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Yamaha YZ250F(S) Owner's Service Manual

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OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGS-HANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
YZ250F(S)
5XC-28199-30

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  • Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250F(S) 5XC-28199-30...
  • Page 2 EC010010 YZ250F(S) OWNER’S SERVICE MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st Edition, July 2003 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 MANUALE DI SERVIZIO DEL HANDBUCH DU PROPRIETAIRE PROPRIETARIO ©2003 Yamaha Motor Co., Ltd. ©2003 Yamaha Motor Co., Ltd. ©2003 by Yamaha Motor Co., Ltd. 1. Auflage, Jnli 2003 1ère édition, juillet 2003 edizione, luglio 2003 Tous droits réservés Alle Rechte vorbehalten.
  • Page 4 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
  • Page 5 Daraus resultiert ein hohes plus élevé de la dextérité manuelle et de massimo grado di quella eccezionalità la fiabilité qui ont fait de Yamaha un lea- Maß an Qualität und die sprichwörtli- qualitativa e affidabilità che hanno reso der.

  • Page 6: Important Notice

    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 regula- tions before riding.
  • Page 7 NOTICE ZUR BEACHTUNG COMUNICAZIONE IMPORTANTE IMPORTANTE Dieses Motorrad ist ausschließlich für den Einsatz im Gelände-Renn- CETTE MACHINE EST STRICTE- QUESTO VEICOLO È STATO PRO- sport auf geschlossenen Kursen MENT DESTINEE A LA COMPETI- GETTATO ESCLUSIVAMENTE PER bestimmt. Die Benutzung dieses TION, UNIQUEMENT SUR CIRCUIT LE COMPETIZIONI SU CIRCUITI...
  • Page 8 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
  • Page 9 L’ESSENCE PEUT CAUSER Benzin ist giftig. LA BENZINA PUÒ PROVO- DES BLESSURES. Sollten Sie versehentlich CARE DANNI PERSONALI. Si vous avalez de l’essence, res- Benzin verschluckt, Ben- In caso di ingestione involonta- pirez des vapeurs d’essence en zindämpfe eingeatmet oder benzina, inalazione excès ou laissez de l’essence...

  • Page 10: Machine Weights

    If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
  • Page 11 Sie sich ou l’entretien de votre machine, veuillez del veicolo, consultare il proprio rivendi- vor Unfällen schützen. consulter votre concessionnaire Yamaha. tore Yamaha. Wenn Sie die vielen Tips der Bedie- N.B.: NOTA: nungsanleitung nutzen, garantieren Ce manuel doit être considéré...

  • Page 12: Description

    EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING 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: Renseignements Generaux

    BENUTZERHINWEISE COMMENT UTILISER COME UTILIZZARE CE MANUEL QUESTO MANUALE KENNZEICHNUNG WICH- TIGER HINWEISE INFORMATIONS PARTI- INFORMAZIONI PARTI- CULIEREMENT IMPOR- COLARMENTE IMPOR- TANTES TANTI Ausrufezeichen bedeutet: “GEFAHR! Achten Sie auf Ihre Sicherheit!” Questo simbolo segnala un pericolo che Le symbole d’alerte de sécurité signifie richiede la MASSIMA ATTENZIONE! ATTENTION! SOYEZ VIGILANT! WARNUNG...
  • 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., Bearings...
  • Page 15 AUFBAU FORMAT DU MANUEL STRUTTURA DEL MANUALE Diese Anleitung wurde zusammen- Dans ce manuel, toutes les procédures gestellt, um dem Benutzer ein leicht sont décrites pas à pas. Les informations Tutte le procedure di questo manuale verständliches Nachschlagewerk in ont été condensées pour fournir au méca- sono organizzate in sequenze passo a die Hand zu geben, in dem alle dar- nicien un guide pratique et facile à...
  • Page 16 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical –...
  • Page 17 ABGEBILDETEN SYM- SYMBOLES GRAPHI- SIMBOLI ILLUSTRATI QUES (Fare riferimento all’illu- (Siehe Abbildung) (Voir l’illustration) strazione) Die unter 1 bis 7 abgebildeten Les symboles graphiques 1 à 7 servent I simboli illustrati da 1 a 7 vengono Symbole weisen auf die Themen der à...
  • Page 18 EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
  • Page 19 INDEX INDEX INDICE ALLGEMEINE RENSEIGNEMENTS INFORMAZIONI GENERAUX GENERALI ANGABEN INFO TECHNISCHE CARACTERISTI- SPECIFICHE QUES DATEN SPEC REGELMÄSSIGE CONTROLES ET ISPEZIONI E REGLAGES INSPEKTION UND REGISTRAZIONI INSP COURANTS REGOLARI EINSTELLARBEITEN MOTOR MOTEUR MOTORE FAHRWERK PARTIE CYCLE PARTE CICLISTICA CHAS – ELEKTRISCHE PARTIE IMPIANTO ELECTRIQUE...

  • 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 ......1-10 FUEL ............1-13 STARTING AND BREAK-IN ....1-14 TORQUE-CHECK POINTS ..... 1-18 CLEANING AND STORAGE ....
  • Page 21 INHALT TABLES DES INDICE MATIERES KAPITEL 1 CAPITOLO 1 CHAPITRE 1 ALLGEMEINE INFORMAZIONI ANGABEN RENSEIGNEMENTS GENERALI GENERAUX FAHRZEUGBESCHREIBUNG ... 1-1 DESCRIZIONE ......1-1 DESCRIPTION ......1-1 FAHRZEUG- IDENTIFICAZIONE DEL IDENTIFICATION DE LA IDENTIFIZIERUNG ..... 1-2 VEICOLO ........1-2 MACHINE ........1-2 WICHTIGE INFORMATIONEN ..
  • Page 22 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ......... 4-1 EXHAUST PIPE AND SILENCER .... 4-3 RADIATOR ..........4-5 CARBURETOR ......... 4-8 CAMSHAFTS .......... 4-21 CYLINDER HEAD ........4-30 VALVES AND VALVE SPRINGS ... 4-33 CYLINDER AND PISTON ....... 4-42 CLUTCH ..........

  • Page 23: Moteur

    KAPITEL 4 CHAPITRE 4 CAPITOLO 4 MOTOR MOTEUR MOTORE SELLE, RESERVOIR DE SITZBANK, SELLA, SERBATOIO CARBURANT ET CACHES KRAFTSTOFFTANK UND CARBURANTE E LATERAUX ........4-1 SEITENABDECKUNGEN ..4-1 CARENATURA LATERALE ..4-1 TUYAU D’ECHAPPEMENT KRÜMMER UND TUBO DI SCARICO E ET SILENCIEUX ......
  • Page 24 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ......6-1 MAP-CONTROLLED CDI UNIT ....6-2 IGNITION SYSTEM ........6-3 THROTTLE POSITION SENSOR SYSTEM ............ 6-7 CHAPTER 7 TUNING ENGINE ............. 7-1 CHASSIS ..........7-11...

  • Page 25: Partie Electrique

    KAPITEL 6 CHAPITRE 6 CAPITOLO 6 ELEKTRISCHE PARTIE IMPIANTO ELECTRIQUE ANLAGE ELETTRICO COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE COMPONENTI ELETTRICI E ET SCHEMA DE CABLAGE ..6-1 UND SCHALTPLAN ....6-1 SCHEMA DI CABLAGGIO ..6-1 BLOC CDI CONTROLE PAR KENNFELDGESTEUERTES UNITÀ CDI CONTROLLATA MICROPROCESSEUR ....

  • Page 26: Description

    DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Hot starter lever The machine you have purchased may differ 3 Front brake lever slightly from those shown in the following. 4 Throttle grip Designs and specifications are subject to 5 Radiator cap change without notice.

  • Page 27: Fahrzeugbeschreibung

    DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIZIONE INFO RENSEIGNEMENTS ALLGEMEINE INFORMAZIONI ANGABEN GENERAUX GENERALI FAHRZEUGBESCHREI- DESCRIPTION DESCRIZIONE BUNG 1 Levier d’embrayage 1 Leva della frizione 2 Levier de démarreur à chaud 2 Leva dell’avviamento a caldo 1 Kupplungshebel 3 Levier de frein avant 3 Leva del freno anteriore 2 Heißstarter-Hebel 4 Poignée des gaz 4 Manopola dell’acceleratore...

  • 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 number to your Yamaha dealer for posi- tive identification 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: Identificazione Del Veicolo

    Diebstahlmeldung concessionnaire Yamaha numero al proprio rivenditore d’identifier clairement la machine. Yamaha per identificare corretta- En cas de vol du véhicule, la mente il modello. police réclamera ces numéros afin Se il veicolo viene rubato, le de faciliter son identification.

  • Page 30: Important Information

    IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts follows. Silencer exhaust port Side cover air intake port Water pump housing hole at the bottom Drain hole on the cylinder head (right...

  • Page 31: Informations Importantes

    INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO INFORMATIONS IMPOR- WICHTIGE INFORMATIO- INFORMAZIONI IMPOR- TANTES TANTI VORBEREITUNG FÜR AUSBAU PREPARATION POUR LA DEPOSE PREPARATIVI PER LA RIMO- UND ZERLEGUNG ET DEMONTAGE ZIONE E IL DISASSEMBLAGGIO Vor dem Ausbau oder Zerle- Eliminer soigneusement crasse, Rimuovere tutto lo sporco, il gen der Bauteile sämtlichen boue, poussière et corps étrangers...
  • 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 by Yamaha for 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 over- hauled.
  • Page 33 Utiliser Yamaha empfohlene Schmier- originali Yamaha per tutte le les huiles/graisses recomman- stoffe verwenden. Fremdfabri- eventuali sostituzioni. Impiegare dées par Yamaha lors des remon- kate erfüllen häufig nicht die esclusivamente oli e/o grassi con- gestellten Qualitätsanforde- tages et réglages.
  • Page 34 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1, make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives.
  • Page 35 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI INFO CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI ARRESTO Avant remontage, tous les circlips Sicherungsringe vor dem Wie- Ispezionare attentamente tutti gli dereinbau sorgfältig überprü- doivent être soigneusement véri- anelli elastici di arresto prima di fen und bei Beschädigung 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: 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: Verification Des Connexions

    VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO VERIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI COL- Die Steckverbinder auf Oxidation, CONNEXIONS LEGAMENTI Rost, Feuchtigkeit usw. prüfen Traitement des taches, de la rouille, de Come gestire macchie, ruggine, umidità, Lösen: l’humidité, etc. sur le connecteur. ecc.

  • Page 38: Special Tools

    SPECIAL TOOLS INFO 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 techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 39 SPECIAL TOOLS INFO Part number Tool name/How to use Illustration YU-33975, 90890-01403 Steering nut wrench YU-33975 90890-01403 This tool is used when tighten the steering ring nut to specification. YM-01442, 90890-01442 Fork seal driver YM-01442 90890-01442 This tool is used when install the fork oil seal. YM-01494, 90890-01494 Damper rod holder YM-01494...
  • Page 40 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition 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. 1 - 9...

  • Page 41: 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 42 OUTILS SPECIAUX INFO Numéros de pièce Nom et usage de l’outil Illustration YU-33975, 90890-01403 Clé à ergots YU-33975 90890-01403 Cet outil est utilisé pour serrer l’écrou crénelé de direction aux spécifications. YM-01442, 90890-01442 Outil d’insertion de joint de fourche YM-01442 90890-01442 Cet outil est utilisé...
  • Page 43 90890-06754 Contrôleur d’allumage Ce testeur est nécessaire pour contrôler les composants du système d’allumage. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond n˚ 1215 Ce mastic est utilisé sur les plans de joint du carter, etc. 1 - 9...

  • Page 44: Spezialwerkzeuge

    SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden wer- den, 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 45 SPEZIALWERKZEUGE INFO Teilenummer Werkzeug/Anwendung Abbildung YU-33975, 90890-01403 Hakenschlüssel YU-33975 90890-01403 Zum Lösen und Festziehen der Lenkkopf-Ringmut- ter. YM-01442, 90890-01442 Gabeldichtring-Treiber YM-01442 90890-01442 Zum Einbau der Gabeldichtringe. YM-01494, 90890-01494 Dämpferrohr-Halter YM-01494 90890-01494 Zum Lösen und Festziehen der Befestigungs- schraube des Teleskopgabel-Dämpferrohrs. YU-3112-C, 90890-03112 Taschen-Multimeter YU-3112-C...
  • Page 46 Einlaß 4,0 mm (0,16 in) Auslaß 4,5 mm (0,18 in) Zum Aufreiben der neuen Ventilführungen. YM-34487 Zündfunkenstreckentester YM-34487 90890-06754 90890-06754 Zündprüfer Zur Überprüfung der Zündanlage.  ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA-Dichtmasse Nr. 1215 Zum Abdichten der Kurbelgehäuse-Paßflächen. 1 - 9...

  • Page 47: Utensili Speciali

    UTENSILI SPECIALI INFO UTENSILI SPECIALI Sono necessari idonei utensili speciali per una messa a punto e un assemblaggio completi e accurati. L’impiego dell’attrezzo speciale adatto aiuterà a prevenire eventuali danni causati dall’impiego di utensili non idonei o di tecniche improvvisate. La forma e il numero di pezzo utilizzato per l’attrezzo speciale differiscono da paese a paese, pertanto ne vengono indicati due tipi.
  • Page 48 UTENSILI SPECIALI INFO Numero di pezzo Nome dell’attrezzo/Come utilizzarlo Figura YU-33975, 90890-01403 Chiave per ghiere YU-33975 90890-01403 Questo attrezzo è utilizzato per serrare le ghiere fino ai valori indicati nelle specifiche. YM-01442, 90890-01442 Utensile per il paraolio della forcella YM-01442 90890-01442 Questo attrezzo è...
  • Page 49 Questo attrezzo è necessario per il controllo dei componenti del sistema di accensione. ® ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond n. 1215 Questo materiale di tenuta (agglomerante) è utilizzato per chiudere ermeticamente due superfici di contatto, ecc. 1 - 9...

  • Page 50: Control Functions

    CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar;...

  • Page 51: Fonctions Des Commandes

    FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO FONCTIONS DES COM- ARMATUREN UND DE- FUNZIONI DI COMANDO REN FUNKTION MANDES INTERRUTTORE ARRESTO DEL MOTORE MOTORSTOPPSCHALTER COUPE-CIRCUIT DU MOTEUR L’interruttore di arresto del motore 1 è Der Motorstoppschalter 1 befindet Le coupe-circuit du moteur 1 est situé...

  • Page 52: Fuel

    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 53 FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO LEVIER DE FREIN AVANT HANDBREMSHEBEL LEVA DEL FRENO ANTERIORE Le levier de frein avant 1 se trouve à la Der Handbremshebel 1 zur Betäti- La leva del freno anteriore 1 è posta sul poignée droite.
  • Page 54 CONTROL FUNCTIONS INFO EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. WARNING Never apply additional force to the side- stand. 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 55 FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO BEQUILLE LATERALE AMOVI- ABNEHMBARER SEITENSTÄN- CAVALLETTO LATERALE SMON- TABILE La béquille latérale 1 est utilisée pour Der Seitenständer 1 dient nur zum Questo cavalletto laterale 1 viene utiliz- soutenir la machine uniquement à l’arrêt Abstützen der Maschine im Stand zato per sostenere il veicolo durante il ou durant le transport.
  • Page 56 FUEL INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher. For ZA: Premium gasoline CAUTION:...

  • Page 57: Essence

    ESSENCE KRAFTSTOFF CARBURANTE INFO ESSENCE KRAFTSTOFF CARBURANTE Ausschließlich empfohlenen Toujours utiliser l’essence recommandée Impiegare sempre il carburante consi- Kraftstoff verwenden. Für Rennen fri- décrite ci-dessous. D’autre part, s’assu- gliato come indicato qui di seguito. Inol- schen Kraftstoff verwenden. rer d’utiliser de l’essence fraîche le jour tre, accertarsi di utilizzare benzina nuova de la course.

  • Page 58: Starting And Break-In

    STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING 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. Always operate the machine in a well-ventilated area. CAUTION: The carburetor on this machine has a built-in...

  • Page 59: Mise En Marche Et Rodage

    MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO MISE EN MARCHE ET ANLASSEN UND EINFAH- AVVIO E RODAGGIO RODAGE AVVERTENZA WARNUNG Non avviare mai né tenere in funzione AVERTISSEMENT il motore in un’area chiusa. I gas di Den Motor keinesfalls in geschlos- Ne jamais mettre le moteur en marche scarico sono velenosi, possono provo-...
  • Page 60 STARTING AND BREAK-IN INFO 6. Return the cold starter knob to its original position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelera- tor pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall.
  • Page 61 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO Ramener le bouton de démarrage Den Kaltstarterknopf wieder in Riportare la manopola di avvia- à froid à sa position d’origine, die ursprüngliche Stellung zu- mento a freddo nella sua posi- puis faire tourner le moteur à...
  • Page 62 STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by kicking the kickstarter crank force- fully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage.
  • Page 63 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO MISE EN MARCHE D’UN MOTEUR STARTEN MIT WARMEM MOTOR AVVIAMENTO DI UN MOTORE CHAUD Zum Anlassen des warmen Motors CALDO Ne pas activer le bouton de démarrage à weder den Kaltstarterknopf drücken Non agire sulla manopola di avviamento froid ni l’accélérateur.

  • Page 64: Torque-Check Points

    STARTING AND BREAK-IN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 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 switch.
  • Page 65 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO PROCEDURE DE RODAGE EINFAHRVORSCHRIFTEN PROCEDURE DI RODAGGIO Avant de mettre le moteur en Vor dem Anlassen des Motors Prima di avviare il motore, riem- marche, faire le plein d’essence. volltanken.
  • Page 66 TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to Steering stem to frame Steering stem to upper bracket...

  • Page 67: 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 Cadre et cadre arrière Fixation entre selle Réservoir de carburant et cadre et réservoir Système d’échappement Silencieux et cadre arrière Cadre et moteur Montage du moteur Du support de moteur au moteur Du support de moteur au cadre...

  • Page 68: Anzugsmomente Kontrollieren

    ANZUGSMOMENTE KONTROLLIEREN INFO ANZUGSMOMENTE KONTROLLIEREN Rahmen Hauptrahmen und Rahmenhinterteil Sitzbank und Kraftstofftank Kraftstofftank und Rahmen Auspuff-System Schalldämpfer an Hinterrahmen Rahmen und Motor Motoraufhängung Motorbügel und Motor Motorbügel und Rahmen Lenkkopf und Teleskopgabel Lenkung Lenkkopf bis Lenkkopf und obere Gabelbrücke Lenker obere Gabelbrücke und Lenker Radaufhängung Vorn...

  • Page 69: Punti Per Il Controllo Del Serraggio

    PUNTI PER IL CONTROLLO DEL SERRAGGIO INFO PUNTI PER IL CONTROLLO DEL SERRAGGIO Struttura del telaio Telaio al telaio posteriore Sella e serbatoio del Serbatoio del carburante al telaio carburante combinati Sistema di scarico Marmitta di scarico al telaio posteriore Supporto motore Telaio al motore Dalla staffa motore al motore...

  • Page 70: Cleaning And Storage

    CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good over- all performance, 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 71: Nettoyage Et Rangement

    NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG PULIZIA ED IMMAGAZZINAGGIO INFO NETTOYAGE ET RANGE- REINIGUNG UND STILLE- PULIZIA ED IMMAGAZ- GUNG MENT ZINAGGIO REINIGUNG NETTOYAGE PULIZIA Eine regelmäßige, gründliche Un nettoyage fréquent de la machine Una pulizia frequente del veicolo ne Wäsche sorgt nicht nur für gutes améliorera son aspect, maintiendra ses migliora l’aspetto, aiuta a mantenere...
  • Page 72 CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float bowl.
  • Page 73 NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG PULIZIA ED IMMAGAZZINAGGIO INFO RANGEMENT STILLEGUNG IMMAGAZZINAGGIO Si l’on remise la machine pour 60 jours Vor einer mehr als zweimonatigen Se il veicolo va immagazzinato 60 giorni ou plus, il faut prendre des mesures de Stillegung sollten einige Schutzvor- o oltre, è...

  • Page 74: General Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ250FS (USA) YZ250F (EUROPE) YZ250F(S) (CDN, AUS, NZ, ZA) Model code number: 5XC1 (USA) 5XC2 (EUROPE) 5XC4 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,165 mm (85.2 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in)

  • Page 75: Chassis

    SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt) With oil filter replacement 1.1 L (0.97 Imp qt, 1.16 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 0.9 L (0.79 Imp qt, 0.95 US qt) Air filter:...
  • Page 76 SPEC GENERAL SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper...

  • Page 77: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00 ~ 77.01 mm ---- (3.0315 ~ 3.0319 in) Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ----...
  • Page 78 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm ---- (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm ---- (0.0067 ~ 0.0087 in) Valve dimensions:...
  • Page 79 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) Valve spring: Free length 37.81 mm (1.49 in)
  • Page 80 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002 ~ 16.013 mm 16.043 mm (0.6300 ~ 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 ~ 16.000 mm 15.971 mm (0.6296 ~ 0.6299 in) (0.6288 in) Piston rings: Top ring: Type Barrel...
  • Page 81 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.9 ~ 3.1 mm 2.7 mm (0.114 ~ 0.122 in) (0.106 in) Quantity ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 in)
  • Page 82 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less 0.20 mm (0.0047 in or less) (0.008 in) Side clearance 0.09 ~ 0.17 mm 0.24 mm (0.0035 ~ 0.0067 in) (0.009 in)
  • Page 83 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 × 1.25 (stud bolt) M9 ×...
  • Page 84 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Silencer M8 × 1.25 Silencer clamp M6 × 1.0 Crankcase M6 × 1.0 Crankcase bearing stopper M6 × 1.0 Crankcase bearing stopper (crankshaft) M6 ×...
  • Page 85 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: Front fork travel 300 mm (11.8 in) ---- Fork spring free length 479 mm (18.9 in) 474 mm (18.7 in) Spring rate, STD K = 4.2 N/mm ---- (0.428 kg/mm, 24.0 lb/in)
  • Page 86 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 × 1.85/Aluminum Rear rim size/material ---- Rim runout limit: Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in)
  • Page 87 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Upper bracket and outer tube M8 × 1.25 Lower bracket and outer tube M24 × 1.0 Upper bracket and steering stem 14.5 M8 × 1.25 Handlebar holder and upper bracket M28 ×...
  • Page 88 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Nipple (spoke) — M8 × 1.25 Rear wheel sprocket M6 × 1.0 Rear brake disc cover M6 × 1.0 Rear brake caliper protector M8 × 1.25 Drive chain puller adjust bolt and locknut Engine mounting: M10 ×...
  • Page 89 Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model (stator)/manufac- 5SF-00/YAMAHA ---- turer 720 ~ 1,080 Ω at 20 ˚C (68 ˚F) Charging coil 1 resistance (color) ---- (Green – Brown) 44 ~ 66 Ω at 20 ˚C (68 ˚F)

  • Page 90: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.

