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YAMAHA WR250F(P) Owner's Service Manual

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  Table of Contents
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGS-HANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
WR250F
P
(
)
5PH-28199-31

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   Summary of Contents for YAMAHA WR250F(P)

  • Page 1 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGS-HANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO WR250F 5PH-28199-31...
  • Page 2 EC010010 WR250F(P) OWNER’S SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, September 2001 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 ©2001 Yamaha Motor Co., Ltd. ©2001 Yamaha Motor Co., Ltd. ©2001 by Yamaha Motor Co., Ltd. 1ère édition, septembre 2001 1. Auflage, September 2001 edizione, settembre 2001 Tous droits réservés Alle Rechte vorbehalten.
  • 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 la fiabilité qui ont fait de Yamaha un lea- Maß an Qualität und die sprichwörtli- qualitativa e affidabilità che hanno reso der.
  • Page 6: Important Notice

    IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding.
  • Page 7 NOTICE ZUR BEACHTUNG COMUNICAZIONE IMPORTANTE IMPORTANTE Dieses Motorrad ist ausschließlich für den Einsatz im Gelände-Renn- CETTE MACHINE EST STRICTE- QUESTO VEICOLO È STATO PRO- sport auf geschlossenen Kursen MENT DESTINEE A LA COMPETI- GETTATO ESCLUSIVAMENTE PER bestimmt. Die Benutzung dieses TION, UNIQUEMENT SUR CIRCUIT LE COMPETIZIONI SU CIRCUITI...
  • Page 8 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
  • Page 9 L’ESSENCE PEUT CAUSER Benzin ist giftig. LA BENZINA PUÒ PROVO- DES BLESSURES. Sollten Sie versehentlich CARE DANNI PERSONALI. Si vous avalez de l’essence, res- Benzin verschluckt, Ben- In caso di ingestione involonta- pirez des vapeurs d’essence en zindämpfe eingeatmet oder benzina, inalazione excès ou laissez de l’essence...
  • Page 10 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 INFORMATIONS PARTI- KENNZEICHNUNG WICH- 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 REGLAGES INSPEKTION UND REGISTRAZIONI INSP COURANTS REGOLARI EINSTELLARBEITEN MOTOR MOTEUR MOTORE FAHRWERK PARTIE CYCLE PARTE CICLISTICA CHAS – ELEKTRISCHE PARTIE IMPIANTO ELECTRIQUE...
  • Page 20: Table Of Contents

    EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 FUEL ............1-14 STARTING AND BREAK-IN ....1-15 TORQUE-CHECK POINTS ..... 1-19 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 LA WICHTIGE INFORMAZIONI MACHINE ........1-2 INFORMATIONEN ......1-3 IMPORTANTI ........1-3 INFORMATIONS ANSCHLÜSSE PRÜFEN ...1-6 CONTROLLO DEI...
  • 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 .......... 4-21 CYLINDER HEAD ........4-30 VALVES AND VALVE SPRINGS ... 4-34 CYLINDER AND PISTON ....... 4-43 CLUTCH ..........
  • Page 23: Moteur

    KAPITEL 4 CHAPITRE 4 CAPITOLO 4 MOTOR MOTEUR MOTORE SELLE, RESERVOIR SITZBANK, SELLA, SERBATOIO CARBURAN- DE CARBURANT ET KRAFTSTOFFTANK UND TE E CARENATURA CACHES LATERAUX ....4-1 SEITENABDECKUNGEN ...4-1 LATERALE ........4-1 TUYAU D’ECHAPPEMENT KRÜMMER UND TUBO DI SCARICO E ET SILENCIEUX ......4-2 SCHALLDÄMPFER ....4-2 SILENZIATORE ......4-2 RADIATEUR ........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 ........ 6-12 CHAPTER 7 TUNING ENGINE ............. 7-1 CHASSIS ..........7-12...
  • Page 25: Partie Electrique

    KAPITEL 6 CHAPITRE 6 CAPITOLO 6 ELEKTRISCHE PARTIE IMPIANTO ELECTRIQUE ANLAGE ELETTRICO ELEKTRISCHE BAUTEILE UND COMPOSANTS ELECTRIQUES COMPONENTI ELETTRICI E SCHALTPLAN ......6-1 ET SCHEMA DE CABLAGE ..6-1 SCHEMA DI CABLAGGIO ..6-1 BLOC CDI CONTROLE PAR KENNFELDGESTEUERTES UNITÀ CDI CONTROLLATA DA MICROPROCESSEUR ....6-2 CDI-ZÜNDSYSTEM ....6-2 MAPPA ..........6-2...
  • 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: Fahrzeugbeschreibung

    DESCRIPTION FAHRZEUGBESCHREIBUNG INFO DESCRIZIONE RENSEIGNEMENTS ALLGEMEINE 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 INFORMAZIONI IMPORTANTI INFO INFORMATIONS IMPOR- WICHTIGE INFORMATIO- INFORMAZIONI IMPOR- TANTES TANTI VORBEREITUNG FÜR AUSBAU PREPARATION POUR LA DEPOSE PREPARATIVI PER LA RIMO- UND ZERLEGUNG ET DEMONTAGE ZIONE E IL DISASSEMBLAGGIO Vor dem Ausbau oder Zerle- Eliminer soigneusement crasse, Rimuovere tutto lo sporco, il gen der Bauteile sämtlichen boue, poussière et corps étrangers...
  • Page 32 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled.
  • Page 33 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 INFORMAZIONI IMPORTANTI INFO CIRCLIPS SICHERUNGSRINGE ANELLI ELASTICI DI ARRESTO Avant remontage, tous les circlips Sicherungsringe vor dem Wie- Ispezionare attentamente tutti gli dereinbau sorgfältig überprü- doivent être soigneusement véri- anelli elastici di arresto prima di fen und bei Beschädigung fiés.
  • Page 36: Checking Of Connection

    CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.
  • Page 37: Verification Des Connexions

    VERIFICATION DES CONNEXIONS ANSCHLÜSSE PRÜFEN CONTROLLO DEI COLLEGAMENTI INFO VERIFICATION DES ANSCHLÜSSE PRÜFEN CONTROLLO DEI COL- Die Steckverbinder auf Oxidation, CONNEXIONS LEGAMENTI Rost, Feuchtigkeit usw. prüfen Traitement des taches, de la rouille, de Come gestire macchie, ruggine, umidità, Lösen: l’humidité, etc. sur le connecteur. ecc.
  • Page 38: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 39 SPECIAL TOOLS INFO Part number Tool name/How to use Illustration YU-33975, 90890-01403 Steering nut wrench YU-33975 90890-01403 This tool is used when tighten the steering ring nut to specification. YM-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

    SPEZIALWERKZEUGE INFO SPEZIALWERKZEUGE Die folgenden Spezialwerkzeuge sind für korrekte und vollständige Einstell- und Montagearbeiten unerläßlich. Durch die Verwendung dieser Werkzeuge können Beschädigungen vermieden werden, die beim Gebrauch ungeeigneter Hilfsmittel oder improvisierter Techniken entstehen können. Bei der Bestellung von Spezialwerkzeug sollten die im folgenden aufgeführten Bezeichnungen und Teilenummern angegeben werden.
  • Page 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 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 FUNZIONI DI COMANDO INFO FONCTIONS DES COM- ARMATUREN UND DE- FUNZIONI DI COMANDO REN FUNKTION MANDES INTERRUTTORE ARRESTO DEL MOTORE MOTORSTOPPSCHALTER COUPE-CIRCUIT DU MOTEUR L’interruttore di arresto del motore 1 è Der Motorstoppschalter 1 befindet Le coupe-circuit du moteur 1 est situé...
  • Page 52 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 FUNZIONI DI COMANDO INFO LEVIER DE DECOMPRESSION DEKOMPRESSIONSHEBEL 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 FUNZIONI DI COMANDO INFO ROBINET DE CARBURANT KRAFTSTOFFHAHN RUBINETTO DEL CARBURANTE Le robinet de carburant fournit le carbu- Der Kraftstoffhahn regelt die Kraft- Il rubinetto del carburante alimenta il rant du réservoir au carburateur et la fil- stoffzufuhr vom Tank zum Vergaser carburante dal serbatoio al carburatore tre.
  • Page 56 CONTROL FUNCTIONS 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 FONCTIONS DES COMMANDES ARMATUREN UND DEREN FUNKTION FUNZIONI DI COMANDO INFO CLAPET DE DURIT DE MISE A AUSLAUFSCHUTZVENTIL 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 FUEL INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher. For ZA: Premium gasoline CAUTION:...
  • Page 59: Essence

    ESSENCE KRAFTSTOFF CARBURANTE INFO ESSENCE KRAFTSTOFF CARBURANTE Ausschließlich empfohlenen Toujours utiliser l’essence recommandée Impiegare sempre il carburante consi- Kraftstoff verwenden. Für Rennen fri- décrite ci-dessous. D’autre part, s’assu- gliato come indicato qui di seguito. Inol- schen Kraftstoff verwenden. rer d’utiliser de l’essence fraîche le jour tre, accertarsi di utilizzare benzina nuova de la course.
  • Page 60: 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 61: Mise En Marche Et Rodage

    MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO MISE EN MARCHE ET ANLASSEN UND EINFAH- AVVIO E RODAGGIO RODAGE AVVERTENZA WARNUNG 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 62 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 63 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO Actionner à fond le levier de Dekompressionshebel Tirare la leva di decompressione décompression et actionner le anziehen und den Kickstarter- verso il manubrio e premere la kick à un angle de 10 à 20˚. hebel um 10–20˚...
  • Page 64 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 65 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO MISE MARCHE D’UN STARTEN MIT WARMEM MOTOR AVVIAMENTO DI UN MOTORE MOTEUR CHAUD Zum Anlassen des warmen Motors CALDO Ne pas activer le bouton de démarrage a weder den Kaltstarterknopf drücken Non agire sulla manopola di avviamento froid ni l’accélérateur.
  • Page 66: 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 67 MISE EN MARCHE ET RODAGE ANLASSEN UND EINFAHREN AVVIO E RODAGGIO INFO PROCEDURE DE RODAGE EINFAHRVORSCHRIFTEN PROCEDURE DI RODAGGIO Avant de mettre le moteur en Vor dem Anlassen des Motors Prima di avviare il motore, riem- marche, faire le plein d’essence. volltanken.
  • Page 68 TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to Steering stem to frame handlebar...
  • Page 69: 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 Du support de moteur au moteur Du support de moteur au cadre...
  • Page 70: 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 Motorbügel und Motor Motorbügel und Rahmen Lenkung Lenkkopf bis Lenkkopf und Teleskopgabel Lenkkopf und obere Gabelbrücke Lenker obere Gabelbrücke und Lenker Radaufhängung Vorn...
  • Page 71: Punti Per Il Controllo Del Serraggio

    PUNTI PER IL CONTROLLO DEL SERRAGGIO INFO PUNTI PER IL CONTROLLO DEL SERRAGGIO Struttura del telaio Telaio al telaio posteriore Sella e serbatoio del Serbatoio del carburante al telaio carburante combinati Sistema di scarico Marmitta di scarico al telaio posteriore Supporto motore Telaio al motore Dalla staffa motore al motore...
  • Page 72: 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 73: Nettoyage Et Rangement

    NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG PULIZIA ED IMMAGAZZINAGGIO INFO NETTOYAGE ET RANGE- REINIGUNG UND STILLE- PULIZIA ED IMMAGAZ- GUNG MENT ZINAGGIO REINIGUNG NETTOYAGE PULIZIA Eine regelmäßige, gründliche Un nettoyage fréquent de la machine Una pulizia frequente del veicolo ne Wäsche sorgt nicht nur für gutes améliorera son aspect, maintiendra ses migliora l’aspetto, aiuta a mantenere...
  • Page 74 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 75 NETTOYAGE ET RANGEMENT REINIGUNG UND STILLEGUNG PULIZIA ED IMMAGAZZINAGGIO INFO RANGEMENT STILLEGUNG IMMAGAZZINAGGIO Si l’on remise la machine pour 60 jours Vor einer mehr als zweimonatigen Se il veicolo va immagazzinato 60 giorni ou plus, il faut prendre des mesures de Stillegung sollten einige Schutzvor- o oltre, è...
  • Page 76: General Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR250FP (USA) WR250F (EUROPE) WR250F(P) (CDN, AUS, NZ, ZA) Model code number: 5PH5 (USA) 5PH6 (EUROPE) 5PH8 (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 77: 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 78 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) 130/90-18 69R (For EUROPE, AUS and NZ) Tire pressure (front and rear) 100 kPa (1.0 kgf/cm , 15 psi) Brake:...
  • Page 79: 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 80 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 81 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 82 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 83 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 84 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 85 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 × 1.25 (stud bolt) M9 ×...
  • Page 86 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Silencer M8 × 1.25 Silencer clamp M6 × 1.0 Spark arrester (for USA) M6 × 1.0 Silencer end pipe (for USA) M6 × 1.0 Crankcase M6 ×...
  • Page 87 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA 300 mm (11.8 in) ← ← Front fork travel 460 mm (18.1 in) ← ← Fork spring free length Spring rate, STD K = 4.31 N/mm K = 4.12 N/mm...
  • Page 88 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: USA, CDN, ZA EUROPE, AUS, NZ ← Front wheel type Spoke wheel ---- ← Rear wheel type Spoke wheel ---- 21 × 1.60/Aluminum ← Front rim size/material ---- 18 × 1.85/Aluminum 18 × 2.15/Aluminum ---- Rear rim size/material Rim runout limit: Radial...
  • Page 89 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Upper bracket and outer tube M8 × 1.25 Lower bracket and outer tube M24 × 1.0 Upper bracket and steering stem 14.5 M8 × 1.25 Handlebar holder and upper bracket M28 ×...
  • Page 90 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M6 × 1.0 Rear brake disc M8 × 1.25 Brake pedal M6 × 1.0 Rear brake master cylinder M6 × 1.0 Rear brake reservoir tank M4 × 0.7 Rear brake reservoir tank cap M10 ×...
  • Page 91 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Headlight stay (lower) and lower bracket M6 × 1.0 Headlight (left and right) M6 × 1.0 Headlight (lower) M6 × 1.0 Taillight M4 × 1.59 Taillight lead clamp and rear fender M6 ×...
  • Page 92 Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model (stator)/manufac- 5NG-50/YAMAHA ---- turer 640 ~ 960 Ω at 20 ˚C (68 ˚F) Charging coil 1 resistance (color) ---- (Green – Brown) 464 ~ 696 Ω at 20 ˚C (68 ˚F)
  • Page 93: 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 94: Caracteristiques Generales

    SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom de modèle: WR250FP (USA) WR250F (EUROPE) WR250F(P) (CDN, AUS, NZ, ZA) Numéro de code de modèle: 5PH5 (USA) 5PH6 (EUROPE) 5PH8 (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 95 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 96 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) 130/90-18 69R (EUROPE, AUS et NZ) Pression de pneu (avant et arrière) 100 kPa (1,0 kgf/cm , 15 psi)
  • Page 97 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 98 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 99 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 100 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 101 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 102 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 103 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M10S × 1,0 Bougie M6 × 1,0 Chapeau d’arbre à cames M12 × 1,0 Vis de plot borgne de culasse M6 × 1,0 Culasse (boulon prisonnier) M8 ×...
  • Page 104 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M8 × 1,25 Silencieux M8 × 1,25 Bride du silencieux M6 × 1,0 Pare-étincelles (pour les USA) M6 × 1,0 Chicane (pour les USA) M6 × 1,0 Carter M6 ×...
  • Page 105 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 106 SPEC CARACTERISTIQUES D’ENTRETIEN Article Standard Limite Roue: USA, CDN, ZA EUROPE, AUS, NZ ← Type de roue avant Roue à rayons ---- ← Type de roue arrière Roue à rayons ---- 21 × 1,60/aluminum ← Taille/matériau de jante avant ---- 18 ×...
  • Page 107 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M8 × 1,25 Té supérieur et fourreau M8 × 1,25 Té inférieur et fourreau M24 × 1,0 Té supérieur et colonne de direction 14,5 M8 × 1,25 Demi-palier de guidon et té...
  • Page 108 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M6 × 1,0 Disque de frein arrière M8 × 1,25 Pédale de frein M6 × 1,0 Maître-cylindre de frein arrière M6 × 1,0 Réservoir de liquide de frein arrière M4 ×...
  • Page 109 SPEC CARACTERISTIQUES D’ENTRETIEN Couple de serrage Taille de Pièce à serrer Qté filetage m·kg ft·lb M8 × 1,25 Support de phare (inférieur) et té inférieur M6 × 1,0 Phare (gauche et droite) M6 × 1,0 Phare (bas) M6 × 1,0 Feu arrière M4 ×...
  • Page 110 Limite Système d’allumage: Type de dispositif d’avance Electrique ---- CDI: Modèle/fabricant de la magnéto (stator) 5NG-50/YAMAHA ---- 640 à 960 Ω à 20 ˚C (68 ˚F) Résistance de bobine de charge 1 ---- (couleur) (vert – brun) 464 à 696 Ω à 20 ˚C (68 ˚F) Résistance de bobines de charge 2...
  • Page 111: 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 112: Technische Daten

    SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellname WR250F Modellcode 5PH6 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 113: 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 114 SPEC ALLGEMEINE TECHNISCHE DATEN Reifen Bauart Schlauchreifen Dimension vorn 90/90-21 54R hinten 130/90-18 69R 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 115: 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 116 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 117 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 118 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 × T) 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 119 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 37,0 mm 36,0 mm Anzahl ---- Kupplungsgehäuse Axialspiel 0,10–0,35 mm ---- Radialspiel 0,010–0,044 mm ---- Kupplungs-Ausrückmechanismus...
  • Page 120 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 121 SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg M10S × 1,0 Zündkerze M6 × 1,0 Zündkerzenstecker M12 × 1,0 Zylinderkopf-Blindstopfenschraube M6 × 1,0 Zylinderkopf (Stiftschraube) M8 × 1,25 (Stiftschraube) M9 × 1,25 (Schraube) M6 × 1,0 (Mutter) M6 × 1,0 Zylinderkopfdeckel M6 ×...
  • Page 122 SPEC WARTUNGSDATEN Anzugs- moment Bauteil Gewinde Anz. m·kg M8 × 1,25 Schalldämpfer M8 × 1,25 Schalldämpfer-Schlauchschelle M6 × 1,0 Funkenfänger (für USA) M6 × 1,0 Schalldämpferendröhre (für USA) M6 × 1,0 Kurbelgehäuse M6 × 1,0 Kurbelkasten-Lageranschlag M6 × 1,0 Kurbelkasten-Lageranschlag (Kurbelwell) M6 ×...
  • Page 123 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 124 SPEC WARTUNGSDATEN Bauteil Spezifikation Grenzwert Räder Bauart: Vorderrad Speichenrad ---- Hinterrad Speichenrad ---- Felgendimension/-material 21 × 1,60/Aluminium Vorderrad ---- 18 × 2,15/Aluminium Hinterrad ---- Max. Felgenschlag Höhenschlag ---- 2,0 mm Seitenschlag ---- 2,0 mm Antriebskette Typ (Hersteller) DID520VM/DAIDO ---- Anzahl der Kettenglieder 113 + Kettenschloß...
  • Page 125 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg M8 × 1,25 Oberbügel und Außenröhre M8 × 1,25 Unterbügel und Außenröhre M24 × 1,0 Oberbügel und Lenkschaft 14,5 M8 × 1,25 Lenkerhalter und Oberbügel M28 × 1,0 Lenkschaft und Lenkringmutter Siehe HINWEIS. M48 ×...
  • Page 126 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg M6 × 1,0 Hinterradbremsscheibe M8 × 1,25 Bremspedal M6 × 1,0 Hinterradbrems-Hauptzylinder M6 × 1,0 Hinterradbrems-Ausgleichsbehälter M4 × 0,7 Hinterradbrems-Ausgleichsbehälterdeckel M10 × 1,25 Hinterradbremsschlauch-Verbindungsschraube M20 × 1,5 Hinterradachse und Achsmutter 12,5 Nippel (Speiche) —...
  • Page 127 SPEC WARTUNGSDATEN Anzugsmoment Bauteil Gewinde Anz. m·kg M8 × 1,25 Scheinwerferstrebe (unten) und unterer Bügel M6 × 1,0 Scheinwerfer (links und rechts) M6 × 1,0 Scheinwerfer (unten) M6 × 1,0 Rückleuchte M4 × 1,59 Rückleuchtenleitungsklemme und hinteres Schutzblech M6 × 1,0 Kühlmittelreservoir (vorne) M6 ×...
  • Page 128 Bauteil Spezifikation Grenzwert Zündsystem Zündversteller elektrisch ---- CDI: Magnetzünder-Modell (stator)/Hersteller 5NG-50/YAMAHA ---- 640–960 Ω bei 20 ˚C Widerstand (Farbe) der Erregerspule 1 ---- (grün – braun) 464–696 Ω bei 20 ˚C Widerstand (Farbe) der Erregerspule 2 ---- (grün – rosa) 0,16–0,24 Ω...
  • Page 129: 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 130: Specifiche

    SPEC SPECIFICHE GENERALI SPECIFICHE SPECIFICHE GENERALI Nome del modello: WR250FP (USA) WR250F (EUROPA) WR250F(P) (CDN, AUS, NZ, ZA) Codice del modello: 5PH5 (USA) 5PH6 (EUROPA) 5PH8 (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 131 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 132 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) 130/90-18 69R (Per l’EUROPA, AUS e NZ) Pressione pneumatici (anteriore e posteriore) 100 kPa (1,0 kgf/cm , 15 psi)
  • Page 133: 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 134 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 135 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 136 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 137 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 138 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 139 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M10S × 1,0 Candela d’accensione M6 × 1,0 Cappello dell’albero a camme M12 × 1,0 Tappo a vite testata del cilindro M6 × 1,0 Testata del cilindro (prigioniero) M8 ×...
  • Page 140 SPEC SPECIFICHE DI MANUTENZIONE Coppia di serraggio Dimensioni Elemento da serrare Quantità della filettatura m·kg ft·lb M8 × 1,25 Marmitta di scarico M8 × 1,25 Morsetto marmitta di scarico M6 × 1,0 Parascintille (per USA) M6 × 1,0 Tubo finale silenziatore (per USA) M6 ×...
  • Page 141 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...
  • Page 142 SPEC SPECIFICHE DI MANUTENZIONE Elemento Standard Limite Ruota: USA, CDN, ZA EUROPE, AUS, NZ ← Tipo ruota anteriore Ruota a raggi ---- ← Tipo ruota posteriore Ruota a raggi ---- 21 × 1,60/alluminio ← Dimensioni/materiale cerchio anteriore ---- Dimensioni/materiale cerchio posteriore 18 × 1,85/alluminio 18 ×...
  • Page 143 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura M8 × 1,25 Staffa superiore e tubo esterno M8 × 1,25 Staffa inferiore e tubo esterno M24 × 1,0 Staffa superiore e cannotto dello sterzo 14,5 M8 ×...
  • Page 144 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura M6 × 1,0 Disco freno posteriore M8 × 1,25 Pedale del freno M6 × 1,0 Pompa freno posteriore M6 × 1,0 Serbatoio del freno posteriore M4 ×...
  • Page 145 SPEC SPECIFICHE DI MANUTENZIONE Dimensioni Coppia di serraggio Elemento da serrare della Quantità m·kg ft·lb filettatura M8 × 1,25 Supporto del faro (inferiore) e staffa inferiore M6 × 1,0 Faro (sinistro e destro) M6 × 1,0 Faro (inferiore) M6 × 1,0 Fanalino posteriore Fascetta stringicavo del fanalino posteriore e M4 ×...
  • Page 146 Impianto di accensione: Tipo di dispositivo di anticipo Elettrico ---- CDI.: Modello/costruttore magneto (statore) 5NG-50/YAMAHA ---- 640 ~ 960 Ω a 20 ˚C (68 ˚F) Resistenza bobina di carica 1 (colore) ---- (Verde – Marrone) 464 ~ 696 Ω a 20 ˚C (68 ˚F)
  • Page 147: Specifiche Relative Alle

    SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO SPEC GENERALI/DEFINIZIONE DELLE UNITÀ DI MISURA SPECIFICHE RELATIVE ALLE COPPIE DI SERRAGGIO GENERALI Questo grafico specifica le coppie di serraggio per dispositivi di fissaggio convenzionali con filetti a passo convenzionale I.S.O. I dati relativi alla coppia di serraggio per i componenti speciali sono inclusi nei relativi paragrafi di questo manuale.
  • Page 148: 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, light switch lead and igni- 2 Brake hose J Coolant reservoir breather hose tion coil lead of the sub-wire har- 3 Voltage regulator K Decompression cable ness.
  • Page 149: Cheminement Des Cables

    CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI CHEMINEMENT DES KABELFÜHRUNG 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 150 SPEC CABLE ROUTING DIAGRAM Á Ò Make sure that the throttle  Pass the clutch cable along the Pass the decompression cable position sensor lead coupler inner side of the cylinder head along the right side of the cylin- does not go outside the chas- breather hose.
  • Page 151 CHEMINEMENT DES CABLES KABELFÜHRUNG SPEC SCHEMA DEL PERCORSO DEI CAVI Ò S’assurer que le raccord du fil du capteur Ò Sicherstellen, daß der TPS-Leitungs- Ò Verificare che l’accoppiatore del cavo del de position de papillon des gaz ne sorte stecker nicht aus dem Chassis her- sensore di posizione della valvola a far- pas du châssis.
  • Page 152 SPEC CABLE ROUTING DIAGRAM Å Fasten the coolant reservoir breather hose and 1 Coolant reservoir breather hose 2 Radiator breather hose carburetor breather hoses together. ı Pass the throttle cables along inner side of the 3 Ignition coil 4 CDI unit spark plug lead.
  • Page 153 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 154 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 155 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 156 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 157 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 158 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 throttle cables between the upper bracket and trip meter. 3 Light switch lead Ç...
  • Page 159 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 160: 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 161 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 162 ● Replace bearings ● Lubricate Lithium base grease THROTTLE, CONTROL CABLE ● ● Check routing and connection Yamaha cable lube or ● ● Lubricate SAE 10W-30 motor oil ● ● Inspect and clean (throttle cable) Inspect dirt and wear on the throttle cable on the carburetor side.
  • Page 163 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 164 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 165 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 ●...
  • Page 166: 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 167: 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 168 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 169: 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 170 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 171 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. ● ●...
  • Page 172: 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 173 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 174 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 175: Controlli Preliminari Emanutenzione

    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 176 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 177: 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 178: 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 179 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- liquide de refroidissement sur les sur- sigkeit auf lackierte Flächen ge- gerante sulle superfici verniciate.
  • Page 180 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 181 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 182 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 183 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 184 INSP CLUTCH ADJUSTMENT NOTE: Do not apply pressure more than specified pressure. Radiator should be filled fully. 4. Inspect: Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. Radiator 1 Radiator hose joint 2 Coolant leakage → Repair or replace. Radiator hose 3 Swelling →...
  • Page 185 REGLAGE DE L’EMBRAYAGE INSP KUPPLUNG EINSTELLEN REGOLAZIONE FRIZIONE N.B.: HINWEIS: NOTA: Ne pas appliquer de pression supé- Den vorgeschriebenen Druck nicht Non applicare pressione superiore a rieure à la pression spécifiée. Überschreiten. quella specificata. Le radiateur doit être entièrement rem- Der Kühler muß...
  • Page 186 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 187 REGLAGE DES CABLES DES GAZ INSP GASZUGSPIEL EINSTELLEN REGOLAZIONE DEL CAVO DELL’ACCELERATORE REGLAGE DES CABLES DES GAZ GASZUGSPIEL EINSTELLEN REGOLAZIONE CAVO Vérifier: Kontrollieren: DELL’ACCELERATORE Jeu à la poignée des gaz a Gaszugspiel a Controllare: Hors spécification → Régler. Unvorschriftsmäßig → Ein- Gioco libero della manopola dell’acceleratore a stellen.
  • Page 188 THROTTLE LUBRICATION/ INSP DECOMPRESSION ADJUSTMENT THROTTLE LUBRICATION 1. Remove: Cover (throttle cable cap) 1 Cover (grip cap) 2 Throttle grip cap 3 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 ·...
  • Page 189 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 Abdeckung (Gaszugkappe) Déposer: Rimuovere: Cache (capuchon du logement Coperchio (cappuccio del cavo du câble des gaz) 1 Abdeckung (Griffkappe) 2 della valvola a farfalla) 1 Gasdrehgriffkappe 3...
  • Page 190 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 191 NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA Régler: Einstellen: 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 192 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 193 NETTOYAGE DU FILTRE A AIR INSP LUFTFILTER REINIGEN PULIZIA FILTRO DELL’ARIA Nettoyer: Reinigen: Pulire: Elément du filtre à air Luftfittereinsatz Elemento filtrante Le nettoyer avec du dissolvant. (in Lösungsmittel) Pulire con solvente. HINWEIS: N.B.: NOTA: Une fois l’entretien terminé, éliminer ce Den Luftfittereinsatz nach dem Reini- Dopo la pulizia rimuovere il solvente qui reste de solvant en serrant l’élément.
  • Page 194 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 195 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE 10. Monter: 10. Montieren: 10. Installare: Elément de filtre à air 1 Luftfittereinsatz 1 Elemento filtrante 1 Rondelle Scheibe Rondella Boulon de fixation Schraube Bullone di fissaggio 2 Nm (0,2 m ·...
  • Page 196 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 197 CONTROLE DU NIVEAU D’HUILE MOTEUR INSP MOTORÖLSTAND KONTROLLIEREN CONTROLLO DEL LIVELLO DELL’OLIO MOTORE (Pour les USA et le CDN) Nur USA und CDN: (Per USA e CDN) Huile recommandée: Empfohlene Ölsorte (Vis- Olio raccomandato: Min. 5 ˚C (40 ˚F) Å: kosität) A 5 ˚C (40 ˚F) o supe- Å...
  • Page 198 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 199 CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE CHANGEMENT DE L’HUILE DE MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTEUR Den Motor starten, mehrere MOTORE Mettre le moteur en marche, le Minuten warmlaufen lassen, Avviare il motore, riscaldarlo per faire chauffer pendant quelques und dann ausschalten und alcuni minuti e quindi spegnerlo minutes, puis le couper et atten-...
  • Page 200: 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 201 CHANGEMENT DE L’HUILE DE MOTEUR INSP MOTORÖL WECHSELN SOSTITUZIONE DELL’OLIO MOTORE S’il est nécessaire de remplacer le Soll auch der Ölfilter gewech- Se è necessario sostituire il filtro filtre à huile lors de cette vidange selt werden, müssen zusätz- dell’olio durante cambio d’huile, déposer les pièces sui-...
  • Page 202 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 203 CONTROLE DE LA PRESSION D’HUILE/REGLAGE DE LA VIS DE RICHESSE INSP ÖLDRUCKPRÜFUNG/LEERLAUFGEMISCH EINSTELLEN CONTROLLO PRESSIONE DELL’OLIO/ REGOLAZIONE DELLA VITE DI REGISTRO DEL MINIMO CONTROLE DE LA PRESSION ÖLDRUCKPRÜFUNG CONTROLLO PRESSIONE D’HUILE Kontrollieren: DELL’OLIO Contrôler: Öldruck Controllare: Pression d’huile Pressione dell’olio Arbeitsschritte Etapes du contrôle: Fasi di controllo:...
  • Page 204 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 205 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 206 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 207 CONTROLE ET REGLAGE DU JEU DE SOUPAPES INSP VENTILSPIEL KONTROLLIEREN UND EINSTELLEN CONTROLLO E REGOLAZIONE DEL GIOCO DELLE VALVOLE Déposer: Demontieren: Rimuovere: Radiateur de droite Rechter Kühler Radiatore destro reporter à section Siehe Abschnitt “KÜHLER” Fare riferimento al paragrafo “RADIATEUR” au CHAPI- in KAPITEL 4.
  • Page 208 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 209 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 210 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 211 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 212 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 213 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 214: 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 215 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 216 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 217 CONTROLLO E REGOLAZIONE DEL GIOCO DELLE INSP VALVOLE ASPIRAZIONE NUMERO SPESSORE INSTALLATO GIOCO MISURATO 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0,00 ~ 0,04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0,05 ~ 0,09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
  • Page 218 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 219 NETTOYAGE DU PARE-ETINCELLES (pour les USA)/ INSP FUNKENFÄNGER REINIGEN (NUR USA) PULIZIA DEL PARASCINTILLE (Per USA) NETTOYAGE DU PARE-ETINCEL- FUNKENFÄNGER REINIGEN (NUR 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 220 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 221: Partie Cycle

