Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU ET PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO WR250F 5PH-28199-30...
Page 2 EC010010 WR250F(N) OWNER’S SERVICE MANUAL ©2000 by Yamaha Motor Co., Ltd. 1st Edition, November 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
Page 3 MANUALE DI SERVIZIO DEL HANDBUCH DU PROPRIETAIRE PROPRIETARIO 2000 Yamaha Motor Co., Ltd. 2000 Yamaha Motor Co., Ltd. ©2000 by Yamaha Motor Co., Ltd. 1. Auflage, November 2000 1ère édition, novembre 2000 edizione, novembre 2000 Alle Rechte vorbehalten. Tous droits réservés Tutti i diritti sono riservati.
Page 4 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR 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 Maß an Qualität und die sprichwörtli- la fiabilité qui ont fait de Yamaha un lea- qualitativa e affidabilità che hanno reso che Yamaha-Zuverlässigkeit. 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 ZUR BEACHTUNG NOTICE COMUNICAZIONE IMPORTANTE IMPORTANTE Dieses Motorrad ist ausschließlich für den Einsatz im Gelände-Renn- CETTE MACHINE EST STRICTE- QUESTO VEICOLO È STATO PRO- sport auf geschlossenen Kursen MENT DESTINEE A LA COMPETI- GETTATO ESCLUSIVAMENTE PER bestimmt. Die Benutzung dieses TION, UNIQUEMENT SUR CIRCUIT LE COMPETIZIONI SU CIRCUITI...
Page 8 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
Page 9 Benzin ist giftig. L’ESSENCE PEUT CAUSER LA BENZINA PUÒ PROVO- Sollten Sie versehentlich DES BLESSURES. CARE DANNI PERSONALI. Si vous avalez de l’essence, res- Benzin verschluckt, Ben- In caso di ingestione involonta- pirez des vapeurs d’essence en zindämpfe eingeatmet oder benzina, inalazione excès ou laissez de l’essence...
Page 10: Machine Weights
If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
Page 11 Sie sich ou l’entretien de votre machine, veuillez del veicolo, consultare il proprio rivendi- vor Unfällen schützen. consulter votre concessionnaire Yamaha. tore Yamaha. Wenn Sie die vielen Tips der Bedie- N.B.: nungsanleitung nutzen, garantieren NOTA: Ce manuel doit être considéré...
Page 12: Description
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
Page 13: Renseignements Generaux
BENUTZERHINWEISE COMMENT UTILISER COME UTILIZZARE CE MANUEL QUESTO MANUALE KENNZEICHNUNG WICH- INFORMATIONS PARTI- INFORMAZIONI PARTI- TIGER HINWEISE CULIEREMENT IMPOR- COLARMENTE IMPOR- TANTES TANTI Questo simbolo segnala un pericolo che Ausrufezeichen bedeutet: Le symbole d’alerte de sécurité signifie richiede la MASSIMA ATTENZIONE! “GEFAHR! Achten Sie auf Ihre ATTENTION! SOYEZ VIGILANT! PERICOLO! LA SICUREZZA DELLE...
Page 14 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings...
Page 15 AUFBAU FORMAT DU MANUEL STRUTTURA DEL MANUALE Diese Anleitung wurde zusammen- Dans ce manuel, toutes les procédures gestellt, um dem Benutzer ein leicht sont décrites pas à pas. Les informations Tutte le procedure di questo manuale verständliches Nachschlagewerk in ont été condensées pour fournir au méca- sono organizzate in sequenze passo a die Hand zu geben, in dem alle dar- nicien un guide pratique et facile à...
Page 16 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical –...
Page 17 ABGEBILDETEN SYM- SYMBOLES GRAPHI- SIMBOLI ILLUSTRATI QUES (Fare riferimento all’illu- (Siehe Abbildung) (Voir l’illustration) strazione) Die unter 1 bis 7 abgebildeten Les symboles graphiques 1 à 7 servent I simboli illustrati da 1 a 7 vengono Symbole weisen auf die Themen der à...
Page 18 EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...
Page 19 INDEX INDEX INDICE ALLGEMEINE RENSEIGNEMENTS- INFORMAZIONI GENERAUX GENERALI ANGABEN INFO TECHNISCHE CARACTERISTI- SPECIFICHE QUES DATEN SPEC REGELMÄSSIGE CONTROLES ET ISPEZIONI E INSPEKTION UND REGLAGES REGISTRAZIONI INSP COURANTS REGOLARI EINSTELLARBEITEN MOTOR MOTEUR MOTORE FAHRWERK PARTIE CYCLE PARTE CICLISTICA CHAS – ELEKTRISCHE PARTIE IMPIANTO ELECTRIQUE...
Page 20: Table Of Contents
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 FUEL ............1-13 STARTING AND BREAK-IN ....1-14 TORQUE-CHECK POINTS ..... 1-18 CLEANING AND STORAGE ....
Page 21 INHALT TABLES DES INDICE MATIERES KAPITEL 1 CAPITOLO 1 CHAPITRE 1 ALLGEMEINE INFORMAZIONI ANGABEN RENSEIGNEMENTS GENERALI GENERAUX FAHRZEUGBESCHREIBUNG ...1-1 DESCRIZIONE .......1-1 FAHRZEUG- IDENTIFICAZIONE DEL DESCRIPTION .......1-1 IDENTIFIZIERUNG .....1-2 VEICOLO ........1-2 IDENTIFICATION DE WICHTIGE INFORMATIONEN ...1-3 INFORMAZIONI LA MACHINE ........1-2 ANSCHLÜSSE PRÜFEN ...1-6 IMPORTANTI ........1-3 INFORMATIONS SPEZIALWERKZEUGE .....1-7...
Page 22 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ......... 4-1 EXHAUST PIPE AND SILENCER .... 4-2 RADIATOR ..........4-4 CARBURETOR ......... 4-7 CAMSHAFTS .......... 4-20 CYLINDER HEAD ........4-29 VALVES AND VALVE SPRINGS ... 4-33 CYLINDER AND PISTON ....... 4-42 CLUTCH ..........
Page 23 KAPITEL 4 CHAPITRE 4 CAPITOLO 4 MOTOR MOTEUR MOTORE SITZBANK, SELLE, RESERVOIR DE SELLA, SERBATOIO KRAFTSTOFFTANK UND CARBURANT ET CACHES CARBURANTE E LATERAUX ........4-1 SEITENABDECKUNGEN ...4-1 CARENATURA LATERALE ..4-1 TUYAU D’ECHAPPEMENT KRÜMMER UND TUBO DI SCARICO ET SILENCIEUX ......4-2 SCHALLDÄMPFER ....4-2 E SILENZIATORE ......4-2 RADIATEUR ........4-4 KÜHLER ........4-4...
Page 24 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ......6-1 MAP-CONTROLLED CDI UNIT ....6-2 IGNITION SYSTEM ........6-3 THROTTLE POSITION SENSOR SYSTEM ........6-7 LIGHTING SYSTEM ....... 6-11 CHAPTER 7 TUNING ENGINE ............. 7-1 CHASSIS ..........7-11...
Page 25 KAPITEL 6 CHAPITRE 6 CAPITOLO 6 ELEKTRISCHE PARTIE IMPIANTO ANLAGE ELECTRIQUE ELETTRICO ELEKTRISCHE BAUTEILE COMPOSANTS ELECTRIQUES COMPONENTI ELETTRICI E UND SCHALTPLAN ....6-1 ET SCHEMA DE CABLAGE ..6-1 SCHEMA DI CABLAGGIO ..6-1 KENNFELDGESTEUERTES BLOC CDI CONTROLE PAR UNITÀ CDI CONTROLLATA CDI-ZÜNDSYSTEM ....6-2 MICROPROCESSEUR ....6-2 DA MAPPA ........6-2 ZÜNDANLAGE ......6-3...
Page 26: Description
DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Decompression lever The machine you have purchased may differ 3 Trip meter slightly from those shown in the following. 4 Light switch Designs and specifications are subject to 5 Front brake lever change without notice.
Page 27: Informazioni Generali
DESCRIPTION FAHRZEUGBESCHREIBUNG INFO DESCRIZIONE ALLGEMEINE RENSEIGNEMENTS INFORMAZIONI ANGABEN GENERAUX GENERALI FAHRZEUGBESCHREI- DESCRIPTION DESCRIZIONE BUNG 1 Levier d’embrayage 1 Leva della frizione 2 Levier de décompression 2 Leva della decompressione 1 Kupplungshebel 3 Compteur de vitesse 3 Contachilometri parziale 2 Dekompressionshebel 4 Contacteur d’éclairage 4 Interruttore luci 3 Tageskilometerzähler...
Page 28: Machine Identification
There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
Page 29: Identificazione Del Veicolo
Diebstahlmeldung concessionnaire Yamaha numero al proprio rivenditore d’identifier clairement la machine. Yamaha per identificare corretta- En cas de vol du véhicule, la mente il modello. police réclamera ces numéros Se il veicolo viene rubato, le afin de faciliter son identification.
Page 30: Important Information
IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts follows. Silencer end Air filter intake hole Water pump housing hole at the bottom Carburetor accelerator pump...
Page 31: Informations Importantes
INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFO INFORMAZIONI IMPORTANTI WICHTIGE INFORMATIO- INFORMATIONS IMPOR- INFORMAZIONI IMPOR- TANTES TANTI VORBEREITUNG FÜR AUSBAU PREPARATION POUR LA DEPOSE PREPARATIVI PER LA RIMO- UND ZERLEGUNG ET DEMONTAGE ZIONE E IL DISASSEMBLAGGIO Vor dem Ausbau oder Zerle- Eliminer soigneusement crasse, Rimuovere tutto lo sporco, il gen der Bauteile sämtlichen boue, poussière et corps étrangers...
Page 32 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled.
Page 33 Yamaha lors des kate erfüllen häufig nicht die esclusivamente oli e/o grassi con- gestellten Qualitätsanforde- remontages et réglages. sigliati da Yamaha per il montag- rungen. gio e le regolazioni. JOINTS, BAGUES D’ETANCHEITE DICHTUNGEN, DICHTRINGE UND GUARNIZIONI, PARAOLIO E O-...
Page 34 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1, make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives.
Page 35 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFO INFORMAZIONI IMPORTANTI SICHERUNGSRINGE CIRCLIPS ANELLI ELASTICI DI ARRESTO Avant remontage, tous les circlips Sicherungsringe vor dem Wie- Ispezionare attentamente tutti gli dereinbau sorgfältig überprü- doivent être soigneusement véri- anelli elastici di arresto prima di fen und bei Beschädigung fiés.
Page 36: Checking Of Connection
CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.
Page 37: Verification Des Connexions
VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO VERIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI COL- Die Steckverbinder auf Oxidation, CONNEXIONS LEGAMENTI Rost, Feuchtigkeit usw. prüfen Traitement des taches, de la rouille, de Come gestire macchie, ruggine, umidità, Lösen: l’humidité, etc. sur le connecteur. ecc.
Page 38: Special Tools
SPECIAL TOOLS INFO EC140001 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-1423, 90890-01423 Damper rod holder YM-1423 90890-01423 Use this tool to remove and install the damper rod. YM-01442, 90890-01442 Fork seal driver YM-01442...
Page 40 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc. 1 - 9...
Page 41: Outils Speciaux
OUTILS SPECIAUX INFO OUTILS SPECIAUX Les outils spéciaux appropriés sont indispensables pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres et aux techniques improvisées entraînées par ceux-ci. La forme et le numéro de pièce des outils spéciaux diffèrent selon les pays.
Page 42 OUTILS SPECIAUX INFO Numéros de pièce Nom et usage de l’outil Illustration YU-33975, 90890-01403 Clé à ergots YU-33975 90890-01403 Cet outil est utilisé pour serrer l’écrou crénelé de direction aux spécifications. YM-1423, 90890-01423 Poignée de tige d’amortisseur YM-1423 90890-01423 Utiliser ces outils pour déposer et poser la tige d’amortis- seur.
Page 43 90890-06754 Contrôleur d’allumage. Ce testeur est nécessaire pour contrôler les composants du système d’allumage. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond n˚ 1215 Ce mastic est utilisé sur les plans de joint du carter, etc. 1 - 9...
Page 44 SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden wer- den, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
Page 45 SPEZIALWERKZEUGE INFO Teilenummer Werkzeug/Anwendung Abbildung YU-33975, 90890-01403 Hakenschlüssel YU-33975 90890-01403 Zum Lösen und Festziehen der Lenkkopf-Ringmut- ter. YM-1423, 90890-01423 Dämpferrohr-Halter YM-1423 90890-01423 Zum Lösen und Festziehen der Befestigungs- schraube des Teleskopgabel-Dämpferrohrs. YM-01442, 90890-01442 Gabeldichtring-Treiber YM-01442 90890-01442 Zum Einbau der Gabeldichtringe. YU-3112-C, 90890-03112 Taschen-Multimeter YU-3112-C...
Page 46 90890-04118 YM-4118, 90890-04118 Einlaß 4,0 mm Auslaß 4,5 mm Zum Aufreiben der neuen Ventilführungen. YM-34487 Zündfunkenstreckentester YM-34487 90890-06754 90890-06754 Zündprüfer Zur Überprüfung der Zündanlage. ACC-QUICK-GS-KT Quick gasket ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA-Dichtmasse Nr. 1215 Zum Abdichten der Kurbelgehäuse-Paßflächen. 1 - 9...
Page 47: Utensili Speciali
UTENSILI SPECIALI INFO UTENSILI SPECIALI Sono necessari idonei utensili speciali per una messa a punto e un assemblaggio completi e accurati. L’impiego dell’attrezzo speciale adatto aiuterà a prevenire eventuali danni causati dall’impiego di utensili non idonei o di tecniche improvvisate. La forma e il numero di pezzo utilizzato per l’attrezzo speciale differiscono da paese a paese, pertanto ne vengono indicati due tipi.
Page 48 UTENSILI SPECIALI INFO Numero di pezzo Nome dell’attrezzo/Come utilizzarlo Figura YU-33975, 90890-01403 Chiave per ghiere YU-33975 90890-01403 Questo attrezzo è utilizzato per serrare le ghiere fino ai valori indicati nelle specifiche. YM-1423, 90890-01423 Utensile di blocco dell’asta ammortizzatore YM-1423 90890-01423 Utilizzare questo attrezzo per rimuovere ed installare l’asta dell’ammortizzatore.
Page 49 Questo attrezzo è necessario per il controllo dei componenti del sistema di accensione. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond n. 1215 Questo materiale di tenuta (agglomerante) è utilizzato per chiudere ermeticamente due superfici di contatto, ecc. 1 - 9...
Page 50: Control Functions
CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar;...
Page 51: Fonctions Des Commandes
FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION INFO FUNZIONI DI COMANDO ARMATUREN UND DE- FONCTIONS DES COM- FUNZIONI DI COMANDO REN FUNKTION MANDES INTERRUTTORE ARRESTO DEL MOTORE MOTORSTOPPSCHALTER COUPE-CIRCUIT DU MOTEUR L’interruttore di arresto del motore 1 è Der Motorstoppschalter 1 befindet Le coupe-circuit du moteur 1 est situé...
Page 52 CONTROL FUNCTIONS INFO DECOMPRESSION LEVER CAUTION: Never use the decompression lever after the engine is started. The engine may be damaged if you use the decompression lever while it is running. The decompression lever 1 is located on the left handlebar and is used when starting the engine.
Page 53 FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION INFO FUNZIONI DI COMANDO DEKOMPRESSIONSHEBEL LEVIER DE DECOMPRESSION LEVA DI DECOMPRESSIONE ATTENTION: ATTENZIONE: ACHTUNG: Ne jamais employer le levier de Den Dekompressionshebel unter Non utilizzare mai la leva di decom- décompression une fois que le moteur keinen Umständen bei laufendem pressione dopo aver avviato il motore.
Page 54: Fuel
CONTROL FUNCTIONS INFO EC158010 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the three positions: OFF:With the lever in this position, fuel will not flow. Always return the lever to this posi- tion when the engine is not running.
Page 55 FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION INFO FUNZIONI DI COMANDO KRAFTSTOFFHAHN ROBINET DE CARBURANT RUBINETTO DEL CARBURANTE Le robinet de carburant fournit le carbu- Der Kraftstoffhahn regelt die Kraft- Il rubinetto del carburante alimenta il stoffzufuhr vom Tank zum Vergaser rant du réservoir au carburateur et la fil- carburante dal serbatoio al carburatore tre.
Page 56 CONTROL FUNCTIONS/FUEL INFO EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. LIGHTS SWITCH The lights switch 1 is located on the handle- bar.
Page 57: Essence
FONCTIONS DES COMMANDES/ESSENCE ARMATUREN UND DEREN FUNKTION/KRAFTSTOFF INFO FUNZIONI DI COMANDO/CARBURANTE AUSLAUFSCHUTZVENTIL CLAPET DE DURIT DE MISE A GIUNTO A VALVOLA LIAIR Das Auslaufschutzventil 1 ist in den Questo giunto a valvola 1 impedisce la Ce clapet 1 évite que l’essence ne Kraft–stofftank-Belüftungsschlauch fuoriuscita di carburante e va installato s’échappe et est monté...
Page 58: Starting And Break-In
STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: The carburetor on this motorcycle has a built-in...
Page 59: Anlassen Und Einfahren
MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN INFO AVVIO E RODAGGIO ANLASSEN UND EINFAH- MISE EN MARCHE ET AVVIO E RODAGGIO RODAGE AVVERTENZA WARNUNG AVERTISSEMENT Non avviare mai né tenere in funzione il motore in un’area chiusa. I gas di Den Motor keinesfalls in geschlos- Ne jamais mettre le moteur en marche scarico sono velenosi, possono provo-...
Page 60 STARTING AND BREAK-IN INFO 6. Pull the decompression lever to the han- dlebar and depress the kickstarter crank 10 ~ 20˚. 7. Release the decompression lever and return the kickstarter crank to its original position and then kick the kickstarter crank.
Page 61 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN INFO AVVIO E RODAGGIO Dekompressionshebel Actionner à fond le levier de Tirare la leva di decompressione décompression et actionner le anziehen und den Kickstarter- verso il manubrio e premere la hebel um 10–20˚ heruntertre- kick à...
Page 62 STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Open the hot starter knob (red) and start the engine by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, push in the hot starter knob to close the air passage.
Page 63 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN INFO AVVIO E RODAGGIO STARTEN MIT WARMEM MOTOR MISE MARCHE D’UN AVVIAMENTO DI UN MOTORE MOTEUR CHAUD Zum Anlassen des warmen Motors CALDO weder den Kaltstarterknopf drücken Ne pas activer le bouton de démarrage a Non agire sulla manopola di avviamento froid ni l’accélérateur.
Page 64: Torque-Check Points
STARTING AND BREAK-IN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.
Page 65 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN INFO AVVIO E RODAGGIO EINFAHRVORSCHRIFTEN PROCEDURE DE RODAGE PROCEDURE DI RODAGGIO Avant de mettre le moteur en Vor dem Anlassen des Motors Prima di avviare il motore, riem- volltanken. marche, faire le plein d’essence. pire 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 Steering Steering stem to Steering stem to frame Steering stem to upper bracket handlebar Upper bracket to handlebar Suspension...
Page 67: Points De Verification De Couple De Serrage
POINTS DE VERIFICATION DE COUPLE DE SERRAGE INFO POINTS DE VERIFICATION DE COUPLE DE SERRAGE Construction du cadre Cadre et cadre arrière Fixation entre selle Réservoir de carburant et cadre et réservoir Système d’échappement Silencieux et cadre arrière Montage du moteur Cadre et moteur Direction Colonne de...
Page 68: Anzugsmomente Kontrollieren
ANZUGSMOMENTE KONTROLLIEREN INFO ANZUGSMOMENTE KONTROLLIEREN Rahmen Hauptrahmen und Rahmenhinterteil Sitzbank und Kraftstofftank Kraftstofftank und Rahmen Auspuff-System Schalldämpfer an Hinterrahmen Motoraufhängung Rahmen und Motor Lenkung Lenkkopf bis Lenkkopf und Teleskopgabel Lenkkopf und obere Gabelbrücke Lenker obere Gabelbrücke und Lenker Radaufhängung Vorn Lenkkopf bis Teleskopgabel obere Gabelbrücke Teleskopgabel...
Page 69: Punti Per Il Controllo Del Serraggio
PUNTI PER IL CONTROLLO DEL SERRAGGIO INFO PUNTI PER IL CONTROLLO DEL SERRAGGIO Struttura del telaio Telaio al telaio posteriore Sella e serbatoio del Serbatoio del carburante al telaio carburante combinati Sistema di scarico Marmitta di scarico al telaio posteriore Supporto motore Telaio al motore Sterzo...
Page 70: Cleaning And Storage
CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good over- all performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
Page 71: Nettoyage Et Rangement
NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG INFO PULIZIA ED IMMAGAZZINAGGIO REINIGUNG UND STILLE- NETTOYAGE ET RANGE- PULIZIA ED IMMAGAZ- GUNG MENT ZINAGGIO REINIGUNG NETTOYAGE PULIZIA Eine regelmäßige, gründliche Un nettoyage fréquent de la machine Una pulizia frequente del veicolo ne Wäsche sorgt nicht nur für gutes améliorera son aspect, maintiendra ses migliora l’aspetto, aiuta a mantenere...
Page 72 CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float bowl.
Page 73 NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG INFO PULIZIA ED IMMAGAZZINAGGIO STILLEGUNG RANGEMENT IMMAGAZZINAGGIO Si l’on remise la machine pour 60 jours Vor einer mehr als zweimonatigen Se il veicolo va immagazzinato 60 giorni Stillegung sollten einige Schutzvor- ou plus, il faut prendre des mesures de o oltre, è...
Page 74: General Specifications
SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR250FN (USA) WR250F (EUROPE) WR250F(N) (CDN, AUS, NZ, ZA) Model code number: 5PH1 (USA) 5PH2 (EUROPE) 5PH4 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,165 mm (85.2 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in)
Page 75: Chassis
SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt) With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt) Total amount 1.7 L (1.50 Imp qt, 1.80 US qt) Coolant capacity (including all routes): 1.3 L (1.14 Imp qt, 1.37 US qt) Air filter:...
Page 76 SPEC GENERAL SPECIFICATIONS Tire: Type With tube Size (front) 80/100-21 51M (For USA, CDN and ZA) 90/90-21 54R (For EUROPE, AUS and NZ) Size (rear) 100/100-18 59M (For USA, CDN and ZA) 120/90-18 65R (For EUROPE, AUS and NZ) Tire pressure (front and rear) 100 kPa (1.0 kg/cm , 15 psi) Brake:...
Page 77: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00 ~ 77.01 mm ---- (3.0315 ~ 3.0319 in) Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ----...
Page 78 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm ---- (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm ---- (0.0067 ~ 0.0087 in) Valve dimensions:...
Page 79 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) Valve spring: Free length 37.81 mm (1.49 in)
Page 80 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002 ~ 16.013 mm 16.043 mm (0.6300 ~ 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 ~ 16.000 mm 15.971 mm (0.6296 ~ 0.6299 in) (0.6288 in) Piston rings: Top ring: Type Barrel...
Page 81 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.9 ~ 3.1 mm 2.7 mm (0.114 ~ 0.122 in) (0.106 in) Quantity ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 in)
Page 82 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Wire mesh 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 Spark plug M10S Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (stud bolt) 1.25 (bolt) 1.25 (nut) Cylinder head cover Oil pressure check bolt Cylinder Balancer weight Balancer shaft driven gear...
Page 84 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Silencer 1.25 Silencer clamp 1.25 Spark arrester (for USA) Silencer end pipe (for USA) Crankcase Crankcase bearing stopper Crankcase bearing stopper (crankshaft) Left crankcase cover Right crankcase cover Clutch cover Crankcase oil drain bolt 1.25...
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 Front fork travel 300 mm (11.8 in) Fork spring free length 460 mm (18.1 in) Spring rate, STD K = 4.31 N/mm K = 4.12 N/mm K = 4.02 N/mm...
Page 86 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 1.60/Aluminum ---- Rear rim size/material 1.85/Aluminum ---- Rim runout limit: Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in) Drive chain:...