  • Page 91: Caracteristiques Generales

    SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: YZ250FS (USA) YZ250F (EUROPE) YZ250F(S) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5XC1 (USA) 5XC2 (EUROPE) 5XC4 (CDN, AUS, NZ, ZA) Dimensions: Longueur hors tout 2.165 mm (85,2 in) Largeur hors tout 827 mm (32,6 in) Hauteur hors tout...
  • Page 92 SPEC CARACTERISTIQUES GENERALES Quantité d’huile: Huile moteur Vidange périodique 1,0 L (0,88 Imp qt, 1,06 US qt) Avec remplacement du filtre à huile 1,1 L (0,97 Imp qt, 1,16 US qt) Quantité totale 1,2 L (1,06 Imp qt, 1,27 US qt) Quantité...
  • Page 93 SPEC CARACTERISTIQUES GENERALES Freins: Type de frein avant Monodisque Commande Main droite Type de frein arrière Monodisque Commande Pied droit Suspension: Suspension avant Fourche télescopique Suspension arrière Bras oscillant (monocross de type biellette) Amortisseurs: Amortisseur avant Ressort hélicoïdal/amortisseur hydraulique Amortisseur arrière Ressort hélicoïdal/amortisseur hydro-pneumatique Débattement: Roue avant...
  • Page 94 SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: Limite de déformation ---- 0,05 mm (0,002 in) Cylindre: Alésage 77,00 à 77,01 mm ---- (3,0315 à 3,0319 in) Limite d’ovalisation ---- 0,05 mm (0,002 in) Arbre à cames: Méthode d’entraînement Transmission par chaîne (gauche) ---- Diamètre intérieur de chapeau...
  • Page 95 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Chaîne de distribution: Type de chaîne de distribution/nbre de maillons 92RH2010-114M/114 ---- Méthode de réglage de la chaîne de distribution Automatique ---- Soupape, siège de soupape, guide de soupape: Jeu de soupape (à froid) 0,10 à...
  • Page 96 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Limite de faux-rond de queue ---- 0,01 mm (0,0004 in) Largeur de siège de soupape 0,9 à 1,1 mm 1,6 mm (0,0354 à 0,0433 in) (0,0630 in) 0,9 à 1,1 mm 1,6 mm (0,0354 à 0,0433 in) (0,0630 in) Ressort de soupape: Longueur libre...
  • Page 97 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Diamètre intérieur d’alésage d’axe de piston 16,002 à 16,013 mm 16,043 mm (0,6300 à 0,6304 in) (0,6316 in) Diamètre extérieur d’axe de piston 15,991 à 16,000 mm 15,971 mm (0,6296 à 0,6299 in) (0,6288 in) Segment: Segment de feu: Type...
  • Page 98 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Embrayage: Epaisseur de disque de friction 2,9 à 3,1 mm 2,7 mm (0,114 à 0,122 in) (0,106 in) Quantité ---- Epaisseur de disque d’embrayage 1,1 à 1,3 mm (0,043 à 0,051 in) ---- Quantité ---- Limite de déformation ----...
  • Page 99 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Système de graissage: Type de filtre à huile En papier ---- Type de pompe à huile Trochoïde ---- Jeu en bout 0,12 mm ou moins 0,20 mm (0,0047 in ou moins) (0,008 in) Jeu latéral 0,09 à...
  • Page 100 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M10S × 1,0 Bougie M6 × 1,0 Chapeau d’arbre à cames M12 × 1,0 Vis de plot borgne de culasse M6 × 1,0 Culasse (boulon prisonnier) M8 ×...
  • Page 101 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M8 × 1,25 Silencieux M8 × 1,25 Bride du silencieux M6 × 1,0 Carter M6 × 1,0 Butoir de roulement de demi-carter M6 × 1,0 Butoir de roulement de demi-carter (vilebrequin) M6 ×...
  • Page 102 SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: Type de roulement de direction Roulement à rouleaux conique ---- Suspension avant: Débattement de fourche avant 300 mm (11,8 in) ---- Longueur libre de ressort de fourche 479 mm (18,9 in) 474 mm (18,7 in) Constante de ressort, standard K = 4,2 N/mm ----...
  • Page 103 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 × 1,85/aluminum Taille/matériau de jante arrière ---- Limite de voile de jante: Radial ---- 2,0 mm (0,08 in)
  • Page 104 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M8 × 1,25 Té supérieur et fourreau M8 × 1,25 Té inférieur et fourreau M24 × 1,0 Té supérieur et colonne de direction 14,5 M8 × 1,25 Demi-palier de guidon et té...
  • Page 105 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb Valve de roue (rayon) — M8 × 1,25 Couronne arrière M6 × 1,0 Cache de disque de frein arrière M6 × 1,0 Protection d’étrier de frein arrière Boulon et écrou de réglage de l’extracteur de chaîne M8 ×...
  • Page 106 Limite Système d’allumage: Type de dispositif d’avance Electrique ---- CDI: Modèle/fabricant de la magnéto (stator) 5SF-00/YAMAHA ---- 720 à 1.080 Ω à 20 ˚C (68 ˚F) Résistance de bobine de change 1 ---- (couleur) (vert – brun) 44 à 66 Ω à 20 ˚C (68 ˚F) Résistance de bobines de change 2...

  • Page 107: Caracteristiques Generales De Couple

    CARACTERISTIQUES GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES CARACTERISTIQUES GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des atta- ches standard avec filetage à pas I.S.O. standard. Les spécifications de couple pour les composants ou ensembles spéciaux sont indiquées dans les sec- tions appropriées de ce manuel.

  • Page 108: Technische Daten

    SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname: YZ250FS (USA) YZ250F (EUROPE) YZ250F(S) (CDN, AUS, NZ, ZA) Modellcode: 5XC1 (USA) 5XC2 (EUROPE) 5XC4 (CDN, AUS, NZ, ZA) Abmessungen: Gesamtlänge 2.165 mm (85,2 in) Gesamtbreite 827 mm (32,6 in) Gesamthöhe 1.303 mm (51,3 in) Sitzhöhe...
  • Page 109 SPEC ALLGEMEINE TECHNISCHE DATEN Füllmenge: Ölwechsel ohne Filterwechsel 1,0 L (0,88 Imp qt, 1,06 US qt) Ölwechsel mit Filterwechsel 1,1 L (0,97 Imp qt, 1,16 US qt) Gesamtmenge 1,2 L (1,06 Imp qt, 1,27 US qt) Kühlsystem-Fassungsvermögen 0,9 L (0,79 Imp qt, 0,95 US qt) (Gesamtmenge): Luftfilter: Naßfilter-Einsatz...
  • Page 110 SPEC ALLGEMEINE TECHNISCHE DATEN Bremsanlage: vorn Bauart Einscheibenbremse Betätigung Handbremshebel (rechts) hinten Bauart Einscheibenbremse Betätigung Fußbremshebel (rechts) Radaufhängung: vorn Teleskopgabel hinten Monocross-Schwinge Federelemente: vorn Hydraulisch gedämpfte Teleskopgabel mit Spi- ralfeder hinten Federbein mit gasdruckunterstütztem Stoß- dämpfer und Spiralfeder Federweg: vorn 300 mm (11,8 in) hinten 315 mm (12,4 in)

  • Page 111: Wartungsdaten

    SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bezeichnung Spezifikation Grenzwert Zylinderkopf: Max. Verzug ---- 0,05 mm (0,002 in) Zylinder: Bohrungsdurchmesser 77,00–77,01 mm ---- (3,0315–3,0319 in) Max. Ovalität ---- 0,05 mm (0,002 in) Nockenwelle: Antrieb Steuerkette (links) ---- Nockenwellenlager-Durchmesser 22,000–22,021 mm ---- (0,8661–0,8670 in) Nockenwellen-Außendurchmesser 21,967–21,980 mm ----...
  • Page 112 SPEC WARTUNGSDATEN Bezeichnung Spezifikation Grenzwert Steuerkette: Typ/Gliederzahl 92RH2010-114M/114 ---- Kettenspannung automatisch ---- Ventile, Ventilsitze, Ventilführungen: Ventilspiel (kalt) Einlaß 0,10–0,15 mm ---- (0,0039–0,0059 in) Auslaß 0,17–0,22 mm ---- (0,0067–0,0087 in) Ventilabmessungen Ventilsitzbreite Ventiltellerstärke Ventiltellerdurchmesser Ventilkegelbreite Ventilteller-Durchmesser Ventilteller-Breite Ventilsitz-Breite Ventilteller-Stärke Ventiltellerdurchmesser “A” Einlaß...
  • Page 113 SPEC WARTUNGSDATEN Bezeichnung Spezifikation Grenzwert Max. Ventilschaftschlag ---- 0,01 mm (0,0004 in) Ventilsitzbreite Einlaß 0,9–1,1 mm (0,0354–0,0433 in) 1,6 mm (0,0630 in) Auslaß 0,9–1,1 mm (0,0354–0,0433 in) 1,6 mm (0,0630 in) Ventilfeder: Ungespannte Länge Einlaß 37,81 mm (1,49 in) 36,81 mm (1,45 in) Auslaß...
  • Page 114 SPEC WARTUNGSDATEN Bezeichnung Spezifikation Grenzwert Kolbenbolzenaugen-Durchmesser 16,002–16,013 mm 16,043 mm (0,6300–0,6304 in) (0,6316 in) Kolbenbolzen-Durchmesser 15,991–16,000 mm 15,971 mm (0,6296–0,6299 in) (0,6288 in) Kolbenringe: 1. Kompressionsring (Topring) Ausführung abgerundet ---- Abmessungen (B × T) 0,90 × 2,75 mm (0,04 × 0,11 in) ---- 0,15–0,25 mm (0,006 ×...
  • Page 115 SPEC WARTUNGSDATEN Bezeichnung Spezifikation Grenzwert Kupplung: Reibscheiben Stärke 2,9–3,1 mm (0,114–0,122 in) 2,7 mm (0,106 in) Anzahl ---- Kupplungsscheiben Stärke 1,1–1,3 mm (0,043–0,051 in) ---- Anzahl ---- Verzug ---- 0,1 mm (0,004 in) Kupplungsfeder ungesp. Länge 40,4 mm (1,59 in) 39,4 mm (1,55 in) Anzahl...
  • Page 116 SPEC WARTUNGSDATEN Bezeichnung Spezifikation Grenzwert Schmiersystem: Ölfilter Papiertyp ---- Ölpumpe Rotorpumpe ---- Radialspiel 0,12 mm oder weniger 0,20 mm (0,0047 in oder weniger) (0,008 in) Axialspiel 0,09–0,17 mm 0,24 mm (0,0035–0,0067 in) (0,009 in) Gehäuse und Rotorabstand 0,03–0,10 mm 0,17 mm (0,0012–0,0039 in) (0,0067 in) Kühlsystem:...
  • Page 117 SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg ft·lb M10S × 1,0 Zündkerze M6 × 1,0 Zündkerzenstecker M12 × 1,0 Zylinderkopf-Blindstopfenschraube M6 × 1,0 Zylinderkopf (Stiftschraube) M8 × 1,25 (Stiftschraube) M9 × 1,25 (Schraube) M6 × 1,0 (Mutter) M6 × 1,0 Zylinderkopfdeckel M6 ×...
  • Page 118 SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg ft·lb M8 × 1,25 Schalldämpfer M8 × 1,25 Schalldämpfer-Schlauchschelle M6 × 1,0 Kurbelgehäuse M6 × 1,0 Kurbelkasten-Lageranschlag M6 × 1,0 Kurbelkasten-Lageranschlag (Kurbelwell) M6 × 1,0 Kurbelgehäusedeckel (links) M6 × 1,0 Kurbelgehäusedeckel (rechts) M6 ×...
  • Page 119 SPEC WARTUNGSDATEN FAHRWERKL Bauteil Spezifikation Grenzwert Lenkung: Lenkkopflager Kegelrollenlager ---- Federelement vorn: Federweg 300 mm (11,8 in) ---- Gabelfeder, ungespannte Länge 479 mm (18,9 in) 474 mm (18,7 in) Standard-Federrate K = 4,2 N/mm ---- (0,428 kg/mm, 24,0 lb/in) Umrüstmöglichkeiten ---- Ölmenge 662 cm...
  • Page 120 SPEC WARTUNGSDATEN Bauteil Spezifikation Grenzwert Räder: Bauart: Vorderrad Speichenrad ---- Hinterrad Speichenrad ---- Felgendimension/-material 21 × 1,60/Aluminium Vorderrad ---- 19 × 1,85/Aluminium Hinterrad ---- Max. Felgenschlag Höhenschlag ---- 2,0 mm (0,08 in) Seitenschlag ---- 2,0 mm (0,08 in) Antriebskette: Typ (Hersteller) DID520DMA2 SDH/DAIDO ---- Anzahl der Kettenglieder...
  • Page 121 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg ft·lb M8 × 1,25 Oberbügel und Außenröhre M8 × 1,25 Unterbügel und Außenröhre M24 × 1,0 Oberbügel und Lenkschaft 14,5 M8 × 1,25 Lenkerhalter und Oberbügel M28 × 1,0 Lenkschaft und Lenkringmutter Siehe HINWEIS. M51 ×...
  • Page 122 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg ft·lb Nippel (Speiche) — M8 × 1,25 Hinterrad-Speiche M6 × 1,0 Hinterrad-Bremsscheibendeckel M6 × 1,0 Hinterrad-Bremssattelschutz Antriebskettenspanner-Einstellschraube und M8 × 1,25 Gegenmutter Motorhalterung: M10 × 1,25 Motor und Motorbügel (vorne) M10 × 1,25 Motor und Rahmen (unten) M8 ×...
  • Page 123 Grenzwert Zündsystem: Zündversteller elektrisch ---- CDI: Magnetzünder-Modell (Stator)/Hersteller Typ (Hersteller) 5SF-00/YAMAHA ---- 720–1.080 Ω bei 20 ˚C (68 ˚F) Widerstand (Farbe) der Erregerspule 1 ---- (grün – braun) 44–66 Ω bei 20 ˚C (68 ˚F) Widerstand (Farbe) der Erregerspule 2 ---- (schwarz –...

  • Page 124: Allgemeine Anzugsmomente

    ALLGEMEINE ANZUGSMOMENTE/ SPEC EINHEITEN ALLGEMEINE ANZUGSMOMENTE Aus der folgenden Tabelle sind die Anzugsmo- mente für normale Schraubverbindungen mit ISO-Normgewinde ersichtlich. Anzugsmomente für spezielle Verschraubungen und Bauteile wer- den in jedem Abschnitt dieser Anleitung geson- dert aufgeführt. Um ein Verziehen der Bauteile zu vermeiden, sollten die Schraubverbindungen über Kreuz angezogen werden, bis die vorge- schriebenen Anzugsmomente erreicht sind.

  • Page 125: Carburante

    SPEC SPECIFICHE GENERALI SPECIFICHE SPECIFICHE GENERALI Nome del modello: YZ250FS (USA) YZ250F (EUROPE) YZ250F(S) (CDN, AUS, NZ, ZA) Codice del modello: 5XC1 (USA) 5XC2 (EUROPE) 5XC4 (CDN, AUS, NZ, ZA) Dimensioni: Lunghezza totale 2.165 mm (85,2 in) Larghezza totale 827 mm (32,6 in) Altezza totale 1.303 mm (51,3 in) Altezza della sella...
  • Page 126 SPEC SPECIFICHE GENERALI Capacità olio: Olio motore Cambio d’olio periodico 1,0 L (0,88 Imp qt, 1,06 US qt) Con cambio filtro olio 1,1 L (0,97 Imp qt, 1,16 US qt) Quantità totale 1,2 L (1,06 Imp qt, 1,27 US qt) Capacità...
  • Page 127 SPEC SPECIFICHE GENERALI Freno: Tipo freno anteriore Freno a disco singolo Azionamento Con la mano destra Tipo freno posteriore Freno a disco singolo Azionamento Con il piede destro Sospensione: Sospensione anteriore Forcella telescopica Sospensione posteriore Forcellone oscillante (sospensione monocross di tipo a biscottino) Ammortizzatore: Ammortizzatore anteriore...

  • Page 128: Specifiche Di Manutenzione

    SPEC SPECIFICHE DI MANUTENZIONE SPECIFICHE DI MANUTENZIONE MOTORE Elemento Standard Limite Testata del cilindro: Limite di deformazione ---- 0,05 mm (0,002 in) Cilindro: Dimensioni alesaggio 77,00 ~ 77,01 mm ---- (3,0315 ~ 3,0319 in) Limite di ovalizzazione ---- 0,05 mm (0,002 in) Albero a camme: Metodo di trasmissione...
  • Page 129 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Catena di distribuzione: Tipo catena di distribuzione/N. di maglie 92RH2010-114M/114 ---- Metodo di regolazione della catena di Automatico ---- distribuzione Valvola, sede valvola, guidavalvola: Gioco valvola (a freddo) 0,10 ~ 0,15 mm ---- (0,0039 ~ 0,0059 in) 0,17 ~ 0,22 mm ----...
  • Page 130 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Limite disassamento stelo ---- 0,01 mm (0,0004 in) Larghezza sede valvola 0,9 ~ 1,1 mm 1,6 mm (0,0354 ~ 0,0433 in) (0,0630 in) 0,9 ~ 1,1 mm 1,6 mm (0,0354 ~ 0,0433 in) (0,0630 in) Molla valvola: Lunghezza libera...
  • Page 131 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Diametro interno foro spinotto 16,002 ~ 16,013 mm 16,043 mm (0,6300 ~ 0,6304 in) (0,6316 in) Diametro esterno spinotto 15,991 ~ 16,000 mm 15,971 mm (0,6296 ~ 0,6299 in) (0,6288 in) Fasce elastiche: Fascia superiore: Tipo Cilindrica...
  • Page 132 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Frizione: Spessore del disco conduttore 2,9 ~ 3,1 mm 2,7 mm (0,114 ~ 0,122 in) (0,106 in) Quantità ---- Spessore del disco condotto 1,1 ~ 1,3 mm (0,043 ~ 0,051 in) ---- Quantità ---- Limite di deformazione ----...
  • Page 133 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Sistema di lubrificazione: Tipo di filtro Tipo di carta ---- Tipo di pompa dell’olio Tipo trocoidale ---- Gioco della punta 0,12 mm o inferiore 0,20 mm (0,0047 in o inferiore) (0,008 in) Gioco laterale 0,09 ~ 0,17 mm 0,24 mm (0,0035 ~ 0,0067 in)
  • Page 134 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M10S × 1,0 Candela d’accensione M6 × 1,0 Cappello dell’albero a camme M12 × 1,0 Tappo a vite testata del cilindro M6 × 1,0 Testata del cilindro (prigioniero) M8 ×...
  • Page 135 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M8 × 1,25 Marmitta di scarico M8 × 1,25 Morsetto marmitta di scarico M6 × 1,0 Carter M6 × 1,0 Tappo cuscinetto carter M6 × 1,0 Tappo cuscinetto carter (albero a gomiti) M6 ×...
  • Page 136 SPEC SPECIFICHE DI MANUTENZIONE PARTE CICLISTICA Elemento Standard Limite Sistema di sterzo: Tipo di cuscinetti sterzo Cuscinetto conico a rulli ---- Sospensione anteriore: Corsa forcella anteriore 300 mm (11,8 in) ---- Lunghezza libera della molla della 479 mm (18,9 in) 474 mm (18,7 in) forcella Flessibilità, STD...
  • Page 137 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Ruota: Tipo ruota anteriore Ruota a raggi ---- Tipo ruota posteriore Ruota a raggi ---- 21 × 1,60/alluminio Dimensioni/materiale cerchio anteriore ---- Dimensioni/materiale cerchio posteriore 19 × 1,85/alluminio ---- Limite di disassamento cerchio: Radiale ---- 2,0 mm (0,08 in)
  • Page 138 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M8 × 1,25 Staffa superiore e tubo esterno M8 × 1,25 Staffa inferiore e tubo esterno M24 × 1,0 Staffa superiore e cannotto dello sterzo 14,5 M8 ×...
  • Page 139 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb Tiraraggi (raggi) — M8 × 1,25 Corona dentata ruota posteriore M6 × 1,0 Carterino disco freno posteriore M6 × 1,0 Protezione pinza del freno posteriore Bullone di regolazione e controdado del tendicatena M8 ×...
  • Page 140 Impianto di accensione: Tipo di dispositivo di anticipo Elettrico ---- CDI.: Modello/costruttore magneto (statore) 5SF-00/YAMAHA ---- 720 ~ 1.080 Ω a 20 ˚C (68 ˚F) Resistenza bobina di carica 1 (colore) ---- (Verde – Marrone) 44 ~ 66 Ω a 20 ˚C (68 ˚F)

  • Page 141: Specifiche Relative Alle

    SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO SPEC GENERALI/DEFINIZIONE DELLE UNITÀ DI MISURA SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO GENERALI Questo grafico specifica le coppie di serraggio per dispositivi di fissaggio convenzionali con filetti a passo convenzionale I.S.O. I dati relativi alla coppia di serraggio per i componenti speciali sono inclusi nei relativi paragrafi di questo manuale.

  • Page 142: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM Å Insert the end of the fuel tank Ï Fasten the neutral switch lead 1 Fuel tank breather hose 2 Clutch cable breather hose into the hole in and CDI magneto lead to the 3 Oil tank breather hose the steering stem cap.

  • Page 143: Cheminement Des Cables

    CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI CHEMINEMENT DES KABELFÜHRUNG SCHEMA DEL PER- 1 Kraftstofftank-Lüfterschlauch CABLES CORSO DEI CAVI 2 Kupplungsseilzug 1 Flexible de reniflard de réservoir à 1 Flessibile di sfiato del serbatoio carbu- 3 Öltank-Lüfterschlauch essence rante 4 Heißstarterseilzug...
  • Page 144 SPEC CABLE ROUTING DIAGRAM Ò Make sure that the throttle  Pass the carburetor breather position sensor coupler does hoses and overflow hose so not go out side the chassis. that all there hoses do not con- ˜ Fasten the throttle position tact the rear shock absorber.
  • Page 145 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI Ò Assurez-vous que le raccord du détecteur Ò Sicherstellen, daß der Drosselpositi- Ò Assicurarsi che l’accoppiatore del sensore de position d’accélération ne ressort pas on-Stecker nicht aus dem Chassis di posizione acceleratore non fuoriesca du châssis.
  • Page 146 SPEC CABLE ROUTING DIAGRAM Å Pass the hot starter cable and Ï First install the CDI unit and 1 CDI unit 2 Hot starter cable throttle cables through the CDI unit band to the CDI unit 3 Throttle cable (pull) cable guides.
  • Page 147 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Bloc CDI 1 CDI-Einheit 1 Unità CDI 2 Câble de démarreur à chaud 2 Heißstarterseilzug 2 Cavo dell’avviamento a caldo 3 Câble d’accélérateur (sortie) 3 Gasseilzug (Zug) 3 Cavo dell’acceleratore (tiraggio) 4 Câble d’accélérateur (entrée) 4 Gasseilzug (Rückzug) 4 Cavo dell’acceleratore (rilascio)
  • Page 148 SPEC CABLE ROUTING DIAGRAM Å Install the brake hose so that its pipe portion 1 Brake master cylinder 2 Brake hose holder directs as shown and lightly touches the projection 3 Brake hose on the brake caliper. ı Pass the brake hose into the brake hose holders. Ç...
  • Page 149 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Cylindre-maître de frein 1 Bremshauptzylinder 1 Cilindretto del freno 2 Support de flexible de frein 2 Bremsschlauchhalter 2 Supporto del flessibile del freno 3 Flexible de frein 3 Bremsschlauch 3 Flessibile del freno Å...
  • Page 150 SPEC CABLE ROUTING DIAGRAM Å Fasten the engine stop switch lead to the handlebar. 1 Throttle cable ı Pass the brake hose in front of the number plate. 2 Fuel tank breather hose 3 Clamp 4 Clutch cable 5 Hot starter cable 6 Engine stop switch lead 7 Brake hose 8 Hose guide...
  • Page 151 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Câble d’accélérateur 1 Gasseilzug 1 Cavo dell’acceleratore 2 Flexible de reniflard de réservoir à 2 Kraftstofftank-Lüfterschlauch 2 Flessibile di sfiato del serbatoio carbu- essence 3 Klammer rante 3 Bride 4 Kupplungsseilzug 3 Morsetto 4 Câble d’embrayage...

