Yamaha YZ250(R)/LC Owner's Service Manual

Yz series

page of 587

/ 587
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

OWNER'S SERVICE MANUAL

MANUEL D'ATELIER DU

PROPRIETAIRE

FAHRER-UND

WARTUNGS-HANDBUCH

MANUALE DI SEVIZIO DEL

PROPRIETARIO

YZ250 ( R ) /LC

5UP-28199-30

Table of Contents

Summary of Contents for Yamaha YZ250(R)/LC

Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER-UND WARTUNGS-HANDBUCH MANUALE DI SEVIZIO DEL PROPRIETARIO YZ250 ( R ) /LC 5UP-28199-30...
Page 2 EC010010 YZ250(R)/LC OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Co., Ltd. 1st Edition, May 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
Page 3 FAHRER-UND MANUALE DI SERVIZIO DEL DU PROPRIETAIRE WARTUNGSHANDBUCH PROPRIETARIO ©2002 Yamaha Motor Co.,Ltd. ©2002 der Yamaha Motor Co., Ltd. ©2002 by Yamaha Motor Co., Ltd. 1ère Edition, Mai 2002 1. Ausgabe, Mai 2002 1a Edizione, Mei 2002 Tous droits réservés.
Page 4 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 5 Wir möchten Ihnen zum Kauf einer Complimenti per avere acquistato una Yamaha séries YZ. Ce modèle est Yamaha YZ Serie, herzlich gratulie- Yamaha serie YZ. Questo modello è il l’aboutissement de la vaste expérience ren. Dieses Modell entspricht fort- culmine della vasta esperienza della...
Page 6: Important Notice
EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.
Page 7: Wichtige Hinweise
IC040001 NOTICE IMPORTANTE WICHTIGE HINWEISE NOTA IMPORTANTE CETTE MACHINE EST STRICTE- DIESE MASCHINE IST NUR FÜR QUESTO VEICOLO È PROGETTA- MENT DESTINEE A LA COMPETI- RENNEN AUF GESCHLOSSENEN TO PER ESSERE USATO RIGORO- TION, UNIQUEMENT SUR CIRCUIT KURSEN KONSTRUIERT. ES VER- SAMENTE IN GARA, SOLTANTO FERME.
Page 8 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refuel- ing. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, con-...
Page 9 5. L’ESSENCE EST HAUTE- 5. LA BENZINA È ALTAMEN- 5. BENZIN IST BRENNBAR. MENT INFLAMMABLE. TE INFIAMMABILE. Immer den Motor abstellen, Toujours arrêter le moteur en Spegnere sempre il motore bevor aufgetankt wird. Dar- faisant le plein. Faire attention durante il rifornimento di car- auf achten, daß...
Page 10 Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS:...
Page 11 SECONDO LA F.I.M.: Maschine auftauchen sollten, wen- Poids des machines sans carbu- Pesi dei veicoli senza carburante den Sie sich bitte an Ihren Yamaha rant I pesi minimi per i veicoli per moto- Fachhändler. Les poids minimum admis pour les cross sono: GEWICHT DER F.I.M.
Page 12: Description
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT IN FORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
Page 13: Chapitre
IC080000 COMMENT VERWENDUNG COME USARE IL UTILISER CE DIESER ANLEITUNG PRESENTE MANUEL MANUALE IC081000 INFORMATIONS WICHTIGE INFORMATION INFORMAZIONI PARTICULIEREMENT PARTICOLARMENTE Sicherheitssymbol bedeutet IMPORTANTES IMPORTANTI „AUFPASSEN“! VORSICHT GEBOTEN Le symbole d’alerte de sécurité signifie Il Simbolo di Allerta in materia di Sicu- IHRER EIGENEN SICHERHEIT.
Page 14 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9 Bearings...
Page 15 IC083000 FORMAT DU MANUEL FORMAT DER ANLEITUNG FORMATO DEL Dans ce manuel, toutes les procédures Allen dieser Anleitung enthaltenen MANUALE sont décrites pas à pas. Les informa- Vorgänge sind sequentiell in der Tutte le procedure contenute nel pre- tions ont été condensées pour fournir au durchzuführenden Reihenfolge aufge- sente manuale sono organizzate in for- mécanicien un guide pratique et facile à...
Page 16 EC085002 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC INFO Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. General information INSP Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning CHAS ELEC Illustrated symbols 8 to r are used to identify the specifications appearing in the text.
Page 17 IC085002 SYMBOLES GRAPHIQUES ABGEBILDETEN SYMBOLE SIMBOLI ILLUSTRATI (Voir l’illustration) (Siehe Abbildung) (Fare riferimento all’illustra- Les symboles graphiques 1 à 7 ser- Die abgebildeten Symbole 1 bis 7 zione) vent à repérer les différents chapitres et sind zur einfachen Auffindung der Sei- I simboli illustrati da 1 a 7 sono pro- à...
Page 18 EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
Page 19 INDEX IC090010 INDEX INDICE ANALITICO ALLGEMEIN RENSEIGNEMENTS INFORMAZIONI ANGABEN GENERAUX GENERALI INFO TECHINSCHE CARACTERISTIQUES SPECIFICHE DATEN SPEC REGELMÄSSIGE VERIFICATION ET ISPEZIONE E PRÜFUNG REGLAGES REGOLAZIONI INSP COURANTS REGOLARI EINSTELLUNGEN MOTOR MOTEUR MOTORE FAHRGESTELL PARTIE CYCLE TELAIO CHAS ELEKTRISCHE PARTIE PARTE ELETTRICA EINRICHTUNGEN ELECTRIQUE ELEC...
Page 20: Table Of Contents
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ..........1-1 MACHINE IDENTIFICATION ......1-2 IMPORTANT INFORMATION .....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS........1-7 CONTROL FUNCTIONS......1-9 FUEL AND ENGINE MIXING OIL.....1-12 STARTING AND BREAK-IN .....1-13 TORQUE-CHECK POINTS.......1-16 CLEANING AND STORAGE ....1-17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....2-1 MAINTENANCE SPECIFICATIONS ...2-3 GENERAL TORQUE SPECIFICATIONS..2-12...
Page 21: Table Of Contents
IC0A0000 TABLES DES INHALTSVERZEICHNIS INDICE MATIERES CAPITOLO 1 CHAPITRE 1 KAPITEL 1 INFORMAZIONI RENSEIGNEMENTS ALLGEMEIN GENERALI GENERAUX ANGABEN DESCRIPTION ...........1-1 BESCHREIBUNG ........1-1 DESCRIZIONE ...........1-1 IDENTIFICATION DE LA MACHINE ...1-2 MASCHINEN-IDENTIFIKATION....1-2 IDENTIFICAZIONE DEL VEICOLO ..1-2 INFORMATIONS IMPORTANTES ..1-3 WICHTIGE INFORMATIONEN ....1-3 INFORMAZIONI IMPORTANTI.....1-3 VERIFICATION DES CONNEXIONS ..1-6 ANSCHLÜSSE PRÜFEN ......1-6...
Page 22: Table Of Contents
CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .............4-1 EXHAUST PIPE AND SILENCER ....4-3 RADIATOR..........4-4 CARBURETOR AND REED VALVE...4-7 CYLINDER HEAD , CYLINDER AND PISTON .............4-18 CLUTCH AND PRIMARY DRIVEN GEAR ............4-33 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR......4-40 YPVS GOVERNOR ........4-49 WATER PUMP ..........4-52 CDI MAGNETO .........4-56...
Page 23 CHAPITRE 4 KAPITEL 4 CAPITOLO 4 MOTEUR MOTOR MOTORE SELLE, RESERVOIR A ESSENCE SITZ, KRAFTSTOFFTANK UND SELLA, SERBATOIO DEL ET COUVERCLES LATERAUX....4-1 CARBURANTE E COPERTURE SEITENDECKEL.........4-1 LATERALI ..........4-1 TUYAU D’ECHAPPEMENT ET AUSPUFFROHR UND SILENCIEUX ..........4-3 SCHALLDÄMPFER ........4-3 TUBO DI SCARICO E SILENZIATORE.........4-3 RADIATEUR ..........4-4 KÜHLER............4-4...
Page 24: Table Of Contents
CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........6-1 IGNITION SYSTEM........6-2 SOLENOID VALVE SYSTEM .....6-7 TPS (THROTTLE POSITION SENSOR) SYSTEM............6-9 CHAPTER 7 TUNING ENGINE............7-1 CHASSIS...........7-13...
Page 25: Table Of Contents
CHAPITRE 6 KAPITEL 6 CAPITOLO 6 PARTIE ELEKTRISCHE PARTE ELETTRICA ELECTRIQUE EINRICHTUNGEN COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE UND COMPONENTI ELETTRICI E SCHEMA ET SCHEMA DE CABLAGE ....6-1 ELETTRICO ..........6-1 SCHALTPLAN ..........6-1 SYSTEME D’ALLUMAGE .......6-2 ZÜNDANLAGE ...........6-2 SISTEMA DI ACCENSIONE ....6-2 SYSTEME D’ELECTROVANNE .....6-7 SISTEMA ELETTROVALVOLA .....6-7 MAGNETVENTILSYSTEM ......6-7 SYSTEME TPS (CAPTEUR DE...
Page 26: Engine
DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 NOTE: DESCRIPTION 1 Clutch lever 9 The machine you have purchased may differ 2 “ENGINE STOP” button slightly from those shown in the following. 3 Front brake lever 9 Designs and specifications are subject to 4 Throttle grip change without notice.
Page 27: Informazioni Generali
DESCRIPTION BESCHREIBUNG DESCRIZIONE INFO IC100000 RENSEIGNEMENTS ALLGEMEIN INFORMAZIONI GENERAUX ANGABEN GENERALI IC110000 DESCRIPTION BESCHREIBUNG DESCRIZIONE 1 Levier d’embrayage 1 Kupplungshebel 1 Leva di comando della frizione 2 Bouton de coupe-circuit de sécurité 2 Motorstoppknopf „ENGINE STOP“ 2 Pulsante “ARRESTO MOTORE” “ENGINE STOP”...
Page 28: Machine Identification
There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive iden- tification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
Page 29: Identification De La Machine
Seriennummer ange- cessionario Yamaha per un’identi- Yamaha qui pourra identifier clai- geben werden, damit Ihr Yamaha ficazione certa del modello posse- rement le modèle correspondant à Fachhändler das Modell richtig duto.
Page 30: Important Information
IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DIS ASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pres- sured water, cover the parts as follows. 9 Silencer exhaust port 9 Side cover air intake port 9 Water pump housing hole at the bottom...
Page 31: Informations Importantes
INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC130000 INFORMATIONS INFORMAZIONI WICHTIGE IMPORTANTES INFORMATIONEN IMPORTANTI IC131010 PREPARATION POUR LA DEPO- VORBEREITUNG FÜR DEN PREPARAZIONE PER LA RIMO- SE ET DEMONTAGE AUSBAU UND DER DEMONTAGE ZIONE E LO SMONTAGGIO 1. Eliminer soigneusement crasse, 1.
Page 32 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended Yamaha assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
Page 33 Yamaha per tutti i ricambi. Bauteile zu verwenden. Für Ein- les remplacements. Utiliser les Usare olio e/o grasso raccomandati bau und Einstellungen nur das huiles/graisses recommandées par dalla Yamaha per il montaggio e la Yamaha empfohlene Öl Yamaha lors des remontages et regolazione.
Page 34 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should 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- tioned opposite to the thrust 3 it receives. See the sectional view.
Page 35 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO IC136000 CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI ARRESTO 1. Avant remontage, tous les circlips 1. Alle Sicherungsringe vor dem Wie- 1. Si dovrebbero ispezionare attenta- doivent être soigneusement véri- dereinbau gründlich prüfen. Die mente tutti gli anelli elastici di fiés.
Page 36: Checking Of Connection
CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: 9 Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.
Page 37: Controllo Dei Collegamenti
VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO IC1C0001 VERIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI Bei Flecken, Rost, Feuchtigkeit u.ä. CONNEXIONS COLLEGAMENTI auf einem Steckverbinder: Traitement des taches, de la rouille, de Come trattare macchie, ruggine, umi- 1. Lösen: l’humidité, etc.
Page 38: Special Tools
SPECIAL TOOLS INFO EC140002 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and part number used for the special tool differ by country, so two types are provid- ed.
Page 39 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the igni- tion system components. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.
Page 40: Outils Speciaux
OUTILS SPECIAUX INFO OUTILS SPECIAUX Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci. La forme et le numéro de pièce des outils spéciaux diffèrent selon les pays.
Page 41 Outil d’insertion de joint de fourche YM-01442 90890-01442 Cet outil est utilisé pour monter les bagues d’étanchéité de fourche. YU-3112-C, 90890-03112 Testeur de poche Yamaha YU-3112-C 90890-03112 Utiliser cet outil pour examiner la résistance de bobine, la tension de sortie et l’intensité. YU-8036-B...
Page 42 SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden werden, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
Page 43 YM-34487 Dynamischen Zündfunkenprüfer YM-34487 90890-06754 90890-06754 Zündungs-Prüfgerät Dieses Prüfgerät wird für die Kontrolle der Bauteile der Zündanlage benötigt. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA bond Nr. 1215 Dieses Dichmittel wird für die Paßflächen der Kurbel- gehäusehälften usw. verwendet.
Page 44: Utensili Speciali
UTENSILI SPECIALI INFO IC140002 UTENSILI SPECIALI Per una messa a punto e un montaggio completi e accurati sono necessari gli utensili speciali adeguati. L’uso dell'utensile speciale corretto contribuirà a evitare danni provocati dall’uso di utensili impropri o di tecniche improvvisate. La forma e il numero categorico usati per l’utensile speciale sono diversi a seconda del paese, quindi vengono forniti due tipi.
Page 45 90890-06754 Controllore dell'accensione Questo strumento è necessario per controllare i compo- nenti del sistema di accensione. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 Questo sigillante (agglomerante) viene usato per la superficie di accoppiamento del carter, ecc..
Page 46: Control Functions
CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS EC151000 “ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handle- bar;...
Page 47: Fonctions Des Commandes
FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC150000 FONCTIONS DES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI COMMANDES IC151000 BOUTON D’ARRET DE MOTEUR MOTORSTOPPKNOPF „ENGINE PULSANTE “ARRESTO “ENGINE STOP” STOP“ MOTORE” Il pulsante “ARRESTO MOTORE” 1 Ce bouton d’arrêt de moteur “ENGINE Dieser Motorstoppknopf „ENGINE...
Page 48 CONTROL FUNCTIONS INFO EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine.
Page 49: Funzioni Dei Comandi
FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC156000 LEVIER DE FREIN AVANT LEVA DI COMANDO DEL FRENO HANDBREMSHEBEL Le levier de frein avant 1 se trouve sur Der Handbremshebel 1 (Vorderrad- ANTERIORE le guidon droit. Le tirer vers le guidon La leva di comando del freno anteriore bremse) befindet sich am rechten 1 è...
Page 50 CONTROL FUNCTIONS INFO EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. 9 Never apply additional force to the side- stand. 9 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.
Page 51 FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE FUNZIONI DEI COMANDI INFO IC15R001 BEQUILLE LATERALE ABNEHMBARER SEITENSTÄNDER CAVALLETTO STACCABILE Der Seitenständer 1 wird nur für das AMOVIBLE Questo cavalletto 1 viene usato per La béquille latérale 1 est utilisée pour Abstützen der Maschine während des supportare soltanto il veicolo quando è...
Page 52: Fuel And Engine Mixing Oil
FUEL AND ENGINE MIXING OIL INFO EC160051 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old.
Page 53 ESSENCE ET HUILE DE MELANGE DU MOTEUR KRAFTSTOFF UND MOTORGEMISCHÖL CARBURANTE E OLIO PER MISCELA PER MOTORI INFO IC160051 ESSENCE ET HUILE DE KRAFTSTOFF UND CARBURANTE E OLIO MELANGE DU MOTEUR MOTORGEMISCHÖL PER MISCELA PER MOTORI Mélanger le carburant à l’huile dans les Öl im nachfolgend angegebenen Ver- Miscelare l’olio con la benzina nel rap- proportions indiquées ci-dessous.
Page 54: Starting And Break-In
STARTING AND BREAK-IN INFO EC190000 STARTING AND BREAK-IN Before starting the machine, perform the checks in the pre-operation check list. Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time.
Page 55: Mise En Marche Et Rodage
MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO IC190000 MISE EN MARCHE ET STARTEN UND EINFAH- AVVIAMENTO E RODAGE RODAGGIO Avant la mise en marche, effectuez Prima di avviare il veicolo, eseguire i les vérifications indiquées dans la controlli della lista di controllo prima Vor dem Anfahren der Maschine, liste de contrôle avant utilisation.
Page 56 STARTING AND BREAK-IN INFO EC194001 BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP”...
Page 57: Starten Und Einfahren
MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO IC194001 PROCEDURE DE RODAGE EINFAHRVORGÄNGE PROCEDURE DI RODAGGIO 1. Avant de lancer le moteur, rem- 1. Vor dem Starten des Motors, den 1. Prima di avviare il motore, riempi- Kraftstofftank für das Einfahren mit plissez le réservoir d’un mélange re il serbatorio del carburante con...
Page 58 STARTING AND BREAK-IN INFO 9 After the break-in or before each race, you must check the entire machine for loose fit- tings and fasteners as per “TORQUE- CHECK POINTS”. Tighten all such fasteners as required. 9 When any of the following parts have been replaced, they must be broken in.
Page 59 MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN AVVIAMENTO E RODAGGIO INFO 9 Après le rodage ou avant chaque 9 Dopo il rodaggio o prima di ciascu- 9 Nach dem Einfahren und vor course, il faut vérifier toutes les na gara, si deve controllare tutto il jedem Rennen müssen Sie gemäß...
Page 60: Torque-Check Points
TORQUE-CHECK POINTS INFO EC1A0013 TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and tank Fuel tank to frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering shaft to Steering shaft to frame handlebar Steering shaft to handle crown Handle crown to handlebar...
Page 61: Points De Verification De Couple De Serrage
POINTS DE VERIFICATION DE COUPLE DE SERRAGE INFO POINTS DE VERIFICATION DE COUPLE DE SERRAGE Construction du cadre Du cadre au cadre arrière Combinasion de siège Du réservoir à essence au cadre et de réservoir Montage du moteur Du cadre au moteur Du support du moteur au moteur Du support du moteur au cadre Direction...
Page 62 ANZUGSMOMENTE-PRÜFPUNKTE INFO ANZUGSMOMENTE-PRÜFPUNKTE Rahmenkonstruktion Rahmen und Hintere Rahmen Kombinierter Sitz und Tank Kraftstofftank am Rahmen Motoraufhängung Rahmen am Motor Motoraufhängung am Motor Motoraufhängung am Rahmen Lenkung Lenkerschaft Lenkerschaft am Rahmen an Lenkstange Lenkerschaft an Lenkerkrone Lenkerkrone an Lenkstange Radaufhängung Vorne Lenkerschaft an Vorderradgabel an Lenkerkrone Vorderradgabel...
Page 63 PUNTI DI CONTROLLO DELLA COPPIA INFO IC1A0013 PUNTI DI CONTROLLO DELLA COPPIA Costruzione del telaio Telaio-telaio posteriore Sella e serbatoio uniti Serbatoio del carburante-telaio Supporto del motore Telaio-motore Staffa motore-motore Staffa motore-telaio Sterzo Albero dello Albero dello sterzo-telaio sterzo-manubrio Albero dello sterzo-corona del manubrio Corona del manubrio-manubrio Sospensione Anteriore...
Page 64: Cleaning And Storage
CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall perfor- mance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
Page 65: Nettoyage Et Rangement
NETTOYAGE ET RANGEMENT REINIGEN UND LAGERUNG PULITURA E IMMAGAZZINAMENTO INFO IC1B0000 NETTOYAGE ET REINIGEN UND PULITURA E IMMAGAZZI- RANGEMENT LAGERUNG NAMENTO NETTOYAGE REINIGEN IC1B1000 Un nettoyage fréquent de la machine Häufiges Reinigen Ihrer Maschine PULITURA stellt gefälliges Aussehen und ausge- réhausserra son aspect, maintiendra ses Una pulitura frequente del veicolo ne zeichnetes Leistungsvermögen sicher...
Page 66 CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken avoid deterioration. After cleaning machine thoroughly, prepare it for storage as fol- lows: 1. Drain the fuel tank, fuel lines, and the carbu- retor float bowl.
Page 67 NETTOYAGE ET RANGEMENT REINIGEN UND LAGERUNG PULITURA E IMMAGAZZINAMENTO INFO IC1B2001 RANGEMENT IMMAGAZZINAMENTO LAGERUNG Si vous remisez votre machine pour 60 Se il veicolo deve essere immagazzina- Falls Ihre Maschine für länger als jours ou plus, vous devez prendre des to per 60 giorni o più, si devono pren- etwa 60 Tage gelagert werden soll, mesures de conservation pour éviter sa...
Page 68: General Specifications
SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ250LC (EUROPE) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Model code number: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPE) 5UP4 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE ← ← Overall length 2,183 mm 2,182 mm (85.9 in)
Page 69: Chassis
SPEC GENERAL SPECIFICATIONS Carburetor: Type/Manufacturer PWK38S/KEIHIN Spark plug: Type/Manufacturer BR8EG/NGK (resistance type) 0.5~0.6 mm (0.020~0.024 in) Clutch type: Wet, multiple-disc Transmission: USA, ZA, AUS, NZ EUROPE, CDN ← Primary reduction system Gear ← Primary reduction ratio 63/21 (3.000) ← Secondary reduction system Chain drive Secondary reduction ratio 50/14 (3.571)
Page 70: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Standard Limit Cylinder head: USA, CDN, ZA, EUROPE AUS, NZ … Combustion chamber capacity 21.0 cm 21.5 cm (0.739 Imp oz, (0.757 Imp oz, 0.710 US oz) 0.727 US oz) … …...
Page 71 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch housing thrust clearance 0.17~0.23 mm (0.007~0.009 in) … Clutch housing radial clearance 0.030~0.055 mm (0.001~0.002 in) … Clutch release method Inner push, cam push … Transmission: … Main axle deflection limit 0.01 mm (0.0004 in) …...
Page 72 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M14 × 1.25 Spark plug M 8 × 1.25 Cylinder head (nut) M 8 × 1.25 (stud) M10 × 1.25 Cylinder (nut) M10 × 1.25 (stud) Power valve : M 5 ×...
Page 73 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M10 × 1.25 Primary drive gear M20 × 1.0 Clutch boss M 6 × 1.0 Clutch spring M 5 × 0.8 Push lever axle M20 × 1.0 Drive sprocket M 6 ×...
Page 74 SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: … Steering bearing type Taper roller bearing Front suspension: USA, CDN, ZA, EUROPE AUS, NZ … ← Front fork travel 300 mm (11.8 in) ← Fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) …...