Page 87 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Upper bracket and outer tube 1.25 Lower bracket and outer tube 1.25 Upper bracket and steering stem 14.5 Handlebar holder and upper bracket 1.25 Steering stem and steering ring nut Refer to NOTE.
Page 88 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Rear brake disc Brake pedal 1.25 Rear brake master cylinder Rear brake reservoir tank Rear brake reservoir tank cap Rear brake hose union bolt 1.25 Rear wheel axle and axle nut 12.5 Nipple (spoke) —...
Page 89 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Headlight stay (lower) and lower bracket Headlight (left and right) Headlight (lower) Taillight Taillight lead clamp and rear fender 1.59 Coolant reservoir Sidestand bracket and frame 1.25 Sidestand 1.25...
Page 90 Item Standard Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model/manufacturer F5NG 00/YAMAHA ---- Charging coil 1 resistance (color) 640 ~ 960 at 20 ˚C (68 ˚F) ---- (Green – Brown) Charging coil 2 resistance (color) 464 ~ 696 at 20 ˚C (68 ˚F) ---- (Green –...
Page 91: 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 92: Caracteristiques Generales
SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: WR250FN (USA) WR250F (EUROPE) WR250F(N) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5PH1 (USA) 5PH2 (EUROPE) 5PH4 (CDN, AUS, NZ, ZA) Dimensions: Longueur hors tout 2.165 mm (85,2 in) Largeur hors tout 827 mm (32,6 in) Hauteur hors tout...
Page 93 SPEC CARACTERISTIQUES GENERALES Quantité d’huile: Huile moteur Vidange périodique 1,5 L (1,32 Imp qt, 1,59 US qt) Avec remplacement du ﬁltre à huile 1,6 L (1,41 Imp qt, 1,69 US qt) Quantité totale 1,7 L (1,50 Imp qt, 1,80 US qt) Quantité...
Page 94 SPEC CARACTERISTIQUES GENERALES Pneu: Type de pneu Avec chambre à air Taille de pneu (avant) 80/100-21 51M (USA, CDN et ZA) 90/90-21 54R (EUROPE, AUS et NZ) Taille de pneu (arrière) 100/100-18 59M (USA, CDN et ZA) 120/90-18 65R (EUROPE, AUS et NZ) Pression de pneu (avant et arrière) 100 kPa (1,0 kg/cm , 15 psi)
Page 95: Caracteristiques D'entretien
SPEC CARACTERISTIQUES D’ENTRETIEN CARACTERISTIQUES D’ENTRETIEN MOTEUR Article Standard Limite Culasse: Limite de déformation ---- 0,05 mm (0,002 in) Cylindre: Alésage 77,00 à 77,01 mm ---- (3,0315 à 3,0319 in) Limite d’ovalisation ---- 0,05 mm (0,002 in) Arbre à cames: Méthode d’entraînement Transmission par chaîne (gauche) ---- Diamètre intérieur de chapeau...
Page 96 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Chaîne de distribution: Type de chaîne de distribution/nbre de maillons 92RH2010-114M/114 ---- Méthode de réglage de la chaîne de distribution Automatique ---- Soupape, siège de soupape, guide de soupape: Jeu de soupape (à froid) 0,10 à...
Page 97 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Limite de faux-rond de queue ---- 0,01 mm (0,0004 in) Largeur de siège de soupape 0,9 à 1,1 mm 1,6 mm (0,0354 à 0,0433 in) (0,0630 in) 0,9 à 1,1 mm 1,6 mm (0,0354 à 0,0433 in) (0,0630 in) Ressort de soupape: Longueur libre...
Page 98 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Décalage d’oriﬁce d’axe de piston 0,5 mm (0,020 in)/côté AD ---- Diamètre intérieur d’alésage d’axe de piston 16,002 à 16,013 mm 16,043 mm (0,6300 à 0,6304 in) (0,6316 in) Diamètre extérieur d’axe de piston 15,991 à...
Page 99 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Embrayage: Epaisseur de disque de friction 2,9 à 3,1 mm 2,7 mm (0,114 à 0,122 in) (0,106 in) Quantité ---- Epaisseur de disque d’embrayage 1,1 à 1,3 mm (0,043 à 0,051 in) ---- Quantité ---- Limite de déformation ----...
Page 100 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Système de graissage: Type de ﬁltre à huile A treillis métallique ---- Type de pompe à huile Trochoïde ---- Jeu en bout 0,12 mm ou moins 0,20 mm (0,0047 in ou moins) (0,008 in) Jeu latéral 0,09 à...
Page 101 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb Bougie M10S Chapeau d’arbre à cames Vis de plot borgne de culasse Culasse (boulon prisonnier) (boulon prisonnier) 1,25 (boulon) 1,25 (écrou) Couvre culasse Boulon de contrôle de la pression d’huile Cylindre Contre-poids de balancier Arbre de balancier...
Page 102 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb Silencieux 1,25 Bride du silencieux 1,25 Pare-étincelles (pour les USA) Chicane (pour les USA) Carter Butoir de roulement de demi-carter Butoir de roulement de demi-carter (vilebrequin) Demi-carter moteur gauche Demi-carter moteur droit Couvercle d’embrayage...
Page 103 SPEC CARACTERISTIQUES D’ENTRETIEN PARTIE-CYCLE Article Standard Limite Direction: Type de roulement de direction Roulement à rouleaux conique ---- Suspension avant: USA, CDN EUROPE AUS, NZ, ZA Débattement de fourche avant 300 mm (11,8 in) Longueur libre de ressort de fourche 460 mm (18,1 in) Constante de ressort, standard K = 4,31 N/mm...
Page 104 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Roue: Type de roue avant Roue à rayons ---- Type de roue arrière Roue à rayons ---- Taille/matériau de jante avant 1,60/aluminum ---- Taille/matériau de jante arrière 1,85/aluminum ---- Limite de voile de jante: Radial ---- 2,0 mm...
Page 105 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb Té supérieur et fourreau 1,25 Té inférieur et fourreau 1,25 Té supérieur et colonne de direction 14,5 Demi-palier de guidon et té supérieur 1,25 Colonne de direction et écrou crénelé de direction Se reporter à...
Page 106 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb Disque de frein arrière Pédale de frein 1,25 Maître-cylindre de frein arrière Réservoir de liquide de frein arrière Couvercle du réservoir de liquide de frein arrière Boulon raccord de durit de frein arrière 1,25 Axe de roue arrière et écrou d’axe...
Page 107 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté ﬁletage m·kg ft·lb Support de phare (inférieur) et té inférieur Phare (gauche et droite) Phare (bas) Feu arrière Bride de ﬁl de feu arrière et garde-boue arrière 1,59 Réservoir de liquide de refroidissement Support de béquille latérale et cadre 1,25...
Page 108 Standard Limite Système d’allumage: Type de dispositif d’avance Electrique ---- CDI: Modèle/fabricant de la magnéto F5NG 00/YAMAHA ---- Résistance de bobine de charge 1 640 à 960 à 20 ˚C (68 ˚F) ---- (couleur) (vert – brun) Résistance de bobines de charge 2 464 à...
Page 109: Caracteristiques Generales De Couple
CARACTERISTIQUES GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES CARACTERISTIQUES GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des atta- ches standard avec filetage à pas I.S.O. standard. Les spécifications de couple pour les composants ou ensembles spéciaux sont indiquées dans les sec- tions appropriées de ce manuel.
Page 110: Allgemeine Technische Daten
SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname WR250F Modellcode 5PH2 Abmessungen Gesamtlänge 2.165 mm Gesamtbreite 827 mm Gesamthöhe 1.303 mm Sitzhöhe 998 mm Radstand 1.475 mm Bodenfreiheit 382 mm Fahrzeuggewicht (fahrfertig, vollgetankt) 110,0 kg Motor Bauart ﬂüssigkeitsgekühlter 1-Zyl.-4-Takt-Ottomotor, 2 obenliegende Nockenwellen (DOHC) Zylinderanordnung 1-Zylinder, nach vorn geneigt...
Page 111: Kraftstoff
SPEC ALLGEMEINE TECHNISCHE DATEN Füllmenge Ölwechsel ohne Filterwechsel 1,5 L Ölwechsel mit Filterwechsel 1,6 L Gesamtmenge 1,7 L Kühlsystem-Fassungsvermögen 1,3 L (Gesamtmenge) Luftﬁlter Naßfilter-Einsatz Kraftstoff Sorte Bleifreies Superbenzin mit einer Oktanzahl von mind. 95 Tankinhalt 8,0 L Reserve 1,4 L Vergaser Modell FCR-MX37...
Page 112: Allgemeine Technische Daten
SPEC ALLGEMEINE TECHNISCHE DATEN Reifen Bauart Schlauchreifen Dimension vorn 90/90-21 54R hinten 120/90-18 65R Reifenluftdruck (vorn und hinten) 100 kPa (1,0 bar) Bremsanlage vorn Bauart Einscheibenbremse Betätigung Handbremshebel (rechts) hinten Bauart Einscheibenbremse Betätigung Fußbremshebel (rechts) Radaufhängung vorn Teleskopgabel hinten Monocross-Schwinge Federelemente vorn hydraulisch gedämpfte Teleskopgabel mit Spi-...
Page 113: Wartungsdaten
SPEC WARTUNGSDATEN WARTUNGSDATEN MOTOR Bezeichnung Speziﬁkation Grenzwert Zylinderkopf Max. Verzug ---- 0,05 mm Zylinder Bohrungsdurchmesser 77,00–77,01 mm ---- Max. Ovalität ---- 0,05 mm Nockenwelle Antrieb Steuerkette (links) ---- Nockenwellenlager-Durchmesser 22,000–22,021 mm ---- Nockenwellen-Außendurchmesser 21,967–21,980 mm ---- Lagerspiel 0,020–0,054 mm 0,08 mm Nockenabmessungen Einlaß...
Page 114 SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Steuerkette Typ/Gliederzahl 92RH2010-114M/114 ---- Kettenspannung automatisch ---- Ventile, Ventilsitze, Ventilführungen Ventilspiel (kalt) Einlaß 0,10–0,15 mm ---- Auslaß 0,17–0,22 mm ---- Ventilabmessungen Ventilsitzbreite Ventiltellerstärke Ventiltellerdurchmesser Ventilkegelbreite Ventilteller-Durchmesser Ventilteller-Breite Ventilsitz-Breite Ventilteller-Stärke Ventiltellerdurchmesser “A” Einlaß 22,9–23,1 mm ---- Auslaß...
Page 115 SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Max. Ventilschaftschlag ---- 0,01 mm Ventilsitzbreite Einlaß 0,9–1,1 mm 1,6 mm Auslaß 0,9–1,1 mm 1,6 mm Ventilfeder Ungespannte Länge Einlaß 37,81 mm 35,9 mm Auslaß 37,54 mm 35,7 mm Einbaulänge (Ventil geschlossen) Einlaß 29,13 mm ---- Auslaß...
Page 116 SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Kolbenbolzenaugen-Durchmesser 16,002–16,013 mm 16,043 mm Kolbenbolzen-Durchmesser 15,991–16,000 mm 15,971 mm Kolbenringe 1. Kompressionsring (Topring) Ausführung abgerundet ---- Abmessungen (B 0,90 2,75 mm ---- Stoßspiel (eingebaut) 0,15–0,25 mm 0,50 mm Ringnutspiel (eingebaut) 0,030–0,065 mm 0,12 mm 2.
Page 117 SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Kupplung Reibscheiben Stärke 2,9–3,1 mm 2,7 mm Anzahl ---- Kupplungsscheiben Stärke 1,1–1,3 mm ---- Anzahl ---- Verzug ---- 0,1 mm Kupplungsfeder ungesp. Länge 39,1 mm 38,1 mm Anzahl ---- Kupplungsgehäuse Axialspiel 0,10–0,35 mm ---- Radialspiel 0,010–0,044 mm ---- Kupplungs-Ausrückmechanismus...
Page 118 SPEC WARTUNGSDATEN Bezeichnung Speziﬁkation Grenzwert Schmiersystem Ölﬁlter Drahtgeﬂecht-Einsatz ---- Ölpumpe Rotorpumpe ---- Radialspiel 0,12 mm oder weniger 0,20 mm Axialspiel 0,09–0,17 mm 0,24 mm Gehäuse und Rotorabstand 0,03–0,10 mm 0,17 mm Kühlsystem Kühlerabmessungen Breite 117,8 mm ---- Höhe 220 mm ---- Tiefe 32 mm...
Page 119 SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg Zündkerze M10S Zündkerzenstecker Zylinderkopf-Blindstopfenschraube Zylinderkopf (Stiftschraube) (Stiftschraube) 1,25 (Schraube) 1,25 (Mutter) Zylinderkopfdeckel Öldruckprüfschraube Zylinder Ausgleichergewicht Ausgleichswellen-Abtriebsrad Steuerkettenführung (Einlaßseite) Dekompressionsvorrichtungs-Welle Dekompressionszugscheibe Steuerkettenspanner Steuerketten-Spannkappenschraube Flügelrad 1,25 Kühlwasserschlauchschelle Kühlmittel-Ablaßschraube Wasserpumpengehäuse Kühler Kühlerschutz Kühlerleitung Ölpumpendeckel Ölpumpe Ölfiltereinsatz-Ablaufstutzen Ölfilterelement-Abdeckung Ölfilter...
Page 120 SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg Schalldämpfer 1,25 Schalldämpfer-Schlauchschelle 1,25 Funkenfänger (für USA) Schalldämpferendröhre (für USA) Kurbelgehäuse Kurbelkasten-Lageranschlag Kurbelkasten-Lageranschlag (Kurbelwell) Kurbelgehäusedeckel (links) Kurbelgehäusedeckel (rechts) Kupplungsdeckel Kurbelgehäuse-Ölablaufstutzen 1,25 Antriebsritzel-Abdeckung Kickstarter-Rastenradführung Kickstarterhebel 1,25 Primärantriebszahnrad Kupplungsfeder Kupplungsnabe Druckhebelwelle Antriebsritzel Öldichtringanschlag der Antriebachse Segment 1,25 Führungsstange...
Page 121 SPEC WARTUNGSDATEN FAHRWERKL Bauteil Speziﬁkation Grenzwert Lenkung Lenkkopflager Kegelrollenlager ---- Federelement vorn Federweg 300 mm Gabelfeder, ungespannte Länge 460 mm Standard-Federrate K = 4,12 N/mm (0,42 kg/mm) Umrüstmöglichkeiten Ölmenge 578 cm Füllhöhe 130 mm <Min.–Max.> 80–150 mm (gemessen von der Oberkante des Standrohres, Gabel und Dämpfer- rohr vollständig eingefedert, ohne Gabelfeder)
Page 122 SPEC WARTUNGSDATEN Bauteil Speziﬁkation Grenzwert Räder Bauart: Vorderrad Speichenrad ---- Hinterrad Speichenrad ---- Felgendimension/-material ---- Vorderrad 1,60/Aluminium ---- Hinterrad 1,85/Aluminium ---- Max. Felgenschlag Höhenschlag ---- 2,0 mm Seitenschlag ---- 2,0 mm Antriebskette Typ (Hersteller) DID520VM/DAIDO ---- Anzahl der Kettenglieder 113 + Kettenschloß ---- Kettendurchhang 40–50 mm...
Page 123 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg Oberbügel und Außenröhre 1,25 Unterbügel und Außenröhre 1,25 Oberbügel und Lenkschaft 14,5 Lenkerhalter und Oberbügel 1,25 Lenkschaft und Lenkringmutter Siehe HINWEIS. Telegabel und Telegabelkappenschraube Telegabel und Basisventil Telegabelkappenschraube und Dämpferstange 1,25 Telegabelentlüftungsschraube und Telegabelkappen- schraube Telegabel und Telegabelschutz Instrumentenkabelhalter und Telekabelprotektor...
Page 124 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg Hinterradbremsscheibe Bremspedal 1,25 Hinterradbrems-Hauptzylinder Hinterradbrems-Ausgleichsbehälter Hinterradbrems-Ausgleichsbehälterdeckel Hinterradbremsschlauch-Verbindungsschraube 1,25 Hinterradachse und Achsmutter 12,5 Nippel (Speiche) — Hinterrad-Speiche 1,25 Hinterrad-Bremsscheibendeckel Hinterrad-Bremssattelschutz Motorhalterung Motor und Motorbügel (vorne) 1,25 Motor und Rahmen (unten) 1,25 Motorbügel und Rahmen 1,25 Motor und Motorbügel (oben) 1,25...
Page 125 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg Scheinwerferstrebe (unten) und unterer Bügel Scheinwerfer (links und rechts) Scheinwerfer (unten) Rückleuchte Rückleuchtenleitungsklemme und hinteres Schutzblech 1,59 Kühlmittelreservoir Seitenständer-Bügel und Rahmen 1,25 Seitenständer 1,25 HINWEIS: : Sicherstellen, daß diese Teile nach dem Einfahren und vor jedem Rennen vorschriftsmäßig festgezogen sind.
Page 126 WARTUNGSDATEN ELEKTRISCHE ANLAGE Bauteil Speziﬁkation Grenzwert Zündsystem Zündversteller elektrisch ---- CDI-Schwungradmagnetzünder Typ (Hersteller) F5NG 00/YAMAHA ---- Widerstand (Farbe) der Erregerspule 1 640–960 bei 20 ˚C ---- (grün – braun) Widerstand (Farbe) der Erregerspule 2 464–696 bei 20 ˚C ---- (grün – rosa) Lichtspulenwiderstand (Farbe) 0,16–0,24...
Page 127: Allgemeine Anzugsmomente
ALLGEMEINE ANZUGSMOMENTE/ SPEC EINHEITEN ALLGEMEINE ANZUGSMOMENTE Aus der folgenden Tabelle sind die Anzugsmo- mente für normale Schraubverbindungen mit ISO-Normgewinde ersichtlich. Anzugsmomente für spezielle Verschraubungen und Bauteile wer- den in jedem Abschnitt dieser Anleitung geson- dert aufgeführt. Um ein Verziehen der Bauteile zu vermeiden, sollten die Schraubverbindungen über Kreuz angezogen werden, bis die vorge- schriebenen Anzugsmomente erreicht sind.
Page 128: Specifiche Generali
SPEC SPECIFICHE GENERALI SPECIFICHE SPECIFICHE GENERALI Nome del modello: WR250FN (USA) WR250F (EUROPA) WR250F(N) (CDN, AUS, NZ, ZA) Codice del modello: 5PH1 (USA) 5PH2 (EUROPA) 5PH4 (CDN, AUS, NZ, ZA) Dimensioni: Lunghezza totale 2.165 mm (85,2 in) Larghezza totale 827 mm (32,6 in) Altezza totale 1.303 mm (51,3 in) Altezza della sella...
Page 129 SPEC SPECIFICHE GENERALI Capacità olio: Olio motore Cambio d’olio periodico 1,5 L (1,32 Imp qt, 1,59 US qt) Con cambio filtro olio 1,6 L (1,41 Imp qt, 1,69 US qt) Quantità totale 1,7 L (1,50 Imp qt, 1,80 US qt) Capacità...
Page 130 SPEC SPECIFICHE GENERALI Pneumatici: Tipo Con camera d’aria Dimensioni (anteriore) 80/100-21 51M (Per USA, CDN e ZA) 90/90-21 54R (Per l’EUROPA, AUS e NZ) Dimensioni (posteriore) 100/100-18 59M (Per USA, CDN e ZA) 120/90-18 65R (Per l’EUROPA, AUS e NZ) Pressione pneumatici (anteriore e posteriore) 100 kPa (1,0 kg/cm , 15 psi)
Page 131: Specifiche Di Manutenzione
SPEC SPECIFICHE DI MANUTENZIONE SPECIFICHE DI MANUTENZIONE MOTORE Elemento Standard Limite Testata del cilindro: Limite di deformazione ---- 0,05 mm (0,002 in) Cilindro: Dimensioni alesaggio 77,00 ~ 77,01 mm ---- (3,0315 ~ 3,0319 in) Limite di ovalizzazione ---- 0,05 mm (0,002 in) Albero a camme: Metodo di trasmissione...
Page 132 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Catena di distribuzione: Tipo catena di distribuzione/N. di maglie 92RH2010-114M/114 ---- Metodo di regolazione della catena di Automatico ---- distribuzione Valvola, sede valvola, guidavalvola: Gioco valvola (a freddo) 0,10 ~ 0,15 mm ---- (0,0039 ~ 0,0059 in) 0,17 ~ 0,22 mm ----...
Page 133 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Limite disassamento stelo ---- 0,01 mm (0,0004 in) Larghezza sede valvola 0,9 ~ 1,1 mm 1,6 mm (0,0354 ~ 0,0433 in) (0,0630 in) 0,9 ~ 1,1 mm 1,6 mm (0,0354 ~ 0,0433 in) (0,0630 in) Molla valvola: Lunghezza libera...
Page 134 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Decentramento del pistone 0,5 mm (0,020 in)/lato INT ---- 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:...
Page 135 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Frizione: Spessore del disco conduttore 2,9 ~ 3,1 mm 2,7 mm (0,114 ~ 0,122 in) (0,106 in) Quantità ---- Spessore del disco condotto 1,1 ~ 1,3 mm (0,043 ~ 0,051 in) ---- Quantità ---- Limite di deformazione ----...
Page 136 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Sistema di lubrificazione: Tipo di filtro Tipo a maglia metallica ---- Tipo di pompa dell’olio Tipo trocoidale ---- Gioco della punta 0,12 mm o inferiore 0,20 mm (0,0047 in o inferiore) (0,008 in) Gioco laterale 0,09 ~ 0,17 mm 0,24 mm...
Page 137 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb Candela d’accensione M10S Cappello dell’albero a camme Tappo a vite testata del cilindro Testata del cilindro (prigioniero) (prigioniero) 1,25 (bullone) 1,25 (dado) Coperchio testata del cilindro Bullone di controllo pressione olio Cilindro Peso bilanciere...
Page 138 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb Marmitta di scarico 1,25 Morsetto marmitta di scarico 1,25 Parascintille (per USA) Tubo finale silenziatore (per USA) Carter Tappo cuscinetto carter Tappo cuscinetto carter (albero a gomiti) Coperchio carter sinistro Coperchio carter destro Carter frizione...
Page 139 SPEC SPECIFICHE DI MANUTENZIONE PARTE CICLISTICA Elemento Standard Limite Sistema di sterzo: Tipo di cuscinetti sterzo Cuscinetto conico a rulli ---- Sospensione anteriore: USA, CDN EUROPE AUS, NZ, ZA Corsa forcella anteriore 300 mm (11,8 in) Lunghezza libera della molla della 460 mm (18,1 in) forcella Flessibilità, STD...
Page 140 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Ruota: Tipo ruota anteriore Ruota a raggi ---- Tipo ruota posteriore Ruota a raggi ---- Dimensioni/materiale cerchio anteriore 1,60/alluminio ---- Dimensioni/materiale cerchio posteriore 18 1,85/alluminio ---- Limite di disassamento cerchio: Radiale ---- 2,0 mm (0,08 in) Laterale ----...
Page 141 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura Staffa superiore e tubo esterno 1,25 Staffa inferiore e tubo esterno 1,25 Staffa superiore e cannotto dello sterzo 14,5 Supporto manubrio e staffa superiore 1,25 Cannotto dello sterzo e ghiera Fare riferimento alle NOTA.
Page 142 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura Disco freno posteriore Pedale del freno 1,25 Pompa freno posteriore Serbatoio del freno posteriore Tappo serbatoio freno posteriore Vite di unione del tubo flessibile del freno 1,25 posteriore Asse ruota posteriore e dado asse...
Page 143 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura Supporto del faro (inferiore) e staffa inferiore Faro (sinistro e destro) Faro (inferiore) Fanalino posteriore Fascetta stringicavo del fanalino posteriore e 1,59 parafango posteriore Serbatoio del liquido di raffreddamento Staffa del cavalletto laterale e telaio 1,25...