  • Page 152: Maintenance Intervals

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 153 INSP MAINTENANCE INTERVALS Every Every After Every As re- third fifth Item Remarks break-in race quired 500 km) 1,000 km) SHIFT FORK, SHIFT CAM, GUIDE BAR ● Inspect Inspect wear ROTOR NUT ● ● Retighten EXHAUST PIPE, SILENCER, PRO- TECTOR ●...
  • Page 154 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 Inspect dirt and wear on ●...
  • Page 155 Sa machine ont une grande influence sur les intervalles d’entretien et de lubrification. En cas de doute au sujet des intervalles d’entretien et de lubrification à adopter, consulter son concessionnaire Yamaha. Chaque Chaque Après...
  • Page 156 INSP PROGRAMME D’ENTRETIEN Chaque Chaque Après Chaque Partie 3ème (ou 5ème (ou néces- Remarques rodage course 500 km) 1.000 km) saire FOURCHETTE, BARILLET, BARRE DE GUIDAGE ● Contrôler Contrôler l’usure. ECROU DU ROTOR ● ● Resserrer POT D’ECHAPPEMENT, SILENCIEUX, PROTECTION ●...
  • Page 157 Contrôler les roulements ● Remplacer les roulements ● Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COM- Yamaha lube pour câble ou MANDE huile moteur SAE 10W-30 ● ● Contrôler le cheminement et le branche- Contrôler le degré de saleté...

  • Page 158: Wartungsintervalle Und Schmierdienst

    Normalbetrieb angesehen werden. Je nach Wetterbedingungen, Belastung und Ein- satzgebiet können in Abweichung des regelmäßigen Wartungsplans kürzere Intervalle notwendig werden. Richten Sie etwaige Fragen zu den Wartungs- und Schmierintervallen bitte an Ihren Yamaha-Händler. Nach 3 Nach 5...

  • Page 159: Anlassen Und Einfahren

    INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach 3 Nach 5 Nach Nach Rennen, Rennen, Nach Bezeichnung jedem Bemerkungen spätest. spätest. Ein- Bedarf nach nach Rennen fahren 500 km 1.000 km GETRIEBE ● Prüfen ● Lager erneuern SCHALTGABEL, SCHALTWALZE, FÜHRUNGSSTANGE ● Prüfen Auf Verschleiß prüfen. ROTORMUTTER ●...
  • Page 160 INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach 3 Nach 5 Nach Nach Rennen, Rennen, Nach Bezeichnung jedem Bemerkungen spätest. spätest. Ein- Bedarf nach nach Rennen fahren 500 km 1.000 km BREMSEN ● ● Hand- und Fußbremshebelposition einstellen ● ● Drehpunkte schmieren ● ●...

  • Page 161: Intervalli Di Manutenzione

    In caso di dubbi su quali intervalli seguire per la manutenzione e la lubrificazione del veicolo, consultare il proprio rivenditore Yamaha. Ad ogni...
  • Page 162 INSP INTERVALLI DI MANUTENZIONE Ad ogni Ad ogni Dopo il Come Ad ogni terza gara quinta Elemento rodag- richie- Osservazioni gara 500 km) 1.000 km) TRASMISSIONE ● Ispezionare ● Sostituire il cuscinetto FORCELLA DEL CAMBIO, CAMMA DEL CAMBIO, BARRA GUIDA ●...
  • Page 163 Ispezionare i cuscinetti ● Sostituire i cuscinetti ● Lubrificare Grasso a base di litio. ACCELERATORE, CAVO DI Lubrificante per cavi. COMANDO Yamaha o olio motore SAE ● ● Controllare il percorso e il collegamento 10W-30 ● ● Lubrificare Verificare se sono presenti ●...

  • Page 164: 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. GENERAL INSPECTION AND MAINTENANCE Item Routine Page...
  • Page 165 INSP CONTROLE ET ENTRETIEN AVANT UTILISATION CONTROLE ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bon état de marche. Avant d’utiliser cette machine, contrôler les points suivants: CONTROLE GENERAL ET ENTRETIEN Partie Routine Page...
  • Page 166 WARTUNGS- UND EINSTELLARBEITEN VOR INSP FAHRTBEGINN WARTUNGS- UND EINSTELLARBEITEN VOR FAHRTBEGINN Der Betriebszustand der Maschine muß sowohl vor dem Einfahren als auch vor jeder Übungs- und Rennfahrt überprüft werden. Vor Fahrtbeginn neben einer gewissenhaften Sichtkontrolle folgende Punkte prüfen. ROUTINEKONTROLLE VOR FAHRTBEGINN Bezeichnung Ausführung Seite...

  • Page 167: Cavi

    INSP CONTROLLI PRELIMINARI E MANUTENZIONE CONTROLLI PRELIMINARI E MANUTENZIONE Prima di mettersi alla guida per il rodaggio, per fare pratica o per la gara, accertarsi che il veicolo sia in buone condizioni di funzionamento. Prima di usare questo veicolo, controllare quanto segue: ISPEZIONE GENERALE E MANUTENZIONE Elemento Routine...
  • Page 168 INSP ENGINE/COOLANT LEVEL INSPECTION EC350000 ENGINE COOLANT LEVEL INSPECTION WARNING Do not remove the radiator cap 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 169: Motore

    INSP MOTEUR/CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT MOTOR/KÜHLFLÜSSIGKEITSTAND KONTROLLIEREN MOTORE/CONTROLLO DEL LIVELLO DI REFRIGERANTE MOTOR MOTEUR MOTORE KÜHLFLÜSSIGKEITSTAND KON- CONTROLE NIVEAU CONTROLLO DEL LIVELLO DI TROLLIEREN LIQUIDE DE REFROIDISSEMENT REFRIGERANTE WARNUNG AVERTISSEMENT AVVERTENZA Der heiße Kühler steht unter Druck. Ne pas déposer le bouchon du radia- Non rimuovere il tappo del radiatore Daher niemals den Kühlerverschluß-...
  • Page 170 INSP COOLANT REPLACEMENT COOLANT REPLACEMENT WARNING Do not remove the radiator cap when the engine is hot. CAUTION: 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.
  • Page 171 CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP KÜHLFLÜSSIGKEIT WECHSELN SOSTITUZIONE REFRIGERANTE CHANGEMENT DU LIQUIDE DE KÜHLFLÜSSIGKEIT WECHSELN SOSTITUZIONE REFRIGERANTE REFROIDISSEMENT WARNUNG AVVERTENZA AVERTISSEMENT Den Kühlerverschlußdeckel unter Non rimuovere il tappo del radiatore a Ne jamais enlever le bouchon du keinen Umständen bei heißem Mo- motore caldo.
  • Page 172 INSP RADIATOR CAP INSPECTION CAUTION: Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be han- dled with special care.
  • Page 173 CONTROLE DU BOUCHON DU RADIATEUR INSP KÜHLERDECKEL KONTROLLIEREN CONTROLLO TAPPO DEL RADIATORE ACHTUNG: ATTENZIONE: ATTENTION: Ne pas mélanger plusieurs solutions Auf keinen Fall verschiedene Non mescolare più di un tipo di antigel à l’éthylène glycol contenant Sorten Äthylenglykol-Frost- antigelo glicole etilenico contenete des produits anticorrosion pour schutzmittel Korrosions-...
  • Page 174 RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2.
  • Page 175 CONTROLE DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR/ CONTROLE DU SYSTEME DE REFROIDISSEMENT KÜHLERVERSCHLUSSDECKEL-ÖFFNUNGSDRUCK KONTROLLIEREN/ INSP KÜHLSYSTEM KONTROLLIEREN CONTROLLO PRESSIONE APERTURA TAPPO DEL RADIATORE/ISPEZIONE DEL SISTEMA DI RAFFREDDAMENTO CONTROLE DE LA PRESSION KÜHLERVERSCHLUSSDECKEL- CONTROLLO PRESSIONE APER- D’OUVERTURE DU BOUCHON DU ÖFFNUNGSDRUCK KONTROLLIE- TURA TAPPO DEL RADIATORE RADIATEUR...
  • Page 176 INSP CLUTCH ADJUSTMENT NOTE: Do not apply pressure more than specified pressure. Radiator should be filled fully. 4. Inspect: Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. Radiator 1 Radiator hose joint 2 Coolant leakage → Repair or replace. Radiator hose 3 Swelling →...
  • Page 177 REGLAGE DE L’EMBRAYAGE INSP KUPPLUNG EINSTELLEN REGOLAZIONE FRIZIONE N.B.: HINWEIS: NOTA: Ne pas appliquer de pression supé- Den vorgeschriebenen Druck nicht Non applicare pressione superiore a rieure à la pression spécifiée. Überschreiten. quella specificata. Le radiateur doit être entièrement rem- Der Kühler muß...
  • Page 178 THROTTLE CABLE ADJUSTMENT/ INSP THROTTLE LUBRICATION THROTTLE CABLE ADJUSTMENT 1. Check: Throttle grip free play a Out of specification → Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: Throttle grip free play Throttle grip free play adjustment steps: Slide the adjuster cover.
  • Page 179 REGLAGE DES CABLES DES GAZ/GRAISSAGE DE L’ACCELERATEUR INSP GASZUGSPIEL EINSTELLEN/GASZUG SCHMIEREN REGOLAZIONE DEL CAVO DELL’ACCELERATORE/LUBRIFICAZIONE DELL’ACCELERATORE REGLAGE DES CABLES DES GAZ GASZUGSPIEL EINSTELLEN REGOLAZIONE CAVO Vérifier: Kontrollieren: DELL’ACCELERATORE Jeu à la poignée des gaz a Gaszugspiel a Controllare: Hors spécification → Régler. Unvorschriftsmäßig →...
  • Page 180 HOT STARTER LEVER ADJUSTMENT/ INSP AIR FILTER CLEANING HOT STARTER LEVER ADJUSTMENT 1. Check: Hot starter lever free play a Out of specification → Adjust. Hot starter lever free play a: 3 ~ 6 mm (0.12 ~ 0.24 in) 2. Adjust: Hot starter lever free play Hot starter lever free play adjustment steps:...
  • Page 181 REGLAGE DU LEVIER DE DEMARREUR A CHAUD/NETTOYAGE DU FILTRE A AIR INSP WARMSTART-HEBEL-EINSTELLUNG/LUFTFILTER REINIGEN REGOLAZIONE DELLA LEVA DELL’AVVIAMENTO A CALDO/ PULIZIA FILTRO DELL’ARIA REGLAGE LEVIER WARMSTART-HEBEL-EINSTEL- REGOLAZIONE DELLA LEVA DEMARREUR A CHAUD LUNG DELL’AVVIAMENTO A CALDO Contrôler: Prüfen: Controllare: Jeu du levier de démarreur à Spiel des Heißstarter-He- Gioco della leva dell’avvia- chaud a...
  • Page 182 INSP AIR FILTER CLEANING 2. Clean: Air filter element Clean them with solvent. NOTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: Do not twist the element when squeezing the element. Leaving too much of solvent in the ele- ment may result in poor starting.
  • Page 183 NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA Nettoyer: Reinigen: Pulire: Elément du filtre à air Luftfittereinsatz Elemento filtrante Le nettoyer avec du dissolvant. (in Lösungsmittel) Pulire con solvente. HINWEIS: N.B.: NOTA: Une fois l’entretien terminé, éliminer ce Den Luftfittereinsatz nach dem Reini- Dopo la pulizia rimuovere il solvente qui reste de solvant en serrant l’élément.
  • Page 184 INSP ENGINE OIL LEVEL INSPECTION 7. Install: Air filter element 1 Washer Fitting bolt 2 Nm (0.2 m · kg, 1.4 ft · lb) NOTE: Align the projection a on filter guide with the hole b in air filter case. ENGINE OIL LEVEL INSPECTION 1.
  • Page 185 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE Monter: Montieren: Installare: Elément de filtre à air 1 Luftfittereinsatz 1 Elemento filtrante 1 Rondelle Scheibe Rondella Boulon de fixation Schraube Bullone di fissaggio 2 Nm (0,2 m · kg, 1,4 ft · lb) 2 Nm (0,2 m ·...
  • Page 186 INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non- Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non- Friction modified)
  • Page 187 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE (Pour les USA et le CDN) Nur USA und CDN: (Per USA e CDN) Huile recommandée: Empfohlene Ölsorte Olio raccomandato: Min. 5 ˚C (40 ˚F) Å: (Viskosität): A 5 ˚C (40 ˚F) o supe- Å...
  • Page 188 INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and warm it up for sev- eral minutes, and then turn off the engine and wait for five minute. 2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.
  • Page 189 CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE CHANGEMENT DE L’HUILE DE MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTEUR Den Motor starten, mehrere MOTORE Mettre le moteur en marche, le Minuten warmlaufen lassen, Avviare il motore, riscaldarlo per faire chauffer pendant quelques und dann ausschalten und fünf alcuni minuti e quindi spegnerlo minutes, puis le couper et atten-...

  • Page 190: Engine Oil Replacement

    INSP ENGINE OIL REPLACEMENT 7. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. Replacement steps: Remove the oil filter element cover 1 and oil filter element 2. Check the O-rings 3, if cracked or dam- aged, replace them with a new one.
  • Page 191 CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE S’il est nécessaire de remplacer le Soll auch der Ölfilter gewech- Se è necessario sostituire il filtro filtre à huile lors de cette vidange selt werden, müssen zusätz- dell’olio durante cambio d’huile, déposer les pièces sui-...
  • Page 192 OIL PRESSURE INSPECTION/ INSP PILOT SCREW ADJUSTMENT OIL PRESSURE INSPECTION 1. Check: Oil pressure Checking steps: Slightly loosen the oil pressure check bolt Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt.
  • Page 193 CONTROLE DE LA PRESSION D’HUILE/REGLAGE DE LA VIS DE RICHESSE INSP ÖLDRUCKPRÜFUNG/LEERLAUFGEMISCH EINSTELLEN CONTROLLO PRESSIONE DELL’OLIO/ REGOLAZIONE DELLA VITE DI REGISTRO DEL MINIMO CONTROLE DE LA PRESSION ÖLDRUCKPRÜFUNG CONTROLLO PRESSIONE D’HUILE Kontrollieren: DELL’OLIO Contrôler: Öldruck Controllare: Pressione dell’olio Pression d’huile Arbeitsschritte: Fasi di controllo: Etapes du contrôle:...
  • Page 194 ENGINE IDLING SPEED ADJUSTMENT/ INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it 2. Adjust: Engine idling speed Adjustment steps: Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. Turn the throttle stop screw 1 until the specified engine idling speed.
  • Page 195 REGLAGE DU REGIME DE RALENTI/CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP LEERLAUFDREHZAHL EINSTELEN/VENTILSPIEL KONTROLLIEREN UND EINSTELLEN REGOLAZIONE DEL MINIMO/ CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE LEERLAUFDREHZAHL EINSTE- REGLAGE DU REGIME DE REGOLAZIONE DEL MINIMO RALENTI Avviare e riscaldare bene il Den Motor anlassen und eini- Mettre le moteur en marche et motore.
  • Page 196 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 3. Remove: Right radiator Refer to “RADIATOR” section in the CHAPTER 4. Carburetor Refer to “CARBURETOR” section in the CHAPTER 4. Spark plug Upper engine bracket Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 4.
  • Page 197 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Déposer: Demontieren: Rimuovere: Radiateur de droite Rechter Kühler Radiatore destro reporter à section Siehe Abschnitt “KÜHLER” Fare riferimento al paragrafo “RADIATEUR” au CHAPI- in KAPITEL 4.
  • Page 198 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. NOTE: In order to be sure that the piston is at Top Dead Center, the punch mark c on the...
  • Page 199 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Etapes de la vérification: Arbeitsschritte: Fasi di controllo: Kurbelwelle mit einem Schrau- Faire tourner le vilebrequin dans le Ruotare l’albero motore in senso sens inverse des aiguilles d’une benschlüssel gegen den Uhr- antiorario con una chiave.
  • Page 200 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Remove the valve lifters 1 and the pads NOTE: Place a rag in the timing chain space to prevent pads from falling into the crank- case. Identity each valve lifter and pad position very carefully so that they can be rein- stalled in their original place.
  • Page 201 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Déposer les poussoirs de soupa- Tassenstößel 1 und Ventil- Rimuovere gli alzavalvola 1 e gli pes 1 et les cales 2. plättchen 2 demontieren.
  • Page 202 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Install the new pads 3 and the valve lift- ers 4. NOTE: Apply the engine oil on the valve lifters. Apply the molybdenum disulfide oil on the valve stem ends. Valve lifter must turn smoothly when rotated with a finger.
  • Page 203 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Installer les nouvelles cales 3 et Neue Ventilplättchen 3 und Installare i nuovi spessori 3 e gli les poussoirs de soupapes 4. Tassenstößel 4 einsetzen.

  • Page 204: Valve Clearance Inspection And Adjustment

    INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
  • Page 205 INSP CONTROLE ET REGLAGE DU JEU DE SOUPAPES ADMISSION NUMERO DE CALE INSTALLEE JEU MESURE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 à...
  • Page 206 INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN EINLASS GEMESSE- NUMMER DES AUSGEBAUTEN VENTILPLÄTTCHENS NES SPIEL 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00–0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05–0,09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0,10–0,15...
  • Page 207 CONTROLLO E REGOLAZIONE DEL GIOCO DELLE INSP VALVOLE ASPIRAZIONE NUMERO SPESSORE INSTALLATO GIOCO MISURATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 ~ 0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05 ~ 0,09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
  • Page 208 INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid is very low. The brake operation is faulty. Å...

  • Page 209: Partie Cycle

    INSP PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTLÜFTEN PARTE CICLISTICA/SPURGO DELL’ARIA DAL SISTEMA FRENANTE FAHRWERK PARTIE CYCLE PARTE CICLISTICA HYDRAULISCHE BREMSANLAGE PURGE DE L’AIR DU SYSTEME SPURGO DELL’ARIA DAL ENTLÜFTEN DE FREINAGE SISTEMA FRENANTE WARNUNG AVERTISSEMENT AVVERTENZA Die Anlage muß...
  • Page 210 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 disap- peared. j. Add brake fluid to the level line on the reservoir.
  • Page 211 REGLAGE DE FREIN AVANT INSP VORDERRADBREMSE EINSTELLEN REGOLAZIONE DEL FRENO ANTERIORE N.B.: HINWEIS: NOTA: Si la purge est difficile, il peut être Kann die Anlage nicht zufrieden- Se lo spurgo risulta difficoltoso, nécessaire de laisser le système du stellend entlüftet werden, sollte die potrebbe essere necessario lasciar liquide de freinage se stabiliser pen- Bremsflüssigkeit einige Stunden...

  • Page 212: Rear Brake Adjustment

    REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: Brake pedal height Pedal height adjustment steps: Loosen the locknut 1.
  • Page 213 REGLAGE DU FREIN ARRIERE/ CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT HINTERRADBREMSE EINSTELLEN/ INSP VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN REGOLAZIONE DEL FRENO POSTERIORE/ ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE REGLAGE DU FREIN ARRIERE HINTERRADBREMSE EINSTEL- REGOLAZIONE FRENO Contôler: POSTERIORE Kontrollieren: Hauteur de la pédale de frein...
  • Page 214 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT Loosen the pad pin 2. Remove the brake hose holder 3 and brake caliper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
  • Page 215 INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE Haltestift 2 demontieren. Svitare la spina della pastiglia 2. Desserrer la goupille de plaquette Bremsschlauchhalterung Rimuovere il supporto tubo flessi- und Bremssattel 4 von der Te- bile del freno 3 e la pinza del Déposer le support de la durit de...
  • Page 216 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Install the pad pin plug B. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake lever operation A softy or spongy feeling →...
  • Page 217 INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE Haltestift B montieren. Installer le bouchon de goupille de Installare la tappo spina delle pasti- plaquette B. glie B. Haltestift-Abdeck- schraube: Bouchon de goupille de...
  • Page 218 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Remove the pad pin 6 and brake pads 7. Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. Loosen the bleed screw and push the brake caliper piston in.
  • Page 219 INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE Déposer la goupille de plaquette 6 Haltestift 6 und Bremsbeläge Rimuovere la spina delle pastiglie et les plaquettes de frein 7. 7 entfernen.
  • Page 220 REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer “BRAKE SYSTEM BLEEDING” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECTION...
  • Page 221 CONTROLE DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/ INSP BREMSFLÜSSIGKEITSSTAND KONTROLLIEREN ISPEZIONE DELL’ISOLANTE DELLA PASTIGLIA DEL FRENO POSTERIORE/ CONTROLLO DEL LIVELLO DEL LIQUIDO DEI FRENI Vérifier: Kontrollieren: Ispezionare: Bremsflüssigkeitsstand Livello del liquido dei freni...
  • Page 222 INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION SPROCKETS INSPECTION 1. Inspect: Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Remove: Master link clip Joint 1 Drive chain 2 2.
  • Page 223 INSP CONTROLE DES PIGNONS/CONTROLE DE LA CHAINE DE TRANSMISSION KETTENRÄDER KONTROLLIEREN/ANTRIEBSKETTE KONTROLLIEREN ISPEZIONE DELLE CORONE DENTATE/ISPEZIONE DELLA CATENA DI TRASMISSIONE KETTENRÄDER KONTROLLIE- CONTROLE DES PIGNONS ISPEZIONE DELLE CORONE DEN- Contrôler: TATE Dens de pignon a Kontrollieren: Ispezionare: Usure excessive → Remplacer. Kettenradzähne a Denti della corona a Übermäßiger Verschleiß...
  • Page 224 INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: Drive chain 1 Joint 2 Master link clip 3 CAUTION: Be sure to install the master link clip to the direction as shown. a Turning direction 6. Lubricate: Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suit- able chain lubricants DRIVE CHAIN SLACK ADJUSTMENT...
  • Page 225 INSP REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION ANTRIEBSKETTEN-DURCHHANG EINSTELLEN REGOLAZIONE DELLA TENSIONE DELLA CATENA DI TRASMISSIONE Montieren: Monter: Installare: Chaîne de transmission 1 Antriebskette 1 Catena di trasmissione 1 Raccord 2 Laschen 2 Maglia di congiunzione 2 Kettenschloßfeder 3 Gancetto a molla 3 Agrafe de l’attache rapide ACHTUNG:...
  • Page 226 INSP FRONT FORK INSPECTION 3. Adjust: Drive chain slack Drive chain slack adjustment steps: Loosen the axle nut 1 and locknuts 2. Adjust the drive chain slack by turning the adjusters 3. To tighten → Turn the adjuster 3 coun- terclockwise.
  • Page 227 CONTROLE DE LA FOURCHE AVANT INSP TELESKOPGABEL KONTROLLIEREN ISPEZIONE FORCELLA ANTERIORE Régler: Einstellen: Regolare: Flèche de chaîne de transmis- Antriebsketten-Durchhang Allentamento catena di tra- sion smissione Arbeitsschritte: Achsmutter 1 und Sicherungs- Etapes de réglage de flèche de Fasi di regolazione allentamento chaîne de transmission: muttern 2 lockern.
  • Page 228 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: Protector Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
  • Page 229 NETTOYAGE DE BAGUE D’ETANCHEITE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/ PURGE DE L’AIR DE LA FOURCHE AVANT/ REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE LA FOURCHE AVANT GABELDICHTRING UND STAUBMANSCHETTE REINIGEN/ INSP TELESKOPKABEL-INNENDRUCKVERRINGERUNG/TELESKOPGABEL-ZUGSTUFENDÄMPFUNG EINSTELLEN PULIZIA DEL PARAOLIO E DEL PARAPOLVERE DELLE FORCELLE ANTERIORI/ ALLEGGERIMENTO DELLA PRESSIONE INTERNA DELLA FORCELLA ANTERIORE/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELLA FORCELLA ANTERIORE NETTOYAGE DE BAGUE D’ETAN-...
  • Page 230 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT Extent of adjustment Maximum Minimum 20 clicks out (from Fully turned in maximum posi- position tion) STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
  • Page 231 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP TELESKOPGABEL-DRUCKSTUFEN-DÄMPFUNG EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI COMPRESSIONE DELLA FORCELLA ANTERIORE Plage de réglage: Einstellungen: Portata della regolazione: Maximum Minimum Maximal Minimal Massimo Minimo Desserrer de 20 20 Rasten Completamente Svitare di 20...

