selle 1 2 Prise d air gauche et droite 2 3 Bande de fixation 1 D poser du c t r servoir de carburant 4 Boulon r serv...

Page 258: ...POINTS Side cover 1 Remove Bolt side cover Left side cover 1 Right side cover 2 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air fil ter case SEAT FUEL TANK...

Page 259: ...lat ral gauche 1 Cache lat ral droit 2 N B Glisser le cache lat ral vers le bas pour le d poser car ses pattes a sont ins r es dans le bo tier de filtre air PUNTI DI RIMOZIONE Fianchetto 1 Togliere Bu...

Page 260: ...l Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt...

Page 261: ...eporter la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Boulon collier pince du silencieux 1 Desserrer uniquement 2 Boulon silencieux avant 1 3 Boulon silencieux arri re 1 4 Entretoise p...

Page 262: ...First temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20 Nm 2 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhaust...

Page 263: ...nt puis serrer le bou lon tube d chappement 20 Nm 2 0 m kg 14 ft lb Resserrer ensuite l crou tube d chappement 13 Nm 1 3 m kg 9 4 ft lb puis le boulon tube d chappement 24 Nm 2 4 m kg 17 ft lb T R 13...

Page 264: ...rain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Ra...

Page 265: ...la section SELLE RESERVOIR DE CAR BURANT ET CACHES LATERAUX 1 Plaque de protection du radiateur 2 2 Collier de durit de radiateur 8 Desserrer uniquement 3 Durit de radiateur 1 1 4 Radiateur gauche 1 5...

Page 266: ...procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect...

Page 267: ...rner dans le sens inverse des aiguilles d une montre puis l enlever CONTROLE Radiateur 1 Contr ler Faisceau de radiateur 1 Obstruction Nettoyer l air comprim par l arri re du radia teur Ailette tordue...

Page 268: ...stall Left radiator 1 Bolt left radiator 2 Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Tighten Radiator hose clamp 4 6 Install Radiator guard 1 Bolt radiator guard 2 NO...

Page 269: ...la section DIA GRAMME D ACHEMINE MENT DES CABLES au CHAPITRE 2 5 Serrer Collier de durit du radiateur 4 6 Monter Plaque de protection de radiateur 1 Boulon protection du radiateur 2 N B Ins rer le cro...

Page 270: ...moval Extent of removal Order Part name Q ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp 1 2 Throttle position sensor...

Page 271: ...il du capteur de position de papillon des gaz 1 3 Couvercle du logement du c ble des gaz 1 4 C ble des gaz 2 5 Collier pince conduit d admission d air 1 Desserrer la vis raccord du filtre air 6 Collie...

Page 272: ...CARBURETOR DISASSEMBLY 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 D...

Page 273: ...levier de soupape 1 3 Vis axe du papillon 1 4 Papillon des gaz 1 5 Support d aiguille 1 6 Aiguille 1 7 Couvercle de la pompe de reprise 1 8 Ressort 1 9 Diaphragme pompe de reprise 1 0 Cuve 1 A Gicleu...

Page 274: ...l Order Part name Q ty Remarks F Main jet 1 G Needle jet 1 H Spacer 1 I Pilot jet 1 J Starter jet 1 K Push rod 1 Pull the push rod L Throttle shaft assembly 1 M Push rod link lever assembly 1 N Pilot...

Page 275: ...lenti 1 J Gicleur de starter 1 K Tige de d brayage 1 Tirer la tige de d brayage L Axe du papillon complet 1 M Ensemble levier articul de la tige de d brayage 1 N Gicleur d air de ralenti 1 O Plongeur...

Page 276: ...crew 1 NOTE To optimize the fuel flow at a small throttle opening each machine s pilot screw has been individually set at the factory Before removing the pilot screw turn it in fully and count the num...

Page 277: ...B Pour optimiser le d bit de carburant faible ouverture du papillon la vis de ralenti de chaque moto a t r gl e indi viduellement en usine Avant de d poser la vis de ralenti la serrer fond en comptant...

Page 278: ...ir Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean EC464301 Throttle valve 1 Check Free movement Stick Repair or replace...

Page 279: ...ointeau 1 Si ge de pointeau 2 Usure en creux a Remplacer Poussi re b Nettoyer Filtre c Bouch Nettoyer Papillon des gaz 1 Contr ler Mouvement Coincement R parer ou rem placer N B Ins rer le papillon de...

Page 280: ...the float will push in the needle valve resulting in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE T...

Page 281: ...isse mesurer la distance entre la surface de contact de la cuve et le haut du flotteur N B Le bras du flotteur doit reposer sur le pointeau mais sans le comprimer Si la hauteur du flotteur est hors sp...

Page 282: ...celerator pump 1 Spring accelerator pump 2 Accelerator pump cover 3 O ring 4 Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spr...

Page 283: ...la pompe de reprise 3 Joint torique 4 Tige de d brayage 5 Craquelures diaphragme endommagement Remplacer Salet Nettoyer 2 Contr ler Axe du papillon 1 Ressort 2 Levier 1 3 Ressort 1 4 Levier 2 5 Ressor...

Page 284: ...Install Spring 2 1 To lever 2 2 1 2 5 Install Push rod link lever assembly 1 NOTE Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 1 a b 6 Install Washer 1 Circlip 2 2...

Page 285: ...vier articul de la tige de d brayage 1 N B Veiller engager la but e a du ressort 2 dans la gorge b du carburateur 6 Monter Rondelle 1 Circlip 2 7 Monter Ressort 1 Sur l axe du papillon 2 N B Monter le...

Page 286: ...ensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throt tle stop screw tip d to the...

Page 287: ...du carburateur Tourner l ensemble axe de papillon vers la gauche tout en maintenant le levier 1 5 abaiss et engager la pointe de la vis de but e de papillon des gaz d sur la but e e de la poulie de l...

Page 288: ...until it is lightly seated Turn out the pilot screw by the number of turns recorded before removing Pilot screw 1 7 8 turns out example 2 1 8 turns out 13 Install O ring Leak jet 1 Float chamber 2 Scr...

Page 289: ...nom bre de tours enregistr avant la d pose Vis de ralenti Desserr e de 1 7 8 tour exemple Desserr e de 2 1 8 tour 13 Monter Joint torique Gicleur de fuite 1 Cuve 2 Vis cuve 3 Support de c ble c ble de...

Page 290: ...Valve lever housing cover 2 Bolt valve lever housing cover 3 18 Install Carburetor breather hose 1 NOTE Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where...

Page 291: ...ura teur 1 N B Monter les durits de mise l air du car burateur sur le carburateur de mani re que les durits ne fassent pas de coude proximit de leur point de montage R glage du calage de la pompe de r...

Page 292: ...play Carburetor installation 1 Install Carburetor joint 1 NOTE Install the projection a on the cylinder between the carburetor joint slots b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Carburetor 1 NOTE In...

Page 293: ...burateur 1 Monter Raccord de carburateur 1 N B Monter l ergot a du cylindre entre les fentes du raccord de carburateur b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Monter Carburateur 1 N B Monter l ergot a entre l...

Page 294: ...LE ADJUST MENT section in the CHAPTER 3 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 7 Install Throttle cable cover 1 Screw throttle cable cover 2 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Ins...

Page 295: ...le du logement du c ble des gaz 1 Vis couvercle du logement de c ble des gaz 2 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Monter Fiche rapide du fil du capteur de position de papillon des gaz 1 Collier pince 2 Se...

Page 296: ...INDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section 1 Spark plug 1 2 Cylinder head breather hose...

Page 297: ...DE CAR BURANT ET CACHES LATERAUX Carburateur Se reporter la section CARBURATEUR 1 Bougie 1 2 Durit de mise l air de la culasse 1 3 Durit de mise l air du r servoir d huile 1 4 Boulon couvre culasse 2...

Page 298: ...emoval Order Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing mark accessing screw 1 Refer to REMOVAL POINTS 2 Crankshaft end accessing screw 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tens...

Page 299: ...EPOSE 2 Vis d acc s axiale du vilebrequin 1 3 Boulon capuchon du tendeur de cha ne de dis tribution 1 4 Tendeur de cha ne de distribution 1 5 Chapeau d arbre cames 2 6 Clip 2 7 Arbre cames d chappemen...

Page 300: ...order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl inder head surface as shown in the...

Page 301: ...es d chappement et le rep re poin onn d de l arbre cames d admission sont align s avec la sur face de la culasse comme le montre l illustration 3 D poser Boulon capuchon du tendeur de cha ne de distri...

Page 302: ...ce 2 Measure Cam lobe length a and b Out of specification Replace Cam lobes length Intake a 30 296 30 346 mm 1 1923 1 1947 in Limit 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm...

Page 303: ...gueur des bossages de cames Admission a 30 296 30 346 mm 1 1923 1 1947 in Limite 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limite 22 35 mm 0 8799 in Echappement a 30 399 30 499 mm 1 1968 1...

Page 304: ...m 1 0 m kg 7 2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camshaf...

Page 305: ...nternes vers les chapeaux ext rieurs Ne pas tourner l arbre cames pendant la mesure du jeu avec le Plastigauge D poser les chapeaux d arbres cames et mesurer la largeur du Plastigauge 1 5 Mesurer Diam...

Page 306: ...ALLATION Camshaft 1 Install Exhaust camshaft 1 Intake camshaft 2 Checking steps Check that the decompression mecha nism cam 1 moves smoothly Check that the decompression mecha nism cam lever pin 2 pro...

Page 307: ...est pas le cas remplacer le tendeur complet ASSEMBLAGE ET MONTAGE Arbre cames 1 Monter Arbre cames d chappement 1 Arbre cames d admission 2 Etapes du montage Tourner le vilebrequin dans le sens invers...