Page 144 Limite Impianto di accensione: Tipo di dispositivo di anticipo Elettrico ---- CDI.: Modello/costruttore magneto F5NG 00/YAMAHA ---- Resistenza bobina di carica 1 (colore) 640 ~ 960 a 20 ˚C (68 ˚F) ---- (Verde – Marrone) Resistenza bobina di carica 2 (colore) 464 ~ 696 a 20 ˚C (68 ˚F)
Page 145: Specifiche Relative
SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO SPEC GENERALI/DEFINIZIONE DELLE UNITÀ DI MISURA SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO GENERALI Questo grafico specifica le coppie di serraggio per dispositivi di fissaggio convenzionali con filetti a passo convenzionale I.S.O. I dati relativi alla coppia di serraggio per i componenti speciali sono inclusi nei relativi paragrafi di questo manuale.
Page 146: Cable Routing Diagram
SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM Î Fasten the engine stop switch 1 Hose guide I Carburetor overflow hose lead and ignition coil lead of the 2 Brake hose J Coolant reservoir breather hose sub-wire harness. 3 Voltage regulator K Decompression cable ‰...
Page 147: Cheminement Des Cables
CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI KABELFÜHRUNG CHEMINEMENT DES SCHEMA DEL PER- 1 Schlauchführung CABLES CORSO DEI CAVI 2 Bremsschlauch 1 Guide de durit 1 Guida del tubo flessibile 3 Spannungsregulator 2 Durit de frein 2 Tubo flessibile del freno 4 Lichtschalterleitung 3 Régulateur de tension 3 Regolatore di tensione...
Page 148 SPEC CABLE ROUTING DIAGRAM Ù Ò Pass the carburetor breather Â Pass the clutch cable in front of Pass the carburetor breather hose overflow hose the radiator mounting boss. hoses and overflow hose so Í Fit the brake hose into the between the connecting rod that all there hoses do not con- and cross tube (frame).
Page 149 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI Ò Faire passer la durit de mise à l’air du car- Ò Den Vergaser-Lüftungsschlauch und Ò Far passare il tubetto di sfiato del carbura- burateur et la durit de trop-plein entre la den Überlaufschlauch zwischen Pleu- tore e il tubo flessibile di troppopieno tra bielle et le tube transversal (cadre).
Page 150 SPEC CABLE ROUTING DIAGRAM Å Fasten the coolant reservoir breather hose and 1 Coolant reservoir breather hose 2 Radiator breather hose carburetor breather hose together. ı Pass the throttle cables along inner side of the 3 Ignition coil 4 CDI unit spark plug lead.
Page 151 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Durit de mise à l’air du vase d’expansion 1 Kühlmittelausgleichsbehälter-Lüf- 1 Tubetto di sfiato del serbatoio del liquido 2 Durit de mise à l’air du radiateur tungsschlauch di raffreddamento 3 Bobine d’allumage 2 Kühler-Lüftungsschlauch 2 Tubetto di sfiato radiatore...
Page 152 SPEC CABLE ROUTING DIAGRAM Å Fasten the coolant reservoir hose and coolant 1 Coolant reservoir hose 2 Coolant reservoir breather hose reservoir breather hose. ı Do not allow the taillight lead to slacken. 3 Clamp Ç Pass the coolant reservoir hose and coolant res- 4 Taillight lead 5 Hose guide ervoir breather hose through the hose guide.
Page 153 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Durit du vase d’expansion 1 Kühlmittel-Ausgleichsbehält- 1 Tubo flessibile del serbatoio del liquido di 2 Durit de mise à l’air du vase d'expansion erschlauch raffreddamento 3 Bride 2 Kühlmittel-Ausgleichsbehälter-Lüf- 2 Tubetto di sfiato del serbatoio del liquido 4 Fil de feu arrière tungsschlauch...
Page 154 SPEC CABLE ROUTING DIAGRAM Å Install the brake hose to the brake caliper with the 1 Brake hose 2 Brake hose holder paint on the pipe facing the brake caliper and with 3 Brake master cylinder the pipe contacting the brake caliper projection. ı...
Page 155 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Durit de frein 1 Bremsschlauch 1 Flessibile del freno 2 Support de durit de frein 2 Bremsschlauchhalter 2 Supporto tubo flessibile del freno 3 Maître-cylindre de frein 3 Hauptbremszylinder 3 Pompa del freno Å...
Page 156 SPEC CABLE ROUTING DIAGRAM Å Fasten the engine stop switch lead to the handlebar with the plastic 1 Throttle cable 2 Light switch band. ı Pass the decompression cable between the brake hose and clutch 3 Light switch lead 4 Clamp cable.
Page 157: Dei Cavi
CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI 1 Câble des gaz 1 Gaszug 1 Cavo acceleratore 2 Contacteur d’éclairage 2 Lichtschalter 2 Interruttore luci 3 Fil de contacteur d’éclairage 3 Lichtschalterleitung 3 Cavo dell’interruttore luci 4 Bride 4 Kabelbinder 4 Morsetto 5 Câble de décompression...
Page 158: 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 159 INSP MAINTENANCE INTERVALS Every Every third race fifth race After Every As re- Item Remarks break-in race quired 500 km 1,000 km (300 mi) (600 mi) SHIFT FORK, SHIFT CAM, GUIDE BAR ● Inspect Inspect wear ROTOR NUT ● ● Retighten EXHAUST PIPE, SILENCER, PRO- TECTOR...
Page 160 Retighten sprocket bolt ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease THROTTLE, CONTROL CABLE Yamaha cable lube or ● ● Check routing and connection SAE 10W-30 motor oil ● ● Lubricate * marked : For USA 3 - 3...
Page 161 Sa machine ont une grande influence sur les intervalles d’entretien et de lubrification. En cas de doute au sujet des intervalles d’entretien et de lubrification à adopter, consulter son concessionnaire Yamaha. Chaque Chaque ème...
Page 162 INSP PROGRAMME D’ENTRETIEN Chaque Chaque ème ème Après Chaque Partie néces- Remarques rodage course 500 km 1.000 km saire (300 mi) (600 mi) FOURCHETTE, BARILLET, BARRE DE GUIDAGE ● Contrôler Contrôler l’usure. ECROU DU ROTOR ● ● Resserrer POT D’ECHAPPEMENT, SILENCIEUX, PROTECTION ●...
Page 163 Contrôler les roulements ● Remplacer les roulements ● Graisser Graisse à base de lithium ACCELERATEUR, CABLES DE COM- MANDE Yamaha lube pour câble ou Contrôler le cheminement et le branche- huile moteur SAE 10W-30 ● ● ment ● ● Graisser Astérique* : Pour les USA...
Page 164: Wartungsintervalle Und Schmierdienst
Die hier empfohlenen Zeitabstände für Wartung und Schmierung sollten jedoch lediglich als Richt- werte für den Normalbetrieb angesehen werden. Je nach Wetterbedingungen, Belastung und Ein- satzgebiet können in Abweichung des regelmäßigen Wartungsplans kürzere Intervalle notwendig werden. Richten Sie etwaige Fragen zu den Wartungs- und Schmierintervallen bitte an Ihren Yamaha-Händler. Nach Jedes Jedes...
Page 165: Anlassen Und Einfahren
INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach Jedes Jedes Nach dritte fünfte Nach Bezeichnung jedem Bemerkungen Ein- oder alle oder alle Bedarf Rennen fahren 500 km 1.000 km SCHALTGABEL, SCHALTWALZE, FÜHRUNGSSTANGE ● Prüfen Auf Verschleiß prüfen. ROTORMUTTER ● ● Nachziehen AUSPUFFROHR, SCHALLDÄMPFER, PROTEKTOR ●...
Page 166 INSP WARTUNGSINTERVALLE UND SCHMIERDIENST Nach Jedes Jedes Nach dritte fünfte Nach Bezeichnung jedem Bemerkungen Ein- oder alle oder alle Bedarf Rennen fahren 500 km 1.000 km TELESKOPGABEL ● ● Prüfen und einstellen ● ● Teleskopgabelöl “01” ver- Öl wechseln ● wenden.
Page 167: Ispezioni Eregistrazioni Regolari
In caso di dubbi su quali intervalli seguire per la manutenzione e la lubrificazione del veicolo, consultare il proprio rivenditore Yamaha. Ogni...
Page 168 INSP INTERVALLI DI MANUTENZIONE Ogni Ogni terza Dopo il Come quinta Ad ogni oppure Elemento rodag- richie- Osservazioni oppure gara 500 km 1.000 km (300 mi) (600 mi) FORCELLA DEL CAMBIO, CAMMA DEL CAMBIO, BARRA GUIDA ● Ispezionare Controllare il grado di usura DADO DEL ROTORE ●...
Page 169 Ispezionare i cuscinetti ● Sostituire i cuscinetti ● Lubrificare. Grasso a base di litio ACCELERATORE, CAVO DI Lubrificante per cavi COMANDO Yamaha o olio motore SAE ● ● Controllare il percorso e il collegamento 10W-30 ● ● Lubrificare. *contrassegnato: Per USA...
Page 170: 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 171 INSP CONTROLE ET ENTRETIEN AVANT UTILISATION CONTROLE ET ENTRETIEN AVANT UTILISATION Avant la conduite pour le rodage, l’entraînement ou une course, s’assurer que la machine est en bon état de marche. Avant d’utiliser cette machine, contrôler les points suivants: CONTROLE GENERAL ET ENTRETIEN Partie Routine Page...
Page 172 WARTUNGS- UND EINSTELLARBEITEN VOR INSP FAHRTBEGINN WARTUNGS- UND EINSTELLARBEITEN VOR FAHRTBEGINN Der Betriebszustand der Maschine muß sowohl vor dem Einfahren als auch vor jeder Übungs- und Rennfahrt überprüft werden. Vor Fahrtbeginn neben einer gewissenhaften Sichtkontrolle folgende Punkte prüfen. ROUTINEKONTROLLE VOR FAHRTBEGINN Bezeichnung Ausführung Seite...
Page 173: Controlli Preliminarie Manutenzione
INSP CONTROLLI PRELIMINARI E MANUTENZIONE CONTROLLI PRELIMINARI E MANUTENZIONE Prima di mettersi alla guida per il rodaggio, per fare pratica o per la gara, accertarsi che il veicolo sia in buone condizioni di funzionamento. Prima di usare questo veicolo, controllare quanto segue: ISPEZIONE GENERALE E MANUTENZIONE Elemento Routine...
Page 174 ENGINE/COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT EC350000 ENGINE EC351011 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 175: Motore
MOTEUR/CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/ CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP MOTOR/KÜHLFLÜSSIGKEITSTAND KONTROLLIEREN/KÜHLFLÜSSIGKEIT WECHSELN MOTORE/CONTROLLO DEL LIVELLO DI REFRIGERANTE/ SOSTITUZIONE LIQUIDO DI RAFFREDDAMENTO MOTEUR MOTOR MOTORE KÜHLFLÜSSIGKEITSTAND KON- CONTROLE NIVEAU CONTROLLO DEL LIVELLO DI TROLLIEREN LIQUIDE DE REFROIDISSEMENT REFRIGERANTE WARNUNG AVVERTENZA...
Page 176: And Side Covers
INSP COOLANT REPLACEMENT 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. Remove: Seat Left side cover Refer to ”SEAT FUEL TANK AND SIDE COVERS”...
Page 177 CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT INSP KÜHLFLÜSSIGKEIT WECHSELN SOSTITUZIONE LIQUIDO DI RAFFREDDAMENTO ATTENZIONE: ACHTUNG: ATTENTION: Prendre garde à ne pas verser de Darauf achten, daß keine Kühlflüs- Fare attenzione a non far cadere refri- sigkeit auf lackierte Flächen ge- liquide de refroidissement sur les sur- gerante sulle superfici verniciate.
Page 178 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 179 CONTROLE DU BOUCHON DU RADIATEUR INSP KÜHLFLÜSSIGKEITSTAND KONTROLLIEREN CONTROLLO TAPPO DEL RADIATORE ATTENZIONE: ACHTUNG: ATTENTION: Ne pas mélanger plusieurs solutions Auf keinen Fall verschiedene Sor- Non mescolare più di un tipo di ten Äthylenglykol-Frostschutzmit- antigel à l’éthylène glycol contenant antigelo glicole etilenico contenete des produits anticorrosion pour Korrosionsschutz für...
Page 180 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 181 CONTROLE DE LA PRESSION D’OUVERTURE DU BOUCHON DU RADIATEUR/ CONTROLE DU SYSTEME DE REFROIDISSEMENT KÜHLERVERSCHLUSSDECKEL-ÖFFNUNGSDRUCK KONTROLLIEREN/ INSP KÜHLSYSTEM KONTROLLIEREN CONTROLLO PRESSIONE APERTURA TAPPO DEL RADIATORE/ ISPEZIONE DEL SISTEMA DI RAFFREDDAMENTO CONTROLE DE LA PRESSION KÜHLERVERSCHLUSSDECKEL- CONTROLLO PRESSIONE APER- D’OUVERTURE DU BOUCHON DU ÖFFNUNGSDRUCK KONTROLLIE- TURA TAPPO DEL RADIATORE RADIATEUR...
Page 182 INSP CLUTCH ADJUSTMENT NOTE: Do not apply pressure more than specified pressure. Radiator should be filled fully. 4. Inspect: Pressure Impossible to maintain the specified pressure for 10 seconds Repair. Radiator 1 Radiator hose joint 2 Coolant leakage Repair or replace. Radiator hose 3 Swelling Replace.
Page 183 REGLAGE DE L’EMBRAYAGE INSP KUPPLUNG EINSTELLEN REGOLAZIONE FRIZIONE HINWEIS: NOTA: N.B.: Ne pas appliquer de pression supé- Den vorgeschriebenen Druck nicht Non applicare pressione superiore a Überschreiten. rieure à la pression spécifiée. quella specificata. Le radiateur doit être entièrement rem- Der Kühler muß...
Page 184 INSP THROTTLE CABLE ADJUSTMENT THROTTLE CABLE ADJUSTMENT 1. Check: Throttle grip free play a Out of specification Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: Throttle grip free play Throttle grip free play adjustment steps: Remove the throttle cable cap 1 and throttle cable cover 2.
Page 185 REGLAGE DES CABLES DES GAZ INSP GASZUGSPIEL EINSTELLEN REGOLAZIONE DEL CAVO DELL’ACCELERATORE GASZUGSPIEL EINSTELLEN REGLAGE DES CABLES DES GAZ REGOLAZIONE CAVO Vérifier: Kontrollieren: DELL’ACCELERATORE Jeu à la poignée des gaz a Gaszugspiel a Controllare: Hors spécification Régler. Unvorschriftsmäßig Ein- Gioco libero della manopola dell’acceleratore a stellen.
Page 186 THROTTLE LUBRICATION/ INSP DECOMPRESSION ADJUSTMENT THROTTLE LUBRICATION 1. Remove: Rubber cover 1 Throttle grip cap 2 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) Rubber cover DECOMPRESSION ADJUSTMENT 1.
Page 187 INSP GRAISSAGE DE L’ACCELERATEUR/REGLAGE DE LA DECOMPRESSION GASZUG SCHMIEREN/EINSTELLUNG DER DEKOMPRESSION LUBRIFICAZIONE DELL’ACCELERATORE/REGOLAZIONE DECOMPRESSIONE GASZUG SCHMIEREN GRAISSAGE DE L’ACCELERA- LUBRIFICAZIONE DELL’ACCE- Demontieren: TEUR LERATORE Gummiabdeckung 1 Déposer: Rimuovere: Couvercle en caoutchouc 1 Gasdrehgriffkappe 2 Coperchio di gomma 1 Logement de la poignée des Coperchio manopola accelera- gaz 2 tore 2...
Page 188 INSP AIR FILTER CLEANING 2. Adjust: Decompression lever free play Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the adjustment is suitable. Tighten the locknut. CAUTION: After the adjustment, start the engine and make sure that the engine does not stop when the handlebar is turned fully both ways.
Page 189 NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA Einstellen: Régler: Regolare: Jeu au levier de décompression Dekompressionszugspiel Gioco della leva della decom- am Hebeldrehpunkt pressione Etapes du réglage: Desserrer le contre-écrou 1. Arbeitsschritte Fasi di regolazione: Serrer ou desserrer le dispositif de Die Sicherungsmutter 1 lok- Svitare il controdado 1.
Page 190 INSP AIR FILTER CLEANING 5. 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 191 NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA Reinigen: Nettoyer: Pulire: Elément du filtre à air Luftfittereinsatz Elemento filtrante (in Lösungsmittel) Le nettoyer avec du dissolvant. Pulire con solvente. HINWEIS: N.B.: NOTA: Den Luftfittereinsatz nach dem Reini- Une fois l’entretien terminé, éliminer ce Dopo la pulizia rimuovere il solvente qui reste de solvant en serrant l’élément.
Page 192 INSP ENGINE OIL LEVEL INSPECTION 10. 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 193 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE 10. Montieren: 10. Monter: 10. Installare: Elément de filtre à air 1 Luftfittereinsatz 1 Elemento filtrante 1 Scheibe Rondelle Rondella Boulon de fixation Schraube Bullone di fissaggio 2 Nm (0,2 m ·...
Page 194 INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SH motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SH motor oil (Non-Friction modified) and/or...
Page 195 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE Nur USA und CDN: (Pour les USA et le CDN) (Per USA e CDN) Huile recommandée: Empfohlene Ölsorte (Vis- Olio raccomandato: Min. 5 ˚C (40 ˚F) Å: kosität) A 5 ˚C (40 ˚F) o supe- Å...
Page 196 INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and warm it up for sev- eral minutes, and then turn off the engine and wait for five minute. 2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.
Page 197 CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE MOTORÖL WECHSELN CHANGEMENT DE L’HUILE DE SOSTITUZIONE DELL’OLIO MOTEUR Den Motor starten, mehrere MOTORE Minuten warmlaufen lassen, Mettre le moteur en marche, le Avviare il motore, riscaldarlo per faire chauffer pendant quelques und dann ausschalten und alcuni minuti e quindi spegnerlo fünf Minuten warten.
Page 198: 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 199 CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE Soll auch der Ölfilter gewech- S’il est nécessaire de remplacer le Se è necessario sostituire il filtro filtre à huile lors de cette vidange selt werden, müssen zusätz- dell’olio durante cambio lich folgende Arbeiten durch-...
Page 200 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 201 CONTROLE DE LA PRESSION D’HUILE/REGLAGE DE LA VIS DE RICHESSE INSP ÖLDRUCKPRÜFUNG/LEERLAUFGEMISCH EINSTELLEN CONTROLLO PRESSIONE DELL’OLIO/ REGOLAZIONE DELLA VITE DI REGISTRO DEL MINIMO ÖLDRUCKPRÜFUNG CONTROLE DE LA PRESSION CONTROLLO PRESSIONE D’HUILE Kontrollieren: DELL’OLIO Öldruck Contrôler: Controllare: Pression d’huile Pressione dell’olio Arbeitsschritte Etapes du contrôle: Fasi di controllo:...
Page 202 ENGINE IDLING SPEED ADJUSTMENT/ INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it 2. Attach: Inductive tachometer To spark plug lead. 3. Adjust: Engine idling speed Adjustment steps: Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT”...
Page 203 REGLAGE DU REGIME DE RALENTI/CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP LEERLAUFDREHZAHL EINSTELEN/VENTILSPIEL KONTROLLIEREN UND EINSTELLEN REGOLAZIONE DEL MINIMO/CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE LEERLAUFDREHZAHL EINSTE- REGLAGE DU REGIME DE REGOLAZIONE DEL MINIMO RALENTI Avviare e riscaldare bene il Den Motor anlassen und eini- Mettre le moteur en marche et motore.
Page 204 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 3. Remove: Right radiator Refer to “RADIATOR” section in the CHAPTER 4. Carburetor Refer to “CARBURETOR” section in the CHAPTER 4. Spark plug Upper engine bracket Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 4.
Page 205 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Demontieren: Déposer: Rimuovere: Radiateur de droite Rechter Kühler Radiatore destro Siehe Abschnitt “KÜHLER” reporter à section Fare riferimento al paragrafo “RADIATEUR” au CHAPI- in KAPITEL 4.
Page 206 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Checking steps: Turn the crankshaft counterclockwise with a wrench. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily. 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 207 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Étapes de la vérification: Arbeitsschritte Fasi di controllo: Kurbelwelle mit einem Schrau- Faire tourner le vilebrequin dans le Ruotare l’albero motore in senso sens inverse des aiguilles d’une benschlüssel gegen den Uhr- antiorario con una chiave.
Page 208 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Remove the decompression cable 1, guide 2, bolt 3 and decompression shaft Remove the valve lifters 5 and the pads NOTE: Place a rag in the timing chain space to prevent pads from falling into the crank- case.
Page 209 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Déposer le câble de décompression Dekompressionszug 1, Füh- Rimuovere il cavo di decompres- 1, le guide 2, le boulon 3 et l’a rung 2, Schraube 3 und De- sione 1, la guida 2, il bullone 3 de décompresseur 4.
Page 210 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjust- ment.
Page 211 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Trouver la valeur arrondie et la Gerundete Ventilplättchen- Individuare il valore arrotondato Nummer und gemessenes Ven- valeur mesurée du jeu de soupapes ed il gioco della valvola misurato sur la “TABLE DE SELECTION tilspiel in der nachfolgenden Ta-...
Page 212: Valve Clearance Inspection And Adjustment
INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
Page 213 INSP CONTROLE ET REGLAGE DU JEU DE SOUPAPES ADMISSION NUMERO DE CALE INSTALLEE JEU MESURE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 à...
Page 214 INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN EINLASS GEMESSE- NUMMER DES AUSGEBAUTEN VENTILPLÄTTCHENS NES SPIEL 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00–0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05–0,09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0,10–0,15...
Page 215 INSP CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE ASPIRAZIONE NUMERO SPESSORE INSTALLATO GIOCO MISURATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 ~ 0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05 ~ 0,09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
Page 216 INSP SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Do not start the engine when cleaning the exhaust system. 1. Remove: Bolt (spark arrester) 1 2.
Page 217 NETTOYAGE DU PARE-ETINCELLES (pour les USA)/ INSP FUNKENFÄNGER REINIGEN (NUR USA) PULIZIA DEL PARASCINTILLE (Per USA) FUNKENFÄNGER REINIGEN (NUR NETTOYAGE DU PARE-ETINCEL- PULIZIA DEL PARASCINTILLE LES (pour les USA) USA) (Per USA) AVVERTENZA WARNUNG AVERTISSEMENT Le tuyau et le pot d’échappement Krümmer Schalldämpfer Accertarsi che il tubo dello scarico e...
Page 218 INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid is very low. The brake operation is faulty. Å...
Page 219: Parte Ciclistica
INSP PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTLÜFTEN PARTE CICLISTICA/SPURGO DELL’ARIA DAL SISTEMA FRENANTE FAHRWERK PARTIE CYCLE PARTE CICLISTICA HYDRAULISCHE BREMSANLAGE PURGE DE L’AIR DU SYSTEME SPURGO DELL’ARIA DAL ENTLÜFTEN DE FREINAGE SISTEMA FRENANTE WARNUNG AVVERTENZA AVERTISSEMENT Die Anlage muß...
Page 220: Front Brake Adjustment
INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared. j. Add brake fluid to the level line on the reservoir.
Page 221 REGLAGE DE FREIN AVANT INSP VORDERRADBREMSE EINSTELLEN REGOLAZIONE DEL FRENO ANTERIORE HINWEIS: N.B.: NOTA: Si la purge est difficile, il peut être Kann die Anlage nicht zufrieden- Se lo spurgo risulta difficoltoso, stellend entlüftet werden, sollte die nécessaire de laisser le système du potrebbe essere necessario lasciar liquide de freinage se stabiliser pen- Bremsflüssigkeit einige Stunden...
Page 222: Rear Brake Adjustment
REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: Brake pedal height a Out of specification Adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: Brake pedal height Pedal height adjustment steps: Loosen the locknut 1.
Page 223 REGLAGE DU FREIN ARRIERE/ CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT HINTERRADBREMSE EINSTELLEN/ INSP VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN REGOLAZIONE DEL FRENO POSTERIORE/ ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE REGLAGE DU FREIN ARRIERE HINTERRADBREMSE EINSTEL- REGOLAZIONE FRENO Contôler: POSTERIORE Kontrollieren: Hauteur de la pédale de frein...