Page 75 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: … Front wheel type Spoke wheel … Rear wheel type Spoke wheel … 21 × 1.60/Aluminum Front rim size/Material … 19 × 2.15/Aluminum Rear rim size/Material Rim runout limit: … Radial 2.0 mm (0.08 in) …...
Page 76 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M 8 × 1.25 Handle crown and outer tube M 8 × 1.25 Under bracket and outer tube M24 × 1.0 Handle crown and steering shaft 14.5 M 8 ×...
Page 77 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M 4 × 0.7 Rear brake master cylinder cap M10 × 1.25 Rear brake hose union bolt (caliper) M10 × 1.25 Rear brake hose union bolt (master cylinder) M20 ×...
Page 78 Ignition timing (B.T.D.C.) 0.18 mm (0.007 in) … Advancer type Electrical CDI: … Magneto-model (stator)/Manufacturer 5CU-02/YAMAHA … 720~1,080 Ω at 20°C (68°F) Source coil 1 resistance (color) (Black-Black/Red) … 44~66 Ω at 20°C (68°F) Source coil 2 resistance (color) (Green/Blue-Green/White) …...
Page 79: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard faste- ners with standard I.S.O. pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid warpage, tighten multi-faste- ner assemblies in a crisscross fashion, in pro- gressive stages, until full torque is reached.
Page 80: Caracteristiques Generales
SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: YZ250LC (EUROPE) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPE) 5UP4 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE ← ← Longueur hors-tout 2.183 mm 2.182 mm...
Page 81 SPEC CARACTERISTIQUES GENERALES Carburateur: Type/fabricant PWK38S/KEIHIN Bougie: Type/fabricant BR8EG/NGK (type à résistance) Ecartement des électrodes 0,5~0,6 mm (0,020~0,024 in) Type d’embrayage: Humide, multi-disques Transmission: USA, ZA, AUS, NZ EUROPE, CDN ← Système de réduction primaire Engrenage ← Taux de réduction primaire 63/21 (3,000) Entraînement par chaîne ←...
Page 82 SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: USA, CDN, ZA, EUROPE AUS, NZ … Capacité de la chambre de combustion 21,0 cm 21,5 cm (0,793 Imp oz, (0,757 Imp oz, 0,710 US oz) 0,727 US oz) … …...
Page 83 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite … Jeu de cloche d’embrayage pousser 0,17~0,23 mm (0,007~0,009 in) … Jeu radial de cloche d’embrayage 0,030~0,055 mm (0,001~0,002 in) … Méthode de débrayage Poussée interne, pousée par came Boîte de vitesses: … Limite de déformation d’arbre primaire 0,01 mm (0,0004 in) Limite de déformation d’arbre secondaire …...
Page 84 SPEC CARACTERISTIQUES D’ENTRETIEN Taille de Couple de serrage Pièce à serrer Q’té filetage m•kg ft•lb M14 × 1,25 Bougie M 8 × 1,25 Culasse (écrou) M 8 × 1,25 (goujon) M10 × 1,25 Cylinder (écrou) M10 × 1,25 (goujon) Clapet de puissance : M 5 ×...
Page 85 SPEC CARACTERISTIQUES D’ENTRETIEN Taille de Couple de serrage Pièce à serrer Q’té filetage m•kg ft•lb M10 × 1,25 Pignon primaire M20 × 1,0 Noix d’embrayage M 6 × 1,0 Ressort d’embrayage M 5 × 0,8 Axe de levier de poussé M20 ×...
Page 86 SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: … Type de roulement de direction Roulement à rouleaux conique Suspention avant: USA, CDN, ZA, EUROPE AUS, NZ … 300 mm (11,8 in) ← Débattement de fourche avant 460 mm (18,1 in) ← Longueur libre de ressort de fourche 455 mm (17,9 in) …...
Page 87 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Roue: … Type de roue avant Roue à rayons … Type de roue arrière Roue à rayons … 21 × 1,60/Aluminum Taille/matériau de jante avant … 19 × 2,15/Aluminum Taille/matériau de jante arrière Limite de voile de jante: …...
Page 88 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Q’té filetage m•kg ft•lb M 8 × 1,25 Couronne de guidon et tube externe M 8 × 1,25 Etrier inférieur et tube externe M24 × 1,0 Couronne de guidon et colonne de direction 14,5 M 8 ×...
Page 89 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Q’té filetage m•kg ft•lb M 4 × 0,7 Coupelle de maître-cylindre de frein arrière M10 × 1,25 Boulon d’union de tuyau de frein arrière (ètrier) M10 × 1,25 Boulon d’union de tuyau de frein arrière (maître-cylindre) M20 ×...
Page 90 Avance d’allumage (AV. PMH) 0,18 mm (0,007 in) … Type de dispositif d’avance Electrique CDI: … Magnéto-modèle (stator)/Fabricant 5CU-02/YAMAHA … 720~1,080 Ω à 20°C (68°F) Résistance de bobinage de source 1 (couleur) (noir-noir/rouge) 44~66 Ω à 20°C (68°F) … Résistance de bobinage de source 2...
Page 91: Definition Des Unites
SPECIFICATIONS GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES SPECIFICATIONS GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des attaches standard avec filetage à pas I.S.O. stan- dard. Les spécifications de couple pour les compo- sants ou ensembles spéciaux sont indiquées das les sections appropriées de ce manuel.
Page 92: Technische Daten
SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname: YZ250LC (EUROPA) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Modell-Code-Nummer: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPA) 5UP4 (AUS, NZ) Abmessungen: USA, ZA AUS, NZ EUROPA ← ← Gesamtlänge 2.183 mm 2.182 mm (85,9 in) (85,9 in)
Page 93: Allgemeine Technische Daten
SPEC ALLGEMEINE TECHNISCHE DATEN Vergaser: Modell/Hersteller PWK38S/KEIHIN Zündkerze: Modell/Hersteller BR8EG/NGK (Widerstand, Typ) Elektrodenabstand 0,5~0,6 mm (0,020~0,024 in) Kupplungsbauart: Mehrscheiben-Naßkupplung Getriebe: USA, ZA, AUS, NZ EUROPA, CDN ← Primäruntersetzungssystem Zahnrad ← Primäruntersetzungsverhältnis 63/21 (3,000) ← Sekundäruntersetzungssystem Kettenantrieb Sekundäruntersetzungsverhältnis 50/14 (3,571) 49/14 (3,500) ←...
Page 94 SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bauteil Standard Grenze Zylinderkopf: USA, CDN, ZA, EUROPA AUS, NZ … Brennkammerkapazität 21,0 cm 21,5 cm (0,739 Imp oz, (0,757 Imp oz, 0,710 US oz) 0,727 US oz) … … Verzugsgrenze 0,03 mm (0,0012 in) Zylinder: Bohrungsdurchmesser 66,400~66,414 mm 66,5 mm (2,618 in)
Page 95 SPEC WARTUNGSDATEN Bauteil Standard Grenze Kupplungsgehäuse: Axialspiel 0,17~0,23 mm (0,007~0,009 in) … Kupplungsgehäuse: Radialspiel 0,030~0,055 mm … (0,001~0,002 in) Kupplungsausrückmechanismus Innendruck, Nockendruck … Getriebe: … Schlaggrenze der Haptwelle 0,01 mm (0,0004 in) … Schlaggrenze der Antriebswelle 0,01 mm (0,0004 in) Schaltung: …...
Page 96 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M14 × 1,25 Zündkerze M 8 × 1,25 Zylinderkopf (Mutter) M 8 × 1,25 (Stehbolzen) M10 × 1,25 Zylinder (Mutter) M10 × 1,25 (Stehbolzen) Leistungsventil: M 5 × 0,8 Halter M 5 × 0,8 Pleuelstange M 5 ×...
Page 97 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M10 × 1,25 Primärantriebszahnrad M20 × 1,0 Kupplungsnabe M 6 × 1,0 Kupplungsfeder M 5 × 0,8 Schubhebelachse M20 × 1,0 Antriebskettenrad M 6 × 1,0 Schaltführung M 6 × 1,0 Anschlaghebel M 8 ×...
Page 98 SPEC WARTUNGSDATEN FAHRGESTELL Bauteil Standard Grenze Lenkungssystem: … Lenkerschaftlager Kegelrollenlager Vorderradaufhängung: USA, CDN, ZA, EUROPA AUS, NZ … ← Hub der Vorderradgabel 300 mm (11,8 in) ← Ungespannte Federlänge 460 mm (18,1 in) 455 mm (17,9 in) … Federkonstante STD K=4,22 N/mm K=ca.
Page 99 SPEC WARTUNGSDATEN Bauteil Standard Grenze Räder: … Bauart: Vorderrad Speichenräder … Hinterrad Speichenräder … 21 × 1,60/Aluminum Felgengröße: Vorderrad/Baustoff … 19 × 2,15/Aluminum Hinterrad/Baustoff Zuläßiger Felgenschlag: … Senkrecht 2,0 mm (0,08 in) … Seitlich 2,0 mm (0,08 in) Antriebskette: … Bauart/Hersteller DID520DMA2 SDH/DAIDO …...
Page 100 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 8 × 1,25 Lenkerkrone und äußere Rohr M 8 × 1,25 Untere Gabelbrücke und äußere Rohr M24 × 1,0 Lenkerkrone und Lenkerschaft 14,5 M 8 × 1,25 Lenkerhalter (obere) M28 × 1,0 Lenkerringmutter Siehe ANMERKUNG.
Page 101 SPEC WARTUNGSDATEN Anzugsmoment Anzuziehendes Teil Gewindegröße Anzahl m•kg ft•lb M 6 × 1,0 Hinterrad-Hauptbremszylinder und Rahmen M 4 × 0,7 Hintrerred-Hauptbremszylinder kappe M10 × 1,25 Hinterrad-Bremsschlauch- Verbindungsschraube (bremssattel) M10 × 1,25 Hinterrad-Bremsschlauch- Verbindungsschraube (Hauptbremszylinder) M20 × 1,5 Hinterradachse und Mutter 12,5 M 8 ×...
Page 102 0,18 mm (0,007 in) (Vor dem oberen Totpunkt) … Zündversteller Elektrisch-Ausführung CDI: … Modell (staor)/Hersteller 5CU-02/YAMAHA … 720~1.080 Ω bei 20°C (68°F) Widerstand der Stromspule 1 (Farbe) (Schwarz-Schwarz/Rot) … 44~66 Ω bei 20°C (68°F) Widerstand der Stromspule 2 (Farbe) (Grün/Blau-Grün/Waiß) …...
Page 103: Allgemeine Anzugsdaten
ALLGEMEINE ANZUGSDATEN/ SPEC DEFINITION DER EINHEITEN ALLGEMEINE ANZUGSDATEN Diese Tabelle spezifiziert Anzugsmomente für normale Befestigungselemente mit normalen I.S.O. Gewindenormen. Anzugsmomente für besondere Bauteile bzw. Bauteileinheiten sind in den einzelnen Abschnitten in dieser Wartungs- anleitung aufgefügrt. Wenn Teile mit mehreren Befestigungselementen festgezogen werden, die Schrauben und Muttern kreuzweise und in...
Page 104: Specifiche Generali
SPEC SPECIFICHE GENERALI IC200000 SPECIFICHE IC211000 SPECIFICHE GENERALI Nome del modello: YZ250LC (EUROPA) YZ250R (USA) YZ250(R) (CDN, AUS, NZ, ZA) Numero di codice del modello: 5UP1 (USA, CDN, ZA) 5UP2 (EUROPA) 5UP4 (AUS, NZ) Dimensioni: USA, ZA AUS, NZ EUROPA CDN, ←...
Page 105 SPEC SPECIFICHE GENERALI Carburatore: Tipo/Costruttore PWK38S/KEIHIN Candela: Tipo/Costruttore BR8EG/NGK (tipo di resistenza) Distanza tra gli elettrodi 0,5~0,6 mm (0,020~0,024 in) Tipo di frizione: Bagnata, a più dischi Trasmissione: USA, ZA, AUS, NZ EUROPA, CDN ← Sistema di riduzione primario Ingranaggio ←...
Page 106: Specifiche Di Manutenzione
SPEC SPECIFICHE DI MANUTENZIONE IC212000 SPECIFICHE DI MANUTENZIONE IC212100 MOTORE Voce Valore normale Limite Testa cilindro: USA, CDN, ZA, EUROPA AUS, NZ … Capacità della camera di combustione 21,0 cm 21,5 cm (0,739 Imp oz, (0,757 Imp oz, 0,710 US oz) 0,727 US oz) …...
Page 107 SPEC SPECIFICHE DI MANUTENZIONE Voce Valore normale Limite … Gioco di spinta del coperchio della frizione 0,17~0,23 mm (0,007~0,009 in) … Gioco radiale del coperchio della frizione 0,030~0,055 mm (0,001~0,002 in) … Metodo di distacco della frizione Spinta interna, spinta camma Trasmissione: …...
Page 108 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni della Coppia di serraggio Parte da serrare Quantità filettatura m•kg ft•lb M14 × 1,25 Candela M 8 × 1,25 Testa cilindro (dado) M 8 × 1,25 (Prigioniero) M10 × 1,25 Cilindro (dado) M10 × 1,25 (prigioniero) Valvola di potenza: M 5 ×...
Page 109 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni della Coppia di serraggio Parte da serrare Quantità filettatura m•kg ft•lb M10 × 1,25 Ingranaggio conduttore primario M20 × 1,0 Mozzo della frizione M 6 × 1,0 Molla della frizione M 5 × 0,8 Asse della leva di spinta M20 ×...
Page 110 SPEC SPECIFICHE DI MANUTENZIONE IC212201 TELAIO Voce Valore normale Limite Sistema dello sterzo: … Tipo di cuscinetto dello sterzo Cuscinetto a sfere conico Sospensione anteriore: USA, CDN, ZA, EUROPA AUS, NZ … 300 mm (11,8 in) ← Corsa della forcella anteriore Lunghezza libera della molla della forcella 460 mm (18,1 in) ←...
Page 111 SPEC SPECIFICHE DI MANUTENZIONE Voce Valore normale Limite Ruota: … Tipo di ruota anteriore Ruota a razze … Tipo di ruota poster Ruota a razze … 21 × 1,60/Alluminio Dimensioni/Materiale del cerchione anteriore … Dimensioni/Materiale del cerchione posteriore 19 × 2,15/Alluminio Limite di scentratura del cerchione: …...
Page 112 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Quantità Parte da serrare filettatura m•kg ft•lb M 8 × 1,25 Corona del manubrio e tubo esterno M 8 × 1,25 Staffa inferiore e tubo esterno M24 × 1,0 Corona del manubrio e albero dello sterzo 14,5 M 8 ×...
Page 113 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni della Quantità Parte da serrare filettatura m•kg ft•lb M10 × 1,25 Bullone di unione del tubo flessibile del freno posteriore (pinza) M10 × 1,25 Bullone di unione del tubo flessibile del freno posteriore (cilindro principale) M20 ×...
Page 114 Messa in fase dell’accensione (B.T.D.C.) 0,18 mm (0,007 in) … Tipo di anticipatore Elettrico CDI: … Modello (statore)/Costruttore del magnete 5CU-02/YAMAHA 720~1.080 Ω à 20°C (68°F) … Resistenza 1 della bobina di origine (colore) (Nero-Nero/Rosso) … 44~66 Ω à 20°C (68°F)
Page 115: Definizione Delle Unit
SPECIFICHE GENERALI RELATIVE ALLA COPPIA/ SPEC DEFINIZIONE DELLE UNITÀ IC220001 SPECIFICHE GENERALI RELATIVE ALLA COPPIA Questa tabella specifica la coppia per i dispositivi di fissaggio standard con filettature a passo I.S.O. standard. Le specifiche relative alla coppia per componenti o gruppi speciali sono incluse nelle sezioni pertinenti di questo manuale.
Page 116: Cable Routing Diagram
SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM A Pass the fuel tank breather hose G Pass the air vent hoses, overflow 1 Fuel tank breather hose 2 Cable guide between the handlebar and ten- hose and transmission oil 3 Throttle cable sion bar, then insert its end into breather hose between the frame 4 Clamp...
Page 117: Schema De Cheminement Des Cables
SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI IC240000 SCHEMA DE DIAGRAMMA DEL KABELFÜHRUNGSÜBER- CHEMINEMENT DES SICHTPLAN PASSAGGIO DEI CAVI 1 Kraftstofftank - Belüftungsschlauch 1 Sfiato del serbatoio del carburante CABLES 2 Kabelführung 2 Guida per cavi 1 Tuyau de reniflard de réservoir à...
Page 118 SPEC CABLE ROUTING DIAGRAM B Clamp the “ENGINE STOP” but- E Clamp the radiator breather 1 Ground lead 2 Ignition coil lead ton lead, ground lead, ignition hose and CDI magneto lead at 3 Clamp coil lead, wireharness and CDI the rear of the down-tube with 4 Wireharness magneto lead with the clamp...
Page 119 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Conduttore di terra 1 Fil de masse 1 Massekabel 2 Zündspulekabel 2 Conduttore de la bobina di accencsione 2 Fil de bobine d’allumage 3 Klemme 3 Brida 3 Bride 4 kalbelbaum 4 Complesso conduttori...
Page 120 SPEC CABLE ROUTING DIAGRAM A Pass the clutch cable into the F Fasten the ground lead together 1 Clutch cable 2 Cable guide cable guide. with the front installation portion B Clamp the clutch cable, high 3 Ground lead of the ingnition coil. G Pass the radiator breather hose 4 Clamp tension cord and wireharness at...
Page 121 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Câble d’embrayage 1 Kupplungskabel 1 Cavo della frizione 2 Kabelführung 2 Guide de câble 2 Guida per cavi 3 Massekabel 3 Fil de masse 3 Conduttore di terra 4 Klemme 4 Bride 4 Brida...
Page 122 SPEC CABLE ROUTING DIAGRAM A Install the brake hose so that its pipe portion 1 Master cylinder 2 Brake hose holder directs as shown and lightly touches the projec- 3 Brake hose tion on the caliper. B Pass the brake hose into the brake hose holders.
Page 123 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Maître-cylindre 1 Hauptbremszylinder 1 Cilindro principale 2 Support de tuyau de frein 2 Bremsschlauchhalter 2 Supporto del tubo flessibile del freno 3 Tuyau de frein 3 Bremsschlauch 3 Tubo flessibile del freno A Bremsschlauch å...
Page 124 SPEC CABLE ROUTING DIAGRAM A Install the brake hose so that its pipe portion 1 Brake hose 2 Master cylinder directs as shown and lightly touches the 3 “ENGINE STOP” button lead projection on the master cylinder. B Pass the “ENGINE STOP” button lead in 4 “ENGINE STOP”...
Page 125 SCHEMA DE CHEMINEMENT DES CABLES KABELFÜHRUNGSÜBERSICHTPLAN SPEC DIAGRAMMA DEL PASSAGGIO DEI CAVI 1 Tuyau de frein 1 Bremsschlauch 1 Tubo flessibile del freno 2 Maître-cylindre 2 Hauptbremszylinder 2 Cilindro principale 3 Fil de bouton d’arrêt du moteur “ENGI- 3 Leitungskabel des Motorstoppknopfes 3 Conduttore del pulsante “ARRESTO NE STOP”...
Page 126: Maintenance Intervals
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. After...
Page 127 Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or Check routing and connection SAE 10W-30 motor oil Lubricate...
Page 128 INSP MEMO...
Page 129 En cas de doute au sujet des inter- valles d’entretien et de lubrification à adopter, consultez votre concessionnaire Yamaha. Chaque Chaque Après Chaque...
Page 130 INSP PROGRAMME D’ENTRETIEN Chaque Chaque Après Chaque Partie trois- cinquiè- nécessa- Remarques rodage course ième BOUGIE Contrôler et nettoyer Changer CHAINE DE TRANSMISSION Utiliser du lubrifiant Graisser, jeu, alignement pour chaîne Changer Jeu de la chaîne: 40~50 mm (1,6~2,0 in) CIRCUIT DE REFROIDISSEMENT Contrôler le niveau du liquide...
Page 131 Resserrer les boulons de la roue dentée Contrôler les roulements Changer les roulements Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COMMANDE Yamaha lube pour câble ou Contrôler le chaminement et le Huile moteur SAE 10W-30 branchement Graisser...
Page 132 Wetterbedingungen, dem Terrain, der geographischen Lage und den individuellen Fahrgewohnhei- ten sind die aufgeführten Wartungs- und Schmierintervalle zu ändern. Falls Fragen hinsichtlich der War- tungs- und Schmierintervalle auftreten sollten, wenden Sie sich bitte an Ihren Yamaha Fachhändler. Nach...
Page 133 INSP WARTUNGSINTERVALLE Nach Nach Nach Nach dem jedem jedem Benennung jedem Bemerunen Einfahren dritten fünften Erforderlich Rennen Rennen Rennen KÜHLANLAGE Kühlmittelstand prüfen und auf Undichtigkeit achten Funktion des Kühlerdeckels kontrollieren Kühlmittel wechseln Alle zwie Jahre Schläuche prüfen MUTTERN UND SCHRAUBEN Siehe Abschnitt AN DER AUSSENSEITE „STARTEN UND...
Page 134 Bemerunen Einfahren dritten fünften Erforderlich Rennen Rennen Rennen RÄDER, REIFEN Reifendruck, Felgenschlag, Reifenverschleiß und Speichen auf Lockerung prüfen Ketternrad-Befestigungsschraube nachziehen Lager prüfen Lager erneuern Schmieren Lithium-Fett GASDREHGRIFF, GASSEIL Yamaha Seilzug- Seilzugführung und Anschlüsse Schmiermittel oder prüfen Motoröl SAE 10W-30 Schmieren...
Page 135: Intervalli Di Manutenzione
Se si hanno dubbi sugli interval- li da seguire per la manutenzione e la lubrificazione del veicolo, consultare il concessionario Yamaha. In base...
Page 136 INSP INTERVALLI DI MANUTENZIONE In base Dopo il Ogni Ogni Voce Ogni alle Osservazioni rodaggio gara cinque necessità IMPIANTO DI RAFFREDDAMENTO Controllo livello e perdite di liquido refrigerante Controllo funzionamento del tappo del radiatore Sostituzione del liquido refrigerante Ogni due anni Ispezione dei tubi flessibili DADI E VITI ESTERNI Consultare la sezione...
Page 137 Riserraggio bullone del rocchetto Ispezione dei cuscinetti Sostituzione dei cuscinetti Lubrificazione Grasso a base di litio VALVOLA A FARFALLA, CAVO DI COMANDO Lubrificante per cavi Controllo dell’instradamento e del Yamaha oppure olio per collegamento motori SAE 10W-30 Lubrificazione...
Page 138: Pre-Operation Inspection And Maintenance
INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page...
Page 139 INSP INSPECTION ET ENTRETIEN AVANT UTILISATION INSPECTION ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bou état de marche. Avant d’utiliser cette machine, contrôler les points suivants: INSPECTION GENERALE ET ENTRETIEN Partie Routine Page...
Page 140 INSP PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME PRÜFUNG UND WARTUNG VOR DER INBETRIEBNAHME Vor dem Einfahren, einer Übungs-oder Rennfahrt, immer die Maschine auf guten Betriebszustand kontrollieren. Vor der Benutzung dieser Maschine sind die folgenden Punkte zu prüfen: ALLGEMEINE PRÜFUNG UND WARTUNG Benennung Vorgang Seite...
Page 141 INSP ISPEZIONE E MANUTENZIONE PRIMA DEL FUNZIONAMENTO IC320000 ISPEZIONE E MANUTENZIONE PRIMA DEL FUNZIONAMENTO Prima di usarlo per il rodaggio, per allenamento o per una gara, accertarsi che il veicolo sia in buone condi- zioni di funzionamento. Prima di usare questo veicolo, controllare i punti che seguono. IC321000 ISPEZIONE E MANUTENZIONE GENERALI Voce...
Page 142 ENGINE/COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION Do not remove the radiator cap 1 1 , drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
Page 143 MOTEUR/VERIFICATION DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT MOTOR/INSPEKTION DES KÜHLMITTELSTANDES/ERNEUERUNG DES KÜHLMITTELS INSP MOTORE/ISPEZIONE DEL LIVELLO DEL LIQUIDO REFRIGERANTE/ SOSTITUZIONE DEL LIQUIDO REFRIGERANTE IC350000 MOTEUR MOTOR MOTORE IC351011 VERIFICATION DU NIVEAU DU INSPEKTION DES ISPEZIONE DEL LIVELLO DEL LIQUIDE DE REFROIDISSEMENT KÜHLMITTELSTANDES LIQUIDO REFRIGERANTE...
Page 144 INSP COOLANT REPLACEMENT Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: 9 Coolant drain bolt 1 3. Remove: 9 Radiator cap Drain the coolant completely.
Page 145 CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP ERNEUERUNG DES KÜHLMITTELS SOSTITUZIONE DEL LIQUIDO REFRIGERANTE Fare attenzione che il liquido refrige- Prendre garde à ne pas verser de Darauf achten, daß kein Kühlmittel rante non schizzi sulle superfici ver- liquide de refroidissement sur les lackierte Flächen verspritzt...
Page 146 INSP RADIATOR CAP INSPECTION 9 Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. 9 Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care.
