Yamaha YZ250F(V) Owner's Service Manual
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Yamaha YZ250F(V) Owner's Service Manual

Yz series
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OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
YZ250F(V)
5XC-28199-32

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Summary of Contents for Yamaha YZ250F(V)

  • Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO YZ250F(V) 5XC-28199-32...
  • Page 2 EC010010 YZ250F(V) OWNER’S SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd. 1st Edition, August 2005 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 WARTUNGSHANDBUCH DU PROPRIETAIRE PROPRIETARIO ©2005 Yamaha Motor Co., Ltd. ©2005 Yamaha Motor Co., Ltd. ©2005 by Yamaha Motor Co., Ltd. 1. Auflage, August 2005 1ère édition, août 2005 edizione, agosto 2005 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 Fahrzeugs auf öffentlichen Straßen...
  • 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 Tipps 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 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!” Le symbole d’alerte de sécurité signifie Questo simbolo segnala un pericolo che ATTENTION! SOYEZ VIGILANT! richiede la MASSIMA ATTENZIONE! 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., •...
  • 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. INSP 1 General information 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- DATI TECNICI QUES DATEN SPEC REGELMÄSSIGE CONTROLES ET CONTROLLI E REGLAGES WARTUNGS- UND REGOLAZIONI INSP PERIODIQUES PERIODICHE EINSTELLARBEITEN MOTOR MOTEUR MOTORE FAHRWERK CHASSIS 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 ....1-19 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS....2-1 MAINTENANCE SPECIFICATIONS...2-4 GENERAL TORQUE SPECIFICATIONS ........2-17 DEFINITION OF UNITS ......2-17 CABLE ROUTING DIAGRAM ....2-18...

  • Page 21: Table Of Contents

    INHALT TABLES DES INDICE MATIERES KAPITEL 1 CAPITOLO 1 CHAPITRE 1 ALLGEMEINE INFORMAZIONI ANGABEN RENSEIGNEMENTS GENERALI GENERAUX FAHRZEUGBESCHREIBUNG..1-1 DESCRIZIONE .......1-1 FAHRZEUG- NUMERO DI SERIE DESCRIPTION ....... 1-1 IDENTIFIZIERUNG...... 1-2 DEL MEZZO ........1-2 IDENTIFICATION WICHTIGE INFORMATIONEN..1-3 INFORMAZIONI DE LA MOTO ......... 1-2 KABELANSCHLÜSSE IMPORTANTI .........1-3 INFORMATIONS...

  • Page 22: Table Of Contents

    CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ........4-1 EXHAUST PIPE AND SILENCER ....4-3 RADIATOR ..........4-6 CARBURETOR...........4-9 CAMSHAFTS..........4-22 CYLINDER HEAD........4-31 VALVES AND VALVE SPRINGS .....4-34 CYLINDER AND PISTON......4-43 CLUTCH............4-50 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER..4-57 BALANCER ..........4-64 OIL PUMP ..........4-67 KICK SHAFT AND SHIFT SHAFT ...4-73 CDI MAGNETO.........4-80...

  • Page 23: Table Of Contents

    KAPITEL 4 CHAPITRE 4 CAPITOLO 4 MOTOR MOTEUR MOTORE SITZBANK, SELLE, RESERVOIR SELLA, SERBATOIO KRAFTSTOFFTANK UND DE CARBURANT CARBURANTE ET CACHES LATERAUX..... 4-1 SEITENABDECKUNGEN.... 4-1 E FIANCHETTI ......4-1 TUBE D’ECHAPPEMENT AUSPUFFKRÜMMER TUBO DI SCARICO ET SILENCIEUX ......4-3 UND SCHALLDÄMPFER.... 4-3 E SILENZIATORE ......4-3 RADIATEUR ........

  • Page 24: Table Of Contents

    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 KAPITEL 6 CHAPITRE 6 CAPITOLO 6 ELEKTRISCHE PARTIE IMPIANTO ELECTRIQUE ANLAGE ELETTRICO COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE UND COMPONENTI ELETTRICI ET SCHEMA DE CABLAGE ..6-1 SCHALTPLAN ......6-1 E SCHEMA ELETTRICO .....6-1 KENNFELDGESTEUERTE BOITIER CDI COMMANDE UNITÀ CDI CONTROLLATA ZÜNDUNG ........6-2 PAR PRESSION ABSOLUE DA UNA MAPPA......6-2 ZÜNDSYSTEM ......

  • Page 26: Engine

    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 5 Radiator cap •...

  • Page 27: Informazioni Generali

    DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIZIONE INFO RENSEIGNEMENTS ALLGEMEINE INFORMAZIONI GENERAUX ANGABEN GENERALI FAHRZEUGBESCHREI- DESCRIPTION DESCRIZIONE 1 Levier d’embrayage 1 Leva della frizione BUNG 2 Levier de démarrage à chaud 2 Leva starter per partenze a caldo 1 Kupplungshebel 3 Levier de frein avant 3 Leva del freno anteriore 2 Warmstarthebel 4 Poignée des gaz...

  • 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 positive 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: Numero Di Serie Del Mezzo

    Bei der Bestellung von Ersatztei- bio, si può riferire il numero di serie len benötigt der Yamaha-Händ- au concessionnaire Yamaha d’iden- al rivenditore Yamaha per una iden- tifier clairement la moto. ler diese Nummer zur exakten tificazione certa del modello.

  • 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 disassembly. When washing the machine with high pres- sured water, cover the parts follows. • Silencer exhaust port •...

  • Page 31: Wichtige Informationen

    INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFO INFORMAZIONI IMPORTANTI INFORMATIONS WICHTIGE INFORMAZIONI INFORMATIONEN IMPORTANTES IMPORTANTI VORBEREITUNG FÜR AUSBAU PREPARATION A LA DEPOSE ET PREPARATIVI PER LA AU DEMONTAGE UND ZERLEGUNG RIMOZIONE E IL Vor dem Ausbau oder Zerlegen Eliminer soigneusement saletés, DISASSEMBLAGGIO boue, poussière et corps étrangers der Bauteile und -gruppen sämt- Prima della rimozione e del disas-...
  • 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 overhauled.

  • Page 33: Informations Importantes

    Es wird empfohlen, nur Original- Si consiglia di utilizzare compo- pièces Yamaha d’origine pour tous Ersatzteile von Yamaha zu ver- nenti originali Yamaha per tutte le les remplacements. Utiliser les wenden. Nur von Yamaha emp- sostituzioni. Per assemblaggio e graisses et/ou huiles recommandées...
  • Page 34 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view.
  • Page 35 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFO INFORMAZIONI IMPORTANTI CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI SICUREZZA Vérifier soigneusement tous les cir- Sicherungsringe vor dem Wie- Controllare accuratamente tutti gli clips avant le remontage. Toujours dereinbau sorgfältig kontrollie- anelli elastici di sicurezza prima remplacer les circlips d’axe de pis- ren.

  • 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: Controllo Del Collegamento

    VERIFICATION DES CONNEXIONS KABELANSCHLÜSSE KONTROLLIEREN INFO CONTROLLO DEL COLLEGAMENTO VERIFICATION DES KABELANSCHLÜSSE CONTROLLO DEL KONTROLLIEREN CONNEXIONS COLLEGAMENTO Sämtliche Steckverbinderkontakte Traitement des taches, de la rouille, de In caso di macchie, ruggine, umidità ecc. l’humidité, etc., sur le connecteur. und Kabelanschlüsse auf Flecke, sul connettore.

  • 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-01500, 90890-01500 Cap bolt wrench YM-01500 90890-01500 This tool is used to loosen or tighten the base valve. YM-01501, 90890-01501 Cap bolt ring wrench YM-01501...
  • Page 40 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 YAMAHA Bond No. 1215 90890-85505 90890-85505  (ThreeBond No. 1215) This sealant (Bond) is used for crankcase mating sur- face, etc.

  • Page 41: Outils Speciaux

    OUTILS SPECIAUX INFO OUTILS SPECIAUX Il est indispensable d’utiliser les outils spéciaux appropriés 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 ou de techniques improvisées. La forme et le numéro de référence des outils spéciaux pouvant différer selon les pays, il existe parfois deux versions d’un outil.
  • Page 42 OUTILS SPECIAUX INFO Numéro de référence Nom et usage de l’outil Illustration YU-33975, 90890-01403 Clé pour écrou de direction YU-33975 90890-01403 Cet outil sert à serrer l’écrou de blocage de la direction au couple spécifié. YM-01500, 90890-01500 Clé pour boulon capuchon YM-01500 90890-01500 Cet outil permet de desserrer ou de serrer la soupape de...
  • Page 43 Testeur d’étincelle dynamique YM-34487 90890-06754 90890-06754 Contrôleur d’allumage Cet instrument sert à contrôler les composants du système d’allumage. 90890-85505 YAMAHA Bond N°1215 90890-85505 90890-85505 ® (ThreeBond N°1215) Cet agent d’étanchéité (pâte) s’utilise sur les surfaces de contact du carter moteur, etc.
  • Page 44 SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerlässlich. Durch die Verwendung dieser Werkzeuge werden Beschädigungen vermieden, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Die Aus- führung und Teilenummer der Spezialwerkzeuge weicht je nach Bestimmungsland ab. Bei der Bestellung von Spezialwerkzeugen sollten die im Folgenden aufgeführten Bezeichnungen und Tei- lenummern angegeben werden.
  • Page 45 SPEZIALWERKZEUGE INFO Teilenummer Werkzeug/Anwendung Abbildung YU-33975, 90890-01403 Hakenschlüssel YU-33975 90890-01403 Zum vorschriftsmäßigen Festziehen der Lenkkopf- Ringmutter YM-01500, 90890-01500 Abdeckschraubenschlüssel YM-01500 90890-01500 Zum Lockern und Festziehen des Gabelventils. YM-01501, 90890-01501 Abdeckschrauben-Ringschlüssel YM-01501 90890-01501 Zum Lockern und Festziehen des Dämpferrohrs. YM-A0948, 90890-01502 Gabeldichtring-Treiber YM-A0948 90890-01502...
  • Page 46 Einlass 4,0 mm (0,16 in) YM-4118 90890-04118 Auslass 4,5 mm (0,18 in) Zum Ausbohren neuer Ventilführungen YM-34487 Zündfunkenstrecken-Tester YM-34487 90890-06754 90890-06754 Zündungstester Zur Prüfung des Zündsystems 90890-85505 YAMAHA-Dichtmasse Nr.1215 90890-85505 90890-85505 (ThreeBond ® Nr.1215) Zum Abdichten von Kurbelgehäuse-Passflächen und dergleichen 1 - 9...

  • Page 47: Attrezzi Speciali

    ATTREZZI SPECIALI INFO ATTREZZI SPECIALI Sono necessari attrezzi speciali idonei per una messa a punto e un assemblaggio completi e accurati. L’uti- lizzo di attrezzi speciali corretti previene i danni causati dall’impiego di attrezzi impropri o di tecniche improvvisate. La forma e i numeri parte utilizzati per gli attrezzi speciali differiscono da Stato a Stato, per cui se ne indicano due tipi.
  • Page 48 ATTREZZI SPECIALI INFO Numero parte Nome dell’attrezzo/Impiego Figura YU-33975, 90890-01403 Chiave per ghiere YU-33975 90890-01403 Questo attrezzo è utilizzato per serrare la ghiera sterzo fino a quanto indicato nella specifica. YM-01500, 90890-01500 Chiave per tappo filettato YM-01500 90890-01500 Questo attrezzo è utilizzato per allentare o serrare la val- vola base.
  • Page 49 YM-34487 90890-06754 90890-06754 Tester dell’accensione Questo strumento è utilizzato per controllare i componenti dell’impianto di accensione. 90890-85505 Sigillante YAMAHA N.1215 90890-85505 90890-85505 ® (ThreeBond N.1215) Questo sigillante è utilizzato per chiudere a tenuta le superfici di contatto del carter, ecc.

  • 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: Bedienungselemente Und Deren Funktion

    FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION INFO FUNZIONI DI CONTROLLO FONCTIONS DES BEDIENUNGSELEMENTE FUNZIONI DI UND DEREN FUNKTION COMMANDES CONTROLLO MOTORSTOPPSCHALTER COUPE-CIRCUIT DU MOTEUR INTERRUTTORE DI ARRESTO Le coupe-circuit du moteur 1 est situé Der Motorstoppschalter 1 befindet MOTORE L’interruttore di arresto motore 1 si sich links am Lenker.

  • Page 52: Front Brake Lever/Rear Brake Pedal

    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 BEDIENUNGSELEMENTE UND DEREN FUNKTION INFO FUNZIONI DI CONTROLLO LEVIER DE FREIN AVANT HANDBREMSHEBEL LEVA DEL FRENO ANTERIORE Le levier de frein avant 1 est situé sur la Der Handbremshebel 1 befindet La leva del freno anteriore 1 si trova sul partie droite du guidon.
  • 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 BEDIENUNGSELEMENTE UND DEREN FUNKTION INFO FUNZIONI DI CONTROLLO BEQUILLE LATERALE ABNEHMBARER CAVALLETTO LATERALE AMOVIBLE SEITENSTÄNDER SMONTABILE La béquille latérale 1 ne sert qu’à sup- Der Seitenständer 1 dient lediglich Questo cavalletto 1 è utilizzato per porter la moto à l’arrêt ou durant le zum Abstützen der Maschine im sostenere il mezzo quando è...
  • 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: Premium unleaded gasoline only with a research octane number of 95 or higher. CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.
  • Page 57 CARBURANT KRAFTSTOFF INFO CARBURANTE CARBURANT KRAFTSTOFF CARBURANTE Toujours utiliser le carburant recom- Nur den empfohlenen Kraftstoff tan- Utilizzare sempre il carburante racco- ken. Am Anfang eines Renntages fri- mandé, comme indiqué ci-après. Le jour mandato di seguito. Inoltre, assicurarsi de la course, toujours utiliser de schen Kraftstoff einfüllen.

  • 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: •...

  • Page 59: Starten Und Einfahren

    MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN INFO AVVIAMENTO E RODAGGIO MISE EN MARCHE ET STARTEN UND AVVIAMENTO E EINFAHREN RODAGE RODAGGIO AVERTISSEMENT WARNUNG AVVERTENZA Ne jamais démarrer ou faire tourner Den Motor unter keinen Umstän- Mai avviare o far funzionare il motore le moteur dans un endroit clos.
  • 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

    MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN INFO AVVIAMENTO E RODAGGIO Repousser la commande de départ à Den Chokehebel zurückschie- Riportare la manopola starter per froid dans sa position d’origine et ben und den Motor einige Minu- partenze a freddo nella posizione 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 STARTEN UND EINFAHREN INFO AVVIAMENTO E RODAGGIO MISE EN MARCHE A CHAUD WARMEN MOTOR ANLASSEN AVVIAMENTO DEL MOTORE A Ne pas utiliser la commande de départ à Weder den Chokehebel noch den CALDO froid ni les gaz. Tirer le levier de démar- Gasdrehgriff betätigen.

  • 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 STARTEN UND EINFAHREN INFO AVVIAMENTO E RODAGGIO PROCEDURE DE RODAGE EINFAHRVORSCHRIFTEN PROCEDURE DI RODAGGIO Avant de démarrer le moteur, faire Vor dem Starten voll tanken. Prima di avviare il motore, riempire le plein du réservoir de carburant. Die “Routinekontrolle vor Fahrt- il serbatoio di carburante.
  • 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 handlebar...

  • Page 67: Points De Verification Des Couples De Serrage

    POINTS DE VERIFICATION DES COUPLES DE SERRAGE INFO POINTS DE VERIFICATION DES COUPLES DE SERRAGE Cadre Cadre au cadre arrière Selle et réservoir de carburant Réservoir de carburant au cadre Système d’échappement Silencieux au cadre arrière Bâti moteur Cadre au moteur Support de moteur au moteur Support de moteur au cadre Direction...

  • Page 68: Anzugsdrehmomente Kontrollieren

    ANZUGSDREHMOMENTE KONTROLLIEREN INFO ANZUGSDREHMOMENTE KONTROLLIEREN Fahrgestell Rahmen und Rahmenhinterteil Sitzbank-Krafstofftank-Baugruppe Kraftstofftank und Rahmen Auspuffsystem Schalldämpfer und Rahmenhinterteil Motorlager Rahmen und Motor Motorhalterung und Motor Motorhalterung und Rahmen Lenkung Lenkkopf und Lenker Lenkrohr und Rahmen Lenkschaft und obere Gabelbrücke Obere Gabelbrücke und Lenker Radaufhängung Vorn Lenkkopf und Gabel-...

  • Page 69: Punti Di Controllo Serraggio

    PUNTI DI CONTROLLO SERRAGGIO INFO PUNTI DI CONTROLLO SERRAGGIO Struttura del telaio Telaio – telaio posteriore Sella combinata e serbatoio del carburante Serbatoio del carburante – telaio Impianto di scarico Silenziatore – telaio posteriore Supporto motore Telaio – motore Staffa motore – motore Staffa 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 overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.

  • Page 71: Nettoyage Et Remisage

    NETTOYAGE ET REMISAGE PFLEGE UND LAGERUNG INFO PULIZIA E CUSTODIA DEL MEZZO NETTOYAGE ET PFLEGE UND PULIZIA E CUSTODIA LAGERUNG REMISAGE DEL MEZZO FAHRZEUGWÄSCHE NETTOYAGE PULIZIA Un nettoyage fréquent de la moto préser- Regelmäßige Wäsche optimiert das Una pulizia frequente del mezzo ne Aussehen, die Leistung und die vera son apparence, maintiendra ses bon- migliorerà...
  • 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 car- buretor float bowl.

  • Page 73: Carburant

    NETTOYAGE ET REMISAGE PFLEGE UND LAGERUNG INFO PULIZIA E CUSTODIA DEL MEZZO REMISAGE LAGERUNG CUSTODIA Si la moto doit être remisée pour 60 Soll das Motorrad länger als 60 Tage Se il mezzo rimane inutilizzato per ses- jours ou plus, il convient de prendre cer- gelagert werden, sind...

  • Page 74: General Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ250FV (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Model code number: 5XC9, 5XCD (USA, CDN) 5XCA (EUROPE) 5XCC, 5XCF (AUS, NZ, ZA) Dimensions: EUROPE USA, CDN, ZA (Except for F) Overall length 2,176 mm 2,170 mm...
  • Page 75 SPEC GENERAL SPECIFICATIONS Oil type or grade: Engine oil (For USA and CDN) At 5 °C (40 °F) or higher È Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non-Friction modified) At 15 °C (60 °F) or lower É Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non-Friction modified)

  • Page 76: Chassis

    SPEC GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 57/17 (3.353) Secondary reduction system Chain drive Secondary reduction ratio 48/13 (3.692) (Except for EUROPE) 49/13 (3.769) (For EUROPE) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 1st 30/14 (2.143) 28/16 (1.750) 29/20 (1.450)

  • 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 plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 in) Clutch spring free length 40.4 mm (1.59 in) 39.4 mm (1.55 in) Quantity ---- Clutch housing thrust clearance 0.10 ~ 0.35 mm...
  • 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 M6 × 1.0 Air filter case M5 × 0.8 Air filter joint and air filter case M6 × 1.0 Air filter element M8 × 1.25 Exhaust pipe (nut) M8 ×...
  • Page 85 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN, EUROPE AUS, NZ, ZA 300 mm (11.8 in) ← Front fork travel ---- 454 mm (17.9 in) ← Fork spring free length 449 mm (17.7 in) ←...
  • Page 86 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Swingarm: Swingarm free play limit ---- 1.0 mm (0.04 in) 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...
  • 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 Handlebar upper holder and handlebar lower M8 ×...
  • 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 89 248 ~ 372 Ω at 20 °C (68 °F) Pickup coil resistance (color) ---- (White – Red) CDI unit-model/manufacturer 5XC-90/YAMAHA (For USA) ---- 5XC-A0/YAMAHA (Except for USA) ---- Ignition coil: Model/manufacturer 5UL-10/DENSO ---- Minimum spark gap 6 mm (0.24 in) ---- 0.08 ~ 0.10 Ω...