Page 308: ...he clips camshaft caps 4 and bolts camshaft cap 5 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Before removing the clips cover the cylin der head with a clean rag to prevent the clips from into...

Page 309: ...Avant de d poser les clips couvrir la culasse avec un chiffon propre pour emp cher les clips de tomber dans la cavit de la culasse Appliquer de l huile moteur sur les filets et la surface de contact d...

Page 310: ...the screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci fied torque T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft lb 5 4 3 Turn Crankshaft Counterc...

Page 311: ...rrer le joint 4 et le boulon capuchon 5 au couple sp cifi T R Boulon capuchon du ten deur 7 Nm 0 7 m kg 5 1 ft lb 3 Tourner Vilebrequin Plusieurs tours dans le sens inverse des aiguilles d une montre...

Page 312: ...cover 3 Bolt cylinder head cover 4 NOTE Apply the sealant on the cylinder head cover gasket Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 7 Install Oil tank...

Page 313: ...duit d tanch it sur le joint de couvre culasse T R 10 Nm 1 0 m kg 7 2 ft lb Quick gasket ACC QUICK GS KT YAMAHA Bond N 1215 90890 85505 7 Monter Durit de mise l air du r servoir d huile Durit de mise...

Page 314: ...IDE COVERS section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHA...

Page 315: ...teur 1 D connecter du c t de la culasse Carburateur Se reporter la section CARBURATEUR Arbre cames Se reporter la section ARBRES A CAMES Support de moteur sup rieur Se reporter la section DEPOSE DU MO...

Page 316: ...ad warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurface ment steps Place a straightedge and a feeler gauge across the cylinder head...

Page 317: ...ier D formation de la culasse Inf rieure 0 05 mm 0 002 in Etapes de la mesure de la limite de d formation et de la rectification Placer un r glet et une jauge d paisseur lames sur la culasse Utiliser...

Page 318: ...3 Bolts L 135 mm 5 31 in 4 Nuts 5 NOTE Apply the molybdenum disulfide grease on the thread and contact surface of the bolts Follow the numerical order shown in the illus tration Tighten the bolts and...

Page 319: ...bisulfure de molybd ne sur les filets et les surfaces de contact des boulons Suivre l ordre num rique indiqu dans l illustration Serrer les boulons et les crous en deux tapes T R 38 Nm 3 8 m kg 27 ft...

Page 320: ...ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cot...

Page 321: ...e 5 Utiliser l outil sp cial Se reporter POINTS DE DEPOSE 2 Cale de r glage 5 3 Clavette de soupape 10 4 Coupelle de ressort de soupape 5 5 Ressort de soupape 5 6 Joint de queue de soupape 5 7 Si ge d...

Page 322: ...lve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly...

Page 323: ...largeur du si ge de soupape Etapes du contr le Verser du solvant de nettoyage 1 dans les lumi res d admission et d chappement Contr ler soigneusement les joints de soupapes Il ne peut y avoir aucune f...

Page 324: ...3 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head i...

Page 325: ...nt N B Afin de faciliter la d pose et le mon tage du guide et afin de maintenir l ajustement correct chauffer la culasse dans un four une temp ra ture de 100 C 212 F D poser le guide de soupape l aide...

Page 326: ...7 90890 04117 Valve guide reamer Intake 4 0 mm 0 16 in YM 4113 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 90890 04118 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pi...

Page 327: ...M 4118 90890 04118 N B Apr s avoir remplac le guide de soupape rectifier le si ge de soupape 3 Contr ler Port e de soupape Piq res usure Rectifier la por t e de soupape Embout de queue de soupape Extr...

Page 328: ...a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps App...

Page 329: ...9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Echappement 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in Etapes de la mesure Appliquer du bleu de m canicien Dykem b sur la port e de sou pape...

Page 330: ...lve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping...

Page 331: ...ts de rodage tapoter l g rement le si ge de soupape tout en faisant tourner la soupape entre les mains avec un mouvement de va et vient Appliquer une p te roder fine sur la port e de soupape et r p te...

Page 332: ...m 1 45 in Exhaust 37 54 mm 1 48 in Limit 36 54 mm 1 44 in Compressed spring force Intake 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in Exhaust 126 144 N at 29 30 mm 12 6 14 4...

Page 333: ...im Admission 99 114 N 29 13 mm 9 9 11 4 kg 29 13 mm 22 27 25 57 lb 1 15 in Echappement 126 144 N 29 30 mm 12 6 14 4 kg 29 30 mm 28 44 32 41 lb 1 15 in 3 Mesurer Inclinaison du ressort a Hors sp cifica...

Page 334: ...e also referring to the painted color as follows Intake middle a yellow Intake right left b white Exhaust no paint Install the valve springs with the larger pitch c facing upward d Smaller pitch 3 Ins...

Page 335: ...ts de soupape en pla ant les spires les plus grandes c vers le haut d Petites spires 3 Monter Clavette de soupape N B Monter les clavettes de soupape tout en comprimant le ressort de soupape l aide d...

Page 336: ...pad 1 Valve lifter 2 NOTE Apply the molybdenum disulfide oil on the valve stem end Apply the engine oil on the valve lifters Valve lifter must turn smoothly when rotated with a finger Be careful to re...

Page 337: ...er de l huile moteur sur les poussoirs de soupapes Le poussoir de soupape doit tourner librement sous la pouss e du doigt Veiller remonter les poussoirs de soupapes et les cales leur emplace ment d or...

Page 338: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin cli...

Page 339: ...S CYLINDRES ET DES PIS TONS Pr paration la d pose Culasse Se reporter la section CULASSE 1 Boulon cylindre 1 2 Cylindre 1 3 Agrafe d axe de piston 2 Utiliser l outil sp cial Se reporter POINTS DE DEPO...

Page 340: ...se a hammer to drive the piston pin out 2 Remove Piston ring 1 NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustrati...

Page 341: ...soulevant le segment de piston par des sus la calotte du piston comme illustr Kit extracteur d axe de pis ton YU 1304 90890 01304 CONTROLE Cylindre et piston 1 Contr ler Parois du cylindre et du pisto...

Page 342: ...re the piston skirt diameter P with a micrometer a 8 mm 0 31 in from the piston bottom edge Piston size P Standard 76 955 76 970 mm 3 0297 3 0303 in If out of specification replace the piston and pist...

Page 343: ...piston Taille du piston P Standard 76 955 76 970 mm 3 0297 3 0303 in Si hors sp cifications remplacer ensemble le piston et les segments de piston 3 me tape Calculer le jeu entre piston et cylindre a...

Page 344: ...rown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 00...

Page 345: ...e feu 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in Segment d tan ch it 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in 3 Mesurer Coupe de segment Hors sp cifications Rempla cer N B Il n est pas p...

Page 346: ...piston and piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 15 991 16 000...

Page 347: ...iston a Si hors sp cifications remplacer l axe de piston Diam tre ext rieur axe de piston 15 991 16 000 mm 0 6296 0 6299 in Mesurer le diam tre int rieur pis ton b Diam tre int rieur pis ton 16 002 16...

Page 348: ...ton Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from...

Page 349: ...ur l axe de piston et le piston Contr ler que la fl che a du piston pointe vers le c t chappement du moteur Avant de monter l agrafe d axe de pis ton couvrir le carter d un chiffon pro pre pour viter...

Page 350: ...h one hand while com pressing the piston rings with the other hand CAUTION Pass the timing chain 3 through the tim ing chain cavity Be careful not to damage the timing chain guide 4 during installatio...

Page 351: ...N Acheminer la cha ne de distribu tion 3 dans la cavit de la cha ne de distribution Veiller ne pas endommager le patin de cha ne de distribution 4 pendant l installation 4 Monter Boulon cylindre 5 T R...

Page 352: ...al Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOV...

Page 353: ...CHANGEMENT DE L HUILE MOTEUR au CHAPITRE 3 P dale de frein Se reporter la section DEPOSE DU MOTEUR C ble d embrayage D connecter du c t du moteur 1 Couvercle d embrayage 1 2 Ressort d appui du plateau...

Page 354: ...ty Remarks 10 Friction plate 9 11 Clutch plate 8 12 Cushion spring 1 13 Seat plate 1 14 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1...

Page 355: ...si ge 1 14 Ecrou noix d embrayage 1 Utiliser l outil sp cial Se reporter POINTS DE DEPOSE 15 Rondelle d arr t 1 16 Noix d embrayage 1 17 Rondelle de but e 1 18 Pignon men de transmission primaire 1 19...

Page 356: ...YM 91042 90890 04086 EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1...

Page 357: ...Remplacer Noix d embrayage 2 Formation de rayures usure endommagement Remplacer Pignon men de transmission primaire 1 Contr ler Jeu p riph rique Pr sence de jeu Remplacer Dents de pignon a Usure endo...

Page 358: ...Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 7 mm 0 106 in Warp limit...

Page 359: ...rbre 1 et une jauge d paisseur 2 Epaisseur du disque garni 2 9 3 1 mm 0 114 0 122 in Limite 2 7 mm 0 106 in Limite de d formation 0 1 mm 0 004 in Arbre de tige de pouss e 1 Contr ler Arbre de tige de...

Page 360: ...the groove a of the push lever shaft and tighten the bolt seat plate T R 10 Nm 1 0 m kg 7 2 ft lb Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on the...

Page 361: ...onter Pignon men de transmission pri maire 1 Rondelle de but e 2 Noix d embrayage 3 N B Appliquer de l huile moteur sur la cir conf rence int rieure du pignon men de transmission primaire 2 Monter Ron...

Page 362: ...l the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying at...