Page 147 VERIFICATION DU BOUCHON DU RADIATEUR INSP INSPEKTION DES KÜHLERDECKELS ISPEZIONE DEL TAPPO DEL RADIATORE 9 Ne pas mélanger plusieurs solutions 9 Non miscelare più di un tipo di anti- 9 Niemals Äthylenglykol-Frost- antigel au glycol d’éthyle contenant gelo a base di glicole etilenico conte- schutzmittel Korrosions- des produits anticorrosion pour...
Page 148 RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION EC356002 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: 9 Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2.
Page 149 VERIFICATION DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR/VERIFICATION DE SYSTEME DE REFROIDISSEMENT INSPEKTION DES KÜHLERDECKELÖFFNUNGSDRUCKS/INSPEKTION DES KÜHLSYSTEMS INSP ISPEZIONE DELLA PRESSIONE DI APERTURA DEL TAPPO DEL RADIATORE/ ISPEZIONE DELL’IMPIANTO DI RAFFREDDAMENTO IC356002 VERIFICATION DE LA PRESSION INSPEKTION KÜHLER- ISPEZIONE DELLA PRESSIONE D’OUVERTURE DU BOUCHON DECKELÖFFNUNGSDRUCKS DI APERTURA DEL TAPPO DEL...
Page 150 INSP CLUTCH ADJUSTMENT NOTE: 9 Do not apply pressure more than specified pressure. 9 Radiator should be filled fully. 4. Inspect: 9 Pressure Impossible to maintain the specified pres- sure for 10 seconds¡Repair. 9 Radiator 1 9 Radiator hose joint 2 Coolant leakage¡Repair or replace.
Page 151 REGLAGE DE L’EMBRAYAGE INSP EINSTELLUNG DER KUPPLUNG REGOLAZIONE DELLA FRIZIONE HINWEIS: N.B.: NOTA: 9 Ne pas appliquer de pression supé- 9 Non applicare pressione superiore alla 9 Den spezifizierten Druck nicht Über- rieure à la pression spécifiée. pressione specificata. schreiten. 9 Le radiateur doit être entièrement 9 Il radiatore dovrebbe essere completa- 9 Der Kühler sollte vollständig gefüllt...
Page 152 THROTTLE CABLE ADJUSTMENT/ INSP THROTTLE LUBRICATION EC35A001 THROTTLE CABLE ADJUSTMENT 1. Check: 9 Throttle grip free play a Out of specification¡Adjust. Throttle grip free play ? a : 3~5 mm (0.12~0.20 in) 2. Adjust: 9 Throttle grip free play Throttle grip free play adjustment steps: 9 Loosen the locknut 1.
Page 153 REGLAGE DU CABLE D’ACCELERATION/GRAISSAGE DE L’ACCÉLÉRATEUR EINSTELLUNG DES GASSEILES/SCHMIERUNG DES GASSEILS INSP REGOLAZIONE DEL CAVO DELL’ACCELERATORE/ LUBRIFICAZIONE DELLA VALVOLA A FARFALLA IC35A001 REGLAGE DU CABLE EINSTELLUNG DES GASSEILES REGOLAZIONE CAVO D’ACCELERATION 1. Kontrollieren: DELL’ACCELERATORE 9 Spiel am Gasdrehgriff a 1. Contrôler: 1.
Page 154 INSP AIR FILTER CLEANING 3. Install: 9 Throttle cable cap 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Cap cover EC35G041 AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and dam- age. Never run the engine without the air filter element in place;...
Page 155 NETTOYAGE DU FILTRE A AIR INSP REINIGUNG DES LUFTFILTERS PULITURA DEL FILTRO DELL’ARIA 3. Monter: 3. Installare: 3. Einbauen: 9 Capuchon du câble d’accéléra- 9 Calotta del cavo dell’accelerato- 9 Gasseilkappe teur 1 Nm (0,1 m•kg, 0,7 ft•lb) 1 Nm (0,1 m•kg, 0,7 ft•lb) 1 Nm (0,1 m•kg, 0,7 ft•lb) 9 Kappenabdeckung 9 Couvercle de capuchon...
Page 156 INSP TRANSMISSION OIL LEVEL CHECK 3. Inspect: 9 Air filter element Damage¡Replace. 4. Apply: 9 Foam-air-filter oil or equivalent oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: 9 Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element.
Page 157 CONTROLE DU NIVEAU DE L’HUILE DE BOITE DE VITESSES INSP PRÜFUNG DES GETRIEBEÖLSTANDES CONTROLLO DEL LIVELLO DELL’OLIO DELLA TRASMISSIONE 3. Examiner: 3. Ispezionare 3. Prüfen: 9 Elément du filtre à air 9 Elemento del filtro dell’aria 9 Luftfilterelement Danni ¡ Sostituirlo. Endommagement¡Changer.
Page 158 INSP TRANSMISSION OIL REPLACEMENT 3. Check: 9 Transmission oil level Transmission oil level checking steps: 9 Remove the oil check bolt 1. 9 Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. Never attempt to remove the oil check bolt just after high speed operation.
Page 159 CHANGEMENT DE L’HUILE DE BOITE DE VITESSES INSP ERNEUERUNG DES GETRIEBEÖLS SOSTITUZIONE DELL’OLIO DELLA TRASMISSIONE 3. Contrôler: 3. Controllare: 3. Kontrollieren: 9 Niveau d’huile de boîte de 9 Livello dell’olio della trasmis- 9 Getriebeölstand vitesses sione Prüfschritte des Getriebeölstan- Passi del controllo del livello Procédure de contrôle de niveau des: dell’olio della trasmissione:...
Page 160 INSP PILOT AIR SCREW ADJUSTMENT 4. Remove: 9 Oil drain bolt 1 9 Oil filler cap 2 Drain the transmission oil. 5. Install: 9 Aluminum washer 9 Oil drain bolt 1 20 Nm (2.0 m•kg, 14 ft•lb) 6. Fill: 9 Transmission oil Recommended oil: Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil...
Page 161 REGLAGE DE LAVIS DE RICHESSE INSP EINSTELLUNG DER LEERLAUFTREGULIERSCHRAUBE REGOLAZIONE DELLA VITE DELL’ARIA PILOTA 4. Déposer: 4. Togliere: 4. Ausbauen: 9 Boulon de vidange d’huile 1 9 Bullone di scarico dell’olio 1 9 Ölablaßschraube 1 9 Bouchon de remplissage d’huile 9 Tappo di riempimento dell’olio 9 Öleinfüllschraube 2 Das Getriebeöl ablassen.
Page 162 INSP IDLE SPEED ADJUSTMENT/MUFFLER INSPECTION/ SILENCER FIBER REPLACEMENT EC35M001 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: 9 Idle speed Adjustment steps: Turn the throttle stop screw 1 until the engine runs at the lowest possible speed. To increase idle speed ¡...
Page 163 REGLAGE DU REGIME DE RALENTI/CONTROLE DU SILENCIEUX D’ECHAPPMENT/CHANGEMENT DE FIBRE DU SILENCIEUX EINSTELLUNG DER LEERLAUFDREHZAHL/INSPEKTION DES INSP SCHALLDÄMPFERS/ERNEUERUNG DES SCHALLDÄMPFERFASEREINSATZES REGOLAZIONE DEL NUMERO DI GIRI AL MINIMO/ISPEZIONE DELLA MARMITTA/ SOSTITUZIONE DELLA FIBRA DEL SILENZIATORE IC35M001 REGLAGE REGIME EINSTELLUNG LEERLAUF- REGOLAZIONE DEL NUMERO DI RALENTI DREHZAHL GIRI AL MINIMO...
Page 164: Silencer Fiber Replacement
Fully apply Quick gasket ® (Yamaha bond No. 1215) or equivalent as shown. Quick gasket ® ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 5. Install: 9 Bolt (fiber) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Silencer 2 9 Bolt [silencer (front)] 3 12 Nm (1.2 m•kg, 8.7 ft•lb)
Page 165 (Yamaha bond Nr. Applicare ovunque Quick Gasket ® ® d’étanchéité Quick Gasket ® (Yamaha 1215) oder gleichwertiges Produkt voll (Yamaha Bond n° 1215) o equivalente, Bond n° 1215) ou équivalent comme auftragen, wie dargestellt. come illustrato. illustré. Quick Gasket ® Quick Gasket ®...
Page 166 INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING Bleed the brake system if: 9 The system has been disassembled. 9 A brake hose has been loosened or removed. 9 The brake fluid is very low. 9 The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed.
Page 167: Partie Cycle
PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE INSP FAHRGESTELL/ENTLÜFTUNG DER BREMSANLAGE TELAIO/ SPURGO DELL’ARIA DALL’IMPIANTO FRENANTE IC360000 PARTIE CYCLE FAHRGESTELL TELAIO PURGE DE L’AIR DU SYSTEME ENTLÜFTUNG DER BREMSANLAGE IC361012 DE FREINAGE SPURGO DELL’ARIA DALL’IMPIAN- TO FRENANTE Die Bremsanlage muß unbedingt in den folgenden Fallen entlüftet werden: Purger le système de freinage si: 9 Nach Demontage und Wiederzu-...
Page 168 INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir.
Page 169 REGLAGE DE FREIN AVANT INSP EINSTELLUNG DER VORDERRADBREMSE REGOLAZIONE DEL FRENO ANTERIORE HINWEIS: N.B.: NOTA: Si la purge est difficile, il peut être Se lo spurgo risulta difficoltoso, Falls das Entlüften schwierig ist, nécessaire de laisser le système du può essere necessario lasciare stabi- dann muß...
Page 170: Rear Brake Adjustment
REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364004 REAR BRAKE ADJUSTMENT 1. Check: 9 Brake pedal height a Out of specification¡Adjust. Brake pedal height a a : Zero mm (Zero in) NOTE: The brake pedal height is the vertical distance from the inside top end of the footrest.
Page 171 REGLAGE DU FREIN ARRIERE/ VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN AVANT EINSTELLUNG DER HINTERRADBREMSE/ INSP INSPEKTION UND ERNEUERUNG DER VORDERRAD-BREMSBELAGPLATTE REGOLAZIONE DEL FRENO POSTERIORE/ ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE IC364004 REGLAGE DU FREIN ARRIERE EINSTELLUNG DER HINTERRAD- REGOLAZIONE FRENO 1.
Page 172 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT 9 Loosen the pad pin 2. 9 Remove the brake hose holder 3 and caliper 4 from the front fork. 9 Remove the pad pin and brake pads 5. 9 Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
Page 173 VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN AVANT INSP INSPEKTION UND ERNEUERUNG DES VORDERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE 9 Desserrer la goupille de plaquette 9 Allentare la spina della pastiglia 9 Bremsbelagstift 2 lösen. 9 Bremsleitungshalter 9 Déposer le support du tuyau de 9 Togliere il supporto del tubo fles- Bremsbelag 4 von der Vorderrad-...
Page 174: Front Wheel And Rear Wheel
INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT 9 Install the pad pin plug w. Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) 3. Inspect: 9 Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: 9 Brake lever operation A softy or spongy feeling ¡...
Page 175 VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN ARRIERE INSP INSPEKTION UND ERNEUERUNG DES HINTERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 9 Installare il tappo della spina della 9 Bremsbelagplattenstifte w 9 Installer le bouchon de goupille anbrin- pastiglia w.
Page 176 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT 9 Remove the pad pin 6 and brake pads 7. 9 Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. 9 Loosen the bleed screw and push the caliper piston in.
Page 177 VERIFICATION ET CHANGEMENT DE LA PLAQUETTE DE FREIN ARRIERE INSP INSPEKTION UND ERNEUERUNG DES HINTERRAD-BREMSBELAGPLATTE ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE 9 Déposer la goupille de plaquette 9 Togliere la spina della pastiglia 6 9 Bremsbelagstift 6 und Bremsbelä- 6 et les plaquettes de frein 7.
Page 178 REAR BRAKE PAD INSULATOR INSPECTION INSP BRAKE FLUID LEVEL INSPECTION EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: 9 Brake pad Refer to “REAR BRAKE PAD INSPEC- TION AND REPLACEMENT” section. 2. Inspect: 9 Rear brake pad insulator 1 Damage ¡ Replace. EC367001 BRAKE FLUID LEVEL INSPECTION 1.
Page 179 VERIFICATION DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/VERIFICATION DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/INSPEKTION DES INSP BREMSFLÜSSIGKEITSSTANDESS ISPEZIONE DELL’ISOLATORE DELLA PASTIGLIA DEL FRENO POSTERIORE/ISPEZIONE DEL LIVELLO DEL LIQUIDO PER FRENI IC36b000 VERIFICATION DE L’ISOLANT INSPEKTION ISOLIERUNG ISPEZIONE...
Page 180 INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: 9 Sprocket teeth a Excessive wear ¡ Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Remove: 9 Master link clip 9 Joint 1 9 Drive chain 2 2.
Page 181 VERIFICATION DES PIGNONS/VERIFICATION DE LA CHAINE DE TRANSMISSION INSP INSPEKTION DER KETTENRÄDER/INSPEKTION DER ANTRIEBSKETTE ISPEZIONE DEI ROCCHETTI/ ISPEZIONE DELLA CATENA DI TRASMISSIONE IC368000 VERIFICATION DES PIGNONS INSPEKTION DER KETTENRÄDER ISPEZIONE DEI ROCCHETTI 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Dent de pignon a 9 Kettenradzahn a 9 Denti dei rocchetti a ¡...
Page 182 INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: 9 Drive chain 1 9 Joint 2 9 Master link clip 3 Be sure to install the master link clip to the direction as shown. a Turning direction 6. Lubricate: 9 Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants...
Page 183 REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION INSP EINSTELLUNG DES ANTRIEBSKETTENDURCHHANGES REGOLAZIONE DEL GIOCO DELLA CATENA DI TRASMISSIONE 5. Monter: 5. Installare: 5. Einbauen: 9 Chaîne de transmission 1 9 Catena di trasmissione 1 9 Antriebskette 1 9 Raccord 2 9 Giunto 2 9 Verbindung 2 9 Agrafe de l’attache rapide 3...
Page 184 INSP FRONT FORK INSPECTION 3. Adjust: 9 Drive chain slack Drive chain slack adjustment steps: 9 Loosen the axle nut 1 and locknuts 2. 9 Adjust chain slack turning adjusters 3. To tighten ¡ Turn adjuster 3 3 counter- clockwise. To loosen ¡...
Page 185 VERIFICATION DE LA FOURCHE AVANT INSP INSPEKTION DER VORDERRADGABEL ISPEZIONE DELLA FORCELLA ANTERIORE 3. Régler: 3. Regolare: 3. Einstellen: 9 Flèche de chaîne de transmis- 9 Gioco della catena di trasmis- 9 Antriebskettendurchhang sion sione Einstellschritte des Antriebsket- Procédure de réglage de flèche de Passi della regolazione del gioco tendurchhands: chaîne de transmission:...
Page 186 FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ INSP FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: 9 Protector 9 Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
Page 187 NETTOYAGE DE BAGUE D’ETANCHETTE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/ DECOMPRESSION INTERNE DE LA FOURCHE AVANT/ REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE LA FOURCHE AVANT REINIGUNG DER ÖLDICHTUNG UND STAUBDICHTUNG DER VORDERRADGABEL/ VORDERRADGABEL-INNENDRUCKENTLASTUNG/ INSP EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL PULITURA DEL PARAOLIO E DEL PARAPOLVERE DELLA FORCELLA ANTERIORE/ COMPENSAZIONE DELLA PRESSIONE INTERNA DELLA FORCELLA ANTERIORE/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELLA FORCELLA ANTERIORE...
Page 188 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) 9 STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
Page 189 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP EINSTELLUNG DER KOMPRESSIONS-DÄMPFUNGSKRAFT DER VORDERRADGABEL REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELLA COMPRES- SIONE DELLA FORCELLA ANTERIORE Ampiezza della Einstellumfang: Etendue de réglage: regolazione: Maximum Minimum Maximum Minimum Massima Minima Voll 20 Raststellungen...
Page 190: Rear Shock Absorber Inspection
INSP REAR SHOCK ABSORBER INSPECTION Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) 9 STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
Page 191 VERIFICATION DE L’AMORTISSEUR ARRIERE INSP INSPEKTION DES HINTERRAD-STOSSDÄMPFERS ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE Ampiezza della Einstellumfang: Etendue de réglage: regolazione: Maximum Minimum Maximum Minimum Massima Minima Voll 20 Raststellungen Position 20 le mettre hors Posizione 20 scatti in senso hineingedrehten herausdrehen complètement circuit (à...
Page 192 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: 9 Rear frame 3. Loosen: 9 Locknut 1 4. Adjust: 9 Spring preload By turning the adjuster 2.
Page 193 REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERVORSPANNUNG DES HINTERRAD-STOSSDÄMPFERS INSP REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE IC36M014 REGLAGE PRECON- EINSTELLUNG DER FEDERVOR- REGOLAZIONE DEL PRECARICO TRAINTE RESSORT SPANNUNG HINTERRAD- DELLA MOLLA DELL’AMMOR- L’AMORTISSEUR ARRIERE STOSSDÄMPFERS TIZZATORE POSTERIORE 1.
Page 194 REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: 9 Rebound damping force By turning the adjuster 1. Stiffer a a ¡ Increase the rebound damping force. (Turn the adjuster 1 1 in.) Softer b b ¡...
Page 195 REGLAGE DE LA FORCE D’AMORTISSEMENT DE REBOND DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER EXPANSIONS-DÄMPFUNGSKRAFT DES INSP HINTERRAD-STOSSDÄMPFERS REGOLAZIONE DELLA FORZA DI SMORZAMENTO DELL’ESTENSIONE DELL’AMMORTIZZATORE POSTERIORE IC36N020 REGLAGE FORCE EINSTELLUNG DER EXPANSIONS- REGOL‹ELLA FORZA DI SMOR- D’AMORTISSEMENT DÄMPFUNGSKRAFT DES HINTER- ZAMENTO DELL’ESTENSIONE REBOND DE L’AMORTISSEUR RAD-STOSSDÄMPFERS D E L L ’...
Page 196 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9 Low compression damping force By turning the adjuster 1. Stiffer a a ¡ Increase the low compression damping force. (Turn the ad- juster 1 1 in.) Softer b b ¡...
Page 197 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION BASSE DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER NIEDRIGEN KOMPRESSIONS-DÄMPFUNGSKRAFT DES HINTERRADSTOSSDÄMPFFRS INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO A BASSA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE IC36c000 REGLAGE FORCE EINSTELLUNG NIEDRIGEN REGOLAZIONE DELLA FORZA D’AMORTISSEMENT DE COM- KOMPRESSIONS-DÄMPFUNGS- DI SMORZAMENTO A BASSA PRESSION BASSE DE L’AMOR- KRAFT...
Page 198 REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9 High compression damping force By turning the adjuster 1. Stiffer a a ¡ Increase the high compression damping force. (Turn the ad- juster 1 1 in.) Softer b b ¡...
Page 199 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION ELEVEE DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER HOHEN KOMPRESSIONS-DÄMPFUNGSKRAFT DES HINTERRADSTOSSDÄMPFFRS INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO AD ALTA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE IC36d000 REGLAGE FORCE EINSTELLUNG DER HOHEN KOM- REGOLAZIONE DELLA FORZA D’AMORTISSEMENT DE COM- PRESSIONS-DÄMPFUNGSKRAFT DI SMORZAMENTO AD ALTA PRESSION ELEVEE DE L’AMOR-...
Page 200 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q001 TIRE PRESSURE CHECK 1. Measure: 9 Tire pressure Out of specification ¡ Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: 9 Check the tire while it is cold. 9 Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
Page 201 CONTROLE DE PRESSION DES PNEUS/VERIFICATION ET SERRAGE DES RAYONS/VERIFICATION DE LA ROUE PRÜFUNG DES REIFENDRUCKS/INSPEKTION UND FESTZIEHEN DER INSP SPEICHEN/INSPEKTION DES RADES CONTROLLO DELLA PRESSIONE DEGLI PNEUMATICI/ ISPEZIONE E SERRAGGIO DEI RAGGI/ ISPEZIONE DELLE RUOTE IC36Q001 CONTROLE DE PRESSION DES PRÜFUNG DES REIFENDRUCKS CONTROLLO DELLA PRESSIONE PNEUS...
Page 202 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: 9 Bearing free play Exist play ¡ Replace. EC36U014 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9 Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth.
Page 203 VERIFICATION ET REGLAGE DE LA TETE DE FOURCHE INSP INSPEKTION UND EINSTELLUNG DES LENKERKOPFES ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO 2. Examiner: 2. Ispezionare: 2. Prüfen: 9 Jeu de roulement 9 Gioco del cuscinetto 9 Lagerspiel Ily a du jeu ¡ Changer. Esiste gioco ¡...
Page 204 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 38 Nm (3.8 m•kg, 27ft•lb) 9 Loosen the ring nut one turn. 9 Retighten the ring nut using the ring nut wrench. Avoid over-tightening. Ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) 9 Check the steering shaft by turning it lock to lock.
Page 205 VERIFICATION ET REGLAGE DE LA TETE DE FOURCHE INSP INSPEKTION UND EINSTELLUNG DES LENKERKOPFES ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Clé pour écrou annulaire: Ringmutterschlüssel: Chiave per ghiera: YU-33975/90890-01403 YU-33975/90890-01403 YU-33975/90890-01403 Ecrou annulaire (serrage Ghiera Ringmutter initial): (serraggio iniziale): (anfängliches 38 Nm (3,8 m•kg, 27 ft•lb) 38 Nm (3,8 m•kg, 27 ft•lb)
Page 206 INSP LUBRICATION EC36a042 LUBRICATION Å Use Yamaha cable lube or equivalent on To ensure smooth operation of all components, these areas. lubricate your machine during setup, after break- ı Use SAE10W-30 motor oil or suitable chain in, and after every race.
Page 207 9 Gasseilende 0 Estremità del cavo della frizione 0 Extrémités des câbles d’embrayage 0 Kupplungsseilenden A Usare lubrificante per cavi Yamaha o A Mettre du lubrifiant Yamaha pour A Yamaha Seilung-Schmiermittel oder equivalente su queste zone. câbles, ou équivalent sur ces parties.
Page 208: Electrical
INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: 9 Spark plug 2. Inspect: 9 Electrode 1 Wear/Damage ¡ Replace. 9 Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color ¡ Check the engine condition.
Page 209: Moteur
PARTIE ELECTRIQUE/VERIFICATION DE LA BOUGIE INSP ELEKTRISCHE EINRICHTUNGEN/INSPEKTION DER ZÜNDKERZE PARTE ELETTRICA/ ISPEZIONE DELLA CANDELA IC370000 PARTIE ELECTRIQUE ELEKTRISCHE PARTE ELETTRICA VERIFICATION DE LA BOUGIE EINRICHTUNGEN IC371001 1. Déposer: ISPEZIONE DELLA CANDELA INSPEKTION DER ZÜNDKERZE 9 Bougie 1. Togliere: 1. Ausbauen: 2.
Page 210 INSP IGNITION TIMING CHECK EC372012 IGNITION TIMING CHECK 1. Remove: 9 Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 9 Spark plug 9 Crankcase cover (left) 2. Attach: 9 Dial gauge 1 9 Spark plug hole dial stand 2 Dial gauge: YU-3097/90890-01252 Spark plug hole dial stand:...
Page 211 CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE IC372012 CONTROLE ET REGLAGE DE PRÜFUNG EINSTELLUNG CONTROLLO DELLA MESSA IN L’AVANCE A L’ALLUMAGE DER ZÜNDZEITPUNKT FASE DELL’ACCENSIONE 1. Déposer: 1. Ausbauen: 1.
Page 212 INSP IGNITION TIMING CHECK 7. Adjust: 9 Ignition timing Adjustment steps: 9 Loosen the screws (stator) 1. 9 Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator. 9 Tighten the screws (stator). Screw (stator): 8 Nm (0.8 m•kg, 5.8 ft•lb) 3-40...
Page 213 CONTROLE ET REGLAGE DE L’AVANCE A L’ALLUMAGE INSP PRÜFUNG UND EINSTELLUNG DER ZÜNDZEITPUNKT CONTROLLO DELLA MESSA IN FASE DELL’ACCENSIONE 7. Régler: 7. Regolare: 7. Einstellen: 9 Avance à l’allumage 9 Messa in fase dell’accensione 9 Zündzeitpunkt Procédure de réglage: Passi della regolazione: Einstellschritte: 9 Desserrer les vis (stator) 1.