  • Page 232: Rear Shock Absorber Inspection

    INSP REAR SHOCK ABSORBER INSPECTION Extent of adjustment Maximum Minimum 20 clicks out Fully turned in (from maximum position position) STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.
  • Page 233 CONTROLE DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN KONTROLLIEREN ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE Plage de réglage: Einstellungen: Portata della regolazione: Maximal Minimal Maximum Minimum Massimo Minimo Dévisser de 20 20 Rasten Completamente svitare di 20 Position com- Vollständig déclics (à par- gelöst (nach avvitato in posi- scatti (dalla posi- hineinge-...
  • Page 234 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: Rear frame 3. Loosen: Locknut 1 4. Adjust: Spring preload By turning the adjuster 2. Stiffer →...
  • Page 235 REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN-FEDERVORSPANNUNG EINSTELLEN REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE REGLAGE DE LA PRECON- FEDERBEIN-FEDERVORSPAN- REGOLAZIONE DEL PRECARICO TRAINTE DE RESSORT DE NUNG EINSTELLEN DELLA MOLLA DELL’AMMOR- L’AMORTISSEUR ARRIERE Das Motorrad am Motor auf- TIZZATORE POSTERIORE Surélever la roue arrière en pla- bocken, um das Hinterrad vom...

  • Page 236: Rear Shock Absorber Rebound Damping Force Adjustment

    REAR SHOCK ABSORBER REBOUND INSP DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b →...
  • Page 237 REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE L’AMORTISSEUR ARRIERE FEDERBEIN-ZUGSTUFENDÄMPFUNG EINSTELLEN INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE FORCE FEDERBEIN-ZUGSTUFENDÄMP- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT DE DETENTE FUNG EINSTELLEN SMORZAMENTO DI ESPANSIONE DE L’AMORTISSEUR ARRIERE Einstellen: DELL’AMMORTIZZATORE Régler:...
  • Page 238 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b →...
  • Page 239 REGLAGE DE LA FORCE D’AMORTISSEMENT A BASSE COMPRESSION DE L’AMORTISSEUR ARRIERE INSP EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI BASSA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE DE LA FORCE EINSTELLUNG DER FEDERBEIN- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT A BASSE DRUCKSTUFENDÄMPFUNG SMORZAMENTO DI BASSA COM- COMPRESSION DE L’AMORTIS- Einstellen:...
  • Page 240 REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b →...
  • Page 241 REGLAGE DE LA FORCE D’AMORTISSEMENT A HAUTE COMPRESSION DE L’AMORTISSEUR ARRIERE INSP EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI COMPRESSIONE ALTA DELL’AMMORTIZZATORE POSTERIORE REGLAGE DE LA FORCE EINSTELLUNG DER FEDERBEIN- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT A HAUTE DRUCKSTUFENDÄMPFUNG SMORZAMENTO DI COMPRES- COMPRESSION DE L’AMORTIS- Einstellen:...
  • Page 242 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
  • Page 243 CONTROLE DE PRESSION DES PNEUS/CONTROLE ET SERRAGE DES RAYONS/ CONTROLE DE LA ROUE REIFENLUFTDRUCK KONTROLLIEREN/SPEICHEN KONTROLLIEREN UND INSP FESTZIEHEN/RÄDER KONTROLLIEREN CONTROLLO DELLA PRESSIONE DEI PNEUMATICI/ ISPEZIONE E SERRAGGIO DEI RAGGI/ISPEZIONE DELLE RUOTE CONTROLE DE PRESSION DES REIFENLUFTDRUCK KONTROL- CONTROLLO DELLA PRESSIONE PNEUS LIEREN DEI PNEUMATICI...
  • Page 244 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: Bearing free play Exist play → Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: Steering stem Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth.
  • Page 245 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Vérifier: Kontrollieren: Ispezionare: Jeu de roulement Lagerspiel Gioco del cuscinetto Il y a du jeu → Remplacer. Spiel → Erneuern. Esiste gioco →...
  • Page 246 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: Apply the lithium soap base grease on the thread of the steering stem. Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 Steering ring nut (initial tightening):...
  • Page 247 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Ringmutter 3 mit dem Haken- Avvitare la ghiera 3 utilizzando la Serrer l’écrou crénelé de direction schlüssel 4 festziehen. 3 en utilisant la clé 4. chiave per ghiere 4.
  • Page 248 INSP LUBRICATION Å Use Yamaha cable lube or equivalent on these LUBRICATION areas. To ensure smooth operation of all compo- ı Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants. after break-in, and after every race.
  • Page 249 0 Extrémité du câble de démarreur à chaud Å Yamaha Seilzug-Schmiermittel oder Å In questi punti utilizzare lubrificante per Å Mettre du lubrifiant Yamaha pour câbles, gleichwertiges Mittel verwenden. cavi Yamaha o equivalente. ou équivalent sur ces parties. ı Motoröl oder Spezial-Kettenspray ver- ı...

  • Page 250: Electrical

    INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: Spark plug 2. Inspect: Electrode 1 Wear/damage → Replace. Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become...

  • Page 251: Parte Elettrica

    PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN PARTE ELETTRICA/ISPEZIONE DELLA CANDELA PARTIE ELECTRIQUE ELEKTRISCHE ANLAGE PARTE ELETTRICA ZÜNDKERZE KONTROLLIEREN CONTROLE DE LA BOUGIE ISPEZIONE DELLA CANDELA Demontieren: Déposer: Rimuovere: Zündkerze Bougie Candela d’accensione Kontrollieren: Contrôler: Ispezionare: Elektrode 1 Electrode 1 Elettrodo 1 Verschleiß/Beschädigung →...
  • Page 252 INSP IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: Timing mark accessing screw 1 2. Attach: Timing light Inductive tachometer To the ignition coil lead (orange lead Timing light: YM-33277-A/90890-03141 3. Adjust: Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT”...
  • Page 253 CONTROLE DE L’AVANCE A L’ALLUMAGE INSP ZÜNDZEITPUNKT KONTROLLIEREN CONTROLLO DELLA FASATURA DI ACCENSIONE CONTROLE DE L’AVANCE A ZÜNDZEITPUNKT KONTROLLIE- CONTROLLO DELLA FASATURA L’ALLUMAGE DI ACCENSIONE Déposer: Demontieren: Rimuovere: Vis d’accès du repère de distri- Steuermarkierung-Zugangs- Vite di accesso al riferimento bution 1 schraube 1 per fasatura 1...

  • Page 254: Engine

    SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal...
  • Page 255 SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SELLA, SERBATOIO CARBURANTE E CARENATURA LATERALE MOTEUR SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX Organisation de la dépose: 1 Dépose du selle 2 Dépose du réservoir de carburant 3 Dépose des caches latéraux 4 Dépose de la plaque de numéro Organisation de la dépose Ordre...

  • Page 256: Seat, Fuel Tank And Side Covers

    SEAT, FUEL TANK AND SIDE COVERS REMOVAL POINTS Side cover 1. Remove: Bolt (side cover) Left side cover 1 Right side cover 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case.
  • Page 257 SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SELLA, SERBATOIO CARBURANTE E CARENATURA LATERALE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Cache latéral Seitenabdeckung Coperchio laterale Déposer: Demontieren: Rimuovere: Boulon (cache latéral) Schraube (seitenabdek- Bullone (coperchio laterale) Cache latéral gauche 1 kung) Coperchio laterale sinistro 1...

  • Page 258: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER Å Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS”...

  • Page 259: Tubo Di Scarico E Silenziatore

    TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUYAU D’ECHAPPEMENT ET SILENCIEUX Å Excepté pour USA Organisation de la dépose: 1 Dépose du silencieux 2 Dépose du tuyau d’échappement Organisation de la dépose Ordre Nom de pièce Qté...
  • Page 260 EXHAUST PIPE AND SILENCER INSPECTION Silencer and exhaust pipe 1. Inspect: Gasket 1 Damage → Replace. ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1. Install: Gasket Exhaust pipe 1 Nut (exhaust pipe) 2 13 Nm (1.3 m · kg, 9.4 ft · lb) Bolt (exhaust pipe) 3 24 Nm (2.4 m ·...
  • Page 261 TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE CONTROLE PRÜFUNG ISPEZIONE Silencieux et tuyau d’échappement Schalldämpfer und krümmer Silenziatore e tubo di scarico Contrôler: Kontrollieren: Ispezionare: Joint 1 Dichtung 1 Guarnizione 1 Endommagement → Rempla- Beschädigung → Erneuern. Danni →...

  • Page 262: Radiator

    RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
  • Page 263 RADIATEUR KÜHLER RADIATORE RADIATEUR Organisation de la dépose: 1 Dépose du radiateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU RADIATEUR Préparation à la dépose Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT”...
  • Page 264 RADIATOR EC456000 HANDLING NOTE WARNING 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 radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-...
  • Page 265 RADIATEUR KÜHLER RADIATORE REMARQUES CONCERNANT LA HANDHABUNGSHINWEIS NOTA PER LA MANIPOLAZIONE MANIPULATION WARNUNG AVVERTENZA AVERTISSEMENT Der heiße Kühler steht unter Non rimuovere il tappo del radiatore a Ne jamais enlever le bouchon du Druck. Daher Kühlerver- motore e radiatore caldi. Si potrebbe radiateur quand le moteur et le radia- schlußdeckel niemals bei heißem verificare la fuoriuscita di fluido bol-...
  • Page 266 RADIATOR 3. Install: Right radiator 1 Bolt (right radiator) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Radiator hose 3 3 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 4. Install: Left radiator 1 Bolt (left radiator) 2 10 Nm (1.0 m ·...
  • Page 267 RADIATEUR KÜHLER RADIATORE Monter: Montieren: Installare: Radiateur de droite 1 Rechter Kühler 1 Radiatore destro 1 Boulon (radiateur droite) 2 Schraube (rechter Kühler) Bullone (radiatore destro) 2 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m · kg, 7,2 ft · lb) Durit de radiateur 3 3 Flessibile radiatore 3 3 10 Nm (1,0 m ·...

  • Page 268: Carburetor

    CARBURETOR CARBURETOR 4 Nm (0.4 m kg, 2.9 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft •...
  • Page 269 CARBURATEUR VERGASER CARBURATORE CARBURATEUR Organisation de la dépose: 1 Dépose du carburateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARBURATEUR Préparation à la dépose Selle et réservoir de carburant Se reporter à la section “SELLE, RESERVOIR DE CAR- BURANT ET CACHES LATERAUX”.
  • Page 270 CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet...
  • Page 271 CARBURATEUR VERGASER CARBURATORE DEMONTAGE DU CARBURATEUR Organisation de la dépose: 1 Démontage du carburateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEMONTAGE DU CARBURATEUR Durit de mise à l’air de carburateur Couvercle de logement de levier de soupape Vis (axe d’accélérateur) Boisseau Support d’aiguille...
  • Page 272 CARBURETOR Extent of removal Order Part name Q’ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger 4 - 10...
  • Page 273 CARBURATEUR VERGASER CARBURATORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Gicleur principal Gicleur de ralenti Entretoise Gicleur de starter Puits d’aiguille Tige de poussée Tirer la tige de poussée Ensemble de l’axe de papillon Ensemble du levier de timonerie de tige de commande Gicleur d’air de ralenti Plongeur de démarrage à...
  • Page 274 CARBURETOR HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. REMOVAL POINTS Pilot screw 1. Remove: Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been...
  • Page 275 CARBURATEUR VERGASER CARBURATORE REMARQUE CONCERNANT LES HINWEIS ZUM HANDLING NOTA PER LA MANIPOLAZIONE MANIPULATIONS ACHTUNG: ATTENZIONE: ATTENTION: (Drosselklappen-Positions- Non svitare le viti (sensore di posizione Ne pas desserrer les vis (capteur de sensor) 1 nicht lösen – außer dell’acceleratore) 1 se non per sosti- position du papillon des gaz) 1 sauf wenn der Drosselklappen-Positi- tuire il sensore di posizione dell’acce-...
  • Page 276 CARBURETOR 2. Inspect: Main jet 1 Pilot jet 2 Needle jet 3 Starter jet 4 Pilot air jet 5 Leak jet 6 Damage → Replace. Contamination → Clean. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air.
  • Page 277 CARBURATEUR VERGASER CARBURATORE Contrôler: Kontrollieren: Ispezionare: Gicleur principal 1 Hauptdüse 1 Getto del massimo 1 Gicleur de ralenti 2 Leerlaufdüse 2 Getto del minimo 2 Puits d’aiguille 3 Nadeldüse 3 Getto a spillo 3 Gicleur de starter 4 Choke-Düse 4 Getto di avviamento 4 Gicleur d’air de ralenti 5 Leerlaufluftdüse 5...
  • Page 278 CARBURETOR Float height 1. Measure: Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: Hold the carburetor in an upside down position. NOTE: Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm.
  • Page 279 CARBURATEUR VERGASER CARBURATORE Hauteur du flotteur Schwimmerhöhe Altezza galleggiante Mesurer: Messen: Misurare: Hauteur du flotteur a Schwimmerhöhe a Altezza galleggiante a Hors spécification → Régler. Unvorschriftsmäßig → Ein- Fuori specifica → Regolare. stellen. Hauteur du flotteur: Altezza galleggiante: 8,0 mm (0,31 in) 8,0 mm (0,31 in) Schwimmerhöhe: 8,0 mm (0,31 in)
  • Page 280 CARBURETOR Starter plunger 1. Inspect: Cold starter plunger 1 Hot starter plunger 2 Wear/damage → Replace. Accelerator pump 1. Inspect: Diaphragm (accelerator pump) 1 Spring (accelerator pump) 2 Accelerator pump cover 3 O-ring 4 Push rod 5 Tears (diaphragm)/damage → Replace. Dirt →...
  • Page 281 CARBURATEUR VERGASER CARBURATORE Plongeur de starter Choke-Schieber Stantuffo dell’avviamento Contrôler: Kontrollieren: Ispezionare: Plongeur de démarrage à froid Kaltstarter-Tauchkolben 1 Stantuffo dell’avviamento a Heißstarter-Tauchkolben 2 freddo 1 Verschleiß/Beschädigung → Plongeur de démarrage à chaud Stantuffo dell’avviamento a Erneuern. caldo 2 Usure/endommagement → Usura/danno →...
  • Page 282 CARBURETOR 3. Install: Spring 1 1 Lever 1 2 To lever 2 3. NOTE: Make sure the spring 1 fits on the stopper a of the lever 2. 4. Install: Spring 2 1 To lever 2 2. 5. Install: Push rod link lever assembly 1 NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor.
  • Page 283 CARBURATEUR VERGASER CARBURATORE Installer: Montieren: Installare: Ressort 1 1 Feder 1 1 Molla 1 1 Levier 1 2 Hebel 1 2 Leva 1 2 Au levier 2 3. (zum Hebel 2 3) Sulla leva 2 3. N.B.: HINWEIS: NOTA: S’assurer que le ressort 1 s’adapte à la Sicherstellen, daß...
  • Page 284 CARBURETOR 8. Install: 1 2 3 Throttle shaft assembly 1 Washer (metal) 2 Washer (resin) 3 Valve lever 4 NOTE: Apply the fluorochemical grease on the bear- ings. Fit the projection a on the throttle shaft assembly into the slot b in the throttle posi- tion sensor.
  • Page 285 CARBURATEUR VERGASER CARBURATORE Installer: Montieren: Installare: Ensemble d’axe de papillon 1 Drosselwellen-Baugruppe Gruppo albero della valvola a Rondelle ordinaire (métal) 2 farfalla 1 Rondelle ordinaire (résine) 3 Unterlegscheibe (Metall) 2 Rondella (metallica) 2 Culbuteur de soupape 4 Unterlegscheibe (Kunst- Rondella (resina) 3 harz) 3 Leva valvola 4 N.B.:...
  • Page 286 CARBURETOR 11. Install: Needle valve 1 Float 2 Float pin 3 NOTE: After installing the needle valve to the float, install them to the carburetor. Check the float for smooth movement. 12. Install: Pilot screw 1 Spring 2 Washer 3 O-ring 4 Note the following installation points: Turn in the pilot screw until it is lightly...
  • Page 287 CARBURATEUR VERGASER CARBURATORE 11. Monter: 11. Montieren: 11. Installare: Nadelventil 1 Pointeau 1 Valvola a spillo 1 Schwimmer 2 Flotteur 2 Galleggiante 2 Schwimmer-Achsstift 3 Axe de flotteur 3 Perno del galleggiante 3 HINWEIS: N.B.: NOTA: Das Nadelventil an den Schwim- Après avoir installé...
  • Page 288 CARBURETOR 15. Install: Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6. 16. Install: Throttle valve assembly 1 Screw (throttle shaft) 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve.
  • Page 289 CARBURATEUR VERGASER CARBURATORE 15. Monter: 15. Montieren: 15. Installare: Aiguille 1 Düsennadel 1 Spillo del getto 1 Collerette 2 Distanzhülse 2 Collarino 2 Ressort 3 Feder 3 Molla 3 Support de pointeau 4 Nadelhalterung 4 Fermaglio spillo 4 Plaquette de boisseau 5 Gasschieber-Scheibe 5 Piastra valvola a farfalla 5 Sur le boisseau 6.
  • Page 290 CARBURETOR Fully turn in the accelerator pump adjust- ing screw 3. Check that the link lever 4 has free play b by pushing lightly on it. Gradually turn out the adjusting screw while moving the link lever until it has no more free play.
  • Page 291 CARBURATEUR VERGASER CARBURATORE Serrer complètement la vis de Die Beschleunigerpumpen-Ein- Girare completamente la vite di réglage 3 de la pompe d’accéléra- stellschraube 3 voll eindrehen. regolazione della pompa della val- teur. Leicht auf den Gestängehebel vola a farfalla 3. 4 drücken, um zu prüfen, ob er Enfoncer légèrement le levier de Controllare che la leva di collega- freies Spiel b hat.
  • Page 292 CARBURETOR 5. Install: Throttle cable (pull) 1 4 Nm (0.4 m · kg, 2.9 ft · lb) Throttle cable (return) 2 11 Nm (1.1 m · kg, 8.0 ft · lb) 6. Adjust: Throttle grip free play Refer to “THROTTLE CABLE ADJUST- MENT”...
  • Page 293 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: Installare: Câble d’accélérateur (sortie) 1 Gasseilzug (Zug) 1 Cavo dell’acceleratore (tirag- gio) 1 4 Nm (0,4 m · kg, 2,9 ft · lb) 4 Nm (0,4 m · kg, 2,9 ft · lb) Câble d’accélérateur (entrée) Gasseilzug (Rückzug) 2 4 Nm (0,4 m ·...

  • Page 294: Camshafts

    CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Carburetor Refer to “CARBURETOR”...