  • 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 du modèle: YZ250FV (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Numéro de code de modèle: 5XC9, 5XCD (USA, CDN) 5XCA (EUROPE) 5XCC, 5XCF (AUS, NZ, ZA) Dimensions: EUROPE USA, CDN, ZA (Sauf F) Longueur totale 2.176 mm 2.170 mm...
  • Page 92 SPEC CARACTERISTIQUES GENERALES Type ou qualité d’huile: Huile moteur (USA et CDN) A 5 °C (40 °F) ou plus È Yamalube 4 (20W-40) ou type SAE 20W-40 Huile moteur SG (non modifiée pour la friction) A 15 °C (60 °F) ou moins É Yamalube 4 (10W-30) ou type SAE 10W-30 Huile moteur SG (non modifiée pour la friction)
  • Page 93 SPEC CARACTERISTIQUES GENERALES Boîte de vitesse: Système de réduction primaire Pignon Taux de réduction primaire 57/17 (3,353) Système de réduction secondaire Transmission par chaîne Taux de réduction secondaire 48/13 (3,692) (Sauf pour l’EUROPE) 49/13 (3,769) (Pour l’EUROPE) Type de boîte de vitesses Toujours en prise, 5-rapports Commande Pied gauche...
  • Page 94 SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Elément 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 de transmission Transmission par chaîne (gauche) ---- Diamètre intérieur du chapeau d’arbre à...
  • Page 95 SPEC CARACTERISTIQUES D’ENTRETIEN Elément 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 aux soupapes (à froid) 0,10 à...
  • Page 96 SPEC CARACTERISTIQUES D’ENTRETIEN Elément Standard Limite Limite de faux-rond de tige de soupape ---- 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...
  • Page 97 SPEC CARACTERISTIQUES D’ENTRETIEN Elément Standard Limite Diamètre intérieur de l’alésage de l’axe de piston 16,002 à 16,013 mm 16,043 mm (0,6300 à 0,6304 in) (0,6316 in) Diamètre extérieur de l’axe de piston 15,991 à 16,000 mm 15,971 mm (0,6296 à 0,6299 in) (0,6288 in) Segments de piston: Segment de feu:...
  • Page 98 SPEC CARACTERISTIQUES D’ENTRETIEN Elément Standard Limite Epaisseur du plateau de pression 1,1 à 1,3 mm (0,043 à 0,051 in) ---- Quantité ---- Limite de déformation ---- 0,1 mm (0,004 in) Longueur libre de ressort d’appui du plateau de 40,4 mm (1,59 in) 39,4 mm pression (1,55 in)
  • Page 99 SPEC CARACTERISTIQUES D’ENTRETIEN Elément Standard Limite Système de lubrification: Type de filtre à huile Papier ---- Type de pompe à huile Type trochoïde ---- Jeu entre rotors 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 Diamètre du Pièce à serrer Qté filet 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 (goujon) M8 ×...
  • Page 101 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Diamètre du Pièce à serrer Qté filet m·kg ft·lb M6 × 1,0 Boîtier de filtre à air M5 × 0,8 Conduit d’admission d’air et boîtier de filtre à air M6 × 1,0 Elément de filtre à air M8 ×...
  • Page 102 SPEC CARACTERISTIQUES D’ENTRETIEN CHASSIS Elément Standard Limite Système de direction: Type de roulement de direction Roulement à rouleaux coniques ---- USA, CDN, Suspension avant: EUROPE AUS, NZ, ZA ← Débattement de fourche 300 mm (11,8 in) ---- ← Longueur libre de ressort de fourche 454 mm (17,9 in) 449 mm (17,7 in) ←...
  • Page 103 SPEC CARACTERISTIQUES D’ENTRETIEN Elément Standard Limite Bras oscillant: Limite de jeu du bras oscillant Extrémité ---- 1,0 mm (0,04 in) Roue: Type de roue avant Roue à rayons ---- Type de roue arrière Roue à rayons ---- 21 × 1,60/Aluminium Taille/matériau de la jante avant ---- 19 ×...
  • Page 104 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Diamètre du Pièce à serrer Qté filet m·kg ft·lb M8 × 1,25 Té supérieur et fourreau M8 × 1,25 Té inférieur et fourreau M24 × 1,0 Té supérieur et arbre de direction 14,5 M8 × 1,25 Support de guidon supérieur et inférieur M12 ×...
  • Page 105 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Diamètre du Pièce à serrer Qté filet m·kg ft·lb Ecrou (rayon) — M8 × 1,25 Pignon de roue arrière M6 × 1,0 Couvre-disque de frein arrière M6 × 1,0 Protection d’étrier de frein arrière Boulon de réglage et contre-écrou du tendeur de la M8 ×...
  • Page 106 248 à 372 Ω à 20 °C (68 °F) Résistance de la bobine d’excitation ---- (couleur) (blanc – rouge) Modèle/fabricant du boîtier CDI 5XC-90/YAMAHA (USA) ---- 5XC-A0/YAMAHA (Sauf USA) ---- Bobine d’allumage: Modèle/fabricant 5UL-10/DENSO ---- Longueur d’étincelle minimum 6 mm (0,24 in) ---- 0,08 à...

  • 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 filet 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 Modellbezeichnung: YZ250FV (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Modellcode: 5XC9, 5XCD (USA, CDN) 5XCA (EUROPE) 5XCC, 5XCF (AUS, NZ, ZA) Abmessungen: USA, CDN, EUROPE (Nicht F) Gesamtlänge 2.176 mm 2.170 mm 2.169 mm (85,67 in) (85,43 in)

  • Page 109: Allgemeine Technische Daten

    SPEC ALLGEMEINE TECHNISCHE DATEN Ölsorte und -viskosität: Motoröl Nur USA und CDN: Über 5 °C (40 °F) È Yamalube 4 (20W-40) oder SAE 20W-40 Motoröl der API-Klasse SG (ohne reibungsmindernde Additive) Unter 15 °C (60 °F) É Yamalube 4 (10W-30) oder SAE 10W-30 Motoröl der API-Klasse SG (ohne reibungsmindernde Additive) bzw.
  • Page 110 SPEC ALLGEMEINE TECHNISCHE DATEN Getriebeabstufung: 1. Gang 30/14 (2,143) 2. Gang 28/16 (1,750) 3. Gang 29/20 (1,450) 4. Gang 27/22 (1,227) 5. Gang 25/24 (1,042) Fahrwerk: EUROPE AUS, NZ, USA, CDN (Nicht F) ← ← ← Rahmenbauart Schleifen- rohrrah- men mit geteiltem Unterzug Lenkkopfwinkel...
  • Page 111 SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bezeichnung Standard 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: Antriebsart Kettenantrieb (links) ---- Nockenwellenlager-Durchmesser 22,000–22,021 mm ---- (0,8661–0,8670 in) Nockenwellen-Lagerzapfen-Durchmesser 21,959–21,972 mm ----...
  • Page 112 SPEC WARTUNGSDATEN Bezeichnung Standard Grenzwert Steuerkette: Typ/Anzahl Kettenglieder 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 Ventilteller-Durchmesser Ventilkegel-Breite Ventilsitz-Breite Ventilteller-Stärke Ventilteller-Durchmesser “A” Einlass 22,9–23,1 mm ---- (0,9016–0,9094 in) Auslass...
  • Page 113 SPEC WARTUNGSDATEN Bezeichnung Standard Grenzwert Max. Ventilschaft-Schlag ---- 0,01 mm (0,0004 in) Ventilsitz-Breite Einlass 0,9–1,1 mm 1,6 mm (0,0354–0,0433 in) (0,0630 in) Auslass 0,9–1,1 mm 1,6 mm (0,0354–0,0433 in) (0,0630 in) Ventilfeder: Ungespannte Länge Einlass 37,81 mm (1,49 in) 36,81 mm (1,45 in) Auslass 37,54 mm (1,48 in)
  • Page 114 SPEC WARTUNGSDATEN Bezeichnung Standard 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) ---- Ringstoß...
  • Page 115 SPEC WARTUNGSDATEN Bezeichnung Standard Grenzwert Stahlscheiben-Stärke 1,1–1,3 mm (0,043–0,051 in) ---- Anzahl ---- Max. Verzug ---- 0,1 mm (0,004 in) Länge der ungespannten Kupplungsfeder 40,4 mm (1,59 in) 39,4 mm (1,55 in) Anzahl ---- Kupplungskorb-Axialspiel 0,10–0,35 mm ---- (0,0039–0,0138 in) Kupplungskorb-Radialspiel 0,010–0,044 mm ----...
  • Page 116 SPEC WARTUNGSDATEN Bezeichnung Standard Grenzwert Schmiersystem: Ölfilter-Ausführung Papiereinsatz ---- Ölpumpen-Bauart Trochoidenpumpe ---- Innenrotor-Radialspiel Max. 0,12 mm 0,20 mm (Max. 0,0047 in) (0,008 in) Innen- und Außenrotor-Radialspiel 0,09–0,17 mm 0,24 mm (0,0035–0,0067 in) (0,009 in) Innen- und Außenrotor-Axialspiel 0,03–0,10 mm 0,17 mm (0,0012–0,0039 in) (0,0067 in) Kühlsystem:...
  • Page 117 SPEC WARTUNGSDATEN Anzugsmoment Gewinde- Festzuziehendes Teil Anz. größe m·kg ft·lb M10S × 1,0 Zündkerze M6 × 1,0 Nockenwellen-Lagerdeckel M12 × 1,0 Zylinderkopf-Abdeckschraube 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 Anzugsmoment Gewinde- Festzuziehendes Teil Anz. größe m·kg ft·lb M6 × 1,0 Luftfiltergehäuse Vergasereinlass-Anschluss und Luftfilterge- M5 × 0,8 häuse M6 × 1,0 Luftfiltereinsatz M8 × 1,25 Auspuffkrümmer (Mutter) M8 × 1,25 (Schraube) M6 × 1,0 Auspuffkrümmerschutz M8 × 1,25 Schalldämpfer M8 ×...
  • Page 119 SPEC WARTUNGSDATEN FAHRWERK Bezeichnung Standard Grenzwert Lenkung: Lenkkopflager-Bauart Schrägkugellager ---- USA, CDN, Vorderradaufhängung: EUROPE AUS, NZ, ZA 300 mm (11,8 in) ← Telskopgabel-Federweg ---- 454 mm (17,9 in) ← Länge der ungespannten Gabelfeder 449 mm (17,7 in) ← Standard-Federrate K = 4,3 N/mm ---- (0,438 kg/mm, 24,5 lb/in)
  • Page 120 SPEC WARTUNGSDATEN Bezeichnung Standard Grenzwert Schwinge: Max. Schwingenspiel Seitenspiel ---- 1,0 mm (0,04 in) Räder: Vorderrad-Bauart Speichenrad ---- Hinterrad-Bauart Speichenrad ---- 21 × 1,60/Aluminium Vorderrad-Felgendimension/-mate- ---- rial 19 × 1,85/Aluminium Hinterrad-Felgendimension/-mate- ---- rial Max. Felgenschlag Höhenschlag ---- 2,0 mm (0,08 in) Seitenschlag ---- 2,0 mm (0,08 in)
  • Page 121 SPEC WARTUNGSDATEN Anzugsmoment Gewinde- Festzuziehendes Teil Anz. größe m·kg ft·lb M8 × 1,25 Obere Gabelbrücke und Standrohr M8 × 1,25 Untere Gabelbrücke und Standrohr M24 × 1,0 Obere Gabelbrücke und Lenkkopf 14,5 M8 × 1,25 Obere und untere Lenkerhalterungen M12 × 1,25 Untere Lenkerhalterung und obere Gabelbrücke M28 ×...
  • Page 122 SPEC WARTUNGSDATEN Anzugsmoment Gewinde- Festzuziehendes Teil Anz. größe m·kg ft·lb Speichennippel — M8 × 1,25 Kettenrad M6 × 1,0 Bremsscheiben-Abdeckung hinten M6 × 1,0 Hinterrad-Bremssattel-Schutz Kettenspanner-Einstellschraube und Siche- M8 × 1,25 rungsmutter Motorlager: M10 × 1,25 Motor und Motorhalterung (vorn) M10 ×...
  • Page 123 Ladespule 2 (Schwarz–Rosa) 248–372 Ω bei 20 °C (68 °F) Impulsgeber-Widerstand (Kabel- ---- farbe) (Weiß–Rot) Zündbox-Typ/-Hersteller 5XC-90/YAMAHA (USA) ---- 5XC-A0/YAMAHA (Nicht USA) ---- Zündspule: Typ/Hersteller 5UL-10/DENSO ---- Min. Zündfunkenstrecke 6 mm (0,24 in) ---- 0,08–0,10 Ω bei 20 °C (68 °F) Primärwicklungs-Widerstand...

  • Page 124: Allgemeine Anzugsmomente

    ALLGEMEINE ANZUGSMOMENTE/ SPEC MASSEINHEITEN ALLGEMEINE ANZUGSMOMENTE Aus der folgenden Tabelle sind die Anzugsmo- mente für normale Schraubverbindungen mit ISO-Normgewinde ersichtlich. Anzugsmo- mente für spezielle Verschraubungen und Bauteile werden in jedem Abschnitt dieser Anleitung gesondert aufgeführt. Um ein Ver- ziehen der Bauteile zu vermeiden, sollten die Schraubverbindungen über Kreuz angezogen werden, bis die vorgeschriebenen Anzugsmo- mente erreicht sind.

  • Page 125: Dati Tecnici

    SPEC DATI TECNICI GENERALI DATI TECNICI DATI TECNICI GENERALI Modello: YZ250FV (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Codice modello: 5XC9, 5XCD (USA, CDN) 5XCA (EUROPE) 5XCC, 5XCF (AUS, NZ, ZA) Dimensioni: USA, CDN, EUROPE (Eccetto F) Lunghezza totale 2.176 mm 2.170 mm 2.169 mm (85,67 in)

  • Page 126: Dati Tecnici Generali

    SPEC DATI TECNICI GENERALI Tipo o gradazione dell’olio: Olio motore (USA e CDN) Temperatura uguale o superiore a 5 °C (40 °F) È Tipo Yamalube 4 (20W-40) o SAE 20W-40 Olio motore SG (Modificato non conduttore) Temperatura uguale o inferiore a 15 °C (60 °F) É Tipo Yamalube 4 (10W-30) o SAE 10W-30 Olio motore SG (Modificato non conduttore)
  • Page 127 SPEC DATI TECNICI GENERALI Trasmissione: Sistema di riduzione primario Ingranaggi Rapporto di riduzione primario 57/17 (3,353) Sistema di riduzione secondario Comando a catena Rapporto di riduzione secondario 48/13 (3,692) (Eccetto EUROPE) 49/13 (3,769) (Per EUROPE) Tipo di trasmissione Sempre in presa, a 5-marce Comando Con il piede sinistro Rapporto di trasmissione:1ª...

  • Page 128: Specifiche Di Manutenzione

    SPEC SPECIFICHE DI MANUTENZIONE SPECIFICHE DI MANUTENZIONE MOTORE Elemento Standard Limite Testata: Limite di distorsione ---- 0,05 mm (0,002 in) Cilindro: Alesaggio 77,00 ~ 77,01 mm ---- (3,0315 ~ 3,0319 in) Limite eccentricità ---- 0,05 mm (0,002 in) Albero a camme: Metodo di trasmissione Comando a catena (lato sinistro) ----...
  • Page 129 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Catena di distribuzione: Tipo di catena di distribuzione/n. di articolazioni 92RH2010-114M/114 ---- Metodo di regolazione della catena di distribu- Automatico ---- zione Valvola, sede valvola, guidavalvola: Gioco valvole (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 di disassamento dello stelo ---- 0,01 mm (0,0004 in) Larghezza della 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 del pistone: Fascia superiore: Tipo Tubolare...
  • Page 132 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Spessore disco condotto 1,1 ~ 1,3 mm (0,043 ~ 0,051 in) ---- Quantità ---- Limite di distorsione ---- 0,1 mm (0,004 in) Lunghezza libera della molla frizione 40,4 mm (1,59 in) 39,4 mm (1,55 in) Quantità...
  • Page 133 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Sistema di lubrificazione: Tipo di filtro olio Tipo di carta ---- Tipo di pompa dell’olio Tipo trocoidale ---- Gioco sull’estremità 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 Elemento da serrare Filettatura Quantità m·kg ft·lb M10S × 1,0 Candela di accensione M6 × 1,0 Cappello dell’albero a camme M12 × 1,0 Vite del tappo cieco coperchio testata M6 × 1,0 Testata (prigioniero) M8 ×...
  • Page 135 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Elemento da serrare Filettatura Quantità m·kg ft·lb M6 × 1,0 Scatola filtro aria M5 × 0,8 Giunto e scatola del filtro dell’aria M6 × 1,0 Cartuccia del filtro dell’aria M8 × 1,25 Tubo di scarico (dado) M8 ×...
  • Page 136 SPEC SPECIFICHE DI MANUTENZIONE PARTE CICLISTICA Elemento Standard Limite Sistema sterzante: Tipo di cuscinetti sterzo Cuscinetto conico a rulli ---- USA, CDN, Sospensione anteriore: EUROPE AUS, NZ, ZA ← Corsa forcella anteriore 300 mm (11,8 in) ---- ← Lunghezza libera molla della forcella 454 mm (17,9 in) 449 mm (17,7 in) ←...
  • Page 137 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Forcellone oscillante: Limite gioco forcellone oscillante Estremità ---- 1,0 mm (0,04 in) Ruota: Tipo ruota anteriore Ruota a raggi ---- Tipo ruota posteriore Ruota a raggi ---- 21 × 1,60/Alluminio Dimensioni/materiale cerchio anteriore ---- 19 ×...
  • Page 138 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Elemento da serrare Filettatura Quantità m·kg ft·lb M8 × 1,25 Staffa superiore e gambale M8 × 1,25 Staffa inferiore e gambale M24 × 1,0 Staffa superiore e fusto dello sterzo 14,5 M8 × 1,25 Supporto superiore e inferiore manubrio M12 ×...
  • Page 139 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Elemento da serrare Filettatura Quantità m·kg ft·lb Chiave tendiraggi — M8 × 1,25 Corona della ruota posteriore M6 × 1,0 Riparo disco freno posteriore M6 × 1,0 Protezione pinza freno posteriore Bullone e controdado di regolazione dell’estrattore M8 ×...
  • Page 140 248 ~ 372 Ω a 20 °C (68 °F) Resistenza bobina pickup (colore) ---- (bianco – rosso) Modello/produttore unità CDI 5XC-90/YAMAHA (USA) ---- 5XC-A0/YAMAHA (Eccetto USA) ---- Bobina di accensione: Modello/produttore 5UL-10/DENSO ---- Lunghezza minima della scintilla 6 mm (0,24 in) ---- 0,08 ~ 0,10 Ω...
  • Page 141 SPECIFICHE GENERALI DI SERRAGGIO/ SPEC DEFINIZIONE DELLE UNITÀ DI MISURA SPECIFICHE GENERALI DI SERRAGGIO La tabella specifica la coppia per i dispositivi di serraggio standard con filettature con passo I.S.O. standard. Le specifiche di serraggio per componenti o gruppi speciali sono contenute nei relativi para- grafi del presente manuale.

  • Page 142: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose È Insert the end of the fuel tank Ì Pass the fuel hose between the 2 Radiator hose 1 breather hose into the hole in hot starter cable and throttle 3 Cylinder head breather hose the steering stem.