Page 214 SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 19 Nm (1.9 m•kg, 13 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 215 SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX SITZ, KRAFTSTOFFTANK UND SEITENDECKEL SELLA, SERBATOIO DEL CARBURANTE E COPERTURE LATERALI MOTEUR SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX 1 Dépose du selle 2 Dépose du réservoir à essence Etendue de dépose: 3 Dépose des couvercles latéraux 4 Dépose de la plaque d’immatriculation Etendue de dépose Ordre...
Page 216 SEAT, FUEL TANK AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413110 Side cover 1. Remove: 9 Bolt (side cover) 9 Side cover (left and right) 1 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case.
Page 217 SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX SITZ, KRAFTSTOFFTANK UND SEITENDECKEL SELLA, SERBATOIO DEL CARBURANTE E COPERTURE LATERALI IC4R3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC413110 Couvercle latéral Seitendeckel Copertura laterale 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (couvercle latéral) 9 Bullone (copertura laterale) 9 Schraube (seitendeckel) 9 Couvercle latéral (gauche et...
Page 218: Exhaust Pipe And Silencer
EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 11 Nm (1.1 m•kg, 8.0 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 1 Silencer removal 2 Exhaust pipe removal Extent of removal:...
Page 219: Tubo Di Scarico E Silenziatore
TUYAU D’ECHAPPEMENT ET SILENCIEUX AUSPUFFROHR UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUYAU D’ECHAPPEMENT ET SILENCIEUX 1 Dépose du silencieux 2 Dépose du tuyau déchappement Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU TUYAU DéCHAPPEMENT ET DU SILENCIEUX Préparation...
Page 220: Radiator
RADIATOR EC450001 RADIATOR 1 Nm (0.1 m•kg, 0.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Radiator removal Extent of removal: Extent of removal Order...
Page 221 RADIATEUR KÜHLER RADIATORE RADIATEUR 1 Dépose du radiateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU RADIATEUR Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU Préparation LIQUIDE DE REFROIDISSEMENT” du pour la dépose CHAPITRE 3.
Page 222 RADIATOR EC456000 HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counter-...
Page 223 RADIATEUR KÜHLER RADIATORE IC456000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA MANIPULATION Wenn der Motor und der Kühler Non togliere il tappo del radiatore heiß sind, darf niemals der Künler- quando il motore e il radiatore sono deckel entfernt werden. Brühend caldi.
Page 224 RADIATOR EC455000 ASSEMBLY AND INSTALLATION EC445353 Radiator 1. Install: 9 Radiator breather hose 1 9 Radiator hose 2 2 1 Nm (0.1 m•kg, 0.7 ft•lb) To radiator (right) 3. 2. Install: 9 Radiator (right) 1 9 Bolt [radiator (right)] 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Radiator hose 4 3 1 Nm (0.1 m•kg, 0.7 ft•lb)
Page 225 RADIATEUR KÜHLER RADIATORE IC455000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Kühler MONTAGE INSTALLAZIONE 1. Einbauen: Radiateur IC445353 9 Kühler-Belüftungsschlauch 1 1. Monter: Radiatore 9 Kühlerschlauch 2 2 9 Tuyau de reniflard de radiateur 1. Installare: 9 Sfiato del radiatore 1 1 Nm (0,1 m•kg, 0,7 ft•lb) 9 Tuyau de radiateur 2 2 9 Manicotto flessibile del radiato-...
Page 226: Carburetor And Reed Valve
CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Carburetor removal 2 Reed valve removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR AND REED VALVE REMOVAL Preparation for Fuel tank...
Page 227: Vergaser Und Zungenventil
CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA CARBURATEUR ET SOUPAPE FLEXIBLE 1 Dépose du carburateur 2 Dépose de la soupape flexible Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU CARBURATEUR ET DE LA SOUPAPE FLEXIBLE Préparation Réservoir à...
Page 228 CARBURETOR AND REED VALVE EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Refer to “REMOVAL POINTS”. Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet...
Page 229 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA DEMONTAGE DU CARBURATEUR 1 Démontage du carburateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DU CARBURATEUR Haut de chambre de mélange Boisseau Se reporter à...
Page 230 CARBURETOR AND REED VALVE EC466020 HANDLING NOTE Do not loosen the screws {TPS (throttle position sensor)} except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1.
Page 231 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC466020 HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO REMARQUES CONCERNANT LA MANIPULATION Schrauben des TPS-Leitungskabels Non allentare le viti [conduttore TPS (Drosselstellungssensor) nur dann (sensore di posizione gas)] se non per lösen wenn das TPS-Leitungskabel cambiare il conduttore TPS (sensore Ne pas desserrer les vis du fil du cap-...
Page 232 CARBURETOR AND REED VALVE EC464000 INSPECTION EC464130 Carburetor 1. Inspect: 9 Carburetor body Contamination ¡ Clean. NOTE: 9 Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. 9 Never use a wire. 2.
Page 233 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464000 VERIFICATION INSPEKTION ISPEZIONE IC464130 Carburateur Vergaser Carburatore 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Corps du carburateur 9 Corpo del carburatore 9 Vergasergehäuse Contaminazione ¡ Pulirlo. Encrassé¡Nettoyer. Verschmutzung¡Reinigen.
Page 234 CARBURETOR AND REED VALVE EC464401 Jet needle 1. Inspect: 9 Jet needle 1 Bends/Wear ¡ Replace. 9 Clip groove Free play exists/Wear ¡ Replace. 9 Clip position Standard clip position: No.2 Groove *No.3 Groove *For EUROPE EC464511 Float height 1. Measure: 9 Float height a Out of specification ¡...
Page 235 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464401 Aiguille Ago a getto Düsennadel 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Aiguille 1 9 Ago a getto 1 9 Düsennadel 1 Déformée/usure¡Changer. Curvature/Usura¡Sostituirlo. Biegung/Verschleiß¡Erneu- 9 Groove du circlips 9 Scanalatura del fermaglio a ern.
Page 236 CARBURETOR AND REED VALVE EC464600 Float 1. Inspect: 9 Float 1 Damage ¡ Replace. EC464701 Reed valve 1. Measure: 9 Reed valve bending a Out of specification ¡ Replace. Reed valve bending limit: 0.2 mm (0.008 in) 9 Valve stopper height b Out of specification ¡...
Page 237 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA IC464600 Flotteur Galleggiante Schwimmer 1. Examiner: 1. Ispezionare 1. Prüfen: 9 Flotteur 1 9 Galleggiante 1 9 Schwimmer 1 Endommagement¡Changer. Danni¡Sostituirlo. Beschädigung¡Erneuern. IC464701 Soupape flexible Zungenventil Valvola a lamella 1.
Page 238 CARBURETOR AND REED VALVE 2. Install: 9 Gasket (reed valve) 1 9 Plate (reed valve) 2 9 Reed valve assembly 3 9 Reed valve spacer 4 NOTE: 9 Install the gasket (reed valve) with its projection a to the left. 9 Install the reed valve spacer with its chamfered side b to the right.
Page 239 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Monter: 2. Installare: 2. Einbauen: 9 Guarnizione (valvola a lamella) 9 Joint (soupape flexible) 1 9 Dichtung (Zungenventil) 9 Plaquette (soupape flexible) 2 9 Distanziale (valvola a lamella) 9 Ens.
Page 240 CARBURETOR AND REED VALVE 2. Install: 9 O-ring 1 9 Solenoid valve 2 9 Clamp 3 9 Screw (clamp) 4 To carburetor 5. 9 Before installing the solenoid valve, blow air on the solenoid valve and its installing location on the carburetor in order to remove any foreign particles such as chips etc.
Page 241 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Monter: 2. Installare: 2. Einbauen: 9 Joint torique 1 9 Anello di tenuta 1 9 O-Ring 1 9 Electrovanne 2 9 Elettrovalvola 2 9 Magnetventil 2 9 Bride 3 9 Brida 3 9 Klemme 3 9 Vis (bride) 4...
Page 242 CARBURETOR AND REED VALVE 6. Install: 9 Needle valve 1 9 Float 2 9 Float pin 3 NOTE: 9 After installing the needle valve to the float, install them to the carburetor. 9 Check the float for smooth movement. 7. Install: 9 Float chamber 1 9 Plate 2 9 Screw (float chamber) 3...
Page 243 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 6. Monter: 6. Installare: 6. Einbauen: 9 Pointeau 1 9 Valvola ad ago 1 9 Nadelventil 1 9 Flotteur 2 9 Galleggiante 2 9 Schwimmer 2 9 Axe de flotteur 3 9 Perno del galleggiante 3 9 Schwimmerstift 3 HINWEIS:...
Page 244 CARBURETOR AND REED VALVE 10. Install: 9 Throttle cable 1 9 Mixing chamber top 2 9 Spring (throttle valve) 3 9 Ring 4 9 Throttle valve 5 NOTE: 9 While compressing the spring, connect the throttle cable. 9 Align the projection a on the ring with the groove b in the needle holder 6.
Page 245 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 10. Monter: 10. Installare: 10. Einbauen: 9 Câble d’accélérateur 1 9 Cavo dell’acceleratore 1 9 Gasseil 1 9 Haut de chambre de mélange 2 9 Parte superiore del diffusore 2 9 Mischkammer-Oberteil 2 9 Ressort (boisseau) 3 9 Molla (valvola regolatrice del...
Page 246 CARBURETOR AND REED VALVE 2. Tighten: 9 Screw (carburetor joint) 1 3. Tighten: 9 Screw (air cleaner joint) 1 NOTE: Place the screw head a with its top as shown and secure the clamp in alignment with the hori- zontal line b that passes the center of the car- buretor bore.
Page 247 CARBURATEUR ET SOUPAPE FLEXIBLE VERGASER UND ZUNGENVENTIL CARBURATORE E VALVOLA A LAMELLA 2. Serrer: 2. Serrare: 2. Festziehen: 9 Vis (raccord du carburateur ) 1 9 Vite (giunto del carburatore) 1 9 Schraube (Vergaserverbin- dung) 1 3. Serrer: 3. Festziehen: 3.
Page 248: Cylinder Head , Cylinder And Piston
CYLINDER HEAD, CYLINDER AND PISTON EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER 34 Nm (3.4 m•kg, 24 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb)
Page 249 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE CULASSE, CYLINDRE ET PISTON CULASSE ET CYLINDRE 1 Dépose de la culasse 2 Dépose du cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA CULASSE ET DU CYLINDRE...
Page 250 CYLINDER HEAD, CYLINDER AND PISTON EC478100 PISTON AND POWER VALVE 6 Nm (0.6 m•kg, 4.3 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Piston and piston ring removal 2 Power valve removal Extent of removal:...
Page 251 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE PISTON ET CLAPET DE PUISSANCE 1 Dépose du piston et segment 2 Dépose du clapet puissance Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU PISTON ET CLAPET DE PUISSANCE...
Page 252 CYLINDER HEAD, CYLINDER AND PISTON EC473000 REMOVAL POINTS EC473220 Push rod 1. Remove: 9 Bolt (push rod) 1 9 Push rod 2 NOTE: Insert the set pin 3 included in owner’s tool kit to remove the bolt (push rod). Be sure to use the set pin. If the set pin is not used, the power valve constituent parts will result in damage.
Page 253 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC473000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC473220 Champignon de débrayage Schubstange Asta di spinta 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (champignon de débra- 9 Bullone (asta di spinta) 1 9 Schraube (Schubstange) 1 yage) 1...
Page 254 CYLINDER HEAD, CYLINDER AND PISTON 3. Remove: 9 Piston ring 1 NOTE: Take care not to scratch the piston or damage the piston ring by expanding it more than neces- sary. EC474000 INSPECTION EC474102 Cylinder head 1. Eliminate: 9 Carbon deposits Use a rounded scraper 1.
Page 255 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Déposer: 3. Ausbauen: 3. Togliere: 9 Segment 1 9 Fascia elastica 1 9 Kolbenring 1 HINWEIS: N.B.: NOTA: Veillez à ne pas rayer le piston et à ne Darauf achten, den Kolben nicht zu Attenzione a non graffiare il pistone o endommager...
Page 256 CYLINDER HEAD, CYLINDER AND PISTON EC474201 Cylinder 1. Eliminate: 9 Carbon deposits Use a rounded scraper 1. NOTE: Do not use a sharp instrument. Avoid scratching the aluminum. 2. Inspect: 9 Cylinder inner surface Score marks ¡ Repair or replace. Use #400~600 grit wet sandpaper.
Page 257 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474201 Zylinder Cilindro Cylindre 1. Entfernen: 1. Eliminare: 1. Éliminer: 9 Ölkohleablagerungen 9 Depositi carboniosi 9 Dépôts du carbone Utiliser le grattoir arrondi 1. Einem abgerundeten Schaber Usare un raschietto arrotondato verwenden 1.
Page 258 CYLINDER HEAD, CYLINDER AND PISTON 3. Measure: 9 Piston skirt diameter Use micrometer 1. Measure the specific distance b from the stepped surface a on inside of the piston. Out of specification ¡ Replace. Distance b b Piston dia. 17.5 mm 66.352~66.367 mm (0.69 in) (2.6120~2.6129 in)
Page 259 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Mesurer: 3. Messen: 3. Misurare: 9 Diamètre de la jupe de piston 9 Diametro della fascia di guida 9 Durchmesser des Kolbenman- Utiliser le micromètre 1. tels del pistone Usare un micrometro 1.
Page 260 CYLINDER HEAD, CYLINDER AND PISTON 5. Check: 9 Free play There should be no noticeable free play. Free play exists ¡ Inspect the connecting rod for wear/Replace the pin and/or con- necting rod as required. EC474502 Piston ring 1. Install: 9 Piston ring Into the cylinder.
Page 261 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 5. Prüfen: 5. Contrôler: 5. Controllare: 9 Spiel 9 Jeu 9 Gioco Es sollte kein spürbares Spiel Il ne doit pas y avoir de jeu Non dovrebbe esservi gioco sein.
Page 262 CYLINDER HEAD, CYLINDER AND PISTON EC474602 Piston clearance 1. Calculate: 9 Piston clearance Out of limit ¡ Replace piston, and piston ring and/or cylinder. Refer to “Cylinder” and “Piston”. PISTON CYLINDER PISTON – CLEARANCE BORE DIAMETER Piston clearance: Standard <Limit> 0.045~0.050 mm 0.1 mm (0.0018~0.0020 in)
Page 263 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC474602 Jeu de piston Gioco del pistone Kolbenspiel 1. Calculer: 1. Calcolare 1. Berechnen: 9 Jeu de piston 9 Gioco del pistone 9 Kolbenspiel Hors limite¡Changer le piston, Fuori limite¡Sostituire il pisto- Außerhalb des Grenzwertes ¡Kolben,...
Page 264 CYLINDER HEAD, CYLINDER AND PISTON 3. Combination: Combine the piston and cylinder by the fol- lowing chart. Cylinder mark Piston mark (color) A (red) B (orange) C (green) D (purple) NOTE: When you purchase a cylinder, you cannot des- ignate its size. Choose the piston that matches the above chart.
Page 265 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Combinaison: 3. Kombination: 3. Combinazione: Combiner le piston et le cylindre à Kolben Zylinder gemäß Combinare il pistone e il cilindro l’aide du tableau suivant. nachfolgender Tabelle kombinie- in base alla tabella che segue.
Page 266 CYLINDER HEAD, CYLINDER AND PISTON EC475000 ASSEMBLY AND INSTALLATION EC475193 Power valve 1. Install: 9 Power valve 1 1 9 Valve holder 2 2 9 Bolt (valve holder 2) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: 9 Install the power valve 1 with its gouge a fac- ing upside.
Page 267 CULASSE, CYLINDRE ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE IC475000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Leistungsventil MONTAGE INSTALLAZIONE 1. Einbauen: Clapet de puissance IC475193 9 Leistungsventil 1 1 1. Monter: Valvola di potenza 9 Ventilhalterung 2 2 9 Clapet de puissance 1 1 1.
Page 268 CYLINDER HEAD, CYLINDER AND PISTON 4. Install: 9 Spring 1 1 9 Link lever 2 9 Pulley 3 9 Spring 2 4 9 Plain washer 5 9 Valve shaft 6 NOTE: 9 Install the spring 1 to the link lever, and then to the cylinder.
Page 269 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 4. Monter: 4. Einbauen: 4. Installare: 9 Ressort 1 1 9 Molla 1 1 9 Feder 1 1 9 Levier articulé 2 9 Leva del biscottino 2 9 Verbindungshebel 2 9 Poulie 3 9 Puleggia 3...
Page 270 CYLINDER HEAD, CYLINDER AND PISTON 7. Install: 9 O-ring 1 9 Side holder 2 9 Screw (side holder) 3 4 Nm (0.4 m•kg, 2.9 ft•lb) 9 YPVS breather hose 4 NOTE: 9 Apply the lithium soap base grease on the O- rings.
Page 271 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 7. Monter: 7. Einbauen: 7. Installare: 9 Joint torique 1 9 Anello di tenuta 1 9 O-ring 1 9 Béquille latérale 2 9 Supporto laterale 2 9 Seitenhalterung 2 9 Vis (béquille latérale) 3 9 Vite (supporto laterale) 3 9 Schraube (Seitenhalterung) 3...
Page 272 CYLINDER HEAD, CYLINDER AND PISTON 3. Install: 9 Piston 1 9 Piston pin 2 9 Piston pin clip 3 NOTE: 9 The arrow a on the piston dome must point to exhaust side. 9 Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the pis- ton pin clip from falling into the crankcase cavi- Do not allow the clip open ends to meet the...
Page 273 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 3. Monter: 3. Ausbauen: 3. Installare: 9 Piston 1 9 Pistone 1 9 Kolben 1 9 Axe de piston 2 9 Spinotto 2 9 Kolbenbolzen 2 9 Agrafe de l’axe de piston 3 9 Fermaglio a graffa dello spinot- 9 Klemme des Kolbenbolzens 3 to 3...
Page 274 CYLINDER HEAD, CYLINDER AND PISTON 4. Install: 9 Push rod 1 9 Bolt (push rod) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) NOTE: 9 Insert the set pin 3 included in owner’s tool kit to install the bolt (push rod). 9 Do not forget to remove the set pin.
Page 275 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 4. Monter: 4. Installare: 4. Einbauen: 9 Champignon de débrayage 1 9 Asta di spinta 1 9 Schubstange 1 9 Boulon (champignon de débra- 9 Bullone (asta di spinta) 2 9 Schraube (Schubstange) 2 yage) 2 5 Nm (0,5 m•kg, 3,6 ft•lb)
Page 276 CYLINDER HEAD, CYLINDER AND PISTON 8. Install: 9 Engine bracket 1 9 Bolt (engine bracket) 2 34 Nm (3.4 m•kg, 24 ft•lb) 9 Engine mounting bolt (upper) 3 69 Nm (6.9 m•kg, 50 ft•lb) NOTE: Install the engine bracket with its damper a on the right side of the body.
Page 277 CULASSE, CYLINDER ET PISTON ZYLINDERKOPF, ZYLINDER UND KOLBEN TESTA CILINDRO, CILINDRO E PISTONE 8. Installare: 8. Einbauen: 8. Monter: 9 Staffa del motore 1 9 Motorhalterung 1 9 Support du moteur 1 9 Bullone (staffa del motore 2 9 Schraube (Motorhalterung) 2 9 Boulon (support du moteur) 2 34 Nm (3,4 m•kg, 24 ft•lb) 34 Nm (3,4 m•kg, 24 ft•lb)
Page 278: Clutch And Primary Driven Gear
CLUTCH AND PRIMARY DRIVEN GEAR EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Clutch plate and friction plate removal Extent of removal: Extent of removal Order Part name Q’ty...
Page 279 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO EMBRAYAGE ET PIGNON MENE PRIMAIRE DISQUE D’EMBRAYAGE ET DISQUE DE FRICTION 1 Dépose du disque d’embrayage et du disque de friction Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 280 CLUTCH AND PRIMARY DRIVEN GEAR EC498200 PRIMARY DRIVEN GEAR, PUSH ROD AND PUSH LEVER AXLE 75 Nm (7.5 m•kg, 54 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 1 Push rod and push lever axle removal 2 Push rod 1 disassembly Extent of removal: 3 Primary driven gear removal Extent of removal...
Page 281 EMBRAYAGE ET PISGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO PIGNON MENE PRIMAIRE, CHAMPINGNON DE DEBRAYAGE ET AXE DE LEVIER DE POUSSE 1 Dépose de champignon de débrayage et de l’axe de levier de poussé Etendue de dépose: 2 Demontage de champignon de débrayage 1 3 Dépose du pignon mené...
Page 282 CLUTCH AND PRIMARY DRIVEN GEAR å å EC493000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: 9 Nut 1 9 Lock washer 2 9 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. ∫...
Page 283 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC493000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC483211 Noix d’embrayage Kupplungsnabe Mozzo della frizione 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou 1 9 Dado 1 9 Mutter 1 9 Rondelle-frein 2 9 Rosetta di sicurezza 2...
Page 284 CLUTCH AND PRIMARY DRIVEN GEAR EC484500 Friction plate 1. Measure: 9 Friction plate thickness Out of specification ¡ Replace friction plate as a set. Measure at all four points. Friction plate thickness: Standard <Limit> 2.9~3.1 mm 2.8 mm (0.114~0.122 in) (0.110 in) EC484600 Clutch plate...
Page 285 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC484500 Disque de friction Disco di innesto Reibscheibe 1. Mesurer: 1. Misurare: 1. Messen: 9 Epaisseur de disque de friction 9 Spessore del disco di innesto 9 Reibscheibendicke Hors-spécification¡...
Page 286 CLUTCH AND PRIMARY DRIVEN GEAR EC495230 Clutch 1. Install: 9 Thrust plate [D=ø 42 mm (1.65 in)] 1 9 Spacer 2 9 Bearing 3 9 Primary driven gear 4 NOTE: Apply the transmission oil on the bearing, spacer and primary driven gear inner circumference. 2.
Page 287 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO IC495230 Embrayage Frizione Kupplung 1. Monter: 1. Installare: 1. Einbauen: 9 Plaque de botée [D=ø42mm 9 Disco di spinta [D=ø42 mm 9 Druckscheibe [D=ø42 (1,65 in)] 1 (1,65 in)] 1 (1,65 in)] 1 9 Entretoise 2...
Page 288 CLUTCH AND PRIMARY DRIVEN GEAR 5. Install: 9 Friction plate 1 9 Clutch plate 2 NOTE: 9 Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate. 9 Apply the transmission oil on the friction plates and clutch plates.
Page 289 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 5. Monter: 5. Installare: 5. Einbauen: 9 Disque de friction 1 9 Disco di innesto 1 9 Reibscheibe 1 9 Disque d’embrayage 2 9 Disco della frizione 2 9 Kupplungsscheibe 2 HINWEIS: N.B.:...