  • Page 295: Arbres A Cames

    ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ARBRES A CAMES COUVRE-CULASSE 1 Dépose du couvercle de culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE Préparation à la dépose Selle et réservoir de carburant Se reporter à...
  • Page 296 CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Refer to “REMOVAL POINTS”. Camshaft cap Clip Exhaust camshaft Intake camshaft...
  • Page 297 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ARBRES A CAMES Organisation de la dépose: 1 Dépose de l’arbre à cames Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’ARBRE A CAMES Vis d’accès du repère de distribution Vis d’accès de l’extrémité...
  • Page 298 CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: Timing mark accessing screw 1 Crankshaft end accessing screw 2 2. Align: T.D.C. mark With align mark. Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C.
  • Page 299 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Arbre à cames Nockenwelle Albero a camme Déposer: Demontieren: Rimuovere: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Vite di accesso al riferimento Bouchon droit 2 be 1 per fasatura 1 Aligner: Rotorzapfen-Abdeckschrau- Vite di accesso estremità...
  • Page 300 CAMSHAFTS 5. Remove: Exhaust camshaft 1 Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft 1. Inspect: Cam lobe Pitting/scratches/blue discoloration → Replace. 2. Measure: Cam lobe length a and b Out of specification →...
  • Page 301 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Déposer: Demontieren: Rimuovere: Arbre à cames d’échappement Auslaß-Nockenwelle 1 Albero a camme di scarico 1 Einlaß-Nockenwelle 2 Albero a camme di aspirazione Arbre à cames d’admission 2 HINWEIS: Die Steuerkette mit einem Draht 3 N.B.: NOTA: Attacher un fil 3 à...
  • Page 302 CAMSHAFTS 4. Measure: Camshaft-to-cap clearance Out of specification → Measure cam- shaft outside diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: Install the camshaft onto the cylinder head. ® Position a strip of Plastigauge 1 onto the camshaft.
  • Page 303 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Mesurer: Messen: Misurare: Jeu entre arbre à cames et cha- Nockenwellen-Lagerspiel Gioco albero a camme-cap- Unvorschriftsmäßig → Nok- peau pello Hors spécifications → Mesu- Fuori specifica → Misurare il kenwellen-Außendurchmes- rer le diamètre extérieur de ser messen.
  • Page 304 CAMSHAFTS Decompression system 1. Check: Decompression system Checking steps: Check that the decompression mecha- nism cam 1 moves smoothly. Check that the decompression mechanism cam lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.
  • Page 305 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Système de décompression Dekompressionssystem Sistema di decompressione Vérifier: Prüfen: Controllare: Système de décompression Dekompressionssystem Sistema di decompressione Prüfschritte: Points à contrôler: Fasi di controllo: S’assurer que la came de décom- Prüfen, ob der Dekompressi- Controllare che la camma del mec- presseur 1 tourne en douceur.
  • Page 306 CAMSHAFTS Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration.
  • Page 307 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Die Steuerkette 3 auf beide Placer la chaîne de distribution 3 Inserire la catena di distribuzione 3 Nockenwellenräder legen und sulle due ruote dentate dell’albero a sur les deux pignons d’arbre à die Nockenwellen am Zylinder- camme e montare l’albero a camme cames et installer les arbres à...
  • Page 308 CAMSHAFTS With the rod fully wound and the chain tensioner UP mark a facing upward, install the gasket 1 and the timing chain tensioner 2, and tighten the bolt 3 to the specified torque. Bolt (timing chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb) Release the screwdriver, check the ten- sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci-...
  • Page 309 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Wenn der Spanner voll aufge- La tige complètement vissée et le Con l’asta completamente svitata dreht ist und die Markierung repère UP a du tendeur de chaîne ed il tenditore con il riferimento “UP”...
  • Page 310 NOTE: Apply the sealant on the cylinder head cover gasket. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 7. Install: Oil tank breather hose Cylinder head breather hose Spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb)
  • Page 311 NOTA: Applicare il materiale di tenuta sulla ® Quick gasket guarnizione del coperchio della testata ACC-QUICK-GS-KT ® Quick gasket del cilindro. YAMAHA Bond n˚ 1215: ACC-QUICK-GS-KT 90890-85505 YAMAHA-Dichtmasse Nr. 1215: ® Quick gasket 90890-85505 ACC-QUICK-GS-KT YAMAHA Bond n. 1215:...
  • Page 312 CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER”...

  • Page 313: Testata Del Cilindro

    CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO CULASSE 1 Dépose de la culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE ET DU CYLIN- Préparation à la dépose Selle et réservoir de carburant Se reporter à...

  • Page 314: Cylinder Head

    CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid dam- aging or scratching: Spark plug threads Valve seats 2. Inspect: Cylinder head Scratches/damage → Replace. 3.
  • Page 315 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO CONTROLE PRÜFUNG ISPEZIONE Culasse Zylinderkopf Testata del cilindro Eliminer: Entfernen: Eliminare: Dépôt de calamine Ölkohleablagerungen (im Depositi carboniosi (dalle (de la chambre de combustion) Brennraum) camere di combustione) Utiliser un grattoir arrondi. Einen abgerundeten Scha- Utilizzare un raschietto arro- ber verwenden.
  • Page 316 CYLINDER HEAD ASSEMBLY AND INSTALLATION Cylinder head 1. Install: Dowel pin 1 Cylinder head gasket 2 Timing chain guide (exhaust side) 3 Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head.
  • Page 317 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Culasse Zylinderkopf ZIONE Monter: Montieren: Testata del cilindro Goujon 1 Paßstift 1 Installare: Joint 2 Dichtung 2 Perno di centraggio 1 Guide de chaîne de distribution Steuerkettenschiene (Aus- Guarnizione testata del cilindro (côté...

  • Page 318: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Valve lifter Use special tool. Adjusting pad Refer to “REMOVAL POINTS”.

  • Page 319: Soupapes Et Ressorts De Soupape

    SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE SOUPAPES ET RESSORTS DE SOUPAPE 1 Dépose des soupapes Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES SOUPAPES ET DES RES- SORTS DE SOUPAPE Préparation à...
  • Page 320 VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: Valve lifter 1 Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: Valve sealing Leakage at the valve seat →...
  • Page 321 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Poussoir de soupape et clavette de sou- Tassenstößel und Ventikeile Alzavalvola e semiconi pape Demontieren: Rimuovere: Déposer: Tassenstößel 1 Alzavalvola 1 Poussoir de soupape 1 Ventilplättchen 2 Spessore 2...
  • Page 322 VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in) Exhaust:...
  • Page 323 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE CONTROLE PRÜFUNG ISPEZIONE Soupape Ventil Valvola Mesurer: Messen: Misurare: Jeu de queue dans le guide Ventilschaftspiel Gioco stelo-guida Ventilschaftspiel = Gioco stelo-guida = Jeu de queue dans le guide de sou- Ventilführungsdurchmesser diametro interno del guidaval- pape =...
  • Page 324 VALVES AND VALVE SPRINGS Valve guide remover: Intake: 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust: 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake: 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust: 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake: 4.0 mm (0.16 in) YM-4113/90890-04113 Exhaust: 4.5 mm (0.18 in) YM-4118/90890-04118...
  • Page 325 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Outil de dépose de guide Ventilführungs-Austrei- Estrattore guidavalvola: de soupape: ber: Aspirazione: 4,0 mm Admission: 4,0 mm Einlaß: 4,0 mm (0,16 in) (0,16 in) (0,16 in) YM-4111/90890-04111 YM-4111/90890-04111 YM-4111/ Scarico: 4,5 mm Echappement: 4,5 mm...
  • Page 326 VALVES AND VALVE SPRINGS 5. Measure: Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: When installing a new valve always replace the guide. If the valve is removed or replaced always replace the oil seal. 6.
  • Page 327 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Mesurer: Messen: Misurare: Ovalisation (queue de soupape) Ventilschaftschlag Disassamento (stelo valvola): Hors spécifications → Rempla- Unvorschriftsmäßig → Fuori specifica → Sostituire. cer. Erneuern. Limite di disassamento: 0,01 mm (0,0004 in) Limite de déformation: Max.
  • Page 328 VALVES AND VALVE SPRINGS 9. Lap: Valve face Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: Apply a coarse lapping compound to the valve face.
  • Page 329 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Roder: Einschleifen: Lappare: Ventilteller Face de soupape Faccia della valvola Ventilsitz Siège de soupape Sede della valvola HINWEIS: N.B.: NOTA: Nach Bearbeitung des Ventilsitzes Après le surfaçage du siège de soupape Dopo aver rettificato la sede della val- oder Erneuerung von Ventil und Ven- ou le remplacement de la soupape et du...
  • Page 330 VALVES AND VALVE SPRINGS Valve spring 1. Measure: Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 37.81 mm (1.49 in) <Limit>: 36.81 mm (1.45 in) Exhaust: 37.54 mm (1.48 in) <Limit>: 36.54 mm (1.44 in) 2.

  • Page 331: Soupapes Et Ressorts De Soupape

    SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Ressort de soupape Ventilfeder Molla valvola Mesurer: Messen: Misurare: Longueur libre du ressort de Ventilfederlänge (ent- Lunghezza libera della molla soupape a spannt) a della valvola a Hors spécifications → Rempla- Unvorschriftsmäßig →...
  • Page 332 VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION Valve and valve spring 1. Apply: Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: Valve 1 Valve spring seat 2 Valve stem seal 3 Valve spring 4 Valve spring retainer 5 To cylinder head.
  • Page 333 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Soupape et ressort de soupape Ventile und Ventilfeder ZIONE Appliquer: Auftragen: Valvola e molla della valvola Huile au bisulfure de molyb- Molybdändisulfidöl Applicare: dène...
  • Page 334 VALVES AND VALVE SPRINGS 5. Install: Adjusting pad 1 Valve lifter 2 NOTE: Apply the molybdenum disulfide oil on the valve stem end. Apply the engine oil on the valve lifters. Valve lifter must turn smoothly when rotated with a finger. Be careful to reinstall valve lifters and pads in their original place.
  • Page 335 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Monter: Montieren: Installare: Cales de réglage 1 Ventilplättchen 1 Spessore di regolazione 1 Poussoir de soupape 2 Tassenstößel 2 Alzavalvola 2 HINWEIS: N.B.: NOTA: Enduire l’extrémité de la queue de Molybdändisulfidfett Ventil- Applicare olio al disolfuro di molib-...

  • Page 336: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Bolt (cylinder) Cylinder Piston pin clip Piston pin Use special tool.

  • Page 337: Cylindre Et Piston

    CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE CYLINDRE ET PISTON 1 Dépose du cylindre 2 Dépose du piston Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES CYLINDRES ET DES PIS- TONS Préparation à...
  • Page 338 CYLINDER AND PISTON REMOVAL POINTS Piston and piston ring 1. Remove: Piston pin clip 1 Piston pin 2 Piston 3 NOTE: Put identification marks on each piston head for reference during reinstallation. Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4.
  • Page 339 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Piston et segment de piston Kolben und Kolbenring Pistone e fascia elastica Déposer: Demontieren: Rimuovere: Agrafe d’axe de piston 1 Kolbenbolzen-Sicherungs- Morsetto spinotto 1 Axe de piston 2 ringe 1 Spinotto 2...
  • Page 340 CYLINDER AND PISTON 77.00 ~ 77.01 mm Cylinder bore “C” (3.0315 ~ 3.0319 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D or D – (Maximum D or D “R”...
  • Page 341 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE 77,00 à 77,00– Alesaggio cilin- 77,00 ~ 77,01 mm Zylinderboh- 77,01 mm Alésage de cylin- 77,01 mm dro “C” (3,0315 ~ 3,0319 in) dre “C” (3,0315 à rung “C” (3,0315– Limite conicità 0,05 mm 3,0319 in) 3,0319 in)
  • Page 342 CYLINDER AND PISTON Piston ring 1. Measure: Ring side clearance Use a feeler gauge 1. Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard <Limit>...
  • Page 343 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Segment de piston Kolbenring Fascia elastica Mesurer: Messen: Misurare: Jeu latéral du segment Ringnutspiel Gioco laterale della fascia Utiliser une jauge d’épaisseur Fühlerlehre 1 verwenden. Utilizzare uno spessimetro 1. Unvorschriftsmäßig → Kol- Se fuori specifica →...
  • Page 344 CYLINDER AND PISTON Piston pin 1. Inspect: Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: Piston pin-to-piston clearance Measurement steps: Measure the outside diameter (piston pin) If out of specification, replace the piston pin. Outside diameter (piston pin): 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) Measure the inside diameter (piston) b.
  • Page 345 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Axe de piston Kolbenbolzen Spinotto Contrôler: Kontrollieren: Ispezionare: Axe de piston Kolbenbolzen Spinotto Décoloration bleue/gorges → Blaufärbung/Riefen → Sbiadimento blu/scanalature → Remplacer puis examiner le Erneuern und Schmiersy- Sostituire quindi ispezionare il système de graissage.
  • Page 346 CYLINDER AND PISTON 2. Position: Top ring 2nd ring Oil ring 45° Offset the piston ring end gaps as 135° 135° shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
  • Page 347 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Positionner: Montieren: Posizione: Segment de feu 1. Kompressionsring Fascia superiore Segment d’étanchéité (Topring) Seconda fascia Segment racleur d’huile 2. Kompressionsring Fascia raschiaolio Décaler les becs de segment Ölabstreifring Decentrare le luci delle estre- comme illustré.
  • Page 348 CYLINDER AND PISTON 3. Install: Cylinder gasket 1 Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. CAUTION: Pass the timing chain 3 through the tim- ing chain cavity. Be careful not to damage the timing chain guide 4 during installation.
  • Page 349 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Monter: Montieren: Installare: Joint de cylindre 1 Dichtung 1 Guarnizione cilindro 1 Cylindre 2 Zylinder 2 Cilindro 2 HINWEIS: N.B.: NOTA: Installer le cylindre d’une main tout en Den Zylinder mit einer Hand einbau- Installare il cilindro con una mano com- comprimant les segments de l’autre en, mit der anderen die Kolbenringe...

  • Page 350: Clutch

    CLUTCH EC4A0000 CLUTCH Extent of removal: 1 Push rod 1, 2 and push lever shaft removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Primary driven gear removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal...
  • Page 351 EMBRAYAGE KUPPLUNG FRIZIONE EMBRAYAGE Organisation de la dépose: 1 Dépose des tiges de commande 1 er 2 et du levier de poussée 2 Démontage de la tige de commande 1 3 Dépose du disque de friction et du disque d’embrayage 4 Dépose du pignon mené...
  • Page 352 CLUTCH Extent of removal Order Part name Q’ty Remarks Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Use special tool. Look washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - 50...
  • Page 353 EMBRAYAGE KUPPLUNG FRIZIONE Organisation de la dépose Ordre Nom de pièce Qté Remarques Disque de friction Disque d’embrayage Ressort amortisseur Plaque d’assise Ecrou (noix d’embrayage) Utiliser un outil spécial. Rondelle d’arrêt Se reporter à “POINTS DE DEPOSE”. Noix d’embrayage Rondelle de butée Pignon mené...
  • Page 354 CLUTCH EC4A3000 REMOVAL POINTS Clutch boss 1. Remove: Nut 1 Lock washer 2 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å ı Clutch holding tool: YM-91042/90890-04086 Å...
  • Page 355 EMBRAYAGE KUPPLUNG FRIZIONE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Noix d’embrayage Kupplungsnabe Mozzo frizione Déposer: Demontieren: Rimuovere: Ecrou 1 Mutter 1 Dado 1 Rondelle-frein 2 Sicherungsscheibe 2 Rondella di bloccaggio 2 Noix d’embrayage 3 Kupplungsnabe 3 Mozzo frizione 3 N.B.: HINWEIS: NOTA:...
  • Page 356 CLUTCH Friction plate 1. Measure: Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) <Limit>: 2.7 mm (0.106 in) EC484600 Clutch plate 1.
  • Page 357 EMBRAYAGE KUPPLUNG FRIZIONE Disque de friction Reibscheiben Disco conduttore Mesurer: Messen: Misurare: Epaisseur de disque de friction Reibscheibenstärke Spessore del disco conduttore Hors-spécification → Changer Unvorschriftsmäßig → Die Fuori specifica → Sostituire in tous les disques de friction. Reibscheiben Satz blocco il disco conduttore.
  • Page 358 CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION Push lever shaft 1. Install: Push lever shaft 1 Bolt (push lever shaft) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the lithium soap base grease on the oil seal lip. Apply the engine oil on the push lever shaft.
  • Page 359 EMBRAYAGE KUPPLUNG FRIZIONE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Levier de poussée Druckhebel ZIONE Monter: Montieren: Alberino della leva spingente Arbre de levier de poussée 1 Druckhebelwelle 1 Installare: Boulon (arbre de levier de Schraube (Druckhebelwel- Alberino della leva spingente poussée) 2 le) 2 Bullone (alberino della leva...
  • Page 360 CLUTCH 3. Bend the lock washer 1 tab. 4. Install: Seat plate 1 Cushion spring 2 NOTE: Install the seat plate with its chamfered por- tion a facing the clutch boss 3. Install the seat plate so that it is not caught on the step b.
  • Page 361 EMBRAYAGE KUPPLUNG FRIZIONE Courber la languette de la ron- Die Lasche der Sicherungs- Piegare la linguetta della rondella delle-frein 1. scheibe 1 umbiegen. di bloccaggio 1. Monter: Montieren: Installare: Ressort amortisseur 1 Polsterfeder 1 Molla cuscinetto 1 Plaque d’assise 2 Sitzplatte 2 Piastra di disinnesto 2 N.B.:...
  • Page 362 CLUTCH 7. Install: Push rod 2 1 Ball 2 Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball. 8. Install: Pressure plate 1 9. Install: Clutch spring 1 Bolt (clutch spring) 2 8 Nm (0.8 m ·...
  • Page 363 EMBRAYAGE KUPPLUNG FRIZIONE Monter: Montieren: Installare: Tige de poussée 2 1 Druckstange 2 1 Asta di punteria 2 1 Bille 2 Kugel 2 Sfera 2 Tige de poussée 1 3 Druckstange 1 3 Asta di punteria 1 3 N.B.: HINWEIS: NOTA: Appliquer de la graisse de savon au Lithiumfett auf Druckstangen 1 und 2...

  • Page 364: Oil Filter Element, Water Pump And Right Crankcase Cover

    OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal: 1 Oil filter element removal 2 Water pump removal 3 Right crankcase cover removal Extent of removal Order Part name Q’ty Remarks OIL FILTER ELEMENT, WATER...
  • Page 365 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT 1 Dépose de l’élément de filtre à huile 2 Dépose de la pompe à...
  • Page 366 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal Order Part name Q’ty Remarks Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Refer to “REMOVAL POINTS”. Oil seal Bearing 4 - 57...
  • Page 367 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Organisation de la dépose Ordre Nom de pièce Qté Remarques Logement de pompe à eau Tuyau d’arrivée d’huile Boulon (durit d’huile) Pédale de kick...
  • Page 368 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL POINTS Impeller shaft 1. Remove: Impeller 1 Washer 2 Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller.
  • Page 369 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Arbre de rotor Flügelradwelle Albero girante Déposer: Demontieren: Rimuovere: Arbre de rotor 1 Flügelradwelle 1...
  • Page 370 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: Gear teeth a Wear/damage → Replace. EC4H4600 Bearing 1. Inspect: Bearing Rotate inner race with a finger.
  • Page 371 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Arbre de rotor Flügelradwelle Albero girante Contrôler: Kontrollieren: Ispezionare: Arbre de rotor 1 Flügelradwelle 1 Albero girante 1 Deformazione/usura/danno →...
  • Page 372 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft 1. Install: Impeller shaft 1 Washer 2 Impeller 3 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: Take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi-...
  • Page 373 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Monter: Montieren: Installare: Roulement 1 Lager 1 Cuscinetto 1 N.B.: HINWEIS: NOTA: Monter le roulement en appuyant paral- Zur Lager-Montage den äußeren Installare il cuscinetto premendo paralle- lèlement sur la cage extérieure.
  • Page 374 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: Right crankcase cover 1 Bolt (right crankcase cover) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the engine oil on the impeller shaft end. Mesh the impeller shaft gear 3 with primary drive gear 4.
  • Page 375 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Monter: Montieren: Installare: Demi-carter droit 1 Rechten Kurbelgehäuse- Coperchio carter destro 1 Boulon (demi-carter droit) 2 deckel 1 Bullone (coperchio...
  • Page 376 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Water pump housing 1. Install: Dowel pin 1 O-ring 2 NOTE: Apply the lithium soap base grease on the O- ring. 2. Install: Water pump housing 1 Bolt (water pump housing) 2 10 Nm (1.0 m ·...
  • Page 377 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Logement de la pompe à eau Wasserpumpengehäuse Alloggiamento della pompa dell’acqua Monter: Montieren: Installare: Goupille 1 Stift 1 Perno di centraggio 1 Joint torique 2...

  • Page 378: Balancer

    BALANCER BALANCER Extent of removal: 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”...
  • Page 379 BALANCIER AUSGLEICHSWELLE BILANCIERE BALANCIER Organisation de la dépose: 1 Pignon mené du balancier 2 Balancier Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BALANCIER Préparation à la dépose Pignon menant primaire Se reporter à la section “EMBRAYAGE”. Couvercle de demi-carter droit Se reporter à...
  • Page 380 BALANCER REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear 1. Straighten the lock washer tab. 2. Loosen: Nut (primary drive gear) 1 Nut (balancer shaft driven gear) 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4.
  • Page 381 BALANCIER AUSGLEICHSWELLE BILANCIERE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Pignon menant et pignon mené du Ausgleichswellen-Antriebs- und - Ingranaggio conduttore dell’albero di balancier Abtriebsräder equilibratura e ingranaggio condotto Redresser l’ongle de rondelle Die Lasche der Sicherungs- dell’albero di equilibratura d’arrêt.
  • Page 382 BALANCER ASSEMBLY AND INSTALLATION Balancer shaft, balancer shaft drive gear and balancer shaft driven gear 1. Install: Balancer shaft 1 NOTE: Apply the engine oil on the bearing. When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crank- shaft and balancer shaft.
  • Page 383 BALANCIER AUSGLEICHSWELLE BILANCIERE ASSEMBLAGE ET INSTALLATION ZUSAMMENBAU UND MONTAGE MONTAGGIO ED INSTALLAZIONE Balancier, pignon menant de balan- Ausgleichswelle, An- und Albero di equilibratura, ingranaggio cier et pignon mené de balancier Abtriebsrad conduttore dell’albero di equilibra- Monter: Montieren: tura e ingranaggio condotto Balancier 1 Ausgleichswelle 1 dell’albero di equilibratura...

  • Page 384: Oil Pump

    OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”...

  • Page 385: Pompe A Huile

    POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO POMPE A HUILE Organisation de la dépose: 1 Dépose de la pompe à huile 2 Démontage de la pompe à huile Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE ET DEMONTAGE DE LA POMPE A HUILE Préparation à...
  • Page 386 OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 4 - 67...
  • Page 387 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Organisation de la dépose Ordre Nom de pièce Qté Remarques Goupille Rondelle Arbre de transmission de la pompe à huile Logement de rotor Reihen- Demontage-Arbeiten Bauteil Anz. Bemerkungen folge Paßstift Beilagscheibe Ölpumpen-Antriebswelle Rotorgehäuse Portata dello smontaggio Ordine Denominazione Quantità...
  • Page 388 OIL PUMP INSPECTION Oil pump 1. Inspect: Oil pump drive gear 1 Oil pump drive shaft 2 Rotor housing 3 Oil pump cover 4 Cracks/wear/damage → Replace. 2. Measure: Tip clearance a (between the inner rotor 1 and outer rotor 2) Side clearance b (between the outer rotor 2 and rotor housing 3)
  • Page 389 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO CONTROLE PRÜFUNG ISPEZIONE Pompe à huile Ölpumpe Pompa dell’olio Contrôler: Kontrollieren: Ispezionare: Pignon menant de pompe à Ölpumpen-Antriebsrad 1 Ingranaggio conduttore della huile 1 Ölpumpen-Antriebswelle 2 pompa dell’olio 1 Arbre menant de pompe à huile Rotorgehäuse 3 Albero comando...
  • Page 390 OIL PUMP ASSEMBLY AND INSTALLATION Oil pump 1. Install: Oil pump drive shaft 1 Washer 2 Dowel pin 3 Inner rotor 1 4 NOTE: Apply the engine oil on the oil pump drive shaft and inner rotor 1. Fit the dowel pin into the groove in the inner rotor 1.
  • Page 391 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO ASSEMBLAGE ET INSTALLATION ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Pompe à huile Ölpumpe ZIONE Installer: Montieren: Pompa dell’olio Arbre de transmission de la Ölpumpen-Antriebswelle 1 Installare: pompe à huile 1 Beilagscheibe 2 Albero comando della Rondelle 2 Paßstift 3 pompa olio 1...
  • Page 392 OIL PUMP 4. Install: Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 10 Nm (1.0 m · kg, 7.2 ft · lb) Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 5 10 Nm (1.0 m ·...
  • Page 393 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Monteur: Montieren: Installare: Rotor extérieur 2 1 Außenrotor 2 1 Rotore esterno 2 1 Goupille de serrage 2 Paßstift 2 Perno di centraggio 2 Essemble pompe à huile 3 Ölpumpe 3 Gruppo pompa dell’olio 3 Boulon (essemble pompe à...