Page 363: ...en ter minant par un disque garni Utiliser les disques garnis 1 comme premier et dernier disques en tenant compte de la diff rence de motifs de la surface Appliquer de l huile moteur sur les disques g...

Page 364: ...essure plate 1 9 Install Clutch spring 1 Bolt clutch spring 2 NOTE Tighten the bolts in stage using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 10 Install Dowel pin 1 Gasket clutch cover 2 11 Ins...

Page 365: ...r Ressort d embrayage 1 Boulon ressort d embrayage 2 N B Serrer les boulons par tapes et en proc dant en croix T R 8 Nm 0 8 m kg 5 8 ft lb 10 Monter Goujon 1 Joint couvercle d embrayage 2 11 Monter Co...

Page 366: ...rks OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to CO...

Page 367: ...n CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT au CHAPITRE 3 Durit de radiateur 3 D connecter du c t de la pompe eau Tube d chappement Se reporter la section TUBE D ECHAPPEMENT ET SILENCIEUX P dale de fre...

Page 368: ...VER Extent of removal Order Part name Q ty Remarks 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to REMOVAL POINTS 9...

Page 369: ...vercle de carter droit 1 8 Rotor 1 Se reporter POINTS DE DEPOSE 9 Rondelle 1 10 Axe de pompe 1 11 Bague d tanch it 2 12 Roulement 1 3 2 Estensione della rimozione Ordine Denominazione Quantit Osservaz...

Page 370: ...oss the flats a with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant le...

Page 371: ...u niveau de liquide de refroidissement une d coloration du liquide de refroidisse ment ou un aspect laiteux de l huile de bo te de vitesses 1 D poser Roulement 1 2 D poser Bague d tanch it 1 CONTROLE...

Page 372: ...Gear teeth a Wear damage Replace EC4H4600 Bearing 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace EC444400 Oil seal 1 Inspect Oil seal 1 Wear damage Replace ASSEMBLY AND...

Page 373: ...tanch it 1 Contr ler Bague d tanch it 1 Usure endommagement Rem placer ASSEMBLAGE ET MONTAGE Bague d tanch it 1 Monter Bague d tanch it 1 N B Appliquer de la graisse savon de lithium sur la l vre de l...

Page 374: ...dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning...

Page 375: ...tra nement Monter l axe tout en le faisant tourner Maintenir l axe de pompe en le saisis sant par les c t s plats a l aide d une cl etc et monter le rotor T R 14 Nm 1 4 m kg 10 ft lb Couvercle de cart...

Page 376: ...kg 7 2 ft lb Kickstarter crank 1 Install Kickstarter crank 1 Washer 2 Bolt kickstarter crank 3 NOTE Install the kickstarter crank so that the kick starter crank is as vertical as possible with the dis...

Page 377: ...tica lement possible la distance a entre la p dale de kick et le cadre tant de 8 mm 0 31 in ou plus 2 Monter Durit d huile 1 Boulon durit d huile 2 T R 33 Nm 3 3 m kg 24 ft lb T R 8 Nm 0 8 m kg 5 8 ft...

Page 378: ...he lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter element 1 Install Oil filter element 1 O ring 2 Oil filter el...

Page 379: ...nt de filtre huile 3 Boulon couvercle d l ment de filtre huile N B Appliquer de la graisse savon de lithium sur le joint torique T R 10 Nm 1 0 m kg 7 2 ft lb Alloggiamento della pompa dell acqua 1 Ins...

Page 380: ...r to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to REMOVAL POIN...

Page 381: ...menant de transmission pri maire 1 Se reporter POINTS DE DEPOSE 2 Ecrou pignon men de l arbre de balancier 1 3 Rondelle frein 1 4 Pignon menant de transmission primaire 1 5 Pignon menant de l arbre d...

Page 382: ...d driven gear 4 Balancer shaft 1 Remove Balancer shaft 1 NOTE When removing the balancer shaft align the center a of the balancer shaft weight along the line connecting the centers of the crank shaft...

Page 383: ...bre de balancier CONTROLE Pignon menant de transmission pri maire pignon menant et pignon men de l arbre de balancier 1 Contr ler Pignon menant de transmission primaire 1 Pignon menant de l arbre de b...

Page 384: ...r shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 NOTE Align the punched mark a on the balancer shaft drive gear with the punched mark b on th...

Page 385: ...rep re poin onn c du pignon menant de l arbre du balancier avec la cannelure inf rieure d de l extr mit du vilebrequin 4 Monter Rondelle frein 1 Ecrou pignon men de l arbre de balancier 2 Pignon mena...

Page 386: ...EMBLY Preparation for removal Primary driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section 1 Circlip 1 2 Washer 1 3 Oil p...

Page 387: ...POMPE A EAU ET COUVERCLE DE CAR TER DROIT 1 Circlip 1 2 Rondelle 1 3 Pignon menant de pompe huile 1 4 Pompe huile compl te 1 5 Rotor externe 2 1 6 Circlip 1 7 Rotor interne 2 1 8 Goujon 1 9 Couvercle...

Page 388: ...4 67 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 2...

Page 389: ...e la d pose Ordre Nom de la pi ce Qt Remarques 12 Goujon 1 13 Rondelle 1 14 Arbre d entra nement de pompe huile 1 15 Bo tier du rotor 1 2 Estensione della rimozione Ordine Denominazione Quantit Osserv...

Page 390: ...he outer rotor 2 and rotor housing 3 Housing and rotor clearance c between the rotor housing 3 and rotors 1 2 Out of specification Replace the oil pump assembly Tip clearance a 0 12 mm or less 0 0047...

Page 391: ...tor 3 et les rotors 1 2 Hors sp cifications Remplacer la pompe huile compl te Jeu entre rotors a 0 12 mm ou moins 0 0047 in ou moins Limite 0 20 mm 0 008 in Jeu lat ral b 0 09 0 17 mm 0 0035 0 0067 in...

Page 392: ...shaft and inner rotor 1 Fit the dowel pin into the groove in the inner rotor 1 2 Install Outer rotor 1 1 NOTE Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover...

Page 393: ...N B Appliquer de l huile moteur sur le rotor externe 1 3 Monter Couvercle de pompe huile 1 Vis couvercle de pompe huile 2 Goujon 3 Rotor interne 2 4 Circlip 5 N B Appliquer de l huile moteur sur le ro...

Page 394: ...5 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 NOTE Apply the engine oil on the outer rotor 2 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install Oil pump drive gear 1 Washer...

Page 395: ...le rotor externe 2 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Monter Pignon menant de pompe huile 1 Rondelle 2 Circlip 3 N B Appliquer de l huile moteur sur la cir conf rence int rieu...

Page 396: ...oval Extent of removal Order Part name Q ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to RE...

Page 397: ...huile Se reporter la section POMPE A HUILE 1 Pignon fou de kick 1 2 Arbre de kick complet 1 Se reporter POINTS DE DEPOSE 3 Guide de ressort 1 4 Ressort de torsion 1 5 Roue rochet 1 6 Pignon de kick 1...

Page 398: ...Q ty Remarks 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to REMOVAL POINTS 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper...

Page 399: ...eur complet 1 16 Levier de s lecteur 1 17 Cliquet 2 18 Goupille de cliquet 2 19 Ressort 2 20 Boulon doigt de verrouillage 1 21 Doigt de verrouillage 1 22 Ressort de torsion 1 23 Segment 1 Se reporter...

Page 400: ...embly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION Kick s...

Page 401: ...egment dans le sens inverse des aiguilles d une montre jusqu la but e et desserrer le boulon CONTROLE Arbre de kick et roue rochet 1 Contr ler Mouvement libre de la roue rochet 1 Mouvement irr gulier...

Page 402: ...assembly 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace ASSE...

Page 403: ...cliquet 4 Ressort 5 Usure endommagement Rem placer Doigt de verrouillage 1 Contr ler Doigt de verrouillage 1 Usure endommagement Rem placer Ressort de torsion 2 Cass Remplacer ASSEMBLAGE ET MONTAGE Se...

Page 404: ...1 Install Spring 1 Pawl pin 2 Pawl 3 To shift lever 4 NOTE Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly 1 To shift guide 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install...

Page 405: ...r de l huile moteur sur le res sort la goupille de cliquet et le cliquet 2 Monter Levier de s lecteur complet 1 Sur le guide de s lecteur 2 3 Monter Levier de s lecteur complet 1 Guide de s lecteur 2...

Page 406: ...1 mm 0 04 in a above the top of the footrest T R 12 Nm 1 2 m kg 8 7 ft lb Kick shaft assembly 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 NOTE...

Page 407: ...Circlip 3 Roue rochet 4 Ressort 5 Rondelle 6 Circlip 7 Sur l arbre de kick 8 N B Appliquer de l huile au bisulfure de molybd ne sur les circonf rences internes du pignon de kick et de la roue rochet A...

Page 408: ...top per a and kick shaft ratchet wheel guide 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft...

Page 409: ...v rifier que la but e d arbre de kick a s engage dans le guide de roue rochet de l arbre de kick 5 Accrocher Ressort de torsion 1 N B Faire tourner le ressort de torsion dans le sens des aiguilles d...

Page 410: ...AL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt left radiator Refer to RADIATOR section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHA...

Page 411: ...CACHES LATERAUX Boulon radiateur gauche Se reporter la section RADIATEUR D connecter le fil du volant magn tique CDI S lecteur Se reporter la section ARBRE DE KICK ET AXE DE SELECTEUR 1 Couvercle de...

Page 412: ...lywheel puller turn it counterclockwise Rotor holding tool YU 1235 90890 01235 Flywheel puller YM 1189 90890 01189 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer...