Page 290 CLUTCH AND PRIMARY DRIVEN GEAR 10. Install: 9 O-ring 1 To clucth cover. 11. Install: 9 Clutch cover 1 9 Bolt (clutch cover) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 12.
Page 291 EMBRAYAGE ET PIGNON MENE PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD FRIZIONE E INGRANAGGIO CONDOTTO PRIMARIO 10. Monter: 10. Installare: 10. Einbauen: 9 Joint torique 1 9 Anello di tenuta 1 9 O-Ring 1 Vers le couvercle d’embrayage. Verso la protezione della frizio- Zum Kupplungsdeckel.
Page 292: Kick Axle, Shift Shaft And Primary Drive Gear
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C0000 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Primary drive gear removal Extent of removal: Extent of removal Order...
Page 293 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE PIGNON DE TRANSMISSION PRIMAIRE 1 Dépose du pignon de transmission primaire Etendue de dépose: Etendue de dépose...
Page 294: Kick Axle And Shift Shaft
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8100 KICK AXLE AND SHIFT SHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Kick axle and kick idle gear removal Extent of removal: 2 Shift shaft and stopper lever removal Extent of removal...
Page 295 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO AXE DE DEMARREUR AU PIED ET ARBRE DE SELECTEUR 1 Dépose de l’axe de démarreur au pied et du pignon de renvoi de démarreur au pied Etendue de dépose: 2 Dépose de l’arbre de sélecteur et du levier de butée Etendue de dépose...
Page 296 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C3000 REMOVAL POINTS EC483111 Primary drive gear 1. Loosen: 9 Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3. EC4B3101 Kick axle assembly 1.
Page 297 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC483111 Ingranaggio conduttore primario Pignon de transmission primaire Primärantriebszahnrad 1.
Page 298 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C4300 Kick gear, kick idle gear and ratchet wheel 1. Inspect: 9 Kick gear 1 9 Kick idle gear 2 9 Ratchet wheel 3 9 Gear teeth a 9 Ratchet teeth b Wear/Damage ¡...
Page 299 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C4300 Pignon de démarreur au pied, pignon Ingranaggio della pedivella ingranag- Kickstarterzahnrad, Kickstarter- gio folle della pedivella e ruota a cric- de renvoi de démarreur au pied et Zwischenzahnrad und Sperrad roue à...
Page 300 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130 Stopper lever 1. Install: 9 Tension spring 1 9 Holder 2 9 Bolt (holder) 3 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Plain washer 4 9 Stopper lever 5 9 Bolt (stopper lever) 6 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE:...
Page 301 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C5000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E INSTALLAZIONE MONTAGE IC4C5130 Leva di fermo Levier de butée Anschlaghebel 1.
Page 302 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Install: 9 Bolt (shift guide) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4C5310 Shift shaft 1. Install: 9 Roller 1 9 Plain washer 2 9 Shift shaft 3 NOTE: Apply the transmission oil on the roller and shift shaft.
Page 303 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 4. Monter: 4. Installare: 4. Einbauen: 9 Boulon (guide de sélecteur) 1 9 Bullone (guida del cambio) 1 9 Schraube (Schaltführung) 1 10 Nm (1,0 m•kg, 7,2 ft•lb) 10 Nm (1,0 m•kg, 7,2 ft•lb)
Page 304 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 3. Install: 9 Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4.
Page 305 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO 3. Monter: 3. Installare: 3. Einbauen: 9 Guide de ressort 1 9 Guida della molla 1 9 Federführung 1 N.B.: HINWEIS:...
Page 306 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5531 Primary drive gear 1. Install: 9 Thrust plate 1 9 Primary drive gear 2 9 Governor drive gear 3 9 Plain washer 4 9 Bolt (primary drive gear) 5 NOTE: 9 Install the plain washer with its chamfered side a toward you.
Page 307 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE PRIMARIO IC4C5531 Ingranaggio conduttore primario Pignon de transmission primaire Primärantriebszahnrad 1. Installare: 1. Monter: 1. Einbauen: 9 Plaque de butée 1 9 Disco di spinta 1 9 Druckscheibe 1...
Page 308 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 6. Install: 9 Bolt [crankcase cover (right)] 1 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 7. Install: 9 Kick starter 1 9 Plain washer 2 9 Bolt (kick starter) 3 30 Nm (3.0 m•kg, 22 ft•lb) NOTE:...
Page 309 AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION PRIMAIRE KICKSTARTERWELLE, SCHALTWELLE UND PRIMÄRANTRIEBSZAHNRAD PEDIVELLA, ALBERO DEL CAMBIO E INGRANAGGIO CONDUTTORE 6. Monter: 6. Installare: 6. Einbauen: 9 Boulon [couvercle de carter 9 Bullone [copertura del carter 9 Schraube (destra)] 1 (droit)]1...
Page 310: Ypvs Governor
YPVS GOVERNOR EC4K0000 YPVS GOVERNOR 5 Nm (0.5 m•kg, 3.6 ft•lb) 1 YPVS governor removal and disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks YPVS GOVERNOR REMOVAL Preparation for Crankcase cover (right) Refer to “KICK AXLE, SHIFT SHAFT AND removal PRIMARY DRIVE GEAR”...
Page 311: Regulateur Ypvs
REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS REGULATEUR YPVS 1 Dépose et démontage du régulateur YPVS Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU REGULATEUR YPVS Préparation pour la dépose Couvercle de carter (droit) Se reporter à la section “AXE DE DEMARREUR AU PIED, ARBRE DE SELECTEUR ET PIGNON DE TRANSMISSION”.
Page 312 YPVS GOVERNOR EC4K3000 REMOVAL POINTS EC4K3100 Governor 1. Remove: 9 Dowel pin 1 NOTE: While compressing the spring, remove the dowel pin. EC4K4000 INSPECTION EC4K4100 Governor groove 1. Inspect: 9 Plain washer 1 9 Collar 2 Wear/Damage ¡ Replace. EC4K4200 Bearing 1.
Page 313 REGULATEUR YPVS YPVS REGLER REGOLATORE YPVS IC4K3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4K3100 Régulateur Regler Regolatore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Goujon 1 9 Paßstift 1 9 Perno di riferimento 1 N.B.: HINWEIS: NOTA: Déposer le goujon tout en comprimant Die Feder zusammendrüken, und den Togliere il perno di riferimento compri- le ressort.
Page 314 YPVS GOVERNOR 2. Install: 9 Ball 1 9 Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. 3. Install: 9 Dowel pin 1 NOTE: 9 While compressing the spring, install the dowel pin. 9 Make sure the dowel pin fits into the groove a in the retainer.
Page 315 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA 2. Monter: 2. Installare: 2. Einbauen: 9 Bille 1 9 Sfera 1 9 Kugel 1 9 Retenue 2 9 Fermo 2 9 Halter 2 sur l’arbre du régulateur 3. Sull’albero del regolatore 3. Zur Reglerachse 3. N.B.: HINWEIS: NOTA:...
Page 316: Water Pump
WATER PUMP EC4G0000 WATER PUMP 10 Nm (1.0 m•kg, 7.2 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Impeller shaft removal 2 Oil seal removal Extent of removal: Extent of removal Order Part name Q’ty Remarks WATER PUMP DISASSEMBLY...
Page 317: Pompe A Eau
POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA POMPE A EAU 1 Dépose du pignon d’axe de turbine 2 Dépose de bague d’étanchéité Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA POMPE A EAU Préparation pour la dépose Couvercle de carter (droit) Se reporter à...
Page 318 WATER PUMP EC4G3000 REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: 9 Impeller 1 9 Plain washer 2 9 Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE:...
Page 319 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC4G3000 POINTS DE DEPOSE PUNTI DI RIMOZIONE AUSBAUPUNKTE IC4G3110 Axe de turbine Flügelradwelle Albero del girante 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Turbine 1 9 Flügelrad 1 9 Girante 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Axe de turbine 3...
Page 320 WATER PUMP EC444300 Impeller shaft gear 1. Inspect: 9 Gear teeth a Wear/Damage ¡ Replace. EC4H4600 Bearing 1. Inspect: 9 Bearing 1 Rotate inner race with a finger. Rough spot/Seizure ¡ Replace. EC444400 Oil seal 1. Inspect: 9 Oil seal 1 Wear/Damage ¡...
Page 321 POMPE A EAU WASSERPUMPE POMPA DELL’ACQUA IC444300 Pignon d’axe de turbine Ingranaggio dell’albero del girante Flügelradwellenzahnrad 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Dents a 9 Denti dell’ingranaggio a 9 Zähne a Usure/endommagement¡ Usura/Danni¡Sostituirli. Abnutzung/Beschädigung¡ Changer. Erneuern. IC4H4600 Cuscinetto Roulement Lager 1.
Page 322 WATER PUMP EC4G5220 Impeller shaft 1. Install: 9 Impeller shaft 1 NOTE: 9 Take care so that the oil seal lip is not dam- aged or the spring does not slip off its position. 9 When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft.
Page 323 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI IC4G5220 Axe de turbine Flügelradwelle Albero del girante 1. Monter: 1. Einbauen: 1. Installare: 9 Axe de turbine 1 9 Flügelradwelle 1 9 Albero del girante 1 N.B.: HINWEIS: NOTA: 9 Prendre garde à ne pas endommager 9 Darauf achten, daß...
Page 324: Cdi Magneto
CDI MAGNETO EC4L0000 CDI MAGNETO 8 Nm (0.8 m•kg, 5.8 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) 56 Nm (5.6 m•kg, 40 ft•lb) 1 CDI magneto removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for Seat and fuel tank Refer to “SEAT, FUEL TANK AND...
Page 325: Magneto Cdi
MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI MAGNETO CDI 1 Dépose de la magnéto CDI Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA MAGNETO CDI Préparation pour la dépose Selle et réservoir à essence Se reporter à la section “SELLE, RESERVOIR A ESSENCE ET COUVERCLES LATERAUX”.
Page 326 CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1. Remove: 9 Nut (rotor) 1 9 Plain washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: 9 Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it coun- terclockwise.
Page 327 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI IC4L3000 POINTS DE DEPOSE PUNTI DI RIMOZIONE AUSBAUPUNKTE IC4L3102 Rotor Rotor Rotore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou (rotor) 1 9 Mutter (Rotor) 1 9 Dado (rotore) 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 Den Rotor-Haltewerkzeug 3 Utiliser l’outil de poignée de...
Page 328 CDI MAGNETO 2. Install: 9 Woodruff key 1 9 Rotor 2 NOTE: 9 Clean the tapered portions of the crankshaft and rotor. 9 When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b.
Page 329 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI 2. Monter: 2. Installare: 2. Einbauen: 9 Clavette de demi-lune 1 9 Linguetta Woodruff 1 9 Einlegekeil 1 9 Rotor 2 9 Rotore 2 9 Rotor 2 N.B.: HINWEIS: NOTA: 9 Nettoyer la paritie conique de l’extré- 9 Pulire le parti coniche dell’albero a 9 Den Kegeligen Teil des Kurbelwel- mité...
Page 330 CDI MAGNETO 7. Connect: 9 CDI magneto lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 8. Install: 9 Gasket [crankcase cover (left)] 9 Crankcase cover (left) 1 9 Screw [crankcase cover (left)] 2 8 Nm (0.8 m•kg, 5.8 ft•lb) NOTE: Tighten the screws in stage, using a crisscross pattern.
Page 331 MAGNETO CDI CDI-MAGNETZÜNDER MAGNETE CDI 7. Connecter: 7. Collegare: 7. Anschließen: 9 Fil de magnéto CDI 1 9 Conduttore del magnete CDI 1 9 Kabel des CDI-Magnetzünders Se référer au paragraphe “DIA- Consultare la sezione “DIA- GRAMME CHEMINE- GRAMMA DEL PASSAGGIO Siehe Abschnitt „KABELFÜH- MENT DE CABLE”...
Page 332: Engine Removal
ENGINE REMOVAL EC4M0000 ENGINE REMOVAL 85 Nm (8.5 m•kg, 61 ft•lb) 34 Nm (3.4 m•kg, 24 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 75 Nm (7.5 m•kg, 54 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) Extent of removal Order...
Page 333: Depose Du Moteur
DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU MOTEUR Préparation pour la dépose Maintenir la machine en plaçant un Bien soutenir la la machine afin qu’elle ne risque support approprié...
Page 334 ENGINE REMOVAL 85 Nm (8.5 m•kg, 61 ft•lb) 34 Nm (3.4 m•kg, 24 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 69 Nm (6.9 m•kg, 50 ft•lb) 75 Nm (7.5 m•kg, 54 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) 1 Engine removal Extent of removal: Extent of removal...
Page 335: Rimozione Del Motore
DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE 1 Dépose du moteur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques Couvercle de chaîne  Ecrou (pignon d’entraînement)  Rondelle-frein  Se reporter à “POINTS DE DEPOSE”. ...
Page 336 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: 9 Nut (drive sprocket) 1 9 Lock washer 2 NOTE: 9 Straighten the lock washer tab. 9 Loosen the nut while applying the rear brake. 2. Remove: 9 Drive sprocket 1 9 Drive chain 2 NOTE: Remove the drive sprocket together with the...
Page 337 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE IC4M3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4F3100 Pignon d’entraînement Antriebskettenrad Rocchetto conduttore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Ecrou (pignon d’entraînement) 1 9 Mutter (Antriebskettenrad) 1 9 Dado (rocchetto conduttore) 1 9 Rondelle-frein 2 9 Sicherungsscheibe 2 9 Rosetta di sicurezza 2...
Page 338 ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION EC4M5124 Engine installation 1. Install: 9 Engine 1 Install the engine from right side. 9 Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) 9 Engine mounting bolt (lower) 3 69 Nm (6.9 m•kg, 50 ft•lb) 9 Engine mounting bolt (front) 4 69 Nm (6.9 m•kg, 50 ft•lb) 9 Engine bracket 5...
Page 339 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE IC4M5000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E MONTAGE INSTALLAZIONE IC4M5124 Montage du moteur Einbau des Motors Installazione del motore 1. Monter: 1. Einbauen: 1. Installare: 9 Moteur 1 9 Motor 1 9 Motore 1 Monter le moteur par le côté...
Page 340 ENGINE REMOVAL EC4M5341 Drive sprocket 1. Install: 9 Drive sprocket 1 9 Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: 9 Lock washer 1 9 Nut (drive sprocket) 2 75 Nm (7.5 m•kg, 54 ft•lb) NOTE: Tighten the nut while applying the rear brake.
Page 341 DEPOSE DU MOTEUR AUSBAU DES MOTORS RIMOZIONE DEL MOTORE Pignon d’entraînement IC4M5341 Antriebskettenrad Rocchetto conduttore 1. Monter: 1. Einbauen: 1. Installare: 9 Pignon d’entraînement 1 9 Antriebskettenrad 1 9 Rocchetto conduttore 1 9 Chaîne de transmission 2 9 Antriebskette 2 9 Catena di trasmissione 2 N.B.: HINWEIS:...
Page 342: Crankcase And Crankshaft
CRANKCASE AND CRANKSHAFT EC4N0000 CRANKCASE AND CRANKSHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Crankcase separation 2 Crankshaft removal Extent of removal: 3 Crankshaft bearing removal Extent of removal Order...
Page 343: Carter Et Vilebrequin
CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI CARTER ET VILEBREQUIN 1 Séparation du carter 2 Dépose du vilebrequin Etendue de dépose: 3 Dépose du roulement de vilebrequin Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU CARTER ET DU VILEBREQUIN Préparation pour la dépose...
Page 344 CRANKCASE AND CRANKSHAFT EC4N3000 REMOVAL POINTS EC4N3100 Segment 1. Remove: 9 Bolt (segment) 1 9 Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. EC4N3212 Crankcase 1. Remove: 9 Crankcase (right) 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE:...
Page 345 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4N3100 Segment Segment Segmento 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Boulon (segment) 1 9 Schraube (Segment) 1 9 Bullone (segmento) 1 9 Segment 2 9 Segment 2 9 Segmento 2...
Page 346 CRANKCASE AND CRANKSHAFT EC4N3302 Crankshaft 1. Remove: 9 Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE: Make appropriate bolts 3 as shown available by yourself and attach the tool with them. Do not use a hammer to drive out the crankshaft.
Page 347 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N3302 Vilebrequin Albero a gomiti Kurbelwelle 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Vilebrequin 1 9 Albero a gomiti 1 9 Kurbelwelle 1 Utilisez le séparateur de carter Usare l’utensile per separare il Kurbelgehäuse-Trennwerkzeug carter 2.
Page 348 CRANKCASE AND CRANKSHAFT 2. Inspect: 9 Bearings 1 Rotate inner race with a finger. Rough spot/Seizure ¡ Replace. 3. Inspect: 9 Oil seal 1 Damage ¡ Replace. EC4N4202 Crankshaft 1. Measure: 9 Runout limit a 9 Small end free play limit b 9 Connecting rod big end side clearance c 9 Crank width d Out of specification ¡...
Page 349 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI 2. Examiner: 2. Ispezionare: 2. Prüfen: 9 Roulements 1 9 Cuscinetti 1 9 Lager 1 Faire tourner la bague intérieure Ruotare l’anello interno con un inneren Laufring avec le doigt. dito.
Page 350 CRANKCASE AND CRANKSHAFT EC4N5102 Oil seal 1. Install: 9 Oil seal (left) 1 9 Oil seal (right) 2 NOTE: 9 Apply the lithium soap base grease on the oil seal lip. 9 Install the oil seal with its manufacture’s marks or numbers facing outward.
Page 351 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI IC4N5102 Bague d’étanchéité Paraolio Öldichtung 1. Monter: 1. Installare: 1. Einbauen: 9 Bague d’étanchéité (gauche) 1 9 Paraolio (sinistro) 1 9 Öldichtung (Links) 1 9 Paraolio (destro) 2 9 Öldichtung (Rechts) 2 9 Bague d’étanchéité...
Page 352 To crankcase (right) 2. 4. Apply: 9 Sealant On the crankcase (right) 1. ® Quick gasket ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant. 5. Install: 9 Dowel pin 1 9 Crankcase (right) 2 To crankcase (left) 3.
Page 353 Sul carter (destro) 1. Kurbelgehäuse (Rechts) 1. Quick Gasket Quick Gasket ® ® ACC-QUICK-GS-KT ACC-QUICK-GS-KT Quick Gasket ® Legante Yamaha No. 1215: Yamaha Bond N°1215: ACC-QUICK-GS-KT 90890-85505 90890-85505 Yamaha Bond Nr. 1215: 90890-85505 N.B.: NOTA: HINWEIS: Nettoyer la surface de contact des...
Page 354 CRANKCASE AND CRANKSHAFT 7. Install: 9 Tension spring 1 9 Holder 2 9 Bolt (holder) 3 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Install the holder so that it contacts the projec- tion a on the crankcase (right). 8. Tighten: 9 Segment 1 9 Bolt (segment) 2 30 Nm (3.0 m•kg, 22 ft•lb)
Page 355 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO A GOMITI 7. Monter: 7. Installare: 7. Einbauen: 9 Ressort de tension 1 9 Molla di tensione 1 9 Zugfeder 1 9 Support 2 9 Supporto 2 9 Halter 2 9 Boulon (support) 3 9 Bullone (supporto) 3 9 Schraube (Halter) 3 10 Nm (1,0 m•kg, 7,2 ft•lb)
Page 356: Transmission, Shift Cam And Shift Fork
TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Main axle, drive axle, shift cam and shift fork removal Extent of removal: Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for Engine Refer to “ENGINE REMOVAL”...
Page 357 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE 1 Dépose de l’arbre principal, de l’arbre d’entraînement, du barillet du sélecteur et de la fourchette du sélecteur. Etendue de dépose: Etendue de dépose Ordre...
Page 358 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: 9 Main axle 1 9 Drive axle 2 9 Shift cam 9 Shift fork 3 9 Shift fork 2 9 Shift fork 1 NOTE: 9 Remove assembly carefully. Note the position of each part.
Page 359 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC4H3230 Boîte à vitesses Getribe Trasmissione 1. Déposer: 1. Togliere: 1. Ausbauen: 9 Axe principal 1 9 Asse principale 1 9 Hauptwelle 1...
Page 360 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: 9 Shift fork 1 Wear/Damage/Scratches ¡ Replace. 2. Inspect: 9 Shift cam 1 9 Segment 2 Wear/Damage ¡ Replace. 3. Check: 9 Shift fork movement Unsmooth operation ¡...
Page 361 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO IC4H4810 Fourchette, barillet de sélecteur et Forcella del cambio, camma del cam- Schaltgabel, Schaltnocke und Segment bio e segmento segment 1.
Page 362 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 9 2nd wheel gear (23 T) 1 9 4th wheel gear (24 T) 2 9 3rd wheel gear (23 T) 3 9 5th wheel gear (20 T) 4 9 1st wheel gear (27 T) 5 9 O-ring 6 To drive axle 7.
Page 363 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 2. Monter: 2. Installare: 2. Einbauen: 9 2e engranage de pignon (23D) 1 9 Ingranaggio a ruota 2 (23T) 1 Zahnrad für 2.
Page 364 TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: 9 Shift fork 1 (L) 1 9 Shift fork 2 (C10) 2 9 Shift fork 3 (R) 3 9 Shift cam 4 To main axle and drive axle. NOTE: 9 Apply the molybdenum disulfide oil on the shift fork grooves.
Page 365 BOITE A VITESSES, BARILLET DE SELECTEUR ET FOURCHETTE GETRIEBE, SCHALTNOCKE UND SCHALTGABEL TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO 5. Monter: 5. Installare: 5. Einbauen: 9 Fourchette 1 (L) 1 9 Forcella del cambio 1 (L) 1 Schaltgabel 1 (L) 1 9 Fourchette 2 (C10) 2 9 Forcella del cambio 2 (C10) 2 Schaltgabel 2 (C10) 2...
Page 366: Front Wheel
CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 23 Nm (2.3 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 105 Nm (10.5 m•kg, 75 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb)
Page 367: Partie Cycle