  • Page 394: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT Extent of removal: 1 Kick shaft removal 2 Kick shaft disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump...

  • Page 395: Arbre De Kick Et Arbre De Selecteur

    ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO ARBRE DE KICK ET ARBRE DE SELECTEUR Organisation de la dépose: 1 Dépose de l’arbre de kick 2 Démontage de l’arbre de kick 3 Dépose arbre de sélecteur 4 Dépose de barillet Organisation de la dépose Ordre...
  • Page 396 KICK SHAFT AND SHIFT SHAFT Extent of removal Order Part name Q’ty Remarks Torsion spring Roller Shift guide Refer to “REMOVAL POINTS”. Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to “REMOVAL POINTS”. 4 - 72...
  • Page 397 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Organisation de la dépose Ordre Nom de pièce Qté Remarques Ressort de torsion Rouleau Guide de sélecteur Se reporter à “POINTS DE DEPOSE”. Ensemble levier de sélecteur Levier de sélecteur Cliquet Goupille de cliquet...
  • Page 398 KICK SHAFT AND SHIFT SHAFT REMOVAL POINTS Kick shaft assembly 1. Remove: Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: Bolt (shift guide) Shift guide 1 Shift lever assembly 2 NOTE:...
  • Page 399 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Arbre de kick complet Kickstarterwelle (komplett) Gruppo albero pedivella Déposer: Demontieren: Rimuovere: Arbre de kick complet 1 Kickstarterwelle (komplett) 1 Gruppo albero pedivella 1 N.B.:...
  • Page 400 KICK SHAFT AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: Shift shaft 1 Bend/damage → Replace. Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear/damage →...
  • Page 401 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Arbre de sélecteur Schaltwelle Albero del cambio Contrôler: Kontrollieren: Ispezionare: Arbre de sélecteur 1 Schaltwelle 1 Albero del cambio 1 Tordu/endommagement → Deformazione/danno → Sosti- Verbiegung/Beschädigung →...
  • Page 402 KICK SHAFT AND SHIFT SHAFT EC4B5111 Stopper lever 1. Install: Torsion spring 1 Stopper lever 2 Bolt (stopper lever) 3 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with the slot on segment.
  • Page 403 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Levier de butée Rastenhebel Leva di arresto Monter: Montieren: Installare: Ressort de torsion 1 Torsionsfeder 1 Molla di torsione 1 Levier de butée 2 Rastenhebel 2 Leva di arresto 2 Boulon (levier de butée) 3...
  • Page 404 KICK SHAFT AND SHIFT SHAFT Shift shaft 1. Install: Roller 1 Collar 2 Torsion spring 3 Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft. 2. Install: Shift pedal 1 Bolt (shift pedal) 2 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: When installing the shift pedal onto the shift shaft, be sure that the center of the shift pedal...
  • Page 405 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Arbre de sélecteur Schaltwelle Albero del cambio Monter: Montieren: Installare: Rouleau 1 Rolle 1 Rullo 1 Collerette 2 Distanzhülse 2 Collarino 2 Ressort de torsion 3 Torsionsfeder 3 Molla di torsione 3 Arbre de sélecteur 4...
  • Page 406 KICK SHAFT AND SHIFT SHAFT 3. Install: Spring guide 1 NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: Kick shaft assembly 1 Washer 2 NOTE: Apply the molybdenum disulfide grease on...
  • Page 407 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Monter: Montieren: Installare: Guide de ressort 1 Federsitz 1 Guida molla 1 N.B.: HINWEIS: NOTA: Coulisser le guide de ressort dans l’arbre Den Federsitz über die Kickstarter- Far scivolare la guida della molla de kick, s’assurer que la gorge a dans le welle führen, wobei die Nut a im Fe-...

  • Page 408: Cdi Magneto

    CDI MAGNETO EC4L0000 CDI MAGNETO Extent of removal: 1 CDI magneto removal Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Bolt (left radiator) Refer to “RADIATOR”...

  • Page 409: Volant Magnetique Cdi

    VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI VOLANT MAGNETIQUE CDI 1 Dépose du volant magnétique CDI Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE CDI Préparation à la dépose Selle et réservoir à essence Se reporter à...
  • Page 410 CDI MAGNETO EC4L3000 REMOVAL POINTS Rotor 1. Remove: Nut (rotor) 1 Washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it counterclockwise.
  • Page 411 VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Rotor Rotor Rotore Déposer: Demontieren: Rimuovere: Ecrou (rotor) 1 Mutter (Rotor) 1 Dado (rotore) 1 Rondelle 2 Beilagscheibe 2 Rondella 2 Utiliser l’outil de maintien de Den Rotorhalter 3 verwen- Utilizzare l’utensile di sostegno rotor 3.
  • Page 412 Apply the sealant on the grommet of the CDI magneto lead. Tighten the screws using the T30 bit. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 2. Install: Woodruff key 1 Rotor 2 NOTE: Clean the tapered portions of the crankshaft and rotor.
  • Page 413 Quick gasket ® ACC-QUICK-GS-KT YAMAHA Bond n˚1215: Quick gasket ® Quick gasket ® 90890-85505 ACC-QUICK-GS-KT ACC-QUICK-GS-KT YAMAHA-Dichtmasse YAMAHA Bond n. 1215: Nr. 1215: 90890-85505 90890-85505 Monter: Montieren: Installare: Clavette de demi-lune 1 Scheibenfeder 1 Linguetta Woodruff 1 Rotor 2 Rotor 2...
  • Page 414 CDI MAGNETO 4. Connect: CDI magneto lead Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 5. Install: Dowel pin Gasket (left crankcase cover) Left crankcase cover 1 Hose guide (cylinder head breather hose) 2 Bolt (left crankcase cover) 3 10 Nm (1.0 m ·...
  • Page 415 VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI Connecter: Anschließen: Collegare: Fil de volant magnétique CDI CDI-Schwungradmagnet- Cavo magnete CDI Se référer au paragraphe “DIA- zünder-Kabel Fare riferimento al paragrafo GRAMME DE CHEMINE- Siehe unter “KABELFÜH- “SCHEMA DEL PERCORSO MENT CABLE” RUNG” im KAPITEL 2. DEI CAVI”...

  • Page 416: Engine Removal

    ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the WARNING suitable stand under the frame. Support the machine securely so there is no danger of it falling over. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...

  • Page 417: Depose Du Moteur

    DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU MOTEUR AVERTISSEMENT Préparation à la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas de approprié...
  • Page 418 ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks Ignition coil Disconnect the CDI magneto lead. Right engine guard Lower engine guard Neutral switch Bolt (oil hose) Drive chain sprocket cover Nut (drive sprocket) Lock washer Refer to “REMOVAL POINTS”.
  • Page 419 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE Organisation de la dépose: 1 Dépose du moteur Organisation de la dépose Ordre Nom de pièce Qté Remarques Bobine d’allumage Déconnecter le fil du volant magnétique CDI. Protège-carter droit Protège-carter inférieur Contacteur de point mort Boulon (durit d’huile) Couvercle de pignon de chaîne de transmission Ecrou (pignon d’entraînement)
  • Page 420 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: Nut (drive sprocket) 1 Lock washer 2 NOTE: Straighten the lock washer tab. Loosen the nut while applying the rear brake. 2. Remove: Drive sprocket 1 Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain.

  • Page 421: Rimozione Del Motore

    DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Pignon d’entraînement Antriebsritzel Corona dentata trasmissione Déposer: Demontieren: Rimuovere: Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 1 Dado (corona dentata trasmis- Sicherungsscheibe 2 sione) 1 Rondelle-frein 2 Rondella di bloccaggio 2 HINWEIS: Die Lasche der Sicherungsscheibe...
  • Page 422 ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: Engine 1 Install the engine from right side. Pivot shaft 2 85 Nm (8.5 m · kg, 61 ft · lb) Engine mounting bolt (lower) 3 69 Nm (6.9 m · kg, 50 ft · lb) Lower engine bracket 4 Bolt (lower engine bracket) 5 34 Nm (3.4 m ·...
  • Page 423 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO ED INSTALLAZIONE Montage du moteur Motor montieren Installazione del motore Monter: Montieren: Installare: Moteur 1 Motor 1 Motore 1 Monter le moteur par le côté (von der rechten Seite) Installare il motore dal lato droit.
  • Page 424 ENGINE REMOVAL 2. Install: Lock washer 1 Nut (drive sprocket) 2 75 Nm (7.5 m · kg, 54 ft · lb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4.
  • Page 425 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE Monter: Montieren: Installare: Rondelle-frein 1 Sicherungsscheibe 1 Rondella di bloccaggio 1 Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 2 Dado (corona dentata trasmis- sione) 2 75 Nm (7,5 m · kg, 54 ft · lb) 75 Nm (7,5 m ·...

  • Page 426: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE AND CRANK- SHAFT REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion.

  • Page 427: Carter Et Vilebrequin

    CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE CARTER ET VILEBREQUIN Organisation de la dépose: 1 Séparation du carter 2 Dépose du carter d’huile Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARTER ET DU VILEBRE- QUIN Préparation à...
  • Page 428 CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q’ty Remarks Bolt [L = 45 mm (1.77 in)] Bolt [L = 55 mm (2.17 in)] Bolt [L = 70 mm (2.76 in)] Hose guide Refer to “REMOVAL POINTS”. Clutch cable holder Right crankcase Left crankcase Oil strainer...
  • Page 429 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Boulon [L = 45 mm (1,77 in)] Boulon [L = 55 mm (2,17 in)] Boulon [L = 70 mm (2,76 in)] Guide de durit Se reporter à...
  • Page 430 CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK” section. Oil seal Bearing Refer to “REMOVAL POINTS”.
  • Page 431 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ROULEMENTS DE CARTER Organisation de la dépose: Dépose des roulements de carter Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES ROULEMENTS DE CAR- Préparation à la dépose Boîte à...
  • Page 432 CRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: Right crankcase Left crankcase Separation steps: Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.
  • Page 433 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Carter Kurbelgehäuse Carter Séparer: Trennen: Separare: Demi-carter droit Rechtes Kurbelgehäusehälf- Carter destro Demi-carter gauche Carter sinistro Linkes Kurbelgehäusehälfte Etapes de la séparation: Fasi per la separazione: Déposer les boulons de carter 1, Arbeitsschritte Rimuovere i bulloni del carter 1,...
  • Page 434 CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase bearing 1. Remove: Bearing 1 NOTE: Remove the bearing from the crankcase by pressing its inner race.
  • Page 435 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Vilebrequin Kurbelwelle Albero motore Déposer: Demontieren: Rimuovere: Vilebrequin 1 Kurbelwelle 1 Albero motore 1 Utiliser l’outil de séparateur de Das Kurbelgehäuse-Trenn- Utilizzare l’utensile per la carter 2. werkzeug 2. separazione del carter 2. Kurbelgehäuse-Trenn- Outil de séparation de Utensile per la separa-...
  • Page 436 CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Standard <Limit>...
  • Page 437 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Vilebrequin Kurbelwelle Albero motore Mesurer: Messen: Misurare: Limite de faux-rond a Schlaggrenze a Limite di disassamento a Pleuel-Radialspiel b Limite gioco piede di biella b Limite de déflexion de pied de bielle b Pleuel-Axialspiel c Gioco laterale della testa di...
  • Page 438 CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: Bearing Bearing stopper Bolt (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw [bearing stopper (crankshaft)] 1 10 Nm (1.0 m ·...
  • Page 439 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Roulement de carter Kurbelwellenlager Cuscinetto del basamento Einbauen: Installer: Installare: Roulement Lager Cuscinetto Butoir de roulement Lageranschlag Fermo cuscinetto Boulon(butoir de roulement) Schraube (Lageranschlag) Bullone (fermo cuscinetto) 10 Nm (1,0 m ·...
  • Page 440 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: Sealant On the right crankcase 1. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant. 5. Install: Dowel pin 1...
  • Page 441 1) Quick gasket ® Quick gasket ® ACC-QUICK-GS-KT ACC-QUICK-GS-KT ® Quick gasket YAMAHA Bond n˚1215: YAMAHA Bond n. 1215: ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA-Dichtmasse Nr. 1215: 90890-85505 N.B.: NOTA: Nettoyer la surface de contact des demi- Pulire la superficie di contatto dei semi- HINWEIS: carters gauche et droit avant d’appliquer...
  • Page 442 CRANKCASE AND CRANKSHAFT 6. Tighten: Hose guide 1 Clutch cable holder 2 Bolt (crankcase) 3 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: Oil delivery pipe 2 1 O-ring 2 Bolt (oil delivery pipe 2) 3 10 Nm (1.0 m ·...
  • Page 443 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Monter: Montieren: Serrare: Guide de durit 1 Kabelführung 1 Guida del flessibile 1 Support de câble d’embrayage Kupplungszug-Halterung 2 Supporto cavo frizione 2 Schraube (Kurbelgehäuse) Bullone (carter) 3 Boulon (carter) 3 12 Nm (1,2 m ·...

  • Page 444: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL”...
  • Page 445 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION Organisation de la dépose: 1 Dépose des fourchettes de sélection, du tambour, de l’arbre primaire et de l’arbre secondaire Organisation de la dépose Ordre Nom de pièce...
  • Page 446 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: Main axle 1 Drive axle 2 Shift cam Shift fork 3 Shift fork 2 Shift fork 1 NOTE: Remove assembly with the collar 3 installed to the crankcase. Remove assembly carefully.
  • Page 447 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Getriebe Boîte à vitesses Trasmissione Demontieren: Déposer: Rimuovere: Arbre primaire 1 Eingangswelle 1 Asse principale 1 Arbre secondaire 2 Ausgangswelle 2...
  • Page 448 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: Shift cam 1 Segment 2 Wear/damage → Replace. 3. Check: Shift fork movement Unsmooth operation → Replace shift fork.
  • Page 449 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Schaltgabeln und Schaltwalze Fourchette, tambour et barillet Forcella del cambio, camma del cam- Kontrollieren: Contrôler: bio e segmento Fourchette 1 Schaltgabel 1 Ispezionare: Verschleiß/Beschädigung/...
  • Page 450 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 2nd wheel gear (28T) 1 4th wheel gear (27T) 2 3rd wheel gear (29T) 3 5th wheel gear (25T) 4 1st wheel gear (30T) 5 O-ring 6 To drive axle 7. NOTE: Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on the end surface.
  • Page 451 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Montieren: Monter: Installare: Pignon de 2ème (28D) 1 Zahnrad 2. Gang Ingranaggio a ruota per la 2a Pignon de 4ème (27D) 2 (28 Zähne) 1 (28T) 1 Pignon de 3ème (29D) 3...
  • Page 452 TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: Shift fork 1 (L) 1 Shift fork 2 (C) 2 Shift fork 3 (R) 3 Shift cam 4 To main axle and drive axle. NOTE: Apply the molybdenum disulfide oil on the shift fork grooves.
  • Page 453 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Montieren: Monter: Installare: Fourchette 1 (L) 1 Schaltgabel 1 (L) 1 Forcella del cambio 1 (L) 1 Fourchette 2 (C) 2 Schaltgabel 2 (C) 2 Forcella del cambio 2 (C) 2 Fourchette 3 (R) 3...

  • Page 454: Chassis

    CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL WARNING Hold the machine by placing the...

  • Page 455: Partie Cycle

    ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT Organisation de la dépose: 1 Dépose de la roue avant 2 Dépose du roulement de roue 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de pièce...
  • Page 456 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks REAR WHEEL REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no danger of it falling over.
  • Page 457 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ROUE ARRIERE Organisation de la dépose: 1 Dépose de la roue arrière 2 Dépose du roulement de roue 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de pièce Qté...
  • Page 458 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.

  • Page 459: Roue Avant Et Roue Arriere

    ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Roue arrière Hinterrad Ruota posteriore Déposer: Demontieren: Rimuovere: Roue 1 Rad 1 Ruota 1 N.B.: HINWEIS: NOTA: Pousser la roue vers l’avant et déposer la Das Rad nach vorne stoßen und die Spingere la ruota in avanti e rimuovere la chaîne de transmission 2 .
  • Page 460 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: 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 461 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Axe de roue Radachse Asse della ruota Mesurer: Messen: Misurare: Déformation de l’axe de roue Radachsschlag Deformazioni asse della ruota Hors-spécification → Rempla- Unvorschriftsmäßig → Fuori specifica → Regolare. cer.
  • Page 462 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: Bearing (left) 1 Spacer 2 Bearing (right) 3 Oil seal 4 NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing. Use a socket that matches the outside diam- eter of the race of the bearing.
  • Page 463 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Roue avant Vorderrad ZIONE Monter: Montieren: Ruota anteriore Roulement (gauche) 1 Lager (links) 1 Installare: Entretoise 2 Distanzstück 2 Cuscinetto (sinistro) 1 Roulement (droit) 3 Lager (rechts) 3...
  • Page 464 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: Nut (wheel axle) 1 105 Nm (10.5 m · kg, 75 ft · lb) 7. Tighten: Bolt (axle holder) 1 23 Nm (2.3 m ·...
  • Page 465 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Axe de roue 1 Radachse 1 Asse della ruota 1 N.B.: HINWEIS: NOTA: Appliquer de la graisse à base de savon Lithiumfett auf das Gewinde und die Applicare grasso a base di sapone di litio au lithium sur le filetage et la surface de Oberfläche der Radachse auftragen.
  • Page 466 CHAS FRONT WHEEL AND REAR WHEEL 9. Install: Brake hose cover 1 Washer 2 Bolt [brake hose cover (M8)] 3 16 Nm (1.6 m · kg, 11 ft · lb) Bolt [brake hose cover (M6)] 4 7 Nm (0.7 m · kg, 5.1 ft · lb) Rear wheel 1.
  • Page 467 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Logement de durit de frein 1 Bremsschlauchabdeckung Coperchio flessibile freno 1 Rondelle 2 Rondella 2 Boulon [logement de durit de Beilagscheibe 2 Bullone [coperchio flessibile frein (M8)] 3 M8-Schraube (Brems- del freno (M8)] 3...
  • Page 468 CHAS FRONT WHEEL AND REAR WHEEL 3. Install: Rear wheel sprocket 1 Bolt (rear wheel sprocket) 2 Washer (rear wheel sprocket) 3 Nut (rear wheel sprocket) 4 42 Nm (4.2 m · kg, 30 ft · lb) NOTE: Tighten the nuts in stage, using a crisscross pattern.
  • Page 469 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Couronne arrière 1 Kettenrad 1 Corona dentata ruota posteriore Boulon (couronne arrière) 2 Schraube (Kettenrad) 2 Rondelle (couronne arrière) 3 Unterlegscheibe (Ketten- Bullone (corona dentata ruota Ecrou (couronne arrière) 4 rad) 3 posteriore) 2...
  • Page 470 CHAS FRONT WHEEL AND REAR WHEEL 8. Install: Right drive chain puller 1 Washer 2 Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: Drive chain slack a Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) Refer “DRIVE CHAIN...
  • Page 471 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Tendeur droit de chaîne de Rechter Antriebskettenzie- Tenditore della catena di tra- transmission 1 her 1 smissione destro 1 Rondelle 2 Unterlegscheibe 2 Rondella 2 Ecrou (axe de roue) 3 Achsmutter (Radachse) 3...

  • Page 472: Front Brake And Rear Brake

    CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Brake caliper removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks FRONT BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the...
  • Page 473 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose du tuyau de frein 2 Dépose de l’étrier de frein Organisation de la dépose: 3 Dépose du maître-cylindre de frein Organisation de la dépose Ordre Nom de pièce...
  • Page 474 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE Extent of removal: 1 Brake master cylinder removal 2 Brake hose removal 3 Brake caliper removal Extent of removal Order Part name Q’ty Remarks REAR BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.