Page 413: ...s d une montre Extracteur de volant magn tique YM 1189 90890 01189 CONTROLE Volant magn tique CDI 1 Contr ler Surface int rieure du rotor a Surface ext rieure du stator b Endommagement Contr ler le fa...

Page 414: ...90 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Woodruff key 1 Rotor 2 NOTE Clean the tapered portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is...

Page 415: ...e 1 Rotor 2 N B Nettoyer les parties coniques du vile brequin et du rotor En montant la clavette demi lune veiller ce que sa surface plane a soit parall le la ligne de centrage du vilebrequin b En mon...

Page 416: ...ING DIAGRAM section in the CHAPTER 2 5 Install Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Bolt left crankcase cover NOTE Tighten the bolts in...

Page 417: ...2 5 Monter Goujon Joint couvercle de carter gau che Couvercle de carter gauche 1 Guide de durit durit de mise l air de la culasse 2 Boulon couvercle de carter gau che N B Serrer les boulons par tapes...

Page 418: ...over Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconn...

Page 419: ...PEMENT ET SILENCIEUX C ble d embrayage D connecter du c t du moteur Radiateur Se reporter la section RADIATEUR S lecteur Se reporter la section ARBRE DE KICK ET AXE DE SELECTEUR Durits de mise l air d...

Page 420: ...ne guard 1 Lower engine guard 1 2 Neutral switch 1 3 Bolt oil hose 2 4 Drive chain sprocket cover 1 5 Nut drive sprocket 1 Refer to REMOVAL POINTS 6 Lock washer 1 7 Drive sprocket 1 8 Clip 1 9 Bolt br...

Page 421: ...5 Ecrou couronne arri re 1 Se reporter POINTS DE DEPOSE 6 Rondelle frein 1 7 Couronne arri re 1 8 Clip 1 9 Boulon p dale de frein 1 10 P dale de frein 1 11 Support de moteur sup rieur 2 12 Support de...

Page 422: ...sprocket 1 Drive chain 2 NOTE Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will...

Page 423: ...pose du moteur 1 D poser Boulon pivot 1 N B Si l on extrait enti rement le boulon pivot le bras oscillant n est plus sup port Si possible ins rer un axe de dia m tre quivalent dans l autre extr mit d...

Page 424: ...uard A NOTE Apply the molybdenum disulfide grease on the pivot shaft T R 85 Nm 8 5 m kg 61 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 34 Nm 3 4 m kg 24 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 44 Nm 4 4 m kg...

Page 425: ...T R 69 Nm 6 9 m kg 50 ft lb T R 44 Nm 4 4 m kg 32 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb P dale de frein 1 Monter Ressort 1 P dale de frein 2 Joint torique 3 Boulon p dale de...

Page 426: ...uide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 T R 8 Nm 0 8 m kg 5 8 ft lb Oil hose and neutral switch 1 Install O ring 1 Dowel pin 2 Oil hose 3 Bolt oil hose 4 NOTE Apply the...

Page 427: ...que 1 Goujon 2 Durit d huile 3 Boulon durit d huile 4 N B Appliquer de la graisse savon de lithium sur le joint torique 2 Monter Ressort 1 Goupille 2 Joint torique 3 Contacteur de point mort 4 Vis con...

Page 428: ...RANKCASE AND CRANK SHAFT REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT sec...

Page 429: ...e de kick complet Se reporter la section ARBRE DE KICK ET AXE DE SELECTEUR Segment Stator Se reporter la section VOLANT MAGNETIQUE CDI Arbre de balancier Se reporter la section BALANCIER 1 Patin de ch...

Page 430: ...ty Remarks 4 Bolt L 45 mm 1 77 in 6 Refer to REMOVAL POINTS 5 Bolt L 55 mm 2 17 in 1 6 Bolt L 70 mm 2 76 in 4 7 Hose guide 1 8 Clutch cable holder 1 9 Right crankcase 1 10 Left crankcase 1 11 Oil str...

Page 431: ...55 mm 2 17 in 1 6 Boulon L 70 mm 2 76 in 4 7 Guide de durit 1 8 Support du c ble d embrayage 1 9 Carter moteur droit 1 10 Carter moteur gauche 1 11 Cr pine huile 1 12 Vilebrequin 1 Utiliser l outil sp...

Page 432: ...1 Crankcase bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift c...

Page 433: ...UR Pr paration la d pose Bo te de vitesses Se reporter la section BOITE DE VITESSES TAM BOUR ET FOURCHETTES DE SELECTION Tambour et fourchette de s lection 1 Bague d tanch it 2 2 Roulement 10 Se repor...

Page 434: ...litting slit a in the crankcase Lift the right crankcase horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mis...

Page 435: ...la noix de montage du moteur l aide d un maillet en caoutchouc laisser le vilebrequin et la bo te de vitesses dans le carter moteur gauche ATTENTION Taper sur le demi carter l aide d un maillet en pl...

Page 436: ...e removed bearing Crankcase separating tool YU 1135 A 90890 01135 INSPECTION Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a...

Page 437: ...ontr ler Cha ne de distribution Fissures rigidit Remplacer ensemble la cha ne de distribu tion et le pignon d arbre cames 2 Contr ler Patin de cha ne de distribution Usure endommagement Rem placer Car...

Page 438: ...auge Dial gauge and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clearance 0 15 0 45 mm 0...

Page 439: ...pied de bielle 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Jeu lat ral 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Largeur de volant 55 95 56 00 mm 2 203 2 205 in Cr pine huile 1 Contr ler Cr pine huil...

Page 440: ...shaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 For USA and CDN Except for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut o...

Page 441: ...aut d une main tout en tournant l crou de l outil de montage de l autre main Actionner l outil de montage jusqu ce que le vilebrequin bute contre le roulement Avant de monter le vilebrequin net toyer...

Page 442: ...nkcase 1 NOTE Clean the contacting surface of left and right crankcase before applying the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase NOTE Fit the right crankcase onto th...

Page 443: ...carters moteur droit et gauche avant d appliquer la p te d tanch it 5 Monter Goujon 1 Joint torique 2 Carter moteur droit Sur le carter moteur gauche N B Adapter le carter moteur droit sur le carter...

Page 444: ...1 O ring 2 Bolt oil delivery pipe 2 3 NOTE Apply the lithium soap base grease on the O rings T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain gu...

Page 445: ...n de cha ne de distribution c t admission 2 Boulon patin de cha ne de distri bution 3 9 D poser P te d tanch it R pandue sur la surface de con tact du cylindre 10 Appliquer Huile moteur Sur le maneton...

Page 446: ...removal Extent of removal Order Part name Q ty Remarks TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRAN...

Page 447: ...n DEPOSE DU MOTEUR S parer le carter moteur Se reporter la section CARTER MOTEUR ET VILE BREQUIN 1 Arbre primaire 1 Se reporter POINTS DE DEPOSE 2 Arbre secondaire 1 3 Tambour 1 4 Fourchette de s lect...

Page 448: ...rticular attention to the location and direction of shift forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham...

Page 449: ...g rement sur l arbre secondaire de la transmission l aide d un marteau en plastique CONTROLE Pignons 1 Contr ler Crabot d accouplement a Dents du pignon b Gorge de fourchette de s lection c Usure endo...

Page 450: ...ift fork NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION Transmission 1 Install 5th pi...

Page 451: ...les deux pignons adjacents ASSEMBLAGE ET MONTAGE Bo te de vitesses 1 Monter Pignon de 5 me 24T 1 Pignon de 3 me 20T 2 Entretoise paul e 3 Pignon de 4 me 22T 4 Pignon de 2 me 16T 5 Sur l arbre primaire...

Page 452: ...the inner surface of the sliding gear then install Apply the lithium soap base grease on the O ring 3 Install Washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite si...

Page 453: ...oppos de la rondelle et du pignon b Monter le circlip en asseyant unifor m ment ses extr mit s c sur les cr tes des cannelures 4 Monter Entretoise paul e 1 N B Appliquer de la graisse savon de lithium...

Page 454: ...oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle...

Page 455: ...te n 3 D avec le pignon de 5 me 7 de l arbre secondaire Engrener la fourchette n 2 C avec le pignon de 3 me 6 de l arbre princi pal 6 Monter Bo te de vitesses compl te 1 Sur le carter moteur gauche 2...

Page 456: ...removal Order Part name Q ty Remarks FRONT WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable...

Page 457: ...paration la d pose Caler la moto en pla ant un support ad quat sous le moteur 1 Boulon support d axe 4 Desserrer uniquement 2 Ecrou axe de roue avant 1 3 Axe de roue avant 1 4 Roue avant 1 5 Entretois...

Page 458: ...machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive ch...

Page 459: ...moteur 1 Ecrou axe de roue arri re 1 2 Axe de roue arri re 1 3 Tendeur de cha ne de transmission 2 4 Roue arri re 1 Se reporter POINTS DE DEPOSE 5 Entretoise paul e 2 6 Pignon de roue arri re 1 7 Bagu...

Page 460: ...necessary 1 Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate in...

Page 461: ...Mesurer Voile de roue Hors sp cifications R parer remplacer Limite de voile de roue Radial 1 2 0 mm 0 08 in Lat ral 2 2 0 mm 0 08 in 2 Contr ler Roulement Faire tourner la cage interne avec le doigt...

Page 462: ...Wheel axle bending limit 0 5 mm 0 020 in EC594200 Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in...

Page 463: ...ri re seulement Utiliser le comparateur cadran 1 Hors sp cifications Contr ler le voile de roue Si le voile de roue est normal remplacer le disque de frein 2 Mesurer Epaisseur du disque de frein a Hor...