Page 224 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT Loosen the pad pin 2. Remove the brake hose holder 3 and brake caliper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end.
Page 225 INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN AVANT VORDERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO ANTERIORE Haltestift 2 demontieren. Svitare la spina della pastiglia 2. Desserrer la goupille de plaquette Bremsschlauchhalterung Rimuovere il supporto tubo flessi- und Bremssattel 4 von der Te- bile del freno 3 e la pinza del Déposer le support de la durit de...
Page 226 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Install the pad pin plug B. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake lever operation A softy or spongy feeling Bleed brake system.
Page 227 INSP CONTROLE ET CHANGEMENT DES PLAQUETTES DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE Haltestift B montieren. Installare la spina delle pastiglie B. Installer le bouchon de goupille de plaquette B. Haltestift-Abdeck- Spina pastiglie: schraube 3 Nm Bouchon de goupille de...
Page 228 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 229 INSP CONTROLE DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE HINTERRAD-BREMSBELÄGE KONTROLLIEREN UND ERNEUERN ISPEZIONE E SOSTITUZIONE DELLE PASTIGLIE DEL FRENO POSTERIORE Déposer la goupille de plaquette 6 Haltestift 6 und Bremsbeläge Rimuovere la spina delle pastiglie et les plaquettes de frein 7. 7 entfernen.
Page 230 REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake pedal operation A softy or spongy feeling Bleed brake system. Refer “BRAKE SYSTEM BLEEDING” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1.
Page 231 CONTROLE DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN INSPEKTION DER ISOLIERUNG DES HINTERRADBREMSBELAGS/ BREMSFLÜSSIGKEITSSTAND KONTROLLIEREN INSP ISPEZIONE DELL’ISOLANTE DELLA PASTIGLIA DEL FRENO POSTERIORE/ CONTROLLO DEL LIVELLO DEL LIQUIDO DEI FRENI Vérifier: Kontrollieren: Ispezionare: Livello del liquido dei freni Bremsflüssigkeitsstand...
Page 232 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. Remove: Drive chain 1 NOTE: Remove the drive chain using a chain cutter 2.
Page 233 INSP CONTROLE DES PIGNONS/CONTROLE DE LA CHAINE DE TRANSMISSION KETTENRÄDER KONTROLLIEREN/ANTRIEBSKETTE KONTROLLIEREN ISPEZIONE DELLE CORONE DENTATE/ISPEZIONE DELLA CATENA DI TRASMISSIONE KETTENRÄDER KONTROLLIE- CONTROLE DES PIGNONS ISPEZIONE DELLE CORONE DEN- Contrôler: TATE Dents de pignon a Kontrollieren: Ispezionare: Kettenradzähne a Denti della corona a Usure excessive Remplacer.
Page 234 INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Install: Chain joint 1 O-ring 2 Drive chain 3 NOTE: When installing the drive chain, apply the lith- ium soap base grease on the chain joint and O-rings. 6. Install: Link plate 4 NOTE: Press the link plate onto the chain joint using a chain rivetter 5.
Page 235 REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION INSP ANTRIEBSKETTEN-DURCHHANG EINSTELLEN REGOLAZIONE DELLA TENSIONE DELLA CATENA DI TRASMISSIONE Montieren: Monter: Installare: Raccord de chaîne 1 Kettenschloß 1 Giunto della catena 1 Joint torique 2 O-Ring 2 O-ring 2 Chaîne de transmission 3 Antriebskette 3 Catena di trasmissione 3 HINWEIS:...
Page 236 INSP FRONT FORK INSPECTION 3. Adjust: Drive chain slack Drive chain slack adjustment steps: Loosen the axle nut 1 and locknuts 2. Adjust chain slack by turning the adjusters To tighten Turn adjuster 3 counter- clockwise. To loosen Turn adjuster 3 clockwise and push wheel forward.
Page 237 CONTROLE DE LA FOURCHE AVANT INSP TELESKOPGABEL KONTROLLIEREN ISPEZIONE FORCELLA ANTERIORE Régler: Einstellen: Regolare: Antriebsketten-Durchhang Flèche de chaîne de transmis- Allentamento catena di tra- sion smissione Arbeitsschritte Etapes de réglage de flèche de Achsmutter 1 und Sicherungs- Fasi di regolazione allentamento chaîne de transmission: muttern 2 lockern.
Page 238 FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ INSP 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 239 NETTOYAGE DE BAGUE D’ETANCHEITE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE LA FOURCHE AVANT GABELDICHTRING UND STAUBMANSCHETTE REINIGEN/ TELESKOPGABEL-ZUGSTUFENDÄMPFUNG EINSTELLEN INSP PULIZIA DEL PARAOLIO E DEL PARAPOLVERE DELLE FORCELLE ANTERIORI/ REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELLA FORCELLA ANTERIORE NETTOYAGE DE BAGUE D’ETAN- GABELDICHTRING UND STAUB-...
Page 240 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.
Page 241 REGLAGE DE LA FORCE D’AMORTISSEMENT DE COMPRESSION DE LA FOURCHE AVANT INSP TELESKOPGABEL-DRUCKSTUFEN-DÄMPFUNG EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI COMPRESSIONE DELLA FORCELLA ANTERIORE ATTENZIONE: ATTENTION: ACHTUNG: Einstellmechanismus Ne pas forcer le dispositif de réglage Non forzare il registro oltre il minimo au-delà...
Page 242 INSP REAR SHOCK ABSORBER INSPECTION STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 10 clicks out **15 clicks out * For EUROPE ** For AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment.
Page 243 CONTROLE DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN KONTROLLIEREN ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE Normaleinstellung POSITION STANDARD: POSIZIONE STANDARD: C’est la position qui se trouve en Zum Erreichen der Normaleinstel- Questa è la posizione raggiunta con un lung die Einstellschraube nach arrière du nombre spécifié de déclics à numero specifico di scatti a partire partir de la position entièrement vis- vollständigem Hineindrehen um...
Page 244 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT EC36M013 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: Rear frame 3. Loosen: Locknut 1 4. Adjust: Spring preload By turning the adjuster 2. Stiffer Increase the spring preload.
Page 245 REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN-FEDERVORSPANNUNG EINSTELLEN REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE FEDERBEIN-FEDERVORSPAN- REGLAGE DE LA PRECON- REGOLAZIONE DEL PRECARICO TRAINTE DE RESSORT DE NUNG EINSTELLEN DELLA MOLLA DELL’AMMOR- Das Motorrad am Motor auf- L’AMORTISSEUR ARRIERE TIZZATORE POSTERIORE Surélever la roue arrière en pla-...
Page 246 REAR SHOCK ABSORBER REBOUND INSP DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: Rebound damping force By turning the adjuster 1. Stiffer a Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b Decrease the rebound damp- ing force.
Page 247 REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE L’AMORTISSEUR ARRIERE FEDERBEIN-ZUGSTUFENDÄMPFUNG EINSTELLEN INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE FORCE FEDERBEIN-ZUGSTUFENDÄMP- REGOLAZIONE DELLA FORZA DI FUNG EINSTELLEN D’AMORTISSEMENT DE DETENTE SMORZAMENTO DI ESPANSIONE Einstellen: DE L’AMORTISSEUR ARRIERE DELL’AMMORTIZZATORE Zugstufendämpfung Régler:...
Page 248 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 Decrease the low compres-...
Page 249 REGLAGE DE LA FORCE D’AMORTISSEMENT A BASSE COMPRESSION DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI BASSA COMPRESSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE FORCE EINSTELLUNG DER FEDERBEIN- REGOLAZIONE DELLA FORZA DI DRUCKSTUFENDÄMPFUNG D’AMORTISSEMENT BASSE SMORZAMENTO DI BASSA COM- Einstellen: COMPRESSION DE L’AMORTIS- PRESSIONE...
Page 250 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 Decrease the high compres-...
Page 251 REGLAGE DE LA FORCE D’AMORTISSEMENT A HAUTE COMPRESSION DE L’AMORTISSEUR ARRIERE EINSTELLUNG DER FEDERBEIN-DRUCKSTUFENDÄMPFUNG INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI COMPRESSIONE ALTA DELL’AMMORTIZZATORE POSTERIORE REGLAGE FORCE EINSTELLUNG DER FEDERBEIN- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT A HAUTE DRUCKSTUFENDÄMPFUNG SMORZAMENTO DI COMPRES- Einstellen: COMPRESSION DE L’AMORTIS- SIONE ALTA DELL’AMMORTIZ-...
Page 252 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 kg/cm , 15 psi) NOTE: Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
Page 253 CONTROLE DE PRESSION DES PNEUS/ CONTROLE ET SERRAGE DES RAYONS/CONTROLE DE LA ROUE REIFENLUFTDRUCK KONTROLLIEREN/ INSP SPEICHEN KONTROLLIEREN UND FESTZIEHEN/RÄDER KONTROLLIEREN CONTROLLO DELLA PRESSIONE DEI PNEUMATICI/ ISPEZIONE E SERRAGGIO DEI RAGGI/ISPEZIONE DELLE RUOTE CONTROLE DE PRESSION DES REIFENLUFTDRUCK KONTROL- CONTROLLO DELLA PRESSIONE PNEUS LIEREN DEI PNEUMATICI...
Page 254 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: Bearing free play Exist play Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: Steering shaft Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth.
Page 255 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Kontrollieren: Vérifier: Ispezionare: Jeu de roulement Lagerspiel Gioco del cuscinetto Spiel Erneuern. Il y a du jeu Remplacer. Esiste gioco Sostituirlo.
Page 256 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 Steering ring nut (initial tighten- ing): 38 Nm (3.8 m •...
Page 257 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Serrer l’écrou crénelé de direction Ringmutter 3 mit dem Haken- Avvitare la ghiera 3 utilizzando la 3 en utilisant la clé 4. schlüssel 4 festziehen.
Page 258 INSP LUBRICATION Å Use Yamaha cable lube or equivalent on these LUBRICATION areas. To ensure smooth operation of all compo- ı Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants. after break-in, and after every race.
Page 259 0 Dekompressionszugende Å Yamaha Seilzug-Schmiermittel oder 0 Extrémité du câble de décompresseur cavi Yamaha o equivalente. Å Mettre du lubrifiant Yamaha pour câbles, gleichwertiges Mittel verwenden. ı Utilizzare olio motore SAE 10W-30 o ı Motoröl oder Spezial-Kettenspray ver- ou équivalent sur ces parties.
Page 260: Electrical
INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: Spark plug 2. Inspect: Electrode 1 Wear/damage Replace. Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in...
Page 261: Parte Elettrica
PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN PARTE ELETTRICA/ISPEZIONE DELLA CANDELA ELEKTRISCHE ANLAGE PARTIE ELECTRIQUE PARTE ELETTRICA ZÜNDKERZE KONTROLLIEREN CONTROLE DE LA BOUGIE ISPEZIONE DELLA CANDELA Demontieren: Déposer: Rimuovere: Zündkerze Bougie Candela d’accensione Kontrollieren: Contrôler: Ispezionare: Elektrode 1 Electrode 1 Elettrodo 1 Verschleiß/Beschädigung...
Page 262 INSP IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: Timing mark accessing screw 1 2. Attach: Timing light Inductive tachometer To the spark plug lead. Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-08036-B Engine tachometer: 90890-03113 3. Check: Ignition timing Checking steps: Start the engine and let it warm up.
Page 263 CONTROLE DE L’AVANCE A L’ALLUMAGE INSP ZÜNDZEITPUNKT KONTROLLIEREN CONTROLLO DELLA FASATURA DI ACCENSIONE ZÜNDZEITPUNKT KONTROLLIE- CONTROLE DE L’AVANCE A CONTROLLO DELLA FASATURA L’ALLUMAGE DI ACCENSIONE Demontieren: Déposer: Rimuovere: Vis d’accès du repère de distri- Steuermarkierung-Zugangs- Vite di accesso al riferimento bution 1 schraube 1 per fasatura 1...
Page 264 INSP REPLACING THE HEADLIGHT BULBS REPLACING THE HEADLIGHT BULBS 1. Remove: Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAP- TER 4. 2. Remove: Headlight bulb holder cover 1 3. Detach: Headlight bulb holder 1 4. Remove: Headlight bulb 2 WARNING Since the headlight bulb gets extremely...
Page 265 REMPLACER LES AMPOULES DU PHARE INSP SCHEINWERFERLAMPE AUSWECHSELN SOSTITUZIONE DELLE LAMPADE DEL FARO SCHEINWERFERLAMPE AUS- REMPLACER LES AMPOULES DU SOSTITUZIONE DELLE LAM- PHARE WECHSELN PADE DEL FARO Demontieren: Déposer: Rimuovere: Phare Scheinwerfer Faro Siehe Abschnitt “SITZ- Se référer à la section “SELLE, Fare riferimento al paragrafo RESERVOIR A ESSENCE ET BANK, KRAFTSTOFF-...
Page 266: Adjusting The Headlight Beams
INSP ADJUSTING THE HEADLIGHT BEAMS ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: Headlight beam (vertically) Adjusting steps: Turn the adjusting screw 1 in direction a or b. Direction a Headlight beam is raised. Direction b Headlight beam is lowered. 3 - 50...
Page 267 REGLAGES DES FAISCEAUX DES PHARES INSP SCHEINWERFER EINSTELLEN REGOLAZIONE DEI FASCI DI LUCE DEL FARO SCHEINWERFER EINSTELLEN REGLAGES DES FAISCEAUX DES REGOLAZIONE DEI FASCI DI PHARES Einstellen: LUCE DEL FARO Scheinwerferstellung (ver- Régler: Regolare: Le faisceau du phare (vertical) tikal) Fascio di luce del faro (in senso verticale) Arbeitsschritte:...
Page 268: Seat, Fuel Tank And Side Covers
SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Headlight removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to “OFF”.
Page 269 SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SELLA, SERBATOIO CARBURANTE E CARENATURA LATERALE MOTEUR SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX Organisation de la dépose: 1 Dépose du selle 2 Dépose du réservoir de carburant 3 Dépose des caches latéraux 4 Dépose du phare Organisation de la dépose Ordre...
Page 270: Exhaust Pipe And Silencer
EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER Å Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 271: Tubo Di Scarico E Silenziatore
TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE TUYAU D’ECHAPPEMENT ET SILENCIEUX Å Excepté pour USA Organisation de la dépose: 1 Dépose du silencieux 2 Dépose du tuyau d’échappement Organisation de la dépose Ordre Nom de pièce Qté...
Page 272 EXHAUST PIPE AND SILENCER INSPECTION Silencer and exhaust pipe 1. Inspect: Gasket 1 Damage Replace. ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1. Install: Gasket Exhaust pipe 1 Nut (exhaust pipe) 2 13 Nm (1.3 m · kg, 9.4 ft · lb) Bolt (exhaust pipe) 3 24 Nm (2.4 m ·...
Page 273 TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE PRÜFUNG CONTROLE ISPEZIONE Silencieux et tuyau d’échappement Schalldämpfer und krümmer Silenziatore e tubo di scarico Kontrollieren: Contrôler: Ispezionare: Joint 1 Dichtung 1 Guarnizione 1 Beschädigung Erneuern. Endommagement Rempla- Danni Sostituire.
Page 274: Radiator
RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat, fuel tank and left Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 275 RADIATEUR KÜHLER RADIATORE RADIATEUR 1 Dépose du radiateur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU RADIATEUR Préparation à la dépose Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT”...
Page 276 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 277 RADIATEUR KÜHLER RADIATORE HANDHABUNGSHINWEIS REMARQUES CONCERNANT LA NOTA PER LA MANIPOLAZIONE MANIPULATION WARNUNG AVVERTENZA AVERTISSEMENT Der heiße Kühler steht unter Non rimuovere il tappo del radiatore a Ne jamais enlever le bouchon du Druck. Daher Kühlerver- motore e radiatore caldi. Si potrebbe radiateur quand le moteur et le radia- schlußdeckel niemals bei heißem verificare la fuoriuscita di fluido bol-...
Page 278 RADIATOR 3. Install: Right radiator 1 Bolt (right radiator) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Radiator hose 3 3 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 4. Install: Left radiator 1 Bolt (left radiator) 2 10 Nm (1.0 m ·...
Page 279 RADIATEUR KÜHLER RADIATORE Montieren: Monter: Installare: Radiateur de droite 1 Rechter Kühler 1 Radiatore destro 1 Boulon (radiateur droite) 2 Schraube (rechter Kühler) Bullone (radiatore destro) 2 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m · kg) 10 Nm (1,0 m ·...
Page 280: Carburetor
CARBURETOR CARBURETOR Extent of removal: 1 Carburetor removal Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Clamp Throttle position sensor lead cou- pler Throttle cable cover Throttle cable...
Page 281 CARBURATEUR VERGASER CARBURATORE CARBURATEUR 1 Dépose du carburateur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARBURATEUR Préparation à la dépose Selle et réservoir de carburant Se reporter à la section “SELLE, RESERVOIR A ESSENCE ET CACHES LATERAUX”.
Page 282 CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve)
Page 283 CARBURATEUR VERGASER CARBURATORE DEMONTAGE DU CARBURATEUR Organisation de la dépose: 1 Démontage du carburateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEMONTAGE DU CARBURATEUR Durit de mise à l’air de carburateur Couvercle de logement de levier de soupape Vis (axe d’accélérateur) Boisseau Support d’aiguille...
Page 284 CARBURETOR Extent of removal Order Part name Q’ty Remarks Float Needle valve Valve seat Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Intake joint Pilot air jet Main air jet Cold starter plunger Hot starter plunger (red)
Page 285 CARBURATEUR VERGASER CARBURATORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Flotteur Pointeau Siège de pointeau Gicleur principal Gicleur de ralenti Entretoise Gicleur de starter Puits d’aiguille Tige de poussée Tirer la tige de poussée. Ensemble de l’axe de papillon Ensemble du levier de timonerie de tige de commande Raccord d’admission...
Page 286 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 287 CARBURATEUR VERGASER CARBURATORE HINWEIS ZUM HANDLING REMARQUE CONCERNANT LES NOTA PER LA MANIPOLAZIONE MANIPULATIONS ATTENZIONE: ACHTUNG: ATTENTION: (Drosselklappen-Positions- Non svitare le viti (sensore di posi- Ne pas desserrer les vis (capteur de sensor) 1 nicht lösen – außer zione dell’acceleratore) 1 se non per position du papillon des gaz) 1 sauf wenn der Drosselklappen-Positi- sostituire il sensore di posizione...
Page 288 CARBURETOR 2. Inspect: Main jet 1 Pilot jet 2 Needle jet 3 Starter jet 4 Main air jet 5 Pilot air jet 6 Leak jet 7 Damage Replace. Contamination Clean. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air.
Page 289 CARBURATEUR VERGASER CARBURATORE Kontrollieren: Contrôler: Ispezionare: Gicleur principal 1 Hauptdüse 1 Getto del massimo 1 Gicleur de ralenti 2 Leerlaufdüse 2 Getto del minimo 2 Puits d’aiguille 3 Nadeldüse 3 Getto a spillo 3 Gicleur de starter 4 Choke-Düse 4 Getto di avviamento 4 Gicleur d’air principal 5 Hauptluftdüse 5...
Page 290 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 291 CARBURATEUR VERGASER CARBURATORE Schwimmerhöhe Hauteur du flotteur Altezza galleggiante Mesurer: Messen: Misurare: Hauteur du flotteur a Schwimmerhöhe a Altezza galleggiante a Hors spécification Régler. Unvorschriftsmäßig Ein- Fuori specifica Regolare. stellen. Hauteur du flotteur: Altezza galleggiante: 8,0 mm (0,31 in) 8,0 mm (0,31 in) Schwimmerhöhe 8,0 mm Procédure de mesure et de réglage:...
Page 292 CARBURETOR Starter plunger 1. Inspect: Cold starter plunger 1 Hot starter plunger (red) 2 Wear/damage Replace. Accelerator pump 1. Inspect: Diaphragm (accelerator pump) 1 Spring (accelerator pump) 2 Accelerator pump cover 3 O-ring 4 Push rod 5 Tears (diaphragm)/damage Replace. Dirt Clean.
Page 293 CARBURATEUR VERGASER CARBURATORE Choke-Schieber Plongeur de starter Stantuffo dell’avviamento Contrôler: Kontrollieren: Ispezionare: Kaltstarter-Tauchkolben 1 Plongeur de démarrage à froid Stantuffo dell’avviamento a Heißstarter-Tauchkolben freddo 1 (rot) 2 Plongeur de démarrage à chaud Stantuffo dell’avviamento a (rouge) 2 Verschleiß/Beschädigung caldo (rosso) 2 Erneuern.
Page 294 CARBURETOR 2. Install: Main air jet 1 Pilot air jet 2 Intake joint 3 5 Nm (0.5 m · kg, 3.6 ft · lb) 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.
Page 295 CARBURATEUR VERGASER CARBURATORE Montieren: Monter: Installare: Gicleur d’air principal 1 Hauptluftdüse 1 Getto dell’aria del massimo 1 Gicleur d’air de ralenti 2 Leerlaufluftdüse 2 Getto dell’aria del minimo 2 Raccord d’admission 3 Ansaugstutzen 3 Giunto ammissione 3 5 Nm (0,5 m · kg) 5 Nm (0,5 m ·...
Page 296 CARBURETOR 7. Install: Spring 1 Joint collar 2 To throttle shaft 3. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley. 8. Install: Throttle shaft assembly 1 Washer (metal) 2 Washer (resin) 3 Valve lever 4 NOTE:...
Page 297 CARBURATEUR VERGASER CARBURATORE Montieren: Installer: Installare: Ressort 1 Feder 1 Molla 1 Manchette de joint 2 Verbindungsmuffe 2 Collarino giunto 2 A l’axe de papillon 3. (zur Drosselwelle 3) All’albero della valvola a far- falla 3. HINWEIS: N.B.: Installer le crochet le plus gros a du res- Den größeren Haken a der Feder NOTA: sort sur la butée b de la poulie d’axe de...
Page 298 CARBURETOR 10. Install: Starter jet 1 Pilot jet 2 Spacer 3 Needle jet 4 Main jet 5 11. Install: Valve seat Screw (valve seat) 1 Needle valve 2 Float 3 Float pin 4 NOTE: After installing the needle valve to the float, install them to the carburetor.
Page 299 CARBURATEUR VERGASER CARBURATORE 10. Montieren: 10. Monter: 10. Installare: Gicleur de starter 1 Choke-Düse 1 Getto dell’avviamento 1 Gicleur de ralenti 2 Leerlaufdüse 2 Getto del minimo 2 Entretoise 3 Distanzstück 3 Distanziatore 3 Puits d’aiguille 4 Nadeldüse 4 Getto a spillo 4 Gicleur principal 5 Hauptdüse 5 Getto del massimo 5...
Page 300 CARBURETOR 14. Install: Diaphragm (air cut valve) 1 Spring (air cut valve) 2 O-ring 3 Air cut valve cover 4 Screw (air cut valve cover) 5 15. Install: Diaphragm (accelerator pump) 1 Spring 2 O-ring 3 Accelerator pump cover 4 Bolt (accelerator pump cover) 5 NOTE: Install the diaphragm (accelerator pump) with...
Page 301 CARBURATEUR VERGASER CARBURATORE 14. Montieren: 14. Monter: 14. Installare: Membrane (clapet de coupure Membran (Luftabschaltven- Membrana (valvola di interru- d’air) 1 til) 1 zione dell’aria) 1 Ressort (clapet de coupure Feder 2 Molla (valvola di interruzione d’air) 2 O-Ring 3 dell’aria) 2 Joint torique 3 Deckel 4...
Page 302 CARBURETOR 19. Install: Carburetor breather hose 1 NOTE: Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed. Carburetor installation 1. Install: Clamp 1 NOTE: Install the projections a on the carburetor joint between the clamp ends.