  • Page 143: D'acheminement Des Cables

    DIAGRAMME D’ACHEMINEMENT DES CABLES KABELFÜHRUNGSDIAGRAMME SPEC SCHEMA PERCORSO DEI CAVI DIAGRAMME KABELFÜHRUNGSDIA- SCHEMA PERCORSO DEI GRAMME D’ACHEMINEMENT DES CAVI 1 Kraftstofftank-Belüftungsschlauch 1 Flessibile di sfiato del serbatoio carbu- CABLES 2 Kühlerschlauch 1 rante 1 Durit de mise à l’air du réservoir de car- 3 Zylinderkopf-Entlüftungsschlauch 2 Flessibile radiatore 1 burant...
  • Page 144 SPEC CABLE ROUTING DIAGRAM 1 Hot starter cable D Sub-wire harness Ê Fasten the neutral switch lead 2 Radiator hose 2 E CDI unit bracket on the oil hose. 3 Clamp F CDI unit Ë Pass the neutral switch lead on 4 Ignition coil lead G Throttle cable the inside of the oil hose.
  • Page 145 DIAGRAMME D’ACHEMINEMENT DES CABLES KABELFÜHRUNGSDIAGRAMME SPEC SCHEMA PERCORSO DEI CAVI 1 Câble de starter à chaud 1 Warmstartzug 1 Cavo starter per partenze a caldo 2 Durit de radiateur 2 2 Kühlerschlauch 2 2 Flessibile radiatore 2 3 Collier à pince 3 Klemme 3 Morsetto 4 Fil de la bobine d’allumage...
  • Page 146 SPEC CABLE ROUTING DIAGRAM Î Pass the radiator breather Ð Locate the clamp ends in the hose in front of the radiator, on arrowed range. Ñ Fasten the neutral switch lead the left of the chassis, and then between the frame and radiator and CDI magneto lead over the hose 4.
  • Page 147 DIAGRAMME D’ACHEMINEMENT DES CABLES KABELFÜHRUNGSDIAGRAMME SPEC SCHEMA PERCORSO DEI CAVI Î Acheminer la durit de mise à l’air du Î Den Kühler-Entlüftungsschlauch vor Î Far passare il flessibile di sfiato radiatore radiateur devant le radiateur, à la gauche den Kühler, links vom Rahmen und davanti al radiatore, nella parte sinistra du châssis, puis entre le cadre et la durit dann zwischen Rahmen und Kühler-...
  • Page 148 SPEC CABLE ROUTING DIAGRAM 1 Throttle cable (pull) È Pass the throttle cables over the radiator hose 2. 2 Throttle cable (return) É Pass the cylinder head breather hose so that it 3 Radiator hose 2 does not contact the ignition coil. 4 Ignition coil Ê...
  • Page 149 DIAGRAMME D’ACHEMINEMENT DES CABLES KABELFÜHRUNGSDIAGRAMME SPEC SCHEMA PERCORSO DEI CAVI 1 Câble des gaz (tiré) 1 Gasgeberzug 1 Cavo acceleratore (tirato) 2 Câble des gaz (retour) 2 Gasnehmerzug 2 Cavo acceleratore (posizione iniziale) 3 Durit de radiateur 2 3 Kühlerschlauch 2 3 Flessibile radiatore 2 4 Bobine d’allumage 4 Zündspule...
  • Page 150 SPEC CABLE ROUTING DIAGRAM 1 Brake master cylinder È Install the brake hose so that its pipe portion 2 Brake hose holder directs as shown and lightly touches the projection 3 Brake hose on the brake caliper. É Pass the brake hose into the brake hose holders. Ê...
  • Page 151 DIAGRAMME D’ACHEMINEMENT DES CABLES KABELFÜHRUNGSDIAGRAMME SPEC SCHEMA PERCORSO DEI CAVI 1 Maître-cylindre de frein 1 Hauptbremszylinder 1 Pompa del freno 2 Support de durit de frein 2 Bremsschlauch-Halterung 2 Supporto tubo flessibile del freno 3 Durit de frein 3 Bremsschlauch 3 Tubo flessibile del freno È...
  • Page 152 SPEC CABLE ROUTING DIAGRAM 1 Throttle cable È Fasten the engine stop switch lead to the handle- 2 Clamp bar. 3 Hot starter cable É Pass the clutch cable and hot starter cable 4 Clutch cable through the cable guide. 5 Engine stop switch lead Ê...
  • Page 153 DIAGRAMME D’ACHEMINEMENT DES CABLES KABELFÜHRUNGSDIAGRAMME SPEC SCHEMA PERCORSO DEI CAVI 1 Câble des gaz 1 Gaszug 1 Cavo acceleratore 2 Collier à pince 2 Klemme 2 Morsetto 3 Câble de starter à chaud 3 Warmstartzug 3 Cavo starter per partenze a caldo 4 Câble d’embrayage 4 Kupplungszug 4 Cavo frizione...

  • Page 154: 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 155 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 Inspect and retighten Clean Replace * Whichever comes first...
  • Page 156 Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or SAE 10W-30 motor oil Check routing and connection Inspect dirt and wear on Lubricate the throttle cable on the Inspect and clean (throttle cable) carburetor side.
  • Page 157 Si une question se pose quant aux fréquences de l’entretien ou de la lubrification du véhicule, demander conseil à son concessionnaire Yamaha. A cha-...

  • Page 158: Mise En Marche Et Rodage

    INSP PROGRAMME D’ENTRETIEN A cha- Selon Toutes les Toutes les Après trois cour- cinq courses Elément les be- Remarques rodage soins course (ou 500 km) 1.000 km) EMBRAYAGE Contrôler la cloche, le dis- que garni, le plateau de pres- Contrôler et régler sion et le ressort d’appui du Remplacer plateau de pression.
  • Page 159 Remplacer les roulements Lubrifier Graisse à base de lithium ACCELERATEUR, CABLE DE COM- Lubrifiant pour câbles MANDE Yamaha ou huile moteur Contrôler le cheminement et le raccorde- SAE 10W-30 ment Contrôler la propreté et l’usure du câble des gaz du Lubrifier côté...
  • Page 160 Die hier empfohlenen Zeitabstände für Wartung und Schmierung sollten lediglich als Richtwerte für den Normalbetrieb angesehen werden. Je nach Wetterbedingungen, Belastung und Einsatzgebiet können in Abweichung des regelmäßigen Wartungsplans kürzere Intervalle notwendig werden. Wenden Sie sich im Zweifelsfalle an Ihren Yamaha-Händler. Nach Nach...
  • Page 161 INSP WARTUNGSINTERVALLE Nach Nach Nach Nach jedem 3. jedem 5. Nach Bezeichnung dem Ein- jedem Bemerkungen Rennen Rennen Bedarf (oder (oder fahren Rennen 500 km) 1.000 km) GETRIEBE Kontrollieren Lager erneuern SCHALTGABELN, SCHALTWALZE UND FÜHRUNGSSTANGE Kontrollieren Auf Verschleiß kontrollie- ren. ROTORMUTTER Festziehen AUSPUFFKRÜMMER, SCHALL-...
  • Page 162 RÄDER UND REIFEN Luftdruck kontrollieren und auf Verzug, Verschleiß sowie lose Speichen prüfen Kettenrad-Schraube festziehen Lager kontrollieren Lager erneuern Schmieren Lithiumseifenfett Yamaha-Seilzugschmier- SEILZÜGE mittel oder SAE 10W-30 Verlauf und Anschluss kontrollieren Motoröl Schmieren Gaszug vergaserseitig Gaszug kontrollieren und reinigen auf Verunreinigung und Verschleiß...

  • Page 163: Intervalli Di Manutenzione

    In caso di dubbio su quale intervallo seguire per la manutenzione e la lubrificazione del mezzo, consultare il rivenditore Yamaha. Ogni...
  • Page 164 INSP INTERVALLI DI MANUTENZIONE Ogni Ad ogni Ogni tre Dopo il Se ne- cinque com- competi- Elemento compe- Osservazioni petizioni zioni rodaggio cessario tizione (o 500 km) 1.000 km) FRIZIONE Controllare la campana, il disco conduttore, il disco Controllare e regolare condotto e la molla della fri- Sostituire zione...
  • Page 165 Serrare il bullone della corona Controllare i cuscinetti Sostituire i cuscinetti Lubrificare Grasso a base di litio ACCELERATORE, CAVO DI Lubrificante cavi Yamaha o COMANDO olio per motori SAE 10W- Controllare il percorso e il collegamento Controllare la sporcizia e Lubrificare l’usura del cavo dell’accele-...

  • Page 166: 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 167 INSP CONTROLE ET ENTRETIEN AVANT UTILISATION CONTROLE ET ENTRETIEN AVANT UTILISATION Avant d’entamer le rodage du véhicule, un entraînement ou une course, s’assurer que la moto est en bon état de marche. Avant d’utiliser cette moto, contrôler les points suivants. CONTROLE GENERAL ET ENTRETIEN Elément Travail...

  • Page 168: Kraftstoff

    INSP ROUTINEKONTROLLE VOR FAHRTBEGINN ROUTINEKONTROLLE VOR FAHRTBEGINN Ob zum Einfahren, Training oder Rennen, vor dem Starten stets die “Routinekontrolle vor Fahrtbe- ginn” ausführen. Vor dem ersten Einsatz folgende Punkte kontrollieren. ALLGEMEINE KONTROLL- UND WARTUNGSARBEITEN Bezeichnung Ausführung Seite Sicherstellen, dass die Kühlflüssigkeit bis zum Kühlerdeckel Kühlflüssigkeit reicht.

  • Page 169: Carburante

    CONTROLLI E MANUTENZIONE DA COMPIERE PRIMA INSP DELLA MESSA IN FUNZIONE CONTROLLI E MANUTENZIONE DA COMPIERE PRIMA DELLA MESSA IN FUNZIONE Prima di procedere al rodaggio, alla marcia normale o ad una competizione, assicurarsi che il mezzo sia in buone condizioni di funzionamento. Prima dell’utilizzo, controllare i seguenti punti.
  • Page 170 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 171 MOTEUR/CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT INSP MOTOR/KÜHLFLÜSSIGKEITSSTAND KONTROLLIEREN MOTORE/CONTROLLO DEL LIVELLO DEL REFRIGERANTE MOTOR MOTEUR MOTORE CONTROLE DU NIVEAU DU KÜHLFLÜSSIGKEITSSTAND CONTROLLO DEL LIVELLO DEL LIQUIDE DE REFROIDISSEMENT KONTROLLIEREN REFRIGERANTE WARNUNG AVERTISSEMENT AVVERTENZA Der Kühlerverschlussdeckel 1, Ne pas déposer le bouchon de radia- Non rimuovere il coperchio del radia- teur 1, le boulon de vidange et les tore 1, il tappo di scarico e i flessibili...
  • Page 172 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 173 CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP KÜHLFLÜSSIGKEIT WECHSELN SOSTITUZIONE DEL REFRIGERANTE CHANGEMENT DU LIQUIDE DE KÜHLFLÜSSIGKEIT WECHSELN SOSTITUZIONE DEL REFROIDISSEMENT REFRIGERANTE WARNUNG AVERTISSEMENT AVVERTENZA Der Kühlerverschlussdeckel darf niemals bei heißem Motor abge- Ne jamais enlever le bouchon de Non togliere il coperchio del radiatore radiateur quand le moteur est chaud.
  • Page 174 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 175 CONTROLE DU BOUCHON DE RADIATEUR INSP KÜHLERVERSCHLUSSDECKEL KONTROLLIEREN CONTROLLO COPERCHIO DEL RADIATORE ATTENTION: ACHTUNG: ATTENZIONE: • Niemals verschiedene Sorten • Ne pas mélanger différents types • Non mischiare tipi diversi di anti- d’antigel à l’éthylène glycol conte- Frostschutzmittel miteinander gelo glicole etilenico con inibitori di vermischen.
  • Page 176 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 177 CONTROLE DE LA PRESSION D’OUVERTURE DU BOUCHON DE RADIATEUR/ CONTROLE DU CIRCUIT DE REFROIDISSEMENT ÖFFNUNGSDRUCK DES KÜHLERVERSCHLUSSDECKELS KONTROLLIEREN/ KÜHLSYSTEM KONTROLLIEREN INSP CONTROLLO PRESSIONE DI APERTURA COPERCHIO RADIATORE/ CONTROLLO SISTEMA DI RAFFREDDAMENTO CONTROLE DE LA PRESSION ÖFFNUNGSDRUCK DES CONTROLLO PRESSIONE DI D’OUVERTURE DU BOUCHON DE KÜHLERVERSCHLUSSDECKELS APERTURA COPERCHIO...
  • Page 178 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 pres- sure for 10 seconds → Repair. • Radiator 1 • Radiator hose joint 2 Coolant leakage →...
  • Page 179 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 una pressione superiore rieure à la pression spécifiée. überschreiten. a quella indicata. • Den Kühler bis zum Rand befüllen. •...
  • Page 180 THROTTLE CABLE ADJUSTMENT/ INSP THROTTLE LUBRICATION 3. Install: • Cap 1 • Boot 2 NOTE: Place the tip a of the cap in the boot. 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.
  • Page 181 REGLAGE DU CABLE DES GAZ/GRAISSAGE DE L’ACCELERATEUR INSP GASZUG EINSTELLEN/GASDREHGRIFF UND -ZUG SCHMIEREN REGOLAZIONE CAVO ACCELERATORE/LUBRIFICAZIONE ACCELERATORE Montieren: Monter: Installare: • Bouchon 1 • Schutzkappe 1 • Coperchio 1 • Manchon 2 • Manschette 2 • Parapolvere 2 HINWEIS: N.B.: NOTA: Placer l’extrémité...
  • Page 182 HOT STARTER LEVER ADJUSTMENT/ INSP AIR FILTER CLEANING 2. Apply: • Lithium soap base grease On the throttle cable end a. 3. Install: • Throttle grip cap • Screw (throttle grip cap) 4 Nm (0.4 m · kg, 2.9 ft · lb) •...
  • Page 183 INSP REGLAGE DU LEVIER DE DEMARRAGE A CHAUD/NETTOYAGE DU FILTRE A AIR WARMSTARTHEBEL EINSTELLEN/LUFTFILTER REINIGEN REGOLAZIONE LEVA STARTER PER PARTENZE A CALDO/PULIZIA DEL FILTRO ARIA Auftragen: Appliquer: Applicare: • Lithiumseifenfett • graisse à savon de lithium • Grasso a base di sapone di litio A l’extrémité...
  • Page 184 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 185 NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA DEL FILTRO ARIA Nettoyer: Reinigen: Pulire: • Elément du boîtier de filtre à air • Luftfiltereinsatz • Cartuccia del filtro dell’aria Nettoyer à l’aide d’un solvant. (in Lösungsmittel) Pulire con un solvente. HINWEIS: N.B.: NOTA:...
  • Page 186 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 187 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO OLIO MOTORE Monter: Montieren: Installare: • Luftfiltereinsatz 1 • Cartuccia del filtro dell’aria 1 • Elément du boîtier de filtre à air • Beilagscheibe • Rondella • Rondelle • Schraube •...
  • Page 188 INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) Recommended oil: At 5 °C (40 °F) or higher È Yamalube 4 (20W-40) or SAE 20W-40 type SG motor oil (Non- Friction modified) At 15 °C (60 °F) or lower É Yamalube 4 (10W-30) or SAE 10W-30 type SG motor oil (Non- Friction modified)
  • Page 189 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO OLIO MOTORE (USA et CDN) (USA und CDN) (USA e CDN) Huile recommandée: Empfohlene Ölsorte: Olio raccomandato: A 5 °C (40 °F) ou plus È Über 5 °C (40 °F) È Temperatura uguale o superiore a 5 °C (40 °F) È...
  • Page 190 INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and warm it up for several 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 191 CHANGEMENT DE L’HUILE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE CHANGEMENT DE L’HUILE MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTEUR Motor anlassen, einige MOTORE Mettre le moteur en marche, le faire Minuten lang betreiben Avviare il motore, farlo riscaldare chauffer pendant quelques minutes dann abstellen;...

  • Page 192: 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 193 CHANGEMENT DE L’HUILE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE Si le filtre à huile doit être remplacé Falls der Ölfilter beim Ölwechsel Se il filtro dell’olio va sostituito à l’occasion du changement d’huile, zu erneuern ist, folgende Bau- durante il cambio dell’olio, togliere déposer et remonter les pièces sui- teile demontieren und anschlie- e reinstallare i seguenti componenti.
  • Page 194 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 195 CONTROLE DE LA PRESSION D’HUILE/REGLAGE DE LA VIS DE RALENTI ÖLDRUCK KONTROLLIEREN/ INSP LEERLAUFGEMISCH-REGULIERSCHRAUBE EINSTELLEN CONTROLLO PRESSIONE OLIO/REGOLAZIONE VITE DEL MINIMO CONTROLE DE LA PRESSION ÖLDRUCK KONTROLLIEREN CONTROLLO PRESSIONE OLIO D’HUILE Kontrollieren: Controllare: Contrôler: • Öldruck • Pressione olio • Pression d’huile Arbeitsvorgang: Operazioni per il controllo: Etapes du contrôle:...

  • Page 196: And Side Covers

    ENGINE IDLING SPEED ADJUSTMENT/ INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: • Engine idling speed Adjustment steps: • Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section.
  • Page 197 REGLAGE DU REGIME DE RALENTI DU MOTEUR/ INSPECTION ET REGLAGE DU JEU AUX SOUPAPES LEERLAUFDREHZAHL EINSTELLEN/VENTILSPIEL KONTROLLIEREN UND EINSTELLEN INSP REGOLAZIONE REGIME DEL MINIMO/ CONTROLLO E REGOLAZIONE GIOCO VALVOLE REGLAGE DU REGIME DE LEERLAUFDREHZAHL REGOLAZIONE REGIME DEL RALENTI DU MOTEUR EINSTELLEN MINIMO Mettre le moteur en marche et bien...
  • Page 198 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 2. Remove: • Spark plug • Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 4. 3. Remove: • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 • O-ring 4. Check: •...
  • Page 199 INSPECTION ET REGLAGE DU JEU AUX SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE GIOCO VALVOLE Déposer: Demontieren: Togliere: • Bougie • Zündkerze • Candela di accensione • Couvre-culasse • Zylinderkopfdeckel • Coperchio testata reporter à section Siehe unter “NOCKENWEL- Fare riferimento al paragrafo “ARBRES A CAMES”...
  • Page 200 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT • Measure the valve clearance e using a feeler gauge 1. NOTE: Record the measured reading if the clear- ance is incorrect. 5. Adjust: • Valve clearance Adjustment steps: • Remove camshaft (intake exhaust). Refer to “CAMSHAFTS”...
  • Page 201 INSPECTION ET REGLAGE DU JEU AUX SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE GIOCO VALVOLE • Mesurer le jeu aux soupapes e à • Das Ventilspiel e mit einer • Misurare il gioco valvole e con Fühlerlehre 1 messen. uno spessimetro 1.
  • Page 202 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE: The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface. • Round off the last digit of the installed pad number to the nearest increment. Last digit of pad Rounded value number 0, 1 or 2...
  • Page 203 INSPECTION ET REGLAGE DU JEU AUX SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE GIOCO VALVOLE N.B.: HINWEIS: NOTA: L’épaisseur a de chaque plaquette Die Stärke a des Ventilplättchens Le dimensioni a di ogni spessore est indiquée en centièmes de millimè- ist in Hundertsteln von Millimetern sono indicate in centesimi di millime- auf dessen Oberseite angegeben.
  • Page 204 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 INSPECTION ET REGLAGE DU JEU AUX SOUPAPES ADMISSION NUMERO DE PLAQUETTE MONTEE 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 EINGEBAUTEN 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 INSP CONTROLLO E REGOLAZIONE GIOCO VALVOLE ASPIRAZIONE NUMERO SPESSORE INSTALLATO GIOCO MISU- RATO 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. •...

  • Page 209: Parte Ciclistica

    CHASSIS/PURGE D’AIR DU CIRCUIT DE FREINAGE INSP FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTLÜFTEN PARTE CICLISTICA/SPURGO ARIA SISTEMA FRENANTE CHASSIS FAHRWERK PARTE CICLISTICA PURGE D’AIR DU CIRCUIT DE HYDRAULISCHE BREMSANLAGE SPURGO ARIA SISTEMA ENTLÜFTEN FREINAGE FRENANTE WARNUNG AVERTISSEMENT AVVERTENZA Purger l’air du circuit de freinage si: Die Bremshydraulik in folgenden Spurgare il circuito dei freni se: Fällen entlüften:...
  • 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. Add brake fluid to the level line on the reservoir.
  • Page 211 REGLAGE DU FREIN AVANT INSP VORDERRADBREMSE EINSTELLEN REGOLAZIONE DEL FRENO ANTERIORE N.B.: HINWEIS: NOTA: Si la purge est difficile, il peut être Kann die Bremsanlage nicht zufrie- Se lo spurgo risulta difficoltoso, den stellend entlüftet werden, sollte nécessaire de laisser le circuit du potrebbe essere necessario lasciar liquide de frein se stabiliser pendant die Flüssigkeit 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: •...
  • Page 213 REGLAGE DU FREIN ARRIERE/ CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN AVANT HINTERRADBREMSE EINSTELLEN/ INSP VORDERRAD-SCHEIBENBREMSBELÄGE KONTROLLIEREN UND ERNEUERN REGOLAZIONE DEL FRENO POSTERIORE/ CONTROLLO E SOSTITUZIONE DELLA PASTIGLIA DEL FRENO ANTERIORE REGLAGE DU FREIN ARRIERE HINTERRADBREMSE REGOLAZIONE DEL FRENO Contrôler: EINSTELLEN POSTERIORE •...
  • Page 214 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT • Loosen the pad pin 2. • Remove the brake caliper 3 from the front fork. • Remove the pad pin and brake pads 4. • Connect the transparent hose 5 to the bleed screw 6 and place the suitable con- tainer under its end.
  • Page 215 CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN AVANT INSP VORDERRAD-SCHEIBENBREMSBELÄGE KONTROLLIEREN UND ERNEUERN CONTROLLO E SOSTITUZIONE DELLA PASTIGLIA DEL FRENO ANTERIORE • Den Bremsbelag-Haltestift 2 • Allentare il perno pastiglia 2. • Desserrer la goupille de plaquette • Rimuovere la pinza del freno 3 lockern.