Page 464: ...talled first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install B...

Page 465: ...ION Ne pas frapper sur la cage interne du roulement Le contact ne peut avoir lieu qu avec la cage externe 2 Monter Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tapes et en pro...

Page 466: ...base grease on the wheel axle 6 Install Nut wheel axle 1 T R 105 Nm 10 5 m kg 75 ft lb 7 Tighten Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking t...

Page 467: ...105 Nm 10 5 m kg 75 ft lb 7 Serrer Boulon support d axe 1 N B Avant de serrer le boulon engager l axe de roue dans le support d axe en pous sant plusieurs fois sur la fourche tout en serrant le frein...

Page 468: ...f bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not strike the inner race of the bearing Contact should be made only with the...

Page 469: ...icant ATTENTION Ne pas frapper sur la cage interne du roulement Le contact ne peut avoir lieu qu avec la cage externe 2 Monter Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tap...

Page 470: ...ctly 6 Install Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 NOTE Install the left drive chain puller and insert the wheel ax...

Page 471: ...transmission 1 Axe de roue 2 N B Monter le tendeur gauche de la cha ne de transmission et ins rer l axe de roue du c t gauche Appliquer de la graisse savon de lithium sur l axe de roue 8 Monter Tende...

Page 472: ...HEEL 9 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 Drive chain slack 48 58 mm 1 9 2 3 in 10 Tighten Nut wheel axle 1 Locknut 2 T R 125 Nm 12 5 m kg 90 ft...

Page 473: ...TRANS MISSION au CHAPITRE 3 Tension de la cha ne de transmission 48 58 mm 1 9 2 3 in 10 Serrer Ecrou axe de roue 1 Contre crou 2 T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb 9 Regolare Gi...

Page 474: ...ely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Drain the brake fluid Refer to REMOVAL POINTS 1 Brake hose holder p...

Page 475: ...liquide de frein Se reporter POINTS DE DEPOSE 1 Support de durit de frein protection 2 2 Support de durit de frein etrier de frein 1 3 Boulon de raccord 2 4 Durit de frein 1 5 Bouchon de goupille de p...

Page 476: ...alling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOVAL POINTS...

Page 477: ...orter la section ROUE AVANT ET ROUE ARRIERE Vidanger le liquide de frein Se reporter POINTS DE DEPOSE 1 P dale de frein 1 2 Ma tre cylindre de frein 1 3 Support de durit de frein 2 4 Boulon de raccord...

Page 478: ...disassembly 2 Rear brake caliper disassembly Extent of removal Order Part name Q ty Remarks BRAKE CALIPER DISASSEM BLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Re...

Page 479: ...DEMONTAGE DE L ETRIER DE FREIN A B 1 Goupille de plaquette 1 1 2 Plaquette de frein 2 2 3 Support de plaquette 1 1 4 Piston d trier de frein 2 1 Se reporter POINTS DE DEPOSE 5 Joint antipoussi re 2 1...

Page 480: ...assembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Bra...

Page 481: ...RE DE FREIN 1 Couvercle de ma tre cylindre de frein 1 2 Diaphragme 1 3 Flotteur du r servoir 1 4 Soufflet de ma tre cylindre de frein 1 5 Circlip 1 Utiliser une pince circlip bec long 6 Rondelle 1 7 T...

Page 482: ...er in or pushing down on the pedal CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Brake caliper piston 1...

Page 483: ...te trace de liquide renvers Piston d trier de frein 1 D poser Piston d trier de frein Utiliser de l air comprim et pro c der prudemment AVERTISSEMENT Recouvrir le piston d un chiffon et faire tr s att...

Page 484: ...s and dust seals WARNING Replace the piston seals and dust seals whenever a caliper is disassembled Front Rear EC5A4000 INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a...

Page 485: ...Avant Arri re CONTROLE Ma tre cylindre de frein 1 Contr ler Surface interne du ma tre cylin dre de frein a Usure rayures Remplacer le ma tre cylindre complet Taches Nettoyer AVERTISSEMENT Utiliser uni...

Page 486: ...per piston 1 Wear score marks Replace brake cali per piston assembly WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Cra...

Page 487: ...ts de pis ton et antipoussi re 2 lors du d mon tage d un trier Durit de frein 1 Contr ler Durit de frein 1 Craquelures endommagement Remplacer ASSEMBLAGE ET MONTAGE AVERTISSEMENT Toutes les pi ces int...

Page 488: ...t on brake caliper correctly Front Rear 3 Install Brake caliper piston 1 NOTE Apply the brake fluid on the piston wall CAUTION Install the piston with its shallow depressed side a facing the brake cal...

Page 489: ...N B Appliquer du liquide de frein sur la paroi du piston ATTENTION Monter le piston en orientant sa face l g rement surbaiss e a vers l trier de frein Ne jamais forcer pour ins rer Avant Arri re Etrie...

Page 490: ...g 17 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb Rear brake caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the brake...

Page 491: ...2 ft lb Etrier de frein arri re 1 Monter Support de plaquette 1 Plaquette de frein 2 Goupille de plaquette 3 N B Monter les plaquettes de frein en ins rant leurs ergots a dans les gorges des triers d...

Page 492: ...e master cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder piston 3 NOTE Apply the brake fluid on th...

Page 493: ...ma tre cylindre secondaire 2 Sur le piston du ma tre cylindre de frein 3 N B Appliquer le liquide de frein sur la cou pelle du ma tre cylindre de frein AVERTISSEMENT Apr s la repose la coupelle du cy...

Page 494: ...ake master cyl inder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers Front Rear Front brake master cylinder 1 Install Brake...

Page 495: ...ium sur l extr mit de la tige de commande Monter le circlip l aide d une pince circlip Avant Arri re Ma tre cylindre de frein avant 1 Monter Ma tre cylindre de frein 1 Support de ma tre cylindre de fr...

Page 496: ...lways use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T...

Page 497: ...et touche l g rement la saillie b du ma tre cylindre de frein T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb T R 30 Nm 3 0 m kg 22 ft lb 2 Monter Ma tre cylindre de frein 1 Boulon ma tre cyl...

Page 498: ...3 WARNING Always use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake cali per T R 30 Nm 3 0 m kg 22 ft...

Page 499: ...l illustration et touche l g rement la saillie b de l trier de frein T R 30 Nm 3 0 m kg 22 ft lb 2 Monter Support de durit de frein 1 Boulon support de durit de frein 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3...

Page 500: ...o that its pipe por tion a directs as shown and lightly touches the projection b on the brake master cylinder T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union b...

Page 501: ...arri re 1 Monter Rondelle en cuivre 1 Durit de frein 2 Boulon de raccord3 AVERTISSEMENT Toujours utiliser des rondelles en cui vre neuves ATTENTION Monter la durit de frein de mani re que sa partie t...

Page 502: ...rake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and...

Page 503: ...me marque de liquide de frein le m lange de liquides de marques diff rentes risque de provoquer une r action chimique nuisible au fonc tionnement des freins Veiller ce que lors du remplis sage de l ea...

Page 504: ...r cap 1 Screw brake master cylinder cap 2 Rear Diaphragm Brake master cylinder cap 1 Bolt brake master cylinder cap 2 CAUTION After installation while pulling the brake lever in or pushing down on the...

Page 505: ...capuchon du ma tre cylindre de frein 2 ATTENTION Apr s le montage rechercher en actionnant le levier ou la p dale de frein les fuites ventuelles de liquide de frein au niveau des boulons de rac cord s...

Page 506: ...WARNING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section N...

Page 507: ...ein avant Se reporter la section FREIN AVANT ET FREIN ARRIERE Plaque d identification 1 Protection 1 2 Boulon de pincement t sup rieur 2 Desserrer uniquement 3 Amortisseur complet 1 Desserrer lors du...

Page 508: ...FRONT FORK DISASSEMBLY 1 Adjuster 1 Drain the fork oil Use special tool Refer to REMOVAL POINTS 2 Fork spring 1 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7...

Page 509: ...che 1 3 Joint antipoussi re 1 Se reporter POINTS DE DEPOSE 4 Bague d arr t 1 5 Tube plongeur 1 6 Fourreau 1 7 Bague coulissante de piston 1 8 Bague antifriction 1 9 Rondelle de bague d tanch it 1 0 Ba...

Page 510: ...con struction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disas sembled and reasse...

Page 511: ...r de corps trangers lors du changement de l huile ou du d montage et remontage de la fourche Avant de retirer les soupapes de base ou les bras de fourche veiller laisser s chapper tout l air du r serv...

Page 512: ...TION Do not remove the locknut as it may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove Dust seal 1 Stopper ring 2 Using slotte...

Page 513: ...ne plus pouvoir en tre retir Cl annulaire pour boulon capuchon YM 01501 90890 01501 Tube plongeur 1 D poser Joint antipoussi re 1 Bague d arr t 2 A l aide d un tournevis lame droite ATTENTION Veiller...

Page 514: ...nch YM 01501 90890 01501 EC554000 INSPECTION Damper assembly 1 Inspect Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace CAUTION The front fork with a built in piston rod has a very s...

Page 515: ...r complet 1 D formation endommagement Remplacer Joint torique 2 Usure endommagement Rem placer ATTENTION La construction interne d une four che tige de piston incorpor e est tr s sophistiqu e et parti...

Page 516: ...f specification Replace EC554502 Inner tube 1 Inspect Inner tube surface a Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specificati...

Page 517: ...ler Surface du tube plongeur a Marques de rayures R parer ou remplacer Utiliser du papier de verre humide n 1 000 Bague de but e en compression endommag e Remplacer D formations du tube plongeur Hors...