  • Page 475: Frein Avant Et Frein Arriere

    FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE FREIN ARRIERE Organisation de la dépose: 1 Dépose du maître-cylindre de frein 2 Dépose du tuyau de frein 3 Dépose de l’étrier de frein Organisation de la dépose Ordre Nom de pièce Qté...
  • Page 476 CHAS FRONT BRAKE AND REAR BRAKE BRAKE CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM- Pad pin Brake pad Pad support Brake caliper piston Dust seal...
  • Page 477 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DE L’ETRIER Å Avant ı Arrière Organisation de la dépose: Démontage de l’étrier de frein avant Démontage de l’étrier de frein arrière Organisation de la dépose Ordre Nom de pièce Qté...
  • Page 478 CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q’ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm...
  • Page 479 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE DE FREIN Å Avant ı Arrière Organisation de la dépose: Démontage de l’étrier de frein avant Démontage de l’étrier de frein arrière Organisation de la dépose Ordre Nom de pièce Qté...
  • Page 480 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 Å REMOVAL POINTS Brake fluid 1. Remove: [Front] Brake master cylinder cap 1 [Rear] Brake master cylinder cap 1 Protector NOTE: Do not remove the diaphragm. ı Å Front ı Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con- tainer under its end.
  • Page 481 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit Liquido dei freni Déposer: Demontieren: Rimuovere: [Arrière] [Vorn] [Anteriore] Couvercle de maître-cylindre Hauptbremszylinderdeckel 1 Coperchio pompa del freno 1 de frein 1 [Hinten] [Posteriore]...
  • Page 482 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit Å 1. Remove: Dust seal 1 Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and ı...
  • Page 483 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Kit de joint de piston d’étrier de frein Bremssattelkolben-Dichtungssatz Set guarnizioni pistoncino della pinza Déposer: Demontieren: freno Joint antipoussière 1 Staubschutzring 1 Rimuovere: Joint de piston 2 Dichtring 2 Guarnizione parapolvere 1 Guarnizione dei pistoncini 2...
  • Page 484 CHAS FRONT BRAKE AND REAR BRAKE 4. Inspect: Å ı Brake master cylinder piston 1 Brake master cylinder cup 2 Wear/damage/score marks → Replace brake master cylinder kit. Å Front ı Rear Brake caliper Å ı 1. Inspect: Brake caliper cylinder inner surface a Wear/score marks →...
  • Page 485 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Contrôler: Kontrollieren: Ispezionare: Piston du maîgre-cylindre de Hauptbremszylinderkolben Pistone pompa del freno 1 frein 1 Bicchierino pompa del freno 2 Usura/danno/rigature → Sosti- Coupelle de cylindre du maître- Hauptbremszylinderdeckel cylindre de frein 2 tuire il set pompa del freno.
  • Page 486 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston Å 1. Clean: Brake caliper Piston seal Dust seal Brake caliper piston Clean them with brake fluid. 2. Install: Piston seal 1 Dust seal 2 ı WARNING Always use new piston seals and dust seals.
  • Page 487 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Piston d’étrier de frein Bremssattelkolben Pistoncino della pinza freno Nettoyer: Reinigen: Pulire: Etrier de frein Bremssattel Pinza del freno Joint de piston Dichtring Guarnizione dei pistoncini Joint antipoussière Staubschutzring Guarnizione parapolvere Piston d’étrier de frein...
  • Page 488 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Copper washer 1 Union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the brake cali- per.
  • Page 489 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Boulon-raccord 2 Hohlschraube 2 Vite di unione 2 30 Nm (3,0 m · kg, 22 ft · lb) 30 Nm (3,0 m ·...
  • Page 490 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake disc cover 1 Bolt (brake disc cover) 2 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: Brake caliper 1 Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL”...
  • Page 491 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Cache de disque de frein 1 Bremsscheiben-Abdeckung Copridisco 1 Boulon (cache de disque de Bullone (copridisco) 2 frein) 2 Schraube (Bremsscheiben- 7 Nm (0,7 m · kg, 5,1 ft · lb) Abdeckung) 2 7 Nm (0,7 m ·...
  • Page 492 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: Å ı Spring 1 To brake master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. Å Front ı Rear 4. Install: Å [Front] Brake master cylinder kit 1 Washer 2 Circlip 3 Brake master cylinder boot 4...
  • Page 493 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Ressort 1 Feder 1 Molla 1 Au piston de maître-cylindre de (am Hauptbremszylinderkol- Sul pistone pompa del freno frein 2. ben 2) N.B.: HINWEIS: NOTA: Reposer le ressort au côté...
  • Page 494 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake lever 1 Bolt (brake lever) 2 6 Nm (0.6 m · kg, 4.3 ft · lb) 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 brake master cylinder piston.
  • Page 495 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Levier de frein 1 Bremshebel 1 Leva del freno 1 Boulon (levier de frein) 2 Schraube (Bremshebel) 2 Bullone (leva del freno) 2 6 Nm (0,6 m · kg, 4,3 ft · lb) 6 Nm (0,6 m ·...
  • Page 496 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Pin 1 Washer 2 Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. Front brake hose 1. Install: Brake hose 1 10 Nm (1.0 m ·...
  • Page 497 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Goupille 1 Stift 1 Perno 1 Rondelle 2 Unterlegscheibe 2 Rondella 2 Goupille fendue 3 Splint 3 Copiglia 3 N.B.: HINWEIS: NOTA: Après de montage, contrôler la hauteur Nach der Montage die Fußbremshe- Dopo l’installazione,...
  • Page 498 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the brake master cylinder.
  • Page 499 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Durit de frein 2 Bremsschlauch 2 Flessibile freno 2 Boulon-raccord 3 Hohlschraube 3 Vite di unione 3 30 Nm (3,0 m ·...
  • Page 500 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake hose holder 1 Screw (brake hose holder) 2 1 Nm (0.1 m · kg, 0.7 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
  • Page 501 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Support de tuyau de frein 1 Bremsschlauch-Halterung Supporto flessibile freno 1 Vis (support de tuyau de frein) Vite (supporto flessibile freno) Schraube (Halterung) 2 1 Nm (0,1 m ·...
  • Page 502 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: Brake system Refer “BRAKE SYSTEM BLEEDING” section in the CHAPTER 3. Inspect: Brake fluid level Fluid at lower level → Fill up. Refer “BRAKE FLUID LEVEL INSPECTION” section in the CHAP- TER 3.
  • Page 503 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Purger l’air: Entlüften: Spurgo dell’aria: Circuit de freinage Bremsanlage Sistema frenante reporter à section Siehe unter “HYDRAULI- Fare riferimento al paragrafo “PURGE DE L’AIR DU SYS- SCHE BREMSANLAGE “SPURGO DELL’ARIA DAL TEME DE FREINAGE”...

  • Page 504: Front Fork

    CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.

  • Page 505: Fourche Avant

    FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE FOURCHE AVANT Organisation de la dépose: 1 Dépose de la fourche avant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA FOURCHE AVANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support approprié...
  • Page 506 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Front fork cap bolt Refer to “REMOVAL POINTS”. Fork spring Drain the fork oil. Dust seal Stopper ring Refer to “REMOVAL POINTS”.
  • Page 507 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE AVANT Organisation de la dépose: 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEMONTAGE D’UN BRAS DE FOURCHE AVANT Bouchon de tube de fourche Se reporter à...
  • Page 508 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should observed: The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to foreign material.
  • Page 509 La fourche avant nécessite une soigneuse dere Aufmerksamkeit und sollte am cautela. Pertanto si consiglia di affidare attention. Il est donc recommandé de la besten vom Yamaha-Händler gewar- la manutenzione della forcella anteriore faire entretenir chez le revendeur. tet werden.
  • Page 510 CHAS FRONT FORK EC553201 Inner tube 1. Remove: Dust seal 1 Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly Repeat this step until the inner tube can be pulled out from the outer tube.
  • Page 511 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Tube interne Gleitrohr Tubo di forza Déposer: Demontieren: Rimuovere: Joint antipoussière 1 Staubschutzring 1 Guarnizione parapolvere 1 Bague d’arrêt 2 Sicherungsring 2 Anello di arresto 2 En utilisant un tournevis à lame Einen Schlitzschraubendre- Utilizzando un cacciavite per droite.
  • Page 512 CHAS FRONT FORK EC554200 Base valve 1. Inspect: Valve assembly 1 Wear/damage → Replace. O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: Fork spring free length a Out of specification → Replace. Fork spring free length: 479 mm (18.9 in) <Limit>: 474 mm (18.7 in) EC554502 Inner tube...
  • Page 513 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Soupape de base Luftventil Valvola base Contrôler: Kontrollieren: Ispezionare: Ensemble clapet 1 Luftventil 1 Gruppo valvola 1 Usure/endommagement → Verschleiß/Beschädigung → Usura/danno → Sostituire. Remplacer. Erneuern. O-ring 2 Danni → Sostituire. Joint torique 2 O-Ring 2 Endommagement →...
  • Page 514 CHAS FRONT FORK Front fork cap bolt 1. Inspect: Front fork cap bolt 1 O-ring 2 Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: Damper rod 1 To inner tube 2.
  • Page 515 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Bouchon de tube de fourche Telegabelverschlußschraube Vite mordente forcella anteriore Contrôler: Kontrollieren: Ispezionare: Bouchon de tube de fourche 1 Telegabelverschlußschrau- Vite mordente forcella ante- Joint torique 2 be 1 riore 1 Vis de purge d’air 3 O-Ring 2 O-ring 2 Usure/endommagement →...
  • Page 516 CHAS FRONT FORK 5. Install: Spring guide 1 Locknut 2 To damper rod 3. NOTE: Install the spring guide with its smaller dia. end a facing downward. With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
  • Page 517 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Monter: Montieren: Installare: Guide de ressort 1 Federsitz 1 Guida molla 1 Contre-écrou 2 Sicherungsmutter 2 Controdado 2 Sur la tige d’amortisseur 3. (am Dämpferrohr 3) Sull’asta pompante 3. N.B.: HINWEIS: NOTA: Installer le guide de ressort avec son Den Federsitz mit Ende mit Kleine- Installare la guida della molla con plus petit diamètre a orienté...
  • Page 518 CHAS FRONT FORK 9. Install: Slide metal 1 Oil seal 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: Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
  • Page 519 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Monter: Montieren: Installare: Bague antifriction 1 Gleitbuchse 1 Metallo di scorrimento 1 Rondelle de bague d’étanchéité Öldichtungsscheibe 2 Rondella paraolio 2 (auf Gleitrohr-Nut) Sulla fessura del fodero. Dans l’ouverture de fourreau. HINWEIS: NOTA: Die Gleitbuchse mit dem Gabeldicht- Premere il metallo di scorrimento nel N.B.: Enfoncer la bague antifriction dans le...
  • Page 520 CHAS FRONT FORK 13. Check: Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “01”...
  • Page 521 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 13. Contrôler: 13. Kontrollieren: 13. Controllare: Mouvement régulier du tube Leichtgängigkeit des Stand- Movimento agevole del tubo di plongeur rohres forza Raideur/coincement/point dur Schwergängigkeit/Festsit- Tenuta/resistenza/punti rugo- → Répéter les étapes du 2 à 12. zen/raube Stellen →...
  • Page 522 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 523 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 19. Attendre dix minutes jusqu’à ce 19. Zehn Minuten warten, bis et- 19. Attendere dieci minuti finché non que les bulles d’air aient disparu waige Luftbläschen sich auf- vengono rimosse le bolle d’aria de la fourche avant et que l’huile gelöst haben, bevor der Ga- dalla forcella anteriore e finché...
  • Page 524 CHAS FRONT FORK 21. Measure: Distance a Out of specification → Turn into the locknut. Distance a: 19 mm (0.75 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: Rebound damping adjuster 1 NOTE: Loosen the rebound damping adjuster finger tight.
  • Page 525 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 21. Mesurer: 21. Messen: 21. Misurare: Distance a Gewindelänge a Distanza a Hors spécification → Serrer le Unvorschriftsmäßig → Die Fuori specifica → Avvitare il contre-écrou. Sicherungsmutter hineindre- controdado. hen. Distance a: Distanza a: 19 mm (0,75 in) ou plus 19 mm (0,75 in) o oltre Gewindelänge a:...
  • Page 526 CHAS FRONT FORK 26. Install: Front fork cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. 27. Install: Protector guide 1 Installation 1. Install: Front fork 1 NOTE: Temporarily tighten the pinch bolts (lower bracket). Do not tighten the pinch bolts (upper bracket) yet.
  • Page 527 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 26. Monter: 26. Montieren: 26. Installare: Bouchon de tube de fourche 1 Telegabelverschlußschrau- Vite mordente forcella ante- Sur le fourreau. be (Sicherungsmutter) 1 riore 1 (am Gleitrohr) Sul fodero. N.B.: Serrer le bouchon de tube de fourche de HINWEIS: NOTA: quelques tours.
  • Page 528 CHAS FRONT FORK 5. Install: Brake hose holder 1 Brake caliper 2 Bolt (brake caliper) 3 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Fit the brake hose holder cut a over the pro- jection b on the front fork and clamp the brake hose.
  • Page 529 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Monter: Montieren: Installare: Support de durit de frein 1 Bremsschlauch-Halterung Supporto flessibile freno 1 Etrier de frein 2 Pinza del freno 2 Boulon (etrier de frein) 3 Bremssattel 2 Bullone (pinza del freno) 3 Schraube (Bremssattel) 3 23 Nm (2,3 m ·...

  • Page 530: Handlebar

    CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Remove the clamp portion only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side.
  • Page 531 GUIDON LENKER CHAS MANUBRIO GUIDON Organisation de la dépose: 1 Dépose du guidon Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU GUIDON Préparation pour la dépose Plaque de numéro Retire seulement le côté bridé. Câble de démarreur à chaud Déconnecter du côté...
  • Page 532 CHAS HANDLEBAR EC5B3000 REMOVAL POINTS Brake master cylinder 1. Remove: Brake master cylinder bracket 1 Brake master cylinder 2 CAUTION: Do not let the brake master cylinder hang on the brake hose. Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1.
  • Page 533 GUIDON LENKER CHAS MANUBRIO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Maître-cylindre de frein Hauptbremszylinder Pompa del freno Déposer: Demontieren: Rimuovere: Demi-palier de maître-cylindre Hauptbremszylinder-Halte- Staffa pompa del freno 1 de frein 1 rung 1 Pompa del freno 2 Maître-cylindre de frein 2 Hauptbremszylinder 2 ATTENZIONE: ATTENTION:...
  • Page 534 CHAS HANDLEBAR EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: Handlebar 1 Handlebar upper holder 2 Bolt (handlebar upper holder) 3 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: The handlebar upper holder should be installed with the punched mark a forward. First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.
  • Page 535 GUIDON LENKER CHAS MANUBRIO REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Guidon Lenker ZIONE Monter: Montieren: Manubrio Guidon 1 Lenker 1 Installare: Demi-palier supérieur de gui- Oberer Lenkerhalter 2 Manubrio 1 don 2 Schraube (Oberer Lenker- Supporto manubrio superiore halter ) 3 Boulon (demi-palier supérieur de guidon) 3...
  • Page 536 CHAS HANDLEBAR 4. Install: Collar 1 Grip cap cover 2 Throttle grip 3 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion.
  • Page 537 GUIDON LENKER CHAS MANUBRIO Monter: Einbauen: Installare: Collerette 1 Hülse 1 Collarino 1 Cache (capuchon de la poignée Abdeckung (Griffkappe) 2 Coperchio cappuccio manopola des gaz) 2 Gasdrehgriff 3 Poignée des gaz 3 Manopola valvola a farfalla 3 HINWEIS: Lithiumfett auf die Gasdrehgriff-Gleit- N.B.: NOTA: Appliquer de la graisse à...
  • Page 538 CHAS HANDLEBAR 8. Install: Brake master cylinder 1 Brake master cylinder bracket 2 Bolt (brake master cylinder bracket) 3 9 Nm (0.9 m · kg, 6.5 ft · lb) NOTE: Install the bracket so that the arrow mark a faces upward. First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side.
  • Page 539 GUIDON LENKER CHAS MANUBRIO Monter: Montieren: Installare: Maître-cylindre de frein 1 Hauptbremszylinder 1 Pompa del freno 1 Demi-palier de maître-cylindre Hauptbremszylinder-Halte- Staffa pompa del freno 2 de frein 2 rung 2 Bullone (staffa pompa del Boulon (demi-palier de maître- Schraube (Hauptbremszy- freno) 3 cylindre de frein) 3...
  • Page 540 CHAS HANDLEBAR 12. Clamp the clamp portion a of the num- ber plate to the handlebar. 13. Insert the end of the fuel tank breather hose 1 into the hole in the steering stem cap 2. 5 - 44...
  • Page 541 GUIDON LENKER CHAS MANUBRIO 12. Fixer la partie de fixation a de la 12. Bloccare la parte del morsetto a 12. Die Nummernschild-Befesti- gung a am Lenker montieren. plaque de numéro au guidon. della targa al manubrio. 13. Introduire l’extrémité de la durit 13.

  • Page 542: Steering

    CHAS STEERING EC560000 STEERING Extent of removal: 1 Lower bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 543 DIRECTION LENKKOPF CHAS STERZO DIRECTION Organisation de la dépose: 1 Dépose du té inférieur 2 Dépose du roulement Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA DIRECTION AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque approprié...
  • Page 544 CHAS STEERING EC563000 REMOVAL POINTS Steering ring nut 1. Remove: Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down. Lower bearing 1. Remove: Lower bearing 1 Use the floor chisel 2.
  • Page 545 DIRECTION LENKKOPF CHAS STERZO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Ecrou crénelé de direction Lenkerringmutter Ghiera Déposer: Demontieren: Rimuovere: Ecrou crénelé de direction 1 Lenkerringmutter 1 Ghiera 1 Utiliser la clé à ergots 2. Den Hakenschlüssel 2 ver- Utilizzare la chiave per ghiere wenden.
  • Page 546 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: Bearing 1 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 547 DIRECTION LENKKOPF CHAS STERZO Roulement et cage à billes Lager und Laufring Cuscinetto e pista Nettoyer les roulements et les Die Lager und Laufringe in Lö- Lavare i cuscinetti e le piste con cages à billes dans du solvant. sungsmittel waschen. un solvente.
  • Page 548 CHAS STEERING 4. Install: Steering ring nut 1 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 2. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT” section in the CHAPTER 3. 5.
  • Page 549 DIRECTION LENKKOPF CHAS STERZO Monter: Montieren: Installare: Ecrou crénelé de direction 1 Lenkerringmutter 1 Ghiera 1 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 crénelé...
  • Page 550 CHAS STEERING 9. Install: Steering stem cap 1 10. After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 11. Adjust: Front fork top end a Front fork top end (standard) a: 5 mm (0.20 in) 12.
  • Page 551 DIRECTION LENKKOPF CHAS STERZO Monter: Montieren: Installare: Chapeau de colonne de direc- Lenksäulenkappe 1 Tappo del cannotto di sterzo 1 tion 1 10. Après avoir serré l’écrou, vérifier 10. Nach dem Festziehen der Mutter 10. Dopo aver serrato la ghiera, con- si le mouvement de la direction den Lenkkopf auf Leichtgängig- trollare il movimento agevole...

  • Page 552: Swingarm

    CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine. danger of it falling over.

  • Page 553: Frein Avant Et Frein Arriere

    BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT Organisation de la dépose: 1 Dépose du bras oscillant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BRAS OSCILLANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque approprié...
  • Page 554 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal...

  • Page 555: Bras Oscillant

    BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT Organisation de la dépose: 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle 3 Dépose et démontage du bras de relais Organisation de la dépose Ordre Nom de pièce Qté...
  • Page 556 CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: Bearing 1 NOTE: Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and cov- ers in a solvent. Swingarm 1. Inspect: Bearing 1 Bushing 2 Free play exists/unsmooth revolution/ rust →...
  • Page 557 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Déposer: Demontieren: Rimuovere: Roulement 1 Lager 1 Cuscinetto 1 N.B.: HINWEIS: NOTA: Retirer le roulement en appuyant sur la Das Lager am äußeren Laufring ein- Rimuovere cuscinetto premendo...
  • Page 558 CHAS SWINGARM EC574310 Connecting rod 1. Inspect: Bearing (polylube bearing) 1 Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: Bearing (polylube bearing) 1 Loss of solid lubrication → Replace. Oil seal 3 Damage →...
  • Page 559 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Bielle Übertragungshebel Biella Contrôler: Kontrollieren: Ispezionare: Roulement (roulement poly- Lager (Polylube-Lager) 1 Cuscinetto lube) 1 Hülse 2 (cuscinetto polylube) 1 Collerette 2 Spiel/Schwergängigkeit/ Collarino 2 Rost → Lager und Hülse im Jeu/rotation irrégulière/rouille Gioco/movimento non agevole/ →...
  • Page 560 CHAS SWINGARM 2. Install: Bearing 1 Oil seal 2 To relay arm. NOTE: Apply the molybdenum disulfide grease on the bearing when installing. Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: 5 mm (0.20 in) 3.
  • Page 561 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: Installare: Roulement 1 Lager 1 Cuscinetto 1 Bague d’étanchéité 2 Dichtring 2 Paraolio 2 Sur le bras relais. (am Umlenkhebel) Sulla leva di rinvio. N.B.: HINWEIS: NOTA: Appliquer une graisse au bisulfure de Molybdändisulfidfett auf die einge- Applicare grasso al disolfuro di molib- molybdène sur le roulement lors de la...
  • Page 562 CHAS SWINGARM 3. Install: Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: Connecting rod 1 Bolt (connecting rod) 2 Washer 3 Nut (connecting rod) 4 80 Nm (8.0 m · kg, 58 ft · lb) To relay arm 5.
  • Page 563 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: Installare: Collerette 1 Hülse 1 Collarino 1 Sur la bielle 2. (am Übertragungshebel 2) Sulla biella 2. HINWEIS: N.B.: NOTA: Appliquer de la graisse au bisulfure de Molybdändisulfidfett auf Hülsen und Applicare grasso al disolfuro di molib- molybdène sur la collerette et les lèvres den Dichringlippen auftragen.
  • Page 564 CHAS SWINGARM 8. Install: Bolt (connecting rod) 1 Washer 2 Nut (connecting rod) 3 NOTE: Apply the molybdenum disulfide grease on the bolt. Do not tighten the nut yet. 9. Install: Bolt (rear shock absorber-relay arm) 1 Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m ·...
  • Page 565 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: Installare: Boulon (bielle) 1 Schraube (Übertragungshe- Bullone (biella) 1 Rondelle 2 bel) 1 Rondella 2 Ecrou (bielle) 3 Unterlegscheibe 2 Dado (biella) 3 Mutter (Übertragungshebel) N.B.: NOTA: Appliquer de la graisse au bisulfure de Applicare grasso al disolfuro di molib- molybdène sur le boulon.
  • Page 566 CHAS SWINGARM 13. Install: Bolt (lower chain tensioner) 1 Washer 2 Collar 3 Lower chain tensioner 4 Nut (lower chain tensioner) 5 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: Drive chain support 1 Drive chain support cover 2 Bolt {drive chain support [r= 50 mm (1.97 in)]} 3 Nut (drive chain support) 4...
  • Page 567 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE 13. Monter: 13. Montieren: 13. Installare: Boulon (tendeur inférieur de Schraube (Unterer Ketten- Bullone (tenditore catena infe- chaîne) 1 spanner) 1 riore) 1 Rondelle 2 Ungerlegscheibe 2 Rondella 2 Collerette 3 Hülse 3 Collarino 3 Tendeur inférieur de chaîne 4 Unterer Kettenspanner 4 Tenditore catena inferiore 4...

  • Page 568: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so there is no Preparation for removal Hold the machine by placing the danger of it falling over.

  • Page 569: Lateraux

    AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE Organisation de la dépose: 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’AMORTISSEUR ARRIERE AVERTISSEMENT Maintenir la machine en plaçant un support Préparation pour la dépose approprié...
  • Page 570 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Upper spring guide Spring (rear shock absorber) Bearing Refer to “REMOVAL POINTS”. 5 - 59...

  • Page 571: Amortisseur Arriere

    AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Guide de ressort supérieur Ressort (amortisseur arrière) Roulement Se reporter à “POINTS DE DEPOSE”. Reihen- Demontage-Arbeiten Bauteil Anz. Bemerkungen folge Oberer Federsitz Feder (Federbein) Lager Siehe unter “AUSBAU”.
  • Page 572 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5 - 60...
  • Page 573 WARNUNG rato, rivolgersi ad un rivenditore Confier la mise au rebut d’un amortis- Den Stoßdämpfer vom Yamaha- Yamaha per questa procedura di seur endommagé ou usé à un conces- Händler entsorgen lassen. smaltimento. sionnaire Yamaha 5 - 60...
  • Page 574 CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
  • Page 575 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Déposer: Demontieren: Rimuovere: Bague d’arrêt (roulement supé- Sicherungsring (Oberes La- Anello di arresto (cuscinetto rieur) 1 ger) 1 superiore) 1 HINWEIS: N.B.: NOTA: Appuyer sur le roulement en poussant Das Lager am äußeren Laufring ein- Spingere dentro il cuscinetto premendo sur la cage extérieure et enlever la bague...
  • Page 576 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: 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 577 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Roulement Lager ZIONE Monter: Montieren: Cuscinetto Roulement supérieur 1 Oberes Lager 1 Installare: Cuscinetto superiore 1 N.B.: HINWEIS: Monter roulement parallèlement Das Lager am äußeren Laufring NOTA: jusqu’à...
  • Page 578 CHAS REAR SHOCK ABSORBER 2. Tighten: Adjuster 1 3. Adjust: Spring length (installed) a Spring length (installed) a: Standard Extent of length adjustment 249 mm (9.80 in) 240.5 ~ 258.5 mm (9.47 ~ 10.18 in) *264.5 mm (10.41 in) *255.5 ~ 273.5 mm (10.06 ~ 10.77 in) * For EUROPE NOTE:...
  • Page 579 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Serrer: Festziehen: Serrare: Dispositif de réglage 1 Einstellmutter 1 Registro 1 Régler: Einstellen: Regolare: Longueur de ressort (monté) a Feder-Einbaulänge a Lunghezza molla (installata) a Longueur de ressort Lunghezza molla (instal- Feder-Einbaulänge a: (monté) a: lata) a: Longueur stan- Etendue de...
  • Page 580 CHAS REAR SHOCK ABSORBER 2. Install: Bushing 1 Collar 2 Dust seal 3 NOTE: Apply the molybdenum disulfide grease on the bearing. Apply the lithium soap base grease on the bushing, collars and dust seals. Install the dust seals with their lips facing outward.
  • Page 581 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Monter: Montieren: Installare: Douille 1 Buchse 1 Boccola 1 Collerette 2 Hülse 2 Collarino 2 Joint antipoussière 3 Staubschutzring 3 Guarnizione parapolvere 3 N.B.: HINWEIS: NOTA: Enduire le roulement de graisse au Molybdändisulfidfett auf das Lager Applicare grasso al disolfuro di molib- bisulfure de molybdène.