Page 303 CARBURATEUR VERGASER CARBURATORE 19. Montieren: 19. Monter: 19. Installare: Durit de mise à l’air de carbu- Vergaser-Entlüftungs- Sfiatatoio carburatore 1 rateur 1 schlauch 1 NOTA: HINWEIS: Collegare lo sfiatatoio del carburatore al N.B.: Die Vergaserlüfterschläuche am Ver- Installer la durit de mise à l’air sur le car- carburatore stesso in modo tale che i burateur de sorte qu’il ne se plie pas à...
Page 304 CARBURETOR 5. Install: Throttle cable cap 1 6. Install: Throttle cable 1 7. Adjust: Throttle grip free play Refer to “THROTTLE CABLE ADJUST- MENT” section in the CHAPTER 3. 8. Install: Throttle cable cover 1 Screw (throttle cable cover) 2 4 Nm (0.4 m ·...
Page 305 CARBURATEUR VERGASER CARBURATORE Montieren: Monter: Installare: Cache du logement des câbles Gasseilzugkappe 1 Tappo del cavo acceleratore 1 des gaz 1 Monter: Montieren: Installare: Câble de gaz 1 Gaszug 1 Cavo acceleratore 1 Régler: Einstellen: Regolare: Gaszugspiel Jeu à la poignée des gaz Gioco libero manopola...
Page 306: Camshafts
CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Carburetor Refer to “CARBURETOR”...
Page 307: Arbres A Cames
ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ARBRES A CAMES COUVRE-CULASSE 1 Dépose du couvercle de culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE Préparation à la dépose Selle et réservoir de carburant Se reporter à...
Page 308 CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Refer to “REMOVAL POINTS”. Camshaft cap Clip Exhaust camshaft Intake camshaft...
Page 309 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ARBRES A CAMES Organisation de la dépose: 1 Dépose de l’arbre à cames Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’ARBRE A CAMES Vis d’accès du repère de distribution Vis d’accès de l’extrémité...
Page 310 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. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily. Align the T.D.C.
Page 311: Alberi A Camme
ARBRES A CAMES NOCKENWELLE ALBERI A CAMME AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Arbre à cames Nockenwelle Albero a camme Demontieren: Déposer: Rimuovere: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Vite di accesso al riferimento Bouchon droit 2 be 1 per fasatura 1 Aligner: Rotorzapfen-Abdeckschrau- Vite...
Page 312 CAMSHAFTS 5. Remove: Exhaust camshaft 1 Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft 1. Inspect: Cam lobe Pitting/scratches/blue discoloration Replace. 2. Measure: Cam lobe length a and b Out of specification Replace.
Page 313 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Demontieren: Déposer: Rimuovere: Arbre à cames d’échappement Auslaß-Nockenwelle 1 Albero a camme di scarico 1 Einlaß-Nockenwelle 2 Albero a camme di aspirazione Arbre à cames d’admission 2 HINWEIS: Die Steuerkette mit einem Draht 3 N.B.: NOTA: Attacher un fil 3 à...
Page 314 CAMSHAFTS 4. Measure: Camshaft-to-cap clearance Out of specification Measure bearing diameter (camshaft) Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: Install the camshaft onto the cylinder head. ® Position a strip of Plastigauge 1 onto the camshaft.
Page 315 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Messen: Mesurer: Misurare: Jeu entre arbre à cames et cha- Nockenwellen-Lagerspiel Gioco albero a camme-cap- Unvorschriftsmäßig Nok- peau pello Hors spécifications Mesu- kenwellenlagerzapfen- Fuori specifica Misurare il Durchmesser messen. rer le diamètre du coussinet diametro del cuscinetto (albero (arbre à...
Page 316 CAMSHAFTS Timing chain tensioner 1. Check: While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise. When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
Page 317 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Steuerkettenspanner Tendeur de la chaîne de distribution Tenditore catena di distribuzione Contrôler: Kontrollieren: Controllare: Steuerkettenspanner- Tout en comprimant légère- Premendo leggermente l’asta ment la tige du tendeur à l’aide kopf leicht mit dem Finger del tenditore con le dita, utiliz- eindrücken und den Span- zare un cacciavite sottile 1 e...
Page 318 CAMSHAFTS CAUTION: Do not turn the crankshaft during the camshaft installation. Damage improper valve timing will result. Install the clips, camshaft caps 4 and bolts (camshaft cap) 5. Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Before removing the clips, cover the cylin- der head with a clean rag to prevent the...
Page 319 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME ACHTUNG: ATTENTION: ATTENZIONE: Ne pas faire tourner le vilebrequin Um Beschädigung und falsche ruotare l’albero motore Ventilsteuerzeiten zu vermei- pendant la mise en place des arbres durante l’installazione dell’albero à cames. Cela risquerait d’entraîner den, die Kurbelwelle während a camme.
Page 320 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. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 4 - 27...
Page 321 NOTA: Applicare il materiale di tenuta sulla ® Quick gasket ® Quick gasket guarnizione del coperchio della testata ACC-QUICK-GS-KT ACC-QUICK-GS-KT del cilindro. Yamaha Bond n˚ 1215: Yamaha-Dichtmasse 90890-85505 Nr. 1215 90890-85505 ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond n. 1215 90890-85505...
Page 322 CAMSHAFTS 7. Install: Oil tank breather hose Cylinder head breather hose Spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) 4 - 28...
Page 323 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Montieren: Monter: Installare: Durit de mise à l’air de réser- Öltank-Belüftungsschlauch Sfiatatoio serbatoio dell’olio Zylinderkopf-Entlüftungs- voir d’huile Sfiatatoio testata del cilindro Durit de mise à l’air de culasse schlauch Candela d’accensione Zündkerze Bougie 13 Nm (1,3 m ·...
Page 324: Cylinder Head
CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER”...
Page 325: Testata Del Cilindro
CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO CULASSE Organisation de la dépose: 1 Dépose de la culasse Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA CULASSE ET DU CYLIN- Préparation à la dépose Selle et réservoir de carburant Se reporter à...
Page 326 CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid dam- aging or scratching: Spark plug threads Valve seats 2. Inspect: Cylinder head Scratches/damage Replace.
Page 327 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO PRÜFUNG CONTROLE ISPEZIONE Culasse Zylinderkopf Testata del cilindro Entfernen: Eliminer: Eliminare: Dépôt de calamine Ölkohleablagerungen (im Depositi carboniosi (dalle Brennraum) (de la chambre de combustion) camere di combustione) Utiliser un grattoir arrondi. Einen abgerundeten Scha- Utilizzare un raschietto arro- ber verwenden.
Page 328 CYLINDER HEAD ASSEMBLY AND INSTALLATION Cylinder head 1. Install: Decompression shaft 1 Copper washer 2 Bolt (decompression shaft) 3 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the engine oil on the decompression shaft. 2. Install: Dowel pin 1 Cylinder head gasket 2 Timing chain guide (exhaust side) 3...
Page 329 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Zylinderkopf Culasse ZIONE Montieren: Monter: Testata del cilindro Axe de décompression 1 Dekompressionswelle 1 Installare: Rondelle en cuivre 2 Kupferunterlegscheibe 2 Albero di decompressione 1 Rondella di rame 2 Boulon (axe de décompres- sion) 3 Schraube...
Page 330 CYLINDER HEAD 3. Install: Washer 1 Cable guide 2 Bolts [L=145 mm (5.71 in)] 3 38 Nm (3.8 m · kg, 27 ft · lb) Bolts [L=135 mm (5.31 in)] 4 38 Nm (3.8 m · kg, 27 ft · lb) Nuts 5 10 Nm (1.0 m ·...
Page 331 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO Monter: Montieren: Installare: Rondelle 1 Unterlegscheibe 1 Rondella 1 Guide de câble 2 Seilzugführng 2 Guida cavo 2 Schrauben [L = 145 mm] 3 Boulons Bulloni [L = 145 mm (5,71 in)] [L = 145 mm (5,71 in)] 3 38 Nm (3,8 m ·...
Page 332: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Valve lifter Use special tool. Adjusting pad Refer to “REMOVAL POINTS”.
Page 333: Soupapes Et Ressorts De Soupape
SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la dépose: 1 Dépose des soupapes Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES SOUPAPES ET DES RES- SORTS DE SOUPAPE Préparation à...
Page 334 VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: Valve lifter 1 Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: Valve sealing Leakage at the valve seat Inspect...
Page 335 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Poussoir de soupape et clavette de sou- Tassenstößel und Ventikeile Alzavalvola e semiconi Demontieren: pape Rimuovere: Déposer: Tassenstößel 1 Alzavalvola 1 Poussoir de soupape 1 Ventilplättchen 2 Spessore 2...
Page 336 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: 0.025 ~ 0.052 mm...
Page 337 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE PRÜFUNG CONTROLE ISPEZIONE Soupape Ventil Valvola Messen: Mesurer: Misurare: Jeu de queue dans le guide Ventilschaftspiel Gioco stelo-guida Ventilschaftspiel = Gioco stelo-guida = Jeu de queue dans le guide de sou- Ventilführungsdurchmesser diametro interno del guidaval- pape =...
Page 338 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 339 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Outil de dépose de guide Ventilführungs-Austrei- Estrattore guidavalvola: de soupape: Aspirazione 4,0 mm Admission 4,0 mm Einlaß 4,0 mm (0,16 in) (0,16 in) YM-4111/ YM-4111/90890-04111 YM-4111/90890-04111 90890-04111 Scarico 4,5 mm (0,18 in) Echappement 4,5 mm Auslaß...
Page 340 VALVES AND VALVE SPRINGS 5. Measure: Runout (valve stem) Out of specification Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: When installing a new valve always replace the guide. If the valve is removed or replaced always replace the oil seal. 6.
Page 341 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Messen: Mesurer: Misurare: Ovalisation (queue de soupape) Ventilschaftschlag Disassamento (stelo valvola): Unvorschriftsmäßig Hors spécifications Rempla- Fuori specifica Sostituire. cer. Erneuern. Limite di disassamento: 0,01 mm (0,0004 in) Limite de déformation: Max.
Page 342 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 343 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Einschleifen: Roder: Lappare: Ventilteller Face de soupape Faccia della valvola Ventilsitz Siège de soupape Sede della valvola HINWEIS: N.B.: NOTA: Nach Bearbeitung des Ventilsitzes Après le surfaçage du siège de soupape Dopo aver rettificato la sede della val- oder Erneuerung von Ventil und Ven- ou le remplacement de la soupape et du...
Page 344 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>: 35.9 mm (1.41 in) Exhaust: 37.54 mm (1.48 in) <Limit>: 35.7 mm (1.41 in) 2.
Page 345 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Ventilfeder Ressort de soupape Molla valvola Mesurer: Messen: Misurare: Ventilfederlänge (ent- Longueur libre du ressort de Lunghezza libera della molla soupape a spannt) a della valvola a Unvorschriftsmäßig Hors spécifications Rempla- Fuori specifica...
Page 346 VALVES AND VALVE SPRINGS Combination of cylinder head and valve lifter 1. Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. Combination Valve lifter mark b Cylinder head mark a (color) (color)
Page 347 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Kombination von Zylinderkopf Combinaisons de culasse et de pous- Combinazione di testata del cilindro e soir de soupape und Ventilheber alzavalvola Kombination: Combinaison: Combinazione: Combiner la culasse et le pous- Für diese Kombination die Per questa combinazione, far cor- Markierungsfarbe auf dem Zy-...
Page 348 VALVES AND VALVE SPRINGS 3. Install: Valve cotter NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-04019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
Page 349 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Montieren: Monter: Installare: Clavette de soupape Ventilkeile Semiconi HINWEIS: N.B.: NOTA: Installer les clavettes de soupape tout en Die Ventilfeder mit Ventilfederspan- Comprimendo la molla della valvola con ner 1 und Halterung zusammen- un apposito compressore 1 installare i comprimant le ressort de soupape avec...
Page 350: Cylinder And Piston
CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Bolt (cylinder) Cylinder Piston pin clip Piston pin Use special tool.
Page 351: Cylindre Et Piston
CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE CYLINDRE ET PISTON 1 Dépose du cylindre 2 Dépose du piston Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES CYLINDRES ET DES PIS- TONS Préparation à...
Page 352 CYLINDER AND PISTON REMOVAL POINTS Piston and piston ring 1. Remove: Piston pin clip 1 Piston pin 2 Piston 3 NOTE: Put identification marks on each piston head for reference during reinstallation. Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4.
Page 353 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Piston et segment de piston Kolben und Kolbenring Pistone e fascia elastica Demontieren: Déposer: Rimuovere: Agrafe d’axe de piston 1 Kolbenbolzen-Sicherungs- Morsetto spinotto 1 Axe de piston 2 ringe 1 Spinotto 2...
Page 354 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 355 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Zylinderboh- 77,00– 77,00 à Alesaggio cilin- 77,00 ~ 77,01 mm rung “C” 77,01 mm Alésage de cylin- 77,01 mm dro “C” (3,0315 ~ 3,0319 in) dre “C” (3,0315 à Konizität “T” 0,05 mm Limite conicità...
Page 356 CYLINDER AND PISTON Piston ring 1. Measure: Ring side clearance Use a feeler gauge 1. Out of specification Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard <Limit>...
Page 357 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Kolbenring Segment de piston Fascia elastica Mesurer: Messen: Misurare: Ringnutspiel Jeu latéral du segment Gioco laterale della fascia Utiliser une jauge d’épaisseur Fühlerlehre 1 verwenden. Utilizzare uno spessimetro 1. Unvorschriftsmäßig Kol- Se fuori specifica Sostituire Hors spécifications...
Page 358 CYLINDER AND PISTON Piston pin 1. Inspect: Piston pin Blue discoloration/grooves Replace, then inspect the lubrication system. 2. Measure: Piston pin-to-piston clearance Measurement steps: Measure the outside diameter (piston pin) If out of specification, replace the piston pin. Outside diameter (piston pin): 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) Measure the inside diameter (piston) b.
Page 359 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Kolbenbolzen Axe de piston Spinotto Contrôler: Kontrollieren: Ispezionare: Kolbenbolzen Axe de piston Spinotto Décoloration bleue/gorges Blaufärbung/Riefen Sbiadimento blu/scanalature Erneuern und Schmiersy- Remplacer puis examiner le Sostituire quindi ispezionare il système de graissage. stem überprüfen.
Page 360 CYLINDER AND PISTON 2. Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
Page 361 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Montieren: Positionner: Posizione: Segment de feu 1. Kompressionsring (Topring) Fascia superiore Segment d’étanchéité 2. Kompressionsring Seconda fascia Segment racleur d’huile Ölabstreifring Fascia raschiaolio Décaler les becs de segment Ringstöße laut Abbildung ver- Decentrare le luci delle estre- comme illustré.
Page 362 CYLINDER AND PISTON 3. Install: Cylinder gasket 1 Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. CAUTION: Pass the timing chain 3 through the tim- ing chain cavity. Be careful not to damage the timing chain guide 4 during installation.
Page 363 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Montieren: Monter: Installare: Joint de cylindre 1 Dichtung 1 Guarnizione cilindro 1 Cylindre 2 Zylinder 2 Cilindro 2 HINWEIS: N.B.: NOTA: Den Zylinder mit einer Hand einbau- Installer le cylindre d’une main tout en Installare il cilindro con una mano com- comprimant les segments de l’autre en, mit der anderen die Kolbenringe...
Page 364: Clutch
CLUTCH EC4A0000 CLUTCH Extent of removal: 1 Push rod 1, 2 and push lever shaft removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Primary driven gear removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal...
Page 365 EMBRAYAGE KUPPLUNG FRIZIONE EMBRAYAGE 1 Dépose des tiges de commande 1 er 2 et du levier de poussée 2 Démontage de la tige de commande 1 Organisation de la dépose: 3 Dépose du disque de friction et du disque d’embrayage 4 Dépose du pignon mené...
Page 366 CLUTCH Extent of removal Order Part name Q’ty Remarks Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Use special tool. Look washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - 50...
Page 367 EMBRAYAGE KUPPLUNG FRIZIONE Organisation de la dépose Ordre Nom de pièce Qté Remarques Disque de friction Disque d’embrayage Ressort amortisseur Plaque d’assise Ecrou (noix d’embrayage) Utiliser un outil spécial. Rondelle d’arrêt Se reporter à “POINTS DE DEPOSE”. Noix d’embrayage Rondelle de butée Pignon mené...
Page 368 CLUTCH EC4A3000 REMOVAL POINTS Clutch boss 1. Remove: Nut 1 Lock washer 2 Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å ı Clutch holding tool: YM-91042/90890-04086 Å...
Page 369 EMBRAYAGE KUPPLUNG FRIZIONE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Noix d’embrayage Kupplungsnabe Mozzo frizione Demontieren: Déposer: Rimuovere: Ecrou 1 Mutter 1 Dado 1 Rondelle-frein 2 Sicherungsscheibe 2 Rondella di bloccaggio 2 Noix d’embrayage 3 Kupplungsnabe 3 Mozzo frizione 3 HINWEIS: N.B.: NOTA:...
Page 370 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 371 EMBRAYAGE KUPPLUNG FRIZIONE Reibscheiben Disque de friction Disco conduttore Mesurer: Messen: Misurare: Reibscheibenstärke Epaisseur de disque de friction Spessore del disco conduttore Hors-spécification Changer Unvorschriftsmäßig Fuori specifica Sostituire in Reibscheiben Satz tous les disques de friction. blocco il disco conduttore. Mesurer chaque disque en qua- erneuern.
Page 372 CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION Push lever shaft 1. Install: Push lever shaft 1 Bolt (push lever shaft) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the lithium soap base grease on the oil seal lip. Apply the engine oil on the push lever shaft.
Page 373 EMBRAYAGE KUPPLUNG FRIZIONE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO ED INSTALLA- Levier de poussée Druckhebel ZIONE Montieren: Monter: Alberino della leva spingente Arbre de levier de poussée 1 Druckhebelwelle 1 Installare: Schraube (Druckhebelwel- Boulon (arbre de levier de Alberino della leva spingente poussée) 2 le) 2 10 Nm (1,0 m ·...
Page 374 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 cushion spring with the paint b facing out.
Page 375 EMBRAYAGE KUPPLUNG FRIZIONE Die Lasche der Sicherungs- Courber la languette de la ron- Piegare la linguetta della ron- delle-frein 1. scheibe 1 umbiegen. della di bloccaggio 1. Monter: Montieren: Installare: Ressort amortisseur 1 Polsterfeder 1 Molla cuscinetto 1 Plaque d’assise 2 Sitzplatte 2 Piastra di disinnesto 2 HINWEIS:...
Page 376 CLUTCH 7. Install: Push rod 2 1 Ball 2 Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball. 8. Install: Pressure plate 1 9. Install: Clutch spring 1 Bolt (clutch spring) 2 8 Nm (0.8 m ·...
Page 377 EMBRAYAGE KUPPLUNG FRIZIONE Montieren: Monter: Installare: Tige de poussée 2 1 Druckstange 2 1 Asta di punteria 2 1 Bille 2 Kugel 2 Sfera 2 Tige de poussée 1 3 Druckstange 1 3 Asta di punteria 1 3 HINWEIS: N.B.: NOTA: Appliquer de la graisse de savon au Lithiumfett auf Druckstangen 1 und 2...
Page 378: Oil Filter Element, Water Pump And Right Crankcase Cover
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal: 1 Oil filter element removal 2 Water pump removal 3 Right crankcase cover removal Extent of removal Order Part name Q’ty Remarks OIL FILTER ELEMENT, WATER...
Page 379 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT 1 Dépose de l’élément de filtre à huile 2 Dépose de la pompe à...
Page 380 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal Order Part name Q’ty Remarks Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Refer to “REMOVAL POINTS”. Oil seal Bearing 4 - 57...
Page 381 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Organisation de la dépose Ordre Nom de pièce Qté Remarques Logement de pompe à eau Tuyau d’arrivée d’huile Boulon (durit d’huile) Pédale de kick...
Page 382 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 383 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Arbre de rotor Flügelradwelle Albero girante Demontieren: Déposer: Rimuovere: Arbre de rotor 1 Flügelradwelle 1...
Page 384 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: Impeller shaft 1 Bend/wear/damage Replace. Fur deposits Clean. EC444300 Impeller shaft gear 1. Inspect: Gear teeth a Wear/damage Replace. EC4H4600 Bearing 1. Inspect: Bearing Rotate inner race with a finger. Rough spot/seizure Replace.
Page 385 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Flügelradwelle Arbre de rotor Albero girante Contrôler: Kontrollieren: Ispezionare: Arbre de rotor 1 Flügelradwelle 1 Albero girante 1 Déformation/usure/endomma- Verbiegung/Verschleiß/...
Page 386 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft 1. Install: Impeller shaft 1 Washer 2 Impeller 3 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: Take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi-...
Page 387 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Montieren: Monter: Installare: Roulement 1 Lager 1 Cuscinetto 1 HINWEIS: N.B.: NOTA: Monter le roulement en appuyant paral- Zur Lager-Montage den äußeren Installare il cuscinetto premendo paralle- Laufring parallel einpressen.
Page 388 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: Right crankcase cover 1 Bolt (right crankcase cover) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the engine oil on the impeller shaft end. Mesh the impeller shaft gear 3 with primary drive gear 4.
Page 389 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Montieren: Monter: Installare: Demi-carter droit 1 Rechten Kurbelgehäuse- Coperchio carter destro 1 Boulon (demi-carter droit) 2 deckel 1 Bullone (coperchio...
Page 390 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 391 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Wasserpumpengehäuse Logement de la pompe à eau Alloggiamento della pompa dell’acqua Monter: Montieren: Installare: Goupille 1 Stift 1 Perno di centraggio 1 Joint torique 2...
Page 392: Balancer
BALANCER BALANCER Extent of removal: 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”...
Page 393 BALANCIER AUSGLEICHSWELLE BILANCIERE BALANCIER Organisation de la dépose: 1 Pignon mené du balancier 2 Balancier Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BALANCIER Préparation à la dépose Pignon menant primaire Se reporter à la section “EMBRAYAGE”. Couvercle de demi-carter droit Se reporter à...
Page 394 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 395 BALANCIER AUSGLEICHSWELLE BILANCIERE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Pignon menant et pignon mené du Ausgleichswellen-Antriebs- und - Ingranaggio conduttore dell’albero di Abtriebsräder balancier equilibratura e ingranaggio condotto Redresser l’ongle de rondelle Die Lasche der Sicherungs- dell’albero di equilibratura scheibe umbiegen.
Page 396 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 397 BALANCIER AUSGLEICHSWELLE BILANCIERE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET INSTALLA- MONTAGGIO ED INSTALLAZIONE TION Ausgleichswelle, An- und Albero di equilibratura, ingranaggio Abtriebsrad Balancier, pignon menant de balan- conduttore dell’albero di equilibra- cier et pignon mené de balancier Montieren: tura e ingranaggio condotto Ausgleichswelle 1 Monter: dell’albero di equilibratura...
Page 398: Oil Pump
OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”...
Page 399: 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 pièce Qté Remarques DEPOSE ET DEMONTAGE DE LA POMPE A HUILE Préparation à...
Page 400 OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 4 - 67...
Page 401 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Organisation de la dépose Ordre Nom de pièce Qté Remarques Goupille Rondelle Arbre de transmission de la pompe à huile Logement de rotor Reihen- Demontage-Arbeiten Bauteil Anz. Bemerkungen folge Paßstift Beilagscheibe Ölpumpen-Antriebswelle Rotorgehäuse Portata dello smontaggio Ordine Denominazione Quantità...
Page 402 OIL PUMP INSPECTION Oil pump 1. Inspect: Oil pump drive gear 1 Oil pump drive shaft 2 Rotor housing 3 Oil pump cover 4 Cracks/wear/damage Replace. 2. Measure: Tip clearance a (between the inner rotor 1 and outer rotor 2) Side clearance b (between the outer rotor 2 and rotor housing 3)
Page 403 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO PRÜFUNG CONTROLE ISPEZIONE Pompe à huile Ölpumpe Pompa dell’olio Kontrollieren: Contrôler: Ispezionare: Pignon menant de pompe à Ölpumpen-Antriebsrad 1 Ingranaggio conduttore della huile 1 Ölpumpen-Antriebswelle 2 pompa dell’olio 1 Arbre menant de pompe à huile Rotorgehäuse 3 Albero comando...