  • Page 216: Front Wheel And Rear Wheel

    INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Install the pad pin plug 0. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4.
  • Page 217 CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN ARRIERE INSP HINTERRAD-SCHEIBENBREMSBELÄGE KONTROLLIEREN UND ERNEUERN CONTROLLO E SOSTITUZIONE DELLA PASTIGLIA DEL FRENO POSTERIORE • Die Bremsbelag-Haltestift- • Monter le bouchon de goupille de • Installare il tappo del perno pasti- plaquette 0. Abdeckung 0 montieren.
  • 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 CONTROLE ET REMPLACEMENT DES PLAQUETTES DE FREIN ARRIERE INSP HINTERRAD-SCHEIBENBREMSBELÄGE KONTROLLIEREN UND ERNEUERN CONTROLLO E SOSTITUZIONE DELLA PASTIGLIA DEL FRENO POSTERIORE • Déposer la goupille de plaquette 6 • Den Bremsbelag-Haltestift 6 • Togliere il perno pastiglia 6 e le et les plaquettes de frein 7.
  • Page 220 REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEED- ING”...
  • Page 221 CONTROLE DE L’ISOLANT DE PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN HINTERRAD-SCHEIBENBREMSBELAG-ISOLIERUNG KONTROLLIEREN/ INSP BREMSFLÜSSIGKEITSSTAND KONTROLLIEREN CONTROLLO DISPOSITIVO ISOLATORE PASTIGLIA DEL FRENO POSTERIORE/ CONTROLLO LIVELLO DEL LIQUIDO DEI FRENI Contrôler: Kontrollieren: Controllare: • Niveau du liquide de frein •...
  • 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. DRIVE CHAIN INSPECTION 1. Measure: • Drive chain length (15 links) a Out of specification →...
  • Page 223 CONTROLE DES PIGNONS/CONTROLE DE LA CHAINE DE TRANSMISSION INSP KETTENRÄDER KONTROLLIEREN/ANTRIEBSKETTE KONTROLLIEREN CONTROLLO DELLE RUOTE DENTATE/CONTROLLO CATENA DI TRASMISSIONE KETTENRÄDER CONTROLE DES PIGNONS CONTROLLO DELLE RUOTE KONTROLLIEREN Contrôler: DENTATE • Dents de pignon a Kontrollieren: Controllare: Usure excessive → Remplacer. •...
  • Page 224 INSP DRIVE CHAIN SLACK ADJUSTMENT 4. Check: • Drive chain stiffness a Clean and oil the drive chain and hold as illustrated. Stiff → Replace drive chain. 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.
  • Page 225 REGLAGE DE LA TENSION DE LA CHAINE DE TRANSMISSION INSP ANTRIEBSKETTEN-DURCHHANG EINSTELLEN REGOLAZIONE DEL GIOCO DELLA CATENA DI TRASMISSIONE Contrôler: Kontrollieren: Controllare: • Beweglichkeit a der Antriebs- • Rigidità catena di trasmissione a • Raideur de la chaîne de transmis- sion a kette Pulire e lubrificare la catena di...
  • 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 INSP TELESKOPGABEL KONTROLLIEREN CONTROLLO FORCELLA ANTERIORE Régler: Einstellen: Regolare: • Tension de la chaîne de transmis- • Antriebsketten-Durchhang • Gioco della catena di trasmis- sion sione Antriebsketten-Durchhang ein- stellen: Etapes du réglage de la tension de Operazioni per la regolazione del •...
  • 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 LA BAGUE D’ETANCHEITE ET DU JOINT ANTIPOUSSIERE DE FOURCHE/ REDUCTION DE LA PRESSION INTERNE DE LA FOURCHE/ REGLAGE DE LA FORCE D’AMORTISSEMENT A LA DETENTE DE LA FOURCHE GABEL-DICHT- UND -STAUBSCHUTZRINGE REINIGEN/GABEL-LUFTDRUCK AUSGLEICHEN/ ZUGSTUFEN-DÄMPFUNGSKRAFT DER TELESKOPGABEL EINSTELLEN INSP PULIZIA PARAOLIO E GUARNIZIONE PARAPOLVERE FORCELLA ANTERIORE/ ALLEGGERIMENTO DELLA PRESSIONE INTERNA DELLA FORCELLA ANTERIORE/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN ESTENSIONE DELLA FORCELLA ANTERIORE...
  • Page 230 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT Extent of adjustment Maximum Minimum Fully turned in 20 clicks out (from position maximum position) • 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 A LA COMPRESSION DE LA FOURCHE DRUCKSTUFEN-DÄMPFUNGSKRAFT DER TELESKOPGABEL EINSTELLEN INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN COMPRESSIONE DELLA FORCELLA ANTERIORE Einstellbereich Plage de réglage Entità della regolazione Maximum Minimum Maximal Minimal Massimo Minimo Desserrer de 20 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 CONTROLLO AMMORTIZZATORE POSTERIORE Einstellbereich Plage de réglage Entità della regolazione Maximum Minimum Maximal Minimal Massimo Minimo dévissé de 20 20. Raststel- 20 scatti verso Position complè- déclics (par rap- Vollständig lung (aus der l’esterno (a par- tement vissée port à...
  • Page 234 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2.
  • Page 235 REGLAGE DE LA PRECONTRAINTE DU RESSORT DE L’AMORTISSEUR ARRIERE INSP FEDERVORSPANNUNG DES FEDERBEINS EINSTELLEN REGOLAZIONE PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE FEDERVORSPANNUNG DES REGLAGE DE LA REGOLAZIONE PRECARICO FEDERBEINS EINSTELLEN PRECONTRAINTE DU RESSORT DELLA MOLLA DELL’AMMOR- Das Motorrad aufbocken, um DE L’AMORTISSEUR ARRIERE TIZZATORE POSTERIORE das Hinterrad vom Boden abzu- Surélever la roue arrière en plaçant...

  • Page 236: Rear Shock Absorber Rebound Damping Force Adjustment

    REAR SHOCK ABSORBER REBOUND INSP DAMPING FORCE ADJUSTMENT 5. Tighten: • Locknut 6. Install: • Rear frame 32 Nm (3.2 m · kg, 23 ft · lb) EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1.
  • Page 237 REGLAGE DE LA FORCE D’AMORTISSEMENT A LA DETENTE DE L’AMORTISSEUR ARRIERE INSP ZUGSTUFEN-DÄMPFUNGSKRAFT DES FEDERBEINS EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN ESTENSIONE DELL’AMMORTIZZATORE POSTERIORE Festziehen: Serrer: Serrare: • Sicherungsmutter • Contre-écrou • Controdado Montieren: Monter: Installare: • Rahmenheck • Cadre arrière •...
  • 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 LA COMPRESSION BASSE DE L’AMORTISSEUR ARRIERE INSP UNTERE DRUCKSTUFEN-DÄMPFUNGSKRAFT DES FEDERBEINS EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN BASSA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE DE LA FORCE UNTERE DRUCKSTUFEN- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT A LA DÄMPFUNGSKRAFT DES SMORZAMENTO IN BASSA COM- COMPRESSION BASSE DE...
  • 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 LA COMPRESSION HAUTE DE L’AMORTISSEUR ARRIERE INSP OBERE DRUCKSTUFEN-DÄMPFUNGSKRAFT DES FEDERBEINS EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN ALTA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE DE LA FORCE OBERE DRUCKSTUFEN- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT A LA DÄMPFUNGSKRAFT DES SMORZAMENTO IN ALTA COM- COMPRESSION HAUTE DE...
  • 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. •...
  • Page 243 CONTROLE DE LA PRESSION DES PNEUS/ CONTROLE ET SERRAGE DES RAYONS/CONTROLE DES ROUES REIFENLUFTDRUCK KONTROLLIEREN/ INSP SPEICHEN KONTROLLIEREN UND SPANNEN/RÄDER KONTROLLIEREN CONTROLLO PRESSIONE DEI PNEUMATICI/ CONTROLLO E SERRAGGIO DEI RAGGI/CONTROLLO DELLE RUOTE CONTROLE DE LA PRESSION DES REIFENLUFTDRUCK CONTROLLO PRESSIONE DEI PNEUS KONTROLLIEREN 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 gently rock the fork assembly back and forth.
  • Page 245 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPFLAGER KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE TESTA DELLO STERZO Contrôler: Kontrollieren: Controllare: • Jeu des roulements • Lagerspiel • Gioco cuscinetti Il y a du jeu → Remplacer. Vorhanden → Erneuern. Presenza di 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.
  • Page 247 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPFLAGER KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE TESTA DELLO STERZO • Serrer l’écrou de direction 3 à • Die Ringmutter 3 mit dem • Serrare la ghiera dello sterzo 3 Hakenschlüssel 4 festziehen. con la chiave per ghiere 4.
  • Page 248 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Steering stem nut: 145 Nm (14.5 m • kg, 105 ft • lb) Handlebar upper holder: 28 Nm (2.8 m • kg, 20 ft • lb) Pinch bolt (upper bracket): 23 Nm (2.3 m • kg, 17 ft • lb) Number plate: 7 Nm (0.7 m •...
  • Page 249 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPFLAGER KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE TESTA DELLO STERZO Ecrou de direction: Lenkkopfmutter: Dado fusto dello sterzo: 145 Nm 145 Nm 145 Nm (14,5 m • kg, 105 ft • lb) (14,5 m •...
  • Page 250 INSP LUBRICATION È LUBRICATION Use Yamaha cable lube or equivalent on these areas. To ensure smooth operation of all compo- É Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants. after break-in, and after every race.
  • Page 251 È Utiliser pour ces zones du lubrifiant È Per questi componenti, utilizzare lubrifi- È Yamaha-Seilzugschmiermittel o. Ä Yamaha pour câbles ou un lubrifiant équi- valent. cante per cavi Yamaha o un prodotto verwenden. É Utiliser de l’huile moteur SAE 10W-30 É...

  • Page 252: 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.

  • Page 253: Moteur

    PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN IMPIANTO ELETTRICO/CONTROLLO CANDELE PARTIE ELECTRIQUE ELEKTRISCHE ANLAGE IMPIANTO ELETTRICO CONTROLE DE LA BOUGIE ZÜNDKERZE KONTROLLIEREN CONTROLLO CANDELE Demontieren: Déposer: Togliere: • Bougie • Zündkerze • Candela di accensione Kontrollieren: Contrôler: Controllare: •...
  • Page 254 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 1). Timing light: YM-33277-A/90890-03141 3. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT”...
  • Page 255 CONTROLE DE L’AVANCE A L’ALLUMAGE INSP ZÜNDZEITPUNKT KONTROLLIEREN CONTROLLO ANTICIPO MINIMO CONTROLE DE L’AVANCE A ZÜNDZEITPUNKT CONTROLLO ANTICIPO MINIMO L’ALLUMAGE KONTROLLIEREN Togliere: Déposer: Demontieren: • Vite di accesso al riferimento per • Rotor-Abdeckschraube 1 fasatura 1 • Vis d’accès de repère d’allumage Fixer: Anschließen: Fissare:...
  • Page 256 SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS 1 Seat removal 2 Fuel tank removal Extent of 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 257 SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SELLA, SERBATOIO CARBURANTE E FIANCHETTI MOTEUR SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX 1 Dépose de la selle 2 Dépose du réservoir de carburant Organisation de la dépose: 3 Dépose des caches latéraux 4 Dépose de la plaque d’identification Organisation de la dépose Ordre...
  • Page 258 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 259 SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SELLA, SERBATOIO CARBURANTE E FIANCHETTI POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Cache latéral Seitenabdeckung Fianchetto Déposer: Demontieren: Togliere: • Boulon (cache latéral) • Seitenabdeckungs-Schraube • Bullone (fianchetto) • Cache latéral gauche 1 •...

  • Page 260: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 1 Silencer removal 2 Exhaust pipe removal Extent of 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 261: Tubo Di Scarico E Silenziatore

    TUBE D’ECHAPPEMENT ET SILENCIEUX AUSPUFFKRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUBE D’ECHAPPEMENT ET SILENCIEUX 1 Dépose du silencieux 2 Dépose du tube d’échappement Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU TUBE D’ECHAPPEMENT ET DU SILENCIEUX Préparation à...
  • Page 262 EXHAUST PIPE AND SILENCER INSPECTION Silencer and exhaust pipe 1. Inspect: • Gasket 1 Damage → Replace. Silencer fiber replacement 1. Remove: • Rivet (front) 1 • Inner pipe 2 CAUTION: Take care not to damage the rivet fitting holes (ø4.9 mm) a in removal. NOTE: Pull out the inner pipe while lightly tapping the stay b on the silencer using a soft hammer.
  • Page 263 TUBE D’ECHAPPEMENT ET SILENCIEUX AUSPUFFKRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE CONTROLE KONTROLLE CONTROLLO Silencieux et tube d’échappement Schalldämpfer und Auspuffkrüm- Silenziatore e tubo di scarico Contrôler: Controllare: • Joint 1 • Guarnizione 1 Kontrollieren: Endommagement → Remplacer. • Dichtung 1 Danno →...
  • Page 264 EXHAUST PIPE AND SILENCER 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 · kg, 17 ft · lb) NOTE: First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhaust pipe)
  • Page 265 TUBE D’ECHAPPEMENT ET SILENCIEUX AUSPUFFKRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Silencieux et tube d’échappement Schalldämpfer und Auspuffkrüm- Silenziatore e tubo di scarico Monter: Installare: • Joint Montieren: • Guarnizione •...

  • Page 266: Radiator

    RADIATOR EC450001 RADIATOR 1 Radiator removal Extent of 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 267 RADIATEUR KÜHLER RADIATORE RADIATEUR 1 Dépose du radiateur Organisation de la dépose: Organisation de la dépose Ordre Nom de la 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 268 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 269 RADIATEUR KÜHLER RADIATORE REMARQUES CONCERNANT LA HANDHABUNGSHINWEISE NOTA PER LA MANIPOLAZIONE MANIPULATION WARNUNG AVVERTENZA AVERTISSEMENT Der Kühlerverschlussdeckel darf Non rimuovere il coperchio del radia- niemals bei heißem Motor abge- Ne pas enlever le bouchon du radia- tore quando il motore e il radiatore teur quand le moteur et le radiateur nommen werden.
  • Page 270 RADIATOR 3. Install: • Right radiator 1 • Bolt (right radiator) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) • Radiator hose 5 3 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Install: • Left radiator 1 •...
  • Page 271 RADIATEUR KÜHLER RADIATORE Monter: Montieren: Installare: • Radiateur droit 1 • Kühler rechts 1 • Radiatore destro 1 • Boulon (radiateur droit) 2 • Schraube (Kühler rechts) 2 • Bullone (radiatore destro) 2 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m ·...

  • Page 272: 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 273 CARBURATEUR VERGASER CARBURATORE CARBURATEUR 1 Dépose du carburateur Organisation de la dépose: Organisation de la dépose Ordre Nom de la 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 274 CARBURETOR EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: 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 275 CARBURATEUR VERGASER CARBURATORE DEMONTAGE DU CARBURATEUR 1 Démontage du carburateur Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEMONTAGE DU CARBURATEUR Durit de mise à l’air du carburateur Couvercle du boîtier du levier de soupape Vis (axe du papillon) Papillon des gaz Support d’aiguille...
  • Page 276 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 - 11...
  • Page 277 CARBURATEUR VERGASER CARBURATORE Organisation de la dépose Ordre Nom de la pièce Qté Remarques Gicleur principal Gicleur d’aiguille Entretoise Gicleur de ralenti Gicleur de starter Tige de débrayage Tirer la tige de débrayage. Axe du papillon complet Ensemble levier articulé de la tige de débrayage Gicleur d’air de ralenti Plongeur de démarrage à...
  • Page 278 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 279 CARBURATEUR VERGASER CARBURATORE REMARQUES CONCERNANT LA HANDHABUNGSHINWEISE NOTA PER LA MANIPOLAZIONE MANIPULATION ACHTUNG: ATTENZIONE: ATTENTION: Die Drosselklappensensor-Schrau- Non allentare le viti (sensore posizione ben 1 dürfen nicht gelockert wer- farfalla) 1 eccetto quando occorre Ne pas desserrer les vis (capteur de position de papillon des gaz) 1 sauf den, außer wenn der Drosselklap- cambiare il sensore posizione farfalla...
  • Page 280 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 281 CARBURATEUR VERGASER CARBURATORE Contrôler: Kontrollieren: Controllare: • Gicleur principal 1 • Hauptdüse 1 • Getto del massimo 1 • Gicleur de ralenti 2 • Leerlaufdüse 2 • Getto del minimo 2 • Gicleur d’aiguille 3 • Nadeldüse 3 • Getto a spillo 3 •...
  • Page 282 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 283 CARBURATEUR VERGASER CARBURATORE Hauteur du flotteur Schwimmerstand Altezza galleggiante Mesurer: Messen: Misurare: • Hauteur du flotteur a • Schwimmerstand a • Altezza galleggiante a Hors spécifications → Régler. Nicht nach Vorgabe → Einstel- Non conforme alle specifiche → len. Regolare. Hauteur du flotteur: 8,0 mm (0,31 in) Schwimmerstand:...
  • Page 284 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 •...
  • Page 285 CARBURATEUR VERGASER CARBURATORE Plongeur de starter Chokeschieber Pistoncino starter Contrôler: Kontrollieren: Controllare: • Plongeur de démarrage à froid 1 • Chokeschieber 1 • Pistoncino starter per partenze a • Warmstartkolben 2 freddo 1 • Plongeur de démarrage à chaud Verschlissen/beschädigt → •...
  • Page 286 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.
  • Page 287 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: Installare: • Ressort 1 1 • Feder 1 1 • Molla 1 1 • Levier 1 2 • Hebel 1 2 • Leva 1 2 Sur le levier 2 3. (am Hebel 2 3) Sulla leva 2 3. N.B.: HINWEIS: NOTA:...
  • Page 288 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 289 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: Installare: • Axe du papillon complet 1 • Drosselklappenwelle 1 • Gruppo albero farfalla 1 • Rondelle (métallique) 2 • Metall-Beilagscheibe 2 • Rondella (metallica) 2 • Rondelle (résine) 3 • Kunstharz-Beilagscheibe 3 • Rondella (di resina) 3 •...
  • Page 290 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 •...
  • Page 291 CARBURATEUR VERGASER CARBURATORE 11. Monter: 11. Montieren: 11. Installare: • Pointeau 1 • Nadelventil 1 • Valvola a spillo 1 • Flotteur 2 • Schwimmer 2 • Galleggiante 2 • Axe de flotteur 3 • Schwimmerachse 3 • Perno galleggiante 3 N.B.: HINWEIS: NOTA:...
  • Page 292 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 293 CARBURATEUR VERGASER CARBURATORE 15. Monter: 15. Montieren: 15. Installare: • Aiguille 1 • Düsennadel 1 • Spillo del getto 1 • Entretoise épaulée 2 • Distanzhülse 2 • Collarino 2 • Ressort 3 • Feder 3 • Molla 3 • Support d’aiguille 4 •...
  • Page 294 CARBURETOR Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 0.8 mm (0.031 in) * 0.7 mm (0.028 in)
  • Page 295 CARBURATEUR VERGASER CARBURATORE Réglage du calage de la pompe de Beschleunigungspumpen-Steue- Regolazione della fasatura della reprise rung einstellen pompa acceleratore Etapes du réglage: Arbeitsvorgang: Operazioni per la regolazione: HINWEIS: N.B.: NOTA: Um die vorgeschriebene Drossel- Afin de donner au papillon la hauteur Affinché...
  • Page 296 CARBURETOR 3. Install: • Hot starter plunger 1 2 Nm (0.2 m · kg, 1.4 ft · lb) 4. Tighten: • Bolt (air filter joint) 1 3 Nm (0.3 m · kg, 2.2 ft · lb) • Bolt (carburetor joint) 2 3 Nm (0.3 m ·...
  • Page 297 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: Installare: • Warmstartkolben 1 • Plongeur de démarrage à chaud • Pistoncino starter per partenze a caldo 1 2 Nm (0,2 m · kg, 1,4 ft · lb) 2 Nm (0,2 m · kg, 1,4 ft · lb) 2 Nm (0,2 m ·...