Page 518: ...Wash the all parts in a clean solvent 2 Stretch the damper assembly fully 3 Fill Front fork oil 1 To damper assembly CAUTION Be sure to use recommended fork oil If other oils are used they may have an...

Page 519: ...irer totalement l amortisseur com plet 3 Remplir Huile de fourche 1 Dans l amortisseur complet ATTENTION Toujours utiliser l huile de fourche recommand e L utilisation d autres huiles peut compromettr...

Page 520: ...retched check that the oil is above the step a on the damper assembly Below the step Replenish fork oil above the step 6 Tighten Locknut 1 NOTE Fully finger tighten the locknut onto the damper assembl...

Page 521: ...r fond manuellement le contre crou sur l amortisseur 7 Desserrer Dispositif de r glage de l amor tissement la compression 1 N B Desserrer la main le dispositif de r glage de l amortissement la com pre...

Page 522: ...ring wrench YM 01501 90890 01501 T R 29 Nm 2 9 m kg 21 ft lb 10 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 11 While protecting the dampe...

Page 523: ...pr s le remplissage effectuer plus de 10 pompages lents de l amortis seur 1 vers le haut et vers le bas pour distribuer l huile de fourche 11 Prot ger l amortisseur 1 l aide d un chiffon et le comprim...

Page 524: ...NOTE Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip Install the oil seal with its manufacture s marks or number fa...

Page 525: ...uille plasti que a enduite d huile de fourche pour prot ger la l vre de la bague d tan ch it Monter la bague d tanch it en veillant placer les marques d usine ou les num ros du c t du support d axe Mo...

Page 526: ...iver 3 Fork seal driver YM 01442 90890 01442 18 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 19 Install Stopper ring 1 N...

Page 527: ...foncer la bague d tanch it dans le fourreau l aide de l outil de montage de joint de fourche 2 Outil de montage de joint de fourche YM 01442 90890 01442 19 Monter Bague d arr t 1 N B Loger correctemen...

Page 528: ...resin 3 To damper assembly 4 NOTE Install the spacer with the plate a facing the fork spring 24 Install Damper assembly 1 To inner tube 2 CAUTION To install the damper assembly into the inner tube ho...

Page 529: ...et 1 Sur le tube plongeur 2 ATTENTION Incliner le tube plongeur avant d y introduire l amortisseur complet Si le tube plongeur est tenu verticalement l amortisseur risque de glisser jusqu au fond et d...

Page 530: ...mper assembly Cap bolt ring wrench YM 01501 90890 01501 27 Inspect Gap a between adjuster 1 and locknut 2 Out of specification Retighten and readjust the locknut NOTE If the adjuster is installed out...

Page 531: ...r ler Jeu a entre le dispositif de r glage 1 et le contre crou 2 Hors sp cifications Resserrer le contre crou et le r gler nou veau N B Un mauvais montage du dispositif de r glage emp che d obtenir la...

Page 532: ...cause poor handling and loss of stabil ity CAUTION Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow fore...

Page 533: ...huile de fourche recommand e L utilisation d autres huiles peut compromettre le bon fonctionnement de la fourche Ne laisser en aucun cas p n trer de corps trangers dans la fourche Huile recommand e Hu...

Page 534: ...cket Do not tighten the pinch bolts upper bracket yet 2 Tighten Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque Cap bolt ring wrench YM 01501...

Page 535: ...omplet 1 N B Utiliser la cl annulaire pour boulon capuchon 2 pour serrer l amortisseur au couple sp cifi T R 30 Nm 3 0 m kg 22 ft lb Cl annulaire pour boulon capuchon YM 01501 90890 01501 3 R gler Ext...

Page 536: ...23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb 5 Install Protector 1 Bolt protector 2 T R 10 Nm 1 0 m kg 7 2 ft lb 6 Adjust Rebound damping force NOTE Turn in the damping adjuster 1 finger tight...

Page 537: ...ion 2 T R 10 Nm 1 0 m kg 7 2 ft lb 6 R gler Force d amortissement la d tente N B Serrer la main le dispositif de r glage d amortissement 1 puis desserrer gra duellement jusqu la position de r glage d...

Page 538: ...lever holder 1 3 Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to REMOVAL POINTS 7 Throttle cable cap 1 8 Throttle cable 1...

Page 539: ...n 1 Se reporter POINTS DE DEPOSE 7 Couvercle du logement de c ble des gaz 1 8 C ble des gaz n 1 tir 1 D connecter du c t acc l rateur 9 C ble des gaz n 2 enfonc 1 D connecter du c t acc l rateur 10 Po...

Page 540: ...master cylinder cap side horizontal to prevent air from coming in EC5B3200 Grip 1 Remove Grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become...

Page 541: ...ercle du ma tre cylindre de frein l horizontale afin d viter toute p n tration d air Poign e 1 D poser Poign e 1 N B Souffler de l air entre le guidon ou le guide de tube et la poign e Retirer ensuite...

Page 542: ...are in place on both sides First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side T R 28 Nm 2 8 m kg 20 ft lb 2 Install Left grip 1 Apply...

Page 543: ...s boulons situ s l avant du support sup rieur du gui don puis serrer les boulons situ s l arri re T R 28 Nm 2 8 m kg 20 ft lb 2 Monter Poign e gauche 1 Appliquer un agent adh sif sur le guidon 2 N B A...

Page 544: ...stall the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown R L 90 3 1 b c 4 Install Collar 1 Grip cap cover 2 Throttle grip 3 NOTE Apply the lithium s...

Page 545: ...ent l angle indiqu 4 Monter Entretoise paul e 1 Cache du capuchon de la poign e 2 Poign e des gaz 3 N B Appliquer de la graisse savon de lithium sur la surface coulissante de la poign e des gaz 5 Mont...

Page 546: ...tment T R 4 Nm 0 4 m kg 2 9 ft lb 7 Install Grip cap cover 1 Cover throttle cable cap 2 8 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder bracket 3 NOTE Inst...

Page 547: ...Cache du capuchon de la poign e 1 Couvercle du logement de c ble des gaz 2 8 Monter Ma tre cylindre de frein 1 Support de ma tre cylindre de frein 2 Boulon support de ma tre cylin dre de frein 3 N B M...

Page 548: ...ver holder T R 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb 10 Install Clutch cable 1 Hot starter cable 2 NOTE Apply the lithium soap base grease on the clutch cable end and hot starter cable e...

Page 549: ...von de lithium sur les extr mit s du c ble d embrayage et du c ble de d marrage chaud 11 R gler Jeu du levier d embrayage Se reporter la section REGLAGE DE L EMBRAYAGE au CHAPI TRE 3 Jeu du levier de...

Page 550: ...l Hold the machine by placing the suitable stand under the engine Number plate Handlebar Front fender Refer to HANDLEBAR section 1 Steering stem cap 1 2 Steering stem nut 1 3 Front fork 2 Refer to FRO...

Page 551: ...IDON 1 Capuchon de la colonne de direction 1 2 Ecrou de la colonne de direction 1 3 Fourche 2 Se reporter la section FOURCHE 4 T sup rieur 1 5 Ecrou de la colonne de direction 1 Utiliser l outil sp ci...

Page 552: ...y not fall down Steering nut wrench YU 33975 90890 01403 Lower bearing 1 Remove Lower bearing 1 Use the floor chisel 2 CAUTION Take care not to damage the steering shaft thread Bearing race 1 Remove B...

Page 553: ...inf rieur 1 D poser Roulement inf rieur 1 Utiliser le burin 2 ATTENTION Veiller ne pas endommager les filets de l arbre de direction Cage de roulement 1 D poser Cage de roulement 1 D poser la cage de...

Page 554: ...the bearing races replace bear ings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Lower bearing 1 NOTE Apply the lithium soap base grease on the dust seal lip...

Page 555: ...EMBLAGE ET MONTAGE T inf rieur 1 Monter Roulement inf rieur 1 N B Appliquer de la graisse savon de lithium sur la l vre de la bague d tan ch it et la circonf rence interne du rou lement 2 Monter Cage...

Page 556: ...0 7 m kg 5 1 ft lb 5 Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 Install Washer 1 7 Install Front f...

Page 557: ...nne de direction en la tournant d une but e l autre S il y a la moindre g ne d monter la colonne de direction et contr ler les paliers de la direction 6 Monter Rondelle 1 7 Monter Fourche 1 T sup rieu...

Page 558: ...eering ring nut little by little 11 Adjust Front fork top end a Front fork top end standard a 5 mm 0 20 in 12 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 CAUTION Tighten the lower br...

Page 559: ...de bras de fourche standard a 5 mm 0 20 in 12 Serrer Boulon de pincement t sup rieur 1 Boulon de pincement t inf rieur 2 ATTENTION Serrer le t inf rieur au couple sp ci fi Un serrage excessif peut co...

Page 560: ...falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Shift the brake pedal backward Rear b...

Page 561: ...AVANT ET FREIN ARRIERE Glisser la p dale de frein vers l arri re Etrier de frein arri re Boulon p dale de frein Cha ne de transmission 1 Support de cha ne de transmission 1 2 Tendeur de cha ne inf rie...

Page 562: ...removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 Refer to REMOVAL POINTS 2 Relay arm 1 3 Connecting rod 1 4 Colla...

Page 563: ...Qt Remarques DEMONTAGE DU BRAS OSCILLANT 1 Capuchon 2 Se reporter POINTS DE DEPOSE 2 Bras relais 1 3 Bielle 1 4 Entretoise paul e 2 5 Bague d tanch it 2 6 Roulement de but e 2 7 Bague 2 8 Bague d tan...