ROUE AVANT ET ROUE ARRIEREF VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue 3 Dépose du disque de frein Etendue de dépose: Etendue de dépose Ordre...
Page 368: Rear Wheel
CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 14 Nm (1.4 m•kg, 10 ft•lb) 125 Nm (12.5 m•kg, 90 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal:...
Page 369: Ruota Anteriore E Ruota Posteriore
ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ROUE ARRIERE 1 Dépose de roue arrière 2 Dépose du roulement de roue 3 Dépose du disque de frein Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 370 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: 9 Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: 9 Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
Page 371 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC593000 PUNTI DI RIMOZIONE POINTS DE DEPOSE AUSBAUPUNKTE Roue arrière Hinterrad IC523101 Ruota posteriore 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Roue 1 9 Rad 1 9 Ruota 1 N.B.: HINWEIS:...
Page 372 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: 9 Wheel axle bends Out of specification ¡ Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading.
Page 373 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC514200 Axe de roue Radachse Asse della ruota 1. Mesurer: 1. Messen: 1. Misurare: 9 Les flexions de l’axe de roue 9 Radachsenbiegung 9 Curvature dell’asse della ruota Hors-spécification ¡...
Page 374 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION EC595101 Front wheel 1. Install: 9 Bearing (left) 1 9 Spacer 2 9 Bearing (right) 3 9 Oil seal 4 NOTE: 9 Apply the lithium soap base grease on the bearing and oil seal lip when installing.
Page 375 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE IC595000 REMONTAGE ET MONTAGE UND EINBAU MONTAGGIO E Vorderrad MONTAGE INSTALLAZIONE 1. Einbauen: Roue avant IC595101 9 Lager (Links) 1 1. Monter: Ruota anteriore 9 Distanzhülse 2 9 Roulement (gauche) 1 1.
Page 376: Front Fork
CHAS FRONT WHEEL AND REAR WHEEL 5. Install: 9 Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: 9 Nut (wheel axle) 1 105 Nm (10.5 m•kg, 75 ft•lb) 7. Tighten: 9 Bolt (axle holder) 1 23 Nm (2.3 m•kg, 17 ft•lb) NOTE: Before tightening the bolt, fit the wheel axle to...
Page 377 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 5. Monter: 5. Installare: 5. Einbauen: 9 Axe de roue 1 9 Asse della ruota 1 9 Radachse 1 N.B.: HINWEIS: NOTA: Appliquer de la graisse à base de savon Applicare sull’asse della ruota il grasso Das Lithiumfett auf Radachse auftra- au lithium sur l’axe de roue.
Page 378 CHAS FRONT WHEEL AND REAR WHEEL 9. Install: 9 Hose cover 1 9 Plain washer 2 9 Bolt [hose cover (M8)] 3 16 Nm (1.6 m•kg, 11 ft•lb) 9 Bolt [hose cover (M6)] 4 7 Nm (0.7 m•kg, 5.1 ft•lb) EC5251A1 Rear wheel 1.
Page 379 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 9. Monter: 9. Installare: 9. Einbauen: 9 Couvercle de tuyau 1 9 Copertura del tubo flessibile 1 9 Schlauchdeckel 1 9 Rondelle ordinaire 2 9 Rosetta 2 9 Beilegescheibe 2 9 Boulon 9 Bullone [copertura del tubo fles-...
Page 380 CHAS FRONT WHEEL AND REAR WHEEL 3. Install: 9 Driven sprocket 1 9 Bolt (driven sprocket) 2 9 Plain washer (driven sprocket) 3 9 Nut (driven sprocket) 4 42 Nm (4.2 m•kg, 30 ft•lb) NOTE: Tighten the nuts in stage, using a crisscross pat- tern.
Page 381 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Pignon mené 1 9 Rocchetto condotto 1 9 Abtriebskettenrad 1 9 Boulon (pignon mené) 2 9 Bullone (rocchetto condotto) 2 9 Schraube (Abtriebskettenrad) 9 Rondelle...
Page 382 CHAS FRONT WHEEL AND REAR WHEEL 8. Install: 9 Chain puller (right) 1 9 Plain washer 2 9 Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: 9 Drive chain slack a Drive chain slack : 40~50 mm (1.6~2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT”...
Page 383 ROUE AVANT ET ROUE ARRIERE VORDERRAD UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE 8. Monter: 8. Installare: 8. Einbauen: 9 Tendeur de chaîne (droit) 1 9 Estrattore per catena (destro) 1 9 Kettenspanner (Rechts) 1 9 Rondelle ordinaire 2 9 Rosetta 2 9 Beilegescheibe 2 9 Ecrou (axe de roue) 3...
Page 384: Front Brake
CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 9 Nm (0.9 m•kg, 6.5 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb)
Page 385: Frein Avant Et Frein Arriere
FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose du tuyau de frein 2 Dépose de l’étrier 3 Dépose du maître-cylindre Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 386: Rear Brake
CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 30 Nm (3.0 m•kg, 22 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb)
Page 387: Freno Posteriore
FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE FREIN ARRIERE 1 Dépose du maître-cylindre 2 Dépose du tuyau de frein 3 Dépose de l’étrier Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 388: Caliper Disassembly
CHAS FRONT BRAKE AND REAR BRAKE EC5A8200 CALIPER DISASSEMBLY 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) A Front B Rear 1 Front caliper disassembly...
Page 389 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE DEMONTAGE DE L’ETRIER A Avant B Arrière 1 Démontage de l’étrier avant 2 Démontage de l’étrier arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 390 CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY å 2 Nm (0.2 m•kg, 1.4 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) ∫ A Front B Rear 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal: Extent of removal Order Part name...
Page 391 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE A Avant B Arrière 1 Démontage du maître-cylindre avant 2 Démontage du maître-cylindre arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té...
Page 392 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 REMOVAL POINTS EC5A3101 Brake fluid 1. Remove: [Front] 9 Master cylinder cap 1 [Rear] 9 Master cylinder cap 1 9 Protector NOTE: Do not remove the diaphragm. A Front B Rear 2. Connect the transparent hose 1 to the bleed screw 2 and place a suitable contain- er under its end.
Page 393 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC5A3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit IC5A3101 1. Déposer: 1. Ausbauen: Liquido per freni [Avant] [Vorne] 1. Togliere: 9 Coupelle du maître-cylindre 1 9 Hauptbremszylinderkappe 1 [Anteriormente] [Arrière]...
Page 394 CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: 9 Dust seal 1 9 Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. Never attempt to pry out piston seals and dust seals.
Page 395 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC533402 Kit de joint de piston Kolbendichtungseinsatz Kit delle guarnizioni di tenuta del 1. Déposer: pistone 1. Ausbauen: 9 Joint antipoussière 1 9 Staubdichtung 1 1. Togliere: 9 Joint de piston 2 9 Parapolvere 1 9 Kolbendichtung 2...
Page 396 CHAS FRONT BRAKE AND REAR BRAKE EC534214 Caliper 1. Inspect: 9 Caliper cylinder inner surface a Wear/Score marks¡Replace caliper as- sembly. A Front B Rear 2. Inspect: 9 Caliper piston 1 Wear/Score marks¡Replace caliper piston assembly. Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled.
Page 397 FREAIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE IC534214 Etrier Bremssattel Pinza 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Surface 9 Inneren Oberfläche des Haupt- interne maître- 9 Superficie interna del cilindro cylindre a bremszylinders a della pinza a U s u r e / r a y u r e s ¡...
Page 398 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Piston seal 1 9 Dust seal 2 Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. A Front B Rear 3.
Page 399 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Joint de piston 1 9 Guarnizione di tenuta del pisto- 9 Kolbendichtung 1 9 Joint antipoussière 2 ne 1 9 Staubdichtung 2 9 Parapolvere 2 Toujours utiliser des joints de piston...
Page 400 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Copper washer 1 9 Union bolt 2 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. Install the brake hose so that its pipe por- tion a a directs as shown and lightly touch- es the projection b b on the caliper.
Page 401 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Rondelle en cuivre 1 9 Rondella in rame 1 9 Kupferscheibe 1 9 Boulon d’union 2 9 Bullone di unione 2 9 Unionschraube 2 30 Nm (3,0 m•kg, 22 ft•lb) 30 Nm (3,0 m•kg, 22 ft•lb)
Page 402 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Disc cover 1 9 Bolt (disc cover) 2 7 Nm (0.7 m•kg, 5.1 ft•lb) 3. Install: 9 Caliper 1 9 Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4.
Page 403 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Couvercle de disque 1 9 Copridisco 1 9 Scheibendeckel 1 9 Boulon (couvercle de disque) 2 9 Bullone (copridisco) 2 9 Schraube (Scheibendeckel) 2 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb)
Page 404 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: 9 Spring 1 To master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. A Front B Rear 4. Install: [Front] 9 Master cylinder kit 1 9 Plain washer 2 9 Circlip 3 9 Master cylinder boot 4 To master cylinder 5.
Page 405 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Ressort 1 9 Molla 1 9 Feder 1 Au piston de maître-cylindre 2. Sul pistone del cilindro princi- Hauptbremszylinderkol- pale 2.
Page 406 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Brake lever 1 9 Bolt (brake lever) 2 6 Nm (0.6 m•kg, 4.3 ft•lb) 9 Nut (brake lever) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston.
Page 407 FREIN AVNAT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Levier de frein 1 9 Leva di comando del freno 1 9 Bremshebel 1 9 Boulon (levier de frein) 2 9 Bullone (leva di comando del 9 Schraube (Bremshebel) 2 freno) 2...
Page 408 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: 9 Spring 1 9 Brake pedal 2 9 O-ring 3 9 Bolt (brake pedal) 4 26 Nm (2.6 m•kg, 19 ft•lb) 9 Clip 5 NOTE: 9 Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket.
Page 409 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Ressort 1 9 Molla 1 9 Feder 1 9 Pédale de frein 2 9 Pedale di comando del freno 2 9 Bremspedal 2 9 Joint torique 3 9 Anello di tenuta 3...
Page 410 CHAS FRONT BRAKE AND REAR BRAKE 3. Pass the brake hose through the cable guide 1, then through the guide a on the protector 2. 4. Install: 9 Copper washer 1 9 Brake hose 2 9 Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers.
Page 411 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE AND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 3. Faire passer la tuyau de frein dans 3. Far passare il tubo flessibile del 3. Den Bremsschlauch durch die le guide de câble 1, puis dans le Kabelführung 1 und danach freno attraverso la guida per cavi guide a sur le protecteur 2.
Page 412 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9 Brake hose holder 1 9 Screw (brake hose holder) 2 1 Nm (0.1 m•kg, 0.7 ft•lb) After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.
Page 413 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Monter: 2. Installare: 2. Einbauen: 9 Support de tuyau de frein 1 9 Supporto del tubo flessibile del 9 Bremsschlauchhalter 1 9 Vis (support de tuyau de frein) 2 freno 1 9 Schraube (Bremsschlauchhal- 9 Vite (supporto del tubo flessibi-...
Page 414 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: 9 Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: 9 Brake fluid level Fluid at lower level¡Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
Page 415 FREIN AVANT ET FREIN ARRIERE VORDERRADBREMSE UND HINTERRADBREMSE CHAS FRENO ANTERIORE E FRENO POSTERIORE 2. Purger de l’air: 2. Spurgo dell’aria: 2. Entlüften: 9 Système de freinage 9 Impianto frenante 9 Bremsanlage Se reporter à la section “PRISE Consultare la sezione “SPUR- Siehe Abschnitt „ENTLÜFTEN D’AIR DU SYSTEME DE GO DELL’ARIA DAL SISTE-...
Page 416 CHAS FRONT FORK EC550000 FRONT FORK 4 Nm (0.4 m•kg, 2.9 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Front fork removal Extent of removal: Extent of removal...
Page 417: Fourche Avant
FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE FOURCHE AVANT 1 Dépose de la fourche avant Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE LA FOURCHE AVANT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas approprié...
Page 418: Front Fork Disassembly
CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 1 Nm (0.1 m•kg, 0.7 ft•lb) 29 Nm (2.9 m•kg, 21 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Oil seal removal 2 Damper rod removal Extent of removal: Extent of removal Order Part name...
Page 419: Forcella Anteriore
FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE AVANT 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DE LA FOURCHE AVANT Boulon capuchon Se reporter à...
Page 420 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- served: 9 The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to...
Page 421 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC556000 REMARQUES HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO CONCERNANT LA HINWEIS: NOTA: MANIPULATION Die Vorderradgabel erfordert beson- La forcella anteriore richiede grande at- dere Aufmerksamkeit. Daher wird N.B.: tenzione. Si raccomanda pertanto di ef- empfohlen, Wartungsarbeiten an der fettuare la manutenzione della forcella La fourche avant nécessite une soigneu- Vorderradgebel...
Page 422 CHAS FRONT FORK EC553201 Inner tube 1. Remove: 9 Dust seal 1 9 Stopper ring 2 Using slotted-head screwdriver. Take care not to scratch the inner tube. 2. Remove: 9 Inner tube 1 Oil seal removal steps: 9 Push in slowly a the inner tube just be- fore it bottoms out and then pull it back quickly b.
Page 423 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC553201 Tube interne Innere Rohr Tubo interno 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Joint antipoussière 1 9 Staubdichtung 1 9 Parapolvere 1 9 Bague d’arrêt 2 9 Anschlagring 2 9 Anello di fermo 2 En utilisant un tournevis à...
Page 424 CHAS FRONT FORK EC554200 Base valve 1. Inspect: 9 Valve assembly 1 Wear/Damage¡Replace. 9 O-ring 2 Damage¡Replace. EC554400 Fork spring 1. Measure: 9 Fork spring free length a Out of specification¡Replace. Fork spring free length: Standard <Limit> 460 mm 455 mm (18.1 in) (17.9 in) EC554502...
Page 425 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554200 Soupare de base Valvola di base Hauptventil 1. Examiner: 1. Ispezionare: 1. Prüfen: 9 Ensemble clapet 1 9 Gruppo valvola 1 9 Ventileinheit 1 Usure/endommagement Usura/Danni¡Sostituirlo. Abnutzung/Beschädigung ¡Changer. ¡Erneuern. 9 Anello di tenuta 2 9 Joint torique 2 9 O-Ring 2 Danni¡Sostituirlo.
Page 426 CHAS FRONT FORK EC554700 Cap bolt 1. Inspect: 9 Cap bolt 1 9 O-ring 2 9 Air bleed screw 3 Wear/Damage¡Replace. EC555000 ASSEMBLY AND INSTALLATION EC5551A1 Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: 9 Damper rod 1 To inner tube 2.
Page 427 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE IC554700 Boulon capuchon Hutschraube Vite mordente 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Boulon capuchon 1 9 Hutschraube 1 9 Vite mordente 1 9 Joint torique 2 9 O-Ring 2 9 Anello di tenuta 2 9 Vis de purge d’air 3 9 Entlüftungschraube 3 9 Vite di spurgo dell’aria 3...
Page 428 CHAS FRONT FORK 5. Install: 9 Spring guide 1 9 Locknut 2 To damper rod 3. NOTE: 9 Install the spring guide with its cut a facing up- ward. 9 With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
Page 429 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 5. Monter: 5. Installare: 5. Einbauen: 9 Guide de ressort 1 9 Guida della molla 1 9 Federführung 1 9 Contre-ecrou 2 9 Controdado 2 9 Sicherungsmutter 2 Au tige d’amortisseur 3. Sulla barra dello smorzatore 3. Zum Dämpfungsstange 3.
Page 430 CHAS FRONT FORK 9. Install: 9 Slide metal 1 9 Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10. Install: 9 Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
Page 431 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 9. Monter: 9. Installare: 9. Einbauen: 9 Bague antifriction 1 9 Metallo di scorrimento 1 9 Gleitmetall 1 9 Rondelle ordinaire 2 9 Rosetta 2 9 Beilegescheibe 2 Vers la fente de tube externe. Sulla fessura del tubo esterno.
Page 432 CHAS FRONT FORK 13. Check: 9 Inner tube smooth movement Tightness/Binding/Rough spots ¡ Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: 9 Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “01”...
Page 433 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 13. Contrôler: 13. Controllare: 13. Kontrollieren: 9 Mouvement régulier du tube in- 9 Facilità di movimento del tubo 9 Glatte Bewegung des inneres terne interno Rohres Festsitz/Klemmung Raideur/coincement/point dure Difficoltà/Inceppamento /Unregel-mäßige Bewegung ¡Répéter les étapes du 2 au 12. ¡Die Schritte 2 bis 12 wieder- /Ruvidità¡Ripetere le operazio- holen.
Page 434 CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.
Page 435 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 19. Attendre dix minutes jusqu’à ce 19. Attendere dieci minuti finché le 19. Vor dem Einstellen des empfoh- que les bulles d’air aient été élimi- bolle d’aria sono state tolte dalla lenen Ölpegels, etwa zehn nées de la fourche avant et que forcella anteriore e l’olio si è...
Page 436 CHAS FRONT FORK 21. Measure: 9 Distance a Out of specification¡Turn into the locknut. Distance a a : 20 mm (0.79 in) or more Between damper rod 1 1 top and locknut 2 2 top. 22. Loosen: 9 Rebound damping adjuster 1 NOTE: 9 Loosen the rebound damping adjuster finger tight.
Page 437 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 21. Mesurer: 21. Misurare: 21. Messen: 9 Distance a 9 Distanza a 9 Maß a Hors spécification¡Rentrer le Fuori specifica¡Avvitare il con- Abweichung von Spezifikation ¡ contre-écrou. trodado. Sicherungsmutter hineindrehen. Distanza a a : Distance a a : Maß...
Page 438 CHAS FRONT FORK 26. Tighten: 9 Cap bolt (locknut) 1 29 Nm (2.9 m•kg, 21 ft•lb) NOTE: 9 While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. 9 Hold the locknut 5 and tighten the cap bolt with specified torque.
Page 439 FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 26. Serrer: 26. Serrare: 26. Festziehen: 9 Boulon capuchon 1 9 Vite mordente (controdado) 1 9 Hutschraube 1 ft•lb) 29 Nm (2,9 m•kg, 21 ft•lb) 29 Nm (2,9 m•kg, 21 29 Nm (2,9 m•kg, 21 ft•lb) HINWEIS: N.B.: NOTA:...
Page 440 CHAS FRONT FORK 4. Tighten: 9 Pinch bolt (handle crown) 1 23 Nm (2.3 m•kg, 17 ft•lb) 9 Pinch bolt (under bracket) 2 20 Nm (2.0 m•kg, 14 ft•lb) Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.
Page 441: Alla Coppia
FOURCHE AVANT VORDERRADGABEL CHAS FORCELLA ANTERIORE 4. Serrer: 4. Serrare: 4. Festziehen: 9 Boulon de bridage (couronne de 9 Bullone di serraggio (corona del 9 Klemmschraube (Lenkerkrone) guidon) 1 manubrio) 1 23 Nm (2,3 m•kg, 17 ft•lb) 23 Nm (2,3 m•kg, 17 ft•lb) 23 Nm (2,3 m•kg, 17 ft•lb) 9 Boulon de bridage (étrier infé- 9 Bullone di serraggio (staffa in-...
Page 442: Handlebar
CHAS HANDLEBAR EC5B0000 HANDLEBAR 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 28 Nm (2.8 m•kg, 20 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Handlebar removal Extent of removal: Extent of removal...
Page 443 GUIDON LENKSTANGE CHAS MANUBRIO GUIDON 1 Dépose du guidon Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU GUIDON Préparation Plaque d’immatriculation Enlever seulement la partie de fixation. pour la dépose Câble d’embrayage Déconnecter du côté levier. Support de levièr d’embrayage Bouton d’arrêt du moteur “ENGINE STOP”...
Page 444 CHAS HANDLEBAR EC5B8000 THROTTLE DISASSEMBLY 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Throttle disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks THROTTLE DISASSEMBLY Grip cap (lower) Grip cap (upper) Grip assembly Grip (right) Refer to “REMOVAL POINTS”. Tube guide 5-40...
Page 445 GUIDON LENKSTANGE CHAS MANUBRIO DEMONTAGE DE L’ACCELERATEUR 1 Démontage de l’accélérateur Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEMONTAGE DE L’ACCELERA- TEUR Capuchon de poigée (inférieur) Capuchon de poigée (supérieur) Ensemble de la poignée Poignée (droite) Se reporter à...
Page 446 CHAS HANDLEBAR EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: 9 Master cylinder bracket 1 9 Master cylinder 2 9 Do not let the master cylinder hang on the brake hose. 9 Keep the master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1.
Page 447 GUIDON LENKSTANGE CHAS MANUBRIO IC5B3000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC5B3100 Maître-cylindre Hauptbremszylinder Cilindro principale 1. Déposer: 1. Ausbausen: 1. Togliere: 9 Etrier de maître-cylindre sur 1 9 Hauptbremszylinderhalterung 9 Staffa del cilindro principale 1 9 Maître-cylindre 2 9 Cilindro principale 2 9 Hauptbremszylinder 2 9 Ne pas laisser pendre le maître-cy-...
Page 448 CHAS HANDLEBAR 2. Install: 9 Grip cap (upper) 1 9 Grip cap (lower) 2 9 Bolt (grip cap) 3 NOTE: Temporarily tighten the bolts (grip cap). EC5B5210 Handlebar 1. Install: 9 Handlebar 1 9 Handlebar holder 2 9 Bolt (handlebar holder) 3 28 Nm (2.8 m•kg, 20 ft•lb) NOTE: 9 The upper handlebar holder should be installed...