  • Page 298: Camshafts

    CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 1 Cylinder head cover removal Extent of 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. Spark plug Cylinder head breather hose Bolt (cylinder head cover)

  • Page 299: Arbres A Cames

    ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME ARBRES A CAMES COUVRE-CULASSE 1 Dépose du couvre-culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU COUVRE-CULASSE Préparation à la dépose Selle et réservoir de carburant Se reporter à...
  • Page 300 CAMSHAFTS CAMSHAFTS 1 Camshaft removal Extent of 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 301 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME ARBRES A CAMES 1 Dépose des arbres à cames Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DES ARBRES A CAMES Vis d’accès de repère d’allumage Vis d’accès axiale du vilebrequin Boulon capuchon du tendeur de chaîne de dis- tribution...
  • Page 302 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 303 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Arbre à cames Nockenwelle Albero a camme Déposer: Demontieren: Togliere: • Rotor-Abdeckschraube 1 • Vis d’accès de repère d’allumage • Vite di accesso al riferimento per fasatura 1 •...
  • Page 304 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: •...
  • Page 305 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME Déposer: Demontieren: Togliere: • Arbre à cames d’échappement 1 • Auslass-Nockenwelle 1 • Albero a camme di scarico 1 • Arbre à cames d’admission 2 • Einlass-Nockenwelle 2 • Albero a camme di aspirazione HINWEIS: N.B.: Attacher un fil 3 à...
  • Page 306 CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head. 1 onto the ®...
  • Page 307 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME Mesurer: Messen: Misurare: • Jeu arbre à cames-chapeau • Nockenwellen-Lagerspiel • Gioco tra albero a camme e cap- Hors spécifications → Mesurer le Nicht nach Vorgabe → Nokken- pello Non conforme alle specifiche → diamètre extérieur de l’arbre à...

  • Page 308: Assembly And Installation Camshaft

    CAMSHAFTS Decompression system 1. Check: • Decompression system Checking steps: • Check that the decompression mecha- nism cam 1 moves smoothly. • Check that the decompression mecha- nism cam lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: •...
  • Page 309 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME Décompresseur Dekompressionssystem Sistema di decompressione Contrôler: Kontrollieren: Controllare: • Décompresseur • Dekompressionssystem • Sistema di decompressione Arbeitsvorgang: Etapes du contrôle: Operazioni per il controllo: • Contrôler que la came du décom- • Sicherstellen, dass die Nocke •...
  • Page 310 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 311 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME • Monter la chaîne de distribution 3 • Die Steuerkette 3 an den Nok- • Montare la catena di distribuzione 3 su entrambe le ruote dentate kenwellenrädern anbringen und sur les deux pignons d’arbre à cames et monter les arbres à...
  • Page 312 CAMSHAFTS • With the rod fully wound and the chain ten- sioner UP mark a facing upward, install the gasket 1 and the timing chain ten- sioner 2, and tighten the bolt 3 to the specified torque. Bolt (timing chain tensioner): 10 Nm (1.0 m •...
  • Page 313 ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME • Den Steuerkettenspanner 2 • La tige étant complètement enrou- • Con l’asta completamente ruotata e (samt Dichtung 1) mit vollstän- lée et le repère UP a du tendeur il riferimento UP del tenditore della catena a rivolto verso l’alto, étant orienté...
  • Page 314 • Cylinder head cover 3 • Bolt (cylinder head cover) 4 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the sealant on the cylinder head cover gasket. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 7. Install: •...
  • Page 315 10 Nm (1,0 m · kg, 7,2 ft · lb) N.B.: Appliquer le produit d’étanchéité sur le HINWEIS: NOTA: joint de couvre-culasse. Dichtmasse auf die Zylinderkopfde- Applicare il sigillante sulla guarnizione ckel-Dichtung auftragen. del coperchio testata. YAMAHA Bond N°1215 ® (ThreeBond N°1215): YAMAHA-Dichtmasse Sigillante YAMAHA 90890-85505 Nr.1215 N.1215 ®...
  • Page 316 CYLINDER HEAD CYLINDER HEAD 1 Cylinder head removal Extent of 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 317 CULASSE ZYLINDERKOPF TESTATA CULASSE 1 Dépose de la culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DE LA CULASSE Préparation à la dépose Selle et réservoir de carburant Se reporter à la section “SELLE, RESERVOIR DE CAR- BURANT ET CACHES LATERAUX”.
  • Page 318 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 damag- ing or scratching: • Spark plug threads • Valve seats 2. Inspect: •...
  • Page 319 CULASSE ZYLINDERKOPF TESTATA CONTROLE KONTROLLE CONTROLLO Culasse Zylinderkopf Testata Eliminer: Entfernen: Eliminare: • Dépôts de calamine (des cham- • Kohleablagerungen (im Brenn- • Depositi carboniosi (dalle camere bres de combustion) raum) di combustione) Utiliser un grattoir arrondi. Einen abgerundeten Schaber Utilizzare un raschietto arroton- verwenden.
  • Page 320 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 321 CULASSE ZYLINDERKOPF TESTATA ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Culasse Zylinderkopf Testata Monter: Montieren: Installare: • Goujon 1 • Passhülse 1 • Grano di centraggio 1 • Joint de culasse 2 • Guarnizione testata 2 • Zylinderkopfdeckel-Dichtung •...

  • Page 322: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS 1 Valve removal Extent of 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 323: Soupapes Et Ressorts De Soupapes

    SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE SOUPAPES ET RESSORTS DE SOUPAPES 1 Dépose de la soupape Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DES SOUPAPES ET RESSORTS DE SOUPAPES Préparation à...
  • Page 324 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.
  • Page 325 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Poussoir de soupape et clavette de sou- Tassenstößel und Ventilkeil Alzavalvola e semicono della valvola pape Demontieren: Togliere: • Tassenstößel 1 •...
  • Page 326 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 327 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE CONTROLE KONTROLLE CONTROLLO Soupape Ventil Valvola Mesurer: Messen: Misurare: • Jeu queue-guide • Ventilschaft-Spiel • Gioco tra stelo e guida Jeu queue-guide = Ventilschaft-Spiel = Gioco tra stelo e guida = diamètre intérieur du guide de Ventilführungs-Innendurch- Diametro interno guidavalvola...
  • Page 328 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 329 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Outil de dépose de guide de Ventilführungs-Austrei- Estrattore per guidavalvole: soupape: ber: Aspirazione: Admission: Einlass: 4,0 mm (0,16 in) 4,0 mm (0,16 in) 4,0 mm (0,16 in) YM-4111/90890-04111 YM-4111/90890-04111 YM-4111/90890-04111 Scarico:...
  • Page 330 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.
  • Page 331 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Mesurer: Messen: Misurare: • Faux-rond (queue de soupape) • Ventilschaft-Schlag • Disassamento (stelo della val- Hors spécifications → Rempla- Nicht nach Vorgabe → Erneu- vola) Non conforme alle specifiche → cer.
  • Page 332 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 333 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Roder: Einschleifen: Lappare: • Portée de soupape • Ventilkegel • Faccia della valvola • Siège de soupape • Ventilsitz • Sede della valvola HINWEIS: N.B.: NOTA: Après rectification du siège de soupape Nach dem Einschleifen des Ventilsit- Dopo aver rettificato la sede della val- zes sowie nach der Erneuerung des...
  • Page 334 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 335 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Ressort de soupape Ventilfeder Molla valvola Mesurer: Messen: Misurare: • Länge a der ungespannten • Longueur libre du ressort de sou- • Lunghezza libera molla della val- pape a vola a Ventilfeder Hors spécifications →...
  • Page 336 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 •...
  • Page 337 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Soupape et ressort de soupape Ventil und Ventilfeder Valvola e molla della valvola Appliquer: Auftragen: Applicare: • Huile au bisulfure de molybdène •...
  • Page 338 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.
  • Page 339 SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Monter: Montieren: Installare: • Cale de réglage 1 • Ventilplättchen 1 • Spessore di regolazione 1 • Poussoir de soupape 2 • Tassenstößel 2 • Alzavalvola 2 HINWEIS: N.B.: NOTA: •...

  • Page 340: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON 1 Cylinder removal 2 Piston removal Extent of 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 341: 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 la pièce Qté Remarques DEPOSE DES CYLINDRES ET DES PIS- TONS Préparation à...
  • Page 342 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.
  • Page 343 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Piston et segment Kolben und Kolbenringe Pistone e fascia elastica del pistone Déposer: Demontieren: Togliere: • Agrafe d’axe de piston 1 • Fermo spinotto 1 •...
  • Page 344 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 345: Cilindro E Pistone

    CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE 77,00–77,01 mm Alésage de cylin- 77,00 à 77,01 mm Foro del cilindro 77,00 ~ 77,01 mm Zylinderboh- (3,0315– dre “C” (3,0315 à 3,0319 in) “C” (3,0315 ~ 3,0319 in) rung “C” 3,0319 in) Limite de coni- Limite di conicità...
  • Page 346 CYLINDER AND PISTON Piston ring 1. Measure: • Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston 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 347 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Segment de piston Kolbenringe Fascia elastica del pistone Mesurer: Messen: Misurare: • Jeu latéral du segment • Ringnutspiel • Gioco laterale della fascia Eine Fühlerlehre 1 verwen- Utilizzare uno spessimetro 1. Utiliser une jauge d’épaisseur à...
  • Page 348 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.
  • Page 349 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Axe de piston Kolbenbolzen Spinotto Contrôler: Kontrollieren: Controllare: • Axe de piston • Kolbenbolzen • Spinotto Décoloration bleue/rainures → Blaubrüchig/riefig → Kolben- Macchia blu/scanalature → Sosti- Remplacer, puis contrôler le sys- bolzen erneuern und Schmier- tuire, quindi controllare il sistema tème de lubrification.
  • Page 350 CYLINDER AND PISTON 2. Position: • Top ring • 2nd ring • Oil ring Offset the piston ring end gaps as shown. Top ring end 2nd ring end Oil ring end (upper) Oil ring Oil ring end (lower) 3. Install: •...
  • Page 351 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Position: Anordnen: Posizione: • Segment de feu • 1. Kompressionsring (Topring) • Fascia superiore • Segment d’étanchéité • 2. Kompressionsring • seconda fascia • Segment racleur d’huile • Ölabstreifring • Fascia raschiaolio Excentrer les coupes des seg- Die Ringspalte, wie in der Sfalsare le luci fra le estremità...
  • Page 352 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. •...
  • Page 353 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Monter: Montieren: Installare: • Joint de cylindre 1 • Zylinder-Dichtung 1 • Guarnizione cilindro 1 • Cylindre 2 • Zylinder 2 • Cilindro 2 HINWEIS: N.B.: NOTA: Monter le cylindre avec une main, tout Den Zylinder mit einer Hand ein- Installare il cilindro con una mano com- bauen, mit der anderen Hand die...

  • Page 354: Clutch

    CLUTCH EC4A0000 CLUTCH 1 Push rod 1, 2 and push lever shaft removal 2 Push rod 1 disassembly Extent of removal: 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 355 EMBRAYAGE KUPPLUNG FRIZIONE EMBRAYAGE 1 Dépose de la tige de débrayage 1, 2 et de l’arbre de tige de poussée 2 Démontage de la tige de débrayage 1 Organisation de la dépose: 3 Dépose du disque garni et du plateau de pression 4 Dépose du pignon mené...
  • Page 356 CLUTCH Extent of removal Order Part name Q’ty Remarks Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Use special tool. Lock washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - 51...
  • Page 357 EMBRAYAGE KUPPLUNG FRIZIONE Organisation de la dépose Ordre Nom de la pièce Qté Remarques Disque garni Plateau de pression Plaquette de progressivité Plaque de siège Ecrou (noix d’embrayage) Utiliser l’outil spécial. Rondelle-frein Se reporter à “POINTS DE DEPOSE”. Noix d’embrayage Rondelle de butée Pignon mené...
  • Page 358 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. È É Clutch holding tool: YM-91042/90890-04086 È...
  • Page 359 EMBRAYAGE KUPPLUNG FRIZIONE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Noix d’embrayage Kupplungsnabe Mozzo frizione Déposer: Demontieren: Togliere: • Ecrou 1 • Mutter 1 • Dado 1 • Rondelle-frein 2 • Sicherungsscheibe 2 • Rondella di bloccaggio 2 • Noix d’embrayage 3 •...
  • Page 360 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 361 EMBRAYAGE KUPPLUNG FRIZIONE Disque garni Reibscheibe Disco conduttore Mesurer: Messen: Misurare: • Epaisseur du disque garni • Reibscheiben-Stärke • Spessore del disco conduttore Hors spécifications → Remplacer Nicht nach Vorgabe → Reib- Non conforme alle specifiche → le disque garni complet. scheiben satzweise erneuern.
  • Page 362 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.
  • Page 363 EMBRAYAGE KUPPLUNG FRIZIONE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Arbre de tige de poussée Kupplungsausrückwelle Albero leva di aggancio Monter: Montieren: Installare: • Arbre de tige de poussée 1 • Kupplungsausrückwelle 1 • Albero leva di aggancio 1 •...
  • Page 364 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 365 EMBRAYAGE KUPPLUNG FRIZIONE Die Lasche 1 der Sicherungs- Replier l’onglet de la rondelle-frein Piegare la linguetta della rondella di bloccaggio 1. scheibe umbiegen. Monter: Installare: • Plaque de siège 1 • Piastra della sella 1 Montieren: • Plaquette de progressivité 2 •...
  • Page 366 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 •...
  • Page 367 EMBRAYAGE KUPPLUNG FRIZIONE Monter: Montieren: Installare: • Tige de débrayage 2 1 • Druckstange 2 1 • Asta di blocco 2 1 • Bille 2 • Kugel 2 • Sfera 2 • Tige de débrayage 1 3 • Druckstange 1 3 •...

  • Page 368: 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 1 Oil filter element removal 2 Water pump removal Extent of removal: 3 Right crankcase cover removal Extent of removal Order Part name Q’ty Remarks OIL FILTER ELEMENT, WATER...
  • Page 369 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT 1 Dépose de l’élément de filtre à...
  • Page 370 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 - 58...
  • Page 371 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Organisation de la dépose Ordre Nom de la pièce Qté Remarques Carter de pompe à eau Tuyau d’amenée d’huile Boulon (durit d’huile) Pédale de kick...
  • Page 372 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 373 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO DEMONTAGE-EINZELHEITEN POINTS DE DEPOSE PUNTI DI RIMOZIONE Laufradwelle Axe de pompe Albero rotore Demontieren: Déposer: Togliere:...
  • Page 374 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.
  • Page 375 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Laufradwelle Axe de pompe Albero rotore Kontrollieren: Contrôler: Controllare: • Axe de pompe 1 •...
  • Page 376 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: •...
  • Page 377 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Montieren: Monter: Installare: • Roulement 1 • Lager 1 • Cuscinetto 1 HINWEIS: N.B.: NOTA: Monter le roulement en appuyant paral-...
  • Page 378 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.
  • Page 379 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Montieren: Monter: Installare: • Couvercle de carter droit 1 • Kurbelgehäusedeckel rechts 1 •...
  • Page 380 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 381 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT ÖLFILTER, WASSERPUMPE UND KURBELGEHÄUSEDECKEL RECHTS ELEMENTO FILTRO OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Wasserpumpengehäuse Carter de pompe à eau Alloggiamento della pompa dell’acqua Montieren: Monter: Installare: •...

  • Page 382: Balancer

    BALANCER BALANCER 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal: 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 383 BALANCIER AUSGLEICHSWELLE EQUILIBRATORE BALANCIER 1 Pignon menant d’arbre de balancier 2 Arbre de balancier Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU BALANCIER Préparation à la dépose Pignon mené de transmission primaire Se reporter à...
  • Page 384 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 385 BALANCIER AUSGLEICHSWELLE EQUILIBRATORE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Pignon menant et pignon mené de Ausgleichswellen-Antriebsritzel Ingranaggi conduttore e condotto l’arbre de balancier und -rad dell’albero equilibratore Redresser l’onglet de la rondelle- Die Lasche der Sicherungs- Spianare la linguetta della rondella frein.
  • Page 386 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 387 BALANCIER AUSGLEICHSWELLE EQUILIBRATORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Arbre de balancier, pignon menant et Ausgleichswelle, Ausgleichswel- Albero equilibratore, ingranaggio pignon mené de l’arbre de balancier len-Antriebsritzel und -rad conduttore e condotto dell’albero Monter: Montieren: equilibratore • Arbre de balancier 1 •...

  • Page 388: Oil Pump

    OIL PUMP OIL PUMP 1 Oil pump removal 2 Oil pump disassembly Extent of removal: 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 389: Pompe A Huile

    POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO POMPE A HUILE 1 Dépose de la pompe à huile 2 Démontage de la pompe à huile Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE ET DEMONTAGE DE LA POMPE A HUILE Préparation à...
  • Page 390 OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 4 - 68...
  • Page 391 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Organisation de la dépose Ordre Nom de la pièce Qté Remarques Goujon Rondelle Arbre d’entraînement de pompe à huile Boîtier du rotor Reihen- Arbeitsumfang Bauteil Anz. Bemerkungen folge Passhülse Beilagscheibe Ölpumpen-Antriebswelle Rotorgehäuse Estensione della rimozione Ordine Denominazione Quantità...
  • Page 392 OIL PUMP OIL TANK 1 Oil tank Extent of removal: Extent of removal Order Part name Q’ty Remarks OIL TANK REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose...
  • Page 393 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO RÉSERVOIR D’HUILE 1 Réservoir d’huile Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DÉPOSE DU RÉSERVOIR D’HUILE Préparation à la dépose Vidanger l’huile moteur. Se reporter à la section “CHANGEMENT DE L’HUILE MOTEUR”...
  • Page 394 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) •...
  • Page 395 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO CONTROLE KONTROLLE CONTROLLO Pompe à huile Ölpumpe Pompa dell’olio Contrôler: Kontrollieren: Controllare: • Ölpumpen-Antriebsritzel 1 • Pignon menant de pompe à huile • Ingranaggio conduttore della • Ölpumpen-Antriebswelle 2 pompa olio 1 • Rotorgehäuse 3 •...
  • Page 396 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. •...
  • Page 397 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Pompe à huile Ölpumpe Pompa dell’olio Monter: Montieren: Installare: • Ölpumpen-Antriebswelle 1 • Arbre d’entraînement de pompe à • Albero di comando della pompa huile 1 •...
  • Page 398 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) •...
  • Page 399 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Monter: Montieren: Installare: • Rotor externe 2 1 • Außenrotor 2 1 • Rotore esterno 2 1 • Goujon 2 • Passhülse 2 • Grano di centraggio 2 • Pompe à huile complète 3 •...

  • Page 400: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT 1 Kick shaft removal 2 Kick shaft disassembly Extent of removal: 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 401: Arbre De Kick Et Axe De Selecteur

    ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO ARBRE DE KICK ET AXE DE SELECTEUR 1 Dépose de l’arbre de kick 2 Démontage de l’arbre de kick. Organisation de la dépose: 3 Dépose de l’axe de sélecteur 4 Dépose des segments Organisation de la dépose Ordre...
  • Page 402 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 - 74...