Page 404 OIL PUMP ASSEMBLY AND INSTALLATION Oil pump 1. Install: Oil pump drive shaft 1 Washer 2 Dowel pin 3 Inner rotor 1 4 NOTE: Apply the engine oil on the oil pump drive shaft and inner rotor 1. Fit the dowel pin into the groove in the inner rotor 1.
Page 405 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET INSTALLA- MONTAGGIO ED INSTALLA- TION Ölpumpe ZIONE Montieren: Pompe à huile Pompa dell’olio Installer: Ölpumpen-Antriebswelle 1 Installare: Beilagscheibe 2 Arbre de transmission de la Albero comando della pompe à huile 1 Paßstift 3 pompa olio 1 Rondelle 2...
Page 406 OIL PUMP 4. Install: Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 10 Nm (1.0 m · kg, 7.2 ft · lb) Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 5 10 Nm (1.0 m ·...
Page 407 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Montieren: Monteur: Installare: Rotor extérieur 2 1 Außenrotor 2 1 Rotore esterno 2 1 Goupille de serrage 2 Paßstift 2 Perno di centraggio 2 Essemble pompe à huile 3 Ölpumpe 3 Gruppo pompa dell’olio 3 Schraube (Ölpumpe) Boulon (essemble pompe à...
Page 408: Kick Shaft And Shift Shaft
KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT Extent of removal: 1 Kick shaft removal 2 Kick shaft disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump...
Page 409: Arbre De Kick Et Arbre De Selecteur
ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO ARBRE DE KICK ET ARBRE DE SELECTEUR 1 Dépose de l’arbre de kick 2 Démontage de l’arbre de kick Organisation de la dépose: 3 Dépose arbre de sélecteur 4 Dépose de segment Organisation de la dépose Ordre...
Page 410 KICK SHAFT AND SHIFT SHAFT Extent of removal Order Part name Q’ty Remarks Torsion spring Roller Shift guide Refer to “REMOVAL POINTS”. Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to “REMOVAL POINTS”. 4 - 72...
Page 411 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Organisation de la dépose Ordre Nom de pièce Qté Remarques Ressort de torsion Rouleau Guide de sélecteur Se reporter à “POINTS DE DEPOSE”. Ensemble levier de sélecteur Levier de sélecteur Cliquet Goupille de cliquet...
Page 412 KICK SHAFT AND SHIFT SHAFT REMOVAL POINTS Kick shaft assembly 1. Remove: Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: Bolt (shift guide) Shift guide 1 Shift lever assembly 2 NOTE:...
Page 413 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Arbre de kick complet Kickstarterwelle (komplett) Gruppo albero pedivella Demontieren: Déposer: Rimuovere: Arbre de kick complet 1 Kickstarterwelle (komplett) 1 Gruppo albero pedivella 1 HINWEIS:...
Page 414 KICK SHAFT AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: Shift shaft 1 Bend/damage Replace. Spring 2 Broken Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear/damage Replace.
Page 415 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Schaltwelle Arbre de sélecteur Albero del cambio Contrôler: Kontrollieren: Ispezionare: Arbre de sélecteur 1 Schaltwelle 1 Albero del cambio 1 Tordu/endommagement Verbiegung/Beschädigung Deformazione/danno Sosti- Erneuern.
Page 416 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 417 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Rastenhebel Levier de butée Leva di arresto Monter: Montieren: Installare: Ressort de torsion 1 Torsionsfeder 1 Molla di torsione 1 Levier de butée 2 Rastenhebel 2 Leva di arresto 2 Boulon (levier de butée) 3...
Page 418 KICK SHAFT AND SHIFT SHAFT 4. Install: Bolt (shift guide) 1 10 Nm (1.0 m · kg, 7.2 ft · lb) 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.
Page 419 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Montieren: Monter: Installare: Boulon (guide de sélecteur) 1 Schraube (Schaltklinke) 1 Bullone (guida cambio) 1 10 Nm (1,0 m · kg) 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m ·...
Page 420 KICK SHAFT AND SHIFT SHAFT 2. Install: Torsion spring 1 To kick shaft 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick 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.
Page 421 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Montieren: Monter: Installare: Ressort de torsion 1 Torsionfeder 1 Molla di torsione 1 Sur l’arbre de kick 2. (an der Kickstarterwelle 2) All’albero pedivella 2. HINWEIS: N.B.: NOTA:...
Page 422: Cdi Magneto
CDI MAGNETO EC4L0000 CDI MAGNETO Extent of removal: 1 CDI magneto removal Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Bolt (left radiator) Refer to “RADIATOR”...
Page 423: Volant Magnetique Cdi
VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI VOLANT MAGNETIQUE CDI 1 Dépose du volant magnétique CDI Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE CDI Préparation à la dépose Selle et réservoir de carburant Se reporter à...
Page 424 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: YU-33270-B/90890-01362 NOTE: Install three bolts 3 of the proper size, as shown in illustration.
Page 425 VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Rotor Rotor Rotore Demontieren: Déposer: Rimuovere: Ecrou (rotor) 1 Mutter (Rotor) 1 Dado (rotore) 1 Rondelle 2 Beilagscheibe 2 Rondella 2 Utiliser l’outil de maintien de Den Rotorhalter 3 verwen- Utilizzare l’utensile di soste- rotor 3.
Page 426 Apply the sealant on the grommet of the CDI magneto lead. Tighten the screws using the T30 bit. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 2. Install: Woodruff key 1 Rotor 2 NOTE: Clean the tapered portions of the crankshaft and rotor.
Page 427 Stecknuß festziehen. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond n˚1215: ® Quick gasket ® Quick gasket 90890-85505 ACC-QUICK-GS-KT ACC-QUICK-GS-KT YAMAHA Bond n. 1215: YAMAHA-Dichtmasse 90890-85505 Nr. 1215 90890-85505 Montieren: Monter: Installare: Clavette de demi-lune 1 Scheibenfeder 1 Linguetta Woodruff 1 Rotor 2...
Page 428 CDI MAGNETO 4. Connect: CDI magneto lead Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 5. Install: Dowel pin Gasket (left crankcase cover) Left crankcase cover 1 Hose guide (cylinder head breather hose) 2 Bolt (left crankcase cover) 3 10 Nm (1.0 m ·...
Page 429 VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI Anschließen: Connecter: Collegare: Fil de volant magnétique CDI CDI-Schwungradmagnet- Cavo magnete CDI zünder-Kabel Se référer au paragraphe “DIA- Fare riferimento al paragrafo GRAMME DE CHEMINE- Siehe unter “KABELFÜH- “SCHEMA DEL PERCORSO RUNG” im KAPITEL 2. MENT CABLE”...
Page 430: 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 431: Depose Du Moteur
DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE DEPOSE DU MOTEUR Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU MOTEUR AVERTISSEMENT Préparation à la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque pas de approprié...
Page 432 ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks Spark plug cap Disconnect the CDI magneto lead. Right engine guard Neutral switch Bolt (oil hose) Drive chain sprocket cover Nut (drive sprocket) Lock washer Refer to “REMOVAL POINTS”.
Page 433 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE 1 Dépose du moteur Organisation de la dépose: Organisation de la dépose Ordre Nom de pièce Qté Remarques Capuchon de bougie Déconnecter le fil du volant magnétique CDI. Protège-carter droit Contacteur de point mort Boulon (durit d’huile) Couvercle de pignon de chaîne de transmission Ecrou (pignon d’entraînement)
Page 434 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: Nut (drive sprocket) 1 Lock washer 2 NOTE: Straighten the lock washer tab. Loosen the nut while applying the rear brake. 2. Remove: Drive sprocket 1 Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain.
Page 435 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Pignon d’entraînement Antriebsritzel Corona dentata trasmissione Demontieren: Déposer: Rimuovere: Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 1 Dado (corona dentata trasmis- Sicherungsscheibe 2 sione) 1 Rondelle-frein 2 Rondella di bloccaggio 2 HINWEIS: Die Lasche der Sicherungsscheibe...
Page 436 ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: Engine 1 Install the engine from right side. Pivot shaft 2 85 Nm (8.5 m · kg, 61 ft · lb) Engine mounting bolt (lower) 3 69 Nm (6.9 m · kg, 50 ft · lb) Lower engine bracket 4 Bolt (engine bracket) 5 34 Nm (3.4 m ·...
Page 437 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO INSTALLA- Montage du moteur Motor montieren ZIONE Montieren: Monter: Installazione del motore Moteur 1 Motor 1 Installare: (von der rechten Seite) Motore 1 Monter le moteur par le côté droit.
Page 438 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 439 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE Montieren: Monter: Installare: Rondelle-frein 1 Sicherungsscheibe 1 Rondella di bloccaggio 1 Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 2 Dado (corona dentata trasmis- sione) 2 75 Nm (7,5 m · kg) 75 Nm (7,5 m · kg, 54 ft · lb) 75 Nm (7,5 m ·...
Page 440: Crankcase And Crankshaft
CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE AND CRANK- SHAFT REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion.
Page 441: Carter Et Vilebrequin
CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE CARTER ET VILEBREQUIN Organisation de la dépose: 1 Séparation du carter 2 Dépose du carter d’huile Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARTER ET DU VILEBRE- QUIN Préparation à...
Page 442 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 443 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Boulon [L = 45 mm (1,77 in)] Boulon [L = 55 mm (2,17 in)] Boulon [L = 70 mm (2,76 in)] Guide de durit Se reporter à...
Page 444: Transmission, Shift Cam And Shift Fork
CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK” section. Oil seal Bearing Refer to “REMOVAL POINTS”.
Page 445 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ROULEMENTS DE CARTER Organisation de la dépose: Dépose des roulements de carter Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DES ROULEMENTS DE CAR- Préparation à la dépose Boîte à...
Page 446 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 447 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Carter Kurbelgehäuse Carter Trennen: Séparer: Separare: Demi-carter droit Rechtes Kurbelgehäusehälf- Carter destro Demi-carter gauche Carter sinistro Linkes Kurbelgehäusehälfte Etapes de la séparation: Fasi per la separazione: Déposer les boulons de carter 1, Arbeitsschritte Rimuovere i bulloni del carter 1,...
Page 448 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 449 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Kurbelwelle Vilebrequin Albero motore Déposer: Demontieren: Rimuovere: Vilebrequin 1 Kurbelwelle 1 Albero motore 1 Utiliser l’outil de séparateur de Das Kurbelgehäuse-Trenn- Utilizzare l’utensile per la carter 2. werkzeug 2. separazione del carter 2. Kurbelgehäuse-Trenn- Outil de séparation de Utensile per la separa-...
Page 450 CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance Crank width d Out of specification Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Standard <Limit>...
Page 451 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Kurbelwelle Vilebrequin Albero motore Mesurer: Messen: Misurare: Limite de faux-rond a Schlaggrenze a Limite di disassamento a Pleuel-Radialspiel b Limite gioco piede di biella b Limite de déflexion de pied de bielle b Pleuel-Axialspiel c Gioco laterale della testa di...
Page 452 CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: Bearing Bearing stopper Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw [bearing stopper (crankshaft)] 1 10 Nm (1.0 m · kg, 7.2 ft · lb) To left and right crankcase.
Page 453 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ZUSAMMENBAU UND MONTAGE ASSEMBLAGE ET MONTAGE MONTAGGIO E INSTALLAZIONE Roulement de carter Kurbelwellenlager Cuscinetto del basamento Einbauen: Installer: Installare: Roulement Lager Cuscinetto Butoir de roulement Lageranschlag Fermo cuscinetto Schraube (Lageranschlag) Vis (butoir de roulement) Vite (fermo cuscinetto) 10 Nm (1,0 m ·...
Page 454 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: Sealant On the right crankcase 1. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant. 5. Install: Dowel pin 1...
Page 455 1) ® ® Quick gasket Quick gasket ACC-QUICK-GS-KT ACC-QUICK-GS-KT ® Quick gasket Yamaha Bond n˚1215: YAMAHA Bond n. 1215: ACC-QUICK-GS-KT 90890-85505 90890-85505 Yamaha-Dichtmasse Nr. 1215 90890-85505 N.B.: NOTA: Nettoyer la surface de contact des demi- Pulire la superficie di contatto dei semi- HINWEIS: carters gauche et droit avant d’appliquer...
Page 456 CRANKCASE AND CRANKSHAFT 6. Tighten: Hose guide 1 Clutch cable holder 2 Bolt (crankcase) 3 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: Oil delivery pipe 2 1 O-ring 2 Bolt (oil delivery pipe 2) 3 10 Nm (1.0 m ·...
Page 457 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Monter: Montieren: Serrare: Guide de durit 1 Kabelführung 1 Guida del flessibile 1 Kupplungszug-Halterung 2 Supporto cavo frizione 2 Support de câble d’embrayage Schraube (Kurbelgehäuse) Bullone (carter) 3 Boulon (carter) 3 12 Nm (1,2 m ·...
Page 458 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL”...
Page 459 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION Organisation de la dépose: 1 Dépose des fourchettes de sélection, du tambour, de l’arbre primaire et de l’arbre secondaire Organisation de la dépose Ordre Nom de pièce...
Page 460 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: Main axle 1 Drive axle 2 Shift cam Shift fork 3 Shift fork 2 Shift fork 1 NOTE: Remove assembly with the collar 3 installed to the crankcase. Remove assembly carefully.
Page 461 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Getriebe Boîte à vitesses Trasmissione Demontieren: Déposer: Rimuovere: Arbre primaire 1 Eingangswelle 1 Asse principale 1 Arbre secondaire 2 Ausgangswelle 2...
Page 462 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: Shift fork 1 Wear/damage/scratches Replace. 2. Inspect: Shift cam 1 Segment 2 Wear/damage Replace. 3. Check: Shift fork movement Unsmooth operation Replace shift fork. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adja- cent to the shift fork.
Page 463 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Schaltgabeln und Schaltwalze Fourchette, tambour et barillet Forcella del cambio, camma del cam- Kontrollieren: Contrôler: bio e segmento Fourchette 1 Schaltgabel 1 Ispezionare: Verschleiß/Beschädigung/...
Page 464 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: 2nd wheel gear (28T) 1 4th wheel gear (25T) 2 3rd wheel gear (28T) 3 5th wheel gear (22T) 4 1st wheel gear (31T) 5 O-ring 6 To drive axle 7. NOTE: Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on the end surface.
Page 465 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Montieren: Monter: Installare: Pignon de 2ème (28D) 1 Zahnrad 2. Gang Ingranaggio a ruota per la 2a Pignon de 4ème (25D) 2 (28 Zähne) 1 (28T) 1 Pignon de 3ème (28D) 3...
Page 466 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 467 BOITE A VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN TRASMISSIONE, CAMMA DEL CAMBIO E FORCELLA DEL CAMBIO Montieren: Monter: Installare: Fourchette 1 (L) 1 Schaltgabel 1 (L) 1 Forcella del cambio 1 (L) 1 Fourchette 2 (C) 2 Schaltgabel 2 (C) 2 Forcella del cambio 2 (C) 2 Fourchette 3 (R) 3...
Page 468 CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL WARNING Preparation for removal...
Page 469: Partie Cycle
ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT 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 pièce...
Page 470 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks WARNING REAR WHEEL REMOVAL Preparation for removal Hold the machine by placing the Support the machine securely so there is no danger of it falling over.
Page 471 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ROUE ARRIERE Organisation de la dépose: 1 Dépose de la roue arrière 2 Dépose du roulement de roue 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de pièce Qté...
Page 472 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 473: Roue Avant Et Roue Arriere
ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Roue arrière Hinterrad Ruota posteriore Demontieren: Déposer: Rimuovere: Roue 1 Rad 1 Ruota 1 HINWEIS: N.B.: NOTA: Pousser la roue vers l’avant et déposer la Das Rad nach vorne stoßen und die Spingere la ruota in avanti e rimuovere chaîne de transmission 2 .
Page 474 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 475 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Radachse Axe de roue Asse della ruota Mesurer: Messen: Misurare: Radachsschlag Déformation de l’axe de roue Deformazioni asse della ruota Hors-spécification Rempla- Unvorschriftsmäßig Fuori specifica Regolare. Erneuern.
Page 476 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: Bearing (left) 1 Spacer 2 Bearing (right) 3 Oil seal 4 NOTE: Apply the lithium soap base grease on the bearing and oil seal lip when installing. Use a socket that matches the outside diam- eter of the race of the bearing.
Page 477 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Roue avant Vorderrad ZIONE Monter: Montieren: Ruota anteriore Roulement (gauche) 1 Lager (links) 1 Installare: Entretoise 2 Distanzstück 2 Cuscinetto (sinistro) 1 Roulement (droit) 3 Lager (rechts) 3...
Page 478 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: Wheel NOTE: Install the brake disc between the brake pads correctly. Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube. 6.
Page 479 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Montieren: Monter: Installare: Roue Ruota HINWEIS: N.B.: NOTA: Reposer correctement le disque du Die Bremsscheibe zwischen die Installare correttamente il disco freno Bremsbeläge führen. frein entre les plaquettes de frein. tra le pastiglie.
Page 480 CHAS FRONT WHEEL AND REAR WHEEL 9. Install: Brake hose 1 10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), pass the brake hose in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).
Page 481 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Montieren: Monter: Installare: Tuyau de frein 1 Bremsschlauch 1 Flessibile freno 1 10 Nm (1,0 m · kg) 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m ·...
Page 482 CHAS FRONT WHEEL AND REAR WHEEL EC5251A0 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. Install the bearing with seal facing outward.
Page 483 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Hinterrad Roue arrière Ruota posteriore Monter: Montieren: Installare: Roulement (droit) 1 Lager (rechts) 1 Cuscinetto (destro) 1 Circlip 2 Sicherungsring 2 Anello elastico di arresto 2 Entretoise 3 Distanzstück 3 Roulement (gauche) 4...
Page 484 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: Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain.
Page 485 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Montieren: Monter: Installare: Collerette 1 Hülse 1 Collarino 1 HINWEIS: N.B.: NOTA: Appliquer la graisse à base de savon au Lithiumseifen-Schmierfett auf der Öl- Applicare grasso a base di sapone di litio dichtungslippe auftragen.
Page 486 CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: Drive chain slack a Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) Refer “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAP- TER 3. 10. Tighten: Nut (wheel axle) 1 125 Nm (12.5 m ·...
Page 487 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Einstellen: Régler: Regolare: Flèche de chaîne de transmis- Antriebsketten-Durchhang Tensione della catena di tra- sion a smissione a Antriebsketten-Durch- Flèche de chaîne de trans- Tensione della catena di hang mission: trasmissione:...
Page 488: Front Brake And Rear Brake
CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Brake caliper removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks FRONT BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the...
Page 489: Frein Avant Et Frein Arriere
FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose du tuyau de frein 2 Dépose de l’étrier de frein Organisation de la dépose: 3 Dépose du maître-cylindre de frein Organisation de la dépose Ordre Nom de pièce...
Page 490 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE Extent of removal: 1 Brake caliper removal 2 Brake hose removal 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks REAR BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 491 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE FREIN ARRIERE Organisation de la dépose: 1 Dépose de l’étrier de frein 2 Dépose du tuyau de frein 3 Dépose du maître-cylindre de frein Organisation de la dépose Ordre Nom de pièce Qté...
Page 492 CHAS FRONT BRAKE AND REAR BRAKE BRAKE CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM- Pad pin Brake pad Pad support Brake caliper piston Refer to “REMOVAL POINTS”.
Page 493 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DE L’ETRIER Å Avant ı Arrière Organisation de la dépose: Démontage de l’étrier de frein avant Démontage de l’étrier de frein arrière Organisation de la dépose Ordre Nom de pièce Qté...
Page 494 CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q’ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm...
Page 495 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE DEMONTAGE DU MAITRE-CYLINDRE DE FREIN Å Avant ı Arrière Organisation de la dépose: Démontage de l’étrier de frein avant Démontage de l’étrier de frein arrière Organisation de la dépose Ordre Nom de pièce Qté...
Page 496 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 Å REMOVAL POINTS Brake fluid 1. Remove: [Front] Brake master cylinder cap 1 [Rear] Brake master cylinder guard 1 Reservoir tank cap 2 NOTE: Do not remove the diaphragm. ı Å Front ı Rear 2.
Page 497 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit Liquido dei freni Demontieren: Déposer: Rimuovere: [Arrière] [Vorn] [Anteriore] Hauptbremszylinderdeckel 1 Coperchio pompa del freno 1 Couvercle de maître-cylindre de frein 1 [Hinten]...
Page 498 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit Å 1. Remove: Dust seal 1 Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and ı...
Page 499 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Bremssattelkolben-Dichtungssatz Kit de joint de piston d’étrier de frein Set guarnizioni pistoncino della pinza Déposer: Demontieren: freno Joint antipoussière 1 Staubschutzring 1 Rimuovere: Joint de piston 2 Dichtring 2 Guarnizione parapolvere 1 Guarnizione dei pistoncini 2...
Page 500 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper Å ı 1. Inspect: Brake caliper cylinder inner surface a Wear/score marks Replace brake caliper assembly. Å Front ı Rear 2. Inspect: Brake caliper piston 1 Wear/score marks Replace brake caliper piston assembly. WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled.
Page 501 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Bremssattel Etrier de frein Pinza del freno Contrôler: Kontrollieren: Ispezionare: Hauptbremszylinder-Boh- Surface interne du maître- Superficie interna cilindro cylindre de frein a rungsfläche a pinza del freno a Verschleiß/Riefen Brems- Usure/rayures...
Page 502 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Å Piston seal 1 Dust seal 2 WARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly. ı Å...
Page 503 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Joint de piston 1 Dichtring 1 Guarnizione dei pistoncini 1 Joint antipoussière 2 Staubschutzring 2 Guarnizione parapolvere 2 WARNUNG AVERTISSEMENT Toujours utiliser des joints de piston Immer neue Bremskolben-Dicht- AVVERTENZA et des joints antipoussière neufs.
Page 504: Front Fork
CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Copper washer 1 Union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as show and lightly touches the projection b on the brake caliper.
Page 505 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Boulon-raccord 2 Hohlschraube 2 Vite di unione 2 30 Nm (3,0 m · kg) 30 Nm (3,0 m ·...
Page 506 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake disc cover 1 Bolt (brake disc cover) 2 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: 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 507 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Cache de disque de frein 1 Bremsscheiben-Abdeckung Copridisco 1 Bullone (copridisco) 2 Boulon (cache de disque de frein) 2 Schraube (Bremsscheiben- 7 Nm (0,7 m · kg, 5,1 ft · lb) Abdeckung) 2 7 Nm (0,7 m ·...
Page 508 CHAS FRONT BRAKE AND REAR BRAKE Brake master cylinder kit 1. Clean: Brake master cylinder Brake master cylinder kit Clean them with brake fluid. 2. Install: Å ı Brake master cylinder cup (primary) 1 Brake master cylinder cup (secondary) To brake master cylinder piston 3. NOTE: Apply the brake fluid on the brake master cyl- inder cup.
Page 509 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Hauptbremszylindersatz Kit de maître-cylindre de frein Kit pompa del freno Nettoyer: Reinigen: Pulire: Hauptbremszylinder Maître-cylindre de frein Pompa del freno Kit de maître-cylindre de frein Hauptbremszylindersatz Kit pompa del freno Mit Bremsflüssigkeit reini- Les nettoyer avec du liquide de Pulire con liquido per freni.
Page 510 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Å [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 Push rod 2 Circlip 3 ı...
Page 511 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: [Avant] [Vorn] [Anteriore] Hauptbremszylindersatz 1 Set pompa del freno 1 Kit de maître-cylindre de frein Unterlegscheibe 2 Rondella 2 Rondelle ordinaire 2 Sicherungsring 3 Anello elastico di arresto 3 Circlip 3 Hauptbremszylinderschutz-...
Page 512 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake lever 1 Bolt (brake lever) 2 6 Nm (0.6 m · kg, 4.3 ft · lb) Nut (brake lever) 3 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the brake master cylinder piston.
Page 513 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Levier de frein 1 Bremshebel 1 Leva del freno 1 Boulon (levier de frein) 2 Schraube (Bremshebel) 2 Bullone (leva del freno) 2 6 Nm (0,6 m · kg) 6 Nm (0,6 m ·...