  • Page 582: And Wiring Diagram

    – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS COLOR CODE 1 Engine stop switch W .....White B...... Black 2 Throttle position sensor Y ......Yellow Br ....Brown 3 Neutral switch B/L ....Black/Blue G .....
  • Page 583 COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE – ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA DI CABLAGGIO PARTIE ELEKTRISCHE IMPIANTO ANLAGE ELECTRIQUE ELETTRICO ELEKTRISCHE BAUTEI- COMPOSANTS ELECTRI- COMPONENTI ELET- LE UND SCHALTPLAN QUES ET SCHEMA DE TRICI SCHEMA ELEKTRISCHE BAUTEILE CABLAGE CABLAGGIO 1 Motorstoppschalter...

  • Page 584: Map-Controlled Cdi Unit

    – ELEC MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the YZ250F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions.

  • Page 585: Bloc Cdi Controle Par Microprocesseur

    – ELEC BLOC CDI CONTROLE PAR MICROPROCESSEUR BLOC CDI CONTROLE PAR MICROPROCESSEUR La YZ250F est dotée d’un système d’allumage CDI contrôlé par microprocesseur. Le microprocesseur du bloc CDI détecte en permanence le régime du moteur ainsi que la position du papillon des gaz, puis détermine l’avance à...

  • Page 586: Motor

    – ELEC KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM Die YZ250F ist mit einer kennfeldgesteuerten CDI-Zündanlage ausgestattet. Der Mikroprozessor in der CDI-Zündbox ist ständig über die Motordrehzahl und Drosselklappenpo- sition informiert und kann dadurch den optimalen Zündzeitpunkt im gesamten Lastbereich bestim- men. Dies sorgt stets für das bestmögliche Ansprechverhalten des Motors. Zündspule Zündeinheit Drosselklappensensor...
  • Page 587 – ELEC UNITÀ CDI CONTROLLATA DA MAPPA UNITÀ CDI CONTROLLATA DA MAPPA Il modello YZ250F impiega un sistema di accensione CDI controllata da mappa. Il microcomputer nell’unità CDI rileva la velocità del motore e la posizione della valvola a farfalla, determi- nando così...
  • Page 588 – ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM 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 589 – ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DU CONTROLE Se référer au tableau suivant lors de l’inspection du système d’allumage lors de pannes. Suivre le procédé suivant pour déterminer si le mauvais fonctionnement du moteur est dû à une panne dans le circuit d’allumage et pour vérifier une bougie qui ne produit pas d’étincelle.
  • Page 590 – ELEC ZÜNDANLAGE ZÜNDANLAGE FEHLERSUCHE Bei der Überprüfung der Zündanlage auf mögliche Störungen ist das folgende Ablaufdiagramm zu beachten. Folgendes Diagramm hilft zündanlagen- und zündkerzenbedingte Motorstörungen zu beheben. Zündfunke Zündfunkenstrecke *Zündkerze reinigen kontrollieren oder erneuern. Kein Zündfunke Die gesamte Lichtanlage auf einwandfreie Verbin- Nicht in Ordnung Erneuern oder instand...

  • Page 591: Utensili Speciali

    – ELEC IMPIANTO DI ACCENSIONE IMPIANTO DI ACCENSIONE FASI DI ISPEZIONE Utilizzare la procedura seguente per controllare la possibilità che un cattivo funzionamento del motore sia attribuibile ad un guasto al sistema di accensione o per controllare la candela che non emette scintille. Scintilla Test della distanza tra gli *Pulire o sostituire la...
  • Page 592 – ELEC IGNITION SYSTEM SPARK GAP TEST Å 1. Disconnect the spark plug cap from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2) as shown. Ignition coil 3 Spark plug 4 Å...

  • Page 593: Impianto Di Accensione

    SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE TEST DE LA LONGUEUR D’ETIN- ZÜNDFUNKENSTRECKE KON- TEST DELLA DISTANZA TRA GLI CELLE D’ALLUMAGE TROLLIEREN ELETTRODI Déconnecter le capuchon de bou- Den Zündkerzenstecker von Staccare il cappuccio della candela. gie de la bougie. der Zündkerze abziehen.
  • Page 594 – ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Inspect: Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil Tester selector resistance position 0.08 ~ 0.10 Ω at Ω...
  • Page 595 SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE CONTROLE BOBINE ZÜNDSPULE KONTROLLIEREN ISPEZIONE BOBINA DI ACCEN- D’ALLUMAGE Kontrollieren: SIONE Vérifier: Primärspulen-Widerstand Ispezionare: Unvorschriftsmäßig → Résistance de bobine primaire Resistenza avvolgimento pri- Hors spécification → Rempla- Erneuern. mario Fuori specifica → Regolare. cer.
  • Page 596 – ELEC IGNITION SYSTEM 2. Inspect: Charging coil 1 resistance Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester (–) lead → Green lead 2 Charging coil 1 Tester selector resistance position 720 ~ 1,080 Ω Ω...

  • Page 597: Elektrische Anlage

    SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE Vérifier: Kontrollieren: Ispezionare: Résistance de bobine de charge Widerstand der Erregerspu- Resistenza bobina di carica 1 Fuori specifica → Sostituire. le 1 Hors spécification → Rempla- Unvorschriftsmäßig → Conduttore (+) del tester → cer.

  • Page 598: Throttle Position Sensor System

    – ELEC THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. No good Check entire ignition Repair or replace. system for connection. No good Check throttle position Throttle posi- Replace.

  • Page 599: Circuit Du Capteur De Papillon Des Gaz

    – ELEC CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ ETAPES DU CONTROLE Si le capteur de papillon des gaz ne fonctionne pas, effectuer les contrôles suivants. Vérifier la connexion de tout le Mauvais Réparer ou remplacer.
  • Page 600 – ELEC DROSSELKLAPPEN-POSITIONSSENSOR DROSSELKLAPPEN-POSITIONSSENSOR INSPEKTIONSSCHRITTE Wenn Drosselklappen-Positionssensor nicht arbeitet, mit den folgenden Schritten überprüfen. Nicht in Ordnung Die gesamte Zündanlage Erneuern oder instand auf Anschluß überprüfen. setzen. In Ordnung Drosselklap- Nicht in Ordnung Den Drosselklappen-Positi- pen-Positions- Erneuern. onssensor prüfen. sensor-Spule In Ordnung Nicht in Ordnung * Den CDI-Schwungrad-...
  • Page 601 SISTEMA SENSORE DELLA POSIZIONE DELLA – ELEC VALVOLA A FARFALLA SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA FASI DI ISPEZIONE Se il sensore di posizione della valvola a farfalla non funziona, seguire la seguente procedura. Controllare il collegamento Non funziona dell’intero Riparare o sostituire.
  • Page 602 – ELEC THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1.
  • Page 603 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA HINWEIS ZUM UMGANG REMARQUE NOTA SUL MANEGGIO ACHTUNG: ATTENZIONE: ATTENTION: Nicht die Schrauben (Drosselposi- Ne pas desserrer les vis (capteur de Non allentare le viti (sensore di posi- position des gaz) 1 sauf s’il faut chan- tionssensor, TPS) 1 lösen, ausge- zione della valvola a farfalla) 1...
  • Page 604 – ELEC THROTTLE POSITION SENSOR SYSTEM 3. Inspect: Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open posi- tion. Out of specification → Replace. Tester (+) lead →...

  • Page 605: Carburateur

    CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA Prüfen: Contrôler: Ispezionare: Resistenza variabile bobina Regelwiderstand der Dros- Résistance variable sensore di posizione della val- selklappen-Positionssensor- bobine du capteur de papillon vola a farfalla Spule des gaz...
  • Page 606 – ELEC THROTTLE POSITION SENSOR SYSTEM 4. Install: Throttle position sensor coupler 5. Adjust: Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAP- TER 3. 6. Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them.
  • Page 607 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA Einbauen: Installer: Installare: TPS-Steckverbindung Fiche rapide du capteur de Sensore di posizione della val- Einstellen: papillon des gaz vola a farfalla Leerlaufdrehzahl Ajuster: Regolare: Siehe hierzu den Abschnitt...
  • Page 608 – ELEC THROTTLE POSITION SENSOR SYSTEM 9. Tighten: Screw (throttle position sensor) 1 NOTE: Tighten the screws (throttle position sensor) using the T25 bit. 10. Stop the engine. THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1. Disconnect the throttle position sensor coupler.
  • Page 609 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA Festziehen: Serrer: Serrare: Schraube (Drosselklappen- Vis (capteur de papillon des Vite (sensore di posizione della gaz) 1 positionssensor) 1 valvola a farfalla) 1 HINWEIS: N.B.: NOTA:...
  • Page 610 T U N SETTING EC700000 TUNING EC710000 ENGINE Carburetor setting The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor. Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling.
  • Page 611 REGLAGE EINSTELLUNG T U N REGISTRAZIONE MISES AU POINT ABSTIMMUNG MESSA A PUNTO MOTOR MOTEUR MOTORE Vergaser einstellen Réglage de carburateur Registrazione del carburatore Das Luft/Kraftstoffgemisch variiert La qualité de l’émulsion air/essence La miscela aria/carburante varia a mit den atmosphärischen Bedin- dépend des conditions atmosphéri- seconda delle condizioni atmosferi- gungen.
  • Page 612 T U N SETTING CAUTION: The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carbure- tor parts may prevent the carburetor from functioning correctly.
  • Page 613 REGLAGE EINSTELLUNG T U N REGISTRAZIONE ACHTUNG: ATTENZIONE: ATTENTION: Le carburateur est extrêmement Der Vergaser ist extrem emp- Il carburatore è estremamente sen- sensible à toute pénétration de cras- findlich gegen Fremdkörper sibile a materiale estraneo (sporco, ses, sable, eau, etc. Bien veiller, lors (Schmutz, Sand, Wasser usw.).
  • Page 614 T U N SETTING Effects of the setting parts on the throttle valve opening Å ı Å Closed ı Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main jet.
  • Page 615 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Effets des réglages sur l’ouverture du Wirkung der Einstellteile in Bezug Effetti della registrazione sull’aper- papillon des gaz auf die Öffnung der Drosselklappe tura della valvola a farfalla Å Fermé Å Geschlossen Å Chiusa ı...
  • Page 616 T U N SETTING 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1. Standard main jet #180 If the air-fuel mixture is too rich or too lean, the...
  • Page 617 REGLAGE EINSTELLUNG T U N REGISTRAZIONE 1 Aiguille 1 Düsennadel 1 Spillo del getto 2 Gicleur principal 2 Hauptdüse 2 Getto dell’aria del minimo 3 Puits d’aiguille 3 Nedeldüse 3 Getto a spillo 4 Gicleur principal 4 Hauptdüse 4 Getto del massimo 5 Gicleur de ralenti 5 Leerlaufdüse 5 Getto del minimo...
  • Page 618 T U N SETTING Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it.
  • Page 619 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de la vis de ralenti Einstellung der Leerlaufgemisch- Regolazione vite di registro del La richesse de l’émulsion air-essence à Regulierschraube minimo une ouverture des gaz de 0 à 1/4 se règle Der Kraftstoffgehalt des Luft-Kraft- È...
  • Page 620 T U N SETTING Effects of adjusting the pilot jet (reference) Å ı –5% Å Idle ı Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open.
  • Page 621 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Effets du réglage du gicleur de ralenti Wirkung der Einstellung der Leer- Effetti della regolazione del getto del (référence) laufdüse minimo (riferimento) Å Å Å ı ı ı N° 45 Nr. 45 N. 45 N°...
  • Page 622 T U N SETTING Jet needle adjustment The jet needle is adjusted by changing it. Standard jet needle OBEKR The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. <Example>...
  • Page 623 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de l’aiguille Düsennadel einstellen Regolazione dello spillo del getto L’aiguille se règle en la changeant. Die Düsennadel wird eingestellt, Lo spillo del getto viene regolato sosti- indem sie ausgetauscht wird. tuendolo. Aiguille standard OBEKR Standard-Düsennadel OBEKR...
  • Page 624 T U N SETTING Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each...
  • Page 625 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage du gicleur de fuite (réglage de Leckdüseneinstellung (Gaspum- Regolazione getto di diffusione (rego- pompe d’accélérateur) peneinstellung) lazione pompa di circolazione) Le gicleur de fuite 1 est une pièce qui Die Leckdüse 1 ist ein Einstellteil, Il getto di diffusione 1 è...
  • Page 626 T U N SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Rich #190 4MX-14943-45 #188 4MX-14943-95 #185 4MX-14943-44 #182 4MX-14943-94 (STD) #180 4MX-14943-43 #178 4MX-14943-93 #175 4MX-14943-42 #172 4MX-14943-92 Lean #170 4MX-14943-41 Pilot jet Rich 4MX-14948-06 4MX-14948-05 (STD) 4MX-14948-04...
  • Page 627 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces modifiables du carburateur Vergaser-Einstellteile Parti di registrazione del carburatore Numéro de Grö- Teilenum- Denomina- Numero di Nom de pièce Taille Bauteil pièce ße zione sura pezzo Gicleur principal N˚190 4MX-14943-45 Hauptdüse Fett Nr.190 4MX-14943-45 Getto del massimo N.190...
  • Page 628 T U N SETTING Examples of carburetor setting depending on symptom Symptom Setting Checking Discoloration of spark plug → At full throttle Increase main jet calibration no. Hard breathing (Gradually) If tan color, it is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat...
  • Page 629 T U N REGLAGE Exemples de réglages de carburateur en fonction des symptômes Symptômes Réglages Contrôles Décoloration de bougie → A pleine ouverture des gaz Monter un gicleur principal de n˚ de cali- Crachotements bre supérieur. Brun clair = bon état Bruits de frottement de piè- (progressivement) Ne peut-être corrigé:...
  • Page 630 T U N EINSTELLUNG Beispiele für die Vergasereinstellung in bezug auf bestimmte Symptome Symptom Einstellung Prüfung Bei Vollgas Hauptdüsen-Nr. erhöhen. (schrittweise) Verfärbung der Zündkerze: “Schweres Atmen” Rehbraune Färbung weist auf guten Abschergeräusch Zustand hin. Weißliche Zündkerze Falls nicht korrigiert werden kann: Schwimmerventilsitz verstopft Mageres Gemisch Kraftstoffschlauch verstopft...
  • Page 631 T U N REGISTRAZIONE Esempi di registrazione del carburatore a seconda dei sintomi Sintomo Registrazione Controllo Scolorimento della candela → Con la valvola a farfalla Aumentare il n. di taratura del getto del completamente aperta massimo. Se di colore bruno, è in buone condizioni. Respirazione difficoltosa (Gradualmente) Se non è...
  • Page 632 T U N SETTING EC720000 CHASSIS Selection of the secondary reduction ratio (Sprocket) Secondary Number of rear wheel sprocket teeth reduction = Number of drive sprocket teeth ratio Standard secondary 48/13 (3.692) reduction ratio *49/13 (3.769) * For EUROPE <Requirement for selection of secondary gear reduction ratio>...
  • Page 633 REGLAGE EINSTELLUNG T U N REGISTRAZIONE PARTIE CYCLE FAHRGESTELL PARTE CICLISTICA Sekundärüntersetzungsverhältnis Sélection du taux de réduction secon- Selezione rapporto di riduzione secon- (Kettenräder) wählen daire (pignons) daria (corona dentata) Anzahl der Zähne Nombre de dents Numero di denti della couronne am angetriebenen corona della ruota poste-...
  • Page 634 T U N SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 9383B-13218 Rear wheel 5ET-25447-00 sprocket 2 (STD) 5NY-25448-00 * (STD) 5NY-25449-00 5NY-25450-00 5NY-25451-00 5NY-25452-00 * For EUROPE EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
  • Page 635 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage des pignons menant Antriebsritzel und Kettenräder Parti di regolazione delle corone den- et de la couronne arrière tate conduttrici e condotte Teilenum- Bauteil Größe Numéro Denomina- Misu Numero di Nom de pièce Taille de pièce zione pezzo...
  • Page 636 T U N SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics Change the fork oil level.

  • Page 637: Fourche Avant

    REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglages de la fourche avant Teleskopgabel einstellen Registrazione forcella anteriore Régler la fourche avant en fonction de la Die Einstellung der Gabel sollte ent- La registrazione della forcella anteriore sensation lors de la conduite ainsi que sprechend dem Gefühl des Fahrers, va effettuata a seconda delle sensazioni des conditions du terrain.
  • Page 638 T U N SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the spring seat 2 and fork spring 3. CAUTION: Do not install three or more adjustment washers for each front fork. WARNING Always adjust each front fork to the same setting.
  • Page 639 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de tension initiale du ressort Federvorspannung einstellen Regolazione precarico Le tension initiale du ressort a été ajustée Die Federvorspannung wird durch Il precarico della molla viene regolato en montant la rondelle de réglage 1 den Einbau einer Einstellscheibe 1 installando la rondella di regolazione 1 entre le siège de ressort 2 et le ressort...
  • Page 640 T U N 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 contact with the road surface or in a vibrating handlebar. To set a stiff spring: Change the rebound damping.

  • Page 641: Guidon

    REGLAGE EINSTELLUNG T U N REGISTRAZIONE Ressort dur Harte Feder Impiego di una molla rigida En principe, un ressort dur offre Eine harte Feder bewirkt prin- Generalmente una molla rigida dà une sensation de conduite dure. zipiell ein hartes Fahrgefühl. una sensazione di guida rigida.
  • Page 642 T U N SETTING EC72P000 Front fork setting parts Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 5XE-23364-00 Front fork spring 2 [Equal pitch spring] I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.398 5XE-23141-00 SOFT 0.408...
  • Page 643 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage de la fourche avant Vorderradgabel-Einstellteile Parti di regolazione della forcella Rondelle de réglage 1 Einstellscheibe 1 anteriore Rondella di regolazione 1 TYPE TEILENUM- Numéro de pièce TYP (Dicke) (épaisseur) NUMERO DI TIPO (spessore) PEZZO T = 2,3 mm...
  • Page 644 T U N 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 fol- lowing two factors: 1. Setting of spring preload Change the set length of the spring.
  • Page 645 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de la suspension arrière Hinterradaufhängung einstellen Registrazione della sospensione poste- Effectuer le réglage de la suspension Die Einstellung der Hinterradaufhän- riore arrière en fonction de la sensation lors de gung soll entsprechend dem Gefühl La registrazione della sospensione poste- la conduite ainsi que des conditions de des Fahrers, nach einer Testfahrt...
  • Page 646 T U N SETTING NOTE: 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.
  • Page 647 REGLAGE EINSTELLUNG T U N REGISTRAZIONE N.B.: HINWEIS: NOTA: Le ressort peut s’allonger au fur et à Die Federeinbaulänge kann sich Se il veicolo è nuovo dopo il rodaggio mesure de la période de rodage. Il est beim Einfahren verändern, u.a. la lunghezza registrata della molla donc important de corriger les régla- weil sich die Feder ermüdet.
  • Page 648 T U N SETTING CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length a does not exceed the stan- dard as it may result in faulty performance. Never use one whose overall length is greater than standard.
  • Page 649 REGLAGE EINSTELLUNG T U N REGISTRAZIONE ACHTUNG: ATTENZIONE: ATTENTION: Lors du remplacement de l’amortis- Beim Austausch des Federbeins Quando si impiega un ammortizzatore seur arrière, veiller à monter un darauf achten, daß die Gesamtlän- posteriore diverso da quello instal- amortisseur dont la longueur totale a ge a das Standardmaß...
  • Page 650 T U N SETTING EC72Q000 Rear shock absorber setting parts 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 STIFF 5UN-22212-50 Yellow/1...
  • Page 651 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage de l’amortisseur Hinterradstoßdämpfer-Einstellteile Parti di regolazione dell’ammortizza- arrière Hinterradstoßämpfer-Schrauben- tore posteriore Ressort d’amortisseur arrière 1 feder 1 Molla dell’ammortizzatore posteriore [Ressort à pas égal] [Feder mit gleichmäßiger Gewinde- steigung] [Molla con passo costante] Cons- Repere Numéro de...

  • Page 652: Suspension Setting

    T U N SETTING EC72H002 Suspension setting Front fork NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in).
  • Page 653 T U N SETTING Rear shock absorber NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Adjust the rebound damping in 2-click increments or decrements. Adjust the low compression damping in 1-click increments or decrements.
  • Page 654 T U N REGLAGE Réglage de la suspension Fourche avant N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière comprimé...
  • Page 655 T U N REGLAGE Amortisseur arrière N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Régler la force de rebondissement de 2 clics dans un sens ou l’autre. Régler la force d’amortissement à...

  • Page 656: Teleskopgabel

    T U N EINSTELLUNG Fahrwerksabstimmung Teleskopgabel HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Vor der Einstellung der Gabel das Federbein auf die Standard-Federeinbaulänge von 90–100 mm (3,5–3,9 in) einstellen. Strecke Große Mittlere Kleine Symptom Prüfen Einstellen Sprung Boden- Boden- Boden-...
  • Page 657 T U N EINSTELLUNG Federbein HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Die Zugstufendämpfung jeweils um 2 Rasterstufen stärker oder schwächer verstellen. Die Tiefdruckdämpfung jeweils um 1 Rasterstufe stärker oder schwächer verstellen. Die Hochdruckdämpfung jeweils um eine 1/6-Drehung stärker oder schwächer verstellen. Strecke Große Mittlere...
  • Page 658 T U N REGISTRAZIONE Registrazione sospensioni Forcella anteriore NOTA: Se si verifica uno dei seguenti sintomi con la posizione standard, effettuare la ri-registrazione facendo rife- rimento alla procedura di registrazione indicata nella stessa tabella. Prima di ogni eventuale modifica, impostare la lunghezza abbassata dell’ammortizzatore posteriore sul valore normale di 90 ~ 100 mm (3,5 ~ 3,9 in).
  • Page 659 T U N REGISTRAZIONE Ammortizzatore posteriore NOTA: Se si verifica uno dei seguenti sintomi con la posizione normale, effettuare la ri-registrazione facendo riferi- mento alla procedura di regolazione indicata nella stessa tabella. Regolare lo smorzamento di espansione in incrementi o decrementi di 2 scatti. Regolare lo smorzamento di compressione bassa in incrementi o decrementi di 1 scatto.
  • Page 662 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.07-2.0×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN (E,F,G,H)

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