  • Page 403: Albero Pedale E Albero Del Cambio

    ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Organisation de la dépose Ordre Nom de la pièce Qté Remarques Ressort de torsion Rouleau Guide de sélecteur Se reporter à “POINTS DE DEPOSE”. Levier de sélecteur complet Levier de sélecteur Cliquet...
  • Page 404 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) •...
  • Page 405 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Arbre de kick complet Kickhebelwelle Gruppo albero pedale Déposer: Demontieren: Togliere: • Arbre de kick complet 1 •...
  • Page 406 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 •...
  • Page 407 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Axe de sélecteur Schaltwelle Albero del cambio Contrôler: Kontrollieren: Controllare: • Axe de sélecteur 1 • Schaltwelle 1 • Albero del cambio 1 Déformation/endommagement → Verbogen/beschädigt →...
  • Page 408 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 409 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Doigt de verrouillage Rastenhebel Leva di arresto Monter: Montieren: Installare: • Ressort de torsion 1 • Torsionsfeder 1 • Molla di torsione 1 • Doigt de verrouillage 2 •...
  • Page 410 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 •...
  • Page 411 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Axe de sélecteur Schaltwelle Albero del cambio Monter: Montieren: Installare: • Rouleau 1 • Rolle 1 • Rullo 1 • Entretoise épaulée 2 • Distanzhülse 2 •...
  • Page 412 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 •...
  • Page 413 ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Monter: Montieren: Installare: • Guide de ressort 1 • Federführung 1 • Guida molla 1 N.B.: HINWEIS: NOTA: Beim Montieren der Federführung an Glisser le guide de ressort dans l’arbre Far scorrere la guida della molla de kick en veillant à...

  • Page 414: Cdi Magneto

    CDI MAGNETO EC4L0000 CDI MAGNETO 1 CDI magneto removal Extent of 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. Disconnect the CDI magneto lead.

  • Page 415: Volant Magnetique Cdi

    VOLANT MAGNETIQUE CDI LICHTMASCHINE MAGNETE CDI VOLANT MAGNETIQUE CDI 1 Dépose du volant magnétique CDI Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU VOLANT MAGNETIQUE Préparation à la dépose Selle et réservoir de carburant Se reporter à...
  • Page 416 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 417 VOLANT MAGNETIQUE CDI LICHTMASCHINE MAGNETE CDI POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Rotor Rotor Rotore Déposer: Demontieren: Togliere: • Ecrou (rotor) 1 • Rotor-Mutter 1 • Dado (rotore) 1 • Rondelle 2 • Beilagscheibe 2 • Rondella 2 Den Rotorhalter 3 verwen- Utiliser l’outil de maintien du Utilizzare l’attrezzo di bloccaggio rotor 3.
  • Page 418 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply the sealant on the grommet of the CDI magneto lead. • Tighten the screws using the T30 bit. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 2.
  • Page 419 CDI. • Die Schrauben mit einem T30-Ein- • Serrare le viti con un attrezzo con satz festziehen. • Serrer les vis à l’aide de la mèche T30. punta T30. YAMAHA Bond N°1215 YAMAHA-Dichtmasse Sigillante YAMAHA ® (ThreeBond N°1215): Nr.1215 N.1215...
  • Page 420 CDI MAGNETO 4. Connect: • CDI magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 5. Install: • Dowel pin • Gasket (left crankcase cover) • Left crankcase cover 1 • Hose guide (cylinder head breather hose) •...
  • Page 421 VOLANT MAGNETIQUE CDI LICHTMASCHINE MAGNETE CDI Connecter: Anschließen: Collegare: • Fil du volant magnétique CDI • Lichtmaschinen-Kabel • Cavo magnete CDI Se reporter à la section “DIA- Siehe unter “KABELFÜH- Fare riferimento al paragrafo GRAMME D’ACHEMINE- RUNGSDIAGRAMME” “SCHEMA PERCORSO MENT CABLES”...

  • Page 422: 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 423: Depose Du Moteur

    DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU MOTEUR Préparation à la dépose Caler la moto en plaçant un support adéquat AVERTISSEMENT sous le cadre. Bien caler la moto afin qu’elle ne risque pas de bascu- ler.
  • Page 424 ENGINE REMOVAL 1 Engine removal Extent of 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 Drive chain sprocket cover Nut (drive sprocket) Lock washer Refer to “REMOVAL POINTS”.
  • Page 425 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE 1 Dépose du moteur Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques Bobine d’allumage Déconnecter le fil du volant magnétique CDI. Protège-carter droit Protège-carter inférieur Contacteur de point mort Couvercle de pignon de chaîne de transmission Ecrou (couronne arrière)
  • Page 426 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 •...

  • Page 427: Rimozione Del Motore

    DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Couronne arrière Antriebsritzel Ruota dentata di trasmissione Déposer: Demontieren: Togliere: • Ecrou (couronne arrière) 1 • Antriebsritzel-Mutter 1 • Dado (ruota dentata di trasmis- • Rondelle-frein 2 •...
  • Page 428 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 53 Nm (5.3 m · kg, 38 ft · lb) •...
  • Page 429 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Montage du moteur Motor montieren Installazione del motore Monter: Montieren: Installare: • Moteur 1 • Motor 1 • Motore 1 Monter le moteur par le côté Den Motor von der rechten Installare il motore dal lato droit.
  • Page 430 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 431 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE Monter: Montieren: Installare: • Rondelle-frein 1 • Sicherungsscheibe 1 • Rondella di bloccaggio 1 • Ecrou (couronne arrière) 2 • Antriebsritzel-Mutter 2 • Dado (ruota dentata di trasmis- sione) 2 75 Nm (7,5 m · kg, 54 ft · lb) 75 Nm (7,5 m ·...

  • Page 432: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 1 Crankcase separation 2 Crankshaft removal Extent of 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 433: Carter Moteur Et Vilebrequin

    CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE CARTER MOTEUR ET VILEBREQUIN 1 Séparation du carter moteur 2 Dépose du vilebrequin Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU CARTER MOTEUR ET DU VILEBREQUIN Préparation à...
  • Page 434 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 435 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Organisation de la dépose Ordre Nom de la 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 436: Transmission, Shift Cam And Shift Fork

    CRANKCASE AND CRANKSHAFT CRANKCASE BEARING 1 Crankcase bearing removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. Shift cam and shift fork Oil seal Bearing Refer to “REMOVAL POINTS”.
  • Page 437 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ROULEMENT DE CARTER MOTEUR 1 Dépose du roulement de carter moteur Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU ROULEMENT DE CARTER MOTEUR Préparation à...
  • Page 438 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 439 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Carter moteur Kurbelgehäuse Carter Séparer: Trennen: Separare: • Carter moteur droit • Kurbelgehäuseteil rechts • Carter destro • Carter moteur gauche • Kurbelgehäuseteil links •...
  • Page 440 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 441 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Vilebrequin Kurbelwelle Albero motore Déposer: Demontieren: Togliere: • Vilebrequin 1 • Kurbelwelle 1 • Albero motore 1 Utiliser l’outil de séparation de Kurbelgehäuse-Trenn- Utilizzare il separatore per il car- carter 2.
  • Page 442 CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge.
  • Page 443 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Vilebrequin Kurbelwelle Albero motore Mesurer: Messen: Misurare: • Limite de faux-rond a • Schlag a • Limite di disassamento a • Limite de jeu de pied de bielle b •...
  • Page 444 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) •...
  • Page 445 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Roulement de carter moteur Kurbelgehäuse-Lager Cuscinetto del carter Monter: Montieren: Installare: • Roulement • Lager • Cuscinetto • Butoir de roulement •...
  • Page 446 • Oil strainer 1 • Bolt (oil strainer) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: • Sealant On the right crankcase 1. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant.
  • Page 447 10 Nm (1,0 m · kg, 7,2 ft · lb) Appliquer: Auftragen: Applicare: • Dichtmasse • Pâte d’étanchéité • Sigillante Sur le carter moteur droit 1. Sul carter destro 1. (auf Kurbelgehäuseteil rechts YAMAHA Bond N°1215 Sigillante YAMAHA ® (ThreeBond N°1215) N.1215 YAMAHA-Dichtmasse ® 90890-85505 (ThreeBond N.1215)
  • Page 448 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.
  • Page 449 CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Serrer: Festziehen: Serrare: • Guide de durit 1 • Schlauchführung 1 • Guida flessibile 1 • Support du câble d’embrayage 2 • Kupplungszug-Halterung 2 • Supporto cavo frizione 2 •...
  • Page 450 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Shift fork, shift cam, main axle and drive axle removal Extent of 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 451 BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION 1 Dépose des fourchettes de sélection, du tambour, de l’arbre primaire et de l’arbre secondaire Organisation de la dépose: Organisation de la dépose Ordre...
  • Page 452 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.
  • Page 453 BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Boîte de vitesses Getriebe Trasmissione Déposer: Demontieren: Togliere: • Arbre primaire 1 • Eingangswelle 1 •...
  • Page 454 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 →...
  • Page 455 BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Fourchette de sélection, tambour et Schaltgabeln, Schaltwalze und Forcella del cambio, camma del cam- segment Stiftplatte bio e segmento Contrôler: Kontrollieren: Controllare: •...
  • Page 456 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.
  • Page 457 BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Monter: Montieren: Installare: • Pignon de 2ème (28T) 1 • Zahnrad 2. Gang (28T) 1 • 2° Ingranaggio della ruota (28T) 1 •...
  • Page 458 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 459 BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Monter: Montieren: Installare: • Fourchette de sélection 1 (G) 1 • Schaltgabel 1 (L) 1 • Forcella del cambio 1 (S) 1 •...
  • Page 460 CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 1 Front wheel removal 2 Wheel bearing removal Extent of removal: 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL WARNING Preparation for removal...

  • Page 461: Roue Avant Et Roue Arriere

    ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE CHASSIS ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de la pièce...
  • Page 462 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 1 Rear wheel removal 2 Wheel bearing removal Extent of 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 suitable stand under the engine.
  • Page 463 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE ROUE ARRIERE 1 Dépose de la roue arrière 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de la pièce Qté...
  • Page 464 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 465 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Roue arrière Hinterrad Ruota posteriore Déposer: Demontieren: Togliere: • Roue 1 • Rad 1 • Ruota 1 N.B.: HINWEIS: NOTA: Das Hinterrad nach vorn drücken Pousser la roue vers l’avant et déposer la Spingere la ruota in avanti e togliere la...
  • Page 466 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 467 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE Axe de roue Radachse Asse della ruota Mesurer: Messen: Misurare: • Déformations de l’axe de roue • Radachs-Verbiegung • Deformazioni dell’asse della Hors spécifications → Rempla- Nicht nach Vorgabe → Erneu- ruota Non conforme alle specifiche →...
  • Page 468 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. •...
  • Page 469 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Roue avant Vorderrad Ruota anteriore Monter: Montieren: Installare: • Roulement (gauche) 1 • Lager (links) 1 • Cuscinetto (sinistro) 1 •...
  • Page 470 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.
  • Page 471 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Axe de roue 1 • Radachse 1 • Asse della ruota 1 N.B.: HINWEIS: NOTA: Die Radachse mit Lithiumseifenfett Appliquer de la graisse à savon de Applicare il grasso a base di sapone di lithium sur l’axe de roue.
  • Page 472 CHAS FRONT WHEEL AND REAR WHEEL Rear wheel 1. Install: • Bearing (right) 1 • Circlip 2 • Spacer 3 • Bearing (left) 4 • Oil seal 5 NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. •...
  • Page 473 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE Roue arrière Hinterrad Ruota posteriore Monter: Montieren: Installare: • Roulement (droit) 1 • Lager (rechts) 1 • Cuscinetto (destro) 1 • Circlip 2 • Sicherungsring 2 • Anello elastico di sicurezza •...
  • Page 474 CHAS FRONT WHEEL AND REAR WHEEL 4. Install: • Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: • Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 6. Install: •...
  • Page 475 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Entretoise épaulée 1 • Distanzhülse 1 • Collarino 1 N.B.: HINWEIS: NOTA: Die Dichtringlippen mit Lithiumsei- Appliquer de la graisse à savon de Applicare il grasso a base di sapone di lithium sur la lèvre de la bague d’étan- fenfett bestreichen.
  • Page 476 CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: • Drive chain slack a Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) Refer “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 10. Tighten: • Nut (wheel axle) 1 125 Nm (12.5 m ·...
  • Page 477 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E POSTERIORE Régler: Einstellen: Regolare: • Antriebsketten-Durchhang a • Tension de la chaîne de transmis- • Gioco della catena di trasmis- sion a sione a Antriebsketten-Durch- hang: Tension de la chaîne de Gioco della catena di tra- 48–58 mm (1,9–2,3 in) transmission:...

  • Page 478: Front Brake And Rear Brake

    CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 1 Brake hose removal 2 Brake caliper removal Extent of 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 479: Frein Avant Et Frein Arriere

    FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose de la durit 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 la pièce...
  • Page 480 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 1 Brake master cylinder removal 2 Brake hose removal Extent of 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 suitable stand under the engine.
  • Page 481 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE FREIN ARRIERE 1 Dépose du maître-cylindre de frein 2 Dépose de la durit de frein Organisation de la dépose: 3 Dépose de l’étrier de frein Organisation de la dépose Ordre Nom de la pièce Qté...
  • Page 482 CHAS FRONT BRAKE AND REAR BRAKE BRAKE CALIPER DISASSEMBLY È Front É Rear 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM- Pad pin Brake pad Pad support Brake caliper piston Dust seal...
  • Page 483 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DE L’ETRIER DE FREIN È Avant É Arrière 1 Démontage de l’étrier de frein avant 2 Démontage de l’étrier de frein arrière Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce...
  • Page 484 CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY È Front É Rear 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm...
  • Page 485 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE DE FREIN È Avant É Arrière 1 Démontage du maître-cylindre de frein avant 2 Démontage du maître-cylindre de frein arrière Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce...
  • Page 486 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 È 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. É È Front É Rear 2.
  • Page 487 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit Liquido dei freni Déposer: Demontieren: Togliere: [Avant] [Vorn] [Anteriore] • Vorratsbehälter-Deckel 1 • Coperchio pompa del freno 1 •...
  • Page 488 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit È 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 É...
  • Page 489 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Kit de joint de piston d’étrier de frein Bremskolben-Dichtringe Componenti guarnizione pistoncino Déposer: Demontieren: della pinza freno • Joint antipoussière 1 • Staubschutzring 1 Togliere: • Joint de piston 2 •...
  • Page 490 CHAS FRONT BRAKE AND REAR BRAKE 4. Inspect: È É • Brake master cylinder piston 1 • Brake master cylinder cup 2 Wear/damage/score marks → Replace brake master cylinder kit. È Front É Rear Brake caliper È É 1. Inspect: •...
  • Page 491 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Contrôler: Kontrollieren: Controllare: • Bremskolben 1 • Pistone pompa del freno 1 • Piston du maître-cylindre de frein • Hauptbremszylinder-Man- • Anello esterno pompa del freno schette 2 •...
  • Page 492 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston È 1. Clean: • Brake caliper • Piston seal • Dust seal • Brake caliper piston Clean them with brake fluid. 2. Install: • Piston seal 1 • Dust seal 2 É...
  • Page 493 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Piston d’étrier de frein Bremskolben Pistoncino della pinza freno Nettoyer: Reinigen: Pulire: • Etrier de frein • Bremssattel • Pinza del freno • Joint de piston • Bremskolben-Dichtring •...
  • Page 494 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake caliper 1 • Bolt (brake caliper) 2 23 Nm (2.3 m · kg, 17 ft · lb) 3. Tighten: • Pad pin 3 18 Nm (1.8 m · kg, 13 ft · lb) 4.
  • Page 495 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Etrier de frein 1 • Bremssattel 1 • Pinza del freno 1 • Boulon (étrier de frein) 2 • Bremssattel-Schraube 2 • Bullone (pinza del freno) 2 23 Nm (2,3 m ·...
  • Page 496 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Brake caliper 1 • Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4. Tighten: • Pad pin 3 18 Nm (1.8 m · kg, 13 ft · lb) 5.
  • Page 497 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Etrier de frein 1 • Bremssattel 1 • Pinza del freno 1 • Roue arrière 2 • Hinterrad 2 • Ruota posteriore 2 Se reporter à...
  • Page 498 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: È [Front] • Brake master cylinder kit 1 • Washer 2 • Circlip 3 • Brake master cylinder boot 4 To brake master cylinder 5. [Rear] • Brake master cylinder kit 1 •...
  • Page 499 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: [Avant] [Vorn] [Anteriore] • Kit de maître-cylindre de frein 1 • Componenti pompa del freno 1 • Hauptbremszylinder-Bauteile • Rondelle 2 • Rondella 2 •...
  • Page 500 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...
  • Page 501 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Levier de frein 1 • Handbremshebel 1 • Leva del freno 1 • Boulon (levier de frein) 2 • Handbremshebel-Schraube 2 • Bullone (leva del freno) 2 6 Nm (0,6 m ·...
  • Page 502 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.
  • Page 503 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Goupille 1 • Stift 1 • Perno 1 • Rondelle 2 • Beilagscheibe 2 • Rondella 2 • Goupille fendue 3 • Splint 3 •...
  • Page 504 CHAS FRONT BRAKE AND REAR BRAKE 4. Pass the brake hose through the cable guide 1. 5. 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.
  • Page 505 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Acheminer la durit de frein dans le Den Bremsschlauch durch die Far passare il tubo flessibile del guide-câble 1. Führung 1 leiten. freno attraverso la guida cavo 1. Monter: Montieren: Installare:...
  • Page 506 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 2 Nm (0.2 m · kg, 1.4 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
  • Page 507 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: • Support de durit de frein 1 • Bremsschlauch-Halterung 1 • Supporto tubo flessibile del freno • Vis (support de durit de frein) 2 •...
  • Page 508 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
  • Page 509 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO ANTERIORE E POSTERIORE Purger l’air: Entlüften: Spurgo aria: • Circuit de freinage • Bremshydraulik • Sistema frenante Se reporter à la section “PURGE Siehe unter “HYDRAULISCHE Fare riferimento al paragrafo D’AIR DU CIRCUIT DE FREI- BREMSANLAGE ENTLÜF-...

  • Page 510: Front Fork

    CHAS FRONT FORK EC550000 FRONT FORK 1 Front fork removal Extent of 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 511: Et Caches Lateraux

    FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE FOURCHE 1 Dépose de la fourche Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DE LA FOURCHE AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de bascu- sous le moteur.
  • Page 512 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 1 Oil seal removal 2 Damper assembly removal Extent of removal: Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Adjuster Drain the fork oil. Use special tool. Refer to “REMOVAL POINTS”. Fork spring Dust seal Stopper ring...
  • Page 513 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortissement Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEMONTAGE DE LA FOURCHE Dispositif de réglage Vidanger l’huile de fourche.
  • Page 514 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. 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 515 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE REMARQUES CONCERNANT LA HANDHABUNGSHINWEISE NOTA PER LA MANIPOLAZIONE MANIPULATION HINWEIS: NOTA: Die Teleskopgabel muss mit großer La forcella anteriore deve essere maneg- N.B.: Vorsicht gehandhabt werden. Es Les interventions sur la fourche sont très giata con cura. Si consiglia di rivolgersi délicates.
  • Page 516 CHAS FRONT FORK Adjuster 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster 1 3. Remove: • Adjuster 1 NOTE: • While compressing the inner tube 2, set the cap bolt ring wrench 4 between the inner tube and locknut 3.
  • Page 517 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Dispositif de réglage Einstellmechanismus Dispositivo di regolazione Vidanger l’huile de fourche du four- Das Öl aus dem Standrohr aus- Scaricare l’olio forcella anteriore reau par le haut. gießen. dal gambale sulla parte superiore. Desserrer: Lockern: Allentare: •...
  • Page 518 CHAS FRONT FORK Base valve 1. Remove: • Base valve 1 From damper assembly 2. NOTE: Hold the damper assembly with the cap bolt ring wrench 3 and use the cap bolt wrench 4 to remove the base valve. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501...
  • Page 519 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Soupape de base Gabelventil Valvola base Déposer: Demontieren: Togliere: • Soupape de base 1 • Gabelventil 1 • Valvola base 1 De l’amortisseur complet 2. (vom Dämpferrohr 2) Dal gruppo ammortizzatore 2. N.B.: HINWEIS: NOTA: Das Dämpferrohr mit dem Abdeck- Maintenir l’amortisseur à...
  • Page 520 CHAS FRONT FORK Base valve 1. Inspect: • Base valve 1 Wear/damage → Replace. Contamination → Clean. • O-ring 2 Wear/damage → Replace. • Piston metal 3 Wear/damage → Replace. • Spring 4 Damage/fatigue → Replace base valve. • Air bleed screw 5 Wear/damage →...
  • Page 521 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Soupape de base Gabelventil Valvola base Contrôler: Kontrollieren: Controllare: • Soupape de base 1 • Gabelventil 1 • Valvola base 1 Usure/endommagement → Rem- Verschlissen/beschädigt → Usura/danni → Sostituire. Contaminazione → Pulire. placer. Erneuern. Encrassé → Nettoyer. Verunreinigt →...
  • Page 522 CHAS FRONT FORK EC554502 Inner tube 1. Inspect: • Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace. • Inner tube bends Out of specification → Replace. Use the dial gauge 1. Inner tube bending limit: 0.2 mm (0.008 in) NOTE:...