Page 449 GUIDON LENKSTANGE CHAS MANUBRIO 2. Monter: 2. Installare: 2. Einbauen: 9 Capuchon de poignée (supé- 9 Calotta della manopola (supe- 9 Griffkappe (Oben) 1 rieur) 1 riore) 1 9 Griffkappe (Unten) 2 9 Capuchon de poignée (inférieur) 9 Calotta della manopola (inferio- 9 Schraube (Griffkappe) 3 re) 2 HINWEIS:...
Page 450 CHAS HANDLEBAR 4. Install: 9 Throttle cable 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throt- tle cable end and tube guide cable winding por- tion. 5. Install: 9 Roller 1 9 Collar 2 NOTE: 9 Apply the lithium soap base grease on the roller sliding surface.
Page 451 GUIDON LENKSTANGE CHAS MANUBRIO 4. Monter: 4. Installare: 4. Einbauen: 9 Câble d’accélérateur 1 9 Cavo dell’acceleratore 1 9 Gasseil 1 Au guide de tube 2. Sulla guida del tubo 2. An der Rohrführung 2. HINWEIS: N.B.: NOTA: Appliquer de la graisse à base de savon Applicare sull’estremità...
Page 452 CHAS HANDLEBAR 10. Install: 9 Bolt (grip cap) 1 4 Nm (0.4 m•kg, 2.9 ft•lb) 9 Install the grip cap so that the gaps a a and b b between the bolt (grip cap) and brake lever 2 2 are equal. If you make a mistake in the grip cap installation position, the brake lever may contact the grip cap, resulting in poor brake performance.
Page 453 GUIDON LENKSTANGE CHAS MANUBRIO 10. Monter: 10. Installare: 10. Einbauen: 9 Boulon (capuchon de poignée) 9 Bullone (calotta della manopo- 9 Schraube (Griffkappe) 1 la) 1 4 Nm (0,4 m•kg, 2,9 ft•lb) 4 Nm (0,4 m•kg, 2,9 ft•lb) 4 Nm (0,4 m•kg, 2,9 ft•lb) 9 Die Griffkappe so einbauen, daß...
Page 454 CHAS HANDLEBAR 14. Clamp the clamp portion a of the number plate to the handlebar. 15. Insert the end of the fuel breather hose 1 into the hole of the number plate. 5-45...
Page 455 GUIDON LENKSTANGE CHAS MANUBRIO 14. Fixer la partie de fixation a de la 14. Bloccare la parte della brida a 14. Das Klemmteil plaque d’immatriculation au gui- Nummernschildes della targa sul manubrio. don. Lenkstange festklemmen. 15. Inserire l’estremità dello sfiato del carburante 1 nel foro della targa.
Page 456: Steering
CHAS STEERING EC560000 STEERING 23 Nm (2.3 m•kg, 17 ft•lb) 145 Nm (14.5 m•kg, 105 ft•lb) TIGHTENING STEPS: 9 Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) 9 Loosen it one turn. 9 Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 1 Under bracket removal 2 Bearing removal Extent of removal:...
Page 457 DIRECTION LENKUNG CHAS STERZO DIRECTION ETAPES DE SERRAGE: 9 Serrer l’ecrou annulaire a environ. 38 Nm (3,8 m•kg, 27 ft•lb) 9 Le desserrer d’un tour. 9 Le resserrer a enviorn. 7 Nm (0,7 m•kg, 5,1 ft•lb) 1 Dépose de l’étrier inférieur 2 Dépose du roulement Etendue de dépose: Etendue de dépose...
Page 458 CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: 9 Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: 9 Bearing (lower) 1 Use the floor chisel 2.
Page 459 DIRECTION LENKUNG CHAS STERZO IC563000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC563202 Ecrou annulaire Ringmutter Ghiera 1. Déposer: 1. Ausbauen: 1. Togilere: 9 Ecrou annulaire 1 9 Ringmutter 1 9 Ghiera 1 Den Ringmutterschlüssel 2 Utiliser la clé pour écrou annu- Usare la chiave per ghiera 2.
Page 460 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a sol- vent. 2. Inspect: 9 Bearing 1 9 Ball race Pitting/Damage ¡ Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand.
Page 461 DIRECTION LENKUNG CHAS STERZO IC564101 Roulement et cage à billes Lager und Laufring Cuscinetto e pista 1. Nettoyer les roulements et les 1. Die Lager Laufringe 1. Lavare i cuscinetti e le piste con cages à billes dans du solvant. Lösungsmittel waschen.
Page 462 CHAS STEERING 4. Install: 9 Plain washer 1 9 Ring nut 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Tighten the ring nut using the ring nut wrench 3. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAP- TER 3. 5.
Page 463 DIRECTION LENKUNG CHAS STERZO 4. Monter: 4. Installare: 4. Einbauen: 9 Rondelle ordinaire 1 9 Rosetta 1 9 Beilegescheibe 1 9 Ecrou annulaire 2 9 Ghiera 2 9 Ringmutter 2 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb) 7 Nm (0,7 m•kg, 5,1 ft•lb) Serrer l’écrou annulaire 3 en Ringmutter...
Page 464 CHAS STEERING 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 10. Adjust: 9 Front fork top end a Front fork top end (standard) a a : Zero mm (Zero in) 11.
Page 465 DIRECTION LENKUNG CHAS STERZO 9. Après avoir serré l’écrou, vérifier 9. Dopo avere serrato il dado, con- 9. Nach dem Festziehen der Mutter, si le mouvement de la direction est trollare che lo sterzo si muova sen- die Lenkung auf glatte Bewegung régulier.
Page 466: Swingarm
CHAS SWINGARM EC570000 SWINGARM 53 Nm (5.3 m•kg, 38 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 1 Swingarm removal Extent of removal: Extent of removal Order Part name...
Page 467: Bras Oscillant
BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT 1 Dépose du bras oscillant Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DU BRAS OSCILLANT Préparation Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas pour la dépose approprié...
Page 468 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 80 Nm (8.0 m•kg, 58 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) 1 Swingarm disassembly 2 Connecting rod removal and disassembly Extent of removal: 3 Relay arm removal and disassembly Extent of removal Order...
Page 469: Forcellone Oscillante
BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Etendue de dépose: 3 Dépose et démontage du bras de relais Etendue de dépose Ordre Nom de pièce Q’té...
Page 470 CHAS SWINGARM EC573000 REMOVAL POINTS EC573201 Bearing 1. Remove: 9 Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent. EC574111 Swingarm 1. Inspect: 9 Bearing 1 9 Bush 2 Free play exists/Unsmooth revolution/Rust ¡...
Page 471 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC573000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC573201 Cuscinetto Roulement Lager 1. Togliere: 1. Déposer: 1. Ausbauen: 9 Cuscinetto 1 9 Roulement 1 9 Lager 1 NOTA: N.B.: HINWEIS: Togliere il cuscinetto premendone Déposez le roulement en appuyant sur Lager durch Drücken auf den äusse- l’anello esterno.
Page 472 CHAS SWINGARM EC574311 Connecting rod 1. Inspect: 9 Bearing (polylube bearing) 1 9 Collar 2 Free play exists/Unsmooth revolution/Rust ¡ Replace bearing and collar as a set. 2. Inspect: 9 Bearing (polylube bearing) 1 Loss of solid lubrication ¡ Replace. 9 Oil seal 3 Damage ¡...
Page 473 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE IC574311 Bielle Pleuelstange Leva di rinvio 1. Examiner: 1. Prüfen: 1. Ispezionare: 9 Roulement (roulement Polylu- 9 Lager (Polylube-Lager) 1 9 Cuscinetto (cuscinetto polylube) be) 1 9 Hülse 2 9 Collerette 2 Freies Spiel besteht/Unrunde 9 Bordino 2 Drehung/Rost ¡...
Page 474 CHAS SWINGARM 2. Install: 9 Bearing 1 9 Oil seal 2 To relay arm. NOTE: 9 Apply the molybdenum disulfide grease on the bearing when installing. 9 Install the bearing by pressing it on the side hav- ing the manufacture's marks or numbers. Installed depth of bearings a a : 5 mm (0.20 in) 3.
Page 475 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 2. Monter: 2. Installare: 2. Einbauen: 9 Roulement 1 9 Cuscinetto 1 9 Lager 1 9 Bague d’étanchéité 2 9 Paraolio 2 9 Öldichtung 2 Au bras de relais. Sul braccio di rinvio. Zum Relaisarm. HINWEIS: N.B.: NOTA:...
Page 476 CHAS SWINGARM 3. Install: 9 Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: 9 Connecting rod 1 9 Bolt (connecting rod) 2 9 Plain washer 3 9 Nut (connecting rod) 4 80 Nm (8.0 m•kg, 58 ft•lb) To relay arm 5.
Page 477 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 3. Monter: 3. Installare: 3. Einbauen: 9 Collerette 1 9 Bordino 1 9 Hülse 1 Au bielle 2. Sulla leva di rinvio 2. Zum Pleuelstange 2. HINWEIS: N.B.: NOTA: Appliquer de la graisse de molybdéne Applicare il grasso a base di bisolfuro Molybdän-Fett auf den Hülse und...
Page 478 CHAS SWINGARM 7. Check: 9 Swingarm side play a Free play exists ¡ Replace thrust bearing. 9 Swingarm up and down movement b Unsmooth movement/Binding/Rough spots¡Grease or replace bearings, bushes and collars. 8. Install: 9 Bolt (connecting rod) 1 9 Plain washer 2 9 Nut (connecting rod) 3 NOTE: 9 Apply the molybdenum disulfide grease on the...
Page 479 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 7. Contrôler: 7. Controllare: 7. Kontrollieren: 9 Jeu latéral du bras oscillant a 9 Gioco laterale del forcellone 9 Seitliches Spiel der Hinterrad- ¡ schwinge a oscillante a Il y a jeu fonctionnel Esiste gioco ¡ Sostituire il cu- Freies Spiel besteht ¡...
Page 480 CHAS SWINGARM 12. Install: 9 Cap 1 NOTE: Install the cap (right) with its mark a facing for- ward. 13. Install: 9 Bolt [chain tensioner (lower)] 1 9 Plain washer 2 9 Collar 3 9 Chain tensioner 4 9 Nut [chain tensioner (lower)] 5 19 Nm (1.9 m•kg, 13 ft•lb) 14.
Page 481 BRAS OSCILLANT HINTERRADSCHWINGE CHAS FORCELLONE OSCILLANTE 12.Monter: 12. Installare: 12. Einbauen: 9 Capuchon 1 9 Coperchio 1 9 Kappe 1 HINWEIS: N.B.: NOTA: Installer le capuchon (droit) avec le Posizionare il coperchio (destra) con il Kappe (rechts) mit ihrer Kennzeich- repère a vers l’avant.
Page 482 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 56 Nm (5.6 m•kg, 40 ft•lb) 53 Nm (5.3 m•kg, 38 ft•lb) 32 Nm (3.2 m•kg, 23 ft•lb) 29 Nm (2.9 m•kg, 21 ft•lb) 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal: Extent of removal Order...
Page 483: Et Couvercles Lateraux
AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Etendue de dépose: Etendue de dépose Ordre Nom de pièce Q’té Remarques DEPOSE DE L’AMORTISSEUR ARRIERE Bien soutenir la machine afin qu’elle ne risque pas Préparation Maintenir la machine en plaçant un support de se renverser.
Page 484 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-60...
Page 485: Ammortizzatore Posteriore
IC587000 REMARQUE CONCER- NOTE SULLO SMALTI- VERSCHROTTUNGSANLEI- MENTO (SOLTANTO CON- NANT LA MISEAU REBUT DE L’AMORTISSEUR TUNG (NUR FÜR YAMAHA CESSIONARI YAMAHA) Prima di smaltire l’ammortizzatore, as- (TRAVAIL A EFFECTUER FACHHÄNDLER) sicurarsi di estrarre l’azoto gassoso dal- Verschrotten CHEZ UN CONCESSION- la valvola 1.
Page 486 CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: 9 Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: 9 Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
Page 487 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE IC583000 POINTS DE DEPOSE AUSBAUPUNKTE PUNTI DI RIMOZIONE IC583320 Roulement Lager Cuscinetto 1. Déposer: 1. Ausbauen: 1. Togliere: 9 Bague d’arrêt (roulement supé- 9 Anschlagring (Oben Lager) 1 9 Anello di fermo (cuscinetto su- rieur) 1 periore) 1 HINWEIS:...
Page 488 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585320 Bearing 1. Install: 9 Upper Bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.
Page 489 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE IC585000 REMONTAGE ET MONTA- MONTAGE UND EINBAU MONTAGGIO E INSTAL- LAZIONE IC585320 Lager Roulement Cuscinetto 1. Einbauen: 1. Monter: 1. Installare: 9 Oben Lager 1 9 Roulement supérieur 1 9 Cuscinetto superiore 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring paral-...
Page 490 CHAS REAR SHOCK ABSORBER 3. Adjust: 9 Spring length (installed) a Spring length (installed) a a : Standard Extent of length adjustment 251 mm (9.88 in) 240.5~258.5 mm (9.47~10.18 in) *261 mm (10.28 in) *255.5~273.5 mm (10.06~10.77 in) *For EUROPE NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.
Page 491 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE 3. Régler: 3. Regolare: 3. Einstellen: 9 Longueur de ressort a 9 Lunghezza della molla (installa- 9 Länge der Feder a ta) a Länge der Feder (einge- Longueur de ressort baute)a: Lunghezza della molla (monté)a: (installata)a: Standard-.
Page 492 CHAS REAR SHOCK ABSORBER 3. Install: 9 Rear shock absorber 4. Install: 9 Bolt (rear shock absorber-frame) 1 9 Nut (rear shock absorber-frame) 2 56 Nm (5.6 m•kg, 40 ft•lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: 9 Bolt (rear shock absorber-relay arm) 1 9 Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m•kg, 38 ft•lb)
Page 493 AMORTISSEUR ARRIERE HINTERRAD-STOSSDÄMPFER CHAS AMMORTIZZATORE POSTERIORE 3. Monter: 3. Installare: 3. Einbauen: 9 Amortisseur arrière 9 Ammortizzatore posteriore Hinterrad-Stoßdämpfer 4. Monter: 4. Installare: 4. Einbauen: 9 Boulon (ammortisseur arrière— 9 Bullone (ammortizzatore poste- Schraube (Hinterrad-Stoß- cadre) 1 riore–telaio) 1 dämpfer—Rahmen) 1 9 Ecrou (amortisseur arrière—...
Page 494: Wiring Diagram
ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS COLOR CODE B....Black 1 CDI unit L ....Blue 2 “ENGINE STOP” button 3 Ignition coil O ....Orange R ....Red 4 TPS (throttle position sensor) Y....Yellow 5 Solenoid valve 6 CDI magneto...
Page 495: Elektrische Einrichtungen
COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA ELETTRICO IC600000 PARTIE ELETRIQUE ELEKTRISCHE PARTE ELETTRICA COMPOSANTS EINRICHTUNGEN IC610000 ELECTRIQUES ET COMPONENTI ELEKTRISCHE BAUTEILE SCHEMA DE CABLAGE ELETTRICI E SCHEMA UND SCHALTPLAN COMPOSANTS ELECTRIQUES ELETTRICO ELEKTRISCHE BAUTEILE 1 Bloc CDI...
Page 496: Ignition System
ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM EC621003 INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark *Clean or replace Spark gap test spark plug.
Page 497 ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DE VERIFICATION Utiliser les étapes suivantes pour vérifier la possibilité d’attribution du mauvais fonctionnement du moteur à une panne du circuit d’allumage et pour vérifier la bougie d’allumage qui n’allume pas. Etincelle Essai de l’intervalle d’étincellement *Nettoyer ou remplacer d’allumage.
Page 498 ELEC ZÜNDANLAGE ZÜNDANLAGE PRÜFVORGÄNGE Durch folgende Schritte auf eine mögliche Störung des Motors durch einen Defekt im Zündsystem prü- fen und Ausfindigmachen einer aussetzenden Zündkerze. Zündfunke *Zündkerze reinigen oder Test der Zündfunkenstrecke erneuern. Kein Zündfunke Die Anschlüsse der gesamten Nicht in Ordnung Erneuern oder reparieren.
Page 499 ELEC SISTEMA DI ACCENSIONE IC620000 SISTEMA DI ACCENSIONE IC621003 OPERAZIONI DI ISPEZIONE Usare le operazioni che seguono per controllare la possibilità che il malfunzionamento del motore sia attribuibile a un guasto del sistema di accensione e per controllare la candela che non emette scintille. Scintilla Test della distanza tra gli elettrodi *Pulire o sostituire la candela.
Page 500 ELEC IGNITION SYSTEM å å EC622001 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (igni- tion checker 2 ) as shown. 9 Spark plug cap 3 9 Spark plug 4 A For USA and CDN B Except for USA and CDN 3.
Page 501: Verification Des Connexions
SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC622001 ESSAI DE L’INTERVALLE TEST DER ZÜNDFUNKENSTRECKE TEST DELLA DISTANZA TRA D’ETINCELLEMENT 1. Den Zündkerzenstecker von der GLI ELETTRODI D’ALLUMAGE Zündkerze abtrennen. 1. Scollegare la calotta della candela 1. Déconnecter le capuchon de bou- 2.
Page 502 ELEC IGNITION SYSTEM EC626003 IGNITION COIL INSPECTION 1. Inspect: 9 Primary coil resistance Out of specification ¡ Replace. Tester (+) lead ¡ Orange lead 1 Tester (–) lead ¡ Black lead 2 Primary coil Tester selector resistance position 0.20~0.30Ω at Ω...
Page 503 SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC626003 VERIFICATION DE LA BOBINE INSPEKTION DER ZÜNDSPULE ISPEZIONE DELLA BOBINA DI D’ALLUMAGE 1. Prüfen: ACCENSIONE 9 Widerstand der Primärspule 1. Examiner: 1. Ispezionare: 9 Résistance de bobine primaire Abweichung von Spezifikation 9 Resistenza della bobina prima- Hors spécification ¡...
Page 504 ELEC IGNITION SYSTEM EC62B000 SPARK PLUG CAP INSPECTION 1.Inspect: 9 Spark plug cap Loose connection ¡ Tighten. Deteriorated/Damaged ¡ Replace. 9 Spark plug cap resistance Out of specification ¡ Replace. Tester (+) lead ¡Spark plug lead terminal 1 Tester (–) lead ¡Spark plug terminal 2 Spark plug cap Tester selector resistance...
Page 505: Magneto Cdi
SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE IC62B000 INSPECTION DU CAPUCHON DE PRÜFEN DES CONTROLLO DEL CAPPUCCIO BOUGIE ZÜNDKERZENSTECKERS DELLA CANDELA 1. Examiner: 1. Prüfen: 1.Ispezionare: 9 Capuchon de bougie 9 Zündkerzenstecker 9 Cappuccio della candela Connexion lâche ¡ Serrez. Lose Verbindung ¡...
Page 506 ELEC IGNITION SYSTEM 3. Inspect: 9 Source coil 2 resistance Out of specification ¡ Replace. Tester (+) lead ¡Green/ Blue lead 1 Tester (–) lead ¡Green/ White lead 2 Source coil 2 Tester selector resistance position 44~66Ω at Ω × 10 20°C (68°F) EC628000 CDI UNIT INSPECTION...
Page 507 SYSTEME D’ALLUMAGE ZÜNDANLAGE ELEC SISTEMA DI ACCENSIONE 3. Examiner: 3. Ispezionare: 3. Prüfen: 9 Résistance de bobine de source 9 Resistenza della bobina sorgen- 9 Widerstand der Stromspule 2 te 2 Abweichung von Spezifikation Hors spécification ¡ Changer. Fuori specifica ¡ Sostituirla. ¡...
Page 508: Solenoid Valve System
ELEC SOLENOID VALVE SYSTEM EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. No good Check each couplers and Repair or replace. wire connection. No good Check solenoid Check solenoid valve. Replace.
Page 509: Systeme D'electrovanne
ELEC SYSTEME D’ELECTROVANNE SYSTEME D’ELECTROVANNE ETAPES DE VERIFICATION Si l’électrovanne ne fonctionne pas, applicuez la proqédure d’inspection suivante. Mauvais Vérifiez chaque coupleur et chaque Changer ou réparer. connexion de fil. O.K. Mauvais Vérifiez le bon fonctionne- Vérifiez l’électrovanne. Changer. ment de l’électrovanne. Mauvais Magnetventilspule Changer.
Page 510: Spezialwerkzeuge
ELEC MAGNETVENTILSYSTEM MAGNETVENTILSYSTEM PRÜFVORGÄNGE Falls das Magnetventil nicht funktioniert, sind die folgenden Überprüfungen durchzuführen. Nicht in Ordnung Erneuern oder Alle Stecker - und Kabelverbin- reparieren. dungen überprüfen. In Ordnung Nicht in Ordnung Betriebsablauf des Magnetventil überprüfen. Erneuern. Magnetventils prüfen. Nicht in Ordnung Magnetventilspule Erneuern.
Page 511: Utensili Speciali
ELEC SISTEMA ELETTROVALVOLA IC650001 SISTEMA ELETTROVALVOLA IC651032 OPERAZIONI DI ISPEZIONE Se l’elettrovalvola non funziona, effettuare i seguenti controlli. Non funziona Controllare tutti gli accoppiatori e i Ripararlo o sostituirlo. collegamenti dei fili. Non funziona Controllare il funziona- Controllare l’elettrovalvola. Sostituirlo. mento dell’elettrovalvola.
Page 512: Solenoid Valve System
ELEC SOLENOID VALVE SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: 9 Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ¡ Repair or replace. EC652040 SOLENOID VALVE OPERATION 1. Disconnect the solenoid valve coupler. 2. Connect 12V battery to the solenoid valve coupler.
Page 513 SYSTEME D’ELECTROVANNE MAGNETVENTILSYSTEM ELEC SISTEMA ELETTROVALVOLA IC624000 VERIFICATION DE CONNEXION INSPEKTION DES ANSCHLUSSES ISPEZIONE DEL DES COUPLEURS ET FILS DER KUPPLUNGEN UND KABEL COLLEGAMENTO DI 1. Contrôler: 1. Kontrollieren: ACCOPPIATORI E CONDUTTORI 9 Connexion des coupleurs et fils 9 Anschluß deren Kupplungen 1.
Page 514: Tps (Throttle Position Sensor System
ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate, use the following inspection steps. No good Check entire ignition Repair or replace. system for connection. No good Check TPS. TPS coil Replace.
Page 515 SYSTEME TPS (CAPTEUR DE POSITION DU ELEC PAPILLON) SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) ETAPES DE VERIFICATION Si le TPS ne fonctionne pas, appliquez la procédure d’inspection suivante. Contrôler du système entierd’allumage Mauvais Changer ou réparer. pour les connexions. O.K.
Page 516 ELEC TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) PRÜFVORGÄNGE Falls das TPS nicht funktioniert, sind die folgenden Überprüfungen durchzuführen. Die Anschlüsse der gesamten Nicht in Ordnung Erneuern oder reparieren. Zündanlage kontrollieren. In Ordnung Nicht in Ordnung TPS kontrollieren. TPS-Spule Erneuern.
Page 517 SISTEMA TPS (SENSORE DI POSIZIONE ELEC DELL’ACCELERATORE) IC690000 SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) IC691001 OPERAZIONI DI ISPEZIONE Se il TPS non funziona, effettuare i seguenti controlli. Controllare il collegamento dell’intero Non funziona Ripararlo o sostituirlo. sistema di accensione. Non funziona Controllare il TPS.
Page 518 ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC69A000 HANDLING NOTE Do not loosen the screws {TPS (throttle position sensor)} except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1.
Page 519: Vergaser Und Zungenventil
SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) IC69A000 REMARQUES CONCERNANT LA HANDHABUNGSHINWEISE NOTA PER IL MANEGGIO MANIPULATION Schrauben des TPS-Leitungskabels Non allentare le viti [conduttore TPS Ne pas desserrer les vis du fil du cap- (Drosselstellungssensor) nur dann (sensore di posizione gas)] se non per teur de position du papillon (TPS),...