Page 514 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Pin 1 Washer 2 Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. Front brake hose 1. Install: Brake hose 1 10 Nm (1.0 m ·...
Page 515 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Goupille 1 Stift 1 Perno 1 Rondelle 2 Unterlegscheibe 2 Rondella 2 Goupille fendue 3 Splint 3 Copiglia 3 HINWEIS: N.B.: NOTA: Après de montage, contrôler la hauteur Nach der Montage die Fußbremshe- Dopo l’installazione,...
Page 516 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that it contacts the master cylinder projection a and that its bent portion b faces downward.
Page 517 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Durit de frein 2 Bremsschlauch 2 Flessibile freno 2 Boulon-raccord 3 Hohlschraube 3 Vite di unione 3 30 Nm (3,0 m ·...
Page 518 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake hose holder 1 Screw (brake hose holder) 2 4 Nm (0.4 m · kg, 2.9 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
Page 519 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Montieren: Monter: Installare: Support de tuyau de frein 1 Bremsschlauch-Halterung Supporto flessibile freno 1 Vis (support de tuyau de frein) Vite (supporto flessibile freno) Schraube (Halterung) 2 4 Nm (0,4 m ·...
Page 520 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: Brake system Refer “BRAKE SYSTEM BLEEDING” section in the CHAPTER 3. Inspect: Brake fluid level Fluid at lower level Fill up. Refer “BRAKE FLUID LEVEL INSPECTION” section in the CHAP- TER 3. 4.
Page 521 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Entlüften: Purger l’air: Spurgo dell’aria: Circuit de freinage Bremsanlage Sistema frenante Siehe unter “HYDRAULI- reporter à section Fare riferimento al paragrafo “PURGE D’AIR DU CIR- SCHE BREMSANLAGE “SPURGO DELL’ARIA DAL ENTLÜFTEN”...
Page 522: Handlebar
CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 523: Fourche Avant
FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE FOURCHE AVANT Organisation de la dépose: 1 Dépose de la fourche avant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA FOURCHE AVANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque approprié...
Page 524 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Front fork cap bolt Refer to “REMOVAL POINTS”. Fork spring Drain the fork oil. Dust seal Stopper ring Refer to “REMOVAL POINTS”.
Page 525 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE DEMONTAGE DE LA FOURCHE AVANT Organisation de la dépose: 1 Dépose de la bague d’étanchéité 2 Dépose de la tige d’amortisseur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEMONTAGE D’UN BRAS DE FOUR- CHE AVANT Bouchon de tube de fourche Se reporter à...
Page 526 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should observed: The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to foreign material.
Page 527 N.B.: La fourche avant nécessite une soi- dere Aufmerksamkeit und sollte am cautela. Pertanto si consiglia di affidare besten vom Yamaha-Händler gewar- gneuse attention. Il est donc recom- la manutenzione della forcella anteriore mandé de la faire entretenir chez le tet werden.
Page 528 CHAS FRONT FORK EC553201 Inner tube 1. Remove: Dust seal 1 Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly Repeat this step until the inner tube can be pulled out from the outer tube.
Page 529 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Gleitrohr Tube interne Tubo di forza Déposer: Demontieren: Rimuovere: Joint antipoussière 1 Staubschutzring 1 Guarnizione parapolvere 1 Bague d’arrêt 2 Sicherungsring 2 Anello di arresto 2 Einen Schlitzschraubendre- En utilisant un tournevis à lame Utilizzando un cacciavite per droite.
Page 530 CHAS FRONT FORK EC554200 Base valve 1. Inspect: Valve assembly 1 Wear/damage Replace. O-ring 2 Damage Replace. EC554400 Fork spring 1. Measure: Fork spring free length a Out of specification Replace. Fork spring free length: 460 mm (18.1 in) <Limit>: 455 mm (17.9 in) EC554502 Inner tube 1.
Page 531 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Luftventil Soupape de base Valvola base Contrôler: Kontrollieren: Ispezionare: Ensemble clapet 1 Luftventil 1 Gruppo valvola 1 Usure/endommagement Verschleiß/Beschädigung Usura/danno Sostituire. Erneuern. O-ring 2 Remplacer. Joint torique 2 O-Ring 2 Danni Sostituire. Beschädigung Erneuern. Endommagement Rempla- cer.
Page 532 CHAS FRONT FORK Front fork cap bolt 1. Inspect: Front fork cap bolt 1 O-ring 2 Air bleed screw 3 Wear/damage Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: Damper rod 1 To inner tube 2.
Page 533 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Telegabelverschlußschraube Bouchon de tube de fourche Vite mordente forcella anteriore Contrôler: Kontrollieren: Ispezionare: Bouchon de tube de fourche 1 Telegabelverschlußschrau- Vite mordente forcella ante- Joint torique 2 be 1 riore 1 Vis de purge d’air 3 O-Ring 2 O-ring 2 Usure/endommagement...
Page 534 CHAS FRONT FORK 5. Install: Spring guide 1 Locknut 2 To damper rod 3. NOTE: Install the spring guide with its cut a facing upward. With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
Page 535 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Montieren: Monter: Installare: Guide de ressort 1 Federsitz 1 Guida molla 1 Contre-écrou 2 Sicherungsmutter 2 Controdado 2 Sur la tige d’amortisseur 3. (am Dämpferrohr 3) Sull’asta pompante 3. HINWEIS: N.B.: NOTA: Den Federsitz mit der Nut a nach Installer le guide de ressort avec Installare la guida della molla con il l’encoche a orientée vers le haut.
Page 536 CHAS FRONT FORK 9. Install: Slide metal 1 Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10. Install: Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
Page 537 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Montieren: Monter: Installare: Bague antifriction 1 Gleitbuchse 1 Metallo di scorrimento 1 Öldichtungsscheibe 2 Rondella paraolio 2 Rondelle de bague d’étanchéité (auf Gleitrohr-Nut) Sulla fessura del fodero. Dans l’ouverture de fourreau. HINWEIS: NOTA: Die Gleitbuchse mit dem Gabeldicht- Premere il metallo di scorrimento nel N.B.: ring-Treiber 3 in das Gleitrohr ein-...
Page 538 CHAS FRONT FORK 13. Check: Inner tube smooth movement Tightness/binding/rough spots Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “01”...
Page 539 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 13. Kontrollieren: 13. Contrôler: 13. Controllare: Mouvement régulier du tube Leichtgängigkeit des Stand- Movimento agevole del tubo di rohres Schwergängigkeit plongeur forza Raideur/coincement/point dur Die Schritte 2 bis 12 wieder- Tenuta/resistenza/punti rugo- holen. Répéter les étapes du 2 à 12. Ripetere le fasi da 2 a 12.
Page 540 CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.
Page 541 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 19. Zehn Minuten warten, bis et- 19. Attendre dix minutes jusqu’à ce 19. Attendere dieci minuti finché non que les bulles d’air aient disparu waige Luftbläschen sich auf- vengono rimosse le bolle d’aria gelöst haben, bevor der Ga- de la fourche avant et que l’huile dalla forcella anteriore e finché...
Page 542 CHAS FRONT FORK 21. Measure: Distance a Out of specification Turn into the locknut. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: Rebound damping adjuster 1 NOTE: Loosen the rebound damping adjuster finger tight.
Page 543 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 21. Messen: 21. Mesurer: 21. Misurare: Distance a Gewindelänge a Distanza a Hors spécification Serrer le Unvorschriftsmäßig Fuori specifica Avvitare il contre-écrou. Sicherungsmutter hineindre- controdado. hen. Distance a: Distanza a: 20 mm (0,79 in) ou plus 20 mm (0,79 in) o oltre Gewindelänge a Entre le haut de la tige...
Page 544 CHAS FRONT FORK 26. Tighten: Front fork cap bolt (locknut) 1 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. Hold the locknut 5 and tighten the front fork cap bolt with specified torque.
Page 545 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 26. Festziehen: 26. Serrer: 26. Serrare: Bouchon de tube de fourche Telegabelverschlußschrau- Vite mordente forcella ante- (contre-écrou) 1 be (Sicherungsmutter) 1 riore (controdado) 1 29 Nm (2,9 m · kg) 29 Nm (2,9 m · kg, 21 ft · lb) 29 Nm (2,9 m ·...
Page 546 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 547 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Festziehen: Serrer: Serrare: Boulon de bridage (té supé- Klemmschraube (obere Ga- Bullone di serraggio (piastra rieur) 1 belbrücke) 1 superiore) 1 23 Nm (2,3 m · kg) 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m ·...
Page 548 CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Headlight Decompression cable Disconnect at the lever side. Decompression lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Light switch...
Page 549 GUIDON LENKER CHAS MANUBRIO GUIDON Organisation de la dépose: 1 Dépose du guidon Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU GUIDON Préparation pour la dépose Phare Câble de décompression Déconnecter du côté levier. Support du levier de décompression Câble d’embrayage Déconnecter du côté...
Page 550 CHAS HANDLEBAR EC5B3000 REMOVAL POINTS Brake master cylinder 1. Remove: Brake master cylinder bracket 1 Brake master cylinder 2 CAUTION: Do not let the brake master cylinder hang on the brake hose. Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1.
Page 551 GUIDON LENKER CHAS MANUBRIO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Maître-cylindre de frein Hauptbremszylinder Pompa del freno Demontieren: Déposer: Rimuovere: Demi-palier de maître-cylin- Hauptbremszylinder-Halte- Staffa pompa del freno 1 dre de frein 1 rung 1 Pompa del freno 2 Maître-cylindre de frein 2 Hauptbremszylinder 2 ATTENZIONE:...
Page 552 CHAS HANDLEBAR EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: Handlebar 1 Handlebar upper holder 2 Bolt (handlebar upper holder) 3 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: The handlebar upper holder should be installed with the punched mark a forward. First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.
Page 553 GUIDON LENKER CHAS MANUBRIO ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Guidon Lenker ZIONE Montieren: Monter: Manubrio Guidon 1 Lenker 1 Installare: Oberer Lenkerhalter 2 Manubrio 1 Demi-palier supérieur de gui- don 2 Schraube (Oberer Lenker- Supporto manubrio superiore halter ) 3 Boulon (demi-palier supérieur de guidon) 3...
Page 554 CHAS HANDLEBAR 4. Install: Collar 1 Throttle cables 2 To tube guide 3. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion. 5. Install: Throttle cable cap 1 Screw (throttle cable cap) 2 4 Nm (0.4 m ·...
Page 555 GUIDON LENKER CHAS MANUBRIO Montieren: Monter: Installare: Collerette 1 Hülse 1 Collarino 1 Câbles d’accélération 2 Gaszüge 2 Cavi acceleratore 2 Sur le guide de tube 3. (am Führungsrohr 3) Alla guida del tubo 3. HINWEIS: N.B.: NOTA: Appliquer de la graisse à base de savon Lithiumfett auf Gaszugenden und - Applicare grasso a base di sapone di litio scheibe auftragen.
Page 556 CHAS HANDLEBAR 7. Install: Light switch 1 2 Nm (0.2 m · kg, 1.4 ft · lb) 8. Install: Engine stop switch 1 Clutch lever holder 2 Bolt (clutch lever holder) 3 4 Nm (0.4 m · kg, 2.9 ft · lb) Decompression lever holder 4 Bolt (decompression lever holder) 5 4 Nm (0.4 m ·...
Page 557 GUIDON LENKER CHAS MANUBRIO Einbauen: Posér: Installare: Contacteur d’éclairage 1 Lichtschalter 1 Interruttore luci 1 2 Nm (0,2 m · kg) 2 Nm (0,2 m · kg, 1,4 ft · lb) 2 Nm (0,2 m · kg, 1,4 ft · lb) Monter: Montieren: Installare:...
Page 558: Steering
CHAS HANDLEBAR 11. Fasten the decompression cable 1 and clutch cable 2 with a clamp 3. 12. Insert the end of the fuel breather hose 1 into the hole of the steering stem. 5 - 46...
Page 559 GUIDON LENKER CHAS MANUBRIO 11. Den Dekompressionsseilzug 11. Attacher le câble de décompres- 11. Fissare il cavo di decompressione sion 1 et le câble d’embrayage 1 und den Kupplungsseilzug 1 ed il cavo della frizione 2 con 2 à l’aide d’une bride 3. 2 mit einer Klammer 3 befe- una fascetta 3.
Page 560 CHAS STEERING EC560000 STEERING Extent of removal: 1 Lower bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 561 DIRECTION LKKOPF CHAS STERZO DIRECTION Organisation de la dépose: 1 Dépose du té inférieur 2 Dépose du roulement Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE LA DIRECTION AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque approprié...
Page 562 CHAS STEERING Extent of removal Order Part name Q’ty Remarks Upper bearing Lower bearing Refer to “REMOVAL POINTS”. Ball race Refer to “REMOVAL POINTS”. 5 - 48...
Page 563 DIRECTION LKKOPF CHAS STERZO Organisation de la dépose Ordre Nom de pièce Qté Remarques Roulement supérieur Roulement inférieur Se reporter à “POINTS DE DEPOSE”. Cage à billes Se reporter à “POINTS DE DEPOSE”. ETAPES DE SERRAGE: Serrer l’écrou crénelé de direction à un couple d’environ 38 Nm (3,8 m • kg, 27 ft • lb). Le desserrer d’un tour.
Page 564 CHAS STEERING EC563000 REMOVAL POINTS Steering ring nut 1. Remove: Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down. Lower bearing 1. Remove: Lower bearing 1 Use the floor chisel 2.
Page 565 DIRECTION LKKOPF CHAS STERZO AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Ecrou crénelé de direction Lenkerringmutter Ghiera Demontieren: Déposer: Rimuovere: Ecrou crénelé de direction 1 Lenkerringmutter 1 Ghiera 1 Den Hakenschlüssel 2 ver- Utiliser la clé pour ecrou cré- Utilizzare la chiave per ghiere nelé...
Page 566 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: Bearing 1 Ball race Pitting/damage Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bear- ings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set.
Page 567 DIRECTION LKKOPF CHAS STERZO Lager und Laufring Roulement et cage à billes Cuscinetto e pista Nettoyer les roulements et les Die Lager und Laufringe in Lö- Lavare i cuscinetti e le piste con sungsmittel waschen. cages à billes dans du solvant. un solvente.
Page 568 CHAS STEERING 4. Install: Washer 1 Steering ring nut 2 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 3. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT” section in the CHAPTER 3.
Page 569 DIRECTION LKKOPF CHAS STERZO Montieren: Monter: Installare: Rondelle 1 Unterlegscheibe 1 Rondella 1 Ecrou crénelé de direction 2 Lenkerringmutter 2 Ghiera 2 7 Nm (0,7 m · kg) 7 Nm (0,7 m · kg, 5,1 ft · lb) 7 Nm (0,7 m · kg, 5,1 ft · lb) Serrer l’écrou crénelé...
Page 570 CHAS STEERING 9. After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 10. Adjust: Front fork top end a Front fork top end (standard) a: 7 mm (0.28 in) * 8mm (0.31 in) ** 10.5 mm (0.41 in)
Page 571 DIRECTION LKKOPF CHAS STERZO Nach dem Festziehen der Après avoir serré l’écrou, vérifier Dopo aver serrato la ghiera, con- Mutter Lenkkopf si le mouvement de la direction trollare il movimento agevole Leichtgängigkeit prüfen. Bei est régulier. Sinon, régler la dello sterzo. Altrimenti, regolare Schwergängigkeit die Lenker- direction en desserrant petit à...
Page 572: Swingarm
CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine. danger of it falling over.
Page 573: Frein Avant Et Frein Arriere
BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE BRAS OSCILLANT Organisation de la dépose: 1 Dépose du bras oscillant Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU BRAS OSCILLANT AVERTISSEMENT Préparation pour la dépose Maintenir la machine en plaçant un support Bien soutenir la machine afin qu’elle ne risque approprié...
Page 574 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal...
Page 575: Bras Oscillant
BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE DEMONTAGE DU BRAS OSCILLANT Organisation de la dépose: 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle 3 Dépose et démontage du bras de relais Organisation de la dépose Ordre Nom de pièce Qté...
Page 576 CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: Bearing 1 NOTE: Install the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and cov- ers in a solvent. Swingarm 1. Inspect: Bearing 1 Bushing 2 Free play exists/unsmooth revolution/ rust Replace bearing and bushing as a set.
Page 577 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Demontieren: Déposer: Rimuovere: Roulement 1 Lager 1 Cuscinetto 1 HINWEIS: N.B.: NOTA: Monter le roulement en appuyant sur la Das Lager am äußeren Laufring ein- Installare cuscinetto premendo...
Page 578 CHAS SWINGARM EC575000 ASSEMBLY AND INSTALLATION EC575201 Bearing and oil seal 1. Install: Bearing 1 Oil seal 2 To swingarm. 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.
Page 579 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Roulement et bague d’étanchéité Lager und Dichtringe ZIONE Montieren: Monter: Cuscinetto e paraolio Roulement 1 Lager 1 Installare: Bague d’étanchéité 2 Dichtringe 2 Cuscinetto 1 Sur le bras oscillant. (an der Schwinge) Paraolio 2 Sul forcellone oscillante.
Page 580 CHAS SWINGARM Swingarm 1. Install: Bushing 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushings, thrust bearings and oil seal lips. 2. Install: Collar 1 To relay arm 2. NOTE: Apply the molybdenum disulfide grease on the collars, bearings and oil seal lips.
Page 581 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Schwinge Bras oscillant Forcellone oscillante Monter: Montieren: Installare: Bague 1 Buchse 1 Boccola 1 Roulement de butée 2 Drucklager 2 Cuscinetto di spinta 2 Bague d’étanchéité 3 Dichtring 3 Paraolio 3 Collerette 4 Hülse 4 Collarino 4 Sur le bras oscillant 5.
Page 582 CHAS SWINGARM 5. Install: Relay arm 1 Bolt (relay arm) 2 Washer 3 Nut (relay arm) 4 To swingarm. NOTE: Apply the molybdenum disulfide grease on the bolt. Do not tighten the nut yet. 6. Install: Swingarm 1 Pivot shaft 2 85 Nm (8.5 m ·...
Page 583 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Montieren: Monter: Installare: Bras de relais 1 Umlenkhebel 1 Leva di rinvio 1 Boulon (bras relais) 2 Schraube (Umlenkhebel) 2 Bullone (leva di rinvio) 2 Rondelle 3 Unterlegscheibe 3 Rondella 3 Ecrou (bras relais) 4 Mutter (Umlenkhebel) 4 Dado (leva di rinvio) 4 Sur le bras oscillant.
Page 584 CHAS SWINGARM 10. Tighten: Nut (connecting rod) 1 80 Nm (8.0 m · kg, 58 ft · lb) 11. Tighten: Nut (relay arm) 1 80 Nm (8.0 m · kg, 58 ft · lb) 12. Install: Cap 1 NOTE: Install the cap with its mark a facing forward. 13.
Page 585 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE 10. Festziehen: 10. Serrer: 10. Serrare: Ecrou (bielle) 1 Mutter (Übertragungshebel) Dado (biella) 1 80 Nm (8,0 m · kg, 58 ft · lb) 80 Nm (8,0 m · kg, 58 ft · lb) 80 Nm (8,0 m ·...
Page 586 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so there is no Preparation for removal Hold the machine by placing the danger of it falling over.
Page 587: Lateraux
AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE AMORTISSEUR ARRIERE Organisation de la dépose: 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DE L’AMORTISSEUR AVERTISSEMENT Préparation pour la dépose ARRIERE Bien soutenir la machine afin qu’elle ne risque Maintenir la machine en plaçant un support...
Page 588 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Locknut Only loosening. Adjuster Only loosening. Lower spring guide Upper spring guide Spring (rear shock absorber) Bearing Refer to “REMOVAL POINTS”. 5 - 61...
Page 589: Amortisseur Arriere
AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Organisation de la dépose Ordre Nom de pièce Qté Remarques Contre-écrou Desserrer uniquement. Dispositif de réglage Desserrer uniquement. Guide de ressort (inférieur) Guide de ressort (supérieur) Ressort (amortisseur arrière) Roulement Se reporter à “POINTS DE DEPOSE”. Reihen- Demontage-Arbeiten Bauteil...
Page 590 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 - 62...
Page 591 WARNUNG Confier la mise au rebut d’un amortis- rato, rivolgersi ad un rivenditore seur endommagé ou usé à un conces- Den Stoßdämpfer vom Yamaha- Yamaha per questa procedura di Händler entsorgen lassen. sionnaire Yamaha smaltimento. 5 - 62...
Page 592 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 593 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE AUSBAU POINTS DE DEPOSE PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Demontieren: Déposer: Rimuovere: Bague d’arrêt (roulement supé- Sicherungsring (Oberes La- Anello di arresto (cuscinetto rieur) 1 ger) 1 superiore) 1 HINWEIS: N.B.: NOTA: Das Lager am äußeren Laufring ein- Appuyer sur le roulement en poussant Spingere dentro il cuscinetto premendo sur la cage extérieure et enlever la bague...
Page 594 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 595 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE ZUSAMMENBAU UND MONTAGE REMONTAGE ET MONTAGE MONTAGGIO INSTALLA- Roulement Lager ZIONE Montieren: Monter: Cuscinetto Roulement supérieur 1 Oberes Lager 1 Installare: Cuscinetto superiore 1 HINWEIS: N.B.: Monter roulement parallèlement Das Lager am äußeren Laufring NOTA: gleichmäßig einpressen, bis die Si- jusqu’à...
Page 596 CHAS REAR SHOCK ABSORBER 2. Tighten: Adjuster 1 3. Adjust: Spring length (installed) a Spring length (installed) a: Standard Extent of length adjustment 240.5 mm (9.47 in) 240.5 ~ 258.5 mm * 247 mm (9.72 in) (9.47 ~ 10.18 in) **243.5 mm (9.59 in) * For EUROPE ** For AUS, NZ and ZA...
Page 597 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Festziehen: Serrer: Serrare: Dispositif de réglage 1 Einstellmutter 1 Registro 1 Régler: Einstellen: Regolare: Longueur de ressort (monté) a Feder-Einbaulänge a Lunghezza molla (installata) Longueur de ressort Feder-Einbaulänge a (monté) a: Lunghezza molla (instal- lata) a Longueur stan- Etendue de...
Page 598 CHAS REAR SHOCK ABSORBER 2. Install: Bushing 1 Collar 2 Dust seal 3 NOTE: Apply the molybdenum disulfide grease on the bearing. Apply the lithium soap base grease on the bushing, collars and dust seals. Install the dust seals with their lips facing outward.
Page 599 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Montieren: Monter: Installare: Douille 1 Buchse 1 Boccola 1 Collerette 2 Hülse 2 Collarino 2 Joint antipoussière 3 Staubschutzring 3 Guarnizione parapolvere 3 HINWEIS: N.B.: NOTA: Enduire le roulement de graisse au Molybdändisulfidfett auf das Lager Applicare grasso al disolfuro di molib- auftragen.
Page 600 CHAS REAR SHOCK ABSORBER 8. Install: Band 1 Taillight connector 2 5 - 67...
Page 601 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Montieren: Monter: Installare: Bande 1 Band 1 Band 1 Rücklicht-Steckverbinder 2 Connecteur de la lampe arrière Connettore del fanalino poste- riore 2 5 - 67...
Page 602: And Wiring Diagram
– ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight COLOR CODE Sb ....Sky blue 2 Voltage regulator B...... Black W .....White Br ....Brown 3 Engine stop switch Y ......Yellow G .....
Page 603: Partie Electrique
COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE – ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA DI CABLAGGIO ELEKTRISCHE PARTIE IMPIANTO ANLAGE ELECTRIQUE ELETTRICO ELEKTRISCHE BAUTEI- COMPOSANTS ELECTRI- COMPONENTI ELET- LE UND SCHALTPLAN QUES ET SCHEMA DE TRICI SCHEMA ELEKTRISCHE BAUTEILE CABLAGE CABLAGGIO 1 Scheinwerfer...
Page 604: Map-Controlled Cdi Unit
– ELEC MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR250F. 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 605: Bloc Cdi Controle Par Microprocesseur
– ELEC BLOC CDI CONTROLE PAR MICROPROCESSEUR BLOC CDI CONTROLE PAR MICROPROCESSEUR La WR250F est dotée d’un système d’allumage CDI contrôlé par microprocesseur. Le microprocesseur du bloc CDI détecte en permanence le régime du moteur ainsi que la position du papillon des gaz, puis détermine l’avance à...