Page 564: ...ing by pressing its outer race INSPECTION Wash the bearings bushings collars and cov ers in a solvent Swingarm 1 Inspect Bearing 1 Bushing 2 Free play exists unsmooth revolution rust Replace bearing a...

Page 565: ...ans du solvant Bras oscillant 1 Contr ler Roulement 1 Bague 2 Jeu rotation irr guli re rouille Remplacer ensemble le roulement et la bague 2 Contr ler Bague d tanch it 3 Endommagement Remplacer Bras r...

Page 566: ...the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bear ings to a specified depth from inside Installed depth of bearings Oute...

Page 567: ...ent int rieur la profon deur sp cifi e partir de l int rieur Profondeur d installation des roulements Ext rieur a Z ro mm z ro in Int rieur b 8 5 mm 0 33 in 2 Monter Roulement 1 Rondelle 2 Bague d tan...

Page 568: ...ure s marks or numbers Installed depth of bearings a 5 mm 0 20 in Swingarm 1 Install Bushing 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5 NOTE Apply the molybdenum disulfide grease on the bush...

Page 569: ...le bras oscillant 5 N B Appliquer de la graisse au bisulfure de molybd ne sur les bagues les roule ments de but e les l vres des bagues d tanch it et les surfaces de contact de l entretoise paul e et...

Page 570: ...elay arm 2 Washer 3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the molybdenum disulfide...

Page 571: ...isulfure de molybd ne sur le boulon Ne pas encore serrer l crou 6 Monter Bras oscillant 1 Boulon pivot 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon pivot Ins rer le boulon piv...

Page 572: ...et 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 53 Nm 5 3 m kg 38 ft lb 10 Tighten Nut connecting rod 1...

Page 573: ...re bras relais 1 Ecrou amortisseur arri re bras relais 2 N B Appliquer de la graisse au bisulfure de molybd ne sur le boulon T R 53 Nm 5 3 m kg 38 ft lb 10 Serrer Ecrou bielle 1 T R 80 Nm 8 0 m kg 58...

Page 574: ...oner 4 Nut lower chain tensioner 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support 50 mm 1 97 in 3 Nut drive chain support 4 Bolt driv...

Page 575: ...de cha ne de transmis sion 1 Couvercle du support de cha ne de transmission 2 Boulon support de cha ne de transmis sion 50 mm 1 97 in 3 Ecrou support de cha ne de trans mission 4 Boulon couvercle du...

Page 576: ...eparation for removal Hold the machine by placing the suitable stand under the engine Seat and fitting band Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST P...

Page 577: ...x Se reporter la section TUBE D ECHAPPEMENT ET SILENCIEUX au CHAPITRE 4 1 Collier pince conduit d admission d air 1 Desserrer uniquement 2 Cadre arri re 1 3 Boulon amortisseur arri re bras relais 1 Ma...

Page 578: ...5 62 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 9 Upper spring guide 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to REMOVAL POINTS 2...

Page 579: ...Nom de la pi ce Qt Remarques 9 Guide de ressort sup rieur 1 10 Ressort amortisseur arri re 1 11 Roulement 2 Se reporter POINTS DE DEPOSE 2 Estensione della rimozione Ordine Denominazione Quantit Osse...

Page 580: ...amage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of t...

Page 581: ...rtissement ou entra nera un mauvais fonctionne ment 4 Veiller ne pas rayer la surface de contact de la tige de piston avec le cylindre afin d viter tout risque de fuite d huile 5 Ne jamais essayer d e...

Page 582: ...E Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear...

Page 583: ...ormation endommagement Remplacer l amortisseur arri re complet Amortisseur 2 Fuite d huile Remplacer l amortisseur arri re complet Fuite de gaz Remplacer l amortisseur arri re complet Ressort 3 Endomm...

Page 584: ...it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contact...

Page 585: ...r 1 N B Apr s avoir install la bague d arr t repousser le roulement jusqu ce qu il touche la bague d arr t 3 Monter Roulement inf rieur 1 N B Monter le roulement en pressant sur le c t o sont imprim s...

Page 586: ...tempt to turn the adjuster beyond the maximum or minimum setting 4 Tighten Locknut 1 Rear shock absorber 1 Install Dust seal 1 O ring 2 Collar 3 NOTE Apply the molybdenum disulfide grease on the beari...

Page 587: ...n 248 5 mm 9 78 in 240 5 258 5 mm 9 47 10 18 in 4 Serrer Contre crou 1 Amortisseur arri re 1 Monter Joint antipoussi re 1 Joint torique 2 Entretoise paul e 3 N B Appliquer de la graisse au bisulfure d...

Page 588: ...t rear shock absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2...

Page 589: ...molybd ne sur le boulon T R 56 Nm 5 6 m kg 40 ft lb 5 Monter Boulon amortisseur arri re bras relais 1 Ecrou amortisseur arri re bras relais 2 N B Appliquer de la graisse au bisulfure de molybd ne sur...

Page 590: ...rk plug 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue EC612000 WIRING DIAGRAM 7 1 5 6 2 3 4 B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P P B...

Page 591: ...allumage 6 Bougie 7 Bo tier CDI CODES DE COULEUR B Noir Br Brun G Vert L Bleu O Orange P Rose R Rouge Sb Bleu ciel W Blanc Y Jaune B L Noir bleu B W Noir blanc B Y Noir jaune G B Vert noir L W Bleu b...

Page 592: ...CDI unit as a throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the throttle p...

Page 593: ...nt galement en compte l ouverture du papillon commande tridimensionnelle Repr sentation en 3D de l avance l allumage diff rente des caract ristiques actuelles Composant Fonction Capteur de position de...

Page 594: ...Ein pr ziseres dreidi mensionales Z ndsystem bezieht also die Drosselklappen Position mit ein Dreidimensionales Z ndzeitpunkt Kennfeld gilt nicht zur Bezugnahme Bauteil Funktion Drosselklappensensor E...

Page 595: ...ratezza l anticipo minimo tenendo in considerazione anche l apertura dell acceleratore controllo tridimensionale Mappa dell immagine tridimensionale dell anticipo minimo diverso dalle reali caratteris...

Page 596: ...ollowing special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark plug Check entire ignitio...

Page 597: ...age 90890 06754 Multim tre YU 3112 C 90890 03112 Test de la longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions de l ensemble du syst me d allumage fiches rapides fils et bobi...

Page 598: ...trol lieren Z ndkerze reinigen ggf erneuern Kabelanschl sse des gesamten Z ndsystems kontrollieren Steckverbinder Kabel Z ndspule Instand setzen ggf erneuern Motorstoppschalter kontrol lieren Erneuern...

Page 599: ...06754 Tester tascabile YU 3112 C 90890 03112 Test lunghezza della scintilla Pulire o sostituire la candela di accensione Controllare tutti i collegamenti dell impianto di accensione accoppiatori cavi...

Page 600: ...Minimum spark gap 6 0 mm 0 24 in COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spar...

Page 601: ...ALLUMAGE 1 Contr ler Connexion des fiches rapides et des fils Rouille poussi re jeu court cir cuit R parer ou remplacer Bobine d allumage et bougie en place Appuyer sur la bobine d allu mage jusqu ce...

Page 602: ...ication Replace 3 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of speci...

Page 603: ...placer CONTROLE DU VOLANT MAGNETIQUE CDI 1 Contr ler R sistance de la bobine d excita tion Hors sp cifications Rempla cer Fil du multim tre fil orange 1 Fil du multim tre borne de bougie 2 R sistance...

Page 604: ...ad Black lead 2 Charging coil 2 resistance Tester selector position 44 66 at 20 C 68 F 10 W R Br G P B 2 1 2 1 2 1 W R Br G P B 2 1 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No contin...

Page 605: ...C 68 F 10 CONTROLE DU CONTACTEUR DE POINT MORT 1 Contr ler Continuit du contacteur de point mort Pas de continuit au point mort Rem placer Continuit en vitesse Remplacer CONTROLE DU BOITIER CDI V rifi...

Page 606: ...IGNITION SYSTEM section NOTE Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Check entire ignition system for connection Repair or replace Check throttle positio...

Page 607: ...le Multim tre YU 3112 C 90890 03112 Contr ler les connexions de l ensemble du syst me d allu mage R parer ou remplacer Capteur de position de papillon des gaz Bobineducapteur de position de papillon d...

Page 608: ...ultimeter YU 3112 C 90890 03112 Kabelanschl sse des gesamten Z ndsystems kontrollieren Instand setzen ggf erneuern Drosselklappensensor kontrollieren Drosselklap pensensor Spule Erneuern Lichtmaschine...

Page 609: ...attrezzi seguenti Tester tascabile YU 3112 C 90890 03112 Controllare tutti i collegamenti dell impianto di accensione Riparare o sostituire Controllare il sensore posi zione farfalla Bobina sensore po...

Page 610: ...TION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace THROTTLE POSITION SENSOR COIL INSPECTION 1 Inspect Throttle position sensor coil resistance Out of specif...

Page 611: ...1 Contr ler R sistance de la bobine du cap teur de position de papillon des gaz Hors sp cifications Rempla cer Fil du multim tre fil bleu 1 Fil du multim tre fil noir 2 R sistancedelabobine du capteur...

Page 612: ...or position Full closed Full opened k 1 Zero 3 k at 20 C 68 F 4 6 k at 20 C 68 F THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1 Remove Throttle position sensor coupler Screw throttle position s...

Page 613: ...posi tion de papillon des gaz Vis capteur de position de papillon des gaz 1 Capteur de position de papillon des gaz 2 N B Desserrer les vis capteur de position de papillon des gaz l aide de la m che T...

Page 614: ...erproof function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 7 Start the engine Tester lead Yellow lead 3...