    INSP PARTIE CYCLE/PURGE DE L’AIR DU SYSTEME DE FREINAGE FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTLÜFTEN PARTE CICLISTICA/SPURGO DELL’ARIA DAL SISTEMA FRENANTE FAHRWERK PARTIE CYCLE PARTE CICLISTICA HYDRAULISCHE BREMSANLAGE PURGE DE L’AIR DU SYSTEME SPURGO DELL’ARIA DAL ENTLÜFTEN DE FREINAGE SISTEMA FRENANTE WARNUNG AVVERTENZA AVERTISSEMENT Die Anlage muß...
  • Page 222: 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 223 REGLAGE DE FREIN AVANT INSP VORDERRADBREMSE EINSTELLEN REGOLAZIONE DEL FRENO ANTERIORE N.B.: HINWEIS: NOTA: Si la purge est difficile, il peut être Kann die Anlage nicht zufrieden- Se lo spurgo risulta difficoltoso, nécessaire de laisser le système du stellend entlüftet werden, sollte die potrebbe essere necessario lasciar liquide de freinage se stabiliser pen- Bremsflüssigkeit einige Stunden...
  • Page 224: 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 225 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 226 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 227 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 228 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT Install the pad pin plug B. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake lever operation A softy or spongy feeling →...
  • Page 229 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 230 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 231 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 232 REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: Brake fluid level Refer “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer “BRAKE SYSTEM BLEEDING” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECTION...
  • Page 233 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 234 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 drive chain cutter 2.
  • Page 235 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: Usure excessive → Remplacer. Kettenradzähne a Denti della corona a Übermäßiger Verschleiß...
  • Page 236 INSP DRIVE CHAIN INSPECTION 5. Check: Drive chain stiffness a Clean and oil the drive chain and hold as illustrated. Stiff → Replace the drive chain. 6. 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.
  • Page 237 CONTROLE DE LA CHAINE DE TRANSMISSION INSP ANTRIEBSKETTE KONTROLLIEREN ISPEZIONE DELLA CATENA DI TRASMISSIONE Contrôler: Kontrollieren: Controllare: Raideur de la chaîne de trans- Antriebskette (Beweglich- Rigidità della catena di tra- mission a keit) a smissione a Nettoyer et huiler la chaîne de Kette reinigen, schmieren Pulire e lubrificare la catena di transmission et la tenir comme...
  • Page 238 INSP DRIVE CHAIN SLACK ADJUSTMENT EC36A060 DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) NOTE:...
  • Page 239 INSP REGLAGE DE LA FLECHE DE CHAINE DE TRANSMISSION ANTRIEBSKETTEN-DURCHHANG EINSTELLEN REGOLAZIONE DELLA TENSIONE DELLA CATENA DI TRASMISSIONE REGLAGE DE LA FLECHE DE ANTRIEBSKETTEN-DURCHHANG REGOLAZIONE DELLA TEN- EINSTELLEN SIONE DELLA CATENA DI TRA- CHAINE DE TRANSMISSION Das Motorrad am Motor auf- SMISSIONE Surélever la roue arrière en pla- bocken, um das Hinterrad vom...
  • Page 240 FRONT FORK INSPECTION/ INSP FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ FRONT FORK INTERNAL PRESSURE RELIEVING EC36C000 FRONT FORK INSPECTION 1. Inspect: Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace.
  • Page 241 CONTROLE DE LA FOURCHE AVANT/NETTOYAGE DE BAGUE D’ETANCHEITE ET DE JOINT ANTIPOUSSIERE DE FOURCHE AVANT/PURGE DE L’AIR DE LA FOURCHE AVANT TELESKOPGABEL KONTROLLIEREN/ GABELDICHTRING UND STAUBMANSCHETTE REINIGEN/TELESKOPKABEL- INNENDRUCKVERRINGERUNG INSP ISPEZIONE FORCELLA ANTERIORE/ PULIZIA DEL PARAOLIO E DEL PARAPOLVERE DELLE FORCELLE ANTERIORI/ALLEGGERIMENTO DELLA PRESSIONE INTERNA DELLA FORCELLA ANTERIORE CONTROLE DE LA FOURCHE TELESKOPGABEL KONTROLLIE-...
  • Page 242 FRONT FORK REBOUND DAMPING FORCE INSP ADJUSTMENT EC36H002 FRONT FORK 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 243 REGLAGE DE LA FORCE D’AMORTISSEMENT INSP DE DETENTE DE LA FOURCHE AVANT TELESKOPGABEL-ZUGSTUFENDÄMPFUNG EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO REGLAGE DE LA FORCE D’AMOR- TELESKOPGABEL-ZUGSTUFEN- REGOLAZIONE DELLA FORZA DI TISSEMENT DE DETENTE DE LA DÄMPFUNG EINSTELLEN SMORZAMENTO DI ESPANSIONE FOURCHE AVANT Einstellen: DELLA FORCELLA ANTERIORE Régler:...
  • Page 244 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1. Remove: Rubber cap 2. Adjust: Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b →...
  • Page 245 REGLAGE DE LA FORCE D’AMORTISSEMENT INSP DE COMPRESSION DE LA FOURCHE AVANT TELESKOPGABEL-DRUCKSTUFEN-DÄMPFUNG EINSTELLEN REGOLAZIONE DELLA FORZA DI SMORZAMENTO REGLAGE FORCE TELESKOPGABEL-DRUCKSTU- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT COM- FEN-DÄMPFUNG EINSTELLEN SMORZAMENTO DI COMPRES- PRESSION FOURCHE Demontieren: SIONE DELLA FORCELLA ANTE- AVANT Gummikappe RIORE...
  • Page 246 REAR SHOCK ABSORBER INSPECTION/REAR SHOCK INSP ABSORBER SPRING PRELOAD ADJUSTMENT EC36K000 REAR SHOCK ABSORBER INSPECTION 1. Inspect: Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace. EC36M013 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1.
  • Page 247 CONTROLE DE L’AMORTISSEUR ARRIERE/REGLAGE DE LA PRECONTRAINTE DE RESSORT DE L’AMORTISSEUR ARRIERE INSP FEDERBEIN KONTROLLIEREN/FEDERBEIN-FEDERVORSPANNUNG EINSTELLEN ISPEZIONE DELL’AMMORTIZZATORE POSTERIORE/REGOLAZIONE DEL PRECARICO DELLA MOLLA DELL’AMMORTIZZATORE POSTERIORE CONTROLE DE L’AMORTISSEUR FEDERBEIN KONTROLLIEREN ISPEZIONE DELL’AMMORTIZZA- ARRIERE Kontrollieren: TORE POSTERIORE Contrôler: Schwinge (Beweglichkeit) Ispezionare: Action régulière bras...
  • Page 248: Rear Shock Absorber Rebound Damping Force Adjustment

    REAR SHOCK ABSORBER REBOUND INSP DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b →...
  • Page 249 REGLAGE DE LA FORCE D’AMORTISSEMENT DE DETENTE DE L’AMORTISSEUR ARRIERE FEDERBEIN-ZUGSTUFENDÄMPFUNG EINSTELLEN INSP REGOLAZIONE DELLA FORZA DI SMORZAMENTO DI ESPANSIONE DELL’AMMORTIZZATORE POSTERIORE REGLAGE FORCE FEDERBEIN-ZUGSTUFENDÄMP- REGOLAZIONE DELLA FORZA DI D’AMORTISSEMENT DE DETENTE FUNG EINSTELLEN SMORZAMENTO DI ESPANSIONE DE L’AMORTISSEUR ARRIERE Einstellen: DELL’AMMORTIZZATORE Régler:...
  • Page 250 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b →...
  • Page 251 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 D’AMORTISSEMENT BASSE DRUCKSTUFENDÄMPFUNG SMORZAMENTO DI BASSA COM- COMPRESSION DE L’AMORTIS- Einstellen: PRESSIONE...
  • Page 252 REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b →...
  • Page 253 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 254 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
  • Page 255 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 256 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 stem Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth.
  • Page 257 CONTROLE ET REGLAGE DE LA TETE DE FOURCHE INSP LENKKOPF KONTROLLIEREN UND EINSTELLEN ISPEZIONE E REGOLAZIONE DELLA TESTA DI STERZO Vérifier: Kontrollieren: Ispezionare: Jeu de roulement Lagerspiel Gioco del cuscinetto Il y a du jeu → Remplacer. Spiel → Erneuern. Esiste gioco →...
  • Page 258 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 259 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 260 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 261 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 ou équivalent sur ces parties. ı Motoröl oder Spezial-Kettenspray ver- lubrificanti per catena idonei.
  • Page 262: Electrical

    INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: Spark plug 2. Inspect: Electrode 1 Wear/damage → Replace. Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become...
  • Page 263: Parte Elettrica

    PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN PARTE ELETTRICA/ISPEZIONE DELLA CANDELA PARTIE ELECTRIQUE ELEKTRISCHE ANLAGE PARTE ELETTRICA ZÜNDKERZE KONTROLLIEREN CONTROLE DE LA BOUGIE ISPEZIONE DELLA CANDELA Demontieren: Déposer: Rimuovere: Zündkerze Bougie Candela d’accensione Kontrollieren: Contrôler: Ispezionare: Elektrode 1 Electrode 1 Elettrodo 1 Verschleiß/Beschädigung →...
  • Page 264 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-8036-B Engine tachometer: 90890-03113 3. Check: Ignition timing Checking steps: Start the engine and let it warm up.
  • Page 265 CONTROLE DE L’AVANCE A L’ALLUMAGE INSP ZÜNDZEITPUNKT KONTROLLIEREN CONTROLLO DELLA FASATURA DI ACCENSIONE CONTROLE DE L’AVANCE A ZÜNDZEITPUNKT KONTROLLIE- CONTROLLO DELLA FASATURA L’ALLUMAGE DI ACCENSIONE Déposer: Demontieren: Rimuovere: Vis d’accès du repère de distri- Steuermarkierung-Zugangs- Vite di accesso al riferimento bution 1 schraube 1 per fasatura 1...
  • Page 266 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 267 REMPLACER LES AMPOULES DU PHARE INSP SCHEINWERFERLAMPE AUSWECHSELN SOSTITUZIONE DELLE LAMPADE DEL FARO REMPLACER LES AMPOULES DU SCHEINWERFERLAMPE AUS- SOSTITUZIONE DELLE LAM- PHARE WECHSELN PADE DEL FARO Déposer: Demontieren: Rimuovere: Phare Scheinwerfer Faro Se référer à la section “SELLE, Siehe Abschnitt “SITZ- Fare riferimento al paragrafo RESERVOIR A ESSENCE ET BANK, KRAFTSTOFF-...
  • Page 268: 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 269 REGLAGES DES FAISCEAUX DES PHARES INSP SCHEINWERFER EINSTELLEN REGOLAZIONE DEI FASCI DI LUCE DEL FARO REGLAGES DES FAISCEAUX DES SCHEINWERFER EINSTELLEN REGOLAZIONE DEI FASCI DI PHARES Einstellen: LUCE DEL FARO Régler: Scheinwerferstellung (ver- Regolare: Le faisceau du phare (vertical) tikal) Fascio di luce del faro (in senso verticale) Arbeitsschritte:...
  • Page 270: 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 271 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 272: 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 273: 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 274 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 275 TUYAU D’ECHAPPEMENT ET SILENCIEUX KRÜMMER UND SCHALLDÄMPFER TUBO DI SCARICO E SILENZIATORE CONTROLE PRÜFUNG ISPEZIONE Silencieux et tuyau d’échappement Schalldämpfer und krümmer Silenziatore e tubo di scarico Contrôler: Kontrollieren: Ispezionare: Joint 1 Dichtung 1 Guarnizione 1 Endommagement → Rempla- Beschädigung → Erneuern. Danni →...
  • Page 276: 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 277 RADIATEUR KÜHLER RADIATORE RADIATEUR Organisation de la dépose: 1 Dépose du radiateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU RADIATEUR Préparation à la dépose Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT”...
  • Page 278 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 279 RADIATEUR KÜHLER RADIATORE REMARQUES CONCERNANT LA HANDHABUNGSHINWEIS NOTA PER LA MANIPOLAZIONE MANIPULATION AVVERTENZA WARNUNG 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 280 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 281 RADIATEUR KÜHLER RADIATORE Monter: Montieren: Installare: Radiateur de droite 1 Rechter Kühler 1 Radiatore destro 1 Boulon (radiateur droite) 2 Schraube (rechter Kühler) Bullone (radiatore destro) 2 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m · kg) 10 Nm (1,0 m ·...
  • Page 282: 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 283 CARBURATEUR VERGASER CARBURATORE CARBURATEUR Organisation de la dépose: 1 Dépose du carburateur Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE DU CARBURATEUR Préparation à la dépose Selle et réservoir de carburant Se reporter à la section “SELLE, RESERVOIR A ESSENCE ET CACHES LATERAUX”.
  • Page 284 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 285 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 286 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 287 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 288 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 289 CARBURATEUR VERGASER CARBURATORE REMARQUE CONCERNANT LES HINWEIS ZUM HANDLING 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 290 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 291 CARBURATEUR VERGASER CARBURATORE Contrôler: Kontrollieren: Ispezionare: Gicleur principal 1 Hauptdüse 1 Getto del massimo 1 Gicleur de ralenti 2 Leerlaufdüse 2 Getto del minimo 2 Puits d’aiguille 3 Nadeldüse 3 Getto a spillo 3 Gicleur de starter 4 Choke-Düse 4 Getto di avviamento 4 Gicleur d’air principal 5 Hauptluftdüse 5...
  • Page 292 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 293 CARBURATEUR VERGASER CARBURATORE Hauteur du flotteur Schwimmerhöhe Altezza galleggiante Mesurer: Messen: Misurare: Hauteur du flotteur a Schwimmerhöhe a Altezza galleggiante a Hors spécification → Régler. Unvorschriftsmäßig → Ein- Fuori specifica → Regolare. stellen. Hauteur du flotteur: Altezza galleggiante: 8,0 mm (0,31 in) 8,0 mm (0,31 in) Schwimmerhöhe 8,0 mm...
  • Page 294 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.
  • Page 295 CARBURATEUR VERGASER CARBURATORE Plongeur de starter Choke-Schieber Stantuffo dell’avviamento Contrôler: Kontrollieren: Ispezionare: Plongeur de démarrage à froid Kaltstarter-Tauchkolben 1 Stantuffo dell’avviamento a Heißstarter-Tauchkolben freddo 1 Plongeur de démarrage à chaud (rot) 2 Stantuffo dell’avviamento a Verschleiß/Beschädigung → (rouge) 2 caldo (rosso) 2 Usure/endommagement →...
  • Page 296 CARBURETOR 2. Install: Main air jet 1 Pilot air jet 2 O-ring 3 Intake joint 4 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 297 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: 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 Joint torique 3 O-Ring 3 O-ring 3 Raccord d’admission 4 Ansaugstutzen 4 Giunto ammissione 4 5 Nm (0,5 m ·...
  • Page 298 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 299 CARBURATEUR VERGASER CARBURATORE Installer: Montieren: 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. N.B.: HINWEIS: 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 300 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 301 CARBURATEUR VERGASER CARBURATORE 10. Monter: 10. Montieren: 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 302 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 303 CARBURATEUR VERGASER CARBURATORE 14. Monter: 14. Montieren: 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 304 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. Accelerator pump timing adjustmet Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc.
  • Page 305 CARBURATEUR VERGASER CARBURATORE 19. Monter: 19. Montieren: 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.: Installer la durit de mise à l’air sur le car- Die Vergaserlüfterschläuche am Ver- carburatore stesso in modo tale che i burateur de sorte qu’il ne se plie pas à...
  • Page 306 CARBURETOR 3. Install: Carburetor 1 NOTE: Install the projection between the carburetor joint slots. 4. Tighten: Screw (air filter joint) 1 3 Nm (0.3 m · kg, 2.2 ft · lb) Screw (carburetor joint) 2 3 Nm (0.3 m · kg, 2.2 ft · lb) 5.
  • Page 307 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: Installare: Carburateur 1 Vergaser 1 Carburatore 1 N.B.: HINWEIS: NOTA: Monter l’extrémité du support de câble Die Nase muß sich zwischen den Installare la sporgenza tra le fessure del des gaz entre les fentes du raccord de Vergaseranschlußschlitzen befinden.
  • Page 308 CARBURETOR 9. Install: Throttle position sensor lead coupler 1 Clamp 2 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 10. Install: Clamp 1 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 4 - 20...
  • Page 309 CARBURATEUR VERGASER CARBURATORE Monter: Montieren: Installare: Fiche rapide de fil de capteur Gaspositionssensor-Leitungs- Accoppiatore cavo del sensore de position de papillon des gaz koppler 1 di posizione dell’acceleratore Schlauchschelle 2 Bride 2 Morsetto 2 Siehe unter “KABEL- Se reporter à la section “CHE- FÜHRUNG”...
  • Page 310: 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 311: 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 312 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 313 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 314 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 315: Alberi A Camme