Page 606: Motor
– ELEC KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM KENNFELDGESTEUERTES CDI-ZÜNDSYSTEM Die WR250F ist mit einer kennfeldgesteuerten CDI-Zündanlage ausgestattet. Der Mikroprozessor in der CDI-Zündbox ist ständig über die Motordrehzahl und Drosselklappenpo- sition informiert und kann dadurch den optimalen Zündzeitpunkt im gesamten Lastbereich bestim- men. Dies sorgt stets für das bestmögliche Ansprechverhalten des Motors. Zündspule Zündeinheit Drosselklappensensor...
Page 607 – ELEC UNITÀ CDI CONTROLLATA DA MAPPA UNITÀ CDI CONTROLLATA DA MAPPA Il modello WR250F impiega un sistema di accensione CDI controllata da mappa. Il microcomputer nell’unità CDI rileva la velocità del motore e la posizione della valvola a farfalla, determi- nando così...
Page 608 – 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 609 – ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DU CONTROLE Se référer au tableau suivant lors de l’inspection du système d’allumage lors de pannes. Suivre le procédé suivant pour déterminer si le mauvais fonctionnement du moteur est dû à une panne dans le circuit d’allumage et pour vérifier une bougie qui ne produit pas d’étincelle.
Page 610 – ELEC ZÜNDANLAGE ZÜNDANLAGE FEHLERSUCHE Bei der Überprüfung der Zündanlage auf mögliche Störungen ist das folgende Ablaufdiagramm zu beachten. Folgendes Diagramm hilft zündanlagen- und zündkerzenbedingte Motorstörungen zu beheben. Zündfunke Zündfunkenstrecke *Zündkerze reinigen kontrollieren oder erneuern. Kein Zündfunke Die gesamte Lichtanlage Nicht in Ordnung Erneuern oder instand auf einwandfreie Verbin-...
Page 611: Utensili Speciali
– ELEC IMPIANTO DI ACCENSIONE IMPIANTO DI ACCENSIONE FASI DI ISPEZIONE Utilizzare la procedura seguente per controllare la possibilità che un cattivo funzionamento del motore sia attribuibile ad un guasto al sistema di accensione o per controllare la candela che non emette scintille. Scintilla Test della distanza tra gli *Pulire o sostituire la...
Page 612 – ELEC IGNITION SYSTEM SPARK GAP TEST Å 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2) as shown. Spark plug cap 3 Spark plug 4 Å For USA and CDN ı...
Page 613: Impianto Di Accensione
SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE ZÜNDFUNKENSTRECKE KON- TEST DE LA LONGUEUR D’ETIN- Test della distanza tra gli elettrodi CELLE D’ALLUMAGE TROLLIEREN Staccare il cappuccio della can- Den Zündkerzenstecker von Déconnecter le capuchon de bou- dela. gie de la bougie. der Zündkerze abziehen.
Page 614 – 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 0.20 ~ 0.30 20 ˚C (68 ˚F) 2.
Page 615 SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE ZÜNDSPULE KONTROLLIEREN CONTROLE BOBINE ISPEZIONE BOBINA DI ACCEN- D’ALLUMAGE Kontrollieren: SIONE Primärspulen-Widerstand Vérifier: Ispezionare: Résistance de bobine primaire Unvorschriftsmäßig Resistenza avvolgimento pri- Erneuern. Hors spécification Rempla- mario cer. Fuori specifica Regolare. Meßkabel (+) orange 1 Meßkabel (–) schwarz 2...
Page 616 – 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 640 ~ 960 20 ˚C (68 ˚F) 3.
Page 617: Elektrische Anlage
SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE Kontrollieren: Vérifier: Ispezionare: Résistance de bobine de charge Widerstand der Erregerspu- Resistenza bobina di carica 1 le 1 Fuori specifica Sostituire. Hors spécification Rempla- Unvorschriftsmäßig Conduttore (+) del tester Erneuern. cer. Conduttore marrone 1 Conduttore (–) del tester Meßkabel (+) braun 1...
Page 618: 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 619: Circuit Du Capteur De Papillon Des Gaz
– ELEC CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ ETAPES DU CONTROLE Si le capteur de papillon des gaz ne fonctionne pas, effectuer les contrôles suivants. Vérifier la connexion de tout le Mauvais Réparer ou remplacer.
Page 620 – ELEC DROSSELKLAPPEN-POSITIONSSENSOR DROSSELKLAPPEN-POSITIONSSENSOR INSPEKTIONSSCHRITTE Wenn Drosselklappen-Positionssensor nicht arbeitet, mit den folgenden Schritten überprüfen. Nicht in Ordnung Die gesamte Zündanlage Erneuern oder instand auf Anschluß überprüfen. setzen. In Ordnung Drosselklap- Nicht in Ordnung Den Drosselklappen-Positi- pen-Positions- Erneuern. onssensor prüfen. sensor-Spule In Ordnung Nicht in Ordnung * Den CDI-Schwungrad-...
Page 621 SISTEMA SENSORE DELLA POSIZIONE DELLA – ELEC VALVOLA A FARFALLA SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA FASI DI ISPEZIONE Se il sensore di posizione della valvola a farfalla non funziona, seguire la seguente procedura. Controllare il collegamento Non funziona dell’intero Riparare o sostituire.
Page 622 – ELEC THROTTLE POSITION SENSOR SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection Rust/dust/looseness/short-circuit Repair or replace. THROTTLE POSITION SENSOR COIL INSPECTION 1. Inspect: Throttle position sensor coil resistance Out of specification Replace. Tester (+) lead Blue lead 1 Tester (–) lead Black lead 2...
Page 623 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA CONTROLE DES CONNEXIONS INSPEKTION DER STECKVERBIN- ISPEZIONE DEI COLLEGAMENTI DUNGEN UND KABELANSCHLÜS- DES COUPLEURS ET DES FILS DEGLI ACCOPPIATORI E DEI Vérifier: CAVI Prüfen: Connexion coupleurs et fils...
Page 624 – ELEC THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1. Remove: Throttle position sensor coupler Screw (throttle position sensor) 1 Washer 2 Throttle position sensor 3 NOTE: Loosen the screws (throttle position sensor) using the T20 bit (tamper resistant fastener type).
Page 625: Carburateur
CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA TPS-AUSTAUSCH UND EINSTEL- REMPLACEMENT ET REGLAGE SOSTITUZIONE REGOLA- LUNG DU CAPTEUR DE PAPILLON DES ZIONE DEL SENSORE DI POSI- Entfernen: ZIONE TPS-Steckverbindung Déposer: Rimuovere: Schraube (Drosselklappen-...
Page 626 – ELEC THROTTLE POSITION SENSOR SYSTEM 6. Adjust: Throttle position sensor coil resistance at idle speed Adjustment steps: Adjust the angle of the throttle position sen- sor 1 to obtain the resistance calculated (example: 650 ~ 750 Tester (+) lead Yellow lead 2 Tester (–) lead Black lead 3...
Page 627 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ – DROSSELKLAPPEN-POSITIONSSENSOR ELEC SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA Einstellen: Régler: Regolare: TPS-Spulenwiderstand bei Résistance de la bobine de cap- Resistenza bobina sensore di Leerlauf teur de papillon des gaz à la posizione della valvola a far- vitesse de ralenti falla al minimo...
Page 628: Lighting System
– ELEC LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. No good Check the bulb and bulb Replace the bulb and/ socket. or bulb socket. No good Check the light switch. Replace.
Page 629 – ELEC SYSTEME D’ECLAIRAGE SYSTEME D’ECLAIRAGE PROCEDURES DE VERIFICATION Se référer au tableau suivant lors de l’inspection du système d’allumage lors de pannes. Mauvais Contrôler l’ampoule et le culot Changer l’ampoule et/ou le d’ampoule. culot d’ampoule. O.K. Mauvais Contrôler la connexion de tout le Remplacer.
Page 630 – ELEC LICHTANLAGE LICHTANLAGE KONTROLLSCHRITTE Bei der Überprüfung der Zündanlage auf mögliche Störungen ist das folgende Ablaufdiagramm zu beachten. Nicht in Ordnung Lampe und Lampenstecker Lampe und/oder Lam- überprüfen. penstecker erneuern. In Ordnung Die gesamte Lichtanlage auf Nicht in Ordnung einwandfreie Verbindungen Erneuern.
Page 631: Magnete Cdi
– ELEC IMPIANTO DI ILLUMINAZIONE IMPIANTO DI ILLUMINAZIONE FASI DI ISPEZIONE Vedere lo schema a blocchi che segue quando si controlla l’impianto di accensione per verificare l’esistenza di possibili problemi. Non funziona Controllare la lampada ed il por- Sostituire la lampada e/o il talampada.
Page 632 – ELEC LIGHTING SYSTEM LIGHT SWITCH INSPECTION 1. Inspect: Light switch continuity Tester (+) lead Yellow lead 1 Tester (–) lead Blue lead 2 Tester selec- tor position No continuous while being Replace. Continuous while being OFF Replace. CDI MAGNETO INSPECTION 1.
Page 633: Impianto Di Illuminazione
SYSTEME D’ECLAIRAGE LICHTANLAGE – ELEC IMPIANTO DI ILLUMINAZIONE LICHTSCHALTER KONTROLLIE- VERIFICATION INTERRUPTEUR ISPEZIONE DELL’INTERRUT- LUMIERES TORE LUCI Kontrollieren: Vérifier: Ispezionare: conducteur interrupteur Lichtschalterfunktion Conduttività dell’interruttore lumière luci Pluskabel des Meßgerätes (+) Gelbes Kabel 1 Fil (+) de multimètre Cavo positivo (+) del tester Pluskabel des Meßgerätes (–) Fil jaune 1 Cavo giallo 1...
Page 634 T U N SETTING EC700000 TUNING EC710000 ENGINE Carburetor setting The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor. Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling.
Page 635 REGLAGE EINSTELLUNG T U N REGISTRAZIONE ABSTIMMUNG MISES AU POINT MESSA A PUNTO MOTOR MOTEUR MOTORE Vergaser einstellen Réglage de carburateur Registrazione del carburatore Das Luft/Kraftstoffgemisch variiert La qualité de l’émulsion air/essence La miscela aria/carburante varia a mit den atmosphärischen Bedin- dépend des conditions atmosphéri- seconda delle condizioni atmosferi- gungen.
Page 636 T U N SETTING CAUTION: The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carbure- tor parts may prevent the carburetor from functioning correctly.
Page 637 REGLAGE EINSTELLUNG T U N REGISTRAZIONE ATTENTION: ATTENZIONE: ACHTUNG: Le carburateur est extrêmement Der Vergaser ist extrem emp- Il carburatore è estremamente sen- sensible à toute pénétration de cras- findlich gegen Fremdkörper sibile a materiale estraneo (sporco, ses, sable, eau, etc. Bien veiller, lors (Schmutz, Sand, Wasser usw.).
Page 638 T U N SETTING Effects of the setting parts on the throttle valve opening ı Å Å ı Å Closed ı Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main jet.
Page 639 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Wirkung der Einstellteile in Bezug Effets des réglages sur l’ouverture du Effetti della registrazione sull’aper- papillon des gaz auf die Öffnung der Drosselklappe tura della valvola a farfalla Å Fermé Å Geschlossen Å Chiusa ı...
Page 640 T U N SETTING 1 Jet needle 2 Main air jet 3 Pilot air jet 4 Needle jet 5 Main jet 6 Pilot jet 7 Pilot screw Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1. Standard main jet #170 If the air-fuel mixture is too rich or too lean, the...
Page 641 REGLAGE EINSTELLUNG T U N REGISTRAZIONE 1 Aiguille 1 Düsennadel 1 Spillo del getto 2 Puits d’aiguille 2 Nadeldüse 2 Getto dell’aria del massimo 3 Gicleur principal 3 Hauptdüse 3 Getto dell’aria del minimo 4 Puits d’aiguille 4 Nedeldüse 4 Getto a spillo 5 Gicleur principal 5 Hauptdüse 5 Getto del massimo...
Page 642 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 643 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Einstellung der Leerlaufgemisch- Réglage de la vis de ralenti Regolazione vite di registro del La richesse de l’émulsion air-essence à Regulierschraube minimo Der Kraftstoffgehalt des Luft-Kraft- une ouverture des gaz de 0 à 1/4 se règle È...
Page 644 T U N SETTING Effects of adjusting the pilot jet (reference) Å ı –5% Å Idle ı Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open.
Page 645 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Wirkung der Einstellung der Leer- Effets du réglage du gicleur de ralenti Effetti della regolazione del getto del (référence) laufdüse minimo (riferimento) Å Å Å ı ı ı N 45 Nr. 45 N. 45 N 42 Nr.
Page 646 T U N SETTING Jet needle adjustment The jet needle is adjusted by changing it. OBELP Standard jet needle *OBEGP **OBEHP * For EUROPE ** For CDN, ZA, AUS and NZ The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.
Page 647 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Düsennadel einstellen Réglage de l’aiguille Regolazione dello spillo del getto L’aiguille se règle en la changeant. Die Düsennadel wird eingestellt, Lo spillo del getto viene regolato sosti- indem sie ausgetauscht wird. tuendolo. OBELP OBELP Aiguille standard *OBEGP OBELP...
Page 648 T U N SETTING Effects of changing the jet needle (reference) (Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. Å ı +10 % –10 % Å...
Page 649 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Wirkung des Austausch Effets du changement d’aiguille (réfé- Effetti della modifica dello spillo del rence) s der Düsennadel getto (riferimento) (Durchmesser des geraden Teils) (Diamètre de la partie recriligne) (Diametro della parte dritta) Une modification du diamètre de la par- Der Durchmesser des geraden Teils Modificando il diametro della parte beeinflußt...
Page 650 T U N SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet Rich #185 4MX-14943-44 #182 4MX-14943-94 #180 4MX-14943-43 #178 4MX-14943-93 #175 4MX-14943-42 #172 4MX-14943-92 (STD) #170 4MX-14943-41 #168 4MX-14943-91 #165 4MX-14943-40 #162 4MX-14943-90 Lean #160 4MX-14943-39 Pilot jet Rich 4MX-14948-07...
Page 651 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Vergaser-Einstellteile Pièces modifiables du carburateur Parti di registrazione del carburatore Grö- Teilenum- Numéro de Denomina- Numero di Nom de pièce Taille Bauteil pièce ße zione sura pezzo Gicleur principal N˚185 4MX-14943-44 Hauptdüse Fett Nr.185 4MX-14943-44 Getto del massimo N.185...
Page 652 T U N SETTING Examples of carburetor setting depending on symptom Symptom Setting Checking At full throttle Increase main jet calibration no. Discoloration of spark plug Hard breathing (Gradually) If tan color, it is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat Clogged fuel hose...
Page 653 T U N REGLAGE Exemples de réglages de carburateur en fonction des symptômes Symptômes Réglages Contrôles Monter un gicleur principal de n˚ de cali- Décoloration de bougie A pleine ouverture des gaz bre supérieur Brun clair = bon état Crachotements (progressivement) Ne peut-être corrigé: Bruits de frottement de piè-...
Page 654 T U N EINSTELLUNG Beispiele für die Vergasereinstellung in bezug auf bestimmte Symptome Symptom Einstellung Prüfung Bei Vollgas Hauptdüsen-Nr. erhöhen (schrittweise) Verfärbung der Zündkerze: “Schweres Atmen” Rehbraune Färbung weist auf guten Abschergeräusch Zustand hin. Weißliche Zündkerze Falls nicht korrigiert werden kann: Schwimmerventilsitz verstopft Mageres Gemisch Kraftstoffschlauch verstopft...
Page 655 T U N REGISTRAZIONE Esempi di registrazione del carburatore a seconda dei sintomi Sintomo Registrazione Controllo Con la valvola a farfalla Aumentare il n. di taratura del getto del Scolorimento della candela completamente aperta massimo. Se di colore bruno, è in buone condizioni. Respirazione difficoltosa (Gradualmente) Se non è...
Page 656 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 52/13 (4.000) reduction ratio <Requirement for selection of secondary gear reduction ratio>...
Page 657 REGLAGE EINSTELLUNG T U N REGISTRAZIONE FAHRGESTELL PARTIE CYCLE PARTE CICLISTICA Sekundärüntersetzungsverhältnis Sélection du taux de réduction secon- Selezione rapporto di riduzione secon- (Kettenräder) wählen daire (pignons) daria (corona dentata) Anzahl der Zähne Nombre de dents Numero di denti della couronne am angetriebenen corona della ruota poste-...
Page 658 T U N SETTING EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 9383B-13218 Rear wheel 5GS-25448-50 sprocket 2 5GS-25450-50 (STD) 5GS-25452-50 5PH-25454-50 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit.
Page 659 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Antriebsritzel und Kettenräder Pièces de réglage des pignons menant Parti di regolazione delle corone den- et de la couronne arrière tate conduttrici e condotte Teilenum- Bauteil Größe Numéro Denomina- Misu Numero di Nom de pièce Taille de pièce zione pezzo...
Page 660 T U N SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics Change the fork oil level.
Page 661: Fourche Avant
REGLAGE EINSTELLUNG T U N REGISTRAZIONE Teleskopgabel einstellen Réglages de la fourche avant Registrazione forcella anteriore La registrazione della forcella anteriore Régler la fourche avant en fonction de la Die Einstellung der Gabel sollte ent- va effettuata a seconda delle sensazioni sprechend dem Gefühl des Fahrers, sensation lors de la conduite ainsi que del pilota in una vera gara e delle condi-...
Page 662 T U N SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. CAUTION: Do not install three or more adjustment washers for each front fork. WARNING Always adjust each front fork to the same setting.
Page 663 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Federvorspannung einstellen Réglage de tension initiale du ressort Regolazione precarico Le tension initiale du ressort a été ajustée Die Federvorspannung wird durch Il precarico della molla viene regolato en montant la rondelle de réglage 1 den Einbau einer Einstellscheibe 1 installando la rondella di regolazione 1 entre le ressort de fourche 2 et la tige...
Page 664 T U N SETTING 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: Change the rebound damping.
Page 665: Guidon
REGLAGE EINSTELLUNG T U N REGISTRAZIONE Harte Feder Ressort dur Impiego di una molla rigida En principe, un ressort dur offre Eine harte Feder bewirkt prin- Generalmente una molla rigida dà zipiell ein hartes Fahrgefühl. une sensation de conduite dure. una sensazione di guida rigida.
Page 666 T U N SETTING EC72P000 Front fork setting parts Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 4SS-23364-L0 Front fork spring 2 [Equal pitch spring] I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.380 4SS-23141-10 SOFT 0.390...
Page 667 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Vorderradgabel-Einstellteile Pièces de réglage de la fourche avant Parti di regolazione della forcella Rondelle de réglage 1 Einstellscheibe 1 anteriore Rondella di regolazione 1 TEILENUM- TYPE Numéro de pièce TYP (Dicke) (épaisseur) NUMERO DI TIPO (spessore) PEZZO T = 2,3 mm...
Page 668 T U N SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1. Setting of spring preload Change the set length of the spring.
Page 669 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Hinterradaufhängung einstellen Réglage de la suspension arrière Registrazione della sospensione poste- Effectuer le réglage de la suspension Die Einstellung der Hinterradaufhän- riore gung soll entsprechend dem Gefühl arrière en fonction de la sensation lors de La registrazione della sospensione poste- la conduite ainsi que des conditions de des Fahrers, nach einer Testfahrt...
Page 670 T U N SETTING NOTE: If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re- evaluation.
Page 671 REGLAGE EINSTELLUNG T U N REGISTRAZIONE HINWEIS: N.B.: NOTA: Le ressort peut s’allonger au fur et à Die Federeinbaulänge kann sich Se il veicolo è nuovo dopo il rodaggio beim Einfahren verändern, u.a. mesure de la période de rodage. Il est la lunghezza registrata della molla donc important de corriger les régla- weil sich die Feder ermüdet.
Page 672 T U N SETTING CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length a does not exceed the stan- dard as it may result in faulty performance. Never use one whose overall length is greater than standard.
Page 673 REGLAGE EINSTELLUNG T U N REGISTRAZIONE ATTENTION: ATTENZIONE: ACHTUNG: Lors du remplacement de l’amortis- Beim Austausch des Federbeins Quando si impiega un ammortizzatore seur arrière, veiller à monter un darauf achten, daß die Gesamtlän- posteriore diverso da quello installato, amortisseur dont la longueur totale a ge a das Standardmaß...
Page 674 T U N SETTING EC72Q000 Rear shock absorber setting parts Rear shock spring 1 [Equal pitch spring] I.D. SPRING SPRING SPRING TYPE COLOR/ FREE RATE PART NUMBER POINT LENGTH 5DH-22212-70 Brown/1 SOFT 5DH-22212-10 Green/1 5DH-22212-20 Red/1 5DH-22212-30 Black/1 5DH-22212-40 Blue/1 STIFF 5DH-22212-50 Yellow/1...
Page 675 REGLAGE EINSTELLUNG T U N REGISTRAZIONE Hinterradstoßdämpfer-Einstell- Pièces de réglage de l’amortisseur Parti di regolazione dell’ammortizza- arrière teile tore posteriore Ressort d’amortisseur arrière 1 Hinterradstoßämpfer-Schrauben- Molla dell’ammortizzatore posteriore [Ressort à pas égal] feder 1 [Feder mit gleichmäßiger Gewinde- [Molla con passo costante] Cons- Repere steigung]...
Page 676: Suspension Setting
T U N SETTING EC72H002 Suspension setting Front fork NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in).
Page 677 T U N SETTING Rear shock absorber NOTE: If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. Adjust the rebound damping in 2-click increments or decrements. Adjust the low compression damping in 1-click increments or decrements.
Page 678 T U N REGLAGE Réglage de la suspension Fourche avant N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Avant d’effectuer toute modification, régler la longueur enfoncée de l’amortisseur arrière comprimé...
Page 679 T U N REGLAGE Amortisseur arrière N.B.: Si un des symptômes décrits ci-dessous apparaît alors que le réglage de la suspension est standard, effectuer un nouveau réglage en se référant aux procédés repris dans ce tableau. Régler la force de rebondissement de 2 clics dans un sens ou l’autre. Régler la force d’amortissement à...
Page 680: Teleskopgabel
T U N EINSTELLUNG Fahrwerksabstimmung Teleskopgabel HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Vor der Einstellung der Gabel das Federbein auf die Standard-Federeinbaulänge von 90–100 mm einstellen. Strecke Große Mittlere Kleine Symptom Prüfen Einstellen Sprung Boden- Boden- Boden- senke senke...
Page 681 T U N EINSTELLUNG Federbein HINWEIS: Liegen bei Normaleinstellung folgende Symptome vor, wie folgt vorgehen. Die Zugstufendämpfung jeweils um 2 Rasterstufen stärker oder schwächer verstellen. Die Tiefdruckdämpfung jeweils um 1 Rasterstufe stärker oder schwächer verstellen. Die Hochdruckdämpfung jeweils um eine 1/6-Drehung stärker oder schwächer verstellen. Strecke Große Mittlere...
Page 682 T U N REGISTRAZIONE Registrazione sospensioni Forcella anteriore NOTA: Se si verifica uno dei seguenti sintomi con la posizione standard, effettuare la ri-registrazione facendo riferimento alla procedura di registrazione indicata nella stessa tabella. Prima di ogni eventuale modifica, impostare la lunghezza abbassata dell’ammortizzatore posteriore sul valore normale di 90 ~ 100 mm (3,5 ~ 3,9 in).
Page 683 T U N REGISTRAZIONE Ammortizzatore posteriore NOTA: Se si verifica uno dei seguenti sintomi con la posizione normale, effettuare la ri-registrazione facendo riferimento alla procedura di regolazione indicata nella stessa tabella. Regolare lo smorzamento di espansione in incrementi o decrementi di 2 scatti. Regolare lo smorzamento di compressione bassa in incrementi o decrementi di 1 scatto.
Page 686 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2000 · 11 - 2.5 1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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