Page 615: ...moteur en marche Fil du multim tre fil jaune 3 Fil du multim tre fil noir 4 8 R gler Tension de sortie du capteur de position de papillon des gaz Etapes du r glage R gler l angle de montage du capteur...

Page 616: ...SENSOR INPUT VOLTAGE INSPECTION 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Inspect Throttle position sensor input voltage Out of specification Replace the CDI unit Tester...

Page 617: ...s gaz 2 Mettre le moteur en marche 3 Contr ler Tension d entr e du capteur de position de papillon des gaz Hors sp cifications Remplacer le bo tier CDI Fil du multim tre fil bleu 1 Fil du multim tre f...

Page 618: ...best possi ble carburetor setting NOTE It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to make fut...

Page 619: ...ques conditions de la piste de la surface temps interm diaire pour faciliter les r glages ult rieurs du carburateur AVERTISSEMENT Le carburateur fait partie du circuit d alimentation Par cons quent ve...

Page 620: ...ed starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carb...

Page 621: ...tion d oxyg ne dans l air d ter mine la richesse ou la pauvret du m lange air carburant Il convient d s lors de se conformer au tableau ci des sus pour la composition du m lange Tenir compte des trois...

Page 622: ...2 3 4 Main system The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing machines since it supplies an even flow of fuel even at full load Use the main jet and the j...

Page 623: ...ipal primaire Ce type de gicleur principal est parfait pour les motos de course car il garantit un d bit de carburant r gulier m me pleine charge Utiliser le gicleur principal et l aiguille pour r gle...

Page 624: ...t The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eratio...

Page 625: ...ange air carburant est trop riche ou trop pauvre la puissance du moteur diminue et les acc l rations sont moins efficaces Gicleur principal stan dard N 182 Effets de la modification du gicleur princip...

Page 626: ...fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this...

Page 627: ...en usine Avant de r gler la vis de ralenti la serrer fond en comptant le nombre de tours Enregistrer ce nombre comme tant le nombre de tours de desserrage r gl en usine Effets du r glage de la vis de...

Page 628: ...the engine will not pick up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes...

Page 629: ...hage de l aiguille et d abaisser cette derni re 2 M lange trop pauvre aux r gimes interm diaires Le moteur crachote et acc l re trop lentement Il faut enrichir le m lange en abais sant d un cran le cl...

Page 630: ...ailable with different straight portion diameters Example OBELR 4 Clip position Diameter a of straight portion Standard jet needle OBELR OBEKS Effects of changing the jet needle refer ence Diameter of...

Page 631: ...m tre a de la par tie droite Aiguille standard OBELR OBEKS Effets du remplacement de l aiguille r f rence Diam tre de la partie droite La modification du diam tre de la partie droite permet de r gler...

Page 632: ...le 90 80 2 Rough engine operation is felt in quick throttle opening Select a leak jet having higher calibrating No than standard to lean out the mixture Example 90 100 Except for USA Standard leak jet...

Page 633: ...95 Relation avec l ouverture du papillon Le d bit du carburant dans le syst me de carburateur principal est contr l par le gicleur principal puis une nouvelle r gu lation s effectue dans la zone entr...

Page 634: ...Rich STD Lean OBELN OBELP OBELQ OBELR OBELS OBELT OBELU 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1 5NL 14916 ER 5NL 14916 ES 5NL 14916 ET 5NL 14916 EU Jet needle Rich STD Lean OBEKP OBEKQ OBEKR OBEKS OBE...

Page 635: ...OBELS OBELT OBELU 5NL 14916 EN 5NL 14916 EP 5NL 14916 E1 5NL 14916 ER 5NL 14916 ES 5NL 14916 ET 5NL 14916 EU AiguilleRiche STD Pauvre OBEKP OBEKQ OBEKR OBEKS OBEKT OBEKU OBEKV 5JG 14916 EP 5JG 14916 E...

Page 636: ...p Check that the accelerator pump oper ates smoothly except for rich mixture symptom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet nee...

Page 637: ...ne correctement sauf si le sympt me indique un m lange riche M lange riche Remonter la position du clip d aiguille 1 cran plus haut Ouverture 1 4 3 4 Crachotements Vitesse r duite Abaisser la position...

Page 638: ...i funktioniert Aus nahme fettes Gemisch Fettes Gemisch D sennadel Clipposition anheben 1 Nut nach oben Bei 1 4 3 4 ge ffneter Drosselklappe Schweres Saugen Drehzahl niedrig D sennadel Clipposition sen...

Page 639: ...etto su di 1 scanalatura Manopola dell acceleratore ruotata di 1 4 3 4 di giro Problemi di sfiato Perdita di velocit Posizione bassa del fermo spillo del getto gi di 1 scanalatura Manopola dell accele...

Page 640: ...he course that has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determine the secondary reduction r...

Page 641: ...diff ren tes parties du circuit afin de calculer la moyenne et d terminer le taux de r duction secondaire Si le parcours comprend de longues lignes droites r gler la machine de mani re qu elle fournis...

Page 642: ...ressure Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact...

Page 643: ...ain boueux sablonneux ou glis sant r duire la pression des pneus pour une meilleure adh rence Sur route pav e ou sur surface dure augmenter la pression des pneus afin d viter les crevaisons Pression d...

Page 644: ...characteristic near the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes th...

Page 645: ...ment comprim e ou le pilote ressent une certaine pression dans les mains ou le corps De m me un niveau d huile trop lev produira rapide ment un bouchon d huile entra nant une r duction de la course d...

Page 646: ...justment washers Standard washer quantity Zero adjustment washers Extent of adjustment Zero 2 adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily af...

Page 647: ...e ment La suspension arri re pouvant influencer le r glage de la fourche il convient donc d quilibrer l arri re et l avant de la machine la position etc avant d effec tuer le r glage de la fourche 1 R...

Page 648: ...ecome weaker resulting in lack of a sense of contact with the road surface or in a vibrating handlebar To set a stiff spring Change the rebound damping Turn in one or two clicks Change the compression...

Page 649: ...surface de la route ou des vibrations du gui don R glage d un ressort dur R gler l amortissement la d tente Visser d un ou deux d clics R gler l amortissement la com pression D visser d un ou deux d...

Page 650: ...III IIII STD 0 438 1P8 23141 L0 STIFF 0 449 0 459 0 469 0 479 1C3 23141 50 1C3 23141 60 1C3 23141 70 1C3 23141 80 I I I II I III I IIII EC72B000 Rear suspension setting The rear suspension setting sh...

Page 651: ...23141 80 I I I II I III I IIII R glage de la suspension arri re Effectuer le r glage de la suspension arri re en fonction de l exp rience du pilote lors de la conduite ainsi que des conditions du ter...

Page 652: ...ing bolt 3 Loosen the locknut 1 and make adjust ment by turning the spring adjuster 2 to achieve the standard figure from the sub traction of the length b from the length a NOTE If the machine is new...

Page 653: ...dre la valeur standard obte nue en soustrayant la longueur b de la longueur a N B Si la moto est neuve et apr s qu elle a t rod e la longueur du ressort peut changer en raison de la fatigue initiale e...

Page 654: ...r its greater spring load Run with the rebound damp ing adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed more or l...

Page 655: ...glage en fonction des pr f rences person nelles Un r glage de l amortissement la d tente entra ne un changement de l amortissement la compression Pour corriger d visser le dispositif de r glage de l a...

Page 656: ...Brown 1 Green 1 Red 1 260 260 260 STD 4 9 5UN 22212 30 Black 1 260 STIFF 5 1 5 3 5 5 5 7 5UN 22212 40 5UN 22212 50 5UN 22212 60 5UN 22212 70 Blue 1 Yellow 1 Pink 1 White 1 260 260 260 260 TYPE SPRING...

Page 657: ...5 3 5 5 5 7 5UN 22212 40 5UN 22212 50 5UN 22212 60 5UN 22212 70 Bleu 1 Jaune 1 Rose 1 Blanc 1 260 260 260 260 TYPE RAI DEUR DE RES SORT approx RESSORT REFERENCE REPERE COU LEUR POINT LON GUEUR LIBRE...

Page 658: ...over entire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to increase damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Repl...

Page 659: ...dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 cl...

Page 660: ...des aiguilles d une montre de 2 d clics pour augmenter l amortisse ment Quantit d huile Augmenter la quantit d huile d environ 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Ressort Monter un ressort dur Dur...

Page 661: ...d clics pour r duire l amor tissement Ressort Monter un ressort mou Mauvaise tenue de route Amortissement la d tente Tourner le dispositif de r glage dans le sens inverse des aiguilles d une montre de...

Page 662: ...ngs kraft Den Einsteller ca 2 Raststellungen im Uhrzeiger sinn drehen um die D mpfungskraft zu erh hen lmenge Die lmenge in 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Schritten erh hen Feder H rtere Feder...

Page 663: ...en im Gegenuhr zeigersinn drehen um die D mpfungskraft zu verrin gern Feder Weichere Feder einbauen Schlechte Bodenhaf tung Zugstufen D mpfungs kraft Den Einsteller ca 2 Raststellungen im Gegenuhr zei...

Page 664: ...l dispositivo di regolazione in senso orario circa 2 scatti per aumentare lo smorzamento Quantit di olio Aumentare la quantit dell olio di circa 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Molla Sostituire...

Page 665: ...circa 2 scatti per diminuire lo smorzamento Molla Sostituire con una molla morbida Scarsa tenuta di strada Smorzamento in estensione Ruotare il dispositivo di regolazione in senso antiorario circa 2 s...

Page 666: ......

Page 667: ......

Page 668: ...PRINTED IN JAPAN 2004 07 2 6 1 CR E F G H PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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