    ARBRES A CAMES NOCKENWELLE ALBERI A CAMME POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Arbre à cames Nockenwelle Albero a camme Déposer: Demontieren: Rimuovere: Bouchon de distribution 1 Schwungrad-Abdeckschrau- Vite di accesso al riferimento Bouchon droit 2 be 1 per fasatura 1 Aligner: Rotorzapfen-Abdeckschrau- Vite...
  • Page 316 CAMSHAFTS 5. Remove: Exhaust camshaft 1 Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft 1. Inspect: Cam lobe Pitting/scratches/blue discoloration → Replace. 2. Measure: Cam lobe length a and b Out of specification →...
  • Page 317 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Déposer: Demontieren: Rimuovere: Arbre à cames d’échappement Auslaß-Nockenwelle 1 Albero a camme di scarico 1 Einlaß-Nockenwelle 2 Albero a camme di aspirazione Arbre à cames d’admission 2 HINWEIS: Die Steuerkette mit einem Draht 3 N.B.: NOTA: Attacher un fil 3 à...
  • Page 318 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 319 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Mesurer: Messen: Misurare: Jeu entre arbre à cames et cha- Nockenwellen-Lagerspiel Gioco albero a camme-cap- Unvorschriftsmäßig → Nok- peau pello Hors spécifications → Mesu- Fuori specifica → Misurare il kenwellenlagerzapfen- rer le diamètre du coussinet Durchmesser messen.
  • Page 320 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 321 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Tendeur de la chaîne de distribution Steuerkettenspanner Tenditore catena di distribuzione Contrôler: Kontrollieren: Controllare: Tout en comprimant légère- Steuerkettenspanner- Premendo leggermente l’asta ment la tige du tendeur à l’aide kopf leicht mit dem Finger del tenditore con le dita, utiliz- du doigt, la visser complète- eindrücken und den Span-...
  • Page 322 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 323 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 324 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 - 28...
  • Page 325 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 326 CAMSHAFTS 7. Install: Oil tank breather hose Cylinder head breather hose Spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) 4 - 29...
  • Page 327 ARBRES A CAMES NOCKENWELLE ALBERI A CAMME Monter: Montieren: Installare: Durit de mise à l’air de réser- Öltank-Belüftungsschlauch Sfiatatoio serbatoio dell’olio voir d’huile Zylinderkopf-Entlüftungs- Sfiatatoio testata del cilindro Durit de mise à l’air de culasse schlauch Candela d’accensione Bougie Zündkerze 13 Nm (1,3 m ·...
  • Page 328: 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 329: 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 330 CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid dam- aging or scratching: Spark plug threads Valve seats 2. Inspect: Cylinder head Scratches/damage → Replace. 3.
  • Page 331 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO CONTROLE PRÜFUNG ISPEZIONE Culasse Zylinderkopf Testata del cilindro Eliminer: Entfernen: Eliminare: Dépôt de calamine Ölkohleablagerungen (im Depositi carboniosi (dalle (de la chambre de combustion) Brennraum) camere di combustione) Utiliser un grattoir arrondi. Einen abgerundeten Scha- Utilizzare un raschietto arro- ber verwenden.
  • Page 332 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 333 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Culasse Zylinderkopf ZIONE Monter: Montieren: 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 334 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 335 CULASSE ZYLINDERKOPF TESTATA DEL CILINDRO Monter: Montieren: Installare: Rondelle 1 Unterlegscheibe 1 Rondella 1 Guide de câble 2 Seilzugführng 2 Guida cavo 2 Boulons Schrauben [L = 145 mm] 3 Bulloni [L = 145 mm (5,71 in)] [L = 145 mm (5,71 in)] 3 38 Nm (3,8 m ·...
  • Page 336: 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 337: 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 338 VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: Valve lifter 1 Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: Valve sealing Leakage at the valve seat →...
  • Page 339 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Poussoir de soupape et clavette de sou- Tassenstößel und Ventikeile Alzavalvola e semiconi pape Demontieren: Rimuovere: Déposer: Tassenstößel 1 Alzavalvola 1 Poussoir de soupape 1 Ventilplättchen 2 Spessore 2...
  • Page 340 VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in) Exhaust:...
  • Page 341 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE CONTROLE PRÜFUNG ISPEZIONE Soupape Ventil Valvola Mesurer: Messen: Misurare: Jeu de queue dans le guide Ventilschaftspiel Gioco stelo-guida Ventilschaftspiel = Gioco stelo-guida = Jeu de queue dans le guide de sou- Ventilführungsdurchmesser diametro interno del guidaval- pape =...
  • Page 342 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 343 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 344 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 345 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Mesurer: Messen: Misurare: Ovalisation (queue de soupape) Ventilschaftschlag Disassamento (stelo valvola): Hors spécifications → Rempla- Unvorschriftsmäßig → Fuori specifica → Sostituire. cer. Erneuern. Limite di disassamento: 0,01 mm (0,0004 in) Limite de déformation: Max.
  • Page 346 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 347 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Roder: Einschleifen: Lappare: Ventilteller Face de soupape Faccia della valvola Ventilsitz Siège de soupape Sede della valvola HINWEIS: N.B.: NOTA: Nach Bearbeitung des Ventilsitzes Après le surfaçage du siège de soupape Dopo aver rettificato la sede della val- oder Erneuerung von Ventil und Ven- ou le remplacement de la soupape et du...
  • Page 348 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 349 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Ressort de soupape Ventilfeder Molla valvola Mesurer: Messen: Misurare: Longueur libre du ressort de Ventilfederlänge (ent- Lunghezza libera della molla soupape a spannt) a della valvola a Hors spécifications → Rempla- Unvorschriftsmäßig →...
  • Page 350 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 351 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Combinaisons de culasse et de pous- Kombination von Zylinderkopf Combinazione di testata del cilindro e soir de soupape und Ventilheber alzavalvola Combinaison: Kombination: Combinazione: Combiner la culasse et le pous- Für diese Kombination die Per questa combinazione, far cor- soir de soupape en combinant la...
  • Page 352 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-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
  • Page 353 SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN VALVOLE E MOLLE VALVOLE Monter: Montieren: Installare: Clavette de soupape Ventilkeile Semiconi N.B.: HINWEIS: NOTA: Installer les clavettes de soupape tout en Die Ventilfeder mit Ventilfederspan- Comprimendo la molla della valvola con comprimant le ressort de soupape avec ner 1 und Halterung zusammen- un apposito compressore 1 installare i...
  • Page 354: 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 355: 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 356 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 357 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Piston et segment de piston Kolben und Kolbenring Pistone e fascia elastica Déposer: Demontieren: Rimuovere: Agrafe d’axe de piston 1 Kolbenbolzen-Sicherungs- Morsetto spinotto 1 Axe de piston 2 ringe 1 Spinotto 2...
  • Page 358 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 359 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE 77,00 à Zylinderboh- 77,00– 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 360 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 361 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Segment de piston Kolbenring Fascia elastica Mesurer: Messen: Misurare: Jeu latéral du segment Ringnutspiel Gioco laterale della fascia Utiliser une jauge d’épaisseur Fühlerlehre 1 verwenden. Utilizzare uno spessimetro 1. Unvorschriftsmäßig → Kol- Se fuori specifica →...
  • Page 362 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 363 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Axe de piston Kolbenbolzen Spinotto Contrôler: Kontrollieren: Ispezionare: Axe de piston Kolbenbolzen Spinotto Décoloration bleue/gorges → Blaufärbung/Riefen → Sbiadimento blu/scanalature → Remplacer puis examiner le Erneuern und Schmiersy- Sostituire quindi ispezionare il système de graissage.
  • Page 364 CYLINDER AND PISTON 2. Position: Top ring 2nd ring Oil ring 45° Offset the piston ring end gaps as 135° 135° shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
  • Page 365 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Positionner: Montieren: 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 366 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 367 CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE Monter: Montieren: Installare: Joint de cylindre 1 Dichtung 1 Guarnizione cilindro 1 Cylindre 2 Zylinder 2 Cilindro 2 HINWEIS: N.B.: NOTA: Installer le cylindre d’une main tout en Den Zylinder mit einer Hand einbau- Installare il cilindro con una mano com- comprimant les segments de l’autre en, mit der anderen die Kolbenringe...
  • Page 368: 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 369 EMBRAYAGE KUPPLUNG FRIZIONE EMBRAYAGE Organisation de la dépose: 1 Dépose des tiges de commande 1 er 2 et du levier de poussée 2 Démontage de la tige de commande 1 3 Dépose du disque de friction et du disque d’embrayage 4 Dépose du pignon mené...
  • Page 370 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 - 51...
  • Page 371 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 372 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 373 EMBRAYAGE KUPPLUNG FRIZIONE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Noix d’embrayage Kupplungsnabe Mozzo frizione Déposer: Demontieren: Rimuovere: Ecrou 1 Mutter 1 Dado 1 Rondelle-frein 2 Sicherungsscheibe 2 Rondella di bloccaggio 2 Noix d’embrayage 3 Kupplungsnabe 3 Mozzo frizione 3 N.B.: HINWEIS: NOTA:...
  • Page 374 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 375 EMBRAYAGE KUPPLUNG FRIZIONE Disque de friction Reibscheiben Disco conduttore Mesurer: Messen: Misurare: Epaisseur de disque de friction Reibscheibenstärke Spessore del disco conduttore Hors-spécification → Changer Unvorschriftsmäßig → Die Fuori specifica → Sostituire in tous les disques de friction. Reibscheiben Satz blocco il disco conduttore.
  • Page 376 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 377 EMBRAYAGE KUPPLUNG FRIZIONE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO ED INSTALLA- Levier de poussée Druckhebel ZIONE Monter: Montieren: Alberino della leva spingente Arbre de levier de poussée 1 Druckhebelwelle 1 Installare: Boulon (arbre de levier de Schraube (Druckhebelwel- Alberino della leva spingente poussée) 2 le) 2 10 Nm (1,0 m ·...
  • Page 378 CLUTCH 3. Bend the lock washer 1 tab. 4. Install: Seat plate 1 Cushion spring 2 NOTE: Install the seat plate with its chamfered por- tion a facing the clutch boss 3. Install the seat plate so that it is not caught on the step b.
  • Page 379 EMBRAYAGE KUPPLUNG FRIZIONE Courber la languette de la ron- Die Lasche der Sicherungs- 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 N.B.:...
  • Page 380 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 381 EMBRAYAGE KUPPLUNG FRIZIONE Monter: Montieren: Installare: Tige de poussée 2 1 Druckstange 2 1 Asta di punteria 2 1 Bille 2 Kugel 2 Sfera 2 Tige de poussée 1 3 Druckstange 1 3 Asta di punteria 1 3 N.B.: HINWEIS: NOTA: Appliquer de la graisse de savon au Lithiumfett auf Druckstangen 1 und 2...
  • Page 382: 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 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 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 384 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal Order Part name Q’ty Remarks Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Refer to “REMOVAL POINTS”. Oil seal Bearing 4 - 58...
  • Page 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 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 386 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 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 POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Arbre de rotor Flügelradwelle Albero girante Déposer: Demontieren: Rimuovere: Arbre de rotor 1 Flügelradwelle 1...
  • Page 388 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: Gear teeth a Wear/damage → Replace. EC4H4600 Bearing 1. Inspect: Bearing Rotate inner race with a finger.
  • Page 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 Arbre de rotor Flügelradwelle Albero girante Contrôler: Kontrollieren: Ispezionare: Arbre de rotor 1 Flügelradwelle 1 Albero girante 1 Deformazione/usura/danno →...
  • Page 390 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 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 Monter: Montieren: Installare: Roulement 1 Lager 1 Cuscinetto 1 N.B.: HINWEIS: NOTA: Monter le roulement en appuyant paral- Zur Lager-Montage den äußeren Installare il cuscinetto premendo paralle- lèlement sur la cage extérieure.
  • Page 392 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 393 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Monter: Montieren: Installare: Demi-carter droit 1 Rechten Kurbelgehäuse- Coperchio carter destro 1 Boulon (demi-carter droit) 2 deckel 1 Bullone (coperchio...
  • Page 394 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 395 ELEMENT DE FILTRE A HUILE, POMPE A EAU ET DEMI-CARTER DROIT ÖLFILTEREINSATZ, WASSERPUMPE UND RECHTE KURBELWELLENABDECKUNG ELEMENTO FILTRANTE DELL’OLIO, POMPA DELL’ACQUA E COPERCHIO CARTER DESTRO Logement de la pompe à eau Wasserpumpengehäuse Alloggiamento della pompa dell’acqua Monter: Montieren: Installare: Goupille 1 Stift 1 Perno di centraggio 1 Joint torique 2...
  • Page 396: 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 397 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 398 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 399 BALANCIER AUSGLEICHSWELLE BILANCIERE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Pignon menant et pignon mené du Ausgleichswellen-Antriebs- und - Ingranaggio conduttore dell’albero di balancier Abtriebsräder equilibratura e ingranaggio condotto Redresser l’ongle de rondelle Die Lasche der Sicherungs- dell’albero di equilibratura d’arrêt.
  • Page 400 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 401 BALANCIER AUSGLEICHSWELLE BILANCIERE ASSEMBLAGE ET INSTALLA- ZUSAMMENBAU UND MONTAGE MONTAGGIO ED INSTALLAZIONE TION Ausgleichswelle, An- und Albero di equilibratura, ingranaggio Balancier, pignon menant de balan- Abtriebsrad conduttore dell’albero di equilibra- cier et pignon mené de balancier Montieren: tura e ingranaggio condotto Monter: Ausgleichswelle 1 dell’albero di equilibratura...
  • Page 402: 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 403: Pompe A Huile

    POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO POMPE A HUILE Organisation de la dépose: 1 Dépose de la pompe à huile 2 Démontage de la pompe à huile Organisation de la dépose Ordre Nom de pièce Qté Remarques DEPOSE ET DEMONTAGE DE LA POMPE A HUILE Préparation à...
  • Page 404 OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 4 - 68...
  • Page 405 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 406 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 407 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO CONTROLE PRÜFUNG ISPEZIONE Pompe à huile Ölpumpe Pompa dell’olio Contrôler: Kontrollieren: Ispezionare: Pignon menant de pompe à Ölpumpen-Antriebsrad 1 Ingranaggio conduttore della huile 1 Ölpumpen-Antriebswelle 2 pompa dell’olio 1 Arbre menant de pompe à huile Rotorgehäuse 3 Albero comando...
  • Page 408 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 409 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO ASSEMBLAGE ET INSTALLA- ZUSAMMENBAU UND MONTAGE MONTAGGIO ED INSTALLA- TION Ölpumpe ZIONE Pompe à huile Montieren: Pompa dell’olio Installer: Ölpumpen-Antriebswelle 1 Installare: Arbre de transmission de la Beilagscheibe 2 Albero comando della pompe à huile 1 Paßstift 3 pompa olio 1 Rondelle 2...
  • Page 410 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 411 POMPE A HUILE ÖLPUMPE POMPA DELL’OLIO Monteur: Montieren: Installare: Rotor extérieur 2 1 Außenrotor 2 1 Rotore esterno 2 1 Goupille de serrage 2 Paßstift 2 Perno di centraggio 2 Essemble pompe à huile 3 Ölpumpe 3 Gruppo pompa dell’olio 3 Boulon (essemble pompe à...
  • Page 412: 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 413: Arbre De Kick Et Arbre De Selecteur

    ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO ARBRE DE KICK ET ARBRE DE SELECTEUR Organisation de la dépose: 1 Dépose de l’arbre de kick 2 Démontage de l’arbre de kick 3 Dépose arbre de sélecteur 4 Dépose de segment Organisation de la dépose Ordre...
  • Page 414 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 - 73...
  • Page 415 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 416 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 417 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Arbre de kick complet Kickstarterwelle (komplett) Gruppo albero pedivella Déposer: Demontieren: Rimuovere: Arbre de kick complet 1 Kickstarterwelle (komplett) 1 Gruppo albero pedivella 1 N.B.:...
  • Page 418 KICK SHAFT AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: Shift shaft 1 Bend/damage → Replace. Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear/damage →...
  • Page 419 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Arbre de sélecteur Schaltwelle Albero del cambio Contrôler: Kontrollieren: Ispezionare: Arbre de sélecteur 1 Schaltwelle 1 Albero del cambio 1 Tordu/endommagement → Deformazione/danno → Sosti- Verbiegung/Beschädigung →...
  • Page 420 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 421 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Levier de butée Rastenhebel Leva di arresto Monter: Montieren: Installare: Ressort de torsion 1 Torsionsfeder 1 Molla di torsione 1 Levier de butée 2 Rastenhebel 2 Leva di arresto 2 Boulon (levier de butée) 3...
  • Page 422 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 423 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Monter: Montieren: Installare: Boulon (guide de sélecteur) 1 Schraube (Schaltklinke) 1 Bullone (guida cambio) 1 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m ·...
  • Page 424 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 425 ARBRE DE KICK ET ARBRE DE SELECTEUR KICKSTARTER UND KICKSTARTERWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Monter: Montieren: 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 426: 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 427: 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 428 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 429 VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Rotor Rotor Rotore Déposer: Demontieren: Rimuovere: Ecrou (rotor) 1 Mutter (Rotor) 1 Dado (rotore) 1 Rondelle 2 Beilagscheibe 2 Rondella 2 Utiliser l’outil de maintien de Den Rotorhalter 3 verwen- Utilizzare l’utensile di soste- rotor 3.
  • Page 430 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 431 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 Monter: Montieren: Installare: Clavette de demi-lune 1 Scheibenfeder 1 Linguetta Woodruff 1 Rotor 2...
  • Page 432 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 433 VOLANT MAGNETIQUE CDI CDI-SCHWUNGRADMAGNETZÜNDER MAGNETE CDI Connecter: Anschließen: Collegare: Fil de volant magnétique CDI CDI-Schwungradmagnet- Cavo magnete CDI Se référer au paragraphe “DIA- zünder-Kabel Fare riferimento al paragrafo GRAMME DE CHEMINE- Siehe unter “KABELFÜH- “SCHEMA DEL PERCORSO MENT CABLE” RUNG” im KAPITEL 2. DEI CAVI”...
  • Page 434: 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 435: 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 436 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 437 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE Organisation de la dépose: 1 Dépose du moteur Organisation de la dépose Ordre Nom de pièce Qté Remarques 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 438 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 439 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Pignon d’entraînement Antriebsritzel Corona dentata trasmissione Déposer: Demontieren: Rimuovere: Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 1 Dado (corona dentata trasmis- Sicherungsscheibe 2 sione) 1 Rondelle-frein 2 Rondella di bloccaggio 2 HINWEIS: Die Lasche der Sicherungsscheibe...
  • Page 440 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 441 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Montage du moteur Motor montieren ZIONE Monter: Montieren: Installazione del motore Moteur 1 Motor 1 Installare: Monter le moteur par le côté (von der rechten Seite) Motore 1 droit.
  • Page 442 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 443 DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE Monter: Montieren: Installare: Rondelle-frein 1 Sicherungsscheibe 1 Rondella di bloccaggio 1 Ecrou (pignon d’entraînement) Mutter (Antriebsritzel) 2 Dado (corona dentata trasmis- sione) 2 75 Nm (7,5 m · kg, 54 ft · lb) 75 Nm (7,5 m ·...
  • Page 444: 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 445: 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 446 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 447 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 448 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 449 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 450 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 451 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Carter Kurbelgehäuse Carter Séparer: Trennen: Separare: Demi-carter droit Rechtes Kurbelgehäusehälf- Carter destro Demi-carter gauche Carter sinistro Linkes Kurbelgehäusehälfte Etapes de la séparation: Fasi per la separazione: Déposer les boulons de carter 1, Arbeitsschritte Rimuovere i bulloni del carter 1,...
  • Page 452 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 453 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Vilebrequin Kurbelwelle Albero motore Déposer: Demontieren: Rimuovere: Vilebrequin 1 Kurbelwelle 1 Albero motore 1 Utiliser l’outil de séparateur de Das Kurbelgehäuse-Trenn- Utilizzare l’utensile per la carter 2. werkzeug 2. separazione del carter 2. Kurbelgehäuse-Trenn- Outil de séparation de Utensile per la separa-...
  • Page 454 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 455 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Vilebrequin Kurbelwelle Albero motore Mesurer: Messen: Misurare: Limite de faux-rond a Schlaggrenze a Limite di disassamento a Pleuel-Radialspiel b Limite gioco piede di biella b Limite de déflexion de pied de bielle b Pleuel-Axialspiel c Gioco laterale della testa di...
  • Page 456 CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: Bearing Bearing stopper Bolt (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) Screw [bearing stopper (crankshaft)] 1 10 Nm (1.0 m ·...
  • Page 457 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ASSEMBLAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO E INSTALLAZIONE Roulement de carter Kurbelwellenlager Cuscinetto del basamento Einbauen: Installer: Installare: Roulement Lager Cuscinetto Butoir de roulement Lageranschlag Fermo cuscinetto Boulon (butoir de roulement) Schraube (Lageranschlag) Bullone (fermo cuscinetto) 10 Nm (1,0 m ·...
  • Page 458 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 459 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 460 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 461 CARTER ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Monter: Montieren: Serrare: Guide de durit 1 Kabelführung 1 Guida del flessibile 1 Support de câble d’embrayage Kupplungszug-Halterung 2 Supporto cavo frizione 2 Schraube (Kurbelgehäuse) Bullone (carter) 3 Boulon (carter) 3 12 Nm (1,2 m ·...
  • Page 462: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL”...
  • Page 463 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 464 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 465 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 466 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: Shift cam 1 Segment 2 Wear/damage → Replace. 3. Check: Shift fork movement Unsmooth operation → Replace shift fork.
  • Page 467 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 468 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 469 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 470 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 471 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 472: Chassis

    CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL WARNING Preparation for removal...
  • Page 473: Partie Cycle

    ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE PARTIE CYCLE ROUE AVANT ET ROUE ARRIERE ROUE AVANT Organisation de la dépose: 1 Dépose de la roue avant 2 Dépose du roulement de roue 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de pièce...
  • Page 474 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 475 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 476 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 477: Roue Avant Et Roue Arriere

    ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Roue arrière Hinterrad Ruota posteriore Déposer: Demontieren: Rimuovere: Roue 1 Rad 1 Ruota 1 N.B.: HINWEIS: NOTA: Pousser la roue vers l’avant et déposer la Das Rad nach vorne stoßen und die Spingere la ruota in avanti e rimuovere chaîne de transmission 2 .
  • Page 478 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 479 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Axe de roue Radachse Asse della ruota Mesurer: Messen: Misurare: Déformation de l’axe de roue Radachsschlag Deformazioni asse della ruota Hors-spécification → Rempla- Unvorschriftsmäßig → Fuori specifica → Regolare. cer.
  • Page 480 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 481 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Roue avant Vorderrad ZIONE Monter: Montieren: Ruota anteriore Roulement (gauche) 1 Lager (links) 1 Installare: Entretoise 2 Distanzstück 2 Cuscinetto (sinistro) 1 Roulement (droit) 3 Lager (rechts) 3...
  • Page 482 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 483 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Roue Ruota N.B.: HINWEIS: NOTA: Reposer correctement le disque du Die Bremsscheibe zwischen die Installare correttamente il disco freno frein entre les plaquettes de frein. Bremsbeläge führen.
  • Page 484 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 485 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Tuyau de frein 1 Bremsschlauch 1 Flessibile freno 1 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m · kg, 7,2 ft · lb) 10 Nm (1,0 m ·...
  • Page 486 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 487 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Roue arrière Hinterrad Ruota posteriore Monter: Montieren: Installare: Roulement (droit) 1 Lager (rechts) 1 Cuscinetto (destro) 1 Circlip 2 Sicherungsring 2 Anello elastico di arresto 2 Entretoise 3 Distanzstück 3 Roulement (gauche) 4...
  • Page 488 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 489 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Monter: Montieren: Installare: Collerette 1 Hülse 1 Collarino 1 N.B.: HINWEIS: NOTA: Appliquer la graisse à base de savon au Lithiumseifen-Schmierfett auf der Öl- Applicare grasso a base di sapone di litio lithium sur la lèvre de la bague d’étan- dichtungslippe auftragen.
  • Page 490 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 491 ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUOTA ANTERIORE E RUOTA POSTERIORE Régler: Einstellen: 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 492: 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 493: 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 494 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 495 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 496 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 497 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 498 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 499 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 500 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 501 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Liquide de frein Bremsflüssigkeit Liquido dei freni Déposer: Demontieren: Rimuovere: [Arrière] [Vorn] [Anteriore] Couvercle de maître-cylindre Hauptbremszylinderdeckel 1 Coperchio pompa del freno 1 de frein 1 [Hinten] [Posteriore]...
  • Page 502 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 503 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Kit de joint de piston d’étrier de frein Bremssattelkolben-Dichtungssatz Set guarnizioni pistoncino della pinza Déposer: Demontieren: freno Joint antipoussière 1 Staubschutzring 1 Rimuovere: Joint de piston 2 Dichtring 2 Guarnizione parapolvere 1 Guarnizione dei pistoncini 2...
  • Page 504 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.
  • Page 505 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Etrier de frein Bremssattel Pinza del freno Contrôler: Kontrollieren: Ispezionare: Surface interne du maître- Hauptbremszylinder-Boh- Superficie interna cilindro cylindre de frein a rungsfläche a pinza del freno a Usure/rayures →...
  • Page 506 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 507 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: 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 508 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 509 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Boulon-raccord 2 Hohlschraube 2 Vite di unione 2 30 Nm (3,0 m · kg, 22 ft · lb) 30 Nm (3,0 m ·...
  • Page 510 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 511 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Cache de disque de frein 1 Bremsscheiben-Abdeckung Copridisco 1 Boulon (cache de disque de Bullone (copridisco) 2 frein) 2 Schraube (Bremsscheiben- 7 Nm (0,7 m · kg, 5,1 ft · lb) Abdeckung) 2 7 Nm (0,7 m ·...
  • Page 512 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 513 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Kit de maître-cylindre de frein Hauptbremszylindersatz Kit pompa del freno Nettoyer: Reinigen: Pulire: Maître-cylindre de frein Hauptbremszylinder Pompa del freno Kit de maître-cylindre de frein Hauptbremszylindersatz Kit pompa del freno Les nettoyer avec du liquide de Mit Bremsflüssigkeit reini- Pulire con liquido per freni.
  • Page 514 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 515 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: [Avant] [Vorn] [Anteriore] Kit de maître-cylindre de frein Hauptbremszylindersatz 1 Set pompa del freno 1 Unterlegscheibe 2 Rondella 2 Rondelle ordinaire 2 Sicherungsring 3 Anello elastico di arresto 3 Circlip 3 Hauptbremszylinderschutz-...
  • Page 516 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 517 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Levier de frein 1 Bremshebel 1 Leva del freno 1 Boulon (levier de frein) 2 Schraube (Bremshebel) 2 Bullone (leva del freno) 2 6 Nm (0,6 m · kg, 4,3 ft · lb) 6 Nm (0,6 m ·...
  • Page 518 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 519 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Goupille 1 Stift 1 Perno 1 Rondelle 2 Unterlegscheibe 2 Rondella 2 Goupille fendue 3 Splint 3 Copiglia 3 N.B.: HINWEIS: NOTA: Après de montage, contrôler la hauteur Nach der Montage die Fußbremshe- Dopo l’installazione,...
  • Page 520 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 521 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Rondelle en cuivre 1 Kupferscheibe 1 Rondella di rame 1 Durit de frein 2 Bremsschlauch 2 Flessibile freno 2 Boulon-raccord 3 Hohlschraube 3 Vite di unione 3 30 Nm (3,0 m ·...
  • Page 522 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: Brake hose holder 1 Screw (brake hose holder) 2 1 Nm (0.1 m · kg, 0.7 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
  • Page 523 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Monter: Montieren: Installare: Support de tuyau de frein 1 Bremsschlauch-Halterung Supporto flessibile freno 1 Vis (support de tuyau de frein) Vite (supporto flessibile freno) Schraube (Halterung) 2 1 Nm (0,1 m ·...
  • Page 524 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: Brake system Refer “BRAKE SYSTEM BLEEDING” section in the CHAPTER 3. Inspect: Brake fluid level Fluid at lower level → Fill up. Refer “BRAKE FLUID LEVEL INSPECTION” section in the CHAP- TER 3.
  • Page 525 FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSE CHAS FRENO ANTERIORE E POSTERIORE Purger l’air: Entlüften: Spurgo dell’aria: Circuit de freinage Bremsanlage Sistema frenante reporter à section Siehe unter “HYDRAULI- Fare riferimento al paragrafo “PURGE D’AIR DU CIR- SCHE BREMSANLAGE “SPURGO DELL’ARIA DAL CUIT DE FREINAGE”...
  • Page 526: Front Fork

    CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 527: 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 528 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 529 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 530 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 531 La fourche avant nécessite une soi- dere Aufmerksamkeit und sollte am cautela. Pertanto si consiglia di affidare gneuse attention. Il est donc recom- besten vom Yamaha-Händler gewar- la manutenzione della forcella anteriore mandé de la faire entretenir chez le tet werden.
  • Page 532 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 533 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Tube interne Gleitrohr Tubo di forza Déposer: Demontieren: Rimuovere: Joint antipoussière 1 Staubschutzring 1 Guarnizione parapolvere 1 Bague d’arrêt 2 Sicherungsring 2 Anello di arresto 2 En utilisant un tournevis à lame Einen Schlitzschraubendre- Utilizzando un cacciavite per droite.
  • Page 534 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...
  • Page 535 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Soupape de base Luftventil Valvola base Contrôler: Kontrollieren: Ispezionare: Ensemble clapet 1 Luftventil 1 Gruppo valvola 1 Usure/endommagement → Verschleiß/Beschädigung → Usura/danno → Sostituire. Remplacer. Erneuern. O-ring 2 Danni → Sostituire. Joint torique 2 O-Ring 2 Endommagement →...
  • Page 536 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 537 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Bouchon de tube de fourche Telegabelverschlußschraube Vite mordente forcella anteriore Contrôler: Kontrollieren: Ispezionare: Bouchon de tube de fourche 1 Telegabelverschlußschrau- Vite mordente forcella ante- Joint torique 2 be 1 riore 1 Vis de purge d’air 3 O-Ring 2 O-ring 2 Usure/endommagement →...
  • Page 538 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 539 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Monter: Montieren: Installare: Guide de ressort 1 Federsitz 1 Guida molla 1 Contre-écrou 2 Sicherungsmutter 2 Controdado 2 Sur la tige d’amortisseur 3. (am Dämpferrohr 3) Sull’asta pompante 3. N.B.: HINWEIS: NOTA: 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 540 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 541 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Monter: Montieren: Installare: Bague antifriction 1 Gleitbuchse 1 Metallo di scorrimento 1 Rondelle de bague d’étanchéité Öldichtungsscheibe 2 Rondella paraolio 2 (auf Gleitrohr-Nut) Sulla fessura del fodero. Dans l’ouverture de fourreau. HINWEIS: NOTA: Die Gleitbuchse mit dem Gabeldicht- Premere il metallo di scorrimento nel N.B.: Enfoncer la bague antifriction dans le...
  • Page 542 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 543 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 13. Contrôler: 13. Kontrollieren: 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- → Répéter les étapes du 2 à 12. holen.
  • Page 544 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 545 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 19. Attendre dix minutes jusqu’à ce 19. Zehn Minuten warten, bis et- 19. Attendere dieci minuti finché non que les bulles d’air aient disparu waige Luftbläschen sich auf- vengono rimosse le bolle d’aria de la fourche avant et que l’huile gelöst haben, bevor der Ga- dalla forcella anteriore e finché...
  • Page 546 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 547 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 21. Mesurer: 21. Messen: 21. Misurare: Distance a Gewindelänge a Distanza a Hors spécification → Serrer le → Fuori specifica → Avvitare il Unvorschriftsmäßig 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 548 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 549 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE 26. Serrer: 26. Festziehen: 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, 21 ft · lb) 29 Nm (2,9 m ·...
  • Page 550 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 551 FOURCHE AVANT TELESKOPGABEL CHAS FORCELLA ANTERIORE Serrer: Festziehen: 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, 17 ft · lb) 23 Nm (2,3 m · kg, 17 ft · lb) 23 Nm (2,3 m ·...
  • Page 552: Handlebar

    CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal 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 553 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 554 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 555 GUIDON LENKER CHAS MANUBRIO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Maître-cylindre de frein Hauptbremszylinder Pompa del freno Déposer: Demontieren: Rimuovere: Demi-palier de maître-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 556 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 557 GUIDON LENKER CHAS MANUBRIO REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Guidon Lenker ZIONE Monter: Montieren: Manubrio Guidon 1 Lenker 1 Installare: Demi-palier supérieur de gui- Oberer Lenkerhalter 2 Manubrio 1 don 2 Schraube (Oberer Lenker- Supporto manubrio superiore halter ) 3 Boulon (demi-palier supérieur de guidon) 3...
  • Page 558 CHAS HANDLEBAR 4. Install: Collar 1 Grip cap cover 2 Throttle grip 3 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion.
  • Page 559 GUIDON LENKER CHAS MANUBRIO Monter: Einbauen: Installare: Hülse 1 Collerette 1 Collare 1 Cache de logement des câbles Griffkappenabdeckung 2 Copertura del cappuccio mano- des gaz 2 Gasdrehgriff 3 pola 2 Poignée des gaz 3 Manopola dell'acceleratore 3 HINWEIS: Lithiumfett auf die Gasdrehgriff-Gleit- N.B.: NOTA: Appliquer de la graisse à...
  • Page 560 CHAS HANDLEBAR 8. Install: Brake master cylinder 1 Brake master cylinder bracket 2 Bolt (brake master cylinder bracket) 3 9 Nm (0.9 m · kg, 6.5 ft · lb) NOTE: Install the bracket so that the arrow mark a faces upward. First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side.
  • Page 561 GUIDON LENKER CHAS MANUBRIO Monter: Montieren: Installare: Maître-cylindre de frein 1 Hauptbremszylinder 1 Pompa del freno 1 Demi-palier de maître-cylin- Hauptbremszylinder-Halte- Staffa pompa del freno 2 dre de frein 2 rung 2 Bullone (staffa pompa del Boulon (demi-palier de maître- Schraube (Hauptbremszy- freno) 3...
  • Page 562 CHAS HANDLEBAR 11. Install: Clutch cable 1 Decompression cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and decompression cable end. 12. Adjust: Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. Decompression lever free play Refer to “DECOMPRESSION LEVER ADJUSTMENT”...
  • Page 563 GUIDON LENKER CHAS MANUBRIO 11. Monter: 11. Montieren: 11. Installare: Câble d’embrayage 1 Kupplungszug 1 Cavo frizione 1 Câble de décompression 2 Dekompressionszug 2 Cavo di decompressione 2 HINWEIS: N.B.: NOTA: Enduire de graisse à base de savon au Lithiumfett auf die Enden des Kupp- Applicare grasso a base di sapone di litio lithium l’extrémité...
  • Page 564: Steering

    CHAS STEERING EC560000 STEERING Extent of removal: 1 Lower bracket removal 2 Bearing removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 565 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 566 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 567 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 568 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 569 DIRECTION LKKOPF CHAS STERZO POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Ecrou crénelé de direction Lenkerringmutter Ghiera Déposer: Demontieren: Rimuovere: Ecrou crénelé de direction 1 Lenkerringmutter 1 Ghiera 1 Utiliser la clé pour ecrou cré- Den Hakenschlüssel 2 ver- Utilizzare la chiave per ghiere nelé...
  • Page 570 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: Bearing 1 Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand.
  • Page 571 DIRECTION LKKOPF CHAS STERZO Roulement et cage à billes Lager und Laufring Cuscinetto e pista Nettoyer les roulements et les Die Lager und Laufringe in Lö- Lavare i cuscinetti e le piste con cages à billes dans du solvant. sungsmittel waschen. un solvente.
  • Page 572 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 573 DIRECTION LKKOPF CHAS STERZO Monter: Montieren: Installare: Rondelle 1 Unterlegscheibe 1 Rondella 1 Ecrou crénelé de direction 2 Lenkerringmutter 2 Ghiera 2 7 Nm (0,7 m · kg, 5,1 ft · lb) 7 Nm (0,7 m · kg, 5,1 ft · lb) 7 Nm (0,7 m ·...
  • Page 574 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: 5 mm (0.20 in) * 8mm (0.31 in) ** 10.5 mm (0.41 in)
  • Page 575 DIRECTION LKKOPF CHAS STERZO Après avoir serré l’écrou, vérifier Nach dem Festziehen der 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 576: Swingarm

    CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine. danger of it falling over.
  • Page 577: 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 578 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 579: 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 580 CHAS SWINGARM EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: Bearing 1 NOTE: Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and cov- ers in a solvent. Swingarm 1. Inspect: Bearing 1 Bushing 2 Free play exists/unsmooth revolution/ rust →...
  • Page 581 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Déposer: Demontieren: Rimuovere: Roulement 1 Lager 1 Cuscinetto 1 N.B.: HINWEIS: NOTA: Retirer le roulement en appuyant sur la Das Lager am äußeren Laufring ein- Rimuovere cuscinetto premendo...
  • Page 582 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 583 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Roulement et bague d’étanchéité Lager und Dichtringe ZIONE Monter: Montieren: 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 584 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 585 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Bras oscillant Schwinge 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 586 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 587 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE Monter: Montieren: 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 588 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 right cap with its mark a facing for- ward.
  • Page 589 BRAS OSCILLANT SCHWINGE CHAS FORCELLONE OSCILLANTE 10. Serrer: 10. Festziehen: 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 590: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so there is no Preparation for removal Hold the machine by placing the danger of it falling over.
  • Page 591: Caches 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 592 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 593: 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 594 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 595 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 596 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 597 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE POINTS DE DEPOSE AUSBAU PUNTI DI RIMOZIONE Roulement Lager Cuscinetto Déposer: Demontieren: Rimuovere: Bague d’arrêt (roulement supé- Sicherungsring (Oberes La- Anello di arresto (cuscinetto rieur) 1 ger) 1 superiore) 1 HINWEIS: N.B.: NOTA: Appuyer sur le roulement en poussant Das Lager am äußeren Laufring ein- Spingere dentro il cuscinetto premendo sur la cage extérieure et enlever la bague...
  • Page 598 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 599 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE REMONTAGE ET MONTAGE ZUSAMMENBAU UND MONTAGE MONTAGGIO INSTALLA- Roulement Lager ZIONE Monter: Montieren: Cuscinetto Roulement supérieur 1 Oberes Lager 1 Installare: Cuscinetto superiore 1 N.B.: HINWEIS: Monter roulement parallèlement Das Lager am äußeren Laufring NOTA: jusqu’à...
  • Page 600 CHAS REAR SHOCK ABSORBER 2. Tighten: Adjuster 1 3. Adjust: Spring length (installed) a Spring length (installed) a: Standard Extent of length adjustment 244 mm (9.61 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 601 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Serrer: Festziehen: Serrare: Dispositif de réglage 1 Einstellmutter 1 Registro 1 Régler: Einstellen: Regolare: Longueur de ressort (monté) a Feder-Einbaulänge a Lunghezza molla (installata) Longueur de ressort Feder-Einbaulänge a (monté) a: Lunghezza molla (instal- lata) a: Longueur stan- Etendue de...
  • Page 602 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 603 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Monter: Montieren: Installare: Douille 1 Buchse 1 Boccola 1 Collerette 2 Hülse 2 Collarino 2 Joint antipoussière 3 Staubschutzring 3 Guarnizione parapolvere 3 N.B.: HINWEIS: NOTA: Enduire le roulement de graisse au Molybdändisulfidfett auf das Lager Applicare grasso al disolfuro di molib- bisulfure de molybdène.
  • Page 604 CHAS REAR SHOCK ABSORBER 8. Install: Band 1 Taillight connector 2 5 - 67...
  • Page 605 AMORTISSEUR ARRIERE FEDERBEIN CHAS AMMORTIZZATORE POSTERIORE Monter: Montieren: Installare: Bande 1 Band 1 Band 1 Connecteur de la lampe arrière Rücklicht-Steckverbinder 2 Connettore del fanalino poste- riore 2 5 - 67...
  • Page 606: And Wiring Diagram

    – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight COLOR CODE W .....White 2 Voltage regulator B...... Black Y ......Yellow Br ....Brown 3 Engine stop switch B/L ....Black/Blue G .....
  • Page 607 COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE – ELEKTRISCHE BAUTEILE UND SCHALTPLAN ELEC COMPONENTI ELETTRICI E SCHEMA DI CABLAGGIO PARTIE ELEKTRISCHE IMPIANTO ANLAGE ELECTRIQUE ELETTRICO ELEKTRISCHE BAUTEI- COMPOSANTS ELECTRI- COMPONENTI ELET- LE UND SCHALTPLAN QUES ET SCHEMA DE TRICI SCHEMA ELEKTRISCHE BAUTEILE CABLAGE CABLAGGIO 1 Scheinwerfer...
  • Page 608: 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 609: 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 610: 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 611 – 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 612 – 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 613 – 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 614 – 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 615: 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 616 – 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 617: Impianto Di Accensione

    SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE TEST DE LA LONGUEUR D’ETIN- ZÜNDFUNKENSTRECKE KON- Test della distanza tra gli elettrodi CELLE D’ALLUMAGE TROLLIEREN Staccare il cappuccio della can- Déconnecter le capuchon de bou- Den Zündkerzenstecker von dela. gie de la bougie. der Zündkerze abziehen.
  • Page 618 – 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 Ω at Ω...
  • Page 619 SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE CONTROLE BOBINE ZÜNDSPULE KONTROLLIEREN ISPEZIONE BOBINA DI ACCEN- D’ALLUMAGE Kontrollieren: SIONE Vérifier: Primärspulen-Widerstand Ispezionare: Unvorschriftsmäßig → Résistance de bobine primaire Resistenza avvolgimento pri- Hors spécification → Rempla- Erneuern. mario Fuori specifica → Regolare. cer.
  • Page 620 – 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 Ω at Ω...
  • Page 621: Elektrische Anlage

    SYSTEME D’ALLUMAGE ZÜNDANLAGE – ELEC IMPIANTO DI ACCENSIONE Vérifier: Kontrollieren: Ispezionare: Résistance de bobine de charge Widerstand der Erregerspu- Resistenza bobina di carica 1 Fuori specifica → Sostituire. le 1 Hors spécification → Rempla- Unvorschriftsmäßig → Conduttore (+) del tester → cer.
  • Page 622: 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 623: 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 624 – 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