Page 520 ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 3. Inspect: 9 TPS coil variable resistance Check that the resistance in increased as the lever 1 is moved from the full close position to the full open position. Out of specification ¡ Replace. Tester (+) lead ¡Yellow lead 2 Tester (–) lead ¡Black lead 3 TPS coil variable...
Page 521 SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) 3.Examiner: 3. Ispezionare: 3.Prüfen: 9 Résistance variable de la bobine 9 Resistenza variabile della bobi- 9 Regelbarer TPS-Spulenwider- du TPS na del TPS stand Vérifier si la résistance augmen- Controllare che la resistenza...
Page 522 ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 4. Install: 9 TPS 1 9 Screw (TPS) 2 NOTE: 9 Align the slot a in the TPS with the projection b on the carburetor while the lever 3 is held down. 9 Temporarily tighten the screws (TPS). 5.
Page 523 SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) 4. Monter: 4. Installare: 4. Ausbauen: 9 TPS 1 9 TPS 1 9 TPS 1 9 Vis (TPS) 2 9 Vite (TPS) 2 9 Schraube (TPS) 2 HINWEIS: N.B.:...
Page 524 ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 8. Start the engine. 9. Adjust: 9 TPS output voltage Adjustment steps: Adjust the installation angle of the TPS 1 to obtain the specified output volt- age. TPS output Tester selector voltage position 0.5~0.7V DCV-20 10.
Page 525 SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) 8. Démarrer le moteur. 8. Avviare il motore. 8. Den Motor anlassen. 9. Régler: 9. Regolare: 9. Einstellen: 9 Tension de sortie TPS 9 Tensione d'uscita del TPS 9 TPS-Ausgangsspannung Einstellschritte:...
Page 526 ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM EC694000 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: 9 TPS input voltage Out of specification ¡ Replace the CDI unit. Tester (+) lead ¡Blue lead 1 Tester (–) lead ¡Black/Blue lead 2 TPS input Tester selector...
Page 527 SYSTEME TPS (CAPTEUR DE POSITION DU PAPILLON) TPS-SYSTEM (TPS = DROSSELSTELLUNGSSENSOR) ELEC SISTEMA TPS (SENSORE DI POSIZIONE DELL’ACCELERATORE) IC694000 VERIFICATION DE LA TENSION KONTROLLE DER TPS-EINGANGS- ISPEZIONE DELLA TENSIONE IN D’ENTREE DU TPS SPANNUNG INGRESSO NEL TPS 1. Déconnecter le coupleur du TPS. 1.
Page 528 SETTING EC700000 TUNING EC710000 ENGINE EC711001 Carburetor setting 9 The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine in addition to power generation. Accord- ingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result.
Page 529 REGLAGE EINSTELLUNG REGISTRAZIONE IC700000 MISE AU POINT TUNING MESSA A PUNTO MOTEUR MOTOR IC710000 Réglage du carburateur Vergasereinstellung MOTORE 9 Le rôle du carburant consiste à 9 Zusätzlich zu der Krafterzeugung IC711001 refroidir le moteur et dans le cas dient der Kraftstoff auch zur Kühlung Registrazione del carburatore d’un moteur à...
Page 530 SETTING That is: 9 Higher temperature expands the air with its resultant reduced density. 9 Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. 9 Lower atmospheric pressure (at a high altitude) reduces the density of the air.
Page 531 REGLAGE EINSTELLUNG REGISTRAZIONE Ainsi: Cioè: Das heißt: 9 Une température plus élevée dilate 9 Una temperatura più alta fa dilatare 9 Eine höhere Temperatur führt zu l’air et en réduit la densité. l’aria; ne risulta una densità ridotta. einer Ausdehnung der Luft und 9 Une humidité...
Page 532 SETTING EC714032 Effects of setting parts in relation to throt- tle valve opening Throttle valve opening Setting part Full-closed 1/4 3/4 Full-open Pilot jet Pilot air screw Diameter of straight portion Clip position Throttle valve Power jet Main jet NOTE: The power jet closes at 8,500 rpm of the engine, after which only the main jet dominates.
Page 533 REGLAGE EINSTELLUNG REGISTRAZIONE IC714032 Ajustement de pièces à l’ouverture Wirkung der Einstellteile in Bezie- Effetto delle parti di registrazione in du papillon des gaz hung zur Öffnung der Drosselklappe relazione all’apertura della valvola regolatrice del flusso Ouverture du papillon des gaz Drosselklappenöffnung Pièce de réglage Fermé...
Page 534 SETTING EC716001 Pilot air screw adjustment The richness of air-fuel mixture with full closed to 1/8 throttle can be set by turning the pilot air screw 1. Turning in the pilot air screw will enrich the mix- ture at low speeds, and turning out it will lean out the mixture.
Page 535 REGLAGE EINSTELLUNG REGISTRAZIONE IC716001 Réglage de la vis de richesse Einstellung der Leerlauf-Luftregu- Regolazione della vite dell’aria pilota La richesse du mélange air-carburant lierschraube La ricchezza della miscela aria-carbu- avec le papillon des gaz fermé à 1/8 Der Kraftstoffgehalt des Luft/Kraftstoffge- rante con la valvola regolatrice del flus- peut être réglée en tournant la vis de misches bei vollständig geschlossener...
Page 536 SETTING 1. Too rich at intermediate speeds Rough engine operation is felt and 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.
Page 537 REGLAGE EINSTELLUNG REGISTRAZIONE 1. Trop riche aux régimes intermé- 1. Zu fett bei mittleren Drehzahlen 1. Troppo ricca a regimi intermedi diaires Rauher Motorbetrieb kann festge- Si sente che il motore funziona in Le fonctionnement du moteur est stellt werden und der Motor kann maniera discontinua e riprende irrégulier et le moteur ne prend pas nicht glatt beschleunigt werden.
Page 538 SETTING EC719081 Jet needle adjustment (For USA, CDN, ZA, AUS and NZ) On the carburetors used in the YZ250, the main nozzle is press-fitted, so it can not be replaced. Therefore, carburetor setting requires the change of the jet needle. 1.
Page 539 REGLAGE EINSTELLUNG REGISTRAZIONE IC719081 Réglage de l’aiguille de gicleur Düsennadel-Einstellung Regolazione dell’ago a getto (Pour USA, CDN, ZA, AUS et NZ) (Für USA, CDN, ZA, AUS und NZ) (Per USA, CDN, ZA, AUS e NZ) Sur les carburateurs utilisés pour le An den in das Modell YZ250 ver- Sui carburatori usati nella YZ250, YZ250, la buse princi;ase est forcée et...
Page 540 SETTING EC719081 Jet needle adjustment (For EUROPE) On the carburetors used in the YZ250, the main nozzle is press-fitted, so it can not be replaced. Therefore, carburetor setting requires the change of the jet needle. 1. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper start- ing positions.
Page 541 REGLAGE EINSTELLUNG REGISTRAZIONE IC719081 Réglage de l’aiguille de gicleur Düsennadel-Einstellung Regolazione dell’ago a getto (Pour EUROPE) (Für EUROPA) (Per EUROPA) Sur les carburateurs utilisés pour le An den in das Modell YZ250 ver- Sui carburatori usati nella YZ250, YZ250, la buse princi;ase est forcée et wendeten Vergasern ist der Hauptzer- l’ugello principale è...
Page 542 SETTING EC71B011 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. On the relationship between the fuel flow and the throttle opening, the fuel flow relates to the jet needle straight por- tion diameter around 1/8 to 1/4 throttle opening,...
Page 543 REGLAGE EINSTELLUNG REGISTRAZIONE IC71B011 Relation avec l’ouverture du papillon Zusammenhang mit der Drosselöff- Rapporto con l’apertura della valvo- L’arrivée du carburant dans le système nung la a farfalla principal du carburateur est contrôlée Die durch das Vergaser-Hauptsystem Il flusso del carburante attraverso il par le gicleur principal, puis est encore strömende Kraftstoffmenge wird durch sistema principale del carburatore è...
Page 544 SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet 1 1 Rich #190 4MX-14943-45 #188 4MX-14943-95 #185 4MX-14943-44 #182 4MX-14943-94 *(STD) #180 4MX-14943-43 (STD) #178 4MX-14943-93 #175 4MX-14943-42 #172 4MX-14943-92 #170 4MX-14943-41 #168 4MX-14943-91 #165 4MX-14943-40 Lean #162 4MX-14943-90 Pilot jet 2 2...
Page 545 REGLAGE EINSTELLUNG REGISTRAZIONE IC71Q000 Pièces de réglage du carburateur Vergaser-Einstellteile Parti di regolazione del carburatore Teilebezeichnung Größe Teilenummer Numéro Particolare Dimen- Numero Nom de pièce Taille de pièce sioni categorico Haupt- Fett #190 4MX-14943-45 düse 1 1 #188 4MX-14943-95 Gicleur Riche #190 4MX-14943-45...
Page 546 SETTING EC71C030 Road condition and examples of carburetor setting Conditions General condition Sandy condition Under 10°C 10~25°C Over 25°C Under 10°C 10~25°C Over 25°C (50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F) Parts (Winter) (Spring, Autumn) (Summer) (Winter) (Spring, Autumn) (Summer) #178 #180 #178 Main jet...
Page 547 SETTING Symptom Setting Checking Number of turns-back ¡ 0~1/4 throttle Use jet needle having a smaller Hard breathing diameter. Correct properly Speed down Overflow from carburetor 0~1/4 throttle Use jet needle having a larger Poor acceleration diameter. White smoke Unstable at low speeds Lower jet needle clip position.
Page 548 REGLAGE Conditions de la route et exemples de réglages de carburateur Conditions Générales Sablonneux Moins 10 à 25°C Plus de 25°C Moins de 10 à 25°C Plus de 25°C de 10°C (50°F) (50 à 77°F) (77°F) 10°C (50°F) (50 à 77°F) (77°F) Pièce (Hiver)
Page 549 REGLAGE Symptômes Réglages Contrôler Nombre de tours de dévissage ¡ 0~1/4 de papillon Utiliser une aiguille de gicleur avec un Attaque difficile diamètre inférieur. Corriger correctement Perte de vitesse Fuite en provenance du carburateur 0~1/4 de papillon Utiliser une aiguille de gicleur avec un Mauvaise accélération diamètre supérieur.
Page 550 EINSTELLUNG Straßenbedingungen und Beispiele für die Vergasereinstellung Normal Sandig Bedingungen Unter 10°C 10~25°C Über 25°C Unter 10°C 10~25°C Über 25°C (50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F) Teile (Winter) (Frühling, Herbst) (Sommer) (Winter) (Frühling, Herbst) (Sommer) #178 #180 #178 Hauptdüse #178 #178 #178 *#180...
Page 551 EINSTELLUNG Symptom Einstellung Prüfung Anzahl der Ausdrehungen ¡ 0~1/4 Gas Eine Düsennadel mit kleinerem Hartes Beatmen Durchmesser verwenden. Richtig korrigieren Überlauf am Niedrige Drehzahl Vergaser 0~1/4 Gas Eine Düsennadel mit größerem Schlechte Beschleunigung Durchmesser verwenden. Weißer Rauch Unstabil bei niedriger Düsennadel-Klemmenposition Drehzahl absenken.
Page 552 REGISTRAZIONE IC71C030 Condizioni stradali ed esempi di registrazione del carburatore Condizioni Condizioni generiche Condizioni di sabbia Meno di 10°C 10~25°C Più di 25°C Meno di 10°C 10~25°C Più di 25°C (50°F) (50~77°F) (77°F) (50°F) (50~77°F) (77°F) Parti (inverno) (primavera, autunno) (estate) (inverno) (primavera, autunno)
Page 553 REGISTRAZIONE Sintomo Registrazione Controllo Numero di giri in senso contrario ¡ Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un Respirazione difficoltosa diametro più piccolo. Correggere adeguatamente Velocità bassa Traboccamento dal carburatore Valvola a farfalla a 0 ~ 1/4 Usare un ago a getto che abbia un Accelerazione scarsa diametro più...
Page 554 SETTING EC71M010 Change of the heat range of spark plugs Judging from the discoloration of spark plugs, if they are found improper, it can be corrected by the following two methods; changing carburetor settings and changing the heat range of spark plug.
Page 555 REGLAGE EINSTELLUNG REGISTRAZIONE IC71M010 Changement de plage de chaleur des Änderung des Wärmebereichs der Cambiamento della gamma termica bougies Zündkerzen delle candele En fonction de la décoloration des bou- Falls anhand der Verfärbung der Giudicando dallo scolorimento delle gies, si elle n’est pas normale, elle peut Zündkerzen eine falsche Einstellung candele, se si rileva che sono inadegua- être corrigée par les deux méthodes qui...
Page 556 SETTING EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction Number of drive sprocket teeth ratio Standard secondary 50/14 (3.571) reduction ratio *49/14 (3.500) *For EUROPE and CDN <Requirement for selection of secondary gear reduction ratio>...
Page 557: Fahrgestell
REGLAGE EINSTELLUNG REGISTRAZIONE IC720000 PARTIE CYCLE FAHRGESTELL TELAIO Sélection du taux de réduction secon- Auswahl des Sekundär- IC71P002 daire (Pignons) Untersetzungsverhältnisses Selezione del rapporto di riduzione (Kettenrad) secondario (Rocchetto) Nombre de dents du pignon mené Anzahl der Zähne am Numero di denti Taux de réduction angetriebenen Kettenrad del rocchetto condotto...
Page 558 SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 1 9383E-13144 (STD) 9383E-14215 Driven sprocket 2 2 5ET-25447-00 5NY-25448-00 *(STD) 5NY-25449-00 (STD) 5NY-25450-00 5NY-25451-00 5NY-25452-00 *For EUROPE and CDN EC721003 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
Page 559 REGLAGE EINSTELLUNG REGISTRAZIONE IC72N000 Pièces de réglage des pignons méné et Antriebs- und Abtriebskettenrad- Parti di regolazione del rocchetto menant Einstellteile conduttore e condotto Teilebezeichnung Größe Teilenummer Numéro Dimen- Numero Nom de pièce Taille Particolare de pièce sioni categorico Antriebskettenrad 9383E-13144 (STD) 9383E-14215...
Page 560 SETTING EC722011 Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the cir- cuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics 9 Change the fork oil level.
Page 561: Fourche Avant
REGLAGE EINSTELLUNG REGISTRAZIONE IC722011 Réglages de la fourche avant Einstellung der Vorderradgabel Registrazione della forcella anteriore Régler la fourche avant en fonction de Die Einstellung der Vorderradgabel La registrazione della forcella anteriore la sensation lors de la conduite ainsi soll entsperechend dem Gefühl des dovrebbe essere effettuata in base alla sen- que des conditions du terrain.
Page 562 SETTING EC727021 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. Do not install three or more adjustment washers for each front fork. Always adjust each front fork to the same setting.
Page 563 REGLAGE EINSTELLUNG REGISTRAZIONE IC727021 Réglage de tension initiale du ressort Einstellung der Federvorspannung Regolazione del precarico della molla Le tension initiale du ressort a été ajus- Die Federvorspannung wird einge- Il precarico della molla viene regolato tée en montant la rondelle de réglage 1 stellt, indem die Einstellscheibe 1 installando la rondella di regolazione entre le ressort de fourche 2 et la tige...
Page 564 SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of con- tact with the road surface or in a vibrating handlebar. To set a stiff spring: 9 Change the rebound damping.
Page 565 REGLAGE EINSTELLUNG REGISTRAZIONE 2. Ressort dur 2. Uso di una molla rigida 2. Verwendung einer harten Feder En principe, un ressort dur offre Generalmente una molla rigida dà Normaleweise bewirkt eine harte une sensation de conduite dure. La una sensazione di guida rigida. Lo Feder ein hartes Fahrgefühl.
Page 566 SETTING EC72P010 Front fork setting parts 9 Adjustment washer 1 TYPE (thickness) PART NUMBER T=2.3 mm (0.09 in) 4SS-23364-L0 9 Front fork spring 2 [Equal pitch spring ] I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.380 4SS-23141-10 0.390 4SS-23141-20 I-II SOFT...
Page 567 REGLAGE EINSTELLUNG REGISTRAZIONE IC72P010 Pièces de réglage de la fourche avant Vorderradgabel-Einstellteile Parti di regolazione della forcella 9 Rondelle de réglage 1 9 Einstellscheibe 1 anteriore 9 Rondella di regolazione 1 TYPE (epaisseur) NUMERO DE PIECE TYP (Dicke) TEILENUMMER TIPO (spessore) NUMERO CATEGORICO T=2,3 mm (0,09 in) 4SS-23364-L0 T=2,3 mm (0,09 in)
Page 568 SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the follow- ing two factors: 1. Setting of spring preload 9 Change the set length of the spring.
Page 569 REGLAGE EINSTELLUNG REGISTRAZIONE IC72B000 Réglage de la suspension arrière Einstellung der Hinterradfederung Registrazione della sospensione posteriore Effectuer le réglage de la suspension Die Einstellung der Hinterradfederung La registrazione della sospensione arrière en fonction de la sensation lors soll entsprechend dem Gefühl des posteriore dovrebbe essere effettuata in de la conduite ainsi que des conditions Fahrers nach einer Testfahrt und den...
Page 570 SETTING NOTE: 9 If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re-evaluation. 9 If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.
Page 571 REGLAGE EINSTELLUNG REGISTRAZIONE N.B.: HINWEIS: NOTA: 9 Le ressort peut s’allonger au fur et à 9 Se il veicolo è nuovo e dopo il rodag- 9 Wenn eine neue Maschine eingefah- mesure de la période de rodage. Il est gio, la stessa lunghezza registrata ren worden ist, kann es sein, daß...
Page 572 SETTING When using a rear cushion other than cur- rently installed, use the one whose overall length a a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a a of standard shock: 490.5 mm (19.31 in) å...
Page 573 REGLAGE EINSTELLUNG REGISTRAZIONE Lors du remplacement du ressort de Quando si usa un ammortizzatore Bei Verwendung eines anderen hin- la suspension arrière, veiller à mon- posteriore diverso da quello attual- teren Stoßdämpfers ter un ressort dont la longueur totale mente installato, usarne uno la cui momentan eingebauten verwenden a a n’excède pas la longueur standard lunghezza totale a a non superi quella...
Page 574 SETTING EC72Q011 Rear shock absorber setting parts 9 Rear shock spring 1 [Equal pitch spring ] I.D. SPRING SPRING SPRING TYPE COLOR FREE RATE PART NUMBER /POINT LENGTH 5UN-22212-00 Brown/1 SOFT 5UN-22212-10 Green/1 5UN-22212-20 Red/1 5UN-22212-30 Black/1 5UN-22212-40 Blue/1 5UN-22212-50 Yellow/1 STIFF 5UN-22212-60...
Page 575 REGLAGE EINSTELLUNG REGISTRAZIONE IC72Q011 Pièces de réglage de l’amortisseur Hinterradstoßdämpfer-Einstellteile Parti di regolazione dell’ammortizza- 9 Hinterradstoßdämpfer-Schrauben arrière tore posteriore 9 Ressort d’amortisseur arrière 1 feder 1 9 Molla dell’ammortizzatore posteriore [Ressort à pas égal] [Feder mit gleichmäßiger Gewinde- steigung] [Molla di passo unguale] CONSTANTE NUMERO DE REPERE Longueur FEDER- I.D.MAR-...
Page 576: Suspension Setting
SETTING EC72H010 Suspension setting 9 Front fork NOTE: 9 If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. 9 Before any change, set the rear shock absorber sunken length to the standard figure 90~100 mm (3.5~3.9 in).
Page 577 SETTING 9 Rear shock absorber NOTE: 9 If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. 9 Adjust the rebound damping in 2-click increments or decrements. 9 Adjust the low compression damping in 1-click increments or decrements.
Page 578 REGLAGE Réglage de la suspension 9 Fourche avant N.B.: 9 Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectur un nouveau réglage en se référant aux procédés repris dans ce tableau. 9 Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière à la valeur stan- dard de 90~100 mm (3,5~3,9 in).
Page 579 REGLAGE 9 Amortisseur arrière N.B.: 9 Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, ettectur un nouveau réglage en se référant aux procédés repris dans ce tableau. 9 Ajuster la force de rebond par incréments et décréments de 2 déclics. 9 Ajuster la force d’amortissement de compression basse par incréments ou décréments de 1 déclic.
Page 580 EINSTELLUNG Federungseinstellung 9 Vorderradgabel HINWEIS: 9Wenn eines der folgenden Symptome mit der Standardeinstellung als Basis auftritt, nehmen Sie eine Nachstellung unter Beachtung der in der Tabelle gezeigten Einstellschritte vor. 9Vor jeder Änderung stellen Sie die eingetauchte Länge des Hinterrad-Stoßdämpfers auf den Stan- dardwert von 90~100 mm (3,5~3,9 in) ein.
Page 581 EINSTELLUNG 9 Hinterradstoßdämpfer HINWEIS: 9Wenn eines der folgenden Symptome mit der Standardeinstellung als Basis auftritt, nehmen Sie eine Nachstellung unter Beachtung der in der Tabelle gezeigten Einstellschritte vor. 9Einstellung der Ausfederdämpfung jeweils in Schritten von 2 Vorwärts- oder Rückwärts-Klickstellun- gen. 9Einstellung der niedrige Einfederdämpfung jeweils in Schritten von 1 Vorwärts- oder Rückwärts-Klick- stellung.
Page 582 REGISTRAZIONE IC72H010 Registrazione della sospensione 9 Forcella anteriore NOTA: 9 Se si verifica uno qualsiasi dei seguenti sintomi con la posizione normale come base, effettuare la ri-regi- strazione facendo riferimento alla procedura di registrazione fornita nella stessa tabella. 9 Prima di qualsiasi modifica, registrare la lunghezza abbassata dell’ammortizzatore posteriore sulla cifra normale di 90~100 mm (3,5~3,9 in).
Page 583 REGISTRAZIONE 9 Ammortizzatore posteriore NOTA: 9 Se si verifica uno qualsiasi dei seguenti sintomi con la posizione normale come base, effettuare la ri-regi- strazione facendo riferimento alla procedura di registrazione fornita nella stessa tabella. 9 Regolare lo smorzamento dell’estensione in incrementi o decrementi di 2 scatti. 9 Regolare lo smorzamento a bassa compressione in incrementi o decrementi di 1 scatto.
Page 584 MEMO...
Page 586 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.5—1.7 × 1 ! 2500 SHINGAI IWATA SHIZUOKA JAPAN (E, F, G, H)

This manual is also suitable for:

Yz250lc Yz250r1 Yz250r Yz250

Yamaha YZ250(R)/LC Owner's Service Manual

Chapter 7

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Quick Links

Related Manuals for Yamaha YZ250(R)/LC

Summary of Contents for Yamaha YZ250(R)/LC

This manual is also suitable for:

Table of Contents