  • Page 523: Forcella Anteriore

    FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Tube plongeur Gleitrohr Tubo di forza Contrôler: Kontrollieren: Controllare: • Surface du tube plongeur a • Gleitrohr-Oberfläche a • Superficie tubo di forza a Marques de rayures → Réparer Riefig → Instand setzen, ggf. Tacche → Riparare o sostituire. ou remplacer.
  • Page 524 CHAS FRONT FORK EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Stretch the damper assembly fully. 3. Fill: • Front fork oil 1 To damper assembly. Recommended oil: Suspension oil “S1” Oil capacity: 195 cm (6.86 Imp oz, 6.59 US oz)
  • Page 525 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Fourche complète Teleskopgabel Gruppo forcella anteriore Laver tous les éléments à l’aide de Sämtliche Bauteile mit frischem Lavare tutti i componenti con sol- solvant propre. Lösungsmittel reinigen. vente pulito.
  • Page 526 CHAS FRONT FORK 5. Measure: • Oil level (left and right) a Out of specification → Adjust. Standard oil level: 145 ~ 148 mm (5.71 ~ 5.83 in) From top of fully stretched damper assembly. 6. Tighten: • Locknut 1 NOTE: Fully finger tighten the locknut onto the damper assembly.
  • Page 527 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Mesurer: Messen: Misurare: • Ölstand (links und rechts) a • Livello olio (sinistro e destro) a • Niveau d’huile (gauche et droit) Nicht nach Vorgabe → Korri- Non conforme alle specifiche → Hors spécifications → Régler. gieren.
  • Page 528 CHAS FRONT FORK 9. Check that the damper assembly is fully stretched. Not fully stretched → Repeat the steps 2 to 8. 10. Tighten: • Base valve 1 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque.
  • Page 529 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Vérifier que l’amortisseur est com- Kontrollieren, dass die Dämpfer- Controllare che il gruppo ammortiz- plètement étendu. Si pas complète- Baugruppe vollständig ausgezo- zatore sia completamente teso. Non ment étendu → Répéter les étapes 2 teso completamente → Ripetere le gen ist.
  • Page 530 CHAS FRONT FORK 14. Check: • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 13. 15. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 • Oil seal washer 4 • Slide metal 5 To inner tube 6.
  • Page 531 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE 14. Contrôler: 14. Kontrollieren: 14. Controllare: • Mouvement régulier de l’amortis- • Leichtgängigkeit des Dämpfer- • Movimento uniforme gruppo seur rohrs ammortizzatore Raideur/coincement/rugosités → Rigidità/blocchi/punti ruvidi → Schwergängig/fest/stockend → Schritte 2–13 wiederholen. Répéter les étapes 2 à 13. Ripetere le operazioni da 2 a 13.
  • Page 532 CHAS FRONT FORK 18. 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-A0948/90890-01502 19. Install: • Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
  • Page 533 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE 18. Monter: 18. Montieren: 18. Installare: • Bague antifriction 1 • Gleitbuchse 1 • Guarnizione metallica di scorri- • Dichtring-Beilagscheibe 2 mento 1 • Rondelle de bague d’étanchéité • Rondella paraolio 2 (an der Standrohr-Nut) Dans la fente du fourreau.
  • Page 534 CHAS FRONT FORK 22. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 15 to 21. 23. Measure: • Distance a Out of specification → Turn into the lock- nut. Distance a: 19 mm (0.75 in) or more Between the damper assembly 1 bottom and locknut 2 bottom.
  • Page 535 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE 22. Contrôler: 22. Kontrollieren: 22. Controllare: • Mouvement régulier du tube • Leichtgängigkeit Gleit- • Movimento uniforme tubo di plongeur rohrs forza Raideur/coincement/rugosités → Rigidità/blocchi/punti ruvidi → Schwergängig/fest/stockend → Schritte 15–21 wiederho- Répéter les étapes 15 à 21. Ripetere le operazioni da 15 a 21.
  • Page 536 CHAS FRONT FORK 27. Install: • Push rod 1 • Copper washer 2 • Adjuster 3 To damper assembly 4. NOTE: • While compressing the inner tube 5, set the cap bolt ring wrench 7 between the inner tube and locknut 6. •...
  • Page 537 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE 27. Monter: 27. Montieren: 27. Installare: • Tige de débrayage 1 • Druckstange 1 • Asta di blocco 1 • Rondelle en cuivre 2 • Kupferscheibe 2 • Rondella di rame 2 • Dispositif de réglage 3 •...
  • Page 538 CHAS FRONT FORK 30. Install: • Adjuster 1 55 Nm (5.5 m · kg, 40 ft · lb) To inner tube. 31. Fill: • Front fork oil 1 From outer tube top. Recommended oil: Suspension oil “S1” Standard oil amount: 335 cm (11.8 Imp oz, 11.3 US oz) * 340 cm...
  • Page 539 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE 30. Monter: 30. Montieren: 30. Installare: • Dispositif de réglage 1 • Einstellmechanismus 1 • Dispositivo di regolazione 1 55 Nm (5,5 m · kg, 40 ft · lb) 55 Nm (5,5 m · kg, 40 ft · lb) 55 Nm (5,5 m ·...
  • Page 540 CHAS FRONT FORK 33. Install: • Protector guide 1 NOTE: Install the protector guide with its wider side a facing downward. Installation 1. Install: • Front fork 1 NOTE: • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet.
  • Page 541 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE 33. Monter: 33. Montieren: 33. Installare: • Guide de protection 1 • Protektor-Führung 1 • Guida protezione 1 N.B.: HINWEIS: NOTA: Die Schutzführung mit der breiteren Monter le guide du dispositif de protec- Installare la guida delle protezioni con tion en orientant son côté...
  • Page 542 CHAS FRONT FORK 4. Tighten: • Pinch bolt (upper bracket) 1 23 Nm (2.3 m · kg, 17 ft · lb) • Pinch bolt (lower bracket) 2 20 Nm (2.0 m · kg, 14 ft · lb) CAUTION: Tighten the lower bracket to specified torque.
  • Page 543 FOURCHE TELESKOPGABEL CHAS FORCELLA ANTERIORE Serrer: Festziehen: Serrare: • Boulon de pincement (té supé- • Klemmschraube (obere • Bullone di serraggio (staffa supe- rieur) 1 Gabelbrücke) 1 riore) 1 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m ·...

  • Page 544: Handlebar

    CHAS HANDLEBAR EC5B0000 HANDLEBAR 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks Preparation for removal HANDLEBAR REMOVAL Number plate Remove the band only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side.
  • Page 545 GUIDON LENKER CHAS MANUBRIO GUIDON 1 Dépose du guidon Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques Préparation à la dépose DEPOSE DU GUIDON Plaque d’identification Déposer le collier uniquement. Câble de démarrage à chaud Déconnecter du côté...
  • Page 546 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.
  • Page 547 GUIDON LENKER CHAS MANUBRIO POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Maître-cylindre de frein Hauptbremszylinder Pompa del freno Déposer: Demontieren: Togliere: • Staffa pompa del freno 1 • Support de maître-cylindre de • Hauptbremszylinder-Halte- frein 1 rung 1 • Pompa del freno 2 •...
  • Page 548 CHAS HANDLEBAR 2. 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. •...
  • Page 549 GUIDON LENKER CHAS MANUBRIO Monter: Montieren: Installare: • Guidon 1 • Lenker 1 • Manubrio 1 • Support supérieur de guidon 2 • obere Lenker-Halterung 2 • Supporto superiore manubrio 2 • Boulon (support supérieur de gui- • Schraube (obere Lenker-Hal- •...
  • Page 550 CHAS HANDLEBAR 4. Install: • Left grip 1 Apply the adhesive to the handlebar 2. NOTE: • Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner. • Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward.
  • Page 551 GUIDON LENKER CHAS MANUBRIO Monter: Montieren: Installare: • Poignée gauche 1 • Lenkergriff links 1 • Manopola sinistra 1 Den Lenker 2 mit Klebstoff Appliquer un agent adhésif sur le Applicare l’adesivo sul manubrio guidon 2. bestreichen. N.B.: HINWEIS: NOTA: •...
  • Page 552 CHAS HANDLEBAR 7. 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. 8. Install: • Throttle cable cap 1 • Screw (throttle cable cap) 2 4 Nm (0.4 m ·...
  • Page 553 GUIDON LENKER CHAS MANUBRIO Monter: Montieren: Installare: • Câbles des gaz 1 • Gaszüge 1 • Cavi acceleratore 1 Sur le guide de tube 2. (an der Führung 2) Sulla guida tubo 2. HINWEIS: N.B.: NOTA: Appliquer de la graisse à savon de Die Gaszug-Enden und Seilzug-Füh- Applicare il grasso a base di sapone di rung mit Lithiumseifenfett bestrei-...
  • Page 554 CHAS HANDLEBAR 11. Install: • Engine stop switch 1 • Clutch lever holder 2 • Bolt (clutch lever holder) 3 4 Nm (0.4 m · kg, 2.9 ft · lb) • Hot starter lever holder 4 • Bolt (hot starter lever holder) 5 4 Nm (0.4 m ·...
  • Page 555 GUIDON LENKER CHAS MANUBRIO 11. Monter: 11. Montieren: 11. Installare: • Coupe-circuit du moteur 1 • Motorstoppschalter 1 • Interruttore di arresto motore 1 • Kupplungshebel-Halterung 2 • Support du levier d’embrayage • Supporto della leva della frizione • Schraube (Kupplungshebel- Halterung) 3 •...

  • Page 556: Steering

    CHAS STEERING EC560000 STEERING 1 Lower bracket removal 2 Bearing removal Extent of 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 suitable stand under the engine. there is no danger of it falling over.
  • Page 557 DIRECTION LENKUNG CHAS STERZO DIRECTION 1 Dépose du té inférieur 2 Dépose du roulement Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DE LA DIRECTION AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de basculer.
  • Page 558 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: •...
  • Page 559 DIRECTION LENKUNG CHAS STERZO POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Ecrou de colonne de direction Ringmutter Ghiera sterzo Déposer: Demontieren: Togliere: • Ecrou de colonne de direction 1 • Ringmutter 1 • Ghiera sterzo 1 Den Hakenschlüssel 2 ver- Utiliser la clé...
  • Page 560 CHAS STEERING Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand.
  • Page 561 DIRECTION LENKUNG CHAS STERZO Roulement et cage de roulement Lager und Laufring Cuscinetto e pista cuscinetto Nettoyer les roulements et les cages Die Lager und Laufringe mit Lavare i cuscinetti e le relative piste de roulements avec du solvant. einem Lösungsmittel reinigen. con un solvente.
  • Page 562 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.
  • Page 563 DIRECTION LENKUNG CHAS STERZO Monter: Montieren: Installare: • Ecrou de colonne de direction 1 • Ringmutter 1 • Ghiera sterzo 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 ·...
  • Page 564 CHAS STEERING 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 10. Adjust: • Front fork top end a Front fork top end (standard) a: 5 mm (0.20 in) 11.
  • Page 565 DIRECTION LENKUNG CHAS STERZO Après avoir serré l’écrou, vérifier si Nach dem festziehen der Mutter Dopo aver serrato il dado, control- lare che lo sterzo si muova in modo le mouvement de la direction est die Lenkung auf Schwergängig- uniforme. Se si muove con diffi- régulier.

  • Page 566: Swingarm

    CHAS SWINGARM EC570000 SWINGARM 1 Swingarm removal Extent of 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 suitable stand under the engine. there is no danger of it falling over.

  • Page 567: Frein Avant Et Frein Arriere

    BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT 1 Dépose du bras oscillant Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU BRAS OSCILLANT AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de bascu- sous le moteur.
  • Page 568 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 1 Swingarm disassembly 2 Connecting rod removal and disassembly Extent of removal: 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Refer to “REMOVAL POINTS”. Relay arm Connecting rod Collar Oil seal Thrust bearing...

  • Page 569: Bras Oscillant

    BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Organisation de la dépose: 3 Dépose et démontage du bras relais Organisation de la dépose Ordre Nom de la pièce Qté...
  • Page 570 CHAS SWINGARM EC573000 REMOVAL POINTS 1. Remove: • Left cap 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the left cap. EC573200 Bearing 1. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings and collars in a solvent.
  • Page 571 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Capuchon Abdecking Caperchio Déposer: Demontieren: Togliere: • Capuchon gauche 1 • Abdeckung links 1 • Coperchio sinistro 1 N.B.: HINWEIS: NOTA: Zum Ausbau einen Schlitz-Schrau- Déposer en insérant un tournevis à lame Rimuovere utilizzando un cacciavite per droite sous le repère a du capuchon bendreher unter der Markierung a...
  • Page 572 CHAS SWINGARM Connecting rod 1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC575000 ASSEMBLY AND INSTALLATION Bearing and oil seal 1.
  • Page 573 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Bielle Übertragungshebel Biella Contrôler: Kontrollieren: Controllare: • Roulement 1 • Lager 1 • Cuscinetto 1 • Entretoise épaulée 2 • Distanzhülse 2 • Collarino 2 Jeu/rotation irrégulière/rouille → Spiel vorhanden/stockend/ros- Presenza di gioco/rotazione non tig →...
  • Page 574 CHAS SWINGARM 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. 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: Zero mm (Zero in) Swingarm...
  • Page 575 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: Installare: • Roulement 1 • Lager 1 • Cuscinetto 1 • Bague d’étanchéité 2 • Dichtring 2 • Paraolio 2 Sur la bielle. (am Übertragungshebel) Sulla biella. N.B.: HINWEIS: NOTA: • Bei der Montage Molybdändisul- •...
  • Page 576 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 ·...
  • Page 577 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: Installare: • Entretoise épaulée 1 • Distanzhülse 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 die Distanz- Applicare il grasso al disolfuro di molib- hülse und Dichtringlippen auftragen.
  • Page 578 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 •...
  • Page 579 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: Installare: • Boulon (bielle) 1 • Bullone (biella) 1 • Übertragungshebel-Schraube • Rondelle 2 • Rondella 2 • Ecrou (bielle) 3 • Beilagscheibe 2 • Dado (biella) 3 • Übertragungshebel-Mutter 3 N.B.: NOTA: •...
  • Page 580 CHAS SWINGARM 13. Install: • Bolt (lower chain tensioner) 1 • Washer 2 • Collar 3 • Lower chain tensioner 4 • Nut (lower chain tensioner) 5 16 Nm (1.6 m · kg, 11 ft · lb) 14. Install: • Drive chain support 1 •...
  • Page 581 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE 13. Monter: 13. Montieren: 13. Installare: • Boulon (tendeur de chaîne infé- • Schraube (unterer Ketten- • Bullone (tenditore inferiore rieur) 1 spanner) 1 catena) 1 • Rondelle 2 • Beilagscheibe 2 • Rondella 2 •...
  • Page 582 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so Preparation for removal Hold the machine by placing the there is no danger of it falling over.

  • Page 583: Tube D'echappement Et Silencieux

    AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DE L’AMORTISSEUR ARRIERE AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de bascu- sous le moteur.
  • Page 584 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 - 63...

  • Page 585: Amortisseur Arriere

    AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Organisation de la dépose Ordre Nom de la pièce Qté Remarques Guide de ressort supérieur Ressort (amortisseur arrière) Roulement Se reporter à “POINTS DE DEPOSE”. Reihen- Arbeitsumfang Bauteil Anz. Bemerkungen folge Federführung oben Feder (Federbein) Lager Siehe unter “DEMONTAGE-EINZELHEITEN”.
  • Page 586 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 - 64...
  • Page 587 Confier la mise au rebut d’un amortis- Die Entsorgung des Stoßdämpfers segnare il pezzo al proprio rivenditore sollte am besten dem YAMAHA- seur endommagé ou usé à un conces- Yamaha che eseguirà la procedura di sionnaire Yamaha. Händler überlassen werden. smaltimento. 5 - 64...
  • Page 588 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 589 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE POINTS DE DEPOSE DEMONTAGE-EINZELHEITEN PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Déposer: Demontieren: Togliere: • Bague d’arrêt (roulement supé- • Sicherungsring (oberes Lager) • Anello di arresto (cuscinetto rieur) 1 superiore) 1 N.B.: HINWEIS: NOTA: Appuyer sur le roulement tout en pous- Das Lager durch Druck auf den Spingere all’interno il cuscinetto pre-...
  • Page 590 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 591 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Roulement Lager Cuscinetto Monter: Montieren: Installare: • Roulement supérieur 1 • Oberes Lager 1 • Cuscinetto superiore 1 N.B.: HINWEIS: NOTA: Zum Einbau des Lagers parallel auf Monter roulement parallèlement...
  • Page 592 CHAS REAR SHOCK ABSORBER 2. Install: • Spring seat 1 NOTE: Install the spring seat with the projection a brought into contact with the spring end, as shown. 3. Tighten: • Adjuster 1 4. Adjust: • Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT”...
  • Page 593 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Monter: Montieren: Installare: • Siège de ressort 1 • Federsitz 1 • Sede della molla 1 N.B.: HINWEIS: NOTA: Den Federsitz so montieren, dass Monter le siège de ressort en mettant Installare la sede della molla con la spor- l’ergot a en contact avec l’embout du der Vorsprung a das Federende genza a a contatto con l’estremità...
  • Page 594 CHAS REAR SHOCK ABSORBER 2. Install: • Bushing 1 • Collar 2 • Dust seal 3 NOTE: • Apply the molybdenum disulfide grease on the bearing and dust seal lips. • Install the dust seals with their lips facing out- ward.
  • Page 595 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Monter: Montieren: Installare: • Bague 1 • Buchse 1 • Bussola 1 • Entretoise épaulée 2 • Distanzhülse 2 • Collarino 2 • Joint antipoussière 3 • Staubschutzring 3 • Guarnizione parapolvere 3 N.B.: HINWEIS: NOTA: •...

  • Page 596: And Wiring Diagram

    – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Engine stop switch COLOR CODE 2 Throttle position sensor B...... Black W .....White Br ....Brown Y ......Yellow 3 Neutral switch G .....

  • Page 597: Partie Electrique

    COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN – ELEC COMPONENTI ELETTRICI E SCHEMA ELETTRICO PARTIE ELEKTRISCHE IMPIANTO ELECTRIQUE ANLAGE ELETTRICO ELEKTRISCHE BAU- COMPOSANTS COMPONENTI TEILE UND SCHALTPLAN ELECTRIQUES ET ELETTRICI E SCHEMA SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE ELETTRICO 1 Motorstoppschalter COMPOSANTS ELECTRIQUES...

  • Page 598: 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 599 BOITIER CDI COMMANDE PAR PRESSION ABSOLUE DE – ELEC LA TUBULURE D’ADMISSION BOITIER CDI COMMANDE PAR PRESSION ABSOLUE DE LA TUBULURE D’ADMISSION Un système d’allumage CDI commandé par pression absolue de la tubulure d’admission est utilisé dans la YZ250F. Le microordinateur du boîtier CDI détecte le régime du moteur et la position du papillon et détermine ainsi l’avance à...

  • Page 600: Motor

    – ELEC KENNFELDGESTEUERTE ZÜNDUNG KENNFELDGESTEUERTE ZÜNDUNG Die YZ250F ist mit einer kennfeldgesteuerten Zündung ausgestattet. Der Mikroprozessor in der Zündbox errechnet aus der Motordrehzahl und der Drosselklappen-Posi- tion die optimale Zündverstellung über den gesamten Betriebsbereich. Auf diese Weise kann erzielt werden, dass der Motor unter verschiedenen Betriebsbedingungen rasch anspricht. Zündspule Zündbox Drosselklappensensor...
  • Page 601 – ELEC UNITÀ CDI CONTROLLATA DA UNA MAPPA UNITÀ CDI CONTROLLATA DA UNA MAPPA YZ250F è dotato di un impianto di accensione CDI controllato da una mappa. Il microcomputer nell’unità CDI rileva la velocità del motore e la posizione dell’acceleratore, calcolando in questo modo l’anticipo minimo ottimale in tutte le condizioni di funzionamento.
  • Page 602 – 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 603 – ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DU CONTROLE Suivre la procédure ci-dessous 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. Etincelle *Nettoyer ou remplacer Test de la longueur d’étincelle...
  • Page 604 – ELEC ZÜNDSYSTEM ZÜNDSYSTEM KONTROLLE Folgende Prüfschritte dienen zur Diagnose von zündungsbedingten Motorstörungen und von Zünd- kerzenausfall. Funke vorhanden Zündfunkenstrecke kontrol- * Zündkerze reinigen, lieren. ggf. erneuern. Kein Funke Kabelanschlüsse des gesamten Zündsystems Nicht in Ordnung Instand setzen, ggf. kontrollieren. erneuern.

  • Page 605: Impianto Di Accensione

    – ELEC IMPIANTO DI ACCENSIONE IMPIANTO DI ACCENSIONE OPERAZIONI PER IL CONTROLLO Eseguire le seguenti operazioni per controllare se si verificano malfunzionamenti del motore attribuibili a guasti dell’impianto di accensione e se la candela di accensione non emette scintille. Scintilla *Pulire o sostituire la Test lunghezza della scintilla candela di accensione.
  • Page 606 – ELEC IGNITION SYSTEM SPARK GAP TEST È 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (igni- tion checker 2) as shown. • Ignition coil 3 • Spark plug 4 È...
  • Page 607 SYSTEME D’ALLUMAGE ZÜNDSYSTEM – ELEC IMPIANTO DI ACCENSIONE TEST DE LA LONGUEUR ZÜNDFUNKENSTRECKE TEST LUNGHEZZA DELLA D’ETINCELLE KONTROLLIEREN SCINTILLA Déconnecter la bobine d’allumage Die Zündspule von der Zünd- Scollegare la bobina di accensione de la bougie. kerze abziehen. dalla candela. Déposer le capuchon de la bobine Den Stecker von der Zündspule Togliere il coperchio della bobina di...
  • Page 608 – 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 609 SYSTEME D’ALLUMAGE ZÜNDSYSTEM – ELEC IMPIANTO DI ACCENSIONE CONTROLE DE LA BOBINE ZÜNDSPULE KONTROLLIEREN CONTROLLO BOBINA DI D’ALLUMAGE Kontrollieren: ACCENSIONE Contrôler: • Primärwicklungs-Widerstand Controllare: Nicht nach Vorgabe → Erneu- • Résistance de l’enroulement pri- • Resistenza bobina primaria Non conforme alle specifiche → maire ern.
  • Page 610 – 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 611 SYSTEME D’ALLUMAGE ZÜNDSYSTEM – ELEC IMPIANTO DI ACCENSIONE Contrôler: Kontrollieren: Controllare: • Résistance de la bobine de charge 1 • Widerstand der Ladespule 1 • Resistenza bobina di carica 1 Hors spécifications → Rempla- Nicht nach Vorgabe → Erneu- Non conforme alle specifiche → cer.

  • Page 612: 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 613 SYSTEME DU CAPTEUR DE POSITION DE PAPILLON – ELEC DES GAZ SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ ETAPES DU CONTROLE Si le capteur de position de papillon des gaz ne fonctionne pas, effectuer les contrôles suivants. Contrôler les connexions de Problème l’ensemble du système d’allu- Réparer ou remplacer.
  • Page 614 – ELEC DROSSELKLAPPENSENSOR DROSSELKLAPPENSENSOR KONTROLLE Folgende Prüfschritte dienen zur Diagnose des Drosselklappensensors, wenn dieser nicht funktio- niert. Kabelanschlüsse des Nicht in Ordnung Instand setzen, ggf. gesamten Zündsystems erneuern. kontrollieren. In Ordnung Drosselklap- Nicht in Ordnung Drosselklappensensor pensensor- Erneuern. kontrollieren. Spule In Ordnung Nicht in Ordnung *Lichtmaschine kontrollie-...

  • Page 615: Sistema Sensore Posizione Farfalla

    – ELEC SISTEMA SENSORE POSIZIONE FARFALLA SISTEMA SENSORE POSIZIONE FARFALLA OPERAZIONI PER IL CONTROLLO Se il sensore posizione farfalla non funziona, eseguire le seguenti operazioni per il controllo. In cattivo stato Controllare tutti i collegamenti Riparare o sostituire. dell’impianto di accensione. In cattivo stato Controllare il sensore posi- Bobina sensore...
  • Page 616 – 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 617 SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR – ELEC SISTEMA SENSORE POSIZIONE FARFALLA REMARQUES CONCERNANT LA HANDHABUNGSHINWEISE NOTA PER LA MANIPOLAZIONE MANIPULATION ACHTUNG: ATTENZIONE: ATTENTION: Die Drosselklappensensor-Schrau- Non allentare le viti (sensore posizione ben 1 dürfen nicht gelockert wer- farfalla) 1 eccetto quando occorre Ne pas desserrer les vis (capteur de position de papillon des gaz) 1 sauf...
  • Page 618 – 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 position. Out of specification → Replace. Tester (+) lead →...

  • Page 619: Carburateur

    SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR – ELEC SISTEMA SENSORE POSIZIONE FARFALLA Contrôler: Kontrollieren: Controllare: • Résistance variable de la bobine • Drosselklappensensor-Wider- • Resistenza variabile bobina sen- du capteur de position de papillon stand sore posizione farfalla des gaz Darauf achten,...
  • Page 620 – ELEC THROTTLE POSITION SENSOR SYSTEM 5. Install: • Carburetor • Throttle position sensor coupler 6. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAPTER 7. Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them.
  • Page 621 SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR – ELEC SISTEMA SENSORE POSIZIONE FARFALLA Monter: Montieren: Installare: • Carburateur • Vergaser • Carburatore • Fiche rapide du capteur de posi- • Drosselklappensensor-Steck- • Accoppiatore sensore posizione tion de papillon des gaz verbinder farfalla Régler:...
  • Page 622 – ELEC THROTTLE POSITION SENSOR SYSTEM 10. Put the aligning marks a on the TPS and carburetor. 11. Stop the engine. 12. Remove the carburetor. 13. Tighten: • Screw (throttle position sensor) 1 NOTE: Tighten the screws (throttle position sensor) using the T25 bit.
  • Page 623 SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ DROSSELKLAPPENSENSOR – ELEC SISTEMA SENSORE POSIZIONE FARFALLA 10. Placer les repères d’alignement a 10. Porre i segni di allineamento a sul 10. Die Ausrichtungsmarkierungen a auf den Drosselklappensen- sur le capteur de position du TPS e sul carburatore.
  • Page 624 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. •...
  • Page 625 REGLAGE EINSTELLUNG T U N REGISTRAZIONE MISE AU POINT ABSTIMMUNG MESSA A PUNTO MOTOR MOTEUR MOTORE Vergaser-Abstimmung Réglage du carburateur Impostazione carburatore • Le mélange air/carburant varie en • Das Gemisch hängt u. a. von den • La miscela aria/carburante varia a fonction des conditions atmosphéri- atmosphärischen Bedingungen ab.
  • Page 626 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 carburetor parts may prevent the carburetor from...
  • Page 627 REGLAGE EINSTELLUNG T U N REGISTRAZIONE ATTENTION: ACHTUNG: ATTENZIONE: • Der Vergaser reagiert besonders • Le carburateur est extrêmement • Il carburatore è estremamente sen- sensible aux corps étrangers (pous- empfindlich Fremdkörper sibile ai materiali estranei (sporci- (Staub, Sand, Wasser usw.). Bei sière, sable, eau, etc.).
  • Page 628 T U N SETTING Effects of the setting parts on the throttle valve opening È É È Closed É 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 629 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Effet des réglages sur l’ouverture du Einflussbereich der einstellbaren Effetti dei componenti di impostazione papillon des gaz Bauteile in Bezug auf die Drossel- sull’apertura della valvola a farfalla È Fermé È Chiuso klappenöffnung É Complètement ouvert É...
  • Page 630 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. #178 Standard main jet *#175...
  • Page 631 REGLAGE EINSTELLUNG T U N REGISTRAZIONE 1 Aiguille 1 Düsennadel 1 Spillo del getto 2 Gicleur d’air de ralenti 2 Leerlauf-Luftdüse 2 Getto aria del minimo 3 Gicleur d’aiguille 3 Nadeldüse 3 Getto a spillo 4 Gicleur principal 4 Hauptdüse 4 Getto del massimo 5 Gicleur de ralenti 5 Leerlaufdüse...
  • Page 632 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 633 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de la vis de ralenti Leerlaufgemisch-Regulier- Regolazione vite del minimo La richesse du mélange air/carburant à schraube einstellen Si può impostare la ricchezza della une ouverture des gaz de 0 à 1/4 se règle Im Bereich zwischen geschlossener miscela di aria e carburante regolando la à...
  • Page 634 T U N SETTING Effects of adjusting the pilot jet (reference) È É –5% È Idle É 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 635 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Effets du réglage du gicleur de ralenti Effekt der Leerlaufdüsen-Einstel- Effetti della regolazione del getto del (référence) lung minimo (riferimento) È É È É È É N˚45 Nr.45 N.45 N˚42 Nr.42 N.42 N˚40 Nr.40 N.40 –5% –5%...
  • Page 636 T U N SETTING Jet needle adjustment The jet needle is adjusted by changing it. OBELQ Standard jet needle * OBEKP * Except for USA and CDN The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.
  • Page 637 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de l’aiguille Düsennadel einstellen Regolazione spillo del getto Si l’aiguille demande un réglage, la rem- Die Düsennadel wird durch Aus- Lo spillo del getto si regola sostituen- placer. wechseln eingestellt. dolo. Standard-Düsen- OBELQ OBELQ Spillo del getto stan- OBELQ...
  • Page 638 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 639 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage du gicleur de fuite (réglage de Ausströmdüse (Beschleunigungs- Regolazione getto di perdita (regola- la pompe de reprise) pumpe) einstellen zione pompa acceleratore) Le gicleur de fuite 1 est l’élément qui Die Ausströmdüse 1 bestimmt den Il getto di perdita 1 è...
  • Page 640 T U N SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Rich #188 4MX-14943-95 #185 4MX-14943-44 #182 4MX-14943-94 #180 4MX-14943-43 (STD) #178 4MX-14943-93 *(STD) #175 4MX-14943-42 #172 4MX-14943-92 #170 4MX-14943-41 #168 4MX-14943-91 Lean #165 4MX-14943-40 Pilot jet Rich 4MX-14948-06 4MX-14948-05...
  • Page 641 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage du carburateur Einstellbare Vergaserbauteile Componenti di impostazione del car- buratore Bauteil Größe Teilenummer Numéro de Nom de la pièce Taille référence Hauptdüse Denominazione Misura Numero parte Gicleur principal Fett Nr.188 4MX-14943-95 Getto del massimo Riche N°188...
  • Page 642 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 643 T U N REGLAGE Exemples de réglages du carburateur en fonction des symptômes Symptômes Réglages Contrôles Décoloration de la bougie → A pleine ouverture des gaz Augmenter le calibre du gicleur principal Crachotements (progressivement) Brun clair = bon état. Bruit de frottement de pièces Si correction impossible: métalliques Siège de pointeau bouché...
  • Page 644 T U N EINSTELLUNG Beispiele von Symptomen mit entsprechenden Vergasereinstellungen Symptom Einstellung Kontrolle Verfärbung der Zündkerze → Bei völlig geöffneter Dros- Hauptdüsen-Nr. erhöhen selklappe (schrittweise) Falls rehbraun, in Ordnung. Schweres Saugen Falls nicht korrigierbar: Schergeräusch Schwimmer-Ventilsitz verstopft Weißliches Zündkerzen- Kraftstoffschlauch verstopft gesicht Kraftstoffhahn verstopft Sicherstellen, dass die Beschleuni-...
  • Page 645 T U N REGISTRAZIONE Esempi di impostazione del carburatore in base al sintomo Sintomo Impostazione Controllo Macchie sulla candela di accensione → A velocità massima Aumentare il calibro del getto del mas- Problemi di sfiato simo Se il colore è marrone, è in buone condi- Rumore simile a quello pro- (gradatamente) zioni.
  • Page 646 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 647: Fahrwerk

    REGLAGE EINSTELLUNG T U N REGISTRAZIONE CHASSIS FAHRWERK PARTE CICLISTICA Sélection du taux de réduction secon- Sekundärübersetzung (Kettenrad) Selezione del rapporto di riduzione auswählen daire (pignons) secondario (ruota dentata) Anzahl Kettenrad- Nombre de dents du Numero dei denti Taux de pignon de roue arrière Zähne della corona della...
  • Page 648 T U N SETTING Drive and rear wheel sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 9383B-13218 Rear wheel 1C3-25447-00 sprocket 2 (STD) 1C3-25448-00 * (STD) 1C3-25449-00 1C3-25450-00 1C3-25451-00 1C3-25452-00 * For EUROPE EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
  • Page 649 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage du pignon d’entraî- Verfügbare Antriebsritzel und Ket- Componenti di impostazione corona nement et de la couronne arrière tenräder della ruota posteriore e ruota dentata di trasmissione Numéro de Bauteil Größe Teilenummer Nom de la pièce Taille référence...
  • Page 650 T U N SETTING 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 •...

  • Page 651: Fourche

    REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage de la fourche Teleskopgabel einstellen Impostazione forcella anteriore Régler la fourche en fonction de l’expé- Teleskopgabel-Einstellung Impostare la forcella anteriore in base rience de conduite du pilote sur le terrain eine Sache persönlichen alla sensazione che il conducente ha della ainsi que des conditions du terrain.
  • Page 652 T U N SETTING EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in posi- tion, etc.) when setting the front fork. 1.

  • Page 653: Lenker

    REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage du ressort après remplace- Feder nach Austausch einstellen Impostazione della molla dopo la ment Da die Einstellung der Hinterradfede- sostituzione La suspension arrière pouvant influencer rung sich auch auf die Vorderradfe- Dal momento che l’impostazione della le réglage de la fourche, il convient donc derung auswirkt,...
  • Page 654 T U N SETTING Front fork setting parts • Front fork spring 1 I.D. SPRING SPRING PART TYPE MARK RATE NUMBER (slits) 0.398 1C3-23141-A0 0.408 1C3-23141-B0 SOFT 0.418 1C3-23141-C0 0.428 1C3-23141-D0 IIII 0.438 5XC-23141-M0 – 0.449 1C3-23141-F0 0.459 1C3-23141-G0 I-II STIFF 0.469 1C3-23141-H0...
  • Page 655 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage de la fourche Einstellbare Teleskopgabel-Bau- Componenti di impostazione forcella • Ressort de fourche 1 teile anteriore • Gabelfeder 1 • Molla forcella anteriore 1 RAI- REFERENCE DEUR REPERE TYPE KENN- CON- DU RESSORT DU RES- (fentes)
  • Page 656 T U N SETTING EC72C001 Choosing set length 1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length a between the rear wheel axle center and the rear fender hold- ing bolt.
  • Page 657 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Choix de la longueur de ressort Einbaulänge wählen Scelta della lunghezza impostata. Placer un support ou un bloc sous le Das Motorrad so am Motor auf- Collocare un cavalletto o un fermo moteur pour surélever la roue bocken, dass das Hinterrad frei sotto il motore per sollevare la ruota arrière et mesurer la longueur a...
  • Page 658 T U N SETTING Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load.

  • Page 659: Federbein

    REGLAGE EINSTELLUNG T U N REGISTRAZIONE Réglage du ressort après remplace- Feder nach Austausch einstellen Impostazione della molla dopo la ment Nach dem Austauschen der Feder sostituzione Après avoir remplacé le ressort, veiller à kontrollieren, ob die Einbaulänge 90– Dopo la sostituzione, assicurarsi di rego- l’ajuster à...
  • Page 660 T U N SETTING EC72Q000 Rear shock absorber setting parts • Rear shock spring 1 [Equal-pitch titanium spring] SPRING TYPE SPRING SPRING I.D. FREE RATE PART NUMBER MARK LENGTH (approx.) 1C3-22212-00 Green SOFT 1C3-22212-10 1C3-22212-20 Black 1C3-22212-30 Blue 1C3-22212-40 Yellow STIFF 1C3-22212-50 Pink...
  • Page 661 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Pièces de réglage de l’amortisseur Einstellbare Federbein-Bauteile Componenti di impostazione ammor- • Hintere Stoßdämpferfeder 1 arrière tizzatore posteriore • Ressort d’amortisseur arrière 1 • Molla ammortizzatore posteriore 1 [Titanfeder mit gleichmäßiger Stei- [Ressort en titane à spires égales] gung] [Molla a passo regolare in titanio] LON-...
  • Page 662 T U N SETTING • Extent of adjustment (spring length) [Titanium spring] SPRING FREE EXTENT OF ADJUSTMENT b LENGTH One I.D. mark 245.5 ~ 263.5 mm (9.67 ~ 10.37 in) Two I.D. marks Approx. 265 mm 251.5 ~ 269.5 mm (10.43 in) (9.90 ~ 10.61 in) Three I.D.
  • Page 663 REGLAGE EINSTELLUNG T U N REGISTRAZIONE • Plage de réglage (longueur du ressort) • Einstellbereich (Federlänge) • Punto regolazione (lunghezza [Ressort en titane] [Titanfeder] molla) [Molla in titanio] UNGE- LONGUEUR EINSTELLBE- PLAGE DE SPANNTE LIBRE DU RES- LUNGHEZZA PUNTO DI REGLAGE b REICH b LÄNGE...

  • Page 664: 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. •...
  • Page 665 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. •...
  • Page 666 T U N REGLAGE Réglage de la suspension • Fourche 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 procédures reprises dans le tableau. •...
  • Page 667 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 procédures reprises dans le tableau. • Régler l’amortissement à la détente de 2 clics, dans un sens ou dans l’autre. •...
  • Page 668 T U N EINSTELLUNG Radaufhängung einstellen • Gabelholm HINWEIS: • Treten bei der Standardeinstellung die in folgender Tabelle aufgeführten Symptome auf, die ent- sprechenden Einstellungen ausführen. • Vor der Einstellung sicherstellen, dass die Einbaulänge der Federbein-Feder 90–100 mm (3,5– 3,9 in) beträgt. Abschnitt Symptom Kontrolle...
  • Page 669 T U N EINSTELLUNG • Federbein HINWEIS: • Treten bei der Standardeinstellung die in folgender Tabelle aufgeführten Symptome auf, die ent- sprechenden Einstellungen ausführen. • Die Zugstufen-Dämpfungskraft um je 2 Raststellungen verstellen. • Die untere Druckstufen-Dämpfungskraft um je eine Raststellung verstellen. •...
  • Page 670 T U N REGISTRAZIONE Impostazione sospensione • Forcella anteriore NOTA: • Se, trovandosi in posizione standard, si verifica uno dei seguenti sintomi, impostare nuovamente utilizzando come riferimento la procedura di regolazione indicata nella stessa tabella. • Prima di apportare qualsiasi modifica, impostare l’affondamento dell’ammortizzatore posteriore al valore standard di 90 ~ 100 mm (3,5 ~ 3,9 in).
  • Page 671 T U N REGISTRAZIONE • Ammortizzatore posteriore NOTA: • Se, trovandosi in posizione standard, si verifica uno dei seguenti sintomi, impostare nuovamente utilizzando come riferimento la procedura di regolazione indicata nella stessa tabella. • Regolare lo smorzamento in estensione con incrementi o diminuzioni di 2 scatti. •...
  • Page 674 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.08-3.0×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN (E,F,G,H)

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